WARNING

THE INSTALLATION SHALL BE

MADE BY QUALIFIED INSTALLATION
PERSONNEL AND SHOULD
CONFORM TO ALL NATIONAL AND
LOCAL CODES
Hyundai Robot Hi5100601CMEN5

Hi5 Controller Maintenance Manual

- Hi5-C10/C20
- Hi5-N00/N30/N50
 The information presented in the manual is the property of HHI.
Any copy or even partial is not allowed without prior written authorization from HHI.
It may not be provided to the third party, nor used for any other purposes.

HHI reserves the right to modify without prior notification.

th
Printed in Korea – Jun. 2010. 5 Edition
Copyright ⓒ 2010 by Hyundai Heavy Industries Co., Ltd.
 Contents

1. 1. Safety
Safety ............................................................................................................................................ 1-1

1.1. Introduction .................................................................................................................... 1-2

1.2. Relevant Safety Regulations ......................................................................................... 1-4
1.3. Safety Training ............................................................................................................... 1-4
1.4. Safety Related Nameplate ............................................................................................. 1-5
1.4.1. Safety Marking ........................................................................................................... 1-5
1.4.2. Safety Nameplate ...................................................................................................... 1-5
1.5. Definition of Safety Functions ...................................................................................... 1-6
1.6. Installation ...................................................................................................................... 1-7
1.6.1. Safety Fence ............................................................................................................. 1-7
1.6.2. Placement of Robot & Peripheral Equipment ............................................................ 1-9
1.6.3. Installing the Robot .................................................................................................. 1-12
1.6.4. Space for Robot Installation ..................................................................................... 1-14
1.7. Safety Operation for Robot Handling......................................................................... 1-15
1.7.1. Safety Precautions for Robot Handling ................................................................... 1-15
1.7.2. Safety Precautions for Operating Test ..................................................................... 1-17
1.7.3. Safety Precautions for Automatic Operation ........................................................... 1-18
1.8. Safety Precautions for Access to Safety Fence ....................................................... 1-19
1.9. Safety Precautions for Maintenance and Repair ...................................................... 1-20
1.9.1. Safety Precautions for Controller Maintenance and Repair .................................... 1-20
1.9.2. Safety Precautions for Robot System & Manipulator Maintenance ........................ 1-21
1.9.3. Necessary Actions after Maintenance and Repair .................................................. 1-21
1.10. Safety Functions ........................................................................................................ 1-22
1.10.1. Operating a Safety Circuit ..................................................................................... 1-22
1.10.2. Emergency stop ..................................................................................................... 1-24
1.10.3. Operating Speed .................................................................................................... 1-25
1.10.4. Connecting the Safety Devices ............................................................................. 1-25
1.10.5. Restricting the working Envelope .......................................................................... 1-25
1.10.6. Monitoring Function ............................................................................................... 1-25
1.11. Safety Related to End Effectors ............................................................................... 1-26
1.11.1. Gripper ................................................................................................................... 1-26
1.11.2. Tool / Workpiece .................................................................................................... 1-26
1.11.3. Pneumatic and Hydraulic Systems ........................................................................ 1-26
1.12. Liabilities..................................................................................................................... 1-27

2. 2. Specifications
Specifications ............................................................................................................................... 2-1

2.1. The Detailed Specifications of Hi5 Robot Controller ................................................. 2-2

3. 3. Installation
Installation of.............................................................................................................
of Controller Controller 3-1

3.1. Components ................................................................................................................... 3-2

3.1.1. Basic Components of Controller and Robot Manipulator .......................................... 3-2
3.1.2. Confirmation of Serial Number .................................................................................. 3-4
3.1.3. Confirmation of Nameplates ...................................................................................... 3-5
3.2. Packing ......................................................................................................................... 3-13
3.3. Transportation of Controller ....................................................................................... 3-13
3.4. Unpacking ..................................................................................................................... 3-13
3.5. Controller Handling ..................................................................................................... 3-14
3.5.1. Weight of Controller ................................................................................................. 3-14

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Contents

3.5.2. Transportation of Controller Using Crane ................................................................ 3-15

3.5.3. Transportation of Controller Using Forklift Truck ..................................................... 3-16
3.6. Space for Installation ................................................................................................... 3-17
3.6.1. Installation of Controller ........................................................................................... 3-17
3.6.2. Space for Installation ............................................................................................... 3-18
3.6.3. Dimension of Controller ........................................................................................... 3-22
3.7. Connection ................................................................................................................... 3-25
3.7.1. Connection of Teach Pendant ................................................................................. 3-25
3.7.2. Connection of Manipulator and Controller ............................................................... 3-27
3.7.3. Connection of Controller and Primary Power .......................................................... 3-30
3.7.4. Controller and Grounding ........................................................................................ 3-33
3.7.5. Other Cautions ........................................................................................................ 3-33
3.7.6. RS232C & Ethernet access of Small Door .............................................................. 3-34

4. 4. Basic
Basic Components
Components of Controller
of Controller ................................................................................................ 4-1

4.1. Components ................................................................................................................... 4-2

4.2. The Arrangement of Parts ............................................................................................. 4-4
4.3. The Function of Each Component ............................................................................. 4-15
4.3.1. Rack and Backplane Board (BD501) ...................................................................... 4-16
4.3.2. Mainboard(BD510) .................................................................................................. 4-17
4.3.3. System Board(BD530/BD531) ................................................................................ 4-21
4.3.4. Servo Board (BD542) .............................................................................................. 4-47
4.3.5. Drive Unit ................................................................................................................. 4-51
4.3.6. DC Multi Power Unit (SMPS : HDI-200) .................................................................. 4-72
4.3.7. Electrical Module and Electrical Board(BD5C0) ...................................................... 4-73
4.3.8. Small Door Board (BD5B1) ..................................................................................... 4-77
4.3.9. Teach pendant (TP510) ........................................................................................... 4-78

5. 5. Controller
Controller Options
Options ....................................................................................................................... 5-1

5.1. Public IO Board (BD580; Terminal Block) ................................................................... 5-2

5.1.1. Outline ....................................................................................................................... 5-2
5.1.2. Connector .................................................................................................................. 5-3
5.1.3. Setting Unit ................................................................................................................ 5-9
5.2. Relay Board (BD581) ................................................................................................... 5-10
5.2.1. Outline ..................................................................................................................... 5-10
5.2.2. Connector ................................................................................................................ 5-11
5.3. Public IO Board (BD582; Connector Type) ................................................................ 5-12
5.3.1. Outline ..................................................................................................................... 5-12
5.3.2. Connector ................................................................................................................ 5-13
5.3.3. Setting Unit .............................................................................................................. 5-22
5.4. CC-Link Board (BD570) ............................................................................................... 5-23
5.4.1. Outline ..................................................................................................................... 5-23
5.4.2. Connector ................................................................................................................ 5-24
5.4.3. Indication and Setting Units ..................................................................................... 5-26
5.5. Conveyor I/F Board (BD585) ....................................................................................... 5-27
5.5.1. Outline ..................................................................................................................... 5-27
5.5.2. Connector ................................................................................................................ 5-28
5.5.3. Display Unit ............................................................................................................. 5-30
5.6. LDIO Board (BD58A; For LCD) ................................................................................... 5-31
5.6.1. Outline ..................................................................................................................... 5-31
5.6.2. Connector ................................................................................................................ 5-32
5.6.3. Setting Unit .............................................................................................................. 5-47

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 5.7. Safety Relay Board (BD58B) ....................................................................................... 5-49
5.7.1. Outline ..................................................................................................................... 5-49
5.7.2. Connector ................................................................................................................ 5-50
5.8. Expansion Public IO Board (BD583; 464-point I/O) .................................................. 5-53
5.8.1. Outline ..................................................................................................................... 5-53
5.8.2. Connector ................................................................................................................ 5-54
5.8.3. Setting Unit .............................................................................................................. 5-62
5.9. Analog/Arc IF Board (BD584) ...................................................................................... 5-63
5.9.1. Outline ..................................................................................................................... 5-63
5.9.2. Connector ................................................................................................................ 5-65

6. Troubleshooting
6. Troubleshooting ........................................................................................................................... 6-1

6.1. Troubleshooting Solution ............................................................................................. 6-2

6.1.1. E0002 Hardware limit switch operating ..................................................................... 6-3
6.1.2. E0010 AMP recovery discharge resistance overheating ......................................... 6-11
6.1.3. E0011 AMP overvoltage (P-N) ................................................................................. 6-18
6.1.4. E0014 Instant contact of safety switch (EM, OTR, TS etc.) .................................... 6-23
6.1.5. E0015 Teaching pendant operation error ................................................................ 6-31
6.1.6. E0022 Communication error between internal modules ......................................... 6-35
6.1.7. E0033 AMP under-voltage error .............................................................................. 6-46
6.1.8. E0034 AMP over-current error................................................................................. 6-50
6.1.9. E0044 Lift axis belt disconnect sensor is operating ................................................ 6-55
6.1.10. E0108 (Axis ○) Encoder error: Encoder reset required ......................................... 6-60
6.1.11. E0112 (○ Axis) IPM fault signal detection .............................................................. 6-62
6.1.12. E0113 (○ Axis) Over-current .................................................................................. 6-68
6.1.13. E0114 Operating device control voltage reduction ................................................ 6-72
6.1.14. E0115 (Axis o) Received command code error ..................................................... 6-78
6.1.15. E0117 ( Axis ○) Location deviation set value exceeded ........................................ 6-84
6.1.16. E0119 (Axis ○) Overload ....................................................................................... 6-89
6.1.17. E0122 Servo ON limit time exceeded ................................................................... 6-97
6.1.18. E0127 MSHP operation error .............................................................................. 6-102
6.1.19. E0140 MSPR operation error .............................................................................. 6-102
6.1.20. E0133 (Axis ○) Command value error ................................................................. 6-115
6.1.21. E0134 (Axis ○) Maximum speed exceeded ......................................................... 6-120
6.1.22. E0165 (Axis o) Servo lock cannot be maintained................................................ 6-123
6.1.23. E0223 (Axis o) Encoder cut-off or communication failure ................................... 6-127
6.1.24. E0224 (Axis o) Encoder status error ................................................................... 6-135
6.1.25. Instructions in examining the Controller‟s input voltage (Single-phase) ............. 6-137
6.1.26. Instructions in examining the Controller‟s input voltage(3-phase) ...................... 6-138
6.1.27. Instructions in examining the Controller‟s internal voltage(3-phase) .................. 6-140
6.2. Instructions in Parts Replacement ........................................................................... 6-141
6.2.1. Instructions in Substrate Replacement .................................................................. 6-141
6.2.2. Instructions in Servo AMP Replacement ............................................................... 6-144
6.2.3. Instructions in Battery Replacement ...................................................................... 6-145
6.2.4. Instructions in SMPS Replacement ....................................................................... 6-146
6.3. Instructions in Adjustment ....................................................................................... 6-147
6.3.1. Adjustment of Power System ................................................................................ 6-147
6.3.2. Transformer (TR1) ................................................................................................. 6-148
6.4. Error Code and Warning ........................................................................................... 6-149
6.4.1. System Error .......................................................................................................... 6-150
6.4.2. Operation Error ...................................................................................................... 6-165
6.4.3. Warning ................................................................................................................. 6-204

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Contents

7. 7. Regular
Regular inspection
inspection ....................................................................................................................... 7-1

7.1. Inspection Schedule ...................................................................................................... 7-2

7.2. General Instructions for Regular Inspection ............................................................... 7-3
7.3. Daily Inspection.............................................................................................................. 7-4
7.4. First Inspection (750 hours inspection) ....................................................................... 7-4
7.5. Daily Inspection.............................................................................................................. 7-5
7.6. Inspection for Long-Term Idleness .............................................................................. 7-7
7.7. Parts List for Maintenance ............................................................................................ 7-8

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 Figure
Figure 목차 contents

Figure 1.1 Recommended size for safety net and entrance gate (slot type entrance gate) .. 1-7
Figure 1.2 Recommended size for safety net and entrance gate (square type entrance gate)
................................................................................................................................. 1-7
Figure 1.3 Arrangement of LCD robot peripheral devices and workers............................... 1-10
Figure 1.4 Arrangement of general robot peripheral devices and workers .......................... 1-11
Figure 1.5 Configuration for safety chain ............................................................................. 1-22
Figure 1.6 Connection with external emergency halt switch through system board terminal
block TBEM ........................................................................................................... 1-24
Figure 3.1 Basic Components of Manipulator and Controller (LCD Robot) ........................... 3-2
Figure 3.2 Basic Components of Manipulator and Controller (Vertical Articulated Robot) .... 3-3
Figure 3.3 Location of Serial Number .................................................................................... 3-4
Figure 3.4 Hi5-C10 Location of Controller Nameplate 1 ........................................................ 3-5
Figure 3.5 Hi5-C10 Location of Controller Nameplate 2 ........................................................ 3-6
Figure 3.6 Hi5-C20 Location of Controller Nameplate 1 ........................................................ 3-7
Figure 3.7 Hi5-C20 Location of Controller Nameplate 2 ........................................................ 3-8
Figure 3.8 Hi5-N** Location of Controller Nameplate 1 ......................................................... 3-9
Figure 3.9 Hi5-N** Location of Controller Nameplate 2 ....................................................... 3-10
Figure 3.10Transportation of Controller Using Crane .......................................................... 3-15
Figure 3.11 Transportation of Controller Using Forklift Truck .............................................. 3-16
Figure 3.12 Installing space for LCD robot .......................................................................... 3-18
Figure 3.13 Installing space for Hi5-C20 controller .............................................................. 3-19
Figure 3.14 Install space for general type robot................................................................... 3-20
Figure 3.15 Installing space for Hi5-C10, Hi5-N** controller ................................................ 3-21
Figure 3.16 Dimension of Hi5-C20 (Unit:mm) ...................................................................... 3-22
Figure 3.17 Dimension of Hi5-C10 Controller (Unit:mm) ..................................................... 3-23
Figure 3.18 Dimension of Hi5-N** Controller (Unit:mm) ...................................................... 3-24
Figure 3.19 Hi5-C20 Connection of Teach Pendant ............................................................ 3-25
Figure 3.20 Hi5-C10 Connection of Teach Pendant ............................................................ 3-26
Figure 3.21 Hi5-N** Connection of Teach Pendant ............................................................. 3-26
Figure 3.22 Connection of Robot Manipulator and Controller (Hi5-C20)............................. 3-27
Figure 3.23 Connection of Robot Manipulator and Controller (Hi5-C10)............................. 3-27
Figure 3.24 Connection of Robot Manipulator and Controller (Hi5-N00)............................. 3-28
Figure 3.25 Connection of Robot Manipulator and Controller (Hi5-N30/N50) ..................... 3-29
Figure 3.26 Hi5-C20 Connection of Primary Power to Controller ........................................ 3-30
Figure 3.27 Hi5-C10 Connection of Primary Power to Controller ........................................ 3-30
Figure 3.28 Hi5-N** Connection of Primary Power to Controller ......................................... 3-31
Figure 4.1 Hi5-N** Controller ................................................................................................. 4-2
Figure 4.2 Hi5-C** Controller ................................................................................................. 4-2
Figure 4.3 Teach pendant (TP510) ........................................................................................ 4-3
Figure 4.4 Internal Composition of Hi5 Controller .................................................................. 4-3
Figure 4.5 Hi5-N00 Part arrangement parts in the exterior of a controller ............................. 4-5
Figure 4.6 Part arrangement in the interior of the front surface of the Hi5-N00 controller .... 4-6
Figure 4.7 Part arrangement in the interior of the rear surface of the Hi5-N00 controller ..... 4-6
Figure 4.8 Hi5-C10 Part arrangement parts in the exterior of the controller .......................... 4-9
Figure 4.9 Part arrangement in the interior of the front surface of the Hi5-C10 controller .... 4-9
Figure 4.10 Part arrangement in the interior of the rear surface of the Hi5-C10 controller . 4-10
Figure 4.11 Part arrangement in the interior of the left side of the Hi5-C20 controller ........ 4-13
Figure 4.12 Part arrangement in the left side door of the Hi5-C20 controller ...................... 4-13
Figure 4.13 Part arrangement in the front and rear surfaces of the Hi5-C20 controller ...... 4-14
Figure 4.14 Part arrangement in the interior of the right side of the Hi5-C20 controller ...... 4-14
Figure 4.15 PCB Rack ......................................................................................................... 4-16

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Contents

Figure 4.16 Backplane Board(BD501) ................................................................................. 4-16

Figure 4.17 Mainboard (BD510) .......................................................................................... 4-17
Figure 4.18 System Board (BD530/BD531) ......................................................................... 4-21
Figure 4.19 The Arrangement of the Connectors of the System Board (BD530) ................ 4-22
Figure 4.20 The Terminal Block of the System Board (BD530) ........................................... 4-25
Figure 4.21 System board (BD530) terminal block TBIO .................................................... 4-26
Figure 4.22 System board (BD530) terminal block TBRMT ................................................ 4-27
Figure 4.23 System board (BD530) terminal block TBPLC ................................................. 4-28
Figure 4.24 Pin arrangement in system CAN connector ..................................................... 4-29
Figure 4.25 The Display Unit of the System Board (BD530) ............................................... 4-30
Figure 4.26 The Setting Unit of the System Board (BD530) ................................................ 4-32
Figure 4.27 Method for connecting the external emergency stop switch to terminal block
TBEM ..................................................................................................................... 4-37
Figure 4.28 Management method when a contact point input type-external emergency stop is
not used. ................................................................................................................ 4-37
Figure 4.29 Method of connecting the automatic safety guard to an NPN output device ... 4-38
Figure 4.30 Management method in cases where the P-COM input external emergency stop
is not used ............................................................................................................. 4-38
Figure 4.31 Output the internal emergency stop switch of terminal block TBPLC .............. 4-39
Figure 4.32 Method for connecting a typical safety guard to terminal block TBPLC ........... 4-40
Figure 4.33 Management method in cases where a typical safety guard is not used ......... 4-40
Figure 4.34 Method for connecting the contact point input automatic safety guard to terminal
block TBEM ........................................................................................................... 4-41
Figure 4.35 Management method in cases where a contact point input automatic safety guard
is not used ............................................................................................................. 4-41
Figure 4.36 Connecting method of an automatic safety guard with respect to an NPN output
device .................................................................................................................... 4-42
Figure 4.37 Management method in cases where P-COM input automatic safety guard is not
used ....................................................................................................................... 4-42
Figure 4.38 Method for inputting the external motor power ON signal into terminal block
TBEM ..................................................................................................................... 4-43
Figure 4.39 for inputting the remote switch signal into terminal block TBRMT .................... 4-43
Figure 4.40 Management method in cases where remote switch input is not used ............ 4-44
Figure 4.41 Connection method of Safety PLC/IO .............................................................. 4-45
Figure 4.42 Method for connecting digital output for a system to terminal block TBIO ....... 4-46
Figure 4.43 Method for connecting digital input for a system to terminal block ................... 4-46
Figure 4.44 Servo Board (BD542) ....................................................................................... 4-47
Figure 4.45 BD552 Component Layout ............................................................................... 4-54
Figure 4.46 BD551 Component Layout ............................................................................... 4-55
Figure 4.47BD561 Component Layout ................................................................................ 4-59
Figure 4.48 BD553 Component Layout ............................................................................... 4-62
Figure 4.49 BD563 Component Layout ............................................................................... 4-63
Figure 4.50 BD554 Component Layout ............................................................................... 4-68
Figure 4.51 BD556 Component Layout ............................................................................... 4-70
Figure 4.52 External appearance of SMPS SR1 and configuration mounted in Rack ........ 4-72
Figure 4.53 Electrical Module .............................................................................................. 4-73
Figure 4.54 The Interior of Electrical Module ....................................................................... 4-73
Figure 4.55 Power system of controller Hi5 ......................................................................... 4-74
Figure 4.56 Connectors of the Electrical Board (BD5C0) .................................................... 4-75
Figure 4.57 The Components of the Small Door Board (BD5B1) ........................................ 4-77
Figure 4.58 The Exterior and Interior of the Small Door Board (BD5B1) ............................ 4-77
Figure 4.59 Appearance of teach pendant TP510 ............................................................... 4-78
Figure 4.60 USB cover of teach pendant TP510 ................................................................. 4-79
Figure 5.1 Public IO Board (BD580) ...................................................................................... 5-2
Figure 5.2 Pin Configuration of Digital Input Terminal Block of Public IO Board (BD580) ..... 5-3
Figure 5.3 Wiring of Input Signals of the Public IO Board (BD580) ....................................... 5-4

vi
Figure 5.4 Pin Configuration of Digital Input/Output Terminal Block of the Public IO
Board(BD580) .......................................................................................................... 5-5
Figure 5.5 Method for the Connection of the Output Signals of the Public IO Board (BD580)
................................................................................................................................. 5-6
Figure 5.6 Power Connectors of the Public IO Board (BD580), CNP1 and CNP2 ................ 5-7
Figure 5.7 Method for the Connection of CAN Connectors of the Public IO Board (BD580) 5-8
Figure 5.8 Relay Output Board of Public IO Board (BD581) ............................................... 5-10
Figure 5.9 Method for the Installation of Relay Board ......................................................... 5-10
Figure 5.10 Public IO Board (BD582) .................................................................................. 5-12
Figure 5.11 CNIN Connector (3M MDR 10240-52A2JL) of the Public IO Board (BD582) .. 5-13
Figure 5.12 3M MDR 10140-3000VE (HOOD:1030-55F0-008) of CNIN Connector Plug of the
Public IO Board (BD582) ....................................................................................... 5-13
Figure 5.13 Method for Wiring Input Signals of the Public IO Board (BD582)..................... 5-16
Figure 5.14 CNOUT Connector (3M MDR 10250-52A2JL) of the Public IO Board (BD582)
............................................................................................................................... 5-17
Figure 5.15 3M MDR 10150-3000VE (HOOD;10350-52F0-008) of the CNOUT Connector
Plug of the Public IO Board (BD582) ..................................................................... 5-17
Figure 5.16 Method for Connection of Output Signals of the Public IO Board (BD582) ...... 5-20
Figure 5.17 Power Connector CNP1 of the Public IO Board (BD582) ................................ 5-21
Figure 5.18 Method for Connection of the CAN Connector of the Public IO Board (BD582)
............................................................................................................................... 5-21
Figure 5.19 CC-LINK Board (BD570) .................................................................................. 5-23
Figure 5.20 CC-LINK Communication Terminal Block of CC-LINK Board (BD570) ............ 5-24
Figure 5.21 Power Connector CNP1 of CC-LINK Board (BD570) ....................................... 5-24
Figure 5.22 Method for the Connection of the CAN Connector of the CC-LINK Board (BD570)
............................................................................................................................... 5-25
Figure 5.23 LED and Detail of Communication Status Indication of CC-LINK Board (BD570)
............................................................................................................................... 5-26
Figure 5.24 Setting Station Number and Communication Speed of the CC-LINK Board
(BD570) ................................................................................................................. 5-26
Figure 5.25 Method for Setting of the Number of Stations of the CC-LINK Board (BD570) 5-26
Figure 5.26 Conveyor I/F Board (BD585) ............................................................................ 5-27
Figure 5.27 Conveyor Connection Terminal Block of the Conveyor I/F Board (BD585) ...... 5-28
Figure 5.28 Power Connector CNP1 of Conveyor I/F Board (BD585) ................................ 5-28
Figure 5.29 Method for the Connection of CAN Connector of the Conveyor I/F Board (BD585)
............................................................................................................................... 5-29
Figure 5.30 LED and Detail for Conveyor I/F Board (BD585) Status Indication .................. 5-30
Figure 5.31 Appearance of the LDIO Board (BD58A) .......................................................... 5-31
Figure 5.32 Digital Input Connector CNI of LDIO Board (BD58A) ....................................... 5-32
Figure 5.33 Digital Input Terminal Block TBI of LDIO Board (BD58A) ................................. 5-35
Figure 5.34 Method for Wiring the Input Signal of LDIO Board (BD58A) ............................ 5-37
Figure 5.35 Digital Output Terminal Block TBO of LDIO Board (BD58A) ............................ 5-38
Figure 5.36 CNO Connector of LDIO Board (BD58A) ......................................................... 5-40
Figure 5.37 Method for Wiring the Output Signal of LDIO Board (BD58A) (Photo MOSFET)
............................................................................................................................... 5-42
Figure 5.38 Method for Wiring the Output Signal of LDIO Board (BD58A) (Relay Contact
Point) ..................................................................................................................... 5-42
Figure 5.39 Serial Communication Terminal Block TBC of LDIO Board (BD58A) ............... 5-43
Figure 5.40 Power Connector CNP1 and CNP2 of LDIO Board (BD58A) ........................... 5-45
Figure 5.41 Method for Connecting the CAN Connector of LDIO Board (BD58A) .............. 5-46
Figure 5.42 Safety Relay Board (BD58B) ............................................................................ 5-49
Figure 5.43 Expansion Public IO Board (BD583) ................................................................ 5-53
Figure 5.44 Connector Configuration for Expansion Public IO Board (BD583) ................... 5-54
Figure 5.45 Pin Configuration of Digital Input Terminal Block on Expansion Public IO Board
(BD583) ................................................................................................................. 5-55
Figure 5.46 Method for Wiring Input Signal of Expansion Public IO Board (BD583) .......... 5-56

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Figure 5.47 Pin Configuration of Digital Input/Output Terminal Block on Expansion Public IO
Board (BD583) ....................................................................................................... 5-57
Figure 5.48 Method for Wiring Output Signal of Expansion Public IO Board (BD583) ........ 5-59
Figure 5.49 Power Connector CNP1 and CNP2 of Expansion Public IO Board (BD583) ... 5-60
Figure 5.50 Method of Connecting the CAN Connector of Expansion Public IO Board
(BD583) ................................................................................................................. 5-61
Figure 5.51 Method for Connecting Terminating Resistance ............................................... 5-61
Figure 5.52 Analog/Arc IF Board (BD584) ........................................................................... 5-63
Figure 5.53 Configuration of Analog/Arc IF Board (BD584)................................................. 5-64
Figure 5.54 Terminal Block for Digital Input on Analog Board (BD584) ............................... 5-65
Figure 5.55 Method for Connecting Digital Input on Analog Board (BD584) ....................... 5-66
Figure 5.56 Common Circuit of Digital Input from Analog Board (BD584) .......................... 5-67
Figure 5.57 Terminal Block for Digital Output on Analog Board (BD584) ............................ 5-68
Figure 5.58 Method for Connecting the Digital Output on Analog Board (BD584) .............. 5-70
Figure 5.59 Common Circuit of Digital Output on Analog Board (BD584) ........................... 5-71
Figure 5.60 Terminal Block for Analog Input on Analog Board (BD584) .............................. 5-72
Figure 5.61 Method for Connecting Analog Input on Analog Board (BD584) ...................... 5-73
Figure 5.62 Analog Output Terminal Block on Analog Board (BD584) ................................ 5-74
Figure 5.63 Method of Connecting Analog Output on Analog Board (BD584) .................... 5-75
Figure 5.64 Analog Stick Check Function on Analog Board (BD584) .................................. 5-76
Figure 5.65 Power Connector CNP1 of Analog Board (BD584) .......................................... 5-77
Figure 5.66 Method of Connecting CAN Connector on Analog Board (BD584) .................. 5-78
Figure 7.1 Inspection Schedule ............................................................................................. 7-2

viii
 Table contents
Table 목차

Table 1-1 Safety marking ....................................................................................................... 1-5

Table 1-2 State of Robot Stop .............................................................................................. 1-16
Table 2-1 The specifications of Hi5 robot controller ............................................................... 2-2
Table 2-2 Power Supply Requirements .................................................................................. 2-3
Table 3-1 Weight of Controller ............................................................................................. 3-14
Table 3-2 Weight of Hi5 Controller by Models...................................................................... 3-14
Table 3-3 Power Conditions ................................................................................................. 3-32
Table 3-4 Recommended Cable of Least Thickness ........................................................... 3-32
Table 3-5 Pin Descriptions (RS232 connector specifications; DSUB9S-M) ........................ 3-34
Table 3-6 Pin Descriptions (RJ45 connector specifications; RJ 45P SHIELD) .................... 3-34
Table 4-1 The Name of Each Part of Hi5-N00 Controller ....................................................... 4-4
Table 4-2 The Name of Each Part of Hi5-C10 Controller ....................................................... 4-7
Table 4-3 The Name of Each Part of Hi5-C20 Controller ..................................................... 4-11
Table 4-4 The Summary on the Function of Each Component ............................................ 4-15
Table 4-5 The Sorts and Uses of Mainboard (BD510) ......................................................... 4-18
Table 4-6 Mainboard (BD510) LED ...................................................................................... 4-18
Table 4-7 The Method for Setting of the [DIP 1] Switch of the Mainboard (BD 510) ........... 4-19
Table 4-8 The Method for Setting of the [DIP 2] Switch of the Mainboard (BD510) ............ 4-19
Table 4-9 The Method for Setting of the Serial Communications Jumper of the Mainboard (BD
510)........................................................................................................................ 4-20
Table 4-10 The Method for Setting of CAN Communications Jumper of the Mainboard
(BD510) ................................................................................................................. 4-20
Table 4-11 The Sorts and Uses of the Connectors of the System Board (BD530) .............. 4-23
Table 4-12 The Terminal Block TBEM of the System Board (BD530) ................................. 4-25
Table 4-13 Terminal Block TBIO of the System Board (BD530) .......................................... 4-26
Table 4-14 System board (BD530) terminal block TBRMT description ............................... 4-27
Table 4-15 System board (BD530) terminal block TBPLC description ................................ 4-28
Table 4-16 Description of the displaying device for the system board (BD530) .................. 4-31
Table 4-17 System board (BD530) DIP switch SW1 (error monitoring) setting method ...... 4-33
Table 4-18 System board (BD530) DIP switch SW2 (AC power monitoring) setting method
............................................................................................................................... 4-33
Table 4-19 System board (BD530) DIP switch SW3 (Motor temperature sensor monitoring)
setting method ....................................................................................................... 4-34
Table 4-20 System board (BD530) DIP switch SW4 (Added axis OVT limit switch) setting
method ................................................................................................................... 4-34
Table 4-21 System board (BD530) DIP switch SW5 (Dark interference, extending axis limit
switch) setting method ........................................................................................... 4-35
Table 4-22 System board (BD530) DIP switch SW6 (Safety IO safety signal monitoring)
setting method ....................................................................................................... 4-35
Table 4-23 System board (BD530) DIP switch SW7 (Power for Safety IO signal) setting
method ................................................................................................................... 4-36
Table 4-24 Description of system board (BD530) toggle switch SWT1-8 operation ............ 4-36
Table 4-25 The Sorts and Uses of Servo Board (BD 542) Connectors ............................... 4-48
Table 4-26Servo Board (BD542) LED .................................................................................. 4-48
Table 4-27 The Method for the Setting of DIP Switches (S1) of the Servo Board (BD542). 4-49
Table 4-28 The Method for the Setting of DIP Switch (DS1) of the Servo Board (BD542) .. 4-49
Table 4-29 The DIP Switch (DS2: Pin 1 and 2)of the Servo Board (BD542) ....................... 4-50
Table 4-30 The DIP Switch (DS2: Pin 3 and 4)of the Servo Board (BD542) ....................... 4-50
Table 4-31 The Components of SA3X3Y(Medium-Scale 6-Axis All-In-One Drive unit) ....... 4-51
Table 4-32 The Mark of Type of Servo Driver Series ........................................................... 4-52
Table 4-33 The Specifications of Drive Unit ......................................................................... 4-52
Table 4-34 IPM Capacity ...................................................................................................... 4-53

ix
Contents

Table 4-35 Hall Sensor Marks .............................................................................................. 4-53

Table 4-36 BD552 Connector ............................................................................................... 4-56
Table 4-37 BD551 Connector ............................................................................................... 4-56
Table 4-38 BD552 LEDs ...................................................................................................... 4-56
Table 4-39 The Mark of Type of Driver Series ..................................................................... 4-58
Table 4-40 The Specifications of Drive Power Unit .............................................................. 4-58
Table 4-41 The Specifications of Regenerative IGBT .......................................................... 4-58
Table 4-42 Chemical Condenser Capacity........................................................................... 4-58
Table 4-43 SD1L2C (Medium-Scale Diode Module Converter) ........................................... 4-58
Table 4-44 Medium-Scale Drive Power Unit (SD1L2C) Connector ..................................... 4-60
Table 4-45 Medium-scale Drive Power Unit (SD1L2C) LED................................................ 4-60
Table 4-46 Construction of SA3A3D (Small sized-6 axes integral type-driving apparatus) . 4-61
Table 4-47 Description of connector BD553 ........................................................................ 4-64
Table 4-48 Description of BD553 LED ................................................................................. 4-64
Table 4-49 Description of connector BD563 ........................................................................ 4-64
Table 4-50 Description of BD563 LED ................................................................................. 4-65
Table 4-51 The Mark of Type of Driver Series ..................................................................... 4-66
Table 4-52 IPM Capacity ...................................................................................................... 4-67
Table 4-53 Hall Sensor Marks .............................................................................................. 4-67
Table 4-54 The Components of SA1X(Medium-Scale 1 Axis Drive Unit ; Option) ............... 4-69
Table 4-55 SA1X (Medium-Scale 1 Axis Drive Unit ; Option) Connector ............................. 4-69
Table 4-56 The Composition of SA1A (Small-scale 1 Axis Drive Unit; Option) .................... 4-71
Table 4-57 SA1A(Small-Scale 1 Axis Drive Unit ; Option) Connector ................................. 4-71
Table 4-58 SMPS(SR1) Standards (Input Voltage ; AC 45V~50V, 50/60Hz) ....................... 4-72
Table 4-59 The Sorts and Uses of Fuses in the Electrical Module ...................................... 4-74
Table 4-60 Types and applications of fuses in the electronic control module ...................... 4-76
Table 5-1 Pin Configuration of Digital Input Terminal Block (TBln*) of Public IO Board (BD580)
................................................................................................................................. 5-3
Table 5-2 Pin Configuration of Digital Input/Output Terminal Block (TBOn*) of the Public IO
Board (BD580) ......................................................................................................... 5-5
Table 5-3 Settings of the DSW1 Switch of the Public IO Board (BD580) .............................. 5-9
Table 5-4 Pin Configuration of the Digital Output Terminal Block (TBOUT) of the Relay Board
(BD581) ................................................................................................................. 5-11
Table 5-5 Pin Configuration of Digital Input Connector CNIN of the Public IO Board (BD582)
............................................................................................................................... 5-14
Table 5-6 Pin Configuration of the Digital Input Connector CNOUT of the Public IO Board
(BD582) ................................................................................................................. 5-18
Table 5-7 Method for Setting of the DSW1 Switch of the Public IO Board (BD582) ............ 5-22
Table 5-8 Pin Configuration of the Digital Input Connector CNI of the LDIO Board (BD58A)
............................................................................................................................... 5-33
Table 5-9 Terminal Configuration of the Digital Input Terminal Block TBI of the LDIO Board
(BD58A) ................................................................................................................. 5-36
Table 5-10 Terminal Configuration of the Digital Output Terminal Block TBI of the LDIO
Board (BD58A) ...................................................................................................... 5-39
Table 5-11 Pin Configuration of the Digital Input Connector CNO of the LDIO Board (BD58A)
............................................................................................................................... 5-41
Table 5-12 Terminal Configuration of Serial Communication Terminal Block TBC of LDIO
Board (BD58A) ...................................................................................................... 5-44
Table 5-13 Pin Configuration of the Power Connector of the LDIO Board (BD58A) ........... 5-45
Table 5-14 Method for Setting Station Number and Communication Speed of CC-LINK in the
LDIO Board (BD58A) ............................................................................................. 5-47
Table 5-15 Method for Setting the Number of Stations of CC-LINK of the LDIO Board
(BD58A) ................................................................................................................. 5-48
Table 5-16 LDIO Jumper SWSEL for Selecting CC-LINK Set in the LDIO Board (BD58A) 5-48
Table 5-17 Pin Configuration of the Belt Sensor Terminal Block TTBO in the Safety Relay
Board (BD58B) ...................................................................................................... 5-50

x
Table 5-18 Pin Configuration of the Limit Sensor Terminal Block TBLS in the Safety Relay
Board (BD58B) ...................................................................................................... 5-51
Table 5-19 Pin Configuration of Power 24V Terminal Block (TBP124) in the Safety Relay
Board (BD58B) ...................................................................................................... 5-51
Table 5-20 Pin Configuration of Power GND Terminal Block (TBM124) in the Safety Relay
Board (BD58B) ...................................................................................................... 5-51
Table 5-21 Connector Type and Usage of Safety Relay Board (BD58B) ............................ 5-52
Table 5-22 Pin Configuration of Digital Input Terminal Block (TBln*) of Expansion Public IO
Board (BD583) ....................................................................................................... 5-55
Table 5-23 Pin Configuration of Digital Output Terminal Block (TBOn*) on Expansion Public
IO Board (BD583) .................................................................................................. 5-57
Table 5-24 Method for Setting DSW1 Switch of Expansion Public IO Board (BD583) ........ 5-62
Table 5-25 Pin Configuration of Digital Input Terminal Block (TBDI) of Analog Board (BD584)
............................................................................................................................... 5-65
Table 5-26 Pin Configuration of Digital Output Terminal Block (TBD01) on Analog Board
(BD584) ................................................................................................................. 5-68
Table 5-27 Pin Configuration of Digital Output Terminal Block (TBD02) on Analog Board
(BD584) ................................................................................................................. 5-69
Table 5-28 Pin Configuration of Analog Input Terminal Block (TBAI) on Analog Board (BD584)
............................................................................................................................... 5-72
Table 5-29 Pin Configuration of Analog Output Terminal Block (TBAI) on Analog Board
(BD584) ................................................................................................................. 5-74
Table 5-30Pin Configuration of Power Connector CNP1 on Analog Board (BD584) ........... 5-77
Table 5-31 Pin Configuration of CAN Connector on Analog Board (BD584) ....................... 5-78
Table 6-1 Location of Fans for Each Controller ................................................................... 6-17
Table 6-2 Method to Check the whether the Rated Voltage on System Board is Normal or Not
............................................................................................................................... 6-37
Table 6-3 Pin Locations for CAN Connector of User‟s Module ............................................ 6-42
Table 6-4 Error on safety related device‟s wiring ............................................................... 6-110
Table 6-1 Power Standard .................................................................................................. 6-147
Table 7-1 Daily Inspection ...................................................................................................... 7-4
Table 7-2 First Inspection ....................................................................................................... 7-4
Table 7-3 Daily Inspection ...................................................................................................... 7-5
Table 7-4 Maintenance Parts Inspection A............................................................................. 7-8
Table 7-5 Maintenance Parts A-1 (Standard accessory parts to prepare) ............................. 7-8
Table 7-6 Maintenance Parts A-2 (Major Backup Parts) ........................................................ 7-9
Table 7-7 Maintenance Parts A-3 (Regular Replacement Parts) ........................................... 7-9
Table 7-8 Maintenance Parts Inspection B .......................................................................... 7-10
Table 7-9 Maintenance Parts B-1 (Parts to purchase from HHI (Co.,Ltd.)) ......................... 7-10
Table 7-10 Maintenance Parts B-2 (Purchasable Parts from Maker) .................................. 7-10

xi
 1. Safety

1. Safety

1
Safety

1-1
 1. Safety Hi5 Controller Maintenance Manual

1.1. Introduction
The main purpose of this chapter is to describe the safety precautions for users and operators who
repair and manipulate the industrial robot.

This manual describes safety precautions for robot manipulator and controller, in complies with the
safety regulation of EU Machinery Directive 98/37/EC(2006/42/EC) and US OSHA. And the robot
manipulator and controller is manufactured to comply with the safety standards EN ISO 10218-1:2006
and ANSI/RIA R15.06-1999.

Every operator, who installs, replaces, adjusts, manipulates, maintains, and repairs, must read
thoroughly and fully understand the manipulation and maintenance manual, in particular, the special
attention must be paid to the WARNING symbol, the most important marking related to the safety.

Installation, replacement, adjustment, manipulation, maintenance, and repair of robot system must be
performed by the personnel who was duly trained for these purposes, following the indicated operating
procedure.

This company is planning and carrying out the relevant training such as maintenance, repair, and
manipulation for the above operations, so robot users make sure that robot operators should get the
relevant training. And make sure that the robot handling work should be carried out only by the
operators who completed this training course.

HHI user of industrial robot has responsibility to observe the safety regulation related to robot adopted
in corresponding countries and responsibility to design, install and operate safety equipment well in
order to protect workers who work at robot system.

The dangerous zone of robot system, that is the working range in which the robot, tool, and peripheral
equipment are operated, must be safeguarded to prevent workers or objects from entering the zone. If
a person or object should nevertheless enter the dangerous zone, make sure that the robot system is
immediately shut down by emergency stop system. The operators of robot system have a
responsibility to take all necessary steps to make correct installation, examination and operation of the
relevant safety devices.

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 1. Safety

Enable application and disable environment of robots are as follows.

Application

It is applied to the industrial robot used by installing on the surface of wall or plane (axes addable). It is
also appropriate for controlling operation in the dotted section or consecutive section.

Major application is

 Spot welding
 Arc welding
 Cutting
 Handling
 Assembly
 Application such as Sealing
 MIG/MAG welding
 Palletizing
 Grinding
 LCD manufacturing process

For the other use than the above emergency application, make a contact with our company to consult
on the robot use and possible applications.

Disable environment

Our robot must not be used in a highly explosive environment and the areas contaminated by oil,
flammable materials or chemical materials. (Prohibited to be installed and manipulated.)

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 Hi5 Controller Maintenance Manual

1.2. Relevant Safety Regulations

The robot is designed as per ISO 10218-1:2006 safety standards for industrial robots, and furthermore
in comply with ANSI/RIA 15.06-1999 regulations.

1.3. Safety Training

All the personnel who intend to teach, operate or inspect the robot must be trained in an approved
robotic operation and safety training course before start-up. The safety training course includes the
following details:

 Purpose and functions of safety devices

 Safety procedure to handle the robot
 Performance of robot or the robot system and possible hazards
 Tasks associated with any specific robot applications
 Safety concepts, etc.

1-4
 1. Safety

1.4. Safety Related Nameplate

1.4.1. Safety Marking
For the purpose of effective safety instructions, the following safety symbols are used in this manual.

Table 1-1 Safety marking

Symbols Descriptions

Indicate a potentially hazardous situation which, if not avoided, could

Warning result in death or serious injury to personnel and damage to equipment.
The special attention must be paid to the operation and handling.

Mandatory Indicate the compulsory measures that should be performed.

Indicate the prohibited actions and/or operations that should not be

Prohibited
performed.

1.4.2. Safety Nameplate

Identification plates, warning label and safety symbols are attached to the robot and to the inside and
outside of control panel. The designation labels and cable Mark for wire harness between the robot
and control panel, and the cables inside/outside of control panel are provided.

All of these plates, labels, symbols and marks constitute safety-relevant parts of the robot and the
control panel. They must remain attached to the robot manipulator and control panel at their clearly
visible positions all the time for the safety and their full performance.

The painted markings on the floor and signs indicating dangerous zones must be clearly distinguished
in form, color, and style from other markings on the machine near the robot system or inside the plant
facilities where the robot system is installed.

It is forbidden to remove, cover, or paint over by way of spoiling the clearly visible
identification plates, warning labels, safety symbols, designation labels and cable
marks.

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 Hi5 Controller Maintenance Manual

1.5. Definition of Safety Functions

Emergency Stop Functions – IEC 204-1,10,7
There is one emergency stop button on the controller and teach pendant respectively. If necessary,
additional emergency buttons should be able to connect to the robot's safety chain circuit. The
emergency stop function, which overrides all other robot controls, stops all moving parts by
disconnecting power supply, and removes drive power to prevent the use of other dangerous functions
controlled by the robot.

Safety Stop Function - EN ISO 10218-1:2006

When a safety stop circuit is provided, each robot must be delivered with the necessary connections
for the safeguards and interlocks associated with this circuit. The robot should have a number of
electrical input signals which can be used to connect external safety devices, such as safety gates,
safety pads, and safety lamps. These signals allow the robot's safety functions to be activated by all
equipment, including peripheral equipment and the robot itself.

Speed Limitation Function - EN ISO 10218-1:2006

In a manual mode, the speed of robot is strictly limited to 250 mm per second as maximum.
The speed limitation applies not only to the TCP(Tool Center Point), but to all parts of manual mode
robot. The speed of equipment mounted on the robot should be possibly monitored.

Restricting working Envelope - ANSI/RIA R15.06-1999

Operation area of each axis is restricted by soft limit and hardware limit. Axis 1, 2, and 3 can also be
restricted by means of mechanical stopper.

Operation Mode Selection - ANSI/RIA R15.06-1999

The robot must be operated either manually or automatically. In a manual mode, the robot must be
operated only by using the teach pendant.

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 1. Safety

1.6. Installation
1.6.1. Safety Fence

Install safety fence against the possible collision between the robot and workers,
so that no worker may approach the robot.

Install safety fence against the possible collision between the robot and workers, so that no worker
may approach the robot. When operators or other personnel enter the robot's working envelope by
accident, it may cause an accident. Install the safety fence to stop the robot when one, who intends to
replace for TIP DRESSING or TIP changing replacement, or to inspect welding equipment, opens the
fence gate and approaches the equipment during operation.

Figure 1.1 Recommended size for safety net and entrance gate (slot type entrance gate)

Figure 1.2 Recommended size for safety net and entrance gate (square type entrance gate)

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 Hi5 Controller Maintenance Manual

(1) Enough space for safety net should be secured by covering robot operating area so as that
workers would not have difficulty in teaching work or repairing work, and the safety net should
have solid structure in order that it would not move easily and man cannot enter over easily.

(2) Safety net should be installed by static type in principle, and should not have hazardous parts
such as prominence and depression or keen part, etc.

(3) Install the safety fence with an entrance gate, and register the safety plug at the gate so that
it does not open unless pulling the plug out. And, please make wiring with interlock so that
robot would be operation ready OFF and motor OFF in the status that safety plug is pulled
out or safety net is open.

(4) When intending to operate the robot with the safety plug pulled out, wire the robot as a
low-speed play mode.

(5) For immediate emergency stop, install emergency stop button within operator‟s easily
accessible distance.

(6) In case of no safety net, please install photoelectric switch, mat switch and so on instead of
safety plug in all range of robot operation, and make robot to stop automatically when man
goes into.

(7) Operation area of robot (hazardous area) should be distinguished by the method like painting
on floor.

1-8
 1. Safety

1.6.2. Placement of Robot & Peripheral Equipment

Please make sure that robot and peripheral equipment should be arranged by
following method.

(1) In case of connecting primary power of controller or peripheral devices, please work after
checking whether supply power has been deleted. There is a possible danger of electric
shock because the high voltage such as 220V and 440V is used as its primary power.

(2) Post a sign [No enter during operation] up the safety fence gate, and inform the operators of
its purport.

(3) Arrange such devices as controller, interlock panel, and other manipulation panels to be
handled outside of the safety fence.

(4) When installing operation stand, install the emergency stop button on the stand. Make sure
that the stand stops in an emergency wherever the robot is handled.

(5) Make sure that the robot manipulator and the wiring and piping of controller, interlock panel,
and timer should not be placed in the way of operator's working range so that they would not
be directly stepped on by FORK and LIFT. The accident by falling down of work or wire cut
can happen.

(6) Place the controller, interlock panel, and handling stand within the sight of robotic
performance. It may cause a serious accident to operate the robot while the operator is
working, or the robot is malfunctioning in an invisible sight.

(7) Restrict the robot's working envelope by using soft limits and mechanical stopper if the
necessary working envelope is narrower than the holding workable envelope. It is possible to
stop the robot in advance when it moves beyond its normal working envelope due to an
abnormal condition. (Refer to the 『Robot Manipulator Maintenance Manual』.)

(8) During weld, spatter can fall down to workers or the workers can be injured by burning, or fire
can break out. Install such devices as a glare shield or a cover in the full sight of robot's
working envelope.

(9) Make sure that the device indicating the robot's running condition whether automatic or
manual mode must be noticeable even in the far distance. In the case of automatic start-up,
warning with a buzzer or warning lamp is also enable.

(10) Make sure that there is no projecting part in the robot's peripheral equipment. Cover it, if
necessary. It usually may cause an accident if the operator comes in touch with it. And it may
lead a serious accident if the operator is astonished at the sudden movement of robot, and
conducts it.

(11) Don't make the system designed to allow the workers to carry the Work in and out using their
hands through the safety fence. It could be a cause of accident associated with compressing
or amputating.

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 Hi5 Controller Maintenance Manual

HC1300C2D 5G 원통형
HC1300C2D 5G 원통형

Operator
Operator

Controller
Interlocked Barrier Guard Controller
Interlocked Barrier Guard

(Cylinder type)
HC1300B1D 5G 빔형
HC1300B1D 5G 빔형

Operator
Operator

Controller

Interlocked Barrier Guard Controller

(Beam type)
Interlocked Barrier Guard
Restricted Maximum Safeguarded
space space space
Restricted Maximum Safeguarded
space space space
Figure 1.3 Arrangement of LCD robot peripheral devices and workers

1-10
 1. Safety

in

11
)M

0
4"

cm
(4

(4
cm

4
")
0
11

M
in

110 cm(44") Min

Operator

Controller
Interlocked Barrier Guard

Restricted Maximum Safeguarded

space space space

Figure 1.4 Arrangement of general robot peripheral devices and workers

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 Hi5 Controller Maintenance Manual

1.6.3. Installing the Robot

Please install the robot in accordance with following method surely.

Install the robot as per the planning and layout which has been previously reviewed and studied for its
optimized performance and functionality. In case of poor conditions for robot installation, the serious
problems can take place, including error of relative position between robot and workpiece during
operation, bad performance quality of robot caused by vibration, shortening lifetime, and cause of
serious accidents. Thus, pay attention to the following precautions when installing the robot.

General Safety Precautions

(1) Design and install the robot system properly in compliance with laws, regulations, and safety
requirements enable in the country where the robot system is installed.

(2) All the workers for the robot system must have the complete knowledge on the information
specified in the application and supplementary manual, and proficiently operate and handle
the industrial robot.

(3) Installation workers of robot must follow the safety instructions and apply them to the
installation when they face any safety problems.

(4) System provider must ensure that all the circuits utilizing safety functions perfectly perform in
a safe way.

(5) Install main power supply to be disconnected from outside of the robot‟s working envelope.

(6) System provider must ensure that all the circuits utilizing emergency stop function perfectly
perform in a safe way.

(7) For the immediate emergency stop, install emergency stop button within the accessible
distance for the operator.

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 1. Safety

Technical Safety Precautions

(1) Eliminate any interference with peripheral equipment considering the dimension and working
envelope.

(2) Avoid such place for installing which is directly exposed to the sun, extremely humid,
contaminated by oil or chemicals, and containing a large amount of metal powder and
explosive gas.

(3) Install at the ambient temperature ranged 0~45℃.

(4) Secure sufficient space for the easier disassembly and maintenance.

(5) Install safety fence with a gate, and prohibit any person from entering the robot's working
envelope.

(6) Remove any obstacles out of the robot‟s working envelope.

(7) Take a special measure, considering thermodynamics of controller, if the robot is installed
near the heating elements or places exposed directly to the sun.

(8) Take a special measure if the robot is installed in a place of abundant dust such as metal
powder in the air.

(9) Install the robot not to transmit welding electric current. In other word, insulate SPOT GUN
with/from the robot‟s wrist.

(10) Grounding is very critical in preventing electric shock and malfunction caused by noise, and
thus install as following instructions.

① Install an exclusive grounding terminal using class 3 or higher. (For the input voltage of
400V of higher, use special class 3 or higher.)

② Connect grounding line into the grounding bus-bar inside of the control panel.

③ In case of direct grounding on the floor by anchoring, two-point grounding both by robot
manipulator and by controller can produce a “ground loop” and contrariwise cause
abnormal operation. In this case, connect the grounding line to the base of robot
manipulator and disconnect the second grounding point to the controller. If the robot
vibrates even after stopping, double-check the grounding status because the possible
main causes could be an incomplete grounding or “ground loop”.

④ In the use of internal transgun(GUN), there is a possible danger of dropping because the
primary power cable is directly connected to the spot gun. In this case, directly connect
the grounding line to the base of robot manipulator in order to prevent any electric shock
and protect the control panel, but do not connect it to the controller.

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 Hi5 Controller Maintenance Manual

1.6.4. Space for Robot Installation

Install robot after securing sufficient space for maintaining the robot manipulator, controller, and other
peripheral equipment. To install the main body and controller, please secure the above mentioned
installation area. Install controller outside of the safety fence in order to monitor the robot manipulator
and to operate in a safe way.
When installing, be sure to make it easier to perform the maintenance when opening the Controller
door. Secure the available space. The specifications of the controller can change according to the type
of the controller. (For more details, please refer to the “Maintenance manual”.)

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 1. Safety

1.7. Safety Operation for Robot Handling

Follow the safety instructions to prevent any accidents. Don't modify nor ignore safety devices or
circuits at any time, and be careful of electric shock.
All the normal operations in an automatic mode must be performed outside of the safety fence. Check
the robot's working envelope if anyone is inside before operating.

1.7.1. Safety Precautions for Robot Handling

Please observe following countermeasures because safety is very important on

operation of robot.

(1) Do not handle the robot other than such personnel as operators handling the robot and other
possible operators and supervisors who were designated as whom duly trained in an
approved robotic training course and become familiar enough with the proper operation of the
safety and robotic functions.

(2) Be sure to wear helmets, goggles, and safety shoes.

(3) Perform the work in pairs. One person must be ready to press the emergency stop button in
an emergency while the other must perform his work quickly but carefully within the robot‟s
working envelope. Always check the escape route before working.

(4) Make sure that there is no one in the working envelope when the power source is on.

(5) Operations such as teaching must be performed outside of the robot's working envelope.
However, if the operation is performed within the working envelope after stopping the robot,
enter the envelope with safety plug or key switch for converting to automatic mode. Make
sure that other operators do not change it into automatic mode by accident. Also, pay close
attention to the specific direction of robotic movement in case of abnormal operation and
malfunction.

(6) Supervisors should follow the instructions below.

① Be located at a place where you could take an entire view of robot, and commit yourself
to monitoring.
② Press the emergency stop button immediately when abnormality is found.
③ Anyone is forbidden to be near the operating area other than those who are engaged in
the operation.

(7) In a manual mode, the speed of teaching is limited to 250mm/sec.

(8) In teaching, post a sign [Under Teaching].

(9) Operators must pull the safety plug out, and enter the safety fence with the plug.

(10) Do not use any devices causing noise in and around the teaching area.

(11) Handle the teach pendant button, while checking the teaching point with your naked eyes,
and do not handle it just relying on your sense.

(12) It is a repairing part to be prepared for when you buy many sets.

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 Hi5 Controller Maintenance Manual

(13) In teaching, check and examine carefully under your feet. In particular, in high teaching for
more than 2M, secure a safe zone on which you may step before teaching.

(14) Instructions for any abnormal operations.

① Press immediately the emergency stop button when any abnormal operations are found.
② Be sure to check if the relevant equipment is stopped when checking the abnormality in
an emergency stop.
③ In case that the robot stops automatically due to power failure, investigate possible
causes and take actions after confirming that the robot completely stops.
④ In case of malfunction of emergency stop devices, immediately disconnect the main
power and investigate possible causes to take necessary actions.
⑤ Investigation of the failure must be conducted only by a designated person. For the
re-operation after emergency stop, operators must clarify the cause of failure and take
necessary actions, and then operate the robot again following the proper procedure.

(15) Write out the operating rules proper to working details and installing location regarding the
operation and handling method for the robot, and the necessary actions for robot's any failure.
In addition, it is recommended to operate the robot in accordance with the operating rules.

(16) Instructions when the robot stops

Make sure not to approach the robot even when it seems to be stopped. Most accidents
occur from a sudden movement of robot which seemed to be stopped when one approaches
it. The conditions that the robot stops are as follows.

Table 1-2 State of Robot Stop

No. State of Robot Drive Power Access

Pause
1 ON X
(Minor failure, Pause switch)
Emergency stop
2 OFF O
(Major failure, Emergency stop switch, Safety gate)
Input signal standby of peripheral equipment
3 ON X
(START INTERLOCK)

4 Playback Completion ON X

5 Standby ON X

Even in the accessible state of robot, be watchful against any possible sudden movement of
robot. Make sure to avoid approaching the robot without precautions for emergency under all
circumstances.

 During temporary halt, the entrance countermeasure same as entrance of teaching

work should be considered at the case (nozzle contact, welded part detected, arc error,
and so on) of opening entrance gate for simple management against error.

(17) Clean up any split oil, tools, and impurities in the safety fence after completing robotic
operation. Accidents such as conduction may occur in the working envelope contaminated by
oil, or scattered tools on its floor. Make a habit of organizing and cleaning things up.

1-16
 1. Safety

1.7.2. Safety Precautions for Operating Test

Please observe following countermeasures because safety on robot operation is

very important.

In case of operating test, errors in design or teaching and inferiority in manufacturing are possibly
seen in the entire system such as teaching program, jig, and sequence. Thus, be more careful and
safe in case of operating test. Accidents may occur by these combined causes.

(1) Before handling, check the stop buttons and signal functions to stop the robot such as
emergency stop button or stop button. And then, check the abnormality - detective
movements. Above all, it is the most critical to check all the stop signals. It would be the most
important to stop the robot when any possible accidents are predicted.

(2) In case of operating test, start the robot at low speed(approximately 20%~30%) in the
variable speed function, and repeat it more than one cycle to check the movements. If any
errors are found, immediately correct them. After then, increase in speed (50% → 75% →
100%) gradually, and repeat more than one cycle respectively to check the movements.
Operating at high speed from the very beginning may cause a serious accident.

(3) In case of operating test, it is hard to predict what problems would happen. Do not enter the
safety fence during operating test. Unexpected accidents are likely to occur because of its
low reliability.

1-17
 Hi5 Controller Maintenance Manual

1.7.3. Safety Precautions for Automatic Operation

Please observe following countermeasures because safety on robot automatic

operation is very important.

(1) While posting a sign [Do Not Enter During Operation] up the safety fence gate, ask the
operators not to enter during operation. If the robot stops, you may enter the safety fence
under your full understanding of the situation.

(2) Be sure to check if any operators are inside of the safety fence when starting the automatic
operation. Operating without checking the presence of operators may cause a personal
injury.

(3) Before starting the automatic operation, check and confirm that the program number, step
number, mode, and starting selection are in the possible state for automatic operation. If
starting with the other programs or steps selected, the robot could move in an unpredicted
way, and lead to an accident.

(4) Before starting the automatic operation, check if the robot is properly located to get started.
Check whether the program number or step number is identical with the location of robot.
Even if it's all identical, accidents are still possible to occur due to an abnormal movement
when the robot is differently located.

(5) Be prepared to immediately press the emergency stop button when starting the automatic
operation. Immediately press the emergency stop button in case of robot's unexpected
movements or emergency.

(6) Be sure to detect any abnormalities by checking the route, condition, or sound of robot
movement. Sometimes the robot may be abnormally operated including a sudden break
down. However, it will show a certain indication before the break down. Understand the
robot's normal condition well in order to catch the symptom in advance.

(7) When any abnormality is detected from the robot, immediately stop and take proper actions
on it. Using the robot before any proper actions taken may cause an interruption of produce
as well as serious failure leading to a very serious personal injury.

(8) When checking the robot‟s movement after the proper actions taken for the abnormality, do
not operate the robot with operators inside of the safety fence. Unexpected accidents are
possibly to occur because its low reliability may cause another abnormality.

1-18
 1. Safety

1.8. Safety Precautions for Access to Safety Fence

Please observe following countermeasures because safety on entering into

safeguard is very important.

The robot is very heavy and strong, even at low speeds. When entering the safety fence, one must
observe the relevant safety regulations of its pertinent country.
The operators always must be aware of the unexpected movements of robot. Robots are able to move
fast shortly after being stopped. The operators should know that the robot is able to move in a different
route, without any notice, by means of external signals. Thus, when trying to stop the robot during
teaching or operating test, one should be able to stop the robot with a teach pendant or control panel.

When entering the working envelope through the safety gate, take the teach pendant with you so that
other people may not operate the robot. Make sure to post up the control panel a sign indicating the
state of robot handling.

Read carefully and be aware of the follows when entering the working envelope.

(1) Do not enter the working envelope other than teaching person.

(2) Operation set-up mode of controller must be a manual mode in the control panel.

(3) Always wear the approved working suite.(Do not wear a loose clothes as you please)

(4) Do not wear gloves when handling controller.

(5) Do not leave innerwear such as underwear, shirts, or necktie out of the working suite.

(6) Do not wear personal accessories such as big earrings, rings, or necklaces.

(7) Make sure to wear safety shoes, helmet, and goggles and if necessary, wear other
self-protective outfit such as safety gloves.

(8) Make sure that the emergency stop circuit is working correctly and in its proper function, turns
MOTOR OFF when pressing the emergency stop button in the control panel and teach
pendant before handling the robot.

(9) Make your posture face-to-face with the robot manipulator when performing your work.

(10) Follow the predetermined working procedure.

(11) Be prepared for emergency exit or safe place considering that the robot may unexpectedly
rush at you.

1-19
 Hi5 Controller Maintenance Manual

1.9. Safety Precautions for Maintenance and Repair

1.9.1. Safety Precautions for Controller Maintenance and Repair

Please observe following safety countermeasures on repair and check for robot
controller.

(1) Maintenance and repair of the robot must be performed by the personnel who was duly
trained in the special maintenance training course and has a good knowledge of
maintenance.

(2) Perform your work following the maintenance procedures for controller.

(3) Perform your maintenance and repair in a safe way by securing emergency exit or safe
place.

(4) Before the daily maintenance, repair, or changing parts, be sure to power down. In addition,
post a warning sign [Do Not Input Power] up the primary power so that other operators may
not input power by accident.

(5) When changing parts, be sure to use the specified ones.

(6) When you open the door of controller, you should turn off power, and please start working
after 3 minutes.

(7) Please do not touch heat radiating plate of servo AMP and recovery resistance because they
are very hot.

(8) After completing maintenance, be sure to close the door completely after checking if tools or
other things are still remained in the controller.

1-20
 1. Safety

1.9.2. Safety Precautions for Robot System & Manipulator Maintenance

Please observe following safety countermeasures on repair and check for robot
controller.

(1) Refer to the safety precautions for Controller maintenance and repair.

(2) Perform your maintenance and repair for the robot system and manipulator, following the
indicated procedures.

(3) Be sure to disconnect the primary power of controller. Post the warning sign [Do not input
power] up the primary power to prevent other workers from connecting the power.

(4) Make sure that the Arm is fixed and immovable before maintenance and repair since
dropping or moving of the robot's Arm may cause a danger during maintenance and repair.
(Refer to the Robot manipulator maintenance manual.)

1.9.3. Necessary Actions after Maintenance and Repair

Please observe following managing articles after the repair and check.

(1) Check if the cables or parts of controller are properly connected.

(2) After maintenance is completed, carefully check that no tools are left around or inside of the
controller and manipulator. Make sure that the door is firmly closed.

(3) Do not turn on the power if any problems or critical failures are detected.

(4) Be sure that there is no one within the working envelope, and that you are in a safe place
before turning on the power.

(5) Turn on the main circuit breaker on the control panel.

(6) Check the current position and status of robot.

(7) Operate the manipulator at low speed.

1-21
 Hi5 Controller Maintenance Manual

1.10. Safety Functions

1.10.1. Operating a Safety Circuit

Figure 1.5 Configuration for safety chain

The robot's safety system is based on a two-channel safety circuit that is continuously monitored. If an
error is detected, the power supply to the motors is disconnected and the motor brake is applied. To
return the robot to MOTOR ON mode, the switches of two-channel circuit must be connected. If one of
the two-channel circuit switches shorts, the contactor of motor will be disconnected leading to the
application of brake, and finally the robot will be stopped. Furthermore, when safety circuit is
disconnected, the interrupting call will be sent automatically to the controller to find out the possible
reason for the interruption.

The safety control circuit of operation is based on dual safety electric circuit in which the controller and
MOTOR ON mode are operated interactively. In order to be in MOTOR ON mode, the safety circuit
consisted of several switches must be all connected. MOTOR ON mode indicates that drive power is
supplied to the motors. If one of the contactors is disconnected, the robot will always return to MOTOR
OFF mode.

MOTOR OFF mode indicates that drive power is removed from the robot's motors and the brakes are
applied. The status of the switches is displayed on the teach pendant. (Refer to the I/O monitoring
screen of "SERVICE" menu, Operation manual.)

1-22
 1. Safety

Safety circuit

The emergency stop buttons on the controller panel and on the teach pendant and external
emergency stop buttons are included in the safety circuit of operation. Users may install the safety
devices (safety plug, safety stop device for safe place) which are operated in the AUTO mode. In a
manual mode, the signals of these safety devices are ignored. You can connect the general safety
stop devices that is active in all operating modes. No one can enter the working envelope in an
automatic operation mode due to the unconditional operation of the safety devices (door, safety mat,
safety plug etc.). These signals are also generated in a manual mode, but the controller will keep the
robot operating while ignoring the robot's teaching. In this case, maximum speed of robot is restricted
to 250mm/s. Thus, the purpose of this safety stop function is to secure the safe area around the
manipulator while one approaches the robot for maintenance and teaching.

When the robot is stopped with the limit switch, change the robot‟s position by operating it with the
pendant key at the constant setting mode. (Constant setting mode refers to the status in the menu:
“『[F2]: System』 → 『3. Robot parameter』 → 『2. Axis constant』 / 『3. Soft limit』 / 『4. Encoder
offset』”.)

The safety circuits must never be by-passed, modified or changed in any way.

1-23
 Hi5 Controller Maintenance Manual

1.10.2. Emergency stop

An emergency stop should be activated when people or equipment is located at the dangerous area.
The emergency stop buttons are located both on the control panel and on the teach pendant.
All safety control devices such as emergency stop buttons on the control panel must be located
outside the working envelope and easily accessible at any time.

Status of Emergency stop

When the button is pressed, the robot will operate as follows.

Robot stops immediately in any cases.

 Disconnect the servo system power.

 Motor brake is activated.
 Emergency stop message is displayed on screen.

For the emergency stop, the following two methods can operated simultaneously.

(1) Emergency stop for control panel and teach pendant (Basic)

Above the control and teach pendant console.

(2) Emergency stop of external system

External emergency stop device (button etc.) can be connected to the safety electric circuit in
accordance with applied standard for the emergency stop circuit.
(Please refer to system board in “basic configuration of controller”) At this time, the
emergency stop must be connected to be “Normal On” and it must be check for proper
operation during test run.

TBEM

Figure 1.6 Connection with external emergency halt switch through system board terminal block TBEM

1-24
 1. Safety

1.10.3. Operating Speed

To teach the robot, the operating mode switch must be in a MANUAL mode. Then the maximum speed
of robot is limited to 250mm/s.

1.10.4. Connecting the Safety Devices

External safety devices such as light beams, light curtains, safety plug, and safety mats which can be
adapted by the system builder execute interlocking the controller by way of connecting with safety
circuit within the controller. These devices are used for safety device during execution of normal
program in an automatic mode.

1.10.5. Restricting the working Envelope

When the robot is not necessary to reach certain area for specific applications, working envelope of
the robot can be limited to secure the sufficient safety working area. This will reduce the damage or
loss in case of robot's collision with external safety devices such as safety fence, etc. The movement
of axes 1, 2, and 3 of HR, HX, HS and HA can be limited by means of mechanical stopper or electrical
limit switches. In this case, the corresponding software limitation parameters must be also changed. If
necessary, movement of wrist 3 axes can be restricted, too. Limitation of working envelope for all the
axes could be carried out by the user. The robot is delivered to customer as the status of full working
envelope setting.

 Manual mode: Maximum speed is 250mm/s.

In a manual mode, by means of worker‟s selection, workers may enter the safeguard area.

 Auto mode : The robot can be operated via remote controller.

All safety devices such as safety door, safety mats, etc. are activated.
No one may enter the safety device area of robot.

1.10.6. Monitoring Function

(1) Motor monitoring function
Motors are protected against overload by means of onboard sensors.

(2) Voltage Monitoring Function

For the protection of, the servo amp module turns off the power switch when the voltage is
too low or too high.

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 Hi5 Controller Maintenance Manual

1.11. Safety Related to End Effectors

1.11.1. Gripper
(1) When a gripper is used to grip a workpiece, there should be safety precautions for
unexpected dropping of the loaded workpiece.

(2) When any end effectors or devices are installed on the robot arm, use the required size and
piece of bolt, and securely fasten as per the required torque using torque wrench. Do not use
the bolt which has rust or dirt on its surface.

(3) End effector must be designed and manufactured not to exceed the maximum allowable load
at the wrist of robot. Even though power or air supply stops, the gripped workpiece must not
be dropped from the gripper. In order to remove any risks and problems which may cause
personal injury and/or physical damage, the sharp edge and projecting part of end effector
must be made dull and smooth.

1.11.2. Tool / Workpiece

(1) It must be possible to replace tools such as milling cutters in a safe manner. Make sure that
safety devices are working correctly until the cutters stop rotating.

(2) Tool must be designed to keep in gripping workpiece securely even though a power failure or
a control failure takes place. It must be possible to release workpiece from the gripper in a
manual mode.

1.11.3. Pneumatic and Hydraulic Systems

(1) The special safety regulations will apply to pneumatic and hydraulic systems.

(2) Since residual energy of pneumatic and hydraulic systems can be still remaining even after
the robot stops, particular care and attention must be paid by users. Internal pressure of
equipment must be removed whenever starting the repair work for pneumatic and hydraulic
systems.

1-26
 1. Safety

1.12. Liabilities
The robot system has been built in accordance with the latest technical standards and approved safety
rules. Nevertheless, the serious accidents such as death or personal injury still may take place due to
the collision between the robot system and peripheral equipment.

The robot system must be used by operator who has a full technical knowledge on its designated use
and also pay his close attention to the possible dangers and risks involved in its operation. The use of
robot system is subject to compliance with these operating instructions and the operation and
maintenance manual supplied together with the robot system. The safety related functions of robot
system must not be used for any purposes other than safety.

When you use the robot system for any other or additional purposes than its designated usage, you
must review whether it is enable in accordance with design criteria. The manufacturers cannot take
any responsibility for any damage or loss which resulted from such misuse or improper use. The users
shall have the full responsibility for the risks caused by such misuse or improper use. When you use
and operate the robot system for its designated use, you must have a good command of all the
information contained at these operating instructions as well as the maintenance manual.

The robot system may not be put into operation until it is ensured that the functional machine or plant
into which the robot system has been integrated conforms to the specifications of the EU Machinery
Directive 98/37/EC(2006/42/EC) and US OSHA.

The following harmonized standards in particular were taken into account with regard to the safety of
the robot system.

 ANSI/RIA R15.06-1999
Industrial Robots and Robot Systems - Safety Requirements
 ANSI/RIA/ISO 10218-1-2007
Robots for Industrial Environment - Safety Requirements - Part 1 - Robot
 ISO 11161:2007
Safety of machinery - Integrated manufacturing systems - Basic requirements
 EN ISO 13849-1:2008
Safety of machinery - Safety-related parts of control systems - Part 1: General principles for
design (ISO 13849-1:2006)
 EN 60204-1:2006
Safety of machinery - Electrical equipment of machines - Part 1: General requirements (IEC
60204-1:2005 (Modified))
 EN ISO 10218-1:2006
Robots for industrial environments - Safety requirements - Part 1: Robot (ISO 10218-1:2006)

Users must take the full responsibility for any accident caused by their negligence or non-observance
of these instructions. The manufacturer will not take any liabilities and responsibilities for any damages
or losses caused by the misuse or malfunction of such equipment which is not included in the contract
between manufacturer and user and provided by user, or such equipment which is installed around the
robot system arbitrarily by the user. User must take the full liabilities and responsibilities for any risks
and damages caused by such equipment.

1-27
 2. Specifications

2. Specifications

2
Specifications

2-1
 2. Specifications Hi5 Controller Maintenance Manual

2.1. The Detailed Specifications of Hi5 Robot Controller

Table 2-1 shows the specifications of Hi5 robot controller.

Table 2-1 The specifications of Hi5 robot controller

Model Hi5-N**(Medium Size) Hi5-C10 (Clean) Hi5-C20 (Clean)

CPU 64 bit RISC (450MHz)

Program Execution
Teaching & Playback
Method
Operation Method Menu-Based Method

Interpolation Type PTP, Linear, and Circular Interpolation

Memory Back-Up
Battery Back-UP IC Memory
Method
Encoder Type Absolute Encoder

Servo Drive Unit 6-Axis All-In-One Type, Digital Servo

Max. No. of Axes Max. 16 Axes Simultaneously

Step 20,000 Points

Program Selection 255(Binary)/8(Discrete)

Teach pendant
7” Color LCD(800x480)
Indication
Digital I/O Input: 32 Points (Max. 256 Points) / Output: 32 Points (Max. 256 Points)
Analog I/O
Input: 8 Points / Output: 4 Points
(Option)
Conveyor Pulse
Line Driver/ Open Collector
Counter
Communications
RS232C : 2 Ports(Also for RS485 1) / Ethernet : 2 Ports / CAN : 2 Ports
Interface
Fieldbus Interface
CC-Link, DeviceNet, Profibus-DP
(Option)
CPU BD510

DSP(Servo) BD542

Back Plane BD501

System BD530/531

Small Door BD5B1

Board
Electrical Part BD5C0

CC-LINK BD570 BD570

BD580, BD581, BD58A
Digital In/Out BD580, BD581
BD582
Analog/Arc I/F BD584 - -

Conveyor I/F BD585 - -

2-2
 2. Specifications

Model Hi5-N**(Medium Size) Hi5-C10 (Clean) Hi5-C20 (Clean)

Drive Unit
SA3X3Y SA1L5X SA4X2Z
(6 Axis)
Servo Drive Unit
Amp SA1X/SA1A - -
(1 Axis)
Diode Module SD1L2C
CMC1, CMC2, CEC1, CMC1, CMC2, CEC1,
Wire Harness CMC1, CMC2, CEC1
CIOC1 AMC1, AEC1, CIOC1
Teach pendant TP510

Cooling Pan 10 ea 4 ea 5 ea

Air Conditioner Hi5-A000 - -

3-phase
220V(50/60Hz)±10% Power: Three-phase Control: Single-phase
Rated Voltage
Options : 380 V, 400 V, 220V (50/60 Hz) ±10% 220V (50/60 Hz) ±10%
440 V
Max. Power Power: 11.5 KVA Power : 10 KVA
7.8 KVA
Consumption Control: 1 KVA Control: 1 KVA
Protection Class IP54 IP20
Operating
0~45℃
Temperature
Noise Level Max. 58dB Max. 68dB Max. 65dB

Operational Humidity 75%

Exterior Dimensions
650x1,100x600(mm) 600x1,100x500(mm) 500x500x1,100(mm)
(WxHxD)
225Kg
Weight (Including power 150 kg
supply transformer)

Table 2-2 Power Supply Requirements

Capacity*1) Input Voltage *2) Peak Current
Controller Type Frequency [Hz]
[KVA] [V] [A]
Hi5-N00 Max. 7.8 KVA 220 V 50/60 30 A

Hi5-N30 Max. 4.4 KVA 220 V 50/60 15 A

Hi5-C10 Max. 12.5 KVA 220 V 50/60 30 A

Hi5-C20 Max. 11 KVA 220 V 50/60 30 A

Note 1) Power capacity:

This refers to the capacity of the power supplied to the controller. Please refer to the “Repair
Manual for the Robot Main Body” for the power capacity of each robot.
Note 2) Voltage Range : ±10% (The power terminal of Hi5-CH5 terminal)

2-3
 3. Installation of Controller

3. Installation of Controller

3
Installation of
Controller

3-1
 3. Installation of Controller Hi5 Controller Maintenance Manual

The Install of the equipments should be performed by qualified engineer, and

related law and regulation should be observed.

3.1. Components
3.1.1. Basic Components of Controller and Robot Manipulator
Basic component of robot manipulator and controller is as follows.

 Robot Manipulator
 Controller
 Teach pendant
 Wire Harness

Manipulator
Controller

Teach pendant

Wire harness

Figure 3.1 Basic Components of Manipulator and Controller (LCD Robot)

3-2
 3. Installation of Controller

Controller

Manipulator
Teach pendant

Wire harness

Figure 3.2 Basic Components of Manipulator and Controller (Vertical Articulated Robot)

3-3
 Hi5 Controller Maintenance Manual

3.1.2. Confirmation of Serial Number

Serial Number is located in the upper right of controller door.

경 고
고전압
- 고전압에 의해 중대한 인명사고가 일어날수
있으므로 다음을 준수해 주십시오.
Manufactured by
- 제어기문을 열 때는 반드시 전원을 OFF해
Hyundai Heavy Industries Co., Ltd.
주십시오. 1, CHEONHA-DONG, DONG-KU, ULSAN CITY, 682-792, KOREA
Tel : 82-52-230-7901 Home page : www.hhi.co.kr
- 수리시에는 전원을 OFF한후 자물쇠를 이용 Fax : 82-52-230-7920 Made in Korea

하여 전원스위치를 OFF로 잠가주십시오.

주 의
주 의 - 로봇 본체,제어기에는 데이타 백업용 밧데리가 부착되어
있습니다. 이 밧데리는 가동시간에 관계없이 매2년마다
교환해 주십시오. 교환은 전원을 ON한 상태에서 하십시오.
- 설치작업전에 조작설명서 및 안전지침서를
주의깊게 읽어주십시오. 다음 교환시기는
- 조작중에는 로봇 작업영역내로 들어가지
1. 년 월입니다. 2. 년 월입니다.
마십시오.
- 케이블을 연결하기 전에 로봇 본체와 3. 년 월입니다. 4. 년 월입니다.
제어기의 일련번호가 동일한지 확인하여
주십시오. 일련번호가 다를 경우,
비정상적인 동작을 일으킬수 있습니다.

Manufactured by
Hyundai Heavy Industries Co., Ltd.
1, CHEONHA-DONG, DONG-KU, ULSAN CITY, 682-792, KOREA
Tel : 82-52-230-7901 Home page : www.hhi.co.kr
Fax : 82-52-230-7920 Made in Korea

경 고
고전압
- 고전압에 의해 중대한 인명사고가 일어날수
있으므로 다음을 준수해 주십시오.
- 제어기문을 열 때는 반드시 전원을 OFF해
주십시오.
- 수리시에는 전원을 OFF한후 자물쇠를 이용
하여 전원스위치를 OFF로 잠가주십시오.

주 의
- 설치작업전에 조작설명서 및 안전지침서를
주의깊게 읽어주십시오.
- 조작중에는 로봇 작업영역내로 들어가지
마십시오.
- 케이블을 연결하기 전에 로봇 본체와
Manufactured by
Hyundai Heavy Industries Co., Ltd. 주 의
1, CHEONHA-DONG, DONG-KU, ULSAN CITY, 682-792, KOREA
제어기의 일련번호가 동일한지 확인하여 Tel : 82-52-230-7901 Home page : www.hhi.co.kr - 로봇 본체,제어기에는 데이타 백업용 밧데리가 부착되어
Fax : 82-52-230-7920 Made in Korea
주십시오. 일련번호가 다를 경우, 있습니다. 이 밧데리는 가동시간에 관계없이 매2년마다
교환해 주십시오. 교환은 전원을 ON한 상태에서 하십시오.
비정상적인 동작을 일으킬수 있습니다.

주 의 다음 교환시기는

- 로봇 본체,제어기에는 데이타 백업용 밧데리가 부착되어

1. 년 월입니다. 2. 년 월입니다.
있습니다. 이 밧데리는 가동시간에 관계없이 매2년마다
교환해 주십시오. 교환은 전원을 ON한 상태에서 하십시오.
3. 년 월입니다. 4. 년 월입니다. Manufactured by
다음 교환시기는 Hyundai Heavy Industries Co., Ltd.
1, CHEONHA-DONG, DONG-KU, ULSAN CITY, 682-792, KOREA
Tel : 82-52-230-7901 Home page : www.hhi.co.kr
1. 년 월입니다. 2. 년 월입니다.
Fax : 82-52-230-7920 Made in Korea

3. 년 월입니다. 4. 년 월입니다.

주 의
- 설치작업전에 조작설명서 및 안전지침서를
주의깊게 읽어주십시오.
- 조작중에는 로봇 작업영역내로 들어가지
CUT SIZE 마십시오.
- 케이블을 연결하기 전에 로봇 본체와
제어기의 일련번호가 동일한지 확인하여
주십시오. 일련번호가 다를 경우,
비정상적인 동작을 일으킬수 있습니다.

알 림
제어기를 이동하지 않을 때에는 반드시 알 림
바퀴의 고정장치를 '고정' 위치로 해
주십시오. 제어기를 이동하지 않을 때에는 반드시
바퀴의 고정장치를 '고정' 위치로 해
주십시오.

Figure 3.3 Location of Serial Number

3-4
 3. Installation of Controller

3.1.3. Confirmation of Nameplates

3
14

운반
아이볼트(M16)
와이어 로프
제어기를 들어올릴 때에는 외함에
최대 60°
2개의 아이볼트를 사용하세요.

Hi5 중량(대략)
모델 대략 중량(kg)
Hi5-M 260 kg
Hi5-M 230 kg

Hi4a-MC 350 kg

12 경 고
고전압
- 고전압에 의해 중대한 인명사고가 일어날수
있으므로 다음을 준수해 주십시오.
- 제어기문을 열 때는 반드시 전원을 OFF해
주십시오.

4 1
- 수리시에는 전원을 OFF한후 자물쇠를 이용
하여 전원스위치를 OFF로 잠가주십시오.

주 의
- 설치작업전에 조작설명서 및 안전지침서를
주의깊게 읽어주십시오.
- 조작중에는 로봇 작업영역내로 들어가지
마십시오. Manufactured by

- 케이블을 연결하기 전에 로봇 본체와

Hyundai Heavy Industries Co., Ltd.
1 , CHEONHA-DONG, DONG-KU, ULSAN CITY, 682-792, KOREA
Tel : 82-5 2-23 0-79 01 Home page : www.hhi.co.kr
제어기의 일련번호가 동일한지 확인하여

5
Fax : 82-52-23 0-792 0 Made in Korea
주십시오. 일련번호가 다를 경우,

17
비정상적인 동작을 일으킬수 있습니다.

주 의
- 로봇 본체,제어기에는 데이타 백업용 밧데리가 부착되어
있습니다. 이 밧데리는 가동시간에 관계없이 매2년마다
교환해 주십시오. 교환은 전원을 ON한 상태에서 하십시오.

다음 교환시기는

1. 년 월입니다. 2. 년 월입니다.

1차 전원 연결
1. 전선 사이즈

항목

전선
최소
3상 전원선(L1,L2,L3)
L= ~50m
L= ~160ft
AWG12
or
L= 50~100m
L=160~320ft
AWG10
or
보호도체(PE)

AWG10
or
23 3. 년 월입니다. 4. 년 월입니다.

굵기 3.5 mm 5.5 mm 5.5 mm

2. 체결 토오크 : 2.6 ~ 3.7 N m(23.0~32.7 lb in)
3. 단자
- 단자 형태 : 링형 단자
- 볼트 규격 : M5

6 주
- 전원선을 결선하기 전에 공급되는 전원이
의
2
적절한지 확인해 주십시오.
- 공급되는 전압과 트랜스포머에서 선택한
입력전압이 동일한지 확인해 주십시오.
- 접지는 단독 3종접지(100Ω 이하)하며
2
접지선은 5.5mm 이상 사용 하십시오
2
- 전원선은 5.5mm 이상 사용하십시오

20
22 AC220 VOLTS

주 의
공기 순환용 흡/배기구를 막지 마십시오.
제어기에 심각한 손상을 입힐수 있습니다.

Figure 3.4 Hi5-C10 Location of Controller Nameplate 1

3-5
 Hi5 Controller Maintenance Manual

11 26

알 림
- PCB는 정전기에 매우 약하므로, 취급 시 충분한 주의를 주 의 주 의
해 주십시오. 이동 및 보관시는 반드시 정전기 방지처리된 규격 볼트 사용:M4X6 규격 볼트 사용:M4X6

포장지를 사용해 주십시오.

- 수리나, 점검후 전원을 공급하기 전에 모든 커넥터가
정상적으로 체결되었는지 확인하십시오.

7 6 5 4 3 2 1

주 의 주 의
7 6 5 4 3 2 1

규격 볼트 사용:M4X6 규격 볼트 사용:M4X6

10 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 13 12 11

7 6 5 4 3 2 1

7 6 5 4 3 2 1

10
주 의
고온
표면이 매우 뜨거울수 있으므로 함부로
만지지 마십시오.

8
경 고 경 고
고전압 ! 충전 에너지! 고전압 ! 충전 에너지!
DC400V의 충전된 에너지가 존재합니다. DC400V의 충전된 에너지가 존재합니다.
완전히 방전 시키기 위해 전원 OFF후 완전히 방전 시키기 위해 전원 OFF후
5분 이상 기다리십시오. 5분 이상 기다리십시오.

Figure 3.5 Hi5-C10 Location of Controller Nameplate 2

3-6
 3. Installation of Controller

와이어 로프

아이볼트(M16)

제어기를 들어올릴 때에는 외함에

4개의 아이볼트를 사용하세요.

Weight of Hi5(approx.)
Model Approx. weight(kg)
Hi5-C 150 kg

주 의
- 로봇 본체,제어기에는 데이타 백업용 밧데리가 부착되어
있습니다. 이 밧데리는 가동시간에 관계없이 매2년마다
교환해 주십시오. 교환은 전원을 ON한 상태에서 하십시오.

다음 교환시기는
경 고
1. 년 월입니다. 2. 년 월입니다.

고전압 3. 년 월입니다. 4. 년 월입니다. Manufactured by

- 고전압에 의해 중대한 인명사고가 일어날수 Hyundai Heavy Industries Co., Ltd.
있으므로 다음을 준수해 주십시오. 1 , CHEONHA-DONG, DONG-KU, ULSAN CITY, 682-792, KOREA
Tel : 82-5 2-23 0-79 01 Home page : www.hhi.co.kr
- 제어기문을 열 때는 반드시 전원을 OFF해 Fax : 82-52-23 0-792 0 Made in Korea

주십시오.
- 수리시에는 전원을 OFF한후 자물쇠를 이용
하여 전원스위치를 OFF로 잠가주십시오.

주 의
- 설치작업전에 조작설명서 및 안전지침서를
주의깊게 읽어주십시오.
- 조작중에는 로봇 작업영역내로 들어가지
CUT SIZE 마십시오.
- 케이블을 연결하기 전에 로봇 본체와
제어기의 일련번호가 동일한지 확인하여
주십시오. 일련번호가 다를 경우,
비정상적인 동작을 일으킬수 있습니다.

알 림
제어기를 이동하지 않을 때에는 반드시 알 림
바퀴의 고정장치를 '고정' 위치로 해
주십시오. 제어기를 이동하지 않을 때에는 반드시
바퀴의 고정장치를 '고정' 위치로 해
주십시오.

CMC2 CIOC1

주 의
공기 순환용 흡/배기구를 막지 마십시오.
제어기에 심각한 손상을 입힐수 있습니다.

CMC1
CEC1
1차 전원 연결
1. 전선 사이즈

AC220 VOLTS
3상 전원선(L1,L2,L3)
항목 L= ~50m L= 50~100m 보호도체(PE)
L= ~160ft L=160~320ft
전선 AWG12 AWG10 AWG10
최소 or or or
굵기 3.5 mm 5.5 mm 5.5 mm
2. 체결 토오크 : 2.6 ~ 3.7 N m(23.0~32.7 lb in)
3. 단자
- 단자 형태 : 링형 단자
- 볼트 규격 : M5

주 의
- 전원선을 결선하기 전에 공급되는 전원이
적절한지 확인해 주십시오.
- 공급되는 전압과 트랜스포머에서 선택한
입력전압이 동일한지 확인해 주십시오.

Figure 3.6 Hi5-C20 Location of Controller Nameplate 1

3-7
 Hi5 Controller Maintenance Manual

PDM30 Rack 알 림
- PCB는 정전기에 매우 약하므로, 취급 시 충분한 주의를
해 주십시오. 이동 및 보관시는 반드시 정전기 방지처리된
포장지를 사용해 주십시오.
TBI1 CANS1 TBI2 TBI3 TBI4 - 수리나, 점검후 전원을 공급하기 전에 모든 커넥터가
CANS2 정상적으로 체결되었는지 확인하십시오.

CNBP1 CNBP2 CNBP3 CNBP4

CNP1 CNP2
CANS1

BD580 TBO1 TBO2 TBO3 TBO4

고전압 !
경 고
충전 에너지! 고전압 !
경 고
충전 에너지!
DC400V의 충전된 에너지가 존재합니다.
완전히 방전 시키기 위해 전원 OFF후
5분 이상 기다리십시오.
DC400V의 충전된 에너지가 존재합니다.
완전히 방전 시키기 위해 전원 OFF후
5분 이상 기다리십시오.
7 6 5 4 3 2 1
BD530
7 6 5 4 3 2 1

10 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 13 12 11

CNSDN CNP1

BD570 CANS2CANS1

BD570 TBFB

FAN1

주 의
고온
표면이 매우 뜨거울수 있으므로 함부로
만지지 마십시오.

NFT TR
FAN2 FAN3 FAN4

Figure 3.7 Hi5-C20 Location of Controller Nameplate 2

3-8
 3. Installation of Controller

12 경 고
1
고전압
- 고전압에 의해 중대한 인명사고가 일어날수
있으므로 다음을 준수해 주십시오.
Manufactured by
- 제어기문을 열 때는 반드시 전원을 OFF해
Hyundai Heavy Industries Co., Ltd.
주십시오. 1, CHEONHA-DONG, DONG-KU, ULSAN CITY, 682-792, KOREA

4
Tel : 82-52-230-7901 Home page : www.hhi.co.kr

5
- 수리시에는 전원을 OFF한후 자물쇠를 이용 Fax : 82-52-230-7920 Made in Korea
하여 전원스위치를 OFF로 잠가주십시오.

주 의
주 의 - 로봇 본체,제어기에는 데이타 백업용 밧데리가 부착되어
있습니다. 이 밧데리는 가동시간에 관계없이 매2년마다
교환해 주십시오. 교환은 전원을 ON한 상태에서 하십시오.
- 설치작업전에 조작설명서 및 안전지침서를
주의깊게 읽어주십시오. 다음 교환시기는
- 조작중에는 로봇 작업영역내로 들어가지
1. 년 월입니다. 2. 년 월입니다.
마십시오.
- 케이블을 연결하기 전에 로봇 본체와 3. 년 월입니다. 4. 년 월입니다.
제어기의 일련번호가 동일한지 확인하여
주십시오. 일련번호가 다를 경우,
비정상적인 동작을 일으킬수 있습니다.

20

AC220 VOLTS

주 의
22
- 전원선을 결선하기 전에 공급되는 전원이
적절한지 확인해 주십시오.
- 공급되는 전압과 트랜스포머에서 선택한
입력전압이 동일한지 확인해 주십시오.
- 접지는 단독 3종접지(100Ω 이하)하며
2
접지선은 5.5mm 이상 사용 하십시오
2
- 전원선은 5.5mm 이상 사용하십시오

운반
아이볼트(M16)
와이어 로프

제어기를 들어올릴 때에는 외함에

최대 60°
2개의 아이볼트를 사용하세요.

Hi5 중량(대략)
모델 대략 중량(kg)
Hi5-M 260 kg
Hi5-M 230 kg

Hi4a-MC 350 kg

23

Figure 3.8 Hi5-N** Location of Controller Nameplate 1

3-9
 Hi5 Controller Maintenance Manual

10

11

19
알 림 R3

- PCB는 정전기에 매우 약하므로, 취급 시 충분한 주의를

해 주십시오. 이동 및 보관시는 반드시 정전기 방지처리된
포장지를 사용해 주십시오.
- 수리나, 점검후 전원을 공급하기 전에 모든 커넥터가
정상적으로 체결되었는지 확인하십시오.

Fuse Ratings
Fuse Fuse
Schematic Current Voltage Fuse Fuse
Circuit ID Rating(A) Rating(V) Type Maker

Control F1 ~ F2 2A 250V GP20 Daito

(PDM30)

SMPS F3 ~ F4 10A 250V GP100 Daito

(PDM30)

Brake F5 ~ F6 5A 250V GP50 Daito

(PDM30)

Surge Detection F1 ~ F2 2A 250V GP20 Daito

(SERVO AMP)

7 6 5 4 3 2 1

7 6 5 4 3 2 1

경 고
고전압 ! 충전된 에너지!
DC400V의 충전된 에너지가 존재합니다.
완전히 방전 시키기 위해 전원 OFF후
5분 이상 기다리십시오.

7 6 5 4 3 2 1

7 6 5 4 3 2 1

10 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 13 12 11

Figure 3.9 Hi5-N** Location of Controller Nameplate 2

3-10
 3. Installation of Controller

No. Name Plate No. Name Plate

1 2
Manufactured by
Hyundai Heavy Industries Co., Ltd.
1, CHEONHA-DONG, DONG-KU, ULSAN CITY, 682-792, KOREA
Tel : 82-52-202-5041 Home page : www.hhi.co.kr
Fax : 82-52-202-7960 Made in Korea

CAUTION
- Carefully read the operation manual and
the safety manual before installation and
using application.
3 4 - Do not enter the working range of the
Robot system under operation.
- Before cables connecting, check that
the S/N is identical on the controller
and on the manipulator.
If the S/N is different, robot may be
operated abnormally..

NOTICE
Batteries for data backup are installed inside
CAUTION
of both controller and manipulator.
- Check appropriate supplied voltage
Batteries must be replaced in every 2 years
before connection.
regardless of operation hours.
- Check supplied voltage with setting
5 Next date for replacement is 6 voltage of transformer.
- Make grounding which is 100Ω resistance
or less for the robot independtly. 2
- Use Grounding Cable more than 5.5mm
- Use power cable more than 5.5mm2
Battery type : ER6C(Lithium Battery, 3.6V) (AWG10)
Battery Maker : Hitachi Maxwell, Ltd.

CAUTION CAUTION
7 Finger Injury 8 High Temperature
Handling without care can cause fatal injury. Do not touch!
The temperature may be very high.

WARNING
CAUTION
High Voltage ! Stored Energy!
9 Ensure no interference for air circulation
of ventiduct.
10 Be careful of stored energy of DC 400V.

Interference may cause controller damage. Wait more than 5 minutes for deenergizing
after power off.

NOTICE WARNING
High Voltage
- Make sure that PCB is handled with care in such a way - High voltage can cause injury or death.
that electrostatic does not occured. - Control cabinet must be turned to "OFF"
11 - Wrap treated with electrostatic-proof must be used for 12 before opening cabinet door.
transportation and storage. - The Robot System must be switched off
before any maintenance, exchange, repair.
- Be sure of normal power connection before supplying
- Padlock must be used to lock the power
main power to control cabinet after repair or maintenance. switch to "OFF" .

3-11
 Hi5 Controller Maintenance Manual

No. Name Plate No. Name Plate

LIFTING
Eyebolts(M16)
Wire Rope

NOTICE Max. 60°

Use the two Eyebolts on the
cabinet when lifting the controller.

13 Lock the caster of control cabinet unless 14 Weight of Hi5(approx.)

Model Approx. weight(kg)
it needs to be moved. 경
고전압
고

- 고전압에 의해 중대한 인명사고가 일어날수

있으므로 다음을 준수해 주십시오.
- 제어기문을 열 때는 반드시 전원을 OFF해
주십시오.
- 수리시에는 전원을 OFF한후 자물쇠를 이용
하여 전원스위치를 OFF로 잠가주십시오.

주 의
- 설치작업전에 조작설명서 및 안전지침서를
주의깊게 읽어주십시오.
- 조작중에는 로봇 작업영역내로 들어가지
마십시오.
- 케이블을 연결하기 전에 로봇 본체와
제어기의 일련번호가 동일한지 확인하여
주십시오. 일련번호가 다를 경우,
비정상적인 동작을 일으킬수 있습니다.
Manufactured by
Hyundai Heavy Industries Co., Ltd.
1, CHEONHA-DONG, DONG-KU, ULSAN CITY, 682-792, KOREA
Tel : 82-52-230-7901
Fax : 82-52-230-7920

다음 교환시기는

1.

3.
년

년
주
- 로봇 본체,제어기에는 데이타 백업용 밧데리가 부착되어
있습니다. 이 밧데리는 가동시간에 관계없이 매2년마다

월입니다. 2.

월입니다. 4.

알
제어기를 이동하지 않을 때에는 반드시
바퀴의 고정장치를 고정의 위치로 해
주십시오.
Home page : www.hhi.co.kr
Made in Korea

교환해 주십시오. 교환은 전원을 ON한 상태에서 하십시오.

의

림
년

년
월입니다.

월입니다.

LIFTING
Wire Rope

Eyebolts(M16)

Use the four Eyebolts on the

cabinet when lifting the controller.
15 Weight of Hi5(approx.)
16 -
Model Approx. weight(kg)

CNRTP

Main Power Connection

1. Conductor size
Phase conductors(L1,L2,L3)
Item L= ~ 50m L= 50 ~ 100m Protective
L= ~ 160ft L=160 ~ 320ft Conductor(PE)
Minimum AWG12 AWG10 AWG10
17 Conductor or or or 18 -
Size 3.5 mm 5.5 mm 5.5 mm
2. Tightening torque : 2.6 ~ 3.7 N m(23.0~32.7 lb in)
3. Terminal
- Terminal type : Ring terminal
- Bolt Size : M5

Fuse Ratings
Fuse Fuse
Schematic Current Voltage Fuse Fuse
Circuit ID Rating(A) Rating(V) Type Maker

Control F1 ~ F2 2A 250V GP20 Daito

(PDM30)

19 SMPS
(PDM30)
F3 ~ F4 10A 250V GP100 Daito 20
Brake F5 ~ F6 5A 250V GP50 Daito
(PDM30)

Surge Detection F1 ~ F2 2A 250V GP20 Daito

(SERVO AMP)

21 22

23
CNRTP 26 -

3-12
 3. Installation of Controller

3.2. Packing

① Attach the nameplate of model to its box.

② Cover all the exposure connectors with dust cap or polyvinyl to protect.
③ For the packing of T/P in a box, use air cushioning materials to keep LCD intact from external
impact during packing
④ Attach the list of waterproof packing to the outer box.

3.3. Transportation of Controller

Since Hi5 controller is a sophisticated device, transport it using crane or forklift truck in an uneven
ground or for long distance.

Be sure to check the following instructions when transporting.

① Check if the front door of controller is completely closed.

② Remove, if any, everything unfixed on the controller
③ Check if the Eye Bolt on controller is securely fastened.
④ Since the controller is a sophisticated device, transport it very carefully without any impacts.
⑤ The weight of controller is 250Kgf. If using a crane, prevent wires from damaging objects on
controller.
⑥ If using a forklift truck, secure the controller to prevent shaking.
⑦ If using a vehicle, secure the manipulator and controller with a squid and so on.

3.4. Unpacking
Caution

① Be fully aware of safety regulations and other instructions before unpacking and installing.
② Unpack the robot and controller, following the unpacking instructions.
③ Check if the place is safe enough to install the robot and controller
④ Check if a traveling path is secured to safely move the robot and controller.
⑤ Transporting robot must be performed by a qualified personnel.
⑥ Check out any damages from transportation or unpacking.

3-13
 Hi5 Controller Maintenance Manual

3.5. Controller Handling

Transport the controller using crane or forklift truck.
Operating forklift truck must be performed by a qualified personnel

3.5.1. Weight of Controller

Table 3-1 Weight of Controller

Weight
Model Power Supply Transformer
Kg lb

Hi5-N00/N50 X/O(Option) 150/230 330/507

Hi5-N30 X/O(Option) 150/200 330/441

Hi5-C10 X 150 330

Hi5-C20 X 150 330

Table 3-2 Weight of Hi5 Controller by Models

Weight
Model
Kg lb

Teach Pendant(7.5m, TP510) 4 9

Wire harness (5m, Hi5-N**) 15 33

wire harness (5m, Hi5-C10, Hi5-C20) 18 40

3-14
 3. Installation of Controller

3.5.2. Transportation of Controller Using Crane

Check the following instructions when transporting the controller using a crane.

① In general, for the transportation of controller, crane wire with Eye Bolt should be used.
② Check if the wire is strong enough to hold Controller.
③ Check if the eye bolt is securely fastened.

Wire Rope

M16 Eye Bolt

Figure 3.10Transportation of Controller Using Crane

3-15
 Hi5 Controller Maintenance Manual

3.5.3. Transportation of Controller Using Forklift Truck

Check the following instructions when transporting the controller using a forklift truck.

① If transporting with wire rope, be sure to use a strong wire to hold controller.
② Check if the eye bolt is securely fastened.
③ Transport the controller as low as possible.

Wire Rope

Bumper for protection

Hi5-C10 Hi5-C20 Hi5-N**

Figure 3.11 Transportation of Controller Using Forklift Truck

3-16
 3. Installation of Controller

3.6. Space for Installation

Check the following instructions before installation.

① Secure the robot working envelope.

② Secure the space for maintenance of robot manipulator and controller.
③ Check if the installing place has such environment as follows.
o o
 Ambient Temperature ; 0 C ~ 45 C
 No dust, oil, or moisture.
 No flammable, corrosive liquid or gas.
 No impact and shaking.
 Far from electrical noise generator.
 No exposed direct to the sun

3.6.1. Installation of Controller

① Install the controller in a safe place outside of robot working envelope.

② If safety fence is located outside of robot working envelope, install the controller in a place
where the robot‟s movement can be monitored from the outside of safety fence.
③ Open the front door and secure enough space for maintenance work.
④ Install the controller in a place where welding spatter and coolant are not reached.

3-17
 Hi5 Controller Maintenance Manual

3.6.2. Space for Installation

Secure enough space for robot manipulator and controller before installing. To install the manipulator
and controller, secure the installing space as shown in the below figure. Install the controller outside of
the safety fence to see the manipulator easily and to work safely. Install the controller at intervals of a
minimum 500mm from the surrounding walls.
HC1300C2D 5G 원통형

(Cylinder type)
HC1300B1D 5G 빔형

(Beam type)
동작영역-안전망간
marginal space safeguarded
robot동작영역
로봇 안전망 설치영역
여유공간 operation
between area
operation
area area and safeguard
area

Figure 3.12 Installing space for LCD robot

3-18
 3. Installation of Controller

Figure 3.13 Installing space for Hi5-C20 controller

3-19
 Hi5 Controller Maintenance Manual

Door

Minimum 110cm
Robot Controller

Safety Fence

Minimum 110cm

Working Envelope

Working Envelope with Tool

and Workpiece installed

Figure 3.14 Install space for general type robot

3-20
 3. Installation of Controller

Figure 3.15 Installing space for Hi5-C10, Hi5-N** controller

3-21
 Hi5 Controller Maintenance Manual

3.6.3. Dimension of Controller

Figure 3.16 Dimension of Hi5-C20 (Unit:mm)

3-22
 3. Installation of Controller

Figure 3.17 Dimension of Hi5-C10 Controller (Unit:mm)

3-23
 Hi5 Controller Maintenance Manual

Figure 3.18 Dimension of Hi5-N** Controller (Unit:mm)

3-24
 3. Installation of Controller

3.7. Connection
Caution

① Turn the main power switch of controller “OFF” before connecting cables, and use a lock to
lock the main power switch.
② There is charged energy of DC 400V in the controller. Be careful. Turn the power switch
“OFF” to discharge the energy, and wait for 5 minutes at least
③ When handling PCB, be careful of any damages from static electricity.
④ Wiring and interconnecting should be preformed by a qualified personnel.

3.7.1. Connection of Teach Pendant

Connect the cable connector of Teach Pendant to CNRTP receptacle in the side of controller.

Teach pendant

CNRTP

Figure 3.19 Hi5-C20 Connection of Teach Pendant

3-25
 Hi5 Controller Maintenance Manual

Teach pendant

CNRTP

Figure 3.20 Hi5-C10 Connection of Teach Pendant

Teach pendant

CNRTP

Figure 3.21 Hi5-N** Connection of Teach Pendant

3-26
 3. Installation of Controller

3.7.2. Connection of Manipulator and Controller

Connect the robot manipulator to the controller by using wire harness. Check the respective name of
receptacles before connecting.

CMC1 CMC2 CIOC1

CMR1 CMR2 CER1 CIOR1

CEC1

Figure 3.22 Connection of Robot Manipulator and Controller (Hi5-C20)

CMC1 CMC2
CMR2 CER1
CIOC CMR1 CIOR1
1

CEC1

Figure 3.23 Connection of Robot Manipulator and Controller (Hi5-C10)

3-27
 Hi5 Controller Maintenance Manual

CMC1
CMR2
CMC2

CMR1
CER1
CEC1

Figure 3.24 Connection of Robot Manipulator and Controller (Hi5-N00)

3-28
 3. Installation of Controller

CMC1

CMR1 CER1
CEC1

Figure 3.25 Connection of Robot Manipulator and Controller (Hi5-N30/N50)

3-29
 Hi5 Controller Maintenance Manual

3.7.3. Connection of Controller and Primary Power

Check if the power is removed from the primary power and braker(CB).
Connect the Hi5-C10 and C20 controllers to the terminal block (TBPW).
For the Hi5-N** controller, insert the power cable into the power service outlet to connect the breaker
(NFB).
Here, use a proper size of terminal for the tip of primary power cable

Power inlet

POWER CABLE

Figure 3.26 Hi5-C20 Connection of Primary Power to Controller

운반
아이볼트(M16)
와이어 로프

제어기를 들어올릴 때에는 외함에

최대 60°
2개의 아이볼트를 사용하세요.

Hi5 중량(대략)
모델 대략 중량(kg)
Hi5-M 260 kg
Hi5-M 230 kg

Hi4a-MC 350 kg

1차 전원 연결
1. 전선 사이즈
3상 전원선(L1,L2,L3)
항목 L= ~50m L= 50~100m 보호도체(PE)
L= ~160ft L=160~320ft
전선 AWG12 AWG10 AWG10
최소 or or or
굵기 3.5 mm 5.5 mm 5.5 mm
2. 체결 토오크 : 2.6 ~ 3.7 N m(23.0~32.7 lb in)
3. 단자
- 단자 형태 : 링형 단자
- 볼트 규격 : M5

주 의
- 전원선을 결선하기 전에 공급되는 전원이
적절한지 확인해 주십시오.
- 공급되는 전압과 트랜스포머에서 선택한
입력전압이 동일한지 확인해 주십시오.
- 접지는 단독 3종접지(100Ω 이하)하며
2
접지선은 5.5mm 이상 사용 하십시오
2
- 전원선은 5.5mm 이상 사용하십시오

Power inlet

POWER CABLE
AC220 VOLTS

Figure 3.27 Hi5-C10 Connection of Primary Power to Controller

3-30
 3. Installation of Controller

AC220 VOLTS

주 의
- 전원선을 결선하기 전에 공급되는 전원이
적절한지 확인해 주십시오.
- 공급되는 전압과 트랜스포머에서 선택한
입력전압이 동일한지 확인해 주십시오.
- 접지는 단독 3종접지(100Ω 이하)하며
2
접지선은 5.5mm 이상 사용 하십시오
2
- 전원선은 5.5mm 이상 사용하십시오

Main braker
경 고
고전압 ! 충전된 에너지!
DC400V의 충전된 에너지가 존재합니다.
완전히 방전 시키기 위해 전원 OFF후
5분 이상 기다리십시오.

7 6 5 4 3 2 1

7 6 5 4 3 2 1

10 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 13 12 11

AC220 VOLTS

주 의
- 전원선을 결선하기 전에 공급되는 전원이
적절한지 확인해 주십시오.

Power inlet
- 공급되는 전압과 트랜스포머에서 선택한
입력전압이 동일한지 확인해 주십시오.
- 접지는 단독 3종접지(100Ω 이하)하며
접지선은 5.5mm2 이상 사용 하십시오
- 전원선은 5.5mm2 이상 사용하십시오

Power Cable

Figure 3.28 Hi5-N** Connection of Primary Power to Controller

3-31
 Hi5 Controller Maintenance Manual

3.7.3.1. Power Conditions

Table 3-3 Power Conditions

Frequency Max. Current
No. Controller Capacity*1) (KVA) Input Voltage*2) (V)
(Hz) (A)

1 Hi5-N00/N50 Max. 7.8KVA 220V/380V/400V/440V 50/60 30A

2 Hi5-N30 Max. 4.4KVA 220V/380V/400V/440V 50/60 15A

3 Hi5-C10 Max. 12.5KVA 220V 50/60 30A

4 Hi5-C20 Max. 11KVA 220V 50/60 30A

Note 1) Power capacity:

This refers to the capacity of the power supplied to the controller. Please refer to the
“Maintenance Manual” for the Robot Main Body” for the power capacity of each robot.
Note 2) Voltage Range : ±10% (Controller Power Terminal)

3.7.3.2. Thickness of Power Cables

Table 3-4 Recommended Cable of Least Thickness

Thickness of Cable
Thickness of Cable
(Hi5-N00, Hi5-N50 Hi5-C10,
(Hi5-N30)
No. Length of Cable m (feet) Hi5-C20)

㎟ AWG ㎟ AWG

1 0 ~ 50(0 ~ 160) 5.5 10 3.5 12

2 50 ~ 100(160 ~ 320) 5.5 10 3.5 12

3 100 ~ 180(320 ~ 590) 8 8 5.5 10

4 180 ~ 300(520 ~ 980) 8 8 5.5 10

3-32
 3. Installation of Controller

3.7.4. Controller and Grounding

Connect the grounding conductor to the controller for safety.
Use the grounding conductor more than 5.5 ㎟. (Class 3 grounding)

3.7.5. Other Cautions

① Please distinguish signal line and power line on wiring for controller and robot main
body. And use a separated DUCT between high power line and signal line for wiring.
② Shield the wires with protection cover against damages, and be careful of damage from
traffic.
③ Be sure to double-check the connecting relations, power specifications of controller,
and specifications of power supply before primary power input.

3-33
 Hi5 Controller Maintenance Manual

3.7.6. RS232C & Ethernet access of Small Door

The small door sector is located on the OP panel in the front of the controller, and is composed of an
RS232C and Ethernet port for external connection. Interconnecting to PC and Pin Description is as
follows.

Table 3-5 Pin Descriptions (RS232 connector specifications; DSUB9S-M)

DSUB9S-M Pin No. Name Abbreviation Direction

2 Receive Data RX In

3 Transmit Data TX Out

5 Signal Ground GND

7 Request to Send RTS Out

8 Clear to Send CTS In

Table 3-6 Pin Descriptions (RJ45 connector specifications; RJ 45P SHIELD)

RJ45 Pin No. Name Abbreviation Direction

1 Transmit Data + TX + Out

2 Transmit Data - TX - Out

3 Receive Data + RX + In

6 Receive Data - RX - In

3-34
 4. Basic Components of Controller

4. Basic Components of Controller

Basic
4
Components of
Controller

4-1
 4. Basic Components of
Controller Hi5 Controller Maintenance Manual

Please learn the components of Hi5 controller, arrangement and functions of

components before doing a repair work.

4.1. Components
Controller consists of the body and the teach pendant as seen in the following picture.

Teach
pendant

Controller

Figure 4.1 Hi5-N** Controller

Teach
pendant

Controller
(Hi5-C20)
Controller
(Hi5-C10)

Figure 4.2 Hi5-C** Controller

4-2
 4. Basic Components of Controller

Figure 4.3 Teach pendant (TP510)

Rack Module MMI Application Module

DSP MAIN TP DIO ADIO CC - Link Conveyor

Paralle
l Bus Ethernet

AMP
CAN Communication (1Mbps)

AC/DC Electrical SYSTEM OP Small

Converter Parts Door

Motors Power

Drive Module Electrical Module OP Module

Figure 4.4 Internal Composition of Hi5 Controller

4-3
 Hi5 Controller Maintenance Manual

4.2. The Arrangement of Parts

Table 4-1 shows the main parts of Hi5-N00 controller and the name of each part, and Figure 4.5, 4.6
and 4.7 show the arrangement of them.

Table 4-1 The Name of Each Part of Hi5-N00 Controller

No. Type Item

1 RACK Rack

2 BD501 Backplane Board

3 SR1 DC Multi Power Unit(SMPS : HDI-200)

4 BD510 Main Board

5 BD542 Servo Board

6 BD530/531 System Board

7 PDM30 Electrical Module

8 SD1L2C Middle-Size Diode Module

9 SA3X3Y Middle-Size 6-Axis Servo Drive Unit (Standard Specifications)

Small-Size 6-Axis Servo Drive Unit

9-1 SA3A3D
(Standard Specifications, Including a DIOD module)

10 SA1X1X Middle-Size 2-Axis Servo Drive Unit (Option)

10-1 SA1X1A Middle-Size 1-Axis, Small-Size 1-Axis Servo Drive Unit (Option)

10-2 SA1A1A Small-Size 2-Axis Servo Drive Unit (Option)

11 EM. SW Emergency stop switch

12 BD5B1 Small Door Board

13 NFB No Fuse Breaker

14 FAN1 Rack radiating fan

15 FAN2 Lower fan for upper circulation

4-4
 4. Basic Components of Controller

No. Type Item

16~17 FAN3~5 Servo-drive unit radiating fan

18 NFT1 Line Noise Filter

19~20 DR1~2 Regeneration discharge resistance

21 TR1 Transformer

22 CMC1 Power Cable Lead-In Connector for Motor Drive 1

23 CMC1 Power Cable Lead-In Connector for Motor Drive 2

24 CEC1 Motor Encoder Communications Cable Lead-In Connector

25 CNRTP Teach pendant Cable Lead-In Connector

11

23
91

25
22
24
11

Figure 4.5 Hi5-N00 Part arrangement parts in the exterior of a controller

4-5
 Hi5 Controller Maintenance Manual

18 10
1
13 15

9 12

5 7

4 6

2 3

1 14

Figure 4.6 Part arrangement in the interior of the front surface of the Hi5-N00 controller

20

19
18 1

17

16 21
1

Figure 4.7 Part arrangement in the interior of the rear surface of the Hi5-N00 controller

4-6
 4. Basic Components of Controller

Table 4-2 shows the main parts of Hi5-C10 controller and the name of each part, and Figure 4.8, 4.9
and 4.10 show the arrangement of them.

Table 4-2 The Name of Each Part of Hi5-C10 Controller

No. Type Item

1 RACK Rack

2 BD501 Backplane Board

3 SR1 DC Multi Power Unit(SMPS : HDI-200)

4 BD510 Main Board

5 BD542 Servo Board

6 BD530/531 System Board

7 PDM30 Electrical Module

8 SD1L2C Middle-Size Diode Module

9 SA3X3Y Middle-Size 6-Axis Servo Drive Unit (Standard Specifications)

9-1 SA1L5X Servo-drive apparatus for HC2500B2D-XXXX-10(optional specifications)

Servo-drive apparatus for HC2500B2D-XXXX-00(optional specifications)

9-2,3 SA3X3Z
Servo-drive apparatus for HC2500B1-XXXX-10(optional specifications)

10 BD58A LDIO board

11 BD58B Safety relay board

12 BD5B1 Small Door Board

13 EM. SW Emergency stop switch

14 SR2 DC power apparatus for a sensor

Elevation shaft fall prevention brake and DC power apparatus for a robot
15 SR3
fan

16 NFB1 Breaker of driving device wiring (No Fuse Breaker)

17 NFB2 Breaker for control power wiring (No Fuse Breaker)

4-7
 Hi5 Controller Maintenance Manual

No. Type Item

18 TBMAIN1 Terminal Block for inputting driving device power(Terminal Block)

19 TBMAIN2 Terminal Block for inputting control power(Terminal Block)

20 TBPW1 Terminal Block for interior power(Terminal Block)

21 FAN1 Rack radiating fan

22~24 FAN2~4 Servo-drive unit radiating fan

25 TR1 Transformer

26 NFT1 Line Noise Filter

27~28 DR1~2 Regeneration discharge resistance

29 CMC1 Power Cable Lead-In Connector for Motor Drive 1

30 CMC2 Power Cable Lead-In Connector for Motor Drive 2

31 CEC1 Motor Encoder Communications Cable Lead-In Connector

32 CNRTP Teach pendant Cable Lead-In Connector

33 CIOC1 Sensor cable inserted in the connector

4-8
 4. Basic Components of Controller

13

30

17 33

16 29

19 32

18 31

Figure 4.8 Hi5-C10 Part arrangement parts in the exterior of the controller

10
7
5
6
4
3
2
12
1
11
21
15
9
14
8

Figure 4.9 Part arrangement in the interior of the front surface of the Hi5-C10 controller

4-9
 Hi5 Controller Maintenance Manual

25

26

20

24

23
27
22
28

Figure 4.10 Part arrangement in the interior of the rear surface of the Hi5-C10 controller

4-10
 4. Basic Components of Controller

Table 4-3 shows the main parts of Hi5-C20 controller and the name of each part, and Figure 4.11, 4.12
and 4.13 show the arrangement of them.

Table 4-3 The Name of Each Part of Hi5-C20 Controller

No. Type Item

1 RACK Rack

2 BD501 Backplane Board

3 SR1 DC Multi Power Unit(SMPS : HDI-200)

4 BD510 Main Board

5 BD542 Servo Board

6 BD530/531 System Board

7 PDM30 Electrical Module

8 SD1L2C Middle-Size Diode Module

9 SA3X3Y Middle-Size 6-Axis Servo Drive Unit (Standard Specifications)

Servo-drive apparatus for HC2500IK-L0 (optional specifications)

9-1 SA4X2Z
Servo-drive apparatus for HC2500IK-R0 (optional specifications)

10 BD580 DIO board

11 BD570 CC-Link board

12 BD5B1 Small Door Board

13 EM. SW Emergency stop switch

14 SR2 DC power apparatus for a sensor

Elevation shaft fall prevention brake and DC power apparatus for a robot
15 SR3
fan

16 NFB1 Breaker of driving device wiring (No Fuse Breaker)

17 NFB2 Breaker for control power wiring (No Fuse Breaker)

18 TBMAIN1 Terminal Block for inputting driving device power

4-11
 Hi5 Controller Maintenance Manual

No. Type Item

19 TBMAIN2 Terminal Block for inputting control power(Terminal Block)

20 TBPW1 Terminal Block for interior power(Terminal Block)

21 FAN1 Rack radiating fan

22~24 FAN2~4 Servo-drive unit radiating fan

25 FAN5 Fan for front surface radiation

26 TR1 Transformer

27 NFT1 Line Noise Filter

28~29 DR1~2 Regeneration discharge resistance

30 CMC1 Power Cable Lead-In Connector for Motor Drive 1

31 CMC2 Power Cable Lead-In Connector for Motor Drive 2

32 CEC1 Motor Encoder Communications Cable Lead-In Connector

33 CNRTP Teach pendant Cable Lead-In Connector

34 CIOC1 Sensor cable inserted in the connector 1

Insertion connector 1 for the power cable to drive a motor in an added

35 AMC1
axis
Insertion connector 1 for the communication cable of a motor encoder in
36 AEC1
an added axis

4-12
 4. Basic Components of Controller

9 8 7 2 1 3

25 6 5 4 21

Figure 4.11 Part arrangement in the interior of the left side of the Hi5-C20 controller

10

11

Figure 4.12 Part arrangement in the left side door of the Hi5-C20 controller

4-13
 Hi5 Controller Maintenance Manual

30 31 36 35 34
13 17

33 12 16 18 19 32

Figure 4.13 Part arrangement in the front and rear surfaces of the Hi5-C20 controller

14 15 28 29

27 20 26 24 23 22

Figure 4.14 Part arrangement in the interior of the right side of the Hi5-C20 controller

4-14
 4. Basic Components of Controller

4.3. The Function of Each Component

Table 4-4 The Summary on the Function of Each Component

Component Function

 Bus for inter-board signal connection(4

Backplane Board (BD501)
Slots)

 Save point saving and operational route

calculation
 Program and robot constant preservation
Main Board (BD510)
 Teach pendant Communications
 PC, PC Card, and Serial Communications
Connection
Board
 CPU for Servo Control
Servo Board(BD542)
 Encoder Connection (Serial I/F)

 In/Out within controller (I/O for system)

 Internal sequence control
 Processing of various input signals from
System Board(BD530/531) the main unit
 Open/close output of servo motor and
brake
 Safety chain circuit
 Power generation for motor drive
∙Middle-Size 6 Axis ; SA3X3Y  Regenerative power discharge
Drive Unit
∙Small-Size 6 Axis ; SA3A3D  Servo motor power amplifier circuit
 Various error reporting
 Board power supply (DC+5V/8.29A)
DC Power HDI-200  T/P(DC+24V/1A),
Supply Unit - Input power supply ; AC45~50V  I/O power supply (DC+24V/1.87A)
(SMPS) - Input frequency ; 50/60Hz  Drive unit(DC+15V/3.5A, DC-15V/0.8A)
 encoder power supply (DC+5V/4A)
 Various information display (LCD)
T/P
 Button switch input (Function/Jog)
(Teach TP510
 Emergency stop. Input of Enable and T/P
Pendant)
On/Off

Cooling  Internal air circulation

Fan
Device  Drive unit cooling

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 Hi5 Controller Maintenance Manual

4.3.1. Rack and Backplane Board (BD501)

4.3.1.1. Outline

The rack has a structure as seen in Figure 4.15, which fixes various PCB boards such as SMPS<
main board, and servo board. As many data and power supplies need to be connected one another in
theses boards, the backplane board (BD501) as seen in Figure 4.16 should be installed at the back of
the PCB rack.

Figure 4.15 PCB Rack

Figure 4.16 Backplane Board(BD501)

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 4. Basic Components of Controller

4.3.2. Mainboard(BD510)
4.3.2.1. Outline

The mainboard carries out operations and controls for the movement of a robot and has various
communications interface functions. Various Man-Machine Interface (MMI) environments can be
established through the connection with surrounding devices via various communication ports such as
Serial, Ethernet, and CAN. Information files regarding, for example, controller constant, error history,
operation history, and teaching program are controlled through teach pendant.

CNSIO

OPSIO

CFCARD

CNETN1

CNETN2

CNETN3

CN1
(OPTION)

CANIO

(LED) BAT
CNBAT

DIP1 DIP2

Figure 4.17 Mainboard (BD510)

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 Hi5 Controller Maintenance Manual

4.3.2.2. Connector

Table 4-5 shows the use of connectors and external connecting devices.

Table 4-5 The Sorts and Uses of Mainboard (BD510)

Name Use External Connecting Device

The small door of the front panel of

CNSIO Serial Port 1: (RS232/RS422/RS485)
the controller

OPSIO Serial Port 2: (RS232/RS422/RS485) -

CFCARD For system -

CNETN1 Ethernet port: for cooperative control -

CNETN2 Ethernet port: for communications between T/P TP510 Connector (CNTP)

The small door of the front of the

CNETN3 Ethernet port: for users (PC 1/F)
controller

CN1 CAN port: CAN3 (Option) -

CANIO CAN port: for stem (CAN1)/ for user (CAN2) System board connector (CAN1)

BATCN Battery connector for back up Battery connector

4.3.2.3. Display Devices

Table 4-6 Mainboard (BD510) LED

Status
Color Normal Abnormal Solution
Name

V33 Green On Off Check out REG1 of the board - DC 3.3V

WD1 Red Off On Make a request for board repair

BAT Yellow On Off Replace the batteries for back up

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 4. Basic Components of Controller

4.3.2.4. Setting Unit

(1) DIP Switch Settings

CAUTION : Users may not change the setting of DIP switch [DIP 1].

Table 4-7 The Method for Setting of the [DIP 1] Switch of the Mainboard (BD 510)

Switch No. 1 2 3 4 5 6 7 8

OFF
Content
ON

Initial Setting OFF OFF OFF OFF OFF OFF OFF OFF

ON
The External
Form of the
Switch 1 2 3 4 5 6 7 8

CAUTION: Users may not change the setting of DIP switch [DIP 2].

Table 4-8 The Method for Setting of the [DIP 2] Switch of the Mainboard (BD510)

Switch No. 1 2 3 4 5 6

OFF Mainboard BOOT

Not Changeable
Content Reserved
(For system)
ON CF CARD BOOT

Initial Setting OFF OFF ON ON OFF OFF

ON
The External
Form of the
Switch 1 2 3 4 5 6

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 Hi5 Controller Maintenance Manual

(2) Jumper Pin Settings

Caution: Users may not change the setting of the JP 1 set in production.

Table 4-9 The Method for Setting of the Serial Communications Jumper of the Mainboard (BD 510)

Jumper No. JP1 JP2 JP3 JP7 JP8

Not [OPSIO] [CNSIO]

Content Changeable In using RS422/RS485 In using RS422/RS485
(For system) Termination Termination

Initial Setting SHORT SHORT SHORT SHORT SHORT

Table 4-10 The Method for Setting of CAN Communications Jumper of the Mainboard (BD510)

Jumper No. JP4 JP5 JP6

[CANIO] [CANIO]
CAN2 External Power : No. 1-2 SHORT
Content CAN2 CAN1
CAN2 Internal Power : No. 2-3 SHORT
Termination Termination

Initial Setting SHORT SHORT No. 2-3 SHORT

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 4. Basic Components of Controller

4.3.3. System Board(BD530/BD531)

4.3.3.1. Outline

The system board consists of the sequence part which open and close the power of the motor
according to the status of safety and the system IO part which enables the communications between
related IOs and super systems. It receives various safety signals from inside and outside of the robot
controller and controls the power required for the drive of the robot.

 Input of various safety signals : Emergency stop, limit switch, and safeguard
 Safety duplex chain with interlock
 Signal interface of the servo drive unit : PWMON, UV, OV, and OC
 Brake operation/release :
8 basic axes (3 main axes, 3 wrist axes, and 2 additional axes); 8 more axes extendable
 Other I/O interface

(a) Front ; BD530 Board(In charge of sequence) (b) Back ; BD531Board(In charge of system IO)

Figure 4.18 System Board (BD530/BD531)

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 Hi5 Controller Maintenance Manual

4.3.3.2. Connector

The following Figure shows the location and use of various connectors on BD530 board.

TBRMT TBEM TBPLC TBIO TBSP CNCP CNMC

Remote SW, External EM, Safety PLC, DI 4points, PLC Singal Circuit Magnetic
General-SG Auto-SG EM out DO 4points Power Input Protectors Contacts

CNP2
DC24V Power

CNP1 CNOP
DC5V Power
Operational
Panel,
EM SW
CAN1
System CAN,
User CAN

CAN2
= CAN1 CNBKE
Extented
Brake Signals
CANS2
System CAN

CNTP
Teaching
CNLSA8 Pendant
Aux. Limit
Switch 2
CNLSA7 CNSGA CNSGC CNLS
Aux. Limit AMP PWM Limit
Switch 1 Module Converter Switch
Module

CNB8 CNPB CNB7 CNB2 CNB1

8 Axis Brake Brake Powers 7 Axis Brake 1~6 Axes 1,4 Axes
Release Release Brake Release Brake Release

Figure 4.19 The Arrangement of the Connectors of the System Board (BD530)

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 4. Basic Components of Controller

Table 4-11 The Sorts and Uses of the Connectors of the System Board (BD530)

Name Use External Connecting Devices

CNP1 DC5V Power Supply SMPS P5(DC5V), M5(DC5V GND)

CNP2 D24V Power Supply SMPS P1(DC24V), M1(DC24V GND)

CAN1 CAN Communications Connection Main CAN Output Port

CAN2 CAN Communications Connection Small Door Board CAN Port

CAN Communications Connection for

CANS2 Preparatory Purpose
System
IN/OUT of Various Switches and LEDs
CNOP OP Board
of Control Panel
Input of Emergency Stop of T/P and
CNTP W/H CNTP
Enabling Device Status
Safeguard Device of the Exterior of the
CNGD GENERAL Safeguard Input
Controller
Arm interference, Input of the Limit
CNLS W/H CNE1
Switch for Detection of Over-Travel
Input limit switch for Over-travel
CNLSA7 Additional Axes (7 Axis) W/H
detection of added axis 7
Input limit switch for Over-travel
CNLSA8 Additional Axes (8 Axis) W/H
detection of added axis 8
/PWMON Signal Output and Various
CNSGC PWM Converter CNSGC
Error Signals Input (OV and OC)

CNSGA /PWMON Signal Output AMP CNSGA

Safety signal I/F when brake output is

CNBKE Brake extension board
extended
Connection of In/Out Signals Relating to CNMC of Electrical Board of Electrical
CNMC
Magnetic Contact (MC1 and 2) Module
Connection of Various Circuit Protectors CNMC of Electrical Board of Electrical
CNPC
and Fuses Module

CNPB Brake Power Supply (PB,MB,PREPB) SMPS Brake SMPS of Electrical Module

Output 2 points of brake release power

CNB1 (for 1-3 axes and 4-6 axes), error (TS) W/H CNM1
input
Separately output 6 points of brake
CNB2 release power (1, 2, 3, 4, 5, and 6 W/H CNM1
axes), error (TS) input
Output of Additional Axis Brake Release
CNB7 Additional Axis(7 axis) W/H
and Error Input

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 Hi5 Controller Maintenance Manual

Name Use External Connecting Devices

Output of Additional Brake Release and

CNB8 Additional Axis (8 axis) W/H
Error Input
Input of Emergency Stop and AUTO Emergency Stop Switch of the Exterior
TBEM
Safeguard of the Controller and Safeguard Device

TBIO In/Out of Preparatory System DIO Preparatory IO Device in the Controller

Connection of safety signal for safety

TBPLC Safety PLC
PLC
Remote mode signal input and general Remote mode operating device and
TBRMT
safety guard input general safety guard
Signal processing power input for PLC
TBSP Power device in the side of PLC
connection (DC24V)

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 4. Basic Components of Controller

(1) Terminal Block for Exterior Safety Signals ; TBEM

TBEM
Coding : pin 2, 10

pin 1

Figure 4.20 The Terminal Block of the System Board (BD530)

Table 4-12 The Terminal Block TBEM of the System Board (BD530)
Terminal Terminal
Use Others
No. Name

1 EXEM1-
Input of External Emergency SHORT unless external
Stop Chain 1 emergency stop chain 1 is used
2 EXEM1+

3 EXEM2+
Input of External emergency Stop SHORT unless external
Chain 2 emergency stop chain 2 is used
4 EXEM2-

5 SGAUTO1-
SHORT unless auto safeguard
Input of Auto Safeguard Chain 1
chain 1 is used
6 SGAUTO1+

7 SGAUTO2+
SHORT unless auto safeguard
Input of Auto Safeguard Chain 2
chain 2 is used
8 SGAUTO2-

9 EXMON External Motor ON Input Input of ON/OFF with M1 being

Common if the robot‟s motor ON
External Motor ON Input is used at the external system
10 M1
(Common)

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 Hi5 Controller Maintenance Manual

(2) Digital input/output terminal block exclusively used for the system (DC24V) ; TBIO

TBIO
Coding : pin 1, 9

pin 1

Figure 4.21 System board (BD530) terminal block TBIO

Table 4-13 Terminal Block TBIO of the System Board (BD530)

Terminal
Terminal Name Use
No.

1 P1 Digital output for the system (+) Common (DC24V)

2 DO1 Digital output signal 1 for the system (opened collector output)

3 DO2 Digital output signal 2for the system (opened collector output)

4 DO3 Digital output signal 3for the system (opened collector output)

5 DO4 Digital output signal 4for the system (opened collector output)

6 DI1 Digital input signal 1 for the system

7 DI2 Digital input signal 2for the system

8 DI3 Digital input signal 3for the system

9 DI4 Digital input signal 4for the system

10 M1 Digital input for the system (-) Common (DC24V GND)

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 4. Basic Components of Controller

(3) Terminal block for remote mode and general safety guard ; TBRMT

TBRMT
Coding : pin 1, 10

pin 1

Figure 4.22 System board (BD530) terminal block TBRMT

Table 4-14 System board (BD530) terminal block TBRMT description

Node No. Node Name Use

1 P1 Outputting power for the system (DC24V)

Outputting a remote state of controller 1 (output M1 in the case of a

2 M1_RMT
remote state)
Inputting a remote enable signal 1 (input M1 in the case of a remote
3 SWREMOTE1
state)
Outputting a remote state of controller 2(output P1 in the case of a
4 P1_RMT
remote state)
Inputting a remote enable signal 2 (input P1 in the case of a remote
5 SWREMOT2
state)

6 SGGEN1-
Inputting general safety guard Providing shorting when general
chain 1 safety guard chain 1 is not used
7 SGGEN1+

8 SGGEN2+
Inputting general safety guard Providing shorting when general
chain 2 safety guard chain 2 is not used
9 SGGEN2-

10 M1 Outputting system power (DC24V GND)

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 Hi5 Controller Maintenance Manual

(4) Terminal block for safety IO connection ; TBPLC

TBPLC
Coding : pin 2, 9

pin 1

Figure 4.23 System board (BD530) terminal block TBPLC

Table 4-15 System board (BD530) terminal block TBPLC description

Node No. Node Name Use

1 T0 Input node for monitoring the output of safety IO

2 FDBK Feedback signal output safety IO for TO

3 SG1 Safety guard input chain 1 from safety IO

4 SG2 Safety guard input chain 2 from safety IO

5 ES1 Emergency stop input chain 1 from safety IO

6 ES2 Emergency stop input chain 2 from safety IO

7 EMOUT1-
Internal emergency stop output chain 1
8 EMOUT1+

9 EMOUT2+
Internal emergency stop output chain 1
10 EMOUT2-

* Node Nos. 1-6 can be applied only to safety IO having an NPN output.

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 4. Basic Components of Controller

(5) Spare system CAN communication connector ; CANS2

Figure 4.24 Pin arrangement in system CAN connector

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 Hi5 Controller Maintenance Manual

4.3.3.3. Display Unit

LED3 LED4 7-SEG LED5

DC5V DC24V Status DC24V
POWER POWER Display PLC POWER INPUT

LED1
CPUERR

LED2
CPUERR

LEDB7 LEDB5 LEDB3 LEDB1

BR7 Release BR5 Release BR3 Release BR1 Release

LEDB8 LEDB6 LEDB4 LEDB2

BR8 Release BR6 Release BR4 Release BR2 Release

Figure 4.25 The Display Unit of the System Board (BD530)

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 4. Basic Components of Controller

Table 4-16 Description of the displaying device for the system board (BD530)
In Normal
Name Content Color Solution
Status
1. Checking for errors in the MAIN board
2. Checking for the interruption of electric
LED1 CPUERR Green On
power
3. Checking the CNIO cable
1. Checking for errors in the MAIN board
LED2 EXOUT Green On
2. Checking the CNIO cable
1. Checking 5V power within a board
LED3 5V POWER Green On 2. Checking SMPS 5V power
3. Checking the power cable CNP1
1. Checking 24V power within a board
LED4 24V POWER Green On 2. Checking SMPS 24V power
3. Checking the power cable CNP2
1. Checking the input of PLC power
PLC POWER
LED5 Green On 2.Checking SW7 when PLC power is not
(DC24V)
connected (internal power use setting)
1. Checking “lowering brake voltage”
monitoring (input signal for Teach
1-8 Axes Brake Hold:OFF pendant)
LEDB1~8 Green
Release Release:ON 2. Checking the brake power (TPPB-TMB;
24V)
3. Checking the power in brake release
Display of
Status Red Repair work according to status
7-SEG status
Information Code information.
information

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 Hi5 Controller Maintenance Manual

4.3.3.4. Setting and checking apparatus

SW6 SW7 SW2

ES1/2, SG1/2 Internal AC Power Fault
unused PLC power Detection
TPG1 TPM1

SW1
MAIN errors
unused

SW4 TPM2
OVTA
unused

SW5
ARM, OVTE
TPPB unused
TPB TMB
SW3
TS, R_FAN
unused SW8
BR8 Manual
Release

SWT7 SWT5 SWT3 SWT1

BR7 Manual BR5 Manual BR3 Manual BR1 Manual
Release Release Release Release

SWT8 SWT6 SWT4 SWT2

BR8 Manual BR6 Manual BR4 Manual BR2 Manual
Release Release Release Release

Figure 4.26 The Setting Unit of the System Board (BD530)

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 4. Basic Components of Controller

Table 4-17 System board (BD530) DIP switch SW1 (error monitoring) setting method

Switch No. 1 2 3 4

Interruption
CPUERR signal EXOUT signal EXIN signal
detection (VE)
Use (MAIN → (MAIN → (SYSTEM →
(SYSTEM →
SYSTEM) SYSTEM) MAIN)
MAIN)

OFF Use Use Use Use

Setting
Content
ON Non-use Non-use Non-use Non-use

Setting taking
OFF OFF OFF OFF
out time
ON
Switch
Appearance
1 2 3 4

Table 4-18 System board (BD530) DIP switch SW2 (AC power monitoring) setting method

Switch No. 1 2 3 4

AC power interruption detection level AC power interruption detection cycle

Use
selection selection (based on 60Hz)

OFF - - - -
Setting
Content Detection level: Detection level:
ON 1.5 cycles 3 cycles
70% 50%
Setting taking
OFF ON ON OFF
out time
ON
Switch
Appearance
1 2 3 4

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 Hi5 Controller Maintenance Manual

Table 4-19 System board (BD530) DIP switch SW3 (Motor temperature sensor monitoring) setting
method

Switch No. 1 2 3 4

R_FAN detection
TS detection TSA detection (7 TSA detection (8
Use (FANs embedded
(base axis) axis) axis)
in a robot)

OFF Use Use Use Use

Setting
Content
ON Non-use Non-use Non-use Non-use

Setting taking
ON ON ON ON
out time
ON
Switch
Appearance
1 2 3 4

Table 4-20 System board (BD530) DIP switch SW4 (Added axis OVT limit switch) setting method

Switch No. 1 2 3 4

Limit switch Limit switch Limit switch (chain Limit switch

Use (chain 1) (chain 2) 1) detection (8 (chain 1)
detection (7 axis) detection (7 axis) axis) detection (8 axis)

OFF Use Use Use Use

Setting
Content
ON Non-use Non-use Non-use Non-use

Setting taking
ON ON ON ON
out time
ON
Switch
Appearance
1 2 3 4

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 4. Basic Components of Controller

Table 4-21 System board (BD530) DIP switch SW5 (Dark interference, extending axis limit switch)
setting method

Switch No. 1 2 3 4

Limit switch Limit switch Limit switch

Limit switch (chain
(chain 1) (chain 2) (chain 1)
Use 1) detection
detection (dark detection (dark detection
(Extending axis)
interference) interference) (Extending axis)
OFF Use Use Use Use
Setting
Content
ON Non-use Non-use Non-use Non-use

Setting taking
ON ON ON ON
out time

ON

Switch
Appearance
1 2 3 4

Table 4-22 System board (BD530) DIP switch SW6 (Safety IO safety signal monitoring) setting method

Switch No. 1 2 3 4

Safety guard Safety guard Emergency stop Emergency stop

Use SG1 (chain 1) SG2 (chain 2) ES1 (chain 1) ES2 (chain 2)
detection detection detection detection

OFF Use Use Use Use

Setting
Content
ON Non-use Non-use Non-use Non-use

Setting taking
ON ON ON ON
out time

ON
Switch
Appearance
1 2 3 4

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 Hi5 Controller Maintenance Manual

Table 4-23 System board (BD530) DIP switch SW7 (Power for Safety IO signal) setting method

Switch No. 1 2 3 4

Use Selecting power for Safety IO signal - -

Power of Safety Power of Safety

OFF - -
Setting IO (DC24V) IO (DC24V GND)
Content Controller power Controller power
ON - -
(P1) (M1)
Setting taking
OFF OFF OFF OFF
out time
ON
Switch
Appearance
1 2 3 4

Table 4-24 Description of system board (BD530) toggle switch SWT1-8 operation

Switch NO. Use

SWT1 Releasing robot basic axis 1 motor brake manually

SWT2 Releasing robot basic axis 2 motor brake manually

SWT3 Releasing robot basic axis 3 motor brake manually

SWT4 Releasing robot basic axis 4 motor brake manually

SWT5 Releasing robot basic axis 5 motor brake manually

SWT6 Releasing robot basic axis 6 motor brake manually

SWT7 Releasing added axis 7 motor brake manually

SWT8 Releasing added axis 8 motor brake manually

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 4. Basic Components of Controller

4.3.3.5. Emergency stop connection

(1) Contact point input external emergency stop

External emergency stop is operated regardless of the mode of the controller, (automatic
mode, manual mode). When the emergency stop switch input occurs, promptly remove motor
power so as to secure safety. The emergency stop switch must be of a structure capable of
contact point outputting. This is because a node is formed in a terminal block so as to
connect the contact output of the external emergency stop switch to a duplicated safety chain
as shown in the picture below. (※ Reference: Description of the node of terminal block
TBEM)

Figure 4.27 Method for connecting the external emergency stop switch to terminal block TBEM

In cases where the external emergency stop is not used, ensure input is ineffective by
connecting the nodes of terminal block TBEM in the manner described below.

pin 1

pin 1(EMEX1-) - pin 2(EMEX1+) Short

pin 3(EMEX2+) - pin 4(EMEX2-) Short

Figure 4.28 Management method when a contact point input type-external emergency stop is not
used.

In cases where an external emergency stop switch is installed for use, a user
must operate the robot only after checking that emergency stop is operating
normally. Additionally, check if emergency stop input has become ineffective.
This step is necessary for worker safety.

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 Hi5 Controller Maintenance Manual

(2) P-COM input external emergency stop

Basically, an automatic safety guard can receive contact point input from terminal block
TBEM. However, a device such as a safety PLC or safety IO transmits safety guard signals to
the controller through NPN output. The Figure below shows a connecting method through
terminal block TBPLC in which the controller can receive NPN type output. (※ Reference:
Description of the node of terminal block TBPLC)

Safety PLC/IO SMPS

TBSP
P(DC24V)
P P(DC24V)

M(DC24V GND)
G M(DC24V GND)

TBPLC
3 8mA SafeGuard (CH1)
SG1

4 8mA SafeGuard (CH2)

SG2

5 8mA EM Stop (CH1)

ES1

6 8mA EM Stop (CH2)

ES2

Figure 4.29 Method of connecting the automatic safety guard to an NPN output device

In cases where the P-COM input external emergency stop is not used, ensure the emergency
stop input becomes ineffective by turning on switch No. 3 and switch No. 4 of DIP switch
SW6, as shown below.
(※ Reference: DIP switch SW6 (safety IO safety signal monitoring) setting method)

ON

1 2 3 4

Figure 4.30 Management method in cases where the P-COM input external emergency stop is not
used

In cases where an external emergency stop switch is installed for use, a user
must operate the robot only after checking that emergency stop is operating
normally. Additionally, check if emergency stop input has become ineffective.
This step is necessary for worker safety.

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 4. Basic Components of Controller

(3) Internal emergency stop contact point output

When you want to use the emergency stop switch (operation panel, teach pendant, etc.)
installed in the interior of the controller, or as external apparatus, use the emergency stop
contact point output within terminal block TBEM.

TBPLC External System

EXOUT1- 7
Load
Internal Emergency Stop +
Switch Output (CH1)
EXOUT1+ 8

EXOUT2+ 9
Load
Internal Emergency Stop +
Switch Output (CH2)
EXOUT2- 10

Figure 4.31 Output the internal emergency stop switch of terminal block TBPLC

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4.3.3.6. Safety guard connection

(1) Typical safety guard

A typical safety guard operates regardless of the mode of the controller (automatic mode or
manual mode). That is, when a person enters the interior of an installed safety guard or when
the guard is cut off, the controller promptly removes motor power. The safety guard to use
must have a structure capable of contact point outputting. A node is included in terminal block
TBRMT so as to connect the contact point output of the safety guard to a safety chain in a
duplicated manner, as shown in the Figure below. (※ Reference: Description of the node of
terminal block TBRMT)

Figure 4.32 Method for connecting a typical safety guard to terminal block TBPLC

In cases where a typical safety guard is not used, ensure input becomes ineffective by
connecting the nodes of terminal block TBRMT in the manner described below.

pin 1

pin 6(SGGEN1-) - pin 7(SGGEN1+) Short

pin 8(SGGEN2+) - pin 9(SGGEN-) Short

Figure 4.33 Management method in cases where a typical safety guard is not used

In cases where an external emergency stop switch is installed for use, a user
must operate the robot only after checking that emergency stop is operating
normally. Additionally, check if emergency stop input has become ineffective.
This step is necessary for worker safety.

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 4. Basic Components of Controller

(2) Contact point input automatic safety guard

An automatic safety guard operates only when the controller is in automatic mode. Similarly
to a typical safety guard, the automatic safety guard must have a structure capable of contact
point outputting. A node is included in terminal block TBEM so as to connect the contact point
output of the safety guard to a safety chain in a duplicated manner, as shown in the Figure
below. (※ Reference: Description of the node of terminal block TBEM)

Figure 4.34 Method for connecting the contact point input automatic safety guard to terminal block
TBEM

In cases where an automatic safety guard is not used, ensure input becomes ineffective by
connecting the nodes of terminal block TBEM in the manner described below.

pin 1

pin 5(SGAUTO1-) - pin 6(SGAUTO1+) Short

pin 7(SGAUTO2+) - pin 8(SGAUTO2-) Short

Figure 4.35 Management method in cases where a contact point input automatic safety guard is not
used

In cases where an automatic safety guard is installed for use, a user must
operate the robot only after checking that the safety guard is operating
normally. Additionally, check if the safety guard input has become ineffective.
This step is necessary for worker safety.

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 Hi5 Controller Maintenance Manual

(3) P-COM input automatic safety guard

Essentially, an automatic safety guard can receive the contact point input from terminal block
TBEM. However, a device such as safety PLC and safety IO, transmits safety guard signals
to a controller through NPN output. The Figure below shows a connecting method through
terminal block TBPLC in which the controller can receive NPN type output. (※ Reference:
Description of the node of terminal block TBPLC)

Safety PLC/IO SMPS

TBSP
P(DC24V)
P P(DC24V)

M(DC24V GND)
G M(DC24V GND)

TBPLC
3 8mA SafeGuard (CH1)
SG1

4 8mA SafeGuard (CH2)

SG2

5 8mA EM Stop (CH1)

ES1

6 8mA EM Stop (CH2)

ES2

Figure 4.36 Connecting method of an automatic safety guard with respect to an NPN output device

In cases where a P-COM input automatic safety guard is not used, ensure input becomes
ineffective by turning on switch No. 1 and switch No. 2 of the DIP switch SW6 as described
below.
(※ Reference: DIP switch SW6 (safety IO safety signal monitoring) setting method)

ON

1 2 3 4

Figure 4.37 Management method in cases where P-COM input automatic safety guard is not used

In cases where an automatic safety guard is installed for use, a user must
operate the robot only after checking that the safety guard is operating
normally. Additionally, check if the safety guard input has become ineffective.
This step is necessary for worker safety.

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 4. Basic Components of Controller

4.3.3.7. Remote control connection

In order to operate a remote control, the robot operation is possible only when a user has formed the
wiring as below.

(1) External motor power ON signal

Figure 4.38 Method for inputting the external motor power ON signal into terminal block TBEM

(2) Remote switch input

TBRMT Remote System

3
SWREMOTE1

Contacts
10
M1(0V)

TP Mode
Switch (CH1)
M1_RMT 2
monitoring

5
SWREMOTE2

Contacts
P1(DC24V) 1

TP Mode
Switch (CH2)
P1_RMT 2
monitoring

Figure 4.39 for inputting the remote switch signal into terminal block TBRMT

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 Hi5 Controller Maintenance Manual

In cases where remote switch input is not used, ensure input becomes ineffective by
connecting the nodes of terminal block TBRMT as described below.

pin 1

pin 1(P1) - pin 5(SWREMOTE2) Short

pin 10(M1) - pin 3(SWREMOTE1) Short

Figure 4.40 Management method in cases where remote switch input is not used

In cases where a remote switch is installed for use, a user must operate the
robot only after checking that the remote switch is operating normally.
Additionally, check if the remote switch input has become ineffective. This
step is necessary for worker safety.

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 4. Basic Components of Controller

4.3.3.8. Safety PLC/IO connection

Between safety PLC or safety IO and a robot controller, emergency input signals and monitoring
output signals are connected with each other as outlined below.

SYSTEM B/D(BD530) Safety PLC/IO

TBSP SMPS
P(DC24V)
P P(DC24V)

M(DC24V GND)
G M(DC24V GND)

TBPLC
T0 1 T0

Magnetic Contact Status

(CH1, CH2)
FDBK 2 IN0

3 8mA OUT0
SafeGuard (CH1) SG1

4 8mA OUT1
SafeGuard (CH2) SG2

EM Stop (CH1) 5 8mA OUT2

ES1

EM Stop (CH2) 6 8mA OUT3

ES2

EXOUT1- 7 T1

Internal Emergency Stop

Switch Output (CH1)
EXOUT1+ 8 IN1

EXOUT2+ 9 T2

Internal Emergency Stop

Switch Output (CH2)
10 IN2
EXOUT2-

Figure 4.41 Connection method of Safety PLC/IO

In cases where external emergency stop is installed for use, a user must operate
the robot only after checking that emergency stop is operating normally.
Additionally, check if emergency stop input has become ineffective. This step is
necessary for worker safety.

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4.3.3.9. Connection of digital input/output signal for a system

(1) Digital output

Figure 4.42 Method for connecting digital output for a system to terminal block TBIO

(2) Digital input

Figure 4.43 Method for connecting digital input for a system to terminal block

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 4. Basic Components of Controller

4.3.4. Servo Board (BD542)

4.3.4.1. Outline

The servo board controls the actions of the motors for 6 axes (max. 8 axes) according to the position
command form the main board, and creates PWM signals of encored signal processing, error status
checking and the drive unit.

SON1
AL1
AL2
DSP1
AL3
(U27)
AL7

1Layer: CNBS1
2Layer: CNBS2
3Layer: CNBS3
JP1
SON2
AL4 JP2
AL6
AL5 DS2
AL7

CNCK
DS1

JP3
CNEC1

CNEC2
S1 : Dip SW
DSP2
(U30)

Figure 4.44 Servo Board (BD542)

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4.3.4.2. Connector

Table 4-25 The Sorts and Uses of Servo Board (BD 542) Connectors

Name Use External Device Connection

CNEC1 Encoder signal connection CNR4

Additional Axis encoder signal

CNEC2 CNR7,CNR8
connection

CNBS1,2,3 Dive unit signal connection CNBS1,2, and 3 of Drive Unit

PWM clock synchronization between Additional Servo Board

CNCK
servo boards in controlling over 9 axes (BD542)CNCK

JP1,3 JTAG Emulator Port(DSP1, DSP2) JTAG Emulator

JP2 EPLD program download port EPLD Program Download Tool

4.3.4.3. Display Unit

Table 4-26Servo Board (BD542) LED

Status
Color Normal Abnormal Remark
Name

AL1~8 Red ON OFF ALX : X Axis (X=1~8)

ON if Motor is OFF if Motor is SON1: 1 DSP,

SON1~2 Green
ON OFF SON2; 2 DSP

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 4. Basic Components of Controller

4.3.4.4. Setting Unit

Caution: DIP switches are initially set as ON, and users may not change them.

Table 4-27 The Method for the Setting of DIP Switches (S1) of the Servo Board (BD542)

Switch No. 1 2 3 4 5 6 7 8

Initial Setting ON ON ON ON ON ON ON ON

ON
External Form
of Switch
1 2 3 4 5 6 7 8

Caution: Users may not change the following settings, and if you want to expand
DSP board, please contact with us.

Table 4-28 The Method for the Setting of DIP Switch (DS1) of the Servo Board (BD542)

Switch No. 1 2 3 4

Boot Mode Settings(Pin 1, 2) HPI Pin Enable

Big Endian
OFF ON, ON : HPI/EMU Boot ( Pin Functions
Mode
Content OFF, ON : 8Bit Flash Boot Setting)
ON, OFF : 16bit Flash Boot Little Endian
ON HPI Pin disable
OFF, OFF : 32Bit Flash Boot Mode

Initial Setting ON ON OFF OFF

ON
Exterior Form of
Switch
1 2 3 4

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 Hi5 Controller Maintenance Manual

Caution:
Users may not change the following settings, and if you want to expand DSP
board, please contact with us.

Table 4-29 The DIP Switch (DS2: Pin 1 and 2)of the Servo Board (BD542)

Name DS2

Content 1 2

Designate 1DSP(U27) and 2DSP(U30) ON ON

Designate 3DSP(U27) and 4DSP(U30) OFF ON

DSP1(U27),
DSP2(U30) Setting
Designate 5DSP(U27) and 6DSP(U30) ON OFF

Designate 7DSP(U27) and 8DSP(U30) OFF OFF

ON

Initial Settings ON ON
1 2 3 4

Table 4-30 The DIP Switch (DS2: Pin 3 and 4)of the Servo Board (BD542)

DS2
Name
Contents
3 4

Flash Write Prohibition ON X

Prohibition of Flash
Write Function
Flash Write Admission OFF X

DSP‟s Own RESET

X ON
+ Admission of Main Reset Command
DSP Reset
Use of DSP‟s Own Reset Only X OFF

ON

Initial Setting ON ON
1 2 3 4

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 4. Basic Components of Controller

4.3.5. Drive Unit

4.3.5.1. SA3X3Y (Medium-Scale 6-Axis All-In-One Drive unit)

The drive unit plays a role of amplifying power by sending current to each motor according to the
current command from the servo board. The 6 axis all-in-one drive unit can operate 6 motors at the
same time, and the following table shows its components.

Table 4-31 The Components of SA3X3Y(Medium-Scale 6-Axis All-In-One Drive unit)

Component Function

Separation of the PWM signal from the servo

BD552(Logic Board) board into upper and lower IPM drive signals, and
execution of error processing

Gate Drive Module Generation of IPM gate signals

BD551 Gate Power Module Generation of gate power

(Strong Electric
Board) Current Detection Unit Detection of the current flowing into the motor

Control of dynamic brake according to the signals

DB Control
from the servo board

Heat Sink Emission of heat generated from IPM

Other Parts
IPM Switching Device

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 The Reference Number of Servo Drive Unit

S A 3 □ 3 □ V □□ □ - □□□□□□ - □□ □□ - xxx

Servo Amplifier
No. of Axes(3)
IPM Mark - 3 Main Axes
No. of Axes(3)
IPM Mark - 3 Wrist Axes
Version No.
Change History(a, b, ……)
Hall Sensor by Axis
Year of Manufacture
Month of Manufacture
Serial Number

Table 4-32 The Mark of Type of Servo Driver Series

Classification Mark of Type

Servo Amp SA

Table 4-33 The Specifications of Drive Unit

Item Classification Application

1L 4X HC2500BD-10

6 Axis All-In-One
IPM Capa. 3X 3Y HS165 applied
Type

3X 3Z HC2500BD-00, HC2500IK

Year 00 ~ 99 Year of Manufacture : 2000 ~ 2099

Month 01 ~ 12 Month of Manufacture : 1 ~ 12

Serial No. 001 ~ 999 No. of units manufactured per month : 1 ~ 999

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 4. Basic Components of Controller

Table 4-34 IPM Capacity

L (IPM Rated Current) 150A, (Hall Sensor Rated Current) 4V/75A

X (IPM Rated Current) 100A, (Hall Sensor Rated Current) 4V/50A

Large/Medium
Size
Y (IPM Rated Current) 75A, (Hall Sensor Rated Current) 4V/50A

Z (IPM Rated Current) 50A, (Hall Sensor Rated Current) 4V/25A

Table 4-35 Hall Sensor Marks

AMP Feedback
AMP Model Hall Sensor Mark(Spec.) Full-Scale Current(Im)
Constant(Iv)

0 (4V/75A) 140.62Apeak PM150CSD060(150A)

1 (4V/50A) 93.75Apeak

Large/Medium 2 (4V/25A) 46.87Apeak

–Scale(6 Axis) PM150CSD060(150A)
Amp PM100CSD060(100A)
3 (4V/15A) 28.12Apeak
PM75CSD060(75A)
PM50CSD060(50A)
4 (4V/10A) 18.75Apeak

5 (4V/ 5A) 9.37Apeak

Caution:
As the drive unit varies depending on the robot, so please check out the form of
it in replacing it.

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 Hi5 Controller Maintenance Manual

Figure 4.45 BD552 Component Layout

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 4. Basic Components of Controller

Figure 4.46 BD551 Component Layout

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 Hi5 Controller Maintenance Manual

Table 4-36 BD552 Connector

Name Use External Device Connection

CNBS1, 2,3 PWM Signal and Error Signal Servo Board(BD542) CNBS1,2,3

CNSGA /PWMON, SVERR, BRAKE Sequence Board (BD530) CNSGA

CNPWM1~6 PWM Signal and Error Signal Servo Amp BD551 CNPWM1~6

Additional Axis PWM Signal and Error

CNPWM7~8 Option Board(BD554, BD556) CNPWM
Signal

Table 4-37 BD551 Connector

Name Use External Device Connection

CNDBPOW Power for DB control CNPB of BD5C0

CNDB7,8 Additional Axis DB drive signal Option board (BD554, BD555) CNDB

CNM1~6 Motor Connection CMC1, CMC2

CNPWM1~6 PWM signal and error signal Servo Amp BD552 CNPWM1~6

CNPPNN Power for motor drive Drive Power Unit (BD561) CNPN1

The frame ground of the Main axis

CNFG1 CMC1
motor
The frame ground of the Wrist Axis
CNFG2 CMC2
motor

Table 4-38 BD552 LEDs

Name Color Status Display

SV Yellow ON if PWM is ON

POW Green OFF if current dip/sag occurs

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 4. Basic Components of Controller

4.3.5.2. SD1L2C (Medium-Scale Diode Module Converter)

The medium-scale diode module converter changes the 3-phase current supplied from the electrical
module into direct current by rectifying it through the diode module, and then store it in the electrolytic
capacitor. The power generated from the motor in the robot slowing down is consumed through the
transistor and resistance, and the following shows its components.

 The Specifications for Drive Power Unit

S D1 □ □C V □□ □ - □□ □□ - xxx

Servo Diode Module

Regenerative IGBT Spec.
Condenser Spec.
Version No.
Change History(a, b, ……)
Year of Manufacture
Month of Manufacture
Serial No.

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Table 4-39 The Mark of Type of Driver Series

Classification Mark of Type

Servo Diode Module SD

Table 4-40 The Specifications of Drive Power Unit

Item Classification Application

Year 00 ~ 99 Year of Manufacture : 2000 ~ 2099

Month 01 ~ 12 Month of Manufacture : 1~ 12

Serial No. 001 ~ 999 No. of units manufactured per month : 1 ~ 999

Table 4-41 The Specifications of Regenerative IGBT

Regenerative IGBT L 150A, Regenerative Resistance: 2Ω 800W 2EA Applicable

Table 4-42 Chemical Condenser Capacity

Chemical
2C 3300uF 2EA (HA165, HA020 + Carriage)
Condenser

Table 4-43 SD1L2C (Medium-Scale Diode Module Converter)

Components Function

Generation of DC power circuit provided from the

Rectifier Unit
AC input main power.
BD561
(Converter Regenerative Control Drive of IGBT if PN voltage increases
Board)
The detection of overvoltage, overheated
Error Detection Unit regenerative resistance, and bibliographic data
input errors
Emission of heat generated from the power
Heat Sink
device
Other
Capacitor DC power smoothing
Components

Regenerative IGBT Execution of regenerative control

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 4. Basic Components of Controller

Figure 4.47BD561 Component Layout

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Table 4-44 Medium-Scale Drive Power Unit (SD1L2C) Connector

Name Use External Device Connection

CNRST 3-Phase Power Input Electrical Module CNRST

CNSGC /PWMON, OV, FLT, FB Sequence Board(BD530) CNSGC

Regenerative Power
CNDR Regenerative Resistance
Output
Detection of Overheated
CNTR Thermal Sensor of Regenerative Resistance
Regenerative Resistance
6-Axis Servo Amp CNPPNN, Additional Axis
CNPN1,2 For Supply of PN Power
CNPN

Table 4-45 Medium-scale Drive Power Unit (SD1L2C) LED

Name Color Status Display

SV Yellow ON if PWN is ON

POW Green OFF if control voltage sag occurs

DR Red ON if regenerative power discharge operates

PN Red ON if PN voltage is over 42V

RYON Red OFF if PN power discharge operates

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 4. Basic Components of Controller

4.3.5.3. SA3A3D (Small sized-6 axes integral type-driving apparatus)

The drive unit plays a role of amplifying power by sending current to each motor according to the
current command from the servo board. The 6 axis all-in-one drive unit can operate 6 motors at the
same time, and the following Table shows its components.

A small sized-diode module converter is formed integrally with a small-sized servoamplifier, and
converts three-phase current provided from an electronic field module to direct current through the
rectification of a diode module so as to store it in a smoothing capacitor. When the speed of the robot
is reduced, power generated from a motor is consumed through a transistor and resistance. The diode
module converter is constructed as shown below.

Table 4-46 Construction of SA3A3D (Small sized-6 axes integral type-driving apparatus)

Component Function

Gate Drive Module Generation of IPM gate signals

BD553
Gate Power Module Generation of gate power
(IPM board)

Current Detection Unit Detection of the current flowing into the motor

Generation of DC power circuit provided from the AC

Rectifier Unit
input main power.
BD563
(Converter Regenerative Control Drive of IGBT if PN voltage increases
Board)
The detection of overvoltage, overheated regenerative
Error Detection Unit
resistance, and bibliographic data input errors

Heat Sink Emission of heat generated from IPM

Capacitor DC power smoothing

Other Parts
Regenerative IGBT Execution of regenerative control

IPM Switching Device

Caution:
As the drive unit varies depending on the robot, so please check out the form of
it in replacing it.

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Figure 4.48 BD553 Component Layout

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 4. Basic Components of Controller

Figure 4.49 BD563 Component Layout

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Table 4-47 Description of connector BD553

Name Use External Device Connection

CNBS1,2,3 PWM Signal and Error Signal Servo Board(BD542) CNBS1,2,3

CNSGA /PWMON, SVERR, BRAKE Sequence Board (BD530) CNSGA

Additional Axis PWM Signal and

CNPWM7~8 Option Board (BD554, BD556) CNPWM
Error Signal

CNM1~6 Motor Connection CMC1

CNPPNN Power for motor drive Drive Power Unit (BD561) CNPN1

The frame ground of the Main

CNFG CMC1
Axis motor

Table 4-48 Description of BD553 LED

Name Color Status Display

SV Yellow ON if PWM is ON

POW Green OFF if current dip/sag occurs

Table 4-49 Description of connector BD563

Name Use External Device Connection

CNRST 3-Phase Power Input Electrical Module CNRST

CNSGC /PWMON, OV, FLT, FB Sequence Board(BD530) CNSGC

CNDR Regenerative Power Output Regenerative Resistance

Detection of Overheated
CNTR Thermal Sensor of Regenerative Resistance
Regenerative Resistance
6-Axis Servo Amp CNPPNN, Additional Axis
CNPN1,2 For Supply of PN Power
CNPN

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 4. Basic Components of Controller

Table 4-50 Description of BD563 LED

Name Color Status Display

SV Yellow ON if PWN is ON

POW Green OFF if control voltage sag occurs

DR Red ON if regenerative power discharge operates

PN Red ON if PN voltage is over 42V

RYON Red OFF if PN power discharge operates

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4.3.5.4. The Specifications of Option Drive Unit

 AMP(DRIVER UNIT) type construction: When 2 axes are configured

S A 1 □ 1 □ V □□ □ - □□ - □□ □□ - xxx

Servo Amplifier
No. of Axis(1)
IPM Mark 1 Axis
No. of Axis(1)
IPM Mark - 1 Axis
Version No.
Change History(a, b, ……)
Hall Sensor by Axis
Year of Manufacture
Month of Manufacture
Serial No.

Table 4-51 The Mark of Type of Driver Series

Classification Mark of Type

Servo AMP SA

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 4. Basic Components of Controller

Table 4-52 IPM Capacity

A (IPM Rated Current) 30A, (Hall Sensor Rated Current) 4V/15A

Small Size
D (IPM Rated Current) 10A, (Hall Sensor Rated Current) 4V/5A

L (IPM Rated Current) 150A, (Hall Sensor Rated Current) 4V/75A

X (IPM Rated Current) 100A, (Hall Sensor Rated Current) 4V/50A

Large/Medium
Size
Y (IPM Rated Current) 75A, (Hall Sensor Rated Current) 4V/50A

Z (IPM Rated Current) 50A, (Hall Sensor Rated Current) 4V/25A

Table 4-53 Hall Sensor Marks

Hall Sensor Mark AMP Feedback
AMP Model Full-Scale Current(Im)
(Spec.) Constant(Iv)

0 (4V/75A) 140.62Apeak PM150CLB060(150A)

1 (4V/50A) 93.75Apeak

Large/Medium 2 (4V/25A) 46.87Apeak

–Scale(6 Axis) PM150CLB060(150A)
Additional axis PM100CLB060(100A)
Amp 3 (4V/15A) 28.12Apeak
PM75CLB060(75A)
PM50CLB060(50A)
4 (4V/10A) 18.75Apeak

5 (4V/5A) 9.37Apeak

3 (4V/15A) 28.12Apeak PM30CSJ060(30A)

Small –Scale
(6 Axis)
4 (4V/10A) 18.75Apeak PM30CSJ060(30A)
Additional axis
Amp
PM30CSJ060(30A)
5 (4V/5A) 9.37Apeak
PM10CSJ060(10A)

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4.3.5.5. SA1X (Medium-Scale 1 Axis Drive Unit ; Option)

The drive unit plays a role of amplifying power by sending current to each motor according to the
current command from the servo board. The medium-scale additional axis drive unit can drive one
motor, and the following figure shows is components.

Figure 4.50 BD554 Component Layout

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 4. Basic Components of Controller

Table 4-54 The Components of SA1X(Medium-Scale 1 Axis Drive Unit ; Option)

Components Function

Conversion of PWM signal from the 6 axis servo amp

Logic Part into upper and lower drive signals of IPM and execution
of error processing and regenerative control
Gate Power
Generation of gate power
BD554 Module
(Amp Board)
Current Detection
Detection of the current flowing into the motor
Unit
Control of dynamic brake according to the signals from
DB Control
the 6 axis servo amp

Heat Sink Emission of heat generated from IPM

Other
Components
IPM Switching Device

Table 4-55 SA1X (Medium-Scale 1 Axis Drive Unit ; Option) Connector

Name Use External Device Connection

CNPWM7 or CNPWM8 of the 6-Axis

CNPWM PWM signal and error signal
Servo Amp (BD552 or BD553)

CNM Power for motor drive AMC1 or AMC2

CNFG Motor frame ground AMC1 or AMC2

PN voltage is inputted from the CNPN2 of the 6-Axis Servo Amp(BD561

CNPN1,2
diode module or BD563)s

CNDB DB drive of Additional Axis 6-Axis Servo Amp CNDB7, CNDB8

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4.3.5.6. SA1A (Small-Scale 1 Axis Drive Unit ; Option)

The drive unit plays a role of amplifying power by sending current to each motor according to the
current command from the servo board. The small-scale additional axis drive unit can drive one motor,
and the following figure shows is components.

Figure 4.51 BD556 Component Layout

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 4. Basic Components of Controller

Table 4-56 The Composition of SA1A (Small-scale 1 Axis Drive Unit; Option)

Components Function

Conversion of PWM signal from the 6 axis servo amp

Logic Section into upper and lower drive signals of IPM and
execution of error processing and regenerative control
BD556
(Amp Board) Gate Power Module Generation of gate power

Current Detection Unit Detection of the current flowing into the motor

Heat Sink Emission of heat generated from IPM

Other
Components
IPM Switching Device

Table 4-57 SA1A(Small-Scale 1 Axis Drive Unit ; Option) Connector

Name Use External Device Connection

PWM signal and error CNPWM7 or CNPWM8 of the 6-Axis Servo Amp
CNPWM
signal (BD552 or BD553)
Motor drive output,
CNM AMC1 or AMC2
Frame Ground

CNPN For input of drive power CNPN2 of the 6-Axis Servo Amp (BD561 or BD563)

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4.3.6. DC Multi Power Unit (SMPS : HDI-200)

The DC multi power unit supplies all the DC power within the controller. With the input voltage of
AC48V, it is a multi power supply device which generates various kinds of stabilized DC voltages and
supplies them to many boards, drive unit, system IN/OUT, and teach pendant within the controller.

Figure 4.52 External appearance of SMPS SR1 and configuration mounted in Rack

Table 4-58 SMPS(SR1) Standards (Input Voltage ; AC 45V~50V, 50/60Hz)

Rated Output Use Connection

ENCODER(5V) Motor Encoder Power: DC5V W/H Connector(CNE1)

CONTROL(5V) Board Power in Rack: DC5V Backplane Board (BD501)

System board and other option

P1-M1 System I/O Power: DC24V
boards

P2-M2 Teach pendant Power: DC24V TP510 Connector (CNTP)

DC-15V Drive Unit Control Power Backplane Board (BD501)

The Control Power for Analog Section of

DC+15V Backplane Board (BD501)
the Servo Board

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 4. Basic Components of Controller

4.3.7. Electrical Module and Electrical Board(BD5C0)

4.3.7.1. Outline

The electrical module plays a role of opening/closing and distributing various electric powers supplied
to the controller. The following picture shows the interior and exterior of the electrical module equipped
with various connectors and fuses.

Moto Power Output Motor Power Input AC Power Output

CP for Motor Power Fuse AC Power Input (CNAC)

Figure 4.53 Electrical Module

Electrical Board
(BD5C0) CP for Motor power

Magnetic Contactor MC2

Magnetic Contactor MC1

SMPS for Brake

Figure 4.54 The Interior of Electrical Module

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The following power flow chart shows the opening/closing of the 3-phase AC power for motor power
supply, generation of brake power, AC control power such as fan operation, and the distribution of
SMPS power for DC device power supply. Each power supply is equipped with a circuit breaker or
fuse to protect components from overcurrent. The electrical board (BD5C0) is used to minimize the
use of the cables used for the distribution of power.

Electric Electric
Module Components B/D Pre-charge
Resistor

Diode
220V
CB Module
MC1 MC2 Converter

220V Fuse SMPS System Brakes

5A (Brake) B/D (본체)
NF
NFB Trans
(opt.)
220V Fuse
FANs
5A

48V Fuse SMPS

10A (Control)
Electric
Components B/D

Figure 4.55 Power system of controller Hi5

Table 4-59 The Sorts and Uses of Fuses in the Electrical Module

Name Use Spec.

F1, F2 Overcurrent Protection Fuse of the Electrical Control Power(AC220) AC220V 2A

AC220V
F3, F4 Overcurrent Protection Fuse of the SMPS Power (AC48)
10A

F5, F6 Overcurrent Protection Fuse of the Brake SMPS Power (AC220) AC220V 5A

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 4. Basic Components of Controller

4.3.7.2. Connector

The following picture shows the layout of the electrical board (BD5C0)‟s connectors, and the table
shows the uses of each connector and other connection devices.

Overcurrent
브레이크전원 Protection
Fuse (5A) of
(AC220V) 과전류 the Brake
Power (AC220V)
보호용 FUSE : 5A

Overcurrent
전장제어전원 Protection
Fuse (2A) of the
(AC220V) 과전류 electrical
Control Power (AC220V) CNPR1
AC Power 입력(CNAC)
AC전원 Input (CNAC) 보호용 FUSE : 2A
CNPR2
CNPB2
CNPK to SMPS
CNPB1
CNPB from SMPS
CNHM
CNPB3 to SYSTEM
CNFN4

CNFN3 CNMC1

CNFN2 CNMC2

CNFN1 CNMC

SMPS전원Protection
Overcurrent
CN48 (AC48V) 과전류 CNCP
Fuse (10A) of the SMPS
보호용
Power FUSE :
(AC48V)
10A CNCP1

Figure 4.56 Connectors of the Electrical Board (BD5C0)

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Table 4-60 Types and applications of fuses in the electronic control module
External Devices
Name Use
Connection

CNAC Various AC power inputs Transformer

CN48 SMPS Power Output (AC48V) SMPS

CNFAN1~3 Power Output (AC220V) for Electrical Drive FAN Module

CNHM Power Output (AC220V) for Hour Meter Hour Meter (Option)

CNPR1 Precharge Resistance Power Input MC2 Input

CNPR2 Precharge Resistance Power Output MC2 Output

CNPK Brake Power Output (AC220V) Brake Power SMPS Input

CNPB Brake Power Input (DC24V) Brake Power SMPS Output

Servo Amp and Extended

CNPB1,2 Brake Power Output (DC24V)
Brake Board

CNPB3 Brake Power Output(DC24V) System Board CNPB Input

Input of Motor Power Circuit Breaker

CNCP1 Motor Power Circuit Breaker
Monitoring
Output of the Monitoring of Circuit Breaker
CNCP System Board CNCP Input
and Fuse
The Drive and Monitoring of Magnetic Magnetic Contactor MC1,
CNMC1,2
Contactor MC2
Drive Signal and Monitoring Signal for
CNMC System Board CNMC
Magnetic Contactor

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 4. Basic Components of Controller

4.3.8. Small Door Board (BD5B1)

The small door board (BD5B1) is the board with various input/output connectors for users to connect
the controller with various communication lines such as Ethernet, RS232, and CAN. It is located under
the control panel in the front side of the controller. If you open the door, you can connect RS232 and
Ethernet through their ports.

RJ1A to MAIN

RS232A to MAIN RJ2B for USER

CANS2 to OPTION RJ2A to T/P

CANS1 to OPTION

CAN2 to SYSTEM
CANU for USER

RS232B for USER

RJ1B for USER

Figure 4.57 The Components of the Small Door Board (BD5B1)

RJ1B for USER

RS232B for USER

Figure 4.58 The Exterior and Interior of the Small Door Board (BD5B1)

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4.3.9. Teach pendant (TP510)

4.3.9.1. Outline

TP510 (teach pendant) performs communication through a main board (BD510) of a controller and
Ethernet, allowing a user to perform many functions as detailed below.

 Monitoring: Work program / data of each axis / input*output signal / robot state, etc.
 History management: System version / operating time / error history / stop history, etc.
 File management: Version & teaching program up/down
 Setting various parameters:
User environment / control/ robot / application / automatic integral number, etc.
 Robot teaching: Jog & teaching program registration
 Robot operation: MOTOR ON / START / STOP / MODE setting

Additionally, the teach pendant is equipped with a three-step enable switch, an emergency stop switch,
etc. to ensure worker safety.

Figure 4.59 Appearance of teach pendant TP510

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 4. Basic Components of Controller

4.3.9.2. USB cover

When you open a cover positioned at the lower side of the teach pendant, you can see the connectors
such as those shown below. The meaning of each connector is the same as shown below.

1 2 3 4

Figure 4.60 USB cover of teach pendant TP510

(1) RESET switch

When you want to re-operate the teach pendant, and not the controller, your can operate the
RESET switch. However, do not operate this unnecessarily.

(2) Slide switch

When delivered, it is set on the right side (to the USB connector direction) as shown in the
picture.

Notice: Slide switch is set when it is produced so that the user cannot change
the position thereof.

(3) USB-A type connector

The user can up/down load necessary files, such as data and teaching programs, etc. as well
as different versions of boards.

(4) USB-B type connector

This connector is not intended for use by a user

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5. Controller Options

5
Controller
Options

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 5. Controller Options Hi5 Controller Maintenance Manual

5.1. Public IO Board (BD580; Terminal Block)

5.1.1. Outline
Public DIO board can be used for interface or configuration with various devices through the digital
input/output port. The specification of the basic board is as follows.

 Digital input (Photocoupler type): 32 points (4 ports)

 (+/-) Two-way digital output (Photo MOS type): 32 points (4 ports)
 1Mbps CAN communication
 When relay contact point is required, the relay board can be installed

7-SEG Display

RS232C DIP Switch: Board number

setting

TBI4 TBI3 TBI2 TBI1

TBO4 TBO3 TBO2 TBO1

CANS 1, 2
DC5V Power : CONNECTOR FOR
CAN COMMUNICATION
DC24V Power for BD581

Figure 5.1 Public IO Board (BD580)

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 5. Controller Options

5.1.2. Connector
5.1.2.1. Digital Input

The following Figure and Table describe the pin composition of the terminal block (TBI1~4) for digital
input. Each terminal block connects to 8 input signals, and different power can be used depending on
the usage.

Common power
st
Input signal (1 )

LED for input display

th
Input signal (8 )

Not connected

Figure 5.2 Pin Configuration of Digital Input Terminal Block of Public IO Board (BD580)

Table 5-1 Pin Configuration of Digital Input Terminal Block (TBln*) of Public IO Board (BD580)
Pin
Signal Name Signal Description
Number

1 COMn* COMMON power (Ground DC24V or DC24V)

2 DI n*1 1st input of nth public input signal port of user

3 DI n*2 2nd input of nth public input signal port of user

4 DI n*3 3rd input of nth public input signal port of user

5 DI n*4 4th input of nth public input signal port of user

6 DI n*5 5th input of nth public input signal port of user

7 DI n*6 6th input of nth public input signal port of user

8 DI n*7 7th input of nth public input signal port of user

9 DI n*8 8th input of nth public input signal port of user

10 N.C No connection

Note *) Terminal block Number n = 1~4 (Ex, TBI1, TBI2, TBI3, TBI4)

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The input specification of each port is as follows

 Input port component: AC input photocoupler

 Input impedance: 3 ㏀
 Common power: Ground 24VDC or 24VDC

The user connects the input signal through the method shown in Figure 5.3 below. First, connect the
user power of +24V or the ground wire to the public IO board (BD580), and then connect each signal
to the input pin according to the usage. For the power, 8 input ports can be composed as a unit, and
can be used differently.

User’s System BD580

+24VDC TBI1~4
(or Ground) (1) Common
R

R C
(2)

SMPS
Contacts
R
or
Open Collectors
R C
(9) Input signals
Ground
(or +24VDC)

Figure 5.3 Wiring of Input Signals of the Public IO Board (BD580)

Caution:
Public IO Board V3.0 or lower does not support two-way digital input. For this
reason, DC24V must be used for common power.

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 5. Controller Options

5.1.2.2. Digital Output

The following Figure and Table show the pin composition of terminal block (TB01~4) for digital output.
Each terminal block can be connected to 8 output signals, and different power can be used depending
on the usage.

Common power

LED for output st

Output signal (1 )
display

th
Output signal (8 )

Figure 5.4 Pin Configuration of Digital Input/Output Terminal Block of the Public IO Board(BD580)

Table 5-2 Pin Configuration of Digital Input/Output Terminal Block (TBOn*) of the Public IO Board
(BD580)
Pin
Signal Name Signal Description
Number

10
COMn* COMMON power (Ground DC24V or DC24V)
9

8 DOn*1 1st output of nth public output signal port of user

7 DOn*2 2nd output of nth public output signal port of user

6 DOn*3 3rd output of nth public output signal port of user

5 DOn*4 4th output of nth public output signal port of user

4 DOn*5 5th output of nth public output signal port of user

3 DOn*6 6th output of nth public output signal port of user

2 DOn*7 7th output of nth public output signal port of user

1 DOn*8 8th output of nth public output signal port of user

Note *) Terminal Block Number n = 1~4 (Ex, TBO1, TBO2, TBO3, TBO4)

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The output specification of each port is as follows.

 Output component: Photo MOSFET output

 Rated output: 125mA (Continuous load current) / 24V DC
 Common power: Ground 24VDC or 24VDC

The user connects the output signal through the method shown in Figure 5.5 below. First, connect the
common signal (COMMON) to the public IO board (BD580), and then connect each signal to the
output pin according to the usage. For the power, 8 output signals can be composed as a unit and can
be used differently.

BD580 User’s System

TBO1~4 +24VDC
(1) Output signal (or Ground)

load

SMPS
(8) Output signal

load Ground
(9),(10) Common (or +24VDC)

Figure 5.5 Method for the Connection of the Output Signals of the Public IO Board (BD580)

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5.1.2.3. Power Connector: CNP1, CNP2

The Power Connector is the connector to supply the power to operate the public IO board (BD580),
and is composed of connectors CNP1 for DC5V and CNP2 for DC24V, as shown in the Figure. As the
power required for the basic operation of the board is DC5V, CNP1 must be connected. The
connection of CNP2 for DC24V power can be made as required by the usage. The purpose of CNP2
is to operate the relay board that is additionally installed to the board. Therefore, CNP2 does not need
to be connected for applications that do not require the relay board.

A3: DC5V GND

A2: DC5V

A1: N.C.
AMP D3100 series
Contact 917511-3
AMP D3100 series
AMP D3100 series Receptacle Housing
Tab header 1-178288-3
1-178313-3
(a) CNP1 (DC5V power)

A3:DC24V GND

A2:N.C

A1: DC24V
AMP D3100 series
Contact 917511-3
AMP D3100 series
AMP D3100 series Receptacle Housing
Tab header 1-178288-3
1-178313-3
(b) CNP2 (DC24V power)

Figure 5.6 Power Connectors of the Public IO Board (BD580), CNP1 and CNP2

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5.1.2.4. CAN Communications Connector: CANS1, CANS2

For the CAN Communications Connector, there are two identical connectors with the same pin
specification, which are installed as shown in Figure 5.7 below. As CAN communication is conducted
through cable, with a Daisy Chaining method, it therefore does not matter which side of the connector
it is connected to, as it does not affect the operation.

Basic module
(MAIN, SYSTEM, st
SmallDoor) 1 IO board nd
2 IO board
(Middle board): (Last board):
Terminating Terminating
resistance not resistance
connected connected

Figure 5.7 Method for the Connection of CAN Connectors of the Public IO Board (BD580)

When connecting several boards, the terminating resistance must be processed precisely. CAN data
communication uses the Daisy Chaining method. Therefore, only the board connecting the CAN
communication cable at the end must be connected to the terminating resistance; all other boards
must not be connected to the terminating resistance. For the connection of terminating resistance, use
the JP1 jumper next to the CAN Connectors 1 and 2. When you short-circuit JP1, the terminating
resistance is connected, and when opened, the terminating resistance is disconnected.

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5.1.3. Setting Unit

5.1.3.1. DIP Switch Settings

DIP switch DSW1 sets the number of the board using a hexadecimal code. Based on the DIP switch
settings, the number of the board is shown in Table 5-3 below.

Table 5-3 Settings of the DSW1 Switch of the Public IO Board (BD580)
Setting
Switch Number 4 3 2 1
(Board Number)

OFF OFF OFF OFF 1

OFF OFF OFF ON 2

Switch
Condition
OFF OFF ON OFF 3

OFF OFF ON ON 4

Default setting OFF OFF OFF OFF 1

ON

Switch exterior
1 2 3 4

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5.2. Relay Board (BD581)

5.2.1. Outline
The relay board is the board installed on the public IO board (BD580) to convert the semi-conductor
output to contact point output in an 8-point unit.

Pins 9, 10: Signal Common

LEDs
Pin 8: Signal output 1

Relays

Pin 1: Signal output 8

Figure 5.8 Relay Output Board of Public IO Board (BD581)

BD580
Remove BD580 BD580에 릴레이
Install relay board
지지대 방향정렬
Align supporter direction
터미널제거
terminal 보드 장착
on BD580

터미널삽입
Insert terminal
장착완료
Installation complete

Figure 5.9 Method for the Installation of Relay Board

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 5. Controller Options

5.2.2. Connector
The output specification of the 8-point connector is as follows.

 Output component: Relay

 Rated output: 3A, 220VAC/24V DC

Table 5-4 Pin Configuration of the Digital Output Terminal Block (TBOUT) of the Relay Board (BD581)

Pin Number Signal Name Signal Description

10
COM COMMON power (DC24V, DC24V ground, AC220V)
9

8 DO1 1st user public relay output signal

7 DO2 2nd user public relay output signal

6 DO3 3rd user public relay output signal

5 DO4 4th user public relay output signal

4 DO5 5th user public relay output signal

3 DO6 6th user public relay output signal

2 DO7 7th user public relay output signal

1 DO8 8th user public relay output signal

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5.3. Public IO Board (BD582; Connector Type)

5.3.1. Outline
The Public DIO board can be used for interface or configuration with various devices through the
digital IO port. The specification of the basic board is as follows.

 Digital input (Photocoupler type): 32 points (4 ports)

 (+/-) Two-way digital output (Photo MOS type): 32 points (4 ports)
 1Mbps CAN communication
 Input/Output connector: MDR-type connector (3M)

7-SEG Display
DC5V power
CANS1,2: CNOUT : outputs
CANcommunication connector

RS232C
CNIN: Inputs

DIP Switch: Board number setting

Figure 5.10 Public IO Board (BD582)

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5.3.2. Connector
5.3.2.1. Digital Input

The following Figure and Table show the pin composition of connector CNIN for digital input. For the
32-point input pin, different power can be used for 8 input signals.

Figure 5.11 CNIN Connector (3M MDR 10240-52A2JL) of the Public IO Board (BD582)

Figure 5.12 3M MDR 10140-3000VE (HOOD:1030-55F0-008) of CNIN Connector Plug of the Public
IO Board (BD582)

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Table 5-5 Pin Configuration of Digital Input Connector CNIN of the Public IO Board (BD582)

Pin Number Signal Name Function Description (Expansion Board/Basic Board)

1 DI01 Public input 1

2 DI02 Public input 2

3 DI03 Public input 3

4 DI04 Public input 4

5 DI05 Public input 5

6 DI06 Public input 6

7 DI07 Public input 7

8 DI08 Public input 8

9
COMIN0 External power input (User power): +24 V (For DI01~DI08)
10

11 DI09 Public input 9

12 DI10 Public input 10

13 DI11 Public input 11

14 DI12 Public input 12

15 DI13 Public input 13

16 DI14 Public input 14

17 DI15 Public input 15

18 DI16 Public input 16

19
COMIN1 External power input (User power): +24 V (For DI09~DI16)
20

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 5. Controller Options

Pin Number Signal Name Function Description (Expansion Board/Basic Board)

21 DI17 Public input 17

22 DI18 Public input 18

23 DI19 Public input 19

24 DI20 Public input 20

25 DI21 Public input 21

26 DI22 Public input 22

27 DI23 Public input 23 (Signal for external operation)

28 DI24 Public input 24

29
COMIN2 External power input (User power): +24 V (For DI17~DI24)
30

31 DI25 Public input 25

32 DI26 Public input 26

33 DI27 Public input 27

34 DI28 Public input 28

35 DI29 Public input 29

36 DI30 Public input 30

37 DI31 Public input 31

38 DI32 Public input 32

39
COMIN3 External power input (User power): +24 V (For DI25~DI32)
40

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The input specification of each port is as follows.

 Input port component: AC input photocoupler

 Input impedance= 3 ㏀
 (+) Common input voltage = 24 VDC
 (-) Common input voltage = 0 VDC

The user connects the input signal through the method shown in Figure 5.13 below. First, connect the
user power +24 V and ground wire to the public IO board (BD582), and then connect each signal to
the input pin, depending on the usage. The power can be differently used by the 8 input port units.

User’s System BD580

+24V
Common R

R C

SMPS
R

R C
contacts
Input signals

0V Ground

Figure 5.13 Method for Wiring Input Signals of the Public IO Board (BD582)

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 5. Controller Options

5.3.2.2. Digital Output

The following Figure and Table show the pin composition of connector CNOUT for digital output. For
the 32-point output pin, different power can used for 8 output signals.

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

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

Figure 5.14 CNOUT Connector (3M MDR 10250-52A2JL) of the Public IO Board (BD582)

Figure 5.15 3M MDR 10150-3000VE (HOOD;10350-52F0-008) of the CNOUT Connector Plug of the
Public IO Board (BD582)

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 Hi5 Controller Maintenance Manual

Table 5-6 Pin Configuration of the Digital Input Connector CNOUT of the Public IO Board (BD582)
Pin
Signal Name Function Description (Expansion Board/Basic Board)
Number
1 DO01 Public output 1

2 DO02 Public output 2

3 DO03 Public output 3

4 DO04 Public output 4

5 DO05 Public output 5

6 DO06 Public output 6

7 DO07 Public output 7

8 DO08 Public output 8

9
COMOUT0 External power input (User power): COMMON (For DO01~DO08)
10

11 DO09 Public output 9

12 DO10 Public output 10

13 DO11 Public output 11

14 DO12 Public output 12

15 DO13 Public output 13

16 DO14 Public output 14

17 DO15 Public output 15

18 DO16 Public output 16

19
COMOUT1 External power input (User power): COMMON (For DO09~DO16)
20

21 N.C Not used

22 N.C Not used

23 N.C Not used

24 N.C Not used

25 N.C Not used

26 N.C Not used

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Pin
Signal Name Function Description (Expansion Board/Basic Board)
Number
27 N.C Not used

28 N.C Not used

29 N.C Not used

30 N.C Not used

31 DO17 Public output 17

32 DO18 Public output 18

33 DO19 Public output 19

34 DO20 Public output 20

35 DO21 Public output 21

36 DO22 Public output 22

37 DO23 Public output 23

38 DO24 Public output 24

39
COMOUT2 External power input (User power): COMMON (For DO17~DO24)
40

41 DO25 Public output 25

42 DO26 Public output 26

43 DO27 Public output 27

44 DO28 Public output 28

45 DO29 Public output 29

46 DO30 Public output 30

47 DO31 Public output 31

48 DO32 Public output 32

49
COMOUT3 External power input (User power): COMMON (For DO25~DO32)
50

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The output specification of each port is as follows.

 Output component: Photo MOSFET output

 Rated output = 125mA (Continuous load current), 24V DC
 (-) Common output voltage = 0V DC (OPEN COLLECTOR)

The user connects the output signal through the method shown in Figure 5.16 below. First, connect
the COMMON signal to the public IO board (BD582), and then connect each signal to the output pin
depending on the usage. The power can be differently used by each 8-output port unit.

BD580 User’s System

Output signal +24V

load

SMPS
Output signal

COMOUT 0V

Figure 5.16 Method for Connection of Output Signals of the Public IO Board (BD582)

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5.3.2.3. Power Connector: CNP1

Power Connector is the connector for DC5V power to operate the public IO board (BD582), and the
pin specification is as shown in Figure 5.17 below.

A1: N.C.

A2: DC5V

A3: DC5V GND AMP D3100 series

1-178313-3
Figure 5.17 Power Connector CNP1 of the Public IO Board (BD582)

5.3.2.4. CAN Communications Connector: CANS1, CANS2

For the CAN Communications Connector, there are two identical connectors with the same pin
specification, which are installed as shown in Figure 5.18 below. As CAN communication is
conducted through cable, with a Daisy Chaining method, it therefore does not matter which side of the
connector it is connected to, as it does not affect the operation.

Figure 5.18 Method for Connection of the CAN Connector of the Public IO Board (BD582)

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5.3.3. Setting Unit

5.3.3.1. DIP Switch Settings

DIP switch DSW1 sets the number of the board in hexadecimal code. Based on the setting of the
switch, the number of the board is shown in the following Table.

Table 5-7 Method for Setting of the DSW1 Switch of the Public IO Board (BD582)

Switch Number 4 3 2 1 Setting (Board Number)

OFF OFF OFF OFF 1

OFF OFF OFF ON 2

Switch
Condition
OFF OFF ON OFF 3

OFF OFF ON ON 4

Default Setting OFF OFF OFF OFF 1

ON

Switch Exterior
1 2 3 4

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 5. Controller Options

5.4. CC-Link Board (BD570)

5.4.1. Outline
To use the robot as the Slave from the field bus configured with CC-LINK communication, CC-LINK
board (BD570) must be used, as shown in Figure 5.19 below. To block various types of noise and
surges from the external environment of the robot, various signals are insulated from the external side.

SW1,
SW1, 2 : 국번설정
2: Number setting DC5V전원
DC5V power

설정방법
Setting 표기
method

CAN 1, 2
CANS1,2
: CAN communication
LED 및
LEDand : CAN통신용 커넥터
connector
Displayed
표시내용표기 content

SW3:
SW3 Baud rate
: Baudrate설정
setting
Terminal
CC-LINK 라인
block to
Point and method to set connect CC-LINK
연결용 터미널블럭 line
점유국 수 설정용
number of stations
점표 및 방법표기

Figure 5.19 CC-LINK Board (BD570)

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 Hi5 Controller Maintenance Manual

5.4.2. Connector
5.4.2.1. CC-Link Communication Terminal Block: TBFB

Use the terminal block TBFB to connect to the CC-LINK communication line. Refer to the indicated
properties of each pin, as shown in Figure 5.20 below.

Figure 5.20 CC-LINK Communication Terminal Block of CC-LINK Board (BD570)

5.4.2.2. Power Connector: CNP1

The Power Connector is the connector for DC5V power to operate the CC-LINK board (BD570), and
the pin specification is as shown in Figure 5.21 below.

A3:DC5V GND

A2:DC5V

A1: N.C. AMP D3100 series

1-178313-3

Figure 5.21 Power Connector CNP1 of CC-LINK Board (BD570)

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 5. Controller Options

5.4.2.3. CAN Communications Connector: CANS1, CANS2

Figure 5.22 Method for the Connection of the CAN Connector of the CC-LINK Board (BD570)

For the CAN Communications Connector, there are two identical connectors with the same pin
specification, which are installed as shown in Figure 5.22 above. As CAN communication is
conducted through cable, with a Daisy Chaining method, it therefore does not matter which side of the
connector it is connected to, as it does not affect the operation.

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 Hi5 Controller Maintenance Manual

5.4.3. Indication and Setting Units

Various LEDs are used to display the communication status of the CC-LINK line. Indicated details of
each LED are displayed on the board, as shown in Figure 5.23 below. You may also use the dip switch
to set the number and communication speed of the CC-LINK board; relevant details are indicated on
the board shown in Figures 5.24 and 5.25 below.

Figure 5.23 LED and Detail of Communication Status Indication of CC-LINK Board (BD570)

Figure 5.24 Setting Station Number and Communication Speed of the CC-LINK Board (BD570)

Figure 5.25 Method for Setting of the Number of Stations of the CC-LINK Board (BD570)

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 5. Controller Options

5.5. Conveyor I/F Board (BD585)

5.5.1. Outline
When configuring the robot system to synchronize with the conveyor, an interface board must be used
to receive the encoder signal to detect the location of the conveyor Figure 5.26 below shows the
configuration of the Conveyor Interface Board (BD585). There are two input ports, for which you can
select the line receiver method or the open collector method.

DC5V power
DC5V전원

LED and
LED 및
displayed detail
표시내용표기 CANS 1, 2
:CANS1,2
CAN communication
: CAN통신용 커넥터
connector

Terminal
컨베이어 block (Channel
I/F용 1)
for conveyor I/F
터미널블록(채널1)

Terminal
컨베이어 block (Channel
I/F용 2)
for conveyor I/F
터미널블록(채널2)

Figure 5.26 Conveyor I/F Board (BD585)

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5.5.2. Connector
5.5.2.1. Conveyor I/F Terminal Block: TBCV1, TBCV2

The input of conveyor pulse can be connected to the two identical terminal blocks with the same pin
specification, as shown in Figure 5.27 below. That is, two conveyors can be connected.

Pin 1:
Pin1 PA+
: PA+

Pin 2:
Pin2 : PA-

Pin 7:: P+ Differential

Differential
Pin7 P+
Line Type
Open
Open Line Type
Pin 3:
Pin3 PB+
: PB+
Collector
Collector Pin 8:: A
Pin8 A
Type
Type Pin 4:
Pin4 PB-
: PB-
Pin
Pin99:: B
B

Pin 10:: OC_LS

OC_LS Pin 5:
Pin5 LD_LS
: LD_LS
Pin10
Pin 6:
Pin6 GND_LS
: GND_LS

Figure 5.27 Conveyor Connection Terminal Block of the Conveyor I/F Board (BD585)

5.5.2.2. Power Connector: CNP1

The Power Connector is the connector for DV5V power to operate the Conveyor I/F Board (BD585),
and the pin specification is as shown in Figure 5.28 below.

A3: DC5V GND

A2: DC5V

A1: N.C. AMP D3100 series

1-178313-3
Figure 5.28 Power Connector CNP1 of Conveyor I/F Board (BD585)

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 5. Controller Options

5.5.2.3. CAN Communications Connector: CANS1, CANS2

For the CAN Communications Connector, there are two identical connectors with the same pin
specification, which are installed as shown in Figure 5.29 below. As CAN communication is conducted
through cable, with a Daisy Chaining method, it therefore does not matter which side of the connector
it is connected to, as it does not affect the operation.

Figure 5.29 Method for the Connection of CAN Connector of the Conveyor I/F Board (BD585)

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5.5.3. Display Unit

The method of counting the conveyor pulse that has been set is displayed with an LED, as shown in
Figure 5.30 below. For each case, the description is shown on the board.

Figure 5.30 LED and Detail for Conveyor I/F Board (BD585) Status Indication

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5.6. LDIO Board (BD58A; For LCD)

5.6.1. Outline
As a board exclusively for LCD, LDIO Board includes the DIO board and CC-LINK, and is installed on
the RACK to ensure space inside the controller. The specification of the basic board is as follows.

 Digital input (Photocoupler type): 32 points

 Digital output (Photo MOS type): 24 points; Replay contact point: 8 points
 CC-LINK communication function included
 RS232 / RS485 select 1 channel
 Installation location: RACK
 1 Mbps CAN communication

DSW1

SWSEL

SWZ 1, 2, 3

SENYU 0, 1

7SEG
CANS 1, 2
CNI CNO CNP
TBI TBO TBC

Figure 5.31 Appearance of the LDIO Board (BD58A)

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5.6.2. Connector
5.6.2.1. Digital Input

The photocoupler is used for digital input, and a total of 32 points are provided. The user can input
each 16-point signal through the connector and terminal as required.

(1) Input through connector

The following Figure and Table show the pin composition of connector CN1 for digital input.

(a)Board side (3M MDR 10226-52A2JL)

(b) Plug side 3M MDR 10126-3000VE (HOOD: 10326-52F0-008)

Figure 5.32 Digital Input Connector CNI of LDIO Board (BD58A)

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Table 5-8 Pin Configuration of the Digital Input Connector CNI of the LDIO Board (BD58A)

Pin Number Signal Name Function Description

1 IN11 Digital input 11

2 IN12 Digital input 12

3 IN13 Digital input 13

4 IN14 Digital input 14

5 IN15 Digital input 15

6 IN16 Digital input 16

7 IN17 Digital input 17

8 IN18 Digital input 18

9
M2 Power output: DC24V GND
10

11

12 P2 Power output: DC24V

13

14 IN21 Digital input 21

15 IN22 Digital input 22

16 IN23 Digital input 23

17 IN24 Digital input 24

18 IN25 Digital input 25

19 IN26 Digital input 26

20 IN27 Digital input 27

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Pin Number Signal Name Function Description

21 IN28 Digital input 28

22
M1 Power output: DC24V GND
23

24

25 P1 Power output: DC24V

26

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(2) Input through terminal block

pin 1

TBI-B

Coding : pin 1,2 Line B - Coding : pin 3,4

Line A - Coding : pin 1,4

TBI-A

Coding : pin 2,3

Figure 5.33 Digital Input Terminal Block TBI of LDIO Board (BD58A)

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Table 5-9 Terminal Configuration of the Digital Input Terminal Block TBI of the LDIO Board (BD58A)
Terminal Block Terminal Signal
Function Description
Name Number Name

1 P2 Power output: DC24V

2 IN31 Digital input 31

3 IN32 Digital input 32

4 IN33 Digital input 33

5 IN34 Digital input 34

TBI - A
6 IN35 Digital input 35

7 IN36 Digital input 36

8 IN37 Digital input 37

9 IN38 Digital input 38

10 M2 Power output: DC24V GND

1 P2 Power output: DC24V

2 IN41 Digital input 41

3 IN42 Digital input 42

4 IN43 Digital input 43

5 IN44 Digital input 44

TBI - B
6 IN45 Digital input 45

7 IN46 Digital input 46

8 IN47 Digital input 47

9 IN48 Digital input 48

10 M2 Power output: DC24V GND

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The input specification of each port is as follows.

 Input port component: AC input photocoupler

 Input impedance= 3 ㏀
 (+) Common input voltage = 24 VDC
 (-) Common input voltage = 0 VDC

The user connects the input signal through the method shown in Figure 5.34 below.

BD58A

DC24V
R

User’s System R C
+24V

SMPS

R 0V

R C
contacts
Input signals

DC24V Ground

Figure 5.34 Method for Wiring the Input Signal of LDIO Board (BD58A)

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5.6.2.2. Digital Output

Two-way output at 32 points using MOSFET is provided for the digital output. The user can output
each 16-point signal through the connector and terminal as required, and the 8-point output is the
relay contact point output.
.

(1) Output through terminal block

pin 1

TBO-B

Coding : pin 1,3 Line B - Coding : pin 2,4

Line A - Coding : pin 1,3

TBO-A

Coding : pin 2,4

Figure 5.35 Digital Output Terminal Block TBO of LDIO Board (BD58A)

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Table 5-10 Terminal Configuration of the Digital Output Terminal Block TBI of the LDIO Board
(BD58A)
Terminal Block Terminal Signal
Function Description
Name Number Name

1 P2 Power output: DC24V

2 OUT11 Digital output 11 (Relay contact point output)

3 OUT12 Digital output 12 (Relay contact point output)

4 OUT13 Digital output 13 (Relay contact point output)

5 OUT14 Digital output 14 (Relay contact point output)

TBO - A
6 OUT15 Digital output 15 (Relay contact point output)

7 OUT16 Digital output 16 (Relay contact point output)

8 OUT17 Digital output 17 (Relay contact point output)

9 OUT18 Digital output 18 (Relay contact point output)

10 M2 Power output: DC24V GND

1 P2 Power output: DC24V

2 OUT21 Digital output 21

3 OUT22 Digital output 22

4 OUT23 Digital output 23

5 OUT24 Digital output 24

TBO - B
6 OUT25 Digital output 25

7 OUT26 Digital output 26

8 OUT27 Digital output 27

9 OUT28 Digital output 28

10 M2 Power output: DC24V GND

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(2) Output through connector

The following Figure and Table show the pin composition of the connector CNO for digital
output.

(a) Board side (3M MDR 10220-52A2JL)

(b) Plug side 3M MDR 10120-3000VE (HOOD: 10320-52F0-008)

Figure 5.36 CNO Connector of LDIO Board (BD58A)

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Table 5-11 Pin Configuration of the Digital Input Connector CNO of the LDIO Board (BD58A)

Pin Number Signal Name Function Description

1 OUT31 Digital output 31

2 OUT32 Digital output 32

3 OUT33 Digital output 33

4 OUT34 Digital output 34

5 OUT35 Digital output 35

6 OUT36 Digital output 36

7 OUT37 Digital output 37

8 OUT38 Digital output 38

9 M2 Power output: DC24V GND

10 P2 Power output: DC24V

11 IN41 Digital input 41

12 IN42 Digital input 42

13 IN43 Digital input 43

14 IN44 Digital input 44

15 IN45 Digital input 45

16 IN46 Digital input 46

17 IN47 Digital input 47

18 IN48 Digital input 48

19 M2 Power output: DC24V GND

20 P2 Power output: DC24V

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The output specifications using photo MOSFET are as follows.

 Output component: Photo MOSFET output

 Rated output = 125 mA (Continuous load current), 24V DC

In addition, the output specification of the relay contact point is as follows.

 Output component: Relay contact point output

 Rated output = 5 A / 24 VDC, 5A / 250 VAC
 (-) Common output voltage = 0V DC (OPEN COLLECTOR)

The user connects the output signal as shown in Figures 5.37 and 5.38 below.

BD58A User’s System

Output signal

load

+24V

SMPS

0V
Output signal

Figure 5.37 Method for Wiring the Output Signal of LDIO Board (BD58A) (Photo MOSFET)

BD58A User’s System

Output signal

load

+24V

SMPS

0V
Output signal

Figure 5.38 Method for Wiring the Output Signal of LDIO Board (BD58A) (Relay Contact Point)

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5.6.2.3. Communication Connection

LDIO board supports serial communication RS232 and RS485 of beam sensor, and includes the
CC-LINK function to facilitate information connections among the robots. Each communication is
connected using the terminal block TBC.

pin 1

TBC-B
Coding : pin 1,4 Line B - Coding : pin 2,3

Line A - Coding : pin 1,2

TBC-A

Coding : pin 3,4

Figure 5.39 Serial Communication Terminal Block TBC of LDIO Board (BD58A)

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Table 5-12 Terminal Configuration of Serial Communication Terminal Block TBC of LDIO Board
(BD58A)
Terminal Terminal
Classification Signal Name Function Description
Block Name Number

1 TxD RS232 Transmission

2 RxD RS232 Receipt

RS232
3 SG RS232 Ground
(DSW1 #4 ON)

4 Shield1 RS232 Cable shield

5 FG1 RS232 Cable ground

TBC - A
6 A RS485 + Side line

7 B RS485 – Side line

RS485
8 G2 RS485 Ground
(DSW1 #4 OFF)

9 Shield2 RS485 Cable shield

10 FG2 RS485 Cable ground

1 DA CC-LINK DA line

2 DB CC-LINK DB line

CC-LINK 3 DG CC-LINK Ground

4 Shield3 CC-LINK Cable shield

5 FG3 CC-LINK Cable ground

TBC - B
6 DA CC-LINK DA line

7 DB CC-LINK DB line

CC-LINK 8 DG CC-LINK Ground

9 Shield3 CC-LINK Cable shield

10 FG3 CC-LINK Cable ground

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5.6.2.4. Power Connector: CNP1, CNP2

The Power Connector is the connector for DC 5 V power to operate the Conveyor I/F Board (BD585),
and the pin specification is as shown in Figure 5.40 below.

Figure 5.40 Power Connector CNP1 and CNP2 of LDIO Board (BD58A)

Table 5-13 Pin Configuration of the Power Connector of the LDIO Board (BD58A)

Connector Name Terminal Number Signal Name Function Description

A1 - N.C

CNP1
A2 P5 SMPS DC 5 V
(Upper level)

A3 M5 SMPS DC 5 V Ground

A1 UP2 User power DC 24 V

CNP2
A2 - N.C
(Bottom level)

A3 UM2 User power DC 24 V Ground

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5.6.2.5. CAN Communications Connector: CANS1, CANS2

For the CAN Communications Connector, there are two identical connectors with the same pin
specification, which are installed as shown in Figure 5.41 below. As CAN communication is conducted
through cable, with a Daisy Chaining method, it therefore does not matter which side of the connector
it is connected to, as it does not affect the operation.

Figure 5.41 Method for Connecting the CAN Connector of LDIO Board (BD58A)

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5.6.3. Setting Unit

5.6.3.1. DIP Switch Settings

The number and communication speed of the DIP switch SWZ1~3 related to CC-LINK are set in
hexadecimal code, as shown in the Tables below.

Table 5-14 Method for Setting Station Number and Communication Speed of CC-LINK in the LDIO
Board (BD58A)
Switch
Usage 1 2 3 4 Remarks
Name

SWZ1 X80 X40 X20 X10 1

Station Number
SWZ2 X8 X4 X2 X1 2

0: 125 kbps
1: 625 kbps
Communication
SWZ3 X8 X4 X2 X1 2: 2.5 Mbps
Speed
3: 5.0 Mbps
4: 10 Mbps
ON

SWZ1 OFF OFF OFF OFF

1 2 3 4

ON
Factory
Default SWZ2 OFF OFF OFF ON
Setting 1 2 3 4

ON

SWZ3 OFF ON OFF OFF

1 2 3 4

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Table 5-15 Method for Setting the Number of Stations of CC-LINK of the LDIO Board (BD58A)

Number of Stations
Jumper Name
1 2 3 4

SENYU0 OPEN SHORT OPEN SHORT

SENYU1 OPEN OPEN SHORT SHORT

Factory Default SENYU0 : SHORT

Setting SENYU1 : SHORT

SHORT

Table 5-16 LDIO Jumper SWSEL for Selecting CC-LINK Set in the LDIO Board (BD58A)

Number of channel
Jumper Name
OPEN SHORT

CC-LINK communication setting by CC-LINK communication setting by

SWSEL
DIP switch and jumper software

Factory default SHORT

SHORT

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5.7. Safety Relay Board (BD58B)

5.7.1. Outline
To detect axis limit and power belt failure with an installed sensor on the robot, the sensor signal must
be received and converted to a contact point format to use the Safety Relay Board (BD58B) connected
to the system board. Figure 5.42 below shows the configuration of the Safety Relay Board (BD58B),
which includes the control power connector, the terminal block to supply the power to the sensor and
receive the signal, and the connector for the brake to prevent falling.

Figure 5.42 Safety Relay Board (BD58B)

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5.7.2. Connector
Table 5-17 Pin Configuration of the Belt Sensor Terminal Block TTBO in the Safety Relay Board
(BD58B)

Pin Number Signal Name Signal Description

1 PI24 24V power for belt sensor

2 BO1 Belt sensor output 1

3 MI24 GND power for belt sensor

4 PI24 24V power for belt sensor

5 BO1 Belt sensor output 2

6 MI24 GND power for belt sensor

7 NC

8 NC

9 NC

10 NC

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Table 5-18 Pin Configuration of the Limit Sensor Terminal Block TBLS in the Safety Relay Board
(BD58B)

Pin Number Signal Name Signal Description

1 PI24 24V power for limit sensor

2 MI24 GND power for limit sensor

3 LS1 Limit sensor output 1

4 LS2 Limit sensor output 2

5 PI24 24V power for limit sensor

6 MI24 GND power for limit sensor

7 LS3 Limit sensor output 3

8 LS4 Limit sensor output 4

9 NC

10 NC

Table 5-19 Pin Configuration of Power 24V Terminal Block (TBP124) in the Safety Relay Board
(BD58B)

Pin Number Signal Name Signal Description

1-10 PI24 24V power

Table 5-20 Pin Configuration of Power GND Terminal Block (TBM124) in the Safety Relay Board
(BD58B)

Pin Number Signal Name Signal Description

1-10 MI24 GND power

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Table 5-21 Connector Type and Usage of Safety Relay Board (BD58B)

Name Usage External Device Connection

CNPI24 Power input for sensor SR2

CNP2 Power output for BD58A BD58A

CNZPB Power input for fall preventive brake SR3

CNZB1 Cancel fall preventive brake 1 CMC1

CNZB2 Cancel fall preventive brake 2 CMC2

Transmit safety relay contact point status to system

CNLS BD530
board

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5.8. Expansion Public IO Board (BD583; 464-point I/O)

5.8.1. Outline
The Expansion Public DIO board can interface and be configured with various devices through the
digital input/output port. The specification of the basic board is as follows.

 2-way digital input

 Photocoupler type input: 64 points (8 ports)

 2-way digital output

 Photo MOS type at 32 points (4 ports)
 Relay contact point type at 32 points (4 ports)

 CAN communication between modules: 1Mbps

 Scan time: Maximum of 1msec

Figure 5.43 Expansion Public IO Board (BD583)

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5.8.2. Connector
There are 4 types of connectors for Expansion Public IO Board (BD583), which are as follows.

 Digital input: TBI1~8

 Digital output: TBO1~8
 Power: CNP1, CNP2
 CAN communication: CANS 1, 2

CAN communication
Power Digital output

Digital input

Figure 5.44 Connector Configuration for Expansion Public IO Board (BD583)

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5.8.2.1. Digital Input

Figure 5.45 below shows the pin composition of the terminal block (TBI1~8) for digital input. Each
terminal block can be connected to the common power for 8 input signals, and can use a different
power supply than the common power of the terminal block for other input.

Input display LED

Common power
st
Input signal (1 )

th
Input signal (8 )

Figure 5.45 Pin Configuration of Digital Input Terminal Block on Expansion Public IO Board (BD583)

Table 5-22 Pin Configuration of Digital Input Terminal Block (TBln*) of Expansion Public IO Board
(BD583)

Pin Number Signal Name Signal Description

1 COMn* COMMON power (Ground DC24V or DC24V)

2 DI n*1 1st input of nth public input signal port of user

3 DI n*2 2nd input of nth public input signal port of user

4 DI n*3 3rd input of nth public input signal port of user

5 DI n*4 4th input of nth public input signal port of user

6 DI n*5 5th input of nth public input signal port of user

7 DI n*6 6th input of nth public input signal port of user

8 DI n*7 7th input of nth public input signal port of user

9 DI n*8 8th input of nth public input signal port of user

Note *) Terminal Block Port Number n = 1~8 (Ex, TBI1, TBI2, TBI3, TBI4)

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The electric specification of each input signal is as follows.

 Input terminal component: AC input photocoupler

 Input impedance: 3 ㏀
 Common power: Ground 24VDC or 24VDC

The user connects the input signal through the method shown in Figure 5.46 below. First, connect the
user power +24V or the ground wire to the IO board (BD583), and then connect each signal to the
input pin according to the usage. The power can be grouped by 8 input signals, and can be applied
differently by port.

User’s System BD583

+24VDC TBI1~8
(or Ground) (1) Common
R

R C
(2)

SMPS
Contacts
R
or
Open Collectors
R C
(9) Input signals
Ground
(or +24VDC)

Figure 5.46 Method for Wiring Input Signal of Expansion Public IO Board (BD583)

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5.8.2.2. Digital Output

Figure 5.47 below shows the pin composition of the terminal block (TBI1~8) for digital output. Each
terminal block can be connected to the common power for 8 input signals, and can use a different
power supply than the common power of the terminal block for other input.

Output display LED

Common power
st
Output signal (1 )

th
Output signal (8 )

Figure 5.47 Pin Configuration of Digital Input/Output Terminal Block on Expansion Public IO Board
(BD583)

Table 5-23 Pin Configuration of Digital Output Terminal Block (TBOn*) on Expansion Public IO Board
(BD583)

Pin Number Signal Name Signal Description

9 COMn* COMMON power (Ground DC24V or DC24V)

8 DOn*1 1st output of nth public output signal port of user

7 DOn*2 2nd output of nth public output signal port of user

6 DOn*3 3rd output of nth public output signal port of user

5 DOn*4 4th output of nth public output signal port of user

4 DOn*5 5th output of nth public output signal port of user

3 DOn*6 6th output of nth public output signal port of user

2 DOn*7 7th output of nth public output signal port of user

1 DOn*8 8th output of nth public output signal port of user

Note *) Terminal Block Number n = 1~8 (Ex, TBO1, TBO2, TBO3, TBO4)

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The electric specification of each output signal is as follows.

 Output component: Photo MOSFET (TBO1~4), relay (TBO5~8)

 Rated output
 Photo MOSFET 125mA (Continuous load current) / 24V DC
 Relay: 3A / DC 24V, AC250V
 Common power: Ground 24VDC or 24VDC

The user connects the output signal through the method shown in Figure 5.48 below. First, connect
the common signal (COMMON) to the Expansion Public IO Board (BD583), and then connect each
signal to the output pin according to the usage. The power can be grouped by 8 output signals, and
can be applied differently by port.

BD583 User’s System

TBO1~4 +24VDC
(1) Output signal (or Ground)

load

SMPS
(8) Output signal

load Ground
(9) Common (or +24VDC)

(a) Photo MOSFET type output type

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BD583 User’s System

TBO4~8 +24VDC
(9) Output signal (or Ground)

load

SMPS
(2) Output signal

load Ground
(1) Common (or +24VDC)

(b) Relay output type

Figure 5.48 Method for Wiring Output Signal of Expansion Public IO Board (BD583)

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5.8.2.3. Power Connector: CNP1, CNP2

The Power Connector is the connector to supply the power to operate the Expansion Public IO Board
(BD583), and is composed of connector CNP1 for DC5V and CNP2 for DC24V, as shown in Figure
5.49 below. CNP1 supplies the power required for the basic operation of the board, and CNP2
supplies the power required to operate the 32-point output relay from the SMPS.

A3: DC5V GND

A2: DC5V

A1: N.C.
AMP D3100 series
Contact 917511-3
AMP D3100 series
AMP D3100 series Receptacle Housing
Tab header 1-178288-3
1-178313-3
(a) CNP1 (DC5V power)

A3: DC24V GND

A2: N.C

A1: DC24V
AMP D3100 series
Contact 917511-3
AMP D3100 series
AMP D3100 series Receptacle Housing
Tab header 1-178288-3
1-178313-3

(b) CNP2 (DC24V power)

Figure 5.49 Power Connector CNP1 and CNP2 of Expansion Public IO Board (BD583)

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5.8.2.4. CAN Communications Connector: CANS1, CANS2

For the CAN Communications Connector, there are two identical connectors with the same pin
specification, which are installed as shown in Figure 5.50 below. As CAN communication is
conducted through cable, with a Daisy Chaining method, it therefore does not matter which side of the
connector it is connected to, as it does not affect the operation.

Figure 5.50 Method of Connecting the CAN Connector of Expansion Public IO Board (BD583)

When connecting several boards, the terminating resistance must be processed precisely. CAN data
communication uses the Daisy Chaining method. Therefore, only the board connecting the CAN
communication cable at the end must be connected to the terminating resistance; all other boards
must not be connected to the terminating resistance. For the connection of terminating resistance, use
the JP1 jumper next to CAN Connectors 1 and 2. When you short-circuit JP1, the terminating
resistance is connected, and when opened, the terminating resistance is disconnected. Please refer to
Figure 5.51 below.

Basic module
(MAIN, SYSTEM,
st
SmallDoor) 1 IO board nd
2 IO board
(Middle board): (Last board):
Terminating Terminating
resistance not resistance
connected connected

Figure 5.51 Method for Connecting Terminating Resistance

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5.8.3. Setting Unit

5.8.3.1. DIP Switch Settings

The board number of the DIP switch DSW1 is set in hexadecimal code. Based on the setting condition
of the switch, the board number is shown in Table 5-24 below.

Table 5-24 Method for Setting DSW1 Switch of Expansion Public IO Board (BD583)

Switch Number 4 3 2 1

Board Number (hex) Setting

Setting Preliminary
X4 X2 X1

OFF OFF OFF OFF 1st board

OFF OFF OFF ON 2nd board

Example of
Setting
OFF OFF ON OFF 3rd board

OFF OFF ON ON 4th board

Factory Default
OFF OFF OFF OFF 1st board
Setting
ON
Exterior of
Switch
1 2 3 4

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5.9. Analog/Arc IF Board (BD584)

5.9.1. Outline
The Analog/Arc IF board provides the analog input/output and digital input/output required to connect
with external devices. The specification of the basic board is as follows.

 Digital input: 8 points

 Digital output: 8 points (Photo MOS type)

 Analog input: 8 points (12-bit resolution)

 Analog output: 8 points (12-bit resolution)

 Analog stick check function

Figure 5.52 Analog/Arc IF Board (BD584)

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The board is 86mm(L) x 156mm(H) in size, and has many functions, which are shown in Figure 5.53
below.

LED for Digital Power CNP1 (DC5V)

Input (DIN1~8)

Terminal Block CAN Communicaton

TBDI for Digital CANS1, CANS2
Input (DIN1~8)

Digital Input
LED for Digital Common Setting
Output SSW1 (DIN_COM1)
(DOUT1~4) (DIN1~8)
Terminal Block
Digital Input
TBDO1 for Digital
Output Common Setting
(DOUT1~4) SSW2 (DIN_COM2)
DIN1~8)
LED for Digital
Output Digital Output Common
(DOUT5~8) Setting SSW3
Terminal Block (DOUT_COM1) (DIN1~8)
TBDO2 for Digital
Output
(DOUT5~8) Digital Output
Common Setting
SSW4 (DOUT_COM2)
Terminal Block
(DIN1~8)
TBAI for Analog
Input (AIN1~8)
Analog Stick Check
Resistance Setting
Terminal Block VAR1 (≤200Ω)
TBAO for Analog
Output
(AOUT1~8)

Figure 5.53 Configuration of Analog/Arc IF Board (BD584)

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5.9.2. Connector
5.9.2.1. Digital Input

The board has 8 digital input ports that can receive ON/OFF input. The photocoupler is used to
electrically insulate from the external device. To expand the applied scope, each input can select and
use the common input signal of two types.

The current used in the unit input is 5mA at 24V voltage. Therefore, if all 8 inputs are used, a total of
40mA of current is consumed.

TBDI

pin 1

Figure 5.54 Terminal Block for Digital Input on Analog Board (BD584)

Use the assigned input to connect the arc welder. Details are shown in Table 5-25 below.

Table 5-25 Pin Configuration of Digital Input Terminal Block (TBDI) of Analog Board (BD584)

Number Name Name for Arc Welder Connection Remarks

1 DIN1 WCR

2 DIN2 SHOCK_SENSOR

3 DIN3 WIRE_STICK

4 DIN4 WELDER_ERR

5 DIN5 WIRE_STATE

6 DIN6 GAS_STATE

7 DIN7 Reserved 1

8 DIN8 Reserved 2

9 DI_COM1 Signal Common 1

10 DI_COM2 Signal Common 2

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The method of connecting the digital input port is shown in Figure 5.55 below. The example depicts
the connection of 4 sensors with contact point or NPN-type output. Sensors 6 and 8 are configured
with SMPS1 power, and Sensors 1 and 4 are configured with SMPS2 power. That is, two different
types of power input can be used. This is set and classified by the SIP switches, SSW1 and SSW2
inside the board. For example, sensor 8 is connected to input port 8. Because this sensor uses
SMPS1 power, the circuit must be configured through the COMMON power connected to 9. Therefore,
turn on SSW1 switch 8, and then turn off SSW2 switch.

BD584(Analog) Borad
TBDI
DI_COM2
10
DI_COM1
9 DC24V DC24V
SSW1 8 DIN8 SMPS1 SMPS2
SSW2 8 8
DIN7 Sensor 8
7
SSW1 6 DIN6
SSW2 6 6 DC24V DC24V
DIN5 GND GND
Sensor 6
SSW1 4 5
DIN4
SSW2 4 4
DIN3 Sensor 4
3
DIN2
2
SSW1 1
DIN1
SSW2 1 1
Sensor 1

Figure 5.55 Method for Connecting Digital Input on Analog Board (BD584)

The installation order can be summarized as follows.

① First, turn off both SIP switches (SSW1 and SSW2).
② Connect the sensor and external power to the input terminal block TBDI.
③ SIP switch (SSW1 and SSW2) setting: For the power configuration, turn the SIP switches
SSW1 and SSW2 ON or OFF according to the applicable sensor.

Caution:
You must not set the same switch number for SIP switches SSW3 and SSW4 to
ON simultaneously. Doing so can short-circuit two different power supplies.

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SIP switches SSW1 and SSW2 are connected within the board, as shown in Figure 5.56 below.
Because the DI_COM1 (#9 pin) of digital input terminal block TBDI is connected to the common
connecting pin (#9 pin) of SIP switch SS1, when you turn ON switches #1~#8 of SSW1, the same
power as DI_COM1 is connected to the input signal processing circuit.
In addition, because the DI_COM2 (#10 pin) of TBDI is connected to the common connecting pin (#9)
of SIP switch SSW2, when you turn ON switches #1~#8 of SSW2, the same power as DI_COM2 is
connected to the input signal processing circuit.
Switches #1~#8 of SSW1 and SSW2 are connected to each other for each number. Therefore, if you
turn ON both SSW1 and SSW2 for the input signal number, the common power will be short-circuited.
For this reason, you must only turn ON one of the two.

TBDI
MCV1.5/10-GF-3.81

1 PS4 nanoSMDM016 DIN1 WCR

2 PS5 nanoSMDM016 DIN2 SHORKSENSOR
3 PS6 nanoSMDM016 DIN3 WIRESTICK
4 PS7 nanoSMDM016 DIN4 WELDERERR
5 PS8 nanoSMDM016 DIN5 WIRESTATE
6 PS9 nanoSMDM016 DIN6 GASSTATE
7 PS10 nanoSMDM016 DIN7 RESERVED
8 PS11 nanoSMDM016 DIN8 RESERVED
9 PS12 nanoSMDM016 DICOM1
10 PS13 nanoSMDM016 DICOM2

SSW1
9
8 DIN8쪽 회로
7 DIN7쪽 회로
6 DIN6쪽 회로
5 DIN5쪽 회로
4 DIN4쪽 회로
3 DIN3쪽 회로
2 DIN2쪽 회로
1
ON

DIN1쪽 회로
1

SSV82

SSW2
9
8
7
6
5
4
3
2
1
ON

SSV82

Figure 5.56 Common Circuit of Digital Input from Analog Board (BD584)

Caution:
You must not set the same switch number for SIP switches SSW3 and SSW4 to
ON simultaneously. Doing so can short-circuit two different power supplies.

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5.9.2.2. Digital Output

The board has 8 digital output ports that can output ON/OFF. These are electrically insulated from the
external device using the photo MOSFET. To expand the applied scope, each input can select and use
common output signal and individual contact point output of two types.
Maxim3um permitted current of unit output is 125mA at 24V voltage. Therefore, when all 8 of the
outputs are used, the total current consumption is about 1000mA.

TBDO1 TBDO2

pin 1 pin 1

Figure 5.57 Terminal Block for Digital Output on Analog Board (BD584)

Use assigned output to connect the arc welder. Details are shown in Table 5-26 below.

Table 5-26 Pin Configuration of Digital Output Terminal Block (TBD01) on Analog Board (BD584)

Number Name Name for Arc Welder Connection Remarks

TBDO1 1 DOUT 1 TORCH_SW

TBDO1 2 DOUT 1 COM

TBDO1 3 DOUT 2 INCHING

TBDO1 4 DOUT 2 COM

TBDO1 5 DOUT 3 RETRACT

TBDO1 6 DOUT 3 COM

TBDO1 7 DOUT 4 STICK_CHECK

TBDO1 8 DOUT 4 COM

TBDO1 9 DO_COM1 Signal Common 1

TBDO1 10 DO_COM2 Signal Common 2

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Table 5-27 Pin Configuration of Digital Output Terminal Block (TBD02) on Analog Board (BD584)

Number Name Name for Arc Welder Connection Remarks

TBDO2 1 DOUT 1 GAS_VALVE

TBDO2 2 DOUT 1 COM

TBDO2 3 DOUT 2 Reserved 1

TBDO2 4 DOUT 2 COM

TBDO2 5 DOUT 3 Reserved 2

TBDO2 6 DOUT 3 COM

TBDO2 7 DOUT 4 Reserved 3

TBDO2 8 DOUT 4 COM

TBDO2 9 WS_A Check connecting terminal A of Analog Wire Stick

TBDO2 10 WS_B Check connecting terminal B of Analog Wire Stick

The connecting method for the digital output port is shown in Figure 5.58. The example shows how to
connect 4 loads in 3 formats. Loads 1 and 3 are connected to SMPS1 power, load 5 is connected to
SMPS3 power and load 7 is connected to SMPS3 power. That is, you can use 3 different power
supplies for the output. This can be set and classified by SIP switches SSW3 and SSW4 inside the
board.

For example, load 1 is connected to output port #1. Because this sensor uses SMPS1 power, the
circuit must be configured through the COMMON power connected through #9. Therefore, turn #1 of
SSW3 switch ON, and then #1 of SSW4 switch OFF.

For load 7, the COMMON power is not used, and SMPS3 is separately used to use the output port
independently. Turn both SIP switches SSW3 and SSW4 OFF, and connect the Ground wire from
SMPS3 directly to the terminal block.

Caution:
You must not set the same switch number for SIP switches SSW3 and SSW4 to
ON simultaneously. Doing so can short-circuit two different power supplies.

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BD584(Analog) Borad
TBDO2
WA_B 10

WA_A 9

SSW3 7 DO8_COM 8

SSW4 7 DO8 7
DO7_COM
6 DC24V

SMPS3
DO7 DC24V GND
5
Load 7
DO6_COM 4
SSW3 5

SSW4 5 DO6 3
DO5_COM
2 DC24V

SMPS2
DO5 DC24V GND
1
Load 5

TBDO1
DO_COM2
10
DO_COM1
9

SSW3 3 DO4_COM 8

SSW4 3 DO4
7
DO3_COM
6 DC24V
SMPS3

DC24V GND
DO3
5
Load 3
DO2_COM 4
SSW3 1
SSW4 1 DO2 3
DO1_COM
2
DO1
1
Load 1

Figure 5.58 Method for Connecting the Digital Output on Analog Board (BD584)

The installation order can be summarized as follows.

① First, turn off both SIP switches (SSW3 and SSW4).
② Connect the load and external power to the output terminal blocks TBDO1 and TBDO2.
③ SIP switch SSW3 and SSW4 setting: For the power configuration, turn the SIP switches
SSW3 and SSW4 ON or OFF according to the applicable load.

Caution:
You must not set the same switch number for SIP switches SSW3 and SSW4 to
ON simultaneously. Doing so can short-circuit two different power supplies.

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 5. Controller Options

Similarly to the input, the SIP switches SSW3 and SSW4 are connected inside the board, as shown in
Figure 5.59 below.

TBDO1
MCV1.5/10-GF-3.81

PS14 nanoSMDM016 1
DOUT1+
TORCHSW
PS15 nanoSMDM016 2
DOUT1-
PS16 nanoSMDM016 3
DOUT2+
INCHING
PS17 nanoSMDM016 4
DOUT2-
PS18 nanoSMDM016 5
DOUT3+
RETRACT
PS19 nanoSMDM016 6
DOUT3-
PS20 nanoSMDM016 7
DOUT4+
STICKCHK
PS21 nanoSMDM016 8
DOUT4-

DOCOM1 1 2 9
FB10 BLM41PG181SN1
DOCOM2 1 2 10
FB11 BLM41PG181SN1

TBDO2
MCV1.5/10-GF-3.81

PS22 nanoSMDM016 1
DOUT5+
GASVALVE
PS23 nanoSMDM016 2
DOUT5-
PS24 nanoSMDM016 3
DOUT6+
RESERVED
PS25 nanoSMDM016 4
DOUT6-
PS26 nanoSMDM016 5
DOUT7+
RESERVED
PS27 nanoSMDM016 6
DOUT7-
PS28 nanoSMDM016 7
DOUT8+
RESERVED
PS29 nanoSMDM016 8
DOUT8-

WS_A 9

WS_B 10

SSW3
1

1
ON

2
3
4
5
6
7
8
9

SSV82

SSW4
1

1
ON

2
3
4
5
6
7
8
9

SSV82

Figure 5.59 Common Circuit of Digital Output on Analog Board (BD584)

Caution:
You must not set the same switch number for SIP switches SSW3 and SSW4 to
ON simultaneously. Doing so can short-circuit two different power supplies.

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5.9.2.3. Analog Input

The board can receive analog voltage input of 8 channels. Each channel has 12-bit resolving power in
the range of -12V~+12V. The input impedance is 20kΩ, and output impedance of the connected
device should ideally be infinite. As the analog value of all 8 channels is transmitted to the MAIN board
every 1msec, the scan time is 1msec.

TBAI

pin 1

Figure 5.60 Terminal Block for Analog Input on Analog Board (BD584)

The pin allocation of terminal block TBAI for analog input is shown in the following Table.

Table 5-28 Pin Configuration of Analog Input Terminal Block (TBAI) on Analog Board (BD584)

Number Name Usage Remarks

1 AIN1 Analog Input Channel 1

2 AIN 2 Analog Input Channel 2

3 AIN 3 Analog Input Channel 3

4 AIN 4 Analog Input Channel 4

5 AIN 5 Analog Input Channel 5

6 AIN 6 Analog Input Channel 6

7 AIN 7 Analog Input Channel 7

8 AIN 8 Analog Input Channel 8

9 AING Analog Input Ground

10 AING Analog Input Ground

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 5. Controller Options

The method of connecting the analog input port is shown in Figure 5.61 below. This example shows
the method of connecting 5 analog signals. Each signal sends input to AIN1~AIN5, and the ground is
connected to AING pin #9 or #10. The input signal is AD converted through the signal control circuit
inside the board. The power used in the analog input circuit uses the insulation separated type DC/DC
converter, and is separated from the internal power of the controller.

BD584(Analog) Borad
TBAI
AIN1
1
AIN2
2
AIN3
3
AIN4
4
MUX
& AIN5
5
ADC
AIN6
6
AIN7 Singal 5 Singal 4 Singal 3 Singal 2 Singal 1
7
AIN8
8
AING
9
AING
10

Signal Ground

Figure 5.61 Method for Connecting Analog Input on Analog Board (BD584)

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5.9.2.4. Analog Output

The board can output analog voltage on 8 channels. Each channel has 12-bit resolving power in the
range of -12V~+12V. The analog voltage value of all 8 channels is transmitted from the MAIN board
every 5msec, to renew the output voltage.

TBAO

pin 1

Figure 5.62 Analog Output Terminal Block on Analog Board (BD584)

The pin allocation of terminal block TBAO for analog output is shown in Table 5-29 below.

Table 5-29 Pin Configuration of Analog Output Terminal Block (TBAI) on Analog Board (BD584)

Number Name Usage Remarks

1 AOUT 1 Analog Output Channel 1

2 AOUT 2 Analog Output Channel 2

3 AOUT 3 Analog Output Channel 3

4 AOUT 4 Analog Output Channel 4

5 AOUT 5 Analog Output Channel 5

6 AOUT 6 Analog Output Channel 6

7 AOUT 7 Analog Output Channel 7

8 AOUT 8 Analog Output Channel 8

9 AOUTG Analog Output Ground

10 AOUTG Analog Output Ground

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 5. Controller Options

The method of connecting the analog output port is shown in Figure 5.63 below. The example shows
the method of connecting to use 4 analog voltage outputs, AOUT1, AOUT3, AOUT5 and AOUT7.
Ground of voltage is connected to AOUTG pin #9 or #10. The power used in the analog output circuit
uses the insulation separation type DC/DC converter to separate from the internal power of the
controller.

BD584(Analog) Borad
TBAO
AOUT1
1
AOUT2
2 Load1
AOUT3
3
AOUT4
4 Load3
DAC AOUT5
5
AOUT6
6 Load5
AOUT7
7
AOUT8
8 Load7
AOUTG
9
AOUTG
10
Signal Ground

Figure 5.63 Method of Connecting Analog Output on Analog Board (BD584)

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5.9.2.5. Analog Stick Check

The board includes a function to check the wire stick of the arc plate through an analog method. As
shown in the Figure 5.64 below, connect to #9 (WS_A) and #10 (WS_B) of TBD02 to check the stick.
The criteria for checking the stick can be set up to 200Ω by using the variable resistance VAR1 of the
board.

BD584(Analog) Borad
TBDO2

4
Comparator
5

7
Rstick
8 (<100Ω)
VAR1
RVAR1 WS_A
9
(~200Ω)
WS_B
10

Figure 5.64 Analog Stick Check Function on Analog Board (BD584)

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 5. Controller Options

5.9.2.6. Power Connector: CNP1

Power is supplied to the board through CNP1 connector. Figure 5.65 describes the exterior and pin
allocation of CNP1.

A3: DC5V GND

A2: DC5V

A1: N.C.
AMP D3100 series
Contact 917511-3
AMP D3100 series
AMP D3100 series Receptacle Housing
Tab header 1-178288-3
1-178313-3

Figure 5.65 Power Connector CNP1 of Analog Board (BD584)

Table 5-30Pin Configuration of Power Connector CNP1 on Analog Board (BD584)

Number Name Usage Remarks

A1 N.C. No connection

A2 DC5V DC 5V power

A3 DC5V GND DC 5V power ground

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5.9.2.7. CAN Communications Connector: CANS1, CANS2

Data communication with the MAIN board uses the CAN of Half Duplex method. Bottom modules of
the controller are configured for CAN data communication using a Daisy Chain method. Therefore,
there are two CAN connectors on the board. Figure 5.66 below describes the CAN connector exterior
and pin allocation. Even though you can connect the power through #6 (VCC-DC5V) and #2 (VCC
Ground) to the board, it is recommended to use the CNP1 power connector.

Figure 5.66 Method of Connecting CAN Connector on Analog Board (BD584)

Table 5-31 Pin Configuration of CAN Connector on Analog Board (BD584)

Number Name Usage Remarks

1 Shield Connect shield of CAN cable

Connect board power DC5V ground

2 DC5V GND
(Recommended to connect through CNP1)

3 CAN_G Connect ground for CAN communication

4 CAN_L1 Connect L signal of CAN communication

5 CAN_H1 Connect H signal of CAN communication

Connect board power DC5V ground

6 DC5V
(Recommended to connect through CNP1)

When connecting several boards, the terminating resistance must be processed precisely. CAN data
communication uses the Daisy Chaining method. For this reason, only the board connecting the CAN
communication cable at the end must be connected to the terminating resistance; all other boards
must not be connected to the terminating resistance. For the connection of the terminating resistance,
use the JP1 jumper next to CANS connectors 1 and 2. When you short-circuit JP1, the terminating
resistance is connected, and when opened, the terminating resistance is disconnected

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 6. Troubleshooting

6. Troubleshooting

6
Troubleshooting

6-1
 6. Troubleshooting Hi5 Controller Maintenance Manual

Hi5 controller emphasizes on high-precision and high-speed(promptness). So, it is designed to

facilitate troubleshooting when troubles occur.
Please be fully aware of this MANUAL for troubleshooting.

6.1. Troubleshooting Solution

Troubleshooting cases are explained hereinafter.

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 6. Troubleshooting

6.1.1. E0002 Hardware limit switch operating

6.1.1.1. Outline

Limit switch that is installed at the end of operation area of Robot‟s each axis has been activated.
The Robot will be immobilized immediately for a safety reason and will not be operational until it is
moved to a safe operation area by an appropriate method.

6.1.1.2. Causes and checking methods

(1) Please confirm if the Robot actually went out of operation area
 Actions to be taken when a Robot went out of operation area

(2) If an error occurs though a Robot is in the operation area

 Checking method from a System Board Connector(CNLS)
 Checking method from a Wire Harness(CER1 or CEC1)
 Checking method by examining a limit switch and internal wiring of main frame

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 Hi5 Controller Maintenance Manual

(1) Please confirm if the Robot actually went out of operation area
Please confirm if the Robot actually went out of operation area. If a soft limit error has
occurred simultaneously, the Robot did go out of operation area.
Please take an appropriate action to move the Robot back into the operation area.
Operation area may vary to the each Robot model, so as the installed location of limit
switches. Please refer to the corresponding Robot‟s maintenance manual - “Limitations of
Operation area”

Figure 6.1 Installed Locations of Hardware Limit Switches for HS165/HS200 Robot

Figure 6.2 Operation Area for S-axis Limit Swith of HS165/HS200 Robot

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 6. Troubleshooting

 Actions to be taken when a Robot went out of operation area

Please take following actions in order to move a Robot while a hardware limit switch is
on. Firstly, enter the system with a manual mode and turn on the enabling switch of
Teach Pendant.

From this stage, execute the Motor On command and move the Robot back into the
operation area by using a jog key

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 Hi5 Controller Maintenance Manual

(2) If an error occurs though a Robot is in the operation area

Firstly, check if the limit (Over-Travel) is being entered consecutively from the Private input
signal window of Teach Pendant
This window can be accessed by selecting “『[F1]: Service』 → 『1: Monitoring』 → 『2:
Input/Output Signal』 → 『1: Private input signal』”
A yellow color status on limit (Over-travel) indicates an error status

 Cautions:
On manual mode, a monitoring is enabled only when a Teach Pendant‟s enabling switch
is on
On automatic mode, a monitoring is enabled regardless of a status of enabling switch

Figure 6.3 Limit (Over-Travel) Monitoring is Displayed from the Private input signal Window

In these cases, cause of this error can be found from the components that are related to the
limit switch. As shown in the diagram below, the limit switch is connected to a controller‟s
System Board from a main frame by using “CER1 – CEC1” cables

6-6
 6. Troubleshooting

Figure 6.4 Wirings that are related to a Limit Switch Status Input

Main check points and their orders are

① System Board
② Internal wiring of a controller and connector
③ Wire harness and connector
④ Limit switch and a wiring of mainframe

and please jump the input line of limit switch at an appropriate point in order to check if a limit
(Over-Travel) from a monitoring windows turns to white color.

Please proceed as follows.

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 Hi5 Controller Maintenance Manual

 Checking method from a System Board Connector(CNLS)

Warning
Please make sure the power of a controller has been completely turned off
before you connect or remove any cables. Electrocution may cause personal
injuries or a property damages

This method uses a CNLS connector of System Board to judge if the board malfunction
caused this error.
Please jumper short the pins that are related to the limit switch‟s input from a CNLS
connector as shown below. At this stage, please check the limit (Over-Travel) from the
Private input signal monitoring windows.

① If it turned to a white color, System Board malfunction caused this error. Please
replace the board.
② If it is still yellow which indicates that the error persists,

Please search a problem that caused this error in an area between the System Board and
the limit switch of main frame.

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 6. Troubleshooting

 Checking method from a Wire Harness(CER1 or CEC1)

Warning
Please make sure the power of a controller has been completely turned off
before you connect or remove any cables. Electrocution may cause personal
injuries or a property damages

This method uses a Wire Harness connector (CER1 or CEC1) to judge if the cable
malfunction caused this error.
Please remove CEC1 Wire Harness, and jumper short the pins that are related to the limit
switch from a CEC1 connector which is attached to a controller. At this stage, please check
the limit (Over-Travel) from the Private input signal monitoring windows.

① If it turned to a white color, internal CEC1 Connector (of a controller) - System Board
cable or a connector malfunction caused this error. Please examine them or replace
them.

② If it is still yellow which indicates that the error persist, please search a problem that
caused this error in an area between the CEC1 connector and the limit switch of main
frame.

Please reconnect CEC1 Wire Harness, and remove the CER1 Wire Harness from a main
frame. After that, please jumper short the pins that are related to a limit switch from a CER1
connector.
At this stage, please check a limit (Over-Travel) from the Private input signal monitoring
windows.

① If it turned to a white color, Wire Harness cable between CER1 Connector-CEC1

Connector or a connector malfunction caused this error. Please examine them or replace
them.

② If it is still yellow which indicates that the error persist, please search a problem that
caused this error in an area between the mainframe side‟s CER1 connector and the limit
switch.

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 Hi5 Controller Maintenance Manual

 Checking method by examining a limit switch and internal wiring of main frame

Warning
Please make sure the power of a controller has been completely turned off
before you connect or remove any cables. Electrocution may cause personal
injuries or a property damages

Please remove the CER1 Wire Harness from a main frame, and use a multi meter to run a
short (shortage) test to examine the lines that are related to the limit switch from a main
frame‟s CER1 connector.

① If resistance is measures as open status, limit switch or a limit switch – CER1 connector,
or a connector malfunction is suspected. Please examine or replace them.

② If resistance is measured as short (shortage) status, other parts need to be examined.

Please make an enquiry to our office.

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 6. Troubleshooting

6.1.2. E0010 AMP recovery discharge resistance overheating

6.1.2.1. Outline

Recovery electric power that generated when Robot reduces a speed or moving toward to a gravity
direction is discharged by resistance.
This error is related to an overheat that caused by the resistance.
This error may occurs due to a reduced performance of cooling fan, overheat detection sensor‟s circuit
malfunction, disconnection of the resistor, overload of recovery discharge capacity that caused by
momentary rapid movement or a continuous movement of robot.

6.1.2.2. Causes and checking methods

<Case : Error always occurs even when the motor is off>

(1) Please examine the components that are related to the overheat error detection
 Please examine the resistor of CNTR cable
 Please replace CNSGC cable and examine it
 Please replace BD530/BD531 board and examine it
 Please replace diode module and examine it

<Case : Error always occurs at the moment when the motor turns on>
(2) Please examine the components that are related to the power
 Please examine the resistance value of CNDR cable
 Please replace diode module and examine it
 Please examine the 3-phase voltage from the inside of controller
 Please examine the controller‟s 3-phase input voltage

<Case : Error occurs at a certain step according to the Robot‟s operation speed>
(3) Please make changes on a speed of Robot‟s operation in order to confirm the error
 Please reduce the speed of Robot‟s operation in order to confirm the error
 Please examine the recovery discharge resistance value

<Case : Error occurs after 5 minutes from the start up of Robot‟s operation>
(4) Please examine the controller‟s cooling system and recovery electric power level
 Please examine the operational status of each fan
 Please examine the power voltage of each fan
 Please reduce the speed of Robot‟s operation in order to confirm the error

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 Hi5 Controller Maintenance Manual

(1) Please examine the components that are related to the overheat error detection
Recovery resistance overheat error is detected by Servo Drive Unit. Each end‟s On/Off status
of overheat sensor that are attached to a recovery resistor is being monitored by CNTR
connector. Detected error will be sent through CNSGC cable to be handled by software at the
BD530/BD531 board.

Figure 6.5 Locations of Components in Hi5-N00 Controller that are related to Recovery Resistance
Overheat Error

Figure 6.6 Locations of Components in Hi5-N30 Controller that are related to Recovery Resistance
Overheat Error

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 6. Troubleshooting

 Examining the CNTR cable

Please examine the sensor from a CNTR connector that connects the overhear detection
sensors.
In a normal status, sensor must be measured less or than 0.1 ohm

Figure 6.7 Measuring Resistance Value from Hi5-N00 Controller‟s CNTR

Figure 6.8 Measuring Resistance Value from Hi5-N30 Controller‟s CNTR

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 Hi5 Controller Maintenance Manual

 Replacement and examining of CNSGC cable

Replace the CNSGC cable with new one and test it. If the error does not persist, cable
connection problem caused this error. Please replace the CNSGC cable with new one.

 Replacement and examining of BD530/BD531

Replace the BD530/BD531 with new one and test it. If the error does not persist, the
board malfunction caused this error. Please replace the BD530/BD531 with new one.

Figure 6.9 Replacement of BD530/BD531

 Replacement and examining of diode module

Components that detects the recovery discharge resistance overheats error are SD1L2C
(large size) and SA3A3D (small size). Please check the components in the controller that
you are currently using and examine it. Please replace it with new one and see if the
error persists.

Figure 6.10 Replacement of SD1L2C in Hi5-N00 Controller when Recovery Discharge Resistance is
Overheated

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 6. Troubleshooting

(2) Please examine the components that are related to the power
Overhear error may occurs in a case when resistor has disconnection or discharge control
malfunction. It also can occur when recovery discharge resistance value and a 3-phase
voltage increases.

 Examining recovery discharge resistor‟s disconnection

If measured resistance value at the end of CNDR cable is many M ohm, the resistor‟s
disconnection or connection problem of internal wiring caused this error. Please replace
the recovery resistor with new one or repair the wiring.

Figure 6.11 Measuring Resistance Value from CNDR of Hi5-N00 Controller

Figure 6.12 Measuring Resistance Value from CNDR of Hi5-N30 Controller

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 Hi5 Controller Maintenance Manual

 Replacement and examining of diode module

Please replace a module (SD1L2C for large size, SA3A3D for small size) that detects a
recovery discharge resistance overheat error and check if an error persists. An error may
occur continuously due to a module‟s internal circuit malfunction. For a large size
controller, diode module is separated from the Servo Drive Unit, and for a small size
controller, it is located inside of the Servo Drive Unit.

 Large size Robot‟s diode module: SD1L2C

 Small size Robot‟s Servo Drive Unit: SA3A3D

 Examine the 3-phase voltage (inside of the controller)

Recovery discharge operation activates from approximately DC 375V
If a voltage over AC242 V enters to the Servo Drive Unit, a recovery discharge
resistance overheat error may occur when the motor turns on.
If the input voltage exceeds the allowed range, please examine according to a
controller‟s input voltage examination procedures and a controller‟s 3-phase internal
voltage examination procedures.

 Servo Drive Unit input voltage specification: 3-phase AC 220V

 Allowed range when motor turns on: 198 V ~ 242 V

(3) Please make changes on a speed of Robot‟s operation in order to confirm the error

In case when a Robot‟s speed is reducing, or moving toward to gravity direction, direct
current voltage of a Servo Drive Unit increases, and the voltage will be discharged with a
recovery discharge resistance in order to prevent damages on components that may caused
by voltage increase.
If a Robot reduces its speed rapidly, or make a high speed movement toward to gravity
direction, it may cause this error. Please confirm if this error occurs according to the speed of
Robot‟s operation.

 Make changes on a speed of Robot‟s operation

If a recovery electric power that generated by Robot‟s operation exceeds the controller‟s
designed specification, recovery resistance overheat error may occurs. Please reduce
the speed of a step that the error occurs and re-operate in order to confirm if the error
persists.

 Examining recovery discharge resistance value

If a measured resistance value at the end of CNDR cable exceeds over 10% of the value
described in the manual, the resistor malfunction is the cause of this error. Please
replace the resistor. Please refer to the previous page for the measuring method.

 Large size (SD1L2C) recovery discharge resistance value : 5 ohm

 Small size (SA3A3D) recovery discharge resistance value : 15 ohm

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 6. Troubleshooting

(4) Please examine the controller‟s cooling system and recovery electric power level

If recovery resistance overheat error occurs after 5 minutes from the start up of Robot‟s
activation, the cause would be either the controller‟s cooling system malfunction or a speed
of Robot‟s operation exceeded the designed specification of the controller.
Fans are being used at rear of the controller in order to cool down the Servo Drive Unit‟s heat
sink and the recovery discharge resistor

Table 6-1 Location of Fans for Each Controller

Hi5-N** Hi5-C1* Hi5-C0*

 Examining the operational status of each fan

Please replace a fan if it does not spin, or the speed is abnormally slow. Lifetime of a fan
may vary according to a operating environment or a amount of operated hours.

 Examining fan‟s power voltage

Please check the input voltage of fans if all of them do not operate. Input voltage of a fan
is set to AC220V and the allowed range is within 10% of the standard voltage. If voltage
is lower than 10% of the standard voltage, the cooling effect will be reduced due to slow
spinning speed of a fan. In case when the voltage is low, please check the input voltage
for fan‟s power supply connector (CNFN2) and a controller.

 Please confirm an occurrence of an error according to the speed of Robot‟s operation

If an overheat error occurs during a continuous operation over 5 minutes, it is because of
the consecutive operation of Robot exceeded the cooling capacity of a controller.
Please reduce the speed of Robot‟s operation and check if the error persists.
In order to resolve this error, if you had to reduce the operation speed too much just to
resolve this error, please enquire at our office

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 Hi5 Controller Maintenance Manual

6.1.3. E0011 AMP overvoltage (P-N)

6.1.3.1. Outline

Direct current voltage (P-N) of Servo Drive Unit that drives the motor exceeded the set value

6.1.3.2. Causes and checking methods

<Case : Error always occurs even when the motor is off >
(1) Please examine the components that are related to the overvoltage error detection
 Please replace CNSGC cable and examine it CNSGC
 Please replace BD530/BD531 board and examine it BD530/BD531
 Please replace diode module and examine it

<Case : Error always occurs at the moment when the motor turns on>
(2) Please examine the components that are related to the power
 Please replace diode module and examine it
 Please examine the 3-phase voltage from the inside of controller
 Please examine the controller‟s 3-phase input voltage

<Case : Error occurs at a certain step according to the Robot‟s operation speed>
(3) make changes on a speed of Robot‟s operation in order to confirm the error
 Please reduce the speed of Robot‟s operation in order to confirm the error
 Please examine the recovery discharge resistance value

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 6. Troubleshooting

(1) Please examine the components that are related to the overheat error detection
AMP overvoltage occurrence error is detected by diode module when direct current voltage
(P-N) that supplied to the Servo Drive Unit exceeds the configured level. Detected error will
be sent through CNSGC cable to be handled by BD530/BD531 board.

Figure 6.13 Locations of Components in Hi5-N00 Controller that are Related to Overvoltage
Occurrence Error

Figure 6.14 Locations of Components in Hi5-N30 Controller that are Related to Overvoltage
Occurrence Error

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 Hi5 Controller Maintenance Manual

 Replacement and examining of CNSGC cable

Replace the CNSGC cable with new one and test it. If the error does not persist, cable
connection problem caused this error. Please replace the CNSGC cable with new one.

 Replacement and examining of BD530/BD531 BD530/BD531

Replace the BD530/BD531 with new one and test it. If the error does not persist, the
board malfunction caused this error. Please replace the BD530/BD531 with new one.

Figure 6.15 Replacement of BD530/BD531

 Replacement and examining of diode module

Components that detects the AMP overvoltage occurrence error are SD1L2C (large size)
and SA3A3D (small size). Please check the components in the controller that you are
currently using and examine it. Please replace it with new one and see if the error
persists.

Figure 6.16 Replacement of SD1L2C in Hi5-N00 Controller when Overvoltage Occured

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 6. Troubleshooting

(2) Please examine the components that are related to the power
Overvoltage error occurs when direct current voltage that exceeds DC395V due to 3-phase
input voltage over AC 220V enters to the Servo Drive Unit.

 Replacement and examining of diode module

Please replace a module (SD1L2C for large size, SA3A3D for small size) that detects
AMP overvoltage error and check if the error persists. An error may occur continuously
due to module‟s internal circuit malfunction.

 Large size Robot‟s Servo Drive Unit : SD1L2C

 Small size Robot‟s Servo Drive Unit : SA3A3D

 Examine the 3-phase voltage

AMP overvoltage error is activated from approximately DC 395V
If voltage over AC242 V enters to the Servo Drive Unit, a recovery discharge resistance
overheat error may occur when the motor turns on.
If the input voltage exceeds the allowed range, please examine according to a
controller‟s input voltage examination procedures and a controller‟s 3-phase internal
voltage examination procedures.

 Servo Drive Unit input voltage specification : 3-phase AC 220V

 Allowed range when motor turns on : 198V ~ 242V

(3) Please confirm the occurrence of error according to the speed of Robot‟s operation
If a robot reduce the speed rapidly, or make a high speed movement toward to gravity
direction, it can cause an overvoltage error. Please confirm if an error occurred according to a
speed of Robot‟s operation.
AMP overvoltage occurrence error also can be caused by an invalid recovery discharge
resistance value or recovery discharge control malfunction.
In case when a Robot‟s speed is reducing, or moving toward to gravity direction, voltage of
the Servo Drive Unit increases, and the voltage will be discharged with a recovery discharge
resistance in order to prevent damages on components that may caused by an increased
voltage.

 Make changes on a speed of Robot‟s operation

If a recovery electric power that generated by Robot‟s operation exceeds the controller‟s
designed specification, overvoltage error may occurs. Please reduce the speed of a step
that the error occurs and re-operate in order to confirm if the error persists. If the error
does not occur when the speed is reduced, please change the speed of step and use it.

 Examining the recovery discharge resistance value

If a recovery resistance value is greater than the specification, recovery discharge does
not perform well and it will cause the overvoltage error. Recovery resistance
specifications are subject to be changed according to the controller‟s specification.
Please refer to a manual and a controller check sheet that provided upon a purchase.
If the resistance value exceeds 10 % of specification, please replace it.

 Large size (SD1L2C) recovery discharge resistance value : 5 ohm

 Small size (SA3A3D) recovery discharge resistance value : 15 ohm

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Figure 6.17 Measuring Resistance Value from CNDR of Hi5-N00 Controller

Figure 6.18 Measuring Resistance Value from CNDR of Hi5-N30 Controller

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 6. Troubleshooting

6.1.4. E0014 Instant contact of safety switch (EM, OTR, TS etc.)

6.1.4.1. Outline

For some reason the motor‟s power supply to AMP has been shut down. Main examines the safety
signals in order find the reason of the motor‟s power shut down. If no reason is found, this message
will be displayed
.
Following diagram shows compositions of various safety signals that can shut down the motor‟s power.
Main periodically examines the ON/OFF status of those safety signals. If a momentary contact
malfunction occurs between the periods, main will not be able to detect it and displays this message
instead

Figure 6.19 Concept Diagram of Safety Circuit for Motor‟s Power ON/OFF

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6.1.4.2. Causes and checking methods

(1) Please check the status of DC 24V (P1-M1) power and cables

(2) Please check if there is a problem with CPUERR, EXOUT signals

(3) Please check the safety switch and signal wirings

(4) Please check the System Board, Electrical Module

(1) Please check the status of DC 24V (P1-M1) power and cables
Please check if the System Board is being supplied with DC 24V control power (P1, M1)
properly. This error can be caused if there is a problem with the power as it will effect the
safety sequence of the System Board. Power is to be supplied by SMPS‟s CN6
Connector-System Board CNP2 Connector. Please check if the power level is varying or is
there any problem with the cable.

Figure 6.20 Method of Connecting DC24V Power and Measuring Voltage of the System Board
(BD530)

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 6. Troubleshooting

(2) Please check if there is a problem with CPUERR, EXOUT signals

Mainboard generates CPUERR or EXOUT signals in a case when systemic error has
occurred (e.g. power shut down, Servo error). This signal will be transferred to the System
Board and block the motor on command in terms of hardware. Motor‟s power will be
immediately shut down for a safety reason. However, these signals may be generated
abnormally, and it will shut down the motor‟s power.

 How to judge:
System Board‟s 7-segment index may give you an indication of the situation.7-segment
displays “H” when CPUERR is being transmitted to the System Board. Also the CPUERR,
EXOUT LED which located at the center of the System Board indicate the error situation
(figure 6.21) These LED lights will be on if it is a normal status, and the lights will be off if
it is not.

However if the signal appears time to time for a very short moments, 7-segment and
LED won‟t be able to indicate it. In such case, error occurrence must be observed while
ignoring the two signals by using DIP switch SW1. Method to ignore the signal is to, as
shown in the figure 6.21, turn on the No 1(to ignore CPUERR) and the No 2 (to ignore
EXOUT) of the DIP switch SW1. At this point all LED lights will be on.

If the error no longer persists after the system restart, mainboard generated these
signals or CANS1 Connector/Cable malfunction is suspected.

Figure 6.21 Location 7-SEG, LED and DIP Switch (CPUERR error related) on a System Board

 Actions :
If a Main Board generating this signal without any other indication of errors, please check
the PLD version of the Main Board. Over V0.7 is normal. If mainboard‟s PLD version is
normal, please examine the CANS1 connector and cables.

Cautions : Please use only No 1(to ignore CPUERR) and No2(to ignore EXOUT) of
the DIP switch SW1 for a testing purpose and please switch it back to normal
after the test. This ignores the emergency safety related functions and it may
cause safety related problems if operates while ignoring these functions.

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(3) Please check the safety switch and signal wirings

Safety switch input may goes OFF for a short moment which cannot be detected by the Main
Board for following reasons

 Switch malfunction
 Wiring malfunction : Exposure or damage on a cable
 Wirings installation problem:
Seperated distance between power lines, cables that consume a large amount of electric
power must be greater than 10 CM. Alternatively electrical shielding by using a metal
marital plates are required.

Cautions : Please use only for a testing purpose and please switch it back to
normal after the test. This ignores the emergency safety related functions and
it may cause safety related problems if operates while ignoring these
functions.

Available safety switches are as below, and they can be connected through a System Board.
Please check the above for the safety switches that are being used.

Types Connecting method Disabling method

Emergency stop
switch(External)
–point of contact type

Emergency stop
switch(External)-semi
conductor type

Safety guard
(Auto)-point of
contact type

Safety guard
(Auto)-semiconductor
type

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 6. Troubleshooting

Types Connecting method Disabling method

Safety
guard(General)

Cautions :
Please use only for a testing purpose and please switch it back to normal
after the test. This ignores the emergency safety related functions and it may
cuase safety related problems if operates while ignoring these functions

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Other switches that are related to a safety and system operation which may effect to this error are
as below

Types Connecting method Disabling method

Enabling
switch(TP)

Remote mode
input

Limit switch

Arm interference
switch

System Board – Wiring between Teach

Pendants

Emegerncy stop
switch(TP)

Emergency stop
switch(OP)

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 6. Troubleshooting

(4) Please check the System Board, Electirical Module

 Cabling (wires, connector etc) malfunction

Please check the cabling between the Electrical Module (PDM30) that an electrical
connector is installed and the System Board (BD530) that collects monitoring signals.
The cable name is CNMS and it enters to the Electrical Module through the top rear of
the System Board (figure 6.22). Please check the connection status of this cable‟s
connector.

Figure 6.22 CNMC Cable on the Electrical Module

 System Board malfunction

Input signal processing unit malfunction from the inside of System Board can be a cause
of this error. Please replace the System Board and examine it.

 Electrical Module malfunction

Internal electirical module malfunction can be categorized as a electrical board (BD5C0),
Electrical connector (MC1, MC2), and wirings between the electrical board and the
electrical connector (figure 6.23) However it is difficult to examine the inside of Electrical
Module in a field where a Robot has already been installed, so alternatively please
replace the Electrical Module.

Figure 6.23 Inner Structure of Electrical Module

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Figure 6.24 Electrical Board (BD5C0)

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 6. Troubleshooting

6.1.5. E0015 Teaching pendant operation error

6.1.5.1. Outline

This error occurs when communication between a Main Board (BD510) and a Teach Pendant (TP510)
has been disconnected due to a bad communication status. If this error occurring during an operation
(AUTO mode), a robot will be immobilized.

6.1.5.2. Causes and examine methods

(1) Please check if the Main Board inside of a controller is in a normal status

(2) Case : Status of 7-Segment from a Main Board is “.” (normal)

 Case : TP communication status indicator icon is white
 Case : TP communication status indicator icon is x

(3) Case : Status of 7-Segment from a Main Board is “u”

 TP communication status indicator icon will be x

(4) Case : Status of 7-Segment from a Main Board is abnorma

 TP communication status indicator icon will be x

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(1) Please check if the Main Board inside of a controller is in a normal status
Communication can be disconnected if a Main Board or a Teach Pendant is in a abnormal
status for any reasons. Please see the 7-Segment from a Main Board to confirm if a Main
Board‟s status is normal or abnormal.

Figure 6.25 7-Segment is in a Normal Status. Others are Abnormal (see the above diagram)

If a controller‟s door is shut when the power is on, please refer to the below diatram in order
to open the door to check.

Caution
Once a controller is opened, please only check the main board‟s status and do
not touch anything else for a safety reasons.
Please make sure to close it after you check the main board‟s status

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 6. Troubleshooting

(2) Case : Status of 7-Segment from a Main Board is “.” (normal)

Please check the status of “TP communication indicator icon” that located on a left side of
“Titles” from TP510.

 If a TP communication status indicator icon is blue, it is a normal status.

 If a TP communication status indicator icon is white,

 LAN cable between a Main Board and TP has a problem (not open) or an abnormal
status of Teach Pendant is suspected.

① Please download Main Board‟s application program as same version as a TP

② Please replace TP510 and test it.
③ Please replace a LAN cable between TP connector and Main Board in a
controller and test it.
④ If a same status persists, please contact to our AS department.

 If a TP communication status indicator icon is x,

 Disconnection (open) of LAN cable between a Main Board and TP is suspected.

① Please replace TP and test it.

② Please replace a LAN cable between TP connector and Main Board in a
controller and test it.
③ If a same status persists, please contact to our AS department.

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(3) Case : Status of 7-Segment from a Main Board is “u”

 TP communication status indicator icon will be x.

 Cable between a main and System Board, or a System Board is suspected.

① Please check if a connector at the both ends of cable have been plugged
properly.
② Please check if a power for CNMC connector is AC48V.

③ Please check if Ve(3pin) of SW1 is DC0V.

④ Please replace a (CANIO↔CAN1)Cable and test it.

⑤ Please replace a System Board and test it.
⑥ If a same status persists, please contact to our AS department.

(4) Case : Status of 7-Segment from a Main Board is abnormal

 TP communication status indicator icon will be x.

 The cause for this case is a Main Board malfunction.

① Please replace a Main Board and test it.
② If a same status persists, please contact to our AS department.

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 6. Troubleshooting

6.1.6. E0022 Communication error between internal modules

6.1.6.1. Outline

Internal modules of controller use CAN communication in order to transfer data. E0022 is an error
code that indicates the Main Board has detected an error in a CAN communication between internal
module System Boards. E0032 error code will be used for users board (BD58x) that uses a same CAN
communication channel.

Figure 6.26 CAN Communication Structure of Hi5 Controller

System Board is a moduel that controls an input/output of controller‟s power sequence. Once this error
occurs, all functions related to this will be stopped and main stops CAN communication. In order to re
active all the functions, a controller must be restarted.

6.1.6.2. Causes and examine methods

(1) General examine

 Please check the connection staus of CAN communication cable
 Please check the power status (power voltage or connection status of cable)

(2) If an error persists even after a restart of contoller

 Please check a System Board malfunction
 Please replace a malfunction parts and test it (Main Board, System Board, cables)

(3) If an error occurs while a controller is normally operating

 Please observe a changes in surrounding environment
 Please examine the CAN communication line
 Please examine the CAN communication connector for users module
 Please examine the connection of termination resistor
 Please examine the wiring structures.
 Please examine if a communication cable uses a twist line.

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(1) General examine

If this error occurred while a system is normally operating, please examine the following for a
start

Reference
Once “E0022 Communication error between internal modules” occurs,
mainboard will not establish a communication with system board even if a
system board initiates communication. Controller must be restarted in order to
reestablish a communication.

 Please check the connection status of CAN communication cable

Please check if a CAN cable between Main Board and System Boards are well
connected. Please remove and reconnect the CAN connectors of Main Board and
System Board and check if an error persists, in order to check connector‟s connection
status.

Figure 6.27 CAN Communication Cable Connection between a Main Board (BD510) and a System
Board (BD530)

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 6. Troubleshooting

 Please check the power status (power voltage or connection status of cable).
Please check if a DC 5V control power is being supplied to System Board properly. If
there is a problem with a power, this error may occur as the System Board will not
operate.
Please check if a power is being supplied or not by using a simple method. As a below
diagram, there are LED CNP1 that indicates DC 5V voltage and 7-segment that indicates
the board operating status on an upper right side of System Board.

Table 6-2 Method to Check the whether the Rated Voltage on System Board is Normal or Not
(LED)
Category 7-SEG Result
CNP1
Power on a System Board is has not been
authorized properly. Please examine the power
1 Off Off
related parts such as SMPS, Cable, Connector
connections etc.
Power of IO related board (BD531) that located at
2 On Off
the rear of system is not authorized or malfunction.

3 On On Please check the power voltage.

Figure 6.28 LED CNP1 for a Power Purpose DC5V of a System Board (BD530)

If the lights of LED CNP1 and 7-segment DC are all on as above table, please check if
the DC 5V control power that authorized on a board is in a range of 5.0V~5.3V.
If the voltage is out of this range, it may effect to the communication. Check points are as
below diagram and it the voltage is out of range, plase configure it to a range of
5.0V~5.3V from a SMPS.

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Figure 6.29 Measuring a Voltage of DC 5V and Controlling Method

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 6. Troubleshooting

(2) If an error persists even after a restart of controller

If a error message displayed because the error is already occurring even after the controller
has been restarted, the faulty area can be identified by performing a series of examines.

Reference
If you are usings a user‟s module (BD58x), please remove a CAN cable that
connected to this module before you perform this test. It is to eliminate
possible elements that will effect to the test. If this error does not persists after
a restart of a controller followed by a removal of user‟s module cable, the
cause of an error is related to a user‟s module. Please refer to the following
paragraph.

In order to remove a user‟s module CAN communication from a controller, please unplug the
CAN2 and CANS2 connectors from a System Board as below diagram. If you restart the
controller, only a Main Board and System Board will keep the CAN communication.

Figure 6.30 Method to Remove CAN Communication Connection from User‟s Module (BD58x)

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 Please check the malfunction status of System Board

System Board has a 7-segment that indicates a various status. By examining it, you may
determine if a System Board is malfunctioning or not. After a controller has been
restarted, if the indicator does not display the content in a rotation as below, System
Board malfunction is suspected. Please replace it.

Figure 6.31 Location of 7-segment on a System Board (BD530)

Figure 6.32 Normal Display of 7-segment on a System board when Restarted

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 6. Troubleshooting

 Please replace a malfunction part and test it.

If above examines do not resolve an error, you will have to replace the parts that related
to this error and test them. The cause might be a circuit malfunction that related to CAN
communication inside of the board and it is difficult to be identified from an outside.
There are 3 parts as below diagram – System Board (BD530), Main Board (BD510),
Cable. (If a Main Board and other option module (BD58x) were having a CAN
communication, the cause of an error is not likely from Main Board or cable. Please
replace a System Board and test it).

Figure 6.33 Location of CAN Communication Cable and a Main Board (BD510)

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(3) Error occurring while a controller is operating normally

 Please observe changes in surrounding environment.

Please observe if there have been any changes in the surrounding field. Check if a new
large capacity electric power device has been installed. Quality of electric power and a
shortage may effect to the communication and cause this error.

 Please examine a CAN communication line CAN.

Property of matter CAN communication line may be connected with a users module
(BD58x) as well as a System Board and this may cause an error due to a effect caused
by a property of line‟s material. So, if a users module is being used, please run the
following examines.

 Please examine a CAN communication connector for user‟s module.

Data communication with a Main Board uses a half duplex CAN. Sub modules of
controllers are consists of a Daisy chain that uses CAN data communication. So the
board has 2 CAN connectors that indicated as CANS1, CANS2. Please check if
those connections are valid.

Figure 6.34 CAN Connector CANS1, CANS2 of User‟s Module

Table 6-3 Pin Locations for CAN Connector of User‟s Module

Number Title Usage

1 Shield To connect the electric shield line of CAN cable

(DC5V To connect board power DC5V ground

2
GND) (Connection with CNP1 is recommended)

3 CAN_G To connect a ground for CAN communication

4 CAN_L1 To connect L signal of CAN communication

5 CAN_H1 To connect H signal of CAN communication

6 (DC5V) To connect board power DC 5V (Connection with CNP1 is recommended)

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 6. Troubleshooting

 Please examine the connection of terminal resistor.

If numbers of boards are connected to each other, a terminal resistor must be
handled clearly. CAN data communication uses daisy chain method. So the terminal
resistor only should be connected to the last CAN communication cable and the
terminal resistor must not be connected to any boards in between. Terminal
resistor‟s connection uses a JP1 jumper that located next to the CANS1 and CANS2
connector on a board. If JP1 has been shorted it means that the terminal resistor is
connected, and if JP1 has been opened, it eliminates the terminal resistor
connection. Please refer to the following diagram.

Basic Module
(MAIN, SYSTEM)
1st UDIO Board 2nd UDIO Board
(Board in between) (Board at the end)
Terminal resistor is Terminal resistor is
not connected not connected
Figure 6.35 Connecting Method of Terminal Resistor on a CAN Communication Line

 Please examine the wiring structure

CAN communication wiring must not have a branch wiring. All connections must
have a series connection from one module to the next module. Following diagram
describes a wrong wiring structure.

Figure 6.36 Bad example of CAN Communication Wiring Structure

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In a diagram, CAN communication line that starts from a System Board has two branches.

 Branch 1:
System Board CAN 2 Connector → Small Door Board → Controller door DIO board

 Branch 2 :
System Board CNAS2 Connector → Analog board on Controller‟s side → DIO borads
on a controller

These can have a negative effect on a quality of communication, so please change the wiring
structure as below.

 Branch 1 :
System Board CAN 2 Connector → Small Door Board → Controller door DIO board →
Analog board on Controller‟s side → DIO boards on a controller
 Branch 2 : Eliminated

Figure 6.37 Good example of CAN communication wiring structure

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 6. Troubleshooting

If user module that used for a controller‟s door is not available, please remove the CAN cable that
connects a System Board to a small door board as shown in a below diagram. Also making a wiring in
order to keep the cable between modules at a minimum distance can increase a quality of
communication

Figure 6.38 Remove the CAN Communication Cable that is Not in Use

(4) Please examine if a communication cable uses a twist line.

CAN communication uses twist pair wiring in order to ensure a high quality of communication
against external noise. CAN_H1 and CAN_L1 signal line must be twisted to each other
(please refer to figure 6.39).

Figure 6.39 Example of Twist pair

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6.1.7. E0033 AMP under-voltage error

6.1.7.1. Outline

Direct current voltage (P-N) that activates a motor in a Servo activation device has been measured
under the under-voltage set value.

6.1.7.2. Causes and examine methods

<Case : Error occurs even when the motor is off>

(1) Please examine the parts that related to an under-voltage error detection.
 Please replace CNSGC cable and test it CNSGC
 Please replace BD530/BD531 board and test it
 Please replace a diode module and test it
.
<Case : Error always at the moment when motor turns on>
(2) Please examine power related parts.
 Please replace a diode module and test it
 Please examine a 3-phase voltage inside of a controller
 Please examine a input 3-phase voltage of a controller

<Case : Error occurs at a certain step according to the robot‟s operation speed>
(3) Please make changes on a speed of robot‟s operation in order to confirm an error.
 Please reduce the speed of robot‟s operation in order to confirm an error
 Please examine a input 3-phase voltage of a controller while a robot is in
operation
 Please examine a internal 3-phase voltage if a input voltage is not 220V

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 6. Troubleshooting

(1) Please examine the parts that related to an under-voltage error detection
Occurrence of under-voltage at AMP error is detected by a diode module when a direct
current voltage (P-N) that supplied to Servo activation device has been measured under the
under-voltage set value. Generated error will be handled by a software at BD530/BD531
through a CNSGC cable

Figure 6.40 Locations of Hi5-N00 Controller‟s Under-Voltage Occurrence Error Related Parts

Figure 6.41 Locations of Hi5-N30 Controller‟s Under-Voltage Occurrence Error Related Parts

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 Replacement of CNGSC and examine CNSGC

Please replace CNGSC cable with a proper one and if an error does not persist, cable
connection fault caused an error. Please replace the CNGSC cable with new one and
use.

 Replacement of BD530/BD531 and examine

Please replace BD530/BD531 with a proper one and if an error does not persist, the
board malfunction caused an error. Please replace the BD530/BD531 with new one and
use.

Figure 6.42 Replacement of BD530/BD531

 Replacement of diode module and test

A module that detects an under-voltage error of AMP is SD1L2C for a large size and
SA3A3D for a small size. Please check the parts of a controller that currently used.
Please replace it with new one to test the persistence of an error.

Figure 6.43 Replacement of DS1L2C when an Under-Voltage Occurs at Hi5-N00 Controller

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 6. Troubleshooting

(2) Please examine the components that are related to power

AMP under-voltage occurrence error occurs when the 3-phase AC 220V that enters to the
Servo Drive Unit exceeds the allowed range. Also this error may occur when recovery
discharge happens at a moment of motor turns on due recovery discharge control circuit
malfunction.

 Replacement and examining of diode module

Please replace a module (SD1L2C for large size, SA3A3D for small size) that detects
AMP under-voltage error and check if an error persists. For a large size controller, diode
module is separated from the Servo Drive Unit, and for a small size controller, it is
located inside of the Servo Drive Unit.

 Large size Robot‟s diode module: SD1L2C

 Small size Robot‟s Servo Drive Unit: SA3A3D

 Examine the 3-phase voltage

AMP under-voltage error starts from approximately DC 210V (or 148V)
If a voltage under AC148V (or 100V) enters to the Servo Drive Unit, under-voltage error
may occur when the motor turns on.
If the input voltage exceeds the allowed range, please examine according to a
controller‟s input 3-phase voltage examination procedures and a controller‟s 3-phase
internal voltage examination procedures.

 Servo Drive Unit input voltage specification: 3-phase AC 220V

 Allowed range when motor turns on: 198V ~ 242V

(3) Please confirm the occurrence of error according to the speed of Robot‟s operation
If a robot reduce the speed rapidly, or make a high speed movement toward to gravity
direction, it can cause AMP under-voltage error. Please confirm if an error occurred, or the
changes of input 3-voltage supplied to Servo Drive Unit according to a speed of Robot‟s
operation.

 Make changes on a speed of Robot‟s operation

If a recovery electric power that generated by Robot‟s operation exceeds the controller‟s
designed specification, under-voltage error may occurs. Please reduce the speed of a
step that the error occurs and re-operate in order to confirm if the error persists. If the
error does not occur when the speed is reduced, please change the speed of step and
use it.

 Examine the 3-phase voltage at the error occurrence step

AMP under-voltage error starts from approximately DC 210V (or 148V)
If a voltage under AC148V (or 100V) enters to the Servo Drive Unit at the error
occurrence step, under-voltage error may occur when the motor turns on.
If the input voltage exceeds the allowed range, please examine according to a
controller‟s input voltage examination procedures and a controller‟s 3-phase internal
voltage examination procedures.

 Servo Drive Unit input voltage specification: 3-phase AC 220V

 Allowed range when motor turns on: 198V ~ 242V

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6.1.8. E0034 AMP over-current error

6.1.8.1. Outline

Over-current on the 3-phase voltage(R, S, T) that supplied to the diode module, or inflow of surge
voltage generated the over-current on a surge protector and it caused a cut-off of safety fuse.

6.1.8.2. Causes and checking methods

(1) Please examine the diode module‟s fuse

 Please examine if the diode module‟s fuse has been cut-off

<Case : Fuse has not been cut-off>

(2) Please examine the components that are related to the over-current error detection
error.
 Please replace CNSGC cable and examine it CNSGC
 Please replace BD530/BD531 and examine it
 Please replace diode module and examine it

<Case : Fuse has been cut-off>

(3) Please examine the components that are related to power
 Please examine the 3-phase voltage from the inside of controller
 Please examine the controller‟s 3-phase input voltage
 Please replace diode module and examine it

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 6. Troubleshooting

(1) Please examine the fuse in the Servo Drive Unit

Occurrence of AMP over-current error is detected by a diode module when the input 3-phase
voltage exceeds the specification. Generated error will be handled by the BD530/BD531
through a CNSGC cable.

Figure 6.44 Locations of Hi5-N00 Controller‟s AMP Over-Current Occurance Error Related Parts

Figure 6.45 Locations of Hi5-N30 Controller‟s AMP Over-Current Occurance Error Related Parts

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Figure 6.46 Locations of AMP Over-Current detection Fuse (in the SD1L2C)

Figure 6.47 Locations of AMP Over-Current Detection Fuse (in the SA3A3D)

Figure 6.48 Appearance of Disconnected AMP Over-Current Detection Fuse

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 6. Troubleshooting

(2) Please examine the parts that are related to over-current error detection
If AMP over-current error occurs while the fuse has not been cut-off, CNSGC, BD530/BD531
or the Servo Drive Unit is faulty. Please refer to the compositions of controller from the
manual and examine the each component.

 Replacement and examining of CNSGC cable CNSGC

Replace the CNSGC cable with new one and test it. If the error does not persist, cable
connection problem caused this error. Please replace the CNSGC cable with new one.

 Replacement and examining of BD530/BD531 BD530/BD531

Replace the BD530/BD531 with new one and test it. If the error does not persist, the
board malfunction caused this error. Please replace the BD530/BD531 with new one.

Figure 6.49 Replacement of BD530/BD531

 Replacement and examining of diode module

Components that detects the AMP over-current error are SD1L2C (large size) and
SA3A3D (small size). Please check the components in the controller that you are
currently using and examine it. Please replace it with new one and see if the error
persists.

 Large size Robot‟s diode module : SD1L2C

 Small size Robot‟s Servo Drive Unit : SA3A3D

Figure 6.50 Replacement of SD1L2C in Hi5-N00 Controller when AMP Over-Current Error Occurs

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(3) Please examine the components that are related to the power
Over-current error occurs when an over-voltage or surge voltage that exceeds 3-phase AC
220V enters to the Servo Drive Unit. Over-voltage will trigger the surge protector, and the
serial connected fuse gets disconnected, so the error will occur.

 Examine the input voltage

If a voltage over AC242 V enters to the Servo Drive Unit, over-current error may occur
when the motor turns on.
If the input voltage exceeds the allowed range, please examine according to a
controller‟s input voltage examination procedures and a controller‟s 3-phase internal
voltage examination procedures.

 Servo Drive Unit input voltage specification: 3-phase AC 220V

 Allowed range when motor turns on: 198V ~ 242V

 Replacement and examining of diode module

Please replace a module (SD1L2C for large size, SA3A3D for small size) that detects
AMP over-current error and check if an error persists. An error may occur continuously
due to a module‟s internal circuit malfunction. For a large size controller, diode module is
separated from the Servo Drive Unit, and for a small size controller, it is located inside of
the Servo Drive Unit.

 Large size Robot‟s diode module: SD1L2C

 Small size Robot‟s Servo Drive Unit: SA3A3D

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6.1.9. E0044 Lift axis belt disconnect sensor is operating

6.1.9.1. Outline

A sensor that is installed on an axis (one of Robot‟s operating axis) which transfers the power to the
belt is determining whether the belt exists or not. This error will occur, if a belt does not exist in the
detection range of the sensor as the belt is broken.
This error also can be caused by an abnormal connection between the sensor and the board that is
installed on a controller.

6.1.9.2. Causes and examine methods

(1) Please check the status of the error

 Please check the Private input signal monitoring window.
 Please check the status of BD58B board‟s relay operation

<Error status on monitoring window, but replay is normal(ON)>

(2) Please examine the components that are related to the error detection
 Please replace CNSGC cable and examine it CNSGC
 Please replace BD530/BD531 board and examine it.

<Error status on monitoring window, and replay is abnormal(OFF)>

(3) Please examine the Robot
 Please check the status of belt in the Robot‟s drive unit
 Please check the operation of the sensor that detects the broken belt

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(1) Please check the status of the error.

 Check the Private input signal from the monitoring window of TP510
Firstly, check if the Lift axis belt/Limit (Arm) is being input. This window can be accessed
from 『[F1]: Service』 → 『1: Monitoring』 → 『2: Input/Output signal』 → 『1: Private
input signal』. If the Lift axis belt/Limit (Arm) is highlighted in yellow, it indicates an error
status.

Figure 6.51 Checking the Lift axis belt from Private input signal

 Checking the status of BD58B board‟s relay operation

Proximity sensor that attached at the Robot‟s operation part detects a break based on
the light reflection from surface of the belt and transmits the ON/OFF signal to the
controller. The received signal will be transferred to BD58B board for the fall prevention
brake system and as well as to the BD530 (the System Board). Please check the
sensor‟s operation status based on the relay operation status of BD58 board.

Figure 6.52 Checking the Relay Status of BD68B Board

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 6. Troubleshooting

Relay operation status of BD58B board can be checked as below diagram. Normal status
relay operates the coil and can see the empty space at the center. .

Figure 6.53 Comparing the Normal and Error Status of BD58B Board‟s Relay

You may confirm which (in the Robot) axis‟s detection sensor is operating based on the
status of BD58B board‟s relay operation

① Normal ② Z1 sensor is off (Z1 axis is broken)

④ Both Z1/Z2 sensor are off (Z1/Z2

③ Z2 sensor is off (Z2 axis is broken)
axis are broken)

Figure 6.54 Checking the Location of Error Based on BD58B Board‟s Relay

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(2) Please examine the components that are related to the error detection
If the Private input signal from the monitoring window and the relay status of BD58B board
are different, CNLS cable that connects the BS58B and BD530/BD531, or the BD530/BD531
is faulty. Please refer to the compositions of controller from the manual and examine the each
component

Figure 6.55 Replacement of BD530/BD531

 Replacement and examining of CNSGC cable

Replace the CNSGC cable with new one and test it. If the error does not persist, cable
connection problem caused this error. Please replace the CNSGC cable with new one

 Replacement and examining of BD530/BD531

Replace the BD530/BD531 with new one and test it. If the error does not persist, the
board malfunction caused this error. Please replace the BD530/BD531 with new one

Figure 6.56 Replacement of BD530/BD531

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 6. Troubleshooting

(3) Please examine the Robot

If the Private input signal from the monitoring window and the status of BD58B board‟s relay,
BD58B actually acknowledged the error operation of the sensor. Robot‟s belt and detection
sensor must to be checked. Please remove the CNZB1 and CNBZ2 connector of BB58B
board in order to prevent a fall of lift axis that may caused by sensor malfunction during the
examination of Robot

Warning
Make sure the CNZB1 and CNBZ2 connectors of BD58B are removed while
examining the Robot‟s belt and break detection sensors in order to prevent the fall
of list axis

 Check the belt‟s status of Robot‟s operation part

Please check the belt of the axis that confirmed by a status of BD58B relay from the
Robot. Applicability and location of the belt may be different to each Robot‟s model.
Please check the status of belt according to the Robot‟s specification and maintenance
manual

Figure 6.57 Lift Axis Belt and the Break Detection Sensor

 Checking the operation of belt break detection sensor

Detection sensor is an optical type and it can only detect when the object is within a
certain distance. If the object if out of the distance, it will process an error. Please change
the distance to the object at the front of detection sensor and check the status of TP510‟s
Private input signal. If the sensor‟s operation and the result of monitoring do not match,
please check the connection of signal line between the sensor and the TBBO terminal
block (inside of BD58B board) in the Robot. Sensor‟s LED green indicates normal status
and red indicates error status.

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6.1.10. E0108 (Axis ○) Encoder error: Encoder reset required

6.1.10.1. Outline

Power must be supplied to the encoder at all time for it to be able to store the motor‟s location data.
Encoder‟s power will be supplied when the controller‟s power is on or from the encoder‟s back up
battery. This error will occur, if the controller‟s power goes off while the encoder‟s back up battery is
discharged (as it will cause the encoder to lose the location data)
The same error will also occur when the motor is being replaced, because the new motor‟s encoder is
not supplied with power.
Please move the Robot to reference position by using an axis coordinate manual control to re-adjust
the axis‟s encoder as encoder reset will change the reference position data of the axis.

6.1.10.2. Causes and examine methods

(1) Please check the voltage of encoder‟s battery

(2) Please examine the Encoder‟s battery connection status

(3) Please replace the motor and test it

(4) Re-adjustment of the encoder from Robot‟s reference position must be done after the
encoder reset

(1) Please check the voltage of encoder‟s battery

Encoder‟s batter uses 3.6V. If the voltage decreases to 3.0V~3.2V, a message of “W0104 ○
Axis) Encoder battery voltage is low” will be displayed. Please replace the encoder‟s battery if
this warning occurs. Replacement of encoder‟s battery must be done while the controller‟s
power is on. If the encoder battery is replaced at this stage, Robot‟s operation will not be
interrupted.

If you miss the time to replace the encoder‟s battery, and the battery voltage reaches to
2.5V~3.0V, and error of “E0108 ○ Axis) Encoder error: Encoder reset required” will occur.
At the point of this error occurs, the encoder already lost the location data.
Please move the Robot to reference position by using an axis coordinate manual control to
re-adjust the axis‟s encoder followed by a replacement of encoder‟s battery and the reset of
encoder.

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Figure 6.58 Location of Encoder‟s Battery Replacement

Encoder reset can be executed from the below menu.

 System
 5. Initialize
 4. Serial encoder reset

(2) Please examine the Encoder‟s battery connection status

Please examine the connection status from encoder‟s battery to the motor.

(3) Please replace the motor and test it

If the above do not solve the problem, there is a high possibility that the encoder itself is the
cause. Please replace the motor and test it

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6.1.11. E0112 (○ Axis) IPM fault signal detection

6.1.11.1. Outline

A fault output has occurred from an IPM (Intelligent Power Module) – a switch device inside of Servo
Drive Unit that drives the motor. IPM fault may occur due to an increased temperature of heat sink,
IPM‟s control voltage reduction or an over-current output

6.1.11.2. Causes and examine methods

<Error occurs non periodically when the motor turns on>

(1) Please examine the motor drive components.
 Please examine the output cable that connects to the Servo Drive Unit
 Please examine the terminal(socket) of switching device in the Servo Drive Unit
 Please replace CNBS1,2,3 cables and confirm the error
 Please replace the Servo Board(BD542) and confirm the error
 Please replace the Servo Drive Unit and confirm the error
 Please replace the Servo motor and confirm the error

<Error occurs at a certain step>

(2) Please examine the Robot at the step that an error occurs
 Please examine the Robot‟s wiring at the location where the error occurs
 Please reduce the speed of Robot‟s operation in order to confirm the error
 Please make changes on Teached step‟s interpolation and confirm the error

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 6. Troubleshooting

(1) Please examine the components that are related to the motor drive
Servo Drive Unit that drives the motor receives a command from the Servo Board (BD542)
through CNBS cable, and the current output of internal amplification circuit will be transferred
to the motor through wirings that connected to each connectors of axis

 Examine the output cable that connects to the Servo Drive Unit
Examine the wirings that connect the Servo Drive Unit to the motor. Please turn off the
power of controller, and remove the connector from the Servo Drive Unit and measure
the resistance value between grounds to inspect the occurrence of short circuit

Figure 6.59 Examining the Output Cable of Servo Drive Unit (Hi5-N00 controller)

Figure 6.60 Examining the Output Cable of Servo Drive Unit (Hi5-N30 controller)

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 Examine the switch device of Servo Drive Unit

Switch device of Servo Drive Unit switches the direct current voltage that supplied from
diode module and output the alternating current for each phases. If a short circuit occurs
at the internal terminal of switch device, over-current flow and it will cause an IPM fault
error. Please remove the connector and check if a short circuit has occurred between the
output terminal in a switch device of Servo Drive Unit and the P (or N)
If a short circuit exists, the Servo Drive Unit need to be replaced and also the cable that
connects the Servo Drive Unit to the motor needs to be examined.

 Large size Robot‟s Servo Drive Unit: SA3X3Y

 Small size Robot‟s Servo Drive Unit: SA3A3D

Figure 6.61 Short Circuit Test on Switching Device of SA3X3Y

Figure 6.62 Short Circuit Test on Switching Device of SA3A3D

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 6. Troubleshooting

 Replacement of CNBS cable and examining the error CNBS

Servo Drive Unit that drives the motor receives a command from the Servo Board
(BD542) through CNBS cable, and the current output of internal amplification circuit will
be transferred to the motor through wirings that connected to each connectors of axis.
If the error does not persist after the replacement of cable, cable is faulty. Please replace
the CNBS cable with new one.

Figure 6.63 Locations of Components in Hi5-N00 Controller that are Related to Motor Drive

Figure 6.64 Locations of Components in Hi5-N30 Controller that are Related to Motor Drive

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 Replacement of Servo Board (BD542) and examine it

If the error does not persist after the replacement of Servo Board (BD542), Servo Board
(BD542) is faulty. Please replace the Servo Board (BD542) with new one.

 Replacement of Servo Drive Unit and examine it

If the error does not persist after the replacement of Servo Drive Unit, Servo Drive Unit is
faulty. Please replace the Servo Drive Unit with new one.

 Small size Robot‟s Servo Drive Unit: SA3X3Y

 Small size Robot‟s Servo Drive Unit: SA3A3D

 Replacement of Servo Motor and examine it

If the error does not persist after the replacement of Servo Motor, Servo Motor is faulty.
Please replace the Servo Motor with new one. Below diagram describes the locations of
each axis‟s motor (HS165 Robot). For other Robot, please refer to the Robot‟s
maintenance manual to replace it.

Figure 6.65 Locations of Each Axis‟s Motor (HS165 Robot)

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 6. Troubleshooting

(2) Please examine the Robot at the step that an error occurs
If IPM fault error occurs at a certain step, it may occur when the device wiring has been
damaged at Teached step or the axis speed changed greatly when the Teached program
changes the position. ,

 Examine the internal wiring at the location of an error

Examine the wiring status of corresponding axis that connected to the motor (inside of
Robot). During the examination, please turn off the controller‟s power and remove the
output connector from the Servo Drive Unit. After that please measure the resistance
value between ground of each phases (cable side) to test a short circuit.

Figure 6.66 Location of Wiring Examination for Each Axis (HS165)

 Reduce the speed of Robot‟s operation in order to confirm the error

If an error occurs at a step that generates rapid changes of axis speed which is caused
by the position changes of Robot, reduce the operation speed to confirm the error. If the
error does not persist after the speed is reduced, please change the Teach speed of
corresponding step and record the job program to use.

 Change the Teached step‟s interpolation to confirm the error

If the axis speed rapidly changes even after the operation speed is reduced by 75%,
please change the Teached step‟s interpolation to „P‟ and confirm the error. If the
changes on interpolation resolve the error, (at the same operation speed) please modify
the Teach.

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6.1.12. E0113 (○ Axis) Over-current

6.1.12.1. Outline

Current that flows in the motor or the drive unit exceeds the allowed voltage range. When the current
that generated by the Servo control to operate the Robot (or the drive unit) exceeds the allowed safe
voltage range, the Servo Board will detect an error and immobilize the Robot

6.1.12.2. Causes and examine methods

(1) Check if the axis with an error has mechanical interference with other equipments.

(2) Examine the Motor power line.

 Check the wiring that connects the Robot and Controller.
 Check the Robot‟s internal wiring.
 Check the Controller‟s internal wiring.

(3) Examine the CNBS cable between the Controller‟s internal Servo Board and the Drive
Unit

(4) Replace other components

(1) Check if the axis with an error has mechanical interference with other equipments
This error may occur if the Robot had a mechanical interference or collisions. If the Robot is
out of the operation area, please move it back into the operation area by using a manual
control.

(2) Examine the Motor power line

Please turn off the primary power and remove the U, V, W of drive unit for the corresponding
axis and examine if short circuit exists in each phase. Please use an equipment such as the
multi meter (tester) and examine each phase‟s wiring one by one.

Warning
Be cautious. Examination while the power is on may cause an electrocution

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 6. Troubleshooting

 Check the wiring that connects the Robot and Controller.

Please remove the wirings that connect the controller, Robot or the drive unit to examine
each phases (U, V, W) for ground, or a short circuit. If a short circuit is found, please
replace the wire

Figure 6.67 Basic Installation Diagram of the Robot and Control Period

 Check the Robot‟s internal wiring

Examine for a short circuit, faulty on a wiring that connected to Robot‟s internal motor is
required

Figure 6.68 Robot‟s Internal Wiring

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 Check the Controller‟s internal wiring.

Examine on a controller‟s internal AMP and installed wiring is required

Figure 6.69 Controller‟s Internal Area (Power unit)

(3) Examine the CNBS cable between the Controller‟s internal Servo Board (DSP board)
and the Drive Unit
Please examine if the CNBS cable is installed properly. If the cable is not installed properly, or
the cable is faulty, this error may occur.

Figure 6.70 Controller‟s Internal Area (CNBS cable)

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 6. Troubleshooting

(4) Replace other components

Replace the component in order of Servo Board (BD542) → Servo Drive Unit → Motor to
confirm the occurrence of an error.

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6.1.13. E0114 Operating device control voltage reduction

6.1.13.1. Outline

Control power that supplied to the Servo Drive Unit +15V has been reduced. This error is detected by
the Servo Drive Unit and transferred to the Servo Board through CNBS cable

6.1.13.2. Causes and examine methods

(1) Please check the power indicator LED

 Please check the „POW‟ LED of Servo Drive Unit
 Please check the „+15V‟ LED of SR1 (control power supply unit)

<Case: Both of module‟s LED are OFF>

(2) Please check the output of SR1(control power supply unit)
 Please remove CNBS cable from BD542 and check the LED
 Please remove the Servo Board from the Rack and check the LED

(3) Please examine the SR1(control power supply unit)

 Please check the input voltage to SR1
 Please replace the SR1 and check the LED

<Case: Only the Servo Drive Unit‟s „POW‟ LED is OFF>

(4) Please replace the related components and check the power indicator LED
 Please replace CNBS cable and check the LED
 Please replace the Servo Board and check the LED
 Please replace the Servo Drive Unit and check the LED

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 6. Troubleshooting

(1) Please check the power indicator LED

Drive unit control voltage reduction error is caused by a reduction of control voltage +15V.
This error will be detected by the Servo Drive Unit and transferred to the Servo Board
(BD542) through CNBS1, 2, 3 cables to be handled.

Figure 6.71 Locations of Components in Hi5-N00 Controller that are Related to Drive Unit Control
Voltage Reduction

Figure 6.72 Locations of Components in Hi5-N30 Controller that are Related to Drive Unit Control
Voltage Reduction

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 Examine the „POW‟ LED of Servo Drive Unit

Please check the „POW‟ of drive unit control voltage error detection module
(SA3X3Y-large, and SA3A3D-small) If the power is being supplied normally, the LED
light should be stays on

 Large size Robot‟s Servo Drive Unit : SA3X3Y

 Small size Robot‟s Servo Drive Unit : SA3A3D

Figure 6.73 Locations of Components in SA3X3Y that are Related to „POW‟ LED

Figure 6.74 Locations of Components in SA3A3Dthat are Related to „POW‟ LED

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 6. Troubleshooting

 Examine the „+15V‟ LED of SR1

Please check the LED of SR1 if the Servo Drive Unit‟s „POW‟ LED light is off.
Please check if the LED of SR1 and the LED of Servo Drive Unit are both off at the same
time.

Figure 6.75 Locations of „+15V‟ LED Related Components of SR1

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(2) Please check the output of SR1

Please remove the wirings and components that are connected to the Servo Drive Unit and
examine the „+15V‟ LED in order to check the output of SR1 itself

 Remove CNBS cable and check the LED

Please remove the CNBS1, CNBS2, CNBS3 that connect the Servo Drive Unit and the
Servo Board. After the removal, please check the LED of SR1. If the „+15V LED‟ of SR1
turns to ON after the removal of cables, the Servo Drive Unit is faulty. Please replace the
Servo Drive Unit with new one

Figure 6.76 Removal of CNBS cable

 Remove the Servo Board (BD542) and examine the LED

Please check the SR1‟s LED after you remove the Servo Board from a Rack. If the „+15V
LED‟ of SR1 turns to ON after the removal of Servo Board, the Servo Board is faulty.
Please replace the Servo Board with new one

Figure 6.77 Removal of Servo Board from the Rack

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 6. Troubleshooting

(3) Please examine the SR1(control power supply unit)

Control power supply unit received AC 48V (input) and output the necessary control power to
each board from the internal circuit.

 Examine the input voltage of SR1

If the input voltage to SR1 exceeds the specification, the output of control power may
have an error. If the input voltage exceeds the allowed range, please examine according
to a controller‟s input voltage examination procedures and a controller‟s single-phase
internal voltage examination procedures.

 SR1 input voltage specification: single-phase AC 48V

 Allowed range: 44V ~ 52V

 Replace the SR1 and check the LED

Please replace the SR1 with new one and check the „+15V‟ LED. If the LED is ON after
the replacement, SR1 is faulty. Please replace it and use.

(4) Please replace the related components and check the power indicator(LED)
Please replace the Servo Drive Unit, Servo Board, CNBS cable and check the „POW‟ LEF of
the Servo Drive Unit.

 Replace the CNBS cable and check the „POW‟ LED

Please replace the CNBS1, CNBS2, CNBS3 that connects the Servo Drive Unit and the
Servo Board, and check the „POW‟ LED. If the „POW‟ LED is ON after the replacement,
cable is faulty. Please replace it with new one.

 Replace the Servo Board and check the „POW‟ LED

Please replace the Servo Board, and check the „POW‟ LED. If the „POW‟ LED is ON after
the replacement, the Servo Board is faulty. Please replace it with new one.

 Replace the Servo Drive Unit and check the „POW‟ LED
Please replace the Servo Drive Unit, and check the „POW‟ LED. If the „POW‟ LED is ON
after the replacement, the Servo Drive Unit is faulty. Please replace it with new one.

 Large size Robot‟s Servo Drive Unit: SA3X3Y

 Small size Robot‟s Servo Drive Unit: SA3A3D

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6.1.14. E0115 (Axis o) Received command code error

6.1.14.1. Outline

Main Board‟s command code that received by the Servo Board does not meet the mutual regulation of
Main Board and the Servo Board. This error may occur due to the communication error or the version
differences between the Main Board and the Servo Board

6.1.14.2. Causes and examine methods

(1) Please examine if the Main Board and the Servo Board are installed properly.
 Examine if the board is installed properly.
 Examine if board is faulty

(2) Examine if the versions of the Main Board and the Servo Board matches

(1) Please examine if the Main Board and the Servo Board are installed properly
This error may be caused by a communication problem if the Main Board and the Servo
Board is not installed properly on a rack, or the board has an error

Warning
In order to protect the previous job programs, please back up all the files of
Main board to the USB memory before you remove the board from the Rack

Method to back up the files from Main Board to USB memory is as below

Figure 6.78 Inserting Method of USB to TP

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 6. Troubleshooting

Once the USB is recognized by TP, the below icon will be displayed on a screen

To back up the files enter to,

 Service
 5. File manager

And the screen that is similar to windows explorer will be displayed.

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At this stage, please copy the files shown in M/B and move them to USB

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 6. Troubleshooting

You may create a new folder on USB, or can rename the folder by using the soft keyboard
just like the windows explorer

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 Examine if the board is installed properly

Please remove the Main Board and the Servo Board from the Rack and re-install them
again

Figure 6.79 Location of Rack Inside of the Controller

 Examine if the board is faulty.

To examine if the board is faulty, please replace it with new one

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 6. Troubleshooting

(2) Examine if the versions of the Main Board and the Servo Board matches
When the controller turns on, it will check the versions of Main Board and the Servo Board
If the version does not match, an error of “E0179~E181 DSP version is old” will be displayed.
Please contact to our A/S department in order to update the system with a proper version

Versions of the Main Board and the Servo Board can be checked from the below menu

 Service
 System diagnosis
 System version

Press F6[next page] to check the version of Servo Board

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6.1.15. E0117 ( Axis ○) Location deviation set value exceeded

6.1.15.1. Ouline

Location (speed) deviation exceeds the set value. If the difference between the location of moving
command and the actual location is too large during the operation of Robot that controlled by the
Servo, the Servo Board will detect an error (during Servo operation) and immobilize the Robot .

6.1.15.2. Causes and examine methods

(1) Check if the axis with an error has mechanical interference with other equipments

(2) Check if the brake release works properly

 Examine if the brake release of each axis has an error
 Examine the error on brake‟s power supply.

(3) Examine the wiring status

(4) Check if the rated load is used

(5) Position deviation setting level error

(6) Please replace other components

(1) Check if the axis with an error has mechanical interference with other equipments
This error may occur if the Robot had a mechanical interference or collisions. If the Robot is
out of the operation area, please move it back into the operation area by using a manual
control

(2) Check if the brake release works properly

Brake release function of the corresponding axis maybe have an error, or the releave voltage
of the brake release may have problem

 Examine if the brake release of each axis has an error

Please remove the motor‟s power supply (motor OFF) and check if you can release the
brake of the axis with manual brake switch. You can confirm it with the sound of brake
release from the motor

Warning
Please be cautious. The Robot‟s axis may fall once the brake is released

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Figure 6.80 Location of the Manual Brake Release Switch

If the corresponding axis‟s brake cannot be released, output status of the brake release
voltage in the System Board need to be examined. Please remove the brake wiring (CNB2,
CNB7, CNB8 connector) and use the manual brake switch for the brake voltage‟s output.
Please measure the brake voltage of corresponding axix output (from the CNB2, CNB7,
CNB8 connector) to check if it is over 20V. If there is an axis which has a voltage output
under the 20V, System Board (BD530) is faulty. Please replace it

Figure 6.81 Pin Locations of CNB2, CNB7 Connectors

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 Examine the error on brake‟s power supply.

If “E0012 Brake power supply error message is displayed at the same time, there is an
error on Brake‟s power supply unit. From TP, please access 『[F1]:Service』→
『1:Monitoring』→『2:I/O signals』→『1:Private input signal』→『Overload(Brake Power
supply)』. If it is highlighted as yellow, the fuse for Brake (in the Electrical Module)‟s
power supply has been disconnected. Please replace the fuse.

Figure 6.82 Electrical Module

If the fuse is normal, please measure the Brake power supply (DC24V) from the System
Board. There are 3 test pins at the center of the board. Use the TMB as a reference terminal
and the TPPB terminal value should be over DC20V. If it is below 20V, the power supply unit
that generates the power for the brake has an error. Please replace the Electrical Module.

Figure 6.83 Brake Power Supply Test Pin

(3) Examine the wiring status

Check if the motor wiring (U, V, W phase) has been short-circuit from the other wiring or
ground lines (FG)

(4) Check if the rated load is used

If the total weight exceeds the rated load, please refer to the Robot‟s specification and adjust
the load to within the rated load.

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(5) Position deviation setting level error

If the position deviation setting value is smaller than the below‟s maximum measured value,
please increate the setting value

Maximum measured value of positon deviation after few cycles of operation x 1.5

Figure 6.84 Monitoring Screen of the Maximum Measured Position Deviation Value from TP

Figure 6.85 Modifying Screen of Position Deviation Value from TP

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(6) Please replace other components.

Replace the component in order of Servo Board (BD542) →Servo Drive Unit→Motor to
confirm the occurance of an error‟

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6.1.16. E0119 (Axis ○) Overload

6.1.16.1. Ouline

Motor or the drive unit is being overloaded. If motor or the drive unit is overloaded, the Servo Board
detects an error and immobilizes the Robot

6.1.16.2. Causes and examine methods

(1) Please check if the Robot is loaded within its rated load

(2) Please examine if there is a possible collision point during the Robot‟s operation

(3) Please check if the axis brake works properly

(4) Please replace the Servo Board and examine an error

(5) Please examine if the Drive Unit operates normally

(1) Please check if the Robot is loaded within its rated load.
Please check if the Robot is loaded within its rated load. This error may occur if the load
exceeds Robot‟s specification (load does not only include the tools that can be attached at
the end of Robot, but also include all the cables and other components that can be attached
to the Robot

Using measuring equipment is recommended, but if it is not an option, load can be measured
by using a „load estimation function‟ from the controller. However this function only can
measure the load of a tool that attached at the end of the Robot

Method to estimate the load is as below

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 Enter to the load estimate function

『[F2]: System』 → 『6: Automatic constant setting』→ 『4: Load estimation function』

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 Select the tool number, estimation method, enable status of inertia estimation from the
load estimation function

 Tool number to save after the load estimation

 Estimation method : Load estimation 2
 Inertia estimation : Enable

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 Click Normal Drive to execute.

Press the Motor On switch, and hold the deadman and click the Play Normal.

Decide if you want to register the result of load estimation

 Once the load estimation drive has completed, the estimated result will be displayed on
the screen

If you press the close button, a message box will appear to ask you if you want to
reflectthe result. If you click „yes‟ it will be saved

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(2) Please examine if there is a possible collision point during the Robot‟s operation
Please check if there is a point where the Robot may be interfered or have a collision in the
operation area. This error may occur if the Robot is interfered by other equipments. In that
case, please modify the job program so the interference will not occur

(3) Please check if the axis brake works properly

Brake release function of the corresponding axis maybe have an error, or the releave voltage
of the brake release may have problem.

 Examine if the brake release of each axis has an error

Please remove the motor‟s power supply (motor OFF) and check if you can release the
brake of the axis with manual brake switch. You can confirm it with the sound of brake
release from the motor .

Figure 6.86 Location of the Manual Brake Release Switch

If the corresponding axis‟s brake cannot be released, output status of the brake release
voltage in the System Board need to be examined. Please remove the brake wiring (CNB2,
CNB7, CNB8 connector) and use the manual brake switch for the brake voltage‟s output.
Please measure the brake voltage of corresponding axix output (from the CNB2, CNB7,
CNB8 connector) to check if it is over 20V. If there is an axis which has a voltage output
under the 20V, System Board (BD530) is faulty. Please replace it

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Figure 6.87 Pin Locations of CNB2, CNB7 Connectors

 Examine the error on brake‟s power supply.

If “E0012 Brake power supply error message is displayed at the same time, there is an
error on Brake‟s power supply unit. From TP, please access 『[F1]:Service』→
『1:Monitoring』→『2:I/O signals』→『1:Private input signal』→『Overload(Brake Power
supply)』. If it is highlighted as yellow, the fuse for Brake (in the Electrical Module)‟s
power supply has been disconnected. Please replace the fuse.

Figure 6.88 Electrical Module

If the fuse is normal, please measure the Brake power supply (DC24V) from the System
Board. There are 3 test pins at the center of the board. Use the TMB as a reference
terminal and the TPPB terminal value should be over DC20V. If it is below 20V, the
power supply unit that generates the power for the brake has an error. Please replace
the Electrical Module

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Figure 6.89 Brake Power Supply Test Pin

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(4) Please replace the Servo Board and examine an error

This error may occur if there is an error on the Servo Board. Please replace the board to
check

(5) Please examine if the Drive Unit operates normally

Please check if the Drive Unit of corresponding axis (Motor, Decelerator) works properly

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6.1.17. E0122 Servo ON limit time exceeded

6.1.17.1. Ouline

This error occurs if the Servo motor does not turn on when the main send out the motor on command
to the Servo. The cause might be a communication problem between the main and the Servo.
Main send Servo error clear command prior to sending motor on, and once the Servo error is cleared
motor on command will be sent out. If the Servo error did not clear, the same error persists and motor
on command will go out. In other words, if the communication between the main and the Servo does
not have a problem, the motor on command will be received, or other Servo error will occur.

6.1.17.2. Causes and examine methods

(1) Please examine if the Main Board and the Servo Board are installed properly
 Examine if the board is installed properly.
 Examine if board is faulty

(1) Please examine if the Main Board and the Servo Board are installed properly
This error may be caused by a communication problem if the Main Board and the Servo
Board is not installed properly on a rack, or the board has an error

Warning
In order to protect the previous job programs, please back up all the files of
Main board to the USB memory before you remove the board from the Rack

Method to back up the files from Main Board to USB memory is as below

Figure 6.90 Inserting Method of USB to TP

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Once the USB is recognized by TP, the below icon will be displayed on a screen

To back up the files enter to

 Service
 5. File manager

And the screen that is similar to windows explorer will be displayed

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At this stage, please copy the files shown in M/B and move them to USB

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You may create a new folder on USB, or can rename the folder by using the soft keyboard
just like the windows explorer

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 Examine if the board is installed properly

Please remove the Main Board and the Servo Board from the Rack and re-install them
again

Figure 6.91 Location of Rack Inside of the Controller

 Examine if the board is faulty.

To examine if the board is faulty, please replace it with new one

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6.1.18. E0127 MSHP operation error

6.1.19. E0140 MSPR operation error
6.1.19.1. Ouline

Motor‟s power supply is suppied to the AMP according to the open/close status of Magnetic
contactor MC1, and MC2
Status of MC1 and MC2 are being monitored by Main‟s conditions and E127 (MSHP operation
error) or E140 (MSPR operaton error) will be generated when an abnormal operation is detected

(1) E0140 (MSPR operation error)

For a reason that cannot be identified by Main, the Magnetic contactor MC1
① Does not turn On while an attemption is made ,
② Turns off while it should stays on

(2) E0127 (MSHP operation error)

For a reason that cannot be identified by Main, the Magnetic contactor MC2
① Does not turn On while an attemption is made ,
② Turns off while it should stays on

In order for MC1 or MC2 to on, many conditions need to be satisfied, and even if when they are
on, they can be off for some reasons. Main can identify the causes for Magnetic contctor‟s
operation error if it is a case that provides a monitoring function such as safety signals. However if
the main cannot identify the Magnetic contactor‟s operation error, a number of examines are
required

6.1.19.2. Causes and examine methods

(1) Command system malfunction

 Error on receiving data from the Main
 CPUERR or EXOUT signal has occurred, or an error of the corresponding line
 Old system I/O Board (BD531V10) is used from the remote mode
 Error on the safety signal system
 Error that occurred due to the safety related unit‟s wiring malfunction
 System Board malfunction

(2) Monitoring system malfunction

 Cabling (Wire, Connector etc) malfunction
 Electrical Module malfunction
 System Board malfunction

(3) Other malfunction

 Case when E0043 and E0140 both occurs at the same time

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To identify the cause of these two errors (MSPR operation error, and MSHP operation error), you must
understand the Motor‟s power supply insertion system. Basic concept of Motor‟s power supply to the
Amp (Drive Unit) is as below.
Main will send out the MC1 Motor power on 1 command (MCON1) and waits (while monitoring the sub
point of contact) until the MC1 is activated. At this stage, if the MC1 does not activates within certain
amount of time, E0140 (MSPR operation error) will occur. On the other hand, if MC1 sucessfully
operated, Main will send out the MC2 Motor power on 2 command (MCON2) and waits (while
monitoring the sub point of contact) until the MC2 is activated. Again, if the MC1 does not activates
within certain amount of time, E0127 (MSHP operation error) will occur
If the Magetic contact MC1 and MC2 turns on according to the Main‟s command, AC220V R, S, T
3-phase power supply will be supplied to the Amp
While the motor is on, the Main will monitor if the MC1, and MC2‟s status is on at all time
If the Magnetic contact goes off for a reason that cannot be identified by the Main, these errors will
occur

Figure 6.92 Concept Diagram of Safety Circuit for Motor Power‟s Opening/Closing

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(1) Command system malfunction

Motor on command from the main has been blocked for some reason, if you do not hear any
sound of operation and a message of „MSPR operation error‟ is displayed while the motor on
attemption is made,

 Error on receiving data from the Main

If a communication error occurs between the Main Board and the System Board, the
System Board will block the Motor On command for a safety reason. Generally the Main
Board also detects the communication error at the same time, so the MSPR operation
error or MSHP operation error will not occur. However if the Main cannot detect the
communication error, these erros can be generated. This is a case when the control
status of safety switch related components (Teach Pendant emergency stop switch input,
OP panel‟s emergency stop switch input) are being transmitted to the Main Board, but
output from the Main Board (Motor ON) will not be transmitted to the System so the
hardware wise Motor On command is cannot be executed.

Figure 6.93 7-SEG Indicator of the System Board when a Communication Error Occurs

 How to judge :
System Board‟s 7-segment index may give you an indication of the situation. 7-segment
displays “o” to indicate that the current communication with the Main Board is in
abnormal status

 Actions :
Firstly, please restart the controller and observe if the same error persists. If it does, the
communication input unit of the System Board has an error. Please replace the System
Board.

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 CPUERR or EXOUT signal has occurred, or an error of the corresponding line

Main Board generates CPUERR or EXOUT signals in a case when systemic error has
occurred (e.g power shut down, Servo error). This signal will be transferred to the
System Board and block the motor on command in terms of hardware. Motor‟s power will
be immediately shut down for a safety reason. However, these signals may be generated
abnormally, and it will shut down the motor‟s power

 How to judge :
System Board‟s 7-segment index may give you an indication of the
situation.7-segment displays “H” when CPUERR is being transmitted to the System
Board. Also the CPUERR, EXOUT LED which located at the center of the System
Board indicate the error situation (Figure 6.93) These LED lights will be on if it is a
normal status, and the lights will be off if it is not

However if the signal appears time to time for a very short moments, 7-segment and
LED won‟t be able to indicate it. In such case, error occurance must be observed while
ignoring the two signals by using DIP switch SW1. Method to ignore the signal is to, as
shown in the Figure 6.94, turn on the No 1(to ignore CPUERR) and the No 2 (to ignore
EXOUT) of the DIP switch SW1. At this point all LED lights will be on

If the error no longer persists after the system restart, Main Board generated these
signals or CANS1 Connector/Cable malfunction is suspected

Figure 6.94 Indication of 7-SEG, LED (on System Board) when CPUERR Error is Occurred

 Actions :
If a Main Board generating this signal without any other indication of errors, please
check the PLD version of the Main Board. Over V0.7 is normal. If Main Board‟s PLD
version is normal, please examine the CANS1 connector and cables

Cautions : Please use only No 1(to ignore CPUERR) and No2(to ignore EXOUT)
of the DIP switch SW1 for a testing purpose and please switch it back to normal
after the test. This ignores the emergency safety related functions and it may
cuase safety related problems if operates while ignoring these functions

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 Old system I/O Board (BD531V10) is used from the remote mode
If an old system IO board (BD531V10) is used on a remote mode, this error may occur.
Motor on command will not be executed because this type of board does not have
remote mode function

Figure 6.95 Checking Method of Old System I/O Board (BD531V10)

 How to judge :
This board is attatched at the back of the System Board. Please remove the System
Board from Electrical Module and check the system I/O board number at the back
(Figure 6.95)

 Actions :
If the installed board is “BD531V10”, please replace it with a board with the
hardware version above “BD531V11”

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 Error on the safety signal system

Motor on command from the main has been blocked for some reason, if you do not hear
any sound of operation and a message of „MSPR operation error‟ is displayed while the
motor on attemption is made without any other error messages

The motor on command will not be executed if there is a problem on a safety signal
system as explained earlier (Figure 6.92) Safety devices (Safety guard, emergency stop
switch etc) are mechanically operating devices, but their monitoring is operated
electronically. So a safety device malfunction, or any electronic shock (noise, surge),
wiring error, short circuit can cause an error. To confirm, please remove the connected
safety device‟s wiring and rewire them to ignore the input. (Figure 6.96, Figure 6.97,
Figure 6.98, Figure 6.99, Figure 6.100)

Cautions : Please use only for a testing purpose and please switch it back to
normal after the test. This ignores the emergency safety related functions and
it may cuase safety related problems if operates while ignoring these functions

Figure 6.96 Method to Ignore the External Emergency Stop Input

Figure 6.97 Method to Ignore the Safety Guard(Auto) Input

Figure 6.98 Method to Ignore the Safety Guard(General) Input

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Figure 6.99 Method to Ignore the (P-COM input) Uuter External Emergency Stop(3,4 of SW6 is ON)

Figure 6.100 Method to Ignore the (P-COM) Safety Guard (Auto)(1,2 of SW6 is ON)

As explained, if the error does not persist when these safety switch inputs are ignored, the
problem exists in the safety switches and wirings. Please check them

Cautions : Please use only for a testing purpose and please switch it back to
normal after the test. This ignores the emergency safety related functions and
it may cuase safety related problems if operates while ignoring these functions

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 Error that occurred due to the safety related unit‟s wiring malfunction
If there is a problem in a wiring of devices that are related to the safety such as Safety
guard(Auto), the error for a corresponding safety signal may not be detected and it will
generate E0140 (MSPR operation error).
This error occurs from a waiting of manual mode drive prepration (Status that the Teach
Pendant‟s motor on LED is flickering) switches to automatic mode, and motor on attempt
is made on an automatic mode

For example, there is a case when the wiring of Safety guard (Auto) is faulty. There are
two types of input method (point of contact input, P-common input) that enters safeguard
to the System Board (BD530) and the point of contact input‟s wiring error may cause a
problem. Proper wiring separates each safechain and connects the each end of point of
contact (Figure 6.101) However if the chain‟s wiring is mixed and connected, the
controller will not be able to detect the Safety guard‟s error due to an electronic error.
(Figure 6.102). If the motor on is attempted at this time, not sufficient power supply for
Magnetic contactor‟s saferelay operation will be supplied and it will generate E0140
(MSPR operation error)

 How to judge :
Phenomenon of Safety guard wiring malfunction is as below

 If a safechain connection is removed, (5,6 wiring or 7,8 wiring) Safety guard

error will be detected in automatic mode and displays E0043 error

 However, if all chains are connected (5,6,7,8 wiring are all connected), Safety
guard error will not be detected in automatic mode (E0043 error does not occur)

If the above phenomenon appears, please examine the Safety guard (Auto)‟s wiring.
Firstly, please remove the terminal block TBEM from the board, and perform a short
circuit test from a removed terminal block connector‟s (TBEM) safeguard input
terminal (socket) while activating the guard device

 If you close the guard device (point of contact – close status), 5, 6 terminal
(socket) will be shorted. Also 7,8 terminal (socket) will be shorted

 If you open the guard device (point of contact – open status), 5,6 terminal
(socket) will be open. Also the 7,8 terminal (socket) must be open status

Figure 6.101 Good example of Safety Guard (Auto) wiring

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Figure 6.102 Bad example of Safety Guard (Auto) wiring

 Actions : Please modify the wiring of Safety guard (Auto) correctly (Figure 6.102)

Error occurance caused by the wiring error of safeguard has been explained in
above. This applies same to all safety related signals (Safety guard (General),
Safety guard (Auto), external emergency stop switch, various limit switches), so
please refer to (table 6-4) to compare the normal and abnormal wiring examples

Table 6-4 Error on safety related device‟s wiring

Classification Normal wiring Abnormal wiring

External
emergency
stop switch

Safety guard
(Auto)

Safety Guard
(General)

 System Board malfunction

When motor on is attempted, if you do not hear the activating sound of controller‟s
internal Magnetic contactor (MC1) and a message of “MSPR operation error” is
displayed, please examine all the above. If no problem is found from the above
examinations and same error persists, System Board malfunction might be the cause.
Please replace it

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(2) Monitoring system malfunction

When motor on is attempted, if you do hear the activating sound of controller‟s internal
Magnetic contactor (MC1) and a message of “MSPR operation error” or “MSHP operation
error” is displayed, the cause of an error might be the Monitoring system malfunction. In order
to confirm the Monitoring system malfunction, please do as below

The status of Magnetic contactor MC1 and MC2 is monitored by using the sub point of
contact and can be accessed by the Teach Pendant. (Figure 6.103) From the Teach Pendant,
MC1 (PreCharge) and MC2 (Motors Power) signal can be accessed by Private input
signalmonitoring window. Motor off status will be displayed as a white color background and
motor on status will be displayed as yellow color backround

Figure 6.103 Method of Magnetic Contactor Monitoring

Please attempt the motor on in automatic or manual mode and confirm the activation sound
of the Magnetic contactor as well as the displayed status of MC1, and MC2

 At first, if MC1 is displayed with a yellow color for a moment (with the sound of Magnetic
contactor‟s acvitvation) and E0140(MSPR operation error) message is appears, it means
that there is no error in MC1‟s sub point of contact and the monitoring system

 After the activation of MC1, if MC2 is displayed with a yellow color for a moment (with
second sound of Magnetic contactor‟s acvitvation) and E0127(MSHP operation error)
message is appears, it means that there is no error in MC1‟s sub point of contact and the
monitoring system

With the above methods, if you confirmed that the monitoring of MC1 and MC2 is not working
(Monitoring signal is not displayed in yellow while you can hear the sound of Magnetic
contactor‟s activation), the following devices has to be examined (Figure 6.104)
① Cable CNMC
② Electrical Board relay SR1, SR2 (inside of Electrical Module)
③ Sub point of contact for MC1 and MC2 – Magnetic contactor (inside of Electrical
Module)
④ Wiring between the Electrical Board and the Magnetic contactor (inside of Electrical
Module)
⑤ System Board (input signal processing unit)

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Figure 6.104 Diagram of the Monitoring System – Magnetic Contactor

 Cabling (wires, connector etc) malfunction

Please check the cabling between the Electrical Module (PDM30) that an electrical
connector is installed and the System Board (BD530) that collects monitoring signals.
The cable name is CNMS and it enters to the Electrical Module through the top rear of
the System Board (Figure 6.105). Please check the connection status of this cable‟s
connector

Figure 6.105 CNMC Cable on the Electrical Module

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 6. Troubleshooting

 Electrical Module malfunction

Monitoring signal of the Magnetic contactor is transmitted to the System Board through
many devices that are inside of the Electrical Module. So if one of those devices has an
error, the Main will not be able to detect even if the Magnetic contator is operated.
Internal electirical module malfunction can be categorized as a electrical board (BD5C0),
Electrical connector (MC1, MC2), and wirings between the electrical board and the
electrical connector (Figure 6.23) However it is difficult to examine the inside of Electrical
Module in a field where a Robot has already been installed, so alternatively please
replace the Electrical Module

Figure 6.106 Inner Structure of Electrical Module

Figure 6.107 Electrical Board BD5C0)

 System Board malfunction

Input signal process unit malfunction of the System Board can be the cause of this error.
Please replace the System Board and check

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(3) Other malfunction

 Case when E0043 and E0140 both occurs at the same time
E0043(Safety Plug or Light Curtain) with the E0140(MSPR operation error) can occurs
from a waiting of manual mode drive preparation (Status that the Teach Pendant‟s motor
on LED is flickering) switches to automatic mode, and motor on attempt is made when
the Safety guard (Auto) is open (and the Main software version is below V30.07-00).
Please check the Main software version from the Teach Pendant and upgrad if the
version is low

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6.1.20. E0133 (Axis ○) Command value error

6.1.20.1. Ouline

This error may occur due to a communication error between the Main Board and the Servo Board, or a
rapid chages of motion. When a communication error occurs, a valid command cannot be transferred
from the Main Board to the Servo Board, so this error will occur and immobilize the Robot to prevent
the Robot‟s abnormal operation based on an invalid command
Also this error will occur and immobilized the Robot because the drive unit may not follow the rapid
changes of motion command

6.1.20.2. Causes and examine methods

(1) Please examine if the Main Board and the Servo Board are installed properly.
 Examine if the board is installed properly.
 Examine if board is faulty

(2) Examine if there is a job program that operates a Robot rapidly

(1) Please examine if the Main Board and the Servo Board are installed properly
This error may be caused by a communication problem if the Main Board and the Servo
Board is not installed properly on a rack, or the board has an error

Waring
In order to protect the previous job programs, please back up all the files of
Main board to the USB memory before you remove the board from the Rack

Method to back up the files from Main Board to USB memory is as below

Figure 6.108 Inserting Method of USB to TP

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Once the USB is recognized by TP, the below icon will be displayed on a screen.

To back up the files enter to

 Service
 5. File manager

And the screen that is similar to windows explorer will be displayed

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At this stage, please copy the files shown in M/B and move them to USB

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You may create a new folder on USB, or can rename the folder by using the soft keyboard
just like the windows explorer

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 Examine if the board is installed properly.

Please remove the Main Board and the Servo Board from the Rack and re-install them
again

Figure 6.109 Location of Rack Inside of the Controller

 Examine if the board is faulty.

To examine if the board is faulty, please replace it with new one

(2) Examine if there is a job program that operates a Robot rapidly

Please check if the error occurs at a point where the Robot‟s motion chages rapidly. If the
error occurs during the rapid motion, modification of job program is required.

The reason that this error occurs during the rapid motion is as below. During the execution of
job program, Robot‟s position may be twisted in order do move a short distance. At that point,
the speed of Robot‟s axis suddenly increases, and the error may occur if the Servo Board
follows the movement. In order to resolve this, please modity the Teaching point of the
location (where the position changes rapidly) or make changes on the position of Robot.

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6.1.21. E0134 (Axis ○) Maximum speed exceeded

6.1.21.1. Ouline

Speed of Robot‟s axis exceeded the maximum speed limit while an operation. An error will be
generated and the Robot will be immobilized since the Robot is not being controlled normally
When the Main Board sends a command to the Servo Board, it will send a limited command so that
the Robot will not exceed the maximum speed limit. Maximum speed exceeded error may occurs if the
Robot‟s speed triggers an overshoot because the Robot could not follow the command

6.1.21.2. Causes and examine methods

(1) Please check if the tool data has entered correctly

(2) Please check if the position of Robot is close to the singular point

(3) Please check the setting value of condensation acceleration/deceleration parameter

and the load factor

(4) Please adjust the job program

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(1) Please check if the tool data has entered correctly

If the weight or the inertia of tool is different from the registered value at the controller,
Robot‟s control performance will be reduced and the maximum speed limit exceeded error
can occur. Tool‟s weight and the inertia can be registered from the below menu according to
the number of tools.

 System
 3. Robot Parameter
 Tool data

You may use the load estimation function in order to set the weight of tool or the inertia
automatically.

 System
 Automatic constant setting
 4. Load estimation function

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(2) Please check if the position of Robot is close to the singular point
This error may occur, if you execute L interpolation or C interpolation instead of PtP
interpolation near the position of singular point
Singular point occurs when the B axis is close to 0 deg, or the center of wrist part is close to
the spin centural axis of S axis. When passing near the singular point is required, please
change the corresponding step to PtP interpolation

Figure 6.110 Axis B Singular Point Figure 6.111 Axis S Singular Point

(3) Please check the setting value of condensation acceleration/deceleration parameter

and the load factor
Motor torque is insufficient, because maximum speed of condensation
acceleration/deceleration parameter is too high or the acceleration time is too short. l/lp
maximum speed had to be reduced with an observation of load factor (while the Robot‟s
operation) or increase the acceleration time

 System
 3. Robot Parameter
 34. Acceleration /Deceleration Parameter

Acceleration /Deceleration Parameter of condensation can be modified from the above

(4) Please adjust the job program

Please make changes of conditions (from the job program) on a corresponding step, or the
one step prior to it. Firstly, try “Acc=0”, secondly, reduce the step speed, and thirdly, add one
more step on a movement routine.

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6.1.22. E0165 (Axis o) Servo lock cannot be maintained

6.1.22.1. Ouline

Power for the drive of Motor or the drive unit is not being supplied. The current that generated by a
Servo control for the Robot or drive unit‟s operation is not being supplied. For such cases, the Servo
Board detects an error and the controller will stop the release of brake and block the current that
supplied to the motor or the drive unit

6.1.22.2. Causes and examine methods

(1) Examine the Motor power line.

 Check the wiring that connects the Robot and Controller
 Check the Robot‟s internal wiring.
 Check the Controller‟s internal wiring.

(2) Examine the CNBS cable between the Controller‟s internal Servo Board and the Servo
AMP .

(3) Replace other components.

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(1) Examine the power line

Please turn off the primary power and remove the U, V, W of drive unit for the corresponding
axis and examine if short circuit exists in each phase. Please use an equipment such as the
multi meter (tester) and examine each phase‟s wiring one by one

Warning
Be cautious. Examination while the power is on may cause an electrocution

 Check the wiring that connects the Robot and Controller

Please remove the wirings that connect the controller, Robot or the drive unit to examine
each phases (U, V, W) for ground, or a short circuit. If a short circuit is found, please
replace the wire

Figure 6.112 Basic Installation Diagram of the Robot and Control Period

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 6. Troubleshooting

 Check the Robot‟s internal wiring.

Examine for a short circuit, faulty on a wiring that connected to Robot‟s internal motor is
required

Figure 6.113 Robot‟s Internal Wiring

 Check the Controller‟s internal wiring

Examine on a controller‟s internal AMP and installed wiring is required

Figure 6.114 Controller‟s Internal Area (Power Unit)

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(2) Examine the CNBS cable between the Controller‟s internal Servo Board (DSP board)
and the Drive Unit
Please examine if the CNBS cable is installed properly. If the cable is not installed properly, or
the cable is faulty, this error may occur

Figure 6.115 Controller‟s Internal Area (CNBS Cable)

(3) Replace other components

Replace the component in order of Servo Board (BD542) →Servo Drive Unit→Motor to
confirm the occurance of an error‟.

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6.1.23. E0223 (Axis o) Encoder cut-off or communication failure

6.1.23.1. Ouline

Servo Board receives data from the encoder periodically through a serial communication in order to
perform a Servo control on the motor. This error occurs if the received data from the encoder violates
the communication protocol.

This error may occurs due to a fault of components that received the data from the encoder, or the
problems in a encoder shield lines or the wiring,

6.1.23.2. Causes and examine methods

(1) Please check the supply voltage to the Encoder

(2) Please replace the Servo Board and test it

(3) Please replace the Motor and test it

(4) Please examine the wiring

(5) Please examine the communication status of wiring after the repair

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(1) Please check the supply voltage to the Encoder

Power supply voltage to the encoder must be in a range of 5V±5% (4.75V ~
5.25V)-(encoder side connector‟s supply voltage). If the voltage is reduced below 4.75V,
encoder may not operate normally and it will cause this error

Please measure the voltage of encoder side‟s connector-pin(3-4)

If the measured voltage is below the standard voltage, please adjust the +5V ADJ(E) voltage
control terminal (socket) in the encoder‟s power supply unit, so that the encoder side‟s
connector voltage can be adjusted according to the standard

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(2) Please replace the Servo Board and test it

After the replacement of the Servo Board, if the error does not persis, the Servo Board is
faulty. Please replace the Servo Board with new one

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(3) Please replace the Servo Motor and test it.

If the error does not persist after the replacement of Servo Motor, Servo Motor is faulty.
Please replace the Servo Motor with new one. Below diagram describes the locations of each
axis‟s motor (HS165 Robot). For other Robot, please refer to the Robot‟s maintenance
manual to replace it

Figure 6.116 HS165 Locations of Each Axis‟s Motor (HS165 Robot).

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 6. Troubleshooting

(4) Please examine the wiring.

Encoder‟s wiring examination orders are asl below

Firstly, Examine the loose contact of the connectors that are related to the Encoder‟s wiring

Secondly, Examine the short-circuit of encoder‟s wiring. Please use equipment such as the
multi meter (tester) and examine each phase‟s wiring one by one

Thirdly, replace the encoder‟s wiring and test it

If the encoder‟s wiring has not been disconnected and if the error caused by certain problems
(loose contact of shield line, contact between the encoder‟s signal line and other electric
power line, or a contact with the metal part of Robot‟s main frame) it cannot be detected by
short-circuit test. So please replace the wiring and test it

 Please examine the internal wiring of the Controller

Please examine the wiring between the CNEC1,2(DB542) connector and the
SMPS(P5E,M5E)
Please examine the wiring between the CNEC1,2(BD542) connector and the CEC1.

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 Please examine the wiring between the Controller and the Robot.
Please examine the wiring bêtween the CNEC1 and the CER1

Figure 6.117 Basic Installation Diagram of the Robot and Control Period

Figure 6.118 Connection Between the Robot‟s Mainframe and the Controller

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 6. Troubleshooting

 Please examine the wiring of the mainframe.

Please examine the wring between the CER1 and CNE1~6(Encoder side‟s connector)
Please refer to the wiring diagram of Robot‟s maintainance manual

Figure 6.119 Robot‟s Internal Wiring

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(5) Please examine the communication status of wiring after the repair

Once actions for the problem are taken, please refer to [Count of encoder communication
failure display function manual] to check the communication status

Count of
Encoder‟s status Content
communication failure

0~2 Normal Normal status

Wiring, encoder or the board need to be

3~5 Examine required
examined

6~8 Warning Dangerous status. Robot may be immobilized

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 6. Troubleshooting

6.1.24. E0224 (Axis o) Encoder status error

6.1.24.1. Ouline

Servo Board receives data from the encoder periodically through a serial communication in order to
perform a Servo control on the motor. This error occurs when the data that received from the encorder
is normal, but the result of encoder‟s self status check shows an error

6.1.24.2. Causes and examine methods

(1) Please check the supply voltage to the Encoder.

(2) Please replace the Motor and test it.

(1) Please check the supply voltage to the Encoder.

Power supply voltage to the encoder must be in a range of 5V±5% (4.75V ~
5.25V)-(encoder side connector‟s supply voltage). If the voltage is reduced below 4.75V,
encoder may not operate normally and it will cause this error

Please measure the voltage of encoder side‟s connector-pin(3-4)

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If the measured voltage is below the standard voltage, please adjust the +5V ADJ(E) voltage
control terminal (socket) in the encoder‟s power supply unit, so that the encoder side‟s
connector voltage can be adjusted according to the standard

(2) Replacement of Servo Motor and examine it

If the error does not persist after the replacement of Servo Motor, Servo Motor is faulty.
Please replace the Servo Motor with new one. Below diagram describes the locations of each
axis‟s motor (HS165 Robot). For other Robot, please refer to the Robot‟s maintenance
manual to replace it

Figure 6.120 Locations of Each Axis‟s Motor (HS165 Robot)

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 6. Troubleshooting

6.1.25. Instructions in examining the Controller‟s input voltage (Single-phase)

(1) Please check the voltage on the rating plate and the actual input voltage
Please check if the voltage of controller‟s power supply is within the allowed voltage range as
described on the rating plate. Allowed reange of input voltage is within the 10% of describe
value on the raing plate, and it should be over 198V (AC220V standard). Below describes
how to measure the input volate of controller. If the measured voltage is out of the allowed
range, please examine the power supply units

Warning
Please be cautious. Short-circuit between phases or with surrounding
components can occur while measuring the high voltage

 Hi5-C1X Controller : Measuring the Side terminal block‟s single-phase terminal (socket)

Figure 6.121 Hi-5-C1X Controller‟s Single-Phase Power Terminal Block

 Hi5-C0X Controller : Measuring the Side Terminal Block‟s Single-Phase Terminal

(Socket)

Figure 6.122 Hi-5-C0X Controller‟s Single-Phase Power Terminal Block

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6.1.26. Instructions in examining the Controller‟s input voltage(3-phase)

(1) Please check the voltage on the rating plate and the actual input voltage

Please check if the voltage of controller‟s power supply is within the allowed voltage range as
described on the rating plate. Allowed reange of input voltage is within the 10% of describe
value on the raing plate, and it should be over 198V (AC220V standard). Below describes
how to measure the input volate of controller. If the measured voltage is out of the allowed
range, please examine the power supply units

 Hi5-N Controller : Measuring the power line of front switch

Figure 6.123 Location of Hi5-N Controller‟s Power Switch

Warning
Please be cautious. Short-circuit between phases or with surrounding
components can occur while measuring the high voltage

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 6. Troubleshooting

1) Hi5-C1X Controller : Measuring the Side terminal block‟s 3-phsae terminal (socket)

Figure 6.124 Hi-5-C1X Controller‟s 3-Phase Power Terminal Block

2) Hi5-C0X Controller : Measuring the Side terminal block‟s 3-phase terminal (socket)

Figure 6.125 Hi-5-C0X Controller‟s 3-Phase Power Terminal Block

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6.1.27. Instructions in examining the Controller‟s internal voltage(3-phase)

(1) Please check the Controller‟s internal 3-phase power voltage
Electrical Module(PDM) that attached at the front of controller is in charge of the distribution
and replay of each power supplies, and the 3-phase power supply wii be turned on/off by a
Magnet switch in the Electrical Module. Please exmine if the input voltage to the Electrical
Module is within the 10% error range of AC220V standard. If the measured voltage is out of
the allowed range, please examine as below

Figure 6.126 3-Phase Power Input to the Electrical Module

Warning
Please be cautious. Short-circuit between phases or with surrounding
components can occur while measuring the high voltage

1) If the input voltage to the controller is AC220V

If the input voltage to the controller is AC220V, input voltage from external to the power
switch or terminal block must be same as the measured voltage from the internal
Electrical Module. If there is a difference, please examine the 3-phase power supply
wiring

2) If the input voltage to the controller is not AC220V

If the input voltage specification to the controller is not AC220V, please use the internally
installed transformer to conver the 3-phase voltage into AC220V and it will be connected
to the Electrical Module. Please exmine if the voltage of the Electrical Module is within
the 10% error range of AC220V standard. Also examine if the voltage is maintaining.
If the measured voltage is out of allowed range, please examine the input of internally
installed transformer and the connection status of output terminal (socket). Primary
column of the internally installed transformer must be connected with the voltage as it is
displayed on a rating panel. Secondary column of the transformer must be set to
AC3-phase 220V at all time. If the output from the output terminal (socket) is not AC
3-phase 220V even when the input and output terminals (socket) are connected properly,
the transformer is faulty. At this stage the output voltage of transformer‟s error rate must
be within 5 %

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6.2. Instructions in Parts Replacement

This instruction shows how to replace the parts and boards during troubleshooting.

6.2.1. Instructions in Substrate Replacement

Pay attention to the followings during boards replacement.

① Be sure to turn power off before working.

② Keep your hands clean to prevent boards from being stained with oils or water. If y
ou need to grasp the board, please hold around the board. Be sure not to touch th
e contacting surface of electric parts or pattern, and especially connector.

③ Align the electric potential between the body(hand) of the user and the controller.

④ Each board has a number of connectors. Be sure to insert completely to prevent fa

lse inserting, omission, or looseness when replacing. Match the printed names on th
e nameplate of connector and on the one of boards.

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Separation of Boards

Please take the followings actions before taking out mainboard.

① If you intend to replace mainboard, you need to back up the necessary program/constant
data by using HR-VIEW S/W or SRAM CARD of (Notebook) PC before replacement.

② Since the teaching-program / constant data is stored in SRAM of BD510 board, the
previous program / constant data you want is not existed after replacement. After
replacement, load the backup contents to the new board before using.

③ Program/constant data remains in SRAM by the battery for backup even when power is
removed.

④ Besides, in case that connectors of battery for backup is separated by mistake or by

board replacement, capacitor for backup maintains program /constant data up to 1 hour.
The battery for backup must be connected to keep the board for long period of time
because program/constant data may be deleted afterwards.

Please be aware of the above cautions, and make a replacement of board following the below
instructions.

① First, remove input power from power unit.

② Loosen slightly the screw upholding the supporting stand which is above and below of
Rack, move the supporting stand to the left, and pull it out.

③ Take all the connectors out of board. Here, for the connector connected by screws,
loosen them by using a suitable screwdriver. And be careful of excessive force to
connector.

④ Pull out the Ejector mounted on the upper and lower front side of board, and the board
will be taken out along the guide rail of Rack.

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 6. Troubleshooting

Insert of Board

① First, turn off the input power of power unit.

② Push inward the Ejector mounted on the upper and lower front side of board along the
guide rail of Rack. Here, push it hard until you feel that the connector is inserted into
backplane board which is located in the back side of Rack.

③ Connect all the connectors of the board. Here, for the connector connected by screws,
tighten it again by using a suitable screwdriver.

④ Move the supporting stand to the right, hooking up to the screw on the upper and lower
part of Rack, and then tighten the screw.

Pay attention to the followings after inserting mainboard.

Make a copy of the program/constant data which is copied prior to the replacement of main in
mainboard memory by using (Notebook) PC or SRAM CARD. And make sure that the battery
connector for backup is connected.
If the battery connector is not connected, it is safe while controller power is ON. However, if
power is OFF for more than 1 hour, program/constant data will be all deleted.

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6.2.2. Instructions in Servo AMP Replacement

Pay attention to the followings during servo AMP replacement.

Check the nameplate in the front side of panel in case that it would not have compatibility
with other types of servo AMP.

Separation of Servo AMP

① First, turn off the input power of power unit.

② Loosen the fixed bolt in servo AMP protection cover to take off.
③ Take off wires tightened to terminal block with screws.
④ Take off all the connected connectors.
⑤ Take off the screws tightening the servo AMP.
⑥ Take out the servo AMP.
Be careful when taking out the servo AMP because it is very heavy. And make sure not
to damage wires around it.

Connection of Servo AMP

① First, turn off input power of power unit.

② Lift the servo AMP carefully and push it in.
Be careful when pushing in the servo AMP because it is very heavy. And make sure not
to damage wires around it.
③ Screw on the servo AMP.
④ Screw on the wires to terminal block.
⑤ Connect all the connectors.
⑥ Tighten the servo AMP protection cover with bolts.

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6.2.3. Instructions in Battery Replacement

This controller is a backup battery for SRAM, and uses 3.6V Lithium battery.
Replace the battery every 2 years on a regular basis.
To prevent a damage of SRAM data, back up SRAM data first by using HRVIEW or SRAM CARD.
When replacing the battery, it can be done with the primary power is ON.

① Prepare a new Lithium battery.

② Disconnect the primary power of controller.

③ Replace Lithium battery with a new one.

④ Supply the primary power to controller.

[Warning]

① Do not litter the spent battery.

② Dispose of the spent battery as an industrial waste under the relevant regulations or
rules.

③ Do not recharge the used-up battery. It involves a danger of explosion.

④ Use the specified battery only.

⑤ Do not make a short circuit of positive and negative poles.

⑥ Do not burn the spent battery, nor leave it in a high temperature.

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6.2.4. Instructions in SMPS Replacement

This SMPS is a complex power unit which is used as a primary control power.
Pay close attention to this sophisticated device.

Separation of SMPS

① First, turn off input power of power unit.

② Unscrew the terminal stand of SMPS to take off the attached wires.

③ Loosen 4 screws tightened to the board Rack.

④ Insert your index finger into the hole in upper and lower side of SMPS, and pull it out.
Then SMPS will be taken out of the Rack. Here, if pulling too hard, you may involve an
injury, so be careful. And make sure not to damage the wires around it.

Connection of SMPS

① First, turn off input power of power unit.

② Grasp the SMPS with the right hand and push it into the first guide rail of Rack, while
clearing the surrounding wires away. Here, make sure not to damage the wires around it.

③ Screw it to the Rack.

④ Screw on the wires to terminal stand.

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 6. Troubleshooting

6.3. Instructions in Adjustment

This controller does not require extra adjustment because it has been fully adjusted when delivered
from warehouse. However, in case of parts replacement, an adjustment may be needed to some
extent. This instructions shows how to adjust and where to adjust. Do not make an adjustment, except
that it is needed, unless the cause of trouble is confirmed.

6.3.1. Adjustment of Power System

In case of power system errors or power change, take a measurement of each power voltage, and
adjust any voltage below the standard(use a digital voltmeter for measurement).

Table 6-5 Power Standard

Power Measuring Location Standard Adjustment

Primary Define the primary tab of

CB1 input terminal AC220V ± 10%
Power transformer TR1 as AC220V
Check the input voltage of CB1 -
R6,S6,T6 Servo AMP R, S, T AC220V ± 10%
AC220V
Secondary Tab turnover of
B2-C2 TB1 B2-C2 AC220V ± 10%
transformer TR1

P1-M1 SR1 +24V-G2 DC24V ± 2.0V (Note 1)

P5-M0 SR1 +5V-G1 DC5.1V ± 0.1V Volume resistance in SR1

P15-M0 SR1 +15V-G1 DC15V ± 0.5V (Note 1)

N15-M0 SR1 -15V-G1 DC-15V ± 0.5V (Note 1)

SR1 +5V-GND DC5.4V ± 0.1V Volume resistance in SR1 (Note 2)

P5E-M5E Terminal block for Robot
external wiring Connectors Pin DC5.1V ± 0.1V Volume resistance in SR1 (Note 2)
P5E-M5E

(Note 1) Replace the SR1 if it is not within the standard.

(Note 2) First, check the standard in the measuring location, and then make a measurement in the
nearest terminal stand from robot encoder and between connector Pins. Here, the standard must be
DC5.1V±0.1V.

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6.3.2. Transformer (TR1)

AC 220V 3-phase must be used for primary power of transformer(TR1).

Do not adjust the secondary terminal because it is connected to power suitable
for the internal parts specifications.

AC 220V 3-phase must be used for input power of this controller.

Tab must not be changed without permission of our staff because this controller has been completed
in adjusting when delivered from warehouse.

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6.4. Error Code and Warning

Errors are classified into general errors and handling errors. General errors are to call user‟s attentions,
and handling errors indicates that operator made a mistake or trouble.

Hi5 controller, with its built-in self-diagnostic function, displays the details of errors on LCD screen of
Teach pendant. Thus, you may check error code, and confirm it in the error code Table for
troubleshooting.

In case of troubleshooting, read carefully 『 troubleshooting cases 』 & 『 Instructions in Parts

Replacement』, and be fully understood on your working details before getting down to work. In
addition, fully inform us of the followings when contacting with our A/S office.

① Robot type name on robot specification plate and controller type of specification plate

② Happened date

③ Symptoms & error code

④ Details conducted by user‟s company

⑤ Software version of robot controller (Main, I/O, DSP, T/P)

⑥ Environment conditions in the occurrence of errors(power failure, collision with Jig, etc.)

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6.4.1. System Error

Code Message Cause Remedy

A power was cut after motor Just to store a power outage

E0001 Power down detected ON or CB(Circuit Breaker) to the error list, Any action is
was OFF. not demanded.

On the motor from system

menu (press motor on button
Limit Switch was actuated at while holding the Enable
E0002 H/W LMT switch on the end of work range for switch), and move it back to
each axis. operation area by using jog
key. Refer to error repair
manual

Fuse was cut off due to Replace the brake power

E0003 Overload of brake power overcurrent at AC220V power suppy fuse in Electrical
line to create brake power. Module

Axis Z break sensor is on Axis Z break sensor is on 1)Examine the Axis Z belt.
working working 2)Examine the safety
E0004
board(BD58B)
3)Examine the System Board

It happens when stored

performing code does not
exist even though DSP
Please make version up DSP
No DSP version on flash performing code, which has
E0005 with system version up
ROM of main board. been stored to flash ROM of
function (R286).
main board, is being
dispatched to servo board in
power on.

Please check whether tool of

Collision sensor is on robot end-effector was
E0006 Collision sensor has worked.
working. deformed. Please start after
removing all error causes.

1)Check the sticking of

Sticking of welds signal is
welds signal.
E0007 Sticking of weld detected detected in completion of
2) Remove the cause of weld
welding sequence.
stick.

If overdrived, reduce the

Excessive raising of motor
operation speed.
Motor temperature is risen temperature was sensed
E0008 If the temperature is too high,
(Hard-wiring) through temperature sensor
stop the operation until the
wired to each axis of robot.
motor cools down

1) Please check whether

Data dispatching performing servo board is mounted.
Verify error after the #(%d)
E0009 code through HPI port of 2) Please check DIP switch of
DSP version download
servo board is wrong. servo board referring to
trouble shooting.

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 6. Troubleshooting

Code Message Cause Remedy

In the case that temperature

Discharge resister of Discharge resister risen for Please refer to trouble
E0010
overheated(AMP) base value, overheated shooting.
detect sensor error.

Check the AC input voltage in

In the case of excess
the controller.
E0011 Overvoltage of AMP establish value of the motor
Check the connection of
voltage(P-N)
discharge resistor.

Examine the brake

power(24V)
1)If it is normal, replace
E0012 Brake power error Brake voltage is lowered.
System Board.
2)If it is abnormal, replace
Electrical Module

Please check CNSG cable of

Due to contact failure of
drive unit.
PWM off line between AMP
PWM error !!, contact failure Please make an inquiry to
E0013 and system board, PWM
of sequence line. HHI if the error happens
command is not inserted to
again even after the above
drive unit.
articles has been managed.

1) Check the Emergency

Instant contact of safety Switch.
Instant contact of safety
switch (emergency halt, If an error occurs after taking
E0014 switch (EM,OTR,TS etc) has
motor overheat, limit switch above steps, contact the
happened.
etc) has happened. Robot A/S team.
2)Refer to error repair manual

1. Has this error happened

after T/P version up? => You
may ignore it.
2. Has this error happened
after being reperformed after
Communication halt between T/P failure occurrence =>
E0015 Teach pendant does not work teach pendant and main Please make an inquiry to
board was sensed. HHI about T/P fallacy.
3. Other cases? =>
Teach pendant error or
communication failure.
Please make an inquiry to
HHI.

You pushed [Motors-on] Take a measure to the error

E0016 Servo drive unit error button in the state that Servo in system initialization and
Drive Unit is abnormal. push [Motors on] button.

1)Check up the conveyor

Failing in conveyor pulse encoder power and
E0017 Conveyor pulse line trouble generating or a break in connections of pulse line
pulse lines. 2) Please replace conveyer
I/F board.

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Code Message Cause Remedy

Please check communication

Connecting error of arc There is a trouble on path and power supply line
E0018
board. connecting with arc board. between arc board and main
board.

1) Check the frequency range

on SYSTEM/ APPLICATION
Bigger value than fixed
PARAMETER/ CONVEYOR/
Conveyor pulse count allowable frequency on
E0019 CONVEYOR CONSTANT
changed a lot conveyer pulse number was
SETTING
input.
2) Check if noise signal exists
in the pulse line

1) Please check the fixed

value of conveyer allowable
Conveyor permission speed
E0021 Conveyor speed is too high speed.
is high
2) Check if noise signal exists
in pulse line.

The error on communication

Communication error among between main board and Please refer to trouble
E0022
inner modules. each inner modules has shooting.
happened.

Manual/automatic mode
switch of operating panel Check the mode switch or
E0031 The mode switch is failure
(OP) has failed or connected connected line status.
status is strange.

Communication trouble
Communication error on user Please refer to trouble
E0032 between user IO board and
IO board. shooting E0022.
main board has happened.

Please check input power of

PN voltage of servo AMP
E0033 under-voltage error of AMP recovery discharging status
became low.
and servo AMP.

Please check power

F1 or F2 was cut off owing to
E0034 over-current error of AMP connecting status inside and
surge voltage at servo AMP.
outside of controller.

On the motor from system

menu (press motor on button
Limit switch, which is installed
while holding the Enable
at end of operation area of
E0035 Hardware limit (auxiliary axis) switch), and move it back to
auxiliary axis (running axis
operation area by using jog
etc), operated.
key. Refer to error repair
manual-E0002

On the motor from system

Limit switch, which is installed menu (press motor on button
Hardware limit (expansion 16
E0036 at end of operation area of while holding the Enable
axes)
expansion, operated. switch), and move it back to
operation area by using jog

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 6. Troubleshooting

Code Message Cause Remedy

key. Refer to error repair

manual-E0002

Fuse has been cut-off due to

After removing the cause of
Overload occurred on a an overcurrent that occurred
E0037 fuse off, please replace the
Control power supply on control power (AC220V)
fuse.
supply line

CP was tripped owing to After removing the cause of

E0038 Overload of motor power over-current at RST line of CP trip, please return CP
motor power. switch.

Fuse was cut off because After removing the cause of

E0039 Overload of SMPS power power line of SMPS power fuse off, please replace the
AC48V has been overloaded. fuse.

Motor temperature of
Motor temperature raising of Please refer to trouble
E0041 auxiliary axis escalated
auxiliary axis (Hard-wiring) shooting E0008.
excessively.

Please check the connecting

Connecting error of general Error happned on connection
E0042 status of general safety guard
guard switch of general safety guard.
or line.

Connecting error of safety Please check the of safety

Connecting error of safety
E0043 plug (auto guard) switch at guard switch or connecting
plug
automatic mode happened. status line.

The belt of the elevation

A sensor for detecting any Replace the belt of the motor
axis-motor driving part was
E0044 breakage of an elevation driving part or check the
cut off, or a sensor cable
axis- belt is operating. sensor cable inside the robot.
within the robot was cut off.

Despite the manual mode of

A change from remote mode
the controller, a change from Change the controller‟s mode
E0045 to automatic mode is
remote mode to automatic to automatic mode.
requested.
mode is requested.

The controller‟s mode was

The remote automatic mode Try to operate the controller
changed from remote
E0046 is changed to a manual after changing the remote
automatic mode to manual
mode. mode to manual mode.
mode.

Where too much allocation

Robot motion calculation has time for the embedded PLC
Exceeding motion control
E0047 not been completed within is set, ask our engineers for a
time.
the reference time. reduction of the allocation
time.

1) Motor on has been Examine the remote

attempted from a remote mode(system) signal from the
Remode mode(system)
E0048 mode while remote mode Private input signal
signal is not entered
signal is not entered monitoring, and make sure
2) Mode switch has been the signal is being entered

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Code Message Cause Remedy

controlled in remote mode

while remote mode(system)
signal is not entered

1) Release joystick mode

2) If external start is not
External start of LCD
External start is possible after possible even after the
E0049 examining Robot is possible
joystick mode release release of joystick mode,
after joystick mode release
please check if the joystick
signal is normal

Check the connection status

Light Curtain dectection Light Curtain dectection
E0050 of Light Curtain detection
signal has been input signal has been input
signal

1) Check up the number to

The number of motors to control motors on the menu
control is larger then the SERVICE/ SYSTEM
E0101 Need more DSP boards
number of controllable DIAGNOSTIC/
motors on servo board SYSTEM VERSION
2) Add the servo board

Check up setup robot type on

No supported robot type was the menu SERVICE/
E0102 Different arm type!
set SYSTEM DIAGNOSTIC/
SYSTEM VERSION

Encoder‟s data receving Refer to E0223, E0224 of

E0107 Enc Err: Bad bit sequence status is bad when error repair manual
controller‟s power transfer

Encoder data gets out of the

Enc Err: Encoder reset Please refer to trouble
E0108 range to apply the offset
needed shooting.
function.

Fuse blown or IPM The fuse in the amplifier was Please refer to trouble
E0112
fault(6Amp) blown or IPM fault happened. shooting.

Overcurrent flows through the Please refer to trouble

E0113 Overcurrent
Motor or amplifier. shooting.

Received packet data from Please refer to trouble

E0115 Command Error
main board was wrong. shooting.

Position Error exceeded the Please refer to trouble

E0117 Too large position drift
set value. shooting.

Please refer to trouble

E0119 Overload Motors were operated overly.
shooting.

Servo On does not work

E0122 Servo On limit time exceeded Refer to error repair manual
within the limit time when the

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 6. Troubleshooting

Code Message Cause Remedy

control of Servo On, or

release of power saving
mode

When executing Servo Off or

1) Replace the servo board.
releasing power saving
2) if the same error occurs,
E0123 Cannot make servo off mode, Servo Off was not
contact with our service
executed
department.
within the set time.

Motor ON was not available

E0124 Cannot clear servo error Clear the servo error
because of servo error

Despite that 10 sec passed Please contact to our office

after command was output,
E0125 Accuracy not satisfied real position was not
accorded
with the command

You tried to move the robot to Check whether the workpiece

E0126 Trial to go out of workspace the position where tool-end and the robot was located
can not arrive. properly.

Please refer to trouble

E0127 MSHP not work MSHP doesn't work.
shooting.

1) Check the connection of

In High Speed Mode CNEC for BD440
(playback), the speed 2) Check the connection of
E0131 Bit jump error (high level) exceeds High Speed CNR4 and CNR5
Detecting Level (Bit Jump 3) Check whether BJH is set
High Level -BJH). to 1.5 times of the maximum
speed.

In Low Speed Mode(Jog, 1) Check the connection of

Step forward/ backward, CNEC for BD440.
Allocation input signals, 2) Check the connection of
E0132 Bit jump error (low level) Teach mode), CNR4.
The speed exceeds Low 3) Check whether BJL is set
Speed Detecting Level(Bit to 1.5 times of the minimum
Jump Low Level-BJL). speed.

The position command to the

Please refer to trouble
E0133 Command error servo board BD440 is
shooting.
abnormal.

The position command on the

packet data to the servo Please refer to trouble
E0134 Overspeed
board exceeds the maximum shooting.
speed.

(Axis 0) PWM OFF at Servo PWM error!! Loose contact Examine the CNSG cable of
E0135
On on sequence line. PWM drive unit. If the error persists,

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Code Message Cause Remedy

command is not being input please contact to our office

to drive unit due to loose
contact on PWM off line
between AMP and sequence
board

Control voltage +15V

Control voltage down of reduction. Error on a
E0136 Refer to error repair manual
Servo AMP recovery control SMPS in
drive unit

In the servo parameters,

Check 'PUL' of servo
E0137 Encoder pulse setting error Encoder Pulse Setting Value
parameters.
('PUL') is unusable.

The distance for returning to 1) Check servo gain.

Can't return to previous
E0138 the previous position 2) Check encoder power.
position
exceeded the set value. 3) Check encoder wiring.

1) Check the insertion of

Communication from the
main board and servo board.
E0139 Can't clean up DSP Filters main board to servo board
2) Replace the main board or
was unable.
servo board.

The MSPR relay for

E0140 MSPR does not work precharging the capacitor did Refer to error repair manual
not work.

Robot can't work because of Contact with out service

E0151 Improper step command
unprofiTable step information department.

Total tip consumption

1) Check maximum tip
detected by gun search
(0 gun)Tip consumption consumption at servo gun
E0154 excess maximum tip
exceeded maximum. parameter
consumption setted servo
2) Replace electrodes.
gun parameter.

Maximum abrasion of the 1) Check up maximum

moving electrode which was abrasion of the moving
(0 gun) Move-tip
E0155 set in servo gun parameter electrode which was set in
consumption exceeded max
setting was excessed by gun servo gun parameter setting
search. 2) Replace electrodes.

Wear of static electrode

1) Check up maximum
detected by gun search
abrasion of the fixed
(0 gun) Fix-tip consumption exceeded the wear of
E0156 electrode which was set in
exceeded max maximum mobile electrode to
servo gun parameter setting
be set at servo gun
2) Replace electrodes.
parameter.

This error occurs in the

Adjust torsion parameter of
synchronizing 2 axes function
E0157 Too large skew error the synchronizing 2 axes
of gantry robots.
function of servo parameter.
Torsion angle to traveling axis

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 6. Troubleshooting

Code Message Cause Remedy

was larger then set

parameter of the
synchronizing
2 axes function

This error occurs in the

1) Put out obstacles of the
synchronizing 2 axes function
moving way
Skew error compensation of gantry robots.
E0158 2) Check up encoder powers
Timeout Returning torsion angle to
and lines
traveling axis exceeded set 5
3) Replace motors
seconds after motor on.

1) Decrease the speed on

Angular velocity of an axis is
(0 axis) exceeding limit value this step.
E0159 high on interpolation
of axis speed 2) Adjust the position made
operation of this position
this error

1) If collision is occurred,
Disturbance torque is over
remove the problems
E0160 (0 axis) collision detect excessed collision detection
2) Adjust collision detection
level
level

1) If collision is occured,
Disturbance torque ratio is
remove the problems
E0161 (0 axis) shock detect over excessed collision
2) Adjust collision detection
detection level
level

1) Check +/-15V voltage in

In the drive unit, large current the SMPS
E0162 (0 axis) current sensor error
feedback offset is detected 2) Change the servo board
3) Change the drive unit

In power saving mode it

Axis drifted during power
E0163 happens that the brake is Replace system I/O board
saving
slipped.

1) Please check CNBS cable

An error happened to
E0164 Dynamic brake error linked to AMP at servo board.
dynamic brake of AMP.
2) Please replace AMP.

(0 axis) impossible to Current supply to motor is Refer to error repair manual

E0165
maintain servo lock impossible.

Decrease sum of times within

5 seconds after converting
acceleration time and
To decrease speed and stop reduction ratio of acceleration
E0170 MotStopWait(5Sec) TimeOut on working exceed 5 seconds and deceleration parameter
after stop signal input into time
Refer to acceleration and
deceleration parameter of
operation manual

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Code Message Cause Remedy

Opening time was exceeded

Check the Gun was welded
5 seconds after
E0171 Gun open time is over to the object or interference
pressurization of spot welding
to the gun occurred.
or gun-search function.

Difference the encoder value 1) Compensate the encoder

of endless axis which was offset value of endless axis
backuped from the encoder again.
E0172 Improper Endless rotation
value of initializing read out 2) Reset the encoder offset
exceeds 0X20000 in hex value of endless axis and
decimal compensate it.

The encoder value of endless Execute R350 code to reset

E0173 Endless rotation overflow axis to record exceeded max. the recorded endless position
encoder value manually, adjust the position.

1) Check up insertion the

servo board.
Initialization response of
2) Examine if the DS1, DS2,
E0174 1st servo CPU initialize error DSP1 in first board was not
S1 switch of servo Board is
received
working
3) Replace the servo board

1) Check up insertion the

servo board.
Initialization response of
2) Examine if the DS1, DS2,
E0175 2nd servo CPU initialize error DSP2 in first board was not
S1 switch of servo board is
received
working
3) Replace the servo board

1) Check up insertion the

servo board.
Initialization response of
2) Examine if the DS1, DS2,
E0176 3rd servo CPU initialize error DSP1 in second board was
S1 switch of servo board is
not received
working
3) Replace the servo board

1) Check up insertion the

servo board.
Initialization response of
2) Examine if the DS1, DS2,
E0177 4th servo CPU initialize error DSP2 in second board was
S1 switch of servo board is
not received
working
3) Replace the servo board

The ROM version of DSP1 in

Incorrect 1st servo CPU Contact with out service
E0178 first board is so low that set
version department.
robot can't use.

The ROM version of DSP2 in

Incorrect 2nd servo CPU Contact with out service
E0179 first board is so low that set
version department.
robot can't use.

Incorrect 3rd servo CPU The ROM version of DSP1 in Contact with out service
E0180
version second servo board is so low department.

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 6. Troubleshooting

Code Message Cause Remedy

that set robot can't use.

The ROM version of DSP2 in

Incorrect 4th servo CPU Contact with out service
E0181 second servo board is so low
version department.
that set robot can't use.

Communication between
1) Check up insertion the
1st servo CPU main CPU board and the
E0182 servo board.
communication error DSP1 of the first servo board
2) Replace the servo board
was not work.

Communication between
1) Check up insertion the
2nd servo CPU main CPU board and the
E0183 servo board.
communication error DSP2 of the first servo board
2) Replace the servo board
was not work.

Communication between
1) Check up insertion the
3rd servo CPU main CPU board and the
E0184 servo board.
communication error DSP1 of the second servo
2) Replace the servo board
board was not work.

Communication between
1) Check up insertion the
4th servo CPU main CPU board and the
E0185 servo
communication error DSP2 of the second servo
2) Replace the servo board.
board was not work.

1) Please check and

decrease PLC execution
time. Contact with our service
Watch dog error of main
1st servo CPU found main department.
E0186 board was detected in the
CPU error 2) Check up insertion the
DSP1 of the first servo board.
main or servo board.
3) Replace the main board or
servo board

1) Please check and

decrease PLC execution
time. Contact with our service
Watch dog error of main
2nd servo CPU found main department.
E0187 board was detected in the
CPU error 2) Check up insertion the
DSP2 of the first servo board.
main or servo board.
3) Replace the main board or
servo board

1) Please check and

decrease PLC execution
Watch dog error of main time. Contact with our service
3rd servo CPU found main board was detected in the department.
E0188
CPU error DSP2 of the second servo 2) Check up insertion the
board. main or servo board.
3) Replace the main board or
servo board

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Code Message Cause Remedy

1) Please check and

decrease PLC execution
Watch dog error of main time. Contact with our service
4th servo CPU found main board was detected in the department.
E0189
CPU error DSP2 of the second servo 2) Check up insertion the
board. main or servo board.
3) Replace the main board or
servo board

1) Please check and

decrease PLC execution
Unexpected error was
time. Contact with our service
occupied from the servo
(0 axis) Improper encoder department.
E0190 board in receiving initial
reception 2) Check up insertion the
values of
main or servo board.
the absolute encoder.
3) Replace the main board or
servo board.

1) Please check and

decrease PLC execution
time. Contact with our service
Unexpected error was
department.
E0191 Not defined servo error found occulted from the servo
2) Check up insertion the
board on working.
main or servo board.
3) Replace the main board or
servo board.

Check up the number of BD,

The drive number of auxiliary
DSP, AXIS of auxiliary
E0192 AUX amp number error axis has assigned as same
parameter set up assigned as
number
same number

Check up the number of

The number of pulses a pulses on the menu, SERVO
(0 axis) Improper Encoder for
E0193 rotation from the endless PARAMETER/ MOTORS,
Endless
encoder was wrong. ENCODERS as
1024,2048,4096 or 8192

1) Check the weight value in

Load weight is over 120% of
E0194 Load weight is too heavy the tool data
normal capacitance
2) Reduce tool load weight

Change the system

configuration so that only 1
DSP controls both of sync
axes.
In order to control the sync If under 5 axes robot is used,
Sync Axes must use only 1 axes you should conFigure 1 DSP in BD440 servo board
E0195
DSP the system as only 1 DSP can handle 2auxiliay axes.
controls both of sync axes but over 6 axes robot is used,
1 DSP in BD440 servo board
can't handle them, so you
should use extra BD440
servo board.

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 6. Troubleshooting

Code Message Cause Remedy

Change Orientation of the

Command exceeds own axis
(0 axis) Speed over while Slave at a reference position
E0200 speed while cooperative
cooperating of COWORK or modify
following.
recorded speed slowly

Read of Sync.
Check communication status.
communication signal is
Cooperative Start time check the running mode.
E0201 wrong among cooperative
mismatch adjust the mode status of
robots, or running mode is
robots in same, and run.
not same each other.

Partner robots is stopped by Check the status of partner

E0203 Partner robot is in emergency motors off. My robot also is robot. and fix the cause of
stopped by motors off error.

Check connection of line and

Rbt#0 Communication is not Communication connection is LAN card.
E0204
working lost with corresponding robot. HiNet check can find the
unusual part of HiNet.

Check connection of line and

LAN card.
HiNet for cooperative control
E0205 HiNet is not working you can find the unusual part
is not working.
of HiNet as using HiNet
Check

Check the DSP version over

Fail of Init. of SVG Fail of SVG connecting 4.13 Check ATC connecting
E0210
Connection initialization is occurred. status and encoder power is
inputted

Servo of servo-gun was not

Servo-gun / Servo ON / Time
E0211 turned ON within the time
limit exceeded
limit.

Communication between
Main board and Servo board
Clear of SVG Filter is failed
SVG's Servo filter clear is is bad.
E0212 while trying to connect SVG
failed Check the connecting status,
axis
or another try after changing
board(servo, main)

Servo off is failed within limit Check if ATC is connect well.

SVG Servo Off fail in time
E0213 time, while SVG Or another try after changing
limit
disconnecting process servo board.

Examine error on Servo gun

Failure of encoder power on
SVG Encoder power is not encoder‟s power control
E0214 is occurred as SVG
connected system and replace if
connecting.
necessary

Failure of encoder power off Examine error on Servo gun

SVG Encoder power off is
E0215 is occurred as SVG encoder‟s power control
failed
disconnecting. system and replace if

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Code Message Cause Remedy

necessary

Check if battery is useless,

Encoder receiving result of and do another try after
E0216 SVG Encoder data error the SVG axis is abnormal encoder try after encoder
while trying to connect. reset. and then encoder
offset should be re-adjusted.

Motive control can be

Please set speed increasing
possible only if maximum
and decreasing parameter of
Error on speed increasing speed, accelerating time and
motive axis to be same by
E0217 and decreasing parameter of speed deceasing rate of 2
checking speed increasing
motive axis motive axes are same,
and decreasing parameter of
however, the parameter is set
robot parameter.
by different value.

Check if rated current is set

Overload of the Axis is
correctly, and check servo
detected.
gun mechanism.
E0218 (0 axis) is overload. Current has lasted over rated
Don't take a pressurization
current to harm the motor of
over rated current for a long
axis.
time.

You could not execute Chose the station # you want

positioner sync. to sync. Correctly or Change
Couldn't execute SMOV W/O
E0219 command(SMOV) without the number of station of
SELSTN
selecting station in a SELSTN SMOV command to the same
command # in a SELSTN command.

Robot current position is not Check encoder voltage,

the same as encoder data. connection of lines and frame
E0220 (0 axis) Encoder noise
There is noise in encoder grounds at controller and
pulse. robot.

Check encoder voltage,

It is failed to receive absolute
(0 axis) failed to receive connection of lines and frame
E0221 encoder data to check if there
encoder grounds at controller and
is encoder noise.
robot.

Robot's TCP enter the cube Turn to manual mode, and

area on which other robot is jog the robot to cube outside.
Coincident entrance to same
E0222 working. And you can modify the robot
cube
You can't playback in status program which can be run
of deadlock. without deadlock status.

1)Examine encoder voltage,

connection status of cable,
It is failed to receive absolute
(0 axis) encoder line cut or controller, contact status of
E0223 encoder data from serial
comm. err Robot
encoder.
2) Refer to error repair
manual

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 6. Troubleshooting

Code Message Cause Remedy

1)If an error persists after

error reset function is
Error status is received from
executed(from encoder reset
(0 axis) encoder status error encoder such as overflow,
E0224 function), replace the
occurred overspeed, inner capacitor
encoder(motor)
voltage drop, LED fail.
2) Refer to error repair
manual

In case that machine integer

file is loaded on controller
newly, please make
initialization in accordance
The current softlimit range of with the order of encoder
(0 axis) Softlimit exceed the axis exceeds the range offset calibration, axis integer
E0225
encoder limit which can be used by setting and soft limit setting
encoder. after encoder reset of the
corresponding axis.
If not, please set at an
appropriate position by
checking the limit.

Turn to the manual mode,

and jog the axis to internal
Robot axis can't reach the direction with system setting
E0226 (0 axis) exceed encoder limit position which exceed the mode.
limit of encoder usable range. If the limit is short abnormally,
you should initialize the
encoder.

Check the network

connection for cooperative
Commands sequence
robot control. And check
Seq. error of Cooperative between the master and the
E0227 whether the slave is doing
control slave make a difference while
power saving.
cooperative robot control.
The function should be
disabled at the slave side.

Find the error step by step go

process.
Current step or next step
E0228 Step target is out of range Check the all shift registers.
target is out of range.
And change the step target
position.

Encoder room temperature is Check the motor temperature

E0229 (0 axis) encoder overheated
increased to limit level. and change the robot speed.

Reset the encoder in encoder

Error status is received from reset menu after connecting
encoder such as overflow, the encoder power with
Encoder status error on
E0230 overspeed, inner capacitor R359.
connecting
voltage drop, LED fail on the If it is still in error state, the
connecting servo gun encoder(motor) should be
changed

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Code Message Cause Remedy

It is failed to receive absolute Check encoder voltage,

Encoder comm. error on encoder data from serial connection of lines and frame
E0231
connecting encoder on the connecting grounds at controller and
servo gun. robot.

Because encoder battery Check encoder battery

(0 axis) Change encoder may be disconnected or voltage, connection cables,
E0232
battery & reset voltage drop, the encoder and change the battery and
alarm is occured. reset the encoder.

Change step position. It is

required to program the step
Step target position is Step target position is
to be capable of avoiding
E0233 interpreted into the collision interpreted into the collision
collision in cases where the
position. position.
step is programmed for
calculation.

If the robot is operated while

exceeding average speeds
The robot is being operated set in each axis of the robot,
0axis) Exceeding average
E0234 while exceeding average the life of the robot may
speed limitation value
speed limitations. decline rapidly. Low operating
robot speeds must be
secured.

Be cautious as the newly

calculated locus may be
Restarting after controls such
Re-Start failed. Cautions on different from the precious
E0235 as backward step and stop
locus when restart one. In order to maintain a
same route, please re-start
the program from first step.

Please contac to the

Robot is immobilized as labrotary. Please change the
E0236 Motion planning failed
motion planning has failed speed or location of steps as
temporary solution

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 6. Troubleshooting

6.4.2. Operation Error

Code Message Cause Remedy

The program to execute was

E1001 Program not found Check if the program exists.
not exist.

You selected the step

Check the step number and
E1002 Step not found number was bigger than the
select
total number of all steps.

Too many files(It's more than Total file number is limited by Delete unnecessary files and
E1003
703) 703 make it.

Number of axes of the

The number of axis not selected program was You select the program of
E1004
match different with the number of other robot. Check it.
the robot.

The selected program is

Main body of program and different from the robot type You seem to select different
E1005
machine integer is different. registered at machine type of robot. Please check.
integer.

The capacity of file memory Delete unnecessary files and

E1006 Memory full
is deficient. make it.

1) Check up the pressure.

2) Check up the slippage of
It happens when the slippage
Brake slipped!(Excess of the motor of every axis and
E1007 of a brake by pressing during
50mm) change the motor with which
stud welding is over 50mm.
slippage is bigger than any
others'

1) Check up the pressure.

Number of brake slip excess
2) Check up the slippage of
by compression of stud
the motor of every axis and
E1008 Excessive brake slip count! welding exceeded detecting
change the motor with which
number of installed deviation
slippage is bigger than any
error.
others'

You can not copy same file,

external → internal and Wait a while until other
Simultaneous file access
E1009
confined internal → external, people's copying is
simultaneously. (RS-232C, completed. And try again.
Ethernet, SRAM card)

1) To tune linear conveyer

Insufficient recoded steps to angle automatically need 2
tune conveyer angle steps
E1010 More teach points required
automatically or to define 2) To tune circular conveyer
user coordinate. angle automatically need 3
steps

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Code Message Cause Remedy

3) To define user coordinate

need 3 steps

Recoded position is so close

Points too close to one that calculation is impossible Try to record positions as
E1011
another to tune conveyer angle possible as wide
automatically

3 steps to define user Refer to operation manual,

E1012 Recorded points are linear coordinate are in a line so locate 3 steps in a plane
calculation is impossible. except 3 steps in a line.

The selected function was Check the function number

E1013 Function not found
not exist of the step.

More than 4 copying

Wait a while until other
operating is tried via several
Failed in allocating file people's copying is
E1014 channel.
handle completed.
(RS-232C, Ethernet, SRAM
And try again
card)

Please execute it after

Protected program can not Protected program can not
E1015 releasing the protection of
be edited. be edited by step unit.
the file.

Can't modify (No You tried to edit the function

E1016 Check the function to edit.
parameters) of no modifiable parameter.

You tried to delete or edit

E1017 No contents Check the selected program.
unmade program.

E1018 Program has no step data Selected step is not exist. Check the step number.

Number of welding condition Check assigned welding

Unassigned weld condition
E1021 output was bigger than the condition signals in System/
signal
assigned number Control parameter/ I/O signal

Check Sum of the taught Delete the selected step and

E1023 Checksum error at the step
step was changed. add it.

You changed the program in

Initialize the palletizing
E1024 Palletizing program changed palletizing and tried to
counter and set again.
operate again

Make 6 steps at least to

Min.4 recoded steps need to
More steps than 4 are estimate auto setup
E1026 estimate auto setup
needed constants and try to make
constants
variety position

Recoded auto step constants Initialize the memory by

E1027 Program damaged.
are broken because of failure assistant of A/S member in

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 6. Troubleshooting

Code Message Cause Remedy

of the back up battery. HHI.

The number of tool to

estimate auto setup
E1028 It is not the same tool Consist tool number.
constants is different from
the number of estimated tool

1) Check up robot type on

Estimation of auto set up SERVICE / SYSTEM
E1029 Robot type not applicable constants is do on only 6 CHECKING/ SYSTEM
axes manipulator. VERSION/ ROBOT TYPE
2) Input measured constants.

Auxiliary axes should not

Additional axes not Record positions only to
E1030 move to estimate auto set up
applicable move main 6 axes.
constants

Processing auto set up Let robot pose different,

constants is not possible teach hand axes to pose as
E1031 Pose data not good
because steps are similar to differently as possible above
each other. all.

1) Check selected robot be

correct.
2) Move to reference position
Compensation values of to calibrate encoders,
processing auto set up initialize axes parameters,
E1032 Axis Const out of soft limit constants is so big that try to process auto setup
operating robot make a constants.
danger. 3) Make steps again to
minimize position error
between steps and try it
again.

Error on automatic integer The calculation for automatic Please make an inquiry to
E1033
setting integer setting is wrong. HHI.

1) Check if the shape of the

tool is ok.
2) Get the robot started
again if there is no cause of
E1034 Collision sensor on Collision happened.
the error more.
3) If collision was happed,
check up collision signal
logic in System/users.

If conveyer parameter in
SYSTEM/ APPLICATION
Works over permitted No. PARAMETER/ CONVEYER Stop the system, clear
E1035
entered is set to APPROACH process, run again.
OBJECTS = PERMISSION,
robot approach objects is

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Code Message Cause Remedy

permitted in conveyer
synchronized operation. sum
of approached objects is
more then 10

1) Check up circuit diagram

in FLOW SIGNAL/
WELDING CONDITION
Welding completion signal is SIGNAL/ COMPLETION
not inputted within waiting SIGNAL OF WELDING and
time of WI in SYSTEM/ surrounding equipments.
APPLICATION 2) Refer to SYSTEM/
PARAMETER/ APPLICATION
E1036 Welding wait time is over
SPOT&STUD/ DATA FOR PARAMETER/
SERVO GUN WELDDING SPOT&STUD/ DATA FOR
(CONDITION, SEQUENCE) / SERVO GUN WELDDING
WELDING SEQUENCE in (CONDITION,SEQUENCE)/
welding by servo gun COMMON DATA whether
wait for welding completion
signal(WI) or stop the robot
when error occurs

Robot position was not

Arrange robot position of
posed to compensate the
length compensating of
Can't record tip consump. length of abraded electrode
E1038 abraded electrode not to
position to record the position to
break away
compensate the length of
operation region.
abraded electrode.

In operation of synchronized
2axes torsion angle to 1) Set the same gain to each
Tolerance of sync. exceeded traveling two axes was larger axis.
E1039
range then set parameter of the 2) Increase Kp gain of
synchronizing 2 axes delayed axis.
function

Robot of synchronized
In this robot type can't Edit interpolation off on the
E1040 traveling 2 axes can not use
provide step, run the robot.
interpolation(linear, circular).

Set the value equal or less

Axes over at this positioner Number of axes in positioner then 2 on the group in
E1041
Group group exceeds 2 SYSTEM/ INITIALIZATION/
POSITIONER GROUP

Reference point(REFP) was

Record reference
Not support REFP step for not recorded in the
E1042 point(REFP) in the step for
calibr. calibration program for the
calibration program
positioner

1) Edit recorded steps for

Floating point calculation
Cannot calculated : Modify calibration program.
E1043 error occurs in calibration
Steps 2) Tilt the direction between
processing.
points by more then 30

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 6. Troubleshooting

Code Message Cause Remedy

degree to calibrate exactly.

No calibrate encoder offsets Calibrate encoder offsets

after selection of the robot after selection of the robot
Can't motor ON without Enc.
E1044 type in SYSTEM/ type in SYSTEM/ INITIALIZE
Compen
INITIALIZE, not to try and try to operate MOTOR
MOTOR ON. ON.

When setting frequency or

palletize count to external Input count number to
E1045 Not input freq/palletize count signal after selected register external signal after selected
doesn't input setting count register before 800ms.
before 800ms.

During the servo gun moving

Gun is opening by external After the servo gun moving is
E1046 by external signal, the
signal over, operate the auto-run.
auto-run signal was inputted.

Program tries to register over

20EA from the state of FIFO Check reserved program
FIFO Registers number is
E1047 function's (1)application count at service/ register/
over 20
at system/ user parameter FIFO register.
menu.

When spot gun manual/ auto

Welding gun connection
connect for external input Check external input signal
E1048 number selection signal is
signal, the value of gun no for Gun connection no.
abnormal
has an error.

Impossible to execute
because
reconnection(GUNCHNG ON
Welding gun already Check spot gun connection
E1049 or manual connection) is
connected stats.
attempted while welding gun
is already connected to the
system

Manual separation
(GUNCHNG ON or manual
Welding gun already Check gun connection
E1050 connection) is attempted
separated status.
while welding gun is already
separated to the system

It is a case that CUNCHNG

Please reinstall the controller
Inappropriate change command or manual gun
into spot gun changing
E1051 circumstance for spot gun. connection or disconnection
conditions.
was performed at no spot
gun changing conditions.

After gun connection on/off

Gun change time by manual was manually execute, within
E1052 Contact the Robot A/S team.
is over 5 second this function
doesn't complete.

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Code Message Cause Remedy

Panel thickness = in case

that negative vale comes out
Please check axis integer
The measured thickness is from the calculation ; ( axis
E1053 installation or worn quantity
minus. integer poison – servo gun
value.
current position – worn
quantity)

It happens if panel thickness Please install “panel

The thickness isn't been is not set when welding thickness” at the menu of the
E1054
setting. position is recorded by spot welding conditions.
opening servo gun.

It happened when it is bigger

Please change “maximum
The panel thickness than “maximum allowable
E1055 allowable thickness of panel”
exceeded range thickness of panel” of servo
at servo parameter menu.
parameter menu.

It is a case that each axes

encoder data of robot has
Please move the robot within
E1101 (0 axis) Soft limit arrived at installed soft limit
the installed range.
on teaching or automatic
operation.

Don't hold the key of AXIS

Motor on under axis MOTOR can't be turned on
E1102 OPERATION in the operation
operation! under axis operation
of MOTOR ON

Number of steps to run Is

Check the final step number
E1105 Step for jump not found bigger than the total number
of the program.
of all steps

Number of functions to run is

Check the final function
E1106 Function for jump not found bigger than the total number
number of the program.
of all functions.

Step to shelter in timer

Check the number of the
E1107 Shelter step not found condition function, etc.
step to shelter.
doesn't exist.

Condition is improper in
Jumping to shelter step Check the received data
E1108 conditional function
occurred status of the program.
execution.

Interpolation was tried in

Change the pose by single
E1109 Interpolation impossible pose where the interpolation
axis movement and operate.
was impossible.

You tried to move tool-end to Check whether the work

E1110 Out of workspace! the position where it can't piece and the robot was
reach. located properly.

Too large angle between The 1st Arm and 2nd Arm got Operate the robot to avoid
E1111
arms into interference state. interference.

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 6. Troubleshooting

Code Message Cause Remedy

Too small angle between The 1st Arm and 2nd Arm got Operate the robot to avoid
E1112
arms into interference state. interference.

There is no target step for

Check the parameter of the
E1113 Step for jump not found step-jump function at
made program.
playback.

There is no target step for

Check the parameter of the
E1114 Step for call not found step-call function at
made program.
playback.

Too many step-calls without Step-call was executed than Don't execute step-call than
E1115
return 9 times without return. 9 times without return.

Return exists without step Use step-return and

E1116 Can't return without step-call
call. step-return together.

The number of the program

Check whether step-call
Can't return to another to step-return is different
E1117 exists before step-return in
program! from the number of the
the
program in executing.

There is no target step of

Check the parameter of the
E1118 Step for return not found step-return function at
made program.
playback.

There is no target program of Check whether the program

E1119 Program for jump not found program-jump function at exists and the parameter of
playback the made program.

The axes number of the

The number of axes program in program-jump Check the program to jump
E1120
mismatch: Jump function is different from the for.
axes number of the robot.

There is no target program of Check whether the program

E1121 Program for call not found program-call function at exists and the parameter of
playback the made program.

The axes number of the

The number of axes program in program-call
E1122 Check the program to call.
mismatch: Call function is different from the
axes number of the robot.

Too many Prog-calls without Program-call is executed Don't execute step-call than
E1123
return than 9 times without return. 9 times without return.

There is no target program of Check whether the program

E1124 Program for return not found program-return function exists and the parameter of
when playback. the made program.

The number of axes Axes number of the target Check whether the program
E1125
mismatch: Return program in program-return exists and the parameter of

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 Hi5 Controller Maintenance Manual

Code Message Cause Remedy

function was different from the made program.

the axes number of the
robot.

A pose unable to take Steps are too close or linear Modify the recorded position
E1126
Cir-Interpol to make a Cir-Interpolation of step.

E1127 Undefined Playback Error.

You specified Signal which

Check the number for the
E1128 Unusable output(DO) signal can't be output in playback,
output signal.
this error occurs.

You tried to playback with

Check the condition of the
E1129 Undefined speed unit other unit except for [%] and
present step.
mm/sec.

You tried to playback the Check the parameter of the

E1130 END step not found
program of no END step. made program.

You designated inexecuTable Check the parameter of the

E1133 InexecuTable function
function in playback. made program.

END Relay Time exceeds 15

sec.
Usually, because the END Constant Parameter is
E1135 End relay output error Relay Time is less than 10 abnormal.
sec in Constant Setting Check the constant file.
Mode,
this error doesn't occur.

1) It is impossible to Please perfom after

playback from step 0. releasing automatic
E1136 Recovery protected program
2) It is impossible to execute operation protection ot the
step go/back. program.

Check the parameter of the

Number of Timer Conditional
E1139 Improper GI signal No made program and change
IB signal is wrong.
it.

Set port designation as

A port for T/P was set in Shift
E1140 Improper port number general in Shift Data Request
Data Request Function.
Function.

Check the use for port in

Improper use of serial port Use of serial port(RS232C) SYSTEM/ CONTROL
E1141
#1 was wrong. PARAMETER in Condition
Setting.

Shift Data Request Function 1) Check whether Shift Data

Repeated requests for shift
E1142 was executed again, before Function is used delicately.
data
Shift Data was input, in 2) Check the connection for

6-172
 6. Troubleshooting

Code Message Cause Remedy

executing the function. the external sensor.

You executed function-jump

Check the parameter of the
E1143 Function M88 needed function without completion
made program.
function in playing back.

You executed completion

Function M86 or M87 function without Check the parameter of the
E1144
needed function-jump function in function jump.
playing back.

Check the parameter of the

Out of range for function Jumping range exceeds the
E1145 made program and change
jump calculated value.
it.

There are palletizing

Use function M78 only 4 Reduce the number of
E1146 functions more than 5 in the
times palletizing function used.
program to be executed.

Palletize start was not There is END only without Check the contents of the
E1147
executed palletize start. made program.

There is palletize start in

Check the contents of the
E1148 Palletizing already executed executing palletizing
made program.
functions.

You selected other program

in executing palletizing Reset the palletizing function
E1149 Start after palletizing stopped
functions and start from step and start.
0.

P reset was executed in

End the palletizing function
E1150 Can't use during palletizing executing palletizing
and execute.
functions.

There is no function number Check the parameter of the

E1151 Function for jump not found to jump in executing made program and change
palletizing functions. it.

Check the parameter of the

Check search function Search On and Off are not
E1152 made program and change
M59(on/off) accorded.
it.

Set search reference position

When executed search data record to 'on' in
Set search reference Pt.
E1153 function without setting condition setting, and record
record on
standard position for search. in 1-Cycle Playback,
execute.

You can record standard

Only in the 1 cycle at AUTO position data for search in 1 Set AUTO Mode to 1-Cycle,
E1154
mode Cycle at AUTO Mode. and execute.
Excepting for this case, error

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 Hi5 Controller Maintenance Manual

Code Message Cause Remedy

occurs.

Robot Interrupt doesn't occur Check the searching object

E1155 Out of the search range despite search range and search range setting of
exceeds setting value. condition setting.

Transformation calculation
can't be made because 3
E1156 3 points are on the same line taught points are on the Check the teaching points.
same line in the coordinate
transfer function.

In On-line Shift or On-line

Coordinate Transformation
Modify the program to input
Function, if the function is
data through RS232C before
E1157 No data in the shift register executed even when data
On-line Shift or On-line
are not input through
Coordinate Transformation.
RS232C port, this error
occurs.

There is no standard step Check the parameter for the

Transfer reference step not
E1158 number in Coordinate Coordinates Transformation
found
Transformation Function. in the program.

Transferred pose is out of Modify the recorded position

E1159 Can't take transferred pose
Robot's Reach. of step.

Interpolation was executed in

Change the pose of robot
E1161 Interpolation impossible pose that interpolation is
and teach.
impossible.

Transformation calculation
can't be made because 3
E1162 Three points too close taught points are too close Check the teaching points.
each other in the coordinate
transfer function.

Shift makes robot leave Shift position is out of work Check the shift amount and
E1163
workspace range. working procedure.

Setting of the standard

Check the parameter for the
Improper coordinate coordinate system was not
E1164 XYZ shift function in the
frame:XYZshift corrective in XYZ shift
program.
function.

Setting of the standard Check the parameter for the

Improper coordinate
E1165 coordinate system was not search function in the
frame :Search
corrective in search function. program.

Setting of the standard Check the parameter for the

Improper coordinate
E1166 coordinate system is not palletize function in the
frame :Pallet
corrective in palletizing program.

6-174
 6. Troubleshooting

Code Message Cause Remedy

function.

Search target is out of Search range got out of work Reduce search range in
E1167
workspace range. condition setting.

Step where search function

Search available in linear Modify the step as
E1168 is to be executed is not in
INPLTN Interpolation On.
'Interpolation On'.

Error in step data which were

Playback errors in fetching Delete the step and make
E1169 fetched to execute a
steps the step again.
program.

In transformation of the
coordinate between on-line Change the robot pose, robot
Transfer makes robot leave
E1171 and off-line transfomated installation or location of the
WRKSPC
data was out of robot work piece and try it again.
operation space.

Fail to generate arc at start

Check the power supply to
E1189 Not inputs WCR at arc start point.(The number of retrial
the welder system.
was exceeded)

1) Check the feedback circuit

of welding current.
The welding current is out of 2) If the work end, set the
Arc sensing error( [A] range
E1192 the abnormal margin for the abnormal processisng
over)
abnormal time. method=<END>.
3) Other case, adjust the
margin/t

1) Check the feedback circuit

While the arc sensing of welding current.
function with the curve fitting 2) Adjust the coef. curve to
Arc sens'g error(Too algorithm, this is out of the small
E1193
unsTable [A]) Allowed error weav'g cycle 3) When you use bead
because of unsTable welding detecting function, plase
current. install as “bead detecting
exisitence = valid”.

Adjust the side coef. of

Arc sens'g error(Side range
E1194 The side tracking range over. Ampere or/and the max.
over)
Distance limit.

Adjust the height coef. of

Arc sens'g error(Height The height tracking range
E1195 ampere or/and the max.
range ov.) over.
distance limit.

Shift level exceeded the Decrease shift length or

E1196 Shift limit over
installed shift limit value. reassign shift limit.

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 Hi5 Controller Maintenance Manual

Code Message Cause Remedy

2 steps at least are required

Invalid step for Add step(s) for circular
E1197 for completing circular
Cir-Interpolation move.
interpolation

Cannot execute a weaving

Add approach step or 'REFP
E1198 Not exist approach step motion without approach
2'.
step or 'REFP 2'

Fails in motion planning

Add step(s) before the step
E1199 Read error of current step during the retry or restart
including 'ARCON' function.
function.

Fails in motion planning

Add step(s) before the step
E1200 Read error of preview step during the retry or restart
including 'ARCON' function.
function.

E1202 Syntax error It is general syntax error. Check the syntax.

Decrease the identifier's

An identifier's length is longer
E1203 Length of identifier exceeded length to be equal or fewer
then 8 characters.
then 8 characters.

1) Check the number of

elements of pose constants
or shift constants.
2) In case of pose, it should
The number of elements in include the additive axes.
pose constant or shift 3) Shift constant is the sum
E1204 The number of element fault
constant is not matched with of basic axes number and
setting. additional axes number.
4) Pose constant is the sum
of basic axes number,
additional axes number and
one(config).

In arithmetic expression,
function, or pose/shift
Check whether the
E1205 Misusage of Parenthesis constant, there is no
parenthesis is used properly.
parenthesis at its required
position.

Misusage of type An postposition of V variable Use '%', '!', or '$' as

E1206
postposition has been used badly. postposition.

Check whether the index is

In variable, there is no index
E1207 '[' missed missed, or '[' and ']' is paired
or '['.
properly in variable.

Check whether the index is

In variable, there is no index
E1208 '[' missed missed, or '[' and ']' is paired
or '['.
properly in variable.

6-176
 6. Troubleshooting

Code Message Cause Remedy

Make the index doesn't

An index value exceeds its
E1209 Index exceeded its range exceeds the variable type's
limit.
index limit.

The syntax of a constant or

Check the syntax of variable
E1210 Misusage of index expression used as variable
index.
index is wrong.

Commend and parameter Separate command and

E1211 Must be separated by space
was sticked parameter with a space.

Syntax of shift calculation

Check syntax of shift
E1212 Shift operating fault was wrong or shift parameter
calculation or shift parameter.
was not described properly.

The syntax of a interpolation Use 'P', 'L', or 'C' as

E1213 Interpolation parameter fault
in move statement is wrong. interpolation.

',' was missed in command

Check the separation with ','
E1214 ',' missed statement or function
properly.
statement.

Check the pose statement

In MOVE statement, the syntax.
E1215 Pose expression fault pose expression is not In case of hidden-pose
proper. MOVE, check the syntax of
speed.

In MOVE statement, speed is Check the syntax of speed.

E1216 Speed parameter fault
not proper. S={Speed}

Check whether a '=' is used

There is no '=' at its required
E1217 '=' missed properly in assignment or
position.
statements.

In MOVE statement, the Use 'cm/min', 'mm/sec', 'sec',

E1218 Unit fault syntax of speed unit is or '%' as speed unit. It must
wrong. be small letters.

In MOVE statement, the Check the syntax of

E1219 Accuracy parameter fault
syntax of accuracy is wrong. accuracy. A={0-3}

In MOVE statement, the Check the syntax of tool.

E1220 Tool no. parameter fault
syntax of tool is wrong. T={0-3}

In MOVE statement, there is

Make output options don't be
E1221 Too many output options more than 5 output
duplicated.
options(MX,MX2,G1,G2,BM).

In certain statement, some

Make parameter values don't
E1222 Value exceeded its range parameter values exceed
exceed their limit.
their limit.

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 Hi5 Controller Maintenance Manual

Code Message Cause Remedy

Output direction of PRINT, or

Use '#0', '#1' or '#2' as
E1223 Input/Output direction fault input direction of INPUT is
input/output direction.
wrong

Step number exceeded its Step no. value exceeds its Use the value of 0 - 999 as
E1224
range limit. step no.

Line number exceeded its Line no. value exceeds its Use the value of 1-9999 as
E1225
range limit. line no.

The syntax of address is

Check the syntax of address,
wrong, or it's attempted to
E1226 Address parameter fault and whether the address
branch to an address not
actually exist.
existed.

Because of broken working

Delete the step, record new
E1227 Failed in getting hidden pose file, it was failed to get
step.
hidden pose of the step.

Check the syntax of pose

An incorrect pose element or element or shift
E1228 Incorrect element
shift element is used. element.(refer to the
operational manual.)

The syntax of string constant Check the syntax of string

E1229 String fault
is wrong. constant.

Check the syntax of program

no.
Program number parameter The syntax of program no. is
E1230 Program no. must be a
fault wrong.
constant, not variable or
arithmetic expression.

The syntax of voltage Check the syntax of voltage

E1231 Voltage parameter fault parameter value is wrong, or parameter value, and the
the value exceeds its limit. value is within its limit.

The syntax of current Check the syntax of current

E1232 Current parameter fault parameter value is wrong, or parameter value, and the
the value exceeds its limit. value is within its limit.

The syntax of time parameter Check the syntax of time

E1233 Time parameter fault value is wrong, or the value parameter value, and the
exceeds its limit. value is within its limit.

The syntax of file no. Check the syntax of file no.

E1234 File parameter fault parameter value is wrong, or parameter value, and the
the value exceeds its limit. value is within its limit.

Make the result of

Divided by zero in arithmetic
E1235 Divided by zero expression used as divisor
expression.
don't be zero in any case.

6-178
 6. Troubleshooting

Code Message Cause Remedy

Check whether the

Fault occurred in arithmetic expression is valid form.
E1236 Mathematical Error
calculation. Infinity value shouldn't
occurred.

Checksum of the encoder Deleted the step and record

E1237 Checksum Error
value of the step was wrong. a step.

Refer to other working file,

The string syntax of working
E1238 Job header fault edit the string syntax of
header was wrong.
working header.

Because of upper version Increase the version of the

Job format version is
E1239 file, loading would not controller, revise the working
different
execute. file as present version.

On GOTO statement, there Use address parameters not

E1240 Too many addresses
are too many addresses. more 10ea.

In M code or I code
Use valid code no.(refer to
E1241 Code number fault statement, the code no. not
the operation manual.)
existed is used.

Because the left side of

Check the error in working
substitute is read only
E1242 Assign. fault file, use substitutional
variable, substitution was not
variables.
possible.

In SMOV statement. the

Use the parameter of jig
syntax or the extend of the
E1243 Fault of Jig number to sync number in 0 to 3 by SMOV
parameter of the jig number
statement syntax
was wrong.

Jig number was inputted

E1244 There is no registered jig Execute jig registration first.
without a registration of jig.

GOSUB - RETURN, IF -
ENDIF, FOR - NEXT of robot
language have too many Reduce inner block number
blocks. about GOSUB, IF and FOR.
E1245 Block stack overflow
or because of mismatched or repair the mismatched
flow control GOSUB, IF, FOR flow control.
executed repeatedly without
RETURN, ENDIF, NEXT.

Grammar designating Please find the wrong points

Designation of coordinate
E1246 coordinate system of integer on grammar, and correct
system is wrong
for pose or shift is wrong. them.

Error happened during

Please make an inquiry to
E1249 Fallacy of block Table execution of controlling
HHI.
sentence of robot language.

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 Hi5 Controller Maintenance Manual

Code Message Cause Remedy

Please find out wrong

Containing structure of flow
commanding sentence order
controlling sentence such as
Block containing structure is or containing structure
E1250 IF/ELSEIF/ELSE/ENDIF,
wrong. among flow controlling
FOR/EXIT FOR/NEXT etc in
sentences, and revised it in
robot language is wrong.
accordance with purpose.

Please supply the JOB

variable with valid value. Or
Reading Un initialized Attempt to read a pose that
E1252 place copy a pose/shift file
variable value has no value or shift variable
that contains a valid value to
main board

Welding segment and

Fails in motion planning
Invalid position move approach step must be
E1260 during the retry or restart
conditions interpolated, PTP move is
function.
not allowed.

Correct the REFP

REFP number can get its
E1261 Incorrect number of REFP number.(Refer to the
value of 1 to 4.
operational manual.)

Wire is sticked to the 1) Check the welder power

workpiece. or 'Auto Stick source.
E1262 Detected wire stick
Recovery' has failed in 2) Remove wire stick to the
repetition. workpiece.

Move the cursor to the

Cannot read WEAV Cannot find the weaving WEAVON statement, press
E1263
CONDITIONS condition file. [Quick Open] to create the
file.

Move the cursor to the

Cannot read ARC START Cannot find the arc start ARCON statement, press
E1264
CONDITIONS condition file. [Quick Open] to create the
file.

Move the cursor to the

Cannot read ARC END Cannot find the arc end ARCOF statement, press
E1265
CONDITIONS condition file. [Quick Open] to create the
file.

Move the cursor to the

Cannot read ARC AUX Cannot find the arc end ARCON or ARCOF
E1266
CONDITIONS condition file. statement, press [Quick-
Open] to create the file.

Move the cursor to the

ARCON or ARCOF
Cannot read ARC START Cannot find the arc end statement, press
E1267
CONDITIONS condition file. [Quick-Open].
Then press [PF2] 'Welder' to
create the file.

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 6. Troubleshooting

Code Message Cause Remedy

1) In case of steady weaving

(1) Record REFP3 point. (2)
In steady weaving reference
There was not agreed
point(REFP3) was not exist
between start step and
Incorrect reference or in normal weaving it was
E1268 object step(try to copy the
pose(REFP 3) occurred to coincide direction
step)
to reference point with the
2) In case of normal weaving
direction to the object point.
(1) Adjust the REFP3
position.

Distance between welding

Incorrect reference Change the position of REFP
E1269 path and REFP 1 is smaller
pose(REFP 1) 1 to the proper one.
than 0.1mm.

Forward direction and wall

Wall and target pose are point are linear. if wall point
E1270 Add REFP 1 or reposition it.
linear does not exist, z-axis is
assumed.

Forward direction and

Incorrect reference Add REFP 2 or reposition the
E1271 approach step(or REFP 2)
pose(REFP 2) approach step.
are linear.

Weaving pattern length is

E1272 Too small weaving width Enlarge the pattern length
smaller than 0.1mm.

Number of sequence is equal

Too small number of weaving Enter weaving sequence
E1273 to or less than 1 in
seq. more than 2.
user-defined pattern.

1) Check the welder power

source
Out of restart number on Restart repeats more than
E1274 2) Adjust the 'ARC OFF
weld line given value.
DETECT TIME' in welder
conditions

1) Charge the shield gas

E1275 An insufficiency of shield gas Shield gas pressure is low. 2) Set gas-off signal 0 to
ignore the low pressure.

1) Replace wire roll.

E1276 A shortage of weld wire Welding wire is run short of. 2) Set wire-off signal 0 to
ignore the wire shortage.

Unable to plan an overlap Increase overlap length or

Cannot overlap pose of
E1277 motion on the circular use the overlap prohibition
cir-interp
welding path. option.

Do it again. if error occurs,

Unable to plan an retry increase retry distance or
Cannot retry pose of
E1278 motion on the circular change operation mode in
cir-interp.
welding path. the welding time & condition
file.

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Code Message Cause Remedy

If 'Power Supply' in welder

Confirm the output voltage in
Check VOL CONFIRM of condition has changed,
E1280 ASF or AEf. And then set 'Vol
conditions 'Voltage Confirm' altered to
Confirm' 'DONE'.
'NOT DONE'.

1) Check welding power

Welder error signal is device.
E1281 Detected welder error signal
detected. 2) To ignore the signal reset
the signal in 'arc application'.

Please change the command

ARCOF ASF# command It happens when ARCOF
format of ARCOF into
E1282 language is unusable on ASF# command is used if
'ARCOF AEF#=_' or 'ARCOF
setting of analogue arc. arc setting is analogue.
C=_,V=_' format.

Option board was not

Arc board is necessary for installed. Please check whether arc
E1283
arc welding. So, the arc welding does not board is loaded.
support.

Set the object of serial port in

the object of serial port in
'SYSTEM/CONTROL
Improper use of serial port 'SYSTEM/CONTROL
E1285 PARAMETER/SERIAL
#2 PARAMETER/SERIAL
PORT'as'SENS' to use the
PORT' was not 'SENS'
serial port as sense.

In individual power control

Voltage output mode was not
mode voltage out was
Different from Power Control correspond to voltage control
E1286 selected as 'voltage', in one
Mode mode in welder character
source or pulse voltage
file.
output was selected as '%'

Adjust selected station in

In execution of 'SMOV' no
Undefined 'SYSTEM/INITIALIZATION/P
E1287 defined station was
Station(PositionerGroup) OSITIONER GROUP
appointed.
CONFIGURATION'

Do the calibration of the

In execution of 'SMOV' it was station in 'SYSTEM/ AUTO
Not executed Calibration of
E1288 selected that the station was CONSTANT SETUP/
S(?)
not calibrated. POSITIONER
CALIBRATION'

When WCR signal was not

inputted in set time, arc off 1) Adjust time of WCR signal
signal was detected in arc and arc off detection.
Detected Arc Off in arc
E1289 welding. 2) To ignore the signal, select
welding.
Arc off detection time was the ignore in 'Aux. welding
adjusted in welding character config. file/restart condition'
file.

Adjust the search range in

Don't detect the start point
E1290 Don't detect the start point. the tracking conditions, or
within the search range.
modify the step's pose.

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 6. Troubleshooting

Code Message Cause Remedy

1) Check the serial port

usage.
The laser vision sensor does 2) Check the laser vision
E1291 No responding of LVS.
not reply. sensor.
3) Check the communication
cable.

When search a start pose

with the laser vision sensor, 1) Modify the search range in
Do modify search start
E1292 at start pose correct with condition.
length.
conditions even if the robot 2) Modify the step pose.
doesn't move.

Refer to the error number in

HISTORY frame, and the
sensor manuals.
1 : PC setup comms error -
serial connection fault to PC
2 : Sensor camera fault - no
video from the sensor head
3 : Sensor link fault - no
comms to sensor head.
Camera cable faulty?
4 : No sensor connection -
no video or comms. Sensor
not plugged in?
5 : Sensor at wrong temp -
too hot or too cold
6 : Sensor power failing - 24v
supply to sensor head out of
range. Camera cable faulty?
7 : Lasers disabled - check
The laser vision sensor
the laser enable keyswitch,
E1293 Error detect at Laser sensor. sends a error number, refer
and the laser warning lamps
to HISTORY frame.
8 : No sensor calibration -
sensor calibration data faulty.
Try a different sensor head
9 : Seam out of range - no
stripe in picture
10: Analysis could not see
the seam. Hit data ok, but
analysis failed, only in search
11: Not used in this interface
12: Seam has not been
setup. Incorrect seam
number?
13: No seam in image in
tracking
14: Esc pressed in tools
program while robot
communicating with the
sensor
15: Control unit memory

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 Hi5 Controller Maintenance Manual

Code Message Cause Remedy

corrupt, reformat and reload

memory from backup.
16: Reading system data fail
17: Error reading seam from
FLASH memory - corrupted?
18: Error reading seam from
FLASH memory - corrupted?
19: Fault in the analogue I/O
circuitry(POST)
20: Error in video acquisition
hardware
21: Error in the on board
timer hardware
22: FLASH memory dead -
needs replacing
23: Data FLASH memory full
24: FLASH memory bad
sector - warning only
25: Error in the error log
26: Power to the I/O on the
SAPEII board missing
27: ESTOP active - check
the ESTOP link or
connections
28: Within 5 degrees of the
temperature limits

Move cursor on the LVSON/

CHGLVS command and,
Cannot read the laser vision
Cannot read LVS press [Quick Open].
E1294 sensor condition file,
CONDITIONS. If not be solved, backup all
ROBOT.LVS.
file and execute the system
format

When the mode of weaving

Set Weav'g mode=single for Set the mode of weaving
E1295 condition is not the single, it's
Track'g condition to the single.
detect

Assign a number of port to

When unassigned the analog
Assign InPORT of weld [A] the analog input port for
E1296 input port for tracking, it's
for TRK. tracking at
detect.
{system>4:>2:>13:}.

Please purchase its function

at HYUNDAI ROBOT
This function requires the
E1297 Not correct the license key. marketer.
license key.
Refer to
{Sys}>{2:}>{19:Licens-}

If a joint type is no problem,

A seam data doesn't exist Laser vision sensor doesn't please adjust the allowed
E1298
with LVS detect a seam pose. value in LVS condition, or
adjust the extend length for

6-184
 6. Troubleshooting

Code Message Cause Remedy

search target.

The step's interpolation Please change next and next

The Search Start supports
E1299 method is not linear for the step interpolation method to
only LIN
moving search start function. linear.

During conveyor tracking,

E1302 Conveyor interpolation error interpolation off step was Change interpolation of step.
executed.

Conveyor running signal is

input. in case of conveyor Either turn conveyor running
Conveyor running signal is
E1304 operation mode was set Test signal off or set conveyor
given
or Simulat. in operation mode to Normal.
synchronization on.

It is a case that
Create Robot.CO1 file for corresponding command is Please check the conveyer
E1305
conveyor performed at off status of motive status.
conveyer motive.

After configuring mechanical

constant file, playing gun
Standard position for gun search", function or spot Record gun search reference
E1306
search was not recorded. welding function was position with new electrodes
executed without record gun
search reference position.

Playing of spot welding

function was occurred
Do the work after detection
without termination of gun
Gun search program is of tip consumption with
E1307 search normally or gun
abnormal execution gun search 1 and
search 2 was executed
2.
without execution of gun
search 1.

The tool number to servo

gun number was not Correspond tool number(G1
Tool No. of selected step is selected correctly when the →T0, G2→T1) in the step
E1308
wrong step was executed with spot with spot welding function
welding function and gun and gun search function.
search function.

Current limit(IP) of the servo

Lower conFigured pressure
Squeeze force exceeded amp was exceed to current
E1310 or increase capacity of the
current LMT limit of calculation by
servo motor.
commanding pressure.

Command pressure was

Squeeze force exceeded Lower command pressure
E1311 exceeded over load
overload not to make over load error.
detection level.

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 Hi5 Controller Maintenance Manual

Code Message Cause Remedy

Out of robot work space was

Squeeze target is out of occurred when pressure Change the pose of robot,
E1312
workspace position(Object position) of record the position.
servo gun calculation.

The pressure in the welding

condition data of spot
welding parameter(M72) was
Squeeze data out of range in
E1313 exceeded conFigured Lower conFigured pressure.
Table
pressure extend of pressure
Table of servo gun
parameter.

Electrode abrasion detected Change electrodes, adjust

Squeeze force delay time is was exceeded max. max. electrode abrasion
E1314
over electrode abrasion of servo value of servo parameter as
parameter. preferable value.

Check the work is with

Gun number for servo gun is To work with gun is not servo
E1315 whether servo gun in
wrong gun
addition axis configuration

When gun search function

Do not use robot search
A robot search or C/V is was executed, the function of
E1316 function or conveyer function
operating robot searching or conveyer
in gun search operation.
was running

When a program was

HRView is going to load After downloading the
E1317 downloaded by HRView, Run
program program, do the program.
command was executed.

The result of addition or

The result value was Max value of count register is
E1318 subtraction with count
overfloor 255, check the program.
register was exceed 255.

The result of addition or

The result value was
E1319 subtraction with count Check the program
underfloor
register was exceed 255.

This error occurs when the 1) When electrodes

sensor does not work though approach sensor check the
the robot approach the object sensor work
Sensor doesn't search
E1320 in searching of fixed 2) Check connection of
operation
electrode abrasion by servo connectors.
gun search function or robot 3) check the kind of sensor
equalize function contact

1) Check palette number on

Use same palette number on a palette with command of
The pallet entry number is a palette such as PAL and TIERST, PALPU, PAL,
E1321
wrong PALEND command or make PALEND and PALRST
this error. 2) Input same pallet number
on the pallet

6-186
 6. Troubleshooting

Code Message Cause Remedy

1) Palletizing pattern
registers were inputted to 1) Check pattern register
palletize. number that was set up.
E1322 Unusable pattern resister.
2) If invalid pattern register in 2) Check used/unused items
16 pattern registers was of palletize pattern register.
used, this error was occurred

Select 'SERVICE' as 'SPOT'

in 'SYSTEM/
The condition to be execute
Equalizerless environment is INITIALIZATION/ SERVICE
E1323 robot equalizer function was
wrong SELECTION' after selection
not enough
of air gun1, air gun2, etc as
EQ'less

There was not selected

'SERVICE' as 'SPOT' in
Set GUN2 as 'palletize' in
Palletizing environment is 'SYSTEM/ INITIALIZATION/
E1324 'SYSTEM/ INITIALIZATION/
wrong SERVICE SELECTION' after
SERVICE SELECTION'
selection of air gun1, air
gun2, etc as EQ'less

Shift quantity of 'PAL'was

needed to use shift quantity
Palletize pick'g up function of PALPU. PALPU put on between PAL
E1325
fault PALPU is to be on between and PALEND in the program.
PAL and PALEND or make
this error.

Change the compensate

Controller is conFigured to
method to use gun search
Invalid environment of GUN compensate consumption of
E1326 method 1,2 either by set the
search2 gun by gun search method 1
value 0 to 'Move tip
only.
consumption rate(%)'

Open position of servo hand

reduce length of the offset of
open step excess maximum
servo hand open step or
Servo hand opening limit open position of system/
E1327 increase maximum open
over application parameter/
position of servo hand
palletizing/ servo hand
parameter menu.
parameter setting.

Squeeze position of servo

hand squeeze step is smaller Increase the length of servo
then Maximum squeeze hand squeeze step's offset or
Servo hand squeezing limit
E1328 position of system/ decrease maximum squeeze
over
application parameter/ position of servo hand
palletizing/ servo hand parameter menu.
parameter menu.

While squeezing at servo 1) Settle servo hand squeeze

hand squeezing step, position.
Servo hand squeezing time
E1329 squeeze force doesn't come 2) Setting the
over
in setting range in spite of Squeeze-Current Table of
passing system/ application system/ application

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 Hi5 Controller Maintenance Manual

Code Message Cause Remedy

parameter/ palletizing / servo parameter/ palletizing/ servo

hand hand parameter
parameter menu's Squeeze 3) Settle squeeze force.
fault check Tm. 4) Settle squeeze fault check
Tm.

You tried to load ladder

Turn the embedded PLC to
Can't load .LD? file while file(.LAD) while embedded
E1330 STOP or Remote-STOP
PLC RUN PLS RUN or Remote-RUN
mode, and try again.
mode

Reserved program exe.

Reserved program exe. Is function has been attempted
E1331 Check the current mode
possible at remote mode while currently mode is not a
remote mode

You tried to start in case of

system/ user parameter
Confirm the setting of
menu's FIFO function
Confirm program strobe program strobe signal use at
E1332 (2)Program is <Ext-Sel> &
signal use system/ user parameter
(1)Application No. is <20EA>
menu.
or <1EA> & program strobe
signal use <DSBL>.

Reserved program is not

Cannot found selected exist on the internal memory Confirm selected program on
E1333
program when execute FIFO register's the internal memory.
reserved program

1) In spite of restart at
current position interference
isn't occur start after set
When motor off for return to
again current step.
previous posi is enable, fall
2) If interference expects
length excess limit for error
when step execute at current
Free-fall! start after step detect. if error isn't occur in
E1334 posi, exchange robot posi at
SETg the case of robot restart
manual mode.
because of stopped step is
3) If error detect length is
out of normal trace this error
unsuiTable, adjust limit for
inform to user warning.
error detect at system/
2:control parameter/return to
the previous posi menu.

When execute program at When apply FIFO Function,

Cannot use continue play at FIFO application, in case of please use after select
E1335
FIFO cycle type of the cond set 1cycle cycle type of the cond
menu is continu input start. set menu

The first select a program

and record 3 steps, the
When execute/input
Undefined User-coordinate origin, the X-direction, and
E1336 User-coordinate without
number. pose on XY-plan for
setting User-coordinate
User-coordinate. Sets
System>2:>12:>1:User-coor

6-188
 6. Troubleshooting

Code Message Cause Remedy

d.
If you want it in program,
refer to the MKUCRD
command.

When execute SOFT

instruction While setting Please set to 0 Accuracy for
E1337 SOFT Instruction execute fail time(5sec) command and step before SOFT
current encoder's difference instruction.
is over 384Bit

When SOFT instruction

Soft floating error distance
E1338 executed, position difference Adjust error detection level.
over
is over error detection level.

Verify communication status,

common coordinate was set,
Invalid condition for co-work Invalid condition of controller
E1340 same between manual
run to do COWORK function
cooperation role and
COWORK's role of robot.

Considerate wait time of

All of cooperative robot are COWORK must be set,
E1341 Cooperation wait time is over not ready to cooperate by considering the other robots.
COWORK wait time. or you can set the time as 0,
waiting until agreement

Cooperate control is set as

COWORK can not be
enable at System setting/
Invailded COWORK or executed as in validity of
E1342 Cooperation control
common coordi. cooperative control, or as no
parameter and common
common coordinate.
coordinate must be set.

COWORK function is
programmed with pairing
Duplicated COWORK is COWORK and COWORK
COWORK execution
E1343 used, or program encounter END.
mismatch
END without COWORK END It is prohibited from repetition
of running COWORK caused
by step change.

Change robot number used

COWORK's partner robot in COWORK
COWORK Para.(M/S,robot
E1344 number is wrong set as my M(S),S(M)=robot number, my
No.) error
robot number. robot number can not be set
as partner robot number.

Don't go to the trouble to

The slave already executed Cursor position of Slave is at
E1345 change step to operate
COWORK. COWORK END.
Master and Slave normally.

You can't repeat steps

Excess of P* repeat limit Insert a hidden pose step
E1346 including P* over 10 times.
(10x) within preceding 10 steps.
(for limit of calculation load)

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 Hi5 Controller Maintenance Manual

Code Message Cause Remedy

You can only add

<base/robot/tool/user coord.
system shift> to <base/robot/
encoder/user coord. system
pose>.
Check the pose or shift
The shift operation of other
Coord. system not variable/ constant and
E1347 coord. system is not
supporting shift convert it to permitted
permitted.
coord.system.[Quick Open]
Shift of base or tool
coordinate system can be
added, and shift calculation
for other coordination is not
permitted.

If connection complete at
ATC, send spot gun
connection complete signal
Time out of connection For marked time gun to controller.
E1348
complete. connection doesn't complete. GUNCHNG ON, commend
execute after connection
between gun and
ATC.(automatic tool changer)

After GUNCHNG OFF

SVG Disconnect error in limit instruction execute, within
E1349 Contact the Robot A/S team.
time 5sec spot gun doesn't
disconnect.

Please input user-coordi.

Don't set an user-coord. Don't set user-coordinate Number with T/P, or execute
E1350
number. number in the [Condi Set]. SELUCRD command with
teaching program

For pre-defined interrupt Define not used interrupt

E1351 Interrupt defined duplicated. number redefine without number or after execution
delete. interrupt delete.

Private interrupt enable After pre-execution for

Pre-execute interrupt instruction executes without interrupt define instruction
E1352
definition. defined number interrupt executes private interrupt
execution. enable instruction.

Modify step's pose or the

Over allowed max. dist. The distance deviation by the
E1353 allowed max. deviation in
deviation. seam tracking is over.
TRK condi.

Modify step's pose or the

Over allowed max. angle The angle deviation by the
E1354 allowed max. deviation in
deviation. seam tracking is over.
LVS cond.

Check the running status

Partner robots aren't ready to
Partner robot is in abnormal mode.
E1355 cooperate. one of them is
stop If you want to rerun after
stop status.
stopping playback of

6-190
 6. Troubleshooting

Code Message Cause Remedy

cooperation, you will run

Master ahead after running
Slave.

Inspect robot number of

Cooperation control is robot connected in HiNet,
Duplicated robot number is impossible because and change overlapped robot
E1356
set duplicated robot number number.
can't be identified the robot After this action, you must
repower the controller.

Check the cooling system.

If there is no error, check the
Coolant circulation error setting of input signal port in
E1357 Detected coolant error signal
signal is detected. controller.
And restart welding step after
removing error state.

When Interrupt Define or

Cannot use interrupt &
Interrupt enable at continue Enable instruction executes,
E1358 continuous path function at
path. continuous path function has
the same time
been executed.

When continuous path set, Cannot use interrupt &

Set continuous path at Int
E1359 Interrupt function already continuous path function at
enable.
executes. the same time

Initialize the memory by

File of control integer was Structure of control integer
E1360 assistant of A/S member in
damaged. file was damaged.
HHI.

Initialize the memory by

File of machie integer was Structure of machine integer
E1361 assistant of A/S member in
damaged. file was damaged.
HHI.

File of control integer has

Data cannot be recorded at Please change the file
E1362 property that writing is
file of control integer. property of control integer.
prohibited.

File of machine integer has

Data cannot be recorded at Please change the file
E1363 property that writing is
file of machine integer. property of machine integer.
prohibited.

Use R351 or F key for

The number of controllers
turning the roles such as
which are set as masters of
E1364 Duplicated setting of master. master/slave.
manual mode is more than
Only one should be selected
2EA.
as a master.

Select a master for

A cooperative status is not A master of manual mode is
E1365 cooperative robots of manual
ready. not selected.
mode.

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 Hi5 Controller Maintenance Manual

Code Message Cause Remedy

The master number selected

Master number of slave is
E1366 by the slave is not coincident This message will be ready.
wrong.
with the master number.

Shift function is applied, but

You should apply the robot
E1367 Can't be Shifted in CMOV the shift coordinate is not
coordinate for CMOV shift.
supported

The coordinate of step data

Select the master coincident
Not select Master for Crd. is the master end effector
E1368 with the master of current
trans. Crd.<M>, but the master
CMOV step
robot is not selected.

The master number from

You should record the CMOV
COWORK S, M=#1,ID=#2 is
Invalided master number,ID position, after the same
E1369 not coincident with the
in CMOV master of COWORK is
master number from CMOV
selected.
R#1#2

Combination angle of H axis You should move H axis or V

E1370 H axis, V axis motion limit
and V axis reached the limit axis within the limit

Conveyor run signal isn't Conveyor run signal isn't

E1371 Check signal input state.
input. input.

WCR can't be off in limit

E1372 WCR did not fall in limit time. Check signal input state.
time.

No use ARCONC=.. on This ARC command is not You should use ARCON
E1373
digital welding valid in digital welding. ASF#=command.

Push the 4th button(Rem) in

When analog active is
Push remote button of ESAB measured screen of U8.
E1374 selected remote button must
welder. If Rem is disappeared, mode
be pushed.
is remote.

When a digital welding

Can't receive Welder CAN machine is selected any Check CAN cable and power
E1375
message. CAN message is received for of the digital machine.
some time.

no welding parameters
available for selected Select other
Welding machine (E00): no
E1376 material-wire-gas material-wire-gas
program for welding set
combination combination.
(no reasonable combination)

Welding machine (E01): thermal sensor of power unit

let machine cool down in
E1377 overheat on power device of measures a too high
standby
welding machine temperature

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 6. Troubleshooting

Code Message Cause Remedy

Welding machine (E02):

main voltage too high (24V check mains voltage and
E1378 Overvoltage error on main
supply > 36V) control transformer
power

Welding machine (E03): too

E1379 welding current is too high check pc-board LSW
high welding current

Temp. sensor of the power

Welding machine (E04): check fan and air hardening
E1380 unit detects that the unit
error in air-cooling system lime
heats up too fast

check connectors of
flowrate of the cooling liquid flow-meter, level of cooling
Welding machine (E05):
E1381 is too low (0.3 l/min) pump is liquid and flowrate check
error in water-cooling system
not working fuse S17 (2.5A) on pc-board
DP-MAPRO

Welding machine (E06): Master detects output

E1382 overvoltage error in voltage is too high (112V or exchange power unit
secondary power more)

No welding program stored

Welding machine (E07): transfer welding programs to
E1383 or error during reading from
EEProm chksum error machine again
memory

power consumption of wire

feed motor too high no tacho
Welding machine (E08):
E1384 signal no CAN-Bus blow out torch package with
Error on wire supply device
connection between MAPRO
and DMR

Welding machine (E09):

measuring difference check wiring of pc-board
E1385 measuring value error of
between Master and Process LSW and pc-board DK-UFI
current / voltage.

short circuit of torch control

Welding machine (E10): cables or between torch check torch control cables
E1386
error of torch socket / cable switch wires and welding and torch interface
potential

Welding machine (E11): check remote control and

short circuit between remote
E1387 connecting error of remote wiring of remote control
control cables
device socket

switch the machine off and

Welding machine (E12): Process is not responding to
E1388 on again optionally exchange
Process does not respond Master.
pc-board DP-MAPRO

Welding machine (E13): check resistor value and

E1389 Temp. sensor is defective
temperature sensor error wiring of the sensor

Welding machine (E14): too supply voltage is too low check mains voltage and
E1390
low supply voltage (<17V) control

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Code Message Cause Remedy

It is an error (E15)of If the trouble is repeated,

Welding machine (E14): too
E1391 undesignated welding please contact to A/S staff of
low supply voltage
machine. HHI.

Welding machine (E16):

power consumption of power
E1392 working of overcurrent exchange power unit
unit 1 is too high
protection of primary power

Welding machine (E17):

If same problem was
error number of
E1393 undefined welder error(E17) repeated, contact A/S
undesignated welding
member in HHI.
machine

Welding machine (E18):

safety shutdown to protect
working of overload let machine cool down in
E1394 electrical components temp.
protection of secondary standby check temp. sensor
sensor is disconnected
power

Welding machine (E19):

If same problem was
error number of
E1395 undefined welder error(E19) repeated, contact A/S
undesignated welding
member in HHI.
machine

Welding machine (E20): too Process reports a too high

E1396 exchange power unit
high output voltage output voltage

Welding machine (E21): external current/voltage or

E1397 measuring error of output measure-difference between exchange power unit
current / voltage Master and Process

Welding machine (E22): too power unit 1 reports mains check mains voltage and
E1398
low voltage of main power voltage too low mains rectifier

Welding machine (E23): too power unit reports mains

E1399 check mains voltage
high voltage of main power voltage too high

Welding machine (E24):

working of overcurrent power consumption of power
E1400 exchange power unit
protection of secondary unit 2 is too high
power.

Welding machine (E25): Jumper on pc-board

check jumper J1, J2 on
E1401 DK-DCDRV jumper setting DK-DCDRV have been set
pc-board DK-DCDRV
error wrong

Welding machine (E26):

If same problem was
error number of
E1402 undefined welder error(E26) repeated, contact A/S
undesignated welding
member in HHI.
machine

select other
Welding machine (E07): no welding programs faulty or
E1403 material-wire-gas
welding program (DSP) not available
combination transfer welding

6-194
 6. Troubleshooting

Code Message Cause Remedy

programs to machine again

Welding machine (E28):

If same problem was
error number of
E1404 undefined welder error(E28) repeated, contact A/S
undesignated welding
member in HHI.
machine

Welding machine (E29):

If same problem was
error number of RS232C port in welder is
E1405 repeated, contact A/S
undesignated welding fault
member in HHI.
machine

Welding machine (E30):

power unit 2 reports mains check mains voltage and
E1406 secondary power voltage is
voltage too low mains rectifier
too low.

Switch the machine off and

Welding machine (E31): Master is not responding to
E1407 on again optionally exchange
Master does not respond. Process
pc-board DP-MAPRO

When welding finished, GAS

Can't stop GAS ACTIVE ACTIVE signal is not Check the CAN cable and
E1408
status. disabled within assigned welding machine
time.

If gun search standard

position recode performs
(0 gun) failure of record for
GUNSEA sentence at ON
E1409 gun search standard Please check the file.
status, standard position is
position!
stored at file. The error
happened at this time.

Gun number VS gun type

Check gun number VS gun
E1410 Mismatched multi gun type!! mismatched at command for
type.
multi gun sync welding.

Gun number setup was gun number setup error at

E1411 Check gun number.
wrong. command

Deviation of stored stop pose Move the robot at welding

Deviation of stop pose is too
E1412 vs. welding path is large then stop pose by Jog, and start
long
2[cm]. execution

Please set the entrance /

Entrance/progressing step Entrance/progressing step
progressing step for arc
E1413 for arc welding is for arc welding is
welding into linear or arc
interpolation OFF. interpolation OFF.
interpolation.

ARCON command should be

ARCON is not usable at step ARCON command is
E1414 recorded other steps beside
0. recorded at program step 0.
command 0.

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Code Message Cause Remedy

1) Please check
communication cable
connected to welding
Arc welding machine does Communication ready for arc
E1415 machine (A07→X7)
not work. welding machine is not input.
2) Please check performing
status of inner PLC (X7 →
DI111).

1) Please check welding tip

Restricted value installed at or supply system.
Restricted value is exceeded
E1416 condition file is exceeded 2) Please adjust the
during arc welding.
during arc welding. restricted value of welding
condition file.

Check the operating

The robot is soon to pass a
The robot passes an limitation cubic and move the
E1417 designated operation
operating limitation cubic. robot to the inside of the
limitation area.
operation limitation area.

Check the mirror position

The robot collided with a The robot is soon to collide setting value and move the
E1418
mirror axis. with a mirror axis. robot so as not to collide with
the mirror.

Check the collision detection

The robot collided with the The robot is soon to collide area of the main body and
E1419
main body. with the main body. move the robot so as not to
collide with the main body.

Check the operation

The robot link is soon to pass
The robot link collided with limitation cubic and move the
E1420 the operation limitation area
an operation limitation area. robot to the inside of the
designated by the user.
operation area.

Select appropriate setting

Arc command has been between analog, digital from
Controller is not arc-welding executed while arc-welding the dialog
E1421
set function is disabled in the
„System→Initialization→contr
controller setting
oller setting‟

Communication error to GB2

1) Check welder‟s power.
welder
2) Check the communication
1) Welder‟s power may be off
status between controller
2) Error on communication
and welder
cable
E1422 No reponse from GB2 welder 3) Check power terminal
3) Error on 24 V power
(socket) of cable
supply of communication
4) Check if controller‟s serial
cable
communication setting is for
4) Error on controller‟s serial
GB2
communication setting

Command are transmitted to 1) Check welder‟s power

Communication error to GB2
E1423 GB2 welder 3 times, but the 2) Check the communication
welderGB2 .
welder did not respond status between controller

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 6. Troubleshooting

Code Message Cause Remedy

and welder
3) Check power terminal
(socket) of cable
4) Check if controller‟s serial
communication setting is for
GB2

Wire supply motor is not

spinning normally, or
disconnection of encoder
GB2 error(B06) encoder signal is expected. Try to
E1427 Replace feeder unit
error detection spin the motor and if it spins
(even a little), encoder
damage or disconnection on
wiring is suspected

Detected the wire supply

motor‟s spinning without the
spin command. If the motor
GB2 error(B07) motor error
E1428 is actually spinning, error on Replace feeder unit
detection
PCB of wire supply device is
suspected

Current that exceeds the

maximum rated voltage flows Turn off the power switch
GB2 error(B09) secondary
E1430 because of short-circuit and remove the cause of
over-current detection
occurred on secondary side short-circuit and over-current
circuit

1) Turn off the power until the

internal temperature goes
down
Internal temperature of 2) Remove the cause of
GB2 error(B10) temperature
E1431 welder has increased over increased internal
increase error detection
the rated value temperature(exceeded rated
operation, blockage of
ventilation system of front
and side)

Turn off the power switch

GB2 error(B11) primary Input voltage exceeds the
and adjust the input voltage
E1432 overvoltage detection allowed range
to be within +10% range of
rated voltage

Turn off the power switch

GB2 error(B12) primary low Input voltage is lower than and adjust the input voltage
E1433
voltage detection. the allowed range to be within -10% range of
rated voltage

Welding has started within 3

GB2 error(B12) torch switch seconds from the power on. Turn off the power switch
E1434
error detection. Welding is only possible after and try it again
3 seconds for safety reason

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Code Message Cause Remedy

Ouput current or output

voltage is detected when the
power switch turned on.
1) Check if power is supplied
GB2 error(B14) CT offset Product malfunction or a
E1435 to welder‟s secondary side
error detection current, voltage may be
2) Replace the welder
supplied to welder‟s
secondary side from external
area.

Turn off the power switch

Emergency stop signal is
GB2 error(B18) emergency and examine the cause of
E1439 being input to Jig terminal
stop error detection emergency stop signal of Jig
(socket)
terminal (socket)

Signal that connected to

GB2 error(B19) outer input 1 Examine the cause of EXT1
E1440 EXT1 of Jig terminal (socket)
error detection signal of Jig terminal (socket)
is being input

Signal that connected to Examine the cause of EXT2

GB2 error(B20) outer input 2
E1441 EXT2 of Jig terminal (socket) signal of Jig terminal
error detection
is being input (socket).

Arc start did not activated

Check if the voltage
GB2 error(B23) Arc start within 4 seconds from the
E1444 detection line is
error detection input of welding activation
disconnected, loose contact
signal

Synergic welding setting that Select synergic welding

GB2 Welding environment
E1445 GB2 welder does not support setting that GB2 welder
not supported by GB2 welder
is selected supports

Robot link exceeds the Move the Robot link into the
Robot link crashed to the
E1446 limited value and going to operation area or adjust the
operation limit area
crash operation limit setting

No license for arc-sensing No license for arc-sensing Please contact to our office
E1447
function function for a license

Please contact to our office

E1448 No license for LVS function No license for LVS function.
for a license

No license for cooperation

No license for cooperation Please contact to our office
E1449 control(CWORK) function
control(CWORK) function for a license

No license for automatic No license for automatic Please contact to our office
E1450
calibration function calibration function for a license

No license for embedded No license for embedded Please contact to our office
E1451
Fieldbus function Fieldbus function. for a license

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 6. Troubleshooting

Code Message Cause Remedy

Servo hand related

Servo hand environment command has been
E1452 Check the setting status.
setting error executed while the status is
not Servo hand environment

Spot welding related

command is executed by
Use it after set the gun type
E1453 Gun type setting error independent drive. Guntype
to stationary
for the gun number is not set
to stationary

Case when a spot welding

related command (recorded
in program) is executed, if
the control status of the axis
for corresponding gun Adjust the control status of
number is off. corresponding axis when a
E1454 (Axis 0) control status error
Or, case when a spot spot welding related
welding related command command is executed
(by independent drive) is
executed, if the control status
of the axis for corresponding
gun number is on .

Adjust the location so that

AXISCTRL ON command try
the AXISCTRL ON command
(Axis 0) Independent drive is to control the designated
E1455 can be executed after the
not terminated axis, and the axis is already
termination of the axis‟s
in independent drive
independent drive

1. Auto mode- Select the

correct program (or copy it
Started while the selected
Cannot find program correctly) and start
E1456 number‟s job program does
XXXX.JOB 2.Outer mode-Copy the
not exist
correct job program into it
and start

1. Auto mode-Outer stop

input signal must be off. Set
outer stop as 0 from the
assigned input signal to
Outer stop signal has
disable the outer stop
Start failed, because outer entered at the time of start
E1457 2.Outer mode- Please adjust
stop is entered (Check from the T/P input
the I/O sequence so that the
signal monitoring window)
outer start is activated after
the outer stop is released. Or
check if the signal
connection is normal

Start after the door is closed.

Door switch signal has
E1458 Start failed, because door Or check if the signal
entered at the time of start
switch signal is entered connection is normal

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Code Message Cause Remedy

Assignment value for input Please adjust the I/O

signal of program selection sequence so that the start
External program selection has changed momentarily signal is entered after the
E1459
input signal is unstable when remote mode started. program number signal has
(Check from the T/P input entered. Or check if the
signal monitoring window) signal connection is normal

Please adjust the I/O

sequence so that the
Program Strobe signal has external start is activated
Program Strobe signal is not
E1460 not been activated when the after the program Strobe
entered
remote mode started signal has entered. Or check
if the signal connection is
normal

Please adjust the I/O

sequence so that the
0 has entered as program external start is activated
Program selection signal
E1461 selection signal value when after the program selection
input is 0
the remote mode started signal value has entered. Or
check if the signal
connection is normal

1) Check the connection

status of communication line
between the controller and
welder
2)Check the status of
Communication error controller communication
Plasma welder is not
E1462 occurred between the Hi5 setting from
responding
controller and Plasma welder „System>>Control
Parameter>>Serial Port‟
3) Check the status of
communication with the
„Communication testing‟
function from the dialog

Check the cause of trouble

Plasma welder error(E01) Pilot ARC ignition has not
and fix it. Release the error
E1463 Pilot ARC ignition has not started within 2 seconds from
status of welder, and try to
started the activaton of Pilot.
ignitiate the Pilot

Check the cause of trouble

Main ARC ignition has not
Plasma welder error(E02) and fix it. Release the error
started within 2 seconds from
E1464 Main ARC ignition has not status of welder, and try to
the activaton of Main ARC
started ignitiate the Main ARC while
Pilot ARC is ignitiated.

Wait for the internal

Trance, reactor, temperature of power supply
Plasma welder error(E03) semiconductor is overheated unit cools down by the
E1465
Device overheat due to an operation internal fan, and release the
over-load error status of welder. Once
the error code that displayed

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 6. Troubleshooting

Code Message Cause Remedy

at the front of welder is gone,

continue with the operation

Check the cause and fix it.

Restart and try to run the
Plasma welder error(E04) Error is detected from the operation. If the problem
E1466
Primary over-current IGBT of welder‟s main persists, stop the operation
and please contact to the
welder‟s manufacturer

Check the pressure of Shield

gas. If the gas valve is
closed, open it and release
Plasma welder error(E06)
Pressure of Shield gas has the error status of welder.
E1467 Shield Gas pressure
reduced to below 0.15MPa Once the error code that
reduction
displayed at the front of
welder is gone, continue with
the operation

1) Check the pressure of

Pilot gas. If the gas valve is
closed, open it and release
the error status of welder.
Once the error code that
1) Pressure of Pilot gas has
displayed at the front of
reduced to below 0.15MPa.
Plasma welder error(E07) welder is gone, continue with
E1468 Pilot gas flux has decreased
Pilot Gas pressure reduction the operation
below 0.08L/min while
2) Check the cause to fix the
welding operation
error, and release the error
status of welder. Once the
error code that displayed at
the front of welder is gone,
continue with the operation

Check the cause (Blockage

of Torch waterway, reduced
pump performance, flux
sensor malfunction) to fix the
Plasma welder error(E06) Insuffienct flux of coolant
E1469 error, and release the error
Insuffienct flux of coolant Plasma
status of welder. Once the
error code that displayed at
the front of welder is gone,
continue with the operation

After the release of

emergency stop, release the
Plasma welder error(E09) Emergency stop signal is error status of welder. Once
E1470
Emergency stop entered the error code that displayed
at the front of welder is gone,
continue with the operation

Plasma welder error(E11) Error occurred from the Check the Chiller‟s
E1471
Chiller error Chiller‟s embedded coolant embedded coolant circulating

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 Hi5 Controller Maintenance Manual

Code Message Cause Remedy

circulating system, or when system to fix the problem

unit cooler is connected and release the error status
of welder. Once the error
code that displayed at the
front of welder is gone,
continue with the operation

Check the power voltage to

fix the problem and release
Plasma welder error(E20) the error status of welder.
Power voltage over 240V
E1472 Input over-voltage Once the error code that
has entered
displayed at the front of
welder is gone, continue with
the operation

Check the power voltage to

fix the problem and release
the error status of welder.
Plasma welder error(E21) Power voltage under 180V
E1473 Once the error code that
Input under-voltage has entered
displayed at the front of
welder is gone, continue with
the operation

Check the power voltage to

fix the problem and release
400V voltage has entered at
the error status of welder.
Plasma welder error(E81) 200V setting status, or 200V
E1474 Once the error code that
Over-voltage input voltage has entered at 400V
displayed at the front of
setting status
welder is gone, continue with
the operation

Restart and try to run the

Plasma welder error(E85) operation. If the problem
E1475 Power activation has failed
Activation failed persists, please contact to
the welder‟s manufacturer

Restart and try to run the

Plasma welder error(E94) Error occurred on a memory operation. If the problem
E1476
Memory error that stores the parameter persists, please contact to
the welder‟s manufacturer

Attempted while the motor is Check the motor on status

E1477 Execute on motor on status
not On and try it

Attemped while it is not on Check the auto mode status

E1478 Execute on auto mode
auto mode and try it

Maximum number of
independent executable
Number of independant
commands is four.
E1479 executable commands (4) Please contact to our office
Independent executable
exceeded
command that exceeds the
limit has been requested

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 6. Troubleshooting

Code Message Cause Remedy

Axis related to the The correspoinding axis to

Check the contro stats of the
independent executable the independent executable
E1480 axis for the operation
command is already in command is already in
Please contact to our office
operation operation

Servo gun related command

Servo gun related command
E1481 cannot be executed at the Please contact to our office
is already executed
same time

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 Hi5 Controller Maintenance Manual

6.4.3. Warning

Code Message Cause Remedy

Initialize the internal memory,

Backup memory It occurs when damage is found
W0001 and load all kinds of files
damaged in all kinds of files.
backed up in a diskette.

Controller temperature It occurs when the controller Refer to Troubleshooting

W0002
risen temperature is above 65. Manual.

Damaged program. Delete the program, and

W0003 Program to execute is damaged.
Delete it reload a backup program.

Emergency stop is It occurs when [Motor ON] in an Release emergency stop and
W0004
entered emergency. execute

Backup battery voltage

Backup battery voltage
W0005 connected to Main board BATCN Replace the backup battery.
dropped
connector is below the standard.

Please check the axis having

It happens when brake slip by the largest slip at brake slip
Brake slip!(Excess of set
W0009 compression during stud welding count.
value)
exceeds the installed value. Replace the motor where axis
has the largest slip.

In case of DeviceNet, check if

+24V of power supply line is
correctly connected, and
Fieldbus power is not measure the voltage with
W0010 Field bus power is not supplied.
supplied multimeter.
Take necessary actions to
correctly supply +24V power
to DeviceNet cable.

Check if field bus connector is

taken off.
Fieldbus network Field bus network connection is
W0011 Check if field bus network
connection error not normal.
cables are all in comply with
each field bus regulation.

Fieldbus IDLE state If PLC is in a program mode,

W0012 Master stops I/O operating.
(PLC STOP) change it to RUN mode.

If you want not to use filed

Field bus module is not
W0013 Field bus module is not sensed. bus, please install field bus
sensed.
use invalid.

Check if parameter setting is

Parameter setting for field bus
correctly done for filed bus
W0014 Fieldbus setting error master is not identical with that
master and slave. If any
of slave.
errors, then correct them

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 6. Troubleshooting

Code Message Cause Remedy

Check if there is any error in

BD420 board field bus has an BD420 field bus setting and
W0015 Fieldbus general error
error. field bus master setting, and
cabling.

- It is different from coworking

robot number.
The specified values for GE or
Improper use of GE or - GE: Min.=(robot #-1)*4+1,
W0016 DE variable are incorrect. The
DE signal No Max.=( robot #-1)*4+4
values are out of range.
- DE: Min.=( robot #-1)*32+1,
Max.=( robot #-1)*32+32

It happens when [motor ON] is Please check the status and

External emergency stop
W0017 done at the status that external manage at monitoring of
on
emergency halt is inserted. Private input signal.

#n node connection of
Occurs if the response is lost
W0018 embedded Fieldbus is Check the cable status
after a normal operation
disconnected

#n node input size of Occurs if the input size of Check the input module of
W0019 embedded Fieldbus corresponding node has been corresponding node, or
does not match changed execute [Re scan] function

#n node output size of Occurs if the output size of Check the output module of
W0020 embedded Fieldbus corresponding node has been corresponding node, or
does not match changed execute [Re scan] function

#n node I/O size of

Occurs if the I/O size of each Distribute input/output by
W0021 embedded Fieldbus is
node exceeds 16 bytes adding a Fieldbus adaptor
too large

#n node of embedded
Occurs if there is no response Check the cable status of
W0022 Fieldbus does not
after the power on corresponding node
respond

Master Mac(0) of Turn off the power and

Occurs if one of the node has
W0023 embedded Fieldbus is change the Mac of a node
Mac as same as Master Mac(0)
crashing with Mac=0

Follow the controller MANUAL

to check the encoder battery
(0 axis) Encoder battery Battery voltage is too low in axis in corresponding axis.
W0104
voltage drop (○) encoder. Check the Battery connection
of corresponding axis
encoder.

It occurs when total tip

consumption detected with gun Inspect the unfixed tip and
(0 gun) Tip consumption
W0105 search is in excess of tip fixed tip consumption, and
exceeded limit!
exchange wear set in servo gun replace the tip.
parameter.

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Code Message Cause Remedy

It occurs when total tip

(0 gun) Move-tip consumption detected with gun Inspect the unfixed tip and
W0106 consumption exceeded search is in excess of tip fixed tip consumption, and
LMT. exchange wear set in servo gun replace the tip.
parameter.

It occurs when fixed tip

(0 gun) Static electrode consumption detected with gun
Inspect the fixed tip, and
W0107 exceeded exchange search is in excess of unfixed tip
replace the tip.
wear level. exchange wear set in servo gun
parameter.

Check if force is sufficiently

It occurs when actual value of set for the axis you intend to
pressure is in excess of set operate.
In jog moving, Pressure
W0108 value in manual pressurizing. Make contact with servo gun
exceeded!
Here operate the servo gun axis manufacturer because
in the opposite direction. mechanical problem is
anticipated in servo gun.

Servo gun should be operated

The servo gun you intend to by manual jog after being
Change gun No. to jog
W0109 operate is different from the selected. Select the servo gun
this SVG
selected servo gun number. you intend to operate with
R210 code before operating.

Check whether the

This occurs when the
pressurization force level of
Set to condition of not pressurization force level of the
the servo gun parameter
W0110 detecting pressurization servo gun parameter menu or
menu or the pressurization
force. the pressurization force error
force error detection delay
detection delay time is not set.
time.

This warning occurs when the

Please expand error detecting
returning distance
distance of previous position
simultaneously with motor ON
Previous position return recovery. Please make
W0111 input is larger than the set value
detection recovery function for previous
of error detecting distance in
positin invalid. Please contact
case of enable returning function
to A/S of HHI..
in [Motor ON].

This occurs when the returning

distance simultaneously with Set the returning distance
Previous position return
W0112 motor ON input is larger than the setting to be larger than the
distance
set value in case of enable existing set value.
returning function in [Motor ON].

1) Please start again from

step having WEAVON
It happens weaving movement,
Impossible to maintain command.
which is made when WEAVON
W0116 weaving movement used 2) If welding, after starting
command is performed, cannot
previously. from command that WEAVON
be maintained.
command is recorded by OFF
status and moving to the point

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 6. Troubleshooting

Code Message Cause Remedy

where weld is cut off, please

change into weld ON status
and make progress on.

Robot is in a posture of high Change the robot‟s posture by

Jog will make overspeed speed while manually operated manipulating with articulation
W0117
CMMD. in rectangular coordinate system coordinate before operating it
or tool coordinate system. manually.

You may use the existing

The robot may be used, but it
functions as they are, but for
1st servo CPU version is has problems in the use of some
W0118 the use of new functions,
Old functions due to the old version
please make contact with our
of 1st servo board CPU.
A/S to update the version.

You may use the existing

The robot may be used, but it
functions as they are, but for
2nd servo CPU version has problems in the use of some
W0119 the use of new functions,
is Old functions due to the old version
please make contact with our
of 1st servo board CPU.
A/S to update the version.

The robot may be used, but it You may use the existing
has problems in the use of some functions as they are, but for
3rd servo CPU version is
W0120 functions due to the old CPU the use of new functions,
Old
version of 1st servo in the 2nd please make contact with our
servo board. A/S to update the version.

The robot may be used, but it You may use the existing
has problems in the use of some functions as they are, but for
4th servo CPU version is
W0121 functions due to the old CPU the use of new functions,
Old
version of 2nd servo in the 2nd please make contact with our
servo board. A/S to update the version.

Stop instruction is received from

Start running a master to
the partner robot during cowork
Stop input from partner resume a program after
W0123 control operation. In this case,
robot starting the robot on the part
the above message is output,
of slave.
and the robot stops.

To operate each robot

individually in a manual mode,
It is set as salve in the condition
change the condition of
Slave is Impossible to of manual cowork control. The
W0124 manual cowork.
jog robot set as slave is impossible
To change the condition of
to operate separately.
manual cowork, users need to
use F key or R351 code.

It is normal if it occurs when

The position of servo gun
servo gun is initially
attached by GUNCHNG ON
connected.
Invalid position of instruction or instruction for
W0125 If it occurs other than the
connected SVG manual gun connection is
initial connection, check the
different from the one remained
followings.
in its memory when separating.
It may occur if an incorrect

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 Hi5 Controller Maintenance Manual

Code Message Cause Remedy

servo gun is selected.

Thus, check this out. And
check if encoder battery of
servo gun is sufficient.

Among robots connected to

Only one Master for manual
Jog Prohibited - Master HiNet are more than two robots
W0131 cowork is possible to set.
overlapped set as Master in their manual
Change the setting.
cowork.

Check if Slave robot is

Jog operation is attempted for
selected, and get it ready to
Jog Prohibited - No Master robot without setting the
W0132 be available to cowork before
slave selected Slave robot to be available to
operating(Jog Off/Enabling
cowork.
Switch On).

A robot chaged its manual

cowork is detected among the Doublecheck the cowork
Slave jog status are
W0133 coworking Slave robots Master condition of Slave before
changed-Stop
during cowork jog operation with operating.
robot.

It occurs when attempting to

operate jog for Slave robot in a
CMOV recording mode( R351,3).
Master robot is not specified.
Or it may occur when using
Master Tool Coord. isn't Set a correct master robot for
W0134 forwarding function of CMOV
selected manual cowork Master.
step.
The currently set number of
Master is different from the
recorded Master number in
CMOV.

During the manual operation of a

Manual operation Check if axis B is near 0deg.
cross coordinate and a tool
generated by a high An axial coordinate must be
W0137 coordinate, the speed of the tool
speed - order from a tool operated in a manual manner
end of the robot exceeded safety
end. when axis B is near 0deg.
speed limits.

Under current operational

conditions, the user is
The remaining rated life of the
N axis] The remaining requested to prepare a
decelerator of the corresponding
rated life of a decelerator replacement of the
W0138 axis is calculated into a value of
of N axis is less than decelerator with reference to
less than 10% of the initial
10%. the expected life of the
specification value.
decelerator of the
corresponding axis.

Tool‟s weight is too small

Tool is in excess of Check the tool‟s weight/center
compare to the actual value.
W0139 permissible value for tool of weight value, gravity
Robot‟s excessive operation is
weight error direction or base position
expected

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 6. Troubleshooting

Code Message Cause Remedy

Based on current operating

Check if the property of
condition, the expected life span
The expected life span material rate for the tool has
of reduction gear for the axis is
W0140 of the reduction gear: been entered correctly. If it is,
less than 40,000 hours. Earliy
less than 40,000 hours please enquire to the
break of reduction gear is
engineer
predicted

If operation requires the

Activating in safe speed as the
Safe restart mode recorded speed rather than
W0143 location corresponding step has
activated safe speed, please turn off the
been changed from the restart
motor and restart

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 7. Regular inspection

7. Regular inspection

7
Regular
inspection

7-1
 7. Regular inspection Hi5 Controller Maintenance Manual

Regular inspection of controller is to minimize robot failures, and to maintain its efficiency. Instructions
and working details for regular inspection are explained here.

7.1. Inspection Schedule

The check is conducted basically according to following review. Regular inspection is to prevent robot
failures, and to secure and maintain its stability even for a long employment of robot and controller.
Regular inspection is a requisite for the use of robot, and even for a normal condition.

750H 1500H 3000H 5000H

Daily일상점검
inspection Repeating3개월
from 점검부터
3 months 반복
inspection

3개월
3 months 점검
inspection 3개월
3 months 점검
inspection 3개월inspection
3 months 점검 3개월inspection
3 months 점검

6개월inspection
6 months 점검 6개월
6 months 점검
inspection 6개월
6 months 점검
inspection

1년
Annual 점검
inspection 1년
Annual 점검
inspection

Figure 7.1 Inspection Schedule

7-2
 7. Regular inspection

7.2. General Instructions for Regular Inspection

① Inspection working should be performed by a personnel who completed our training

course in robot school.
② Check the necessary parts & tools, and drawings before inspection work.
③ Be sure to use special replacement parts specified by our company.
④ Be sure to turn power OFF when inspecting robot manipulator.
⑤ Turn primary power OFF when working with controller door open. Prevent dust or other
things from entering the working area.
⑥ Pay close attention to IC breaking by static electricity if you need to touch the parts of
controller. ( Beware of it when touching a connector)
⑦ Be sure to forbid anyone to enter robot‟s working envelope when performing an
inspection with robot manipulator operated.
⑧ Perform a voltage measurement in a specified place, and be careful of electric shock
and short circuit.
⑨ Do not inspect robot and controller at the same time.
⑩ Be sure to perform a test operation after inspection to check robot‟s movement before
normal operation.

7-3
 Hi5 Controller Maintenance Manual

7.3. Daily Inspection

Table 7-1 Daily Inspection
Inspection
No. Inspection Details Remarks
Part
Check with the
1 Controller Is display lamp working (normal)?
naked eye
Check with the
Is door completely closed?
naked eye
Check with the
Are there any errors in Teach Pendant screen?
naked eye

Is there a noise during operation? Listen out

Robot
2
Manipulator
Is a tip joint unscrewed? Fasten

Are there any scratch, stain, and damage in a wiring and Check with the
Wire harness of manipulator? naked eye
Check with the
Are there any other impediments such as dust soil
naked eye &
causing a damage to manipulator?
clean
Are there any obstacles around controller and robot Check with the
3 Others
manipulator? naked eye

7.4. First Inspection (750 hours inspection)

Table 7-2 First Inspection

No. Inspection Part Inspection Details Remarks

1 External, major screws Unscrewed Fasten

2 Manipulator wiring connector & Wire harness Loose connector Fasten

3 Dog & limit switch screws Unscrewed Fasten

7-4
 7. Regular inspection

7.5. Daily Inspection

Table 7-3 Daily Inspection
Cycle
Inspection
No. (months) Inspection Details Remarks
Part
3 6 12
Packing of
1 ◎ ◎ ‧ Transformed & torn part
door
‧ Dust & rotation in cooling fan wings of
heat exchanger
‧ Damage & dust in regenerative discharge
2 ◎ ◎ ◎ Back side
resistance
‧ Check a heating of Transformer Room by
touch, and clean the room.
3 ◎ ◎ ◎ Wire harness ‧ Loose & damaged connector
4 ◎ ◎ Drive Unit ‧ Loose & damaged connector
Connectors of
5 ◎ ◎ ‧ Check a loose connector by touch
each board
Operating
6 ◎ ◎ ◎ ‧ Check Button switch & LED
panel
Overall
7 ◎ ◎ ‧ Dust cleaning
Controller
8 ◎ ◎ ◎ Nameplate ‧ Inspect all kinds of nameplates

‧ Primary power voltage

‧ R1, S1, T1 Refer to

“6.3.1
Voltage
9 ◎ ◎ ‧ C2, B2 Adjustment
measurement
of Power
‧ SMPS (HDI-200) System”
‧ BKSMPS (CP SNT 250W) : Brake power
10 ◎ ◎ Grounding ‧ Check a loose & removed terminal
11 ◎ ◎ Battery ‧ Voltage inspection & regular replacement Main LED
‧ Exterior inspection, and damage & joint
part of connector checking
12 ◎ ◎ ◎ Teach Pendant ‧ Check LCD Display
‧ Check LED Display
‧ Check emergency stop switching
◎ ◎ ◎
(operating panel, teach pendant)
‧ Check primary power disconnecting
◎ ◎ ◎
switch(DS1)
Safety related
13 ◎ ◎ ◎ ‧ Check enabling device of teach pendant
parts
◎ ◎ ◎ ‧ Check circuit protector (CP1,CP2)
‧ Check magnet connector
◎ ◎ ◎
(MSHP,MSPB,MSDB)

7-5
 Hi5 Controller Maintenance Manual

Cycle
Inspection
No. (months) Inspection Details Remarks
Part
3 6 12
Safety related ‧ Check for BD530 board (connector,
14 ◎ ◎ ◎
PCB exterior relay of board)

7-6
 7. Regular inspection

7.6. Inspection for Long-Term Idleness

In case of long-term idleness, inspect the followings before turning off power.

(1) Check if LED for battery discharge detection is normal in mainboard. If there is an error in
battery, LED is turned OFF. In this case, replace it with a rated battery. If turning off a primary
power with errors in battery, all program/constant data in a board will be deleted after about 7
days. Thus be sure to back up the program data by using HRView, etc.

(2) Check if controller door is completely closed.

7-7
 Hi5 Controller Maintenance Manual

7.7. Parts List for Maintenance

It explains the characteristics of parts.

Maintenance Parts A

Major maintenance parts to prepare in daily inspection.

To maintain a normal operation, parts A-2 and A-3 is a minimum of essential parts, and prepare more
than 1 set of these parts.

Table 7-4 Maintenance Parts Inspection A

Type Details Remarks

Maintenance Parts A-1 Standard accessory parts to prepare

Maintenance Parts A-2 Major backup parts

Maintenance Parts A-3 Regular replacement parts

Table 7-5 Maintenance Parts A-1 (Standard accessory parts to prepare)

No. Product Name Type Maker Quantity(EA) Remarks

1 Fuse (F1,F2) GP50 Daito 2 250V, 5A

2 Fuse (F3,F4) GP100 Daito 2 250V, 10A

3 Fuse (F5,F6) GP50 Daito 2 250V, 5A

4 Fuse (Servo AMP) GP20 Daito 2 250V, 2A

7-8
 7. Regular inspection

Table 7-6 Maintenance Parts A-2 (Major Backup Parts)

No. Product Name Type Maker Quantity(EA) Remarks

Middle size /
1 Servo AMP HHI 1
Small size

2 Complex Power Unit HDI-200 HHI 1 SMPS

3 Teach Pendant TP510 HHI 1

4 Electronic module PDM30/PDM15 HHI 1

Back plain
BD501 HHI 1
board

BD510 HHI 1 Main board

5 Board
BD542 HHI 2 Servo board

System
BD530/531 HHI 1
board

Table 7-7 Maintenance Parts A-3 (Regular Replacement Parts)

No. Product Name Type Maker Quantity(EA) Remarks

Hitachi Maxwell Replacement required

1 Battery(3.6V AA size) ER6C 1
(JAPAN) every 2 years

7-9
 Hi5 Controller Maintenance Manual

Maintenance Parts B

To many maintain a normal operation parts.

Table 7-8 Maintenance Parts Inspection B

Type Details Remarks (reference)

Maintenance Parts B-1 Parts to purchase from HHI, Ltd.

Maintenance Parts B-2 Purchasable Parts from Maker

Table 7-9 Maintenance Parts B-1 (Parts to purchase from HHI (Co.,Ltd.))

No. Product Name Type Maker Quantity(EA) Remarks

CMC1 HHI (Co.,Ltd.) 1

Controller ⇔ Robot
1 Wire harness CMC2 HHI (Co.,Ltd.) 1
Manipulator

CEC1 HHI (Co.,Ltd.) 1

Table 7-10 Maintenance Parts B-2 (Purchasable Parts from Maker)

No. Product Name Type Maker Quantity(EA) Remarks

Circuit Breaker for

1 - - 1
wiring (NFB)
Magnetic Contactor
2 - - 2
(MC1, MC2)
Circuit Protector
3 - - 1
(CP1)

7-10
 7. Regular inspection

Caution : Pay attention to the followings for maintenance because

high-performance parts are mounted on board.

Storage Temperature 0℃ ~ +45℃

To store for a long period of time and maintain high-reliability, keep temperature ranged 25±10℃ and
avoid sudden change of temperature(±10℃/time).

Storage Humidity 20% ~ 80%

To store for a long period of time and maintain high-reliability, keep humidity ranged 45%~65%, and in
particulas, be careful of dew condensation.

Electric Shock Prevention

If extremes are kept dry, static electricity is likely to be charged. Here, semiconductor is likely to be
ruined when the charged static electricity is discharged. Thus, when keeping the board separately, use
an antistatic treated packing materials.

Others

Please keep at the place where noxious gas, dust and load do not exist.

7-11
● Head Office ● A/S Center
Tel. 82-52-202-7901 / Fax. 82-52-202-7900 Tel. 82-52-202-5041 / Fax. 82-52-202-7960
1, Jeonha-dong, Dong-gu, Ulsan, Korea

● Seoul Office
Tel.82-2-746-4711 / Fax. 82-2-746-4720
140-2, Gye-dong, Jongno-gu, Seoul, Korea

● Ansan Office
Tel.82-31-409-4945 / Fax.82-31-409-4946
1431-2, Sa-dong, Sangnok-gu, Ansan-si, Gyeonggi-do, Korea

● Cheonan Office
Tel.82-41-576-4294 / Fax.82-41-576-4296
355-15, Daga-dong, Cheonan-si, Chungcheongnam-do, Korea

● Daegu Office
Tel.82-53-746-6232 / Fax.82-53-746-6231
223-5, Beomeo 2-dong, Suseong-gu, Daegu, Korea

● Gwangju Office
Tel. 82-62-363-5272 / Fax. 82-62-363-5273
415-2, Nongseong-dong, Seo-gu, Gwangju, Korea

● 본사 ● A/S 센터
Tel. 052-202-7901 / Fax. 052-202-7900 Tel. 82-52-202-5041 / Fax. 82-52-202-7960
울산광역시 동구 전하동 1 번지

● 서울 사무소
Tel. 02-746-4711 / Fax. 02-746-4720
서울특별시 종로구 계동 140-2 번지

● 안산 사무소
Tel. 031-409-4945 / Fax. 031-409-4946
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● 천안 사무소
Tel. 041-576-4294 / Fax. 041-576-4296
충남 천안시 다가동 355-15 번지

● 대구 사무소
Tel. 053-746-6232 / Fax. 053-746-6231
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● 광주 사무소
Tel. 062-363-5272 / Fax. 062-363-5273
광주광역시 서구 농성동 415-2 번지