r-j2 controller p-200 maintenance manual

FANUC RoboticsSYSTEM R-J2 ControllerP–10, P–15 and P–200 ElectricalMaintenance Manual

MARO2P10203704E REV B

This publication contains proprietary information of FANUC RoboticsNorth America, Inc. furnished for customer use only. No other uses areauthorized without the express written permission of FANUC RoboticsNorth America, Inc.

FANUC Robotics North America, Inc.3900 W. Hamlin RoadRochester Hills, Michigan 48309-3253

MARO2P10203704E REV B2

The descriptions and specifications contained in this manual were in effectat the time this manual was approved for printing. FANUC RoboticsNorth America, Inc, hereinafter referred to as FANUC Robotics, reservesthe right to discontinue models at any time or to change specifications ordesign without notice and without incurring obligations.

FANUC Robotics manuals present descriptions, specifications, drawings,schematics, bills of material, parts, connections and/or procedures forinstalling, disassembling, connecting, operating and programming FANUCRobotics’ products and/or systems. Such systems consist of robots,extended axes, robot controllers, application software, the KAREL

programming language, INSIGHT vision equipment, and special tools.

FANUC Robotics recommends that only persons who have been trained inone or more approved FANUC Robotics Training Course(s) be permittedto install, operate, use, perform procedures on, repair, and/or maintainFANUC Robotics’ products and/or systems and their respectivecomponents. Approved training necessitates that the courses selected berelevant to the type of system installed and application performed at thecustomer site.

WARNINGThis equipment generates, uses, and can radiate radiofrequency energy and if not installed and used inaccordance with the instruction manual, may causeinterference to radio communications. As temporarilypermitted by regulation, it has not been tested forcompliance with the limits for Class A computing devicespursuant to subpart J of Part 15 of FCC Rules, which aredesigned to provide reasonable protection against suchinterference. Operation of the equipment in a residentialarea is likely to cause interference, in which case the user,at his own expense, will be required to take whatevermeasure may be required to correct the interference.

FANUC Robotics conducts courses on its systems and products on aregularly scheduled basis at its headquarters in Rochester Hills, Michigan.For additional information contact

FANUC Robotics North America, Inc.Training Department3900 W. Hamlin RoadRochester Hills, Michigan 48309-3253Tel: (248)377-7234FAX: (248)377-7367 or (248)377-7362web site: www.fanucrobotics.com

Send your comments and suggestions about this manual to:[email protected]

3MARO2P10203704E REV B

Copyright 2000 by FANUC Robotics North America, Inc.All Rights Reserved

The information illustrated or contained herein is not to be reproduced,copied, translated into another language, or transmitted in whole or in partin any way without the prior written consent of FANUC Robotics NorthAmerica, Inc.

AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL ,KAREL , INSIGHT, INSIGHT II , PaintTool, PaintWorks,PalletTool, SOCKETS, SOFT PARTS SpotTool,TorchMate, and YagTool are Registered Trademarks of FANUCRobotics.

FANUC Robotics reserves all proprietary rights, including but not limitedto trademark and trade name rights, in the following names:

AccuFlowARC MateARC Mate Sr.IntelliTrakLaserToolMotionPartsPaintWorks IIPalletMateSureWeldTurboMove

This manual includes information essential to the safety of personnel,equipment, software, and data. This information is indicated by headingsand boxes in the text.

WARNINGInformation appearing under WARNING concerns theprotection of personnel. It is boxed and in bold type to setit apart from other text.

CAUTIONInformation appearing under CAUTION concerns the protectionof equipment, software, and data. It is boxed to set it apartfrom other text.

NOTE Information appearing next to NOTE concerns related informationor useful hints.

Conventions Used inthis Manual

Issued United States Patents iv

One or more of the following U.S. patents might be related to the FANUC Robotics products described in thismanual.

3,906,3234,274,8024,289,4414,299,5294,336,9264,348,6234,359,8154,366,4234,374,3494,396,9734,396,9754,396,9874,406,5764,415,9654,416,5774,430,9234,431,3664,458,1884,462,7484,465,4244,466,7694,475,1604,479,6734,479,7544,481,5684,482,2894,482,9684,484,8554,488,2424,488,7464,489,8214,492,3014,495,4534,502,8304,504,7714,530,0624,530,6364,538,6394,540,2124,542,4714,543,6394,544,971

4,549,2764,549,8464,552,5064,554,4974,556,3614,557,6604,562,5514,575,6664,576,5374,591,9444,603,2864,626,7564,628,7784,630,5674,637,7734,638,1434,639,8784,647,7534,647,8274,650,9524,652,2034,653,9754,659,2794,659,2804,663,7304,672,2874,679,2974,680,5184,697,9794,698,7774,700,1184,700,3144,701,6864,702,6654,706,0004,706,0014,706,0034,707,6474,708,1754,708,5804,712,9724,723,207

4,727,3034,728,2474,728,8724,732,5264,742,2074,742,6114,750,8584,753,1284,754,3924,771,2224,773,5234,773,8134,774,6744,775,7874,776,2474,777,7834,780,0454,780,7034,782,7134,785,1554,796,0054,805,4774,807,4864,812,8364,813,8444,815,0114,815,1904,816,7284,816,7334,816,7344,827,2034,827,7824,828,0944,829,4544,829,8404,831,2354,835,3624,836,0484,837,4874,842,4744,851,754

4,852,0244,852,1144,855,6574,857,7004,859,1394,859,8454,866,2384,873,4764,877,9734,892,4574,892,9924,894,5944,894,5964,894,9084,899,0954,902,3624,903,5394,904,9114,904,9154,906,1214,906,8144,907,4674,908,5594,908,7344,908,7384,916,3754,916,6364,920,2484,922,4364,931,6174,931,7114,934,5044,942,5394,943,7594,953,9924,956,5944,956,7654,965,5004,967,1254,969,1094,969,722

4,969,7954,970,3704,970,4484,972,0804,972,7354,973,8954,974,2294,975,9204,979,1274,979,1284,984,1754,984,7454,988,9344,990,7295,004,9685,006,0355,008,8325,008,8345,012,1735,013,9885,034,6185,051,6765,055,7545,057,7565,057,9955,060,5335,063,2815,063,2955,065,3375,066,8475,066,9025,075,5345,085,6195,093,5525,094,3115,099,7075,105,1365,107,7165,111,0195,111,7095,115,690

Revised: 12/15/99

Technical Support Hot–Line

Service personnel dispatch

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

Marketing Information

Application Review

New Robot Sales

Systems Solution Sales

SERVICE & REPAIRPRESS 1

Tel: 248–377–7159 / Fax: 248–377–746324 Hour Hot–Line

PARTS & PART REPAIRPRESS 2

Tel: 248–377–7278 / Fax: 248–377–78328:00 am to 8:00 pm / Mon – Fri

TRAININGPRESS 3


MARKETING & SALESPRESS 4


Parts for down robots

Replenishment part order

Warranty part replacement

Robot software and PACs

Training class registration

Consultation for special training or on–site requests

________________________

For best call results have:

Customer number (if known)

Company name

Your name

Your phone & fax numbers

Robot & controller type

“F#” or serial number of robot

Hour meter reading (if available)

Software type and edition

Any error messages and LED displays (if applicable)

Your P.O., Credit Card, or Receiving # for warranty or down robot or preventive

________________________



Company name

Your name


Part name & number (if known)

“F#” or serial number of robot,

P.O., Credit Card, or Receiving # for warranty, down units, or software

Shipping & billing addresses

Reason for repair (any symptoms,

________________________



Company name

Your name


Your shipping or billing address

Types of courses needed

Robot and controller type

Number of people attending

Method of payment (P.O., credit

________________________


Company name

Your name


Description of your need

1–800–47–ROBOT(1–800–477–6268)

(International: 011–1–248–377–7159)

*NOTE: A RETURN AUTHORIZATION (“RA”) FROM “PARTS” IS REQUIRED BEFORE SHIPPING ANY MATERIAL BACK

CUSTOMER FOCUS CENTER

maintenance service orders

if available (req’d for warranty)

error codes, or diagnostic LEDsthat were identified)

Special Requirements

Proposed Schedules

card, etc.)

Company address

TO FANUC ROBOTICS FOR PROPER RECEIVING & TRACKING. F# IS LOCATED ON THE ROBOT BASE OR OP. PANEL.

3MXXXXXXXXXXXXXE REV X

UPDATES

UPDATESMARO2P10203704E Updates–1

This section lists the update that has been made to the FANUC RoboticsSYSTEM R–J2 Controller P–10, P–15 and P–200 Electrical MaintenanceManual in the following area:

Page

Table 5–1 Fused Flange–Mounted DisconnectSwitch, C–Size Controller

5–3

Figure A–1 Transportation A–2

Figure 14–40 P–200 Brake Release OptionPackage

14–81

Fused Flange–Mounted Disconnect Switch, C–Size Controller

The correct part number for the 50A fuse is XGMF–00382.

The correct part number for the 30A fuse is XGMF–00160.

Transportation and Installation Addendum A

When transporting a controller, an appropriate certified lifting strap shouldbe used. The term rope is incorrect.

P–200 Brake Release Option Package, Figure 14–40

The correct terminations for the Axis 4 and 5 wires is as follows:

Wire Terminal LocationBKP3(Blk–5) and BKP3(Blk–11) BKP(Terminal 3)BKM3(Blk–6) and BKM3(Blk–12) BKM(Terminal 4)

MARO2P10203704EUpdates–2

UPDATES

MARO2P10203704E

UPDATES

Updates–3

Figure 1–1. Main Disconnect Location

MAINDISCONNECT

FL1 FL2 FL3

Fuse Block

Table 1–1. Fused Flange-Mounted Disconnect Switch, C-Size Cabinet

Inp tFused Flange-Mounted Disconnect Switch

InputVoltage Fuse

Size Part Number

220240

50A Fuse XGMF-00382 (A60L–0001-0042 #JG2-50)

380416460480500550

30A Fuse XGMF-00160 (A60L–0001-0042 #JG1-30)

575 20A Fuse XGMF-04148 (A60L–0001-0042 #JG1-20)

MARO2P10203704E

UPDATES

Updates–4

The controller is transported by a crane. Attach a lifting strap to the eyebolts at the top of the controller, as shown in Figure A–1.

Figure A–1. Transportation

Î

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎ

ÏÏ

ÏÏ

1.1TRANSPORTATION

UPDATES

MARO2P10203704E Updates–5

Figure 2. P-200 Brake Release Option Package

BATTERYPACK

ISBUNIT

TO PURGE BRAKE BOARD

MOUNT SWITCHES AND RC’S ONALTERED COVER PLATE

MOUNT TERMINALS AND RELAYON HEAT EXCHANGER

BK

P1

BK

M1

EE–3287–122–XXX

EE–3287–121–XXX

EE–3287–120–XXXAXES 1 & 2

AXES 4,5,6

AXES 3 & 7

BK

P2

BK

P1

BK

M1

BK

P3

BK

M2

BK

M3

BK

P3

BK

M3

BK

P2

BK

M2

OPENER CONNECTIONS

INSTALLATION IN C SIZE CONTROLLER

ROBOT CABLE CONNECTION

PURGEUNIT

1 2 3 4 5 6 7 8 9 10 11 12 13 14

BK

P4

BK

M4

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

EE–3287–110–XXX

EE–3287–111–XXX

EE–3287–112–XXX

NOTE: AXIS 6 WIRES CONNECTEDEVEN IN UNITS WHEREAXIS 6 DOES NOT HAVE BRAKES

INSIDE

VIEW

TO TERMINAL STRIP

2’’

6’’ 2 3/4 ’’

AXES

1 & 7

AXES

4 & 5

AXIS 6 AXIS 2 AXIS 3

BLUE–17BLUE–18

BLUE 19BLUE–20

BLUE 19BLUE–20

BLUE–17BLUE–18

BLACK–5BLACK–6

BLACK–11BLACK–12


P–200 BRAKE RELEASE

OPTION PACKAGE

EE–3287–516

TERMINAL STRIP

MOUNTED ON CONTROLLER DOOR HEAT EXCHANGER

UPDATES

UPDATES

MARO2P10203704E UPDATES –3

Figure 1. P-200 Brake Release Option Package

BATTERYPACK

ISBUNIT


MOUNT SWITCHES AND RC’S ONALTERED COVER PLATE


BK

P1

BK

M1

EE–3287–122–XXX

EE–3287–121–XXX

EE–3287–120–XXXAXES 1 & 2

AXES 4,5,6

AXES 3 & 7

BK

P2

BK

P1

BK

M1

BK

P3

BK

M2

BK

M3

BK

P3

BK

M3

BK

P2

BK

M2

OPENER CONNECTIONS

INSTALLATION IN C SIZE CONTROLLER


PURGEUNIT

1 2 3 4 5 6 7 8 9 10 11 12 13 14

BK

P4

BK

M4

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

EE–3287–110–XXX

EE–3287–111–XXX

EE–3287–112–XXX

NOTE: AXIS 6 WIRES CONNECTEDEVEN IN UNITS WHEREAXIS 6 DOES NOT HAVE BRAKES

INSIDE

VIEW

TO TERMINAL STRIP

2’’

6’’ 2 3/4 ’’

AXES

1 & 7

AXES

4 & 5

AXIS 6 AXIS 2 AXIS 3

BLUE–17BLUE–18

BLUE 19BLUE–20

BLUE 19BLUE–20

BLUE–17BLUE–18

BLACK–5BLACK–6



P–200 BRAKE RELEASE

OPTION PACKAGE

EE–3287–516

TERMINAL STRIP

MOUNTED ON CONTROLLER DOOR HEAT EXCHANGER

UPDATESMARO2P10203704E Updates–1

This section lists the update that has been made to the FANUC RoboticsSYSTEM R–J2 Controller P–10, P–15 and P–200 Electrical MaintenanceManual in the following area:

Page

Figure 14–40 P–200 Brake Release OptionPackage

14–81

P–200 Brake Release Option Package, Figure 14–40

The correct terminations for the Axis 4 and 5 wires are as follows:

Wire Terminal LocationBKP3(Blk–5) and BKP3(Blk–11) BKP(Terminal 3)BKM3(Blk–6) and BKM3(Blk–12) BKM(Terminal 4)

MARO2P10203704EUpdates–2

UPDATES

UPDATES

UPDATES

MARO2P10203704E UPDATES –1

Figure 1–1. P-200 R-J2 Robot Control Drawing Purge and Intrinsic Wiring sheet 1 NOTE: This page replaces page 12–43.

NOTICENO REVISIONS WITHOUT PRIOR

APPROVAL FROM FACTORY MUTUAL (FM)

OPERATORPANEL

EMGIN1EMGIN2

E–STOP PCB

CRR5

CRR22

BKP4BKM4

CRR21

CNIN

CNCA

CNPG

PURGE CIRCUITS

CRM10

MAIN CPU

CNPG PANEL I/F

BRAKE CONTROL

RDI/RDO

220 VAC

+24P

0V

220V (43)

220V (44)

SERVO TRANSFORMER

FOR PAINT R–J TYPE

SOL1

SOL2

A1

A2

A3

A4

A5

A6

C1

C2

C3

C4

C5

C6

P1

P2

P3

P4

P5

P6

N1

N2

N3

N4

N5

N6

123456789101112131415161718192021222324

PSA1PSA2PSB1PSB2FSA1FSA2FSB1FSB2OT11OT12OT21OT22OT31OT32OT41OT42OT51OT52HBK1HBK2TP1TP2

EOAT1EOAT2

ISTB

INTRINSIC SAFETY BARRIER

1 32

STAHL 9001/01–252–100–14

4

14

PRESSURESWITCH

OPENERPRESS

SWITCH

FLOWSWITCH

OPENERFLOW

SWITCH

PURGESOLENOID

VALVE

+V

0V

G

R

SAC

+24VDC PSU

FIRE ALARM

CNIS

32

ISB1

ISB2

PRESSURESWITCH

FLOW

ROBOTOVERTRAVEL

HANDBROKEN

TPDISCONNECT

MISC.

(RDI2)

SWITCH

SWITCH

SWITCH

SWITCH

EE–3044–345–001

EE–3287–340–001

EE–3287–348–001

ROBOT

ROBOT

OPTIONAL

ENCODER

X6 FOR PEDESTALX7 FOR RAIL

NON–HAZARDOUS LOCATION(250 VAC MAXIMUM)

HAZARDOUS LOCATION CLASS I, II & III

DIVISION 1 GROUPS C D E F & G

EE–3287–117–XXXCONNECTION CABLE

ROBOT WIRE HARNESSEE–3287–323–001

ROBOT PURGED CAVITY

ENCODER

IS GND

IS GND

P–200 R–J2 MODELS

MODEL

MODEL

MODEL

MODEL

P–200–6–J2

P–200–7–J2

P–200–6+2–J2

P–200–7+2–J2

+

+

1

6I.S. GND

I.S.BATTERY

PACK

NOTES:ACCEPTABLE I.S. BATTERY PACKS:A05B–2363–C040EE–3185–551

I.S. GROUND CONNECTION SHALL BEPER NEC(NFPA 70) SECTION 504–50AND ANSI/ISA RP 12.6

1.)

2.)

3.)

ALTERNATE I.S. BATTERY PACKS:A05B–2072–C181A05B–2047–C182SHALL BE USED PEREG–00127–SECTION VI

SOLENOID CABLE

IBRC6062R

(FMRC APPROVED)

FRAME GND.

TO CRS1

(MAIN CPU)

F1 F2 F3 F4 F5

I/S TEACH PENDANT

I/SGROUND

A05B–2308–C300

ISB UNITA05B–2308–C370

MODEL P–200–7+3–J2

24VDCPOWERSUPPLY

120VACFROM

CONVEYOR

OVPUNIT

EE–3112–600

24V 24V

789101112

ISB3

ISB4

46

KHD2–SR–EX1.2S.P+24

12

7824V KFD2–SD–EX1.36

12

91078

+24

+

+

+

24V

I/PSIG ISB5

KHD2–CD–1.P32

78

34

1ISB6

56

2+

+

24V

SIGZ787

127

8 +ISB7 Z728

127

8 +Z728ISB8

+

+

ISB3–4ISB3–6

ISB4–1ISB4–2ISB5–1

ISB6–1

ISB7–1

ISB8–1

ISB5–2

ISB6–2ISB6–4

ISB7–2

ISB8–2

TO ACCUFLOW

FROM I/O

FROM I/O

FROM I/O

P&F

P&F

P&F

P&F

P&F

EE–3287–328–001 CBLBYPASSSWITCH

I/P

UNIT

FLOWMETER

TRIGGER 1

TRIGGER 2

DELTRONW112A

EE–3287–324–001

M1

EE–3185–356–001N1 N4

M4

P1 P4

HAND BRKNO1 O4

PRES. SW CABLE

FLOW SW CABLE

M1

M1

S1 S4

M4

M4

SOL SOL

PS1 PS1

FS1 FS1

BATT

OPTIONAL DOOR OPENER DEVICE

OPENERSOLENOID

CABLEEE–3066–115–00XOPTIONAL CATRAC CABLE

EE–3066–215–00XAK1

AJ1

AH1

X2

AE1

AK2 AK3 AK4

AJ2 AJ3 AJ4

AH2 AH3 AH4

AE2EE–3066–316–001

EE–3066–321–001

EE–3066–322–001

EE–3066–323–001

I.S. GND

I.S. GND

MODEL Q–DRQ

IDEC

AE3 AE4

EE-3287-550-001

BATT

PrefaceMARO2P10203703E vii

The SYSTEM R-J2 Controller P-10, P-15 and P-200 ElectricalMaintenance Manual provides specific information regarding FANUCRobotics electrical hardware. The information contained within themanual has been arranged so that it can answer specific questions quicklyand accurately.

Use this table to locate specific information in the manual.

If you want to Refer to

Find information about a specific topic Table of Contents

Identify the components of the SYSTEMR-J2 controller

Chapter 1 , Overview

Use diagnostic and controller initializationutilities

Chapter 2 , DiagnosticScreens

View status information on teach pendantscreens and using other indicators

Chapter 3 , Lights, Indicators,and LEDs

Perform troubleshooting procedures andidentify specific errors

Chapter 4 , Troubleshooting

Look at fuse information or replace a fuse Chapter 5 , Replacing Fuses

Release the brakes Chapter 6 , Brakes

Turn outputs on or off and simulate inputs Chapter 7 , Controlling I/O

Master the robot Chapter 8 , Mastering

Replace controller components Chapter 9 , ReplacingComponents

Adjust switch settings and potentiometerson PCBs

Chapter 10 , BoardAdjustments and Calibrations

Find controller connection schematics andconnector configurations

Chapter 11 , Connections

Find complete schematics of the controllercircuitry

Chapter 12, Schematics

Find wiring diagrams of the P-200 cables. Chapter 13, Cables

Find wiring diagrams and schematics forthe P-10 and P-15 openers, Integral PumpControl, and the Brake Release Option

Chapter 14, Openers andOptions

Use controller transportation and installationinformation

Appendix A , Transportationand Installation

Purpose of this Manual

How to Use thisManual

PREFACE MARO2P10203703Eviii

This manual includes information essential to the safety of personnel,equipment, software, and data. This information is indicated by headingsand boxes in the text.

WARNINGInformation appearing under WARNING concerns theprotection of personnel. It is boxed and in bold type to setit apart from other text.

CAUTIONInformation appearing under CAUTION concerns the protectionof equipment, software, and data. It is boxed to set it apartfrom other text.

NOTE Information appearing next to NOTE concerns related informationor useful hints.

Conventions Used inthis Manual

TABLE OF CONTENTS

Table of ContentsMARO2P10203703E ix

Preface vii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety xxv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 1OVERVIEW 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 OVERVIEW 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 BACKPLANE 1–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 MAIN CPU PRINTED CIRCUIT BOARD 1–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.1 Identifying Kinds of Memory 1–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 SUB CPU PRINTED CIRCUIT BOARD 1–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 AUX AXIS PRINTED CIRCUIT BOARD 1–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 POWER SUPPLY UNIT PRINTED CIRCUIT BOARD 1–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 EMERGENCY STOP CONTROL PRINTED CIRCUIT BOARD 1–18. . . . . . . . . . . . . . . . . . . . . .

1.8 SERVO AMPLIFIERS 1–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.9 MULTI-TAP TRANSFORMER 1–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.10 INTERFACE DEVICES 1–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.1 Modular I/O Unit 1–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.10.2 ABRIO and Genius I/O 1–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.11 ETHERNET REMOTE PRINTED CIRCUIT BOARDS 1–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.12 USER TRANSFORMER 1–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 OPERATOR PANEL 1–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.14 TEACH PENDANT 1–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.15 HEAT EXCHANGE AND FANS 1–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.16 PURGE CONTROL UNIT A05B–2363–C020 1–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17 PURGE SYSTEM IBRC 1–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.18 PURGE UNIT POWER SUPPLY 1–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.19 PURGE INTRINSICALLY SAFE BARRIERS AND SIGNAL REPEATERS 1–45. . . . . . . . . . . . 1.20 BRAKE RELEASE (OPTION) 1–55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.21 P-10 DOOR OPENER P-15 HOOD AND DECK OPENER (OPTIONS) 1–56. . . . . . . . . . . . . . . .

1.22 INTEGRAL PUMP CONTROL (OPTION) 1–57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 2DIAGNOSTIC SCREENS 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 SAFETY SIGNAL STATUS 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 VERSION IDENTIFICATION STATUS 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 MEMORY STATUS 2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 POSITION STATUS 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 AXIS STATUS 2–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 ALARM LOG 2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 I/O STATUS 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS MARO2P10203703Ex

Chapter 3LIGHTS, INDICATORS, AND LEDS 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 TEACH PENDANT DIAGNOSTIC INDICATORS 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 OPERATOR PANEL AND CABINET LIGHTS 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 SERVO ON LIGHT 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 CIRCUIT BOARD DIAGNOSTIC LEDS 3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 Power Supply Unit (PSU) Diagnostic LEDs 3–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.2 Main CPU Board Diagnostic LEDs 3–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.3 Sub CPU Board Diagnostic LEDs 3–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.4 Modular (Model A) I/O LEDs 3–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.5 Servo Amplifier Diagnostic LED (7-Segment Display) 3–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.6 Emergency Stop Control Printed Circuit Board 3–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.7 Module Assembly # EE–3044–401 3–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.8 Contact Signal Transducer (IBRC) 3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.9 R-J2 Ethernet LEDs 3–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4TROUBLESHOOTING 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 POWER ON SEQUENCE 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 CONTROLLER SHUTDOWN 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 SERVO LOCKOUT 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 CLASS 1 FAULT TROUBLESHOOTING 4–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 CLASS 2 FAULTS TROUBLESHOOTING 4–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 CLASS 3 FAULT TROUBLESHOOTING 4–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 SRVO-001 ER_SVAL1 Operator Panel E-Stop 4–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.2 SRVO-002 ER_SVAL1 Teach Pendant E-stop 4–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.3 SRVO-003 ER_SVAL1 Deadman switch released 4–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.4 SRVO-004 ER_SVAL1 Fence open 4–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.5 SRVO-005 ER_SVAL1 Robot Overtravel 4–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.6 SRVO-006 ER_SVAL1 Hand Broken 4–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.7 SRVO-007 ER_SVAL1 External Emergency Stops 4–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.8 SRVO-011 ER_SVAL1 TP Released While Enabled 4–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.9 SRVO-012 ER_SVAL1 Power Failure Recovery 4–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.10 SRVO-014 Fan Motor Abnormal (Group:i Axis:j) 4–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.11 SRVO-015 ER_SVAL1 System Over Heat (Group:i Axis:j) 4–35. . . . . . . . . . . . . . . . . . . . . . . .

4.6.12 SRVO-019 ER_SVAL1 SVON input 4–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.13 SRVO-020 ER_SVAL1 SRDY off (TP) 4–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.14 SRVO-021 ER_SVAL1 SRDY off (Group:i Axis:j) 4–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.15 SRVO-022 ER_SVAL1 SRDY on (Group:i Axis:j) 4–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.16 SRVO-023 ER_SVAL1 Stop Error Excess (Group:i Axis:j) 4–40. . . . . . . . . . . . . . . . . . . . . . . .

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4.6.17 SRVO-024 ER_SVAL1 Move Error Excess (Group:i Axis:j) 4–40. . . . . . . . . . . . . . . . . . . . . . . 4.6.18 SRVO-026 ER_WARN Motor Speed Limit (Group:i Axis:j) 4–41. . . . . . . . . . . . . . . . . . . . . . . 4.6.19 SRVO-027 ER_WARN Robot Not Mastered (Group:i Axis:j) 4–41. . . . . . . . . . . . . . . . . . . . . . 4.6.20 SRVO-033 ER_WARN Robot Not Calibrated (Group:i Axis:j) 4–41. . . . . . . . . . . . . . . . . . . . . 4.6.21 SRVO-035 ER_WARN Joint Speed Limit (Group:i Axis:j) 4–41. . . . . . . . . . . . . . . . . . . . . . . . 4.6.22 SRVO-036 Imposition Time Over (Group:i Axis:j) 4–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.23 SRVO-037 ER_SVAL1 IMSTP Input (Group:i Axis:j) 4–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.24 SRVO-038 PULSE MISMATCH (Group:i Axis:j) 4–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.25 SRVO-042 ER_SVAL2 MCAL Alarm (Group:i Axis:j) 4–43. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.26 SRVO-043 ER_SVAL2 DCAL Alarm (Group:i Axis:j) 4–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.27 SRVO-044 ER_SVAL2 HVAL Alarm (Group:i Axis:j) 4–46. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.28 SRVO-045 ER_SVAL2 HCAL Alarm (Group:i Axis:j) 4–47. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.29 SRVO-046 ER_SVAL2 OVC Alarm (Group:i Axis:j) 4–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.30 SRVO-047 ER_SVAL2 LVAL Alarm (Group:i Axis:j) 4–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.31 SRVO-049 ER_SVAL1 OHAL1 Alarm (Group:i Axis:j) 4–49. . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.32 SRVO-050 ER_SVAL1 CLALM Alarm (Group:i Axis:j) 4–49. . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.33 SRVO-051 ER_SVAL2 CUER Alarm (Group:i Axis:j) 4–50. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.34 SRVO-053 ER_WARN Disturbance excess (Group:i Axis: J) 4–50. . . . . . . . . . . . . . . . . . . . . . . 4.6.35 SRVO-054 ER_SVAL1 DSM memory error (DS:i) 4–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.36 SRVO-061 ER_SVAL2 CKAL Alarm (Group:i Axis:j) 4–50. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.37 SRVO-062 ER_SVAL2 BZAL Alarm (Group:i Axis:j) 4–51. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.38 SRVO-063 ER_SVAL2 RCAL Alarm (Group:i Axis:j) 4–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.39 SRVO-064 ER_SVAL2 PHAL Alarm (Group:i Axis:j) 4–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.40 SRVO-065 ER_WARN BLAL Alarm (Group:i Axis:j) 4–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.41 SRVO-066 ER_SVAL2 CSAL Alarm (Group:i Axis:j) 4–53. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.42 SRVO-067 ER_SVAL2 OHAL2 Alarm (Group:i Axis:j) 4–53. . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.43 SRVO-068 ER_SVAL2 DTERR Alarm (Group:i Axis:j) 4–54. . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.44 SRVO-069 ER_SVAL2 CRCERR Alarm (Group:i Axis:j) 4–56. . . . . . . . . . . . . . . . . . . . . . . . . 4.6.45 SRVO-070 ER_SVAL2 STBERR Alarm (Group:i Axis:j) 4–56. . . . . . . . . . . . . . . . . . . . . . . . . 4.6.46 SRVO-071 ER_SVAL2 SPHAL Alarm (Group:i Axis:j) 4–56. . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.47 SRVO-072 ER_SVAL2 PMAL alarm (Group:%d Axis:%d) 4–57. . . . . . . . . . . . . . . . . . . . . . . . 4.6.48 SRVO-073 ER_SVAL2 CMAL alarm (Group:%d Axis:%d) 4–57. . . . . . . . . . . . . . . . . . . . . . . . 4.6.49 SRVO-074 ER_SVAL2 LDAL alarm (Group:%d Axis:%d) 4–57. . . . . . . . . . . . . . . . . . . . . . . . 4.6.50 SRVO-075 ER_WARN Pulse not established (G:%d A:%d) 4–58. . . . . . . . . . . . . . . . . . . . . . . . 4.6.51 SRVO-081 ER_WARN EROFL Alarm (Track encoder:n) 4–58. . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.52 SRVO-082 ER_WARN DAL Alarm (Track encoder:n) 4–59. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.53 SRVO-083 ER_WARN CKAL Alarm (Track encoder:n) 4–59. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.54 SRVO-084 ER_WARN BZAL Alarm (Track encoder:n) 4–59. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.55 SRVO-085 ER_WARN RCAL Alarm (Track encoder:n) 4–59. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.56 SRVO-086 ER_WARN PHAL Alarm (Track encoder:n) 4–59. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.57 SRVO-087 ER_WARN BLAL Alarm (Track encoder:n) 4–60. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.58 SRVO-088 ER_WARN CSAL Alarm (Track encoder:n) 4–60. . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS MARO2P10203703Exii

4.6.59 SRVO-089 ER_WARN OHAL2 Alarm (Track encoder:n) 4–60. . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.60 SRVO-090 ER_WARN DTERR Alarm (Track encoder:n) 4–60. . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.61 SRVO-091 ER_WARN CRCERR Alarm (Track encoder:n) 4–60. . . . . . . . . . . . . . . . . . . . . . . .

4.6.62 SRVO-092 ER_WARN STBERR Alarm (Track encoder:n) 4–60. . . . . . . . . . . . . . . . . . . . . . . .

4.6.63 SRVO-093 ER_WARN SPHAL Alarm (Track encoder:n) 4–61. . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.64 SRVO-147 SERVO LVAL(DCLK) alarm (G:%d A:%d) 4–61. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.65 SRVO-163 ER_FATL DSM Hardware Mismatch 4–61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.66 SRVO-164 ER_FATL DSM/Servo param mismatch 4–61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.67 SRVO-165 ER_FATL Panel (SVON abnormal) E-Stop 4–61. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.68 SRVO-166 ER_FATL TP (SVON abnormal) E-Stop 4–61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.69 SRVO-167 ER_FATL Deadman switch (SVON abnormal) 4–62. . . . . . . . . . . . . . . . . . . . . . . . .

4.6.70 SRVO-168 ER_FATL External/SVON (SVON abnormal) E-Stop 4–62. . . . . . . . . . . . . . . . . . .

4.7 CLASS 4 FAULTS 4–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.1 Process Fault - Both Guns Do Not Trigger or Work Intermittently 4–64. . . . . . . . . . . . . . . . . . . .

4.7.2 Both Guns Will Not Shut Off 4–65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.3 Paint Gun Trigger Troubleshooting Procedure (Electrical) 4–66. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.4 Process Fault - Transducer Troubleshooting Procedure 4–73. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.5 Process Fault - Flow Meter Troubleshooting Procedure 4–76. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 5REPLACING FUSES 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 FUSED FLANGE-MOUNTED DISCONNECT FUSES 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 MULTI-TAP TRANSFORMER FUSES 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 POWER SUPPLY UNIT FUSES 5–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 SERVO AMPLIFIER FUSES 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 EMERGENCY STOP CONTROL PCB FUSES 5–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 PURGE POWER SUPPLY FUSES 5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 MODULAR I/O (MODEL A) FUSES 5–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 SUB CPU PRINTED CIRCUIT BOARD FUSE 5–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 6BRAKE RELEASE 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 BRAKE RELEASE 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7CONTROLLING I/O 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 FORCING OUTPUTS 7–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 SIMULATING INPUTS AND OUTPUTS 7–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 SOP I/O STATUS 7–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Chapter 8MASTERING 8–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 RESETTING ALARMS AND PREPARING FOR MASTERING 8–2. . . . . . . . . . . . . . . . . . . . .

8.2 STANDARD MASTERING FOR THE P-200 ROBOT 8–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 SINGLE AXIS MASTERING FOR THE P-200 ROBOT 8–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4 STANDARD MASTERING FOR THE P-10 DOOR OPENER AND THE P-15 HOOD ANDDECK OPENER 8–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 9REPLACING COMPONENTS 9–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 REPLACING R-J2 BATTERIES 9–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 REPLACING RELAYS 9–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2.1 Operator Control Panel Relays 9–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2.2 Emergency Stop Control Board (EMG) Printed Circuit Board Relay Replacement 9–7. . . . . . .

9.2.3 Purge Control PCB Relay 9–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 REPLACING A PRINTED CIRCUIT BOARD 9–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3.1 Removal and Replacement of a Printed Circuit Board from theBackplane Printed Circuit Board 9–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3.2 Replacing the Backplane Printed Circuit Board 9–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4 REPLACING A MODULE ON THE MAIN CPU OR AUX AXIS CONTROLPRINTED CIRCUIT BOARD REFER TO CHAPTER 1 FOR PART NUMBERS. 9–13. . . . . . . .

9.5 REPLACING AN I/O MODULE (MODEL A) 9–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5.1 Replacing a Model A Interface Module 9–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5.2 Replacing a Model A I/O Module 9–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6 REPLACING THE MULTI-TAP TRANSFORMER 9–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.7 REPLACING A SERVO AMPLIFIER 9–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.8 REPLACING THE OPERATOR PANEL 9–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.9 REPLACING THE FAN MOTOR IN THE BACKPLANE 9–22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.10 REPLACING THE TEACH PENDANT 9–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.11 REPLACING A SERIAL PULSE CODER 9–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 10BOARD ADJUSTMENTS AND CALIBRATIONS 10–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 I/P TRANSDUCER/ REGULATOR PERFORMANCE CHECK 10–2. . . . . . . . . . . . . . . . . . . . . .

10.2 MANUAL FLOW TEST (BEAKERING TEST) 10–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3 COLD START (START COLD) 10–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.4 POWER ON SEQUENCE 10–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.5 CONTROLLER SHUTDOWN 10–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.6 SERVO LOCKOUT 10–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS MARO2P10203703Exiv

Chapter 11CONNECTIONS 11–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1 NOISE REDUCTION GUIDELINES 11–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 MODULAR I/O OUTPUTS 11–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 ETHERNET REMOTE PRINTED CIRCUIT BOARD DIAGNOSTICS 11–11. . . . . . . . . . . . . . . . 11.4 MODULAR I/O INPUTS 11–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 ANALOG INPUT MODULE 11–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 12SCHEMATICS 12–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 13CABLES 13–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 14OPENERS AND OPTIONS 14–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix ATRANSPORTATION AND INSTALLATION A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 TRANSPORTATION A–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2 INSTALLATION A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.1 Installation Area A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.2 Assembly During Installation A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3 Adjustment and Checks at Installation A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of ProceduresProcedure 2–1 Displaying Safety Signal Status 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 2–2 Displaying the Version Identification Status 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 2–3 Displaying Memory Status 2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 2–4 Displaying Position Status 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 2–5 Displaying the Axis Status Pulse Screen 2–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 2–6 Displaying the Alarm Log 2–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 2–7 Displaying I/O Status 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 4–1 Troubleshooting Purge Problems 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 4–2 Controller Shutdown Procedure 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 4–3 Servo Lockout Procedure 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 4–4 Troubleshooting Turn-on Problems 4–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 4–5 Both Guns Do Not Trigger or Work Intermittently 4–64. . . . . . . . . . . . . . . . . . . . . . . . Procedure 4–6 Both Guns Will Not Shut Off 4–65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 4–7 Paint Gun Trigger Troubleshooting Procedure (Electrical) 4–66. . . . . . . . . . . . . . . . . . Procedure 4–8 Transducer Troubleshooting 4–73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 4–9 Flow Meter Troubleshooting 4–76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 6–1 Brake Release Using the Operator Panel Switch 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 7–1 Forcing Outputs 7–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 7–2 Simulating and Unsimulating Inputs and Outputs 7–4. . . . . . . . . . . . . . . . . . . . . . . . . Procedure 7–3 Displaying and Forcing SOP I/O 7–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTSMARO2P10203703E xv

Procedure 8–1 Preparing the Robot or Opener for Mastering 8–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 8–2 Standard Mastering 8–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 8–3 Mastering a Single Axis 8–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 8–4 Standard Mastering for the P-10 Door Opener and the P-15 Hood and

Deck Opener 8–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–1 Replacing the PSU Battery 9–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–2 Replacing the SPC Batteries 9–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–3 Replace PCMCIA Memory Card (Optional) Battery 9–4. . . . . . . . . . . . . . . . . . . . . . . Procedure 9–4 Printed Circuit Board Removal and Replacement 9–10. . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–5 Replacing Backplane Printed Circuit Board 9–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–6 Replacing a Module on the Main CPU or Aux Axis Control Printed Circuit Board 9–13Procedure 9–7 Replacing the Base Unit 9–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–8 Replacing a Model A Interface Module 9–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–9 Replacing a Model A I/O Module 9–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–10 Replacing the Multi-Tap Transformer 9–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–11 Replacing a Servo Amplifier 9–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–12 Replacing the Operator Panel 9–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–13 Fan Motor Replacement 9–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–14 Replacing Internal Mounted Serial Pulse Coder 9–25. . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 9–15 Replacing an Externally Mounted Serial Pulse Coder 9–27. . . . . . . . . . . . . . . . . . . . . . Procedure 10–1 Transducer/Regulator Performance Check 10–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 10–2 Manual Flow Test (Beakering Test) 10–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 10–3 Performing a Cold Start 10–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 10–4 Powering on the Robot Systems 10–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 10–5 Controller Shutdown Procedure 10–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 10–6 Servo Lockout Procedure 10–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of FiguresFigure 1–1. External View of the P-200 R-J2 Controller 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–2. Internal View of the P-200 R-J2 Controller 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–3. R-J2 C-Size Controller with Side Cabinet 1–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–4. 2-Slot Backplane (A05B-2316-C107) 1–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–5. 3-Slot Backplane (A05B-2316-C105) 1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–6. 5-Slot Backplane (A05B-2316-C111) 1–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–7. Main CPU Printed Circuit Board 1–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–8. Sub-CPU Printed Circuit Board 1–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–9. Block Diagram 1–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–10. Aux Axis Printed Circuit Board 1–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–11. Power Supply Unit 1–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–12. Emergency Stop Control Printed Circuit Board 1–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–13. Servo Amplifier 1–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–14. Servo Amplifier Specifications 1–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–15. Mounting Locations of Servo Amplifiers for the P-200 6 Axis Robot 1–22. . . . . . . . . . . Figure 1–16. Mounting Locations of Servo Amplifiers for the P-200 7 Axis Robot 1–23. . . . . . . . . . . Figure 1–17. Mounting Locations of Servo Amplifiers for the P-200 6+2 Robot 1–23. . . . . . . . . . . . .

TABLE OF CONTENTS MARO2P10203703Exvi

Figure 1–18. Mounting Locations of Servo Amplifiers for the P-200 7+2 Robot 1–24. . . . . . . . . . . . . Figure 1–19. Mounting Locations of Servo Amplifiers for the P-200 7+3 Robot 1–24. . . . . . . . . . . . . Figure 1–20. Multi-Tap Transformer 1–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1–21. Modular I/O 1–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–22. ER-1 Ethernet Printed Circuit Boards 1–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–23. ER-2 Ethernet Printed Circuit Boards 1–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1–24. User Transformer 1–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–25. Operator Panel without Teach Panel Disconnect 1–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–26. Teach Pendant 1–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1–27. Heat Exchange System 1–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–28. Purge Control Unit 1–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1–29. Contact Signal Transducer (IBRC) 1–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–30. Purge Power Supply 1–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–31. Intrinsic Safety Barrier Stahl 9001/01-252-100-14 1–48. . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1–32. Intrinsic Safety Barrier Pepperl + Fuchs KFD2-SR-Ex1.P and KFD2-SR2-Ex1.W 1–49. Figure 1–33. Intrinsic Safety Barrier Pepperl+Fuchs KFD2-SD-Ex1.36 1–49. . . . . . . . . . . . . . . . . . . . Figure 1–34. Intrinsic Safety Barrier Pepperl+Fuchs KHD2-CD-1P32 and KFD2-CD-Ex1.32 1–50. . .

Figure 1–35. Intrinsic Safety Barrier Pepperl+Fuchs Z727 and Z787 1–50. . . . . . . . . . . . . . . . . . . . . . . Figure 1–36. Intrinsic Safety Barrier Pepperl+Fuchs KFD2-SR-Ex1.2S.P and

KFD2-SR-Ex1.W.LB 1–51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–37. C Size R-J2 Controller With Optional Brake Release Switches 1–55. . . . . . . . . . . . . . . . Figure 1–38. P-10 Door opener and P-15 Hood and Deck Opener 1–56. . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1–39. Integral Pump Control Component Locator Diagram 1–58. . . . . . . . . . . . . . . . . . . . . . . . Figure 1–40. Top Hat and Side Saddle Mounted Models 1–59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2–1. Teach Pendant 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2–2. Alarm Log 2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–1. Teach Pendant Indicators 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–2. Operator Panel LEDS 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3–3. Servo Amp Light 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–4. Diagnostic LEDs 3–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–5. Power Supply Unit (PSU) Diagnostic LEDs 3–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3–6. Main CPU Board Diagnostic LEDs 3–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–7. Sub CPU Board Diagnostic LEDs 3–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–8. Modular I/O LEDs 3–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3–9. Servo Amplifier LED 3–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–10. Emergency Stop Control Printed Circuit Board 3–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–11. Intrinsic Barrier Relay Control Indicators 3–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3–12. Intrinsic Barrier Relay Control Indicators 3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–13. ER-1 and ER-2 Printed Circuit Board LEDs 3–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–14. ER-2 Ethernet Printed Circuit Boards 3–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4–1. 24 Volt (24V) Power Distribution Chart 4–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–2. 24 Volt (24E) Power Distribution Chart 4–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTSMARO2P10203703E xvii

Figure 4–3. Servo Amplifier Switch Settings 4–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–4. Connector and Terminal (T1) Identification 4–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–5. Switch 3 and 4 Settings 4–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–6. Servo LED Display 4–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–7. Module Assembly # EE-3044-401 4–55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–8. I/O Module LEDS 4–67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–9. Interface Module PWR LED 4–68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–10. Interface Module 4–69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–11. Pin Out and Locator for Connector CP32 4–70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–12. Interface Module PWR LED 4–70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–13. Intrinsic Safety Barrier 4–71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–14. Intrinsic Safety Barrier 4–72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–1. Main Disconnect Location 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–2. Replacing Transformer Fuses 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–3. Replacing a Fuse of the Power Supply Unit 5–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–4. Replacing Fuses of Servo Amplifier 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–5. Replacing Emergency Stop Control Board Fuses 5–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–6. Purge Power Supply Location 5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–7. Interface Module AIF01A Fuse Location 5–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–8. Modular I/O Fuse Locations – AOA05E, ADA08E, and AOA12F 5–10. . . . . . . . . . . . . . . Figure 5–9. Modular I/O Fuse Locations – AOS08C and AOD08D 5–11. . . . . . . . . . . . . . . . . . . . . . . . Figure 5–10. Main CPU Printed Circuit Board 5–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6–1. Operator Panel 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6–2. C Size R-J2 Controller With Optional Brake Release Switches 6–3. . . . . . . . . . . . . . . . . Figure 8–1. Zero Degree Position of the P-200 Robot 8–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–2. Axes 4, 5, and 6 1005 Wrist Assembly 8–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–3. Axes 4, 5, and 6 1005 Wrist Mastering Positions 8–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–4. Axes 4, 5, and 6 1405 Wrist Mastering Positions 8–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–5. Robot Pedestal Axis 1 1005/1405 Mastering Surface Location 8–8. . . . . . . . . . . . . . . . . . Figure 8–6. Axis 2 1005/1405 Mastering Surface Location 8–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–7. Axis 3 1005 Mastered Position 8–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–8. Axis 3 Mastering Position (1405 Wrist) 8–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–9. Mastering Block 8–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–10. Axis 7 Mastering Position 8–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–11. Mastering Position of the P-200 robot 8–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–12. P-10 and P-15 Opener Mastering Position 8–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–13. P-10 and P-15 Axis One Mastering Position 8–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–14. P-10 and P-15 Axis Two Mastering Position 8–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8–15. P-10 and P-15 Axis Three Mastered Position 8–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–1. Replacing the Battery 9–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–2. Internal View of the P-200 R-J2 Controller 9–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–3. Replacing Memory Card Battery 9–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS MARO2P10203703Exviii

Figure 9–4. 3-Slot Backplane (A05B-2316-C105) 9–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–5. Operator Control Panel Relay Locations 9–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–6. EMG Printed Circuit Board Relay Locations for B-Size Cabinet 9–7. . . . . . . . . . . . . . . . Figure 9–7. Purge Control Unit 9–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–8. Battery Transfer to Maintain CMOS RAM Memory 9–9. . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–9. Replacing the Components on the Backplane Printed Circuit Board 9–11. . . . . . . . . . . . . . Figure 9–10. Replacing the Backplane Printed Circuit Board 9–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–11. Moving the Latches on the End of the Module Socket 9–13. . . . . . . . . . . . . . . . . . . . . . . Figure 9–12. Installing a New Module at an Angle 9–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–13. Pushing in the Module 9–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–14. Mounting Locations of the Modules 9–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–15. Replacing the Base Unit of the Model A I/O 9–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–16. Replacing a Model A I/O Module 9–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–17. Replacing the Multi-Tap Transformer 9–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–18. Replacing a Servo Amplifier 9–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–19. Replacing the Operator Panel 9–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–20. Replacing the Fan Motor 9–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–21. Replacing the Teach Pendant 9–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–22. Removing the Internally Mounted serial pulse coder 9–26. . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–23. Removing the Black Plastic Coupling 9–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10–1. Emergency Stop Control Board Jumpers 10–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10–2. Teach Pendant and Operator Panel 10–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–1. ER-1 and ER-2 Printed Circuit Board LEDs 11–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–1. R-J2 P-200 Controller Total Circuit Diagram 12–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–2. R-J2 P-200 Controller Total Circuit Diagram (Multi-Tap Transformer Details) 12–5. . . . Figure 12–3. R-J2 P-200 Controller Total Circuit Diagram (Amplifier Configurations) 12–7. . . . . . . . Figure 12–4. R-J2 P-200 Controller Total Circuit Diagram (Amplifier Configurations) 12–9. . . . . . . . Figure 12–5. R-J2 P-200 Controller Total Circuit Diagram (Amplifier Configurations) 12–11. . . . . . . . Figure 12–6. R-J2 P-200 Controller Total Circuit Diagram (AMP PWM Signal Connections) 12–13. . . Figure 12–7. R-J2 P-200 Controller Total Circuit Diagram (Power Supply Connections) 12–15. . . . . . . Figure 12–8. R-J2 P-200 Controller Total Circuit Diagram (CPU Connector Details) 12–17. . . . . . . . . Figure 12–9. R-J2 P-200 Controller Total Circuit Diagram (ESTOP Connection Details) 12–19. . . . . . . Figure 12–10. R-J2 P-200 Controller Total Circuit Diagram (Optional Process I/O Connections) 12–21Figure 12–11. R-J2 P-200 Controller Total Circuit Diagram (Optional I/O Connections) 12–23. . . . . . . Figure 12–12. R-J2 P-200 Controller Total Circuit Diagram (Purge Circuitry) 12–25. . . . . . . . . . . . . . . Figure 12–13. R-J2 P-200 Controller Total Circuit Diagram (Purge Wiring Diagram) 12–27. . . . . . . . . Figure 12–14. R-J2 P-200 Controller Total Circuit Diagram (Purge Board Details) 12–29. . . . . . . . . . . Figure 12–15. R-J2 P-200 Controller Total Circuit Diagram (ESTOP Wiring Detail) 12–31. . . . . . . . . . Figure 12–16. R-J2 P-200 Controller Total Circuit Diagram (OP Panel Details) 12–33. . . . . . . . . . . . . . Figure 12–17. R-J2 P-200 Controller Total Circuit Diagram (Operator Panel) 12–35. . . . . . . . . . . . . . . . Figure 12–18. R-J2 Controller P-200 Amplifier Configurations 12–37. . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–19. R-J2 Robot Controller Cabinet Layout 12–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTSMARO2P10203703E xix

Figure 12–20. P-200 R-J2 Controller FM Retrofit Package Cabinet Layout 12–41. . . . . . . . . . . . . . . . . Figure 12–21. P-200 R-J2 Robot Control Drawing Purge and Intrinsic Wiring sheet 1 12–43. . . . . . . . . Figure 12–22. P-200 R-J2 Robot Control Drawing Purge and Intrinsic Wiring sheet 2 12–45. . . . . . . . . Figure 12–23. P-200 R-J2 Control Drawing Purge and Intrinsic Wiring Sheet 3 12–47. . . . . . . . . . . . . . Figure 12–24. P-200 R-J2 Pedestal North American Purge, No PGS (Seal Off Req’d)

Cable Layout 12–49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–25. P-200 R-J2 Rail Robot North American Purge, PGS For

Penetration Plate Cable Layout 12–51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–26. P-200 R-J2 Pedestal Robot PTB Purge, PGS For Penetration Plate Cable Layout 12–53. Figure 12–27. P-200 R-J2 Rail Robot PTB Purge, PGS For Penetration Plate 12–55. . . . . . . . . . . . . . . . Figure 12–28. P-200 Controller Basic Process Option I/P Flow and Trigger 12–57. . . . . . . . . . . . . . . . . Figure 12–29. P-200 Controller Process Option Basic Option With Second Trigger 12–59. . . . . . . . . . . Figure 12–30. P-200 Controller Bypass Option 12–61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–31. AccuFlow Counter Input Board 12–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–32. Trigger Valve/Regulator Assembly 12–65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–33. Color Changer 24 Color Moduclean 12–67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–34. Upper Gun Control Lines 12–69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–35. Color Changer Lines 24 Color Pedestal 12–71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–36. Lower Gun Control Lines Pedestal 12–73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–37. Lower Gun Control Lines Rail 12–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–38. Color Changer Rail 4 Color Lines 12–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–39. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With

Connector Option 12–79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–40. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With

Connector Option 12–81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–41. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With

Connector Option 12–83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–42. Flow Meter Interface Circuitry FANUC R-J2 P-200 Single Stage Purge Paint

Process Control With Connector Option 12–85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–43. I/O Rack Layout FANUC R-J2 P-200 Single Stage Purge Paint Control With

Connector Option 12–87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–1. P-200 Purge/Battery/Paint Connection Cable 13–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–2. P-200 R-J2 Paint Control Robot Arm Cable Dual Trigger 13–5. . . . . . . . . . . . . . . . . . . . . Figure 13–3. P-200 I/P Cable 13–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–4. P-200 Trigger Cable 13–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–5. P-200 Flow Detector Signal 13–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–6. Axes 1 and 2 Power Connection Cable 13–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–7. Axes 4, 5, and 6 Motor Connection Cable 13–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–8. Axes 3 and 7 Power Connection Cable 13–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–9. EE-3287-113-005 through 155 Pulse Cable 13–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–10. P-200 R-J2 Purge/Battery Connection Cable 13–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–11. P-200 Robot Ground Cable 13–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–12. Axes 1, 2, and 3 Power and Pulse Harness 13–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–13. Axes 4, 5, and 6 Power Harness 13–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS MARO2P10203703Exx

Figure 13–14. Purge Control Cable 13–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–15. Six Axis Battery Harness 13–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–16. Purge Flow Switch Arm Cable 13–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–17. Solenoid Cable 13–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–18. Purge Pressure Switch Cable 13–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–19. R-J2 Robot Bypass Switch Arm Cable (Optional) 13–39. . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–1. P-10 Door Opener Electrical Layout 14–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–2. P-10 Door Opener Euro Electrical Layout 14–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–3. P-200 Plus P-10 or P-15 Controller Bypass Package 14–7. . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–4. P-10 or P-15 Power Connection Cable 14–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–5. P-10 or P-15 European Shielded Power Connection Cable 14–11. . . . . . . . . . . . . . . . . . . . Figure 14–6. P-10 or P-15 Axis 1 Rail Power/Brake Cable 14–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–7. P-10 or P-15 Axis 2 Inner Arm Power/Brake Cable 14–15. . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–8. P-10 or P-15 Axis 3 Outer Arm Power/Brake Cable 14–17. . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–9. P-10 or P-15 Axis 1 Encoder Cable 14–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–10. P-10 or P-15 Axis 2 Pulse Cable 14–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–11. P-10 or P-15 Axis 3 Pulse Coder Cable 14–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–12. P-10 or P-15 Purge Flow Switch 14–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–13. P-10 or P-15 European Purge Connect Arm Cable 14–27. . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–14. P-10 or P-15 European Solenoid Cable 14–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–15. P-10 or P-15 Sensor Splitout Cable 14–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–16. P-10 or P-15 End of Arm Tool Cable 14–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–17. P-10 Magnet Sensor Breakaway Cable 14–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–18. P-10 or P-15 Solenoid Cable 14–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–19. Ground Cable M5 to M5 Stud 14–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–20. P-10 Breakaway Magnet Sensor 14–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–21. P-15 Hood/Deck Opener Electrical Layout Domestic Version 14–43. . . . . . . . . . . . . . . . . Figure 14–22. P-15 Hood/Deck Opener Electrical Layout European Version 14–45. . . . . . . . . . . . . . . . . Figure 14–23. P-15 Opener End of Arm Tooling Cable 14–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–24. P-15 Part Present Proximity Cable 14–49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–25. Integral Pump Control Drawing Index and System Index 14–51. . . . . . . . . . . . . . . . . . . . Figure 14–26. Integral Pump Control I/O Rack Layout 14–53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–27. Integral Pump Control Controller Layout 14–55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–28. Top Hat Option Drawing Index and System Layout 14–57. . . . . . . . . . . . . . . . . . . . . . . . Figure 14–29. Side Saddle Option Drawing Index and System Layout 14–59. . . . . . . . . . . . . . . . . . . . . Figure 14–30. Top Hat and Side Saddle Option Drawing Index and System Layout 14–61. . . . . . . . . . . Figure 14–31. Top Hat and Side Saddle Option Cable and Wiring Diagram 14–63. . . . . . . . . . . . . . . . . Figure 14–32. Top Hat and Side Saddle Option Purge and Intrinsic Wiring Control Drawing 14–65. . . . Figure 14–33. Top Hat and Side Saddle Options Cable Layout Diagram 14–67. . . . . . . . . . . . . . . . . . . . Figure 14–34. Top Hat Option Intrinsic Connections 14–69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–35. Side Saddle Option Intrinsic Connections 14–71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–36. Top Hat and Side Saddle Options Axis 3, Pumps 1 and 2 Motor Power Cable

Reference 14–73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTSMARO2P10203703E xxi

Figure 14–37. Top Hat and Side Saddle Options Pumps 1 and 2 Pulse Cable Reference 14–75. . . . . . . . Figure 14–38. Top Hat and Side Saddle Options Intrinsic Cable Reference 14–77. . . . . . . . . . . . . . . . . .

Figure 14–39. Integral Pump Control Process Flow Diagram 14–79. . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 14–40. P-200 Brake Release Option Package 14–81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 14–41. P-200 Brake Release Wiring Diagram 14–83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A–1. Transportation A–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure A–2. Installation Area A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A–3. Assembly During Installation A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of TablesTable 1–1. Main CPU Modules 1–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 1–2. Sub CPU Modules 1–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 1–3. Servo Amplifiers 1–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1–4. Dip Switch Settings 1–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 1–5. Multi-Tap Transformer Part Numbers 1–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1–6. Selecting Transformer Taps 1–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 1–7. Digital Input Module Specifications 1–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1–8. Digital Output Module Specifications 1–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 1–9. I/O Module Part Numbers 1–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1–10. FANUC R-J2 Ethernet Remote Style Printed Circuit Board Part Numbers 1–34. . . . . . . Table 1–11. Purge Intrinsically Safety Barriers and Signal Repeaters 1–45. . . . . . . . . . . . . . . . . . . . .

Table 1–12. Troubleshooting 1–51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 2–1. Safety Signals 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 2–2. Version Identification Status Items 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 2–3. Memory Status 2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 2–4. Axis Status Pulse Screen Items 2–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3–1. Teach Pendant Status Indicators 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3–2. Standard Operator Panel Status Indicators 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3–3. Servo Amp On Description 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3–4. Troubleshooting Main CPU Board Diagnostic LEDs 3–9. . . . . . . . . . . . . . . . . . . . . . . . .

Table 3–5. Troubleshooting Sub CPU Board STATUS LEDs (Green) 3–11. . . . . . . . . . . . . . . . . . . . . Table 3–6. Troubleshooting Sub CPU Board ALARM LEDs (Red) 3–12. . . . . . . . . . . . . . . . . . . . . .

Table 3–7. Troubleshooting Sub CPU Board ALARM LEDs (Red) 3–12. . . . . . . . . . . . . . . . . . . . . . Table 3–8. Modular I/O LEDs 3–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3–9. Servo Amplifier LED Functions 3–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3–10. Emergency Stop Control Printed Circuit Board LED Functions 3–17. . . . . . . . . . . . . . .

Table 3–11. Modular I/O LEDs 3–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3–12. Modular I/O LEDs 3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3–13. ER-1 Alarm LEDs 3–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3–14. ER-2 Alarm LEDs 3–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4–1. Troubleshooting Procedure 1

(Initial Purge Troubleshooting Procedure) 4–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS MARO2P10203703Exxii

Table 4–2. Troubleshooting Procedure 2 (IBRC Troubleshooting Procedure) 4–9. . . . . . . . . . . . . . . Table 4–3. Troubleshooting Procedure 3 (Non-Specific Purge Problems) 4–10. . . . . . . . . . . . . . . . . . Table 4–4. Troubleshooting Procedure 4

(General Power Supply Troubleshooting) 4–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4–5. Troubleshooting Procedure 5 (Transformer) 4–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 4–6. Troubleshooting Procedure 6 (Power Supply Alarms) 4–17. . . . . . . . . . . . . . . . . . . . . . . . Table 4–7. Troubleshooting Procedure 7 (Power Supply Output) 4–19. . . . . . . . . . . . . . . . . . . . . . . . Table 4–8. Class 2 Faults Troubleshooting Procedure 4–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 4–9. SRVO-001 Troubleshooting Procedure 4–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4–10. SRVO-002 Troubleshooting Procedure 4–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4–11. SRVO-003 Troubleshooting Procedure 4–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 4–12. SRVO-004 Troubleshooting Procedure 4–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4–13. SRVO-005 Troubleshooting Procedure 4–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 4–14. SRVO-006 Troubleshooting Procedure 4–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4–15. SRVO-006 Troubleshooting Procedure 4–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4–16. SRVO-014 Troubleshooting Procedure 4–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Table 4–23. SRVO-038 Alarm Reset Procedure 4–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4–24. SRVO-042 Troubleshooting Procedure 4–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4–25. SRVO-043 Troubleshooting Procedure 4–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .







TABLE OF CONTENTSMARO2P10203703E xxiii


Table 4–45. SRVO-081 Troubleshooting Procedure 4–58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 4–46. SRVO-082 Troubleshooting Procedure 4–59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 5–1. Fused Flange-Mounted Disconnect Switch, C-Size Cabinet 5–3. . . . . . . . . . . . . . . . . . .

Table 5–2. Multi-Tap Transformer Fuses 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 5–3. PSU Fuse Ratings 5–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 5–4. Servo Fuse Ratings 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 5–5. Emergency Stop Control Printed Circuit Board Fuses 5–7. . . . . . . . . . . . . . . . . . . . . . . .

Table 5–6. Emergency Stop Control PCB Fuses 5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 5–7. Emergency Stop Control PCB Fuses 5–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 5–8. Emergency Stop Control PCB Fuses 5–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 7–1. Standard Operator Panel Input Signals 7–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 7–2. Standard Operator Panel Output Signals 7–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 9–1. EMG Printed Circuit Board Relay Identification 9–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 9–2. EMG Printed Circuit Board Relay Identification 9–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 9–3. EMG Printed Circuit Board Relay Identification 9–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 9–4. Teach Pendant Part Numbers 9–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 10–1. I/P Transducer/Regulator Performance Check 10–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 11–1. Output Module AOD32A, Non-isolated 11–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 11–2. Output Modules AOD08C and AOD08D 11–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 11–3. Output Modules AOD16C and AOD16D 11–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 11–4. Output Module AOD32C 11–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 11–5. Output Module AOD32D 11–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 11–6. Output Modules AOA05E and AOA08E 11–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 11–7. Output Module AOA12F 11–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 11–8. Output Modules AOR08G and AOR16G 11–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 11–9. Output Module ADA02A 11–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 11–10. Input Module AID32B, Non-isolated 11–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 11–11. Input Modules AID16C and AID16D 11–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 11–12. Analog Input Module AAD04A 11–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table A–1. Physical Characteristics A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SA

FE

TY

SafetyMARO2P10203703E xxv

FANUC Robotics is not and does not represent itself as an expert in safetysystems, safety equipment, or the specific safety aspects of your companyand/or its work force. It is the responsibility of the owner, employer, oruser to take all necessary steps to guarantee the safety of all personnel inthe workplace.

The appropriate level of safety for your application and installation canbest be determined by safety system professionals. FANUC Roboticstherefore, recommends that each customer consult with such professionalsin order to provide a workplace that allows for the safe application, use,and operation of FANUC Robotic systems.

According to the industry standard ANSI/RIA R15–06, the owner or useris advised to consult the standards to ensure compliance with its requestsfor Robotics System design, usability, operation, maintenance, and service.Additionally, as the owner, employer, or user of a robotic system, it is yourresponsibility to arrange for the training of the operator of a robot systemto recognize and respond to known hazards associated with your roboticsystem and to be aware of the recommended operating procedures for yourparticular application and robot installation.

FANUC Robotics therefore, recommends that all personnel who intend tooperate, program, repair, or otherwise use the robotics system be trained inan approved FANUC Robotics training course and become familiar withthe proper operation of the system. Persons responsible for programmingthe system-including the design, implementation, and debugging ofapplication programs-must be familiar with the recommendedprogramming procedures for your application and robot installation.

The following guidelines are provided to emphasize the importance ofsafety in the workplace.

SAFETY MARO2P10203703Exxvi

Safety is essential whenever robots are used. Keep in mind the followingfactors with regard to safety:

The safety of people and equipmentUse of safety enhancing devicesTechniques for safe teaching and manual operation of the robot(s)Techniques for safe automatic operation of the robot(s)Regular scheduled inspection of the robot and workcellProper maintenance of the robot

The safety of people is always of primary importance in any situation. However, equipment must be kept safe, too. When prioritizing how to apply safety to your robotic system, consider thefollowing:

PeopleExternal devicesRobot(s)ToolingWorkpiece

Always give appropriate attention to the work area that surrounds therobot. The safety of the work area can be enhanced by the installation ofsome or all of the following devices:

Safety fences, barriers, or chainsLight curtainsInterlocksPressure matsFloor markingsWarning lightsMechanical stopsEMERGENCY STOP buttonsDEADMAN switches

A safe workcell is essential to protect people and equipment. Observe thefollowing guidelines to ensure that the workcell is set up safely. Thesesuggestions are intended to supplement and not replace existing federal,state, and local laws, regulations, and guidelines that pertain to safety.

Sponsor your personnel for training in approved FANUC Roboticstraining course(s) related to your application. Never permit untrainedpersonnel to operate the robots.

Install a lockout device that uses an access code to preventunauthorized persons from operating the robot.

Use anti-tie-down logic to prevent the operator from bypassing safetymeasures.

Arrange the workcell so the operator faces the workcell and can seewhat is going on inside the cell.

CONSIDERINGSAFETY FOR YOURROBOTINSTALLATION

Keeping People andEquipment Safe

Using SafetyEnhancing Devices

Setting Up a SafeWorkcell

SAFETYMARO2P10203703E xxvii

Clearly identify the work envelope of each robot in the system withfloor markings, signs, and special barriers. The work envelope is thearea defined by the maximum motion range of the robot, including anytooling attached to the wrist flange that extend this range.

Position all controllers outside the robot work envelope.

Never rely on software as the primary safety element.

Mount an adequate number of EMERGENCY STOP buttons orswitches within easy reach of the operator and at critical points insideand around the outside of the workcell.

Install flashing lights and/or audible warning devices that activatewhenever the robot is operating, that is, whenever power is applied tothe servo drive system.

Wherever possible, install safety fences to protect against unauthorizedentry by personnel into the work envelope.

Install special guarding that prevents the operator from reaching intorestricted areas of the work envelope.

Use interlocks.

Use presence or proximity sensing devices such as light curtains, mats,and capacitance and vision systems to enhance safety.

Periodically check the safety joints or safety clutches that can beoptionally installed between the robot wrist flange and tooling. If thetooling strikes an object, these devices dislodge, remove power fromthe system, and help to minimize damage to the tooling and robot.

Make sure all external devices are properly filtered, grounded,shielded, and suppressed to prevent hazardous motion due to theeffects of electro-magnetic interference (EMI), radio frequencyinterference (RFI), and electro-static discharge (ESD).

Make provisions for power lockout/tagout at the controller.

Eliminate pinch points. Pinch points are areas where personnel couldget trapped between a moving robot and other equipment.

Provide enough room inside the workcell to permit personnel to teachthe robot and perform maintenance safely.

Program the robot to load and unload material safely.

If high voltage electrostatics are present, be sure to provide appropriateinterlocks, warning, and beacons.

If materials are being applied at dangerously high pressure, provideelectrical interlocks for lockout of material flow and pressure.

SAFETY MARO2P10203703Exxviii

Advise all personnel who must teach the robot or otherwise manuallyoperate the robot to observe the following rules:

Never wear watches, rings, neckties, scarves, or loose clothing thatcould get caught in moving machinery.

Know whether or not you are using an intrinsically safe teach pendantif you are working in a hazardous environment.

Before teaching, visually inspect the robot and work envelope to makesure that no potentially hazardous conditions exist. The workenvelope is the area defined by the maximum motion range of therobot. These include tooling attached to the wrist flange that extendsthis range.

The area near the robot must be clean and free of oil, water, or debris.Immediately report unsafe working conditions to the supervisor orsafety department.

FANUC Robotics recommends that no one enter the work envelope ofa robot that is on, except for robot teaching operations. However, ifyou must enter the work envelope, be sure all safeguards are in place,check the teach pendant DEADMAN switch for proper operation, andplace the robot in teach mode. Take the teach pendant with you, turn iton, and be prepared to release the DEADMAN switch. Only theperson with the teach pendant should be in the work envelope.

WARNINGNever bypass, strap, or otherwise deactivate a safety device,such as a limit switch, for any operational convenience.Deactivating a safety device is known to have resulted inserious injury and death.

Know the path that can be used to escape from a moving robot; makesure the escape path is never blocked.

Isolate the robot from all remote control signals that can cause motionwhile data is being taught.

Test any program being run for the first time in the following manner:

WARNINGStay outside the robot work envelope whenever a programis being run. Failure to do so can result in injury.

– Using a low motion speed, single step the program for at least onefull cycle.

– Using a low motion speed, test run the program continuously forat least one full cycle.

– Using the programmed speed, test run the program continuouslyfor at least one full cycle.

Make sure all personnel are outside the work envelope before runningproduction.

Staying Safe WhileTeaching or ManuallyOperating the Robot

SAFETYMARO2P10203703E xxix

Advise all personnel who operate the robot during production to observethe following rules:

Make sure all safety provisions are present and active.

Know the entire workcell area. The workcell includes the robot and itswork envelope, plus the area occupied by all external devices andother equipment with which the robot interacts.

Understand the complete task the robot is programmed to performbefore initiating automatic operation.

Make sure all personnel are outside the work envelope beforeoperating the robot.

Never enter or allow others to enter the work envelope duringautomatic operation of the robot.

Know the location and status of all switches, sensors, and controlsignals that could cause the robot to move.

Know where the EMERGENCY STOP buttons are located on both therobot control and external control devices. Be prepared to press thesebuttons in an emergency.

Never assume that a program is complete if the robot is not moving.The robot could be waiting for an input signal that will permit it tocontinue activity.

If the robot is running in a pattern, do not assume it will continue torun in the same pattern.

Never try to stop the robot, or break its motion, with your body. Theonly way to stop robot motion immediately is to press anEMERGENCY STOP button located on the controller panel, teachpendant, or emergency stop stations around the workcell.

When inspecting the robot, be sure to

Turn off power at the controller.

Lock out and tag out the power source at the controller according tothe policies of your plant.

Turn off the compressed air source and relieve the air pressure.

If robot motion is not needed for inspecting the electrical circuits,press the EMERGENCY STOP button on the operator panel.


Staying Safe DuringAutomatic Operation

Staying Safe DuringInspection

SAFETY MARO2P10203703Exxx

If power is needed to check the robot motion or electrical circuits, beprepared to press the EMERGENCY STOP button, in an emergency.

Be aware that when you remove a servomotor or brake, the associatedrobot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.

When performing maintenance on your robot system, observe the following rules:

Never enter the work envelope while the robot or a program is inoperation.

Before entering the work envelope, visually inspect the workcell tomake sure no potentially hazardous conditions exist.


Consider all or any overlapping work envelopes of adjoining robotswhen standing in a work envelope.

Test the teach pendant for proper operation before entering the workenvelope.

If it is necessary for you to enter the robot work envelope while poweris turned on, you must be sure that you are in control of the robot. Besure to take the teach pendant with you, press the DEADMAN switch,and turn the teach pendant on. Be prepared to release the DEADMANswitch to turn off servo power to the robot immediately.

Whenever possible, perform maintenance with the power turned off.Before you open the controller front panel or enter the work envelope,turn off and lock out the 3-phase power source at the controller.


WARNINGLethal voltage is present in the controller WHENEVER IT ISCONNECTED to a power source. Be extremely careful toavoid electrical shock.

HIGH VOLTAGE IS PRESENT at the input side wheneverthe controller is connected to a power source. Turning thedisconnect or circuit breaker to the OFF position removespower from the output side of the device only.

Release or block all stored energy. Before working on the pneumaticsystem, shut off the system air supply and purge the air lines.

Staying Safe DuringMaintenance

SAFETYMARO2P10203703E xxxi

Isolate the robot from all remote control signals. If maintenance mustbe done when the power is on, make sure the person inside the workenvelope has sole control of the robot. The teach pendant must beheld by this person.

Make sure personnel cannot get trapped between the moving robot andother equipment. Know the path that can be used to escape from amoving robot. Make sure the escape route is never blocked.

Use blocks, mechanical stops, and pins to prevent hazardousmovement by the robot. Make sure that such devices do not createpinch points that could trap personnel.

WARNINGDo not try to remove any mechanical component from therobot before thoroughly reading and understanding theprocedures in the appropriate manual. Doing so can resultin serious personal injury and component destruction.


When replacing or installing components, make sure dirt and debris donot enter the system.

Use only specified parts for replacement. To avoid fires and damageto parts in the controller, never use nonspecified fuses.

Before restarting a robot, make sure no one is inside the workenvelope; be sure that the robot and all external devices are operatingnormally.

SAFETY MARO2P10203703Exxxii

Certain programming and mechanical measures are useful in keeping themachine tools and other external devices safe. Some of these measures areoutlined below. Make sure you know all associated measures for safe useof such devices.

Implement the following programming safety measures to prevent damageto machine tools and other external devices.

Back-check limit switches in the workcell to make sure they do notfail.

Implement ‘‘failure routines” in programs that will provide appropriaterobot actions if an external device or another robot in the workcellfails.

Use handshaking protocol to synchronize robot and external deviceoperations.

Program the robot to check the condition of all external devices duringan operating cycle.

Implement the following mechanical safety measures to prevent damage tomachine tools and other external devices.

Make sure the workcell is clean and free of oil, water, and debris.

Use software limits, limit switches, and mechanical hardstops toprevent undesired movement of the robot into the work area ofmachine tools and external devices.

KEEPING MACHINETOOLS ANDEXTERNALDEVICES SAFE

Programming SafetyPrecautions

Mechanical SafetyPrecautions

SAFETYMARO2P10203703E xxxiii

Observe the following operating and programming guidelines to preventdamage to the robot.

The following measures are designed to prevent damage to the robotduring operation.

Use a low override speed to increase your control over the robot whenjogging the robot.

Visualize the movement the robot will make before you press the jogkeys on the teach pendant.

Make sure the work envelope is clean and free of oil, water, or debris.

Use circuit breakers to guard against electrical overload.

The following safety measures are designed to prevent damage to the robotduring programming:

Establish interference zones to prevent collisions when two or morerobots share a work area.

Make sure that the program ends with the robot near or at the homeposition.

Be aware of signals or other operations that could trigger operation oftooling resulting in personal injury or equipment damage.

In dispensing applications, be aware of all safety guidelines withrespect to the dispensing materials.

NOTE Any deviation from the methods and safety practices described inthis manual must conform to the approved standards of your company. Ifyou have questions, see your supervisor.

KEEPING THEROBOT SAFE

Operating SafetyPrecautions

Programming SafetyPrecautions

SAFETY MARO2P10203703Exxxiv

Process technicians are sometimes required to enter the paint booth, forexample, during daily or routine calibration or while teaching new paths toa robot. Maintenance personnel also must work inside the paint boothperiodically.

Whenever personnel are working inside the paint booth, ventilationequipment must be used. Instruction on the proper use of ventilatingequipment usually is provided by the paint shop supervisor.

Although paint booth hazards have been minimized, potential dangers stillexist. Therefore, today’s highly automated paint booth requires thatprocess and maintenance personnel have full awareness of the system andits capabilities. They must understand the interaction that occurs betweenthe vehicle moving along the conveyor and the robot(s), hood/deck anddoor opening devices, and high-voltage electrostatic tools.

Paint robots are operated in three modes:

Teach or manual modeAutomatic mode, including automatic and exercise operationDiagnostic mode

During both teach and automatic modes, the robots in the paint booth willfollow a predetermined pattern of movements. In teach mode, the processtechnician teaches (programs) paint paths using the teach pendant.

In automatic mode, robot operation is initiated at the System OperatorConsole (SOC) or Manual Control Panel (MCP), if available, and can bemonitored from outside the paint booth. All personnel must remainoutside of the booth or in a designated safe area within the booth wheneverautomatic mode is initiated at the SOC or MCP.

In automatic mode, the robots will execute the path movements they weretaught during teach mode, but generally at production speeds.

When process and maintenance personnel run diagnostic routines thatrequire them to remain in the paint booth, they must stay in a designatedsafe area.

ADDITIONALSAFETYCONSIDERATIONSFOR PAINT ROBOTINSTALLATIONS

SAFETYMARO2P10203703E xxxv

Process technicians and maintenance personnel must become totallyfamiliar with the equipment and its capabilities. To minimize the risk ofinjury when working near robots and related equipment, personnel mustcomply strictly with the procedures in the manuals.

This section provides information about the safety features that areincluded in the paint system and also explains the way the robot interactswith other equipment in the system.

The paint system includes the following safety features:

Most paint booths have red warning beacons that illuminate when therobots are armed and ready to paint. Your booth might have otherkinds of indicators. Learn what these are.

Some paint booths have a blue beacon that, when illuminated,indicates that the electrostatic devices are enabled. Your booth mighthave other kinds of indicators. Learn what these are.

EMERGENCY STOP buttons are located on the robot controller andteach pendant. Become familiar with the locations of all E-STOPbuttons.

An intrinsically safe teach pendant is used when teaching in hazardouspaint atmospheres.

A DEADMAN switch is located on each teach pendant. When thisswitch is held in, and the teach pendant is on, power is applied to therobot servo system. If the engaged DEADMAN switch is releasedduring robot operation, power is removed from the servo system, allaxis brakes are applied, and the robot comes to an EMERGENCYSTOP. Safety interlocks within the system might also E-STOP otherrobots.

WARNINGAn EMERGENCY STOP will occur if the DEADMAN switchis released on a bypassed robot.

Overtravel by robot axes is prevented by software limits. All of themajor and minor axes are governed by software limits. Limit switchesand hardstops also limit travel by the major axes.

Paint System SafetyFeatures

SAFETY MARO2P10203703Exxxvi

EMERGENCY STOP limit switches and photoelectric eyes might bepart of your system. Limit switches, located on the entrance/exit doorsof each booth, will EMERGENCY STOP all equipment in the booth ifa door is opened while the system is operating in automatic or manualmode. For some systems, signals to these switches are inactive whenthe switch on the SCC is in teach mode.

When present, photoelectric eyes are sometimes used to monitorunauthorized intrusion through the entrance/exit silhouette openings.

System status is monitored by computer. Severe conditions result inautomatic system shutdown.

When you work in or near the paint booth, observe the following rules, inaddition to all rules for safe operation that apply to all robot systems.

WARNINGObserve all safety rules and guidelines to avoid injury.

WARNINGNever bypass, strap, or otherwise deactivate a safety device,such as a limit switch, for any operational convenience.Deactivating a safety device is known to have resulted inserious injury and death.

Know the work area of the entire paint station (workcell).

Know the work envelope of the robot and hood/deck and door openingdevices.

Be aware of overlapping work envelopes of adjacent robots.

Know where all red, mushroom-shaped EMERGENCY STOP buttonsare located.

Know the location and status of all switches, sensors, and/or controlsignals that might cause the robot, conveyor, and opening devices tomove.

Make sure that the work area near the robot is clean and free of water,oil, and debris. Report unsafe conditions to your supervisor.

Become familiar with the complete task the robot will performBEFORE starting automatic mode.

Make sure all personnel are outside the paint booth before you turn onpower to the robot servo system.

Staying Safe WhileOperating the PaintRobot

SAFETYMARO2P10203703E xxxvii

Never enter the work envelope or paint booth before you turn offpower to the robot servo system.

Never enter the work envelope during automatic operation unless asafe area has been designated.


Remove all metallic objects, such as rings, watches, and belts, beforeentering a booth when the electrostatic devices are enabled.

Stay out of areas where you might get trapped between a movingrobot, conveyor, or opening device and another object.

Be aware of signals and/or operations that could result in the triggeringof guns or bells.

Be aware of all safety precautions when dispensing of paint isrequired.

Follow the procedures described in this manual.

When you perform maintenance on the painter system, observe thefollowing rules, and all other maintenance safety rules that apply to allrobot installations. Only qualified, trained service or maintenancepersonnel should perform repair work on a robot.

Paint robots operate in a potentially explosive environment. Usecaution when working with electric tools.

When a maintenance technician is repairing or adjusting a robot, thework area is under the control of that technician. All personnel notparticipating in the maintenance must stay out of the area.

For some maintenance procedures, station a second person at thecontrol panel within reach of the EMERGENCY STOP button. Thisperson must understand the robot and associated potential hazards.

Be sure all covers and inspection plates are in good repair and in place.

Always return the robot to the ‘‘home’’ position before you disarm it.

Never use machine power to aid in removing any component from therobot.

During robot operations, be aware of the robot’s movements. Excessvibration, unusual sounds, and so forth, can alert you to potentialproblems.

Whenever possible, turn off the main electrical disconnect before youclean the robot.

Staying Safe DuringMaintenance

SAFETY MARO2P10203703Exxxviii

When using vinyl resin observe the following:

– Wear eye protection and protective gloves during application andremoval

– Adequate ventilation is required. Overexposure could causedrowsiness or skin and eye irritation.

– If there is contact with the skin, wash with water.

When using paint remover observe the following:

– Eye protection, protective rubber gloves, boots, and apron arerequired during booth cleaning.

– Adequate ventilation is required. Overexposure could causedrowsiness.

– If there is contact with the skin or eyes, rinse with water for atleast 15 minutes.

1 OVERVIEW

1 OVERVIEW

1–1MARO2P10203703E

Topics In This Chapter Page

Overview This manual describes the SYSTEM R-J2 controller which is used in conjunction with the P-200 robot, P-10 door opener, P-15 hood and deck opener and the Systems PaintTool software. This chapter describes the major components used in the controller. 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Backplane Three styles of backplane are available. 1–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main CPU Printed CircuitBoard

The main CPU PC board contains the central processing units,integrated circuit, and all the memory used by the controller. 1–10. . . . . . . . . . . . . . . .

Sub-CPU Printed CircuitBoard

The sub CPU performs all calculations required by the controller. 1–13. . . . . . . . . . . .

Aux Axis Printed CircuitBoard

The aux axis printed circuit board contains up to five servo control modules that provide servo control to the available auxiliary axes. 1–16. . . . . . . . . . .

Power Supply UnitPrinted Circuit Board

The power supply unit printed circuit board is supplied with 210 VAC nominal.from the multi-tap transformer and produces DC voltages. 1–17. . . . . . . . . . . . . . . . . .

Emergency Stop ControlPrinted Circuit Board

Supplies 24 VDC to the (Magnetic Control Contactor), turns off 24 VDC to the (Magnetic Control Contactor) during fault conditions, supplies power to the motor brakes and to the serial pulse coders. 1–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servo Amplifiers The servo amplifier drives the motor(s) in response to signals from the axis control circuitry. 1–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multi-Tap Transformer The multi-tap transformer is supplied 3 phase VAC from the main disconnect or circuit breaker. This supply voltage can range from 220 - 575 volts. To accommodate the various levels of supply, tap selections are provided on the primary side of the transformer. 1–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interface Devices The interface between controller and peripheral devices is provided by input and output signals. 1–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modular I/O Unit 1–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABRIO and Genius I/O 1–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ethernet Remote PrintedCircuit Boards

Ethernet remote PCB’s are an R-J2 option that use communication protocols to back up and restore all the information on a controller to and from an external device, or host computer. 1–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

User Transformer The option user transformer supplies 120VAC single phase power to a outlet receptacle. 1–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Panel Pushbuttons and LEDs on the operator panel of the R-J2 are used to start and shut down the robot and indicate status. 1–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Teach Pendant The teach pendant is a hand held device used to operate and program the robot and controller. 1–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heat Exchange and Fans The temperature in the controller is kept within operating range through the use of an air-to-airheat exchange system. 1–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Purge Control Unit The purge control unit consists of an purge intrinsically safe barrier unit module, contact signal transducer, purge control PCB, and 24VDC power supply. 1–41. . . . . .

Purge System IBRC The IBRC is an intrinsically safe barrier unit that is used as part of the purge system. 1–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Purge Unit Power Supply The purge unit power supply is a 24VDC auxiliary power supply used exclusively for the purge system. 1–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–2

1. OVERVIEW

MARO2P10203703E


Purge Intrinsically SafeBarriers

The Purge Intrinsically Safety Barriers are used in the purge system in that they restrict power that may cause a spark. 1–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Release (Option) The brake release option adds (4) optional brake switches to selectively release the gravity and non-gravity axes of the P-200 robot. 1–55. . . . . . . . . . . . . . . . . . . . . . . .

P-10 Door Opener andP-15 Hood and DeckOpener (Option)

The P-10 opener is a three axis, electrically-driven door opener and the P-15 opener is a three axis, electrically-driven hood and deck opener. 1–56. . . . . . . .

Integral Pump Control(Option)

The Integral Pump Control option is the FANUC Robotics integrated two component fluid delivery system which features metering pumps directly coupled to FANUC servomotors that are controlled by the FANUC R-J2 controller. 1–57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–3

1. OVERVIEW

MARO2P10203703E

The R-J2 controller, hereafter referred to as the controller, contains thecomputer that operates the robots. It executes a user-defined program toperform the following functions:

Supply drive power to the servomotors of the P-10, P-15, and P-200,robots to move it through a series of program motions.

Send control signals to process devices and other peripheralequipment.

The controller consists of modular circuit boards, components, controlsand indicators that are housed in a C-size cabinet with or without a sidecabinet depending if a door or hood and deck opener are included.

Figure 1–1 illustrates an external view of the controller. Figure 1–2illustrates the internal view of the controller. Figure 1–3 illustrates a R-J2C-size controller with side cabinet.

Figure 1–1. External View of the P-200 R-J2 Controller

Teachpendant

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎ


ÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

1.1OVERVIEW

1–4

1. OVERVIEW

MARO2P10203703E

Figure 1–2. Internal View of the P-200 R-J2 Controller

Operator panel

Main CPU

Power supply unit

Multi-tap transformer

Modular I/O rack

Main power disconnect

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

Servo amplifiers #1–3Fuses FL1–3

ÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÏÏ

User transformer

ISB unit

SPC battery case

SERVO ON Light

Emergency stop controlprinted circuit board

Servo amplifier #4

Front Door

Aux axis board

Teach pendant

Flowmeter interface module

ISBUIBRC

Purge Control Power Supply

Purge Control PCB

1–5

1. OVERVIEW

MARO2P10203703E

Figure 1–3. R-J2 C-Size Controller with Side Cabinet

OFF

ON

OFF

ON

DISCONNECT

USERTRANS.

FANUCAC SERVOAMPLIFIERC series


OPT

PURGE CONTROL UNIT

CONTACT SIGNAL

TRANSDUCER

1 1/2 ”W X 4”H DUCT

1”W X 4”H DUCT

AMP 1 AMP 2

EMGBOARD

I/O RACK

OFF

ON


AMP 3

MAINPSUCPU

FANUCAC SERVOAMPLIFIER

STATUS

8

0

1

AMP 4

OFF

ON


AMP 5 AMP 6

DELTRONW112A24V @ 1.2A

OVP

ISB3ISB4ISB5ISB6ISB7ISB8ISB9

OFF

ON


R-J2-C Size cabinet with door removedSide cabinet

1–6

1. OVERVIEW

MARO2P10203703E

Three styles of backplane are available:

2-Slot3-Slot5-Slot

These three printed circuit boards are interchangeable. The backplaneconsists of a printed circuit board and two, three, or five board racksattached to it.

The controller printed circuit boards are mounted on the backplane printedcircuit board. See Figure 1–4, Figure 1–5, and Figure 1–6. It provides thebus structure for communication between the controller printed circuitboards.

A thermostat switch is mounted on the backplane printed circuit board. Itsenses the temperature within the controller. If the internal temperatureexceeds 65 degrees centigrade (149 degrees Fahrenheit), the thermostatwill open, generating a system overheat alarm.

The board racks support the printed circuit boards and guides them intotheir electrical connectors on the backplane printed circuit board.

A 24 VDC cooling fan is mounted in the top of each backplane board rack.

1.2BACKPLANE

2-SLOT A05B-2316-C1073-SLOT A05B-2316-C1055-SLOT A05B-2316-C111

1–7

1. OVERVIEW

MARO2P10203703E

Figure 1–4. 2-Slot Backplane (A05B-2316-C107)

Fan

Backplane PrintedCircuit Board

Main CPU Power Supply

Fan

GND1

Total version2 slot back plane printed circuit boardA20B-2001-0860

PCMCIA Memory Card

1–8

1. OVERVIEW

MARO2P10203703E


FanFans



Main CPUPower Supply

PCMCIA Memory Card

1–9

1. OVERVIEW

MARO2P10203703E


Fan

Fan

Backplane Printed Circuit Board



PCMCIA Memory Card

1–10

1. OVERVIEW

MARO2P10203703E

The main Central Processor Unit printed circuit board is mounted in theslot marked “1” at the far left end of the backplane. It contains the centralprocessing units, integrated circuit, and all the memory used by thecontroller.

The main CPU performs all calculations required by the controller. Itgenerates axis drive signals on the basis of programmed requirements andfeedback signals from encoders driven by each axis.

The main CPU also acts as the interface between the controller and theoperator and attached devices, through connections to:

The I/O unit(s)The teach pendantOne or more general purpose serial communication portsThe operator panel lights and push buttons

A storage capacitor on the main CPU printed circuit board maintainspower to the CMOS RAM for short periods of time (up to 30 minutes) ifthe main CPU is removed from the backplane. The BAT-VBAT connectorcan be used to connect the battery from the power supply unit to the mainCPU when either of the two printed circuit boards is removed from thebackplane for an extended period of time.

The main CPU consists of a main mother board with several modulesinstalled perpendicular to it. The modules are small printed circuit boardswith components surface-mounted on both sides. The modules areinstalled in sockets, allowing them to be changed quickly and easily.

The following kinds of memory exist in the controller:

Controller memoryFlash ROM (F-ROM or FROM)C-MOS RAMD-RAM (or DRAM)

Controller memory consists of Flash Read Only Memory (Flash ROM),Complementary Metal Oxide Semiconductor Random Access Memory(C-MOS RAM), and Dynamic Random Access Memory (D-RAM).C-MOS RAM memory stores some robot system software, someapplication software, and some user programs. Flash ROM stores themajority of the robot system software such as core, and applicationsoftware.

Most of the SYSTEM R-J2 system software executes from D-RAM.When the controller is turned on, the system software is loaded from FlashROM to D-RAM and then is executed. Teach pendant programs are storedand are executed from C-MOS RAM.

1.3MAIN CPU PRINTEDCIRCUIT BOARDA16B–3200–0040

NOTE: This part numberspecifies a Main CPU withoutdaughter boards.

1.3.1 Identifying Kinds ofMemory

Controller Memory

1–11

1. OVERVIEW

MARO2P10203703E

Flash ROM Module contains System and Application Software. FlashROM (F-ROM or FROM disk) is not battery-backed but is non-volatile.Non-volatile means that all data in Flash ROM is saved even after you turnoff and turn on the controller. Flash ROM has three parts: a systemmemory section, an image memory section, and a flash file section.

The system memory section contains the software that executes all systemsoftware. Image memory contains software options. The flash file systemsection contains space for backing up user programs and robotconfiguration information. It also holds hidden files required for Re-INITstart (CMOSINIT).

CMOS RAM Module stores user programs, system variables, I/Oconfiguration files, and mastering data. C-MOS RAM is battery-backed.C-MOS RAM is non-volatile only while the batteries are working. If thebatteries are faulty or removed, C-MOS RAM is lost. C-MOS RAM hastwo parts: the TPP memory pool, and the permanent (PERM) memorypool.

The TPP memory pool contains the teach pendant programs. ThePERM memory pool contains system variables.

PERM can also contain system software and options.

DRAM (Dynamic) Module loads information from Flash ROM, eliminatesfragmentation and must reload after a cold start. D-RAM is volatile, but itis loaded from flash ROM when the controller is turned on. D-RAM alsohas three parts: a SYSTEM memory pool, an IMAGE memory pool, and aTEMP memory pool. The SYSTEM memory pool contains the softwarethat executes all system software. The IMAGE memory pool containsKAREL programs and software options. The TEMP memory poolcontains the read/write scratch space for system and KAREL software andKAREL programs.

CAUTIONData in C-MOS RAM can be lost if the battery is removed orloses its charge, or if new core software is loaded on thecontroller. The C-MOS RAM memory will last for 30 minuteswithout the battery when power is off. To prevent loss of data,back up or copy all files for permanent storage.

CAUTIONTo transport or store the contents of the MAIN CPU, you canplug the battery into the VBAT connector in the MAIN CPU.However, do not plug it into the RESET connector; otherwiseyou could damage equipment.

Figure 1–7 shows the board layout.

Table 1–1 lists the modules available for installation on the board.

Flash ROM

C-MOS RAM

D-RAM

1–12

1. OVERVIEW

MARO2P10203703E

Figure 1–7. Main CPU Printed Circuit Board

CMOS module

DRAM module

Axis module (J1,-J2)

Axis module (J3, J4)


Flash ROM module

Table 1–1. Main CPU Modules

Name Part Number Remarks

Flash ROM Module A20B-2902-0370 2.0 Mbyte




CMOS RAM Module A20B-2902-0211 0.5 Mbyte



DRAM Module A20B-2902-0021 3.0 Mbyte



Axis Control Module A20B-2902-0070 Three required

Robot Output Driver DV1 and DV2 A76L-0151-0062 Two required

1–13

1. OVERVIEW

MARO2P10203703E

The sub Central Processor Unit printed circuit board is mounted in the slotmarked “1” at the far left end of the backplane. It contains the centralprocessing units, integrated circuit, and all the memory used by thecontroller.

The sub CPU performs all calculations required by the controller. Itgenerates axis drive signals on the basis of programmed requirements andfeedback signals from encoders driven by each axis.

The Sub CPU also acts as the interface between the controller and theoperator and attached devices, through connections to:

The I/O unit(s)The teach pendantOne or more general purpose serial communication portsThe operator panel lights and push buttons

The sub CPU consists of a main mother board with one module installedperpendicular to it. The module is a small printed circuit board withcomponents surface-mounted on both sides. The module is installed in asocket, allowing it to be changed quickly and easily.

1.4SUB CPU PRINTEDCIRCUIT BOARDA16B–3200–015

NOTE: This part numberspecifies a Sub CPU withoutdaughter boards.

1–14

1. OVERVIEW

MARO2P10203703E

Figure 1–8. Sub-CPU Printed Circuit Board

A16B-3200-015FANUC

ÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

LV ALM

F21 5A

RISC-B

STATUSALARM

VD1

PC

3

PC

5

PC

13

PR

1

EP

RO

M M

OD

ULE

JNA

BAT

1

5.0A

D16

Table 1–2. Sub CPU Modules

Name Part Number Remarks

ROM Module Memory for the sub-CPU

1–15

1. OVERVIEW

MARO2P10203703E

Figure 1–9. Block Diagram

SUB-CPU

BUS I/F

FANUC BUS

BUS I/F

DRAM

SHARED RAM

SUB-CPUSystem ROM

1–16

1. OVERVIEW

MARO2P10203703E

The auxiliary axis control printed circuit board is mounted in the slotmarked “3” at the right end of the backplane. It contains up to five servocontrol modules that provided servo control of the available auxiliary axes(7 through 16). It is required whenever more than six axes are used, suchas for a rail-mounted P-200 robot. See Figure 1–10.

Figure 1–10. Aux Axis Printed Circuit Board

Servo control module (for axis15 and 16)

Servo control module (for axis 13 and 14)

JRY2

JNA




AM

P15

JV15

AM

P16

JV16

AM

P14

JV14

AM

P13

JV13

AM

P12

JV12

AM

P11

JV11

AM

P9

JV9

AM

P10

PV

10

AM

P8

JV8

AM

P7

JV7

AU

X.A

XIS

CO

NT.

PC

B

EN

C16

JRF

1B

EN

C15

JRF

1A

EN

C14

JF14

EN

C13

JF13

EN

C12

JF12

EN

C11

JF11

EN

C10

JF10

EN

C9

JF9

EN

C8

JF8

EN

C7

JF7

LINE

2JF

22R

S232C

/RS

422JD

29

A20B–2902–0070

A20B–2902–0070

A20B–2902–0070

A20B–2902–0070

A20B–2902–0070

1.5AUX AXIS PRINTEDCIRCUIT BOARD

A16B–2202–0820

MARO2P10203703E 1–17

1. OVERVIEW

The power supply unit printed circuit board is mounted on the backplanein the slot marked PSU. See Figure 1–11.

The power supply unit printed circuit board is supplied with 210 VACnominal from the multi-tap transformer and produces the following DCvoltages:+24V used:

– For inputs, outputs receivers, drivers, and relays– As the power source for the teach pendant power supply circuitry

+15V, –15V, and +5V used:– For logic power within the controller

The power supply unit printed circuit board also contains the ON/OFFlogic circuits used by the controller.

CAUTIONThe CMOS RAM backup battery is mounted on the powersupply unit printed circuit board. Do not remove the board forlonger than 30 minutes; otherwise, all controller software will belost and will need to be reloaded.

Figure 1–11. Power Supply Unit

Battery cover

Battery

F1:7.5A fuse forAC input

PIL:Green LED forindicating the ACpower supplystatus

ALM:Red LED forindicating analarm

F4:5A fuse for +24E

F3:5A Slow-Blow

(With the batterycover removed)

fuse for +24V

JNPO

PCMCIA receptacle

1.6POWER SUPPLY UNITPRINTED CIRCUITBOARD

A16B-1212-0870

MARO2P10203703E1–18

1. OVERVIEW

The emergency stop control printed circuit board is mounted on the side ofthe board rack adjacent to the CPU. See Figure 1–2, for location. Itcontains the circuits that:

Supply 24VDC to the servo amplifiers magnetic control contactors(MCCs) during normal operation.

Turn off 24VDC for the MCC during fault conditions such as:

– Emergency stop– Axis overtravel– Safety fence open– Teach pendant DEADMAN switch– Hand breakage detection

Supply power to the motor brakes to release them during normaloperation. Brake power is turned off (applying motor brakes) duringmajor alarm conditions, or when regulated by the software. There is asecond brake circuit that is manually operated by a front panel keyswitch. See Section 6. This key switch operated circuit provides amethod to move the robot manually should servo power fail, or whenmastering is required.

Supply 24VDC required for serial pulse code (SPC) encoder operationthrough the 24 to 5VDC converter unit located within the robot baseand switched on through the purge complete relay contacts forprotection from explosive gases.

Figure 1–12 shows the emergency stop control printed circuit boardlayout.

1.7EMERGENCY STOPCONTROL PRINTEDCIRCUIT BOARD

A16B-1212-0931

1–19

1. OVERVIEW

MARO2P10203703E

Figure 1–12. Emergency Stop Control Printed Circuit Board

Door interlock jumper/connector

COM

HBK

AB

B A

COMMON JUMPERA=0VDC commonB=24VDC common

HAND BROKEN JUMPERA= USING SWITCHB= BY-PASSING SWITCH

RLY4 RLY5 RLY6

RLY2 RLY3RLY1

1–20

1. OVERVIEW

MARO2P10203703E

The servo amplifiers are mounted on the back wall of the controller.See Figure 1–2 for component location.

The servo amplifier drives the motor(s) in response to signals from theaxis control circuitry.

Servo amplifiers are supplied in single, double or triple-axisconfigurations.

CAUTIONWhile two servo amplifiers might look identical, they might havedifferent output power capabilities. If you replace a servoamplifier, make sure that the new unit has the same partnumber as the old one. Otherwise, the servo amplifier orservomotor might be damaged or destroyed.

See Figure 1–13 for a typical servo amplifier.

The P-200 controller uses α-series SVU type amplifiers. The features ofthe servo amplifier units are as follows:

Compact – The servo amplifier unit is integrated with a powersupply. It enables implementation of a compact system with one ortwo feed axes.

Satisfies safety standards – The servo amplifier unit is designed tocomply with the VDE 0160 (Europe), UL (USA), and CSA (Canada)safety standards.

New interfacing capability – The servo amplifier unit provides anew interface (type B) as well as the conventional interface (type A)for the CNC.

Up-to-date power device – The servo amplifier unit uses anup-to-date power device, IPM (intelligent power module), to reducepower loss and enhance alarm detection, thereby increasing itsreliability.

1.8SERVO AMPLIFIERS

Refer to Table 1–3 forpart numbers.

1–21

1. OVERVIEW

MARO2P10203703E

Figure 1–13. Servo Amplifier

LED

Terminal board T1

Circuit breaker

IRLISL

0V

IRMISM

+5VFuse

PE (G)L1 (R)

L2 (S)

L3 (T)

100A100B

MC1MC2

UV

W

G

L1CL2C

TH1TH2

RC

RIRE

FAN1FAN2

12

3

4

5

6

78

910

11

12

1314

1516

17

1819

20

21

1–22

1. OVERVIEW

MARO2P10203703E

Figure 1–14. Servo Amplifier Specifications

Item Specifications

Three-phase inputfor power

Single-phase inputfor control power

Voltage : 200/220/230 VAC +10 %. –15 %Frequency : 50/60 Hz +/- 2HzVoltage deviation due to load (at maximum output) shall be 79% or less).

Voltage : 200/220/230 VAC + 10 %, - 15%Frequency : 50/60 Hz +/- 2Hz

Control of main circuit Sine-wave PWM control by transistor bridge (IPM)

Alarm and protection functions Over-voltage alarmLow control power voltage alarmLow DC link voltage alarmRegenerative discharge control circuit failure alarmOver-regenerative discharge alarmDynamic brake circuit failure alarmOver-current alarmIPM alarmCircuit breaker

Power Supply

Figure 1–15 through Figure 1–19 show the mounting location ofamplifiers for various robot locations.

Figure 1–15. Mounting Locations of Servo Amplifiers for the P-200 6 Axis Robot

Amp 4

J2

Amp1 Amp2 Amp 3

J1-J4 J3-J5 J6

1–23

1. OVERVIEW

MARO2P10203703E

Figure 1–16. Mounting Locations of Servo Amplifiers for the P-200 7 Axis Robot

Amp 1 Amp 2

J1-J4

Amp 3

J6-J7J3-J5

Amp 4

J2

Figure 1–17. Mounting Locations of Servo Amplifiers for the P-200 6+2 Robot

Amp 1

J1-J4

Amp 2 Amp 3

J3-J5 J6

J2

Amp 4 Amp 5

J7–J8

1–24

1. OVERVIEW

MARO2P10203703E


Amp 3

Amp 5

Amp 1 Amp 2

Amp 4

J2

J1-J4 J3-J5 J6–J7

J8-J9


Amp 1

J1-J4

Amp 2 Amp 3

J3-J5 J6–J7

J2

Amp 4 Amp 5

J8

Amp 6

J9-J10

Side CabinetC-Size Cabinet

1–25

1. OVERVIEW

MARO2P10203703E

Table 1–3. Servo Amplifiers

Amp Spec. Servo Amplifier 1 Servo Amplifier 2 Servo Amplifier 3 Servo Amplifier 4 Servo Amplifier 5

P-200 6 Axes Control

SVU2-12/80L(12A)=J4M(80A)=J1

A06B–6089-H209

SVU2–12/80L(12A)=J5M(80A)=J3

A06B-6089–H209

SVU1-12J6

A06B-6089–H101

SVU1–130J2

A06B–6089-H106

P-200 7 Axes Control

SVU2-12/80L(12A)=J4M(80A)=J1

A06B–6089-H209

SVU2-12/80L(12A)=J5M(80A)=J3

A06B-6089-H209

SVU2-12/80L(12A)=J6M(80A)=J7

A06B-6089-H209

SVU1-130J2

A06B–6089–H106

P-200 6+2(Door Opener)Axes Control

SVU2-12/80L(12A)=J4M(80A)=J1

A06B–6089-H209

SVU2–12/80L(12A)=J5M(80A)=J3

A06B–6089-H209

SVU1–12J6

A06B-6089–H101

SVU1-130J2

A06B–6089–H106

SVU2-12/12L(12A)=J7M(12A)=J8

A06B–6089-H201

P-200 6+2(Hood – Deck)Axes Control

SVU2–12/80L(12A)=J4M(80A)=J1

A06B-6089-H209

SVU2-12/80L(12A)–J5M(80A)=J3

A06B-6089–H209

SVU1-12J6

A06B-6089-H101

SVU1-130J2

A06B-6089-H106

SVU2-80/80L(80A)=J7M(80A)=J8

A06B–6089–H208

P-200 7+2(Door Opener)Axes Control

SVU2-12/80L(12A)=J4M(80A)=J1

A06B-6089–H209

SVU2-12/80L(12A)=J5M(80A)=J3

A06B-6089-H209

SVU2–12/80L(12A)=J6M(80A)=J7

A06B-6089-H209

SVU1–130J2

A06B-6089-H106

SVU2-12/12L(12A)=J8M(12A)=J9

A06B-6089–H201

P-200 7+2(Hood–Deck)Axes Control

SVU2-12/80L(12A)=J4M(80A)=J1

A06B-6089-H209

SVU2–12/80L(12A)=J5M(80A)=J3

A06B-6089-H209

SVU2-12/80L(12A)=J6M(80A)=J7

A06B-6089-H209

SVU1-130J2

A06B–6089-H106

SVU2–80/80L(80A)=J8M(80A)=J9

A06B-6089–H208

P-200 7+3(Opener) Axes Control

SVU2-12/80L(12A)=J4M(80A)=J1

A06B-6089-H209

SVU2–12/80L(12A)=J5M(80A)=J3

A06B-6089-H209

SVU2-12/80L(12A)=J6M(80A)=J7

A06B-6089-H209

SVU1-130J2

A06B–6089-H106

SVU1–80J8=(80A)

A06B-6089–H208

Amp Spec. Servo Amplifier 6

P-200 7+3(Opener) Axes Control

SVU2–80/80L(80A)=J9

M(80A)=J10A06B-6089–H208

1–26

1. OVERVIEW

MARO2P10203703E

Table 1–4. Dip Switch Settings

Machine Type Servo Amplifier1

Servo Amplifier2

Servo Amplifier3

Servo Amplifier4

Servo Amplifier5

P-200 – 6 Axes 1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

P-200 – 7 Axes 1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

P-200 – 6 + 2 1 ON2 OFF3 ON4 OFF

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

P-200 – 7 + 2 1 ON2 OFF3 ON4 OFF

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

P-200 – 7 + 3 1 ON2 OFF3 ON4 OFF

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

1 ON2 OFF3 ON4 ON

Machine Type Servo Amplifier6

P-200 – 7 + 3 1 ON2 OFF3 ON4 OFF

1–27

1. OVERVIEW

MARO2P10203703E

The multi-tap transformer is located on the floor of the controller on theright side of the rear cabinet. See Figure 1–2 for component location.

The multi-tap transformer is supplied 3-phase VAC from the maindisconnect or circuit breaker. This supply voltage can range from 220 – 575 volts. To accommodate the various levels of supply, tapselections are provided on the primary side of the transformer.

The transformer output supplies the following voltages:

3–phase 210 VAC nominal for the servo amplifiers1–phase 210 VAC nominal for the backplane–mounted components1–phase 210 VAC nominal for the IBRC module1–phase 210 VAC nominal for the 24VDC Purge Power Supply1–phase 100VAC nominal for the brakes and servo amplifier

A06B–6066–Hxxx MCC

Two series-connected thermostats are mounted on the transformer. Theyare connected to fault detection circuitry in one servo amplifier. If thetransformer overheats, the controller will signal a SRVO–0043 DCALalarm.

Figure 1–20 shows the transformer. Table 1–5 and Table 1–6 list theinformation necessary for selecting a proper primary tap.

Table 1–5. Multi-Tap Transformer Part Numbers

Transformer Type Part Number

7.5kVA A80L–0026–0010#A

5kVA A80L–0024–0010#A

1.9MULTI-TAPTRANSFORMER

Refer to TABLE 1–5 for partnumbers.

MARO2P10203703E1–28

1. OVERVIEW

Figure 1–20. Multi-Tap Transformer

575V550V500V480V460V

240/415V220V/380V

1

234

5

6

7

0V575V550V500V480V460V

240/415V220V/380V

8

91011

12

13

14

0V575V550V500V480V460V

240/415V220V/380V

0V

16

171819

20

21

22

15

23

24

F1 F2 F3

1 3 5

2 4 6

13

31

32

14

23

41

42

24

A1 A2

F4 7.5

F5 7.5

Table 1–6. Selecting Transformer Taps

S pply VoltagePrimary Tap

Connection TypeSupp ly VoltageL1 L2 L3 Jumper

Connect ion Type

220 7 15 23 8–15/16–23/24–7

240 6 14 22 8–14/16–22/24–6

DELTA

380 7 15 23

415 6 14 22

460 5 13 21Y480 4 12 20

8–16 16–24Y

STAR500 3 11 19

8–16 16–24 STAR

550 2 10 18

575 1 9 17

1–29

1. OVERVIEW

MARO2P10203703E

The interface between the controller and peripheral devices is provided byinput and output signals from one or more of the following:

Modular I/O (Model A) Unit

Distributed I/O (Model B) UnitProcess I/O printed circuit board

A printed circuit board specializing in communicating with a logiccontroller, which includes

– ABRIO for communication to an Allen-Bradley PLC– Genius I/O for communication to a GE Fanuc programmable

controller

Digital I/O to and from the robot through the axis control board.

External E-Stop peripheral device connections.

The modular I/O unit provides communication between the controller andvarious peripheral devices. See Figure 1–21.

Figure 1–21. Modular I/O

Modular I/O Rack(Backplane)

I/O ModuleSlot I/F

Slot 1Slot 2

Interface Module

I/O ModuleInterface Module

F

1.10INTERFACE DEVICES

1.10.1 Modular I/O Unit

MARO2P10203703E1–30

1. OVERVIEW

The modular I/O unit uses the following communication modes:

Discrete (On or Off) input and output signal lines at 24VDC or120VAC. Outputs can be sink or source outputs.

Analog signal lines, which can vary from –10VDC to +10VDC

The modular I/O unit consists of the following:

The base unitThe interface moduleVarious discrete input and output (I/O) modules

The control can use as many as 64 modular I/O modules concatenated(daisy-chained) together on multiple racks.

A single modular I/O unit is referred to as rack 1. The I/O modules arelocated in slots 1 to 5 or 1 - 10, depending on the model used.

The base unit is the backplane for the modular I/O unit. The interfacemodule and the I/O modules plug into it.

The base unit has no LEDs, fuses, or electrical connections, except for themodule sockets.

The first slot to the left (I/F) always contains the interface module. Theother slots are used for the I/O modules.

The interface module transfers data between the main CPU and the I/Omodules.

The interface module is connected to the JD4 connector on the main CPUprinted circuit board through connector JD1B. The interface module isalways mounted in the I/F (first) slot.

Discrete input modules receive 24VDC or 120VAC signals on theirterminals and relay the data to the interface module.

Discrete output modules transmit 24VDC or 120VAC signals on theirterminals under command of the interface module.

Base Unit5 I/O Module SlotA03B-0807-C002

10 I/O Module SlotA03B-0807-C001

Interface ModuleWith 1 RackA03B-0807-C011

Additional RacksA03B-0807-C012

Discrete Input ModulesRefer to Table 1–7 andTable 1–9 for specificationsand part numbers.

Discrete Output ModulesRefer to Table 1–8 andTable 1–9 for specificationsand part numbers.

1–31

1. OVERVIEW

MARO2P10203703E

Table 1–7. Digital Input Module Specifications

Input Type ModuleName

RatedVoltage

RatedCurrent Polarity* Response

Time Points ExternalConnection LED Display

Non-isolatedDC input

AID32A 24VDC 7.5 mA Both Maximum20 ms

32 Connector Not provided

AID32B 24VDC 7.5 mA Both Maximum2 ms


OpticallyisolatedDC inp t

AID16C 24 VDC 7.5 mA NEG Maximum20 ms

16 Terminal block Provided

DC input AID16D 24VDC 7.5 mA POS Maximum20 ms


AID32E 24VDC 7.5 mA Both Maximum20 ms


AID32F 24VDC 7.5 mA Both Maximum2 ms


AC input AIA16G 100~120VAC

10.5 mA(120VAC)

ON Max 35 msOFF Max 45 ms


* Polarity is defined as follows: Negative : 0 V common (current source type); ON when input is at low level.Positive : 24 V common (current sink type); ON when input is at high level.

Table 1–8. Digital Output Module Specifications

OutputType

ModuleName

RatedVoltage

MaximumCurrent Polarity* Points Points/

CommonExternal

ConnectionLED

Display Fuses

Not fusedDC output

AOD32A 5 ~24 VDC

0.3A NEG 32 8 Connector Notprovided

Notprovided

FusedDC output

AOD08C 12 ~24 VDC

2 A NEG(Sink)

8 8 Terminal block Provided Provided

AOD08D 2 A POS(Source)

8 8 Terminal block Provided Provided

Not fusedDC output

AOD16C 0.5 A NEG(Sink)

16 8 Terminal block Provided Notprovided

AOD16D 0.5 A POS(Source)

16 8 Terminal block Provided Notprovided

AOD32C 0.3 A NEG(Sink)

32 8 Connector Notprovided

Notprovided

AOD32D 0.3 A POS(Source)

32 8 Connector Notprovided

Notprovided

Fused ACoutput

AOA05E 100 ~240 VAC

2 A — 5 1 Terminal block Provided Providedoutput AOA08E 240 VAC 1 A — 8 4 Terminal block Provided Provided

AOA12F 100 ~120 VAC

0.5 A — 12 6 Terminal block Provided Provided

Relayoutput

AOR08G Maximum250 VAC/30 VD

4 A — 8 1 Terminal block Provided Notprovided

AOR16G /30 VD 2 A — 16 4 Terminal block Provided Notprovided

* Polarity is defined as follows: Negative : 0 V common (current sink type); output is at low level when ON.Positive : 24 V common (current source type); output is at high level when ON.

MARO2P10203703E1–32

1. OVERVIEW

Table 1–9. I/O Module Part Numbers

Name Part Number

DC inputmodule

Non-isolated 32 points20 ms

AID32A A03B-0807-C101

32 points2 ms

AID32B A03B-0807-C102

Opticallyisolated

16 pointsNEG

AID16C A03B-0807-C103

16 pointsPOS

AID16D A03B-0807-C104

32 points20 ms

AID32E A03B-0807-C105

32 points2 ms

AID32F A03B-0807-C106

AC input module16 points

AIA16G A03B-0807-C107

DC outputmodule

Not fused 32 pointsNEG

A0D32A A03B-0807-C162

Fused 8 pointsNEG

AOD08C A03B-0807-C151

8 pointsPOS

AOD08D A03B-0807-C152

Not fused 16 pointsNEG

AOD16C A03B-0807-C153

16 pointsPOS

AOD16D A03B-0807-C154

32 pointsNEG

AOD32C A03B-0807-C155

32 pointsPOS

AOD32D AO3B-0807-C156

AC outputmodule

Fused 5 points, 2 A AOA05E A03B-0807-C157module 8 points

1 AAOA08E A03B-0807-C158

12 points0.5 A

AOA12F A03B-0807-C159

Relay output module 8 points4 A

AOR08G A03B-0807-C160

16 points2 A

AOR16G A03B-0807-C161

Analog input module AAD04A A03B-0807-C051

Analog output module ADA02A A03B-0807-C052

1–33

1. OVERVIEW

MARO2P10203703E

The ABRIO and Genius I/O printed circuit boards use serialcommunication to interface to a programmable controller. These printedcircuit boards are used for communicating control information between theR-J2 controller and the programmable controller.

Refer to the following manuals for information on these boards.

A User’s Guide to the FANUC Robotics Genius Network Interface forGEFanuc

A User’s Guide to the FANUC Robotics Genius Network Interface forGEFanuc (R-H Style Board in R-J2 Controller)

A User’s Guide to the FANUC Robotics Remote I/O Interface for anAllen-Bradley PLC (R-H Style Board in R-J2 Controller)

A User’s Guide to the FANUC Robotics SYSTEM R-J2 ControllerRemote I/O Interface for an Allen Bradley PLC.

1.10.2 ABRIO and Genius I/O

R-J2 style: A20B-8001-0120-RIO withEthernetand A20B-8001-0121-RIOA15L-0001-0026-GENIUSI/O Daughter Board andA16B-2203-0291-GENIUSMother Board PCB

1–34

1. OVERVIEW

MARO2P10203703E

Two general styles of the Ethernet Remote printed circuit board areavailable. These are

Ethernet Remote-1 Printed Circuit Board (ER-1)Ethernet Remote-2 Printed Circuit Board (ER-2)

The ER-1 style consists of a full-size motherboard printed circuit boardwith an optionally attached daughter printed circuit board. The five kindsof ER-1 printed circuit boards that support Ethernet are listed inTable 1–10. See Figure 1–22 for the ER-1 Printed Circuit Boards.

The ER-2 style consists of a single printed circuit board in a half-slot formfactor that allows it to be installed in the half slot available in the powersupply unit. The three kinds of ER-2 that support Ethernet are listed inTable 1–10. See Figure 1–23 for the ER-2 Printed Circuit Boards.

Table 1–10. FANUC R-J2 Ethernet Remote Style Printed Circuit BoardPart Numbers

Part Greenbook PartNumber

Spare PartNumber

ER-2 Ethernet PCB (10Base2) A05B-2350-J121 A20B-8001-0122

ER-2 A-B RIO/Ethernet PCB(10Base2)

A05B-2350-J122 A20B-8001-0120

ER-2 A-B RIO-Ethernet 10BaseTPCB

Contact FANUC Robotics CustomerService for part numbers

ER-1 PLC I/O-Ethernet 10Base5 PCB A05B-2300-J122 A16B-2201-0892

Order also: ER-1 A-B RIO D-PCB A05B-2300-J130 A20B-9001-0610

ER-1 PLC I/O-Ethernet PCB(10Base2)

A05B-2300-J121 A16B-2201-0891

Order also: ER-1 Genius I/O D-PCB A05B-2300-J131 A15L-0001-0026


Order also: ER-1 Genius I/O D-PCB A05B-2300-J131 A15L-0001-0026


ER-1 A-B RIO/Ethernet 10BaseT Kit Contact FANUC Robotics CustomerService for part numbers

ER-1T + A-B/RIO A05B-2350-J127 A16B-2203-0290

ER-1T + GENIUS (Motherboard) A05B-2350-J128 A16B-2203-0291

ER-1T + GENIUS (Daughterboard) A05B-2300-J131 A15L-0001-0026

Refer to the appropriate application-specific SYSTEM R-J2 SoftwareInstallation Manual for software part number information.

1.11ETHERNET REMOTEPRINTED CIRCUITBOARDS

1–35

1. OVERVIEW

MARO2P10203703E

Figure 1–22. ER-1 Ethernet Printed Circuit Boards

1 2 3 4

A – B

ER-1

ER-1 PLC I/O-EthernetPrinted CircuitBoard(10Base2)

1 2 3 4

A – B

2.0A

F12.0A

AUICD27


1 2 3 4

ACTIVE

POWER

RACK SEL

SMGN

BAUD SEL

DISC/BLK

LAST RACK

LAST STAT

RACK SIZ

RESTART

ETHER

NET

LINK OK

10 BASE T

AB RIO

PF

PC IP

ER-1 PLC I/O-EthernetPrinted CircuitBoard(10BaseT)

1–36

1. OVERVIEW

MARO2P10203703E


ER-2

ER-2 EthernetPrinted CircuitBoard(10Base2)

ER-2 A-B RIO/Ethernet Printed CircuitBoard(10Base2)

1–37

1. OVERVIEW

MARO2P10203703E

The controller can contain an optional user transformer. It supplies120VAC single-phase power to a National Electrical ManufacturersAssociation (NEMA) outlet receptacle and is located on the lower left sideof the controller. See Figure 1–24.

Figure 1–24. User Transformer

Multi-tap transformer

1.12USER TRANSFORMER

A80L-0001-0520

MARO2P10203703E1–38

1. OVERVIEW

Pushbuttons and LEDs on the operator panel of the R-J2 are used to startthe robot and indicate status. The panel has a port for serial interface to anexternal device. The operator panel can be equipped with one or both ofthe following

Disconnectable teach pendant port with a switch for operation withoutserial interface to an external device.

DB–25 connector for serial interface (External disk drive, forexample.)

An emergency stop button on the operator panel places the system into theemergency stop condition when pressed.

Figure 1–25. Operator Panel without Teach Panel Disconnect

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

ÎÎ

ÎÎÎÎÎ

ÎÎÎÎ

ÎÎ

BATTERY

ALARM CYCLE STARTON

OFF

REMOTE

REMOTE

LOCAL

HOLD

PURGECOMPLETE

PURGE ENABLE

PURGEFAULT

EMERGENCY STOP

ENABLED

FAULT RESET

FAULT

ÏÏÏÏ

ÏÏÏÏ

ON

OFF HOUR METERPORT

BRAKE ENABLE

1.13OPERATOR PANEL

A05B-2363-C001A05B-2363-C002

1–39

1. OVERVIEW

MARO2P10203703E

The teach pendant is a hand held device used to operate and program therobot and controller. See Figure 1–26. Keys on the teach pendant are used to enter data, jog the robot, and to display menus.

The pendant has a liquid crystal display 16 lines long by 40 characterswide. The teach pendant also has an emergency stop button that, whenpressed, places the robot into an emergency stop condition.

A DEADMAN switch mounted on the back of the teach pendant enablesservo drive power if held with the teach pendant on/off switch turned toON. When the teach pendant switch is turned to OFF, pressing theDEADMAN switch is not required to keep servo drive power enabled.

WARNINGThe robot will become fully functional and capable of beingstarted at the operator panel if the teach pendant is turnedoff and the fence circuit is not installed or closed. Whenworking in the robot envelope, ALWAYS CARRY THETEACH PENDANT and HAVE THE TEACH PENDANTENABLED. Otherwise, you could injure personnel ordamage equipment.

Seven of the keys on the teach pendant provide different functionsdepending on the software in the controller. Eleven indicators, located onthe left side of the LCD display, indicate status of the system. Theindicator labels are different based on software operating in the controller.

Refer to Chapter 3, “Lights, Indicators, and LEDs,” for an explanation ofthe indicators.

Figure 1–26. Teach Pendant

Software-Dependent Keys

LCD Display

IndicatorLabels

DEADMANSwitches

Emergency Stop Button

Indicators

Enable/disableswitch

1.14TEACH PENDANTA05B–2308–C300

MARO2P10203703E1–40

1. OVERVIEW

The temperature in the controller is kept within operating range throughthe use of an air-to-air heat exchange system. The controller is sealed toprohibit outside air from entering the controller cabinet. Internal controllerair is circulated by fans around the inside of the controller and downwardthrough the internal side of the heat exchange unit. Outside air iscirculated upward through the external side of the heat exchange unit alsoby using a fan. This process cools the inside air.

Fans are provided on the printed circuit board racks mounted on thebackplane to circulate air over the printed circuit boards.

Cooling fins connected to the servo amplifiers are within the heatexchange unit to keep the heat generated by the servo power circuits out ofthe controller.

Figure 1–27 shows the heat exchange system for the controller.

Figure 1–27. Heat Exchange System

Outside air in

Internal air

Outsideair

Backplane fan(s)

Air flow

Fan 3

Fan 1

Fan 2

A05B–2301–C901 Fan AssyA90L–0001–0213 Fan

A05B–2051–C902 Fan AssyA90L–0001–219#A Fan

A02B–0056–C904 Fan AssyA90L–0001–0219#A Fan

A90L–0001–0378A90L–0001–0385#A

1.15HEAT EXCHANGE ANDFANSRefer to Figure 1–27 forFan Part Numbers

1–41

1. OVERVIEW

MARO2P10203703E

The purge control unit consists of an Intrinsically Safe Barrier Unit (ISBU)module, an IDEC model IBRC contact signal transducer (IBRC), purgecontrol PCB, and 24VDC power supply. There are no authorizedadjustments on the purge control unit. Refer to Figure 1–28 foridentification of components and Figure 1–2 for component locations.

WARNINGThe purge control timer is set at five minutes to conform toFactory Mutual Specifications. Do not adjust the purgecontrol timer; otherwise, an explosion or fire could occur.

Figure 1–28. Purge Control Unit

Power supplyIBRCISBU

Purge control PCB

CH1 CH2 CH3 CH4 CH5 CH6

A1 C1 A2 C2 A3 C3 A4 C4 A5 A6C5 C6 0V 220V200V

P1 N1 P2 N2 P3 P4N3 N4 P5 P6 N6N5 G G FG

1

1

2 3 4 5 6 7 8 9

2 3 4 5 6 7 8 9

1011 12 1314 1516 171819 20 21 222324

1011 12 13 14 15 16 1718 19 20 21 22 2324

1.16PURGE CONTROLUNITA05B–2363–C020

1–42

1. OVERVIEW

MARO2P10203703E

The IDEC model IBRC contact signal transducer is an intrinsically safeisolation unit that is used as part of the purge system. It has sixphoto-isolated relays and provides an intrinsically safe barrier for thefollowing signals. See Figure 1–29.

Channel 1 (P1-N1) Pressure switch from robot or pressure switchesfrom robot and opener in series.

Channel 2 (P2-N2) Flow switch from robot or flow switches fromrobot and opener in series.

Channel 3 (P3-N3) Robot overtravel switches, If used.Channel 4 (P4-N4) Hand broken signal, If used.Channel 5 (P5-N5) Teach pendant disconnected, If used.Channel (P6-N6) End of arm tooling input, Not used.

The IBRC operates on 220 (max. 250)VAC from a secondary winding ofTF1.

There are six red LEDs, one for each device used in the field. There are apair of terminals, labeled Px and Nx, for each hazardous signal, while thecorresponding safe side terminals have Ax and Cx. Ax and Cx are thenormally open contact output located on the safe side. When thehazardous location switches are closed, the IBRC LED will be illuminatedfor that particular contact. Should a jumper be installed across the P and Nterminals, the LED for those terminals will be illuminated.

When plant air is supplied to the robot, and power is available to the IBRCwhen the disconnect switch is in the ON position, the PS-1 LED will beilluminated.

1.17PURGE SYSTEMIBRC

A15L–0001–0048

1–43

1. OVERVIEW

MARO2P10203703E

Figure 1–29. Contact Signal Transducer (IBRC)

A1 C1 A2 C2 A3 C3 A4 C4

CH1

A5 C5

CH2 CH3 CH4 CH5 CH6

A6 C6 0V 200V 220V

P1 N1 P2 N2 P3 N3 P4 N4 P5 N5 P6 N6 G G FG

idec IZBARLRelay Barrier

Type IBRC6062RIntrinsically Sake Circuit

DC16V 14mA

Relay AC/DC 250VSafety Rating of Out Put

1–44

1. OVERVIEW

MARO2P10203703E

The Purge Unit Power Supply is a 24VDC auxiliary power supply usedexclusively for the purge system. It is mounted alongside the IBRC unit.It provides voltage necessary to energize the purge solenoid valve withinthe robot and opening devices when applicable. It also provides 24VDC tothe relay coils mounted on the piggy-back Purge Control PCB in the EMGmodule.

It requires 210VAC supplied by TF1 and is internally fused by two fusesmounted on the power supply PCB itself, F-11 and F-12. See Figure 1–30.

Figure 1–30. Purge Power Supply

Cover

F12F11

Purge Power Supply

Contact Signal Transducer IBRC

1.18PURGE UNIT POWERSUPPLYA20B–1000–0472

1–45

1. OVERVIEW

MARO2P10203703E

The P-200 R-J2 controller contains a number of Intrinsically SafetyBarriers (ISB) units and signal repeaters. They are used for the robot oropener purge circuits. The number of barriers and repeaters installed isdependant on the options ordered for that particular installation. ThePurge Intrinsically Safety Barriers and repeaters are mounted to the left ofthe IBRC unit. These devices limit the energy in their respective circuitsto eliminate the possibility of an explosion in the hazardous environmentof the paint booth. The internal atmosphere of the robot must beconsidered hazardous prior to operation, therefore a Purge IntrinsicallySafe Barrier or repeater device is used to safely control the purge process.

Purge Intrinsically Safe Barriers and repeaters are similar to a fuse. If oneshould be found defective, it must be replaced by a known good PurgeIntrinsically Safe Barrier or repeater, and you must discard the defectiveone. Refer to Table 1–11 for part number used for specific ISB functions.

For detailed illustrations of the Purge Intrinsically Safe Barriers and Signalrepeaters see Figure 1–31 through Figure 1–36. To troubleshoot faults youmight encounter with the Purge Intrinsically Safe Barriers and Signalrepeaters refer to Table 1–12.

The barriers ISB1 and ISB2 are used to energize the purge air solenoidvalves in the base of the robot or opener.

ISB3 and ISB10 are Intrinsically Safe repeater relays which are used toisolate the signals from the robot/opener bypass switches, used to detectthat powered down units are out of the way and it is safe for the conveyorto run.

ISB4, 5, 6, 7, and 8 are used to provide power and control to the variouscircuits which control paint flow.

ISB9 is use specifically for the P-10 and P-15 openers. ISB9 detects thestatus of the proximity switch in the openers arm. Refer to Table 1–11 foradditional information regarding intrinsically safety barriers and signalrepeaters.

Table 1–11. Purge Intrinsically Safety Barriers and Signal Repeaters

Part Number ISB# Terminals Figure Description

9001/01-252-100-14

1

InputTerminals 1 and 2

24VOutput

Terminals 3 and 4 topurge solenoid

Figure 1–31Refer to

Figure 12–13Figure 12–21Figure 12–22Figure 12–23

P-200 Purge Solenoid

For P-200+2 versionsthis barrier is Stahl9001/01-280-165-10For openers thebarrier is Stahl9001/01-252-100-14

2

InputTerminals 1 and 2

24VOutput

Terminals 3 and 4 toopener purge

solenoid



Opener Purge SolenoidFor P-200-+2 versions ISB2 use

Stahl 9001-01/-280-165-10For P-200-+3 (P10) ISB2 use Stahl

9001-01/-252-100-14

1.19PURGEINTRINSICALLY SAFEBARRIERS ANDSIGNAL REPEATERS

STAHL and PEPPERL+FUCH

1–46

1. OVERVIEW

MARO2P10203703E

Table 1–11. (Cont’d) Purge Intrinsically Safety Barriers and Signal Repeaters

Part Number DescriptionFigureTerminalsISB#

KHD2-SR-Ex1.2S.PKFD2-SR2-Ex1.W.LB

SWITCH POSITIONSS1 = IS2 = IS3 = II

3

InputTerminals 1+,3≈DC8V/≈8mA

Intrinsically safeOutput I

Terminals 7,8,9Output II

Terminals 10,11,12Terminals

14(L+).-.15(L-)DC 20V 30V



P-200 Bypass SwitchSingle ChannelDC 24 V Nominal Power SupplySelectable Mode of OperationOutput: 1 Signal Output with 2 Form

“C” RelaysOptional Lead Breakage (LB)

Monitoring

KFD2-SD-Ex1.36 4

InputTerminals

7 (L+) - 8 (L-)DC 15V 35V

Not intrinsically safeOutput

Terminals 1+ - 2-≤24V

Intrinsically safe



I/P PowerSingle ChannelDC 24 V Loop PoweredMax. 80mA Output Current

KHD2-CD-1.P 32KFD2-CD-Ex1.32.

5

InputPower Rail and

Terminals 7 (L+),8(L-)DC 20V...35V

OutputTerminals 1+,2-

Input not intrinsically safe

Terminals 9+,10-,11+



I/P SignalSingle ChannelDC 24 V Nominal Power SupplyVoltage/Current or Current /Voltage

ConversionAdjustable “Zero Point Zero”Conversion Ranges: 0/4-20mA,

0/1-5V, 0/2-10V

Z787

6

28 V, 300 ΩHazard AreaConnections

Terminals 1 and 2Safe Area Terminals

7 and 8



24 V Power for Flow meterSingle or Double ChannelPositive PolaritySafeSnap Zener Barrier

Z728

7 and 8

28 V, 300 ΩHazard AreaConnections

Terminals 1 and 2Safe Area Terminals

7 and 8



ISB7 = Trigger 1 SignalISB8 = Trigger 2 SignalSingle ChannelPositive PolaritySafeSnap Zener Barrier

1–47

1. OVERVIEW

MARO2P10203703E

Table 1–11. (Cont’d) Purge Intrinsically Safety Barriers and Signal Repeaters

Part Number DescriptionFigureTerminalsISB#

KHD2-SR-Ex1.PKFD2-SR2-Ex1.W

SWITCH POSITIONSS1 = IS2 = IIS3 = I

9


Output Terminals Notintrinsically safe

7,8,9Terminals

14(L+).-.15(L-)DC 20V 30V


Figure 12–13Figure 12–23

Single ChannelDC 24 V Nominal Power SupplySelectable Mode of Operation1 Signal Output with 1 Form “C”

RelayLead Breakage (LB) Monitoring

KHD2-SR-Ex1.PKFD2-SR2-Ex1.W

SWITCH POSITIONSS1 = IS2 = IS3 = II

10


Output Terminals Notintrinsically safe

7,8,9Terminals

14(L+).-.15(L-)DC 20V 30V


Figure 12–13

From P-10 Bypass SwitchSingle ChannelDC 24 V Nominal Power SupplySelectable Mode of Operation1 Signal Output with 1 Form “C”

RelayLead Breakage (LB) Monitoring

WARNINGWhen you replace this Purge Intrinsically Safe Barrierdevice, pay careful attention to the exact model or partnumber. Many models appear physically identical, buthave different power ratings and entity ratings.Also, careful observance of which end of the device isconsidered to be the “SAFE” side, or the “HAZARDOUS”side is critical. Typically the end with the “Blue” coloredcap should be connected to the device located in theHAZARDOUS zone for STAHL barriers. Otherwise, youcould injure personnel or damage equipment.

1–48

1. OVERVIEW

MARO2P10203703E

Figure 1–31. Intrinsic Safety Barrier Stahl 9001/01-252-100-14

STAHL

1 2

3 4

“BLUE” colored cap

9001/01-252-100-14STAHL

1–49

1. OVERVIEW

MARO2P10203703E

Figure 1–32. Intrinsic Safety Barrier Pepperl + Fuchs KFD2-SR-Ex1.P andKFD2-SR2-Ex1.W

KFD2-SR-Ex1.PPepperl+Fuchs

KFD2-SR2-Ex1.W

LEDRelay output (yellow)

LEDLB (red)

Switch S1= I For Open SW = De-Energized

LEDPower (green)

Switch S2 = II For Lead Breakage on 10-11-12

Switch S3 = I For Namur Input

(mode of operation)

(switch for output II)

(LB Monitoring)

7 8 910 11 1213 14 15

I II

1 2 34 5 6

Figure 1–33. Intrinsic Safety Barrier Pepperl+Fuchs KFD2-SD-Ex1.36

KFD2-SD-Ex1.36Pepperl+Fuchs

1 2 34 5 6

7 8 910 11 12

1–50

1. OVERVIEW

MARO2P10203703E

Figure 1–34. Intrinsic Safety Barrier Pepperl+Fuchs KHD2-CD-1P32 andKFD2-CD-Ex1.32

KFD2-CD-Ex1.32

Pepperl+FuchsKHD2-CD-1.P32

1 2 34 5 6

7 8 910 11 12

Figure 1–35. Intrinsic Safety Barrier Pepperl+Fuchs Z727 and Z787

1 2

3 4

5 6

7 8

Pepperl+Fuchs

Z787

Zener BarriersZ727

1–51

1. OVERVIEW

MARO2P10203703E

Figure 1–36. Intrinsic Safety Barrier Pepperl+Fuchs KFD2-SR-Ex1.2S.P andKFD2-SR-Ex1.W.LB

7 8 910 11 12

KFD2-SR-Ex1.2S.PPepperl+Fuchs

KFD2-SR2-Ex1.W.LB

13 14 15

LEDRelay output (yellow)

LEDLB (red)

Switch S1

LEDPower (green)

Switch S2

Switch S3(mode of operation)

(no functions)

(LB Monitoring)I II

1 2 34 5 6

ISB3 and ISB10 Switch Positions

S1 = I S2 = IIS3 = I

ISB9 Switch Positions

S1 = I S2 = IS3 = II

Table 1–12. Troubleshooting

ISB Manufacturer Troubleshooting

1 Stahl Symptom: Incomplete purge cycle.See Figure 1–31 and Refer to Table 1–11 for additional information.

1. Check for 24 VDC on terminals 1 and 2 during controller purge cycle. If24VDC is not present troubleshoot controller. If 24VDC is present go toStep 2.

2. Check for 18 VDC on terminals 3 and 4 during controller purge cycle. If18V is not present barrier is defective. If 18V is present troubleshoot flowswitch or robot.

2 Stahl Symptom: Incomplete purge cycle.See Figure 1–31 and Refer to Table 1–11 for additional information.

1. Check for 24 VDC on terminals 1 and 2 during controller purge cycle. If24VDC is not present troubleshoot controller. If 24VDC is present go toStep 2.

2. Check for 18 VDC on terminals 3 and 4 during controller purge cycle. If18V is not present barrier is defective. If 18V is present troubleshoot theopener.

1–52

1. OVERVIEW

MARO2P10203703E

Table 1–12. (Cont’d) Troubleshooting

ISB TroubleshootingManufacturer

3 Pepperl+Fuchs Symptom:No bypass signal in “parked” position.Robot and or opener are safely parked out of the path of the conveyer.Provides signal to conveyer system.Bypass circuitsSee Figure 1–32 or Figure 1–36 and Refer to Table 1–11 for additionaltroubleshooting information.Yellow LED OFF : Problem in the hazard area (ex. proximity switch wires) go

to Step 7.Green LED power indicator

1. Check for green power ON LED. If LED is not ON go to Step 2. If LED isON go to Step 7.

2. Check input 120VAC to Deltron 24V power supply. If voltage is present goto Step 3. If voltage is not present troubleshoot 120 VAC from theconveyer.

3. Check output 24V from Deltron to OVP (EE-3112-600). If 24 VDC ispresent go to Step 4. If 24VDC is not present replace the power supply.

4. Check input 24V to OVP. If 24VDC is present go to Step 5. If 24VDC is notpresent replace wiring between the power supply and the OVP.

5. Check the output voltage from the OVP. If 24 VDC is present go to Step 6.If 24VDC is not present replace the OVP.

6. Check for 24 VDC between terminals 14 and 15 on the ISB. If 24 VDC ispresent the ISB is defective . If 24VDC is not present replace the wiringbetween the OVP and the ISB.

7. Check for signal on terminals 1 and 3 .If signal is present barrier isdefective. If signal is not present robot proximity switch may be out ofadjustment or defective.

4 Pepperl+Fuchs Symptom:Problem controlling atomizing pressure.Supplies power to the current to pressure solenoid.See Figure 1–33 and Refer to Table 1–11 for additional troubleshootinginformation.

1. Check for 24VDC input signal on terminals 7 and 8. If 24V is not presenttroubleshoot the P-200 I/O. If 24VDC is present go to Step 2.

2. Check for 18VDC output signal on terminals 1 and 2. If 18V is not presentthe barrier is defective . If the 18 VDC output signal is present troubleshoot the current to pressure solenoid

5 Pepperl+Fuchs Symptom:Problem controlling atomizing pressure.Relays signal to the current to pressure transducer.See Figure 1–34 and Refer to Table 1–11 for additional troubleshootinginformation.

1. Check for 24VDC input signal on terminals 9 and 10. If 24VDC is notpresent troubleshoot the P-200 I/O. If 24VDC is present go to Step 3.

2. Check for 24VDC output signal on terminals 7 and 8. If 24V is not present check connection to purge control printed circuit board(A16B-1310-0601). If 24VDC is present go to Step 3.

3. Check for 18VDC output signal on terminals 1 and 2. If 18V is not presentdefective barrier. If 18 VDC signal is present transducer is defective.

1–53

1. OVERVIEW

MARO2P10203703E



6 Pepperl+Fuchs Symptom:No flowmeter data, accuflow errors.See Figure 1–35 and Refer to Table 1–11 for additional troubleshootinginformation.

1. Check for 24VDC input signal on terminals 7 and 8. If 24VDC is notpresent troubleshoot controller. If 24VDC is present go to Step 2.

2. Check for 24VDC output signal on terminals 1 and 2. If 24VDC is notpresent the barrier is defective. If 24VDC is present go to Step 3.

3. Check for input signal on terminals 2 and 4. If input signal from the P-200flow meter is not present troubleshoot the flow meter. If the input signal ispresent go to Step 4.

4. Check for output signal on terminals 7 and 8. If the signal is not presentthe barrier is defective. If the signal is present troubleshoot the P-200 I/O.

7 Pepperl+Fuchs Symptom:Paint gun will not trigger.Paint process trigger one signal.See Figure 1–35 and Refer to Table 1–11 for additional troubleshootinginformation.

1. Check for 24VDC input signal on terminals 7 and 8. If 24V is not presenttroubleshoot the P-200 I/O. If the 24VDC is present go to Step 2.

2. Check for output signal on terminals 1 and 2. If the output signal is notpresent defective barrier. If the output signal is present trouble shoot thenumber one trigger.

8 Pepperl+Fuchs Symptom:Paint gun #2 will not trigger.Paint process trigger two signal.See Figure 1–35 and Refer to Table 1–11 for additional troubleshootinginformation.

1. Check for 24VDC input signal on terminals 7 and 8. If 24V is not presenttroubleshoot the P-200 I/O. If the 24VDC is present go to Step 2.

2. Check for output signal on terminals 1 and 2. If the output signal is notpresent defective barrier. If the output signal is present trouble shoot thenumber two trigger.

1–54

1. OVERVIEW

MARO2P10203703E



9 Pepperl+Fuchs Symptom: Opener “acquire” signal inoperative.See Figure 1–36 and Refer to Table 1–11 for additional information.Yellow LED magnet on opener acquired the door or hood.Red LED lead breakage indicatorGreen LED power is ON.


2. Check for 24VDC input between terminals 8 and 15, 11 and 15, 14 and 15.If 24VDC is not present at any one of the tested terminals troubleshoot thecontroller. If 24VDC is present go to Step 3.

3. Check for signal on terminals 1 and 3 .If signal is present barrier isdefective. If signal is not present opener lead break switch may be out ofadjustment or defective.

10 Pepperl+Fuchs Symptom: No opener “bypass” signal in parked position.Robot and or opener are safely parked out of the path of the conveyor.Provides signal to conveyor system.Bypass circuitsSee Figure 1–36 and Refer to Table 1–11 for additional troubleshootinginformation.Yellow LED OFF : Problem in the hazard area (ex. proximity switch wires) go

to Step 7.Green LED power indicator


2. Check input 120VAC to Deltron 24V power supply. If voltage is present goto Step 3. If voltage is not present troubleshoot 120 VAC from theconveyer.

3. Check output 24V from Deltron to OVP (EE-3112-600). If 24 VDC ispresent go to Step 4. If 24VDC is not present replace the power supply.

4. Check input 24V to OVP. If 24VDC is present go to Step 5. If 24VDC is notpresent replace wiring between the power supply and the OVP.

5. Check the output voltage from the OVP. If 24 VDC is present go to Step 6.If 24VDC is not present replace the OVP.

6. Check for 24 VDC between terminals 14 and 15 on the ISB. If 24 VDC ispresent the ISB is defective . If 24VDC is not present replace the wiringbetween the OVP and the ISB.

7. Check for signal on terminals 1 and 3 .If signal is present barrier isdefective. If signal is not present opener proximity switch might be out ofadjustment or defective.

1–55

1. OVERVIEW

The brake release option adds (4) optional brake switches to selectivelyrelease the gravity and non-gravity axes of the P-200 robot. Refer toProcedure 6–1 . For circuit schematics and cable diagrams refer toChapter 14 Openers and Options.

WARNINGReleasing the brakes could cause the robot to move.Provide support for the arm of the robot before releasingthe brakes; otherwise, you could injure personnel ordamage equipment.

Figure 1–37. C Size R-J2 Controller With Optional Brake Release Switches

SYSTEM R–J2

AXESAXIS

2 3

OPENERALL

P-200AXES1,4,5,7

P-200AXIS

P-200

P-200 BRAKE SELECT SWITCHES

AXESAXIS

2 3

OPENERALL

P-200AXES1,4,5,7

P-200AXIS

P-200


1.20BRAKE RELEASE(OPTION)

1–56

1. OVERVIEW

MARO2P10203703E

The P-10 opener is a three axis, electrically-driven door opener and theP-15 opener is a three axis, electrically-driven hood and deck opener.Refer to Chapter 14, “Openers and Options,” for schematics and diagrams.

Figure 1–38. P-10 Door opener and P-15 Hood and Deck Opener

Axis 2

Axis 3

Outer Arm

Axis 1

Base

Link

Carriage

Rail

Inner Arm

Riser (P-15 only)

P-15 End of Arm Tool

P-10 End of Arm Tool

1.21P-10 DOOR OPENERP-15 HOOD AND DECKOPENER (OPTIONS)

1–57

1. OVERVIEW

MARO2P10203703E

The Integral Pump Control option is the FANUC Robotics integrated twocomponent fluid delivery system which features metering pumps directlycoupled to FANUC servomotors that are controlled by the FANUC R-J2controller.

This is a high performance fluid delivery system that accurately controlsvariable ratios and flow rates of two component materials. The P-200robot and the R-J2 controller provide control for the color changesequence, fluid metering and fluid flow control operations.

The paint process control enclosure provides the electro-pneumaticinterface between the R-J2 controller and the spray applicator. Theoperator interface is provided via the R-J2 teach pendant. See Figure 1–39.For circuit schematics and cable diagrams refer to Chapter 14 Openers andOptions.

Two different styles of the Integral Pump Control are available. The Tophat model which is mounted atop the outer arm and the Side Saddle modelwhich is mounted on the rail next to the robot. See Figure 1–40.

The integrated two component fluid delivery system offers the followingfeatures and benefits:

Enhanced trigger response time

Common fluid control and robot motion control architecture

Gear pump and servo motor integral to P-200 robot mechanical unit

Reduced color change time and paint waste compared to conventionalwall mounted two component systems

Accurate flow and ratio control through precise pump control

The integrated two component fluid delivery system consists of thefollowing major components:

Two mechanical coupled gear pump assemblies

Two FANUC servo controlled motors

One FANUC servo amplifier

Four pressure transducers

One mixing block assembly

One trigger assembly

One purged enclosure

One by-pass manifold

One Sames Moduflow valve stack assembly

1.22INTEGRAL PUMPCONTROL (OPTION)

1–58

1. OVERVIEW

MARO2P10203703E

Figure 1–39. Integral Pump Control Component Locator Diagram

OUT

IN

Axis 3

OUT#2

IN

OUT

OUT

IN

OUT

IN

IN

OUT

REG. 1BP 1

BP 2

REG. 2

0–100 P.S.I.

0–500 P.S.I.

0–500 P.S.I.

0–100 P.S.I.

#1IN

FAR SIDE

FAR SIDE

PR2

PR1

View From Front of Arm

Mix Tube

Motor and Gear Reducer Assy.

To Gun

Trigger Valve Ass’y

Mix Valves

By-Pass Block

Gear Pump #1

Gear Pump #2Pump Inlet Transducers

Pump Outlet TransducersInlet Regulators

Purge Enclosure

1–59

1. OVERVIEW

MARO2P10203703E

Figure 1–40. Top Hat and Side Saddle Mounted Models

Side Saddle Mounted

Top Hat Mounted

2 DIAGNOSTIC SCREENS

2 DIAGNOSTIC SCREENS

2–1MARO2P10203703E


Safety Signals The safety signal screen displays the status of safety-related control signals coming into the controller. 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Version ID Status The STATUS Version ID screen displays information specific to your controller. 2–5

Memory Status The STATUS Memory screen displays information about controller memory. 2–8. . .

Position Status The POSITION screen displays positional information in joint angles or Cartesian coordinates. 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axis Status The axis status screen displays information for each axis. 2–12. . . . . . . . . . . . . . . . . .

Alarm Log The Alarm Log displays a list of the 100 most recent alarms. 2–16. . . . . . . . . . . . . . . .

I/O Status You can view the status of an I/O signal by displaying a status screen. 2–18. . . . . . . .

Various built-in diagnostic screens reveal important information regardingthe status of the controller. This section describes each of these screens indetail. The diagnostic screen section provides coverage of the P-200.Figure 2–1 displays the teach pendant that displays the Status Screens.

2–2

2. DIAGNOSTIC SCREENS

MARO2P10203703E

Figure 2–1. Teach Pendant

OFF ON

POSN

MANFCTNS

MOVEMENU

QUEUE

APPLINST

STATUSALARMS

FAULT

HOLDSTEPBUSY

RUNNING

MAN ENBL

TOOL

XYZ

JOINT

PROD MODE

2–3


MARO2P10203703E

The safety signal screen displays the status of safety-related control signalscoming into the controller.

The safety signal screen displays the current state (TRUE or FALSE) ofeach safety signal. You cannot change the condition of the safety signalusing this screen. Table 2–1 lists and describes each safety signal. UseProcedure 2–1 to display safety signal status.

Table 2–1. Safety Signals

SAFETYSIGNAL DESCRIPTION

SOP E-Stop Indicates whether the EMERGENCY STOP button on the operator panel has been pressed. Thestatus is TRUE if the operator panel EMERGENCY STOP button has been pressed.

TP E-Stop Indicates whether the EMERGENCY STOP button on the teach pendant has been pressed. Thestatus is TRUE if the teach pendant EMERGENCY STOP button has been pressed.

Ext E-Stop Indicates whether an external emergency exists. The status is TRUE if the external emergency stopcontacts are open on the emergency control (EMG) printed circuit board and the following conditionsexist:SOP E-STOP is FALSETP E-Stop is FALSEHand Broken is FALSEOvertrave l is FALSE

If any one of these conditions is TRUE, Ext E-Stop is displayed as FALSE even though thesecontacts could be open.

Fence Open Indicates whether the safety fence switch is open. The status is TRUE if the safety fence contactsare open on the emergency control (EMG) printed circuit board.

TP Deadman Indicates when either the left or right teach pendant DEADMAN switch is pressed. The status isTRUE if either DEADMAN switch is pressed. When released with teach pendant enabled, thisalarm shuts off servo power.

TP Enable Indicates whether the teach pendant ON/OFF switch is ON. The status is TRUE when the teachpendant ON/OFF switch is ON.

Hand Broken Indicates whether the safety joint switch in the robot hand has been tripped and the hand might bedamaged. The status is TRUE when the safety joint switch has been tripped. This turns off the handbroken signal (*HBK) to the axis control printed circuit board. This alarm shuts off servo power.

Overtravel Indicates whether the robot has moved beyond its overtravel limits. The status is TRUE when therobot has moved beyond its overtravel limits tripping the overtravel switch. This turns off (*ROT) tothe axis control printed circuit board. This alarm shuts off servo power.

Low Air Alarm Indicates whether the air pressure has decreased below the acceptable limit. Low Air Alarm isusually connected to an air pressure sensing device. The status is TRUE when the air pressure isbelow the acceptable limit. This opens the pressure switch which turns off (*PPABN) to the axiscontrol printed circuit board. You must set the $PPABN_ENBL system variable to TRUE to use thissignal. This alarm shuts off servo power.

2.1 SAFETY SIGNALSTATUS

2–4


MARO2P10203703E

Procedure 2–1 Displaying Safety Signal Status

1 Press MENUS.

2 Select STATUS.

3 Press F1, [TYPE].

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

SIGNAL NAME STATUS 1/10 1 SOP E–Stop: TRUE 2 TP E–Stop: FALSE 3 Ext E–Stop: FALSE 4 Fence Open: FALSE 5 TP Deadman: FALSE 6 TP Enable: FALSE 7 Hand Broken: FALSE 8 Overtravel: FALSE 9 Low Air Alarm FALSE

[ TYPE ]

STATUS Safety JOINT 10 %

SOP E–Stop

Step

2–5


MARO2P10203703E

The STATUS Version ID screen displays information specific to yourcontroller. Use this information when you call the FANUC RoboticsHotline if a problem occurs with your controller. You cannot change theinformation displayed on this screen. Table 2–2 lists and describes theversion identification status information.

Table 2–2. Version Identification Status Items

ITEM DESCRIPTION

SOFTWARE Lists the software item loaded.

ID Lists the version number of the software item loaded.

Use Procedure 2–2 to display version identification status.

Procedure 2–2 Displaying the Version Identification Status

1 Press STATUS.

2 Press F1, [TYPE].

3 Select Version ID. You will see a screen similar to the following.

1/24SOFTWARE: ID:

1: PaintTool V4.302: P-200 Robot V4.303: Servo Code JB08.034: Motion Parameter5: Std Operating System6: PaintTool Softparts7:8: Core Built-ins9: Paint Built-ins10: User Frame

11: Background Editing12: PLC I/O (A-B/GENIUS)13: Core PaintTool14: Paint Tool Tracking15: Color Change V4.3016: MOTET Interface V4.3017: KAREL Command Lang V4.3018:19:20:21:22:23:24:[ TYPE ] SOFTWARE MOT_ID MOT_INF SER_PAR

STATUS Version ID JOINT 10 %

1

2.2VERSIONIDENTIFICATIONSTATUS

Step

2–6


MARO2P10203703E

4 Press the key that corresponds to the version ID status screen you wantto display:

To display software version information, press F2,SOFTWARE.

To display motor types for each axis, press F3, MOT_ID. Youwill see a screen similar to the following.

GRP: AXIS: MOTOR ID: 1/16 1: 1 1 ACA3/3000 40A 2: 1 2 ACA3/3000 40A 3: 1 3 ACA1/3000 12A 4: 1 4 ACA0.5B/3000 12A 5: 1 5 ACA0.5B/3000 12A 6: 1 6 ACA0.5B/3000 12A 7: * * Uninitialized 8: * * Uninitialized 9: * * Uninitialized 10: * * Uninitialized

[ TYPE ] SOFTWARE MOT_ID MOT_INF SER_PAR

STATUS Version IDs JOINT 10 %

To display the motor information for each axis, press F4,MOT_INF. You will see a screen similar to the following.

GRP: AXIS: MOTOR INFO: 1/16 1: 1 1 H1 DSP1–L 2: 1 2 H2 DSP1–M 3: 1 3 H3 DSP2–L 4: 1 4 H4 DSP2–M 5: 1 5 H5 DSP3–L 6: 1 6 H6 DSP3–M 7: * * Uninitialized 8: * * Uninitialized 9: * * Uninitialized 10: * * Uninitialized


STATUS Version IDs JOINT 10 %

To display the servo parameters for each axis, press F5,SER_PAR. You will see a screen similar to the following.

2–7


MARO2P10203703E

GRP: AXIS: SERVO PARAM ID: 1/16 1: 1 1 PB08.02 2: 1 2 PB08.02 3: 1 3 PB08.02 4: 1 4 PB08.02 5: 1 5 PB08.02 6: 1 6 PB08.02 7: * * Uninitialized 8: * * Uninitialized 9: * * Uninitialized 10: * * Uninitialized


STATUS Version ID JOINT 10 %E1

1

2–8


MARO2P10203703E

The STATUS Memory screen displays information about controllermemory. Table 2–3 lists and describes each memory status item.

Use Procedure 2–3 to display memory status.

Table 2–3. Memory Status

MEMORY STATUS DESCRIPTION

Pools Indicates the amount of memory forTPP contains teach pendant programsPERM contains system variables and some KAREL variablesSYSTEM contains the operating systemIMAGE contains KAREL programs and optionsTEMP contains temporary memory used for system operations

Hardware Indicates the total amount of memory forFROM Flash ROMDRAM D-RAMCMOS CMOS RAM

Procedure 2–3 Displaying Memory Status

1 Press STATUS.

2 Press F1, [TYPE].

3 Select Memory. You will see a screen similar to the following.

Total AvailablePools -----------------------TPP CMOS 600.0 KB 554.4 KBPERM CMOS 999.8 KB 275.8 KBTEMP DRAM5054.9 KB 4340.4 KB

Description:TPP: Used by .TP, .MR, .JB, .PRPERM: Used by .VR, RD:, OptionsTEMP: USed by .PC, .VR, Options

[ TYPE ] DETAIL HELP

STATUS Memory JOINT 10 %E1

2.3MEMORY STATUS

Step

2–9


MARO2P10203703E

4 To display the DETAIL screen, press F2, DETAIL. You will see ascreen similar to the following.

Total Free Lrgst FreePools––––––––––––––––––––––––––––––––––––––

TPP 1200.0 KB 1181.8 KB 1181.8 KBPERM 2023.9 KB 564.7 KB 564.6 KBSYSTEM 1010.4 KB 7.1 KB 7.1 KBIMAGE 2303.9 KB 358.8 KB 358.8 KBTEMP 3774.9 KB 2954.5 KB 2943.3 KB

Hardware–––––––––––––––––––––––––––––––––––FROM 6.0 MBDRAM 8.0 MBCMOS 2.0 MB

[ TYPE ] BASIC HELP

STATUS Memory JOINT 10 %E1

5 To display the first screen, press F2, BASIC.

2–10


MARO2P10203703E

The POSITION screen displays positional information in joint angles orCartesian coordinates. The positional information on this screen isupdated continuously when the robot moves. You cannot change thedisplayed information using this screen.

NOTE E1, E2, and E3 indicate extended axis positional information ifextended axes are installed in your system.

The joint screen displays positional information in degrees for each robotaxis. Tool indicates the number of the active tool frame.

The user screen displays positional information in Cartesian coordinatesbased on the user frame. Tool indicates the number of the active toolframe. Frame indicates the number of the active user frame.

The world screen displays positional information in Cartesian coordinatesbased on the world frame. Tool indicates the number of the active toolframe.

Use Procedure 2–4 to display position status.

Procedure 2–4 Displaying Position Status

1 Press POSN.

2 Select the appropriate coordinate system.

For joint , press F2, JNT. You will see a screen similar to thefollowing.

J1: .001 J2: 10.028 J3: –35.025 J4: –.000 J5: 34.998 J6: .001 E1: .000 E2: .001 E3: .001

[ TYPE ] JNT USER WORLD

POSITION JOINT 10 %

Joint Tool: 1

E1

NOTE E1:, E2:, and E3 are displayed only if you have extended axes.

2.4POSITION STATUS

Joint

User

World

Step

2–11


MARO2P10203703E

For user, press F3, USER. You will see a screen similar to thefollowing.

Configuration: F, 0, 0, 0 x: 1906.256 y: .041 z: 361.121 w: 178.752 p: –89.963 r: 1.249 E1: .001 E2: .001 E3: .001


POSITION JOINT 10 %

User Frame: 0 Tool: 1

E1

For world , press F4, WORLD. You will see a screen similar tothe following.

Configuration: F, 0, 0, 0 x: 1906.256 y: .041 z: 361.121 w: 178.752 p: –89.963 r: 1.249


POSITION WORLD 10 %

World Tool: 1

E1

2–12


MARO2P10203703E

The axis status screen displays information for each axis. Thisinformation is continually updated. Use this information when you callthe FANUC Robotics Hotline if a problem occurs with your robot.

This screen displays:

Status 1Status 2PulseMonitorTrackingDisturbance Torque

The Axis Status Pulse screen displays information about axis motion.Table 2–4 lists and describes each kind of information displayed on thisscreen.

Use Procedure 2–5 to display the axis status pulse screen.

Table 2–4. Axis Status Pulse Screen Items

ITEM DESCRIPTION

MotionCommand

Displays the desired value of the Serial Pulse Coder (SPC) when the robot gets to the positioncommanded by the controller.

Machine Pulse Shows the actual SPC count as read by the controller.

Position Error Displays the difference between the commanded SPC count versus the actual SPC count.

You cannot change any information on this screen except for the groupnumber. Group number only applies if you have multiple groups;otherwise, it remains as 1.

2.5AXIS STATUS

2–13


MARO2P10203703E

Procedure 2–5 Displaying the Axis Status Pulse Screen

1 Press STATUS.

2 Press F1, [TYPE].

3 Select Axis.

4 Display the status screen you want:

For Status 1, press F2, STATUS1.

GRP [ 1] Flag Bits 1/2 HistoryJ1: 0000000000001011 0000000000000000J2: 0000000000001011 0000000000000000J3: 0000000000001011 0000000000000000J4: 0000000000001011 0000000000000000J5: 0000000000001011 0000000000000000J6: 0000000000001011 0000000000000000

[ TYPE ] STATUS1 STATUS2 PULSE GRP# >

STATUS JOINT 10 %

J1:

For Status 2, press F3, STATUS2.

GRP [ 1] Alarm Status HistoryJ1: 000000000000 0000000000000000J2: 000000000000 0000000000000000J3: 000000000000 0000000000000000J4: 000000000000 0000000000000000J5: 000000000000 0000000000000000J6: 000000000000 0000000000000000

[ TYPE ] STATUS1 STATUS2 PULSE GRP# >

STATUS JOINT 10 %

J1:

For Pulse, press F4, PULSE.

Step

2–14


MARO2P10203703E

GRP [ 1] Position Machine Motion Error Pulse CommandJ1: 0 00000000 0J2: 0 00000000 0J3: 0 00000000 0J4: 0 00000000 0J5: 0 00000000 0J6: 0 00000000 0

[ TYPE ] STATUS1 STATUS2 PULSE [UTIL] >

STATUS JOINT 10 %

J1:

E1

For Monitor, press MORE, >, and then press F2, MONITOR.

GRP [ 1] Torque Monitor Ave. / Max. Inpos OT VRDYJ1: 0.000 0.000 1 0 ON J2: 0.000 0.000 1 0 ONJ3: 0.000 0.000 1 0 ONJ4: 0.000 0.000 1 0 ONJ5: 0.000 0.000 1 0 ONJ6: 0.000 0.000 1 0 ON

[ TYPE ] MONITOR TRACKING DISTURB GRP# >

STATUS JOINT 10 %

J1:

For Tracking, press MORE, >, and then press F3, TRACKING.

For Disturbance Torque, press MORE, >, and then press F4,DISTURB.

GRP [ 1]Tracking Status Flag Bits 1 Flag Bits 2P1: 0000000000000000 0000000000000000 P2: 0000000000000000 0000000000000000

Alarm Status Counter ValueP1: 000000000000 0 P2: 000000000000 0


J1:

STATUS JOINT 10 %

2–15


MARO2P10203703E

5 To change the group number, press F5, GRP#.

Disturbance Torque GRP [ 1] Current Max. Min.J1: –46080.000 / 0.000 / –91802.813J2: –46080.000 / 0.000 / –91802.813J3: –46080.000 / 0.000 / –91802.813J4: –23040.000 / 0.000 / –45901.406J5: –23040.000 / 0.000 / –45901.406J6: –23040.000 / 0.000 / –45901.406


STATUS JOINT 10 %

2–16


MARO2P10203703E

The Alarm Log displays a list of the 100 most recent alarms. Figure 2–2shows an example of the Alarm Log.

Figure 2–2. Alarm Log

1/1001 SRVO–049 OHAL 1 alarm (Group:1 Axis:6)2 SRVO–042 MCAL 1 Alarm (Group:1 Axis:6)3 R E S E T

[ TYPE ] CLEAR HELP

Alarm JOINT 10%

SRVO–049 OHAL 1 alarm (Group=1 Axis=6)PROGRAM LINE 4

14

2

3

1

The areas of the Alarm Log are as follows:

1. This is the most recent alarm message. This message will bedisplayed in this line regardless of the screen you choose.

2. Indicates the program name and line number of program last havingbeen acted upon.

3. Lists all of the alarm messages, up to 100, with the most recent alarmon the top of the list. When the RESET key is pressed, a RESET islogged on the alarm message screen.

4. Indicates the line number the cursor is on in proportion to how manylines numbers available.

Use Procedure 2–6 to display the Alarm Log.

2.6ALARM LOG

2–17


MARO2P10203703E

Procedure 2–6 Displaying the Alarm Log

An error has occurred.

1 Press ALARMS.

2 Press F1, [TYPE].

3 Select Alarm Log. The alarm log will be displayed. This lists allerrors. See the following screen for an example.

1/1001 SRVO–002 Teach pendant emergency sto2 SRVO–001 Operator panel emergency st3 R E S E T4 SRVO–029 Robot calibrated (Group:1)5 SRVO–001 Operator panel emergency st6 SRVO–012 Power fail recovery7 INTP–127 Power fail detected8 SRVO–047 LVAL alarm (Group:1 Axis:5)9 SRVO–047 LVAL alarm (Group:1 Axis:4)

10 SRVO–002 Teach pendant emergency sto

[ TYPE ] CLEAR HELP

Alarm WORLD 100 %

SRVO–002 Teach pendant emergency stopTEST1 LINE 15 ABORTED

1

The most recent error is number 1.To display the complete message for a message that does not fit on thescreen, press and hold the SHIFT key and press the right arrow key.

4 To display the motion log, which lists only motion-related errors,press F1, [TYPE], and select Motion Log.

5 To display the system log, which displays only system errors, pressF1, [TYPE], and select System Log.

6 To display the application log, which displays onlyapplication-specific errors, press F1, [TYPE], and select Appl Log.

7 To display more information about an error, move the cursor to theerror and press F5, HELP. The error help screen displays informationspecific to the error you selected. When you are finished viewing theinformation, press PREV.

8 To remove all of the error messages displayed on the screen, pressF4, CLEAR.

Condition

Step

2–18


MARO2P10203703E

You can view the status of an I/O signal by displaying a status screen. UseProcedure 2–7 to display I/O status.

Procedure 2–7 Displaying I/O Status

1 Press MENUS.

2 Select I/O.

3 Press F1, [TYPE].

4 Select the kind of I/O for which you want to display status: spotwelding, digital, analog, group, robot, UOP, or SOP.

For digital outputs for example, you will see a screen similar to thefollowing.

# SIM STATUSDO[ 1] U OFF [ ]DO[ 2] U ON [ ]DO[ 3] U OFF [ ]DO[ 4] U OFF [ ]DO[ 5] U OFF [ ]DO[ 6] U ON [ ]DO[ 7] U OFF [ ]DO[ 8] U OFF [ ]DO[ 9] U OFF [ ]DO[ 10] U OFF [ ]

[ TYPE ] CONFIG IN/OUT SIMULATE UNSIM

I/O Digital Out WORLD 10%

U

5 To change the display between inputs and outputs, press F3,IN/OUT.

6 To view the I/O configuration of the signal, press F2, CONFIG.

2.7I/O STATUS

Step

Inde

x

3 LIGHTS, INDICATORS,AND LEDS

3 LIGHTS, INDICATORS, AND LEDS

3–1MARO2P10203703E


Teach PendantDiagnostic Indicators

The teach pendant has several indicators to assist you in determining controller status. 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Panel andCabinet Lights

The operator panel has several LEDs to assist you in determining the status of the controller. 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servo On Lights The controller cabinet has a single Servo On light on the right-hand side of the cabinet. 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circuit Boards DiagnosticLEDs

The R-J2 controller contains several diagnostic LEDs within the controller. 3–5. . . . Power supply unit (PSU) 3–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main CPU board 3–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sub CPU board 3–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modular I/O (Model A) 3–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo Amplifier 3–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Stop Control Printed Circuit Board 3–16. . . . . . . . . . . . . . . . . . . . . . . . Module Assembly # EE–3044–401 3–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Signal Transducer (IBRC) 3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-J2 Ethernet LEDS 3–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

This chapter describes the lights, indicators and LEDs you can use fordiagnostics.

3–2

3. LIGHTS, INDICATORS, AND LEDS

MARO2P10203703E

The teach pendant has several indicators to assist you in determiningcontroller status. Figure 3–1 shows the teach pendant indicators andTable 3–1 lists and describes the teach pendant indicators. The indicatorswhose labels are blank vary depending on the application.

Refer to the Systems PaintTool Setup and Operations Manual forinformation on indicators.

Figure 3–1. Teach Pendant Indicators

ÎÎÎÎ

FAULT

ÎÎÎÎ

HOLD

ÎÎSTEP

ÎÎBUSY

ÎÎÎÎ

RUNNING


JOINT

ÎÎXYZTOOL

OFF ON

Indicators

MAN ENBLMODEPROD

Table 3–1. Teach Pendant Status Indicators

INDICATOR DESCRIPTION

FAULT Indicates that a fault condition has occurred.

HOLD Indicates that the robot is in a hold condition. HOLD is not on continuously during a hold condition.

STEP Indicates that the robot is in step mode.

BUSY Indicates that the controller is processing information.

RUNNING Indicates that a program is being executed.

MAN ENBL Indicates that the robot is in MANUAL MODE.

PROD MODE Indicates that the robot is in PRODUCTION MODE.

JOINT Indicates that the current jog coordinate system is JOINT.

XYZ Indicates that the current jog coordinate system is CARTESIAN (JOG FRAME OR WORLD).

TOOL Indicates that the current jog coordinate system is TOOL.

3.1TEACH PENDANTDIAGNOSTICINDICATORS

3–3


MARO2P10203703E

The operator panel has several LEDs to assist you in determining thestatus of the controller. Figure 3–2 shows the operator panel LEDs for theP-200 robot. Table 3–2 describes the indicator functions.

Figure 3–2. Operator Panel LEDS

ÎÎÎÎ

ÎÎÎÎ ÎÎ

ÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

BATTERY

ALARM CYCLE STARTON

OFF

REMOTE

REMOTE

LOCAL

PURGECOMPLETE

PURGE ENABLE

PURGEFAULT

EMERGENCY STOP

TEACH PENDANT

ENABLED

FAULT RESET

FAULT

ÏÏÏÏ

ÏÏÏÏ

ON

OFFPORT

BRAKE ENABLE

HOUR METER

H

H

h

m

h

h

HOUR METER

HOLD

Table 3–2. Standard Operator Panel Status Indicators


BATTERY ALARM Indicates that the backup battery voltage is low. Replace the battery.Refer to Procedure 9–1 .

TEACH PENDANT ENABLED Indicates that the teach pendant is enabled and has motion control.

FAULT Indicates a fault condition has occurred.

REMOTE Indicates that robot motion can only be started by a remote device (PLC or otherremote device). The operator panel cycle start pushbutton cannot cause robotmotion. This is determined by the position of the REMOTE/LOCAL keyswitch.

PURGE COMPLETE Identifies that the robot cavities for the P-200 motor cavity containment cases havebeen purged and are presently at the prescribed pressure as outlined in the FANUCRobotics SYSTEM R-J2 Controller P-200 and In Booth Rail Mechanical Unit Parts andService Manuals .

This LED must be illuminated in order to turn power on to the R-J2 controller.

PURGE FAULT Indicates a fault exists with the purge system.

PURGE ENABLE PUSHBUTTON Indicates that the purge cycle has started. You can now release the pushbutton if youare holding it.

POWER ON PUSHBUTTON LED Indicates that the robot is powered on.

CYCLE START PUSHBUTTON LED Indicates that the robot is currently running a program

HOLD Indicates that the robot is in a software hold condition.

3.2OPERATOR PANELAND CABINET LIGHTS

3–4


MARO2P10203703E

The controller cabinet has a single Servo On light on the right-hand side ofthe cabinet. See Figure 3–3 for light location. Refer to Table 3–3 for adescription of the Servo On light.

Figure 3–3. Servo Amp Light

ÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎ

ÎÎ


ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ


ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

SERVO ON Light

Table 3–3. Servo Amp On Description


SERVO ON Indicates that power is available to the servo amplifiers.

3.3SERVO ON LIGHT

3–5


MARO2P10203703E

The R-J2 controller contains several diagnostic LEDs within the controller.They are on the circuit boards that plug into the backplane, on the servoamplifiers, and on the Modular I/O (Model A) and Distributed I/O(Model B) units as well as the Intrinsic Barrier Relay Control (IBRC)Purge Control Unit. Figure 3–4 shows an overview of the circuit boarddiagnostic LEDs. Refer to the following sections for descriptions of eachcircuit board diagnostic LED:

Power supply unit (PSU)Main CPU boardSub CPU boardModular I/O (Model A)Servo amplifierEmergency Stop Control Printed Circuit BoardModule Assembly #EE-3044-401Contact Signal Transducer (IBRC)ABRIO PCB (optional)

3.4CIRCUIT BOARDDIAGNOSTIC LEDS

3–6


MARO2P10203703E

Figure 3–4. Diagnostic LEDs

Main CPU

Main CPU LEDsSection 3.4.2

PSU LEDsSection 3.4.1

Servo Amplifier

SERVO AMPLIFIERLEDSection 3.4.4

PSU

12345671234567

AB

InterfaceModule

I/O Module

MODEL A

INTERFACEMODULESection3.4.3

I/O MODULESection 3.4.3

EMG StopControl PCBSection 3.4.5


IBRC

IBRC Section3.4.6

3–7


MARO2P10203703E

Figure 3–5 shows each power supply unit (PSU) diagnostic LED.

Figure 3–5. Power Supply Unit (PSU) Diagnostic LEDs

PIL LED

ALM LED

The PIL LED lights if 210 VAC nominal isbeing supplied to the PSU from the Transformer(circuit breaker is on), if Fuse F1 is notblown, if 24VDC Aux is supplied, and thepower supply internal circuitry is in goodcondition.

The ALM LED will light if one of thefollowing conditions exist:– Bad DC Power Supply– Alarm received from the remotedevice– Fuse F3 on the Power Supply unitis blown

3.4.1 Power Supply Unit(PSU) Diagnostic LEDs

3–8


MARO2P10203703E

The Main CPU printed circuit board alarm LEDs are shown in Figure 3–6.Table 3–4 provides information for troubleshooting problems.

Figure 3–6. Main CPU Board Diagnostic LEDs

3.4.2 Main CPU BoardDiagnostic LEDs

3–9


MARO2P10203703E

Table 3–4. Troubleshooting Main CPU Board Diagnostic LEDs

LEDs Remarks Procedure

1 2 3 4STATUSALARM

Parity alarm onRAM in the MainCPU.

1. Restart the controller.

2. Reload Software.

3. Replace the Main CPU.

1 2 3 4STATUSALARM

The battery voltagethat backs up theMain CPU CMOSRAM memory islow.

1. Get a replacement battery.

2. Turn off controller power and lock out the controller.

3. Replace the battery.

The controller will retain memory for at least a half hour between the timethe controller is turned off and the new battery is installed.

WARNING: Lethal voltage is present in the controller WHENEVER ITIS CONNECTED to a power source. Be extremely careful to avoidelectrical shock.

1 2 3 4STATUSALARM

Non-maskableinterrupt occurred inthe ABC chip on theMain CPU Board.


2. Reload software.


1 2 3 4STATUSALARM

Servo alarmoccurred on theMain CPU Board.


2. Reload software.


1 2 3 4STATUSALARM

Non-maskableinterrupt occurred inthe SLC2 chip onthe Main CPUBoard


2. Reload software.


1 2 3 4STATUSALARM

SYS FAIL Signaloccurred


2. Reload software.


1 2 3 4STATUSALARM

Normal Status Controller should be operational.

= OFF = ON

NOTE To save time during board replacement, preload software on aspare main CPU board first. Refer to the appropriate software installationmanual specific to your software for software loading information.

CAUTIONTo prevent software loss in the CMOS RAM module of theremoved board, be sure a battery backup is attached to themain CPU before the board is removed from the controller.

3–10


MARO2P10203703E

The Sub CPU printed circuit board alarm LEDs are shown in Figure 3–7.Table 3–5 provides information for troubleshooting problems.

Figure 3–7. Sub CPU Board Diagnostic LEDs

LV ALM

F21 5A

RISC-B

STATUSALARM

5.0A

3.4.3 Sub CPU BoardDiagnostic LEDs

3–11


MARO2P10203703E

Table 3–5. Troubleshooting Sub CPU Board STATUS LEDs (Green)

LEDs DESCRIPTION

1 2 3 4STATUSALARM

Power-off

1 2 3 4STATUSALARM

Power on

1 2 3 4STATUSALARM

SUBCPU start up

1 2 3 4STATUSALARM

DRAM test OK

1 2 3 4STATUSALARM

Software loading complete. Operating system start.

1 2 3 4STATUSALARM

Software internal checking. (Kernel software initialization complete)

1 2 3 4STATUSALARM

Software internal checking. (Task scheduling start)

STATUSALARM

1 2 3 4 Software internal checking. (Operating system initialization start)

1 2 3 4STATUSALARM

Software internal checking. (Operating system initialization end)

1 2 3 4STATUSALARM

Software internal checking. (INIT task initialization process start)

1 2 3 4STATUSALARM

Software internal checking. (System work area initialization)

1 2 3 4STATUSALARM

Software internal checking. (Non-volatile memory initialization)

1 2 3 4STATUSALARM

Software internal checking. (Non-volatile memory recover)

1 2 3 4STATUSALARM

Software internal checking. (Create system tasks)

3–12


MARO2P10203703E

Table 3–5. (Cont’d) Troubleshooting Sub CPU Board STATUS LEDs (Green)

LEDs DESCRIPTION

1 2 3 4STATUSALARM

Software internal checking. (Create system tasks)

1 2 3 4STATUSALARM

Software internal checking. (Task creation complete)

1 2 3 4STATUSALARM

Software internal checking. ((INIT task initialization process complete)

= OFF = ON

Table 3–6. Troubleshooting Sub CPU Board ALARM LEDs (Red)

LEDs Procedure

1 2 3 4STATUSALARM

The Sub-CPU is not started.

1 2 3 4STATUSALARM

A parity alarm occured in the SRAM.

1 2 3 4STATUSALARM

A parity alarm occured in the DRAM on the Sub-CPU board

= OFF = ON

Table 3–7. Troubleshooting Sub CPU Board ALARM LEDs (Red)

LEDs Procedure

LV ALM (Red)

The output voltage of the 3.3V power supply exceeded the specified range.

= ON

NOTE To save time during board replacement, preload software on aspare sub CPU board first. Refer to the appropriate software installationmanual specific to your software for software loading information.

3–13


MARO2P10203703E

The LEDs associated with module I/O are on the interface module printedcircuit board and on each I/O module. Figure 3–8 shows the modular I/OLEDs. Table 3–8 describes the I/O LEDs.

Figure 3–8. Modular I/O LEDs

1 2 3 4 5 6 7

1 2 3 4 5 6 7

A

B

JD1B JD1A

CP32 JD2

PWR LINK

BAO

BAI

AIF0IA

LEDS

LEDS

INTERFACE MODULE I/O MODULE

0

0

Table 3–8. Modular I/O LEDs

LED Location Description

PWR Interfacemodule

ON: The interface module is supplied with24 VDC power.

Link Interfacemodule

ON: The I/O Link is operating properly.Normally, this LED lights several secondsafter the power is turned on.

BA1 Interfacemodule

These LEDs indicate that a fault hasoccurred in the modular I/O system.

BA0 Interfacemodule

A 0 1 2 3 4 5 6 7 B 0 1 2 3 4 5 6 7

I/O Module Indicates if the input or output is on.

3.4.4 Modular (Model A) I/OLEDs

3–14


MARO2P10203703E

Figure 3–9 shows the servo amplifier seven-segment LED and Table 3–9shows and describes the LED displays.

Figure 3–9. Servo Amplifier LED

LED

Circuit breaker

ON

1

2

3

4

DIP SWITCH

α

3.4.5 Servo AmplifierDiagnostic LED(7-Segment Display)

3–15


MARO2P10203703E

Table 3–9. Servo Amplifier LED Functions

Name Indication Description

Over–voltage alarm (HV) This alarm occurs if the DC voltage of the main circuit power supply is abnormallyhigh.

Low control powervoltage alarm (LV)

This alarm occurs if the control power voltage is abnormally low.

Low DC link voltagealarm (LVDC)

This alarm occurs if the DC voltage of the main circuit power supply is abnormallylow or the circuit breaker trips.

Regenerative dischargecontrol circuit failurealarm (DCSW)

This alarm occurs if:–The short-time regenerative discharge energy is too high–The regenerative discharge circuit is abnormal.

Over-regenerativedischarge alarm (DCOH)

This alarm occurs if:–The average regenerative discharge energy is too high (too frequentacceleration/deceleration).–The transformer overheats.

Dynamic brake circuitfailure alarm (DBRLY)

This alarm occurs if the relay contacts of the dynamic brake welds together.

L-axis over-currentalarm (HCL)

This alarm occurs if an abnormally high current flows in the L-axis motor.

M-axis over-currentalarm (HCM)

This alarm occurs if an abnormally high current flows in the M-axis motor.

L- and M- axis overcurrent alarm (HCLM)

This alarm occurs if an abnormally high current flows in the L- and M axis-motors

L-Axis IPM alarm (IPML) This alarm is detected by the IPM (intelligent power module) of the L-axis.*

M-Axis IPM alarm(IPMM)

This alarm is detected by the IPM (intelligent power module) of the M-axis.*

L- and M- axis IPM alarm(IPMLM)

The MCC contactor in the servo amplifier is turned on. The amplifier is armed andcan drive the motor.

Circuit breakerTrips

The circuit breaker trips if an abnormally high current (exceeding the working currentof the circuit breaker) flows through it. **

Amplifier not ready Indicates that the servo amplifier is not ready to drive the motor.

Amplifier ready Indicates that the servo amplifier is ready to drive the motor

*NOTE The IPM can detect the following alarms.

Over-currentOver-heatDrop in IPM control power voltage

** NOTE When the control power is separated from the main power, if the circuit breaker for the servoamplifier is off, low DC link voltage alarm (LVDC) is detected.

3–16


MARO2P10203703E

The LEDs associated with the Emergency Stop Control Printed CircuitBoards are shown in Figure 3–10 and described in Table 3–10.

Figure 3–10. Emergency Stop Control Printed Circuit Board

Brake fuse blown alarm LED

1 4

2 3

3.4.6 Emergency StopControl Printed CircuitBoard

3–17


MARO2P10203703E

Table 3–10. Emergency Stop Control Printed Circuit Board LEDFunctions

LED Function

BRAKE FUSE ALARM Brake fuse blown.

1 LED SVON

2 LED Q1 and Q2 ON (Brakes 1, 2, and 3)

3 LED Q4 ON (Brake 4)

4 LED Q3 ON (Brakes 6 and 7)

3–18


MARO2P10203703E

The Module Assembly # EE–3044–401 is located in the robot purgecavity. Before you enter to the purge cavity, be sure to perform theprocedures and warnings in Section 4.6.43 shall be performed. The LEDindicators are described in Table 3–11 and are shown in Figure 3–11.

Figure 3–11. Intrinsic Barrier Relay Control Indicators

DC/DC MODULE

CR1

24V 6.5V

24V LED

6.5V LED

MODULE ASSY # EE–3044–401

‘


Channel Function

24V Indicates 24VDC input from 24VDC power supply in controller

6.5V Indicates output of 6.5 VDC through relay CR1

3.4.7 Module Assembly # EE–3044–401

3–19


MARO2P10203703E

The Intrinsic Barrier Relay Control (IBRC) LED indicators are describedin Table 3–12 and are shown in Figure 3–12.

Figure 3–12. Intrinsic Barrier Relay Control Indicators



Channel Function Description

CH1 Air pressureswitch

Monitors internal air pressure. The switch is closed when the robot is in a safeoperating state.

CH2 Flow switch Monitors air flow during purge sequence.

CH3 *ROT switch Robot overtravel closed when robot is not in an overtravel condition.

CH4 *HBK switch Hand broken switch. Robot wrist is broken. Normally this is a closed input.

CH5 TPDSC switch Teach pendant disconnect switch.

CH6 EOAT switch End of arm tooling switch triggers RDI2.

3.4.8 Contact SignalTransducer (IBRC)

3–20


MARO2P10203703E

Figure 3–13 and Figure 3–14 show ER-1 and ER-2 R-J2 Ethernet printedcircuit boards. Refer to A User’s Guide to the FANUC Robotics SYSTEMR-J2 Controller Remote I/O Interface for an Allen-Bradley PLC for LEDdescriptions.

Figure 3–13. ER-1 and ER-2 Printed Circuit Board LEDs

1 2 3 4

A – B

ER-1


1 2 3 4

A – B

2.0A

F12.0A

AUICD27


1 2 3 4

ACTIVE

POWER

RACK SEL

SMGN

BAUD SEL

DISC/BLK

LAST RACK

LAST STAT

RACK SIZ

RESTART

ETHER

NET

LINK OK

10 BASE T

AB RIO

PF

PC IP

ER-1 PLC I/O-EthernetPrinted CircuitBoard(10BaseT)

3.4.9 R-J2 Ethernet LEDs

3–21


MARO2P10203703E


ER-2

ER-2 EthernetPrinted CircuitBoard(10Base2)

ER-2 A-B RIO/Ethernet Printed CircuitBoard(10Base2)

3–22


MARO2P10203703E

Table 3–13 lists and describes the ER-1 alarm LEDs.

Table 3–13. ER-1 Alarm LEDs

ALARM DESCRIPTION

1 2 3 4

Fuse Alarm

DRAM Parity ErrorSoft Alarm LED

STATUSALARM

Soft Alarm LED Turned on and off by system software.

DRAM Parity Error Turns on when a DRAM parity error occurs.

Fuse Alarm Turns on when a fuse has blown (for 10BASE5 PCBs only).

Table 3–14 lists and describes the ER-2 alarm LEDs.

Table 3–14. ER-2 Alarm LEDs

ALARM DESCRIPTION

Not used

Not usedDRAM Parity Error

Soft Alarm LED

ALARM

A1

A2

A4

A3

Soft Alarm LED Turned on and off by system software.

DRAM Parity Error Turns on when a DRAM parity error occurs.

ER-1 Alarm LEDs

ER-2 Alarm LEDs

4 TROUBLESHOOTING

4 TROUBLESHOOTING

4–1MARO2P10203703E


Power ON Sequence The following procedures are applicable to all P-200 robot systems including those on a pedestal, rail or with an opener. 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller shutdown Use this procedure for complete controller shutdown including purge circuitry. 4–4.

Servo Lockout Servo Lockout Procedure 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Class 1 FaultTroubleshooting

A Class 1 Fault is a malfunction that prevents the controller from operating. The main contactor might or might not be energized. No text is displayed on the teach pendant. Refer to Section 4.1. 4–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


A Class 2 Fault is a malfunction that prevents the Boot ROM operating system from turning the system over to the application software. Text will be displayed on the the teach pendant, but the teach pendant display will be frozen and will not respond to keypad entries. Refer to Section 4.5. 4–21. . . . . . . . . . . . . . . . . . . . . . .


A Class 3 Fault is a malfunction that prevents the robot from operating normally,even though the application software is running. A numbered alarm message will be displayed on the teach pendant. You can access teach pendant menus and diagnostic screens during a Class 3 fault. Refer to Section 4.6. 4–23. . . . . . . . . SRVO-001 Operator Panel E-Stop 4–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-002 Teach Pendant E-stop 4–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-003 Deadman switch released 4–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-004 Fence Open 4–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-005 Robot Overtravel 4–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-006 Hand Broken 4–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-007 External Emergency Stops 4–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-011 TP Released While Enabled 4–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-012 Power Failure Recovery 4–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-014 Fan Motor Abnormal 4–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-015 System Over Heat 4–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-019 ER_SVAL1 SVON input 4–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-020 ER_SVAL1 SRDY off (TP) 4–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-021 ER_SVAL1 SRDY off 4–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-022 ER_SVAL1 SRDY on 4–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-023 ER_SVAL1 Stop Error Excess 4–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-024 ER_SVAL1 Move Error Excess 4–40. . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-026 ER_WARN Motor Speed Limit 4–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-027 ER_WARN Robot Not Mastered 4–41. . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-033 ER_WARN Robot Not Calibrated 4–41. . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-035 ER_WARN Joint Speed Limit 4–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-036 Imposition Time Over 4–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-037 ER_SVAL1 IMSTP Input 4–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-038 PULSE MISMATCH 4–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-042 ER_SVAL2 MCAL Alarm 4–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-043 ER_SVAL2 DCAL Alarm 4–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-044 ER_SVAL2 HVAL Alarm 4–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-045 ER_SVAL2 HCAL Alarm 4–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-046 ER_SVAL2 OVC Alarm 4–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-047 ER_SVAL2 LVAL Alarm 4–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-049 ER_SVAL2 OHAL1 Alarm 4–49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-050 ER_SVAL1 CLALM Alarm 4–49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-051 ER_SVAL2 CUER Alarm 4–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-053 ER_WARN Disturbance excess 4–50. . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-054 ER_SVAL1 DSM memory error 4–50. . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-061 ER_SVAL2 CKAL Alarm 4–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-062 ER_SVAL2 BZAL Alarm 4–51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–2

4. TROUBLESHOOTING

MARO2P10203703E

Topics In This Chapter PageClass 3 FaultTroubleshooting(continued)

SRVO-063 ER_SVAL2 RCAL Alarm 4–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-064 ER_SVAL2 PHAL Alarm 4–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-065 ER_WARN BLAL Alarm 4–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-066 ER_SVAL2 CSAL Alarm 4–53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-067 ER_SVAL2 OHAL2 Alarm 4–53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-068 ER_SVAL2 DTERR Alarm 4–54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-069 ER_SVAL2 CRCERR Alarm 4–56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-070 ER_SVAL2 STBERR Alarm 4–56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-071 ER_SVAL2 SPHAL Alarm 4–56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-072 ER_SVAL2 PMAL Alarm 4–57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-073 ER_SVAL2 CMAL Alarm 4–57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-074 ER_SVAL2 LDAL Alarm 4–57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-075 ER_WARN Pulse Not Established 4–58. . . . . . . . . . . . . . . . . . . . . . . . . SRVO-081 ER_WARN EROFL Alarm 4–58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-082 ER_WARN DAL Alarm 4–59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-083 ER_WARN CKAL Alarm 4–59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-084 ER_WARN BZAL Alarm 4–59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-085 ER_WARN RCAL Alarm 4–59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-086 ER_WARN PHAL Alarm 4–59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-087 ER_WARN BLAL Alarm 4–60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-088 ER_WARN CSAL Alarm 4–60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-089 ER_WARN OHAL2 Alarm 4–60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-090 ER_WARN DTERR Alarm 4–60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-091 ER_WARN CRCERR Alarm 4–60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-092 ER_WARN STBERR Alarm 4–60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-093 ER_WARN SPHAL Alarm 4–61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-147 SERVO LVAL(DCLK) Alarm 4–61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-163 ER_FATL DSM Hardware Mismatch 4–61. . . . . . . . . . . . . . . . . . . . . . . SRVO-164 ER_FATL DSM/Servo Param Mismatch 4–61. . . . . . . . . . . . . . . . . . . . SRVO-165 ER_FATL Panel (SVON Abnormal) E-Stop 4–61. . . . . . . . . . . . . . . . . SRVO-166 ER_FATL TP (SVON Abnormal) E-Stop 4–61. . . . . . . . . . . . . . . . . . . . SRVO-167 ER_FATL Deadman Switch (SVON Abnormal) 4–62. . . . . . . . . . . . . . SRVO-168 ER_FATL External/SVON(SVON Abnormal) E-Stop 4–62. . . . . . . . . .


A Class 4 Fault is a malfunction that prevents the robot paint system components in the outer arm of the P-200 from operating normally, even though the application software is running. No numbered alarm messages will be displayed as in the case of a class 3 fault. Process defects will be noticed on each job as a result. 4–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trigger Valve 4–64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shut Off 4–65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trigger (Electrical) 4–66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process Fault Transducer 4–73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flow Meter 4–76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

This chapter describes the steps you must follow to repair electrical faultsin the R-J2 controller.

WARNINGThe procedures described in this section require you towork with high voltage circuits. Carelessness orinattention can kill you. Do not attempt any of theseprocedures unless you are trained and experienced inelectrical repair.

4–3

4. TROUBLESHOOTING

MARO2P10203703E

The following procedures are applicable to all P-200 robot systemsincluding those on a pedestal, rail or with an opener. In the case of aP-200 robot and opener, both units must be properly purged before thecontroller can be turned on.

Procedure 4–1 Troubleshooting Purge Problems

1 With the main disconnect ON, you should observe:

Purge complete LED is off.Purge enable pushbutton (purging) lamp is off.ON pushbutton lamp is off.Purge fault LED is on

2 Push and hold the PURGE ENABLE pushbutton. You should observe

Purge solenoid engages when minimum pressure requirements aremet.

Purge fault LED turn off.Purging lamp (behind purge enable pushbutton) lights.

3 Release the purge enable pushbutton.

4 At the end of the 5 minute purge, the pushbutton purging lamp willturn off and the purge complete LED will turn on. Also, the purgesolenoid will shut off.

5 If this procedure does not work, go to troubleshooting Table 4–1. Ifthe purge cycle works correctly but the robot will not power up, go toProcedure 4–4 .

4.1POWER ONSEQUENCE

Step

4–4

4. TROUBLESHOOTING

MARO2P10203703E

Use this procedure for complete controller shutdown including purgecircuitry.

Procedure 4–2 Controller Shutdown Procedure

1 Push the E-stop push button.

2 Push the controller “OFF” pushbutton.

3 Pull the Main Disconnect switch.

For servo lockout use the following procedure:

Procedure 4–3 Servo Lockout Procedure


2 Open the servo lockout disconnect switch.

3 Lockout switch

4.2CONTROLLERSHUTDOWN

Step

4.3SERVO LOCKOUT

Step

4–5

4. TROUBLESHOOTING

MARO2P10203703E

This section contains troubleshooting information for Class 1 Faults. A Class 1 fault prevents the controller from operating. The main A.C. linecontractor (ALC) might be energized. The Purge Complete light might beon. No text is displayed on the teach pendant.

This section contains several tables. Each table provides procedures tocorrect the fault. To troubleshoot a Class 1 fault, always start atProcedure 4–1 . Perform the procedures in order. You will either correctthe fault using Table 4–1 or it will refer you to another table in thissection.

Use the other tables only when Table 4–1 refers you to them.

If the following conditions are true, follow the steps in Table 4–1.

The main disconnect is ON.The ON button has been pressed.The power on sequence (Procedure 4–1 ) has been attempted.The controller does not operate.

Without turning off the main disconnect, open the controller door.Release the disconnect latch by turning the screw to the lower right of thedisconnect handle.

4.4CLASS 1 FAULT TROUBLESHOOTING

How to use theTroubleshooting Tables

Class 1 Fault Condition

4–6

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–1. Troubleshooting Procedure 1(Initial Purge Troubleshooting Procedure)

Troubleshooting Procedure Illustration

1. Find the Purge Complete light on the StandardOperator Panel. If the light is on this indicatesthat the purge cycle was successful.

If the light is on go to Table 4–4.

If the light is off continue troubleshooting.

PurgeCompleteLight

ÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

ÎÎÎ

ÎÎÎÎ

ÎÎÎÎÎÎ

ÎÎÎ

BATTERY

ALARM CYCLE STARTON

OFF

REMOTE

REMOTE

LOCAL

HOLD

PURGECOMPLETE

PURGE ENABLE

PURGEFAULT

TEACH PENDANTENABLED

FAULT RESET

FAULT

ÏÏÏÏPurge

EnablePushbuttonand Lamp

2. Find the Purge Fault light on the Standard OperatorPanel.

If the light is on go to Step 4.

If the light is out continue troubleshooting.

PurgeFaultLight

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

ÎÎÎ

REMOTE

REMOTE

LOCAL

PURGECOMPLETE

BRAKE ENABLE

PURGE ENABLE

PURGEFAULT

EMERGENCY STOP

FAULT RESET

ÏÏÏÏ

ÏÏÏÏ

ON

OFF HOUR METER

PORT

4–7

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–1. (Cont’d) Troubleshooting Procedure 1(Initial Purge Troubleshooting Procedure)


3. Press and hold the Purge Enable pushbutton on theStandard Operator Panel until it lights (1 - 5 seconds) andthen release.

If the Purge Complete light comes on test thecontroller for proper operation. Go to Table 4–4.

If the Purge Enable or Purge Complete light does notcome on and/or the Purge Fault light comes on

continue troubleshooting.

Purgeenable

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎ

ÎÎÎÎ

PURGECOMPLETE

PURGEFAULT

ÏÏÏÏ

ÏÏ

Purgefault

PURGE ENABLE

HOUR METER

FAULT RESET

REMOTE

ON

OFF

LOCAL

EMERGENCY STOP

PORT

BRAKE ENABLE

4. Turn off the main disconnect handle.

5. On the Intrinsically Safe Terminal Board (ISTB) unit,connect test jumper wires between terminals 1 and 4, andbetween terminals 5 and 8 on the ISTB.These terminals are the inputs from the

robot-mounted air pressure and air flow switches. Goto Step 6.

Refer to Figure 12–13.

ISTBTest Jumpers

NOTE: Jumper 1-2 simulates the pressure switch from the robot. Jumper 3-4 simulates the pressure switch from the opener, If applicable (If there is no opener all ready jumpered). Jumper 5-6 simulates the flow switch from the robot. Jumper 7-8 simulates the flow switch from the opener, if applicable (If there is no opener all ready jumpered).

6. Turn on the main disconnect handle.

4–8

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–1. (Cont’d) Troubleshooting Procedure 1(Initial Purge Troubleshooting Procedure)


7. Press and hold the Purge Enable pushbutton on theStandard Operator Panel until it lights (1 - 5 seconds) andthen release it.If the purge circuit is cycling, the purge enable

pushbutton will stay lit until the 5 minute purge iscomplete. The Purge Fault light will be out.

If the robot does not purge with jumpers inserted goto step 8.

If the purge is successful with jumpers the problemcould be:

– The wiring connected to the pressure switch(s) or

the flow switch(s)

– The pressure switch in robot (or opener if

applicable)

– The flow switch in robot (or opener if applicable)

– Possibly a casting leak in robot (or opener if

applicable)Locate the problem and replace faulty component.If problem still exists check any Auxiliary device

pressure and flow switches. If not used checkjumpers across terminals 3 and 4, and terminals 5and 6.

Locate the problem and replace faulty component.Refer to Figure 12–13.Remove jumpers from step 5 and retest purge

system.If the purge is successful without jumpers Go to

Table 4–4.

PurgeEnable

ÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

ÏÏ

ÏÏÏÏ

PurgeFault

PORT

REMOTE

OFF HOUR METER

ON

EMERGENCY STOP

LOCAL

BRAKE ENABLE

PURGE FAULT

PURGE ENABLE

8. Replace purge control PCB.Retest purge control without jumpers.If purge control is still not working go to Table 4–2.

WARNINGThe purge control timer is adjusted to five minutes toconform to Factory Mutual Specifications. Do not adjustthe purge control timer; otherwise, an explosion or firecould occur.

4–9

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–2. Troubleshooting Procedure 2 (IBRC TroubleshootingProcedure)


1. Observe the lights on the IDEC IBRC unit .

If all of the lights are off go to Step 2.

If one or more of the lights are on go to Table 4–3. Lights CH1 CH2 CH3 CH4 CH5 CH6

2. Measure the AC voltage coming into the IDEC IBRC unit atterminals 220 VAC and 0V.

If the voltage is 200 to 240 VAC replace the IDEC IBRCUnit.

If there is no voltage continue troubleshooting.

Refer to Figure 12–1, Figure 12–12, Figure 12–13 andFigure 12–15.

MultiTap TransformerTF1

43 44

3. Measure the AC Voltage at terminals R and S on the purgecontrol PCB

If the voltage is 200 to 240 VAC replace the wires betweenIDEC IBRC and CP1 on the purge control PCB.

If there is no voltage check for continuity between terminalsFRA1 and FRA2 on purge control PCB.

If there is no continuity replace jumper between FRA1 andFRA2.

If there is continuity continue troubleshooting.

Refer to Figure 12–1, Figure 12–7 and Figure 12–13.

1 2FRA

SR

G

200A 200B

FRA

Purge Control PCB

. .4. Measure the AC voltage coming into the purge control PCB at

terminals 200A and 200B.

If there is 200 to 240 VAC replace purge control PCB.

If there is no voltage turn off main power disconnect andcheck for continuity between terminals 200A and 200B onpurge control PCB and terminals 43 and 44 on the multi-taptransformer. Continue troubleshooting.


G

15ma MAX.24VDC PSU

IDEC IBRC

220VAC 0VAC IN

5. If there is no continuity replace the wires betweenterminals 200A and 200B on the purge control PCB andterminals 43 and 44 on the multi-tap transformer.

If there is continuity go to Table 4–5.

4–10

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–3. Troubleshooting Procedure 3 (Non-Specific Purge Problems)


1. Turn off the power disconnect handle.Continue troubleshooting.

2. Reseat the following connectors: Contact signal transducer(IDEC IBRC) connector CNCA. Purge control printed circuitboard (mounted with EMG control PCB) connector CNIN.Continue troubleshooting.Refer to Figure 12–1, Figure 12–12, Figure 12–13 and

Figure 12–14.

3. Turn off the power disconnect handle.

ÎÎÎ ÎÎ

ÎÎÎÎÎÎ

REMOTE

REMOTE

LOCAL

PURGECOMPLETE

BRAKE ENABLE

PURGE ENABLE

PURGEFAULT

FAULT RESET

ÏÏÏÏ

ÏÏÏÏ

ON

OFF

PurgeFault

4. Observe on the Standard Operator Panel that the purge faultlight is lit.

ÎÎÎÎÎÎ

EMERGENCY STOP

ÏÏÏÏ

OFF HOUR METER

PORT

4–11

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–3. (Cont’d) Troubleshooting Procedure 3 (Non-Specific Purge Problems)


5. Re-initiate the purge sequence. Go to Procedure 4–1 .

If the controller does not purge properly go to Step 6.

If the purge was successful go to Table 4–4.PSU2

6. Measure the DC voltage between the (+) and (-) on PSU2.

If the voltage is 24 VDC go to Step 9.

If there is no voltage check fuses F11 and F12 on the purgeunit power supply board.

If either fuse or both fuses are blown replace bad fuses.

If new fuses blow check 24VDC wiring.

If fuses are not bad continue troubleshooting.

Refer to Figure 12–13.

Power supply(+)(–)

F11

F12

3.2A

3.2A

7. If CH1 light is on, go to Step 8. If CH1 light is out, test jumperISTB terminals 1 to 4 and observe if the light comes on.

If the CH 1 light did not light replace the IDEC IBRC unit

If the light comes on replace the pressure switch or wiringfor proper operation. Continue troubleshooting.

Remove test jumpers at the end of each step.

ISTB

Test Jumpers for step 7

Test Jumpers for Step 8

4–12

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–3. (Cont’d) Troubleshooting Procedure 3 (Non-Specific Purge Problems)


8. If CH 2 light is out, test jumper ISTB terminals 5 to 8 andobserve if the light comes on.

If the CH 2 light does not come on go to step 9.

If the light comes on replace the auxiliary flow switch orwiring or replace the jumper, when auxiliary flow switch is notused.

NOTE Remove test jumpers at the end of each step.

Lights


IDEC IBRC

9. Replace the following in the order shown:

Purge enable switchPurge control PCBIBRC unit

Procedure 4–4 Troubleshooting Turn-on Problems

You have performed Procedure 4–1 and the system is purged.

The following conditions exist:

Purge complete LED onPurge enable pushbutton (purging) lamp is off.ON pushbutton lamp is off.Purge fault LED off.

1 Attempt normal power by pressing the ON pushbutton.

The ON pushbutton will light.Main CPU and axis control PCBs also execute internal diagnostics.

When the diagnostics are all complete the MCC on all servo amplifierswill energize and “click”. When this occurs, the teach pendant is on andthe controller is ready to operate.

If unit powered up correctly go to Section 4.5.

If the unit did not turn ON normally, go to Table 4–4.

Condition

Step

4–13

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–4. Troubleshooting Procedure 4(General Power Supply Troubleshooting)


1. Check and see if the green PIL light in the center of thePower Supply Unit module is ON.

If the light is on go to Table 4–6.

If the light is off continue troubleshooting.

CP1G

S

R1

2

3

2. Check fuse F1 in the top center of the Power Supply Unitmodule.

A white flag in the center of the fuse indicates it isbad.

If the fuse is bad, replace it and attempt the power upProcedure 4–4 .

If the fuse is good go to step 3.

If the fuse continues to blow go to step 5.

Battery

F1: 7.5A fusefor AC input

CP2

G1

S1

R1

CP3

S2

R2

G2

11

2 2

3 3

3. If the white flag does not appears in the center fuse windowand the green PIL light still does not come on, check fusewith an ohmeter

If the fuse is blown replace the fuse.

If the fuse blows again replace the Power Supply Unit.

If the fuse is OK and the green PIL light does not come on continue troubleshooting.

Battery

PIL: Green LEDfor indicatingthe AC powersupply status

ALM: RedLED f4. Disconnect CP1 at the top of the Power Supply Unit module.

Measure the voltage coming into the PSU on the two redwires in the harness connector (S and R).

Check to see if the voltage is 220 to 240 VAC.If the voltage is ok go to step 5.

If their is no voltage go to Table 4–5.

F4:

LED forindicating analarm

5. Turn off the main disconnect switch and, using an ohmmeter,to test for a short in the wiring harnesses at CP2 and CP3.

If no short is evident go to step 6.

If there is a short replace the shorted wiring harness andattempt power up sequence.

F4:5A fuse for +24E

F3:5A Slow-Blowfuse for +24V

4–14

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–4. (Cont’d) Troubleshooting Procedure 4(General Power Supply Troubleshooting)


6. Reconnect harnesses CP2 and CP3 and turn the maindisconnect switch to on. Press the ON pushbutton and checkfor proper operation.

If the fuse continues to blow Continue troubleshooting.

Power Supply Unit Module

PIL: Green LEDAC Power Supply Status

7. If fuse F1 has blown again it is due to a short in one of thefollowing. Replace components one at a time the untilproblem is solved.

Wiring harness to servo power control coilServo power control coilWiring harness to fans (check in particular where cable and

front door hinge point meet).Fan motor shorted.

Replace fan motor, replace fuse.

F3: 5-AS slow–blowfuse for +24V

F4: 5-Afuse for +24E

ALM Red Alarm Light

AC Power Su ly Status

4–15

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–5. Troubleshooting Procedure 5 (Transformer)


1. Measure the AC voltage between Multi-Tap Transformerterminals 43 and 44 of TF1.

You should see 200 to 240 VAC.If 200 to 240 VAC is present replace the harness betweenthe Power Supply Unit and the Multi-Tap Transformer.

If voltage is not present or incorrect continuetroubleshooting.

Refer to Figure 12–1 and Figure 12–3.

CAPACITY SPECIFICATION F1,F2,F3 F4,F5

7.5KVA A80L–0026–0010#A 30A 7.5A

SPECIFICATION OF TF1

575550500480460415/240380/220

OV575550500480460415/240380/220

OV575550

480460415/240380/220

500

OV24

L1

L2

L343

44

51

52

F4

F5

SERVO POWER CONTROL

SERVO POWER

100 VAC

THERMOSTAT

FOR OVERHEAT

F2

F1

220 VAC

(210 VAC)

(220VAC)

30A

3 4

1 2

5 6

13 14

23 24ST1

ST2

A1

A2

MULTI–TAP TRANSFORMER TF1

EE–0989–550

7.5A

F3

2. Check Multi-Tap Transformer tap settings. As shown inSection 1.9.

If the tap settings are set incorrectly Set to correct values.

If the tap settings are correct continue troubleshooting.


F1BREAKER

L1L2

IN CASE OF CIRCUIT BREAKER

3. Check AC voltage between transformer primary terminals.

Check between terminals L1 and L2.Check between terminals L2 and L3.Check between terminals L1 and L3.All voltage readings should be the be the same depending on

plant supplied 3 phase voltage.If proper voltage is present replace Multi-Tap Transformer.

If incorrect or no input voltage is present continuetroubleshooting.


L2

L3G

FL1

FL2

FL3

DISCONNECTSWITCH

IN CASE OF DISCONNECT SWITCH

FUSE UNIT

4–16

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–5. (Cont’d) Troubleshooting Procedure 5 (Transformer)


4. Check AC voltage between bottom terminals of fuses FL1,FL2, & FL3.

All voltage readings should be the be the same depending onplant supplied 3 phase voltage.

If voltage is present replace wiring harness betweenMulti-Tap Transformer and Fuse Block.

If voltage is not present continue troubleshooting.


FL1 FL2 FL3Fuse Block

5. Check AC voltage between top terminals of fuses FL1, FL2,and FL3.


If voltage is present fuses F1, F2, F3 is/are blown Replacethe bad fuse. If it blows again, replace the Multi-TapTransformer.



6. Check AC voltage between terminals at bottom of the MainDisconnect Switch.


If voltage is present replace wiring harness between FuseBlock and Main Disconnect Switch.


MainDisconnectSwitch

7. Check AC voltage between terminals at top of disconnect.

All voltage readings should be the be the same dependingon plant supplied 3 phase voltage.

Replace Main Disconnect Switch if voltage is present;otherwise, contact plant maintenance.

FL1, FL2, FL3Fuse Block

4–17

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–6. Troubleshooting Procedure 6 (Power Supply Alarms)


1. Check the red alarm light in the center of the Power SupplyUnit module.

The alarm light should be off.If the light is ON go to Table 4–7.

If the light is OFF continue troubleshooting.

F3: 5-AS slow–blowfuse for +24V

F4: 5-A fuse for +24E

ALM Red Alarm Light


PIL: Green LEDAC Power Supply Status

2. Listen and look for main cabinet cooling fans to be running.

Fans should be running indicating that the 200V outputs fromPSU, CPZ, ,and CP3 are ON.

If fans are not running go to Step 3.

If fans are running go to Table 4–7.

Fan#1

Fan#2

Fan#3

Backplane Fan

COOLING FANS

3. Check for 200 to 240 VAC at Power Supply Unit Module onconnector CP2 by checking contacts R1 and S1 or on CP3by checking contacts R2 and S2.

You should see 200 to 240 VAC on either connector.If there is 200 to 240 VAC replace the wiring to the fansand/or the Servo power control relay.

If there is not 200 to 240 VAC go to Step 4.



CP2CP3

CP2 CP3

R1 R2

S1 S2

G1 G2

4–18

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–6. (Cont’d) Troubleshooting Procedure 6 (Power Supply Alarms)


4. Check the terminal block TBOP1 on the operator panel forjumpers between terminals (EX COM) and (EX OFF).

If you use an external OFF button, there will be a wire on eachterminal.

If the terminals are connected with a jumper wire check forloose screws and good contact.

If an external OFF button is used test for continuity of theexternal OFF, and DIL circuits replace it if necessary. Continue troubleshooting.


CNHM

PORT 2CRS1

CNOP

KA1

KA2

EXON

EXCOM

EXOFF

SVON1

SVON2

E STOP1

5. On the operator panel, momentarily connect (Ex ON) to (ExCOM).

Controller should turn on.If the controller turns on there is a break in the on/offswitch circuit replace any damaged wire or the on/off switchcircuit.

If the controller does not turn on replace the Power SupplyUnit module.


KA3

KA4

EMGIN1

EMGIN2

FENCE 1

FENCE 2

E STOP2

EMGOUT2

EMGOUTC

EMGOUT1

TBOP2 TBOP1

4–19

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–7. Troubleshooting Procedure 7 (Power Supply Output)


1. Check fuse F3 at the bottom of the Power Supply Unit.

A white flag in the center of the fuse indicates it is bad and that24V power is missing.

If the fuse is blown there might be a short circuit in one of thefollowing:

-Backplane (See Figure 4–1 and Figure 4–2)-24VDC Cooling Fans for module card cage-Process I/O 24 VDC supply-Main CPU Module-Modular I/O 24 VDC supply-Option #1 Card-Option #2 Card-Option #3 Card

Isolate the short and replace the defective component.If the fuse is good replace the Power Supply Unit.



F3: 5-AS slow blowfuse for +24V

ALM: Red LEDfor indicating analarm


Figure 4–1. 24 Volt (24V) Power Distribution Chart

CA44

JRM

10

JRM

3

CNOP (FOR PAINT ONLY)

JD1A

For 5 slot backplane only

JNA

3

3

4–20

4. TROUBLESHOOTING

MARO2P10203703E

Figure 4–2. 24 Volt (24E) Power Distribution ChartJR

A5

JRA

5

CR

M10

ISB

CNOP

JNA

3

For 5 slot backplaneonly

#3

4–21

4. TROUBLESHOOTING

MARO2P10203703E

A Class 2 Fault occurs when frozen text (letters or numbers) are displayedon the teach pendant. This indicates a problem with the main CPU printedcircuit board caused by either the memory, processor, the board itself, or abad teach pendant cable. Use Table 4–8 to troubleshoot a class 2 fault.

Table 4–8. Class 2 Faults Troubleshooting Procedure

Troubleshooting Procedure

1. Is the Battery light on the main CPU module on?

If the Battery light is on replace the battery. Refer to Procedure 9–1 . Continue troubleshooting.

2. Perform a cold start of the controller following the procedures in the Systems PaintTool Setup and Operations Manual.Go to Step 3.

3. Are all four green LEDs on the main CPU board turned on?

If all four green LEDs are on continue troubleshooting.

If all four green LEDs are not on troubleshoot the controller using Table 3–4 .

4. Turn the controller off. Hold down the NEXT and PREV keys on the teach pendant and press the ON button.

Check the teach pendant cable by swapping it with a known working cable or by doing a continuity test. Does the “BMON>” prompt appear on the teach pendant? If it does not appear, replace the main CPU printed circuit

board and reload the software. Otherwise, continue troubleshooting.

5. Perform the following steps on the teach pendant to check the CMOS memory:

a. Press the NEXT key twice.

b. Press F1, DIAG.

c. Press ENTER.The prompt changes to DIAG> (diagnostic monitor).

d. Press the NEXT key three times.

e Press F5, TEST.

f. Press F1, CMOS.

g. Press ENTER.

The teach pendant will display a message that gives you an opportunity to exit without destroying the contents of CMOSmemory.

CAUTIONDo not continue unless your controller actually has a Class 2 fault. Continuing beyond thispoint will erase all software stored in the controller including all taught positions in yourapplication. Otherwise, a complete software reload will be required.

h. Press 1, and then press ENTER if you want to continue with the test.

The CMOS memory test will take a few minutes to run. If an error is encountered, replace the CMOS module and reload thesoftware. Refer to the Paint Tool SYSTEM R-J2 Controller Software installation manual for more information.

If the CMOS memory test passes, continue troubleshooting.

4.5CLASS 2 FAULTSTROUBLESHOOTING

4–22

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–8. (Cont’d) Class 2 Faults Troubleshooting Procedure


6. Perform the following steps on the teach pendant to check the FROM:

a. Press the NEXT key three times.

b. Press F5, TEST.

c. Press F3, FROM.

d. Press ENTER.

The teach pendant will display a message that gives you an opportunity to exit without destroying thecontents of Flash ROM memory.

e. Press 1, and then ENTER if you want to continue with the test.

The Flash ROM memory test will take a few minutes to run. If an error is encountered, replace the FlashROM module and reload the software. Otherwise, continue troubleshooting.

7. Perform the following steps on the teach pendant to check the DRAM:

a. Press the NEXT key three times.

b. Press F2, DRAM.

c. Press ENTER.

The teach pendant will display a message that gives you an opportunity to exit without destroying the contents of the DRAM memory.

d. Press 1 and then ENTER if you want to continue with the test.

The DRAM memory test will take a few minutes to run. If an error is encountered, replace the DRAM module. The software does not have to be reloaded. Otherwise, go to Step 8.

8. The hardware in your controller is OK. Reload your application software. Refer to the Paint Tool SYSTEM R-J2Controller Software installation manual for more information.

4–23

4. TROUBLESHOOTING

MARO2P10203703E

A class 3 fault occurs when the teach pendant displays a fault message.This section contains troubleshooting procedures for each class 3 faultmessage. To determine which procedure to use, perform the followingsteps:

1. Press the MENUS key on the teach pendant.

2. Select ALARM.

3. Refer to the appropriate section and follow the correspondingtroubleshooting procedure. The subsections that follow are arrangedin numerical error code order.

4.6CLASS 3 FAULTTROUBLESHOOTING

4–24

4. TROUBLESHOOTING

MARO2P10203703E

The operator panel emergency stop pushbutton is pressed.

Remedy: Twist the operator panel emergency stop push button clockwiseto reset. Press RESET.

If the problem still exists, it is caused by an error in the emergency stopcircuit or a bad main CPU. Perform the following troubleshootingprocedure:

Table 4–9. SRVO-001 Troubleshooting Procedure


1. Make sure that the teach pendant E-stop button is notpressed and that the external emergency stop inputs andfence switch inputs are jumpered or closed.

2. Reseat the CNOP connector on the operator panel. Reseatthe JRM10 connector on the main CPU.

3. Turn on the controller and check for proper operation. If theproblem is still present, continue troubleshooting.

4. Open the door of the controller. Press and release the E-stopbutton several times. Listen for relay KA4 to click. Does therelay KA4 on the standard operator panel click?

If yes replace the cable between the operator panel CNOPand main CPU JRM10.

If no continue troubleshooting.

5. Connect jumper wires across terminals 1 and 2 of eachswitch section of the E-stop switch and then press reset onteach pendant. Does the fault reset?

If yes replace the E-stop switch assembly

If no replace the operator panel.


CNHM

PORT 2CRS1

CNOP

KA1

KA2

KA3

KA4

EXON

EXCOM

EXOFF

EMGIN1

EMGIN2

FENCE 1

FENCE 2

SVON1

SVON2

E STOP1

E STOP2

EMGOUT2

EMGOUTC

EMGOUT1

TBOP2 TBOP1

NCNC

1

1

2

2

E-Stop Switch

E-Stopbutton

4.6.1 SRVO-001 ER_SVAL1Operator Panel E-Stop

4–25

4. TROUBLESHOOTING

MARO2P10203703E

The teach pendant emergency stop (E-Stop) pushbutton has been pressed.

Remedy: Twist the teach pendant emergency stop pushbutton clockwiseto release and press RESET.

If the problem still exists, it is caused by the loss of 24VDC to the teachpendant relay RLY2 or the 5VDC signal to the matrix decoding from thenormally closed contact of the teach pendant relay RLY2.

Any of the following can cause this problem:

A defective teach pendant emergency stop switch.A defective component on the teach pendant printed circuit board.Loss of 24VDC to the E-STOP switch (not part of the teach pendant

power).

This loss of power can be caused by a bad teach pendant emergencystop switch, a broken wire in the teach pendant cable, a bad operatorpanel, or a bad cable between the operator panel CNOP and the mainCPU JRM10. You can fix it by replacing the teach pendant.

If you want to troubleshoot the problem further, perform the followingtroubleshooting procedure:



1. Turn off the controller.

2. Reseat CNOP at the operator panel interface and connector JRM10 at the main CPU.

3. Turn on the controller and check for proper operation. If the problem is still present,continue troubleshooting.

4. One of the following components is bad.

Replace the teach pendant.Replace the operator panel.Replace cable between CNOP on the operator panel and JRM10 on the main CPU.Replace main CPU.

Determine the bad component by substituting it with a new component.


4.6.2 SRVO-002 ER_SVAL1Teach Pendant E-stop

4–26

4. TROUBLESHOOTING

MARO2P10203703E

The teach pendant DEADMAN switch is released while the teach pendantis enabled.

Remedy: Press and hold the teach pendant DEADMAN switch. PressRESET.

If the problem still exists, perform the following steps:




2. Reseat the teach pendant cable at both ends, connector JRM10 at the operator panel printed circuit board, andconnector JRM10 at the main CPU.

3. Turn on the controller and check for proper operation. If the problem is still present, continue troubleshooting.

4. Open the controller door. Turn on the controller. Make sure the teach pendant E-Stop pushbutton is not pressed.

5. Press and release a DEADMAN switch several times. You should be able to hear relay KA1 click on the operator panelinterface.

If the relay clicks replace cable between the operator panel interface and the main CPU.

After replacing the cable check the DEADMAN switch for proper operation, if problem still exists continue troubleshooting.Go to step 6.

If the relay does not click one of the following components is bad:

The teach pendant The teach pendant cable The operator panel interface.

Determine the bad component by substitution. Problem solved.

6. If your teach pendant is bad, and you want to troubleshooting the teach pendant continue troubleshooting.


8. Remove the seven screws on the teach pendant back.8. Remove the seven screws on the teach endant back.

9. Remove the teach pendant back but leave all electrical connectors in place.

10. Press each DEADMAN switch bar while you watch the switch body inside the teach pendant.

11. Make sure that the copper strip presses the switch actuator all the way into the switch body.You should be able to hear and feel it click into place.

12. If the actuator is frozen or will not click sharply, replace the switch.

13. Slide the wiring connector half way off the circuit board connector.

14. Measure the resistance between:

Pins 1 and 2Pins 3 and 4.

NOTE When the DEADMAN switch is not pressed, there is continuity between pins 1 and 2 and nocontinuity between pins 3 and 4.

NOTE When the DEADMAN switch is pressed, there is no continuity between pins 1 and 2 andcontinuity between pins 3 and 4.

If one or more measurements are bad replace the DEADMAN switch assembly.

If the measurements are good the teach pendant is defective replace the teach pendant.

4.6.3 SRVO-003 ER_SVAL1Deadman switchreleased

4–27

4. TROUBLESHOOTING

MARO2P10203703E

The safety fence gate is open.

Remedy: Close the gate. Several gates in the workcell might beinvolved.

If the problem still exists, perform the following troubleshootingprocedure:



1. Look at terminals Fence 1 and Fence 2 on TBOP1 on theoperator panel interface. Check for a jumper connecting theterminals or a wire on each terminal. There should becontinuity between the two terminals.

If there is no continuity install a jumper or repair theexternal fence circuit.


PORT 2

EXONSVON1

CRS1

CNOP

CNHM

2. Turn off the controller.EXCOM

KA1

3. Reseat CNOP at the operator panel interface and connectorJRM10 at the main CPU.

EXCOMSVON2

4. Make sure that no EMERGENCY STOP buttons are pressed. EXOFFE STOP1 KA2

5. Open the controller door.EMGIN1E STOP2

6. Disconnect one end of the fence jumper or external fencecircuit.

EMGOUT1

EMGIN1

EMGIN2

E STOP2

KA3

7. Briefly short the two fence terminals on the operator panelinterface together. You should be able to hear and see relayKA4 click on the operator panel interface.

If the relay clicks replace the cable between the operatorpanel interface CNOP and the main CPU connector JRM10.

If the relay does not click replace the operator panel.


EMGOUT2

EMGOUTC

EMGOUT1 EMGIN2

FENCE 1

FENCE 2

TBOP1TBOP2

KA4

4.6.4 SRVO-004 ER_SVAL1Fence open

4–28

4. TROUBLESHOOTING

MARO2P10203703E

An overtravel error occurs when the robot moves beyond the softwaremotion limits, tripping the overtravel limit switch.

If more than one axis is moving when the switch is tripped, the controllerwill report an overtravel error on several axes.



1. If you have not already done so, continuously press and holdthe DEADMAN switch and turn the teach pendant ON/OFFswitch to ON.

2. Hold down the SHIFT key and press RESET.

3. Press COORD until you select the JOINT coordinate system.

4. Jog the axis in overtravel off of the overtravel switch.

5. If you cannot jog the robot off of the overtravel switch thewrong motion inhibit flag has been set; therefore, continue toStep 6. Otherwise, the axis (or axes) are no longer inovertravel and you can end the procedure now.

6. Cold start the controller and go to Step 1. If the overtravel stillcannot be cleared, continue troubleshooting.

NOTE In some instances, the teach pendant screen willindicate a FALSE for a given axis when a TRUE should beset because of the way overtravel is read in the software. It isbest to perform the following procedure on all of the axes.

7. Press MENUS.

8. Select MANUAL FCTNS.

9. Press F1, [TYPE].

10. Select OT Release.

11. Move the cursor to the OT PLUS or OT MINUS value of theaxis in overtravel. The status of OT PLUS or OT MINUS forthat axis is TRUE.

12. Press and hold SHIFT and press F2, RELEASE.

13. Press and hold SHIFT and press RESET.

14. Press COORD until you select the JOINT coordinate system.

15. Continuously press and hold the DEADMAN switch and turnthe teach pendant ON/OFF switch to ON.

16. Jog the axis off of the overtravel switch.

MENUS

RESET

COORD

SHIFT

4.6.5 SRVO-005 ER_SVAL1Robot Overtravel

4–29

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–13. (Cont’d) SRVO-005 Troubleshooting Procedure


17. Turn the teach pendant ON/OFF switch OFF and release theDEADMAN switch.

If the error cannot be reset continue troubleshooting.

18. Check fuse F4 on the power supply unit.

If the fuse is blown replace it and check for a short circuit inthe external 24V circuit (I/O and/or end effector power.)

If fuse is not blown continue troubleshooting.

19. Reseat connector JRF2 at the main CPU and connectorsCRM11 and JRF2 on the emergency stop control board.

20. Turn on the controller and check for proper operation. If theproblem is still present, continue troubleshooting.

21. Using an ohmmeter and the wiring diagrams, check theCRM11 (Emergency Stop Control Board) cable for continuity.If a break is found, replace the cable on CRM11 emergencystop control board.

22. If error still exist, one of the following is bad:

Determine the bad component by substitution.

The ribbon connector between the main CPU connectorJRF2 and Emergency Stop Control Board connector JRF2.

The Emergency Stop Control Board. The main CPU.Refer to Figure 12–8 and Figure 12–9.

JRF2

Central Processing Unit


Power Supply Unit

4–30

4. TROUBLESHOOTING

MARO2P10203703E

A hand breakage error occurs when the hand (wrist) breakage detectionswitch or aux hand breakage detection switch is tripped.

Remedy:

If you are not using the hand broken function, ensure that the HBKjumper on the Emergency Stop Control Printed Circuit Board is set to theA side.

If you are using the hand broken function, perform the following steps:

1. If you have not already done so, continuously press and hold theDEADMAN switch and turn the teach pendant ON/OFF switch to ON.

2. Hold down the SHIFT key and press RESET. The robot can now bemoved.

3. Jog the robot to a safe position off of the limit switch.

4. Turn the teach pendant ON/OFF switch to OFF and release theDEADMAN switch.

4.6.6 SRVO-006 ER_SVAL1Hand Broken

4–31

4. TROUBLESHOOTING

MARO2P10203703E




1. Turn off the controller and check fuse F4 on thepower supply unit.

If the fuse is blown replace it and check for a shortcircuit in the external 24V circuit (I/O and/or endeffector power.)

If fuse is not blown continue troubleshooting.


Power Supply Unit

2. Reseat the CRM10 and JRF2 connectors on themain CPU and the CRM11 and JRF2 connectors onthe emergency stop control board.

3. Turn on the controller and check for proper operation. If the problem still exists, continuetroubleshooting.

4. Test the end effector switch and its wires at the robotfor continuity.

If there is no continuity replace the switch or itswires.

If there is continuity continue troubleshooting. HBK

EmergencyStopControlBoard

HAND BROKEN5. Set the HBK jumper on the Emergency Stop Control

Board to the A side and test the robot for properoperation.

If the fault is fixed replace the cable between themain CPU connector CRM10 and the robot. Be sure toreset the jumper on the emergency stop control boardto the B side.

If the fault is not fixed one of the followingcomponents is bad.

Determine the bad component by substitution.The Emergency Stop control board.The ribbon cable between the Emergency Stop

Control Board and the main CPU.Main CPU.

Power Supply Unit

HAND BROKENJUMPER

CRM 10

4–32

4. TROUBLESHOOTING

MARO2P10203703E

An external emergency stop button somewhere in the workcell has beenpressed.

Remedy: Locate and release the external emergency stop button. Pressreset on the operator panel or teach pendant.




1. Look at terminals EMGIN1 and EMGIN2 on the operatorpanel interface. Check for a jumper connecting the terminalsor a wire on each terminal. There should be continuitybetween the two terminals.

If there is no continuity install a jumper or repair theexternal fence circuit.


CNHM

PORT 2CRS1

CNOP

KA1

KA2

KA3

KA4

EXON

EXCOM

EXOFF

EMGIN1

EMGIN2

FENCE 1

FENCE 2

SVON1

SVON2

E STOP1

E STOP2

EMGOUT2

EMGOUTC

EMGOUT1

TBOP2 TBOP12. Turn off the controller.

3. Reseat the JRM10 connector at the operator panel interfaceand the JRM10 connector at the main CPU.

MAIN CPU

4.6.7 SRVO-007 ER_SVAL1External EmergencyStops

4–33

4. TROUBLESHOOTING

MARO2P10203703E

Table 4–15. (Cont’d) SRVO-006 Troubleshooting Procedure


4. Turn off the controller and check for proper operation. If theproblem still exists continue troubleshooting.

PORT 2CRS1

CNOP

5. Make sure that no EMERGENCY STOP push buttons arepressed. Check the operator panel, teach pendant and anyother external EMERGENCY STOP buttons that wereadded.

CNHM

PORT 2CRS1

KA1

EXON

EXCOM

SVON1

6. Open the controller door.

KA2

EXCOM

EXOFF

SVON2

E STOP17. Disconnect one end of the EMGIN1 and 2 jumper or external

emergency stop circuit.

KA2

KA3

EXOFF

EMGIN1

E STOP1

E STOP2

8. Briefly short the EMGIN1 and EMGIN2 terminals on theoperator panel interface TBOP1 together. You should beable to hear relay KA4 click on the operator panel interface.

If the relay clicks replace cable between the operatorpanel CNOP and the main CPU

If not replace the operator panel.


KA3

KA4

EMGIN2

FENCE 1

FENCE 2EMGOUT2

EMGOUTC

EMGOUT1

TBOP2 TBOP1

4–34

4. TROUBLESHOOTING

MARO2P10203703E

Teach pendant DEADMAN switch was released while enabled.

Remedy: Press the DEADMAN switch, then press RESET.

Normal power is on (hot start).

Remedy: This message is normal and does not indicate a problem. Noaction is required by the operator.

One or all of the 24VDC cooling fans in the backplane cage are notrunning.

Each double-board board cage in the backplane has a cooling fan mountedin its top. Each fan contains a centrifugal switch that opens when the fanis not running.



1. With power on, test whether each fan is turning by passing a strip of paperover the top of each board cage.

If all fans are turning go to Step 3.

If one or more fans are motionless continue troubleshooting.

2. Remove the circuit boards from the board cage with the motionless fan.Reconnect the four-wire connector on the backplane behind the boardcage. Re-install the boards and turn on the controller.

If the fault is not fixed replace the fan. Fanmotor

Cable

3. One of the fans or the board is probably defective. Determine which part isbad by temporarily replacing it with a known-good part.

If the fault is not fixed continue troubleshooting.Connector

Backplane4. Replace the backplane.

Back lane

4.6.8 SRVO-011ER_SVAL1TP Released WhileEnabled

4.6.9 SRVO-012ER_SVAL1Power FailureRecovery

4.6.10 SRVO-014 Fan Motor Abnormal(Group:i Axis:j)

4–35

4. TROUBLESHOOTING

MARO2P10203703E

The temperature in the controller is too high, or the overheat sensorlocated on the backplane has opened.


Troubleshooting Procedure Print Reference

1. Check the heat exchanger fans for operation.

If the fans are operating replace the backplane.

If one or more fans do not work continue troubleshooting.

Figure 12–1.

2. Check the AC voltage at the terminals of the non-working fan(s).

If the voltage is 200 to 240 VAC replace the non operational fan(s).

If the voltage is out of tolerance replace the fan motor wiring harness.

4.6.11 SRVO-015 ER_SVAL1System Over Heat(Group:i Axis:j)

4–36

4. TROUBLESHOOTING

MARO2P10203703E

The SVON (servo ON/OFF) input is asserted.

Perform the following troubleshooting steps.



1. Check for continuity between SVON1 and SVON2 on the operator panel interface terminal stripTBOP2.

If no continuity jumper terminals together or replace application wiring.

If there is continuity replace the operator panel.

If the alarms still exist replace the cable between the operator panel (CNOP) and the Main CPU(JRM10).

If alarm still exists replace the main CPU.

Figure 12–16.

The teach pendant cable is disconnected or a momentary break occurred inany of the teach pendant emergency stop circuits; DEADMAN switch orteach pendant EMERGENCY STOP button.




1. Replace the teach pendant cable or teach pendant as necessary.

If alarm still exists replace the cable between the operator panel (CNOP) and the main CPU

If alarm still exists replace the main CPU.

Figure 12–8 andFigure 12–16.

4.6.12 SRVO-019 ER_SVAL1SVON input

4.6.13 SRVO-020 ER_SVAL1SRDY off (TP)

4–37

4. TROUBLESHOOTING

MARO2P10203703E

The Magnetic Control Contactor on the servo amplifier cannot turn on andno obvious emergency stop conditions exist.

Perform the following troubleshooting steps. Refer to Table 4–20.

NOTE The paint robot is normally set up for Group 1, Axes 1-6 or Group 1, Axes 1-7.

The opener, if present is usually set up as Group 2.

The alarms will indicate which group is having problems.



1. Check the continuity of the plunger switch that detects an open controller door. The switch shouldshow continuity when the actuator is pressed.

Figure 12–1Figure 12 –15.show continuity when the actuator is ressed.

If the plunger switch does not show continuity replace the plunger switch.

Figure 12–15.

p g y g

If the plunger switch shows continuity continue troubleshooting.

2. Remove connector from CRM15 on the Emergency Stop Control Board and check switchcontinuity thru CRM15 socket.

3. Check the servo amplifier connections between the Emergency Stop Control Board.

4. Check servo amplifier switch settings. See Figure 4–3.

5. Check for proper cable connections between Emergency Stop Control Board and servo amplifier.See Figure 4–4.

6. Turn on the controller and check for proper operation. If the problem is still exists continuetroubleshooting.

7. Check the Magnetic Control Contactor coil for continuity:

If the Magnetic Control Contactor (MCC) coil is bad replace the MCC.

If the MCC coil is good continue troubleshooting.

8. One of the following components is bad.

Determine the bad component by substituting it with a new component. Replace the followingcomponents one at a time until problem the is solved. The Emergency Stop Control Board Cable between the Emergency Stop Control Board (CRR15) and the MCC. The cable between the MCC (CRR20) and the servo amplifiers. The ribbon connector between the main CPU and the Emergency Stop Control Board (JRV1). Cable from Emergency Stop Control board JS1 thru JS6 and servo amplifier. The servo amplifier.

4.6.14 SRVO-021 ER_SVAL1SRDY off(Group:i Axis:j)

4–38

4. TROUBLESHOOTING

MARO2P10203703E

Figure 4–3. Servo Amplifier Switch Settings

OFF ON

123

4

LED

There are four channel switches above the 7-segment LEDbehind the terminal board cover on the front of the servo amplifier. These switches should be set as described belowbefore you use the servo amplifier.

ON

OFF

Type B Interface

Type A Interface

Set switch 2 to OFF. If the setting is incorrect, SRVO-021 SRDY OFF alarm might occur.

Switch 1

The switches are sequentially numbered 1, 2, 3, and 4with the one at the bottom as switch 1. The OFFposition is on the left and the ON position is on theright.

Switch 1 determines the interface type.Paint controllers use the Type Binterface for Robot Axes 1–6

Normal settings for switches 3 and 4 are in the ON position.Refer to Figure 4–6.

4–39

4. TROUBLESHOOTING

MARO2P10203703E

Figure 4–4. Connector and Terminal (T1) Identification

AO6B-6089-H101-H106 AO6B-6089-H201-H210

1

357

89

34567

12

89

NAME INDICATION REMARK

1

2

3

4

5

6

7

8

9

TYPE A InterfaceJV1B

Connector for M-Axis (minor channel)type A interface

Connector for L-Axis (major channel)type B interface

Connector for L-Axis (minor channel)type B interface

TYPE A Interface

TYPE B Interface

TYPE B Interface

TYPE B Interface

TYPE B Interface

TYPE B Interface

N/A

N/A

N/A

Connector for main powersupply (Y key)

Connector for expo signal(X key)

CX4

CX3

JA4

JF2

JF1

JS2B

JS1B

JV2B

3 pin1 pin

2 pin: ESP (at open)3 pin: 24V

Connector for L-Axis (major channel) type Ainterface

4–40

4. TROUBLESHOOTING

MARO2P10203703E

The Magnetic Control Contactor on the servo amplifier is on before it isexpected to be on.




1. Check the Magnetic Control Contactor (MCC) for stuck contacts.

If the contacts are stuck replace the MCC.

If the MCC is OK continue troubleshooting.

2. Refer to the Section 4.6.14.

The axis position is too far from its commanded position when the robot isstopping, or the robot is stopped and it will not move. The torquenecessary to decelerate an overloaded motor could cause this alarm tooccur.




1. Make sure that the load on the robot is not excessive.

2. Check that the affected axis is not binding and rotates freely. Especially, make sure that the brakeis not stuck.

3. Check that the motor power cables do not have any open wires and that the cables are notmisconnected.

4. Either the motor or the servo amplifier is bad. Determine the bad component by substituting it witha new component.

The servo error is too big when the robot is moving, or the robot moveswhen it is supposed to be stopped.

Remedy: Same as SRVO-023, Stop Error Excess.

4.6.15 SRVO-022 ER_SVAL1SRDY on(Group:i Axis:j)

4.6.16 SRVO-023 ER_SVAL1Stop Error Excess(Group:i Axis:j)

4.6.17 SRVO-024ER_SVAL1Move Error Excess(Group:i Axis:j)

4–41

4. TROUBLESHOOTING

MARO2P10203703E

The motor cannot rotate as fast as the calculated speed required for thecurrent motion.

Remedy: Even though this is just a warning, every attempt should bemade to eliminate this error by modifying the programmed speed ormotion.

The robot is not mastered.

Remedy: Master the robot. Refer to Chapter 8.

The robot is not calibrated.Remedy: Calibrate the robot. Refer to Chapter 8.

Joint cannot rotate as fast as the calculated speed required for the currentmotion.

Remedy: Even though this is just a warning, every attempt should bemade to eliminate this error by modifying the programmed or motionspeed.

The robot is not in position for the specified period, or the servo error is inexcess of the specified position when the robot is stopping, or the robot isstopped and it will not move. The torque necessary to decelerate anoverloaded motor could cause this alarm to occur.

Remedy: Same as SRVO-023, Stop Error Excess.

IMSTP (immediate stop) UOP (User Operator Panel) input asserted.

Remedy: If using a UOP, determine the cause and repair. If not usingUOP, select the I/O menus and zero UOP mapping.

4.6.18 SRVO-026 ER_WARNMotor Speed Limit(Group:i Axis:j)

4.6.19 SRVO-027 ER_WARNRobot Not Mastered(Group:i Axis:j)

4.6.20 SRVO-033 ER_WARNRobot Not Calibrated(Group:i Axis:j)

4.6.21 SRVO-035 ER_WARNJoint Speed Limit(Group:i Axis:j)

4.6.22 SRVO-036 Imposition Time Over(Group:i Axis:j)

4.6.23 SRVO-037 ER_SVAL1IMSTP Input(Group:i Axis:j)

4–42

4. TROUBLESHOOTING

MARO2P10203703E

When the controller was powered up, one or more of its axes was at adifferent position from when it was powered off. This might occur when amotor is replaced or when a CPU from one controller is installed inanother.

Remedy: Perform the following procedure:

Table 4–23. SRVO-038 Alarm Reset Procedure

Reset Procedure Print Reference

1. Press MENUS.

2. Select SYSTEM.

3. Press F1, [TYPE].

4. Select MASTER/CAL

If MASTER/CAL is not displayed, perform the following:a. Select VARIABLES.b. Select $MASTER_ENB.c. Set $MASTER_ENB to 1.d. Press F1 [TYPE] and select MASTER/CAL.

5. Press F3, RES_PCA.

6. Press F4, YES.

7. Press RESET to clear the alarm without turning off the controller. If the fault does not reset, coldstart the controller. Refer to Procedure 10–3 .

4.6.24 SRVO-038PULSE MISMATCH(Group:i Axis:j)

4–43

4. TROUBLESHOOTING

MARO2P10203703E

The servo amplifier magnetic control contactor (MCC) is welded closed.If the contact of the MCC is already closed when the contactor is turnedon, this alarm circuit regards the contact as welded closed and the MCCalarm occurs. This error code can also be caused by improper controllershut down sequence (see Procedure 10–5 ) or improper servo lockoutprocedure (see Procedure 10–6 ).

Perform the following troubleshooting procedure:



1. Does this alarm occur with SRVO-049?

If SRVO-049 occurs check for the absence of input three-phase voltage. Connect as necessary.Check (reseat) the cable between the servo amplifier and the Emergency Stop Control Board.

Figure 12–8Figure 12–9.

2. Turn the controller power off for fifteen second and then turn it on again. See Procedure 4–1 . If thealarm is still present, continue troubleshooting.

3. Replace the servo amplifier.

If error still exists replace the cable between the Emergency Stop Control Board and the servoIf error still exists re lace the cable between the Emergency Sto Control Board and the servoamplifier.

If error still exists replace the cable between the Emergency Stop Control Board (JRV1) and theIf error still exists re lace the cable between the Emergency Sto Control Board (JRV1) and themain CPU.

If error still exists replace the Emergency Stop Control BoardIf error s till exists replace the Emergency Stop Control Board.

If error still exists replace the main CPU.

4.6.25 SRVO-042ER_SVAL2MCAL Alarm(Group:i Axis:j)

4–44

4. TROUBLESHOOTING

MARO2P10203703E

The regenerative energy produced by the motor exceeded thespecifications.

NOTE The amplifier supplies the energy (velocity energy) to the motorwhen the axis (without gravity) moves at the acceleration and constantspeed. When the axis moves at the deceleration and constant speed andwith gravity (gravity energy), the motor supplies this energy (velocityenergy plus gravity energy) to the amplifier.

This energy from the motor to the amplifier is the regenerative energy.The amplifier discharges this energy by converting this energy to heatenergy through the discharge resistor. If the charged energy exceeds thedischarged energy, this alarm occurs.

Remedy: Check the LED on the amplifier, then perform the followingtroubleshooting procedure.



1. Is “4” or “5” indicated on the servo amplifier 7-segment display?

If 4 is indicated go to Step 2.


If 4 is indicated go to Ste 2.

If 5 is indicated go to Step 3.

If no number is indicated check the cables between the servo amplifier and Emergency StopControl Board Verify the correct switch 3 and 4 setting (see Figure 4 5)Control Board. Verify the correct switch 3 and 4 setting (see Figure 4–5).

If the error still exists replace the servo amplifier.

If the error still exists replace the cable between the servo amplifier and the Emergency StopIf the error still exists re lace the cable between the servo am lifier and the Emergency StoControl Board.

If the error still exists replace the ribbon cable (JRV1) between the main CPU and EmergencyStop Control Board.Sto Control Board.

If the error still exists replace the Emergency Stop Control Board.

If the error still exists replace the main CPU.

2. A “4” is indicated (DCSW alarm) when the regenerative transistor is on continuously for one secondor longer. See Figure 4–6. Reduce the load of the robot.If error still exists replace the servo amplifier.

3. A “5” is indicated (DCOH alarm). See Figure 4–6. The DCOH alarm is caused when theregenerative resistor overheats and is sensed by the thermostat or the thermostat in transformerTF1 opensTF1 opens.

If the average regenerative energy is excessive This alarm occurs when theacceleration/deceleration frequency is high or gravity energy at the axis is large. Relax the operatingacceleration/deceleration frequency is high or gravity energy at the axis is large. Relax the o eratingconditions.

For robots with extended axes or if the thermostat is incorrectl y wired or is defective When aFor robots with extended axes or if the thermostat is incorrectly wired or is defective When aseparate regenerative discharge unit or power transformer for the servo controller is used, check thewiring for the thermostat according to the connection diagrams for proper wiring.

4.6.26 SRVO-043ER_SVAL2DCAL Alarm(Group:i Axis:j)

4–45

4. TROUBLESHOOTING

MARO2P10203703E

Figure 4–5. Switch 3 and 4 Settings

SWITCH 3 AND 4 SETTINGS The setting varies depending on the regenerative discharge resistance used. If the setting is incorrect, theregenerative discharge control circuit failure alarm (DCSW) cannot be detected. Normal setting for switches 3 and 4 are ON.

3 4

3 4

3 4

Regenerative Discharge Resistor



SVU1 (12, 20)

SVU1 (130)

ON ON

ON OFF

OFF OFF

Built-in

Separate A06B-6089-H510


SVU1 (40, 80), SVU2 /

ON ON

OFF OFF

ON OFF

ON ON

OFF OFF

ON OFF

Built-in

Built-in

Separate A06B–6089-H500

Separate A06B-6089 H713(800W), A06B-6089-H714(1200W)



Figure 4–6. Servo LED Display

SERVO LED DISPLAY

Regenerativedischargecontrol circuitfailure alarm(DCSW)

Overregenerativedischarge alarm(DC0II)

This alarm occurs if:

The short-time regenerative discharge energy is too high.

The regenerative discharge circuit is abnormal.

The average regenerative discharge energy is too high (too frequent acceleration/deceleration).

The transformer overheats.

4

5

This alarm occurs if:

4–46

4. TROUBLESHOOTING

MARO2P10203703E

The DC voltage on the main power circuit of the servo amplifier exceededspecification. HVAL (High Voltage Alarm)

Remedy: Check the three-phase voltage to the servo amplifier input. Itshould not exceed 253 VAC phase-to-phase.




1. Is the voltage of the three-phase input servo to the amplifier higher than 253 VAC?

If the voltage than 253 VAC check multi-tap transformer TF1 taps.

If it is within limits 200 to 240 VAC continue troubleshooting.

Figure 12–3

2. Is the load of the robot within the specification? This alarm can be caused by the charge of theregenerative energy when the load exceeds the specification.

If it exceeds the specification reduce the load of the robot.

If the specification is not exceeded continue troubleshooting.


If the error still exists replace the cable between the Emergency Stop Control Board andIf the error st ill exists replace the cable between the Emergency Stop Control Board andthe servo amplifier.

If error still exists replace the cable (JRV1) between the Emergency Stop Control Boardand the main CPUand the main CPU.

If error still exists replace the Emergency Stop Control Board.If error still exists re lace the Emergency Sto Control Board.


4.6.27 SRVO-044 ER_SVAL2HVAL Alarm(Group:i Axis:j)

4–47

4. TROUBLESHOOTING

MARO2P10203703E

The current in the main power circuit of the servo amplifier exceededspecification. The servo amplifier LED should display “8”, “9”, “6”, “8.”,“9.”, or “6.”.

Remedy: If no alarm is indicated on the servo amplifier 7-segmentdisplay, check the cabling between the servo amplifier (JS1B or JS2B) andthe Emergency Stop Control Printed Circuit Board (JS1-6).




1. Disconnect the motor power lines from the amplifier terminals and turn on the power. This alarmwill re-occur if the servo amplifier is defective.

If an HCAL (High Current Alarm) alarm occurs replace the servo amplifier.

If an HCAL alarm does not occur continue troubleshooting.

2. Remove the motor power lines from the amplifier terminals and check the continuity between GNDand each of the lines U, V, and W that go to the motor.

If any are short-circuited go to Step 3.

If all are not shorted go to Step 4.

3. Remove the power lines from the motor connectors (J1-6) and re-check the continuity betweenGND and each of the lines U, V, and W to the robot motor.

If any lines are shorted, the motor is defective replace the motor.

If all lines are open the power lines to the motor are defective replace the line that wasshorted to GND.

4. Remove the motor power lines from the amplifier terminals and measure the resistancebetween U-V, V-W, and W-U on the servo amplifier using a measuring instrument sensitiveenough to detect small resistances.

If the three measured values are the same go to Step 5.

If the three measured values are different go to Step 6.

5. Remove the power lines from the motor connectors and remeasure the resistance between U-V, V-W, and W-U using a measuring instrument sensitive enough to detect small resistances.

If the three measured values are the same the power lines are defective. Replace thepower lines.

If the three measured values are different the motor is defective replace the motor. Goto Step 7.

6. Replace the servo amplifier. Continue troubleshooting.

7. Check whether you are using the robot under conditions that exceed the specification. Forexample, load, duty, and so forth. If there is no mechanical reason (binding and so forth) to causethis alarm this alarm might occur under conditions that exceed the specification If you are usingthis alarm, this alarm might occur under conditions that exceed the specification. If you are usingthe robot over the specification, relax the operating conditions.

If the error still exists replace the cable between the servo amplifier and the EmergencyIf the error s till exists replace the cable between the servo amplifier and the EmergencyStop Control Board.

If the error still exists replace the cable between the Emergency Stop Control Board (JRV1)If the error still exists replace the cable between the Emergency Stop Control Board (JRV1)and the main CPU.

If the error still exists replace the Emergency Stop Control BoardIf the error still exists replace the Emergency Stop Control Board.

If the error still exists replace the main CPU.

4.6.28 SRVO-045 ER_SVAL2 HCAL Alarm(Group:i Axis:j)

4–48

4. TROUBLESHOOTING

MARO2P10203703E

The average current calculated by the servo software exceededspecification. OVC (Over Current Alarm).

This is caused by excessive load or by a collision with an axis hard stop oran object in the robot work envelope.

The DC voltage on the main power circuit of the servo amplifier is lowerthan specification. LVAL (Low Voltage Alarm)

Remedy: If no alarm is indicated on the servo amplifier LED, check thecabling between the servo amplifier and the Emergency Stop ControlBoard.




1. Does the LED of the amplifier indicate “2” ? Check the three-phase input voltage to the amplifier.

If the LED indicates a “2” the voltage is lower than the recommended specification. Thephase-to-phase input voltage at the servo amplifier terminals should measure at least 170VACbetween each phase

Check for 200 to 240 VAC input power to terminals 13 and 14 of the servo amplifier. If it is low ormissing, check multi-tap transformer TF1 taps, fuses, and Magnetic Control Contactor (MCC).

If the alarm occurs again replace the servo amplifier. Go to Step 4.


2. Does the LED of the amplifier indicate “3” ? This indicates the DC current in the main power circuit is too low.

Check the three-phase 200 to 240 VAC input voltage to the amplifier.

If the voltage is lower than 170VAC the three-phase input voltage needs to be adjusted to withinthe FANUC specifications. Check the multi-tap transformer TF1 taps and fuses.

3. Did the circuit breaker on the servo amplifier trip? (If a circuit breaker trips, this alarm will occurincidentally.)

If a circuit breaker trips turn on the breaker. If it trips again, replace the servo amplifier.Continue troubleshooting.

4. Does the LED of the amplifier indicate a “7”? This alarm could occur when the contact of the magnetic contactor (MCC) is melted (welded together).

Refer to the SRVO-042 MCAL alarm. See Section 4.6.25.

5. If the servo amplifier has been replaced and the error still exists; replace the cable between theservo amplifier and the Emergency Stop Control Board.servo am lifier and the Emergency Sto Control Board.

If error still exists replace the cable between the Emergency Stop Control Board (JRV1) and themain CPUmain CPU.

If error still exists replace the Emergency Stop Control Board.If error still exists re lace the Emergency Sto Control Board.


4.6.29 SRVO-046ER_SVAL2OVC Alarm(Group:i Axis:j)

4.6.30 SRVO-047ER_SVAL2LVAL Alarm(Group:i Axis:j)

4–49

4. TROUBLESHOOTING

MARO2P10203703E

The servo amplifier or transformer is overheated. OHAL1 (Over HeatAlarm 1)

Remedy: Check the fans and the heat exchange unit for proper operation.




1. Relax the operating condition (duty cycle).

If the alarm no longer occurs the operating condition of the robot exceeded the specification.

Figure 12–8Figure 12–15g g

If the alarm still occurs replace the servo amplifier

If no alarm is indicated on the servo am plifier 7-se gment dis play check the cabling betweenIf no alarm is indicated on the servo amplifier 7-segment display check the cabling betweenthe servo amplifier and the Emergency Stop Control Board. If the cabling is not bad, continuetroubleshooting.

2. Replace the cable between the Emergency Stop Control Board (JRV1) and the main CPU.

If the alarm still occurs replace the Emergency Stop Control Board.

If the alarm still occurs replace the main CPU.

The servo software detected a disturbance torque that was too high or acollision occurred and tripped a collision detection alarm. CLALM(Collision Alarm)

Remedy: Reset the robot by using the teach pendant reset and jog therobot away from obstructions.




1. Does the load exceed the specifications? (When the robot moves over the specifications, theestimated disturbance torque might become larger and this alarm could occur.)

If the load exceeds the specifications lower the load to within the specifications.

If the load does not exceed the specifications continue troubleshooting.


2. Is the three-phase AC input voltage to the servo amplifier lower than 170VAC phase-to-phase(O-V, V-W, U-W).

If the voltage is lower than 170VAC increase the input voltage to within the specifications.Check multi-tap transformer TF1 taps and fuses.

If the voltage is not lower than 170VAC continue troubleshooting.

3. Check the continuity of the motor power wires (from the servo amplifier to the motor).

If the motor power wires are defective replace as required.

If after the motor power wires have been replaced and the problem still exists replace themain CPU.

4.6.31 SRVO-049 ER_SVAL1OHAL1 Alarm(Group:i Axis:j)

4.6.32 SRVO-050 ER_SVAL1CLALM Alarm(Group:i Axis:j)

4–50

4. TROUBLESHOOTING

MARO2P10203703E

The feedback current is abnormal. CUER (Current Error)




If the error still exists continue troubleshooting.

2. Replace the main CPU.

The servo software detected a disturbance torque that was too high.

Remedy: Reset the robot and try again.

The DSP module program memory is defective. DSM (Digital ServoModule).

Remedy: Replace the appropriate DSP module on the main CPU andcontinue.

The clock for the rotation counter in the serial pulse coder is abnormal.CKAL (Clock Alarm)



1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with thisalarm?

If YES disregard error SRVO_061 and refer to the remedy of any of the other three alarms.

If NO alarms occur replace the serial pulse coder on the specified axis and master the robot.See Chapter 8.

4.6.33 SRVO-051 ER_SVAL2CUER Alarm(Group:i Axis:j)

4.6.34 SRVO-053ER_WARNDisturbance excess(Group:i Axis: J)

4.6.35 SRVO-054ER_SVAL1DSM memory error(DS:i)

4.6.36 SRVO-061 ER_SVAL2 CKAL Alarm(Group:i Axis:j)

4–51

4. TROUBLESHOOTING

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The battery voltage for the serial pulse coders is zero volts. BZAL(Battery Zero Alarm).




If YES disregard the BZAL alarm and refer to the procedure for the other alarm(SRVO-68 - SRVO-70).

If NO continue troubleshooting.

2. Did this alarm message list only one axis?

If YES check the battery cable for the serial pulse coder of the axis listed in the alarm message.Reconnect, or replace as necessary. Go to Step 4.


3. Press the teach pendant emergency stop button. Turn the controller on. Check the pulse coderbatteries for 6 VDC at the battery terminals on the battery box in the door of the controller.

Do the batteries read 6 VDC ?Do the batteries read 6 VDC ?If YES replace the battery compartment cable. Go to Step 4.

If NO replace the batteries. Continue troubleshooting.

4. Perform serial pulse coder reset procedure under SRVO-038 alarm.

5. Turn the controller off and then back on.

6. It might be necessary to perform the SRVO-038 procedure again.If alarm still exists on only one axis Replace the serial pulse coder (after verifying batterycable is good) .

4.6.37 SRVO-062ER_SVAL2BZAL Alarm(Group:i Axis:j)

4–52

4. TROUBLESHOOTING

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The built-in rotation counter on the serial pulse coder is abnormal.RCAL (Revolution Clock Alarm).




If YES disregard SRVO_063 and refer to the remedy of any of the other three alarms.

If NO replace the serial pulse coder on the specified axis and master the robot. See Chapter 8.

The relationship between the analog signals on the serial pulse coder areabnormal. PHAL (Phase Alarm).





If NO replace the serial pulse coder on the specified axis and master the robot. See Chapter 8.

The serial pulse coder batteries are low. BLAL (Battery Low Alarm).




If YES disregard SPC_065 and refer to the remedy of any of the other three alarms.

If NO replace the SPC backup batteries with controller power on.

NOTE: Replace the battery as soon as possible when this alarm occurs, otherwise, if the batteryvoltage goes to zero volts, the robot will require remastering.

4.6.38 SRVO-063ER_SVAL2RCAL Alarm(Group:i Axis:j)

4.6.39 SRVO-064ER_SVAL2PHAL Alarm(Group:i Axis:j)

4.6.40 SRVO-065ER_WARN BLAL Alarm(Group:i Axis:j)

4–53

4. TROUBLESHOOTING

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The serial pulse coder ROM checksum data are abnormal. CSAL (CheckSum Alarm).





If No alarms occur replace the serial pulse coder on the specified axis and master the robot.See Chapter 8.

The serial pulse coder overheated. OHAL2 (Over Heat Alarm).




If YES disregard SRVO-067 and refer to the remedy of any of the other three alarms.


2. Does the operating condition (load, duty) exceed the specifications?

If the operating condition exceeds the specifications relax the operating condition within thespecification. (Reduce the load, change the program).

If it operating conditions does not exceed the specifications continue troubleshooting.

3. Turn off the controller and when the temperature of the motor returns to normal, turn it back on.

If the alarm immediately occurs again the built-in thermostat in the serial pulse coder isdefective. Replace the serial pulse coder.

If the alarm occurs again, but not immediately the motor is generating too much heat. Replacethe motor.

4.6.41 SRVO-066ER_SVAL2 CSAL Alarm(Group:i Axis:j)

4.6.42 SRVO-067ER_SVAL2 OHAL2 Alarm(Group:i Axis:j)

4–54

4. TROUBLESHOOTING

MARO2P10203703E

The main CPU sent the serial data request signal to the serial pulse coder,but did not receive serial data from the serial pulse coder.

In order to troubleshoot the 24V to 5V converter, it will be necessary tooperate the power supply with the covers removed from the robot. Thefollowing procedure is necessary to insure the proper pre-test conditionsare met.

WARNINGThe robot is designed to operate in a hazardous location.The covers are an integral part of the protection thereforeall of the steps listed below must be followed EXACTLYAND IN THE ORDER PRESENTED. These steps must betaken IN ADDITION TO NORMAL SAFETY PRECAUTIONS.Failure to follow these procedures could result in anexplosion.

1 Consult your plant procedures to insure the area around the robot isKNOWN to be NON HAZARDOUS. Typically this will include thebooth in which the robot is located.

2 Take steps to insure the area around the robot will REMAIN NONHAZARDOUS for the duration of the test procedure and until thecovers are replaced on the robot.

3 Install a TEMPORARY jumper between terminals ISTB 1 and ISTB 4.

4 Install a TEMPORARY jumper from terminals ISTB 5 to ISTB 8.

5 Shut off the air supply to the robot.

6 If the above procedure causes a loss of controller power, press thepurge enable pushbutton and wait 5 minutes. When the PURGECOMPLETE light comes on, the controller can be turned on.

7 After you complete Steps 1-6 remove the covers on the robot and withthe controller powered ON, perform the required troubleshooting.

8 After the troubleshooting is complete, replace the covers tightly.

9 Turn on the air supply to the robot.

10 Turn off the controller and open the disconnect switch.

11 Remove both temporary jumpers and insure the connections to theISTB are correct.

WARNINGDO NOT TAMPER WITH THE SETTING of the purge timer;otherwise, you could cause an explosion.

4.6.43 SRVO-068ER_SVAL2 DTERR Alarm(Group:i Axis:j)

Step

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WARNINGFor continued safety, the temporary jumpers must beremoved; otherwise, you could cause an explosion.

12 Close the main disconnect to the controller.

13 Press the PURGE ENABLE pushbutton. Hold the pushbutton until itlights (approximately 10 seconds). This indicates adequate purge airflow. If the pushbutton does not light, purge air flow is not adequateand the robot should be checked for leaks.

14 After the PURGE COMPLETE light comes on, the controller can beturned back on. The controller can not be turned on before the purgecomplete light comes on.



1. If an individual axes has failed, check for connection and continuity of the serial pulse coder cable.Replace if necessary.

If all axes indicate failure or if the alarm occurs again continue troubleshooting.

2. Check the 24V and 6.5 V LEDs on Module Assembly EE-3044-401 located in the purge cavity.See Steps 1 through 14 and Warnings of SRVO-068 and Figure 4-7.

If the 24V LED is not illuminated check the wiring between the Module Assembly EE-3044-401and the 24V power supply in the controller.

If the 24V LED is illuminated and 6.5V LED is not illuminated disconnect CONN1 throughCONN7 on Module Assy EE-3044-401. If 6.5V LED illuminates, check for shorted Cable. If 6.5Vdoes not illuminate, replace the Module Assembly EE-3044-401.

If the 24V LED is illuminated and 6.5 LED is illuminated continue troubleshooting.


If the alarm occurs again continue troubleshooting.

4. Replace the serial pulse coder.

Figure 4–7. Module Assembly # EE-3044-401

DC/DC MODULECR1

MODULE ASSY #EE-3044-401

24V 6.5V

LEDs

4–56

4. TROUBLESHOOTING

MARO2P10203703E

The serial data from the serial pulse coder changed during communicationto the main Central Processor Unit. CRCERR (Cyclical RedundancyCheck Error).

This fault is frequently caused by electrical noise induced on the serialpulse coder cable. Make sure that the cable does not lie parallel or close topower cables. Make sure that the robot-mounted relays and solenoids havespark suppression diodes. Check all pulsecoder cable shield groundspoints.

Make sure that all cable connections are properly connected.

Only as a last resort should the cable or a serial pulse coder be replaced.

The communication stop and start bits are abnormal. STBERR (Stop BitError).

Refer to the SRVO-068 remedy.

The feedback velocity exceeds the specifications. SPHAL (SoftwarePhase Alarm).




1. Does this alarm occur with any other alarm?

If another alarm occurs this alarm is caused by the previous alarm of the serial serial pulsed R f t th th l f d t il

ycoder. Refer to the other alarm for details.

If another alarm does not occur replace the serial pulse coder.

4.6.44 SRVO-069ER_SVAL2 CRCERR Alarm(Group:i Axis:j)

4.6.45 SRVO-070ER_SVAL2 STBERR Alarm(Group:i Axis:j)

4.6.46 SRVO-071ER_SVAL2 SPHAL Alarm(Group:i Axis:j)

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The serial pulse coder fails.



1. Does this alarm occur with any other alarm?

If this alarm occurs along with a SRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070STBERR disregard this alarm and refer to the other three alarm remedies.

If this alarm does not occur along with a SRVO-068 DTERR, SRVO-069 CRCERR, orSRVO-070 STBERR continue troubleshooting.

2. Replace the serial pulse coder and master the robot. See Chapter 8 Mastering.

Incorrect position data detected in the serial pulse coder, or abnormal serialpulse coder data caused by noise.



1. If this alarm occurs along with a SRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070 STBERR, disregard this alarm and refer to the other three alarm remedies. If theSRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070 STBERR, does not occur with this alarm,continue troubleshooting.

2. Master the robot. See Chapter 8 then continue troubleshooting.

3. Check the grounding of the serial pulse coder cable shield.

If the serial pulse coder cable shield is grounded go to step 4.

If the serial pulse coder cable shield is not grounded ground the shield or replace the cable.

4. Replace the serial pulse coder and master the robot. See Chapter 8, “Mastering”.

The Serial pulse coder failure.



1. If this alarm occurs along with a SRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070 STBERR, disregard this alarm and refer to the other three alarm remedies. Otherwise,continue troubleshooting.

2. Replace the serial pulse code and master the robot. See Chapter 8, “Mastering”.

4.6.47 SRVO-072ER_SVAL2PMAL alarm(Group:%d Axis:%d)

4.6.48 SRVO-073ER_SVAL2CMAL alarm(Group:%d Axis:%d)

4.6.49 SRVO-074ER_SVAL2LDAL alarm(Group:%d Axis:%d)

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4. TROUBLESHOOTING

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The pulse position is not established until the serial pulse coder is rotated onecomplete revolution.



1. The pulse position is not established until the serial pulse coder is rotated one completerevolution.

Line Tracking Overflow Error.



1. Check the connection between the controller and the line tracking device (absolute encoder orpulse generator).

2. Check that the line speed is within the recommended specification.

If the line speed is not within the specification relax the line speed.

4.6.50 SRVO-075ER_WARNPulse not established(G:%d A:%d)

4.6.51 SRVO-081ER_WARNEROFL Alarm(Track encoder:n)

4–59

4. TROUBLESHOOTING

MARO2P10203703E

Line Tracking serial pulse coder is disconnected.

Remedy: Check axis control printed circuit board for proper line trackingcable connections.





2. Replace the line tracking serial pulse coder.

The clock for the rotation counter in the line tracking serial pulse coder isabnormal.

Remedy: Refer to SRVO-061 remedy.

The battery voltage for the line tracking serial pulse coder is zero volts.


The built-in rotation counter on the line tracking serial pulse coder isabnormal.


The relationship between the analog signals on the line tracking serialpulse coder are abnormal.


4.6.52 SRVO-082ER_WARNDAL Alarm(Track encoder:n)

4.6.53 SRVO-083ER_WARNCKAL Alarm(Track encoder:n)

4.6.54 SRVO-084ER_WARNBZAL Alarm(Track encoder:n)

4.6.55 SRVO-085ER_WARNRCAL Alarm(Track encoder:n)

4.6.56 SRVO-086ER_WARNPHAL Alarm(Track encoder:n)

4–60

4. TROUBLESHOOTING

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The line tracking serial pulse coder batteries are low.


The line tracking serial pulse coder ROM checksum data is abnormal.


The line tracking serial pulse coder overheated.


The axis control printed circuit board sent the request signal, but did notreceive serial data from the line tracking serial pulse coder.


The serial data from the line tracking serial pulse coder changed duringcommunication to the axis control printed circuit board.

Remedy: Refer to SRVO-069 remedy

The communication stop and start bits for line tracking axis are abnormal.


4.6.57 SRVO-087ER_WARNBLAL Alarm(Track encoder:n)

4.6.58 SRVO-088ER_WARNCSAL Alarm(Track encoder:n)

4.6.59 SRVO-089ER_WARNOHAL2 Alarm(Track encoder:n)

4.6.60 SRVO-090ER_WARNDTERR Alarm(Track encoder:n)

4.6.61 SRVO-091ER_WARNCRCERR Alarm(Track encoder:n)

4.6.62 SRVO-092ER_WARNSTBERR Alarm(Track encoder:n)

4–61

4. TROUBLESHOOTING

MARO2P10203703E

The feedback velocity exceeds the specification for line tracking axis.


The back-up charge circuit for the amplifier has an abnormal voltage. Thiserror code can also be caused by improper controller shut down sequence(See Procedure 10–5 ) or improper servo lockout procedure (SeeProcedure 10–6 ).

Remedy: Check the cables and connections between amplifier (CN1) andMCC. Check the fuse (F1,F2) in transformer. Replace the amplifier.

The DSM (Digital Servo Module) hardware does not all match.

Remedy: Remove the main Central Processor Unit from the controllerand check the part numbers on the DSM boards mounted in the axismodule slots. The part numbers should be the same. If the robot has morethan six axes, also check the multifunction board DSM hardware. AllDSM hardware must have the same part number to prevent this alarm.(See Figure 1–7 and Table 1–1).

The current servo parameters do not match the DSM hardware installed.

Remedy: Replace all DSP-IV DSM modules with DSP-V type. (See Figure 1–7 and Table 1–1).

The panel emergency stop button is pressed and the controller detected awiring error on SVON or EMGIN terminals.

Remedy: Turn off the controller and check EMGIN and SVON wiring tooperator panel interface terminals. Correct external wiring as necessary.

The teach pendant emergency stop button is pressed and the controllerdetected a wiring error on SVON or EMGIN terminals.

Remedy: Turn of the controller and check EMGIN and SVON wiring tooperator panel interface terminals. Correct external wiring as necessary.

4.6.63 SRVO-093ER_WARNSPHAL Alarm(Track encoder:n)

4.6.64 SRVO-147SERVO LVAL(DCLK)alarm (G:%d A:%d)

4.6.65 SRVO-163ER_FATLDSM HardwareMismatch

4.6.66 SRVO-164ER_FATLDSM/Servo parammismatch

4.6.67 SRVO-165ER_FATLPanel (SVONabnormal) E-Stop

4.6.68 SRVO-166ER_FATLTP (SVON abnormal)E-Stop

4–62

4. TROUBLESHOOTING

MARO2P10203703E

The teach pendant DEADMAN was released and the controller detected awiring error on SVON or EMGIN.

Remedy: Turn off the controller and check EMGIN and SVON wiring tooperator panel interface terminals. Correct external wiring as necessary.

The external emergency stop or external SVON switch is pressed and thecontroller detected a wiring error on the SVON or EMGIN terminals.

Remedy: This error is applicable is the redundant external emergencystop or SVON wiring is used. If so, turn off the controller and check theEMGIN and SVON wiring to the operator panel interface terminals.Correct external wiring as necessary.

4.6.69 SRVO-167ER_FATLDeadman switch(SVON abnormal)

4.6.70 SRVO-168ER_FATLExternal/SVON(SVON abnormal)E-Stop

4–63

4. TROUBLESHOOTING

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A Class 4 Fault occurs when the process equipment within the outer armof the P-200 robot fails to perform correctly. This section containstroubleshooting procedures for each kind of malfunction.

Trigger Valve Malfunctions and Troubleshooting

Gun(s) that do not turn on (Trigger) or work intermittently. Refer toProcedure 4–5 .

Gun(s) that do not shut off Refer to Procedure 4–6

Paint Gun Trigger Troubleshooting Procedure (Electrical). Refer toProcedure 4–7 .

Current to Pressure Transducer Troubleshooting Refer to Section 4.7.4

Poor Film Build (Too heavy or light)

Repeated “Adapted Out Of Range” messages

Need for continual Preset corrections

Transducer Troubleshooting Procedure. Refer to Procedure 4–8 .

Flow Meter Troubleshooting Procedure. Refer to Procedure 4–9 .

P-200 end of arm troubleshooting error descriptions

Error #178, Cal. Timeout at maximum flow

Error #179, Cal. Timeout at low flow

Error #183, Min. output has flow > setpoint

Error # 189, Failed to reach setpoint

Display reads 0 cc/min when paint is actually flowing from the gun.

Display reads the exact same cc/min value whether paint is flowing ornot.

Depending on the manufacturer, style and/or type of gun assembly used,these malfunctions could be attributed to a single gun assembly when twoguns are mounted on a common manifold having a common supply pilotsignal. In this case, the problem would be in the individual gun assembly;the gun assembly would be suspected first and replaced before lookinginto the supply.

4.7CLASS 4 FAULTS

4–64

4. TROUBLESHOOTING

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Remedy: There is no clear cut remedy for this type of malfunction.

Considerations: This function is electrical and pneumatic in operation.Procedure 4–5 first considers the most common causes which may bepneumatic in nature, then , if the problem still exists, will continuetroubleshooting the electrical components.

Procedure 4–5 Both Guns Do Not Trigger or Work Intermittently


1 Shut off the plant supplied air to the pilot trigger valve.

2 Remove the output pilot line from the pilot trigger valve.

3 Apply plant supplied air to the pilot trigger valve.

4 Push the mechanical override button on the valve body. Refer to theTrigger Valve/ Regulator Assembly in Figure 12–32.

5 Determine whether pilot air is coming out of the pilot trigger valve.

If NO > Remove and replace pilot trigger valve.If YES > Go to step 6.

WARNINGThis valve is intrinsically safe. Repair of the solenoid andpilot section is prohibited. If the solenoid portion is faulty,you must replace the solenoid and pilot section as oneassembly. They are assembled as a matched set andshould not be exchanged with other components.

6 Is pilot air sufficient and constant with plant supplied air pressure?Refer to gun manufacture’s specification.

If NO > Go to step 7.If YES > Troubleshoot pilot trigger line to gun assembly. Refer to the Trigger Valve/ Regulator Assembly in Figure 12–32.

If problem still exists , Go to step 8.

7 Is the air supply to the system sufficient and consistent with plantsupplied air pressure?

If NO > Troubleshoot air supply.If YES > Remove and replace pilot trigger valve. Is problem solved.If NO > Go to step 9.

4.7.1 Process Fault - BothGuns Do Not Trigger orWork Intermittently

Step

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4. TROUBLESHOOTING

MARO2P10203703E


8 Troubleshoot the paint spray gun assembly. Determine whether theproblem is solved.If NO > go to step 9.

9 Continue troubleshooting with Procedure 4–7 .

Remedy: There is no clear cut remedy for this type of malfunction.

Considerations: This function is electrical and pneumatic in operation.Procedure 4–6 first considers the most common causes which may bepneumatic in nature, then , if the problem still exists will continuetroubleshooting the electrical components.

Procedure 4–6 Both Guns Will Not Shut Off


1 Shut off the air supply to the pilot trigger valve. Refer to the Trigger Valve/ Regulator Assembly in Figure 12–32.

2 Remove the output pilot line from the pilot trigger valve.

3 Apply air supply to the pilot trigger valve.

4 Is air leaking from valve output port? Refer to the Trigger Valve/Regulator Assembly in Figure 12–32.

If NO > troubleshoot trigger (s) in gun assembly.If YES > Go to step 5.

5 Check for 12Vdc on solenoid/pilot trigger valve. Refer to the TriggerValve/ Regulator Assembly in Figure 12–32.


If NO > Remove and replace pilot trigger valve. If YES > Go to Procedure 4–7 .

4.7.2 Both Guns Will NotShut Off

Step

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4. TROUBLESHOOTING

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Use Procedure 4–7 to troubleshoot the electrical paint gun triggercomponents.

Procedure 4–7 Paint Gun Trigger Troubleshooting Procedure (Electrical)

1 Is DOUT [145] (PT) configured correctly?

If NO > Go to step 2.If YES > Go to step 3.

# SIM STATUS 145/256DO[ 140] U OFF [ Reserved ]DO[ 141] U OFF [ Reserved ]DO[ 142] U OFF [ Reserved ]DO[ 143] U OFF [ Reserved ]DO[ 144] U OFF [ Reserved ]DO[ 145] U OFF [ Gun 1 pilot ]DO[ 146] U OFF [ ]DO[ 147] U OFF [ ]DO[ 148] U OFF [ ]DO[ 149] U OFF [ ]

[ TYPE ] CONFIG IN/OUT ON OFF

I/O Digital Out G2 JOINT 100%

OFF

2 Reconfigure using Site I/O program, then go to step 3.

3 Is DOUT [145] (PT) ON ?


4 Set DOUT [145] (PT) to ON. Refer to Procedure 7–1 .Is output led (AO) on the output module ON? Refer to Figure 4–8.


4.7.3 Paint Gun TriggerTroubleshootingProcedure (Electrical)

Step

4–67

4. TROUBLESHOOTING

MARO2P10203703E

Figure 4–8. I/O Module LEDS

1 2 3 4 5 6 7

1 2 3 4 5 6 7

A

B

LEDS

I/O MODULE

0

0

A0 LED

5 Is DOUT [145] (PT) simulated. Refer to Procedure 7–2 .

If YES > Go to step 6If NO > Go to step 7.

6 Unsimulate DOUT [145] (PT).Go to step 3.

4–68

4. TROUBLESHOOTING

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7 Determine whether the interface module power LED (PWR) is on?Refer to Figure 4–9.


Figure 4–9. Interface Module PWR LED

JD1B JD1A

CP32 JD2

PWR LINK

BAO

BAI

AIF0IA

INTERFACE MODULE

PWR LED

LINK LED

4–69

4. TROUBLESHOOTING

MARO2P10203703E

8 Determine whether the 24V input fuse is good? Refer to Figure 4–10.

If NO > Replace 24VDC input fuses.If YES > Go to step 9.

Figure 4–10. Interface Module

InterfacemoduleAIFO1A

Fuse

3.2A

3.2AInput

Fuse5.0AOutput

5.0AF2

F1

4–70

4. TROUBLESHOOTING

MARO2P10203703E

9 Determine whether 24E at input connector (CP32) to I/F (InterfaceModule)? Refer to Figure 4–11.

If NO > Troubleshoot the 24E circuit and wiring.If YES > Replace I/F module.

Figure 4–11. Pin Out and Locator for Connector CP32

MODULAR I/O5–SLOT BASE UNIT A03B–0807–J002

MODULAR I/OINTERFACE

MODULEA03B–0807–J011

CP32

JD1B

JD1A

JD2

MODULAR I/O

POWER SUPPLYA16B–1212–0870

MAIN CPUA16B–3200–0040

CP6

JD1A

123

+24V0V

CP32

I/O UNIT MODEL A

10–SLOT BASE UNIT A03B–0807–J001

10 Determine whether the interface module Link LED is ON? Refer to Figure 4–12.

If NO > Go to step 11.If YES > Replace output module, AOD16D.

Figure 4–12. Interface Module PWR LED

JD1B JD1A

CP32 JD2

PWR LINK

BAO

BAI

AIF0IA

INTERFACE MODULE

LINK LED

4–71

4. TROUBLESHOOTING

MARO2P10203703E

11 Is output fuse good? Refer to Figure 4–10.

If No > Replace output fuse.If YES > Replace interface module.

12 Replace output module, AOD16D.

13 Is there 24Vdc at ISB7 input terminals 7 and 8? Refer to Figure 4–13


Figure 4–13. Intrinsic Safety Barrier

8

7

1

2

ISB7

ISB7-1

ISB7-2

P1

I.S. GROUND

EE-3287-328-001

INTRINSIC CABLEEE-3287-117-XXX

LOCATED IN P-200 ROBOT ARM

8663SOL

GRNWHT

DC OUTPUT MODULE

8336F.5 AMP

2

14 Is wiring from the output module to ISB7 okay? Refer to Figure 4–13.

If NO > Repair wiring.If YES > Go to step 16.

15 Is fuse 8336F/0.5A blown? Refer to Figure 4–13.

If NO > Replace output module, AOD16D.If YES > Replace 8336F 0.5A Fuse.

4–72

4. TROUBLESHOOTING

MARO2P10203703E

16 Is 12Vdc at ISB7 output terminals 1 and 2 correct. Refer toFigure 4–14.

WARNINGNever apply test leads to output terminals during paintbooth operations. To do so could injure personnel ordamage equipment. Remove ISB7 output terminals 1 and 2before any voltage measurements are taken.

If NO > Replace Intrinsic Safety BarrierIf YES > Go to step 17.

Figure 4–14. Intrinsic Safety Barrier

8

7

1

2

ISB7

ISB7-1

ISB7-2

P1

I.S. GROUND

EE-3287-328-001

INTRINSIC CABLEEE-3287-117-XXX

LOCATED IN P-200 ROBOT ARM

8663SOL

GRNWHT

DC OUTPUT MODULE

8336F.5 AMP

2

17 Is 12Vdc at pilot trigger valve connector? Refer to Trigger Valve/Regulator Assembly Figure 12–32.

If NO > Check the cables and connector.If YES > Replace the 8336SOL valve assembly.

WARNINGThe 8336SOL valve is intrinsically safe. Repair of thesolenoid and pilot section is prohibited. If the solenoidportion is faulty, you must replace the solenoid and pilotsection as one assembly. They are assembled as amatched set and should not be exchanged with othercomponents.

4–73

4. TROUBLESHOOTING

MARO2P10203703E

Use Procedure 4–8 to cover:

Poor Film Build (Too heavy or light)

Repeated “Adapted Out Of Range” Messages

Need for Continual Preset Corrections

Remedy: There is no clear remedy for these types of symptoms. It mightbe caused by a faulty current to pressure transducer (I/P) or a faulty flowmeter.

Considerations: The current to pressure transducer is an electrical andpneumatic device that is intrinsically safe. The only troubleshooting thatcan be done to the transducer is covered in Procedure 4.7.4.

Procedure 4–8 Transducer Troubleshooting

1 Is AOUT[1] set to a count of 200?


# SIM VALUE 1/25AO[ 1] U 200 [ Fluid Flow 1 ]AO[ 2] U 200 [ Atom. Air 1 ]AO[ 3] U 200 [ Fan Air 1 ]AO[ 4] U 200 [ Estats 1 ]DO[ 5] U 0 [ Flw setpoint ]DO[ 6] U 0 [ Flw diag out ]DO[ 7] * * [ ]DO[ 8] * * [ ]DO[ 9] * * [ ]DO[ 10] * * [ ]


I/O Analog Out G1 JOINT 10%

U

2 Set AOUT[1] to a count of 200. Refer to Procedure 7.1.

3 Attach an analog 0 to 60 psi gauge to the gage port on the current topressure transducer. Refer to Trigger Valve/Regulator AssemblyFigure 12–32.

4 Set AOUT[1] to a count of 1000. Refer to Procedure 7.1.

5 Is there any output pressure?


4.7.4 Process Fault -TransducerTroubleshootingProcedure

Step

4–74

4. TROUBLESHOOTING

MARO2P10203703E

6 Is the plant air supply ON?

If NO > Turn ON air supply.If YES > Go to step 7.

7 Is your paint system in the proper mode of operation? (Proper modeof operation will depend upon the unique characteristics of yoursystem).

If NO > Set paint mode to proper mode of operation.If YES > Go to step 8.

8 Is there 14.5 VDC at the current to pressure transducer I/P connectorP1 pins 1 and 6. Refer to Trigger Valve/ Regulator AssemblyFigure 12–32.


WARNINGNever apply test leads to output terminals during paintbooth operations. Otherwise, you could injure personaland damage equipment.

9 Is there 14.5 Vdc at ISB4 terminals 1 and 2? Refer to Single StagePurge Process Control Figure 12–41.


10 Is there 24Vdc at ISB4 input terminals 7 and 8? Refer to Single StagePurge Process Control Figure 12–41.

If NO > Check power supply and wiring.If YES > Replace ISB4.

11 Check the cable and connector wiring from ISB4 to I/P transducer P1.

12 Check for pressure leaks at pneumatic connections. This can beaccomplished using a soapy liquid solution.

If No > Tighten pneumatic connections.If YES. Go to step 13.

4–75

4. TROUBLESHOOTING

MARO2P10203703E

13 Perform calibration on the Current to Pressure Transducer I/P. Refer to Procedure 10.1.

Consider the following while doing the calibration procedure:

– Non-Linearity

– Hunting

– Poor Response

– No Reaction at Output

– Poor Hysteresis

– Poor Accuracy

– Poor Repeatability

– Inaccurate Span

14 Did the Current to Pressure Transducer (I/P) pass the calibration?

If NO > Go to step 15.If YES > Troubleshoot other process equipment.

15 Connect a mA meter in series with terminal 8 of the D/A module(ADA02A) in slot 3 of the I/O rack. Refer to Single Stage PurgeProcess Control Figure 12–41.

16 Set the AOUT[1] on the teach pendant to 600 counts

# SIM VALUE 1/25AO[ 1] U 600 [ Fluid Flow 1 ]AO[ 2] U 200 [ Atom. Air 1 ]AO[ 3] U 200 [ Fan Air 1 ]AO[ 4] U 200 [ Estats 1 ]DO[ 5] U 0 [ Flw setpoint ]DO[ 6] U 0 [ Flw diag out ]DO[ 7] * * [ ]DO[ 8] * * [ ]DO[ 9] * * [ ]DO[ 10] * * [ ]


I/O Analog Out G1 JOINT 10%

U

17 Is there 12.00mA on the meter?

If NO > Go to step 18.If YES > Go to step 19

18 Is there 24 Vdc at ISB5 terminals 7 & 8? Refer to Single Stage PurgeProcess Control Figure 12–41.

If NO > Check source of 24 Vdc power.If YES > Go to step 22.

4–76

4. TROUBLESHOOTING

MARO2P10203703E

19 Connect mA meter in series with terminal 1 of ISB5.

20 Is there 12.00 mA on the meter?

If NO > Go to step 21.If YES > Replace I/P transducer.

21 Check the cable and wiring from the ISB5 to the I/P transducer. Is thewiring defective?

If NO > Replace the ISB5.If YES. Replace the wiring or cable.

22 Is AOUT[1] configured correctly?

If NO use Site I/O program. Refer to PaintTool Manual SetupChapter.IF YES > Go to step 23.

23 Is AOUT[1] Simulated? Refer to Procedure 7.2

If NO > Check cable/wiring from D/A module to IBS5, terminals 9 and 10.If YES > Unsimulate.

Remedy: There is no clear remedy for these types of symptoms. It may becaused by a faulty flow meter.

Considerations:The Flow Meter is a mechanical to electrical feedbacktransducer. The only troubleshooting that can be done to the transducer iscovered in Procedure 4–9 .

Procedure 4–9 Flow Meter Troubleshooting

1 Remove MODUFLOW/Flow Meter assembly from the P-200 robotarm. Refer to Figure 12–33.

2 Remove the Flow Meter from the MODUFLOW assembly.

3 Remove the electrical connector from the Flow Meter.

4 Blow air into the Flow Meter input port. Do the gears spin?

If NO > Disassemble, clean, and then reassemble the Flow Meter.Return to step 4.If gears do not spin after Flow Meter has been cleaned replace FlowMeter.If YES > Go to step 5.

4.7.5 Process Fault - FlowMeter TroubleshootingProcedure

Step

4–77

4. TROUBLESHOOTING

MARO2P10203703E

5 Reconnect the sensor cable.

6 Monitor GIN[8] and GIN[9] at the teach pendant from the I/O menu.

# SIM VALUE 1/25GI[ 1] S 0 [ Init data ]GI[ 2] S 0 [ Init type ]GI[ 3] U 0 [ CC cycsel ]GI[ 4] U 0 [ CC shared ]GI[ 5] U 0 [ CC group ]GI[ 6] U 0 [ Flw/tpar ]GI[ 7] U 0 [ Parm/indc ]GI[ 8] U 59147 [ Totl cnt ]GI[ 9] U 32767 [ Rate cnt ]GI[ 10] U 0 [ Job type ]


I/O Group In JOINT 100%

U

7 Blow air into the Flow Meter input port. Did you see a change inGIN[8] and GIN[9]?

If NO > Go to step 8If YES > Go to step

8 Is GIN[8] & GIN[9] configured correctly?

If NO > Run Site I/O program Refer to PaintTool Setup Chapter.then > Go back to step 6.If YES > Go to step 9.

9 Is there 24 Vdc at the terminal block of the Flow Meter Interfacemodule, wires 82091 and 82092? Refer to schematics 47 A sheet 082and 087

If NO > Check wiring and CPU power supplyIf YES > Go to step 10.

10 Is there +5 Vdc at the terminal block of the Flow Meter Interfacemodule, wires 82142 and 82092? Refer to Figure 12–39 andFigure 12–42.

If NO > Go to step 11If YES > Go to step

11 Is fuse 8214F blown? Refer to Figure 12–43.

If NO > Go to step 12If YES > Replace fuse

4–78

4. TROUBLESHOOTING

MARO2P10203703E

12 Check connector and wiring at JD1A port of the I/F module. Refer toFigure 4–11.

If the wiring is damaged replace wiringIf the connector is damaged replace I/F moduleVerify for proper operation. If the problem still exists > Go to step 13.

13 Is there 24 Vdc at the terminal block of the Flow Meter Interfacemodule, wires 87091 and 87101? Refer to Figure 12–39 andFigure 12–42.

If No > Replace Flow Meter Interface module.If YES > Go to step 14.

14 Is there 24 Vdc at ISB6, terminals 7 and 8. Refer to Figure 12–42.

If NO > Replace wiringIf YES > Go to step 15.

15 Is there zero ohms at the terminal block of the Flow Meter Interfacemodule, -Sig. and wire 87101? Refer to Figure 12–42.

If NO > Tighten jumper connections or Replace jumper.If YES > Go to step 16.

16 Is there 24 Vdc at ISB6, terminals 1 and 2. Refer Figure 12–42.

If NO > Replace ISB6If YES > Go to step 17.

WARNINGNever apply test leads to these pins during paint boothoperations. Otherwise, you could injure personnel anddamage equipment.

17 Is there 24 Vdc at the Flow Meter connector P1, pins A and B. Referto Figure 12–42.

If NO > Replace wiringIf YES > Replace Flow Meter

18 Perform a Flow Test (Beakering Test). Refer to Procedure 10–2 .

4–79

4. TROUBLESHOOTING

MARO2P10203703E

19 Does the amount in the beaker equal the Total (cc) and Flow Ratecalled for?

If NO > Go to step 20.If YES > Troubleshooting completed.

STATUS AccuFlow JOINT 100 % AccuFlow Status Display Selected Operating Mode: Adaptive Current Operating Mode: Open Loop Color Valve Number: 1 Calibration Status: Complete Actual yield ((cc/min)/cnt): .78 Total (cc): 216 Set Point/Actual (cc/min): 600/594 Applicator Trigger: ON Set point reached: ON[ TYPE ] RES TOT HELP

20 Calculate new KFT factor and enter into the Equipment Characteristicsparameter section on the teach pendant.

cc in beakertotalizer

X * old KFT new KFT

4–80

4. TROUBLESHOOTING

MARO2P10203703E

AccuFlow Global Parameters 1/25

1 Mode selection source: Pendant2 Selected operating mode: Adaptive3 Percent Tolerance Band: 1.84 Min. tolerance band: 55 Sample amount: 36 Normal gain modifier (%): 95.07 Pulsing pump gain mod. (%): 70.0

Equipment characteristics8 KFT factor (CC): 23669 Equipment learn done: Done

10 Trigger delay (ms): 5011 Flow delay (ms): 3212 Time up (ms/1000 cnts): 72

Calibration parameters14 Hysteresis checks: YES15 Leveling trys: 216 Cal time out (sec): 1517 Cal step delay (ms): 80018 Table point no. 2 (cc/min): 200

Table adjustment parameters19 Flow in-tol trys: 220 Indep point shift band (%): 30.0

Alarm parameters21 Adaptive tolerance (%): 10.022 Max. error from setpoint (%): 6.023 Max. control out (ms): 20024 Min. set point reached (ms): 300025 Grace period (ms): 4000

[ TYPE ] CHAN KFT_CAL [CHOICE] HELP

SETUP AccuFlow JOINT 100 %

21 Preform a Flow Test (Beakering Test). Refer to Procedure 10–2

22 Does the amount in the beaker equal the Total (cc) and Flow Ratecalled for?

If NO > Replace Flow Meter Interface module. Verify problem issolved by rerunning the Flow Test if problem still exists ReplaceDigital 32 bit Input module (AID32B) in the I/O rack.If YES > Troubleshooting completed.

5 REPLACING FUSES

5 REPLACING FUSES

5–1MARO2P10203703E


Fused Flange MountedDisconnect Fuses

The fused flange-mounted disconnect provides overcurrent protection supply through three fuses; one for each leg of the 3-phase supply. 5–2. . . . . . . . . . . . . . . .

Multi-Tap TransformerFuses

Five fuses reside on the multi-tap transformer with fuses F1, F2, and F3 for thethree-phase 200 VAC servo power and F4 and F5 for 100 VAC. 5–4. . . . . . . . . . . . .

Power Supply Unit Fuses Three fuses are located in the power supply unit F1 AC input, F3 and F4 +24V. 5–5

Servo Amplifier Fuses The servo amplifiers for the P-200 contain one fuse (F1), except for ModelA06B–6089–H106 which includes a second fuse (F2). 5–6. . . . . . . . . . . . . . . . . . . . .

Emergency Stop ControlPCB Fuses

Two fuses reside on the Emergency Stop Control printed circuit board. 5–7. . . . . . .

Purge Power SupplyFuses

Two fuses reside on the Purge Power Supply F11 and F12. 5–8. . . . . . . . . . . . . . . . .

Modular I/O (Model A)Fuses

The modular I/O (Model A) modules that contain fuses are described in this section. 5–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sub-CPU Printed CircuitBoard Fuse

One fuse resides on the Sub-CPU printed circuit board. 5–12. . . . . . . . . . . . . . . . . . . .

If a fuse blows in the controller, determine the cause, repair or replace thedefective part or unit and replace the fuse with the same type and rating.Fuse replacement procedures are provided for the following fuses in thecontroller

WARNINGBefore replacing a fuse, turn the power off and lock out thecontroller; otherwise, you could injure personnel ordamage equipment.

5–2

5. REPLACING FUSES

MARO2P10203703E

The controller is supplied with a fused flange-mounted disconnect.

The fused flange-mounted disconnect provides overcurrent protectionsupply through three fuses; one for each leg of the 3-phase supply. SeeFigure 5–1 for fused flange-mounted disconnect location and Table 5–1for description of the fuse flange-mounted disconnect and fuses.

The fused flange-flange disconnect provides a means for shutting offpower to the controller and locking the power out.


Turning the disconnect to the OFF position removes powerfrom the output side of the device only. High voltage isalways present at the input side whenever the controller isconnected to a power source.

5.1FUSEDFLANGE-MOUNTEDDISCONNECT FUSES

5–3

5. REPLACING FUSES

MARO2P10203703E

Figure 5–1. Main Disconnect Location

MAINDISCONNECT

FL1 FL2 FL3

Fuse Block

Table 5–1. Fused Flange-Mounted Disconnect Switch, C-Size Cabinet

Inp tFused Flange-Mounted Disconnect Switch

InputVoltage Fuse

Size Part Number

220240

50A Fuse XGMF-00160 (A60L–0001-0042 #JG2-50)

380416460480500550

30A Fuse XGMF-04148 (A60L–0001-0042 #JG1-30)

575 20A Fuse XGMF-04148 (A60L–0001-0042 #JG1-20)

5–4

5. REPLACING FUSES

MARO2P10203703E

Five fuses reside on the multi-tap transformer with fuses F1, F2, and F3for the three-phase 200 VAC servo power and F4 and F5 for 100 VAC.The fuses are described in Table 5–2 and are located in Figure 5–2.

Table 5–2. Multi-Tap Transformer Fuses

Fuse Number Robot RatedCurrent Part Number

F1, F2, F3 P-200 30A A60L–0001–0042#JG1–30

F4, F5 P-200 7.5A A60L–0001–0101#P475H

Figure 5–2. Replacing Transformer Fuses

FuseFuse

WARNINGBefore you replace a fuse, turn the power off and lock outthe controller. Otherwise, you could injure personnel ordamage equipment.

5.2MULTI-TAPTRANSFORMERFUSES

5–5

5. REPLACING FUSES

MARO2P10203703E

Refer to Figure 5–3 for fuse locations on the PSU and Table 5–3 for fuseratings.

Table 5–3. PSU Fuse Ratings

Fuse No. Rated current Part number

F1(AC Input)

7.5A A60L00010245#GP75

F3 (+24V)

5A A60L00010075#5.0

F4(+24E)

5A A60L00010046#5.0

Figure 5–3. Replacing a Fuse of the Power Supply Unit

F1 : 7.5Afuse for AC input

F3 : 5AS (slow-blow)fuse for +24V

F4 : 5Afuse for +24E

5.3POWER SUPPLY UNITFUSES

5–6

5. REPLACING FUSES

MARO2P10203703E

The servo amplifiers for the P-200 contain one fuse (F1), except for ModelA06B–6089–H106 which includes a second fuse (F2). The fuse(s) arelocated behind the servo front cover as located in Figure 5–4 and aredescribed in Table 5–4.

Table 5–4. Servo Fuse Ratings

Fuse Number Rating Part Number

F1 5A– 250V A60L–0001–0359

F2 5A – 250V A60L–0001–0359

Figure 5–4. Replacing Fuses of Servo Amplifier

F1

Circuit breaker

F2 (In servo A06B–6089–H106 only)

5.4SERVO AMPLIFIERFUSES

5–7

5. REPLACING FUSES

MARO2P10203703E

Two fuses reside on the Emergency Stop Control printed circuit board.The location of these fuses are shown in Figure 5–5 and the specificationsare listed in Table 5–5.

Table 5–5. Emergency Stop Control Printed Circuit Board Fuses

Fuse Number Rated Current Part Number Purpose

F1 5A XGMF-00762 Fuse for brake power supply.

F2 0 32 A60L–0001–0046#0 32 Fuse for +24EF2 0.32 A60L–0001–0046#0.32 Fuse for +24E.

Figure 5–5. Replacing Emergency Stop Control Board Fuses

Fuse2

Fuse1

F1

F2

5.5EMERGENCY STOPCONTROL PCB FUSES

5–8

5. REPLACING FUSES

MARO2P10203703E

The two fuses that reside on the Purge Power Supply are described inTable 5–6 and are shown in Figure 5–6.

Table 5–6. Emergency Stop Control PCB Fuses

Fuse Number RatedCurrent Part Number

F11 3.2A A60L–0001–0175#3.2

F12 3.2A A60L–0001–0175#3.2

Figure 5–6. Purge Power Supply Location

Purge Power Supply

F11 F12

5.6PURGE POWERSUPPLY FUSES

5–9

5. REPLACING FUSES

MARO2P10203703E

The modular I/O (Model A) modules that contain fuses are described inTable 5–7 and are shown in Figure 5–7, Figure 5–8, and Figure 5–9.


ModuleNumber

RatedCurrent Part Number

AIF01A 5.0A A60L–0001–0290#LM50

AIF01A 3.2A A60L–0001–0290#LM32

AOD08C 5A A60L–0001–0260#5R00

AOD08D 5A A60L–0001–0260#5R00

AOA05E 3.15A A60L–0001–0276#3.15

AOA08E 3.15A A60L–0001–0276#3.15

AOA12F 3.15A A60L–0001–0276#3.15

Figure 5–7. Interface Module AIF01A Fuse Location

InterfacemoduleAIFO1A

Fuse

3.2A

3.2A

5.0AF2

Fuse5.0A

5.7MODULAR I/O (MODEL A) FUSES

5–10

5. REPLACING FUSES

MARO2P10203703E

Figure 5–8. Modular I/O Fuse Locations – AOA05E, ADA08E, and AOA12F

AOA05E ADA08E

AOA12F

FUSES

FUSES

FUSES

5–11

5. REPLACING FUSES

MARO2P10203703E

Figure 5–9. Modular I/O Fuse Locations – AOS08C and AOD08D

AOD08C AOD08D

FUSES FUSES

5–12

5. REPLACING FUSES

MARO2P10203703E

One fuse resides on the Sub-CPU printed circuit board. The location ofthis fuse is shown in Figure 5–10 and the specifications are listed inTable 5–8.

Figure 5–10. Main CPU Printed Circuit Board

A16B-3200-015FANUC

ÎÎÎÎÎ


ÎÎÎÎÎÎ

ÎÎÎÎÎÎ

LV ALM

F21 5A

RISC-B

STATUSALARM

D16

VD1

PC

3

PC

5

PC

13

PR

1

EP

RO

M M

OD

ULE

JNA

BAT

1

5.0A

FUSE


Fuse Number Rated Current Part Number

F21 5.0A XGMF-00762

5.8SUB CPU PRINTEDCIRCUIT BOARD FUSE

6 BRAKE RELEASE

6 BRAKE RELEASE

6–1MARO2P10203703E


Brake Release You can release the axes brakes using the operator panel switch. 6–2. . . . . . . . . . .

When you troubleshoot and perform some error recovery procedures onthe P-200 robot you might need to release the brakes. Refer toProcedure 6–1 for the brake release procedure.

6–2

6. BRAKE RELEASE

MARO2P10203703E

Use Procedure 6–1 to release the brakes using the operator key.

Procedure 6–1 Brake Release Using the Operator Panel Switch

Insure that the following conditions exist:

Controller main power disconnect is ON.

Purge complete.

Controller power on

Insure that area around robot is clear and that all personnel are clear ofthe area.

1 Press the EMERGENCY STOP push button on the operator panel.

WARNINGReleasing the brakes could cause the robot to move.Provide support for the arm of the robot before releasingthe brakes; otherwise, you could injure personnel ordamage equipment.

2 Insert the key into BRAKE ENABLE key switch on the operator paneland turn to the ON position. See Figure 6–1.

3 If you have the optional brake release switches for individual axescontinue to step 4.

Figure 6–1. Operator Panel

ÎÎÎÎÎÎ

ÎÎÎÎ

ÎÎÎÎÎÎÎÎ

ÎÎÎÎ

ÎÎ

ÎÎÎÎ

BATTERY

ALARM

OFF

LOCAL

PURGECOMPLETE

PURGE ENABLE

PURGEFAULT

EMERGENCY STOP


FAULT RESET

FAULT

ÏÏÏÏ

ÏÏÏÏ

ON

OFF HOUR METERPORT

HOLD

CYCLE START

REMOTE

REMOTE

BRAKE ENABLE

ON

6.1BRAKE RELEASE

Condition

Step

MARO2P10203703E 6–3

6. BRAKE RELEASE

4 Activate the enable switch for axis:

SW1 – P-200 axes 1, 4, 5 and 7

SW2 - P-200 axes 2 *

SW3 – P-200 axes 3 *

SW4 – Opener all axes *

NOTE * P-200 axes 2, 3 and opener axes 2 and 3 will drop due to gravity.They do not have balancers.

NOTE * Enable switches must be held, they are momentary switches.

Figure 6–2. C Size R-J2 Controller With Optional Brake Release Switches

SYSTEM R–J2

AXESAXIS

2 3

OPENERALL

P-200AXES1,4,5,7

P-200AXIS

P-200


AXESAXIS

2 3

OPENERALL

P-200AXES1,4,5,7

P-200AXIS

P-200


7 CONTROLLING I/O

7 CONTROLLING I/O

7–1MARO2P10203703E


Forcing Outputs Forcing outputs is turning output signals on or off. 7–2. . . . . . . . . . . . . . . . . . . . . . . . .

Simulating Inputs andOutputs

Simulating inputs and outputs is forcing inputs and outputs without signals entering or leaving the controller. 7–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SOP I/O Status The I/O SOP screen indicates the status of the standard operator panel signals. 7–5

Controlling I/O allows you to test the I/O in your system for properfunction.

MARO2P10203703E7–2

7. CONTROLLING I/O

Forcing outputs is turning output signals on or off. Outputs can also beforced within a program using I/O instructions. Use Procedure 7–1 toforce outputs outside of a program.

NOTE RO[1] and RO[2] control HAND 1, and RO[3] and RO[4] controlHAND 2.

Procedure 7–1 Forcing Outputs

The outputs you are forcing have been configured.

1 Press MENUS.

2 Select I/O.

3 Press F1, [TYPE].

4 Select the type of output you want to force: digital, analog, group,robot, UOP, or SOP.

WARNINGForcing digital outputs causes connected devices tofunction. Make certain you know what the digital output isconnected to and how it will function before forcing it;otherwise, you could injure personnel or damageequipment.

7.1FORCING OUTPUTS

Condition

Step

MARO2P10203703E 7–3

7. CONTROLLING I/O

For digital outputs for example, you will see a screen similar to thefollowing.

# SIM STATUS DO[ 1] OFF [ ] DO[ 2] U ON [ ] DO[ 3] U OFF [ ] DO[ 4] U OFF [ ] DO[ 5] U OFF [ ] DO[ 6] U ON [ ] DO[ 7] U OFF [ ] DO[ 8] U OFF [ ] DO[ 9] U OFF [ ] DO[ 10] U OFF [ ]


I/O Digital Out WORLD 10%

U

E1

5 Move the cursor to the STATUS of the output you want to force.

6 Press the function key that corresponds to the value you want.

For digital, robot, UOP, and SOP outputs, press :

F4 for ON

F5 for OFF

For analog and group outputs, move the cursor to value, and use thenumeric keys to type the value. Value entry is always in decimalformat. To change the displayed value from decimal to hexadecimal,press F4, FORMAT. Hexadecimal numbers are followed by an ‘‘H’’on the screen.

DO[ 4] U OFF

AO[ 4] U 12H

MARO2P10203703E7–4

7. CONTROLLING I/O

Simulating inputs and outputs is forcing inputs and outputs without signalsentering or leaving the controller. Simulate I/O to test program logic andmotion when I/O devices and signals are not set up. You can simulatedigital, analog, and group I/O only; you cannot simulate robot, UOP, orSOP I/O. When you are finished simulating a signal, you can reset, orunsimulate it. Use Procedure 7–2 to simulate and unsimulate I/O.

Procedure 7–2 Simulating and Unsimulating Inputs and Outputs

The input or output has been configured.

1 Press MENUS.

2 Select I/O.

3 Press F1, [TYPE].

4 Select the type of input or output you want to simulate: digital, analog,or group.

For digital inputs for example, you will see a screen similar to thefollowing.

# SIM STATUS DI[ 1] U OFF [ ] DI[ 2] ON [ ] DI[ 3] U OFF [ ] DI[ 4] U OFF [ ] DI[ 5] U OFF [ ] DI[ 6] U ON [ ] DI[ 7] U OFF [ ] DI[ 8] S OFF [ ] DI[ 9] U OFF [ ] DI[ 10] U OFF [ ]


I/O Digital Input WORLD 10%

S

E1

5 If you simulate a signal, you can force the status by setting it to avalue. When the signal is unsimulated, its actual status is displayed.

6 Move the cursor to the SIM column of the signal you want to simulate.

U means the signal is not simulated or unsimulated.

S means the signal is simulated.

7 Simulate or unsimulate the signal.

To simulate, press F4, SIMULATE.

To unsimulate, press F5, UNSIM.

8 To unsimulate all simulated signals, press FCTN and then selectUNSIM ALL I/O.

7.2SIMULATING INPUTS AND OUTPUTS

Condition

Step

DO[ 4] OFF

MARO2P10203703E 7–5

7. CONTROLLING I/O

The I/O SOP screen indicates the status of the standard operator panelsignals. SOP input signals (SI) and SOP output signals (SO) correspondto internal controller software Panel Digital Input signals (PDI) and PanelDigital Output signals (PDO). Refer to Table 7–1 and Table 7–2.

Table 7–1. Standard Operator Panel Input Signals

SI PDI Function Description

0 1 EMERGENCYSTOP

Input signal is normally turned ON, indicating that the EMERGENCY STOP button isnot being pressed.

1 2 FAULT RESET Input signal is normally turned OFF, indicating that the FAULT RESET button is notbeing pressed.

2 3 REMOTE Input signal is normally turned OFF, indicating that the controller is not set to remote.

3 4 HOLD Input signal is normally turned ON, indicating that the HOLD push button is not beingpressed.

4 5 PURGE ENABLE Input signal is normally turned OFF, indicating that the PURGE ENABLE push buttonis not being pressed.

6 7 CYCLE START Input signal is normally turned OFF, indicating that the CYCLE START push button isnot being pressed.

7-15 8-16 NOT USED Open for additional PDI.

Table 7–2. Standard Operator Panel Output Signals

SO PDO Function Description

0 1 REMOTE LED Output signal indicates the controller is set to remote.

1 2 CYCLE START Output signal indicates the CYCLE START button has been pressed or a program isrunning.

2 3 HOLD Output signal indicates the HOLD button has been pressed or a hold condition exists.

3 4 FAULT LED Output signal indicates a fault has occurred.

4 5 BATTERY ALARM Output signal indicates the voltage in the battery is low.

5 6 PURGECOMPLETE

Output signal indicates the purge cycle is complete.

6 7 PURGE FAULT Output signal indicates a purge fault condition exists.

7 8 TEACH PENDANTENABLED

Output signal indicates the teach pendant is enabled.

8-15 9-16 NOT USED Open for additional PDO.

Use Procedure 7–3 to display and force SOP I/O.

7.3SOP I/O STATUS

MARO2P10203703E7–6

7. CONTROLLING I/O

Procedure 7–3 Displaying and Forcing SOP I/O

1 Press MENUS.

2 Select I/O.

3 Press F1, [TYPE].

4 Select SOP. You will see a screen similar to the following.

# STATUS SO[ 1] OFF [ ] SO[ 2] OFF [ ] SO[ 3] OFF [ ] SO[ 4] OFF [ ] SO[ 5] OFF [ ] SO[ 6] OFF [ ] SO[ 7] OFF [ ] SO[ 8] OFF [ ] SO[ 9] OFF [ ] SO[ 10] OFF [ ]

[ TYPE ] IN/OUT ON OFF

I/O SOP Out JOINT 10 %

OFF

E1

To change between the display of the input and output screens, pressF3, IN/OUT.

To move quickly through the information, press and hold the SHIFTkey and press the down or up arrow keys.

NOTE You can only view the status of input signals. Input signals cannotbe forced.

5 To force an output signal, move the cursor to the output you want tochange:

To turn on an output signal, press F4, ON.

To turn off an output signal, press F5, OFF.

Step

Inde

x

8 MASTERING

8 MASTERING

MARO2P10203703E 8–1


Resetting Alarms and Preparing for Mastering

Before mastering the robot or opener you must reset the alarm 8–2. . . . . . . . . . . . .

Standard Mastering forthe P-200 Robot

Method of choice for the P-200 robot. (To perform Standard Mastering, Select Fixture Position Master) 8–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single Axis Mastering forthe P-200 Robot

Use when mastering was lost due to a single axis going bad, and that axis is the only axis affected.. 8–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Mastering forthe P-10 Door Opener andP-15 Hood and DeckOpener

Method of choice for the P-10 and P-15 openers. 8–19. . . . . . . . . . . . . . . . . . . . . . . . . . When mastery was lost due to mechanical disassembly or repair.When a quick master reference position was not previously set.

When you master a robot or an opener you electronically calibrate theserial pulse coders of the servomotor on the robot or opener against amechanical zero position. When a robot or opener is mastered, theposition data from the encoders are stored while the robot or opener is at aknown mechanical position. Mastering is required to ensure that the unitaxes motion is limited to the designed travel range.

Robot and openers must be mastered to operate properly. Robots andopeners are usually mastered before they leave FANUC Robotics.However, it is possible that they might lose their mastering data and needremastering. This chapter provides mastering methods for the P-200 robotand P-10 and P-15 openers.

Before you master the robot or openers, you must clear any faults thatprevent servo power from being restored or that prevent masteringcompletion.

CAUTIONRecord the quick master reference position after the robot oropener is installed to preserve the factory mastering settingsfor future remastering.

8–2

8. MASTERING

MARO2P10203703E

When you turn on the robot or opener after disconnecting the pulsecoderbackup batteries you might see a SRVO–062 BZAL or SRVO–038 Pulsemismatch alarm. Before mastering the robot or opener you must reset thealarm and rotate the motor of each axis that lost battery power to preparethe robot or opener for mastering.

Use Procedure 8–1 to reset these alarms and prepare the robot or openerfor mastering.

NOTE These SRVO errors will also appear after you have installed allnew application software on a robot or opener.

Procedure 8–1 Preparing the Robot or Opener for Mastering

You see a SRVO–062 BZAL or SRVO–038 Servo mismatch alarm.

1 Replace the robot and opener batteries with four new 1.5 volt alkalinebatteries, size D. Observe the direction arrows in the battery box forproper orientation of the batteries. Refer to Procedure 9–2 .

2 Press MENUS.

3 Select SYSTEM.

4 Press F1, [TYPE].

5 Select Master/Cal.

If Master/Cal is not listed on the [TYPE] menu, do the following;otherwise, continue to Step 6.

a Select VARIABLE from the [TYPE] menu.

b Move the cursor to $MASTER_ENB.

c Press the numeric key “1” and then press ENTER on the teachpendant.

d Press F1, [TYPE].

e Select Master/Cal. You will see a screen similar to the following.

SYSTEM Master/Cal JOINT 10%

[ TYPE ] LOAD RES_PCA

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

Press ’ENTER’ or number key to select.

DONE

8.1 RESETTING ALARMSAND PREPARING FORMASTERING

Condition

Step

8–3

8 MASTERING

MARO2P10203703E

6 Press F3, RES_PCA. You will see a screen similar to the following.

‘


[ TYPE ] YES NO

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

Press ’ENTER’ or number key to select.

Reset pulse coder alarm? [NO]

E1

7 Press F4, YES.

8 Cold start the controller.

a Turn off the robot or the opener.

b Press and continue pressing the FAULT RESET button on theoperator panel.

c While still pressing FAULT RESET, press the ON button on theoperator panel.

9 If the SRVO–062 alarm is still present, there is a battery, cable or pulsecoder problem. Refer to the FANUC Robotics SYSTEM R-J2Controller Series Electrical Connection and Maintenance Manual forfurther information.

10 If a SRVO–038 alarm is present at this time, repeat Step 6 to reset it.It is not necessary to cold start the robot or opener after resetting toclear this alarm.

11 Rotate each axis that lost battery power by at least one motorrevolution in either direction to clear SRVO–075 Pulse NotEstablished.

a Jog each rotary axis at least twenty degrees.

b Jog each linear axis at least thirty millimeters.

12 Perform any of the mastering procedures from the MASTER/CALmenu.

8–4

8. MASTERING

MARO2P10203703E

Standard mastering is the preferred method used to master the P-200 robot.

Use Procedure 8–2 to perform standard mastering.

Procedure 8–2 Standard Mastering

NOTE You do not need a fixture to master the P-200 robot. To performStandard Mastering, select Fixture Position Master.

You have cleared any servo faults that prevent you from jogging therobot.

You have jogged each axis that has lost mastery at least one motorturn.

You have reset all “Pulse not established (SRVO-075)” errors .

1 Jog the robot to the approximate mastering position shown inFigure 8–1.

Figure 8–1. Zero Degree Position of the P-200 Robot

8.2STANDARDMASTERING FOR THEP-200 ROBOT

Condition

Step

8–5

8 MASTERING

MARO2P10203703E

NOTE Align surfaces using a 1 - 2 - 3 block or other straight edge device.

NOTE Always rotate each axis into the mastered position from the samedirection to insure backlash errors are not added to the mastering data.

Figure 8–2. Axes 4, 5, and 6 100° Wrist Assembly

Axis 5 Bearing Surface


Inner Knuckle

Outer Knuckle


8–6

8. MASTERING

MARO2P10203703E

2 Rotate the inner knuckle counter-clockwise. Align the edge of thenotch on the inner knuckle and the pin in the bearing retainer (axis 4)See Figure 8–2. See Figure 8–3 if the wrist is 100°, or Figure 8–4 ifthe wrist is 140.

Figure 8–3. Axes 4, 5, and 6 100° Wrist Mastering Positions

Axis 4 Mastering Position



Mastering Pin

Mastering Surface


8–7

8 MASTERING

MARO2P10203703E

Figure 8–4. Axes 4, 5, and 6 140° Wrist Mastering Positions




Mastering Pin

Mastering Surface

AXIS 5 Bearing Surface

3 Rotate the outer knuckle counter-clockwise aligning the edge of thenotch on the outer knuckle and the pin in the bearing retainer (axis 5)See Figure 8–2. See Figure 8–3 if the wrist is 100°, or Figure 8–4 ifthe wrist is 140.

4 Rotate the wrist faceplate counter-clockwise aligning the edge of thenotch on the faceplate and the pin in the bearing retainer (axis 6). SeeFigure 8–2. See Figure 8–3 if the wrist is 100°, or Figure 8–4 if thewrist is 140.

8–8

8. MASTERING

MARO2P10203703E

5 Align the witness marks on the turret and pedestal (axis 1). SeeFigure 8–5.

Figure 8–5. Robot Pedestal Axis 1 100°/140° Mastering Surface Location

P-200 Robot Pedestal

Mastering Surface

MASTERED POSITION:AXIS 1 = 75

P-200 Robot Pedestal

P-200 Robot Turret

Turret Witness Mark

°

Left Hand MasteringSurface

Right Hand MasteringSurface

8–9

8 MASTERING

MARO2P10203703E

6 Lower the inner arm aligning the witness marks on the inner arm andturret (axis 2). See Figure 8–6.

Figure 8–6. Axis 2 100°/140° Mastering Surface Location

Right Hand Witness Marks

Left Hand Witness Marks

Inner Arm

P-200 Turret

Mastering SurfaceMastering Surface

MASTERED POSITION:AXIS 2 = 20 °

Mastering Surface

P-200 Turret

Inner Arm

Witness Mark

8–10

8. MASTERING

MARO2P10203703E

NOTE If you are mastering a 100 wrist robot, go to step 7. If your robothas a 140° wrist, go to step 8.

7 Lower the outer arm aligning the notches on the inner and outer arm(axis 3). See Figure 8–7. Go to step 14.

Figure 8–7. Axis 3 100° Mastered Position

MASTERED POSITION:AXIS 3 = –65°

Inner ArmOuter Arm

Inner Arm

Outer Arm

Witness Mark

Witness Mark

8–11

8 MASTERING

MARO2P10203703E

8 Lower the outer arm aligning the mastering pin on the 140° wrist tothe mastering surface located on the inner arm (axis 3). SeeFigure 8–8.

NOTE If your robot is not mounted on a rail, go to to step 16.

Figure 8–8. Axis 3 Mastering Position (140° Wrist)

MASTERED POSITION:AXIS 3

Mastering Surface

ARM LENGTH

1200 MM

1400 MM

94.366°

97.0°

Inner Arm

Outer Arm

140° Wrist

Mastering Pin

Left and Right SideMastering Pins

8–12

8. MASTERING

MARO2P10203703E

NOTE If your robot is using a P-200 Clean Wall Retrofit (P-150 Retrofit)rail, go to to step 9. If not continue to step 14.

9 Attach the mastering block to the side of the saddle. See Figure 8–9.

Figure 8–9. Mastering Block

10 Release the brakes for the rail axis.

11 Manually push the saddle until the mastering block comes in contactwith the rail axis master stop. See Figure 8–9.

8–13

8 MASTERING

MARO2P10203703E

12 Engage the brakes for the rail axis and reset all faults.

13 Go to Step 16.

14 Jog the robot to the approximate mastering position shown inFigure 8–10.

Figure 8–10. Axis 7 Mastering Position

Mastering Surface

Witness MarkRail

AXIS 7Side View

15 Align the mastering surface on the pedestal to the witness mark on therail using a 1-2-3 block or other straight edge device.

16 Press MENUS.

17 Select SYSTEM.

18 Press F1, [TYPE].


8–14

8. MASTERING

MARO2P10203703E

NOTE You do not need a fixture to master the P-200 robot. To performStandard Mastering, select Fixture Position Master. See the followingscreen for an example.

SYSTEM Master/Cal G1 JOINT 10 %

TORQUE =[ON]

1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE

Press ‘Enter’ or number key to select.


20 Select FIXTURE POSITION MASTER. You will see a screen similarto the following.


TORQUE =[ON]



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

8–15

8 MASTERING

MARO2P10203703E

21 Press F4, YES. You will see a screen similar to the following.

TORQUE = [ON]


Robot Mastered! Mastering Data:<0> <–3943083> <14942207><0> <0> <0>< 0> < 0> < 0>

[ TYPE ] LOAD RES_PCA DONE


NOTE If there is an encoder fault that was not reset, the teach pendant will notconfirm mastering and the mastering position will not be entered.

22 Select CALIBRATE. You will see a screen similar to the following.

TORQUE = [ON]


Press ’Enter’ or number key to select

Calibrate [NO][ TYPE ] YES NO


23 Press F4, YES.

SYSTEM Master/Cal G1 JOINT 10 %TORQUE = [ON]


Robot Calibrated! CUR JNT ANG (deg):<75.000> <20.000> <-65.000><0.000> <0.000> <0.000><0.000>

[ TYPE ]

8–16

8. MASTERING

MARO2P10203703E

When a single axis of the P-200 has been positioned at its masteringlocation, single axis mastering can be performed. See Figure 8–11.

Figure 8–11. Mastering Position of the P-200 robot

Use Procedure 8–3 to master a single axis.

Procedure 8–3 Mastering a Single Axis

You have cleared any servo faults that prevent you from jogging themachine.

You have jogged each axis that has lost mastery at least one motorturn.

1 Press MENUS.

2 Select SYSTEM.

3 Press F1, [TYPE].


If Master/Cal is not listed on the [TYPE] menu, do the following;otherwise, continue to Step 5.

8.3SINGLE AXISMASTERING FOR THEP-200 ROBOT

Condition

Step

8–17

8 MASTERING

MARO2P10203703E

a Select VARIABLE from the [TYPE] menu.

b Move the cursor to $MASTER_ENB.

c Press the numeric key “1” and then press ENTER on the teachpendant.

d Press F1, [TYPE].

e Select Master/Cal. You will see a screen similar to the following.



[ TYPE ] LOAD RES_PCA DONE


5 Select 4, Single Axis Master. You will see a screen similar to thefollowing.

1/9ACTUAL POS (MSTR POS) (SEL) [ST]

J1 0.000 ( 75.000) (0) [2] J2 3.514 ( 20.000) (0) [0] J3 -7.164 ( -65.000) (0) [2] J4 -357.366 ( 0.000) (0) [2] J5 -1.275 ( 0.000) (0) [2] J6 4.571 ( 0.000) (0) [2] E1 0.000 ( 0.000) (0) [0] E2 0.000 ( 0.000) (0) [0] E3 0.000 ( 0.000) (0) [0]

[ TYPE ] GROUP EXEC

SINGLE AXIS MASTER JOINT 10%

6 Jog all unaffected axes to their respective mastering positions so thatthe actual position matches that of the master position column.

7 Using a 1-2-3 block, or other straight edge device, align theunmastered axis (axes) to their witness mark(s) as described inProcedure 8–2 .

8 Move the cursor to the SEL column for each unmastered axis (axes)and press the numeric key “1”, then press ENTER.

8–18

8. MASTERING

MARO2P10203703E

WARNINGDo not modify the values in the column labeled (MSTRPOS). Otherwise, unexpected motion could occur whichcould injure personnel or damage equipment.

9 Press F5, EXEC. Mastering will be performed automatically.

10 Press PREV.

11 Select Calibrate.

12 Press F4, YES.

Single axis mastering is now complete.

8–19

8 MASTERING

MARO2P10203703E

Use Procedure 8–4 to master the P-10 Door Opener and the P-15 Hoodand Deck opener.

NOTE You do not need a fixture to master the P-10 or P-15 openers. Toperform Standard Mastering, select Fixture Position Master on the teachpendant.

Procedure 8–4 Standard Mastering for the P-10 Door Opener and the P-15Hood and Deck Opener

You have cleared any servo faults that prevent you from jogging theopener.

You have reset all “Pulse not established (SRVO-075)” errors.

1 Select Motion Group 2.

a Press FCTN.

b Select CHANGE GROUP. G2 should be displayed in the title lineof the teach pendant screen.

2 Jog the opener to the approximate mastering position shown inFigure 8–12.

NOTE Align surfaces using a 1 - 2 - 3 block or other straight edge device.

8.4STANDARDMASTERING FOR THEP-10 DOOR OPENERAND THE P-15 HOODAND DECK OPENER

Condition

Step

8–20

8. MASTERING

MARO2P10203703E

Figure 8–12. P-10 and P-15 Opener Mastering Position

45°

45°

BO

OT

H W

ALL AXIS 2

AXIS 3

AXIS 1

8–21

8 MASTERING

MARO2P10203703E

3 Align the mastering surfaces on the x-drive housing and the rail. See Figure 8–13.

Figure 8–13. P-10 and P-15 Axis One Mastering Position

25T700T A

RAIL – REF.

Mastering Surfaces Line Up Machine Edge On RailWith Cover As Shown

View A

8–22

8. MASTERING

MARO2P10203703E

4 Align the mastering surfaces on the base and the inner arm. SeeFigure 8–14.

Figure 8–14. P-10 and P-15 Axis Two Mastering Position

FrontOf Opener

Line Up TheseSurfaces

Mastering Surfaces(Inner Arm To Base)

View A

A

View B (rear view) B

B

Inner Arm

Base

Inner Arm

Base

8–23

8 MASTERING

MARO2P10203703E

5 Align the mastering surfaces on the crank and base. See Figure 8–15.

Figure 8–15. P-10 and P-15 Axis Three Mastered Position

FrontOf Opener

BASE

Line Up These

Surfaces

(Crank To Base)s

45°REF

A

B

View A

View BB

Mastering Surfaces (Crank To base)

6 Press MENUS.

7 Select SYSTEM.

8 Press F1, [TYPE].

8–24

8. MASTERING

MARO2P10203703E


NOTE You do not need a fixture to master the P-10 opener. To performStandard Mastering, select Fixture Position Master on the teach pendant.You will see a screen similar to the following.


TORQUE =[ON]




10 Select FIXTURE POSITION MASTER. You will see a screensimilar to the following.

TORQUE =[ON]



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


11 Press F4, [YES]. You will see a screen similar to the following.

NOTE If there is an encoder fault that was not reset, the teach pendantwill not confirm mastering and the mastering position will not be entered.

8–25

8 MASTERING

MARO2P10203703E

12 Select CALIBRATE. You will see a screen similar to the following.

TORQUE =[ON]



Calibrate [NO][ TYPE ] YES NO


13 Press F4, YES. The robot is now calibrated and can be jogged incoordinate frames.

TORQUE = [ON]


Robot Mastered! Mastering Data:<0> <–3943083> <14942207><0> <0> <0>< 0> < 0> < 0>

[ TYPE ]


9 REPLACINGCOMPONENTS

9 REPLACING COMPONENTS

9–1MARO2P10203703E


Replacing R-J2 Batteries Replacing R-J2 Batteries 9–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the PSU Battery 9–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the SPC Batteries 9–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace PCMCIA Memory Card (Optional) Battery 9–4. . . . . . . . . . . . . . . . . . . . .

Replacing Relays Replacing Relays 9–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Control Panel Relays 9–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Stop Control Board (EMG) Printed Circuit Board Relay

Replacement 9–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purge Control PCB Relay 9–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a PrintedCircuit Board

Replacing a Printed Circuit Board 9–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Replacement of a Printed Circuit Board from the Backplane

Printed Circuit Board 9–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Backplane Printed Circuit Board 9–12. . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Module onthe Main CPU or Aux AxisControl PCB

Use this procedure to replace a module. 9–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing an I/O Module(Model A)

Replacing an I/O Module (Model A) 9–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Base Unit 9–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing a Model A Interface Module 9–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing a Model A I/O Module 9–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Multi-TapTransformer

Replacing the Multi-Tap Transformer 9–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a ServoAmplifiers

Replacing a Servo Amplifier. 9–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the OperatorPanel

Replacing the Operator Panel 9–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the BackplaneFan Motors

Replacing the Fan Motors in the Backplane. 9–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Teach Pendant Replacing the Teach Pendant 9–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Serial PulseCoders

Replacing Serial Pulse Coder 9–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Internal Mounted Serial Pulse Coder 9–25. . . . . . . . . . . . . . . . . . . . . . . Replacing Externally Mounted Serial Pulse Coder 9–27. . . . . . . . . . . . . . . . . . . . .

9–2

9. REPLACING COMPONENTS

MARO2P10203703E

FANUC Robotics recommends that all batteries be changed immediatelyprior to production start up. Change the batteries annually to assurereliable robot performance for extended periods of time. Use Procedure 9–1 to replace the PSU battery, Procedure 9–2 to replacethe SPC battery, and Procedure 9–3 to replace the PCMCIA memory cardbattery.

Procedure 9–1 Replacing the PSU Battery

1 Get the new battery. (number: A98L-0031-0012)

2 Turn off and lock out the controller.

CAUTIONThe battery must be replaced within 30 minutes. If the power isturned off and the battery is removed for 30 minutes or more,the contents of the memory on the main CPU printed circuitboard may be lost.

WARNINGDo not short circuit or incinerate a discarded battery.Follow your company’s procedures for disposing of lithiumbatteries. Otherwise, you could injure personnel ordamage equipment.


3 Remove the battery case from the front panel of the power supply unit.See Figure 9–1. The case can be removed easily by squeezing the topand bottom of it and pulling.

Figure 9–1. Replacing the Battery

Front panel of thepower supply unit

Battery caseBattery(ordering drawingnumber:A98L-0031-0007)

BATTERY

Cable connector

BatteryPC boardconnector

Front panel of thepower supply unit

9.1REPLACING R-J2BATTERIES

Step

9–3


MARO2P10203703E

4 Remove the battery and connector from the PSU.

5 Replace the battery and reconnect the connector.

6 Install the battery case.

Procedure 9–2 Replacing the SPC Batteries

1 Get four new alkaline D-cell batteries.

2 Turn on the controller.

3 Press the operator panel Emergency Stop button and the teach pendantEmergency Stop button.

4 Remove the black plastic battery cover from the battery box on theinside of the controller cabinet front door. See Figure 9–2.

5 Remove the old batteries.

6 Insert the new batteries while observing battery polarity as shown onthe battery case.

7 Replace the battery cover.

8 Cold start the controller. The teach pendant might display aSRVO–065 BLAL alarm. This is normal. It will reset when you coldstart the controller.

Step

9–4


MARO2P10203703E

Figure 9–2. Internal View of the P-200 R-J2 Controller

Main CPU

Power supply unit

Main power disconnect

SPC battery case

Emergency stop controlprinted circuit board

Aux axis board

Procedure 9–3 Replace PCMCIA Memory Card (Optional) Battery

1 Get one new BR2325 3V lithium battery.

2 Remove the PCMCIA (memory) card from the Memory Card Interfaceboard (PN A 20B-2000-0600).

3 Insert a small diameter pointed object into the hole on the upper sideof the 2 MG SRAM PC card (PN DISKMF32M1LCDA7).

4 Release the battery holder by pressing the small diameter objectagainst the battery holder catch and pull the battery holder straight outfrom the card. See Figure 9–3 for the location of the battery.

5 Replace the old battery with the new battery. Insure that the (+)symbol on the battery is located as shown on the battery holder.

Step

9–5


MARO2P10203703E

WARNINGDO NOT Install the Memory Card Interface board with thepower on. This will damage the Interface board.

6 With the new battery in the holder, install the battery holder into thememory card and reinstall the card into the controller. See Figure 9–4.

Figure 9–3. Replacing Memory Card Battery


FanFans




PCMCIA Memory Card

9–6


MARO2P10203703E

This section includes relays located on the back of the operator controlpanel and the EMG printed circuit boards relay replacement procedures.

See Figure 9–5 for relay locations and Table 9–1 for operator controlpanel relay identification.

Table 9–1. EMG Printed Circuit Board Relay Identification

Relay Designation Relay Identification

Relays KA1 – KA4 A58L–0001–0192#1231R

Figure 9–5. Operator Control Panel Relay Locations

CNHM

PORT 2

CRS1CNOP

KA1 KA2 KA4

FE

NC

E 2

KA3

FE

NC

E 1

EM

GIN

2

EM

GIN

1

EX

OF

F

EX

CO

M

EX

ON

SV

ON

1

SV

ON

2

E–S

TO

P1

E–S

TO

P2

EM

GO

UT

1

EM

GO

UT

C

EM

GO

UT

2

SW1

LED6

SW5

SW10

SW9

SW3

SW6

LED4

SW7

SW8

LED1

LED3

SWOCNPG PDIO

SW2

LED2

TB

OP

2T

BO

P1

LED5

Replaceable Relays

9.2REPLACING RELAYS

9.2.1 Operator Control PanelRelays

9–7


MARO2P10203703E

See Figure 9–6 for relay locations and refer to Table 9–2 for relayidentification.



RLY1 A58L–0001–0422#3232K

RLY2 A58L–0001–0192#1509A

RLY 3 , RLY4, RLY5, and RLY6 A58L–0001–0192#1472R

Figure 9–6. EMG Printed Circuit Board Relay Locations for B-Size Cabinet

RLY4 RLY5 RLY6

RLY2 RLY3RLY1

9.2.2 Emergency StopControl Board (EMG)Printed Circuit BoardRelay Replacement

9–8


MARO2P10203703E

Refer to Table 9–3 for relay identification and see Figure 9–7 for relaylocations on the purge control printed circuit board.



Relays KA5 and KA6 A58L–0001–0192#1231R

Figure 9–7. Purge Control Unit

Power supplyIBRCISBU

Purge control PCB


A1 C1 A2 C2 A3 C3 A4 C4 A5 A6C5 C6 0V 220V200V

P1 N1 P2 N2 P3 P4N3 N4 P5 P6 N6N5 G G FG

1

1

2 3 4 5 6 7 8 9

2 3 4 5 6 7 8 9

1011 12 1314 1516 171819 20 21 222324

1011 12 13 14 15 16 1718 19 20 21 22 2324

Relays KA5 and KA6

9.2.3 Purge Control PCBRelay

9–9


MARO2P10203703E

When replacing a printed circuit board, insure that the followingprecautions are followed:

The controller is locked out and tagged out.Remove the battery from the power supply unit and plug it into the

battery connector (BAT. VBAT) on the front panel of the main CPU, ifthe power supply unit or the main CPU are to be removed from thebackplane. See Figure 9–8.

Figure 9–8. Battery Transfer to Maintain CMOS RAM Memory

BatteryAuxConnection

Main CPU Printed Circuit BoardPower Supply Unit

(BAT. VBAT)

Battery

9.3REPLACING APRINTED CIRCUITBOARD

9–10


MARO2P10203703E

Removal and replacement of a printed circuit board from the backplaneprinted circuit board is provided in Procedure 9–4 and is shown inFigure 9–9.

Procedure 9–4 Printed Circuit Board Removal and Replacement

1 Turn the power off and remove the cable(s) from the power supply unitor printed circuit board to be replaced. If the cable markings aremissing or difficult to read, write them down before removing thecables.

CAUTIONBe sure to back up all program and setup data on a floppy diskbefore you replace a printed circuit board otherwise, you couldlose data.

CAUTIONWhen either the power supply or main CPU printed circuitboards are removed from the controller, the data storagebattery is disconnected. All boards must be reinstalled properlywithin half an hour to avoid data loss.

NOTE When removing the printed circuit board, do not touchsemiconductor components on it and do not let the components touchother components.

9.3.1 Removal andReplacement of aPrinted Circuit Boardfrom the BackplanePrinted Circuit Board

9–11


MARO2P10203703E

2 Squeeze the removal tabs at the top and bottom of the front panel ofthe power supply unit or printed circuit board. The latches of thecontrol unit rack are released. Holding the tabs in this state, pull outthe unit or printed circuit board. See Figure 9–9.

Figure 9–9. Replacing the Components on the Backplane Printed Circuit Board

Main CPU printed circuit board

Power supply unit

Optional boards

Removal tab

Removal tab

NOTE If you are removing the printed circuit boards in preparation toremove the backplane go to Procedure 9–5 .

3 Insert a new power supply unit or printed circuit board into the slot ofthe control unit rack. Carefully push it into the slot until the frontpanel is latched at the top and bottom.

4 Check that the printed circuit board to be installed is correctly set andadjusted.

5 Connect the cables removed for replacement to the original positions.

9–12


MARO2P10203703E

Procedure 9–5 provides instructions for replacement of the backplaneprinted circuit boards and Figure 9–10 shows an example of boardreplacement.

Procedure 9–5 Replacing Backplane Printed Circuit Board

1 When you replace the backplane printed circuit board, remove theentire rack. Remove the power supply unit printed circuit board, mainCPU printed circuit board, and any optional printed circuit boardsusing Procedure 9–4 .

2 Remove the ground cable from the backplane printed circuit board.

3 Loosen the screws fastening the rack at the top. Then remove thescrews fastening the rack at the bottom. See Figure 9–10.

4 Lift up on backplane until slots have cleared the mounting screws andcarefully move it forward until the backplane is clear of the controller.

5 Install the new backplane in reverse order.

Figure 9–10. Replacing the Backplane Printed Circuit Board

Backplaneprinted circuit board

Loosen screws

Remove screws

9.3.2 Replacing theBackplane PrintedCircuit Board

9–13


MARO2P10203703E

Use Procedure 9–6 to replace a module.

CAUTIONFollowing electrostatic discharge procedures when handling allcircuit boards.

Procedure 9–6 Replacing a Module on the Main CPU or Aux Axis ControlPrinted Circuit Board

1 Move the latches at both ends of the module socket toward the outside.The spring of the contact tilts the module. See Figure 9–11.

Figure 9–11. Moving the Latches on the End of the Module Socket

2 If the tilted module touches the next module, it might be difficult toremove it. In this case, release the latches of the next module asdescribed in step 1 above.

3 Now the module is free in the socket. Pull out the module carefully ina straight line. Do not pull it out in an arc. The contacts of the socketor module might be damaged.

4 Install a new module in the socket at an angle. Push it into the socketuntil the bottom of the module reaches the bottom of the socketgroove. Be sure you have the module facing in the proper direction.align the groove in the module with the tab as shown in Figure 9–12.

9.4REPLACING AMODULE ON THEMAIN CPU OR AUXAXIS CONTROLPRINTED CIRCUITBOARDRefer to Chapter 1 for part numbers.

Step

9–14


MARO2P10203703E

Figure 9–12. Installing a New Module at an Angle

Short Long

Fit the recess onthe module overthe tab in themodule socket.

5 Push the module in the top edge so that the module stands upright.See Figure 9–13.

Figure 9–13. Pushing in the Module

6 Check that the module is latched properly at both ends of the socket.If it is insufficiently latched, the electrical contact might be improperand a malfunction could occur.

9–15


MARO2P10203703E

Figure 9–14. Mounting Locations of the Modules

Flash ROM module DRAM module




CMOS module




JNA

JRY2



MAIN CPU

AUX AXIS CONTROL PCB

9–16


MARO2P10203703E

Use Procedure 9–8 and Procedure 9–9 to replace an Interface Module andI/O Module (Model A). Replacement of the Interface Module is providedin Procedure 9–8 and replacement of the I/O Module is provided inProcedure 9–9 and shown in Figure 9–16. Use Procedure 9–7 to replacethe base unit if needed after you remove the I/O Interface Module.

Procedure 9–7 Replacing the Base Unit

1 Remove the I/O modules from the base unit.

2 Loosen the upper two mounting screws.

3 Remove the lower two mounting screws and replace the base unit.

Figure 9–15. Replacing the Base Unit of the Model A I/O

M4 screw

9.5REPLACING AN I/OMODULE (MODEL A)

Step

9–17


MARO2P10203703E

Use Procedure 9–8 to replace a Model A Interface Module.

Procedure 9–8 Replacing a Model A Interface Module


2 Disconnect the signal and power cables from the interface module.

3 Press the latch on the bottom of the module and rotate the moduletoward you and up.

4 Engage the hook at the top rear of the module with the bar above thebase unit socket.

5 Rotate the module downward until the latch engages.

6 Reconnect the signal and power cables to the interface module.

Use Procedure 9–9 to replace a Model A I/O Module.

Procedure 9–9 Replacing a Model A I/O Module


2 Remove the wiring harness block.

a Lift the latch at the lower left corner of the module window.

b Rotate the block toward you and down.

3 Press the latch on the bottom of the module and rotate the moduletoward you and up. See Figure 9–16.

4 Engage the hook at the top read of the module with the bar above thebase unit socket.

5 Rotate the module downward until the latch engages.

9.5.1 Replacing a Model AInterface Module

Step

9.5.2 Replacing a Model AI/O Module

Step

9–18


MARO2P10203703E

Figure 9–16. Replacing a Model A I/O Module

6 Install the wiring harness block.

a Engage the hook at the bottom rear of the block with the bar at the bottom of the module.

b Rotate the block upward until the latch engages.

9–19


MARO2P10203703E

Use Procedure 9–10 to replace the multi-tap transformer.

Procedure 9–10 Replacing the Multi-Tap Transformer


2 Remove the acrylic covers from the transformer and ALC relay.

3 Disconnect the wiring harnesses and ground wire from the transformer.

4 Disconnect the three wires from the bottom of the ALC relay.

5 After removing the eight screws fastening the transformer, remove thetransformer. See Figure 9–17. Put a new transformer on the rail in thecontroller and push it into the controller along the rail. Then reinstallthe screws.

6 Reconnect the wires and harnesses.

7 Reinstall the acrylic covers.

Figure 9–17. Replacing the Multi-Tap Transformer

M5 screws

9.6REPLACING THEMULTI-TAPTRANSFORMERRefer to Chapter 1 for partnumbers.

Step

9–20


MARO2P10203703E

Use Procedure 9–11 to replace a servo amplifier. See Figure 9–18.

Procedure 9–11 Replacing a Servo Amplifier


2 Remove the five bus bars from the servo amplifier bank.

3 Disconnect the wires from the servo amplifier terminal strip. Removethe two screws fastening the servo amplifier and remove the amplifier.

4 Set the terminal strip jumpers on the new servo amplifier to matchthose of the one you removed.

5 Install the new servo amplifier by following these steps in reverseorder.

Figure 9–18. Replacing a Servo Amplifier

Screw

9.7REPLACING A SERVOAMPLIFIERRefer to Chapter 1 for partnumbers.

Step

9–21


MARO2P10203703E

Use Procedure 9–12 to replace the operator panel. See Figure 9–19.

Procedure 9–12 Replacing the Operator Panel

1 Power down and lock out the controller.

2 Remove all connectors and wires from the rear of the rear operatorpanel and all connectors from the front panel. Identify all wires andconnectors for installation of new operator panel.

3 Remove the six nuts fastening the operator panel and remove theoperator panel.

4 Install new operator panel using 6 nuts removed during removal of oldoperator panel.

5 Reconnect all wires and connectors removed during Step 2.

Figure 9–19. Replacing the Operator Panel

Î

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÏÏÏ ON

Nuts (Qyt 6)

9.8REPLACING THEOPERATOR PANELRefer to Chapter 1 for partnumbers.

Step

9–22


MARO2P10203703E

Replace a defective fan motor using Procedure 9–13 and as shown inFigure 9–20.

Procedure 9–13 Fan Motor Replacement

1 Identify the defective fan motor and remove any printed circuit boarddirectly below the fan to be replaced.

2 The cable connected to the fan motor is connected to the backplaneprinted circuit board in the slot. Holding the connector, remove thecable from the backplane printed circuit board.

3 Open the lid at the top of the backplane rack by placing the tip of aflat-blade screwdriver into the center hole at the front of the lid andmoving the screwdriver like a lever in the direction in Figure 9–20.this will release the latch.

4 Replace the fan motor.

5 Close the lid until it is latched.

6 Connect the cable of the fan motor to the connector on the backplaneprinted circuit board. Suspend the center of the cable on the hook inthe back of the rack.

7 Reinstall the removed printed circuit board.

9.9REPLACING THE FANMOTOR IN THEBACKPLANE

Step

9–23


MARO2P10203703E

Figure 9–20. Replacing the Fan Motor

Fan motor

Cable

Connector

9–24


MARO2P10203703E

Replace a defective teach pendant using Table 9–4 for ordering and asshown in Figure 9–21.

Figure 9–21. Replacing the Teach Pendant

Table 9–4. Teach Pendant Part Numbers

Part Number(s) Use Remarks

A05B-2301-C305 General use English

A05B-2308-C300Intrinsically Safe Teach

PendantR-J2

Paint

9.10REPLACING THETEACH PENDANT

9–25


MARO2P10203703E

Use Procedure 9–14 to replace an externally or internally mounted serialpulse coder.

Procedure 9–14 Replacing Internal Mounted Serial Pulse Coder

NOTE The robot will have to be remastered after this procedure.

1 Turn off and lock out the robot.

2 At the end of the motor, remove both cables from the serial pulsecoder cover.

3 Remove the four bolts that secure the serial pulse coder cover to themotor housing.

4 Remove the four screws holding the large serial pulse coder cableconnector to the serial pulse coder cover.

5 Retract the rubber boot on the inside of the serial pulse coder cableconnector.

6 Remove the snap ring on the inside of the serial pulse coder cableconnector.

7 Separate the two-wire connector on the inside of the internalconnector.

8 Detach the serial pulse coder cable from the serial pulse coder housing.

CAUTIONIn the next step, be sure to remove the correct bolts, as shownin Figure 9–22. Removing the wrong bolts can destroy theserial pulse coder.

9 Remove the four bolts attaching the serial pulse coder to the motor.See Figure 9–22.

10 Remove the serial pulse coder and the black plastic coupling and retainthe black plastic coupling to be installed with the new serial pulsecoder. See Figure 9–23.

11 Position the new serial pulse coder, with black plastic coupling, ontothe motor so that the coupling engages both motor and pulse coder. Ifthere are witness marks on the serial pulse coder case and the motorcase, make sure that they line up.

12 Install the new serial pulse coder to the motor housing using fourbolts.

13 Attach the serial pulse coder cable to the serial pulse coder housing.

9.11REPLACING A SERIALPULSE CODER

Step

9–26


MARO2P10203703E

14 Install the snap ring on the inside of the serial pulse coder cableconnector.

15 Reposition the rubber boot on the inside of the serial pulse coder cableconnector.

16 Install the screws holding the serial pulse coder cable connector to theserial pulse coder housing.

17 Connect the two-wire cable connectors together.

18 Install the serial pulse coder housing to the motor, using four bolts

19 Attach both outside cables to the serial pulse coder housing.

Figure 9–22. Removing the Internally Mounted serial pulse coder

FANUC

REAR VIEW

DO NOT REMOVE THESCREWS FROM THESE FOURRIBBED HOLES. THE SERIALPULSE CODER WILLSEPARATE AND BEDESTROYED.

CAUTION:

M4 MountingHoles

9–27


MARO2P10203703E

Figure 9–23. Removing the Black Plastic Coupling

CouplingBlack Plastic

Serial Pulse Coder

Procedure 9–15 Replacing an Externally Mounted Serial Pulse Coder

NOTE The robot will have to be remastered after this procedure.

1 Turn off and lock out the robot.

2 At the end of the motor, remove the two screws securing the serialpulse coder connector cover.

3 Remove the two screws securing the cable connector to the serial pulsecoder receptacle.

CAUTIONIn the next step, be sure to remove the correct bolts, as shownin Figure 9–22. Removing the wrong bolts can destroy theserial pulse coder.

4 Remove the four screws holding the serial pulse coder to the motorhousing and carefully remove the serial pulse coder. See Figure 9–22.Remove the coupling from the motor and serial pulse coder. SeeFigure 9–23.

Step

9–28


MARO2P10203703E

5 Position the new serial pulse coder, with coupling, onto the motor sothat the coupling engages both the shaft of the serial pulse coder andthe motor. See If there are witness marks on the serial pulse codercase and the motor case, make sure that they line up.

6 Install four new screws and secure the serial pulse coder housing to themotor.

7 Attach the serial pulse coder connector to the serial pulse coderhousing using two screws.

8 Attach the connector cover to the serial pulse coder housing using twoscrews.

10 BOARD ADJUSTMENTS AND CALIBRATIONS

10MARO2P10203703E 10–1

BOARD ADJUSTMENTS ANDCALIBRATIONS


I/P transducer/RegulatorPerformance Check

On a periodic basis, and whenever a transducer/regulator is replaced, this procedure should be preformed (Procedure 10–1 ). 10–2. . . . . . . . . . . . . . . . . . . . . . . .

Manual Flow Test(Beakering Test)

Measure paint Flow rate in cc/min (Procedure 10–2 ). 10–5. . . . . . . . . . . . . . . . . . . . . .

Cold Start Standard Method For Turning On Power To The Robot And Controller.(Procedure 10–3 ) 10–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powering on the RobotSystems

The following procedures are applicable to all P-200 robot systems including those on a pedestal, rail or with an opener. 10–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller ShutdownProcedure

Use this procedure for complete controller shutdown including purge circuitry. 10–11.

Servo Lockout Procedure For servo lockout use the following procedure. 10–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

No board adjustments are required on the controller. However, EmergencyStop Control Board jumper settings are included for reference. SeeFigure 10–1. These jumpers are set at installation and are not to bechanged. To set servo amplifier dip switches, refer to Chapter 1.

MARO2P10203703E10–2

10. BOARD ADJUSTMENTS AND CALIBRATIONS

On a periodic basis, and whenever a transducer/regulator is replaced, thisprocedure should be preformed to check out the Paint Regulator (PR) andthe Proportion Air transducer/regulator assembly in the P-200 outer arm.

Tools Required:

0–60 psi precision pressure gauge with ±0.5 psi accuracy

Appropriate hand tools

Tubing and fittings as required

Procedure 10–1 Transducer/Regulator Performance Check

The robot/controller has been reset, and the system is in the MANUALor PRODUCTION mode.

1 Remove the air supply to the panel.

2 Remove output line from the regulator.

NOTE If a gauge port is available, connect the gauge here.

3 Connect a precision 0-60 psi pressure gauge at the output port on thePR I/P regulator section. This will register a pneumatic output signalwhile testing the transducer/regulator.

NOTE When testing the I/P transducer for acceptable performance,connect at least a volume of approximately one cubic foot to the output ofthe regulator. Ensure that the inlet pressure is at least 5% higher than thedesired output pressure but no more than +10% of the I/P transducersystem range being used (maximum of 300 psi).

4 Turn on the air supply to the panel.

5 Ensure all connections are “bubble tight”.

NOTE The signal to the transducer/regulator can be varied by selectingthe desired transducer count at the analog output (AOUT[1]) menu screenon the teach pendant.

6 Full scale response check: at the teach pendant select I/O, then PressF1 [TYPE].

7 Select AO (Analog Out) menu.

8 Enter a value of 1000 transducer counts, and press [ENTER] Thegauge should climb swiftly and smoothly to a maximum value (it isnot important what this value is).

9 Set the AO equal to 200. The gauge will fall steadily (usually slowerthan climbing) back to zero. Any observable irregular responseindicates a problem.

10.1I/P TRANSDUCER/REGULATORPERFORMANCECHECK

Condition

Step

MARO2P10203703E 10–3


10 Supply 4 mA to the transducer.

11 Starting at 0% (4mA) electrical signal, supply electrical signals in thefollowing incremental and decremental order and observe thecorresponding pneumatic output signals: (Refer to Table 10–1)

– Incremental (mA) 4, 8, 12, 16, 20.

– Decremental (mA) 20, 16, 12, 8, 4.

12 Verify that the pressure output falls within the tolerance range as listedin Table 10–1 (including the hysteresis between the up and downsetpoints).

13 If a unit is found to be defective - Replace the unit.

WARNINGThis I/P transducer/regulator is intrinsically safe and anyrepair is prohibited. Replacement must be done byProportionAir. If you attempt any repair yourself, you willviolate the warranty and could injure personnel or damageequipment.

Table 10–1. I/P Transducer/Regulator Performance Check

Input counts toFanuc AnalogOutput Module

Current (mA)Output from

Fanuc AnalogOutput

Module/Current(mA) Input to PRTransducer (mA)

Percent ofMaximum Output

from PRTransducer (%)

Output from PRTransducer ( ±1%)

of Full Output

200 4 0 0

400 8 25 12.5

600 12 50 25

800 16 75 37.5

1000 20 100 50

MARO2P10203703E10–4


Figure 10–1. Emergency Stop Control Board Jumpers

Door interlock jumper/connector

B=24VDC commonA= 0VDC common

B=By–Passing SwitchA= Using Switch

Common Jumper

Hand Broken Jumper

Remove jumper when usingAux. *BRK ON3 as separate

SBK1−1 Adds Surge Suppression Across Brake Outputs BKP&M1. SBK1−2Adds A Diode Across TheBrake Coil At BKP&M1.SBK2−1 Adds Surge Suppression Across Brake Outputs BKP&M4. SBK2−2Adds A Diode Across TheBrake Coil At BKP&M4.

Aux. brake control input plugCRM16−P1=*BRKON3CRM16−P2=*BRKON4

control

MARO2P10203703E 10–5


Use Procedure 10–2 to perform a beaker test.

Procedure 10–2 Manual Flow Test (Beakering Test)

All personnel and unnecessary equipment are out of the workcell.

The applicator is functioning properly.

The controller is in manual mode. This is performed either by the cellcontroller or by turning on the manual enable input.

Turn off the servo disconnect.

Place a graduated beaker under gun assembly.

1 Press MAN FCTNS.

2 Press F1, [TYPE].

3 Select Gun Control. You will see a screen similar to the following.

Manual/Appl./Con/ JOINT 10 %

** Entries Affect Outputs Immediately **Pulse time (sec.): 0.0

Gun Gun Select Color

Paint Fluid Atomizing Ai Fan Air

Electrostatic

OFF 1 1

0.0 30.0 0.0

0.0

Press a function key[ TYPE ] ON PULSE ALLOFF [GROUP] >

[ TYPE ] HELP >

CAUTIONThe following steps will actually turn on and off the outputs. Besure your workcell is set up properly.

10.2MANUAL FLOW TEST(BEAKERING TEST)

Condition

Step

MARO2P10203703E10–6


4 Move the cursor to each item you want to set, and set the itemappropriately.

Set pulse time.

Set gun select

Set color number

Set paint fluid (Flow rate in cc/min)

Set Atomizing Ai, Fam Air and Electrostatic to 0.

5 To pulse the selected output, select the item to be pulsed and pressF3, PULSE. The output will pulse on then off automatically. Thesystem will dispense selected color for 30 seconds then turn off.

6 Measure paint in graduated beaker for proper results.

7 To turn off or set all outputs to 0, press NEXT, >, then press F4,ALLOFF.

NOTE Any outputs turned on will remain until they are turned off or untilall outputs are set to off.

MARO2P10203703E 10–7


A cold start (START COLD) is the standard method for turning on powerto the robot and controller. A cold start does the following:

Initializes changes to system variablesInitializes changes to I/O setupDisplays the UTILITIES Hints screen

A cold start will be complete in approximately 30 seconds.

Use Procedure 10–3 to perform a cold start.

Procedure 10–3 Performing a Cold Start

All personnel and unnecessary equipment are out of the workcell.

WARNINGDO NOT turn on the robot if you discover any problems orpotential hazards. Report them immediately. Turning on arobot that does not pass inspection could result in seriousinjury.

1 Visually inspect the robot, controller, workcell, and the surroundingarea. During the inspection make sure all safeguards are in place andthe work envelope is clear of personnel.

2 Turn the power disconnect circuit breaker on the operator box oroperator panel to ON.

3 On the teach pendant, press and hold the PREV and NEXT keys. SeeFigure 10–2.

4 While still pressing PREV and NEXT on the teach pendant, press theON button on the operator panel. See Figure 10–2.

10.3COLD START(START COLD)

Condition

Step

ON

OFF

POWER DISCONNECTC-SIZE CONTROLLER

MARO2P10203703E10–8


Figure 10–2. Teach Pendant and Operator Panel

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

ÎÎÎ

ÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

ÎÎ

ÎÎÎ

ÎÎÎÎÎ

ÎÎÎÎÎÎ

PORT

BATTERYALARM

CYCLE START ON

OFF

REMOTE

REMOTE

HOLD

PURGECOMPLETE

PURGEFAULT

EMERGCY STOP


FAULT RESET

FAULT

ÏÏÏÏ

ÏÏÏÏ

ON

OFFHOUR METER

Î

BRAKE ENABLE

PURGE ENABLE

LOCAL

ON BUTTON

PREVIOUSKEY

NEXT KEY

(FAULT)RESET KEY

FAULT

HOLD

STEP

BUSY

RUNNING

MAN ENBL

PROD MODE

JOINT

XYZ

TOOL

OFF ON

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

BMON>

MARO2P10203703E 10–9


6 Turn on the controller. You will see a screen similar to the following.

COLD CTRL INIT START >

*** BOOT MONITOR for R-J2 CONTROLLER ***Version 4.22P(OIE) 01-JAN-199x

F-ROM/D-RAM/C-MOS : 8.0/8.0/2 MBTP Version : ICurrent TIME : 01-JAN-199x 22:52:53

Slot ID FC OP0 9B 1 0 R-J2 Main CPU1 AF 1 0 R4600 Sub-CPU V4.20D 6A 0 0 MCARD I/FE 8A 0 0 AB/Ether I/F

BMON>

NOLOAD

optionaloptionaloptional

7 Press F1, COLD, and press ENTER.

8 Press F5, START, and press ENTER.

On the operator panel or operator box, the ON button will beilluminated, indicating robot power is on.

On the teach pendant screen, you will see a screen similar to thefollowing.

UTILITIES Hints JOINT 10 %

PaintTool (TM)

V4.30-x

Copyright 1997, FANUC Robotics

North America, Inc.

All Rights Reserved

[TYPE ] HELP

BMON> COLD

BMON> START

MARO2P10203703E10–10


The following procedures are applicable to all P-200 robot systemsincluding those on a pedestal, rail or with an opener. In the case of aP-200 robot and opener, both units must be properly purged before thecontroller can be turned on.

Procedure 10–4 Powering on the Robot Systems

1 With the main disconnect ON, you should observe:

Purge complete LED is off.Purge enable pushbutton (purging) lamp is off.ON pushbutton lamp is off.Purge fault LED is on

2 Push and hold the PURGE ENABLE pushbutton. You should observe

Purge solenoid engages when minimum pressure requirements aremet.

Purge fault LED turn off.Purging lamp (behind purge enable pushbutton) lights.

At this point you can release the purge enable pushbutton, no changeshould occur.

3 At the end of the 5 minute purge, the pushbutton purging lamp willturn off and the purge complete LED will turn on. Also, the purgesolenoid will shut off.

4 If this procedure does not work, go to Chapter 4 Troubleshooting.

10.4POWER ONSEQUENCE

Step

MARO2P10203703E 10–11


Use this procedure for complete controller shutdown including purgecircuitry.

Procedure 10–5 Controller Shutdown Procedure


2 Push the controller “OFF” pushbutton.

3 Pull the Main Disconnect switch.

For servo lockout use the following procedure:

Procedure 10–6 Servo Lockout Procedure


2 Open the servo lockout disconnect switch.

3 Lockout switch

10.5CONTROLLERSHUTDOWN

Step

10.6SERVO LOCKOUT

Step

11 CONNECTIONS

CONNECTIONS

11–1MARO2P10203703E 11This section includes the connections and specifications for modular I/Ounits. It also contains diagrams for the cables connecting the R-J2 to theP-200 robot and noise reduction guidelines.


Noise ReductionGuidelines

Excessive noise might cause errors in the controller. 11–1. . . . . . . . . . . . . . . . . . . . . . .

Modular I/O Outputs Connections and specifications for modular I/O outputs. 11–2. . . . . . . . . . . . . . . . . . . . Output Module AOD32A, Non-isolated 11–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Modules AOD08C and AOD08D 11–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Modules AOD16C and AOD16D 11–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Module AOD32C 11–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Module AOD32D 11–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Modules AOA05E and AOA08E 11–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Module AOA12F 11–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Modules AOR08G and AOR16G 11–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Module ADA02A 11–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ethernet Remote PrintedCircuit Board Diagnostics

Two general styles of the Ethernet Remote printed circuit board are available. 11–11.

Modular I/O Inputs This section describes the connections and specifications for modular I/O units. 11–12Input Module AID32B, Non-isolated 11–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Modules AID16C and AID16D 11–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Input Module This section describes the connections and specifications for analog input module AAD04A. 11–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Input Module AAD04A 11–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Excessive noise might cause errors in the controller. Wiring guidelines foreliminating these conditions include routing I/O wiring well away fromany conductors connected to the pulse coder and other internal controlwiring.

I/O wiring must not occupy the same wireways as the internal controlwiring. Where possible avoid parallel runs of I/O and internal controlwiring. Cross internal control wiring with I/O wiring at right angles. A minimum separation of 100 mm is recommended.

Provide all I/O wiring with a separate power supply. Do not use controllerinternal voltages such as +5VDC or 24VDC for I/O. Insure that commonconductors for power supplies are not shared. Use separate commons foreach power supply used for I/O.

Insure that all coils for electromechanical devices such as relays,contactors, pneumatic solenoids, etc. are equipped with suppressiondevices. For DC circuits, diode suppressors are recommended and for ACcircuits the suppressors should be a combination of a MOV with aresistor/capacitor network.

11.1NOISE REDUCTIONGUIDELINES

MARO2P10203703E11–2

11. CONNECTIONS

This section describes the connections and specifications for modular I/Ooutputs.

Table 11–1. Output Module AOD32A, Non-isolated

Item AOD32A

Points/module 32 points

Points/common 8 points/common

Sink/source current Sink current type

Rated load voltage 5 ~ 24VDC +20% –15%

Maximum load current 0.3A (however 2A/common)

Maximum voltagedrop when ON

0.24V (load current 0.8)

Maximum leak currentwhen OFF

0.1 mA

ResponseTime

OFF ON Max. 1 msTime

ON OFF Max. 1 ms

Output display Not provided

External connection Connector (HONDA TSUSIN MR-50RMA)

08072439062338223740,41

Terminal connectionand circuitry

32481531473046

+24A16

+

–

: output circuitO +5~+24

L : load

1716A0

A1A2A3A3A4A4A5A5A6A6A7A7

32481531473046

A0A1A2

CMA 49,50

CM

InternalCircuit

LLLLLLLL

+

–

+

–

OOOOOOOO

28441127431042

1312

B3B4B5B6B7

B0B1B2

+24BLLLLLLLL

OOOOOOOO

CMB 29,45 21,36

D3D4D5D6D7

0403D0

D1D2

20350219340133

+24DLLLLLLLL

OOOOOOOO

CMD

C3C4C5D6D7

C0C1C2

+24CLLLLLLLL

OOOOOOOO

CMC

+

–

11.2MODULAR I/OOUTPUTS

MARO2P10203703E 11–3

11. CONNECTIONS

Table 11–2. Output Modules AOD08C and AOD08D

Item AOD08C AOD08D

Points/module 8 points 8 points

Points/common 8 points/common 8 points/common

Sink/source current Sink current type Source current type

Rated load voltage 12 ~ 24VDC +20% –15% 12 ~ 24VDC +20% –15%

Maximum load current 2A (however 4A/fuse) 2A (however 4A/fuse)

Limit of load — Refer to load derating curve

Maximum voltage dropwhen ON

0.8V (load current 0.4) 1.2V (load current 0.6)


0.1mA 0.1mA

ResponseTime OFF ON Max. 2 ms

This is the value from input tooutput in the module. Theactual value is determined by

Max. 2 msThis is the value from input tooutput in the module. Theactual value is determined by

ON OFF Max. 2 ms

actual value is determined byadding it to the scanning timedepending on each system.

Max. 2 ms


Output display LED display LED display

External connection Terminal block connector (20 terminal, M3.5screw terminal)

Terminal block connector (20 terminal, M3.5screw terminal)

Fuse 5A, 1 piece for each output A0-A3 and A4-A7 5A, 1 piece for each output A0-A3 and A4-A7

Terminal connectionand circuitry

A0

A1

A2

A3

A4

A5

A6

A7

: output circuit

O

O

O

O

L

L

L

L

L

L

L

+–

InternalCircuit

LED

load

O

Fuses

L

O

O

O

O

23

4

56

78

910

11

1213

1415

1617

1

1819

20

2

20

Fuses

A0

A1

A2

A3

A4

A5

A6

A7

: output circuit

L

L

L

L

L

L

L

+

–

InternalCircuit LED

load

O

Fuses

23

4

56

78

910

11

1213

1415

1617

1

1819

20

L

2

20

O

O

O

O

O

O

O

O

MARO2P10203703E11–4

11. CONNECTIONS

Table 11–3. Output Modules AOD16C and AOD16D

Item AOD16C AOD16D



Sink/source current Sink current type Source current type

Rated load voltage 12 ~ 24VDC +20% –15% 12 ~ 24VDC +20% –15%

Maximum load current 0.5A (however 2A/common) 0.5A (however 2A/common)


0.7V (load current 1.4) 0.7V (load current 1.4)


0.1mA 0.1mA



Max. 2 msThis is the value from input tooutput in the module. Theactual value is determined by

ON OFF Max. 2 ms


Max. 2 ms



External connection Terminal block connector (20 terminal, M3.5screw terminal)

Terminal block connector (20 terminal, M3.5screw terminal)

Terminal connection andcircuitry

1

A1

A3

A5

A7

B1

B3

B5

10

L

L

L

L

L

L

L

+

–

InternalCircuit

A0L

A2L

A4L

A6L

B0L

B2L

B4L

B6LB7L

2

34

5

67

89

1011

1213

1415

1617

1

20

1819

: output circuitO

L : load

+

–

O

O

O

O

O

O

OO

O

O

O

O

O

O

O

O

LED

A1

A3

A5

A7

B1

B3

B5

L

L

L

L

L

L

L

+

–

A0L

A2L

A4L

A6L

B0L

B2L

B4L

B6LB7

2

34

5

67

89

1011

1213

1415

1617

1

20

1819

L : load

+

– O

O

O

O

O

O

O

O

OO

O

O

O

O

O

O

L

: output circuit

InternalCircuit

LED

O

1

10

MARO2P10203703E 11–5

11. CONNECTIONS

Table 11–4. Output Module AOD32C

Item AOD32C



Sink/source current Sink current type






0.1mA

ResponseTime

OFF ON Max. 2 ms This is the value from input to output in the module. The actual value isdetermined by adding it to the scanning time depending on each systemTime

ON OFF Max. 2 msdetermined by adding it to the scanning time depending on each system.




O

O

21,36

284411274310

42

1312

324815314730

46

+24A16

+

–

: output circuitO+24

L : load

B3B4B5B6B7

B0B1B2

C3C4C5C6C7

1716A0


324815314730

46

0807C0

C1C2

243906233822

37

+24CA0A1A2

+24B

D3D4D5D6D7

0403D0

D1D2

203502193401

33

+24D

CMA 49,50

CM

InternalCircuit

LLLLLLLL

LLLLLLLL

LLLLLLLL

LLLLLLLL

OOOOO

OO

OOO

OOOO

OOOOOOOO

OOOOOOOO

CMC 40,41

+

–

+

–

CMB 29,45 CMD

Note: For the common (CMA, CMB CMC, CMD) make sure to use both.

MARO2P10203703E11–6

11. CONNECTIONS

Table 11–5. Output Module AOD32D

Item AOD32D



Sink/source current Source current type






0.1mA

ResponseTime OFF ON Max. 2 ms This is the value from input to output in the module. The actual value is

determined by adding it to the scanning time depending on each system.

ON OFF Max. 2 ms




05

284411274310

42

29,4512

324815314730

46

CMA16

+

–

: output circuitO

L : load

B3B4B5B6B7

B0B1B2

C3C4C5C6C7

49,5016A0


324815314730

46

40,4107C0

C1C2

243906233822

37

CMCA0A1A2

CMB 21,3603203502193401

33

CMD

0A 1B

CMInternalCircuit

LLLLLLLL

LLLLLLLL

LLLLLLLL

LLLLLLLL

OOOOOOOO

OOOOOOOO

OOOOOOOO

0C 09

+

–

+

–

0B 14

Note: For the common (CMA, CMB CMC, CMD) make sure to use both.

0

D3D4D5D6D7

D0D1D2

0D

+

–

O

O

OOO

O

OO

MARO2P10203703E 11–7

11. CONNECTIONS

Table 11–6. Output Modules AOA05E and AOA08E

Item AOA05E AOA08E


Points/common 1 point/common 4 points/common

Rated load voltage 100 ~ 230VAC 15%, 47 ~ 63Hz 100 ~ 230VAC 15%, 47 ~ 63Hz

Maximum load current 2A (however 5A/module) 1A (however 2A/common)

Maximum in rush current 25A (1 period) 10A (1 period)

Limit of load Refer to load derating curve —


1.5Vrms 1.5Vrms


3.0mA (115VAC), 6.0mA (230VAC) 3.0mA (115VAC), 6.0mA (230VAC)

ResponseTime

OFF ON Max. 1 ms This is the value from input tooutput in the module The

Max. 1 ms This is the value from input tooutput in the module TheTime

ON OFF

Half of theloadfrequencyor less

output in the module. Theactual value is determined byadding it to the scanning timedepending on each system.

Half of theloadfrequencyor less

output in the module. Theactual value is determined byadding it to the scanning timedepending on each system.


External connection Terminal block connector (20 terminals, M3.5screw terminal)

Terminal block connector (20 terminals, M3.5screw terminal)

Fuse 3.2A, 1 piece for each output A0 ~ A4 3.2A, 1 piece for each output A0 ~ A3 andA4~ A7


load

A0

A1

A2

A3

O

O

O

O

OA4

4

O

2

LED

3

4

5

6

7

8

910

11

12

13

14

15

16

17

1

1819

20

2

L

L

L

L

L

: output circuit

A1

A3

A4

A6

OL

L

L

L

O

O

O

load

: output circuitO

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

1

1819

20

2

Fuse

Fuse

O

O

O

O

20

LED

L

L

L

L

A0

A2

A5

A7

10

MARO2P10203703E11–8

11. CONNECTIONS

Table 11–7. Output Module AOA12F

Item AOA12F



Rated load voltage 100 ~ 115VDC 15% 47 ~ 63Hz

Maximum load current 0.5A/point (however 2A/common)

Maximum in rush current 5A (1 period)

Limit of load Refer to load derating curve


1.5Vrms


1.5mA (115 VAC)



ON OFF Half of the load frequency or less


Output display LED display

External connection Terminal block connector (20 terminal, M3.5 screw terminal)

Fuse 3.2A, 1 piece for each output A0 ~ A5 andB0 ~ B5


A1

A3

A5

B1

B3

B5

O

O

O

O

O

O

O

L

L

L

L

L

A0L

A2L

A4L

B0L

B2L

B4L

OO

O

O

O

O

O

O

: output circuitO

O

LED

Fuse

Fuse

12

3

45

67

89

1011

1213

1415

1617

20

1819

L

9 19

: loadL

NOTE:Each output signal group (A0–A5 andB0–B5) contains six output signals.However, each group must have an entiregroup of eight signals assigned to it.For example, A0–A5 might be occupiedby digital outputs 1 through 6 and B0–B5might be occupied by digital outputs9 through 14. Digital outputs 7 and 8 anddigital outputs 15 and 16 are unusuable.

MARO2P10203703E 11–9

11. CONNECTIONS

Table 11–8. Output Modules AOR08G and AOR16G

Item AOR08G AOR16G


Points/common 1 point/common 4 points/common

Maximum load 30VDC/250VAC, 4A (resistance load) 30VDC/250VAC, 2A (resistance load)

Minimum load 5VDC, 10mA 1A (however 2A/common)

Maximum current — 4A/common

Limit of load Refer to load derating curve Refer to load derating curve

Response Time

OFF ON Max. 15ms

This is the valuefrom input tooutput in themodule. Theactual value is

Max. 15ms

This is the valuefrom input tooutput in themodule. Theactual value is

ON OFF Max. 15ms

actual value isdetermined byadding it to thescanning timedepending oneach system.

Max. 15ms

actual value isdetermined byadding it to thescanning timedepending oneach system.


External connection Terminal block connector (20 terminals,M3.5 screw terminal)

Terminal block connector (20 terminals,M3.5 screw terminal)

Relay life Mechanical Min. 20,000,000 times Min. 20,000,000 times

Electrical Min. 100,000 times (resistance load) Min. 100,000 times (resistance load)


v

v

v

v

A4

A5

A7

A6

L

L

L

L

1

23

45

67

89

1011

1213

1415

1617

20

1819

v

v

v

v

A0

A1

A3

A2

L

L

L

L

: Direct current power or alternating current power

v

A7

1

23

45

67

89

10

v

v

A0

A1

A3A2

L

L

L

L

L

L

L

A4

A5A6

L

B3

v

L

LL

BO

B1B2

L

11

1213

1415

B7

L

LL

B4

B5B6

L

17

1819

20

16v

: Direct current power or alternating current powerv

MARO2P10203703E11–10

11. CONNECTIONS

Table 11–9. Output Module ADA02A

Item ADA02A

Number of outputchannels

2 channels/module

Digital input 12-bit binary (2’s complement representation)

Analog output –10VDC ~ +10VDC (external load resistance: 10K or more) selectable0mADC ~ + 20mADC (external load resistance: 400 or less) usable

Input/outputcorrespondence

Digital Input Analog Output

+2000 +10V+1000 +5V or +20mA 0 0V or 0mA–1000 –5V–2000 –10V

Resolution 5mV or 20 A

Comprehensive accuracy Voltage output 0.5% (for the full scale)Current output 1% (for the full scale)

Converting time 1ms or less. The converting time is the one only inside the module. The actual response timeis added a scan time that is determined by the system.

Isolation Photocopier isolation (between output signal and base). However, non-isolation betweenoutput channels.

External connection At removable terminal block (20 terminals, M3.5 screw terminals)

Number of occupiedoutput points

82

(Note 1) Use a 2–core twisted shielded cable as the connection cable.(Note 2) Ground the cable shield on the load side

ADA02A

Channel 0

D/Aconverter

V0+

Voltageamp.

V0–

Currentamp.

10+

10–

Channel 1

D/Aconverter

Voltageamp.

Currentamp.

V1+

V1–

10+

10–

Current outputLoad

400 ohms or less

Voltage outputLoad

10K ohms or more2

4

6

8

10

12

14

16

18

20

MARO2P10203703E 11–11

11. CONNECTIONS

Figure 11–1 shows both the ER-1 and ER-2 R-J2 Allen-Bradley RemoteI/O (ABRIO) printed circuit boards. For more detailed information on thetypes and styles of the Ethernet Remote Printed Circuit Board, seeSection 1.11, Table 3–13, and Table 3–14 which list the functions of thealarm LEDs.

Figure 11–1. ER-1 and ER-2 Printed Circuit Board LEDs

1 2 3 4

A - B

ER-1 ER-2

Alarm LEDs

Alarm LEDs

11.3ETHERNET REMOTEPRINTED CIRCUITBOARD DIAGNOSTICS

MARO2P10203703E11–12

11. CONNECTIONS

This section describes the connections and specifications for modular I/Ounits.

Table 11–10. Input Module AID32B, Non-isolated

Item AID32B



Sink/source cur-rent

Both directions

Input voltage 24 VDC +10% –20%

Input current 7.5mA (average)

ON voltage cur-rent

Min. 18 VDC min. 6 mA

OFF voltage cur-rent

Max. 6VDC max. 1.5 mA

Response

OFF ON Max. 2 ms This is the value from input to output in the module. The actual value is determined byadding it to the scanning time depending on each systemnse

Time ON OFF Max. 2 msadding it to the scanning time depending on each system.

Input display Not provided

External connec-tion

Connector (HONDA TSUSIN MR-50RMA)

Terminalconnection andcircuitry

A0A1A2A3A4A5A6A7B0B1B2B3B4B5B6B7

16324815314730461228441127431042

29,4549,50CMA

13,17 ––+24V

14,18 ––GND

C0C1C2C3C4C5C6D7D0D1D2D3D4D5D6D7

07243906233822370320350219340133

21,3640,41CMC

04,08 ––+24V

05,09 ––GND

: input circuit CMInternalCircuit

+24V or GND can be selected for input common as above figure.Note: Make sure to connect all common (CMA, CMC) pins.

11.4MODULAR I/O INPUTS

MARO2P10203703E 11–13

11. CONNECTIONS

Table 11–11. Input Modules AID16C and AID16D

Item AID16C AID16D



Sink/source current Source current type Sink current type

Input voltage 24VDC +10% –20% 24 VDC +10% –20%

Input current 7.5 mA (average) 7.5 mA (average)

ON voltage current Min. 15VDC min. 4 mA Min. 15 VDC min. 4 mA

OFF voltage current Max. 5VDC max. 1.5 mA Max. 5VDC max. 1.5 mA

ResponseTime OFF ON Max. 20ms


Max. 20msThis is the value from input tooutput in the module. Theactual value is determined by

ON OFF Max. 20ms


Max. 20ms


Input display LED display LED display

External connection Terminal block connector (20 terminals, M3.5screw terminal)

Terminal block connector (20 terminals, M3.5screw terminal)


A0A1A2A3A4A5A6A7B0B1B2B3B4B5B6B7

23

45

67

89

1011

1213

1415

1617

1

1819

20

: input circuit

1LED

(C) (D)

FOR AID16C

: input circuitLED

FOR AID16D

+

– +

–

1

MARO2P10203703E11–14

11. CONNECTIONS

This section describes the connections and specifications for analog inputmodule AAD04A.

Table 11–12. Analog Input Module AAD04A

Item AAD04A

Number of input channels 4 channels/module

Analog input –10VDC to +10VDC (input resistance 4.7M) –20mADC to +20mADC (input resistance: 250 selectable

Digital output 12-bit binary (complementary representation of “2”)

Input/outputcorrespondence

Analog Input Digital Output

+10V +2000+5V or +20mA +10000V or 0mA 0–5V or –20mA –1000–10V –2000

Resolution 5mV or 20 A

Total precision Voltage input 0.5% (for the full scale)Current input 1% (for the full scale)

Conversionary time Maximum 2ms. NOTE: Actual response speed is determined by adding the scanning timedepending on each system to this conversion time.

Maximum inputvoltage/current

15V 30mA

Insulation Photocopier insulation (between output signal and base). However, non-insulation betweenoutput channels.

External connection At removable terminal block (20 terminals, M3.5 screw terminals)

Number of occupiedoutput points

82

(Note 1) Though the example above shows the connection of channels 0 and 2, it is just thesame with the channel 1 (I1+, V1+, V1–, COM1 and FG1) and the channel 3 (I3+, V3+,V3–, COM3 and FG3).(Note 2) Either voltage input or current input can be specified for each channel. When current input is specified,make sure to short–circuit in + and Vn+.

(Note 3) Use shielded cables of twisted pair for connecting.

Voltage input

Voltage

supply

Current input

Current

supply

2

4

6

8

10+

11+V0+

V0–

V1+

V1–

COM0

COM1

FG0

1

3

5

7

11

13

15

17

16

14

12

10

9

FG1

12+

13+ 250

V2+

V3+

V2–

V3–

COM2

18

19

20

COM3

FG2

FG3

MULTIPROCESSOR

11.5ANALOG INPUTMODULE

12 SCHEMATICS

SCHEMATICS

MARO2P10203703E 12–112Topics In This Chapter Page

Schematics The following section includes separate print sets for the P-200 robot. Each print set includes the R-J2 controller schematic with R-J2 internal cable connector pinouts and an overview of the C-size cabinet with component locations. 12–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MARO2P10203703E12–2

12. SCHEMATICS

NOTES

MARO2P10203703E

12. SCHEMATICS

12–3

Figure 12–1. R-J2 P-200 Controller Total Circuit Diagram

BACK PLANE

JNPO

JRA5

JNA

MAIN CPU

PSU CP1

CP2

CP3

CP5

JRV1

JRF2

CRM10

JD1A

JF21

CRS1

JD17

JRM3

JRM10

FAN UNIT

A1

A2

1 2

3 4

5 6

F1

F2

F3

F5

F4 13 14

23 24

41

42

43

44

51

52ST

MULTI–TAP TRANSFORMERTF1 (SEE SHEET 4)

F2F1

L1

L2

L3

G

FL1

FL2

FL3

DISCONNECTSWITCH

IN CASE OF DISCONNECT SWITCH

(REFER TO 002)IN CASE OF CIRCUIT BREAKER

INPUT VOLTAGEREFER TO PAGE 002

FUSE UNIT

200A200BBRD1BRDCBRD2

OTSVON

EES2EES1

SVON1SVONCSVON2BKM4BKP4BKM3BKP3BKM2BKP2BKM1BKP1

FRA2FRA1

CNPG

CNCA

CNIN

PURGE CONTROLBRAKE RELEASE

UNIT

E–STOP PCBJRV1

JRF2

CRM9

CRM11

CRM15

CRM16

CRR20

CRR21

CRR22 CRR5

CRR15

JS5

JS6

JS4

JS3

JS2

JS1

BKP4BKM4

OPERATORPANEL

EMGIN1EMGIN2

CNOP

PDIO

CNPG

SURGEABSORBER

UNIT

CRS1

PORT1

PORT2

ISBCRS1 CRS2

TEACHPENDANT

SERVO POWER CONTROL(220 VAC)

SERVO POWER(210 VAC)

100 VAC

220 VAC

THERMOSTAT FOR OVERHEAT

M M M

USER TRANSFORMER (OPTION)

MOTOR BRAKE(J1–J9)

PULSE CODER(J1–J6)

CRF1

TF2 (SEE SHEET 4)

SEE SHEET 8

SEE SHEET 9

SEE SHEET 10

SEESHEETS

13, 14 & 15

SEESHEETS

16, 17 & 18

ROBOTCONNECTIONS

AC 200V

SERVO POWER

PWM SIGNALSTO AMPLIFIERS

ESTOPSIGNAL

AMPLIFIER CONNECTIONS

OVERHEAT(TF1)

AUX AXES BDJV1

REFER TO SHEETS 2 , 3 AND 4

EE-3287-500-001

12–4

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–5

Figure 12–2. R-J2 P-200 Controller Total Circuit Diagram (Multi-Tap Transformer Details)

VOLTAGEINPUT CIRCUIT

BREAKERLEAKAGEBREAKER

220240380415460480500550575

50A 50A

30A 30A

POWERSUPPLY

VOLTAGECONNECTION OF PRIMARY TAP

L1 L2 L3 JUMPER8–15

CONNECTINGSTYLE

DELTA220240380415440460480500550575

7

76

6

54321

15

1514

14

131211109

23

2322

22

1718192021 8–16 16–24

STAR

CAPACITY SPECIFICATION F1,F2,F3 F4,F5

7.5KVA A80L–0026–0010#A 30A 7.5A

SPECIFICATION OF TF1

* BREAKER, FUSE SIZE

8–1416–2316–22

24–724–6

575550500480460

415/240380/220

OV575550500480460

415/240380/220

OV575550

480460

415/240380/220

500

OV

234567

89101112131415

1617181920212223

24

L1

L2

L3

43

44

51

52

F4

F5

SERVO POWER CONTROL

SERVO POWER

100 VAC

THERMOSTATFOR OVERHEAT

F3

F2

F1

220 VAC

(210 VAC)

(220VAC)

L1

L2

L3

G

AC POWERSUPPLY

220/240380/415460/480500/550575

50/60Hz

+10%–15%

30A

30A

3 4

1 2

5 6

13 14

23 24ST1

ST2

x

x

x

CIRCUIT BREAKER

IN CASE OFDISCONNECT SWITCHFUSE UNIT

DISCONNECT SWITCH

A1A2

575550500480460440415380240220

COM F1

10A

L2L2

L1L1

9.6A

115V

115 VACTO OUTLET UNIT

USER TRANSFORMER (OPTION)TF2

A80L–0001–0520

DISCONNECTSWITCH

FL1 FL2 FL3

50A

30A

* CONNECTION TO TF1

1

F2

20A

@ SELECTEDVOLTAGE

FL1

FL2

FL3

MULTI–TAP TRANSFORMER TF1EE–0989–550

30A

7.5A

7.5A

EE-3287-500-00620A 20A 20A

IN CASE OF

12–6

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–7

Figure 12–3. R-J2 P-200 Controller Total Circuit Diagram (Amplifier Configurations)

123456789

101112

1314151617181920212223

L1CL2CTH1TH2RCRIRE

[UL][VL][WL][ ]

L1(R)L2(S)L3(T)

(100A)(100B)

RL2RL3

U[UM]V[VM]W[WM]

T1(TERMINAL BLOCK)

1 2 3

1 2 3

MCCOFF3 MCCOFF4

ESP +24V

CX3 (Y–KEY)(MCC CONTROL)

CX4 (X–KEY)(E–STOP CONTROL)

ULVLWLPE

JS1B

AMP 1

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

AC 200V(CP3)

SERVOPOWER

RCRIRE

OVER HEATTF1

PWM CABLE

E–STOPSIGNAL

ULVLWLPE

JS1B

AMP 2

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

ULVLWLPEUMVMWMPE

JS1B JS2B

AMP 3

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS4 JS3 JS6JS5 MOTORPOWER(J1–J7)

J5 J6

J3

J4

UVWPE

JS1B

AMP 4

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

J2

JS2(JS1–JS6, JV7)

JS2B

JS1

UMVMWMPE

J1

22/3000

J1 J2 J3 J6

2/3000P–200 6 AXES CONTROL

J4, J5

6/3000 12/3000 0.5/3000

SVU2–12/80

AMP1 AMP2 AMP3 AMP4

P–200 6 AXES CONTROL SVU1–130J2J4

J1 J3J5 J6

A06B–6089 A06B–6089 A06B–6089 A06B–6089–H209 –H106

J7J1 J2 J3 J6

P–200 7 AXES CONTROL

J4, J5

12/300022/3000 2/30006/3000 12/3000 0.5/3000

SVU2–12/80L(12A)=J4M(80A)=J1

SVU2–12/80L(12A)=J5M(80A)=J3

SVU2–12/80L(12A)=J6M(80A)=J7

SVU1–130J2

AMP1 AMP2 AMP3 AMP4


A06B–6089–H209 A06B–6089–H106A06B–6089–H101

A06B–6089–H209 A06B–6089–H106A06B–6089–H209 A06B–6089–H209

ON1234

AMP DIP SWITCHSETTINGSALL CASES

1 – ON2 – OFF3 – ON4 – ON

ON1234

AMP DIP SWITCHSETTINGSALL CASES

1 – ON2 – OFF3 – ON4 – ON

ON1234

P–200 (7) AXES CONTROL

SVU2–12/80

A06B–6089–H209

SVU1–12

ULVLWLPE

JS1B

AMP 1

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

AC 200V(CP3)

SERVOPOWER

RCRIRE

OVER HEATTF1

PWM CABLE

E–STOPSIGNAL

ULVLWLPE

JS1B

AMP 2

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

UVWPE

JS1B

AMP 3

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS4 JS3 JS6JS5 MOTORPOWER(J1–J6)

J5 J6

J3

J4UVWPE

JS1B

AMP 4

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE J2

JS2

JS2B

JS1

UMVMWMPE

J1

A06B–6089 A06B–6089 A06B–6089 A06B–6089–H209 –H101 –H106

P–200 (6) AXES CONTROL

UMVMWMPE

JS2B

–H209

UMVMWMPE

J7

JS2B

JV7

–H209 –H209

M(80A)=L(12A)= L(12A)=M(80A)=

TO ROBOT

TO ROBOT

MOTOR TYPE

AMP SPECIFICATION

AXES

MOTOR TYPE

AMP SPECIFICATION

#

#

AXES #

#

AMP

AMP

(JS1–JS6)

1234

ON

ON1234

ON1234

ON1234

ON1234

ON1234

ON1234

EE-3287-500-002

12–8

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–9


P–200 R–J2

123456789101112

1314151617181920212223

L1CL2CTH1TH2RCRIRE

[UL][VL][WL]

L1(R)L2(S)L3(T)(100A)(100B)

RL2RL3

U[VM]V[VM]W[WM]

T1(TERMINAL BLOCK)

1 2 3

1 2 3

MCCOFF3 MCCOFF4

+24V



SVU2–12/80L(12A)=J4M(80A)=J1

SVU2–12/80L(12A)=J5M(80A)=J3

SVU2–12/80L(12A)=J4M(80A)=J1

SVU2–12/80

AMP1 AMP2 AMP3 AMP4 AMP5

J4,J5 J6 J7 J8

6/3000

6/3000 6/3000

ULVLWLPEUMVMWM

JS1B JS2B

AMP 1

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

SERVOPOWER

RCRIRE

PWM CABLE

SIGNAL

WLPEUMVMWMPE

JS1B JS2B

AMP 2

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

ULVLWLPEUMVMWMPE

JS1B JS2B

AMP 3

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS4 JS1 MOTORPOWER(J1–J9)

J6

J3

J5 J2J4

J1

ULVLWLPE

JS1B

AMP 4

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

J7

JS1B JS2B

AMP 1

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS1B JS2B

AMP 2

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS1B JS2B

AMP 3

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS4 JS1

JS1B

AMP 4

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS1B JS2B

AMP 1

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

E–STOP

JS1B JS2B

AMP 2

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS1B JS2B

AMP 3

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS4 JS1

JS1B

AMP 4

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

ULVL

PE

JS1B

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE J8

JS1B

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS1B

AMP 5

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

UMVMWMPE

J9

JS2B

(JS1–JS6.J7–J9)

AXES CONTROL

AXES CONTROL 6/3000

2/30002/3000

AXES CONTROL

AXES CONTROL

SVU2–12/12L(12A)=J7M(12A)=J8

SVU2–80/80L(80A)=J7M(80A)=J8

P–200 6+2 (HOOD–DECK)

A06B–6089–H201

A06B–6089–H208

TO ROBOT

A06B–6089–H209

A06B–6089–H209 A06B–6089–H209

A06B–6089–H209

ON1234 AMP DIP SWITCH

SETTINGSALL CASES

1 – ON2 – OFF3 – ON4 – ON

P–200 7+2 AXES CONTROL

J1 J2

22/3000P–200 6+2 (DOOR OPENER)

22/3000

J3

12/3000

12/3000

2/3000

2/3000

0.5/3000

0.5/3000

P–200 6+2 (DOOR OPENER)

P–200 6+2 (HOOD–DECK)L(12A)=J5M(80A)=J3

SVU1–130J2

SVU1–12J6

A06B–6089–H101 A06B–6089–H106

SVU1–12J6

A06B–6089–H101

SVU1–130J2

A06B–6089–H106

AC200V(CP3)

OVERHEATTF1

ULVLWLPEUMVMWMPE

JS1B JS2B

AMP 1

L1L2L3L1CL2CTH1TH2

CX4

T1

T1

SERVOPOWER

RCRIRE

PWM CABLE

SIGNAL

ULVLWLPEUMVMWMPE

JS1B JS2B

AMP 2

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE V

WPE

JS1B

AMP 3

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS4 JS1 JS5 JS6JS3 MOTORPOWER(J1–J9)

J6

J3

J5 J2J4

J1

JS1B

AMP 4

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS1B JS2B

AMP 1

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS1B JS2B

AMP 2

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS1B

AMP 3

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS4 JS1

JS1B

AMP 4

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS1B JS2B

AMP 1

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

E–STOP

JS1B JS2B

AMP 2

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS1B

AMP 3

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS4 JS1

JS1B

AMP 4

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

ULVLWLPE

JS1B

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

J8

JS1B

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS1B

AMP 5

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

UMVMWMPE

JS2B

(JS1–JS6.J7–J9)

TO ROBOT

ON1234


AC200V

(CP3)

OVERHEATTF1

SVU2–12/80L(12A)=J4

M(80A)=J1

SVU2–12/80L(12A)=J6

M(80A)=J3

SVU2–12/80L(12A)=J4M(80A)=J1

SVU2–12/80


J4,J5 J6 J7 J8

6/3000

6/3000 6/3000 6/3000

2/30002/3000

AXES CONTROL

AXES CONTROL

SVU2–12/12

SVU2–80/80

A06B–6089–H201

A06B–6089–H208

A06B–6089–H209

A06B–6089–H209 A06B–6089–H209

A06B–6089–H209

J1 J2

22/3000

22/3000

J3

12/3000

12/3000

2/3000

2/3000

0.5/3000

0.5/3000


P–200 7+2 (HOOD–DECK)L(12A)=J6

M(80A)=J3

SVU1–130J2

A06B–6089–H106

SVU1–130J2

A06B–6089–H106


P–200 7+2 (HOOD–DECK)

12/3000

12/3000

J9

SVU2–12/80

SVU2–12/80

A06B–6089–H209

A06B–6089–H209

L(12A)=M(80A)=

L(12A)=M(80A)=

J5

J5

J7

J7

L(12A)=

L(12A)=

M(80A)=

M(80A)=

J8J9

J8J9

JS2

JS6JS3JS5 JV7 JS2

J7

JV7 JV8

ON1234

AMP DIP SWITCHSETTINGS

ALL CASES1 – ON

2 – OFF3 – ON4 – ON

A06B–6089–H209 A06B–6089–H209 A06B–6089–H101 A06B–6089–H106 SEE CHART

SEE CHARTA06B–6089–H209 A06B–6089–H209 A06B–6089–H106

UVW

JV8 JV9

MOTOR SPEC.

MOTOR SPEC.

AXES

AMP SPECIFICATION

AMP SPECIFICATION

MOTOR SPEC.

MOTOR SPEC.

AMP SPECIFICATION

AMP SPECIFICATION

#

AMP #

AXES #

AMP #

ON1234

ON1234

ON1234

ON1234

ON1234

ON1234

ON1234

ON1234

ON1234

U

PE

A06B–6089–H209

WLVLUL

PE

[ ]

EE-3287-500-003

ESP

12–10

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–11


1

2

34

5

6

78

9101112

13

14151617

1819

2021

22

23

L1CL2CTH1TH2RCRIRE

[UL][VL][WL][ ]

L1(R)L2(S)L3(T)

(100A)(100B)

RL2RL3

U[VM]V[VM]W[WM]

T1(TERMINAL BLOCK)

1 2 3

1 2 3

MCCOFF3 MCCOFF4

ESP +24V



SVU2–12/80L(12A)=J4M(80A)=J1

SVU2–12/80L(12A)=J5M(80A)=J3

AMP1 AMP2 AMP3 AMP4AMP5

J4,J5 J6 J7J8

6/3000 2/3000 L(80A)=J9M(80A)=J10

A06B–6089–H208A06B–6089–H209 A06B–6089–H209

ON1234 AMP DIP SWITCH

SETTINGSALL CASES

1 – ON2 – OFF3 – ON4 – ON

J1 J2

22/3000

J3

12/3000 2/3000 0.5/3000SVU1–130J2

A06B–6089–H209 A06B–6089–H106

ULVLWLPEUMVMWMPE

JS1B JS2B

AMP 1

L1L2L3L1CL2CTH1TH2

CX4

T1

T1

SERVOPOWER

RCRIRE

PWM CABLES

SIGNAL

ULVLWLPEUMVMWMPE

JS1B JS2B

AMP 2

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS1B

AMP 3

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS4 JS1 JS5 JV7JS3

J6

J3

J5 J2J4

J1

PE

JS1B

AMP 4

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS1B JS2B

AMP 1

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS1B JS2B

AMP 2

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS1B

AMP 3

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS4 JS1

JS1B

AMP 4

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS1B JS2B

AMP 1

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

E–STOP

JS1B JS2B

AMP 2

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS1B

AMP 3

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS4 JS1

JS1B

AMP 4

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS1B

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

UL

JS1B

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE VL

PE

JS1B

AMP 5

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

(JS1–JS6.J7–J9)

ON1234


AC200V(CP3)

OVERHEATTF1

JS2

J8

A06B–6089–H209 A06B–6089–H209 A06B–6089–H209 A06B–6089–H106

UVW

P–200 & P–10 OPENER

MOTORPOWER(J1–J10)

ULVLWLPE

JS1B

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

T1

RCRIRE

JS1B

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

JS1B

L1L2L3L1CL2CTH1TH2

CX3

CX4

T1

RCRIRE

UMVMWMPE

JS2B

J9

JV8

TO ROBOT& OPENER

A06B–6089–H105 A06B–6089–H208AMP 6

ULVLWLPEUMVMWMPE J7

W

J10

JV9 JV10

SIDE CABINET

MOTOR TYPE6/3000

J9 J10

6/3000 6/3000

OPENER

SVU2–12/80L(12A)=J6M(80A)=J7

AMPLIFIER SPECIFICATION J8 (RAIL)

A06B–6089–H105

AMP6SVU2–80/80SVU1–80

OPENER SIDE CABINETAXIS

#AMP

#

1234

ON1234

ON1234

ON 1234

ON1234

ON

JS6

JS2B

EE-3287-500-004

12–12

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–13

Figure 12–6. R-J2 P-200 Controller Total Circuit Diagram (AMP PWM Signal Connections)

JV8

JNA

BA

CK

PLA

NE

AUX AXIS PCB

JV7

JRA5

MAIN CPU PCB

JV9

JV11

JV10

JV12

JV14

JV13

JV15

JRV1

JS1

JS3

JS2

JS4

JS6

JS5

JRV1

E–STOP PCB

JV16

JV8

JV7

JV9

J1–J6

J1–J6

JS1

JS3

JS2

JS4

JS6

JS5

REFER TOPWM SIGNALCONNECTIONTABLE

REFER TOPWM SIGNALCONNECTIONTABLE

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

GNDS

*PWMA

*PWMC

*DRDY

*MCON

AMP 2PWM SIGNAL CONNECTION AMP 1 AMP 3 AMP 4 AMP 5

PWM SIGNAL CONNECTION TABLE

IR

GNDR

0V

0V

*PWME

0V

IS

*ENBL

0V

0V

0V

JS1B/JS2BJS1–JS6

(SERVO CONTROL)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

GNDS

*PWMA

*PWMB

*DRDY*MCON

IR

GNDR

0V

0V

*PWMC

0V

IS

*PWMD

0V

0V

*PWME

0V

*PWMF

JV1–JV10

(SERVO CONTROL)



JS1B=JS4JS2B=JS1

JS1B=JS4JS2B=JS1

JS1B=JS5JS2B=JS3

JS1B=JS6JS2B=JV7 JS1B=JS2

JS1B=JS2

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

*DRDY

*MCONJMPR

JS1–JS6(DUMMY CONNECTOR)

A250–2361–0001

JS2B=JS3JS1B=JS6

JS1B=JS5



JS1B=JS4JS2B=JS1

JS1B=JS4JS2B=JS1

JS1B=JS5JS2B=JS3

JS1B=JS5JS2B=JS3

JS1B=JS6 JS1B=JS2


JS1B=JV7JS2B=JV8

JS1B=JV8JS2B=JV9

AMP 6

P–200 7+3 AXES CONTROL JS1B=JS4JS2B=JS1

JS1B=JS5JS2B=JS3


JS1B=JV8 JS1B=JV9JS2B=JV10

JV10

EE-3287-500-007

12–14

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–15

Figure 12–7. R-J2 P-200 Controller Total Circuit Diagram (Power Supply Connections)

B1 B2 B3

A1 A2 A3

AL FA FB

ON OFF COM

B1 B2 B3

+24V 0V

B1 B2 B3

+24E 0V

CP4

CP5

CP6

1 2 3

R S G

1 2 3

R1 S1 G1

1 2 3

R2 S2 G2

CP1

CP2

CP3

B1 B2

BAT+ BAT–

200V

+24V

CP1

CP3

CP4

CP5

CP6

JNPO

BA

CK

PLA

NE

POWER ON/OFFALARM

FAN

CA39A

CP8BATTERY

+24 VDC OUTPUT

+24 VDC OUTPUT

POWER SUPPLY

CP8

200–240 VAC INPUT

200–240 VAC OUTPUT

200–240 VAC OUTPUT

A16B–1212–0871

CP2

3–S

LOT

A20

B–2

001–

0670

5–S

LOT

A20

B–2

001–

0990

SPECIFICATION OF FUSE

NAME FUSE VOLTAGE

F1

F3

F4

7.5A

5A

5A +24E

POWER SUPPLY UNIT

EE-3287-500-008

12–16

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–17

Figure 12–8. R-J2 P-200 Controller Total Circuit Diagram (CPU Connector Details)

JRA5

FAN

CA39A

SERVO AMPLIFIER

ROBOT FEEDBACK

LINE TRACKING

TO OPERATION BOX

I/O LINK

RS–232C/485 INTERFACE (OPTION)

TO OPERATION BOX

TO TEACH PENDANT

RDI/RDO

VBAT

JRV1

JRF2

JF21

JRM10

JRY4(FOR TEST)

12 0V

VBAT(BATTERY)

12

34

56

789

10

11

121314

15

16

17181920

2122

2324

25

26

272829

3031

32

3334

353637

3839

4041

42

4344

45

464748

4950

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V

RTS1

DTR1

TXD1

RTSA

DTRA

TXDATXTP

TXTP

TX485A

OPEMGEXEMGEMGDM

SVON

RX485A

RX485ARXTPRXTP

RXDA

DSRA

CISA

RXD1

DSR1

CTS1

(OPERATION BOX)

01020304050607

080910111213

14151617181920

01020304050607

080910111213

14151617181920

TXTP

RXTPEMGDM

+24V

+24V0V

0VEMGB1EMGB2

EMGTP

EMGENRXTP

TXTP

RDO1

RDO2RDO3

RDO4

RDO5RDO6

+24E

RDI7

RDI8

RDI9HBK

RDO7

RDO8

RDI1RDI2

RDI3

RDI4

RDI5

RDI6

0V

CRS1(TEACH PENDANT)

1

234

56

78910

11

121314151617181920

JRM3

PDI1

PDI2PDI3

PDI4PDI5PDI6PDI7

TPOFF+24V

0V0V

PDO1

PDO2PDO3PDO4

PDO5PDO6PDO7+24V

PDO8

1

234

56

78910

11

121314151617181920

JF21

PAPA

PBPBPZPZ

REQ

+5V+5V

+5V

0V

0V

0V

(LINE TRACKING)

(PDI/PDO)

1

234

56

78910

11

12

1314151617

181920

JF17

RXDB0V

DSRBC

0VCTSB

0VRX485BRX485B

+24E

TXDB0V

DTRB0V

RTSB0V

TX485BTX485B

+24E

1

234

56

78910

11

121314151617181920

JD1B

RXSLCRXSLCTXSLCTXSLC

+5V+5V

+5V

0V0V0V

0V0V

0V

TX485AONOFF

COM

EMGEMTPEMG

0V

0V+24V+24V

+24V

+24V+24V

EMGB1EMGB2

JRM10

(ROBOT FEEDBACK)

A1A2

A3

A4A5

A6A7

A8A9

A10A11

A12A13

A14A15A16

A17

A18

A19A20

A21A22A23

A24A25A26

A27A28

A29A30

A31A32A33

A34A35

A36A37

A38A39A40A41A42

A43

A44A45

A46A47A48A49

A50

B1B2B3B4B5B6

B7B8B9B10B11B12B13B14

B15B16

B17B18

B19B20B21

B22B23

B24B25

B26B27B28B29B30B31

B32B33B34

B35B36B37

B38B39

B40B41B42B43B44B45B46B47B48B49

B50

PD60V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V0V0V

PRQ6

PD5

PRQ5

PD4

PRQ4

PD3

PRQ3

PD2

PRQ2

PD1

PRQ1

+5V

+5V+5V

+5V+5V

+5V+5V

+5V

+5V+5V

+5V+5V+5V+5V

+5V+5V

0V0V

+24E

PD60V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V0V0V

PRQ6

PD5

PRQ5

PD4

PRQ4

PD3

PRQ3

PD2

PRQ2

PD1

PRQ1

+5V

+5V+5V

+5V+5V

+5V+5V

+5V

+5V+5V

+5V+5V+5V+5V

+5V+5V

0V0V

+24E

OTRST

+24E 0V

SVON

RDICOM HBKRELHBKROT

OTREL

A1A2

A3

A4A5

A6A7

A8A9

A10A11

A12A13

A14A15A16

A17

A18

A19A20

A21A22A23

A24A25A26

A27A28

A29A30

A31A32A33

A34A35

A36A37

A38A39A40A41A42

A43

A44A45

A46A47A48A49

A50

B1B2B3B4B5B6

B7B8B9B10B11B12B13B14

B15B16

B17B18

B19B20B21

B22B23

B24B25

B26B27B28B29B30B31

B32B33B34

B35B36B37

B38B39

B40B41B42B43B44B45B46B47B48B49

B50

IR1

IR2

IR3

IR4

IR5

IR6

IS1

IS2

IS3

IS4

IS5

IS6

GNDR1

GNDR2

GNDR3

GNDR4

GNDR5

GNDR6

GNDS1

GNDS2

GNDS3

GNDS4

GNDS5

GNDS6

ENBL1

ENBL2

ENBL3

ENBL4

ENBL5

ENBL6

PWMA1

PWMA2

PWMA3

PWMA4

PWMA5

PWMA6

PWMC1

PWMC2

PWMC3

PWMC4

PWMC5

PWMC6

PWME1

PWME2

PWME3

PWME4

PWME5

PWME60V0V

0V0V

0V0V

0V

0V0V

0V0V0V

0V0V

0V

0V0V

0V0V0V

0V0V

0V0V

+5V+5V+5V

+5V+5V+5V

+5V+5V+5V

+5V+24V

+24V+24V+24V

MCONDRDY

0V0V

+15V+15V

0V0V

0V0V

–15V–15V

BRKONBRKALM

JRF2 JRV1(SERVO AMPLIFIER)

(RS–232C/485)

EXVBAT

JD1B

JD17

CRS1

CRM10

CRM10RDI/RDO

MAIN CPUBATTERY UNIT FOR

MAINTENANCE

(I/O LINK)

JRA5

BA

CK

PLA

NE

FAN

CA39A

5–S

LOT

A20

B–2

001–

0990

SERVO AMPLIFIER

ROBOT FEEDBACK

LINE TRACKING

TO OPERATION BOX

I/O LINK

RS–232C/485 INTERFACE (OPTION)

TO OPERATION BOX

TO TEACH PENDANT

RDI/RDO

VBAT

JRV1

JRF2

JF21

JRM10

JRY4(FOR TEST)

12 0V

12

34

56

789

10

11

121314

15

16

17181920

2122

2324

25

26

272829

3031

32

3334

353637

3839

4041

42

4344

45

464748

4950

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V

RTS1

DTR1

TXD1

RTSA

DTRA

TXDATXTP

TXTP

TX485A

OPEMGEXEMGEMGDM

SVON

RX485A

RX485ARXTPRXTP

RXDA

DSRA

CISA

RXD1

DSR1

CTS1

01020304050607

080910111213

14151617181920

01020304050607

080910111213

14151617181920

TXTP

RXTPEMGDM

+24V

+24V0V

0VEMGB1EMGB2

EMGTP

EMGENRXTP

TXTP

RDO1

RDO2RDO3

RDO4

RDO5RDO6

+24E

RDI7

RDI8

RDI9HBK

RDO7

RDO8

RDI1RDI2

RDI3

RDI4

RDI5

RDI6

0V

1

234

56

78910

11

121314151617181920

PDI1

PDI2PDI3

PDI4PDI5PDI6PDI7

TPOFF+24V

0V0V

PDO1

PDO2PDO3PDO4

PDO5PDO6PDO7+24V

PDO8

1

234

56

78910

11

121314151617181920

PAPA

PBPBPZPZ

REQ

+5V+5V

+5V

0V

0V

0V

1

234

56

78910

11

12

1314151617

181920

RXDB0V

DSRBC

0VCTSB

0VRX485BRX485B

+24E

TXDB0V

DTRB0V

RTSB0V

TX485BTX485B

+24E

1

234

56

78910

11

121314151617181920

RXSLCRXSLCTXSLCTXSLC

+5V+5V

+5V

0V0V0V

0V0V

0V

TX485AONOFF

COM

EMGEMTPEMG

0V

0V+24V+24V

+24V

+24V+24V

EMGB1EMGB2

A1A2

A3

A4A5

A6A7

A8A9

A10A11

A12A13

A14A15A16

A17

A18

A19A20

A21A22A23

A24A25A26

A27A28

A29A30

A31A32A33

A34A35

A36A37

A38A39A40A41A42

A43

A44A45

A46A47A48A49

A50

B1B2B3B4B5B6

B7B8B9B10B11B12B13B14

B15B16

B17B18

B19B20B21

B22B23

B24B25

B26B27B28B29B30B31

B32B33B34

B35B36B37

B38B39

B40B41B42B43B44B45B46B47B48B49

B50

PD60V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V0V0V

PRQ6

PD5

PRQ5

PD4

PRQ4

PD3

PRQ3

PD2

PRQ2

PD1

PRQ1

+5V

+5V+5V

+5V+5V

+5V+5V

+5V

+5V+5V

+5V+5V+5V+5V

+5V+5V

0V0V

+24E

PD60V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V0V0V

PRQ6

PD5

PRQ5

PD4

PRQ4

PD3

PRQ3

PD2

PRQ2

PD1

PRQ1

+5V

+5V+5V

+5V+5V

+5V+5V

+5V

+5V+5V

+5V+5V+5V+5V

+5V+5V

0V0V

+24E

OTRST

+24E 0V

SVON

RDICOM HBKRELHBKROT

OTREL

A1A2

A3

A4A5

A6A7

A8A9

A10A11

A12A13

A14A15A16

A17

A18

A19A20

A21A22A23

A24A25A26

A27A28

A29A30

A31A32A33

A34A35

A36A37

A38A39A40A41A42

A43

A44A45

A46A47A48A49

A50

B1B2B3B4B5B6

B7B8B9B10B11B12B13B14

B15B16

B17B18

B19B20B21

B22B23

B24B25

B26B27B28B29B30B31

B32B33B34

B35B36B37

B38B39

B40B41B42B43B44B45B46B47B48B49

B50

IR1

IR2

IR3

IR4

IR5

IR6

IS1

IS2

IS3

IS4

IS5

IS6

GNDR1

GNDR2

GNDR3

GNDR4

GNDR5

GNDR6

GNDS1

GNDS2

GNDS3

GNDS4

GNDS5

GNDS6

ENBL1

ENBL2

ENBL3

ENBL4

ENBL5

ENBL6

PWMA1

PWMA2

PWMA3

PWMA4

PWMA5

PWMA6

PWMC1

PWMC2

PWMC3

PWMC4

PWMC5

PWMC6

PWME1

PWME2

PWME3

PWME4

PWME5

PWME60V0V

0V0V

0V0V

0V

0V0V

0V0V0V

0V0V

0V

0V0V

0V0V0V

0V0V

0V0V

+5V+5V+5V

+5V+5V+5V

+5V+5V+5V

+5V+24V

+24V+24V+24V

MCONDRDY

0V0V

+15V+15V

0V0V

0V0V

–15V–15V

BRKONBRKALM

EXVBAT

3–S

LOT

A20

B–2

001–

0670

A16B–3200–0040

JRM3

EE-3287-500-009

12–18

12. SCHEMATICS

MARO2P10203703E

MARO2P10203703E

12. SCHEMATICS

12–19

Figure 12–9. R-J2 P-200 Controller Total Circuit Diagram (ESTOP Connection Details)

E–STOP PCB

CRF1

JS1

JS2

JS3

JS4

JS5

JS6

CRM11

CRR5

CRR22

JRV1

JRF2

CRM9

CRM15

CRM16

CRR20

CRR21

SERVO CONTROL

ROBOT FEEDBACK

E–STOP CONTROL

DOOR INTERLOCK

AUX BRAKE CONTROL

E–STOP CONTROL

100VAC INPUT FOR BRAKE POWER

TO ROBOT (FEEDBACK)

SERVO CONTROL

ROBOT OVERTRAVEL

MOTOR BRAKE POWER

(ROBOT FEEDBACK)

A1A2

A3

A4A5

A6A7

A8A9

A10A11

A12A13

A14A15A16

A17

A18

A19A20

A21A22A23

A24A25A26

A27A28

A29A30

A31A32A33

A34A35

A36A37

A38A39A40A41A42

A43

A44A45

A46A47A48A49

A50

B1B2B3B4B5B6

B7B8B9

B10B11B12B13B14

B15B16

B17B18

B19B20

B21

B22B23

B24B25

B26B27B28B29B30B31B32B33B34

B35B36B37

B38B39

B40B41B42B43B44B45

B46B47B48B49

B50

PD60V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V0V0V

PRQ6

PD5

PRQ5

PD4

PRQ4

PD3

PRQ3

PD2

PRQ2

PD1

PRQ1

+5V

+5V+5V

+5V+5V

+5V+5V

+5V

+5V+5V

+5V+5V+5V+5V

+5V+5V

0V0V

+24E

PD60V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V

0V0V0V

PRQ6

PD5

PRQ5

PD4

PRQ4

PD3

PRQ3

PD2

PRQ2

PD1

PRQ1

+5V

+5V+5V

+5V+5V

+5V+5V

+5V

+5V+5V

+5V+5V+5V+5V

+5V+5V

0V0V

+24E

OTRST

+24E 0V

SVON

RDICOM HBKRELHBKROT

OTREL

JRF2

A1A2

A3

A4A5

A6A7

A8A9

A10A11

A12A13

A14A15A16

A17

A18

A19A20

A21A22A23

A24A25A26

A27A28

A29A30

A31A32A33

A34A35

A36A37

A38A39A40A41A42

A43

A44A45

A46A47A48A49

A50

B1B2B3B4B5B6

B7B8B9

B10B11B12B13B14

B15B16

B17B18

B19B20

B21

B22B23

B24B25

B26B27B28B29B30B31B32B33B34

B35B36B37

B38B39

B40B41B42B43B44B45

B46B47B48B49

B50

IR1

IR2

IR3

IR4

IR5

IR6

IS1

IS2

IS3

IS4

IS5

IS6

GNDR1

GNDR2

GNDR3

GNDR4

GNDR5

GNDR6

GNDS1

GNDS2

GNDS3

GNDS4

GNDS5

GNDS6

ENBL1

ENBL2

ENBL3

ENBL4

ENBL5

ENBL6

PWMA1

PWMA2

PWMA3

PWMA4

PWMA5

PWMA6

PWMC1

PWMC2

PWMC3

PWMC4

PWMC5

PWMC6

PWME1

PWME2

PWME3

PWME4

PWME5

PWME60V0V

0V0V

0V0V

0V

0V0V

0V0V0V

0V0V

0V

0V0V

0V0V0V

0V0V

0V0V

+5V+5V+5V

+5V+5V+5V

+5V+5V+5V

+5V+24V

+24V+24V+24V

MCONDRDY

0V0V

+15V+15V

0V0V

0V0V

–15V–15V

BRKONBRKALM

JRV1

B1B2B3

A1A2A3

123

0102

0304

0506

07

0809

1011

1213

14

15

161718

1920

212223

242526272829

303132

33

343536

3738

39404142

43444546

4748

4950

CRF1

2

MCCON SVOUT

13

DIL1DIL2

12

BRKON4 BRKON3

200T 200S 200R

AC3 AC2 AC1

123

100A100B

(E–STOP CONTROL)CRM9

(DOOR INTERLOCK)CRM15

(AUX BRAKE CONTROL)CRM16

(EMG CONTROL)CRR20

(BRAKE POWER)CRR21

123

CRR22

100OUT2 100OUT1

(100VAC OUT)

1

234

56

78910

11

12

1314151617

181920

IRGNDRPWMA

0V

0V

0V

0V

0V0V

PWMC

PWME

DRDYMCON

ISGNDSENBL

(SERVO CONTROL)JS1–JS6

SPDJ5SPDJ5

SPRQJ5SPRQJ5

SPDJ6SPDJ6SPRQJ6SPRQJ6


SPDJ4SPDJ4

SPRQJ4SPRQJ4

SPDJ1SPDJ1SPRQJ1

SPRQJ1


+5V+5V+5V+5V+5V+5V+5V+5V+5V

+5V

+5V+5V+5V

0V0V0V

0V0V0V0V0V

0V0V0V0V

0V

2 13

+24E

CRM11

ROTIN

(ROBOT OVERTRAVEL)

(SERVO CONTROL)

**

**

***

*

*

*

*

**

**************

*

*

*

*

*

*

*

*

**********

CRR15MCC CONTROL

100VAC OUTPUT

* *

*

*

*

**

*

2 13

200A

CRR15

*

(MCC CONTROL)

MCCA

200B

MCCB

(PULSE CODER INTERFACE)

*

*

*

*

*

*

*

*

*

*

*

*

1D 2D 3D

BKM3 BKM3 BKM3

1C 2C 3C

BKP3 BKP3 BKP3

1B 2B 3B

BKM1 BKM2 BKM2

1A 2A 3A

BKP1 BKP2 BKP2

CRR5

B A

B A

TB4

COM(RDI COM)

HBK(HANDBROKEN)

A=PULLDOWNB=PULLUP

A=NO HBKNB=HBKN USED

EE-3287-500-10

12–20

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–21

Figure 12–10. R-J2 P-200 Controller Total Circuit Diagram (Optional Process I/O Connections)

CR2A

CR2B

CR2B

CR2B

CRW1

1

234

56

78910

11

121314

151617181920

RX 0V0V0V

0V0V0V

+24V+24V

TX

010203

04

0506

0708

09

10111213

1415

1617

18

19

202122

232425

262728

29

3031

32

33343536

3738

394041

424344

4546

47484950

(RS–422/SLC)

0V0V

COM–B4

COM–B5

COM–B1

COM–B2

COM–B3

+24E+24E

CRM2B(SDI/SDO)

0102

03

04050607

08

0910111213

1415

1617

18

19

202122

232425

26272829

3031

32

33

343536

3738

39404142

43444546

4748

4950

FAULT RESET

RSR1/PNS1

*IMSTP*HOLD

*SFSPDCSTOPI

STARTHOMEENBL

RSR2/PNS2RSR3/PNS3RSR4/PNS4RSR5/PNS5RSR6/PNS6RSR7/PNS7RSR8/PNS8

0V0V

ACK3/SN03ACK4/SN04ACK5/SN05ACK6/SN06

COM–A4ACK7/SN07ACK8/SN08

SNACKRESERVED

COM–A5PNSTROBE

PROD STARTSDI01SDI02

CMDENBLSYSRDY

PROGRUNPAUSEDCOM–A1HELD

FAULTATPERCHTPENBLCOM–A2BATALM

BUSYACK1/SN01ACK2/SN02

COM–A3

+24E+24E

CRM2A(SDI/SDO)

SDI03SDI04SDI05SDI06SDI07SDI08SDI09SDI10SDI11SDI12SDI13SDI14SDI15SDI16SDI17SDI18

SDI19SDI20SDI21SDI22

SDO13SDO14SDO15SDO16





010203

04

0506

0708

09

1011

1213

14

151617

18

192021222324

25262728

29

30

3132

33343536

3738

394041

424344

4546

47484950

0V0V

COM–C4

COM–C5

COM–C1

COM–C2

COM–C3

+24E+24E

CRM2C(SDI/SDO)SDI23

SDO33

SDO21

0102

0304

0506

07

0809

1011

1213

14

15161718

1920

21222324

2526272829

30

3132

3334

3536

3738

394041

4243

444546

474849

50

0V0V

COM–D4

COM–D5

COM–D1

COM–D2

COM–D3

+24E+24E

CRM2D(SDI/SDO)SDI43

SDO53

SDO41

SDI24SDI25SDI26SDI27SDI28SDI29SDI30SDI31SDI32SDI33SDI34SDI35SDI36SDI37SDI38

SDO34SDO35SDO36



SDO22SDO23SDO24



SDI44SDI45SDI46SDI47SDI48SDI49SDI50SDI51SDI52SDI53SDI54SDI55SDI56SDI57SDI58

SDO54SDO55SDO56



SDO42SDO43SDO44



0102

03

04050607

0809

101112

13

14151617

1819

20

COM–E2COM–E1

CRM4A(SDI/SDO)

SDI63SDO65

SDO61SDI64SDI65SDI66SDI67SDI68SDI69

SDO66SDO67SDO68

SDI70

SDO62SDO63SDO64

+24E0V

010203

04

050607

0809

101112

13

14151617

1819

20

COM–F2COM–F1

CRM4B(SDI/SDO)

SDI71 SDO69

+24E0V

SDI72SDI73SDI74SDI75SDI76SDI77


SDI78

SDO70SDO71SDO72

010203

04

0506

0708

09

101112

1314

151617

1819202122

23242526

2728

293031

323334

DACH1ADCH1

CAMDA1DACH2

CAMDA2

COMAD1ADCH2

COMAD2

CRW1(WELD INTERFACE OPTION)

WDI1WDI2WDI3WDI4WDI5WDI6WDI7WDI8

0V0V0V0V

WDO1WDO2WDO3WDO4WDO5WDO6WDO7WDO8WDI+WDI–+24E+24E

010203

04

050607

0809

101112

13

14151617

1819

20

ADCH5

ADCH6ADCH3

COMAD6COMAD3ADCH3

COMAD4

CRW2(A/D INTERFACE OPTION)

COMAD5

CR2B

CR2B

CRW2

JD4A

JD4B

PROCESS I/O

JD1A


JD4A, B

+5V

+5V–15V

+5V+15V

*RX

*TX

*ENBL

I/O LINK SLAVE

TO ANALOG INTERFACE (A/D)

TO WELD MACHINE (A/D, D/A, WDI, WDO)

SDI/SDOCACB

DA

A16B–2201–0470A16B–2201–0472A16B–2201–0480

SPECIFICATION CRM2A CRM2B CRM2C CRM2D CRM4A CRM4B CRW1 CRW2OOO

OOO O O O O

O OXX

XX

XX

XX X

XXX

TYPE OF PROCESS I/O (SINK TYPE)

NOTE: THE PROCESS I/O IS NOT NORMALLY USED WITH P–200 ROBOTS

EE-3287-500-011

12–22

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–23

Figure 12–11. R-J2 P-200 Controller Total Circuit Diagram (Optional I/O Connections)

MODULAR I/O5–SLOT BASE UNIT A03B–0807–J002

MODULAR I/OINTERFACE

MODULEA03B–0807–J011

CP32

JD1B

JD1A

JD2

MODULAR I/O



CP6

JD1A

1

2

3

+24V

0V

123456789

10

0V11121314

151617181920

0V

0V

0V

+5V

+5V+5V

RX

RX

TXTX

S1S1S2S2

S3S3S4

S4ID1

ID2ID3

S5S5S6S60V

0V

CP32 JD1A/JD1B JD2



CP6

JD1A

24V0V

S1+S1–FG

S2+S2–FG

S3+S3–FG

S4+S4–FG

I/O UNIT MODEL BINTERFACE UNITA03B–0808–C001

BASIC UNIT EXPANSIONUNIT

FG S– S+ 0V 24V

TO BASIC UNIT 2–4

TO BASIC UNIT 2

TO BASIC UNIT 3

TO BASIC UNIT 4

I/O LINK SLAVE

123456789

10

11121314

151617181920

123456789

10

0V11121314

151617181920

0V

0V

0V

+5V

+5V+5V

RX

RX

TXTX

JD1A/JD1B

I/O UNIT MODEL B

I/O UNIT MODEL A

JD1B

JD1A

24V0V

10–SLOT BASE UNIT A03B–0807–J001

EE-3287-500-012

12–24

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–25

Figure 12–12. R-J2 P-200 Controller Total Circuit Diagram (Purge Circuitry)

OPERATORPANEL

EMGIN1EMGIN2

CNOP

PDIO

CRS1

PORT1

PORT2

E–STOP PCBJRV1

JRF2

CRR5

CRR22

BKP4BKM4

CRM9

CRM11

CRR20

CRR21


EOAT1EOAT2

ISB1–3ISB1–4ISB2–3ISB2–4ISB3–3ISB3–4

PRESSURE SWITCH

FLOW SWITCH

HAND BROKEN

TEACH PENDANTDISCONNECT SWITCH

PURGE SOLENOID (OPTION)

FG

PGC2PGC1ROTSVONOPG24PG

BRD2

BRD1BRDC

OFF2OFF1200B200A

EES2EES1

SVON1SVONCSVON2BKM4BKP4BKM3BKP3BKM2BKP2BKM1BKP1

FRA1FRA2

CNIN

CNCA

CNPGPURGE/BRAKE BD

PURGECOMPLETE

REFER TO PAGE 003–006AMP ESP (CX4)

100VAC (TF1)

200VAC (TF1)

CRF1

JRM10

JRM3

JRF2

JRV1 CRM10

JD1A

JF21

CRS1

JD17

MAIN CPU

CNPG

ISB UNIT

CRS1 CRS2

FG ISG

PANEL I/F

BRAKE CONTROL

FIRE ALARMRDI/RDO

+6V

1

2233445566

1+

+

+

–BATTERY UNIT

PULSE CODER BATTERY

DC–DCCONVERTER24V TO +5V

PULSE CODER POWER

BRAKE POWER (J1–J9)BKP1,BKM1=J1,J2,J3BKP2,BKM2=J4,J5,J6BKP3,BKM3,BKP4,BKM4=J7,J8,J9

TB

ISTB

ISB

PGTB

FASTON TERMINAL

I.S.TEACH

PENDANT

PAINT BOOTH

0102

03

04050607

08

091011

12

2324

2526

2728

29303132

3334

13

141516

171819

2021

22

RDI9

RDI1

RDI6

RDI5

RDI3RDI4

RDI7HBK*RDI2

RDI8

RDO1RDO2

RDO3RDO4RDO5

RDO6RDO7

RDO8

+24E0V

CNCA (RDI/RDO)

12

345

67

89

10

11

1213

14

151617

18

19202122

2324

PSA1PSA2PSB1PSB2FSA1FSA2FSB1FSB2

OT11OT12

OT21

OT22OT31OT32OT41OT42OT51OT52

HBK1HBK2TP1TP2

EOAT1EOAT2

12

345

67

89

10

11

1213

14

151617

18

192021

FRA1FRA2

BKP1BKM1

BKP2

BKP3

BKP4

BKM2

BKM3

BKM4SVON2SVONC

SVON1PG1PG2

EES1EES2SOL1

SOL2

FG+24V

0V+24V

0VOFF1OFF2BRD1

BRDCBRD2200A

200BRS

010203

04

0506

07

080910111213

14151617181920

TPDSC

PGCPPGFLT

PGTPDSC2

PGEN1

PGEN2

0V0V0V

OFF1OFF2

BKRL1BKRL2

CNPG

369

12

25811

147

10 100 OUT2100A

BKM1 BKP1BKP2BKP3 BKM2BKM3

100 OUT1EMG2

100BEMG1

CNIN (BRAKE CONTROL)

ISTB TB FASTON

SEE SHEET14 & 15

E–STOPSIGNAL

END OF ARM TOOLING

–

–

–

–

–

ISG

RDI2: EOAT (ENDOF ARM TOOLING)

RDI1: BKRL (BRAKERELEASE DETECT)

PURGE AND I.S. CIRCUITS

RELAY BARRIERIDEC IBRC

PC BD

PC BD

PC BD

PC BD

PC BD

UNITS

ISB4–1ISB4–2 I/P POWER

I/P SIGNALISB5–1ISB5–2ISB6–1ISB6–2ISB6–4

FLOW SENSORPOWER AND SIGNAL

ISB7–1

ISB8–1ISB7–2

ISB8–2

I.S. GND

I.S. G

I.S. GND ISB9–4ISB9–6 P–10 MAGNET SENSOR

POWER TO P–10POWER TO P–200 PURGE SOLENOID

P–200 BYPASS SW

TRIGGER #1 SIGNAL

TRIGGER #2 SIGNAL (OPTION)

+

EE-3287-500-13

12–26

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–27

Figure 12–13. R-J2 P-200 Controller Total Circuit Diagram (Purge Wiring Diagram)

2

1 1

2

3

4

25

5

6

7

FS1A

FS1B

0V

SVON

TPDSC2

+24P

SOL1

SOL2

SVON2

SVONC

SVON1

PS1A

TPDSC1

FG G0V220VAC

C2

A2

C5

A5

C1

A1

A4

C4

A6

C6

A3

C3ROT

SWITCH

EOATSWITCH

HBKSWITCH

SWITCH

SWITCHFLOW

TPDSC

PRESSURESWITCH

IDEC IBRC 6062RFMRELAY BARRIER

RSG

EOAT

RDI8+24E

RDI3

RDI4

RDI7

RLA

123456KA6

5

6

24PG0PGSVON*ROTPGC1PGC2

8 1

32

KA64 3

P4

N4

P6

N6

P3

N3

N2

P2

P5

N5

P1

N1

PGTB

24

22

21

20

23

17

16

15

CNCA

04 CR5A

13

12

11

19

20

34

18

10

RDO1

RDI7

RDI4

RDI3

RDI1(BKRL)

RDI8

RDI2

*HBK

+24E

FRA1

FRA2FIRE

ALARM200A200B

FG

OFF2

OFF115

14

OFF2OFF1

CR1B

TPDSC2

0V

PGFLT

PG

PGEN2

PG2

PG1

PGEN1

8

15

14

TB

CR1B

7

(PURGECOMPLETE)

CR2A

CR2B

TR1

3

R1:0

R3:0

CR1A

TR1

CR1A

CR1B

CR1A

(PURGECOMPLETE)

CR3 CR2A

(PURGING)

CR2A

CR1ACR3

CR45

4

11 12 13

R6:0

R4:0

R5:0

18

19D7CR2B

CR4

CR4

11

12

13

+24P

0V

PURGE CONTROL PCB A16B–1310–0601

KA58

3 2

R16 R17R18

CNPG CNIS

6

PS

TPDSC1

PGCP

*HBK

KA5

1

2

1

PARTIAL SCHEMATIC (SEE SHEET 12)

PURGEFAULT

0V

0V

0V

0V

0V

0V

0V

0V

+24P

0V

+24P

BKRL1

BKRL2+24E

16

17

CR5A

CR5B

C1R7100

CR6

CR7A

CR7B

CR7B

CR7B

CR5A CR6

CR8

33OuF

SH1A

BKRA

BRD1BRDCBRD2

0V

8

+24E 9

0V

TERM 8–10 ON SHEET 12

+24P

0V

0V

0V

0V

0V

0V

14

15

16

17

18

19

23

13RDI5

RDI6 6

7810111415

789

1415

RDI5

ISB10

ISB4

CNCR15

17

CNIN1112

16

17

EES1

EES2

CR5B

EMG1

EMG2TO OPPANEL

1

3

3

24V P.S.A20B–1000–0472

TO IDEC

12345678910111213141516171819202122

2324

PSB1PSB2

FSB1FSB2OT1–1

OT5–2

OT’SNOTUSED

FROM PURGE CABLE

TP1TP2EOAT1EOAT2

CONVEYOR24V OVP

SYSP–10 OR P–15 BYPASS SWITCH

FROM PURGE CABLE+24

+24

12

78

I/P POWERVIA PURGE CABLE

12

91078

+24

+

+

+ I/P SIGNALVIA PURGE CABLE

ISB5

78

34

1ISB6

56

2+

+

24V POWER0VSIGNAL

FLOW METERVIA PURGE CABLE

127

8 +ISB7

127

8 +ISB8

+

+

TRIGGER ONE SIGNALVIA PURGE CABLETRIGGER TWO SIGNALVIA PURGE CABLE

+24V

FROM P–10 OR P–15 SENSORVIA P–10 OR P–15 PURGE CABLE

12

+ISB11

2+

ISB2

STAHL 9001/01–252–100–14 P–200 PURGE SOL

OPENER PURGE SOLENOID

3434

ISTB

1–PSA11–PSA2

5–FSA16–FSA2

PS VIAPURGE CBL

FS VIAPURGE CBL

19–HBK120–HBK2

ISB1–3ISB1–4

ISB3–1

ISB3–3


ISB6–1

ISB7–1

ISB8–1

ISB5–2

ISB6–2ISB6–4

ISB7–2

ISB8–2

ISB9

SEE APPLICATION PACKAGE FOR WIRING DETAILS

P&F

P&F BARRIER

P&F BARRIER

120VAC FROM 24V POWER SUPPLY

P&F

EE–3112–600

DELTRON

EE-3287-500-014

* SEE NOTE

USED WITH 7+3 VERSION

2

8

111415

7

21

21

ISB3

EOAT–6

EOAT–5

FROM PURGE CABLE

P–200 BYPASS SW

P&F

XI II

XI II

ISRR

ISRR

SYSTO

FROM P-200 I/O

P&F BARRIER

P&F BARRIERFROM P-200 I/O

TO P-200 I/O SIG

FROM P-200 I/O

FROM P-200 I/O

* BARRIER NOTE:

FOR P-200-6 OR -7 THISBARRIER NOT MOUNTED

FOR P-200 +2 VERSIONSTHIS BARRIER IS STAHL9001/01-280-165-10

FOR P-200 +3 (P-10, P-15)THIS BARRIER IS STAHL9001/01-252-100-14

NOTE: SEE PROCESS PACKAGES FOR BARRIER TYPES

TRIGGER, I/P,FLOWMETERPROCESS PKGEE-3287-510

DUAL TRIGGER, I/P,FLOWMETER PROCESSPKG EE-3287-511

P&F

10

+24

XX

IIII

II

KFD2-SR2-Ex1.W.LB

KFD2-SR2-Ex1.W.LB

XX

IIII

II

S1S2S3

S3S2S1

3

111012

SENSOR

LEADBROKEN

KFD2-SR2-Ex1.W.LB

X

XX

IIIIII

III

S1S2S3

TO

S1 = I FOR OPEN SW = DE-ENERGIZED

I FOR NAMUR INPUTS2 = II FOR LEAD BREAKAGE ON 10-11-12S3 =

12–28

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–29

Figure 12–14. R-J2 P-200 Controller Total Circuit Diagram (Purge Board Details)

12

34

56

789

10

11

121314

15

16

17181920

21

FRA2

BKM1

BKM2

BKM3

BKM4

PG1

01020304050607

080910111213

14151617181920

BKRL1OFF2

OFF1

CNPG

SOL1

SOL2

(TO PANEL)

TPDSC1

PGCP

PGFLTPG

TPDSC2

PGEN1

PGEN2

0V0V0V

BKRL2

01020304050607

101112131415

17181920

CNIS(TO IBRC)

TPDSC1

TPDSC2

0809

16

2122232425

PS1A

FS1AFS1BSVON

+24PBKRABKRB

*HBKEOATRDI8+24E

FG

RDI5RDI3RDI4RDI7

RLA0V

01020304050607

131415

CNCA

0809

16

(TO MAIN CPU)

101112

171819202122

232425262728293031323334 +24E

RDO1

RDI1

RDI5

RDI3RDI4RDI7*HBKRDI2RDI8

0102

0304

0506

070809

10

11

121314

15

16

17181920

2122

2324

PSA2

PSB2

FSA2

FSB2

OT12

OT22OT31

OT32

OT52

HBK1

EOAT1EOAT2

TB LED

FRA1

BKP1

BKP2

BKP3

BKP4

SVON2

SVONCSVON1

PG2

EES1EES2

+24V

PSA1

PSB1

FSA1

FSB1

OT11

OT21

OT41

OT42OT51

HBK2TP1TP2

ISTB

0102

0304

0506

OPG

*ROT

PGC2

SVON

PGC1

PGTB

BKP2

BKM3

3

6

9

100OUT1

12EMG2

BKM1

BKP3

2

5

8

11EMG1

BKP1

BKM2

1

4

7

10

100B 100A

100OUT2

CNIN(BRAKE)

PURGE CONTROL PCBA16B–1310–0601

BKRL1

BKRL2

+24E

EMG1

EMG2

EES1

EES2

16

17

11

12

16

17

BKP1

BKM1

BKP2

BKM2

BKP3

BKM3

0V1

2

3

4

5

6

9

10

7

8

D4 D5 D6

3

4

5

6

7

8

9

10

TBCNIN

8

9

CR5A

CR5B

CNIN

CR5BC1R7

100

CR6

CR7A

CR7B

CR7B

CR7BCR5A CR6

CR8

33OuF

CNPG CNISSH1A

DS1CR7A

CR7A

CR8100OUT1

100OUT2

100A

100B

BRD1

BRDC

BRD2

BKP1

BKM1

BKP2

BKM2

BKP3

BKM3

BKP4

BKM4

J1, J2

J3, J7

J4, J5

J6

BRAKERELEASE

FROM XFMR

CR7B

24PG

EE-3287-500-015

12–30

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–31

Figure 12–15. R-J2 P-200 Controller Total Circuit Diagram (ESTOP Wiring Detail)

R–J2MAIN CPU

+24V

0V 0V

0V

RV

RV

RV

AXESCONTROL

JRV1 JRV1

JRF2RV

RV

+24E

ROTOTREL

RDICOM

BRKALM

POWERTRANSFORMER

100A

100B

200A200B

DC POWER SUPPLYON/OFFCONTROL

100A

100B0V

0V

CRM16

BRK1

BRK2 +24E

0V

+24E

0V

+24E

0VA

B

BRK3 +24E

BRAKE CONTROL CIRCUIT

BRK1–3

BRK4

BRK5–7

CRR20200R200S200T

AC1AC2AC3

RL–EMG

0V

CRR5

CRM9

SVOUT

DIL1

DIL2

CRM15

ROTIN

+24E CRM11

0V

JS1JS2JS3JS4JS5JS6

CRF1

TO MOTOR PULSE CODER(I/F IS SAME AS R–J)

LOGIC FORAMPLIFIER

EMERGENCY STOP CONTROL PCB

BRKALM

MCON

DRDY

+24E

ROTOTREL

OTRST

RDICOM

SVON

MOTORBRAKE

PULSECODER

ROBOT MECHANICAL UNIT

DOORINTERLOCK

ROT

OTREL

ACPOWERINPUT

DEAD–MAN

ENABLE/DISABLE

JRM10

0V

0V

RV

+24V

+24V

EMGOUT2EMGOUTCEMGOUT1

SVON2SVON1

EMGIN2EMGIN1

E–STOP2E–STOP1

FENCE1FENCE2

0V 0V+24V

PANEL E–STOP

KA4

KA1 KA2

(TBOP1)

(TBOP1)

I.S. TEACH PENDANT

(12)

(3)

(16)

(10)

(11)

(CRS1)

ISB

TPEMG

OPEMG

RV. RECEIVER

FOR DI

BRAKON#1*

*

HBKREL

OTRST

BRAKON#2*

PWMA/C/E, ENBLIS,GRDS,IR,GNDR

BRKON#1

+5V,0VPREQ1–6/ PREQ1–6PD1–6/ PD1–6

HBKREL

BRKON#2

BRKON#4

BRKON#3

200R200S200T

MCCON

CRR22

CRR15 CRR15

HBKREL

RL–OT/HBK

CONTROLCIRCUIT

+24V +24V

ESP

MCCOFF3

MCCOFF4

SVU

CX3

CX4

CONTROLCIRCUIT

+24V

ESP

MCCOFF3

MCCOFF4

SVU

CX3

CX4

EMERGENCY CIRCUIT

0V

OPERATOR PANEL

MCC

SVON

EXEMG

CNOP

PURGE BOARD

EXT ESTOPCNIN1112

BK1 – BK4

EES1

EES2

OPTIONAL

24VCR5

CR5CR5 CR6

CR7

100A100B

CR7

CR7

CNPG

CR8

FROM XFMR

CRR21

EE-3287-500-016

1

2

OPTIONEE-3287-401

12–32

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–33

Figure 12–16. R-J2 P-200 Controller Total Circuit Diagram (OP Panel Details)

(12)(13)(14)(15)(16)(17)(18)(20)(1)(3)(4)(5)(6)(7)(8)

(9)

(10,19)(2,11)

+24V

0V

0V

(NOT USED)(NOT USED)

(NOT USED)

(12)(3)(16)(10)(11)

+24V

PDO1PDO2PDO3

PDO5PDO6PDO7PDO8PDI1PDI2PDI3PDI4PDI5PDI6PDI7

+24V0V

+24V

ESTOP1ESTOP2

FENCE1FENCE2

EMGIN1

EMGIN2

SVON1SVON2

(CRS1)

(TBOP1)

(5)(6)(7)(8)

EMGDMEMGEN

EMGB2

(10)

(24)

123 4

HOUR METER+24V

0V

EMGOUT1EMGOUTC

(TBOP1)

(TBOP2)EXON1EXCOMEXOFF1

ONCOMOFF

(21)

(23)(22)

TXTPTXTPRXTPRXTP

(1)

(2)

(4)

(1)(14)(2)

(15)(6,7)

(17,19)+24V

0V

+24V

0V

(18)(16)(14)(12)(32)(30)

TXD1RXD1RTS1CTS1DSR1

DTR1

(1)

(25)(7)

(2)(3)(4)(5)(6)

(20)

(1)

TXDARXDARTSACTSADSRADTRA

TX485A

RX485A

TX485ATX485ARX485ARX485A

(CRS1)TXTP

RXTP

+24V0VFG

TO TEACH PENDANT

(PORT1)

TXD1RXD1RTS1CTS1DSR1DTR1

FG

RS–232–C

OPERATOR PANEL

OPERATOR PANEL

FROM MAIN CPU

(CNOP)

(3)*

*

(NOTE 1) +24V

(NOTE 2)

0V

+24V

0V(NOTE 1)+24V: CNOP–19, 27

28, 37, 38(NOTE 2)0V: CNOP–11, 13, 15,

17, 20, 29,31, 39, 41,43, 45, 47,49

+24V

0V

(25)(7)

(2)(3)(4)(5)(6)

(20)

(1)

*

*

(14)(15)(16)(17)

FG

*TXTP

*RXTP

+24V0V

(PORT2)TXD1RXD1RTS1CTS1DSR1DTR1

FG

RS–232–C

+24V0V

*TX485A

*RX485A

(50)(48)(46)(44)(42)(40)

(36)(35)(34)(33)

SW1: ONLED4LED5SW7

SW8

SW7

(CNPG)

PGCPPGFLTPG

BKRL1BKRL2PGEN1PGEN2TPDSC1TPDSC2

(JRM10)

FROM MAIN CPU (JRM3)PDIO

KA3

0V 0V

KA1 KA2

(10)

(24)

+24V0V

KA4

(26)

(25)EXEMG

EMGOUT2

(CNHM)

HM1

(1)(2)(3)

SVON

OFF1

OFF2

(CNPG)

SW1: ON

SW2: OFF

(6,7)(18)

+24V

LED1: REMOTESW4: C–START

LED2: F–RESETSW6: HOLD

LED1: BATTERY

LED3: TP ENABLE

(CRT3)

F–RESET REMOTE

USER PB1 (PGEN)(USER PB 2) (ON)CY START

TO BRAKE/PURGE BDOPEMG

TPEMG

TPOFF

PDO4

HOLD

EMGB1

EE-3287-500-017

12–34

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–35

Figure 12–17. R-J2 P-200 Controller Total Circuit Diagram (Operator Panel)

01020304050607

080910111213

14151617181920

TXTP

RXTPEMGDM

+24T

+24T0V

0VEMGB1EMGB2

EMGTP

EMGENRXTP

TXTP

(TEACH PENDANT)

1

234

56

78910

11

12

1314151617

181920

JRM3

0V

(MAIN CPU I/F)

12

34

56

789

10

11

121314

15

16

17181920

2122

2324

25

26

272829

3031

32

3334

353637

3839

4041

42

4344

45

464748

4950

JRM10

0V0V

0V

0V

0V

0V

0V

0V0V

0V

0V

0V

0V

0VCTS1

DSR1

RXD1

CTSA

DSRA

RXDARXTPRXTP

TX485ARX485A

+24V+24V+24V+24V+24V

EMGB1EMGB2 SVON

TPEMGEMGENEMGDMEXEMGOPEMG

COMOFFON

TX485ARX485A

TXTPTXTPTXDA

DTRA

RTS1

DTR1

TXD1

RTSA

PDO10V

PDO2PDO3PDO4PDO5PDO6PDO7

+24V+24VPDO8

PDI1

PDI2PDI3PDI4PDI5PDI6PDI7

TPOFF

HONDA PCR–E20 MALE01020304050607

080910111213

14151617181920

01020304050607

080910111213

14151617181920

PDI1

PDI2PDI3PDI4PDI5PDI6

PDI7TPOFF0V

+24V0V

PDO1PDO2

PDO3PDO4PDO5PDO6PDO7

PDO8+24V

PDIO(M)PANEL I/O

CRS1 (F)

TPDSC1

PGCPPGFLT

PGTPDSC2

PGEN1

PGEN2

0V0V0V

OFF1OFF2BKRL1BKRL2

CNPG (F)(PURGE I/F)

01020304050607

01020304050607

010203

EMONEMCOMEMOFFEMGIN1EMGIN2FENCE1FENCE2

TBOP1TERMINAL TERMINAL

TBOP2

SVON1SVON2ESTOP1ESTOP2

EMGOUT1EMGOUTCEMGOUT2

24V0V

SVON

HOUR METERCNHM

01020304050607080910111213

141516171819202122232425

FGTXD1RXD1RTS1CTS1DSR1

0VDTR1

+24V

PORT1

D–SUB 25P FEMALE01020304050607080910111213

141516171819202122232425

FG

0V

+24V

PORT2

D–SUB 25P FEMALE

TXDARXDARTSACTSADSRA

DTRA

THIS CONNECTOR IS OPTIONTHIS CONNECTOR IS MOUNTED ONINTERNAL SIDE OF THE BOX

THIS CONNECTOR IS MOUNTED ONEXTERNAL SIDE OF THE BOX

3334

353637

3839

4041

42

4344

45

464748

4950

TX485A

RX485A 12

34

56

789

10

11

121314

15

16

1718

1920212223242526272829303132

24V24V

24V24V

24V

0V

0V

0V

0V

0V

0V 0V

0V

0V

0V

RX485

TX485

DTRA

DSRA

CTSA

RTSA

RXDA

TXDA

0V

0V

ONCOMOFF

OPEMGSVON

EXEMG

DTR1

DSR1

0V

TXTPTXTPRXTPRXTP

EMGDMEMGENEMGB1EMGB2

TPEMG

CTS1

RTS1

RXD1

TXD1

CNOPOPERATOR PANEL I/F (M)

C–STARTREMOTE

HOLDFAULT

======

PDO1PDO2PDO3PDO4PDO5PDO6

= PDO7

FAULTREMOTEHOLDPGENONC–START

=======

PDI1PDI2PDI3PDI4PDI5PDI6PDI7

OPERATOR PANEL

HONDA PCR50 MALE

BATTERY

(MAIN CPU I/F) (RS–232–C: PORT–1) (RS–232–C: PORT–2)

EE-3287-500-018

12–36

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–37

Figure 12–18. R-J2 Controller P-200 Amplifier Configurations

OFF

ON

OFF

ON

DISCONNECT

USERTRANS.



OPT

PURGE CONTROL UNIT

CONTACT SIGNALTRANSDUCER

1 1/2 ”W X 4”H DUCT

1”W X 4”H DUCT

CONTROLLER FRONT VIEWCONTROLLER W/DOOR REMOVED

AMP 1 AMP 2

BATTERYPACK

TO ISBGND BAR

GRN/YEL14 AWG.

SYSTEM R–J2

CONTROLLER DOOR INSIDE VIEW

ISBUNIT EMG

BOARD

I/O RACK

OFF

ON


AMP 3

MAIN PSUCPU

P–200 R–J2ILLUSTRATED

FANUCAC SERVO

AMPLIFIERS

STATUS

8

0

1

SVU2–12/80L(12A)=J4M(80A)=J1

SVU2–12/80L(12A)=J5M(80A)=J3

SVU2–12/80L(12A)=J4M(80A)=J1

SVU2–12/80


AXES CONTROL

AXES CONTROL

SVU2–12/12L(12A)=J7M(12A)=J8

SVU2–80/80L(80A)=J7M(80A)=J8

A06B–6089–H201

A06B–6089–H208A06B–6089–H209

A06B–6089–H209 A06B–6089–H209

A06B–6089–H209


P–200 6+2 (HOOD–DECK)L(12A)=J5M(80A)=J3

SVU1–130J2

SVU1–12J6

A06B–6089–H101 A06B–6089–H106

SVU1–12J6

A06B–6089–H101

SVU1–130J2

A06B–6089–H106

SVU2–12/80L(12A)=J4M(80A)=J1

SVU2–12/80L(12A)=J6

M(80A)=J3

SVU2–12/80L(12A)=J4M(80A)=J1


AXES CONTROL

AXES CONTROL

SVU2–12/12

SVU2–80/80

A06B–6089–H201

A06B–6089–H208A06B–6089–H209

A06B–6089–H209 A06B–6089–H209

A06B–6089–H209


P–200 7+2 (HOOD–DECK)L(12A)=J6

M(80A)=J3

SVU1–130J2

A06B–6089–H106

SVU1–130J2

A06B–6089–H106

SVU2–12/80

SVU2–12/80

A06B–6089–H209

A06B–6089–H209

L(12A)=M(80A)=

L(12A)=M(80A)=

J5

J5

J7

J7

L(12A)=

L(12A)=

M(80A)=

M(80A)=

J8J9

J8J9



BOM EE–3287–500–003

BOM EE–3287–500–004

BOM EE–3287–500–005

BOM EE–3287–500–006

AMP1 AMP2 AMP3 AMP4

AMP1 AMP2 AMP3 AMP4

SVU2–12/80P–200 6 AXES CONTROL SVU1–130J2J4

J1 J3J5 J6

SVU2–12/80L(12A)=J4M(80A)=J1

SVU2–12/80L(12A)=J5M(80A)=J3

SVU2–12/80L(12A)=J6M(80A)=J7

SVU1–130J2


A06B–6089–H209 A06B–6089–H106A06B–6089–H101

A06B–6089–H209 A06B–6089–H106A06B–6089–H209 A06B–6089–H209

SVU2–12/80

A06B–6089–H209

SVU1–12

M(80A)=L(12A)= L(12A)=M(80A)=

BOM EE–3287–500–001

BOM EE–3287–500–002

P–155/P–200 CONVERSION

AMP 4

AMP 5

AMP SPEC.

AMP SPEC.

AMP SPEC.

AMP SPEC.

AMP SPEC.

AMP #

AMP #

AMP #

AMP #

AMP #

AMP #SVU2–12/80

AMP SPEC.

EE-3287-500-019

12–38

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–39

Figure 12–19. R-J2 Robot Controller Cabinet Layout

OFF

ON

OFF

ON

DISCONNECT

USERTRANS.



OPT

PURGE CONTROL UNIT

CONTACT SIGNAL

TRANSDUCER

1 1/2 ”W X 4”H DUCT

1”W X 4”H DUCT

AMP 1 AMP 2

EMGBOARD

I/O RACK

OFF

ON


AMP 3

MAINPSUCPU


STATUS

8

0

1

AMP 4

OFF

ON


AMP 5 AMP 6

SVU2–12/80L(12A)=J4M(80A)=J1

SVU2–12/80L(12A)=J5M(80A)=J3


L(12A)=J9M(12A)=J10

A06B–6089–H208A06B–6089–H209 A06B–6089–H209

SVU1–130J2

A06B–6089–H209 A06B–6089–H106

SVU2–12/80L(12A)=J6M(80A)=J7

J8 (RAIL)

A06B–6089–H105

AMP6SVU2–80/80SVU1–80

OPENER SIDE CABINET

P–200 7+3 (OPENER)AXES CONTROLAMP SPEC.

BOM EE–3287–500–007

CONTROLLER WITH SIDE CABINET

SHOWN WITH DOOR REMOVED

AMP #

DELTRONW112A24V @ 1.2A

OVP

ISB3ISB4ISB5ISB6ISB7ISB8ISB9

OFF

ON


EE-3287-500-020

12–40

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–41

Figure 12–20. P-200 R-J2 Controller FM Retrofit Package Cabinet Layout

FACTORY MUTUAL RESEARCHMODIFICATION WILL VOID

PURGE TIMER SET AT5 MINUTES

WARNING

CORPORATION APPROVAL

NOTE: ATTACH ALL TAGS WITH

1

OFF

ON

OFF

ON

DISCONNECT

USERTRANS.



OPT

PURGE CONTROL UNIT


1 1/2 ”W X 4”H DUCT

1”W X 4”H DUCT

CONTROLLER FRONT VIEW CONTROLLER W/DOOR REMOVED

AMP 1 AMP 2

TAPE OR DRIVE RIVETS.PERMANENT TYPE FOAM

PLACE LABEL OVER ADJUSTMENTSCREW ON PURGE TIMER AFTERMFG. PURGE TESTING.

BATTERYPACK

TO ISBGND BAR

GRN/YEL

FactoryMutualSystemApproved PER DWG.

ASSEMBLY NO.

SERIAL NO.

MADE IN USA

XXXXEO–3287–XXX

SEE MECHANICAL ASSEMBLYFOR TAG NUMBER.

STAMP NUMBER AS SHOWN

2

3

FOR CONNECTION TO:CLASS I, II & III DIV. 1GRP. C,D,E,F & G HAZ. LOC.

EE–3287–550

2000 SOUTH ADAMS RD. AUBURN HILLS, MI 48326

VIEW LOCATED IN CIRCLE ”A”

”A”

14 AWG.

SYSTEM R–J2

CONTROLLER DOOR INSIDE VIEW

ISBUNIT

EMGBOARD

I/O RACK

MODEL P–200 R–J2

I.S. GNDNOTE

OFF

ON


AMP 3

MAINPSUCPU

P–200 R–J2ILLUSTRATED


STATUS

8

0

1

AMP 4

3

2

EE–3287–575

CABINET LAYOUT

12–42

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–43

Figure 12–21. P-200 R-J2 Robot Control Drawing Purge and Intrinsic Wiring sheet 1



OPERATORPANEL

EMGIN1EMGIN2

E–STOP PCB

CRR5

CRR22

BKP4BKM4

CRR21

CNIN

CNCA

CNPG

PURGE CIRCUITS

CRM10

MAIN CPU

CNPG PANEL I/F

BRAKE CONTROL

RDI/RDO

220 VAC

+24P

0V

220V (43)

220V (44)

SERVO TRANSFORMER


SOL1

SOL2

A1

A2

A3

A4

A5

A6

C1

C2

C3

C4

C5

C6

P1

P2

P3

P4

P5

P6

N1

N2

N3

N4

N5

N6

123456789101112131415161718192021222324


EOAT1EOAT2

ISTB


1 32

STAHL 9001/01–252–100–14

4

14

PRESSURESWITCH

OPENERPRESS

SWITCH

FLOWSWITCH

OPENERFLOW

SWITCH

PURGESOLENOID

VALVE

+V

0V

G

R

SAC

+24VDC PSU

FIRE ALARM

CNIS

32

ISB1

ISB2

PRESSURESWITCH

FLOW

ROBOTOVERTRAVEL

HANDBROKEN

TPDISCONNECT

MISC.

(RDI2)

SWITCH

SWITCH

SWITCH

SWITCH

EE–3044–345–001

EE–3044–340–001

EE–3287–348–001

ROBOT

ROBOT

OPTIONAL

ENCODER







ROBOT PURGED CAVITY

ENCODER

IS GND

IS GND


MODEL

MODEL

MODEL

MODEL

P–200–6–J2

P–200–7–J2

P–200–6+2–J2

P–200–7+2–J2

+

+

1

6I.S. GND

I.S.BATTERY

PACK



1.)

2.)

3.)


SOLENOID CABLE

IBRC6062R

(FMRC APPROVED)

FRAME GND.

TO CRS1

(MAIN CPU)

F1 F2 F3 F4 F5

I/S TEACH PENDANT

I/SGROUND

A05B–2308–C300


MODEL P–200–7+3–J2

24VDCPOWERSUPPLY

120VACFROM

CONVEYOR

OVPUNIT

EE–3112–600

24V 24V

789101112

ISB3

ISB4

46


12


12

91078

+24

+

+

+

24V

I/PSIG ISB5

KHD2–CD–1.P32

78

34

1ISB6

56

2+

+

24V

SIGZ787

127

8 +ISB7 Z728

127

8 +Z728ISB8

+

+

ISB3–4ISB3–6


ISB6–1

ISB7–1

ISB8–1

ISB5–2

ISB6–2ISB6–4

ISB7–2

ISB8–2

TO ACCUFLOW

FROM I/O

FROM I/O

FROM I/O

P&F

P&F

P&F

P&F

P&F


I/P

UNIT

FLOWMETER

TRIGGER 1

TRIGGER 2

DELTRONW112A

EE–3287–324–001

M1

EE–3185–356–001N1 N4

M4

P1 P4

HAND BRKNO1 O4

PRES. SW CABLE

FLOW SW CABLE

M1

M1

S1 S4

M4

M4

SOL SOL

PS1 PS1

FS1 FS1

BATT

OPTIONAL DOOR OPENER DEVICE

OPENERSOLENOID


EE–3066–215–00XAK1

AJ1

AH1

X2

AE1

AK2 AK3 AK4

AJ2 AJ3 AJ4

AH2 AH3 AH4

AE2EE–3066–316–001

EE–3066–321–001

EE–3066–322–001

EE–3066–323–001

I.S. GND

I.S. GND

MODEL Q–DRQ

IDEC

AE3 AE4

EE-3287-550-001

BATT

12–44

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–45

Figure 12–22. P-200 R-J2 Robot Control Drawing Purge and Intrinsic Wiring sheet 2

TITLE:



OPERATORPANEL

EMGIN1EMGIN2

E–STOP PCB

CRR5

CRR22

BKP4BKM4

CRR21

CNIN

CNCA

CNPG

PURGE CIRCUITS

CRM10

MAIN CPU

CNPGPANEL I/F

BRAKE CONTROL

RDI/RDO

220 VAC

+24P

0V

220V (43)220V (44)

SERVO TRANSFORMER


SOL1

SOL2

A1

A2

A3

A4

A5

A6

C1

C2

C3

C4

C5

C6

P1

P2

P3

P4

P5

P6

N1

N2

N3

N4

N5

N6

123456789101112131415161718192021222324


EOAT1EOAT2

IZUMI

ISTB


1 32

STAHL 9001/01–252–100–14

4

14

PRESSURESWITCH

OPENERPRESS

SWITCH

FLOWSWITCH

OPENERFLOWSWITCH

PURGESOLENOID

VALVE

+V

0V

G

R

SAC

+24VDC PSU

FIRE ALARM

CNIS

32

ISB1

ISB2

PRESSURESWITCH

FLOW

ROBOTOVERTRAVEL

HANDBROKEN

TPDISCONNECT

MISC.

(RDI2)

SWITCH

SWITCH

SWITCH

SWITCH

EE–3044–345–001

EE–3044–340–001

EE–3287–348–001

ROBOT

ROBOT

OPTIONAL



HAZARDOUS LOCATION CLASS I, II & IIIDIVISION 1 GROUPS C D E F & G



ROBOT PURGED CAVITY

ENCODER

IS GND

IS GND


MODEL

MODEL

MODEL

MODEL

P–200–6–J2

P–200–7–J2

P–200–6+2–J2

P–200–7+2–J2

+

+

1

6

I.S. GND

I.S.BATTERY

PACK

NOTES:

ACCEPTABLE I.S. BATTERY PACKS:A05B–2363–C040EE–3185–551


1.)

2.)

3.)


SOLENOID CABLE

IBRC6062R

(FMRC APPROVED)

FRAME GND.

TO CRS1(MAIN CPU)

F1F2F3F4F5

I/S TEACH PENDANT

I/SGROUND

A05B–2308–C300


MODEL P–200–7+3–J2

24VDCPOWERSUPPLY

120VAC

FROMCONVEYOR

OVPUNIT

EE–3112–600

24V 24V

789101112

ISB3

ISB4

46


12


12

91078

+24

+

+

+

24V

I/PSIG ISB5

KHD2–CD–1.P32

78

34

1ISB65

6

2+

+

24V

SIGZ787

127

8 +ISB7 Z728127

8 +Z728ISB8

+

+

ISB3–4

ISB3–6

ISB4–1ISB4–2

ISB5–1

ISB6–1

ISB7–1

ISB8–1

ISB5–2

ISB6–2ISB6–4

ISB7–2

ISB8–2

TO ACCUFLOW

FROM I/O

FROM I/O

FROM I/O

P&F

P&F

P&F

P&F

P&F

EE–3287–328–001 CBL

BYPASSSWITCH

I/P

UNIT

FLOWMETER

TRIGGER 1

TRIGGER 2

DELTRONW112A

EE–3287–324–001

M1

EE–3185–356–001N1 N4

M4

P1 P4

O1 O4

PRES. SW CABLE

FLOW SW CABLE

M1

M1

S1 S4

M4

M4

SOL SOL

PS1 PS1

FS1 FS1

BATT BATT

OPENER

SOLENOID


EE–3067–215–00XAK1

AH1

X2

AE1

AK2 AK3 AK4

AJ2 AJ3 AJ4

AH2 AH3 AH4

AE2 AE3 AE4EE–3066–316–001

EE–3066–321–001

EE–3066–322–001

EE–3066–323–001

OPTIONAL HOOD/DECK OPENER DEVICE

OT

OT

OT OT

OT OT

EE–3067–317–001

AJ1

I.S. GND

I.S. GND

MODEL Q–HDQ

HANDBRKN

ENCODER

EE-3287-550-002

12–46

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–47

Figure 12–23. P-200 R-J2 Control Drawing Purge and Intrinsic Wiring Sheet 3

NOTICE

NO REVISIONS WITHOUT PRIORAPPROVAL FROM FACTORY MUTUAL (FM)

OPERATORPANEL

EMGIN1EMGIN2

E–STOP PCB

CRR5

CRR22

BKP4BKM4

CRR21

CNIN

CNCA

CNPG

PURGE CIRCUITS

CRM10

MAIN CPU

CNPG PANEL I/F

BRAKE CONTROL

RDI/RDO

220 VAC

+24P

0V

220V (43)220V (44)

SERVO TRANSFORMERFOR PAINT R–J2 TYPE

SOL1

SOL2

A1

A2

A3

A4

A5

A6

C1

C2

C3

C4

C5

C6

P1

P2

P3

P4

P5

P6

N1

N2

N3

N4

N5

N6

123456789101112131415161718192021222324


EOAT1EOAT2

ISTB


1 32

STAHL 9001/01–252–100–14

4

14

PRESSURESWITCH

OPENERPRESS

SWITCH

FLOWSWITCH

OPENERFLOW

SWITCH

PURGESOLENOID

VALVE

+V

0V

G

R

SAC

+24VDC PSU

FIRE ALARM

CNIS

32

ISB1

ISB2

PRESSURESWITCH

FLOW

ROBOTOVERTRAVEL

HANDBROKEN

TPDISCONNECT

MISC.

(RDI2)

SWITCH

SWITCH

SWITCH

SWITCH

EE–3044–345–001

EE–3044–340–001

EE–3287–348–001

ROBOT

ROBOT

OPTIONAL

ENCODER



HAZARDOUS LOCATION CLASS I, II & IIIDIVISION 1 GROUPS C D E F & G



ROBOT PURGED CAVITY

ENCODER

IS GND

IS GND


MODELMODELMODELMODEL

P–200–6–J2P–200–7–J2P–200–6+2–J2P–200–7+2–J2

+

+

1

6

I.S. GND

I.S.BATTERY

PACK



1.)

2.)

3.)


SOLENOID CABLE

IBRC6062R

FRAME GND.

TO CRS1(MAIN CPU)

F1 F2 F3 F4 F5

I/S TEACH PENDANT

I/SGROUND

A05B–2308–C300


MODEL P–200–7+3–J2

24VDCPOWERSUPPLY

120VACFROM

CONVEYOR

OVPUNIT

EE–3112–600

24V 24V

789101112

78

91112

ISB3

ISB4

4

46

6


127824V KFD2–SD–EX1.3612910

78+24+

+

+

24V

I/PSIG ISB5

KHD2–CD–1.P32

78

34

1ISB65

6

2+

+24VSIG Z787

1278 +ISB7 Z7281278 +Z728ISB8

+

+

+24V

+

+24V

ISB3–4ISB3–6


ISB6–1

ISB7–1

ISB8–1

ISB5–2

ISB6–2ISB6–4

ISB7–2

ISB8–2

TO ACCUFLOW

FROM I/O

FROM I/O

TO I/O

FROM I/O

ISB9 KHD2–SR–EX1.P

P&F

P&F

P&F

P&F

P&F

P&F


I/PUNIT

FLOWMETER

TRIGGER 1

TRIGGER 2

DELTRONW112A

EE–3287–324–001

M1

EE–3185–356–001N1 N4

M4

P1 P4

O1 O4

PRES. SW CABLE

FLOW SW CABLE

M1

M1

S1 S4

M4

M4

SOL SOL

PS1 PS1

FS1 FS1

BATT BATT

OPENERSOLENOID

DOORSENSOR

X3

OPTIONAL P–10 DOOR OPENER DEVICEEE–3186–115–1XXAG1

AH1

AJ1

AK1

AL1 AM1 AN1

AG4

AK4

AJ4

AH4

I.S. GND

I.S. GND

IDEC

HANDBRKN

EE-3287-550-003

12–48

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–49

Figure 12–24. P-200 R-J2 Pedestal North American Purge, No PGS (Seal Off Req’d) Cable Layout

50MM

CABLE

GNDCLAMP

CABLESHIELD

AT CONTROLLER ENTRANCEGROUNDING OF NON–IS SHIELDED CABLE

FS1

SOL1

PS1

EE–3287–340–001

EE–3044–345–001

FS1

PS1INTRINSIC DEVICE

HARNESS

INTRINSIC BATTERYHARNESS AXIS 1–6

BATTERY

I.S. GND

EE–3287–323–001

EE–3287–324–001

T–14685

4

2 M4

S4S1

R1

N1

M1

CONNECTSHIELD TO

IS GND

SOL

FS/PS

BYPASS SWEE–3185–356–001

2BYPASS

INTRINSIC 20.5MM

EE–3287–116–

005010015017035045055030033

EE–3287–117–EE–3287–117–EE–3287–117–EE–3287–117–EE–3287–117–EE–3287–117–EE–3287–117–EE–3287–117–EE–3287–117–

055

I/PPROPORTIONAIR

TRIGGER

FLOW METER

HND BROKEN

TO ISTB

TO ISB1

TO ISB3

2I/P POWER

I/P SIG

FLOW MTR

TRIG 1

TRIG 2

TO ISB4

TO ISB5

TO ISB6

TO ISB7

TO ISB8

3

2

2

2

2

HBKTO ISTB

BATTERY

BATTERY

2

2

2

TRIGGER

O1

P1

EE–3287–328–001

PG29

PG11

POWER

POWER & BRK

POWER & BRK

POWER & BRK

PULSE BAT

BRK

POWER

PULSE BAT

BRK

POWER

PULSE BAT

BRK

EE

–304

4–40

1

6 AXIS ROBOT HARNESS AND CABLE LAYOUT

UPPER LEVEL BILL OF MATERIALBATTERY IN CONTROLLER

DC/DC CONVERTER

AXIS 4, 5 & 6 PWR & PULSE HARNESS

AXIS 1, 2 & 3PWR & PULSE HARNESS

CONTROLLER GROUND

CRF1

A1 A4

B1 B4

C1 C4

D1 D4

E1

H1 H4

J1 J4

K1 K4

L1

F1

JF7

AXIS 4AXIS 5AXIS 6

AXIS 1

AXIS 2

AXIS 3

444

24PG, 0PG

8

8

3

aMODEL

MODEL

MODEL

a

a

MODEL

MODEL

MODEL

a

a

a

PULSE & BATT

PULSE & BATT

PULSE & BATT

6BRAKES

BRAKES

BRAKES

4

4

OUTER ARMGROUND

ROBOT ARM

INNER ARMGROUND

TURRETGROUND

4

12

EE–3287–322–001

EE–3287–321–001

R–J2 CONTROLLER

T–14107

T–14685

T–14379

T–14379

0.5

SEAL OFFS USEDWITH NA PEDESTAL

EE–3287–301–011

6/3000

22/3000

12/3000

2/3000

2/3000

AMP 1AMP 2AMP 3

EMG BD

AUX AXIS BD

PURGE UNIT PGTBCHASSISGROUND

AMP 1

AMP 4

AMP 2

CABLE CLAMP

SHIELD TO

(L)(L)(L)

PURGE BD (BK)

(M)

(M)

PURGE BD (BK)

PURGE BD (BK)

GND

MOTOR

PULSE

MOTOR

MOTOR

UPPER LEVEL BOMS

13.5MM

19.8MM

21.0MM

21.0MM

6.9MM

CONNECTION CABLE SETS W/O PG

EE–3287–111–EE–3287–111–EE–3287–111–EE–3287–111–EE–3287–111–EE–3287–111–EE–3287–111–

005010015025035045055

EE–3287–113–EE–3287–113–EE–3287–113–EE–3287–113–EE–3287–113–EE–3287–113–EE–3287–113–

005010015025035045055

EE–3287–110–EE–3287–110–EE–3287–110–EE–3287–110–EE–3287–110–EE–3287–110–EE–3287–110–

005010015025035045055

EE–3287–112–EE–3287–112–EE–3287–112–EE–3287–112–EE–3287–112–EE–3287–112–EE–3287–112–

005010015025035045055

EE–3287–116–EE–3287–116–EE–3287–116–EE–3287–116–EE–3287–116–EE–3287–116–

EE–3287–100–EE–3287–100–EE–3287–100–EE–3287–100–

EE–3287–100–EE–3287–100–EE–3287–100–

005010015025

035045055

005010015017035045

5M10M15M25M

35M45M55M

(NO PG FITTINGS)

NOT USED

BATTERY 2

P4

EE–3287–348–001

AXIS 6 A06B–0113–B078/0008

AXIS 5

AXIS 4

A06B–0373–B175

A06B–0373–B175

AXIS 1

AXIS 2

AXIS 3 A06B–0143–B175/0008

A06B–0148–B675

A06B–0128–B175

SOL1

I/P

TRIG

TRIG2

FLOW

OPTIONALBYPASS

OPTIONAL

EE-3287-001

12–50

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–51

Figure 12–25. P-200 R-J2 Rail Robot North American Purge, PGS For Penetration Plate Cable Layout

FS1

SOL1

PS1

EE–3287–340–001

EE–3044–345–001

FS1

PS1INTRINSIC DEVICE

HARNESS


BATTERY

I.S. GND

EE–3287–323–001

EE–3287–324–001

T–14685

4

2 M4

S4S1

R1

N1

M1

CONNECTSHIELD TO

IS GND

SOL

FS/PS


2BYPASS

INTRINSIC20.5MM005010015017035045055030033


I/PPROPORTIONAIR

TRIGGER

FLOW METER

HND BROKEN

TO ISTB

TO ISB1

TO ISB3

2I/P POWER

I/P SIG

FLOW MTR

TRIG 1

TRIG 2

TO ISB4

TO ISB5

TO ISB6

TO ISB7

TO ISB8

3

2

2

2

2

HBKTO ISTB

BATTERY

BATTERY

2

2

2 TRIGGER

O1

P1

EE–3287–328–001

PG29

PG11

POWER

POWER & BRK

POWER & BRK

POWER & BRK

PULSE BAT

BRK

POWER

PULSE BAT

BRK

POWER

PULSE BAT

BRK

EE

–304

4–40

1


UPPER LEVEL BILL OF MATERIAL

DC/DC CONVERTER

CONTROLLER GROUND

CRF1

GND

MOTOR

PULSE

MOTOR

MOTOR

A1 A4

B1 B4

C1 C4

D1 D4

E1

H1 H4

J1 J4

K1 K4

L1

F1

JF7

AXIS 4AXIS 5AXIS 6

AXIS 1

AXIS 2

AXIS 3

AXIS 7

444

8

8

24PG, 0PG

8

8

UPPER LEVEL BOMS

13.5MM

19.8MM

3

21.0MM

21.0MM

6.9MM

aMODEL

MODEL

MODEL

a

a

2

2

MODEL

MODEL

MODEL

a

a

a

12

22

6

PULSE & BATT

PULSE & BATT

PULSE & BATT

6BRAKES

BRAKES

BRAKES

4

4

POWER & BK

EE–3185–316–001

EE–3287–339–001

PULSE & BATTMODEL a 12

ROBOT ARM

T–14107

T–14685

T–14379

T–14379

0.5

R–J2 CONTROLLER



OUTER ARMGROUND

INNER ARMGROUND

TURRETGROUND

EE–3287–322–001

EE–3287–321–001

EE–3287–111EE–3287–111EE–3287–111

EE–3287–111EE–3287–111EE–3287–111EE–3287–111

–105–110–115

EE–3287–113EE–3287–113EE–3287–113EE–3287–113EE–3287–113EE–3287–113EE–3287–113

–105–110–115

EE–3287–110–105–110–115

EE–3287–110EE–3287–110EE–3287–110EE–3287–110EE–3287–110EE–3287–110

EE–3287–112EE–3287–112EE–3287–112EE–3287–112EE–3287–112EE–3287–112EE–3287–112

–105–110–115

EE–3287–116EE–3287–116EE–3287–116

EE–3287–116EE–3287–116EE–3287–116EE–3287–116

–105–110–115

/3000

/3000

/3000

/3000

/3000

/3000

EE–3287–102EE–3287–102EE–3287–102EE–3287–102EE–3287–102EE–3287–102EE–3287–102

–105–110–115–125–135

5M10M15M25M35M

CONNECTION CABLE SETS W/ (2) PG

EE–3287–302–011

BATTERY IN CONTROLLER, NA PURGE

–145–155

45M55M

–125–135–145–155

–125–135–145–155

–125–135–145–155

–125–135–145–155

–125–135–145–155

AMP 1AMP 2AMP 3

EMG BD

AUX AXIS BDCABLECLAMP SHIELD TOCHASSISGROUND

AMP 1

AMP 4

AMP 2

AMP 3

PURGE UNIT

PG 29

PG 29

PG 29

PG 29

PG 9

(L)(L)(L)

PURGE BD (BK)

PURGE BD PGTB

(M)

(M)

PURGE BD (BK)

(M)

(M)

PG29 EE–3185–344–001

NON–HAZARDOUS HAZARDOUS

AXIS 1

AXIS 2

AXIS 3

AXIS 4

AXIS 5

AXIS 6

AXIS 7

A06B–0128–B175

A06B–0148–B675

A06B–0143–B175/0008

A06B–0143–B175/0008

A06B–0373–B175

A06B–0373–B175

A06B–0113–B078/0008

EE–3287–348–0001

P4

R4

BATTERY 2

SOL1

I/P

TRIG

TRIG2

FLOW

OPTIONALBYPASS

OPTIONAL

EE-3287-002

12–52

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–53

Figure 12–26. P-200 R-J2 Pedestal Robot PTB Purge, PGS For Penetration Plate Cable Layout

POWER

POWER & BRK

POWER & BRK

POWER & BRK

PULSE BAT

BRK

POWER

PULSE BAT

BRK

POWER

PULSE BAT

BRK

EE

–304

4–40

1



DC/DC CONVERTER



CONTROLLER GROUND

CRF1

A1 A4

B1 B4

H1 H4

J1 J4

K1 K4

L1

F1

50MM

CABLE

GNDCLAMP

CABLESHIELD

AT CONTROLLER ENTRANCE

JF7

AXIS 4AXIS 5AXIS 6

AXIS 1

AXIS 2

AXIS 3

AXIS 7

444

24PG, 0PG

8

8

UPPER LEVEL BOMS

3

aMODEL

MODEL

MODEL

a

a

2

2

MODEL

MODEL

MODEL

a

a

a

12

22

6

PULSE & BATT

PULSE & BATT

PULSE & BATT

6BRAKES

BRAKES

BRAKES

4

4

OUTER ARMGROUND

ROBOT ARM

INNER ARMGROUND

TURRETGROUND

BOOTHWALL

4

12

EE–3287–322–001

EE–3287–321–001

R–J2 CONTROLLER

T–14107

T–14685

T–14379

T–14379

PG29

PG29

PG29

PG29

PG9

0.5

BATTERY IN CONTROLLER, PTB PURGE

GND

MOTOR

PULSE

MOTOR

MOTOR

13.5MM

19.8MM

21.0MM

21.0MM

6.9MM

EE–3287–111EE–3287–111EE–3287–111

EE–3287–111EE–3287–111EE–3287–111EE–3287–111

–105–110–115

EE–3287–113EE–3287–113EE–3287–113EE–3287–113EE–3287–113EE–3287–113EE–3287–113

–105–110–115

EE–3287–110–105–110–115

EE–3287–110EE–3287–110EE–3287–110EE–3287–110EE–3287–110EE–3287–110

EE–3287–112EE–3287–112EE–3287–112EE–3287–112EE–3287–112EE–3287–112EE–3287–112

–105–110–115

EE–3287–116EE–3287–116EE–3287–116

EE–3287–116EE–3287–116EE–3287–116EE–3287–116

–105–110–115

EE–3287–102EE–3287–102EE–3287–102EE–3287–102EE–3287–102EE–3287–102EE–3287–102

–105–110–115–125–135

5M10M15M25M35M

CONNECTION CABLE SETS W/ 2 PG

EE–3287–303–011

–145 45M–155 55M

–125–135–145–155

–125–135–145–155

–125–135–145–155

–125–135–145–155

–125–135–145–155

AMP 1

AMP 1

AMP 2AMP 3

AMP 4

PURGE UNIT PGTB

EMG BD

AUX AXIS BD

AMP 2

AMP 3

CLAMP SHIELD TO

CHASSISGROUND

GROUNDING OF NON–IS SHIELDED CABLE

C3C1

D1

E1

C4

D3 D4

EE–3185–601

EE–3185–602

(L)(L)(L)

PURGE BD (BK)

(M)

(M)

(M)

(M)

PURGE BD (BK)

PURGE BD (BK)

HAZARDOUSNON–HAZARDOUS

FS1

PS1INTRINSIC DEVICE

HARNESS


BATTERY

I.S. GND

EE–3287–323–001

EE–3287–324–001

T–14685

4

2 M4

S4S1

R1

N1

M1

CONNECTSHIELD TO

IS GND

SOL

FS/PS


2BYPASS

INTRINSIC 20.5MM005010015017035045055030033


I/PPROPORTIONAIR

TRIGGER

FLOW METER

HND BROKEN

TO ISTB

TO ISB1

TO ISB3

2I/P POWER

I/P SIG

FLOW MTR

TRIG 1

TRIG 2

TO ISB4

TO ISB5

TO ISB6

TO ISB7

TO ISB8

3

2

2

2

2

HBKTO ISTB

BATTERY

BATTERY

2

2

2

TRIGGER

O1

P1

EE–3287–328–001

PG29

PG11

SOL1 SOLENOIDSOL1

EE–3044–341–001

EE–3287–348–001

PRES.CONTROL

UNIT

AXIS 1

AXIS 2

AXIS 3

AXIS 4

AXIS 5

AXIS 6

A06B–0128–B175

A06B–0148–B675

A06B–0143–B175/0008

A06B–0373–B175

A06B–0373–B175

A06B–0113–B078/0008

P4

BATTERY 2

I/P

TRIG

TRIG2

FLOW

OPTIONALBYPASS

OPTIONAL

PG29

EE-3287-003

12–54

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–55

Figure 12–27. P-200 R-J2 Rail Robot PTB Purge, PGS For Penetration Plate

POWER

POWER & BRK

POWER & BRK

POWER & BRK

PULSE BAT

BRK

POWER

PULSE BAT

BRK

POWER

PULSE BAT

BRK

EE

–304

4–40

1



DC/DC CONVERTER

CONTROLLER GROUND

CRF1

A1 A4

B1 B4

H1 H4

J1 J4

K1 K4

L1

F1

JF7

AXIS 4AXIS 5AXIS 6

AXIS 1

AXIS 2

AXIS 3

AXIS 7

444

8

8

24PG, 0PG

8

8

3

aMODEL

MODEL

MODEL

a

a

2

2

MODEL

MODEL

MODEL

a

a

a

12

22

6

PULSE & BATT

PULSE & BATT

PULSE & BATT

6BRAKES

BRAKES

BRAKES

4

4

POWER & BK

EE–3185–316–001

EE–3287–339–001

PULSE & BATTMODELa 12


ROBOT ARM

50MM

CABLE

GNDCLAMP

CABLESHIELD

AT CONTROLLER ENTRANCE

T–14107

T–14685

T–14379

T–14379

0.5

R–J2 CONTROLLER



OUTER ARMGROUND

INNER ARMGROUND

TURRETGROUND

EE–3287–322–001

EE–3287–321–001

BATTERY IN CONTROLLER, PTB PURGE

EE–3287–304–011

GND

MOTOR

PULSE

MOTOR

MOTOR

UPPER LEVEL BOMS

13.5MM

19.8MM

21.0MM

21.0MM

6.9MM

EE–3287–111EE–3287–111EE–3287–111

EE–3287–111EE–3287–111EE–3287–111EE–3287–111

–105–110–115

EE–3287–113EE–3287–113EE–3287–113EE–3287–113EE–3287–113EE–3287–113EE–3287–113

EE–3287–112EE–3287–112EE–3287–112EE–3287–112EE–3287–112EE–3287–112EE–3287–112

–105–110–115

EE–3287–116EE–3287–116EE–3287–116

EE–3287–116EE–3287–116EE–3287–116EE–3287–116

–115

EE–3287–102EE–3287–102EE–3287–102EE–3287–102EE–3287–102EE–3287–102EE–3287–102

–105–110–115–125–135

5M10M15M25M35M

CONNECTION CABLE SETS W/ (2) PG

–145 45M–155 55M

–125–135–145–155

–125–135–145–155

AMP 1AMP 2AMP 3

AMP 4

AMP 1

AMP 2

AMP 3

EMG BD

AUX AXIS BD

PURGE UNIT PGTB

CLAMPSHIELD TOCHASSIS GROUND

GROUNDING OF NON–IS SHIELDED CABLE

PG 29

PG 29

PG 29

PG 29

PG 29

PG 9

C3C1

D1

E1

C4

D3 D4

EE–3185–601EE–3185–602

E3 E4

EE–3185–603

(L)(L)(L)

PURGE BD (BK)

(M)

(M)

(M)

PURGE BD (BK)

PURGE BD (BK)


PG 29

FS1

PS1INTRINSIC DEVICE

HARNESS


BATTERY

I.S. GND

EE–3287–323–001

EE–3287–324–001

T–14685

4

2 M4

S4S1

R1

N1

M1

CONNECTSHIELD TOIS GND

SOL

FS/PS


2BYPASS

INTRINSIC 20.5MM005010015017

045055

I/PPROPORTIONAIR

TRIGGER

FLOW METER

HND BROKEN

TO ISTB

TO ISB1

TO ISB3

2I/P POWER

I/P SIG

FLOW MTR

TRIG 1

TRIG 2

TO ISB4

TO ISB5

TO ISB6

TO ISB7

TO ISB8

3

2

2

2

2

HBKTO ISTB

BATTERY

BATTERY

2

2

2

TRIGGER

O1

P1

EE–3287–328–001

PG29

PG11

SOLENOIDSOL1

EE–3044–341–001

EE–3287–348–001

DRUCKWACHTERFS–810

SOL

AXIS 1

AXIS 2

AXIS 3

AXIS 4

AXIS 5

AXIS 6

AXIS 7

A06B–0128–B175

A06B–0148–B675

A06B–0143–B175/0008

A06B–0143–B175/0008

A06B–0373–B175

A06B–0373–B175

A06B–0113–B078/0008

E–3185–344–001

P4

R4

BATTERY 2

I/P

TRIG

TRIG2

FLOW

OPTIONALBYPASS

OPTIONAL

EE

–304

4–40

1

DC/DC CONVERTER

CRF1

A1 A4

B1 B4

H1 H4

J1 J4

K1 K4

L1

F1

JF7

AXIS 4AXIS 5AXIS 6

AXIS 1

AXIS 2

AXIS 3

AXIS 7

444

8

8

24PG, 0PG

8

8

3

a

a

a

2

2

a

a

22

6

6

4

4 EE–3185–316–001

EE–3287–339–001 a 12


ROBOT ARM

50MM

CABLESHIELD

T–14107

T–14685

T–14379

T–14379

0.5

R–J2 CONTROLLER


GROUND

EE–3287–322–001

GND

MOTOR

PULSE

MOTOR

MOTOR

UPPER LEVEL BOMS

13.5MM

19.8MM

21.0MM

21.0MM

6.9MM

EE–3287–111EE–3287–111

EE–3287–112

EE–3287–116

–105–110

EE–3287–102

–145

–125–135–145–155

AMP 1AMP 2AMP 3

AMP 4

AMP 1

AMP 2

AMP 3

EMG BD

AUX AXIS BD

PG 29

PG 29

PG 29

PG 29

PG 29

PG 9

C3C1

D1

E1

C4

D3 D4

E3 E4

(L)(L)(L)

(M)

(M)

(M)


PG 29

FS1

PS1

BATTERY

I.S. GND

T–14685

M4

S4S1

R1

N1

M1SOL

FS/PS

BYPASS SW2BYPASS

INTRINSIC 20.5MM

035

030033


TRIGGER

HND BROKEN

TO ISTB

TO ISB1

TO ISB3

2I/P POWER

I/P SIG

FLOW MTR

TRIG 1

TRIG 2

TO ISB4

TO ISB5

TO ISB6

TO ISB7

TO ISB8

2

HBKTO ISTB

BATTERY

BATTERY

TRIGGER

O1

P1

EE–3287–328–001

PG29

PG11

SOLENOIDSOL1

EE–3044–341–001

EE–3287–348–001

DRUCKWACHTER

SOL

AXIS 1

AXIS 3

AXIS 4

AXIS 5

AXIS 6

AXIS 7

A06B–0143–B175/0008

A06B–0143–B175/0008

A06B–0373–B175

A06B–0373–B175

A06B–0113–B078/0008

E–3185–344–001

P4

R4

BATTERY

I/P

OPTIONALBYPASS

OPTIONAL

–105–110–115–125–135–145–155

EE–3287–110–105–110–115

EE–3287–110EE–3287–110EE–3287–110EE–3287–110EE–3287–110EE–3287–110

–125–135–145–155

EE-3287-004

12–56

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–57

Figure 12–28. P-200 Controller Basic Process Option I/P Flow and Trigger

DELTRONW112A

24V @ 1.2A

IDEC IBRCB

YP

AS

S L

S

I/P

TR

IGG

ER

FLO

W

2ND

TR

IGG

ER

P–1

0 M

AG

NE

T

SO

LEN

OID

SO

LEN

OID

I/P P

OW

ER

ISB1ISB2

EE–3287–510

ISB3 ISB4 ISB5 ISB6 ISB7 ISB8 ISB9

P&

F K

FD

2–S

D–E

X1.

36

KF

D2–

CD

–EX

1.32

EE

–311

2–60

0–00

1

EE

–311

2–60

0

Z78

7

Z72

8

P–200 CONTROLLER BACKPANEL

UPPER LEFT CORNER

ISTB TERMINAL STRIP

1’’

IS GND FOR CABLE WIRING, SEE EE–3287–500

SHIELD CONNECTS TO INTRINSICALLY SAFE GROUND

EE–3287–117–XXX

TYPICAL INTRINSICALLY SAFE CABLE ROUTING

NOTES:

FOR CONTROLS WIRING, SEE EE–3287–500 AND APPLICATION PACKAGE

MAINTAIN 50MM SPACING I.S. WIRING ANDALL OTHER CIRCUITS, INCL EE–3112–600

SEE DETAIL 1

DETAIL 1

INTRINSICALLY SAFE GROUND CONNECTION

ZENER BARRIERS MOUNTEDON INSULATING BLOCK

9

PS OVP

1 2 3 4 8

6 7

NOTICE

NO REVISIONS WITHOUT PRIOR APPROVAL FROM FACTORY MUTUAL (FM)

12–58

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–59

Figure 12–29. P-200 Controller Process Option Basic Option With Second Trigger

DELTRONW112A

24V @ 1.2A

BY

PA

SS

LS

I/P

TR

IGG

ER

FLO

W

2ND

TR

IGG

ER

P–1

0 M

AG

NE

T

SO

LEN

OID

SO

LEN

OID

I/P P

OW

ER

ISB1ISB2

EE–3287–511

ISB3 ISB4 ISB5 ISB6 ISB7 ISB8 ISB9

P&

F K

FD

2–S

D–E

X1.

36

KF

D2–

CD

–EX

1.32

EE

–311

2–60

0–00

1

EE

–311

2–60

0 Z78

7

Z72

8


UPPER LEFT CORNER

ISTB TERMINAL STRIP

1’’

IS GND FOR CABLE WIRING, SEE EE–3287–500

EE–3287–117–XXX

NOTES:



SEE DETAIL 1

DETAIL 1


9

1 2 3 4 4 8

6 7



IDEC IBRC




12–60

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–61

Figure 12–30. P-200 Controller Bypass Option

DELTRONW112A

24V @ 1.2A

KH

D2–

SR

–EX

1.P

BY

PA

SS

LS

I/P

TR

IGG

ER

FLO

W

2ND

TR

IGG

ER

P–1

0 M

AG

NE

T

SO

LEN

OID

SO

LEN

OID

I/P P

OW

ER

ISB1ISB2

EE–3287–512

ISB3E

E–3

112–

600–

001

EE

–311

2–60

0 Z78

7

Z72

8


UPPER LEFT CORNER

ISTB TERMINAL STRIP

1’’

IS GNDFOR CABLE WIRING, SEE EE–3287–500

EE–3287–117–XXX

NOTES:



SEE DETAIL 1

DETAIL 1


9

PS OVP

12 3 4

5



IDEC IBRC




12–62

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–63

Figure 12–31. AccuFlow Counter Input Board

RESET CNTR

BEGIN CNT’G

SET NEW DATA C15

LS161A

34 5

67

8 9

10

1615

18

17

19

14

13

1211C

15

LS161A

STOP CNTR

TRANSFER COUNT

10US

16MS

C

D

A

11

9

10

100KHZ

0V

LS221

3

1614 15

8

13

1

2

5V

11514131112910

316

4 2

6

5

8

7 A<B

A=B

A>B

5V

LS85

C

D

Q3

2

1

CL

PR 1

2

LS–164

7

14

CLK

QA

QB

QC

QD

3

4

5

6

8

QE10

9

11

12

13

QF

QG

QHCLR

A

B

C

D

C

D

Q

CL

PR

S

R

Q2

31

4

S

R

Q

ONESHOT

S

R

Q

Q

LS221

14

13

1211

14

13

1211

14

13

1211

VCC=PIN 160V=PIN 8

LS161A

LS161A

LS161A

15

15

15

1 2 10 7

1 2 10 7

1 2 10 7

1 2 10 7

VCC

VCC

96543

96543

96543

96543

96543

96543

1 2 10 7

1 2 10 7

LS161A

96543

96543

15

15

15

11

12

13

14

11

12

13

14

11

12

13

14

11

12

13

14

1 2 10 7

1 2 10 7

1

3

59

1113

2

4

6

8

10

12

13

5

9

11

13

1

3

5

9

11

13

2

4

6

8

10

12

2

4

6

8

10

12

24V

OC

OC

OC

7407

7407

7407

24V

1

3

5

9

11

13

2

4

6

8

10

12

1

3

5

9

11

13

1

3

5

9

11

13

2

4

6

8

10

12

2

4

6

8

10

12

24V

OC

OC

OC

7407

7407

7407

24V

VCC=PIN 14

VCC=PIN 140V=PIN 7

0V=PIN 7

+5V

+24V

TERM

BLOCK

JP1

JP2

1

2

4

51N4148

5V

5V

3.3K

LS04

LS04

1 2

3 4

5 6

1/2

0.01UF

10K

70US

12

A CLK

A CLK

345 6

1312

91011

8

9 8

LS279

LS279

LS279

5

6 7

10

1112 9

6 7

10911 5

20

13

14

2

12

1

11

B

56

9

1615

19

2

12

34

7

8

18

17

13

14

LS273

LS273

B

111 10

8

7

14

1100KHZ

5V

10

13

5V

11

12

9

8

S

R

Q

LS279

14

15 13

45

65V

5V

VCC=PIN 140V=PIN 7

LS74A

IN A

IN B

ACCUFLOW COUNTER INPUT BOARD

SCHEMATIC

1110

13

12

LS04

LS04

FRONT MOUNTED

D0

D15

TOTAL COUNT

D0

D14

TIMER COUNT

22K OHM SIP TYP

LS161A

LS161A

(25) 0.1UF BYPASS

– SIG

+ SIG

24v24V

0VSENSOR INTF

POWER SUPPLY

INTERFACE

NOTES:– RESISTORS 5% 1/4W UNLESS NOTED

33

34

19

35

20

3722

38

23

39

24

41

40

NEW DATA AVAIL

36

21

2945

42

10

43

27

11

24V

44

28

12

24V 50

49

46

30

4731

15

48

32

16

24V

24V

HONDA MR–50RFAFEMALE RT ANGLE

Q1Q2Q3Q4Q5Q6Q7Q8Q9Q03

14

13

15 R

FOX F1100E 1.0MHZ OR EQUIV

74HC4017

PHOENIX MSTBA2.5/7–G

W/ MATE MVSTBW2.5/7–ST

24V

0V

5VC1

C2C5–C30

R1D1

OPTO1

IC2IC1

IC3

IC4

IC5

IC6

CRY1

IC7

IC8

IC4

IC5

10UF 50V

47UF 25V

R3C3

IC9

IC10

IC11

IC12

IC13

IC18

IC19

IC14

IC15

IC16

IC17IC25

IC24

IC23

IC22

IC21

IC20

RP1

10 PIN BOURNS 4610X–101–RC

NOTE: ONLY 9 PINS SHOWN

RP2

RP3

RP4

PC BOARD ASSEMBLY

EE–1063–101

1

23

4

56

9

108

1112

13

LS08

LS08

LS08

IC26

IC26

IC26

IC26

8MS

16MSTIME– OUT

D

12

75461413

15123

16 MS TIMEOUT

IC2

IC2

IC2

12Q

/Q ND OS

IC4

LS10

ND OS

IC2

IC2

IC3

IC3

IC1

IC3

8MS TIMEOUT

D

TIMEOUT

74HC4060

A

LS08

A

A

5V

5V

5V

R4 10KC4 0.01UF

R5330K

C31

– ARTWORK NOTES”PC BD: EE–1063–101–001”ASSY #: EE–1063–001”

IDENTIFY PINOUTS OF HONDACONNECTOR, CORNER PINS

1/06/92

BLANK BD #: EE–1063–101–001ASSEMBLED BD #: EE–1063–101

2.2KR2

1

2

3

6

7

0.47UF

D21N4002

5V

5V

5V

6

3

MOC5007( OR H11L1 )

12–64

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–65

Figure 12–32. Trigger Valve/Regulator Assembly

TRIGGER VALVE/REGULATOR ASSEMBLYEO-3150-122-000Solenoid Trigger Valve Override Button

Solenoid Trigger Valve

Air Bleed Off”Do Not Adjust”

Air Supply Input

Electrical Input

Valve Output Port>Input To Pilot Trigger Line

Air Supply “T” Air Input To Pilot Section

I/P Tranducer Assembly

Output To Gun Regulator

Quick Exhaust

Quick Exhaust

Electrical InputAir Input To Regulator

Gauge Port Plug

12–66

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–67

Figure 12–33. Color Changer 24 Color Moduclean

EO–3150–123–000COLOR CHANGER 24 COLOR MODUCLEAN

Paint Line Connection To Gun

Transducer/Sensor

Flowmeter Paint Supply In

Paint Supply Out

Paint Value Pilot Out

Purge Air And Solvent Connections

12–68

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–69

Figure 12–34. Upper Gun Control Lines

UPPER GUN CONTROL LINESEO-3150-127-000

Paint Line To Gun

12–70

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–71

Figure 12–35. Color Changer Lines 24 Color Pedestal

CP23 – [5/32 OD.]CP21 – [5/32 OD.]CP19 – [5/32 OD.]CP17 – [5/32 OD.]CP15 – [5/32 OD.]CP13 – [5/32 OD.]CP11 – [5/32 OD.]CP9 – [5/32 OD.]CP7 – [5/32 OD.]CP5 – [5/32 OD.]CP3 – [5/32 OD.]CP1 – [5/32 OD.]

RO

BO

T IN

TE

RFA

CE

RO

BO

T IN

TE

RFA

CE

CP24 – [5/32 OD.]CP22 – [5/32 OD.]CP20 – [5/32 OD.]CP18 – [5/32 OD.]CP16 – [5/32 OD.]CP14 – [5/32 OD.]CP12 – [5/32 OD.]

CP2 – [5/32 OD.]CP4 – [5/32 OD.]CP6 – [5/32 OD.]CP8 – [5/32 OD.]CP10 – [5/32 OD.]

PSP – [5/32 OD.]CCSS – [3/8 OD.]CCAS – [3/8 OD.]PAP – [5/32 OD.]

PS23 – [3/8 OD.]PS21 – [3/8 OD.]PS19 – [3/8 OD.]PS17 – [3/8 OD.]PS15 – [3/8 OD.]PS13 – [3/8 OD.]PS11 – [3/8 OD.]PS9 – [3/8 OD.]PS7 – [3/8 OD.]PS5 – [3/8 OD.]PS3 – [3/8 OD.]PS1 – [3/8 OD.]PR23 – [5/16 OD.]PR21 – [5/16 OD.]PR19 – [5/16 OD.]PR17 – [5/16 OD.]PR15 – [5/16 OD.]PR13 – [5/16 OD.]PR11 – [5/16 OD.]PR9 – [5/16 OD.]PR7 – [5/16 OD.]PR5 – [5/16 OD.]PR3 – [5/16 OD.]PR1 – [5/16 OD.]

TERMINATE INSIDE OFPAINT DROP BOX


BO

OT

H W

ALL

PR2 – [5/16 OD.]PR4 – [5/16 OD.]PR6 – [5/16 OD.]PR8 – [5/16 OD.]PR10 – [5/16 OD.]PR12 – [5/16 OD.]PR14 – [5/16 OD.]PR16 – [5/16 OD.]PR18 – [5/16 OD.]PR20 – [5/16 OD.]PR22 – [5/16 OD.]PR24 – [5/16 OD.]

PS2 – [3/8 OD.]PS4 – [3/8 OD.]PS6 – [3/8 OD.]PS8 – [3/8 OD.]PS10 – [3/8 OD.]PS12 – [3/8 OD.]PS14 – [3/8 OD.]PS16 – [3/8 OD.]PS18 – [3/8 OD.]PS20 – [3/8 OD.]PS22 – [3/8 OD.]PS24 – [3/8 OD.]TERMINATE INSIDE OF

PAINT DROP BOX

P–200

P–200

CP6COLOR PILOT 6

PS1PAINT SUPPLY 1

PR3PAINT RETURN 3

CP5COLOR PILOT 5

PLACE IN CABLECARRIER BEFORECLAMP

COLOR CHANGER ASM.24 COLOR

PS2PAINT SUPPLY 2

PR4PAINT RETURN 4

SEE NOTE 1

TO PPCE

COLOR CHANGER LINES24 COLOR PEDESTAL

EO3150–128– 000A000B

12–72

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–73

Figure 12–36. Lower Gun Control Lines Pedestal

BO

OT

H W

ALL

24 COLOREO–3150–121–012 REF12 COLOREO–3150–129–001 REF8 COLOREO–3150–220–001 REF4 COLOREO–3150–221–001 REF

L1EO3150–222–000AEO3150–222–000B

7.3 M [24 FT]15.3 M [50 FT]

REVCC

ERN/ECNE60586E60586

TERMINATE ATEO–3150–122–000TRIGGER VALVE/REGULATOR ASM.

PT – [5/16 OD.]PR – [5/16 OD.]FM – [5/16 OD.]WW – [5/16 OD.]

TERMINATE ATEO–3150–122–000

TERMINATE AT24 COLOR – EO–3150–123–000TERMINATE AT

EO–3150–127–000

RP – [1/2 OD.]

CLAMP

ESTAT – [5/16 OD.]

GROUND – [1/4 OD.]

FA – [1/2 OD.]

AA – [1/2 OD.]

PD – [1/4 OD.]

DUMP – [1/2 OD.]

PTS – [3/8 OD.]

L27.0 M [23 FT]15.0 M [44 FT]

L38.0 M [26 FT]

16.1 M [53 FT]

NOTE:MARK BOTH ENDS OF TUBINGWITH LABLE SHOWN

TERMINATE ATSOLVENT RECOVERY

EO3150–222–000A000B

LOWER GUN CONTROL LINESPEDESTAL

Quick Exhaust

E-Stat Junction Box On Robot Base

Low Voltage E-Stat Cable To Cascade Amplifier On Gun

12–74

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–75

Figure 12–37. Lower Gun Control Lines Rail

BO

OT

H W

ALL

24 COLOREO–3150–121–012 REF12 COLOREO–3150–129–001 REF8 COLOREO–3150–220–001 REF4 COLOREO–3150–221–001 REF

TERMINATE ATEO–3150–122–000TRIGGER VALVE/REGULATOR ASM.

PT – [5/16 OD.]PR – [5/16 OD.]FM – [5/16 OD.]WW – [5/16 OD.]


TERMINATE AT24 COLOR – EO–3150–123–00012 COLOR – EO–3150–124–0008 COLOR – EO–3150–125–0004 COLOR – EO–3150–126–000


MOUNT TO CABLE CARRIER

AREA FOR PLACEMENTOF INLINE UNION

CLAMP

PR – [5/16 OD.]PT – [5/16 OD.]

FM – [5/16 OD.]WW – [5/16 OD.]

NOTE:MARK BOTH ENDS OF TUBINGWITH LABLE SHOWN.

EO–3150–223–001MOUNT OPPOSITE OFCABLE CARRIER

TERMINATE ATSOLVENTRECOVERY

ESTAT – [5/16 OD.]GROUND – [1/4 OD.]

RP – [1/2 OD.]

FAS – [1/2 OD.]

AAS – [1/2 OD.]

FAS – [3/8 OD.]

AAS – [3/8 OD.]

FAP – [1/4 OD.]

AAP – [1/4 OD.]

PD – [1/4 OD.]

DUMP – [1/2 OD.]

PTS – [3/8 OD.]PTS – [3/8 OD.]

LOWER GUN CONTROL LINES RAIL

EO3150–223–000A000B

AIR VALVE TO SHUTOFF

1:1 Ratio Boosters

12–76

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–77

Figure 12–38. Color Changer Rail 4 Color Lines

CP3 – [5/32 OD.]CP1 – [5/32 OD.]

CP2 – [5/32 OD.]CP4 – [5/32 OD.]

PSP – [5/32 OD.]CCSS – [3/8 OD.]

CCAS – [3/8 OD.]PAP – [5/32 OD.]

PS3 – [3/8 OD.]PS1 – [3/8 OD.]

PR3 – [5/16 OD.]PR1 – [5/16 OD.]


TERMINATE INSIDE OFPAINT DROP BOXBO

OT

H W

ALL

PR2 – [5/16 OD.]PR4 – [5/16 OD.]

PS2 – [3/8 OD.]PS4 – [3/8 OD.]


P–200

P–200

PLACE IN CABLECARRIER BEFORECLAMP

PR2PR4

PS2PS4

CP2CP4

CCASPAP

CP3CP1

PSPCCSS

PS3PS1

PR3PR1

PS1PAINT SUPPLY 1

PS2PAINT SUPPLY 2

COLOR CHANGER ASM.4 COLOR

CP4COLOR PILOT 4

PR2PAINT RETURN 2

PR1PAINT RETURN 1

CP3COLOR PILOT 3

AREA FOR PLACEMENTOF INLINE UNIONSSTAGER UNIONS THRU BRACKET

TO PPCE

4.0 METERS[13.0 FT]

SEE NOTE 1

COLOR CHANGER LINES4 COLOR RAIL

EO3150–227–000A000B

12–78

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–79

Figure 12–39. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option

0VDC

CP32–2CP32–1

+5VDC

RACK INTERFACEMODULE 0VDC

0VDC

13 14A1 A2

INSERT INTO FANUC I/O RACK

(14 AWG YELLOW) (14 AWG YELLOW)

0VDC

INTERNAL DC WIRE TO BE16 AWG BLUE–TYPICAL

FLOWMETERINTERFACEMODULE

LEGEND

1.

NOTES:

BLUE–TYPICAL.

8200

8201

8202

8203

8204

8205

8206

8207

8208

8209

I/O POWERENABLE8204CR

8210

8211

8212

8213

8214

8215

8216

8217

8218

8219

8221

8222

8226

8227

8220

RC RC

16 AWG BLUE16 AWG BLUE

CP6–1 CP6–2ON CPU POWER SUPPLY

XGMF–09989

+5VDC JD1A PORTON INTERFACE MODULE CUT END OF CABLE AND TIE

THE FOLLOWING TOGETHERAT FUSE TERMINAL:PINK/2 BLACK DOTSYELLOW/2 BLACK DOTSPINK/1 BLACK DOT

TO LINE 8300 TO LINE 8300

DC WIRES TO BE 16 AWG

RC TERMINAL IN ROBOT CONTROLLER

TERMINAL IN REMOTE EQUIPMENTDEVICE OUTSIDE THIS ENCLOSURE

120VAC FROMCELL CONTROL PANEL

NEUTRAL FROMCELL CONTROL PANEL

8228

8229

8230

8231

8232

8233

8234

8235

8236

8237

8238

0VDC

ROBOT MAIN AIRSUPPLY VALVE(FIRE VALVE)

8239

8240

8241

8242

8243

8244

8245

8246

8247

8248

8249

8250

8251

8252

8253

8254

8255

RC RC

RC

TERMINAL IN PAINT PROCESSVALVE PANEL

PP

PP1 AMP

.5 AMP

82091 82092

82092

820118204CR/SUPPRESSOR

14132

82091 82092

821428214F

82321

82231

82231

I/O POWERENABLE(8222,SP,SP,SP)

82291

82292822928232SOL8232F

8223

8224

8225

+24VDC

+24VDC

+24VDC

+24VDC

14132[3][47]

82011

82091 82092[07][04]

[11][11]

(5)

(9)

[15] [15][14]

2. NUMBERS IN BRACKETS [ ] ARETERMINALS ON TERMINAL STRIPT1, UNLESS OTHERWISE NOTED.

(TERMINAL STRIP T2)

FROM SPADE CONNECTORS

ON POWER INPUT UNIT (PIU)(REF. NE–2000–411)

+24F

IPCBL–21 (REF) IPCBL–6 (REF)

PPCBL–1 PPCBL–2

82141

NE–2200–47A

PURGE PAINT PROCESS CONTROL

WITH CONNECTOR OPTION

FROM CP6 CONNECTOR

PP

SHT. 82

FANUC R-J2 P-200 SINGLE STAGE

12–80

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–81


+24VDC 0VDC+24VDC 0VDC

1

11

2

3

5

6

7

8

9

12

13

15

16

17

18

19

10

20

AOD16DSLOT 1

4

BLACKSOLENOID

PIGTAIL–TYP.

REDSOLENOID

PIGTAIL–TYP.

14

DC OUTPUT MODULE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

1

11

2

3

5

6

7

8

9

12

13

15

16

17

18

19

10

20

AOD16DSLOT 2

4

14

DC OUTPUT MODULE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

PILOT DUMP

(PT)8

7

1

2

(PD)

SPARE

ALL FUSES.5 AMP

SPARE

SPARE

8300

8301

8302

8303

8304

8305

8306

8307

8308

8309

8310

8311

8312

8313

8314

8315

8316

8317

8318

8319

8321

8322

8325

8326

8327

8323

8324

8320

8353

8352

8351

8350

8349

8348

8347

8346

8345

8344

8343

8342

8341

8340

8339

8338

8337

8336

8333

8332

8331

8330

8329

8328

8354

8355


FROM LINE 8327 FROM LINE 8327FROM LINE 8227 FROM LINE 8227

(PSP)

(PAP)

APPLICATOR CLEANERSOLVENT PILOT

APPLICATOR CLEANERAIR PILOT

PURGE SOLVENT PILOT

PURGE AIR PILOT

EE–3287–117–XXX

LOCATEDIN P–200

ROBOT ARM

GRNWHT PILOT TRIGGER


LEGEND RC TERMINAL IN ROBOT CONTROLLER



PP

SPARE

PP

PP

PP

PP

PP

PP

TO LINE8411

8308SOL83081

83082

8309SOL83091

83092

8308F

8309F

83101

83111

83121

83131

83141

83112

83122

8310SOL

8311SOL

8312SOL

82231

83102

82231

82231

82231

8310F

8311F

8312F

8313F

8314F

8336SOL83361

8336F

82092

82092

82092

82092

8334

I.S. GROUND

8335

P1

ISB7

EE–3287–328–001

SUPPLIED AS PART OF ROBOT PRODUCT

REF. EE–3287–550

ISB7–1

ISB7–2

[16][16]

[17]

[18]

[19]

[20]

[21]

[22] [22]

[21]

[20]

[19]

[18]

[17]

.5 AMP

[23] [23]

NOTES:1. NUMBERS IN BRACKETS [ ] ARE

TERMINALS ON TERMINAL STRIP T1.

(ACSP)

(ACAP)

INTRINSIC CABLE

82092

PPCBL–3

PPCBL–4

PPCBL–5

PPCBL–6

PPCBL–7

PP

83132

PPCBL–8

PP

83142

PPCBL–9

PPCBL–10

NE–2200–47A

PURGE PAINT PROCESS CONTROLWITH CONNECTOR OPTIONSHT. 83


12–82

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–83


4–20 maI/P PAINT

PRESSURETRANSDUCER

0VDC

(+)

(+)

(–)

(–)

SHIELD CLEAR

BLACK

1.

CABLE C1INTERNAL TOTHIS PANEL

2.

NOTES:

+24VDC

ANALOG OUTPUT MODULE

FLOWCOMMAND

ATOMIZINGAIR

8

10

18

20

6(FG)

3.

16(FG)

SLOT 3ADA02A

NOTE THAT CARD OUTPUTS ARE NOT

4.

5.

ALL WIRING NOT ACCOMPLISHED BYBELDEN CABLE #8761 OR TRANSDUCERPIGTAIL TO BE 16 AWG BLUE WIRE.

JUM

PE

R

TERMINATE THE SHIELD DRAIN WIRESAT TERMINALS 6 AND 16 ON THEANALOG OUTPUT MODULE. AT THETRANSDUCER END OF THE CABLE CUTTHE DRAIN WIRE SHORT AND TAPEOR SHRINK WRAP.

ISOLATED, THEY SHARE A COMMON

(OF THE 24VDC SUPPLY).RETURN LINE THAT IS TIED TO 0VDCBELDEN CABLE

#8761–TYPICAL LOCATED IN P–200ROBOT ARM

9 1

210

7

8

1

82

7

8400

8401

8402

8403

8404

8405

8406

8407

8408

8409

8410

8411

8412

8413

8414

8415

8416

8417

8418

8419

8421

8422

8425

8426

8427

8423

8424

8420

8403XDUCER

FROM LINE 8355


TERMINAL IN REMOTE EQUIPMENT

DEVICE OUTSIDE THIS ENCLOSURE

INTRINSIC CABLE#EE–3287–117–XXX

82092 82231

84061

84071

TRANSDUCERS ARE SUPPLIED WITH 72”LONG PIGTAIL (RED/WHT, RED, GREEN,RED/YEL, AND RED/BLU CONDUCTORS).I.S. GROUND

I.S. GROUND

P1

P1

P1

P1

EE–3287–328–001

ISB5

ISB4

REF. EE–3287–550SUPPLIED AS PART OF ROBOT PRODUCT

ISB4–1

ISB4–2

ISB5–1

ISB5–2

6.NUMBERS IN BRACKETS [ ] ARETERMINALS ON TERMINAL STRIPT1, UNLESS OTHERWISE NOTED.

RC

RC

84071

84061[25]

[26]

[27]

(FG) TERMINALS 6 AND 16 ARE TIEDTOGETHER INTERNALLY AT THEMODULE AND ARE BROUGHT TO”FRAME GROUND” USING THEGROUND WIRE TERMINATED ATTHE GROUND BAR.

SHEILD 1

NE–2200–47A

PURGE PAINT PROCESS CONTROLWITH CONNECTOR OPTION

SHT.84

RC

TO LINE 8500

82092 82231


12–84

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–85

Figure 12–42. Flow Meter Interface Circuitry FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option

12345678

1011

1314

222324252627282930

323334

9

CONTACT

FLOWMETERINTERFACE

353637

394041424344454647484950

DC INPUT MODULECONTACT–INPUT

NUMBER1–D62–D33–D0

6–C37–C0

10–B611–B3

22–C623–C424–C1

27–B428–B1

30–A6

32–A133–D734–D535–D2

37–C7

39–C2

42–B743–B544–B2

46–A747–A548–A2

3131–A4

1212–B0

15161718192021

15–A316–A0

19–D420–D1

NEW DATA AVAILABLE

PULSE PERIOD BIT 0

PULSE PERIOD BIT 1

PULSE PERIOD BIT 2

PULSE PERIOD BIT 3

PULSE PERIOD BIT 4

PULSE PERIOD BIT 5

PULSE PERIOD BIT 6

PULSE PERIOD BIT 7

PULSE PERIOD BIT 8

PULSE PERIOD BIT 9

PULSE PERIOD BIT 10

PULSE PERIOD BIT 11

PULSE PERIOD BIT 12

PULSE PERIOD BIT 13

PULSE PERIOD BIT 14

PULSE COUNTER BIT 0PULSE COUNTER BIT 3

PULSE COUNTER BIT 1PULSE COUNTER BIT 4PULSE COUNTER BIT 6

PULSE COUNTER BIT 7

PULSE COUNTER BIT 2

PULSE COUNTER BIT 8

PULSE COUNTER BIT 9

PULSE COUNTER BIT 10


PULSE COUNTER BIT 12


CABLE–40 CM LONGFLOWMETER INTERFACE

REFERENCE ONLY

SPARE4

SPARESPARE

SPARESPARE

SPARESPARE

+24VDC

89

1314

1718

SPARESPARE

+24VDC

21

29

2526

+24VDC

+24VDC+24VDC

+24VDC

+24VDC+24VDC

36

4041

45

4950

+24V

0V+24V

0VJUMPER

+24V

+5V

0V

HONDA #MR–50RMACONNECTOR

+SIG

–SIG

HONDA #MR–50RFACONNECTOR

5 SPARE

PULSE COUNTER BIT 53838–C5

REFERENCE ONLY

ACCUFLOW COUNTER INPUT/DC INPUT MODULE CONNECTIONS

REFERENCE ONLY

SIGNAL DESCRIPTION(SEE NOTE 2)

A

B

C +SIG

POWER INPUT TO ACCUFLOW COUNTERINPUT PRINTED CIRCUIT BOARD

NOTES:

1.

FLOW METER

HONDA #MR–50LWFXGMF–00782

HONDA #MR–50LWMXGMF–00788

TERMINALS 3 AND 7 ON THEINTRINSICALLY SAFE BARRIER(ISB) ARE TIED TOGETHERTHROUGH THE ISB BUSS BAR.

DC INPUT MODULEAID32B1SLOT 10

FLOWMETERINTERFACEMODULE

SLOT 9SLOTSPARE

1

4

8

5

7 2

BLACK

RED

WHITE

ALPHA CABLE#5163C 18 AWG3 CONDUCTOR




PP

8700

8701

8702

8703

8704

8705

8706

8707

8708

8709

8710

8711

8712

8713

8714

8715

8716

8717

8718

8719

8721

8722

8725

8726

8727

8723

8724

8720

INTRINSIC CABLE#EE–3287–117–XXX

LOCATED IN P–200ROBOT ARM

(SEE SHEET 02 FOR CONNECTIONS)

87091

87101

87111

I.S. GROUND

087

FLOW METERINTERFACE CIRCUITRY

ISB6

P1

P1

P1

EE–3287328–001

SUPPLIED AS PART OF ROBOT PRODUCTREF. EE–3287–550

#EE–1063–201–001

ISB6–1

ISB6–2

ISB6–4

NE–2200–47A

PURGE PAINT PROCESS CONTROLWITH CONNECTOR OPTION

SHT.


12–86

12. SCHEMATICS

MARO2P10203703E

NOTES

MARO2P10203703E

12. SCHEMATICS

12–87

Figure 12–43. I/O Rack Layout FANUC R-J2 P-200 Single Stage Purge Paint Control With Connector Option

1 2 3 4 5 6 7 8 9 10

FLOWMETERINTERFACE

MODULE

SLOT NUMBER

MAIN CPU

JD1

CP32

JD1B

JD1A

RACK POWERCABLE

RACK COMMUNICATIONCABLE–1 METER

ADA02A

AOD16D

AID32B1

AIF01A

+5VDC 0VDC

CABLES/WIRING BY FANUC

+24VDC 0VDC

AOD16D

ADA02A

AOD16D

+24VDC

WIRE AS SHOWN ON SHEET 082

WIRE AS SHOWN ON SHEET 082

+5VDC FROM #XGMF–09989CABLE PLUGGED INTO JD1A PORT

+24VDC, 0VDC FROM CP5CONNECTOR ON CPU POWER SUPPLY

CABLE/WIRING BY FANUC

PCB

I/O RACK LAYOUT

AOD16D

CP6

+24VDC 0VDC

MAIN CPU

PSU MODULE

089

TO MAIN AIRSUPPLY SOLENOIDAS SHOWN ON SHEET 082

82142 82091 82092

82091 82092 82291 82292

8214F.5 AMP

RESEVED

RESEVED

RESEVED

[11]

[11]

POWER INPUT

(PIU)

+24VDC, 0VDC FROM SPADECONNECTORS ON POWER INPUT UNIT

82141

82142

NE–2200–47A

PURGE PAINT PROCESS CONTROL

WITH CONNECTOR OPTION

SHT.

UNIT

In Robot ControllerConverts Frequency Input To 32 bit Output

32 Bit Input Module Read Interface Module Output

Channel 1 = 200-100 Transducer Counts to 4-20 mA ConversionFor I/P Transducer In P-200 Outer Arm


12–88

12. SCHEMATICS

MARO2P10203703E

40NOTES

Inde

x

13 CABLES

CABLES


Cables The following section includes separate print cable sets for the P-200 robot. 13–1. . .

MARO2P10203703E13–2

13. CABLES

NOTES

MARO2P10203703E

13. CABLES

13–3

Figure 13–1. P-200 Purge/Battery/Paint Connection Cable

SEE NOTE 1

CABLE SPECIFICATION

HYPALON JACKET

MFG. NAME MFG. NAME

16PR #20 AWG CABLE

INTRINSIC REV. INTRINSIC REV.

NAME

SOC/PINNO.

SIGNAL

1 2 345 6

1 2

5 6

131415

PS1–PPS1–NFS1–PFS1–NPSOL–1PSOL–2

PSOL–2

TWISTEDPAIR

NUMBER

NUMBERD

LABEL

1

2

3

4

5

6

15 POSSOC

SOC

APPLY 4” OF BLUE SHRINK TUBINGUNDER CABLE I.D. LABELS AND FOR INTRINSIC CABLE MARKING:

ALSO AT 22’ INTERVALS AS REQ’D.

EE–3287–117–XXX

EE–3287–117–XXX

1

2

3

4

5

6

7

8

TWISTPAIRNO.

WIRECOLOR/NUMBER

PS1–P PS1–N FS1–P FS1–N PSOL–1 PSOL–2

IS GND M1

N1

1

5 3

712

9 POS

7 8 9

ASSEMBLY NOTES:

MUST CORRESPOND TO THE LENGTH ANDVERSION NUMBER

1. PART NUMBER SHOWN ON CABLE LABEL

DENOTES LENGTH MEASUREMENT POINTS.

IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE

INCLUDED ON CABLE LABEL.

SEE TABLE FOR DIMENSION.ALL LENGTH DIMENSIONS + 1/2 IN.

2.

WIRECOLOR

10

SEE NOTE 3

8

SEE NOTE 5

SEE NOTE 4

4.

15 POS

SOC

SOC

3 4

1 2 345 6

1 2 34

789 101112131415

R1

6V–10V–16V–20V–26V–30V–3

6V–40V–46V–50V–56V–60V–6

SHIELD

4 POS

S1

SHIELDKEY

20 AWGKEY

TWISTPAIRNO.

WIRE

0V–3

COLOR/NUMBER

6V–1 0V–1 6V–2 0V–2 6V–3

6V–4 0V–4

WIRETAG

13

2 3 4

0

14

11

6

WHITE–1BLUE–2

WHITE–3ORANGE–4WHITE–5GREEN–6WHITE–7BROWN–8WHITE–9GRAY–10RED–11

BLUE–12RED–13

ORANGE–14RED–15

GREEN–16RED–17

BROWN–18RED–19

GRAY–20BLACK–21BLUE–22BLACK–23

ORANGE–24

BLACK–25GREEN–26BLACK–27BROWN–28BLACK–29GRAY–30

9

10

11

12

13

14

15

WHITE–1BLUE–2

WHITE–3ORANGE–4WHITE–5GREEN–6

WHITE–7BROWN–8

WHITE–9GRAY–10RED–11

BLUE–12

BLACK–21BLUE–22

BLACK–25GREEN–26BLACK–27BROWN–28

11

13

14

A

P/N=T–14685

15

6V–1

0V–1

6V–3

0V–3

6V–4

0V–4

6V–2

0V–2

CONNECTIONPOINT

BATTERYPACK

2 3 4

TYP TYP

M1

N1

R1

S1

1’’ TYP

REV LEV. CABLE VERSION DIM (IN – MM) PG

EE–3287–117–110 IN MM YES492 12500

EE–3287–117–115 IN MM YES689 17500

IN MM YESEE–3287–117–125

IN MM YES

1083 27500

YESIN MM

EE–3287–117–135

YESIN MM

1476 37500

EE–3287–117–105 295 IN 7500 MM YESA

A

A

A

A

A

A

MAX. CABLE O.D. = 20.5mm (0.805” MAX.)

BULKCABLE

SHRINK TUBINGBRAIDED SHIELD

CONDUCTORSBETWEEN SHIELDS

BRAIDED SHIELDCONDUCTORS

SOLDERED CONNECTION

BULKCABLE

SOLDERED CONNECTIONSHIELD CONDUCTOR 20 AWG BLACK TYP

SHIELDSLEEVING

SLEEVE TUBING

3. TYP. TERMINATION OF SHIELD TO SHIELD AND SHIELD TO CONDUCTOR.

DETAIL ”A”

DETAIL ”B”

10

10

SEE DETAIL 3B

TYP.

SEEDETAIL 3A

TYP.TYP.

6.0’’4.0’’

TYP.TYP.

TYP.

TUBING OVERBRAIDTYP.

BLACKSHIELDWIRE

TYP.

TYP TYP

65.0’’

DETAIL 3B

ISTB

1 – PSA12 – PSA25 – FSA16 – FSA2

1–PSA1

CONNECT POINT

WIRE TAG2–PSA2

SIGNALNAME

ISB1–3

ISB1–4

BLACK, 20 AWG.MTW, 12’’ LONG

TWO PLACES

320’’

EE–3287–117–145

EE–3287–117–155

47500

57500

1870

2264

4.0’’

1.0’’3.0’’

SEE NOTE 5

SEE NOTE 5


EE–3287–117–010 IN MM NO 492 12500

EE–3287–117–015 IN MM NO 689 17500

IN MM NO EE–3287–117–025

IN MM NO

1083 27500

NO IN MM

EE–3287–117–035

NO IN MM

1476 37500

EE–3287–117–005 295 IN 7500 MM NO A

A

A

A

A

A

A

EE–3287–117–045

EE–3287–117–055

47500

57500

1870

2264

IF REQUIRED

16YELLOW–31

BLUE–32

I/P 24V +I/P 0V

I/P + SIGI/P – SIG

TRIG + SIGTRIG – SIG

FLOW 24VFLOW 0V

FLOW + SIG

HND BRK +HND BRK –

SPARE

BLACK–29GRAY–30

15

16YELLOW–31BLUE–32

7

8

RED–13ORANGE–14

RED–15GREEN–16RED–17

BROWN–18RED–19

GRAY–20

9

10

I/P 24V +I/P 0VI/P + SIGI/P – SIG


FLOW 24VFLOW 0V

FLOW +SIGSPARE

1 2 345 6 789 101112131415

20 AWG

20 AWG

20 AWG

20 AWG

15 POSSOC

2 3 4

KEYSHIELD

KEY

KEY

5–FSA1

6–FSA2

TRIG2 + SIGTRIG2 – SIG

SPARESPARE

SPARE

SPARE

SHIELD

SHIELD

6V–40V–4

JUMPERJUMPERJUMPERJUMPERJUMPERJUMPER

PER CONTACT

1 2 34

BLACK–23ORANGE–24

12SPARESPARE

O1

P1

TRIG2 +SIGTRIG2 –SIG

HND BRK+HND BRK–

SOC

3

4 POS

6

O1

P1

NOTE: PINS 7

THRU 12NOT

34

18

16 17

11

ISB3–4

ISB4–1

ISB5–1

ISB6–1

ISB7–1

ISB8–1

SPARESPARE

ISB8–2

ISB7–2

ISB6–2

ISB5–2

ISB4–2

ISB3–6

BYPASS–1BYPASS–2

ISB3–4ISB3–6ISB4–1ISB4–2

1

2

3

4

5

6

7

8

9

10

11

12

ISB5–1ISB5–2

ISB6–4

SPAREISB6–1ISB6–2ISB6–4SPAREISB7–1ISB7–2

ISB1–3ISB1–4

ISB8–1ISB8–2

19 – HBK120 – HBK2

19–HBK1

20–HBK2


KEYSHIELD 20 AWG

5. FOR CABLE EE–3287–117–105 ONLY, USE 200’’ FOR LEFT PG LOCATION

20 AWG

4

4

(2) WIRES

4.0’’

8.0’’

8.0’’

24’’

MTW, 12’’ LONG

EE-3278-117-005

SHOWN

MARO2P10203703E

13. CABLES

13–4

NOTES

MARO2P10203703E

13. CABLES

13–5

Figure 13–2. P-200 R-J2 Paint Control Robot Arm Cable Dual Trigger

SEE NOTE 1

CABLE SPECIFICATION

HYPALON JACKET

MFG. NAME MFG. NAME

9 PR #20 AWG CABLE

INTRINSIC REV.



EE–3287–328–XXX

1

2

3

4

5

6

7

8

TWISTPAIRNO.

WIRE

COLOR/NUMBER

110

ASSEMBLY NOTES:







2.

9

SEE NOTE 4

4.

A

P/N=T–11762MAX. CABLE O.D. = 17.4mm (0.685” MAX.)


BULKCABLE

SOLDERED CONNECTION

SLEEVE TUBING


4.0’’

TYP.

TYP.

TYP TYP

SIGNALNAME


EE–3287–328–001 IN MM YESA

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

BLACK

BROWN

RED

ORANGE

BLUE

YELLOW

GREENWHITE

WHITE

I/P 24VI/P 0V

I/P + SIGI/P – SIGFLOW 24VFLOW 0V

FLOW + SIG


9

FLOW

I/P

1

2

3

4

5

7

8

TWISTPAIRNO.

WIRE

COLOR/NUMBER

SIGNALNAME

WHITE

WHITE

WHITE

WHITE

WHITE

BLACK

BROWN

RED

ORANGE

BLUE

GREEN

VIOLET

GRAY

WHITE

WHITE

WHITE

I/P 24VI/P 0VI/P + SIGI/P – SIG

FLOW 24VFLOW 0VFLOW + SIG


9

6142

TRIG

12

SPARE

TWISTPAIRNO.

WIRECOLOR/NUMBER

SIGNALNAME

TWISTPAIRNO.

WIRECOLOR/NUMBER

SIGNALNAME

ABC

PINNUMBER

PAIR

PAIR

PAIR

CUT OFF SPARE PAIRS:

SHIELD CONDUCTOR 20 AWG BLACK

15 PIN

P4 INTRINSIC

REV.

1 2 3 4 5 6 7 8 9

PIN#

101112131415


12

TWISTPAIRNO.

WIRECOLOR/NUMBER

SIGNALNAME

SPARE

SHIELDSHIELD


2 3

4

5

6

7 8

11

5

0

VIOLET

GRAYWHITE

CUT OF SPARE SPARES:

TRIG2

WHITE

YELLOW6

174 4420

46’’ 16’’

12

TUBING

REV.

SEE NOTE 3

6’’

KEY

13

3’’TYP

SHIELD STOPS HERE

CUT OFF SPARE ORANGE WIRE

NUMBER

NUMBER

NUMBER

PIN

PIN

PIN

4.0’’6.0’’

EE–3287–328–XXX

EE-3287-328-001

MARO2P10203703E

13. CABLES

13–6

NOTES

MARO2P10203703E

13. CABLES

13–7

Figure 13–3. P-200 I/P Cable

A

WIRECOLOR/

NUMBERSIGNALNAME

I/P 24V

I/P 0V

I/P + SIG

I/P – SIG

6

1

4

2

0

12

24V0V

+SIG–SIG

I/P

PIN #

RED

BLK

WHITE

GREEN

WIRECOLOR/NUMBER

RED

BLK

WHITEGREEN

WIRETAG

0V

24V+SIG–SIG

SHIELD(TO I.S. GND)

3

EE–3287–334–00XMANUF REV

45

I/PEE–3287–334–00XMANUF REV

CABLE VERSIONREV A DIM

A

A

EE–3287–334–001

EE–3287–334–002

24 FT

50 FT

3

5

ASSEMBLY NOTES:







2.

SEE NOTE 1

6’’12’’1’’ TYP

SIGNALNAME

I/P 0VI/P –SIGI/P +SIGI/P 24V

3’’TYP

TYPTUBING OVER CABLE

288 IN7315MM

600 IN15240MM

3’’

SUPERSEDED BY EE-3287-328-001

EE-3287-334-001 and 002

MARO2P10203703E

13. CABLES

13–8

NOTES

MARO2P10203703E

13. CABLES

13–9

Figure 13–4. P-200 Trigger Cable

A


12

SIGNALNAME

0

12

WIRE COLOR

PIN#

3

REDBLK

WHITE GND

TRIG+SIG

–SIG

GND

SHIELD(TO I.S. GND)

3’’

3TYP

WIRE COLOR

REDBLK

WHITE

WIRETAG

+SIG–SIGGND

EE–3287–335–00XMANUF REV

45

TYP

TRIGEE–3287–335–00XMANUF REV


A

A

EE–3287–335–001

EE–3287–335–002

24 FT

50 FT

ASSEMBLY NOTES:







2.

12’’

TRIG +SIGTRIG –SIG

SIGNALNAME

GND

2’’ TYP

0.5’’TUBING OVER CABLE

288 IN

600 IN

7315MM

15240MMSUPERSEDED BY EE-3287-328-001

EE-3287-335-001 and 002

MARO2P10203703E

13. CABLES

13–10

NOTES

MARO2P10203703E

13. CABLES

13–11

Figure 13–5. P-200 Flow Detector Signal

A

FLOWFLOW 24VFLOW 0V

FLOW + SIG

SIGNALNAME

ABC

PINNUMBER

A

12

REDBLACKWHITE

24V

0V

+SIG

SHIELD(TO I.S. GND)

REDBLACKWHITE

WIRE COLOR

WIRETAG24V0V

+SIG

FLOWWIRE

COLOREE–3287–336–00XMANUF REV

FLOWEE–3287–336–001MANUF REV

3

45

3’’


A

A

EE–3287–336–001

EE–3287–336–002

24 FT

50 FT

ASSEMBLY NOTES:







2.

12’’0.5’’ 2’’ TUBING OVER CABLE

288 IN7315MM

600 IN15240MM

3’’

FLOW 24VFLOW 0VFLOW +SIG

SUPERSEDED BY EE-3287-328-001

EE-3287-336-001 and 002

MARO2P10203703E

13. CABLES

13–12

NOTES

MARO2P10203703E

13. CABLES

13–13

Figure 13–6. Axes 1 and 2 Power Connection Cable

ASSEMBLY NOTES:


1” TYP.




CABLE SPECIFICATION


SEE TABLE FOR DIMENSION.

MAX

MOTOR REV. MOTOR REV.

ALL LENGTH DIMENSIONS + / – 1/2 IN

HYPALON JACKET 16–#14 & 4–#18 AWG CONDUCTORS

P/N=T–14379 CABLE O.D.= 21.0 MM (0.825”)

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

SOC/PINNO.

WIRECOLOR/NUMBER

TYP

SIGNALNAME

1U

1V

1W

1G

2U

2V

2W

2G

2U

2V

2W

2G

1BKM

2BKP

2BKM

11

12

11

12 KEY PLUG

KEY PLUG

NOT USED

NOT USED

CONNECTOR

LABEL

PWR/BRK

AXIS 2PWR/BRK

AXIS 1

AXIS 2

1BKP

12 POSSOC

SOC12 POS

1”

TYP6”

H1

J1

POWER/BRK H1

POWER/BRK J1

EE–3287–110–XXXMFG. NAME


WIRECOLOR/NUMBER

1U 1V 1W 1G

2U

2V

2W

WIRETAG

1G

1W

1U

1V

2W

2V

2U

2G

WIRECOLOR/NUMBER

A

BLACK/3

GRN/YEL/8

RED/1WHITE/2

GRN/YEL/4

RED/5WHITE/6BLACK/7

RED/9

WHITE/10

BLACK/11

GRN/YEL/12

RED/13

WHITE/14

BLACK/15

GRN/YEL/16

BLUE/18 BLUE/19

BLUE/17

BLUE/20

BLACK/3

GRN/YEL/8

RED/1WHITE/2

GRN/YEL/4

RED/5WHITE/6

BLACK/7

RED/9WHITE/10BLACK/11

GRN/YEL/12RED/13

WHITE/14BLACK/15

GRN/YEL/16

BLUE/18

BLUE/19

BLUE/17

BLUE/20

2.

24’’

WIRETAG

1BKP 1BKM 2BKP

2BKM

SIGNALNAME

BKP1

BKP1

BKP1BKM1

BKM1

BKM1

BKM1

BKP1

2U 2V 2W 2G

2U

2V

2W

2G

AXIS 1 & 22U 2V 2W

2G

PS95437–110–155

PS95437–110–155

2G

THIS GROUP HASTWO WIRES

PER TERMINAL

320’’SEE NOTE 3

3. FOR CABLE EE–3287–110–105, USE 200’’ FOR LEFT PG LOCATION

18 AWG

18 AWG

EE-3287-110-005

MARO2P10203703E

13. CABLES

13–14

NOTES

MARO2P10203703E

13. CABLES

13–15

Figure 13–7 . Axes 4, 5, and 6 Motor Connection Cable

ASSEMBLY NOTES:

BLACKBLACKBLACK

BLACK

BLACKBLACKBLACK

BLACKBLACK

4U4V4W4G5U5V5W5G6U6V6W6G

NAME

SOC/PINNO.

SIGNALWIRECONNECTOR

1 2 345 6

PWR/BRAKE

1 2 34

BLACKBLACKBLACK

BLACKBLACK

BLACK

BLACKBLACK

BLACKBLACKBLACK

BLACKBLACK

COLOR

789 10 1112

5 6

PWR/BRAKE

BLACKBLACK

4U4V4W4G

4BKP4BKM

5U5V5W5G

5BKP5BKM

6U6V6W6G

6BKP 6BKM

AXIS 6

131415

KEY

789 KEY

LABEL





HYPALON JACKET



MAX

AXIS 6

MOTOR REV. MOTOR REV.


BLACK

BLACK

BLACK

123456789101112

131415161718

12347891013141516

BLACK

BLACK

BLACK

18C #18 AWG CABLE

CABLE O.D.=13.5 MM (0.530”)P/N=T–14107

15 POS

9 POS

AXIS 4 & 5

CABLE SPECIFICATION

1’’TYPTYP

A1

B1

MFG. NAME

MFG. NAMEEE–3287–111–XXX

POWER/BRK A1AXIS 4 & 5

POWER/BRK B1

AXISNUMBER

AXIS 4

AXIS 5

AXIS 6

4U

4V

4W

4G

5U

5V

5W

5G

6U

6V

6W

6G

0

WIRE

BLACKBLACKBLACK

BLACKBLACK

COLOR

BLACK

4BKP4BKM5BKP5BKM6BKP6BKM

5611121718

SOC

SOC KEY

75’’

2.

FOR PROPER PG FITTING DIA.

RETAIN EPDM STRIP MAT’L WITH 6” OF SHRINK TUBING.

A SMALL AMOUNT OF ADHESIVE SHOULD BE USED TO SECUREEPDM STRIP PRIOR TO APPLICATION OF SHRINK TUBING.

3. BUILD UP CABLE DIA. WITH 1/32 X 2” EPDM STRIP MATERIAL

A

1’’ TYP

24’’

WIRE TAG

WIRETAG

WIRECOLOR


B EE–3287–111–110 IN MM YES492 12500

B EE–3287–111–115 IN MM YES

B IN MM YES

B

EE–3287–111–125

IN MM YES

B YESIN MM

B

EE–3287–111–135

YESIN MM

B EE–3287–111–105 IN MM YES

SIGNALNAME

BKP3

BKP3

BKP3

BKP3BKM3

BKM3

BKM3

BKM3BKP4

BKP4

BKM4

BKM4

7500

17500

27500

37500

295

689

1083

1476

320’’

EE–3287–111–XXX

EE–3287–111–145

EE–3287–111–155

47500

57500

1870

2264

EXTRACTION TOOL: AMP #455822–2

1’’ TYP

6’’

SEE NOTE 4

4. FOR CABLE EE–3287–111–105, USE 200’’ AS LEFT PG LOCATION


A EE–3287–111–010 IN MM NO 492 12500

A EE–3287–111–015 IN MM NO

A IN MM NO

A

EE–3287–111–025

IN MM NO

A NO IN MM

A

EE–3287–111–035

NO IN MM

A EE–3287–111–005 IN MM NO 7500

17500

27500

37500

295

689

1083

1476

EE–3287–111–045

EE–3287–111–055

47500

57500

1870

2264

EE-3287-111-005 Through 155

MARO2P10203703E

13. CABLES

13–16

NOTES

MARO2P10203703E

13. CABLES

13–17

Figure 13–8. Axes 3 and 7 Power Connection Cable

ASSEMBLY NOTES:





CABLE SPECIFICATION



MFG. NAME

MAX

MOTOR REV.



P/N=T–14379 CABLE O.D.= 21.0 MM (0.825”)

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

SOC/PINNO.

WIRE

COLOR/NUMBER

SIGNALNAME

7BKP

7BKM

11

12

11

12

18 AWG

18 AWG

KEY PLUG

CONNECTORLABEL

PWR/BRK

PWR/BRK

AXIS 3

AXIS 7

KEY PLUG

KEY PLUG

NOT USED

7U

7V

7W

7G

7U

7V

7W

7G

AXIS 7

AXIS 3

3U

3V

3W

3G

3U

3V

3W

3G

3BKP

3BKM

12 POS

12 POS

SOC

SOC1’’TYP

EE–3287–112–XXX

K1

L1

POWER/BRK K1

POWER/BRK L1

WIRECOLOR/NUMBER

WIRETAG

WIRECOLOR/NUMBER

0

MOTOR REV.

MFG. NAMEEE–3287–112–XXX

A

3U

3V

3W

3G

3U

3V

3W

3G

7U

7V

7W

7G

7U

7V

7W

7G

3V 3U

3W

3G

3V

3U

3W

3G

7U 7V

7W 7G 7U

7V 7W

7G

3BKM

75’’

BLACK/3

GRN/YEL/8

RED/1

WHITE/2

GRN/YEL/4

RED/5

WHITE/6

BLACK/7

RED/9

WHITE/10BLACK/11

GRN/YEL/12

RED/13

WHITE/14BLACK/15

GRN/YEL/16

BLUE/17 BLUE/18BLUE/19BLUE/20

BLACK/3

GRN/YEL/8

RED/1WHITE/2

GRN/YEL/4

RED/5WHITE/6

BLACK/7


GRN/YEL/12RED/13

WHITE/14BLACK/15

GRN/YEL/16

BLUE/18

BLUE/19

BLUE/17

BLUE/20

2.

24’’

7BKM

WIRETAG


B EE–3287–112–105 IN MM YES295 7500

B EE–3287–112–110 IN MM YES492 12500

B EE–3287–112–115 IN MM YES689 17500

B IN MM YES

B

EE–3287–112–125

YESIN MM

1083 27500

B YESIN MM

B

EE–3287–112–135

YESIN MM

1476 37500

3BKP

7BKP

BKP2

BKP2

BKP2

BKP2BKM2

BKM2

BKM2

BKM2

SIGNALNAME

EE–3287–112–145

EE–3287–112–155

47500

57500

1870

2264

1’’ TYP

320’’

6’’ TYP1’’ TYP

SEE NOTE 3

SEE NOTE 3



A EE–3287–112–005 IN MM NO 295 7500

A EE–3287–112–010 IN MM NO 492 12500

A EE–3287–112–015 IN MM NO 689 17500

A IN MM NO

A

EE–3287–112–025

NO IN MM

1083 27500

A NO IN MM

A

EE–3287–112–035

NO IN MM

1476 37500

EE–3287–112–045

EE–3287–112–055

47500

57500

1870

2264

EE-3287-112-005 Through 155

MARO2P10203703E

13. CABLES

13–18

NOTES

MARO2P10203703E

13. CABLES

13–19

Figure 13–9 . EE-3287-113-005 through 155 Pulse Cable

MARO2P10203703E

13. CABLES

13–20

NOTES

MARO2P10203703E

13. CABLES

13–21

Figure 13–10 . P-200 R-J2 Purge/Battery Connection Cable

CABLE SPECIFICATION

HYPALON JACKET

MFG. NAME MFG. NAME

16PR #20 AWG CABLE


NAMESOC/PINNO.

SIGNALCONNECTOR

1 2 345 6

1 2 34

789 101112

5 6

131415

XOT–PXOT–N

CRASH–PCRASH–NSHIELDSHIELD

PS1–PPS1–NFS1–PFS1–N

OT2–POT2–NOT3–POT3–N

OT1–POT1–N

PSOL–1PSOL–2

PSOL–2NKEY

TWISTEDPAIR

NUMBERLABEL1

2

3

4

5

6

7

8

18 AWG18 AWG

15 POSSOC

SOC



SHIELD

SHIELD

18 AWG

18 AWG

EE–3287–115–XXX

EE–3287–115–XXX

1

2

3

4

5

6

7

8

TWISTPAIRNO.

WIRE

COLOR/NUMBER

PS1–P PS1–N FS1–P FS1–N PSOL–1 PSOL–2

OT2–P OT2–N OT3–P OT3–N

OT1–P OT1–N

XOTP XOTN CRASHP CRASHN

IS GND

M1

N19 POS

7 8 9

KEY

ASSEMBLY NOTES:




IN TABLE. VENDOR NAME AND REVISION LEVEL MUST ALSO BE INCLUDED ON CABLE LABEL.


2.

WIRECOLOR

FOR PROPER PG FITTING DIA.A SMALL AMOUNT OF ADHESIVE SHOULD BE USED TO SECUREEPDM STRIP PRIOR TO APPLICATION OF SHRINK TUBING.


4.

RETAIN EPDM STRIP MAT’L WITH 2” OF BLUE SHRINK TUBING.

15 POS

SOC

SOC

1 2 345 6

1 2 34

789 101112131415

6V–7R1

6V–10V–16V–20V–26V–30V–3

6V–40V–46V–50V–56V–60V–6

0V–7

SHIELD

4 POS

S1

SHIELDKEY

CUT SPARE WIRES AT STRIP BACK

18 AWG

18 AWGKEY

TWISTPAIRNO.

WIRE

0V–3

COLOR/NUMBER

6V–1 0V–1 6V–2 0V–2 6V–3

6V–5 0V–5 6V–6 0V–6

6V–4 0V–4

WIRETAG

6V–7 0V–7

CUT SPARE WIRES AT STRIP BACK

0

WHITE–1BLUE–2


BLUE–12RED–13

ORANGE–14RED–15

GREEN–16

RED–17BROWN–18

RED–19GRAY–20

BLACK–21BLUE–22

BLACK–23ORANGE–24BLACK–25GREEN–26BLACK–27BROWN–28BLACK–29GRAY–30

99

101011111212131314141515

PR–16 YELLOW–31 & BLUE–32

WHITE–1BLUE–2


BLUE–12

RED–13ORANGE–14RED–15

GREEN–16

RED–17BROWN–18RED–19

GRAY–20BLACK–21BLUE–22



BLACK–29GRAY–30

9

10

11

12

13

14

15

PR–16 YELLOW–31 & BLUE–32

A

P/N=T–14685

6V–5

0V–5

6V–1

0V–1

6V–3

0V–3

6V–4

0V–4

6V–6

0V–6

6V–2

6V–7

0V–2

0V–7

CONNECTIONPOINT

BATTERYPACK

M1

N1

R1

S1

1’’ TYP


EE–3287–115–110 IN MM YES492 12500

EE–3287–115–115 IN MM YES689 17500

IN MM YESEE–3287–115–125

IN MM YES

1083 27500

YESIN MM

EE–3287–115–135

YESIN MM

1476 37500

EE–3287–115–105 295 IN 7500 MM YESB

B

B

B

B

B

B


BULKCABLE

SHRINK TUBINGBRAIDED SHIELD

CONDUCTORS

BETWEEN SHIELDS


SOLDERED CONNECTION

BULKCABLE

SOLDERED CONNECTIONSHIELD CONDUCTOR 18 AWG BLACK (2)

SHIELDSLEEVING

SLEEVE TUBING


DETAIL ”A”

DETAIL ”B”

6.0’’4.0’’

TYP.TYP.

TYP.

TYP TYP

65.0’’

ISTB

1 – PSA12 – PSA25 – FSA16 – FSA2

1–PSA1

CONNECT POINT

WIRE TAG 2–PSA2

5–FSA1

6–FSA2

SIGNALNAME

ISB1–3

ISB1–4ISB1 – 3ISB1 – 4

TIE–WRAPSPARES

PARK–PPARK–N

PARK–P

PARK–N

320’’

EE–3287–115–145

EE–3287–115–155

47500

57500

1870

2264

EXTRACTION TOOL: AMP # 455822–2

4.0’’

GND

GND

GND

GND

GND

GND

GND

GND

GNDGNDGNDGNDGNDGNDGNDGND

1.0’’3.0’’

SEE NOTE 6

SEE NOTE 6



EE–3287–115–010 IN MM NO 492 12500

EE–3287–115–015 IN MM NO 689 17500

IN MM NO EE–3287–115–025

IN MM NO

1083 27500

NO IN MM

EE–3287–115–035

NO IN MM

1476 37500

EE–3287–115–005 295 IN 7500 MM NO A

A

A

A

A

A

A

EE–3287–115–045

EE–3287–115–055

47500

57500

1870

2264

4.0’’

8.0’’

8.0’’

24’’

EE-3287-115-005 through 155

MARO2P10203703E

13. CABLES

13–22

NOTES

MARO2P10203703E

13. CABLES

13–23

Figure 13–11 . P-200 Robot Ground Cable

NOTES:




EE–3287–116–XXX

#8 AWG TINNED COPPER


CABLE SPECIFICATION

CABLE O.D.=6.9 MM (0.27 ”)



MFG. NAME MFG. NAME

1” TYP.

GRN W/2 CO–EXTRUDED YELLOW STRIPS

P/N=#XP0845168–165

FOR CABLE FABRICATION SPECIFICATIONS.REF. ENGINEERING GUIDELINE EG–000842.

MAX

EE–3287–116–XXX

GROUND REV. GROUND REV.

3. SEE LENGTH CHART FOR CABLE VERSIONREVISION LEVEL.

ALL DIMENSIONS +/– 0.5’’


B EE–3287–116–110 IN MM YES492 12500

B EE–3287–116–115 IN MM YES688 17500

B IN MM YES

B

EE–3287–116–125

IN MM YES

1083 27500

B YESIN MM

B

EE–3287–116–135

YESIN MM

1476 37500

24’’

B EE–3287–116–105 295 IN 7500 MM YES

EE–3287–116–145

EE–3287–116–155

47500

57500

1870

2264

320’’

SEE NOTE 4

SEE NOTE 4



A EE–3287–116–010 IN MM NO 492 12500

A EE–3287–116–015 IN MM NO 688 17500

A IN MM NO

A

EE–3287–116–025

IN MM NO

1083 27500

A NO IN MM

A

EE–3287–116–035

NO IN MM

1476 37500

A EE–3287–116–005 295 IN 7500 MM NO

EE–3287–116–045

EE–3287–116–055

47500

57500

1870

2264

EE-3287-116-005 through 155

MARO2P10203703E

13. CABLES

13–24

NOTES

MARO2P10203703E

13. CABLES

13–25

Figure 13–12 . Axes 1, 2, and 3 Power and Pulse Harness

NAME

NO.LABELSIGNAL WIRE BRAIDED

SHIELDTYPE

& COLORCONNECTOR

20 AWG19 /32

36 AWGTINNEDCOPPER

BLACK BRAID

SLEEVE

PTFF INS

CONN 1

CONN 2

CONN 3

1

2

1

2

1

2

5V

5V

0V

5V

0V

CONN 1

0V

CONN 2

CONN 3

TWISTEDPAIRS

3

TWISTED

1

2

3

1 2

4

5

6

7

8

9

345 6

9 10

1D

1*RQ2D

2*RQ3D

3*RQ

EXPANDOBLACK

15 PIN C4

7 8

1112

1*D1RQ

2*D2RQ

3*D3RQ

131415

C4

SHIELDSHIELD

PAIR #

H4

J4

(2) 18 AWG WIRESCONNECTED TO THE BRAID

12 POSPIN

12 POSPIN

NAMEPINNO.LABEL

SIGNAL WIRECONNECTOR SLEEVE

1 2 345 6

CONDUCTOR

1U1V1W1G

1BKP1BKM

2BKP2BKM

2U2V2W2G

1 2 34

2U2V2W2G

2U2V2W2G

BLACK1BLACK2BLACK3

BLACK5BLACK6BLACK7

BLACK9

GRN/YEL4

GRN/YEL8

COLOR

18 AWG18 AWG

18 AWG18 AWG

SIZE

789

10 1112 KEY PLUG

KEY PLUG

5 6 789 101112

H4

J4

16 AWG16 AWG16 AWG16 AWG16 AWG16 AWG16 AWG16 AWG

16 AWG16 AWG16 AWG16 AWG16 AWG16 AWG 16 AWG16 AWG

K412 POSPIN

1 2 345 6

18 AWG18 AWG

16 AWG16 AWG16 AWG16 AWG

789 10 1112

3U3V3W3G

3BKP3BKM

BRAKE WIRE = 18 AWG 19/ 30 600V UL1199 PTFE W/BLK INS.

K4

5V 0V

4

5

1

6

7

2

8

9

3

1D

1*RQ

3D

3*RQ

A D

A B CD

A B

1U

1BKP

1V

1BKM

1W1G

3U

3BKP

3V

3BKM

3W3G

SHELL/KEY ASSEMBLY POSITION

SEC. A–A

1*D1RQ

3*D3RQ

TYPICAL 3 PLACES

PWR/PULSE 1–3EE–3287–321–001MFG NAME REV

4’’

40’’

EXPANDO OVER CONDUCTORS

20 AWG41/36

TINNEDCOPPERBLACK

PVC INS

TWISTEDPAIRS

6

36 AWGTINNEDCOPPERBRAID

BLACKEXPANDO

NAMEPINNO.LABEL

SIGNAL WIRE BRAIDEDSHIELD

TYPE& COLOR

CONNECTOR SLEEVETWISTEDPAIR #

2 POS

2 POS

2 POS

SOC

SOC

SOC

SOCKET

600V

10’’

10’’

10’’

11’’

11’’

11’’

22’’

23’’ 24’’

NO SHIELD CONNECTIONAT THESE CONNECTORS

22’’

22’’

22’’

23’’

23’’

23’’

24’’

24’’

24’’

115’’

115’’

113’’

BLACK 10BLACK 9

BLACK 19BLACK 20

BLACK 29BLACK 30

(1) 18 AWG

(1) 16 AWG(1) 16 AWG(1) 16 AWG(1) 16 AWG

(2) 16 AWG(1) 16 AWG(2) 16 AWG(1) 16 AWG

(2) 16 AWG(2) 16 AWG(2) 16 AWG

(1) 18 AWG

(1) 18 AWG(1) 18 AWG

(1) 18 AWG(1) 18 AWG

(2) 16 AWG

BLACK10

BLACK11BLACK12BLACK13

GRN/YEL14BLACK15BLACK16BLACK17

BLACK19BLACK20

BLACK21BLACK22BLACK23

GRN/YEL24 BLACK 25BLACK 26BLACK 27

BLACK 29BLACK 30

GRN/YEL28

3U3V3W3G

BLACK

BLACK

BLACK

EXPANDO

EXPANDO

EXPANDO16 AWG16 AWG16 AWG16 AWG

POWER WIRE = 16 AWG 19/ 29 600V UL1199 PTFE W/BLK OR GRN/YEL INS.

SPLIT POINTS

CONNECT SHIELDSCOVER W/TAPE WRAP

EX

PA

ND

O O

VE

R S

HIE

LD O

VE

R C

ON

DU

CT

OR

S

EX

PA

ND

O O

VE

R S

HIE

LD O

VE

R C

ON

DU

CT

OR

S

6” LG BRANCH

2 PINSHIELDED

6VA

6VA0VA

0VA12

F G J N S R

SHIELDFRONT VIEW OF SOCKETS

115’’

115’’

CB

A

GUIDE KEY

CABLE RUN 10SL–3

SEC. B–B

PWR–2

PWR–3

SEE NOTE 4BPWR–1

PWR–2

PWR–3 PULSE–1

BATT–1

PULSE–3

BATT–3

PWR–1

BRK–1

PWR–2

BRK–2

PWR–1

BRK–1

PWR–3

BRK–3

20–29SWCABLERUN

GUIDE KEY

EXPANDO OVER CONDUCTORS

113’’

BB

C C

FRONT VIEW OF SOCKETS

SEC. C–C

CD

BA

GUIDE KEY

CABLE RUN 18–10


SOLDERED CONNECTIONCOVER W/SHRINK TUBING

SLEEVE TUBING

SLEEVING


BRAIDED SHIELD

CONDUCTORSBETWEEN SHIELDSSOLDERED CONNECTION SHIELD

SLEEVING

DETAIL ”B”

SLEEVING

DETAIL ”A”

4. TERMINATION OF SHIELD TO CONDUCTOR & SHIELD TO SHIELD

TAPE WRAP TRUNK TO LEGS

ASSEMBLY NOTES:

1. ALL LENGTH DIMENSIONS + 1/2 IN.

SHOWN WITH ALL INFORMATION INDICATED.

2. SPECIFIC WIRE, LABELS, SHIELD AND SLEEVE MATERIAL NOT CALLED OUT ON BOM.

3. HARNESS ASS’Y. LABEL TO BE ATTACHED AS

G BLACK 17

(3) 16 AWG(1) 18 AWG(2) 18 AWGE

F

BLACK 15

BLACK18

TYPE

TYPE

TYPE

BLK1 BLK2BLK3

GRN/YEL4

BLACK 16

BRK 1 ,2 & 3 BRAKE CONNECTOR

A A

115’’

6” LG BRANCH

2 PINSHIELDED

PULSE–1

BATT–1

115’’113’’

2 PINSHIELDED

PULSE–2

BATT–2

TWISTEDPAIRS

20 AWG19/ 32

600VBLACK

PTFE INS

BLACKEXPANDO


NAMENO.LABELSIGNALCONNECTOR SLEEVECOND. QTY. BRAIDED

SHIELD

5V 0V

2D

2*RQ

A D

A B CD

A B

2U

2BKP

2V

2BKM

2W2G

2*D2RQ

6VA

6VA0VA

0VA12

F G J N S R

SHIELD

PULSE–2

BATT–2

PWR–2

BRK–2

SOC/PIN WIRE COLOR& SIZE TYPEOR PAIR #

TWISTEDPAIRS

20 AWG19/ 32

600VBLACK

PTFE INS

BLACKEXPANDO


2U

2V2W

BLK 5 & 11

BLK 6 &12

BLK 7 & 13

G/Y 8,14,18

5V 0V

A D

A B CD

A B

6VA

6VA0VA

0VA12

F G J N S R

SHIELD

PULSE–3

BATT–3

PWR–3

BRK–3

TWISTEDPAIRS

20 AWG19/ 32

600VBLACK

PTFE INS

BLACKEXPANDO


BLK 21 & 25

BLK 22 & 26

BLK 23 & 27

G/Y 24 & 28

POTTEDBACKSHELL

20–29S

10SL–3S

18–10S

POTTEDBACKSHELL

22–22SFF

DD

AXIS 1 POWER CONNECTOR

SEC. D–D

CD

BA

GUIDE KEY

CABLE RUN


SEC. E–E

CD

BA

GUIDE KEY

CABLE RUN


EF

G

24–10S

22–22S

150’’

TYPICAL FOR POWER AND BRAKE

TYPICAL FOR PULSEEXPANDO OVER SHIELD OVER CONDUCTORS

120’’

95’’0’’

PWR 1&2

SHIELDED 20 AWG PTFE

BLACK WIREJUMPERS


BLACK WIREJUMPERS


BLACK WIREJUMPERS

GROUND 1

GROUND 2

GROUND 1

GROUND 2

TYP

TYP

SEE NOTE 5

5. HEIGHT OF POTTED CONNECTORS

1.75’’ MAX



45’’

PULSE 1 AND PULSE 2 ENCODER CONNECTOR

20–29SWCABLERUN

GUIDE KEY

PULSE 3 ENCODER CONNECTOR

SEC. F – F

E E

148

150’’

150’’

150’’

148’’

148’’

148’’

130’’

113’’

113’’

113’’

20–29S

POTTED BACKSHELLSEE NOTE 5

20–29S

10SL–3S

A A

TYP

EE-3287-321-001

MARO2P10203703E

13. CABLES

13–26

NOTES

MARO2P10203703E

13. CABLES

13–27

Figure 13–13 . Axes 4, 5, and 6 Power Harness

NAME

SOC/ PINNO.LABEL


TYPE& COLOR

CONNECTOR

20 AWG 36 AWGTINNEDCOPPER

BLACKBRAID

SLEEVE

CONN 4

CONN 5

CONN 6

1

2

1

2

1

2

5V

5V

0V

5V

0V

CONN 4

0V

CONN 5

CONN 6

TWISTEDPAIRS

6

TWISTED

1

2

3

1 2

4

5

6

7

8

9

345 6

9 10

4D

4*RQ5D

5*RQ6D

6*RQ

NAMESOC/ PIN

NO.LABEL SIGNAL WIRE TYPE

& COLORCONNECTOR

UL1199

BLACK

SLEEVENUMBER

1

2

3

4

5

6

9

10

CONDUCTOR

18 AWG19/30

13

14

1

2

3

4

5

6

7

8

9

10

11

12

4U

4V

4W

4G

5U

5V

5W

5G

6U

6V

6W

6G

NAMESOC/

PIN NO.LABELSIGNAL WIRE TYPE

& COLORCONNECTOR

TINNED COPPER

SLEEVENUMBER

1 2

34

CONDUCTOR

18 AWG 19/30

A1 A2 A3B1B2 B3

123456789101112131415161718

4U4V4W4G

5U5V5W5G

6U6V

6W6G

4BKP4BKM

5BKP5BKM

6BKP6BKM

5 6 123 4 56

#8 AWG 168/30 TINNED COPPERFLEXIBLE POLYETHYLENE JACKETGREEN WITH TWO CO–EXTRUDED YELLOW STRIPES 180 APART

GROUND

BLACK

EXPANDOBLACK

EXPANDO

BLACKEXPANDO



SLEEVE TUBING

SLEEVING


NAME

PINNO.


TYPE& COLOR

CONNECTOR

20 AWG19/ 32UL1199


SLEEVE

PAIRS

TWISTED

0V

LABEL3

6VA0VA

SHIELDED

BLACK WIREJUMPERS

NAME

PINNO.


TYPE& COLOR

CONNECTOR


SLEEVETWISTED

1 0V8 56

10

1213

LABEL

1 2

SHIELDED

BLACK WIREJUMPERS

6*RQ

6*D6D

1

5

4BLACK

EXPANDO

2

7

6BLACK

EXPANDO

BRAIDED SHIELD

CONDUCTORSBETWEEN SHIELDSSOLDERED CONNECTION

SHIELDSLEEVING

DETAIL ”B”

SLEEVING

DETAIL ”A”

DISCARD RETAINING SCREWS SUPPLIED

USE O–RING ITEM 14 AS RETAINERWITH BACKSHELL AND REPLACE WITH ITEM 13.

FOR CONNECTOR MTG SCREWS (INTERNAL TO SHELL).

5MMTYP

15 POS

GROUND WIRE

PAIR #

PAIR #

NAME

PINNO.


TYPE& COLOR

CONNECTOR


SLEEVE

5V

TWISTED

SHIELD

A1 0VA2 A3B3

A6

A4B4

B60VA6VA

LABEL

1 2

6VA0VA

SHIELDED

BLACK WIREJUMPERS

3

9

8BLACK

EXPANDO

PAIR #D4

7 8

1112

4*D4RQ

5*D5RQ

6*D6RQ

131415

D4

SHIELDSHIELD

15 POS

9 POS

PAIR # DESCRIP

7

8

11

12

15

4BKP

4BKM

DESCRIP

A4

5BKP

5BKM

KEY

NAMESOC/ PIN

NO.LABEL SIGNAL WIRE TYPE

& COLORCONNECTOR

BLACK

SLEEVENUMBER

1

2

3

4

5

6

9

CONDUCTOR

18 AWG

13

14

15

16

17

18

BLACK

EXPANDO

7

8

6BKP

6BKM

DESCRIP

B4

KEY

PWR/PULSE 4–6EE–3287–322–001MFG NAME REV

A4

B4 TYP 17–PLACES

(2) 18AWG WIRESCONNECTED TO THE BRAID

BLACKBLACKBLACK

BLACKBLACKBLACKBLACKBLACK


BLACKBLACK

GRN/YEL

GRN/YEL

GRN/YEL

19/ 32 UL1199

600V

PTFE

20 AWG

BLACK

TWISTEDPAIRS

3

19/ 32 UL1199

600V

PTFE


EXPANDOBLACK

NAMESOC/ PIN

NO.LABELSIGNAL WIRE BRAIDED

SHIELDTYPE

& COLORCONNECTOR SLEEVETWISTED

PAIR # DESCRIP

0’’

0’’

1’’

1’’

4’’

2 POS

2 POS

2 POS

SOC

SOC

SOC

12’’

13’’ 14’’

PIN

PIN

30’’

12’’

12’’

13’’

13’’ 14’’

14’’

PIN

KEY

PTFE

600V

19/30UL1199

600V

PTFE

20 AWG PTFE

20 AWG PTFE

2 PIN

2 PIN

2 PIN

600VPTFE

20 AWG PTFE

20 AWG19/ 32UL1199

PAIRS3

600VPTFE

20 AWG19/ 32UL1199

PAIRS3

600VPTFE

PTFE

TAPE WRAP ,TRUNK TO LEGS

EX

PA

ND

O O

VE

R C

ON

DU

CT

OR

S

SPLIT POINTSSPLICE SHIELDS

SEE NOTE 4APPLY TAPE WRAP

EX

PA

ND

O O

VE

R C

ON

DU

CT

OR

S

CONNECT SHIELDSEE NOTE 4

BRAND REX #XP0845168–165

EX

PAN

DO

OV

ER

SH

IELD

OV

ER

CO

ND

UC

TO

RS

EX

PAN

DO

OV

ER

SH

IELD

OV

ER

CO

ND

UC

TO

RS

GRN/YEL

GRN/YEL

GRN/YEL

NOTE: SCREW THREAD SHOULD NOT EXCEED 5mm BEYOND CONNECTOR FACE.

TYPE

TYPE

TYPE

TYPE

A5

6RQ

5*RQ

5*D5D

SHIELD0VA6VA

6VA0VA

5RQ 5V

4*RQ

4*D4D

SHIELD0VA6VA

4RQ 5V

14

N/C

1 8 56

10

1213

1 2

14

N/C

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACKBLACKBLACKBLACKBLACKBLACK

BLACKBLACKBLACKBLACKBLACKBLACKBLACK


6’’ LG BRANCH

6’’ LG BRANCH

6’’ LG BRANCH

24’’ LENGTH

35’’

GR

OU

ND

PWR 4 PWR 4

PWR 5

PWR 6

PWR 5

PWR 6

PULSE 4

PULSE 4

PULSE 5

PULSE 6

PULSE 5

PULSE 6

BATT 4

BATT 4

BATT 5

BATT 6

BATT 5

BATT 6

EXTRACTION TOOL: AMP 455822–2

210’’

204’’

204’’202’’

202’’

202’’

165’’

130’’

OUTSIDEHARNESS

202’’

202’’

202’’

204’’

204’’

EE-3287-322-001

TERMINATION OF SHIELD TO CONDUCTOR AND SHIELD TO SHIELD

MARO2P10203703E

13. CABLES

13–28

NOTES

MARO2P10203703E

13. CABLES

13–29

Figure 13–14 . Purge Control Cable

EE-3287-323-001

MARO2P10203703E

13. CABLES

13–30

NOTES

MARO2P10203703E

13. CABLES

13–31

Figure 13–15 . Six Axis Battery Harness

NAME

SOC/PINNO.

LABELSIGNAL WIRE BRAIDED

SHIELDTYPE& COLOR

CONNECTOR

20 AWG36 AWGTINNEDCOPPER

BLACK

BRAID

AXIS 1

AXIS 2

AXIS 3

1

2

1

2

1

2

TYP. END POINT OF SHIELD/JACKET

SOC

SOC

SOC

TWISTEDPAIR

NUMBER

1

2

3

6V–1

0V–1

6V–2

0V–2

6V–3

0V–3

15 PIN MINI

NAMEPINNO.

SIGNAL

1 2 345 6 789

101112

LABEL

S4

CONNECTOR WIRE BRAIDEDSHIELD

TYPE& COLOR

20 AWG 36 AWGTINNEDCOPPERBRAID

TWISTEDPAIRS

TWISTEDPAIR

NUMBER

1

2

3

131415

SHIELD 18AWG BLK

5

6

4

66V–10V–16V–20V–26V–30V–3

6V–40V–46V–50V–56V–60V–6

EE–3287–324–001REV ––

3 PAIRS

19/ 32

600VPTFE

SEE NOTE 4, DETAIL A FOR SHIELD CONNECTION

SEE DET 4B

UL 1199

UL 119919/ 32

600VPTFEBLACK

0’’ 1’’ 3’’ 5’’

TAPE WRAPPEDSPLIT POINT

SHIELDS SPLICED

SEE DET 4B

TAPE WRAPPEDSPLIT POINT

SHIELDS SPLICED

TYP 7 PLACES

BLUE EXPANDO OVER BRAID SHIELD OVER CONDUCTORS, TYP.

SOC

SOC

SOC

NAME

SOC/PINNO.

LABELSIGNAL WIRE BRAIDED

SHIELDTYPE& COLOR

CONNECTOR

20 AWG36 AWGTINNEDCOPPER

BLACK

BRAID

AXIS 4

AXIS 5

AXIS 6

1

2

1

2

1

2

TWISTEDPAIR

NUMBER

4

5

6

6V–4

0V–4

6V–5

0V–5

6V–6

0V–6

3 PAIRS

19/ 32

600VPTFE

UL 1199

BATT

BATT

BATT

BATT

BATT

BATT

BATT

BATT

BATT

BATT

BATT

BATT

AXIS 4

AXIS 5

AXIS 6

AXIS 1

AXIS 2

AXIS 3

S4MANUF

INTRINSICALLY SAFE

SHIELD STOPS BEFORE SLEEVE.TYP. END POINT OF SHIELD & SLEEVE

2 POS

2 POS

2 POS

0



SLEEVE TUBING

SLEEVING


BRAIDED SHIELD

CONDUCTORSBETWEEN SHIELDSSOLDERED CONNECTION SHIELD

SLEEVING

DETAIL ”B”

SLEEVING

DETAIL ”A”TAPE WRAP TRUNK TO LEGS



160’’

204’’

204’’

204’’

202’’

202’’

202’’

105’’

105’’

140’’

80’’

TERMINATION OF SHIELD TO CONDUCTOR AND SHIELD TO SHIELD

EE-3287-324-001

MARO2P10203703E

13. CABLES

13–32

NOTES

MARO2P10203703E

13. CABLES

13–33

Figure 13–16 . Purge Flow Switch Arm Cable

FS1 FS1/NOFS1/C

FLOW SWITCH

BLUEBLACK

0

2 PIN

NAMEPINNO.

SIGNAL

1 2

CONNECTORLABEL

WIRESLEEVECOLOR& MAT’L

LT. BLUE

FS1 REV. EE–3287–340–001

MANUF. NAME

COLOR

A

2’’

CUT OFF SPARE RED WIRE

EE–3287–340–00118 IN

DIM. ACABLE VERSIONREV LEVEL

A

PG

NO






INCLUDED ON CABLE LABEL.SEE LENGTH CHART FOR REV LEVEL

457 MM

EXPANDO

EE-3287-340-001

MARO2P10203703E

13. CABLES

13–34

NOTES

MARO2P10203703E

13. CABLES

13–35

Figure 13–17 . Solenoid Cable

A

SOL1MFG. NAME

SEE NOTE 1

INTRINSICALLY SAFE

0

EE–3287–348–XXX2 PIN

9”

2”

NAME

SOC/PINNO.

SIGNALLABEL

CONNECTOR

PSOL–1PSOL–2

1 2 SOL1

SOL REV. SOL1

WIRECOLOR

REDBLACK

EE–3287–348–00118 IN457 MM


B

PG

NO

NOTES:







3 NC

NAMEPINNO.

SIGNAL

PSOL–1PSOL–2

1 2

CONNECTORLABEL

WIRE

SOL1

COLOR

REDBLACK

EE-3287-348-001

MARO2P10203703E

13. CABLES

13–36

NOTES

MARO2P10203703E

13. CABLES

13–37

Figure 13–18 . Purge Pressure Switch Cable

A

NAMESIGNAL

LABEL

PS1–P

PS1–N

CONNECTOR

PS1 N.O.

PS1 COM

MFG. NAME

INTRINSICALLY SAFE

0

EE–3044–345–XXX2 PINNAMEPINNO.

SIGNAL

PS1–PPS1–N

1 2

CONNECTORLABEL

WIRESLEEVECOLOR

& MAT’L

ASSEMBLY NOTES:





SYMBOL DENOTES DIMENSIONS IN INCHES.2.

PS1N.O.

PS1COM

PRES SW REV.

PS1

COLORRED

BLACKBLUE

PVC

9’’

EE–3044–345–001 18 IN457 MM


A PG

NO

2’’WIRE

COLOR

RED

BLACK

PS1

2’’

EE-3287-345-001

MARO2P10203703E

13. CABLES

13–38

NOTES

MARO2P10203703E

13. CABLES

13–39

Figure 13–19. R-J2 Robot Bypass Switch Arm Cable (Optional)

3.00” 3.00”

TYP.

EE–3185–356–XXX

MFG. NAME

SEE NOTE 1

NOTES:







INTRINSICALLY SAFE

A

3.00”

EE–3185–356–001 60 IN 1524 MM

DIM. ACABLE VERSION

9 PIN

NAMEPINNO.

SIGNAL

1 2

CONNECTORLABEL

SLEEVECOLOR& MAT’L

EE–3185–356–XXX

MFG. NAME

INTRINSICALLY SAFE

PG

NO

0

RED

BLACK

WIRECOLORS

BLACKEXPANDO

BYPASS REV. BYPASS REV. BYPASS BYPASS3456789

BYPASS

3.00”

BLUE

SHIELD

SHIELDAND

COMN.O.

N.C.

NO SHIELD CONNECTION

AT THIS END

1’’

EE-3185-356-001

R-J2 Robot Bypass Switch Arm Cable

MARO2P10203703E

13. CABLES

13–40

NOTES

14 OPENERS AND OPTIONS

OPENERS AND OPTIONS


Openers and Options The following section includes schematics and cable drawings. 14–1. . . . . . . . . . . . . . P-10 door opener and P-15 hood and deck opener. 14–3. . . . . . . . . . . . . . . . . . . . Integral Pump Control (Option) 14–51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Release Option 14–81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MARO2P10203703E14–2

14. OPENERS AND OPTIONS

NOTES

MARO2P10203703E


14–3

Figure 14–1. P-10 Door Opener Electrical Layout

CONNECTIONS

JF8

JF9

SWITCH

PURGE VALVE

MOTOR/BRAKE

PULSE

DOOR OPENER

UPPER LEVEL BOM

DOOR OPENER

UPPER LEVEL BOM

PRESSURE

PS2

EE–3186–340–001

REFERENCE

REFERENCE EE–3066–322–001

GROUND CABLE (6.8MM)

UNIT

EE–3044–401

EE–3044–401

EE–3186–112–105

EE–3186–111–105

SOL2

EE–3186–301–001

FLOW SWITCH FS2

EE–3186–323–001

AA1 AA4

AB1 AB4

AC1AC4

AD1 AD4

PWR INPUT

AE1 AE4

AF1 AF4

PRES SW SHOWNON MECH BOM

SOL VALVE SHOWNON MECH BOM

FLOW SW ASSY

INTERCONNECTION CABLES FOR US

R–J2

CONTROLLER

AUXAXISBD

PURGECONTROL

UNIT

JF10

AXIS 1

INNER ARM

AXIS 2

OUTER ARM

AXIS 3

RAIL

a6/3000

a6/3000

a6/3000

A06B–0128–B175

A06B–0128–B175

RAIL

INNER ARM

OUTERARM

EE–3186–311–001

EE–3186–312–001

EE–3186–313–001

EE–3186–314–001

EE–3186–315–001

EE–3186–316–001

PG29

PG29

PG29

PG9

ISGND

EE–3186–111–110EE–3186–111–115EE–3186–111–125EE–3186–111–135EE–3186–111–145EE–3186–111–155

EE–3186–112–110EE–3186–112–115EE–3186–112–125EE–3186–112–135EE–3186–112–145EE–3186–112–155

EE–3186–101–105EE–3186–101–110EE–3186–101–115EE–3186–101–125EE–3186–101–135EE–3186–101–145EE–3186–101–155

EE–3287–116–105EE–3287–116–110EE–3287–116–115EE–3287–116–125EE–3287–116–135EE–3287–116–145EE–3287–116–155

EE–3186–115–105EE–3186–115–110EE–3186–115–115EE–3186–115–125EE–3186–115–135EE–3186–115–145EE–3186–115–155

DC/DC

BATTERY

ISB2–3ISB2–4

3

3

6V

0V

ISRR

LTERMS

MTERMS

PURGECONTROL 4

6BKPBKM

PURGEBD

4

4

4

324VPG0V PG

3 PSB1PSB2FSB1FSB2

ISTB 78

SENSOROUTPUT

PURGED

CAVITY

ARM CABLES

AG

1

AH

1A

H4

AJ1

AJ4

AK

1A

K4

AL1

AM

1A

M4

AL4

AN

1A

N4

A06B–0128–B675–0008

EOAT1EOAT2

AMP 5 AXIS 1 RAIL

AMP 6 (L)AXIS 2

INNER ARMAMP 6 (M)

AXIS 3OUTER ARM

NOTE: I.S. GROUND IS A SEPARATE

INTRINSICALLY SAFE GROUND

AT THE PURGE CONTROL UNIT

MOTOR POWER (16.9 MM DIA.)

ENCODER SIGNALS (17.4 MM DIA)

INTRINSICALLY SAFE (17.4 MM DIA)

EE–3186–333–001MAGNETSWITCH

EE–3186–319–001

EE–3185–356–001BYPASS

EE–3186–351–001

SEE NOTE 1

AG

4

NOTES1. CABLES EE–3186–319–001 AND EE–3186–333–001

NEED TO BE SOLDERED TO THE BREAKAWAY JOINT PINSAS SHOWN HERE

SOLDER ANDCOVER W/ SHRINK


PURGEBARRIER

ISRRBYPASSOUTPUT

EOAT5EOAT6

AXIS 1

AXIS 2

AXIS 3

INNERARM

OUTERARM

CRANK

LINK

INTERNALGND WIRE

GND WIRES

EE–3158–316–001

(2) EE–3158–316–001(2) EE–3158–316–002

2. SPARE SPRING CONTACT PART NUMBER HDWMO0000046590

EE-3186-333-001EE-3186-319-001

EE-3186-001

MARO2P10203703E


14–4

NOTES

MARO2P10203703E


14–5

Figure 14–2. P-10 Door Opener Euro Electrical Layout

CONNECTIONS

JF8

JF9

PURGE VALVE

MOTOR/BRAKE

PULSE

DOOR OPENER

UPPER LEVEL BOM

DOOR OPENER

UPPER LEVEL BOM

EE–3186–340–001

REFERENCE


UNIT

EE–3044–401

EE–3186–112–105

EE–3186–121–105

SOL2

EE–3186–301–001

EE–3186–348–001

AA1 AA4

AB1 AB4

AC1AC4

AD1 AD4

PWR INPUT

AE1 AE4

AF1 AF4



R–J2CONTROLLER

AUXAXISBD

PURGECONTROL

UNIT

JF10

AXIS 1

INNER ARMAXIS 2

OUTER ARMAXIS 3

RAIL

a6/3000

a6/3000

a6/3000

A06B–0128–B175

A06B–0128–B175

RAIL

INNER ARM

OUTERARM

EE–3186–311–001

EE–3186–312–001

EE–3186–313–001

EE–3186–314–001

EE–3186–315–001

EE–3186–316–001

PG29

PG29

PG29

PG9

ISGND

EE–3186–121–110EE–3186–121–115EE–3186–121–125EE–3186–121–135EE–3186–121–145EE–3186–121–155

EE–3186–112–110EE–3186–112–115EE–3186–112–125EE–3186–112–135EE–3186–112–145EE–3186–112–155

EE–3186–102–105EE–3186–102–110EE–3186–102–115EE–3186–102–125EE–3186–102–135EE–3186–102–145EE–3186–102–155

EE–3287–116–105EE–3287–116–110EE–3287–116–115EE–3287–116–125EE–3287–116–135EE–3287–116–145EE–3287–116–155

EE–3186–115–105EE–3186–115–110EE–3186–115–115EE–3186–115–125EE–3186–115–135EE–3186–115–145EE–3186–115–155

DC/DC

BATTERY

ISB2–3ISB2–4

3

3

6V

0V

ISRR

LTERMS

MTERMS

PURGECONTROL 4

6BKPBKM

PURGEBD

4

4

4

324VPG0V PG

3 PSB1PSB2FSB1FSB2

ISTB 78

SENSOROUTPUT

PURGED CAVITY

ARM CABLES

AG

1

AH

1A

H4

AJ1

AJ4

AK

1A

K4

AL1

AM

1A

M4

AL4

AN

1A

N4

A06B–0128–B675–0008

EOAT1EOAT2

AMP 5 AXIS 1 RAIL

AMP 6 (L)AXIS 2

INNER ARMAMP 6 (M)

AXIS 3OUTER ARM

NOTE: I.S. GROUND IS A SEPARATE

INTRINSICALLY SAFE GROUND

AT THE PURGE CONTROL UNIT




EE–3186–333–001MAGNETSWITCH

EE–3186–319–001

EE–3185–356–001BYPASS

EE–3186–351–001

SEE NOTE 1

AG

4

NOTES1. CABLES EE–3186–319–001 AND EE–3186–333–001

NEED TO BE SOLDERED TO THE BREAKAWAY JOINT PINSAS SHOWN HERE



PURGEBARRIER

ISRRBYPASSOUTPUT

EOAT5EOAT6

AXIS 1

AXIS 2

AXIS 3

INNERARM

OUTERARM

CRANK

LINK

INTERNALGND WIRE

GND WIRES

EE–3158–316–001

(3) EE–3186–326–001(1) EE–3186–326–002

2. SPARE SPRING CONTACT PART NUMBER HDWMO0000046590

EE-3186-333-001EE-3186-319-001

4

7

65

JUMPER REMOVED

HR2151PRES & FLOWSWITCHES

FL

OPPR

7

6

5

4

EE-3186-002

MARO2P10203703E


14–6

NOTES

MARO2P10203703E


14–7

Figure 14–3. P-200 Plus P-10 or P-15 Controller Bypass Package

DELTRONW112A

24V @ 1.2A

BY

PA

SS

LS

I/P

TR

IGG

ER

FLO

W

2ND

TR

IGG

ER

P–1

0 or

P–1

5

SO

LEN

OID

SO

LEN

OID

I/P P

OW

ER

ISB1ISB2

ISB3

EE

–311

2–60

0–00

1

EE

–311

2–60

0


UPPER LEFT CORNER

ISTB TERMINAL STRIP

1’’

IS GND

FOR CABLE WIRING, SEE EE–3287–500



NOTES:




PS OVP

12 3 4

5

KF

D2–

SR

–Ex1

.W.L

BP

–10

or P

–15

KF

D2–

SR

–Ex1

.W.L

B

ISB10

IDEC IBRC

EE-3287-513

PA

RT

S S

EN

SE

BY

PAS

SLS

MARO2P10203703E


14–8

NOTES

MARO2P10203703E


14–9

Figure 14–4 . P-10 or P-15 Power Connection Cable

ASSEMBLY NOTES:


1’’TYP.



TYP

SEE NOTE 1


CABLE SPECIFICATION



MAX

ALL LENGTH DIMENSIONS + 1/2 IN.


P/N=T–13038 CABLE O.D.= 16.9 MM (0.665”)

1 2 3 4 5 6 7 8 9 10

SOC/PINNO.

WIRECOLOR/NUMBER

TYP

SIGNALNAME

1U 1V 1W 1G

1BKM 1112

18 AWG

KEY PLUG

CONNECTORLABEL

1BKP

12 POS SOC

SOC12 POS

TYP

1

5

6

4

7 89

10

EE–3186–111–XXX

MFG. NAME

EE–3186–111–XXX

MFG. NAME

TYP

TYP

WIRECOLOR/NUMBER

WIRETAG

1G

1W

1U

1V

2W

2V

2G

WIRECOLOR/NUMBER TAG

CONTROLLER

POINT

0

A

BLACK/3

2

3 10 TYP

65’’

19’’

RED/1

WHITE/2

RED/1WHITE/2

2.

16’’ TYP 3 PL

REV

OPENER POWER

AA1

AC1

AA1

WIRECONNECTING

BKP4

TYP

11

2U REV

OPENER POWER

3U

3V

3W

3G

3U

3V

3W

3G

WHITE/4

RED/5

GREEN/6

RED/7

WHITE/8

BLACK/9

GREEN/10

RED/11

WHITE/12

BLACK/13

GREEN/14

RED/15

WHITE/16

BLACK/17

GREEN/18

CONTROLLER

POINTCONNECTING


C EE–3186–111–110 IN MM YES492 12500

C EE–3186–111–115 IN MM YES

C IN MM YES

C

EE–3186–111–125

IN MM YES

C YESIN MM

C

EE–3186–111–135

YESIN MM

C EE–3186–111–105 IN MM YES7500

17500

27500

37500

295

689

1083

1476

EE–3186–111–145

EE–3186–111–155

47500

57500

1870

2264

AB1

1 2 3 4 5 6 7 8 9 10

SOC/PINNO.

WIRECOLOR/NUMBER

SIGNALNAME

2BKM 1112

18 AWG

KEY PLUG

CONNECTORLABEL

2BKP

AB1

1 2 3 4 5 6 7 8 9 10

SOC/PINNO.

WIRECOLOR/NUMBER

SIGNALNAME

3BKM 1112

18 AWG

CONNECTORLABEL

3BKP

AC1

2U

3U

2V

3V

2W

3W

2G

3G

12 POS SOC

RED/7WHITE/8BLACK/9

GREEN/10

RED/11WHITE/12BLACK/13GREEN/14

BLACK/3WHITE/4

RED/5GREEN/6

RED/15WHITE/16BLACK/17GREEN/18

RAIL

RAIL

INNER

INNER

OUTER

OUTER

AMPLIFIER

AMPLIFIER

AMPLIFIER

5

6

6

BKP4

BKP4

BKP4

BKP4

BKP4

BKM4

BKM4

BKM4

BKM4BKM4

BKM4

6’’

1’’

RED/1 BLACK/3

WHITE/2 WHITE/4

RED/5

GREEN/6

1U

2U

2V

1V

2W

1W

2G

1G

1BKP

1BKM

2BKP

3BKP

2BKM

3BKM

L

L

L

L

L

L

L

L

M

M

M

M

M

M

M

M

1U

1V

1W

1G

2U

3U

2V

3V

2W

3W

2G

3G

SIGNAL

SIGNAL

NAME

NAMETWO PLACES

SEE NOTE 3

3. FOR CABLE EE–3186–111–105, USE200 INCHES FOR LEFT PG LOCATION.

320’’

EE-3186-111-105 thru 155

MARO2P10203703E


14–10

NOTES

MARO2P10203703E


14–11

Figure 14–5 . P-10 or P-15 European Shielded Power Connection Cable

ASSEMBLY NOTES:


1’’TYP.



TYP

SEE NOTE 1


CABLE SPECIFICATION



MAX

ALL LENGTH DIMENSIONS + 1/2 IN.

16–#14 & 4–#18 AWG CONDUCTORS

P/N=T–14847 CABLE O.D.= 16.9 MM (0.665”)

1

2

3

4

5

6

7

8

9

10

SOC/PINNO.

WIRECOLOR/NUMBER

TYP

SIGNALNAME

1U

1V

1W

1G

1BKM

11

12

18 AWG

KEY PLUG

CONNECTORLABEL

1BKP

12 POS SOC

SOC12 POS

TYP

1

5

6

4

7 89

10



TYP

TYP

WIRECOLOR/

NUMBER

WIRETAG

1G

1W

1U

1V

2W

2V

2G

WIRECOLOR/NUMBER TAG

CONTROLLER

POINT

0A

BLACK/3

2

3 10 TYP

65’’

19’’

RED/1

WHITE/2

2.

BWPRODUCTION RELEASE

16’’ TYP 3 PL

REV

OPENER POWER

AA1

AC1

AA1

WIRECONNECTING

BKP4

TYP

11

BF

2U REV

OPENER POWER

3U

3V

3W

3G

3U

3V

3W

3G

RED/5

CONTROLLER

POINTCONNECTING


EE–3186–121–110 IN MM YES492 12500

EE–3186–121–115 IN MM YES

IN MM YESEE–3186–121–125

IN MM YES

YESIN MM

EE–3186–121–135

YESIN MM

EE–3186–121–105 IN MM YES7500

17500

27500

37500

295

689

1083

1476

EE–3186–121–145

EE–3186–121–155

47500

57500

1870

2264

AB1

1

2

3

4

5

6

7

8

9

10

SOC/PINNO.

WIRECOLOR/NUMBER

SIGNALNAME

2BKM

11

12

18 AWG

KEY PLUG

CONNECTORLABEL

2BKP

AB1

1

2

3

4

5

6

7

8

9

10

SOC/PINNO.

WIRECOLOR/NUMBER

SIGNALNAME

3BKM

11

12

18 AWG

CONNECTORLABEL

3BKP

AC1

2U

3U

2V

3V

2W

3W

2G

3G

12 POS SOC

RAIL

RAIL

INNERINNER

OUTER

OUTER

AMPLIFIER

AMPLIFIER

AMPLIFIER

5

6

6

BKP4

BKP4

BKP4

BKP4

BKP4

BKM4

BKM4

BKM4

BKM4

BKM4

BKM4

6’’

1’’1U

2U

2V

1V

2W

1W

2G

1G

1BKP

1BKM

2BKP

3BKP

2BKM

3BKM

L

L

L

L

L

L

L

L

M

M

M

M

M

M

M

M

1U

1V

1W

1G

2U

3U

2V

3V

2W

3W

2G

3G

SIGNAL

SIGNAL

NAME

NAME

TWO PLACES

SEE NOTE 3

3. FOR CABLE EE–3186–111–105, USE200 INCHES FOR LEFT PG LOCATION.

SHIELDED W/HYPALON JACKET

11/96

A

A

A

A

A

A

A

GREEN/4

WHITE/6

BLACK/7

GREEN/8

RED/9

WHITE/10

BLACK/11

GREEN/12

BLUE/17

BLUE/18

BLUE/19

BLUE/20

RED/13

WHITE/14

CUT OFF BLACK/15 AND GREEN/16

BLUE/17 BLUE/18

BLUE/19 BLUE/20

RED/13

WHITE/14

RED/1

WHITE/2

BLACK/3GREEN/4

BLUE/17

BLUE/18

RED/5

WHITE/6

BLACK/7

GREEN/8

BLUE/19

BLUE/20

RED/9

WHITE/10

BLACK/11

GREEN/12

RED/13

WHITE/14

CUT OFF BLACK/15 AND GREEN/16

2’’ 2’’

108’’

E60766

320’’

EE-3186-121-105 thru 155

MARO2P10203703E


14–12

NOTES

MARO2P10203703E


14–13

Figure 14–6. P-10 or P-15 Axis 1 Rail Power/Brake Cable

EE–3186–311–001

GUIDE KEY

CABLE RUN

REV. PIN12 POS

60 IN1524 mm


B EE–3186–311–001

PG

NO

NOTES:







REVISION LEVEL.2. SEE LENGTH CHART FOR CABLE VERSION

LABELWIRE

COLORSIGNALNAMENO.

PIN

AA4SIGNAL

NAMEWIRE

COLOR/NUMBER

SOC/PIN NO.

A

B

C

D

1U

1V

1W

1G

AB C

D

GUIDE KEY

CABLE RUNA

BC

SEC. A–A

SEC. B–B

A A

B B

BRAKEAXIS 1

SIGNALNAME

WIRECOLOR/

NUMBER

SOC/PIN NO.

A

B

C

1BKP

1BKM

A0

TYP.

3.0”

1

2

3

4

5

6

7

8

9

10

11

12

1U

1V

1W

1G

1BKP

1BKM

MANUF.POWERAXIS 1

3.0”

18–10S

10SL–3S

WIRE GAGE

18 AWG

18 AWG

WIRE GAGE

AXIS 1 PWRAA4

BLACK, FINE STRANDED


KEY PLUG GRN/YEL

14 AWG

14 AWG

14 AWG

14 AWG

LABEL

LABEL

BRAKEAXIS 1

POWERAXIS 1

WIREGAGE

14 AWG

14 AWG

14 AWG

14 AWG

18 AWG

18 AWG

2

10’’

1 2

3 4 5

6 7

8 9

1011

14 AWG PTFE TEFLON, UL1199


3.

4.WIRE SPECIFICATION NOT SHOWN ON BOM

BLK

BLK

BLK

GRN/YEL

BLK

BLK

1’’

TOL +/– 0.5’’

HEAT SHRINK

BLK

BLK

BLK

BLK

BLK

EE-3186-311-001

MARO2P10203703E


14–14

NOTES

MARO2P10203703E


14–15

Figure 14–7. P-10 or P-15 Axis 2 Inner Arm Power/Brake Cable

EE–3186–312–001REV. PIN

12 POS

24 IN 610 mm


B EE–3186–312–001

PG

NO

NOTES:








LABEL WIRECOLOR

SIGNALNAMENO.

PIN

AB4

SIGNALNAME

WIRECOLOR/

NUMBER

SOC/PIN NO.

A

B

C

D

2U

2V

2W

2G

A A

B B

BRAKEAXIS 2

SIGNALNAME

WIRECOLOR/

NUMBER

SOC/PIN NO.

A

B

C

2BKP

2BKM

A0

TYP.

3.0”

1

2

3

4

5

6

7

8

9

10

11

12

2U

2V

2W

2G

2BKP

2BKM

MANUF.POWERAXIS 2

3.0”

WIRE GAGE

18 AWG

18 AWG

WIRE GAGE

AXIS 2 PWRAB4

KEY PLUG

14 AWG

14 AWG

14 AWG

14 AWG

LABEL

LABEL

BRAKEAXIS 1

POWERAXIS 2

WIREGAGE

14 AWG

14 AWG

14 AWG

14 AWG

18 AWG

18 AWG

1



10’’

GUIDE KEY

CABLE RUNA

BC

SEC. B–B

GUIDE KEY

CABLE RUN

AB C

D

SEC. A–A20–15S

2

3 4 5

6 7

8 9

10

11

2



BLK

BLK

BLK

GRN/YEL

BLK

BLK

1’’

HEAT SHRINK

3.

4.WIRE SPECIFICATION NOT SHOWN ON BOM

TOL +/– 0.5’’

BLK

GRN/YEL

BLK

BLK

BLK

BLK

EE-3186-312-001

MARO2P10203703E


14–16

NOTES

MARO2P10203703E


14–17

Figure 14–8. P-10 or P-15 Axis 3 Outer Arm Power/Brake Cable

EE–3186–313–001REV. PIN

12 POS

36 IN914 mm


B EE–3186–313–001

PG

NO

LABELWIRE

COLORSIGNALNAMENO.

PIN

AC4

SIGNALNAME

WIRECOLOR/NUMBER

SOC/PIN NO.

A

B

C

D

3U

3V

3W

3G

A A

B B

BRAKEAXIS 3 SIGNAL

NAME

WIRECOLOR/NUMBER

SOC/PIN NO.

A

B

C

3BKP

3BKM

A0

TYP.

3.0”

1

2

3

4

5

6

7

8

9

10

11

12

3U

3V

3W

3G

3BKP

3BKM

MANUF.POWERAXIS 3

3.0”

WIRE GAGE

18 AWG

18 AWG

WIRE GAGE

AXIS 3 PWRAC4

KEY PLUG

14 AWG

14 AWG

14 AWG

14 AWG

LABEL

LABEL

BRAKEAXIS 3

POWERAXIS 3

WIREGAGE

14 AWG

14 AWG

14 AWG

14 AWG

18 AWG

18 AWG

1

10’’

GUIDE KEY

CABLE RUN

AB C

D

GUIDE KEY

CABLE RUNA

BC

SEC. A–A

SEC. B–B

18–10S

10SL–3S

2

3 4 5

6 7

8 9

1011

2

BLK

KEY PLUG

BLK

BLK

BLK

BLK

GRN/YEL

1.0’’

HEAT SHRINK

BLKBLK

BLKBLKBLK

GRN/YEL

NOTES:












3.

4. WIRE SPECIFICATION NOT SHOWN ON BOM

TOL. +/– 0.5’’

EE-3186-313-001

MARO2P10203703E


14–18

NOTES

MARO2P10203703E


14–19

Figure 14–9 . P-10 or P-15 Axis 1 Encoder Cable

NOTES:







MFG. NAME

0

REV LEVEL


B

EE–3186–314–001

A

CONN1

EE–3186–314–00174 IN

1879 MM

DIM. ACABLE VERSION

1

2

3

4

5

6

KEY

LABELWIRE

COLORSIGNALNAMENO. NO.

PAIR

1D

1*D

1RQ

1*RQ

1

2

PIN

CONN1

SHIELD

1

2

LABELWIRE


PAIR

3

PIN

5V

0V

REV.

PGNO

20GA BLK


SOLDERED CONNECTION

SHRINK TUBINGDETAIL ”A”

7

9

8

9 PIN

AD4

AD4

AXIS 1 PULSE 2 POS

SOC


3. TERMINATION OF SHIELD TO CONDUCTOR

SIGNALNAME

TWISTPAIRNO.

WIRECOLOR/NUMBER

SOC/PIN NO.

CABLE RUN

SHELL/KEY ASSEMBLY POSITION20–29SW

1.0”TYP.

1

SEE NOTES1 & 2

TYP.

CONNECTOR

CONNECTOR

ABCDEFGHJKLMNPRST

1D

1*D

1RQ1*RQ

5V

0V

1

1

2

3

3

SEC. A–A

A A AL4

1

2

LABELWIRE


PAIRPINCONNECTOR

AL4BLACK BLACK

6V–1

0V–1

3

4

SHIELD20GA BLKSHIELD FROM THIS LEGCONNECTED TO PIN 3 SHIELDS NOT CONNECTED AT THIS END

2

3 4

5

6

7 8

9 10

11

12

5

CABLE SPECIFICATION

HYPALON JACKETMAX. CABLE OD = 0.365’’ (9.27MM)

BRAND REX T–13981

CABLE SPECIFICATION

PVC JACKETMAX CABLE OD = 0.245’’(6.22MM)

BRAND REX T–13103

BROWN

WHT/GRAY PAIRFROM ITEM 1

13

14 BROWN

WHITE

ORANGE

WHITE

YELLOW

WHITE

GRAY

WHITE

WHITE

WHITE

YELLOW

ORANGE

GRAY

PAIR 1CABLE 2

PAIR 1CABLE 2

3 FT LENGTH

14’’

TYP

3.0’’

W/BRAID SHIELD &EXPANDO SLEEVE

15

CONNECT SHIELDS TOGETHERCOVER WITH SHRINK

1.5’’ TYP

3 PAIRS 20 AWG SHIELDED

1 PAIR 20 AWG SHIELDED

TOL +/– 0.5’’

6V–10V–1

1.0”

EE-3186-314-001

4 POSPIN

MARO2P10203703E


14–20

NOTES

MARO2P10203703E


14–21

Figure 14–10 . P-10 or P-15 Axis 2 Pulse Cable

NOTES:







MFG. NAME

0

REV LEVEL


A

EE–3186–315–001

A

EE–3186–315–001 24 IN610 MM

DIM. ACABLE VERSION

1 2 345 6

LABELWIRE


PAIR

2D2*D

2RQ2*RQ

1

2

PIN

CONN2

SHIELD

1 2

LABELWIRE

COLORSIGNALNAMENO.

PIN

5V0V

REV.

PG

NO

20GA BLK


SOLDERED CONNECTION


7

98

9 PIN

AXIS 2 PULSE 2 POSSOC



SIGNALNAME

TWISTPAIR

NO.

WIRECOLOR/

NUMBER

SOC/PIN NO.

1.0” TYP.

1.0”TYP.

SEE NOTES1 & 2

TYP.

CONNECTOR

CONNECTOR

ABCDEFGHJKLMNPRST

2D

2*D

2RQ2*RQ

5V

0VA A

BLACK

BLACK1 2

LABELWIRE

COLORSIGNALNAMENO.

PINCONNECTOR

AM4

AM4

AE4AE4

BLACK

BLACK

THIS SHIELD NOTCONNECTED

34

4 POSPIN

SHIELD20GA BLK

CABLE RUN


SEC. A–A

AE4 AND CONN2 SHIELDS CONNECTED TO EACH OTHER, BUT NOT CONNECTED TO ANY PIN.

THIRD SHIELD, AM4, NOT CONNECTED AT THIS END

WHITE

WHITE

ORANGE

YELLOW

BROWN

BROWN

1

2

3 4 5

6

7 8

9 10

11

12

5

2

CUT OFF PAIR 3, WHITE/GRAY

13

4’’

CABLE SPECIFICATION

CABLE SPECIFICATION3 PAIRS 20 AWG W/ SHIELDHYPALON JACKET

MAX OD = 0.365”(9.27MM)

1 PAIR 20 AWG W/SHIELDPVC JACKET

MAX OD = 0.245’’ (6.22MM)BRAND REX T–13103

BRAND REX T–13981

CABLE SPECIFICATION1 PAIR 20 AWG W/SHIELD

PVC JACKETMAX OD = 0.245’’ (6.22MM)

BRAND REX T–13103

CABLE 1

CABLE 1

CABLE 1

PR 1

PR 1

PR 2

CABLE 2

CABLE 3

CABLE 2

PR 1

PR 1

PR 1

NO.PAIR

PAIRNO.

1

1

CONN2

KEY

WHITE

ORANGE

WHITEYELLOW

BROWN

BROWN 6V–20V–2

6V–20V–2

SEE NOTE 4

4.

SEE NOTE 3

SEE NOTE 3

EE-3186-315-001

MARO2P10203703E


14–22

NOTES

MARO2P10203703E


14–23

Figure 14–11 . P-10 or P-15 Axis 3 Pulse Coder Cable

NOTES:







MFG. NAME

0

REV LEVEL


A

EE–3186–316–001

A

CONN3

EE–3186–316–001 36 IN914 MM

DIM. ACABLE VERSION

1 2 345 6

LABELWIRE


PAIR

3D3*D

3RQ3*RQ

1

2

PIN

CONN3

SHIELD

1 2

LABELWIRE


PAIRPIN

5V0V

REV.

PG

NO

20GA BLK


SOLDERED CONNECTION


7

98

9 PIN

AXIS 3 PULSE 2 POSSOC



SIGNALNAME

TWISTPAIRNO.

WIRECOLOR/

NUMBER

SOC/PIN NO.

6V–30V–3

1.0” TYP.

1.0”TYP.

SEE NOTES1 & 2

TYP.

CONNECTOR

CONNECTOR

ABCDEFGHJKLMNPRST

3D

3*D

3RQ3*RQ

5V

0VA A

BLACK1 2

LABELWIRE


PAIRPINCONNECTOR

AN4

AN4

AF4AF4

BLACK

THIS SHIELD NOTCONNECTED

4 POSPIN

34

SHIELD20GA BLK

CABLE RUN


SEC. A–A

AF4 & CONN3 SHIELDS CONNECTED TO EACHOTHER BUT NOT CONNECTED TO ANY PINAN4 SHIELD NOT CONNECTED THIS END

WHITE

WHITE

ORANGE

YELLOW

BROWN

BROWN

BLACK

3

4

5

6

7 8

9 10

11

12

135

12’’16’’

1

1

CUT OFF 3RD PAIR, WHITE/GRAY

SEE NOTE 3

SEE NOTE 3

1

2

2

CABLE SPECIFICATION

CABLE SPECIFICATION3 PAIRS 20 AWG W/ SHIELD

HYPALON JACKETMAX OD = 0.365”(9.27MM)

1 PAIR 20 AWG W/SHIELDPVC JACKET

MAX OD = 0.245’’ (6.22MM)BRAND REX T–13103

BRAND REX T–13981

CABLE SPECIFICATION1 PAIR 20 AWG W/SHIELD

PVC JACKETMAX OD = 0.245’’ (6.22MM)

BRAND REX T–13103

SEE NOTE 4

4.

TOL +/– 0.5”

6V–30V–3

CABLE 1

CABLE 1

CABLE 1

CABLE 2

CABLE 3

PR 1

PR 1

PR 2

PR 1

PR 1

PR 1

CABLE 2

WHITE

ORANGE

WHITEYELLOW

BROWN

BROWN

BLACK

EE-3186-316-001

MARO2P10203703E


14–24

NOTES

MARO2P10203703E


14–25

Figure 14–12 . P-10 or P-15 Purge Flow Switch

FS1

FS1/NOFS1/C

FLOW SWITCH

BLUEBLACK

0

4 PIN

NAMEPINNO.

SIGNAL

1 2

CONNECTORLABEL

WIRE SLEEVECOLOR& MAT’L

LT. BLUEEE–3186–340–001

MANUF. NAME

COLOR

A

2’’

CUT OFF SPARE RED WIRE

4

EE–3186–340–00124 INDIM. ACABLE VERSIONREV LEVEL

A

PG

NO







SEE NOTE 1

610 MM

1

32

EXPANDO

6

34 SHIELD

CONNECT SHIELD WITH 20 AWG BLACK WIRE

REV.

AH4 INTRINSICALLY SAFE

EXPANDO OVERBRAIDED SHIELD

EE-3186-340-001

5

MARO2P10203703E


14–26

NOTES

MARO2P10203703E


14–27

Figure 14–13 . P-10 or P-15 European Purge Connect Arm Cable

NOTES:







EE–3186–341–00124 IN610 MM


B

2. SEE LENGTH CHART FOR CABLE VERSIONREVISION LEVEL.

PG

NO

NOT CALLED OUT ON BILL OF MATERIALS3. SPECIFIC CONDUCTOR PART NUMBER

WIRE SPEC: 20 AWG, 19/ 32, UL1199, 600V, PTFE INSULATION

4

MFG. NAME

INTRINSICALLY SAFE

1

SEE NOTE 1

SIGNALNAME

WIRE

BLACK/1 BLACK/2 BLACK/3

COLOR/NUMBER

A

3” TYP

TYP

78

EE–3186–341–00X

AJ1

FS1–P

PS1–PPS1–N

2

REV.

4 PIN

NAMEPINNO.

SIGNAL

PS1–N1

2

CONNECTORLABEL


PS1–P

0

BLACK1

WIRECOLORS

EXPANDO

NAMEPINNO.

SIGNAL

1 2

CONNECTORLABEL


FS1–P

WIRECOLORS

EXPANDO

BLACK2

BLACK3

AH1

4

WIRELABEL

WIRE SPEC: 20 AWG, 19/ 32, UL1199, 600V, PTFE INSULATION

6

1.0”

CRIMP FERRULETO WIRE

5

BLUE

BLUE

34

34 SHIELD

4 PIN

EXPANDO OVER BRAIDED SHIELD

20 AWG WIRESHIELD CONNECTION

3

SHIELD AND EXPANDOOVER WIRES

BLACK4 FS1–N

567

4567BLACK/4 FS1–N

EE-3186-341-001

MARO2P10203703E


14–28

NOTES

MARO2P10203703E


14–29

Figure 14–14 . P-10 or P-15 European Solenoid Cable

A

SOL1

7

MFG. NAME

SEE NOTE 1

INTRINSICALL Y SAFE

0


2 3 5

9”

2”

NAMEPINNO.

SIGNAL

PSOL–1PSOL–2

1 2

CONNECTORLABEL

WIRE

NAMESOC/PINNO.

SIGNAL

LABELCONNECTOR

PSOL–1PSOL–2

1 2 SOL1

SOL REV.

AK1

COLOR

BLACK

AK1

76 4

1

WIRECOLOR

BLACK

EE–3186–348–001 24 IN610 MM


A

PG

NO

NOTES:







3 NC

34 SHIELD

TUBING OVER DRAIN WIRE

BROWN

BROWN

BRAND REX T–131032 COND 20 AWG

SHIELDED

EE-3186-341-001

MARO2P10203703E


14–30

NOTES

MARO2P10203703E


14–31

Figure 14–15 . P-10 or P-15 Sensor Splitout Cable

1 2

SOC9 POS

AG4

SENSOR

3456789

EOAT–1EOAT–2

SHIELD

9 PIN

0

NAMEPINNO.

SIGNAL

1 2

CONNECTORLABEL

WIRECOLORS

3456789 SHIELD

SOC9 POSBYPASS

NAMEPINNO.

SIGNAL

1 2

CONNECTORLABEL

WIRECOLORS

3456789

SHIELD

EOAT–1EOAT–2

KEY PINKEY PIN

KEY PINKEY PIN

A

EE–3186–351–001REVMANUF

SENSOR

INTRINSICALLY SAFEAG4 SENSOR

SENSOR

BYPASS

SENSOR–1SENSOR–2


BLUE–1

1.0 in. 4.0 in.

BLUE–2BLUE–3BLUE–4BLUE–5BLUE–6

SENSOR–1SENSOR–2


BLUE–1BLUE–2BLUE–3BLUE–4

BLUE–5BLUE–6

123

4 5 6

7 8

4 5

EE–3186–351–001

DIM. ACABLE VERSION PGREV

A 203 mm8 IN

NO

EE-3186-351-001

MARO2P10203703E


14–32

NOTES

MARO2P10203703E


14–33

Figure 14–16 . P-10 or P-15 End of Arm Tool Cable

3.00”3.00”TYP.


APPLY LABEL OVER 3” OF BLUESHRINK TUBING, TYP. BOTH ENDS

SEE NOTE 1

NOTES:







INTRINSICALLY SAFE

A

3.00”

EE–3186–317–001144 IN3658 MM

DIM. ACABLE VERSION

9 PIN

NAMEPINNO.

SIGNAL

1 2

CONNECTORLABEL


INTRINSICALLY SAFE

PG

0

BLACK

WIRECOLORS

SENSOR REV. SENSOR3

456789

3.00”

SHIELD

1’’

AG4 REV.

1

2 3

46 78 910

AG4

EOAT–1EOAT–2

BROWN

YES

CABLE SPECIFICATION

HYPALON JACKET

BRAND REX T–13103

REV

B

NAMEPINNO.

SIGNAL

1 2

CONNECTORLABEL

BLACK

WIRECOLORS

EOAT–1EOAT–2

BROWNSENSOR

48’’

ONE PAIR 20 AWG W/SHIELD

3

5

SHIELD




ALL LENGTH DIMENSIONS +/– 0.5’’

MAX. CABLE O.D. = 6.22mm (0.245in)

11

EE-3186-317-001

MARO2P10203703E


14–34

NOTES

MARO2P10203703E


14–35

Figure 14–17 . P-10 Magnet Sensor Breakaway Cable

3.00”3.00”TYP.



SEE NOTE 1

NOTES:







INTRINSICALLY SAFE

A

3.00”

EE–3186–319–001144 IN3658 MM

DIM. ACABLE VERSION

9 PIN

NAMEPINNO.

SIGNAL

1 2

CONNECTORLABEL


INTRINSICALLY SAFE

PG

0

BLACK

WIRECOLORS

SENSOR REV. SENSOR

3456789

3.00”

SHIELD

1’’

1

2 3

4 56 78

AG4

EOAT–1EOAT–2

BROWN

YES

CABLE SPECIFICATION

REV

A

48’’




ALL LENGTH DIMENSIONS +/– 0.5’’

MAX. CABLE O.D. = 6.68mm (0.263in)

SENSOR REV.

2.0in.STRIP BACKOUTER SHEATH

TWO CONDUCTOR 20 AWG. CABLEBRAID SHIELD

BROWN HYPALON JACKET

BELDEN #8402

EE-3186-319-001

MARO2P10203703E


14–36

NOTES

MARO2P10203703E


14–37

Figure 14–18 . P-10 or P-15 Solenoid Cable

A

SOL1

7

MFG. NAME

SEE NOTE 1

INTRINSICALLY SAFE

0


2 3 5

NAMEPINNO.

SIGNAL

PSOL–1PSOL–2

1 2

CONNECTORLABEL

WIRE

NAME

SOC/PINNO.

SIGNALLABEL

CONNECTOR

PSOL–1PSOL–2

1 2 SOL1

COLOR

BLACK

76 4

1

WIRECOLOR

BLACK

EE–3186–323–001 610 MM


B

PG

NO

NOTES:







3 NC

34

AK4

AK4

2 COND 20 AWG SHIELDEDHYPAON JACKET

B–R T–13103

BROWN

SHIELD

9’’

2’’

BROWN

TOL +/– 0.5’’

24 IN

REV

AK4

4’’

CONNECT SHIELDW/ 20AWG BLACK

EE-3186-323-001

MARO2P10203703E


14–38

NOTES

MARO2P10203703E


14–39

Figure 14–19 . Ground Cable M5 to M5 Stud

DIM. ACABLE VERSION

NOTES:

MUST CORRESPOND TO THE LENGTH AND

VERSION NUMBER



IN TABLE. VENDOR NAME

AND REVISION LEVEL MUST ALSO BE



B

ALL DIMENSIONS +/– 0.5’’

REVISION

1

2

4

(2) PLACES

1.0in.

TYP.

3

EE–3186–326–00110 IN254 MM

EE–3186–326–001REV MANUF

0.5’’

M5 STUD M5 STUD

2

(2) PLACES

B EE–3186–326–00216 IN406 MM

EE-3186-326-001

MARO2P10203703E


14–40

NOTES

MARO2P10203703E


14–41

Figure 14–20 . P-10 Breakaway Magnet Sensor

EE–3186–333–001SENSOR

MANUF REV

REV CABLE VERSION DIM A PG

NOINMM

EE–3186–333–001A

1

NOTES:







0

24610

A

INTRINSICALLY SAFE

2

APPLY LABEL OVER 3’’ OF BLUE SHRINK NOTE: CABLE COMES WITH PROX SW

TOL +/– 0.5’’

3

2.0in.STRIP BACK

OUTER SHEATH

EE-3186-333-001

MARO2P10203703E


14–42

NOTES

MARO2P10203703E


14–43

Figure 14–21 . P-15 Hood/Deck Opener Electrical Layout Domestic Version

EE–3715–001

ELECTRICAL LAYOUT

CONNECTIONS

JF8

JF9

SWITCH

PURGE VALVE

MOTOR/BRAKE

PULSE

DOOR OPENERUPPER LEVEL BOM

UPPER LEVEL BOM

PRESSUREPS2

EE–3186–340–001

REFERENCE

REFERENCE EE–3066–322–001


UNIT

EE–3044–401

EE–3044–401

EE–3186–112–105

EE–3186–111–105

SOL2

EE–3715–301–001

FLOW SWITCH FS2

EE–3186–323–001

AA1 AA4

AB1 AB4

AC1 AC4

AD1 AD4

PWR

INPUT

AE1 AE4

AF1 AF4

PRES SW SHOWNON MECH BOM


FLOW SW ASSY


R–J2CONTROLLER

AUXAXISBD

PURGECONTROLUNIT

JF10

AXIS 1

INNER ARMAXIS 2

OUTER ARMAXIS 3

RAIL

a6/3000

a6/3000

a6/3000

A06B–0128–B175

A06B–0128–B175

RAIL

INNER ARM

OUTERARM

EE–3186–311–002

EE–3186–312–001

EE–3186–313–001

EE–3186–314–002

EE–3186–315–001

EE–3186–316–001

PG29

PG29

PG29

PG9

ISGND

EE–3186–111–110EE–3186–111–115EE–3186–111–125EE–3186–111–135EE–3186–111–145EE–3186–111–155

EE–3186–112–110EE–3186–112–115EE–3186–112–125EE–3186–112–135EE–3186–112–145EE–3186–112–155

EE–3186–101–105EE–3186–101–110EE–3186–101–115EE–3186–101–125EE–3186–101–135EE–3186–101–145EE–3186–101–155

EE–3287–116–105EE–3287–116–110EE–3287–116–115EE–3287–116–125EE–3287–116–135EE–3287–116–145EE–3287–116–155

EE–3186–115–105EE–3186–115–110EE–3186–115–115EE–3186–115–125EE–3186–115–135EE–3186–115–145EE–3186–115–155

DC/DC

BATTERY

ISB2–3ISB2–4

3

3

6V

0V

ISRR

LTERMS

MTERMS

PURGECONTROL 4

6BKPBKM

PURGEBD

4

4

4

324VPG0V PG

3 PSB1PSB2FSB1FSB2ISTB 7

8

SENSOROUTPUT

220VAC

PURGED CAVITY

ARM CABLES

AG

1

AH

1A

H4

AJ1

AJ4

AK

1A

K4

AL1

AM

1A

M4

AL4

AN

1A

N4

A06B–0128–B675–0008

EOAT1EOAT2

AMP 5 AXIS 1 RAILAMP 6 (L)AXIS 2

INNER ARMAMP 6 (M)

AXIS 3OUTER ARM

NOTE: I.S. GROUND IS A SEPARATEINTRINSICALLY SAFE GROUNDAT THE PURGE CONTROL UNIT




EE–3186–331–001MAGNET

SWITCH

EE–3186–317–001

EE–3185–356–001BYPASS

EE–3186–351–001

AG

4

PURGEBARRIER

ISRRBYPASSOUTPUT

EOAT5EOAT6

AXIS 1

AXIS 2AXIS 3

INNERARM

OUTERARM

CRANK

LINK

INTERNALGND WIRE

GND WIRESEE–3158–316–001

(3) EE–3186–326–003(1) EE–3186–326–004

DOMESTIC VERSION

HOOD DECK OPENER

P–15 HOOD/DECK OPENER

MARO2P10203703E


14–44

NOTES

MARO2P10203703E


14–45

Figure 14–22 . P-15 Hood/Deck Opener Electrical Layout European Version

EE–3715–002

CONNECTIONS

JF8

JF9

PURGE VALVE

MOTOR/BRAKE

PULSE

DOOR OPENERUPPER LEVEL BOM

UPPER LEVEL BOM

REFERENCE


UNIT

EE–3044–401

EE–3044–401

EE–3186–112–105

EE–3186–121–105

SOL2

EE–3715–302–001

EE–3186–348–001

AA1 AA4

AB1 AB4

AC1 AC4

AD1 AD4

PWR INPUT

AE1 AE4

AF1 AF4



R–J2CONTROLLER

AUXAXISBD

PURGECONTROLUNIT

JF10

AXIS 1

INNER ARMAXIS 2

OUTER ARMAXIS 3

RAIL

a6/3000

a6/3000

a6/3000

A06B–0128–B175

A06B–0128–B175

RAIL

INNER ARM

OUTERARM

EE–3186–311–002

EE–3186–312–001

EE–3186–313–001

EE–3186–314–002

EE–3186–315–001

EE–3186–316–001

PG29

PG29

PG29

PG9

ISGND

EE–3186–121–110EE–3186–121–115EE–3186–121–125EE–3186–121–135EE–3186–121–145EE–3186–121–155

EE–3186–112–110EE–3186–112–115EE–3186–112–125EE–3186–112–135EE–3186–112–145EE–3186–112–155

EE–3186–102–105EE–3186–102–110EE–3186–102–115EE–3186–102–125EE–3186–102–135EE–3186–102–145EE–3186–102–155

EE–3287–116–105

EE–3287–116–110EE–3287–116–115

EE–3287–116–125EE–3287–116–135EE–3287–116–145EE–3287–116–155

EE–3186–115–105EE–3186–115–110EE–3186–115–115EE–3186–115–125EE–3186–115–135EE–3186–115–145EE–3186–115–155

DC/DC

ISRR

LTERMS

MTERMS

6BKPBKMPURGE

BD

4

4

4

324VPG0V PG

SENSOROUTPUT

220VAC

PURGED CAVITY

ARM CABLES

AG

1A

G4

AH

1A

H4

AJ1

AJ4

AK

1A

K4

AL1

AM

1A

M4

AL4

AN

1A

N4

A06B–0128–B675–0008

EOAT1EOAT2

AMP 5 AXIS 1 RAIL

AMP 6 (L)AXIS 2

INNER ARMAMP 6 (M)

AXIS 3OUTER ARM

NOTE: I.S. GROUND IS A SEPARATEINTRINSICALLY SAFE GROUNDAT THE PURGE CONTROL UNIT




EE–3186–317–001

EE–3185–356–001BYPASS

MAGNETSWITCH

EE–3186–351–001

BATTERY

ISB2–3ISB2–4

3

3

6V

0V

PURGECONTROL 4

3 PSB1PSB2FSB1FSB2ISTB

78

PURGEBARRIER

ISRRBYPASSOUTPUT

EOAT5EOAT6

4

5

6

7

JUMPER REMOVEDHR2151

OPPRFL

PRES & FLOWSWITCHES

4

5

6

7 EE–3186–341–001

BOOTH WALL

AXIS 1

AXIS 2AXIS 3

INNERARM

OUTERARM

CRANK

LINK

INTERNALGND WIRE

GND WIRESEE–3158–316–001

(3) EE–3186–326–003(1) EE–3186–326–004

EE–3186–331–001

ELECTRICAL LAYOUTEUROPEAN VERSION

P–15 HOOD/DECK OPENER

HOOD/DECK OPENER

MARO2P10203703E


14–46

NOTES

MARO2P10203703E


14–47

Figure 14–23 . P-15 Opener End of Arm Tooling Cable

3.00” 3.00”TYP.



SEE NOTE 1

NOTES:







INTRINSICALLY SAFE

A

3.00”

EE–3186–317–001144 IN3658 MM

DIM. ACABLE VERSION

9 PIN

NAMEPINNO.

SIGNAL

1 2

CONNECTORLABEL


INTRINSICALLY SAFE

PG

0

BLACK

WIRECOLORS

SENSOR REV. SENSOR

3456789

3.00”

SHIELD

1’’

AG4 REV.

1

2 3

46 78 910

AG4

EOAT–1EOAT–2

WHITE

YES

CABLE SPECIFICATION

HYPALON JACKET

EE–3186–317–001

REV

B

NAMEPINNO.

SIGNAL

1 2

CONNECTORLABEL

BLACK

WIRECOLORS

EOAT–1EOAT–2

WHITESENSOR

48’’

ONE PAIR 20 AWG W/SHIELD

3

5

SHIELD




ALL LENGTH DIMENSIONS +/– 0.5’’ MAX. CABLE O.D. = 6.68mm (0.263in)

11

BELDEN #8402

OPENER END OF ARM TOOLING CABLE

MARO2P10203703E


14–48

NOTES

MARO2P10203703E


14–49

Figure 14–24 . P-15 Part Present Proximity Cable

EE–3186–331–001SENSOR

MANUF REV

REV CABLE VERSION DIM A PG

NOINMMEE–3186–331–001A

12 3

EE–3186–331–001

NOTES:







0

24610

A

INTRINSICALLY SAFE

4

APPLY LABEL OVER 3’’ OF BLUE SHRINK NOTE: CABLE COMES WITH PROXIMITY SWITCH

PIN # WIRECOLOR

SIGNALNAME

12

BROWN + SIGNAL– SIGNAL

TOL +/– 0.5’’

3 UNUSED

5

BLUE

PART PRESENT PROXIMITY CABLE

MARO2P10203703E


14–50

NOTES

MARO2P10203703E


14–51

Figure 14–25 . Integral Pump Control Drawing Index and System Index

ELECTROSTATICPOWER SUPPLY(E–STAT UNIT)

ROBOT CONTROLLER (RC)

ANALOGCONDUIT

24VDCCONDUIT

PAINTPROCESSVALVEPANEL

APPLICATOR

BOOTHWALL

E–STAT CABLE

E–STAT CABLECES3 (PARAFLEX)

MACVALVE

WRIST PLATEGROUND

E–STAT CABLECES2 (PARAFLEX)

COLLISIONDETECT

P–200 ROBOT UPPER ARM

MOUNTING PLATE

NE–2000–977–003

P–200 PURGE CAVITY

SUPPLIED WITHCOLLISION DETECTION UNIT

JUNCTION BOX

CONDUIT

EXPLOSIONPROOFJUNCTION BOX(ROBOT TURET)

PUMPREGULATOR

BLOCK

INTRINSIC CABLENE–2000–977–XXX

NE–2000–477

VARIABLE RATIO 2K SINGLESTAGE PAINT PROCESS CONTROL

14–52


MARO2P10203703E

NOTES

MARO2P10203703E


14–53

Figure 14–26. Integral Pump Control I/O Rack Layout

1 2 3 4 5 6 7 8 9 10

SLOT NUMBER

MAIN CPU

JD1

CP32

JD1B

JD1A

RACK POWERCABLE

RACK COMMUNICATIONCABLE–1 METER

ADA02A

AOD16D

AIF01A

+24VDC 0VDC

AOD16D

AOD16D

WIRE AS SHOWN ON SHEET 082CABLE/WIRING BY FANUC

PCB

I/O RACK LAYOUT

AOD16D

CP6

+24VDC 0VDC

MAIN CPUPSU MODULE

TO MAIN AIRSUPPLY SOLENOIDAS SHOWN ON SHEET 08282091 82092 82291 82292

RESEVED

RESEVED

POWER INPUT UNIT(PIU)

+24VDC, 0VDC FROM SPADECONNECTORS ON POWER INPUT UNIT

AAD04A

ADA02A

109109109109109109

109

109

109109

RESEVED

NE–2000–477

14–54


MARO2P10203703E

NOTES

MARO2P10203703E


14–55

Figure 14–27. Integral Pump Control Controller Layout

DISCONNECT

OPT

PURGE CONTROL UNIT


1 1/2 ”W X 4”H DUCT

CONTROLLER W/DOOR REMOVED

AMP 1 AMP 2

EMGBOARD

AMP 3

MAIN PSUCPU

AMP 4

SLOT SLOT SLOTSLOTSLOTSLOTSLOTSLOTSLOT1 2 3 4 5 6 7 8 9 10

SLOTCOMM.MODULE

TB2

2” W X 4” H DUCT

8308F (ACSP)8309F (ACAP)

8617F (CP10)8618F (CP11)8619F (CP12)8620F (CP13)8621F (CP14)8622F (CP15)8623F (CP16)8636F (CP17)8637F (CP18)8638F (CP19)8639F (CP20)8640F (CP21)8641F (CP22)8642F (CP23)8643F (CP24)

SPARE

82292 (0VDC)8232F (+24VDC)

82231 (+24VDC)

82092 (0VDC)82092 (0VDC)82092 (0VDC)82092 (0VDC)

FUSEFUSEFUSEFUSE

FUSEFUSEFUSEFUSEFUSEFUSEFUSE

FUSE

FUSE

FUSEFUSE

8336F (PT)

SPARE

82091 (+24VDC)82091 (+24VDC)

FUSE

8214F (+5VDC)

8310F (LPSP)8311F (LPAP)

84121 (CLEAR)84131 (BLACK)84141 (CLEAR)84151 (BLACK)

84401 (CLEAR)84411 (BLACK)

8608F (CP1)8609F (CP2)8610F (CP3)8611F (CP4)8612F (CP5)8613F (CP6)8614F (CP7)8615F (CP8)8616F (CP9)

82231 (+24VDC)

FUSE

8204CRI/O POWERENABLE

TERMINAL STRIPT1

0607080910

0102030405

111213141516171819202122232425262728293031323334353637383940414243444546474849505152535455565758

0607080910

02030405

111213141516171819202122232425262728293031323334353637383940414243444546474849505152535455565758

01SPARESPARE

SPARE

MOUNT TERMINALSTRIP T1TO SIDE WALLINSIDE OF ROBOTCONTROLLER.

CABLE ROUTING

CABLE ROUTING

CONTROLLERINTERIOR VIEW

LEFT SIDE

AREA RESERVEDFOR SYSTEMINTEGRATION

SPARE

ANALOG INPUT CABLE ROUTING

8312F (RS1P)8313F (RS2P)8314F (RPSP)

5960616263646566676869707172737475

FUSEFUSEFUSEFUSEFUSEFUSEFUSEFUSEFUSEFUSEFUSEFUSEFUSEFUSEFUSE

85131 (BLACK)85121 (CLEAR)

FUSE7574737271706968676665646362616059

8344F (MHP)8345F (MRP)8346F (HP1)

8348F (HP3)

FUSE

FUSEFUSEFUSEFUSEFUSEFUSEFUSEFUSEFUSEFUSEFUSE

8315F (RAP)8316F (RPBP)8317F (RPDP)8318F (HS1P)8319F (HS2P)8320F (HPSP)8321F (HAP)8322F (HPBP)8323F (HPDP)

FUSEFUSEFUSE

8347F (HP2)

124 124 124 124

124

124

124

124

124

124

124

124

124

124

124

124

124

124

124

CONTROLLER LAYOUT

SHEILD 1

SHEILD 2SHEILD 3

SHEILD 5

124

124

NE–2000–477

14–56


MARO2P10203703E

NOTES

MARO2P10203703E


14–57

Figure 14–28. Top Hat Option Drawing Index and System Layout

DC/DC

DC/DC

AXIS3

2K PURGEDCAVITY

PUMP #2

PUMP #1

PUMP PRESSURECONTROL BLOCK

9PIN

15PIN

15 PIN

PTVALVE

RJ–2 ROBOT CONTROLLER

9PIN

4 PIN

2K PUMPCAVITY

NEW PULSECODER &MOTOR POWER HARNESS

NE–2000–996–401

UPPER ARMCAVITY NEW BATTERY CABLE

NE–2000–977–004

ADDED DC/DCCONVERTER

EE–3044–401

ADDED JUMPEREE–3044–403–001

PULSE CABLENE–2000–996–205

ROBOT ARM

ROUTED THRU PROCESS CAT–TRACK

P/I TRANSDUCERAND TRIGGER CABLENE–2000–977–003

MOTOR POWER CABLENE–2000–996–005 THRU 055

INTRINSIC CABLENE–2000–977–005 THRU 055

ROBOT BASE PURGED CAVITY

CURRENT ROBOTDC/DC CONVERTER

DUAL DC/DC CONVERTERMOUNTING BRACKETNE–2000–396–103

(REF.)

(REF.)

100

100

100

100

100

100

NE–2000–396

(REF.)THRU 255

14–58


MARO2P10203703E

NOTES

MARO2P10203703E


14–59

Figure 14–29. Side Saddle Option Drawing Index and System Layout

DC/DC

DC/DC

AXIS3

2K PURGEDCAVITY

PUMP #2

PUMP #1PUMP PRESSURECONTROL BLOCK

ROBOT PURGEDCAVITY

9PIN

15PIN

15 PIN4 PIN

UPPER ARM

PTVALVE

RJ–2 ROBOT CONTROLLER

9PIN

PG

4 PIN

VACULOCK HOSE

2K PUMPCAVITY

ADDED DC/DCCONVERTEREE–3044–401

PULSE CABLENE–2000–996–205THRU 255

MOTOR POWER CABLENE–2000–996–005 THRU 055

INTRINSIC CABLENE–2000–977–005 THRU 055

(REF.) (REF.)

(REF.)

P/I TRANSDUCERAND BATTERY CABLE

NE–2000–977–001

MOTOR POWER &PULSECODER HARNESSNE–2000–996–400

ROBOTDC/DC

CONVERTER

JUMPEREE–3044–403–001

PILOT TRIGGER CABLENE–2000–977–002

ROUTED THRU PROCESS CAT–TRACK

DUAL DC/DC CONVERTERMOUNTING BRACKETNE–2000–396–103

100

100

100

100

100

100

NE–2000–397

14–60


MARO2P10203703E

NOTES

MARO2P10203703E


14–61

Figure 14–30. Top Hat and Side Saddle Option Drawing Index and System Layout

R–J2 ROBOT CONTROLLER

2K SYSTEMCONTROLCABLES

2K PUMPASSEMBLY

DC/DC

DC/DC

DC TO DC CONVERTER JUMPER

2K TOP HATROBOT CABLES

(INTRINSIC CABLE: NE–2000–977–005 THRU 055)

(PULSE CABLE: NE–2000–996–205–355)(POWER CABLE: NE–2000–996–005 THRU 155)

ADDED DC TO DC CONVERTER

ROBOT DC TO DC CONVERTER

P–200PURGEDCAVITY

MOTOR/ PULSE HARNESS: NE–2000–996–401BATTERY CABLE: NE–2000–977–004

INTRINSIC PROCESS CABLE: NE–2000–977–003

REF.

REF.

REFERENCE NE–2000–396

REF.

REF.

B

B

B

NE–2000–496

2K SIDE SADDLEROBOT CABLES

MOTOR/ PULSE HARNESS: NE–2000–996–400BATTERY/INTRINSIC CABLE: NE–2000–977–001TRIGGER CABLE: NE–2000–977–002

REFERENCE NE–2000–398B

NE–2000–498

or

and

14–62


MARO2P10203703E

NOTES

MARO2P10203703E


14–63

Figure 14–31. Top Hat and Side Saddle Option Cable and Wiring Diagram

E–STOP PCB

AUX AXIS BOARD

CRX4JS1BCRX4

24V INTERLOCK HARNESS#NE–2000–996–003

JF13

JV13

2K PUMP PULSE CABLE#NE–2000–996–2XX(REFERENCE ONLY)

JV14

JF14

FROM PUMP 2 MOTOR ENCODER

FROM PUMP 1 MOTOR ENCODER

CRR20

WIREPINCOLOR

123

SIGNALNAME

BLUE1BLUE2 ESP

+24V

WIREPINCOLOR

123

SIGNALNAME

BLUE1

BLUE2456

ESP

+24V

CRR20 AMP 5 (IPC) CRX4

##

IPC AMP 5

JS2B

WIREPINCOLOR

123

SIGNALNAME

BLUE2 ESP

#

AMP 4 CRX4

CRX4

WIREPINCOLOR

123

SIGNALNAME

BLUE2 ESP

#

AMP 1 CRX4

CRX4

WIREPINCOLOR

123

SIGNALNAME

BLUE2 ESP

#

AMP 2 CRX4

CRX4

WIREPINCOLOR

123

SIGNALNAME

BLUE2 ESP

#

AMP 3 CRX4

104

104

AMP 4 AMP 1 AMP 2 AMP 3

AXIS BOARD TO AMPLIFIER CABLE#XGMF–10064

D D D

NE–2000–496 NE–2000–498and

14–64


MARO2P10203703E

NOTES

MARO2P10203703E


14–65

Figure 14–32. Top Hat and Side Saddle Option Purge and Intrinsic Wiring Control Drawing

OPERATORPANEL

EMGIN1EMGIN2

E–STOP PCB

CRR5

CRR22

BKP4BKM4

CRR21

CNIN

CNCA

CNPG

PURGE CIRCUITS

CRM10

MAIN CPU

CNPGPANEL I/F

BRAKE CONTROL

RDI/RDO

220 VAC

+24P

0V

220V (43)

220V (44)

SERVO TRANSFORMERFOR PAINT R–J TYPE

SOL1

SOL2

PRESSURESWITCH

FLOWSWITCH

PURGESOLENOID

VALVE

+V

0V

G

R

SAC

+24VDC PSU

FIRE ALARM

CNIS

EE–3044–345–001

EE–3044–340–001

EE–3287–348–001

ROBOT

ROBOT

ENCODER

NON–HAZARDOUS LOCATION

(250 VAC MAXIMUM)



NE–2000–977–XXXCONNECTION CABLE


ROBOT PURGED CAVITY


NOTES:

ACCEPTABLE I.S. BATTERY PACKS:A05B–2363–C040EE–3185–551

SOLENOID CABLE

TO CRS1(MAIN CPU)

F1F2F3F4F5

I/S TEACH PENDANTA05B–2308–C300


24VDCPOWERSUPPLY

120VACFROM

CONVEYOR

OVPUNIT

EE–3112–60024V 24V

BYPASSSWITCH

TRIGGER 1

DELTRONW112A

EE–3287–324–001

M1

EE–3185–356–001N1 N4

M4

P1 P4

HAND BRKNO1 O4

PRES. SW CABLE

FLOW SW CABLE

M1

M1

S1 S4

M4

M4

SOL SOL

PS1 PS1

FS1 FS1

BATT BATT

3.

2.

1.

NO REVISIONS WITHOUT PRIORAPPROVAL FROM FACTORY MUTUAL (FM)

NOTICE

A1

A2

A3

A4

A5

A6

C1

C2

C3

C4

C5

C6

P1

P2

P3

P4

P5

P6

N1

N2

N3

N4

N5

N6

123456789101112131415161718192021222324


EOAT1EOAT2

ISTB

PRESSURESWITCH

FLOW

ROBOTOVERTRAVEL

HANDBROKEN

TPDISCONNECT

MISC.

(RDI2)

SWITCH

SWITCH

SWITCH

SWITCH

+

+

1

6

I.S.BATTERY

PACK


1 32

STAHL 9001/01–252–100–14

4

ISB1

ISB3KHD2–SR–EX1.2S.P

78

34

1

56

2+

+

24VZ787

ISB7Z728FROM I/O

P&F

P&F

P&F

13

789101112

+24

78

12

+ISB7–2ISB7–1

ISB3–3ISB3–1

8533ISB–1

8533ISB–48533ISB–28533ISB

TO I/O

78

34

1

56

2+

+

24VZ787P&F

8538ISB–1

8538ISB–48538ISB–28538ISB

TO I/O

78

34

1

56

2+

+

24VZ787P&F

8543ISB–1

8543ISB–48543ISB–28543ISB

TO I/O

78

34

1

56

2+

+

24VZ787P&F

8548ISB–1

8548ISB–48548ISB–28548ISB

TO I/O

ENCODERR1 R1 BATT BATT

NE–2000–977–001

FRAMEGROUND

PUMP #1

PRESSURE

OVERPUMP #1

PRESSURE

UNDER

PUMP #2

PRESSURE

OVERPUMP #2

PRESSURE

UNDER

X6 FORROBOT

X2 FOR2K PUMPS

NE–2000–498–500 and NE–200–496–500

I.S.GROUND

I.S.GROUND

I.S.

GROUND

NE–2000–977–001

NE–2000–977–002

I.S. GROUND

P–200–6J2+2K / P–200–6–2KS

CONTROLLER / ROBOT

P–200–6LJ2+2K / P–200–6L–2KS

P–200–6+2J2+2K / P–200–6–2KS

P–200–6L+2J2+2K / P–200–6L–2KS



B

P–200 TOP HAT MOUNTED


P–200–6J2+2K / P–200–6–2KT

CONTROLLER / ROBOT

P–200–6LJ2+2K / P–200–6L–2KT

P–200–6+2J2+2K / P–200–6–2KT

P–200–6L+2J2+2K / P–200–6L–2KT

P–200 SIDE SADDLE MOUNTED


VARIABLE RATIO 2K PURGE ANDINTRINSIC WIRING CONTROL DRAWING

14–66


MARO2P10203703E

NOTES

MARO2P10203703E


14–67

Figure 14–33. Top Hat and Side Saddle Options Cable Layout Diagram

50MM

CABLE

GNDCLAMP

CABLESHIELD

AT CONTROLLER ENTRANCEGROUNDING OF NON–IS SHIELDED CABLE

EE–3287–116–055

POWER

POWER & BRK

POWER & BRK

POWER & BRK

PULSE BAT

BRK

POWER

PULSE BAT

BRK

POWER

PULSE BAT

BRK

EE

–304

4–40

1


DC/DC CONVERTERS



CONTROLLER GROUND

CRF1

A1 A4

B1 B4

C1 C4

D1 D4

E1

H1H4

J1 J4

K1 K4

F1

JF7

AXIS 4AXIS 5AXIS 6

AXIS 1

AXIS 2

AXIS 3

444

24PG, 0PG

8

4

3

PULSE & BATT

PULSE & BATT

PULSE & BATT

6BRAKES

BRAKES

BRAKES

4

4

OUTER ARMGROUND

ROBOT ARM

INNER ARMGROUND

TURRETGROUND

4

12

EE–3287–322–001

EE–3287–321–001

R–J2 CONTROLLER

SEAL OFFS USEDWITH NA PEDESTAL

AMP 1AMP 2AMP 3

EMG BD

AUX AXIS BD

PURGE UNIT PGTBCHASSISGROUND

AMP 1

AMP 4

AMP 2

CABLE CLAMP

SHIELD TO

(L)(L)(M)

PURGE BD (BK)

(M)

(M)

PURGE BD (BK)

PURGE BD (BK)

GND

MOTOR

PULSE

MOTOR

MOTOR

13.5MM

19.8MM

21.0MM

21.0MM

6.9MM

EE–3287–111–EE–3287–111–EE–3287–111–EE–3287–111–EE–3287–111–EE–3287–111–EE–3287–111–

005010015025035045055

EE–3287–113–EE–3287–113–EE–3287–113–EE–3287–113–EE–3287–113–EE–3287–113–EE–3287–113–

005010015025035045055

EE–3287–110–EE–3287–110–EE–3287–110–EE–3287–110–EE–3287–110–EE–3287–110–EE–3287–110–

005010015025035045055

NE–2000–996–NE–2000–996–NE–2000–996–NE–2000–996–NE–2000–996–NE–2000–996–NE–2000–996–

005010015025035045055

EE–3287–116–EE–3287–116–EE–3287–116–EE–3287–116–EE–3287–116–EE–3287–116–

005010015025035045

(NO PG FITTINGS)

AXIS 5

AXIS 4

AXIS 1

AXIS 2

AXIS 3

POWER

PULSE BAT

BRK

POWER

PULSE BAT

BRK

PUMP 1

PUMP 2NE–2000–401PUMPS 1 & 2

PWR & PULSE HARNESS

2K1 2K1

EE

–304

4–40

1

F1

F2

4

PUMP 1AMP 5

PUMP 2AMP 5

(M)

(L)

(M)

JF13AUX AXIS BD

CHASSISGROUND

CABLE CLAMPSHIELD TO

JF14AUX AXIS BD

PULSE 17.4MMNE–2000–996–NE–2000–996–NE–2000–996–NE–2000–996–NE–2000–996–NE–2000–996–NE–2000–996–

205210215225235245255

2K2 2K2

R1 R1

S1 S4

AXIS 6

(SEE SHEET 004)

EE–3287–324–001INTRINSIC BATTERY HARNESS AXIS 1–6

NE–2000–977–004INTRINSIC BATTERY HARNESS PUMPS 1 & 2

20.5MMINTRINSIC

UPPER LEVEL BOMS

5M

10M

15M

25M

35M

45M

55M

CONNECTION CABLE SETS

NE–2000–896–005

NE–2000–896–010

NE–2000–896–015

NE–2000–896–025

NE–2000–896–035

NE–2000–896–045

NE–2000–896–055

NE–2000–977–005NE–2000–977–010NE–2000–977–015NE–2000–977–025

NE–2000–977–045NE–2000–977–035

NE–2000–977–055

B

NE–2000–896–005 THRU –055

UPPER LEVEL BOMS

5M

10M

15M

25M

35M

45M

55M

CONNECTION CABLE SETS

NE–2000–898–005

NE–2000–898–010

NE–2000–898–015

NE–2000–898–025

NE–2000–898–035

NE–2000–898–045

NE–2000–898–055

NE–2000–898–005 THRU –055

14–68


MARO2P10203703E

NOTES

MARO2P10203703E


14–69

Figure 14–34. Top Hat Option Intrinsic Connections

PRESSURESWITCH

FLOWSWITCH

PURGESOLENOID

VALVE

EE–3044–345–001

EE–3044–340–001

EE–3287–348–001

ROBOT

ROBOT

ENCODER

NE–2000–977–XXX


ROBOT PURGED CAVITY

SOLENOID CABLE

BYPASSSWITCH

TRIGGER 1

EE–3287–324–001

M1

EE–3185–356–001N1 N4

M4

P1 P4

HAND BRKNO1 O4

PRES. SW CABLE

FLOW SW CABLE

M1

M1

S1 S4

M4

M4

SOL SOL

PS1 PS1

FS1 FS1

BATT BATT

A1

A2

A3

A4

A5

A6

C1

C2

C3

C4

C5

C6

P1

P2

P3

P4

P5

P6

N1

N2

N3

N4

N5

N6

123456789101112131415161718192021222324


EOAT1EOAT2

ISTB

PRESSURESWITCH

FLOW

ROBOTOVERTRAVEL

HANDBROKEN

TPDISCONNECT

MISC.

(RDI2)

SWITCH

SWITCH

SWITCH

SWITCH

+

+

1

6

I.S.BATTERY

PACK


1 32

STAHL 9001/01–252–100–14

4

ISB1


78

34

1

56

2+

+Z787

ISB7Z728

P&F

P&F

P&F

13

789101112

+24

78

12

+ISB7–2ISB7–1

ISB3–3

ISB3–1

8533ISB–1

8533ISB–48533ISB–28533ISB

78

34

1

56

2+

+Z787P&F

8538ISB–1

8538ISB–48538ISB–28538ISB

78

34

1

56

2+

+Z787P&F

8543ISB–1

8543ISB–48543ISB–28543ISB

78

34

1

56

2+

+Z787P&F

8548ISB–1

8548ISB–48548ISB–28548ISB


NE–2000–977–004

PUMP #1

PRESSURE

OVERPUMP #1

PRESSURE

UNDER

PUMP #2

PRESSURE

OVERPUMP #2

PRESSURE

UNDER

X6 FORROBOT

X2 FOR2K PUMPS

I.S.GROUND

I.S.GROUND

NE–2000–977–003

I.S. GROUND


INTRINSICCONNECTION CABLE

P4 P4

O1 O4

ROBOT WIRE HARNESSEE–3287–323–001(MUST BE REV. D)

NOTES:

1. SIGNAL NAMES IN THE PRODUCT CABLEEE–3287–323–001 WILL NOT MATCH SIGNALNAMES ON THE INTRINSIC CABLENE–2000–977–XXX OR THE PROCESSCABLE NE–2000–977–003.

C

SEE NOTE 1. NE–2000–896–005THRU –055


14–70


MARO2P10203703E

NOTES

MARO2P10203703E


14–71

Figure 14–35. Side Saddle Option Intrinsic Connections

PRESSURESWITCH

FLOWSWITCH

PURGESOLENOID

VALVE

EE–3044–345–001

EE–3044–340–001

EE–3287–348–001

ROBOT

ROBOT

ENCODER

NE–2000–977–XXX


ROBOT PURGED CAVITY

SOLENOID CABLE

BYPASSSWITCH

TRIGGER 1

EE–3287–324–001

M1

EE–3185–356–001N1 N4

M4

P1 P4

HAND BRKNO1 O4

PRES. SW CABLE

FLOW SW CABLE

M1

M1

S1 S4

M4

M4

SOL SOL

PS1 PS1

FS1 FS1

BATT BATT

A1

A2

A3

A4

A5

A6

C1

C2

C3

C4

C5

C6

P1

P2

P3

P4

P5

P6

N1

N2

N3

N4

N5

N6

123456789101112131415161718192021222324


EOAT1EOAT2

IZUMI

ISTB

PRESSURESWITCH

FLOW

ROBOTOVERTRAVEL

HANDBROKEN

TPDISCONNECT

MISC.

(RDI2)

SWITCH

SWITCH

SWITCH

SWITCH

+

+

1

6

I.S.BATTERY

PACK

IBRC6062R


1 32

STAHL 9001/01–252–100–14

4

ISB1


78

34

1

56

2+

+Z787

ISB7Z728

P&F

P&F

P&F

13

789101112

+24

78

12

+ISB7–2ISB7–1

ISB3–3ISB3–1

8533ISB–1

8533ISB–48533ISB–28533ISB

78

34

1

56

2+

+Z787P&F

8538ISB–1

8538ISB–48538ISB–28538ISB

78

34

1

56

2+

+Z787P&F

8543ISB–1

8543ISB–48543ISB–28543ISB

78

34

1

56

2+

+Z787P&F

8548ISB–1

8548ISB–48548ISB–28548ISB


NE–2000–977–001

PUMP #1

PRESSURE

OVERPUMP #1

PRESSURE

UNDER

PUMP #2

PRESSURE

OVERPUMP #2

PRESSURE

UNDER

X6 FORROBOT

X2 FOR2K PUMPS

I.S.GROUND

I.S.GROUND

NE–2000–977–001

I.S. GROUND

NE–2000–977–002


INTRINSICCONNECTION CABLE

NE–2000–898–005THRU –055

14–72


MARO2P10203703E

NOTES

MARO2P10203703E


14–73

Figure 14–36. Top Hat and Side Saddle Options Axis 3, Pumps 1 and 2 Motor Power Cable Reference

CABLE SPECIFICATION

MFG. NAME

MAX

MOTOR REV.


P/N=T–14379 CABLE O.D.= 21.0 MM (0.825”)

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9

SOC/PINNO.

WIRE

COLOR/NUMBER

SIGNALNAME

1112

KEY PLUG

CONNECTORLABEL

PWR/BRK

AXIS 3

KEY PLUG

AXIS 3

12 POS

9 POS

SOC

SOC

K1

POWER/BRK K1

WIRE

COLOR/NUMBER

WIRETAG

WIRECOLOR/NUMBER

MOTOR REV.

MFG. NAME

3U

3V

3W

3G

3U

3V

3W

3G

P1U

P1V

P1W

P1G

P2U

P2V

P2W

P2G

3BKM

BLACK/3

GRN/YEL/8

RED/1WHITE/2

GRN/YEL/4RED/5

WHITE/6BLACK/7


GRN/YEL/12RED/13

WHITE/14BLACK/15

GRN/YEL/16

BLUE/17 BLUE/18

BLACK/3

GRN/YEL/8

RED/1WHITE/2

GRN/YEL/4RED/5

WHITE/6BLACK/7


GRN/YEL/12


GRN/YEL/16

BLUE/18BLUE/17

WIRETAG

3BKP BKP2

BKP2

BKM2BKM2

SIGNALNAME

PUMP #1 & #2PUMP

#1 & #2

2K1

NE–2000–996–XXX NE–2000–996–XXX

104

3U3V3W3G3U3V3W3GP1UP1VP1WP1GP2UP2VP2WP2G

PWR

3BKM

POWER 2K1

NE–2000–898–005THRU –055

NE–2000–896–005THRU –055

14–74


MARO2P10203703E

NOTES

MARO2P10203703E


14–75

Figure 14–37. Top Hat and Side Saddle Options Pumps 1 and 2 Pulse Cable Reference

NE–2000–996–XXX

CABLE SPECIFICATION

MFG. NAME MFG. NAME

LABELWIRE

COLORSIGNALNAME

1234

NO.

WHITEBLACK P1*D

NO.PAIR

WHITE

NE–2000–996–XXX

CONN PIN

PINPIN

PINPIN

JF13

56

LABELWIRE

COLORSIGNALNAME

1234

NO.

WHITERED

NO.PAIR

WHITE

CONN PIN

PINPIN

PIN

56

JF14

P2*D

P2RQORANGE

3

4

1

2P1RQ

JF13

JF14

BROWN1 2 345 6

9 POSSOC

WHITE

BLACK P1*D

WHITE

LABELWIRE

COLORSIGNALNAMENO.

WHITE

RED

NO.PAIR

WHITE

CONN

P2*DP2RQ

ORANGE

3

4

1

2P1RQ

BROWN

PIN

REV. REV.

SHIELD

789

PUMP 1+2 PULSE PUMP 1+2 PULSE2K2

2K2

#18 BLK

P1D

P1*RQ

P2D

P2*RQ

P1D

P1*RQP2D

P2*RQ

105

CABLE O.D.=17.4MM (.685”)

P/N=T–117629 PAIR #20 AWG

BLACK HYPALON JACKET

NE–2000–898–005THRU –055

NE–2000–896–005THRU –055

14–76


MARO2P10203703E

NOTES

MARO2P10203703E


14–77

Figure 14–38 . Top Hat and Side Saddle Options Intrinsic Cable Reference

CABLE SPECIFICATION

HYPALON JACKET

MFG. NAME MFG. NAME

16PR #20 AWG CABLE


NAME

SOC/PINNO.

SIGNAL

1 2 345 6

1 2 5

1314

PS1–PPS1–NFS1–PFS1–N

PSOL–1PSOL–2PSOL–2AME

TWISTEDPAIR

NUMBER

NUMBERD

LABEL

1

2

3

4

5

6

15 POSSOC

SOC

NE–2000–977–XXX

NE–2000–977–XXX

5

6

7

8

TWISTPAIRNO.

WIRECOLOR/NUMBER

PS1–P PS1–N FS1–P FS1–N

IS GND

M1

N1

9 POS

8

WIRECOLOR

15 POS

SOC

SOC

1 2 345 6

1 2 34

789 101112131415

R1

6V–10V–16V–20V–26V–30V–3

6V–40V–46V–50V–56V–60V–6

SHIELD

4 POS

S1

SHIELDKEY

20 AWGKEY

TWISTPAIRNO.

WIRECOLOR/NUMBER

WIRETAG

WHITE–1BLUE–2WHITE–3

ORANGE–4WHITE–5GREEN–6WHITE–7BROWN–8WHITE–9GRAY–10RED–11

BLUE–12RED–13

ORANGE–14RED–15

GREEN–16RED–17

BROWN–18RED–19

GRAY–20BLACK–21BLUE–22BLACK–23

ORANGE–24

BLACK–25GREEN–26BLACK–27BROWN–28BLACK–29GRAY–30

9

10

11

12

13

14

15

WHITE–1BLUE–2WHITE–3

ORANGE–4WHITE–5GREEN–6

WHITE–7BROWN–8

WHITE–9GRAY–10RED–11

BLUE–12

BLACK–21BLUE–22


11

13

14

P/N=T–14685

6V–1

0V–1

6V–3

0V–3

6V–4

0V–4

6V–2

0V–2

CONNECTIONPOINT

BATTERYPACK

M1

N1

R1

S1


ISTB

1 – PSA12 – PSA25 – FSA16 – FSA2

1–PSA1

WIRE TAG

2–PSA2

SIGNALNAME

ISB1–3

ISB1–4

16YELLOW–31

BLUE–32


HND BRK +HND BRK –

BLACK–29GRAY–30

15

16YELLOW–31

BLUE–32

7

8

RED–13ORANGE–14

RED–15GREEN–16

RED–17BROWN–18

RED–19GRAY–20

9

10


1 2 345 6 789 101112131415

20 AWG

20 AWG

20 AWG

20 AWG

15 POSSOC

SHIELD

KEY

KEY

5–FSA1

6–FSA2

SHIELD

SHIELD

6V–40V–4


12

P1

HND BRK+HND BRK–

SOC4 POSO1

P1

ISB3–1

ISB3–3


ISB3–1ISB3–3

1

2

3

4

5

6

7

8

9

10

11

12

ISB7–1ISB7–2

ISB1–3ISB1–4

19 – HBK120 – HBK2

19–HBK1

20–HBK2


1 2

O1

20 AWGKEY

SHIELD34

CONN. POINT

1

2

3

4

PSOL–2PSOL–1

0V–46V–40V–36V–30V–26V–20V–16V–1

106

P1URP1US

P1UGP1OGP1OSP1OR

P2URP2US

P2UGP2OGP2OSP2OR

P1URP1US

P1UGP1OGP1OSP1OR

P2URP2US

P2UGP2OGP2OSP2OR

8533ISB–18533ISB–4

8538ISB–18538ISB–48543ISB–18543ISB–4

8548ISB–18548ISB–4

ISB7–2

ISB7–1

8548ISB–4

8548ISB–1

8543ISB–1

8543ISB–4

8538ISB–1

8533ISB–1

8538ISB–4

8533ISB–4

8538ISB–28533ISB–2

8543ISB–28548ISB–2

8548ISB–2

8543ISB–2

8533ISB–2

8538ISB–2

JUMP TO 1JUMP TO 2JUMP TO 3JUMP TO 4JUMP TO 5JUMP TO 6

NE–2000–898–005THRU –055

14–78


MARO2P10203703E

NOTES

MARO2P10203703E


14–79

Figure 14–39. Integral Pump Control Process Flow Diagram

FANUCSERVOMOTOR

& BAYSIDEGEAR

PAINTTEFLON

MIX TUBE

APPLICATOR

5/16 O.D.

5/16” O.D. FROM AIR SUPPLY

PT

3CC/REV PUMP

FANUCSERVOMOTOR

& BAYSIDEGEAR

3/8” O.D.

5/16” O.D.

FANUC P–200 ROBOTINTERIOR OF OUTER ARM

GEAR PUMP ASSEMBLYFANUC #NO–2000–810

3/8” O.D. 3/8” O.D.

AIRSUPPLY

SOLVENTSUPPLY

RESINSUPPLY

ENCLOSUREPURGE

SPARE 3/8” O.D.

3/8” O.D. 3/8” O.D.AIR

SUPPLYSOLVENTSUPPLY

5/16” O.D.

3/8” O.D.

AIRSUPPLY

SOLVENTSUPPLY

RESINSUPPLY

1/4” O.D.

HARDENERSUPPLY

HARDENERSUPPLY

PRESS TRANS.0–100 PSIPRESS. TRANS.

0–100 PSI

3CC/REV PUMP

RETURN PURGE TO ROBOT

COLOR VALVE ASSEMBLY

0–500 PSIPRESS. TRANS.

(TYP)

SAMES BYPASS BLOCK

5/32” O.D.

5/32” O.D.

5/32” O.D.

RESIN INLET PILOT (IPTR)

HARDENER INLET PILOT (IPTH)

RESIN PUMP BYPASS (RPBP)

FROMPPVP

5/32” O.D.

5/32” O.D. PILOT

0–500 PSIPRESS. TRANS.

(TYP)

SEE SYSTEM DRAWINGFOR CORRECT QUANTITYOF VALVES & LOCATION

HPBPHARDENER PUMP BYPASS

5/32” O.D.

TEFLON

5/16” O.D.TEFLON

TEFLON

5/16” O.D.TEFLON

SUPPLYSOLVENT

3/8

” O

.D.

SUPPLYAIR

3/8

” O

.D.

RAP 5/32” O.D. RS1P

RESINSUPPLY

CP15/32” O.D.

HS1P5/32” O.D.

HP25/32” O.D.

5/32” O.D. CP2

5/32” O.D. HAP

5/32” O.D. HP1

RESINRETURN

5/16” O.D.RESINRETURN

5/16” O.D.

MBSP

MBAP

5/32” O.D. MBRP MBHP5/32” O.D.

HARDENER PUMP BYPASS (HPBP)5/32” O.D.

DIVISION I GROUPS C D E F & GHAZARDOUS LOCATION CLASS I, II & III

3/8” O.D.

SPRAY GUN

14–80


MARO2P10203703E

NOTES

MARO2P10203703E


14–81

Figure 14–40 . P-200 Brake Release Option Package

BATTERYPACK

ISBUNIT


EE–3287–516

MOUNT SWITCHES AND RC’S ON ALTERED COVER PLATE


BK

P

BK

M

BK

P

BK

P

BK

P

BK

P

BK

P

BK

M

BK

M

BK

M

BK

M

BK

M

BK

P1

BK

M1

CABLEEE–3287–122–XXX

EE–3287–121–XXX

EE–3287–120–XXX

CABLE

CABLEAXES 1 & 2

AXES 4,5,6

AXES 3 & 7AX

IS 1

AX

IS 2

AX

IS 3

AX

IS 4

AX

IS 5

AX

IS 7

BLU–17

BLU–18BLU–19 BLU–20

AXIS 6 NOT USED

BK

P2

BK

P1

BK

M1

BK

P3

BK

M2

BK

M3

BK

P3

BK

M3

BLK–5 BLK–11BLK–6 BLK–12

BK

P2

BK

M2

BLUE–17

BLUE–18

BLUE–19

BLUE–20

OPENER CONNECTIONS

INSTALLATION OF CONTROLLER WIRING


PURGEUNIT

14–82


MARO2P10203703E

NOTES

MARO2P10203703E


14–83

Figure 14–41 . P-200 Brake Release Wiring Diagram

EE–3287–516

123

4

5678

9101112

1314+ –

REAR VIEW

1 = P–200 1, 4, 5, 7

2 = P–200 AXIS 2

3 = P–200 AXIS 3

4 = P–10

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

OF SWITCHES

RELAY

SW

SW

SW

SW

BK TB

LABEL

LABEL

LABEL

SWITCH

RC NETWORK

RELAYSOCKET

RAILEND END

BARR ANC TERM

WIRE18 AWG

BLUE

1 2

3 4

5 6 7 8 9 12

BRDC

24V

0V

FORK TERM

SCR NUT WASH

TERM

13

14

15

PURGE/BRAKE

BOARD

BRAKE TB

BRD2

PURGE CONTROL PCBA16B–1310–0601

BKRL1

BKRL2

+24E

EMG1

EMG2

EES1

EES2

16

17

11

12

16

17

BKP1

BKM1

BKP2

BKM2

BKP4

BKM4

0V

1

2

3

4

5

6

9

10

7

8

D4 D5 D6

3

4

5

6

7

8

9

10

TBCNIN

8

9

CR5A

CR5B

CNIN

CR5BC1R7

100

CR6

CR7A

CR7B

CR7B

CR7B

CR5A CR6

CR8

33OuF

CNPG CNISSH1A

DS1CR7A

CR7A

CR8100OUT1

100OUT2

100A

100B

CR7B

24V

CR1

CR1

CR1

CR1

RC

CR1

RC

RC

RC

P–200 AXES 1 + 7

P–200 AXES 4 + 5

OPENER AXIS 1

OPENER AXES 2 + 3

P–200 AXIS 2

P–200 AXIS 3

0V

SCHEMATICWIRING DIAGRAM

BRAKE RELEASEKEYSWITCH

SEE EE–3287–516–001 FORPLATE MODIFICATION DETAILS

SW1SW2SW3SW4

14 13

BRDC

BRD2

1 9

1

2

3

4

5

6

7

8

9

10

11

12

2

3

4

10

11

12

51601

51602

51603

51604

51605 51606

51607

51608

51609

51610

51611 51612

51613

51614

51615

51602

51603

51604

51605

51607

51608

51610

51611

51613

51614

5160

4

5160

7

5160

6

5160

6

5160

9

5160

9

5161

2

5161

2

5161

5

5161

5

5160

2

5160

3

5160

1

5161

0

5161

3

5160

5

5160

8

5161

1

5161

4

51614

5160

5

5160

8

5161

1

5161

4

5161

5

5161

2

5160

9

5160

6

CR1

BK

P

BK

M

BK

P

BK

P

BK

P

BK

P

BK

P

BK

M

BK

M

BK

M

BK

M

BK

M

SEE SHT FOR CABLE HOOKUP

PURGE BD

3

4

5

6

7

8

9

10

BKP

BKP

BKP

BKP

BKP

BKP

BKM

BKM

BKM

BKM

BKM

BKM

SW1

SW2

SW3

SW4

BKP1

BKM1

BKP2

BKP3

BKP4

BKM2

BKM3

BKM4

14–84


MARO2P10203703E

NOTES

A TRANSPORTATIONAND INSTALLATION

A TRANSPORTATION AND INSTALLATION

MARO2P10203703E A–1

This appendix includes information on transporting and installing an R-J2controller.


Transportation The controller is transported by a crane. A–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Installation and Assembly A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Area A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly During Installation A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment and Checks at Installation A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MARO2P10203703EA–2

A. TRANSPORTATION AND INSTALLATION

The controller is transported by a crane. Attach a rope to the eye bolts atthe top of the controller, as shown in Figure A–1.

Figure A–1. Transportation

Î

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎ

ÏÏ

ÏÏ

A.1TRANSPORTATION

MARO2P10203703E A–3


When you install the controller, allow the space for maintenance as shownin Figure A–2.

Figure A–2. Installation Area

Controller Controller Controller

A.2INSTALLATION

A.2.1 Installation Area

MARO2P10203703EA–4


Figure A–3. Assembly During Installation

ÎÎÎÎ

ÎÎÎÎÎÎ

ÎÎ

ÎÎÎÎÎÎ

ÏÏÏ

Mechanical unitconnectioncables (5)

Peripheral deviceconnection cable

Input power cable

ISB

Intrinsically safeteach pendant

A.2.2 Assembly DuringInstallation

MARO2P10203703E A–5


Procedure A–1 Adjustment and Checks at InstallationSTEP ACTION ITEM # Q’TY SERVICE NOTES

1 Visually check the inside and outside of the controller.

2 Verify that the screwed terminal is connected properly.

3 Check that the connectors and printed circuit boards areinserted correctly.

4 Check transformer tap setting.

5 Connect the controller unit and mechanical unit cables.

6 Turn the breaker or disconnect off and connect the input powercable.

7 Check the input power voltage.

8 Press the EMERGENCY STOP button on the operator paneland turn the power on. Check the output voltage.

9 Check the interface signals between the control unit andmechanical unit.

10 Check the parameters. If necessary, set them.

11 Release the EMERGENCY STOP button on the operator panel.Turn on the controller.

12 Check the movement along each axis in the manual jog mode.

13 Check the end effector interface signals.

14 Check the peripheral device control interface signals.

A.2.3 Adjustment andChecks at Installation

MARO2P10203703EA–6


The physical characteristic of the C-Size R-J2 controller are provided inTable A–1.

Table A–1. Physical Characteristics

ItemModel

Specifications/Condition

Transformer All models Three-phase 220, 240, 380, 415, 460, 480, 500, 550, or 575 V +10% –15%, 50/60+/–1 Hz

Input powersource capacity

All models 7.5 kVA + 1.1 kVA for optional user transformer

Average powerconsumption

All models 3.5KW nominal – path dependent (During rapid acceleration, the unit will temporarilyrequire two times the continuous rated power value.)

Permissibleambienttemperature

All models 0 degrees C to 45 degrees C

Permissibleambienthumidity

All models 75% RH or less, non-condensing, up to 95% RH for a limited period(within one month)

Surroundinggas

All models No corrosive gas. When you use the robot in an environment with a highconcentration of dust or coolant, consult with your FANUC Robotics salesrepresentative.

Vibration All models 0.5 G or less. When you use the robot in a location subject to serious vibration,consult with your FANUC Robotics sales representative.

Weight ofcontrol unit

C cabinet About 300 kg (660 lbs)

r-j2 controller p-200 maintenance manual

Documents