controller maintenancefs1.gongyeku.com/data/usershare/2014-10/20141015044308.pdf · 2015. 7....

Chapter1 Notes on Safety Chapter2 Components Chapter3 Replacement and Adjustment of Components Chapter4 Periodic Inspection

Chapter5 Parts Layout and Electrical Circuit

Chapter6 Error Code

Chapter7 Welding Specifications

Chapter8 Specifications of External Axis

CONTROLLER MAINTENANCE

CONTENS

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CONTENTS

Chapter 1 Notes on Safety

1.1 Safe Use of the Robot System ..................................................................................................1-1 1.1.1 Safety Measures on Robot................................................................................................... 2 1.1.2 Safety Measures on Teaching and Inspection ..................................................................... 6 1.1.3 Safety Measures on Test Operation ..................................................................................... 8 1.1.4 Safety Measures on Automatic Operation............................................................................ 9 1.1.5 Relocation, Transfer and Sale of Robot ............................................................................. 11 1.1.6 Disposition of Robot ........................................................................................................... 11 1.1.7 Labels on Robot and Robot Controller............................................................................... 12

Chapter 2 Components

2.1 Component Layout in AX-C Controller ......................................................................................2-1 2.1.1 Component Layout in AX-C Controller ..............................................................................2-1

2.2 Block Diagram of AX-C Controller .............................................................................................2-3 2.2.1 Block Diagram of AX-C Controller .....................................................................................2-3 2.2.2 Outline and Specifications of Components .......................................................................2-4

2.3 Function of Components and Units ...........................................................................................2-8 2.3.1 Multi Power Supply Unit (L8810A00) ................................................................................2-8 2.3.2 CPU Board (L8800C00) ....................................................................................................2-9 2.3.3 Storage Board (L8800S00).............................................................................................. 2-11 2.3.4 I/O Board (L8800M00).....................................................................................................2-12 2.3.5 Riser Board (L8800R00) .................................................................................................2-13 2.3.6 Sequence Board (L8800F00) ..........................................................................................2-14 2.3.7 IPM Drive Unit .................................................................................................................2-18 2.3.8 High-power Unit...............................................................................................................2-21 2.3.9 Teach Pendant.................................................................................................................2-22 2.3.10 Operation Box and Start Box (Option)...........................................................................2-23

2.4 Function of Optional Items.......................................................................................................2-24 2.4.1 Relay Unit ........................................................................................................................2-24 2.4.2 Step-down Transformer (Floor-installation type) .............................................................2-29 2.4.3 Robot I/F Board ...............................................................................................................2-34 2.4.4 CAN I/F Board (Option) ...................................................................................................2-36 2.4.5 Welding Power Supply I/F ...............................................................................................2-37

Chapter 3 Replacement of Components and Adjustment

3.1 Replacement of Components ....................................................................................................3-1 3.1.1 Replacement of Board and Multi Power Unit ....................................................................3-2 3.1.2 Replacement of Sequence Board .....................................................................................3-4 3.1.3 Replacement of IPM Drive Unit .........................................................................................3-5 3.1.4 Replacement of High-power Unit ......................................................................................3-6 3.1.5 Replacement of Battery .....................................................................................................3-7 3.1.6 Replacement of Cooling Fan.............................................................................................3-8

3.2 Adjustment .................................................................................................................................3-9 3.2.1 Adjustment of Power System ............................................................................................3-9 3.2.2 How to Replace Primary Power Supply ..........................................................................3-10

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Chapter 4 Periodic Inspection

4.1 Periodic Inspection Schedule ....................................................................................................4-1 4.1.1 Safety Measures in Inspection, Maintenance, Adjustment and Repair.............................4-1 4.1.2 Inspection Schedule ..........................................................................................................4-3 4.1.3 Notes on Periodic Inspection.............................................................................................4-3 4.1.4 Warrantee Period ..............................................................................................................4-3 4.1.5 Inspection Item ..................................................................................................................4-4 4.1.6 Inspection before Long Vacation .......................................................................................4-5

4.2 Maintenance Parts.....................................................................................................................4-6 4.2.1 Maintenance Parts.............................................................................................................4-6 4.2.2 AXC*** ...............................................................................................................................4-7 4.2.3 Operation Box AXOP-00**............................................................................................4-10 4.2.4 Start Box AXST-00** ..................................................................................................... 4-11 4.2.5 Welding Power Supply I/F (2CH specifications) AXWF-00** .......................................4-12 4.2.6 Welding Power Supply I/F (4CH specifications) AXWF-01** .......................................4-12 4.2.7 Control Cables.................................................................................................................4-13 4.2.8 Alarm Display...................................................................................................................4-17

Chapter 5 Parts Layout and Electrical Circuit

5.1 Parts Layout and Electrical Circuit Diagram of AXCMN1..........................................................5-1 5.1.1 General View of AXCMN1 .................................................................................................5-1 5.1.2 Parts Layout of AXCMN1...................................................................................................5-2 5.1.3 Electrical Connection of AXCMN1 (Whole) .......................................................................5-3 5.1.4 Electrical Connection of AXCMN1 (for Power)..................................................................5-4 5.1.5 Electrical Connection of AXCMN1 (for Welding Power Supply)........................................5-5 5.1.6 Electrical Connection of AXCMN1 (for Encoder)...............................................................5-6 5.1.7 Electrical Connection of AXCMN1 (for Motor)...................................................................5-7 5.1.8 Electrical Connection of AXCMN1 (for Operation/Start Box) ............................................5-8

Chapter 6 Error Code 6

6.1 When fault has occurred............................................................................................................6-1

6.2 Concerning the fault details .......................................................................................................6-2 6.2.1 Fault category....................................................................................................................6-2 6.2.2 Concerning criticality codes and fault codes .....................................................................6-2

Chapter 7 Welding Specifications

7.1 Connecting Welding Power Supply ...........................................................................................7-1 7.1.1 Connecting Almega Digital Welding Power Supply...........................................................7-1 7.1.2 Connecting Digital Welding Power Supply ........................................................................7-9 7.1.3 Connecting Welding Power Supply I/F............................................................................7-13

Chapter 8 Specifications of External Axis

8.1 External Axis ..............................................................................................................................8-1 8.1.1 Specifications of External Axis...........................................................................................8-1 8.1.2 External Axis Cable ...........................................................................................................8-3 8.1.3 Connecting External Axis Cable ........................................................................................8-5

CONTENS

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Chapter 1 Notes on Safety

This chapter describes the notes on safety of the robot system.

These are only the general notes and procedures about safety, not giving full instructions. Create the safety control standards or equivalent on your own, containing the work regulations.

Perform the safety control to secure the safety of operators. 1.1 Safe Use of the Robot System....................................................................1-1

1.1.1 Safety Measures on Robot.......................................................................2 1.1.2 Safety Measures on Teaching and Inspection..........................................6 1.1.3 Safety Measures on Test Operation.........................................................8 1.1.4 Safety Measures on Automatic Operation................................................9 1.1.5 Relocation, Transfer and Sale of Robot ................................................. 11 1.1.6 Disposition of Robot............................................................................... 11 1.1.7 Symbols on Robot and Robot Controller................................................12

1.1 Safe Use of the Robot System

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Before installation, operation, maintenance and inspection, read this manual and other attached documents thoroughly to fully understand the knowledge of each equipment, safety information and all the notices.

In this instruction manual, following signs respectively show the importance of the contents.

DANGER

If handling the robot in a wrong way, an user may die or get severely injured. Besides, in the case of the exigencies of alarming in a danger situation (a level of urgency) is quite high, which is a limitative occasion.

WARNING

If handling the robot in a wrong way, an user may die or get severely injured.

CAUTION

If handling the robot in a wrong way, an user may get slightly injured or only the property damage may occur.

Additionally, the following mark is used in this manual for a special important notice.

This is a notice especially to take the utmost care.

Notes on safe adjustment, operation and maintenance

(1) An operator must wear a working uniform, a helmet, a pair of safety shoes etc. (2) Before turning the power ON, check that no operator is inside the robot work area. (3) Before operating in the robot work area, check that the power is OFF. (4) There may be a case that an operator has to perform the inspection, maintenance and other

operations with the power ON. In this case, be sure to perform at least by two persons in a pair so that one person can keep the position for pressing the emergency stop button anytime. And the other, performs the required operation quickly with carefully watching the robot work area and its motion. Besides, make sure that the evacuation route is clear before operation.

A robot is enabled to safely stop with the self diagnostic function and the error detection function in the event

of the error. However, accidents cannot be perfectly avoided. Here are some examples of the possible robot accident.

･An operator performed Automatic operation without making sure that no one was inside the robot work area.

･A robot suddenly started moving after entering the robot work area still in Automatic operation mode.

･An operator only concentrated in the robot only under his/her nose but not another one.

Points in common among the accidents above are ;

･Safety procedures were neglected. ･A robot performed an abrupt motion even though it seemed all right.


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In short, these accidents are all resulted from human errors such as careless mistake, failure of following the instructions etc. For these kinds of “abrupt happenings”, an operator cannot evade the accidents by performing Emergency stop, running away etc. This will highly possibly result in a serious accident. Here are some cases.

･ The speed of robot motion changed from low to high. ･ Other personnel carelessly operated. ･ A robot moved by the wrong program because of the abnormal action of peripheral equipment or the

program error. ･ Abnormal motion because of the noise, trouble, fault etc. ･ Mis-operation ･ A robot moved at a high speed even though intended at low speed. ･ Workpiece being transported by a robot dropped and flew in directions. ･ A robot was on standby waiting for the interlock, however the interlocking was released and the robot

suddenly moved. ･ The robot adjacent to or at the rear started its operation.

There will be more of “abrupt happenings” patterned accidents. In most practical situations, it is impossible to stop the robot that has once started moving or to run away from it. Therefore, thoroughly understand and follow the notices below to avoid those accidents.

DANGER

Do not approach to the robot. If the robot abruptly moved, and the personnel is touched or caught, then a death or serious accident will occur.

DANGER

When the robot is not supposed to move, it must not be enabled. If the robot abruptly moved, and the personnel is touched or caught, then a serious accident will occur.

DANGER

When the robot should move, appoint a monitor to always monitor the safety. If the robot abruptly moved, and the personnel is touched or caught, then a death or serious accident will occur.

DANGER

When the robot should move, always be ready to press the emergency stop button while you work. If the robot abruptly moved, and the personnel is touched or caught, then a death or serious accident will occur.

1.1.1 Safety Measures on Robot

The robot must be designed and manufactured with suitable material and structure for its use environment, containing no unnecessary protrusions or sharp edges. Also, it has provided with the fail-safe function with no damage or accident occurs during operation. Besides, the robot should maintain a good level of safety with functions as follows. ･Function to detect the incorrect motion and stop the robot ･Emergency stop function ･Interlocking function to prevent the dangerous situation caused by robot in the abnormal action of peripheral equipment


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WARNING

The robot is of multi-articular structure, which allows each articulation always to form a variety of angles depending on the robot motion. Take great care especially in teaching so that you won’t get pinched in the articulations. (Note : Mechanical stoppers are provided at the end of movable range of articulation, which is highly dangerous to be pinched in.) Besides, the arm may fall by its own weight or move in unexpected directions if motors are removed or the brakes are released. Be sure to take measures to prevent it from falling and check that the surrounding is in a safe condition before you start operating.

WARNING

The arm may fall if removing the motor without properly holding it. Be sure to properly hold it before removing the motor.

If removing the motor withoutproperly holding the arm…,

The arm will drop.

For securing the arm, do not rely on the positioning pin only since it may be inserted in a wrong way or only a half way. Use a wooden block, a sling or other items to hold the arm securely before removing the motor. However, do NOT support the arm by human hands.

CAUTION

A balance spring device is internally compressed under the normal condition. Therefore, do NOT remove or disassemble it. It is a hazardous act.

CAUTION

To fabricate the end effector and equipment on the arm, use designated bolts; desired size and number and tighten them with a torque wrench by a specified torque. Besides, be sure to use clean and rust-free bolts, otherwise, the bolts will be loosened to result in a serious accident with an incorrect way.

CAUTION

To fabricate the end effector, set the weight and the static load moment within the range of the allowable moment and of inertia on wrist axis of the robot.

CAUTION

Provide a fail-safe mechanism to ensure that the workpiece will be held even if when the power or air supply to the end effector is shut off. Be sure to sharp edges or protrusions so that the damage to either personnel or object can be avoided.


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CAUTION

Supply the electric power, plant air and welding cooling water to drive the robot, following specifications. Failure to follow the specifications will cause problems; affecting the robot performance, and causing the abnormal behavior or trouble. Be sure to follow the specifications.

CAUTION

As for the electromagnetic disturbance, there are no measures to completely cut it with the technology today, no matter the kind or the strength of the electromagnetic wave. Follow the notes for applying the power during robot operation. With the electromagnetic wave, other noises or the defective board, recorded programs may be sometimes erased. As a safeguard, back up programs or constants in a compact flash card or other storage media.


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~ Brake Positive Release ~ If the operators are pinched in the robot, follow the procedures to save them. (1) Press the emergency stop button immediately and stop the robot.

(2) Turn OFF the robot controller.

(3) The robot brakes are all released by performing the following procedures. To prevent the robot arm from

falling off, sling the 2nd and the 3rd axis arm with a wire rope or other items

(4) Remove the brake positive release connector (CNBKSW) fixed on the IPM drive unit in the robot controller. To release the brake of robot arm, connect the brake positive release connector with the connector (CNBKSW) on the IPM drive unit of robot controller. (Refer to the following figure.)

(5) Brakes on all the axes are released when turning the power ON. Check that the arms have been secured before turning ON. Then, turn ON the robot controller. Do not apply the servo power.

(6) Operate the arms manually to save the personnel pinched in a robot.

(7) After saving the personnel, be sure to remove the brake positive release connector. And, fix them again onto the IPM drive unit.

Position of the brake positive release connector

WARNING

Follow the notes below when applying the primary power with the controller door opened due to the brake positive release etc. Otherwise, the robot and its controller will malfunction or cause a trouble. 1. Do not expose the controller to the direct sunlight. 2. After opening the door, do not apply the strong sunlight such as a penlight to the

internal parts of controller.


1.1.2 Safety Measures on Teaching and Inspection

CAUTION

Robot must be operated by only those who have taken the specified training and are fully aware of safety and functions of robots. If unskilled personnel operated the robot, accidents may occur due to mishandling of the robot.

CAUTION

When entering the robot work area with Motors ON, the emergency stop button must be within reach of operators. In addition, be sure to position the monitor outside the robot work area, being ready to immediately press the emergency stop button. Then, an emergency stop can be immediately made in the event of the abnormality.

WARNING

Wear protective equipment such as a helmet or safety shoes when operating the robot or the robot work area.

WARNING

When you enter the robot work area, carry the key SW, for switching the robot operation to Automatic, and the safety plug with you, so that nobody may accidentally start Automatic operation resulting in serious accident.

WARNING

Display a sign “Teaching Under Way” on each operation panel so that other workers are enabled aware of that the teaching operation is under way. Otherwise, they may start Automatic operation, resulting in serious or fatal accidents.

CAUTION

When a number of operators are engaged in the teaching operation, the one with the teach pendant must give orders to other operators to follow. If more than one personnel give different orders at the same time, each operator will perform wrong operation, maybe causing accidents.

CAUTION

When a number of operators are engaged in the teaching operation in the large robot system, be sure to establish how to communicate exactly in a distance such as by gesture. Accidents may occur due to poor communication among operators because of noises around.

CAUTION

Operators must be provided with the escape route to immediately escape in an emergency.

WARNING

Always watch out the robot motion, performing the operation facing the front. Do not work with your back toward the robot. because the operator may not notice the start of robot motion.


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WARNING

Press the emergency stop button immediately if you notice anything abnormal. Please make this action thoroughly known to every operator. Otherwise you may be in imminent danger of the abrupt robot motion if you are just watching something abnormal.

CAUTION

Prepare an appropriate working prescription and checklist for startup, the way of operation and the actions to be taken in an emergency of robot according to its installation location and working condition. Then, follow the working prescription to operate the robot. If not, but operating by the operator’s memory and knowledge only, accidents may occur due to the wrong idea or the mistakes.

CAUTION

If the robot motion is not necessary, turn OFF the power before operating. Then, the robot will not even accidentally work.

CAUTION

Check the program No. and the step No. before teaching. Editing the wrong program or step No. will sometimes cause accidents.

CAUTION

Protect the completed programs by such as the memory protect function so that no operators will edit afterwards by mistake. (AX controller is equipped with the memory protect function forbidding the editing performance by each program or constant file.)

CAUTION

After completing the teaching operation, check the robot motion at low speed using the check go/ back function and the velocity override function. If operating the robot at a full speed in the playback mode without this check, a program error or other errors may possibly cause collision.

CAUTION

After completing the teaching operation, clean up the area within the safety fence and check that anything is not left as tolls. A workplace foul with oil and grease or with scattered tools will sometimes cause the accidents; falling down, slipping on them. Neatness is the first step for safety.


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1.1.3 Safety Measures on Test Operation In the taught program, jigs, sequence etc., some design-originated errors, teaching errors or manufacturing errors may be contained. Therefore, when performing the test run, more careful actions must be taken for safety. See below for some points.

WARNING

At first, perform the motion check on all the buttons and the signals; emergency stop button and other stop buttons essential to halt the robot motion. Then, perform it on the error detecting –related functions. Confirming the ability of robot halt is the first priority. Unless otherwise the robot can come to a halt in emergency situations, serious accidents are never preventable.

CAUTION

Before the test run, perform the motion check at low speed (approx. 5%~10%), using the velocity override function. Repeat this check 2 to 3 cycles and correct the errors immediately, if found. Then, gradually increase speed (50%→70%→100%) and repeat the motion check respectively 2 to 3 cycles. Operating the robot at high speed from the beginning will cause accidents since the robot cannot immediately stop even if teaching errors are found.

DANGER

Never perform the motion check within the safety fence since unexpected happenings may occur during the test run. At the stage of test run, unpredictable errors may occur due to low reliability, mostly resulting in the accidents.


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1.1.4 Safety Measures on Automatic Operation

CAUTION

At the beginning and end of the work, clean up the workplace and keep everything neat If the workplace is foul or messy, operators may fall down.

CAUTION

At the beginning of a day, ensure to perform the specified daily inspection following the checklist so that the errors can be found to prevent the accidents in advance. (Refer to the MAINTENANCE INSTRUCTION MANUAL for daily inspection items. Also, create a checklist on yourself based on this information for a thorough inspection.)

CAUTION

Display ”OFF LIMITS” sign at every entrance of the safety fence to keep operators away from the fence even if the robot is not in motion.

DANGER

Be sure there is no one within the safety fence before starting Automatic operation. Accidents caused by neglecting this check is the most typical type of accidents.

CAUTION

Before Automatic operation, confirm that the condition is ready for Automatic operation including the program No., step No., mode and startup select. If starting without noticing the wrong program or step is selected, robot may perform unpredictably and result in an accident.

CAUTION

Before Automatic operation, be sure that the robot is in a position to start Automatic operation. Check both the program No. and the step No. match the robot position. sIf not, the robot will abnormally behave to result in an accident.

CAUTION

Before startup, make sure the emergency stop button can be immediately pressed. This is essential when unexpected robot movement occurred.

CAUTION

Operators must be always familiarized with motion path, operating condition, running noise of the robot so that abnormalities can be immediately observed. Since the robot will sometime shows signs before the failure, be fully aware of the normal condition to detect these signs in advance.

WARNING

Make an emergency stop immediately if any abnormalities are observed. And, report it to superiors or the personnel in charge of maintenance to take proper actions. Rush attitude “Robot is moving anyway. That’ll be fine.” may cause not only a halt in production by the trouble but also a serious injury to personnel.


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WARNING

When performing the motion check after the measures taken to the initial failure, be sure that the failure has completely remedied. Do not operate the robot if somebody is inside the safety fence, until this was confirmed, even at low speed. Since this is still under the low reliable condition, another related errors may occur.


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1.1.5 Relocation, Transfer and Sale of Robot

CAUTION

Hand over all the manuals including maintenance manuals and other related documents to a new owner when relocating, transferring and selling the robot. Particularly when this action is to be done overseas, the original user is responsible for preparing and supplying all the documents in their languages, revising the display languages, applying to their local legislation and others. If you fail to complete this process, the new owner may operate the robot without the proper information, resulting in accidents.

CAUTION

When the robot is relocated or transferred overseas and sold in either domestic or overseas, the initial contractual terms on sale are not transferred to the new owner including the safety related items unless otherwise special agreement has been concluded. The original user and the new owner must conclude a new agreement on their own.

1.1.6 Disposition of Robot

CAUTION

Do not disassemble, heat or burn batteries already used for the robot and robot controller. They may ignite, explode or burn.

CAUTION

Do not disassemble the robot controller into smaller than PCBs or units. It may burst or you may be injured with a sharp edge or electric wires.

CAUTION

Do not disassemble the wire harness and the robot external wirings into further smaller than disconnecting from connectors or terminal blocks. Semiconductors and other pieces may cause injury to your hands or eyes.

CAUTION

Take the utmost care when scrapping robots to avoid accidents such as pinching your hands or fingers.

CAUTION

Discard scrapped items with utmost care to avoid injury.


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1.1.7 Labels on Robot and Robot Controller

Robots and robot controllers of DAIHEN robots “Almega series” are labeled with alarm signs for safe use. Do not tear them off, damage them or cover. If it is the case, contact our engineers for making an order. For how to order, inquire of our sales engineers in your local area. The following shows the alarm signs attached to robot and robot controller. (Labels partly differ depending on

the types.)

Attaching alarm signs to MV6/MV6L/MV16


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Attaching alarm signs to MG3


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Attaching alarm signs to MH3

Attaching alarm signs to MS3


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Attaching alarm signs to robot controller

Chapter 2 Components

This chapter describes the components of robot controller.

2.1 Component Layout in AX-C Controller........................................................2-1

2.1.1 Component Layout in AX-C Controller ..................................................2-1 2.2 Block Diagram of AX-C Controller...............................................................2-3

2.2.1 Block Diagram of AX-C Controller.........................................................2-3 2.2.2 Outline and Specifications of Components............................................2-4

2.3 Function of Components and Units.............................................................2-8 2.3.1 Multi Power Supply Unit (L8810A00) ....................................................2-8 2.3.2 CPU Board (L8800E00) ........................................................................2-9 2.3.3 Storage Board (L8800S00) ................................................................. 2-11 2.3.4 I/O Board (L8800M00) ........................................................................2-12 2.3.5 Riser Board (L8800R00) .....................................................................2-13 2.3.6 Sequence Board (L8800F00)..............................................................2-14 2.3.7 IPM Drive Unit.....................................................................................2-18 2.3.8 High-power Unit ..................................................................................2-21 2.3.9 Teach Pendant ....................................................................................2-22 2.3.10 Operation Box and Start Box (Option)...............................................2-23

2.4 Function of Optional Items........................................................................2-24 2.4.1 Relay Unit ...........................................................................................2-24 2.4.2 Step-down Transformer (Floor-installation type) .................................2-29 2.4.3 Robot I/F Board...................................................................................2-34 2.4.4 CAN I/F Board (Option).......................................................................2-36 2.4.5 Welding Power Supply I/F...................................................................2-37

2.1 Component Layout in AX-C Controller

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AX-C controller varies in its component layout depending on the series. Before performing the maintenance, fully understand the function of each unit and component layout in the controller.

2.1.1 Component Layout in AX-C Controller

The outline drawing of AX-C robot controller is shown below.

Outline drawing of AX-C


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The component layout in AX-C controller is shown below.

AX-C component layout

Details of unit

2.2 Block Diagram of AX-C Controller

2-3


2.2.1 Block Diagram of AX-C Controller

The block diagram of AX-C controller is shown below.

Block diagram


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2.2.2 Outline and Specifications of Components The table below shows the outline of each component.

Outline of components

No. Component Function 1 Multi power supply unit

(L8810A00) ・Power interruption detecting circuit ・DC+5V power supply ・DC+12V power supply ・DC+24V power supply ・DC+3V power supply (Option)

2 Riser board (L8800R00) ・Bus connection and power supply between each board 3 CPU board (L8800C00) ・Microprocessor and its surrounding circuit

・Fixed disk I/F (IDE) ・Floppy disk I/F ・LCD I/F ・RS422 ・RS232C ・Ethernet ・PCI bus ・SA bus

4 Storage board (L8800S00) ・Compact flash card (For system use) ・Compact flash card (For user data backup) ・Teach pendant I/F ・CAN I/F

5 I/O board (L8800M00) ・Internal I/O circuit ・External interlocking I/O circuit

6 Sequence board (L8800F00)

・Internal sequence circuit ・I/O circuit ・Emergency stop safety circuit

7 High-power unit (L8811A00)

・Magnet switch control for motor power supply ・ Brake power supply ・Encoder power supply

8 IPM drive unit (L8800J00)

・Servo control CPU ・Encoder I/F ・Motor drive power supply ・Motor drive circuit ・Brake control circuit ・Magnet switch control

9 Teach pendant ・Operation switch circuit (Emergency stop, Auto/ teach select, Deadman switch)

・Teaching, Keyboard for multiple settings, LCD, Touch panel circuit (option)

The table below shows the specifications of AX-C controller.

Specifications of AX-C controller

Item Specifications

Name AX-C

Model AXCMN1 (For MV6), ACXML1 (MV6L, MV16) AXCMG1 (For MG3), AXCSN1 (MH3, MS3)

Teaching system Teaching/ playback system Driving system AC servo motor Number of control axes Total independent simultaneous control (Max. 54 axes) Positioning system PTP (Fast-forward) / CP (welding) control Speed control system Constant speed control of torch tip (Independent control of Max. 6 paths)

Control system

Coordinate system Joint coordinates, Right angle coordinates (Machine coordinates, Tool coordinates, Workpiece coordinates, World coordinates (Absolute coordinates)), User-defined coordinates


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Item Specifications

Storage media Compact flash card Memory capacity 160,000 instructions (by PTP instruction in a single mechanism)

Position (Positioning, Straight line, arc) Memory contents Condition (Welding condition, Weaving condition, Timer, I/O etc.) Number of task programs

9999 (The max. sequences per program is 9999 within the memory capacity.)

Memory

External storage media

Compact flash card or PC (Connection cables and the dedicated software are optional. PC is prepared by customer’s arrangements.)

Welding power supplies in connection

Maximum 4

Condition setting Direct value setting, Designation of welding condition files

Welding method CO2, MAG/ MIG, TIG welding (Note: Configuration of welding peripheral equipment varies when applied in MIG or TIG

welding.)

Welding condition

Pre-flow time : 0.0～9.9 seconds (set by 0.1 sec.) Welding current : 0 ～500A (set by 1A) Arc voltage : 0.0～50.0V (set by 0.1V) Crater time : 0.0～9.9 seconds (set by 0.1 sec.) Post-flow time : 0.0～9.9 seconds (set by 0.1 sec.) Gas OFF delay time : 0.0～9.9 seconds (set by 0.1 sec.) (Note : 1)

Welding signal input

Wire outage, Shortage of gas pressure, Cooling water outage, Wire inching/ retracting etc.

Welding signal output Arc outage, Wire outage, Shortage of gas pressure, Cooling water outage etc.

Welding control function

Weaving method Fixed patterned weaving (Linear function, Trigonometric function, Arc) Joint weaving, Teaching weaving (Option)

Interpolation function Linear interpolation, Circular interpolation (3 dimensions)

Checking operation CHECK GO, CHECK BACK Sequence jump function

Manual operation speed

Joint coordinates : 5-step selection (Limited to 250mm/sec or lower at the torch tip.) Right angle coordinates : 5-step selection including the pitch feeding (per 0.1mm) (Limited to 250mm/sec or lower at the torch tip.)

Checking operation speed 5-step selection

Operation

Wire inching/ retracting function Available (Individually applied to each welding power supply on Teach pendant.)

Editing function Copy, Add, Delete, Cut-and-paste, Modify, Undo, Redo Symmetrical shift, Parallel, Axis angle shift, Mirror image, Zoom, 3-dimension : Value input by the mechanism operation (Standard equipment) Shifting function External axis shift (Option)

Program call Call, Jump, Condition jump (Condition setting is available by constants or variables.)

Edit

Hot edit Program editing function available during playback

Welding error recovery function

Arc retry Overlap function Automatic wire stick release function Auxiliary

welding function Welding condition

guidance function

The optimum welding conditions (current/ voltage/ speed) are automatically selected by inputting the thickness, the groove shape and other factors of workpiece. (Note : Available with CPDRA, CPDPAS and DM under the condition of “CO2/MAG

welding, Wire φ:1.2, Parallel fillet”.) (Note: 1)

Post-flow time : Period of time since the robot has stopped until the gas flow ends. Gas OFF delay : Period of time until the gas is shut off after the post-flow time. When setting both Post-flow time and Gas OFF delay to 0sec. enables to prevent the corrosion of wire tip and improve the arc start performance.


2-6

Item Specifications

Condition setting system Setting the direct general-purpose logical I/O port in the task programs

Allocation setting system

Allocating the dedicated logical I/O signals to arbitrary physical I/O port in the I/O conversion table

Dedicated physical I/O

Output : 4 points Input : 7 points

General purpose physical I/O Relay unit : Expandable to 64 points by 32 points in each input and output (Option)

Electrical input specifications ON/OFF switching (DC24V, 10m)

External control input

Electrical output specifications Relay contact (Dry contact) output : AC100V or 30V, 1A Minimum current : 5V 1mA

Condition setting system Editing the LD program files on Teach pendant

Program capacity 32K words ( = 3.2k words /file × 10 files) Software

PLC Sequence command

Full support for 5 of “IEC1131-3” languages <Note> The workbench (option) is separately required to use the languages other than LD. LD is the only language that can be displayed and edited on Teach pendant.

Start support unit Starting by designation of the task program No. or from the user-defined sequence. Automatic operation speed

In positioning : Refer to the specifications of manipulator to be used. In welding : 1～999cm/min (Setting is available by 1cm/min.)

Start system Selecting the multi-station system or the program No. direct designation system

Number of stations 1 station (Standard) Max. 4 stations by adding the start box (Option)

Program No. direct designation

Designating the program No. by BCD code (Number of start available programs : 9999) Designating the program No. by Binary code (Number of start available programs : 9999)Discrete system (1～16) : Directly starting the programs that support bit 1～16

Start reservation function

Start reservation is available for the task programs currently not in operation or reservation. (Multi station system) FIFO system (External signal)

Online modification of welding conditions

Modification or record of the welding current, Arc voltage and the welding speed is available during automatic operation.

Temporary stop

In automatic operation – During positioning : Robot slows down and stops. During welding : Robot stops welding performance and its motion.

Program editing is available after a temporary stop. And then after editing, restart can be made from the designated sequence or position.

Emergency stop Function to shut off the motor voltage and then allow the operator to enter into the robot motion area. (Emergency stop button)

Playback function Machine lock, Dry run, Speed override (Switching the playback speed Low/High), Weld ON/OFF, Weaving ON/OFF, 1 step playback, Nonstop step playback, Cycle playback

Automatic operation

Control function

Cycle time Welding time Production amount counter In-section time measurement function

Safety function Door interlock, Mat switch, Safety plug Teach mode interlock, Auto mode interlock, Deadman switch

Protection function

Mechanical shock sensor Servo shock sensor (Option) Mechanical stopper Overrun limit switch Software limit switch Internal temperature monitor Power voltage monitor Interference area check

Maintenance function

Inspection due notification Error history log Arc monitor (Only when using CPDRA､CPDACA､CPDPAS､CPDA or DM) Automatic backup


2-7

Item Specifications

Error detection function

Emergency stop error Control sequence error CPU board related error Servo error Amplifier unit error Encoder error Teach pendant error PLC error User error Operation error Spot welding error Arc welding error Sensor error

Diagnostic function

Connection check between Robot controller and Teach pendant Connection check between Robot controller and Robot dedicated welding power supply Connection check between Robot controller and Manipulator Internal circuit check inside Robot controller Internal circuit check inside Teach pendant

Origin restoration Origin restoration is not required when the power turned ON supported by the battery-backup absolute position detection function (Note: Replacement of the battery is required every three years.)

Cooling system Indirect cooling system (Robot controller is a closed structure.) Acoustic noise 70dB or less Ambient temperature range 0～45℃

Ambient humidity range 20～80%RH (Non-condensing) 1.5 kVA (for Almega AX-S3) 1.5 kVA (for Almega AX-H3) 2 kVA (for Almega AX-G3) 3 kVA (for Almega AX-V6) 6 kVA (for Almega AX-V6L)

Power supply 3-phase AC200V+10%､ -15% 50/60Hz

6 kVA (for Almega AX-V16) Grounding D-type or higher robot dedicated grounding system External dimensions of controller 558m (W) × 503mm (D) × 865mm (H)

Outside dimensions with External axis controller 1114m (W) × 503mm (D) × 865mm (H)

Weight Approx. 80 kg Color Manipulator/ Panel : 10GY9/1, Ｍunsell scale

2.3 Function of Component

2-8

2.3 Function of Components and Units

The function of each component and unit is described in the following.

2.3.1 Multi Power Supply Unit (L8810A00) This unit supplies DC power to use in the robot controller. Also, this is equipped with the primary power

monitoring circuit to interrupt into CPU in the occurrence of power interruption. ~Function~

・DC+5V power ・DC+12V power ・DC+24V power ・DC+3V power (Option) ・Primary power monitoring circuit

~General appearance~

~Connection~

Connector Function Connection destination CNP DC+24V power output Connected to the sequence board CNP5V DC+5V power output Connected to IPM drive unit CNSWO AC200V power output Connected to IPM drive unit CNAC AC200V power input Connected to the high-power unit CNPS Power supply to the rack board Connected to the riser board

Be sure to check the motion of each switching regulator using the riser board (2.3.5 Riser Board (L8800R00))

by its LED. The value of output voltage for checking in each switching regulator is as follows. ・DC5V 5.1±0.05V ・DC12V 12.0±0.5V ・DC24V 24.0±1V


2-9

2.3.2 CPU Board (L8800C00)

CPU board is not only to control the robot but also communicate with the user-interfaced peripheral equipment.

~Function~ ･Microprocessor and its surrounding circuit ･Fixed disk I/F (IDE) ･Floppy disk I/F ･LCD I/F ･RS422 ･RS232C ･Ethernet ･PCI bus ･ISA bus


CPU

CN1DIMM1DIMM2 CN2 CN3 CN4

CN5

CN

9

JP1JP2 JP3

JP5

CN10

JP8

BatteryバッテリCR203

2

JP9

JP7

JP4

CN12

CN6

CN

7CN11

LAN

MOUSE

VGA

KEY

~Connection~

Connector Function Connection destination CN1 Parallel port No connection CN2 RS232C No connection CN3 RS422 Connected to the storage board (L8800S00) CN4 USB Connected to the drive unit CN5 LCD Connected to the storage board (L8800S00) CN6 Mouse No connection CN7 VGA No connection CN9 CPU fan Connected to CPU fan on board CN10 External battery No connection CN11 Keyboard No connection CN12 LAN No connection


2-10

~Jumper (JP) setting~

×：Open (single-ended) ○：Short-circuit

Location Status Description 1-2 ○ 3-4 × 5-6 ○ 7-8 ○

9-10 × 11-12 ○ 13-14 ○ 15-16 × 17-18 ○ 19-20 ○ 21-22 ×

JP1

23-24 ○ 1-3 ○ 2-4 × 5-6 ○ 7-8 ○

JP2

9-10 ○

Setting COM2(CN3) to RS-422.

1-2 × 3-4 × 5-6 ○

JP3

7-8 ○

Terminating resistor on with RXD/TXD when using RS422.

1-2 ○ JP4 3-4 ○

Disk-on-chip address : D000H～D1FFH

1-2 × 3-4 ○ 5-6 ×

JP5

7-8 ×

Display mode TFT 640×480

JP6 1-2 ○ Setting the output of WDT to NMI JP7 1-2 ○ Onboard LAN : ON JP8 1-2 ○ CMOS details hold JP9 1-2 ○ Onboard VGA : ON


2-11

2.3.3 Storage Board (L8800S00)

Storage board (L8800S00) is a memory board equipped with the compact flash card, the compact flash card I/F and the teach pendant interface circuit (RS422 is connected through the storage board.). The compact flash card is for storing the system software and the task programs, and the compact flash card I/F is for the user data backup.

~Function~

・Compact flash card (for storing the system software and the task programs) ・Compact flash card (for user data backup) ・Teach pendant interface ・CAN I/F (For communication with the welding power supply)


CNPC

CN

CF

CNTPC

CNISA

CNLCD

CN

422

CNSIO

CNCAN

~Connection~

Connector Function Connection destination CNCF IDE signal Compact flash card for storing the system software and the

task programs is mounted.(For L8800E: 256M) CNPC PCMCIA signal Compact flash card I/F for user data backup is connected.

(For L8800U: 64M) CNISA CPU bus Connected to the riser board (L8800R). CNTPC Panel link signal

RS422 signal Connected to the teach pendant.

CNLCD LCD signal Connected to CN5 on CPU board. (LCD I/F) CN422 RS422 signal Connected to CN3 on CPU board. (RS422) CNCAN CAN communication Connected to the welding power supply.

~DSW setting ~

Setting location Setting status Board No. 1 2 3 4 5 6 7 8

Storage board DIPSW1 OFF OFF OFF OFF OFF OFF - -

~Jumper(JP) setting~ ×：Open (single-ended) ○：Short-circuit Setting location Status

J1 1-2 × J2 1-2 × J3 1-2 ○ J4 1-2 × J13 1-2 ○ J14 1-2 ○ J15 1-2 ○ J16 1-2 × J17 1-2 ○ J18 1-2 ○


2-12

2.3.4 I/O Board (L8800M00) I/O board (L8800M00) is to control the digital I/O signals in the robot controller and also to and from the

peripheral equipment. ~Function~

・Internal I/O circuit ・I/O circuit for the external interlock


CNIN CNOUTCNSQ

P1P2

~Connection~

Connector Function Connection destination CNIN Digital input Connected to the external input signals. CNOUT Digital output Connected to the external output signals. CNSQ Digital I/O Connected to the sequence board (L8800F).

No connection if using as an extension I/O.

I/O circuit

P1 CPU bus Connected to the riser board (L8800R) for CPU bus signal connection. P2 CPU bus Connected to the riser board (L8800R).

~DSW setting~

Setting location Setting status Description Board No. 2 1

OFF OFF 1st I/O board (Default) I/O board SW1 OFF ON 2nd I/O board


2-13

2.3.5 Riser Board (L8800R00) Riser board (L8800R00) is a backplane board to mount CPU board, the storage board, I/O board, the multi

power supply unit, PCI card and other components. ~General appearance~

Storage board

I/O board

CPU board

PCI slot

Multi-power unit

LED circuits

~LED~

LED Description K12V LED Lights while the switching regulator (12V) in the multi power

supply unit properly works. K3V LED Lights while the switching regulator (3V) in the multi power supply

unit (Option) properly works. K5V LED Lights while the switching regulator (5V) in the multi power supply

unit (Option) properly works. K MLX LED Lights while CPU board is properly mounted.


2-14

2.3.6 Sequence Board (L8800F00) Sequence board (L8800F00) is to control the sequences in the robot controller. The emergency stop circuit is a dual circuit supporting ANSI/RIA15.06.

~Function~

・Sequence circuit in the robot controller ・Emergency stop safety circuit


~Connection~

Connector Signal Description CNP DC+24V power input Connected with the multi power supply unit. CNSQ Digital I/O signal Connected with I/O signals. CNTP TP switch signal Connected with Teach pendant. CNOP Operation box signal Connected with the operation box.

If not using the operation box, joint the short connector. CNSV Servo amplifier I/O signal Connected with IPM drive unit. CNOPT Option Optional connector CNWEL Welding power supply signal Connected with the robot dedicated welding power supply.


2-15

・ TBEX3 (User connection)

Pin No. Signal Description

8 M2 External power ground 7 P2 External power 24V input 6 Magnet ON signal output (Dry “b” contact) - 5

HPB Magnet ON signal output (Dry “b” contact) +

4 Magnet ON signal output (Dry “a” contact) - 3

HPA Magnet ON signal output (Dry “a” contact) +

2 M1 24V ground 1 P1 24V


Pin No. Signal Description Common

11 RMD_EN External mode select (IN10) M1 10 E.H-TEACH External high-speed (IN11) MONCOM 9 E.MODE External teach/ playback (IN8） MONCOM 8 E.MON External Motors ON (IN24) MONCOM 7 MONCOM Motors ON common － 6 CPU error output - － 5

CPU.ERROR CPU error output + －

4 Emergency stop output 2 - － 3

E.STOP.OUT2Emergency stop output 2+ －

2 Emergency stop output 1- － 1

E.STOP.OUT1Emergency stop output 1+ －


Be sure to make a dual contact when applying either of the external emergency stop, the safety plug or Mat SW.

< Example > When applying the external emergency stop : Pin1-2 and Pin3-4

Pin No. Signal Description

12 Mat SW input 2- 11

MATSW2 Mat SW input 2+

10 Mat SW input 1- 9

MATSW1 Mat SW input 1+

8 Safety plug input 2- 7

SFP2 Safety plug input 2+

6 Safety plug input 1- 5

SFP1 Safety plug input 1+

4 External emergency stop input 2 - 3

E.STOP2 External emergency stop input 2 +

2 External emergency stop input 1 - 1

E.STOP1 External emergency stop input 1 +

Jumper setting on Terminal block (Default)

Terminal block Terminal No. for short circuit Description

1-2 External emergency stop input 1 3-4 External emergency stop input 2 5-6 Safety plug input 1 7-8 Safety plug input 2 9-10 Mat SW input 1

TBEX1

11-12 Mat SW input 2


2-16


2-17

~LED~

LED No Function Details LED1 Teach/playback mode Lights in the playback mode. LED2 Motors ON Lights with Motors ON. LED3 Motors ON enable Lights when the software is in “Motors ON” status. LED4 Internal/ external

select Lights while the external signal has been controlling “Motors ON/OFF” signal.

LED5 MS ON enable Lights when the software enables the servo power ON. LED6 TP enable Lights in the playback mode, interlocking with the selector SW on

Teach pendant. LED7 External mode select Lights when the external mode is selected. LED8 Deadman ON Lights when both Deadman switches are gripped. LED9 Deadman OFF Lights when either one, or both, of Deadman switches is released. LED10 Emergency stop Lights when EMG from TP, the operation box or the external EMG

input is released. LED11 Safety plug Lights when the safety plug is short-circuited. LED12 Servo ON -1 Lights while the servo power is being supplied to the drive unit. LED13 Servo ON -2 Lights while the servo power is being supplied to the drive unit. LED14 Servo ON Lights while the servo power is being supplied to the drive unit. LED16 Over travel LS2 Lights when the over travel LS is short-circuited. LED17 Over travel LS Lights when the over travel LS is short-circuited. LED18 Emergency stop -1 Lights unless the emergency stop button on Teach pendant or the

operation box is depressed, interlocking with the emergency stop output signal of TPEX2.

LED19 Emergency stop -2 Lights unless the emergency stop button on Teach pendant or the operation box is depressed, interlocking with the emergency stop output signal of TPEX2.

LED20 WPS check Lights when the software allows the inching/retracting function of the welding power supply.

LED21 OFF check Lights while the magnet SW is OFF. LED does not light up when the magnet SW or the relay in the emergency stop circuit is in contact stick.

LED26 CPU error Lights when the CPU error occurs. LED30 24V power Lights while 24V power is being supplied.

JP setting ×：Open (Single-ended) ○：Short-circuit

Setting location Setting status JP1A 1-2 : ○ JP1B 1-2 : ○ JP2 1-2 : ○ JP3 1-2 : ○ JP5A 1-2 : ○


2-18

2.3.7 IPM Drive Unit

IPM drive unit is a servo amplifier to drive the motor, consisting of the encoder I/F, the motor drive circuit, the brake control circuit and other components. ~Function~

・Servo control CPU ・Encoder interface ・Motor drive power supply ・Motor drive circuit ・Brake control circuit

~General appearance ~


2-19

～Connection～

Connector Function Details CNRST Motor power input Connecting to the high-power unit. CNAP Built-in power input Connecting to the multi power supply unit. CNPN Motor power output Connecting to the additional axis dedicated drive unit. CNR Regeneration discharge

resistor I/F Connecting to the regeneration discharge resistor.

CNP1～5 Motor I/F Connecting to the manipulator motor. CNEC1 Encoder I/F Connecting to the manipulator encoder. CNEC2 Encoder I/F Connecting to the encoder of external axis (7th axis). CNP5E Encoder power input Connecting to the encoder power inside IPM drive unit. CNP5V 5V control power input Connecting to the multi power supply unit. CNUSB Upper CPU communication

I/F Connecting to CN4 on CPU board.

CNSV Sequence board I/F Connecting to the sequence board (UM213). CNMS High-power unit I/F Connecting to the high-power unit. CNBK90 Brake power DC90V output (AC100V full-wave rectification) A1-B1 Output For 1st ～3rd axis A2-B2

A3-B3 For 4th ~ 6th axis

A4-B4 A5-B5 A6-B6

For 7th axis

CNBKSW Brake positive release input Connecting to the brake positive release connector. CNDB Dynamic brake I/F Containing the output signal that can control the short-circuit

relay used as a dynamic brake. (Both the dynamic brake and the short-circuit relay are external items for connection.) Note that only the type MS3,MH2 and MG3 allow to connect the dynamic brake.

CNBKA Additional axis brake signal Connecting to the additional axis dedicated IPM drive unit. CNSVA Additional axis sequence

signal Connecting to the additional axis dedicated IPM drive unit.

CNACI Brake power input AC100V input CNACO Brake power output AC100V output

(For the brake positive release unit : Option) CNSHK Shock sensor signal input Connecting to the shock sensor of manipulator. CNSHLA Additional axis shock sensor

signal Connecting to the additional axis dedicated IPM drive unit.

CNEX Additional axis servo signal Connecting to the additional axis dedicated IPM drive unit. ~LED display~

(UM221)

LED No Function Details LED color

LED1 Clock stop Flashes during the initial diagnosis. Orange LED2 Communication CPU

error Lights when the communication CPU error occurs. Red

LED3 Communication CPU motion monitor

Flashes while the communication CPU normally works. Green

LED4 Main axis servo CPU motion monitor

Flashes while the main axis servo CPU normally works. Green

LED5 Wrist axis servo CPU motion monitor

Flashes while the wrist axis servo CPU normally works. Green


2-20

(L8800Y)

LED No Function Details LED1 Brake release (DC) Lights while the brake voltage on DC side is ON. LED3 Servo error Lights when the servo error occurs. LED4 M1–1 Lights when J1~J3 axis are effective. LED5 M1 –2 Lights when J4~J6 axis are effective. LED6 M1 –3 Lights when J7 axis is effective. LED8 Teach/playback mode Lights in the playback mode. LED9 Over travel Lights when Over travel LS is ON, however, not when the signal is dual. LED10 Servo ON Lights when the servo power is supplied to the drive unit. LED101 Brake release (AC1) Lights while the brake voltage on AC side (relay) of J1～J3 axis are ON. LED102 Brake release (AC2) Lights while the brake voltage on AC side (relay) of J4～J6 axis are ON. LED103 Brake release (AC3) Lights while the brake voltage on AC side (relay) of J7 axis is ON. LED111 Brake voltage check 1 Lights while the brake voltage on AC side (relay) of J1～J3 axis are normal. LED112 Brake voltage check 2 Lights while the brake voltage on AC side (relay) of J4～J6 axis are normal. LED113 Brake voltage check 3 Lights while the brake voltage on AC side (relay) of J7 axis is normal. LED114 Brake voltage check Lights when AC100V is input from CNACI with the normal fuse.

~Check pin~

No. Details

Servo board (UM221) CTP5 5V control power CTM0 GND of 5V/15V control power CTP15 15V control power P5E 5V encoder power M5E 5V encoder GND CH1-4 Analog monitor (Option)

Brake board (L8800Y) CTP1 24V power CTM1 24V GND

~JP settings~ （UM221）

Setting location Default setting Remarks J2 1-2 ○ Do not change the preset default setting.

（L8800Y）

Setting location Default setting Remarks

J1 1-2 ○ Brake timing switch

Emergency stop delay ON：1-2 Emergency stop delay OFF：2-3

1-2 ○ J2

4-5 ○

Overrun system switch 1 system：1 – 2 ○, 4 - 5 ○

2 systems：2 - 3 ○, 4 - 5 ×

J101 1-2 × The alternative of 2 emergency stop output systems

Controlling by the additional axis brake board：× Controlling by the main board ：○

J103 1-2 ○ If independently controlling MS3 and 4 of the additional axis with the individual mechanism servo function, applying the additional axis : ×Also when using the external 2-axes unit : ×

J104 1-2 ○ If independently controlling MS5 and 6 of the additional axis with the individual mechanism servo function, applying the additional axis : ×Also when using the external 2-axes unit : ×


2-21

~Fuse~ （L8800Y）

Setting location Rating F101 250V 2A (φ 5.2×20)

2.3.8 High-power Unit High-power unit consists of the following items. ・ Power unit (Supplying AC200V input to each part in the controller) ・ Magnet SW (Controlling the power applied to the drive unit by signals from the brake board.) ・ Current limiting resistor (Limiting the inrush current when the servo turned ON.)

~Function~ ・Motor power supply magnet SW control ・ Noise filter function ・Inrush current limiting function



2-22

2.3.9 Teach Pendant

This part describes the technical information of AX-C teach pendant.

RX+X+ RX-X-

Y- Y+ RY- RY+

RZ+RZ-Z+Z-

７

４

８

５６

９

１２３

BS・０

FN

ENTER

ON OFF

-+

F1

F2

F4

F3

F5

F6

F7

F8

F9

General appearance of AX-C teach pendant

~Switches provided in Teach pendant~ (1) LCD unit LCD screen displays the details of operation currently being performed, the error log and others. (2) Sheet key A variety of keys including Numerical key, Function key, Axis key, Command key are allocated to the sheet keys. See the instruction manual about how to use each key, operation procedures and so on. (3) Selector switch This switch enables the servo power to be applied from Teach pendant. To apply the servo power, set the change-over SW in the operation box to Teach mode and this SW to the Teach side, and grip Deadman SW. If the change-over SW in the operation box had been set to Playback mode, set this SW also to the Playback side to turn the servo ON, no matter the status of Deadman SW. Unless the change-over SW in the operation box and this selector SW are set at the same status, no servo can be applied. (4) Emergency stop button Depress this button to urgently stop the robot. The servo power is shut off and the brake works by pressing this button. To release the emergency stop, then pull up this button. If you wish to bring the robot ready for the operation again, you need to press “Motors ON” button. (5) Deadman switch Gripping the teach pendant with both hands, Deadman switch is the one equipped in your left hand side. This switch can be operated only in Teach mode, by gripping for the servo ON and releasing for OFF. Servo power can be ON again by gripping Deadman SW only in the case that the servo power was turned OFF by releasing this SW. For the safety sake, Deadman switch should not be invalidated.


2-23

2.3.10 Operation Box and Start Box (Option)

Brief diagrams of the operation box and the start box are shown below.

Operation box Start box

General appearance of the operation box and the start box ~ Switches provided in Operation box and Start box~ (1) Teach/playback switch (TEACH/PLAYBACK) This switch is used when switching the mode of robot operation to TEACH/PLAYBACK. To keep the servo power ON, in Playback mode, set the selector switch on TP to “PLAYBACK” and press “Motor ON” button. In Teach mode, set it to “TEACH” and press “Motor ON” button. Then, grip Deadman switch. (2) Motors ON switch (MOTOR ON) By pressing this button, the robot operation mode changes to “Motors ON” status, changing its condition from OFF to flashing. When the servo power is ON, this button lights up. (3) Start switch (START) The taught program starts running by pressing this button in PLAYBACK mode. This button lights while that program is running. (4) Temporary stop switch (STOP) A robot temporarily stops by pressing this button during playback operation. This button lights while the robot is temporarily in halt. (5) Emergency stop switch (EMERGENCY STOP) Press this button to urgently stop the robot. Then, the servo power is shut off and the brake works. To release this emergency stop, turn this switch to the arrow direction.


2-24

2.4 Function of Optional Items

2.4.1 Relay Unit With the Relay unit (L9110), the general-purpose physical I/O can be connected on the terminal board, and the

general-purpose physical output can be output at the relay contact. A relay unit can be connected to I/O board by one-to-one, which means the extension of relay unit requires the same number of I/O board.

Condition setting Setting the direct general-purpose logical I/O port in the task programs. Allocation setting Allocating the logical I/O port to the physical I/O port in the I/O conversion table. General-purpose physical I/O

Relay unit : Extension is available up to 64 I/O points by a unit of 32 points (Option). (2 units maximum in a single case)

Electrical input specifications ON/OFF of DC24V, 10mA

Exte

rnal

con

trol i

nput

Electrical output specifications

Relay contact (Dry contact) output : AC100V or DC30V, 1A Note) Minimum : DC5V, 1mA

Note) This value is only a rough standard for the minimum load. It may vary in a practical operation depending on the switching frequency, the ambient condition and the expected reliability. Be sure to check with the actual load.


2-25

~Allocation on Terminal block~ ・Input signal AX-C controller (Standard specifications) is equipped with 32 points of DC24V input signals. These signals can be arbitrarily allocated to either general-purpose input signals or status input signals (significant such as the external start signals). The following table shows the default at the factory shipment.

List of input signals (TBIN1)

TB pin No. Signal name (IN*) Description

1 IN1 General input signal 2 IN2 General input signal 3 IN3 General input signal 4 IN4 General input signal 5 IN COM1 Common for Pin No.1～4 (IN1～IN4) 6 IN5 General input signal 7 IN6 General input signal 8 IN7 General input signal 9 IN8 General input signal

10 IN COM2 Common for Pin No.6～9 (IN5～IN8) 11 IN9 General input signal 12 IN10 General input signal 13 IN11 General input signal 14 IN12 General input signal 15 IN COM3 Common for Pin No.11～14 (IN9～IN12) 16 IN13 General input signal 17 IN14 General input signal 18 IN15 General input signal 19 IN16 General input signal 20 IN COM4 Common for Pin No.16～19 (IN13～IN16) 21 24V Internal power supply 24V 22 EX 24VA External power input (24V) 23 EX 24VB External power output (24V)

List of input signals (TBIN2)

TB pin No. Signal name (IN*) Description

1 EX 0VB External power output (0V) 2 EX 0VA External power input (0V) 3 0V Internal power 0V 4 IN17 Program select bit 1 5 IN18 Program select bit 2 6 IN19 Program select bit 3 7 IN20 Program select bit 4 8 IN COM5 Common for Pin No.4～8 (IN21～IN24) 9 IN21 Program select bit 5

10 IN22 Program select bit 6 11 IN23 Program select bit 7 12 IN24 Program select bit 8 13 IN COM6 Common for Pin No.9～12 (IN21～IN24) 14 IN25 Program strobe U1 15 IN26 General input signal 16 IN27 General input signal 17 IN28 General input signal 18 IN COM7 Common for Pin No.14～17 (IN25～IN28) 19 IN29 General input signal 20 IN30 General input signal 21 IN31 External stop (Input a signal when not used.) 22 IN32 External “Motors” OFF 23 IN COM8 Common for Pin No.19～22 (IN29～IN32)


2-26

TBIN1,TBIN2

IN1

IN2

INCOM

P1

EXP1(24V)

　　TBIN1-22pin

EXP1(24V)

　　TBIN1-23pin

EXM1(0V)

　　TBIN2-1pin

EXM1(0V)

　　TBIN2-2pin

M1

24V

Relay boardI/O board

CNIN

Signal input from the

external jigs etc.

.....

.....

.....

.....

.....

.....

.....

Basic configuration of input circuit

TBIN2 TBIN1 TBIN2 TBIN1

TBIN2 TBIN1

TBIN1TBIN2

2221

231

32

23

2122

123

23

2122

1

32

22213

21 23

External power supply input(0V)

External power supply input(24V)

1 2

3

4

External power supply output(24V)

External power supply output(0V)

Idea about the external 24V power supply

(1) Check that the short-circuit cable is connected to TBIN1 and TBIN2. (2) Unfix the short-circuit cable connected to each TBIN1 and TBIN2. (3) Connect the terminals for external power input (24V) and (0V) as shown in (3) above.

If applying multiple relay units or supplying 24V power to another, connect the 24V output terminal as shown in (4) above.


2-27

･Output signal AX control unit (standard specifications) is equipped with 32 points of DC24V output signals. These signals can be arbitrarily allocated to either the general-purpose output signals or the status output signals (significant signal such as “In starting-up”). The following table shows the default at the factory shipment.

List of output signals (TBOUT1)

TB pin No. Signal name ( OUT*) Description

1 OUT1 General output signal 2 OUT2 General output signal 3 OUT3 General output signal 4 OUT4 General output signal 5 OUT COM1 Common for Pin No.1～4 (OUT1～OUT4) 6 OUT5 General output signal 7 OUT6 General output signal 8 OUT7 General output signal 9 OUT8 General output signal

10 OUT COM2 Common for Pin No.6～9 (OUT5～OUT8) 11 OUT9 General output signal 12 OUT10 General output signal 13 OUT11 General output signal 14 OUT12 General output signal 15 OUT COM3 Common for Pin No.11～14 (OUT9～OUT12) 16 OUT13 General output signal 17 OUT14 General output signal 18 OUT15 General output signal 19 OUT16 General output signal 20 OUT COM4 Common for Pin No.16～19 (OUT13～OUT16)

List of output signals (TBOUT2)

TB pin No. Signal name ( OUT*) Description

1 OUT17 General output signal 2 OUT18 General output signal 3 OUT19 Unit READY U1 4 OUT20 Program end U1 5 OUT COM5 Common for Pin No.4～8 (OUT17～OUT20) 6 OUT21 Error U1 7 OUT22 Interlock alarm U1 8 OUT23 Alarm U1 9 OUT24 On emergency stop

10 OUT COM6 Common for Pin No.9～12 (OUT21～OUT24) 11 OUT25 In teach mode 12 OUT26 On starting U1 13 OUT27 External programs are selected. 14 OUT28 External startup is selected. 15 OUT COM7 Common for Pin No.14～17 (OUT25～OUT28) 16 OUT29 Motors ON 17 OUT30 Status output 1 18 OUT31 Task origin position 1 U1 19 OUT32 Information U1 20 OUT COM8 Common for Pin No.19～22 (OUT29～OUT32)


2-28

Signal output to the external jigs etc.

.....

.....

.....

.....

.....

.....

.....

TBOUT1

CNOUT

I/O board Relay board

OUT1

OUTCOM

OUT4

EXM1

EXP1

Standard configuration of output circuit


2-29

2.4.2 Step-down Transformer (Floor-installation type)

The primary-side input voltage of the standard robot controller is 3-phase AC200V+10％, -15％(50/60Hz). With any other higher input voltage, this transformer enables to step down the spplied voltage to 200V by being connected with the robot controller.

・ Types of step-down transformer

The following table shows types of step-down transformer (TF10). Two of them in the table, except L8472A, are the individual-installation type set up separately with the robot controller.

Types of step-down transformer

Type Capacity Applicable system configuration (Note) Remarks

L9095 3 kVA AX-MV6/MG3/Roboland series (single unit) AX-MV6/MG3/

Installed at the bottom of controller

(Note) The applicable system configurations in the table above are only the examples. For selecting a step-down

transformer applying to your system, contact our company.

・ Connection of step-down transformer

Mounting location and connection way of the step-down transformer (3kVA capacity type) is shown below.

Mounting location and connection way of the step-down transformer


2-30

Connection of step-down transformer


2-31

・ Voltage switching tap of Auxiliary transformer (TF10)

The auxiliary transformer (TF10) supports the primary input voltage of AC190, 200, 208, 220, 230, 240, 380, 400, 415, 440, 460, 480 and 575V. To choose one of these voltage alternatives, the auxiliary transformer (TF10) is provided with the voltage switching tap as shown in Fig 2.16.3.1. Connect the jumper wire as shown in the table 2.16.3.1 according to the power voltage to be applied for switching the tap.

U U1 U2 U3 U4 U5 U6 U7 V V1 V2 V3 V4 V5 V6 V7 W W1 W2 W3 W4 W5 W6 W7

U8 U9 U10U11U12U13U14U15V8 V9 V10V11V12V13 V14V15W8W9W10 W11W12W13W14W15

R R1 R2 S S1 S2 T T1 T2 Sh

Voltage switching tap of Auxiliary transformer (TF10)


2-32

(U

)

(U1)

(U2)

(U3)

(U4)

(U5)

(U6)

(U7)

190V

200V

207.

5V22

0V23

0V24

0V28

7.5V

U

0V

(U8)

(U9)

(U10

)(U

11)

(U12

)(U

13)

(U14

)(U

15)

0V

(V)

(V1)

(V2)

(V3)

(V4)

(V5)

(V6)

(V7)

V

(V8)

(V9)

(V10

)(V

11)

(V12

)(V

13)

(V14

)(V

15)

(W)

(W1)

(W2)

(W3)

(W4)

(W5)

(W6)

(W7)

W

(W8)

(W9)

(W10

)(W

11)

(W12

)(W

13)

(W14

)(W

15)

0V 200V

220V

(R)

(R1)

(R2)

R

0V 200V

220V

(S)

(S1)

(S2)

S

0V 200V

220V

(T)

(T1)

(T2)

T

sh

190V

200V

207.

5V22

0V23

0V24

0V28

7.5V

0V 190V

200V

207.

5V22

0V23

0V24

0V28

7.5V

0V 190V

200V

207.

5V22

0V23

0V24

0V28

7.5V

0V 190V

200V

207.

5V22

0V23

0V24

0V28

7.5V

0V 190V

200V

207.

5V22

0V23

0V24

0V

287.

5V

Internal circuit of the auxiliary transformer (TF10)

CAUTION

To avoid the electric shock hazard, be sure that the auxiliary transformer has not been impressed before switching the voltage switch tap. In addition, hang up a sign “Under operation” or others beside the power supply switch for enough safety measures.

Connection of jumper wires by the primary-side power voltage

Connection of the jumper wires Primary power voltage Primary-side tap Secondary-side tap 190V U-U8, U1-U9, U1-V, V-V8, V1-V9, V1-W, W-W8, W1-W9, W1-U 200V U-U8, U2-U10, U2-V, V-V8, V2-V10, V2-W, W-W8, W2-W10, W2-U 208V U-U8, U3-U11, U3-V, V-V8, V3-V11, V3-W, W-W8, W3-W11, W3-U 220V U-U8, U4-U12, U4-V, V-V8, V4-V12, V4-W, W-W8, W4-W12, W4-U 230V U-U8, U5-U13, U5-V, V-V8, V5-V13, V5-W, W-W8, W5-W13, W5-U 240V U-U8, U6-U14, U6-V, V-V8, V6-V14, V6-W, W-W8, W5-W13, W5-U 380V U1-U8, U9-V, V1-V8, V9-W, W1-W8, W9-U 400V U2-U8, U10-V, V2-V8, V10-W, W2-W8, W10-U 415V U3-U8, U11-V, V3-V8, V11-W, W3-W8, W11-U 440V U4-U8, U12-V, V4-V8, V12-W, W4-W8, W12-U 460V U5-U8, U13-V, V5-V8, V13-W, W5-W8, W13-U 480V U6-U8, U14-V, V6-V8, V14-W, W6-W8, W14-U 575V U7-U8, U15-V, V7-V8, V15-W, W7-W8, W15-U

R-T1 R1-S S1-T


2-33

(U

)

(U1)

(U2)

(U3)

(U4)

(U5)

(U6)

(U7)

190V

200V

207.

5V22

0V23

0V24

0V28

7.5V0V

(U8)

(U9)

(U10

)(U

11)

(U12

)(U

13)

(U14

)(U

15)

0V

(V)

(V1)

(V2)

(V3)

(V4)

(V5)

(V6)

(V7)

(V8)

(V9)

(V10

)(V

11)

(V12

)(V

13)

(V14

)(V

15)

(W)

(W1)

(W2)

(W3)

(W4)

(W5)

(W6)

(W7)

(W8)

(W9)

(W10

)(W

11)

(W12

)(W

13)

(W14

)(W

15)

0V 200V

220V

(R)

(R1)

(R2)

R0V 20

0V

220V

(S)

(S1)

(S2)

S

0V 200V

220V

(T)

(T1)

(T2)

T

sh

190V

200V

207.

5V22

0V23

0V24

0V28

7.5V

0V 190V

200V

207.

5V22

0V23

0V24

0V

287.

5V0V 19

0V20

0V20

7.5V

220V

230V

240V

287.

5V

0V 190V

200V

207.

5V22

0V23

0V24

0V

287.

5V0V 19

0V20

0V20

7.5V

220V

230V

240V

287.

5V

U V W

Connection example of the case - 240V input voltage -

(U)

(U1)

(U2)

(U3)

(U4)

(U5)

(U6)

(U7)

190V

200V

207.

5V

220V

230V

240V

287.

5V

U

0V

(U8)

(U9)

(U10

)(U

11)

(U12

)(U

13)

(U14

)(U

15)

0V

(V)

(V1)

(V2)

(V3)

(V4)

(V5)

(V6)

(V7)

V

(V8)

(V9)

(V10

)(V

11)

(V12

)(V

13)

(V14

)(V

15)

(W)

(W1)

(W2)

(W3)

(W4)

(W5)

(W6)

(W7)

W

(W8)

(W9)

(W10

)(W

11)

(W12

)(W

13)

(W14

)(W

15)

190V

200V

207.

5V

220V

230V

240V

287.

5V

0V 190V

200V

207.

5V

220V

230V

240V

287.

5V0V 19

0V20

0V20

7.5V

220V

230V

240V

287.

5V

0V 190V

200V

207.

5V

220V

230V

240V

287.

5V0V 19

0V20

0V20

7.5V

220V

230V

240V

287.

5V

0V 200V

220V

(R)

(R1)

(R2)

R

0V 200V

220V

(S)

(S1)

(S2)

S

0V 200V

220V

(T)

(T1)

(T2)

T

sh

Connection example of the case - 415V input voltage -

CAUTION

Robot controller may be damaged with the impression of over voltage. Before turning the power ON, check that the jumper wires suit to the actually supplied power voltage and are in a proper connection.


2-34

2.4.3 Robot I/F Board

This is to control the communication between the robot controller and the welding power supply. Applicable combination of welding power supplies and robot I/F boards are shown in the table below.

Type of Welding power supply and Robot I/F board

Welding power supply Robot I/F board

CPDRA-351 L8268R00 CPDRA-501 L8268R00 CPDPAS-351 L8268P00 CPDPAS-501 L8268P00 CPDACA-201 L8268M00

ADPA-301 L8268T00 ~Connection~

Connector Connection destination

CN 52 CN 52 on Robot I/F board CN 53 CN 54 CN 55

When applying a sensor

CN 56 When applying Arc sensor CN 57 CN 27 on Relay unit CN 58 2nd welding power supply (L8268C CN58) CN 59 Terminal resistor CN 60 For maintenance (CAN flash writer card & cable) CN 61 For maintenance (PC cable) FC 51 Welding power supply (P6840P CN 1)

~Test pin~

Test pin No. Connected to :

TP 1 15G TP 2 -15V TP 3 +15V TP 4 GND TP 5 +5V

~Jumper pin~

Setting location Function Setting status

(at shipment) Remarks

1-2 Short-circuit 3-4 5-6 7-8 Open JP1 Do not change from the

standard setting. 9-10

Setting the interrupt port to sensor from the robot I/F. 1-2 :IRQ 9 3-4 :IRQ 70 5-6 :IRQ 5 7-8 :IRQ 4 9-10 :IRQ 3 IRQ 9 is fixed set. Do not change the standard setting.

JP2 Do not change from the standard setting.

1-2 Short-circuit Communication circuit section: For switching power supply (5V)

Short-circuit: Using the internal power supply

Open: Using the external power supply

JP3 Do not change from the standard setting.

1-2 Short-circuit Communication circuit section: For switching power supply (GND)

Short-circuit: Using the internal power supply

Open: Using the external power supply


2-35

~Connection of emergency stop signal~ Follow the instructions below for connecting the emergency stop signals to the welding power supply. (1) For CPDPAS-351/501, CPDACA-201 and CPDRA-351/501

プリント板P6981Q

端子台NO.→＋＋＋

8 7 1

CN5

(2) For ADPA-301

プリント板P10216Q

端子台NO.→＋

2 1＋

CN1

~Dip SW on Robot I/F Board~

Normal 1 2 3 4 5 6 7 8 Dip Switch 0 1 2 CKP MD RD BT U2

Robot I/F board 1 OFF OFF OFF OFF OFF ON OFF OFF Robot I/F board 2 OFF ON OFF OFF OFF ON OFF OFF

Terminal block Terminal No. Cable CN5 7 EMG+: Blue 8 EMG-: White

Terminal block Terminal No. Cable CN1 1 EMG-: White 2 EMG+: Blue

Terminal block No.

Terminal block No.

Print board

Print board


2-36

2.4.4 CAN I/F Board (Option)

CAN I/F board (option) is required when connecting DM power supply and the robot controller. ~Connection~

Connector No. Remarks

CN 1 24V power supply CN 2 Communication connector CN 3 CAN input connector CN 4 CAN output connector

~Test pin~

Test pin No. Remarks

CH101 24V CH102 0V (GND of 24V and CAN5V) CH103 CAN5V CH104 D5V CH105 D0V

~Connection of the emergency stop signal~ Stop signals to the welding power supply must be connected as follows. < For DM350 >

端子台NO.→＋

4 3 2 1＋＋＋

CN2

プリント板P10260T

Terminal block Terminal No. Cable CN2 1 EMG +: Blue 2 EMG -: White

Terminal block No. Print board


2-37

2.4.5 Welding Power Supply I/F

< Welding power supply I/F AXWF-0005 >

Welding power supply I/F is required when applying the robot coupling with the general semi-automatic welding power supply that does not build in the robot I/F function.

~Function of welding power supply I/F~

(1) Following the robot task programs to send out the start instruction to the welding power supply. (2) Calculating the welding conditions taught in the task programs by following the welding characteristics data

stored in the system parameters, and outputting the command voltage to the welding power supply. (3) Controlling the wire feed unit and the gas solenoid valve. (4) Detecting Arc start failure, Arc outage and Wire stick in the welding end position.

To install the welding power supply I/F, screw 4 pieces of locking nuts (M8) to the anchor bolt.

General appearance of welding power supply I/F

~Details of welding power supply I/F~ Power lamp AC200V power is supplied to the welding power supply I/F from the robot controller. The lamp provided in the front panel of welding power supply I/F as shown above lights up when the proper power is supplied. If this lamp does not light up even though the robot controller is turned ON, check that either the fuse F1 in the welding power supply I/F or the fuse F10 in the power cable is not blown.


2-38

~About Print board (L8770L) in the welding power supply I/F~

Components layout on Print board (L8770L)

(1) Display of motion status on Print board (L8770L)

LED function on the print board (L8770L), to display the motion status of the welding power supply I/F, is shown below.

Motion status LED on Print board (L8770L) Motion status

LED No. Color Function Description

Inching

Retracting

Gas

checking

Welding

At w

elding end

During

emergency

stop

LED 1 Green Emergency stop Lights off while inputting the

emergency stop signal.

Lights off during emergency stop

OFF

LED21

Green Arc start Lights on while the Arc start

command signal is being output to the welding power supply.

Lights on during welding performance

ON ON

LED22 Green Wire inching

Lights on while operating inching/ retracting directly on TP.

Lights on during wire inching/ retracting operation

ON ON

LED23

Green Wire feed Lights on while the wire feed

command signal is output to the wire feed unit and the welding power supply.

Lights on during welding performance and wire inching/ retracting operation

ON ON ON ON

LED24 LED29

Green Wire feed motor +/- rotation Lights on when rotating the

motor of wire feed unit the other way.

Lights on during wire retracting

ON

LED25

Green Wire stick Lights on while the welding

power supply I/F is detecting wire stick.

Lights on when the welding performance ends. However, it lights out if the wire stick detection function has been set to OFF in the system parameter.

LED27

Green Gas valve motion Lights on while the opening

command for gas solenoid valve is being output.

Lights on during gas checking or welding performance

ON ON ON


2-39

(2) Setting SW on Print board (L8770L)

The switches in the table below are provided on the print board (L8770L) inside the welding power supply I/F to specify the command voltage and the polarity for each welding power supply.

Switch on Print board (L8770L)

Switch Function Description

JP11 (REF1 switch)

Welding current designated switch

This is to switch the setting of base current command signal.

JP12 (REF2 switch)

Welding voltage designated switch

This is to switch the setting of filler wire feeding command signal.

Select the range of command signal voltage from 0 ～ 5V, 0 ～ 10V and 0 ～ 15V and the polarity from either positive (+) or negative (-). Refer to the table below to properly connect the jumper pins.

Range of command voltage for each welding power supply

Welding current command SW Welding voltage command SW Welding power supply

Voltage range Polarity Voltage range Polarity TIG welding power supply AVP-300P / 500P 15V Positive 15V Negative

Plasma cutter TRC-121 10V Positive - -


2-40

~ Motion sequence of welding power supply I/F ~

Welding power supply I/F outputs a signal to the welding power supply by the timing as shown below, using the setting of system parameters and the commands such as Arc start/ end or wire inching given from the robot controller.

Information in the table below is only an example of motion sequence of the welding power supply I/F. The actual motion may differ depending on the type of welding power supply to be used and the setting details of system parameters.

1. If coupling the welding power supply and the robot both from DAIHEN, the default setting of wire slow down,

hot start voltage and hot start time are all set in advance to the optimum values for each welding power supply. For this reason, these parameters cannot be changed on the robot side.

2. If coupling the welding power supply from other companies and our robot, wire slow down, hot start voltage

and hot start time can be even specified on the robot side.

Example of the motion sequence of welding power supply I/F Signal Specifications Timing chart

Welding start (Torch SW)

Dry contact (relay CR21) OMRON LY2,DC24V MAX :5A, AC110V, DC24V MIN :0.1A, DC5V

Wire inching ON/OFF

Dry contact (relay CR22) FUJITSU COMPONENT

VS-24MB MAX :2.5A, AC110V, DC24V MIN :0.1A, DC5V

Current value command (REF 1)

0～15V DC MAX :50mA (A polarity differs depending on the type of welding power supply.)

Current value command (REF 2)

0～15V DC MAX :50mA (A polarity differs depending on the type of welding power supply.)

Wire feeding motor ON/OFF

Dry contact (relay CR22) OMRON LY2,DC24V MAX :5.0A, AC110V, DC24V MIN :0.1A, DC5V

Gas valve ON/OFF

DC24V Output MAX :300mA

Wire stick detection current

DC24V Output MAX :100mA

Welding current

0～500A(MAX) (Depending on the welding power supply)

OFF

ON

OFF

ON

OFF

ON

AS AE

WCR-ON WCR-OFF

ワイヤスローダウン

クレータフィラ

ホットスタート電圧

ホットスタート時間

アンチスティック

ワイヤ溶着解除の為のアンチスティック

アフターフロープリフロー

100mA

Wire slow down

Crater filler

Anti wire stick Hot start voltage

Anti wire stick for releasing the wire stick

Hot start time

Pre-flow Post-flow

Chapter 3 Replacement of Components and Adjustment

This chapter describes how to replace and adjust the components.

3.1 Replacement of Components .....................................................................3-1

3.1.1 Replacement of Board and Multi Power Unit ........................................3-2 3.1.2 Replacement of Sequence Board .........................................................3-4 3.1.3 Replacement of IPM Drive Unit.............................................................3-5 3.1.4 Replacement of High-power Unit ..........................................................3-6 3.1.5 Replacement of Battery.........................................................................3-7 3.1.6 Replacement of Cooling Fan.................................................................3-8

3.2 Adjustment ..................................................................................................3-9 3.2.1 Adjustment of Power System ................................................................3-9 3.2.2 How to Replace Primary Power Supply ..............................................3-10

3.1 Replacement of Components

3-1


For replacement of the print board and the unit in AX controller, it takes about 10 minutes or less respectively. Be sure to obey the following notes to safely perform the operation.

WARNING

Before replacing the components, be sure that 5 minutes or more has passed since the primary power was shut off. Do not perform the operation with wet hands, otherwise, you may sustain a serious injury or be shocked to death by electricity.

WARNING

Replacement operation must be performed only by the engineers who have taken our robot school (maintenance course). Inexpert operators may be shocked to death by electricity or caught in an unexpectedly moved robot to result in a serious injury or a fatal accident.

WARNING

Before operation, short-circuit between the operator’s hands and “G terminal” in the robot controller, to make the same level of electric potential. Otherwise, you may sustain a serious injury or be shocked to death by electricity.

WARNING

When replacing the connectors, be sure not to make wrong connection or skip any of them. Each print board is connected with multiple connectors. Any mistakes in connection may cause the electric shock or burning down to result in a serious injury or a fatal accident.

WARNING

Do not damage the cables when replacing the components. Do not touch any electrical parts on the print board or any contact parts of the connector. When you hold the print board, do it with the edges. If you accidentally touch the electrical parts, you may sustain a serious injury or be shocked to death by electricity.

WARNING

Follow the notes below when applying the primary power with the controller door opened due to the maintenance work etc. Otherwise, the robot and its controller will malfunction or cause a trouble. 1. Do not expose the controller to the direct sunlight. 2. After opening the door, do not apply the strong sunlight such as a serchlight to the

internal parts of controller.


3-2

3.1.1 Replacement of Board and Multi Power Unit

Before operation, be sure to check that 5 minutes or more has passed since the primary power was shut off. Otherwise, an electric charge must be still remained on a board and an electrolytic condenser.

How to remove :

(1) Loosen 2 pieces of screws at the base of AX-C robot controller. (These screws are fixing the rack.) After this operation, remove the cable and other items connected to the rack and pull it out to this side.

(2) Each board can be taken out by removing the screws fixing the metal fittings.


3-3

How to install :

(1) Insert a board into the rack along the board rail. Next, push it down until the connector goes in, and then fix it with screws.

(2) Slide the rack into the base of AX-C controller. Be sure that the rack has slid under the stopper at the base as shown in the figure below. Then, fix it with 2 pieces of screws and reconnect the cables.


3-4

3.1.2 Replacement of Sequence Board


How to remove :

(1) Remove all the connectors jointed to the sequence board (L8800F00). (2) Remove the screws that fix the sequence board. (6 locations)

How to install :

(1) Fix the sequence board with screws. (2) Attach the connectors originally connected to the sequence board.

Note : ・ Do not damage the removed connectors during operation. ・ Attach all the required connectors. Otherwise, it will cause a trouble.


3-5

3.1.3 Replacement of IPM Drive Unit


How to remove :

(1) Remove all the external connectors. (2) Remove 4 pieces of screws that fix IPM drive unit. (3) Pull out the IPM drive unit to the front. When doing this operation, do not touch the board and the

electrolytic condenser but hold the can part.

How to install :

(1) Insert IPM drive unit from the front of robot controller. (2) Fix IPM drive unit with screws. (3) Attach the connectors originally connected to IPM drive unit.

Note :

・ Do not hit the heat sink on the back. ・ Do not damage the removed connectors. ・ Do not drop IPM drive unit at your feet. It weighs about 15kg. ・ Attach all the required connectors. Otherwise, it will cause a trouble.


3-6

3.1.4 Replacement of High-power Unit


How to remove :

(1) Remove all the connectors jointed to the high-power unit. (2) Remove the screws that fix the high-power unit. (2 locations as shown in the figure below.) (3) Pull out the high-power unit to the front.

How to install :

(1) Insert the high-power unit from the front of robot controller. (2) Fix the high-power unit with screws. (3) Attach all the necessary connectors for connecting the high-power unit.

Note :

・ Do not damage the removed connectors. ・ Fix all the required connectors. Otherwise, it will cause a trouble.


3-7

3.1.5 Replacement of Battery Before operation, be sure to check that 5 minutes or more has passed since the primary power was shut off. Otherwise, an electric charge must be still remained on a board and an electrolytic condenser.

How to remove :

(1) Follow the information in 3.1.1 (Replacement of Board and Multi Power Unit) to pull out CPU board. (2) Remove the battery (CR2032) attached on the board.

How to install :

(1) Mount the battery (CR2032) on CPU board. (2) Follow the information in 3.1.1 (Replacement of Board and Multi Power Unit) to install CPU board.

Note :

After replacing the battery (CR2032), reset the date and time.

CPU

CN1DIMM1DIMM2 CN2 CN3 CN4

CN5

CN

9

JP1JP2 JP3

JP5

CN10

JP8Bttery

CR2032

JP9

JP7

JP4

CN12

CN6

CN

7

CN11

LAN

MOUSE

VGA

KEY

Battery for replacement


3-8

3.1.6 Replacement of Cooling Fan

Before operation, check that 5 minutes or more has passed since the primary power was shut off.

How to remove :

(1) Detach the panel on the back of robot controller, the cooling unit and the rack. (2) Remove the power cable of fan. (3) Detach the panel, on which the fan is fixed, from the controller. (4) Finally, remove the fan from the panel.

How to install :

(1) Fix the fan onto the fan-fixing panel. (2) Attach the panel, on which the fan is fixed in ①, onto the controller. (3) Fix the power cable of fan. (4) Attach the panel on the back of robot controller, the cooling unit and the rack.

Note :

Consider the direction when fixing the fan so that the air convection occurs upwards.

3.2 Adjustment

3-9

3.2 Adjustment

AX controller usually does not require the adjustment except the replacing the power components. The points of adjustment and its locations are described as follows. Note that you should not touch any adjustment parts, unless otherwise required. Do not perform the adjustment operation before thoroughly inspecting the cause of trouble even if a trouble or fault occurs..

3.2.1 Adjustment of Power System When a trouble occurs in the power system or after the battery was replaced, measure the voltage of each power supply by inserting a tester check pin into the wire part of connector. Perform an adjustment if the measured value is out of the range of reference value. Use a digital voltmeter for the measurement.

Power Measurement location (See the following page.)

Reference value Adjustment point

Primary power supply Breaker CB1 Specified

voltage ±10% Switching the primary power supply (Note 1)

P1－M1 Sequence board (L8800F) Terminal block TBEX3 : P1 (P24V) - M1 (N0V)

DC24V±1.0V None If the measured value is out of range of the reference value, replace the DC power unit.

P5－M0 Drive unit (CNP5V connector) : P5 - M0

DC5.1V＋0.1V / -0.0V

The volume on the switching power in the multi power supply unit.

P5E－M0E Encoder power on IPM drive unit (CNP5E connector) : P5E – M0E

DC5.3V The volume on the IPM drive unit The voltage P5E - M0E is DC5.1V±0.1V in the closest part to the robot encoder.This value in the controller differs depending on a type of robot. It is about 5.3V if the wire harness is 5m.

(Note 1) For how to switch the primary power supply, refer to the following page.

3.2 Adjustment

3-10

3.2.2 How to Replace Primary Power Supply

< How to replace the primary power supply>

(1) Shut off the primary power supply. (2) Take out the high-power unit. (3) Change the connector of power unit to the one according to the desired voltage. Connector pins differ depending on the voltage specifications in each primary power supply.

Chapter 4 Periodic Inspection

This chapter describes the periodic inspection.

4.1 Periodic Inspection Schedule......................................................................4-1

4.1.1 Safety Measures in Inspection, Maintenance, Adjustment and Repair .4-1 4.1.2 Inspection Schedule..............................................................................4-3 4.1.3 Notes on Periodic Inspection ................................................................4-3 4.1.4 Warrantee Period ..................................................................................4-3 4.1.5 Inspection Item......................................................................................4-4 4.1.6 Inspection before Long Vacation...........................................................4-5

4.2 Maintenance Parts......................................................................................4-6 4.2.1 Maintenance Parts ................................................................................4-6 4.2.2 AXC*** ..................................................................................................4-7 4.2.3 Operation Box AXOP-00**................................................................4-10 4.2.4 Start Box AXST-00**......................................................................... 4-11 4.2.5 Welding Power Supply I/F (2CH specifications) AXWF-00** ............4-12 4.2.6 Welding Power Supply I/F (4CH specifications) AXWF-01** ............4-12 4.2.7 Control Cables ....................................................................................4-13 4.2.8 Alarm Display ......................................................................................4-17

4.1 Periodic Inspection Schedule

4-1


Perform the daily and periodic inspection to prevent troubles, ensure the safety and maintain the performance. This section describes the notes and details on periodic inspection operation.

4.1.1 Safety Measures in Inspection, Maintenance, Adjustment and Repair To perform the inspection, maintenance, adjustment and repair of AX controller, you may be required to enter the robot work area or to operate with the primary/ servo power ON. Be sure to follow the notes below in all cases.

WARNING

Do not enter the robot work area while the power is ON. Do not approach the robot while it is moving. Approaching the moving robot may cause a fatal accident resulting in a serious injury or death.

WARNING

Do not touch any live electrical parts. If you touch them, you may receive a fatal electric shock hazard or a burn.

WARNING

Keep your hands, fingers, hair, clothes and other belongings away from the revolving part. If you bring them to the parts such as the feed roll of wire feeder or the revolving part of the fan, you may be caught in a revolving part and get injured.

(1) To ensure your safety, perform the inspection, maintenance, adjustment and repair with wearing proper clothes

specified by laws and regulations such as a protective hard hat, a pair of safety shoes, a pair of gloves and so on. (2) Before operation, be sure to check that the robot can certainly stop when needed by testing the emergency stop or

temporary stop. Also, check that the fail-safe devices such as the safety plug or deadman SW, if equipped, properly work. If errors occur, stop the operation and immediately shut off the power supply. Then, inspect the cause of trouble to take remedies appropriate to the situation.

(3) Inexpert operators must not approach the robot safety fence. (4) Before operation, hang out a noticeable sign

“INSPECTION IN PROGRESS” as shown on the right to notify the operators of that the inspection is going.

(5) Do not use any devices to possibly cause electromagnetic noises in and around the area where the inspection is

going on. (6) Operations including the inspection must be performed by 2 or more persons; one for the practical operation and the

other as a monitor. (7) Only the operators who have been trained for the function, operation and maintenance of robots can perform the

work such as inspection, maintenance, adjustment, repairs and so on. Also, if the special equipment is provided, be fully acquainted with the equipment in details.

(8) Operators, even if qualified, must not perform the operation of the particular equipment without thorough knowledge.

INSPECTION IN PROGRESS


4-2

(9) The signals and gestures used for the inspection operator, monitor and other operators of related devices must be

carried out based on the safety management standards of each user. (10) Monitors must follow the notes below.

(A) Be in a position to overlook the entire robot work area to pay full attention for monitoring.

(B) Always carry the emergency stop button with you so that you can immediately press it when the error occurs.

(C) Do not allow anybody else to approach the robot work area unless they are engaged in the operation such as inspection.

(11) Operators to perform the inspection and other works must follow the notes below.

(A) Be sure to check if it is possible to perform some operations outside the robot work area. If it is the case,

perform all the operations outside that area. (B) Normally, turn off the robot before performing the inspection etc. If you have no choice but to operate while the

robot is working, be sure to report to the safety manager to ask for permission. After you obtain permission, then perform the operation outside the robot work area.

(C) If you are required to perform the operation with the robot stand-by, check the procedures beforehand to safely

carry them out. If not specially required, shut off the input power supply of robot controller, welding power supply etc. before operation. Besides, shut off the input power supply of jigs and peripheral equipment, or make it invalid unless the special procedure is needed.

(D) When entering the robot work area, prepare for the malfunction of robot so that you can immediately press the

emergency stop button. (E) Be sure to check the safety around your feet before operation. Do not work in an insecure or elevated (2m or

higher) scaffold. (F) When working in the robot work area, be sure that you could see the entire robot motion. Never turn your back

to the robot. (G) When replacing the print board inside the robot controller or the teach pendant, take the antistatic measures such

as using a static protective sheet and so on. (12) Follow the notes below when an error occurs during the operation.

(A) If you find any abnormal motions of robot, press the emergency stop button immediately. (B) Inform a monitor of the abnormality and turn off the robot controller.

Then, hang out the sign ”Do not turn ON.” Shown on the left. (C) Check that the peripheral equipment has also been turned off. (D) If you are required to enter the safety fence, be sure to remove the safety plug and keep it by yourself during

operation. (E) Even if the robot automatically stops by the abnormalities in such as the voltage supply to robot, oil pressure in

the peripheral equipment, air pressure or other factors, be sure to make it completely stop. Then, inspect the cause of trouble to take the measures against it.

(F) If the fail-safe function of the emergency stop button. does not work, shut off the main power immediately and

inspect the cause of trouble to take the measures against it. (G) When restarting after the emergency stop, inspect the cause of trouble and take the remedies first. Then, insert

the safety plug again and restart from the outside the fence.

(13) When you finish the work, be sure to always check that the required connectors, covers and panel are properly fixed and connected.

Do not turn ON.


4-3

4.1.2 Inspection Schedule Periodic inspection is essential to efficiently operate Almega series. Perform the inspection following the schedule as shown below.

4.1.3 Notes on Periodic Inspection ① Only the operators who have taken our robot school (maintenance course) can perform the inspection

operation.

② Before operating the inspection, be sure to have the required parts, tools and a drawing.

③ Use our specified parts for replacement.

④ Before inspecting the robot, be sure to turn OFF the power.

⑤ Be sure that the primary power has been turned off before opening the controller door. Pay great attention to avoid as much dust from the outside.

⑥ Wash your hands thoroughly before touching the parts in the controller. Especially when you touch the

print board and the connectors, pay great attention not to break IC parts by the discharge of static electricity etc.

⑦ Never enter the robot work area when you perform the inspection with robot working.

⑧ Measure the voltage only at the specified location and take the utmost care about an electric shock and a

short-circuit of wire.

⑨ Do not perform the inspection for robot and controller at the same time. Do it one after another.

⑩ After the inspection finishes, be sure to idle the robot for a while to check its motion and then perform the normal operation.

4.1.4 Warrantee Period

(1) We guarantee the robot system and provide the repair free of charge if the failures occurred within the

shorter period of the followings under the condition that the robot system has been properly operated and periodically inspected as described in the instruction manual, and that the failures are due to the manufacturing defects.

14 months after shipped from Japan if directly shipped from DAIHEN to the outside Japan (1 year after shipped from DAIHEN if shipped from DAIHEN to other manufacturers, and then

exported to the outside Japan.) Practical cumulative operating time of 2000 hours

(2) However, the warrantee policy shall not apply to the following cases even during the guarantee period.

Your repair will be charged.

(A) Failure due to an abuse or a misuse (B) Failure due to unauthorized repairs or model changes made by other than DAIHEN (C) Damage or failure due to act of God such as earthquake, fire and flood (D) Failure due to improper transfer or storage after delivery (E) Others similar to above (F) Consumable or maintenance parts

3-year inspection

1-year inspection 1-year

inspection 1-year inspection

3-month inspection

3-month inspection

3-month inspection

3-month inspection

3-month inspection

3-month inspection

3-month inspection

3-month inspection

3-month inspection

3-month inspection

3-month inspection

3-month inspection

Daily inspection

0 3 months 6 months 9 months 1 year 1 year &

3 months1 year & 6 months

1 year & 9 months 2 years 2 years &

3 months 2 years & 6 months

2 years & 9 months 3 years ~


4-4

4.1.5 Inspection Item

For performing the maintenance and inspection, refer to “3.2 Adjustment” and “5 Parts Arrangement” in ”Maintenance Manual for AX-C Controller” and carry out the inspection on the items listed below.

No. Cycle Item Check point Means

Dai

ly

3 m

onth

s

6 m

onth

s

1 ye

ar

3 ye

ars

1 ○ ○ ○ ○ ○ Whole outside • Adhesion of spatter, dust etc. Visual observation and cleaning2 ○ ○ ○ ○ ○ Display • Peeling, staining Visual observation and cleaning

3 ○ ○ ○ ○ ○

Controller back side • Cleaning the fin of cooling fan and turning check

• Checking and cleaning of the regeneration discharge resistance

Visual observation and cleaning

4 ○ ○ ○ ○ ○ Wire harness cable External cable Lead wire

• Damage, crush • Looseness of connector

Visual observation Tightening up

5 ○ ○ ○ ○ ○ Operation SW • Function of push button etc. Visual observation and cleaning

6 ○ ○ ○ ○ ○ Teach pendant Operation box Start box

• Display lamp Visual observation check

7 ○ ○ ○ ○ ○ Teach pendant Operation box Start box

• Emergency stop motion Be sure to check that pressing the emergency stop button can shut off the servo power.

8 ○ ○ ○ ○ ○ Entire controller • Dust, grime Visual observation and cleaning

9 ○ ○ ○ ○ Transformer • Heat, abnormal noise and abnormal odor

Visual observation, noise check and touching

10 ○ ○ ○ ○ Lead wire on terminal block

• Looseness of the lead wire on terminal block and

Visual observation and tightening up

11 ○ ○ ○ ○ Print board in the controller

• Looseness Secure it firmly.

12 ○ ○ ○ ○ Door gasket Lock key

• Gap and modified shape of gasket • Key locking

Visual observation Visual observation

13 ○ ○ ○ ○ Teach pendant • Damage

• Cleaning the operation sheet and display check

Visual observation Visual observation and cleaning

14 ○ ○ ○ Earth • Looseness and damage Visual observation, tightening up15 ○ ○ ○ Drive unit • Looseness of connector Tightening up 16 ○ ○ ○ Board connector • Looseness of connector Pushing by hands

17 ○ ○ ○

Inside the controller (Relay and power relay) Relay unit (Option)

• Dirt and deficit • Condition of contact

If damage is found by the visual observation, replace the parts with new one.

18 ○ ○ ○ Battery • Battery voltage 3.0V or more (Using a tester)

19 ○ ○ ○ Cooling fan • Adhesion of oil, fumes, dust etc. Visual observation and cleaning

20 ○ ○ ○

Voltage measurement

• Primary power voltage • R4-S4-T4 • P5-M0 • P1-M1 • P5E-M5E (Note 1)

Voltage specification±10% AC200V±10% DC+5V+0.1V/ -0.0V DC+24V±1.0V DC+5.1V±0.1V

21 ○ Magnetic contactor • Replacement of magnetic contactor 22 ○ Battery • Replacement of battery

(Note 1) The voltage at P5E-M0E is DC5.1V±0.1V on the robot side. Inside the robot controller, it slightly differs depending on the type of robot. It is about 5.3V with 5m of wire harness.


4-5

4.1.6 Inspection before Long Vacation

Before entering the vacation, check the following points and then turn off the power of robot. ① Check if the error “W1016 Encoder failure” is listed in the error history. If it is, replace the manipulator

battery with new one. Refer to “Robot Maintenance Manual” for how to replace it.

Check that the controller door is closed

4.2 Maintenance Parts

4-6


4.2.1 Maintenance Parts

The print circuit board applies the highly reliable parts. Comply with the following notes in performing

maintenance.

• Storage temperature –10 ~ +50 degrees When storing parts over the long term, it is recommended to keep in the range of 25±10 deg. Besides, abrupt variations in temperatures (over 10deg./hr.) must be avoided.

• Storage humidity 20 ~ 85% RH

When storing parts over the long term, it is recommended to keep in the range of 45～65%. Besides, choose the location in which no sign of dew condensation and mold are shown.

• Prevention of static electricity

Store the parts in the antistatic bag. If storing them in the extremely dry condition, static electricity likely to occur and maybe result in damaging the semiconductor by the shock of its electrical discharge.

• Other ambient conditions Store the parts in the location with no harmful fumes and the minimal dust. Besides, no load must be applied while they are in stores.


4-7

4.2.2 AXC***

For AXCNM1

No. Item Type Part No. Recommended Qt.. Remarks

1 IPM drive unit L8800J00 L8800J00 1 (Note 1)

1-1 Fuse F101 FGMB250V-2A 4610-065 1 IPM drive unit (Brake board)

2 CPU board L8800C00 (PC-686BXWLX)-F/D

L8800C00 1

2-1

Battery (Button cell)

Distributed by any manufacturer

CR2032 1 For CPU board Replace the battery every 3 years no matter its operating time.

3 CF card assembly L8800E00 L8800E00 For system(256M) 4 Print board L8800F00 L8800F00 1 Sequence board 5 Print board L8800M00 L8800M00 1 I/O board 6 Print board L8800R00 L8800R00 1 Riser board 7 Print board L8800S00 L8800S00 1 Storage board 8 Power unit L8810A00 L8810A00 1 Multi-power unit

8-1 Print board L8810P00 L8810P00 1 Multi-power board

8-2 Switching regulator (75W 5V)

LDA75F-5-XFJKC 4814-044 1


ZWS50-12/J 4814-043 1


LDA100W-24 5096-527 1

8-5 Fuse F3 GP-32 4610-066 1 Multi-power unit 9 High-power unit L8811A00 L8811A00 1

9-1 Power unit L8811C00 L8811C00 9-2 Magnetic contactor SN-N11 4340-116 2 9-3 Auxiliary contactor UN-AX11 4340-117 2 9-4 Fuse F1,2 FGMB250V-2A 4610-065 2 High-power unit 9-5 Fuse F3 FGMB250V-1A 4610-057 1 High-power unit

10

Auxiliary transformer

W-L01547 4810-914 1

11 Cooling fan 4715MS-20T-B50-B18 4805-075 6 12 Automatic breaker SA33C/30(3Φ) 1 13 Breaker handle BZ6N10C 4614-089 1 14 Terminal cover BZ6TS10C3 4614-090 1 Breaker part 15 Pilot lamp L9092G00 L9092G00 1

16 Regeneration resistor

L9092T00 L9092T00 1

(Note 1) Check the specification of the number of robot axes and the motor capacity of additional axes. Type of drive unit depends on those factors.


4-8

For the following models, the other components other than described below are the same as that for AXCNM1.

For AXCNL1

No. Item Type Part No. Recommended Qt. Remarks

1 IPM drive unit L8801J00 L8801J00 1

16 Regeneration resistor

L9171T00 L9171T00 1

For AXCNG1


1-3 Dynamic brake unit L8698A00 L8698A00 1

For AXCNS1


1 IPM drive unit L8802J00 L8802J00 1 1-3 L8698A00 L8698A00 1


4-9


4-10

4.2.3 Operation Box AXOP-00**


1 Press button SW (Emergency stop)

HA1B-V2E2R 4250-124 1

2 Selector SW AH164-P2B11 4250-125 1

3 Lighting press button SW (Red) < Stop >

AH164TLR11E3 4250-071 1

3-1 LED lamp (Red) AHX695-24R 4533-405 (1)

4 Lighting press button SW (Green) < Start/Motor ON >

AH164TLG11E3 4250-071 2

4-1 LED lamp (Green) AHX695-24G 4533-406 (2) 5 Waterproof cover AHX668 5096-051 1 6 Protection cover AHX669 5096-185 2 7 Case L9111B01 L9111B00 1 8 Panel L9111B02 L9111B02 1 9 Print board L9111C00 L9111C00 1 10 Cable (For AXOP-0005) L9111F00 L9111F00 1 Cable (For AXOP-0010) L9112F00 L9112F00 (1) Cable (For AXOP-0015) L9113F00 L9113F00 (1)

11 Connector L9111G00 L9111G00 3


4-11

4.2.4 Start Box AXST-00**


1 Press button SW (Emergency stop)

HA1B-V2E2R 4250-124 1

2 Lighting press button SW (Red) < Stop >

AH164TLR11E3 4250-071 1

2-1 LED lamp (Red) AHX695-24R 4533-405 (1)

3 Lighting press button SW (Green) < Start >

AH164TLG11E3 4250-071 1

3-1 LED lamp (Green) AHX695-24G 4533-406 (1) 4 Waterproof cover AHX668 5096-051 1 5 Protection cover AHX669 5096-185 1 6 Case E6039B01 E6039B01 1 7 Panel L9115B02 L9115B02 (1)

Cable (For AXOP-0005) L9115E00 L9115E00 1 Cable (For AXOP-0010) L9116E00 L9116E00 (1) 8 Cable (For AXOP-0015) L9117E00 L9117E00 (1)


4-12

4.2.5 Welding Power Supply I/F (2CH specifications) AXWF-00**


1 Power board L8770E00 L8770E00 1 2 Analog I/F board L8770L00 L8770L00 1 3 Robot I/F board L8700C00 L8700C00 1

4 Constant-voltage power supply 5V

ZWS50-5/J 4814-033 1

5 Constant-voltage power supply 24V

ZWS50-24/J 4814-034 1

6 DC fan 3610KL-05W-B40-L00 5096-526 1

6

PS2 Constant voltage power supply (24V) (top)PS1 Constant voltatge power supply (5V) (bottom)

(bottom)

1 3

2

5

4

(top)

4.2.6 Welding Power Supply I/F (4CH specifications) AXWF-01**


1 Power board L8775E00 L8775E00 1 2 Analog I/F board L8770L00 L8770L00 1 3 Robot I/F board L8700C00 L8700C00 2 4 Constant-voltage power 5V ZWS50-5/J 4814-033 1 5 Constant-voltage power 24V LDA100W-24 5096-527 1 6 DC fan 3610KL-05W-B40-L00 5096-526 1 7 DA extension board L8775L00 L8775L00 1

1 3

(3 layrs:bottom)

(3 layers:middle)

2

PS2 Constant voltage power supply (24V) (top)PS1 Constant voltage power supply (5V) (bottom)

46

5

(3 layrs:top)

3

(2 layrs:bottom)

(2 layrs:top)

7


4-13

4.2.7 Control Cables

Cables connecting Robot ~ Robot controller Control cable 1, 2 For AX-MV6/MV6L/MV16/MG3/MH3 (1) AXRB-1003 L9101A (3m)

Ref. No. Item Type Qt. Part No. ① Control cable1 (3m) L9101B00 1 L9101B00 ② Control cable2 (3m) L9101C00 1 L9101C00

(2) AXRB-1005 L9102A (5m)


(3) AXRB-1010 L9103A(10m)


(4) AXRB-1015 L9104A(15m)



4-14

For AX-MS3 (1) AXRB-1403 L9106A (3m)


(2) AXRB-1405 L9107A (5m)


(3) AXRB-1410 L9108A (10m)


(4) AXRB-1415 L9109A (15m)


Cables around the welding power supply (For Robot dedicated digital welding power supply series) Control cable 4 (1) EXRB-4005 (5m)

Ref. No. Item Type Qt. Part No. ③ Gas hose (5m) L2527B00 1 L2527B00 ④ Torch-side welding cable (5m) L2527D00 1 L2527D00 ⑤ Workpiece-side welding cable (5m) L3442B00 1 L3442B00 ⑥ Control cable 4 (5m) CN4 L8905B00 1 L8905B00

(2) EXRB-4010 (10m)

Ref. No. Item Type Qt. Part No. ③ Gas hose (10m) L3375T00 1 L3375T00 ④ Torch-side welding cable (10m) L3375E00 1 L3375E00

⑤ Workpiece-side welding cable (10m) L3375L00 1 L3375L00

⑥ Control cable 4 (10m) CN4 L8906B00 1 L8906B00

(3) EXRB-4015 (15m)

Ref. No. Item Type Qt. Part No. ③ Gas hose (15m) L3375V00 1 L3375V00 ④ Torch-side welding cable (15m) L3375G00 1 L3375G00 ⑤ Torch-side welding cable (15m) L3375N00 1 L3375N00 ⑥ Control cable 4 (15m) CN4 L8907B00 1 L8907B00


4-15

Control cable 5 (1) AXRB-5001 (1.6m)

Ref. No. Item Type Qt. Part No. ⑦ Control cable 5 (1.6m) L9130B00 1 L9130B00

(2) AXRB-5005 (5m)

Ref. No. Item Type Qt. Part No. ⑦ Control cable 5 (5m) L9131B00 1 L9131B00

(3) AXRB-5010 (10m)


(4) AXRB-5005 (15m)


Cables around the welding power supply (For Digital welding power supply series) Control cable 4 (1) AXRB-4105 (5m)

Ref. No. Item Type Qt. Part No. ③ Gas hose (5m) L2527B00 1 L2527B00 ④ Torch-side welding cable (5m) L9155C00 1 L9155C00 ⑤ Workpiece-side welding cable (5m) L9155D00 1 L9155D00 ⑥ Control cable 4 (5m) CN4 L9155B00 1 L9155B00

(2) AXRB-4110 (10m)

Ref. No. Item Type Qt. Part No. ③ Gas hose (10m) L3375T00 1 L3375T00 ④ Torch-side welding cable (10m) L9156C00 1 L9156C00

⑤ Workpiece-side welding cable (10m) L9156D00 1 L9156D00

⑥ Control cable 4 (10m) CN4 L9156B00 1 L9156B00

(3) AXRB-4115 (15m)

Ref. No. Item Type Qt. Part No. ③ Gas hose (15m) L3375V00 1 L3375V00 ④ Torch-side welding cable (15m) L9157C00 1 L9157C00 ⑤ Torch-side welding cable (15m) L9157D00 1 L9157D00 ⑥ Control cable 4 (15m) CN4 L9157B00 1 L9157B00


4-16

Control cable 5 (1) AXRB-5101 (1.6m)

Ref. No. Item Type Qt. Part No. ⑦ Control cable 5 (1.6m) L9150B00 1 L9150B00

(2) AXRB-5105 (5m)


(3) AXRB-5110 (10m)


(4) AXRB-5105 (15m)


When connecting multiple welding power supplies Control cable 7 (1) AXRB-7101 (1m)

Ref. No. Item Type Qt. Part No. ⑧ Control cable 7 (1m) L9140B00 1 L9140B00

(2) AXRB-7102 (2m)


(3) AXRB-7105 (5m)


(4) AXRB-7110 (10m)


(5) AXRB-7105 (15m)



4-17

4.2.8 Alarm Display

Almega series manipulator and robot controller are labeled an alarm display that mentions important notes so that the robot can be safely operated. If it is peeled off or damaged, contact our engineers for order.

For how to make an order, contact your nearest distributor.

Labeling location Item Part No. Qt.

Alarm display NK3636 1 Alarm display NK3637 1 Alarm display NK3638 1 Alarm display NB10402 1

Robot controller

Alarm display NB10424 1

Alarm display of robot controller

Chapter 5 Parts Layout and Electrical Circuit

This chapter describes the parts layout and the electrical circuit diagram.

5.1 Parts Layout and Electrical Circuit Diagram of AXCMN1............................5-1

5.1.1 General View of AXCMN1.....................................................................5-1 5.1.2 Parts Layout of AXCMN1 ......................................................................5-2 5.1.3 Electrical Connection of AXCMN1 (Whole) ...........................................5-3 5.1.4 Electrical Connection of AXCMN1 (for Power) ......................................5-4 5.1.5 Electrical Connection of AXCMN1 (for Welding Power Supply) ............5-5 5.1.6 Electrical Connection of AXCMN1 (for Encoder)...................................5-6 5.1.7 Electrical Connection of AXCMN1 (for Motor) .......................................5-7 5.1.8 Electrical Connection of AXCMN1 (for Operation/Start Box) .................5-8

5.1 Parts Layout and Electrical Circuit Diagram of AXCMN1

5-1


5.1.1 General View of AXCMN1

General View of AXCMN1


5-2

5.1.2 Parts Layout of AXCMN1

Parts layout of AXCMN1


5-3

5.1.3 Electrical Connection of AXCMN1 (Whole)

MO

TO

R P

OW

ER

->

P5E

->

<-

EN

CO

DER

,<-

SH

OC

K,L

S

RELA

Y U

NIT

CN

P15

V

CN

P5E

<- BRAKE

AC

200V

(PO

WER

) ->

UN

IT2

PO

WER

UN

IT

L88

11D

00

MS2

MS1

L88

11H

00

R12

R13

R11

L88

11E00

CN

RST

CN

P2

CN

P1

CN

P3

<- M

SO

N

M

SA

,MSB

->

L90

92U

00

<- A

C100V

AC

200V

->

L881

1F00

L909

2K00

L881

1G00

TF1

CN

MSP

1C

NM

SP

2C

NTF

CN

AC

V

L88

11J00

CN

100P

CN

200P

CN

PU

CN

FA

NS

CN

CO

NPO

WER

B

OA

RD

PC

B11

L47

98G

00

AC200V ->

FA

N6

L90

92X

00

L90

92G

00

FA

N5

FA

N4

L909

2H00FA

N F

OR

C

PU

RA

CK

FA

N1

FA

N2

<- MSON, EMG<- P24V(P1)

IPM

DR

IVE U

NIT

CN

SV

SEQ

UEN

CE

BO

AR

D

CN

SV

AC

200V

(CO

NTR

OL)

->

P5V

->

CN

MS

CN

P5V

L909

2N00

L90

92M

00

CＮ

ＵＳ

Ｂ

AC

100V

(FO

R B

RA

KE)

->

CN

AC

IC

NA

P

P24V

(P1)-

>C

HP

(CN

P)

L9092P00

LS, SHOCK -> SVERR->

(L90

92Y

00)

(Nor

mal

ly d

isco

nnect

)

UN

IT1C

NR

CN

BKSW

CN

EC

1

CN

BK90

CN

P5

CN

P4

CN

SH

KA

CN

EC

2

R51

L909

2S00

L90

92E00

CN

RA

PC

B6

L90

92T

00

TB

EX2

P12V

, V

GA

->

<- C

OM

->

<- U

SB

->

CN

WEL

CF C

AR

DC

F C

AR

D(E

XT.M

EM

OR

Y)

DSW<- EMG

CN

TP

<- EMGL8801R00

L9092Q00

AUTO

ST STOP

CN

SQ

CN

OP

P24V(P1) -><- OUT, IN ->

P24V

(P1) ->

OU

T -

><- IN

CN

NFB

1

L90

92C

00

CN

NFB

2

NFB

1

MU

LTI P

OW

ER

SU

PP

LY U

NIT

CN

P5VP12

V

P24

V

P5V

PC

B4

FA

N F

OR

C

OO

LIN

G U

NIT

NL1

W

FA

N3

CN

SW

O

FA

NFO

R IP

M

DR

IVE U

NIT

CN

AC

CN

P

P12V ->

P5V ->

(<- P3V)<- P5V

(P3V ->)

PC

IP

CI

PC

I

NLX

STR

AG

E

BO

AR

D

CN

SIO

PC

B3

CN

CF

CN

PC

CN

TPC

CN

CA

NC

ND

N

CN

LC

D

<-

VG

A

CN

422

L909

2L00

<- C

OM

->

RA

ISER

BO

AR

DP

CB

5

ISA

CP

U

BO

AR

DI/

O B

OR

AD

ＣＮ

４PC

B1

CN

5

CN

3

CN

OU

TC

NSQ

CN

IN

PC

B2

<- CP12V<- P5V

ISA

ISA

ISA

MA

NIP

ULA

TO

R

EM

G -

>A

C20

0V

->

<- C

AN

->

W.P

.SO

RW

.I/F

OP

ER

ATIN

G

BO

XTEA

CH

P

EN

DA

NT

AC

100V

CP12V ->

<- AC200V

<- P12V

<- P12V<- P5V

<- P12V<- P5V

P15

V

P5E

TB

EX3

TB

EX1

CN

LS

TPENB

CN

TP

CN

2

CN

1

Electrical connection diagram of AXCMN1 (whole)


5-4

5.1.4 Electrical Connection of AXCMN1 (for Power)

Electrical connection diagram of AXCMN1 (for power)


5-5

5.1.5 Electrical Connection of AXCMN1 (for Welding Power Supply)

Electrical connection diagram of AXCMN1 (for welding power supply)


5-6

5.1.6 Electrical Connection of AXCMN1 (for Encoder)

Electrical connection diagram of AXCMN1 (for encoder)


5-7

5.1.7 Electrical Connection of AXCMN1 (for Motor)

Electrical connection diagram of AXCMN1 (for motor)


5-8

5.1.8 Electrical Connection of AXCMN1 (for Operation/Start Box)

Electrical connection diagram of AXCMN1 (for operation box and start box)

Chapter 6 Error Code

This chapter describes the symptom and its measures on the error code of AX-C robot controller.

6.1 When fault has occurred

6-1

6.1 When fault has occurred

When fault has occurred in the robot, the fault monitor starts, and the details of the fault (name of its category, date/ time of its occurrence, description and remedial action) are displayed on the teach pendant.

①

②

③

④

⑤

⑦

⑥

① Fault category The name of the fault category appears here.

② Fault code and cause The fault code and cause appear here. The fault code is expressed in alphanumerics. In the example of the screen shown above, “A2101” is the fault code.

③ Details and remedial action The details of the fault and the remedial action to be taken appear here. Use the remedial action displayed here as a reference, and eliminate the cause of the fault.

④ Release method The method used to release the fault display appears here. When all the contents of ③ and ④ do not appear in the display area, scroll the screen using [up or down].

⑤ Number of fault incidents The figure on the right indicates the number of fault incidents which have occurred simultaneously. Only one fault incident is displayed on the screen at one time. To view other types of trouble, press [ENABLE] and [up or down].

⑥ Date/time of occurrence The date and time of the fault occurrence appear here.

⑦ f12 <Failure Reset> Press this to release the fault display. The fault display can also be released by pressing [RESET/R] twice.

6.2 Concerning the fault details

6-2

6.2 Concerning the fault details

6.2.1 Fault category The fault categories which are displayed at ① on the previous page are established to enable

where the fault has occurred to be pinpointed to some extent.

Table 6.2.1 Fault category

Fault category Main fault

Emergency stop fault Emergency stop triggered by input from overrun, shock sensor, etc.

Control sequence fault Fault detected by monitoring of control systems such as magnet switches and circuit protectors, etc.

CPU board failure Watchdog timer detection or other CPU board-related fault occurrence Servo fault Fault detected by servo driver Amplifier unit fault Fault detected by amplifier unit Encoder fault Encoder-related fault Teach pendant fault Fault detected by teach pendant PLC fault Fault detected by PLC User fault Fault defined by the operator Operation fault Fault caused by error in operation made by operator Spot welding fault Fault inherent to “spot welding function” (but not included above) Arc welding fault Fault inherent to “arc welding function” (but not included above)

6.2.2 Concerning criticality codes and fault codes

The fault codes displayed at ② on the previous page are expressed using the following format. [Example] Control sequence fault code E1103

E 1 1 0 3

(A) (B) (A) Criticality codes

The fault detected by the robot is classified into three types by their level of criticality.

Table 6.2.2 Criticality codes

Type of fault Details

E (errors) Fault caused by parts failure or internal data fault which prohibits continued operation until the cause of the fault is eliminated, and fault which may potentially injure the operator or damage the robot system if operation is continued are classified as errors.

A (alarms) Fault which may lead to an error at a future point in time, fault which must be remedied now or fault requiring simple operations, checks and/or remedial action before robot operation or movements are continued even though it may not potentially injure the operator or damage the robot system are classified as alarms.

I (Information) Fault requiring that the operator and ambient devices be informed of the occurrence of irregularities even though they will not interfere with continued robot operations or movements is classified as information. Information may sometimes be conveyed not when fault has occurred but when the robot is operating normally.

(B) Fault codes

These are 4-digit numbers used to identify fault. (See the following pages.)

No Classification Condition Contents Measure Release4 CPU board

failurePower failure auto-saving fault duringlatest shut-down.

When Primary power is lost orvoltage drops the current statusof the controller is saved toRESUME.DAT.

Check that output from the powerunit(SR1) on the PCB rack is 5V. If notreplace power unit(SR1).

Error reset

12 Servo failure The robot is notcorresponding to therecord point.

This error occurs when the robotdoes not reach the position evenif ten seconds have passedsince the command position wasoutput to the robot

There are another equipment and apossibility to interfere.

Please do error resetor turn on the drivepreparation.

20 Servo failure Abnormal velocitycommand. Modifyabnormal axis motion.

Abnormal velocity commanddata is calculated.

Modify abnormal axis motion to beminimized. Contact NACHI servicedepartment in case axis motion is not sobig.

After removal offailure, please carryout "failure-reset".

21 Servo failure abnormal servotracking

This failure occurs when therobot does not follow to thecommand position.

1. Please confirm whether the power-supply voltage decreases. 2. Pleaseconfirm whether set value is differentfrom actual value of tool weight or toolgravity center or tool inertia moment. Itis thought that there is a problem in therobot manipurator or hardware besides


22 Servo failure Position Deviation error This failure occurs when thedeviation between the commandand encoder data positionexceeds the set permissibledeviation.

(1)Please confirm whether the robotmanipulator interferes insomething.(2)Please confirm that thePay-load is within the nominalrating.(3)If failure persists, the problemmay be a mechanical defect in themanipulator contact NACHI service


23 Amplifier unitfailure

Encoder wiringdisconnection

This failure occurs when thewiring for the encoder has beendisconnected, or there is noencoder power supply.

(1)Please confirm whether connectorCNEC1/CNEC2 of servo substrateUM221 is correctly connected.(2)Pleaseconfirm the power supply voltage of theencoder.(3)Please confirm whetherCNR4 is correctly connected.(4)Pleaseconfirm wiring in the robot manipulatorreferring to "Manipulator Maintenance



Servo CPU stop This failure occurs when theservo CPU on servo substrateUM221 stops.

(1)Please confirm servo substrateUM221 insertion.(2)Please confirm thepower supply of servo substrateUM221.(3)Please replace the drive unit.

After removal offailure, please turn onpower supply of thecontroller again.

25 Servo failure Encoder Bit jump This failure occurs when theamount of the change of theencoder data is abnormal



26 Servo failure Interference detected This failure occurs when therobot manipulator collides withsomething.

(1)Please confirm whether the robotmanipulator interferes insomething.(2)Please confirm that thePay-load is within the nominalrating.(3)Please confirm the interferencedetection level.(4)If failure persists, theproblem may be a mechanical defect inthe manipulator contact NACHI service


27 Servo failure Encoder data changeafter stop

This failure occurs when theencoder data continues tochange after the commandposition is stops changing(i.e.manipulator should not bemoving).

(1)Please confirm whether connectorCNEC1/CNEC2 of servo substrateUM221 is correctly connected.(2)Pleaseconfirm whether CNR4 is correctlyconnected.(3)Please confirm wiring inthe robot manipulator referring to"Manipulator MaintenanceManual".(4)Please confirm themanipulator is not obstructed byanything (5)Please confirm that the Pay



Low voltage of motorpower

This failure occurs when theMotor power supply voltage(P-N) are lower than regular setting

(1)Please confirm whether the supplyvoltage decreases more than a normalvalue.(2)Please replace the drive unit.


30 Encoder failure Encoder absolute datafailure

This failure occurs when fault isdetected in the encoder.

(1)Please confirm the supply voltage ofthe encoder refering to "AX controllermaintenance manual".(2)Please confirmthe wiring of the encoder.(3)Please resetthe encoder


31 Encoder failure Motor rotation too fastwhen turning MotorsON

This failure occurs if at the timeof turning Motors ON, theencoder speed is too fast.



6-1

No Classification Condition Contents Measure Release32 Servo failure Over current This failure occurs when the

current in the drive unit exceedsthe rated value.

(1)Please confirm whether the robotmanipulator interferes insomething.(2)Please confirm that thePay-load is within the nominalrating.(3)Please confirm the cablebetween the controller and the robot


38 Servo failure Over load This failure occurs when thecurrent in the motor or drive unitexceeds the rated value.

(1)Please confirm whether the robotmanipulator interferes insomething.(2)Please confirm that thePay-load is within the nominalrating.(3)Please confirm the cablebetween the controller and the robot


39 Servo failure Over rotation This failure occurs when thenumber of rotations of motorsexceeds a maximum rotationspeed limit.

(1)Please confirm whether setting of thePay-load and center of gravity iscorrect.(2)Please confirm that the Pay-load is within the nominal rating.(3)Iffailure persists, the problem may be amechanical defect in the manipulator,contact NACHI service department


40 TP failure The abnormalities inCPU in a T/P

CPU built in the teach pendantstopped.

Please check whether there are anyabnormalities in a T/P and a connectioncable. Please reswitch on a powersupply. Please exchange a T/P, whenan error still comes out

Control power supplyis re-switched on.


Over temperature ofmotor

This failure occurs when themotor temperature risesabnormally.

(1)Please confirm that the Pay-load iswithin the nominal rating.(2)Pleaseconfirm the wiring of the motorthermostat refering to "ManipulatorMaintenance Manual".(3)Please stop therobot in order to lowering the motortemperature, and restart.(4)If failurepersists please lower the operation



Over speed This failure occurs when therotation speed of motors isabnormal.

(1)Please confirm whether connectorCNEC1/CNEC2 of servo substrateUM221 is correctly connected.(2)Pleaseconfirm whether CNR4 is correctlyconnected.(3)Please confirm wiring inthe robot manipulator referring to"Manipulator Maintenance Manual"



Over voltage of motorpower

This failure occurs when theMotor power supply voltage(P-N) are higher than regularsetting level.

(1)Please confirm whether CNR iscorrectly connected.(2)Please confirmthat the Pay-load is within the nominalrating.(3)Please confirm the cablebetween the controller and the robot



Over temperature ofregenerative dischargeresister

This failure occurs when thetemperature of the regenerativedischarge resister risesabnormally.

(1)Check the fans areoperating.(2)Please secure space 20cmor more in backside ofcontroller.(3)Please check wiring of thethermostat for regenerative discharge


50 Encoder failure Encoder counteroverflow/underflow

This failure occurs when thecounter overflow/underflow ofthe encoder is occured.



51 Servo failure Encoder datatransmission failure

This failure occurs when thecommunication data with theencoder is abnormal or theencoder has been disconnected.



52 Encoder failure Encoder battery chargelow

This failure occurs when thevoltage of the battery in theencoder has decreased.



54 Servo failure Encoder data abnormal This failure occurs when thechange in the encoder data isabnormal.

(1)Please confirm the supply voltage ofthe encoder refering to "AX controllermaintenance manual".(2)Please confirmthe wiring of the encoder.


55 Encoder failure Motor rotation too fastwhen power off

Because the motor had beenrotated at high speed when thepower off, the amount of therotation of the encoder was notable to be detected correctly



56 Servo failure Encoder pre-loadfailure

This failure occurs if the pre-loadoperation of the encoder wasnot correctly done.

(1)Please confirm the supply voltage ofthe encoder refering to "AX controllermaintenance manual".(2)Please confirmwhether the robot manipulator interferesin something.(3)Please confirm thewiring of the encoder


6-2

sunyansheng

高亮

No Classification Condition Contents Measure Release57 Encoder failure Encoder count status

failureThis failure occurs when theEncoder data(absolute) isabnormal.




Circuit protector tripped This failure occurs when a circuitbreaker trips.

(1)Please confirm wire harness andwiring in the robot manipulator.(2)Please confirm whether the motorpower line does the short-circuit.


62 Control failure Emergency stop wasshortly input orMagnetic SW was cutoff.

Error occurs when it has acondition that communicationcable, connection of Emergencystop, Over travel limit switch,Arm interference limit switch ormotor thermostats is open orpoor connection

Turn power ON again and try again. After removal offailure, please carryout "failure-reset".

63 CPU boardfailure

Controller temperaturefault.

Error occurs when thetemperature of the core of thecontroller becomes abnormality

Check the fans are operating, or cleanup the heat exchanger.

Failure reset by"reset-key" ispossible


Drive unit power failure This failure occurs when driveunit power VP15(+15V) was notsupplied.

Please replace the drive unit. After removal offailure, please turn onpower supply of thecontroller again.


Over travel limit switchactivated

This failure occurs when an axisreaches the end of its travel andactuates an Over travel limitswitch(LS). This error seldomoccurs because the Softwarelimit usually stops themanipulator before it reaches

(1) If no LS is physically being actuatedthen wiring to a LS is disconnected orcut off.(2) If LS is physically beingactuated, then move the manipulator bythe teach pendant operation while LSreleasing switch ON.



Low voltage of brakepower

This failure occurs when brakepower supply PB(+24v)decreases.

(1)Please confirm the CNMS connectorof the power unit is connected.(2)Please confirm the CNPW connectorof the power unit is connected.(3) Please confirm whether fuse (F2) of



Drive unit IPM failure This failure occurs when currentof power module (IPM) in thedrive unit flows more thanpermitted range.

(1)Please confirm the cable between thecontroller and the robotmanipulator.(2)Please replace the driveunit.



Drive Unit heatsinktemperature fault

This failure occurs when thetemperature of the heatsink inthe drive unit exceeds thepermitted range.

(1)Please confirm whether the ambienttemperature exceeds the specification.(2) Please confirm the power-supplyvoltage is within ±10%. (3)Pleaseconfirm the rear fan rotates. (4)Pleaseconfirm whether the heat sink is



Motor regenerationcircuit fault

This failure occurs when theregenerative discharge circuit isdisconnected by a large currentor heat.

(1)Please confirm whether the CNRconnector of the drive unit is connected.(2)Please confirm resistance of thedischarge register 5 ohm.


77 CPU boardfailure

CPU fan fault. Error occurs when the fan of theCPU becomes 2000 r.p.m. or

Check the fans are operating, orexchange CPU board.

Failure reset by"reset-key" is

78 CPU boardfailure

CPU bord power fault. Error occurs when the power ofthe CPU becomes 5% or less

Check the power supply unit, orexchange the Power supply unit.

Failure reset by"reset-key" is

79 CPU boardfailure

CPU bord temperaturefault.

Error occurs when thetemperature of the CPUbecomes abnormality high.

Check the fans are operating, or cleanup the fans.

Failure reset by"reset-key" ispossible

82 Operational99 Operational

failure5th axis operatingrange exceeded.

Error occurs when 5th-axismoves out of its Operatingrange(not software motionrange!). The Operating range isfixed by the machine design andis based on the angle ofinterference between 5th-axisand arm 1(not encoder value).Operating range can beexceeded when the 5th-axis(and6th-axis) is moved via therotation of the 4th-axis. Thiseffect is due to the mechanical

Select [Constants][Machine constants]and use the correct axis operation keysto move back into the 5th-axis Operatingrange. Warning! damage can occur if5th-axis hits arm 1.

No reset operationsneccesary.

105 Control failure Ext. Motors-off' signalis being given orMotors-OFF buttonbeing held.

Error occurs when Motors-ONbutton is pressed while theMotors-OFF button is held orexternal motors-OFF signal is

Ensure that Motors-OFF is not beinggiven when pressing Motors-ON button.


106 Operationalfailure

The motors are not ON. The motors are not ON. Turn motors ON by pressing the Motor-ON button.

No reset operationsneccesary

116 TP failure TP connect failure It becomes this failure when TPisn't connected and a cable is

Connect TP properly. Exchange TPwhen it is out.

A power supply isturn on again.


The robot's joint angleexceeded the softwarestroke range.

It will become this error if a robotjoint angle reaches the softwarestroke range.

Please move to software stroke withinthe limits by manual operation (eachaxis).

Error reset.

6-3

No Classification Condition Contents Measure Release122 Servo failure The robot's joint angle

exceeded the softwarestroke range.(Currentposition)

It will become this error if a robotjoint angle reaches the softwarestroke range.(Current position)

Please motor power on in machineconstant/software limit at the EXPERTlevel and move to software stroke withinthe limit by manual operation.

Error reset.


The angle which anarm makes is too large.

The 1st arm and the 2nd armmay cause interference with aposition.

Please move in the direction whereinterference does not take place bymanual operation.

Error reset.


The angle which anarm makes is too small.

The 1st arm and the 2nd armmay cause interference with aposition.

Please move in the direction whereinterference does not take place bymanual operation.

Error reset.

131 Control failure Collision sensoractuated.

Error occurs when a signal isreceived from the collisionsensor.

Remove obstruction, check condition ofthe tool, reset the collision sensor, andrestart robot.



The robot's joint angleexceeded the linksoftware stroke range.

It will become this error if a robotjoint angle reaches the linksoftware stroke range.

Please move to link software strokewithin the limits by manual operation(each axis).

Error reset.


Shift value limitexceeded.

This error occurs if the allowableshift distance is too large.

Reset the limit value[Constants][Shiftlimit & evaluation value] and retry


177 Emergency stopfailure

Primary power supplyfault.

Error occurs when the Powerdetection unit on I/O board,UM212, detects that primarypower is below nominal level.

Check the status of the Primary(mains)power supply.

Error reset.

179 Control failure An axis key was heldwhile 'Motors-ON'signal was given.

This error occurs when an axiskey on the teach pendant isactuated while motors-ON signal

Input Motors-ON signal ensuring theaxis keys are not held down.


201 Palletize-end does notfollow Palletizefunction.

This error occurs when apalletize-end function(M47) doesnot follow Palletize

Correct the sequence of Palletize andPalletize end functions in the program.


202 More than 32Palletizing routines notallowed.

When palletizing of 32 or moreis executed at the same time,this error is detected.

Please refer to Palletize function manualfor details.


203 Palletize data isabnormal.

This error occured caliculateshift value is failed from palletize

Please refer to palletize data. No reset operationsneccesary.


Designated commandposition exceeds Robotoperating area.

Error occurs when a shiftfunction, etc. tries to send therobot out of the robot operating

Correct the program. No reset operationsneccesary.


Danger of Robotinterference.

Robot wrist may interfere withunder the part of manipulator

Correct the program. No reset operationsneccesary.


Pose calculation failed. This error occurs when all axisangles can not be calculated inrobot language file.

Check pose data. No reset operationsneccesary.

367 PLC failure The error was detectedby Built-in PLC.

It becomes this error when Built-in PLC detects an error.

Check the environment of Built-in PLCof operation.

Unusual reset iscarried out afterchanging Built-in PLCinto a running state.

379 Control failure Safety plug is notinserted or the state ofsafety plug signal haschanged in teachmode.

This error occurs when a MotorsON command(button) is given inAuto mode when the Safety plugis not inserted or the state ofsafety plug signal has changedin teach mode

Insert the Safety plug in Auto mode. After removal offailure, please carryout "failure-reset".

550 PLC failure It is scan time over ofBuilt-in PLC.

It detects, when the scanningtime of Built-in PLC is too long.

Correct Ladder program. An error will becanceled if it isdownload aftercorrecting ladderprogram so that Scantime may be set toless than 30 msecs

674 Spot weld failure Welder communicationfault(No reply).

Error occurs when the welderboard is not correctly connected.

Check power supply of the welder andcommunication cables, and power ONagain.

Error reset

675 Spot weld failure Welder communicationfault(Check sum).

Error occurs when received datafrom the welder board isabnormal.


Error reset

676 Spot weld failure Welder communicationfault(Message wrong).

Error occurs when received datafrom the welder board isabnormal.


Error reset

677 Spot weld failure Major Welder fault. Error occurs when the welderboard generate the weld fault.

Remove the cause of weld fault. Error reset

694 Spot weld failure Executive EPROMchecksum error.

Error occurs when a systemsoftware checksum error ofwelder timer substrate is

Install the system software once more. Turn off the power.

695 Spot weld failure LCA EPROMchecksum error.

Error occurs when a systemsoftware checksum error ofwelder timer substrate is


696 Spot weld failure Application EPROMchecksum error.

Error occurs when anapplication EPROM checksumerror of welder timer substrate is


697 Spot weld failure DPR error. Error occurs when a DPR errorof welder timer substrate is



The angle between 3rdaxis and ground isover.

The 3rd axis tended to operateexceeding 3rd angle incline.

Please move in the direction where 3rdangle incline does not take place bymanual operation.

Error reset.

6-4

No Classification Condition Contents Measure Release749 Spot weld failure Spot Welder SCR1

thermal switchactuated.

Failure occurs when theThermo. Temp. fault signal isreceived by the controller.

Check the Thermo. Temp. fault signaland the spot welding unit.


750 Spot weld failure Spot Welder SCR2thermal switchactuated.

Failure occurs when theThermo. Temp. fault signal isreceived by the controller.

Check the Thermo. Temp. fault signaland the spot welding unit.


759 Spot weld failure Isolation contact failedto pull in.

Failure occurs when theisolation contact of the welderfails to actuate correctly.

Refer to the Welder timing Manual. After removal offailure, please carryout "failure-reset".

760 Spot weld failure Isolation contact stuckclose.

Failure occurs when theisolation contact of the welderfails to actuate correctly.

Refer to the Welder timing Manual. After removal offailure, please carryout "failure-reset".

762 Spot weld failure Welder board notinstalled.

Error occurs if the welding timerPCB does not exists in thecontroller when welding isattempted.

Install the welder board. Error reset.

777 Control failure Robot moved duringMotors-on sequence.

This error occurs when shocksensor actuated while torchtouches a work.

Check manipulator arm interference withjig. if error persists, abort Motor-on andcontact NACHI dept.


783 CPU boardfailure

Motion stop. It becomes this error when mainCPU detects a motion stop.

Turn on the power again. If the error isnot released, reinstall the system.

Turn on the poweragain.

785 CPU boardfailure

I/O timeout. It becomes this error when mainCPU detects a I/O system stop.



898 Servo failure Servo command stop This failure occurs when theupdate of the command valuetransmitted to the servo stopsduring a certain time.

Please refer to the troubleshooting ofthe controller maintenance manual.



serveo clock halted This failure occurs when theclock of servo substrate UM221halted.

(1)Please confirm the supply voltage ofthe servo substrate UM221.(2)Pleasereplace the drive unit.



Servo communicationstop

This failure occurs when thecommunication between CPUsubstrate and the servosubstrate stops.

(1)Please confirm whether connectorCNUSB of servo substrate UM221 iscorrectly connected.(2)Please confirmthe supply voltage of the servo substrateUM221.(3)Please replace the drive unit.

After removal offailure, please carryout "failure-reset".Wait more than 5seconds for nextmotor power on

956 The communicationerror occurred.

The details of a communicationerror should check a sub code.

An unusual cause is removed based ona sub code.

Unusual reset iscarried out afterremoving an unusual

957 The system error wasdetected.

The details of a communicationerror should check a sub code.

Please inform system service of a subcode.

Unusual reset iscarried out afterremoving an unusual

958 The error was detectedwith the self check of acommunication board.

They are the abnormalities of acommunication board. Pleasecheck the details ofabnormalities to system service.

The defect of a communication board isconsidered.

A communicationboard is exchanged.

959 A communication boardis not found.

The communication boardspecified on the constant settingscreen is not found.

Please check the slot ID of a field bushardware setup.

The setting value of afield bus hardwaresetup is changed.

960 A part or all I/O linksare stopping.

Since the between title hasoccurred in the I/O device, arobot cannot be started.

Please check the device which theproblem has generated by the field busmonitor.

If a problem issolved, it will restoreautomatically. (Inorder to solve aproblem, the re-injection of a powersupply may be

967 Control failure T/P selector switch isMANUAL.

Playback is impossible while T/Pselector switch is set toMANUAL.

Set T/P selector switch to AUTO. After removal offailure, please carryout "failure-reset".

975 Control failure Magnetic switch is notactive.

Error occurs when a signal froma magnetic switch is notreceived within the specifiedtime after Motors ON signal is

Please exchange sequence boardUM213.


### Control failure Analog input board isnot installed. Or analogoutput board is notinstalled.

Although analog input (output)board is not installed, analoginput (output) function isexecuted.

Turn off the power and connect analogInput (output) board correctly.

Error reset.

### Control failure PWM of thedisconnectedmechanism has beenturned on.

This error occurs when PWM isnot turned off even if a certaintime passes after themechanism diconnection.

There are some problems in the brakeand the PWM control circuit of sequencePCB. Please replace the sequence PCBor the drive unit.


### Encoder failure Manipulator batterywarning

This warning occurs when thevoltage of the battery in therobot manipulator decreases.

Please exchange the battery referring to"Robot Manipulator MaintenanceManual".

After the battery isexchanged, pleasecarry out "failure-reset" and then turnon the power supplyof the controller

### Control failure Safety unit circuit isabnormal.

Error occurs when thedisagreement detection orabnormal of the relay is detectedwith safety unit.

Turn power OFF and ON again. Afterwiring is confirmed, safety unit isexchanged when the error occurs again.


6-5

No Classification Condition Contents Measure Release### Spot weld failure This IWB does not

support MFDCError occurs when the IWBversion is old.

Replace new version. After removal offailure, please carryout "failure-reset".

### Analog output boardnot installed.

Analog output board is not existsin the controller.

Install the analog output board. Error reset.

### Control failure Playback unavailablebecause motors-offsequence is executing.

Error occurs when input playbkcommand while it is executingthe motor-off sequence.

Please input playback command aftermotors-on is thrown.


### Spot weld failure Spot welding functioncan not be carried out.

The mistake of the method ofrecording the welding function isfound.

Please record spot welding functionafter step 1.Or, you tried to drive theGUN mechanism which was not able tobe driven with this unit.

After recording themove step, PleaseCheck Go.

### Control failure T/P selector switch isAUTO.

Manual operation is impossiblewhile T/P selector switch is setto AUTO.

Set T/P selector switch to MANUAL. After removal offailure, please carryout "failure-reset".

### Spot weld failure The change in the tipconsumption detectedby search 3 isabnormal.

The difference between theconsumption detected by search3 and the consumption detectedby search 1 exceeded thesearch 3 abnormal tip change

Check the lack of gun tip. If it is notrouble, execute gun search 1.

Error reset

### Spot weld failure The encoder data ofgun axis is not steady.

The servo gun axis did not stopwhile waiting to reach thespecified pressure.

Please reconsider the recorded position.If the position has no problem, replacethe Drive Unit

Error reset

### Spot weld failure Ready to weld statusfrom welder board isn'tcompleted, or a weld-enabled signal isn't

Welder power turned off orwelder error occurred, a weld-enabled signal not given.

Check the peripheral system or welder. Error reset.

### Operationalfailure

There is a possibilitythat the interpolationoperation and the de-and accelerationcontrol are not correctlydone due to a setdisagreement ofrectangular coordinate

Setting rectangular coordinatesystem is different registeringthe tool and now.

Please set the tool constant (length andcenter of gravity) again by presentrectangular coordinate system. Or,please change setting rectangularcoordinate system.

The error is notreleased untilmeasures areexecuted.


The memory medium isnot prepared.

The detection reason is that thespecified device was notdetected when the file operationis done.

Whether the device such as memorycards and floppy disks specified by thefile operation menu is correctly installedis confirmed.

An error will becanceled if somekeys are pushed.


The memory medium isread-only.

When it is going to copy a file toa write-protected floppy disketc., this error sets.

Please prepare the memory medium towhich writing is made and perform acopy from the beginning once again.



It cannot process in thesame device.

It was going to copy to the samedevice by the same file name.

Please change a file name or a deviceand redo copy operation again.



Stop or External stopsignal being given.

Error occurs when a Startcommand is given while theStop button is being held orExternal stop signal is being

Release Stop button or External stopsignal(if External stop signal cable is cutthe external stop signal is considered asbeing given.

Error reset.


The emergency stopbutton or the externalemergency stop isinputted.

Where an emergency stopbutton or an external emergencystop signal is inputted, it detects,when the Motors-ON signal orthe External Motors-ON signal isinputted

Please cancel an emergency stopbutton and an external emergency stopsignal.

Abnormalities arereset.


Motors-OFF button orexternal Motors-OFF isinputted.

In the state where the Motors-OFF button or the externalMotors-OFF signal is inputted,when the Motors-ON signal orthe external Motors-ON signal is

Please cancel a Motors-OFF button andan external Motors-OFF signal.



Playback unavailablebecause servo systemhas not been turned onyet.

The start is impossible, becausethe start operation is donebefore MSHP is turned on.

Please start after turning on MSHP. Abnormalities arereset.


It is not possible to startby specifying thefunction step

This It is prohibited to startspecifying the function becausethere is the position where thefunction is executed is not anoriginal position but a possibility

Please start after specifying the movestep.

abnormally resets.


The internal operationsignal was inputted inthe state of externalselection.

It detects, when startingselection tends to push theMotors-ON button or a startingbutton in the state of the exterioror it is going to choose aprogram from TP in the state of

Please operate it after setting startingselection or program selection as aninside.



The external operationsignal was inputted inthe state of internalselection.

It detects, when the Motors-ONor the start signals are inputtedfrom the exterior in the state ofan inside of start selection or aprogram selection signal isinputted from the exterior in thestate of the inside of program

Please perform external operation aftersetting up starting selection or programselection outside.


6-6

No Classification Condition Contents Measure Release### Shift register contains

no data.Error occurs when data aren'testablished in specified shiftregister.

Setting data in shift register. abnormally resets.


Setting the callinstruction is improper.

This error occurs when thenumber of step call and returninstruction is match or themultiple call exceeds eight

Please correct the program so that thenumber of call return instructions iscorresponding, and a multiple callshould not exceed eight times.

This error is releasedif the step set do overagain and restartplayback.


The unit composition isa different program.

This error occurs when theprogram jump or call instructiondirectly jumps or calls theprogram that the unit is different.

Please correct the called programnumber value.

This error is releasedif the correct programset do over again andrestart playback.


Program numberselected is notavailable.

This error occurs when theprogram number designated ismore than 9999.

Check the desired program number andretry.



There is no end. If there is no end mark whenplayback executing, this error isdetected after the last step isexecuted.

Please record the end instruction. This error is releasedif restart playback.


Program is too large. Error occurs when number ofbytes of a program is too large.

Edit program in order to reduce its size. No reset operationsneccesary.


The program or the filedoes not exist.

This error occurs when theprogram number is specifiedwhich does not exist in theprogram jump call instruction.

Please correct the program number to acorrect value the jump call ahead.

This error is releasedif a correct programis setted again andrestart playback.


The step does notexist.

This error is detected when thestep number which does notexist in the step jump callinstruction is specified.

Please correct the step number to acorrect value at the jump destination.

This error is releasedif the correct step setdo over again andrestart playback.


Change of a coordinatesystem cannot beperformed duringcircular.

This error occurs if a coordinatesystem is changed duringcircular.

Please teach by the same coordinatesystem during circular.

This error will becanceled if a programis corrected andrestarted.


Change of a toolcannot be performedduring circular.

This error occurs if a tool ischanged during circular.

Please teach by the same tool duringcircular.



The file is protected. All protected files or filespartially protected (program orconstant) tried to be corrected

Because the specified file (program orconstant) contains important data,protecting is put so that

Please releaseprotecting the file(program or


The reproductionprotection of theprogram is carried out.

It detects, when it is going tocarry out reproduction or checkGO of the work program whichrequired reproduction protectionfrom a head step (Step 0)

The specified work program is not aprogram which should be used foroperation operation.

When you start,please choose Step 1from T/P.


The amount of themovement of each axisis too small in theautomatic tool constantsetting. Or, the numberof record steps does

When there is no point or less10 point data effective to thecalculation, and the program isnot clearly recorded the samepoint excluding the error by theteaching

Recreate the 10 point program (4 pointunder tool constant setting only)ensuring the recorded points are exactlythe same point in space.

Error reset

### Preventivemaintenancemessage

There is an axis of lessthan 1,000 hours tilloverhaul cycleattainment.

In the state of the presentoperation, the life-expectancytime (time until it reaches a life)of the displayed axis turned into1,000 or less hours.

Please exchange the slowdown machineof the axis displayed as early aspossible. Please clear "the consumptiontime by present" zero with an overhaulcycle prediction menu after exchange.(The qualification more than Expert is


### Shift value limitexceeded.

This error occurs if the allowableshift distance is too large.

Reset the limit value[Constants][Shiftlimit & evaluation value] and retry



Step number selectedis not available.

This error occurs whendesignated step number does

Check the desired step number andretry.



The program is notrecorded nor selected.

This error occurs when theprogram which is not recorded isselclted and start playback.

Please start after recording the programor selecting other programs.

This error is releasedif it sets a correctprogram and restartplayback.

### Palletize-end does notfollow Palletizefunction.

This error occurs when apalletize-end function(M47) doesnot follow Palletize

Correct the sequence of Palletize andPalletize end functions in the program.


### More than 32Palletizing routines notallowed.

When palletizing of 32 or moreis executed at the same time,this error is detected.

Please refer to Palletize function manualfor details.


### Palletize data isabnormal.

This error occured caliculateshift value is failed from palletize

Please refer to palletize data. No reset operationsneccesary.

### Multiplex palletize over. This error occured multiplexpalletize beyond 8 is carried out.

Please confirm a robot program. No reset operationsneccesary.


The step data isabnormal.

This error occurs when the valuewhich is not permitted as aparameter of the functioninstruction is setted whileplayback executing and the

Please set a correct parameter again. This error is releasedif a correct programor step is setted andrestart playback.


The program can notreserve any more.

This error occurs when thenumber of program reservationsexceeds ten.

The number of program reservationshould cope with it by the sequence etc.not to accumulate too much.

Please do error reset.

6-7

No Classification Condition Contents Measure Release### Spot weld failure Analog input override

and digital inputoverride can not beused at same time.

Error occurs when analog inputoverride (FN169) and digitalinput override (FN277) areplayed at the same time.

Check the program, and delete function. Error reset.

### Spot weld failure No signal input whileexecuting FN227

The specified interruption signalwas not input whiel executingFN227.

Please confirm the state of the sensor,the connection with the controller andthe number of the signal.

Error reset


There is no referring topoint for the circlemiddle point (C1).

This error occurs when theprogram on which the movecommand is not recorded beforeor after the circle middle point(C1) is started

Please start after recording a movecommand before or after the circlemiddle point (C1).



There is no referring topoint for the circle endpoint (C2).

This error occurs when theprogram on which the movecommand is not recorded beforethe circle middle end (C2) isstarted

Please start after recording a movecommand before the circle end point(C2).



It is protected with thepassword.

It detects, when it is going tocorrect or delete the file (aprogram, constant) protectedwith the password.

Since the specified file (program orconstant) contains important data,protection is applied

Please releaseprotecting the file(program orconstant).

### Playback mode ofSearch write function isnot corrected.

This error occurs when Searchwrite function is attempted whennot in <1 cycle> mode.

Select <1 cycle> mode. No reset operationsneccesary.

### Search rangeexceeded.

This error occurs when the robotmoves beyond search range

Modify(enlarge) the search range orprogram to rectify error.


### Search base stepposition is not defined.

This error occurs if a Search isattempted without the existenceof the Search base step

The Search base step position(s) will beautomatically written into the functions.


### Search Start notfollowed by SearchEnd.

This error occurs when a Searchstart does not follow a SearchEnd function.

Alter program to give correct Searchstart/end sequence.



The setting of a casejump function isunsuitable.

This failure occurs when a casejump and a case jump end donot correspond while playbackexecuting, and the robot will

Please check a case jump andcorrespondence of a case jump end.

This failure isreleased if a correctprogram is settedand restart playback.


It was going to jumpbeyond the case jumprange.

This failure occurs when thecondition value of a case jump istoo large and there is no jumpstep in the program whileplayback executing, thisabnormality is detected and the

Please set a correct parameter again. This failure isreleased if a correctprogram is settedand restart playback.

### PLC failure Scan of Built-in PLChas stopped.

Although Built-in PLC status isexcept <Disabled>, when scanof Built-in PLC has stopped, itbecomes this error at the time ofrobot operation

Built-in PLC status is set as <RUN> byconstant mode, and scan is started.

Unusual reset iscarried out afterchanging Built-in PLCinto a run state.

### PLC failure Connection with Built-inPLC cannot beperformed.

It becomes this error whenconnection with Built-in PLCcannot be performed.

Please check the environment of Built-inPLC of operation.

Unusual reset iscarried out afterchanging Built-in PLCinto a starting state.

### PLC failure Built-in PLC cannot bestarted.

It becomes this error when Built-in PLC cannot be started.



### PLC failure Built-in PLC cannot bestopped.

It becomes this error when Built-in PLC cannot be stopped.



### PLC failure There is no resourceperformed by Built-inPLC.

It will become this error if astarting demand is performed inthe state where there is noresource performed by Built-in

Download a PLC ladder program. After download, itchanges into astarting state andunusual reset is

### PLC failure PLC-Engine has notbeen started.

It becomes this error when it isnot able to start by the startingdemand of PLC-Engine.


Again, a startingsetup is carried out, itchanges into astarting state, andunusual reset is

### PLC failure The error was detectedby Program check atthe time of PLC-Enginestarting.

It becomes this error when anerror is detected by Programcheck at the time of PLC-Enginestarting.

Please carry out program check by [3PLC program check] of [14 PLCprogram Edit] of Service.

Unusual reset iscarried out.


The function data isabnormal.

This error occurs when thefunction instruction which is notpermitted is setted whileplayback executing, and the

Please set the function again. This error is releasedif a correct programor step is setted andrestart playback.

### 3 of the step points forOn-transfer are in line.

Error occurs when 3 step pointsare situated along the same linefor the On-lineTransfer(M53,M54).

Designate step positions not in the sameline for the On-line transfer function.

Designate steppositions not in thesame line for the On-line transfer function.


User failure is notdefined.

The error file was not found. Please define Failure by [Service]→[25Robot diagnosis]→[6 User error].

Error reset

6-8

No Classification Condition Contents Measure Release### There is the axis in 0

hours for overhaul.The life time of the axisdisplayed with present operated(time to reaching to longevity)became 0 hour or less.

Exchange the axis. After that 0 clearingof "Consumption time until present".


### Spot weld failure The specified weldercannot be used withthis unit.

The servo gun connected withthe specified welder is notdefined as a mechanism of this

Modify the program. Error reset

### Spot weld failure The servo gun is notconnected with thespecified welder.

The welder with which the servogun was not connected whenthe servo gun function was usedwas specified.

Modify the program. Error reset

### Spot weld failure Abnormal panelthickness detected.

Dramatic difference of panelthickness exists betweenrecorded value in weld conditionand detected value.

Check the weld condition data and realwork piece thickness.

This error is releasedif restart playback.

### RIO detected thecommunications error.

An abnormal communicationwas generated by the RIO link.

Please check the connection and theRIO scanner of the communication

Error reset.

### The RIO interface isabnormal.

There is no answer from the RIOinterface.

Please exchange the RIO interface. Error reset.


Step number notdesignated.

This error occurs when acommand only valid afterdesignating a step number isattempted without step

Please designate a step number andretry.

This error is releasedif a correct programor step is setted andrestart playback.


The memory medium isnot discriminable.

When memory media, such as aFIROPPI disk and an memorycard, are not initialized, this error

By Service / File Manager / Formatmemory card/Floppy disk, please use itafter initializing a memory medium.

It will be canceled ifsome keys arepushed.

### Spot weld failure Welder fault. Error occurs when a Welderfault input signal is received bythe controller after thecompletion of a welding

Check the welder unit. This error is releasedif restart playback.

### Spot weld failure Welding time exceededlimit.

Error occurs if a Weld competedsignal is not input before thedesignated time period.

Check the welder is operating normally. This error is releasedif restart playback.

### Spot weld failure The gun not open. Error occurs if the Gun closedsignal is received after thewelding sequence ends.

Check the GUN or welding unit. This error is releasedif restart playback.

### Spot weld failure The gun is not halfopen.

Error occurs if the Gun half-opensignal is not received after Opengun half signal is output by thecontroller.


### Spot weld failure The gun is not fullyopen.

Error occurs if the Gun full-opensignal is not received after Opengun fully signal is output by thecontroller.


### Spot weld failure Stuck Weld GUNdetected.

Error occurs if the System faultsignal is detected aftercompletion of a welding

Error occurs if the Weld stuck signal isreceived when the welding sequenceends.


### Spot weld failure Coolant fault #1. Error occurs if the Water flowswitch #1 signal is detected aftercompletion of a welding




### Spot weld failure Air pressure fault. Error occurs if the Air pressureswitch signal is detected aftercompletion of a welding


### Spot weld failure Transformertemperature fault.

Error occurs if the Thermo.temp. fault signal is detectedafter completion of a welding


### Spot weld failure Peripheral system fault. Error occurs if the System faultsignal is detected aftercompletion of a welding


### Spot weld failure Both of half-open andfull-open signals aregiven.

Error occurs if both the Gunhalf-open signal and Gun full-open signal are receivedsimultaneously after Open gunhalf signal is output by the

Check the GUN or welding unit todetermine the cause of the twosimultaneous signals.



Servo gun auto-settinggets abnormal data.

It is not possible to compute theservo gun inertia using currentgathered by parametor auto-setting

(1)Please make the servo gun positionmore wildly between pose 1 and pose 2.(2)Please confirm the servo parametersof target servo gun mechanism.



User coordinate doesnot exist.

Failure occurs when use of Usercoordinate is attempted withoutthe coordinate system beingpre-defined.

Define User coordinate system(s) in[Service][10 User Coord.Definition]before attempting to use it.


### Spot weld failure Tip dresser abnormal. This error occurs when normalinput signal from tip dresser islost during tip dress function.

Please check the normal input signalfrom the tip dresser.



Data level too low forAuto tool load centersetting.

In the automatic tool center ofgravity set function, it is notpossible to calculate by thegathered current value.

(1)Teach points that enough unbalancedtorque is exerted on J3,J5 and J6 axis.(2)Make the wrist posture vary greatlybetween step 1 and step 2 positions.


6-9

No Classification Condition Contents Measure Release### Spot weld failure Servo gun pressure is

not achieved.Error occurs when the set gunpressure is not achieved withinthe time period set in[Constant][Generalcharacteristic of Servo Gun]

Error occurs when the set gun pressureis not achieved within the time period setin [Constant][General characteristic ofServo Gun].


### Spot weld failure WI signal does notbecome off.

Error occurs when a WI signal,from the last weld sequence,remains on more than 5s after aGUN or WELD signal is outputby the controller

Check the welder is operating normally. This error is releasedif restart playback.

### Spot weld failure Weld control is notsupported by MEDLANcommand.

Error occurs when the weldcontrol software is too old.

Install the latest software version. Error reset.

### Spot weld failure Different spot weldinggun mounted.

Error occurs when a gundifferent from the gun specifiedin a Spot welding function is

Correct the program, otherwise attachthe correct gun before using Spotwelding function.

Error reset

### Spot weld failure Servo Gun Move-tipconsumption exceededmaximum limit.

Servo Gun Move-tipconsumption exceeded themaximum limit.

Replace the worn Move-tip and detecttip consumption again.

Error reset

### Spot weld failure Servo Gun Settle-tipconsumption exceededmaximum limit.

Servo Gun Settle-tipconsumption exceeded themaximum limit.

Replace the worn Settle-tip and detecttip consumption again.

Error reset


Mechanism is notmounted.

Error occurs when a mountmechanism function isattempted without a mechanismbeing attached. Or, the sub-mechanism input signal line hasbeen disconnected

Attach a mechanism before using amount mechanism function.

Error reset


Sub-mechanism cannotbe selected.

Because two or moresubmechanism input signal hasbeen turned on, the connectedmechanism cannot be selected.

Please input the submechanism inputsignal correctly, and using a mountmechanism function.

Error reset


Mechanism number iswrong.

The mechanism number whichwas not able to change themechanism was selected.

Please set the mechanism numbercorrectly.

Error reset


Different mechanismmounted.

Error occurs when a mechanismdifferent from the mechanismspecified in a step is detected.

Please correct the program. Error reset


Conflict of mechanismchange.

Error occurs when the changefunction was executed for themechanism using other units.

Please correct the program. Error reset

### Spot weld failure The specified welder isnot effective.

The specified welder is noteffectively set by the spotwelding constant.

Modify the welder number. Error reset

### Spot weld failure Spot welding gun is notmechanicallyconnected

It was judged that spot weldinggun was not mechanicallyconnected because theconnection signal was not input.

Connect gun mechanically. When gun isconnected, check the disconnection ofthe signal line.

Error reset


Signals of multi inputare not designated.

Error occurs when a multi inputfunction was attempted playbackwith no condition number.

Create the multi input conditions, orreplace the function to normal input.

Please carry out"failure-reset".

### User coordinatenumber is not selected.

It is necessary to select usercoordinate number before shiftfunction at user coordinate.

Execute [FN113 Change coordinate forshift] before shift functions.



Stationary tool is notselected.

Failure occurs when Stationarytool is not selected althoughstep is Stationary tool

Please select stationary tool usingFN67.



Pause or Externalpause signal beinggiven.

Error occurs when a Startcommand is given while thepause signal is being held orExternal pause signal is being

Release Pause or External pausesignal(if External pause signal cable iscut the external pause signal isconsidered as being given.


### Control failure Far distance between acurrent position and aposition at puttingservo-power off.

Since stopping during high-speed playback and so on, robotcouldn't normally stop on thetrajectry. Since the distance isover the limit for error detectionvalue robot can't recovery

If a limit for error detection is too small,change the value in constant setting.Position Recovery is invalidated settingboth recovery limit values to zero.

Robot can restartfrom there withoutreset operation.

### Spot weld failure Weld tip may be worn. This warning occurs when theWeld counter exceeds the limitvalue.

Check the Gun tip and reset thecounter.


### Control failure Too far distancebetween a currentposition and a positionat putting servo-poweroff.

Since stopping during high-speed playback and so on, robotcouldn't normally stop on thetrajectry. Since the distance isover the limit for error detectionvalue robot can't recovery

If a limit for error detection is too small,change the value in constant setting.

After carry out"failure-reset", robotcan restart.


Take care of notrecovering position atthe next servo on.

Since the position for recoverycouldn't recorded, never recoverthe position at the next servo onwithout related to distance. Thismight be occured at servo offduring recovery position

There is no way. No reset operationsneccesary.

6-10

No Classification Condition Contents Measure Release### Operational

failureAbnormality occurredwhile backing upautomatically.

The thing backed upautomatically cannot be done.The storage medium is notprepared, and read-only andmemory capacity shortage etc

Please confirm the state of the storagemedium.



The memory medium isread-only.

When it is going to copy a file toa write-protected floppy disketc., this error sets.

Please prepare the memory medium towhich writing is made and perform acopy from the beginning once again.



The memory medium isnot prepared.

The detection reason is that thespecified device was notdetected when the file operationis done.

Whether the device such as memorycards and floppy disks specified by thefile operation menu is correctly installedis confirmed.



It cannot process in thesame device.

It was going to copy to the samedevice by the same file name.

Please change a file name or a deviceand redo copy operation again.



Number of axes miss-matched.

Failure occurs when the numberof axes used in a program is notcompatible with the unit constantfiles.

Check the program file type is comptiblewith the constants currently in use.



Data given is incorrect. Data keyed-in is out of range ornot defined.

Input suitable data. No reset operationsneccesary

### Spot weld failure Servo Gun Dramatic tipconsumption changedetected.

Warning is given when the setwarning limit for gun tipconsumption is exceeded. Tipconsumption warning signal isoutputted

Check the lack of gun tip. No reset operationsneccesary.

### Spot weld failure Welder version isunmatched.

Welder version is unmatched. Initialize welder data. No reset operationsneccesary.

### Spot weld failure Welder backup file isnot found.

Welder backup file is not found. Initialize welder data. No reset operationsneccesary.

### Spot weld failure Welder error occurred. Welder detects ALERT orFAULT.

Refer to the Welder Manual. No reset operationsneccesary.


There is an axis whichexceeds the allowanceand maximum torque.

The presumption generationtorque exceeded a permissiblevalue by displayed program stepand axis.

1.Change to ratings or less when therobot load condition is investigated, andweight and the wrist torque exceed it toratings. (Gravity setting is used)2.Thereis a possibility to exceed theacceleration which can be used. (Checkthe step before and after)3.There is apossibility with a large interferencetorque too (Drop the acceleration of the



It is a program whichremarkably shortenslongevity.

In the displayed program,longevity is within at 5000hours.There is a possibilitywhich is the program ofcall/jump origin when the

1.Change to ratings or less when therobot load condition is investigated, andweight and the wrist torque exceed it toratings. (Gravity setting is used)

Please do errorreset.(Overridefunction is used)


The program or the filedoes not exist.

This error occurs when theprogram number is specifiedwhich does not exist in theprogram jump call instruction.

Please correct the program number to acorrect value the jump call ahead.

This error is releasedif a correct programis setted again andrestart playback.

### Spot weld failure Servo Gun Move-tipconsumptionapproaching limit.

Warning is given when the setwarning for Move-tipconsumption limit is exceeded.Tip consumption warning signal

Check the Gun tip. If tips are goodcheck the setting otherwise change thetip to the new one, and detect tipconsumption again.


### Spot weld failure Servo Gun Settle-tipconsumptionapproaching limit.

Warning is given when the setwarning for Settle-tipconsumption limit is exceeded.Tip consumption warning signal

Check the Gun tip. If tips are goodcheck the setting otherwise change thetip to the new one, and detect tipconsumption again.



The file is protected. All protected files or filespartially protected (program orconstant) tried to be corrected

Because the specified file (program orconstant) contains important data,protecting is put so that

Please releaseprotecting the file(program or


There is the axis in1000 hours foroverhaul.

The life time of the axisdisplayed with present operated(time to reaching to longevity)became 1,000 hours or less.

Exchange the axis early. After that 0clearing of "Consumption time untilpresent".



There is the axis in 0hours for overhaul.

The life time of the axisdisplayed with present operated(time to reaching to longevity)became 0 hour or less.

Exchange the axis. After that 0 clearingof "Consumption time until present".



It was going to start,when unit was notready.

This error occurs if it starts whenunit is not ready.

Please check unit ready signal outputconditions, and start after making it theunit ready.

This error is releasedif it starts again aftermaking it the unit

### Spot weld failure Abnormal panelthickness detected.

Dramatic difference of panelthickness exists betweenrecorded value in weld conditionand detected value.

Check the weld condition data and realwork piece thickness.


### CPU boardfailure

Controller temperaturefault.

Information occurs when thetemperature of the core of thecontroller exceeds 60℃. If thisstate lasts 10 min, motor powerwill be automatically shutdownand E0063 displayed

Check the fans are operating, or cleanup the heat exchanger.


6-11

No Classification Condition Contents Measure Release### Spot weld failure Re-weld is not allowed. You did re-weld except for the

time of abnormal welding.Please restart after set a step in automode, or do manual weld.



The program is notrecorded nor selected.

This error occurs when theprogram which is not recorded isselclted and reserve playback.

Please reserve after recording theprogram or selecting other programs.

This error is releasedif it sets a correctprogram and reserveplayback.


Command not possiblewhile running program.

This command is not able to beused during the execution of aprogram.

Stop the program and retry thecommand.



The memory medium isnot discriminable.

When memory media, such as aFIROPPI disk and an memorycard, are not initialized, this error

By Service / File Manager / Formatmemory card/Floppy disk, please use itafter initializing a memory medium.

It will be canceled ifsome keys arepushed.

### Spot weld failure Welder fault. Error occurs when a Welderfault input signal is received bythe controller after thecompletion of a welding

Check the welder unit. No reset operationsneccesary.

### Spot weld failure Welding time exceededlimit.

Error occurs if a Weld competedsignal is not input before thedesignated time period.

Check the welder is operating normally. No reset operationsneccesary.

### Spot weld failure The gun not open. Error occurs if the Gun closedsignal is received after thewelding sequence ends.

Check the GUN or welding unit. No reset operationsneccesary.

### Spot weld failure The gun is not halfopen.

Error occurs if the Gun half-opensignal is not received after Opengun half signal is output by thecontroller.


### Spot weld failure The gun is not fullyopen.

Error occurs if the Gun full-opensignal is not received after Opengun fully signal is output by thecontroller.


### Spot weld failure Stuck Weld GUNdetected.

Error occurs if the System faultsignal is detected aftercompletion of a welding

Error occurs if the Weld stuck signal isreceived when the welding sequenceends.






### Spot weld failure Air pressure fault. Error occurs if the Air pressureswitch signal is detected aftercompletion of a welding


### Spot weld failure Transformertemperature fault.

Error occurs if the Thermo.temp. fault signal is detectedafter completion of a welding


### Spot weld failure Peripheral system fault. Error occurs if the System faultsignal is detected aftercompletion of a welding


### Spot weld failure Both of half-open andfull-open signals aregiven.

Error occurs if both the Gunhalf-open signal and Gun full-open signal are receivedsimultaneously after Open gunhalf signal is output by the

Check the GUN or welding unit todetermine the cause of the twosimultaneous signals.


### Spot weld failure Manual axis movingcannot be operatedduring waiting for WI.

Error occurs if manual axismoving during waiting for WI.

Please releasing WI. Please release theWI.


It stopped in the homestop position.

It will generate, if it comes to theposition registered by setup of ahome stop position function.

Please carry out manual operationagain.


### Arc weld failure Communication timeoutoccurred between thecontroller and thewelding power supply.

The welding power supply didn'trespond.

Check the connection of the weldingpower supply to the controller.

Turn on the controllerand the weldingpower supply again.

### Arc weld failure Received data failure. The data which are receivedfrom the welding power supplyare incorrect.

Check the connection of the weldingpower supply to the controller.


### Arc weld failure Can't communicatewith the welding powersupply.

The communication between thecontroller and the welding powersupply is shutdown.

Check the connection of the weldingpower supply to UM204.


### Arc weld failure Can't communicatewith the welding powersupply.

The communication driverdetected the failure.

Check the connection of the weldingpower supply to the controller. Andcheck the connection of UM204 board.


### Arc weld failure The registration of thewelding power supply isincorrect.

The kind of registered WPS andactual WPS are not same, or theDip switch setting of Robot I/Fboard inside the welding powersupply is wrong

Register WPS correctly, or set Dipswitch of Robot I/F board correctly.

Afterregisteration/setting,turn on the controllerand the weldingpower supply again

### Emergency stopfailure

Alarm carried outnumber-of-timesgenerating ofregulation, and was

Alarm carried out number-of-times generating of regulation,and was breaking down.

Please fix failure from the cause ofalarm.

Error reset

6-12

No Classification Condition Contents Measure Release### Arc weld failure The welding current

value has exceededthe allowable limit.

The difference between thewelding current value measuredby the welding power supply andthe taught one has exceededthe allowable limit set by the arcconstants.

Check the welding conditions(wireextension etc). There is possibility ofmissmatch the welding characteristicdata to your environment if this failureoccurs over and over again. In suchcase, adjust the welding characteristicdata by the adjudstment of welding

Reset failure.

### Arc weld failure The welding voltagevalue has exceededthe allowable limit.

The difference between thewelding voltage value measuredby the welding power supply andthe taught one has exceededthe allowable limit set by the arcconstants.


Reset failure.

### Arc weld failure The welding powersupply has been turnedoff.

The controller couldn'tcommunicate with the weldingpower supply.

Turn on the welding power supply. Incase the welding power supply has beenalready turned on, check the connectionof the welding power supply to the

Reset failure.

### Arc weld failure Arc start failure. No arc is generated afterretrying.

Check the workpiece's condition, wire'scondition, and connection of the cable.

This failure isreleased if restart

### Arc weld failure Arc outage wasdetected.

Arc outage occurred duringwelding.

Eliminate all causes of arc outage, forinstance by adjusting the wedlingconditions, fixing wire feed failure, and

This failure isreleased if restartplayback.

### Arc weld failure Wire stick wasdetected.

Wire is stuck. Cut stuck wire. This failure isreleased if restart

### Arc weld failure Low gas pressure. Low gas pressure signal isinputted.

Supply gas. Reset faliure.

### Arc weld failure Lack of wire wasdetected.

Wire not fed signal is inputted. Supply wire. Reset failure.

### Arc weld failure Lack of water wasdetected.

Cooling water signal is inputted. Supply water. Reset faliure.

### Arc weld failure Arc weldingcharacteristic datafailure.

The registered weldingcharacteristic data isn't for theconnected welding power

Reisger the welding characteristic datafor the using one.

Reset faliure.

### Arc weld failure Welding voltageadjustment methodcan't be changed whilewelding.

Welding voltage adjustmentmethod has been changed fromthe synergetic control to theindividual control, and vise versawhile welding

Modify the task program. Reset faliure.

### Arc weld failure Failure of the weldingpower supply occurred.

W.P.S failure signal is inputted,or failure of the welding powersupply occurs.

Read through the welding power supplyinstruction manual and eliminate allcauses.

Reset faliure.

### Arc weld failure Input voltage shortagefailure ocurred in thewelding power supply.

The primary input voltage of thewelding power supply is lessthan 80 % of the normal value.

Refer to the instruction manual of thewelding power supply(Failure Name:Input voltage shortage error) andeliminate all causes.

Reset failure.

### Arc weld failure Output overcurrentoccurred in the weldingpower supply.

The average current used forthe inner control of the weldingpower supply exceeds the limit.

Refer to the instruction manual of thewelding power supply (Failure Name:Output overcurrent) and eliminate all

Reset faliure.

### Arc weld failure Thermal overloadoccurred in the weldingpower supply.

The surface temperature of theheat sink of the welding powersupply exceeds 90oC.

Refer to the instruction manual of thewelding power supply (Failure Name:Thermal overload) and eliminate all

Reset faliure.

### Arc weld failure Input overvoltageoccurred in the weldingpower supply.

The primary input voltage of thewelding power supply exceeds115 % of the rated value.

Refer to the instruction manual of thewelding power supply (Failure Name:Input overvoltage) and eliminate all

Reset faliure.

### Arc weld failure Loss of phase occurredin the welding powersupply.

Loss of phase in the primaryinput of the welding powersupply.

Refer to the instruction manual of thewelding power supply (Failure Name:Loss of phase) and eliminate all causes.

Reset faliure.

### Arc weld failure Inverter drive circuitfailure occurred in thewelding power supply.

The failure occurs around theinverter drive circuit of thewelding power supply.

Refer to the instruction manual of thewelding power supply (Failure Name:Inverter drive circuit error) and eliminateall causes.

Reset failure.

### Arc weld failure Arc voltage detectingline failure occurred inthe welding powersupply.

The failure(contact failure,broken wire, wrong electrode)occurs in arc voltage detectingcable of the welding power

Refer to the instruction manual of thewelding power supply (Failure Name:Arc voltage detecting line error) andeliminate all causes.

Reset faiuler.

### Arc weld failure Microcomputer failureoccurred in the weldingpower supply.

The failure occurs in the weldingpower supply.

Refer to the instruction manual of thewelding power supply (Failure Name:Microcomputer failure) and eliminate allcauses.

Reset failure.

### Arc weld failure Encoder failure wasdetected by the weldingpower supply.

Failure exists in the encoder of awire feed unit or encoder cablesare not connected.

Refer to the instruction manual of thewelding power supply (Failure Name:Encoder error) and eliminate all causes.

Reset failure.

### Arc weld failure Current detection linefailure occurred in thewelding power supply.

The failure(the connector isdisconnected etc) exists in thecurrent detecting cable of thewelding power supply.

Refer to the instruction manual of thewelding power supply (Failure Name: 9.Current detection error).

Reset failure.

### Arc weld failure Gas check failureoccurred in the weldingpower supply.

The gas check switch of thewelding power supply is ON formore than two minutes without abreak.

Turn OFF the gas check switch of thewelding power supply.

Reset failure.

6-13

No Classification Condition Contents Measure Release### Arc weld failure Secondaly transistor

failure occurred in thewelding power supply.

The surge power of the secondtransistor for the welding powersupply is abnormally high.

Refer to the instruction manual of thewelding power supply (Failure Name:Secondaly transistor failure) andeliminate all causes.

Reset failure.

### Arc weld failure Water pressure failureoccurred in the weldingpower supply.

Cooling water flow is notsufficient when using a watercooled torch.

Refer to the instruction manual of thewelding power supply (Failure Name:Water pressure error) and eliminate all

Reset failure.

### Arc weld failure Secondaly transistorfailure occurred in thewelding power supply.

The surge power of the secondtransistor for the robot weldingpower supply is abnormally high.

Refer to the instruction manual of thewelding power supply (Failure Name:Secondaly transistor failure) andeliminate all causes.

Reset failure.

### Arc weld failure The specified weldingpower supply can't usein this unit.

The specified welding powersupply isn't defined in this unit.

Register the welding power supply whichis specified by the task program, ormodify the task program.

Reset failure.

### Arc weld failure A control power supplywrong point occurred inwelding power supply.

A control power supply wrongpoint occurred in welding powersupply.

Refer to the instruction manual of thewelding power supply (Failure Name:Control power supply) and eliminate allcauses.

Reset failure.

### Arc weld failure An electric detectionvessel wrong pointoccurred in weldingpower supply.

It has the possibility that aconnector inside welding powersupply is missing.

Refer to the instruction manual of thewelding power supply (Failure Name:The first･second electric current error)and eliminate all causes.

Reset failure.

### Arc weld failure The excess wrongpoint of the use rateoccurred in weldingpower supply.

Inside temperature of thewelding power supply rises.

Refer to the instruction manual of thewelding power supply (Failure Name:The excess of the use rate) andeliminate all causes.

Reset failure.

### Arc weld failure A temperature wrongpoint occurred in thewire feed control circuiting the welding power

An unusual fever appears on thewire feed control circuit of thewelding power supply.

Refer to the instruction manual of thewelding power supply (Failure Name:The temperature wrong point of the wirefeed control circuit) and eliminate all

Reset failure.

### Arc weld failure The load of wire feedexceeded allowablevalue.

It exceeded the allowable valuewhich the load of wire feed wasset up to by the welding fixed

A load is on the wire feed department bywear of the liner, the chip defect, and soon. Get rid of load factors.

Reset failure.

### Arc weld failure The control powersupply of the weldingpower supply was

The control power supply of thewelding power supply was reset.

It has the possibility that an input voltageon the first side decreases momentarily.Confirm voltage capacity on the first

Reset failure.

### Arc weld failure The weldingcharacteristic data arenot installed.

If the welding characteristic dataare not installed, Arc functioncommands can't be execute.

Turn on the welding power supply again. Reset failure.

### Arc weld failure The arc characteristiccan't be changed whilearc welding.

The arc function attemptedchanging the arc characteristicinto the incorrect one.

Please modify the task program. Reset failure.

### Arc weld failure The incorrect weldingmethod is specified.

The welding method of the arcfunction and the welding methodof the arc characteristic aren'tthe same.


### Arc weld failure The arc characteristicfile can't be read.

Read file failure occurs whilereading the arc characteristic

Please initialize the arc characteristicfile.

Reset failure.

### Arc weld failure The wire feedcharacteristic file can'tbe read.

Read file failure occurs whilereading the wire feedcharacteristic file.

Please initialize the wire feedcharacteristic file.

Reset failure.

### Arc weld failure The arc welding wavecontrol file can't beread.

Read file failure occurs whilereading the arc welding wavecontrol file.

Please initialize the arc welding wavedata file.

Reset failure.

### Arc weld failure The arc constant filecan't be read.

Read file failure occurs whilereading the arc constant file.

Please initialize the arc constant file. Reset failure.

### Arc weld failure Welding voltageadjustment methoddiffers.

The voltage adjusting methodcurrently taught differs from thevoltage adjusting method ofcharacteristic data.

Modify the task program. Reset faliure.

### Arc weld failure WCR Short-circuitError

WCR of W-I/F had connectedtoo hastily at the time of an arc

Please check the state of W-I/F, and awelding power supply.


### Arc weld failure The electrode short-circuited failure.

The electrode and the work areshort-circuited while arc welding.



Resources were notsecurable at the time ofstarting.

It passed over the waiting timeof resources reservation.

Starting and a branch-unit outsidecommand need to be looked again.

An unusual releasekey is pushed.

### Arc weld failure The welding currentvalue has exceededthe allowable limit.

The difference between thewelding current value measuredby the welding power supply andthe taught one has exceededthe allowable limit set by the arcconstants.


Reset failure.

### Arc weld failure The welding voltagevalue has exceededthe allowable limit.

The difference between thewelding voltage value measuredby the welding power supply andthe taught one has exceededthe allowable limit set by the arcconstants.


Reset failure.

### Arc weld failure Arc start failure. No arc is generated afterretrying.

Check the workpiece's condition, wire'scondition, and connection of the cable.


6-14

No Classification Condition Contents Measure Release### Arc weld failure Arc outage was

detected.Arc outage occurred duringwelding.

Eliminate all causes of arc outage, forinstance by adjusting the wedlingconditions, fixing wire feed failure, and

This failure isreleased if restartplayback.

### Arc weld failure Wire stick wasdetected.

Wire is stuck. Cut stuck wire. This failure isreleased if restart

### Arc weld failure Wire shortage wasdetected.

Not enough wire signal isinputted.

Supply wire. No reset operationsneccesary.

### Arc weld failure The load of wire feedexceeded allowablevalue.

It exceeded the allowable valuewhich the load of wire feed wasset up to by the welding fixed

A load is on the wire feed department bywear of the liner, the chip defect, and soon. Get rid of load factors.


### Arc weld failure The battery of weldingpower supply isexhausted.

The battery of welding powersupply is exhausted.

Exchange a battery because it can't beconnected any more with the weldingpower supply.


### Arc weld failure WCR Short-circuitError

WCR of W-I/F had connectedtoo hastily at the time of an arc

Please check the state of W-I/F, and awelding power supply.



It was going to start theunit under starting.

It will generate, if the unit understarting is started.

Please start after waiting for thecompletion of starting.

Special release is notrequired.


System Error (MailBoxTimeout Error).

System Error. MailBox Timeout. Turn on the power again. If the error isnot released, reinstall the system.



Motion process is notrecognized.

Can't recongnize Motionprocess.




I/O system is notrecognized.

Can't recognize I/O system. Turn on the power again. If the error isnot released, reinstall the system.



Servo communicationinitialization failure

This failure occurs when thecommunication between CPUsubstrate and the servosubstrate cannot begin.

(1)Please confirm whether connectorCNUSB of servo substrate UM221 iscorrectly connected.(2)Please confirmthe supply voltage of the servo substrateUM221 (3)Please replace the drive unit

After removal offailure, please turn onthe power supply ofthe controller again.

### Amplifier unitfailure

Brake fuse off This failure occurs when thefuse F1-1 or F1-2 or F1-3 onbrake control substrate UM222

Please exchange the brake fuse. After removal offailure, please carryout "failure-reset".


Brake fuseoff.(additional axis)

This failure occurs when thefuse F1-1 or F1-2 on brakecontrol substrate UM226 was

Please exchange the brake fuse. After removal offailure, please carryout "failure-reset".


Contact of brake powercontrol relay was stuck

This failure occurs when thecontact of brake power controlrelay (CRBC1) on brake controlsubstrate UM222 was stuck.

Please exchange the brake controlsubstrate UM222 referring to "AXcontroller maintenance manual".



Drive unit power failure This failure occurs when driveunit power PG15(+15V) was notsupplied.



Over temperature ofmotor.(additional axis)

This failure occurs when themotor temperature risesabnormally.

(1)Please confirm that the Pay-load iswithin the nominal rating.(2)Pleaseconfirm the wiring of the motorthermostat refering to "ManipulatorMaintenance Manual".(3)Please stop therobot in order to lowering the motortemperature, and restart.(4)If failurepersists please lower the operation



Over temperature ofregenerative dischargeresister.(additionalaxis)

This failure occurs when thetemperature of the regenerativedischarge resister risesabnormally.

(1)Check the fans areoperating.(2)Please secure space 20cmor more in backside ofcontroller.(3)Please check wiring of thethermostat for regenerative discharge



Servo shared memoryabnormal

This failure occurs when readingor wrinting data to the sharedmemory between servocommunication CPU and servoCPU was not successfully



Servo CPU(#2) DPmemory error.

Servo CPU(#2) D.P.memoryerror

Replace the Drive Unit. No reset operations


Servo CPU(#3) DPmemory error.

Servo CPU(#3) D.P.memoryerror



Servo CPU(#1 axis) isnot ready.

Nothing acknowledge formservo CPU(#1 axis)


































6-15

Chapter 7 Welding Specifications

This chapter describes the welding specifications of welding power supply.

7.1 Connecting Welding Power Supply.............................................................7-1

7.1.1 Connecting Almega Digital Welding Power Supply ...............................7-1 7.1.2 Connecting Digital Welding Power Supply ............................................7-9 7.1.3 Connecting Welding Power Supply I/F................................................7-13

7.1 Connecting Welding Power Supply

7-1


7.1.1 Connecting Almega Digital Welding Power Supply

This section describes how to connect the robot dedicated welding power supply, using CPDRA-351 as an example.

1. Types of Almega Digital Welding Power Supply

Type Robot dedicated CO2/MAG/MIG CPDRA-351/501

welding power supply CPDACA-201 CPDPAS-351/501

TIG welding power supply ADPA-301

2. Connection Cable for Welding Power Supply To connect the robot dedicated welding power supply, the external connection cables shown in the following

are required.

Control cable 4 ：Connection cable ( Robot - Robot controller ) Component

Type Gas hose Torch-side welding cable

Workpiece-sidewelding cable Control cable4 Specifications

EXRB-4005 (Standard) L2527B L2527D L3442B L8905B Length: 5mEXRB-4010 L3375T L3375E L3375L L8906B Length: 10mEXRB-4015 L3375V L3375G L3375N L8907B Length: 15m

Control cable 5 ：Connection cable ( Robot - Robot controller ) Type Specifications

AXRB-5005 (Standard) Length: 5m AXRB-5010 Length: 10m AXRB-5015 Length: 15m

Fig 7.1.1 Connecting Almega Digital Welding Power Supply


7-2

3. How to connect cables

WARNING

Turn OFF the primary power and the breaker of robot controller. Check that the voltage of primary power meets the voltage specification of controller. The voltage of controller is indicated beside the breaker.

(a) Control cable5 : Connection cable (Robot controller - Welding power supply)

(1) Drawing Control cable 5 (AXRB-5005)

Draw the connector of control cable 5 from the inlet, the shaded part in Fig 7.1.2, into the robot controller. Then, fix the cable flange.

(2) Connecting Control cable 5 (AXRB-5005) -- (1) Joint the connector CNCAN drawn into the robot controller with the connector CNCAN on the storage board, and the connector CNWEL with CNWEL on the sequence board.

(3) Connecting Control cable 5 (AXRB-5005) -- (2) Clamp the shield part of control cable 5.

Fig 7.1.2 Drawing Control cable 5 (AXRB-5005)


7-3

(4) Connecting Control cable 5 (AXRB-5005) -- (3)

・ Remove the top cover from the welding power supply. ・ Draw the control cable 5 into the welding power supply through its back, and then fix the cable flange using

the supplied tapping screws. ・ Joint the connector to the connector CN57 on PCB (L8268C), and the crimp-style terminal to the terminal

block (No. 7&8) on PCB (P6981Q).（See Fig 7.1.3）・ After connecting the cables, connect the grounding and then fix the top cover.

(Refer to ・

・ Fig 7.1.1 for the location of PCB.)

Fig 7.1.3 Terminal Block (P6981Q)

(b) Control cable 4 (L8905B) : Connection cable (Robot – Robot controller )

Joint the control cable 4 to the connector ICN4 in welding power supply and to the connector CN4 in manipulator.

(c) Workpiece-side welding cable (L3442B) : Connection cable (Welding power supply – Workpiece )

Connect the workpiece-side welding cable to the (-) terminal of the welding power supply.

(d) Torch-side welding cable (L2527D) : Connection cable (Welding power supply – Robot )

Connect the torch-side welding cable to the (+) terminal of the welding power supply.

:Important 1. For the outline drawing, the internal structure and others about a welding power supply,

see the instruction manual attached to each welding power supply. 2. For the maintenance of welding power supply, see the instruction manual attached to

each welding power supply.


7-4

4. Modifying Parameters

CPDRA-351/501


7-5

CPDACA-201


7-6

CPDPAS-351/501


7-7

ADPA-301 (with no Filler wire feeder)


7-8

ADPA-301 (with Filler wire feeder)


7-9

7.1.2 Connecting Digital Welding Power Supply

This chapter describes how to connect the digital welding power supply, using DM-350 as an example.

1. Types of Digital Welding Power Supply

Type CO2/MAG Welding Power Supply DM-350

2. Connection Cable for Welding Power Supply To connect the robot dedicated welding power supply, the following external connection cables are required.

Control cable 4 ：Connection cable ( Robot - Robot controller ) Type Component

Gas hose Torch-side welding cable

Workpiece-sidewelding cable Control cable4 Specifications

AXRB-4105 L2527B L9155C L9155D L9155B Length: 5m AXRB-4110 L3375T L9156C L9156D L9156B Length: 10m AXRB-4115 L3375V L9157C L9157D L9157B Length: 15m

Control cable 5 ：Connection cable ( Robot - Robot controller ) Type Specifications

AXRB-5105 (Standard) Length: 5m AXRB-5110 Length: 10m AXRB-5115 Length: 15m

CAN I/F board : Communication board (Robot controller – Welding power supply)

Type Specifications L9129C Welding power supply CANI/F board

Fig 7.1.4 Connecting the Digtal Welding Power Supply


7-10


WARNING


(a) Control cable5 : Connection cable (Robot controller - Welding power supply)

(1) Drawing Control cable 5 (AXRB-5105)

Draw the connector of control cable 5 from the inlet, the shaded part in Fig 7.1.5, into the robot controller. Then, fix the cable flange

(2) Connecting Control cable 5 (AXRB-5105) -- (1) Joint the connector CNCAN drawn into the robot controller with the connector CNCAN on the storage board, and the connector CNWEL with CNWEL on the sequence board.

(3) Connecting Control cable 5 (AXRB-5105) -- (2) Clamp the shield part of control cable 5.

Fig 7.1.5 Drawing Control cable 5 (AXRB-5105)


7-11

(4) Connecting Control cable 5 (AXRB-5105) -- (3)

・ Remove the top cover from the welding power supply. ・ Draw the control cable 5 into the welding power supply through its back, and then fix the cable flange using

the supplied tapping screws. ・ Joint the connector to the connector CN3 on PCB (L9129C), and the crimp-style terminal to the terminal

block (No.1&2) on PCB (P10260T). (See Fig 7.1.6) ・ After connecting the cables, connect the grounding and then fix the top cover.

(Refer to Fig 7.1.4 for the location of PCB.)

Fig 7.1.6 Terminal Block

(e) Control cable 4 (L9155B) : Connection cable (Robot – Robot controller )

Joint the control cable 4 to the connector ICN4 in welding power supply and to the connector CN4 in manipulator.

(b) Workpiece-side welding cable (L9155D) : Connection cable (Welding power supply – Workpiece)

Connect the workpiece-side welding cable to the (-) terminal of the welding power supply and secure it by turning the connector.

(c) Torch-side welding cable(L9155C) : Connection cable (Welding power supply – Robot)

Connect the torch-side welding cable to the (+) terminal of the welding power supply and secure it by turning the connector.

:Important 1. For the outline drawing, the internal structure and others about a welding power supply,

see the instruction manual attached to each welding power supply. 2. For the maintenance of welding power supply, see the instruction manual attached to

each welding power supply.

4. Modifying Parameters

After connecting cables, be sure to modify the setting of welding parameters. For how to modify the parameters, refer to “APPLICATION MANUAL (ARC WELDING)”

CAUTION

1. Arc voltage detecting cable (+ side ) is included in the control cable 4. 2. Arc voltage detecting cable (- side ) is required when the to-and-fro length of

welding cable is 30m or longer. 3. To use the arc voltage detecting cable (- side ), connect it away from the

workpiece cable. 4. Wire feed unit attached with encoder can be combined with a fixed bracket, but

not with a rotational bracket.


7-12

DM-350


7-13

7.1.3 Connecting Welding Power Supply I/F

This section describes how to connect the analog welding power supply.

1. Types of Analog welding power supply

Type CPVB-350 VRTP-200/300 AEP-300 AVP-200/300/500 D-12000 TRC-120 D-8000 VRC-81

2. Connection cables for welding power supply

Type Length AXWF-0005 (Standard) Length: 5m

AXWF-0010 Length: 10m AXWF-0015 Length: 15m

Welding power supply I/F Power cable, Communication cable

Type of welding power supply Connection cable

CPVB-350 E5642B E5642C L8786D <With no filler wire feeder> VRTP-200/300 AEP-300 AVP-200/300/500

E5243E E5243F L8786B L8786C L8786E

<With filler wire feeder> VRTP-200/300 ﾊﾟﾙｽｺﾝﾊﾟ AEP-300 AVP-200/300/500

Filler wire feed control unitE5223A

E5239E E5239F L8786B L8786C L8786E

D-12000 TRC-120 E5769B L8786F D-8000 VRC-81 E5641F L8786F


WARNING


(a) Communication cable/ Power cable : Connection cable (robot controller – Welding power supply I/F)

(1) Drawing the communication cable (L9500B) and the power cable (L8792B)

Draw the connector of each cable from the inlet, the shaded part on the left side in Fig 7.1.7, into the robot controller. Then, fix the cable flange.

(2) Connecting the communication cable (L9500B) and the power cable (L8792B) – (1) Joint the connector CNCAN drawn into the robot controller with the connector CNCAN on the storage board, and the connector CNWEL with CNWEL on the sequence board. In addition, connect the power cable to the breaker.

(3) Connecting the communication cable (L9500B) and the power cable (L8792B) – (2) Clamp the shield part of communication cable.


7-14

Fig 7.1.7 Drawing the communication cable (L9500B) and the power cable (L8792B)

(4) Connection inside the welding power supply I/F

・ Remove the cover of welding power supply I/F. ・ Draw the control cable from the specified inlet on the welding power supply I/F. And then, secure the

cable flange with the attached tapping screw. ・ Next, see Fig 7.1.8 and joint each connector. After completing cable connections, connect the grounding

and fix the cover.

Fig 7.1.8 Connection inside the welding power supply I/F

:Important

1. For the outline drawing, the internal structure and others about a welding power supply, see the instruction manual attached to each welding power supply.

2. For the maintenance of welding power supply, see the instruction manual attached to each welding power supply.

4. Modifying Parameters After connecting cables, be sure to modify the setting of welding parameters. For how to modify the parameters, refer to “APPLICATION MANUAL (ARC WELDING)”

Chapter 8 Specifications of External Axis

This chapter describes the specifications of external axis.

8.1 External Axis ...............................................................................................8-1

8.1.1 Specifications of External Axis ..............................................................8-1 8.1.2 External Axis Cable...............................................................................8-3 8.1.3 Connecting External Axis Cable............................................................8-5

8.1 External Axis

8-1

8.1 External Axis

8.1.1 Specifications of External Axis

To use the manipulator combining with the peripheral jig equipment such as positioner or slider, the optional

external axis unit is needed to extend. This unit is called “External axis unit (for motor of 1500w or smaller)”. Building this unit inside the standard robot controller enables to extend the maximum of 3 external axes.

(Refer to Note3) below the table.)

Item Details Name External axis unit Driving system AC servo

< For connecting the robot dedicated peripheral jig unit controlling without the motor of 1500W or smaller >

Combination of applicable motor Type 500W～1500W × 1 axis L9171 500W～1500W × 2 axes L9172 500W～1500W × 3 axes L9171 + L9172 < For connecting the robot dedicated peripheral jig unit

controlling with the motor of 1500W or smaller > Combination of applicable motor Type

Number and type of control axes (Note 1,2 and 3)

1500W ×1axis +1500W (or smaller) ×1 axis L9172 Automatic operation speed

For positioning : Refer to the specifications of peripheral jig unit. For welding : 10cm ～ 999cm/min. (Setting is available by 1cm /min.)

Origin return Not necessary -- Provided with the absolute position detecting function by battery backup. (Note 4) 3-phase AC200V+10%, -15% 50/60Hz

Type Rating Type Rating Power supply (Note 5) L9171 2kVA L9172 4kVA

Weight Standard robot controller + L9171 : Approx. 80kg Standard robot controller + L9172 : Approx. 88kg Standard robot controller + L9171+L9172 : Approx. 88kg

Note1) The number and type of external axes depend on your peripheral jig equipment. When you order, be sure to select the suitable one for your system.

Note2) If the combination of external axes in your system is not in the example above, contact our sales

engineer.

Note3) By extending the additional external axis unit, the maximum of 48 external axes can be extended (total of 54 axes).

Note4) The duration of the absolute encoder battery is approx. 3 years with the power OFF. This may be even

shorter depending on the ambient temperature, the use condition etc. After this duration period, be sure to perform “Absolute offset setting” and replace the battery.

Note5) The rating of the primary power indicated here is only of the external axis unit. The rating of the total

robot system is the addition of this value and the rating of robot controller. Remember this note when performing the power construction.

8.1 External Axis

8-2

We provide the products shown in Table 8.1.1 below as the peripheral jig unit to combine with the robot.

Table 8.1.1 Robot dedicated peripheral unit

Item Type Specification

AX-1PB250 Max. payload 250 kg AX-1PB500 Max. payload 500 kg 1-axis Headstock Positioner AX-1PB1000 Max. payload 1000 kg AX-2PE150 Max. payload 150 kg 2-axes Double Support Positioner AX-2PE300 Max. payload 300 kg AX-2PT500 Max. payload 500 kg 2-axes Tilting Positioner AX-2PT1000 Max. payload 1000 kg AX-1SB10 Stroke 1.0 m Linear Slider (Light type) AX-1SB20 Stroke 2.0 m AX-1SR29 Stroke 2.9 m AX-1SR39 Stroke 3.9 m AX-1SR49 Stroke 4.9 m Linear Slider (Standard type)

AX-1SR59 Stroke 5.9 m AX-1SR19P Stroke 1.9 m AX-1SR29P Stroke 2.9 m AX-1SR39P Stroke 3.9 m AX-1SR49P Stroke 4.9 m

Linear Slider (with carriage type)

AX-1SR59P Stroke 5.9 m

The standard controller can be connected with the peripheral jig unit of 3 axes of the maximum. This system must be the combination of 1 axis or 2 axes jig. As for the standard combination of 1 axis and 2 axes, see Table 8.1.2.

Table 8.1.2 System configuration

Peripheral jig Example of configuration Number of

axes Jig 1 Jig 2

Number of required external axis cables for peripheral jigs

1-axis positioner － 1 axis 1-axis slider － 2-axes positioner － 2 axes 1-axis positioner 1-axis positioner

External axis cables for 1 and 2 axes (1 set)

3 axes 1-axis slider 2-axes positioner External axis cables for 1 and 2 axes (2 sets)

8.1 External Axis

8-3

8.1.2 External Axis Cable

When connecting the peripheral jig unit with the external axis controller, the external cables shown in Table

8.1.3 are required. This external axis cable for connecting a single peripheral jig unit consists of two cables; one motor cable (External axis cable 1) and one encoder cable (External axis cable 2).

Table 8.1.3 External axis cable

Length of external axis cable Type Item Part No. Remarks

External axis cable 1 L9125B00 3m L9125 External axis cable 2 L9125C00 External axis cable 1 L9126B00 5m L9126 External axis cable 2 L9126C00 External axis cable 1 L9127B00 10m L9127 External axis cable 2 L9127C00 External axis cable 1 L9128B00 15m L9128 External axis cable 2 L9128C00

For using the motor of 1500W or smaller External axis cables for the external 1 axis and 2 axes jig are common.

When applying jigs from other manufacturer, additional external axis relay cable is required other than the

external axis cable. As for the cable length and the type of external axis relay cable, see Table 8.1.4 and Table 8.1.5.

Besides, see Fig 8.1.1 for the relay cable.

Table 8.1.4 External axis relay cable - Motor cable -

Cable length and part No. RemarksCable name Motor rating Part No.

0.2 0.3 0.5 1 2 3 4 5 6 7 8 9 10 Relay connector cable for external axis motor

L7464○00 B B

External axis relay motor cable

For motor of 750W or smaller L7465○00 B C D E F G H J K L M N Use

L7464B. External axis relay motor cable

For motor of 1.2KW～2KW or smaller L7466○00 B C D E F G H J K L M N Use

L7464B. External axis extension motor cable

For motor of 750W or smaller L7467○00 B C D E F G H J K L M N

Table 8.1.5 External axis relay cable - Encoder cable -

Cable length and part No. RemarksCable name Motor rating Part No.

0.2 0.3 0.5 1 2 3 4 5 6 7 8 9 10 Relay connector cable for external axis encoder

With LS wire L7468○00 B B

External axis relay encoder cable With LS wire L7469○00 B C D E F G H J K L M N Use

L7468B Joint the short-circuit connector “L6390K” to the end of encoder cable (jig side) when the overrun function is OFF (not used). < Part No. > Part No. is described such as “L7465○00”. The ○ part indicates the length of cable using an alphabet. For example, the part No. for “External axis relay motor cable 4m” is L7465G00.

8.1 External Axis

8-4

Fig 8.1.1 External axis relay cable

8.1 External Axis

8-5

8.1.3 Connecting External Axis Cable

This section describes how to connect the external axis cable.

1. Specifications for 7 axes (Example: Using a single 1-axis slider)

.

WARNING

Turn OFF the primary power and the breaker of robot controller. Check that the primary power voltage meets the voltage specification of the controller indicated beside the breaker.

Joint the wire harness (External axis cable 1 and 2) connected on the jig side to the robot controller. See Fig 8.1.2 for the inlet of wire harness and the connector position.

・ Shut off the power supply and turn OFF the breaker of the unit. ・ Draw the wire harness (External axis cable 1 and 2) from the side of robot controller to the inside.

Then clamp the shield part of the control cable 1 and fix the grounding cable, for the external cable 2, to the earth stud on the left flank side of controller. When drawing the cable, use the inlet shown in Fig 8.1.2.

・ Joint the connector, referring to Fig 8.1.2.

Fig 8.1.2 Connecting wire harness (External axis cable 1 and 2)

CAUTION

Arrange the wire harness (External axis cable 2) away from both the primary power cable and the wire harness connected to the Arc welding power supply. ･When wiring inside the robot controller, keep the both wire harness; Control cable 1 and 2, away from each other. Do not bind these two wire harnesses together.

･Do not use the wire harness (control cable 2) for the movable/flexion part such as in the cable bare of slider since this cable is not made movable. If you need to use it for that purpose, contact our sales engineers.

CAUTION

After connecting the cables to a robot controller, be sure to close the door. If it is not completely closed, the controller will be exposed to dust, dirt etc. and result in a trouble.

8.1 External Axis

8-6

2. Specifications for 8 axes (Example: Using a single 2-axes positioner)

WARNING






Fig 8.1.3 Connecting wire harness (External axis cable 1 and 2)

CAUTION



CAUTION


8.1 External Axis

8-7

3. Specifications for 8 axes (Example: Using two 1-axis sliders)

WARNING


~ 1st slider ~





Fig 8.1.4 Connecting wire harness (External axis cable 1 and 2) 1st slider

8.1 External Axis

8-8

~ 2nd slider ~





Fig 8.1.5 Connecting wire harness (External axis cable 1 and 2) 2nd slider

CAUTION



CAUTION


8.1 External Axis

8-9

4. Specifications for 9 axes (Example: Using a single 1-axis slider and 2-axes positioner)

WARNING


~ Slider ~

Joint the wire harness (External axis cable 1 and 2) connected on the jig side to the robot controller.

See Fig 8.1.6 for the inlet of wire harness and the connector position.

・ Shut off the power supply and turn OFF the breaker of the unit.

・ Draw the wire harness (External axis cable 1 and 2) from the side of robot controller to the inside.

Then clamp the shield part of the control cable 1 and fix the grounding cable, for the external cable 2, to

the earth stud on the left flank side of controller.

When drawing the cable, use the inlet shown in ・ Fig 8.1.6.

・ Joint the connector, referring to ・ Fig 8.1.6.

Fig 8.1.6 Connecting wire harness (External axis cable 1 and 2) Slider

8.1 External Axis

8-10

~ 1st positioner ~

Joint the wire harness (External axis cable 1 and 2) connected on the jig side to the robot controller.

See Fig8.1.7 for the inlet of wire harness and the connector position.

・ Shut off the power supply and turn OFF the breaker of the unit.

・ Draw the wire harness (External axis cable 1 and 2) from the side of robot controller to the inside.

Then clamp the shield part of the control cable 1 and fix the grounding cable, for the external cable 2, to

the earth stud on the left flank side of controller.

When drawing the cable, use the inlet shown in ・ Fig8.1.7.

・ Joint the connector, referring to ・ Fig8.1.7.

Fig8.1.7 Connecting wire harness (External axis cable 1 and 2) 1st positioner

CAUTION



CAUTION


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