fanuc r-j3ib - maintenance manual for europe - b-81465en-1-02

FANUC Robot series

MAINTENANCE MANUAL

B--81465EN--1/02

FOR EUROPE

R--J3iB CONTROLLER

B--81465EN--1/02 Table of Contents

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

I SAFETY PRECAUTIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. SAFETY PRECAUTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 OPERATOR SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.1 Operator Safety 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1.2 Safety of the Teach Pendant Operator 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1.3 Safety During Maintenance 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.1 Precautions in Programming 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.2 Precautions for Mechanism 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 SAFETY OF THE ROBOT MECHANISM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.1 Precautions in Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.2 Precautions in Programming 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.3 Precautions for Mechanisms 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 SAFETY OF THE END EFFECTOR 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.1 Precautions in Programming 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 SAFETY IN MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 WARNING LABEL 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II MAINTENANCE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. OVERVIEW 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. CONFIGURATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 EXTERNAL VIEW OF THE CONTROLLER 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 COMPONENT FUNCTIONS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 PREVENTIVE MAINTENANCE 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. TROUBLESHOOTING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 POWER CANNOT BE TURNED ON 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 ALARM OCCURRENCE SCREEN 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 SAFETY SIGNALS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 MASTERING 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 TROUBLESHOOTING USING THE ERROR CODE 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 FUSED--BASED TROUBLESHOOTING 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 TROUBLESHOOTING BASED ON LED INDICATIONS 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION(POSITIONING) 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 VIBRATION OBSERVED DURING MOVEMENT 132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 MANUAL OPERATION IMPOSSIBLE 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. PRINTED CIRCUIT BOARDS 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 MAIN BOARD (A16B--3200--0412, --0413) 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 EMERGENCY STOP CONTROL PC BOARD (A20B--1007--0800) 139. . . . . . . . . . . . . . . . . . . . . . . .

4.3 BACKPLANE PC BOARD 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.4 PANEL BOARD (A20B--2100--0770) 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 PROCESS I/O BOARD CA (A16B--2201--0470) 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 PROCESS I/O BOARD CB (A16B--2201--0472) 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 PROCESS I/O BOARD DA (A16B--2201--0480) 148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 PROCESS I/O BOARD HA (A16B--2203--0760) 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 PANEL SWITCH BOARD (A20B--1007--0850) 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. SERVO AMPLIFIERS 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 LED OF SERVO AMPLIFIER 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 SETTING OF SERVO AMPLIFIER 155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 DRIVER CHIP FOR ROBOT DI/DO 156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. SETTING THE POWER SUPPLY 157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 BLOCK DIAGRAM OF THE MAIN POWER INCLUDING POWER SUPPLY 158. . . . . . . . . . . . . .

6.2 SELECTING TRANSFORMER TAPS 159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 CHECKING THE POWER SUPPLY UNIT 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. REPLACING A UNIT 164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 REPLACING THE PRINTED--CIRCUIT BOARDS 165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 Replacing the Backplane Board (Unit) 165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1.2 Replacing the Power Unit and Printed--Circuit Boards on the Backplane Unit 166. . . . . . . . . . . . . . . . . . .7.1.3 Replacing the Panel Board 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 REPLACING CARDS AND MODULES ON THE MAIN BOARD 169. . . . . . . . . . . . . . . . . . . . . . . .

7.3 REPLACING THE TRANSFORMER 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 REPLACING THE REGENERATIVE RESISTOR UNIT 176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 REPLACING THE E--STOP UNIT 177. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 REPLACING SERVO AMPLIFIERS 178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.7 REPLACING I/O UNIT MODEL A 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7.1 Replacing the Base Unit of I/O Unit Model A 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7.2 Replacing a Module 183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8 REPLACING THE TEACH PENDANT 184. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9 REPLACING THE CONTROL SECTION FAN MOTOR 185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.10 REPLACING THE AC FAN MOTOR 186. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10.1 Replacing External Air Fan Unit and Door Fan (B--cabinet) 186. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.11 REPLACING THE OPERATOR PANEL AND PANEL SWITCH BOARD 188. . . . . . . . . . . . . . . . . .

7.12 REPLACE THE MODE SWITCH 189. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13 REPLACING FUSES 190. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13.1 Replacing Fuses in the Servo Amplifier 190. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13.2 Replacing Fuses in the Power Unit 191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13.3 Replacing the Fuse on the Process I/O Boards 192. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13.4 Replacing the Fuse on the Panel Board 194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.14 REPLACING RELAYS 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14.1 Replacing Relays on the Panel Board 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.15 REPLACING BATTERY 196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15.1 Battery for Memory Backup (3 VDC) 196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

1. GENERAL 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. BLOCK DIAGRAM 202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. ELECTRICAL CONNECTIONS 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS 204. . . . . . . . . . . . . . . . . . . . . . . . .

3.2 EXTERNAL CABLE WIRING DIAGRAM 206. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.1 Robot Connection Cables 206. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.2 Teach Pendant Cable 207. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.3 Connecting the Input Power 208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.4 Connecting the External Power Supply ON/OFF Switch 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.5 Connecting the External Emergency Stop 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. PERIPHERAL DEVICE, ARC WELDING,AND END EFFECTOR INTERFACES 220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM 221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 When Process I/O Board CA/CB/HA is Used (B--cabinet) 221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1.2 When Process I/O Board DA is Used (B--cabinet) 223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1.3 When I/O Unit--MODEL A is Used 224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.3.1 In case of B--cabinet 224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.4 When Two or more Process I/O Boards and I/O Unit (Model A or Model B) are Used 225. . . . . . . . . . . .

4.2 PERIPHERAL DEVICE INTERFACE COMBINATION 226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.1 In Case of B--cabinet 226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 PROCESS I/O BOARD SIGNALS 227. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS 231. . . . . . . . . .4.4.1 Peripheral Device and Control Unit Connection 232. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.2 Connection Between the Mechanical Unit and End Effector 245. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.3 Connection Between the Control Unit and Welder 247. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 DIGITAL I/O SIGNAL SPECIFICATIONS 253. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.1 Peripheral Device Interface 253. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.2 End Effector Control Interface 255. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.3 I/O Signal Specifications for ARC--Welding Interface 257. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICESAND WELDERS 261. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins) 261. . . . . . . . . . . . . . . . . . . . . . . .4.6.2 Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins) 261. . . . . . . . . . . . . . . . . . . . . . . .4.6.3 ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins) 262. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS,AND ARC WELDERS 263. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.1 Peripheral Device Connection Cable 263. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7.2 Peripheral Device Cable Connector 264. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7.3 End Effector Cable Connector 266. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7.4 Recommended Cables 267. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 CONNECTION OF HDI 268. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8.1 Connecting HDI 268. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8.2 Input Signal Rules for the High--speed Skip (HDI) 270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 CONNECTING THE COMMUNICATION UNIT 271. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.9.1 RS--232--C Interface 271. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.1.1 Interface 271. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.9.1.2 RS--232--C Interface Signals 272. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.1.3 Connection between RS--232--C Interface and External Device 273. . . . . . . . . . . . . . . . . . . . . . . .

4.9.2 Ethernet Interface 275. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.1 Connection to Ethernet 276. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.2 10/100 BASE--T Connector (CD38) Pin Assignments 277. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.3 Cable Connection 277. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.4 Lead Materials 278. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.5 Connector Specification 279. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.6 Cable Clamp and Shielding 280. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.7 Grounding the Network 281. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. TRANSPORTATION AND INSTALLATION 283. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 TRANSPORTATION 284. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 INSTALLATION 285. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.1 Installation Method 285. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.2 Assemble at installation 287. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 INSTALLATION CONDITION 288. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 ADJUSTMENT AND CHECKS AT INSTALLATION 289. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION 290. . . . . . . . . . . . . .5.5.1 Peripheral Device Interface Processing 290. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5.2 Resetting Overtravel 290. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5.3 How to Disable/Enable HBK 291. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5.4 How to Disable/Enable Pneumatic Pressure Alarm (PPABN) 292. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX 293. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A. TOTAL CONNECTION DIAGRAM 295. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE 316. . . . . . . . . . . . . . . . .B.1 SIGNALS 317. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.2 SETTING COMMON VOLTAGE 319. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.3 I/O SIGNALS 320. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.3.1 Input Signals 320. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.3.2 Output Signals 325. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT 329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.4.1 Overview 329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.4.2 Input/Output Hardware Usable in the R-J3iB Controller 329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.4.3 Software Specifications 330. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C. POWER DISTRIBUTION CIRCUIT DIAGRAM 331. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D. OPTICAL FIBER CABLE 338. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E. CARD INTERFACE 341. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B--81465EN--1/02 PREFACE

p--1

PREFACE

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

Model Abbreviation

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

FANUC Robot R--2000iA/200F R--2000iA/200F

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

FANUC Robot R--2000iA/200R R--2000iA/200RR--2000iA

FANUC Robot R--2000iA/125L R--2000iA/125L

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

FANUC Robot M--6iB M--6iBFANUC Robot ARC Mate 100iB ARC Mate 100iB

I SAFETY PRECAUTIONS

B--81465EN--1/02 1. SAFETY PRECAUTIONSSAFETY PRECAUTIONS

3

1 SAFETY PRECAUTIONS

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

1. SAFETY PRECAUTIONS B--81465EN--1/02SAFETY PRECAUTIONS

4

Operator safety is the primary safety consideration. Because it is verydangerous to enter the operating space of the robot during automaticoperation, adequate safety precautions must be observed.

The following lists the general safety precautions. Careful considerationmust be made to ensure operator safety.

(1) Have the robot system operators attend the training courses held byFANUC.

FANUC provides various training courses. Contact our sales office for details.

(2) Even when the robot is stationary, it is possible that the robot is stillready to move state and is waiting for a signal. In this state, the robotis regarded as still in motion. To ensure operator safety, provide thesystem with an alarm to indicate visually or aurally that the robot isin motion.

(3) Install a safety fence with a gate so that no operator can enter the workarea without passing through the gate. Equip the gate with aninterlock that stops the robot when the gate is opened.

The controller is designed to receive this interlock signal. When the gate isopened and this signal received, the controller stops the robot in an emergency.For connection, see Fig.1.1.

(4) Provide the peripheral devices with appropriate grounding (Class 1,Class 2, or Class 3).

(5) Try to install the peripheral devices outside the work area.

(6) Draw an outline on the floor, clearly indicating the range of the robotmotion, including the tools such as a hand.

(7) Install a mat switch or photoelectric switch on the floor with aninterlock to a visual or aural alarm that stops the robot when anoperator enters the work area.

(8) If necessary, install a safety lock so that no one except the operatorin charge can turn on the power of the robot.

The circuit breaker installed in the controller is designed to disable anyone fromturning it on when it is locked with a padlock.

1.1OPERATOR SAFETY


5

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

Limit switch forthe safety gate

Panel board

Note) Terminals FENCE1 and FENCE2 areon the PC board in the operator panel.Fence circuit is a safety stop circuit.

EAS1

EAS11

EAS2

EAS21

Fig.1.1 Safety Fence and Safety Gate


6

The operator is a person who operates the robot system. In this sense, aworker who operates the teach pendant is also an operator. However, thissection does not apply to teach pendant operators.

(1) If it is not necessary for the robot to operate, turn off the power of therobot controller or press the EMERGENCY STOP button, and thenproceed with necessary work.

(2) Operate the robot system at a location outside the work area.

(3) Install a safety fence with a safety gate to prevent any worker otherthan the operator from entering the work area unexpectedly and alsoto prevent the worker from entering a dangerous area.

(4) Install an EMERGENCY STOP button within the operator’s reach.

The robot controller is designed to be connected to an external EMERGENCYSTOP button. With this connection, the controller stops the robot operationwhen the external EMERGENCY STOP button is pressed. See the diagrambelow for connection.

EES1

Panel board

Note) Connect to EES1 and EES11, EES2 and EES21.

External EMERGENCY STOP button

EES11EES2EES21

Fig.1.1.1 Connection Diagram for External Emergency Stop Switch

1.1.1Operator Safety


7

While teaching the robot, it is necessary for the operator to enter the workarea of the robot. It is particularly necessary to ensure the safety of theteach pendant operator.

(1) Unless it is specifically necessary to enter the robot work area, carryout all tasks outside the area.

(2) Before teaching the robot, check that the robot and its peripheraldevices are all in the normal operating condition.

(3) When entering the robot work area and teaching the robot, be sure tocheck the location and condition of the safety devices (such as theEMERGENCY STOP button and the deadman switch on the teachpendant).

The teach pendant supplied by FANUC is provided with a teach pendant en-able switch and a deadman switch in addition to the EMERGENCY STOP but-ton. The functions of each switch are as follows.

EMERGENCY STOP button : Pressing this button stops the robot in anemergency, irrespective to the condition ofthe teach pendant enable switch.

Deadman switch : The function depends on the state of theteach pendant enable switch.

When the enable switch is on -- Releasing the finger from the dead manswitch or holding the deadman switchstrongly stops the robot in an emergency.

When the enable switch is off -- The deadman switch is ineffective.

NOTEThe deadman switch is provided so that the robot operation canbe stopped simply by releasing finger from the teach pendant orholding the deadman switch strongly in case of emergency.The R--J3iB has adopted a 3--position deadman switch asan RIA--specification teach pendant. Pressing the3--position deadman switch halfway makes the robotoperable. Releasing the finger from the deadman switch orholding the deadman switch strongly causes the robot toenter the emergency stop state.

1.1.2Safety of the TeachPendant Operator


8

(4) The teach pendant operator should pay careful attention so that noother workers enter the robot work area.

NOTEIn addition to the above, the teach pendant enable switch and thedeadman switch also have the following function.

By pressing the deadman switch while the enable switch is on, theemergency stop factor (normally the safety gate) connected toEAS1 and EAS11, EAS2 and EAS21 of the controller isinvalidated. In this case, it is possible for an operator to enter thefence during teach operation without making the robot in theemergency stop condition. In other words, the system understandsthat the combined operations of pressing the teach pendantenable switch and pressing the deadman switch indicates the startof teaching. The teach pendant operator should be well aware thatthe safety gate is not functional under this condition and bear fullresponsibility to ensure that no one enters the fence during teaching.

(5) When entering the robot work area, the teach pendant operator shouldenable the teach pendant whenever he or she enters the robot workarea. In particular, while the teach pendant enable switch is off, makecertain that no start command is sent to the robot from any operatorpanel other than the teach pendant.

The teach pendant, operator panel, and peripheral device interface send eachrobot start signal. However the validity of each signal changes as follows de-pending on the mode of the teach pendant enable switch and the remote switchon the operator’s panel.

Teach pen-dant enable

switch

Remotecondition

Teachpendant

Operatorpanel

Peripheraldevices

On Independent Allowed tostart

Not allowed Not allowed

Off Local Not allowed Allowed tostart

Not allowed

Off Remote Not allowed Not allowed Allowed tostart

(6) To start the system using the operator panel, make certain that nobodyis in the robot work area and that there are no abnormal conditions inthe robot work area.

(7) When a program is completed, be sure to carry out a test run accordingto the procedure below.(a) Run the program for at least one operation cycle in the single step

mode at low speed.(b) Run the program for at least one operation cycle in the continuous

operation mode at low speed.(c) Run the program for one operation cycle in the continuous

operation mode at the intermediate speed and check that noabnormalities occur due to a delay in timing.

(d) Run the program for one operation cycle in the continuousoperation mode at the normal operating speed and check that thesystem operates automatically without trouble.

(e) After checking the completeness of the program through the testrun above, execute it in the automatic operation mode.


9

(8) While operating the system in the automatic operation mode, theteach pendant operator should leave the robot work area.

For the safety of maintenance personnel, pay utmost attention to thefollowing.

(1) Except when specifically necessary, turn off the power of thecontroller while carrying out maintenance. Lock the power switch,if necessary, so that no other person can turn it on.

(2) When disconnecting the pneumatic system, be sure to reduce thesupply pressure.

(3) Before the start of teaching, check that the robot and its peripheraldevices are all in the normal operating condition.

(4) If it is necessary to enter the robot work area for maintenance whenthe power is turned on, the worker should indicate that the machineis being serviced and make certain that no one starts the robotunexpectedly.

(5) Do not operate the robot in the automatic mode while anybody is inthe robot work area.

(6) When it is necessary to maintain the robot alongside a wall orinstrument, or when multiple workers are working nearby, makecertain that their escape path is not obstructed.

(7) When a tool is mounted on the robot, or when any moving deviceother than the robot is installed, such as belt conveyor, pay carefulattention to its motion.

(8) If necessary, have a worker who is familiar with the robot systemstand beside the operator panel and observe the work beingperformed. If any danger arises, the worker should be ready to pressthe EMERGENCY STOP button at any time.

(9) When replacing or reinstalling components, take care to preventforeign matter from entering the system.

(10)When handling each unit or printed circuit board in the controllerduring inspection, turn off the power of the controller and also turnoff the circuit breaker to protect against electric shock.

(11) When replacing parts, be sure to use those specified by FANUC.In particular, never use fuses or other parts of non-specified ratings.They may cause a fire or result in damage to the components in thecontroller.

1.1.3Safety DuringMaintenance


10

(1) Use a limit switch or other sensor to detect a dangerous condition and,if necessary, design the program to stop the robot when the sensorsignal is received.

(2) Design the program to stop the robot when an abnormal conditionoccurs in any other robots or peripheral devices, even though therobot itself is normal.

(3) For a system in which the robot and its peripheral devices are insynchronous motion, particular care must be taken in programmingso that they do not interfere with each other.

(4) Provide a suitable interface between the robot and its peripheraldevices so that the robot can detect the states of all devices in thesystem and can be stopped according to the states.

(1) Keep the component cells of the robot system clean, and operate therobot in an environment free of grease, water, and dust.

(2) Employ a limit switch or mechanical stopper to limit the robot motionso that the robot does not come into contact with its peripheral devicesor tools.

1.2SAFETY OF THETOOLS ANDPERIPHERALDEVICES

1.2.1Precautions inProgramming

1.2.2Precautions forMechanism


11

(1) When operating the robot in the jog mode, set it at an appropriatespeed so that the operator can manage the robot in any eventuality.

(2) Before pressing the jog key, be sure you know in advance whatmotion the robot will perform in the jog mode.

(1) When the work areas of robots overlap, make certain that the motionsof the robots do not interfere with each other.

(2) Be sure to specify the predetermined work origin in a motion programfor the robot and program the motion so that it starts from the originand terminates at the origin.Make it possible for the operator to easily distinguish at a glance thatthe robot motion has terminated.

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

1.3SAFETY OF THEROBOT MECHANISM

1.3.1Precautions inOperation


1.3.3Precautions forMechanisms


12

(1) To control the pneumatic, hydraulic and electric actuators, carefullyconsider the necessary time delay after issuing each control commandup to actual motion and ensure safe control.

(2) Provide the end effector with a limit switch, and control the robotsystem by monitoring the state of the end effector.

1.4SAFETY OF THE ENDEFFECTOR



13

(1) Never enter the robot work area while the robot is operating. Turn offthe power before entering the robot work area for inspection andmaintenance.

(2) If it is necessary to enter the robot work area with the power turnedon, first press the EMERGENCY STOP button on the operator panel.

(3) When replacing or reinstalling components, take care to preventforeign matter from entering the system.When replacing the parts in the pneumatic system, be sure to reducethe pressure in the piping to zero by turning the pressure control onthe air regulator.

(4) When handling each unit or printed circuit board in the controllerduring inspection, turn off the power of the controller and turn off thecircuit breaker to protect against electric shock.

(5) When replacing parts, be sure to use those specified by FANUC.In particular, never use fuses or other parts of non-specified ratings.They may cause a fire or result in damage to the components in thecontroller.

(6) Before restarting the robot, be sure to check that no one is in the robotwork area and that the robot and its peripheral devices are all in thenormal operating state.

1.5SAFETY INMAINTENANCE


14

Do not step on or climb the robot or controller as it may adversely affectthe robot or controller and you may get hurt if you lose your footing aswell.

(1) Step--on prohibitive label

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

Be cautious about a section where this label is affixed, as the sectiongenerates heat. If you have to inevitably touch such a section when it ishot, use a protective provision such as heat--resistant gloves.

(2) High--temperature warning label

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

A high voltage is applied to the places where this label is attached.Before starting maintenance, turn the power to the control unit off, thenturn the circuit breaker off to avoid electric shock hazards. Be careful withservo amplifier and other units because high--voltage places in these unitsmay remain in the high--voltage state for a fixed time.

1.6WARNING LABELDescription

Description

Description


15

(3) High--voltage warning label

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

There may be a high voltage in a place with this label. Before workingon such a portion, turn off the power to the controller and set its circuitbreaker to the off position to avoid shock hazards.In addition, be careful about servo amplifiers and other electric circuitsbecause a high voltage may remain in them for a certain period of timeafter the power is turned off.

Description

II MAINTENANCE

B--81465EN--1/02 1. OVERVIEWMAINTENANCE

19

1 OVERVIEW

This manual describes the maintenance and connection of the R--J3iBrobot controller (called the R--J3iB).

Maintenance Part : Troubleshooting, and the setting, adjustment,and replacement of units

Connection Part : Connection of the R--J3iB controller to the robotmechanical unit and peripheral devices, andinstallation of the controller

WARNINGBefore you enter the robot working area, be sure to turn offthe power to the controller or press the EMERGENCYSTOP button on the operator panel or teach pendant.Otherwise, you could injure personnel or damageequipment.

- For information on third party approvals, contact your FANUCrepresentative.

2. CONFIGURATION B--81465EN--1/02MAINTENANCE

20

2 CONFIGURATION

B--81465EN--1/02 2. CONFIGURATIONMAINTENANCE

21

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

Teach pendantOperator panelMode switch

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

2.1EXTERNAL VIEW OFTHE CONTROLLER


22

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


23

Fig.2.1 (c) R--J3iB B--cabinet overview (Back)

Table 2.1 Servo amplifier and regenerative resistor unit

Robot models Servo amplifier Regenerative resistor unitR--2000iA A06B--6105--H002 A05B--2452--C200 (B--cabinet)

M--6iB A06B--6105--H003 A05B--2452--C201 (B--cabinet)

ARC Mate 100iB

( )

2.CO

NF

IGU

RAT

ION

B--81465E

N--1/02

MA

INT

EN

AN

CE

24

Breaker

210VAC

Output

24VD

C

210VAC

Input

HS

SB

,TPS

ignal

Servo

Signal(FS

SB

)

Battery

24VD

CE

MG

signals

AC input380 -- 415 VAC440 -- 500 VACφ3

Transformer

Transformer overheat signal

210VAC

EMG signals

210VAC

Regenerativeresistor

Motor power supply, Brake power supply

Pulse coder signals, Robot DI/DO signals

Servo amplifier(6--axis amplifier)

Switch

Memory cardPanelboard

Operator’s panel

I/O unitMODEL A

ProcessI/O

Backplane

Powersupplyunit

Mainboard

Fan

Robot

External on/off

Teachpendant

(Ethernet)

peripheraldevice

peripheraldevice

peripheraldevice(Serial)

(I/O)

External E--stop

Noise filter

E--stop unit

Fig

.2.1(d

)B

lock

diag

ramo

fthe

R--J3iB

(B--cab

inet)


25

-- Main boardThe main board contains a microprocessor, its peripheral circuits,memory, and operator panel control circuit. The main CPU controlsservo mechanism positioning and servo amplifier voltages.

- Battery retains main board memory when controller power is off.- I/O printed circuit board, FANUC I/O Unit MODEL--A

Various types of printed circuit boards are provided for applicationsincluding process I/O. The FANUC I/O unit MODEL-A can also beinstalled. When it is used, various I/O types can be selected. Theseare connected with FANUC I/O Link.

- E--stop unitThis unit controls the emergency stop system with control reliableE--stop performance criteria for both of the magnetic contactor andthe precharge of the servo amplifier.

- Power supply unitThe power supply unit converts the AC power to various levels of DCpower.

- Backplane printed circuit boardThe various control printed circuit boards are mounted on thebackplane printed circuit board.

- Teach pendantAll operations including robot programming are performed with thisunit. The controller status and data are indicated on the liquid-crystaldisplay (LCD) on the pendant.

- Servo amplifierThe servo amplifier controls servomotor power, pulse coder, brakecontrol, overtravel and hand broken.

- Operator panelButtons and LEDs on the operator panel are used to start the robot andto indicate the robot status. The panel has a port for the serial interfaceto an external device and an interface to connect the memory card fordata backup. It also controls the emergency stop control circuit.

- TransformerThe supply voltage is converted to an AC voltage required for thecontroller by the transformer.

- Fan unit, heat exchangerThese components cool the inside of the control unit.

- Circuit breakerIf the electric system in the controller malfunctions, or if abnormalinput power causes high current in the system, the input power isconnected to the circuit breaker to protect the equipment.

- Regenerative resistorTo discharge the counter electromotive force from the servomotor,connect a regenerative resistor to the servo amplifier.

2.2COMPONENTFUNCTIONS


26

Daily maintenance and periodic maintenance/inspection ensure reliablerobot performance for extended periods of time.

(1) Daily maintenanceBefore operating the system each day, clean each part of the systemand check the system parts for any damage or cracks. Also check thefollowing:(a) Before service operation

Check the cable connected to the teach pendant for excessivetwisting. Check the controller and peripheral devices forabnormalities.

(b) After service operationAt the end of service operation, return the robot to the specifiedposition, then turn off the controller. Clean each part, and checkfor any damage or cracks. If the ventilation port of the controlleris dusty, clean it.

(c) Check after one monthCheck that the fan is rotating normally. If the fan has dirt and dustbuilt up, clean the fan according to step (d) described below forinspection to be performed every 6 months.

(d) Periodic inspection performed every six monthsRemove the top cover, louver, and back panel (if possible), thenremove any dirt and dust from the inside of the transformercompartment. Wipe off dirt and dust from the fan andtransformer.

(2) Maintenance toolsThe following maintenance tools are recommended:(a) Measuring instruments

AC/DC voltmeter (A digital voltmeter is sometimes required.)Oscilloscope with a frequency range of 5 MHz or higher, twochannels

(b) ToolsPhillips screwdrivers : Large, medium, and smallStandard screwdrivers: Large, medium, and smallNut driver set (Metric)PliersNeedle-nose pliersDiagonal cutting pliers

2.3PREVENTIVEMAINTENANCE

B--81465EN--1/02 3. TROUBLESHOOTINGMAINTENANCE

27

3 TROUBLESHOOTING

This chapter describes the checking method and corrective action for eacherror code indicated if a hardware alarm occurs. Refer to the operator’smanual to release program alarms.

3. TROUBLESHOOTING B--81465EN--1/02MAINTENANCE

28

Check and Corrective action Figure

(Check 1) Check that the circuit breaker is on and has not tripped.

(Correctiveaction)

Turn on the circuit breaker.

Breaker

(Check 2) Check whether the LED (PIL: green) on the power supply unitis on.

(Correctiveaction)

If the LED is not on, 200 VAC is not supplied to the power supplyunit. It is likely that fuse F1 in the power supply unit has blown.-- If 200 VAC is not supplied:

Find the cause by referencing the general schematic diagrampresented in the appendix.

-- If 200 VAC is supplied:Find the cause of the blown fuse. Fuse F1 is in the power sup-ply unit. Before you start troubleshooting, turn off the circuitbreaker.a) If fuse F1 has blown:

-- See Corrective action (1).b) If fuse F1 has not blown:

-- Replace the power supply unit.

F1 8.0AFuse for AC input

F3 7.5AFuse for +24E

F4 7.5A

Diode stackDB1

Surge absorberVS1

Spare powersupply moduleH1

CP1 connector

(Correctiveaction(1))

Causes of blown fuses F1 and corrective actiona) Check whether the unit and printed--circuit board connected

to the connectors CP2 and CP3 in the power supply unit areabnormal, by referencing the general schematic diagrampresented in the appendix.

b) Short-circuit in the surge absorber VS1VS1 is inserted to absorb surge voltage between input lines.If the surge voltage is excessive or sustained, excessivelyhigh voltage is applied to VS1 and a failure occurs in theshort-circuit mode, causing F1 to blow. If a short-circuit oc-curs in VS1, and there is not a spare part, the system is per-mitted to operate without VS1. In this case, however, obtainand install a new VS1 as soon as possible.VS1 ordering number: A50L-2001-0122#G431k

c) Short-circuit of diode stack DB1d) The secondary power supply module is faulty :

If one of the causes (b) to (c) above is detected, replace thepower supply unit with a spare unit.The spec. for F1 is : A60L-0001-0396#8.0A

F4 7.5AFuse for +24VPILLED (green)for AC powersupply display

H1

CP6 connectorCP5 connector

LED (red) foralarm display

3.1POWER CANNOT BETURNED ON


29

Check and Corrective action Figure

(Check 3) Check whether the EXON1 and EXON2 signals, and theEXOFF1 and EXOFF2 signals are connected on the terminalblock on the panel board.

Short piece : between 1 (EXON1) and 2 (EXON2)between 3 (EXOFF1) and 4 (EXOFF2)

(Correctiveaction)

If the external ON/OFF function is not used, connect the EXON1and EXON2 the EXOFF1 and EXOFF2. If the external ON andOFF lines are already used, check the mating contacts and thecable.

between 3 (EXOFF1) and 4 (EXOFF2)

Connector (JRS11)

(Check 4) Check whether the connector (JRS11) on the main board or theconnector (JRS11) on the panel board is connected properly.Another probable cause is that the cable connected to either ofthese connectors is faulty.


Diode stackDB1

(Check 5) Check 1 to 3 above confirm that 200 VAC power is supplied toconnector CP1 of the power supply unit and that the ON/OFFswitch functions normally. Therefore check the power supplyunit using the following procedure:If the LED (ALM: red) on the power supply unit is onCheck if the +24 V external connection cable is connected to 0V or ground.a) Fuse F4 blown :

See corrective action (2).b) None of the above fuses blown [d) is also probable] :

A printed circuit board or unit that uses a DC supply volt-age (+3.3V, +5V, +24V, or ±15V) is faulty.

c) None of the above fuses blown :Check that 200 VAC is supplied to connector CP1. If itis supplied replace the power supply unit.


F4 7.5AFuse for +24VPILLED (green)for AC powersupply display

Surge absorberVS1

Spare powersupply moduleH1

CP1 connector

CP6 connectorCP5 connector

LED (red) for

(Correctiveaction)

If the power supply unit is not faulty, replace the panel board oroperator panel.

LED (red) foralarm display

(Correctiveaction(2))

Causes of blown fuse F4 and corrective actionThe device connected to connector CP5 of the power supply unitmay be faulty. If no device is connected to CP5 or the connecteddevice is normal, the +24 V power used in a printed circuit boardconnected to the backplane is faulty.The code of F4 is A60L--0001--0046#7.5 :


30

The alarm occurrence screen displays only the alarm conditions that arecurrently active. If an alarm reset signal is input to reset the alarmconditions, the alarm occurrence screen displays the message “PAUSE ormore serious alarm has not occurred.”

The alarm occurrence screen displays only the alarm conditions (if any)that occur after the most recently entered alarm reset signal. To erase allalarm displays from the alarm occurrence screen. Press the CLEAR key(+ shift) on the alarm history screen.The alarm occurrence screen is intended to display PAUSE or moreserious alarms. It will not display WARN, NONE, or a reset. It is possibleto disable PAUSE and some of more serious alarms from being displayedby setting the $ER_NOHIS system variable appropriately.If two or more alarms have occurred, the display begins with the mostrecent alarm.Up to 100 lines can be displayed.If an alarm has a cause code, it is displayed below the line indicating thealarm.

Press the screenselection key to select[4 ALARM]. Press the alarm key.

Automatic alarm displayupon occurrence

Alarm occurrence screen display

Press F3 [ACTIVE]. Press F3 [HIST].

Alarm history screen display

Fig.3.2 Alarm Occurrence Screen and Alarm History Screen DisplayProcedure

3.2ALARMOCCURRENCESCREEN


31

Displaying the alarm history/alarm detail information

(1) Press the MENUS key to display the screen menu.

(2) Select [ALARM].You will see a screen similar to the following

MENUS

34 ALARM5 I/O

INTP-224 (SAMPLE1, 7) Jump label is failMEMO-027 Specified line does not existAlarm JOINT 30 %

1/251 INTP-224 (SAMPLE1, 7) Jump label is2 SRVO-002 Teach pendant E-stop3 R E S E T4 SRVO-027 Robot not mastered(Group:1)5 SYST-026 System normal power up

[ TYPE ] CLEAR HELP

NOTEThe latest alarm is assigned number 1. To view messagesthat are currently not on the screen, press the F5, HELP,then press the right arrow key.

(3) To display the alarm detail screen, press F5, [HELP].

CLEAR HELP

F5

INTP-224 (SAMPLE1, 7) Jump label is fail

INTP-224 (SAMPLE1, 7) Jump label is failMEMO-027 Specified line does not exist30-MAY-44 07:15STOP.L 00000110Alarm

1/251 INTP-224 (SAMPLE1, 7) Jump label is2 SRVO-002 Teach pendant E-stop

[ TYPE ] CLEAR HELP

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

PREV

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

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

CLEAR HELP

F4SHIFT

Step


32

The following map indicates teach pendant operations used to check analarm.

4 ALARM

F1 [TYPE]

Alarm : Active

F1 [TYPE]

F3 HIST

Alarm : HIST

F1 [TYPE]

F3 [ACTIVE]

F4 CLEAR

F5 HELP

DETAIL Alarm

F1 [TYPE]

F3 [ACTIVE]

F4 CLEAR

F5 HELP


33

The safety signal screen indicates the state of signals related to safety. Tobe specific, the screen indicates whether each safety signal is currently on.On this screen, it is impossible to change the state of any safety signal.

Table 3.3 Safety Signals

Safety signal Description

Operator panel emergency stop This item indicates the state of the emergency stop button on the operator panel. If theEMERGENCY STOP board is pressed, the state is indicated as “TRUE”.

Teach pendant emergency stop This item indicates the state of the emergency stop button on the teach pendant. If theEMERGENCY STOP board is pressed, the state is indicated as “TRUE”.

External emergency stop This item indicates the state of the external emergency stop signal. If the EMERGENCYSTOP signal is input, the state is indicated as “TRUE”.

Fence open This item indicates the state of the safety fence. If the safety fence is open, the state isindicated as “TRUE”.

Deadman switch This item indicates whether the DEADMAN switch on the teach pendant is grasped. Ifthe teach pendant is operable, and the DEADMAN switch is grasped, the state is indi-cated as “TRUE”. If the deadman switch is released when the teach pendant is operable,an alarm occurs, causing the servo power to be switched off.

Teach pendant operable This item indicates whether the teach pendant is operable. If the teach pendant is oper-able, the state is indicated as “TRUE”.

Hand broken This item indicates the state of the hand safety joint. If the hand interferes with a work-piece or anything like this, and the safety joint is opened, the state is indicated as“TRUE”. In this case, an alarm occurs, causing the servo power to be switched off.

Robot overtravel This item indicates whether the current position of the robot is out of the operation range.If any robot articulation goes out of the operation range beyond the overtravel switch, thestate is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to beswitched off.

Abnormal air pressure This item indicates the state of the air pressure. The abnormal air pressure signal is con-nected to the air pressure sensor. If the air pressure is not higher than the specifiedvalue, the state is indicated as “TRUE”.

(1) Press the MENUS key to display the screen menu.

(2) Select STATUS on the next page.

(3) Press F1, [TYPE] to display the screen switching menu.

(4) Select Safety Signal. You will see a screen similar to the following.

SYSTEM Safety JOINT 30%

SIGNAL NAME STATUS 1/11

1 SOP E-Stop: FALSE2 TP E-stop: FALSE3 Ext E-Stop: FALSE4 Fence Open: FALSE5 TP Deadman: TRUE6 TP Enable: TRUE7 Hand Broken: FALSE8 Over Travel: FALSE9 Low Air Alarm: FALSE

[TYPE]

3.3SAFETY SIGNALS

Step


34

Mastering is needed if:

(1) The SRVO--062 BZAL or SRVO--038 pulse mismatch alarm occurs,or

(2) The pulse coder is replaced.

Item (1) requires simplified mastering, while item (2) requireszero--degree or jig position mastering. (Zero--degree position masteringis just for quick--fix purposes. After zero--degree position mastering isused, jig position mastering should be performed later.)The mastering procedure is described below. For details, refer to anapplicable maintenance manual of mechanical unit or operator’s manualof control unit.

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

SYSTEM Variables JOINT 10%57/136

57 $MASTER_ENB 1

(1) Press <MENUS>.

(2) Select SYSTEM.

(3) Press F1, TYPE.

(4) Select Master/Cal you will see a screen similar to the following.

F1

Master/Cal

TYPE

SYSTEM Master/Cal JOINT 30%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE

Press ’ENTER’ or number key to select.

[TYPE] LOAD RES_PCA DONE

5 POSITION6 SYSTEM7

MENUS

9 USER0 -- NEXT --

(5) Move the robot by jog feed to the mastering position. Release thebrake on the manual brake control screen if necessary.

NOTEMastering can not be performed until axis is rotated enoughto establish a pulse.

3.4MASTERING

Condition

Step


35

(6) Select “1 FIXTURE POSITION MASTER” and press the F4 key(yes). Mastering data is set.

F4

SYSTEM Master/Cal

1 FIXTURE POSITION MASTER2 ZERO POSITION MASTERMaster at master position? [NO]

ENTER

Master at master position? [NO][ TYPE ] YES NO

SYSTEM Master/Cal JOINT 30 %

1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE

Robot Mastered! Mastering Data:<0> <11808249> <38767856><9873638> <122000309> <2000319>

[ TYPE ] LOAD RES_PCA DONE

(7) Select “6 CALIBRATE” and press the F4 key (yes). Calibration isperformed.Alternatively, to perform positioning, turn the power off, then turn iton again. Calibration is performed whenever the power is turned on.

F4

5 SET QUICK MASTER REF6 CALIBRATECalibrate? [NO] ENTER

Calibrate? [NO][ TYPE ] YES NO

SYSTEM Master/Cal JOINT 30 %

1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE

Robot Calibrated! Cur Jnt Ang(deg):<10.000> <-25.000> <40.000><5.000> <-15.000> <0.000>

[ TYPE ] LOAD RES_PCA DONE

(8) Press F5 “DONE”, after mastering.

F5

DONE


36

(1) SRVO--001 SVAL1 Operator panel E--stop(Explanation) The emergency stop button on the operation operator

panel or is pressed.If the SYST--067 (Panel HSSB disconnect) alarm isalso generated, or if the LED (green) on the panelboard is turned off, communication between the mainboard (JRS11) and the panel board (JRS11) isabnormal. The connectors of the cable between themain board and the panel board may be loose. Or, thecable, panel board, or main board may be faulty.(Note)

(Action 1) Release the emergency stop button pressed on theoperator panel.

(Action 2) Check the wires connecting the emergency stopswitch connector CRT8 for continuity. If an open wireis found replace the entire harness.

(Action 3) With the emergency stop in the released position,check for continuity across the terminals of theswitch. If continuity is not found, replace the switch.If continuity is found replace the operator panel PCB.Before executing the (Action 4), perform a completecontroller back--up to save all your programs andsettings.

(Action 4) Replace the Main Board.

NOTEIf the LED is turned off, the following alarms are alsogenerated.

SRVO--001 Operator panel E--stop.SRVO--004 Fence open.SRVO--007 External emergency stop.SRVO--199 Control stop.SRVO--204 External (SVEMG abnormal) E--stop.SRVO--213 Fuse blown (Panel PCB).SRVO--277 Panel E--stop (SVEMG abnormal).SRVO--280 SVOFF input

Check the alarm history display on the teach pendant.

3.5TROUBLESHOOTINGUSING THE ERRORCODE


37

Emergency stop button

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


38

Panel board

Connector (CRT8)

LED (Green) Connector (JRS11)

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

Main board

Connector (JRS11)

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


39

(2) SRVO--002 SVAL1 Teach pendant E--stop(Explanation) The emergency stop button on the operator’s Teach

Pendant was pressed.(Action 1) Release the emergency stop button on the teach

pendant.(Action 2) Replace Teach Pendant.


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

(3) SRVO--003 SVAL1 Deadman switch released(Explanation) The teach pendant is enabled, but the deadman switch

is not pressed.Deadman switch is three position switch.Don’t press the switch to the second “open” position.Switch is enabled in middle position only.

(Action 1) Press the deadman switch to run the robot.(Action 2) Replace the teach pendant.

Deadman switch

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


40

(4) SRVO--004 SVAL1 Fence open(Explanation) On the terminal block TBOP4 of the panel board, no

connection is made between 5 (EAS1) and 6 (EAS11)or between 7 (EAS2) and 8 (EAS21). If a safety fenceis connected between 5 (EAS1) and 6 (EAS11) orbetween 7 (EAS2) and 8 (EAS21), the door of thesafety fence is open.If the SYST--067 (Panel HSSB disconnect) alarm isalso generated, or if the LED (green) on the panelboard is turned off, communication between the mainboard (JRS11) and the panel board (JRS11) isabnormal. The connectors of the cable between themain board and the panel board may be loose. Or, thecable, panel board, or main board may be faulty.(Note)

(Action 1) If a safety fence is connected, close the door.(Action 2) Check the switch and cable connected to 5 (EAS1)

and 6 (EAS11) or 7 (EAS2) and 8 (EAS21).(Action 3) When this signal is not used, make a connection

between 5 (EAS1) and 6 (EAS11) or between 7(EAS2) and 8 (EAS21).

(Action 4) If SRVO--004 (Fence open), SRVO--007 (Externalemergency stops), SRVO--213 (Fuse Blown (PanelPCB)), and SRVO--280 (SVOFF input) occursimultaneously, it is likely that FUSE1 on the panelboard has blown. Check the fuse. If it has blown,remove the cause, then replace the fuse.(Refer to Section 3.6 in Part II, “Maintenance,” of“Maintenance Manual.”)

(Action 5) Replace the panel board.

NOTEFENCE input (AUTO STOP) is a safety stop input when thisinput is opened, the robot decelerates in a controlledmanner and then stops, the magnetic contactor opens afterthe robot stops.

WARNINGDo NOT short--circuit, or disable, this signal in a system inwhich the Fence signal is in use, as it is very dangerous. Ifit is necessary to run the robot by short--circuiting the signaleven temporarily, an additional safety provision must beprovided.


41




Panel board

Connector (CRT8)


Short connection5 (EAS1) and 6 (EAS11)

Short connection7 (EAS2) and 8 (EAS21)

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

Main board

Connector (JRS11)

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


42

(5) SRVO--005 SVAL1 Robot overtravel(Explanation) The robot has moved beyond a hardware limit switch

on the axes. It is factory--placed in the overtravel statefor packing purposes.If the Overtravel signal is not in use, it may have beendisabled by short--circuiting in the mechanical unit.

(Action 1) 1) Select [System OT release] on the overtravelrelease screen to release each robot axis from theovertravel state.

2) Hold down the shift key, and press the alarmrelease button to reset the alarm condition.

3) Still hold down the shift key, and jog to bring allaxes into the movable range.

(Action 2) Check the FS2 fuse on the servo amplifier.If the SRVO--214 Fuse blown alarm is also generated,FS2 fuse have been blown.

(Action 3) Verify the following for connector RP1 at the base ofthe robot :1) There are no bent or dislocated pins in the male

or female connectors.2) The connector is securely connected.Then verify that connectors CRF7 and CRM68 on theservo amplifier are securely connected. Also verifythat the RP1 cable is in good condition, and there areno cuts or kinks visible. If no limit switch is in use,a jumper connector must be attached in themechanical unit. Check for the jumper connector.

(Action 4) Replace the servo amplifier.


43

Servo amplifier

Connector (CRM68)

Connector (CRF7)

FS2

Servo amplifier

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


44

(6) SRVO--006 SVAL1 Hand broken(Explanation) The safety joint (if in use) might have been broken.

Alternatively, the HBK signal on the robotconnection cable might be a ground fault or a cabledisconnection.If the Hand broken signal is not in use, it can bedisabled by software setting.Refer to Subsection 5.5.3 in Part III, “Connections,”of “Maintenance Manual” for how to disable theHand broken signal.

(Action 1) Hold down the shift key, and press the alarm releasebutton to reset the alarm condition. Still hold downthe shift key, and jog the tool to the work area.1) Replace the safety joint.2) Check the safety joint cable.

(Action 2) Check the FS2 fuse on the servo amplifier. If theSRVO--214 Fuse blown alarm is also generated, FS2fuse have been blown.

(Action 3) Verify the following for connector RP1 at the base ofthe robot :1) There are no bent or dislocated pins in the male

or femail connectors.2) The connector is securely connected.Then verify that connector CRF7 on the servoamplifier is securely connected. Also verify that theRP1 cable is in good condition, and there are no cutsor kinks visible. Check the robot connection cable(RP1) for a ground fault or a cable disconnection.



45

Servo amplifier

Connector (CRF7)

FS2

Servo amplifier

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


46

(7) SRVO--007 SVAL1 External E--stop(Explanation) On the terminal block TBOP4 of the panel board, no

connection is made between 1 (EES1) and 2 (EES11)or between 3 (EES2) and 4 (EES21). If an externalemergency stop switch is connected between 1(EES1) and 2 (EES11) or between 3 (EES2) and 4(EES21), the switch is pressed.If the SYST--067 (Panel HSSB disconnect) alarm isalso generated, or if the LED (green) on the panelboard is turned off, communication between the mainboard (JRS11) and the panel board (JRS11) isabnormal. The connectors of the cable between themain board and the panel board may be loose. Or, thecable, panel board, or main board may be faulty.(Note)

(Action 1) If an external emergency stop switch is connected,releases the switch.

(Action 2) Check the switch and cable connected to 1 (EES1)and 2 (EES11) or 3 (EES2) and 4 (EES21).

(Action 3) When this signal is not used, make a connectionbetween 1 (EES1) and 2 (EES11) or between 3(EES2) and 4 (EES21).

(Action 4) If SRVO--004 (Fence open), SRVO--007 (Externalemergency stops), SRVO--213 (Fuse blown (PanelPCB)), and SRVO--280 (SVOFF input) occursimultaneously, it is likely that FUSE1 on the panelboard has blown. Check the fuse. If it has blown,remove the cause, then replace the fuse.(Refer to Section 3.6 in Part II, “Maintenance,” of“Maintenance Manual.”)


WARNINGDo NOT short--circuit, or disable, this signal in a system inwhich the External emergency stop input signal is in use, asit is very dangerous. If it is necessary to run the robot byshort--circuiting the signal even temporarily, an additionalsafety provision must be provided.

NOTEIf the LED is turned off, the SRVO--001 (Operator panelE--stop), SRVO--004 (Fence open), SRVO--007 (Externalemergency stops), or SRVO--280 (SVOFF input), alarm isalso generated. Check the alarm history display on the teachpendant.


47


Short connection1 (EES1) and 2 (EES11)

Short connection3 (EES2) and 4 (EES21)

Panel board

Panel board

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

Main board

Connector (JRS11)

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


48

(8) SRVO--009 SVAL1 Pneumatic pressure alarm(Explanation) An abnormal air pressure was detected. The input

signal is located on the end effector of the robot.Refer to the manual of your robot.

(Action 1) If an abnormal air pressure is detected, check the cause.If the peripheral device are normal, check the robotcable and if the peripheral device are abnormal,replace the device.


Servo amplifier

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

Pneumatic pressure alarm input is disabled/enabled by software. Pleaserefer to Subsection 5.5.4. in Part III Connections of this MaintenanceManual.


49

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

necessary.

Fan motor

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


50

(10)SRVO--015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j)(Explanation) The temperature in the control unit exceeds the

specified value.(Action 1) If the ambient temperature is higher than specified

(45°C), cool down ambient temperature.(Action 2) If the fan motor is not running, check it and its cables.

Replace them if necessary.(Action 3) If the thermostat on the main board is defective,

replace the main board.

Main board

External air Fan unit

Door fanFloor fan unit

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


51

(11) SRVO--018 SVAL1 Brake abnormal(Explanation) An excessive brake current is detected. The ALM

LED on the servo amplifier is lit.(Action 1) Check the robot connection cable (RM1) and cables

internal to the mechanical section for a short--circuitand connection to the ground.

(Action 2) This alarm may occur if the brake connector is notattached.Make sure that connector CRR64 is securely attachedto the servo amplifier.


Servo amplifier

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


52

(12)SRVO--021 SVAL1 SRDY off (Group : i Axis : j)(Explanation) The HRDY is on and the SRDY is off, although there

is no other cause of an alarm. (HRDY is a signal withwhich the host detects the servo system whether toturn on or off the servo amplifier magnetic contactor.SRDY is a signal with which the servo systeminforms the host whether the magnetic contactor isturned on.)If the servo amplifier magnetic contactor cannot beturned on when directed so, it is most likely that aservo amplifier alarm has occurred. If a servoamplifier alarm has been detected, the host will notissue this alarm (SRDY off). Therefore, this alarmindicates that the magnetic contactor cannot be turnedon for an unknown reason.

(Action 1) Make sure that the CP2 and CRM73 of the E--stopunit and the servo amplifier CNMC2 and CNMC3 areconnected tightly.

(Action 2) Check whether an outage has occurred on anemergency stop line (teach pendant emergency stop,teach pendant enable/disable switch, teach pendantdeadman switch, operator panel emergency stop,external emergency stop input, fence input, servo--offinput, or door switch). This alarm occurs if the alarmcause cannot be detected by software because of ashort break and magnetic contactor off.

(Action 3) Replace the servo amplifier.(Action 4) Replace the E--stop unit.(Action 5) Replace the cable between the E--stop unit and the

panel board.(Action 6) Replace the cable between the E--stop unit and the

servo amplifier.(Action 7) Replace axis control card on the main board.


53

Servo amplifier

Main board E--stop unitAxis control card

Main board

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


54

(13)SRVO--022 SVAL1 SRDY on (Group : i Axis : j)(Explanation) When the HRDY is about to go on, the SRDY is already

on. (HRDY is a signal with which the host directs theservo system whether to turn on or off the servoamplifier magnetic contactor. SRDY is a signal withwhich the servo system informs the host whether themagnetic contactor is turned on.

(Action 1) Replace the axis control card on the main board.(Action 2) Replace the servo amplifier.

Servo amplifier

Main board E--stop unit

Axis control card

Main board

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


55

(14)SRVO--023 SVAL1 Stop error excess (Group : i Axis : j)(Explanation) When the servo is at stop, the position error is

abnormally large.(Action 1) Check whether the motor brake has been released.(Action 2) Make sure that the servo amplifier CNJ1A to CNJ6

are connected tightly.(Action 3) Check to see if the load is greater than the rating. If

greater, reduce it to within the rating. (If the load istoo greater, the torque required for acceleration /deceleration becomes higher than the capacity of themotor. As a result, the motor becomes unable tofollow the command, and an alarm is issued.)

(Action 4) Check each phase voltage of the CRR38A or CRR38Bconnector of the three--phase power (200 VAC) input tothe servo amplifier. If it is 170 VAC or lower, check theline voltage. (If the voltage input to the servo amplifierbecomes low, the torque output also becomes low. Asa result the motor may become unable to follow thecommand, hence possibly an alarm.)

(Action 5) If the line voltage is 170 VAC or higher, replace theservo amplifier.

(Action 6) Check disconnection of motor power cable (RM1,RM2).

(Action 7) Replace the motor.

Servo amplifier


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


56

(15)SRVO--024 SVAL1 Move error excess (Group : i Axis : j)(Explanation) When the robot is running, its position error is greater

than a specified value ($PARAM _ GROUP.$MOVER _ OFFST or $PARAM _ GROUP.$TRKERRLIM). It is likely that the robot cannotfollow the speed specified by program.

(Action 1) Check the robot for binding axis.(Action 2) Take the same actions as described for the above

alarm.(16)SRVO--025 SVAL1 Motn dt overflow (Group : i Axis : j)

(Explanation) The specified value is too great.(17)SRVO--026 WARN2 Motor speed limit (Group : i Axis : j)

(Explanation) A value higher than the maximum motor speed($PARAM_GROUP.$MOT_SPD_LIM) wasspecified. The actual motor speed is clamped to themaximum speed.

(18)SRVO--027 WARN Robot not mastered (Group : i)(Explanation) An attempt was made to calibrate the robot, but the

necessary adjustment had not been completed.(Action) Master the robot.

(19)SRVO--030 SVAL1 Brake on hold (Group : i)(Explanation) This alarm occurs when the robot pauses, if the brake

on hold function has been enabled ($SCR.$BRKHOLD _ ENB = 1). Disable the function if it isnot necessary.

(Action) Disable [Servo--off during pause] on the generalsetting menu (Select Setting general).

(20)SRVO--031 SVAL1 User servo alarm (Group : i)(Explanation) An user servo alarm occurred.

(21)SRVO--033 WARN Robot not calibrated (Group : i)(Explanation) An attempt was made to set up a reference point for

simplified adjustment, but the robot had not beencalibrated.

(Action) Calibrate the robot.1.Supply power.2.Set up a simplified adjustment reference point

using [Positioning] on the positioning menu.(22)SRVO--034 WARN Ref pos not set (Group : i)

(Explanation) An attempt was made to perform simplifiedadjustment,but the reference point had not been set up.

(Action) Set up a simplified adjustment reference point on thepositioning menu.

(23)SRVO--035 WARN2 Joint speed limit (Group : i Axis : j)(Explanation) A value higher than the maximum axis speed

($PARAM_GROUP.$JNTVELLIM) was specified.Each actual axis speed is clamped to the maximumspeed.

(24)SRVO--036 SVAL1 Inpos time over (Group : i Axis : j)(Explanation) The robot did not get to the effective area ($PARAM _

GROUP.$ STOPTOL) even after the position checkmonitoring time ($PARAM _ GROUP. $INPOS _TIME) elapsed.

(Action) Take the same actions as for SRVO--23 (large positionerror at a stop).

(25)SRVO--037 SVAL1 Imstp input (Group : i)(Explanation) The *IMSTP signal for a peripheral device interface

was input.(Action) Turn on the *IMSTP signal.


57

(26)SRVO--038 SVAL2 Pulse mismatch (Group : i Axis : j)(Explanation) The pulse count obtained when power is turned off

does not match the pulse count obtained when poweris applied. This alarm is asserted after exchange thepulsecoder or battery for back up of the pulsecoderdata or loading back up data to the Main Board.

(Action) Perform APC reset and remaster robot (RES--PCA)1. Press MENUS.2. Select SYSTEM.3. Press F1 [TYPE].4. Select MASTER/CAL.5. Press F3, PES--PCA.6. Press RESET.

The fault condition should reset. If the controlleris still faulted with additional servo--relatederrors,cold start the controller.It might be necessary to remaster the robot.

(27)SRVO--041 SVAL2 MOFAL alarm (Group : i Axis : j)(Explanation) The servo value was too high.(Action) Cold start the controller.

(28)SRVO--042 MCAL alarm (Group : i Axis : j)(Explanation) This alarm means that the contacts of the magnetic

contactor have stuck to each other. The alarm conditionoccurs if the magnetic contactor turns out to be alreadyon when an attempt is made to turn it on. The alarmcondition is detected between the time contact stickingoccurs and the time an attempt is made to turn on themagnetic contactor.

(Action 1) Check the magnetic contactor, and replace it ifnecessary.If the contacts of the magnetic contactor have stuckto each other, turn off the circuit breaker. If the poweris switched off without turning off the circuit breaker,the servo amplifier may get damaged, because thestuck contacts keep three--phase 200 V applied to theservo amplifier.

(Action 2) Replace the E--stop unit.(Action 3) Replace the servo amplifier.


58

Servo amplifier


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

(29)SRVO--043 SVAL1 DCAL alarm (Group : i Axis : j)(Explanation) The regenerative discharge energy was too high to be

dissipated as heat. (To run the robot, the servoamplifier supplies energy to the robot. When goingdown the vertical axis, the robot operates from thepotential energy. If a reduction in the potential energyis higher than the energy needed for acceleration, theservo amplifier receives energy from the motor. Asimilar phenomenon occurs even when no gravity isapplied, for example, at deceleration on a horizontalaxis. The energy that the servo amplifier receivesfrom the motor is called the regenerative energy. Theservo amplifier dissipates this energy as heat. If theregenerative energy is higher than the energydissipated as heat, the difference is stored in the servoamplifier, causing an alarm.)

(Action 1) This alarm may occur if the axis is subjected to frequentacceleration/deceleration or if the axis is vertical andgenerates a large amount of regenerative energy. If thisalarm has occurred, relax the service conditions.

(Action 2) Check fuse FS3 in the servo amplifier. If it has blown,remove the cause, and replace the fuse. One of theprobable causes of a blown fuse is a ground fault inthe servo amplifier for auxiliary axis.

(Action 3) Make sure that the servo amplifier CRR63A,CRR63B and CRR63C are connected tightly, thendetach the cable from CRR63A, CRR63B andCRR63C connector on the emergency stop board, andcheck for continuity between pins 1 and 2 of thecable--end connector. If there is no continuity betweenthe pins, replace the regenerative resistance.


59

(Action 4) Make sure that the servo amplifier CRR45A,CRR45B and CRR45C are connected tightly thendetach the cables from CRR45A, CRR45B andCRR45C on the servo amplifier and check theresistance between pins 1 and 2 of each cable endconnector. If the resistance is not 9--16Ω, replace theregenerative resistor.


Servo amplifier Regenerative resistor

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


60

(30)SRVO--044 SVAL1 HVAL alarm (Group : i Axis : j)(Explanation) The DC voltage (DC link voltage) of the main circuit

power supply is abnormally high.(Action 1) Check the three--phase input voltage at the servo

amplifier. If it is 253 VAC or higher, check the linevoltage. (If the three--phase input voltage is higherthan 253 VAC, high acceleration/deceleration canresult in this alarm.)

(Action 2) Check that the load weight is within the rating. If itis higher than the rating, reduce it to within the rating.(If the machine load is higher than the rating, theaccumulation of regenerative energy might result inthe HVAL alarm even when the three--phase inputvoltage is within the rating.


Servo amplifier

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


61

(31)SRVO--045 SVAL1 HCAL alarm (Group : i Axis : j)(Explanation) Abnormally high current flowed in the main circuit of

the servo amplifier.(Action 1) Disconnect the Robot connection cable (Motor power)

from the servo amplifier.(Action 2) Disconnect the Robot connection cable (Motor power)

from the servo amplifier connector (CNJ**), andcheck the insulation of each Robot connection cable(Motor power) (U, V, or W) and the GND line. If thereis a short--circuit, the motor, robot interconnectioncable, or intra--robot cable is defective. Check themand replace them if necessary.

(Action 3) Disconnect the Robot connection cable (Motor power)from the servo amplifier connector (CNJ**), andmeasure the resistance between the U and V, V and W,and W and U with a ohmmeter with a very lowresistance range. If the resistances at these threeplaces are different from each other, the motor, robotinterconnection cable, or intra--robot cable isdefective. Check each item in detail and replace it ifnecessary.

Servo amplifier

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


62

(32)SRVO--046 SVAL2 OVC alarm (Group : i Axis : j)(Explanation) This alarm is issued to prevent the motor from

thermal damage that might occur when the root meantsquare current calculated within the servo system isout of the allowable range.

(Action 1) Check the operating conditions for the robot and relaxthe service conditions.

(Action 2) Check each phase voltage of the three--phase inputpower (200 VAC for the servo amplifier. If it is 170VAC or lower, check the line voltage.

(Action 3) Replace the servo amplifier.(Action 4) Check the robot connection cable (RM1, RM2). If any

problems are found in the cables, replace the cables.(Action 5) Replace the motor.

Servo amplifier

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


63

Relationships among the OVC, OVL, and HC alarmsOverviewThis section points out the differences among the OVC, OVL, and HCalarms and describes the purpose of each alarm.Alarm detection section

Abbreviation Designation Detection section

OVC Overcurrent alarm Servo software

OVL Overload alarm Thermal relay in the motor OHAL2Thermal relay in the servo amplifier OHAL1Thermal relay in the separate regenerative dis-charge unit DCAL

HC High current alarm Servo amplifier

Purpose of each alarm1) HC alarm (high current alarm)

If high current flow in a power transistor momentarily due toabnormality or noise in the control circuit, the power transistor andrectifier diodes might be damaged, or the magnet of the motor mightbe degaussed. The HC alarm is intended to prevent such failures.

2) OVC and OVL alarms (overcurrent and overload alarms)The OVC and OVL alarms are intended to prevent overheat that maylead to the burnout of the motor winding, the breakdown of the servoamplifier transistor, and the separate regenerative resistor.The OVL alarm occurs when each built--in thermal relay detects atemperature higher than the rated value. However, this method is notnecessarily perfect to prevent these failures. For example, if themotor frequently repeats to start and stop, the thermal time constantof the motor, which has a large mass, becomes higher than the timeconstant of the thermal relay, because these two components aredifferent in material, structure, and dimension. Therefore, if themotor repeats to start and stop within a short time as shown in Fig.1, the temperature rise in the motor is steeper than that in the thermalrelay, thus causing the motor to burn before the thermal relay detectsan abnormally high temperature.

Temperature

Start StartStartStop Stop

Temperature atwhich the windingstarts to burn

Thermal time constantof the motor is high.

Thermal time constantof the thermal relay islow.

Time

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

To prevent the above defects, software is used to monitor the currentin the motor constantly in order to estimate the temperature of themotor. The OVC alarm is issued based on this estimated temperature.This method estimates the motor temperature with substantialaccuracy, so it can prevent the failures described above.

Reference


64

To sum up, a double protection method is used; the OVCalarm isusedfor protection from a short--time overcurrent, and the OVL alarm isused for protection from long--term overload. The relationshipbetween the OVC and OVL alarms is shown in Fig 2.

CurrentProtection area forthe motor andservo amplifier

Protection by the OVLLimit current

Protection bythe OVC

Rated continuous current

Time

Fig.2 Relationship between the OVC and OVL alarms

NOTEThe relationship shown in Fig. 2 is taken into considerationfor the OVC alarm. The motor might not be hot even if theOVC alarm has occurred. In this case, do not change theparameters to relax protection.

(33)SRVO--047 SVAL1 LVAL alarm (Group : i Axis : j)(Explanation) The control power supply voltage (+5 V, etc.) supplied

from the power supply circuit in the servo amplifieris abnormally low.


Servo amplifier

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


65

(34)SRVO--049 SVAL1 OHAL1 alarm (Group : i Axis : j)(Explanation) The thermostat in the transformer worked.

Alternatively, fuse F1 or F2 in the servo amplifier hasblown.

(Action 1) Make sure that the CRM73 connector of the E--stopunit is connected tightly.


(Action 3) If fuses F1 and F2 have blown, replace the servoamplifier.(See II MAINTENANCE, Section 3.6.)

(Action 4) If the fan motor is not running, check it and its cables.Replace them if necessary.

(Action 5) Replace the transformer.

Servo amplifier

Transformer

E--stop unit

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


66

(35)SRVO--050 SVAL1 CLALM alarm (Group : i Axis : j)(Explanation) The disturbance torque estimated by the servo software

is abnormally high. (A collision has been detected.)(Action 1) Check that the robot has collided with anything. If it

has, reset the robot and jog--feed it to recover from thecollision.

(Action 2) Make sure that the load setting is correct.(Action 3) Check that the load weight is within the rating. If it

is higher than the rating, reduce it to within the rating.(If the robot is used out of its usable range, theestimated disturbance torque becomes abnormallyhigh, possibly resulting in this alarm being detected.)

(Action 4) Check the phase voltage of the three--phase inputpower (200 VAC) to the servo amplifier. If it is 170VAC or lower, check the line voltage.


Servo amplifier

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


67

(36)SRVO--051 SVAL2 CUER alarm (Group : i Axis : j)(Explanation) The offset of the current feedback value is abnormally

high.(Action) Replace the servo amplifier.

Servo amplifier

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


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

Servo amplifier


Main board

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


69

(38)SRVO--055 SVAL2 FSSB com error 1 (Group : i Axis : j)(Explanation) A communication error has occurred between the

main board and servo amplifier. (from main board toservo amplifier.)

(Action 1) Check the communication cable (optical fiber)between the main board and servo amplifier. Replaceit if it is faulty.


Before continuing to the next step, perform acomplete controller back--up to save all yourprograms and settings. Failure to perform this couldresult in damage to equipment or lost data.

(Action 4) Replace the main board.

Servo amplifier


Main board

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


70

(39)SRVO--056 SVAL2 FSSB com error 2 (Group : i Axis : j)(Explanation) A communication error has occurred between the

main board and servo amplifier. (from servo amplifierto main board.)





Servo amplifier


Main board

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


71

(40)SRVO--057 SVAL2 FSSB disconnect (Group : i Axis : j)(Explanation) Communication was interrupted between the main

board and servo amplifier.(Action 1) Check whether fuse F3 in the power supply unit has

blown.(Action 2) Check whether fuse FS1 in the servo amplifier has

blown.(Action 3) Check the communication cable (optical fiber)

between the main board and servo amplifier. Replaceit if it is faulty.



(Action 6) Replace the main board.(Action 7) Check the RP1 cable of robot connection cable.

(+5V ground fault)

Servo amplifier


Main board

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


72

(41)SRVO--058 SVAL2 FSSB init error (Group : i Axis : j)(Explanation) Communication was interrupted between the main

board and servo amplifier.(Action 1) Check whether fuse F3 in the power supply unit and

fuse FS1 in the servo amplifier have blown.If they have blown, see Section 3.6, “Troubleshootingfor Blown Fuse.”

(Action 2) Check whether LEDs (P5V and P3.3V) on the servoamplifier are on.If they are on, perform “Action 4” and all actions thatfollow it. If they are not on, perform “Action 3” andall actions that follow it.

(Action 3) Check whether connectors CP6 and CRM67 on theemergency stop unit are securely connected toconnector CP6 on the power supply unit and connectorCRM67 on the servo amplifier, respectively.





Servo amplifier


Main board

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


73

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

Servo amplifier

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

(43)SRVO--60 FATL FSSB init error(Explanation) Communication between the additional axis board

and additional axis amplifier was interrupted.(Action 1) Check whether the optical cable between the

additional axis board and additional axis amplifier isconnected securely.

(Action 2) Replace the additional axis board.(Action 3) Replace the additional axis amplifier.(Action 4) Replace the main board.(Action 5) Replace the backplane.

(44)SRVO--061 SVAL2 CKAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if the rotation speed count in the

pulse coder is abnormal (abnormal count clock).(Action) Replace the pulse coder.

NOTEThis alarm might accompany the DTERR, CRCERR, orSTBERR alarm. In this case, however, there is no actualcondition for this alarm.

(45)SRVO--062 SVAL2 BZAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if battery for pulse coder

absolute-position backup is empty.A probable cause is a broken battery cable or nobatteries in the robot.

(Action) Check the battery and battery cable, and replace thenew battery.Then set the system variable $MCR.$SPC_RESETto TRUE, then supply power again.After this, mastering is required or follow SRVO--038RECOVERY PROCEDURE.


74

(46)SRVO--063 SVAL2 RCAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if the rotation speed count in the

pulse coder is abnormal (abnormal counter).(Action) Replace the pulse coder.


(47)SRVO--064 SVAL2 PHAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if the phase of the pulses generated

in the pulse coder is abnormal.(Action) Replace the pulse coder.


(48)SRVO--065 WARN BLAL alarm (Group : i Axis : j)(Explanation) The battery voltage for the pulse coder is lower than

the rating.(Action) Replace the battery.

(If this alarm occurs, turn on the AC power andreplace the battery as soon as possible. A delay inbattery replacement may result in the BZAL alarmbeing detected. In this case, the position data will belost. Once the position data is lost, mastering willbecome necessary.

(49)SRVO--066 SVAL2 CSAL alarm (Group : i Axis : j)(Explanation) The ROM in the pulse coder is abnormal.(Action) Replace the pulse coder.


(50)SRVO--067 SVAL2 OHAL2 alarm (Group : i Axis : j)(Explanation) The temperature inside the pulse coder or motor is

abnormally high, and the built--in thermostat hasoperated.


(Action 2) When power is supplied to the motor after it hasbecome sufficiently cool, if the alarm still occurs,replace the motor.

(51)SRVO--068 SVAL2 DTERR alarm (Group : i Axis : j)(Explanation) The serial pulse coder does not return serial data in

response to a request signal.--See actions on SRVO--070

(52)SRVO--069 SVAL2 CRCERR alarm (Group : i Axis : j)(Explanation) The serial data has disturbed during communication.

--See actions on SRVO--070


75

(53)SRVO--070 SVAL2 STBERR alarm (Group : i Axis : j)(Explanation) The start and stop bits of the serial data are abnormal.(Action 1) Make sure that the CRF7 connector of servo amplifire

is connected tightly.(Action 2) Check that the shielding of the robot interconnection

cable (for the pulse coder) and the peripheral equipmentcable is connected securely to the grounding plate.

(Action 3) Check that each unit is grounded securely.(Action 4) Replace the servo amplifier.(Action 5) Replace the pulse coder.(Action 6) Replace the robot interconnection cable (for the pulse

coder).

Servo amplifier

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

(54)SRVO--071 SVAL2 SPHAL alarm (Group : i Axis : j)(Explanation) The feedback speed is abnormally high.(Action 1) If this alarm occurs together with the PHAL alarm

(No. 064), this alarm does not correspond to the majorcause of the failure.

(Action 2) Replace the pulse coder.(55)SRVO--072 SVAL2 PMAL alarm (Group : i Axis : j)

(Explanation) It is likely that the pulse coder is abnormal.(Action) Replace the pulse coder and remaster the robot.

(56)SRVO--073 SVAL2 CMAL alarm (Group : i Axis : j)(Explanation) It is likely that the pulse coder is abnormal or thepulse

coder has malfunctioned due to noise.(Action) Master the robot and enhance the shielding.

(57)SRVO--074 SVAL2 LDAL alarm (Group : i Axis : j)(Explanation) The LED in the pulse coder is broken.(Action) Replace the pulse coder, and remaster the robot.

(58)SRVO--075 WARN Pulse not established (Group : i Axis : j)(Explanation) The absolute position of the pulse coder cannot be

established.(Action) Reset the alarm, and jog the axis on which the alarm

has occurred until the same alarm will not occuragain. (Jog one motor revolution)


76

(59)SRVO--076 SVAL1 Tip Stick Detection (Group : i Axis : j)(Explanation) An excessive disturbance was assumed in servo

software at the start of operation. (An abnormal loadwas detected. The cause may be welding.)

(Action 1) Check whether the robot comes into collision withforeign matter. If a collision occurs, reset the system,then switch it to the jog feed mode to avoid thecollision.

(Action 2) Check whether the load settings are valid.(Action 3) Check whether the load weight is within the rated

range. If the weight exceeds the upper limit, decreaseit to the limit.(Use of the robot with a load exceeding the limitapplied may abnormally increase the assumeddisturbance, resulting in this alarm.)

(Action 4) Check each inter--phase voltage of the three--phaseinput (200 VAC) to the servo amplifier. If the voltageis 170 VAC or lower, check the input power supplyvoltage.


Servo amplifier

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

(60)SRVO--081 WARN EROFL alarm (Track enc : i)(Explanation) The pulse counter for line tracking has overflowed.

(61)SRVO--082 WARN DAL alarm (Track ebc : i)(Explanation) The line tracking pulse coder has not been connected.(Action 1) Check the pulse coder connection cable, and replace

it if necessary.(Action 2) Replace the pulse coder.

(62)SRVO--083 WARN CKAL alarm (Track ebc : i)(Explanation) This alarm occurs if the rotation speed count in the

pulse coder is abnormal (abnormal count clock).(Action) See the description about the SRVO--061 CKAL

alarm.


77

(63)SRVO--084 WARN BZAL alarm (Track enc : i)(Explanation) This alarm occurs if the backup battery for the absolute

position of the pulse coder has not been connected. Seethe description about the BZAL alarm (SRVO--062).

(64)SRVO--085 WARN RCAL alarm (Track ebc : i)(Explanation) This alarm occurs if the rotation speed count in the

pulse coder is abnormal (abnormal counter).(Action) See the description about the SRVO--063 RCAL

alarm.(65)SRVO--086 WARN PHAL alarm (Track enc : i)

(Explanation) This alarm occurs if the phase of pulses generated inthe pulse coder is abnormal. See the descriptionabout the PHAL alarm (SRVO--064).

(66)SRVO--087 WARN BLAL alarm (Track enc : i)(Explanation) This alarm occurs if the voltage of the backup battery

for the absolute position of the pulse coder is low. Seethe description about the BLAL alarm (SRVO--065).

(67)SRVO--088 WARN CSAL alarm (Track ebc : i)(Explanation) The ROM in the pulse coder is abnormal.(Action) See the description about the SRVO--066 CSAL

alarm.(68)SRVO--089 WARN OHAL2 alarm (Track enc : i)

(Explanation) The motor has overheated. See the description aboutthe OHAL2 alarm (SRVO--067).

(69)SRVO--090 WARN DTERR alarm (Track enc : i)(Explanation) Communication between the pulse coder and line

tracking interface board is abnormal. See thedescription about the DTERR alarm (SRVO--068).

(70)SRVO--091 WARN CRCERR alarm (Track enc : i)(Explanation) Communication between the pulse coder and line

tracking interface board is abnormal. See thedescription about the CRCERR alarm (SRVO--069).

(71)SRVO--092 WARN STBERR alarm (Track enc : i)(Explanation) Communication between the pulse coder and line

tracking interface board is abnormal. See thedescription about the STBERR alarm (SRVO--070).

(72)SRVO--093 WARN SPMAL alarm (Track enc : i)(Explanation) This alarm occurs if the current position data from the

pulse coder is higher than the previous position data.See the description about the SPHAL alarm(SRVO--071).

(73)SRVO--094 WARN PMAL alarm (Track enc : i)(Explanation) It is likely that the pulse coder is abnormal. See the

description about the PMAL alarm (SRVO--072).(74)SRVO--095 WARN CMAL alarm (Track enc : i)

(Explanation) It is likely that the pulse coder is abnormal or thepulsecoder has malfunctioned due to noise. See thedescription about the CMAL alarm (SRVO--073).

(75)SRVO--096 WARN LDAL alarm (Track enc : i)(Explanation) The LED in the pulse coder is broken. See the

description about the LDAL alarm (SRVO--074).


78

(76)SRVO--097 WARN Palse not established (enc : i)(Explanation) The absolute position of the pulse coder cannot be

established. See the description about (SRVO--075).Pulse not established.

(77)SRVO--105 SVAL1 Door open or E--stop(Explanation) The cabinet door is open.(Action 1) When the door is open, close it. If no door switch is

mounted, go to [Action 3].(Action 2) Check the door switch and door switch connection

cable. If the switch or cable is faulty, replace it.(Action 3) Check that the CRM70, CRM71, and CRM72

connectors on the E--STOP unit are connectedsecurely.

(Action 4) This alarm is also issued if software cannot determinethe cause of disconnection of the emergency stop line.Reference the total connection diagram in Appendixand check whether the emergency stop line is normal.


Servo amplifier

E--stop unit

Electromagneticcontactor

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

(78)SRVO--136 SVAL1 DCLVAL alarm (Group : i Axis : j)(Explanation) The servo the DC current of amplifier (DC link

voltage) of the main power supply is abnormally low.--This alarm occured in the robot operation.(Action 1) Check the phase voltage of the three--phase input

power (200 VAC) to the servo amplifier. If it is 170VAC or lower, check the line voltage.

(Action 2) Replace the servo amplifier.--If this alarm occurs before the magnetic contactor is turned on:(Action 1) Check whether the circuit breaker in the emergency

stop unit is OFF. If it is OFF, check the servoamplifier and the wiring between the servo amplifierand the emergency stop unit. If anything is abnormal,replace it.


79

(Action 2) Check each phase--to--phase voltage of thethree--phase input (200 VAC) on the primary side ofthe magnetic contactor. If the input is not higher than170 VAC, check the input power supply voltage.

(Action 3) Replace the E--stop unit.(Action 4) Replace the servo amplifier.

Servo amplifier


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

(79)SRVO--138 SDAL alarm(Group : i Axis : j)(Explanation) The feedback data from pulse coder was abnormal by

noise on the pulse coder.Or the inter polation circuit of the pulse coder isbroken.

(Action) If the alarm disappeared by power OFF/ON, pleasemake sure the cable shields are grounded.

(Action) If this problem occurs repeatedly, replase the pulsecoder and master the robot.

(80)SRVO--153 SVAL1 CHGAL(CNV) alarm (Group : i Axis : j)(Explanation) The main circuit could not be charged within the

specified time.(Action 1) A short circuit may occur in the DC link. Check the

connection.(Action 2) The charging current control resistor may be faulty.

Replace the E--STOP unit.(Action 3) Replace the servo amplifier.


80

Servo amplifier

E--stop unit

Panel board

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

(81)SRVO--156 SVAL1 IPMAL alarm (Group : i Axis : j)(Explanation) Abnormally high current flowed through the main

circuit of the servo amplifier.(Action 1) Detach the motor power lines from the respective

terminals on the servo amplifier, and switch on thepower, then check to see if the alarm occurs again. Ifthe alarm occurs, replace the servo amplifier.

(Action 2) Detach the motor power lines from the respectiveterminals on the servo amplifier, and check for isolationbetween each motor power line (U, V, or W) and aground potential (GND). If a motor power line isshort--circuited to a ground, the motor, robot connectioncable, or robot internal cable is likely to be defective.Check each of them, and replace it if necessary.

(Action 3) Detach the motor power lines from the respectiveterminals on the servo amplifier, and check theresistance between each motor power line pair (U andV, V and W, or W and U) using a meter that is capableof measuring a very low resistance. If the measuredthree resistances are different, the motor, robotconnection cable, or robot internal cable is likely bedefective. Check each of them, and replace it ifnecessary.


81

Servo amplifier

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

(82)SRVO--157 SVAL1 CHGAL alarm (Group : i Axis : j)(Explanation) The capacitor for the DC link voltage of the servo

amplifier was not charged within the specified time.(Action 1) A short circuit may occur in the DC link voltage.

Check the connection.(Action 2) The charging current control resistor may be faulty.

Replace the E--STOP unit.(Action 3) Replace the servo amplifier.

Servo amplifier

E--stop unit

Panel board

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


82

(83)SRVO--194 Servo disconnect(Explanation) On the terminal block TBOP3 of the panel board, no

connection is made between 5 (SD4) and 6 (SD41) orbetween 7 (SD5) and 8 (SD51). If a servo disconnectswitch is connected between 5 (SD4) and 6 (SD41) orbetween 7 (SD5) and 8 (SD51), the switch is pressed.If the SYST--067 (Panel HSSB disconnect) alarm isalso generated, or if the LED (green) on the panelboard is turned off, communication between the mainboard (JRS11) and the panel board (JRS11) isabnormal. The connectors of the cable between themain board and the panel board may be loose. Or, thecable, panel board, or main board may be faulty.(Note)

(Action 1) If a servo disconnect switch is connected, releases theswitch.

(Action 2) Check the switch and cable connected to 5 (SD4) and6 (SD41) or 7 (SD5) and 8 (SD51).

(Action 3) When this signal is not used, make a connectionbetween 5 (SD4) and 6 (SD41) or between 7 (SD5)and 8 (SD51).

(Action 4) Replace the PC board.





83

LED (Green)Short connection7 (SD5) and 8 (SD51)

Short connection5 (SD4) and 6 (SD41)

Connector (JRS11)Connector (JRS11)

Panel board

Panel board

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

Main board

Connector (JRS11)

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

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

alarm or SVOFF input alarm.


84

(85)SRVO--201 SVAL1 Panel E--stop or SVEMG abnormal(Explanation) The EMERGENCY STOP button on the operator

panel was pressed, but the EMERGENCY STOP linewas not disconnected.

(Action 1) Check the EMERGENCY STOP button on theoperator panel, and replace it if necessary.

(Action 2) Replace the panel board.(Action 3) Replace the servo amplifier.

NOTEThis alarm might occur if the EMERGENCY STOP buttonis pressed slowly.

Servo amplifier

Panel board


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


85

(86)SRVO--202 SVAL1 TP E--stop or SVEMG abnormal(Explanation) The EMERGENCY STOP button on the operator

panel was pressed, but the EMERGENCY STOP linewas not disconnected.

(Action 1) Check the teach pendant connection cable, andreplace it if necessary.

(Action 2) Replace the teach pendant.(Action 3) Replace the panel board.(Action 4) Replace the servo amplifier.

NOTEThis alarm might occur if the EMERGENCY STOP buttonis pressed slowly.

Servo amplifier

Panel board


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


86

(87)SRVO--204 SVAL1 External (SVEMG abnormal) E--stop(Explanation) The switch connected across EES1 and EES11, EES2

and EES21 on the TBOP4 terminal board on the panelboard was pressed, but the EMERGENCY STOP linewas not disconnected.


Servo amplifier

Panel board


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


87

(88)SRVO--205 SVAL1 Fence open (SVEMG abnormal)(Explanation) The switch connected across EAS1 and EAS11,

EAS2 and EAS21 on the TBOP4 terminal board onthe panel board was pressed, but the EMERGENCYSTOP line was not disconnected.


Servo amplifier

Panel board


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


88

(89)SRVO--206 SVAL1 Deadman switch (SVEMG abnormal)(Explanation) The DEADMAN switch was released when the teach

pendant was operable, but the EMERGENCY STOPline was not disconnected.

(Action 1) Check the teach pendant connection cable. Replace itif necessary.


Servo amplifier

Panel board


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


89

(90)SRVO--207 SVAL1 TP switch abnormal or door open(Explanation) The teach pendant is operable, and the deadman

switch has been grasped, but the EMERGENCYSTOP line is kept disconnected.

(Action 1) Check the teach pendant connection cable, andreplace it if necessary.


Servo amplifier

Panel board


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


90

(91)SRVO--213 WARN Fuse blown (Panel PCB)(Explanation) A fuse on the panel board has blown.(Action 1) Check whether fuse FUSE1 on the panel board is

blown.When the fuse is blown, eliminate the cause, thenreplace the fuse.(See II MAINTENANCE, Section 3.6.)


Servo amplifier

E--stop unit

Panel board

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


91

(92)SRVO--214 WARN Fuse blown (Panel PCB)(Explanation) A fuse in the servo amplifier has blown.(Action 1) Check whether fuse F1, F2, FS2, or FS3 in the servo

amplifier is blown.When a fuse is blown, eliminate the cause, thenreplace the fuse.(See II MAINTENANCE, Section 3.6.)


Servo amplifier

E--stop unit

Panel board

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


92

(93)SRVO--215 WARN Fuse blown (Aux axis)(Explanation) The fuse in the additional axis amplifier has blown.(Action 1) Check the cause and solve the problem, then replace

the fuse.

(94)SRVO--216 SVAL1 OVC (total) (Robot : i)(Explanation) The current (total current for six axes) flowing

through the motor is too large.(Action 1) Slow the motion of the robot where possible. Check

the robot operation conditions. If the robot is usedwith a condition exceeding the duty or load weightrobot rating, reduce the load condition value to thespecification range.

(Action 2) Check each inter--phase voltage of the three--phaseinput (200 VAC) to the servo amplifier. If the voltageis 170 VAC or lower, check the input power supplyvoltage.

(95)SRVO--221 SVAL1 Lack of DSP (Group : i Axis : j)(Explanation) A controlled axis card corresponding to the set

number of axes is not mounted.(Action 1) Check whether the set number of axes is valid. If the

number is invalid, set the correct number.(Action 2) Replace the controlled axis card with a card

corresponding to the set number of axes.(Example)When six axes are set, a controlled axis card for sixor eight axes is available. For how to replace thecontrolled axis card, see II MAINTENANCE,Section 7.2 in this manual.

(96)SRVO--222 SVAL1 Lack of Amp (Amp : i)(Explanation) The FSSB has no SVM.(Action 1) Check that the optical cable is securely connected to

the SVM.(Action 2) Replace the optical cable.(Action 3) Check whether power is properly supplied to the

SVM.Check that there is no problem with each SVM inputvoltage.

(Action 4) Replace the SVM.

(97)SRVO--230 SVAL1 Chain 1 (+24V) abnormalSRVO--231 SVAL1 Chain 2 (0V) abnormal(Explanation) Single chain 1 (+24V)/chain 2 (0V) failure occured

on emergency stop of operator panel or emergencystop of teach pendant or deadman switch or fenceswitch or external emergency stop or servo ON/OFFswitch or NTED input or door switch.Please check history of alarm by Alarm Log.¯ Single chain failure is ;

One of emergency stop chain is emergency stopcondition, and another chain is not emergency stopcondition.

¯ Cause of this alarm is ;-- Weld of contact-- Wire broken or shorted-- Half release of deadman switch-- Half operation of emergency stop of operator

panel and emergency stop of teach pendant


93

-- Irregular input from external emergency stopand etc. (Out of specified timing.)

The single chain failure occurred on the emergencystop switch of the operator panel, emergency stopswitch of the teach pendant and the deadman switch.This failure can be recovered by performing thecorrect stop operation.The detecting circuit for the single chain failure isreset by either entering another stop cause, or turningthe power on again. Hold the alarm state for theduration that the alarm history is being checked.

CAUTION1 This alarm is controlled by the software and requires a

special reset procedure.After resolving the cause of the alarm, please issue thespecial reset procedure according to end of Explanationsand Actions shown below.

2 The RESET operation is inhibited until the special resetprocedure is performed.The message of “SRVO--237 Cannot reset chain failure” isdisplayed, if the RESET operation is issued before thespecial reset procedure is performed.

3 If a successful operator panel emergency stop, or teachpendant emergency stop, or when the deadman switch isreleased after this alarm, the message of “SRVO--236Chain failure is repaired” is displayed.

Single chain 1 (+24V) failure is ;(Example of external emergency stop)

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

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


94

(Example)

(98)SRVO--230 SVAL1 Chain 1 (+24V) abnormalwith SRVO--001 Operator panel E--stop

SRVO--231 SVAL1 Chain 2 (0V) abnormalwith SRVO--001 Operator panel E--stop

(Action 1) Re--operate emergency stop of operator panel.If this alarm is reset, the message of “SRVO--236Chain failure is repaired” is displayed.

(Action 2) Replace the panel board.(Action 3) Replace the operator panel.(Action 4) Replace the E--stop unit.(Action 5) Replace the servo amplifier.

E--stop unit

Operator panel

Servo amplifier Teach pendant

Mode switch

Panel board

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


95

(99)SRVO--230 SVAL1 Chain 1 (+24V) abnormalwith SRVO--002 Teach pendant E--stop

SRVO--231 SVAL1 Chain 2 (0V) abnormalwith SRVO--002 Teach pendant E--stop

(Action 1) Re--operate emergency stop of teach pendant.If this alarm is reset, the message of “SRVO--236Chain failure is repaired” is displayed.

(Action 2) Check the teach pendant connection cable and replaceit if necessary.

(Action 3) Replace the panel board.(Action 4) Replace the operator panel.(Action 5) Replace the E--stop unit.(Action 6) Replace the servo amplifier.

E--stop unit

Operator panel


Mode switch

Panel board



96

(100) SRVO--230 SVAL1 Chain 1 (+24V) abnormalwith SRVO--003 Deadman switch released

SRVO--231 SVAL1 Chain 2 (0V) abnormalwith SRVO--003 Deadman switch released

(Action 1) Re--operate deadman switch. If this alarm is reset. themessage of “SRVO--236 Chain failure is repaired” isdisplayed.


(Action 3) Replace the panel board.(Action 4) Replace the teach pendant.(Action 5) Replace the E--stop unit.(Action 6) Replace the servo amplifier.(Action 7) Replace the mode switch.

E--stop unit

Operator panel


Mode switch

Panel board



97

(101) SRVO--240 Chain1 (FENCE) abnormalwith SRVO--230 SVAL1 Chain 1 (+24V) abnormaland SRVO--004 Fence open

SRVO--241 Chain2 (FENCE) abnormalwith SRVO--231 SVAL1 Chain 2 (0V) abnormaland SRVO--004 Fence open

(Action 1) Check the +24V connection of safety fence (EAS1 --EAS11), or the 0V connection of safety fence (EAS2-- EAS21)

(Action 2) Replace the panel board.(Action 3) Replace the E--stop unit.(Action 4) Replace the servo amplifier.(Action 5) Replace the mode switch.

E--stop unit

Operator panel


Mode switch

Panel board

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


98

(102) SRVO--242 Chain1 (EXEMG) abnormalwith SRVO--230 SVAL1 Chain 1 (+24V) abnormaland SRVO--007 External emergency stops

SRVO--243 Chain2 (EXEMG) abnormalwith SRVO--231 SVAL1 Chain 2 (0V) abnormaland SRVO--007 External emergency stops

(Action 1) Check the +24V connection of external emergencystop (EES1 -- EES11), or the 0V connection ofexternal emergency stop (EES2 -- EES21).

(Action 2) Replace the panel board.(Action 3) Replace the E--stop unit.(Action 4) Replace the servo amplifier.

E--stop unit

Operator panel


Mode switch

Panel board

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


99

(103) SRVO--230 SVAL1 Chain 1 (+24V) abnormalwith SRVO--232 SVAL1 NTED input

SRVO--231 SVAL1 Chain 2 (0V) abnormalwith SRVO--232 SVAL1 NTED input

(Action 1) Check the +24V connection of NTED input (NTED1-- NTED11), or the 0V connection of NTED input(NTED2 -- NTED21).

(Action 2) Replace the panel board.(Action 3) Replace the E--stop unit.(Action 4) Replace the servo amplifier.(Action 5) Replace the mode switch.

E--stop unit

Operator panel


Mode switch

Panel board



100

(104) SRVO--230 SVAL1 Chain 1 (+24V) abnormalwith SRVO--233 SVAL1 TP disabled in T1, T2/Door open

SRVO--231 SVAL1 Chain 2 (0V) abnormalwith SRVO--233 SVAL1 TP disabled in T1, T2/Door open


(Action 2) Replace the panel board.(Action 3) Replace the teach pendant.(Action 4) Replace the E--stop unit.(Action 5) Replace the servo amplifier.(Action 6) Replace the mode switch.

E--stop unit

Operator panel


Mode switch

Panel board



101

[Special reset operation]

CAUTIONDo not issue this operation before resolving the cause of thealarm.

1. Press E--stop button for correct emergency stop condition.2. Press “MENU” on the teach pendant.3. Press “0” on the teach pendant, [0 ---- NEXT ----].4. Press “6” on the teach pendant, [6 SYSTEM].5. Press F1, [TYPE].6. Select Config.7. Search item 28.8. Press F4, [TRUE].

The display of “28 Reset CHAIN FAILURE detection : ”changes “TRUE” from “FALSE”.And few seconds later the display changes “FALSE” from“TRUE” again.

9. The RESET operation is allowed.


102

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

E--stop unit

Operator panel


Mode switch

Panel board

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


103

(106) SRVO--233 SVAL1 TP disabled in T1, T2/Door open(Explanation) Teach pendant is disabled when the mode switch isT1

or T2.Or controller door is opened.

(Action 1) Close the controller door, if open.(Action 2) Check the door switch, and replace it if necessary.(Action 3) Replace the panel board.(Action 4) Replace the teach pendant.(Action 5) Replace the mode switch.

E--stop unit

Operator panel


Mode switch

Panel board

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


104

(107) SRVO--235 Short term Chain abnormal(Explanation) Short term single chain failure condition is detected.

¯ Short term single chain failure is ;If any cause of stop is issued for a short time,detecting circuit for single chain failure detects assingle chain failure depending on hardwarespecification.In this case, cause of stop is not detected bysoftware, so this alarm is distinguished from“SRVO--230” and “SRVO--231”.

¯ Cause of this alarm is ;-- Half release of deadman switch-- Half operation of emergency stop of operator

panel and emergency stop of teach pendantShort term single chain failures occured onemergency stop of operator panel, emergency stop ofteach pendant and deadman switch are recoverableissuing correct stop operation.

(Action 1) To reset detecting circuit for single chain failure,re--operate emergency stop of operator panel oremergency stop of teach pendant or deadman switchaccording previous operation.If this alarm is reset, the message of “SRVO--236Chain failure is repaired” is displayed.

CAUTIONThis alarm is an un--clear single chain failure condition.The software waits for a correct operation response to resetthe single chain failure condition.If another cause is issued, then the software detects the realsingle chain failure and displays “Chain 1 (+24V) abnormal”or “Chain 2 (0V) abnormal”.

NOTE1 This alarm may occur when an operator panel emergency

stop, teach pendant emergency stop or when the deadmanswitch is released.The above are operated by the operator.This alarm is provided for un--clear and fast--repeatedoperation by the operator.

2 If correct action is issued after this alarm, the messege of“SRVO--236 Chain failure is repaired” is displayed.

(108) SRVO--236 SVAL1 Chain failure is repaired(Explanation) A chain failure was repaired. For details, see the

explanation of SRVO--230 and SRVO--231.

(109) SRVO--237 SVAL1 Not reset chain failure(Explanation) A chain failure could not be repaired. See the

explanation of SRVO--230 and SRVO--231.(Action 1) Check the alarm history and see the explanation of the

displayed alarm.


105

(110) SRVO--240 SVAL1 Chain 1 (FENCE) abnormal

(111) SRVO--241 SVAL1 Chain 2 (FENCE) abnormal(Explanation) Although the circuit connected between EAS11 and

EAS1 or between EAS21 and EAS2 on the TBOP4terminal block on the panel board was disconnected,the emergency stop line was not disconnected. Theemergency stop circuit is faulty.

(Action 1) Check the +24 V connection (between EAS11 andEAS1) and 0 V connection (between EAS21 andEAS2) for the fence.

(Action 2) Replace the panel board.(Action 3) Replace the E--STOP unit.(Action 4) Replace the servo amplifier.

NOTEEliminate the cause of the abnormal chain, then execute“special reset operation” to release the alarm.

Servo amplifier

E--stop unit

Panel board

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


106

(112) SRVO--242 SVAL1 Chain 1 (EXEMG) abnormalSRVO--243 SVAL1 Chain 2 (EXEMG) abnormal

(Explanation) Although the external emergency stop circuit wasdisconnected, the emergency stop line was notdisconnected. The emergency stop circuit is faulty.

(Action 1) Check the +24 V connection (between EES11 andEES1) and 0 V connection (between EES21 andEES2) for the external emergency stop circuit.



Servo amplifier

E--stop unit

Panel board

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


107

(113) SRVO--260 SVAL1 Chain 1 (NTED) abnormalSRVO--261 SVAL1 Chain 2 (NTED) abnormal

(Explanation) Although the non--teacher--enabling devicedisconnected the NTED circuit in the T1/T2 mode,the emergency stop line was not disconnected. Theemergency stop circuit is faulty.

(Action 1) Check the +24 V connection (between NTED11 andNTED1) and 0 V connection (between NTED21 andNTED2) for the NTED circuit.


Servo amplifier

E--stop unit

Panel board

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

(114) SRVO--262 SVAL1 Chain 1 (SVDCT) abnormalSRVO--263 SVAL1 Chain 2 (SVDCT) abnormal

(Explanation) Although the SVDCT circuit was disconnected, theemergency stop line was not disconnected. Theemergency stop circuit is faulty.

(Action 1) Check the +24 V connection (between SD41 andSD1) and 0 V connection (between SD51 and SD5)for the SVDCT circuit.



108

Servo amplifier

E--stop unit

Panel board

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

(115) SRVO--264 SVAL1 “E.STOP circuit abnormal 1”(Explanation) An error occurred in the emergency stop circuit.(Action 1) Check whether the CRM67 and CRM72 connectors

on the E--STOP unit are connected securely.(Action 2) Check whether the circuits connected to CRM67 and

CRM72 in the emergency stop circuit are normal.(Action 3) Replace the E--STOP unit.(Action 4) Replace the servo amplifier.

Servo amplifier

E--stop unit

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


109

(116) SRVO--265 SVAL1 E.STOP circuit abnormal 2(Explanation) When the servo entered the activated state, MON3

was in the on state. The MON3 state is abnormal.(Action 1) Replace the E--STOP unit.(Action 2) Replace the servo amplifier.(Action 3) Replace the panel board.

Servo amplifier

E--stop unit

Panel board

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

(117) SRVO--280 SVAL1 SVOFF input(Explanation) On the terminal block TBOP4 of the panel board, no

connection is made between 9 (EGS1) and 10(EGS11) or between 11 (EGS2) and 12 (EGS21). Ifa switch is connected between 9 (EGS1) and 10(EGS11) or between 11 (EGS2) and 12 (EGS21), theswitch is pressed.

(Action 1) If a switch is connected, releases the switch.If the SYST--067 (Panel HSSB disconnect) alarm isalso generated, or if the LED (green) on the panelboard is turned off, communication between the mainboard (JRS11) and the panel board (JRS11) isabnormal. The connectors of the cable between themain board and the panel board may be loose. Or, thecable, panel board, or main board may be faulty.(Note)

(Action 2) Check the switch and cable connected to 9 (EGS1)and 10 (EGS11) or 11 (EGS2) and 12 (EGS21).

(Action 3) When this signal is not used, make a connectionbetween 9 (EGS1) and 10 (EGS11) or between 11(EGS2) and 12 (EGS21).

(Action 4) If SRVO--004 (Fence open), SRVO--007 (Externalemergency stops), SRVO--213 (Fuse blown (PanelPCB)), and SRVO--280 (SVOFF input) occursimultaneously, it is likely that FUSE1 on the panelboard has blown. Check the fuse. If it has blown,remove the cause, then replace the fuse. (Refer toSection 3.6 in Part II, “Maintenance,” of“Maintenance Manual.”)


110

(Action 5) Replace the panel board.Before performing “Action 6,” make a backup copyof all programs and settings in the control unit.


NOTESVOFF input (GENERAL STOP) is a safety stop input.When this input is opened, the robot decelerates in acontrolled manner and then stops. The magnetic contactoropens after the robot stops.

WARNINGDo NOT short--circuit, or disable, this signal in a system inwhich the Servo off emergency stop signal input is in use,as it is very dangerous. If it is necessary to run the robot byshort--circuiting the signal even temporarily, an additionalsafety provision must be provided.

NOTEIf the LED is turned off, the SRVO--001 (Operator panelE--stop), SRVO--004 (Fence open), SRVO--007 (Externalemergency stops), or SRVO--280 (SVOFF input), alarm isalso generated. Check the alarm history display on the teachpendant.





111

Panel boardLED (Green) Connector (JRS11)

Short connection9 (EGS1) and 10 (EGS11)

Short connection11 (EGS2) and 12 (EGS21)

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

Main board

Connector (JRS11)

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

(118) SRVO--266 SVAL1 FENCE1 status abnormalSRVO--267 SVAL1 FENCE2 status abnormal

(Explanation) The fence circuit is abnormal.(Action 1) Check the +24 V connection (between EAS11 and

EAS1) and 0 V connection (between EAS21 andEAS2) for the fence.

(Action 2) Check the fence switch.(Action 3) Replace the panel board.



112

(119) SRVO--268 SVAL1 SVOFF1 status abnormalSRVO--269 SVAL1 SVOFF2 status abnormal

(Explanation) The SVOFF circuit is abnormal.(Action 1) Check the +24 V connection (between EGS11 and

EGS1) and 0 V connection (between EGS21 andEGS2) for the SVOFF circuit.

(Action 2) Check the SVOFF switch.(Action 3) Replace the panel board.


(120) SRVO--270 SVAL1 EXEMG1 status abnormalSRVO--271 SVAL1 EXEMG2 status abnormal

(Explanation) The EXEMG circuit is abnormal.(Action 1) Check the +24 V connection (between ESPB11 and

ESPB1) and 0 V connection (between ESPB21 andESPB2) for the EXEMG circuit.

(Action 2) Check the EXEMG switch.(Action 3) Replace the panel board.


(121) SRVO--272 SVAL1 SVDISC1 status abnormalSRVO--273 SVAL1 SVDISC2 status abnormal

(Explanation) The SVDISC circuit is abnormal.(Action 1) Check the +24 V connection (between SD41 and

SD4) and 0 V connection (between SD51 and SD5)for the SVDISC circuit.

(Action 2) Check the SVDISC switch.(Action 3) Replace the panel board.


(122) SRVO--274 SVAL1 NTED1 status abnormalSRVO--275 SVAL1 NTED2 status abnormal

(Explanation) The NTED circuit is abnormal.(Action 1) Check the +24 V connection (between NTED11 and

NTED1) and 0 V connection (between NTED21 andNTED2) for the NTED circuit.

(Action 2) Check the NTED switch.(Action 3) Replace the panel board.



113

(123) SRVO--281 SVAL1 SVOFF input (SVEMG abnormal)(Explanation) When the SVOFF signal was input, an SVEMG error

was detected. The emergency stop circuit is faulty.(Action 1) Replace the panel board.(Action 2) Replace the servo amplifier.(Action 3) Replace the E--STOP unit.

Servo amplifier

E--stop unit

Panel board

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


114

(124) SRVO--282 SVAL1 Chain1 (SVOFF) abnormalSRVO--283 SVAL1 Chain2 (SVOFF) abnormal

(Explanation) Although the switch connected between EGS11 andEGS1 or between EGS21 and EGS2 on the TBOP4terminal block on the panel board was pressed, theemergency stop line was not disconnected. Theemergency stop circuit is faulty.

(Action 1) Replace the panel board.(Action 2) Replace the servo amplifier.(Action 3) Replace the E--STOP unit.

Servo amplifier

E--stop unit

Panel board

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

(125) SRVO--282 Chain1 (SVOFF) abnormalwith SRVO--230 SVAL1 Chain 1 (+24V) abnormaland SRVO--280 SVOFF input

SRVO--283 Chain2 (SVOFF) abnormalwith SRVO--231 SVAL1 Chain 2 (0V) abnormaland SRVO--280 SVOFF input

(Action 1) Check the +24V connection of servo ON/OFF switch(EGS1 -- EGS11), or the 0V connection of servoON/OFF switch (EGS2 -- EGS21).

(Action 2) Replace the panel board.(Action 3) Replace the E--stop unit.(Action 4) Replace the servo amplifier.


115

E--stop unit

Operator panel


Mode switch

Panel board

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

(126) SRVO--291 SVAL1 “IPM over heat (Group : i Axis : j)”(Explanation) The IPM in the servo amplifier overheats.(Action 1) Check whether the amplifier fan stops.(Action 2) Reduce the override because the use condition is too

hard.(Action 3) If this alarm is frequently issued, replace the

amplifier.

(127) SRVO--292 SVAL1 EXT FAN alarm (Group : i A : j)(Explanation) The external fan for the αSVMi is faulty.(Action 1) Replace the external fan for the SVM.

(128) SRVO--293 SVAL1 DClink (PSM) HCAL (Group : i Axis : j)(Explanation) The three--phase input power supply is abnormal or

the PSM is faulty.(Action 1) Check the three--phase input power supply.(Action 2) Replace the PSM.

(129) SRVO--294 SVAL1 EXT FAN (PSM) alarm (Group : i Axis : j)(Explanation) The external fan for theαPSM and αPSMR is faulty.(Action 1) Replace the external fan.

(130) SRVO--295 SVAL1 PSM COM alarm (Group : i Axis : j)(Explanation) The cable between the PSM and SVM may be faulty

or the PSM or SVM may be faulty.(Action 1) Replace the cable between the PSM and SVM.(Action 2) Replace the PSM.(Action 3) Replace the SVM.

(131) SRVO--296 SVAL1 PSM DISCHG alarm (Group : i Axis : j)(Explanation) The use condition is too hard or the fan for cooling the

regenerative resistance for the PSMR stops.(Action 1) Reduce the taught feedrate because the use condition

is too hard.(Action 2) Check whether the fan for cooling the regenerative

resistance for the PSMR stops.


116

(132) SRVO--297 SVAL1 PSM Low Volt alarm (Group : i Axis : j)(Explanation) The three--phase input voltage may drop or the PSM

or SVM may be faulty.(Action 1) Check the three--phase input power supply.(Action 2) Replace the PSM.(Action 3) Replace the SVM.

(133) SRVO--300 SVAL1 Hand broken/HBK disabledSRVO--302 SVAL1 Set Hand broken to ENABLE

(Explanation) Although HBK was disabled, the HBK signal wasinput.

(Action 1) Press RESET on the teach pendant to release thealarm.

(Action 2) Check whether the hand broken signal is connected tothe robot. When the hand broken signal circuit isconnected, enable hand broken. (See IIICONNECTION, Subsection 5.5.3 in this manual.)


117

(1) When the fuses of the power supply unit have blownF1: Fuse for AC inputF3: Fuse for +24 EF4: Fuse for +24 V

Name Symptom observed when fuse has blown Action

F1 The LED (PIL: Green) of the power supply unit does not light, andthe power cannot be turned on.

1 Check the units (fans) and cables connected to the CP2 andCP3 connectors of the power supply unit to see if there is anyshort circuit.

2 Replace the power supply unit.

F3 If the fuse blows when the power supply is turned on, an alarmsuch as for overtravel, hand broken, FSSB disconnect, LVAL isoutput on the teach pendant.If the fuse turns out to have already blown when the power supplyis turned on, the FSSB initialization alarm is displayed on theteach pendant.

1 Check the printed circuit boards, units, and cables using +24E according to the power supply system diagram. Replace afaulty printed circuit board, unit, servo amplifier or cable if any.


F4 The power, when turned on, is immediately turned off. At thistime, the LED (ALM: Red) lights.

1 Check the printed circuit boards, units, and cables using +24V according to the power supply system diagram. Replace afaulty printed circuit board, unit, or cable if any. The LED ofALM is turned off by pressing the OFF button once.



F4 7.5AFuse for +24V

PILLED (green) for AC powersupply display

ALMLED (red) for alarm display


Power supply unit

3.6FUSED--BASEDTROUBLESHOOTING


118

(2) Servo amplifier fuseFS1 : For generation of the power to the amplifier control circuitFS2 : For protection of the 24V output to the end effector, ROT,

and HBKFS3 : For protection of the 24V output to the regenerative

resistance and the additional axis amplifierF1, F2 : For protection of the circuit failure in the servo amplifier.


FS1 All LEDs on the servo amplifier go out.The FSSB disconnection or initialization alarm is dis-played on the teach pendant.

Replace the servo amplifier.

FS2 The fuse blown (Amp) alarm (SRVO--214), hand bro-ken (SRVO--006), and ROBOT OVER TRAVEL(SRVO--005) are displayed on the teach pendant.

1 Check +24E used by the end effector for a ground fault.2 Check the robot connection cable and the robot’s internal cable.3 Replace the servo amplifier.

FS3 The blown fuse (Amp) alarm (SRVO--214) and DCAL(SRVO--043) are displayed on the teach pendant.

1 Check the regenerative resistance, and replace it if required.2 Check the additional axis amplifier and its wiring, and replace them if re-

quired.3 Replace the servo amplifier.

F1F2

The OHAL1 alarm is output on the teach pendant. 1 Check if the cables connected to three phase input of servo amplifier isdefective.

2 Replace the servo amplifier.

Fuse F1

Fuse F2

Fuse FS1Fuse FS3Fuse FS2

Servo amplifier


119

(3) Panel board fuses

FUSE1: For protection of the +24EXT line (emergency stop line)FUSE2: For protection of the teach pendant emergency stop line


FUSE1 The external emergency stop, open fence, SVOFF in-put, and blown fuse (panel PCB) alarm are displayedon the teach pendant.

1 Check the +24EXT line (emergency stop line) for a short--circuit andground fault.

2 Replace the panel board.

FUSE2 The display on the teach pendant disappears. 1 Check the teach pendant cable for a fault, and replace it if required.2 Check the teach pendant for a fault, and replace it if required.3 Replace the panel board.

FUSE2 FUSE1

Panel board


120

(4) Fuse on the process I/O board

FUSE1: Fuse for +24 E


FUSE1 The LED (ALM--2 or FALM) on the process I/O board lights, andan alarm such as IMSTP input is output on the teach pendant.(The display data depends on state of peripheral equipment con-nection.)

1 Check if the cables and peripheral equipment connected tothe process I/O printed circuit board are normal.

2 Replace the process I/O printed circuit board.

Process I/O board CA,CB

Process I/O board DA

FUSE1

FUSE1


121

Process I/O board HA

FUSE1

Total version


122

The printed circuit boards and servo amplifier are provided with alarmLEDs and status LEDs. The LED status and correspondingtroubleshooting procedures are described below.

Main board

Power supply unit

Servo amplifier

3.7TROUBLESHOOTINGBASED ON LEDINDICATIONS


123

(1) TROUBLESHOOTING USING THE LEDS ON THE MAINBOARDTo troubleshoot an alarm that arises before the teach pendant is readyto display, check the status LEDs (green) on the main board atpower--on.After power--on, the LEDs light as described in steps 1 to 17, in theorder described. If an alarm is detected, the step in which the alarmoccurred can be determined from which LEDs are lit.

Step LED Action to be taken

1: After power--on, all LEDs arelit.

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

2: Software operation start--up. [Action1] Replace the CPU card* [Action2] Replace the main board.

3: The initialization of dram onthe CPU card is completed.

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

4: The initialization of SRAMand DPRAM is completed.

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

5: The initialization of the com-munication IC is completed.

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

6: The loading of the basic soft-ware is completed.


7: Basic software start--up. * [Action1] Replace the main board.* [Action2] Replace the FROM/SRAM module.

8: Start--up of communicationwith the teach pendant.


9: The loading of optional soft-ware is completed.

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

10:DI/DO initialization * [Action1] Replace the FROM/SRAM module.* [Action2] Replace the main board.

11:The preparation of the SRAMmodule is completed.

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

[Action3] Replace the servo amplifier.

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


124

Step Action to be takenLED

12:Axis control card initialization [Action1] Replace the axis control card.* [Action2] Replace the main board.


13:Calibration is completed. [Action1] Replace the axis control card.* [Action2] Replace the main board.


14:Start--up of power applicationfor the servo system

* [Action1] Replace the main board.

15:Program execution * [Action1] Replace the main board.[Action2] Replace the process I/O board.

16:DI/DO output start--up. * [Action1] Replace the main board.

17: Initialization is terminated. Initialization has ended normally.

18:Normal status Status LEDs 1 and 2 blink when the system is operating normally.


CPU cardFROM/SRAM module

Axis control card

Main board


125

(2) TROUBLESHOOTING BY 7--SEGMENT LED INDICATOR

7--segment LEDindicator Description

[Description] A parity alarm condition has occurred in RAM on the CPU card installed on the mainboard.

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

[Description] A parity alarm condition has occurred in RAM on the FROM/SRAM module installedon the main board.

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

[Description] A bus error has occurred in the communication controller.[Action] Replace the main board.

[Description] A parity alarm condition has occurred in DRAM controlled by the communication con-troller.

[Action] Replace the main board.

[Description] A communication error has occurred during communication with the panel board.[Action1] Check the communication cable (optical cable) between the main and panel boards,

and replace it if necessary.[Action2] Replace the main board.[Action3] Replace the panel board.

[Description] A servo alarm condition has occurred on the main board.[Action1] Replace the axis control card.[Action2] Replace the main board.

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

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



126

Troubleshooting by LEDs on power supply unit

LED indication Failure description and required measure

[Description] When ALM LED (red) turned on, power supply alarm has occurred.[Action1] Check fuse F4 (+24V) on the power supply unit, and replace it if it has blown.[Action2] Check the printed--circuit boards powered by the DC power supplies (+5V, 15V,

and +24V), the relevant units, and cables, and replace them if defective.[Action3] Replace the power supply unit.

[Description] If the PIL LED (Green) does not light, the power supply unit has not been sup-plied with 200 VAC.

[Action1] Check fuse F1 on the power supply unit, and replace it if it has blown.For detailed causes of fuse blown out, please refer to section 3.1.

[Action2] Replace the power supply unit.


F4 7.5AFuse for +24V

PILLED (green) for AC powersupply display

ALMLED (red) for alarm display


Power supply unit


127

Troubleshooting by LED on the panel board

LED indication Failure description and required measure

RDY [Description] When the LED (green) does not light. Communication with the main board doesnot execute.

[Action1] Check the communication cable between the main and panel boards, andreplace it if necessary.

[Action2] Replace the main board.[Action3] Replace the panel board.

PON [Description] When the LED does not light. The power supply inside the panel board doesnot generate +5 V normally.

[Action1] Check the CRM63 connector and check that 24 V is supplied.[Action2] Replace the panel board.

PON LED (Green)

RDY LED (Green)

Panel board


128

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

LED Description and action to be taken

Process I/O CA/CB/DA/HA [Description] A communication alarm occurred between the main CPU PC board and process[ p ] pI/O board.

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

[Action3] Replace the I/O link connection cable.

Process I/O CA/CB/DA/HA [Description] A fuse on the process I/O board is blown.[ p ] p /[Action1] Replace the blown fuse on the process I/O board.[Action2] Examine the cables and peripheral devices connected to the process I/O board.

Replace any failed components.[Action3] Replace the process I/O board.

Fuse

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


129

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

Troubleshooting byLEDs on servo amplifier


130

LED Color Description

P5V Green

Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally.If the LED does not light:[Measure 1] Check the robot connection cable (RP1) to see if there is a ground fault in the +5 v wire.[Measure 2] Replace the servo amplifier.

P3.3V GreenLights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V normally.If the LED does not light:[Measure] Replace the servo amplifier.

SVEMG Red

Lights when an emergency stop signal is input to the servo amplifier.If the LED lights when the machine is not at an emergency stop:[Measure] Replace the servo amplifier.If the LED does light when the machine is at an emergency stop:[Measure] Replace the servo amplifier.

ALM Red

Lights when the servo amplifier detects an alarm.If the LED lights when there is no alarm condition in the machine:[Measure] Replace the servo amplifier.If the LED does not light when there is an alarm condition in the machine:[Measure] Replace the servo amplifier.

RDY GreenLights when the servo amplifier is ready to drive the servo motor.If the LED does not light when the motor is activated:[Measure] Replace the servo amplifier.

OPEN Green

Lights when the communication between the servo amplifier and the main board is normal.If the LED does not light:[Measure 1] Check for the connection of the FSSB optical cable.[Measure 2] Replace the servo card.[Measure 3] Replace the servo amplifier.

WD Red

Lights when a watch dog alarm is detected in the servo amplifier.[Measure 1] Replace the servo amplifier.[Measure 2] Replace the servo card.[Measure 3] Replace the CPU card.[Measure 4] Replace the main board.

D7 Red

Lights when the DCLINK circuit inside the servo amplifier is charged to reach the specified voltage.If the LED does not light after pre--charge is finished:[Measure 1] It is likely that the DC Link may be short--circuited. Check for connection.[Measure 2] It is likely that the charge current control resistor may be defective. Replace the emer-gency stop unit.[Measure 3] Replace the servo amplifier.


131

(Check 1) On the status screen, check the position deviation in thestopped state. To display the position deviation, press thescreen selection key, and select STATUS from the menu.Press F1, [TYPE], select AXIS from the menu, then pressthe F4, PULSE.(Corrective action)Correct the parameters related to return to the referenceposition (positioning).

(Check 2) Check whether the motor axis can be positioned normally.(Corrective action)If the motor axis can be positioned normally, check themechanical unit.

(Check 3) Check the mechanical unit for backlash.(Corrective action)Replace a faulty key of motor shaft or other faulty parts.

(Check 4) If checks 1 to 3 show normal results(Corrective action)Replace the pulse coder and main board.

3.8POSITION DEVIATIONFOUND IN RETURNTO THE REFERENCEPOSITION(POSITIONING)


132

(Check 1) Check the settings of parameters such as the position loopgain parameter.(Corrective action)Correct parameters.

(Check 2) Check the mechanical unit for backlash.(Corrective action)Replace a faulty key of motor shaft or other faulty parts.

3.9VIBRATIONOBSERVED DURINGMOVEMENT


133

The following explains checking and corrective action required if therobot cannot be operated manually after the controller is turned on:

(1) Check and corrective action to be made if manual operation isimpossible

(Check 1) Check whether the teach pendant is enabled.(Corrective action)Turn on the teach pendant “enable”.

(Check 2) Check whether the teach pendant is handled correctly.(Corrective action)To move an axis by manual operation, press the axisselection key and case shift key at the same time.Set the override for manual feed to a position other than theFINE and VFINE positions.

(Check 3) Check whether the ENBL signal of the peripheral devicecontrol interface is set to 1.(Corrective action)Place the peripheral device control interface in the ENBLstatus.

(Check 4) Check whether the HOLD signal of the peripheral devicecontrol interface or the HOLD switch on the operator’s panelis on (hold status). (Check whether the hold lamp on theteach pendant is on.)(Corrective action)Turn off the HOLD signal of the peripheral device controlinterface or the HOLD switch on the operator’s panel.

(Check 5) Check whether the previous manual operation has beencompleted.(Corrective action)If the robot cannot be placed in the effective area because ofthe offset of the speed command voltage preventing theprevious operation from being completed, check the positiondeviation on the status screen, and change the setting.

(Check 6) Check whether the controller is in the alarm status.(Corrective action)Release the alarm.

(2) Check and corrective action to be taken if the program cannot beexecuted

(Check 1) Check whether the ENBL signal for the peripheral-devicecontrol interface is on.(Corrective action)Put the peripheral-device control interface in the ENBL state.

(Check 2) Check whether the HOLD signal for the peripheral-devicecontrol interface is on. Also check whether the HOLDswitch on the operator’s panel is on. (Check whether theHOLD lamp on the teach pendant is on.)(Corrective action)If the HOLD signal is on, turn it off. If the HOLD switchis on, turn it off.

3.10MANUALOPERATIONIMPOSSIBLE


134

(Check 3) Check whether the previous manual operation has beencompleted.(Corrective action)If the robot cannot be placed in the effective area because ofthe offset of the speed command voltage, which prevents theprevious operation from being completed, check the positiondeviation on the status screen, then change the setting.

(Check 4) Check whether the controller is in the alarm status.(Corrective action)Release the alarm.

B--81465EN--1/02 4. PRINTED CIRCUIT BOARDSMAINTENANCE

135

4 PRINTED CIRCUIT BOARDS

The printed circuit boards are factory-set for operation. Usually, you donot need to set or adjust them. This chapter describes the standard settingsand adjustment required if a defective printed circuit board is replaced.It also describes the test pins and the LED indications.The standard printed circuit board includes the main unit printed circuitboard and one or more cards or modules installed horizontally to themain--unit printed--circuit board.These PC boards have interface connectors, LED indicators, and a plasticpanel at the front. At the rear, there is a backplane connector.

4. PRINTED CIRCUIT BOARDS B--81465EN--1/02MAINTENANCE

136

CPU cardTotal version

Axis control card

FROM/SRAM module

TBDL exists in case of --0413

Fig.4.1 Main board

Name Ordering Specification Board Specification Note

CPU card A05B--2450--H010 A20B--3300--0104 SDRAM 8M (Standard)

A05B--2450--H011 A20B--3300--0105 SDRAM 16M

Axis control card A05B--2450--H021 A20B--3300--0240 8--axis

A05B--2450--H020 A20B--3300--0241 6--axis (Standard)

TBD A20B--3300--0242 4--axis

FROM/SRAM module A05B--2450--H031 A20B--3900--0160 FROM 16M, SRAM 1M

A05B--2450--H032 A20B--3900--0161 FROM 16M, SRAM 2M





Main board A05B--2450--H001 A16B--3200--0412 Standard

TBD A16B--3200--0413 With distributed link (Option)

4.1MAIN BOARD(A16B--3200--0412,--0413)


137

(1) Test pinsName Use

GND1GND2GND3

CACHOFFLOAD

MCBOOTCORE

For testing the printed circuit board

(2) LEDsSeven segment LED Description

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

A parity alarm occurred in a RAM of the SRAM mod-ule on the main board.

Bus error occurred on the communication controller.

A parity alarm occurred in DRAM controlled by com-munication controller.

A communication error occurred between panelboards and main board.

A servo alarm occurred on the main board.

SYSEMG occurred.

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


138

Status LED Description

STATUSLED

Operating status of the system.

ETHERNET LED Color Description

TX Green Flashes during data transmission.

RX Green Flashes during data reception.

L Yellow Lights when a connection to a network is made.

FDX Green Lights during full duplex communication.

COL Red Lights if a COLLISION occurs during half duplexcommunication.

BT Green Lights during communication with 10BASE--T.

BTX Green Lights during communication with 100BASE--T.

(3) Driver/receiver ICIf the teach pendant cannot display anything because of, for example,a broken wire in the teach pendant connection cable, it is likely thatthe communication driver or receiver may be defective.

Name Drawing number

75172 A76L--0151--0098

75173 A76L--0151--0099

Please refer to Fig.4.1 Main board.


139

Total version

LED 1

LED 2

LED 3

Fig.4.2 Emergency stop control PC board

(1) LEDName Use

LED1Status of Relay KA1--1

ON ActiveOFF Inactive

LED2Status of KA2--1


LED3Status of KA3--1


4.2EMERGENCY STOPCONTROL PCBOARD(A20B--1007--0800)


140

Total version

(A20B--2002--0771)

Fig.4.3 (a) Backplane PC Board


HI1TEST1LOW1


4.3BACKPLANE PCBOARD


141

(A20B--2002--0761)

Totalversion

Test pins

Fig.4.3 (b) Backplane PC Board

(1) Test pins

Name Use

HI1TEST1LOW1



142

RDY LEDTotal version

PON LED

Fig.4.4 Panel Board

(1) LED

Name Use

RDYCommunication status with main board

ON NormalOFF Communication error

PON Lights when the internal power supply of the panel board outputs +5V normally.

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


143

Totalversion

Fig.4.8 Process I/O Board CA


P24VP5V

P15VCM15VCGND1GND2

+24V+5V+15V--15VGNDGND

For measuring the DC supply voltage

P10V +10V For measuring the reference voltage of thedigital/analog converter

P15VFM15VFGNDF

+15V--15VGND

Power for the digital/analog converter

AI1AI2AI3AI4AI5AI6

Channel 1Channel 2Channel 3Channel 4Channel 5Channel 6

For measuring the voltage of the analog inputsignal (analog/digital)

AOUT1AOUT2

Channel 1Channel 2

For measuring the voltage of the analog outputsignal (digital/analog)

4.5PROCESS I/OBOARD CA(A16B--2201--0470)


144

(2) Settings

Name Standardsetting Description

ICOM1 UDI1 to UDI20(Connector CRM2A) The common voltage is

ICOM2 UDI21 to UDI40(Connector CRM2B) Side A

The common voltage isadjusted to:

Side A : +24 V common

ICOM3 WDI01 to WDI08(Connector CRW1)

Side A : +24 V commonSide B : 0 V common

SP1 Channel 1Open

The polarity of the output voltageis switched to:

SP2 Channel 2Open

is switched to:Strapped : Negative (--)Open : Positive (+)

(3) AdjustmentVR1: Adjusts the gain of channel 1.

Execute a robot program and set AOUT[1] to 4095 on the teachpendant. Connect a digital voltmeter to test pin AOUT1 androtate VR1 until the meter reads 12.0 V.Connect the negative (--) lead of the digital voltmeter to test pinGNDF.

VR2: Adjusts the gain of channel 2.Execute a robot program and set AOUT[2] to 4095 on the teachpendant. Connect the digital voltmeter to test pin AOUT2 androtate VR2 until the meter reads 12.0 V.Connect the negative (--) lead of the digital voltmeter to test pinGNDF. (The 0VF test pin is different from the common 0V testpin.)

VR3: Adjusts the reference supply voltage of the digital/analogconverter.Connect the digital voltmeter to test pin P10V and rotate VR3until the meter reads 10.0 0.1 V.

(4) LEDs

Color Description

Red A communication alarm occurred betweenthe main CPU and process input/output.

Red A fuse (FUSE 1) in the process input/outputblew.


145

(5) Correspondence between driver chips and DO signalsOrdering code for the driver chips: A76L-0151-0062

Driver chip DO signal

DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED

DV2 HELD, FALT, ATPERCH, TPENBL

DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2

DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6

DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED

DV6 SDO01, SDO02, SDO03, SDO04





DV11 WDO01, WDO02, WDO03, WDO04

DV12 WDO05, WDO06, WDO07, WDO08

RESERVED For replacement


146

Test pins

Totalversion

Fig.4.9 Process I/O Board CB


P24V

P5V

P15VC

M15VC

GND1

GND2

+24V

+5V

+15V

--15V

GND

GND


(2) Settings


ICOM1 UDI1 to UDI20(Connector CRM2A)

Side A


ICOM2 UDI21 to UDI40(Connector CRM2B)

Side Aadjusted to:


4.6PROCESS I/OBOARD CB(A16B--2201--0472)


147

(3) LEDs

Color Description


Red A fuse (FUSE 1) in the process input/outputblew.





DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO










148

Total version

Test pins

Fig.4.10 Process I/O Board DA

(1) Test pins

Name Description

P24V

P5V

GND1

GND2

+24V

+5V

GND

GND


(2) Settings


ICOM1 UDI01 to 20(Connector CRM2A)

ICOM2 UDI21 to 40(Connector CRM2B)

ICOM3 UDI41 to 60(Connector CRM2C)

Side A


ICOM4 UDI61 to 80(Connector CRM2D)

Side Aadjusted to:


ICOM5 UDI81 to 88(Connector CRM4A)

ICOM6 UDI89 to 96(Connector CRM4B)

4.7PROCESS I/OBOARD DA(A16B--2201--0480)


149

(3) LEDs

Color Description


Red A fuse (FUSE 1) in the process input/outputbelow.





DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2








DV11 ADO21, SDO22, SDO23, SDO24
















150

Total version

Fig.4.11 Process I/O Board HA

(1) Test pins

Name Use

P24VP5V

GND1GND2GND3

+24V+5VGNDGNDGND


P24VFP5VFGNDF

+24V+5VGND

Power for the digital/analog converter

AO1AO2

Channel 1Channel 2

For measuring the voltage of the analog output sig-nal (digital/analog)

(2) Settings


ICOM1 UDI1 to UDI20(Connector CRM2A) The common voltage is

ICOM2 UDI21 to UDI40(Connector CRM2B) Side A


Side A : +24 V commonSid B 0 V

ICOM3 WDI01 to WDI08(Connector CRW7)

Side B : 0 V common

4.8PROCESS I/OBOARD HA(A16B--2203--0760)


151

(3) AdjustmentVR1/VR2: Adjusts the gain and the offset of channel 1.

Execute a robot program and set AOUT[1] to 3413 on the teachpendant. Connect a digital voltmeter to test pin AOUT1 androtate VR1 or VR2 until the meter reads 15.0 V.Connect the negative (--) lead of the digital voltmeter to test pinGNDF.

VR3/VR4: Adjusts the gain and the offset of channel 2.Execute a robot program and set AOUT[2] to 3413 on the teachpendant. Connect the digital voltmeter to test pin AOUT2 androtate VR3 or VR4 until the meter reads 15.0 V.Connect the negative (--) lead of the digital voltmeter to test pinGNDF. (The 0VF test pin is different from the common 0V testpin.)

(4) LEDs

Color Description

ALMO

FALM

Red A communication alarm occurred betweenthe main CPU and process I/O board.

ALMO

FALM

Red A fuse (FUSE 1) in the process I/O boardblew.



DV1 CMDENBL, SYSRDY, PROGRUN, PAUSEDDV2 HELD, FALT, ATPERCH, TPENBLDV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVEDDV6 SDO01, SDO02, SDO03, SDO04DV7 SDO05, SDO06, SDO07, SDO08DV8 SDO09, SDO10, SDO11, SDO12DV9 SDO13, SDO14, SDO15, SDO16



152

Total version

Fig.4.12 Panel Switch Board

4.9PANEL SWITCHBOARD(A20B--1007--0850)

B--81465EN--1/02 5. SERVO AMPLIFIERSMAINTENANCE

153

5 SERVO AMPLIFIERS

The servo amplifiers are factory-set for operation. Usually, you do notneed to set or adjust them.This chapter describes the standard settings and adjustment required if adefective servo amplifier is replaced. It also describes the use of test pinsand meanings of the LED indications.

Table 5 Servo amplifier specifications

Robot models Servo amplifier Regenerative resistor unitR--2000iA A06B--6105--H002 A05B--2452--C200 (B--cabinet)

M--6iB A06B--6105--H003 A05B--2452--C201 (B--cabinet)

ARC Mate 100iB

( )

Check that the voltage is not higher than 50 V.

NOTEBefore touching the servo amplifier, for example, formaintenance purposes, check the voltage at the screwabove the LED “D7” with a DC voltage tester to see if theremaining voltage is not higher than 50 V.

5. SERVO AMPLIFIERS B--81465EN--1/02MAINTENANCE

154

LED D7

LED Color Description

P5V Green Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally.

P3.3V Green Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V normally.

SVEMG Red Lights when an emergency stop signal is input to the servo amplifier.

ALM Red Lights when the servo amplifier detects an alarm.

RDY Green Lights when the servo amplifier is ready to drive the servo motor.

OPEN Green Lights when the communication between the servo amplifier and the main board is normal.

WD Red Lights when a watch dog alarm is detected in the servo amplifier.

D7 Red Lights when the DCLINK circuit inside the servo amplifier is charged to reach a specific voltage.

5.1LED OF SERVOAMPLIFIER

B--81465EN--1/02 5. SERVO AMPLIFIERSMAINTENANCE

155

Settings


COM1 Side A This jumper sets the common voltage for theRobot digital Inputs (RDI) to:

Side A : +24V commonSide B : 0V common

Fuse F2Fuse F1

Fuse FS1

Setjumper

Fuse FS2

Fuse FS3

5.2SETTING OF SERVOAMPLIFIER

5. SERVO AMPLIFIERS B--81465EN--1/02MAINTENANCE

156

DIO19 DIO18 DIO17

Correspondence between driver chips and DO signalsOrdering code for the driver chips : A76L--0151--0062


DIO17 RDO1, RDO2, RDO3, RDO4

DIO18 RDO5, RDO6, RDO7, RDO8

DIO19 XRESERVE, XBRKRLS1, XBRKRLS2, XBRKRLS3

5.3DRIVER CHIP FORROBOT DI/DO

B--81465EN--1/02 MAINTENANCE 6. SETTING THE POWER SUPPLY

157

6 SETTING THE POWER SUPPLY

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

B--81465EN--1/02MAINTENANCE6. SETTING THE POWER SUPPLY

158

CR

M64

CR

M64

+24V

+24E

200VAC

Robot

AC input380 -- 415 VAC440 -- 500 VAC3φ

Transformer

Breaker210VAC

210VAC

Servo amplifier(6--axis amplifier)

Backplane Power supplyunit

CP1

CP2

CP3

CP5

CP6

DC/DC+5V, +3.3V+15V, --15V+24V, +24E

FAN

210VAC

+24V

+24E

CP5A

CP6

CRR38

CRM67CRM67

CP2

+24E

Main board

JD5A

BATTERY

Process I/Oboard

CRM2CRM4

End Effector

Motor

Panel board

DC/DC+5V

CRS16Teach pendant

Handy file etc.

+24T

Peripheral device+24F

F1

F4

F3

FUSE2

+24V

+24EXTFUSE1

E--STOPCIRCUIT

DC/DC+5V, +3.3V+15V, --15V

FS1

FS3 Regenerative res.Aux.Axis

FS2

Breaker

+24E

CP5A

FUSE1

+24E

+24E

+24E

CP8B

JD5B

JD17

+24E+24V--15V+15V+5V+3.3V

CR

M64

CR

M64

Pow

er

Brake

Pulsecoder

+5V

+24VF

CN

J

CR

R64

CR

F7

Noise

filter

E--stop unit

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

6.1BLOCK DIAGRAM OFTHE MAIN POWERINCLUDING POWERSUPPLY


159

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

Rated Transformer specificationRatedVoltage 7.5KVA 3KVA

Type I500-575

A80L 0026 0035 A80L 0024 0025Type I440-480

A80L--0026--0035 A80L--0024--0025

Type II380-415

A80L 0026 0036 A80L 0024 0026Type II440-500

A80L--0026--0036 A80L--0024--0026

Type III380-400

A80L 0026 0037 A80L 0024 0027Type III200-230

A80L--0026--0037 A80L--0024--0027

Fig.6.2 (a) Transformer mounting locations and structure

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

Insert the connector connected to the circuitbreaker into connector LB and the dummyplug into connector LA.

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

Insert the connector connected to the circuitbreaker into connector LA and the dummyplug into connector LB.

6.2SELECTINGTRANSFORMERTAPS

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

Transformer

Structure of transformer

B--81465EN--1/02MAINTENANCE6. SETTING THE POWER SUPPLY

160

3 Type III: 200--230 V Use the ∆ connection cable.

4 Type III: 380--400 V Insert the connector connected to the circuitbreaker into connector LA and use the Y con-nection cable for connector LB.

Fig.6.2 (b) Setting a tap


161

The power supply unit need not be set or adjusted.

Table 6.3 Rating of the Power supply unit

Output Rated voltage Tolerance

+5V +5.1V 3%

+3.3V +3.3V 3%

+24V +24V 5%

+24E +24E 5%

+15V +15V 10%

--15V --15V 10%

6.3CHECKING THEPOWER SUPPLYUNIT

B--81465E

N--1/02

MA

INT

EN

AN

CE

6.S

ET

TIN

GT

HE

PO

WE

RS

UP

PLY

162

F3 7.5Afuse for +24E

F4 7.5Afuse for +24V

PILLED for indicating theAC power supplystatus (Green)

ALMLED for indicatingthe alarm (Red)


CP5 : +24V

CP6 : +24E

Fig

.6.3(a)

Interface

ofth

ep

ow

ersu

pp

lyu

nit

B--81465E

N--1/02

MA

INT

EN

AN

CE

6.SE

TT

ING

TH

EP

OW

ER

SU

PP

LY

163

F3

F4

R2

R1

S2

S1

G2G1

AC

OUTPUT

+5.1V

0V

+3.3V

0V

+24E

+24V

0V

+15V

--15V

ENA

EN5

FA

FB

+5.1

0V

+3.3

0V7.5A

7.5A

+15

--15

0V

+24

+3.3VDC

REGULATOR

REGULATOR

15VDC

+5.1VDC REGULATOR

+24VDC REGULATOR

P280

P0

NF

A24A12

A5

0V

P280 P22 A24 A5

+5.1+3.3

+24+15

--15

CONTROLCIRCUIT

P0 0V

AUX P.S.

P0

P22

F1 8AR

S

G

AC INPUT

ON

COMOFF

ALM

A24HILO

Fig

.6.3(b

)B

lock

diag

ramo

fthe

po

wer

sup

ply

un

it

7. REPLACING A UNIT B--81465EN--1/02MAINTENANCE

164

7 REPLACING A UNIT

This section explains how to replace each unit in the control section.

WARNINGBefore you start to replace a unit, turn off the control unitmain power. Also keep all machines in the area of the controlunit switched off. Otherwise, you could injure personnel ordamage equipment.

B--81465EN--1/02 7. REPLACING A UNITMAINTENANCE

165

CAUTIONSWhen you replace printed--circuit boards, observe thefollowing cautions:

1 Keep the control unit power switched off.2 When you remove a printed--circuit board, do not touch the

semiconductor devices on the board with your hand ormake them touch other components.

3 Make sure that the replacement printed--circuit board hasbeen set up appropriately. (Setting plug etc.)

4 If the backplane board, power supply unit, or main board(including cards and modules) is replaced, it is likely thatrobot parameters and taught data are lost. Before you startto replace these components, save a backup copy of therobot parameters and taught data to a memory card, floppydisk, or any other external memory device.

5 Before you disconnect a cable, note its location. If a cableis detached for replacement, reconnect it exactly as before.

When replacing the backplane board, do so together with the plastic rack.

(1) Detach the cables from the power unit and boards on the backplaneboard.

CAUTIONWhen you remove the main board, be sure that the batteryis good (3.1--3.3VDC) and it is installed correctly. USESTATIC PROTECTION.

(2) Remove the power unit and boards from the rack. (See Section 7.1.2.)(3) Detach the grounding cable from the backplane unit.(4) Loosen the retaining screws in the upper section of the rack. Remove

the retaining screws from the lower section of the rack.(5) Side rack up and out.(6) To replace the backplane and rack, reverse steps (1) -- (6).

CAUTIONThere is a possibility of data loss when a backplane--mounted printed circuit board is replaced. Be sure to backup all program and setup data on a floppy disk beforeproceeding.

7.1REPLACING THEPRINTED--CIRCUITBOARDS

7.1.1Replacing theBackplane Board (Unit)


166

Fig.7.1.1 Replacing the Backplane Board

The backplane unit incorporates the power unit, main board, and optionboards. There are two types of option boards: Full--size board andmini--size board. A full--size board occupies one slot. A mini--size boarduses part of a full--size board.

CAUTIONBefore starting replacement, turn off the control unit mainpower. The main board is equipped with battery--backedmemory devices for holding robot parameters and taughtdata, for example. When the main board is replaced, thedata in the memory devices is lost.

(1) Detach the cable from the power supply unit or the printed--circuitboard, whichever is to be replaced.

(2) Pinch the barbed handles on the upper and lower sections of the boardto unlatch it, then pull it toward you.

(3) Place the replacement board on the rail in the appropriate slot of therack, then push it in gently by the handles until it is latched.

(4) There are two rails in the main board SLOT (slot 1). When insertingthe main board, align it to the right--side rail.

(5) There are two rails in slots 3 and 5 (slots for a full--size option board).When you insert a full--size option board, align it to the left--side rail.

7.1.2Replacing the PowerUnit andPrinted--Circuit Boardson the Backplane Unit


167

SLOT 1

Handles

SLOT 2SLOT 3

SLOT 1

SLOT 10

SLOT 9SLOT 8

PSU(Power supplySLOT)

Handles

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


168

The panel board is at the back of the operator panel.

(1) Detach all cables from the panel board. The terminal blocks (TBOP3,TBOP4 and TBOP6) are of a connector type. Pull out the upperterminal block sections.

(2) Remove four retaining screws from the panel board, and remove thepanel board.

4--M3screws

B--cabinet

Fig.7.1.3 Panel board replacement

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

2--M3 screws

(4) Attach two plates to new panel board by two screws, then attach thepanel board to the oparator panel by four screws.

7.1.3Replacing the PanelBoard


169

CAUTIONBefore you start to replace a card or module, make a backupcopy of robot parameters and taught data. If the FROM/SRAMmodule is replaced, memory contents are lost.

Demounting a Card(1) Pull outward the clip of each of the two spacers used to secure the card

PCB, then release each latch.(2) Extract the card upward.

Card Card

Card

Card

Spacer

Spacer

Connector

Connector

Card

Fig.7.2(a) Demounting a card

7.2REPLACING CARDSAND MODULES ONTHE MAIN BOARD


170

Mounting a Card(1) Check that the clip of each of the two spacers is latched outward, then

insert the card into the connector.(2) Push the clip of each spacer downward to secure the card PCB.

Card

CardCard

Card

Spacer

Spacer

Connector

Connector

CardCard

Fig.7.2(b) Mounting a card


171

Demounting a module

CAUTIONWhen replacing the module, be careful not to touch themodule contact. If you touch the contact inadvertently, wipeout dirt on the contact with a clean cloth.

(1) Move the clip of the socket outward. (a)(2) Extract the module by raising it at a 30 degree slant and pulling

outward.

Mounting a module(1) Insert the module at a 30 degree slant into the module socket, with

side B facing upward. (b)(2) Push the module inward and downward until it is locked. (c)

(a)

(b)

(c)

Fig.7.2(c) Demounting/Mounting a module


172

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

FROM/SRAM module

Main board

CPU card

Axis control card

Fig.7.2(d) Locations of Cards and Modules


173

WARNINGBefore you start replacement procedure, turn off the mainpower to the control unit. The transformer is quite heavy; itweighs 45 to 60 kg.

In case of B--cabinet

(1) Remove the six M4 screws and detach the back panel.

6--M4 screws

7.3REPLACING THETRANSFORMER


174

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

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


175

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

2--M6 screwsShape of the transformer

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


176

WARNINGBefore you start, turn off the control unit main power.Be careful not to get burned, because the regenerativeresistor unit is very hot immediately after operation.

In case of B--cabinet(1) Remove the servo amplifier. (See “Replacing the servo amplifier.”)(2) Remove two M4 screws, then detach the housing that fastens cables.

2--M4 screws

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

2--M5 nuts

(4) Install a replacement regenerative resistor unit and a servo amplifierby reversing the procedure (1) to (3).

7.4REPLACING THEREGENERATIVERESISTOR UNIT


177

WARNINGBefore you start replacement, turn off the control unit mainpower.

B--cabinet(1) Detach the cables from the emergency stop unit.

(2) Remove retaining screws (4--M4) from the emergency stop unit, andreplace the emergency stop unit.

(3) Reconnect the cables.

B--cabinet

E--stop unit

4--M4 screws

Fig.7.5 Replacing the Emergency Stop Unit

7.5REPLACING THEE--STOP UNIT


178


In case of B--cabinet

(1) Turn the four screws, detach the amplifier cover, and pull out thecable.

Amplifier cover

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

7.6REPLACING SERVOAMPLIFIERS


179

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

Check that the voltage is not higher than 50 V.

(3) Remove the two screws located on the top of the amplifier.At the middle of the top of the amplifier, there is an M5 screw thatfastens the amplifier during transport of the cabinet. After theinstallation of the cabinet, remove the screw.This improves maintainability.

ScrewFixation screw fortransport (MS)

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


180

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

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

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

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


181

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

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

(7) Install a replacement servo amplifier by reversing step (b).

(8) Re--attach the cables.


182


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

M4 screw (4 pieces)

B--cabinet

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

7.7REPLACING I/O UNITMODEL A

7.7.1Replacing the BaseUnit of I/O Unit Model A


183

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

(a) Put the upper hook of the module into the upper hole of the base unit.

(b) Fit the connectors of the module and the base unit to each other.

(c) Push the module until the lower stopper of the module is caught in thelower hole of the base unit.

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

(b) Lift the module up.

Fig.7.7.2 Replacing the module

7.7.2Replacing a Module

Installing a module

Removing a module


184

The specifications of the teach pendant vary with its use. When youreplace the teach pendant, check its specifications carefully.

(1) Be sure that the power of a robot controller is off.

(2) Detach the cable from the teach pendant.

(3) Replace the teach pendant.

Detach or attach the cable by rotatingthe connector retaining ring.

Fig.7.8 Replacing the Teach Pendant

7.8REPLACING THETEACH PENDANT


185

The control section fan motor can be replaced without using a tool. Thefan motor is mounted on the fan unit rack.

(1) Be sure that the power of a robot controller is off.

(2) Put your finger in the dent in the upper section of the fan unit, and pullthe fan unit until it is unlatched.

(3) Lift the fan unit slightly, and dismount it from the rack.

(4) Place a replacement fan on the upper section of the rack, and slide itgently until it is latched.

Fan motor connector

Fan motor

Pull the fan motor unittoward you to unlatch it.

Fig.7.9 Replacing the Control Section Fan Motor

7.9REPLACING THECONTROL SECTIONFAN MOTOR


186

WARNINGBefore you start replacement, turn off the control unit mainpower. Do not touch the fan motor when it is rotating, or youcould be injured.

Door fan

(1) Detach the cable from the fan unit.

(2) Remove the two retaining M4 screws from the fanunit, thendismountit.

(3) Install a new fan unit by reversing the dismounting procedure.

External Air fan unit

(1) Detach the cable.

(2) Remove the six M4 screws and pull out the fan unit toward you.

(3) Install a new fan unit by reversing the dismounting procedure.

Screw (2--M4)

Screw (6--M4)

Floor fan unit

(1) Remove the cable from the fan unit.

(2) Remove the fan by unscrewing the two retaining M4 screws.

(3) Reverse the procedure to mount a spare fan unit.

7.10REPLACING THE ACFAN MOTOR

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


187

Floor fan unitScrew (2--M4)


188

(1) Detach the cable (CRT8, CRM51)

(2) Straighten the 12 claws on the printed circuit board, then remove theprinted circuit board.

(3) Remove the six (6--M3) screws, then remove the panel switch board.

(4) Install a new panel switch board by reversing the dismountingprocedure.

Screw (6--M3)

Straighten the claws.

Fig.7.11 Replacing the operator panel and Panel switch board

7.11REPLACING THEOPERATOR PANELAND PANEL SWITCHBOARD


189

(a) Remove the cable from the mode switch.

(b) Remove the screws fastening the mode switch, and replace the modeswitch.

NOTE1 When mounting the mode switch, do not overtighten the

screws. (Tightening torque: 2.5 kg·cm)2 Tighten the screws evenly so that the mode switch flat

surface becomes parallel-- to the sheet metal.

Door

Mode switch

Screw

Fig.7.12 Replacing the Mode Switch

7.12REPLACE THE MODESWITCH


190

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

The following fuses are in the servo amplifier.

F1, F2:Fuses for detection of the circuits failure in the servo amplifier,(A60L--0001--0245#GP20)If either of these fuses has blown, it is likely that the servo amplifieris defective. Replace the servo amplifier.

FS1:For generation of the power to the amplifier control circuit(A60L--0001--0290#LM32C)

FS2:For protection of the 24 V output to the end effector, ROT, and HBK(A60L--0001--0290#LM32C)

FS3:For protection of the 24 V output to the regenerative resistance andthe additional axis amplifier (A60L--0001--0290#LM50C)

Fuse F2Fuse F1

Fuse FS1

FuseFS2

Fuse FS3

Fig.7.13.1 Replacing Fuses in the Servo Amplifier

7.13REPLACING FUSES

7.13.1Replacing Fuses in theServo Amplifier


191

The following fuses are in the power unit.

F1: Fuse for the AC input, A60L--0001--0396#8.0AF3: Fuse for protecting the +24E output, A60L--0001--0046#7.5F4: Fuse for protecting the +24V output, A60L--0001--0046#7.5

F1 8.0AAC input fuse

F3 7.5A+24E fuse

F4 7.5A+24V fuse

Fig.7.13.2 Replacing Fuses in the Power Unit

7.13.2Replacing Fuses in thePower Unit


192

The following fuse is on each process I/O board.

FUSE1:Fuse for protecting the +24V output for peripheral equipmentinterfaces.

A60L--0001--0046#2.0

FUSE1

Total version


Process I/O board DA

FUSE1

Total version

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

7.13.3Replacing the Fuse onthe Process I/O Boards


193


FUSE1

Total version


194

The following fuse is on the panel board.FUSE1 : For protection of the +24EXT line (emergency stop line)FUSE2 : For protection of the teach pendant emergency stop line

A60L--0001--0046#1.0

Fuse 1

Fuse 2

Fig.7.13.4 Replacing the fuse on the panel board

7.13.4Replacing the Fuse onthe Panel Board


195

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

KA21, KA22: Relay for emergency stop circuitA58L--0001--0192#1509A

KA22 KA21

Fig.7.14.1 Replacing Relays on the Panel Board

7.14REPLACING RELAYS

7.14.1Replacing Relays onthe Panel Board


196

The programs, and system variables are stored in the SRAM in the mainboard. The power to the SRAM memory is backed up by a lithium batterymounted on the front panel of the main board. The above data is not losteven when the main battery goes dead. A new battery can maintain thecontents of memory for about 4 years (Note).When the voltage of the battery becomes low, the low--voltage batteryalarm (system--035) is displayed on the teach pendant. When this alarmis displayed, replace the battery as soon as possible. In general, thebatterycan be replaced within one or two weeks, however, this depends on thesystem configuration.If the battery voltage gets lower, it becomes impossible to back up thecontent of the SRAM. Turning on the power to the in this state causessystem not to start and LED of seven segment on the main board to bedisplayed “1” because the contents of memory are lost. Clear the entireSRAM memory and reenter data after replacing the battery. Importantdata should be saved to the memory card or floppy disk beforehand in caseof emergency.When replacing the memory backup battery, do so while the robotcontroller is turned off in case of emergency.

NOTEIn a newly introduced robot, the battery is factory--installed.Battery replacement may, therefore, be needed within 4years after the introduction of the robot.

(1)Prepare a new lithium battery (ordering drawing number:A02B--0200--K102).

(2)Turn the robot controller on for about 30 seconds.(3)Turn the robot controller off.(4)Remove the old battery from the top of the main board.

First unlatch the battery, remove it from the battery holder, and detachits connector.

7.15REPLACINGBATTERY

7.15.1Battery for MemoryBackup (3 VDC)

Replacing the lithiumbattery


197

Battery latch

Lithium batteryBatteryconnector

(5)Remove the old battery, insert a new one into the battery holder, andattach the connector. Confirm that the battery is latched firmly.

WARNINGUsing other than the recommended battery may result in thebattery exploding.Replace the battery only with the specified battery(A02B--0200--K102).

CAUTIONComplete the steps (3) to (5) within 30 minutes.If the battery is left disconnected for a long time, thecontents of memory will be lost.To prevent possible data loss, it is recommended that therobot data such as programs and system variables bebacked up before battery replacement.

Dispose of the replaced battery as an industrial waste, according to thelaws and other rules in the country where the controller is installed andthose established by the municipality and other organizations that havejurisdiction over the area where the controller is installed.

III CONNECTIONS

B--81465EN--1/02 1. GENERALCONNECTIONS

201

1 GENERAL

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

2. BLOCK DIAGRAM B--81465EN--1/02CONNECTIONS

202

2 BLOCK DIAGRAM

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

Pneumaticpressure sourceR--J3iB

(B--cabinet)

Mechanical unit

Memory card(PCMCIA)

Teach pendant

RS--232--C

Peripheral device

Welding machine

Ethernet

AC power supply

End effector

(Note2)

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

NOTE1 : Indicates electrical connection.

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

B--81465EN--1/02 3. ELECTRICAL CONNECTIONSCONNECTIONS

203

3 ELECTRICAL CONNECTIONS

3. ELECTRICAL CONNECTIONS B--81465EN--1/02CONNECTIONS

204

RobotR-J3iB

CRF7(Pulsecoder signal,

RDI/RDO, ROT,HBK)

CNJ1A(J1 motor power)






CNGA(J1--J3 ground)

CNGB(J4--J6 ground)

CRR64(Brake control)

End effector

RP1(Pulsecoder signalRDI/RDO, ROT, HBK)

(Note)

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

EE

Fig.3.1 (a) Mechanical Connection Diagram

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

3.1CONNECTIONDIAGRAM BETWEENMECHANICAL UNITS


205

(NOTE2)

(NOTE2)

(NOTE2)

(NOTE2)

R-J3iB

CRS16(Panel board)

CRM2, CRM4(Process I/O)

Port A(Operator panel)

Panel board(TBOP3)

JD5B(Main board)

JD17(Main board)

CD38(Main board)

L1L2L3G

Braker

ON1ON2

OFF1OFF2

EES1EES11EES2

EES21

Panel board(TBOP4)

EAS1EAS11EAS2

EAS21

Panel board(TBOP4)

EGS1EGS11EGS2

EGS21

Panel board(TBOP4)

(NOTE1)

(NOTE2)

(NOTE2)

(NOTE2)

Teach pendant

Peripheral device

Handy File

External device

External device

Ethernet

Input power

External powerON/OFF switch

Fence

Servo off switch

External emergencystop switch

Fig.3.1 (b) Mechanical Connection Unit

NOTE1 For detail of the peripheral device connection, see the section of Peripheral device interface.2 This cable is not included. It must be supplied by the customer.


206

Robot Model R--2000iAM--6iBARC Mate 100iB

(B--Cabinet)

D Detail of cable connection to servo amplifier.

Robot

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

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

R--J3iB (Servo amplifier)

CRR64 CNGA CNJ6 CNJ5

CNJ4 CNJ3A CNJ2A CNJ1A

CNGB

CRF7

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

3.2EXTERNAL CABLEWIRING DIAGRAM

3.2.1Robot ConnectionCables


207

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

Teach pendantconnection cable

Teach pendant

Fig.3.2.2 Teach Pendant Cable

3.2.2Teach Pendant Cable


208

Considering the robot power capacity and the circuit breaker capacity,connect the power supply whose voltage conforms to the installationconditions to the terminal located above the circuit breaker.

Provide a class--D or better ground.The resistance to the ground must not exceed 100Ω.Be sure to ground the work table or jig used by an arc welding robot orthe like so that it can handle a large current.Use a thick wire to withstand the maximum current used.Selection of an input transformer tap is necessary depending on the inputvoltage.The tap is set to the specified voltage before shipment. However, checkit referring to section 6.2 in “Maintenance” before supplying power(before the breaker switch is turned on).The motor is driven by the PWM inverter system using a power transistorbridge. If the servo amplifier is used without a transformer, ahigh-frequency leakage current flows through the stray capacitancebetween the ground and the motor coils, power cable, and amplifier. Thismight cause the leakage-current circuit breaker or leakage-protectionrelay installed in the path of the power supply to cut out.Use the following leakage current circuit breaker for inverters to preventincorrect operation.

Example of Leakage Current Circuit Breaker for Inverters

Manufacture Type

Fuji Electric Co., Ltd. EG A seriesSG A series

Hitachi, Ltd. ES100C typeES225C type

Matsushita ElectricWorks, Ltd.

Leakage current circuit breaker, C typeLeakage current circuit breaker, KC type

Fig. 3.2.3 shows the cable connection.

3.2.3Connecting the InputPower


209

(Note) Always replace the coverafter completing

B--cabinet

Input Power supplycable

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


210

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

TBOP3

Panel board

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

3.2.4Connecting theExternal Power SupplyON/OFF Switch


211

EXOFF1--2

ON/OFF SW

on operator panel

Power

Note1) In case of using the external ON/OFF control, the ON/OFF switch on operator panel must be turned ON.Note2) When the external ON/OFF switch is turned ON (Closed), the ON/OFF switch on operator panel can turn ON the

controller.Note3) When the external ON/OFF switch is turned OFF (Open), the ON/OFF switch on operator panel can not turn ON

the controller.

ON

OFF

Close

Open

ON

OFF

TOFF--ON

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

Short piece between EXON1 and EXON2

External ON/OFF switch.

In case of using externalON/OFF switch, removethe short piece between EXOFF1and EXOFF2, then connectthe wires.

TOFF--ON ≧ 5 sec

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


212

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

3.2.5Connecting theExternal EmergencyStop


213

.

Signal Description Current, voltage

ESPB1ESPB11

ESPB2ESPB21

Emergency stop output signals.These contacts are open if anemergency stop of teach pendantor operator panel occurs or the

Rated contact:250 VAC, 5-A or

ESPB3ESPB31

ESPB4ESPB41

or operator panel occurs or thepower is turned off. (Note 1)These contacts are closed duringnormal operation.

250 VAC, 5 A or30 VDC, 5A re-sistor load

Fig.3.2.5 (b) External emergency stop output

NOTE1 The relays for emergency stop output signals can be connected external power source.

The power for relays are connected controller’s power at the factory, and please connectexternal power source if emergency stop output must not be effected controller’s power.Please refer to “External power connection”.

External emergency stop output


214

Signal Description Current, voltage

EES1EES11

EES2EES21

Connect the contacts of the external emergency stop switch to these termi-nals. When using the contacts of a relay of contactor instead of the switch,connect a spark killer to the coil of the relay or contactor, to suppress noise.When these terminals are not used, jumper them.

Open and close of24VDC 10mA

EAS1EAS11

EAS2EAS21

These signals are used to stop the robot when the door on the safety fenceis open.While the deadman’s switch on the teach pendant is pressed and the teachpendant enable switch is validated, these signals are ignored and an emer-gency stop does not occur.If these signals are not used, short these terminals.


EGS1EGS11

EGS2EGS21

Connect the contacts of the servo--on input switch to these terminals. Whenusing the contacts of a relay or contactor instead of the switch, connect aspark killer to the coil of the relay or contactor, to suppress noise.When these terminals are not used, jumper them.


SD4SD41

SD5SD51

Connect the contacts of the servo--disconnect input switch to these termi-nals. When using the contacts of a relay or contactor instead of the switch,connect a spark killer to the coil of the relay or contactor, to suppress noise.When these terminals are not used, jumper them.


External emergency stop input

After connecting an external emergency stop switch and safety fence door switch, be sure to check the operations of thoseswitches, the emergency stop switch on the operator’s panel, and the emergency stop switch on the teach pendant.

Use a contact which minimum load is 5mA less.


215

l.

CAUTION1 Single chain failure will occure, if this input requirements are

not satisfied.2 Single chain failure can’t be reset until special reset

operation even if controller power is OFF and ON.

Input requirement for external emergency stop and etc.

The emergency stop circuit is composed of a chain of contacts.D Please connect dual contacts, which work same time, for external emergency stop, safety fence switch, servo ON/OFF

switch and servo disconnect switch.D Please observe following timing.If input requirements are not satisfied, it may occure single chain failure.


216

Extenal power connection

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


217

Details of the signal wires are shown below:

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

Bare wire length: 8 to 9 mm

Compliant wire size: 0.08 to 2.5 mm2

How to attach signal wires to connectors

Manipulation slot

Flat--blade screwdriver

Plug connector block

Signal wire

1. Detach the plug connector block from the panel board.2. Insert the tip of a flat--blade screwdriver into the manipulation slot and push down its handle.3. Insert the end of the signal wire into the wire slot.4. Pull out the screwdriver.5. Attach the plug connector block to the panel board.

Do not insert a wire into the wire hole of a plug connector or pull it out with the plug connectorblock mounted on the panel board; otherwise, the panel board may be damaged.

If you want to use a rod terminal, select one that is suitable for the wire shown above.The following table lists recommended products (manufactured by Weissmuller).

Wire (mm2) Specification Remark0.5 H0.5/14

Withinsulation

cover

0.75 H0.75/141.0 H1.0/141.5 H1.5/142.5 H2.5/14

(Crimping tool : PZ3, PZ4, PZ6/5)


218

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

Handling of the LeverWire stripping

Wiring

Replace the lever

Fit to header

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

F Please check the strip length carefully.

F Please readjust the loose end.

F Hold the connector, andpush down the lever byfinger

F Don’t handle the leverafter fit the connectorinto the PCB, otherwisePCB will be damaged byhandling stress.

(1) Pull down the lever.

(2) Hook the leverto the rectanglehole.

(2) Push in the conductorwith holding the lever.

(3) Set the lever free.L And pull the conductor

softly to check the clamping

L Don’t pull strongly

(1) Pull off thelever.

(3) Push down the lever untillclick in.

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

L Be careful to fit theshape of each other.


219

Installation of “Jumper”

Availability of wires

Installation of “Ferrules”

Specifications of Ferrules

F Without jumpers

(1) Attach levers to connector. L Please check the directionof the jumper.

(2) Hold down levers at the sametime, then put the jumper intoconnector.

F With jumper F With two jumpers

L Max wire size … 2.0mm2 (AWG14)(with “Ferrule”)

F Additional wire is available underthe jumper.

F Additional wire isNOT avairable underthe jumper.L Max wire size … 0.5mm2 (AWG20)

(with “Ferrule”)

(1) Put the wire through thehole of ferrules.

(2) Introduce wirewith ferrule intocramping station.

(3) Squeeze handles untilratchet mechanism isreleased.

Crimping Toole ( : WAGO Item--No.206--204)

(4) Please check ifthe wire crimpedcorrectly.

WAGOItem--No.

216--301216--302

216--201216--202216--203

216--204216--205

Sleep formm2 (AWG)

0.25 (24)0.34 (24)

0.5 (22)0.75 (20)1.0 (18)

1.5 (16)2.0 (14)

Color

yellowgreen

whitegrayred

blackyellow

StrippedLengt (m)

9.59.5

9.510.010.0

10.010.0

L1

8.08.0

8.08.08.0

8.08.0

D2

0.80.8

1.01.21.4

1.72.0

Pack.--unitpcs

100100

100100100

100100

L

12.512.5

14.014.014.0

14.014.0

D(m)

2.52.5

3.13.33.5

4.04.2

D1

2.02.0

2.62.83.0

3.53.7

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

4. PERIPHERAL DEVICE, ARC WELDING,AND END EFFECTOR INTERFACES B--81465EN--1/02CONNECTIONS

220

4PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTORINTERFACES

R-J3iB I/O peripheral device interfaces include printed circuit boards anda unit selected according to the applications. Table 4 lists details of theprinted--circuit boards and units. Figure 4 shows the locations of these boardsand units.

Table 4 Peripheral Device Interface Types

No Name Drawing numberNumber of I/O points

RemarksNo. Name Drawing numberDI DO D/A A/D

Remarks

1 Process I/O board CA A05B--2450--J001 40 40 2 6 Installed in backplane

2 Process I/O board CB A05B--2450--J002 40 40 0 0 Installed in backplane

3 Process I/O board DA A05B--2450--J003 96 96 0 0 Installed in backplane

4 Process I/O board HA A05B--2450--J004 40 40 2 0 Installed in backplane

5I/O Unit--MODEL A(B--cabinet)

A05B-2452-J100(Base and interface unit)

Depending on selected I/O mod-ule

NOTEGeneral purpose I/O (SDI/SDO) is a number which subtract an exclusive signal from the tablevalue.Example: Process I/O board CB

Table value Exclusive DI General purpose DIDI; 40 -- 18 = 22 points

Table value Exclusive DO General purpose DODO; 40 -- 20 = 20 points

I/O unit model A(5 slots)

Process I/Oprinted board

Fig.4 Locations of Peripheral Device Interfaces

B--81465EN--1/024. PERIPHERAL DEVICE, ARC WELDING,

AND END EFFECTOR INTERFACESCONNECTIONS

221

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

B--cabinet

Mainboard

JD1A(JD4)

Process I/OboardCA/CB/HA

CRM2A

CRM2B

CRW1or CRW7(NOTE2)

CRW2

JD4A(JD1B)

JD4B(JD1A)

Peripheraldevice

Process I/OboardCA/CB/HA

CRM2A

CRM2B

CRW1or CRW7(NOTE 2)

CRW2

JD4A(JD1B)

JD4B(JD1A)

1

2

3

4

5

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

4.1PERIPHERALDEVICE INTERFACEBLOCK DIAGRAM

4.1.1When Process I/OBoard CA/CB/HA isUsed (B--cabinet)


222

NOTE1 CRW1 and CRW2 are not provided for process I/O board

CB2 In case of process I/O CA : CRW1

In case of process I/O HA : CRW7

No. Name Drawing number Remarks

I/O link cable A05B--2452--J140 Between main board and process I/O

I/O link cable A05B--2452--J141 Between process I/O and process I/O

Peripheral device connection cable A05B--2452--J200 Cable length 10m (one cable)p

A05B--2452--J201 Cable length 20m (one cable)

A05B--2452--J202 Cable length 30m (one cable)

Welding device connection cable A05B--2452--J270 Cable length 3m (one cable) CRW1g(Process I/O CA)(FANUC interface)

A05B--2452--J271 Cable length 7m (one cable) CRW1(FANUC interface)

A05B--2452--J272 Cable length 14m (one cable) CRW1

Welding device connection cable A05B--2452--J273 Cable length 3m (one cable) CRW7g(Process I/O HA)(General interface)

A05B--2452--J274 Cable length 7m (one cable) CRW7(General interface)


Welding device connection cable A05B--2452--J276 Cable length 3m (one cable) CRW7g(Process I/O HA)(FANUC interface)

A05B--2452--J277 Cable length 7m (one cable) CRW7(FANUC interface)


1

2

3

4

5



223

B--cabinetPeripheraldevice

Main board

JD1A

CRM2A

CRM2B

Process I/Oboard DA

JD4A

JD4B

CRM2C

CRM2D

CRM4A

CRM4B

Process I/Oboard DA

JD4A

JD4B

CRM2D

CRM4A

CRM4B

CRM2C

CRM2B

CRM2A

1

2

3

4

5

6

7

8

Fig.4.1.2 Block diagram of the process I/O board DA

Cablenumber Name Drawing number Remarks

I/O link cable A05B--2452--J140 Between main board and process I/O

I/O link cable A05B--2452--J141 Between process I/O and process I/O

Peripheral device connection cable A05B--2452--J200 Connected length 10m (one cable)p

A05B--2452--J201 Connected length 20m (one cable)


Peripheral device connection cable A05B--2452--J250 Connected length 10m (one cable)p



4.1.2When Process I/OBoard DA is Used(B--cabinet)

1

2

3 4

5 6

7

8


224

Main board

JD1A

Peripheraldevice

Interface module

E--Stop unit

CP5A

1

2

2

2

2

2

Fig.4.1.3.1 Block diagram of I/O Unit--A (In case of B--cabinet)

Cablenumber Name Drawing number Remarks

I/O link cable — Included in A05B--2452--J100

Peripheral device connection cable — Must be supplied by the cus-tomer.

4.1.3When I/O Unit--MODELA is Used

4.1.3.1In case of B--cabinet

1

2



225

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

JD1B

JD1A

CP32

JD1A JD4A

JD4B

JD4A

JD4B

Main board B--cabinet

ProcessI/O board

ProcessI/O board

I/O Unit--AInterface module

Back plane (5--slot)

A05B--2452--J140

A05B--2452--J141

Included in modelA base unit

DC power is suppliedfrom the back plane.

CP5A

E--stop unit

4.1.4When Two or moreProcess I/O Boardsand I/O Unit (Model Aor Model B) are Used


226

One board or one unit is used

Combination C Process I/O board CA/CB/HA (40 points)

Combination D Process I/O board DA(96 points)

Combination E I/O Unit--A

Two boards/units are used in combinationCombination CC Process I/O board CA/CB/HA (40 points)

+Process I/O board CA/CB/HA (40 points)

Combination CE Process I/O board CA/CB/HA (40 points)+

I/O Unit--A

Combination DC Process I/O board DA (96 points)+

Process I/O board CA/CB/HA (40 points)

Combination DD Process I/O board DA (96 points)+

Process I/O board DA (96 points)

Combination DE Process I/O board DA (96 points)+

I/O Unit--A

Three boards/units are used in combinationCombination CCE Process I/O board CA/CB/HA (40 points)

+Process I/O board CA/CB/HA (40 points)

+I/O Unit--A

Combination DCE Process I/O board DA (96 points)+

Process I/O board CA/CB/HA (40 points)+

I/O Unit--A

Combination DDE Process I/O board DA (96 points)+

Process I/O board DA (96 points)+

I/O Unit--A

4.2PERIPHERALDEVICE INTERFACECOMBINATION

4.2.1In Case of B--cabinet



227

There are 18 exclusive data inputs (DI) and 20 exclusive data outputs(DO) for a process I/O board.

These signals are allocated to the process I/O board connected first whentwo or more printed boards are combined. (General signals SDI/SDO areallocated to the second and the following process I/O boards.)The common voltage of the DI signals input to pins 1 to 4 of connectorCRM2A is clamped +24 V (common) in each process I/O board.Table 4.3 shows signals of a process I/O board.

Table 4.3 Process I/O Board Signals (1/4)

(DI signals)

Connectornumber Signal name Description Remarks

CRM2A-1 *IMSTP Immediate stop Clamped at +24 Vcommon

CRM2A-2 *HOLD Temporary stop Clamped at +24 Vcommon

CRM2A-3 *SFSD Safe speed Clamped at +24 Vcommon

CRM2A-4 CSTOPI Cycle stop Clamped at +24 Vcommon

CRM2A-5 FAULT RESET External reset

CRM2A-6 START Start

CRM2A-7 HOME Return to homeposition

CRM2A-8 ENBL Operation enabled

CRM2A-9 RSR1 Robot service request

PNS1 Program numberselection

Option



Option



Option



Option



Option



Option



Option



Option

4.3PROCESS I/OBOARD SIGNALS


228

Table4.3 Process I/O Board Signals (2/4)

(DI signals)


CRM2A-29 PNSTROBE PNS strobe

CRM2A-30 PROD START Start of automaticoperation

CRM2A-31 SDI01 Peripheral devicestatus

General signal

CRM2A-32 SDI02

pstatus

CRM2B-1 SDI03

CRM2B-2 SDI04

CRM2B-3 SDI05

CRM2B-4 SDI06

CRM2B-5 SDI07

CRM2B-6 SDI08

CRM2B-7 SDI09

CRM2B-8 SDI10

CRMSB-9 SDI11

CRM2B-10 SDI12

CRM2B-11 SDI13

CRM2B-12 SDI14

CRM2B-13 SDI15

CRM2B-14 SDI16

CRM2B-15 SDI17

CRM2B-16 SDI18

CRM2B-29 SDI19

CRM2B-30 SDI20

CRM2B-31 SDI21

CRM2B-32 SDI22



229


(DO signals)


CRM2A-33 CMDENBL During automaticoperation

CRM2A-34 SYSRDY Preparationcompleted

CRM2A-35 PROGRUN Program running

CRM2A-36 PAUSED Program beinginterrupted

CRM2A-38 HELD During temporary stop

CRM2A-39 FAULT Alarm

CRM2A-40 ATPERCH Home position

CRM2A-41 TPENBL Teach pendantenabled

CRM2A-43 BATALM Battery voltage drop

CRM2A-44 BUSY During operation

CRM2A-45 ACK1 Robot service requestacceptance

SNO1 Selected programnumber

Option



Option



Option



Option



Option



Option



Option



Option

CRM2A-26 SNACK Response signal toPNS

CRM2A-27 RESERVED


230


(DO signals)


CRM2B-33 SDO01 Peripheral devicecontrol signal

General signal

CRM2B-34 SDO02

pcontrol signal

CRM2B-35 SDO03

CRM2B-36 SDO04

CRM2B-38 SDO05

CRM2B-39 SDO06

CRM2B-40 SDO07

CRM2B-41 SDO08

CRM2B-43 SDO09

CRM2B-44 SDO10

CRMSB-45 SDO11

CRM2B-46 SDO12

CRM2B-19 SDO13

CRM2B-20 SDO14

CRM2B-21 SDO15

CRM2B-22 SDO16

CRM2B-24 SDO17

CRM2B-25 SDO18

CRM2B-26 SDO19

CRM2B-27 SDO20



231

4.4INTERFACE FORPERIPHERALDEVICES, ENDEFFECTORS, ANDWELDERS


232

1 *IMSTP

*HOLD3 *SFSPD

CSTOPI5 FAULT RESET

7

9

2

4

6

8

10

12

14

16

11

13

15

1817

Peripheral device control interface A1CRM2A

START

HOMEENBL

RSR8/PNS80V0V

RSR7/PNS7RSR6/PNS6RSR5/PNS5RSR4/PNS4RSR3/PNS3RSR2/PNS2RSR1/PNS1

SNACK

SDI01PROD STARTPNSTROBE

COM--A5RESERVED

SDI02

ACK6/SNO6ACK5/SNO5ACK4/SNO4ACK3/SNO3

COM--A4

ACK8/SNO8ACK7/SNO7 ATPERCH

FAULTHELD

COM--A1PAUSED

PROGRUNSYSRDY

CMDENBL

COM--A3ACK2/SNO2ACK1/SNO1

BUSYBATALMCOM--A2TPENBL

+24E+24E

Control unit

33

35

37

39

41

34

36

38

40

42

44

46

48

43

45

47

5049

19

21

23

25

27

20

22

24

26

28

30

32

29

31

Peripheraldevice A1

1 SDI03

SDI043

SDI065

7

9

2

4

6

8

10

12

14

16

11

13

15

18

17

Peripheral device control interface A2CRM2B

SDI08

SDI09SDI10

SDI180V0V

SDI17SDI16SDI15SDI14SDI13SDI12SDI11

33

35

37

39

41

34

36

38

40

42

44

46

48

43

45

47

50

49

19

21

23

25

27

20

22

24

26

28

30

32

29

31

Peripheraldevice A2

SDI07

SDI05

SDO01

SDO02

SDO04

SDO05

SDO06SDO07

+24E+24E

COM--B3SDO12SDO11SDO10SDO09

COM--B2SDO08

COM--B1

SDO03SDO13

SDO14

SDO16

SDO17

SDO18SDO19

SDI22SDI21SDI20SDI19

COM--B5SDO20

COM--B4

SDO15

NOTE1 The peripheral device connection cables are optional.2 All of COM-** are connected to 0 V.

Applicable process I/O board type

CA, CB, DA, HA

4.4.1Peripheral Device andControl UnitConnection



233

Peripheral device control interface A3CRM2C

Control unit

1 SDI43

SDI443

SDI465

7

9

2

4

6

8

10

12

14

16

11

13

15

18

17

Peripheral device control interface A4CRM2D

SDI48

SDI49SDI54

SDI580V0V


33

35

37

39

41

34

36

38

40

42

44

46

48

43

45

47

50

49

19

21

23

25

27

20

22

24

26

28

30

32

29

31

Pripheraldevice A4

SDI47

SDI45

SDO41

SDO42

SDO44

SDO45

SDO46SDO47

+24E+24E

COM--D3SDO52SDO51SDO50SDO49

COM--D2SDO48

COM--D1

SDO43SDO53

SDO54

SDO56

SDO57

SDO58SDO59


COM--D5SDO60

COM--D4

SDO55

1 SDI23

SDI243

SDI265

7

9

2

4

6

8

10

12

14

16

11

13

15

1817

SDI28

SDI29SDI30

SDI380V0V


33

35

37

39

41

34

36

38

40

42

44

46

48

43

45

47

5049

19

21

23

25

27

20

22

24

26

28

30

32

29

31

Pripheraldevice A3

SDI27

SDI25

SDO21

SDO22

SDO24

SDO25

SDO26SDO27

+24E+24E

COM--C3SDO32SDO31SDO30SDO29

COM--C2SDO28

COM--C1

SDO23SDO33

SDO34

SDO36

SDO37

SDO38SDO39


COM--C5SDO40

COM--C4

SDO35

NOTE1 The peripheral device connection cables are optional.2 All of COM-** are connected to 0 V.


DA


234

Peripheral device control interface B1CRM4A

Control unit

Peripheral device control interface B1CRM4B

Peripheraldevice B2

SDI6302

SDI6504

06

01

03

05

07

SDI67

SDI68SDI69

15

17

19

14

16

18

20

08

10

12

09

11

13

Peripheraldevice B1

SDI66

SDI64SDO61

SDO63

COM--E1

+240V

SDO64

SDO62SDO65

SDO66

SDO68

SDI70COM--E2

SDO67

SDI7102

SDI7304

06

01

03

05

07

SDI75

SDI76SDI77

15

17

19

14

16

18

20

08

10

12

09

11

13

SDI74

SDI72SDO69

SDO71

COM--F1

+240V

SDO72

SDO70SDO73

SDO74

SDO76

SDI78COM--F2

SDO75

Control unit

NOTE1 The peripheral device connection cables are optional.2 All of COM--** are connected to 0V.


DA



235

RV

RV

RV

RV

*IMSTP

*HOLD

*SFSPD

RV

RV

RV

RV

RV

RV

RV

START

HOME

ENBL

RSR1/PNS1

RSR2/PNS2

RSR3/PNS3

RSR4/PNS4

+24E

RV

RV

RV

RV

RV

RV

RSR5/PNS5

RSR6/PNS6

RSR7/PNS7

RSR8/PNS8

PNSROBE

PROD START

RVSDI01

SDI02

RV

+24EB A

Common settingpin (ICOM1)

Receiver circuit

Connector pin No. Peripheral deviceControl unit(peripheral device control interface A1)

RV

FAULT RESET

CSTOPI

CRM2A (1)

CRM2A (2)

CRM2A (49,50)

CRM2A (3)

CRM2A (4)

CRM2A (5)

CRM2A (6)

CRM2A (7)

CRM2A (8)

CRM2A (9)

CRM2A (10)

CRM2A (11)

CRM2A (12)

CRM2A (13)

CRM2A (14)

CRM2A (15)

CRM2A (16)

CRM2A (29)

CRM2A (30)

CRM2A (31)

CRM2A (32)

NOTEThis is a connection diagram for +24v common.


236

CMDENBL

DV

DV

DV

DV

DV

DV

DV

FAULT

ATPERCH

TPENBL

BATALM

BUSY

ACK1/SNO1

ACK2/SNO2 DV

DV

DV

DV

DV

DV

ACK3/SNO3

ACK4/SNO4

ACK5/SNO5

ACK6/SNO6

ACK7/SNO7

ACK8/SNO8

DVSNACK

RESERVED

DV

Receiver circuit


DV

HELD

CRM2A (33)

CRM2A (38)

CRM2A (39)

CRM2A (40)

CRM2A (41)

CRM2A (43)

CRM2A (44)

CRM2A (45)

CRM2A (46)

CRM2A (19)

CRM2A (20)

CRM2A (21)

CRM2A (22)

CRM2A (24)

CRM2A (25)

CRM2A (26)

CRM2A (27)

DV

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

DV

DV

DV

PROGRUN

PAUSED

SYSRDYCRM2A (34)

CRM2A (35)

CRM2A (36)

LOAD

LOAD

LOAD

RELAY

0V +24V

+24 V regulatedpower supply

LOAD

CRM2A(23,28,37,42,47)



237

RV

RV

RV

RV

RV

RV

RV

SDI08

SDI09

SDI10

SDI11

SDI12

SDI13

SDI14

+24E

RV

RV

RV

RV

RV

RV

SDI15

SDI16

SDI17

SDI18

SDI19

SDI20

RVSDI21

SDI22

RV

+24EB A


Receiver circuit


RV

SDI07

CRM2B (49,50)

CRM2B (5)

CRM2B (6)

CRM2B (7)

CRM2B (8)

CRM2B (9)

CRM2B (10)

CRM2B (11)

CRM2B (12)

CRM2B (13)

CRM2B (14)

CRM2B (15)

CRM2B (16)

CRM2B (29)

CRM2B (30)

CRM2B (31)

CRM2B (32)

RV

RV

RV

RV

SDI04

SDI05

SDI06

SDI03CRM2B (1)

CRM2B (2)

CRM2B (3)

CRM2B (4)

NOTEThis is a connection diagram for +24V common.


238

SDO01

DV

DV

DV

DV

DV

DV

DV

SDO06

SDO07

SDO08

SDO09

SDO10

SDO11

SDO12 DV

DV

DV

DV

DV

DV

SDO13

SDO14

SDO15

SDO16

SDO17

SDO18

DVSDO19

SDO20

DV

Connector pin No.

Peripheral deviceControl unit(peripheral device control interface A2)

DV

SDO05

CRM2B (33)

CRM2B (38)

CRM2B (39)

CRM2B (40)

CRM2B (41)

CRM2B (43)

CRM2B (44)

CRM2B (45)

CRM2B (46)

CRM2B (19)

CRM2B (20)

CRM2B (21)

CRM2B (22)

CRM2B (24)

CRM2B (25)

CRM2B (26)

CRM2B (27)

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

DV

DV

DV

SDO03

SDO04

SDO02CRM2B (34)

CRM2B (35)

CRM2B (36)

LOAD

LOAD

LOAD

RELAY

0V +24V


LOAD

CRM2A(23,28,37,42,47)

DV



239

RV

RV

RV

RV

RV

RV

RV

SDI28

SDI29

SDI30

SDI31

SDI32

SDI33

SDI34

+24E

RV

RV

RV

RV

RV

RV

SDI35

SDI36

SDI37

SDI38

SDI39

SDI40

RVSDI41

SDI42

RV

+24EB A


Receiver circuit

Connector pin No.Peripheral deviceControl unit

(peripheral device control interface A3)

RV

SDI27

CRM2C (49,50)

CRM2C (5)

CRM2C (6)

CRM2C (7)

CRM2C (8)

CRM2C (9)

CRM2C (10)

CRM2C (11)

CRM2C (12)

CRM2C (13)

CRM2C (14)

CRM2C (15)

CRM2C (16)

CRM2C (29)

CRM2C (30)

CRM2C (31)

CRM2C (32)

RV

RV

RV

RV

SDI24

SDI25

SDI26

SDI23CRM2C (1)

CRM2C (2)

CRM2C (3)

CRM2C (4)



240

SDO21

DV

DV

DV

DV

DV

DV

DV

SDO26

SDO27

SDO28

SDO29

SDO30

SDO31

SDO32 DV

DV

DV

DV

DV

DV

SDO33

SDO34

SDO35

SDO36

SDO37

SDO38

DVSDO39

SDO40

DV

Connector pin No.


DV

SDO25

CRM2C (33)

CRM2C (38)

CRM2C (39)

CRM2C (40)

CRM2C (41)

CRM2C (43)

CRM2C (44)

CRM2C (45)

CRM2C (46)

CRM2C (19)

CRM2C (20)

CRM2C (21)

CRM2C (22)

CRM2C (24)

CRM2C (25)

CRM2C (26)

CRM2C (27)

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

DV

DV

DV

SDO23

SDO24

SDO22CRM2C (34)

CRM2C (35)

CRM2C (36)

LOAD

LOAD

LOAD

RELAY

0V +24V


LOAD

CRM2C(23,28,37,42,47)

DV



241

RV

RV

RV

RV

RV

RV

RV

SDI48

SDI49

SDI50

SDI51

SDI52

SDI53

SDI54

+24E

RV

RV

RV

RV

RV

RV

SDI55

SDI56

SDI57

SDI58

SDI59

SDI60

RVSDI61

SDI62

RV

+24EB A


Receiver circuit


(peripheral device control interface A4)

RV

SDI47

CRM2D (49,50)

CRM2D (5)

CRM2D (6)

CRM2D (7)

CRM2D (8)

CRM2D (9)

CRM2D (10)

CRM2D (11)

CRM2D (12)

CRM2D (13)

CRM2D (14)

CRM2D (15)

CRM2D (16)

CRM2D (29)

CRM2D (30)

CRM2D (31)

CRM2D (32)

RV

RV

RV

RV

SDI44

SDI45

SDI46

SDI43CRM2D (1)

CRM2D (2)

CRM2D (3)

CRM2D (4)



242

SDO41

DV

DV

DV

DV

DV

DV

DV

SDO46

SDO47

SDO48

SDO49

SDO50

SDO51

SDO52 DV

DV

DV

DV

DV

DV

SDO53

SDO54

SDO55

SDO56

SDO57

SDO58

DVSDO59

SDO60

DV

Connector pin No.


DV

SDO45

CRM2D (33)

CRM2D (38)

CRM2D (39)

CRM2D (40)

CRM2D (41)

CRM2D (43)

CRM2D (44)

CRM2D (45)

CRM2D (46)

CRM2D (19)

CRM2D (20)

CRM2D (21)

CRM2D (22)

CRM2D (24)

CRM2D (25)

CRM2D (26)

CRM2D (27)

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

DV

DV

DV

SDO43

SDO44

SDO42CRM2D (34)

CRM2D (35)

CRM2D (36)

LOAD

LOAD

LOAD

RELAY

0V +24V+24 V regulatedpower supply

LOAD

CRM2D(23,28,37,42,47)

DV



243

RV

RV

RV

RV

SDI68

SDI69

SDI70

+24E

+24E B A


Receiver circuit


(peripheral device control interface B1)

SDI67

CRM4A (19)

CRM4A (5)

CRM4A (6)

CRM4A (7)

CRM4A (13)

RV

RV

RV

RV

SDI64

SDI65

SDI66

SDI63CRM4A (1)

CRM4A (2)

CRM4A (3)

CRM4A (4)

SDO61

DV

DV

DV

DV

SDO66

SDO67

SDO68

Connector pin No.

SDO65

CRM4A (14)

CRM4A (8)

CRM4A (9)

CRM4A (10)

CRM4A (11)

LOAD

LOAD

LOAD

LOAD

DV

DV

DV

SDO63

SDO64

SDO62CRM4A (15)

CRM4A (16)

CRM4A (17)

LOAD

LOAD

LOAD

RELAY

LOAD

DV


CRM4A (20)



244

RV

RV

RV

RV

SDI76

SDI77

SDI78

+24E

+24E B A


Receiver circuit


(peripheral device control interface B2)

SDI75

CRM4B (19)

CRM4B (5)

CRM4B (6)

CRM4B (7)

CRM4B (13)

RV

RV

RV

RV

SDI72

SDI73

SDI74

SDI71CRM4B (1)

CRM4B (2)

CRM4B (3)

CRM4B (4)

SDO69

DV

DV

DV

DV

SDO74

SDO75

SDO76

Connector pin No.

SDO73

CRM4B (14)

CRM4B (8)

CRM4B (9)

CRM4B (10)

CRM4B (11)

LOAD

LOAD

LOAD

LOAD

DV

DV

DV

SDO71

SDO72

SDO70CRM4B (15)

CRM4B (16)

CRM4B (17)

LOAD

LOAD

LOAD

RELAY

LOAD

DV


CRM4B (20)




245

E E

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

4.4.2Connection Betweenthe Mechanical Unitand End Effector


246

RDI9(Pneumatic pressureabnormal signal)

(COM1)

NOTE1 This is a connection diagram for +24V common.2 The common--level change--over setting pin (COM1) is in

the 6--axis servo amplifier.



247

Control unit

Welder interfaceCRW1

Welder

Peripheral device

Analog input interfaceCRW2

NOTEWelder and peripheral device connection cable are optional.


CA

4.4.3Connection Betweenthe Control Unit andWelder


248

Control unit(Welding interface)Process I/O CA Connector pin number

Welder

MS connector pin number

Output signalswithout ripples.

Welding voltagecommand signal

Wire speedcommand signal

Welding voltagedetection signal

Welding currentdetector signal

Wire stickdetection signal

R=100Ω or more

Welding power supply

The input impedanceshall be more than 3.3kΩhigh--pass filter shall beprovided.

COMDA1

COMDA2

COMAD1

COMAD2



249

Control unit(Welding interface)Process I/O CA

Welder

Welding startsignal

Gas signal

Wire inching(positive) signal

Wire inching(negative) signal

Arc detectionsignal

Gas shortagedetection signal

Wire cutdetection signal

Cooling watershortage detectionsignal

Welding powersupplu abnomalitysignal

Common switchingset pin

FG (cabinet ground)Shield

+24V regulatedpower supply

Receiver circuit

CRWI (33,34)

CRWI (25) T

CRWI (28) W

CRWI (29) X

CRWI (30) Z

a, m

b, n

WD06

WD07

WD08

cCRWI (5)WDI1

jCRWI (11)WDI7

kCRWI (12)WDI8

WD01

WD02

WD03

WD04

WD05

WDI2

WDI3

WDI4

WDI5

WDI6

NOTEThis is the connection for +24V.


250

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

Peripheral device

Output signals withoutripples.

COMAD3

COMAD4

COMAD5

COMAD6



251

Control unit

Welder interfaceCRW7

Welder

NOTEWelder and peripheral device connection cable is option.


HA


252

RV

RVWDI (6)

+24V

B A

Control unit (welding interface)Process I/O HA

WDI (2)CRW7 (6)

CRW7 (10)

COMDA

DACH (2)

COMDA

DACH (1)CRW7 (1)

CRW7 (2)

CRW7 (3)

CRW7 (4)

WDO (5)

WCOM (5)

WDI +

WCOM (4)CRW7 (30)

CRW7 (13)

CRW7 (14)

CRW7 (31)

WCOM (1)

WDO (4)

WDO (1)CRW7 (23)

CRW7 (24)

CRW7 (29)

+24V

WDI --CRW7 (32)

+

--

Welding voltagecommand signal

0 V for analog output

Connector pin numbers

Wire speed commandsignal

Arc

No arc(power supply error)

0 V for analog output

No gas

No wire

Welding start signal

DO common

Wire inching (+)

Wire inching (--)

DO common

Wire stickdetection signal

DO common

Welding machineMS connector pin numbers

CRW7 (7)

CRW7 (8)

CRW7 (33, 34)

WDI (4)

WDI (3)

B

C

D

A

R

P

T

S

E

K

F

G

L

H

J

N

M

NOTEThis is the connection for +24V.



253

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

(1) Output signals in peripheral device interface AExample of connection

Protective resistance

Lamp

0.2 Aor less

0V

+24V

Spark killer diode

0.2 Aor less

0V

+24V

Electrical specificationsRated voltage : 24 VDCMaximum applied voltage : 30 VDCMaximum load current : 0.2 ATransistor type : Open collector NPNSaturation voltage at connection : 1.0 V (approx.)

Spark killer diodeRated peak reverse voltage : 100 V or moreRated effective forward current : 1 A or more

NOTEDo not use the +24 V power supply of the robot.When you load a relay, solenoid, and so on directly, connectthem in parallel with diodes to prevent back electromotiveforce.If a load is connected causing a surge current when a lampis turned on, use a protective resistance.

Applicable signalsOutput signals of process I/O board CRM2 and CRM4CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT,ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNO1 toSNO8, SNACK, SDO1 to SDO76

4.5DIGITAL I/O SIGNALSPECIFICATIONS

4.5.1Peripheral DeviceInterface


254

(2) Input signals in peripheral device interface AExample of connection

AB

3.3 kΩ

+24V

RV

+24V

ICOM

Electrical specifications of the receiverType : Grounded voltage receiverRated input voltage : Contact close

: +20 V to +28 VContact open

: 0 V to +4 VMaximum applied input voltage : +28 VDCInput impedance : 3.3 kΩ (approx.)Response time : 5 ms to 20 ms

Specifications of the peripheral device contactRated contact capacity : 30 VDC, 50 mA or moreInput signal width : 200 ms or more (on/off)Chattering time : 5 ms or lessClosed circuit resistance : 100 Ω or lessOpened circuit resistance : 100 kΩ or more

(Signal)(Signal)

TCTC

TBTBTB

Peripheral devicecontact signal

Robot receiver signalTB ; Chattering 5 ms or lessTC ; 5 to 20 ms

NOTEApply the +24 V power at the robot to the receiver.However, the above signal specifications must be satisfiedat the robot receiver.

Applicable signalsInput signals of process I/O board CRM2 and CRM4*IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET, START,HOME, ENBL, RSR1 to RSR8, PNS1 to PNS8, PNSTROBE,PROD START, SDI1 to SDI78



255

(1) Output signalsExample of connection

Protective resistance

Lamp

0.2 Aor less

0V

+24V

Spark killer diode

0.2 Aor less

0V

+24V

Electrical specificationsRated voltage : 24 VDCMaximum applied voltage : 30 VDCMaximum load current : 0.2 ATransistor type : Open collector NPNSaturation voltage at connection : 1.0 V (approx.)


NOTEThe +24 V power supply at the robot can be used when thetotal current of the welding interface and end effectorinterface is 0.7 A or less.When you load a relay, solenoid, and so on directly, connectthem in parallel with diodes to prevent back electromotiveforce.If a load is connected causing a surge current when a lampis turned on, use a protective resistance.

Applicable signalsOutput signals of the end effector control interface RDO1 to RDO8

4.5.2End Effector ControlInterface


256

(2) Input signalExample of connection

AB

3.3 kΩ

+24V

RV

+24V

COM1

Electrical specifications of the receiverType : Grounded voltage receiverRated input voltage : Contact close : +20 V to +28 VContact open : 0 V to +4 VMaximum applied input voltage : +28 VDCInput impedance : 3.3 kΩ (approx.)Response time : 5 ms to 20 ms

Specifications of peripheral device contactRated contact capacity : 30 VDC, 50 mA or moreInput signal width : 200 ms or more (on/off)Chattering time : 5 ms or lessClosed circuit resistance : 100 Ω or lessOpened circuit resistance : 100 kΩ or more

(Signal)(Signal)

TCTC

TBTBTB

Peripheral devicecontact signal

Robot receiver signal

TB ; Chattering 5 ms or lessTC ; 5 to 20 ms

NOTEApply the +24 V power at the robot to the receiver.However, the above signal specifications must be satisfiedat the robot receiver.

Applicable signalsInput signals of the end effector control interfaceRDI1 to RDI8, *HBK, *PPABN



257

(1) Digital output signal specifications for an arc welding interfaceIn case of process I/O CA

0.2 A orless

Example connectionSpark killer diode

Electrical characteristicsRated voltage : 24 VDCMaximum applied voltage : 30 VDCMaximum load current : 0.2 ATransistor type : Open--collector NPNSaturation voltage at on : About 1.0 V


NOTEA power voltage of +24 V, provided for the robot, can beused for interface signals of up to 0.7 A. This limit appliesto the sum of the currents flowing through the arc--weldingand end--effector control interfaces. To drive a relay orsolenoid directly, connect a diode preventing backelectromotive force to the load in parallel. To connect a loadwhich generates an inrush current when you turn on thecontrol unit, connect a protective resistor.

Applicable signals-- Output signals on the arc--welding interface-- WDO1 to WDO8

4.5.3I/O SignalSpecifications forARC--Welding Interface


258

In case of process I/O HA

0.3 A orless

Example connectionSpark killer diode

Electrical characteristicsRated voltage : 24 VDCMaximum applied voltage : 30 VDCMaximum load current : 0.3 AOutput type : Relay connect output


NOTEDo not use the +24 V power supply of the robot.When you load a relay, solenoid, and so on directly, connectthem in parallel with diodes for preventing backelectromotive force.If a load is connected causing a surge current when a lampis turned on, use a protective resistance.

Applicable signals-- Output signals on the arc--welding interface-- WDO1 to WDO4



259

(2) Digital input signal specifications for arc welding interface

Example connection

Electrical characteristics of receiversType: Grounded voltage receiverRated input voltage : +20 to +28 V with contacts closed0 to +4 V when openMaximum input voltage : +28 VDCInput impedance : About 3.3 kResponse time : 5 to 20 ms

Contact specifications for peripheralsRated contact capacity : 30 VDC, 50 mA or moreInput signal width : 200 ms or more for on and off statesChattering period : 5 ms or lessClosed--circuit resistance : 100 or lessOpen--circuit resistance : 100 k or more

Contact signalfor peripheral

Receiversignal for robot

(Signal) (Signal)

TB: Chattering of 5 ms or lessTC: 5 to 20 ms

NOTESupply the +24 V power, provided for the robot, to thereceivers. The receiver signal on the robot must satisfy thesignal timing specified above.

Applicable signals-- Input signals for arc welding interface-- WDI1 to WDI8


260

(3) Analog output signal specifications for arc welding interface(Welding voltage command, wire--feed rate command)

WelderExample connection

0V

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

NOTEInput impedance: 3.3 kΩ or moreConnect a high--pass filter.

(4) Analog input signal specifications for arc welding interface(Welding--voltage detection, welding--current detection)

--10V to +10V

Welder

Example connection

0V

NOTEThe analog input signal should have no ripple for the circuitto operate properly.

(Wire deposit detection: WDI+ and WDI--)

Welding electrode

WelderExample connection

NOTEConnect a resistor of 100Ω or more between the positiveand negative electrodes of the welder. Isolate the depositdetection signals for TIG welding from the welding circuit,which uses high--frequency components. The dielectricwithstand voltage of this circuit is 80 V.



261

If the customer manufactures cables, conform to the FANUC standardcables described in this section.

(See the description in “Peripheral Device Interface” in this manual forthe specifications of the FANUC standard cables.)

Process I/O

Honda TsushinMR50RMA

Peripheraldevice

Honda TsushinMR50LWF01(MR50LF)

Honda TsushinMR50LM01(MR50LM)

Honda Tsushin’s MR50RFSupplied with an ordered cable

Process I/O

Honda TsushinMR20RMA

Peripheraldevice

Honda TsushinMR20LWF01(MR20LF)

Honda TsushinMR20LM01(MR20LM)

Honda Tsushin’s MR20RFSupplied with an ordered cable

CRM4*

4.6SPECIFICATIONS OFTHE CABLES USEDFOR PERIPHERALDEVICES ANDWELDERS

4.6.1Peripheral DeviceInterface A Cable(CRM2: HondaTsushin, 50 pins)

4.6.2Peripheral DeviceInterface B Cable(CRM4: HondaTsushin, 20 pins)


262

Be sure to use our cable to connect the welder.

Process I/O

Honda TsushinMR34RFA

ARC welder

Honda Tsushin

Japan Aviation ElectronicsIndustry Ltd.MS3108B28--21PMS3057--16

Japan Aviation ElectronicsIndustry Ltd.MS3102A28--21SStandard position of guide key

CRW1or

CRW7

4.6.3ARC Weld ConnectionCable (CRW1: HondaTsushin, 34 pins)



263

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

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

Metallic clamp

External shield

Shield plate

B cabinet

Process I/O CRW1 or CRW7

CRM2B

CRM2A

To peripheraldevice

Fig.4.7.1 Peripheral Device Cable Connection

4.7CABLECONNECTION FORTHE PERIPHERALDEVICES, ENDEFFECTORS, ANDARC WELDERS

4.7.1Peripheral DeviceConnection Cable


264

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

Connector Applicable DimensionsRemark

Connectorspecifications

Applicableinterface A (B) C (D)

Remark

MR50LM CRM2 67.9 73.5 44.8 18 Honda Tsushin Kogyo,50 pins

MR20LM CRM4 39.3 44.9 39.8 17 Honda Tsushin Kogyo,20 pins

Symbol Name

¡ Connector cover

© Cable clamp screw

¢ Connector clamp spring

£ Connector clamp screw

¤ Connector 50 pins (male) MR50M20 pins (male) MR20M

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

4.7.2Peripheral DeviceCable Connector



265

(2) Peripheral device connector

Connectorspecifications

Applicableinterface

Dimen-sions Remark

specifications interfaceA B

Remark

MR50RF (CRM2) 61.4 56.4 Honda Tsushin Kogyo,50 pins

MR20RF (CRM4) 39.3 44.9 Honda Tsushin Kogyo,20 pins

Symbol Name

¡ Connector clamp screw

© Screw M2.6×8

¢ Connector (MR50RF)(MR20RF)

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


266

(1) Connector external view (For R--2000iA. Refer to the each maintenancemanual for other robots.)

A : M30¢1 E : ø33B : 63.0 F : 11.2C : 54.5 G : 24.7D : 9.6 to 15.0 (Inside diameter)Manufactured by Daiichi Denshi Kogyo JMLP2524M

Fig.4.7.3 (a) Connector (Elbow Type)

A : M30¢1 E : ø33B : 54.1 F : 11.2C : 37.5 G : 24.7D : 9.6 to 15.0 (Inside diameter)Manufactured by Daiichi Denshi Kogyo JMLP2524M

Fig.4.7.3 (b) Connector (Straight Type)

4.7.3End Effector CableConnector



267

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

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

ConductorSheath Effective Electrical characteristics

Numberof wires

Wire specifications(FANUC specifications) Diameter

(mm)Configura-

tion

Sheaththickness

(mm)

Effectiveoutside

diameter(mm)

Conductorresistance

(Ω/km)

Allowablecurrent

(A)

50 A66L-0001-0042 ø1.05 7/0.18AWG24

1.5 ø12.5 106 1.6

20 A66L-0001-0041 ø1.05 7/0.18AWG24

1.5 ø10.5 106 1.6

(2) End effector connection cableConnect an end effector using a heavily protected cable with amovable wire conforming to the specifications in Table 4.7.4 (b).The cable length is determined so that the cable will not interfere withthe end effector and the wrist can move through its full stroke.

Table 4.7.4 (b) Recommended Cable (for End Effector Connection)

ConductorSheath Effective Electrical characteristics

Numberof wires

Wire specifications(FANUC specifications) Diameter

(mm)Configura-

tion

Sheaththickness

(mm)

Effectiveoutside

diameter(mm)

Conductorresistance

(Ω/km)

Allowablecurrent

(A)

6 A66L-0001-0143 ø1.1 40/0.08AWG24

1.0 ø5.3 91 3.7

20 A66L-0001-0144 ø1.1 40/0.08AWG24

1.0 ø8.6 91 2.3

4.7.4Recommended Cables


268

The HDI signals are used in combination with special applicationsoftware. The HDI signals cannot be used as general--purpose DIs.

Main board

JRL5

R--J3iB

Main boardJRL5

1 HDI0 11 HDI1

2 0V 12 0V

3 HDI2 13 HI3

4 0V 14 0V

5 0V 15 HDI5

6 HDI4 16 0V

7 17 HDI6

8 18 0V

9 19 HDI7

10 20 0V

4.8CONNECTION OF HDI

4.8.1Connecting HDI



269

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

HDI0

0V

HDI1

0V

HDI2

0V

HDI3

0V

HDI4

0V

HDI5

0V

HDI6

0V

HDI7

0V

1

2

11

12

3

4

13

14

6

5 or 10

15

16

17

18

19

20

7

8

9

10

JRL5

Shield

Ground plate

Cable connections


270

R--J3iB

VH/VL

DRIVER

SHIELD

FILTERliL/liH RECEIVER

Absolute maximum ratingInput voltage range Vin: --3.6 to +10.0 VInput characteristics

Unit Symbol Specification Unit Remark

High level input voltage VH 3.6 to 7 V

Low level input voltage VL 0 to 1.0 V

High level input current liH 2 max mA Vin=5 V

11 max mA Vin = 10 V

Low level input current liL --8.0 max mA Vin = 0 V

Input signal pulse duration 20 min μ s

Input signal delay or varia-tions

0.02(max) ms

NOTE1 The plus (+) sign of IiH/IiL represents the direction of flow

into the receiver. The minus (--) sign of IiH/IiL represents thedirection of flow out of the receiver.

2 The high--speed skip signal is assumed to be 1 when theinput voltage is at the low level and 0 when it is at the highlevel.

4.8.2Input Signal Rules forthe High--speed Skip(HDI)

Circuit configuration



271

This interface can be connected to a handy file or another communicationunit from FANUC.

RS--232--C port

4.9CONNECTING THECOMMUNICATIONUNIT

4.9.1RS--232--C Interface

4.9.1.1Interface


272

ER

+24V

14

1615

17

1918

20

2221

23

2524

SDFG

RD

CSRS

DRSG

1

32

4

65

7

98

10

1211

13

R--J3iB

i h

Main boardOperator’s panelconnector(DBM--25S)

i

NOTE1 +24 V can be used as the power supply for FANUC

RS--232--C equipment.2 Do not connect anything to those pins for which signal

names are not indicated.

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

R--J3iB

SD (Send data)

RD (Recieve data)

RS (Request to Send)

CS (Enable to send)

ER (Ready)

DR (Data set ready)

SG (Signal ground)

FG (Frame ground)

When CS is not usedshort CS and RS.

When DR is notused short DRand ER.

Output

Input

Fig.4.9.1.2 RS--232--C interface

4.9.1.2RS--232--C InterfaceSignals



273

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

R--J3iB External devicesideSD

RD

RS

CS

ER

DR

CD

SG

FG

SD

RD

RS

CS

ER

DR

CD

SG

FG

4.9.1.3Connection betweenRS--232--C Interface andExternal Device


274

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

External devicesideSD

RD

RS

CS

ER

DR

SG

FG

SD

RD

RS

CS

ER

DR

CD

SG

FG

R--J3iB

Prepare the cable as follows :

DR

R--J3iB

Cable : twist 10 pairs × 0.18mm2, with shield

SDRD

RSCS

SG

ER



275

CAUTIONBefore connecting or disconnecting cables to and from theEthernet board, cut the power supply of R--J3iB, and makesure that the power is off.

NOTEPlease inqure of each manufacturer about the networkconstruction or the condition of using the equipment exceptthe Ethernet board (hub, transceiver, cable etc.). Whenconfiguring your network, you must take other sources ofelectrical noise into consideration to prevent your networkfrom being influenced by electrical noise. Make sure thatnetwork wiring is sufficiently separated from power linesand other sources of electrical noise such as motors, andground each of the devices as necessary. Also, a high andinsufficient ground impedance may cause interferenceduring communications. After installing the machine,conduct a communications test before you actually startoperating the machine.We cannot ensure operation that is influenced by networktrouble caused by a device other than the main board.

4.9.2Ethernet Interface


276

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

SSS

R--J3iB

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

4.9.2.1Connection to Ethernet



277

CD38

Pin No. Signal Name Description

1 TX+ Send +

2 TX-- Send --

3 RX+ Receive +

4 Not used

5 Not used

6 RX-- Receive --

7 Not used

8 Not used

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

10/100BASE--T connector

D For details on shielding, see “4.9.2.6 Cable clamp and shielding”.D Keep the total cable length to within 100 m.

Do not extend the cable longer than necessary.

4.9.2.210/100 BASE--TConnector (CD38) PinAssignments

4.9.2.3Cable Connection


278

Unshielded cable (UTP cable) is commercially available as 10/100BASE--T twisted--pair cable. However, be sure to use shielded Category5 twisted--pair cable (STP) to improve the resistance to electrical noise inan FA environment. (For details on shielding, see “4.9.2.6 Cable clampand shielding.”

Recommended Cable

Manufacturer Specification

Furukawa Electric Co., Ltd. DTS5087

Nissei Electric Co., Ltd. F--4PFWMF

Inquiries

Manufacturer Contact Address

Furukawa Electric Co., Ltd.,Sales Headquarters

Maru--no--uchi 2--6--1, Chiyoda--ku.Tokyo 100--8322TEL: 03--3286--3126FAX: 03--3286--3979

Remarks

Nissei Electric Co., Ltd.,Machida Branch

3F MU Bldg., Minami--narise 1--9--1,Machida City, Tokyo 194--0045TEL: 0427--29--2153FAX: 0427--29--3375

Overseas Sales Office NISSEI ELECTRIC CO., LTD1509 Okubo--cho, Hamamatsu--shiShizuoka--ken, 432--8006 JapanTEL: 053--485--4114FAX: 053--485--6908E--mail: [email protected]

Remarks Cables with connectors at both endscan be supplied.

NOTEThe recommended cables cannot be connected to movableportions.

Recommended Cable (For movable parts)

Manufacturer Specification Remarks

Oki Electric Cable Co., Ltd. AWG26 4P TPMC--C5--F(SB) FANUC--specificcable

Cable specifications (FANUC--specific cable No connector)Drawing number: A66L--0001--0453Manufacturer: Oki Electric Cable Co., Ltd.

Nagano Sales Office TEL: 0266--27--1597

4.9.2.4Lead Materials



279

Specifications

D Electric characteristics: Conform to EIA/TIA 568A categories 3 and 5.For reasons related to attenuation performance, the distance to the hubmust be 50 m or shorter.

D Structure: Common shield cable (braided shield). Drain wire provided.The conductor is AWG26 annealed copper stranded wire. The sheaththickness is 0.8 mm. The outside diameter is 6.70.3 mm.

D Flame resistance: UL1581 VW--1D Oil resistance: Based on the FANUC standard.

(equivalent to the conventional oil--resistant electric cables)D Flexing resistance: 1 million times or more with 50 mm of a bend

radius (U--shape flexing test)D UL style No.: AWM 20276 (80°C/30 V/VW--1)

NOTEAlways use connector TM21CP--88P(03) manufactured byHirose Electric for this cable.Cable assembly

Oki Electric Cable Co., Ltd. also supplies cableassemblies using connector TM21CP--88P(03)manufactured by Hirose Electric. Make arrangementsdirectly with the manufacturer for the specifications(length, outgoing inspection, packing, and others) andpurchase cable assemblies.

Contact point: Oki Electric Cable Co., Ltd.Sales contact point) Nagano Sales OfficeTEL: 0266--27--1597

As a connector used with a twisted pair cable for Ethernet, an 8--bitmodular connector called RJ--45 is used. Use the following connector orequivalent:

Specification Manufacturer Remarks

For solid wire 5--569530--3 AMP Japan, Ltd.

For solid wire MS8--RSZT--EMC SK KOHKI Co., Ltd. Special tool required

For twisted wire 5--569552--3 AMP Japan, Ltd.

For twisted wire TM11AP--88P Hirose Electric Co., Ltd. Special tool required

For movable parts Specification Manufacturer Remarks

For cable AWG26 4PTPMC--C5--F(SB)

TM21CP--88P(03) Hirose Electric Co., Ltd. (Note)

4.9.2.5Connector Specification


280

NOTETM21CP--88P(03)

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

Shield the cables as like as other cables are shielded. (See 4.7.1)4.9.2.6Cable Clamp andShielding



281

Even if the grounding conditions on the machine are satisfied, electricalnoise from the machine sometimes enters the communications line andcauses communications interference depending on the installationconditions and the peripheral environment of the machine. To prevent theentry of such electrical noise, separating and insulating the machine fromthe Ethernet trunk cable and the personal computer effectively reduces theinfluence of electrical noise.

The following figure shows an example of such a connection.

Large--scale Network

Small--scale Network

Electrically separatedby 10/100 BASE--Tcable connection

Electrically separatedby 10/100 BASE--Tcable connection

4.9.2.7Grounding the Network


282

NOTE1 The ground between the PC/Trunk line side and machine

system side must be separated. If it is impossible toseparate the ground because there is only one groundingpoint, connect the ground cable for each system to thegrounding point independently. (Refer Fig.1)The resistance for grounding must be less than 100--ohm(Class 3).The thickness of the ground cable is the same as thethickness of AC power cable or more. At least thickness of5.5mm2 is necessary.

2 Please use the HUB that has unshielded interfaceconnector. FANUC recommends the HCN--7500(Hitachi--Densen LTD) or equivalent.

3 There is the possibility that noise makes the obstacle ofcommunication even if the ground is separated using the10/100 BASE--T. In the case of using the Ethernet boardunder the worst environment, please separate between thePC/Trunk line side and machine system side completelyusing the 10/100 BASE--FL (Optical fiber media).

Fig.4.9.2.7 Wiring on a Single Ground Point

B--81465EN--1/025. TRANSPORTATION AND

INSTALLATIONCONNECTIONS

283

5 TRANSPORTATION AND INSTALLATION

5. TRANSPORTATION ANDINSTALLATION B--81465EN--1/02CONNECTIONS

284

This section describes the transportation and installation for the controlunit.

The control unit is transported by a crane. Attach a strap to eye bolts atthe top of the control unit.

B--cabinet

Fig.5.1 Transportation

5.1TRANSPORTATION



285

Following is the installation method for B--cabinet.

When installing the control unit, allow the space for maintenance shownin the following figure.

Fig.5.2.1 (a) External dimension

5.2INSTALLATION

5.2.1Installation Method


286

ControllerController Controller

740100 100

100

1000

550

300

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



287

Teach pendant

R--3iB controller

Input power connection cable

Peripheral device connection cable

Robot connection cable

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

5.2.2Assemble atinstallation


288

Item Model Specifications/condition

Transformer All models I 440--480, 500--575 VAC (+10%--15%)II 380--415, 440--500 VAC (+10%--15%)III 200--230, 380--400 VAC (+10%--15%)

50/60Hz1Hz 3phases

Input power source capacity R--2000iA 12KVAp p p y

M--6iBARC Mate100iB

2.5KVA

Average power consumption R--2000iA 2.5KWg p p

M--6iBARC Mate100iB

1.0KW

Permissible ambienttemperature

All models 0 to 45 ºC during operation, and --20 to 60ºC during ship-ment and storage with a temperature coefficient of1.1ºC/min

Permissible ambienthumidity

All models Relative humidity: 30% to 95%, non--condensing

Surrounding gas All models An additional protective provision is necessary if the ma-chine is installed in an environment in which there are rela-tively large amounts of contaminants (dust, dielectric fluid,organic solvent, acid, corrosive gas, and/of salt).

Vibration All models 0.5G or less. When using the robot in a location subject toserious vibration, consult with your FANUC sales repre-sentative.

Altitude Common to all models Not higher than 1,000m above sea level

Ionized and nonionized radiation Common to all models A shielding provision is necessary if the machine isinstalled in an environment in which it is exposed to radi-ation (microwave, ultraviolet rays, laser beams, and/or X--rays).

Mass of control unit A--cabinet Approx. 120kg

B--cabinet Approx. 180kg

NOTEDuring rapid acceleration, robot power draw can be severaltimes the continuous rating value.

5.3INSTALLATIONCONDITION



289

Adjust the robot according to the following procedure at installation.

No. Description

1 Visually check the inside and outside of the control unit.

2 Check the screw terminals for proper connection.

3 Check that the connectors and printed circuit boards are firmly con-nected.

4 Check transformer tap setting. (See II MAINTENANCE section 6.2)

5 The breaker off and connect the input power cable.

6 Check the input power voltage and transformer outputs.

7 Press the EMERGENCY STOP button on the operator panel and turn onthe control unit.

8 Check the interface signals between control unit and robot mechanicalunit.

9 Check the parameters. If necessary, set them.

10 Release the EMERGENCY STOP button on the operator panel. Turn onthe controller.

11 Check the movement along each axis in manual jog mode.

12 Check the end effector interface signals.

13 Check the peripheral device control interface signals.

5.4ADJUSTMENT ANDCHECKS ATINSTALLATION


290

An overtravel and emergency stop occur when the robot is operated forthe first time after it is installed and the mechanical and control units arewired. This section describes how to reset the overtravel and emergencystop.

Remove the red plate fastening the swiveling axis beforehand.The J2 and J3 axes are pressed against the hard stops at shipment.Therefore, an overtravel alarm occurs when the power is turned on afterinstallation.The robot can also be in an emergency stop state if the peripheral devicecontrol interface is not connected.

Take the following actions if signals *IMSTP, *HOLD, *SFSD, andENBL are not used.

49, 50+24F

1*IMSTPRV

2*HOLDRV

3*SFSDRV

4ENBLRV

CRM2A

1) Select [OT release] on the overtravel release screen to release eachrobot axis from the overtravel state.

2) Hold down the shift key, and press the alarm release button to resetthe alarm condition.

3) Still hold down the shift key, and jog to bring all axes into the movablerange.

5.5RESETTINGOVERTRAVEL ANDEMERGENCY STOPAT INSTALLATION

5.5.1Peripheral DeviceInterface Processing

5.5.2Resetting Overtravel



291

1) Press [MENUS] on the teach pendant.2) Select [NEXT].3) Select [SYSTEM].4) Press “F1” (TYPE) on the teach pendant.5) Select “Config” to disable/enable HBK.

Status Hand Broken enable/disable setting HBK (*1) HBK detection Robot operation Message

1 Enable CLOSE Yes Possible None

2 Enable OPEN Yes Impossible SRVO--006

3 Disable CLOSE Yes(*2) Possible None

4 Disable OPEN No Possible At cold start, SRVO--300

Notes1 Robot end effector connector

2 The moment the HBK circuit is closed, HBK detection becomes enabled.When the HBK circuit is opened again, alarm “Servo 300” or “Servo 302” occurs, causing therobot to stop.

3 If the power is turned off and on again under the condition stated in *2, status 4 is entered, sothe alarm condition is removed.

24V

*HBK

24V

*HBK

CLOSE OPEN

5.5.3How to Disable/EnableHBK


292

1) Press [MENU] on the teach pendant.2) Select [NEXT].3) Select [SYSTEM].4) Press “F1” (TYPE) on the teach pendant.5) Select “Config” to disable/enable PPABN.

5.5.4How to Disable/EnablePneumatic PressureAlarm (PPABN)

APPENDIX

B--81465EN--1/02 A. TOTAL CONNECTION DIAGRAMAPPENDIX

295

A TOTAL CONNECTION DIAGRAM

A. TOTAL CONNECTION DIAGRAM B--81465EN--1/02APPENDIX

296

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


297


298

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


299

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


300

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


301

Fig.A (c) Power supply unit


302

Fig.A (d) Main CPU


303

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


304

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


305

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


306

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


307

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


308

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


309

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


310

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


311

Fig.A (k) Mechanical interface


312

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


313

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


314

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


315

B. SPECIFICATIONS OF PERIPHERALDEVICE INTERFACE B--81465EN--1/02APPENDIX

316

B SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE

B--81465EN--1/02B. SPECIFICATIONS OF PERIPHERAL

DEVICE INTERFACEAPPENDIX

317

The following table lists the I/O signals used for the peripheral deviceinterface in the R-J3iB controller.

Input signals (Refer to B.3.1)

Signal Description

*IMSTP*HOLD*SFSPDCSTOPIFAULT_RESETSTARTHOMEENBLRSR1/PNS1RSR2/PNS2RSR3/PNS3RSR4/PNS4RSR5/PNS5RSR6/PNS6RSR7/PNS7RSR8/PNS8PNSTROBEPROD_STARTSDI01SDI02

SDI03SDI04SDI05SDI06SDI07SDI08SDI09SDI10SDI11SDI12SDI13SDI14SDI15SDI16SDI17SDI18SDI19SDI20SDI21SDI22

Instantaneous stop signalHold signalSafety speed signalCycle stop signalAlarm release signalCycle start signalRobot service request/program number select signal (*1)Enabling signalRobot service request/program number select signal (*1)Robot service request/program number select signal (*1)Robot service request/program number select signal (*1)Robot service request/program number select signal (*1)Robot service request/program number select signal (*1)Robot service request/program number select signal (*1)Robot service request/program number select signal (*1)Robot service request/program number select signal (*1)PNS strobe signalAutomatic operation start signalGeneral-purpose input signalGeneral-purpose input signal

General-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signalGeneral-purpose input signal

*1: RSR : Robot Service Request (RSR5 to RSR8 are optional)PNS : Program Number Select Input (optional)Whether RSR is used or PNS is used can be preset.

B.1SIGNALS


318

Output signals (Refer to B.3.2)

Signal Description

CMDENBLSYSRDYPROGRUNPAUSEDHELDFAULTATPERCHTPENBLBATALMBUSYACK1/SNO1ACK2/SNO2ACK3/SNO3ACK4/SNO4ACK5/SNO5ACK6/SNO6ACK7/SNO7ACK8/SNO8SNACK______

SDO01SDO02SDO03SDO04SDO05SDO06SDO07SDO08SDO09SDO10SDO11SDO12SDO13SDO14SDO15SDO16SDO17SDO18SDO19SDO20

Command acceptance enabled signalSystem ready signalProgram run signalProgram paused signalHeld signalAlarm signalReference point signalTeach pendant enabled signalBattery alarm signalOperating signalRSR acknowledge/Selected program number signalRSR acknowledge/Selected program number signalRSR acknowledge/Selected program number signalRSR acknowledge/Selected program number signalRSR acknowledge/Selected program number signalRSR acknowledge/Selected program number signalRSR acknowledge/Selected program number signalRSR acknowledge/Selected program number signalPNS acknowledge signalNot used (for future expansion)

General-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signalGeneral-purpose output signal



319

All process I/O printed boards have a jumper to set the common voltageof input signals to 0 V or 24 V. The system automatically adjusts thepolarity by software according to the status of this pin. Therefore, you canoperate the system without being concerned about the setting of thecommon voltage.

To ensure safety, the common reference voltage of the following foursignals, is remains at +24V.

*IMSTP

*HOLD*SFSPDCSTOPI

B.2SETTING COMMONVOLTAGE


320

This section describes the specifications of each input signal.

(1) Instantaneous stop signal (input) *IMSTP

Effective : At any timeFunction : Use the normally-closed switch because it is a reverse

signal.The system turns off power to the servo unit when the

*IMSTP is open (turned off). This signal has the sameeffect as that of the emergency stop signal, but it is con-trolled by software. For this reason, use the emergencystop external interface on the emergency stop controlboard for wiring of the emergency stop signal.Do not use *IMSTP.

(2) Alarm release signal (input) FAULT RESET

Effective : In the alarm status

Function : The FAULT RESET signal releases the alarm status. Ifthe servo unit has been turned off, it also turns on theunit. At the same time, the alarm display on the teachpendant (the top line) is cleared.

Description : This signal releases only the alarm status. It does not re--start execution of the program.The robot will keep running if the signal is triggered“ON” during operation.

(3) Hold signal (input) *HOLD

Effective : At any time

Function : Use the normally-closed switch because it is a reversesignal.The *HOLD signal has the same function as the holdbutton on the operator panel. It halts the current pro-gram and stops the operation of the robot. While thissignal is being input, the held signal (output) HELD isturned on and the robot cannot be operated.

B.3I/O SIGNALS

B.3.1Input Signals



321

(4) Start signal (input) START

Effective : When the command acceptance enabled signal (output)CMDENBL is turned on.See the description of CMDENBL in Section B.3.2 (1)for details.

Function : This input signal starts the selected program at the fal-ling edge when the signal is turned off after being turnedon. Its function differs according to the setting of pa-rameter $SHELL_CFG.$CONT_ONLY.- If parameter $SHELL_CFG.$CONT_ONLY is set to

DISABLED, the START signal starts the programwhich has been selected from the teach pendant. Bydefault, the program starts from the current cursorposition.

- If parameter $SHELL_CFG.$CONT_ONLY is set toENABLED, the START signal only resumes theexecution of the temporarily held program. Toexecute an inactivated program from the start, inputthe PROD_START signal.

(5) Cycle stop signal (input) CSTOPI


Function : - If parameter $SHELL_CFG.$USE_ABORT is set toDISABLED, the CSTOPI signal releases the programfrom the wait status caused by an RSR. It does notstop the execution of the current program and allowsit to continue processing (by default).

- If parameter $SHELL_CFG.$USE_ABORT is set toENABLED, the CSTOPI signal immediately cancelsthe execution of the current program. The program re-turns to the status in which it was before execution,and the information for the subprogram to return to themain program is lost. At the same time, this signalalso releases the program from the wait status causedby RSR.

(6) Enabling signal (input) ENBL


Function : If the ENBL signal is turned off, the operation of the ro-bot or the activation of a program is inhibited, and theexecution of the current program is suspended.


322

(7) Safety speed signal (input) *SFSPD


Function : - Use the normally-closed switch because it is a reversesignal. Usually this switch should be connected tosafety fence. It must be set normally on.

- Since the *SFSPD signal is counted as a remote condi-tion, such input signals as RSR and START to the pe-ripheral device interface cannot take effect unless thissignal is turned on.

- If this signal is turned from on to off during robot op-eration, the execution of the current program is sus-pended. At the same time, the overriding value isswitched to a preset value (parameter $SCR.$FENCEOVER.)

- As long as this signal is off, the overriding value can-not be increased beyond the preset value($SCR.$SFJOGOVLIM: For jog, $SCR. $SFRU-NOVLIM : For test execution.)

(8) Robot service request signal (input) RSR1/RSR2/RSR3/RSR4


Function : - The user can choose between RSR and PNS (optional),although they cannot be used simultaneously.

- Four input signals, RSR1 to RSR4, are used.- If a signal is input to an RSR input, a specified. pro-

gram is started. The program number can be set by amenu.

- If another program has already started processing, thenewly activated program enters the wait status. Assoon as the current program terminates, the waitingprogram starts processing.

- By using an RSR instruction, each RSR in a programcan be enabled or disabled.

- A menu is provided to register the program number ofa specified program when each RSR is input. (Referto the application manual for details of the menu).



323

- When an RSR is input, the program whose programname consists of the specified program number plus abase value is started. For exam ple, if a signal is inputto RSR2 when program number 23 is registered inRSR2, the program to be started is the one with the pro-gram name calculated from the expression

RSR + (RSR2 program number + basenumber),

i.e., RSR0123.The base number is stored in parameter$SHELL_CFG.$JOB_BASE, and can be changed ina program with a parameter instruction. (Forexample,$SHELL_ CFG. $JOB_BASE =100). In this way, thecombination of programs which can be started byRSRs can be changed.

- Whether the system should output an acknowledge sig-nal to an RSR can be selected from the menu. If so spe-cified, a pulse is output from the signal correspondingto the RSR, one of signals ACK1 to ACK4, when theinput of the RSR is accepted. From the same menu, thewidth of the pulse can also be specified.It is possible to accept other RSRs while outputting anacknowledge signal.

- Input of a CSTOPIT signal can clear the program queuewaiting for execution after acceptance of RSRs.

(9) PNS/PNSTROBE (input)Signal name : PNS : Program number select

PNSTROBE: Strobe input for PNS


Function : - The PNS/PNSTROBE signal selects whether theRSRfunction is used or the PNS function (optional) isused. If the PNS function is enabled, the RSR func-tion cannot be used.

- The eight signals PNS1 to PNS8 are used to specifya program at the instant the strobe signal PNSTROBErises.

- A menu is provided to specify the information aboutPNS.


324

If a number other than zero is entered to PNS input, aprogram is selected whose program number is the en-tered value plus the base number. For example, if thePNS value is 23, the program to be started has the pro-gram name calculated from the expression

PNS + (entered PNS value + base number),i.e., PNS0123.If zero is entered to PNS input, it is cleared as if no selec-tion has been made.- A PNS signal, which can only select a program, can-

not execute the selected program. The execution ofthe selected program can only be started after input ofautomatic operation start signal PROD_START.

- For safety, the selected program cannot be changedfrom the teach pendant unless PNSTROBE is turnedoff.

- If a program is selected by PNS, the program numberis output to selected program number signal (output)SNO, and a pulse is output to program selection ac-knowledge signal SNACK. Using these signals, pe-ripheral devices can confirm the correct program hasbeen selected. For the timing of these signals, see thesections describing SNO and SNACK.

- The following operations are effective for the programselected by PNS. You can:· Start up a program by input of automatic operation

start signal PROD_START· Restart the program that has been suspended.

Inputting the START signal restarts the programselected by PNS when $SHELL_CFG.$CONT_ONLY is set to ENABLED.

· Input of CSTOPI cancels execution of the pro-gramsselected by PNS when $SHELL_CFG.$USE_ABORT is set to ENABLED.

(10)Automatic operation start signal (input) PROD_START


Function : This input signal executes the selected program at thefalling edge when the signal is turned off after beingturned on.



325

This section describes the specifications of output signals for theperipheral device interface.

(1) Command acceptance enabled signal (output) CMDENBL

Turned on : When the remote conditions are satisfied and the systemis not in the alarm status

Turned off : When the remote conditions are not satisfied or the sys-tem is in the alarm status

The remote conditions are satisfied when all of the following are satis-fied.

- The teach pendant is in the DISABLED status.- The remote switch on the operator’s panel is set to RE-

MOTE side.- Parameter $RMT_MASTER is set to 0 (external in-

terface).- Signal *SFSPD is set to on, or in the normal status.

(2) System ready signal (output) SYSRDY

Turned on : When power is applied to the motor of the robot.

Turned off : When power is not applied to the motor of the robot.

(3) Program run signal (output) PROGRUN

Turned on : When the program is being executed.Turned off : When the program is not being executed.

(4) Held signal (output) HELD

This signal is used to check the status of the hold input.

Turned on : When the hold button (or input) is being pressed down(or turned on).

Turned off : When the hold button (or input) is not being presseddown (or is turned off).

(5) Program paused signal (output) PAUSED

This signal is used together with output signal PROGRUN to determinewhether a program can be restarted while it is being held.Turned on : When a program is held and has not been restarted yet.

While this signal is on, the program can be restarted andretains information such as that to return from a subpro-gram to the main program.

Turned off : When a program is being executed or is ready to start.If signal PROGRUN is on, the program is beingexecuted. If signal PROGRUN is off, the program hasnot been executed and can be started from this status.

(6) Alarm status signal (output) FAULT

Turned on : When the system is in the alarm status (or an alarmwhich can stop a program execution is detected.) Theindicator lamp does not go on in warning.

Turned off : When the alarm status is released by an alarm release op-eration.

B.3.2Output Signals


326

(7) Reference point signal (output) ATPERCH

Turned on : When the robot is in the reference position specified inthe parameter. (the reference point No.1 in referencepoint setup screen.)

Turned off : When the robot is not in the reference position specifiedin the parameter. (the reference point No.1 in referencepoint setup screen.)

Up to three reference positions can be specified, but this signal is outputwhen the robot is in the first reference position. For the other two refer-ence positions, general-purpose signals can be assigned to output assuch. (They can be set from the setup screen.)

(8) Teach pendant enabled signal (output) TPENBL

Turned on : When the teach pendant is enabled.

Turned off : When the teach pendant is disabled.

(9) Battery alarm signal (output) BATALM

Turned on : When the voltage of the battery for the CMOS memorybackup drops below the reference.

Turned off : When the voltage of the battery for the CMOS memorybackup is at the normal level.

(10)Operating signal (output) BUSY

Turned on : When a program is being executed or is being processedfrom operation panels such as the teach pendant. (Thishas the same function as that of the BUSY lamp on theteach pendant.)

Turned off : When a program is not being executed nor is being pro-cessed from operation panels such as the teach pendant.



327

(11) RSR acknowledge signals (output) ACK1/ACK2/ACK3/ACK4

These signals are used together with the RSR function. They can bespecified to be enabled or disabled from the RSR setup menu.

Turned on : When one of the signals from RSR1 to RSR4 is inputand accepted. A pulse whose width is specified from themenu is output to acknowledge the signal.

Turned off : Normally. Since these signals are always output aspulses, they are normally in the off status.

The following chart shows the timing of the RSR input and ACK out-put.

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

RSR1 (I)

The maximum delay is 32 msec.

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

ACK1 (O)

RSR2 (I)

ACK2 (O)

RSR3 (I)

ACK3 (O)

RSR4 (I)

ACK4 (O)

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


328

(12)PNS acknowledge signal (output) SNO/SNACK

These signals are used together with the PNS function.

Turned on : Whenever the PNS function is enabled.The selected program number is displayed in binarycode (SN01 to SN08) on the teach pendant. If the num-ber cannot be represented as an eight-bit number, it be-comes zero.After selecting a program by PNS, a pulse is output fromsignal SNACK as a part of the PNS operation. Thewidth of the pulse can be specified from the menu. Seethe timing chart below.

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

PNS1-8 (I)

(A strobe is input for PNS.)PNSTROBE (I)

Detection andprocessing ofPNSTROBE bysoftware.

SNO1-8 (O)

SNACK (O)

PROD_START (I)

PROGRUN (O)

(A value is input.)

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

(Program executionstarts within 32 msec.)



329

This section describes the external specifications of digital and analoginput/output in the R--J3iB controller.

The R--J3iB controller can use up to 512 digital input and output pointsor an equivalent number of analog input and output points. One analoginput/output point uses the resources equivalent to those used by 16digital I/O points. The R--J3iB can use a total of up to 512 I/O points.

The R--J3iB controller can use the following I/O hardware.- Process I/O printed circuit board- I/O unit model A

The process I/O printed circuit board and the I/O unit model A can be usedtogether.

B.4SPECIFICATIONS OFDIGITALINPUT/OUTPUT

B.4.1Overview

B.4.2Input/Output HardwareUsable in the R-J3iBController


330

(1) RDI/RDOThese are signals sent to the connector at the wrist of the robot.They cannot be assigned (redefined) and are fixed.The standard format is eight inputs and eight outputs. The number ofpoints that can be used for the connector at the wrist depends on theindividual robot.

(2) SDI/SDOThe signal No. that is determined at hardware can be changed bysoftware operation.

(3) Analog I/OAn analog I/O signal can access the analog I/O port (optional) on theprocess I/O printed circuit board or the I/O port on the analog I/Omodule (used together with the I/O unit model A).It reads and writes the digital value converted from the analog valueof the I/O voltage. It means that the value does not always representthe real I/O voltage.

(4) Group I/OGroup I/O is a function which can input or output multiple DI/DOsignals as binary codes.Any number of continuous signals of up to 16 bits can be set for itsuse.It can be set in the menu DETAILS on the group I/O screen.

B.4.3SoftwareSpecifications

B--81465EN--1/02C. POWER DISTRIBUTION

CIRCUIT DIAGRAMAPPENDIX

331

C POWER DISTRIBUTION CIRCUIT DIAGRAM

C. POWER DISTRIBUTIONCIRCUIT DIAGRAM B--81465EN--1/02APPENDIX

332

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



333


334

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



335

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


336

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



337

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

D. OPTICAL FIBER CABLE B--81465EN--1/02APPENDIX

338

D OPTICAL FIBER CABLE

The R--J3iB uses fiber optic cables for communication between the mainboard and servo amplifiers. Observe the following cautions whenhandling these fiber optic cables. Handle fiber optic cables with utmostcare, especially when installing the unit.

(1) Protection during storageWhen the electrical/optical conversion module (mounted on theprinted) circuit board and the fiber optic cable are not in use, theirmating surfaces must be protected with the lid and caps with whichthey are supplied. If left uncovered, the mating surfaces are likely tobecome dirty, possibly resulting in a poor cable connection.

Electrical/optical conversion module Lid

Fiber optic cable Fiber opticcable caps

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

B--81465EN--1/02 D. OPTICAL FIBER CABLEAPPENDIX

339

(2) Fiber optic cable

D Although the reinforcing cover of the external optical cable hassufficient mechanical strength, be careful not to drop heavy objectson the cable.

D Grasp the optical connector firmly when connecting ordisconnecting the cable. Do not pull on the fiber optic cord itself.(The maximum tensile strength between the fiber cord andconnector is 2 kg. Applying greater force to the cord is likely tocause the connector to come off, making the cable unusable.)

Fiber optic cord diameter : 2.2 mm × 2 cordsDiameter of cable with reinforced cover : 7.6 mmTensile strength : Cable with reinforced cover :75 kg

Fiber optic cord :7 kg per cordBetween fiber optic cord and connector : 2 kg

Minimum bending radius of fiber optic cord :25 mmMinimum bending radius of cable with reinforced cover : 50 mmBending resistance (cable with reinforced cover) :

10 million bending cycles at room temperature(when the bending radius is 100 mm)

Flame resistance : Equivalent to UL VW--1Operating temperature : --20 to 70°C

60 max.

8.2

21

6.7 19 max. 35typ.

Code Bush Reinforced cover

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

D Afler it is connected, the optical connector is automatically lockedby the lock levers on its top. To remove the connector, release thelock levers and pull the connector.

D Although optical connectors cannot be connected in other than thecorrect orientation, always take note of the connector’s orientationbefore making the connection.

D Take care to keep both parts of the optical connector (cable side andPCB side) clean. If they become dirty, wipe them with tissue paperor absorbent cotton to remove dirt. The tissue paper or absorbentcotton may be moistened with ethyl alcohol. Do not use anyorganic solvent other than ethyl alcohol.

D Fix the reinforcing cover by using a cable clamp, as shown in Fig.D(c), to prevent the weight of the fiber optic cable from beingapplied directly to the connecting part of the optical connector.

D. OPTICAL FIBER CABLE B--81465EN--1/02APPENDIX

340

Optical connector Part of optical fiber cord Part of reinforcing cover

Bending radius of 25 mm or more(Make the bending radius as large aspossible.)

Cable clamp

Bending radius of 50 mm or more(Make the bending radius as large as possible.)

(Don’t clamp tight)

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

D Any superfluous portion of the cable might be wound into a loops.Should this prove necessary, make sure the diameter of each loopis at least 150 mm (for an external cable). Winding the cable intosmaller loops can produce sharp curves that exceed the specifiedbend radius limit. Such bending can result in transmission loss,ultimately leading to a communication failure.

D When using a nylon band (cable tie) as a cable clamp, follow theinstructions given below. Also, take care not to apply a bendingforce to one particular part of the cable when fixing it with a clamp.Failing to clamp the cable correctly might cut or damage it.

External cable :Do not clamp the uncovered portion of the cable with a nylonband. When clamping the cable by the reinforcing cover, theclamping force is not an important factor to consider. However,ensure that the clamping force is as small as possible to ensurethat the reinforcing cover is not deformed by the clamping. Ifpossible, the clamping force should be 5kg (111bs) or less.

B--81465EN--1/02 E. CARD INTERFACEAPPENDIX

341

E CARD INTERFACE

Connector for card

Card

Card

Fig.E Precautions for card interface

IndexB--81465EN--1/02

i--1

[Numbers]10/100 BASE--T Connector (CD38) Pin Assignments,

277

[A]Adjustment and Checks at Installation, 289

Alarm Occurrence Screen, 30

ARC Weld Connection Cable (CRW1: Honda Tsushin,34 pins), 262

Assemble at installation, 287

[B]Backplane PC Board, 140

Battery for memory backup (3 VDC), 196

Block Diagram, 202

Block Diagram of the Main Power Including PowerSupply, 158

[C]Cable Clamp and Shielding, 280

Cable Connection, 277

Cable Connection for the Peripheral Devices, end Ef-fectors, and ARC Welders, 263

Card Interface, 341

Checking the Power Supply Unit, 161

Component Functions, 25

Configuration, 20

Connecting the Communication Unit, 271

Connecting the External Emergency Stop, 212

Connecting the External Power Supply ON/OFFSwitch, 210

Connecting the Input Power , 208

Connection between RS--232--C Interface and Exter-nal Device, 273

Connection Between the Control Unit and Welder,247

Connection Between the Mechanical Unit and EndEffector, 245

Connection Diagram Between Mechanical Units, 204

Connection to Ethernet, 276

Connector Specification, 279

[D]Digital I/O Signal Specifications, 253

Driver Chip for Robot DI/DO, 156

[E]Electrical Connections, 203

Emergency Stop Control PC Board(A20B--1007--0800), 139

End Effector Cable Connector, 266

End Effector Control Interface, 255

Ethernet Interface, 275

External Cable Wiring Diagram, 206

External View of the Controller, 21

[F]Fused--Based Troubleshooting, 117

[G]Grounding the Network, 281

[H]How to Disable/Enable Pneumatic Pressure Alarm

(PPABN), 292

[I]I/O Signal Specifications for Arc--Welding Interface,

257I/O Signals, 320

In Case of B--Cabinet, 224

In Case of B--cabinet, 226

Input Signals, 320

Input/Output Hardware Usable in the R--J3iB Control-ler, 329

Installation, 285

Installation Condition, 288

Installation Method, 285

Interface, 271

Interface for Peripheral Devices, End Effectors, andWelders, 231

[L]Lead Materials, 278

Index B--81465EN--1/02

i--2

LED of Servo Amplifier, 154

[M]Main Board (A16B--3200--0412, --0331), 136

Manual Operation Impossible, 133

Mastering, 34

[O]Operator Safety, 4, 6

Optical Fiber Cable, 338

Output Signals, 325

[P]Panel Board (A20B--2100--0770), 142

Panel Switch Board (A20B--9002--0310), 152

Peripheral Device and Control Unit Connection, 232

Peripheral Device Cable Connector, 264

Peripheral Device Connection Cable, 263

Peripheral Device Interface, 253

Peripheral Device Interface A Cable (CRM2: HondaTsushin, 50 pins), 261

Peripheral Device Interface B Cable (CRM4: HondaTsushin, 20 pins), 261

Peripheral Device Interface Block Diagram, 221

Peripheral Device Interface Combination, 226

Peripheral Device Interface Processing, 290

Peripheral Device, ARC Welding, and End EffectorInterfaces, 220

Position Deviation Found in Return to the ReferencePosition (Positioning), 131

Power Cannot be Turned On, 28

Power Distribution Circuit Diagram, 331

Precautions for Mechanism, 10

Precautions for Mechanisms, 11

Precautions in Operation, 11

Precautions in Programming, 10, 11, 12

Preventive Maintenance, 26

Printed Circuit Boards, 135

Process I/O Board CA (A16B--2201--0470), 143

Process I/O Board CB (A16B--2201--0472), 146

Process I/O Board DA (A16B--2201--0480), 148

Process I/O Board Signals, 227

[R]Recommended Cables, 267

Replace the Mode Switch, 189

Replacing a Module, 183

Replacing a Unit, 164

Replacing Battery, 196

Replacing Cards and Modules on the Main Board, 169

Replacing External Air Fan Unit and Door Fan Unit(B--cabinet), 186

Replacing Fuses, 190

Replacing Fuses in the Power Unit, 191

Replacing Fuses in the Servo Amplifier, 190

Replacing I/O Unit Model A, 182

Replacing Relays, 195

Replacing Relays on the Panel Board, 195

Replacing Servo Amplifiers, 178

Replacing the AC Fan Motor, 186

Replacing the Backplane Board (Unit), 165

Replacing the Base Unit of I/O Unit Model A, 182

Replacing the Control Section Fan Motor, 185

Replacing the Fuse on the Panel Board, 194

Replacing the Fuse on the Process I/O Boards, 192

Replacing the Operator Panel and Panel SwitchBoard, 188

Replacing the Panel Board, 168

Replacing the Power Unit and Printed--Circuit Boardson the Backplane Unit, 166

Replacing the Printed--Circuit Boards, 165

Replacing the Redundant E--stop Unit, 177

Replacing the Regenerative Resistor Unit, 176

Replacing the Teach Pendant, 184

Replacing the Transformer, 173

Resetting Overtravel, 290, 291

Resetting Overtravel and Emergency Stop at Installa-tion, 290

Robot Connection Cables, 206

RS--232--C Interface, 271

RS--232--C Interface Signals, 272

[S]Safety During Maintenance, 9

Safety in Maintenance, 13

B--81465EN--1/02 Index

i--3

Safety of the End Effector, 12

Safety of the Robot Mechanism, 11

Safety of the Teach Pendant Operator, 7

Safety of the Tools and Peripheral Devices, 10

Safety Precautions, 3

Safety Signals, 33

Selecting Transformer Taps, 159

Servo Amplifiers, 153

Setting Common Voltage, 319

Setting of Servo Amplifier, 155

Setting the Power Supply, 157

Signals, 317

Software Specifications, 330

Specifications of Digital Input/Output, 329

Specifications of Peripheral Device Interface, 316

Specifications of the Cables Used for Peripheral De-vices and Welders, 261

[T]Teach Pendant Cable, 207

Total Connection Diagram, 295

Transportation, 284

Transportation and Installation, 283

Troubleshooting, 27

Troubleshooting Based on LED Indications, 122

Troubleshooting Using the Error Code, 36

[V]Vibration Observed During Movement, 132

[W]Warning Label, 14

When I/O Unit--MODEL A is Used, 224

When Process I/O Board CA/CB/HA is Used (B--cabi-net), 221

When Process I/O Board DA is Used (B--cabinet), 223

When Two or more Process I/O Boards and I/O Unit(Model A or Model B) are Used, 225

Revision Record

FANUC Robot series R--J3iB CONTROLLER FOR EUROPE MAINTENANCE MANUAL (B--81465EN--1)

02 Oct., 2001 Addition of R--2000iA/165F/200F/165R/200R/125L/CF,M--6iB and ARC Mate100iB

01 Mar., 2001

Edition Date Contents Edition Date Contents

fanuc r-j3ib - maintenance manual for europe - b-81465en-1-02

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