3 Parts replacement and Adjustment

This chapter explains how to parts replacement and adjustment.

3.1 Parts replacement.......................................................................................3-1

3.1.1 Replacement of a CPU board ...............................................................3-2
3.1.2 Replacement of a storage board.........................................................3-13
3.1.3 Replacement of an I/O board ..............................................................3-14
3.1.4 Replacement of a DC Power supply unit.............................................3-15
3.1.5 Replacement of a sequence board .....................................................3-16
3.1.6 Replacement of a drive unit ................................................................3-17
3.1.7 Replacement of a power unit ..............................................................3-19
3.1.8 Replacement of a battery for calendar ................................................3-21
3.1.9 Replacement of cooling fan motor ......................................................3-22
3.2 Adjustment................................................................................................3-24
3.2.1 Adjustment of power system ...............................................................3-24
3.2.2 Transformer tap change......................................................................3-26
3.3 Moving the robot in an emergency............................................................3-27
3.3.1 Brake release switches (option) ..........................................................3-27
3.3.2 Over-travel LS release switch .............................................................3-30
3.3.3 Software limit ......................................................................................3-30
 3.1 Parts replacement

3.1 Parts replacement

Replacement of Printed circuit boards or drive unit of an AX controller can be performed in about 10 minutes.
Consider safety first and observe the following cautions.

Proceed with inspection or replacement after supply power has been

OFF 5 minutes or more. ( : IMPORTANT)
Do not perform work with wet hands. ( : DO NOT)
Electric shock may cause fatal or serious injury.

Maintenance can only be performed by persons who have completed

the Robot Maintenance Course given by Nachi-Fujikoshi.( :
MANDATORY)
Maintenance by unskilled persons may cause fatal or serious injury.

Before handling electrical components/circuit boards momentarily

connect the operator hand with "Ground terminal" of the controller to
ensure both are the same electric potential.( : MANDATORY)
Electric shock may cause fatal or serious injury.

When replacing electrical components (teach pendant, power supply,

circuit boards, etc.) the main power must be OFF.（ （ : IMPORTNAT)
When replacing components check and be sure that all connection
are correctly installed. Do not leave any connectors disconnected
before main power is turned ON.（ （ : IMPORTNAT)
Electric shock or electrical fire may cause fatal or serious injury.

Do not damage wiring/cables when replacing the components. ( :

IMPORTNAT)
Take care not to touch electronic parts on circuit boards. Handle
PCBs by their edge. Take care not to touch the electronic connector
pin.( : IMPORTNAT)
Electric shock may cause fatal or serious injury.

If controller door is open and main power is ON use caution.

1. Use caution when using extension lights not to burn wires/cables or
over heat electrical components. ( : IMPORTNAT)
2. Use caution not to press brake release switch. ( : IMPORTNAT)
3. Do not leave controller door open during normal operation.
May cause fatal or serious injury.

3-1
3.1 Parts replacement

3.1.1 Replacement of a CPU board

Make sure that the primary power source is turned off, and carry out the work after lapse of five minutes or more.
Electric charge is still left in the board and the electrolytic capacitor. According to the shipment time of the controller,
there are two kinds of CPU boards (AXCPU10-10 and AXCPU10-20). As for details, refer to the following pages.

(1) When to replace AXCPU10-10 →p3-3

(2) When to replace AXCPU10-20 →p3-4
(3) When to replace AXCPU10-10 with AXCPU10-20 →p3-5
(4) When to replace AXCPU10-20 with AXCPU10-10 →p3-12

(Reference) Comparison of AXCPU10-10 and AXCPU10-20

Board name AXCPU10-10 AXCPU10-20
• Micro processor and its peripheral circuit
• Communications with a drive unit
Same function • Ethernet
• I/F with an optional board
• Calendar (backup by battery)
Part of functions of the storage board
The following functions are used via
(UM204) are moved to the CPU
the storage board (UM204).
Different function board.
System CF, Backup CF
System CF, Backup CF
Communications with a teach pendant
Communications with a teach pendant
Storage board / UM204-10 (Standard specifications) UM235-10 (Standard specifications) (Note)
interrupt output board UM204-20 (Arc welding specifications) UM204-10 (Arc welding specifications)
Connected to CN1 on a riser board
Note in attaching Storage and CPU shall be connected by Connection between storage and CPU
the following two cables. shall be only by TP 12V cable.
CPU board
TP screen display cable : CNLCD - CN5 UM235: CNP122 - CNEXTPOW (Note)
RS422 cable : CN422 - CN3 UU204: CNTPC - CNEXTPOW
Connected to CNCF on CPU board
Connected to CNCF on a storage
System CF (CNCF of a storage board is not in
board
use)
Connected to CPU board
Connected to CNPC on a storage
Backup CF (CNPC of a storage board is not in
board
use)
Connected to CNTPC on CPU board
Connected to CNTPC on a storage
Teach pendant (Teach pendant cannot be connected
board
to CNTPC of a storage board.)
AX system AXV06 or higher required
All versions are available Version that supports AXCPU10-20
System OS
required
Note) The name of the UM235 board is "interrupt output board", but is used in the place of "storage board".

! When optional software is installed:

After you replace the CPU boards, ask our service center to reset the optional
CAUTION software. If it is not set, all the optional software items will be locked after two weeks.

When using AXCPU10-20:

! System CF card is attached to AXCPU10-20 at shipment.

The system CF card (loaded on a storage board) of the controller shipped at the same
CAUTION time with AXCPU10-10 cannot be used in AXCPU10-20. If the system CF card for
AXCPU10-20 is necessary, contact our service center.

3-2
 3.1 Parts replacement

When system CF card is damaged:

! When system CF card is damaged, prepare a new system CF card. In this case, it is
necessary to create a temporary setting (Refer to p3-7), and to restore the file (Refer
CAUTION to p3-11). As for the new system CF card, contact our service center.

[When to replace AXCPU10-10]

Procedures
(1) Remove the screws at the top and the bottom of (2) Loosen the connector fixing plate attachment screw
the fixing bracket. on the fixing bracket. (There is no need to remove the
connector fixing plate.)

(3) Pull out the CPU board together with the fixing (4) Remove the connector connected to the CPU
bracket. board, and pull out the board.

(5) Connect the connector to the CPU board.

(6) Insert the CPU board into the riser board (UM209) in the board rack.
(7) Fix the board to the rack with screws at the top and the bottom of the fixing bracket.
(8) Slide the connector fixing plate on the fixing bracket to fix the connector, and fix the connector fixing plate with screws.

(9) Turn ON the main power source of the AX controller, and confirm that the AX system starts normally.

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3.1 Parts replacement

[When to replace AXCPU10-20]

Procedures
(1) Remove all the 12V power cables CNEXTPOW, (2) Remove the screws (2 portions) on the CPU board
CNTPC, and CN4 from the CPU board. fixing bracket, and remove the CPU board.

CNEXTPOW

CNTPC

CN4

(3) Remove the system CF card from CNCF on the (4) Insert the new CPU board into the CPU unit, and
CPU board. Attach the removed CF card to a new fix it with screws.
CPU board.

CNCF

CNPC

(5) Connect all the connectors. (6) Turn ON the main power source of the AX
controller, and confirm that the AX system starts
normally.
CNEXTPOW

CNTPC

CN4

3-4
 3.1 Parts replacement

[When to replace AXCPU10-10 with AXCPU10-20]]

In this case, the storage board (UM204) attached originally can be used as it is. However, it must be started by a new
system CF card, therefore it is necessary to create a temporary setting. Pay attention to it.

Preparation

• CPU board (AXCPU10-20)

• 12V power cable (for connection of CNEXTPOW and CNTPC)
• System CF card (for AXCPU10-20)
• Backup CF card

Procedures

(1) First, back up the work program and settings by use of the backup CF card. As for the backup procedure, refer to
the operation manual "Basic Operations".

(2) Remove CNTPC, CN422, and CNLCD from the storage board.

CN422

CNTPC

CNLCD

(3) Pull out the storage board from the slot, and then disconnect the system CF card from CNCF of the storage board.
Remove the CF card from CNPC too. Then, attach tapes etc. to CNCF and CNPC to make them not to be used.
Then, attach the storage board to the CPU unit.

CNPC

Backup CF card

System CF card

CNCF

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3.1 Parts replacement

(4) By reference to "When to replace AXCPU10-10" (p.3-3), remove AXCPU10-10 from the CPU unit.

(5) Attach the backup CF card to CNPC of AXCPU10-20. Use the system CF card that is originally loaded on CNCF
of AXCPU10-20.

CNPC Backup CF card

(6) By reference to "When to replace AXCPU10-20" (p.3-4), attach AXCPU10-20 to the CPU unit.

(7) Connect the CNEXTPOW of AXCPU10-20 and CNTPC of the storage board by the power cable.
(Connect the CNEXTPOW connector in advance.)

Storage board
(UM204)

CPU board
CNTPC CN422 (AXCPU10-20)
CNLCD

CNPC
CNCF
CNEXTPOW

CNTPC

(8) Connect the teach pendant cable to CNTPC of AXCPU10-20.

CNTPC

Now, the hardware connection is complete.

In the next step, temporary setting necessary for startup of the AX system software is created.

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 3.1 Parts replacement

[Performing a temporary setting]

The temporary setting necessary for startup of the controller is created. The setting created here is overwritten by a
backup file later, therefore, there is no need to set it same as the actual structure.

(1) Turn on the main power source of the AX controller.

(2) In the case of a new system CF card, because there is not a constant file necessary for startup, the following
screen is displayed.

(3) Press [Enter].

>> The following menu is displayed. (Japanese or English is displayed.)

(4) In order to change languages, select "12 Change the displaying language" and press [Enter].
>> The displaying language is changed as shown below.

(5) Select "1 Format" and press [Enter].

>> The confirmation screen is displayed.

3-7
3.1 Parts replacement

(6) Select [OK] and press [Enter].

>> The following screen is displayed.

(7) Press [1] and press [Enter].

>> The following screen is displayed.

(8) Select "SH166-03" in the column of mechanism 1, press [Enter] and press the f12 "Complete".
>> The message is displayed, so select [OK] and press [Enter].

(9) The following screen is displayed automatically.

3-8
 3.1 Parts replacement

(10) Press the f12 "Complete".

>> The following confirmation screen is displayed, so select [OK] and press [Enter].

(11) The following confirmation screens are displayed, so select [OK] and [Yes] in all the screens.

(12) The following screen is displayed.

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3.1 Parts replacement

(13) Select "7 axis Amplifier" in the item of "Servo Amplifier 1", and press the f12 "Complete".
>> The following screen is displayed.

(14) Set 1 to "Amp. number" and 1 to "Start axis", and press the f12 "Complete".
>> The following message is displayed.

(15) Turn OFF the main power source of the AX controller, and then turn it ON.

(16) The following screen is displayed. Press [R reset] to exit the screen.

Now, the temporary setting is complete.

Go on to the step of the "File Restore" (p3-11).

! At this stage, the robot will not work normally. Do not turn ON the motor power.
Otherwise, the robot works unexpectedly, and if a worker is contacted or caught in,
DANGER death or serious accident results.

3-10
 3.1 Parts replacement

[File Restore]

(1) Input [R] [3] [1] [4] [Enter] [Enter], and switch the operator qualification into EXPERT.
Note) As for details of the operator qualification, refer to the operation manual "Installation".

(2) Select [Service Utilities] [File Manager] [File Restore].

>> The following screen is displayed.

(3) Select "IC Card 1" in "Device (src)".

(4) Move to the folder selection column by use of left and right of cursor keys, select the folder of the backup file you
want to restore, and press [Enter]. Example: "NRA2001-2004-11-23-0927"

(5) Press the f12 "Execute".

>> File restore process is started.
In the course, a message "Option data is restored. In the case of a CPU board different from one at backup, option
has a time limit" is displayed, and then select [Yes] and press [Enter].

Now, file restoring is complete.

! When optional software is installed:

After you replace the CPU boards, ask our service center to reset the optional
CAUTION software. If it is not set, all the optional software items will be locked after two weeks.

3-11
3.1 Parts replacement

[When to replace AXCPU10-20 with AXCPU10-10]

Preparation
• CPU board (AXCPU10-10)
• Storage board (UM204-10) * Only when UM235 is used in the controller
• RS422 cable (blue and white cable)
• LCD cable (green flat cable covered with rubber)
Procedures
(1) If UM235 is attached to the CPU unit, remove UM235.
In the case of the storage board (UM204) too, remove the board from the CPU unit.

(2) By reference to "When to replace AXCPU10-20" (p.3-4), remove AXCPU10-20.

(3) Remove the system CF card from CNCF of AXCPU10-20, and attach it to CNCF of the storage board.(When
CNCF and CNPC are covered with tapes, remove the tapes.)

System CF
CNCF card

CNPC

Backup CF card
CPU board (AXCPU10-20) Storage board

(4) By reference to "3.1.2 Replacement of a storage board", attach the storage board to the CPU unit.

(5) By reference to "When to replace AXCPU10-10" (p.3-3), attach AXCPU10-10 to the CPU unit.
(Connect the RS422 cable and the LCD cable too without fail.)

(6) Connect the teach pendant connector to CNTPC of the storage board.

CNTPC

(7) Turn ON the main power source of the AX controller, and confirm that the AX system starts normally.

3-12
 3.1 Parts replacement

3.1.2 Replacement of a storage board

In the case when the system CF card is damaged, prepare a new system CF card,
! and attach it to CNCF of the storage board. In this case, it is necessary to create a
temporary setting once (Refer to p3-7), and restore the file (Refer to p3-11). As for the
CAUTION new system CF card, contact our service center.

In the case to use AXCPU10-20 as the CPU board, part of procedures are different.

! • CN422 and CNLCD are not used.

• 12V power source cable is connected to the CNTPC connector.
CAUTION • The system CF card is not connected to CNCF.
(The system CF card is connected to the CPU board.)
Removal
(1) Remove screws (2 portions) of the fixing (2) Remove all the connectors. (CNTPC, CN422,
bracket. CNLCD)

CN422

CNTPC

CNLCD

(3) Take out the storage board. Remove the system

CF card from CNCF.

CNCF

Installing
(1) Attach the system CF card to CNCF of the new storage board.
(2) Insert the board into the rack along the board guide rail of the rack, and make sure that the board is inserted to the
depth.
(3) Fix the fixing bracket with screws.
(4) Attach the connectors (CNTPC, CN422, CNLCD) to the board.

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3.1 Parts replacement

3.1.3 Replacement of an I/O board

Removal
(1) Remove screws (2 portions) of the fixing metal. (2) Remove all the connectors attached to the board
(CNIN, CNSQ, CNOUT). Open the lock levers at both
the sides outward to remove the CNSQ connector.
Loosen screws fixing the connectors to remove CNIN
and CNOUT.

CNIN

CNSQ

CNOUT

(3) Grip the fixing bracket attached to the board,

and take out the board.

Installing
(1) Insert the board into the rack along the board guide rail of the rack, and make sure that the board is inserted to the
depth.
(2) Fix the fixing bracket with screws.
(3) Attach the connectors to the board. Insert the CNSQ connector and fasten it until the lock levers at both the sides
sound click. Fix CNIN and CNOUT with screws.

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 3.1 Parts replacement

3.1.4 Replacement of a DC Power supply unit

Please confirm the controller power supply is turned off, and work after the passage of five minutes or more. The
charge remains in the PCB and the capacitor.

Removal
1) Remove all connectors attaching the unit.
2) Removing screws fixing the unit to the cabinet.
3) Pull the unit clear of the cabinet. At this time, please take care not to touch internal switching regulated power
supply (SR1, SR2 and SR3).

1) 2)

Installing
1) Place the unit into the correct position in the cabinet.
2) Fix the unit to cabinet with screws.
3) Correct reattach all connectors to the unit.

Note
• Take care not damage the unit when removing wires that are hooked around other parts of the unit.
• Ensure all connectors are attached. If not connected an error will result.

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3.1 Parts replacement

3.1.5 Replacement of a sequence board

Please confirm the controller power supply is turned off, and work after the passage of five minutes or more. The
charge remains in the PCB and the capacitor.

Removal
1) Remove all connectors attaching the sequence board (UM213).
2) Removing screws fixing the board to the cabinet.

Installing
1) Fix the board to cabinet with screws.
2) Correct reattach all connectors to the board.

Note
• Take care not damage the unit when removing wires that are hooked around other parts of the unit.
• Ensure all connectors are attached. If not connected an error will result.

CNIN

CNP

CNP5V

CNSQ

CNSWO

CN422

CNTPC CNAC
CNOUT

CNPC F1
CN3

CN4

CNSQ

CNTP

D/A CNFAN
CNOP
Sequence board
CNP5V
1

(UM213)
CNFM

HC7244
CNUSB

HC32
NF5

CNSV
CNSV
H8S

HC7244

HC7244

HC7244
CNSB4

LVX4245

HC7244

HC7244
2
1

CNMS

CNH
CNBK1

CP1
CNBK2

CNAC1 CNAC

NF NF NF NF

CNEC1 CNEC2 CNP5E F1(R)

F2(L)
17

25

27 26 2 1
18

24

1
35

19

50
CNH

36

20

49

F2 F1

CNH CNPW

3-16
 3.1 Parts replacement

3.1.6 Replacement of a drive unit

Please confirm the controller power supply is turned off, and work after the passage of five minutes or more. The
charge remains in the PCB and the capacitor.

Removal
1) Remove all connectors attaching the unit.
2) Removing screws fixing the unit to the cabinet.
3) Pull the unit clear of the cabinet. At this time, please have the case so as not to touch internal capacitor or
PCB.

Installing
1) Place the unit into the correct position in the cabinet.
2) Fix the unit to cabinet with screws.
3) Correctly install connectors to the unit.

Note
• Do not hit the heat sink with the rear of the drive unit.
• Take care not to damage the drive unit when removing wires that are hooked around other parts of the drive
unit.
• The drive unit is heavy (about 15kg (33lbs)) therefore do not drop it on people’s feet.
• Ensure all connectors are attached. (If not connected an error will result.)
• Tighten screws on the encoder connector CNEC1, CNEC2.

CNIN

CNP

CNP5V

CNSQ

CNSWO

CN422

CNTPC CNAC
CNOUT

CNPC F1
CN3

CN4

Screws to fix the unit to the

controller
CNSQ

CNTP

CNOP
D/A CNFAN
CNP5V
1

This figure is applied to a controller

CNFM

HC7244
CNUSB

HC32
NF5

CNSV
CNSV

shipped in or before January 2003.

H8S

HC7244

HC7244

HC7244
CNSB4

LVX4245

HC7244

HC7244
2
1

CNMS

CNH
CNBK1

CP1
CNBK2

CNAC1 CNAC
NF NF NF NF

CNEC1 CNEC2 CNP5E

F1(R)
F2(L)
17

20 19 2 1

25

27 26 2 1
18

24

1
35

50
CNH

36

49

F2 F1

CNH CNPW

CNEC1 CNEC2

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3.1 Parts replacement

Screws to fix the unit to the

controller

This figure is applied to a

controller shipped in or after
January 2003.

Because the communications between the drive unit in which the servo

! communication software below CX01.50 is installed and the system software

AXV06.08 or higher cannot be made, "E9208 Servo communication initialization
failure" occurs, and the robot cannot be operated. In the case of use in combination
CAUTION
with the system software of AXV06.08 or higher, prepare a drive unit in which the
servo communication software of CX01.50 or higher is installed, or upgrade the drive
unit. As for details, contact our service center.

How to confirm the servo communication software version (1)

In the case when the sticker of the servo communication board (UM221) of the drive
unit is CX01.50 or higher, the drive unit works with AXV06.08 or higher. If the above
error occurs though the sticker indication is CX01.50 or higher, there may be other
cause. (Incomplete connection of CNUSB, or so)

How to confirm the servo communication software version (2)

1. Input [R] [3] [1] [4] [Enter] [Enter], and switch the operator qualification into EXPERT
or higher.
(As for details of the operator qualification, refer to the operation manual "Installation
manual".)
2. Open [Service Utilities] [13 System environment] menu.
3. Check the following item.

Servo communication CXxx.xx

When the servo communication is not established, CX00.00 is displayed. In this case,
there is a possibility that the version of the servo communication software may be old.
However, there may be other possibilities (for example, incomplete connection of
CNUSB, or so). Please attention to it.

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 3.1 Parts replacement

3.1.7 Replacement of a power unit

Please confirm the controller power supply is turned off, and work after the passage of five minutes or more. The
charge remains in the PCB and the capacitor.

Removal
1) Remove the sequence board (UM213).
2) Remove all connectors attaching the unit.
3) Remove screws fixing the unit to the cabinet.
4) Pull the unit clear of the cabinet. At this time, please have the case so as not to touch internal switching
regulators.

Installing
1) Place the unit into the correct position in the cabinet.
2) Fix the unit to cabinet with screws.
3) Correctly reattach all connectors to the unit.
4) Fix the sequence board (UM213).

Note
• Take care not damage the unit when removing wires that are hooked around other parts of the unit.
• Ensure all connectors are attached. If not connected an error will result.

CNIN

CNP

CNP5V

CNSQ

CNSWO

CN422

CNTPC CNAC
CNOUT

CNPC F1
CN3

Screws to fix the unit to

CN4

the controller

CNSQ This figure is applied to a

CNTP

CNOP
controller shipped in or before
January 2003.
D/A CNFAN
CNP5V
1

4
CNFM

HC7244
CNUSB

HC32
NF5

CNSV
CNSV
H8S

HC7244

HC7244

HC7244
CNSB4

LVX4245

HC7244

HC7244
2
1

CNMS

CNH
CNBK1

CP1
CNBK2

CNAC1 CNAC

NF NF NF NF

CNEC1 CNEC2 CNP5E F1(R)

F2(L)
17

25

27 26 2 1
18

24

1
35

19

50
CNH

36

20

49

F2 F1

CNH CNPW

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3.1 Parts replacement

Screws to fix the unit to the

controller

This figure is applied to a controller

shipped in or after January 2003.

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 3.1 Parts replacement

3.1.8 Replacement of a battery for calendar

Please confirm the controller power supply is turned OFF, and work after the passage of five minutes or more. The
charge remains in the PCB and the capacitor.

Replace the battery with a new one periodically, once in three years. When you
! have replaced the battery (CR2032), reset the date and time. Otherwise, the date
may be wrong, and the automatic backup function and so forth may not work
CAUTION normally.

Removal
1) Remove the CPU board according to "3.1.1 Replacement of a CPU board".
2) Remove the battery (CR2032) of CPU board.

Installing
1) Install the battery (CR2032) of CPU board.
2) Install the CPU board according to "3.1.1 Replacement of a CPU board".

Note
• When exchanging battery, the date and time must be reset in the AX controller.
• The battery should be routinely replaced one every 3 years.

[AXCPU10-10]

DIMM1 CN1
DIMM2 CN2 CN3 CN4
JP1
JP2 JP3

CN12 LAN
CN5

JP4
JP5

CN6 MOUSE
CPU
CN7

JP9 VGA
CN9

JP8 バッテリ JP7

CR2032
CN10
CN11 KEY

CR2032
battery

[AXCPU10-20]

CR2032
battery

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3.1 Parts replacement

3.1.9 Replacement of cooling fan motor

Please confirm the controller power is turned OFF.

! Irrespective of operating hours, replace the cooling fan with a new one periodically,
once in four years. Otherwise, the temperature in the controller may increase
CAUTION abnormally, leading to an error or malfunction.

! Attach the cooling fan so that air convection should be made in the direction shown
in the figure. Otherwise, the temperature in the controller may increase abnormally,
CAUTION leading to an error or malfunction.

There are 4 cooling fan motors (FM1, FM2, FM3, and FM4)

[How to replace FM3 and FM4]

Removal
(1) Remove all the connectors connected to respective boards of the CPU unit.
(2) Loosen the screws shown in the figure below and remove the CPU unit from the cabinet.
(3) Remove the power source cable of the fan.
(4) Remove the fan from the CPU unit.

Installing
(1) Attach the fan to the CPU unit.
(2) Attach the CPU unit to which the fan is attached to the control panel.
(3) Attach the power source cable of the fan.

FM4 FM3

Screws

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 3.1 Parts replacement

[How to replace FM1 and FM2]

Removal
(1) Remove the power source cable of the fan.
(2) Remove the panel to which the fan attached from the control panel.
(3) Remove the fan from the panel.

Installing
(1) Attach the fan to the panel.
(2) Attach the panel to which the fan attached to the control panel.
(3) Attach the power source cable of the fan.

DSR10
Panel of the fan motor
installation

FM1 FM2

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3.2 Adjustment

3.2 Adjustment
It is usually unnecessary to adjust the AX controller when parts are replaced, with the exception of power system
adjustment. Adjustment positions and adjustment procedures are explained below. Do not touch adjusting points
unless otherwise necessary and do not make adjustment until the cause of an error is clarified.
3.2.1 Adjustment of power system
Measure the voltage of each power supply output when trouble occurs in the power supply system or the power unit
is replaced. Make adjustment of voltages from SR1 and SR5E is out of specified values.
(Use a digital voltmeter for measurement.)
Power Measurement point Specified value Adjustment point
Primary power Measurement point Spec. Volt. ±10% Primary tap change of T11, T12.
Sequence board No adjustment. Please exchange the
(UM213) DC power supply unit when the
P1－M1 DC24V±1.0V
TBEX3 terminal block measurement voltage not satisfy
24V-0V specified value.
CNP5V connector pins on
P5－M0 DC5.1V +0.1V / -0.0V Volume pot on DC power supply unit.
drive unit, P5-M0
Storage board (UM204) No adjustment. Please exchange the
P12-M0 connector CNTP pins A1 DC12V±0.5V DC power supply unit if SR2 power
and B1 supply is outside specified value.
Volume pot on SR5E of power unit.
P5E-M5E is DC5.1±0.1V at the
P5E and M5E connector
P5E－M5E DC5.3V nearest point to the robot encoder.
on SR5E of power unit.
The voltage is about 5.3V inside the
controller.

This figure is applied to a

controller shipped in or
before January 2003. P5-M0 Volume pot
CNIN

CNP

DC12V on Storage board

CNP5V

CNSQ

(UM204) connector CNTP

CNSWO

CN422

CNP5V connector
CNOUT
CNTPC CNAC
pins A1 and B1
CNPC F1

Pin position
CN3

CN4

1 2 3 4
P P M M CNSQ P5E-M5E Volume pot
CNTP

5 5 0 0
CNOP
CNFAN
CNP5V

D/A
1

4
CNFM

HC7244
CNUSB

HC32
NF5

CNSV
CNSV
H8S

HC7244

HC7244

HC7244

TBEX2 terminal block

CNSB4

LVX4245

HC7244

HC7244
1

CNMS

CNH
CNBK1

CP1
SRE
CNBK2

CNAC1 CNAC

CNP5 connector
NF NF NF NF

CNEC1 CNEC2 CNP5E F1(R)

F2(L)
17

20 19 2 1

25

1
18

24

1
35

50

26
CNH

36

49

27

F2 F1
Pin position
Brake power is from REC1 (DC CNH CNPW

22V to DC28V) and can be 1 2 3 4

checked at two test points on
the Brake board UM222. The P P M M
test points are above connector
5 5 5 5
CNBK1. Test pins CTPB and
CTMB. Ｅ Ｅ Ｅ Ｅ

3-24
 3.2 Adjustment

This figure is applied to a controller shipped in or after January 2003.

5V volume pot

CNP5V connector
Pin layout
1 2 3 4
DC12V Storage board
P P M M
UM204 connector CNTP 5 5 0 0
pins A1 and B1

Terminal box TBEX3

Brake power is from REC1
(DC 22V to DC28V) and can
be checked at two test
points on the Brake board SR5E, DC5V volume pot
UM222. The test points are for Encoders
above connector CNBK1.
Test pins CTPB and CTMB.

CNP5E connector
Pin layout
1 2 3 4 5
P P M M
5 5 5 5
E E E E

(Supplement)
When using AXCPU10-20, the voltage of DC12V can be measured on the CNTPC connector on the CPU board
(AXCPU10-20).

3-25
3.2 Adjustment

3.2.2 Transformer tap change

Procedure
1) Turn controller main power OFF and lock out main power.
2) Remove the transformer cover plate on the controller.
3) Remove the R, S, T wiring connected to primary terminal of the transformer.
4) Connect the R, S, T wiring to the primary terminals of the desired voltage.
5) Insulate any disconnected wiring with tape so as not to short anything.

Connection point of the terminal block varies between supply power voltage specifications.

(1) 200V (T12) (2) 220V (T12)

100V 100V
240V 240V
0 0
220V T 220V
200V 200V
T 200V 200V
0 0
190V 190V
28V 28V
R 0 R 0
22V 22V
20V 20V
E E
0 0

(3) 380V (T11) (4) 400V (T11)

T T
S S
R R

4 4 4 4 4 3 4 4 4 4 4 3 4 4 4 4 4 3 4 4 4 4 4 3 4 4 4 4 4 3 4 4 4 4 4 3
8 6 4 2 0 8 8 6 4 2 0 8 8 6 4 2 0 8 8 6 4 2 0 8 8 6 4 2 0 8 8 6 4 2 0 8
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
U V W U V W

U1 V1 W1 U1 V1 W1
2 1 2 1 2 1 2 1 1 2 2 1 2 1 2 1 2 1 1 2
E 0 9 0 9 0 9 0 0 0 0 1 3 0 2 2
0 2 E 0 9 0 9 0 9 0 0 0 0 1 3 0 2 2
0 2
0 0 0 0 0 0 0 0 5 0 0 0 0 0 0 0 0 0 5 0

(5) 420V (T11) (6) 440V (T11)

T T
S S
R R

4 4 4 4 4 3 4 4 4 4 4 3 4 4 4 4 4 3 4 4 4 4 4 3 4 4 4 4 4 3 4 4 4 4 4 3
8 6 4 2 0 8 8 6 4 2 0 8 8 6 4 2 0 8 8 6 4 2 0 8 8 6 4 2 0 8 8 6 4 2 0 8
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
U V W U V W

U1 V1 W1 U1 V1 W1
2 1 2 1 2 1 2 1 1 2 2 1 2 1 2 1 2 1 1 2
E 0 9 0 9 0 9 0 0 0 0 1 3 0 2 2
0 2 E 0 9 0 9 0 9 0 0 0 0 1 3 0 2 2
0 2
0 0 0 0 0 0 0 0 5 0 0 0 0 0 0 0 0 0 5 0

(7) 460V (T11) (8) 480V (T11)

T T
S S
R R

4 4 4 4 4 3 4 4 4 4 4 3 4 4 4 4 4 3 4 4 4 4 4 3 4 4 4 4 4 3 4 4 4 4 4 3
8 6 4 2 0 8 8 6 4 2 0 8 8 6 4 2 0 8 8 6 4 2 0 8 8 6 4 2 0 8 8 6 4 2 0 8
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
U V W U V W

U1 V1 W1 U1 V1 W1
2 1 2 1 2 1 2 1 1 2 2 1 2 1 2 1 2 1 1 2
E 0 9 0 9 0 9 0 0 0 0 1 3 0 2 2
0 2 E 0 9 0 9 0 9 0 0 0 0 1 3 0 2 2
0 2
0 0 0 0 0 0 0 0 5 0 0 0 0 0 0 0 0 0 5 0

3-26
 3.3 Moving the robot in an emergency

3.3 Moving the robot in an emergency

The AX controller features the following facilities in case the robot cannot be moved with normal operation keys.
Read and thoroughly understand this section before operation of the AX controller and robot arm.

3.3.1 Brake release switches (option)

These switches force the release of an axis brake while the motors are not energized. The AX controller must
be turned ON to energize the axis brake inside the motor. The brake release switches may be installed inside
the AX controller or a portable brake release board can be used. The clicking sound of the brake opening can
be heard when an axis brake is released.

Layout of brake release switches on UM217 board.

BRAKE RELEASE SWITCH

J1 J2 J3 J4 J5 J6 J7 LS

CNSW

Layout of brake release switches on UM217A board.

BRAKE RELEASE SWITCH UM217A

J1 J2 J3 J4 J5 J6 J7 J8 J9

CNSW CNSW1

(NOTE) Over-travel LS release switch is located on the Seqnence board (UM213) located on the power unit
in the AX controller.

The robot arm drops under the force of gravity if the brake switch is released.
Release the brake only after taking steps to hold or support the robot arm or any
other part that may drop. The first time the switch is released, toggle the switch
momentarily. Then conduct a SAFETY check on the equipment if required.
Death or serious injury may result if you make contact with the robot arm or
are squeezed between the robot arm and other equipment.

3-27
3.3 Moving the robot in an emergency

[How to connect the portable brake release board]

- In case of UM217 board (7 axes specification / Additional axis specification)
- In case of UM217A board (Standard 7 axes specification)

FM4 FM3
CNIN

CNP

Portable Brake Release Board CNP5V

CPUユニット
CNSQ

UM217 or UM217A CB1 CNSWO

CPU　UNIT CNTPC CNAC

CNOUT

CNPC F1
CN3

CN4

BRAKE RELEASE SWITCH

J1 J2 J3 J4 J5 J6 J7 LS
▼

CNH CNAC

F1 F2
CNSW
CNFAN

CNP5V
D/A

HC7244
HC32
NF5

CNSV
H8S
CNSB4

HC7244

HC7244

HC7244
ｼｰｹﾝｽ基板

LVX4245
1

HC7244

HC7244

CNMS
CNUSB
ﾄﾞﾗｲﾌﾞﾕﾆｯﾄ
DRIVE UNIT

CNBK1
CNPWA CNEAC CNACIN CNPW

CNBK2
CNSW

The brake release switches for

CNEC1 CNEC2 CNP5E

1
36 35 18 17

25
20 19 2

24

1
50

26
CNH

49

27
J8 and J9 axis.
(When using UM217 board) CNSW
CNSW

- In case of UM217A board (Additional axis specification)

CNIN

CNP

CNP5V

CPUユニット
CNSQ

CNSWO

CPU　UNIT CNTPC CNAC

CNOUT

CNPC F1
CN3

CN4

Portable Brake
Release Board
UM217A
CNH CNAC

F1 F2

CNFAN
CNP5V

D/A
1

HC7244
HC32
NF5

CNSV
H8S

HC7244

HC7244

HC7244
CNSB4

ｼｰｹﾝｽ基板
LVX4245

HC7244

HC7244
1

CNMS
CNUSB

ﾄﾞﾗｲﾌﾞﾕﾆｯﾄ
DRIVE UNIT
CNSW1 (J8, J9)
CNBK1

CNPWA CNEAC CNACIN CNPW

CNBK2

CNSW (J1 - J7)

CNSW

CNEC1 CNEC2 CNP5E

17

25

1
18

20 19 2

24

1
35

50

26
CNH

36

49

27

3-28
 3.3 Moving the robot in an emergency

[Location of the fixed type Brake release switch in the controller]

Brake switch board location if

installed in AX10 controller
CNIN

CNP

CNP5V
UM217 board
CPUユニット
CNSQ

CNSWO

CPU　UNIT CNTPC CNAC

CNOUT

CNPC F1
CN3

CN4

CNH CNAC

F1 F2

CNFAN
CNP5V

D/A
1

HC7244
HC32
NF5

CNSV
H8S

HC7244

HC7244

HC7244
CNSB4

ｼｰｹﾝｽ基板
LVX4245

HC7244

HC7244
1

CNMS
CNUSB

ﾄﾞﾗｲﾌﾞﾕﾆｯﾄ
DRIVE UNIT
CNBK1

CNPWA CNEAC CNACIN CNPW

CNBK2

CNSW

CNEC1 CNEC2 CNP5E

17

20 19 2 1

25

1
18

24

1
35

50

26
CNH

36

49

27

3-29
3.3 Moving the robot in an emergency

3.3.2 Over-travel LS release switch

When the robot passes the software limit and actuates an axis limit switch the LS release switch must be
used in order to energize the motors and move the robot off the limit switch. When the LS switch is energized
Error [E0065 Over-travel limit switch was activated] is displayed. The LS switch in located on the Sequence
board UM213.

CNIN

CNP

CNP5V

CPUユニット
CNSQ

CNSWO

CPU　UNIT CNTPC CNAC

CNOUT

CNPC F1
CN3

CN4

CNH CNAC

F1 F2

CNFAN
CNP5V

D/A
1

Over-travel LS release switch

HC7244
HC32
NF5

CNSV
H8S

location on the sequence board

HC7244

HC7244

HC7244
CNSB4

ｼｰｹﾝｽ基板
LVX4245

HC7244

HC7244
1

UM213.
CNMS
CNUSB

ﾄﾞﾗｲﾌﾞﾕﾆｯﾄ
DRIVE UNIT
CNBK1

CNPWA CNEAC CNACIN CNPW

CNBK2

CNSW

CNEC1 CNEC2 CNP5E

17

25

1
18

20 19 2

24

1
35

50

26
CNH

36

49

27

Procedure

1. Select [ConstantSetting] mode with f5 key.

2. Select item [3 Machine constant].
3. Press the Motors ON button while holding down the LS switch.
4. Manually move the robot arm back into the operating area using the axis operation keys.
CAUTION : Hold the LS release switch ON until the robot arm stops actuating the limit switch.

3.3.3 Software limit

When moving the robot arm the Software limits must be set before the limit switches are reached. If Alarm
message [A0121 - The robot's joint angle exceeded the software stroke range] appears and the robot cannot
be moved, use the following procedure.

1. Select [ConstantSetting] mode with f5 key.

2. Select item [3 Machine constant].
3. With motors ON move the robot arm back into the operating area using the axis operation keys.

3-30