FANUC Robot series

R--J3iB CONTROLLER FOR EUROPE

MAINTENANCE MANUAL

B--81465EN--1/02

B--81465EN--1/02

Table of Contents
1
3
4
6 7 9

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p--1

I SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 OPERATOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.1 1.1.2 1.1.3 Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety of the Teach Pendant Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

SAFETY OF THE TOOLS AND PERIPHERAL DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1 1.2.2

10
10 10

1.3

SAFETY OF THE ROBOT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.1 1.3.2 1.3.3

11
11 11 11

1.4 1.5 1.6

SAFETY OF THE END EFFECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.1

12
12

SAFETY IN MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 14

II MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 2.2 2.3 EXTERNAL VIEW OF THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17
19 20
21 25 26

3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 POWER CANNOT BE TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALARM OCCURRENCE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING USING THE ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSED--BASED TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING BASED ON LED INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIBRATION OBSERVED DURING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MANUAL OPERATION IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27
28 30 33 34 36 117 122 131 132 133

4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

4.1 4.2 4.3 MAIN BOARD (A16B--3200--0412, --0413) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMERGENCY STOP CONTROL PC BOARD (A20B--1007--0800) . . . . . . . . . . . . . . . . . . . . . . . . BACKPLANE PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 139 140

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4.4 4.5 4.6 4.7 4.8 4.9

PANEL BOARD (A20B--2100--0770) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCESS I/O BOARD CA (A16B--2201--0470) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCESS I/O BOARD CB (A16B--2201--0472) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCESS I/O BOARD DA (A16B--2201--0480) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCESS I/O BOARD HA (A16B--2203--0760) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL SWITCH BOARD (A20B--1007--0850) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142 143 146 148 150 152

5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

5.1 5.2 5.3 LED OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SETTING OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVER CHIP FOR ROBOT DI/DO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 155 156

6. SETTING THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

6.1 6.2 6.3 BLOCK DIAGRAM OF THE MAIN POWER INCLUDING POWER SUPPLY . . . . . . . . . . . . . . SELECTING TRANSFORMER TAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 159 161

7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

7.1 REPLACING THE PRINTED--CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 7.1.2 7.1.3 Replacing the Backplane Board (Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Power Unit and Printed--Circuit Boards on the Backplane Unit . . . . . . . . . . . . . . . . . . . Replacing the Panel Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

165
165 166 168

7.2 7.3 7.4 7.5 7.6 7.7

REPLACING CARDS AND MODULES ON THE MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE REGENERATIVE RESISTOR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE E--STOP UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING I/O UNIT MODEL A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.1 7.7.2 Replacing the Base Unit of I/O Unit Model A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

169 173 176 177 178 182

182 183

7.8 7.9 7.10 7.11 7.12 7.13

REPLACING THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE CONTROL SECTION FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE AC FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.10.1 Replacing External Air Fan Unit and Door Fan (B--cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

184 185 186

186

REPLACING THE OPERATOR PANEL AND PANEL SWITCH BOARD . . . . . . . . . . . . . . . . . . REPLACE THE MODE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.13.1 7.13.2 7.13.3 7.13.4 Replacing Fuses in the Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Fuses in the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Process I/O Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Panel Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Relays on the Panel Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery for Memory Backup (3 VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188 189 190

190 191 192 194

7.14 7.15

REPLACING RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.14.1 7.15.1

195
195

REPLACING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196
196

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III CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 3. ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3.1 3.2 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS . . . . . . . . . . . . . . . . . . . . . . . . . EXTERNAL CABLE WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 Robot Connection Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teach Pendant Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the External Power Supply ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the External Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204 206
206 207 208 210 212

4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 4.1.2 4.1.3 4.1.4 When Process I/O Board CA/CB/HA is Used (B--cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When Process I/O Board DA is Used (B--cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When I/O Unit--MODEL A is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3.1 In case of B--cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When Two or more Process I/O Boards and I/O Unit (Model A or Model B) are Used . . . . . . . . . . . . In Case of B--cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

221
221 223 224 224 225

4.2 4.3 4.4

PERIPHERAL DEVICE INTERFACE COMBINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1

226
226

PROCESS I/O BOARD SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS . . . . . . . . . .
4.4.1 4.4.2 4.4.3 Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection Between the Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection Between the Control Unit and Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End Effector Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O Signal Specifications for ARC--Welding Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

227 231
232 245 247

4.5

DIGITAL I/O SIGNAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.1 4.5.2 4.5.3

253
253 255 257

4.6

SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 4.6.2 4.6.3 Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins) . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins) . . . . . . . . . . . . . . . . . . . . . . . . ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

261
261 261 262

4.7

CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS, AND ARC WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.1 4.7.2 4.7.3 4.7.4 Peripheral Device Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End Effector Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting HDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Signal Rules for the High--speed Skip (HDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS--232--C Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9.1.1 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

263
263 264 266 267

4.8

CONNECTION OF HDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.1 4.8.2

268
268 270

4.9

CONNECTING THE COMMUNICATION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.1

271
271 271

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4.9.1.2 4.9.2

RS--232--C Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

272 273 275 276 277 277 278 279 280 281

4.9.1.3 Connection between RS--232--C Interface and External Device . . . . . . . . . . . . . . . . . . . . . . . . Ethernet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9.2.1 Connection to Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9.2.2 4.9.2.3 4.9.2.4 4.9.2.5 4.9.2.6 4.9.2.7 10/100 BASE--T Connector (CD38) Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lead Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connector Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Clamp and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding the Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

5.1 5.2 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 5.2.2 Installation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assemble at installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

284 285
285 287

5.3 5.4 5.5

INSTALLATION CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT AND CHECKS AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION . . . . . . . . . . . . . .
5.5.1 5.5.2 5.5.3 5.5.4 Peripheral Device Interface Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Disable/Enable HBK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Disable/Enable Pneumatic Pressure Alarm (PPABN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

288 289 290

290 290 291 292

APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
A. TOTAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE . . . . . . . . . . . . . . . . . 316
B.1 B.2 B.3 SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SETTING COMMON VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.3.1 B.3.2 Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input/Output Hardware Usable in the R-J3iB Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

317 319 320

320 325

B.4

SPECIFICATIONS OF DIGITAL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.4.1 B.4.2 B.4.3

329
329 329 330

C. POWER DISTRIBUTION CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 D. OPTICAL FIBER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 E. CARD INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

c--4

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PREFACE

PREFACE

This manual describes the following models (R--J3iB controller).

Model Abbreviation

FANUC Robot R--2000iA/165F FANUC Robot R--2000iA/200F FANUC Robot R--2000iA/165R FANUC Robot R--2000iA/200R FANUC Robot R--2000iA/125L FANUC Robot M--6iB FANUC Robot ARC Mate 100iB

R--2000iA/165F R--2000iA/200F R--2000iA/165R R--2000iA/200R R--2000iA/125L M--6iB ARC Mate 100iB R--2000iA R 2000iA

FANUC Robot R--2000iA/165CF R--2000iA/165CF

p--1

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1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell.

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1.1
OPERATOR SAFETY

Operator safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure operator safety. (1) Have the robot system operators attend the training courses held by FANUC.
FANUC provides various training courses. Contact our sales office for details.

(2) Even when the robot is stationary, it is possible that the robot is still ready to move state and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure operator safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. (3) Install a safety fence with a gate so that no operator can enter the work area without passing through the gate. Equip the gate with an interlock that stops the robot when the gate is opened.
The controller is designed to receive this interlock signal. When the gate is opened and this signal received, the controller stops the robot in an emergency. For connection, see Fig.1.1.

(4) Provide the peripheral devices with appropriate grounding (Class 1, Class 2, or Class 3). (5) Try to install the peripheral devices outside the work area. (6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when an operator enters the work area. (8) If necessary, install a safety lock so that no one except the operator in charge can turn on the power of the robot.
The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.

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(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.

Limit switch for the safety gate Panel board EAS1 EAS11

EAS2 EAS21 Note) Terminals FENCE1 and FENCE2 are on the PC board in the operator panel. Fence circuit is a safety stop circuit.

Fig.1.1 Safety Fence and Safety Gate

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1.1.1
Operator Safety

The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators. (1) If it is not necessary for the robot to operate, turn off the power of the robot controller or press the EMERGENCY STOP button, and then proceed with necessary work. (2) Operate the robot system at a location outside the work area. (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the work area unexpectedly and also to prevent the worker from entering a dangerous area. (4) Install an EMERGENCY STOP button within the operators reach.
The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

External EMERGENCY STOP button

Panel board EES1 EES11 EES2 EES21

Note)

Connect to EES1 and EES11, EES2 and EES21.

Fig.1.1.1 Connection Diagram for External Emergency Stop Switch

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1.1.2
Safety of the Teach Pendant Operator

While teaching the robot, it is necessary for the operator to enter the work area of the robot. It is particularly necessary to ensure the safety of the teach pendant operator. (1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating condition. (3) When entering the robot work area and teaching the robot, be sure to check the location and condition of the safety devices (such as the EMERGENCY STOP button and the deadman switch on the teach pendant).
The teach pendant supplied by FANUC is provided with a teach pendant enable switch and a deadman switch in addition to the EMERGENCY STOP button. The functions of each switch are as follows. EMERGENCY STOP button : Pressing this button stops the robot in an emergency, irrespective to the condition of the teach pendant enable switch. Deadman switch : The function depends on the state of the teach pendant enable switch.

When the enable switch is on -- Releasing the finger from the dead man switch or holding the deadman switch strongly stops the robot in an emergency. When the enable switch is off -- The deadman switch is ineffective.

NOTE
The deadman switch is provided so that the robot operation can be stopped simply by releasing finger from the teach pendant or holding the deadman switch strongly in case of emergency.

The R--J3iB has adopted a 3--position deadman switch as an RIA--specification teach pendant. Pressing the 3--position deadman switch halfway makes the robot operable. Releasing the finger from the deadman switch or holding the deadman switch strongly causes the robot to enter the emergency stop state.

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(4) The teach pendant operator should pay careful attention so that no other workers enter the robot work area. NOTE
In addition to the above, the teach pendant enable switch and the deadman switch also have the following function. By pressing the deadman switch while the enable switch is on, the emergency stop factor (normally the safety gate) connected to EAS1 and EAS11, EAS2 and EAS21 of the controller is invalidated. In this case, it is possible for an operator to enter the fence during teach operation without making the robot in the emergency stop condition. In other words, the system understands that the combined operations of pressing the teach pendant enable switch and pressing the deadman switch indicates the start of teaching. The teach pendant operator should be well aware that the safety gate is not functional under this condition and bear full responsibility to ensure that no one enters the fence during teaching.

(5) When entering the robot work area, the teach pendant operator should enable the teach pendant whenever he or she enters the robot work area. In particular, while the teach pendant enable switch is off, make certain that no start command is sent to the robot from any operator panel other than the teach pendant.
The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode of the teach pendant enable switch and the remote switch on the operators panel.

Teach pendant enable switch On Off Off

Remote condition Independent Local Remote

Teach pendant Allowed to start Not allowed Not allowed

Operator panel Not allowed Allowed to start Not allowed

Peripheral devices Not allowed Not allowed Allowed to start

(6) To start the system using the operator panel, make certain that nobody is in the robot work area and that there are no abnormal conditions in the robot work area. (7) When a program is completed, be sure to carry out a test run according to the procedure below. (a) Run the program for at least one operation cycle in the single step mode at low speed. (b) Run the program for at least one operation cycle in the continuous operation mode at low speed. (c) Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing. (d) Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble. (e) After checking the completeness of the program through the test run above, execute it in the automatic operation mode.
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(8) While operating the system in the automatic operation mode, the teach pendant operator should leave the robot work area.

1.1.3
Safety During Maintenance

For the safety of maintenance personnel, pay utmost attention to the following. (1) Except when specifically necessary, turn off the power of the controller while carrying out maintenance. Lock the power switch, if necessary, so that no other person can turn it on. (2) When disconnecting the pneumatic system, be sure to reduce the supply pressure. (3) Before the start of teaching, check that the robot and its peripheral devices are all in the normal operating condition. (4) If it is necessary to enter the robot work area for maintenance when the power is turned on, the worker should indicate that the machine is being serviced and make certain that no one starts the robot unexpectedly. (5) Do not operate the robot in the automatic mode while anybody is in the robot work area. (6) When it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers are working nearby, make certain that their escape path is not obstructed. (7) When a tool is mounted on the robot, or when any moving device other than the robot is installed, such as belt conveyor, pay careful attention to its motion. (8) If necessary, have a worker who is familiar with the robot system stand beside the operator panel and observe the work being performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time. (9) When replacing or reinstalling components, take care to prevent foreign matter from entering the system. (10) When handling each unit or printed circuit board in the controller during inspection, turn off the power of the controller and also turn off the circuit breaker to protect against electric shock. (11) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of non-specified ratings. They may cause a fire or result in damage to the components in the controller.

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1.2
SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 1.2.1
Precautions in Programming
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received. (2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal. (3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other. (4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states.

1.2.2
Precautions for Mechanism

(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of grease, water, and dust. (2) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot does not come into contact with its peripheral devices or tools.

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1.3
SAFETY OF THE ROBOT MECHANISM 1.3.1
Precautions in Operation
(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality. (2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the jog mode.

1.3.2
Precautions in Programming

(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere with each other. (2) Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

1.3.3
Precautions for Mechanisms

(1) Keep the work area of the robot clean, and operate the robot in an environment free of grease, water, and dust.

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1.4
SAFETY OF THE END EFFECTOR 1.4.1 Precautions in Programming
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control. (2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.

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1.5
SAFETY IN MAINTENANCE

(1) Never enter the robot work area while the robot is operating. Turn off the power before entering the robot work area for inspection and maintenance. (2) If it is necessary to enter the robot work area with the power turned on, first press the EMERGENCY STOP button on the operator panel. (3) When replacing or reinstalling components, take care to prevent foreign matter from entering the system. When replacing the parts in the pneumatic system, be sure to reduce the pressure in the piping to zero by turning the pressure control on the air regulator. (4) When handling each unit or printed circuit board in the controller during inspection, turn off the power of the controller and turn off the circuit breaker to protect against electric shock. (5) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of non-specified ratings. They may cause a fire or result in damage to the components in the controller. (6) Before restarting the robot, be sure to check that no one is in the robot work area and that the robot and its peripheral devices are all in the normal operating state.

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1.6
WARNING LABEL
Description
Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing as well. (1) Step--on prohibitive label

Fig.1.6 (a) Step--on Prohibitive Label

Description

Be cautious about a section where this label is affixed, as the section generates heat. If you have to inevitably touch such a section when it is hot, use a protective provision such as heat--resistant gloves. (2) High--temperature warning label

Fig.1.6 (b) High--Temperature Warning Label

Description

A high voltage is applied to the places where this label is attached. Before starting maintenance, turn the power to the control unit off, then turn the circuit breaker off to avoid electric shock hazards. Be careful with servo amplifier and other units because high--voltage places in these units may remain in the high--voltage state for a fixed time.
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(3) High--voltage warning label

Fig.1.6 (c) High--Voltage Warning Label

Description

There may be a high voltage in a place with this label. Before working on such a portion, turn off the power to the controller and set its circuit breaker to the off position to avoid shock hazards. In addition, be careful about servo amplifiers and other electric circuits because a high voltage may remain in them for a certain period of time after the power is turned off.

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II MAINTENANCE

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MAINTENANCE

1. OVERVIEW

OVERVIEW

This manual describes the maintenance and connection of the R--J3iB robot controller (called the R--J3iB). Maintenance Part : Troubleshooting, and the setting, adjustment, and replacement of units Connection Part : Connection of the R--J3iB controller to the robot mechanical unit and peripheral devices, and installation of the controller WARNING Before you enter the robot working area, be sure to turn off the power to the controller or press the EMERGENCY STOP button on the operator panel or teach pendant. Otherwise, you could injure personnel or damage equipment. - For information on third party approvals, contact your FANUC representative.

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2. CONFIGURATION

MAINTENANCE

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CONFIGURATION

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MAINTENANCE

2. CONFIGURATION

2.1
EXTERNAL VIEW OF THE CONTROLLER

The appearance and components might slightly differ depending on the controlled robot, application, and options used. Fig.2.1 (a) shows the view of R--J3iB. Fig.2.1 (b) and (c) show the R--J3iB consists of the R--J3iB controller.
Mode switch Teach pendant Operator panel

Fig.2.1 (a) External View of the R--J3iB Controller (B--cabinet)

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Fig.2.1 (b) R--J3iB B--cabinet interior (Front)

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2. CONFIGURATION

Fig.2.1 (c) R--J3iB B--cabinet overview (Back) Table 2.1 Servo amplifier and regenerative resistor unit Robot models R--2000iA M--6iB ARC Mate 100iB Servo amplifier A06B--6105--H002 A06B--6105--H003 Regenerative resistor unit A05B--2452--C200 (B--cabinet) A05B--2452--C201 ( (B--cabinet) )

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2. CONFIGURATION

Backplane

Power supply unit

Main board
Battery

Process I/O I/O unit MODEL A peripheral device (I/O) peripheral device (Serial)
Memory card

Fig.2.1 (d) Block diagram of the R--J3iB (B--cabinet)

Fan
Servo Signal (FSSB) HSSB, TP Signal

Operators panel Panel board

210VAC Output

210VAC Input

24VDC

MAINTENANCE

Switch

peripheral device (Ethernet) Teach pendant

24

Transformer
24VDC EMG signals

E--stop unit

Servo amplifier (6--axis amplifier)

External E--stop External on/off Robot

210VAC

210VAC EMG signals

Pulse coder signals, Robot DI/DO signals Motor power supply, Brake power supply

Noise filter

AC input 380 -- 415 VAC 440 -- 500 VAC 3

Breaker

Transformer overheat signal

Regenerative resistor B--81465EN--1/02

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2. CONFIGURATION

2.2
COMPONENT FUNCTIONS

-- Main board The main board contains a microprocessor, its peripheral circuits, memory, and operator panel control circuit. The main CPU controls servo mechanism positioning and servo amplifier voltages. - Battery retains main board memory when controller power is off. - I/O printed circuit board, FANUC I/O Unit MODEL--A Various types of printed circuit boards are provided for applications including process I/O. The FANUC I/O unit MODEL-A can also be installed. When it is used, various I/O types can be selected. These are connected with FANUC I/O Link. - E--stop unit This unit controls the emergency stop system with control reliable E--stop performance criteria for both of the magnetic contactor and the precharge of the servo amplifier. - Power supply unit The power supply unit converts the AC power to various levels of DC power. - Backplane printed circuit board The various control printed circuit boards are mounted on the backplane printed circuit board. - Teach pendant All operations including robot programming are performed with this unit. The controller status and data are indicated on the liquid-crystal display (LCD) on the pendant. - Servo amplifier The servo amplifier controls servomotor power, pulse coder, brake control, overtravel and hand broken. - Operator panel Buttons and LEDs on the operator panel are used to start the robot and to indicate the robot status. The panel has a port for the serial interface to an external device and an interface to connect the memory card for data backup. It also controls the emergency stop control circuit. - Transformer The supply voltage is converted to an AC voltage required for the controller by the transformer. - Fan unit, heat exchanger These components cool the inside of the control unit. - Circuit breaker If the electric system in the controller malfunctions, or if abnormal input power causes high current in the system, the input power is connected to the circuit breaker to protect the equipment. - Regenerative resistor To discharge the counter electromotive force from the servomotor, connect a regenerative resistor to the servo amplifier.

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2.3
PREVENTIVE MAINTENANCE

Daily maintenance and periodic maintenance/inspection ensure reliable robot performance for extended periods of time. (1) Daily maintenance Before operating the system each day, clean each part of the system and check the system parts for any damage or cracks. Also check the following: (a) Before service operation Check the cable connected to the teach pendant for excessive twisting. Check the controller and peripheral devices for abnormalities. (b) After service operation At the end of service operation, return the robot to the specified position, then turn off the controller. Clean each part, and check for any damage or cracks. If the ventilation port of the controller is dusty, clean it. (c) Check after one month Check that the fan is rotating normally. If the fan has dirt and dust built up, clean the fan according to step (d) described below for inspection to be performed every 6 months. (d) Periodic inspection performed every six months Remove the top cover, louver, and back panel (if possible), then remove any dirt and dust from the inside of the transformer compartment. Wipe off dirt and dust from the fan and transformer. (2) Maintenance tools The following maintenance tools are recommended: (a) Measuring instruments AC/DC voltmeter (A digital voltmeter is sometimes required.) Oscilloscope with a frequency range of 5 MHz or higher, two channels (b) Tools Phillips screwdrivers : Large, medium, and small Standard screwdrivers: Large, medium, and small Nut driver set (Metric) Pliers Needle-nose pliers Diagonal cutting pliers

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MAINTENANCE

3. TROUBLESHOOTING

TROUBLESHOOTING

This chapter describes the checking method and corrective action for each error code indicated if a hardware alarm occurs. Refer to the operators manual to release program alarms.

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MAINTENANCE

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3.1
POWER CANNOT BE TURNED ON
Check and Corrective action
(Check 1) (Corrective action) Check that the circuit breaker is on and has not tripped. Turn on the circuit breaker.

Figure

Breaker

(Check 2) (Corrective action)

Check whether the LED (PIL: green) on the power supply unit is on. If the LED is not on, 200 VAC is not supplied to the power supply unit. It is likely that fuse F1 in the power supply unit has blown. -- If 200 VAC is not supplied: Find the cause by referencing the general schematic diagram presented in the appendix. -- If 200 VAC is supplied: Find the cause of the blown fuse. Fuse F1 is in the power supply unit. Before you start troubleshooting, turn off the circuit breaker. a) If fuse F1 has blown: -- See Corrective action (1). b) If fuse F1 has not blown: -- Replace the power supply unit. Causes of blown fuses F1 and corrective action a) Check whether the unit and printed--circuit board connected to the connectors CP2 and CP3 in the power supply unit are abnormal, by referencing the general schematic diagram presented in the appendix. b) Short-circuit in the surge absorber VS1 VS1 is inserted to absorb surge voltage between input lines. If the surge voltage is excessive or sustained, excessively high voltage is applied to VS1 and a failure occurs in the short-circuit mode, causing F1 to blow. If a short-circuit occurs in VS1, and there is not a spare part, the system is permitted to operate without VS1. In this case, however, obtain and install a new VS1 as soon as possible. VS1 ordering number: A50L-2001-0122#G431k c) Short-circuit of diode stack DB1 d) The secondary power supply module is faulty : If one of the causes (b) to (c) above is detected, replace the power supply unit with a spare unit. The spec. for F1 is : A60L-0001-0396#8.0A
Diode stack DB1 F1 8.0A Fuse for AC input

CP1 connector

Surge absorber VS1 Spare power supply module H1

F3 7.5A Fuse for +24E F4 7.5A Fuse for +24V PIL LED (green) for AC power supply display CP6 connector CP5 connector LED (red) for alarm display

(Corrective action(1))

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Check and Corrective action

(Check 3) Check whether the EXON1 and EXON2 signals, and the EXOFF1 and EXOFF2 signals are connected on the terminal block on the panel board. If the external ON/OFF function is not used, connect the EXON1 and EXON2 the EXOFF1 and EXOFF2. If the external ON and OFF lines are already used, check the mating contacts and the cable. Short piece :

Figure
between 1 (EXON1) and 2 (EXON2) between 3 (EXOFF1) and 4 (EXOFF2)

(Corrective action)

Connector (JRS11) (Check 4) Check whether the connector (JRS11) on the main board or the connector (JRS11) on the panel board is connected properly. Another probable cause is that the cable connected to either of these connectors is faulty. Check 1 to 3 above confirm that 200 VAC power is supplied to connector CP1 of the power supply unit and that the ON/OFF switch functions normally. Therefore check the power supply unit using the following procedure: If the LED (ALM: red) on the power supply unit is on Check if the +24 V external connection cable is connected to 0 V or ground. a) Fuse F4 blown : See corrective action (2). b) None of the above fuses blown [d) is also probable] : A printed circuit board or unit that uses a DC supply voltage (+3.3V, +5V, +24V, or 15V) is faulty. c) None of the above fuses blown : Check that 200 VAC is supplied to connector CP1. If it is supplied replace the power supply unit. If the power supply unit is not faulty, replace the panel board or operator panel. Causes of blown fuse F4 and corrective action The device connected to connector CP5 of the power supply unit may be faulty. If no device is connected to CP5 or the connected device is normal, the +24 V power used in a printed circuit board connected to the backplane is faulty. The code of F4 is A60L--0001--0046#7.5 :
Diode stack DB1 F1 8.0A Fuse for AC input

(Check 5)

CP1 connector

Surge absorber VS1 Spare power supply module H1

F3 7.5A Fuse for +24E F4 7.5A Fuse for +24V PIL LED (green) for AC power supply display CP6 connector CP5 connector LED (red) for alarm display

(Corrective action) (Corrective action(2))

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3.2
ALARM OCCURRENCE SCREEN

The alarm occurrence screen displays only the alarm conditions that are currently active. If an alarm reset signal is input to reset the alarm conditions, the alarm occurrence screen displays the message PAUSE or more serious alarm has not occurred. The alarm occurrence screen displays only the alarm conditions (if any) that occur after the most recently entered alarm reset signal. To erase all alarm displays from the alarm occurrence screen. Press the CLEAR key (+ shift) on the alarm history screen. The alarm occurrence screen is intended to display PAUSE or more serious alarms. It will not display WARN, NONE, or a reset. It is possible to disable PAUSE and some of more serious alarms from being displayed by setting the $ER_NOHIS system variable appropriately. If two or more alarms have occurred, the display begins with the most recent alarm. Up to 100 lines can be displayed. If an alarm has a cause code, it is displayed below the line indicating the alarm.
Press the screen selection key to select [4 ALARM]. Automatic alarm display upon occurrence

Press the alarm key.

Alarm occurrence screen display

Press F3 [ACTIVE].

Press F3 [HIST].

Alarm history screen display

Fig.3.2 Alarm Occurrence Screen and Alarm History Screen Display Procedure

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Displaying the alarm history/alarm detail information

Step

(1) Press the MENUS key to display the screen menu. (2) Select [ALARM]. You will see a screen similar to the following
3 4 ALARM 5 I/O
MENUS

INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Specified line does not exist Alarm JOINT 30 % 1/25 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop 3 R E S E T 4 SRVO-027 Robot not mastered(Group:1) 5 SYST-026 System normal power up

[ TYPE ]

CLEAR

HELP

NOTE The latest alarm is assigned number 1. To view messages that are currently not on the screen, press the F5, HELP, then press the right arrow key. (3) To display the alarm detail screen, press F5, [HELP].
CLEAR HELP F5 INTP-224 (SAMPLE1, 7) Jump label is fail INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Specified line does not exist 30-MAY-44 07:15 STOP.L 00000110 Alarm 1/25 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop

[ TYPE ]

CLEAR

HELP

(4) To return to the alarm history screen, press the PREV key.
PREV

(5) To delete all the alarm histories, press and hold down the SHIFT key, then press F4, [CLEAR].
CLEAR F4 HELP

SHIFT

NOTE When system variable $ER_NOHIS = 1, NONE alarms or WARN alarms are not recorded. When $ER_NOHIS=2, resets are not recorded in the alarm history. When $ER_NOHIS=3, resets, WARN alarms, and NONE alarms are not recorded.

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The following map indicates teach pendant operations used to check an alarm. 4 ALARM F1 [TYPE] Alarm : Active F1 [TYPE] F3 HIST Alarm : HIST F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP DETAIL Alarm F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP

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3.3
SAFETY SIGNALS
Safety signal Operator panel emergency stop Teach pendant emergency stop External emergency stop Fence open Deadman switch

The safety signal screen indicates the state of signals related to safety. To be specific, the screen indicates whether each safety signal is currently on. On this screen, it is impossible to change the state of any safety signal.
Table 3.3 Safety Signals Description This item indicates the state of the emergency stop button on the operator panel. If the EMERGENCY STOP board is pressed, the state is indicated as TRUE. This item indicates the state of the emergency stop button on the teach pendant. If the EMERGENCY STOP board is pressed, the state is indicated as TRUE. This item indicates the state of the external emergency stop signal. If the EMERGENCY STOP signal is input, the state is indicated as TRUE. This item indicates the state of the safety fence. If the safety fence is open, the state is indicated as TRUE. This item indicates whether the DEADMAN switch on the teach pendant is grasped. If the teach pendant is operable, and the DEADMAN switch is grasped, the state is indicated as TRUE. If the deadman switch is released when the teach pendant is operable, an alarm occurs, causing the servo power to be switched off. This item indicates whether the teach pendant is operable. If the teach pendant is operable, the state is indicated as TRUE. This item indicates the state of the hand safety joint. If the hand interferes with a workpiece or anything like this, and the safety joint is opened, the state is indicated as TRUE. In this case, an alarm occurs, causing the servo power to be switched off. This item indicates whether the current position of the robot is out of the operation range. If any robot articulation goes out of the operation range beyond the overtravel switch, the state is indicated as TRUE. In this case, an alarm occurs, causing the servo power to be switched off. This item indicates the state of the air pressure. The abnormal air pressure signal is connected to the air pressure sensor. If the air pressure is not higher than the specified value, the state is indicated as TRUE.

Teach pendant operable Hand broken

Robot overtravel

Abnormal air pressure

Step

(1) Press the MENUS key to display the screen menu. (2) Select STATUS on the next page. (3) Press F1, [TYPE] to display the screen switching menu. (4) Select Safety Signal. You will see a screen similar to the following.
SYSTEM Safety SIGNAL NAME 1 2 3 4 5 6 7 8 9 SOP E-Stop: TP E-stop: Ext E-Stop: Fence Open: TP Deadman: TP Enable: Hand Broken: Over Travel: Low Air Alarm: JOINT 30% STATUS FALSE FALSE FALSE FALSE TRUE TRUE FALSE FALSE FALSE 1/11

[TYPE]

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3.4
MASTERING

Mastering is needed if: (1) The SRVO--062 BZAL or SRVO--038 pulse mismatch alarm occurs, or (2) The pulse coder is replaced. Item (1) requires simplified mastering, while item (2) requires zero--degree or jig position mastering. (Zero--degree position mastering is just for quick--fix purposes. After zero--degree position mastering is used, jig position mastering should be performed later.) The mastering procedure is described below. For details, refer to an applicable maintenance manual of mechanical unit or operators manual of control unit.

Condition

System variable $MASTER_ENB must be set to 1 or 2.

SYSTEM Variables 57 $MASTER_ENB JOINT 10% 57/136 1

Step

(1) Press <MENUS>. (2) Select SYSTEM. (3) Press F1, TYPE. (4) Select Master/Cal you will see a screen similar to the following.
9 USER 0 -- NEXT -SYSTEM Master/Cal 1
MENUS

JOINT 30%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE

5 POSITION 6 SYSTEM 7

2 3 4 5 6

Master/Cal TYPE

Press ENTER or number key to select.

[TYPE]

LOAD RES_PCA

DONE

F1

(5) Move the robot by jog feed to the mastering position. Release the brake on the manual brake control screen if necessary. NOTE Mastering can not be performed until axis is rotated enough to establish a pulse.

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(6) Select 1 FIXTURE POSITION MASTER and press the F4 key (yes). Mastering data is set.
SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER Master at master position? [NO] Master at master position? [NO] [ TYPE ] YES
ENTER

SYSTEM Master/Cal

JOINT

30 %

NO

F4

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> <11808249> <38767856> <9873638> <122000309> <2000319>

[ TYPE ]

LOAD

RES_PCA

DONE

(7) Select 6 CALIBRATE and press the F4 key (yes). Calibration is performed. Alternatively, to perform positioning, turn the power off, then turn it on again. Calibration is performed whenever the power is turned on.
5 SET QUICK MASTER REF 6 CALIBRATE ENTER Calibrate? [NO] Calibrate? [NO] [ TYPE ] SYSTEM Master/Cal JOINT 30 %

YES

NO

F4

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): <10.000> <-25.000> <40.000> <5.000> <-15.000> <0.000> [ TYPE ] LOAD RES_PCA DONE

(8) Press F5 DONE, after mastering.

DONE

F5

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3.5
TROUBLESHOOTING USING THE ERROR CODE

(1) SRVO--001 SVAL1 Operator panel E--stop (Explanation) The emergency stop button on the operation operator panel or is pressed. If the SYST--067 (Panel HSSB disconnect) alarm is also generated, or if the LED (green) on the panel board is turned off, communication between the main board (JRS11) and the panel board (JRS11) is abnormal. The connectors of the cable between the main board and the panel board may be loose. Or, the cable, panel board, or main board may be faulty. (Note) (Action 1) Release the emergency stop button pressed on the operator panel. (Action 2) Check the wires connecting the emergency stop switch connector CRT8 for continuity. If an open wire is found replace the entire harness. (Action 3) With the emergency stop in the released position, check for continuity across the terminals of the switch. If continuity is not found, replace the switch. If continuity is found replace the operator panel PCB. Before executing the (Action 4), perform a complete controller back--up to save all your programs and settings. (Action 4) Replace the Main Board. NOTE If the LED is turned off, the following alarms are also generated. SRVO--001 Operator panel E--stop. SRVO--004 Fence open. SRVO--007 External emergency stop. SRVO--199 Control stop. SRVO--204 External (SVEMG abnormal) E--stop. SRVO--213 Fuse blown (Panel PCB). SRVO--277 Panel E--stop (SVEMG abnormal). SRVO--280 SVOFF input Check the alarm history display on the teach pendant.

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Emergency stop button

Fig.3.5 (1) (a) SRVO--001 SVAL1 Operator panel E--stop

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Connector (CRT8)

LED (Green)

Connector (JRS11)

Panel board
Fig.3.5 (1) (b) SRVO--001 SVAL1 Operator panel E--stop

Connector (JRS11)

Main board
Fig.3.5 (1) (c) SRVO--001 SVAL1 Operator panel E--stop

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(2) SRVO--002 SVAL1 Teach pendant E--stop (Explanation) The emergency stop button on the operators Teach Pendant was pressed. (Action 1) Release the emergency stop button on the teach pendant. (Action 2) Replace Teach Pendant.
Emergency stop button

Fig.3.5 (2) SRVO--002 SVAL1 Teach pendant E--stop

(3) SRVO--003 SVAL1 Deadman switch released (Explanation) The teach pendant is enabled, but the deadman switch is not pressed. Deadman switch is three position switch. Dont press the switch to the second open position. Switch is enabled in middle position only. (Action 1) Press the deadman switch to run the robot. (Action 2) Replace the teach pendant.

Deadman switch

Fig.3.5 (3) SRVO--001 SVAL1 Deadman switch released

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(4) SRVO--004 SVAL1 Fence open (Explanation) On the terminal block TBOP4 of the panel board, no connection is made between 5 (EAS1) and 6 (EAS11) or between 7 (EAS2) and 8 (EAS21). If a safety fence is connected between 5 (EAS1) and 6 (EAS11) or between 7 (EAS2) and 8 (EAS21), the door of the safety fence is open. If the SYST--067 (Panel HSSB disconnect) alarm is also generated, or if the LED (green) on the panel board is turned off, communication between the main board (JRS11) and the panel board (JRS11) is abnormal. The connectors of the cable between the main board and the panel board may be loose. Or, the cable, panel board, or main board may be faulty. (Note) (Action 1) If a safety fence is connected, close the door. (Action 2) Check the switch and cable connected to 5 (EAS1) and 6 (EAS11) or 7 (EAS2) and 8 (EAS21). (Action 3) When this signal is not used, make a connection between 5 (EAS1) and 6 (EAS11) or between 7 (EAS2) and 8 (EAS21). (Action 4) If SRVO--004 (Fence open), SRVO--007 (External emergency stops), SRVO--213 (Fuse Blown (Panel PCB)), and SRVO--280 (SVOFF input) occur simultaneously, it is likely that FUSE1 on the panel board has blown. Check the fuse. If it has blown, remove the cause, then replace the fuse. (Refer to Section 3.6 in Part II, Maintenance, of Maintenance Manual.) (Action 5) Replace the panel board. NOTE FENCE input (AUTO STOP) is a safety stop input when this input is opened, the robot decelerates in a controlled manner and then stops, the magnetic contactor opens after the robot stops.

WARNING Do NOT short--circuit, or disable, this signal in a system in which the Fence signal is in use, as it is very dangerous. If it is necessary to run the robot by short--circuiting the signal even temporarily, an additional safety provision must be provided.

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NOTE If the LED is turned off, the following alarms are also generated. SRVO--001 Operator panel E--stop. SRVO--004 Fence open. SRVO--007 External emergency stop. SRVO--199 Control stop. SRVO--204 External (SVEMG abnormal) E--stop. SRVO--213 Fuse blown (Panel PCB). SRVO--277 Panel E--stop (SVEMG abnormal). SRVO--280 SVOFF input Check the alarm history display on the teach pendant.
Short connection 5 (EAS1) and 6 (EAS11) Connector (CRT8) Short connection 7 (EAS2) and 8 (EAS21)

LED (Green)

Connector (JRS11)

Panel board
Fig.3.5 (4) (a) SRVO--004 SVAL1 Fence open

Connector (JRS11)

Main board
Fig.3.5 (4) (b) SRVO--004 SVAL1 Fence open

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(5) SRVO--005 SVAL1 Robot overtravel (Explanation) The robot has moved beyond a hardware limit switch on the axes. It is factory--placed in the overtravel state for packing purposes. If the Overtravel signal is not in use, it may have been disabled by short--circuiting in the mechanical unit. (Action 1) 1) Select [System OT release] on the overtravel release screen to release each robot axis from the overtravel state. 2) Hold down the shift key, and press the alarm release button to reset the alarm condition. 3) Still hold down the shift key, and jog to bring all axes into the movable range. (Action 2) Check the FS2 fuse on the servo amplifier. If the SRVO--214 Fuse blown alarm is also generated, FS2 fuse have been blown. (Action 3) Verify the following for connector RP1 at the base of the robot : 1) There are no bent or dislocated pins in the male or female connectors. 2) The connector is securely connected. Then verify that connectors CRF7 and CRM68 on the servo amplifier are securely connected. Also verify that the RP1 cable is in good condition, and there are no cuts or kinks visible. If no limit switch is in use, a jumper connector must be attached in the mechanical unit. Check for the jumper connector. (Action 4) Replace the servo amplifier.

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Servo amplifier

FS2

Connector (CRF7) Connector (CRM68) Servo amplifier

Fig.3.5 (5) SRVO--005 SVAL1 Robot overtravel

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(6) SRVO--006 SVAL1 Hand broken (Explanation) The safety joint (if in use) might have been broken. Alternatively, the HBK signal on the robot connection cable might be a ground fault or a cable disconnection. If the Hand broken signal is not in use, it can be disabled by software setting. Refer to Subsection 5.5.3 in Part III, Connections, of Maintenance Manual for how to disable the Hand broken signal. (Action 1) Hold down the shift key, and press the alarm release button to reset the alarm condition. Still hold down the shift key, and jog the tool to the work area. 1) Replace the safety joint. 2) Check the safety joint cable. (Action 2) Check the FS2 fuse on the servo amplifier. If the SRVO--214 Fuse blown alarm is also generated, FS2 fuse have been blown. (Action 3) Verify the following for connector RP1 at the base of the robot : 1) There are no bent or dislocated pins in the male or femail connectors. 2) The connector is securely connected. Then verify that connector CRF7 on the servo amplifier is securely connected. Also verify that the RP1 cable is in good condition, and there are no cuts or kinks visible. Check the robot connection cable (RP1) for a ground fault or a cable disconnection. (Action 4) Replace the servo amplifier.

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Servo amplifier

FS2

Connector (CRF7) Servo amplifier

Fig.3.5 (6) SRVO--006 SVAL1 Hand broken

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(7) SRVO--007 SVAL1 External E--stop (Explanation) On the terminal block TBOP4 of the panel board, no connection is made between 1 (EES1) and 2 (EES11) or between 3 (EES2) and 4 (EES21). If an external emergency stop switch is connected between 1 (EES1) and 2 (EES11) or between 3 (EES2) and 4 (EES21), the switch is pressed. If the SYST--067 (Panel HSSB disconnect) alarm is also generated, or if the LED (green) on the panel board is turned off, communication between the main board (JRS11) and the panel board (JRS11) is abnormal. The connectors of the cable between the main board and the panel board may be loose. Or, the cable, panel board, or main board may be faulty. (Note) (Action 1) If an external emergency stop switch is connected, releases the switch. (Action 2) Check the switch and cable connected to 1 (EES1) and 2 (EES11) or 3 (EES2) and 4 (EES21). (Action 3) When this signal is not used, make a connection between 1 (EES1) and 2 (EES11) or between 3 (EES2) and 4 (EES21). (Action 4) If SRVO--004 (Fence open), SRVO--007 (External emergency stops), SRVO--213 (Fuse blown (Panel PCB)), and SRVO--280 (SVOFF input) occur simultaneously, it is likely that FUSE1 on the panel board has blown. Check the fuse. If it has blown, remove the cause, then replace the fuse. (Refer to Section 3.6 in Part II, Maintenance, of Maintenance Manual.) (Action 5) Replace the panel board. WARNING Do NOT short--circuit, or disable, this signal in a system in which the External emergency stop input signal is in use, as it is very dangerous. If it is necessary to run the robot by short--circuiting the signal even temporarily, an additional safety provision must be provided. NOTE If the LED is turned off, the SRVO--001 (Operator panel E--stop), SRVO--004 (Fence open), SRVO--007 (External emergency stops), or SRVO--280 (SVOFF input), alarm is also generated. Check the alarm history display on the teach pendant.

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Short connection 1 (EES1) and 2 (EES11)

Short connection 3 (EES2) and 4 (EES21)

Panel board

LED (Green)

Connector (JRS11)

Panel board
Fig.3.5 (7) (a) SRVO--007 SVAL1 External E--stop

Connector (JRS11)

Main board
Fig.3.5 (7) (b) SRVO--007 SVAL1 External E--stop

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(8) SRVO--009 SVAL1 Pneumatic pressure alarm (Explanation) An abnormal air pressure was detected. The input signal is located on the end effector of the robot. Refer to the manual of your robot. (Action 1) If an abnormal air pressure is detected, check the cause. If the peripheral device are normal, check the robot cable and if the peripheral device are abnormal, replace the device. (Action 2) Replace the servo amplifier.
Servo amplifier

Fig.3.5 (8) SRVO--009 SVAL1 Pneumatic pressure alarm

Pneumatic pressure alarm input is disabled/enabled by software. Please refer to Subsection 5.5.4. in Part III Connections of this Maintenance Manual.

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(9) SRVO--014 WARN Fan motor abnormal (Explanation) A fan motor in the backplane unit is abnormal. (Action) Check the fan motor and its cables. Replace them if necessary.
Fan motor

Fig.3.5 (9) SRVO--014 WARN Fan motor abnormal

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(10) SRVO--015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j) (Explanation) The temperature in the control unit exceeds the specified value. (Action 1) If the ambient temperature is higher than specified (45C), cool down ambient temperature. (Action 2) If the fan motor is not running, check it and its cables. Replace them if necessary. (Action 3) If the thermostat on the main board is defective, replace the main board.
External air Fan unit

Door fan Floor fan unit Main board

Fig.3.5 (10) SRVO--015 SVAL1 SYSTEM OVER HEAT

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(11) SRVO--018 SVAL1 Brake abnormal (Explanation) An excessive brake current is detected. The ALM LED on the servo amplifier is lit. (Action 1) Check the robot connection cable (RM1) and cables internal to the mechanical section for a short--circuit and connection to the ground. (Action 2) This alarm may occur if the brake connector is not attached. Make sure that connector CRR64 is securely attached to the servo amplifier. (Action 3) Replace the servo amplifier.
Servo amplifier

Fig.3.5 (11) SRVO--018 SVAL1 Brake abnormal

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(12) SRVO--021 SVAL1 SRDY off (Group : i Axis : j) (Explanation) The HRDY is on and the SRDY is off, although there is no other cause of an alarm. (HRDY is a signal with which the host detects the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on.) If the servo amplifier magnetic contactor cannot be turned on when directed so, it is most likely that a servo amplifier alarm has occurred. If a servo amplifier alarm has been detected, the host will not issue this alarm (SRDY off). Therefore, this alarm indicates that the magnetic contactor cannot be turned on for an unknown reason. (Action 1) Make sure that the CP2 and CRM73 of the E--stop unit and the servo amplifier CNMC2 and CNMC3 are connected tightly. (Action 2) Check whether an outage has occurred on an emergency stop line (teach pendant emergency stop, teach pendant enable/disable switch, teach pendant deadman switch, operator panel emergency stop, external emergency stop input, fence input, servo--off input, or door switch). This alarm occurs if the alarm cause cannot be detected by software because of a short break and magnetic contactor off. (Action 3) Replace the servo amplifier. (Action 4) Replace the E--stop unit. (Action 5) Replace the cable between the E--stop unit and the panel board. (Action 6) Replace the cable between the E--stop unit and the servo amplifier. (Action 7) Replace axis control card on the main board.

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Servo amplifier

Main board Axis control card

E--stop unit

Main board

Fig.3.5 (12) SRVO--021 SVAL1 SRDY off

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(13) SRVO--022 SVAL1 SRDY on (Group : i Axis : j) (Explanation) When the HRDY is about to go on, the SRDY is already on. (HRDY is a signal with which the host directs the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on. (Action 1) Replace the axis control card on the main board. (Action 2) Replace the servo amplifier.
Servo amplifier

Main board Axis control card

E--stop unit

Main board

Fig.3.5 (13) SRVO--022 SVAL1 SRDY on

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(14) SRVO--023 SVAL1 Stop error excess (Group : i Axis : j) (Explanation) When the servo is at stop, the position error is abnormally large. (Action 1) Check whether the motor brake has been released. (Action 2) Make sure that the servo amplifier CNJ1A to CNJ6 are connected tightly. (Action 3) Check to see if the load is greater than the rating. If greater, reduce it to within the rating. (If the load is too greater, the torque required for acceleration / deceleration becomes higher than the capacity of the motor. As a result, the motor becomes unable to follow the command, and an alarm is issued.) (Action 4) Check each phase voltage of the CRR38A or CRR38B connector of the three--phase power (200 VAC) input to the servo amplifier. If it is 170 VAC or lower, check the line voltage. (If the voltage input to the servo amplifier becomes low, the torque output also becomes low. As a result the motor may become unable to follow the command, hence possibly an alarm.) (Action 5) If the line voltage is 170 VAC or higher, replace the servo amplifier. (Action 6) Check disconnection of motor power cable (RM1, RM2). (Action 7) Replace the motor.
Servo amplifier

Main board

E--stop unit

Fig.3.5 (14) SRVO--023 SVAL1 Stop error excess

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(15) SRVO--024 SVAL1 Move error excess (Group : i Axis : j) (Explanation) When the robot is running, its position error is greater than a specified value ($PARAM _ GROUP. $MOVER _ OFFST or $PARAM _ GROUP. $TRKERRLIM). It is likely that the robot cannot follow the speed specified by program. (Action 1) Check the robot for binding axis. (Action 2) Take the same actions as described for the above alarm. (16) SRVO--025 SVAL1 Motn dt overflow (Group : i Axis : j) (Explanation) The specified value is too great. (17) SRVO--026 WARN2 Motor speed limit (Group : i Axis : j) (Explanation) A value higher than the maximum motor speed ($PARAM_GROUP.$MOT_SPD_LIM) was specified. The actual motor speed is clamped to the maximum speed. (18) SRVO--027 WARN Robot not mastered (Group : i) (Explanation) An attempt was made to calibrate the robot, but the necessary adjustment had not been completed. (Action) Master the robot. (19) SRVO--030 SVAL1 Brake on hold (Group : i) (Explanation) This alarm occurs when the robot pauses, if the brake on hold function has been enabled ($SCR. $BRKHOLD _ ENB = 1). Disable the function if it is not necessary. (Action) Disable [Servo--off during pause] on the general setting menu (Select Setting general). (20) SRVO--031 SVAL1 User servo alarm (Group : i) (Explanation) An user servo alarm occurred. (21) SRVO--033 WARN Robot not calibrated (Group : i) (Explanation) An attempt was made to set up a reference point for simplified adjustment, but the robot had not been calibrated. (Action) Calibrate the robot. 1.Supply power. 2.Set up a simplified adjustment reference point using [Positioning] on the positioning menu. (22) SRVO--034 WARN Ref pos not set (Group : i) (Explanation) An attempt was made to perform simplified adjustment, but the reference point had not been set up. (Action) Set up a simplified adjustment reference point on the positioning menu. (23) SRVO--035 WARN2 Joint speed limit (Group : i Axis : j) (Explanation) A value higher than the maximum axis speed ($PARAM_GROUP.$JNTVELLIM) was specified. Each actual axis speed is clamped to the maximum speed. (24) SRVO--036 SVAL1 Inpos time over (Group : i Axis : j) (Explanation) The robot did not get to the effective area ($PARAM _ GROUP.$ STOPTOL) even after the position check monitoring time ($PARAM _ GROUP. $INPOS _ TIME) elapsed. (Action) Take the same actions as for SRVO--23 (large position error at a stop). (25) SRVO--037 SVAL1 Imstp input (Group : i) (Explanation) The *IMSTP signal for a peripheral device interface was input. (Action) Turn on the *IMSTP signal.
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(26) SRVO--038 SVAL2 Pulse mismatch (Group : i Axis : j) (Explanation) The pulse count obtained when power is turned off does not match the pulse count obtained when power is applied. This alarm is asserted after exchange the pulsecoder or battery for back up of the pulsecoder data or loading back up data to the Main Board. (Action) Perform APC reset and remaster robot (RES--PCA) 1. Press MENUS. 2. Select SYSTEM. 3. Press F1 [TYPE]. 4. Select MASTER/CAL. 5. Press F3, PES--PCA. 6. Press RESET. The fault condition should reset. If the controller is still faulted with additional servo--related errors, cold start the controller. It might be necessary to remaster the robot. (27) SRVO--041 SVAL2 MOFAL alarm (Group : i Axis : j) (Explanation) The servo value was too high. (Action) Cold start the controller. (28) SRVO--042 MCAL alarm (Group : i Axis : j) (Explanation) This alarm means that the contacts of the magnetic contactor have stuck to each other. The alarm condition occurs if the magnetic contactor turns out to be already on when an attempt is made to turn it on. The alarm condition is detected between the time contact sticking occurs and the time an attempt is made to turn on the magnetic contactor. (Action 1) Check the magnetic contactor, and replace it if necessary. If the contacts of the magnetic contactor have stuck to each other, turn off the circuit breaker. If the power is switched off without turning off the circuit breaker, the servo amplifier may get damaged, because the stuck contacts keep three--phase 200 V applied to the servo amplifier. (Action 2) Replace the E--stop unit. (Action 3) Replace the servo amplifier.

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Servo amplifier

Main board

E--stop unit

Fig.3.5 (28) SRVO--042 MCAL alarm

(29) SRVO--043 SVAL1 DCAL alarm (Group : i Axis : j) (Explanation) The regenerative discharge energy was too high to be dissipated as heat. (To run the robot, the servo amplifier supplies energy to the robot. When going down the vertical axis, the robot operates from the potential energy. If a reduction in the potential energy is higher than the energy needed for acceleration, the servo amplifier receives energy from the motor. A similar phenomenon occurs even when no gravity is applied, for example, at deceleration on a horizontal axis. The energy that the servo amplifier receives from the motor is called the regenerative energy. The servo amplifier dissipates this energy as heat. If the regenerative energy is higher than the energy dissipated as heat, the difference is stored in the servo amplifier, causing an alarm.) (Action 1) This alarm may occur if the axis is subjected to frequent acceleration/deceleration or if the axis is vertical and generates a large amount of regenerative energy. If this alarm has occurred, relax the service conditions. (Action 2) Check fuse FS3 in the servo amplifier. If it has blown, remove the cause, and replace the fuse. One of the probable causes of a blown fuse is a ground fault in the servo amplifier for auxiliary axis. (Action 3) Make sure that the servo amplifier CRR63A, CRR63B and CRR63C are connected tightly, then detach the cable from CRR63A, CRR63B and CRR63C connector on the emergency stop board, and check for continuity between pins 1 and 2 of the cable--end connector. If there is no continuity between the pins, replace the regenerative resistance.

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(Action 4)

(Action 5)

Make sure that the servo amplifier CRR45A, CRR45B and CRR45C are connected tightly then detach the cables from CRR45A, CRR45B and CRR45C on the servo amplifier and check the resistance between pins 1 and 2 of each cable end connector. If the resistance is not 9--16, replace the regenerative resistor. Replace the servo amplifier.

Servo amplifier

Regenerative resistor

Fig.3.5 (29) SRVO--043 SVAL1 DCAL alarm

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(30) SRVO--044 SVAL1 HVAL alarm (Group : i Axis : j) (Explanation) The DC voltage (DC link voltage) of the main circuit power supply is abnormally high. (Action 1) Check the three--phase input voltage at the servo amplifier. If it is 253 VAC or higher, check the line voltage. (If the three--phase input voltage is higher than 253 VAC, high acceleration/deceleration can result in this alarm.) (Action 2) Check that the load weight is within the rating. If it is higher than the rating, reduce it to within the rating. (If the machine load is higher than the rating, the accumulation of regenerative energy might result in the HVAL alarm even when the three--phase input voltage is within the rating. (Action 3) Replace the servo amplifier.
Servo amplifier

Fig.3.5 (30) SRVO--044 SVAL1 HVAL alarm

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(31) SRVO--045 SVAL1 HCAL alarm (Group : i Axis : j) (Explanation) Abnormally high current flowed in the main circuit of the servo amplifier. (Action 1) Disconnect the Robot connection cable (Motor power) from the servo amplifier. (Action 2) Disconnect the Robot connection cable (Motor power) from the servo amplifier connector (CNJ**), and check the insulation of each Robot connection cable (Motor power) (U, V, or W) and the GND line. If there is a short--circuit, the motor, robot interconnection cable, or intra--robot cable is defective. Check them and replace them if necessary. (Action 3) Disconnect the Robot connection cable (Motor power) from the servo amplifier connector (CNJ**), and measure the resistance between the U and V, V and W, and W and U with a ohmmeter with a very low resistance range. If the resistances at these three places are different from each other, the motor, robot interconnection cable, or intra--robot cable is defective. Check each item in detail and replace it if necessary.
Servo amplifier

Fig.3.5 (31) SRVO--045 SVAL1 HCAL alarm

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(32) SRVO--046 SVAL2 OVC alarm (Group : i Axis : j) (Explanation) This alarm is issued to prevent the motor from thermal damage that might occur when the root meant square current calculated within the servo system is out of the allowable range. (Action 1) Check the operating conditions for the robot and relax the service conditions. (Action 2) Check each phase voltage of the three--phase input power (200 VAC for the servo amplifier. If it is 170 VAC or lower, check the line voltage. (Action 3) Replace the servo amplifier. (Action 4) Check the robot connection cable (RM1, RM2). If any problems are found in the cables, replace the cables. (Action 5) Replace the motor.
Servo amplifier

Fig.3.5 (32) SRVO--046 SVAL2 OVC alarm

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Reference

Relationships among the OVC, OVL, and HC alarms Overview This section points out the differences among the OVC, OVL, and HC alarms and describes the purpose of each alarm. Alarm detection section
Abbreviation Designation Overcurrent alarm Overload alarm Detection section Servo software Thermal relay in the motor OHAL2 Thermal relay in the servo amplifier OHAL1 Thermal relay in the separate regenerative discharge unit DCAL Servo amplifier

OVC OVL

HC

High current alarm

Purpose of each alarm 1) HC alarm (high current alarm) If high current flow in a power transistor momentarily due to abnormality or noise in the control circuit, the power transistor and rectifier diodes might be damaged, or the magnet of the motor might be degaussed. The HC alarm is intended to prevent such failures. 2) OVC and OVL alarms (overcurrent and overload alarms) The OVC and OVL alarms are intended to prevent overheat that may lead to the burnout of the motor winding, the breakdown of the servo amplifier transistor, and the separate regenerative resistor. The OVL alarm occurs when each built--in thermal relay detects a temperature higher than the rated value. However, this method is not necessarily perfect to prevent these failures. For example, if the motor frequently repeats to start and stop, the thermal time constant of the motor, which has a large mass, becomes higher than the time constant of the thermal relay, because these two components are different in material, structure, and dimension. Therefore, if the motor repeats to start and stop within a short time as shown in Fig. 1, the temperature rise in the motor is steeper than that in the thermal relay, thus causing the motor to burn before the thermal relay detects an abnormally high temperature.
Temperature Start Stop Start Stop Start Thermal time constant of the motor is high. Thermal time constant of the thermal relay is low.

Temperature at which the winding starts to burn

Time

Fig.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles

To prevent the above defects, software is used to monitor the current in the motor constantly in order to estimate the temperature of the motor. The OVC alarm is issued based on this estimated temperature. This method estimates the motor temperature with substantial accuracy, so it can prevent the failures described above.
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To sum up, a double protection method is used; the OVC alarm is used for protection from a short--time overcurrent, and the OVL alarm is used for protection from long--term overload. The relationship between the OVC and OVL alarms is shown in Fig 2.
Current Protection area for the motor and servo amplifier Protection by the OVL Limit current

Protection by the OVC

Rated continuous current Time

Fig.2 Relationship between the OVC and OVL alarms

NOTE The relationship shown in Fig. 2 is taken into consideration for the OVC alarm. The motor might not be hot even if the OVC alarm has occurred. In this case, do not change the parameters to relax protection. (33) SRVO--047 SVAL1 LVAL alarm (Group : i Axis : j) (Explanation) The control power supply voltage (+5 V, etc.) supplied from the power supply circuit in the servo amplifier is abnormally low. (Action 1) Replace the servo amplifier.
Servo amplifier

Fig.3.5 (33) SRVO--047 SVAL1 LVAL alarm

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(34) SRVO--049 SVAL1 OHAL1 alarm (Group : i Axis : j) (Explanation) The thermostat in the transformer worked. Alternatively, fuse F1 or F2 in the servo amplifier has blown. (Action 1) Make sure that the CRM73 connector of the E--stop unit is connected tightly. (Action 2) Check the operating conditions for the robot and relax the service conditions. (Action 3) If fuses F1 and F2 have blown, replace the servo amplifier.(See II MAINTENANCE, Section 3.6.) (Action 4) If the fan motor is not running, check it and its cables. Replace them if necessary. (Action 5) Replace the transformer.

Servo amplifier

Transformer

E--stop unit

Fig.3.5 (34) SRVO--049 SVAL1 OHAL1 alarm

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(35) SRVO--050 SVAL1 CLALM alarm (Group : i Axis : j) (Explanation) The disturbance torque estimated by the servo software is abnormally high. (A collision has been detected.) (Action 1) Check that the robot has collided with anything. If it has, reset the robot and jog--feed it to recover from the collision. (Action 2) Make sure that the load setting is correct. (Action 3) Check that the load weight is within the rating. If it is higher than the rating, reduce it to within the rating. (If the robot is used out of its usable range, the estimated disturbance torque becomes abnormally high, possibly resulting in this alarm being detected.) (Action 4) Check the phase voltage of the three--phase input power (200 VAC) to the servo amplifier. If it is 170 VAC or lower, check the line voltage. (Action 5) Replace the servo amplifier.
Servo amplifier

Fig.3.5 (35) SRVO--050 SVAL1 CLALM alarm

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(36) SRVO--051 SVAL2 CUER alarm (Group : i Axis : j) (Explanation) The offset of the current feedback value is abnormally high. (Action) Replace the servo amplifier.
Servo amplifier

Fig.3.5 (36) SRVO--051 SVAL2 CUER alarm

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(37) SRVO--054 DSM Memory Error (Explanation) An access to the servo module memory fails. (Action) Replace the axis control card on the main board.
Servo amplifier

Main board Axis control card

E--stop unit

Main board

Fig.3.5 (37) SRVO--054 DSM Memory Error

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(38) SRVO--055 SVAL2 FSSB com error 1 (Group : i Axis : j) (Explanation) A communication error has occurred between the main board and servo amplifier. (from main board to servo amplifier.) (Action 1) Check the communication cable (optical fiber) between the main board and servo amplifier. Replace it if it is faulty. (Action 2) Replace the axis control card on the main board. (Action 3) Replace the servo amplifier. Before continuing to the next step, perform a complete controller back--up to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data. (Action 4) Replace the main board.
Servo amplifier

Main board Axis control card

E--stop unit

Main board

Fig.3.5 (38) SRVO--055 SVAL2 FSSB com error 1

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(39) SRVO--056 SVAL2 FSSB com error 2 (Group : i Axis : j) (Explanation) A communication error has occurred between the main board and servo amplifier. (from servo amplifier to main board.) (Action 1) Check the communication cable (optical fiber) between the main board and servo amplifier. Replace it if it is faulty. (Action 2) Replace the axis control card on the main board. (Action 3) Replace the servo amplifier. Before continuing to the next step, perform a complete controller back--up to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data. (Action 4) Replace the main board.
Servo amplifier

Main board Axis control card

E--stop unit

Main board

Fig.3.5 (39) SRVO--056 SVAL2 FSSB com error 2

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(40) SRVO--057 SVAL2 FSSB disconnect (Group : i Axis : j) (Explanation) Communication was interrupted between the main board and servo amplifier. (Action 1) Check whether fuse F3 in the power supply unit has blown. (Action 2) Check whether fuse FS1 in the servo amplifier has blown. (Action 3) Check the communication cable (optical fiber) between the main board and servo amplifier. Replace it if it is faulty. (Action 4) Replace the axis control card on the main board. (Action 5) Replace the servo amplifier. Before continuing to the next step, perform a complete controller back--up to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data. (Action 6) Replace the main board. (Action 7) Check the RP1 cable of robot connection cable. (+5V ground fault)
Servo amplifier

Main board Axis control card

E--stop unit

Main board

Fig.3.5 (40) SRVO--057 SVAL2 FSSB disconnect

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(41) SRVO--058 SVAL2 FSSB init error (Group : i Axis : j) (Explanation) Communication was interrupted between the main board and servo amplifier. (Action 1) Check whether fuse F3 in the power supply unit and fuse FS1 in the servo amplifier have blown. If they have blown, see Section 3.6, Troubleshooting for Blown Fuse. (Action 2) Check whether LEDs (P5V and P3.3V) on the servo amplifier are on. If they are on, perform Action 4 and all actions that follow it. If they are not on, perform Action 3 and all actions that follow it. (Action 3) Check whether connectors CP6 and CRM67 on the emergency stop unit are securely connected to connector CP6 on the power supply unit and connector CRM67 on the servo amplifier, respectively. (Action 4) Check the communication cable (optical fiber) between the main board and servo amplifier. Replace it if it is faulty. (Action 5) Replace the axis control card on the main board. (Action 6) Replace the servo amplifier. Before continuing to the next step, perform a complete controller back--up to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data. (Action 7) Replace the main board.
Servo amplifier

Main board Axis control card

E--stop unit

Main board

Fig.3.5 (41) SRVO--058 SVAL2 FSSB init error

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(42) SRVO--059 SVAL2 Servo amp init error (Explanation) Servo amplifier initiazation is failed. (Action 1) Check the wiring of the servo amplifier. (Action 2) Replace the servo amplifier.
Servo amplifier

Fig.3.5 (42) SRVO--059 SVAL2 Servo amp init error

(43) SRVO--60 FATL FSSB init error (Explanation) Communication between the additional axis board and additional axis amplifier was interrupted. (Action 1) Check whether the optical cable between the additional axis board and additional axis amplifier is connected securely. (Action 2) Replace the additional axis board. (Action 3) Replace the additional axis amplifier. (Action 4) Replace the main board. (Action 5) Replace the backplane. (44) SRVO--061 SVAL2 CKAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal count clock). (Action) Replace the pulse coder. NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm. (45) SRVO--062 SVAL2 BZAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if battery for pulse coder absolute-position backup is empty. A probable cause is a broken battery cable or no batteries in the robot. (Action) Check the battery and battery cable, and replace the new battery. Then set the system variable $MCR.$SPC_RESET to TRUE, then supply power again. After this, mastering is required or follow SRVO--038 RECOVERY PROCEDURE.
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(46) SRVO--063 SVAL2 RCAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal counter). (Action) Replace the pulse coder. NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm. (47) SRVO--064 SVAL2 PHAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the phase of the pulses generated in the pulse coder is abnormal. (Action) Replace the pulse coder. NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm. (48) SRVO--065 WARN BLAL alarm (Group : i Axis : j) (Explanation) The battery voltage for the pulse coder is lower than the rating. (Action) Replace the battery. (If this alarm occurs, turn on the AC power and replace the battery as soon as possible. A delay in battery replacement may result in the BZAL alarm being detected. In this case, the position data will be lost. Once the position data is lost, mastering will become necessary. (49) SRVO--066 SVAL2 CSAL alarm (Group : i Axis : j) (Explanation) The ROM in the pulse coder is abnormal. (Action) Replace the pulse coder. NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm. (50) SRVO--067 SVAL2 OHAL2 alarm (Group : i Axis : j) (Explanation) The temperature inside the pulse coder or motor is abnormally high, and the built--in thermostat has operated. (Action 1) Check the operating conditions for the robot and relax the service conditions. (Action 2) When power is supplied to the motor after it has become sufficiently cool, if the alarm still occurs, replace the motor. (51) SRVO--068 SVAL2 DTERR alarm (Group : i Axis : j) (Explanation) The serial pulse coder does not return serial data in response to a request signal. --See actions on SRVO--070 (52) SRVO--069 SVAL2 CRCERR alarm (Group : i Axis : j) (Explanation) The serial data has disturbed during communication. --See actions on SRVO--070
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(53) SRVO--070 SVAL2 STBERR alarm (Group : i Axis : j) (Explanation) The start and stop bits of the serial data are abnormal. (Action 1) Make sure that the CRF7 connector of servo amplifire is connected tightly. (Action 2) Check that the shielding of the robot interconnection cable (for the pulse coder) and the peripheral equipment cable is connected securely to the grounding plate. (Action 3) Check that each unit is grounded securely. (Action 4) Replace the servo amplifier. (Action 5) Replace the pulse coder. (Action 6) Replace the robot interconnection cable (for the pulse coder).
Servo amplifier

Fig.3.5 (53) SRVO--070 SVAL2 STBERR alarm

(54) SRVO--071 SVAL2 SPHAL alarm (Group : i Axis : j) (Explanation) The feedback speed is abnormally high. (Action 1) If this alarm occurs together with the PHAL alarm (No. 064), this alarm does not correspond to the major cause of the failure. (Action 2) Replace the pulse coder. (55) SRVO--072 SVAL2 PMAL alarm (Group : i Axis : j) (Explanation) It is likely that the pulse coder is abnormal. (Action) Replace the pulse coder and remaster the robot. (56) SRVO--073 SVAL2 CMAL alarm (Group : i Axis : j) (Explanation) It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. (Action) Master the robot and enhance the shielding. (57) SRVO--074 SVAL2 LDAL alarm (Group : i Axis : j) (Explanation) The LED in the pulse coder is broken. (Action) Replace the pulse coder, and remaster the robot. (58) SRVO--075 WARN Pulse not established (Group : i Axis : j) (Explanation) The absolute position of the pulse coder cannot be established. (Action) Reset the alarm, and jog the axis on which the alarm has occurred until the same alarm will not occur again. (Jog one motor revolution)
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(59) SRVO--076 SVAL1 Tip Stick Detection (Group : i Axis : j) (Explanation) An excessive disturbance was assumed in servo software at the start of operation. (An abnormal load was detected. The cause may be welding.) (Action 1) Check whether the robot comes into collision with foreign matter. If a collision occurs, reset the system, then switch it to the jog feed mode to avoid the collision. (Action 2) Check whether the load settings are valid. (Action 3) Check whether the load weight is within the rated range. If the weight exceeds the upper limit, decrease it to the limit. (Use of the robot with a load exceeding the limit applied may abnormally increase the assumed disturbance, resulting in this alarm.) (Action 4) Check each inter--phase voltage of the three--phase input (200 VAC) to the servo amplifier. If the voltage is 170 VAC or lower, check the input power supply voltage. (Action 5) Replace the servo amplifier.

Servo amplifier

Fig.3.5 (60) SRVO--076 SVAL1 Tip Stick Detection

(60) SRVO--081 WARN EROFL alarm (Track enc : i) (Explanation) The pulse counter for line tracking has overflowed. (61) SRVO--082 WARN DAL alarm (Track ebc : i) (Explanation) The line tracking pulse coder has not been connected. (Action 1) Check the pulse coder connection cable, and replace it if necessary. (Action 2) Replace the pulse coder. (62) SRVO--083 WARN CKAL alarm (Track ebc : i) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal count clock). (Action) See the description about the SRVO--061 CKAL alarm.
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(63) SRVO--084 WARN BZAL alarm (Track enc : i) (Explanation) This alarm occurs if the backup battery for the absolute position of the pulse coder has not been connected. See the description about the BZAL alarm (SRVO--062). (64) SRVO--085 WARN RCAL alarm (Track ebc : i) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal counter). (Action) See the description about the SRVO--063 RCAL alarm. (65) SRVO--086 WARN PHAL alarm (Track enc : i) (Explanation) This alarm occurs if the phase of pulses generated in the pulse coder is abnormal. See the description about the PHAL alarm (SRVO--064). (66) SRVO--087 WARN BLAL alarm (Track enc : i) (Explanation) This alarm occurs if the voltage of the backup battery for the absolute position of the pulse coder is low. See the description about the BLAL alarm (SRVO--065). (67) SRVO--088 WARN CSAL alarm (Track ebc : i) (Explanation) The ROM in the pulse coder is abnormal. (Action) See the description about the SRVO--066 CSAL alarm. (68) SRVO--089 WARN OHAL2 alarm (Track enc : i) (Explanation) The motor has overheated. See the description about the OHAL2 alarm (SRVO--067). (69) SRVO--090 WARN DTERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the DTERR alarm (SRVO--068). (70) SRVO--091 WARN CRCERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the CRCERR alarm (SRVO--069). (71) SRVO--092 WARN STBERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the STBERR alarm (SRVO--070). (72) SRVO--093 WARN SPMAL alarm (Track enc : i) (Explanation) This alarm occurs if the current position data from the pulse coder is higher than the previous position data. See the description about the SPHAL alarm (SRVO--071). (73) SRVO--094 WARN PMAL alarm (Track enc : i) (Explanation) It is likely that the pulse coder is abnormal. See the description about the PMAL alarm (SRVO--072). (74) SRVO--095 WARN CMAL alarm (Track enc : i) (Explanation) It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. See the description about the CMAL alarm (SRVO--073). (75) SRVO--096 WARN LDAL alarm (Track enc : i) (Explanation) The LED in the pulse coder is broken. See the description about the LDAL alarm (SRVO--074).
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(76) SRVO--097 WARN Palse not established (enc : i) (Explanation) The absolute position of the pulse coder cannot be established. See the description about (SRVO--075). Pulse not established. (77) SRVO--105 SVAL1 Door open or E--stop (Explanation) The cabinet door is open. (Action 1) When the door is open, close it. If no door switch is mounted, go to [Action 3]. (Action 2) Check the door switch and door switch connection cable. If the switch or cable is faulty, replace it. (Action 3) Check that the CRM70, CRM71, and CRM72 connectors on the E--STOP unit are connected securely. (Action 4) This alarm is also issued if software cannot determine the cause of disconnection of the emergency stop line. Reference the total connection diagram in Appendix and check whether the emergency stop line is normal. (Action 5) Replace the servo amplifier.

Servo amplifier

Electro magnetic contactor

E--stop unit

Fig.3.5 (79) SRVO--105 SVAL1 Door open or E--stop

(78) SRVO--136 SVAL1 DCLVAL alarm (Group : i Axis : j) (Explanation) The servo the DC current of amplifier (DC link voltage) of the main power supply is abnormally low. --This alarm occured in the robot operation. (Action 1) Check the phase voltage of the three--phase input power (200 VAC) to the servo amplifier. If it is 170 VAC or lower, check the line voltage. (Action 2) Replace the servo amplifier. --If this alarm occurs before the magnetic contactor is turned on: (Action 1) Check whether the circuit breaker in the emergency stop unit is OFF. If it is OFF, check the servo amplifier and the wiring between the servo amplifier and the emergency stop unit. If anything is abnormal, replace it.
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(Action 2)

(Action 3) (Action 4)

Check each phase--to--phase voltage of the three--phase input (200 VAC) on the primary side of the magnetic contactor. If the input is not higher than 170 VAC, check the input power supply voltage. Replace the E--stop unit. Replace the servo amplifier.
Servo amplifier

Main board

E--stop unit

Fig.3.5 (78) SRVO--136 SVAL1 DCLVAL alarm

(79) SRVO--138 SDAL alarm(Group : i Axis : j) (Explanation) The feedback data from pulse coder was abnormal by noise on the pulse coder. Or the inter polation circuit of the pulse coder is broken. (Action) If the alarm disappeared by power OFF/ON, please make sure the cable shields are grounded. (Action) If this problem occurs repeatedly, replase the pulse coder and master the robot. (80) SRVO--153 SVAL1 CHGAL(CNV) alarm (Group : i Axis : j) (Explanation) The main circuit could not be charged within the specified time. (Action 1) A short circuit may occur in the DC link. Check the connection. (Action 2) The charging current control resistor may be faulty. Replace the E--STOP unit. (Action 3) Replace the servo amplifier.

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Servo amplifier Panel board

E--stop unit

Fig.3.5 (80) SRVO--153 SVAL1 CHGAL(CNV) alarm

(81) SRVO--156 SVAL1 IPMAL alarm (Group : i Axis : j) (Explanation) Abnormally high current flowed through the main circuit of the servo amplifier. (Action 1) Detach the motor power lines from the respective terminals on the servo amplifier, and switch on the power, then check to see if the alarm occurs again. If the alarm occurs, replace the servo amplifier. (Action 2) Detach the motor power lines from the respective terminals on the servo amplifier, and check for isolation between each motor power line (U, V, or W) and a ground potential (GND). If a motor power line is short--circuited to a ground, the motor, robot connection cable, or robot internal cable is likely to be defective. Check each of them, and replace it if necessary. (Action 3) Detach the motor power lines from the respective terminals on the servo amplifier, and check the resistance between each motor power line pair (U and V, V and W, or W and U) using a meter that is capable of measuring a very low resistance. If the measured three resistances are different, the motor, robot connection cable, or robot internal cable is likely be defective. Check each of them, and replace it if necessary.

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Servo amplifier

Fig.3.5 (81) SRVO--156 SVAL1 IPMAL alarm

(82) SRVO--157 SVAL1 CHGAL alarm (Group : i Axis : j) (Explanation) The capacitor for the DC link voltage of the servo amplifier was not charged within the specified time. (Action 1) A short circuit may occur in the DC link voltage. Check the connection. (Action 2) The charging current control resistor may be faulty. Replace the E--STOP unit. (Action 3) Replace the servo amplifier.

Servo amplifier Panel board

E--stop unit

Fig.3.5 (82) SRVO--157 SVAL1 CHGAL alarm

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(83) SRVO--194 Servo disconnect (Explanation) On the terminal block TBOP3 of the panel board, no connection is made between 5 (SD4) and 6 (SD41) or between 7 (SD5) and 8 (SD51). If a servo disconnect switch is connected between 5 (SD4) and 6 (SD41) or between 7 (SD5) and 8 (SD51), the switch is pressed. If the SYST--067 (Panel HSSB disconnect) alarm is also generated, or if the LED (green) on the panel board is turned off, communication between the main board (JRS11) and the panel board (JRS11) is abnormal. The connectors of the cable between the main board and the panel board may be loose. Or, the cable, panel board, or main board may be faulty. (Note) (Action 1) (Action 2) (Action 3) (Action 4) If a servo disconnect switch is connected, releases the switch. Check the switch and cable connected to 5 (SD4) and 6 (SD41) or 7 (SD5) and 8 (SD51). When this signal is not used, make a connection between 5 (SD4) and 6 (SD41) or between 7 (SD5) and 8 (SD51). Replace the PC board.

NOTE If the LED is turned off, the following alarms are also generated. SRVO--001 Operator panel E--stop. SRVO--004 Fence open. SRVO--007 External emergency stop. SRVO--199 Control stop. SRVO--204 External (SVEMG abnormal) E--stop. SRVO--213 Fuse blown (Panel PCB). SRVO--277 Panel E--stop (SVEMG abnormal). SRVO--280 SVOFF input Check the alarm history display on the teach pendant.

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Short connection 5 (SD4) and 6 (SD41) Panel board

LED (Green)

Connector (JRS11)

Short connection 7 (SD5) and 8 (SD51)

Panel board
Fig.3.5 (83) (a) SRVO--194 Servo disconnect

Connector (JRS11)

Main board
Fig.3.5 (83) (b) SRVO--194 Servo disconnect

(84) SRVO--199 Control Stop (Explanation) This alarm is displayed together with a Fence open alarm or SVOFF input alarm.

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(85) SRVO--201 SVAL1 Panel E--stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator panel was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Check the EMERGENCY STOP button on the operator panel, and replace it if necessary. (Action 2) Replace the panel board. (Action 3) Replace the servo amplifier. NOTE This alarm might occur if the EMERGENCY STOP button is pressed slowly.

Servo amplifier

Emergency stop button Panel board

Fig.3.5 (85) SRVO--201 SVAL1 Panel E--stop or SVEMG abnormal

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(86) SRVO--202 SVAL1 TP E--stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator panel was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Check the teach pendant connection cable, and replace it if necessary. (Action 2) Replace the teach pendant. (Action 3) Replace the panel board. (Action 4) Replace the servo amplifier. NOTE This alarm might occur if the EMERGENCY STOP button is pressed slowly.

Servo amplifier

Emergency stop button Panel board

Fig.3.5 (86) SRVO--202 SVAL1 TP E--stop or SVEMG abnormal

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(87) SRVO--204 SVAL1 External (SVEMG abnormal) E--stop (Explanation) The switch connected across EES1 and EES11, EES2 and EES21 on the TBOP4 terminal board on the panel board was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Replace the panel board. (Action 2) Replace the servo amplifier.
Servo amplifier

Emergency stop button Panel board

Fig.3.5 (87) SRVO--204 SVAL1 External (SVEMG abnormal) E--stop

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(88) SRVO--205 SVAL1 Fence open (SVEMG abnormal) (Explanation) The switch connected across EAS1 and EAS11, EAS2 and EAS21 on the TBOP4 terminal board on the panel board was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Replace the panel board. (Action 2) Replace the servo amplifier.
Servo amplifier

Emergency stop button Panel board

Fig.3.5 (88) SRVO--205 SVAL1 Fence open (SVEMG abnormal)

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(89) SRVO--206 SVAL1 Deadman switch (SVEMG abnormal) (Explanation) The DEADMAN switch was released when the teach pendant was operable, but the EMERGENCY STOP line was not disconnected. (Action 1) Check the teach pendant connection cable. Replace it if necessary. (Action 2) Replace the teach pendant. (Action 3) Replace the panel board. (Action 4) Replace the servo amplifier.
Servo amplifier

Emergency stop button Panel board

Fig.3.5 (89) SRVO--206 SVAL1 Deadman switch (SVEMG abnormal)

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(90) SRVO--207 SVAL1 TP switch abnormal or door open (Explanation) The teach pendant is operable, and the deadman switch has been grasped, but the EMERGENCY STOP line is kept disconnected. (Action 1) Check the teach pendant connection cable, and replace it if necessary. (Action 2) Replace the teach pendant. (Action 3) Replace the panel board. (Action 4) Replace the servo amplifier.
Servo amplifier

Emergency stop button Panel board

Fig.3.5 (90) SRVO--207 SVAL1 TP switch abnormal or door open

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(91) SRVO--213 WARN Fuse blown (Panel PCB) (Explanation) A fuse on the panel board has blown. (Action 1) Check whether fuse FUSE1 on the panel board is blown. When the fuse is blown, eliminate the cause, then replace the fuse. (See II MAINTENANCE, Section 3.6.) (Action 2) Replace the panel board.

Servo amplifier Panel board

E--stop unit

Fig.3.5 (91) SRVO--213 WARN Fuse blawon (Panel PCB)

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(92) SRVO--214 WARN Fuse blown (Panel PCB) (Explanation) A fuse in the servo amplifier has blown. (Action 1) Check whether fuse F1, F2, FS2, or FS3 in the servo amplifier is blown. When a fuse is blown, eliminate the cause, then replace the fuse. (See II MAINTENANCE, Section 3.6.) (Action 2) Replace the servo amplifier.

Servo amplifier Panel board

E--stop unit

Fig.3.5 (92) SRVO--214 WARN Fuse blown (Panel PCB)

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(93) SRVO--215 WARN Fuse blown (Aux axis) (Explanation) The fuse in the additional axis amplifier has blown. (Action 1) Check the cause and solve the problem, then replace the fuse. (94) SRVO--216 SVAL1 OVC (total) (Robot : i) (Explanation) The current (total current for six axes) flowing through the motor is too large. (Action 1) Slow the motion of the robot where possible. Check the robot operation conditions. If the robot is used with a condition exceeding the duty or load weight robot rating, reduce the load condition value to the specification range. (Action 2) Check each inter--phase voltage of the three--phase input (200 VAC) to the servo amplifier. If the voltage is 170 VAC or lower, check the input power supply voltage. (95) SRVO--221 SVAL1 Lack of DSP (Group : i Axis : j) (Explanation) A controlled axis card corresponding to the set number of axes is not mounted. (Action 1) Check whether the set number of axes is valid. If the number is invalid, set the correct number. (Action 2) Replace the controlled axis card with a card corresponding to the set number of axes. (Example) When six axes are set, a controlled axis card for six or eight axes is available. For how to replace the controlled axis card, see II MAINTENANCE, Section 7.2 in this manual. (96) SRVO--222 SVAL1 Lack of Amp (Amp : i) (Explanation) The FSSB has no SVM. (Action 1) Check that the optical cable is securely connected to the SVM. (Action 2) Replace the optical cable. (Action 3) Check whether power is properly supplied to the SVM. Check that there is no problem with each SVM input voltage. (Action 4) Replace the SVM. (97) SRVO--230 SVAL1 Chain 1 (+24V) abnormal SRVO--231 SVAL1 Chain 2 (0V) abnormal (Explanation) Single chain 1 (+24V)/chain 2 (0V) failure occured on emergency stop of operator panel or emergency stop of teach pendant or deadman switch or fence switch or external emergency stop or servo ON/OFF switch or NTED input or door switch. Please check history of alarm by Alarm Log. Single chain failure is ; One of emergency stop chain is emergency stop condition, and another chain is not emergency stop condition. Cause of this alarm is ; -- Weld of contact -- Wire broken or shorted -- Half release of deadman switch -- Half operation of emergency stop of operator panel and emergency stop of teach pendant
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-- Irregular input from external emergency stop and etc. (Out of specified timing.) The single chain failure occurred on the emergency stop switch of the operator panel, emergency stop switch of the teach pendant and the deadman switch. This failure can be recovered by performing the correct stop operation. The detecting circuit for the single chain failure is reset by either entering another stop cause, or turning the power on again. Hold the alarm state for the duration that the alarm history is being checked. CAUTION 1 This alarm is controlled by the software and requires a special reset procedure. After resolving the cause of the alarm, please issue the special reset procedure according to end of Explanations and Actions shown below. 2 The RESET operation is inhibited until the special reset procedure is performed. The message of SRVO--237 Cannot reset chain failure is displayed, if the RESET operation is issued before the special reset procedure is performed. 3 If a successful operator panel emergency stop, or teach pendant emergency stop, or when the deadman switch is released after this alarm, the message of SRVO--236 Chain failure is repaired is displayed. Single chain 1 (+24V) failure is ; (Example of external emergency stop)

Single chain 2 (0V) failure is ; (Example of external emergency stop)

[Displaying the Alarm Log] Please refer to Setup and Operations Manual. 1. Press MENUS on the teach pendant. 2. Press 4 on the teach pendant. [4 ALARM]. 3. Press F1, [TYPE]. 4. Select Alarm Log.
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(Example)

(98) SRVO--230 SVAL1 Chain 1 (+24V) abnormal with SRVO--001 Operator panel E--stop SRVO--231 SVAL1 Chain 2 (0V) abnormal with SRVO--001 Operator panel E--stop (Action 1) Re--operate emergency stop of operator panel. If this alarm is reset, the message of SRVO--236 Chain failure is repaired is displayed. (Action 2) Replace the panel board. (Action 3) Replace the operator panel. (Action 4) Replace the E--stop unit. (Action 5) Replace the servo amplifier.
Servo amplifier Panel board Mode switch Operator panel Teach pendant

E--stop unit

Fig.3.5 (98) SRVO--230 SVAL1 Chain 1 (+24V) abnormal

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(99) SRVO--230 SVAL1 Chain 1 (+24V) abnormal with SRVO--002 Teach pendant E--stop SRVO--231 SVAL1 Chain 2 (0V) abnormal with SRVO--002 Teach pendant E--stop (Action 1) Re--operate emergency stop of teach pendant. If this alarm is reset, the message of SRVO--236 Chain failure is repaired is displayed. (Action 2) Check the teach pendant connection cable and replace it if necessary. (Action 3) Replace the panel board. (Action 4) Replace the operator panel. (Action 5) Replace the E--stop unit. (Action 6) Replace the servo amplifier.
Servo amplifier Panel board Mode switch Operator panel Teach pendant

E--stop unit

Fig.3.5 (99) SRVO--230 SVAL1 Chain 1 (+24V) abnormal

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(100) SRVO--230 SVAL1 Chain 1 (+24V) abnormal with SRVO--003 Deadman switch released SRVO--231 SVAL1 Chain 2 (0V) abnormal with SRVO--003 Deadman switch released (Action 1) Re--operate deadman switch. If this alarm is reset. the message of SRVO--236 Chain failure is repaired is displayed. (Action 2) Check the teach pendant connection cable and replace it if necessary. (Action 3) Replace the panel board. (Action 4) Replace the teach pendant. (Action 5) Replace the E--stop unit. (Action 6) Replace the servo amplifier. (Action 7) Replace the mode switch.
Servo amplifier Panel board Mode switch Operator panel Teach pendant

E--stop unit

Fig.3.5 (100) SRVO--230 SVAL1 Chain 1 (+24V) abnormal

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(101) SRVO--240 Chain1 (FENCE) abnormal with SRVO--230 SVAL1 Chain 1 (+24V) abnormal and SRVO--004 Fence open SRVO--241 Chain2 (FENCE) abnormal with SRVO--231 SVAL1 Chain 2 (0V) abnormal and SRVO--004 Fence open (Action 1) Check the +24V connection of safety fence (EAS1 -EAS11), or the 0V connection of safety fence (EAS2 -- EAS21) (Action 2) Replace the panel board. (Action 3) Replace the E--stop unit. (Action 4) Replace the servo amplifier. (Action 5) Replace the mode switch.
Servo amplifier Panel board Mode switch Operator panel Teach pendant

E--stop unit

Fig.3.5 (101) SRVO--240 Chain1 (FENCE) abnormal

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(102) SRVO--242 Chain1 (EXEMG) abnormal with SRVO--230 SVAL1 Chain 1 (+24V) abnormal and SRVO--007 External emergency stops SRVO--243 Chain2 (EXEMG) abnormal with SRVO--231 SVAL1 Chain 2 (0V) abnormal and SRVO--007 External emergency stops (Action 1) Check the +24V connection of external emergency stop (EES1 -- EES11), or the 0V connection of external emergency stop (EES2 -- EES21). (Action 2) Replace the panel board. (Action 3) Replace the E--stop unit. (Action 4) Replace the servo amplifier.
Servo amplifier Panel board Mode switch Operator panel Teach pendant

E--stop unit

Fig.3.5 (102) SRVO--242 Chain1 (EXEMG) abnormal

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(103) SRVO--230 SVAL1 Chain 1 (+24V) abnormal with SRVO--232 SVAL1 NTED input SRVO--231 SVAL1 Chain 2 (0V) abnormal with SRVO--232 SVAL1 NTED input (Action 1) Check the +24V connection of NTED input (NTED1 -- NTED11), or the 0V connection of NTED input (NTED2 -- NTED21). (Action 2) Replace the panel board. (Action 3) Replace the E--stop unit. (Action 4) Replace the servo amplifier. (Action 5) Replace the mode switch.
Servo amplifier Panel board Mode switch Operator panel Teach pendant

E--stop unit

Fig.3.5 (103) SRVO--230 SVAL1 Chain 1 (+24V) abnormal

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(104) SRVO--230 SVAL1 Chain 1 (+24V) abnormal with SRVO--233 SVAL1 TP disabled in T1, T2/Door open SRVO--231 SVAL1 Chain 2 (0V) abnormal with SRVO--233 SVAL1 TP disabled in T1, T2/Door open (Action 1) Check the teach pendant connection cable and replace it if necessary. (Action 2) Replace the panel board. (Action 3) Replace the teach pendant. (Action 4) Replace the E--stop unit. (Action 5) Replace the servo amplifier. (Action 6) Replace the mode switch.
Servo amplifier Panel board Mode switch Operator panel Teach pendant

E--stop unit

Fig.3.5 (104) SRVO--230 SVAL1 Chain 1 (+24V) abnormal

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[Special reset operation] CAUTION Do not issue this operation before resolving the cause of the alarm. 1. 2. 3. 4. 5. 6. 7. 8. Press E--stop button for correct emergency stop condition. Press MENU on the teach pendant. Press 0 on the teach pendant, [0 ---- NEXT ----]. Press 6 on the teach pendant, [6 SYSTEM]. Press F1, [TYPE]. Select Config. Search item 28. Press F4, [TRUE]. The display of 28 Reset CHAIN FAILURE detection : changes TRUE from FALSE. And few seconds later the display changes FALSE from TRUE again. 9. The RESET operation is allowed.

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(105) SRVO--232 SVAL1 NTED input (Explanation) Non teacher enabling device is released. (Action 1) Check the connection of non teacher enabling device. (Action 2) Replace the panel board. (Action 3) Replace the mode switch.
Servo amplifier Panel board Mode switch Operator panel Teach pendant

E--stop unit

Fig.3.5 (105) SRVO--232 SVAL1 NTED input

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(106) SRVO--233 SVAL1 TP disabled in T1, T2/Door open (Explanation) Teach pendant is disabled when the mode switch is T1 or T2. Or controller door is opened. (Action 1) Close the controller door, if open. (Action 2) Check the door switch, and replace it if necessary. (Action 3) Replace the panel board. (Action 4) Replace the teach pendant. (Action 5) Replace the mode switch.
Servo amplifier Panel board Mode switch Operator panel Teach pendant

E--stop unit

Fig.3.5 (106) SRVO--233 SVAL1 TP disabled in T1, T2/Door open

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(107) SRVO--235 Short term Chain abnormal (Explanation) Short term single chain failure condition is detected. Short term single chain failure is ; If any cause of stop is issued for a short time, detecting circuit for single chain failure detects as single chain failure depending on hardware specification. In this case, cause of stop is not detected by software, so this alarm is distinguished from SRVO--230 and SRVO--231. Cause of this alarm is ; -- Half release of deadman switch -- Half operation of emergency stop of operator panel and emergency stop of teach pendant Short term single chain failures occured on emergency stop of operator panel, emergency stop of teach pendant and deadman switch are recoverable issuing correct stop operation. (Action 1) To reset detecting circuit for single chain failure, re--operate emergency stop of operator panel or emergency stop of teach pendant or deadman switch according previous operation. If this alarm is reset, the message of SRVO--236 Chain failure is repaired is displayed. CAUTION This alarm is an un--clear single chain failure condition. The software waits for a correct operation response to reset the single chain failure condition. If another cause is issued, then the software detects the real single chain failure and displays Chain 1 (+24V) abnormal or Chain 2 (0V) abnormal. NOTE 1 This alarm may occur when an operator panel emergency stop, teach pendant emergency stop or when the deadman switch is released. The above are operated by the operator. This alarm is provided for un--clear and fast--repeated operation by the operator. 2 If correct action is issued after this alarm, the messege of SRVO--236 Chain failure is repaired is displayed. (108) SRVO--236 SVAL1 Chain failure is repaired (Explanation) A chain failure was repaired. For details, see the explanation of SRVO--230 and SRVO--231. (109) SRVO--237 SVAL1 Not reset chain failure (Explanation) A chain failure could not be repaired. See the explanation of SRVO--230 and SRVO--231. (Action 1) Check the alarm history and see the explanation of the displayed alarm.

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(110) SRVO--240 SVAL1 Chain 1 (FENCE) abnormal (111) SRVO--241 SVAL1 Chain 2 (FENCE) abnormal (Explanation) Although the circuit connected between EAS11 and EAS1 or between EAS21 and EAS2 on the TBOP4 terminal block on the panel board was disconnected, the emergency stop line was not disconnected. The emergency stop circuit is faulty. (Action 1) Check the +24 V connection (between EAS11 and EAS1) and 0 V connection (between EAS21 and EAS2) for the fence. (Action 2) Replace the panel board. (Action 3) Replace the E--STOP unit. (Action 4) Replace the servo amplifier. NOTE Eliminate the cause of the abnormal chain, then execute special reset operation to release the alarm.

Servo amplifier Panel board

E--stop unit

Fig.3.5 (111) SRVO--241 SVAL1 Chain 2 (FENCE) abnormal

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(112) SRVO--242 SVAL1 Chain 1 (EXEMG) abnormal SRVO--243 SVAL1 Chain 2 (EXEMG) abnormal (Explanation) Although the external emergency stop circuit was disconnected, the emergency stop line was not disconnected. The emergency stop circuit is faulty. (Action 1) Check the +24 V connection (between EES11 and EES1) and 0 V connection (between EES21 and EES2) for the external emergency stop circuit. (Action 2) Replace the panel board. (Action 3) Replace the E--STOP unit. (Action 4) Replace the servo amplifier. NOTE Eliminate the cause of the abnormal chain, then execute special reset operation to release the alarm.

Servo amplifier Panel board

E--stop unit

Fig.3.5 (112) SRVO--242 SVAL1 Chain 1 (EXEMG) abnormal SRVO--243 SVAL1 Chain 2 (EXEMG) abnormal

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(113) SRVO--260 SVAL1 Chain 1 (NTED) abnormal SRVO--261 SVAL1 Chain 2 (NTED) abnormal (Explanation) Although the non--teacher--enabling device disconnected the NTED circuit in the T1/T2 mode, the emergency stop line was not disconnected. The emergency stop circuit is faulty. (Action 1) Check the +24 V connection (between NTED11 and NTED1) and 0 V connection (between NTED21 and NTED2) for the NTED circuit. (Action 2) Replace the panel board. (Action 3) Replace the E--STOP unit. (Action 4) Replace the servo amplifier.

Servo amplifier Panel board

E--stop unit

Fig.3.5 (113) SRVO--260 SVAL1 Chain 1 (NTED) abnormal SRVO--261 SVAL1 Chain 2 (NTED) abnormal

(114) SRVO--262 SVAL1 Chain 1 (SVDCT) abnormal SRVO--263 SVAL1 Chain 2 (SVDCT) abnormal (Explanation) Although the SVDCT circuit was disconnected, the emergency stop line was not disconnected. The emergency stop circuit is faulty. (Action 1) Check the +24 V connection (between SD41 and SD1) and 0 V connection (between SD51 and SD5) for the SVDCT circuit. (Action 2) Replace the panel board. (Action 3) Replace the E--STOP unit. (Action 4) Replace the servo amplifier.

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Servo amplifier Panel board

E--stop unit

Fig.3.5 (114) SRVO--262 SVAL1 Chain 1 (SVDCT) abnormal SRVO--263 SVAL1 Chain 2 (SVDCT) abnormal

(115) SRVO--264 SVAL1 E.STOP circuit abnormal 1 (Explanation) An error occurred in the emergency stop circuit. (Action 1) Check whether the CRM67 and CRM72 connectors on the E--STOP unit are connected securely. (Action 2) Check whether the circuits connected to CRM67 and CRM72 in the emergency stop circuit are normal. (Action 3) Replace the E--STOP unit. (Action 4) Replace the servo amplifier.

Servo amplifier

E--stop unit

Fig.3.5 (115) SRVO--264 SVAL1 E.STOP circuit abnormal 1

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(116) SRVO--265 SVAL1 E.STOP circuit abnormal 2 (Explanation) When the servo entered the activated state, MON3 was in the on state. The MON3 state is abnormal. (Action 1) Replace the E--STOP unit. (Action 2) Replace the servo amplifier. (Action 3) Replace the panel board.

Servo amplifier Panel board

E--stop unit

Fig.3.5 (116) SRVO--265 SVAL1 E.STOP circuit abnormal 2

(117) SRVO--280 SVAL1 SVOFF input (Explanation) On the terminal block TBOP4 of the panel board, no connection is made between 9 (EGS1) and 10 (EGS11) or between 11 (EGS2) and 12 (EGS21). If a switch is connected between 9 (EGS1) and 10 (EGS11) or between 11 (EGS2) and 12 (EGS21), the switch is pressed. (Action 1) If a switch is connected, releases the switch. If the SYST--067 (Panel HSSB disconnect) alarm is also generated, or if the LED (green) on the panel board is turned off, communication between the main board (JRS11) and the panel board (JRS11) is abnormal. The connectors of the cable between the main board and the panel board may be loose. Or, the cable, panel board, or main board may be faulty. (Note) (Action 2) Check the switch and cable connected to 9 (EGS1) and 10 (EGS11) or 11 (EGS2) and 12 (EGS21). (Action 3) When this signal is not used, make a connection between 9 (EGS1) and 10 (EGS11) or between 11 (EGS2) and 12 (EGS21). (Action 4) If SRVO--004 (Fence open), SRVO--007 (External emergency stops), SRVO--213 (Fuse blown (Panel PCB)), and SRVO--280 (SVOFF input) occur simultaneously, it is likely that FUSE1 on the panel board has blown. Check the fuse. If it has blown, remove the cause, then replace the fuse. (Refer to Section 3.6 in Part II, Maintenance, of Maintenance Manual.)
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(Action 5) (Action 6)

Replace the panel board. Before performing Action 6, make a backup copy of all programs and settings in the control unit. Replace the main board.

NOTE SVOFF input (GENERAL STOP) is a safety stop input. When this input is opened, the robot decelerates in a controlled manner and then stops. The magnetic contactor opens after the robot stops.

WARNING Do NOT short--circuit, or disable, this signal in a system in which the Servo off emergency stop signal input is in use, as it is very dangerous. If it is necessary to run the robot by short--circuiting the signal even temporarily, an additional safety provision must be provided. NOTE If the LED is turned off, the SRVO--001 (Operator panel E--stop), SRVO--004 (Fence open), SRVO--007 (External emergency stops), or SRVO--280 (SVOFF input), alarm is also generated. Check the alarm history display on the teach pendant. NOTE If the LED is turned off, the following alarms are also generated. SRVO--001 Operator panel E--stop. SRVO--004 Fence open. SRVO--007 External emergency stop. SRVO--199 Control stop. SRVO--204 External (SVEMG abnormal) E--stop. SRVO--213 Fuse blown (Panel PCB). SRVO--277 Panel E--stop (SVEMG abnormal). SRVO--280 SVOFF input Check the alarm history display on the teach pendant.

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Short connection 9 (EGS1) and 10 (EGS11)

Short connection 11 (EGS2) and 12 (EGS21)

LED (Green)

Connector (JRS11)

Panel board
Fig.3.5 (117) (a) SRVO--280 SVAL1 SVON input

Connector (JRS11)

Main board
Fig.3.5 (117) (b) SRVO--280 SVAL1 SVON input

(118) SRVO--266 SVAL1 FENCE1 status abnormal SRVO--267 SVAL1 FENCE2 status abnormal (Explanation) The fence circuit is abnormal. (Action 1) Check the +24 V connection (between EAS11 and EAS1) and 0 V connection (between EAS21 and EAS2) for the fence. (Action 2) Check the fence switch. (Action 3) Replace the panel board. NOTE Eliminate the cause of the abnormal chain, then execute special reset operation to release the alarm.

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(119) SRVO--268 SVAL1 SVOFF1 status abnormal SRVO--269 SVAL1 SVOFF2 status abnormal (Explanation) The SVOFF circuit is abnormal. (Action 1) Check the +24 V connection (between EGS11 and EGS1) and 0 V connection (between EGS21 and EGS2) for the SVOFF circuit. (Action 2) Check the SVOFF switch. (Action 3) Replace the panel board. NOTE Eliminate the cause of the abnormal chain, then execute special reset operation to release the alarm.

(120) SRVO--270 SVAL1 EXEMG1 status abnormal SRVO--271 SVAL1 EXEMG2 status abnormal (Explanation) The EXEMG circuit is abnormal. (Action 1) Check the +24 V connection (between ESPB11 and ESPB1) and 0 V connection (between ESPB21 and ESPB2) for the EXEMG circuit. (Action 2) Check the EXEMG switch. (Action 3) Replace the panel board. NOTE Eliminate the cause of the abnormal chain, then execute special reset operation to release the alarm.

(121) SRVO--272 SVAL1 SVDISC1 status abnormal SRVO--273 SVAL1 SVDISC2 status abnormal (Explanation) The SVDISC circuit is abnormal. (Action 1) Check the +24 V connection (between SD41 and SD4) and 0 V connection (between SD51 and SD5) for the SVDISC circuit. (Action 2) Check the SVDISC switch. (Action 3) Replace the panel board. NOTE Eliminate the cause of the abnormal chain, then execute special reset operation to release the alarm.

(122) SRVO--274 SVAL1 NTED1 status abnormal SRVO--275 SVAL1 NTED2 status abnormal (Explanation) The NTED circuit is abnormal. (Action 1) Check the +24 V connection (between NTED11 and NTED1) and 0 V connection (between NTED21 and NTED2) for the NTED circuit. (Action 2) Check the NTED switch. (Action 3) Replace the panel board. NOTE Eliminate the cause of the abnormal chain, then execute special reset operation to release the alarm.

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(123) SRVO--281 SVAL1 SVOFF input (SVEMG abnormal) (Explanation) When the SVOFF signal was input, an SVEMG error was detected. The emergency stop circuit is faulty. (Action 1) Replace the panel board. (Action 2) Replace the servo amplifier. (Action 3) Replace the E--STOP unit.

Servo amplifier Panel board

E--stop unit

Fig.3.5 (123) SRVO--281 SVAL1 SVOFF input (SVEMG abnormal)

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(124) SRVO--282 SVAL1 Chain1 (SVOFF) abnormal SRVO--283 SVAL1 Chain2 (SVOFF) abnormal (Explanation) Although the switch connected between EGS11 and EGS1 or between EGS21 and EGS2 on the TBOP4 terminal block on the panel board was pressed, the emergency stop line was not disconnected. The emergency stop circuit is faulty. (Action 1) Replace the panel board. (Action 2) Replace the servo amplifier. (Action 3) Replace the E--STOP unit.

Servo amplifier Panel board

E--stop unit

Fig.3.5 (124) SRVO--282 SVAL1 Chain1 (SVOFF) abnormal SRVO--283 SVAL1 Chain2 (SVOFF) abnormal

(125) SRVO--282 Chain1 (SVOFF) abnormal with SRVO--230 SVAL1 Chain 1 (+24V) abnormal and SRVO--280 SVOFF input SRVO--283 Chain2 (SVOFF) abnormal with SRVO--231 SVAL1 Chain 2 (0V) abnormal and SRVO--280 SVOFF input (Action 1) Check the +24V connection of servo ON/OFF switch (EGS1 -- EGS11), or the 0V connection of servo ON/OFF switch (EGS2 -- EGS21). (Action 2) Replace the panel board. (Action 3) Replace the E--stop unit. (Action 4) Replace the servo amplifier.

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Servo amplifier Panel board Mode switch Operator panel

Teach pendant

E--stop unit

Fig.3.5 (125) SRVO--282 Chain1 (SVOFF) abnormal

(126) SRVO--291 SVAL1 IPM over heat (Group : i Axis : j) (Explanation) The IPM in the servo amplifier overheats. (Action 1) Check whether the amplifier fan stops. (Action 2) Reduce the override because the use condition is too hard. (Action 3) If this alarm is frequently issued, replace the amplifier. (127) SRVO--292 SVAL1 EXT FAN alarm (Group : i A : j) (Explanation) The external fan for the SVMi is faulty. (Action 1) Replace the external fan for the SVM. (128) SRVO--293 SVAL1 DClink (PSM) HCAL (Group : i Axis : j) (Explanation) The three--phase input power supply is abnormal or the PSM is faulty. (Action 1) Check the three--phase input power supply. (Action 2) Replace the PSM. (129) SRVO--294 SVAL1 EXT FAN (PSM) alarm (Group : i Axis : j) (Explanation) The external fan for the PSM and PSMR is faulty. (Action 1) Replace the external fan. (130) SRVO--295 SVAL1 PSM COM alarm (Group : i Axis : j) (Explanation) The cable between the PSM and SVM may be faulty or the PSM or SVM may be faulty. (Action 1) Replace the cable between the PSM and SVM. (Action 2) Replace the PSM. (Action 3) Replace the SVM. (131) SRVO--296 SVAL1 PSM DISCHG alarm (Group : i Axis : j) (Explanation) The use condition is too hard or the fan for cooling the regenerative resistance for the PSMR stops. (Action 1) Reduce the taught feedrate because the use condition is too hard. (Action 2) Check whether the fan for cooling the regenerative resistance for the PSMR stops.
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(132) SRVO--297 SVAL1 PSM Low Volt alarm (Group : i Axis : j) (Explanation) The three--phase input voltage may drop or the PSM or SVM may be faulty. (Action 1) Check the three--phase input power supply. (Action 2) Replace the PSM. (Action 3) Replace the SVM. (133) SRVO--300 SVAL1 Hand broken/HBK disabled SRVO--302 SVAL1 Set Hand broken to ENABLE (Explanation) Although HBK was disabled, the HBK signal was input. (Action 1) Press RESET on the teach pendant to release the alarm. (Action 2) Check whether the hand broken signal is connected to the robot. When the hand broken signal circuit is connected, enable hand broken. (See III CONNECTION, Subsection 5.5.3 in this manual.)

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3.6
FUSED--BASED TROUBLESHOOTING
Name F1

(1) When the fuses of the power supply unit have blown F1: Fuse for AC input F3: Fuse for +24 E F4: Fuse for +24 V
Action

Symptom observed when fuse has blown

The LED (PIL: Green) of the power supply unit does not light, and 1 Check the units (fans) and cables connected to the CP2 and the power cannot be turned on. CP3 connectors of the power supply unit to see if there is any short circuit. 2 Replace the power supply unit. If the fuse blows when the power supply is turned on, an alarm 1 Check the printed circuit boards, units, and cables using +24 such as for overtravel, hand broken, FSSB disconnect, LVAL is E according to the power supply system diagram. Replace a output on the teach pendant. faulty printed circuit board, unit, servo amplifier or cable if any. If the fuse turns out to have already blown when the power supply 2 Replace the power supply unit. is turned on, the FSSB initialization alarm is displayed on the teach pendant. The power, when turned on, is immediately turned off. At this 1 Check the printed circuit boards, units, and cables using +24 time, the LED (ALM: Red) lights. V according to the power supply system diagram. Replace a faulty printed circuit board, unit, or cable if any. The LED of ALM is turned off by pressing the OFF button once. 2 Replace the power supply unit.

F3

F4

Power supply unit

F1 8.0A Fuse for AC input

F3 7.5A Fuse for +24E F4 7.5A Fuse for +24V PIL LED (green) for AC power supply display ALM LED (red) for alarm display

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(2) Servo amplifier fuse FS1 : For generation of the power to the amplifier control circuit FS2 : For protection of the 24V output to the end effector, ROT, and HBK FS3 : For protection of the 24V output to the regenerative resistance and the additional axis amplifier F1, F2 : For protection of the circuit failure in the servo amplifier.
Name
FS1

Symptom observed when fuse has blown

All LEDs on the servo amplifier go out. The FSSB disconnection or initialization alarm is displayed on the teach pendant. The fuse blown (Amp) alarm (SRVO--214), hand broken (SRVO--006), and ROBOT OVER TRAVEL (SRVO--005) are displayed on the teach pendant. The blown fuse (Amp) alarm (SRVO--214) and DCAL (SRVO--043) are displayed on the teach pendant. Replace the servo amplifier.

Action

FS2

1 Check +24E used by the end effector for a ground fault. 2 Check the robot connection cable and the robots internal cable. 3 Replace the servo amplifier. 1 Check the regenerative resistance, and replace it if required. 2 Check the additional axis amplifier and its wiring, and replace them if required. 3 Replace the servo amplifier. 1 Check if the cables connected to three phase input of servo amplifier is defective. 2 Replace the servo amplifier.

FS3

F1 F2

The OHAL1 alarm is output on the teach pendant.

Servo amplifier

Fuse F1 Fuse F2

Fuse FS1 Fuse FS3 Fuse FS2

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(3) Panel board fuses FUSE1: For protection of the +24EXT line (emergency stop line) FUSE2: For protection of the teach pendant emergency stop line
Name
FUSE1

Symptom observed when fuse has blown

The external emergency stop, open fence, SVOFF input, and blown fuse (panel PCB) alarm are displayed on the teach pendant. The display on the teach pendant disappears.

Action
1 Check the +24EXT line (emergency stop line) for a short--circuit and ground fault. 2 Replace the panel board. 1 Check the teach pendant cable for a fault, and replace it if required. 2 Check the teach pendant for a fault, and replace it if required. 3 Replace the panel board.

FUSE2

Panel board

FUSE2

FUSE1

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(4) Fuse on the process I/O board FUSE1: Fuse for +24 E
Name
FUSE1

Symptom observed when fuse has blown

Action

The LED (ALM--2 or FALM) on the process I/O board lights, and 1 Check if the cables and peripheral equipment connected to an alarm such as IMSTP input is output on the teach pendant. the process I/O printed circuit board are normal. (The display data depends on state of peripheral equipment con- 2 Replace the process I/O printed circuit board. nection.)

Process I/O board CA,CB FUSE1

Process I/O board DA FUSE1

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Process I/O board HA FUSE1

Total version

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3.7
TROUBLESHOOTING BASED ON LED INDICATIONS

The printed circuit boards and servo amplifier are provided with alarm LEDs and status LEDs. The LED status and corresponding troubleshooting procedures are described below.

Servo amplifier

Main board Power supply unit

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3. TROUBLESHOOTING

(1) TROUBLESHOOTING USING THE LEDS ON THE MAIN BOARD To troubleshoot an alarm that arises before the teach pendant is ready to display, check the status LEDs (green) on the main board at power--on. After power--on, the LEDs light as described in steps 1 to 17, in the order described. If an alarm is detected, the step in which the alarm occurred can be determined from which LEDs are lit.
Step
1: After power--on, all LEDs are lit.

LED

Action to be taken
[Action1] Replace the CPU card * [Action2] Replace the main board.

2: Software operation start--up.

[Action1] Replace the CPU card * [Action2] Replace the main board.

3: The initialization of dram on the CPU card is completed.

[Action1] Replace the CPU card * [Action2] Replace the main board.

4: The initialization of SRAM and DPRAM is completed.

[Action1] Replace the CPU card * [Action2] Replace the main board. * [Action3] Replace the FROM/SRAM module. * [Action1] Replace the main board. * [Action2] Replace the FROM/SRAM module.

5: The initialization of the communication IC is completed.

6: The loading of the basic software is completed.

* [Action1] Replace the main board. * [Action2] Replace the FROM/SRAM module.

7: Basic software start--up.

* [Action1] Replace the main board. * [Action2] Replace the FROM/SRAM module.

8: Start--up of communication with the teach pendant.

* [Action1] Replace the main board. * [Action2] Replace the FROM/SRAM module.

9: The loading of optional software is completed.

* [Action1] Replace the main board. [Action2] Replace the process I/O board.

10:DI/DO initialization

* [Action1] Replace the FROM/SRAM module. * [Action2] Replace the main board.

11: The preparation of the SRAM module is completed.

[Action1] Replace the axis control card. * [Action2] Replace the main board. [Action3] Replace the servo amplifier.

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.
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Step
12:Axis control card initialization

LED

Action to be taken
[Action1] Replace the axis control card. * [Action2] Replace the main board. [Action3] Replace the servo amplifier.

13:Calibration is completed.

[Action1] Replace the axis control card. * [Action2] Replace the main board. [Action3] Replace the servo amplifier. * [Action1] Replace the main board.

14:Start--up of power application for the servo system

15:Program execution

* [Action1] Replace the main board. [Action2] Replace the process I/O board.

16:DI/DO output start--up.

* [Action1] Replace the main board.

17: Initialization is terminated.

Initialization has ended normally.

18:Normal status

Status LEDs 1 and 2 blink when the system is operating normally.

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.
Main board FROM/SRAM module CPU card

Axis control card

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(2) TROUBLESHOOTING BY 7--SEGMENT LED INDICATOR

7--segment LED indicator Description [Description] A parity alarm condition has occurred in RAM on the CPU card installed on the main board. [Action1] Replace the CPU card. [Action2] Replace the main board. [Description] A parity alarm condition has occurred in RAM on the FROM/SRAM module installed on the main board. [Action1] Replace the FROM/SRAM module. [Action2] Replace the main board. [Description] A bus error has occurred in the communication controller. [Action] Replace the main board.

[Description] A parity alarm condition has occurred in DRAM controlled by the communication controller. [Action] Replace the main board.

[Description] A communication error has occurred during communication with the panel board. [Action1] Check the communication cable (optical cable) between the main and panel boards, and replace it if necessary. [Action2] Replace the main board. [Action3] Replace the panel board. [Description] A servo alarm condition has occurred on the main board. [Action1] Replace the axis control card. [Action2] Replace the main board.

[Description] The SYSEMG alarm has occurred. [Action1] Replace the axis control card. [Action2] Replace the CPU card. [Action3] Replace the main board. [Description] The SYSFAIL alarm has occurred. [Action1] Replace the axis control card. [Action2] Replace the CPU card. [Action3] Replace the main board.

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.

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Troubleshooting by LEDs on power supply unit

LED indication Failure description and required measure [Description] When ALM LED (red) turned on, power supply alarm has occurred. [Action1] Check fuse F4 (+24V) on the power supply unit, and replace it if it has blown. [Action2] Check the printed--circuit boards powered by the DC power supplies (+5V, 15V, and +24V), the relevant units, and cables, and replace them if defective. [Action3] Replace the power supply unit.

[Description] If the PIL LED (Green) does not light, the power supply unit has not been supplied with 200 VAC. [Action1] Check fuse F1 on the power supply unit, and replace it if it has blown. For detailed causes of fuse blown out, please refer to section 3.1. [Action2] Replace the power supply unit.

Power supply unit

F1 8.0A Fuse for AC input

F3 7.5A Fuse for +24E

F4 7.5A Fuse for +24V PIL LED (green) for AC power supply display

ALM LED (red) for alarm display

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Troubleshooting by LED on the panel board

LED indication
RDY

Failure description and required measure [Description] When the LED (green) does not light. Communication with the main board does not execute. [Action1] Check the communication cable between the main and panel boards, and replace it if necessary. [Action2] Replace the main board. [Action3] Replace the panel board. [Description] When the LED does not light. The power supply inside the panel board does not generate +5 V normally. [Action1] Check the CRM63 connector and check that 24 V is supplied. [Action2] Replace the panel board.
PON LED (Green)

PON

Panel board

RDY LED (Green)

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Troubleshooting by alarm LEDs on the process I/O printed circuit board

LED
Process I/O CA/CB/DA/HA

Description and action to be taken [ [Description] A communication alarm occurred between the main CPU PC board and process p ] p I/O board. [Action1] Replace the process I/O board. * [Action2] Replace the main CPU board. [Action3] Replace the I/O link connection cable.

Process I/O CA/CB/DA/HA

[ [Description] A fuse on the process I/O board is blown. p ] p / [Action1] Replace the blown fuse on the process I/O board. [Action2] Examine the cables and peripheral devices connected to the process I/O board. Replace any failed components. [Action3] Replace the process I/O board.

Fuse

For process I/O board CA/CB/DA/HA Specificalion : A60L--0001--0046#2.0

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Troubleshooting by LEDs on servo amplifier

The servo amplifier has alarm LEDs. Troubleshoot the alarm indicated by the LEDs, referring also to the alarm indication on the teach pendant.

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LED
P5V

Color
Green

Description
Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally. If the LED does not light: [Measure 1] Check the robot connection cable (RP1) to see if there is a ground fault in the +5 v wire. [Measure 2] Replace the servo amplifier. Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V normally. If the LED does not light: [Measure] Replace the servo amplifier. Lights when an emergency stop signal is input to the servo amplifier. If the LED lights when the machine is not at an emergency stop: [Measure] Replace the servo amplifier. If the LED does light when the machine is at an emergency stop: [Measure] Replace the servo amplifier. Lights when the servo amplifier detects an alarm. If the LED lights when there is no alarm condition in the machine: [Measure] Replace the servo amplifier. If the LED does not light when there is an alarm condition in the machine: [Measure] Replace the servo amplifier. Lights when the servo amplifier is ready to drive the servo motor. If the LED does not light when the motor is activated: [Measure] Replace the servo amplifier. Lights when the communication between the servo amplifier and the main board is normal. If the LED does not light: [Measure 1] Check for the connection of the FSSB optical cable. [Measure 2] Replace the servo card. [Measure 3] Replace the servo amplifier. Lights when a watch dog alarm is detected in the servo amplifier. [Measure 1] Replace the servo amplifier. [Measure 2] Replace the servo card. [Measure 3] Replace the CPU card. [Measure 4] Replace the main board. Lights when the DCLINK circuit inside the servo amplifier is charged to reach the specified voltage. If the LED does not light after pre--charge is finished: [Measure 1] It is likely that the DC Link may be short--circuited. Check for connection. [Measure 2] It is likely that the charge current control resistor may be defective. Replace the emergency stop unit. [Measure 3] Replace the servo amplifier.

P3.3V

Green

SVEMG

Red

ALM

Red

RDY

Green

OPEN

Green

WD

Red

D7

Red

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3.8
POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING)

(Check 1) On the status screen, check the position deviation in the stopped state. To display the position deviation, press the screen selection key, and select STATUS from the menu. Press F1, [TYPE], select AXIS from the menu, then press the F4, PULSE. (Corrective action) Correct the parameters related to return to the reference position (positioning). (Check 2) Check whether the motor axis can be positioned normally. (Corrective action) If the motor axis can be positioned normally, check the mechanical unit. (Check 3) Check the mechanical unit for backlash. (Corrective action) Replace a faulty key of motor shaft or other faulty parts. (Check 4) If checks 1 to 3 show normal results (Corrective action) Replace the pulse coder and main board.

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3.9
VIBRATION OBSERVED DURING MOVEMENT

(Check 1) Check the settings of parameters such as the position loop gain parameter. (Corrective action) Correct parameters. (Check 2) Check the mechanical unit for backlash. (Corrective action) Replace a faulty key of motor shaft or other faulty parts.

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3.10
MANUAL OPERATION IMPOSSIBLE

The following explains checking and corrective action required if the robot cannot be operated manually after the controller is turned on: (1) Check and corrective action to be made if manual operation is impossible (Check 1) Check whether the teach pendant is enabled. (Corrective action) Turn on the teach pendant enable. (Check 2) Check whether the teach pendant is handled correctly. (Corrective action) To move an axis by manual operation, press the axis selection key and case shift key at the same time. Set the override for manual feed to a position other than the FINE and VFINE positions. (Check 3) Check whether the ENBL signal of the peripheral device control interface is set to 1. (Corrective action) Place the peripheral device control interface in the ENBL status. (Check 4) Check whether the HOLD signal of the peripheral device control interface or the HOLD switch on the operators panel is on (hold status). (Check whether the hold lamp on the teach pendant is on.) (Corrective action) Turn off the HOLD signal of the peripheral device control interface or the HOLD switch on the operators panel. (Check 5) Check whether the previous manual operation has been completed. (Corrective action) If the robot cannot be placed in the effective area because of the offset of the speed command voltage preventing the previous operation from being completed, check the position deviation on the status screen, and change the setting. (Check 6) Check whether the controller is in the alarm status. (Corrective action) Release the alarm. (2) Check and corrective action to be taken if the program cannot be executed (Check 1) Check whether the ENBL signal for the peripheral-device control interface is on. (Corrective action) Put the peripheral-device control interface in the ENBL state. (Check 2) Check whether the HOLD signal for the peripheral-device control interface is on. Also check whether the HOLD switch on the operators panel is on. (Check whether the HOLD lamp on the teach pendant is on.) (Corrective action) If the HOLD signal is on, turn it off. If the HOLD switch is on, turn it off.
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(Check 3) Check whether the previous manual operation has been completed. (Corrective action) If the robot cannot be placed in the effective area because of the offset of the speed command voltage, which prevents the previous operation from being completed, check the position deviation on the status screen, then change the setting. (Check 4) Check whether the controller is in the alarm status. (Corrective action) Release the alarm.

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4. PRINTED CIRCUIT BOARDS

PRINTED CIRCUIT BOARDS

The printed circuit boards are factory-set for operation. Usually, you do not need to set or adjust them. This chapter describes the standard settings and adjustment required if a defective printed circuit board is replaced. It also describes the test pins and the LED indications. The standard printed circuit board includes the main unit printed circuit board and one or more cards or modules installed horizontally to the main--unit printed--circuit board. These PC boards have interface connectors, LED indicators, and a plastic panel at the front. At the rear, there is a backplane connector.

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4.1
MAIN BOARD (A16B--3200--0412, --0413)
CPU card FROM/SRAM module Total version

Axis control card

TBDL exists in case of --0413

Fig.4.1 Main board Name

CPU card

Ordering Specification
A05B--2450--H010 A05B--2450--H011

Board Specification
A20B--3300--0104 A20B--3300--0105 A20B--3300--0240 A20B--3300--0241 A20B--3300--0242 A20B--3900--0160 A20B--3900--0161 A20B--3900--0162 A20B--3900--0163 A20B--3900--0164 A20B--3900--0165 A16B--3200--0412 A16B--3200--0413

Note
SDRAM 8M (Standard) SDRAM 16M 8--axis 6--axis (Standard) 4--axis FROM 16M, SRAM 1M FROM 16M, SRAM 2M FROM 16M, SRAM 3M FROM 32M, SRAM 1M FROM 32M, SRAM 2M FROM 32M, SRAM 3M Standard With distributed link (Option)

Axis control card

A05B--2450--H021 A05B--2450--H020 TBD

FROM/SRAM module

A05B--2450--H031 A05B--2450--H032 A05B--2450--H033 A05B--2450--H035 A05B--2450--H036 A05B--2450--H037

Main board

A05B--2450--H001 TBD

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(1) Test pins

Name GND1 GND2 GND3 CACHOFF LOAD MCBOOT CORE Use

For testing the printed circuit board

(2) LEDs
Seven segment LED Description A parity alarm occurred in a RAM of the main CPU card on the main board.

A parity alarm occurred in a RAM of the SRAM module on the main board.

Bus error occurred on the communication controller.

A parity alarm occurred in DRAM controlled by communication controller.

A communication error occurred between panel boards and main board.

A servo alarm occurred on the main board.

SYSEMG occurred.

SYSFAIL occurred.
This number appears temporarily after the power is switched on, but it is not abnormal.

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Status LED

Description

Operating status of the system.

STATUS LED

ETHERNET LED
TX RX L FDX COL BT BTX

Color
Green Green Yellow Green Red Green Green

Description
Flashes during data transmission. Flashes during data reception. Lights when a connection to a network is made. Lights during full duplex communication. Lights if a COLLISION occurs during half duplex communication. Lights during communication with 10BASE--T. Lights during communication with 100BASE--T.

(3) Driver/receiver IC If the teach pendant cannot display anything because of, for example, a broken wire in the teach pendant connection cable, it is likely that the communication driver or receiver may be defective.
Name 75172 75173 Drawing number A76L--0151--0098 A76L--0151--0099

Please refer to Fig.4.1 Main board.

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4. PRINTED CIRCUIT BOARDS

4.2
EMERGENCY STOP CONTROL PC BOARD (A20B--1007--0800)

LED 3 LED 2

LED 1

Total version

Fig.4.2 Emergency stop control PC board

(1) LED
Name LED1 Status of Relay KA1--1 ON Active OFF Inactive Status of KA2--1 ON Active OFF Inactive Status of KA3--1 ON Active OFF Inactive Use

LED2

LED3

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4.3
BACKPLANE PC BOARD
(A20B--2002--0771)

Total version

Fig.4.3 (a) Backplane PC Board

(1) Test pins

Name HI1 TEST1 LOW1 Use For testing the printed circuit board

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(A20B--2002--0761)

Total version

Test pins

Fig.4.3 (b) Backplane PC Board

(1) Test pins

Name
HI1 TEST1 LOW1

Use
For testing the printed circuit board

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4.4
PANEL BOARD (A20B--2100--0770)

PON LED

Total version

RDY LED

Fig.4.4 Panel Board

(1) LED
Name RDY PON Use Communication status with main board ON Normal OFF Communication error
Lights when the internal power supply of the panel board outputs +5V normally.

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4.5
PROCESS I/O BOARD CA (A16B--2201--0470)

Total version

Fig.4.8 Process I/O Board CA

(1) Test pins

Name P24V P5V P15VC M15VC GND1 GND2 P10V P15VF M15VF GNDF AI1 AI2 AI3 AI4 AI5 AI6 AOUT1 AOUT2 +24V +5V +15V --15V GND GND +10V +15V --15V GND Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 1 Channel 2 Use

For measuring the DC supply voltage

For measuring the reference voltage of the digital/analog converter Power for the digital/analog converter

For measuring the voltage of the analog input signal (analog/digital)

For measuring the voltage of the analog output signal (digital/analog)

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(2) Settings
Name ICOM1 UDI1 to UDI20 (Connector CRM2A) Side A Standard setting Description

UDI21 to UDI40 ICOM2 (Connector CRM2B) ICOM3 SP1 SP2 WDI01 to WDI08 (Connector CRW1) Channel 1

The common voltage is adjusted to: Side A : +24 V common Side B : 0 V common The polarity of the output voltage is switched to: Strapped : Negative (--) Open : Positive (+)

Open Channel 2

(3) Adjustment VR1: Adjusts the gain of channel 1. Execute a robot program and set AOUT[1] to 4095 on the teach pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 until the meter reads 12.0 V. Connect the negative (--) lead of the digital voltmeter to test pin GNDF. VR2: Adjusts the gain of channel 2. Execute a robot program and set AOUT[2] to 4095 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR2 until the meter reads 12.0 V. Connect the negative (--) lead of the digital voltmeter to test pin GNDF. (The 0VF test pin is different from the common 0V test pin.) VR3: Adjusts the reference supply voltage of the digital/analog converter. Connect the digital voltmeter to test pin P10V and rotate VR3 until the meter reads 10.0 0.1 V. (4) LEDs
Color Description

Red

A communication alarm occurred between the main CPU and process input/output.

Red

A fuse (FUSE 1) in the process input/output blew.

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(5) Correspondence between driver chips and DO signals Ordering code for the driver chips: A76L-0151-0062
Driver chip DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 DV11 DV12 RESERVED DO signal CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED SDO01, SDO02, SDO03, SDO04 SDO05, SDO06, SDO07, SDO08 SDO09, SDO10, SDO11, SDO12 SDO13, SDO14, SDO15, SDO16 SDO17, SDO18, SDO19, SDO20 WDO01, WDO02, WDO03, WDO04 WDO05, WDO06, WDO07, WDO08 For replacement

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4.6
PROCESS I/O BOARD CB (A16B--2201--0472)

Test pins

Total version

Fig.4.9 Process I/O Board CB

(1) Test pins

Name P24V P5V P15VC M15VC GND1 GND2 +24V +5V +15V --15V GND GND For measuring the DC supply voltage Use

(2) Settings
Name ICOM1 ICOM2 UDI1 to UDI20 (Connector CRM2A) UDI21 to UDI40 (Connector CRM2B) Side A Standard setting Description The common voltage is adjusted to: Side A : +24 V common Side B : 0 V common

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(3) LEDs
Color Description

Red

A communication alarm occurred between the main CPU and process input/output.

Red

A fuse (FUSE 1) in the process input/output blew.

(4) Correspondence between driver chips and DO signals Ordering code for the driver chips: A76L-0151-0062
Driver chip DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 RESERVED DO signal CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED SDO01, SDO02, SDO03, SDO04 SDO05, SDO06, SDO07, SDO08 SDO09, SDO10, SDO11, SDO12 SDO13, SDO14, SDO15, SDO16 SDO17, SDO18, SDO19, SDO20 For replacement

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4.7
PROCESS I/O BOARD DA (A16B--2201--0480)

Total version Test pins

Fig.4.10 Process I/O Board DA

(1) Test pins

Name P24V P5V GND1 GND2 +24V +5V GND GND For measuring the DC supply voltage Description

(2) Settings
Name ICOM1 ICOM2 ICOM3 ICOM4 ICOM5 ICOM6 UDI01 to 20 (Connector CRM2A) UDI21 to 40 (Connector CRM2B) UDI41 to 60 (Connector CRM2C) UDI61 to 80 (Connector CRM2D) UDI81 to 88 (Connector CRM4A) UDI89 to 96 (Connector CRM4B) The common voltage is adjusted to: Side A : +24 V common Side B : 0 V common Standard setting Description

Side A

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(3) LEDs
Color Description

Red

A communication alarm occurred between the main CPU and process input/output.

Red

A fuse (FUSE 1) in the process input/output below.

(4) Correspondence between driver chips and DO signals Ordering code for the driver chips: A76L-0151-0062
Driver chip DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 DV11 DV12 DV13 DV14 DV15 DV16 DV17 DV18 DV19 DV20 DV21 DV22 DV23 DV24 RESERVED DO signal CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED SDO01, SDO02, SDO03, SDO04 SDO05, SDO06, SDO07, SDO08 SDO09, SDO10, SDO11, SDO12 SDO13, SDO14, SDO15, SDO16 SDO17, SDO18, SDO19, SDO20 ADO21, SDO22, SDO23, SDO24 SDO25, SDO26, SDO27, SDO28 SDO29, SDO30, SDO31, SDO32 SDO33, SDO34, SDO35, SDO36 SDO37, SDO38, SDO39, SDO40 SDO41, SDO42, SDO43, SDO44 SDO45, SDO46, SDO47, SDO48 SDO49, SDO50, SDO51, SDO52 SDO53, SDO54, SDO55, SDO56 SDO57, SDO58, SDO59, SDO60 SDO61, SDO62, SDO63, SDO64 SDO65, SDO66, SDO67, SDO68 SDO69, SDO70, SDO71, SDO72 SDO73, SDO74, SDO75, SDO76 For replacement

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4.8
PROCESS I/O BOARD HA (A16B--2203--0760)

Total version

Fig.4.11 Process I/O Board HA

(1) Test pins

Name P24V P5V GND1 GND2 GND3 P24VF P5VF GNDF AO1 AO2 +24V +5V GND GND GND +24V +5V GND Channel 1 Channel 2 Use

For measuring the DC supply voltage

Power for the digital/analog converter For measuring the voltage of the analog output signal (digital/analog)

(2) Settings
Name ICOM1 UDI1 to UDI20 (Connector CRM2A) Side A Standard setting Description

UDI21 to UDI40 ICOM2 (Connector CRM2B) ICOM3 WDI01 to WDI08 (Connector CRW7)

The common voltage is adjusted to: Side A : +24 V common Side Sid B : 0 V common

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(3) Adjustment VR1/VR2: Adjusts the gain and the offset of channel 1. Execute a robot program and set AOUT[1] to 3413 on the teach pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 or VR2 until the meter reads 15.0 V. Connect the negative (--) lead of the digital voltmeter to test pin GNDF. VR3/VR4: Adjusts the gain and the offset of channel 2. Execute a robot program and set AOUT[2] to 3413 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR3 or VR4 until the meter reads 15.0 V. Connect the negative (--) lead of the digital voltmeter to test pin GNDF. (The 0VF test pin is different from the common 0V test pin.) (4) LEDs
Color Description

ALMO

Red

A communication alarm occurred between the main CPU and process I/O board.

FALM

ALMO

Red

A fuse (FUSE 1) in the process I/O board blew.

FALM

(5) Correspondence between driver chips and DO signals Ordering code for the driver chips: A76L-0151-0062
Driver chip DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 DO signal CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED SDO01, SDO02, SDO03, SDO04 SDO05, SDO06, SDO07, SDO08 SDO09, SDO10, SDO11, SDO12 SDO13, SDO14, SDO15, SDO16 SDO17, SDO18, SDO19, SDO20

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4.9
PANEL SWITCH BOARD (A20B--1007--0850)
Total version

Fig.4.12 Panel Switch Board

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5. SERVO AMPLIFIERS

SERVO AMPLIFIERS

The servo amplifiers are factory-set for operation. Usually, you do not need to set or adjust them. This chapter describes the standard settings and adjustment required if a defective servo amplifier is replaced. It also describes the use of test pins and meanings of the LED indications.
Table 5 Servo amplifier specifications Robot models R--2000iA M--6iB ARC Mate 100iB Servo amplifier A06B--6105--H002 A06B--6105--H003 Regenerative resistor unit A05B--2452--C200 (B--cabinet) A05B--2452--C201 ( (B--cabinet) )

Check that the voltage is not higher than 50 V.

NOTE Before touching the servo amplifier, for example, for maintenance purposes, check the voltage at the screw above the LED D7 with a DC voltage tester to see if the remaining voltage is not higher than 50 V.

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5.1
LED OF SERVO AMPLIFIER

LED D7

LED
P5V P3.3V SVEMG ALM RDY OPEN WD D7

Color
Green Green Red Red Green Green Red Red

Description
Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally. Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V normally. Lights when an emergency stop signal is input to the servo amplifier. Lights when the servo amplifier detects an alarm. Lights when the servo amplifier is ready to drive the servo motor. Lights when the communication between the servo amplifier and the main board is normal. Lights when a watch dog alarm is detected in the servo amplifier. Lights when the DCLINK circuit inside the servo amplifier is charged to reach a specific voltage.

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5. SERVO AMPLIFIERS

5.2
SETTING OF SERVO AMPLIFIER

Settings
Name COM1 Standard setting Side A Description This jumper sets the common voltage for the Robot digital Inputs (RDI) to: Side A : +24V common Side B : 0V common

Fuse F1 Fuse F2

Fuse FS1 Fuse FS3 Fuse FS2

Set jumper

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5.3
DRIVER CHIP FOR ROBOT DI/DO

DIO19 DIO18 DIO17

Correspondence between driver chips and DO signals Ordering code for the driver chips : A76L--0151--0062
Driver chip DIO17 DIO18 DIO19 DO signal RDO1, RDO2, RDO3, RDO4 RDO5, RDO6, RDO7, RDO8 XRESERVE, XBRKRLS1, XBRKRLS2, XBRKRLS3

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6. SETTING THE POWER SUPPLY

SETTING THE POWER SUPPLY

The power supply is factory-set for operation. Usually, you do not need to set or adjust it.

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6.1
BLOCK DIAGRAM OF THE MAIN POWER INCLUDING POWER SUPPLY
AC input

380 -- 415 VAC 440 -- 500 VAC 3

Transformer
210VAC

E--stop unit Breaker

210VAC

Servo amplifier (6--axis amplifier)

FS3

Regenerative res. Aux.Axis DC/DC +5V, +3.3V +15V, --15V

Noise filter

Breaker

CRR38 CRM67 +24E FS1 CRM67 CRR64 CRF7 FS2 CNJ

+5V

+24VF

200VAC

Backplane

Power supply unit

F1 CP1 CP2 CP3 DC/DC F4 +5V, +3.3V +15V, --15V F3 +24V, +24E CP5 CP6 +24V +24E CP5A CP6 CP5A CRM64 210VAC Power Brake FAN CP2 Motor

Robot
Pulsecoder End Effector

+24V

Main board

BATTERY CRM64 CRM64

+24V

CRS16 FUSE2

+24T

CP8B

Teach pendant

DC/DC +5V +24EXT FUSE1 E--STOP CIRCUIT

Panel board
+24E +24E +24E JD5A JD5B JD17

Handy file etc.

Process I/O board

+24E FUSE1 CRM2 CRM4 +24E +24E +24V --15V +15V +5V +3.3V +24F

Peripheral device

Fig.6.1 Block diagram of the power supply (B--cabinet)

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6. SETTING THE POWER SUPPLY

6.2
SELECTING TRANSFORMER TAPS

Select a transformer and tap according to the supply voltage. Select a transformer tap such that the rated voltage is +10% to --15% of the induced voltage.

Rated Voltage 500-575 Type I 440-480 380-415 Type II 440-500 380-400 Type III 200-230

Transformer specification 7.5KVA A80L--0026--0035 A80L 0026 0035 3KVA A80L--0024--0025 A80L 0024 0025

A80L--0026--0036 A80L 0026 0036

A80L--0024--0026 A80L 0024 0026

A80L--0026--0037 A80L 0026 0037

A80L--0024--0027 A80L 0024 0027

Structure of transformer

Mounting locations of transformer (B--cabinet, back side)

Transformer

Fig.6.2 (a) Transformer mounting locations and structure

Type I:440--480 V Type II:380--415 V

Insert the connector connected to the circuit breaker into connector LB and the dummy plug into connector LA. Insert the connector connected to the circuit breaker into connector LA and the dummy plug into connector LB.

Type I: 500--575 V Type II: 440--500 V

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3 4

Type III: 200--230 V Type III: 380--400 V

Use the connection cable. Insert the connector connected to the circuit breaker into connector LA and use the Y connection cable for connector LB.

Fig.6.2 (b) Setting a tap

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6. SETTING THE POWER SUPPLY

6.3
CHECKING THE POWER SUPPLY UNIT

The power supply unit need not be set or adjusted.

Table 6.3 Rating of the Power supply unit Output +5V +3.3V +24V +24E +15V --15V Rated voltage +5.1V +3.3V +24V +24E +15V --15V Tolerance 3% 3% 5% 5% 10% 10%

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F1 8.0A Fuse for AC input

F3 7.5A fuse for +24E

Fig.6.3 (a) Interface of the power supply unit

F4 7.5A fuse for +24V

MAINTENANCE

CP5 : +24V CP6 : +24E

PIL LED for indicating the AC power supply status (Green)

162

ALM LED for indicating the alarm (Red)

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R2 R1 S2 S1 G2 G1 P280 F1 R AC INPUT NF S P0 G +3.3VDC REGULATOR 0V A24 A12 P22 AUX P0 P280 P.S. 0V P22 A24 A5 +15 +5.1 +3.3 +24 +15 --15 ALM CONTROL CIRCUIT +15V 15VDC REGULATOR 0V ENA EN5 FA FB --15 --15V +24VDC REGULATOR A5 +24 F3 F4 0V 7.5A +24E 7.5A +24V 0V +5.1VDC REGULATOR 0V +3.3 +3.3V 0V 8A +5.1 +5.1V AC OUTPUT

Fig.6.3 (b) Block diagram of the power supply unit

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ON COM OFF

A24 HI LO

P0

0V

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REPLACING A UNIT

This section explains how to replace each unit in the control section. WARNING Before you start to replace a unit, turn off the control unit main power. Also keep all machines in the area of the control unit switched off. Otherwise, you could injure personnel or damage equipment.

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7. REPLACING A UNIT

7.1
REPLACING THE PRINTED--CIRCUIT BOARDS
CAUTIONS When you replace printed--circuit boards, observe the following cautions: 1 Keep the control unit power switched off. 2 When you remove a printed--circuit board, do not touch the semiconductor devices on the board with your hand or make them touch other components. 3 Make sure that the replacement printed--circuit board has been set up appropriately. (Setting plug etc.) 4 If the backplane board, power supply unit, or main board (including cards and modules) is replaced, it is likely that robot parameters and taught data are lost. Before you start to replace these components, save a backup copy of the robot parameters and taught data to a memory card, floppy disk, or any other external memory device. 5 Before you disconnect a cable, note its location. If a cable is detached for replacement, reconnect it exactly as before.

7.1.1
Replacing the Backplane Board (Unit)

When replacing the backplane board, do so together with the plastic rack. (1) Detach the cables from the power unit and boards on the backplane board. CAUTION When you remove the main board, be sure that the battery is good (3.1--3.3VDC) and it is installed correctly. USE STATIC PROTECTION. (2) Remove the power unit and boards from the rack. (See Section 7.1.2.) (3) Detach the grounding cable from the backplane unit. (4) Loosen the retaining screws in the upper section of the rack. Remove the retaining screws from the lower section of the rack. (5) Side rack up and out. (6) To replace the backplane and rack, reverse steps (1) -- (6). CAUTION There is a possibility of data loss when a backplane-mounted printed circuit board is replaced. Be sure to back up all program and setup data on a floppy disk before proceeding.

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Fig.7.1.1 Replacing the Backplane Board

7.1.2
Replacing the Power Unit and Printed--Circuit Boards on the Backplane Unit

The backplane unit incorporates the power unit, main board, and option boards. There are two types of option boards: Full--size board and mini--size board. A full--size board occupies one slot. A mini--size board uses part of a full--size board. CAUTION Before starting replacement, turn off the control unit main power. The main board is equipped with battery--backed memory devices for holding robot parameters and taught data, for example. When the main board is replaced, the data in the memory devices is lost. (1) Detach the cable from the power supply unit or the printed--circuit board, whichever is to be replaced. (2) Pinch the barbed handles on the upper and lower sections of the board to unlatch it, then pull it toward you. (3) Place the replacement board on the rail in the appropriate slot of the rack, then push it in gently by the handles until it is latched. (4) There are two rails in the main board SLOT (slot 1). When inserting the main board, align it to the right--side rail. (5) There are two rails in slots 3 and 5 (slots for a full--size option board). When you insert a full--size option board, align it to the left--side rail.

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7. REPLACING A UNIT

SLOT 1 SLOT 2 SLOT 3 PSU (Power supply SLOT)

Handles

SLOT 1

SLOT 10

Handles

SLOT 9

SLOT 8

Fig.7.1.2 Replacing the Power Unit and Printed--Circuit Boards on the Backplane Unit

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7.1.3
Replacing the Panel Board

The panel board is at the back of the operator panel. (1) Detach all cables from the panel board. The terminal blocks (TBOP3, TBOP4 and TBOP6) are of a connector type. Pull out the upper terminal block sections. (2) Remove four retaining screws from the panel board, and remove the panel board.

4--M3 screws

B--cabinet

Fig.7.1.3 Panel board replacement

(3) Remove two retaining screws from the panel board, and remove two plates.

2--M3 screws

(4) Attach two plates to new panel board by two screws, then attach the panel board to the oparator panel by four screws.
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7. REPLACING A UNIT

7.2
REPLACING CARDS AND MODULES ON THE MAIN BOARD
CAUTION Before you start to replace a card or module, make a backup copy of robot parameters and taught data. If the FROM/SRAM module is replaced, memory contents are lost. Demounting a Card (1) Pull outward the clip of each of the two spacers used to secure the card PCB, then release each latch. (2) Extract the card upward.

Card

Card

Card Card

Spacer Connector

Card

Spacer Connector Fig.7.2(a) Demounting a card

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Mounting a Card (1) Check that the clip of each of the two spacers is latched outward, then insert the card into the connector. (2) Push the clip of each spacer downward to secure the card PCB.

Card

Spacer Connector

Card

Card

Card Card

Spacer Connector Fig.7.2(b) Mounting a card

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7. REPLACING A UNIT

Demounting a module CAUTION When replacing the module, be careful not to touch the module contact. If you touch the contact inadvertently, wipe out dirt on the contact with a clean cloth. (1) Move the clip of the socket outward. (a) (2) Extract the module by raising it at a 30 degree slant and pulling outward. Mounting a module (1) Insert the module at a 30 degree slant into the module socket, with side B facing upward. (b) (2) Push the module inward and downward until it is locked. (c)
(a)

(b)

(c)

Fig.7.2(c) Demounting/Mounting a module

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Figure 7.2 (d) shows the locations of the cards and modules.
Main board

CPU card

Axis control card

FROM/SRAM module

Fig.7.2(d) Locations of Cards and Modules

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7.3
REPLACING THE TRANSFORMER
WARNING Before you start replacement procedure, turn off the main power to the control unit. The transformer is quite heavy; it weighs 45 to 60 kg. In case of B--cabinet (1) Remove the six M4 screws and detach the back panel.

6--M4 screws

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(2) Detach the connectors of LA, LB, OUT, CP1, and TOH. If a cable is fastened with nylon ties, cut them with a diagonal cutter to release the cable. Be careful not to damage the cable.

(3) Remove the retaining screws from the transformer terminal board and remove metal plate.

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(4) Remove the two retaining M6 screws from the transformer, then remove the transformer.

Shape of the transformer 2--M6 screws

(5) Install a replacement transformer by reversing procedure (1) to (4).

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7.4
REPLACING THE REGENERATIVE RESISTOR UNIT
WARNING Before you start, turn off the control unit main power. Be careful not to get burned, because the regenerative resistor unit is very hot immediately after operation. In case of B--cabinet (1) Remove the servo amplifier. (See Replacing the servo amplifier.) (2) Remove two M4 screws, then detach the housing that fastens cables.
2--M4 screws

(3) Remove the two retaining M5 nuts and lift away the regenerative resistor unit.

2--M5 nuts

(4) Install a replacement regenerative resistor unit and a servo amplifier by reversing the procedure (1) to (3).
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7.5
REPLACING THE E--STOP UNIT
WARNING Before you start replacement, turn off the control unit main power. B--cabinet (1) Detach the cables from the emergency stop unit. (2) Remove retaining screws (4--M4) from the emergency stop unit, and replace the emergency stop unit. (3) Reconnect the cables.

E--stop unit

4--M4 screws B--cabinet

Fig.7.5 Replacing the Emergency Stop Unit

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7.6
REPLACING SERVO AMPLIFIERS
WARNING Before you start replacement, turn off the control unit main power. In case of B--cabinet (1) Turn the four screws, detach the amplifier cover, and pull out the cable.

Amplifier cover

Fig.7.6 (a) Replacing the servo Amplifier (B--cabinet)

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(2) Check the voltage at the screw above the LED D7 with a DC voltage tester to see if the remaining voltage is not higher than 50 V.
Check that the voltage is not higher than 50 V.

(3) Remove the two screws located on the top of the amplifier. At the middle of the top of the amplifier, there is an M5 screw that fastens the amplifier during transport of the cabinet. After the installation of the cabinet, remove the screw. This improves maintainability.
Screw Fixation screw for transport (MS)

Fig.7.6 (b) Replacing the servo Amplifier (B--cabinet)

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(4) Holding the handles located at the top and bottom of the amplifier, pull out the amplifier toward you. Be careful not to touch any components, such as capacitors, on the lower part of the servo amplifier printed--circuit board. Also, be careful not to damage the cables that are routed under the servo amplifier when pulling it out.

Fig.7.6 (c) Replacing the servo Amplifier (B--cabinet)

(5) Pull out the lower part of the amplifier further toward you and slant the amplifier.

Fig.7.6 (d) Replacing the servo Amplifier (B--cabinet)

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(6) Take the amplifier out while keeping it slanted.

Fig.7.6 (e) Replacing the servo Amplifier (B--cabinet)

(7) Install a replacement servo amplifier by reversing step (b). (8) Re--attach the cables.

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7.7
REPLACING I/O UNIT MODEL A
WARNING Before you start replacement, turn off the control unit main power.

7.7.1
Replacing the Base Unit of I/O Unit Model A

First dismount the modules from the base unit of I/O unit model A. The base unit is retained with 4 screws. Of these screws, loosen the upper 2 screws and remove the lower 2 screws, then replace the base unit.

M4 screw (4 pieces)

B--cabinet

Fig.7.7.1 Replacing the Base Unit of I/O Unit Model A

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7.7.2
Replacing a Module
Installing a module

An interface module and input/output module can be easily installed in and removed from the base unit, as described below.

(a) Put the upper hook of the module into the upper hole of the base unit. (b) Fit the connectors of the module and the base unit to each other. (c) Push the module until the lower stopper of the module is caught in the lower hole of the base unit.

Removing a module

(a) Press the lever at the bottom of the module to release the stopper. (b) Lift the module up.

Fig.7.7.2 Replacing the module

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7.8
REPLACING THE TEACH PENDANT

The specifications of the teach pendant vary with its use. When you replace the teach pendant, check its specifications carefully. (1) Be sure that the power of a robot controller is off. (2) Detach the cable from the teach pendant. (3) Replace the teach pendant.

Detach or attach the cable by rotating the connector retaining ring.

Fig.7.8 Replacing the Teach Pendant

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7.9
REPLACING THE CONTROL SECTION FAN MOTOR

The control section fan motor can be replaced without using a tool. The fan motor is mounted on the fan unit rack. (1) Be sure that the power of a robot controller is off. (2) Put your finger in the dent in the upper section of the fan unit, and pull the fan unit until it is unlatched. (3) Lift the fan unit slightly, and dismount it from the rack. (4) Place a replacement fan on the upper section of the rack, and slide it gently until it is latched.

Fan motor connector

Fan motor

Pull the fan motor unit toward you to unlatch it.

Fig.7.9 Replacing the Control Section Fan Motor

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7.10
REPLACING THE AC FAN MOTOR
WARNING Before you start replacement, turn off the control unit main power. Do not touch the fan motor when it is rotating, or you could be injured.

7.10.1
Replacing External Air Fan Unit and Door Fan (B--cabinet)

Door fan (1) Detach the cable from the fan unit. (2) Remove the two retaining M4 screws from the fan unit, then dismount it. (3) Install a new fan unit by reversing the dismounting procedure. External Air fan unit (1) Detach the cable. (2) Remove the six M4 screws and pull out the fan unit toward you. (3) Install a new fan unit by reversing the dismounting procedure.

Screw (2--M4) Screw (6--M4)

Floor fan unit (1) Remove the cable from the fan unit. (2) Remove the fan by unscrewing the two retaining M4 screws. (3) Reverse the procedure to mount a spare fan unit.
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Floor fan unit

Screw (2--M4)

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7.11
REPLACING THE OPERATOR PANEL AND PANEL SWITCH BOARD

(1) Detach the cable (CRT8, CRM51) (2) Straighten the 12 claws on the printed circuit board, then remove the printed circuit board. (3) Remove the six (6--M3) screws, then remove the panel switch board. (4) Install a new panel switch board by reversing the dismounting procedure.

Straighten the claws.

Screw (6--M3)

Fig.7.11 Replacing the operator panel and Panel switch board

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7.12
REPLACE THE MODE SWITCH

(a) Remove the cable from the mode switch. (b) Remove the screws fastening the mode switch, and replace the mode switch. NOTE 1 When mounting the mode switch, do not overtighten the screws. (Tightening torque: 2.5 kgcm) 2 Tighten the screws evenly so that the mode switch flat surface becomes parallel-- to the sheet metal.

Door Screw

Mode switch

Fig.7.12 Replacing the Mode Switch

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7.13
REPLACING FUSES 7.13.1
Replacing Fuses in the Servo Amplifier

If a fuse in the control unit has blown, find the cause and take an appropriate measure before replacing the fuse.

The following fuses are in the servo amplifier. F1, F2: Fuses for detection of the circuits failure in the servo amplifier, (A60L--0001--0245#GP20) If either of these fuses has blown, it is likely that the servo amplifier is defective. Replace the servo amplifier. FS1: For generation of the power to the amplifier control circuit (A60L--0001--0290#LM32C) FS2: For protection of the 24 V output to the end effector, ROT, and HBK (A60L--0001--0290#LM32C) FS3: For protection of the 24 V output to the regenerative resistance and the additional axis amplifier (A60L--0001--0290#LM50C)
Fuse F1 Fuse F2

Fuse FS1 Fuse FS3 Fuse FS2

Fig.7.13.1 Replacing Fuses in the Servo Amplifier

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7.13.2
Replacing Fuses in the Power Unit

The following fuses are in the power unit. F1: Fuse for the AC input, A60L--0001--0396#8.0A F3: Fuse for protecting the +24E output, A60L--0001--0046#7.5 F4: Fuse for protecting the +24V output, A60L--0001--0046#7.5
F1 8.0A AC input fuse

F3 7.5A +24E fuse F4 7.5A +24V fuse

Fig.7.13.2 Replacing Fuses in the Power Unit

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7.13.3
Replacing the Fuse on the Process I/O Boards

The following fuse is on each process I/O board. FUSE1:Fuse for protecting the +24V output for peripheral equipment interfaces. A60L--0001--0046#2.0

Process I/O board CA,CB FUSE1

Total version

Process I/O board DA FUSE1

Total version

Fig.7.13.3 (c) Replacing the Fuse on the Process I/O Boards

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Process I/O board CA,CB FUSE1

Total version

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7.13.4
Replacing the Fuse on the Panel Board

The following fuse is on the panel board. FUSE1 : For protection of the +24EXT line (emergency stop line) FUSE2 : For protection of the teach pendant emergency stop line A60L--0001--0046#1.0
Fuse 2

Fuse 1

Fig.7.13.4 Replacing the fuse on the panel board

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7.14
REPLACING RELAYS

Prolonged use of a relay might result in its contacts failing to make a secure connection or sticking to each other permanently. If such a failure occurs, replace the relay.

7.14.1
Replacing Relays on the Panel Board

KA21, KA22: Relay for emergency stop circuit A58L--0001--0192#1509A

KA22

KA21

Fig.7.14.1 Replacing Relays on the Panel Board

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7.15
REPLACING BATTERY 7.15.1
Battery for Memory Backup (3 VDC)
The programs, and system variables are stored in the SRAM in the main board. The power to the SRAM memory is backed up by a lithium battery mounted on the front panel of the main board. The above data is not lost even when the main battery goes dead. A new battery can maintain the contents of memory for about 4 years (Note). When the voltage of the battery becomes low, the low--voltage battery alarm (system--035) is displayed on the teach pendant. When this alarm is displayed, replace the battery as soon as possible. In general, the battery can be replaced within one or two weeks, however, this depends on the system configuration. If the battery voltage gets lower, it becomes impossible to back up the content of the SRAM. Turning on the power to the in this state causes system not to start and LED of seven segment on the main board to be displayed 1 because the contents of memory are lost. Clear the entire SRAM memory and reenter data after replacing the battery. Important data should be saved to the memory card or floppy disk beforehand in case of emergency. When replacing the memory backup battery, do so while the robot controller is turned off in case of emergency. NOTE In a newly introduced robot, the battery is factory--installed. Battery replacement may, therefore, be needed within 4 years after the introduction of the robot.

Replacing the lithium battery

(1) Prepare a new lithium battery (ordering drawing number: A02B--0200--K102). (2) Turn the robot controller on for about 30 seconds. (3) Turn the robot controller off. (4) Remove the old battery from the top of the main board. First unlatch the battery, remove it from the battery holder, and detach its connector.

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Battery latch

Lithium battery

Battery connector

(5) Remove the old battery, insert a new one into the battery holder, and attach the connector. Confirm that the battery is latched firmly. WARNING Using other than the recommended battery may result in the battery exploding. Replace the battery only with the specified battery (A02B--0200--K102).

CAUTION Complete the steps (3) to (5) within 30 minutes. If the battery is left disconnected for a long time, the contents of memory will be lost. To prevent possible data loss, it is recommended that the robot data such as programs and system variables be backed up before battery replacement. Dispose of the replaced battery as an industrial waste, according to the laws and other rules in the country where the controller is installed and those established by the municipality and other organizations that have jurisdiction over the area where the controller is installed.

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CONNECTIONS

1. GENERAL

GENERAL

This section describes the electrical interface connections in the R-J3iB. It also includes information about installation of the R-J3iB.

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BLOCK DIAGRAM

Fig. 2 is a block diagram of electrical interface connections with the R-J3iB.

Pneumatic pressure source

R--J3iB (B--cabinet)

Mechanical unit

End effector

Memory card (PCMCIA)

Teach pendant

RS--232--C

(Note2)

Peripheral device

Welding machine

Ethernet

AC power supply

Fig.2 Block Diagram of Electrical Interface Connection (In case of B--cabinet)

NOTE 1

: Indicates electrical connection. : Indicates mechanical connectin. 2 For more information, contact our service section.

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ELECTRICAL CONNECTIONS

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3.1
CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS
R-J3iB Robot RP1 (Pulsecoder signal RDI/RDO, ROT, HBK)

CRF7 (Pulsecoder signal, RDI/RDO, ROT, HBK)

CNJ1A (J1 motor power) CNJ2A (J2 motor power) CNJ3A (J3 motor power) CNJ4A (J4 motor power) CNJ5A (J5 motor power) CNJ6A (J6 motor power) CNGA (J1--J3 ground) CNGB (J4--J6 ground) CRR64 (Brake control)

RM1 (J1--J6 motor power, Motor brake)

EE (Note)

End effector

Fig.3.1 (a) Mechanical Connection Diagram

NOTE This cable is not included. It must be supplied by the customer.

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R-J3iB CRS16 (Panel board) Teach pendant

CRM2, CRM4 (Process I/O)

(NOTE1)

Peripheral device

Port A (Operator panel)

Handy File

JD5B (Main board)

(NOTE2)

External device

JD17 (Main board)

(NOTE2)

External device

CD38 (Main board) L1 L2 Braker L3 G Panel board (TBOP3) ON1 ON2 OFF1 OFF2 EES1 EES11 EES2 EES21 EAS1 EAS11 EAS2 EAS21 EGS1 EGS11 EGS2 EGS21

(NOTE2)

Ethernet

Input power

(NOTE2)

External power ON/OFF switch

Panel board (TBOP4)

(NOTE2)

External emergency stop switch

Panel board (TBOP4)

(NOTE2) Fence

Panel board (TBOP4)

(NOTE2) Servo off switch

Fig.3.1 (b) Mechanical Connection Unit

NOTE 1 For detail of the peripheral device connection, see the section of Peripheral device interface. 2 This cable is not included. It must be supplied by the customer.

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3.2
EXTERNAL CABLE WIRING DIAGRAM 3.2.1
Robot Connection Cables
Robot Model R--2000iA M--6iB ARC Mate 100iB

(B--Cabinet)

D Detail of cable connection to servo amplifier.

R--J3iB (Servo amplifier) CRR64 CNGA CNJ6 CNJ5 Robot

CNGB

CRF7 Pulse coder (Pulse coder,RDI/RDO,HBK,ROT)

Motor power/brake (J1M, J2M, J3M, J4M, J5M, J6M, BK)

CNJ4

CNJ3A

CNJ2A

CNJ1A

Fig.3.2.1 (a) Robot Connection Cable (B--cabinet)

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3.2.2
Teach Pendant Cable

(1) Teach pendant cable The teach pendant connection cable is connected to the operator panel as follows. This figure applies to all robot models.
Teach pendant

Teach pendant connection cable

Fig.3.2.2 Teach Pendant Cable

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3.2.3
Connecting the Input Power

Considering the robot power capacity and the circuit breaker capacity, connect the power supply whose voltage conforms to the installation conditions to the terminal located above the circuit breaker. Provide a class--D or better ground. The resistance to the ground must not exceed 100. Be sure to ground the work table or jig used by an arc welding robot or the like so that it can handle a large current. Use a thick wire to withstand the maximum current used. Selection of an input transformer tap is necessary depending on the input voltage. The tap is set to the specified voltage before shipment. However, check it referring to section 6.2 in Maintenance before supplying power (before the breaker switch is turned on). The motor is driven by the PWM inverter system using a power transistor bridge. If the servo amplifier is used without a transformer, a high-frequency leakage current flows through the stray capacitance between the ground and the motor coils, power cable, and amplifier. This might cause the leakage-current circuit breaker or leakage-protection relay installed in the path of the power supply to cut out. Use the following leakage current circuit breaker for inverters to prevent incorrect operation.
Example of Leakage Current Circuit Breaker for Inverters Manufacture Fuji Electric Co., Ltd. Hitachi, Ltd. Matsushita Electric Works, Ltd. EG A series SG A series ES100C type ES225C type Leakage current circuit breaker, C type Leakage current circuit breaker, KC type Type

Fig. 3.2.3 shows the cable connection.

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B--cabinet

Input Power supply cable

(Note) Always replace the cover after completing

Fig.3.2.3 Input Power Supply Connection (B--cabinet)

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3.2.4
Connecting the External Power Supply ON/OFF Switch
Panel board

The External Power On/Off signal turns on and off the power supply from the outside of the control unit, and is connected as follows.

TBOP3

Fig.3.2.4 (a) Connection of the external power supply ON/OFF switch

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Short piece between EXON1 and EXON2 External ON/OFF switch.

In case of using external ON/OFF switch, remove the short piece between EXOFF1 and EXOFF2, then connect the wires.

Use a contact conforming to the following : Voltage rating : 50 VDC, 100mA or more The power supply on/off timing chart is as follows

ON/OFF SW on operator panel TOFF--ON EXOFF1--2

ON OFF Close Open ON

Power

OFF TOFF--ON 5 sec Note1) In case of using the external ON/OFF control, the ON/OFF switch on operator panel must be turned ON. Note2) When the external ON/OFF switch is turned ON (Closed), the ON/OFF switch on operator panel can turn ON the controller. Note3) When the external ON/OFF switch is turned OFF (Open), the ON/OFF switch on operator panel can not turn ON the controller.

Fig.3.2.4 (b) Connection of the external power supply switch ON and OFF

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3.2.5
Connecting the External Emergency Stop

Fig.3.2.5 (a) Connection of the external emergency stop

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External emergency stop output

Signal
ESPB1 ESPB11 ESPB2 ESPB21 ESPB3 ESPB31 ESPB4 ESPB41

Description Emergency stop output signals. These contacts are open if an emergency stop of teach pendant or operator panel occurs or the power is turned off. (Note 1) These contacts are closed during normal operation.

Current, voltage

Rated contact: 250 VAC, 5 A or 5-A 30 VDC, 5A resistor load

Fig.3.2.5 (b) External emergency stop output

NOTE 1 The relays for emergency stop output signals can be connected external power source. The power for relays are connected controllers power at the factory, and please connect external power source if emergency stop output must not be effected controllers power. Please refer to External power connection.

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External emergency stop input After connecting an external emergency stop switch and safety fence door switch, be sure to check the operations of those switches, the emergency stop switch on the operators panel, and the emergency stop switch on the teach pendant.

Use a contact which minimum load is 5mA less.

Signal
EES1 EES11 EES2 EES21 EAS1 EAS11 EAS2 EAS21 EGS1 EGS11 EGS2 EGS21 SD4 SD41 SD5 SD51

Description

Current, voltage

Connect the contacts of the external emergency stop switch to these terminals. When using the contacts of a relay of contactor instead of the switch, Open and close of connect a spark killer to the coil of the relay or contactor, to suppress noise. 24VDC 10mA When these terminals are not used, jumper them. These signals are used to stop the robot when the door on the safety fence is open. While the deadmans switch on the teach pendant is pressed and the teach Open and close of pendant enable switch is validated, these signals are ignored and an emer- 24VDC 10mA gency stop does not occur. If these signals are not used, short these terminals. Connect the contacts of the servo--on input switch to these terminals. When using the contacts of a relay or contactor instead of the switch, connect a Open and close of spark killer to the coil of the relay or contactor, to suppress noise. 24VDC 10mA When these terminals are not used, jumper them. Connect the contacts of the servo--disconnect input switch to these terminals. When using the contacts of a relay or contactor instead of the switch, Open and close of connect a spark killer to the coil of the relay or contactor, to suppress noise. 24VDC 10mA When these terminals are not used, jumper them.

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Input requirement for external emergency stop and etc. The emergency stop circuit is composed of a chain of contacts. D Please connect dual contacts, which work same time, for external emergency stop, safety fence switch, servo ON/OFF switch and servo disconnect switch. D Please observe following timing. If input requirements are not satisfied, it may occure single chain failure.

l.

CAUTION 1 Single chain failure will occure, if this input requirements are not satisfied. 2 Single chain failure cant be reset until special reset operation even if controller power is OFF and ON.

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Extenal power connection The relays for emergency stop input and output can be separated from controllers power. Please connect external +24V instead of internal +24V, if emergency stop output must not be effected controllers power.

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Connecting external on/off and external emergency stop signal input/output wires

Details of the signal wires are shown below:

Bare wire length: 8 to 9 mm Compliant wire size: 0.08 to 2.5 mm2 If you want to use a rod terminal, select one that is suitable for the wire shown above. The following table lists recommended products (manufactured by Weissmuller). Wire (mm2) 0.5 0.75 1.0 1.5 2.5 Specification H0.5/14 H0.75/14 H1.0/14 H1.5/14 H2.5/14 Remark With insulation cover (Crimping tool : PZ3, PZ4, PZ6/5)

How to attach signal wires to connectors

Manipulation slot Flat--blade screwdriver

Plug connector block Signal wire 1. 2. 3. 4. 5. Detach the plug connector block from the panel board. Insert the tip of a flat--blade screwdriver into the manipulation slot and push down its handle. Insert the end of the signal wire into the wire slot. Pull out the screwdriver. Attach the plug connector block to the panel board. Do not insert a wire into the wire hole of a plug connector or pull it out with the plug connector block mounted on the panel board; otherwise, the panel board may be damaged.

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FANUC recommonds the lever (A05B--2400--K030) for connecting the signal wire to the plug connector block instead of Flat--blade screwdriver.

Wire stripping
F Available wire size AWG 28--14 (0.08 to 2.5mm2)

Handling of the Lever

F Hold the connector, and push down the lever by finger F Dont handle the lever after fit the connector into the PCB, otherwise PCB will be damaged by handling stress.

F Please check the strip length carefully.

F Please readjust the loose end.

Wiring
(1) Pull down the lever. (2) Push in the conductor with holding the lever. (3) Set the lever free. L And pull the conductor softly to check the clamping

L Dont pull strongly

Replace the lever

(1) Pull off the lever. (2) Hook the lever to the rectangle hole. (3) Push down the lever untill click in.

Fit to header
(1) Push in the connector to header. (2) Please check if the latch is hooked to header.

L Be careful to fit the shape of each other.

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Installation of Jumper

(1) Attach levers to connector.

(2) Hold down levers at the same time, then put the jumper into connector.

L Please check the direction of the jumper.

Availability of wires
F Without jumpers F With jumper F With two jumpers

L Max wire size 2.0mm2 (AWG14) (with Ferrule)

F Additional wire is available under F Additional wire is the jumper. NOT avairable under the jumper. L Max wire size 0.5mm2 (AWG20) (with Ferrule)

Installation of Ferrules
(3) Squeeze handles until ratchet mechanism is released.

(1) Put the wire through the hole of ferrules.

(2) Introduce wire with ferrule into cramping station.

(4) Please check if the wire crimped correctly. Crimping Toole ( : WAGO Item--No.206--204)

Specifications of Ferrules
WAGO Item--No. 216--301 216--302 216--201 216--202 216--203 216--204 216--205 Sleep for mm2 (AWG) 0.25 (24) 0.34 (24) 0.5 (22) 0.75 (20) 1.0 (18) 1.5 (16) 2.0 (14) Color Stripped Lengt (m) 9.5 9.5 9.5 10.0 10.0 10.0 10.0 L L1 D (m) 2.5 2.5 3.1 3.3 3.5 4.0 4.2 D1 D2 Pack.--unit pcs 100 100 100 100 100 100 100

yellow green white gray red black yellow

12.5 12.5 14.0 14.0 14.0 14.0 14.0

8.0 8.0 8.0 8.0 8.0 8.0 8.0

2.0 2.0 2.6 2.8 3.0 3.5 3.7

0.8 0.8 1.0 1.2 1.4 1.7 2.0

L CAUTION Please make sure to use WAGO 206--204 to crimp the ferrules.

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4
No. No 1 2 3 4 5 Name

PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES

R-J3iB I/O peripheral device interfaces include printed circuit boards and a unit selected according to the applications. Table 4 lists details of the
printed--circuit boards and units. Figure 4 shows the locations of these boards and units.
Table 4 Peripheral Device Interface Types
Drawing number A05B--2450--J001 A05B--2450--J002 A05B--2450--J003 A05B--2450--J004 A05B-2452-J100 (Base and interface unit) Number of I/O points DI 40 40 96 40 DO 40 40 96 40 D/A 2 0 0 2 A/D 6 0 0 0 Remarks Installed in backplane Installed in backplane Installed in backplane Installed in backplane

Process I/O board CA Process I/O board CB Process I/O board DA Process I/O board HA I/O Unit--MODEL A (B--cabinet)

Depending on selected I/O module

NOTE General purpose I/O (SDI/SDO) is a number which subtract an exclusive signal from the table value. Example: Process I/O board CB Table value Exclusive DI General purpose DI DI; 40 -18 = 22 points Table value Exclusive DO General purpose DO DO; 40 -20 = 20 points

Process I/O printed board

I/O unit model A (5 slots)

Fig.4 Locations of Peripheral Device Interfaces

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4.1
PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM 4.1.1
When Process I/O Board CA/CB/HA is Used (B--cabinet)

Following are a block diagram of the peripheral device interface and the specifications.

B--cabinet Process I/O board CA/CB/HA 3 CRM2A 1 JD4A (JD1B) CRM2B JD4B (JD1A) CRW1 or CRW7 (NOTE2) CRW2 2 Process I/O board CA/CB/HA CRM2A JD4A (JD1B) CRM2B JD4B (JD1A) CRW1 or CRW7 (NOTE 2) CRW2 5 4 Peripheral device

Main board JD1A (JD4)

Fig.4.1.1 Block diagram of the process I/O board CA/CB/HA

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NOTE 1 CRW1 and CRW2 are not provided for process I/O board CB 2 In case of process I/O CA : CRW1 In case of process I/O HA : CRW7
No. 1 2 3 4 5 Welding device connection cable g (Process I/O CA) (FANUC interface) Welding device connection cable g (Process I/O HA) (General interface) Welding device connection cable g (Process I/O HA) (FANUC interface) I/O link cable I/O link cable Peripheral device connection cable p Name Drawing number A05B--2452--J140 A05B--2452--J141 A05B--2452--J200 A05B--2452--J201 A05B--2452--J202 A05B--2452--J270 A05B--2452--J271 A05B--2452--J272 A05B--2452--J273 A05B--2452--J274 A05B--2452--J275 A05B--2452--J276 A05B--2452--J277 A05B--2452--J278 Remarks Between main board and process I/O Between process I/O and process I/O Cable length 10m (one cable) Cable length 20m (one cable) Cable length 30m (one cable) Cable length 3m (one cable) CRW1 Cable length 7m (one cable) CRW1 Cable length 14m (one cable) CRW1 Cable length 3m (one cable) CRW7 Cable length 7m (one cable) CRW7 Cable length 14m (one cable) CRW7 Cable length 3m (one cable) CRW7 Cable length 7m (one cable) CRW7 Cable length 14m (one cable) CRW7

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4.1.2
When Process I/O Board DA is Used (B--cabinet)
B--cabinet Main board Process I/O board DA Peripheral device

JD1A

JD4A CRM2A JD4B CRM2B CRM2C CRM2D

3 4 5 6 7 8
CRM4B

CRM4A

Process I/O board DA JD4A CRM2A JD4B CRM2B CRM2C CRM2D CRM4A CRM4B

Fig.4.1.2 Block diagram of the process I/O board DA Cable number 1 2 3 5 7 8 4 6 Peripheral device connection cable p I/O link cable I/O link cable Peripheral device connection cable p Name Drawing number A05B--2452--J140 A05B--2452--J141 A05B--2452--J200 A05B--2452--J201 A05B--2452--J202 A05B--2452--J250 A05B--2452--J251 A05B--2452--J252 Remarks Between main board and process I/O Between process I/O and process I/O Connected length 10m (one cable) Connected length 20m (one cable) Connected length 30m (one cable) Connected length 10m (one cable) Connected length 20m (one cable) Connected length 30m (one cable)

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CONNECTIONS

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4.1.3
When I/O Unit--MODEL A is Used

4.1.3.1
In case of B--cabinet

E--Stop unit CP5A

Main board

JD1A

Peripheral device

Interface module

2 2 2 2 2

Fig.4.1.3.1 Block diagram of I/O Unit--A (In case of B--cabinet) Cable number 1 2 I/O link cable Peripheral device connection cable

Name

Drawing number

Remarks Included in A05B--2452--J100 Must be supplied by the customer.

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4.1.4
When Two or more Process I/O Boards and I/O Unit (Model A or Model B) are Used

In case of B--cabinet. When several units of the process I/O board, I/O Unit--A are used, connect them as shown below.

Main board

B--cabinet Process I/O board

JD1A

A05B--2452--J140

JD4A JD4B

DC power is supplied from the back plane.

Process I/O board A05B--2452--J141 JD4A E--stop unit JD4B

CP5A Included in model A base unit I/O Unit--A Interface module JD1B JD1A CP32 Back plane (5--slot)

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CONNECTIONS

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4.2
PERIPHERAL DEVICE INTERFACE COMBINATION 4.2.1
In Case of B--cabinet
One board or one unit is used
Combination C Combination D Combination E Process I/O board CA/CB/HA (40 points) Process I/O board DA (96 points) I/O Unit--A

Two boards/units are used in combination

Combination CC Process I/O board CA/CB/HA (40 points) + Process I/O board CA/CB/HA (40 points) Process I/O board CA/CB/HA (40 points) + I/O Unit--A Process I/O board DA (96 points) + Process I/O board CA/CB/HA (40 points) Process I/O board DA (96 points) + Process I/O board DA (96 points) Process I/O board DA (96 points) + I/O Unit--A

Combination CE

Combination DC

Combination DD

Combination DE

Three boards/units are used in combination

Combination CCE Process I/O board CA/CB/HA (40 points) + Process I/O board CA/CB/HA (40 points) + I/O Unit--A Process I/O board DA (96 points) + Process I/O board CA/CB/HA (40 points) + I/O Unit--A Process I/O board DA (96 points) + Process I/O board DA (96 points) + I/O Unit--A

Combination DCE

Combination DDE

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4.3
PROCESS I/O BOARD SIGNALS

There are 18 exclusive data inputs (DI) and 20 exclusive data outputs (DO) for a process I/O board. These signals are allocated to the process I/O board connected first when two or more printed boards are combined. (General signals SDI/SDO are allocated to the second and the following process I/O boards.) The common voltage of the DI signals input to pins 1 to 4 of connector CRM2A is clamped +24 V (common) in each process I/O board. Table 4.3 shows signals of a process I/O board.
Table 4.3 Process I/O Board Signals (1/4) (DI signals) Connector number CRM2A-1 CRM2A-2 CRM2A-3 CRM2A-4 CRM2A-5 CRM2A-6 CRM2A-7 CRM2A-8 CRM2A-9 Signal name
*IMSTP *HOLD *SFSD

Description Immediate stop Temporary stop Safe speed Cycle stop External reset Start Return to home position Operation enabled Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection

Remarks Clamped at +24 V common Clamped at +24 V common Clamped at +24 V common Clamped at +24 V common

CSTOPI FAULT RESET START HOME ENBL RSR1 PNS1

Option

CRM2A-10

RSR2 PNS2

Option

CRM2A-11

RSR3 PNS3

Option

CRM2A-12

RSR4 PNS4

Option

CRM2A-13

RSR5 PNS5

Option

CRM2A-14

RSR6 PNS6

Option

CRM2A-15

RSR7 PNS7

Option

CRM2A-16

RSR8 PNS8

Option

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Table4.3 Process I/O Board Signals (2/4) (DI signals) Connector number CRM2A-29 CRM2A-30 CRM2A-31 CRM2A-32 CRM2B-1 CRM2B-2 CRM2B-3 CRM2B-4 CRM2B-5 CRM2B-6 CRM2B-7 CRM2B-8 CRMSB-9 CRM2B-10 CRM2B-11 CRM2B-12 CRM2B-13 CRM2B-14 CRM2B-15 CRM2B-16 CRM2B-29 CRM2B-30 CRM2B-31 CRM2B-32 Signal name PNSTROBE PROD START SDI01 SDI02 SDI03 SDI04 SDI05 SDI06 SDI07 SDI08 SDI09 SDI10 SDI11 SDI12 SDI13 SDI14 SDI15 SDI16 SDI17 SDI18 SDI19 SDI20 SDI21 SDI22 Description PNS strobe Start of automatic operation Peripheral device p status General signal Remarks

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4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES

Table4.3 Process I/O Board Signals (3/4) (DO signals) Connector number CRM2A-33 CRM2A-34 CRM2A-35 CRM2A-36 CRM2A-38 CRM2A-39 CRM2A-40 CRM2A-41 CRM2A-43 CRM2A-44 CRM2A-45 Signal name CMDENBL SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1 SNO1 CRM2A-46 ACK2 SNO2 CRM2A-19 ACK3 SNO3 CRM2A-20 ACK4 SNO4 CRM2A-21 ACK5 SNO5 CRM2A-22 ACK6 SNO6 CRM2A-24 ACK7 SNO7 CRM2A-25 ACK8 SNO8 CRM2A-26 CRM2A-27 SNACK RESERVED Description During automatic operation Preparation completed Program running Program being interrupted During temporary stop Alarm Home position Teach pendant enabled Battery voltage drop During operation Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Response signal to PNS Option Option Option Option Option Option Option Option Remarks

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Table4.3 Process I/O Board Signals (4/4) (DO signals) Connector number CRM2B-33 CRM2B-34 CRM2B-35 CRM2B-36 CRM2B-38 CRM2B-39 CRM2B-40 CRM2B-41 CRM2B-43 CRM2B-44 CRMSB-45 CRM2B-46 CRM2B-19 CRM2B-20 CRM2B-21 CRM2B-22 CRM2B-24 CRM2B-25 CRM2B-26 CRM2B-27 Signal name SDO01 SDO02 SDO03 SDO04 SDO05 SDO06 SDO07 SDO08 SDO09 SDO10 SDO11 SDO12 SDO13 SDO14 SDO15 SDO16 SDO17 SDO18 SDO19 SDO20 Description Peripheral device p control signal Remarks General signal

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4.4
INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS

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4.4.1
Peripheral Device and Control Unit Connection
Control unit Peripheral device control interface A1 CRM2A *IMSTP 33 34 *HOLD ACK3/SNO3 19 35 *SFSPD 20 ACK4/SNO4 36 CSTOPI ACK5/SNO5 21 FAULT RESET 37 ACK6/SNO6 22 38 START COM--A4 23 39 HOME 24 ACK7/SNO7 40 ENBL 25 ACK8/SNO8 RSR1/PNS1 41 26 SNACK RSR2/PNS2 42 27 RESERVED RSR3/PNS3 43 COM--A5 28 RSR4/PNS4 44 PNSTROBE 29 RSR5/PNS5 45 PROD START 30 46 RSR6/PNS6 31 SDI01 RSR7/PNS7 47 32 SDI02 RSR8/PNS8 48 49 0V 50 0V Peripheral device control interface A2 CRM2B SDI03 33 34 SDI04 SDO13 19 35 SDI05 20 SDO14 36 SDI06 21 SDO15 SDI07 37 SDO16 22 38 SDI08 COM--B4 23 39 SDI09 24 SDO17 40 SDI10 25 SDO18 SDI11 41 26 SDO19 SDI12 42 27 SDO20 SDI13 43 COM--B5 28 SDI14 44 SDI19 29 SDI15 45 SDI20 30 46 SDI16 SDI21 31 SDI17 47 32 SDI22 SDI18 48 49 0V 0V 50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CMDENBL SYSRDY PROGRUN PAUSED COM--A1 HELD FAULT ATPERCH TPENBL COM--A2 BATALM BUSY ACK1/SNO1 ACK2/SNO2 COM--A3 +24E +24E

Peripheral device A1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

SDO01 SDO02 SDO03 SDO04 COM--B1 SDO05 SDO06 SDO07 SDO08 COM--B2 SDO09 SDO10 SDO11 SDO12 COM--B3 +24E +24E

Peripheral device A2

NOTE 1 The peripheral device connection cables are optional. 2 All of COM-** are connected to 0 V. Applicable process I/O board type CA, CB, DA, HA

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Control unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Peripheral device control interface A3 CRM2C SDI23 33 34 SDI24 19 SDO33 35 SDI25 20 SDO34 SDI26 36 21 SDO35 SDI27 37 22 SDO36 38 SDI28 COM--C4 23 39 SDI29 24 SDO37 40 SDI30 25 SDO38 SDI31 41 26 SDO39 SDI32 42 27 SDO40 SDI33 43 COM--C5 28 SDI34 44 SDI39 29 SDI35 45 SDI40 30 46 SDI36 SDI41 31 SDI37 47 32 SDI42 SDI38 48 49 0V 50 0V Peripheral device control interface A4 CRM2D SDI43 33 SDI44 SDI45 SDI46 SDI47 SDI48 SDI49 SDI54 SDI51 SDI52 SDI53 SDI54 SDI55 SDI56 SDI57 SDI58 0V 0V 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SDO53 SDO54 SDO55 SDO56 COM--D4 SDO57 SDO58 SDO59 SDO60 COM--D5 SDI59 SDI60 SDI61 SDI62 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 SDO21 SDO22 SDO23 SDO24 COM--C1 SDO25 SDO26 SDO27 SDO28 COM--C2 SDO29 SDO30 SDO31 SDO32 COM--C3 +24E +24E

Pripheral device A3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

SDO41 SDO42 SDO43 SDO44 COM--D1 SDO45 SDO46 SDO47 SDO48 COM--D2 SDO49 SDO50 SDO51 SDO52 COM--D3 +24E +24E

Pripheral device A4

NOTE 1 The peripheral device connection cables are optional. 2 All of COM-** are connected to 0 V. Applicable process I/O board type DA

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Control unit Peripheral device control interface B1 CRM4A 01 02 03 04 05 06 07 SDI63 SDI64 SDI65 SDI66 SDI67 SDI68 SDI69 08 09 10 11 12 13 SDO65 SDO66 SDO67 SDO68 COM--E2 SDI70 14 15 16 17 18 19 20 SDO61 SDO62 SDO63 SDO64 COM--E1 +24 0V

Peripheral device B1

Control unit Peripheral device control interface B1 CRM4B 01 02 03 04 05 06 07 SDI71 SDI72 SDI73 SDI74 SDI75 SDI76 SDI77 08 09 10 11 12 13 SDO73 SDO74 SDO75 SDO76 COM--F2 SDI78 14 15 16 17 18 19 20 SDO69 SDO70 SDO71 SDO72 COM--F1 +24 0V

Peripheral device B2

NOTE 1 The peripheral device connection cables are optional. 2 All of COM--** are connected to 0V. Applicable process I/O board type DA

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4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES

Control unit (peripheral device control interface A1)

Connector pin No. +24E CRM2A (49,50) Receiver circuit CRM2A (1) CRM2A (2) CRM2A (3) CRM2A (4)

Peripheral device

*IMSTP *HOLD *SFSPD CSTOPI

RV RV RV RV

FAULT RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSROBE PROD START SDI01 SDI02

RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV +24E B

CRM2A (5) CRM2A (6) CRM2A (7) CRM2A (8) CRM2A (9) CRM2A (10) CRM2A (11) CRM2A (12) CRM2A (13) CRM2A (14) CRM2A (15) CRM2A (16) CRM2A (29) CRM2A (30) CRM2A (31) CRM2A (32)

Common setting pin (ICOM1)

NOTE This is a connection diagram for +24v common.

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CONNECTIONS

B--81465EN--1/02

Control unit (peripheral device control interface A1)

Connector pin No.

Peripheral device

Receiver circuit DV CMDENBL CRM2A (33)

LOAD RELAY

SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK RESERVED

DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV

CRM2A (34) CRM2A (35) CRM2A (36) CRM2A (38) CRM2A (39) CRM2A (40) CRM2A (41) CRM2A (43) CRM2A (44) CRM2A (45) CRM2A (46) CRM2A (19) CRM2A (20) CRM2A (21) CRM2A (22) CRM2A (24) CRM2A (25) CRM2A (26) CRM2A (27)

LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD

CRM2A(23,28,37, 42,47)
0V +24V +24 V regulated power supply

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4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES

Control unit (peripheral device control interface A2)

Connector pin No. +24E CRM2B (49,50)

Peripheral device

Receiver circuit SDI03 SDI04 SDI05 SDI06 SDI07 SDI08 SDI09 SDI10 SDI11 SDI12 SDI13 SDI14 SDI15 SDI16 SDI17 SDI18 SDI19 SDI20 SDI21 SDI22 RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV +24E B A CRM2B (1) CRM2B (2) CRM2B (3) CRM2B (4) CRM2B (5) CRM2B (6) CRM2B (7) CRM2B (8) CRM2B (9) CRM2B (10) CRM2B (11) CRM2B (12) CRM2B (13) CRM2B (14) CRM2B (15) CRM2B (16) CRM2B (29) CRM2B (30) CRM2B (31) CRM2B (32)

Common setting pin (ICOM2)

NOTE This is a connection diagram for +24V common.

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CONNECTIONS

B--81465EN--1/02

Control unit (peripheral device control interface A2)

Peripheral device

Connector pin No. SDO01 DV CRM2B (33)

LOAD RELAY

SDO02 SDO03 SDO04 SDO05 SDO06 SDO07 SDO08 SDO09 SDO10 SDO11 SDO12 SDO13 SDO14 SDO15 SDO16 SDO17 SDO18 SDO19 SDO20

DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV

CRM2B (34) CRM2B (35) CRM2B (36) CRM2B (38) CRM2B (39) CRM2B (40) CRM2B (41) CRM2B (43) CRM2B (44) CRM2B (45) CRM2B (46) CRM2B (19) CRM2B (20) CRM2B (21) CRM2B (22) CRM2B (24) CRM2B (25) CRM2B (26) CRM2B (27)

LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD

CRM2A(23,28,37, 42,47)
0V +24V +24 V regulated power supply

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4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES

Control unit (peripheral device control interface A3)

Connector pin No. +24E CRM2C (49,50)

Peripheral device

Receiver circuit SDI23 SDI24 SDI25 SDI26 SDI27 SDI28 SDI29 SDI30 SDI31 SDI32 SDI33 SDI34 SDI35 SDI36 SDI37 SDI38 SDI39 SDI40 SDI41 SDI42 RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV +24E B A CRM2C (1) CRM2C (2) CRM2C (3) CRM2C (4) CRM2C (5) CRM2C (6) CRM2C (7) CRM2C (8) CRM2C (9) CRM2C (10) CRM2C (11) CRM2C (12) CRM2C (13) CRM2C (14) CRM2C (15) CRM2C (16) CRM2C (29) CRM2C (30) CRM2C (31) CRM2C (32)

Common setting pin (ICOM3)

NOTE This is a connection diagram for +24V common.

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CONNECTIONS

B--81465EN--1/02

Control unit (peripheral device control interface A3)

Peripheral device

Connector pin No. SDO21 DV CRM2C (33)

LOAD RELAY

SDO22 SDO23 SDO24 SDO25 SDO26 SDO27 SDO28 SDO29 SDO30 SDO31 SDO32 SDO33 SDO34 SDO35 SDO36 SDO37 SDO38 SDO39 SDO40

DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV

CRM2C (34) CRM2C (35) CRM2C (36) CRM2C (38) CRM2C (39) CRM2C (40) CRM2C (41) CRM2C (43) CRM2C (44) CRM2C (45) CRM2C (46) CRM2C (19) CRM2C (20) CRM2C (21) CRM2C (22) CRM2C (24) CRM2C (25) CRM2C (26) CRM2C (27)

LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD

CRM2C(23,28,37, 42,47)
0V +24V +24 V regulated power supply

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CONNECTIONS

4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES

Control unit (peripheral device control interface A4)

Connector pin No. +24E CRM2D (49,50)

Peripheral device

Receiver circuit SDI43 SDI44 SDI45 SDI46 SDI47 SDI48 SDI49 SDI50 SDI51 SDI52 SDI53 SDI54 SDI55 SDI56 SDI57 SDI58 SDI59 SDI60 SDI61 SDI62 RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV +24E B A CRM2D (1) CRM2D (2) CRM2D (3) CRM2D (4) CRM2D (5) CRM2D (6) CRM2D (7) CRM2D (8) CRM2D (9) CRM2D (10) CRM2D (11) CRM2D (12) CRM2D (13) CRM2D (14) CRM2D (15) CRM2D (16) CRM2D (29) CRM2D (30) CRM2D (31) CRM2D (32)

Common setting pin (ICOM4)

NOTE This is a connection diagram for +24V common.

241

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CONNECTIONS

B--81465EN--1/02

Control unit (peripheral device control interface A4)

Peripheral device

Connector pin No. SDO41 DV CRM2D (33)

LOAD RELAY

SDO42 SDO43 SDO44 SDO45 SDO46 SDO47 SDO48 SDO49 SDO50 SDO51 SDO52 SDO53 SDO54 SDO55 SDO56 SDO57 SDO58 SDO59 SDO60

DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV

CRM2D (34) CRM2D (35) CRM2D (36) CRM2D (38) CRM2D (39) CRM2D (40) CRM2D (41) CRM2D (43) CRM2D (44) CRM2D (45) CRM2D (46) CRM2D (19) CRM2D (20) CRM2D (21) CRM2D (22) CRM2D (24) CRM2D (25) CRM2D (26) CRM2D (27)

LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD

CRM2D(23,28,37, 42,47) 0V +24V +24 V regulated power supply

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Control unit (peripheral device control interface B1)

Connector pin No. +24E CRM4A (19)

Peripheral device

Receiver circuit SDI63 SDI64 SDI65 SDI66 SDI67 SDI68 SDI69 SDI70 RV RV RV RV RV RV RV RV +24E B CRM4A (1) CRM4A (2) CRM4A (3) CRM4A (4) CRM4A (5) CRM4A (6) CRM4A (7) CRM4A (13)

Common setting pin (ICOM5)

Connector pin No. SDO61 DV CRM4A (14)

LOAD RELAY

SDO62 SDO63 SDO64 SDO65 SDO66 SDO67 SDO68

DV DV DV DV DV DV DV

CRM4A (15) CRM4A (16) CRM4A (17) CRM4A (8) CRM4A (9) CRM4A (10) CRM4A (11)

LOAD LOAD LOAD LOAD LOAD LOAD LOAD

CRM4A (20) 0V +24V +24 V regulated power supply

NOTE This is a connection diagram for +24V common.

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Control unit (peripheral device control interface B2)

Connector pin No. +24E CRM4B (19)

Peripheral device

Receiver circuit SDI71 SDI72 SDI73 SDI74 SDI75 SDI76 SDI77 SDI78 RV RV RV RV RV RV RV RV +24E B CRM4B (1) CRM4B (2) CRM4B (3) CRM4B (4) CRM4B (5) CRM4B (6) CRM4B (7) CRM4B (13)

Common setting pin (ICOM5)

Connector pin No. SDO69 DV CRM4B (14)

LOAD RELAY

SDO70 SDO71 SDO72 SDO73 SDO74 SDO75 SDO76

DV DV DV DV DV DV DV

CRM4B (15) CRM4B (16) CRM4B (17) CRM4B (8) CRM4B (9) CRM4B (10) CRM4B (11)

LOAD LOAD LOAD LOAD LOAD LOAD LOAD

CRM4B (20) 0V +24V +24 V regulated power supply

NOTE This is a connection diagram for +24V common.

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4.4.2
Connection Between the Mechanical Unit and End Effector

EE

Fig.4.4.2 In case of the R--2000i (For other robots, referto the each maintenance manual.)

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RDI9 (Pneumatic pressure abnormal signal)

(COM1)

NOTE 1 This is a connection diagram for +24V common. 2 The common--level change--over setting pin (COM1) is in the 6--axis servo amplifier.

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4.4.3
Connection Between the Control Unit and Welder
Control unit Welder interface CRW1

Welder

Analog input interface CRW2

Peripheral device

NOTE Welder and peripheral device connection cable are optional. Applicable process I/O board type CA

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CONNECTIONS

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Control unit (Welding interface) Process I/O CA

Welder Connector pin number MS connector pin number

Welding voltage command signal

COMDA1

The input impedance shall be more than 3.3k high--pass filter shall be provided.

Wire speed command signal

COMDA2

Welding voltage detection signal

COMAD1 Output signals without ripples.

Welding current detector signal

COMAD2

R=100 or more

Wire stick detection signal

Welding power supply

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Control unit (Welding interface) Process I/O CA Welding start signal

Welder

WD01

Gas signal

WD02 WD03 CRWI (25)

T

Wire inching (positive) signal Wire inching (negative) signal

WD04 WD05 WD06 WD07 WD08 CRWI (28) CRWI (29) CRWI (30)
W X Z a, m b, n
+24V regulated power supply Receiver circuit

WDI1
Arc detection signal Gas shortage detection signal Wire cut detection signal

CRWI (5)

WDI2 WDI3 WDI4

Cooling water WDI5 shortage detection signal

WDI6 Welding power supplu abnomality signal WDI7 WDI8

CRWI (11) CRWI (12)

j k

Common switching set pin

CRWI (33,34) FG (cabinet ground) Shield

NOTE This is the connection for +24V.

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Control unit (Analog input interface) Process I/O CA

Peripheral device

COMAD3

COMAD4 Output signals without ripples.

COMAD5

COMAD6

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Control unit Welder interface CRW7

Welder

NOTE Welder and peripheral device connection cable is option. Applicable process I/O board type HA

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Control unit (welding interface) Process I/O HA Connector pin numbers Welding voltage command signal 0 V for analog output DACH (1) COMDA CRW7 (1) CRW7 (2) CRW7 (3) CRW7 (4) RV RV +24V B A CRW7 (6) CRW7 (10)

Welding machine MS connector pin numbers

A B C D P R

Wire speed command DACH (2) signal 0 V for analog output Arc No arc (power supply error) COMDA WDI (2) WDI (6)

No gas No wire

WDI (3) WDI (4) +24V

CRW7 (7) CRW7 (8) CRW7 (33, 34)

T S E

Welding start signal DO common Wire inching (+) DO common Wire inching (--) DO common

WDO (1) WCOM (1) WDO (4) WCOM (4) WDO (5) WCOM (5)

CRW7 (23) CRW7 (24) CRW7 (29) CRW7 (30) CRW7 (13) CRW7 (14)

L K F G H J M N

WDI + Wire stick detection signal WDI --

CRW7 (31) CRW7 (32)

+ --

NOTE This is the connection for +24V.

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4.5
DIGITAL I/O SIGNAL SPECIFICATIONS 4.5.1
Peripheral Device Interface

This section describes the specifications of the digital I/O signals interfaced with the peripheral device, end effector, and arc welder.

(1) Output signals in peripheral device interface A Example of connection

Spark killer diode +24V

0.2 A or less

0V +24V Lamp 0.2 A or less

0V Protective resistance

Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at connection Spark killer diode Rated peak reverse voltage Rated effective forward current

: : : : :

24 VDC 30 VDC 0.2 A Open collector NPN 1.0 V (approx.)

: 100 V or more : 1 A or more

NOTE Do not use the +24 V power supply of the robot. When you load a relay, solenoid, and so on directly, connect them in parallel with diodes to prevent back electromotive force. If a load is connected causing a surge current when a lamp is turned on, use a protective resistance.

Applicable signals Output signals of process I/O board CRM2 and CRM4 CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT, ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNO1 to SNO8, SNACK, SDO1 to SDO76
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(2) Input signals in peripheral device interface A Example of connection

+24V

RV 3.3 k +24V B A

ICOM

Electrical specifications of the receiver Type : Grounded voltage receiver Rated input voltage : Contact close : +20 V to +28 V Contact open : 0 V to +4 V Maximum applied input voltage : +28 VDC Input impedance : 3.3 k (approx.) Response time : 5 ms to 20 ms Specifications of the peripheral device contact Rated contact capacity : 30 VDC, 50 mA or more Input signal width : 200 ms or more (on/off) Chattering time : 5 ms or less Closed circuit resistance : 100 or less Opened circuit resistance : 100 k or more
TB (Signal) TB (Signal) TB

Peripheral device contact signal

Robot receiver signal TC TC TB ; TC ; Chattering 5 ms or less 5 to 20 ms

NOTE Apply the +24 V power at the robot to the receiver. However, the above signal specifications must be satisfied at the robot receiver. Applicable signals Input signals of process I/O board CRM2 and CRM4 *IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET, START, HOME, ENBL, RSR1 to RSR8, PNS1 to PNS8, PNSTROBE, PROD START, SDI1 to SDI78
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4.5.2
End Effector Control Interface
(1) Output signals Example of connection
Spark killer diode +24V

0.2 A or less

0V +24V Lamp 0.2 A or less

0V Protective resistance

Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at connection Spark killer diode Rated peak reverse voltage Rated effective forward current

: : : : :

24 VDC 30 VDC 0.2 A Open collector NPN 1.0 V (approx.)

: 100 V or more : 1 A or more

NOTE The +24 V power supply at the robot can be used when the total current of the welding interface and end effector interface is 0.7 A or less. When you load a relay, solenoid, and so on directly, connect them in parallel with diodes to prevent back electromotive force. If a load is connected causing a surge current when a lamp is turned on, use a protective resistance. Applicable signals Output signals of the end effector control interface RDO1 to RDO8

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(2) Input signal Example of connection

+24V

RV 3.3 k +24V B A

COM1

Electrical specifications of the receiver Type : Rated input voltage : Contact close : Contact open : Maximum applied input voltage : Input impedance : Response time :

Grounded voltage receiver +20 V to +28 V 0 V to +4 V +28 VDC 3.3 k (approx.) 5 ms to 20 ms

Specifications of peripheral device contact Rated contact capacity : 30 VDC, 50 mA or more Input signal width : 200 ms or more (on/off) Chattering time : 5 ms or less Closed circuit resistance : 100 or less Opened circuit resistance : 100 k or more
TB (Signal) TB (Signal) TB

Peripheral device contact signal

Robot receiver signal TC TC TB ; TC ; Chattering 5 ms or less 5 to 20 ms

NOTE Apply the +24 V power at the robot to the receiver. However, the above signal specifications must be satisfied at the robot receiver.

Applicable signals Input signals of the end effector control interface RDI1 to RDI8, *HBK, *PPABN
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4.5.3
I/O Signal Specifications for ARC--Welding Interface
(1) Digital output signal specifications for an arc welding interface In case of process I/O CA
Example connection
Spark killer diode

0.2 A or less

Electrical characteristics Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at on

: : : : :

24 VDC 30 VDC 0.2 A Open--collector NPN About 1.0 V

Spark killer diode Rated peak reverse voltage : 100 V or more Rated effective forward current : 1 A or more NOTE A power voltage of +24 V, provided for the robot, can be used for interface signals of up to 0.7 A. This limit applies to the sum of the currents flowing through the arc--welding and end--effector control interfaces. To drive a relay or solenoid directly, connect a diode preventing back electromotive force to the load in parallel. To connect a load which generates an inrush current when you turn on the control unit, connect a protective resistor. Applicable signals -- Output signals on the arc--welding interface -- WDO1 to WDO8

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In case of process I/O HA

Example connection
Spark killer diode

0.3 A or less

Electrical characteristics Rated voltage Maximum applied voltage Maximum load current Output type

: : : :

24 VDC 30 VDC 0.3 A Relay connect output

Spark killer diode Rated peak reverse voltage : 100 V or more Rated effective forward current : 1 A or more NOTE Do not use the +24 V power supply of the robot. When you load a relay, solenoid, and so on directly, connect them in parallel with diodes for preventing back electromotive force. If a load is connected causing a surge current when a lamp is turned on, use a protective resistance. Applicable signals -- Output signals on the arc--welding interface -- WDO1 to WDO4

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(2) Digital input signal specifications for arc welding interface

Example connection

Electrical characteristics of receivers Type: Grounded voltage receiver Rated input voltage : +20 to +28 V with contacts closed 0 to +4 V when open Maximum input voltage : +28 VDC Input impedance : About 3.3 k Response time : 5 to 20 ms Contact specifications for peripherals Rated contact capacity : 30 VDC, 50 mA or more Input signal width : 200 ms or more for on and off states Chattering period : 5 ms or less Closed--circuit resistance : 100 or less Open--circuit resistance : 100 k or more

(Signal) Contact signal for peripheral

(Signal)

Receiver signal for robot

TB: Chattering of 5 ms or less TC: 5 to 20 ms

NOTE Supply the +24 V power, provided for the robot, to the receivers. The receiver signal on the robot must satisfy the signal timing specified above. Applicable signals -- Input signals for arc welding interface -- WDI1 to WDI8
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(3) Analog output signal specifications for arc welding interface (Welding voltage command, wire--feed rate command)
Example connection
Welder

Process I/O CA, EA : --10V to +10V Process I/O GA, HA : 0V to +15V 0V

NOTE Input impedance: 3.3 k or more Connect a high--pass filter. (4) Analog input signal specifications for arc welding interface (Welding--voltage detection, welding--current detection)
Example connection
Welder --10V to +10V 0V

NOTE The analog input signal should have no ripple for the circuit to operate properly. (Wire deposit detection: WDI+ and WDI--)
Example connection
Welder

Welding electrode

NOTE Connect a resistor of 100 or more between the positive and negative electrodes of the welder. Isolate the deposit detection signals for TIG welding from the welding circuit, which uses high--frequency components. The dielectric withstand voltage of this circuit is 80 V.

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4.6
SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS 4.6.1
Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins)

If the customer manufactures cables, conform to the FANUC standard cables described in this section. (See the description in Peripheral Device Interface in this manual for the specifications of the FANUC standard cables.)

Honda Tsushin MR50LWF01 (MR50LF) Process I/O

Honda Tsushin MR50LM01 (MR50LM) Peripheral device

Honda Tsushin MR50RMA

Honda Tsushins MR50RF Supplied with an ordered cable

4.6.2
Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins)
Honda Tsushin MR20LWF01 (MR20LF) Process I/O CRM4* Honda Tsushin MR20LM01 (MR20LM) Peripheral device

Honda Tsushin MR20RMA

Honda Tsushins MR20RF Supplied with an ordered cable

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CONNECTIONS

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4.6.3
ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins)

Be sure to use our cable to connect the welder.

ARC welder Honda Tsushin

Process I/O CRW1 or CRW7

Honda Tsushin MR34RFA

Japan Aviation Electronics Industry Ltd. MS3108B28--21P MS3057--16

Japan Aviation Electronics Industry Ltd. MS3102A28--21S Standard position of guide key

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4.7
CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS, AND ARC WELDERS 4.7.1
Peripheral Device Connection Cable
B cabinet CRM2A CRM2B

Fig. 4.7.1 shows the connection of the peripheral device cable in the cabinet.

Metallic clamp External shield To peripheral device

Process I/O

CRW1 or CRW7 Shield plate Noise protection: Remove a part of the sheath of a peripheral cable to expose the outside shield. Secure the cable to the shield plate with the metallic clamp at the exposed position.

Fig.4.7.1 Peripheral Device Cable Connection

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4.7.2
Peripheral Device Cable Connector
(1) Fig. 4.7.2 shows the connector for peripheral device cables A and B.

Connector specifications MR50LM MR20LM

Applicable interface CRM2 CRM4

Dimensions A 67.9 39.3 (B) 73.5 44.9 C 44.8 39.8 (D) 18 17 Remark Honda Tsushin Kogyo, 50 pins Honda Tsushin Kogyo, 20 pins

Symbol Connector cover Cable clamp screw

Name

Connector clamp spring Connector clamp screw Connector 50 pins (male) MR50M 20 pins (male) MR20M

Fig.4.7.2 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo)

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(2) Peripheral device connector

Connector specifications MR50RF MR20RF

Applicable interface (CRM2) (CRM4)

Dimensions A 61.4 39.3 B 56.4 44.9

Remark Honda Tsushin Kogyo, 50 pins Honda Tsushin Kogyo, 20 pins

Symbol

Name Connector clamp screw Screw M2.68 Connector (MR50RF) (MR20RF)

Fig.4.7.2 (b) Peripheral Device Connector (Honda Tsushin Kogyo)

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4.7.3
End Effector Cable Connector
(1) Connector external view (For R--2000iA. Refer to the each maintenance manual for other robots.)

A : M301 E : 33 B : 63.0 F : 11.2 C : 54.5 G : 24.7 D : 9.6 to 15.0 (Inside diameter) Manufactured by Daiichi Denshi Kogyo JMLP2524M

Fig.4.7.3 (a) Connector (Elbow Type)

A : M301 E : 33 B : 54.1 F : 11.2 C : 37.5 G : 24.7 D : 9.6 to 15.0 (Inside diameter) Manufactured by Daiichi Denshi Kogyo JMLP2524M

Fig.4.7.3 (b) Connector (Straight Type)

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4.7.4
Recommended Cables
(1) Peripheral device connection cable Connect a peripheral device using a completely shielded, heavily protected cable conforming to the specifications in Table 4.7.4 (a). Allow an extra 50 cm for routing the cable in the control unit. The maximum cable length is 30 m.

Table 4.7.4 (a) Recommended Cable (for Peripheral Device Connection)

Conductor Number of wires 50 20 Wire specifications (FANUC specifications) A66L-0001-0042 A66L-0001-0041 Diameter (mm) 1.05 1.05 Configuration 7/0.18 AWG24 7/0.18 AWG24 Sheath thickness (mm) 1.5 1.5 Effective outside diameter (mm) 12.5 10.5 Electrical characteristics Conductor resistance (/km) 106 106 Allowable current (A) 1.6 1.6

(2) End effector connection cable Connect an end effector using a heavily protected cable with a movable wire conforming to the specifications in Table 4.7.4 (b). The cable length is determined so that the cable will not interfere with the end effector and the wrist can move through its full stroke.
Table 4.7.4 (b) Recommended Cable (for End Effector Connection)
Conductor Number of wires 6 20 Wire specifications (FANUC specifications) A66L-0001-0143 A66L-0001-0144 Diameter (mm) 1.1 1.1 Configuration 40/0.08 AWG24 40/0.08 AWG24 Sheath thickness (mm) 1.0 1.0 Effective outside diameter (mm) 5.3 8.6 Electrical characteristics Conductor resistance (/km) 91 91 Allowable current (A) 3.7 2.3

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4.8
CONNECTION OF HDI 4.8.1
Connecting HDI
The HDI signals are used in combination with special application software. The HDI signals cannot be used as general--purpose DIs.

Main board

JRL5

R--J3iB Main board JRL5

1 2 3 4 5 6 7 8 9 10 HDI0 0V HDI2 0V 0V HDI4 11 12 13 14 15 16 17 18 19 20 HDI1 0V HI3 0V HDI5 0V HDI6 0V HDI7 0V

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Cable connections
JRL5 HDI0 0V HDI1 0V HDI2 0V HDI3 0V HDI4 0V HDI5 0V HDI6 0V HDI7 0V 1 2 11 12 3 4 13 14 6 5 or 10 15 16 17 18 19 20 7 8 9 10 Shield Ground plate

Recommended cable connector: PCR--E20FA (Honda Tsushin Kogyo) FI30--20S (Hirose Electric) FCN--247J020--G/E (Fujitsu) 52622--2011 (Molex Japan)

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4.8.2
Input Signal Rules for the High--speed Skip (HDI)
Circuit configuration

R--J3iB
DRIVER liL/liH FILTER VH/VL SHIELD RECEIVER

Absolute maximum rating Input voltage range Vin: --3.6 to +10.0 V Input characteristics
Unit High level input voltage Low level input voltage High level input current Symbol VH VL liH Specification 3.6 to 7 0 to 1.0 2 max 11 max Low level input current Input signal pulse duration Input signal delay or variations liL --8.0 max 20 min 0.02(max) Unit V V mA mA mA s ms Vin=5 V Vin = 10 V Vin = 0 V Remark

NOTE 1 The plus (+) sign of IiH/IiL represents the direction of flow into the receiver. The minus (--) sign of IiH/IiL represents the direction of flow out of the receiver. 2 The high--speed skip signal is assumed to be 1 when the input voltage is at the low level and 0 when it is at the high level.

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4.9
CONNECTING THE COMMUNICATION UNIT 4.9.1
RS--232--C Interface

4.9.1.1
Interface

This interface can be connected to a handy file or another communication unit from FANUC.
RS--232--C port

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R--J3iB Main board Operators panel connector (DBM--25S) 1 2 3 4 5 6 7 8 9 10 11 12 13 FG SD RD RS CS DR SG 14 15 16 17 18 19 20 ER 21 22 23 24 25 +24V

NOTE 1 +24 V can be used as the power supply for FANUC RS--232--C equipment. 2 Do not connect anything to those pins for which signal names are not indicated.

4.9.1.2
RS--232--C Interface Signals

Generally signals as follows are used in RS--232--C interface.

R--J3iB Output Input RD (Recieve data) RS (Request to Send) CS (Enable to send) ER (Ready) DR (Data set ready) SG (Signal ground) FG (Frame ground) When DR is not used short DR and ER. SD (Send data)

When CS is not used short CS and RS.

Fig.4.9.1.2 RS--232--C interface

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4.9.1.3
Connection between RS--232--C Interface and External Device

The figure below shows a connection with the handshaking of the ER and DB signals.

R--J3iB
SD SD

External device side

RD

RD

RS

RS

CS

CS

ER

ER

DR

DR

CD

CD

SG

SG

FG

FG

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D The figure below shows a connection without the handshaking of the ER and DB signals.

R--J3iB
SD SD

External device side

RD

RD

RS

RS

CS

CS

ER

ER

DR

DR

CD

SG

SG

FG

FG

Prepare the cable as follows :

R--J3iB SD RD RS CS SG ER DR

Cable : twist 10 pairs

0.18mm2, with shield

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4.9.2
Ethernet Interface
CAUTION Before connecting or disconnecting cables to and from the Ethernet board, cut the power supply of R--J3iB, and make sure that the power is off.

NOTE Please inqure of each manufacturer about the network construction or the condition of using the equipment except the Ethernet board (hub, transceiver, cable etc.). When configuring your network, you must take other sources of electrical noise into consideration to prevent your network from being influenced by electrical noise. Make sure that network wiring is sufficiently separated from power lines and other sources of electrical noise such as motors, and ground each of the devices as necessary. Also, a high and insufficient ground impedance may cause interference during communications. After installing the machine, conduct a communications test before you actually start operating the machine. We cannot ensure operation that is influenced by network trouble caused by a device other than the main board.

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4.9.2.1
Connection to Ethernet

The main board is provided with a 10/100 BASE--T interface. Prepare a hub for connecting the Ethernet board to the Ethernet trunk. The following shows an example of a general connection.

S S S

R--J3iB

Some devices (hub, transceiver, etc.) that are needed for building a network do not come in a dust--proof construction. Using such devices in an atmosphere where they are subjected to dust or oil mist will interfere with communications or damage the Ethernet board. Be sure to install such devices in a dust--proof cabinet.

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4.9.2.2
10/100 BASE--T Connector (CD38) Pin Assignments

CD38
Pin No. 1 2 3 4 5 6 7 8 RX-Signal Name TX+ TX-RX+ Send + Send -Receive + Not used Not used Receive -Not used Not used Description

4.9.2.3
Cable Connection

The figure below shows the cable connection between the 10/100 BASE--T connector (CD38) of the main board and hub.

10/100BASE--T connector

D For details on shielding, see 4.9.2.6 Cable clamp and shielding. D Keep the total cable length to within 100 m. Do not extend the cable longer than necessary.

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4.9.2.4
Lead Materials

Unshielded cable (UTP cable) is commercially available as 10/100 BASE--T twisted--pair cable. However, be sure to use shielded Category 5 twisted--pair cable (STP) to improve the resistance to electrical noise in an FA environment. (For details on shielding, see 4.9.2.6 Cable clamp and shielding. Recommended Cable
Manufacturer Furukawa Electric Co., Ltd. Nissei Electric Co., Ltd. DTS5087 F--4PFWMF Specification

Inquiries
Manufacturer Furukawa Electric Co., Ltd., Sales Headquarters Contact Address Maru--no--uchi 2--6--1, Chiyoda--ku. Tokyo 100--8322 TEL: 03--3286--3126 FAX: 03--3286--3979 Remarks Nissei Electric Co., Ltd., Machida Branch 3F MU Bldg., Minami--narise 1--9--1, Machida City, Tokyo 194--0045 TEL: 0427--29--2153 FAX: 0427--29--3375

Overseas Sales Office NISSEI ELECTRIC CO., LTD 1509 Okubo--cho, Hamamatsu--shi Shizuoka--ken, 432--8006 Japan TEL: 053--485--4114 FAX: 053--485--6908 E--mail: KYH05470@niftyserve.or.jp Remarks Cables with connectors at both ends can be supplied.

NOTE The recommended cables cannot be connected to movable portions. Recommended Cable (For movable parts)
Manufacturer Oki Electric Cable Co., Ltd. Specification AWG26 4P TPMC--C5--F(SB) Remarks FANUC--specific cable

Cable specifications (FANUC--specific cable No connector) Drawing number: A66L--0001--0453 Manufacturer: Oki Electric Cable Co., Ltd. Nagano Sales Office TEL: 0266--27--1597

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Specifications D Electric characteristics: Conform to EIA/TIA 568A categories 3 and 5. For reasons related to attenuation performance, the distance to the hub must be 50 m or shorter. D Structure: Common shield cable (braided shield). Drain wire provided. The conductor is AWG26 annealed copper stranded wire. The sheath thickness is 0.8 mm. The outside diameter is 6.70.3 mm. D Flame resistance: UL1581 VW--1 D Oil resistance: Based on the FANUC standard. (equivalent to the conventional oil--resistant electric cables) D Flexing resistance: 1 million times or more with 50 mm of a bend radius (U--shape flexing test) D UL style No.: AWM 20276 (80C/30 V/VW--1) NOTE Always use connector TM21CP--88P(03) manufactured by Hirose Electric for this cable. Cable assembly Oki Electric Cable Co., Ltd. also supplies cable assemblies using connector TM21CP--88P(03) manufactured by Hirose Electric. Make arrangements directly with the manufacturer for the specifications (length, outgoing inspection, packing, and others) and purchase cable assemblies. Contact point: Oki Electric Cable Co., Ltd. Sales contact point) Nagano Sales Office TEL: 0266--27--1597

4.9.2.5
Connector Specification

As a connector used with a twisted pair cable for Ethernet, an 8--bit modular connector called RJ--45 is used. Use the following connector or equivalent:
Specification
For solid wire For solid wire For twisted wire For twisted wire 5--569530--3 MS8--RSZT--EMC 5--569552--3 TM11AP--88P

Manufacturer
AMP Japan, Ltd. SK KOHKI Co., Ltd. AMP Japan, Ltd. Hirose Electric Co., Ltd.

Remarks
Special tool required Special tool required

For movable parts

For cable AWG26 4P TPMC--C5--F(SB)

Specification
TM21CP--88P(03)

Manufacturer
Hirose Electric Co., Ltd.

Remarks
(Note)

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NOTE TM21CP--88P(03) Connector (manufacturer standard part) Drawing number: A63L--0001--0823#P Manufacturer: Hirose Electric Co., Ltd. Manufacturer catalog number: TM21CP--88P(03) Conforms to EIA/TIA 568A categories 3 and 5. For how to assemble the connector and cable, contact Hirose Electric. (Hirose Electric technical document TM21CP--88P(03) Connection Procedure Specifications (technical specification No. ATAD--E2367) is available.)

4.9.2.6
Cable Clamp and Shielding

Shield the cables as like as other cables are shielded. (See 4.7.1)

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4.9.2.7
Grounding the Network

Even if the grounding conditions on the machine are satisfied, electrical noise from the machine sometimes enters the communications line and causes communications interference depending on the installation conditions and the peripheral environment of the machine. To prevent the entry of such electrical noise, separating and insulating the machine from the Ethernet trunk cable and the personal computer effectively reduces the influence of electrical noise. The following figure shows an example of such a connection.

Electrically separated by 10/100 BASE--T cable connection

Large--scale Network

Electrically separated by 10/100 BASE--T cable connection

Small--scale Network

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NOTE 1 The ground between the PC/Trunk line side and machine system side must be separated. If it is impossible to separate the ground because there is only one grounding point, connect the ground cable for each system to the grounding point independently. (Refer Fig.1) The resistance for grounding must be less than 100--ohm (Class 3). The thickness of the ground cable is the same as the thickness of AC power cable or more. At least thickness of 5.5mm2 is necessary. 2 Please use the HUB that has unshielded interface connector. FANUC recommends the HCN--7500 (Hitachi--Densen LTD) or equivalent. 3 There is the possibility that noise makes the obstacle of communication even if the ground is separated using the 10/100 BASE--T. In the case of using the Ethernet board under the worst environment, please separate between the PC/Trunk line side and machine system side completely using the 10/100 BASE--FL (Optical fiber media).

Fig.4.9.2.7 Wiring on a Single Ground Point

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TRANSPORTATION AND INSTALLATION

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5.1
TRANSPORTATION

This section describes the transportation and installation for the control unit. The control unit is transported by a crane. Attach a strap to eye bolts at the top of the control unit.

B--cabinet

Fig.5.1 Transportation

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5.2
INSTALLATION 5.2.1
Installation Method
Following is the installation method for B--cabinet. When installing the control unit, allow the space for maintenance shown in the following figure.

Fig.5.2.1 (a) External dimension

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300

100 Controller

740 Controller 550

100 Controller

100

1000

Fig.5.2.1 (b) Installation Method (B--cabinet)

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5.2.2
Assemble at installation
Teach pendant

R--3iB controller

Input power connection cable

Peripheral device connection cable Robot connection cable

Fig.5.2.2 (a) Assemble at Installation (B--cabinet)

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5.3
INSTALLATION CONDITION
Item Transformer Model All models Specifications/condition I 440--480, 500--575 VAC (+10%--15%) II 380--415, 440--500 VAC (+10%--15%) III 200--230, 380--400 VAC (+10%--15%) 50/60Hz1Hz 3phases 12KVA 2.5KVA 2.5KW 1.0KW 0 to 45 C during operation, and --20 to 60C during shipment and storage with a temperature coefficient of 1.1C/min Relative humidity: 30% to 95%, non--condensing An additional protective provision is necessary if the machine is installed in an environment in which there are relatively large amounts of contaminants (dust, dielectric fluid, organic solvent, acid, corrosive gas, and/of salt). 0.5G or less. When using the robot in a location subject to serious vibration, consult with your FANUC sales representative. Not higher than 1,000m above sea level A shielding provision is necessary if the machine is installed in an environment in which it is exposed to radiation (microwave, ultraviolet rays, laser beams, and/or X-rays). Approx. 120kg Approx. 180kg

Input p p power source capacity p y

R--2000iA M--6iB ARC Mate100iB

Average power consumption g p p

R--2000iA M--6iB ARC Mate100iB

Permissible ambient temperature Permissible ambient humidity Surrounding gas

All models

All models All models

Vibration

All models

Altitude Ionized and nonionized radiation

Common to all models Common to all models

Mass of control unit

A--cabinet B--cabinet

NOTE During rapid acceleration, robot power draw can be several times the continuous rating value.

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5.4
ADJUSTMENT AND CHECKS AT INSTALLATION

Adjust the robot according to the following procedure at installation.

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Description Visually check the inside and outside of the control unit. Check the screw terminals for proper connection. Check that the connectors and printed circuit boards are firmly connected. Check transformer tap setting. (See II MAINTENANCE section 6.2) The breaker off and connect the input power cable. Check the input power voltage and transformer outputs. Press the EMERGENCY STOP button on the operator panel and turn on the control unit. Check the interface signals between control unit and robot 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 manual jog mode. Check the end effector interface signals. Check the peripheral device control interface signals.

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5.5
RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION

An overtravel and emergency stop occur when the robot is operated for the first time after it is installed and the mechanical and control units are wired. This section describes how to reset the overtravel and emergency stop. Remove the red plate fastening the swiveling axis beforehand. The J2 and J3 axes are pressed against the hard stops at shipment. Therefore, an overtravel alarm occurs when the power is turned on after installation. The robot can also be in an emergency stop state if the peripheral device control interface is not connected.

5.5.1
Peripheral Device Interface Processing

Take the following actions if signals *IMSTP, *HOLD, *SFSD, and ENBL are not used.
CRM2A +24F 49, 50

*IMSTP

RV
*HOLD

RV
*SFSD

RV ENBL RV 4

5.5.2
Resetting Overtravel

1) Select [OT release] on the overtravel release screen to release each robot axis from the overtravel state. 2) Hold down the shift key, and press the alarm release button to reset the alarm condition. 3) Still hold down the shift key, and jog to bring all axes into the movable range.

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5.5.3
How to Disable/Enable HBK
Hand Broken enable/ disable setting Enable Enable Disable Disable

1) 2) 3) 4) 5)

Press [MENUS] on the teach pendant. Select [NEXT]. Select [SYSTEM]. Press F1 (TYPE) on the teach pendant. Select Config to disable/enable HBK.
HBK detection Yes Yes Yes(*2) No Robot operation Possible Impossible Possible Possible Message None SRVO--006 None At cold start, SRVO--300

Status 1 2 3 4

HBK (*1) CLOSE OPEN CLOSE OPEN

Notes 1 Robot end effector connector

CLOSE 24V 24V OPEN

*HBK

*HBK

2 The moment the HBK circuit is closed, HBK detection becomes enabled. When the HBK circuit is opened again, alarm Servo 300 or Servo 302 occurs, causing the robot to stop. 3 If the power is turned off and on again under the condition stated in *2, status 4 is entered, so the alarm condition is removed.

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5.5.4
How to Disable/Enable Pneumatic Pressure Alarm (PPABN)

1) 2) 3) 4) 5)

Press [MENU] on the teach pendant. Select [NEXT]. Select [SYSTEM]. Press F1 (TYPE) on the teach pendant. Select Config to disable/enable PPABN.

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A. TOTAL CONNECTION DIAGRAM

TOTAL CONNECTION DIAGRAM

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Fig.A (a) Total connection diagram (B--cabinet)

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Fig.A (b) Transformer type I (B--cabinet) (1/3)

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Fig.A (b) Transformer type II (B--cabinet) (2/3)

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Fig.A (b) Transformer type III (B--cabinet) (3/3)

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Fig.A (c) Power supply unit

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Fig.A (d) Main CPU

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Fig.A (e) E--stop unit (B--cabinet, 1/2)

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Fig.A (e) E--stop unit (B--cabinet, 2/2)

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Fig.A (f) 6--axis servo amplifier (1/2)

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Fig.A (f) 6--axis servo amplifier (2/2)

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Fig.A (g) Motor power connection (R--2000iA)

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Fig.A (h) Motor power connection (M-6iB, ARC Mate 100iB)

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A. TOTAL CONNECTION DIAGRAM

Fig.A (i) Operator panel (without E--stop)

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Fig.A (j) Operator panel (B--cabinet)

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Fig.A (k) Mechanical interface

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Fig.A (l) I/O device (B--cabinet) (1/2)

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Fig.A (l) I/O device (interface) (2/2)

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Fig.A (m) Emergency stop circuit of B--cabinet

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A. TOTAL CONNECTION DIAGRAM

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B.1
SIGNALS

The following table lists the I/O signals used for the peripheral device interface in the R-J3iB controller.
Input signals (Refer to B.3.1) Signal *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 PNSTROBE PROD_START SDI01 SDI02 SDI03 SDI04 SDI05 SDI06 SDI07 SDI08 SDI09 SDI10 SDI11 SDI12 SDI13 SDI14 SDI15 SDI16 SDI17 SDI18 SDI19 SDI20 SDI21 SDI22 Description Instantaneous stop signal Hold signal Safety speed signal Cycle stop signal Alarm release signal Cycle start signal Robot service request/program number select signal (*1) Enabling signal Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) PNS strobe signal Automatic operation start signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal

*1: RSR : Robot Service Request (RSR5 to RSR8 are optional)

PNS : Program Number Select Input (optional) Whether RSR is used or PNS is used can be preset.

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Output signals (Refer to B.3.2) Signal CMDENBL SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK ______ SDO01 SDO02 SDO03 SDO04 SDO05 SDO06 SDO07 SDO08 SDO09 SDO10 SDO11 SDO12 SDO13 SDO14 SDO15 SDO16 SDO17 SDO18 SDO19 SDO20 Description Command acceptance enabled signal System ready signal Program run signal Program paused signal Held signal Alarm signal Reference point signal Teach pendant enabled signal Battery alarm signal Operating signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal PNS acknowledge signal Not used (for future expansion) General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal

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B.2
SETTING COMMON VOLTAGE

All process I/O printed boards have a jumper to set the common voltage of input signals to 0 V or 24 V. The system automatically adjusts the polarity by software according to the status of this pin. Therefore, you can operate the system without being concerned about the setting of the common voltage. To ensure safety, the common reference voltage of the following four signals, is remains at +24V. *IMSTP *HOLD *SFSPD CSTOPI

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B.3
I/O SIGNALS B.3.1
Input Signals
This section describes the specifications of each input signal. (1) Instantaneous stop signal (input) *IMSTP Effective Function : At any time : Use the normally-closed switch because it is a reverse signal. The system turns off power to the servo unit when the *IMSTP is open (turned off). This signal has the same effect as that of the emergency stop signal, but it is controlled by software. For this reason, use the emergency stop external interface on the emergency stop control board for wiring of the emergency stop signal. Do not use *IMSTP.

(2) Alarm release signal (input) FAULT RESET Effective Function : In the alarm status : The FAULT RESET signal releases the alarm status. If the servo unit has been turned off, it also turns on the unit. At the same time, the alarm display on the teach pendant (the top line) is cleared. Description : This signal releases only the alarm status. It does not re-start execution of the program. The robot will keep running if the signal is triggered ON during operation. : At any time : Use the normally-closed switch because it is a reverse signal. The *HOLD signal has the same function as the hold button on the operator panel. It halts the current program and stops the operation of the robot. While this signal is being input, the held signal (output) HELD is turned on and the robot cannot be operated.

(3) Hold signal (input) *HOLD Effective Function

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(4) Start signal (input) START Effective : When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details. : This input signal starts the selected program at the falling edge when the signal is turned off after being turned on. Its function differs according to the setting of parameter $SHELL_CFG.$CONT_ONLY. - If parameter $SHELL_CFG.$CONT_ONLY is set to DISABLED, the START signal starts the program which has been selected from the teach pendant. By default, the program starts from the current cursor position. - If parameter $SHELL_CFG.$CONT_ONLY is set to ENABLED, the START signal only resumes the execution of the temporarily held program. To execute an inactivated program from the start, input the PROD_START signal. : At any time : - If parameter $SHELL_CFG.$USE_ABORT is set to DISABLED, the CSTOPI signal releases the program from the wait status caused by an RSR. It does not stop the execution of the current program and allows it to continue processing (by default). - If parameter $SHELL_CFG.$USE_ABORT is set to ENABLED, the CSTOPI signal immediately cancels the execution of the current program. The program returns to the status in which it was before execution, and the information for the subprogram to return to the main program is lost. At the same time, this signal also releases the program from the wait status caused by RSR. : At any time : If the ENBL signal is turned off, the operation of the robot or the activation of a program is inhibited, and the execution of the current program is suspended.

Function

(5) Cycle stop signal (input) CSTOPI Effective Function

(6) Enabling signal (input) ENBL Effective Function

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(7) Safety speed signal (input) *SFSPD Effective Function : At any time : - Use the normally-closed switch because it is a reverse signal. Usually this switch should be connected to safety fence. It must be set normally on. - Since the *SFSPD signal is counted as a remote condition, such input signals as RSR and START to the peripheral device interface cannot take effect unless this signal is turned on. - If this signal is turned from on to off during robot operation, the execution of the current program is suspended. At the same time, the overriding value is switched to a preset value (parameter $SCR. $FENCEOVER.) - As long as this signal is off, the overriding value cannot be increased beyond the preset value ($SCR.$SFJOGOVLIM: For jog, $SCR. $SFRUNOVLIM : For test execution.)

(8) Robot service request signal (input) RSR1/RSR2/RSR3/RSR4 Effective : When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details. : - The user can choose between RSR and PNS (optional), although they cannot be used simultaneously. - Four input signals, RSR1 to RSR4, are used. - If a signal is input to an RSR input, a specified. program is started. The program number can be set by a menu. - If another program has already started processing, the newly activated program enters the wait status. As soon as the current program terminates, the waiting program starts processing. - By using an RSR instruction, each RSR in a program can be enabled or disabled. - A menu is provided to register the program number of a specified program when each RSR is input. (Refer to the application manual for details of the menu).

Function

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- When an RSR is input, the program whose program name consists of the specified program number plus a base value is started. For exam ple, if a signal is input to RSR2 when program number 23 is registered in RSR2, the program to be started is the one with the program name calculated from the expression RSR + (RSR2 program number + base number), i.e., RSR0123. The base number is stored in parameter $SHELL_CFG.$JOB_BASE, and can be changed in a program with a parameter instruction. (For example, $SHELL_ CFG. $JOB_BASE =100). In this way, the combination of programs which can be started by RSRs can be changed. - Whether the system should output an acknowledge signal to an RSR can be selected from the menu. If so specified, a pulse is output from the signal corresponding to the RSR, one of signals ACK1 to ACK4, when the input of the RSR is accepted. From the same menu, the width of the pulse can also be specified. It is possible to accept other RSRs while outputting an acknowledge signal. - Input of a CSTOPIT signal can clear the program queue waiting for execution after acceptance of RSRs. (9) PNS/PNSTROBE (input) Signal name : PNS : Program number select PNSTROBE: Strobe input for PNS Effective : When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details. Function : - The PNS/PNSTROBE signal selects whether the RSR function is used or the PNS function (optional) is used. If the PNS function is enabled, the RSR function cannot be used. - The eight signals PNS1 to PNS8 are used to specify a program at the instant the strobe signal PNSTROBE rises. - A menu is provided to specify the information about PNS.

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If a number other than zero is entered to PNS input, a program is selected whose program number is the entered value plus the base number. For example, if the PNS value is 23, the program to be started has the program name calculated from the expression PNS + (entered PNS value + base number), i.e., PNS0123. If zero is entered to PNS input, it is cleared as if no selection has been made. - A PNS signal, which can only select a program, cannot execute the selected program. The execution of the selected program can only be started after input of automatic operation start signal PROD_START. - For safety, the selected program cannot be changed from the teach pendant unless PNSTROBE is turned off. - If a program is selected by PNS, the program number is output to selected program number signal (output) SNO, and a pulse is output to program selection acknowledge signal SNACK. Using these signals, peripheral devices can confirm the correct program has been selected. For the timing of these signals, see the sections describing SNO and SNACK. - The following operations are effective for the program selected by PNS. You can: Start up a program by input of automatic operation start signal PROD_START Restart the program that has been suspended. Inputting the START signal restarts the program selected by PNS when $SHELL_CFG.$CONT_ ONLY is set to ENABLED. Input of CSTOPI cancels execution of the pro-grams selected by PNS when $SHELL_CFG.$USE_ ABORT is set to ENABLED. (10) Automatic operation start signal (input) PROD_START Effective : When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details. : This input signal executes the selected program at the falling edge when the signal is turned off after being turned on.

Function

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B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE

B.3.2
Output Signals

This section describes the specifications of output signals for the peripheral device interface. (1) Command acceptance enabled signal (output) CMDENBL Turned on : When the remote conditions are satisfied and the system is not in the alarm status Turned off : When the remote conditions are not satisfied or the system is in the alarm status The remote conditions are satisfied when all of the following are satisfied. - The teach pendant is in the DISABLED status. - The remote switch on the operators panel is set to REMOTE side. - Parameter $RMT_MASTER is set to 0 (external interface). - Signal *SFSPD is set to on, or in the normal status. (2) System ready signal (output) SYSRDY Turned on : When power is applied to the motor of the robot. Turned off : When power is not applied to the motor of the robot. (3) Program run signal (output) PROGRUN Turned on : When the program is being executed. Turned off : When the program is not being executed. (4) Held signal (output) HELD This signal is used to check the status of the hold input. Turned on : When the hold button (or input) is being pressed down (or turned on). Turned off : When the hold button (or input) is not being pressed down (or is turned off). (5) Program paused signal (output) PAUSED This signal is used together with output signal PROGRUN to determine whether a program can be restarted while it is being held. Turned on : When a program is held and has not been restarted yet. While this signal is on, the program can be restarted and retains information such as that to return from a subprogram to the main program. Turned off : When a program is being executed or is ready to start. If signal PROGRUN is on, the program is being executed. If signal PROGRUN is off, the program has not been executed and can be started from this status. (6) Alarm status signal (output) FAULT Turned on : When the system is in the alarm status (or an alarm which can stop a program execution is detected.) The indicator lamp does not go on in warning. Turned off : When the alarm status is released by an alarm release operation.
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B--81465EN--1/02

(7) Reference point signal (output) ATPERCH Turned on : When the robot is in the reference position specified in the parameter. (the reference point No.1 in reference point setup screen.) Turned off : When the robot is not in the reference position specified in the parameter. (the reference point No.1 in reference point setup screen.) Up to three reference positions can be specified, but this signal is output when the robot is in the first reference position. For the other two reference positions, general-purpose signals can be assigned to output as such. (They can be set from the setup screen.) (8) Teach pendant enabled signal (output) TPENBL Turned on : When the teach pendant is enabled. Turned off : When the teach pendant is disabled. (9) Battery alarm signal (output) BATALM Turned on : When the voltage of the battery for the CMOS memory backup drops below the reference. Turned off : When the voltage of the battery for the CMOS memory backup is at the normal level. (10) Operating signal (output) BUSY Turned on : When a program is being executed or is being processed from operation panels such as the teach pendant. (This has the same function as that of the BUSY lamp on the teach pendant.) Turned off : When a program is not being executed nor is being processed from operation panels such as the teach pendant.

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B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE

(11) RSR acknowledge signals (output) ACK1/ACK2/ACK3/ACK4 These signals are used together with the RSR function. They can be specified to be enabled or disabled from the RSR setup menu. Turned on : When one of the signals from RSR1 to RSR4 is input and accepted. A pulse whose width is specified from the menu is output to acknowledge the signal. Turned off : Normally. Since these signals are always output as pulses, they are normally in the off status. The following chart shows the timing of the RSR input and ACK output.

CMDENBL (O) (The remote conditions need to be satisfied.) RSR1 (I) The maximum delay is 32 msec.

ACK1 (O) (The width of the pulse is set in the parameter.)

RSR2 (I)

ACK2 (O)

RSR3 (I)

ACK3 (O)

RSR4 (I)

ACK4 (O)

* Other RSR signals can be accepted even when the ACK signal is being output.

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(12) PNS acknowledge signal (output) SNO/SNACK These signals are used together with the PNS function. Turned on : Whenever the PNS function is enabled. The selected program number is displayed in binary code (SN01 to SN08) on the teach pendant. If the number cannot be represented as an eight-bit number, it becomes zero. After selecting a program by PNS, a pulse is output from signal SNACK as a part of the PNS operation. The width of the pulse can be specified from the menu. See the timing chart below.

CMDENBL (O) (The remote conditions need to be satisfied.)

PNS1-8 (I)

(A value is input.)

PNSTROBE (I) Detection and processing of PNSTROBE by software.

(A strobe is input for PNS.)

(PNS is read within a maximum of 32 msec after PNSTROBE is turned on.)

SNO1-8 (O)

SNACK (O)

PROD_START (I)

(Program execution starts within 32 msec.)

PROGRUN (O)

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APPENDIX

B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE

B.4
SPECIFICATIONS OF DIGITAL INPUT/OUTPUT B.4.1
Overview
This section describes the external specifications of digital and analog input/output in the R--J3iB controller.

B.4.2
Input/Output Hardware Usable in the R-J3iB Controller

The R--J3iB controller can use up to 512 digital input and output points or an equivalent number of analog input and output points. One analog input/output point uses the resources equivalent to those used by 16 digital I/O points. The R--J3iB can use a total of up to 512 I/O points. The R--J3iB controller can use the following I/O hardware. - Process I/O printed circuit board - I/O unit model A The process I/O printed circuit board and the I/O unit model A can be used together.

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B--81465EN--1/02

B.4.3
Software Specifications
(1) RDI/RDO These are signals sent to the connector at the wrist of the robot. They cannot be assigned (redefined) and are fixed. The standard format is eight inputs and eight outputs. The number of points that can be used for the connector at the wrist depends on the individual robot. (2) SDI/SDO The signal No. that is determined at hardware can be changed by software operation. (3) Analog I/O An analog I/O signal can access the analog I/O port (optional) on the process I/O printed circuit board or the I/O port on the analog I/O module (used together with the I/O unit model A). It reads and writes the digital value converted from the analog value of the I/O voltage. It means that the value does not always represent the real I/O voltage. (4) Group I/O Group I/O is a function which can input or output multiple DI/DO signals as binary codes. Any number of continuous signals of up to 16 bits can be set for its use. It can be set in the menu DETAILS on the group I/O screen.

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APPENDIX

C. POWER DISTRIBUTION CIRCUIT DIAGRAM

POWER DISTRIBUTION CIRCUIT DIAGRAM

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C. POWER DISTRIBUTION CIRCUIT DIAGRAM

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B--81465EN--1/02

Fig.C (a) 200VAC Power supply Circuit Diagram (B--cabinet)

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C. POWER DISTRIBUTION CIRCUIT DIAGRAM

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C. POWER DISTRIBUTION CIRCUIT DIAGRAM

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B--81465EN--1/02

Fig.C (b) +5V, +3.3V, +15V, --15V Power Supply Circuit Diagram (B--cabinet)

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APPENDIX

C. POWER DISTRIBUTION CIRCUIT DIAGRAM

Fig.C (c) Robot Mechanical Unit +5V Power Supply Circuit Diagram

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C. POWER DISTRIBUTION CIRCUIT DIAGRAM

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B--81465EN--1/02

Fig.C (d) +24V Power Supply Circuit Diagram (B--cabinet)

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APPENDIX

C. POWER DISTRIBUTION CIRCUIT DIAGRAM

Fig.C (e) Robot Mechanical Unit +24V Power Supply Circuit Diagram

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D. OPTICAL FIBER CABLE

APPENDIX

B--81465EN--1/02

OPTICAL FIBER CABLE

The R--J3iB uses fiber optic cables for communication between the main board and servo amplifiers. Observe the following cautions when handling these fiber optic cables. Handle fiber optic cables with utmost care, especially when installing the unit. (1) Protection during storage When the electrical/optical conversion module (mounted on the printed) circuit board and the fiber optic cable are not in use, their mating surfaces must be protected with the lid and caps with which they are supplied. If left uncovered, the mating surfaces are likely to become dirty, possibly resulting in a poor cable connection.
Electrical/optical conversion module Lid

Fiber optic cable

Fiber optic cable caps

Fig.D(a) Protection of electrical/optical conversion module and fiber optic cable (when not in use)

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D. OPTICAL FIBER CABLE

(2) Fiber optic cable D Although the reinforcing cover of the external optical cable has sufficient mechanical strength, be careful not to drop heavy objects on the cable. D Grasp the optical connector firmly when connecting or disconnecting the cable. Do not pull on the fiber optic cord itself. (The maximum tensile strength between the fiber cord and connector is 2 kg. Applying greater force to the cord is likely to cause the connector to come off, making the cable unusable.) Fiber optic cord diameter : 2.2 mm 2 cords Diameter of cable with reinforced cover : 7.6 mm Tensile strength : Cable with reinforced cover :75 kg Fiber optic cord :7 kg per cord Between fiber optic cord and connector : 2 kg Minimum bending radius of fiber optic cord :25 mm Minimum bending radius of cable with reinforced cover : 50 mm Bending resistance (cable with reinforced cover) : 10 million bending cycles at room temperature (when the bending radius is 100 mm) Flame resistance : Equivalent to UL VW--1 Operating temperature : --20 to 70C

8.2 6.7 19 max. 60 max. 35typ.

21 Code Bush Reinforced cover

Fig.D(b) External dimensions of external optical cable Unit : mm

D Afler it is connected, the optical connector is automatically locked by the lock levers on its top. To remove the connector, release the lock levers and pull the connector. D Although optical connectors cannot be connected in other than the correct orientation, always take note of the connectors orientation before making the connection. D Take care to keep both parts of the optical connector (cable side and PCB side) clean. If they become dirty, wipe them with tissue paper or absorbent cotton to remove dirt. The tissue paper or absorbent cotton may be moistened with ethyl alcohol. Do not use any organic solvent other than ethyl alcohol. D Fix the reinforcing cover by using a cable clamp, as shown in Fig. D(c), to prevent the weight of the fiber optic cable from being applied directly to the connecting part of the optical connector.
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B--81465EN--1/02

Optical connector

Part of optical fiber cord

Part of reinforcing cover

Bending radius of 25 mm or more (Make the bending radius as large as possible.) Cable clamp (Dont clamp tight) Bending radius of 50 mm or more (Make the bending radius as large as possible.)

Fig.D(c) Fixing the cable with a clamp

D Any superfluous portion of the cable might be wound into a loops. Should this prove necessary, make sure the diameter of each loop is at least 150 mm (for an external cable). Winding the cable into smaller loops can produce sharp curves that exceed the specified bend radius limit. Such bending can result in transmission loss, ultimately leading to a communication failure. D When using a nylon band (cable tie) as a cable clamp, follow the instructions given below. Also, take care not to apply a bending force to one particular part of the cable when fixing it with a clamp. Failing to clamp the cable correctly might cut or damage it. External cable : Do not clamp the uncovered portion of the cable with a nylon band. When clamping the cable by the reinforcing cover, the clamping force is not an important factor to consider. However, ensure that the clamping force is as small as possible to ensure that the reinforcing cover is not deformed by the clamping. If possible, the clamping force should be 5kg (111bs) or less.

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APPENDIX

E. CARD INTERFACE

CARD INTERFACE

Connector for card

Card

Card

Fig.E Precautions for card interface

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Index
[Numbers] [D]
Digital I/O Signal Specifications, 253 Driver Chip for Robot DI/DO, 156

10/100 BASE--T Connector (CD38) Pin Assignments, 277

[A]
Adjustment and Checks at Installation, 289 Alarm Occurrence Screen, 30 ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins), 262 Assemble at installation, 287

[E]
Electrical Connections, 203 Emergency Stop Control PC Board (A20B--1007--0800), 139 End Effector Cable Connector, 266 End Effector Control Interface, 255 Ethernet Interface, 275 External Cable Wiring Diagram, 206 External View of the Controller, 21

[B]
Backplane PC Board, 140 Battery for memory backup (3 VDC), 196 Block Diagram, 202 Block Diagram of the Main Power Including Power Supply, 158

[F]
Fused--Based Troubleshooting, 117

[G]
Grounding the Network, 281

[C]
Cable Clamp and Shielding, 280 Cable Connection, 277 Cable Connection for the Peripheral Devices, end Effectors, and ARC Welders, 263 Card Interface, 341 Checking the Power Supply Unit, 161 Component Functions, 25 Configuration, 20 Connecting the Communication Unit, 271 Connecting the External Emergency Stop, 212 Connecting the External Power Supply ON/OFF Switch, 210 Connecting the Input Power , 208 Connection between RS--232--C Interface and External Device, 273 Connection Between the Control Unit and Welder, 247 Connection Between the Mechanical Unit and End Effector, 245 Connection Diagram Between Mechanical Units, 204 Connection to Ethernet, 276 Connector Specification, 279 Lead Materials, 278 i--1

[H]
How to Disable/Enable Pneumatic Pressure Alarm (PPABN), 292

[I]
I/O Signal Specifications for Arc--Welding Interface, 257 I/O Signals, 320 In Case of B--Cabinet, 224 In Case of B--cabinet, 226 Input Signals, 320 Input/Output Hardware Usable in the R--J3iB Controller, 329 Installation, 285 Installation Condition, 288 Installation Method, 285 Interface, 271 Interface for Peripheral Devices, End Effectors, and Welders, 231

[L]

Index

B--81465EN--1/02

LED of Servo Amplifier, 154

[M]
Main Board (A16B--3200--0412, --0331), 136 Manual Operation Impossible, 133 Mastering, 34

[R]
Recommended Cables, 267 Replace the Mode Switch, 189 Replacing a Module, 183 Replacing a Unit, 164 Replacing Battery, 196 Replacing Cards and Modules on the Main Board, 169 Replacing External Air Fan Unit and Door Fan Unit (B--cabinet), 186 Replacing Fuses, 190 Replacing Fuses in the Power Unit, 191 Replacing Fuses in the Servo Amplifier, 190 Replacing I/O Unit Model A, 182

[O]
Operator Safety, 4, 6 Optical Fiber Cable, 338 Output Signals, 325

[P]
Panel Board (A20B--2100--0770), 142 Panel Switch Board (A20B--9002--0310), 152 Peripheral Device and Control Unit Connection, 232 Peripheral Device Cable Connector, 264 Peripheral Device Connection Cable, 263 Peripheral Device Interface, 253 Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins), 261 Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins), 261 Peripheral Device Interface Block Diagram, 221 Peripheral Device Interface Combination, 226 Peripheral Device Interface Processing, 290 Peripheral Device, ARC Welding, and End Effector Interfaces, 220 Position Deviation Found in Return to the Reference Position (Positioning), 131 Power Cannot be Turned On, 28 Power Distribution Circuit Diagram, 331 Precautions for Mechanism, 10 Precautions for Mechanisms, 11 Precautions in Operation, 11 Precautions in Programming, 10, 11, 12 Preventive Maintenance, 26 Printed Circuit Boards, 135 Process I/O Board CA (A16B--2201--0470), 143 Process I/O Board CB (A16B--2201--0472), 146 Process I/O Board DA (A16B--2201--0480), 148 Process I/O Board Signals, 227 i--2

Replacing Relays, 195 Replacing Relays on the Panel Board, 195 Replacing Servo Amplifiers, 178 Replacing the AC Fan Motor, 186 Replacing the Backplane Board (Unit), 165 Replacing the Base Unit of I/O Unit Model A, 182 Replacing the Control Section Fan Motor, 185 Replacing the Fuse on the Panel Board, 194 Replacing the Fuse on the Process I/O Boards, 192 Replacing the Operator Panel and Panel Switch Board, 188 Replacing the Panel Board, 168 Replacing the Power Unit and Printed--Circuit Boards on the Backplane Unit, 166 Replacing the Printed--Circuit Boards, 165 Replacing the Redundant E--stop Unit, 177 Replacing the Regenerative Resistor Unit, 176 Replacing the Teach Pendant, 184 Replacing the Transformer, 173 Resetting Overtravel, 290, 291 Resetting Overtravel and Emergency Stop at Installation, 290 Robot Connection Cables, 206 RS--232--C Interface, 271 RS--232--C Interface Signals, 272

[S]
Safety During Maintenance, 9 Safety in Maintenance, 13

B--81465EN--1/02

Index

Safety of the End Effector, 12 Safety of the Robot Mechanism, 11 Safety of the Teach Pendant Operator, 7 Safety of the Tools and Peripheral Devices, 10 Safety Precautions, 3 Safety Signals, 33 Selecting Transformer Taps, 159 Servo Amplifiers, 153 Setting Common Voltage, 319 Setting of Servo Amplifier, 155 Setting the Power Supply, 157 Signals, 317 Software Specifications, 330 Specifications of Digital Input/Output, 329 Specifications of Peripheral Device Interface, 316 Specifications of the Cables Used for Peripheral Devices and Welders, 261

Total Connection Diagram, 295 Transportation, 284 Transportation and Installation, 283 Troubleshooting, 27 Troubleshooting Based on LED Indications, 122 Troubleshooting Using the Error Code, 36

[V]
Vibration Observed During Movement, 132

[W]
Warning Label, 14 When I/O Unit--MODEL A is Used, 224 When Process I/O Board CA/CB/HA is Used (B--cabinet), 221 When Process I/O Board DA is Used (B--cabinet), 223 When Two or more Process I/O Boards and I/O Unit (Model A or Model B) are Used, 225

[T]
Teach Pendant Cable, 207

i--3

Revision Record FANUC Robot series R--J3iB CONTROLLER FOR EUROPE MAINTENANCE MANUAL (B--81465EN--1)

02

Oct., 2001

Addition of R--2000iA/165F/200F/165R/200R/125L/CF, M--6iB and ARC Mate100iB

01

Mar., 2001

Edition

Date

Contents

Edition

Date

Contents