Mitsubishi Electric has announced the discontinuation of MELFA FR-Q type robot controllers. For Japanese manufacturers operating in Thailand, the first decision is not to replace every robot immediately. It is to identify which cells contain affected CR800-Q or CR860-Q controllers, compare the manufacturer’s deadlines with production and maintenance risks, and plan a controlled transition. Technical News BFP-A6079-0428E, issued in October 2026, states that acceptance of orders ends at the end of September 2027 and production ends at the end of March 2028. Repair support is scheduled to end at the end of September 2034, but even before then a repair may be unavailable if electronic components or other parts cannot be obtained. A separate notice, BFP-A6079-0429E, ends CE marking for affected products manufactured from November 2026.
This guide turns those notices into an actionable scope, request for proposal, factory acceptance test (FAT), site acceptance test (SAT), and cutover plan. Model compatibility and legal applicability must still be confirmed against the actual cell, destination market, and the manufacturer’s latest documents.
Identify the affected robot controller before planning a replacement
The announcement concerns the FR-Q type controller of MELFA industrial robots, specifically CR800-Q and CR860-Q. It is not a blanket notice about every MELSEC-Q motion controller. The manufacturer lists RV-FR-Q vertical articulated, RH-FRH-Q horizontal articulated, and RH-FRHR-Q ceiling-mounted robots; special-order products and dedicated options are included. Inventory the robot arm and controller as a pair. Photograph both nameplates, record serial numbers and production dates, and compare the bill of materials and current drawings with the actual cabinet. A “-Q” in a drawing is not enough to classify a complete cell.
| Item | Evidence to collect | Decision supported |
|---|---|---|
| Robot arm | RV/RH model, serial number, nameplate | Check the exact row in the manufacturer’s alternative-model table |
| Controller | CR800-Q/CR860-Q model, date, firmware | Define deadline and maintenance exposure |
| Platform | MELSEC-Q CPU, base, I/O and network | Determine the scope of the iQ-R transition |
| Safety | E-stop, gates, light curtain, safety PLC, external axis | Define risk reassessment and validation |
| Application | Programs, taught positions, tool, vision, tracking | Price conversion, retouching and retuning |
| Production | Parts, cycle time, uptime, permitted outage | Prioritize cells and schedule a cutover |
Mitsubishi Electric’s FR configuration distinguishes the CR800-Q as dedicated to MELSEC Q and the CR800-R as dedicated to MELSEC iQ-R. Therefore an FR-R candidate is not evidence that a controller can be swapped without work on PLC integration, signals, communications, software and safety. Draw the complete cell architecture before setting a purchase boundary.
Put the MELFA FR-Q deadlines on one timeline
BFP-A6079-0428E gives the schedule current at its October 2026 issue date. It explicitly says the order and production dates may be revised according to the transition schedule for laws, regulations and standards; a revision would be announced separately. Check the latest notice when approving the capital request and again before issuing the purchase order.
| Milestone | Manufacturer’s statement | Practical implication |
|---|---|---|
| Products manufactured from November 2026 | CE marking of affected FR-Q products discontinued | Verify manufacture date and destination for EU-related projects |
| On or after 20 January 2027 | Manufacturer says affected products cannot be placed on the EU market | Review EU deliveries with the manufacturer and legal specialists |
| End of September 2027 | Planned end of order acceptance | Complete model confirmation and procurement with margin |
| End of March 2028 | Planned production end | Plan the remaining installed-base period |
| End of September 2034 | Planned repair-support end | Account for possible earlier inability to repair due to parts |
An order deadline is different from a production deadline. A repair-support deadline is not a promise that every failure can be repaired until that day. For a high-utilization cell, consider failures, spare stock, international shipping, production loss and the lead time for a retrofit. A low-utilization redundant cell can have a different priority. Treat the dates as constraints in a risk-based schedule, not as a single mandatory replacement date for all assets.
Interpret the CE notice for the actual destination market
BFP-A6079-0429E states that CE marking ends for affected products manufactured from November 2026 and explains that the products cannot be placed on the EU market on or after 20 January 2027. The notice mentions the EU Machinery Regulation, the industrial robot safety standard and future EU Cyber Resilience Act requirements as reasons for the manufacturer’s decision. It does not, by itself, establish a blanket prohibition on continued use of installed machines in Thailand. For a new EU-bound machine, an EU customer’s line, or a future relocation, assess the manufactured item, declaration, final machine and contractual responsibilities case by case. Thai requirements and customer specifications need their own review. Seek legal and manufacturer confirmation rather than treating this article as a conformity opinion.
Check CR800-Q and CR860-Q alternatives against the model table
The discontinuation notice identifies MELFA FR-R type controllers as alternatives and provides separate tables for CR800 and CR860. The CR800 examples include RV-2/4/7/13/20FR-Q and RH-3/6/12/20FRH-Q as well as RH-3FRHR-Q, each with a corresponding -R model. The CR860 list includes RV-35/50/80FR-Q and their -R alternatives. These are candidate model mappings, not a guarantee of mechanical, electrical, software or safety compatibility in a modified production cell.
| Installed example | Listed alternative example | Verify before ordering |
|---|---|---|
| RV-4FR-Q with CR800-Q | RV-4FR-R family | PLC integration, programs, wiring, teaching, safety |
| RH-6FRH-Q with CR800-Q | RH-6FRH-R family | SCARA tool, camera, conveyor tracking, I/O |
| RH-3FRHR-Q with CR800-Q | RH-3FRHR-R family | Ceiling mount, interference, cable route |
| RV-50FR-Q with CR860-Q | RV-50FR-R family | Cabinet, power, heavy-load safety and maintenance |
The examples simplify the manufacturer’s table. Special orders, dedicated options and past modifications require a model-by-model answer from Mitsubishi Electric or an authorized channel. Attach the current standard specifications, controller setup and maintenance manuals, safety manual, and iQ Platform integration instructions to the selection file. The manufacturer’s FR-series manual index is a useful document entry point.
Count every interface in an industrial robot controller migration
The robot exchanges commands and states with more than a PLC. A cell may use conveyors, vision, force sensing, welding power supplies, grippers, MES, traceability systems and maintenance terminals. A quotation based on the controller alone can miss the interfaces that determine the outage. For each cell, record which device initiates which command, the signal or message, its timing and the safe response to a fault. Validate drawings against actual wiring and software versions.
| Interface | As-found record | Acceptance test |
|---|---|---|
| Host PLC | CPU, signal list, registers, handshake, timeout | Start, stop, fault recovery and duplicate commands |
| Safety | Stop behavior, gates, light curtains, restart interlocks | Validate safety functions including relevant fault cases |
| Motion | Program versions, taught positions, speed and interference | Measure all representative workpieces and positions |
| Peripherals | Camera, tool, external axis, welding, conveyor | Run synchronized motion and error handling |
| Data | Recipe, lot, result, alarm and timestamp | Reconcile transactions with the host system |
| Maintenance | Backups, spare parts, terminal and user access | Restore test and technician recovery drill |
In a cell coupled tightly to a MELSEC-Q rack, decide whether an iQ-R controller requires a PLC change, a different integration method, or another architectural choice. Make that decision from the actual I/O, network, safety and control design rather than from a matching robot model name. Check cabinet space and heat, supply, cable length, grounding and network traffic. Whether the existing robot arm and end effector can remain is also an as-built question.
A backup file is only the beginning of recovery planning
Inventory programs, parameters, coordinates, tools, taught positions, I/O allocation, users, network settings, vision calibration and option data. Identify the date and device for each backup, then test a restoration under documented conditions. Whether an old file imports into a new controller depends on the model, version and options; request the manufacturer’s or integrator’s conversion procedure. A successful file import is not proof that the robot clears fixtures, meets cycle time or produces acceptable parts. Test conversion before FAT and price any re-teaching explicitly.
Prioritize Thai factory cells by business impact
Changing all cells at once concentrates outage and engineering workload. Combine destination-market and contract exposure, failure impact, repair uncertainty and engineering complexity. An EU-bound project warrants early scrutiny of the CE notice, but it does not decide the legality of every installed Thai cell. Operations and finance should estimate the cost of an hour of lost output, including buffers and alternative capacity.
| Factor | High-priority example | Evidence |
|---|---|---|
| Customer or shipment | New EU-bound machine or contractual deadline | Contract, destination, manufacturer response |
| Production loss | Single bottleneck cell with no substitute | OEE, downtime, available buffer |
| Reliability | Rising alarms, no spare, long repair lead time | Alarm log, maintenance history, parts list |
| Integration | Special tool and tight PLC/safety coupling | Schematics, I/O table, software inventory |
| Opportunity | Planned shutdown or product change | Production and investment plans |
Ten identical controllers can justify different dates if only one sits at the bottleneck. Record both the priority and the interim risk control. A spare controller may bridge the transition, but do not assume its storage life, configuration or repairability without checking. Spare procurement buys time; it does not remove the need for a migration decision.
Write an RFP that defines a complete transition
“Replace CR800-Q” is not enough for comparable bids. Give every supplier the same cell inventory, current drawings, production target, outage limit, acceptance criteria and deliverables. If the as-built documents are incomplete, commission a bounded survey first. The owner must provide site access, current program versions, representative workpieces and named signatories for cutover.
| RFP topic | Question to ask | Expected evidence |
|---|---|---|
| Model fit | Why does the proposed FR-R match this arm and controller? | Manufacturer answer, model table, exceptions |
| Boundary | Which arm, cabinet, PLC, network and safety items change? | Before/after architecture and bill of materials |
| Program | How are conversion, teaching and option gaps handled? | Trial conversion and work estimate |
| Output | What establishes equivalent production? | Cycle time, yield and position measurement plan |
| Safety | Who owns risk assessment and validation? | Safety function list, test and signatures |
| Cutover | What are the outage limit and return criteria? | Timed plan, backups, recovery steps |
| Support | What support and spare stock are available in Thailand? | Response commitment and training plan |
Separate hardware from engineering, wiring, cabinet modification, program conversion, safety testing, FAT, shipment and customs, SAT, training, spares and production downtime. State currency, quote validity and long-lead component assumptions. The supplier quote expiry and manufacturer’s final order-acceptance date are not interchangeable.
Run FAT and SAT as distinct evidence gates
FAT tests representative control and safety scenarios before shipment. SAT tests the installed cell using real workpieces, real conveying, actual communications and actual operators in Thailand. A FAT pass does not account for installation tolerance, cabling, temperature, fixture variation or PLC timing at the site. Define measured acceptance values rather than writing only “operates normally.”
| Test | FAT evidence | SAT evidence | Record |
|---|---|---|---|
| Basic motion | Axes, homing, manual/automatic modes | Reach, clearance and interference in place | Video and position data |
| PLC handshake | Commands, acknowledgments, recipe, timeout | Continuous line operation | Time-stamped I/O trace |
| Faults | Power, communication and sensor failure | Real recovery route and technician actions | Fault sheet and recovery time |
| Safety | E-stop, gate, light curtain, restart | Installed guarding and neighboring machines | Validation record |
| Quality | Representative grip, process and transfer | All product variants, yield, defects, cycle time | Measurement and quality approval |
| Data | Result and alarm output | MES/traceability reconciliation | Per-transaction comparison |
The fact that the old cell ran is not proof that the revised cell is safe. Revisit stopping behavior, restart, reduced speed, area sensors, safety PLC and personnel access. The plant’s risk assessment determines the test method and accountable signatories. Use the manuals for the selected controller version as controlled references in the acceptance package.
Decide Go/No-Go and recovery before the shutdown
Establish the latest time at which a return is possible before booking the outage. A weekend plan might include electrical work, program load, homing and safety, representative workpieces and continuous running, with a fixed Sunday deadline for a decision. If the old cabinet has been removed or wiring irreversibly changed, a paper “rollback” has no value. Provide a spare cabinet, parallel wiring, or another production path where necessary.
| Gate | Example Go condition | Example No-Go or recovery condition |
|---|---|---|
| Machine | Motion, tool and external axis within approved envelope | Interference, position error or critical alarm |
| Safety | Critical safety functions validated | Open issue with E-stop, gate or restart |
| Output | Cycle time, quality and yield accepted | Critical product variant untested or out of spec |
| Interfaces | PLC, MES and recovery verified | Missing signals or production records |
| People | Production, maintenance, safety and quality sign | No recovery owner or incomplete training |
| Time | Enough outage remains for recovery | Remaining time below restoration requirement |
Name the person authorized to stop the cutover, with production, maintenance, safety, quality, IT/OT, integrator and manufacturer contacts available. Do not carry an unresolved decision into the next shift. After Go, monitor alarms, cycle time, quality, missing records and manual intervention for an agreed number of shifts covering the relevant product mix.
Operate an asset register, spares and change control together
The project should leave a better recovery process, not only a newly installed controller. Give every cell a unique ID and link the arm, controller, PLC, safety equipment, tool, vision system and peripherals to their model, serial number and software version. Separate the as-found state, with its inspection date, from the proposed state and approval status. This shows where FR-Q remains, where FR-R is accepted, which spare is assigned and which model exception awaits a manufacturer answer. Resolve drawing discrepancies before work or record them as approved deviations that SAT must verify.
Manage a spare with more than a part number and quantity. Record its location, purchase date, applicable cell, firmware and parameter condition, latest readiness check, restoration procedure and Thailand service contact. Because the scheduled repair period depends on parts availability, a sequential “request repair, then look for a spare, then plan a retrofit” response can prolong a critical shutdown. For important cells, predefine when alternative production, spare replacement or planned migration becomes the primary response and the decision deadline. Set an inspection frequency for stored spares according to manufacturer guidance and plant risk, then keep the results.
Version-control the software at cell level. Store the program, parameters and I/O table accepted at FAT separately from the set accepted at SAT. Link each later change to its author, reason, test result and approver. A single taught-point edit or changed timeout during SAT can become a repeat defect when copied to the next cell. Define in advance which changes trigger a repeated interference or safety test. Store the outcome of a restore test alongside each backup so that “file exists” and “recoverable configuration” remain distinct statuses.
| Record | Minimum contents | Decision enabled |
|---|---|---|
| Asset register | Cell ID, arm/controller models and serials, versions, interfaces, inspection date | Scope and affected-model decision |
| Spare register | Compatible models, storage, settings, check date, assigned cell | Response during a fault |
| Change log | Changed file, reason, author, approval, retest scope | Root cause and rollout |
| Acceptance file | FAT/SAT measurements, open items, signatures, recovery drill | Go decision and warranty questions |
Share this register across maintenance, production, procurement, quality and safety. Production needs outage windows and alternate capacity; procurement needs order dates and spares; quality needs product-specific acceptance; safety needs validation after change. Assign an owner for each field and review dates and exceptions at a monthly equipment meeting. When procurement is urgent, label unanswered questions with an owner and due date rather than silently marking them resolved.
A practical 90-day first-cell plan
Ninety days is an illustrative project structure, not a statutory deadline or a promise that any factory can finish in that period. A complex line may need more time. Starting design just before the planned September 2027 order deadline risks missing the manufacturer response, parts and shutdown window. Ordering all cells before surveying them risks buying the wrong scope.
| Example period | Work | Decision document |
|---|---|---|
| Days 1–30 | Inventory, affected-model check, EU exposure, interfaces, safety and software survey | Model register, drawings, risk ranking |
| Days 31–60 | Manufacturer confirmation, RFP, bid comparison, conversion trial, FAT plan | Model mapping, bids, test procedure |
| Days 61–90 | First-cell FAT, installation, SAT, cutover rehearsal and Go decision | Acceptance evidence, recovery and training records |
Choose a first cell representative of PLC, safety and peripheral interfaces, not merely the easiest arm. Feed discovered wiring differences, conversion problems and cycle-time changes back into the standard design and bid schedule. Keep deviations for each subsequent cell visible.
Separate installed-controller migration from adjacent equipment decisions
For broader arm selection, see industrial robot types and selection. For the safeguarding work associated with a controller transition, use the safety PLC validation guide. This article addresses the FR-Q robot controller notices; a separate MELSEC-Q motion-controller announcement needs its own model inventory and plan.
FAQ: MELFA FR-Q and FR-R migration
When do CR800-Q and CR860-Q orders close?
BFP-A6079-0428E, issued in October 2026, gives the end of September 2027 for order acceptance and the end of March 2028 for production. It notes that dates may change with regulatory and standards transitions. Verify the current notice, order terms and lead time before ordering.
Can we wait until the September 2034 repair deadline?
There is no universal answer. Repair support is scheduled until the end of September 2034, but the manufacturer warns that component availability may prevent repairs even before then. Balance downtime loss, spares, repair logistics and the next viable installation window.
Is FR-R a plug-and-play controller swap?
No such compatibility is promised by the notice. FR-R is a listed alternative family. CR800-Q and CR800-R are presented as dedicated to different MELSEC platforms. Verify PLC integration, wiring, program, teaching, safety and options in the real cell, then prove operation in FAT and SAT.
Does the CE change prohibit operating a Thai factory’s installed robot?
The manufacturer’s notice describes CE marking of products manufactured from November 2026 and EU-market placement on or after 20 January 2027. It does not itself declare a blanket prohibition on use of an installed machine in Thailand. Check the applicable destination, customer contract, Thai requirements and manufacturer’s advice for the particular project.
Is this the same notice as a MELSEC-Q motion-controller discontinuation?
No. This article concerns MELFA FR-Q industrial robot controllers CR800-Q and CR860-Q. Other MELSEC-Q motion equipment has its own affected-model list and notice. Record them separately even if installed in the same cabinet.
What should be attached to a bid request?
Supply both nameplates, software and option inventory, PLC/safety/peripheral schematics, actual parts and recipes, historical cycle and quality measurements, and allowable downtime. Require bidders to answer model fit, scope, conversion, safety, FAT, SAT, recovery and Thailand support in the same format.
Conclusion
The FR-Q transition is neither a blanket immediate replacement nor a reason to defer every decision until 2034. Use the announced September 2027 order, March 2028 production and September 2034 repair dates, their qualifications, and the separate CE notice to rank each cell by model, interfaces, safety and production impact. FR-R is the manufacturer’s alternative family; prove suitability against the installed machine. A well-documented first cell can establish an RFP, FAT, SAT and cutover pattern for the rest.
If your Thailand plant is beginning a CR800-Q/CR860-Q inventory or needs to define the FR-R migration scope, contact TOMAS TECH. We can help structure the survey and acceptance questions with the drawings and available outage window you already have.
Sources
- Mitsubishi Electric, BFP-A6079-0428E: discontinuation of MELFA FR-Q type controllers, October 2026.
- Mitsubishi Electric, BFP-A6079-0429E: CE-marking discontinuation for MELFA FR-Q type controllers, October 2026.
- Mitsubishi Electric, RV-FR series system configuration.
- Mitsubishi Electric, FR-series manuals.
- Mitsubishi Electric, CR800-Q specifications.
- European Union, Machinery safety requirements summary.
