R-J2 Controller P-200 Maintenance Manual

FANUC Robotics SYSTEM R-J2 Controller P10, P15 and P200 Electrical Maintenance Manual
MARO2P10203704E REV B
This publication contains proprietary information of FANUC Robotics North America, Inc. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics North America, Inc. FANUC Robotics North America, Inc. 3900 W. Hamlin Road Rochester Hills, Michigan 48309-3253
The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. FANUC Robotics North America, Inc, hereinafter referred to as FANUC Robotics, reserves the right to discontinue models at any time or to change specifications or design without notice and without incurring obligations. FANUC Robotics manuals present descriptions, specifications, drawings, schematics, bills of material, parts, connections and/or procedures for installing, disassembling, connecting, operating and programming FANUC Robotics products and/or systems. Such systems consist of robots, extended axes, robot controllers, application software, the KARELD programming language, INSIGHTD vision equipment, and special tools. FANUC Robotics recommends that only persons who have been trained in one or more approved FANUC Robotics Training Course(s) be permitted to install, operate, use, perform procedures on, repair, and/or maintain FANUC Robotics products and/or systems and their respective components. Approved training necessitates that the courses selected be relevant to the type of system installed and application performed at the customer site.
WARNING This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual, may cause interference to radio communications. As temporarily permitted by regulation, it has not been tested for compliance with the limits for Class A computing devices pursuant to subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measure may be required to correct the interference.
FANUC Robotics conducts courses on its systems and products on a regularly scheduled basis at its headquarters in Rochester Hills, Michigan. For additional information contact FANUC Robotics North America, Inc. Training Department 3900 W. Hamlin Road Rochester Hills, Michigan 48309-3253 Tel: (248)377-7234 FAX: (248)377-7367 or (248)377-7362 web site: www.fanucrobotics.com Send your comments and suggestions about this manual to: product.documentation@fanucrobotics.com
Copyright '2000 by FANUC Robotics North America, Inc. All Rights Reserved
The information illustrated or contained herein is not to be reproduced, copied, translated into another language, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics North America, Inc. AccuStatD , ArcToolD , DispenseToolD , FANUC LASER DRILLD , KARELD , INSIGHTD , INSIGHT IID , PaintToolD , PaintWorksD , PalletToolD , SOCKETSD , SOFT PARTSD SpotToolD , TorchMateD , and YagToolD are Registered Trademarks of FANUC Robotics. FANUC Robotics reserves all proprietary rights, including but not limited to trademark and trade name rights, in the following names: AccuFlowE ARC MateE ARC Mate Sr.E IntelliTrakE LaserToolE MotionPartsE PaintWorks IIE PalletMateE SureWeldE TurboMoveE
Conventions Used in this Manual
This manual includes information essential to the safety of personnel, equipment, software, and data. This information is indicated by headings and boxes in the text.
WARNING Information appearing under WARNING concerns the protection of personnel. It is boxed and in bold type to set it apart from other text.
CAUTION Information appearing under CAUTION concerns the protection of equipment, software, and data. It is boxed to set it apart from other text.
NOTE Information appearing next to NOTE concerns related information or useful hints.
Issued United States Patents

One or more of the following U.S. patents might be related to the FANUC Robotics products described in this manual. 3,906,323 4,274,802 4,289,441 4,299,529 4,336,926 4,348,623 4,359,815 4,366,423 4,374,349 4,396,973 4,396,975 4,396,987 4,406,576 4,415,965 4,416,577 4,430,923 4,431,366 4,458,188 4,462,748 4,465,424 4,466,769 4,475,160 4,479,673 4,479,754 4,481,568 4,482,289 4,482,968 4,484,855 4,488,242 4,488,746 4,489,821 4,492,301 4,495,453 4,502,830 4,504,771 4,530,062 4,530,636 4,538,639 4,540,212 4,542,471 4,543,639 4,544,971 4,549,276 4,549,846 4,552,506 4,554,497 4,556,361 4,557,660 4,562,551 4,575,666 4,576,537 4,591,944 4,603,286 4,626,756 4,628,778 4,630,567 4,637,773 4,638,143 4,639,878 4,647,753 4,647,827 4,650,952 4,652,203 4,653,975 4,659,279 4,659,280 4,663,730 4,672,287 4,679,297 4,680,518 4,697,979 4,698,777 4,700,118 4,700,314 4,701,686 4,702,665 4,706,000 4,706,001 4,706,003 4,707,647 4,708,175 4,708,580 4,712,972 4,723,207 4,727,303 4,728,247 4,728,872 4,732,526 4,742,207 4,742,611 4,750,858 4,753,128 4,754,392 4,771,222 4,773,523 4,773,813 4,774,674 4,775,787 4,776,247 4,777,783 4,780,045 4,780,703 4,782,713 4,785,155 4,796,005 4,805,477 4,807,486 4,812,836 4,813,844 4,815,011 4,815,190 4,816,728 4,816,733 4,816,734 4,827,203 4,827,782 4,828,094 4,829,454 4,829,840 4,831,235 4,835,362 4,836,048 4,837,487 4,842,474 4,851,754 4,852,024 4,852,114 4,855,657 4,857,700 4,859,139 4,859,845 4,866,238 4,873,476 4,877,973 4,892,457 4,892,992 4,894,594 4,894,596 4,894,908 4,899,095 4,902,362 4,903,539 4,904,911 4,904,915 4,906,121 4,906,814 4,907,467 4,908,559 4,908,734 4,908,738 4,916,375 4,916,636 4,920,248 4,922,436 4,931,617 4,931,711 4,934,504 4,942,539 4,943,759 4,953,992 4,956,594 4,956,765 4,965,500 4,967,125 4,969,109 4,969,722 4,969,795 4,970,370 4,970,448 4,972,080 4,972,735 4,973,895 4,974,229 4,975,920 4,979,127 4,979,128 4,984,175 4,984,745 4,988,934 4,990,729 5,004,968 5,006,035 5,008,832 5,008,834 5,012,173 5,013,988 5,034,618 5,051,676 5,055,754 5,057,756 5,057,995 5,060,533 5,063,281 5,063,295 5,065,337 5,066,847 5,066,902 5,075,534 5,085,619 5,093,552 5,094,311 5,099,707 5,105,136 5,107,716 5,111,019 5,111,709 5,115,690
iv
CUSTOMER FOCUS CENTER 180047ROBOT

(18004776268) (International: 01112483777159)
SERVICE & REPAIR PRESS 1 Tel: 2483777159 / Fax: 2483777463 24 Hour HotLine
H Technical H Service
PARTS & PART REPAIR PRESS 2 Tel: 2483777278 / Fax: 2483777832 8:00 am to 8:00 pm / Mon Fri
H Parts
TRAINING PRESS 3 Tel: 2483777234 / Fax: 2483777367 8:00 am to 5:00 pm / Mon Fri
H Training
MARKETING & SALES PRESS 4 Tel: 2483777000 / Fax: 2483777366 8:00 am to 5:00 pm / Mon Fri
H Marketing
Support HotLine
for down robots part order part replacement
class registration
Information Review
personnel dispatch
H Replenishment H Warranty H Robot
H Consultation
H Afterhours
parts support (8:00 p.m. to 8:00 a.m.)
for special training or onsite requests
H Application H New
Robot Sales Solution Sales
software and PACs ________________________ For best call results have:

H Customer H Company H Your H Your H Your
H Systems
________________________ For best call results have:

H Customer H Company H Your H Your

H Customer H Company H Your H Your H Part H F#

H Company
number (if known) name
Company H
H Your H Your
name address
name phone & fax numbers & controller type
name phone & fax numbers name & number (if known)
name phone & fax numbers shipping or billing address of courses needed Requirements and controller type Schedules of people attending
name phone & fax numbers of your need
H Robot H F#
H Description
or serial number of robot meter reading (if available) type and edition
H Hour
or serial number of robot, if available (reqd for warranty)
H Types H Robot
H Software H Any
H P.O.,
error messages and LED displays (if applicable)
Credit Card, or Receiving # for warranty, down units, or software & billing addresses
H Special
H Shipping H Reason
H Proposed H Number H Method
H Your
P.O., Credit Card, or Receiving # for warranty or down robot or preventive maintenance service orders
for repair (any symptoms, error codes, or diagnostic LEDs that were identified)
of payment (P.O., credit card, etc.)
*NOTE: A RETURN AUTHORIZATION (RA) FROM PARTS IS REQUIRED BEFORE SHIPPING ANY MATERIAL BACK TO FANUC ROBOTICS FOR PROPER RECEIVING & TRACKING. F# IS LOCATED ON THE ROBOT BASE OR OP. PANEL.
Revised: 12/15/99
MXXXXXXXXXXXXXE REV X
UPDATES
Page4
UPDATES
MARO2P10203704E
Updates1
This section lists the update that has been made to the FANUC Robotics SYSTEM RJ2 Controller P10, P15 and P200 Electrical Maintenance Manual in the following area:
Page
Table 51 Fused FlangeMounted Disconnect Switch, CSize Controller Figure A1 Transportation Figure 1440 P200 Brake Release Option Package
53 A2 1481
Fused FlangeMounted Disconnect Switch, CSize Controller

The correct part number for the 50A fuse is XGMF00382. The correct part number for the 30A fuse is XGMF00160.
Transportation and Installation Addendum A

When transporting a controller, an appropriate certified lifting strap should be used. The term rope is incorrect.
P200 Brake Release Option Package, Figure 1440

The correct terminations for the Axis 4 and 5 wires is as follows: Wire BKP3(Blk5) and BKP3(Blk11) BKM3(Blk6) and BKM3(Blk12) Terminal Location BKP(Terminal 3) BKM(Terminal 4)
UPDATES Updates2
MARO2P10203704E
UPDATES
MARO2P10203704E
Updates3
Figure 11. Main Disconnect Location MAIN DISCONNECT
Fuse Block
FL1 FL2 FL3
Table 11. Input Inp t Voltage 220 240 380 416 460 480 500 550 575
Fused Flange-Mounted Disconnect Switch, C-Size Cabinet
Fused Flange-Mounted Disconnect Switch Fuse Size 50A Part Number Fuse XGMF-00382 (A60L0001-0042 #JG2-50)
30A
Fuse XGMF-00160 (A60L0001-0042 #JG1-30)
20A
Fuse XGMF-04148 (A60L0001-0042 #JG1-20)
UPDATES Updates4
MARO2P10203704E
1.1
TRANSPORTATION
The controller is transported by a crane. Attach a lifting strap to the eye bolts at the top of the controller, as shown in Figure A1.
Figure A1. Transportation
UPDATES
MARO2P10203704E
Updates5
Figure 2. P-200 Brake Release Option Package
MOUNT SWITCHES AND RCS ON ALTERED COVER PLATE
MOUNT TERMINALS AND RELAY ON HEAT EXCHANGER
PURGE UNIT
ROBOT CABLE CONNECTION TO TERMINAL STRIP
BLUE17 BLUE18 BLUE 19 BLUE20 2 TO PURGE BRAKE BOARD BLUE 19 BLUE20 BLUE17 BLUE18 ISB UNIT 6 2 3/4 BLACK5 BLACK6 BLACK11 BLACK12 BLACK17 BLACK18 BATTERY PACK EE3287112XXX AXES 3 & 7 EE3287122XXX EE3287110XXX AXES 1 & 2 EE3287120XXX
EE3287111XXX EE3287121XXX
AXES 4,5,6
NOTE: AXIS 6 WIRES CONNECTED EVEN IN UNITS WHERE AXIS 6 DOES NOT HAVE BRAKES 10 BKM2 OPENER CONNECTIONS INSIDE VIEW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TERMINAL STRIP MOUNTED ON CONTROLLER DOOR HEAT EXCHANGER 1 1 2 2 3 3 4 4 5 6 7 8 9 BKP2
BKM2
BKM1
BKM3
BKM3
BKM4
AXES
AXES 4&5
AXIS 6
AXIS 2
BKM1
BKP2
BKP1
BKP3
BKP3
BKP4
BKP1
AXIS 3
INSTALLATION IN C SIZE CONTROLLER
1&7
P200 BRAKE RELEASE OPTION PACKAGE EE3287516
UPDATES
Page4
UPDATES
MARO2P10203704E
UPDATES 3
MOUNT SWITCHES AND RCS ON ALTERED COVER PLATE
MOUNT TERMINALS AND RELAY ON HEAT EXCHANGER
PURGE UNIT
ROBOT CABLE CONNECTION TO TERMINAL STRIP
BLUE17 BLUE18 BLUE 19 BLUE20 2 TO PURGE BRAKE BOARD BLUE 19 BLUE20 BLUE17 BLUE18 ISB UNIT 6 2 3/4 BLACK5 BLACK6 BLACK11 BLACK12 BLACK17 BLACK18 BATTERY PACK EE3287112XXX AXES 3 & 7 EE3287122XXX EE3287110XXX AXES 1 & 2 EE3287120XXX
EE3287111XXX EE3287121XXX
AXES 4,5,6
NOTE: AXIS 6 WIRES CONNECTED EVEN IN UNITS WHERE AXIS 6 DOES NOT HAVE BRAKES 10 BKM2 OPENER CONNECTIONS INSIDE VIEW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TERMINAL STRIP MOUNTED ON CONTROLLER DOOR HEAT EXCHANGER 1 1 2 2 3 3 4 4 5 6 7 8 9 BKP2
BKM2
BKM1
BKM3
BKM3
BKM4
AXES
AXES 4&5
AXIS 6
AXIS 2
BKM1
BKP2
BKP1
BKP3
BKP3
BKP4
BKP1
AXIS 3
INSTALLATION IN C SIZE CONTROLLER
1&7
P200 BRAKE RELEASE OPTION PACKAGE EE3287516
UPDATES
MARO2P10203704E
Updates1
This section lists the update that has been made to the FANUC Robotics SYSTEM RJ2 Controller P10, P15 and P200 Electrical Maintenance Manual in the following area:
Page
Figure 1440 P200 Brake Release Option Package
1481
P200 Brake Release Option Package, Figure 1440

The correct terminations for the Axis 4 and 5 wires are as follows: Wire BKP3(Blk5) and BKP3(Blk11) BKM3(Blk6) and BKM3(Blk12) Terminal Location BKP(Terminal 3) BKM(Terminal 4)
UPDATES
Updates2
MARO2P10203704E
UPDATES
Page2
UPDATES
MARO2P10203704E
UPDATES 1
Figure 11. P-200 R-J2 Robot Control Drawing Purge and Intrinsic Wiring sheet 1
NONHAZARDOUS LOCATION (250 VAC MAXIMUM) DELTRON W112A 120VAC 24VDC FROM POWER CONVEYOR SUPPLY
NOTE: This page replaces page 1243.

NOTICE NO REVISIONS WITHOUT PRIOR APPROVAL FROM FACTORY MUTUAL (FM)
HAZARDOUS LOCATION CLASS I, II & III DIVISION 1 GROUPS C D E F & G 3 4 CONNECTION CABLE EE3287117XXX N1
ISB34 ISB36
EE3112600 24V OVP UNIT 24V
INTRINSIC SAFETY BARRIER STAHL 9001/0125210014 1 2 IS GND 1 2 ISB1 3 4
OPERATOR PANEL
CNPG EMGIN1 EMGIN2
PANEL I/F
PURGE CIRCUITS CNPG
SOL1 SOL2
BRAKE CONTROL
CNIN FROM I/O
24V I/P SIG 24V
MAIN CPU CRM10 RDI/RDO CNCA
24V TO ACCUFLOW SIG FROM I/O FROM I/O
ISB2 OPTIONAL IS GND 7 4 8 ISB3 6 9 10 KHD2SREX1.2S.P 11 +24 P&F 12 7ISB4KFD2SDEX1.36 + 1 2 8 9 + +1 P&F 10 ISB5 2 7 +24 KHD2CD1.P32 8 8 +1 P&F 2 ISB6 Z787 7 +4 5 3 6 8+ ISB7 Z728 P&F 7 8+ ISB8 Z728 P&F 7 +1 2 +1 2
N4
EE3185356001 BYPASS SWITCH
EE3287328001 CBL
I/P
P1 P4
ISB41 ISB42 ISB51 ISB52 ISB61 ISB62 ISB64 ISB71 ISB72 ISB81 ISB82
UNIT FLOW METER TRIGGER 1 TRIGGER 2
O1 O4
HAND BRKN
ROBOT WIRE HARNESS SOLENOID CABLE EE3287323001 EE3287348001 M1 M4 SOL SOL PURGE PRES. SW CABLE EE3044345001 PS1 PS1 FLOW SW CABLE EE3287340001 FS1 FS1 EE3287324001 BATT BATT
ENCODER
SOLENOID VALVE ROBOT PRESSURE SWITCH ROBOT FLOW SWITCH
ESTOP PCB
A1 C1
IDEC IBRC6062R PRESSURE SWITCH P1 N1 P2 N2 P3 N3 P4 N4 P5 N5 P6 N6
M1 M4
M1 M4 ISTB 1 PSA1 2 PSA2 3 PSB1 4 PSB2 5 FSA1 6 FSA2 7 FSB1 8 FSB2 9 OT11 10 OT12 11 OT21 12 OT22 13 OT31 14 OT32 15 OT41 16 OT42 17 OT51 18 OT52 19 HBK1 20 HBK2 21 TP1 22 TP2 23 EOAT1 24 EOAT2
CRR21 CRR22
A2 C2 FLOW SWITCH
S1 S4
CRR5 BKP4 BKM4 CNIS SERVO TRANSFORMER FOR PAINT RJ TYPE C4 A5 220 VAC C5 +24P A6 0V C6 MISC. SWITCH (RDI2) A3 C3 A4 HAND BROKEN ROBOT OVERTRAVEL SWITCH
I.S. GND X6 FOR PEDESTAL CABLE ROBOT PURGED CAVITY X7 FOR RAIL EE306611500X OPTIONAL CATRAC CABLE OPTIONAL DOOR OPENER DEVICE (FMRC APPROVED) MODEL QDRQ AK1AK2EE306621500XAK3 AK4 EE3066323001
OPENER SOLENOID
AJ1 AJ2
AJ3
AJ4
EE3066322001
OPENER PRESS SWITCH
AH1 AH2
AH3
AH4
EE3066321001
OPENER FLOW SWITCH
220V (43) 220V (44)
TP DISCONNECT SWITCH
AE1 AE2
AE3
AE4
EE3066316001
ENCODER
I.S. GND
X2
FIRE ALARM +24VDC PSU
NOTES: 1.)ACCEPTABLE I.S. BATTERY PACKS: A05B2363C040 EE3185551 2.) ALTERNATE I.S. BATTERY PACKS: A05B2072C181 A05B2047C182 SHALL BE USED PER EG00127SECTION VI 3.) I.S. GROUND CONNECTION SHALL BE PER NEC(NFPA 70) SECTION 50450 AND ANSI/ISA RP 12.6 TO CRS1 (MAIN CPU)
I.S. BATTERY PACK
+ P200 RJ2 MODELS MODEL P2006J2 P2007J2 P2006+2J2 P2007+2J2 P2007+3J2
I.S. GND
6 +
MODEL
F1 F2 F3 F4 F5
R AC S
+V 0V G
MODEL MODEL MODEL
I/S GROUND
ISB UNIT A05B2308C370 I/S TEACH PENDANT A05B2308C300 FRAME GND.
EE-3287-550-001
MARO2P10203703E
Preface
vii
Purpose of this Manual
The SYSTEM R-J2 Controller P-10, P-15 and P-200 Electrical Maintenance Manual provides specific information regarding FANUC Robotics electrical hardware. The information contained within the manual has been arranged so that it can answer specific questions quickly and accurately. Use this table to locate specific information in the manual.
If you want to Find information about a specific topic Identify the components of the SYSTEM R-J2 controller Use diagnostic and controller initialization utilities View status information on teach pendant screens and using other indicators Perform troubleshooting procedures and identify specific errors Look at fuse information or replace a fuse Release the brakes Turn outputs on or off and simulate inputs Master the robot Replace controller components Adjust switch settings and potentiometers on PCBs Find controller connection schematics and connector configurations Find complete schematics of the controller circuitry Find wiring diagrams of the P-200 cables. Find wiring diagrams and schematics for the P-10 and P-15 openers, Integral Pump Control, and the Brake Release Option Use controller transportation and installation information Refer to Table of Contents Chapter 1, Overview Chapter 2, Diagnostic Screens Chapter 3, Lights, Indicators, and LEDs Chapter 4, Troubleshooting Chapter 5, Replacing Fuses Chapter 6, Brakes Chapter 7, Controlling I/O Chapter 8, Mastering Chapter 9, Replacing Components Chapter 10, Board Adjustments and Calibrations Chapter 11, Connections Chapter 12, Schematics Chapter 13, Cables Chapter 14, Openers and Options Appendix A, Transportation and Installation
How to Use this Manual
viii
PREFACE
MARO2P10203703E
Conventions Used in this Manual
This manual includes information essential to the safety of personnel, equipment, software, and data. This information is indicated by headings and boxes in the text.
WARNING Information appearing under WARNING concerns the protection of personnel. It is boxed and in bold type to set it apart from other text.
CAUTION Information appearing under CAUTION concerns the protection of equipment, software, and data. It is boxed to set it apart from other text.
NOTE Information appearing next to NOTE concerns related information or useful hints.
TABLE OF CONTENTS
Page3
MARO2P10203703E
Table of Contents
ix vii xxv
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 BACKPLANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MAIN CPU PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.1 Identifying Kinds of Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 SUB CPU PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 AUX AXIS PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 POWER SUPPLY UNIT PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 EMERGENCY STOP CONTROL PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . 1.8 SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 MULTI-TAP TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 INTERFACE DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.1 Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.2 ABRIO and Genius I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 ETHERNET REMOTE PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 USER TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 HEAT EXCHANGE AND FANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 PURGE CONTROL UNIT A05B2363C020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17 PURGE SYSTEM IBRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 PURGE UNIT POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 PURGE INTRINSICALLY SAFE BARRIERS AND SIGNAL REPEATERS . . . . . . . . . . . . 1.20 BRAKE RELEASE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21 P-10 DOOR OPENER P-15 HOOD AND DECK OPENER (OPTIONS) . . . . . . . . . . . . . . . . 1.22 INTEGRAL PUMP CONTROL (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 13 16 110 110 113 116 117 118 120 127 129 129 133 134 137 138 139 140 141 142 144 145 155 156 157
Chapter 2
DIAGNOSTIC SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 SAFETY SIGNAL STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 VERSION IDENTIFICATION STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MEMORY STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 POSITION STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 AXIS STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 ALARM LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 I/O STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 23 25 28 210 212 216 218
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Chapter 3
LIGHTS, INDICATORS, AND LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 TEACH PENDANT DIAGNOSTIC INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 OPERATOR PANEL AND CABINET LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 SERVO ON LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 CIRCUIT BOARD DIAGNOSTIC LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.1 Power Supply Unit (PSU) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.2 Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.3 Sub CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.4 Modular (Model A) I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.5 Servo Amplifier Diagnostic LED (7-Segment Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.6 Emergency Stop Control Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.7 Module Assembly # EE3044401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.8 Contact Signal Transducer (IBRC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.9 R-J2 Ethernet LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 32 33 34 35 37 38 310 313 314 316 318 319 320
Chapter 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 POWER ON SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 CONTROLLER SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 SERVO LOCKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 CLASS 1 FAULT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 CLASS 2 FAULTS TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 CLASS 3 FAULT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.1 SRVO-001 ER_SVAL1 Operator Panel E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.2 SRVO-002 ER_SVAL1 Teach Pendant E-stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.3 SRVO-003 ER_SVAL1 Deadman switch released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.4 SRVO-004 ER_SVAL1 Fence open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.5 SRVO-005 ER_SVAL1 Robot Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.6 SRVO-006 ER_SVAL1 Hand Broken . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.7 SRVO-007 ER_SVAL1 External Emergency Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.8 SRVO-011 ER_SVAL1 TP Released While Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.9 SRVO-012 ER_SVAL1 Power Failure Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.10 SRVO-014 Fan Motor Abnormal (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.11 SRVO-015 ER_SVAL1 System Over Heat (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . 4.6.12 SRVO-019 ER_SVAL1 SVON input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.13 SRVO-020 ER_SVAL1 SRDY off (TP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.14 SRVO-021 ER_SVAL1 SRDY off (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.15 SRVO-022 ER_SVAL1 SRDY on (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.16 SRVO-023 ER_SVAL1 Stop Error Excess (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . 41 43 44 44 45 421 423 424 425 426 427 428 430 432 434 434 434 435 436 436 437 440 440
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xi 440 441 441 441 441 441 441 442 443 444 446 447 448 448 449 449 450 450 450 450 451 452 452 452 453 453 454 456 456 456 457 457 457 458 458 459 459 459 459 459 460 460
4.6.17 4.6.18 4.6.19 4.6.20 4.6.21 4.6.22 4.6.23 4.6.24 4.6.25 4.6.26 4.6.27 4.6.28 4.6.29 4.6.30 4.6.31 4.6.32 4.6.33 4.6.34 4.6.35 4.6.36 4.6.37 4.6.38 4.6.39 4.6.40 4.6.41 4.6.42 4.6.43 4.6.44 4.6.45 4.6.46 4.6.47 4.6.48 4.6.49 4.6.50 4.6.51 4.6.52 4.6.53 4.6.54 4.6.55 4.6.56 4.6.57 4.6.58
SRVO-024 ER_SVAL1 Move Error Excess (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . SRVO-026 ER_WARN Motor Speed Limit (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . SRVO-027 ER_WARN Robot Not Mastered (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . SRVO-033 ER_WARN Robot Not Calibrated (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . SRVO-035 ER_WARN Joint Speed Limit (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . SRVO-036 Imposition Time Over (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-037 ER_SVAL1 IMSTP Input (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-038 PULSE MISMATCH (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-042 ER_SVAL2 MCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-043 ER_SVAL2 DCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-044 ER_SVAL2 HVAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-045 ER_SVAL2 HCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-046 ER_SVAL2 OVC Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-047 ER_SVAL2 LVAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-049 ER_SVAL1 OHAL1 Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-050 ER_SVAL1 CLALM Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-051 ER_SVAL2 CUER Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-053 ER_WARN Disturbance excess (Group:i Axis: J) . . . . . . . . . . . . . . . . . . . . . . . SRVO-054 ER_SVAL1 DSM memory error (DS:i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-061 ER_SVAL2 CKAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-062 ER_SVAL2 BZAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-063 ER_SVAL2 RCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-064 ER_SVAL2 PHAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-065 ER_WARN BLAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-066 ER_SVAL2 CSAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-067 ER_SVAL2 OHAL2 Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-068 ER_SVAL2 DTERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-069 ER_SVAL2 CRCERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-070 ER_SVAL2 STBERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-071 ER_SVAL2 SPHAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-072 ER_SVAL2 PMAL alarm (Group:%d Axis:%d) . . . . . . . . . . . . . . . . . . . . . . . . SRVO-073 ER_SVAL2 CMAL alarm (Group:%d Axis:%d) . . . . . . . . . . . . . . . . . . . . . . . . SRVO-074 ER_SVAL2 LDAL alarm (Group:%d Axis:%d) . . . . . . . . . . . . . . . . . . . . . . . . SRVO-075 ER_WARN Pulse not established (G:%d A:%d) . . . . . . . . . . . . . . . . . . . . . . . . SRVO-081 ER_WARN EROFL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-082 ER_WARN DAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-083 ER_WARN CKAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-084 ER_WARN BZAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-085 ER_WARN RCAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-086 ER_WARN PHAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-087 ER_WARN BLAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-088 ER_WARN CSAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.6.59 SRVO-089 ER_WARN OHAL2 Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.60 SRVO-090 ER_WARN DTERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.61 SRVO-091 ER_WARN CRCERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . 4.6.62 SRVO-092 ER_WARN STBERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . 4.6.63 SRVO-093 ER_WARN SPHAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.64 SRVO-147 SERVO LVAL(DCLK) alarm (G:%d A:%d) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.65 SRVO-163 ER_FATL DSM Hardware Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.66 SRVO-164 ER_FATL DSM/Servo param mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.67 SRVO-165 ER_FATL Panel (SVON abnormal) E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.68 SRVO-166 ER_FATL TP (SVON abnormal) E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.69 SRVO-167 ER_FATL Deadman switch (SVON abnormal) . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.70 SRVO-168 ER_FATL External/SVON (SVON abnormal) E-Stop . . . . . . . . . . . . . . . . . . . 4.7 CLASS 4 FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.1 Process Fault - Both Guns Do Not Trigger or Work Intermittently . . . . . . . . . . . . . . . . . . . . 4.7.2 Both Guns Will Not Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.3 Paint Gun Trigger Troubleshooting Procedure (Electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.4 Process Fault - Transducer Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.5 Process Fault - Flow Meter Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
460 460 460 460 461 461 461 461 461 461 462 462 463 464 465 466 473 476
Chapter 5
REPLACING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 FUSED FLANGE-MOUNTED DISCONNECT FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 MULTI-TAP TRANSFORMER FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 POWER SUPPLY UNIT FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 SERVO AMPLIFIER FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 EMERGENCY STOP CONTROL PCB FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 PURGE POWER SUPPLY FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 MODULAR I/O (MODEL A) FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 SUB CPU PRINTED CIRCUIT BOARD FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 52 54 55 56 57 58 59 512
Chapter 6
BRAKE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 BRAKE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 62
Chapter 7
CONTROLLING I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 FORCING OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 SIMULATING INPUTS AND OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 SOP I/O STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 72 74 75
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Chapter 8
MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 RESETTING ALARMS AND PREPARING FOR MASTERING . . . . . . . . . . . . . . . . . . . . . 8.2 STANDARD MASTERING FOR THE P-200 ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 SINGLE AXIS MASTERING FOR THE P-200 ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 STANDARD MASTERING FOR THE P-10 DOOR OPENER AND THE P-15 HOOD AND DECK OPENER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 82 84 816 819
Chapter 9
REPLACING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 REPLACING R-J2 BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 REPLACING RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.1 Operator Control Panel Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.2 Emergency Stop Control Board (EMG) Printed Circuit Board Relay Replacement . . . . . . . 9.2.3 Purge Control PCB Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 REPLACING A PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3.1 Removal and Replacement of a Printed Circuit Board from the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3.2 Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 REPLACING A MODULE ON THE MAIN CPU OR AUX AXIS CONTROL PRINTED CIRCUIT BOARD REFER TO CHAPTER 1 FOR PART NUMBERS. . . . . . . . . 9.5 REPLACING AN I/O MODULE (MODEL A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5.1 Replacing a Model A Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5.2 Replacing a Model A I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 REPLACING THE MULTI-TAP TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 REPLACING A SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 REPLACING THE OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9 REPLACING THE FAN MOTOR IN THE BACKPLANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 REPLACING THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11 REPLACING A SERIAL PULSE CODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 92 96 96 97 98 99 910 912 913 916 917 917 919 920 921 922 924 925
Chapter 10
BOARD ADJUSTMENTS AND CALIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 I/P TRANSDUCER/ REGULATOR PERFORMANCE CHECK . . . . . . . . . . . . . . . . . . . . . . 10.2 MANUAL FLOW TEST (BEAKERING TEST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 COLD START (START COLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 POWER ON SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 CONTROLLER SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 SERVO LOCKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 102 105 107 1010 1011 1011
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Chapter 11
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 NOISE REDUCTION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 MODULAR I/O OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 ETHERNET REMOTE PRINTED CIRCUIT BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . 11.4 MODULAR I/O INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 ANALOG INPUT MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 111 112 1111 1112 1114 121 131 141
Chapter 12
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 13
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 14
OPENERS AND OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A
TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.1 Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.2 Assembly During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3 Adjustment and Checks at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1 A2 A3 A3 A4 A5 24 25 28 210 213 217 218 43 44 44 412 464 465 466 473 476 62 72 74 76
List of Procedures
Procedure 21 Procedure 22 Procedure 23 Procedure 24 Procedure 25 Procedure 26 Procedure 27 Procedure 41 Procedure 42 Procedure 43 Procedure 44 Procedure 45 Procedure 46 Procedure 47 Procedure 48 Procedure 49 Procedure 61 Procedure 71 Procedure 72 Procedure 73 Displaying Safety Signal Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displaying the Version Identification Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displaying Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displaying Position Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displaying the Axis Status Pulse Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displaying the Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displaying I/O Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Purge Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo Lockout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Turn-on Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Both Guns Do Not Trigger or Work Intermittently . . . . . . . . . . . . . . . . . . . . . . . . Both Guns Will Not Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paint Gun Trigger Troubleshooting Procedure (Electrical) . . . . . . . . . . . . . . . . . . Transducer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flow Meter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Release Using the Operator Panel Switch . . . . . . . . . . . . . . . . . . . . . . . . . . Forcing Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simulating and Unsimulating Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . Displaying and Forcing SOP I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Preparing the Robot or Opener for Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Standard Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Mastering a Single Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816 Standard Mastering for the P-10 Door Opener and the P-15 Hood and Deck Opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 819 Procedure 91 Replacing the PSU Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Procedure 92 Replacing the SPC Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Procedure 93 Replace PCMCIA Memory Card (Optional) Battery . . . . . . . . . . . . . . . . . . . . . . . 94 Procedure 94 Printed Circuit Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 910 Procedure 95 Replacing Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912 Procedure 96 Replacing a Module on the Main CPU or Aux Axis Control Printed Circuit Board 913 Procedure 97 Replacing the Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 916 Procedure 98 Replacing a Model A Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917 Procedure 99 Replacing a Model A I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917 Procedure 910 Replacing the Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919 Procedure 911 Replacing a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 920 Procedure 912 Replacing the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 921 Procedure 913 Fan Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 922 Procedure 914 Replacing Internal Mounted Serial Pulse Coder . . . . . . . . . . . . . . . . . . . . . . . . . . 925 Procedure 915 Replacing an Externally Mounted Serial Pulse Coder . . . . . . . . . . . . . . . . . . . . . . 927 Procedure 101 Transducer/Regulator Performance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Procedure 102 Manual Flow Test (Beakering Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Procedure 103 Performing a Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Procedure 104 Powering on the Robot Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010 Procedure 105 Controller Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1011 Procedure 106 Servo Lockout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1011
Procedure 81 Procedure 82 Procedure 83 Procedure 84
List of Figures
Figure 11. External View of the P-200 R-J2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12. Internal View of the P-200 R-J2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13. R-J2 C-Size Controller with Side Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14. 2-Slot Backplane (A05B-2316-C107) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 15. 3-Slot Backplane (A05B-2316-C105) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 16. 5-Slot Backplane (A05B-2316-C111) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 17. Main CPU Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 18. Sub-CPU Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 19. Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 110. Aux Axis Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 111. Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 112. Emergency Stop Control Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 113. Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 114. Servo Amplifier Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 115. Mounting Locations of Servo Amplifiers for the P-200 6 Axis Robot . . . . . . . . . . . Figure 116. Mounting Locations of Servo Amplifiers for the P-200 7 Axis Robot . . . . . . . . . . . Figure 117. Mounting Locations of Servo Amplifiers for the P-200 6+2 Robot . . . . . . . . . . . . . 13 14 15 17 18 19 112 114 115 116 117 119 121 122 122 123 123
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Figure 118. Figure 119. Figure 120. Figure 121. Figure 122. Figure 123. Figure 124. Figure 125. Figure 126. Figure 127. Figure 128. Figure 129. Figure 130. Figure 131. Figure 132. Figure 133. Figure 134. Figure 135. Figure 136.
Mounting Locations of Servo Amplifiers for the P-200 7+2 Robot . . . . . . . . . . . . . Mounting Locations of Servo Amplifiers for the P-200 7+3 Robot . . . . . . . . . . . . . Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modular I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ER-1 Ethernet Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ER-2 Ethernet Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . User Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel without Teach Panel Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat Exchange System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purge Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Signal Transducer (IBRC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purge Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intrinsic Safety Barrier Stahl 9001/01-252-100-14 . . . . . . . . . . . . . . . . . . . . . . . . . . Intrinsic Safety Barrier Pepperl + Fuchs KFD2-SR-Ex1.P and KFD2-SR2-Ex1.W . Intrinsic Safety Barrier Pepperl+Fuchs KFD2-SD-Ex1.36 . . . . . . . . . . . . . . . . . . . . Intrinsic Safety Barrier Pepperl+Fuchs KHD2-CD-1P32 and KFD2-CD-Ex1.32 . . . Intrinsic Safety Barrier Pepperl+Fuchs Z727 and Z787 . . . . . . . . . . . . . . . . . . . . . . . Intrinsic Safety Barrier Pepperl+Fuchs KFD2-SR-Ex1.2S.P and KFD2-SR-Ex1.W.LB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 137. C Size R-J2 Controller With Optional Brake Release Switches . . . . . . . . . . . . . . . . Figure 138. P-10 Door opener and P-15 Hood and Deck Opener . . . . . . . . . . . . . . . . . . . . . . . . . Figure 139. Integral Pump Control Component Locator Diagram . . . . . . . . . . . . . . . . . . . . . . . . Figure 140. Top Hat and Side Saddle Mounted Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 21. Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 22. Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 31. Teach Pendant Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 32. Operator Panel LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 33. Servo Amp Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 34. Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 35. Power Supply Unit (PSU) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 36. Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 37. Sub CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 38. Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 39. Servo Amplifier LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 310. Emergency Stop Control Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 311. Intrinsic Barrier Relay Control Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 312. Intrinsic Barrier Relay Control Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 313. ER-1 and ER-2 Printed Circuit Board LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 314. ER-2 Ethernet Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 41. 24 Volt (24V) Power Distribution Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 42. 24 Volt (24E) Power Distribution Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
124 124 128 129 135 136 137 138 139 140 141 143 144 148 149 149 150 150 151 155 156 158 159 22 216 32 33 34 36 37 38 310 313 314 316 318 319 320 321 419 420
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xvii 438 439 445 445 455 467 468 469 470 470 471 472 53 54 55 56 57 58 59 510 511 512 62 63 84 85 86 87 88 89 810 811 812 813 816 820 821 822 823 92 94 95
Figure 43. Servo Amplifier Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 44. Connector and Terminal (T1) Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 45. Switch 3 and 4 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 46. Servo LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 47. Module Assembly # EE-3044-401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 48. I/O Module LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 49. Interface Module PWR LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 410. Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 411. Pin Out and Locator for Connector CP32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 412. Interface Module PWR LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 413. Intrinsic Safety Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 414. Intrinsic Safety Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 51. Main Disconnect Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 52. Replacing Transformer Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 53. Replacing a Fuse of the Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 54. Replacing Fuses of Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 55. Replacing Emergency Stop Control Board Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 56. Purge Power Supply Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 57. Interface Module AIF01A Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 58. Modular I/O Fuse Locations AOA05E, ADA08E, and AOA12F . . . . . . . . . . . . . . . Figure 59. Modular I/O Fuse Locations AOS08C and AOD08D . . . . . . . . . . . . . . . . . . . . . . . . Figure 510. Main CPU Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 61. Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 62. C Size R-J2 Controller With Optional Brake Release Switches . . . . . . . . . . . . . . . . . Figure 81. Zero Degree Position of the P-200 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 82. Axes 4, 5, and 6 1005 Wrist Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 83. Axes 4, 5, and 6 1005 Wrist Mastering Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 84. Axes 4, 5, and 6 1405 Wrist Mastering Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 85. Robot Pedestal Axis 1 1005/1405 Mastering Surface Location . . . . . . . . . . . . . . . . . . Figure 86. Axis 2 1005/1405 Mastering Surface Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 87. Axis 3 1005 Mastered Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 88. Axis 3 Mastering Position (1405 Wrist) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 89. Mastering Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 810. Axis 7 Mastering Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 811. Mastering Position of the P-200 robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 812. P-10 and P-15 Opener Mastering Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 813. P-10 and P-15 Axis One Mastering Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 814. P-10 and P-15 Axis Two Mastering Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 815. P-10 and P-15 Axis Three Mastered Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 91. Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 92. Internal View of the P-200 R-J2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 93. Replacing Memory Card Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Figure 94. 3-Slot Backplane (A05B-2316-C105) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 95. Operator Control Panel Relay Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 96. EMG Printed Circuit Board Relay Locations for B-Size Cabinet . . . . . . . . . . . . . . . . Figure 97. Purge Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 98. Battery Transfer to Maintain CMOS RAM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 99. Replacing the Components on the Backplane Printed Circuit Board . . . . . . . . . . . . . . Figure 910. Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 911. Moving the Latches on the End of the Module Socket . . . . . . . . . . . . . . . . . . . . . . . Figure 912. Installing a New Module at an Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 913. Pushing in the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 914. Mounting Locations of the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 915. Replacing the Base Unit of the Model A I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 916. Replacing a Model A I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 917. Replacing the Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 918. Replacing a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 919. Replacing the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 920. Replacing the Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 921. Replacing the Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 922. Removing the Internally Mounted serial pulse coder . . . . . . . . . . . . . . . . . . . . . . . . . Figure 923. Removing the Black Plastic Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 101. Emergency Stop Control Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 102. Teach Pendant and Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 111. ER-1 and ER-2 Printed Circuit Board LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 121. R-J2 P-200 Controller Total Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 122. R-J2 P-200 Controller Total Circuit Diagram (Multi-Tap Transformer Details) . . . . Figure 123. R-J2 P-200 Controller Total Circuit Diagram (Amplifier Configurations) . . . . . . . . Figure 124. R-J2 P-200 Controller Total Circuit Diagram (Amplifier Configurations) . . . . . . . . Figure 125. R-J2 P-200 Controller Total Circuit Diagram (Amplifier Configurations) . . . . . . . . Figure 126. R-J2 P-200 Controller Total Circuit Diagram (AMP PWM Signal Connections) . . . Figure 127. R-J2 P-200 Controller Total Circuit Diagram (Power Supply Connections) . . . . . . . Figure 128. R-J2 P-200 Controller Total Circuit Diagram (CPU Connector Details) . . . . . . . . . Figure 129. R-J2 P-200 Controller Total Circuit Diagram (ESTOP Connection Details) . . . . . . . Figure 1210. R-J2 P-200 Controller Total Circuit Diagram (Optional Process I/O Connections) Figure 1211. R-J2 P-200 Controller Total Circuit Diagram (Optional I/O Connections) . . . . . . . Figure 1212. R-J2 P-200 Controller Total Circuit Diagram (Purge Circuitry) . . . . . . . . . . . . . . . Figure 1213. R-J2 P-200 Controller Total Circuit Diagram (Purge Wiring Diagram) . . . . . . . . . Figure 1214. R-J2 P-200 Controller Total Circuit Diagram (Purge Board Details) . . . . . . . . . . . Figure 1215. R-J2 P-200 Controller Total Circuit Diagram (ESTOP Wiring Detail) . . . . . . . . . . Figure 1216. R-J2 P-200 Controller Total Circuit Diagram (OP Panel Details) . . . . . . . . . . . . . . Figure 1217. R-J2 P-200 Controller Total Circuit Diagram (Operator Panel) . . . . . . . . . . . . . . . . Figure 1218. R-J2 Controller P-200 Amplifier Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1219. R-J2 Robot Controller Cabinet Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95 96 97 98 99 911 912 913 914 914 915 916 918 919 920 921 923 924 926 927 104 108 1111 123 125 127 129 1211 1213 1215 1217 1219 1221 1223 1225 1227 1229 1231 1233 1235 1237 1239
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xix 1241 1243 1245 1247 1249 1251 1253 1255 1257 1259 1261 1263 1265 1267 1269 1271 1273 1275 1277 1279 1281 1283 1285 1287 133 135 137 139 1311 1313 1315 1317 1319 1321 1323 1325 1327
Figure 1220. P-200 R-J2 Controller FM Retrofit Package Cabinet Layout . . . . . . . . . . . . . . . . . Figure 1221. P-200 R-J2 Robot Control Drawing Purge and Intrinsic Wiring sheet 1 . . . . . . . . . Figure 1222. P-200 R-J2 Robot Control Drawing Purge and Intrinsic Wiring sheet 2 . . . . . . . . . Figure 1223. P-200 R-J2 Control Drawing Purge and Intrinsic Wiring Sheet 3 . . . . . . . . . . . . . . Figure 1224. P-200 R-J2 Pedestal North American Purge, No PGS (Seal Off Reqd) Cable Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1225. P-200 R-J2 Rail Robot North American Purge, PGS For Penetration Plate Cable Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1226. P-200 R-J2 Pedestal Robot PTB Purge, PGS For Penetration Plate Cable Layout . Figure 1227. P-200 R-J2 Rail Robot PTB Purge, PGS For Penetration Plate . . . . . . . . . . . . . . . . Figure 1228. P-200 Controller Basic Process Option I/P Flow and Trigger . . . . . . . . . . . . . . . . . Figure 1229. P-200 Controller Process Option Basic Option With Second Trigger . . . . . . . . . . . Figure 1230. P-200 Controller Bypass Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1231. AccuFlow Counter Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1232. Trigger Valve/Regulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1233. Color Changer 24 Color Moduclean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1234. Upper Gun Control Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1235. Color Changer Lines 24 Color Pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1236. Lower Gun Control Lines Pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1237. Lower Gun Control Lines Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1238. Color Changer Rail 4 Color Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1239. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1240. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1241. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1242. Flow Meter Interface Circuitry FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1243. I/O Rack Layout FANUC R-J2 P-200 Single Stage Purge Paint Control With Connector Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 131. P-200 Purge/Battery/Paint Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 132. P-200 R-J2 Paint Control Robot Arm Cable Dual Trigger . . . . . . . . . . . . . . . . . . . . . Figure 133. P-200 I/P Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 134. P-200 Trigger Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 135. P-200 Flow Detector Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 136. Axes 1 and 2 Power Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 137. Axes 4, 5, and 6 Motor Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 138. Axes 3 and 7 Power Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 139. EE-3287-113-005 through 155 Pulse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1310. P-200 R-J2 Purge/Battery Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1311. P-200 Robot Ground Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1312. Axes 1, 2, and 3 Power and Pulse Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1313. Axes 4, 5, and 6 Power Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Figure 1314. Purge Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1315. Six Axis Battery Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1316. Purge Flow Switch Arm Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1317. Solenoid Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1318. Purge Pressure Switch Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1319. R-J2 Robot Bypass Switch Arm Cable (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 141. P-10 Door Opener Electrical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 142. P-10 Door Opener Euro Electrical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 143. P-200 Plus P-10 or P-15 Controller Bypass Package . . . . . . . . . . . . . . . . . . . . . . . . . Figure 144. P-10 or P-15 Power Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 145. P-10 or P-15 European Shielded Power Connection Cable . . . . . . . . . . . . . . . . . . . . Figure 146. P-10 or P-15 Axis 1 Rail Power/Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 147. P-10 or P-15 Axis 2 Inner Arm Power/Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . Figure 148. P-10 or P-15 Axis 3 Outer Arm Power/Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . Figure 149. P-10 or P-15 Axis 1 Encoder Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1410. P-10 or P-15 Axis 2 Pulse Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1411. P-10 or P-15 Axis 3 Pulse Coder Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1412. P-10 or P-15 Purge Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1413. P-10 or P-15 European Purge Connect Arm Cable . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1414. P-10 or P-15 European Solenoid Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1415. P-10 or P-15 Sensor Splitout Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1416. P-10 or P-15 End of Arm Tool Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1417. P-10 Magnet Sensor Breakaway Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1418. P-10 or P-15 Solenoid Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1419. Ground Cable M5 to M5 Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1420. P-10 Breakaway Magnet Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1421. P-15 Hood/Deck Opener Electrical Layout Domestic Version . . . . . . . . . . . . . . . . . Figure 1422. P-15 Hood/Deck Opener Electrical Layout European Version . . . . . . . . . . . . . . . . . Figure 1423. P-15 Opener End of Arm Tooling Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1424. P-15 Part Present Proximity Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1425. Integral Pump Control Drawing Index and System Index . . . . . . . . . . . . . . . . . . . . Figure 1426. Integral Pump Control I/O Rack Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1427. Integral Pump Control Controller Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1428. Top Hat Option Drawing Index and System Layout . . . . . . . . . . . . . . . . . . . . . . . . Figure 1429. Side Saddle Option Drawing Index and System Layout . . . . . . . . . . . . . . . . . . . . . Figure 1430. Top Hat and Side Saddle Option Drawing Index and System Layout . . . . . . . . . . . Figure 1431. Top Hat and Side Saddle Option Cable and Wiring Diagram . . . . . . . . . . . . . . . . . Figure 1432. Top Hat and Side Saddle Option Purge and Intrinsic Wiring Control Drawing . . . . Figure 1433. Top Hat and Side Saddle Options Cable Layout Diagram . . . . . . . . . . . . . . . . . . . . Figure 1434. Top Hat Option Intrinsic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1435. Side Saddle Option Intrinsic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1436. Top Hat and Side Saddle Options Axis 3, Pumps 1 and 2 Motor Power Cable Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1329 1331 1333 1335 1337 1339 143 145 147 149 1411 1413 1415 1417 1419 1421 1423 1425 1427 1429 1431 1433 1435 1437 1439 1441 1443 1445 1447 1449 1451 1453 1455 1457 1459 1461 1463 1465 1467 1469 1471 1473
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Figure 1437. Top Hat and Side Saddle Options Pumps 1 and 2 Pulse Cable Reference . . . . . . . . Figure 1438. Top Hat and Side Saddle Options Intrinsic Cable Reference . . . . . . . . . . . . . . . . . . Figure 1439. Integral Pump Control Process Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1440. P-200 Brake Release Option Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1441. P-200 Brake Release Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A1. Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2. Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A3. Assembly During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Tables
Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table 11. Main CPU Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. Sub CPU Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13. Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14. Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15. Multi-Tap Transformer Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16. Selecting Transformer Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. Digital Input Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18. Digital Output Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19. I/O Module Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110. FANUC R-J2 Ethernet Remote Style Printed Circuit Board Part Numbers . . . . . . . 111. Purge Intrinsically Safety Barriers and Signal Repeaters . . . . . . . . . . . . . . . . . . . . . 112. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21. Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22. Version Identification Status Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23. Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24. Axis Status Pulse Screen Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31. Teach Pendant Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32. Standard Operator Panel Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33. Servo Amp On Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34. Troubleshooting Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . 35. Troubleshooting Sub CPU Board STATUS LEDs (Green) . . . . . . . . . . . . . . . . . . . . . 36. Troubleshooting Sub CPU Board ALARM LEDs (Red) . . . . . . . . . . . . . . . . . . . . . . 37. Troubleshooting Sub CPU Board ALARM LEDs (Red) . . . . . . . . . . . . . . . . . . . . . . 38. Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39. Servo Amplifier LED Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310. Emergency Stop Control Printed Circuit Board LED Functions . . . . . . . . . . . . . . . 311. Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312. Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313. ER-1 Alarm LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314. ER-2 Alarm LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41. Troubleshooting Procedure 1 (Initial Purge Troubleshooting Procedure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 114 125 126 127 128 131 131 132 134 145 151 23 25 28 212 32 33 34 39 311 312 312 313 315 317 318 319 322 322 46
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Table 42. Table 43. Table 44. Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table
Troubleshooting Procedure 2 (IBRC Troubleshooting Procedure) . . . . . . . . . . . . . . . Troubleshooting Procedure 3 (Non-Specific Purge Problems) . . . . . . . . . . . . . . . . . . Troubleshooting Procedure 4 (General Power Supply Troubleshooting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45. Troubleshooting Procedure 5 (Transformer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46. Troubleshooting Procedure 6 (Power Supply Alarms) . . . . . . . . . . . . . . . . . . . . . . . . 47. Troubleshooting Procedure 7 (Power Supply Output) . . . . . . . . . . . . . . . . . . . . . . . . 48. Class 2 Faults Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49. SRVO-001 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410. SRVO-002 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411. SRVO-003 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412. SRVO-004 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413. SRVO-005 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414. SRVO-006 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415. SRVO-006 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416. SRVO-014 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417. SRVO-015 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418. SRVO-019 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419. SRVO-020 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420. SRVO-021 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421. SRVO-022 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422. SRVO-023 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423. SRVO-038 Alarm Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424. SRVO-042 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425. SRVO-043 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426. SRVO-044 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427. SRVO-045 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428. SRVO-047 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429. SRVO-049 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430. SRVO-050 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431. SRVO-051 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432. SRVO-061 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433. SRVO-062 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434. SRVO-063 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435. SRVO-064 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436. SRVO-065 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437. SRVO-066 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438. SRVO-067 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439. SRVO-068 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440. SRVO-071 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441. SRVO-072 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442. SRVO-071 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 410 413 415 417 419 421 424 425 426 427 428 431 432 434 435 436 436 437 440 440 442 443 444 446 447 448 449 449 450 450 451 452 452 452 453 453 455 456 457 457
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xxiii 457 458 458 459 53 54 55 56 57 58 59 512 75 75 96 97 98 924 103 112 113 114 115 116 117 118 119 1110 1112 1113 1114 A6
Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table
443. SRVO-071 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444. SRVO-071 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445. SRVO-081 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446. SRVO-082 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51. Fused Flange-Mounted Disconnect Switch, C-Size Cabinet . . . . . . . . . . . . . . . . . . . 52. Multi-Tap Transformer Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53. PSU Fuse Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54. Servo Fuse Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55. Emergency Stop Control Printed Circuit Board Fuses . . . . . . . . . . . . . . . . . . . . . . . . 56. Emergency Stop Control PCB Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57. Emergency Stop Control PCB Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58. Emergency Stop Control PCB Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71. Standard Operator Panel Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72. Standard Operator Panel Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91. EMG Printed Circuit Board Relay Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92. EMG Printed Circuit Board Relay Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93. EMG Printed Circuit Board Relay Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94. Teach Pendant Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101. I/P Transducer/Regulator Performance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111. Output Module AOD32A, Non-isolated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112. Output Modules AOD08C and AOD08D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113. Output Modules AOD16C and AOD16D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114. Output Module AOD32C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115. Output Module AOD32D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116. Output Modules AOA05E and AOA08E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117. Output Module AOA12F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118. Output Modules AOR08G and AOR16G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119. Output Module ADA02A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1110. Input Module AID32B, Non-isolated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1111. Input Modules AID16C and AID16D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112. Analog Input Module AAD04A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1. Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY
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Safety
xxv
FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner, employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace. The appropriate level of safety for your application and installation can best be determined by safety system professionals. FANUC Robotics therefore, recommends that each customer consult with such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC Robotic systems. According to the industry standard ANSI/RIA R1506, the owner or user is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to recognize and respond to known hazards associated with your robotic system and to be aware of the recommended operating procedures for your particular application and robot installation. FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use the robotics system be trained in an approved FANUC Robotics training course and become familiar with the proper operation of the system. Persons responsible for programming the system-including the design, implementation, and debugging of application programs-must be familiar with the recommended programming procedures for your application and robot installation. The following guidelines are provided to emphasize the importance of safety in the workplace.
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CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION
Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety: D The safety of people and equipment D Use of safety enhancing devices D Techniques for safe teaching and manual operation of the robot(s) D Techniques for safe automatic operation of the robot(s) D Regular scheduled inspection of the robot and workcell D Proper maintenance of the robot The safety of people is always of primary importance in any situation. However, equipment must be kept safe, too. When prioritizing how to apply safety to your robotic system, consider the following: D People D External devices D Robot(s) D Tooling D Workpiece Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the installation of some or all of the following devices: D Safety fences, barriers, or chains D Light curtains D Interlocks D Pressure mats D Floor markings D Warning lights D Mechanical stops D EMERGENCY STOP buttons D DEADMAN switches A safe workcell is essential to protect people and equipment. Observe the following guidelines to ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace existing federal, state, and local laws, regulations, and guidelines that pertain to safety. D Sponsor your personnel for training in approved FANUC Robotics training course(s) related to your application. Never permit untrained personnel to operate the robots. D Install a lockout device that uses an access code to prevent unauthorized persons from operating the robot. D Use anti-tie-down logic to prevent the operator from bypassing safety measures. D Arrange the workcell so the operator faces the workcell and can see what is going on inside the cell.
Keeping People and Equipment Safe
Using Safety Enhancing Devices
Setting Up a Safe Workcell
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D Clearly identify the work envelope of each robot in the system with floor markings, signs, and special barriers. The work envelope is the area defined by the maximum motion range of the robot, including any tooling attached to the wrist flange that extend this range. D Position all controllers outside the robot work envelope. D Never rely on software as the primary safety element. D Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the operator and at critical points inside and around the outside of the workcell. D Install flashing lights and/or audible warning devices that activate whenever the robot is operating, that is, whenever power is applied to the servo drive system. D Wherever possible, install safety fences to protect against unauthorized entry by personnel into the work envelope. D Install special guarding that prevents the operator from reaching into restricted areas of the work envelope. D Use interlocks. D Use presence or proximity sensing devices such as light curtains, mats, and capacitance and vision systems to enhance safety. D Periodically check the safety joints or safety clutches that can be optionally installed between the robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove power from the system, and help to minimize damage to the tooling and robot. D Make sure all external devices are properly filtered, grounded, shielded, and suppressed to prevent hazardous motion due to the effects of electro-magnetic interference (EMI), radio frequency interference (RFI), and electro-static discharge (ESD). D Make provisions for power lockout/tagout at the controller. D Eliminate pinch points. Pinch points are areas where personnel could get trapped between a moving robot and other equipment. D Provide enough room inside the workcell to permit personnel to teach the robot and perform maintenance safely. D Program the robot to load and unload material safely. D If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and beacons. D If materials are being applied at dangerously high pressure, provide electrical interlocks for lockout of material flow and pressure.
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Staying Safe While Teaching or Manually Operating the Robot
Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules: D Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. D Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment. D Before teaching, visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These include tooling attached to the wrist flange that extends this range. D The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe working conditions to the supervisor or safety department. D FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except for robot teaching operations. However, if you must enter the work envelope, be sure all safeguards are in place, check the teach pendant DEADMAN switch for proper operation, and place the robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the DEADMAN switch. Only the person with the teach pendant should be in the work envelope. WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death. D Know the path that can be used to escape from a moving robot; make sure the escape path is never blocked. D Isolate the robot from all remote control signals that can cause motion while data is being taught. D Test any program being run for the first time in the following manner: WARNING Stay outside the robot work envelope whenever a program is being run. Failure to do so can result in injury.
Using a low motion speed, single step the program for at least one
full cycle. Using a low motion speed, test run the program continuously for at least one full cycle. Using the programmed speed, test run the program continuously for at least one full cycle. D Make sure all personnel are outside the work envelope before running production.
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Staying Safe During Automatic Operation
Advise all personnel who operate the robot during production to observe the following rules: D Make sure all safety provisions are present and active. D Know the entire workcell area. The workcell includes the robot and its work envelope, plus the area occupied by all external devices and other equipment with which the robot interacts. D Understand the complete task the robot is programmed to perform before initiating automatic operation. D Make sure all personnel are outside the work envelope before operating the robot. D Never enter or allow others to enter the work envelope during automatic operation of the robot. D Know the location and status of all switches, sensors, and control signals that could cause the robot to move. D Know where the EMERGENCY STOP buttons are located on both the robot control and external control devices. Be prepared to press these buttons in an emergency. D Never assume that a program is complete if the robot is not moving. The robot could be waiting for an input signal that will permit it to continue activity. D If the robot is running in a pattern, do not assume it will continue to run in the same pattern. D Never try to stop the robot, or break its motion, with your body. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel, teach pendant, or emergency stop stations around the workcell.
Staying Safe During Inspection
When inspecting the robot, be sure to D Turn off power at the controller. D Lock out and tag out the power source at the controller according to the policies of your plant. D Turn off the compressed air source and relieve the air pressure. D If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY STOP button on the operator panel. D Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery.
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D If power is needed to check the robot motion or electrical circuits, be prepared to press the EMERGENCY STOP button, in an emergency. D Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
Staying Safe During Maintenance
When performing maintenance on your robot system, observe the following rules: D Never enter the work envelope while the robot or a program is in operation. D Before entering the work envelope, visually inspect the workcell to make sure no potentially hazardous conditions exist. D Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. D Consider all or any overlapping work envelopes of adjoining robots when standing in a work envelope. D Test the teach pendant for proper operation before entering the work envelope. D If it is necessary for you to enter the robot work envelope while power is turned on, you must be sure that you are in control of the robot. Be sure to take the teach pendant with you, press the DEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switch to turn off servo power to the robot immediately. D Whenever possible, perform maintenance with the power turned off. Before you open the controller front panel or enter the work envelope, turn off and lock out the 3-phase power source at the controller. D Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake. WARNING Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit breaker to the OFF position removes power from the output side of the device only. D Release or block all stored energy. Before working on the pneumatic system, shut off the system air supply and purge the air lines.
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D Isolate the robot from all remote control signals. If maintenance must be done when the power is on, make sure the person inside the work envelope has sole control of the robot. The teach pendant must be held by this person. D Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked. D Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure that such devices do not create pinch points that could trap personnel.
WARNING Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Doing so can result in serious personal injury and component destruction.
D Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake. D When replacing or installing components, make sure dirt and debris do not enter the system. D Use only specified parts for replacement. To avoid fires and damage to parts in the controller, never use nonspecified fuses. D Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot and all external devices are operating normally.
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KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

Programming Safety Precautions
Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. Some of these measures are outlined below. Make sure you know all associated measures for safe use of such devices.
Implement the following programming safety measures to prevent damage to machine tools and other external devices. D Back-check limit switches in the workcell to make sure they do not fail. D Implement failure routines in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails. D Use handshaking protocol to synchronize robot and external device operations. D Program the robot to check the condition of all external devices during an operating cycle.
Mechanical Safety Precautions
Implement the following mechanical safety measures to prevent damage to machine tools and other external devices. D Make sure the workcell is clean and free of oil, water, and debris. D Use software limits, limit switches, and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices.
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KEEPING THE ROBOT SAFE

Operating Safety Precautions
Observe the following operating and programming guidelines to prevent damage to the robot. The following measures are designed to prevent damage to the robot during operation. D Use a low override speed to increase your control over the robot when jogging the robot. D Visualize the movement the robot will make before you press the jog keys on the teach pendant. D Make sure the work envelope is clean and free of oil, water, or debris. D Use circuit breakers to guard against electrical overload.
Programming Safety Precautions
The following safety measures are designed to prevent damage to the robot during programming: D Establish interference zones to prevent collisions when two or more robots share a work area. D Make sure that the program ends with the robot near or at the home position. D Be aware of signals or other operations that could trigger operation of tooling resulting in personal injury or equipment damage. D In dispensing applications, be aware of all safety guidelines with respect to the dispensing materials. NOTE Any deviation from the methods and safety practices described in this manual must conform to the approved standards of your company. If you have questions, see your supervisor.
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ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS
Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personnel also must work inside the paint booth periodically. Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor. Although paint booth hazards have been minimized, potential dangers still exist. Therefore, todays highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its capabilities. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and high-voltage electrostatic tools. Paint robots are operated in three modes: D Teach or manual mode D Automatic mode, including automatic and exercise operation D Diagnostic mode During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant. In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth or in a designated safe area within the booth whenever automatic mode is initiated at the SOC or MCP. In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds. When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.
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Paint System Safety Features
Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment, personnel must comply strictly with the procedures in the manuals. This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system. The paint system includes the following safety features: D Most paint booths have red warning beacons that illuminate when the robots are armed and ready to paint. Your booth might have other kinds of indicators. Learn what these are. D Some paint booths have a blue beacon that, when illuminated, indicates that the electrostatic devices are enabled. Your booth might have other kinds of indicators. Learn what these are. D EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become familiar with the locations of all E-STOP buttons. D An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres. D A DEADMAN switch is located on each teach pendant. When this switch is held in, and the teach pendant is on, power is applied to the robot servo system. If the engaged DEADMAN switch is released during robot operation, power is removed from the servo system, all axis brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within the system might also E-STOP other robots.
WARNING An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed robot.
D Overtravel by robot axes is prevented by software limits. All of the major and minor axes are governed by software limits. Limit switches and hardstops also limit travel by the major axes.
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D EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all equipment in the booth if a door is opened while the system is operating in automatic or manual mode. For some systems, signals to these switches are inactive when the switch on the SCC is in teach mode. When present, photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit silhouette openings. D System status is monitored by computer. Severe conditions result in automatic system shutdown.
Staying Safe While Operating the Paint Robot
When you work in or near the paint booth, observe the following rules, in addition to all rules for safe operation that apply to all robot systems.
WARNING Observe all safety rules and guidelines to avoid injury.
WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death. D Know the work area of the entire paint station (workcell). D Know the work envelope of the robot and hood/deck and door opening devices. D Be aware of overlapping work envelopes of adjacent robots. D Know where all red, mushroom-shaped EMERGENCY STOP buttons are located. D Know the location and status of all switches, sensors, and/or control signals that might cause the robot, conveyor, and opening devices to move. D Make sure that the work area near the robot is clean and free of water, oil, and debris. Report unsafe conditions to your supervisor. D Become familiar with the complete task the robot will perform BEFORE starting automatic mode. D Make sure all personnel are outside the paint booth before you turn on power to the robot servo system.
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D Never enter the work envelope or paint booth before you turn off power to the robot servo system. D Never enter the work envelope during automatic operation unless a safe area has been designated. D Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. D Remove all metallic objects, such as rings, watches, and belts, before entering a booth when the electrostatic devices are enabled. D Stay out of areas where you might get trapped between a moving robot, conveyor, or opening device and another object. D Be aware of signals and/or operations that could result in the triggering of guns or bells. D Be aware of all safety precautions when dispensing of paint is required. D Follow the procedures described in this manual.
Staying Safe During Maintenance
When you perform maintenance on the painter system, observe the following rules, and all other maintenance safety rules that apply to all robot installations. Only qualified, trained service or maintenance personnel should perform repair work on a robot. D Paint robots operate in a potentially explosive environment. Use caution when working with electric tools. D When a maintenance technician is repairing or adjusting a robot, the work area is under the control of that technician. All personnel not participating in the maintenance must stay out of the area. D For some maintenance procedures, station a second person at the control panel within reach of the EMERGENCY STOP button. This person must understand the robot and associated potential hazards. D Be sure all covers and inspection plates are in good repair and in place. D Always return the robot to the home position before you disarm it. D Never use machine power to aid in removing any component from the robot. D During robot operations, be aware of the robots movements. Excess vibration, unusual sounds, and so forth, can alert you to potential problems. D Whenever possible, turn off the main electrical disconnect before you clean the robot.
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D When using vinyl resin observe the following:
Wear eye protection and protective gloves during application and

removal
Adequate ventilation is required. Overexposure could cause

drowsiness or skin and eye irritation.
If there is contact with the skin, wash with water.

D When using paint remover observe the following:
Eye protection, protective rubber gloves, boots, and apron are

required during booth cleaning.
Adequate ventilation is required. Overexposure could cause

drowsiness.
If there is contact with the skin or eyes, rinse with water for at
least 15 minutes.
1 OVERVIEW
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Topics In This Chapter

Overview
Page
This manual describes the SYSTEM R-J2 controller which is used in conjunction with the P-200 robot, P-10 door opener, P-15 hood and deck opener and the Systems PaintTool software. This chapter describes the major components used in the controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Three styles of backplane are available. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 The main CPU PC board contains the central processing units, integrated circuit, and all the memory used by the controller. . . . . . . . . . . . . . . . . 110 The sub CPU performs all calculations required by the controller. . . . . . . . . . . . . 113 The aux axis printed circuit board contains up to five servo control modules that provide servo control to the available auxiliary axes. . . . . . . . . . . . 116 The power supply unit printed circuit board is supplied with 210 VAC nominal. from the multi-tap transformer and produces DC voltages. . . . . . . . . . . . . . . . . . . 117 Supplies 24 VDC to the (Magnetic Control Contactor), turns off 24 VDC to the (Magnetic Control Contactor) during fault conditions, supplies power to the motor brakes and to the serial pulse coders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 The servo amplifier drives the motor(s) in response to signals from the axis control circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 The multi-tap transformer is supplied 3 phase VAC from the main disconnect or circuit breaker. This supply voltage can range from 220 - 575 volts. To accommodate the various levels of supply, tap selections are provided on the primary side of the transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 The interface between controller and peripheral devices is provided by input and output signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 D Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 D ABRIO and Genius I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Ethernet remote PCBs are an R-J2 option that use communication protocols to back up and restore all the information on a controller to and from an external device, or host computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 The option user transformer supplies 120VAC single phase power to a outlet receptacle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Pushbuttons and LEDs on the operator panel of the R-J2 are used to start and shut down the robot and indicate status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 The teach pendant is a hand held device used to operate and program the robot and controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 The temperature in the controller is kept within operating range through the use of an air-to-airheat exchange system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 The purge control unit consists of an purge intrinsically safe barrier unit module, contact signal transducer, purge control PCB, and 24VDC power supply. . . . . . . 141 The IBRC is an intrinsically safe barrier unit that is used as part of the purge system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 The purge unit power supply is a 24VDC auxiliary power supply used exclusively for the purge system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Backplane Main CPU Printed Circuit Board Sub-CPU Printed Circuit Board Aux Axis Printed Circuit Board Power Supply Unit Printed Circuit Board Emergency Stop Control Printed Circuit Board Servo Amplifiers Multi-Tap Transformer
Interface Devices
Ethernet Remote Printed Circuit Boards User Transformer Operator Panel Teach Pendant Heat Exchange and Fans Purge Control Unit Purge System IBRC Purge Unit Power Supply
1. OVERVIEW
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MARO2P10203703E

Purge Intrinsically Safe Barriers Brake Release (Option) P-10 Door Opener and P-15 Hood and Deck Opener (Option) Integral Pump Control (Option)
Page
The Purge Intrinsically Safety Barriers are used in the purge system in that they restrict power that may cause a spark. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 The brake release option adds (4) optional brake switches to selectively release the gravity and non-gravity axes of the P-200 robot. . . . . . . . . . . . . . . . . . . . . . . . . 155 The P-10 opener is a three axis, electrically-driven door opener and the P-15 opener is a three axis, electrically-driven hood and deck opener. . . . . . . . . 156 The Integral Pump Control option is the FANUC Robotics integrated two component fluid delivery system which features metering pumps directly coupled to FANUC servomotors that are controlled by the FANUC R-J2 controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1. OVERVIEW
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13
1.1
OVERVIEW
The R-J2 controller, hereafter referred to as the controller, contains the computer that operates the robots. It executes a user-defined program to perform the following functions: D Supply drive power to the servomotors of the P-10, P-15, and P-200, robots to move it through a series of program motions. D Send control signals to process devices and other peripheral equipment. The controller consists of modular circuit boards, components, controls and indicators that are housed in a C-size cabinet with or without a side cabinet depending if a door or hood and deck opener are included. Figure 11 illustrates an external view of the controller. Figure 12 illustrates the internal view of the controller. Figure 13 illustrates a R-J2 C-size controller with side cabinet.
Figure 11. External View of the P-200 R-J2 Controller

Teach pendant
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14
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Front Door Servo amplifiers #13
Figure 12. Internal View of the P-200 R-J2 Controller Operator panel Servo amplifier #4 Purge Control Power Supply Purge Control PCB ISBU IBRC Modular I/O rack
Main power disconnect
Flowmeter interface module Fuses FL13 Main CPU
Power supply unit SERVO ON Light Aux axis board
Teach pendant ISB unit SPC battery case
Emergency stop control printed circuit board
User transformer
Multi-tap transformer
1. OVERVIEW
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15
Figure 13. R-J2 C-Size Controller with Side Cabinet
Side cabinet
R-J2-C Size cabinet with door removed
PURGE CONTROL UNIT
24V @ 1.2A
OVP DELTRON W112A

ISB3 ISB4 ISB5 ISB7 ISB9
ISB6 ISB8
AMP 3
AMP 5 ON
AMP 6
AMP 1 AMP 2
CONTACT SIGNAL TRANSDUCER
ON
ON
ON
ON
DISCONNECT
OFF
FANUC AC SERVO AMPLIFIER
OFF
OFF
FANUC AC SERVO AMPLIFIER C series
OFF
OFF
I/O RACK
1W X 4H DUCT EMG BOARD 1 0

MAIN PSU CPU
OPT
AMP 4
STATUS
1 1/2 W X 4H DUCT
USER TRANS.
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16
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1.2
BACKPLANE
2-SLOT A05B-2316-C107 3-SLOT A05B-2316-C105 5-SLOT A05B-2316-C111
Three styles of backplane are available: D 2-Slot D 3-Slot D 5-Slot These three printed circuit boards are interchangeable. The backplane consists of a printed circuit board and two, three, or five board racks attached to it. The controller printed circuit boards are mounted on the backplane printed circuit board. See Figure 14, Figure 15, and Figure 16. It provides the bus structure for communication between the controller printed circuit boards. A thermostat switch is mounted on the backplane printed circuit board. It senses the temperature within the controller. If the internal temperature exceeds 65 degrees centigrade (149 degrees Fahrenheit), the thermostat will open, generating a system overheat alarm. The board racks support the printed circuit boards and guides them into their electrical connectors on the backplane printed circuit board. A 24 VDC cooling fan is mounted in the top of each backplane board rack.
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Figure 14. 2-Slot Backplane (A05B-2316-C107)
2 slot back plane printed circuit board A20B-2001-0860
Total version
Fan
Fan
GND1
Main CPU
Power Supply PCMCIA Memory Card
Backplane Printed Circuit Board
1. OVERVIEW
18
3 slot back plane printed circuit board A20B-2001-0670 Total version
MARO2P10203703E
Fan
Fans
Main CPU Power Supply PCMCIA Memory Card Backplane Printed Circuit Board
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19
5 slot back plane printed circuit board A20B-2001-0990
Total version
Fan
Fan Main CPU Power Supply PCMCIA Memory Card
Backplane Printed Circuit Board
1. OVERVIEW
110
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1.3
MAIN CPU PRINTED CIRCUIT BOARD
A16B32000040
NOTE: This part number specifies a Main CPU without daughter boards.
The main Central Processor Unit printed circuit board is mounted in the slot marked 1 at the far left end of the backplane. It contains the central processing units, integrated circuit, and all the memory used by the controller. The main CPU performs all calculations required by the controller. It generates axis drive signals on the basis of programmed requirements and feedback signals from encoders driven by each axis. The main CPU also acts as the interface between the controller and the operator and attached devices, through connections to: D The I/O unit(s) D The teach pendant D One or more general purpose serial communication ports D The operator panel lights and push buttons A storage capacitor on the main CPU printed circuit board maintains power to the CMOS RAM for short periods of time (up to 30 minutes) if the main CPU is removed from the backplane. The BAT-VBAT connector can be used to connect the battery from the power supply unit to the main CPU when either of the two printed circuit boards is removed from the backplane for an extended period of time. The main CPU consists of a main mother board with several modules installed perpendicular to it. The modules are small printed circuit boards with components surface-mounted on both sides. The modules are installed in sockets, allowing them to be changed quickly and easily.
1.3.1
Identifying Kinds of Memory
The following kinds of memory exist in the controller: D Controller memory D Flash ROM (F-ROM or FROM) D C-MOS RAM D D-RAM (or DRAM)
Controller Memory
Controller memory consists of Flash Read Only Memory (Flash ROM), Complementary Metal Oxide Semiconductor Random Access Memory (C-MOS RAM), and Dynamic Random Access Memory (D-RAM). C-MOS RAM memory stores some robot system software, some application software, and some user programs. Flash ROM stores the majority of the robot system software such as core, and application software. Most of the SYSTEM R-J2 system software executes from D-RAM. When the controller is turned on, the system software is loaded from Flash ROM to D-RAM and then is executed. Teach pendant programs are stored and are executed from C-MOS RAM.
1. OVERVIEW
MARO2P10203703E
111 Flash ROM Module contains System and Application Software. Flash ROM (F-ROM or FROM disk) is not battery-backed but is non-volatile. Non-volatile means that all data in Flash ROM is saved even after you turn off and turn on the controller. Flash ROM has three parts: a system memory section, an image memory section, and a flash file section. The system memory section contains the software that executes all system software. Image memory contains software options. The flash file system section contains space for backing up user programs and robot configuration information. It also holds hidden files required for Re-INIT start (CMOSINIT).
Flash ROM
C-MOS RAM
D-RAM
CMOS RAM Module stores user programs, system variables, I/O configuration files, and mastering data. C-MOS RAM is battery-backed. C-MOS RAM is non-volatile only while the batteries are working. If the batteries are faulty or removed, C-MOS RAM is lost. C-MOS RAM has two parts: the TPP memory pool, and the permanent (PERM) memory pool. D The TPP memory pool contains the teach pendant programs. The PERM memory pool contains system variables. D PERM can also contain system software and options. DRAM (Dynamic) Module loads information from Flash ROM, eliminates fragmentation and must reload after a cold start. D-RAM is volatile, but it is loaded from flash ROM when the controller is turned on. D-RAM also has three parts: a SYSTEM memory pool, an IMAGE memory pool, and a TEMP memory pool. The SYSTEM memory pool contains the software that executes all system software. The IMAGE memory pool contains KAREL programs and software options. The TEMP memory pool contains the read/write scratch space for system and KAREL software and KAREL programs. CAUTION Data in C-MOS RAM can be lost if the battery is removed or loses its charge, or if new core software is loaded on the controller. The C-MOS RAM memory will last for 30 minutes without the battery when power is off. To prevent loss of data, back up or copy all files for permanent storage.
CAUTION To transport or store the contents of the MAIN CPU, you can plug the battery into the VBAT connector in the MAIN CPU. However, do not plug it into the RESET connector; otherwise you could damage equipment. Figure 17 shows the board layout. Table 11 lists the modules available for installation on the board.
1. OVERVIEW
112
Figure 17. Main CPU Printed Circuit Board
MARO2P10203703E
CMOS module Flash ROM module DRAM module Axis module (J1,-J2) Axis module (J3, J4) Axis module (J5, J6)
Table 11. Name Flash ROM Module Flash ROM Module Flash ROM Module Flash ROM Module CMOS RAM Module CMOS RAM Module CMOS RAM Module DRAM Module DRAM Module DRAM Module Axis Control Module Robot Output Driver DV1 and DV2
Main CPU Modules Part Number Remarks 2.0 Mbyte 4.0 Mbyte 6.0 Mbyte 8.0 Mbyte 0.5 Mbyte 1.0 Mbyte 2.0 Mbyte 3.0 Mbyte 4.0 Mbyte 8.0 Mbyte Three required Two required
A20B-2902-0370 A20B-2902-0371 A20B-2902-0372 A20B-2902-0373 A20B-2902-0211 A20B-2902-0210 A20B-2902-0380 A20B-2902-0021 A20B-2902-0531 A20B-2902-0530 A20B-2902-0070 A76L-0151-0062
1. OVERVIEW
MARO2P10203703E
113
1.4
SUB CPU PRINTED CIRCUIT BOARD
A16B3200015
NOTE: This part number specifies a Sub CPU without daughter boards.
The sub Central Processor Unit printed circuit board is mounted in the slot marked 1 at the far left end of the backplane. It contains the central processing units, integrated circuit, and all the memory used by the controller. The sub CPU performs all calculations required by the controller. It generates axis drive signals on the basis of programmed requirements and feedback signals from encoders driven by each axis. The Sub CPU also acts as the interface between the controller and the operator and attached devices, through connections to: D The I/O unit(s) D The teach pendant D One or more general purpose serial communication ports D The operator panel lights and push buttons The sub CPU consists of a main mother board with one module installed perpendicular to it. The module is a small printed circuit board with components surface-mounted on both sides. The module is installed in a socket, allowing it to be changed quickly and easily.
1. OVERVIEW
114
Figure 18. Sub-CPU Printed Circuit Board
MARO2P10203703E
RISC-B FANUC A16B-3200-015 STATUS ALARM
D16
BAT1
VD1

PC3 PC5
JNA

PC13
EPROM MODULE
LV ALM F21 5A
5.0 A
PR1
Table 12. Name ROM Module
Sub CPU Modules Part Number Remarks Memory for the sub-CPU
1. OVERVIEW
MARO2P10203703E
115
Figure 19. Block Diagram
SUB-CPU
DRAM
BUS I/F
SHARED RAM
SUB-CPU
System ROM
FANUC BUS BUS I/F
1. OVERVIEW
116
MARO2P10203703E
1.5
AUX AXIS PRINTED CIRCUIT BOARD
A16B22020820
The auxiliary axis control printed circuit board is mounted in the slot marked 3 at the right end of the backplane. It contains up to five servo control modules that provided servo control of the available auxiliary axes (7 through 16). It is required whenever more than six axes are used, such as for a rail-mounted P-200 robot. See Figure 110.
Figure 110. Aux Axis Printed Circuit Board
JNA
Servo control module (for axis 7 and 8) A20B29020070 Servo control module (for axis 9 and 10) A20B29020070 JRY2 Servo control module (for axis 11 and 12) A20B29020070 Servo control module (for axis 13 and 14) A20B29020070 Servo control module (for axis15 and 16) A20B29020070
LINE2 JF22 RS232C /RS422 JD29
ENC7 JF7
ENC10 JF10
ENC11 JF11
ENC12 JF12
ENC13 JF13
ENC14 JF14
ENC15 JRF1A
ENC16 JRF1B
JV8 AMP7 JV7
AMP8
AMP9 JV9
AMP10 PV10
AMP11 JV11
AMP12 JV12
AMP13 JV13
AMP14 JV14
AMP16 JV16 AMP15 JV15
AUX.AXIS CONT. PCB
ENC8 JF8
ENC9 JF9
1. OVERVIEW
MARO2P10203703E
117
1.6
POWER SUPPLY UNIT PRINTED CIRCUIT BOARD
A16B-1212-0870
The power supply unit printed circuit board is mounted on the backplane in the slot marked PSU. See Figure 111. The power supply unit printed circuit board is supplied with 210 VAC nominal from the multi-tap transformer and produces the following DC voltages: D +24V used: For inputs, outputs receivers, drivers, and relays As the power source for the teach pendant power supply circuitry D +15V, 15V, and +5V used: For logic power within the controller The power supply unit printed circuit board also contains the ON/OFF logic circuits used by the controller. CAUTION The CMOS RAM backup battery is mounted on the power supply unit printed circuit board. Do not remove the board for longer than 30 minutes; otherwise, all controller software will be lost and will need to be reloaded.
Figure 111. Power Supply Unit
JNPO
F1: 7.5A fuse for AC input
PCMCIA receptacle
Battery cover Battery PIL: Green LED for indicating the AC power supply status ALM: Red LED for indicating an alarm F4: 5A fuse for +24E F3: 5A Slow-Blow fuse for +24V (With the battery cover removed)
1. OVERVIEW
118
MARO2P10203703E
1.7
EMERGENCY STOP CONTROL PRINTED CIRCUIT BOARD
A16B-1212-0931
The emergency stop control printed circuit board is mounted on the side of the board rack adjacent to the CPU. See Figure 12, for location. It contains the circuits that: D Supply 24VDC to the servo amplifiers magnetic control contactors (MCCs) during normal operation. D Turn off 24VDC for the MCC during fault conditions such as:
Emergency stop Axis overtravel Safety fence open Teach pendant DEADMAN switch Hand breakage detection
D Supply power to the motor brakes to release them during normal operation. Brake power is turned off (applying motor brakes) during major alarm conditions, or when regulated by the software. There is a second brake circuit that is manually operated by a front panel key switch. See Section 6. This key switch operated circuit provides a method to move the robot manually should servo power fail, or when mastering is required. D Supply 24VDC required for serial pulse code (SPC) encoder operation through the 24 to 5VDC converter unit located within the robot base and switched on through the purge complete relay contacts for protection from explosive gases. Figure 112 shows the emergency stop control printed circuit board layout.
1. OVERVIEW
MARO2P10203703E
119
Figure 112. Emergency Stop Control Printed Circuit Board
COM B HBK B A A
COMMON JUMPER
A=0VDC common B=24VDC common
HAND BROKEN JUMPER
A= USING SWITCH B= BY-PASSING SWITCH
RLY4 RLY5 RLY6 Door interlock jumper/connector
RLY1
RLY2 RLY3
1. OVERVIEW
120
MARO2P10203703E
1.8
SERVO AMPLIFIERS
The servo amplifiers are mounted on the back wall of the controller. See Figure 12 for component location. The servo amplifier drives the motor(s) in response to signals from the axis control circuitry.
Refer to Table 13 for part numbers.
Servo amplifiers are supplied in single, double or triple-axis configurations. CAUTION While two servo amplifiers might look identical, they might have different output power capabilities. If you replace a servo amplifier, make sure that the new unit has the same part number as the old one. Otherwise, the servo amplifier or servomotor might be damaged or destroyed. See Figure 113 for a typical servo amplifier. The P-200 controller uses -series SVU type amplifiers. The features of the servo amplifier units are as follows: D Compact The servo amplifier unit is integrated with a power supply. It enables implementation of a compact system with one or two feed axes. D Satisfies safety standards The servo amplifier unit is designed to comply with the VDE 0160 (Europe), UL (USA), and CSA (Canada) safety standards. D New interfacing capability The servo amplifier unit provides a new interface (type B) as well as the conventional interface (type A) for the CNC. D Up-to-date power device The servo amplifier unit uses an up-to-date power device, IPM (intelligent power module), to reduce power loss and enhance alarm detection, thereby increasing its reliability.
1. OVERVIEW
MARO2P10203703E
121
Figure 113. Servo Amplifier
Circuit breaker Terminal board T1
13 L1C 14 L2C 15 TH1 16 TH2 17 18 19 RC RI RE
1 PE (G) 2 L1 (R) 3 4 5 6 7 8 9 10 11 12 L2 (S) L3 (T) 100A 100B MC1 MC2 U V W G
20 FAN1 21 FAN2
IRL ISL 0V
IRM ISM +5V
LED Fuse
1. OVERVIEW
122
Figure 114. Servo Amplifier Specifications
MARO2P10203703E
Item
Three-phase input for power Single-phase input for control power Control of main circuit Alarm and protection functions
Specifications
Voltage : 200/220/230 VAC +10 %. 15 % Frequency : 50/60 Hz +/- 2Hz Voltage deviation due to load (at maximum output) shall be 79% or less). Voltage : 200/220/230 VAC + 10 %, - 15% Frequency : 50/60 Hz +/- 2Hz Sine-wave PWM control by transistor bridge (IPM) Over-voltage alarm Low control power voltage alarm Low DC link voltage alarm Regenerative discharge control circuit failure alarm Over-regenerative discharge alarm Dynamic brake circuit failure alarm Over-current alarm IPM alarm Circuit breaker
Power Supply
Figure 115 through Figure 119 show the mounting location of amplifiers for various robot locations.
Figure 115. Mounting Locations of Servo Amplifiers for the P-200 6 Axis Robot
Amp1
Amp2
Amp 3
J1-J4
J3-J5
J6
Amp 4 J2
1. OVERVIEW
MARO2P10203703E
123
Figure 116. Mounting Locations of Servo Amplifiers for the P-200 7 Axis Robot
Amp 1
Amp 2
Amp 3
J1-J4
J3-J5
J6-J7
Amp 4 J2
Figure 117. Mounting Locations of Servo Amplifiers for the P-200 6+2 Robot
Amp 1 J1-J4
Amp 2 J3-J5
Amp 3 J6
Amp 4 J2
Amp 5 J7J8
1. OVERVIEW
124
MARO2P10203703E
Figure 118. Mounting Locations of Servo Amplifiers for the P-200 7+2 Robot
Amp 1
Amp 2
Amp 3
J1-J4
J3-J5
J6J7
Amp 4
Amp 5
J2
J8-J9
Figure 119. Mounting Locations of Servo Amplifiers for the P-200 7+3 Robot C-Size Cabinet Side Cabinet
Amp 1 J1-J4
Amp 2 J3-J5
Amp 3 J6J7
Amp 4 J2
Amp 5 J8
Amp 6 J9-J10
1. OVERVIEW
MARO2P10203703E
125
Table 13. Servo Amplifiers Servo Amplifier 3 SVU1-12 J6 A06B-6089H101 SVU2-12/80 L(12A)=J6 M(80A)=J7 A06B-6089-H209 SVU112 J6 A06B-6089H101 SVU1-12 J6 A06B-6089-H101 SVU212/80 L(12A)=J6 M(80A)=J7 A06B-6089-H209 SVU2-12/80 L(12A)=J6 M(80A)=J7 A06B-6089-H209 SVU2-12/80 L(12A)=J6 M(80A)=J7 A06B-6089-H209 Servo Amplifier 4 SVU1130 J2 A06B6089-H106 SVU1-130 J2 A06B6089H106 SVU1-130 J2 A06B6089H106 SVU1-130 J2 A06B-6089-H106 SVU1130 J2 A06B-6089-H106 SVU1-130 J2 A06B6089-H106 SVU1-130 J2 A06B6089-H106 SVU2-12/12 L(12A)=J7 M(12A)=J8 A06B6089-H201 SVU2-80/80 L(80A)=J7 M(80A)=J8 A06B6089H208 SVU2-12/12 L(12A)=J8 M(12A)=J9 A06B-6089H201 SVU280/80 L(80A)=J8 M(80A)=J9 A06B-6089H208 SVU180 J8=(80A) A06B-6089H208 Servo Amplifier 5
Amp Spec. P-200 6 Axes Control
Servo Amplifier 1 SVU2-12/80 L(12A)=J4 M(80A)=J1 A06B6089-H209 SVU2-12/80 L(12A)=J4 M(80A)=J1 A06B6089-H209 SVU2-12/80 L(12A)=J4 M(80A)=J1 A06B6089-H209 SVU212/80 L(12A)=J4 M(80A)=J1 A06B-6089-H209 SVU2-12/80 L(12A)=J4 M(80A)=J1 A06B-6089H209 SVU2-12/80 L(12A)=J4 M(80A)=J1 A06B-6089-H209 SVU2-12/80 L(12A)=J4 M(80A)=J1 A06B-6089-H209 Servo Amplifier 6 SVU280/80 L(80A)=J9 M(80A)=J10 A06B-6089H208
Servo Amplifier 2 SVU212/80 L(12A)=J5 M(80A)=J3 A06B-6089H209 SVU2-12/80 L(12A)=J5 M(80A)=J3 A06B-6089-H209 SVU212/80 L(12A)=J5 M(80A)=J3 A06B6089-H209 SVU2-12/80 L(12A)J5 M(80A)=J3 A06B-6089H209 SVU2-12/80 L(12A)=J5 M(80A)=J3 A06B-6089-H209 SVU212/80 L(12A)=J5 M(80A)=J3 A06B-6089-H209 SVU212/80 L(12A)=J5 M(80A)=J3 A06B-6089-H209
P-200 7 Axes Control
P-200 6+2 (Door Opener) Axes Control P-200 6+2 (Hood Deck) Axes Control P-200 7+2 (Door Opener) Axes Control P-200 7+2 (HoodDeck) Axes Control P-200 7+3 (Opener) Axes Control Amp Spec. P-200 7+3 (Opener) Axes Control
1. OVERVIEW
126
Table 14. Machine Type P-200 6 Axes Servo Amplifier 1 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 OFF 1 ON 2 OFF 3 ON 4 OFF 1 ON 2 OFF 3 ON 4 OFF Servo Amplifier 6 1 ON 2 OFF 3 ON 4 OFF Dip Switch Settings Servo Amplifier 3 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON Servo Amplifier 4 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON
MARO2P10203703E
Servo Amplifier 2 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON
Servo Amplifier 5
P-200 7 Axes
P-200 6 + 2
1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON 1 ON 2 OFF 3 ON 4 ON
P-200 7 + 2
P-200 7 + 3
Machine Type P-200 7 + 3
1. OVERVIEW
MARO2P10203703E
127
1.9
MULTI-TAP TRANSFORMER
Refer to TABLE 15 for part numbers.
The multi-tap transformer is located on the floor of the controller on the right side of the rear cabinet. See Figure 12 for component location. The multi-tap transformer is supplied 3-phase VAC from the main disconnect or circuit breaker. This supply voltage can range from 220 575 volts. To accommodate the various levels of supply, tap selections are provided on the primary side of the transformer. The transformer output supplies the following voltages: D 3phase 210 VAC nominal for the servo amplifiers D 1phase 210 VAC nominal for the backplanemounted components D 1phase 210 VAC nominal for the IBRC module D 1phase 210 VAC nominal for the 24VDC Purge Power Supply D 1phase 100VAC nominal for the brakes and servo amplifier A06B6066Hxxx MCC Two series-connected thermostats are mounted on the transformer. They are connected to fault detection circuitry in one servo amplifier. If the transformer overheats, the controller will signal a SRVO0043 DCAL alarm. Figure 120 shows the transformer. Table 15 and Table 16 list the information necessary for selecting a proper primary tap.
Table 15. Multi-Tap Transformer Part Numbers Part Number A80L00260010#A A80L00240010#A
Transformer Type 7.5kVA 5kVA
1. OVERVIEW
128
Figure 120. Multi-Tap Transformer
MARO2P10203703E
575V 550V 500V 480V 460V 240/415V 220V/380V F4 7.5 F5 7.5 F1 F2 F3 0V 575V 550V 500V 480V 460V 240/415V 220V/380V 0V 575V 550V 500V 480V 460V 240/415V 220V/380V 0V
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
13 31 32 14
A1
A2
23 41 42 24
1 2
3 4
5 6
24
Table 16.
Selecting Transformer Taps Primary Tap Connection Type D DELTA
S pply Voltage Supply 220 240 380 415 460 480 500 550 575
L1 7 6 7 6 5 4 3 2 1
L2 15 14 15 14 13 12 11 10 9
L3 23 22 23 22 21 20 19 18 17
Jumper 815/1623/247 814/1622/246
816
1624
Y STAR
1. OVERVIEW
MARO2P10203703E
129
1.10
INTERFACE DEVICES
The interface between the controller and peripheral devices is provided by input and output signals from one or more of the following: D Modular I/O (Model A) Unit D Distributed I/O (Model B) Unit D Process I/O printed circuit board D A printed circuit board specializing in communicating with a logic controller, which includes
ABRIO for communication to an Allen-Bradley PLC Genius I/O for communication to a GE Fanuc programmable
controller D Digital I/O to and from the robot through the axis control board. D External E-Stop peripheral device connections.
1.10.1
Modular I/O Unit
The modular I/O unit provides communication between the controller and various peripheral devices. See Figure 121.
Figure 121. Modular I/O
Interface Module
I/O Module
Modular I/O Rack (Backplane)
Slot 2 Slot 1 Slot I/F
I/O Module
Interface Module
1. OVERVIEW
130
MARO2P10203703E
The modular I/O unit uses the following communication modes: D Discrete (On or Off) input and output signal lines at 24VDC or 120VAC. Outputs can be sink or source outputs. D Analog signal lines, which can vary from 10VDC to +10VDC The modular I/O unit consists of the following: D The base unit D The interface module D Various discrete input and output (I/O) modules The control can use as many as 64 modular I/O modules concatenated (daisy-chained) together on multiple racks. A single modular I/O unit is referred to as rack 1. The I/O modules are located in slots 1 to 5 or 1 - 10, depending on the model used. Base Unit
5 I/O Module Slot A03B-0807-C002 10 I/O Module Slot A03B-0807-C001
The base unit is the backplane for the modular I/O unit. The interface module and the I/O modules plug into it. The base unit has no LEDs, fuses, or electrical connections, except for the module sockets. The first slot to the left (I/F) always contains the interface module. The other slots are used for the I/O modules. The interface module transfers data between the main CPU and the I/O modules. The interface module is connected to the JD4 connector on the main CPU printed circuit board through connector JD1B. The interface module is always mounted in the I/F (first) slot. Discrete input modules receive 24VDC or 120VAC signals on their terminals and relay the data to the interface module.
Interface Module
With 1 Rack A03B-0807-C011 Additional Racks A03B-0807-C012
Discrete Input Modules

Refer to Table 17 and Table 19 for specifications and part numbers.
Discrete Output Modules

Refer to Table 18 and Table 19 for specifications and part numbers.
Discrete output modules transmit 24VDC or 120VAC signals on their terminals under command of the interface module.
1. OVERVIEW
MARO2P10203703E
131
Table 17. Digital Input Module Specifications Polarity* Both Both NEG POS Both Both Response Time Maximum 20 ms Maximum 2 ms Maximum 20 ms Maximum 20 ms Maximum 20 ms Maximum 2 ms Points 32 32 16 16 32 32 16 External Connection Connector Connector LED Display Not provided Not provided
Input Type Non-isolated DC input
Module Name AID32A AID32B
Rated Voltage 24VDC 24VDC 24 VDC 24VDC 24VDC 24VDC 100~ 120VAC
Rated Current 7.5 mA 7.5 mA 7.5 mA 7.5 mA 7.5 mA 7.5 mA 10.5 mA (120VAC)
Optically isolated DC input inp t
AID16C AID16D AID32E AID32F
Terminal block Provided Terminal block Provided Connector Connector Not provided Not provided
AC input
AIA16G
ON Max 35 ms OFF Max 45 ms
Terminal block Provided
* Polarity is defined as follows:
Negative: 0 V common (current source type); ON when input is at low level. Positive: 24 V common (current sink type); ON when input is at high level. Table 18. Digital Output Module Specifications Points/ Common 8 8 8 8 8 8 External Connection Connector LED Display Not provided Terminal block Provided Terminal block Provided Terminal block Provided Terminal block Provided Connector Not provided Not provided Fuses Not provided Provided Provided Not provided Not provided Not provided Not provided Provided Provided Provided Not provided Not provided
Output Type Not fused DC output Fused DC output
Module Name AOD32A AOD08C AOD08D
Rated Voltage 5~ 24 VDC 12 ~ 24 VDC
Maximum Polarity* Points Current 0.3A NEG 32 2A 2A 0.5 A 0.5 A 0.3 A NEG (Sink) POS (Source) NEG (Sink) POS (Source) NEG (Sink) POS (Source) 8 8 16 16 32
Not fused DC output
AOD16C AOD16D AOD32C
AOD32D Fused AC output AOA05E AOA08E AOA12F Relay output AOR08G AOR16G 100 ~ 240 VAC 100 ~ 120 VAC Maximum 250 VAC /30 VD
0.3 A 2A 1A 0.5 A 4A 2A
32 5 8 12 8 16
8 1 4 6 1 4
Connector
Terminal block Provided Terminal block Provided Terminal block Provided Terminal block Provided Terminal block Provided
* Polarity is defined as follows:
Negative: 0 V common (current sink type); output is at low level when ON. Positive: 24 V common (current source type); output is at high level when ON.
1. OVERVIEW
132
Table 19. DC input module I/O Module Part Numbers Name Non-isolated 32 points 20 ms 32 points 2 ms Optically isolated 16 points NEG 16 points POS 32 points 20 ms 32 points 2 ms AC input module 16 points DC output Not fused module Fused AID32A AID32B AID16C AID16D AID32E AID32F AIA16G 32 points NEG 8 points NEG 8 points POS Not fused 16 points NEG 16 points POS 32 points NEG 32 points POS AC output module Fused 8 points 1A 12 points 0.5 A Relay output module 8 points 4A 16 points 2A Analog input module Analog output module A0D32A AOD08C AOD08D AOD16C AOD16D AOD32C AOD32D
MARO2P10203703E
Part Number A03B-0807-C101 A03B-0807-C102 A03B-0807-C103 A03B-0807-C104 A03B-0807-C105 A03B-0807-C106 A03B-0807-C107 A03B-0807-C162 A03B-0807-C151 A03B-0807-C152 A03B-0807-C153 A03B-0807-C154 A03B-0807-C155 AO3B-0807-C156 A03B-0807-C157 A03B-0807-C158 A03B-0807-C159 A03B-0807-C160 A03B-0807-C161 A03B-0807-C051 A03B-0807-C052
5 points, 2 A AOA05E AOA08E AOA12F AOR08G AOR16G AAD04A ADA02A
1. OVERVIEW
MARO2P10203703E
133
1.10.2
ABRIO and Genius I/O
R-J2 style: A20B-8001-0120-RIO with Ethernet and A20B-8001-0121-RIO A15L-0001-0026-GENIUS I/O Daughter Board and A16B-2203-0291-GENIUS Mother Board PCB
The ABRIO and Genius I/O printed circuit boards use serial communication to interface to a programmable controller. These printed circuit boards are used for communicating control information between the R-J2 controller and the programmable controller. Refer to the following manuals for information on these boards. D A Users Guide to the FANUC Robotics Genius Network Interface for GEFanuc D A Users Guide to the FANUC Robotics Genius Network Interface for GEFanuc (R-H Style Board in R-J2 Controller) D A Users Guide to the FANUC Robotics Remote I/O Interface for an Allen-Bradley PLC (R-H Style Board in R-J2 Controller) D A Users Guide to the FANUC Robotics SYSTEM R-J2 Controller Remote I/O Interface for an Allen Bradley PLC.
1. OVERVIEW
134
MARO2P10203703E
1.11
ETHERNET REMOTE PRINTED CIRCUIT BOARDS
Two general styles of the Ethernet Remote printed circuit board are available. These are D Ethernet Remote-1 Printed Circuit Board (ER-1) D Ethernet Remote-2 Printed Circuit Board (ER-2) The ER-1 style consists of a full-size motherboard printed circuit board with an optionally attached daughter printed circuit board. The five kinds of ER-1 printed circuit boards that support Ethernet are listed in Table 110. See Figure 122 for the ER-1 Printed Circuit Boards. The ER-2 style consists of a single printed circuit board in a half-slot form factor that allows it to be installed in the half slot available in the power supply unit. The three kinds of ER-2 that support Ethernet are listed in Table 110. See Figure 123 for the ER-2 Printed Circuit Boards.
Table 110. FANUC R-J2 Ethernet Remote Style Printed Circuit Board Part Numbers Part ER-2 Ethernet PCB (10Base2) ER-2 A-B RIO/Ethernet PCB (10Base2) ER-2 A-B RIO-Ethernet 10BaseT PCB Greenbook Part Number A05B-2350-J121 A05B-2350-J122 Spare Part Number A20B-8001-0122 A20B-8001-0120
Contact FANUC Robotics Customer Service for part numbers A16B-2201-0892 A20B-9001-0610 A16B-2201-0891 A15L-0001-0026 A16B-2201-0892 A15L-0001-0026 A16B-2201-0892
ER-1 PLC I/O-Ethernet 10Base5 PCB A05B-2300-J122
Order also: ER-1 A-B RIO D-PCB

ER-1 PLC I/O-Ethernet PCB (10Base2)
A05B-2300-J130 A05B-2300-J121 A05B-2300-J131
Order also: ER-1 Genius I/O D-PCB
ER-1 PLC I/O-Ethernet 10Base5 PCB A05B-2300-J122
Order also: ER-1 Genius I/O D-PCB
A05B-2300-J131
ER-1 PLC I/O-Ethernet 10Base5 PCB A05B-2300-J122 ER-1 A-B RIO/Ethernet 10BaseT Kit ER-1T + A-B/RIO ER-1T + GENIUS (Motherboard) ER-1T + GENIUS (Daughterboard)
Contact FANUC Robotics Customer Service for part numbers A05B-2350-J127 A05B-2350-J128 A05B-2300-J131 A16B-2203-0290 A16B-2203-0291 A15L-0001-0026
Refer to the appropriate application-specific SYSTEM R-J2 Software Installation Manual for software part number information.
1. OVERVIEW
MARO2P10203703E
135
Figure 122. ER-1 Ethernet Printed Circuit Boards
ER-1
1 23 4
1 23 4
AB RIO
PF PC IP
ACTIVE POWER
AB
AB
RACK SEL
SMGN
AUI CD27
BAUD SEL DISC/BLK LAST RACK LAST STAT RESTART RACK SIZ
ETHER NET
F1 2.0A
LINK OK
2.0
A
10 BASE T
ER-1 PLC I/O-Ethernet Printed Circuit Board(10Base2)
ER-1 PLC I/O-Ethernet Printed Circuit Board(10BaseT)
1. OVERVIEW
136
MARO2P10203703E
ER-2
ER-2 Ethernet Printed Circuit Board(10Base2)
ER-2 A-B RIO/Ethernet Printed Circuit Board(10Base2)
1. OVERVIEW
MARO2P10203703E
137
1.12
USER TRANSFORMER
A80L-0001-0520
The controller can contain an optional user transformer. It supplies 120VAC single-phase power to a National Electrical Manufacturers Association (NEMA) outlet receptacle and is located on the lower left side of the controller. See Figure 124.
Figure 124. User Transformer
Multi-tap transformer
1. OVERVIEW
138
MARO2P10203703E
1.13
OPERATOR PANEL
A05B-2363-C001 A05B-2363-C002
Pushbuttons and LEDs on the operator panel of the R-J2 are used to start the robot and indicate status. The panel has a port for serial interface to an external device. The operator panel can be equipped with one or both of the following D Disconnectable teach pendant port with a switch for operation without serial interface to an external device. D DB25 connector for serial interface (External disk drive, for example.) An emergency stop button on the operator panel places the system into the emergency stop condition when pressed.
Figure 125. Operator Panel without Teach Panel Disconnect
BATTERY ALARM
ENABLED HOLD OFF
FAULT
FAULT RESET
CYCLE START
ON
PURGE ENABLE
PORT

PURGE FAULT
PURGE COMPLETE

REMOTE REMOTE
LOCAL
BRAKE ENABLE ON OFF HOUR METER
EMERGENCY STOP
1. OVERVIEW
MARO2P10203703E
139
1.14
TEACH PENDANT
A05B2308C300
The teach pendant is a hand held device used to operate and program the robot and controller. See Figure 126. Keys on the teach pendant are used to enter data, jog the robot, and to display menus. The pendant has a liquid crystal display 16 lines long by 40 characters wide. The teach pendant also has an emergency stop button that, when pressed, places the robot into an emergency stop condition. A DEADMAN switch mounted on the back of the teach pendant enables servo drive power if held with the teach pendant on/off switch turned to ON. When the teach pendant switch is turned to OFF, pressing the DEADMAN switch is not required to keep servo drive power enabled.
WARNING The robot will become fully functional and capable of being started at the operator panel if the teach pendant is turned off and the fence circuit is not installed or closed. When working in the robot envelope, ALWAYS CARRY THE TEACH PENDANT and HAVE THE TEACH PENDANT ENABLED. Otherwise, you could injure personnel or damage equipment.
Seven of the keys on the teach pendant provide different functions depending on the software in the controller. Eleven indicators, located on the left side of the LCD display, indicate status of the system. The indicator labels are different based on software operating in the controller. Refer to Chapter 3, Lights, Indicators, and LEDs, for an explanation of the indicators.
Figure 126. Teach Pendant Indicators LCD Display Indicator Labels Emergency Stop Button
DEADMAN Switches
Enable/disable switch Software-Dependent Keys
1. OVERVIEW
140
MARO2P10203703E
1.15
HEAT EXCHANGE AND FANS
Refer to Figure 127 for Fan Part Numbers
The temperature in the controller is kept within operating range through the use of an air-to-air heat exchange system. The controller is sealed to prohibit outside air from entering the controller cabinet. Internal controller air is circulated by fans around the inside of the controller and downward through the internal side of the heat exchange unit. Outside air is circulated upward through the external side of the heat exchange unit also by using a fan. This process cools the inside air. Fans are provided on the printed circuit board racks mounted on the backplane to circulate air over the printed circuit boards. Cooling fins connected to the servo amplifiers are within the heat exchange unit to keep the heat generated by the servo power circuits out of the controller. Figure 127 shows the heat exchange system for the controller.
Figure 127. Heat Exchange System
Backplane fan(s) A90L00010378 A90L00010385#A
Fan 1 A05B2301C901 Fan Assy A90L00010213 Fan
Air flow Internal air Outside air
Fan 2
A05B2051C902 Fan Assy A90L0001219#A Fan
Outside air in
Fan 3 A02B0056C904 Fan Assy A90L00010219#A Fan
1. OVERVIEW
MARO2P10203703E
141
1.16
PURGE CONTROL UNIT
A05B2363C020
The purge control unit consists of an Intrinsically Safe Barrier Unit (ISBU) module, an IDEC model IBRC contact signal transducer (IBRC), purge control PCB, and 24VDC power supply. There are no authorized adjustments on the purge control unit. Refer to Figure 128 for identification of components and Figure 12 for component locations.
WARNING The purge control timer is set at five minutes to conform to Factory Mutual Specifications. Do not adjust the purge control timer; otherwise, an explosion or fire could occur.
Figure 128. Purge Control Unit
Purge control PCB

1 2 3 4 5 6 7 8 9 1011 12 1314 1516 171819 20 21 222324
1 2 3 4
5 6 7 8 9 1011 12 13 14 15 16 1718 19 20 21 22 2324
P1 N1 P2 N2 P3 N3 P4 N4 P5 N5 P6 N6 G
G FG
CH1 CH2 CH3 CH4 CH5 CH6

A1 C1 A2 C2 A3 C3 A4 C4 A5 C5 A6 C6 0V 200V 220V
ISBU
IBRC
Power supply
1. OVERVIEW
142
MARO2P10203703E
1.17
PURGE SYSTEM IBRC
The IDEC model IBRC contact signal transducer is an intrinsically safe isolation unit that is used as part of the purge system. It has six photo-isolated relays and provides an intrinsically safe barrier for the following signals. See Figure 129. D Channel 1 (P1-N1) Pressure switch from robot or pressure switches from robot and opener in series. D Channel 2 (P2-N2) Flow switch from robot or flow switches from robot and opener in series. D Channel 3 (P3-N3) Robot overtravel switches, If used. D Channel 4 (P4-N4) Hand broken signal, If used. D Channel 5 (P5-N5) Teach pendant disconnected, If used. D Channel (P6-N6) End of arm tooling input, Not used. The IBRC operates on 220 (max. 250)VAC from a secondary winding of TF1. There are six red LEDs, one for each device used in the field. There are a pair of terminals, labeled Px and Nx, for each hazardous signal, while the corresponding safe side terminals have Ax and Cx. Ax and Cx are the normally open contact output located on the safe side. When the hazardous location switches are closed, the IBRC LED will be illuminated for that particular contact. Should a jumper be installed across the P and N terminals, the LED for those terminals will be illuminated. When plant air is supplied to the robot, and power is available to the IBRC when the disconnect switch is in the ON position, the PS-1 LED will be illuminated.
A15L00010048
1. OVERVIEW
MARO2P10203703E
143
Figure 129. Contact Signal Transducer (IBRC)
P1 N1 P2 N2 P3 N3 P4 N4 P5 N5 P6 N6 G
FG
idec IZBARL Relay Barrier Type IBRC6062R

Intrinsically Sake Circuit
DC16V
14mA
Safety Rating of Out Put
Relay AC/DC 250V
CH1
CH2
CH3
CH4
CH5
CH6
1. OVERVIEW
144
MARO2P10203703E
1.18
PURGE UNIT POWER SUPPLY
A20B10000472
The Purge Unit Power Supply is a 24VDC auxiliary power supply used exclusively for the purge system. It is mounted alongside the IBRC unit. It provides voltage necessary to energize the purge solenoid valve within the robot and opening devices when applicable. It also provides 24VDC to the relay coils mounted on the piggy-back Purge Control PCB in the EMG module. It requires 210VAC supplied by TF1 and is internally fused by two fuses mounted on the power supply PCB itself, F-11 and F-12. See Figure 130.
Figure 130. Purge Power Supply
Cover
Purge Power Supply F12 F11 Contact Signal Transducer IBRC
1. OVERVIEW
MARO2P10203703E
145
1.19
PURGE INTRINSICALLY SAFE BARRIERS AND SIGNAL REPEATERS
STAHL and PEPPERL+FUCH
The P-200 R-J2 controller contains a number of Intrinsically Safety Barriers (ISB) units and signal repeaters. They are used for the robot or opener purge circuits. The number of barriers and repeaters installed is dependant on the options ordered for that particular installation. The Purge Intrinsically Safety Barriers and repeaters are mounted to the left of the IBRC unit. These devices limit the energy in their respective circuits to eliminate the possibility of an explosion in the hazardous environment of the paint booth. The internal atmosphere of the robot must be considered hazardous prior to operation, therefore a Purge Intrinsically Safe Barrier or repeater device is used to safely control the purge process. Purge Intrinsically Safe Barriers and repeaters are similar to a fuse. If one should be found defective, it must be replaced by a known good Purge Intrinsically Safe Barrier or repeater, and you must discard the defective one. Refer to Table 111 for part number used for specific ISB functions. For detailed illustrations of the Purge Intrinsically Safe Barriers and Signal repeaters see Figure 131 through Figure 136. To troubleshoot faults you might encounter with the Purge Intrinsically Safe Barriers and Signal repeaters refer to Table 112. The barriers ISB1 and ISB2 are used to energize the purge air solenoid valves in the base of the robot or opener. ISB3 and ISB10 are Intrinsically Safe repeater relays which are used to isolate the signals from the robot/opener bypass switches, used to detect that powered down units are out of the way and it is safe for the conveyor to run. ISB4, 5, 6, 7, and 8 are used to provide power and control to the various circuits which control paint flow. ISB9 is use specifically for the P-10 and P-15 openers. ISB9 detects the status of the proximity switch in the openers arm. Refer to Table 111 for additional information regarding intrinsically safety barriers and signal repeaters.
Table 111. Purge Intrinsically Safety Barriers and Signal Repeaters Figure Figure 131 Refer to Figure 1213 Figure 1221 Figure 1222 Figure 1223 Figure 131 Refer to Figure 1213 Figure 1221 Figure 1222 Figure 1223 Description D P-200 Purge Solenoid
Part Number 9001/01-252-100-14
ISB#
Terminals Input Terminals 1 and 2 24V Output Terminals 3 and 4 to purge solenoid Input Terminals 1 and 2 24V Output Terminals 3 and 4 to opener purge solenoid
For P-200+2 versions this barrier is Stahl 9001/01-280-165-10 For openers the barrier is Stahl 9001/01-252-100-14
D Opener Purge Solenoid D For P-200-+2 versions ISB2 use Stahl 9001-01/-280-165-10 D For P-200-+3 (P10) ISB2 use Stahl 9001-01/-252-100-14
1. OVERVIEW
146
MARO2P10203703E
Table 111. (Contd) Purge Intrinsically Safety Barriers and Signal Repeaters Part Number KHD2-SR-Ex1.2S.P KFD2-SR2-Ex1.W.LB SWITCH POSITIONS S1 = I S2 = I S3 = II ISB# Terminals Input Terminals 1+,3 DC8V/8mA Intrinsically safe Output I Terminals 7,8,9 Output II Terminals 10,11,12 Terminals 14(L+).-.15(L-) DC 20V 30V Input Terminals 7 (L+) - 8 (L-) DC 15V 35V Not intrinsically safe Output Terminals 1+ - 224V Intrinsically safe Input Power Rail and Terminals 7 (L+),8(L-) DC 20V...35V Output Terminals 1+,2Input not intrinsically safe Terminals 9+, 10-,11+ 28 V, 300 Hazard Area Connections Terminals 1 and 2 Safe Area Terminals 7 and 8 28 V, 300 Hazard Area Connections Terminals 1 and 2 Safe Area Terminals 7 and 8 Figure Figure 132 Refer to Figure 1213 Figure 1221 Figure 1222 Figure 1223 Description D P-200 Bypass Switch D Single Channel D DC 24 V Nominal Power Supply D Selectable Mode of Operation D Output: 1 Signal Output with 2 Form C Relays D Optional Lead Breakage (LB) Monitoring
KFD2-SD-Ex1.36
Figure 133 Refer to Figure 1213 Figure 1221 Figure 1222 Figure 1223
D I/P Power D Single Channel D DC 24 V Loop Powered D Max. 80mA Output Current
KHD2-CD-1.P 32 KFD2-CD-Ex1.32.
Figure 134 Refer to Figure 1213 Figure 1221 Figure 1222 Figure 1223
D I/P Signal D Single Channel D DC 24 V Nominal Power Supply D Voltage/Current or Current /Voltage Conversion D Adjustable Zero Point Zero D Conversion Ranges: 0/4-20mA, 0/1-5V, 0/2-10V D 24 V Power for Flow meter D Single or Double Channel D Positive Polarity D SafeSnap Zener Barrier D ISB7 = Trigger 1 Signal D ISB8 = Trigger 2 Signal D Single Channel D Positive Polarity D SafeSnap Zener Barrier
Z787 6
Figure 135 Refer to Figure 1213 Figure 1221 Figure 1222 Figure 1223 Figure 135 Refer to Figure 1213 Figure 1221 Figure 1222 Figure 1223
Z728 7 and 8
1. OVERVIEW
MARO2P10203703E
147
Table 111. (Contd) Purge Intrinsically Safety Barriers and Signal Repeaters
Part Number KHD2-SR-Ex1.P KFD2-SR2-Ex1.W SWITCH POSITIONS S1 = I S2 = II S3 = I KHD2-SR-Ex1.P KFD2-SR2-Ex1.W SWITCH POSITIONS S1 = I S2 = I S3 = II
ISB#
Terminals Input Terminals 1+,3 DC8V/8mA Output Terminals Not intrinsically safe 7,8,9 Terminals 14(L+).-.15(L-) DC 20V 30V Input Terminals 1+,3 DC8V/8mA Output Terminals Not intrinsically safe 7,8,9 Terminals 14(L+).-.15(L-) DC 20V 30V
Figure Figure 136 Refer to Figure 1213 Figure 1223
Description D Single Channel D DC 24 V Nominal Power Supply D Selectable Mode of Operation D 1 Signal Output with 1 Form C Relay D Lead Breakage (LB) Monitoring
Figure 136 Refer to Figure 1213
10
D From P-10 Bypass Switch D Single Channel D DC 24 V Nominal Power Supply D Selectable Mode of Operation D 1 Signal Output with 1 Form C Relay D Lead Breakage (LB) Monitoring
WARNING When you replace this Purge Intrinsically Safe Barrier device, pay careful attention to the exact model or part number. Many models appear physically identical, but have different power ratings and entity ratings. Also, careful observance of which end of the device is considered to be the SAFE side, or the HAZARDOUS side is critical. Typically the end with the Blue colored cap should be connected to the device located in the HAZARDOUS zone for STAHL barriers. Otherwise, you could injure personnel or damage equipment.
1. OVERVIEW
148
Figure 131. Intrinsic Safety Barrier Stahl 9001/01-252-100-14
MARO2P10203703E
STAHL 9001/01-252-100-14
BLUE colored cap
STAHL
1. OVERVIEW
MARO2P10203703E
149
Figure 132. Intrinsic Safety Barrier Pepperl + Fuchs KFD2-SR-Ex1.P and KFD2-SR2-Ex1.W
Pepperl+Fuchs KFD2-SR-Ex1.P KFD2-SR2-Ex1.W
LED Relay output (yellow)
1 4
2 5
3 6
Power (green) LED
LED LB (red) Switch S1= I For Open SW = De-Energized (mode of operation) Switch S2 = II For Lead Breakage on 10-11-12 (switch for output II) I II 7 8 9 10 11 12 13 14 15
Switch S3 = I For Namur Input (LB Monitoring)
Figure 133. Intrinsic Safety Barrier Pepperl+Fuchs KFD2-SD-Ex1.36
Pepperl+Fuchs KFD2-SD-Ex1.36
1 4
2 5
3 6
7 8 9 10 11 12
1. OVERVIEW
150
MARO2P10203703E
Figure 134. Intrinsic Safety Barrier Pepperl+Fuchs KHD2-CD-1P32 and KFD2-CD-Ex1.32
Pepperl+Fuchs KHD2-CD-1.P32 KFD2-CD-Ex1.32
1 4
2 5
3 6
7 8 9 10 11 12
Figure 135. Intrinsic Safety Barrier Pepperl+Fuchs Z727 and Z787
Pepperl+Fuchs Zener Barriers Z727 Z787

1 2 3 4
5 6 7 8
1. OVERVIEW
MARO2P10203703E
151
Figure 136. Intrinsic Safety Barrier Pepperl+Fuchs KFD2-SR-Ex1.2S.P and KFD2-SR-Ex1.W.LB
Pepperl+Fuchs KFD2-SR-Ex1.2S.P KFD2-SR2-Ex1.W.LB
LED Relay output (yellow)
1 4
2 5
3 6
Power (green) LED
LED LB (red) Switch S1 (mode of operation) Switch S2 (no functions) I II 7 8 9 10 11 12 13 14 15 Switch S3 (LB Monitoring)
ISB3 and ISB10 Switch Positions S1 = I S2 = I S3 = II ISB9 Switch Positions S1 = I S2 = II S3 = I
Table 112. ISB 1 Manufacturer Stahl
Troubleshooting Troubleshooting
Symptom: Incomplete purge cycle. See Figure 131 and Refer to Table 111 for additional information. 1. Check for 24 VDC on terminals 1 and 2 during controller purge cycle. If 24VDC is not present troubleshoot controller. If 24VDC is present go to Step 2. 2. Check for 18 VDC on terminals 3 and 4 during controller purge cycle. If 18V is not present barrier is defective. If 18V is present troubleshoot flow switch or robot. Symptom: Incomplete purge cycle. See Figure 131 and Refer to Table 111 for additional information. 1. Check for 24 VDC on terminals 1 and 2 during controller purge cycle. If 24VDC is not present troubleshoot controller. If 24VDC is present go to Step 2. 2. Check for 18 VDC on terminals 3 and 4 during controller purge cycle. If 18V is not present barrier is defective. If 18V is present troubleshoot the opener.
Stahl
1. OVERVIEW
152
Table 112. (Contd) Troubleshooting ISB 3 Manufacturer Pepperl+Fuchs Troubleshooting
MARO2P10203703E
Symptom:No bypass signal in parked position. Robot and or opener are safely parked out of the path of the conveyer. Provides signal to conveyer system. Bypass circuits See Figure 132 or Figure 136 and Refer to Table 111 for additional troubleshooting information. D Yellow LED OFF : Problem in the hazard area (ex. proximity switch wires) go to Step 7. D Green LED power indicator 1. Check for green power ON LED. If LED is not ON go to Step 2. If LED is ON go to Step 7. 2. Check input 120VAC to Deltron 24V power supply. If voltage is present go to Step 3. If voltage is not present troubleshoot 120 VAC from the conveyer. 3. Check output 24V from Deltron to OVP (EE-3112-600). If 24 VDC is present go to Step 4. If 24VDC is not present replace the power supply. 4. Check input 24V to OVP. If 24VDC is present go to Step 5. If 24VDC is not present replace wiring between the power supply and the OVP. 5. Check the output voltage from the OVP. If 24 VDC is present go to Step 6. If 24VDC is not present replace the OVP. 6. Check for 24 VDC between terminals 14 and 15 on the ISB. If 24 VDC is present the ISB is defective . If 24VDC is not present replace the wiring between the OVP and the ISB. 7. Check for signal on terminals 1 and 3 .If signal is present barrier is defective. If signal is not present robot proximity switch may be out of adjustment or defective. Symptom:Problem controlling atomizing pressure. Supplies power to the current to pressure solenoid. See Figure 133 and Refer to Table 111 for additional troubleshooting information. 1. Check for 24VDC input signal on terminals 7 and 8. If 24V is not present troubleshoot the P-200 I/O. If 24VDC is present go to Step 2. 2. Check for 18VDC output signal on terminals 1 and 2. If 18V is not present the barrier is defective . If the 18 VDC output signal is present trouble shoot the current to pressure solenoid Symptom:Problem controlling atomizing pressure. Relays signal to the current to pressure transducer. See Figure 134 and Refer to Table 111 for additional troubleshooting information. 1. Check for 24VDC input signal on terminals 9 and 10. If 24VDC is not present troubleshoot the P-200 I/O. If 24VDC is present go to Step 3. 2. Check for 24VDC output signal on terminals 7 and 8. If 24V is not present check connection to purge control printed circuit board (A16B-1310-0601). If 24VDC is present go to Step 3. 3. Check for 18VDC output signal on terminals 1 and 2. If 18V is not present defective barrier. If 18 VDC signal is present transducer is defective.
Pepperl+Fuchs
Pepperl+Fuchs
1. OVERVIEW
MARO2P10203703E
153
Table 112. (Contd) Troubleshooting
ISB 6
Manufacturer Pepperl+Fuchs
Troubleshooting Symptom:No flowmeter data, accuflow errors. See Figure 135 and Refer to Table 111 for additional troubleshooting information. 1. Check for 24VDC input signal on terminals 7 and 8. If 24VDC is not present troubleshoot controller. If 24VDC is present go to Step 2. 2. Check for 24VDC output signal on terminals 1 and 2. If 24VDC is not present the barrier is defective. If 24VDC is present go to Step 3. 3. Check for input signal on terminals 2 and 4. If input signal from the P-200 flow meter is not present troubleshoot the flow meter. If the input signal is present go to Step 4. 4. Check for output signal on terminals 7 and 8. If the signal is not present the barrier is defective. If the signal is present troubleshoot the P-200 I/O. Symptom:Paint gun will not trigger. Paint process trigger one signal. See Figure 135 and Refer to Table 111 for additional troubleshooting information. 1. Check for 24VDC input signal on terminals 7 and 8. If 24V is not present troubleshoot the P-200 I/O. If the 24VDC is present go to Step 2. 2. Check for output signal on terminals 1 and 2. If the output signal is not present defective barrier. If the output signal is present trouble shoot the number one trigger. Symptom:Paint gun #2 will not trigger. Paint process trigger two signal. See Figure 135 and Refer to Table 111 for additional troubleshooting information. 1. Check for 24VDC input signal on terminals 7 and 8. If 24V is not present troubleshoot the P-200 I/O. If the 24VDC is present go to Step 2. 2. Check for output signal on terminals 1 and 2. If the output signal is not present defective barrier. If the output signal is present trouble shoot the number two trigger.
Pepperl+Fuchs
Pepperl+Fuchs
1. OVERVIEW
154
Table 112. (Contd) Troubleshooting ISB 9 Manufacturer Pepperl+Fuchs Troubleshooting
MARO2P10203703E
Symptom: Opener acquire signal inoperative. See Figure 136 and Refer to Table 111 for additional information. D Yellow LED magnet on opener acquired the door or hood. D Red LED lead breakage indicator D Green LED power is ON. 1. Check for green power ON LED. If LED is not ON go to Step 2. If LED is ON go to Step 3. 2. Check for 24VDC input between terminals 8 and 15, 11 and 15, 14 and 15. If 24VDC is not present at any one of the tested terminals troubleshoot the controller. If 24VDC is present go to Step 3. 3. Check for signal on terminals 1 and 3 .If signal is present barrier is defective. If signal is not present opener lead break switch may be out of adjustment or defective. Symptom: No opener bypass signal in parked position. Robot and or opener are safely parked out of the path of the conveyor. Provides signal to conveyor system. Bypass circuits See Figure 136 and Refer to Table 111 for additional troubleshooting information. D Yellow LED OFF : Problem in the hazard area (ex. proximity switch wires) go to Step 7. D Green LED power indicator 1. Check for green power ON LED. If LED is not ON go to Step 2. If LED is ON go to Step 7. 2. Check input 120VAC to Deltron 24V power supply. If voltage is present go to Step 3. If voltage is not present troubleshoot 120 VAC from the conveyer. 3. Check output 24V from Deltron to OVP (EE-3112-600). If 24 VDC is present go to Step 4. If 24VDC is not present replace the power supply. 4. Check input 24V to OVP. If 24VDC is present go to Step 5. If 24VDC is not present replace wiring between the power supply and the OVP. 5. Check the output voltage from the OVP. If 24 VDC is present go to Step 6. If 24VDC is not present replace the OVP. 6. Check for 24 VDC between terminals 14 and 15 on the ISB. If 24 VDC is present the ISB is defective . If 24VDC is not present replace the wiring between the OVP and the ISB. 7. Check for signal on terminals 1 and 3 .If signal is present barrier is defective. If signal is not present opener proximity switch might be out of adjustment or defective.
10
Pepperl+Fuchs
1. OVERVIEW
155
1.20
BRAKE RELEASE (OPTION)
The brake release option adds (4) optional brake switches to selectively release the gravity and non-gravity axes of the P-200 robot. Refer to Procedure 61 . For circuit schematics and cable diagrams refer to Chapter 14 Openers and Options. WARNING Releasing the brakes could cause the robot to move. Provide support for the arm of the robot before releasing the brakes; otherwise, you could injure personnel or damage equipment.
Figure 137. C Size R-J2 Controller With Optional Brake Release Switches
SYSTEM RJ2
P-200 AXES 1,4,5,7
P-200 AXIS 2
P-200 OPENER ALL AXIS 3 AXES
P-200BRAKE SELECT SWITCHES
P-200 AXES 1,4,5,7
P-200 AXIS 2
P-200 BRAKE SELECT SWITCHES
1. OVERVIEW
156
MARO2P10203703E
1.21
P-10 DOOR OPENER P-15 HOOD AND DECK OPENER (OPTIONS)
The P-10 opener is a three axis, electrically-driven door opener and the P-15 opener is a three axis, electrically-driven hood and deck opener. Refer to Chapter 14, Openers and Options, for schematics and diagrams.
Figure 138. P-10 Door opener and P-15 Hood and Deck Opener
Outer Arm
Axis 3 Link
Inner Arm
Riser (P-15 only) Base
Axis 2
P-10 End of Arm Tool Carriage Axis 1 Rail
P-15 End of Arm Tool
1. OVERVIEW
MARO2P10203703E
157
1.22
INTEGRAL PUMP CONTROL (OPTION)
The Integral Pump Control option is the FANUC Robotics integrated two component fluid delivery system which features metering pumps directly coupled to FANUC servomotors that are controlled by the FANUC R-J2 controller. This is a high performance fluid delivery system that accurately controls variable ratios and flow rates of two component materials. The P-200 robot and the R-J2 controller provide control for the color change sequence, fluid metering and fluid flow control operations. The paint process control enclosure provides the electro-pneumatic interface between the R-J2 controller and the spray applicator. The operator interface is provided via the R-J2 teach pendant. See Figure 139. For circuit schematics and cable diagrams refer to Chapter 14 Openers and Options. Two different styles of the Integral Pump Control are available. The Top hat model which is mounted atop the outer arm and the Side Saddle model which is mounted on the rail next to the robot. See Figure 140. The integrated two component fluid delivery system offers the following features and benefits: D Enhanced trigger response time D Common fluid control and robot motion control architecture D Gear pump and servo motor integral to P-200 robot mechanical unit D Reduced color change time and paint waste compared to conventional wall mounted two component systems D Accurate flow and ratio control through precise pump control The integrated two component fluid delivery system consists of the following major components: D Two mechanical coupled gear pump assemblies D Two FANUC servo controlled motors D One FANUC servo amplifier D Four pressure transducers D One mixing block assembly D One trigger assembly D One purged enclosure D One by-pass manifold D One Sames Moduflow valve stack assembly
1. OVERVIEW
158
MARO2P10203703E
Figure 139. Integral Pump Control Component Locator Diagram
Purge Enclosure
View From Front of Arm By-Pass Block
Mix Valves
OUT
IN
To Gun Axis 3 Trigger Valve Assy Mix Tube
Motor and Gear Reducer Assy. Inlet Regulators Pump Outlet Transducers Gear Pump #1
IN
PR1
BP 1 OUT REG. 1 0100 P.S.I. 0500 P.S.I. IN 0500 P.S.I. IN 0100 P.S.I. REG. 2 BP 2 OUT
FAR SIDE
IN
#1
OUT OUT
PR2
IN
FAR SIDE
#2
OUT
Pump Inlet Transducers
Gear Pump #2
1. OVERVIEW
MARO2P10203703E
159
Figure 140. Top Hat and Side Saddle Mounted Models
Top Hat Mounted
Side Saddle Mounted
2 DIAGNOSTIC SCREENS
Page2
MARO2P10203703E
DIAGNOSTIC SCREENS
21

Safety Signals Version ID Status Memory Status Position Status Axis Status Alarm Log I/O Status
Page
The safety signal screen displays the status of safety-related control signals coming into the controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 The STATUS Version ID screen displays information specific to your controller. 25 The STATUS Memory screen displays information about controller memory. . . . 28 The POSITION screen displays positional information in joint angles or Cartesian coordinates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 The axis status screen displays information for each axis. . . . . . . . . . . . . . . . . . . 212 The Alarm Log displays a list of the 100 most recent alarms. . . . . . . . . . . . . . . . . 216 You can view the status of an I/O signal by displaying a status screen. . . . . . . . . 218
Various built-in diagnostic screens reveal important information regarding the status of the controller. This section describes each of these screens in detail. The diagnostic screen section provides coverage of the P-200. Figure 21 displays the teach pendant that displays the Status Screens.
2. DIAGNOSTIC SCREENS
22
Figure 21. Teach Pendant
MARO2P10203703E
FAULT HOLD STEP BUSY RUNNING MAN ENBL PROD MODE JOINT XYZ TOOL
OFF
ON
MAN FCTNS MOVE MENU
QUEUE
APPL INST
POSN
ALARMS
STATUS
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23
2.1
SAFETY SIGNAL STATUS
The safety signal screen displays the status of safety-related control signals coming into the controller. The safety signal screen displays the current state (TRUE or FALSE) of each safety signal. You cannot change the condition of the safety signal using this screen. Table 21 lists and describes each safety signal. Use Procedure 21 to display safety signal status.
Table 21. Safety Signals DESCRIPTION
SAFETY SIGNAL SOP E-Stop TP E-Stop Ext E-Stop
Indicates whether the EMERGENCY STOP button on the operator panel has been pressed. The status is TRUE if the operator panel EMERGENCY STOP button has been pressed. Indicates whether the EMERGENCY STOP button on the teach pendant has been pressed. The status is TRUE if the teach pendant EMERGENCY STOP button has been pressed. Indicates whether an external emergency exists. The status is TRUE if the external emergency stop contacts are open on the emergency control (EMG) printed circuit board and the following conditions exist: D SOP E-STOP is FALSE D TP E-Stop is FALSE D Hand Broken is FALSE D Overtravel is FALSE If any one of these conditions is TRUE, Ext E-Stop is displayed as FALSE even though these contacts could be open.
Fence Open TP Deadman
Indicates whether the safety fence switch is open. The status is TRUE if the safety fence contacts are open on the emergency control (EMG) printed circuit board. Indicates when either the left or right teach pendant DEADMAN switch is pressed. The status is TRUE if either DEADMAN switch is pressed. When released with teach pendant enabled, this alarm shuts off servo power. Indicates whether the teach pendant ON/OFF switch is ON. The status is TRUE when the teach pendant ON/OFF switch is ON. Indicates whether the safety joint switch in the robot hand has been tripped and the hand might be damaged. The status is TRUE when the safety joint switch has been tripped. This turns off the hand broken signal (*HBK) to the axis control printed circuit board. This alarm shuts off servo power. Indicates whether the robot has moved beyond its overtravel limits. The status is TRUE when the robot has moved beyond its overtravel limits tripping the overtravel switch. This turns off (*ROT) to the axis control printed circuit board. This alarm shuts off servo power. Indicates whether the air pressure has decreased below the acceptable limit. Low Air Alarm is usually connected to an air pressure sensing device. The status is TRUE when the air pressure is below the acceptable limit. This opens the pressure switch which turns off (*PPABN) to the axis control printed circuit board. You must set the $PPABN_ENBL system variable to TRUE to use this signal. This alarm shuts off servo power.
TP Enable Hand Broken
Overtravel
Low Air Alarm
24
MARO2P10203703E
Procedure 21 Step
Displaying Safety Signal Status 1 Press MENUS. 2 Select STATUS. 3 Press F1, [TYPE]. 4 Select Safety Signal. You will see a screen similar to the following.
STATUS Safety 1 2 3 4 5 6 7 8 9 SIGNAL NAME SOP EStop: EStop SOP TP EStop: Ext EStop: Fence Open: TP Deadman: TP Enable: Hand Broken: Overtravel: Low Air Alarm STATUS TRUE FALSE FALSE FALSE FALSE FALSE FALSE FALSE FALSE JOINT 10 % 1/10
[ TYPE ]
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25
2.2
VERSION IDENTIFICATION STATUS
The STATUS Version ID screen displays information specific to your controller. Use this information when you call the FANUC Robotics Hotline if a problem occurs with your controller. You cannot change the information displayed on this screen. Table 22 lists and describes the version identification status information.
Table 22. Version Identification Status Items DESCRIPTION Lists the software item loaded. Lists the version number of the software item loaded.
ITEM SOFTWARE ID
Use Procedure 22 to display version identification status. Procedure 22 Step Displaying the Version Identification Status 1 Press STATUS. 2 Press F1, [TYPE]. 3 Select Version ID. You will see a screen similar to the following.
STATUS Version ID SOFTWARE: PaintTool P-200 Robot Servo Code Motion Parameter Std Operating System PaintTool Softparts Core Built-ins Paint Built-ins User Frame JOINT ID: V4.30 V4.30 JB08.03 10 % 1/24
1 1: 2: 3: 4: 5: 6: 7: 8: 9: 10:
11: Background Editing 12: PLC I/O (A-B/GENIUS) 13: Core PaintTool 14: Paint Tool Tracking 15: Color Change V4.30 16: MOTET Interface V4.30 17: KAREL Command Lang V4.30 18: 19: 20: 21: 22: 23: 24: [ TYPE ] SOFTWARE MOT_ID MOT_INF
SER_PAR
26
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4 Press the key that corresponds to the version ID status screen you want to display: D To display software version information, press F2, SOFTWARE. D To display motor types for each axis, press F3, MOT_ID. You will see a screen similar to the following.
STATUS Version IDs 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: GRP: 1 1 1 1 1 1 * * * * AXIS: 1 2 3 4 5 6 * * * *
JOINT MOTOR ID: ACA3/3000 40A ACA3/3000 40A ACA1/3000 12A ACA0.5B/3000 12A ACA0.5B/3000 12A ACA0.5B/3000 12A Uninitialized Uninitialized Uninitialized Uninitialized MOT_ID MOT_INF
10 % 1/16
[ TYPE ] SOFTWARE
SER_PAR
D To display the motor information for each axis, press F4, MOT_INF. You will see a screen similar to the following.
STATUS Version IDs GRP: AXIS: 1: 1 1 2: 1 2 3: 1 3 4: 1 4 5: 1 5 6: 1 6 7: * * 8: * * 9: * * 10: * * [ TYPE ] SOFTWARE JOINT 10 % MOTOR INFO: 1/16 H1 DSP1L H2 DSP1M H3 DSP2L H4 DSP2M H5 DSP3L H6 DSP3M Uninitialized Uninitialized Uninitialized Uninitialized MOT_ID MOT_INF SER_PAR
D To display the servo parameters for each axis, press F5, SER_PAR. You will see a screen similar to the following.
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27
STATUS Version ID GRP: AXIS: 1 1: 1 1 2: 1 2 3: 1 3 4: 1 4 5: 1 5 6: 1 6 7: * * 8: * * 9: * * 10: * * [ TYPE ] SOFTWARE
E1 JOINT SERVO PARAM ID: PB08.02 PB08.02 PB08.02 PB08.02 PB08.02 PB08.02 Uninitialized Uninitialized Uninitialized Uninitialized MOT_ID MOT_INF
10 % 1/16
SER_PAR
28
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2.3
MEMORY STATUS
The STATUS Memory screen displays information about controller memory. Table 23 lists and describes each memory status item. Use Procedure 23 to display memory status.
Table 23. Memory Status
MEMORY STATUS Pools
DESCRIPTION Indicates the amount of memory for D TPP contains teach pendant programs D PERM contains system variables and some KAREL variables D SYSTEM contains the operating system D IMAGE contains KAREL programs and options D TEMP contains temporary memory used for system operations Indicates the total amount of memory for D FROM Flash ROM D DRAM D-RAM D CMOS CMOS RAM
Hardware
Procedure 23 Step
Displaying Memory Status 1 Press STATUS. 2 Press F1, [TYPE]. 3 Select Memory. You will see a screen similar to the following.
STATUS Memory E1 JOINT 10 %
Total Available Pools ----------------------TPP CMOS 600.0 KB 554.4 KB PERM CMOS 999.8 KB 275.8 KB TEMP DRAM 5054.9 KB 4340.4 KB Description: TPP: Used by .TP, .MR, .JB, .PR PERM: Used by .VR, RD:, Options TEMP: USed by .PC, .VR, Options [ TYPE ] DETAIL HELP
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29 4 To display the DETAIL screen, press F2, DETAIL. You will see a screen similar to the following.
STATUS Memory E1 JOINT 10 %
Total Free Lrgst Free Pools TPP 1200.0 KB 1181.8 KB 1181.8 KB PERM 2023.9 KB 564.7 KB 564.6 KB SYSTEM 1010.4 KB 7.1 KB 7.1 KB IMAGE 2303.9 KB 358.8 KB 358.8 KB TEMP 3774.9 KB 2954.5 KB 2943.3 KB Hardware FROM 6.0 MB DRAM 8.0 MB CMOS 2.0 MB [ TYPE ] BASIC HELP
5 To display the first screen, press F2, BASIC.
210
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2.4
POSITION STATUS
The POSITION screen displays positional information in joint angles or Cartesian coordinates. The positional information on this screen is updated continuously when the robot moves. You cannot change the displayed information using this screen. NOTE E1, E2, and E3 indicate extended axis positional information if extended axes are installed in your system.
Joint User
The joint screen displays positional information in degrees for each robot axis. Tool indicates the number of the active tool frame. The user screen displays positional information in Cartesian coordinates based on the user frame. Tool indicates the number of the active tool frame. Frame indicates the number of the active user frame. The world screen displays positional information in Cartesian coordinates based on the world frame. Tool indicates the number of the active tool frame. Use Procedure 24 to display position status.
World
Procedure 24
Displaying Position Status
Step
1 Press POSN. 2 Select the appropriate coordinate system. D For joint, press F2, JNT. You will see a screen similar to the following.
POSITION Joint
E1
JOINT
10 % Tool: 1
J1: J4: E1:
.001 J2: .000 J5: .000 E2:
10.028 J3: 34.998 J6: .001 E3:
35.025 .001 .001
[ TYPE ]
JNT
USER
WORLD
NOTE E1:, E2:, and E3 are displayed only if you have extended axes.
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211 D For user, press F3, USER. You will see a screen similar to the following.
POSITION User
E1
JOINT Frame: 0
10 % Tool: 1
Configuration: F, 0, 0, 0 x: 1906.256 y: .041 w: 178.752 p: 89.963 E1: .001 E2: .001
z: 361.121 r: 1.249 E3: .001
[ TYPE ]
JNT
USER
WORLD
D For world, press F4, WORLD. You will see a screen similar to the following.
POSITION World
E1
WORLD
10 % Tool: 1
Configuration: F, 0, 0, 0 x: 1906.256 y: .041 w: 178.752 p: 89.963
z: r:
361.121 1.249
[ TYPE ]
JNT
USER
WORLD
212
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2.5
AXIS STATUS
The axis status screen displays information for each axis. This information is continually updated. Use this information when you call the FANUC Robotics Hotline if a problem occurs with your robot. This screen displays: D Status 1 D Status 2 D Pulse D Monitor D Tracking D Disturbance Torque The Axis Status Pulse screen displays information about axis motion. Table 24 lists and describes each kind of information displayed on this screen. Use Procedure 25 to display the axis status pulse screen.
Table 24. Axis Status Pulse Screen Items DESCRIPTION Displays the desired value of the Serial Pulse Coder (SPC) when the robot gets to the position commanded by the controller. Shows the actual SPC count as read by the controller. Displays the difference between the commanded SPC count versus the actual SPC count.
ITEM Motion Command Machine Pulse Position Error
You cannot change any information on this screen except for the group number. Group number only applies if you have multiple groups; otherwise, it remains as 1.
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213
Procedure 25 Step
Displaying the Axis Status Pulse Screen 1 Press STATUS. 2 Press F1, [TYPE]. 3 Select Axis. 4 Display the status screen you want: D For Status 1, press F2, STATUS1.
STATUS JOINT 10 %
J1: J2: J3: J4: J5: J6:
Flag Bits 1/2 0000000000001011 0000000000001011 0000000000001011 0000000000001011 0000000000001011 0000000000001011
GRP [ 1] History 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000
[ TYPE ]
STATUS1
STATUS2
PULSE
GRP# >
D For Status 2, press F3, STATUS2.

STATUS Alarm Status 000000000000 000000000000 000000000000 000000000000 000000000000 000000000000 JOINT 10 %
J1: J2: J3: J4: J5: J6:
GRP [ 1] History 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000
[ TYPE ]
STATUS1
STATUS2
PULSE
GRP# >
D For Pulse, press F4, PULSE.
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STATUS
E1
JOINT
10 %
J1: J1: J2: J3: J4: J5: J6:
Position Error 0 0 0 0 0 0
Machine Pulse 00000000 00000000 00000000 00000000 00000000 00000000
GRP [ 1] Motion Command 0 0 0 0 0 0
[ TYPE ]
STATUS1
STATUS2
PULSE
[UTIL] >
D For Monitor, press MORE, >, and then press F2, MONITOR.
STATUS JOINT GRP [ 1] J1: J1: J2: J3: J4: J5: J6: Torque Monitor Ave. / Max. 0.000 0.000 0.000 0.000 0.000 0.000 Inpos OT VRDY 1 0 ON 1 0 ON 1 0 ON 1 0 ON 1 0 ON 1 0 ON 10 %
0.000 0.000 0.000 0.000 0.000 0.000
[ TYPE ]
MONITOR TRACKING DISTURB
GRP# >
D For Tracking, press MORE, >, and then press F3, TRACKING. D For Disturbance Torque, press MORE, >, and then press F4, DISTURB.
STATUS JOINT 10 %
GRP [ 1] Tracking Status J1: Flag Bits 1 P1: 0000000000000000 P2: 0000000000000000 Alarm Status 000000000000 000000000000 Flag Bits 2 0000000000000000 0000000000000000 Counter Value 0 0
P1: P2:
[ TYPE ]
GRP# >
MARO2P10203703E
215 5 To change the group number, press F5, GRP#.

STATUS Disturbance Torque Current J1: 46080.000 / J2: 46080.000 / J3: 46080.000 / J4: 23040.000 / J5: 23040.000 / J6: 23040.000 / Max. 0.000 0.000 0.000 0.000 0.000 0.000 JOINT 10 %
/ / / / / /
GRP [ 1] Min. 91802.813 91802.813 91802.813 45901.406 45901.406 45901.406
[ TYPE ]
GRP# >
216
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2.6
ALARM LOG
The Alarm Log displays a list of the 100 most recent alarms. Figure 22 shows an example of the Alarm Log.
Figure 22. Alarm Log
1 2 3
SRVO049 OHAL 1 alarm (Group=1 Axis=6) PROGRAM LINE 4 Alarm JOINT 10% 1/100 1 SRVO049 OHAL 1 alarm (Group:1 Axis:6) 2 SRVO042 MCAL 1 Alarm (Group:1 Axis:6) 3 R E S E T
[ TYPE ]
CLEAR
HELP
The areas of the Alarm Log are as follows: 1. This is the most recent alarm message. This message will be displayed in this line regardless of the screen you choose. 2. Indicates the program name and line number of program last having been acted upon. 3. Lists all of the alarm messages, up to 100, with the most recent alarm on the top of the list. When the RESET key is pressed, a RESET is logged on the alarm message screen. 4. Indicates the line number the cursor is on in proportion to how many lines numbers available. Use Procedure 26 to display the Alarm Log.
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217
Procedure 26
Displaying the Alarm Log H An error has occurred. 1 Press ALARMS. 2 Press F1, [TYPE]. 3 Select Alarm Log. The alarm log will be displayed. This lists all errors. See the following screen for an example.
SRVO002 Teach pendant emergency stop TEST1 LINE 15 ABORTED Alarm WORLD 100 % 1/100 1 SRVO002 Teach pendant emergency sto 2 SRVO001 Operator panel emergency st 3 R E S E T 4 SRVO029 Robot calibrated (Group:1) 5 SRVO001 Operator panel emergency st 6 SRVO012 Power fail recovery 7 INTP127 Power fail detected 8 SRVO047 LVAL alarm (Group:1 Axis:5) 9 SRVO047 LVAL alarm (Group:1 Axis:4) 10 SRVO002 Teach pendant emergency sto [ TYPE ] CLEAR HELP
Condition Step
The most recent error is number 1. To display the complete message for a message that does not fit on the screen, press and hold the SHIFT key and press the right arrow key. 4 To display the motion log, which lists only motion-related errors, press F1, [TYPE], and select Motion Log. 5 To display the system log, which displays only system errors, press F1, [TYPE], and select System Log. 6 To display the application log, which displays only application-specific errors, press F1, [TYPE], and select Appl Log. 7 To display more information about an error, move the cursor to the error and press F5, HELP. The error help screen displays information specific to the error you selected. When you are finished viewing the information, press PREV. 8 To remove all of the error messages displayed on the screen, press F4, CLEAR.
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2.7
I/O STATUS
Procedure 27 Step
You can view the status of an I/O signal by displaying a status screen. Use Procedure 27 to display I/O status. Displaying I/O Status 1 Press MENUS. 2 Select I/O. 3 Press F1, [TYPE]. 4 Select the kind of I/O for which you want to display status: spot welding, digital, analog, group, robot, UOP, or SOP. For digital outputs for example, you will see a screen similar to the following.
I/O Digital Out # SIM STATUS DO[ 1] U [ U OFF DO[ 2] U ON [ DO[ 3] U OFF [ DO[ 4] U OFF [ DO[ 5] U OFF [ DO[ 6] U ON [ DO[ 7] U OFF [ DO[ 8] U OFF [ DO[ 9] U OFF [ DO[ 10] U OFF [ [ TYPE ] CONFIG IN/OUT WORLD 10% ] ] ] ] ] ] ] ] ] ] SIMULATE UNSIM
5 To change the display between inputs and outputs, press F3, IN/OUT. 6 To view the I/O configuration of the signal, press F2, CONFIG.
3 LIGHTS, INDICATORS, AND LEDS
Index
MARO2P10203703E
LIGHTS, INDICATORS, AND LEDS

31

Teach Pendant Diagnostic Indicators Operator Panel and Cabinet Lights Servo On Lights Circuit Boards Diagnostic LEDs
Page
The teach pendant has several indicators to assist you in determining controller status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 The operator panel has several LEDs to assist you in determining the status of the controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 The controller cabinet has a single Servo On light on the right-hand side of the cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 The R-J2 controller contains several diagnostic LEDs within the controller. . . . . D Power supply unit (PSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Main CPU board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Sub CPU board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Modular I/O (Model A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Emergency Stop Control Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . D Module Assembly # EE3044401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Contact Signal Transducer (IBRC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D R-J2 Ethernet LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 37 38 310 313 314 316 318 319 320
This chapter describes the lights, indicators and LEDs you can use for diagnostics.
3. LIGHTS, INDICATORS, AND LEDS
32
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3.1
TEACH PENDANT DIAGNOSTIC INDICATORS
The teach pendant has several indicators to assist you in determining controller status. Figure 31 shows the teach pendant indicators and Table 31 lists and describes the teach pendant indicators. The indicators whose labels are blank vary depending on the application. Refer to the Systems PaintTool Setup and Operations Manual for information on indicators.
Figure 31. Teach Pendant Indicators

OFF
Indicators
FAULT HOLD STEP BUSY RUNNING MAN ENBL PROD MODE JOINT XYZ TOOL ON
Table 31. INDICATOR FAULT HOLD STEP BUSY RUNNING MAN ENBL PROD MODE JOINT XYZ TOOL
Teach Pendant Status Indicators DESCRIPTION
Indicates that a fault condition has occurred. Indicates that the robot is in a hold condition. HOLD is not on continuously during a hold condition. Indicates that the robot is in step mode. Indicates that the controller is processing information. Indicates that a program is being executed. Indicates that the robot is in MANUAL MODE. Indicates that the robot is in PRODUCTION MODE. Indicates that the current jog coordinate system is JOINT. Indicates that the current jog coordinate system is CARTESIAN (JOG FRAME OR WORLD). Indicates that the current jog coordinate system is TOOL.

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33
3.2
OPERATOR PANEL AND CABINET LIGHTS
The operator panel has several LEDs to assist you in determining the status of the controller. Figure 32 shows the operator panel LEDs for the P-200 robot. Table 32 describes the indicator functions.
Figure 32. Operator Panel LEDS
TEACH PENDANT FAULT h m PURGE COMPLETE

BATTERY ALARM ENABLED
CYCLE START
ON
HOLD
OFF
FAULT RESET
PURGE ENABLE
BRAKE ENABLE ON PORT

REMOTE REMOTE PURGE FAULT OFF h
LOCAL
HOUR METER METER HOUR
EMERGENCY STOP
Table 32. INDICATOR BATTERY ALARM TEACH PENDANT ENABLED FAULT REMOTE
Standard Operator Panel Status Indicators
PURGE COMPLETE
DESCRIPTION Indicates that the backup battery voltage is low. Replace the battery. Refer to Procedure 91 . Indicates that the teach pendant is enabled and has motion control. Indicates a fault condition has occurred. Indicates that robot motion can only be started by a remote device (PLC or other remote device). The operator panel cycle start pushbutton cannot cause robot motion. This is determined by the position of the REMOTE/LOCAL keyswitch. Identifies that the robot cavities for the P-200 motor cavity containment cases have been purged and are presently at the prescribed pressure as outlined in the FANUC Robotics SYSTEM R-J2 Controller P-200 and In Booth Rail Mechanical Unit Parts and Service Manuals . This LED must be illuminated in order to turn power on to the R-J2 controller.
PURGE FAULT PURGE ENABLE PUSHBUTTON
Indicates a fault exists with the purge system. Indicates that the purge cycle has started. You can now release the pushbutton if you are holding it. POWER ON PUSHBUTTON LED Indicates that the robot is powered on. CYCLE START PUSHBUTTON LED Indicates that the robot is currently running a program HOLD Indicates that the robot is in a software hold condition.
34
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3.3
SERVO ON LIGHT
The controller cabinet has a single Servo On light on the right-hand side of the cabinet. See Figure 33 for light location. Refer to Table 33 for a description of the Servo On light.
Figure 33. Servo Amp Light
SERVO ON Light
Table 33. INDICATOR SERVO ON
Servo Amp On Description
DESCRIPTION Indicates that power is available to the servo amplifiers.

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35
3.4
CIRCUIT BOARD DIAGNOSTIC LEDS
The R-J2 controller contains several diagnostic LEDs within the controller. They are on the circuit boards that plug into the backplane, on the servo amplifiers, and on the Modular I/O (Model A) and Distributed I/O (Model B) units as well as the Intrinsic Barrier Relay Control (IBRC) Purge Control Unit. Figure 34 shows an overview of the circuit board diagnostic LEDs. Refer to the following sections for descriptions of each circuit board diagnostic LED: D Power supply unit (PSU) D Main CPU board D Sub CPU board D Modular I/O (Model A) D Servo amplifier D Emergency Stop Control Printed Circuit Board D Module Assembly #EE-3044-401 D Contact Signal Transducer (IBRC) D ABRIO PCB (optional)
36
Figure 34. Diagnostic LEDs
MARO2P10203703E
IBRC Section 3.4.6
Main CPU LEDs Section 3.4.2
PSU LEDs Section 3.4.1
IBRC
MODEL A
INTERFACE MODULE Section 3.4.3
A1234567 B1234567
I/O MODULE Section 3.4.3
Interface I/O Module Module
SERVO AMPLIFIER LED Section 3.4.4
Servo Amplifier
EMG Stop Control PCB Section 3.4.5
Main CPU
PSU

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37
3.4.1
Power Supply Unit (PSU) Diagnostic LEDs
Figure 35 shows each power supply unit (PSU) diagnostic LED.

Figure 35. Power Supply Unit (PSU) Diagnostic LEDs
The PIL LED lights if 210 VAC nominal is being supplied to the PSU from the Transformer (circuit breaker is on), if Fuse F1 is not blown, if 24VDC Aux is supplied, and the power supply internal circuitry is in good condition.
PIL LED ALM LED

The ALM LED will light if one of the following conditions exist: Bad DC Power Supply Alarm received from the remote device Fuse F3 on the Power Supply unit is blown
38
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3.4.2
Main CPU Board Diagnostic LEDs
The Main CPU printed circuit board alarm LEDs are shown in Figure 36. Table 34 provides information for troubleshooting problems.
Figure 36. Main CPU Board Diagnostic LEDs

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39
Table 34. Troubleshooting Main CPU Board Diagnostic LEDs Procedure 1. Restart the controller. 2. Reload Software. 3. Replace the Main CPU. 1. Get a replacement battery. 2. Turn off controller power and lock out the controller. 3. Replace the battery. The controller will retain memory for at least a half hour between the time the controller is turned off and the new battery is installed. WARNING: Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. 1. Restart the controller.
LEDs
1 STATUS ALARM 2 3 4
Remarks Parity alarm on RAM in the Main CPU. The battery voltage that backs up the Main CPU CMOS RAM memory is low.
1 STATUS ALARM
1 STATUS ALARM
Non-maskable interrupt occurred in 2. Reload software. the ABC chip on the 3. Replace the Main CPU. Main CPU Board. Servo alarm occurred on the Main CPU Board. 1. Restart the controller. 2. Reload software. 3. Replace the Main CPU.
1 STATUS ALARM
1 STATUS ALARM
Non-maskable 1. Restart the controller. interrupt occurred in 2. Reload software. the SLC2 chip on 3. Replace the Main CPU. the Main CPU Board SYS FAIL Signal occurred 1. Restart the controller. 2. Reload software. 3. Replace the Main CPU. Controller should be operational.
1 STATUS ALARM
1 STATUS ALARM
Normal Status
= OFF
= ON
NOTE To save time during board replacement, preload software on a spare main CPU board first. Refer to the appropriate software installation manual specific to your software for software loading information.
CAUTION To prevent software loss in the CMOS RAM module of the removed board, be sure a battery backup is attached to the main CPU before the board is removed from the controller.
310
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3.4.3
Sub CPU Board Diagnostic LEDs
The Sub CPU printed circuit board alarm LEDs are shown in Figure 37. Table 35 provides information for troubleshooting problems.
Figure 37. Sub CPU Board Diagnostic LEDs
RISC-B
STATUS ALARM
LV ALM F21 5A
5.0 A

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311
Table 35. Troubleshooting Sub CPU Board STATUS LEDs (Green) DESCRIPTION
3 4
LEDs
1 STATUS ALARM 2
Power-off
1 STATUS ALARM 1 STATUS ALARM
Power on
SUBCPU start up
1 STATUS ALARM
DRAM test OK
Software loading complete. Operating system start.
Software internal checking. (Kernel software initialization complete)
1 STATUS ALARM
Software internal checking. (Task scheduling start)
Software internal checking. (Operating system initialization start)
Software internal checking. (Operating system initialization end)
1 STATUS ALARM
Software internal checking. (INIT task initialization process start)
1 STATUS ALARM
Software internal checking. (System work area initialization)
1 STATUS ALARM
Software internal checking. (Non-volatile memory initialization)
1 STATUS ALARM
Software internal checking. (Non-volatile memory recover)
1 STATUS ALARM
Software internal checking. (Create system tasks)
312
MARO2P10203703E
Table 35. (Contd) Troubleshooting Sub CPU Board STATUS LEDs (Green) LEDs
DESCRIPTION Software internal checking. (Create system tasks)
1 STATUS ALARM
Software internal checking. (Task creation complete)
1 STATUS ALARM
Software internal checking. ((INIT task initialization process complete)
= OFF
Table 36. LEDs
= ON
Procedure
Troubleshooting Sub CPU Board ALARM LEDs (Red)
The Sub-CPU is not started.
A parity alarm occured in the SRAM.
A parity alarm occured in the DRAM on the Sub-CPU board
= OFF
Table 37. LEDs LV ALM (Red)
= ON
Procedure
Troubleshooting Sub CPU Board ALARM LEDs (Red)
The output voltage of the 3.3V power supply exceeded the specified range.
= ON NOTE To save time during board replacement, preload software on a spare sub CPU board first. Refer to the appropriate software installation manual specific to your software for software loading information.

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313
3.4.4
Modular (Model A) I/O LEDs
The LEDs associated with module I/O are on the interface module printed circuit board and on each I/O module. Figure 38 shows the modular I/O LEDs. Table 38 describes the I/O LEDs.
Figure 38. Modular I/O LEDs
LEDS
PWR LINK BAI BAO AIF0IA LEDS A0 1 2 3 4 5 6 7 B0 1 2 3 4 5 6 7
JD1B
JD1A
CP32
JD2 I/O MODULE
INTERFACE MODULE
Table 38. LED PWR Link
Modular I/O LEDs Location Interface module Interface module Interface module Description ON: The interface module is supplied with 24 VDC power. ON: The I/O Link is operating properly. Normally, this LED lights several seconds after the power is turned on. These LEDs indicate that a fault has occurred in the modular I/O system.
BA1
BA0
Interface module
A01234567 B01234567
I/O Module
Indicates if the input or output is on.
314
MARO2P10203703E
3.4.5
Servo Amplifier Diagnostic LED (7-Segment Display)
Figure 39 shows the servo amplifier seven-segment LED and Table 39 shows and describes the LED displays.
Figure 39. Servo Amplifier LED
4 3 2 1 ON
LED Circuit breaker
DIP SWITCH

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315
Table 39. Servo Amplifier LED Functions Description This alarm occurs if the DC voltage of the main circuit power supply is abnormally high. This alarm occurs if the control power voltage is abnormally low. This alarm occurs if the DC voltage of the main circuit power supply is abnormally low or the circuit breaker trips. This alarm occurs if: The short-time regenerative discharge energy is too high The regenerative discharge circuit is abnormal. This alarm occurs if: The average regenerative discharge energy is too high (too frequent acceleration/deceleration). The transformer overheats. This alarm occurs if the relay contacts of the dynamic brake welds together. This alarm occurs if an abnormally high current flows in the L-axis motor. This alarm occurs if an abnormally high current flows in the M-axis motor. This alarm occurs if an abnormally high current flows in the L- and M axis-motors This alarm is detected by the IPM (intelligent power module) of the L-axis.* This alarm is detected by the IPM (intelligent power module) of the M-axis.* The MCC contactor in the servo amplifier is turned on. The amplifier is armed and can drive the motor. The circuit breaker trips if an abnormally high current (exceeding the working current of the circuit breaker) flows through it. ** Indicates that the servo amplifier is not ready to drive the motor. Indicates that the servo amplifier is ready to drive the motor
Name Overvoltage alarm (HV) Low control power voltage alarm (LV) Low DC link voltage alarm (LVDC) Regenerative discharge control circuit failure alarm (DCSW) Over-regenerative discharge alarm (DCOH)
Indication
Dynamic brake circuit failure alarm (DBRLY) L-axis over-current alarm (HCL) M-axis over-current alarm (HCM) L- and M- axis over current alarm (HCLM) L-Axis IPM alarm (IPML) M-Axis IPM alarm (IPMM) L- and M- axis IPM alarm (IPMLM) Circuit breaker Trips Amplifier not ready Amplifier ready
*NOTE The IPM can detect the following alarms. D Over-current D Over-heat D Drop in IPM control power voltage **NOTE When the control power is separated from the main power, if the circuit breaker for the servo amplifier is off, low DC link voltage alarm (LVDC) is detected.
316
MARO2P10203703E
3.4.6
Emergency Stop Control Printed Circuit Board
The LEDs associated with the Emergency Stop Control Printed Circuit Boards are shown in Figure 310 and described in Table 310.
Figure 310. Emergency Stop Control Printed Circuit Board
BrakefuseblownalarmLED
1 2
4 3

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317
Table 310. Functions Emergency Stop Control Printed Circuit Board LED Function Brake fuse blown. SVON Q1 and Q2 ON (Brakes 1, 2, and 3) Q4 ON (Brake 4) Q3 ON (Brakes 6 and 7)
LED BRAKE FUSE ALARM 1 LED 2 LED 3 LED 4 LED
318
MARO2P10203703E
3.4.7
Module Assembly # EE3044401
The Module Assembly # EE3044401 is located in the robot purge cavity. Before you enter to the purge cavity, be sure to perform the procedures and warnings in Section 4.6.43 shall be performed. The LED indicators are described in Table 311 and are shown in Figure 311.
Figure 311. Intrinsic Barrier Relay Control Indicators
CR1 DC/DC MODULE
6.5V LED 24V LED MODULE ASSY # EE3044401
24V 6.5V
Table 311. Channel 24V 6.5V
Modular I/O LEDs
Function Indicates 24VDC input from 24VDC power supply in controller Indicates output of 6.5 VDC through relay CR1

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319
3.4.8
Contact Signal Transducer (IBRC)
The Intrinsic Barrier Relay Control (IBRC) LED indicators are described in Table 312 and are shown in Figure 312.
Figure 312. Intrinsic Barrier Relay Control Indicators
CH1
CH2
CH3
CH4
CH5
CH6
Table 312. Channel CH1 CH2 CH3 CH4 CH5 CH6 Function Air pressure switch Flow switch *ROT switch *HBK switch TPDSC switch EOAT switch
Modular I/O LEDs
Description Monitors internal air pressure. The switch is closed when the robot is in a safe operating state. Monitors air flow during purge sequence. Robot overtravel closed when robot is not in an overtravel condition. Hand broken switch. Robot wrist is broken. Normally this is a closed input. Teach pendant disconnect switch. End of arm tooling switch triggers RDI2.
320
MARO2P10203703E
3.4.9
R-J2 Ethernet LEDs
Figure 313 and Figure 314 show ER-1 and ER-2 R-J2 Ethernet printed circuit boards. Refer to A Users Guide to the FANUC Robotics SYSTEM R-J2 Controller Remote I/O Interface for an Allen-Bradley PLC for LED descriptions.
Figure 313. ER-1 and ER-2 Printed Circuit Board LEDs
ER-1
1 23 4
1 23 4
AB RIO
PF PC IP
ACTIVE POWER
AB
AB
RACK SEL
SMGN
AUI CD27
BAUD SEL DISC/BLK LAST RACK LAST STAT RESTART RACK SIZ
ETHER NET
F1 2.0A
LINK OK
2.0
A
10 BASE T
ER-1 PLC I/O-Ethernet Printed Circuit Board(10BaseT)

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321
ER-2
ER-2 Ethernet Printed Circuit Board(10Base2)
ER-2 A-B RIO/Ethernet Printed Circuit Board(10Base2)
322 ER-1 Alarm LEDs Table 313 lists and describes the ER-1 alarm LEDs.
Table 313. ALARM 1 2 3 4 ER-1 Alarm LEDs DESCRIPTION
MARO2P10203703E
STATUS ALARM
Fuse Alarm DRAM Parity Error Soft Alarm LED Soft Alarm LED DRAM Parity Error Fuse Alarm Turned on and off by system software. Turns on when a DRAM parity error occurs. Turns on when a fuse has blown (for 10BASE5 PCBs only).
ER-2 Alarm LEDs
Table 314 lists and describes the ER-2 alarm LEDs.

Table 314. ER-2 Alarm LEDs DESCRIPTION Soft Alarm LED DRAM Parity Error
ALARM
A1 A2
ALARM
A4 A3
Not used Not used
Soft Alarm LED DRAM Parity Error
Turned on and off by system software. Turns on when a DRAM parity error occurs.
4 TROUBLESHOOTING
Page23
MARO2P10203703E
TROUBLESHOOTING
41

Power ON Sequence Controller shutdown Servo Lockout Class 1 Fault Troubleshooting Class 2 Fault Troubleshooting
Page
The following procedures are applicable to all P-200 robot systems including those on a pedestal, rail or with an opener. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Use this procedure for complete controller shutdown including purge circuitry. . 44 Servo Lockout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 A Class 1 Fault is a malfunction that prevents the controller from operating. The main contactor might or might not be energized. No text is displayed on the teach pendant. Refer to Section 4.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 A Class 2 Fault is a malfunction that prevents the Boot ROM operating system from turning the system over to the application software. Text will be displayed on the the teach pendant, but the teach pendant display will be frozen and will not respond to keypad entries. Refer to Section 4.5. . . . . . . . . . . . . . . . . . . . . . . . 421 A Class 3 Fault is a malfunction that prevents the robot from operating normally, even though the application software is running. A numbered alarm message will be displayed on the teach pendant. You can access teach pendant menus and diagnostic screens during a Class 3 fault. Refer to Section 4.6. . . . . . . . . . 423 D SRVO-001 Operator Panel E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 D SRVO-002 Teach Pendant E-stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 D SRVO-003 Deadman switch released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426 D SRVO-004 Fence Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 D SRVO-005 Robot Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 D SRVO-006 Hand Broken . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430 D SRVO-007 External Emergency Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432 D SRVO-011 TP Released While Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 D SRVO-012 Power Failure Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 D SRVO-014 Fan Motor Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 D SRVO-015 System Over Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435 D SRVO-019 ER_SVAL1 SVON input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 D SRVO-020 ER_SVAL1 SRDY off (TP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 D SRVO-021 ER_SVAL1 SRDY off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 D SRVO-022 ER_SVAL1 SRDY on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 D SRVO-023 ER_SVAL1 Stop Error Excess . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 D SRVO-024 ER_SVAL1 Move Error Excess . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 D SRVO-026 ER_WARN Motor Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 D SRVO-027 ER_WARN Robot Not Mastered . . . . . . . . . . . . . . . . . . . . . . . . . . 441 D SRVO-033 ER_WARN Robot Not Calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . 441 D SRVO-035 ER_WARN Joint Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 D SRVO-036 Imposition Time Over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 D SRVO-037 ER_SVAL1 IMSTP Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 D SRVO-038 PULSE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442 D SRVO-042 ER_SVAL2 MCAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443 D SRVO-043 ER_SVAL2 DCAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 D SRVO-044 ER_SVAL2 HVAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446 D SRVO-045 ER_SVAL2 HCAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 D SRVO-046 ER_SVAL2 OVC Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448 D SRVO-047 ER_SVAL2 LVAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448 D SRVO-049 ER_SVAL2 OHAL1 Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449 D SRVO-050 ER_SVAL1 CLALM Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449 D SRVO-051 ER_SVAL2 CUER Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 D SRVO-053 ER_WARN Disturbance excess . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 D SRVO-054 ER_SVAL1 DSM memory error . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 D SRVO-061 ER_SVAL2 CKAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 D SRVO-062 ER_SVAL2 BZAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Class 3 Fault Troubleshooting
4. TROUBLESHOOTING
42
MARO2P10203703E

Class 3 Fault Troubleshooting (continued) D SRVO-063 ER_SVAL2 RCAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-064 ER_SVAL2 PHAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-065 ER_WARN BLAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-066 ER_SVAL2 CSAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-067 ER_SVAL2 OHAL2 Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-068 ER_SVAL2 DTERR Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-069 ER_SVAL2 CRCERR Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-070 ER_SVAL2 STBERR Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-071 ER_SVAL2 SPHAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-072 ER_SVAL2 PMAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-073 ER_SVAL2 CMAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-074 ER_SVAL2 LDAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-075 ER_WARN Pulse Not Established . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-081 ER_WARN EROFL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-082 ER_WARN DAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-083 ER_WARN CKAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-084 ER_WARN BZAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-085 ER_WARN RCAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-086 ER_WARN PHAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-087 ER_WARN BLAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-088 ER_WARN CSAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-089 ER_WARN OHAL2 Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-090 ER_WARN DTERR Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-091 ER_WARN CRCERR Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-092 ER_WARN STBERR Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-093 ER_WARN SPHAL Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-147 SERVO LVAL(DCLK) Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D SRVO-163 ER_FATL DSM Hardware Mismatch . . . . . . . . . . . . . . . . . . . . . . . D SRVO-164 ER_FATL DSM/Servo Param Mismatch . . . . . . . . . . . . . . . . . . . . D SRVO-165 ER_FATL Panel (SVON Abnormal) E-Stop . . . . . . . . . . . . . . . . . D SRVO-166 ER_FATL TP (SVON Abnormal) E-Stop . . . . . . . . . . . . . . . . . . . . D SRVO-167 ER_FATL Deadman Switch (SVON Abnormal) . . . . . . . . . . . . . . D SRVO-168 ER_FATL External/SVON(SVON Abnormal) E-Stop . . . . . . . . . . A Class 4 Fault is a malfunction that prevents the robot paint system components in the outer arm of the P-200 from operating normally, even though the application software is running. No numbered alarm messages will be displayed as in the case of a class 3 fault. Process defects will be noticed on each job as a result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Trigger Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Trigger (Electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Process Fault Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
452 452 452 453 453 454 456 456 456 457 457 457 458 458 459 459 459 459 459 460 460 460 460 460 460 461 461 461 461 461 461 462 462
Class 4 Fault Troubleshooting
463 464 465 466 473 476
This chapter describes the steps you must follow to repair electrical faults in the R-J2 controller.
WARNING The procedures described in this section require you to work with high voltage circuits. Carelessness or inattention can kill you. Do not attempt any of these procedures unless you are trained and experienced in electrical repair.
4. TROUBLESHOOTING
MARO2P10203703E
43
4.1
POWER ON SEQUENCE
The following procedures are applicable to all P-200 robot systems including those on a pedestal, rail or with an opener. In the case of a P-200 robot and opener, both units must be properly purged before the controller can be turned on.
Procedure 41 Step
Troubleshooting Purge Problems 1 With the main disconnect ON, you should observe: D Purge complete LED is off. D Purge enable pushbutton (purging) lamp is off. D ON pushbutton lamp is off. D Purge fault LED is on 2 Push and hold the PURGE ENABLE pushbutton. You should observe D Purge solenoid engages when minimum pressure requirements are met. D Purge fault LED turn off. D Purging lamp (behind purge enable pushbutton) lights. 3 Release the purge enable pushbutton. 4 At the end of the 5 minute purge, the pushbutton purging lamp will turn off and the purge complete LED will turn on. Also, the purge solenoid will shut off. 5 If this procedure does not work, go to troubleshooting Table 41. If the purge cycle works correctly but the robot will not power up, go to Procedure 44 .
4. TROUBLESHOOTING
44
MARO2P10203703E
4.2
CONTROLLER SHUTDOWN
Procedure 42 Step
Use this procedure for complete controller shutdown including purge circuitry.
Controller Shutdown Procedure 1 Push the E-stop push button. 2 Push the controller OFF pushbutton. 3 Pull the Main Disconnect switch.
4.3
SERVO LOCKOUT
For servo lockout use the following procedure:
Procedure 43 Step
Servo Lockout Procedure 1 Push the E-stop push button. 2 Open the servo lockout disconnect switch. 3 Lockout switch
4. TROUBLESHOOTING
MARO2P10203703E
45
4.4
CLASS 1 FAULT TROUBLESHOOTING
How to use the Troubleshooting Tables
This section contains troubleshooting information for Class 1 Faults. A Class 1 fault prevents the controller from operating. The main A.C. line contractor (ALC) might be energized. The Purge Complete light might be on. No text is displayed on the teach pendant. This section contains several tables. Each table provides procedures to correct the fault. To troubleshoot a Class 1 fault, always start at Procedure 41 . Perform the procedures in order. You will either correct the fault using Table 41 or it will refer you to another table in this section. Use the other tables only when Table 41 refers you to them.
Class 1 Fault Condition
If the following conditions are true, follow the steps in Table 41. D The main disconnect is ON. D The ON button has been pressed. D The power on sequence (Procedure 41 ) has been attempted. D The controller does not operate. Without turning off the main disconnect, open the controller door. Release the disconnect latch by turning the screw to the lower right of the disconnect handle.
4. TROUBLESHOOTING
46
MARO2P10203703E
Table 41. Troubleshooting Procedure 1 (Initial Purge Troubleshooting Procedure) Troubleshooting Procedure 1. Find the Purge Complete light on the Standard Operator Panel. If the light is on this indicates that the purge cycle was successful. If the light is on 'go to Table 44. If the light is off 'continue troubleshooting.
Purge Complete Light
Illustration

FAULT
BATTERY ALARM
CYCLE START
ON
TEACH PENDANT ENABLED HOLD OFF
FAULT RESET
PURGE ENABLE
Purge Enable Pushbutton and Lamp

PURGE COMPLETE REMOTE REMOTE PURGE FAULT
LOCAL
2.
Find the Purge Fault light on the Standard Operator Panel. If the light is on 'go to Step 4. If the light is out 'continue troubleshooting.
FAULT RESET
PURGE ENABLE
Purge Fault Light
BRAKE ENABLE ON
PORT

PURGE COMPLETE REMOTE REMOTE PURGE FAULT OFF
LOCAL
HOUR METER
EMERGENCY STOP
4. TROUBLESHOOTING
MARO2P10203703E
47
Table 41. (Contd) Troubleshooting Procedure 1 (Initial Purge Troubleshooting Procedure)
Troubleshooting Procedure 3. Press and hold the Purge Enable pushbutton on the Standard Operator Panel until it lights (1 - 5 seconds) and then release. If the Purge Complete light comes on ' test the controller for proper operation. Go to Table 44.
FAULT RESET
Illustration
PURGE COMPLETE
PURGE ENABLE

ON
Purge enable Purge fault
PURGE FAULT
REMOTE
LOCAL
If the Purge Enable or Purge Complete light does not come on and/or the Purge Fault light comes on ' continue troubleshooting.
BRAKE ENABLE HOUR METER
OFF
PORT

4. 5. Turn off the main disconnect handle. On the Intrinsically Safe Terminal Board (ISTB) unit, connect test jumper wires between terminals 1 and 4, and between terminals 5 and 8 on the ISTB. D These terminals are the inputs from the robot-mounted air pressure and air flow switches. Go to Step 6. Refer to Figure 1213. Test Jumpers ISTB
EMERGENCY STOP
NOTE: Jumper 1-2 simulates the pressure switch from the robot. Jumper 3-4 simulates the pressure switch from the opener, If applicable (If there is no opener all ready jumpered). Jumper 5-6 simulates the flow switch from the robot. Jumper 7-8 simulates the flow switch from the opener, if applicable (If there is no opener all ready jumpered).
6.
Turn on the main disconnect handle.
4. TROUBLESHOOTING
48
Table 41. (Contd) Troubleshooting Procedure 1 (Initial Purge Troubleshooting Procedure) Troubleshooting Procedure 7. Press and hold the Purge Enable pushbutton on the Standard Operator Panel until it lights (1 - 5 seconds) and then release it. D If the purge circuit is cycling, the purge enable pushbutton will stay lit until the 5 minute purge is complete. The Purge Fault light will be out. D If the robot does not purge with jumpers inserted go to step 8. D If the purge is successful with jumpers the problem could be: The wiring connected to the pressure switch(s) or the flow switch(s) Illustration
MARO2P10203703E
PURGE ENABLE
Purge Enable Purge Fault
PORT
The pressure switch in robot (or opener if applicable) The flow switch in robot (or opener if applicable)

ON
PURGE FAULT
REMOTE
LOCAL
BRAKE ENABLE
OFF
HOUR METER
EMERGENCY STOP
Possibly a casting leak in robot (or opener if applicable) D Locate the problem and replace faulty component. D If problem still exists check any Auxiliary device pressure and flow switches. If not used check jumpers across terminals 3 and 4, and terminals 5 and 6. D Locate the problem and replace faulty component. D Refer to Figure 1213. D Remove jumpers from step 5 and retest purge system. D If the purge is successful without jumpers Go to Table 44. 8. Replace purge control PCB. D Retest purge control without jumpers. D If purge control is still not working go to Table 42.
WARNING The purge control timer is adjusted to five minutes to conform to Factory Mutual Specifications. Do not adjust the purge control timer; otherwise, an explosion or fire could occur.
4. TROUBLESHOOTING
MARO2P10203703E
49
Table 42. Procedure) Troubleshooting Procedure Troubleshooting Procedure 2 (IBRC Troubleshooting Illustration
1.
Observe the lights on the IDEC IBRC unit . If all of the lights are off 'go to Step 2. If one or more of the lights are on 'go to Table 43. Lights
2.
Measure the AC voltage coming into the IDEC IBRC unit at terminals 220 VAC and 0V. If the voltage is 200 to 240 VAC 'replace the IDEC IBRC Unit. If there is no voltage 'continue troubleshooting. Refer to Figure 121, Figure 1212, Figure 1213 and Figure 1215.
MultiTap Transformer
TF1
43 44
3.
Measure the AC Voltage at terminals R and S on the purge control PCB If the voltage is 200 to 240 VAC 'replace the wires between IDEC IBRC and CP1 on the purge control PCB. If there is no voltage 'check for continuity between terminals FRA1 and FRA2 on purge control PCB. If there is no continuity 'replace jumper between FRA1 and FRA2. If there is continuity 'continue troubleshooting. Refer to Figure 121, Figure 127 and Figure 1213.
Purge Control PCB 200A 200B FRA 1 FRA 2
. .
G
4.
Measure the AC voltage coming into the purge control PCB at terminals 200A and 200B. If there is 200 to 240 VAC 'replace purge control PCB. If there is no voltage 'turn off main power disconnect and check for continuity between terminals 200A and 200B on purge control PCB and terminals 43 and 44 on the multi-tap transformer. Continue troubleshooting. Refer to Figure 121, Figure 127 and Figure 1213.
AC IN 24VDC PSU 15ma MAX.
220VAC
0V
IDEC IBRC
5.
If there is no continuity 'replace the wires between terminals 200A and 200B on the purge control PCB and terminals 43 and 44 on the multi-tap transformer. If there is continuity 'go to Table 45.
4. TROUBLESHOOTING
410
Table 43. Troubleshooting Procedure 1. 2. Turn off the power disconnect handle. Continue troubleshooting. Reseat the following connectors: Contact signal transducer (IDEC IBRC) connector CNCA. Purge control printed circuit board (mounted with EMG control PCB) connector CNIN. Continue troubleshooting. D Refer to Figure 121, Figure 1212, Figure 1213 and Figure 1214. Turn off the power disconnect handle.
FAULT RESET PURGE COMPLETE
MARO2P10203703E
Troubleshooting Procedure 3 (Non-Specific Purge Problems) Illustration
3.
PURGE ENABLE
Purge Fault
BRAKE ENABLE ON
4.
Observe on the Standard Operator Panel that the purge fault light is lit.
PORT

REMOTE REMOTE PURGE FAULT OFF
LOCAL
HOUR METER
EMERGENCY STOP
4. TROUBLESHOOTING
MARO2P10203703E
411
Table 43. (Contd) Troubleshooting Procedure 3 (Non-Specific Purge Problems) Troubleshooting Procedure Illustration
5.
Re-initiate the purge sequence. Go to Procedure 41 . If the controller does not purge properly 'go to Step 6. If the purge was successful 'go to Table 44.
PSU2
6.
Measure the DC voltage between the (+) and (-) on PSU2. If the voltage is 24 VDC 'go to Step 9. If there is no voltage 'check fuses F11 and F12 on the purge unit power supply board. If either fuse or both fuses are blown 'replace bad fuses. If new fuses blow 'check 24VDC wiring. If fuses are not bad 'continue troubleshooting. Refer to Figure 1213.
F11 F12 3.2A 3.2A
Power supply ()
7. If CH1 light is on, go to Step 8. If CH1 light is out, test jumper ISTB terminals 1 to 4 and observe if the light comes on. If the CH 1 light did not light 'replace the IDEC IBRC unit If the light comes on 'replace the pressure switch or wiring for proper operation. Continue troubleshooting. Remove test jumpers at the end of each step.
(+)
Test Jumpers for step 7 Test Jumpers for Step 8 ISTB
4. TROUBLESHOOTING
412
MARO2P10203703E
Table 43. (Contd) Troubleshooting Procedure 3 (Non-Specific Purge Problems) Troubleshooting Procedure 8. If CH 2 light is out, test jumper ISTB terminals 5 to 8 and observe if the light comes on. If the CH 2 light does not come on 'go to step 9. If the light comes on 'replace the auxiliary flow switch or wiring or replace the jumper, when auxiliary flow switch is not used.
CH1
Illustration IDEC IBRC
CH2
CH3
CH4
CH5
CH6
NOTE Remove test jumpers at the end of each step.
Lights 9. Replace the following in the order shown: D Purge enable switch D Purge control PCB D IBRC unit
Procedure 44 Condition
Troubleshooting Turn-on Problems H You have performed Procedure 41 and the system is purged. H The following conditions exist: D Purge complete LED on D Purge enable pushbutton (purging) lamp is off. D ON pushbutton lamp is off. D Purge fault LED off.
Step
1 Attempt normal power by pressing the ON pushbutton. D The ON pushbutton will light. D Main CPU and axis control PCBs also execute internal diagnostics. When the diagnostics are all complete the MCC on all servo amplifiers will energize and click. When this occurs, the teach pendant is on and the controller is ready to operate. If unit powered up correctly go to Section 4.5. If the unit did not turn ON normally, go to Table 44.
4. TROUBLESHOOTING
MARO2P10203703E
413
Table 44. Troubleshooting Procedure 4 (General Power Supply Troubleshooting) Troubleshooting Procedure Illustration CP1 3 G 2 1 S R
1.
Check and see if the green PIL light in the center of the Power Supply Unit module is ON. If the light is on 'go to Table 46. If the light is off 'continue troubleshooting.
2.
Check fuse F1 in the top center of the Power Supply Unit module. D A white flag in the center of the fuse indicates it is bad. If the fuse is bad, replace it and attempt the power up Procedure 44 . If the fuse is good 'go to step 3. If the fuse continues to blow 'go to step 5.
F1: 7.5A fuse for AC input
CP2 CP3 3 G1 G2 3 2 S1 S2 1 R1 R2 2 1
3.
If the white flag does not appears in the center fuse window and the green PIL light still does not come on, check fuse with an ohmeter If the fuse is blown 'replace the fuse. If the fuse blows again 'replace the Power Supply Unit. If the fuse is OK and the green PIL light does not come on 'continue troubleshooting.
Battery
PIL: Green LED for indicating the AC power supply status ALM: Red LED f for indicating an alarm
4.
Disconnect CP1 at the top of the Power Supply Unit module. Measure the voltage coming into the PSU on the two red wires in the harness connector (S and R). Check to see if the voltage is 220 to 240 VAC. If the voltage is ok 'go to step 5. If their is no voltage 'go to Table 45.
5.
Turn off the main disconnect switch and, using an ohmmeter, to test for a short in the wiring harnesses at CP2 and CP3. If no short is evident 'go to step 6. If there is a short 'replace the shorted wiring harness and attempt power up sequence.
F4: 5A fuse for +24E
F3: 5A Slow-Blow fuse for +24V
4. TROUBLESHOOTING
414
Table 44. (Contd) Troubleshooting Procedure 4 (General Power Supply Troubleshooting) Troubleshooting Procedure 6. Reconnect harnesses CP2 and CP3 and turn the main disconnect switch to on. Press the ON pushbutton and check for proper operation. If the fuse continues to blow 'Continue troubleshooting. If fuse F1 has blown again it is due to a short in one of the following. Replace components one at a time the until problem is solved. Wiring harness to servo power control coil Servo power control coil Wiring harness to fans (check in particular where cable and front door hinge point meet). Fan motor shorted. Replace fan motor, replace fuse. Illustration
MARO2P10203703E
Power Supply Unit Module

PIL: Green LED Su ly Status AC Power Supply
ALM Red Alarm Light
7.
F4: 5-Afuse for +24E F3: 5-AS slowblow fuse for +24V
4. TROUBLESHOOTING
MARO2P10203703E
415
Table 45. Troubleshooting Procedure Troubleshooting Procedure 5 (Transformer) Illustration
MULTITAP TRANSFORMER TF1 EE0989550 575 550 500 480 460 415/240 380/220 OV 575 550 500 480 460 415/240 380/220 ST1 OV 575 550 500 480 460 415/240 380/220 24 OV 51 ST2 52 THERMOSTAT FOR OVERHEAT F1 F2 F3 30A 1 3 5 A1 A2 2 4 6 SERVO POWER CONTROL (220VAC) SERVO POWER (210 VAC)
1.
Measure the AC voltage between Multi-Tap Transformer terminals 43 and 44 of TF1. You should see 200 to 240 VAC. If 200 to 240 VAC is present 'replace the harness between the Power Supply Unit and the Multi-Tap Transformer. If voltage is not present or incorrect 'continue troubleshooting. Refer to Figure 121 and Figure 123.
L1
F4 F5 7.5A
13 23
14 100 VAC 24
L2
43 44 220 VAC
L3
SPECIFICATION OF TF1 CAPACITY 7.5KVA SPECIFICATION A80L00260010#A F1,F2,F3 30A F4,F5 7.5A
2.
Check Multi-Tap Transformer tap settings. As shown in Section 1.9. If the tap settings are set incorrectly 'Set to correct values. If the tap settings are correct 'continue troubleshooting. Refer to Figure 121 and Figure 123.
L1 L2 L3 G
IN CASE OF CIRCUIT BREAKER BREAKER
F1
3.
Check AC voltage between transformer primary terminals. Check between terminals L1 and L2. Check between terminals L2 and L3. Check between terminals L1 and L3. All voltage readings should be the be the same depending on plant supplied 3 phase voltage. If proper voltage is present 'replace Multi-Tap Transformer. If incorrect or no input voltage is present 'continue troubleshooting. Refer to Figure 121 and Figure 123.
FUSE UNIT FL1 FL2 FL3
DISCONNECT SWITCH IN CASE OF DISCONNECT SWITCH
4. TROUBLESHOOTING
416
MARO2P10203703E
Table 45. (Contd) Troubleshooting Procedure 5 (Transformer) Troubleshooting Procedure 4. Check AC voltage between bottom terminals of fuses FL1, FL2, & FL3. All voltage readings should be the be the same depending on plant supplied 3 phase voltage. If voltage is present 'replace wiring harness between Multi-Tap Transformer and Fuse Block. If voltage is not present 'continue troubleshooting. Refer to Figure 121 and Figure 123. 5. Check AC voltage between top terminals of fuses FL1, FL2, and FL3. All voltage readings should be the be the same depending on plant supplied 3 phase voltage. If voltage is present fuses F1, F2, F3 is/are blown 'Replace the bad fuse. If it blows again, replace the Multi-Tap Transformer. If voltage is not present 'continue troubleshooting. Refer to Figure 121 and Figure 123. 6. Check AC voltage between terminals at bottom of the Main Disconnect Switch. All voltage readings should be the be the same depending on plant supplied 3 phase voltage. If voltage is present 'replace wiring harness between Fuse Block and Main Disconnect Switch. If voltage is not present 'continue troubleshooting. Illustration
Fuse Block
FL1 FL2 FL3
Main Disconnect Switch
7.
Check AC voltage between terminals at top of disconnect. All voltage readings should be the be the same depending on plant supplied 3 phase voltage. Replace Main Disconnect Switch if voltage is present; otherwise, contact plant maintenance.
Fuse Block FL1, FL2, FL3
4. TROUBLESHOOTING
MARO2P10203703E
417
Table 46. Troubleshooting Procedure Troubleshooting Procedure 6 (Power Supply Alarms) Illustration
1.
Check the red alarm light in the center of the Power Supply Unit module. The alarm light should be off. If the light is ON 'go to Table 47. If the light is OFF 'continue troubleshooting.

PIL: Green LED AC Power Supply Status
ALM Red Alarm Light
F4: 5-A fuse for +24E F3: 5-AS slowblow fuse for +24V 2. Listen and look for main cabinet cooling fans to be running. Fans should be running indicating that the 200V outputs from PSU, CPZ, ,and CP3 are ON. If fans are not running 'go to Step 3. If fans are running 'go to Table 47.
COOLING FANS
Fan#1 Backplane Fan
Fan#2 Fan#3
3.
Check for 200 to 240 VAC at Power Supply Unit Module on connector CP2 by checking contacts R1 and S1 or on CP3 by checking contacts R2 and S2. You should see 200 to 240 VAC on either connector. If there is 200 to 240 VAC 'replace the wiring to the fans and/or the Servo power control relay. If there is not 200 to 240 VAC 'go to Step 4. Refer to Figure 1216 and Figure 1217.
CP2 CP3

CP2 CP3 G1 G2 S1 S2 R1 R2
4. TROUBLESHOOTING
418
MARO2P10203703E
Table 46. (Contd) Troubleshooting Procedure 6 (Power Supply Alarms) Troubleshooting Procedure 4. Check the terminal block TBOP1 on the operator panel for jumpers between terminals (EX COM) and (EX OFF). If you use an external OFF button, there will be a wire on each terminal. If the terminals are connected with a jumper wire check for loose screws and good contact. If an external OFF button is used test for continuity of the external OFF, and DIL circuits 'replace it if necessary. Continue troubleshooting. Refer to Figure 1216 and Figure 1217.
SVON2 EXCOM
Illustration
CNOP CRS1 PORT 2 CNHM

SVON1 EXON
KA1
E STOP1
EXOFF
KA2
5.
On the operator panel, momentarily connect (Ex ON) to (Ex COM). Controller should turn on. If the controller turns on there is a break in the on/off switch circuit 'replace any damaged wire or the on/off switch circuit. If the controller does not turn on 'replace the Power Supply Unit module. Refer to Figure 1216 and Figure 1217.
E STOP2
EMGIN1
KA3
EMGOUT1 EMGIN2
EMGOUTC
FENCE 1
KA4
EMGOUT2
FENCE 2
TBOP2
TBOP1
4. TROUBLESHOOTING
MARO2P10203703E
419
Table 47. Troubleshooting Procedure Troubleshooting Procedure 7 (Power Supply Output) Illustration
1.
Check fuse F3 at the bottom of the Power Supply Unit. A white flag in the center of the fuse indicates it is bad and that 24V power is missing. If the fuse is blown there might be a short circuit in one of the following: -Backplane (See Figure 41 and Figure 42) -24VDC Cooling Fans for module card cage -Process I/O 24 VDC supply -Main CPU Module -Modular I/O 24 VDC supply -Option #1 Card -Option #2 Card -Option #3 Card Isolate the short and replace the defective component. If the fuse is good 'replace the Power Supply Unit. Refer to Figure 126, Figure 127 and Figure 128.

ALM: Red LED for indicating an alarm
F4: 5-A fuse for +24E
F3: 5-AS slow blow fuse for +24V
Figure 41. 24 Volt (24V) Power Distribution Chart
CA44 JNA3
3
JRM10 JRM3 JD1A
For 5 slot backplane only
CNOP (FOR PAINT ONLY)
4. TROUBLESHOOTING
420
Figure 42. 24 Volt (24E) Power Distribution Chart
MARO2P10203703E
JRA5
JRA5
JNA3
#3
CRM10
For 5 slot backplane only
ISB
CNOP
4. TROUBLESHOOTING
MARO2P10203703E
421
4.5
CLASS 2 FAULTS TROUBLESHOOTING
A Class 2 Fault occurs when frozen text (letters or numbers) are displayed on the teach pendant. This indicates a problem with the main CPU printed circuit board caused by either the memory, processor, the board itself, or a bad teach pendant cable. Use Table 48 to troubleshoot a class 2 fault.
Table 48. Class 2 Faults Troubleshooting Procedure
Troubleshooting Procedure 1. Is the Battery light on the main CPU module on? If the Battery light is on ' replace the battery. Refer to Procedure 91 . Continue troubleshooting.
Perform a cold start of the controller following the procedures in the S ystems PaintTool Setup and Operations Manual. Go to Step 3. 3. Are all four green LEDs on the main CPU board turned on? If all four green LEDs are on 'continue troubleshooting. 2. If all four green LEDs are not on 'troubleshoot the controller using Table 34 . 4. Turn the controller off. Hold down the NEXT and PREV keys on the teach pendant and press the ON button. D Check the teach pendant cable by swapping it with a known working cable or by doing a continuity test. D Does the BMON> prompt appear on the teach pendant? If it does not appear, replace the main CPU printed circuit board and reload the software. Otherwise, continue troubleshooting. Perform the following steps on the teach pendant to check the CMOS memory: a. Press the NEXT key twice. b. Press F1, DIAG. c. Press ENTER.The prompt changes to DIAG> (diagnostic monitor). d. Press the NEXT key three times. e f. Press F5, TEST. Press F1, CMOS.
5.
g. Press ENTER. The teach pendant will display a message that gives you an opportunity to exit without destroying the contents of CMOS memory.
CAUTION
Do not continue unless your controller actually has a Class 2 fault. Continuing beyond this point will erase all software stored in the controller including all taught positions in your application. Otherwise, a complete software reload will be required.
h. Press 1, and then press ENTER if you want to continue with the test. The CMOS memory test will take a few minutes to run. If an error is encountered, replace the CMOS module and reload the software. Refer to the Paint Tool SYSTEM R-J2 Controller Software installation manual for more information. If the CMOS memory test passes, continue troubleshooting.
4. TROUBLESHOOTING
422
Table 48. (Contd) Class 2 Faults Troubleshooting Procedure Troubleshooting Procedure 6. Perform the following steps on the teach pendant to check the FROM: a. Press the NEXT key three times. b. Press F5, TEST. c. Press F3, FROM. d. Press ENTER. The teach pendant will display a message that gives you an opportunity to exit without destroying the contents of Flash ROM memory. e. Press 1, and then ENTER if you want to continue with the test.
MARO2P10203703E
The Flash ROM memory test will take a few minutes to run. If an error is encountered, replace the Flash ROM module and reload the software. Otherwise, continue troubleshooting. 7. Perform the following steps on the teach pendant to check the DRAM: a. Press the NEXT key three times. b. Press F2, DRAM. c. Press ENTER. The teach pendant will display a message that gives you an opportunity to exit without destroying the contents of the DRAM memory. d. Press 1 and then ENTER if you want to continue with the test. The DRAM memory test will take a few minutes to run. If an error is encountered, replace the DRAM module. The software does not have to be reloaded. Otherwise, go to Step 8. 8. The hardware in your controller is OK. Reload your application software. Refer to the Paint Tool SYSTEM R-J2 Controller Software installation manual for more information.
4. TROUBLESHOOTING
MARO2P10203703E
423
4.6
CLASS 3 FAULT TROUBLESHOOTING
A class 3 fault occurs when the teach pendant displays a fault message. This section contains troubleshooting procedures for each class 3 fault message. To determine which procedure to use, perform the following steps: 1. Press the MENUS key on the teach pendant. 2. Select ALARM. 3. Refer to the appropriate section and follow the corresponding troubleshooting procedure. The subsections that follow are arranged in numerical error code order.
4. TROUBLESHOOTING
424
MARO2P10203703E
4.6.1
SRVO-001 ER_SVAL1 Operator Panel E-Stop
The operator panel emergency stop pushbutton is pressed. Remedy: Twist the operator panel emergency stop push button clockwise to reset. Press RESET. If the problem still exists, it is caused by an error in the emergency stop circuit or a bad main CPU. Perform the following troubleshooting procedure:
Table 49. Troubleshooting Procedure SRVO-001 Troubleshooting Procedure Illustration
1.
Make sure that the teach pendant E-stop button is not pressed and that the external emergency stop inputs and fence switch inputs are jumpered or closed. Reseat the CNOP connector on the operator panel. Reseat the JRM10 connector on the main CPU. Turn on the controller and check for proper operation. If the problem is still present, continue troubleshooting. Open the door of the controller. Press and release the E-stop button several times. Listen for relay KA4 to click. Does the relay KA4 on the standard operator panel click? If yes'replace the cable between the operator panel CNOP and main CPU JRM10. If no'continue troubleshooting. CNOP CRS1
SVON1 EXON
2. 3. 4.
E-Stop button
5.
Connect jumper wires across terminals 1 and 2 of each switch section of the E-stop switch and then press reset on teach pendant. Does the fault reset? If yes'replace the E-stop switch assembly If no'replace the operator panel. Refer to Figure 129, Figure 1215 and Figure 1216.
PORT 2 CNHM KA1
SVON2
EXCOM
E STOP1
EXOFF
KA2
E STOP2 EMGOUT1
EMGIN1
KA3
EMGIN2
EMGOUTC
FENCE 1
KA4
EMGOUT2
FENCE 2
TBOP2 TBOP1
1 E-Stop Switch NC NC 2 1 2
4. TROUBLESHOOTING
MARO2P10203703E
425
4.6.2
SRVO-002 ER_SVAL1 Teach Pendant E-stop
The teach pendant emergency stop (E-Stop) pushbutton has been pressed. Remedy: Twist the teach pendant emergency stop pushbutton clockwise to release and press RESET. If the problem still exists, it is caused by the loss of 24VDC to the teach pendant relay RLY2 or the 5VDC signal to the matrix decoding from the normally closed contact of the teach pendant relay RLY2. Any of the following can cause this problem: D A defective teach pendant emergency stop switch. D A defective component on the teach pendant printed circuit board. D Loss of 24VDC to the E-STOP switch (not part of the teach pendant power). This loss of power can be caused by a bad teach pendant emergency stop switch, a broken wire in the teach pendant cable, a bad operator panel, or a bad cable between the operator panel CNOP and the main CPU JRM10. You can fix it by replacing the teach pendant. If you want to troubleshoot the problem further, perform the following troubleshooting procedure:
Table 410. SRVO-002 Troubleshooting Procedure Troubleshooting Procedure
1. 2. 3. 4.
Turn off the controller. Reseat CNOP at the operator panel interface and connector JRM10 at the main CPU. Turn on the controller and check for proper operation. If the problem is still present, continue troubleshooting. One of the following components is bad. D Replace the teach pendant. D Replace the operator panel. D Replace cable between CNOP on the operator panel and JRM10 on the main CPU. D Replace main CPU. Determine the bad component by substituting it with a new component.
Refer to Figure 128 and Figure 1216.
4. TROUBLESHOOTING
426
MARO2P10203703E
4.6.3
SRVO-003 ER_SVAL1 Deadman switch released
The teach pendant DEADMAN switch is released while the teach pendant is enabled. Remedy: Press and hold the teach pendant DEADMAN switch. Press RESET. If the problem still exists, perform the following steps:
Table 411. 1. 2. 3. 4. 5. Turn off the controller.
SRVO-003 Troubleshooting Procedure
Troubleshooting Procedure Reseat the teach pendant cable at both ends, connector JRM10 at the operator panel printed circuit board, and connector JRM10 at the main CPU. Turn on the controller and check for proper operation. If the problem is still present, continue troubleshooting. Open the controller door. Turn on the controller. Make sure the teach pendant E-Stop pushbutton is not pressed. Press and release a DEADMAN switch several times. You should be able to hear relay KA1 click on the operator panel interface. If the relay clicks 'replace cable between the operator panel interface and the main CPU. After replacing the cable check the DEADMAN switch for proper operation, if problem still exists continue troubleshooting. Go to step 6. If the relay does not click 'one of the following components is bad: D The teach pendant D The teach pendant cable D The operator panel interface. Determine the bad component by substitution. Problem solved . 6. 7. 8. 9. If your teach pendant is bad, and you want to troubleshooting the teach pendant continue troubleshooting. Turn off the controller. Remove the seven screws on the teach pendant endant back. Remove the teach pendant back but leave all electrical connectors in place.
10. Press each DEADMAN switch bar while you watch the switch body inside the teach pendant. 11. Make sure that the copper strip presses the switch actuator all the way into the switch body. You should be able to hear and feel it click into place. 12. If the actuator is frozen or will not click sharply, replace the switch. 13. Slide the wiring connector half way off the circuit board connector. 14. Measure the resistance between: Pins 1 and 2 Pins 3 and 4.
NOTE When the DEADMAN switch is not pressed, there is continuity between pins 1 and 2 and no
continuity between pins 3 and 4.
NOTE When the DEADMAN switch is pressed, there is no continuity between pins 1 and 2 and
continuity between pins 3 and 4. If one or more measurements are bad 'replace the DEADMAN switch assembly. If the measurements are good the teach pendant is defective 'replace the teach pendant.
4. TROUBLESHOOTING
MARO2P10203703E
427
4.6.4
SRVO-004 ER_SVAL1 Fence open
The safety fence gate is open. Remedy: Close the gate. Several gates in the workcell might be involved. If the problem still exists, perform the following troubleshooting procedure:
Table 412. Troubleshooting Procedure SRVO-004 Troubleshooting Procedure Illustration CNOP CRS1 PORT 2 CNHM
SVON1 EXON
1.
Look at terminals Fence 1 and Fence 2 on TBOP1 on the operator panel interface. Check for a jumper connecting the terminals or a wire on each terminal. There should be continuity between the two terminals. If there is no continuity 'install a jumper or repair the external fence circuit. If there is continuity 'continue troubleshooting.
2. 3. 4. 5. 6. 7.
Turn off the controller. Reseat CNOP at the operator panel interface and connector JRM10 at the main CPU. Make sure that no EMERGENCY STOP buttons are pressed. Open the controller door. Disconnect one end of the fence jumper or external fence circuit. Briefly short the two fence terminals on the operator panel interface together. You should be able to hear and see relay KA4 click on the operator panel interface. If the relay clicks 'replace the cable between the operator panel interface CNOP and the main CPU connector JRM10. If the relay does not click 'replace the operator panel. Refer to Figure 128 and Figure 1216.
E STOP2 EMGIN1 SVON2 EXCOM
KA1
E STOP1
EXOFF
KA2
KA3
EMGOUT1 EMGIN2
EMGOUTC
FENCE 1
KA4
EMGOUT2
FENCE 2
TBOP2
TBOP1
4. TROUBLESHOOTING
428
MARO2P10203703E
4.6.5
SRVO-005 ER_SVAL1 Robot Overtravel
An overtravel error occurs when the robot moves beyond the software motion limits, tripping the overtravel limit switch. If more than one axis is moving when the switch is tripped, the controller will report an overtravel error on several axes.
Table 413. SRVO-005 Troubleshooting Procedure Illustration
Troubleshooting Procedure 1. If you have not already done so, continuously press and hold the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. Hold down the SHIFT key and press RESET. Press COORD until you select the JOINT coordinate system. Jog the axis in overtravel off of the overtravel switch. If you cannot jog the robot off of the overtravel switch the wrong motion inhibit flag has been set; therefore, continue to Step 6. Otherwise, the axis (or axes) are no longer in overtravel and you can end the procedure now. Cold start the controller and go to Step 1. If the overtravel still cannot be cleared, continue troubleshooting. NOTE In some instances, the teach pendant screen will indicate a FALSE for a given axis when a TRUE should be set because of the way overtravel is read in the software. It is best to perform the following procedure on all of the axes. 7. 8. 9. Press MENUS. Select MANUAL FCTNS. Press F1, [TYPE].
2. 3. 4. 5.
6.
10. Select OT Release. 11. Move the cursor to the OT PLUS or OT MINUS value of the axis in overtravel. The status of OT PLUS or OT MINUS for that axis is TRUE. 12. Press and hold SHIFT and press F2, RELEASE. 13. Press and hold SHIFT and press RESET. 14. Press COORD until you select the JOINT coordinate system. 15. Continuously press and hold the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. 16. Jog the axis off of the overtravel switch.
MENUS SHIFT RESET
COORD
4. TROUBLESHOOTING
MARO2P10203703E
429
Table 413. (Contd) SRVO-005 Troubleshooting Procedure Troubleshooting Procedure Illustration
17. Turn the teach pendant ON/OFF switch OFF and release the DEADMAN switch. If the error cannot be reset 'continue troubleshooting. 18. Check fuse F4 on the power supply unit. If the fuse is blown 'replace it and check for a short circuit in the external 24V circuit (I/O and/or end effector power.) If fuse is not blown 'continue troubleshooting. 19. Reseat connector JRF2 at the main CPU and connectors CRM11 and JRF2 on the emergency stop control board. 20. Turn on the controller and check for proper operation. If the problem is still present, continue troubleshooting. 21. Using an ohmmeter and the wiring diagrams, check the CRM11 (Emergency Stop Control Board) cable for continuity. If a break is found, replace the cable on CRM11 emergency stop control board. 22. If error still exist, one of the following is bad: Determine the bad component by substitution. D The ribbon connector between the main CPU connector JRF2 and Emergency Stop Control Board connector JRF2. D The Emergency Stop Control Board. D The main CPU. Refer to Figure 128 and Figure 129.
Central Processing Unit Power Supply Unit
JRF2
4. TROUBLESHOOTING
430
MARO2P10203703E
4.6.6
SRVO-006 ER_SVAL1 Hand Broken
A hand breakage error occurs when the hand (wrist) breakage detection switch or aux hand breakage detection switch is tripped. Remedy: If you are not using the hand broken function, ensure that the HBK jumper on the Emergency Stop Control Printed Circuit Board is set to the A side. If you are using the hand broken function, perform the following steps: 1. If you have not already done so, continuously press and hold the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. 2. Hold down the SHIFT key and press RESET. The robot can now be moved. 3. Jog the robot to a safe position off of the limit switch. 4. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch.
4. TROUBLESHOOTING
MARO2P10203703E
431 If the problem still exists, perform the following troubleshooting procedure:
Table 414. SRVO-006 Troubleshooting Procedure Illustration
Troubleshooting Procedure 1. Turn off the controller and check fuse F4 on the power supply unit. If the fuse is blown 'replace it and check for a short circuit in the external 24V circuit (I/O and/or end effector power.) If fuse is not blown 'continue troubleshooting. 2. Reseat the CRM10 and JRF2 connectors on the main CPU and the CRM11 and JRF2 connectors on the emergency stop control board. Turn on the controller and check for proper operation. If the problem still exists, continue troubleshooting. Test the end effector switch and its wires at the robot for continuity. If there is no continuity 'replace the switch or its wires. If there is continuity 'continue troubleshooting.
Power Supply Unit

3.
4.
Emergency Stop Control Board

HBK
5.
Set the HBK jumper on the Emergency Stop Control Board to the A side and test the robot for proper operation. If the fault is fixed 'replace the cable between the main CPU connector CRM10 and the robot. Be sure to reset the jumper on the emergency stop control board to the B side. If the fault is not fixed 'one of the following components is bad. Determine the bad component by substitution.
HAND BROKEN JUMPER
Power Supply Unit
D The Emergency Stop control board. D The ribbon cable between the Emergency Stop
Control Board and the main CPU.
CRM 10
D Main CPU.
4. TROUBLESHOOTING
432
MARO2P10203703E
4.6.7
SRVO-007 ER_SVAL1 External Emergency Stops
An external emergency stop button somewhere in the workcell has been pressed. Remedy: Locate and release the external emergency stop button. Press reset on the operator panel or teach pendant. If the problem still exists, perform the following troubleshooting procedure:
Table 415. SRVO-006 Troubleshooting Procedure Illustration CNOP CRS1
SVON1
Troubleshooting Procedure 1. Look at terminals EMGIN1 and EMGIN2 on the operator panel interface. Check for a jumper connecting the terminals or a wire on each terminal. There should be continuity between the two terminals. If there is no continuity 'install a jumper or repair the external fence circuit. If there is continuity 'continue troubleshooting.
PORT 2 CNHM
EXON
KA1
SVON2 EXCOM
E STOP1
EXOFF
KA2
E STOP2 EMGOUT1
EMGIN1
KA3
EMGIN2
EMGOUTC
FENCE 1
KA4
EMGOUT2
FENCE 2
TBOP2
2. 3. Turn off the controller. Reseat the JRM10 connector at the operator panel interface and the JRM10 connector at the main CPU.
TBOP1
MAIN CPU
4. TROUBLESHOOTING
MARO2P10203703E
433
Table 415. (Contd) SRVO-006 Troubleshooting Procedure Troubleshooting Procedure Illustration CNOP CRS1 PORT 2 CNHM
SVON1 EXON
4.
Turn off the controller and check for proper operation. If the problem still exists continue troubleshooting.
5.
Make sure that no EMERGENCY STOP push buttons are pressed. Check the operator panel, teach pendant and any other external EMERGENCY STOP buttons that were added.
KA1 6. Open the controller door.

SVON2 EXCOM
7.
Disconnect one end of the EMGIN1 and 2 jumper or external emergency stop circuit.
E STOP1
EXOFF
KA2
E STOP2
EMGIN1
KA3 8. Briefly short the EMGIN1 and EMGIN2 terminals on the operator panel interface TBOP1 together. You should be able to hear relay KA4 click on the operator panel interface. If the relay clicks 'replace cable between the operator panel CNOP and the main CPU If not 'replace the operator panel. Refer to Figure 128, Figure 129 and Figure 1216.
EMGOUT1 EMGIN2
EMGOUTC
FENCE 1
KA4
EMGOUT2
FENCE 2
TBOP2
TBOP1
4. TROUBLESHOOTING
434
MARO2P10203703E
4.6.8
SRVO-011 ER_SVAL1 TP Released While Enabled
Teach pendant DEADMAN switch was released while enabled. Remedy: Press the DEADMAN switch, then press RESET.
4.6.9
SRVO-012 ER_SVAL1 Power Failure Recovery
Normal power is on (hot start). Remedy: This message is normal and does not indicate a problem. No action is required by the operator.
4.6.10
SRVO-014 Fan Motor Abnormal (Group:i Axis:j)
One or all of the 24VDC cooling fans in the backplane cage are not running. Each double-board board cage in the backplane has a cooling fan mounted in its top. Each fan contains a centrifugal switch that opens when the fan is not running.
Table 416. Troubleshooting Procedure 1.
SRVO-014 Troubleshooting Procedure Illustration
With power on, test whether each fan is turning by passing a strip of paper over the top of each board cage. If all fans are turning 'go to Step 3. If one or more fans are motionless 'continue troubleshooting.
2.
Remove the circuit boards from the board cage with the motionless fan. Reconnect the four-wire connector on the backplane behind the board cage. Re-install the boards and turn on the controller. If the fault is not fixed 'replace the fan.
Fan motor Cable
3.
One of the fans or the board is probably defective. Determine which part is bad by temporarily replacing it with a known-good part. If the fault is not fixed 'continue troubleshooting.
Connector
Backplane Back lane
4.
Replace the backplane.
4. TROUBLESHOOTING
MARO2P10203703E
435
4.6.11
SRVO-015 ER_SVAL1 System Over Heat (Group:i Axis:j)
The temperature in the controller is too high, or the overheat sensor located on the backplane has opened.
Table 417. 1. Check the heat exchanger fans for operation. If the fans are operating 'replace the backplane.
SRVO-015 Troubleshooting Procedure Print Reference Figure 121.
Troubleshooting Procedure
If one or more fans do not work 'continue troubleshooting. 2. Check the AC voltage at the terminals of the non-working fan(s). If the voltage is 200 to 240 VAC 'replace the non operational fan(s). If the voltage is out of tolerance 'replace the fan motor wiring harness.
4. TROUBLESHOOTING
436
MARO2P10203703E
4.6.12
SRVO-019 ER_SVAL1 SVON input
The SVON (servo ON/OFF) input is asserted. Perform the following troubleshooting steps.
Table 418. 1.
SRVO-019 Troubleshooting Procedure Print Reference Figure 1216.
Troubleshooting Procedure Check for continuity between SVON1 and SVON2 on the operator panel interface terminal strip TBOP2. If no continuity 'jumper terminals together or replace application wiring. If there is continuity 'replace the operator panel. If the alarms still exist 'replace the cable between the operator panel (CNOP) and the Main CPU (JRM10). If alarm still exists 'replace the main CPU.
4.6.13
SRVO-020 ER_SVAL1 SRDY off (TP)
The teach pendant cable is disconnected or a momentary break occurred in any of the teach pendant emergency stop circuits; DEADMAN switch or teach pendant EMERGENCY STOP button. Perform the following troubleshooting steps.
Table 419. 1.
SRVO-020 Troubleshooting Procedure Print Reference Figure 128 and Figure 1216.
Troubleshooting Procedure Replace the teach pendant cable or teach pendant as necessary. If alarm still exists 'replace the cable between the operator panel (CNOP) and the main CPU If alarm still exists 'replace the main CPU.
4. TROUBLESHOOTING
MARO2P10203703E
437
4.6.14
SRVO-021 ER_SVAL1 SRDY off (Group:i Axis:j)
The Magnetic Control Contactor on the servo amplifier cannot turn on and no obvious emergency stop conditions exist. Perform the following troubleshooting steps. Refer to Table 420. NOTE The paint robot is normally set up for Group 1, Axes 1-6 or Group 1, Axes 1-7. The opener, if present is usually set up as Group 2. The alarms will indicate which group is having problems.
Table 420.
SRVO-021 Troubleshooting Procedure Print Reference
Troubleshooting Procedure 1.
Check the continuity of the plunger switch that detects an open controller door. The switch should Figure 121 show continuity when the actuator is pressed. ressed. Figure 1215. If the plunger p g switch does not show continuity y 'replace the plunger g switch. If the plunger switch shows continuity 'continue troubleshooting. Remove connector from CRM15 on the Emergency Stop Control Board and check switch continuity thru CRM15 socket. Check the servo amplifier connections between the Emergency Stop Control Board. Check servo amplifier switch settings. See Figure 43. Check for proper cable connections between Emergency Stop Control Board and servo amplifier. See Figure 44. Turn on the controller and check for proper operation. If the problem is still exists continue troubleshooting. Check the Magnetic Control Contactor coil for continuity: If the Magnetic Control Contactor (MCC) coil is bad 'replace the MCC. If the MCC coil is good ' continue troubleshooting. One of the following components is bad. Determine the bad component by substituting it with a new component. Replace the following components one at a time until problem the is solved. D The Emergency Stop Control Board D Cable between the Emergency Stop Control Board (CRR15) and the MCC. D The cable between the MCC (CRR20) and the servo amplifiers. D The ribbon connector between the main CPU and the Emergency Stop Control Board (JRV1). D Cable from Emergency Stop Control board JS1 thru JS6 and servo amplifier. D The servo amplifier.
2. 3. 4. 5. 6. 7.
8.
4. TROUBLESHOOTING
438
Figure 43. Servo Amplifier Switch Settings
MARO2P10203703E
OFF There are four channel switches above the 7-segment LED behind the terminal board cover on the front of the servo amplifier. These switches should be set as described below before you use the servo amplifier. The switches are sequentially numbered 1, 2, 3, and 4 with the one at the bottom as switch 1. The OFF position is on the left and the ON position is on the right. Switch 1 ON Type B Interface OFF Type A Interface Switch 1 determines the interface type. Paint controllers use the Type B interface for Robot Axes 16 Set switch 2 to OFF. If the setting is incorrect, SRVO-021 SRDY OFF alarm might occur. Normal settings for switches 3 and 4 are in the ON position. Refer to Figure 46.
ON 4 3 2 1 LED
4. TROUBLESHOOTING
MARO2P10203703E
439
Figure 44. Connector and Terminal (T1) Identification
AO6B-6089-H101-H106 7 5 3
AO6B-6089-H201-H210 7 6 5 4 3
8 9 1
8 9 2 1
NAME 1 2 3 4 5 6 7 Connector for L-Axis (major channel) type A interface Connector for M-Axis (minor channel) type A interface Connector for L-Axis (major channel) type B interface Connector for L-Axis (minor channel) type B interface N/A N/A N/A
INDICATION JV1B JV2B JS1B JS2B JF1 JF2 JA4 CX3 CX4
REMARK TYPE A Interface TYPE A Interface TYPE B Interface TYPE B Interface TYPE B Interface TYPE B Interface TYPE B Interface 1 pin 3 pin 2 pin: ESP (at open) 3 pin: 24V
8 Connector for main power supply (Y key) Connector for expo signal 9 (X key)
4. TROUBLESHOOTING
440
MARO2P10203703E
4.6.15
SRVO-022 ER_SVAL1 SRDY on (Group:i Axis:j)
The Magnetic Control Contactor on the servo amplifier is on before it is expected to be on. Perform the following troubleshooting steps.
Table 421. 1.
Troubleshooting Procedure Check the Magnetic Control Contactor (MCC) for stuck contacts. If the contacts are stuck 'replace the MCC. If the MCC is OK 'continue troubleshooting. 2. Refer to the Section 4.6.14.
4.6.16
SRVO-023 ER_SVAL1 Stop Error Excess (Group:i Axis:j)
The axis position is too far from its commanded position when the robot is stopping, or the robot is stopped and it will not move. The torque necessary to decelerate an overloaded motor could cause this alarm to occur. Perform the following troubleshooting steps.
Table 422. 1. 2. 3. 4.
Troubleshooting Procedure Make sure that the load on the robot is not excessive. Check that the affected axis is not binding and rotates freely. Especially, make sure that the brake is not stuck. Check that the motor power cables do not have any open wires and that the cables are not misconnected. Either the motor or the servo amplifier is bad. Determine the bad component by substituting it with a new component.
4.6.17
SRVO-024 ER_SVAL1 Move Error Excess (Group:i Axis:j)
The servo error is too big when the robot is moving, or the robot moves when it is supposed to be stopped. Remedy: Same as SRVO-023, Stop Error Excess.
4. TROUBLESHOOTING
MARO2P10203703E
441
4.6.18
SRVO-026 ER_WARN Motor Speed Limit (Group:i Axis:j)
The motor cannot rotate as fast as the calculated speed required for the current motion. Remedy: Even though this is just a warning, every attempt should be made to eliminate this error by modifying the programmed speed or motion. The robot is not mastered. Remedy: Master the robot. Refer to Chapter 8.
4.6.19
SRVO-027 ER_WARN Robot Not Mastered (Group:i Axis:j)
4.6.20
SRVO-033 ER_WARN Robot Not Calibrated (Group:i Axis:j)
The robot is not calibrated. Remedy: Calibrate the robot. Refer to Chapter 8.
4.6.21
SRVO-035 ER_WARN Joint Speed Limit (Group:i Axis:j)
Joint cannot rotate as fast as the calculated speed required for the current motion. Remedy: Even though this is just a warning, every attempt should be made to eliminate this error by modifying the programmed or motion speed.
4.6.22
SRVO-036 Imposition Time Over (Group:i Axis:j)
The robot is not in position for the specified period, or the servo error is in excess of the specified position when the robot is stopping, or the robot is stopped and it will not move. The torque necessary to decelerate an overloaded motor could cause this alarm to occur. Remedy: Same as SRVO-023, Stop Error Excess.
4.6.23
SRVO-037 ER_SVAL1 IMSTP Input (Group:i Axis:j)
IMSTP (immediate stop) UOP (User Operator Panel) input asserted. Remedy: If using a UOP, determine the cause and repair. If not using UOP, select the I/O menus and zero UOP mapping.
4. TROUBLESHOOTING
442
MARO2P10203703E
4.6.24
SRVO-038 PULSE MISMATCH (Group:i Axis:j)
When the controller was powered up, one or more of its axes was at a different position from when it was powered off. This might occur when a motor is replaced or when a CPU from one controller is installed in another. Remedy: Perform the following procedure:
Table 423. 1. 2. 3. 4. Press MENUS. Select SYSTEM. Press F1, [TYPE]. Select MASTER/CAL
SRVO-038 Alarm Reset Procedure Print Reference
Reset Procedure
If MASTER/CAL is not displayed, perform the following: a. Select VARIABLES. b. Select $MASTER_ENB. c. Set $MASTER_ENB to 1. d. Press F1 [TYPE] and select MASTER/CAL. 5. 6. 7. Press F3, RES_PCA. Press F4, YES. Press RESET to clear the alarm without turning off the controller. If the fault does not reset, cold start the controller. Refer to Procedure 103 .
4. TROUBLESHOOTING
MARO2P10203703E
443
4.6.25
SRVO-042 ER_SVAL2 MCAL Alarm (Group:i Axis:j)
The servo amplifier magnetic control contactor (MCC) is welded closed. If the contact of the MCC is already closed when the contactor is turned on, this alarm circuit regards the contact as welded closed and the MCC alarm occurs. This error code can also be caused by improper controller shut down sequence (see Procedure 105 ) or improper servo lockout procedure (see Procedure 106 ). Perform the following troubleshooting procedure:
Table 424. 1.
SRVO-042 Troubleshooting Procedure Print Reference Figure 128 Figure 129.
Troubleshooting Procedure Does this alarm occur with SRVO-049? If SRVO-049 occurs 'check for the absence of input three-phase voltage. Connect as necessary. Check (reseat) the cable between the servo amplifier and the Emergency Stop Control Board. Turn the controller power off for fifteen second and then turn it on again. See Procedure 41 . If the alarm is still present, continue troubleshooting. Replace the servo amplifier. If error still exists 'replace re lace the cable between the Emergency Stop Sto Control Board and the servo amplifier. If error still exists 're replace lace the cable between the Emergency Stop Sto Control Board (JRV1) and the main CPU. If error still exists 'replace the Emergency Stop Control Board. Board If error still exists 'replace the main CPU.
2. 3.
4. TROUBLESHOOTING
444
MARO2P10203703E
4.6.26
SRVO-043 ER_SVAL2 DCAL Alarm (Group:i Axis:j)
The regenerative energy produced by the motor exceeded the specifications.
NOTE The amplifier supplies the energy (velocity energy) to the motor when the axis (without gravity) moves at the acceleration and constant speed. When the axis moves at the deceleration and constant speed and with gravity (gravity energy), the motor supplies this energy (velocity energy plus gravity energy) to the amplifier.
This energy from the motor to the amplifier is the regenerative energy. The amplifier discharges this energy by converting this energy to heat energy through the discharge resistor. If the charged energy exceeds the discharged energy, this alarm occurs. Remedy: Check the LED on the amplifier, then perform the following troubleshooting procedure.
Table 425. 1.
SRVO-043 Troubleshooting Procedure Print Reference Figure 121 Figure 123
Troubleshooting Procedure Is 4 or 5 indicated on the servo amplifier 7-segment display? Step 2. If 4 is indicated 'go to Ste If 5 is indicated 'go to Step 3. If no number is indicated ' check the cables between the servo amplifier and Emergency Stop Control Board. Board Verify the correct switch 3 and 4 setting (see Figure 45). 4 5) If the error still exists 'replace the servo amplifier. If the error still exists 're replace lace the cable between the servo amplifier am lifier and the Emergency Stop Sto Control Board. If the error still exists 'replace the ribbon cable (JRV1) between the main CPU and Emergency Stop Control Board. Sto If the error still exists 'replace the Emergency Stop Control Board. 2. If the error still exists 'replace the main CPU. A 4 is indicated (DCSW alarm) when the regenerative transistor is on continuously for one second or longer. See Figure 46. Reduce the load of the robot. If error still exists 'replace the servo amplifier. A 5 is indicated (DCOH alarm). See Figure 46. The DCOH alarm is caused when the regenerative resistor overheats and is sensed by the thermostat or the thermostat in transformer TF1 opens. opens If the average regenerative energy is excessive ' This alarm occurs when the acceleration/deceleration frequency is high or gravity energy at the axis is large. Relax the o operating erating conditions. For robots with extended axes or if the thermostat is incorrectly wired or is defective 'When a separate regenerative discharge unit or power transformer for the servo controller is used, check the wiring for the thermostat according to the connection diagrams for proper wiring.
3.
4. TROUBLESHOOTING
MARO2P10203703E
445
Figure 45. Switch 3 and 4 Settings
SWITCH 3 AND 4 SETTINGS The setting varies depending on the regenerative discharge resistance used. If the setting is incorrect, the regenerative discharge control circuit failure alarm (DCSW) cannot be detected. Normal setting for switches 3 and 4 are ON. SVU1 (12, 20) 3 ON ON OFF 4 ON OFF OFF Built-in Separate A06B-6089-H510 Separate A06B-6089-H500 Regenerative Discharge Resistor
SVU1 (40, 80), SVU2 3 ON ON OFF 4 ON OFF OFF Built-in Separate A06B6089-H500
Regenerative Discharge Resistor
Separate A06B-6089 H713(800W), A06B-6089-H714(1200W) SVU1 (130)
3 ON ON OFF
4 ON OFF OFF Built-in
Regenerative Discharge Resistor
Separate A06B-6089-H711 Separate A06B-6089-H712
Figure 46. Servo LED Display SERVO LED DISPLAY Regenerative discharge control circuit failure alarm (DCSW) Over regenerative discharge alarm (DC0II)
4 5
This alarm occurs if: The short-time regenerative discharge energy is too high. The regenerative discharge circuit is abnormal. This alarm occurs if: The average regenerative discharge energy is too high (too frequent acceleration/deceleration). The transformer overheats.
4. TROUBLESHOOTING
446
MARO2P10203703E
4.6.27
SRVO-044 ER_SVAL2 HVAL Alarm (Group:i Axis:j)
The DC voltage on the main power circuit of the servo amplifier exceeded specification. HVAL (High Voltage Alarm) Remedy: Check the three-phase voltage to the servo amplifier input. It should not exceed 253 VAC phase-to-phase. If the problem still exists, perform the following troubleshooting procedure:
Table 426. SRVO-044 Troubleshooting Procedure Print Reference Figure 123
Troubleshooting Procedure 1. Is the voltage of the three-phase input servo to the amplifier higher than 253 VAC? If the voltage than 253 VAC 'check multi-tap transformer TF1 taps. If it is within limits 200 to 240 VAC 'continue troubleshooting. 2. Is the load of the robot within the specification? This alarm can be caused by the charge of the regenerative energy when the load exceeds the specification. If it exceeds the specification 'reduce the load of the robot. If the specification is not exceeded 'continue troubleshooting. 3. Replace the servo amplifier. If the error still exists 'replace the cable between the Emergency Stop Control Board and the servo amplifier. If error still exists 'replace the cable (JRV1) between the Emergency Stop Control Board and the main CPU. CPU replace Stop Control Board. If error still exists're lace the Emergency Sto If error still exists 'replace the main CPU.
4. TROUBLESHOOTING
MARO2P10203703E
447
4.6.28
SRVO-045 ER_SVAL2 HCAL Alarm (Group:i Axis:j)
The current in the main power circuit of the servo amplifier exceeded specification. The servo amplifier LED should display 8, 9, 6, 8., 9., or 6.. Remedy: If no alarm is indicated on the servo amplifier 7-segment display, check the cabling between the servo amplifier (JS1B or JS2B) and the Emergency Stop Control Printed Circuit Board (JS1-6). If the problem still exists, perform the following troubleshooting procedure:
Table 427. SRVO-045 Troubleshooting Procedure Print Reference
Troubleshooting Procedure 1. Disconnect the motor power lines from the amplifier terminals and turn on the power. This alarm will re-occur if the servo amplifier is defective. If an HCAL (High Current Alarm) alarm occurs 'replace the servo amplifier. If an HCAL alarm does not occur 'continue troubleshooting. 2. Remove the motor power lines from the amplifier terminals and check the continuity between GND and each of the lines U, V, and W that go to the motor. If any are short-circuited 'go to Step 3. If all are not shorted 'go to Step 4. 3. Remove the power lines from the motor connectors (J1-6) and re-check the continuity between GND and each of the lines U, V, and W to the robot motor. If any lines are shorted, the motor is defective 'replace the motor. If all lines are open the power lines to the motor are defective 'replace the line that was shorted to GND. 4. Remove the motor power lines from the amplifier terminals and measure the resistance between U-V, V-W, and W-U on the servo amplifier using a measuring instrument sensitive enough to detect small resistances. If the three measured values are the same 'go to Step 5. If the three measured values are different 'go to Step 6. 5. Remove the power lines from the motor connectors and remeasure the resistance between U-V, V-W, and W-U using a measuring instrument sensitive enough to detect small resistances. If the three measured values are the same 'the power lines are defective. Replace the power lines. If the three measured values are different the motor is defective 'replace the motor. Go to Step 7. 6. 7. Replace the servo amplifier. Continue troubleshooting. Check whether you are using the robot under conditions that exceed the specification. For example, load, duty, and so forth. If there is no mechanical reason (binding and so forth) to cause this alarm, alarm this alarm might occur under conditions that exceed the specification. specification If you are using the robot over the specification, relax the operating conditions. If the error still exists'replace the cable between the servo amplifier and the Emergency Stop Control Board. If the error still exists 'replace the cable between the Emergency Stop Control Board (JRV1) and the main CPU. If the error still exists 'replace the Emergency Stop Control Board Board. If the error still exists 'replace the main CPU.
4. TROUBLESHOOTING
448
MARO2P10203703E
4.6.29
SRVO-046 ER_SVAL2 OVC Alarm (Group:i Axis:j)
The average current calculated by the servo software exceeded specification. OVC (Over Current Alarm). This is caused by excessive load or by a collision with an axis hard stop or an object in the robot work envelope.
4.6.30
SRVO-047 ER_SVAL2 LVAL Alarm (Group:i Axis:j)
The DC voltage on the main power circuit of the servo amplifier is lower than specification. LVAL (Low Voltage Alarm) Remedy: If no alarm is indicated on the servo amplifier LED, check the cabling between the servo amplifier and the Emergency Stop Control Board. If the problem still exists, perform the following troubleshooting procedure:
Table 428. SRVO-047 Troubleshooting Procedure Print Reference Figure 121 Figure 123
Troubleshooting Procedure 1. Does the LED of the amplifier indicate 2 ? Check the three-phase input voltage to the amplifier. If the LED indicates a 2 'the voltage is lower than the recommended specification. The phase-to-phase input voltage at the servo amplifier terminals should measure at least 170VAC between each phase Check for 200 to 240 VAC input power to terminals 13 and 14 of the servo amplifier. If it is low or missing, check multi-tap transformer TF1 taps, fuses, and Magnetic Control Contactor (MCC). If the alarm occurs again 'replace the servo amplifier. Go to Step 4. 2. Does the LED of the amplifier indicate 3 ? This indicates the DC current in the main power circuit is too low. Check the three-phase 200 to 240 VAC input voltage to the amplifier. If the voltage is lower than 170VAC 'the three-phase input voltage needs to be adjusted to within the FANUC specifications. Check the multi-tap transformer TF1 taps and fuses. 3. Did the circuit breaker on the servo amplifier trip? (If a circuit breaker trips, this alarm will occur incidentally.) If a circuit breaker trips 'turn on the breaker. If it trips again, replace the servo amplifier. Continue troubleshooting. Does the LED of the amplifier indicate a 7? This alarm could occur when the contact of the magnetic contactor (MCC) is melted (welded together). If the servo amplifier has been replaced and the error still exists; replace the cable between the servo amplifier am lifier and the Emergency Stop Sto Control Board. If error still exists ' replace the cable between the Emergency Stop Control Board (JRV1) and the main CPU CPU. If error still exists're replace Stop Control Board. lace the Emergency Sto If error still exists 'replace the main CPU.
4.
Refer to the SRVO-042 MCAL alarm. See Section 4.6.25. 5.
4. TROUBLESHOOTING
MARO2P10203703E
449
4.6.31
SRVO-049 ER_SVAL1 OHAL1 Alarm (Group:i Axis:j)
The servo amplifier or transformer is overheated. OHAL1 (Over Heat Alarm 1) Remedy: Check the fans and the heat exchange unit for proper operation. If the problem still exists, perform the following troubleshooting procedure:
Troubleshooting Procedure 1. Relax the operating condition (duty cycle). If the alarm no longer g occurs 'the operating g condition of the robot exceeded the specification. If the alarm still occurs 'replace the servo amplifier If no alarm is indicated on the servo amplifier 7-segment display 'check the cabling between the servo amplifier and the Emergency Stop Control Board. If the cabling is not bad, continue troubleshooting. 2. Replace the cable between the Emergency Stop Control Board (JRV1) and the main CPU. If the alarm still occurs 'replace the Emergency Stop Control Board. If the alarm still occurs 'replace the main CPU.
4.6.32
SRVO-050 ER_SVAL1 CLALM Alarm (Group:i Axis:j)
The servo software detected a disturbance torque that was too high or a collision occurred and tripped a collision detection alarm. CLALM (Collision Alarm) Remedy: Reset the robot by using the teach pendant reset and jog the robot away from obstructions. If the problem still exists, perform the following troubleshooting procedure:
Troubleshooting Procedure 1. Does the load exceed the specifications? (When the robot moves over the specifications, the estimated disturbance torque might become larger and this alarm could occur.) If the load exceeds the specifications 'lower the load to within the specifications. If the load does not exceed the specifications 'continue troubleshooting. 2. Is the three-phase AC input voltage to the servo amplifier lower than 170VAC phase-to-phase (O-V, V-W, U-W). If the voltage is lower than 170VAC 'increase the input voltage to within the specifications. Check multi-tap transformer TF1 taps and fuses. If the voltage is not lower than 170VAC 'continue troubleshooting. 3. Check the continuity of the motor power wires (from the servo amplifier to the motor). If the motor power wires are defective 'replace as required. If after the motor power wires have been replaced and the problem still exists 'replace the main CPU.
4. TROUBLESHOOTING
450
MARO2P10203703E
4.6.33
SRVO-051 ER_SVAL2 CUER Alarm (Group:i Axis:j)
The feedback current is abnormal. CUER (Current Error)
Table 431. 1. 2. Replace the servo amplifier. If the error still exists 'continue troubleshooting. Replace the main CPU.
4.6.34
SRVO-053 ER_WARN Disturbance excess (Group:i Axis: J)
The servo software detected a disturbance torque that was too high. Remedy: Reset the robot and try again.
4.6.35
SRVO-054 ER_SVAL1 DSM memory error (DS:i)
The DSP module program memory is defective. DSM (Digital Servo Module). Remedy: Replace the appropriate DSP module on the main CPU and continue.
4.6.36
SRVO-061 ER_SVAL2 CKAL Alarm (Group:i Axis:j)
The clock for the rotation counter in the serial pulse coder is abnormal. CKAL (Clock Alarm)
Table 432. 1.
Troubleshooting Procedure Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm? If YES ' disregard error SRVO_061 and refer to the remedy of any of the other three alarms. If NO alarms occur 'replace the serial pulse coder on the specified axis and master the robot. See Chapter 8.
4. TROUBLESHOOTING
MARO2P10203703E
451
4.6.37
SRVO-062 ER_SVAL2 BZAL Alarm (Group:i Axis:j)
The battery voltage for the serial pulse coders is zero volts. BZAL (Battery Zero Alarm).
Table 433. 1.
Troubleshooting Procedure Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm? If YES ' disregard the BZAL alarm and refer to the procedure for the other alarm (SRVO-68 - SRVO-70). If NO 'continue troubleshooting. 2. Did this alarm message list only one axis? If YES ' check the battery cable for the serial pulse coder of the axis listed in the alarm message. Reconnect, or replace as necessary. Go to Step 4. If NO 'continue troubleshooting. 3. Press the teach pendant emergency stop button. Turn the controller on. Check the pulse coder batteries for 6 VDC at the battery terminals on the battery box in the door of the controller. Do the batteries read 6 VDC ? If YES 'replace the battery compartment cable. Go to Step 4. If NO 'replace the batteries. Continue troubleshooting. 4. 5. 6. Perform serial pulse coder reset procedure under SRVO-038 alarm. Turn the controller off and then back on. It might be necessary to perform the SRVO-038 procedure again. If alarm still exists on only one axis 'Replace the serial pulse coder (after verifying battery cable is good) .
4. TROUBLESHOOTING
452
MARO2P10203703E
4.6.38
SRVO-063 ER_SVAL2 RCAL Alarm (Group:i Axis:j)
The built-in rotation counter on the serial pulse coder is abnormal. RCAL (Revolution Clock Alarm).
Table 434. 1.
Troubleshooting Procedure Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm? If YES 'disregard SRVO_063 and refer to the remedy of any of the other three alarms. If NO 'replace the serial pulse coder on the specified axis and master the robot. See Chapter 8.
4.6.39
SRVO-064 ER_SVAL2 PHAL Alarm (Group:i Axis:j)
The relationship between the analog signals on the serial pulse coder are abnormal. PHAL (Phase Alarm).
Table 435. 1.
Troubleshooting Procedure Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm? If YES ' disregard SRVO_064 and refer to the remedy of any of the other three alarms. If NO 'replace the serial pulse coder on the specified axis and master the robot. See Chapter 8.
4.6.40
SRVO-065 ER_WARN BLAL Alarm (Group:i Axis:j)
1.
The serial pulse coder batteries are low. BLAL (Battery Low Alarm).
Table 436.
Troubleshooting Procedure Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm? If YES 'disregard SPC_065 and refer to the remedy of any of the other three alarms. If NO 'replace the SPC backup batteries with controller power on. NOTE: Replace the battery as soon as possible when this alarm occurs, otherwise, if the battery voltage goes to zero volts, the robot will require remastering.
4. TROUBLESHOOTING
MARO2P10203703E
453
4.6.41
SRVO-066 ER_SVAL2 CSAL Alarm (Group:i Axis:j)
The serial pulse coder ROM checksum data are abnormal. CSAL (Check Sum Alarm).
Table 437. 1.
Troubleshooting Procedure Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm? If YES 'disregard SRVO_066 and refer to the remedy of any of the other three alarms. If No ' alarms occur replace the serial pulse coder on the specified axis and master the robot. See Chapter 8.
4.6.42
SRVO-067 ER_SVAL2 OHAL2 Alarm (Group:i Axis:j)
1.
The serial pulse coder overheated. OHAL2 (Over Heat Alarm).
Table 438.
Troubleshooting Procedure Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm? If YES ' disregard SRVO-067 and refer to the remedy of any of the other three alarms. If NO 'continue troubleshooting. 2. Does the operating condition (load, duty) exceed the specifications? If the operating condition exceeds the specifications 'relax the operating condition within the specification. (Reduce the load, change the program). If it operating conditions does not exceed the specifications 'continue troubleshooting. 3. Turn off the controller and when the temperature of the motor returns to normal, turn it back on. If the alarm immediately occurs again 'the built-in thermostat in the serial pulse coder is defective. Replace the serial pulse coder. If the alarm occurs again, but not immediately 'the motor is generating too much heat. Replace the motor.
4. TROUBLESHOOTING
454
MARO2P10203703E
4.6.43
SRVO-068 ER_SVAL2 DTERR Alarm (Group:i Axis:j)
The main CPU sent the serial data request signal to the serial pulse coder, but did not receive serial data from the serial pulse coder. In order to troubleshoot the 24V to 5V converter, it will be necessary to operate the power supply with the covers removed from the robot. The following procedure is necessary to insure the proper pre-test conditions are met. WARNING The robot is designed to operate in a hazardous location. The covers are an integral part of the protection therefore all of the steps listed below must be followed EXACTLY AND IN THE ORDER PRESENTED. These steps must be taken IN ADDITION TO NORMAL SAFETY PRECAUTIONS. Failure to follow these procedures could result in an explosion. Step 1 Consult your plant procedures to insure the area around the robot is KNOWN to be NON HAZARDOUS. Typically this will include the booth in which the robot is located. 2 Take steps to insure the area around the robot will REMAIN NON HAZARDOUS for the duration of the test procedure and until the covers are replaced on the robot. 3 Install a TEMPORARY jumper between terminals ISTB 1 and ISTB 4. 4 Install a TEMPORARY jumper from terminals ISTB 5 to ISTB 8. 5 Shut off the air supply to the robot. 6 If the above procedure causes a loss of controller power, press the purge enable pushbutton and wait 5 minutes. When the PURGE COMPLETE light comes on, the controller can be turned on. 7 After you complete Steps 1-6 remove the covers on the robot and with the controller powered ON, perform the required troubleshooting. 8 After the troubleshooting is complete, replace the covers tightly. 9 Turn on the air supply to the robot. 10 Turn off the controller and open the disconnect switch. 11 Remove both temporary jumpers and insure the connections to the ISTB are correct. WARNING DO NOT TAMPER WITH THE SETTING of the purge timer; otherwise, you could cause an explosion.
4. TROUBLESHOOTING
MARO2P10203703E
455
WARNING For continued safety, the temporary jumpers must be removed; otherwise, you could cause an explosion. 12 13
Close the main disconnect to the controller. Press the PURGE ENABLE pushbutton. Hold the pushbutton until it lights (approximately 10 seconds). This indicates adequate purge air flow. If the pushbutton does not light, purge air flow is not adequate and the robot should be checked for leaks. After the PURGE COMPLETE light comes on, the controller can be turned back on. The controller can not be turned on before the purge complete light comes on.
14
Table 439. 1.
Troubleshooting Procedure If an individual axes has failed, check for connection and continuity of the serial pulse coder cable. Replace if necessary. If all axes indicate failure or if the alarm occurs again 'continue troubleshooting. Check the 24V and 6.5 V LEDs on Module Assembly EE-3044-401 located in the purge cavity. See Steps 1 through 14 and Warnings of SRVO-068 and Figure 4-7. If the 24V LED is not illuminated 'check the wiring between the Module Assembly EE-3044-401 and the 24V power supply in the controller. If the 24V LED is illuminated and 6.5V LED is not illuminated 'disconnect CONN1 through CONN7 on Module Assy EE-3044-401. If 6.5V LED illuminates, check for shorted Cable. If 6.5V does not illuminate, replace the Module Assembly EE-3044-401. If the 24V LED is illuminated and 6.5 LED is illuminated 'continue troubleshooting. 3. 4. Replace the main CPU. If the alarm occurs again 'continue troubleshooting. Replace the serial pulse coder. Figure 47. Module Assembly # EE-3044-401
2.
CR1 DC/DC MODULE

LEDs
MODULE ASSY #EE-3044-401
24V
6.5V
4. TROUBLESHOOTING
456
MARO2P10203703E
4.6.44
SRVO-069 ER_SVAL2 CRCERR Alarm (Group:i Axis:j)
The serial data from the serial pulse coder changed during communication to the main Central Processor Unit. CRCERR (Cyclical Redundancy Check Error). This fault is frequently caused by electrical noise induced on the serial pulse coder cable. Make sure that the cable does not lie parallel or close to power cables. Make sure that the robot-mounted relays and solenoids have spark suppression diodes. Check all pulsecoder cable shield grounds points. Make sure that all cable connections are properly connected. Only as a last resort should the cable or a serial pulse coder be replaced.
4.6.45
SRVO-070 ER_SVAL2 STBERR Alarm (Group:i Axis:j)
The communication stop and start bits are abnormal. STBERR (Stop Bit Error). Refer to the SRVO-068 remedy.
4.6.46
SRVO-071 ER_SVAL2 SPHAL Alarm (Group:i Axis:j)
The feedback velocity exceeds the specifications. SPHAL (Software Phase Alarm). If the problem still exists, perform the following troubleshooting procedure:
Table 440. 1.
Troubleshooting Procedure Does this alarm occur with any other alarm? If another alarm occurs 'this alarm is caused by y the previous alarm of the serial serial pulse coder. d Refer R f to t the th other th alarm l f for d details. t il If another alarm does not occur 'replace the serial pulse coder.
4. TROUBLESHOOTING
MARO2P10203703E
457
4.6.47
SRVO-072 ER_SVAL2 PMAL alarm (Group:%d Axis:%d)
The serial pulse coder fails.
Table 441. 1.
Troubleshooting Procedure Does this alarm occur with any other alarm? If this alarm occurs along with a SRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070 STBERR 'disregard this alarm and refer to the other three alarm remedies. If this alarm does not occur along with a SRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070 STBERR 'continue troubleshooting. 2. Replace the serial pulse coder and master the robot. See Chapter 8 Mastering.
4.6.48
SRVO-073 ER_SVAL2 CMAL alarm (Group:%d Axis:%d)
1.
Incorrect position data detected in the serial pulse coder, or abnormal serial pulse coder data caused by noise.
Table 442.
Troubleshooting Procedure If this alarm occurs along with a SRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070 STBERR, disregard this alarm and refer to the other three alarm remedies. If the SRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070 STBERR, does not occur with this alarm, continue troubleshooting. Master the robot. See Chapter 8 then continue troubleshooting. Check the grounding of the serial pulse coder cable shield. If the serial pulse coder cable shield is grounded 'go to step 4. If the serial pulse coder cable shield is not grounded 'ground the shield or replace the cable. 4. Replace the serial pulse coder and master the robot. See Chapter 8, Mastering.
2. 3.
4.6.49
SRVO-074 ER_SVAL2 LDAL alarm (Group:%d Axis:%d)
1.
The Serial pulse coder failure.
Table 443.
Troubleshooting Procedure If this alarm occurs along with a SRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070 STBERR, disregard this alarm and refer to the other three alarm remedies. Otherwise, continue troubleshooting. Replace the serial pulse code and master the robot. See Chapter 8, Mastering.
2.
4. TROUBLESHOOTING
458
MARO2P10203703E
4.6.50
SRVO-075 ER_WARN Pulse not established (G:%d A:%d)
The pulse position is not established until the serial pulse coder is rotated one complete revolution.
Table 444. 1.
Troubleshooting Procedure The pulse position is not established until the serial pulse coder is rotated one complete revolution.
4.6.51
SRVO-081 ER_WARN EROFL Alarm (Track encoder:n)
Line Tracking Overflow Error.
Table 445. 1. 2.
Troubleshooting Procedure Check the connection between the controller and the line tracking device (absolute encoder or pulse generator). Check that the line speed is within the recommended specification. If the line speed is not within the specification 'relax the line speed.
4. TROUBLESHOOTING
MARO2P10203703E
459
4.6.52
SRVO-082 ER_WARN DAL Alarm (Track encoder:n)
Line Tracking serial pulse coder is disconnected. Remedy: Check axis control printed circuit board for proper line tracking cable connections. If the problem still exists, perform the following troubleshooting procedure:
Table 446. 1. 2. Replace the main CPU. Replace the line tracking serial pulse coder.
4.6.53
SRVO-083 ER_WARN CKAL Alarm (Track encoder:n)
The clock for the rotation counter in the line tracking serial pulse coder is abnormal. Remedy: Refer to SRVO-061 remedy.
4.6.54
SRVO-084 ER_WARN BZAL Alarm (Track encoder:n)
The battery voltage for the line tracking serial pulse coder is zero volts. Remedy: Refer to SRVO-062 remedy.
4.6.55
SRVO-085 ER_WARN RCAL Alarm (Track encoder:n)
The built-in rotation counter on the line tracking serial pulse coder is abnormal. Remedy: Refer to SRVO-063 remedy.
4.6.56
SRVO-086 ER_WARN PHAL Alarm (Track encoder:n)
The relationship between the analog signals on the line tracking serial pulse coder are abnormal. Remedy: Refer to SRVO-064 remedy.
4. TROUBLESHOOTING
460
MARO2P10203703E
4.6.57
SRVO-087 ER_WARN BLAL Alarm (Track encoder:n)
The line tracking serial pulse coder batteries are low. Remedy: Refer to SRVO-065 remedy.
4.6.58
SRVO-088 ER_WARN CSAL Alarm (Track encoder:n)
The line tracking serial pulse coder ROM checksum data is abnormal. Remedy: Refer to SRVO-066 remedy.
4.6.59
SRVO-089 ER_WARN OHAL2 Alarm (Track encoder:n)
The line tracking serial pulse coder overheated. Remedy: Refer to SRVO-067 remedy.
4.6.60
SRVO-090 ER_WARN DTERR Alarm (Track encoder:n)
The axis control printed circuit board sent the request signal, but did not receive serial data from the line tracking serial pulse coder. Remedy: Refer to SRVO-068 remedy.
4.6.61
SRVO-091 ER_WARN CRCERR Alarm (Track encoder:n)
The serial data from the line tracking serial pulse coder changed during communication to the axis control printed circuit board. Remedy: Refer to SRVO-069 remedy
4.6.62
SRVO-092 ER_WARN STBERR Alarm (Track encoder:n)
The communication stop and start bits for line tracking axis are abnormal. Remedy: Refer to SRVO-070 remedy.
4. TROUBLESHOOTING
MARO2P10203703E
461
4.6.63
SRVO-093 ER_WARN SPHAL Alarm (Track encoder:n)
The feedback velocity exceeds the specification for line tracking axis. Remedy: Refer to SRVO-071 remedy.
4.6.64
SRVO-147 SERVO LVAL(DCLK) alarm (G:%d A:%d)
The back-up charge circuit for the amplifier has an abnormal voltage. This error code can also be caused by improper controller shut down sequence (See Procedure 105 ) or improper servo lockout procedure (See Procedure 106 ). Remedy: Check the cables and connections between amplifier (CN1) and MCC. Check the fuse (F1,F2) in transformer. Replace the amplifier.
4.6.65
SRVO-163 ER_FATL DSM Hardware Mismatch
The DSM (Digital Servo Module) hardware does not all match. Remedy: Remove the main Central Processor Unit from the controller and check the part numbers on the DSM boards mounted in the axis module slots. The part numbers should be the same. If the robot has more than six axes, also check the multifunction board DSM hardware. All DSM hardware must have the same part number to prevent this alarm. (See Figure 17 and Table 11). The current servo parameters do not match the DSM hardware installed. Remedy: Replace all DSP-IV DSM modules with DSP-V type. (See Figure 17 and Table 11).
4.6.66
SRVO-164 ER_FATL DSM/Servo param mismatch
4.6.67
SRVO-165 ER_FATL Panel (SVON abnormal) E-Stop
The panel emergency stop button is pressed and the controller detected a wiring error on SVON or EMGIN terminals. Remedy: Turn off the controller and check EMGIN and SVON wiring to operator panel interface terminals. Correct external wiring as necessary.
4.6.68
SRVO-166 ER_FATL TP (SVON abnormal) E-Stop
The teach pendant emergency stop button is pressed and the controller detected a wiring error on SVON or EMGIN terminals. Remedy: Turn of the controller and check EMGIN and SVON wiring to operator panel interface terminals. Correct external wiring as necessary.
4. TROUBLESHOOTING
462
MARO2P10203703E
4.6.69
SRVO-167 ER_FATL Deadman switch (SVON abnormal)
The teach pendant DEADMAN was released and the controller detected a wiring error on SVON or EMGIN. Remedy: Turn off the controller and check EMGIN and SVON wiring to operator panel interface terminals. Correct external wiring as necessary.
4.6.70
SRVO-168 ER_FATL External/SVON (SVON abnormal) E-Stop
The external emergency stop or external SVON switch is pressed and the controller detected a wiring error on the SVON or EMGIN terminals. Remedy: This error is applicable is the redundant external emergency stop or SVON wiring is used. If so, turn off the controller and check the EMGIN and SVON wiring to the operator panel interface terminals. Correct external wiring as necessary.
4. TROUBLESHOOTING
MARO2P10203703E
463
4.7
CLASS 4 FAULTS
A Class 4 Fault occurs when the process equipment within the outer arm of the P-200 robot fails to perform correctly. This section contains troubleshooting procedures for each kind of malfunction. Trigger Valve Malfunctions and Troubleshooting D Gun(s) that do not turn on (Trigger) or work intermittently. Refer to Procedure 45 . D Gun(s) that do not shut off Refer to Procedure 46 D Paint Gun Trigger Troubleshooting Procedure (Electrical). Refer to Procedure 47 . Current to Pressure Transducer Troubleshooting Refer to Section 4.7.4 D Poor Film Build (Too heavy or light) D Repeated Adapted Out Of Range messages D Need for continual Preset corrections D Transducer Troubleshooting Procedure. Refer to Procedure 48 . D Flow Meter Troubleshooting Procedure. Refer to Procedure 49 . P-200 end of arm troubleshooting error descriptions D Error #178, Cal. Timeout at maximum flow D Error #179, Cal. Timeout at low flow D Error #183, Min. output has flow > setpoint D Error # 189, Failed to reach setpoint D Display reads 0 cc/min when paint is actually flowing from the gun. D Display reads the exact same cc/min value whether paint is flowing or not. Depending on the manufacturer, style and/or type of gun assembly used, these malfunctions could be attributed to a single gun assembly when two guns are mounted on a common manifold having a common supply pilot signal. In this case, the problem would be in the individual gun assembly; the gun assembly would be suspected first and replaced before looking into the supply.
4. TROUBLESHOOTING
464
MARO2P10203703E
4.7.1
Process Fault - Both Guns Do Not Trigger or Work Intermittently
Remedy: There is no clear cut remedy for this type of malfunction. Considerations: This function is electrical and pneumatic in operation. Procedure 45 first considers the most common causes which may be pneumatic in nature, then , if the problem still exists, will continue troubleshooting the electrical components. Both Guns Do Not Trigger or Work Intermittently Perform the following troubleshooting steps. Step 1 Shut off the plant supplied air to the pilot trigger valve. 2 Remove the output pilot line from the pilot trigger valve. 3 Apply plant supplied air to the pilot trigger valve. 4 Push the mechanical override button on the valve body. Refer to the Trigger Valve/ Regulator Assembly in Figure 1232. 5 Determine whether pilot air is coming out of the pilot trigger valve. If NO > Remove and replace pilot trigger valve. If YES > Go to step 6.
Procedure 45
WARNING This valve is intrinsically safe. Repair of the solenoid and pilot section is prohibited. If the solenoid portion is faulty, you must replace the solenoid and pilot section as one assembly. They are assembled as a matched set and should not be exchanged with other components.
6 Is pilot air sufficient and constant with plant supplied air pressure? Refer to gun manufactures specification. If NO > Go to step 7. If YES > Troubleshoot pilot trigger line to gun assembly. Refer to the Trigger Valve/ Regulator Assembly in Figure 1232. If problem still exists , Go to step 8. 7 Is the air supply to the system sufficient and consistent with plant supplied air pressure? If NO > Troubleshoot air supply. If YES > Remove and replace pilot trigger valve. Is problem solved. If NO > Go to step 9.
4. TROUBLESHOOTING
MARO2P10203703E
465
WARNING This valve is intrinsically safe. Repair of the solenoid and pilot section is prohibited. If the solenoid portion is faulty, you must replace the solenoid and pilot section as one assembly. They are assembled as a matched set and should not be exchanged with other components. 8 Troubleshoot the paint spray gun assembly. Determine whether the problem is solved. If NO > go to step 9. 9 Continue troubleshooting with Procedure 47 .
4.7.2
Both Guns Will Not Shut Off
Remedy: There is no clear cut remedy for this type of malfunction. Considerations: This function is electrical and pneumatic in operation. Procedure 46 first considers the most common causes which may be pneumatic in nature, then , if the problem still exists will continue troubleshooting the electrical components. Both Guns Will Not Shut Off Perform the following troubleshooting steps. Step 1 Shut off the air supply to the pilot trigger valve. Refer to the Trigger Valve/ Regulator Assembly in Figure 1232. 2 Remove the output pilot line from the pilot trigger valve. 3 Apply air supply to the pilot trigger valve. 4 Is air leaking from valve output port? Refer to the Trigger Valve/ Regulator Assembly in Figure 1232. If NO > troubleshoot trigger (s) in gun assembly. If YES > Go to step 5. 5 Check for 12Vdc on solenoid/pilot trigger valve. Refer to the Trigger Valve/ Regulator Assembly in Figure 1232. WARNING This valve is intrinsically safe. Repair of the solenoid and pilot section is prohibited. If the solenoid portion is faulty, you must replace the solenoid and pilot section as one assembly. They are assembled as a matched set and should not be exchanged with other components. If NO > Remove and replace pilot trigger valve. If YES > Go to Procedure 47 .
Procedure 46
4. TROUBLESHOOTING
466
MARO2P10203703E
4.7.3
Paint Gun Trigger Troubleshooting Procedure (Electrical)
Procedure 47 Step
Use Procedure 47 to troubleshoot the electrical paint gun trigger components.
Paint Gun Trigger Troubleshooting Procedure (Electrical) 1 Is DOUT [145] (PT) configured correctly? If NO > Go to step 2. If YES > Go to step 3.
I/O Digital Out # SIM STATUS DO[ 140] U OFF [ DO[ 141] U OFF [ DO[ 142] U OFF [ DO[ 143] U OFF [ DO[ 144] U OFF [ DO[ 145] U OFF [ DO[ 146] U OFF [ DO[ 147] U OFF [ DO[ 148] U OFF [ DO[ 149] U OFF [ [ TYPE ] CONFIG G2 JOINT 100% 145/256 Reserved ] Reserved ] Reserved ] Reserved ] Reserved ] Gun 1 pilot ] ] ] ] ] ON OFF
IN/OUT
2 Reconfigure using Site I/O program, then go to step 3. 3 Is DOUT [145] (PT) ON ? If NO > Go to step 4. If YES > Go to step 5. 4 Set DOUT [145] (PT) to ON. Refer to Procedure 71 . Is output led (AO) on the output module ON? Refer to Figure 48. If NO > Go to step 5. If YES > Go to step 13.
4. TROUBLESHOOTING
MARO2P10203703E
467
Figure 48. I/O Module LEDS
LEDS
A0 1 2 3 4 5 6 7 B0 1 2 3 4 5 6 7
A0 LED
I/O MODULE
5 Is DOUT [145] (PT) simulated. Refer to Procedure 72 . If YES > Go to step 6 If NO > Go to step 7. 6 Unsimulate DOUT [145] (PT). Go to step 3.
4. TROUBLESHOOTING
468
MARO2P10203703E
7 Determine whether the interface module power LED (PWR) is on? Refer to Figure 49. If NO > Go to step 8. If YES > Go to step 10.
Figure 49. Interface Module PWR LED
PWR
LINK BAI BAO
LINK LED
AIF0IA
PWR LED
JD1B
JD1A
CP32
JD2
INTERFACE MODULE
4. TROUBLESHOOTING
MARO2P10203703E
469 8 Determine whether the 24V input fuse is good? Refer to Figure 410. If NO > Replace 24VDC input fuses. If YES > Go to step 9.
Figure 410. Interface Module Interface module AIFO1A
Output 5.0A Fuse
Input 3.2A Fuse
5.0A F2
F1 3.2A
4. TROUBLESHOOTING
470
MARO2P10203703E
9 Determine whether 24E at input connector (CP32) to I/F (Interface Module)? Refer to Figure 411. If NO > Troubleshoot the 24E circuit and wiring. If YES > Replace I/F module.
Figure 411. Pin Out and Locator for Connector CP32
I/O UNIT MODEL A POWER SUPPLY A16B12120870 CP6 1 2 3 CP32 +24V 0V
MODULAR I/O 5SLOT BASE UNIT A03B0807J002 10SLOT BASE UNIT A03B0807J001 MODULAR I/O INTERFACE MODULAR I/O CP32 MODULE A03B0807J011 JD1B JD1A JD2
MAIN CPU A16B32000040 JD1A
10
Determine whether the interface module Link LED is ON? Refer to Figure 412. If NO > Go to step 11. If YES > Replace output module, AOD16D.
Figure 412. Interface Module PWR LED
PWR
LINK BAI BAO
LINK LED
AIF0IA
JD1B
JD1A
CP32
JD2
INTERFACE MODULE
4. TROUBLESHOOTING
MARO2P10203703E
471 11 Is output fuse good? Refer to Figure 410. If No > Replace output fuse. If YES > Replace interface module. 12 13 Replace output module, AOD16D. Is there 24Vdc at ISB7 input terminals 7 and 8? Refer to Figure 413 If NO > Go to step 14. If YES > Go to step 15.
Figure 413. Intrinsic Safety Barrier
DC OUTPUT MODULE EE-3287-328-001 INTRINSIC CABLE EE-3287-117-XXX ISB7
8336F .5 AMP 2
LOCATED IN P-200 ROBOT ARM 8663SOL WHT GRN
ISB7-1
P1 7 2 ISB7-2
I.S. GROUND
14
Is wiring from the output module to ISB7 okay? Refer to Figure 413. If NO > Repair wiring. If YES > Go to step 16.
15
Is fuse 8336F/0.5A blown? Refer to Figure 413. If NO > Replace output module, AOD16D. If YES > Replace 8336F 0.5A Fuse.
4. TROUBLESHOOTING
472 16
MARO2P10203703E
Is 12Vdc at ISB7 output terminals 1 and 2 correct. Refer to Figure 414.
WARNING Never apply test leads to output terminals during paint booth operations. To do so could injure personnel or damage equipment. Remove ISB7 output terminals 1 and 2 before any voltage measurements are taken.
If NO > Replace Intrinsic Safety Barrier If YES > Go to step 17.

Figure 414. Intrinsic Safety Barrier
DC OUTPUT MODULE EE-3287-328-001 INTRINSIC CABLE EE-3287-117-XXX ISB7
8336F .5 AMP 2
LOCATED IN P-200 ROBOT ARM 8663SOL WHT GRN
ISB7-1
P1 7 2 ISB7-2
I.S. GROUND
17
Is 12Vdc at pilot trigger valve connector? Refer to Trigger Valve/ Regulator Assembly Figure 1232. If NO > Check the cables and connector. If YES > Replace the 8336SOL valve assembly.
WARNING The 8336SOL valve is intrinsically safe. Repair of the solenoid and pilot section is prohibited. If the solenoid portion is faulty, you must replace the solenoid and pilot section as one assembly. They are assembled as a matched set and should not be exchanged with other components.
4. TROUBLESHOOTING
MARO2P10203703E
473
4.7.4
Process Fault Transducer Troubleshooting Procedure
Use Procedure 48 to cover: D Poor Film Build (Too heavy or light) D Repeated Adapted Out Of Range Messages D Need for Continual Preset Corrections Remedy: There is no clear remedy for these types of symptoms. It might be caused by a faulty current to pressure transducer (I/P) or a faulty flow meter. Considerations: The current to pressure transducer is an electrical and pneumatic device that is intrinsically safe. The only troubleshooting that can be done to the transducer is covered in Procedure 4.7.4. Procedure 48 Step Transducer Troubleshooting 1 Is AOUT[1] set to a count of 200? If NO > Go to step 2. If YES > Go to step 3.
I/O Analog Out # SIM VALUE AO[ 1] U 200 AO[ 2] U 200 AO[ 3] U 200 AO[ 4] U 200 DO[ 5] U 0 DO[ 6] U 0 DO[ 7] * * DO[ 8] * * DO[ 9] * * DO[ 10] * * [ TYPE ] CONFIG
G1 [ [ [ [ [ [ [ [ [ [
JOINT 10% 1/25 Fluid Flow 1 ] Atom. Air 1 ] Fan Air 1 ] Estats 1 ] Flw setpoint ] Flw diag out ] ] ] ] ] SIMULATE UNSIM
IN/OUT
2 Set AOUT[1] to a count of 200. Refer to Procedure 7.1. 3 Attach an analog 0 to 60 psi gauge to the gage port on the current to pressure transducer. Refer to Trigger Valve/Regulator Assembly Figure 1232. 4 Set AOUT[1] to a count of 1000. Refer to Procedure 7.1. 5 Is there any output pressure? If NO > Go to step 6. If YES > Go to step 12.
4. TROUBLESHOOTING
474 6 Is the plant air supply ON? If NO > Turn ON air supply. If YES > Go to step 7.
MARO2P10203703E
7 Is your paint system in the proper mode of operation? (Proper mode of operation will depend upon the unique characteristics of your system). If NO > Set paint mode to proper mode of operation. If YES > Go to step 8. 8 Is there 14.5 VDC at the current to pressure transducer I/P connector P1 pins 1 and 6. Refer to Trigger Valve/ Regulator Assembly Figure 1232. If NO > Go to step 9. If YES > Go to step 12.
WARNING Never apply test leads to output terminals during paint booth operations. Otherwise, you could injure personal and damage equipment.
9 Is there 14.5 Vdc at ISB4 terminals 1 and 2? Refer to Single Stage Purge Process Control Figure 1241. If NO > Go to step 10. If YES > Go to step 11. 10 Is there 24Vdc at ISB4 input terminals 7 and 8? Refer to Single Stage Purge Process Control Figure 1241. If NO > Check power supply and wiring. If YES > Replace ISB4. 11 Check the cable and connector wiring from ISB4 to I/P transducer P1. 12 Check for pressure leaks at pneumatic connections. This can be accomplished using a soapy liquid solution. If No > Tighten pneumatic connections. If YES. Go to step 13.
4. TROUBLESHOOTING
MARO2P10203703E
475 13 Perform calibration on the Current to Pressure Transducer I/P. Refer to Procedure 10.1.
Consider the following while doing the calibration procedure:

14
Non-Linearity Hunting Poor Response No Reaction at Output Poor Hysteresis Poor Accuracy Poor Repeatability Inaccurate Span
Did the Current to Pressure Transducer (I/P) pass the calibration? If NO > Go to step 15. If YES > Troubleshoot other process equipment.
15
Connect a mA meter in series with terminal 8 of the D/A module (ADA02A) in slot 3 of the I/O rack. Refer to Single Stage Purge Process Control Figure 1241. Set the AOUT[1] on the teach pendant to 600 counts
16
I/O Analog Out # SIM VALUE AO[ 1] U 600 AO[ 2] U 200 AO[ 3] U 200 AO[ 4] U 200 DO[ 5] U 0 DO[ 6] U 0 DO[ 7] * * DO[ 8] * * DO[ 9] * * DO[ 10] * * [ TYPE ] CONFIG
G1 [ [ [ [ [ [ [ [ [ [
JOINT 10% 1/25 Fluid Flow 1 ] Atom. Air 1 ] Fan Air 1 ] Estats 1 ] Flw setpoint ] Flw diag out ] ] ] ] ] SIMULATE UNSIM
IN/OUT
17
Is there 12.00mA on the meter? If NO > Go to step 18. If YES > Go to step 19
18
Is there 24 Vdc at ISB5 terminals 7 & 8? Refer to Single Stage Purge Process Control Figure 1241. If NO > Check source of 24 Vdc power. If YES > Go to step 22.
4. TROUBLESHOOTING
476 19 20 Connect mA meter in series with terminal 1 of ISB5. Is there 12.00 mA on the meter? If NO > Go to step 21. If YES > Replace I/P transducer. 21
MARO2P10203703E
Check the cable and wiring from the ISB5 to the I/P transducer. Is the wiring defective? If NO > Replace the ISB5. If YES. Replace the wiring or cable.
22
Is AOUT[1] configured correctly? If NO use Site I/O program. Refer to PaintTool Manual Setup Chapter. IF YES > Go to step 23.
23
Is AOUT[1] Simulated? Refer to Procedure 7.2 If NO > Check cable/wiring from D/A module to IBS5, terminals 9 and 10. If YES > Unsimulate.
4.7.5
Process Fault - Flow Meter Troubleshooting Procedure
Remedy: There is no clear remedy for these types of symptoms. It may be caused by a faulty flow meter. Considerations:The Flow Meter is a mechanical to electrical feedback transducer. The only troubleshooting that can be done to the transducer is covered in Procedure 49 . Flow Meter Troubleshooting 1 Remove MODUFLOW/Flow Meter assembly from the P-200 robot arm. Refer to Figure 1233. 2 Remove the Flow Meter from the MODUFLOW assembly. 3 Remove the electrical connector from the Flow Meter. 4 Blow air into the Flow Meter input port. Do the gears spin? If NO > Disassemble, clean, and then reassemble the Flow Meter. Return to step 4. If gears do not spin after Flow Meter has been cleaned replace Flow Meter. If YES > Go to step 5.
Procedure 49 Step
4. TROUBLESHOOTING
MARO2P10203703E
477 5 Reconnect the sensor cable. 6 Monitor GIN[8] and GIN[9] at the teach pendant from the I/O menu.
I/O Group In # SIM VALUE GI[ 1] S 0 [ U GI[ 2] S 0 [ GI[ 3] U 0 [ GI[ 4] U 0 [ GI[ 5] U 0 [ GI[ 6] U 0 [ GI[ 7] U 0 [ GI[ 8] U 59147 [ GI[ 9] U 32767 [ GI[ 10] U 0 [ [ TYPE ] CONFIG
JOINT 100% 1/25 Init data ] Init type ] CC cycsel ] CC shared ] CC group ] Flw/tpar ] Parm/indc ] Totl cnt ] Rate cnt ] Job type ] SIMULATE UNSIM
IN/OUT
7 Blow air into the Flow Meter input port. Did you see a change in GIN[8] and GIN[9]? If NO > Go to step 8 If YES > Go to step 8 Is GIN[8] & GIN[9] configured correctly? If NO > Run Site I/O program Refer to PaintTool Setup Chapter. then > Go back to step 6. If YES > Go to step 9. 9 Is there 24 Vdc at the terminal block of the Flow Meter Interface module, wires 82091 and 82092? Refer to schematics 47 A sheet 082 and 087 If NO > Check wiring and CPU power supply If YES > Go to step 10. 10 Is there +5 Vdc at the terminal block of the Flow Meter Interface module, wires 82142 and 82092? Refer to Figure 1239 and Figure 1242. If NO > Go to step 11 If YES > Go to step 11 Is fuse 8214F blown? Refer to Figure 1243. If NO > Go to step 12 If YES > Replace fuse
4. TROUBLESHOOTING
478 12
MARO2P10203703E
Check connector and wiring at JD1A port of the I/F module. Refer to Figure 411. If the wiring is damaged replace wiring If the connector is damaged replace I/F module Verify for proper operation. If the problem still exists > Go to step 13.
13
Is there 24 Vdc at the terminal block of the Flow Meter Interface module, wires 87091 and 87101? Refer to Figure 1239 and Figure 1242. If No > Replace Flow Meter Interface module. If YES > Go to step 14.
14
Is there 24 Vdc at ISB6, terminals 7 and 8. Refer to Figure 1242. If NO > Replace wiring If YES > Go to step 15.
15
Is there zero ohms at the terminal block of the Flow Meter Interface module, -Sig. and wire 87101? Refer to Figure 1242. If NO > Tighten jumper connections or Replace jumper. If YES > Go to step 16.
16
Is there 24 Vdc at ISB6, terminals 1 and 2. Refer Figure 1242. If NO > Replace ISB6 If YES > Go to step 17.
WARNING Never apply test leads to these pins during paint booth operations. Otherwise, you could injure personnel and damage equipment.
17
Is there 24 Vdc at the Flow Meter connector P1, pins A and B. Refer to Figure 1242. If NO > Replace wiring If YES > Replace Flow Meter
18
Perform a Flow Test (Beakering Test). Refer to Procedure 102 .
4. TROUBLESHOOTING
MARO2P10203703E
479 19 Does the amount in the beaker equal the Total (cc) and Flow Rate called for? If NO > Go to step 20. If YES > Troubleshooting completed.
STATUS AccuFlow JOINT 100 % AccuFlow Status Display Selected Operating Mode: Adaptive Current Operating Mode: Open Loop Color Valve Number: 1 Calibration Status: Complete Actual yield ((cc/min)/cnt): .78 Total (cc): 216 Set Point/Actual (cc/min): 600/594 Applicator Trigger: ON Set point reached: ON [ TYPE ] RES TOT HELP
20
Calculate new KFT factor and enter into the Equipment Characteristics parameter section on the teach pendant.
cc in beaker + X * old KFT + new KFT totalizer
4. TROUBLESHOOTING
480
MARO2P10203703E
SETUP AccuFlow AccuFlow Global Parameters 1 2 3 4 5 6 7
JOINT
100 % 1/25 Pendant Adaptive 1.8 5 3 95.0 70.0
Mode selection source: Selected operating mode: Percent Tolerance Band: Min. tolerance band: Sample amount: Normal gain modifier (%): Pulsing pump gain mod. (%):
Equipment characteristics 8 KFT factor (CC): 9 Equipment learn done: 10 Trigger delay (ms): 11 Flow delay (ms): 12 Time up (ms/1000 cnts): Calibration parameters 14 Hysteresis checks: 15 Leveling trys: 16 Cal time out (sec): 17 Cal step delay (ms): 18 Table point no. 2 (cc/min): Table adjustment parameters 19 Flow in-tol trys: 20 Indep point shift band (%):
2366 Done 50 32 72
YES 2 15 800 200
2 30.0
Alarm parameters 21 Adaptive tolerance (%): 10.0 22 Max. error from setpoint (%): 6.0 23 Max. control out (ms): 200 24 Min. set point reached (ms): 3000 25 Grace period (ms): 4000 [ TYPE ] CHAN KFT_CAL [CHOICE] HELP
21 22
Preform a Flow Test (Beakering Test). Refer to Procedure 102 Does the amount in the beaker equal the Total (cc) and Flow Rate called for? If NO > Replace Flow Meter Interface module. Verify problem is solved by rerunning the Flow Test if problem still exists Replace Digital 32 bit Input module (AID32B) in the I/O rack. If YES > Troubleshooting completed.
5 REPLACING FUSES
Page81
MARO2P10203703E
REPLACING FUSES
51

Fused Flange Mounted Disconnect Fuses Multi-Tap Transformer Fuses Power Supply Unit Fuses Servo Amplifier Fuses Emergency Stop Control PCB Fuses Purge Power Supply Fuses Modular I/O (Model A) Fuses Sub-CPU Printed Circuit Board Fuse
Page
The fused flange-mounted disconnect provides overcurrent protection supply through three fuses; one for each leg of the 3-phase supply. . . . . . . . . . . . . . . . . 52 Five fuses reside on the multi-tap transformer with fuses F1, F2, and F3 for the three-phase 200 VAC servo power and F4 and F5 for 100 VAC. . . . . . . . . . . . . . 54 Three fuses are located in the power supply unit F1 AC input, F3 and F4 +24V. 55 The servo amplifiers for the P-200 contain one fuse (F1), except for Model A06B6089H106 which includes a second fuse (F2). . . . . . . . . . . . . . . . . . . . . . 56 Two fuses reside on the Emergency Stop Control printed circuit board. . . . . . . . 57 Two fuses reside on the Purge Power Supply F11 and F12. . . . . . . . . . . . . . . . . . 58 The modular I/O (Model A) modules that contain fuses are described in this section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 One fuse resides on the Sub-CPU printed circuit board. . . . . . . . . . . . . . . . . . . . . 512
If a fuse blows in the controller, determine the cause, repair or replace the defective part or unit and replace the fuse with the same type and rating. Fuse replacement procedures are provided for the following fuses in the controller
WARNING Before replacing a fuse, turn the power off and lock out the controller; otherwise, you could injure personnel or damage equipment.
5. REPLACING FUSES
52
MARO2P10203703E
5.1
FUSED FLANGE-MOUNTED DISCONNECT FUSES
The controller is supplied with a fused flange-mounted disconnect. The fused flange-mounted disconnect provides overcurrent protection supply through three fuses; one for each leg of the 3-phase supply. See Figure 51 for fused flange-mounted disconnect location and Table 51 for description of the fuse flange-mounted disconnect and fuses. The fused flange-flange disconnect provides a means for shutting off power to the controller and locking the power out.
WARNING Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. Turning the disconnect to the OFF position removes power from the output side of the device only. High voltage is always present at the input side whenever the controller is connected to a power source.
5. REPLACING FUSES
MARO2P10203703E
53
Figure 51. Main Disconnect Location MAIN DISCONNECT Fuse Block
FL1 FL2 FL3
Table 51. Inp t Input Voltage 220 240 380 416 460 480 500 550 575
Fused Flange-Mounted Disconnect Switch, C-Size Cabinet
Fused Flange-Mounted Disconnect Switch Fuse Size 50A Part Number Fuse XGMF-00160 (A60L0001-0042 #JG2-50)
30A
Fuse XGMF-04148 (A60L0001-0042 #JG1-30)
20A
Fuse XGMF-04148 (A60L0001-0042 #JG1-20)
5. REPLACING FUSES
54
MARO2P10203703E
5.2
MULTI-TAP TRANSFORMER FUSES
Five fuses reside on the multi-tap transformer with fuses F1, F2, and F3 for the three-phase 200 VAC servo power and F4 and F5 for 100 VAC. The fuses are described in Table 52 and are located in Figure 52.
Table 52. Multi-Tap Transformer Fuses Robot P-200 P-200 Rated Current 30A 7.5A Part Number A60L00010042#JG130 A60L00010101#P475H
Fuse Number F1, F2, F3 F4, F5
Figure 52. Replacing Transformer Fuses
Fuse
Fuse
WARNING Before you replace a fuse, turn the power off and lock out the controller. Otherwise, you could injure personnel or damage equipment.
5. REPLACING FUSES
MARO2P10203703E
55
5.3
POWER SUPPLY UNIT FUSES
Refer to Figure 53 for fuse locations on the PSU and Table 53 for fuse ratings.
Table 53. Fuse No. F1 (AC Input) F3 (+24V) F4 (+24E) PSU Fuse Ratings Rated current Part number
7.5A 5A 5A
A60L00010245#GP75 A60L00010075#5.0 A60L00010046#5.0
Figure 53. Replacing a Fuse of the Power Supply Unit
F1 : 7.5A fuse for AC input
F3 : 5AS (slow-blow) fuse for +24V
F4 : 5A fuse for +24E
5. REPLACING FUSES
56
MARO2P10203703E
5.4
SERVO AMPLIFIER FUSES
The servo amplifiers for the P-200 contain one fuse (F1), except for Model A06B6089H106 which includes a second fuse (F2). The fuse(s) are located behind the servo front cover as located in Figure 54 and are described in Table 54.
Table 54. Servo Fuse Ratings Rating 5A 250V 5A 250V Part Number A60L00010359 A60L00010359 Fuse Number F1 F2
Figure 54. Replacing Fuses of Servo Amplifier F1 F2 (In servo A06B6089H106 only)
Circuit breaker
5. REPLACING FUSES
MARO2P10203703E
57
5.5
EMERGENCY STOP CONTROL PCB FUSES
Fuse Number F1 F2 Rated Current 5A 0 32 0.32
Two fuses reside on the Emergency Stop Control printed circuit board. The location of these fuses are shown in Figure 55 and the specifications are listed in Table 55.
Table 55. Emergency Stop Control Printed Circuit Board Fuses Part Number XGMF-00762 A60L00010046#0 32 A60L00010046#0.32 Purpose Fuse for brake power supply. Fuse for +24E +24E.
Figure 55. Replacing Emergency Stop Control Board Fuses
Fuse2
F2
Fuse1
F1
5. REPLACING FUSES
58
MARO2P10203703E
5.6
PURGE POWER SUPPLY FUSES
The two fuses that reside on the Purge Power Supply are described in Table 56 and are shown in Figure 56.
Table 56. Emergency Stop Control PCB Fuses Rated Current 3.2A 3.2A Part Number A60L00010175#3.2 A60L00010175#3.2
Fuse Number F11 F12
Figure 56. Purge Power Supply Location Purge Power Supply
F11 F12
5. REPLACING FUSES
MARO2P10203703E
59
5.7
MODULAR I/O (MODEL A) FUSES
The modular I/O (Model A) modules that contain fuses are described in Table 57 and are shown in Figure 57, Figure 58, and Figure 59.
Table 57. Module Number AIF01A AIF01A AOD08C AOD08D AOA05E AOA08E AOA12F Emergency Stop Control PCB Fuses Rated Current 5.0A 3.2A 5A 5A 3.15A 3.15A 3.15A Part Number A60L00010290#LM50 A60L00010290#LM32 A60L00010260#5R00 A60L00010260#5R00 A60L00010276#3.15 A60L00010276#3.15 A60L00010276#3.15
Figure 57. Interface Module AIF01A Fuse Location
Interface module AIFO1A
5.0A Fuse
3.2A
Fuse
5.0A F2
3.2A
5. REPLACING FUSES
510
MARO2P10203703E
Figure 58. Modular I/O Fuse Locations AOA05E, ADA08E, and AOA12F
AOA05E
ADA08E
FUSES FUSES
AOA12F
FUSES
5. REPLACING FUSES
MARO2P10203703E
511
Figure 59. Modular I/O Fuse Locations AOS08C and AOD08D AOD08C AOD08D
FUSES
FUSES
5. REPLACING FUSES
512
MARO2P10203703E
5.8
SUB CPU PRINTED CIRCUIT BOARD FUSE
One fuse resides on the Sub-CPU printed circuit board. The location of this fuse is shown in Figure 510 and the specifications are listed in Table 58.
Figure 510. Main CPU Printed Circuit Board

RISC-B FANUC A16B-3200-015 STATUS ALARM
D16
BAT1
VD1
Table 58. Fuse Number F21
Emergency Stop Control PCB Fuses Rated Current 5.0A Part Number XGMF-00762
PC13
PC3
PC5
JNA
EPROM MODULE
LV ALM F21 5A
5.0 A
FUSE
PR1
6 BRAKE RELEASE
Page13
MARO2P10203703E
BRAKE RELEASE
61

Brake Release
Page
When you troubleshoot and perform some error recovery procedures on the P-200 robot you might need to release the brakes. Refer to Procedure 61 for the brake release procedure.
You can release the axes brakes using the operator panel switch. . . . . . . . . . . . 62
6. BRAKE RELEASE
62
MARO2P10203703E
6.1
BRAKE RELEASE
Use Procedure 61 to release the brakes using the operator key.
Brake Release Using the Operator Panel Switch H Insure that the following conditions exist: D Controller main power disconnect is ON. D Purge complete. D Controller power on H Insure that area around robot is clear and that all personnel are clear of the area.
Step
1 Press the EMERGENCY STOP push button on the operator panel. WARNING Releasing the brakes could cause the robot to move. Provide support for the arm of the robot before releasing the brakes; otherwise, you could injure personnel or damage equipment. 2 Insert the key into BRAKE ENABLE key switch on the operator panel and turn to the ON position. See Figure 61. 3 If you have the optional brake release switches for individual axes continue to step 4.
Figure 61. Operator Panel
BATTERY ALARM
FAULT
FAULT RESET
CYCLE START
ON
PURGE COMPLETE
PURGE ENABLE
BRAKE ENABLE ON PORT OFF

REMOTE REMOTE PURGE FAULT
LOCAL
HOUR METER
EMERGENCY STOP
6. BRAKE RELEASE
MARO2P10203703E
63 4 Activate the enable switch for axis: D SW1 P-200 axes 1, 4, 5 and 7 D SW2 - P-200 axes 2 * D SW3 P-200 axes 3 * D SW4 Opener all axes * NOTE * P-200 axes 2, 3 and opener axes 2 and 3 will drop due to gravity. They do not have balancers. NOTE * Enable switches must be held, they are momentary switches.
Figure 62. C Size R-J2 Controller With Optional Brake Release Switches
SYSTEM RJ2
P-200 AXES 1,4,5,7
P-200 AXIS 2
P-200BRAKE SELECT SWITCHES
P-200 AXES 1,4,5,7
P-200 AXIS 2
P-200 BRAKE SELECT SWITCHES
7 CONTROLLING I/O
Page2
MARO2P10203703E
CONTROLLING I/O
71

Forcing Outputs Simulating Inputs and Outputs SOP I/O Status
Page
Forcing outputs is turning output signals on or off. . . . . . . . . . . . . . . . . . . . . . . . . . 72 Simulating inputs and outputs is forcing inputs and outputs without signals entering or leaving the controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 The I/O SOP screen indicates the status of the standard operator panel signals. 75
Controlling I/O allows you to test the I/O in your system for proper function.
7.
CONTROLLING I/O
MARO2P10203703E
72
7.1
FORCING OUTPUTS
Forcing outputs is turning output signals on or off. Outputs can also be forced within a program using I/O instructions. Use Procedure 71 to force outputs outside of a program. NOTE RO[1] and RO[2] control HAND 1, and RO[3] and RO[4] control HAND 2.
Procedure 71 Condition Step
Forcing Outputs H The outputs you are forcing have been configured. 1 Press MENUS. 2 Select I/O. 3 Press F1, [TYPE]. 4 Select the type of output you want to force: digital, analog, group, robot, UOP, or SOP.
WARNING Forcing digital outputs causes connected devices to function. Make certain you know what the digital output is connected to and how it will function before forcing it; otherwise, you could injure personnel or damage equipment.
7. CONTROLLING I/O
MARO2P10203703E
73 For digital outputs for example, you will see a screen similar to the following.
I/O Digital Out # SIM STATUS DO[ 1] U OFF DO[ 2] U ON DO[ 3] U OFF DO[ 4] U OFF DO[ 5] U OFF DO[ 6] U ON DO[ 7] U OFF DO[ 8] U OFF DO[ 9] U OFF DO[ 10] U OFF [ TYPE ] CONFIG
E 1
[ [ [ [ [ [ [ [ [ [
WORLD
10% ] ] ] ] ] ] ] ] ] ]
IN/OUT
SIMULATE UNSIM
DO[
4] U
OFF
5 Move the cursor to the STATUS of the output you want to force.
6 Press the function key that corresponds to the value you want. For digital, robot, UOP, and SOP outputs, press : D F4 for ON D F5 for OFF
AO[
4] U
12H
For analog and group outputs, move the cursor to value, and use the numeric keys to type the value. Value entry is always in decimal format. To change the displayed value from decimal to hexadecimal, press F4, FORMAT. Hexadecimal numbers are followed by an H on the screen.
7.
CONTROLLING I/O
MARO2P10203703E
74
7.2
SIMULATING INPUTS AND OUTPUTS
Simulating inputs and outputs is forcing inputs and outputs without signals entering or leaving the controller. Simulate I/O to test program logic and motion when I/O devices and signals are not set up. You can simulate digital, analog, and group I/O only; you cannot simulate robot, UOP, or SOP I/O. When you are finished simulating a signal, you can reset, or unsimulate it. Use Procedure 72 to simulate and unsimulate I/O. Simulating and Unsimulating Inputs and Outputs H The input or output has been configured. 1 Press MENUS. 2 Select I/O. 3 Press F1, [TYPE]. 4 Select the type of input or output you want to simulate: digital, analog, or group. For digital inputs for example, you will see a screen similar to the following.
I/O Digital Input # SIM STATUS DI[ 1] U OFF DI[ 2] S ON DI[ 3] U OFF DI[ 4] U OFF DI[ 5] U OFF DI[ 6] U ON DI[ 7] U OFF DI[ 8] S OFF DI[ 9] U OFF DI[ 10] U OFF [ TYPE ] CONFIG
E 1
[ [ [ [ [ [ [ [ [ [ IN/OUT
WORLD
10% ] ] ] ] ] ] ] ] ] ]
SIMULATE UNSIM
5 If you simulate a signal, you can force the status by setting it to a value. When the signal is unsimulated, its actual status is displayed.
DO[ 4] OFF
6 Move the cursor to the SIM column of the signal you want to simulate. D U means the signal is not simulated or unsimulated. D S means the signal is simulated. 7 Simulate or unsimulate the signal. D To simulate, press F4, SIMULATE. D To unsimulate, press F5, UNSIM. 8 To unsimulate all simulated signals, press FCTN and then select UNSIM ALL I/O.
7. CONTROLLING I/O
MARO2P10203703E
75
7.3
SOP I/O STATUS
The I/O SOP screen indicates the status of the standard operator panel signals. SOP input signals (SI) and SOP output signals (SO) correspond to internal controller software Panel Digital Input signals (PDI) and Panel Digital Output signals (PDO). Refer to Table 71 and Table 72.
Table 71. Standard Operator Panel Input Signals Description Input signal is normally turned ON, indicating that the EMERGENCY STOP button is not being pressed. Input signal is normally turned OFF, indicating that the FAULT RESET button is not being pressed. Input signal is normally turned OFF, indicating that the controller is not set to remote. Input signal is normally turned ON, indicating that the HOLD push button is not being pressed. Input signal is normally turned OFF, indicating that the PURGE ENABLE push button is not being pressed. Input signal is normally turned OFF, indicating that the CYCLE START push button is not being pressed. Open for additional PDI.
SI 0 1 2 3 4 6 7-15
PDI 1 2 3 4 5 7 8-16
Function EMERGENCY STOP FAULT RESET REMOTE HOLD PURGE ENABLE CYCLE START NOT USED
Table 72. SO 0 1 2 3 4 5 6 7 8-15 PDO 1 2 3 4 5 6 7 8 9-16 Function REMOTE LED CYCLE START HOLD FAULT LED BATTERY ALARM PURGE COMPLETE PURGE FAULT TEACH PENDANT ENABLED NOT USED
Standard Operator Panel Output Signals Description
Output signal indicates the controller is set to remote. Output signal indicates the CYCLE START button has been pressed or a program is running. Output signal indicates the HOLD button has been pressed or a hold condition exists. Output signal indicates a fault has occurred. Output signal indicates the voltage in the battery is low. Output signal indicates the purge cycle is complete. Output signal indicates a purge fault condition exists. Output signal indicates the teach pendant is enabled. Open for additional PDO.
Use Procedure 73 to display and force SOP I/O.
7.
CONTROLLING I/O
MARO2P10203703E
76
Procedure 73 Step
Displaying and Forcing SOP I/O 1 Press MENUS. 2 Select I/O. 3 Press F1, [TYPE]. 4 Select SOP. You will see a screen similar to the following.
I/O SOP Out # SO[ SO[ SO[ SO[ SO[ SO[ SO[ SO[ SO[ SO[ STATUS 1] OFF OFF 2] OFF 3] OFF 4] OFF 5] OFF 6] OFF 7] OFF 8] OFF 9] OFF 10] OFF [ [ [ [ [ [ [ [ [ [
E1
JOINT ] ] ] ] ] ] ] ] ] ]
10 %
[ TYPE ]
IN/OUT
ON
OFF
To change between the display of the input and output screens, press F3, IN/OUT. To move quickly through the information, press and hold the SHIFT key and press the down or up arrow keys. NOTE You can only view the status of input signals. Input signals cannot be forced. 5 To force an output signal, move the cursor to the output you want to change: D To turn on an output signal, press F4, ON. D To turn off an output signal, press F5, OFF.
8 MASTERING
Index
MARO2P10203703E
MASTERING
81

Resetting Alarms and Preparing for Mastering Standard Mastering for the P-200 Robot Single Axis Mastering for the P-200 Robot Standard Mastering for the P-10 Door Opener and P-15 Hood and Deck Opener
Page
Before mastering the robot or opener you must reset the alarm . . . . . . . . . . . . . 82 Method of choice for the P-200 robot. (To perform Standard Mastering, Select Fixture Position Master) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Use when mastering was lost due to a single axis going bad, and that axis is the only axis affected.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816 Method of choice for the P-10 and P-15 openers. . . . . . . . . . . . . . . . . . . . . . . . . . . 819 D When mastery was lost due to mechanical disassembly or repair. D When a quick master reference position was not previously set.
When you master a robot or an opener you electronically calibrate the serial pulse coders of the servomotor on the robot or opener against a mechanical zero position. When a robot or opener is mastered, the position data from the encoders are stored while the robot or opener is at a known mechanical position. Mastering is required to ensure that the unit axes motion is limited to the designed travel range. Robot and openers must be mastered to operate properly. Robots and openers are usually mastered before they leave FANUC Robotics. However, it is possible that they might lose their mastering data and need remastering. This chapter provides mastering methods for the P-200 robot and P-10 and P-15 openers. Before you master the robot or openers, you must clear any faults that prevent servo power from being restored or that prevent mastering completion.
CAUTION Record the quick master reference position after the robot or opener is installed to preserve the factory mastering settings for future remastering.
8. MASTERING
82
MARO2P10203703E
8.1
RESETTING ALARMS AND PREPARING FOR MASTERING
When you turn on the robot or opener after disconnecting the pulsecoder backup batteries you might see a SRVO062 BZAL or SRVO038 Pulse mismatch alarm. Before mastering the robot or opener you must reset the alarm and rotate the motor of each axis that lost battery power to prepare the robot or opener for mastering. Use Procedure 81 to reset these alarms and prepare the robot or opener for mastering. NOTE These SRVO errors will also appear after you have installed all new application software on a robot or opener.
Preparing the Robot or Opener for Mastering H You see a SRVO062 BZAL or SRVO038 Servo mismatch alarm. 1 Replace the robot and opener batteries with four new 1.5 volt alkaline batteries, size D. Observe the direction arrows in the battery box for proper orientation of the batteries. Refer to Procedure 92 . 2 Press MENUS. 3 Select SYSTEM. 4 Press F1, [TYPE]. 5 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6. a Select VARIABLE from the [TYPE] menu. b Move the cursor to $MASTER_ENB. c Press the numeric key 1 and then press ENTER on the teach pendant. d Press F1, [TYPE]. e Select Master/Cal. You will see a screen similar to the following.
SYSTEM Master/Cal 1 2 3 4 5 6 FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ENTER or number key to select. [ TYPE ] LOAD RES_PCA DONE JOINT 10%
8 MASTERING
MARO2P10203703E
83 6 Press F3, RES_PCA. You will see a screen similar to the following.
SYSTEM Master/Cal 1 2 3 4 5 6 E1 JOINT 10%
FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ENTER or number key to select.
Reset pulse coder alarm? [NO]
[ TYPE ]
YES
NO
7 Press F4, YES. 8 Cold start the controller. a Turn off the robot or the opener. b Press and continue pressing the FAULT RESET button on the operator panel. c While still pressing FAULT RESET, press the ON button on the operator panel. 9 If the SRVO062 alarm is still present, there is a battery, cable or pulse coder problem. Refer to the FANUC Robotics SYSTEM R-J2 Controller Series Electrical Connection and Maintenance Manual for further information. 10 If a SRVO038 alarm is present at this time, repeat Step 6 to reset it. It is not necessary to cold start the robot or opener after resetting to clear this alarm.
11 Rotate each axis that lost battery power by at least one motor revolution in either direction to clear SRVO075 Pulse Not Established. a Jog each rotary axis at least twenty degrees. b Jog each linear axis at least thirty millimeters.
12 Perform any of the mastering procedures from the MASTER/CAL

menu.
8. MASTERING
84
MARO2P10203703E
8.2
STANDARD MASTERING FOR THE P-200 ROBOT
Procedure 82
Standard mastering is the preferred method used to master the P-200 robot. Use Procedure 82 to perform standard mastering.
Standard Mastering
NOTE You do not need a fixture to master the P-200 robot. To perform Standard Mastering, select Fixture Position Master. Condition
H You have cleared any servo faults that prevent you from jogging the
robot.
H You have jogged each axis that has lost mastery at least one motor
turn. H You have reset all Pulse not established (SRVO-075) errors . Step
1 Jog the robot to the approximate mastering position shown in

Figure 81.
Figure 81. Zero Degree Position of the P-200 Robot
8 MASTERING
MARO2P10203703E
85 NOTE Align surfaces using a 1 - 2 - 3 block or other straight edge device. NOTE Always rotate each axis into the mastered position from the same direction to insure backlash errors are not added to the mastering data.
Figure 82. Axes 4, 5, and 6 100 Wrist Assembly
Axis 4 Bearing Surface
Axis 6 Bearing Surface Inner Knuckle
Outer Knuckle
Axis 5 Bearing Surface
8. MASTERING
86
MARO2P10203703E
2 Rotate the inner knuckle counter-clockwise. Align the edge of the notch on the inner knuckle and the pin in the bearing retainer (axis 4) See Figure 82. See Figure 83 if the wrist is 100, or Figure 84 if . the wrist is 140_
Figure 83. Axes 4, 5, and 6 100 Wrist Mastering Positions
Axis 4 Mastering Position
Axis 5 Bearing Surface Axis 5 Mastering Position
Mastering Surface
Axis 6 Mastering Position Mastering Pin
8 MASTERING
MARO2P10203703E
87
Figure 84. Axes 4, 5, and 6 140 Wrist Mastering Positions
Axis 4 Mastering Position
AXIS 5 Bearing Surface Axis 5 Mastering Position
Axis 6 Mastering Position Mastering Pin Mastering Surface
3 Rotate the outer knuckle counter-clockwise aligning the edge of the notch on the outer knuckle and the pin in the bearing retainer (axis 5) See Figure 82. See Figure 83 if the wrist is 100, or Figure 84 if . the wrist is 140_ 4 Rotate the wrist faceplate counter-clockwise aligning the edge of the notch on the faceplate and the pin in the bearing retainer (axis 6). See Figure 82. See Figure 83 if the wrist is 100, or Figure 84 if the . wrist is 140_
8. MASTERING
88
MARO2P10203703E
5 Align the witness marks on the turret and pedestal (axis 1). See Figure 85.
Figure 85. Robot Pedestal Axis 1 100/140 Mastering Surface Location
Right Hand Mastering Surface
Left Hand Mastering Surface
P-200 Robot Pedestal
Turret Witness Mark
MASTERED POSITION: AXIS 1 = 75

Mastering Surface
P-200 Robot Pedestal P-200 Robot Turret
8 MASTERING
MARO2P10203703E
89 6 Lower the inner arm aligning the witness marks on the inner arm and turret (axis 2). See Figure 86.
Figure 86. Axis 2 100/140 Mastering Surface Location
Inner Arm
Right Hand Witness Marks Left Hand Witness Marks Mastering Surface Mastering Surface
P-200 Turret
Mastering Surface
Witness Mark
P-200 Turret
Inner Arm
8. MASTERING
810
MARO2P10203703E
NOTE If you are mastering a 100_ wrist robot, go to step 7. If your robot has a 140 wrist, go to step 8. 7 Lower the outer arm aligning the notches on the inner and outer arm (axis 3). See Figure 87. Go to step 14.
Figure 87. Axis 3 100 Mastered Position
Outer Arm Inner Arm Witness Mark Witness Mark Outer Arm Inner Arm
8 MASTERING
MARO2P10203703E
811 8 Lower the outer arm aligning the mastering pin on the 140 wrist to the mastering surface located on the inner arm (axis 3). See Figure 88. NOTE If your robot is not mounted on a rail, go to to step 16.
Figure 88. Axis 3 Mastering Position (140 Wrist)
Outer Arm Mastering Pin
Inner Arm 140 Wrist Mastering Surface
Left and Right Side Mastering Pins
MASTERED POSITION: AXIS 3 ARM LENGTH 1200 MM 1400 MM 94.366 97.0
8. MASTERING
812
MARO2P10203703E
NOTE If your robot is using a P-200 Clean Wall Retrofit (P-150 Retrofit) rail, go to to step 9. If not continue to step 14. 9 Attach the mastering block to the side of the saddle. See Figure 89.
Figure 89. Mastering Block
10
Release the brakes for the rail axis.
11 Manually push the saddle until the mastering block comes in contact with the rail axis master stop. See Figure 89.
8 MASTERING
MARO2P10203703E
813 12 13 14 Engage the brakes for the rail axis and reset all faults. Go to Step 16. Jog the robot to the approximate mastering position shown in Figure 810.
Figure 810. Axis 7 Mastering Position
Rail
Witness Mark
Mastering Surface
Side View
AXIS 7
15 16 17 18 19 Align the mastering surface on the pedestal to the witness mark on the rail using a 1-2-3 block or other straight edge device. Press MENUS. Select SYSTEM. Press F1, [TYPE]. Select Master/Cal.
8. MASTERING
814
MARO2P10203703E
NOTE You do not need a fixture to master the P-200 robot. To perform Standard Mastering, select Fixture Position Master. See the following screen for an example.
SYSTEM Master/Cal G1 JOINT 10 % TORQUE =[ON]
1 2 3 4 5 6
FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE
Press Enter or number key to select.
[ TYPE ]
LOAD
RES_PCA
20
Select FIXTURE POSITION MASTER. You will see a screen similar to the following.
G1 JOINT 10 % TORQUE =[ON]
SYSTEM Master/Cal
1 2 3 4 5 6
Press Enter or number key to select. Master at master position? [NO] [ TYPE ] YES
NO
8 MASTERING
MARO2P10203703E
815 21 Press F4, YES. You will see a screen similar to the following.
G1 JOINT 10 % TORQUE = [ON]
SYSTEM Master/Cal
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0> <3943083> <14942207> <0> <0> <0> < 0> < 0> < 0> [ TYPE ] LOAD RES_PCA DONE
NOTE If there is an encoder fault that was not reset, the teach pendant will not confirm mastering and the mastering position will not be entered. 22 Select CALIBRATE. You will see a screen similar to the following.
SYSTEM Master/Cal G1 JOINT 10 % TORQUE = [ON]
1 2 3 4 5 6
Press Enter or number key to select Calibrate [NO] [ TYPE ]
YES
NO
23
Press F4, YES.

SYSTEM Master/Cal
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! CUR JNT ANG (deg): <75.000> <20.000> <-65.000> <0.000> <0.000> <0.000> <0.000> [ TYPE ]
8. MASTERING
816
MARO2P10203703E
8.3
SINGLE AXIS MASTERING FOR THE P-200 ROBOT
When a single axis of the P-200 has been positioned at its mastering location, single axis mastering can be performed. See Figure 811.
Figure 811. Mastering Position of the P-200 robot
Use Procedure 83 to master a single axis. Procedure 83 Mastering a Single Axis
Condition
H You have cleared any servo faults that prevent you from jogging the
machine.
H You have jogged each axis that has lost mastery at least one motor
turn. Step
1 Press MENUS.
2 Select SYSTEM. 3 Press F1, [TYPE]. 4 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 5.
8 MASTERING
MARO2P10203703E
817
a Select VARIABLE from the [TYPE] menu.

b Move the cursor to $MASTER_ENB. c Press the numeric key 1 and then press ENTER on the teach pendant. d Press F1, [TYPE]. e Select Master/Cal. You will see a screen similar to the following.
SYSTEM Master/Cal JOINT 10%
1 2 3 4 5 6
[ TYPE ]
LOAD
RES_PCA
DONE
5 Select 4, Single Axis Master. You will see a screen similar to the
following.
SINGLE AXIS MASTER ACTUAL POS J1 0.000 J2 3.514 J3 -7.164 J4 -357.366 J5 -1.275 J6 4.571 E1 0.000 E2 0.000 E3 0.000 [ TYPE ] (MSTR POS) ( 75.000) ( 20.000) ( -65.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000) JOINT (SEL) (0) (0) (0) (0) (0) (0) (0) (0) (0) GROUP 10% 1/9 [ST] [2] [0] [2] [2] [2] [2] [0] [0] [0] EXEC
6 Jog all unaffected axes to their respective mastering positions so that the actual position matches that of the master position column. 7 Using a 1-2-3 block, or other straight edge device, align the unmastered axis (axes) to their witness mark(s) as described in Procedure 82 .
8 Move the cursor to the SEL column for each unmastered axis (axes)
and press the numeric key 1, then press ENTER.
8. MASTERING
818
MARO2P10203703E
WARNING Do not modify the values in the column labeled (MSTR POS). Otherwise, unexpected motion could occur which could injure personnel or damage equipment.
9 Press F5, EXEC. Mastering will be performed automatically. 10 Press PREV.
11 Select Calibrate. 12 Press F4, YES.
Single axis mastering is now complete.
8 MASTERING
MARO2P10203703E
819
8.4
STANDARD MASTERING FOR THE P-10 DOOR OPENER AND THE P-15 HOOD AND DECK OPENER
Procedure 84
Use Procedure 84 to master the P-10 Door Opener and the P-15 Hood and Deck opener. NOTE You do not need a fixture to master the P-10 or P-15 openers. To perform Standard Mastering, select Fixture Position Master on the teach pendant.
Standard Mastering for the P-10 Door Opener and the P-15 Hood and Deck Opener H You have cleared any servo faults that prevent you from jogging the opener. H You have reset all Pulse not established (SRVO-075) errors. 1 Select Motion Group 2. a Press FCTN. b Select CHANGE GROUP. G2 should be displayed in the title line of the teach pendant screen. 2 Jog the opener to the approximate mastering position shown in Figure 812. NOTE Align surfaces using a 1 - 2 - 3 block or other straight edge device.
Condition
Step
8. MASTERING
820
Figure 812. P-10 and P-15 Opener Mastering Position
MARO2P10203703E
45 45 BOOTH WALL
AXIS 2
AXIS 3
AXIS 1
8 MASTERING
MARO2P10203703E
821 3 Align the mastering surfaces on the x-drive housing and the rail. See Figure 813.
Figure 813. P-10 and P-15 Axis One Mastering Position
700T 25T A View A
RAIL REF.
Mastering Surfaces Line Up Machine Edge On Rail With Cover As Shown
8. MASTERING
822
MARO2P10203703E
4 Align the mastering surfaces on the base and the inner arm. See Figure 814.
Figure 814. P-10 and P-15 Axis Two Mastering Position Inner Arm
Mastering Surfaces (Inner Arm To Base)
Inner Arm Base
Line Up These Surfaces
View B (rear view)
Base
B A
View A
Front Of Opener
8 MASTERING
MARO2P10203703E
823 5 Align the mastering surfaces on the crank and base. See Figure 815.
Figure 815. P-10 and P-15 Axis Three Mastered Position Line Up These Surfaces (Crank To Base)s Mastering Surfaces (Crank To base)
BASE
B
45 REF
View B
A
Front Of Opener
View A
6 Press MENUS. 7 Select SYSTEM. 8 Press F1, [TYPE].
8. MASTERING
824 9 Select Master/Cal.
MARO2P10203703E
NOTE You do not need a fixture to master the P-10 opener. To perform Standard Mastering, select Fixture Position Master on the teach pendant. You will see a screen similar to the following.
SYSTEM Master/Cal G2 JOINT 10 % TORQUE =[ON]
1 2 3 4 5 6
[ TYPE ]
LOAD
RES_PCA
10
Select FIXTURE POSITION MASTER. You will see a screen similar to the following.
SYSTEM Master/Cal
1 2 3 4 5 6
Press Enter or number key to select. Master at master position? [NO] [ TYPE ] YES
NO
11 Press F4, [YES]. You will see a screen similar to the following. NOTE If there is an encoder fault that was not reset, the teach pendant will not confirm mastering and the mastering position will not be entered.
8 MASTERING
MARO2P10203703E
825 12 Select CALIBRATE. You will see a screen similar to the following.
SYSTEM Master/Cal
1 2 3 4 5 6
Press Enter or number key to select. Calibrate [NO] [ TYPE ]
YES
NO
13
Press F4, YES. The robot is now calibrated and can be jogged in coordinate frames.
SYSTEM Master/Cal
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0> <3943083> <14942207> <0> <0> <0> < 0> < 0> < 0> [ TYPE ]
9 REPLACING COMPONENTS
Page2
MARO2P10203703E
REPLACING COMPONENTS
91

Replacing R-J2 Batteries Replacing R-J2 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Replacing the PSU Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Replacing the SPC Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Replace PCMCIA Memory Card (Optional) Battery . . . . . . . . . . . . . . . . . . . . . Replacing Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Operator Control Panel Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Emergency Stop Control Board (EMG) Printed Circuit Board Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Purge Control PCB Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
92 92 93 94 96 96 97 98
Replacing Relays
Replacing a Printed Circuit Board
Replacing a Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 D Removal and Replacement of a Printed Circuit Board from the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910 D Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . 912 Use this procedure to replace a module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 913
Replacing a Module on the Main CPU or Aux Axis Control PCB Replacing an I/O Module (Model A)
Replacing an I/O Module (Model A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Replacing the Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Replacing a Model A Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Replacing a Model A I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
916 916 917 917
Replacing the Multi-Tap Transformer Replacing a Servo Amplifiers Replacing the Operator Panel Replacing the Backplane Fan Motors Teach Pendant Replacing Serial Pulse Coders
Replacing the Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919 Replacing a Servo Amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 920 Replacing the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 921 Replacing the Fan Motors in the Backplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 922 Replacing the Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 924 Replacing Serial Pulse Coder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925 D Replacing Internal Mounted Serial Pulse Coder . . . . . . . . . . . . . . . . . . . . . . . 925 D Replacing Externally Mounted Serial Pulse Coder . . . . . . . . . . . . . . . . . . . . . 927
9. REPLACING COMPONENTS
92
MARO2P10203703E
9.1
REPLACING R-J2 BATTERIES
FANUC Robotics recommends that all batteries be changed immediately prior to production start up. Change the batteries annually to assure reliable robot performance for extended periods of time. Use Procedure 91 to replace the PSU battery, Procedure 92 to replace the SPC battery, and Procedure 93 to replace the PCMCIA memory card battery. Replacing the PSU Battery 1 Get the new battery. (number: A98L-0031-0012) 2 Turn off and lock out the controller. CAUTION The battery must be replaced within 30 minutes. If the power is turned off and the battery is removed for 30 minutes or more, the contents of the memory on the main CPU printed circuit board may be lost. WARNING Do not short circuit or incinerate a discarded battery. Follow your companys procedures for disposing of lithium batteries. Otherwise, you could injure personnel or damage equipment.
Procedure 91 Step
WARNING Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. 3 Remove the battery case from the front panel of the power supply unit. See Figure 91. The case can be removed easily by squeezing the top and bottom of it and pulling.
Figure 91. Replacing the Battery Front panel of the power supply unit Cable connector
BATTERY Front panel of the power supply unit

Battery (ordering drawing number: A98L-0031-0007)
Battery case
PC board connector
Battery
MARO2P10203703E
93 4 Remove the battery and connector from the PSU. 5 Replace the battery and reconnect the connector. 6 Install the battery case. Procedure 92 Step Replacing the SPC Batteries 1 Get four new alkaline D-cell batteries. 2 Turn on the controller. 3 Press the operator panel Emergency Stop button and the teach pendant Emergency Stop button. 4 Remove the black plastic battery cover from the battery box on the inside of the controller cabinet front door. See Figure 92. 5 Remove the old batteries. 6 Insert the new batteries while observing battery polarity as shown on the battery case. 7 Replace the battery cover. 8 Cold start the controller. The teach pendant might display a SRVO065 BLAL alarm. This is normal. It will reset when you cold start the controller.
94
Figure 92. Internal View of the P-200 R-J2 Controller
MARO2P10203703E
Main power disconnect
Main CPU
Power supply unit
Aux axis board
Emergency stop control printed circuit board SPC battery case
Procedure 93 Step
Replace PCMCIA Memory Card (Optional) Battery 1 Get one new BR2325 3V lithium battery. 2 Remove the PCMCIA (memory) card from the Memory Card Interface board (PN A 20B-2000-0600). 3 Insert a small diameter pointed object into the hole on the upper side of the 2 MG SRAM PC card (PN DISKMF32M1LCDA7). 4 Release the battery holder by pressing the small diameter object against the battery holder catch and pull the battery holder straight out from the card. See Figure 93 for the location of the battery. 5 Replace the old battery with the new battery. Insure that the (+) symbol on the battery is located as shown on the battery holder.
MARO2P10203703E
95
WARNING DO NOT Install the Memory Card Interface board with the power on. This will damage the Interface board.
6 With the new battery in the holder, install the battery holder into the memory card and reinstall the card into the controller. See Figure 94.
Figure 93. Replacing Memory Card Battery

3 slot back plane printed circuit board A20B-2001-0670 Total version
Fan
Fans
Main CPU Power Supply PCMCIA Memory Card Backplane Printed Circuit Board
96
MARO2P10203703E
9.2
REPLACING RELAYS
This section includes relays located on the back of the operator control panel and the EMG printed circuit boards relay replacement procedures. See Figure 95 for relay locations and Table 91 for operator control panel relay identification.
Table 91. EMG Printed Circuit Board Relay Identification Relay Identification
A58L00010192#1231R
9.2.1
Operator Control Panel Relays
Relay Designation
Relays KA1 KA4
Figure 95. Operator Control Panel Relay Locations
SW1 SW2
SW3
LED1
SW6
LED3
LED6
LED4
LED2
Replaceable Relays
SWO PDIO
SW5
SW7
CNPG
LED5
SW8
CNHM KA1 KA2 KA3 KA4
FENCE 1
PORT 2
FENCE 2
EMGIN1
EMGIN2
EXCOM
EXON
EXOFF
SW9
CNOP CRS1
TBOP1
EMGOUT1
EMGOUTC
EMGOUT2
ESTOP1
ESTOP2
SVON1
SVON2
TBOP2
SW10
MARO2P10203703E
97
9.2.2
Emergency Stop Control Board (EMG) Printed Circuit Board Relay Replacement
See Figure 96 for relay locations and refer to Table 92 for relay identification.
A58L00010422#3232K A58L00010192#1509A A58L00010192#1472R
Relay Designation
RLY1 RLY2 RLY 3 , RLY4, RLY5, and RLY6
Figure 96. EMG Printed Circuit Board Relay Locations for B-Size Cabinet
RLY4 RLY5 RLY6
RLY1
RLY2 RLY3
98
MARO2P10203703E
9.2.3
Purge Control PCB Relay
Refer to Table 93 for relay identification and see Figure 97 for relay locations on the purge control printed circuit board.
A58L00010192#1231R
Relay Designation
Relays KA5 and KA6
Figure 97. Purge Control Unit
Purge control PCB

1 2 3 4 5 6 7 8 9 1011 12 1314 1516 171819 20 21 222324
1 2 3 4 5 6 7 8 9 1011 12 13 14 15 16 1718 19 20 21 22 2324
P1 N1 P2 N2 P3 N3 P4 N4 P5 N5 P6 N6 G
G FG

ISBU
IBRC
Relays KA5 and KA6
Power supply
MARO2P10203703E
99
9.3
REPLACING A PRINTED CIRCUIT BOARD
When replacing a printed circuit board, insure that the following precautions are followed: D The controller is locked out and tagged out. D Remove the battery from the power supply unit and plug it into the battery connector (BAT. VBAT) on the front panel of the main CPU, if the power supply unit or the main CPU are to be removed from the backplane. See Figure 98.
Figure 98. Battery Transfer to Maintain CMOS RAM Memory
Power Supply Unit
Main CPU Printed Circuit Board
Aux Battery Connection (BAT. VBAT)
Battery
910
MARO2P10203703E
9.3.1
Removal and Replacement of a Printed Circuit Board from the Backplane Printed Circuit Board
Removal and replacement of a printed circuit board from the backplane printed circuit board is provided in Procedure 94 and is shown in Figure 99.
Procedure 94
Printed Circuit Board Removal and Replacement
1 Turn the power off and remove the cable(s) from the power supply unit or printed circuit board to be replaced. If the cable markings are missing or difficult to read, write them down before removing the cables.
CAUTION Be sure to back up all program and setup data on a floppy disk before you replace a printed circuit board otherwise, you could lose data.
CAUTION When either the power supply or main CPU printed circuit boards are removed from the controller, the data storage battery is disconnected. All boards must be reinstalled properly within half an hour to avoid data loss.
NOTE When removing the printed circuit board, do not touch semiconductor components on it and do not let the components touch other components.
MARO2P10203703E
911 2 Squeeze the removal tabs at the top and bottom of the front panel of the power supply unit or printed circuit board. The latches of the control unit rack are released. Holding the tabs in this state, pull out the unit or printed circuit board. See Figure 99.
Figure 99. Replacing the Components on the Backplane Printed Circuit Board
Main CPU printed circuit board Power supply unit Optional boards
Removal tab
Removal tab
NOTE If you are removing the printed circuit boards in preparation to remove the backplane go to Procedure 95 . 3 Insert a new power supply unit or printed circuit board into the slot of the control unit rack. Carefully push it into the slot until the front panel is latched at the top and bottom. 4 Check that the printed circuit board to be installed is correctly set and adjusted. 5 Connect the cables removed for replacement to the original positions.
912
MARO2P10203703E
9.3.2
Replacing the Backplane Printed Circuit Board
Procedure 95
Procedure 95 provides instructions for replacement of the backplane printed circuit boards and Figure 910 shows an example of board replacement.
Replacing Backplane Printed Circuit Board 1 When you replace the backplane printed circuit board, remove the entire rack. Remove the power supply unit printed circuit board, main CPU printed circuit board, and any optional printed circuit boards using Procedure 94 . 2 Remove the ground cable from the backplane printed circuit board. 3 Loosen the screws fastening the rack at the top. Then remove the screws fastening the rack at the bottom. See Figure 910. 4 Lift up on backplane until slots have cleared the mounting screws and carefully move it forward until the backplane is clear of the controller. 5 Install the new backplane in reverse order.
Figure 910. Replacing the Backplane Printed Circuit Board
Loosen screws
Backplane printed circuit board
Remove screws
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913
9.4
REPLACING A MODULE ON THE MAIN CPU OR AUX AXIS CONTROL PRINTED CIRCUIT BOARD
Refer to Chapter 1 for part numbers. Procedure 96
Use Procedure 96 to replace a module.
CAUTION Following electrostatic discharge procedures when handling all circuit boards.
Replacing a Module on the Main CPU or Aux Axis Control Printed Circuit Board 1 Move the latches at both ends of the module socket toward the outside. The spring of the contact tilts the module. See Figure 911.
Figure 911. Moving the Latches on the End of the Module Socket
Step
2 If the tilted module touches the next module, it might be difficult to remove it. In this case, release the latches of the next module as described in step 1 above. 3 Now the module is free in the socket. Pull out the module carefully in a straight line. Do not pull it out in an arc. The contacts of the socket or module might be damaged. 4 Install a new module in the socket at an angle. Push it into the socket until the bottom of the module reaches the bottom of the socket groove. Be sure you have the module facing in the proper direction. align the groove in the module with the tab as shown in Figure 912.
914
Figure 912. Installing a New Module at an Angle
MARO2P10203703E
Short
Long
Fit the recess on the module over the tab in the module socket.
5 Push the module in the top edge so that the module stands upright. See Figure 913.
Figure 913. Pushing in the Module
6 Check that the module is latched properly at both ends of the socket. If it is insufficiently latched, the electrical contact might be improper and a malfunction could occur.
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915
Figure 914. Mounting Locations of the Modules
CMOS module Flash ROM module DRAM module Axis module (J1, J2) Axis module (J3, J4) Axis module (J5, J6)
MAIN CPU
JNA
Servo control module (for axis 9 and 10) Servo control module (for axis 7 and 8) JRY2 Servo control module (for axis 5 and 6) Servo control module (for axis 3 and 4) Servo control module (for axis 1 and 2)
AUX AXIS CONTROL PCB
916
MARO2P10203703E
9.5
REPLACING AN I/O MODULE (MODEL A)
Use Procedure 98 and Procedure 99 to replace an Interface Module and I/O Module (Model A). Replacement of the Interface Module is provided in Procedure 98 and replacement of the I/O Module is provided in Procedure 99 and shown in Figure 916. Use Procedure 97 to replace the base unit if needed after you remove the I/O Interface Module. Replacing the Base Unit 1 Remove the I/O modules from the base unit. 2 Loosen the upper two mounting screws. 3 Remove the lower two mounting screws and replace the base unit.
Figure 915. Replacing the Base Unit of the Model A I/O
Procedure 97 Step
M4 screw
MARO2P10203703E
917
9.5.1
Replacing a Model A Interface Module
Procedure 98 Step
Use Procedure 98 to replace a Model A Interface Module.
Replacing a Model A Interface Module 1 Turn off and lock out the controller. 2 Disconnect the signal and power cables from the interface module. 3 Press the latch on the bottom of the module and rotate the module toward you and up. 4 Engage the hook at the top rear of the module with the bar above the base unit socket. 5 Rotate the module downward until the latch engages. 6 Reconnect the signal and power cables to the interface module.
9.5.2
Replacing a Model A I/O Module
Procedure 99 Step
Use Procedure 99 to replace a Model A I/O Module.
Replacing a Model A I/O Module 1 Turn off and lock out the controller. 2 Remove the wiring harness block. a Lift the latch at the lower left corner of the module window. b Rotate the block toward you and down. 3 Press the latch on the bottom of the module and rotate the module toward you and up. See Figure 916. 4 Engage the hook at the top read of the module with the bar above the base unit socket. 5 Rotate the module downward until the latch engages.
918
Figure 916. Replacing a Model A I/O Module
MARO2P10203703E
6 Install the wiring harness block. a Engage the hook at the bottom rear of the block with the bar at the bottom of the module. b Rotate the block upward until the latch engages.
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919
9.6
REPLACING THE MULTI-TAP TRANSFORMER
Refer to Chapter 1 for part numbers. Procedure 910 Step
Use Procedure 910 to replace the multi-tap transformer.
Replacing the Multi-Tap Transformer 1 Turn off and lock out the controller. 2 Remove the acrylic covers from the transformer and ALC relay. 3 Disconnect the wiring harnesses and ground wire from the transformer. 4 Disconnect the three wires from the bottom of the ALC relay. 5 After removing the eight screws fastening the transformer, remove the transformer. See Figure 917. Put a new transformer on the rail in the controller and push it into the controller along the rail. Then reinstall the screws. 6 Reconnect the wires and harnesses. 7 Reinstall the acrylic covers.
Figure 917. Replacing the Multi-Tap Transformer
M5 screws
920
MARO2P10203703E
9.7
REPLACING A SERVO AMPLIFIER
Refer to Chapter 1 for part numbers. Procedure 911
Use Procedure 911 to replace a servo amplifier. See Figure 918.
Replacing a Servo Amplifier
Step
1 Turn off and lock out the controller. 2 Remove the five bus bars from the servo amplifier bank. 3 Disconnect the wires from the servo amplifier terminal strip. Remove the two screws fastening the servo amplifier and remove the amplifier. 4 Set the terminal strip jumpers on the new servo amplifier to match those of the one you removed. 5 Install the new servo amplifier by following these steps in reverse order.
Figure 918. Replacing a Servo Amplifier
Screw
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921
9.8
REPLACING THE OPERATOR PANEL
Refer to Chapter 1 for part numbers. Procedure 912 Step
Use Procedure 912 to replace the operator panel. See Figure 919.
Replacing the Operator Panel 1 Power down and lock out the controller. 2 Remove all connectors and wires from the rear of the rear operator panel and all connectors from the front panel. Identify all wires and connectors for installation of new operator panel. 3 Remove the six nuts fastening the operator panel and remove the operator panel. 4 Install new operator panel using 6 nuts removed during removal of old operator panel. 5 Reconnect all wires and connectors removed during Step 2.
Figure 919. Replacing the Operator Panel
Nuts (Qyt 6)

ON
922
MARO2P10203703E
9.9
REPLACING THE FAN MOTOR IN THE BACKPLANE
Procedure 913 Step
Replace a defective fan motor using Procedure 913 and as shown in Figure 920.
Fan Motor Replacement 1 Identify the defective fan motor and remove any printed circuit board directly below the fan to be replaced. 2 The cable connected to the fan motor is connected to the backplane printed circuit board in the slot. Holding the connector, remove the cable from the backplane printed circuit board. 3 Open the lid at the top of the backplane rack by placing the tip of a flat-blade screwdriver into the center hole at the front of the lid and moving the screwdriver like a lever in the direction in Figure 920. this will release the latch. 4 Replace the fan motor. 5 Close the lid until it is latched. 6 Connect the cable of the fan motor to the connector on the backplane printed circuit board. Suspend the center of the cable on the hook in the back of the rack. 7 Reinstall the removed printed circuit board.
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923
Figure 920. Replacing the Fan Motor
Fan motor
Cable
Connector
924
MARO2P10203703E
9.10
REPLACING THE TEACH PENDANT
Replace a defective teach pendant using Table 94 for ordering and as shown in Figure 921.
Figure 921. Replacing the Teach Pendant
Table 94.
Teach Pendant Part Numbers Use General use Paint Remarks English
Part Number(s) A05B-2301-C305 A05B-2308-C300 Intrinsically Safe Teach Pendant R-J2
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925
9.11
REPLACING A SERIAL PULSE CODER
Procedure 914
Use Procedure 914 to replace an externally or internally mounted serial pulse coder.
Replacing Internal Mounted Serial Pulse Coder
NOTE The robot will have to be remastered after this procedure. Step 1 Turn off and lock out the robot. 2 At the end of the motor, remove both cables from the serial pulse coder cover. 3 Remove the four bolts that secure the serial pulse coder cover to the motor housing. 4 Remove the four screws holding the large serial pulse coder cable connector to the serial pulse coder cover. 5 Retract the rubber boot on the inside of the serial pulse coder cable connector. 6 Remove the snap ring on the inside of the serial pulse coder cable connector. 7 Separate the two-wire connector on the inside of the internal connector. 8 Detach the serial pulse coder cable from the serial pulse coder housing.
CAUTION In the next step, be sure to remove the correct bolts, as shown in Figure 922. Removing the wrong bolts can destroy the serial pulse coder.
9 Remove the four bolts attaching the serial pulse coder to the motor. See Figure 922. 10 Remove the serial pulse coder and the black plastic coupling and retain the black plastic coupling to be installed with the new serial pulse coder. See Figure 923.
11 Position the new serial pulse coder, with black plastic coupling, onto the motor so that the coupling engages both motor and pulse coder. If there are witness marks on the serial pulse coder case and the motor case, make sure that they line up. 12 13 Install the new serial pulse coder to the motor housing using four bolts. Attach the serial pulse coder cable to the serial pulse coder housing.
926 14 15 16 17 18 19
MARO2P10203703E
Install the snap ring on the inside of the serial pulse coder cable connector. Reposition the rubber boot on the inside of the serial pulse coder cable connector. Install the screws holding the serial pulse coder cable connector to the serial pulse coder housing. Connect the two-wire cable connectors together. Install the serial pulse coder housing to the motor, using four bolts Attach both outside cables to the serial pulse coder housing.
Figure 922. Removing the Internally Mounted serial pulse coder
CAUTION:
DO NOT REMOVE THE SCREWS FROM THESE FOUR RIBBED HOLES. THE SERIAL PULSE CODER WILL SEPARATE AND BE DESTROYED.
M4 Mounting Holes
FANUC
REAR VIEW
MARO2P10203703E
927
Figure 923. Removing the Black Plastic Coupling
Serial Pulse Coder
Black Plastic Coupling
Procedure 915
Replacing an Externally Mounted Serial Pulse Coder
NOTE The robot will have to be remastered after this procedure. Step 1 Turn off and lock out the robot. 2 At the end of the motor, remove the two screws securing the serial pulse coder connector cover. 3 Remove the two screws securing the cable connector to the serial pulse coder receptacle.
CAUTION In the next step, be sure to remove the correct bolts, as shown in Figure 922. Removing the wrong bolts can destroy the serial pulse coder. 4 Remove the four screws holding the serial pulse coder to the motor housing and carefully remove the serial pulse coder. See Figure 922. Remove the coupling from the motor and serial pulse coder. See Figure 923.
928
MARO2P10203703E
5 Position the new serial pulse coder, with coupling, onto the motor so that the coupling engages both the shaft of the serial pulse coder and the motor. See If there are witness marks on the serial pulse coder case and the motor case, make sure that they line up. 6 Install four new screws and secure the serial pulse coder housing to the motor. 7 Attach the serial pulse coder connector to the serial pulse coder housing using two screws. 8 Attach the connector cover to the serial pulse coder housing using two screws.
10 BOARD ADJUSTMENTS AND CALIBRATIONS
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10
BOARD ADJUSTMENTS AND CALIBRATIONS

101

I/P transducer/Regulator Performance Check Manual Flow Test (Beakering Test) Cold Start Powering on the Robot Systems Controller Shutdown Procedure Servo Lockout Procedure
Page
On a periodic basis, and whenever a transducer/regulator is replaced, this procedure should be preformed (Procedure 101 ). . . . . . . . . . . . . . . . . . . . . . . . . 102 Measure paint Flow rate in cc/min (Procedure 102 ). . . . . . . . . . . . . . . . . . . . . . . 105 Standard Method For Turning On Power To The Robot And Controller. (Procedure 103 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 The following procedures are applicable to all P-200 robot systems including those on a pedestal, rail or with an opener. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010 Use this procedure for complete controller shutdown including purge circuitry. . 1011 For servo lockout use the following procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1011
No board adjustments are required on the controller. However, Emergency Stop Control Board jumper settings are included for reference. See Figure 101. These jumpers are set at installation and are not to be changed. To set servo amplifier dip switches, refer to Chapter 1.
10. BOARD ADJUSTMENTS AND CALIBRATIONS

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10.1
I/P TRANSDUCER/ REGULATOR PERFORMANCE CHECK
On a periodic basis, and whenever a transducer/regulator is replaced, this procedure should be preformed to check out the Paint Regulator (PR) and the Proportion Air transducer/regulator assembly in the P-200 outer arm. Tools Required: D 060 psi precision pressure gauge with 0.5 psi accuracy D Appropriate hand tools D Tubing and fittings as required
Transducer/Regulator Performance Check H The robot/controller has been reset, and the system is in the MANUAL or PRODUCTION mode. 1 Remove the air supply to the panel. 2 Remove output line from the regulator. NOTE If a gauge port is available, connect the gauge here. 3 Connect a precision 0-60 psi pressure gauge at the output port on the PR I/P regulator section. This will register a pneumatic output signal while testing the transducer/regulator. NOTE When testing the I/P transducer for acceptable performance, connect at least a volume of approximately one cubic foot to the output of the regulator. Ensure that the inlet pressure is at least 5% higher than the desired output pressure but no more than +10% of the I/P transducer system range being used (maximum of 300 psi). 4 Turn on the air supply to the panel. 5 Ensure all connections are bubble tight. NOTE The signal to the transducer/regulator can be varied by selecting the desired transducer count at the analog output (AOUT[1]) menu screen on the teach pendant. 6 Full scale response check: at the teach pendant select I/O, then Press F1 [TYPE]. 7 Select AO (Analog Out) menu. 8 Enter a value of 1000 transducer counts, and press [ENTER] The gauge should climb swiftly and smoothly to a maximum value (it is not important what this value is). 9 Set the AO equal to 200. The gauge will fall steadily (usually slower than climbing) back to zero. Any observable irregular response indicates a problem.

MARO2P10203703E
103 10 Supply 4 mA to the transducer.
11 Starting at 0% (4mA) electrical signal, supply electrical signals in the following incremental and decremental order and observe the corresponding pneumatic output signals: (Refer to Table 101)
Incremental (mA) 4, 8, 12, 16, 20. Decremental (mA) 20, 16, 12, 8, 4.
12 Verify that the pressure output falls within the tolerance range as listed in Table 101 (including the hysteresis between the up and down setpoints). If a unit is found to be defective - Replace the unit. WARNING This I/P transducer/regulator is intrinsically safe and any repair is prohibited. Replacement must be done by ProportionAir. If you attempt any repair yourself, you will violate the warranty and could injure personnel or damage equipment.
Table 101. I/P Transducer/Regulator Performance Check Current (mA) Output from Fanuc Analog Output Module/Current (mA) Input to PR Transducer (mA) 4 8 12 16 20 Percent of Maximum Output from PR Transducer (%) Output from PR Transducer (1%) of Full Output
13
Input counts to Fanuc Analog Output Module
200 400 600 800 1000
0 25 50 75 100
0 12.5 25 37.5 50

MARO2P10203703E
104
Figure 101. Emergency Stop Control Board Jumpers
Common Jumper A= 0VDC common B=24VDC common Hand Broken Jumper A= Using Switch B=ByPassing Switch
Removejumperwhenusing Aux.*BRK ON3asseparate control
Aux. brake control input plug CRM16P1=*BRKON3 CRM16P2=*BRKON4
Doorinterlockjumper/connector
SBK11 Adds Surge Sup pression Across Brake Out puts BKP&M1. SBK12 Adds A Diode Across The Brake Coil At BKP&M1. SBK21 Adds Surge Sup pression Across Brake Out puts BKP&M4. SBK22 Adds A Diode Across The Brake Coil At BKP&M4.

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105
10.2
MANUAL FLOW TEST (BEAKERING TEST)
Use Procedure 102 to perform a beaker test.
Procedure 102 Manual Flow Test (Beakering Test) Condition H All personnel and unnecessary equipment are out of the workcell. H The applicator is functioning properly. H The controller is in manual mode. This is performed either by the cell controller or by turning on the manual enable input. H Turn off the servo disconnect. H Place a graduated beaker under gun assembly. Step 1 Press MAN FCTNS. 2 Press F1, [TYPE]. 3 Select Gun Control. You will see a screen similar to the following.
Manual/Appl./Con/ JOINT 10 %
** Entries Affect Outputs Immediately ** Pulse time (sec.): 0.0 Gun OFF Paint Fluid 0.0 Gun Select 1 Atomizing Ai 30.0 Color 1 Fan Air 0.0
Electrostatic 0.0 Press a function key [ TYPE ] ON PULSE [ TYPE ]
ALLOFF
[GROUP] HELP
> >
CAUTION The following steps will actually turn on and off the outputs. Be sure your workcell is set up properly.

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106
4 Move the cursor to each item you want to set, and set the item appropriately. D Set pulse time. D Set gun select D Set color number D Set paint fluid (Flow rate in cc/min) D Set Atomizing Ai, Fam Air and Electrostatic to 0. 5 To pulse the selected output, select the item to be pulsed and press F3, PULSE. The output will pulse on then off automatically. The system will dispense selected color for 30 seconds then turn off. 6 Measure paint in graduated beaker for proper results. 7 To turn off or set all outputs to 0, press NEXT, >, then press F4, ALLOFF. NOTE Any outputs turned on will remain until they are turned off or until all outputs are set to off.

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10.3
COLD START (START COLD)
A cold start (START COLD) is the standard method for turning on power to the robot and controller. A cold start does the following: D Initializes changes to system variables D Initializes changes to I/O setup D Displays the UTILITIES Hints screen A cold start will be complete in approximately 30 seconds. Use Procedure 103 to perform a cold start.
Performing a Cold Start H All personnel and unnecessary equipment are out of the workcell. WARNING DO NOT turn on the robot if you discover any problems or potential hazards. Report them immediately. Turning on a robot that does not pass inspection could result in serious injury.
Step
ON
1 Visually inspect the robot, controller, workcell, and the surrounding area. During the inspection make sure all safeguards are in place and the work envelope is clear of personnel. 2 Turn the power disconnect circuit breaker on the operator box or operator panel to ON. 3 On the teach pendant, press and hold the PREV and NEXT keys. See Figure 102. 4 While still pressing PREV and NEXT on the teach pendant, press the ON button on the operator panel. See Figure 102.
OFF POWER DISCONNECT C-SIZE CONTROLLER

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108
Figure 102. Teach Pendant and Operator Panel
BATTERY ALARM
ON BUTTON
FAULT HOLD STEP BUSY RUNNING MAN ENBL PROD MODE
FAULT RESET

FAULT
CYCLE START
ON
JOINT XYZ TOOL OFF ON
NEXT KEY
PORT
PURGE ENABLE

PURGE FAULT
PURGE COMPLETE
PREVIOUS KEY
REMOTE
REMOTE LOCAL
BRAKE ENABLE ON HOUR METER OFF
(FAULT) RESET KEY

EMERGCY STOP
BMON>
5 After the BMON> prompt appears on the teach pendant screen, release the PREV and NEXT keys.

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109 6 Turn on the controller. You will see a screen similar to the following.
*** BOOT MONITOR for R-J2 CONTROLLER *** Version 4.22P(OIE) 01-JAN-199x F-ROM/D-RAM/C-MOS : TP Version : Current TIME : Slot 0 1 D E BMON> COLD ID 9B AF 6A 8A CTRL FC 1 1 0 0 OP 0 0 0 0 INIT 8.0/8.0/2 MB I 01-JAN-199x 22:52:53
R-J2 Main CPU R4600 Sub-CPU V4.20 MCARD I/F AB/Ether I/F NOLOAD START >
optional optional optional
BMON> COLD BMON> START
7 Press F1, COLD, and press ENTER. 8 Press F5, START, and press ENTER. D On the operator panel or operator box, the ON button will be illuminated, indicating robot power is on. D On the teach pendant screen, you will see a screen similar to the following.
UTILITIES Hints PaintTool (TM) V4.30-x
JOINT 10 %
Copyright 1997, FANUC Robotics North America, Inc. All Rights Reserved [TYPE ] HELP

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1010
10.4
POWER ON SEQUENCE
The following procedures are applicable to all P-200 robot systems including those on a pedestal, rail or with an opener. In the case of a P-200 robot and opener, both units must be properly purged before the controller can be turned on.
Procedure 104 Step
Powering on the Robot Systems 1 With the main disconnect ON, you should observe: D Purge complete LED is off. D Purge enable pushbutton (purging) lamp is off. D ON pushbutton lamp is off. D Purge fault LED is on 2 Push and hold the PURGE ENABLE pushbutton. You should observe D Purge solenoid engages when minimum pressure requirements are met. D Purge fault LED turn off. D Purging lamp (behind purge enable pushbutton) lights. At this point you can release the purge enable pushbutton, no change should occur. 3 At the end of the 5 minute purge, the pushbutton purging lamp will turn off and the purge complete LED will turn on. Also, the purge solenoid will shut off. 4 If this procedure does not work, go to Chapter 4 Troubleshooting.

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10.5
CONTROLLER SHUTDOWN
Use this procedure for complete controller shutdown including purge circuitry.
Procedure 105 Step
Controller Shutdown Procedure 1 Push the E-stop push button. 2 Push the controller OFF pushbutton. 3 Pull the Main Disconnect switch.
10.6
SERVO LOCKOUT
For servo lockout use the following procedure:
Procedure 106 Step
Servo Lockout Procedure 1 Push the E-stop push button. 2 Open the servo lockout disconnect switch. 3 Lockout switch
11 CONNECTIONS
Page2
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11
CONNECTIONS
111
This section includes the connections and specifications for modular I/O units. It also contains diagrams for the cables connecting the R-J2 to the P-200 robot and noise reduction guidelines.

Noise Reduction Guidelines Modular I/O Outputs
Page
Excessive noise might cause errors in the controller. . . . . . . . . . . . . . . . . . . . . . . . 111 Connections and specifications for modular I/O outputs. . . . . . . . . . . . . . . . . . . . . D Output Module AOD32A, Non-isolated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Output Modules AOD08C and AOD08D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Output Modules AOD16C and AOD16D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Output Module AOD32C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Output Module AOD32D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Output Modules AOA05E and AOA08E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Output Module AOA12F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Output Modules AOR08G and AOR16G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Output Module ADA02A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 112 113 114 115 116 117 118 119 1110
Ethernet Remote Printed Circuit Board Diagnostics Modular I/O Inputs
Two general styles of the Ethernet Remote printed circuit board are available. . 1111 This section describes the connections and specifications for modular I/O units. 1112 D Input Module AID32B, Non-isolated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112 D Input Modules AID16C and AID16D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1113 This section describes the connections and specifications for analog input module AAD04A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1114 D Analog Input Module AAD04A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1114
Analog Input Module
11.1
NOISE REDUCTION GUIDELINES
Excessive noise might cause errors in the controller. Wiring guidelines for eliminating these conditions include routing I/O wiring well away from any conductors connected to the pulse coder and other internal control wiring. I/O wiring must not occupy the same wireways as the internal control wiring. Where possible avoid parallel runs of I/O and internal control wiring. Cross internal control wiring with I/O wiring at right angles. A minimum separation of 100 mm is recommended. Provide all I/O wiring with a separate power supply. Do not use controller internal voltages such as +5VDC or 24VDC for I/O. Insure that common conductors for power supplies are not shared. Use separate commons for each power supply used for I/O. Insure that all coils for electromechanical devices such as relays, contactors, pneumatic solenoids, etc. are equipped with suppression devices. For DC circuits, diode suppressors are recommended and for AC circuits the suppressors should be a combination of a MOV with a resistor/capacitor network.
11. CONNECTIONS
112
MARO2P10203703E
11.2
MODULAR I/O OUTPUTS
Item Points/module Points/common Sink/source current Rated load voltage Maximum load current Maximum voltage drop when ON Maximum leak current when OFF Response Time OFF 'ON ON 'OFF 32 points
This section describes the connections and specifications for modular I/O outputs.
Table 111. Output Module AOD32A, Non-isolated AOD32A
8 points/common Sink current type 5 ~ 24VDC +20% 15% 0.3A (however 2A/common) 0.24V (load current 0.8W) 0.1 mA Max. 1 ms Max. 1 ms Not provided Connector (HONDA TSUSIN MR-50RMA)
Output display External connection Terminal connection and circuitry
O : output circuit +5~+24

Internal Circuit
L : load
L L L L L L L L
CM
+24A A0 A1 A2 A3 A4 A5 A6 A7 CMA
17 16 32 48 15 31 47 30 46 49,50
O O O O O O O O
L L L L L L L L
+24C C0 C1 C2 C3 C4 C5 D6 D7 CMC
08 07 24 39 06 23 38 22 37 40,41
O O O O O O O O
L L L L L L L L
+24B B0 B1 B2 B3 B4 B5 B6 B7 CMB
13 12 28 44 11 27 43 10 42 29,45
O O O O O O O O
L L L L L L L L
+24D D0 D1 D2 D3 D4 D5 D6 D7 CMD
04 03 20 35 02 19 34 01 33 21,36
O O O O O O O O
11. CONNECTIONS
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113
Table 112. Output Modules AOD08C and AOD08D AOD08D 8 points 8 points/common Source current type 12 ~ 24VDC +20% 15% 2A (however 4A/fuse) Refer to load derating curve 1.2V (load current 0.6W) 0.1mA This is the value from input to output in the module. The actual value is determined by adding it to the scanning time depending on each system. This is the value from input to output in the module. The actual value is determined by adding it to the scanning time depending on each system.
Item Points/module Points/common Sink/source current Rated load voltage Maximum load current Limit of load Maximum voltage drop when ON Maximum leak current when OFF Response Time OFF 'ON ON 'OFF Output display External connection Fuse 8 points 8 points/common Sink current type
AOD08C
12 ~ 24VDC +20% 15% 2A (however 4A/fuse) 0.8V (load current 0.4W) 0.1mA
Max. 2 ms Max. 2 ms LED display
Terminal block connector (20 terminal, M3.5 screw terminal) 5A, 1 piece for each output A0-A3 and A4-A7
Fuses
1 2 load L L L L L L L L A0 5 A1 7 A2 9 A3 11 A4 13 A5 15 A6 17 A7 19 20 18 O 16 O 14 O 12 O 8 10 O O 6 O 3 4 O
Terminal block connector (20 terminal, M3.5 screw terminal) 5A, 1 piece for each output A0-A3 and A4-A7
1 2
Terminal connection and circuitry
Fuses
load
L L L A0
3 4 5 A1 7 A2 9 A3 11 A4 13 A5 15 A6 17 A7 19 20 8 10 12 14 16 18 O O O O O O 6 O O
L L L L L
Fuses
O : output circuit 2
Internal Circuit
O : output circuit
2
LED
Internal Circuit
LED
20
20
11. CONNECTIONS
114
Table 113. Item Points/module Points/common Sink/source current Rated load voltage Maximum load current Maximum voltage drop when ON Maximum leak current when OFF Response Time OFF 'ON ON 'OFF Output display External connection Terminal connection and circuitry 16 points 8 points/common Sink current type 12 ~ 24VDC +20% 15% 0.5A (however 2A/common) 0.7V (load current 1.4W) 0.1mA This is the value from input to output in the module. The actual value is determined by adding it to the scanning time depending on each system. Output Modules AOD16C and AOD16D AOD16D 16 points 8 points/common Source current type 12 ~ 24VDC +20% 15% 0.5A (however 2A/common) 0.7V (load current 1.4W) 0.1mA
MARO2P10203703E
AOD16C
This is the value from input to output in the module. The actual value is determined by adding it to the scanning time depending on each system.
Terminal block connector (20 terminal, M3.5 screw terminal)

L : load 1 L L L A0 A1 A2 A3 A4 A5 A6 A7 7 8 9 10 11 L 3 4 5 6 2 O O O O O O O O
Terminal block connector (20 terminal, M3.5 screw terminal)

L : load 1 L L L L L L L L A0 A1 A2 A3 A4 A5 A6 A7 7 8 9 10 11 3 4 5 6 2 O O O O O O O O
L
L
L
L
L
L +
B0 B1 B2 B3 B4 B5 B6 B7
12 13 14 15 16 17 18 19 20
O O O O O O O O +
L L L L L L L L
B0 B1 B2 B3 B4 B5 B6 B7
12 13 14 15 16 17 18 19 20
O O O O O O O O
L
L
L L L
O : output circuit 1
Internal Circuit
O : output circuit 1 LED

Internal Circuit
LED
10
10
11. CONNECTIONS
MARO2P10203703E
115
Table 114. Output Module AOD32C AOD32C 32 points 8 points/common Sink current type 12 ~ 24VDC +20% 15% 0.3A (however 2A/common) 0.24V (load current 0.8W) 0.1mA Max. 2 ms Max. 2 ms Not provided Connector (HONDA TSUSIN MR-50RMA)
O : output circuit +24
Item Points/module Points/common Sink/source current Rated load voltage Maximum load current Maximum voltage drop when ON Maximum leak current when OFF Response Time Output display External connection Terminal connection and circuitry OFF 'ON ON 'OFF
This is the value from input to output in the module. The actual value is determined by adding it to the scanning time depending on each system system.
Internal Circuit
: load +24A L L L L L L L L A0 A1 A2 A3 A4 A5 A6 A7 CMA 17 16 32 48 15 31 47 30 46 49,50
CM +24C C0 C1 C2 C3 C4 C5 C6 C7 CMC 08 07 24 39 06 23 38 22 37 40,41
O O O O O O O O
L L L L L L L L
O O O O O O O O
L L L L L L L L
+24B B0 B1 B2 B3 B4 B5 B6 B7 CMB
13 12 28 44 11 27 43 10 42 29,45
O O O O O O O O
L L L L L L L L
+24D D0 D1 D2 D3 D4 D5 D6 D7 CMD
04 03 20 35 02 19 34 01 33 21,36
O O O O O O O O
Note: For the common (CMA, CMB CMC, CMD) make sure to use both.
11. CONNECTIONS
116
Table 115. Item Points/module Points/common Sink/source current Rated load voltage Maximum load current Maximum voltage drop when ON Maximum leak current when OFF Response Time OFF 'ON ON 'OFF Output display External connection Terminal connection and circuitry 32 points 8 points/common Source current type 12 ~ 24VDC +20% 15% 0.3A (however 2A/common) 0.24V (load current 0.8W) 0.1mA Max. 2 ms Max. 2 ms Not provided Connector (HONDA TSUSIN MR-50RMA)
O : output circuit CM
Internal Circuit
MARO2P10203703E
Output Module AOD32D AOD32D
: load CMA L L L L L L L L A0 A1 A2 A3 A4 A5 A6 A7 0A 49,50 16 32 48 15 31 47 30 46 1B
0 CMC C0 C1 C2 C3 C4 C5 C6 C7 0C 40,41 07 24 39 06 23 38 22 37 09
O O O O O O O O
L L L L L L L L
O O O O O O O O
L L L L L L L L
CMB B0 B1 B2 B3 B4 B5 B6 B7 0B
29,45 12 28 44 11 27 43 10 42 14
O O O O O O O O
L L L L L L L L
CMD D0 D1 D2 D3 D4 D5 D6 D7 0D
21,36 03 20 35 02 19 34 01 33 05
O O O O O O O O
Note: For the common (CMA, CMB CMC, CMD) make sure to use both.
11. CONNECTIONS
MARO2P10203703E
117
Table 116. Output Modules AOA05E and AOA08E AOA08E 8 points 4 points/common 100 ~ 230VAC 15%, 47 ~ 63Hz 1A (however 2A/common) 10A (1 period) 1.5Vrms 3.0mA (115VAC), 6.0mA (230VAC) Max. 1 ms Half of the load frequency or less LED display Terminal block connector (20 terminals, M3.5 screw terminal) 3.2A, 1 piece for each output A0 ~ A3 and A4~ A7
1 2 3 L A0 5 6 7 L A1 9 10 11 L A2 13 14 15 L A3 17 18 19 L load O 2 : output circuit O A4 20 load : output circuit O L A7 19 20 16 O L A6 17 18 Fuse O L A5 15 16 O 12 O L A4 13 14 O 11 12 O 8 O L A3 9 10 L A2 7 8 Fuse O 4 O L A1 5 6 O L A0 3 4 O 2 O
Item Points/module Points/common Rated load voltage Maximum load current Maximum in rush current Limit of load Maximum voltage drop when ON Maximum leak current when OFF Response Time OFF 'ON ON 'OFF Output display External connection Fuse Terminal connection and circuitry 5 points 1 point/common
AOA05E
100 ~ 230VAC 15%, 47 ~ 63Hz 2A (however 5A/module) 25A (1 period) Refer to load derating curve 1.5Vrms 3.0mA (115VAC), 6.0mA (230VAC) Max. 1 ms Half of the load frequency or less LED display Terminal block connector (20 terminals, M3.5 screw terminal) 3.2A, 1 piece for each output A0 ~ A4 This is the value from input to output in the module module. The actual value is determined by adding it to the scanning time depending on each system.
This is the value from input to output in the module module. The actual value is determined by adding it to the scanning time depending on each system.
LED 4 10 20
LED
11. CONNECTIONS
118
Table 117. Item Points/module Points/common Rated load voltage Maximum load current Maximum in rush current Limit of load Maximum voltage drop when ON Maximum leak current when OFF Response Time OFF 'ON ON 'OFF Output display External connection Fuse Terminal connection and circuitry 12 points 6 points/common 100 ~ 115VDC 15% 47 ~ 63Hz 0.5A/point (however 2A/common) 5A (1 period) Refer to load derating curve 1.5Vrms 1.5mA (115 VAC) Output Module AOA12F AOA12F
MARO2P10203703E
Max. 1 ms Half of the load frequency or less LED display Terminal block connector (20 terminal, M3.5 screw terminal) 3.2A, 1 piece for each output A0 ~ A5 and B0 ~ B5
L : load L L L L L L A0 A1 A2 A3 A4 A5 7 8 9 10 L L L L L L B0 B1 B2 B3 B4 B5 17 18 19 20 O : output circuit Fuse 11 12 13 14 15 16 O O O O O O O O 1 2 3 4 5 6 O O O O O O O O Fuse
LED
9 19
NOTE: Each output signal group (A0A5 and B0B5) contains six output signals. However, each group must have an entire group of eight signals assigned to it. For example, A0A5 might be occupied by digital outputs 1 through 6 and B0B5 might be occupied by digital outputs 9 through 14. Digital outputs 7 and 8 and digital outputs 15 and 16 are unusuable.
11. CONNECTIONS
MARO2P10203703E
119
Table 118. Item Output Modules AOR08G and AOR16G AOR08G 8 points 1 point/common 30VDC/250VAC, 4A (resistance load) 5VDC, 10mA Refer to load derating curve This is the value from input to output in the module. The actual value is determined by adding it to the scanning time depending on each system. 8 points 4 points/common 30VDC/250VAC, 2A (resistance load) 1A (however 2A/common) 4A/common Refer to load derating curve This is the value from input to output in the module. The actual value is determined by adding it to the scanning time depending on each system. AOR16G
Points/module Points/common Maximum load Minimum load Maximum current Limit of load Response Time OFF 'ON
Max. 15ms
Max. 15ms
ON 'OFF
Max. 15ms
Max. 15ms
Output display External connection Relay life Mechanical Electrical Terminal connection and circuitry
LED display Terminal block connector (20 terminals, M3.5 screw terminal) Min. 20,000,000 times Min. 100,000 times (resistance load)
LED display Terminal block connector (20 terminals, M3.5 screw terminal) Min. 20,000,000 times Min. 100,000 times (resistance load)
1 v L v L v L v L A3 9 10 11 v L v L v L v L A7 19 20 A6 17 18 A5 15 16 A4 13 14 12 A2 7 8 A1 5 6 A0 3 4 2
v L L L L v L L L L v L L L L v L L L L B4 B5 B6 B7 BO B1 B2 B3 A4 A5 A6 A7 A0 A1 A2 A3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
v : Direct current power or alternating current power
: Direct current power or alternating current power
11. CONNECTIONS
1110
Table 119. Item Number of output channels Digital input Analog output Input/output correspondence 2 channels/module 12-bit binary (2s complement representation) 10VDC ~ +10VDC (external load resistance: 10K W or more) selectable 0mADC ~ + 20mADC (external load resistance: 400 W or less) usable Digital Input +2000 +1000 0 1000 2000 Resolution Comprehensive accuracy Converting time Isolation External connection Number of occupied output points 5mV or 20 mA Voltage output " 0.5% (for the full scale) Current output " 1% (for the full scale) Analog Output +10V +5V or +20mA 0V or 0mA 5V 10V Output Module ADA02A ADA02A
MARO2P10203703E
1ms or less. The converting time is the one only inside the module. The actual response time is added a scan time that is determined by the system. Photocopier isolation (between output signal and base). However, non-isolation between output channels. At removable terminal block (20 terminals, M3.5 screw terminals) 82
ADA02A
V0+ Channel 0 D/A converter
Voltage output
2
Load 10K ohms or more
Voltage V0 4 amp. Current amp.

6
10+
8
10
10
V1+ Channel 1 D/A converter

12
Voltage V1 14 amp. Current 16 amp. 10+

18
Current output
Load 400 ohms or less
10
20
(Note 1) Use a 2core twisted shielded cable as the connection cable. (Note 2) Ground the cable shield on the load side
11. CONNECTIONS
MARO2P10203703E
1111
11.3
ETHERNET REMOTE PRINTED CIRCUIT BOARD DIAGNOSTICS
Figure 111 shows both the ER-1 and ER-2 R-J2 Allen-Bradley Remote I/O (ABRIO) printed circuit boards. For more detailed information on the types and styles of the Ethernet Remote Printed Circuit Board, see Section 1.11, Table 313, and Table 314 which list the functions of the alarm LEDs.
Figure 111. ER-1 and ER-2 Printed Circuit Board LEDs
ER-1
ER-2
1 23 4
Alarm LEDs
A-B
Alarm LEDs
11. CONNECTIONS
1112
MARO2P10203703E
11.4
MODULAR I/O INPUTS
Item Points/module Points/common Sink/source current Input voltage Input current ON voltage current OFF voltage current Respo OFF 'ON nse ON 'OFF Time Input display External connection Terminal connection and circuitry 32 points 16 points/common Both directions
This section describes the connections and specifications for modular I/O units.
Table 1110. Input Module AID32B, Non-isolated AID32B
24 VDC +10% 20% 7.5mA (average) Min. 18 VDC min. 6 mA Max. 6VDC max. 1.5 mA Max. 2 ms Max. 2 ms Not provided Connector (HONDA TSUSIN MR-50RMA) : input circuit CM Internal Circuit
CMA A0 A1 A2 A3 A4 A5 A6 A7 B0 B1 B2 B3 B4 B5 B6 B7 29,45 49,50 16 32 48 15 31 47 30 46 12 28 44 11 27 43 10 42 13,17 +24V 14,18 GND CMC C0 C1 C2 C3 C4 C5 C6 D7 D0 D1 D2 D3 D4 D5 D6 D7 21,36 40,41 07 24 39 06 23 38 22 37 03 20 35 02 19 34 01 33 04,08 +24V 05,09 GND
This is the value from input to output in the module. The actual value is determined by adding it to the scanning time depending on each system. system
+24V or GND can be selected for input common as above figure. Note: Make sure to connect all common (CMA, CMC) pins.
11. CONNECTIONS
MARO2P10203703E
1113
Table 1111. Item Points/module Points/common Sink/source current Input voltage Input current ON voltage current OFF voltage current Response Time OFF 'ON ON 'OFF Input display External connection Terminal connection and circuitry 16 points 16 points/common Source current type 24VDC +10% 20% 7.5 mA (average) Min. 15VDC min. 4 mA Max. 5VDC max. 1.5 mA Max. 20ms Max. 20ms LED display AID16C
Input Modules AID16C and AID16D AID16D 16 points 16 points/common Sink current type 24 VDC +10% 20% 7.5 mA (average) Min. 15 VDC min. 4 mA Max. 5VDC max. 1.5 mA Max. 20ms Max. 20ms LED display Terminal block connector (20 terminals, M3.5 screw terminal) This is the value from input to output in the module. The actual value is determined by adding it to the scanning time depending on each system.
Terminal block connector (20 terminals, M3.5 screw terminal)

(C) (D)
A0 A1 A2 A3 A4 A5 A6 A7 B0 B1 B2 B3 B4 B5 B6 B7
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
FOR AID16C : input circuit 1 LED
FOR AID16D : input circuit LED 1
11. CONNECTIONS
1114
MARO2P10203703E
11.5
ANALOG INPUT MODULE
Item Number of input channels Analog input Digital output Input/output correspondence
This section describes the connections and specifications for analog input module AAD04A.
Table 1112. Analog Input Module AAD04A AAD04A 4 channels/module 10VDC to +10VDC (input resistance 4.7MW) 20mADC to +20mADC (input resistance: 250W selectable 12-bit binary (complementary representation of 2) Analog Input +10V +5V or +20mA 0V or 0mA 5V or 20mA 10V Digital Output +2000 +1000 0 1000 2000
Resolution Total precision Conversionary time Maximum input voltage/current Insulation External connection Number of occupied output points
5mV or 20 mA Voltage input " 0.5% (for the full scale) Current input " 1% (for the full scale) Maximum 2ms. NOTE: Actual response speed is determined by adding the scanning time depending on each system to this conversion time. "15V "30mA Photocopier insulation (between output signal and base). However, non-insulation between output channels. At removable terminal block (20 terminals, M3.5 screw terminals) 82
10+
1 11+ 2 V1+
Voltage input Voltage supply
V0+
3 V0 5 4
V1 6 COM1 8 9 MULTI PROCESSOR
COM0 7 FG0 FG1
Current input Current supply
10 12+ 11 250 13+ 12 V2+ 13 V3+ 14 V2 15 V3 16 COM2 17 COM3 18 FG2 19 FG3 20
(Note 1) Though the example above shows the connection of channels 0 and 2, it is just the same with the channel 1 (I1+, V1+, V1, COM1 and FG1) and the channel 3 (I3+, V3+, V3, COM3 and FG3). (Note 2) Either voltage input or current input can be specified for each channel. When current input is specified, make sure to shortcircuit in + and Vn+. (Note 3) Use shielded cables of twisted pair for connecting.
12 SCHEMATICS
Page15
MARO2P10203703E
12
SCHEMATICS
121

Schematics
Page
The following section includes separate print sets for the P-200 robot. Each print set includes the R-J2 controller schematic with R-J2 internal cable connector pinouts and an overview of the C-size cabinet with component locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12. SCHEMATICS
122 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
123
Figure 121. R-J2 P-200 Controller Total Circuit Diagram
USER TRANSFORMER (OPTION) TF2 (SEE SHEET 4) (REFER TO 002) IN CASE OF CIRCUIT BREAKER
L1 F2 F1 MULTITAP TRANSFORMER TF1 (SEE SHEET 4) A1 A2 F1 F2 F3 1 3 5 2 4 6 SERVO POWER (210 VAC) SERVO POWER CONTROL (220 VAC)
INPUT VOLTAGE REFER TO PAGE 002
L2 L3 G
FUSE UNIT
FL1 FL2 FL3 DISCONNECT SWITCH IN CASE OF DISCONNECT SWITCH ST FAN UNIT M M M AC 200V 220 VAC 100 VAC F4 F5 13 23 14 24 41 42 43 44 51 THERMOSTAT FOR OVERHEAT 52
BACK PLANE
PSU CP1 SEE SHEET 8

CP2
ESTOP PCB
JRV1 SEE SHEET 10 CRF1 SERVO POWER SURGE ABSORBER UNIT
JNPO CP3
AMPLIFIER CONNECTIONS REFER TO SHEETS 2 , 3 AND 4
JRF2 CP5 CRM9
JS1 JS2 JS3 JS4 JS5 JS6 CRR15 CRR5 BKP4 BKM4
OVERHEAT (TF1)
MAIN CPU SEE SHEET 9
CRM11 CRM15 CRM16
JRV1
PWM SIGNALS TO AMPLIFIERS ESTOP SIGNAL
JRF2
CRR20 CRR21
CRM10 JRA5 CRR22 JD1A JF21 CRS1 JD17 JRM3 JRM10 CNCA FRA1 SEE SHEETS FRA2 13, 14 & 15 BKP1 BKM1 200A BKP2 200B BRD1 BKM2 BRDC BKP3 BRD2 BKM3 BKP4 BKM4 OT SVON2 SVON SVONC SVON1 EES1 EES2 PDIO CNOP EMGIN1 EMGIN2
ROBOT CONNECTIONS PULSE CODER (J1J6)
CNIN
PURGE CONTROL BRAKE RELEASE

UNIT
CNPG CNPG
OPERATOR PANEL
CRS1 SEE SHEETS 16, 17 & 18 PORT1 PORT2
ISB
CRS1 CRS2
TEACH PENDANT
MOTOR BRAKE (J1J9)
AUX AXES BD
JNA
JV1
EE-3287-500-001
12. SCHEMATICS
124 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
125
Figure 122. R-J2 P-200 Controller Total Circuit Diagram (Multi-Tap Transformer Details)
IN CASE OF CIRCUIT BREAKER
MULTITAP TRANSFORMER TF1 EE0989550

1 575 L1 2 550 3 500 4 480 5 460 6 415/240 7 380/220 8 OV 9 575 L2 10 550 11 500 12 480 13 460 14 415/240 15 380/220 16 OV 17 575 L3 18 550 19 500 20 480 21 460 22 415/240 23 380/220 24 OV ST1 F1 30A F2 30A F3 30A 1 3 5
A1 A2 2 4 6
SERVO POWER CONTROL (220VAC)
L1 AC POWER SUPPLY
SERVO POWER (210 VAC)
L2 220/240 380/415 460/480 500/550 575 +10% 15% @ SELECTED VOLTAGE 50/60Hz L3
F4 7.5A F5 7.5A
13 23
14 100 VAC 24
43 44 51 ST2 52 THERMOSTAT FOR OVERHEAT 220 VAC
IN CASE OF DISCONNECT SWITCH FUSE UNIT FL1 FL2 FL3 DISCONNECT SWITCH
USER TRANSFORMER (OPTION) TF2 A80L00010520 575 550 500 480 460 440 415 380 240 220 COM F1 10A
SPECIFICATION OF TF1
CAPACITY 7.5KVA F2 20A 115V L1 L1 L2 L2 9.6A SPECIFICATION A80L00260010#A F1,F2,F3 30A F4,F5 7.5A
115 VAC TO OUTLET UNIT
* CONNECTION TO TF1 * BREAKER, FUSE SIZE

INPUT VOLTAGE 220 240 380 415 460 480 500 550 575 CIRCUIT BREAKER 50A LEAKAGE BREAKER 50A DISCONNECT SWITCH FL1 FL2 FL3 50A POWER SUPPLY VOLTAGE 220 240 380 415 440 460 480 500 550 575 CONNECTION OF PRIMARY TAP L1 L2 L3 JUMPER 1623 7 815 15 23 6 814 1622 14 22 7 15 23 6 5 4 3 2 1 14 13 12 11 10 9 22 STAR 21 20 19 18 17 816 1624 CONNECTING STYLE 247 246 DELTA
30A
30A
30A
20A
20A
20A
EE-3287-500-006
12. SCHEMATICS
126 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
127
Figure 123. R-J2 P-200 Controller Total Circuit Diagram (Amplifier Configurations)
4 3 2 1 ON
AMP DIP SWITCH SETTINGS ALL CASES 1 ON 2 OFF 3 ON 4 ON
AC 200V (CP3)
AMP 1 H209 A06B6089 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 CX4
AMP 2 H209 A06B6089 L1 L2 L3 L1C T1 L2C TH1 TH2 RC UL RI VL RE WL T1 PE CX3 UM VM CX4 4 WM 3 2 PE 1

ON
AMP 3 H101 A06B6089 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 CX4
AMP 4 H106 A06B6089 L1 L2 L3 L1C T1 L2C TH1 TH2 RC U RI V RE T1 W CX3 PE CX4

4 3 2 1 ON
AXES # P200 6 AXES CONTROL MOTOR TYPE
J1
J2
J3
J4, J5
J6
a 6/3000
a22/3000
a12/3000
a 2/3000
a 0.5/3000
SERVO POWER OVER HEAT TF1
# P200 6 AXES CONTROL AMP SPECIFICATION
AMP
AMP1 SVU212/80 L(12A)= J4 M(80A)= J1 A06B6089H209
AMP2 SVU212/80 L(12A)= J5 M(80A)= J3 A06B6089H209
AMP3 SVU112 J6 A06B6089H101
AMP4 SVU1130 J2 A06B6089H106
UL VL WL PE T1 UM VM 4 3 WM 2 1 PE ON JS2B
J4 J1
J5 J3
U V W T1 PE
J6
J2
4 3 2 1 ON
T1 (TERMINAL BLOCK) CX3 (YKEY) (MCC CONTROL)

MOTOR POWER (J1J6) TO ROBOT 1 MCCOFF3 2 3 MCCOFF4 13 14 15 16 17 18 19 20 21 22 23 L1C L2C TH1 TH2 RC RI RE [UL] [VL] [WL] [ ] 1 2 3 4 5 6 7 8 9 10 11 12 J6 L1(R) L2(S) L3(T) (100A) (100B) RL2 RL3 U[UM] V[VM] W[WM]
JS1B
JS1B
JS2B
JS1B
JS1B
PWM CABLE (JS1JS6) ESTOP SIGNAL
JS4
JS1
JS5
JS3
JS6
JS2
P200 (6) AXES CONTROL
CX4 (XKEY) (ESTOP CONTROL)

1 2 ESP 3 +24V
AC 200V (CP3)
AXES # P200 7 AXES CONTROL MOTOR TYPE AMP 1 H209 A06B6089 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 CX4 AMP 2 H209 A06B6089 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 CX4 AMP 3 H209 A06B6089 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 CX4 AMP 4 A06B6089 H106 L1 L2 L3 L1C T1 L2C TH1 TH2 RC U RI V RE T1 W CX3 PE CX4
4 3 2 1 ON
J1
J2
J3
J4, J5
J7
a6/3000
a22/3000
a12/3000
a2/3000
b0.5/3000
a12/3000
# P200 7 AXES CONTROL AMP SPECIFICATION
AMP
AMP1 SVU212/80 L(12A)=J4 M(80A)=J1 A06B6089H209
AMP4 SVU1130 J2 A06B6089H106
J4 J1
UL VL WL T1 PE UM VM 4 3 WM 2 1 PE ON JS2B
J5 J3
J6 J7
J2
JS1B
JS1B
JS1B
JS1B
4 3 2 1 ON MOTOR POWER (J1J7) TO ROBOT
PWM CABLE (JS1JS6, JV7) ESTOP SIGNAL
JS4
JS1
JS5
JS3
JS6
JV7
JS2
P200 (7) AXES CONTROL
EE-3287-500-002
12. SCHEMATICS
128 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
129
4 3 2 1 ON

J1 J2 J3 J4,J5 J6 J7 J8
AC 200V (CP3)
AMP 1 A06B6089H209 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 T1 CX4

4 3 2 1 ON
AMP 2 A06B6089H209 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 T1 CX4 J1 JS1B

4 3 2 1 ON
AMP 3 A06B6089H101 L1 L2 L3 L1C T1 L2C TH1 TH2 RC U RI V RE T1 W CX3 PE CX4 J3 JS1B

4 3 2 1 ON
AMP 4 A06B6089H106 L1 L2 L3 L1C T1 L2C TH1 TH2 J2 RC U RI RE T1 V W CX3 PE CX4

4 3 2 1 ON
AMP 5 SEE CHART L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 CX4
# P200 6+2 (DOOR OPENER) AXES CONTROL MOTOR SPEC. P200 6+2 (HOODDECK) AXES CONTROL MOTOR SPEC.
AMP #
AXES
a 6/3000 a 6/3000
AMP1 SVU212/80 L(12A)=J4 M(80A)=J1 A06B6089H209 SVU212/80 L(12A)=J4 M(80A)=J1 A06B6089H209
a22/3000 a22/3000
AMP2
a12/3000 a12/3000
a2/3000 a2/3000
AMP3
a0.5/3000 a 0.5/3000
AMP4 SVU1130 J2
a2/3000 a6/3000
a2/3000 a6/3000
AMP5
UL VL WL PE UM VM WM PE
J4
J5
J6
ON
UL VL WL PE T1 UM VM 4 3 WM 2 1 PE JS2B
J7
P200 6+2 (DOOR OPENER) AXES CONTROL AMP SPECIFICATION P200 6+2 (HOODDECK) AXES CONTROL AMP SPECIFICATION
J8
SVU212/80 L(12A)=J5 M(80A)=J3 A06B6089H209 SVU212/80 L(12A)=J5 M(80A)=J3 A06B6089H209
SVU112 J6 A06B6089H101 SVU112 J6 A06B6089H101
SVU212/12 L(12A)=J7 M(12A)=J8 A06B6089H106 A06B6089H201 SVU280/80 SVU1130 L(80A)=J7 J2 M(80A)=J8 A06B6089H106 A06B6089H208 T1
JS1B
JS2B
JS2B
JS1B
JS1B
(TERMINAL BLOCK) CX3 (YKEY) (MCC CONTROL)

13 14 15 16 17 18 19 20 21 22 23 J3 J4,J5 L1C L2C TH1 TH2 RC RI RE [UL] [VL] [WL] [ ] J6 1 2 3 4 5 6 7 8 9 10 11 12 L1(R) L2(S) L3(T) (100A) (100B) RL2 RL3 U[VM] V[VM] W[WM]
PWM CABLE (JS1JS6 .J7J9) ESTOP SIGNAL
JS4
JS1
JS5
JS3
JS6
JS2
JV7
JV8
MOTOR POWER (J1J9) TO ROBOT
1 MCCOFF3
3 MCCOFF4
P200 6+2 AXES CONTROL

1

2 ESP 3 +24V
AC 200V (CP3)
AXES AMP 1 A06B6089H209 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 CX4

4 3 2 1 ON
J1
J2
J7
J8
J9
AMP 2 A06B6089H209 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 CX4 J1

4 3 2 1 ON
AMP 3 A06B6089H209 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 CX4
AMP 4 A06B6089H106 L1 L2 L3 L1C T1 L2C TH1 TH2 RC UL RI RE VL T1 WL CX3 PE CX4 J7 JS1B

4 3 2 1 ON
AMP 5 SEE CHART L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 CX4
P200 7+2 (DOOR OPENER) MOTOR SPEC. P200 7+2 (HOODDECK) MOTOR SPEC.
AMP #
a6/3000 a6/3000
a22/3000 a22/3000
a 12/3000 a12/3000
a2/3000 a2/3000
b0.5/3000 b0.5/3000
a12/3000 a 2/3000 a 12/3000 a6/3000
a2/3000 a6/3000
AMP2
AMP3
AMP4
AMP5
UL VL WL PE T1 UM VM WM PE JS2B
J4
J5 UL VL WL T1 PE UM VM WM PE J3 JS2B
ON
UL VL WL T1 PE UM VM 4 3 WM 2 1 PE JS2B
J6
J2
UL VL WL PE T1 UM 4 VM 3 2 WM 1 PE ON JS2B
P200 7+2 (DOOR OPENER) AXES CONTROL J8 AMP SPECIFICATION P200 7+2 (HOODDECK) J9 AXES CONTROL AMP SPECIFICATION
SVU212/80 SVU212/80 SVU212/12 SVU1130 L(12A)= J5 L(12A)=J6 A06B6089H201 J2 L(12A)= J8 M(80A)= J7 M(80A)=J3 M(80A)= J9 A06B6089H209 A06B6089H209 A06B6089H106 A06B6089H208 SVU212/80 SVU212/80 SVU212/80 SVU1130 SVU280/80 L(12A)= J5 L(12A)=J6 L(12A)=J4 J2 L(12A)= J8 M(80A)= J7 M(80A)=J3 M(80A)=J1 M(80A)= J9 A06B6089H209 A06B6089H209 A06B6089H209 A06B6089H106
JS1B
JS1B
JS1B
JS1B
PWM CABLE (JS1JS6 .J7J9) ESTOP SIGNAL
JS4
JS1
JS5
JS3
JS6
JV7
JS2
JV8
JV9
MOTOR POWER (J1J9) TO ROBOT
4 3 2 1 ON
P200 RJ2
EE-3287-500-003
12. SCHEMATICS
1210 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1211
SIDE CABINET
AC 200V (CP3) AMP 1 A06B6089H209 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 T1 CX4
4 3 2 1 ON
AMP 2 A06B6089H209 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE CX3 T1 CX4 J1 JS1B

4 3 2 1 ON
AMP 3 A06B6089H209 L1 L2 L3 L1C T1 L2C TH1 TH2 RC J6 UL RI VL RE T1 WL CX3 PE UM 4 VM CX4 3 2 WM 1 PE J7 ON JS1B JS2B
AMP 4 A06B6089H106 L1 L2 L3 L1C T1 L2C TH1 TH2 RC RI RE T1 CX3 CX4

4 3 2 1 ON
J4
J5
U V W PE
J2
4 3 2 1 ON
T1
UL VL W PE
J8
J3
4 3 2 1 ON
J9 UL VL WL T1 PE UM VM 4 3 2 WM 1 PE J10 ON JS2B 13 14 15 16 17 18 19 20 21 22 23
JS1B
JS2B
JS2B
JS1B
JS1B
JS1B
T1 (TERMINAL BLOCK) MOTOR POWER (J1J10) TO ROBOT & OPENER

L1C L2C TH1 TH2 RC RI RE [UL] [VL] [WL] [ ] 1 2 3 4 5 6 7 8 9 10 11 12 L1(R) L2(S) L3(T) (100A) (100B) RL2 RL3 U[VM] V[VM] W[WM]
PWM CABLES (JS1JS6 .J7J9) ESTOP SIGNAL
JS4
JS1
JS5
JS3
JS6
JV7
JS2
JV8
JV9
JV10
AXIS
J1
J2
J3
J4,J5
J6
J7
J8
OPENER J9 J10
AMP
AMP2
AMP3
AMP4 SVU1130 J2 A06B6089H106
P200 & P10 OPENER MOTOR TYPE
a 6/3000 a 22/3000 a 12/3000
a2/3000
b0.5/3000 a 2/3000
a 6/3000 a 6/3000 6/3000 a
AMPLIFIER SPECIFICATION
SVU212/80 SVU212/80 L(12A)=J5 L(12A)=J6 M(80A)=J7 M(80A)=J3 A06B6089H209 A06B6089H209
OPENER SIDE CABINET AMP5 AMP6 SVU280/80 SVU180 L(80A)=J9 J8 (RAIL) M(80A)=J10 A06B6089H105 A06B6089H208
CX3 (YKEY) (MCC CONTROL)

1 MCCOFF3 2 3 MCCOFF4

1 2 ESP 3 +24V
EE-3287-500-004
12. SCHEMATICS
1212 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1213
Figure 126. R-J2 P-200 Controller Total Circuit Diagram (AMP PWM Signal Connections) ESTOP PCB JS1 JS2 JS3 JS4 JS5 JS6 JS1 JS2 JS3 JS4 JS5 P200 7 AXES CONTROL JS6 P200 6+2 AXES CONTROL JRV1 J1J6 P200 7+2 AXES CONTROL REFER TO PWM SIGNAL CONNECTION TABLE PWM SIGNAL CONNECTION TABLE PWM SIGNAL CONNECTION P200 6 AXES CONTROL AMP 1 JS1B=JS4 JS2B=JS1 JS1B=JS4 JS2B=JS1 JS1B=JS4 JS2B=JS1 JS1B=JS4 JS2B=JS1 JS1B=JS4 JS2B=JS1 AMP 2 JS1B=JS5 JS2B=JS3 JS1B=JS5 JS2B=JS3 JS1B=JS5 JS2B=JS3 JS1B=JS5 JS2B=JS3 JS1B=JS5 JS2B=JS3 AMP 3 JS1B=JS6 JS1B=JS6 JS2B=JV7 JS1B=JS6 JS1B=JS6 JS2B=JV7 JS1B=JS6 JS2B=JV7 AMP 4 JS1B=JS2 AMP 5 AMP 6
JS1B=JS2 JS1B=JV7 JS2B=JV8 JS1B=JV8 JS2B=JV9 JS1B=JV8 JS1B=JV9 JS2B=JV10
JS1B=JS2
JS1B=JS2
P200 7+3 AXES CONTROL MAIN CPU PCB JRA5 JRV1 J1J6
JS1B=JS2
AUX AXIS PCB BACK PLANE JV7 JV8 JV9 JV10 JNA JV11 JV12 JV13 JV14 JV15 JV16 JV7 JV8 JV9 JV10 REFER TO PWM SIGNAL CONNECTION TABLE JS1B/JS2B JS1JS6 (SERVO CONTROL) 1 2 3 4 5 6 7 8 9 10 IR GNDR *PWMA 0V *PWMC 0V *PWME 0V *DRDY *MCON 11 12 13 14 15 16 17 18 19 20 0V 0V IS GNDS *ENBL 0V 1 2 3 4 5 6 7 8 9 10 *MCON JS1JS6 (DUMMY CONNECTOR) A25023610001 1 2 3 4 5 6 7 8 JMPR 9 10 *DRDY *MCON 11 12 13 14 15 16 17 18 19 20
JV1JV10 (SERVO CONTROL) IR GNDR *PWMA 0V *PWMB 0V *PWMC 0V 11 12 13 14 15 16 17 18 19 20 *DRDY IS GNDS *PWMD 0V *PWME 0V *PWMF 0V
EE-3287-500-007
12. SCHEMATICS
1214 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1215
Figure 127. R-J2 P-200 Controller Total Circuit Diagram (Power Supply Connections)
FAN
CA39A
CP1
1 2 S 3 G B1 AL
CP4
B2 FA B3 FB B1
CP8
B2 BAT
POWER SUPPLY A16B12120871

CP1 200240 VAC INPUT
BAT+
A1 ON
A2 OFF
A3 COM
CP2
200240 VAC OUTPUT 1
CP2
2 S1 3 G1 B1 +24V
CP3 JNPO CP4
200240 VAC OUTPUT R1 POWER ON/OFF ALARM +24 VDC OUTPUT
CP5
B2 0V B3
CP5
CP3
CP6 +24 VDC OUTPUT 1 R2 2 S2 3 G2 B1 +24E
CP6
B2 0V B3
BATTERY
CP8
BACK PLANE 3SLOT A20B20010670 5SLOT A20B20010990
SPECIFICATION OF FUSE
NAME F1 F3 F4 FUSE 7.5A 5A 5A VOLTAGE 200V +24V +24E
POWER SUPPLY UNIT
EE-3287-500-008
12. SCHEMATICS
1216 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1217
Figure 128. R-J2 P-200 Controller Total Circuit Diagram (CPU Connector Details)
JD1B (I/O LINK)
FAN
JRF2 (ROBOT FEEDBACK)

CA39A A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 (OPTION) A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 PD6 0V PRQ6 0V PD5 0V PRQ5 0V PD4 0V PRQ4 0V PD3 0V PRQ3 0V PD2 0V PRQ2 0V PD1 0V PRQ1 0V 0V 0V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V 0V 0V +24E +24E OTRST SVON RDICOM B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 B33 B34 B35 B36 B37 B38 B39 B40 B41 B42 B43 B44 B45 B46 B47 B48 B49 B50 PD6 0V PRQ6 0V PD5 0V PRQ5 0V PD4 0V PRQ4 0V PD3 0V PRQ3 0V PD2 0V PRQ2 0V PD1 0V PRQ1 0V 0V 0V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V 0V 0V +24E 0V OTREL ROT HBK HBKREL A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50
JRV1 (SERVO AMPLIFIER)

IS6 IR6 IS5 IR5 IS4 IR4 IS3 IR3 IS2 IR2 IS1 IR1 ENBL6 PWME6 PWMC6 PWMA6 ENBL5 PWME5 PWMC5 PWMA5 ENBL4 PWME4 PWMC4 PWMA4 ENBL3 PWME3 PWMC3 PWMA3 ENBL2 PWME2 PWMC2 PWMA2 ENBL1 PWME1 PWMC1 PWMA1 MCON DRDY 0V 0V +15V +15V 0V 0V 15V 15V 0V 0V BRKON BRKALM B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 B33 B34 B35 B36 B37 B38 B39 B40 B41 B42 B43 B44 B45 B46 B47 B48 B49 B50 GNDS6 GNDR6 GNDS5 GNDR5 GNDS4 GNDR4 GNDS3 GNDR3 GNDS2 GNDR2 GNDS1 GNDR1 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +24V +24V +24V +24V
1 2 3 4 5 6 7 8 9 10
RXSLC RXSLC TXSLC TXSLC
MAIN CPU A16B32000040 VBAT

JRV1
BATTERY UNIT FOR MAINTENANCE
+5V
SERVO AMPLIFIER
11 12 13 14 15 16 17 18 19 20
0V 0V 0V 0V 0V 0V +5V +5V
VBAT (BATTERY)
1 2 EXVBAT 0V
JRF2 JRA5 JF21 JRM10 JRY4 (FOR TEST) JD1B
ROBOT FEEDBACK LINE TRACKING TO OPERATION BOX
JF17 (RS232C/485)
1 2 3 4 5 6 7 8 9 10 RXDB 0V DSRBC 0V CTSB 0V RX485B RX485B +24E 11 12 13 14 15 16 17 18 19 20 TXDB 0V DTRB 0V RTSB 0V TX485B TX485B +24E
JRM10 (OPERATION BOX)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 0V RTS1 0V DTR1 0V TXD1 0V RTSA 0V DTRA 0V TXDA TXTP TXTP TX485A TX485A ON OFF COM OPEMG EXEMG EMGDM EMGEM TPEMG SVON 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 0V CTS1 0V DSR1 0V RXD1 0V CISA 0V DSRA 0V RXDA RXTP RXTP RX485A RX485A 0V 0V +24V +24V +24V +24V +24V EMGB1 EMGB2
I/O LINK RS232C/485 INTERFACE TO OPERATION BOX TO TEACH PENDANT RDI/RDO
BACK PLANE 3SLOT A20B20010670 5SLOT A20B20010990
JD17 JRM3 CRS1 CRM10
JF21 (LINE TRACKING)

1 2 3 4 5 6 7 8 9 10 PA PA PB PB PZ PZ REQ +5V 11 12 13 14 15 16 17 18 19 20 0V 0V 0V +5V +5V
CRS1 (TEACH PENDANT)

01 02 03 04 05 06 07 TXTP RXTP EMGDM 08 09 10 11 12 13 14 15 16 17 18 19 20 TXTP RXTP EMGEN 0V 0V
+24V +24V
EMGB1 EMGB2 EMGTP
CRM10 RDI/RDO
14 15 16 17 18 19 20 RDO1 RDO2 RDO3 RDO4 RDO5 RDO6 +24E 08 09 10 11 12 13 RDI7 RDI8 RDI9 HBK RDO7 RDO8 01 02 03 04 05 06 07 RDI1 RDI2 RDI3 RDI4 RDI5 RDI6 0V
JRM3 (PDI/PDO)
1 2 3 4 5 6 7 8 9 10 PDI1 0V PDI2 PDI3 PDI4 PDI5 PDI6 PDI7 TPOFF +24V 11 12 13 14 15 16 17 18 19 20 0V PDO1 PDO2 PDO3 PDO4 PDO5 PDO6 PDO7 +24V PDO8
EE-3287-500-009
12. SCHEMATICS
1218
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1219
Figure 129. R-J2 P-200 Controller Total Circuit Diagram (ESTOP Connection Details)
JRF2 (ROBOT FEEDBACK)

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50 PD6 0V PRQ6 0V PD5 0V PRQ5 0V PD4 0V PRQ4 0V PD3 0V PRQ3 0V PD2 0V PRQ2 0V PD1 0V PRQ1 0V 0V 0V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V 0V 0V +24E +24E * OTRST SVON RDICOM B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 B33 B34 B35 B36 B37 B38 B39 B40 B41 B42 B43 B44 B45 B46 B47 B48 B49 B50 * PD6 0V * PRQ6 0V * PD5 0V * PRQ5 0V * PD4 0V * PRQ4 0V * PD3 0V * PRQ3 0V * PD2 0V * PRQ2 0V * PD1 0V * PRQ1 0V 0V 0V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V 0V 0V +24E 0V * OTREL * ROT * HBK * HBKREL A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 A40 A41 A42 A43 A44 A45 A46 A47 A48 A49 A50
JRV1 (SERVO CONTROL)

IS6 IR6 IS5 IR5 IS4 IR4 IS3 IR3 IS2 IR2 IS1 IR1 ENBL6 PWME6 PWMC6 PWMA6 ENBL5 PWME5 PWMC5 PWMA5 ENBL4 PWME4 PWMC4 PWMA4 ENBL3 PWME3 PWMC3 PWMA3 ENBL2 PWME2 PWMC2 PWMA2 ENBL1 PWME1 PWMC1 PWMA1 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 B33 B34 B35 B36 B37 B38 B39 B40 B41 B42 B43 B44 B45 B46 B47 B48 B49 B50 GNDS6 GNDR6 GNDS5 GNDR5 GNDS4 GNDR4 GNDS3 GNDR3 GNDS2 GNDR2 GNDS1 GNDR1 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V +24V +24V +24V +24V SERVO CONTROL JRV1
ESTOP PCB
CRF1 COM (RDI COM) ROBOT FEEDBACK JRF2 B A A=PULLDOWN B=PULLUP HBK (HANDBROKEN) A B A=NO HBKN B=HBKN USED JS1 JS2 JS3 SERVO CONTROL AUX BRAKE CONTROL CRM16 JS4 JS5 JS6 CRM11 CRR5 CRR22 ROBOT OVERTRAVEL MOTOR BRAKE POWER 100VAC OUTPUT TO ROBOT (FEEDBACK)
ESTOP CONTROL DOOR INTERLOCK
CRM9 CRM15
* * * * * * * * * * * * * * * * * * * * * * * *
ESTOP CONTROL 100VAC INPUT FOR BRAKE POWER MCC CONTROL
CRR20 CRR21 CRR15 TB4
CRR5
1D 2D BKM3 2C BKP3 2B BKM2 2A BKP2 3D BKM3 3C BKP3 3B BKM2 3A BKP2 3
CRM9 (ESTOP CONTROL)

3 2 MCCON 1 SVOUT 3
BKM3
CRR21 (BRAKE POWER)

2 100B 1 100A
1C BKP3 1B BKM1 1A BKP1 1
CRM11 (ROBOT OVERTRAVEL)

2 * ROTIN 1 +24E
CRM15 (DOOR INTERLOCK)

3 2 DIL2 1 DIL1 3
CRR22 (100VAC OUT)

2 100OUT2 100OUT1
CRF1 (PULSE CODER INTERFACE)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 SPDJ5 * SPDJ5 SPRQJ5 * SPRQJ5 SPDJ6 * SPDJ6 SPRQJ6 * SPRQJ6 +5V +5V +5V +5V +5V +5V +5V +5V +5V +5V 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SPDJ3 SPDJ3 SPRQJ3 SPRQJ3 SPDJ4 SPDJ4 SPRQJ4 SPRQJ4 0V 0V 0V +5V +5V +5V 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 SPDJ1 * SPDJ1 SPRQJ1 * SPRQJ1 SPDJ2 * SPDJ2 SPRQJ2 * SPRQJ2 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V
CRR15 (MCC CONTROL)

3 2 200B MCCB 1 200A MCCA
* MCON * DRDY 0V 0V +15V +15V 0V 0V 15V 15V 0V 0V * BRKON * BRKALM
CRM16 (AUX BRAKE CONTROL)

2 * BRKON4 1 * BRKON3 1 2 3 4 5 6 7 8 9 10
* * * *
JS1JS6 (SERVO CONTROL)

IR GNDR * PWMA 0V * PWMC 0V * PWME 0V * DRDY * MCON 11 12 13 14 15 16 17 18 19 20 IS GNDS * ENBL 0V
CRR20 (EMG CONTROL)

A3 200T A2 200S A1 200R
B3 AC3
B2 AC2
B1 AC1
0V 0V
EE-3287-500-10
12. SCHEMATICS
1220 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1221
Figure 1210. R-J2 P-200 Controller Total Circuit Diagram (Optional Process I/O Connections)
PROCESS I/O CR2A MAIN CPU A16B32000040

JD1A JD4A JD4B CR2B CR2B SDI/SDO CR2B CR2B CR2B CRW1 CRW2 TO WELD MACHINE (A/D, D/A, WDI, WDO) TO ANALOG INTERFACE (A/D) I/O LINK SLAVE
TYPE OF PROCESS I/O (SINK TYPE)

CA CB DA SPECIFICATION A16B22010470 A16B22010472 A16B22010480 CRM2A CRM2B O O O O O O CRM2C CRM2D CRM4A CRM4B CRW1 X X X X O X X X X X O O O O X CRW2 O X X
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
*IMSTP *HOLD *SFSPD CSTOPI FAULT RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 0V 0V
CRM2A (SDI/SDO)
19 20 21 22 23 24 25 26 27 28 29 30 31 32 ACK3/SN03 ACK4/SN04 ACK5/SN05 ACK6/SN06 COMA4 ACK7/SN07 ACK8/SN08 SNACK RESERVED COMA5 PNSTROBE PROD START SDI01 SDI02
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
CMDENBL SYSRDY PROGRUN PAUSED COMA1 HELD FAULT ATPERCH TPENBL COMA2 BATALM BUSY ACK1/SN01 ACK2/SN02 COMA3 +24E +24E
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
SDI23 SDI24 SDI25 SDI26 SDI27 SDI28 SDI29 SDI30 SDI31 SDI32 SDI33 SDI34 SDI35 SDI36 SDI37 SDI38 0V 0V
CRM2C (SDI/SDO)
19 20 21 22 23 24 25 26 27 28 29 30 31 32 SDO33 SDO34 SDO35 SDO36 COMC4 SDO37 SDO38 SDO39 SDO40 COMC5 SDI39 SDI40 SDI41 SDI42
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
SDO21 SDO22 SDO23 SDO24 COMC1 SDO25 SDO26 SDO27 SDO28 COMC2 SDO29 SDO30 SDO31 SDO32 COMC3 +24E +24E
CRM4A (SDI/SDO)
01 02 03 04 05 06 07 SDI63 SDI64 SDI65 SDI66 SDI67 SDI68 SDI69 08 09 10 11 12 13 SDO65 SDO66 SDO67 SDO68 COME2 SDI70 14 15 16 17 18 19 20 SDO61 SDO62 SDO63 SDO64 COME1 +24E 0V 01 02 03 04 05 06 07
CRW2 (A/D INTERFACE OPTION)

08 09 10 11 12 13 ADCH6 COMAD6 14 15 16 17 18 19 20 ADCH3 COMAD3 ADCH3 COMAD4 ADCH5 COMAD5
CRM4B (SDI/SDO)
01 02 03 04 05 06 07 SDI71 SDI72 SDI73 SDI74 SDI75 SDI76 SDI77 08 09 10 11 12 13 SDO73 SDO74 SDO75 SDO76 COMF2 SDI78 14 15 16 17 18 19 20 SDO69 SDO70 SDO71 SDO72 COMF1 +24E 0V
JD4A, B (RS422/SLC)
1 2 3 4 5 6 7 8 9 10 RX *RX TX *TX 11 12 13 14 15 16 17 18 19 20 0V 0V 0V 0V 0V 0V 15V +5V +24V +5V
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
CRM2B (SDI/SDO)
19 20 21 22 23 24 25 26 27 28 29 30 31 32 SDO13 SDO14 SDO15 SDO16 COMB4 SDO17 SDO18 SDO19 SDO20 COMB5 SDI19 SDI20 SDI21 SDI22
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
SDO01 SDO02 SDO03 SDO04 COMB1 SDO05 SDO06 SDO07 SDO08 COMB2 SDO09 SDO10 SDO11 SDO12 COMB3 +24E +24E
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
CRM2D (SDI/SDO)
19 20 21 22 23 24 25 26 27 28 29 30 31 32 SDO53 SDO54 SDO55 SDO56 COMD4 SDO57 SDO58 SDO59 SDO60 COMD5 SDI59 SDI60 SDI61 SDI62
CRW1 (WELD INTERFACE OPTION)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 SDO41 SDO42 SDO43 SDO44 COMD1 SDO45 SDO46 SDO47 SDO48 COMD2 SDO49 SDO50 SDO51 SDO52 COMD3 +24E +24E 01 02 03 04 05 06 07 08 09 10 11 12 DACH1 CAMDA1 DACH2 CAMDA2 WDI1 WDI2 WDI3 WDI4 WDI5 WDI6 WDI7 WDI8 13 14 15 16 17 18 19 20 21 22 ADCH1 COMAD1 ADCH2 COMAD2 23 24 25 26 27 28 29 30 31 32 33 34 WDO1 WDO2 WDO3 WDO4 WDO5 WDO6 WDO7 WDO8 WDI+ WDI +24E +24E
*ENBL +15V +5V +24V
0V 0V 0V 0V
NOTE: THE PROCESS I/O IS NOT NORMALLY USED WITH P200 ROBOTS
EE-3287-500-011
12. SCHEMATICS
1222 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1223
Figure 1211. R-J2 P-200 Controller Total Circuit Diagram (Optional I/O Connections)
I/O UNIT MODEL A POWER SUPPLY A16B12120870

CP6
MODULAR I/O 5SLOT BASE UNIT A03B0807J002 10SLOT BASE UNIT A03B0807J001 MODULAR I/O INTERFACE MODULE A03B0807J011 MODULAR I/O
CP32
1 2 3 +24V 0V 1 2 3 4 5 6 7 8 9 10 RX RX TX TX
JD1A/JD1B
11 12 13 14 15 16 17 18 19 20 0V 0V 0V 0V 1 2 3 4 5 6 7 8 9 10 S1 S1 S2 S2 S3 S3 S4 S4 ID1
JD2
11 12 13 14 15 16 17 18 19 20 S5 S5 S6 S6 0V 0V ID2 ID3
CP32 JD1B JD1A JD2
MAIN CPU A16B32000040

JD1A
+5V +5V
+5V
I/O UNIT MODEL B
BASIC UNIT
EXPANSION UNIT
POWER SUPPLY A16B12120870

CP6 24V 0V
I/O UNIT MODEL B INTERFACE UNIT A03B0808C001

24V 0V S1+ S1 FG S2+ S2 FG S3+ S3 FG S4+ S4 FG
FG S S+ 0V 24V
TO BASIC UNIT 24
JD1B
TO BASIC UNIT 2
MAIN CPU A16B32000040

JD1A
JD1A
TO BASIC UNIT 3
TO BASIC UNIT 4
I/O LINK SLAVE
JD1A/JD1B
1 2 3 4 5 6 7 8 9 10 RX RX TX TX 11 12 13 14 15 16 17 18 19 20 0V 0V 0V 0V
+5V +5V
+5V
EE-3287-500-012
12. SCHEMATICS
1224 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1225
Figure 1212. R-J2 P-200 Controller Total Circuit Diagram (Purge Circuitry)
ISB UNIT OPERATOR PANEL

CRS1 PORT1 PDIO CNOP PORT2 CNPG EMGIN1 EMGIN2 PANEL I/F CRS1 FG CRS2 ISG I.S. GND
PAINT BOOTH I.S. TEACH PENDANT

01 02 03 04 05 06 07 08 09 10 11 12 01 02 03 04 05 06 07 RDI9
CNCA (RDI/RDO)
13 14 15 16 17 18 19 20 21 22 RDI5 RDI3 RDI4 RDI7 * HBK RDI2 RDI8 23 24 25 26 27 28 29 30 31 32 33 34 14 15 16 17 18 19 20 RDO1 RDO2 RDO3 RDO4 RDO5 RDO6 RDO7 RDO8
RDI1 RDI6
RDI1: BKRL (BRAKE RELEASE DETECT) RDI2: EOAT (END OF ARM TOOLING)
PURGE AND I.S. CIRCUITS

PC BD PURGE/BRAKE BD CNPG RELAY BARRIER PC BD CNCA
IDEC IBRC
SEE SHEET 14 & 15
BRAKE CONTROL
PC BD CNIN
0V
+24E OFF1 OFF2 BKRL1 BKRL2
MAIN CPU
JRV1 CRM10 JD1A JRF2 JRM3 JRM10 JF21 CRS1 JD17 RDI/RDO FIRE ALARM FRA1 FRA2 BKP1 BKM1 BKP2 BKM2 BKP3 PC BD BKM3 TB BKP4 BKM4 SVON2 SVONC SVON1 EES1 EES2 200A 200B OFF1 PC BD OFF2 FASTON BRD1 TERMINAL BRDC BRD2 ESTOP SIGNAL 24PG OPG SVON PGTB ROT PGC1 PURGE COMPLETE PGC2
PSA1 PSA2 PSB1 PSB2 FSA1 FSA2 FSB1 FSB2 OT11 OT12 OT21 ISTB OT22 OT31 OT32 OT41 OT42 OT51 OT52 HBK1 HBK2 TP1 TP2 EOAT1 EOAT2
PRESSURE SWITCH TPDSC PGCP PGFLT PG TPDSC2 PGEN1 FLOW SWITCH 08 09 10 11 12 13
CNPG
PGEN2
0V 0V 0V
CNIN (BRAKE CONTROL)

HAND BROKEN TEACH PENDANT DISCONNECT SWITCH END OF ARM TOOLING 3 6 9 12 BKP2 BKM3 100 OUT1 EMG2 2 5 8 11 BKM1 BKP3 100B EMG1 1 4 7 10 BKP1 BKM2 100A 100 OUT2
ISTB
POWER TO P200 PURGE SOLENOID POWER TO P10 PURGE SOLENOID (OPTION) P200 BYPASS SW I/P POWER I/P SIGNAL FLOW SENSOR POWER AND SIGNAL TRIGGER #1 SIGNAL TRIGGER #2 SIGNAL (OPTION) P10 MAGNET SENSOR DCDC PULSE CODER POWER CONVERTER 24V TO +5V BRAKE POWER (J1J9) BKP1,BKM1=J1,J2,J3 BKP2,BKM2=J4,J5,J6 BKP3,BKM3,BKP4,BKM4=J7,J8,J9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PSA1 PSA2 PSB1 PSB2 FSA1 FSA2 FSB1 FSB2 OT11 OT12 OT21 OT22 OT31 OT32 OT41 OT42 OT51 OT52 HBK1 HBK2 TP1 TP2 EOAT1 EOAT2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
TB
FRA1 FRA2 BKP1 BKM1 BKP2 BKM2 BKP3 BKM3 BKP4 BKM4 SVON2 SVONC SVON1 PG1 PG2 EES1 EES2 SOL1 SOL2
FASTON
FG +24V 0V +24V 0V OFF1 OFF2 BRD1 BRDC BRD2 200A 200B R S
ESTOP PCB
JRV1 JRF2 CRF1
CRM9 CRM11 CRR20 CRR21 CRR22 CRR5 BKP4 BKM4 REFER TO PAGE 003006 AMP ESP (CX4) 100VAC (TF1) 200VAC (TF1) I.S. GND FG I.S. G
ISB13 ISB14 ISB23 ISB24 ISB33 ISB34 ISB41 ISB42 ISB51 ISB UNITS ISB52 ISB61 ISB62 ISB64 ISB71 ISB72 ISB81 ISB82 ISB94 ISB96
BATTERY UNIT 1+ 1 2+ 2 3 3 4+ 4 5 5 6+ 6 +6V ISG
PULSE CODER BATTERY
EE-3287-500-13
12. SCHEMATICS
1226 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1227
Figure 1213. R-J2 P-200 Controller Total Circuit Diagram (Purge Wiring Diagram)
PURGE CONTROL PCB A16B13100601 PARTIAL SCHEMATIC (SEE SHEET 12)
TPDSC1 PS PGCP PGFLT PG TPDSC2 PGEN1 CNPG 1 2 3 4 5 6 7 CR1A CR3 8 11 12 13 CR1B 14 15 16 17 +24E CR8 CR7B CR7B CNCA 18 19 20 34 04 13 15 16 6 17 23 R16 R17 R18 FRA1 TB 1 FIRE ALARM SVON2 SVONC SVON1 PG1 PG2 CR5A CR5A CR6 CR2A (PURGING) SH1A 0V CR2A CR2B0V 0V CR5A CR5B R7 100 C1 33OuF CR6 CR7A CR7B 0V RDI5 R3:0 PURGE CR3 FAULT R4:0 CR2A TR1 R5:0 R6:0 CR1A CR1A CR1B 0V TR1 (PURGE 0V COMPLETE) R1:0 CNIS 1 2 3 0V 0V CR1A 4 CR4 5 0V 6 +24P 7 8 +24E 9 10 11 12 13 14 15 16 17 18 19 *HBK EOAT RDI8 +24E A5 C5 A6 C6 220VAC 0V EOAT SWITCH FG G TPDSC SWITCH TPDSC2 +24P BKRA A4 C4 HBK SWITCH A3 C3 ROT SWITCH P3 N3 P4 N4 P5 N5 P6 N6 8 1 KA6 0V 4 2 0V 1 STAHL ISB1 9001/0125210014 + 3 4 2 +3 1 ISB2 * SEE NOTE 4 2 8 ISB9 P&F SENSOR 7 9 S1 I X II 1 11 LEAD X II S2 I 2 BROKEN S3 I X 10 II 3 12 14 +24V KFD2-SR2-Ex1.W.LB USED WITH 7+3 VERSION 15 120VAC FROM CONVEYOR
DELTRON 24V POWER SUPPLY EE3112600
IDEC IBRC 6062RFM RELAY BARRIER

PS1A TPDSC1 FS1A FS1B SVON 8 KA5 1 0V A1 C1 A2 C2 FLOW SWITCH PRESSURE SWITCH P1 N1 P2 N2
ISTB
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1PSA1 PS VIA 1PSA2 PURGE CBL PSB1 PSB2 5FSA1 6FSA2 FSB1 FSB2 OT11 FS VIA PURGE CBL
3 2 KA5
PGEN2 0V OFF1 OFF2 BKRL1 BKRL2 OFF1 OFF2 BRD1 BRDC BRD2 *HBK RDI2 RDI8 +24E RDI1 (BKRL) RDI5 RDI3 RDI4 RDI6 RDI7 RDO1 TO IDEC 24V P.S. A20B10000472 200A 200B R S G FG +24P 0V TO OP EMG1 PANEL EMG2
OTS NOT USED
OT52 19HBK1 FROM PURGE CABLE 20HBK2
TP1 TP2 23 EOAT1 24 EOAT2 3 3 0V
RDI3 20 RDI4 21
RDI7 22 23 RLA 24 0V 25 0V CNCR 15 17
5 KA6 ISB13 P200 PURGE SOL 6 ISB14 OPENER PURGE SOLENOID
PGTB 1 2 3 4 5 6
24PG 0PG SVON *ROT PGC1 PGC2
FROM P10 OR P15 SENSOR VIA P10 OR P15 PURGE CABLE

S1 = I FOR OPEN SW = DE-ENERGIZED S2 = II FOR LEAD BREAKAGE ON 10-11-12 S3 = I FOR NAMUR INPUT
* BARRIER NOTE: FOR P-200-6 OR -7 THIS BARRIER NOT MOUNTED FOR P-200 +2 VERSIONS THIS BARRIER IS STAHL 9001/01-280-165-10 FOR P-200 +3 (P-10, P-15) THIS BARRIER IS STAHL 9001/01-252-100-14 TRIGGER, I/P, FLOWMETER PROCESS PKG EE-3287-510 DUAL TRIGGER, I/P,
+24 24V OVP
FRA2 2 TERM 810 ON SHEET 12 CR4 11 12 CR4 +24P 0V CNIN 11 12 (PURGE COMPLETE) CR5B CR1B 13 14 15 EES1 16 EES2 17 0V +24P 18 CR2B D7 0V 19
SOL1 SOL2
7 S1 I X II 8 II S2 I X TO 10 X II S3 I SYS 11 ISB3 P&F ISRR 14+24 KFD2-SR2-Ex1.W.LB 15 7 II S1 I X TO 8 II S2 I X SYS 10 X II S3 I 11 ISB10 14+24 P&F ISRR KFD2-SR2-Ex1.W.LB 15 7 ISB4 P&F FROM P-200 I/O 8 9 + ISB5 FROM P-200 I/O 10 P&F BARRIER 7 +24 8 8 7 ISB6 TO P-200 I/O SIG 5 P&F BARRIER 6 8+ ISB7 P&F BARRIER FROM P-200 I/O 7 8+ P&F BARRIER ISB8 FROM P-200 I/O 7 SEE APPLICATION PACKAGE FOR WIRING DETAILS
1 2 3
ISB31 P200 BYPASS SW ISB33 FROM PURGE CABLE
1 2 3 +1 2 +1 2 + 1 2 + 4 3 +1 2 +1 2
EOAT5 P10 OR P15 BYPASS SWITCH EOAT6 FROM PURGE CABLE ISB41 ISB42 ISB51 ISB52 I/P POWER VIA PURGE CABLE I/P SIGNAL VIA PURGE CABLE
ISB61 24V POWER FLOW METER ISB62 0V VIA PURGE CABLE ISB64 SIGNAL
FLOWMETER PROCESS ISB71 TRIGGER ONE SIGNAL PKG EE-3287-511 ISB72 VIA PURGE CABLE ISB81 TRIGGER TWO SIGNAL ISB82 VIA PURGE CABLE NOTE: SEE PROCESS PACKAGES FOR BARRIER TYPES
EE-3287-500-014
12. SCHEMATICS
1228 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1229
Figure 1214. R-J2 P-200 Controller Total Circuit Diagram (Purge Board Details)
BRAKE RELEASE BKRL1
PURGE CONTROL PCB A16B13100601

CNPG 16 +24E 17 9 SH1A CNIS 8 01 02 03 04 05 06 07 TPDSC1 PGCP PGFLT PG TPDSC2 PGEN1 08 09 10 11 12 13
CNPG (TO PANEL)

PGEN2 14 15 16 17 18 19 20 OFF1 OFF2 BKRL1 BKRL2
TB
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 FRA1 FRA2 BKP1 BKM1 BKP2 BKM2 BKP3 BKM3 BKP4 BKM4 SVON2 SVONC SVON1 PG1 PG2 EES1 EES2 SOL1 SOL2
LED
01 02 +24V 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
ISTB
PSA1 PSA2 PSB1 PSB2 FSA1 FSA2 FSB1 FSB2 OT11 OT12 OT21 OT22 OT31 OT32 OT41 OT42 OT51 OT52 HBK1 HBK2 TP1 TP2 EOAT1 EOAT2
BKRL2 CNIN 11 12 16 17 EES2 CR8 CR5A CR6 CR5B R7 100 C1 33OuF CR6 CR7A CR7B CR7B 0V CR7B BRD1 BRDC BRD2 CR5A CR5B
EMG1 EMG2 EES1
0V 0V 0V
CNIS (TO IBRC)

01 02 03 04 05 06 07 08 09 J1, J2 BKM1 BKP2 J3, J7 BKM2 BKP3 J4, J5 BKM3 BKP4 J6 BKM4 01 02 03 04 05 06 07 08 09 10 11 12 PS1A TPDSC1 FS1A FS1B SVON TPDSC2 +24P BKRA BKRB 10 11 12 13 14 15 16 *HBK EOAT RDI8 +24E 17 18 19 20 21 22 23 24 25
RDI5 RDI3 RDI4 RDI7 RLA 0V
FG
BKP1 BKM1 BKP2 BKM2 BKP3 BKM3 100OUT1 100OUT2 100A FROM XFMR 100B
CNIN 1 2 3 4 5 6 9 CR8 10 7 8 CR7A CR7A DS1
TB 3 4 5 6 7 8 9 10
BKP1
CNCA (TO MAIN CPU)

13 14 15 16 17 18 19 20 21 22 RDI5 RDI3 RDI4 RDI7 *HBK RDI2 RDI8 23 24 25 26 27 28 29 30 31 32 33 34 RDO1 01 02 03 04 05 06
PGTB
24PG OPG SVON *ROT PGC1 PGC2
RDI1
D4 CR7B
D5
D6
CNIN (BRAKE)
3 BKP2 6 BKM3 9 100OUT1 12 EMG2 2 BKM1 5 BKP3 8 100B 11 EMG1 1 BKP1 4 BKM2 7 100A 10 100OUT2
+24E
EE-3287-500-015
12. SCHEMATICS
1230 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1231
Figure 1215. R-J2 P-200 Controller Total Circuit Diagram (ESTOP Wiring Detail)
+24V JRM10 CNOP
OPERATOR PANEL
+24V
(12) (3) (16) (10) (11)
(CRS1)
DEADMAN
RJ2 MAIN CPU

KA1 EXEMG RV 0V 0V +24V 0V KA2 PANEL ESTOP
ENABLE/ DISABLE
EMERGENCY CIRCUIT
ISB I.S. TEACH PENDANT

CNPG PURGE BOARD CR5 24V CR7 CR5 CR6 CR5 11 12 CR8 FROM XFMR (TBOP1) 100A CR7 100B CR7 BK1 BK4 BRAKE OPTIONAL EXT ESTOP
TPEMG OPEMG
RV RV 0V 0V 0V KA4 +24V
FENCE1 FENCE2 ESTOP1 ESTOP2 EMGIN1 EMGIN2 SVON1 SVON2 EMGOUT1 EMGOUTC EMGOUT2
CNIN (TBOP1)
EES1 EES2
ROBOT MECHANICAL UNIT

PULSE CODER
SVON
RV 0V
MOTOR
RV. RECEIVER FOR DI JRV1 AXES CONTROL * BRAKON#1 * BRKALM HBKREL ROT OTREL OTRST RDICOM BRAKON#2 * 0V CRM16 BRKON#4 BRKON#3 BRK3 +24E RV +24E RV JRF2 JRV1 DRDY EMERGENCY STOP PWMA/C/E, ENBL IS,GRDS,IR,GNDR MCON BRK1 +24E BRKON#1 BRKALM PD16/ PD16 PREQ16/ PREQ16 +5V,0V +24E HBKREL ROT OTREL OTRST +24E B RDICOM A BRKON#2 SVON 0V
CONTROL PCB
LOGIC FOR AMPLIFIER
JS1 JS2 JS3 JS4 JS5 JS6 CRF1
TO MOTOR PULSE CODER (I/F IS SAME AS RJ)
0V HBKREL OTREL ROT
+24E
CRM11
ROTIN DIL1 0V RLOT/HBK DIL2 0V SVOUT MCCON RLEMG 0V CRR22 BRK13 CRR5 OPTION EE-3287-401 1 2 MCCOFF4 CRM9 ESP CX3 MCCOFF3 CONTROL CIRCUIT MCCOFF4 CX3 ESP MCCOFF3 CONTROL CIRCUIT CRM15 DOOR INTERLOCK CX4 +24V SVU +24V SVU CX4 +24V
BRK2 +24E 0V
100A
100A CRR21
BRK4 BRK57
POWER TRANSFORMER
100B
100B
0V
BRAKE CONTROL CIRCUIT
200R 200S 200T AC POWER INPUT DC POWER SUPPLY ON/OFF CONTROL
200R 200S 200T AC1 AC2 AC3 CRR15
CRR20
CRR15
MCC
200A 200B
EE-3287-500-016
12. SCHEMATICS
1232 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1233
Figure 1216. R-J2 P-200 Controller Total Circuit Diagram (OP Panel Details)
OPERATOR PANEL
FROM MAIN CPU (JRM3)
OPERATOR PANEL
(CNOP) TXTP * TXTP RXTP * RXTP
PDIO
(CRT3) (12) (13) (14) (15) (16) (17) (18) (20) (1) (3) (4) (5) (6) (7) (8)
+24V LED1: REMOTE SW4: CSTART SW6: HOLD LED2: FRESET LED1: BATTERY
(1) (2) (3) (4) +24V 0V
(1) (14) (2) (15) (6,7) (17,19) (1) (2) (3) (4) (5) (6) (20) (25) (7) (1)
(CRS1) TXTP *TXTP RXTP TO TEACH PENDANT *RXTP +24V 0V FG (PORT1) TXD1 RXD1 RTS1 CTS1 DSR1 DTR1 +24V 0V FG
TXD1 RXD1 RTS1 CTS1 DSR1 DTR1 +24V (NOTE 1) 0V +24V: CNOP19, 27 28, 37, 38 (NOTE 2) 0V: CNOP11, 13, 15, 17, 20, 29, 31, 39, 41, 43, 45, 47,49 TXDA RXDA RTSA CTSA DSRA DTRA
(18) (16) (14) (12) (32) (30) (NOTE 1) (NOTE 2) +24V +24V 0V
PDO1 PDO2 PDO3 PDO4 PDO5 PDO6 PDO7 PDO8 PDI1 PDI2 PDI3 PDI4 PDI5 PDI6 PDI7
(NOT USED) (NOT USED) LED3: TP ENABLE (NOT USED) FRESET REMOTE HOLD USER PB1 (PGEN) (USER PB 2) (ON) CY START SW1: ON LED4 LED5 SW7 SW8 SW7 +24V (12) (3) (16) (10) (11) (6,7) (18) (CRS1)
RS232C TPOFF +24V 0V (9) (10,19) +24V (2,11) 0V 0V
(CNPG) PGCP PGFLT PG BKRL1 BKRL2 PGEN1 PGEN2 TPDSC1 TPDSC2
0V
(50) (48) (46) (44) (42) (40) +24V 0V
(2) (3) (4) (5) (6) (20) (25) (7) (1) (14) (15) (16) (17)
(PORT2) TXD1 RXD1 RTS1 CTS1 RS232C DSR1 DTR1 +24V 0V FG TX485A * TX485A RX485A * RX485A
FROM MAIN CPU EMGDM EMGEN EMGB1 EMGB2
(JRM10) (5) (6) (7) (8) KA1 +24V 0V KA2 0V KA3
TX485A *TX485A RX485A *RX485A
(36) (35) (34) (33)
FENCE1 FENCE2 ESTOP1 ESTOP2 TPEMG OPEMG (10) (24) KA4 0V +24V EMGIN1 EMGIN2 SVON1 SVON2
(TBOP1)
TO BRAKE/PURGE BD
FG EXEMG SVON (26) (25)
EMGOUT1 EMGOUTC EMGOUT2 +24V 0V (1) (2) (3)
(TBOP1)
(CNHM) HM1
HOUR METER 1 2 3
SW1: ON ON COM OFF (21) (22) (23) SW2: OFF EXON1 EXCOM EXOFF1 (TBOP2)
(CNPG) OFF1 OFF2
EE-3287-500-017
12. SCHEMATICS
1234 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1235
Figure 1217. R-J2 P-200 Controller Total Circuit Diagram (Operator Panel)
JRM10 (MAIN CPU I/F) HONDA PCR50 MALE

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 0V CTS1 0V DSR1 0V RXD1 0V CTSA 0V DSRA 0V RXDA RXTP RXTP TX485A RX485A 0V 0V +24V +24V +24V +24V +24V EMGB1 EMGB2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 0V RTS1 0V DTR1 0V TXD1 0V RTSA 0V DTRA 0V TXDA TXTP TXTP RX485A TX485A ON OFF COM OPEMG EXEMG EMGDM EMGEN TPEMG SVON 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 RX485A RX485 TX485A TX485 24V 24V 0V DTRA 0V DSRA 0V CTSA 0V RTSA 0V RXDA 0V TXDA
CNOP OPERATOR PANEL I/F (M)

19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 TXTP TXTP RXTP RXTP EMGDM EMGEN EMGB1 EMGB2 TPEMG 0V CTS1 0V RTS1 0V RXD1 0V TXD1 01 02 03 04 05 06 07 08 09 10 11 12 13
24V 0V ON COM OFF OPEMG SVON EXEMG 24V 24V 0V DTR1 0V DSR1
FG TXD1 RXD1 RTS1 CTS1 DSR1 0V
PORT1 (RS232C: PORT1) DSUB 25P FEMALE

14 15 16 17 18 19 20 21 22 23 24 25
DTR1
+24V
01 02 03 04 05 06 07 08 09 10 11 12 13
FG TXDA RXDA RTSA CTSA DSRA 0V
PORT2 (RS232C: PORT2) DSUB 25P FEMALE

14 15 16 17 18 19 20 21 22 23 24 25
DTRA
+24V
THIS CONNECTOR IS MOUNTED ON EXTERNAL SIDE OF THE BOX
THIS CONNECTOR IS OPTION THIS CONNECTOR IS MOUNTED ON INTERNAL SIDE OF THE BOX
JRM3 (MAIN CPU I/F) HONDA PCRE20 MALE

11 12 13 14 15 16 17 18 19 20 0V PDO1 PDO2 PDO3 PDO4 PDO5 PDO6 PDO7 +24V PDO8 1 2 3 4 5 6 7 8 9 10 PDI1 0V PDI2 PDI3 PDI4 PDI5 PDI6 PDI7 TPOFF +24V 01 02 03 04 05 06 07 PDI1 0V PDI2 PDI3 PDI4 PDI5 PDI6 08 09 10 11 12 13
PDIO(M) PANEL I/O

PDI7 TPOFF +24V 0V PDO1 PDO2 14 15 16 17 18 19 20 PDO3 PDO4 PDO5 PDO6 PDO7 +24V PDO8 01 02 03 04 05 06 07 TXTP RXTP EMGDM
CRS1 (F) (TEACH PENDANT)

08 09 10 11 12 13 14 15 16 17 18 19 20 TXTP RXTP EMGEN 0V 0V 01 02 03 04 05 06 07 TPDSC1 PGCP PGFLT PG TPDSC2 PGEN1
CNPG (F) (PURGE I/F)

08 09 10 11 12 13 PGEN2 14 15 16 17 18 19 20 OFF1 OFF2 BKRL1 BKRL2
+24T +24T
EMGB1 EMGB2 EMGTP
0V 0V 0V
REMOTE CSTART HOLD FAULT BATTERY
= = = = = = =
PDO1 PDO2 PDO3 PDO4 PDO5 PDO6 PDO7
= FAULT = REMOTE = HOLD = PGEN = ON = CSTART =
PDI1 PDI2 PDI3 PDI4 PDI5 PDI6 PDI7
TBOP1 TERMINAL
01 02 03 04 05 06 07 EMON EMCOM EMOFF EMGIN1 EMGIN2 FENCE1 FENCE2 01 02 03 04 05 06 07
TBOP2 TERMINAL
SVON1 SVON2 ESTOP1 ESTOP2 EMGOUT1 EMGOUTC EMGOUT2
CNHM HOUR METER

01 02 03 24V 0V SVON
OPERATOR PANEL
EE-3287-500-018
12. SCHEMATICS
1236 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1237
Figure 1218. R-J2 Controller P-200 Amplifier Configurations
P155/P200 CONVERSION
SYSTEM RJ2
PURGE CONTROL UNIT
BOM EE3287500001 AMP #

P200 6 AXES CONTROL AMP SPEC.
AMP1
SVU212/80 L(12A)= J4 M(80A)= J1 A06B6089H209
AMP2
SVU212/80 L(12A)= J5 M(80A)= J3 A06B6089H209
AMP3
SVU112 J6 A06B6089H101
AMP4
SVU1130 J2 A06B6089H106

AMP 1 ON AMP 2 ON AMP 3 ON
BOM EE3287500002
OFF FANUC AC SERVO AMPLIFIER C series OFF FANUC AC SERVO AMPLIFIER C series OFF FANUC AC SERVO AMPLIFIER C series
DISCONNECT
AMP #
P200 7 AXES CONTROL AMP SPEC.
AMP1
AMP2
AMP3
AMP4
SVU212/80 SVU212/80 L(12A)=J4 L(12A)=J5 M(80A)=J1 M(80A)=J3 A06B6089H209 A06B6089H209
SVU212/80 SVU1130 L(12A)=J6 J2 M(80A)=J7 A06B6089H209 A06B6089H106
I/O RACK
BOM EE3287500003 AMP #

P200 6+2 (DOOR OPENER) AXES CONTROL AMP SPEC.
AMP1
AMP2
AMP3
AMP4
AMP5
SVU212/12 L(12A)=J7 M(12A)=J8 A06B6089H201
ISB UNIT 1 0 BATTERY PACK AMP 4 GRN/YEL 14 AWG. TO ISB GND BAR
STATUS
1W X 4H DUCT
EMG BOARD
FANUC AC SERVO AMPLIFIERS
MAIN PSU CPU OPT
SVU212/80 L(12A)=J4 M(80A)=J1 A06B6089H209
SVU212/80 SVU112 SVU1130 J2 L(12A)=J5 J6 M(80A)=J3 A06B6089H209 A06B6089H101 A06B6089H106
BOM EE3287500004 AMP #

P200 6+2 (HOODDECK) AXES CONTROL AMP SPEC.
AMP1
AMP2
AMP3
AMP4
AMP5
SVU280/80 L(80A)=J7 M(80A)=J8 A06B6089H208
AMP 5 8
SVU212/80 SVU212/80 SVU112 SVU1130 L(12A)=J4 L(12A)=J5 J6 J2 M(80A)=J1 M(80A)=J3 A06B6089H209 A06B6089H209 A06B6089H101 A06B6089H106
BOM EE3287500005 AMP # 1 1/2 W X 4H DUCT

P200 7+2 (DOOR OPENER) AXES CONTROL AMP SPEC.
AMP1
AMP2
AMP3
AMP4
SVU1130 J2
AMP5
SVU212/12 L(12A)= J8 M(80A)= J9
SVU212/80 SVU212/80 L(12A)= J5 L(12A)=J6 M(80A)= J7 M(80A)=J3 A06B6089H209 A06B6089H209 A06B6089H209
SVU212/80 L(12A)=J4 M(80A)=J1
A06B6089H106 A06B6089H201
BOM EE3287500006 AMP # USER TRANS.

P200 7+2 (HOODDECK) AXES CONTROL AMP SPEC.
AMP1
SVU212/80
AMP2
SVU212/80
AMP3
SVU212/80
AMP4
SVU1130
AMP5
SVU280/80
L(12A)=J6 J2 L(12A)= J8 L(12A)=J4 L(12A)= J5 M(80A)= J7 M(80A)=J1 M(80A)=J3 M(80A)= J9 A06B6089H209 A06B6089H209 A06B6089H209 A06B6089H106 A06B6089H208
CONTROLLER DOOR INSIDE VIEW
CONTROLLER FRONT VIEW
CONTROLLER W/DOOR REMOVED
P200 RJ2 ILLUSTRATED
EE-3287-500-019
12. SCHEMATICS
1238 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1239
Figure 1219. R-J2 Robot Controller Cabinet Layout
PURGE CONTROL UNIT

OVP DELTRON W112A 24V @ 1.2A ISB3 ISB4 ISB5 ISB7 ISB9 ISB6 ISB8
AMP 5
ON
AMP 6
AMP 1
ON ON
AMP 2
ON
AMP 3
ON
OFF FANUC AC SERVO AMPLIFIER
OFF FANUC AC SERVO AMPLIFIER
OFF FANUC AC SERVO AMPLIFIER C series
DISCONNECT
I/O RACK
BOM EE3287500007
1W X 4H DUCT EMG BOARD 1 0
AMP
MAIN PSU CPU OPT
AMP1
SVU212/80 L(12A)=J4 M(80A)=J1 A06B6089H209
AMP2
SVU212/80 L(12A)=J5 M(80A)=J3 A06B6089H209
AMP3
SVU212/80 L(12A)=J6 M(80A)=J7 A06B6089H209
AMP4
SVU1130 J2 A06B6089H106
OPENER SIDE CABINET AMP5 AMP6

SVU180 J8 (RAIL) A06B6089H105 SVU280/80 L(12A)=J9 M(12A)=J10 A06B6089H208
P200 7+3 (OPENER) AXES CONTROL AMP SPEC.
AMP 4
STATUS
1 1/2 W X 4H DUCT
USER TRANS.
CONTROLLER WITH SIDE CABINET SHOWN WITH DOOR REMOVED
EE-3287-500-020
12. SCHEMATICS
1240 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1241
Figure 1220. P-200 R-J2 Controller FM Retrofit Package Cabinet Layout
CABINET LAYOUT
1 WARNING PURGE TIMER SET AT 5 MINUTES MODIFICATION WILL VOID FACTORY MUTUAL RESEARCH CORPORATION APPROVAL
SYSTEM RJ2 PURGE CONTROL UNIT

ON ON ON
OFF FANUC AC SERVO AMPLIFIER C series I.S. GND NOTE
DISCONNECT
I/O RACK AMP 1 AMP 2 AMP 3 1W X 4H DUCT EMG BOARD 1 0

ISB UNIT
MAINPSU CPU
OPT
Factory Mutual System Approved
FOR CONNECTION TO: CLASS I, II & III DIV. 1 GRP. C,D,E,F & G HAZ. LOC.
PER DWG.
EE3287550
STAMP NUMBER AS SHOWN
BATTERY PACK AMP 4

STATUS
2000 SOUTH ADAMS RD. AUBURN HILLS, MI 48326
2 8
GRN/YEL 14 AWG.
TO ISB GND BAR 1 1/2 W X 4H DUCT 3
MODEL P200 RJ2 MADE IN USA SERIAL NO. XXXX ASSEMBLY NO. EO3287XXX
SEE MECHANICAL ASSEMBLY FOR TAG NUMBER. VIEW LOCATED IN CIRCLE A NOTE: ATTACH ALL TAGS WITH PERMANENT TYPE FOAM TAPE OR DRIVE RIVETS. PLACE LABEL OVER ADJUSTMENT SCREW ON PURGE TIMER AFTER MFG. PURGE TESTING.
A 2 USER TRANS.
CONTROLLER DOOR INSIDE VIEW
CONTROLLER FRONT VIEW P200 RJ2 ILLUSTRATED
CONTROLLER W/DOOR REMOVED
EE3287575
12. SCHEMATICS
1242 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1243
NONHAZARDOUS LOCATION (250 VAC MAXIMUM) DELTRON W112A 120VAC 24VDC FROM POWER CONVEYOR SUPPLY INTRINSIC SAFETY BARRIER STAHL 9001/0125210014 1 2 IS GND 1 2 CNPG EMGIN1 EMGIN2 PANEL I/F PURGE CIRCUITS CNPG ISB1 3 4 3 4 HAZARDOUS LOCATION CLASS I, II & III DIVISION 1 GROUPS C D E F & G CONNECTION CABLE EE3287117XXX N1
ISB34 ISB36
OPERATOR PANEL
SOL1 SOL2
BRAKE CONTROL
CNIN FROM I/O
24V I/P SIG 24V
MAIN CPU CRM10 RDI/RDO CNCA
24V TO ACCUFLOW SIG FROM I/O FROM I/O
ISB2 OPTIONAL IS GND 7 4 8 ISB3 6 9 10 KHD2SREX1.2S.P 11+24 P&F 12 7ISB4KFD2SDEX1.36 + 1 2 8 9 + +1 P&F 10 ISB5 7 +24 KHD2CD1.P32 2 8 8 +1 P&F 2 ISB6 Z787 7 +4 5 3 6 8+ ISB7 Z728 P&F 7 8+ ISB8 Z728 P&F 7 +1 2 +1 2
N4
EE3185356001 BYPASS SWITCH
EE3287328001 CBL
I/P
P1 P4
UNIT FLOW METER TRIGGER 1 TRIGGER 2
O1 O4
HAND BRKN
ROBOT WIRE HARNESS SOLENOID CABLE EE3287323001 EE3287348001 M1 M4 SOL SOL PURGE PRES. SW CABLE EE3044345001 PS1 PS1 FLOW SW CABLE EE3044340001 FS1 FS1 EE3287324001 BATT BATT
ENCODER
SOLENOID VALVE ROBOT PRESSURE SWITCH ROBOT FLOW SWITCH
ESTOP PCB
A1 C1
IDEC IBRC6062R PRESSURE SWITCH P1 N1 P2 N2 P3 N3 P4 N4 P5 N5 P6 N6
M1 M4
M1 M4 ISTB 1 PSA1 2 PSA2 3 PSB1 4 PSB2 5 FSA1 6 FSA2 7 FSB1 8 FSB2 9 OT11 10 OT12 11 OT21 12 OT22 13 OT31 14 OT32 15 OT41 16 OT42 17 OT51 18 OT52 19 HBK1 20 HBK2 21 TP1 22 TP2 23 EOAT1 24 EOAT2
CRR21 CRR22
A2 C2 FLOW SWITCH
S1 S4
CRR5 BKP4 BKM4 CNIS SERVO TRANSFORMER FOR PAINT RJ TYPE C4 A5 220 VAC 220V (44) +24P A6 0V C6 MISC. SWITCH (RDI2) C5 A3 C3 A4 HAND BROKEN ROBOT OVERTRAVEL SWITCH
I.S. GND X6 FOR PEDESTAL CABLE ROBOT PURGED CAVITY X7 FOR RAIL EE306611500X OPTIONAL CATRAC CABLE OPTIONAL DOOR OPENER DEVICE (FMRC APPROVED) MODEL QDRQ AK1AK2EE306621500XAK3 AK4 EE3066323001
OPENER SOLENOID
AJ1 AJ2
AJ3
AJ4
EE3066322001
OPENER PRESS SWITCH
AH1 AH2
AH3
AH4
EE3066321001
OPENER FLOW SWITCH
220V (43)
AE1 AE2
AE3
AE4
EE3066316001
ENCODER
I.S. GND
X2
NOTES: 1.)ACCEPTABLE I.S. BATTERY PACKS: A05B2363C040 EE3185551 2.) ALTERNATE I.S. BATTERY PACKS: A05B2072C181 A05B2047C182 SHALL BE USED PER EG00127SECTION VI 3.) I.S. GROUND CONNECTION SHALL BE PER NEC(NFPA 70) SECTION 50450 AND ANSI/ISA RP 12.6 TO CRS1 (MAIN CPU)
I.S. BATTERY PACK
+ P200 RJ2 MODELS MODEL P2006J2 P2007J2 P2006+2J2 P2007+2J2 P2007+3J2
I.S. GND
6 +
MODEL
F1 F2 F3 F4 F5
R AC S
+V 0V G
MODEL MODEL MODEL
I/S GROUND
EE-3287-550-001
12. SCHEMATICS
1244 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1245
NONHAZARDOUS LOCATION (250 VAC MAXIMUM)

120VAC FROM CONVEYOR
DELTRON W112A 24VDC POWER SUPPLY
EE3112600 24V OVP UNIT
INTRINSIC SAFETY BARRIER STAHL 9001/0125210014 1 2 IS GND 1 2 ISB1 3 4 IS GND ISB2 OPTIONAL
ISB34 ISB36
24V
3 4
NOTICE NO REVISIONS WITHOUT PRIOR APPROVAL FROM FACTORY MUTUAL (FM) HAZARDOUS LOCATION CLASS I, II & III DIVISION 1 GROUPS C D E F & G
CONNECTION CABLE EE3287117XXX EE3185356001 BYPASS SWITCH EE3287328001 CBL I/P UNIT
ISB41 ISB42 ISB51 ISB52
OPERATOR PANEL
CNPG EMGIN1 EMGIN2
PANEL I/F
PURGE CIRCUITS CNPG
N1 P1
N4 P4
SOL1 SOL2
BRAKE CONTROL
CNIN
FROM I/O
24V I/P SIG 24V 24V SIG
MAIN CPU
CRM10 RDI/RDO TO ACCUFLOW CNCA
FROM I/O FROM I/O
7 4 8 6 9 ISB3 10 11 +24 KHD2SREX1.2S.P P&F 12 +1 7 8 ISB4 KFD2SDEX1.36 2 9 + +1 10 ISB5 2 P&F 7 +24 KHD2CD1.P32 8 +1 8 P&F 2 7 ISB6 Z787 5 +4 6 3 8 + ISB7 Z728 P&F + 1 7 2 8 + ISB8 Z728 P&F + 1 7 2
FLOW METER TRIGGER 1 TRIGGER 2 HAND BRKN ROBOT WIRE HARNESS SOLENOID CABLE EE3287323001 EE3287348001 M1 M4 PURGE SOL SOL SOLENOID VALVE PRES. SW CABLE EE3044345001 M1 M4 PS1 PS1 ROBOT PRESSURE SWITCH FLOW SW CABLE EE3044340001 M1 M4 FS1 FS1 ROBOT FLOW SWITCH BATT BATT S1 S4 EE3287324001 ENCODER I.S. GND X6 FOR PEDESTAL CABLE ROBOT PURGED CAVITY X7 FOR RAIL EE306711500X OPTIONAL HOOD/DECK OPENER DEVICE OPTIONAL CATRAC CABLE (FMRC APPROVED) MODEL QHDQ AK3 AK4 AK1AK2 EE306721500X EE3066323001 OPENER SOLENOID AJ1 AJ2 AJ3 AJ4 EE3066322001 OPENER PRESS SWITCH OPENER FLOW SWITCH O1 O4
ISB61 ISB62 ISB64 ISB71 ISB72 ISB81 ISB82
ESTOP PCB
A1 C1
IZUMI IBRC6062R PRESSURE SWITCH P1 N1 P2 N2 P3 N3 P4 N4 P5 N5 P6 N6 I.S. GND ISTB 1 PSA1 2 PSA2 3 PSB1 4 PSB2 5 FSA1 6 FSA2 7 FSB1 8 FSB2 9 OT11 10 OT12 11 OT21 12 OT22 13 OT31 14 OT32 15 OT41 16 OT42 17 OT51 18 OT52 19 HBK1 20 HBK2 21 TP1 22 TP2 23EOAT1 24EOAT2
CRR21 CRR22
A2 C2 FLOW SWITCH
CRR5 BKP4 BKM4 CNIS A3 C3 A4 SERVO TRANSFORMER FOR PAINT RJ TYPE C4 A5 220 VAC C5 +24P A6 0V C6 MISC. SWITCH (RDI2) HAND BROKEN ROBOT OVERTRAVEL SWITCH
220V (43) 220V (44)
AH1 AH2
AH3
AH4
EE3066321001
AE1 AE2
AE3
EE3066316001 AE4 ENCODER EE3067317001OT OT OT OT X2 OT OT
NOTES:
1.) ACCEPTABLE I.S. BATTERY PACKS: A05B2363C040 EE3185551 2.) ALTERNATE I.S. BATTERY PACKS: A05B2072C181 A05B2047C182 SHALL BE USED PER EG00127SECTION VI
I.S. BATTERY PACK
+ P200 RJ2 MODELS MODEL P2006J2 P2007J2 P2006+2J2 P2007+2J2 P2007+3J2 TITLE:
6 I.S. GND
+
F1 F2 F3 F4 F5
MODEL MODEL MODEL MODEL
R AC S
+V 0V G
3.) I.S. GROUND CONNECTION SHALL BE PER NEC(NFPA 70) SECTION 50450 I/S AND ANSI/ISA RP 12.6
TO CRS1 (MAIN CPU)
GROUND
EE-3287-550-002
12. SCHEMATICS
1246 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1247
Figure 1223. P-200 R-J2 Control Drawing Purge and Intrinsic Wiring Sheet 3
NONHAZARDOUS LOCATION (250 VAC MAXIMUM)
DELTRON W112A 24VDC 120VAC POWER FROM CONVEYOR SUPPLY
INTRINSIC SAFETY BARRIER STAHL 9001/0125210014 1 2 IS GND 1 2 ISB1 3 4 IS GND 3 4
NOTICE
APPROVAL FROM FACTORY MUTUAL (FM)
NO REVISIONS WITHOUT PRIOR
OPERATOR PANEL
CNPG EMGIN1 EMGIN2
HAZARDOUS LOCATION CLASS I, II & III DIVISION 1 GROUPS C D E F & G

CONNECTION CABLE EE3287117XXX
ISB34 ISB36
PANEL I/F
PURGE CIRCUITS
CNPG SOL1 SOL2
BRAKE CONTROL
CNIN
MAIN CPU
CRM10 RDI/RDO CNCA
24V I/P FROM I/O SIG 24V TO ACCUFLOW24V SIG FROM I/O FROM I/O TO I/O +24V
ISB2 OPTIONAL 7 4 8 ISB3 6 9 10 KHD2SREX1.2S.P 11+24 P&F 12 7 ISB4 KFD2SDEX1.36 + 1 8 2 9 + +1 P&F 10 ISB5 2 7 +24 KHD2CD1.P32 8 8 +1 P&F 7 2 ISB6 5 +4 Z787 3 6 8 + ISB7 Z728 P&F +1 7 2 8+ +1 7 2 ISB8 Z728 P&F 8 +4 7 P&F 9 6 11 +24V 12 ISB9 KHD2SREX1.P
N1 N4 EE3185356001 BYPASS SWITCH P1 P4
EE3287328001 CBL
I/P UNIT FLOW METER TRIGGER 1 TRIGGER 2
O1 O4 ROBOT WIRE HARNESS SOLENOID CABLE EE3287323001 EE3287348001 M1 M4 PURGE SOL SOL M1 M4
HAND BRKN
ESTOP PCB
A1 C1
IDEC IBRC6062R
PRESSURE SWITCH
PRES. SW CABLE EE3044345001 PS1 ROBOT PS1
SOLENOID VALVE
P1 N1 P2 N2 P3 N3 P4 N4 P5 N5 P6 N6 I.S. GND ISTB 1 PSA1 2 PSA2 3 PSB1 4 PSB2 5 FSA1 6 FSA2 7 FSB1 8 FSB2 9 OT11 10 OT12 11 OT21 12 OT22 13 OT31 14 OT32 15 OT41 16 OT42 17 OT51 18 OT52 19 HBK1 20 HBK2 21 TP1 22 TP2 23 EOAT1 24 EOAT2 M1 M4 S1 S4 I.S. GND EE31861151XX AG1 AK1
FLOW SW CABLE SWITCH EE3044340001 FS1 FS1 ROBOT

FLOW SWITCH
PRESSURE
CRR21 CRR22 CRR5 BKP4 BKM4 CNIS SERVO TRANSFORMER FOR PAINT RJ2 TYPE 220V (43) 220V (44)
A2 C2 A3 C3 A4 C4 A5 220 VAC +24P 0V C5 A6 C6 HAND BROKEN FLOW SWITCH
EE3287324001 BATT BATT

ENCODER
ROBOT PURGED CAVITY
X6 FOR PEDESTAL X7 FOR RAIL
ROBOT OVERTRAVEL SWITCH
OPTIONAL P10 DOOR OPENER DEVICE AG4 AK4
DOOR SENSOR OPENER SOLENOID
AJ1
AJ4
TP DISCONNECT SWITCH MISC. SWITCH (RDI2)
OPENER PRESS SWITCH OPENER FLOW SWITCH ENCODER
AH1 AL1 AM1 AN1
AH4
R S
AC
+V 0V G
NOTES: 1.)ACCEPTABLE I.S. BATTERY PACKS: A05B2363C040 EE3185551 2.) ALTERNATE I.S. BATTERY PACKS: A05B2072C181 A05B2047C182 SHALL BE USED PER EG00127SECTION VI
3.) I.S. GROUND CONNECTION SHALL BE
X3
I.S. BATTERY PACK
1+ P200 RJ2 MODELS 6 +

F1 F2 F3 F4 F5
I.S. GND I/S GROUND ISB UNIT A05B2308C370 I/S TEACH PENDANT A05B2308C300 FRAME GND.
PER NEC(NFPA 70) SECTION 50450 AND ANSI/ISA RP 12.6

TO CRS1 (MAIN CPU)
MODEL MODEL MODEL MODEL MODEL
P2006J2 P2007J2 P2006+2J2 P2007+2J2 P2007+3J2
EE-3287-550-003
12. SCHEMATICS
1248 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1249
Figure 1224. P-200 R-J2 Pedestal North American Purge, No PGS (Seal Off Reqd) Cable Layout
CONNECTION CABLE SETS W/O PG UPPER LEVEL BOMS 6 AXIS ROBOT HARNESS AND CABLE LAYOUT BATTERY IN CONTROLLER UPPER LEVEL BILL OF MATERIAL EE3287301011 ROBOT ARM
A1 A4 B1 B4 PULSE BAT MODEL a 0.5 POWER BRK AXIS 6 A06B0113B078/0008
RJ2 CONTROLLER
AMP 1 AMP 2 AMP 3 (L) (L) (L) AXIS 4 AXIS 5 AXIS 6
EE3287100 005 EE3287100 010 EE3287100 015 EE3287100 025
5M 10M 15M 25M
EE3287100 035 35M EE3287100 045 45M EE3287100 055 55M
4 4 4 6
SEAL OFFS USED WITH NA PEDESTAL (NO PG FITTINGS)
T14107
PURGE BD (BK) BRAKES
MOTOR 13.5MM EE3287111 005 EE3287111 010 EE3287111 015 EE3287111 025 EE3287111 035 EE3287111 045 EE3287111 055
C1 C4 EMG BD AUX AXIS BD CRF1 JF7 CABLE CLAMP SHIELD TO CHASSIS GROUND T14685 PULSE 19.8MM EE3287113005 EE3287113010 EE3287113015 EE3287113025 EE3287113035 EE3287113045 EE3287113055 F1 D1 D4 E1 EE3287322001 AXIS 4, 5 & 6 PWR & PULSE HARNESS EE3044401
OUTER ARM GROUND
PULSE BAT MODEL a 2/3000 POWER BRK AXIS 5 A06B0373B175
PULSE BAT MODEL a 2/3000 POWER BRK AXIS 4 A06B0373B175
PURGE UNIT PGTB
24PG, 0PG 3
INNER ARM GROUND
PULSE & BATT MODELa 12/3000 POWER & BRK AXIS 3 A06B0143B175/0008
DC/DC CONVERTER H1 H4 AMP 1 AMP 4 (M) (M) AXIS 1 AXIS 2 BRAKES 4 12 4 T14379 MOTOR 21.0MM EE3287110 005 EE3287110 010 EE3287110 015 EE3287110 025 EE3287110 035 EE3287110 045 EE3287110 055 J1 J4 TURRET GROUND PULSE & BATT MODEL a 22/3000 POWER & BRK AXIS 2 A06B0148B675
PURGE BD (BK)
EE3287321001 AXIS 1, 2 & 3 PWR & PULSE HARNESS K1 K4 L1
AMP 2
AXIS 3 NOT USED
PULSE & BATT MODEL a 6/3000 POWER & BRK AXIS 1 A06B0128B175
8 8 4
T14379
MOTOR 21.0MM EE3287112005 EE3287112010 EE3287112015 EE3287112025 EE3287112035 EE3287112045 EE3287112055
CONTROLLER GROUND TO ISTB TO ISB1 TO ISB3 TO ISB4 TO ISB5 TO ISB6 TO ISB7 TO ISB8 TO ISTB FS/PS SOL BYPASS I/P POWER I/P SIG FLOW MTR TRIG 1 TRIG 2 HBK BATTERY BATTERY BATTERY BATTERY 4 2 2 2 2 3 2 2 2 2 2 2 2 I.S. GND CONNECT SHIELD TO IS GND T14685
GND 6.9MM EE3287116005 EE3287116010 EE3287116015 EE3287116017 EE3287116035 EE3287116045 EE3287116055
SOL1 M1 M4 N1 O1 BYPASS OPTIONAL BYPASS SW EE3185356001 EE3287323001 INTRINSIC DEVICE HARNESS PS1 FS1
EE3287348001 EE3044345001 EE3287340001
SOL1 PS1 FS1
GROUNDING OF NONIS SHIELDED CABLE AT CONTROLLER ENTRANCE
50MM
GND CLAMP CABLE
INTRINSIC 20.5MM EE3287117005 EE3287117010 EE3287117015 EE3287117017 EE3287117035 EE3287117045 EE3287117055 EE3287117030 EE3287117033
P1 R1 S1
P4
CABLE SHIELD
S4
EE3287324001 INTRINSIC BATTERY HARNESS AXIS 16 OPTIONAL PG11 I/P EE3287328001 PG29 TRIG TRIG2 FLOW I/P PROPORTIONAIR TRIGGER TRIGGER FLOW METER
HND BROKEN
EE-3287-001
12. SCHEMATICS
1250 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1251
Figure 1225. P-200 R-J2 Rail Robot North American Purge, PGS For Penetration Plate Cable Layout
CONNECTION CABLE SETS W/ (2) PG UPPER LEVEL BOMS RJ2 CONTROLLER
EE3287102105 5M EE3287102110 10M EE3287102115 15M EE3287102125 25M EE3287102135 35M EE3287102145 45M EE3287102155 55M 4 4 4 6 T14107 MOTOR 13.5MM EE3287111105 EE3287111110 EE3287111115 EE3287111125 EE3287111135 EE3287111145 EE3287111155
7 AXIS ROBOT HARNESS AND CABLE LAYOUT BATTERY IN CONTROLLER, NA PURGE UPPER LEVEL BILL OF MATERIAL EE3287302011 ROBOT ARM
A1 A4 B1 B4 PG 29 PULSE BAT MODEL a 0.5 POWER BRK AXIS 6 A06B0113B078/0008
AMP 1 AMP 2 AMP 3
(L) (L) (L)
AXIS 4 AXIS 5 AXIS 6 BRAKES
PURGE BD (BK)
OUTER ARM GROUND C1 C4
PULSE BAT MODEL a 2 /3000 POWER BRK AXIS 5 A06B0373B175
EMG BD AUX AXIS BD
CRF1 JF7 CABLE CLAMP SHIELD TO CHASSIS GROUND
T14685
24PG, 0PG PURGE BD PGTB 3
F1
EE3044401
PULSE 19.8MM EE3287113105 EE3287113110 EE3287113115 EE3287113125 EE3287113135 EE3287113145 EE3287113155
D1 D4 E1 PG 29 EE3287322001 AXIS 4, 5 & 6 PWR & PULSE HARNESS PULSE BAT MODEL a 2 /3000 POWER BRK AXIS 4 A06B0373B175
INNER ARM GROUND
PULSE & BATT MODEL a 12/3000 POWER & BRK AXIS 3 A06B0143B175/0008
DC/DC CONVERTER H1 H4 AMP 1 AMP 4 (M) (M) AXIS 1 AXIS 2 BRAKES 8 8 4 T14379 MOTOR 21.0MM EE3287110105 EE3287110 110 EE3287110 115 EE3287110 125 EE3287110 135 EE3287110 145 EE3287110 155 J1 J4 PG 29 TURRET GROUND PULSE & BATT MODEL a 22 /3000 POWER & BRK AXIS 2 A06B0148B675
PURGE BD (BK)
EE3287321001 AXIS 1, 2 & 3 PWR & PULSE HARNESS K1 K4 L1 PG 29 EE3185316001 EE3287339001
PULSE & BATT MODEL a 6 /3000 POWER & BRK AXIS 1 A06B0128B175
AMP 2 AMP 3
(M) (M)
AXIS 3 AXIS 7 BRAKES
8 8 4
T14379
PURGE UNIT
21.0MM MOTOR EE3287112 105 EE3287112 110 EE3287112 115 EE3287112 125 EE3287112 135 EE3287112 145 EE3287112 155
PULSE & BATT MODEL a 12 /3000 POWER & BK AXIS 7 A06B0143B175/0008
CONTROLLER GROUND
TO ISTB TO ISB1 TO ISB3 TO ISB4 TO ISB5 TO ISB6 TO ISB7 TO ISB8 TO ISTB
FS/PS SOL BYPASS I/P POWER I/P SIG FLOW MTR TRIG 1 TRIG 2 HBK BATTERY BATTERY BATTERY BATTERY
4 2 2 2 2 3 2 2 2 2 2 2 2 I.S. GND CONNECT SHIELD TO IS GND
GND 6.9MM EE3287116 105 EE3287116 110 EE3287116 115 EE3287116 125 EE3287116 135 EE3287116 145 EE3287116 155
PG 9 SOL1 M1 N1 O1 M4 BYPASS OPTIONAL BYPASS SW EE3185356001 EE3287323001 INTRINSIC DEVICE HARNESS PS1 FS1 EE32873480001 EE3044345001 EE3287340001 SOL1 PS1 FS1
T14685
INTRINSIC 20.5MM EE3287117 005 EE3287117 010 EE3287117 015 EE3287117 017 EE3287117 035 EE3287117 045 EE3287117 055 EE3287117 030 EE3287117 033
P1 PG29 R1 S1
P4 R4 S4 EE3185344001 EE3287324001 INTRINSIC BATTERY HARNESS AXIS 16 OPTIONAL PG11 I/P I/P PROPORTIONAIR TRIGGER TRIGGER FLOW METER
HND BROKEN
NONHAZARDOUS
HAZARDOUS
EE3287328001 PG29
TRIG TRIG2 FLOW
EE-3287-002
12. SCHEMATICS
1252 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1253
Figure 1226. P-200 R-J2 Pedestal Robot PTB Purge, PGS For Penetration Plate Cable Layout
CONNECTION CABLE SETS W/ 2 PG UPPER LEVEL BOMS
EE3287102 105 EE3287102 110 EE3287102 115 EE3287102 125 EE3287102 135 EE3287102 145 EE3287102 155 T14107 MOTOR 13.5MM EE3287111105 EE3287111110 EE3287111115 EE3287111125 EE3287111135 EE3287111145 EE3287111155 5M 10M 15M 25M 35M 45M 55M
RJ2 CONTROLLER
AMP 1 (L) AMP 2 (L) AMP 3 (L) AXIS 4 AXIS 5 AXIS 6
BOOTH WALL
A1 A4 B1 B4 PG29
6 AXIS ROBOT HARNESS AND CABLE LAYOUT BATTERY IN CONTROLLER, PTB PURGE UPPER LEVEL BILL OF MATERIAL EE3287303011 ROBOT ARM
4 4 4 6
PULSE BAT MODELa 0.5 POWER BRK AXIS 6 A06B0113B078/0008 EE3185601 EE3185602 C4 D4 EE3287322001 AXIS 4, 5 & 6 PWR & PULSE HARNESS PULSE BAT MODEL a 2 POWER BRK AXIS 4 A06B0373B175 OUTER ARM GROUND
C1 EMG BD AUX AXIS BD CRF1 JF7 CLAMP SHIELD TO CHASSIS GROUND T14685 PULSE 19.8MM EE3287113 105 EE3287113 110 EE3287113 115 125 EE3287113 EE3287113 135 EE3287113 145 EE3287113 155 D1 PG29 E1
C3 D3
PULSE BAT MODEL a 2 POWER BRK AXIS 5 A06B0373B175
F1
EE3044401
PURGE UNIT PGTB
24PG, 0PG
INNER ARM GROUND
PULSE & BATT MODELa 12 POWER & BRK AXIS 3 A06B0143B175/0008
DC/DC CONVERTER H1 H4 AMP 1 (M) AMP 4 (M) AXIS 1 AXIS 2 4 12 4 T14379 MOTOR 21.0MM EE3287110 105 EE3287110 110 EE3287110 115 EE3287110 125 EE3287110 135 EE3287110 145 EE3287110 155 J1 J4 PG29 TURRET GROUND PULSE & BATT MODELa 22 POWER & BRK AXIS 2 A06B0148B675
EE3287321001 AXIS 1, 2 & 3 PWR & PULSE HARNESS K1 K4 L1 PG29
PULSE & BATT MODELa 6 POWER & BRK AXIS 1 A06B0128B175
AMP 2 (M) AMP 3 (M)
AXIS 3 AXIS 7
8 8 4
T14379
MOTOR 21.0MM EE3287112 105 EE3287112 110 EE3287112 115 EE3287112 125 EE3287112 135 EE3287112 145 EE3287112 155

CONTROLLER GROUND TO ISTB TO ISB1 TO ISB3 TO ISB4 TO ISB5 FS/PS SOL BYPASS I/P POWER I/P SIG 4 2 2 2 2 3 2 2 2 2 2 2 2 PG11 I/P I.S. GND CONNECT SHIELD TO IS GND GND 6.9MM EE3287116 105 EE3287116 110 EE3287116 115 EE3287116 125 EE3287116 135 EE3287116 145 EE3287116 155 PG9 M1 M4 N1 BYPASS O1 T14685 INTRINSIC 20.5MM EE3287117 005 EE3287117 010 EE3287117015 EE3287117017 EE3287117035 EE3287117045 EE3287117055 EE3287117 030 EE3287117 033 P1 PG29 R1 S1 S4 EE3287324001 INTRINSIC BATTERY HARNESS AXIS 16 OPTIONAL P4 OPTIONAL BYPASS SW EE3185356001 EE3287323001 INTRINSIC DEVICE HARNESS SOL1 PS1 EE3044341001 FS1 EE3287348001
SOL1
SOLENOID PRES. CONTROL UNIT CABLE
50MM GND CLAMP CABLE SHIELD
TO ISB6 FLOW MTR TO ISB7 TO ISB8 TO ISTB TRIG 1 TRIG 2 HBK BATTERY BATTERY BATTERY BATTERY
HND BROKEN I/P PROPORTIONAIR TRIGGER TRIGGER FLOW METER
NONHAZARDOUS
HAZARDOUS
EE3287328001
TRIG TRIG2 FLOW
PG29
EE-3287-003
12. SCHEMATICS
1254 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1255
Figure 1227. P-200 R-J2 Rail Robot PTB Purge, PGS For Penetration Plate
CONNECTION CABLE SETS W/ (2) PG UPPER LEVEL BOMS EE3287102 105 5M EE3287102110 10M EE3287102115 15M EE3287102125 25M EE3287102135 35M EE3287102145 45M EE3287102155 55M 4 4 4 6 T14107 MOTOR 13.5MM EE3287111105 EE3287111110 EE3287111115 EE3287111125 EE3287111135 EE3287111145 EE3287111155 7 AXIS ROBOT HARNESS AND CABLE LAYOUT BATTERY IN CONTROLLER, PTB PURGE UPPER LEVEL BILL OF MATERIAL EE3287304011 ROBOT ARM
RJ2 CONTROLLER
AMP 1 (L) AMP 2 (L) AMP 3 (L)
AXIS 4 AXIS 5 AXIS 6
A1 A4 B1 B4 PG 29 PULSE BAT MODEL a 0.5 POWER BRK AXIS 6 A06B0113B078/0008 EE3185601 EE3185602 EE3185603 C4 D4 E4 EE3287322001 AXIS 4, 5 & 6 PWR & PULSE HARNESS OUTER ARM GROUND
C1 EMG BD AUX AXIS BD CRF1 JF7 CLAMP SHIELD TO CHASSIS GROUND T14685 PULSE 19.8MM EE3287113 105 EE3287113 110 EE3287113 115 EE3287113 125 EE3287113 135 EE3287113 145 EE3287113 155 D1 PG 29 E1
C3 D3 E3
F1
EE3044401
PURGE UNIT PGTB
24PG, 0PG 3
INNER ARM GROUND
PULSE & BATT MODEL a 12 POWER & BRK AXIS 3 A06B0143B175/0008
DC/DC CONVERTER H1 H4 AMP 1 (M) AMP 4 AXIS 1 AXIS 2 8 8 4 T14379 MOTOR 21.0MM EE3287110105 EE3287110110 EE3287110115 EE3287110125 EE3287110135 EE3287110145 EE3287110155 J1 J4 PG 29 TURRET GROUND PULSE & BATT a 22 MODEL POWER & BRK AXIS 2 A06B0148B675 PULSE & BATT a6 MODEL POWER & BRK AXIS 1 A06B0128B175
EE3287321001 AXIS 1, 2 & 3 PWR & PULSE HARNESS K1 K4 L1 PG 29 EE3185316001 EE3287339001
AMP 2 (M) AMP 3 (M)
AXIS 3 AXIS 7
8 8 4
T14379
MOTOR 21.0MM EE3287112 105 EE3287112110 EE3287112115 EE3287112125 EE3287112135 EE3287112145 EE3287112 155
PULSE & BATT a 12 MODEL POWER & BK AXIS 7 A06B0143B175/0008

50MM
CONTROLLER GROUND TO ISTB TO ISB1 TO ISB3 FS/PS SOL BYPASS 4 2 2 2 2 3 2 2 2 2 2 2 2 I.S. GND CONNECT SHIELD TO IS GND
GND 6.9MM EE3287116 105 EE3287116 110 EE3287116 115 EE3287116 125 EE3287116135 EE3287116145 EE3287116155
PG 9 M1 M4 N1 BYPASS O1 OPTIONAL BYPASS SW EE3185356001 EE3287323001 INTRINSIC DEVICE HARNESS
SOL PS1
EE3287348001 EE3044341001
SOL1
SOLENOID CABLE
GND CLAMP
CABLE SHIELD
FS1
FS810 DRUCKWACHTER
TO ISB4 I/P POWER TO ISB5 I/P SIG
T14685
TO ISB6 FLOW MTR TO ISB7 TO ISB8 TO ISTB TRIG 1 TRIG 2 HBK BATTERY BATTERY BATTERY BATTERY
INTRINSIC 20.5MM EE3287117 005 EE3287117010 EE3287117015 EE3287117017 EE3287117035 EE3287117045 EE3287117055 EE3287117030 EE3287117033
P1 PG 29 R1
P4 R4 E3185344001 EE3287324001 INTRINSIC BATTERY HARNESS AXIS 16 OPTIONAL PG11 I/P EE3287328001 TRIG TRIG2 FLOW I/P PROPORTIONAIR TRIGGER TRIGGER FLOW METER
S1 S4
HND BROKEN
NONHAZARDOUS
HAZARDOUS PG29
EE-3287-004
12. SCHEMATICS
1256 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1257
Figure 1228. P-200 Controller Basic Process Option I/P Flow and Trigger TYPICAL INTRINSICALLY SAFE CABLE ROUTING SHIELD CONNECTS TO INTRINSICALLY SAFE GROUND EE3287117XXX
NOTICE
NO REVISIONS WITHOUT PRIOR APPROVAL FROM FACTORY MUTUAL (FM)
ISTB TERMINAL STRIP I/P POWER P&F KFD2SDEX1.36 EE3112600001
I/P KFD2CDEX1.32
TRIGGER Z728
EE3112600
FLOW
DELTRON W112A
2ND TRIGGER
P10 MAGNET
BYPASS LS
Z787
24V @ 1.2A
ISB2 ISB1
PS OVP ISB3 ISB4 ISB5 ISB6 ISB7 ISB8 ISB9
SOLENOID
SEE DETAIL 1
SOLENOID
IDEC IBRC
6 7
INTRINSICALLY SAFE GROUND CONNECTION
IS GND P200 CONTROLLER BACKPANEL UPPER LEFT CORNER
NOTES: FOR CABLE WIRING, SEE EE3287500 FOR CONTROLS WIRING, SEE EE3287500 AND APPLICATION PACKAGE MAINTAIN 50MM SPACING I.S. WIRING AND ALL OTHER CIRCUITS, INCL EE3112600
DETAIL 1
ZENER BARRIERS MOUNTED ON INSULATING BLOCK
EE3287510
12. SCHEMATICS
1258 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1259
Figure 1229. P-200 Controller Process Option Basic Option With Second Trigger
TYPICAL INTRINSICALLY SAFE CABLE ROUTING SHIELD CONNECTS TO INTRINSICALLY SAFE GROUND EE3287117XXX
ISTB TERMINAL STRIP

I/P POWER P&F KFD2SDEX1.36 I/P KFD2CDEX1.32 EE3112600001 TRIGGER Z728 Z787 2ND TRIGGER 24V @ 1.2A EE3112600 P10 MAGNET
BYPASS LS
DELTRON W112A
FLOW
ISB2 ISB3 1 ISB4 ISB5 ISB6 ISB7 ISB8 ISB9
ISB1
SEE DETAIL 1
SOLENOID
SOLENOID
IDEC IBRC
P200 CONTROLLER BACKPANEL UPPER LEFT CORNER
IS GND
DETAIL 1
EE3287511
12. SCHEMATICS
1260 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1261
Figure 1230. P-200 Controller Bypass Option TYPICAL INTRINSICALLY SAFE CABLE ROUTING SHIELD CONNECTS TO INTRINSICALLY SAFE GROUND EE3287117XXX
ISTB TERMINAL STRIP EE3112600001 BYPASS LS KHD2SREX1.P 24V @ 1.2A 2ND TRIGGER P10 MAGNET Z787 I/P FLOW Z728 TRIGGER
EE3112600
DELTRON W112A
I/P POWER
ISB2 ISB3 PS OVP 1
ISB1
SOLENOID
SEE DETAIL 1
SOLENOID
IDEC IBRC
P200 CONTROLLER BACKPANEL UPPER LEFT CORNER
IS GND
DETAIL 1
EE3287512
12. SCHEMATICS
1262 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1263
Figure 1231. AccuFlow Counter Input Board
10 TERM BLOCK +24V C1 POWER SUPPLY INTERFACE 0V 47UF 25V 24V 0V SENSOR INTF + SIG JP1 SIG JP2 3 PHOENIX MSTBA2.5/7G W/ MATE MVSTBW2.5/7ST 4 R1 3.3K D1 1 2 6 5 24v 5V R2 2.2K 1
IC2 IC2
11 LS04
LS279 24V 10UF 50V 5V C2 (25) 0.1UF BYPASS C5C30 0V C3 0.01UF 5V 14 15 16 3 IC1 2 2 1/2 13 1 LS221 8 70US C 5V 10K R3 3 4 A CLK D 2 D IC2 4 3S Q 6 1 5 R A IC2 IC3 LS279 LS04 A 9 IC2 8 5V 9 8 10 IC26 LS08 16 3 5 A>B IC9 6 A=B LS85 7 A<B 42 8 15 9 6 5 LS161A 4 IC10 3 1 2 10 7 15 9 6 5 LS161A 4 3 IC11 1 2 10 7 5V 14 IC6 QA 3 LS164 QB 4 QC 5 1 IN A QD 6 2 IN B QE 10 QF 11 8 CLK QG12 13 CLR QH 7 A 9 12 IC2 LS04 15 9 6 5 LS161A 4 3 IC14 VCC1 2 10 7 15 9 6 5 LS161A 4 3 IC15 1 2 10 7 15 9 6 5 LS161A 4 IC16 3 1 2 10 7 13 A STOP CNTR B TRANSFER COUNT C RESET CNTR D BEGIN CNTG SET NEW DATA 9 6 5 LS161A 4 3 IC12 1 2 10 7 15 9 C 6 5 LS161A 4 IC13 3 1 2 10 7 11 12 13 14 4 B 5 IC26 LS08 6 15 11 12 13 14 B 1 15 14 13 11 12 9 10 5V 6 S Q7 D IC3 A 12 11 5 R IC26 13 LS08 5V 1 2 12 13 IC4 16MS TIME OUT
+5V
R5 330K
1N4148
11 12 13 14
C31 0.47 UF
R4 10K C4 0.01UF 5V 7 6 11 Q5 9 12 ND OS 10 /Q LS221 IC1 D2 ONE 1N4002 SHOT 3 4 7 8 13 14 17 18 IC18 2 5 6 9 12 15 16 LS273 11 3 1 IC19 20 2 5 6 9 12 15 16 LS273 11 10 19 1 10 19
12 9 11 S Q IC3 10 R LS279 24V
ACCUFLOW COUNTER INPUT BOARD PC BOARD ASSEMBLY 1/06/92 SCHEMATIC EE1063101 BLANK BD #: EE1063101001 ASSEMBLED BD #: EE1063101
NOTE: ONLY 9 PINS SHOWN 22K OHM SIP TYP 10 PIN BOURNS 4610X101RC
8MS TIMEOUT 1 3 5 9 11 13 1 3 5 9 11 13
RP1 2 4 6 8 10 IC20 12 2 4 6 8 10 IC21 12 2 4 6 8 10 12
24V
36 21 33 1 34 19 2 35 20 3 NEW DATA AVAIL
OC 7407
D14
LS04
OPTO1 MOC5007 ( OR H11L1 )
11 12 13 14 1 2 IC26 LS08
OC 7407
24V
41 40 37 22 38 23 6 39 D0 24 7
TIMER COUNT
5V 4 3 CPR Q 5 IC5 6 2 D 5V CL 1 LS74A VCC=PIN 14 0V=PIN 7
3 4 7 8 13 14 17 18
1 3 OC 5 7407 9 11 13 IC22 VCC=PIN 14 0V=PIN 7
RP2 24V 24V
5V
10US 100KHZ A CLK 74HC4060 3 2 9 1 15 IC8 11 13 14 6 10 4 5 7 12
11 12 13 14
5V 14 1 CRY1 8 74HC4017 3 100KHZ IC7 Q0 Q9 Q8 14 Q7 Q6 13 Q5 Q4 15 R Q3 Q2 Q1
5V 10 11 CPR Q9 IC5 12 D Q 8 CL 13 5V
LS10 9 10 IC4 8 11 16MS
LS279 15 S Q 13 IC3 14 R 16 MS TIMEOUT
11 12 13 14
RP3 VCC=PIN 14 0V=PIN 7 1 2 3 OC 4 5 7407 6 9 8 11 10 13 IC23 12 1 2 3 OC 4 5 7407 6 9 8 11 10 13 IC24 12 1 2 3 OC 4 5 7407 6 9 8 11 10 13 IC25 12
24V D15
29 45 42 10 43 27 11 44 28 12
24V
3 4 IC4 5 6
ND OS 8MS TIMEOUT
11 12 13 14
50 49 46 30 47 31 15 48 32 16
TOTAL COUNT
FOX F1100E 1.0MHZ OR EQUIV
NOTES: RESISTORS 5% 1/4W UNLESS NOTED ARTWORK NOTES PC BD: EE1063101001 ASSY #: EE1063001 IDENTIFY PINOUTS OF HONDA CONNECTOR, CORNER PINS
15 9 C 11 6 12 5 LS161A 13 4 IC17 14 3 1 2 10 7 VCC VCC=PIN 16 0V=PIN 8
D0
RP4 24V
HONDA MR50RFA FEMALE RT ANGLE FRONT MOUNTED
12. SCHEMATICS
1264 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1265
Figure 1232. Trigger Valve/Regulator Assembly
Air Supply Input
Air Bleed Off Do Not Adjust
Electrical Input
Valve Output Port>Input To Pilot Trigger Line Air Supply T Air Input To Pilot Section
I/P Tranducer Assembly
Output To Gun Regulator Solenoid Trigger Valve
Quick Exhaust Gauge Port Plug Air Input To Regulator Electrical Input Quick Exhaust TRIGGER VALVE/REGULATOR ASSEMBLY EO-3150-122-000
Solenoid Trigger Valve Override Button
12. SCHEMATICS
1266 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1267
Figure 1233. Color Changer 24 Color Moduclean
Paint Line Connection To Gun Transducer/Sensor
Purge Air And Solvent Connections
Paint Value Pilot Out Flowmeter Paint Supply In Paint Supply Out
COLOR CHANGER 24 COLOR MODUCLEAN EO3150123000
12. SCHEMATICS
1268 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1269
Figure 1234. Upper Gun Control Lines
Paint Line To Gun
UPPER GUN CONTROL LINES EO-3150-127-000
12. SCHEMATICS
1270 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1271
Figure 1235. Color Changer Lines 24 Color Pedestal
SEE NOTE 1
TERMINATE INSIDE OF PAINT DROP BOX
PS2 [3/8 OD.] PS4 [3/8 OD.] PS6 [3/8 OD.] PS8 [3/8 OD.] PS10 [3/8 OD.] PS12 [3/8 OD.] PS14 [3/8 OD.] PS16 [3/8 OD.] PS18 [3/8 OD.] PS20 [3/8 OD.] PS22 [3/8 OD.] PS24 [3/8 OD.] PR2 [5/16 OD.] PR4 [5/16 OD.] PR6 [5/16 OD.] PR8 [5/16 OD.] PR10 [5/16 OD.] PR12 [5/16 OD.] PR14 [5/16 OD.] PR16 [5/16 OD.] PR18 [5/16 OD.] PR20 [5/16 OD.] PR22 [5/16 OD.] PR24 [5/16 OD.] CP2 [5/32 OD.] CP4 [5/32 OD.] CP6 [5/32 OD.] CP8 [5/32 OD.] CP10 [5/32 OD.] CP12 [5/32 OD.] CP14 [5/32 OD.] CP16 [5/32 OD.] CP18 [5/32 OD.] CP20 [5/32 OD.] CP22 [5/32 OD.] CP24 [5/32 OD.] PAP [5/32 OD.] CCAS [3/8 OD.] CCSS [3/8 OD.] PSP [5/32 OD.] CP23 [5/32 OD.] CP21 [5/32 OD.] CP19 [5/32 OD.] CP17 [5/32 OD.] CP15 [5/32 OD.] CP13 [5/32 OD.] CP11 [5/32 OD.] CP9 [5/32 OD.] CP7 [5/32 OD.] CP5 [5/32 OD.] CP3 [5/32 OD.] CP1 [5/32 OD.] PS23 [3/8 OD.] PS21 [3/8 OD.] PS19 [3/8 OD.] PS17 [3/8 OD.] PS15 [3/8 OD.] PS13 [3/8 OD.] PS11 [3/8 OD.] PS9 [3/8 OD.] PS7 [3/8 OD.] PS5 [3/8 OD.] PS3 [3/8 OD.] PS1 [3/8 OD.] PR23 [5/16 OD.] PR21 [5/16 OD.] PR19 [5/16 OD.] PR17 [5/16 OD.] PR15 [5/16 OD.] PR13 [5/16 OD.] PR11 [5/16 OD.] PR9 [5/16 OD.] PR7 [5/16 OD.] PR5 [5/16 OD.] PR3 [5/16 OD.] PR1 [5/16 OD.]
COLOR CHANGER ASM. 24 COLOR CP6 COLOR PILOT 6 PR4 PAINT RETURN 4 PS2 PAINT SUPPLY 2
TO PPCE
CP5 COLOR PILOT 5
BOOTH WALL
ROBOT INTERFACE
PS1 PAINT SUPPLY 1 PR3 PAINT RETURN 3
P200
PLACE IN CABLE CARRIER BEFORE CLAMP
ROBOT INTERFACE
P200
COLOR CHANGER LINES 24 COLOR PEDESTAL 000A EO3150128 000B
12. SCHEMATICS
1272 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1273
Figure 1236. Lower Gun Control Lines Pedestal
24 COLOR EO3150121012 REF 12 COLOR EO3150129001 REF 8 COLOR EO3150220001 REF 4 COLOR EO3150221001 REF RP [1/2 OD.] FA [1/2 OD.]
CLAMP
AA [1/2 OD.]
PD [1/4 OD.]
TERMINATE AT DUMP [1/2 OD.] SOLVENT RECOVERY PTS [3/8 OD.] TERMINATE AT EO3150122000 TRIGGER VALVE/ REGULATOR ASM.
Quick Exhaust
NOTE: MARK BOTH ENDS OF TUBING WITH LABLE SHOWN
BOOTH WALL
E-Stat Junction Box On Robot Base
ESTAT [5/16 OD.] GROUND [1/4 OD.] PT [5/16 OD.] PR [5/16 OD.] FM [5/16 OD.] WW [5/16 OD.]
Low Voltage E-Stat Cable To Cascade Amplifier On Gun
TERMINATE AT EO3150122000 TERMINATE AT 24 COLOR EO3150123000 TERMINATE AT EO3150127000
EO3150222000A EO3150222000B
ERN/ECN E60586 E60586
L2 REV L1 L3 C 7.3 M [24 FT] 7.0 M [23 FT] 8.0 M [26 FT] C 15.3 M [50 FT] 15.0 M [44 FT] 16.1 M [53 FT]
LOWER GUN CONTROL LINES PEDESTAL
000A EO3150222 000B
12. SCHEMATICS
1274 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1275
Figure 1237. Lower Gun Control Lines Rail
AREA FOR PLACEMENT OF INLINE UNION
1:1 Ratio Boosters

24 COLOR EO3150121012 REF 12 COLOR EO3150129001 REF 8 COLOR EO3150220001 REF 4 COLOR EO3150221001 REF RP [1/2 OD.] FAS [1/2 OD.] FAP [1/4 OD.] AAS [1/2 OD.] AAP [1/4 OD.] PD [1/4 OD.] DUMP [1/2 OD.] PTS [3/8 OD.] TERMINATE AT EO3150122000 TRIGGER VALVE/ REGULATOR ASM. CLAMP MOUNT TO CABLE CARRIER AAS [3/8 OD.] FAS [3/8 OD.] EO3150223001 MOUNT OPPOSITE OF CABLE CARRIER
TERMINATE AT SOLVENT RECOVERY PTS [3/8 OD.]
BOOTH WALL
ESTAT [5/16 OD.] GROUND [1/4 OD.]
AIR VALVE TO SHUTOFF
PT [5/16 OD.] PR [5/16 OD.] FM [5/16 OD.] WW [5/16 OD.]
PT [5/16 OD.] PR [5/16 OD.] FM [5/16 OD.] WW [5/16 OD.]
TERMINATE AT EO3150122000
TERMINATE AT 24 COLOR EO3150123000 TERMINATE AT EO315012700012 COLOR EO3150124000 8 COLOR EO3150125000 4 COLOR EO3150126000
NOTE: MARK BOTH ENDS OF TUBING WITH LABLE SHOWN.
LOWER GUN CONTROL LINES RAIL 000A EO3150223 000B
12. SCHEMATICS
1276 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1277
Figure 1238. Color Changer Rail 4 Color Lines
SEE NOTE 1 4.0 METERS [13.0 FT]
PS2 PS4 TERMINATE INSIDE OF PAINT DROP BOX
PS2 [3/8 OD.] PS4 [3/8 OD.] COLOR CHANGER ASM. 4 COLOR
PR2 PR4
PR2 [5/16 OD.] PR4 [5/16 OD.]
CP2 CP4 PAP CCAS TERMINATE INSIDE OFCCSS PAINT DROP BOX PSP CP3 CP1
CP2 [5/32 OD.] CP4 [5/32 OD.] PAP [5/32 OD.] CCAS [3/8 OD.] CCSS [3/8 OD.] PSP [5/32 OD.] CP3 [5/32 OD.] CP1 [5/32 OD.]
CP4 COLOR PILOT 4 PR2 PAINT RETURN 2 PS2 PAINT SUPPLY 2
TO PPCE
BOOTH WALL
PS1 PAINT SUPPLY 1 PR1 PAINT RETURN 1 CP3 COLOR PILOT 3
PS3 PS1
PS3 [3/8 OD.] PS1 [3/8 OD.]
PLACE IN CABLE CARRIER BEFORE CLAMP
TERMINATE INSIDE OF PAINT DROP BOX PR3 PR1 PR3 [5/16 OD.] PR1 [5/16 OD.]
P200
AREA FOR PLACEMENT OF INLINE UNIONS STAGER UNIONS THRU BRACKET
P200
COLOR CHANGER LINES 4 COLOR RAIL EO3150227000A 000B
12. SCHEMATICS
1278 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1279
Figure 1239. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option 120VAC FROM CELL CONTROL PANEL (14 AWG YELLOW) NEUTRAL FROM CELL CONTROL PANEL (14 AWG YELLOW)
8200 8201 RC 82011 8202 8203 8204 8205 8206 8207 8208 8209 8210
+24VDC CP61 FROM CP6 CONNECTOR ON CPU POWER SUPPLY CP62 0VDC [47] IPCBL21 (REF) 82011 (REF. NE2000411) (TERMINAL STRIP T2) 14132 RC [3] IPCBL6 (REF) 14132 I/O POWER ENABLE (8222,SP,SP,SP)
8228 8229 8230 8231 8232 8233 8234 8235 8236 8237 8238
+24F 82291
FROM SPADE CONNECTORS ON POWER INPUT UNIT (PIU)
0VDC
8204CR/SUPPRESSOR A1 A2 13 14
8232F 1 AMP [15]
82292 82321 8232SOL 82292 RC PP PP [15] PPCBL1 PPCBL2 [14]
ROBOT MAIN AIR SUPPLY VALVE (FIRE VALVE)
CP321 INSERT INTO FANUC I/O RACK CP322 RACK INTERFACE 82091 82092 8239 8211 0VDC +24VDC MODULE 16 AWG BLUE 16 AWG BLUE 8240 8212 RC 82091 82092 RC [04] [07] +5VDC JD1A PORT 8241 8213 8214F ON INTERFACE MODULE 82141 .5 CUT END OF CABLE AND TIE AMP 82142 THE FOLLOWING TOGETHER
NOTES: 1. DC WIRES TO BE 16 AWG BLUETYPICAL. 2. NUMBERS IN BRACKETS [ ] ARE TERMINALS ON TERMINAL STRIP T1, UNLESS OTHERWISE NOTED.
8214 8215 8216
XGMF09989
[11]
[11]
AT FUSE TERMINAL: PINK/2 BLACK DOTS YELLOW/2 BLACK DOTS PINK/1 BLACK DOT
8242 8243 8244 8245 8246 8247 8248
8217 8218 8219 8220 8221 8222

(9) 82091 I/O POWER ENABLE 8204CR 82231
+5VDC +24VDC
FLOWMETER INTERFACE MODULE
LEGEND
RC TERMINAL IN ROBOT CONTROLLER PP TERMINAL IN PAINT PROCESS VALVE PANEL TERMINAL IN REMOTE EQUIPMENT DEVICE OUTSIDE THIS ENCLOSURE
(5)
0VDC
82092
8249 8250 8251 8252 8253 8254
8223 8224 8225 8226 8227
TO LINE 8300
82231 +24VDC
INTERNAL DC WIRE TO BE 16 AWG BLUETYPICAL
82092 0VDC
8255
TO LINE 8300
FANUC R-J2 P-200 SINGLE STAGE PURGE PAINT PROCESS CONTROL WITH CONNECTOR OPTION NE220047A SHT. 82
12. SCHEMATICS
1280 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1281
Figure 1240. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option
8300 8301 8302 8303 8304 8305 8306 8307 8308 8309 8310 8311 8312 8313 8314 8315 8316 8317 8318 8319 8320 8321 8322 8323 8324 8325 8326 8327
FROM LINE 8227 82231 +24VDC
FROM LINE 8227 FROM LINE 8327 82231 82092 +24VDC 8328 0VDC
8329 8330
FROM LINE 8327 82092 0VDC
DC OUTPUT MODULE AOD16D SLOT 1 1 11

ALL FUSES .5 AMP 83081 83091 8308F [16] [16] 8309F PPCBL3 PPCBL4 PPCBL5 PPCBL6 PPCBL7 PPCBL8 PPCBL9 83082 PP 83092 PP 83102 PP 83112 PP 83122 PP 83132 PP 83142 PP 8308SOL 82092 RED BLACK SOLENOID SOLENOID PIGTAILTYP. PIGTAILTYP.
8331 8332 8333 8334 8335

APPLICATOR CLEANER PP SOLVENT PILOT (ACSP) 8309SOL PPCBL10 APPLICATOR CLEANER (ACAP) AIR PILOT 8310SOL PURGE SOLVENT PILOT (PSP) 8311SOL PURGE AIR PILOT (PAP) 8312SOL PILOT DUMP (PD) SPARE
DC OUTPUT MODULE AOD16D SLOT 2 1 11 SUPPLIED AS PART OF ROBOT PRODUCT REF. EE3287550
EE3287328001 LOCATED INTRINSIC CABLE IN P200 EE3287117XXX ROBOT ARM
2 3 4 5 6 7 8 9 12
8336 8337 8338 8339 8340 8341 8342 8343 8344 8345 8346 8347 8348 8349 8350 8351 8352 8353 8354
2 3 4 5
83361
8336F .5 AMP [23] [23]
ISB7 8 7 1 2 ISB71 P1 ISB72 I.S. GROUND WHT
8336SOL GRN PILOT TRIGGER (PT) SPARE SPARE SPARE
[17] [17] 8310F 83101 [18] [18] 8311F 83111 [19] [19] 8312F 83121 [20] [20] 8313F 83131 [21] [21] 8314F 83141 [22] [22]
NOTES: 1. NUMBERS IN BRACKETS [ ] ARE TERMINALS ON TERMINAL STRIP T1.
6
SPARE
7
SPARE
TO LINE 8411
8
SPARE
SPARE SPARE SPARE
9
SPARE
LEGEND
RC TERMINAL IN ROBOT CONTROLLER PP TERMINAL IN PAINT PROCESS VALVE PANEL TERMINAL IN REMOTE EQUIPMENT DEVICE OUTSIDE THIS ENCLOSURE
12
SPARE
13
SPARE
13
SPARE
14
SPARE
14
SPARE
15
SPARE
15
SPARE
16
SPARE
16
SPARE
17
SPARE
17
SPARE
18
SPARE
18
SPARE
19
SPARE
19
SPARE
10 20
10 20
82231 TO LINE 8328
82092 TO LINE 8328
82231 TO LINE 8400
8355
82092 TO LINE 8400
FANUC R-J2 P-200 SINGLE STAGE PURGE PAINT PROCESS CONTROL WITH CONNECTOR OPTION NE220047A SHT. 83
12. SCHEMATICS
1282 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1283
Figure 1241. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option
8400 8401 8402 8403 8404 8405 8406 8407 8408

ISB5
NOTES: 1. TERMINATE THE SHIELD DRAIN WIRES AT TERMINALS 6 AND 16 ON THE ANALOG OUTPUT MODULE. AT THE TRANSDUCER END OF THE CABLE CUT THE DRAIN WIRE SHORT AND TAPE OR SHRINK WRAP. SUPPLIED AS PART OF ROBOT PRODUCT REF. EE3287550
7 8
FROM LINE 8355 82231 82092

0VDC +24VDC
8409 8410 8411 8412 8413 8414 8415 8416 8417 8418 8419 8420 8421 8422 8423 8424 8425 8426 8427
FLOW COMMAND ANALOG OUTPUT MODULE ADA02A BELDEN CABLE SLOT 3 #8761TYPICAL
6(FG) 8 (+) 10 () 18 (+) 20 () 16(FG) SHIELD 84061 CLEAR 84071 BLACK
2. (FG) TERMINALS 6 AND 16 ARE TIED TOGETHER INTERNALLY AT THE MODULE AND ARE BROUGHT TO FRAME GROUND USING THE GROUND WIRE TERMINATED AT THE GROUND BAR. 3. NOTE THAT CARD OUTPUTS ARE NOT ISOLATED, THEY SHARE A COMMON RETURN LINE THAT IS TIED TO 0VDC (OF THE 24VDC SUPPLY). 4. ALL WIRING NOT ACCOMPLISHED BY BELDEN CABLE #8761 OR TRANSDUCER PIGTAIL TO BE 16 AWG BLUE WIRE.
EE3287328001
SHEILD 1 RC [25] 84061 RC [26] 84071 RC [27]
JUMPER
9 10 1 2 ISB51 P1 ISB52 P1
LOCATED IN P200 ROBOT ARM 8403XDUCER 420 ma I/P PAINT PRESSURE TRANSDUCER
P1 ISB4 ISB41 1 7
ATOMIZING AIR
CABLE C1 INTERNAL TO THIS PANEL
I.S. GROUND
INTRINSIC CABLE #EE3287117XXX
P1
ISB42 2
5. TRANSDUCERS ARE SUPPLIED WITH 72 LONG PIGTAIL (RED/WHT, RED, GREEN, RED/YEL, AND RED/BLU CONDUCTORS). 6. NUMBERS IN BRACKETS [ ] ARE TERMINALS ON TERMINAL STRIP T1, UNLESS OTHERWISE NOTED.
I.S. GROUND
82092
82231
TO LINE 8500
LEGEND
RC TERMINAL IN ROBOT CONTROLLER
TERMINAL IN REMOTE EQUIPMENT DEVICE OUTSIDE THIS ENCLOSURE
FANUC R-J2 P-200 SINGLE STAGE PURGE PAINT PROCESS CONTROL WITH CONNECTOR OPTION SHT.84 NE220047A
12. SCHEMATICS
1284 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1285
Figure 1242. Flow Meter Interface Circuitry FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option
ACCUFLOW COUNTER INPUT/ DC INPUT MODULE CONNECTIONS
8700 8701 8702 8703 8704 8705 8706 8707 8708 8709 8710 8711 8712 8713 8714 8715 8716 8717 8718 8719 8720 8721 8722 8723 8724 8725 8726 8727
SPARE SLOT SLOT 9
DC INPUT MODULE AID32B1 SLOT 10
DC INPUT MODULEFLOWMETER SIGNAL DESCRIPTION CONTACTINPUT INTERFACE (SEE NOTE 2) CONTACT NUMBER 1 1D6 PULSE COUNTER BIT 14 2 2D3 PULSE COUNTER BIT 11 3 3D0 PULSE COUNTER BIT 8 4 SPARE 4 5 SPARE 5 6 6C3 PULSE COUNTER BIT 3 7 7C0 PULSE COUNTER BIT 0 SPARE 8 8 SPARE 9 9 10 10B6 PULSE PERIOD BIT 13 11 11B3 PULSE PERIOD BIT 10 12B0 12 PULSE PERIOD BIT 7 SPARE 13 13 SPARE 14 14 15 PULSE PERIOD BIT 2 15A3 16 16A0 NEW DATA AVAILABLE SPARE 17 17 SPARE 18 18 PULSE COUNTER BIT 12 19 19D4 PULSE COUNTER BIT 9 20 20D1 +24VDC 21 21 22 22C6 PULSE COUNTER BIT 6 23 23C4 PULSE COUNTER BIT 4 24 24C1 PULSE COUNTER BIT 1 25 25 SPARE 26 26 SPARE 27 27B4 PULSE PERIOD BIT 11 28 28B1 PULSE PERIOD BIT 8 29 29 +24VDC 30 30A6 PULSE PERIOD BIT 5 31A4 31 PULSE PERIOD BIT 3 32 32A1 PULSE PERIOD BIT 0 33 PULSE COUNTER BIT 15 33D7 34 PULSE COUNTER BIT 13 34D5 35 PULSE COUNTER BIT 10 35D2 +24VDC 36 36 37 PULSE COUNTER BIT 7 37C7 38C5 38 PULSE COUNTER BIT 5 39 PULSE COUNTER BIT 2 39C2 +24VDC 40 40 +24VDC 41 41 42 PULSE PERIOD BIT 14 42B7 43 PULSE PERIOD BIT 12 43B5 44 44B2 PULSE PERIOD BIT 9 +24VDC 45 45 46 46A7 PULSE PERIOD BIT 6 47 47A5 PULSE PERIOD BIT 4 48 48A2 PULSE PERIOD BIT 1 +24VDC 49 49 +24VDC 50 50

+24V +5V 0V +24V 0V +SIG SIG
POWER INPUT TO ACCUFLOW COUNTER INPUT PRINTED CIRCUIT BOARD (SEE SHEET 02 FOR CONNECTIONS) SUPPLIED AS PART OF ROBOT PRODUCT REF. EE3287550
ISB6 87091 BLACK 87101 WHITE 87111 RED ALPHA CABLE #5163C 18 AWG 3 CONDUCTOR 8 7 5 1 ISB61 P1 2 ISB62 P1 4 ISB64 P1 I.S. GROUND B C 0V +SIG FLOW METER LOCATED IN P200 ROBOT ARM A +24V
NOTES:
1. TERMINALS 3 AND 7 ON THE
JUMPER
INTRINSICALLY SAFE BARRIER (ISB) ARE TIED TOGETHER THROUGH THE ISB BUSS BAR.
EE3287328001 INTRINSIC CABLE #EE3287117XXX
RC
LEGEND TERMINAL IN ROBOT CONTROLLER VALVE PANEL TERMINAL IN REMOTE EQUIPMENT DEVICE OUTSIDE THIS ENCLOSURE
PP TERMINAL IN PAINT PROCESS
REFERENCE ONLY FLOWMETER INTERFACE CABLE40 CM LONG #EE1063201001
REFERENCE ONLY HONDA #MR50LWF XGMF00782 HONDA #MR50RMA CONNECTOR
REFERENCE ONLY HONDA #MR50LWM XGMF00788 HONDA #MR50RFA CONNECTOR
FLOW METERINTERFACE CIRCUITRY FANUC R-J2 P-200 SINGLE STAGE PURGE PAINT PROCESS CONTROL WITH CONNECTOR OPTION SHT. 087 NE220047A
12. SCHEMATICS
1286 NOTES
MARO2P10203703E
12. SCHEMATICS
MARO2P10203703E
1287
Figure 1243. I/O Rack Layout FANUC R-J2 P-200 Single Stage Purge Paint Control With Connector Option
82142 82091 +5VDC +24VDC
82092 0VDC
+5VDC FROM #XGMF09989 CABLE PLUGGED INTO JD1A PORT +24VDC, 0VDC FROM CP5 CONNECTOR ON CPU POWER SUPPLY CABLES/WIRING BY FANUC WIRE AS SHOWN ON SHEET 082 In Robot Controller Converts Frequency Input To 32 bit Output
MAIN CPU PCB
82142 [11] 8214F .5 AMP [11] 82141
JD1
RACK COMMUNICATION CABLE1 METER
SLOT NUMBER 1
JD1A JD1B
2 A O D 1 6 D
3 A D A 0 2 A
4 A D A 0 2 A
5 R E S E V E D
6 R E S E V E D
7 A O D 1 6 D
8 A O D 1 6 D
9 R E S E V E D
10 A I D 3 2 B 1
CP32
A I F 0 1 A
A O D 1 6 D
32 Bit Input Module Read Interface Module Output
RACK POWER CABLE +24VDC, 0VDC FROM SPADE CONNECTORS ON POWER INPUT UNIT CABLE/WIRING BY FANUC WIRE AS SHOWN ON SHEET 082 82091 +24VDC 82092 0VDC 82291 +24VDC 82292 0VDC
Channel 1 = 200-100 Transducer Counts to 4-20 mA Conversion For I/P Transducer In P-200 Outer Arm
TO MAIN AIR SUPPLY SOLENOID AS SHOWN ON SHEET 082
CP6 MAIN CPU PSU MODULE POWER INPUT UNIT (PIU)
I/O RACK LAYOUT FANUC R-J2 P-200 SINGLE STAGE PURGE PAINT PROCESS CONTROL WITH CONNECTOR OPTION SHT. 089 NE220047A
12. SCHEMATICS
1288 40 NOTES
MARO2P10203703E
13 CABLES
Index
MARO2P10203703E
13
CABLES
131

Cables
Page
The following section includes separate print cable sets for the P-200 robot. . . . 131
13. CABLES
132 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
133
Figure 131. P-200 Purge/Battery/Paint Connection Cable
REV LEV. CABLE VERSION DIM (IN MM) PG REV LEV. CABLE VERSION DIM (IN MM) PG
0 65.0 4.0 8.0 MTW, 12 LONG BLACK, 20 AWG. MTW, 12 LONG
11
IS GND
A A A A A A A
EE3287117005 EE3287117010 EE3287117015 EE3287117025 EE3287117035 EE3287117045 EE3287117055
295 492 689 1083 1476 1870 2264
IN IN IN IN IN IN IN
7500 12500 17500 27500 37500 47500 57500
MM MM MM MM MM MM MM
NO NO NO NO NO NO NO
A A A A A A A
EE3287117105 EE3287117110 EE3287117115 EE3287117125 EE3287117135 EE3287117145 EE3287117155
295 492 689 1083 1476 1870 2264
IN IN IN IN IN IN IN
7500 MM 12500 MM 17500 MM 27500 MM 37500 MM 47500 MM 57500 MM
YES YES YES YES YES YES YES
SEE NOTE 5 SOC/ PIN NO.

1 2 3 4 5 6 13 14 15 1 2 3 4 5 6 7 8 9 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4
LABEL
WIRE COLOR
TWISTED PAIR NUMBER
SIGNAL NAME
PS1P PS1N FS1P FS1N PSOL1 PSOL2 20 AWG
A
M1
15
14
1 TYP
1PSA1 2PSA2
320 24
1
SEE NOTE 5 2 3 4 15 POS SOC

3
WHITE1 1 BLUE2 WHITE3 2 ORANGE4 WHITE5 3 GREEN6 NUMBERD SHIELD PSOL2 KEY WHITE7 BROWN8
WIRE COLOR/ NUMBER

WHITE1 BLUE2 WHITE3 ORANGE4 WHITE5 GREEN6 WHITE7 BROWN8 WHITE9 GRAY10 RED11 BLUE12 RED13 ORANGE14 RED15 GREEN16 RED17 BROWN18 RED19 GRAY20 BLACK21 BLUE22 BLACK23 ORANGE24
TWIST WIRE TAG PAIR ISTB CONNECT POINT NO.

1 PSA1 2 PSA2 5 FSA1 6 FSA2 ISB13 ISB14 ISB34 ISB36 ISB41 ISB42 ISB51 ISB52 ISB61 ISB62 ISB64 SPARE ISB71 ISB72 ISB81 ISB82 19 HBK1 20 HBK2 SPARE SPARE 1 2 3 4 5 6 7 8 9 10 11 12
NOTE: PINS 7 THRU 12 NOT SHOWN
SIGNAL NAME
PS1P PS1N FS1P FS1N PSOL1 PSOL2 BYPASS1 BYPASS2 I/P 24V + I/P 0V I/P + SIG I/P SIG FLOW 24V FLOW 0V FLOW + SIG SPARE TRIG + SIG TRIG SIG TRIG2 + SIG TRIG2 SIG HND BRK + HND BRK SPARE SPARE
5FSA1 6FSA2 ISB13 ISB14 ISB34 ISB36 ISB41 ISB42 ISB51 ISB52 ISB61 ISB62 ISB64 SPARE ISB71 ISB72 ISB81 ISB82 19HBK1 20HBK2 SPARE SPARE
2 M1 3 4 5 6 7 8 9 10 11 12 4 5
BYPASS1 BYPASS2
N1
SEE DETAIL 3B 10 TYP. TYP. 10 12 1 SEE NOTE 1 SEE NOTE 4 4.0 TYP.
INTRINSIC REV. EE3287117XXX MFG. NAME INTRINSIC REV. EE3287117XXX MFG. NAME N1
SHIELD 20 AWG BLACK23 12 ORANGE24 KEY BLACK21 11 BLUE22 KEY SHIELD 20 AWG WHITE9 GRAY10 RED11 BLUE12 RED13 ORANGE14 RED15 GREEN16 RED17 BROWN18 RED19 GRAY20 5 6 7 8 9 10
SPARE SPARE
9 POS SOC 6
O1
SEE NOTE 5 7 8
SEE NOTE 3 DETAIL 3B 11 BLACK SHIELD WIRE 20 AWG
HND BRK+ HND BRK
TWO PLACES IF REQUIRED
O1
4 POS SOC
P1
SEE DETAIL 3A 10 TYP. 16 17 TYP.
2 CABLE SPECIFICATION 16PR #20 AWG CABLE HYPALON JACKET MAX. CABLE O.D. = 20.5mm (0.805 MAX.) P/N=T14685 4.0 TYP 6.0 TYP
4 15 POS SOC
P1
I/P 24V + I/P 0V I/P + SIG I/P SIG FLOW 24V FLOW 0V FLOW +SIG SPARE TRIG + SIG TRIG SIG TRIG2 +SIG TRIG2 SIG
KEY SHIELD 20 AWG YELLOW31 16 BLUE32 SHIELD 20 AWG KEY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 BLACK25 GREEN26 BLACK27 BROWN28 BLACK29 GRAY30 JUMPER JUMPER JUMPER JUMPER JUMPER JUMPER SHIELD KEY 6V4 0V4
8.0
6V1 0V1
TUBING OVER BRAID TYP.
6
R1
WIRE COLOR/ NUMBER

BLACK25 GREEN26 BLACK27 BROWN28 BLACK29 GRAY30 YELLOW31 BLUE32
WIRE TAG
6V1 0V1 6V2 0V2 6V3 0V3 6V4 0V4
TWIST PAIR NO.

13 14 15 16
CONNECTION
6V2 0V2 6V3 0V3 6V4 0V4
POINT
R1
4 POS SOC 4
13 14 15
BATTERY PACK
18 TYP
13 TYP
3. TYP. TERMINATION OF SHIELD TO SHIELD AND SHIELD TO CONDUCTOR. CONDUCTORS SOLDERED CONNECTION SHIELD BETWEEN SHIELDS SLEEVING BULK CABLE DETAIL A
S1
15 POS SOC 1.0 TYP.
6V1 0V1 6V2 0V2 6V3 0V3 6V4 0V4 6V5 0V5 6V6 0V6
S1
3.0 TYP.
ASSEMBLY NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND IN TABLE. VENDOR NAME VERSION NUMBER AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL LENGTH DIMENSIONS + 1/2 IN.
BRAIDED SHIELD SHRINK TUBING DETAIL B SHIELD CONDUCTOR 20 AWG BLACK TYP SOLDERED CONNECTION BULK CABLE CONDUCTORS BRAIDED SHIELD SLEEVE TUBING 4.
(2) WIRES PER CONTACT
20 AWG
FOR INTRINSIC CABLE MARKING: APPLY 4 OF BLUE SHRINK TUBING UNDER CABLE I.D. LABELS AND ALSO AT 22 INTERVALS AS REQD. 5. FOR CABLE EE3287117105 ONLY, USE 200 FOR LEFT PG LOCATION
EE-3278-117-005
13. CABLES
134 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
135
Figure 132. P-200 R-J2 Paint Control Robot Arm Cable Dual Trigger
REV LEV.
A
CABLE VERSION
EE3287328001
DIM (IN MM)

174 IN
PG
4420 MM YES
0
16
46
11 12 PIN #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
WIRE COLOR/ NUMBER

WHITE BLACK WHITE BROWN
TWIST PIN PAIR NUMBER NO.

6 1 4 2 1 2
SIGNAL NAME
I/P 24V I/P 0V I/P + SIG I/P SIG
WIRE COLOR/ NUMBER

WHITE BLACK WHITE BROWN WHITE RED WHITE ORANGE WHITE BLUE WHITE YELLOW KEY
TWIST PAIR NO.

1 2 3 4 5 6
SIGNAL NAME
I/P 24V I/P 0V I/P + SIG I/P SIG FLOW 24V FLOW 0V FLOW + SIG SPARE TRIG + SIG TRIG SIG TRIG2 +SIG TRIG2 SIG
TUBING
I/P
2 3 TYP
13
TYP. 8
10
1 4.0 TYP
INTRINSIC REV. EE3287328XXX MFG. NAME REV.
5 6.0 TYP
SEE NOTE 1 SEE NOTE 4 4.0 TYP.

P4 INTRINSIC EE3287328XXX MFG. NAME REV.
WIRE COLOR/ NUMBER

WHITE BLUE

1 2 5
SIGNAL NAME
TRIG + SIG TRIG SIG
TRIG
15 PIN SEE NOTE 3 CABLE SPECIFICATION 9 PR #20 AWG CABLE HYPALON JACKET MAX. CABLE O.D. = 17.4mm (0.685 MAX.) P/N=T11762 ASSEMBLY NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL LENGTH DIMENSIONS + 1/2 IN.
WIRE COLOR/ NUMBER

WHITE YELLOW
TWIST PIN NUMBER PAIR NO.

1 2 6
SIGNAL NAME
TRIG2 +SIG TRIG2 SIG
SHIELD STOPS HERE 6
TRIG2
SHIELD
CUT OF SPARE SPARES: WHITE GREEN 7 WHITE VIOLET 8 WHITE 9 GRAY
FLOW
WIRE COLOR/ NUMBER

WHITE RED WHITE ORANGE

A B C 3 4
SIGNAL NAME
FLOW 24V FLOW 0V FLOW + SIG SPARE
CUT OFF SPARE ORANGE WIRE
3. TYP. TERMINATION OF SHIELD TO SHIELD AND SHIELD TO CONDUCTOR. SHIELD CONDUCTOR 20 AWG BLACK SOLDERED CONNECTION BULK CABLE CONDUCTORS BRAIDED SHIELD SLEEVE TUBING
CUT OFF SPARE PAIRS: WHITE PAIR 7 GREEN WHITE PAIR 8 VIOLET WHITE PAIR 9 GRAY
4. FOR INTRINSIC CABLE MARKING:APPLY 4 OF BLUE SHRINK TUBING UNDER CABLE I.D. LABELS AND ALSO AT 22 INTERVALS AS REQD.
EE-3287-328-001
13. CABLES
136 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
137
Figure 133. P-200 I/P Cable
REV
A A
CABLE VERSION
EE3287334001 EE3287334002
A DIM
288 IN 7315MM 600 IN 15240MM 24 FT 50 FT
SUPERSEDED BY EE-3287-328-001
5 6
24V 0V +SIG SIG
4 3 TYP
I/P EE328733400X MANUF REV
1 12 3
I/P EE328733400X MANUF REV
3 PIN #
1 2 3 4 5 6
1 TYP WIRE COLOR/ NUMBER

BLK GREEN WHITE RED
TYP TUBING OVER CABLE WIRE COLOR/ NUMBER

BLK GREEN WHITE RED
WIRE TAG
0V SIG +SIG 24V
SIGNAL NAME
I/P 0V I/P SIG I/P +SIG I/P 24V
SIGNAL NAME
I/P 0V I/P SIG I/P + SIG I/P 24V
SEE NOTE 1
SHIELD (TO I.S. GND)
ASSEMBLY NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL.
2.
DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL LENGTH DIMENSIONS + 1/2 IN.
EE-3287-334-001 and 002
13. CABLES
138 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
139
Figure 134. P-200 Trigger Cable
REV
A
CABLE VERSION
EE3287335001
A DIM
288 IN 7315MM 600 IN 15240MM 24 FT 50 FT
EE3287335002
5 TYP WIRE COLOR

RED BLK WHITE
4 TYP 2 TYP
TRIG EE328733500X MANUF REV
1 12
TRIG EE328733500X MANUF REV
WIRE TAG
+SIG SIG GND
SIGNAL NAME
TRIG +SIG TRIG SIG GND
0.5
+SIG SIG GND
TUBING OVER CABLE
PIN #
1 2 3
WIRE COLOR
RED BLK WHITE
SIGNAL NAME
TRIG + SIG TRIG SIG GND
2.
EE-3287-335-001 and 002
13. CABLES
1310 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1311
Figure 135. P-200 Flow Detector Signal
REV
A
CABLE VERSION
EE3287336001
A DIM
288 IN 7315MM 600 IN 15240MM 24 FT
EE3287336002
50 FT
5 3 0.5 WIRE COLOR

RED BLACK WHITE
4 2
FLOW EE328733600X MANUF REV
1 3 3
FLOW EE3287336001 MANUF REV
TUBING OVER CABLE 12

FLOW
WIRE TAG
24V 0V +SIG FLOW 24V FLOW 0V FLOW +SIG
24V 0V +SIG
PIN NUMBER
A B C
WIRE COLOR
RED BLACK WHITE
SIGNAL NAME
FLOW 24V FLOW 0V FLOW + SIG
2.
EE-3287-336-001 and 002
13. CABLES
1312 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1313
Figure 136. Axes 1 and 2 Power Connection Cable
WIRE COLOR/ NUMBER

BLUE/17 BLUE/18 BLUE/19 BLUE/20
WIRE TAG
BKP1 BKM1 BKP1 BKM1
SIGNAL NAME
1BKP 1BKM 2BKP 2BKM
BKP1 BKM1 BKP1 BKM1
SEE NOTE 3 320 24
CONNECTOR LABEL
SOC/ PIN NO.

1 2 3
WIRE COLOR/ NUMBER

RED/1 WHITE/2 BLACK/3 GRN/YEL/4 RED/5 WHITE/6 BLACK/7 GRN/YEL/8 BLUE/17 BLUE/18 KEY PLUG NOT USED RED/9 WHITE/10 BLACK/11 GRN/YEL/12 RED/13 WHITE/14 BLACK/15 GRN/YEL/16 BLUE/19 BLUE/20 NOT USED KEY PLUG
SIGNAL NAME
1U 1V 1W 1G 2U 2V 2W 2G 1BKP 1BKM 18 AWG
WIRE COLOR/ NUMBER

RED/1 WHITE/2 BLACK/3 GRN/YEL/4 RED/5 WHITE/6 BLACK/7 GRN/YEL/8 RED/9 RED/13 WHITE/10 WHITE/14 BLACK/11 BLACK/15 GRN/YEL/12 GRN/YEL/16
WIRE TAG
1U 1V 1W 1G 2U 2V 2W 2G 2U 2V 2W 2G
1U 1V 1W 1G
4 AXIS 1 & 2 PWR/BRK H1 5 6 7 8 9 10

MOTOR REV. EE3287110XXX MFG. NAME MOTOR REV. EE3287110XXX MFG. NAME
2U 2V 2W 2G
AXIS 1 POWER/BRK H1
PS95437110155
12 POS SOC
11 12 1 2 3 4 AXIS 2 PWR/BRK J1 5 6 7 8 9 10 11 12
2U 2V 2W 2G
CABLE SPECIFICATION 16#14 & 4#18 AWG CONDUCTORS HYPALON JACKET MAX CABLE O.D.= 21.0 MM (0.825) P/N=T14379
AXIS 2 POWER/BRK J1
PS95437110155 1 TYP 1 TYP. 6 TYP
12 POS SOC
THIS GROUP HAS TWO WIRES PER TERMINAL
ASSEMBLY NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL LENGTH DIMENSIONS + / 1/2 IN
3. FOR CABLE EE3287110105, USE 200 FOR LEFT PG LOCATION
EE-3287-110-005
13. CABLES
1314 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1315
Figure 137. Axes 4, 5, and 6 Motor Connection Cable
REV LEV.
A A A A A A
CABLE VERSION
EE3287111005 EE3287111010 EE3287111015 EE3287111025 EE3287111035 EE3287111045 EE3287111055 492
DIM (IN MM)

295 IN 7500 MM MM MM MM MM MM MM IN 12500 IN 17500
PG
REV LEV.
B B B B B B B
CABLE VERSION
EE3287111105 EE3287111110 EE3287111115 EE3287111125 EE3287111135 EE3287111145 EE3287111155
DIM (IN MM)

295 492 689 IN 7500 MM MM MM MM MM MM MM IN 12500 IN 17500
PG
689
1083 IN 27500 1476 IN 37500 1870 IN 47500 2264 IN 57500
1083 IN 27500 1476 IN 37500 1870 IN 47500 2264 IN 57500
0 75 WIRE COLOR
BLACK BLACK BLACK BLACK BLACK BLACK 5 6 11 12 17 18
WIRE TAG
BKP3 BKM3 BKP3 BKM3 BKP4 BKM4
SIGNAL NAME
4BKP 4BKM 5BKP 5BKM 6BKP 6BKM
BKP3 BKM3 BKP3 BKM3 BKP4 BKM4
A SEE NOTE 4 320 24 CONNECTOR LABEL SOC/ PIN NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9
WIRE COLOR
BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK KEY KEY BLACK BLACK BLACK BLACK BLACK BLACK 1 2 3 4 5 6 7 8 9 10 11 12
SIGNAL NAME
4U 4V 4W 4G 4BKP 4BKM 5U 5V 5W 5G 5BKP 5BKM
1 TYP AXIS NUMBER

AXIS 4
WIRE COLOR
BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK 1 2 3 4 7 8 9 10 13 14 15 16
WIRE TAG
4U 4V 4W 4G 5U 5V 5W 5G 6U 6V 6W 6G
4U 4V 4W 4G 5U 5V 5W 5G 6U 6V 6W 6G MOTOR REV. EE3287111XXX MFG. NAME MOTOR REV. EE3287111XXX MFG. NAME
AXIS 4 & 5 POWER/BRK A1
15 POS SOC
AXIS 4 & 5 PWR/BRAKE A1
AXIS 5
AXIS 6
CABLE SPECIFICATION 18C #18 AWG CABLE HYPALON JACKET MAX CABLE O.D.=13.5 MM (0.530) P/N=T14107 ASSEMBLY NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2.
AXIS 6 POWER/BRK B1
9 POS SOC 1 TYP
1TYP
6 TYP EXTRACTION TOOL: AMP #4558222

AXIS 6 PWR/BRAKE B1
13 14 15 16 17 18
6U 6V 6W 6G 6BKP 6BKM
KEY
DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL LENGTH DIMENSIONS + / 1/2 IN
3. BUILD UP CABLE DIA. WITH 1/32 X 2 EPDM STRIP MATERIAL FOR PROPER PG FITTING DIA. A SMALL AMOUNT OF ADHESIVE SHOULD BE USED TO SECURE EPDM STRIP PRIOR TO APPLICATION OF SHRINK TUBING. RETAIN EPDM STRIP MATL WITH 6 OF SHRINK TUBING. 4. FOR CABLE EE3287111105, USE 200 AS LEFT PG LOCATION
EE-3287-111-005 Through 155
13. CABLES
1316 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1317
Figure 138. Axes 3 and 7 Power Connection Cable
REV LEV.
A A A A A A
CABLE VERSION
EE3287112005 EE3287112010 EE3287112015 EE3287112025 EE3287112035 EE3287112045 EE3287112055
DIM (IN MM)

295 IN 492 IN 689 IN 7500 MM
PG
REV LEV.
B B B B B B B
CABLE VERSION
EE3287112105 EE3287112110 EE3287112115 EE3287112125 EE3287112135 EE3287112145 EE3287112155 295 492 689
DIM (IN MM)

IN 7500 MM MM MM MM MM MM MM
PG
SEE NOTE 3
12500 MM 17500 MM
IN 12500 IN 17500 IN 27500 IN 37500
1083 IN 27500 MM 1476 IN 37500 MM 1870 IN 47500 MM 2264 IN 57500 MM
1083 1476
1870 IN 47500 2264 IN 57500
0 75 WIRE COLOR/ NUMBER

BLUE/17 BLUE/18 BLUE/19 BLUE/20
WIRE TAG
BKP2 BKM2 BKP2 BKM2
SIGNAL NAME
3BKP 3BKM 7BKP 7BKM
BKP2 BKM2 BKP2 BKM2
A SEE NOTE 3 320 1 TYP 24
CONNECTOR LABEL
SOC/ PIN NO.

1 2 3 4 5 6 7 8 9 10
WIRE COLOR/ NUMBER

RED/1 WHITE/2 BLACK/3 GRN/YEL/4 RED/5 WHITE/6 BLACK/7 GRN/YEL/8 BLUE/17 BLUE/18 KEY PLUG KEY PLUG RED/9 WHITE/10 BLACK/11 GRN/YEL/12 RED/13 WHITE/14 BLACK/15 GRN/YEL/16 KEY PLUG NOT USED BLUE/19 BLUE/20
SIGNAL NAME
WIRE COLOR/ NUMBER

RED/1 WHITE/2 BLACK/3 GRN/YEL/4 RED/5 WHITE/6 BLACK/7 GRN/YEL/8 RED/9 WHITE/10 BLACK/11 GRN/YEL/12 RED/13 WHITE/14 BLACK/15 GRN/YEL/16
WIRE TAG
3U 3V 3W 3G 3U 3V 3W 3G 7U 7V 7W 7G 7U 7V 7W 7G
3U 3V 3W 3G 3U 3V 3W 3G MOTOR REV. EE3287112XXX MFG. NAME 7U 7V 7W 7G 7U 7V 7W 7G

AXIS 7 POWER/BRK L1 AXIS 3 POWER/BRK K1
AXIS 3 PWR/BRK K1
MOTOR REV. EE3287112XXX MFG. NAME
12 POS SOC
11 12 1 2 3 4 AXIS 7 PWR/BRK L1 5 6 7 8 9 10 11 12
7U 7V 7W 7G 7U 7V 7W 7G
CABLE SPECIFICATION 16#14 & 4#18 AWG CONDUCTORS HYPALON JACKET MAX CABLE O.D.= 21.0 MM (0.825) P/N=T14379 1 TYP
1TYP 6 TYP
12 POS SOC
ASSEMBLY NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL LENGTH DIMENSIONS + / 1/2 IN
7BKP 7BKM
18 AWG
3. FOR CABLE EE3287112105, USE 200 FOR LEFT PG LOCATION
EE-3287-112-005 Through 155
13. CABLES
1318 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1319
Figure 139. EE-3287-113-005 through 155 Pulse Cable
13. CABLES
1320 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1321
Figure 1310. P-200 R-J2 Purge/Battery Connection Cable
REV LEV.
CABLE VERSION EE3287115005 EE3287115010 EE3287115015 EE3287115025 EE3287115035 EE3287115045 EE3287115055
DIM (IN MM) 295 492 689 1083 1476 1870 2264 IN IN IN IN IN IN IN 7500 12500 17500 27500 37500 47500 57500 MM MM MM MM MM MM MM
PG NO NO NO NO NO NO NO
REV LEV. B B B B B B B
CABLE VERSION EE3287115105 EE3287115110 EE3287115115 EE3287115125 EE3287115135 EE3287115145 EE3287115155
DIM (IN MM) 295 492 689 1083 1476 1870 2264 IN IN IN IN IN IN IN 7500 12500 17500 27500 37500 47500 57500 MM MM MM MM MM MM MM
PG YES YES YES YES YES YES YES
0 65.0 4.0 8.0
A A A A A A A
SEE NOTE 6
IS GND
CONNECTOR LABEL A
SOC/ PIN NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
WIRE SIGNAL TWISTED PAIR NAME NUMBER COLOR

PS1P 1 PS1N FS1P 2 FS1N PSOL1 3 PSOL2 OT1P 4 OT1N OT2P 5 OT2N OT3P 6 OT3N SHIELD PSOL2N KEY SHIELD 18 AWG XOTP 7 XOTN CRASHP 8 CRASHN SHIELD 18 AWG SHIELD 18 AWG KEY 6V7 0V7 SHIELD KEY 6V1 0V1 6V2 0V2 6V3 0V3 6V4 0V4 6V5 0V5 6V6 0V6 SHIELD
1 TYP
1PSA1
SEE NOTE 6 320 24
WIRE COLOR/ NUMBER WHITE1 BLUE2 WHITE3 ORANGE4 WHITE5 GREEN6 WHITE7 BROWN8 WHITE9 GRAY10 RED11 BLUE12 RED13 ORANGE14 RED15 GREEN16
TWIST WIRE TAG PAIR ISTB NO. CONNECT POINT 1 PSA1 1 2 PSA2 5 FSA1 2 6 FSA2 ISB1 3 3 ISB1 4 GND 4 GND GND 5 GND GND 6 GND GND 7 GND PARKP 8 PARKN
SIGNAL NAME PS1P PS1N FS1P FS1N PSOL1 PSOL2 OT1P OT1N OT2P OT2N OT3P OT3N XOTP XOTN CRASHP CRASHN
2PSA2
M1
5FSA1
6FSA2
ISB13
ISB14
GND GND GND GND GND GND GND GND
PARKP PARKN
WHITE1 BLUE2 WHITE3 ORANGE4 WHITE5 GREEN6 WHITE7 BROWN8 WHITE9 GRAY10 RED11 BLUE12
M1
15 POS SOC
18 AWG
RED13 ORANGE14 RED15 GREEN16
TIEWRAP SPARES
N1
4.0 TYP.
INTRINSIC REV. EE3287115XXX MFG. NAME INTRINSIC REV. EE3287115XXX MFG. NAME
9 POS SOC
N1
R1
6.0 TYP
15 18 AWG 9 10 11 12 13 14 18 AWG
BLACK29 GRAY30
8.0
6V1
WIRE COLOR/ NUMBER RED17 BROWN18 RED19 GRAY20 BLACK21 BLUE22 BLACK23 ORANGE24 BLACK25 GREEN26 BLACK27 BROWN28 BLACK29 GRAY30
WIRE TAG 6V1 0V1 6V2 0V2 6V3 0V3 6V4 0V4 6V5 0V5 6V6 0V6 6V7 0V7
TWIST PAIR NO. 9 9 10 10 11 11 12 12 13 13 14 14 15 15
CONNECTION POINT
0V1 6V2 0V2 6V3 0V3
CABLE SPECIFICATION 16PR #20 AWG CABLE HYPALON JACKET MAX. CABLE O.D. = 20.5mm (0.805 MAX.) P/N=T14685
4.0 TYP
R1
4 POS SOC
S1
RED17 BROWN18 RED19 GRAY20 BLACK21 BLUE22 BLACK23

ORANGE24
BATTERY PACK
6V4 0V4 6V5 0V5 6V6 0V6 6V7
S1
ASSEMBLY NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL LENGTH DIMENSIONS + 1/2 IN. 3.0 TYP. 1.0 TYP.
15 POS SOC
BLACK25 GREEN26 BLACK27 BROWN28
KEY
CUT SPARE WIRES AT STRIP BACK PR16 YELLOW31 & BLUE32
EXTRACTION TOOL: AMP # 4558222
CUT SPARE WIRES AT STRIP BACK PR16 YELLOW31 & BLUE32
0V7
3. TYP. TERMINATION OF SHIELD TO SHIELD AND SHIELD TO CONDUCTOR.
CONDUCTORS SHIELD SLEEVING DETAIL A
SOLDERED CONNECTION BETWEEN SHIELDS BULK CABLE 4. FOR INTRINSIC CABLE MARKING: APPLY 4 OF BLUE SHRINK TUBING UNDER CABLE I.D. LABELS AND ALSO AT 22 INTERVALS AS REQD. 5. BUILD UP CABLE DIA. WITH 1/32 X 2 EPDM STRIP MATERIAL FOR PROPER PG FITTING DIA. A SMALL AMOUNT OF ADHESIVE SHOULD BE USED TO SECURE EPDM STRIP PRIOR TO APPLICATION OF SHRINK TUBING. RETAIN EPDM STRIP MATL WITH 2 OF BLUE SHRINK TUBING. 6. FOR CABLE EE3287115105, USE 200 FOR LEFT PG LOCATION
BRAIDED SHIELD SHRINK TUBING DETAIL B SHIELD CONDUCTOR 18 AWG BLACK (2) SOLDERED CONNECTION BULK CABLE CONDUCTORS BRAIDED SHIELD SLEEVE TUBING
EE-3287-115-005 through 155
13. CABLES
1322 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1323
Figure 1311. P-200 Robot Ground Cable
REV LEV.
A A A A A A A
CABLE VERSION
EE3287116005 EE3287116010 EE3287116015 EE3287116025 EE3287116035 EE3287116045 EE3287116055 295 492 688 1083 1476 1870 2264
DIM (IN MM)

IN IN IN IN IN IN IN 7500 12500 17500 27500 37500 47500 57500 MM MM MM MM MM MM MM
PG
REV LEV.
B B B B B B B
CABLE VERSION
EE3287116105 EE3287116110 EE3287116115 EE3287116125 EE3287116135 EE3287116145 EE3287116155 295 492 688 1083 1476 1870 2264
DIM (IN MM)

IN IN IN IN IN IN IN 7500 12500 17500 27500 37500 47500 57500 MM MM MM MM MM MM MM
PG
SEE NOTE 4
SEE NOTE 4 320 24
GROUND REV. EE3287116XXX MFG. NAME
GROUND REV. EE3287116XXX MFG. NAME
1 TYP. CABLE SPECIFICATION #8 AWG TINNED COPPER GRN W/2 COEXTRUDED YELLOW STRIPS MAXCABLE O.D.=6.9 MM (0.27 ) P/N=#XP0845168165 NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2. REF. ENGINEERING GUIDELINE EG00084 FOR CABLE FABRICATION SPECIFICATIONS. 3. SEE LENGTH CHART FOR CABLE VERSION REVISION LEVEL. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL DIMENSIONS +/ 0.5 4. FOR CABLE EE3287116105, USE 200 FOR LEFT PG LOCATION
EE-3287-116-005 through 155
13. CABLES
1324 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1325
Figure 1312. Axes 1, 2, and 3 Power and Pulse Harness
SHELL/KEY ASSEMBLY POSITION
FRONT VIEW OF SOCKETS
CONNECTOR LABEL CONN 1
SOCKET NO. 1 2
SIGNAL NAME 5V
TWISTED PAIR # 1
WIRE TYPE & COLOR 3 TWISTED PAIRS 20 AWG 19 /32 600V BLACK PTFF INS
BRAIDED SHIELD
SLEEVE TYPE
148 GROUND 2
150
0V 5V 2 0V 5V 3 0V SIGNAL NAME 1D 1*D 1RQ 1*RQ 2D 2*D 2RQ 2*RQ 3D 3*D 3RQ 3*RQ SHIELD SHIELD TWISTED PAIR # 4 5 6 7 8 9
CONN 2
1 2 1
36 AWG TINNED COPPER BRAID
148
PWR3
150
BLACK EXPANDO 10 11 2 POS SOC 10
CABLE RUN
GUIDE KEY
F
2222S 148
BRK3
F BACKSHELL
2222S
POTTED
CONN 3 2 CONNECTOR LABEL PIN NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PIN NO. 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
SEC. F F AXIS 3 POWER CONNECTOR
CONNECTOR LABEL
SOC/PIN NO. A B C D A B A D F G J N S R 1 2
SIGNAL NAME 3U 3V 3W 3G 3BKP 3BKM 3D 3*D 3RQ 3*RQ 5V 0V 0VA 6VA SHIELD 6VA 0VA
WIRE COLOR COND. QTY. & SIZE OR PAIR #

BLK 21 & 25
BLK 22 & 26 BLK 23 & 27 G/Y 24 & 28
BRAIDED SHIELD
SLEEVE TYPE
150 10SL3S
CONN 1
11 4
EXPANDO OVER SHIELD OVER CONDUCTORS
PWR3
WIRE TYPE & COLOR
BRAIDED SHIELD
SLEEVE TYPE
(2) 16 AWG (2) 16 AWG (2) 16 AWG (2) 16 AWG (1) 18 AWG (1) 18 AWG TWISTED PAIRS 20 AWG 19/ 32 600V BLACK PTFE INS BLACK EXPANDO
BRK3
BLACK 29 BLACK 30 8 9 3
C4
6 TWISTED PAIRS 20 AWG 41/36 TINNED COPPER BLACK PVC INS
2 POS SOC 10 36 AWG TINNED COPPER BRAID
CONN 2
CABLE RUN
2029SW
148 130
2 PIN PULSE3
BATT3
150
11 BLACK EXPANDO 2 POS SOC
CONN 3
NO SHIELD CONNECTION AT THESE CONNECTORS
GUIDE KEY
SEC. EE PULSE 3 ENCODER CONNECTOR
2029S POTTED BACKSHELL SEE NOTE 5 E
PULSE3
6 LG BRANCH
SHIELDED
EXTRACTION TOOL: AMP #4558222
GUIDE KEY
G E A F
BATT3
SHIELDED 20 AWG PTFE BLACK WIRE JUMPERS
(2) 18 AWG WIRES CONNECTED TO THE BRAID
EXTRACTION TOOL: AMP #4558222

22 23 24
15 PIN
CABLE RUN
CONNECTOR LABEL
SIGNAL NAME 1U 1V 1W 1G 2U 2V 2W 2G 1BKP 1BKM
WIRE COLOR BLACK1 BLACK2 BLACK3 GRN/YEL4 BLACK5 BLACK6 BLACK7 GRN/YEL8 BLACK9 BLACK10 KEY PLUG BLACK11 BLACK12 BLACK13 GRN/YEL14 BLACK15 BLACK16 BLACK17 BLACK18 BLACK19 BLACK20 KEY PLUG BLACK21 BLACK22 BLACK23 GRN/YEL24 BLACK 25 BLACK 26 BLACK 27 GRN/YEL28 BLACK 29 BLACK 30
SLEEVE TYPE
CONDUCTOR SIZE 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 18 AWG 18 AWG
C4
SEC. DD AXIS 2 POWER CONNECTOR

2410S
PWR2
120 GROUND 2 GROUND 1
A B C D E F G A B A D F G J N S R 1 2
2U 2U 2V 2V 2W 2W 2G 2BKP 2BKM 2D 2*D 2RQ 2*RQ 5V 0V 0VA 6VA SHIELD 6VA 0VA
BLK 5 & 11 BLACK 15
BLK 6 &12
BLACK 16
BLK 7 & 13
BLACK 17 G/Y 8,14,18 BLACK 19 BLACK 20 6 7 2
(2) 16 AWG (1) 16 AWG (2) 16 AWG (1) 16 AWG (2) 18 AWG (1) 18 AWG (3) 16 AWG (1) 18 AWG (1) 18 AWG TWISTED PAIRS 20 AWG 19/ 32 600V BLACK PTFE INS BLACK EXPANDO
H4
PWR1
BLACK EXPANDO
0 GROUND 1
40
SPLIT POINTS COVER W/TAPE WRAP CONNECT SHIELDS SEE NOTE 4B
BRK2
45
PWR/PULSE 13 EE3287321001 MFG NAME REV
95
113 PWR2
115
22 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 18 AWG 18 AWG
TYPICAL 3 PLACES 23 24
D
113 BRK2 115
PULSE2
J4
PWR2
2U 2V 2W 2G 2U 2V 2W 2G 2BKP 2BKM
12 POS
PIN
PWR 1&2
H4
BLACK EXPANDO
BATT2
EXPANDO OVER CONDUCTORS

22 23 24
CABLE RUN
B A
10SL3
113 PULSE2
115
2029S
PWR1 A B C D A B A D F G J N S R 1 2 1U 1V 1W 1G 1BKP 1BKM 1D 1*D 1RQ 1*RQ 5V 0V 0VA 6VA SHIELD 6VA 0VA BLK1 BLK2 BLK3 GRN/YEL4 BLACK 9 BLACK 10 4 5 1 (1) 16 AWG (1) 16 AWG (1) 16 AWG (1) 16 AWG (1) 18 AWG (1) 18 AWG TWISTED PAIRS 20 AWG 19/ 32 600V BLACK PTFE INS BLACK EXPANDO
GUIDE KEY
PWR2
12 POS
PIN
J4
SEC. CC
BRK 1 ,2 & 3 BRAKE CONNECTOR
2 PIN
BATT2
SHIELDED
A
115
A
1810S
K4
PWR3
3U 3V 3W 3G 3U 3V 3W 3G 3BKP 3BKM
BLACK EXPANDO
16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 16 AWG 18 AWG 18 AWG
GUIDE KEY
22 23 24 PWR3
D A
113
PWR1 1810
C B
BRK1
CABLE RUN
12 POS
PIN
K4
SEC. BB AXIS 1 POWER CONNECTOR

FRONT VIEW OF SOCKETS
TYPICAL FOR POWER AND BRAKE 113

BRK1
B
115
B
PULSE1
GUIDE KEY
CABLE RUN
TYP
2029SW
C
115
10SL3S TYP
BATT1
POWER WIRE = 16 AWG 19/ 29 600V UL1199 PTFE W/BLK OR GRN/YEL INS. BRAKE WIRE = 18 AWG 19/ 30 600V UL1199 PTFE W/BLK INS.
EXPANDO OVER SHIELD OVER CONDUCTORS TYPICAL FOR PULSE 113

PULSE1
ASSEMBLY NOTES: 1. ALL LENGTH DIMENSIONS + 1/2 IN. 2. SPECIFIC WIRE, LABELS, SHIELD AND SLEEVE MATERIAL NOT CALLED OUT ON BOM. 3. HARNESS ASSY. LABEL TO BE ATTACHED AS SHOWN WITH ALL INFORMATION INDICATED.
SEC. AA PULSE 1 AND PULSE 2 ENCODER CONNECTOR
2 PIN
BATT1
2029S TYP POTTED BACKSHELL SEE NOTE 5
6 LG BRANCH
SHIELDED
4. TERMINATION OF SHIELD TO CONDUCTOR & SHIELD TO SHIELD

SHIELD CONDUCTOR 18 AWG BLACK SOLDERED CONNECTION COVER W/SHRINK TUBING SLEEVING CONDUCTORS BRAIDED SHIELD SLEEVE TUBING SOLDERED CONNECTION BETWEEN SHIELDS SLEEVING 1.75 MAX BRAIDED SHIELD TAPE WRAP TRUNK TO LEGS CONDUCTORS SHIELD SLEEVING
5. HEIGHT OF POTTED CONNECTORS
DETAIL A
DETAIL B
EE-3287-321-001
13. CABLES
1326 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1327
Figure 1313. Axes 4, 5, and 6 Power Harness
DISCARD RETAINING SCREWS SUPPLIED WITH BACKSHELL AND REPLACE WITH ITEM 13. USE ORING ITEM 14 AS RETAINER FOR CONNECTOR MTG SCREWS (INTERNAL TO SHELL). NOTE: SCREW THREAD SHOULD NOT EXCEED 5mm BEYOND CONNECTOR FACE. 210
36 AWG TINNED COPPER BRAID BLACK EXPANDO
CONNECTOR SOC/ PIN LABEL NO.

CONN 4 1 2 CONN 5 1 2 1 CONN 6 2
SIGNAL NAME
5V
TWISTED WIRE TYPE BRAIDED PAIR # & COLOR SHIELD

1 3 TWISTED PAIRS 20 AWG 19/ 32 UL1199 600V BLACK PTFE
SLEEVE DESCRIP
CONNECTOR LABEL
PIN NO.
1 8 5 6 12 13 14 10 N/C 1 2
SIGNAL NAME
0V 5V
4RQ
TWISTED PAIR #
1 5 4
WIRE TYPE & COLOR

3 PAIRS 20 AWG 19/ 32 UL1199 600V PTFE
BRAIDED SHIELD
SLEEVE TYPE
0V 5V 2 0V 5V 3 0V
2 POS SOC 0 2 POS SOC 0 2 POS SOC
GROUND WIRE #8 AWG 168/30 TINNED COPPER FLEXIBLE POLYETHYLENE JACKET GREEN WITH TWO COEXTRUDED YELLOW STRIPES 180 APART BRAND REX #XP0845168165
CONN 4
GROUND
202
PULSE 4 6 LG BRANCH BATT 4
204
PULSE 4
BATT 4
2 PIN
4*RQ 4D 4*D 6VA 0VA SHIELD 6VA 0VA
BLACK EXPANDO
1
CONN 5
4
TYP 5MM
CONNECTOR LABEL
PIN NO.
1 8 5 6 12 13 14 10 N/C 1 2
SIGNAL NAME
0V 5V
5RQ
TWISTED PAIR #
2 7 6
WIRE TYPE & COLOR

BRAIDED SHIELD
SLEEVE TYPE
1
CONN 6
CONNECTOR SOC/ PIN LABEL NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
SIGNAL NAME
4D 4*D 4RQ 4*RQ 5D 5*D 5RQ 5*RQ 6D 6*D 6RQ 6*RQ SHIELD SHIELD
TWISTED WIRE TYPE BRAIDED PAIR # & COLOR SHIELD

4 5 6 7 8 9 6 TWISTED PAIRS 20 AWG 19/ 32 UL1199 600V BLACK PTFE
SLEEVE DESCRIP
202
PULSE 5
PULSE 5
6 LG BRANCH
BATT 5 2 PIN
BATT 5
D4
BLACK EXPANDO
BLACK EXPANDO
12 15 POS PIN 13 14
D4
CONNECTOR LABEL
202 204
PIN NO.
A1 A2 A3 B3 A4 B4 A5 A6 B6 1 2
SIGNAL NAME
0V 5V
6RQ
TWISTED PAIR #
3 9 8
WIRE TYPE & COLOR

BRAIDED SHIELD
SLEEVE TYPE
CONNECT SHIELD SEE NOTE 4 SPLIT POINTS SPLICE SHIELDS APPLY TAPE WRAP SEE NOTE 4
PULSE 6
PULSE 6
(2) 18AWG WIRES CONNECTED TO THE BRAID
6 LG BRANCH
30
35
165
BATT 6
2 PIN
CONNECTOR LABEL
SOC/ PIN CONDUCTOR NUMBER NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 KEY
BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK
SIGNAL NAME
4U 4V 4W 4G 4BKP 4BKM 5U 5V 5W 5G 5BKP 5BKM
WIRE TYPE & COLOR
SLEEVE DESCRIP
15 POS PIN
PWR/PULSE 46 EE3287322001 MFG NAME REV
130
GROUND
BATT 6
12 13 14
A4
BLACK EXPANDO
1 2 3 4 5 6 7 8 9 10 11 12
GRN/YEL 18 AWG 19/30 UL1199 600V BLACK PTFE GRN/YEL
24 LENGTH OUTSIDE HARNESS
CONNECTOR LABEL 202

PWR 4
PWR 4
CONDUCTOR SOC/ NUMBER PIN NO.

1 2 3 4 5 6 1 2 3 4 5 6 A1 A2 A3 B1 B2 B3
BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK
SIGNAL NAME
4U 4V 4W 4G 4BKP 4BKM 5U 5V 5W 5G 5BKP 5BKM 6U 6V 6W 6G 6BKP 6BKM
WIRE TYPE & COLOR

BLACK BLACK BLACK GRN/YEL BLACK BLACK BLACK BLACK BLACK GRN/YEL BLACK BLACK BLACK BLACK BLACK GRN/YEL BLACK BLACK
SLEEVE TYPE
BLACK EXPANDO
A4
12 9 POS PIN 13 14
B4
TYP 17PLACES 202

PWR 5
204
PWR 5
EXTRACTION TOOL: AMP 4558222
202
PWR 6
204
PWR 6
CONNECTOR LABEL
SOC/ PIN CONDUCTOR NUMBER NO.

1 2 3 4
BLACK BLACK BLACK BLACK BLACK BLACK
SIGNAL NAME
6U 6V 6W 6G 6BKP 6BKM
WIRE TYPE & COLOR
SLEEVE DESCRIP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
BLACK EXPANDO
13 14 15 16 17 18
BLACK GRN/YEL 18 AWG 19/30 UL1199 600V BLACK PTFE EXPANDO
18 AWG TINNED PTFE
19/30 COPPER
B4
5 6 7 8 9
TERMINATION OF SHIELD TO CONDUCTOR AND SHIELD TO SHIELD

SHIELD CONDUCTOR 14 AWG BLACK SOLDERED CONNECTION COVER W/SHRINK TUBING
SLEEVING
KEY KEY
SOLDERED CONNECTION BETWEEN SHIELDS

SLEEVING
CONDUCTORS SHIELD SLEEVING
CONDUCTORS
BRAIDED SHIELD SLEEVE TUBING
BRAIDED SHIELD
TAPE WRAP ,TRUNK TO LEGS
DETAIL A
DETAIL B
EE-3287-322-001
13. CABLES
1328 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1329
Figure 1314. Purge Control Cable
EE-3287-323-001
13. CABLES
1330 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1331
Figure 1315. Six Axis Battery Harness
202 204
TAPE WRAPPED SPLIT POINT SHIELDS SPLICED SEE DET 4B
BATT AXIS 4
SOC
CONNECTOR LABEL
BATT
SOC/ PIN NO.

1 2 1 2 1 2
SIGNAL NAME
6V4
TWISTED PAIR NUMBER

4
WIRE TYPE & COLOR
BRAIDED SHIELD
160 BLUE EXPANDO OVER BRAID SHIELD OVER CONDUCTORS, TYP.
202 204
BATT AXIS 5
AXIS 4
0V4 6V5 5 0V5 6V6 6 0V6
SOC
BATT
202 204
BATT AXIS 6
AXIS 5
SOC
BATT AXIS 6
3 PAIRS 20 AWG 19/ 32 UL 1199 600V PTFE BLACK
105
BATT AXIS 1
TYP 7 PLACES 0 15 PIN MINI 0 1 3 5

EE3287324001 REV MANUF
INTRINSICALLY SAFE
TAPE WRAPPED SPLIT POINT SHIELDS SPLICED SEE DET 4B 80

BATT AXIS 2
2 POS SOC
TYP. END POINT OF SHIELD/JACKET EXTRACTION TOOL: AMP # 4558222
105 2 POS SOC
S4
SEE NOTE 4, DETAIL A FOR SHIELD CONNECTION
CONNECTOR LABEL
BATT
SOC/ PIN NO.

1 2 1 2 1
SIGNAL NAME
6V1
TWISTED PAIR NUMBER

1
WIRE TYPE & COLOR
BRAIDED SHIELD
CONNECTOR LABEL
PIN NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
SIGNAL NAME
6V1 0V1 6V2 0V2 6V3 0V3 6V4 0V4 6V5 0V5 6V6 0V6 SHIELD
TWISTED PAIR NUMBER

1 2 3
WIRE TYPE & COLOR

6 TWISTED PAIRS 20 AWG 19/ 32 UL 1199 600V PTFE BLACK
BRAIDED SHIELD
BATT AXIS 3
140 2 POS SOC
AXIS 1
0V1 6V2 2 0V2 6V3 3 0V3
TYP. END POINT OF SHIELD & SLEEVE SHIELD STOPS BEFORE SLEEVE. EXTRACTION TOOL: AMP # 4558222 36 AWG TINNED COPPER BRAID
BATT AXIS 2
3 PAIRS 20 AWG 19/ 32 UL 1199 600V PTFE BLACK
BATT AXIS 3 2
S4
4 5 6
18AWG BLK
TERMINATION OF SHIELD TO CONDUCTOR AND SHIELD TO SHIELD

SHIELD CONDUCTOR 14 AWG BLACK SOLDERED CONNECTION COVER W/SHRINK TUBING
SLEEVING
SOLDERED CONNECTION BETWEEN SHIELDS

SLEEVING
CONDUCTORS SHIELD SLEEVING
CONDUCTORS
BRAIDED SHIELD SLEEVE TUBING DETAIL A
BRAIDED SHIELD DETAIL B
TAPE WRAP TRUNK TO LEGS
EE-3287-324-001
13. CABLES
1332 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1333
Figure 1316. Purge Flow Switch Arm Cable
REV LEVEL
CABLE VERSION EE3287340001
DIM. A 18 IN 457 MM
PG
NO
0 2 CONNECTOR LABEL FS1 PIN NO. 1 2 WIRE COLOR BLUE BLACK SIGNAL NAME FS1/NO FS1/C SLEEVE COLOR & MATL LT. BLUE EXPANDO
FLOW SWITCH
2 PIN
FS1 REV. EE3287340001 MANUF. NAME
CUT OFF SPARE RED WIRE
1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. SEE LENGTH CHART FOR REV LEVEL DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION.
EE-3287-340-001
13. CABLES
1334 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1335
Figure 1317. Solenoid Cable
REV LEVEL
B
CABLE VERSION
EE3287348001
DIM. A
18 IN 457 MM
PG
NO
CONNECTOR LABEL
SOL1
PIN NO.
1 2
WIRE COLOR
RED BLACK
SIGNAL NAME
PSOL1 PSOL2
0 9 2 2 PIN
SOL REV. EE3287348XXX MFG. NAME
INTRINSICALLY SAFE
CONNECTOR LABEL
SOL1
SOL1
SOC/ PIN NO.

1 2 3
WIRE COLOR
RED BLACK NC
SIGNAL NAME
PSOL1 PSOL2
SOL1
SEE NOTE 1 NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. SEE LENGTH CHART FOR REV LEVEL DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION.
EE-3287-348-001
13. CABLES
1336 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1337
Figure 1318. Purge Pressure Switch Cable
REV LEVEL
CABLE VERSION
EE3044345001
DIM. A
18 IN 457 MM
PG
NO
A
0 9 2 CONNECTOR LABEL
PS1
PS1 N.O.
INTRINSICALLY SAFE
PIN NO.
1 2
WIRE COLOR
RED BLACK
SIGNAL NAME
PS1P PS1N
SLEEVE COLOR & MATL

BLUE PVC
2 PIN
PS1
PRES SW REV. EE3044345XXX MFG. NAME PS1 COM
CONNECTOR LABEL
PS1 N.O. PS1 COM
WIRE COLOR
RED BLACK
SIGNAL NAME
PS1P PS1N
ASSEMBLY NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2. SYMBOL DENOTES DIMENSIONS IN INCHES.
EE-3287-345-001
13. CABLES
1338 NOTES
MARO2P10203703E
13. CABLES
MARO2P10203703E
1339
Figure 1319. R-J2 Robot Bypass Switch Arm Cable (Optional)
CABLE VERSION
EE3185356001
DIM. A
60 IN 1524 MM
PG
NO
0 CONNECTOR LABEL PIN NO.

1 2 3 4 5 6 7 8 9
WIRE COLORS
BLACK BLUE
SIGNAL NAME
COM N.O.
SLEEVE COLOR & MATL
BYPASS
SHIELD
SHIELD AND BLACK EXPANDO
INTRINSICALLY SAFE
INTRINSICALLY SAFE
9 PIN
BYPASS
BYPASS REV. EE3185356XXX MFG. NAME
BYPASS REV. EE3185356XXX MFG. NAME
BYPASS
3.00
RED N.C.
3.00 SEE NOTE 1
3.00 TYP.
3.00
NO SHIELD CONNECTION AT THIS END
NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION.
R-J2 Robot Bypass Switch Arm Cable EE-3185-356-001
13. CABLES
1340 NOTES
MARO2P10203703E
14 OPENERS AND OPTIONS
Page41
MARO2P10203703E
14
OPENERS AND OPTIONS

141

Openers and Options The following section includes schematics and cable drawings. . . . . . . . . . . . . . . D P-10 door opener and P-15 hood and deck opener. . . . . . . . . . . . . . . . . . . . . D Integral Pump Control (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Brake Release Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
141 143 1451 1481
14. OPENERS AND OPTIONS
142 NOTES
MARO2P10203703E

MARO2P10203703E
143
Figure 141. P-10 Door Opener Electrical Layout
UPPER LEVEL BOM DOOR OPENER INTERCONNECTION CABLES FOR US EE3186101105 EE3186101110 EE3186101115 EE3186101125 EE3186101135 EE3186101145 EE3186101155
DOOR OPENER ARM CABLES UPPER LEVEL BOM EE3186301001
RJ2 CONTROLLER CONNECTIONS
PURGED AXIS 3 OUTER ARM a6/3000 A06B0128B175 CAVITY DC/DC EE3044401 PWR INPUT UNIT AXIS 2 INNER ARM a6/3000 A06B0128B175 EE3044401 EE3186333001 MAGNET SWITCH SEE NOTE 1
AMP 5 AXIS 1 RAIL AMP 6 (L) L AXIS 2 INNER ARM TERMS AMP 6 (M) M AXIS 3 OUTER ARM TERMS PURGE BD BKP BKM JF8 RAIL AUX AXIS BD JF9 INNER ARM JF10 OUTER ARM
MOTOR/BRAKE 4 4 4 6 MOTOR POWER (16.9 MM DIA.) EE3186111105 EE3186111110 EE3186111115 EE3186111125 EE3186111135 EE3186111145 EE3186111155 ENCODER SIGNALS (17.4 MM DIA) EE3186112105 EE3186112110 EE3186112115 EE3186112125 EE3186112135 EE3186112145 EE3186112155 AA1 AA4 AB1 AB4 EE3186311001 EE3186312001 EE3186313001 BYPASS EE3185356001 EE3186319001
PG29
AC1 AC4
PULSE AD1 AD4 AE1 AE4
EE3186314001 EE3186315001 EE3186316001 EE3186351001 EE3186323001 LINK AG1 AG4 AH1 AH4 AN1 AN4 AK1 AK4 AL1 AL4 AJ1 AJ4 EE3066322001 AM1AM4 PS2 SWITCH PRESSURE FS2 FLOW SWITCH OUTER ARM
PG29
AF1 AF4
PURGE CONTROL 24VPG 0V PG UNIT SENSOR OUTPUT BYPASS OUTPUT PURGE CONTROL ISTB
3
EOAT1 EOAT2 EOAT5 EOAT6
REFERENCE SOL VALVE SHOWN ON MECH BOM REFERENCE PRES SW SHOWN ON MECH BOM FLOW SW ASSY
SOL2 PURGE VALVE
ISRR ISRR
CRANK
INNER INTERNAL ARM GND WIRE EE3158316001 GND WIRES (2) EE3158316001 (2) EE3158316002 AXIS 3 AXIS 2
EE3186340001
3 4 7 8
PSB1 PSB2 FSB1 FSB2 ISB23 ISB24
PURGE BARRIER
6V
BATTERY
3 3
0V
INTRINSICALLY SAFE (17.4 MM DIA) EE3186115105 EE3186115110 EE3186115115 IS EE3186115125 GND EE3186115135 EE3186115145 EE3186115155 GROUND CABLE (6.8MM) EE3287116105 EE3287116110 EE3287116115 EE3287116125 EE3287116135 EE3287116145 EE3287116155
PG29
AXIS 1 RAIL a6/3000 A06B0128B6750008 AXIS 1
PG9
NOTE: I.S. GROUND IS A SEPARATE INTRINSICALLY SAFE GROUND AT THE PURGE CONTROL UNIT
NOTES 1. CABLES EE3186319001 AND EE3186333001 NEED TO BE SOLDERED TO THE BREAKAWAY JOINT PINS AS SHOWN HERE SOLDER AND SOLDER AND COVER W/ SHRINK COVER W/ SHRINK EE-3186-319-001 EE-3186-333-001
2. SPARE SPRING CONTACT PART NUMBER HDWMO0000046590
EE-3186-001
144 NOTES
MARO2P10203703E

MARO2P10203703E
145
Figure 142. P-10 Door Opener Euro Electrical Layout
UPPER LEVEL BOM DOOR OPENER INTERCONNECTION CABLES FOR US EE3186102105 EE3186102110 EE3186102115 EE3186102125 EE3186102135 EE3186102145 EE3186102155
DOOR OPENER ARM CABLES UPPER LEVEL BOM EE3186301001
AXIS 3 OUTER ARM a6/3000 A06B0128B175
PURGED CAVITY
DC/DC EE3044401 PWR INPUT UNIT
AXIS 2 INNER ARM a6/3000 A06B0128B175

MOTOR/BRAKE 4 4 4 6 MOTOR POWER (16.9 MM DIA.) EE3186121105 EE3186121110 EE3186121115 EE3186121125 EE3186121135 EE3186121145 EE3186121155 ENCODER SIGNALS (17.4 MM DIA) EE3186112105 EE3186112110 EE3186112115 EE3186112125 EE3186112135 EE3186112145 EE3186112155 AA1 AA4 AB1 AB4 EE3186311001 EE3186312001 EE3186313001
EE3186333001 MAGNET SWITCH SEE NOTE 1
AMP 5 AXIS 1 RAIL AMP 6 (L) L AXIS 2 INNER ARM TERMS AMP 6 (M) M AXIS 3 OUTER ARM TERMS PURGE BD BKP BKM JF8 RAIL AUX AXIS BD JF9 INNER ARM JF10 OUTER ARM
EE3186319001
PG29
AC1 AC4
BYPASS EE3185356001
EE3186314001 EE3186315001 EE3186316001 EE3186351001 EE3186348001 EE3186340001 4 5 6 7 LINK AG1 AG4 AM1AM4 AH1 AH4 AN1 AN4 AK1 AK4 AL1 AL4 AJ1 AJ4 OUTER ARM
PG29
AF1 AF4
PURGE CONTROL 24VPG 0V PG UNIT SENSOR OUTPUT BYPASS OUTPUT PURGE CONTROL ISTB
3
EOAT1 EOAT2 EOAT5 EOAT6 PSB1 PSB2 FSB1 FSB2 ISB23 ISB24
REFERENCE SOL VALVE SHOWN ON MECH BOM JUMPER REMOVED HR2151 PRES & FLOW SWITCHES
SOL2 PURGE VALVE PR OP4 FL 5 6 7
ISRR ISRR
CRANK
INNER INTERNAL ARM GND WIRE EE3158316001 GND WIRES (3) EE3186326001 (1) EE3186326002 AXIS 3 AXIS 2
3 4 7 8
PURGE BARRIER
6V
BATTERY
3 3
0V
INTRINSICALLY SAFE (17.4 MM DIA) EE3186115105 EE3186115110 EE3186115115 IS EE3186115125 GND EE3186115135 EE3186115145 EE3186115155 GROUND CABLE (6.8MM) EE3287116105 EE3287116110 EE3287116115 EE3287116125 EE3287116135 EE3287116145 EE3287116155
PG29
AXIS 1 RAIL a6/3000 A06B0128B6750008
AXIS 1
PG9
NOTES 1. CABLES EE3186319001 AND EE3186333001 NEED TO BE SOLDERED TO THE BREAKAWAY JOINT PINS AS SHOWN HERE SOLDER AND SOLDER AND COVER W/ SHRINK COVER W/ SHRINK EE-3186-319-001 EE-3186-333-001
2. SPARE SPRING CONTACT PART NUMBER HDWMO0000046590
EE-3186-002
146 NOTES
MARO2P10203703E

MARO2P10203703E
147
Figure 143. P-200 Plus P-10 or P-15 Controller Bypass Package
TYPICAL INTRINSICALLY SAFE CABLE ROUTING SHIELD CONNECTS TO INTRINSICALLY SAFE GROUND
1
ISTB TERMINAL STRIP
BYPASS LS KFD2SREx1.W.LB
EE3112600001
P10 or P15 BYPASSLS KFD2SREx1.W .LB
EE3112600
I/P POWER
24V @ 1.2A
DELTRON
W112A
P10 or P15 PARTS SENSE

ISB2 ISB1
ISB3 ISB10 PS OVP
2ND TRIGGER
TRIGGER
FLOW
I/P
SOLENOID
SOLENOID
IDEC IBRC
INTRINSICALLY SAFE GROUND CONNECTION P200 CONTROLLER BACKPANEL UPPER LEFT CORNER IS GND NOTES: FOR CABLE WIRING, SEE EE3287500 FOR CONTROLS WIRING, SEE EE3287500 AND APPLICATION PACKAGE MAINTAIN 50MM SPACING I.S. WIRING AND ALL OTHER CIRCUITS, INCL EE3112600
EE-3287-513
148 NOTES
MARO2P10203703E

MARO2P10203703E
149
Figure 144. P-10 or P-15 Power Connection Cable
REV LEV.
C C C C C C C
CABLE VERSION
EE3186111105 EE3186111110 EE3186111115 EE3186111125 EE3186111135 EE3186111145 EE3186111155
DIM (IN MM)

295 492 689 1083 1476 1870 2264 IN IN IN IN IN IN IN 7500 12500 17500 27500 37500 47500 57500 MM MM MM MM MM MM MM
PG
SEE NOTE 3
0 CONTROLLER CONNECTING POINT

BKP4
CONNECTOR LABEL
SOC/ PIN NO.

1 2 3 4 5 6 7 8 9 10 11 12
WIRE COLOR/ NUMBER

RED/7 WHITE/8 BLACK/9 GREEN/10
SIGNAL NAME
1U 1V 1W 1G
WIRE COLOR/ NUMBER

RED/1 BLACK/3 WHITE/2 WHITE/4 RED/5 GREEN/6
WIRE TAG
BKP4
SIGNAL NAME
1BKP 1BKM BKP4 BKM4 BKP4 BKM4
65
320 16 TYP 3 PL 4 10 6 5
RAIL
AA1
RED/1 WHITE/2 RED/5 GREEN/6
BLACK/3 WHITE/4
BKM4 BKP4 BKM4
BKM4 BKP4 BKM4
2BKP 2BKM 3BKP 3BKM
RED/1 WHITE/2
KEY PLUG
1BKP 1BKM
18 AWG
19 11 TYP
1U 1V 1W 1G 2U L 2V L 2W L
OPENER POWER EE3186111XXX MFG. NAME REV OPENER POWER EE3186111XXX MFG. NAME REV
RAIL
AA1
CONNECTOR LABEL
12 POS SOC
SOC/ PIN NO.

1 2 3 4 5 6 7 8 9 10 11 12
WIRE COLOR/ NUMBER

SIGNAL NAME
2U 2V 2W 2G
INNER
AB1
12 POS SOC
INNER
AB1
CONTROLLER CONNECTING POINT

AMPLIFIER 5
WIRE COLOR/ NUMBER

RED/7 WHITE/8 BLACK/9 GREEN/10 RED/11 WHITE/12 BLACK/13 GREEN/14 RED/15 WHITE/16 BLACK/17 GREEN/18
WIRE TAG
1U
SIGNAL NAME
1U 1V 1W 1G
2G L 3U M 3V M
TYP SEE NOTE 1 9 1
TWO PLACES 7 8
OUTER
AC1
BLACK/3 WHITE/4
KEY PLUG
2BKP 2BKM
18 AWG
1V 1W 1G
2U L L L L M M M M
TYP
3W M 3G M
2U 2V 2W 2G 3U 3V 3W 3G
AMPLIFIER 6
AMPLIFIER 6
2V 2W 2G 3U 3V 3W 3G
TYP
10 TYP
CABLE SPECIFICATION 12#14 & 6#18 AWG CONDUCTORS HYPALON JACKET 1TYP. MAX CABLE O.D.= 16.9 MM (0.665) P/N=T13038
6 TYP
1 TYP
12 POS SOC
CONNECTOR LABEL
SOC/ PIN NO.

1 2 3 4 5 6 7 8 9 10 11 12
WIRE COLOR/ NUMBER

SIGNAL NAME
3U 3V 3W 3G
OUTER
AC1
ASSEMBLY NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL LENGTH DIMENSIONS + 1/2 IN.
RED/5 GREEN/6
3BKP 3BKM
18 AWG
3. FOR CABLE EE3186111105, USE 200 INCHES FOR LEFT PG LOCATION.
EE-3186-111-105 thru 155
1410 NOTES
MARO2P10203703E

MARO2P10203703E
1411
Figure 145. P-10 or P-15 European Shielded Power Connection Cable
E60766 PRODUCTION RELEASE 11/96 BWBF
REV LEV.
A A A
CABLE VERSION
EE3186121105 EE3186121110 EE3186121115 EE3186121125 EE3186121135 EE3186121145 EE3186121155
DIM (IN MM)

295 492 689 1083 1476 1870 2264 IN IN IN IN IN IN IN 7500 12500 17500 27500 37500 47500 57500 MM MM MM MM MM MM MM
PG
SEE NOTE 3 SOC/ PIN NO.

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

BKP4 BKM4 BKP4 BKM4
WIRE COLOR/ NUMBER

BLUE/17 BLUE/18 BLUE/19 BLUE/20 RED/13 WHITE/14
CONNECTOR LABEL
WIRE COLOR/ NUMBER

RED/1 WHITE/2 BLACK/3
GREEN/4
SIGNAL NAME
1U 1V 1W 1G
WIRE TAG
BKP4 BKM4 BKP4 BKM4
SIGNAL NAME
1BKP 1BKM 2BKP 2BKM 3BKP 3BKM
A A
0 108 65
A 320 16
BLUE/17 BLUE/18 BLUE/19 BLUE/20 RED/13 WHITE/14
RAIL
AA1
BLUE/17 BLUE/18 KEY PLUG
TYP 3 PL 4 10 6 5
1BKP 1BKM
18 AWG
BKP4 BKM4 BKP4 BKM4
19 11 TYP
1U 1V 1W 1G 2U L 2V L 2W L 2G L OPENER POWER EE3186121XXX MFG. NAMEREV OPENER POWER EE3186121XXX MFG. NAME REV
RAIL
AA1
CONNECTOR LABEL 12 POS SOC
SOC/ PIN NO.

1 2 3 4 5 6 7 8 9 10 11 12
WIRE COLOR/ NUMBER

SIGNAL NAME
2U 2V 2W 2G
INNER INNER
AB1
12 POS SOC TYP SEE NOTE 1 9

AB1

AMPLIFIER 5
WIRE COLOR/ NUMBER

RED/1 WHITE/2 BLACK/3
GREEN/4
3U M
TWO PLACES 1 7 8
OUTER
AC1
BLUE/19 BLUE/20 KEY PLUG
WIRE TAG
1U
SIGNAL NAME
1U 1V 1W 1G
2BKP 2BKM
18 AWG
3V M
TYP
3W M 3G M
12 POS SOC CABLE SPECIFICATION 16#14 & 4#18 AWG CONDUCTORS SHIELDED W/HYPALON JACKET 1TYP. MAX CABLE O.D.= 16.9 MM (0.665) P/N=T14847 6 TYP 1 TYP
1V 1W 1G
2U L L L L M M M M
TYP
10 TYP
AMPLIFIER 6
AMPLIFIER 6
RED/5 WHITE/6 BLACK/7 GREEN/8 RED/9 WHITE/10 BLACK/11 GREEN/12
2U 2V 2W 2G 3U 3V 3W 3G
2V 2W 2G 3U 3V 3W 3G
CONNECTOR LABEL
SOC/ PIN NO.

1 2 3 4 5 6 7 8 9 10 11 12
WIRE COLOR/ NUMBER

SIGNAL NAME
3U 3V 3W 3G
ASSEMBLY NOTES: CUT OFF BLACK/15 AND GREEN/16 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL LENGTH DIMENSIONS + 1/2 IN.
OUTER
AC1
RED/13 WHITE/14
3BKP 3BKM
18 AWG
CUT OFF BLACK/15 AND GREEN/16
3. FOR CABLE EE3186111105, USE 200 INCHES FOR LEFT PG LOCATION.
EE-3186-121-105 thru 155
1412 NOTES
MARO2P10203703E

MARO2P10203703E
1413
Figure 146. P-10 or P-15 Axis 1 Rail Power/Brake Cable
SEC. BB
REV LEVEL CABLE VERSION
EE3186311001
DIM. A
60 IN 1524 mm
PG
NO
CABLE RUN
C
10SL3S
GUIDE KEY
A 10 3.0 8 9 LABEL SOC/ PIN NO.

A BRAKE AXIS 1 B C
WIRE COLOR/ NUMBER

BLK BLK
WIRE GAGE
18 AWG 18 AWG
SIGNAL NAME
1BKP 1BKM
BRAKE AXIS 1
2 LABEL PIN NO.

1 2 3 4 5 6 7 8 9 10 11 12
KEY PLUG
WIRE COLOR
BLK BLK BLK GRN/YEL
WIRE GAGE
14 AWG 14 AWG 14 AWG 14 AWG
SIGNAL NAME
1U 1V 1W 1G
3.0 1
AA4 AXIS 1 PWR EE3186311001 MANUF. REV.
B
6 7
AA4
12 POS PIN
POWER AXIS 1
LABEL TYP.
BLK BLK
18 AWG 18 AWG
SOC/ PIN NO.

A B C D
WIRE COLOR/ NUMBER

BLK BLK BLK
WIRE GAGE
SIGNAL NAME
1U 1V 1W 1G
1BKP 1BKM
11
HEAT SHRINK
10
POWER AXIS 1
GRN/YEL
A
NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2. SEE LENGTH CHART FOR CABLE VERSION REVISION LEVEL. 3. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. TOL +/ 0.5
SEC. AA
1810S
CABLE RUN
C D B
4.WIRE SPECIFICATION NOT SHOWN ON BOM 14 AWG PTFE TEFLON, UL1199 BLACK, FINE STRANDED 18 AWG PTFE TEFLON, UL1199 BLACK, FINE STRANDED
GUIDE KEY
EE-3186-311-001
1414 NOTES
MARO2P10203703E

MARO2P10203703E
1415
Figure 147. P-10 or P-15 Axis 2 Inner Arm Power/Brake Cable
REV LEVEL
CABLE VERSION
EE3186312001
DIM. A
24 IN 610 mm
PG
NO
SEC. BB
C
CABLE RUN
B A
GUIDE KEY
0 10 3.0
LABEL
SOC/ PIN NO.

A B C
WIRE COLOR/ NUMBER

BLK BLK
WIRE GAGE
18 AWG 18 AWG
SIGNAL NAME
2BKP 2BKM
BRAKE AXIS 2
BRAKE AXIS 1
2 3 PIN NO.
1 2 3 4 5
3.0 1
AB4 AXIS 2 PWR EE3186312001 MANUF. REV.
TYP. 10
B
6 7 SOC/ PIN NO.
A B C D
LABEL
WIRE COLOR
BLK BLK BLK GRN/YEL
WIRE GAGE
SIGNAL NAME
2U 2V 2W 2G
12 POS PIN
POWER AXIS 2
LABEL
WIRE COLOR/ NUMBER

BLK BLK BLK
WIRE SIGNAL GAGE NAME

2U 2V 2W 2G
AB4
6 7 8 9 10 11 12 BLK BLK
KEY PLUG 18 AWG 18 AWG
11
2BKP 2BKM
1 HEAT SHRINK
POWER AXIS 2
GRN/YEL
NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2. SEE LENGTH CHART FOR CABLE VERSION REVISION LEVEL. 3. 4. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. TOL +/ 0.5 WIRE SPECIFICATION NOT SHOWN ON BOM 14 AWG PTFE TEFLON, UL1199 BLACK, FINE STRANDED 18 AWG PTFE TEFLON, UL1199 BLACK, FINE STRANDED
SEC. AA
2015S
C D B
CABLE RUN
A
GUIDE KEY
EE-3186-312-001
1416 NOTES
MARO2P10203703E

MARO2P10203703E
1417
Figure 148. P-10 or P-15 Axis 3 Outer Arm Power/Brake Cable
REV LEVEL
CABLE VERSION
EE3186313001
DIM. A
36 IN 914 mm
PG
NO
SEC. BB
A
CABLE RUN
C
GUIDE KEY 0 10 3.0 8 9 A
10SL3S
BRAKE AXIS 3
LABEL 2 LABEL PIN NO.

1 2 3 4 5
SOC/ PIN NO.

A B C
WIRE COLOR/ NUMBER

BLK BLK
WIRE GAGE
18 AWG 18 AWG
SIGNAL NAME
3BKP 3BKM
WIRE COLOR
BLK BLK BLK GRN/YEL
WIRE GAGE
SIGNAL NAME
3U 3V 3W 3G
3.0 1.0
AC4 AXIS 3 PWR EE3186313001 REV. MANUF.
B
6 7
BRAKE AXIS 3
AC4
6 7 8 9 10 11 12
BLK BLK KEY PLUG KEY PLUG 18 AWG 18 AWG
12 POS PIN
POWER AXIS 3
3BKP 3BKM
11 NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. 2. SEE LENGTH CHART FOR CABLE VERSION REVISION LEVEL. 3. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. TOL. +/ 0.5
HEAT SHRINK
2 10 TYP. LABEL SOC/ PIN NO.

A POWER AXIS 3 B C D
WIRE COLOR/ NUMBER

BLK BLK BLK
GRN/YEL
WIRE GAGE
SIGNAL NAME
3U 3V 3W 3G
SEC. AA
1810S
CABLE RUN
D A C B
4. WIRE SPECIFICATION NOT SHOWN ON BOM 14 AWG PTFE TEFLON, UL1199 BLACK, FINE STRANDED 18 AWG PTFE TEFLON, UL1199 BLACK, FINE STRANDED
GUIDE KEY
EE-3186-313-001
1418 NOTES
MARO2P10203703E

MARO2P10203703E
1419
Figure 149. P-10 or P-15 Axis 1 Encoder Cable
SEC. AA
REV LEVEL CABLE VERSION
EE3186314001
DIM. A
74 IN 1879 MM
PG
NO
CABLE RUN
2029SW SHELL/KEY ASSEMBLY POSITION
CONNECTOR LABEL
PIN NO.
1 2 3
WIRE COLOR
WHITE ORANGE
SIGNAL NAME
1D 1*D
PAIR NO.
1
14
3 4 5 1
3.0 1.0 TYP
CABLE SPECIFICATION 3 PAIRS 20 AWG SHIELDED HYPALON JACKET MAX. CABLE OD = 0.365 (9.27MM) BRAND REX T13981 SEE NOTES 1&2
12
AD4
4 5 6
20GA BLK WHITE YELLOW

KEY
SHIELD 1RQ 1*RQ 2
7 8 9
9 PIN
AD4
10
CONNECT SHIELDS TOGETHER
COVER WITH SHRINK
1.5 TYP CONNECTOR LABEL

CONN1
PIN NO.
1 2
WIRE COLOR
WHITE GRAY
SIGNAL NAME
5V 0V
PAIR NO.
3
2 POS SOC
7 8 11
CONN1
13
15
3 FT LENGTH WHT/GRAY PAIR FROM ITEM 1 W/BRAID SHIELD & EXPANDO SLEEVE CABLE SPECIFICATION 1 PAIR 20 AWG SHIELDED 2 PVC JACKET MAX CABLE OD = 0.245(6.22MM) BRAND REX T13103
1.0 TYP.
AXIS 1 PULSE EE3186314001 MFG. NAME REV.
SOC/ PIN NO.

A B C D E F G H J K L M N P R S T
WIRE COLOR/ NUMBER

WHITE
SIGNAL NAME
1D
TWIST PAIR NO.

1
ORANGE WHITE YELLOW WHITE
1*D 1RQ 1*RQ 5V
1 2
TYP. CONNECTOR LABEL

AL4
PIN NO.
1 2 3 4
WIRE COLOR
BROWN
SIGNAL NAME
6V1 0V1 SHIELD
PAIR NO.
PAIR 1 CABLE 2
4 POS PIN
5 6
AL4
A
14
GRAY BROWN BLACK
0V
6V1 0V1
3
PAIR 1 CABLE 2
NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. TOL +/ 0.5 2. SEE LENGTH CHART FOR CABLE VERSION REVISION LEVEL. 3. TERMINATION OF SHIELD TO CONDUCTOR SHIELD CONDUCTOR 20 AWG BLACK SOLDERED CONNECTION
BLACK
20GA BLK
SHIELD FROM THIS LEG CONNECTED TO PIN 3
SHIELDS NOT CONNECTED AT THIS END
CONDUCTORS
BRAIDED SHIELD SHRINK TUBING DETAIL A
EE-3186-314-001
1420 NOTES
MARO2P10203703E

MARO2P10203703E
1421
Figure 1410. P-10 or P-15 Axis 2 Pulse Cable
SEC. AA
REV LEVEL
A
CABLE VERSION
EE3186315001
DIM. A 24 IN 610 MM
PG
NO
CABLE RUN
0 CUT OFF PAIR 3, WHITE/GRAY CONNECTOR LABEL PIN NO. 1 2 3 4 5 6 7 8 9 PIN NO. 1 2 WIRE SIGNAL COLOR NAME 2D WHITE 2*D ORANGE KEY
20GA BLK SHIELD 2RQ WHITE 2*RQ YELLOW
3
PAIR NO.
1
5
4 1.0 TYP. SEE NOTE 3 CABLE SPECIFICATION 1 3 PAIRS 20 AWG W/ SHIELD HYPALON JACKET MAX OD = 0.365(9.27MM) BRAND REX T13981 CABLE SPECIFICATION 1 PAIR 20 AWG W/SHIELD PVC JACKET MAX OD = 0.245 (6.22MM) BRAND REX T13103
SEE NOTES 1&2
9 PIN
AE4
AE4
12 2
1.0 TYP.
SEE NOTE 4
10
SOC/ PIN NO. A B C D E F G H J K L M N P R S T
WIRE COLOR/ NUMBER WHITE

ORANGE WHITE YELLOW BROWN
SIGNAL NAME 2D
2*D 2RQ 2*RQ 5V
TWIST PAIR NO. PR 1 CABLE 1

CABLE 1 CABLE 1 CABLE 2 PR 1 PR 2 PR 1
2 POS SOC WIRE COLOR BROWN BLACK SIGNAL NAME 5V 0V PAIR NO.
1
CONN2
CONNECTOR LABEL
CONN2
11
TYP. 4 POS PIN SEE NOTE 3
AM4
CABLE SPECIFICATION 2 1 PAIR 20 AWG W/SHIELD PVC JACKET MAX OD = 0.245 (6.22MM) BRAND REX T13103 NOTES:
THIS SHIELD NOT CONNECTED
CONNECTOR LABEL
AM4
PIN NO. 1 2 3 4
WIRE COLOR BROWN BLACK 20GA BLK
SIGNAL NAME 6V2 0V2 SHIELD
PAIR NO.
1
13
1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. 2. SEE LENGTH CHART FOR CABLE VERSION REVISION LEVEL. 3. TERMINATION OF SHIELD TO CONDUCTOR SHIELD CONDUCTOR 20 AWG BLACK SOLDERED CONNECTION
BLACK BROWN BLACK
0V 6V2 0V2
CABLE 2 CABLE 3
PR 1 PR 1
CONDUCTORS
BRAIDED SHIELD SHRINK TUBING DETAIL A
4. AE4 AND CONN2 SHIELDS CONNECTED TO EACH OTHER, BUT NOT CONNECTED TO ANY PIN. THIRD SHIELD, AM4, NOT CONNECTED AT THIS END
EE-3186-315-001
1422 NOTES
MARO2P10203703E

MARO2P10203703E
1423
Figure 1411. P-10 or P-15 Axis 3 Pulse Coder Cable
SEC. AA
REV LEVEL A CABLE VERSION EE3186316001 DIM. A 36 IN 914 MM PG NO
CABLE RUN
3 4 CUT OFF 3RD PAIR, WHITE/GRAY PIN SIGNAL CONNECTOR WIRE NO. NAME LABEL COLOR 1 3D WHITE 2 3*D ORANGE 3 4 5 AF4 6 20GA BLK SHIELD 7 3RQ WHITE 3*RQ 8 YELLOW 9 5 PAIR NO. 1 12 1.0 TYP. 0 16 CABLE SPECIFICATION 3 PAIRS 20 AWG W/ SHIELD HYPALON JACKET 1 MAX OD = 0.365(9.27MM) BRAND REX T13981
A
SEE NOTES 1&2 12
9 PIN
2
AF4
9
1.0 TYP.
SEE NOTE 4
10
SEE NOTE 3
2 1 PAIR 20 AWG W/SHIELD

2 POS SOC
7 8
CABLE SPECIFICATION
PVC JACKET MAX OD = 0.245 (6.22MM) BRAND REX T13103

CONN3
CONNECTOR LABEL CONN3
PIN NO. 1 2
WIRE COLOR BROWN BLACK
SIGNAL NAME 5V 0V
PAIR NO.
1
11 TYP.
CABLE SPECIFICATION 1 PAIR 20 AWG W/SHIELD PVC JACKET MAX OD = 0.245 (6.22MM) BRAND REX T13103
THIS SHIELD NOT CONNECTED
4 POS PIN CONNECTOR LABEL AN4 PIN NO. 1 2 3 4 WIRE SIGNAL COLOR NAME BROWN 6V3 BLACK 0V3 20GA BLK SHIELD PAIR NO. 1
AN4
SEE NOTE 3
5 6 13
NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. TOL +/ 0.5 2. SEE LENGTH CHART FOR CABLE VERSION REVISION LEVEL. 3. TERMINATION OF SHIELD TO CONDUCTOR SHIELD CONDUCTOR 20 AWG BLACK SOLDERED CONNECTION
SOC/ PIN NO. A B C D E F G H J K L M N P R S T
WIRE COLOR/ NUMBER

WHITE ORANGE WHITE YELLOW BROWN
SIGNAL NAME
3D 3*D 3RQ 3*RQ 5V
TWIST PAIR NO.

CABLE 1 CABLE 1 CABLE 1 CABLE 2 PR 1 PR 1 PR 2 PR 1
BLACK BROWN BLACK
0V 6V3 0V3
CABLE 2 CABLE 3
PR 1 PR 1
CONDUCTORS
BRAIDED SHIELD SHRINK TUBING DETAIL A 4. AF4 & CONN3 SHIELDS CONNECTED TO EACH OTHER BUT NOT CONNECTED TO ANY PIN AN4 SHIELD NOT CONNECTED THIS END
EE-3186-316-001
1424 NOTES
MARO2P10203703E

MARO2P10203703E
1425
Figure 1412. P-10 or P-15 Purge Flow Switch
REV LEVEL A
DIM. A 24 IN 610 MM
PG NO
1
SEE NOTE 1
0 2 CONNECTOR LABEL PIN NO. 1 2 3 4 WIRE COLOR BLUE BLACK SHIELD SIGNAL NAME FS1/NO FS1/C SLEEVE COLOR & MATL LT. BLUE EXPANDO
EXPANDO OVER BRAIDED SHIELD
FS1
4 PIN
AH4 INTRINSICALLY SAFE EE3186340001 MANUF. NAME REV.
FLOW SWITCH
CONNECT SHIELD WITH 20 AWG BLACK WIRE CUT OFF SPARE RED WIRE
3
1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. SEE LENGTH CHART FOR REV LEVEL DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION.
EE-3186-340-001
1426 NOTES
MARO2P10203703E

MARO2P10203703E
1427
Figure 1413. P-10 or P-15 European Purge Connect Arm Cable
REV LEVEL B
DIM. A 24 IN 610 MM
PG NO
0 CONNECTOR LABEL PIN NO. 1 2 3 4 WIRE COLORS BLACK1 BLACK2 SIGNAL NAME PS1P PS1N SLEEVE COLOR & MATL 4 PIN BLUE EXPANDO
AH1
A 3 TYP 1.0 EXPANDO OVER BRAIDED SHIELD

INTRINSICALLY SAFE
EE318634100X REV. MFG. NAME
CONNECTOR LABEL
PIN NO. 1 2 3 4
WIRE COLORS BLACK3 BLACK4 SHIELD
SIGNAL NAME FS1P FS1N
SLEEVE COLOR & MATL BLUE EXPANDO 4 PIN
4 5 6 7
SEE NOTE 1 AJ1
WIRE COLOR/ NUMBER BLACK/1 BLACK/2 BLACK/3 BLACK/4
WIRE LABEL 4 5 6 7
SIGNAL NAME PS1P PS1N FS1P FS1N
20 AWG WIRE SHIELD CONNECTION 8

1 2 5
3 4 SHIELD AND EXPANDO OVER WIRES
7 TYP
6 CRIMP FERRULE TO WIRE
WIRE SPEC: 20 AWG, 19/ 32, UL1199, 600V, PTFE INSULATION
NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. 2. SEE LENGTH CHART FOR CABLE VERSION REVISION LEVEL. 3. SPECIFIC CONDUCTOR PART NUMBER NOT CALLED OUT ON BILL OF MATERIALS WIRE SPEC: 20 AWG, 19/ 32, UL1199, 600V, PTFE INSULATION
EE-3186-341-001
1428 NOTES
MARO2P10203703E

MARO2P10203703E
1429
Figure 1414. P-10 or P-15 European Solenoid Cable
REV LEVEL A
DIM. A 24 IN 610 MM
PG NO
0 CONNECTOR LABEL AK1 PIN NO. 1 2 3 4 WIRE COLOR BROWN BLACK SHIELD
INTRINSICALL Y SAFE
SIGNAL NAME PSOL1 PSOL2 2 SOL1 4 PIN

AK1 SOL REV. EE3148348XXX MFG. NAME
CONNECTOR LABEL
SOC/ PIN NO. 1 2 3
WIRE COLOR BROWN BLACK NC
SIGNAL NAME PSOL1 PSOL2
SOL1
TUBING OVER DRAIN WIRE 7 5 6 1 BRAND REX T13103 2 COND 20 AWG SHIELDED
SEE NOTE 1 NOTES:
1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBERIN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. SEE LENGTH CHART FOR REV LEVEL DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION.
EE-3186-341-001
1430 NOTES
MARO2P10203703E

MARO2P10203703E
1431
Figure 1415. P-10 or P-15 Sensor Splitout Cable
REV A
DIM. A 8 IN 203 mm
PG NO
CONNECTOR LABEL 4 5
PIN NO. 1 2 3 4 5 6 7 8 9
WIRE COLORS BLUE1 BLUE2 BLUE3 BLUE4
SIGNAL NAME SENSOR1 SENSOR2 EOAT1 EOAT2
2 1.0 in. 4.0 in.
1 SENSOR
9 POS SOC
SENSOR
AG4 SENSOR
1 2 3 4 5 6 7 8 9
BLUE1 BLUE2 BLUE3 BLUE4 BLUE5 BLUE6
SENSOR1 SENSOR2 EOAT1 EOAT2 BYPASS1 BYPASS2
SHIELD
AG4 SENSOR
9 PIN
INTRINSICALL Y SAFE
EE3186351001 MANUF REV
6 CONNECTOR LABEL PIN NO. 1 2 3 4 5 6 7 8 9 WIRE COLORS BLUE5 BLUE6 KEY PIN KEY PIN SHIELD KEY PIN KEY PIN SIGNAL NAME BYPASS1 BYPASS2
SHIELD BYPASS 9 POS SOC BYPASS
EE-3186-351-001
1432 NOTES
MARO2P10203703E

MARO2P10203703E
1433
Figure 1416. P-10 or P-15 End of Arm Tool Cable
REV CABLE VERSION B
DIM. A 144 IN EE3186317001 3658 MM
PG YES
48
10
11
CONNECTOR LABEL
PIN NO. 1 2 3 4 5 6 7 8 9
WIRE COLORS BROWN BLACK
SIGNAL NAME
1
EOAT1 EOAT2 9 PIN
3.00
INTRINSICALLY SAFE INTRINSICALLY SAFE
CONNECTOR LABEL
SENSOR
PIN NO. 1 2 3
AG4
AG4 REV. EE3186317XXX MFG. NAME
SENSOR REV. EE3186317XXX MFG. NAME
WIRE COLORS BROWN BLACK SHIELD
SIGNAL NAME EOAT1 EOAT2
SENSOR
3.00 APPLY LABEL OVER 3 OF BLUE SHRINK TUBING, TYP. BOTH ENDS
SEE NOTE 1
3.00 TYP.
3.00
SHIELD
CABLE SPECIFICATION ONE PAIR 20 AWG W/SHIELD HYPALON JACKET MAX. CABLE O.D. = 6.22mm (0.245in) BRAND REX T13103 NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL LENGTH DIMENSIONS +/ 0.5 2. BUILD UP CABLE DIA. WITH 1/32 X 2 EPDM STRIP MATERIAL FOR PROPER PG FITTING DIA. A SMALL AMOUNT OF ADHESIVE SHOULD BE USED TO SECURE EPDM STRIP PRIOR TO APPLICATION OF SHRINK TUBING. RETAIN EPDM STRIP MATL WITH 2 OF BLUE SHRINK TUBING.
EE-3186-317-001
1434 NOTES
MARO2P10203703E

MARO2P10203703E
1435
Figure 1417. P-10 Magnet Sensor Breakaway Cable
REV CABLE VERSION A
DIM. A 144 IN EE3186319001 3658 MM
PG YES
A 48
CONNECTOR LABEL
PIN NO. 1 2 3 4 5 6 7 8 9
WIRE COLORS BROWN BLACK
SIGNAL NAME 1 EOAT1 EOAT2 9 PIN 3.00

INTRINSICALLY SAFE INTRINSICALLY SAFE
AG4
SENSOR
3.00 APPLY LABEL OVER 3 OF BLUE SHRINK TUBING, TYP. BOTH ENDS
SEE NOTE 1
3.00 TYP.
3.00
2.0in. STRIP BACK OUTER SHEATH
SHIELD
CABLE SPECIFICATION TWO CONDUCTOR 20 AWG. CABLE BRAID SHIELD BROWN HYPALON JACKET MAX. CABLE O.D. = 6.68mm (0.263in) BELDEN #8402
NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL LENGTH DIMENSIONS +/ 0.5 2. BUILD UP CABLE DIA. WITH 1/32 X 2 EPDM STRIP MATERIAL FOR PROPER PG FITTING DIA. A SMALL AMOUNT OF ADHESIVE SHOULD BE USED TO SECURE EPDM STRIP PRIOR TO APPLICATION OF SHRINK TUBING. RETAIN EPDM STRIP MATL WITH 2 OF BLUE SHRINK TUBING.
EE-3186-319-001
1436 NOTES
MARO2P10203703E

MARO2P10203703E
1437
Figure 1418. P-10 or P-15 Solenoid Cable
REV LEVEL B
DIM. A 24 IN 610 MM
PG NO
A CONNECTOR LABEL 9 SOC/ PIN NO. 1 2 3 WIRE COLOR BROWN BLACK NC SIGNAL NAME PSOL1 PSOL2
CONNECTOR LABEL
PIN NO. 1 2 3 4
WIRE COLOR BROWN BLACK SHIELD
SIGNAL NAME PSOL1 PSOL2 4 PIN
SOL1 2 4
AK4
AK4
AK4 INTRINSICALLY SAFE EE3186323XXX MFG. NAME REV
SOL1
CONNECT SHIELD W/ 20AWG BLACK
7 5 6
1
2 COND 20 AWG SHIELDED HYPAON JACKET BR T13103
SEE NOTE 1
NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. SEE LENGTH CHART FOR REV LEVEL DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. TOL +/ 0.5
EE-3186-323-001
1438 NOTES
MARO2P10203703E

MARO2P10203703E
1439
Figure 1419. Ground Cable M5 to M5 Stud
REVISION
CABLE VERSION EE3186326001 EE3186326002
DIM. A 10 IN 254 MM 16 IN 406 MM
B B
(2) PLACES
(2) PLACES
2 3 4 1
M5 STUD
EE3186 326001 REV MANUF
M5 STUD
0.5 1.0in. TYP.
NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL DIMENSIONS +/ 0.5
EE-3186-326-001
1440 NOTES
MARO2P10203703E

MARO2P10203703E
1441
Figure 1420. P-10 Breakaway Magnet Sensor
REV A
DIM A
PG
24 IN NO 610 MM
2.0in.
STRIP BACK OUTER SHEATH
INTRINSICALLY SAFE
SENSOR EE3186333001 MANUF REV APPLY LABEL OVER 3 OF BLUE SHRINK NOTE: CABLE COMES WITH PROX SW
NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. TOL +/ 0.5
EE-3186-333-001
1442 NOTES
MARO2P10203703E

MARO2P10203703E
1443
Figure 1421. P-15 Hood/Deck Opener Electrical Layout Domestic Version
UPPER LEVEL BOM DOOR OPENER INTERCONNECTION CABLES FOR US
EE3186101105 EE3186101110 EE3186101115 EE3186101125 EE3186101135 EE3186101145 EE3186101155
HOOD DECK OPENER ARM CABLES UPPER LEVEL BOM EE3715301001

PURGED CAVITY
DC/DC EE3044401 PWR INPUT UNIT EE3186331001 MAGNET SWITCH
AXIS 3 OUTER ARM a6/3000 A06B0128B175 AXIS 2 INNER ARM a6/3000 A06B0128B175
AMP 5 AXIS 1 RAIL AMP 6 (L) AXIS 2 INNER ARM AMP 6 (M) AXIS 3 OUTER ARM PURGE BD 4 L TERMS M TERMS BKP BKM JF8 RAIL AUX AXIS BD JF9 INNER ARM JF10 OUTER ARM 4 4 6 MOTOR/BRAKE AA1 AA4 EE3186311002
EE3044401
EE3186317001
MOTOR POWER (16.9 MM DIA.)

EE3186111105 EE3186111110 EE3186111115 EE3186111125 EE3186111135 EE3186111145 EE3186111155
AB1 AB4
EE3186312001 EE3186313001 BYPASS EE3185356001
PG29
AC1 AC4
ARM OUTER INNER INTERNAL ARM GND WIRE EE3158316001 GND WIRES (1) EE3186326004 (3) EE3186326003 AXIS 3 AXIS 2
ENCODER SIGNALS (17.4 MM DIA)

EE3186112105 EE3186112110 EE3186112115 EE3186112125 EE3186112135 EE3186112145 EE3186112155
EE3186314002 EE3186315001 EE3186316001 EE3186351001 EE3186323001
PG29
AF1 AF4
LINK
PURGE CONTROL 24VPG 0V PG UNIT 220VAC SENSOR OUTPUT BYPASS OUTPUT ISRR ISRR 3 4 7 8
REFERENCE SOL VALVE SHOWN ON MECH BOM REFERENCE PRES SW SHOWN ON MECH BOM FLOW SW ASSY
SOL2 PURGE VALVE PS2 SWITCH PRESSURE FS2 FLOW SWITCH
CRANK
AG1 AG4 AM1AM4 AH1 AH4 AN1 AN4 AK1 AK4 AL1 AL4 AJ1 AJ4
EE3066322001
EOAT1 EOAT2 EOAT5 EOAT6 PSB1 PSB2 FSB1 FSB2 ISB23 ISB24
EE3186340001
PURGE CONTROL ISTB
INTRINSICALLY SAFE (17.4 MM DIA)

IS
PURGE BARRIER 6V BATTERY 0V
GND
3 3
GROUND CABLE (6.8MM)

EE3287116105 EE3287116110 EE3287116115 EE3287116125 EE3287116135 EE3287116145 EE3287116155
EE3186115105 EE3186115110 EE3186115115 EE3186115125 EE3186115135 EE3186115145 EE3186115155
PG29 AXIS 1 RAIL a6/3000 A06B0128B6750008
AXIS 1
PG9
P15 HOOD/DECK OPENER ELECTRICAL LAYOUT DOMESTIC VERSION EE3715001
1444 NOTES
MARO2P10203703E

MARO2P10203703E
1445
Figure 1422. P-15 Hood/Deck Opener Electrical Layout European Version
UPPER LEVEL BOM DOOR OPENER INTERCONNECTION CABLES FOR US RJ2 CONTROLLER CONNECTIONS
EE3186102105 EE3186102110 EE3186102115 EE3186102125 EE3186102135 EE3186102145 EE3186102155
HOOD/DECK OPENER ARM CABLES UPPER LEVEL BOM EE3715302001

PURGED CAVITY
DC/DC
EE3044401
AXIS 3 OUTER ARM a6/3000 A06B0128B175 AXIS 2 INNER ARM a6/3000 A06B0128B175 MOTOR/BRAKE MOTOR POWER (16.9 MM DIA.)
PURGE BD
BKP BKM
PWR INPUT UNIT AMP 5 AXIS 1 RAIL AMP 6 (L) AXIS 2 INNER ARM AMP 6 (M) AXIS 3 OUTER ARM
EE3186331001 EE3044401
MAGNET SWITCH
L TERMS M TERMS
4 4
AA1 AA4 AB1 AB4
EE3186311002 EE3186312001 EE3186313001
EE3186317001
JF8
RAIL
EE3186121105 EE3186121110 EE3186121115 EE3186121125 EE3186121135 EE3186121145 EE3186121155
PG29
AC1 AC4
BYPASS EE3185356001
PULSE
AD1 AD4 AE1 AE4 AF1 AF4 EE3186314002 EE3186315001 EE3186316001 EE3186351001 EE3186348001
AUX AXIS BD PURGE CONTROL UNIT SENSOR OUTPUT BYPASS OUTPUT PURGE CONTROL ISTB
JF9
INNER ARM JF10 OUTER ARM 24VPG 0V PG 220VAC ISRR ISRR 3 4 7 8
EOAT1 EOAT2 EOAT5 EOAT6 PSB1 PSB2 FSB1 FSB2 ISB23 ISB24 3 3
ENCODER SIGNALS (17.4 MM DIA)

EE3186112105 EE3186112110 EE3186112115 EE3186112125 EE3186112135 EE3186112145 EE3186112155
PG29
OUTER ARM INTERNAL INNER GND WIRE ARM EE3158316001 GND WIRES (1) EE3186326004 (3) EE3186326003 AXIS 3 AXIS 2
REFERENCE
SOL VALVE SHOWN ON MECH BOM JUMPER REMOVED HR2151 PRES & FLOW SWITCHES
SOL2 PURGE VALVE PR OP 4 FL 5 6 7
LINK
AG1 AG4 AM1AM4 AH1 AH4 AN1 AN4 AK1 AK4 AL1 AL4 AJ1 AJ4
4 5 6 7
EE3186341001
CRANK
INTRINSICALLY SAFE (17.4 MM DIA)

IS
GND
EE3186115105 EE3186115110 EE3186115115 EE3186115125 EE3186115135 EE3186115145 EE3186115155
PG29 AXIS 1 RAIL a6/3000 A06B0128B6750008

AXIS 1
PURGE BARRIER
6V BATTERY 0V
GROUND CABLE (6.8MM)

EE3287116105 EE3287116115 EE3287116110 EE3287116125 EE3287116135 EE3287116145 EE3287116155
PG9
BOOTH WALL NOTE: I.S. GROUND IS A SEPARATE INTRINSICALLY SAFE GROUND AT THE PURGE CONTROL UNIT
P15 HOOD/DECK OPENER ELECTRICAL LAYOUT EUROPEAN VERSION EE3715002
1446 NOTES
MARO2P10203703E

MARO2P10203703E
1447
Figure 1423. P-15 Opener End of Arm Tooling Cable
REV B
DIM. A 144 IN 3658 MM
PG YES
0 48
10
11
CONNECTOR LABEL
PIN NO. 1 2 3 4 5 6 7 8 9
WIRE COLORS WHITE BLACK
SIGNAL NAME EOAT1 EOAT2 9 PIN 3.00 1

INTRINSICALLY SAFE AG4 REV. EE3186317XXX MFG. NAME
AG4
INTRINSICALLY SAFE SENSOR REV. EE3186317XXX MFG. NAME
CONNECTOR LABEL
SENSOR
PIN NO. 1 2 3
WIRE COLORS WHITE BLACK SHIELD
SIGNAL NAME EOAT1 EOAT2
SENSOR 3.00
3.00
SEE NOTE 1
SHIELD 2
APPLY LABEL OVER 3 OF BLUE SHRINK TUBING, TYP. BOTH ENDS 3
3.00 TYP.
NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. ALL LENGTH DIMENSIONS +/ 0.5 2. BUILD UP CABLE DIA. WITH 1/32 X 2 EPDM STRIP MATERIAL FOR PROPER PG FITTING DIA. A SMALL AMOUNT OF ADHESIVE SHOULD BE USED TO SECURE EPDM STRIP PRIOR TO APPLICATION OF SHRINK TUBING. RETAIN EPDM STRIP MATL WITH 2 OF BLUE SHRINK TUBING.
CABLE SPECIFICATION ONE PAIR 20 AWG W/SHIELD HYPALON JACKET MAX. CABLE O.D. = 6.68mm (0.263in) BELDEN #8402
OPENER END OF ARM TOOLING CABLE EE3186317001
1448 NOTES
MARO2P10203703E

MARO2P10203703E
1449
Figure 1424. P-15 Part Present Proximity Cable
REV A 0
DIM A IN 24 610 MM
PG NO A
2 PIN # 1 2 3 WIRE SIGNAL COLOR NAME BROWN + SIGNAL BLUE SIGNAL UNUSED
INTRINSICALLY SAFE SENSOR EE3186331001 MANUF REV
APPLY LABEL OVER 3 OF BLUE SHRINK
NOTE: CABLE COMES WITH PROXIMITY SWITCH
NOTES: 1. PART NUMBER SHOWN ON CABLE LABEL MUST CORRESPOND TO THE LENGTH AND VERSION NUMBER IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL. DENOTES LENGTH MEASUREMENT POINTS. SEE TABLE FOR DIMENSION. TOL +/ 0.5
PART PRESENT PROXIMITY CABLE EE3186331001
1450 NOTES
MARO2P10203703E

MARO2P10203703E
1451
Figure 1425. Integral Pump Control Drawing Index and System Index
ROBOT CONTROLLER (RC)
24VDC CONDUIT
VARIABLE RATIO 2K SINGLE STAGE PAINT PROCESS CONTROL
ANALOG CONDUIT
PAINT PROCESS VALVE PANEL
INTRINSIC CABLE NE2000977XXX
ELECTROSTATIC POWER SUPPLY (ESTAT UNIT)
ESTAT CABLE CONDUIT JUNCTION BOX BOOTH WALL
P200 PURGE CAVITY ESTAT CABLE CES2 (PARAFLEX)
NE2000977003 EXPLOSIONPROOF JUNCTION BOX (ROBOT TURET)
SUPPLIED WITH COLLISION DETECTION UNIT
MAC VALVE P200 ROBOT UPPER ARM

PUMP REGULATOR BLOCK
ESTAT CABLE CES3 (PARAFLEX)
COLLISION DETECT MOUNTING PLATE APPLICATOR
WRIST PLATE GROUND
NE2000477
1452 NOTES
MARO2P10203703E

MARO2P10203703E
1453
Figure 1426. Integral Pump Control I/O Rack Layout
MAIN CPU PCB
JD1
109
RACK COMMUNICATION CABLE1 METER
SLOT NUMBER
1 JD1A A I F JD1B 0 1 A CP32 A O D 1 6 D
2 A O D 1 6 D
3 A D A 0 2 A
4 A D A 0 2 A
5 R E S E V E D
6 A A D 0 4 A
7 A O D 1 6 D
8 A O D 1 6 D
9 R E S E V E D
10 R E S E V E D
109 109 109 109 109 109 109 RACK POWER CABLE +24VDC, 0VDC FROM SPADE CONNECTORS ON POWER INPUT UNIT CABLE/WIRING BY FANUC WIRE AS SHOWN ON SHEET 082 TO MAIN AIR SUPPLY SOLENOID AS SHOWN ON SHEET 082
82091 82092 +24VDC 0VDC 109 109 CP6 MAIN CPU PSU MODULE
82291 82292 +24VDC 0VDC
POWER INPUT UNIT (PIU)
I/O RACK LAYOUT

NE2000477
1454 NOTES
MARO2P10203703E

MARO2P10203703E
1455
Figure 1427. Integral Pump Control Controller Layout
TERMINAL STRIP
T1
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 SPARE SPARE SPARE 82091 (+24VDC) 82091 (+24VDC) SPARE 82092 (0VDC) 82092 (0VDC) 82092 (0VDC) 82092 (0VDC) 8214F (+5VDC) 82231 (+24VDC) 82231 (+24VDC) 82292 (0VDC) 8232F (+24VDC) 8308F (ACSP) 8309F (ACAP) 8310F (LPSP) 8311F (LPAP) 8312F (RS1P) 8313F (RS2P) 8314F (RPSP) 8315F (RAP) 8316F (RPBP) 8317F (RPDP) 8318F (HS1P) 8319F (HS2P) 8320F (HPSP) 8321F (HAP) 8322F (HPBP) 8323F (HPDP) 8336F (PT) 8344F (MHP) 8345F (MRP) 8346F (HP1) 8347F (HP2) 8348F (HP3) SPARE SHEILD 1 84121 (CLEAR) 84131 (BLACK) 84141 (CLEAR) 84151 (BLACK) SHEILD 2 SHEILD 3 84401 (CLEAR) 84411 (BLACK) 85121 (CLEAR) 85131 (BLACK) SHEILD 5 SPARE 8608F (CP1) 8609F (CP2) 8610F (CP3) 8611F (CP4) 8612F (CP5) 8613F (CP6) 8614F (CP7) 8615F (CP8) 8616F (CP9) 8617F (CP10) 8618F (CP11) 8619F (CP12) 8620F (CP13) 8621F (CP14) 8622F (CP15) 8623F (CP16) 8636F (CP17) 8637F (CP18) 8638F (CP19) 8639F (CP20) 8640F (CP21) 8641F (CP22) 8642F (CP23) 8643F (CP24) I/O POWER ENABLE
124 124 124 124 124 124 124 124 124 124 124 124 124 124 124 124
ANALOG INPUT CABLE ROUTING
FUSE
124 PURGE CONTROL UNIT
FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE
MOUNT TERMINAL STRIP T1 TO SIDE WALL INSIDE OF ROBOT CONTROLLER.

AMP 1 AMP 2 AMP 3
DISCONNECT
COMM. SLOT SLOTSLOTSLOTSLOTSLOTSLOTSLOTSLOTSLOT MODULE 1 2 3 4 5 6 7 8 9 10
CABLE ROUTING
2 W X 4 H DUCT
EMG BOARD MAIN PSU CPU OPT
AREA RESERVED FOR SYSTEM INTEGRATION
AMP 4
FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE
CABLE ROUTING
1 1/2 W X 4H DUCT
TB2
CONTROLLER INTERIOR VIEW LEFT SIDE CONTROLLER W/DOOR REMOVED CONTROLLER LAYOUT
NE2000477
8204CR
124 124 124 124
1456 NOTES
MARO2P10203703E

MARO2P10203703E
1457
Figure 1428. Top Hat Option Drawing Index and System Layout
2K PUMP CAVITY
PUMP #1
PUMP PRESSURE CONTROL BLOCK
2K PURGED CAVITY
RJ2 ROBOT CONTROLLER
PUMP #2
NEW PULSECODER & MOTOR POWER HARNESS NE2000996401 100 CURRENT ROBOT DC/DC CONVERTER
DUAL DC/DC CONVERTER MOUNTING BRACKET 100 NE2000396103
UPPER ARM CAVITY

PT VALVE
NEW BATTERY CABLE NE2000977004
PULSE CABLE NE2000996205 THRU 255 (REF.)
MOTOR POWER CABLE NE2000996005 THRU 055 (REF.)
100
ROBOT ARM
ROBOT BASE PURGED CAVITY INTRINSIC CABLE NE2000977005 THRU 055 (REF.) 9 PIN 15 PIN AXIS 3 4 PIN 9 PIN
100 EE3044403001
ADDED DC/DC
ADDED JUMPER
DC/DC DC/DC
100 CONVERTER
EE3044401
P/I TRANSDUCER AND TRIGGER CABLE NE2000977003 100
15 PIN ROUTED THRU PROCESS CATTRACK
NE2000396
1458 NOTES
MARO2P10203703E

MARO2P10203703E
1459
Figure 1429. Side Saddle Option Drawing Index and System Layout
UPPER ARM
PT VALVE
DUAL DC/DC CONVERTER 100 MOUNTING BRACKET NE2000396103 PILOT TRIGGER CABLE NE2000977002 100 100 ADDED DC/DC CONVERTER EE3044401 JUMPER EE3044403001
ROBOT DC/DC CONVERTER
PULSE CABLE NE2000996205 THRU 255 (REF.)
MOTOR POWER CABLE NE2000996005 THRU 055 (REF.)
100
DC/DC DC/DC
INTRINSIC CABLE NE2000977005 THRU 055 (REF.)

9 PIN 15 PIN AXIS 3 9 PIN
ROBOT PURGED CAVITY

4 PIN 15 PIN 4 PIN
ROUTED THRU PROCESS CATTRACK
MOTOR POWER & PULSECODER HARNESS NE2000996400
100
100
P/I TRANSDUCER AND BATTERY CABLE NE2000977001
VACULOCK HOSE PUMP PRESSURE CONTROL BLOCK
PUMP #1
PG 2K PURGED CAVITY PUMP #2
2K PUMP CAVITY
NE2000397
1460 NOTES
MARO2P10203703E

MARO2P10203703E
1461
Figure 1430. Top Hat and Side Saddle Option Drawing Index and System Layout
2K SYSTEM (INTRINSIC CABLE: NE2000977005 THRU 055) CONTROL (POWER CABLE: NE2000996005 THRU 155) REF. CABLES (PULSE CABLE: NE2000996205355) ROBOT DC TO DC CONVERTER REF. P200 PURGED CAVITY DC/DC DC/DC DC TO DC CONVERTER JUMPER REF. B ADDED DC TO DC CONVERTER REF.
2K TOP HAT ROBOT CABLES or 2K SIDE SADDLE ROBOT CABLES
MOTOR/ PULSE HARNESS: NE2000996401 BATTERY CABLE: NE2000977004 INTRINSIC PROCESS CABLE: NE2000977003 MOTOR/ PULSE HARNESS: NE2000996400 BATTERY/INTRINSIC CABLE: NE2000977001 TRIGGER CABLE: NE2000977002
REFERENCE NE2000396
B REFERENCE NE2000398
2K PUMP ASSEMBLY
NE2000496 and
NE2000498
1462 NOTES
MARO2P10203703E

MARO2P10203703E
1463
Figure 1431. Top Hat and Side Saddle Option Cable and Wiring Diagram
ESTOP PCB
IPC AMP 5
AMP 4
AMP 1
AMP 2
AMP 3
CRR20
PIN # 1 2 3 4 5 6 CRR20 SIGNAL WIRE NAME COLOR BLUE1 ESP
CRX4 JS2B JS1B

AMP 5 (IPC) CRX4 SIGNAL PIN WIRE # COLOR NAME 1 2 BLUE2 ESP BLUE1 3 +24V AMP 4 CRX4 SIGNAL PIN WIRE NAME # COLOR 1 2 BLUE2 ESP 3
CRX4
D
AMP 1 CRX4 SIGNAL PIN WIRE NAME # COLOR 1 2 BLUE2 ESP 3
CRX4
D
CRX4
D
CRX4
BLUE2
+24V
24V INTERLOCK HARNESS #NE2000996003

104
AXIS BOARD TO AMPLIFIER CABLE #XGMF10064
AUX AXIS BOARD

JV13 JV14
104
JF13 JF14
FROM PUMP 2 MOTOR ENCODER FROM PUMP 1 MOTOR ENCODER 2K PUMP PULSE CABLE #NE20009962XX (REFERENCE ONLY)
NE2000496 and
NE2000498
1464 NOTES
MARO2P10203703E

MARO2P10203703E
1465
Figure 1432. Top Hat and Side Saddle Option Purge and Intrinsic Wiring Control Drawing
NONHAZARDOUS LOCATION (250 VAC MAXIMUM) A1 C1 OPERATOR PANEL PURGE CIRCUITS CNPG EMGIN1 EMGIN2 PANEL I/F CNPG A2 C2 A3 C3 BRAKE CONTROL CNIS CNIN A4 C4 RDI/RDO CNCA A5 C5 220 VAC +24P 0V ESTOP PCB SOL1 SOL2 INTRINSIC SAFETY BARRIER ISB1 STAHL 9001/0125210014 CRR21 CRR22 CRR5 BKP4 BKM4 I.S. BATTERY PACK 1 + 1 2 3 4 I.S. GROUND A6 C6 HAND BROKEN P4 N4 P5 N5 P6 N6 FLOW SWITCH VARIABLE RATIO 2K PURGE AND INTRINSIC WIRING CONTROL DRAWING HAZARDOUS LOCATION CLASS I, II & III IDEC IBRC 6062RFM DIVISION 1 GROUPS C D E F & G RELAY BARRIER P1 PRESSURE SWITCH N1 ISTB P2 N2 P3 N3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PSA1 PSA2 PSB1 PSB2 FSA1 FSA2 FSB1 FSB2 OT11 OT12 OT21 OT22 OT31 OT32 OT41 OT42 OT51 OT52 HBK1 HBK2 TP1 TP2 EOAT1 EOAT2
CONNECTION CABLE NE2000977XXX

ROBOT WIRE HARNESS EE3287323001
ROBOT PURGED CAVITY
M1 M4
M1 M4
MAIN CPU CRM10
M1 M4
PRES. SW CABLE EE3044345001 PS1 PS1 ROBOT PRESSURE SWITCH FLOW SW CABLE EE3044340001 FS1 FS1 ROBOT FLOW SWITCH SOLENOID CABLE EE3287348001 SOL SOL PURGE SOLENOID VALVE BATT ENCODER
P200 TOP HAT MOUNTED P200 RJ2 MODELS CONTROLLER / ROBOT P2006J2+2K / P20062KT P2006LJ2+2K / P2006L2KT P2006+2J2+2K / P20062KT P2006L+2J2+2K / P2006L2KT P200 SIDE SADDLE MOUNTED P200 RJ2 MODELS CONTROLLER / ROBOT P2006J2+2K / P20062KS P2006LJ2+2K / P2006L2KS P2006+2J2+2K / P20062KS P2006L+2J2+2K / P2006L2KS
S1
EE3287324001 BATT S4
MISC. SWITCH (RDI2)
X6 FOR ROBOT
R1
R1
NE2000977001 BATT
BATT
X2 FOR ENCODER 2K PUMPS
N1
N4
EE3185356001
BYPASS SWITCH
6 I.S. SERVO TRANSFORMER FOR PAINT RJ TYPE 220V (43) 220V (44) 120VAC FROM CONVEYOR GROUND DELTRON W112A 24VDC POWER SUPPLY EE3112600 24V 24V OVP UNIT FROM I/O 24V TO I/O 24V TO I/O 24V TO I/O FIRE ALARM +24VDC PSU +V R AC S 0V G TO CRS1 (MAIN CPU) 24V TO I/O
7 8 9 10 11 +24 12 7 8 8 7 5 6 8 7 5 6 8 7 5 6 8 7 5 6
ISB3 KHD2SREX1.2S.P P&F ISB7 P&F Z728 8533ISB P&F Z787 8538ISB P&F Z787 8543ISB P&F Z787 8548ISB P&F Z787
+ 1 2 + 1 2 +4 3 + 1 2 +4 3 + 1 2 +4 3 + 1 2 +4 3
1 3
ISB31 ISB33
O1 P1
O4
HAND BRKN
ISB71 ISB72 8533ISB1 8533ISB2 8533ISB4 8538ISB1 8538ISB2 8538ISB4 8543ISB1 8543ISB2 8543ISB4 8548ISB1 8548ISB2 8548ISB4
P4
NE2000977002 TRIGGER 1 PUMP #1 UNDER PRESSURE PUMP #1 OVER PRESSURE PUMP #2 UNDER PRESSURE PUMP #2 OVER PRESSURE
NOTES: 1. ACCEPTABLE I.S. BATTERY PACKS: A05B2363C040 EE3185551 2. ALTERNATE I.S. BATTERY PACKS: A05B2072C181 A05B2047C182 SHALL BE USED PER EG00127SECTION VI 3. I.S. GROUND CONNECTION SHALL BE PER NEC(NFPA 70) SECTION 50450 AND ANSI/ISA RP 12.6
I.S. GROUND ISB UNIT A05B2308C370 I.S. GROUND FRAME GROUND
NE2000977001
F1F2F3 F4 F5
I/S TEACH PENDANT A05B2308C300 NE2000498500 and NE200496500
1466 NOTES
MARO2P10203703E

MARO2P10203703E
1467
Figure 1433. Top Hat and Side Saddle Options Cable Layout Diagram
6 AXIS ROBOT HARNESS AND CABLE LAYOUT RJ2 CONTROLLER
AMP 1 (L) AMP 2 (L) AMP 3 (M) AXIS 4 AXIS 5 AXIS 6 4 4 4 6 SEAL OFFS USED WITH NA PEDESTAL (NO PG FITTINGS) A1 A4 B1 B4 PULSE BAT AXIS 6 POWER BRK
ROBOT ARM
MOTOR 13.5MM EE3287111 005 EE3287111010 EE3287111015 EE3287111025 EE3287111035 EE3287111045 EE3287111055 PULSE 19.8MM EE3287113005 EE3287113010 EE3287113015 EE3287113025 EE3287113035 EE3287113045 EE3287113055
C1
C4 OUTER ARM GROUND PULSE BAT AXIS 5 POWER BRK
EMG BD
CRF1
D1 D4 E1
AUX AXIS BD JF7 CABLE CLAMP SHIELD TO CHASSIS GROUND
F1 F2 GROUNDING OF NONIS SHIELDED CABLE AT CONTROLLER ENTRANCE

50MM GND CLAMP CABLE CABLE SHIELD
EE3044401
24PG, 0PG PURGE UNIT PGTB 3
EE3287322001 AXIS 4, 5 & 6 PWR & PULSE HARNESS
PULSE BAT AXIS 4 POWER BRK CONNECTION CABLE SETS UPPER LEVEL BOMS PULSE & BATT AXIS 3 POWER & BRK 5M 10M 15M 25M 35M PULSE & BATT AXIS 2 POWER & BRK 45M 55M NE2000896005 NE2000896010 NE2000896015 NE2000896025 NE2000896035 NE2000896045 NE2000896055
DC/DC CONVERTERS EE3044401
INNER ARM GROUND
F1
TURRET GROUND
H1H4 AMP 1 (M) AMP 4 (M) AXIS 1 AXIS 2 4 12 4 MOTOR 21.0MM EE3287110 005 EE3287110 010 EE3287110 015 EE3287110 025 EE3287110 035 EE3287110 045 EE3287110 055 J1 J4 EE3287321001 AXIS 1, 2 & 3 PWR & PULSE HARNESS PULSE & BATT AXIS 1 POWER & BRK
CONNECTION CABLE SETS UPPER LEVEL BOMS 5M 10M 15M 25M 35M 45M 55M NE2000898005 NE2000898010 NE2000898015 NE2000898025 NE2000898035 NE2000898045 NE2000898055
K1 K4 AMP 2 (M) AMP 5 (L) AMP 5 (M) AXIS 3 PUMP 1 PUMP 2 8 4 4 4 MOTOR 21.0MM NE2000996005 NE2000996010 NE2000996015 NE2000996025 NE2000996035 NE2000996045 NE2000996055 2K1 2K1
PULSE BAT PUMP 1 POWER BRK
NE2000401 PUMPS 1 & 2 PWR & PULSE HARNESS
PULSE BAT PUMP 2 POWER BRK
AUX AXIS BD JF13 AUX AXIS BD JF14 CABLE CLAMP SHIELD TO CHASSIS GROUND
PULSE 17.4MM NE2000996205 NE2000996210 NE2000996215 NE2000996225 NE2000996235 NE2000996245 NE2000996255
2K2 2K2
CONTROLLER GROUND
6.9MM GND EE3287116 005 EE3287116 010 EE3287116 015 EE3287116 025 EE3287116 035 EE3287116 045 EE3287116 055 INTRINSIC 20.5MM NE2000977005 NE2000977010 B NE2000977015 NE2000977025 NE2000977035 NE2000977045 NE2000977055
R1 R1
NE2000977004 INTRINSIC BATTERY HARNESS PUMPS 1 & 2
(SEE SHEET 004)
S1 S4
EE3287324001 INTRINSIC BATTERY HARNESS AXIS 16 NE2000896005 THRU 055 NE2000898005 THRU 055
1468 NOTES
MARO2P10203703E

MARO2P10203703E
1469
Figure 1434. Top Hat Option Intrinsic Connections
A1 C1 A2 C2 A3 C3 A4 C4 A5 C5 A6 C6
IDEC IBRC 6062RFM RELAY BARRIER PRESSURE SWITCH P1 N1 P2 N2 P3 N3 P4 N4 P5 N5 P6 N6
FLOW SWITCH
HAND BROKEN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
ISTB PSA1 PSA2 PSB1 PSB2 FSA1 FSA2 FSB1 FSB2 OT11 OT12 OT21 OT22 OT31 OT32 OT41 OT42 OT51 OT52 HBK1 HBK2 TP1 TP2 EOAT1 EOAT2
INTRINSIC CONNECTION CABLE NE2000977XXX

ROBOT WIRE HARNESS ROBOT PURGED CAVITY EE3287323001 PRES. SW CABLE EE3044345001 M1 M4 PS1 PS1 ROBOT
PRESSURE SWITCH
NOTES: 1. SIGNAL NAMES IN THE PRODUCT CABLE EE3287323001 WILL NOT MATCH SIGNAL NAMES ON THE INTRINSIC CABLE NE2000977XXX OR THE PROCESS CABLE NE2000977003.
M1 M4
FLOW SW CABLE EE3044340001 FS1 FS1 ROBOT
FLOW SWITCH
M1 M4
SOLENOID CABLE EE3287348001 SOL SOL PURGE
SOLENOID VALVE
S1
S4
EE3287324001 BATT
BATT
ENCODER
MISC. SWITCH (RDI2)
X6 FOR ROBOT
R1
R1
NE2000977004 BATT
BATT
ENCODER
X2 FOR 2K PUMPS
INTRINSIC SAFETY BARRIER ISB1 STAHL 9001/0125210014 N1 1 2 3 4 I.S. GROUND N4 EE3185356001

BYPASS SWITCH
I.S. BATTERY PACK
6 I.S. GROUND
7 1 8 ISB3 3 9 10 KHD2SREX1.2S.P 11 +24 P&F 12 7 8 8 7 5 6 8 7 5 6 8 7 5 6 8 7 5 6
ISB31 ISB33
O1 P1
O4 P4
O1 P4
O4
HAND BRKN
ISB7 P&F Z728 8533ISB P&F Z787 8538ISB P&F Z787 8543ISB P&F Z787 8548ISB P&F Z787
+ 1 2 + 1 2 +4 3 + 1 2 +4 3 + 1 2 +4 3 + 1 2 +4 3
P4
TRIGGER 1 PUMP #1 UNDER PRESSURE PUMP #1 OVER PRESSURE PUMP #2 UNDER PRESSURE PUMP #2 OVER PRESSURE
I.S. GROUND
NE2000977003 ROBOT WIRE HARNESS EE3287323001 (MUST BE REV. D) SEE NOTE 1.
NE2000896005 THRU 055
1470 NOTES
MARO2P10203703E

MARO2P10203703E
1471
Figure 1435. Side Saddle Option Intrinsic Connections

A1 C1 A2 C2 A3 C3 A4 C4 A5 C5 A6 C6 HAND BROKEN FLOW SWITCH IZUMI IBRC6062R PRESSURE SWITCH P1 N1 P2 N2 P3 N3 P4 N4 P5 N5 P6 N6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ISTB PSA1 PSA2 PSB1 PSB2 FSA1 FSA2 FSB1 FSB2 OT11 OT12 OT21 OT22 OT31 OT32 OT41 OT42 OT51 OT52 HBK1 HBK2 TP1 TP2 EOAT1 EOAT2
INTRINSIC CONNECTION CABLE NE2000977XXX

ROBOT PURGED CAVITY ROBOT WIRE HARNESS PRES. SW CABLE EE3287323001 EE3044345001 M1 M4 PS1 PS1 ROBOT
PRESSURE SWITCH
M1 M4
FLOW SW CABLE EE3044340001 FS1 FS1 ROBOT
FLOW SWITCH
M1 M4
SOLENOID CABLE EE3287348001 SOL SOL PURGE

SOLENOID VALVE
S1
S4
EE3287324001 BATT
BATT
ENCODER
MISC. SWITCH (RDI2)
X6 FOR ROBOT
R1
R1
NE2000977001 BATT
BATT
ENCODER X2 FOR
INTRINSIC SAFETY BARRIER ISB1 STAHL 9001/0125210014 N1 1 2 3 4 I.S. GROUND N4 EE3185356001

BYPASS SWITCH
2K PUMPS
I.S. BATTERY PACK
6 I.S. GROUND
7 1 8 9 ISB3 3 10 KHD2SREX1.2S.P 11+24 P&F 12 ISB7 7 + 1 P&F Z728 8 2 8 + 1 8533ISB 7 2 5 +4 P&F Z787 6 3 8 + 1 8538ISB 7 2 5 +4 P&F Z787 6 3 8 + 1 8543ISB 7 2 5 +4 P&F Z787 6 3 8 + 1 8548ISB 7 2 5 +4 P&F Z787 6 3
ISB31 ISB33
O1 P1
O4
HAND BRKN
P4
NE2000977002
TRIGGER 1 PUMP #1 UNDER PRESSURE PUMP #1 OVER PRESSURE PUMP #2 UNDER PRESSURE PUMP #2 OVER PRESSURE
I.S. GROUND
NE2000977001
NE2000898005 THRU 055
1472 NOTES
MARO2P10203703E

MARO2P10203703E
1473
Figure 1436. Top Hat and Side Saddle Options Axis 3, Pumps 1 and 2 Motor Power Cable Reference
WIRE COLOR/ NUMBER BLUE/17 BLUE/18
WIRE TAG BKP2 BKM2
SIGNAL NAME 3BKP 3BKM
BKP2 BKM2
3U 3V WIRE COLOR/ NUMBER RED/1 WHITE/2 BLACK/3 GRN/YEL/4 RED/5 WHITE/6 BLACK/7 GRN/YEL/8 RED/9 WHITE/10 BLACK/11 GRN/YEL/12 RED/13 WHITE/14 BLACK/15 GRN/YEL/16 WIRE TAG 3U 3V 3W 3G 3U 3V 3W 3G P1U P1V P1W P1G P2U P2V P2W P2G 3W 3G 3U 3V 3W 3G
MOTOR REV. NE2000996XXX MFG. NAME MOTOR REV. NE2000996XXX MFG. NAME
CONNECTOR LABEL
SOC/ PIN NO. 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
WIRE COLOR/ NUMBER RED/1 WHITE/2 BLACK/3 GRN/YEL/4 RED/5 WHITE/6 BLACK/7 GRN/YEL/8 BLUE/17 BLUE/18 KEY PLUG KEY PLUG RED/9 WHITE/10 BLACK/11 GRN/YEL/12 RED/13 WHITE/14 BLACK/15 GRN/YEL/16
SIGNAL NAME
AXIS 3 PWR/BRK K1 104

AXIS 3 POWER/BRK K1
3BKM
12 POS SOC
P1U P1V P1W P1G P2U P2V P2W P2G
CABLE SPECIFICATION 16#14 & 4#18 AWG CONDUCTORS HYPALON JACKET MAX CABLE O.D.= 21.0 MM (0.825) P/N=T14379
PUMP #1 & #2 POWER 2K1
PUMP #1 & #2 PWR 2K1 9 POS SOC
NE2000898005THRU 055 NE2000896005THRU 055
1474 NOTES
MARO2P10203703E

MARO2P10203703E
1475
Figure 1437. Top Hat and Side Saddle Options Pumps 1 and 2 Pulse Cable Reference
CONN LABEL
PIN NO. 1 2 3 4 5 6
WIRE COLOR WHITE BLACK
SIGNAL NAME P1D P1*D
PAIR NO. 1 PIN PIN JF13 105 CONN LABEL PIN NO. 1 2 3 4 5 6 7 8 9 WIRE COLOR WHITE BLACK WHITE BROWN WHITE RED WHITE ORANGE #18 BLK SIGNAL NAME P1D P1*D P1RQ P1*RQ P2D P2*D P2RQ P2*RQ SHIELD PAIR NO. 1 2 3 4
JF13
WHITE BROWN
P1RQ P1*RQ
2 PIN PIN
PUMP 1+2 PULSE NE2000996XXX MFG. NAME REV. PUMP 1+2 PULSE NE2000996XXX MFG. NAME REV.
2K2
9 POS SOC
2K2
CONN LABEL
PIN NO. 1 2 3 4 5 6
WIRE COLOR WHITE RED
SIGNAL NAME P2D P2*D
PAIR NO. 3 PIN PIN
JF14
JF14
WHITE ORANGE
P2RQ P2*RQ
4 PIN
CABLE SPECIFICATION CABLE O.D.=17.4MM (.685) BLACK HYPALON JACKET P/N=T11762 9 PAIR #20 AWG
NE2000898005THRU 055 NE2000896005THRU 055
1476 NOTES
MARO2P10203703E

MARO2P10203703E
1477
Figure 1438. Top Hat and Side Saddle Options Intrinsic Cable Reference
IS GND
1PSA1
1
2PSA2 5FSA1
WIRE WIRE TAG TWIST COLOR/ PAIR ISTB NUMBER CONN. POINT NO. WHITE1 1 PSA1 BLUE2 2 PSA2 WHITE3 5 FSA1 ORANGE4 6 FSA2 WHITE5 ISB13 GREEN6 ISB14 ISB31 WHITE7 ISB33 BROWN8 WHITE9 8533ISB1 GRAY10 8533ISB4 RED11 8533ISB2 BLUE12 8538ISB2 8538ISB1 RED13 ORANGE14 8538ISB4 8543ISB1 RED15 GREEN16 8543ISB4 RED17 8543ISB2 BROWN18 8548ISB2 8548ISB1 RED19 GRAY20 8548ISB4 BLACK21 19 HBK1 BLUE22 20 HBK2 BLACK23 ISB71 ORANGE24 ISB72 1 2 3 4 5 6 7 8 9 10 11 12
2 SIGNAL NAME PS1P PS1N FS1P FS1N PSOL1 PSOL2 BYPASS1 BYPASS2 P1US P1UR P1UG P1OG P1OS P1OR P2US P2UR P2UG P2OG P2OS P2OR HND BRK + HND BRK TRIG +SIG TRIG SIG
6FSA2 ISB13
3
ISB14 ISB31
4
ISB33 8533ISB1
SOC/ LABEL PIN NO.
WIRE COLOR
TWISTED PAIR NUMBER
SIGNAL NAME PS1P PS1N FS1P FS1N PSOL1 PSOL2
5
8533ISB4 8533ISB2
M1
15 POS SOC
M1
6
8538ISB2 8538ISB1
1 2 3 4 5 6 13 14 1 2 5 8 1 2 3 4
WHITE1 1 BLUE2 WHITE3 2 ORANGE4 3 WHITE5 NUMBERD GREEN6 PSOL2AME SHIELD 20 AWG KEY WHITE7 4 BROWN8 SHIELD 20 AWG KEY
7
8538ISB4 8543ISB1
N1
8
9 POS SOC
N1
BYPASS1 BYPASS2
8543ISB4 8543ISB2
9
8548ISB2 8548ISB1
106 O1
INTRINSIC REV. NE2000977XXX MFG. NAME INTRINSIC REV. NE2000977XXX MFG. NAME
4 POS SOC
O1
BLACK21 HND BRK+ 11 BLUE22 HND BRK KEY SHIELD 20 AWG
10
8548ISB4 19HBK1
11
20HBK2 ISB71
12
ISB72
CABLE SPECIFICATION 16PR #20 AWG CABLE HYPALON JACKET MAX. CABLE O.D. = 20.5mm (0.805 MAX.) P/N=T14685
P1
15 POS SOC
P1
WIRE TWIST CONNECTION COLOR/ PAIR POINT NUMBER NO. BLACK25 13 GREEN26 BLACK27 BATTERY 14 BROWN28 PACK BLACK29 15 GRAY30 YELLOW31 BLUE32 16
6V1
WIRE TAG 6V1 0V1 6V2 0V2 6V3 0V3 6V4 0V4
0V1 6V2 0V2 6V3 0V3 6V4 0V4
WHITE9 1 P1US 5 GRAY10 2 P1UR RED11 3 P1UG 6 BLUE12 4 P1OG RED13 5 P1OS 7 6 ORANGE14 P1OR RED15 7 P2US 8 GREEN16 8 P2UR RED17 9 P2UG 9 10 BROWN18 P2OG RED19 11 P2OS 10 12 GRAY20 P2OR TRIG +SIG 13 BLACK23 12 TRIG SIG 14 ORANGE24 SHIELD 20 AWG 15 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 YELLOW31 16 BLUE32 SHIELD 20 AWG KEY BLACK25 GREEN26 BLACK27 BROWN28 BLACK29 GRAY30 JUMP TO 1 JUMP TO 2 JUMP TO 3 JUMP TO 4 JUMP TO 5 JUMP TO 6 SHIELD KEY 13 14 15 6V4 0V4
R1
4 POS SOC
R1
S1
15 POS SOC
S1
6V1 0V1 6V2 0V2 6V3 0V3 6V4 0V4 6V5 0V5 6V6 0V6
20 AWG
NE2000898005THRU 055
1478 NOTES
MARO2P10203703E

MARO2P10203703E
1479
Figure 1439. Integral Pump Control Process Flow Diagram
FANUC SERVO MOTOR & BAYSIDE GEAR FANUC SERVO MOTOR & BAYSIDE GEAR
ENCLOSURE PURGE RETURN PURGE TO ROBOT
3CC/REV PUMP
3CC/REV PUMP
HAZARDOUS LOCATION CLASS I, II & III DIVISION I GROUPS C D E F & G
HPBP SAMES BYPASS BLOCK RESIN PUMP BYPASS (RPBP) RESIN INLET PILOT (IPTR) FROM PPVP
5/32 O.D. 5/32 O.D. HARDENER PUMP BYPASS
0100 PSI PRESS TRANS.
0500 PSI PRESS. TRANS. (TYP)
0500 PSI PRESS. TRANS. (TYP)
0100 PSI PRESS. TRANS.
GEAR PUMP ASSEMBLY FANUC #NO2000810
HARDENER INLET PILOT (IPTH) HARDENER PUMP BYPASS (HPBP)

AIR SUPPLY
3/8 O.D.
5/32 O.D. 5/32 O.D.
SOLVENT SUPPLY
3/8 O.D.
MBAP
5/32 O.D. 5/32 O.D.
MBSP
RAP
5/32 O.D. PILOT
5/32 O.D.
RS1P
AIR SUPPLY
1/4 O.D.
SOLVENT SUPPLY
3/8 O.D.
AIR SUPPLY
3/8 O.D. 5/32 O.D.
SOLVENT SUPPLY
3/8 O.D.
MBRP CP2
3/8 O.D. 5/16 O.D. 5/32 O.D.
5/32 O.D.
5/32 O.D.
MBHP
CP1
3/8 O.D. 5/16 O.D. 5/16 O.D. TEFLON
RESIN SUPPLY RESIN RETURN
RESIN SUPPLY RESIN RETURN
RESIN SUPPLY
HARDENER SUPPLY
5/16 O.D. TEFLON
5/16 O.D. FROM AIR SUPPLY 5/16 O.D. TEFLON
HAP
3/8 O.D.
5/32 O.D.
5/32 O.D.
HS1P
3/8 O.D. SEE SYSTEM DRAWING FOR CORRECT QUANTITY OF VALVES & LOCATION
MIX TUBE PT PAINT 5/16 O.D. TEFLON
AIR SUPPLY
SOLVENT SUPPLY
HP1
3/8 O.D.
5/32 O.D.
5/32 O.D.
HP2
FANUC P200 ROBOT INTERIOR OF OUTER ARM
HARDENER SUPPLY
SPARE
APPLICATOR
5/16 O.D. TEFLON
SPRAY GUN
COLOR VALVE ASSEMBLY
1480 NOTES
MARO2P10203703E

MARO2P10203703E
1481
MOUNT SWITCHES AND RCS ON ALTERED COVER PLATE MOUNT TERMINALS AND RELAY ON HEAT EXCHANGER
PURGE UNIT
BLU17 BLU18 BLU19 BLU20 BLK5 BLK6 BLK11 BLK12 AXIS 6 NOT USED BLUE17 AXIS 3 BLUE18
BKM2
CABLE EE3287120XXX CABLE EE3287121XXX CABLE EE3287122XXX
AXES 1 & 2 AXES 4,5,6 AXES 3 & 7
AXIS 1
AXIS 4
TO PURGE BRAKE BOARD
AXIS 5
AXIS 2
BKM1 BKP1
BKM1
ISB UNIT
BKP3 BKM3 BKP3 BKM3
BKP1
BKP2
OPENER CONNECTIONS BKM BKM BKM BKM BKM BKP BKP BKM BKP BKP BKP BKP
BATTERY PACK
BKM2 BKP2
AXIS 7
BLUE20 BLUE19
ROBOT CABLE CONNECTION
INSTALLATION OF CONTROLLER WIRING
EE3287516
1482 NOTES
MARO2P10203703E

MARO2P10203703E
1483
Figure 1441.
P-200 Brake Release Wiring Diagram
LABEL
SEE EE3287516001 FOR PLATE MODIFICATION DETAILS SWITCH 3 4 RC NETWORK SW 1 = P200 1, 4, 5, 7 SW 2 = P200 AXIS 2 SW 3 = P200 AXIS 3 LABEL SW 4 = P10
BRAKE RELEASE KEYSWITCH CNPG 16 BKRL1 17 BKRL2 FORK TERM 14 RAIL END END BARR ANC TERM SCR NUT WASH LABEL 6 7 8 9 12
51604 51605 51607
PURGE CONTROL PCB A16B13100601 CNIS SH1A +24E 9 0V EMG1 EMG2 EES1 CNIN 11 12 CR5A 24V CR7B 51601 51602 8
SW4
SW3
SW2
SW1
CR5B
51612 51611
51609 51608
51615 51614
51606 51605
15
18 AWG WIRE BLUE
RELAY SOCKET
16 CR5B 17 R7 100 CR8 C1 33OuF CR6
PURGE BD BRAKE TB 3 BKP1 4 5 6 7 8 9 BKM1 BKP2 BKM2 BKP3 BKM3 BKP4
BRDC CR7B
51603
14 CR1
13
EES2
BRD2 51604
REAR VIEW
51608
OF SWITCHES
51610 51611 51608 51611 51605 51613 51614
CR5A CR6
CR7A
51605
CR1 1 9
51606
1 BKP P200 AXES 1 + 7 2 BKM 3 BKP 4 BKM SW1 P200 AXES 4 + 5
CR7B
10 BKM4 BKP1 CNIN 1 2 3 4 5 6 9 CR8
SEE SHT FOR CABLE HOOKUP BKM BKM BKM BKM BKM
8 3 7 2 6 1 5
0V
BKM
BKP
BKP
BKP
BKP
BKP
BKP
TB 3 CR1 4 2 5 6 7 8 9 10 51607 51608 51610 51611 51613 51614 3 CR1 11 51612 10 51609
RC 5 BKP P200 AXIS 2 6 BKM
BK TB CR1 RELAY 51614 1 2 3 4 5 6 7 8 9 10 11 12
51602
0V 24V
BKM1 BKP2 BKM2
51601
SW2 RC 7 BKP P200 AXIS 3 8 BKM SW3 RC
12 4 51615
11 + 14
10 13
51614
BRDC 51604
51606 51609 51612 51607 51610 51613 51615 51603
BKP4 BKM4 100OUT1
51612 51603 51609 51602
51606
BRD2
TERM 13
100OUT2 PURGE/BRAKE BOARD 100A
10 CR7A 7 CR7A DS1 D4 CR7B 4 D5 D6 CR1 51615 9 BKP OPENER AXIS 1 10 BKM 11 BKP OPENER AXES 2 + 3 12 BKM SW4 RC
12
100B
WIRING DIAGRAM
SCHEMATIC
EE3287516
1484 NOTES
MARO2P10203703E
A TRANSPORTATION AND INSTALLATION
Page85
MARO2P10203703E
TRANSPORTATION AND INSTALLATION

A1 This appendix includes information on transporting and installing an R-J2 controller.

Transportation Installation Installation and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Assembly During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Adjustment and Checks at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
A3 A3 A4 A5
The controller is transported by a crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
A. TRANSPORTATION AND INSTALLATION
A2
MARO2P10203703E
A.1
TRANSPORTATION
The controller is transported by a crane. Attach a rope to the eye bolts at the top of the controller, as shown in Figure A1.
Figure A1. Transportation

MARO2P10203703E
A3
A.2
INSTALLATION
A.2.1
Installation Area
When you install the controller, allow the space for maintenance as shown in Figure A2.
Figure A2. Installation Area
Controller
Controller
Controller
A4
MARO2P10203703E
A.2.2
Assembly During Installation
Figure A3. Assembly During Installation

Intrinsically safe teach pendant
ISB
Mechanical unit connection cables (5)
Peripheral device connection cable
Input power cable

MARO2P10203703E
A5
A.2.3
Adjustment and Checks at Installation
Procedure A1 Adjustment and Checks at Installation
STEP ACTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Visually check the inside and outside of the controller. Verify that the screwed terminal is connected properly. Check that the connectors and printed circuit boards are inserted correctly. Check transformer tap setting. Connect the controller unit and mechanical unit cables. Turn the breaker or disconnect off and connect the input power cable. Check the input power voltage. Press the EMERGENCY STOP button on the operator panel and turn the power on. Check the output voltage. Check the interface signals between the control unit and mechanical unit. Check the parameters. If necessary, set them. Release the EMERGENCY STOP button on the operator panel. Turn on the controller. Check the movement along each axis in the manual jog mode. Check the end effector interface signals. Check the peripheral device control interface signals. ITEM # QTY SERVICE NOTES
A6
MARO2P10203703E
The physical characteristic of the C-Size R-J2 controller are provided in Table A1.
Table A1. Physical Characteristics
Item Transformer Input power source capacity Average power consumption Permissible ambient temperature Permissible ambient humidity Surrounding gas Vibration Weight of control unit
Model All models All models All models All models
Specifications/Condition Three-phase 220, 240, 380, 415, 460, 480, 500, 550, or 575 V +10% 15%, 50/60 +/1 Hz 7.5 kVA + 1.1 kVA for optional user transformer 3.5KW nominal path dependent (During rapid acceleration, the unit will temporarily require two times the continuous rated power value.) 0 degrees C to 45 degrees C
All models
75% RH or less, non-condensing, up to 95% RH for a limited period (within one month) No corrosive gas. When you use the robot in an environment with a high concentration of dust or coolant, consult with your FANUC Robotics sales representative. 0.5 G or less. When you use the robot in a location subject to serious vibration, consult with your FANUC Robotics sales representative. About 300 kg (660 lbs)
All models
All models C cabinet

R-J2 Controller P-200 Maintenance Manual

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R-J2 Controller P-200 Maintenance Manual

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FANUC Robotics SYSTEM R-J2 Controller P10, P15 and P200 Electrical Maintenance Manual

Conventions Used in this Manual

Issued United States Patents

CUSTOMER FOCUS CENTER 180047ROBOT

for down robots part order part replacement

H Replenishment H Warranty H Robot

parts support (8:00 p.m. to 8:00 a.m.)

for special training or onsite requests

Robot Sales Solution Sales

software and PACs ________________________ For best call results have:

________________________ For best call results have:

________________________ For best call results have:

________________________ For best call results have:

number (if known) name

number (if known) name

number (if known) name

name phone & fax numbers & controller type

name phone & fax numbers of your need

or serial number of robot, if available (reqd for warranty)

error messages and LED displays (if applicable)

H Proposed H Number H Method

of payment (P.O., credit card, etc.)

Fused FlangeMounted Disconnect Switch, CSize Controller

Transportation and Installation Addendum A

P200 Brake Release Option Package, Figure 1440

FL1 FL2 FL3

Fused Flange-Mounted Disconnect Switch, C-Size Cabinet

Fuse XGMF-00160 (A60L0001-0042 #JG1-30)

Fuse XGMF-04148 (A60L0001-0042 #JG1-20)

MOUNT SWITCHES AND RCS ON ALTERED COVER PLATE

MOUNT TERMINALS AND RELAY ON HEAT EXCHANGER

ROBOT CABLE CONNECTION TO TERMINAL STRIP

INSTALLATION IN C SIZE CONTROLLER

P200 BRAKE RELEASE OPTION PACKAGE EE3287516

MOUNT SWITCHES AND RCS ON ALTERED COVER PLATE

MOUNT TERMINALS AND RELAY ON HEAT EXCHANGER

ROBOT CABLE CONNECTION TO TERMINAL STRIP

INSTALLATION IN C SIZE CONTROLLER

P200 BRAKE RELEASE OPTION PACKAGE EE3287516

Figure 1440 P200 Brake Release Option Package

P200 Brake Release Option Package, Figure 1440

NOTE: This page replaces page 1243.

EE3112600 24V OVP UNIT 24V

INTRINSIC SAFETY BARRIER STAHL 9001/0125210014 1 2 IS GND 1 2 ISB1 3 4

CNPG EMGIN1 EMGIN2

PURGE CIRCUITS CNPG

CNIN FROM I/O

24V I/P SIG 24V

MAIN CPU CRM10 RDI/RDO CNCA

24V TO ACCUFLOW SIG FROM I/O FROM I/O

EE3185356001 BYPASS SWITCH

UNIT FLOW METER TRIGGER 1 TRIGGER 2

SOLENOID VALVE ROBOT PRESSURE SWITCH ROBOT FLOW SWITCH

IDEC IBRC6062R PRESSURE SWITCH P1 N1 P2 N2 P3 N3 P4 N4 P5 N5 P6 N6

220V (43) 220V (44)

FIRE ALARM +24VDC PSU

I.S. BATTERY PACK

+ P200 RJ2 MODELS MODEL P2006J2 P2007J2 P2006+2J2 P2007+2J2 P2007+3J2

MODEL MODEL MODEL

ISB UNIT A05B2308C370 I/S TEACH PENDANT A05B2308C300 FRAME GND.

Purpose of this Manual

How to Use this Manual

Conventions Used in this Manual