B-83525EN_01

March 21, 2018 | Author: SamirdeOliveira | Category: Electrical Connector, Technology, Robot, Switch, Safety
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< > seriesR-30+B Mate CONTROLLER MAINTENANCE MANUAL B-83525EN/01 • Original Instructions Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand the content. • No part of this manual may be reproduced in any form. • All specifications and designs are subject to change without notice. The products in this manual are controlled based on Japan’s “Foreign Exchange and Foreign Trade Law”. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. The products in this manual are manufactured under strict quality control. However, when using any of the products in a facility in which a serious accident or loss is predicted due to a failure of the product, install a safety device. In this manual we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as “impossible”. B-83525EN/01 SAFETY PRECAUTIONS SAFETY PRECAUTIONS Thank you for purchasing FANUC Robot. This chapter describes the precautions which must be observed to ensure the safe use of the robot. Before attempting to use the robot, be sure to read this chapter thoroughly. Before using the functions related to robot operation, read the relevant operator's manual to become familiar with those functions. If any description in this chapter differs from that in the other part of this manual, the description given in this chapter shall take precedence. For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell. In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”. 1 WORKING PERSON The personnel can be classified as follows. Operator: • Turns robot controller power ON/OFF • Starts robot program from operator’s panel Programmer or teaching operator: • Operates the robot • Teaches robot inside the safety fence Maintenance engineer: • Operates the robot • Teaches robot inside the safety fence • Maintenance (adjustment, replacement) - - An operator cannot work inside the safety fence. A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance, etc.. To work inside the fence, the person must be trained on proper robot operation. During the operation, programming, and maintenance of your robotic system, the programmer, teaching operator, and maintenance engineer should take additional care of their safety by using the following safety precautions. - Use adequate clothing or uniforms during system operation Wear safety shoes Use helmet s-1 SAFETY PRECAUTIONS 2 B-83525EN/01 NOTATION OF “WARNING”, “CAUTION” and “NOTE” This manual contains safety precautions against injury and property damage. Those precautions are labeled ”Warning” or ”Caution,” according to the degree of importance. Supplementary explanation is given under ”Note.” Before starting to use a robot, carefully read the ”Warning,” ”Caution,” and ”Note.” WARNING Failure to follow the instruction given under ”Warning” can cause fatal or serious injury to the user. This information is indicated in bold type in a box so that it can be easily distinguished from the main body of this manual. CAUTION Failure to follow the instruction given under ”Caution” can cause injury to the user or property damage. This information is indicated in a box so that it can be easily distinguished from the main body of this manual. NOTE The information given under ”Note” is a supplementary explanation, which is neither a warning nor a caution. Carefully read and save this manual. 3 WORKING PERSON SAFETY Working person safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure working person safety. (1) Have the robot system working persons attend the training courses held by FANUC. FANUC provides various training courses. Contact our sales office for details. (2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working person safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. (3) Install a safety fence with a gate so that no working person can enter the work area without passing through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened. The controller is designed to receive this interlocking signal of the door switch. When the gate is opened and this signal received, the controller stops the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). For connection, see Fig.3 (b). (4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D). s-2 B-83525EN/01 SAFETY PRECAUTIONS (5) Try to install the peripheral devices outside the work area. (6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when a working person enters the work area. (8) If necessary, install a safety lock so that no one except the working person in charge can turn on the power of the robot. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock. (9) When adjusting each peripheral device independently, be sure to turn off the power of the robot (10) Operators should be ungloved while manipulating the operator’s panel or teach pendant. Operation with gloved fingers could cause an operation error. (11) Programs, system variables, and other information can be saved on memory card or USB memories. Be sure to save the data periodically in case the data is lost in an accident. (12) The robot should be transported and installed by accurately following the procedures recommended by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe injury to workers. (13) In the first operation of the robot after installation, the operation should be restricted to low speeds. Then, the speed should be gradually increased to check the operation of the robot. (14) Before the robot is started, it should be checked that no one is in the area of the safety fence. At the same time, a check must be made to ensure that there is no risk of hazardous situations. If detected, such a situation should be eliminated before the operation. (15) When the robot is used, the following precautions should be taken. Otherwise, the robot and peripheral equipment can be adversely affected, or workers can be severely injured. - Avoid using the robot in a flammable environment. - Avoid using the robot in an explosive environment. - Avoid using the robot in an environment full of radiation. - Avoid using the robot under water or at high humidities. - Avoid using the robot to carry a person or animal. - Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.) (16) After connecting the safety signals like external emergency stop signal and/or safety fence signal, verify that, ･All safety signals stop the robot as intended. ･There is no mistake in connection of safety signals. s-3 3 (b) Limit switch circuit diagram of the safety fence 3.3 (a) Safety fence and safety gate Emergency stop board EAS1 EAS11 EAS2 (Note) Connect EAS1 and EAS11.EA11.1 OPERATOR SAFETY The operator is a person who operates the robot system. this section does not apply to teach pendant operators. and then proceed with necessary work.XHBK.EAS2. (4) Install an EMERGENCY STOP button within the operator’s reach. However. EAS2 and EAS21. Fig.EAS21 are on the emergency stop board. In this sense.XROT RM1 Motor power/brake EARTH Safety fence Interlocking device and safety plug that are activated if the gate is opened. (1) If you do not have to operate the robot.SAFETY PRECAUTIONS B-83525EN/01 RP1 Pulsecoder RI/RO. a worker who operates the teach pendant is also an operator. turn off the power of the robot controller or press the EMERGENCY STOP button. Terminals EAS1. EAS21 Fig. (2) Operate the robot system at a location outside of the safety fence (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the work area unexpectedly and to prevent the worker from entering a dangerous area. s-4 . .EES11. External EMERGENCY STOP button Emergency stop board EES1 EES11 EES2 (Note) Connect EES1 and EES11.EES2. check the locations. check that the robot and its peripheral devices are all in the normal operating condition. carry out all tasks outside the area. (2) Before teaching the robot. Before entering the inside of the safety fence for the purpose of teaching. . With this connection. Terminals EES1. The operator must ensure (1) Unless it is specifically necessary to enter the robot work area. settings.1. the operator must enter the work area of the robot.SAFETY PRECAUTIONS B-83525EN/01 The robot controller is designed to be connected to an external EMERGENCY STOP button. The programmer should understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety fence. when the external EMERGENCY STOP button is pressed. ensure that there is no risk of dangerous situations in the area.EES21 are on the emergency stop board.Before starting programming. 3. If the safety gate is opened with the automatic operation mode set.Before entering the area of the safety fence. (4) The programmer must be extremely careful not to let anyone else enter the robot work area. s-5 . After the switch is set to a teach mode. and other conditions of the safety devices (such as the EMERGENCY STOP button.Be prepared to press the emergency stop button whenever necessary. set the switch to a teach mode. remove the key from the mode switch to prevent other people from changing the operation mode carelessly. For connection. (5) Programming should be done outside the area of the safety fence as far as possible. see Fir.3. the controller stops the robot operation (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). .1 Connection Diagram for External Emergency Stop Button 3. the DEADMAN switch on the teach pendant) before entering the area. EES2 and EES21. the safety of the teach pendant operator especially. the safety gate is disabled. the programmer should take the following precautions: . The operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation mode (AUTO) and the teach modes (T1 and T2). the robot stops (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type).Robot motions should be made at low speeds. then open the safety gate. (3) If it is inevitable to enter the robot work area to teach the robot. EES21 Fig. If programming needs to be done in the area of the safety fence. check the entire system status to ensure that no remote instruction to the peripheral equipment or motion would be dangerous to the user.2 SAFETY OF THE PROGRAMMER While teaching the robot. (c) Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing. Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or presses the pendant strongly in case of emergency. the teach pendant operator should leave the robot work area. The teach pendant. The operator should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely. (a) Disable: The DEADMAN switch is disabled. s-6 . and peripheral device interface send each robot start signal.T2 mode: DEADMAN switch is effective. the robot stops immediately. make certain that nobody is the robot work area and that there are no abnormal conditions in the robot work area. (7) When a program is completed. operator panel. (a) Run the program for at least one operation cycle in the single step mode at low speed. The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. Based on the risk assessment by FANUC. (2) DEADMAN switch: Functions differently depending on the teach pendant enable/disable switch setting status. T2 mode Teach pendant enable/disable switch On Off On Off Software remote condition Teach pendant Operator panel Peripheral device Local Remote Local Remote Local Remote Local Remote Not allowed Not allowed Not allowed Not allowed Allowed to start Allowed to start Not allowed Not allowed Not allowed Not allowed Allowed to start Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Allowed to start Not allowed Not allowed Not allowed Not allowed T1. (d) Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble. execute it in the automatic operation mode. DEADMAN switch as well as an emergency stop button. The R-30iB Mate employs a 3-position DEADMAN switch. (b) Enable: Servo power is turned off when the operator releases the DEADMAN switch or when the operator presses the switch strongly. (6) To start the system using the operator’s panel. When the operator releases the DEADMAN switch or presses the switch strongly. the teach pendant enable/disable switch and the remote condition on the software. (b) Run the program for at least one operation cycle in the continuous operation mode at low speed. (8) While operating the system in the automatic operation mode. These button and switch function as follows: (1) Emergency stop button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type) when pressed. Mode AUTO mode T1. (e) After checking the completeness of the program through the test operation above. However the validity of each signal changes as follows depending on the mode switch of the operator panel. number of operation of DEADMAN SW should not exceed about 10000 times per year.SAFETY PRECAUTIONS B-83525EN/01 The teach pendant is provided with an enable/disable switch. be sure to carry out a test operation according to the procedure below. which allows the robot to operate when the 3-position DEADMAN switch is pressed to its intermediate point. . s-7 . If there are two cabinets. turn off the circuit breaker to protect against electric shock. (4) When entering the area enclosed by the safety fence. the emergency stop button must be pressed. the worker should be ready to press the EMERGENCY STOP button at any time. The maintenance personnel must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly. If other parts are used. (10) If necessary. (3) If it becomes necessary to enter the robot operation range while the power is on. for any maintenance operation. Therefore. (5) Before the maintenance of the pneumatic system is started. pay utmost attention to the following. causing damage to the robot and injury to the worker. If necessary. make sure in advance that there is no person in the work area and that the robot and the peripheral devices are not abnormal.Inside the controller (19) Maintenance should be done under suitable light. (2) A hazardous situation may arise when the robot or the system. or the teach pendant before entering the range. press the emergency stop button on the operator panel. have a worker who is familiar with the robot system stand beside the operator panel and observe the work being performed. (9) When a tool is mounted on the robot. pay careful attention to its motion. it should be removed as quickly as possible to prevent dangerous falls. the robot arm should be supported with a crane or other equipment beforehand so that the arm would not fall during the removal. or when multiple workers are working nearby. never enter the robot work area. the supply pressure should be shut off and the pressure in the piping should be reduced to zero. If a wrong procedure is followed. If the worker needs to enter the area of the fence while a dangerous situation exists. turn off the both circuit breaker. (13) When handling each unit or printed circuit board in the controller during inspection. (8) When you maintain the robot alongside a wall or instrument. a lock should be in place in order to prevent any other person from turning on the robot and/or the system. If a maintenance worker needs to touch such a part in the heated state. (1) During operation. (14) A part should be replaced with a part recommended by FANUC. In case maintenance needs to be executed in the power-on state. (6) Before the start of teaching. (11) When replacing a part. the maintenance worker should check the entire system to make sure that no dangerous situations are present. (18) The following parts are heated. (15) When restarting the robot system after completing maintenance work. or when any moving device other than the robot is installed. (12) When replacing or reinstalling components. (16) When a motor or brake is removed. Care must be taken that the light would not cause any danger. such as belt conveyor. (7) Do not operate the robot in the automatic mode while anybody is in the robot work area. check that the robot and its peripheral devices are all in the normal operating condition. Such a fuse may cause a fire. the robot and the system should be put into the power-off state.3 SAFETY PRECAUTIONS SAFETY OF THE MAINTENANCE ENGINEER For the safety of maintenance engineer personnel. take care to prevent foreign matter from entering the system. malfunction or damage would occur. (17) Whenever grease is spilled on the floor. an accident may occur. make certain that their escape path is not obstructed. a fuse that is not recommended by FANUC should not be used. If any danger arises.Servo motor . the worker should wear heat-resistant gloves or use other protective tools. the worker should always take extreme care and check the current system status. please contact FANUC service center. are kept with their power-on during maintenance operations.B-83525EN/01 3. Especially. (See TESTING section of “Controller operator’s manual”.2 PRECAUTIONS FOR MECHANISM (1) Keep the component cells of the robot system clean. • Please do not obstruct the movement of the mechanical unit cable when cables are added to outside of mechanical unit. particular care must be taken in programming so that they do not interfere with each other. monitor continuously the whole system so that your escape route will not become blocked by the robot.SAFETY PRECAUTIONS B-83525EN/01 (20) When a motor. or by peripheral equipment. the maintenance staff should work outside the safety fence. (3) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot or cable does not strike against its peripheral devices or tools. spilled oil or water and metal chips should be removed from the floor around the robot and within the safety fence. (26) After a part is replaced. If it is attempted. and operate the robot in an environment free of grease. and be prepared to press the emergency stop button whenever necessary. unexpected troubles might occur. (24) In case robot motion is required during maintenance. decelerator. if necessary. (2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices. When theses attentions are not kept. . And during the maintenance motion itself.) During the test operation. (4) Observe the following precautions about the mechanical unit cables. 4. 4 4. • Use mechanical unit cable that have required user interface.Always pay attention to potentially dangerous situations. A careful check must be given to ensure that no components are missing or left unmounted. (23) When a part is replaced. the robot would be adversely affected.) A failure to do the periodical inspection can adversely affect the performance or service life of the robot and also may cause an accident.Foresee an escape route. a crane or other equipment should be used to protect maintenance workers from excessive load. design the program to stop the robot when the sensor signal is received. (Refer to the manual of the controller or mechanical unit. (3) For a system in which the robot and its peripheral devices are in synchronous motion. In addition. (25) The robot should be periodically inspected. s-8 . and dust. the maintenance workers would be severely injured. a test operation should be given for the robot according to a predetermined method. all bolts and other related components should put back into their original places. (21) The robot should not be stepped on or climbed up during maintenance. • Don’t add user cable or hose to inside of mechanical unit. (4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states. (2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid. even though the robot itself is normal. or other heavy load is handled. Otherwise. the following precautions should be taken : . a misstep can cause injury to the worker.1 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES PRECAUTIONS IN PROGRAMMING (1) Use a limit switch or other sensor to detect a dangerous condition and. water. (22) After the maintenance is completed. • An area sensor or a mat switch connected to safety signal operate routinely and power-off stop is executed for the robot. (2) Before pressing the jog key. Please avoid the system construction that power-off stop would be operated routinely. and dust. (6) Robot stops urgently when collision detection alarm (SRVO-050) etc. (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type. • An operator pushes the emergency stop button frequently. 5. 5.) Please execute power-off stop after reducing the speed of the robot and stopping it by hold stop or cycle stop when it is not urgent.) (Bad case example) • Whenever poor product is generated. Please do not perform remodeling (Adding a protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the cable. a line stops by emergency stop.g. s-9 . Please refer to this manual and mechanical unit operator’s manual for using method of brake release unit and method of supporting robot. water.3 PRECAUTIONS FOR MECHANISMS (1) Keep the work areas of the robot clean. (2) Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin. 5 SAFETY OF THE ROBOT MECHANISM 5.2 PRECAUTIONS IN PROGRAMMING (1) When the work areas of robots overlap. 5. and a line stops. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated. and operate the robot in an environment free of grease. occurs. • Please do not interfere with the other parts of mechanical unit when install equipments in the robot. too. set it at an appropriate speed so that the operator can manage the robot in any eventuality. make certain that the motions of the robots do not interfere with each other.B-83525EN/01 SAFETY PRECAUTIONS • In the case of the model that a cable is exposed. So remove the causes of the alarm.1 PRECAUTIONS IN OPERATION (1) When operating the robot in the jog mode. The frequent urgent stop by alarm causes the trouble of the robot. be sure you know in advance what motion the robot will perform in the jog mode. safety switch is operated by opening safety fence and power-off stop is executed for the robot during operation. persons trapped in or by the robot). • When alteration was necessary. brake release unit can be used to move the robot axes without drive power. (5) The frequent power-off stop for the robot during operation causes the trouble of the robot. (Refer to bad case example.4 PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER IN EMERGENCY OR ABNORMAL SITUATIONS For emergency or abnormal situations (e. The configuration of stop type for each situation is called stop pattern. Hold (Category 2 following IEC 60204-1) The robot is decelerated until it stops. and servo power is turned off. (2) Provide the end effector with a limit switch. Controlled stop (Category 1 following IEC 60204-1) The robot is decelerated until it stops. which takes into consideration the increased stopping distance and stopping time.1 PRECAUTIONS IN PROGRAMMING B-83525EN/01 (1) To control the pneumatic. The following processing is performed at Hold. The robot operation is stopped immediately. A risk assessment for the whole robot system. is necessary when Controlled stop is used. s-10 . The following processing is performed at Power-Off stop. hydraulic and electric actuators. 7 STOP TYPE OF ROBOT The following three robot stop types exist: Power-Off Stop (Category 0 following IEC 60204-1) Servo power is turned off and the robot stops immediately. An alarm is generated and servo power is turned off. WARNING The stopping distance and stopping time of Controlled stop are longer than the stopping distance and stopping time of Power-Off stop. Execution of the program is paused. carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control. The stop pattern is different according to the controller type or option configuration. and the motion path of the deceleration is uncontrolled. The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. the stop type of robot is Power-Off stop or Controlled stop. When the E-Stop button is pressed or the FENCE is open. and control the robot system by monitoring the state of the end effector. The following processing is performed at Controlled stop. An alarm is generated and servo power is turned off. The robot operation is decelerated until it stops. and servo power remains on. Servo power is turned off when the robot is moving. Execution of the program is paused. Execution of the program is paused.SAFETY PRECAUTIONS 6 SAFETY OF THE END EFFECTOR 6. The stopping distance and stopping time of Controlled stop is longer than the stopping distance and stopping time of Power-Off stop. This function is effective for systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized. the stop type of the following alarms becomes Controlled stop but only in AUTO mode. s-11 . External emergency stop input (EES1-EES11. Controlled stop is different from Power-Off stop as follows: In Controlled stop. The stop type of DCS Position and Speed Check functions is not affected by the loading of this option. "Controlled stop by E-Stop" option "Controlled stop by E-Stop" option (A05B-2600-J570) is an optional function. In DCS Safe I/O connect function. In Controlled stop. the robot is stopped on the program path. Alarm SRVO-001 Operator panel E-stop SRVO-002 Teach pendant E-stop SRVO-007 External emergency stops SRVO-408 DCS SSO Ext Emergency Stop SRVO-409 DCS SSO Servo Disconnect Condition Operator panel E-stop is pressed. this function can not be disabled. The following table indicates the Stop pattern according to the controller type or option configuration. SSO[3] is OFF. SSO[4] is OFF. Stop pattern Mode E-Stop button External E-Stop FENCE open SVOFF input A AUTO T1 T2 P-Stop P-Stop P-Stop P-Stop P-Stop P-Stop C-Stop - C-Stop C-Stop C-Stop C AUTO T1 T2 C-Stop P-Stop P-Stop C-Stop P-Stop P-Stop C-Stop - C-Stop C-Stop C-Stop P-Stop: C-Stop: -: Power-Off stop Controlled stop Disable WARNING In this manual. When this option is loaded. EES2-EES21) is open.SAFETY PRECAUTIONS B-83525EN/01 There are the following 2 Stop patterns. Please refer to above table for actual stop type. the stop type is Power-Off stop which is the normal operation of the system. Please refer the operator's manual of a particular robot model for the data of stopping distance and stopping time. In DCS Safe I/O connect function. the term “Emergency-stop” is used for the stop by above safety signals. When this option is loaded. physical impact is less than Power-Off stop. Please refer "Software version" in operator's manual of controller for the detail of software version screen. depending on the robot model and axis. Teach pendant E-stop is pressed. This function is effective for a system where the robot can interfere with other devices if it deviates from the program path. Option Stop pattern Standard Controlled stop by E-Stop (A05B-2600-J570) A C The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. In T1 or T2 mode. 8 (b) High-Temperature warning label Description Be cautious about a section where this label is affixed. use a protective provision such as heat-resistant gloves. A risk assessment for the whole robot system. as the section generates heat. s-12 . which takes into consideration the increased stopping distance and stopping time.8 (a) Step-on prohibitive label Description Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing. 8 WARNING LABEL (1) Step-on prohibitive label Fig. is necessary when this option is loaded. (2) High-temperature warning label Fig.SAFETY PRECAUTIONS B-83525EN/01 WARNING The stopping distance and stopping time of Controlled stop are longer than the stopping distance and stopping time of Power-Off stop. If you must touch such a section when it is hot. and turn the circuit breaker off to avoid electric shock hazards. turn the power to the controller off. because high-voltage remains in these units for a certain amounts of time s-13 .B-83525EN/01 SAFETY PRECAUTIONS (3) High-voltage warning label Fig.8 (c) High-voltage warning label Description A high voltage is applied to the places where this label is attached. Before starting maintenance. Take additional precautions with the servo amplifier and other equipment. . PREFACE B-83525EN/01 PREFACE This manual describes the following models (R-30iB Mate controller). Model FANUC Robot LR Mate 200iD LR Mate 200iD p-1 Abbreviation LR Mate 200iD . . ................................2 3............................. 3 2 CONFIGURATION .......................12 BLOCK DIAGRAM OF THE POWER SUPPLY ..................2 4...........................................7....................... 84 4...................... 95 REPLACING UNITS ....1.......................................5 4.......................................................................................................4 3.................. MAINTENANCE 1 OVERVIEW ...........5 3...............................4 3.............................................................................................................................................................................................................................................78 Troubleshooting by Alarm LEDs on the Process I/O Board ................................ 94 POWER SUPPLY.................................. 88 PROCESS I/O BOARD MB (A20B-2101-0731) .. 68 TROUBLESHOOTING BASED ON LED INDICATIONS ................... 92 SETTING OF SERVO AMPLIFIER..............1.............................................................................................9.......................................................................................... 9 TROUBLESHOOTING .............................80 MANUAL OPERATION IMPOSSIBLE ....................2 3...... 93 6-AXIS SERVO AMPLIFIER SPECIFICATIONS .... 17 TROUBLESHOOTING USING THE ERROR CODE ........................... 16 MASTERING ..................... 87 PROCESS I/O BOARD MA (A20B-2004-0381) ..76 Troubleshooting by LED on the Emergency Stop Board.... 4 2....................... 89 I/O CONNECTOR CONVERTER BOARD (A20B-2004-0411) ...............8 3.........................................3 6 Meanings of LEDs on Units Supporting I/O Link i ....................................................... 72 3............7.................82 PRINTED CIRCUIT BOARDS ................................................................7.........4 4.................................................. 13 STOP SIGNALS .....................................................1 4............................................... 11 3........................2 5................11 When the Teach Pendant Does not Change from the Initial Screen.1 7 MAIN BOARD .............1 4 When the Teach Pendant Cannot be Powered on....................................................... 81 LEDS ON UNITS SUPPORTING I/O LINK i .....3 3 EXTERNAL VIEW OF THE CONTROLLER ...............................................................7 ALARM OCCURRENCE SCREEN...................................................1 3.........................p-1 I. 87 BACKPLANE ...........................TABLE OF CONTENTS B-83525EN/01 TABLE OF CONTENTS SAFETY PRECAUTIONS.......................2 3.................................................... 90 SERVO AMPLIFIERS . 85 EMERGENCY STOP BOARD:A20B-2005-0150 ..............................................................................................................................73 Troubleshooting by LEDs on the 6-Axis Servo Amplifier .......................................... 4 COMPONENT FUNCTIONS................... 82 3.3 3......................6 3............. 96 c-1 .....................3 4.....2 2......... 19 FUSE-BASED TROUBLESHOOTING .......1 5.........................1 POWER CANNOT BE TURNED ON .. 8 PREVENTIVE MAINTENANCE .............................3 3............... 95 6..s-1 PREFACE ..................................................................................6 5 Troubleshooting Using the LEDS On the Main Board .......................7........................1 2............... 11 3.9 LEDS OF SERVO AMPLIFIER ........ 91 5.............................................1 3..... ...........................113 II................... 106 REPLACING THE REGENERATIVE RESISTOR UNIT ..............97 Replacing the Main Board... 108 REPLACING THE TEACH PENDANT.......140 In the Case of the Process I/O Board MB .............................1 7..................... 96 7..................................................................1....................... 125 3..................... ARC WELDING........4 7............................4 3.........................1..TABLE OF CONTENTS 7...............121 Connection of the I/O Link Cable .4...................2 3.................. 119 FANUC I/O LINK....2 7.................... 143 INTERFACE FOR PERIPHERAL DEVICES............................4 In Case of Main Board (CRMA15............................................... 118 3 ELECTRICAL CONNECTIONS...............................................2 4......................122 EXTERNAL CABLE WIRING DIAGRAM ....... 138 4.............11 B-83525EN/01 Replacing the Heat Exchanger and Door Fan Unit (A-cabinet) .........................................................1......136 Connecting the Auxiliary Axis Over Travel (CRM68) .................1............................................................ CONNECTIONS 1 GENERAL .......... 156 4......................3 7..............................................3.......140 In the Case of the Process I/O Board MA ...........1 4......... 99 REPLACING THE E-STOP UNIT .......................145 Connection between the Connector Conversion Board and Peripheral Devices.....................................................................................................................1..............3......3.......2 4. 104 REPLACING THE EMERGENCY STOP BOARD .......11.............................. 129 Connecting the External Emergency Stop............ 119 3.......................................................1 REPLACING THE PRINTED-CIRCUIT BOARDS ...........................10.125 Teach Pendant Cable ................2.............1 Connection between the Process I/O Board MB and Welding Machines .......................................141 In the Case of the Connector Conversion Board .............................................137 PERIPHERAL DEVICE......128 3......................................................................3..... 112 7.............................................112 REPLACING THE BATTERY ..........1.6 4 Connecting the input power cable .................................................................................3 Connection of I/O Link ........ 105 REPLACING THE POWER SUPPLY UNIT .....3........... 117 2 BLOCK DIAGRAM........................................ 110 REPLACING THE CONTROL SECTION FAN MOTOR ................................. 128 Leakage breaker...............................156 c-2 ..........................2 7..... 145 4...........2 3....................................1 3.142 Connection between the Main Board (CRMA15.........1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM...............2 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS ...............1 4........3 Robot Connection Cables.........................................1 3.1 7............................1 3................................. AND EE INTERFACES ..................................3................98 REPLACING CARDS AND MODULES ON THE MAIN BOARD .3 I/O SIGNALS OF MAIN BOARD.............151 Connection between the Process I/O Board MA and Peripheral Devices...............................1 Battery for Memory Backup (3 VDC)...................5 3....... CRMA16) and Peripheral Devices..................9 7....................................3...................5 7.....3......................127 Connecting the Input Power ...6 7.............................................8 7...............3...................................................10 Replacing the Backplane Board (Unit)........................3........129 Connecting the Auxiliary Axis Brake (CRR65 A/B) ...152 INTERFACE FOR WELDING MACHINES ...... 113 7......... 140 4.........2 4..........................................4 4............................2 3..... CRMA16) ..........3...................... 107 REPLACING THE 6-AXIS SERVO AMPLIFIER .........3 4................3 4...............3............................................7 7.........3................... 121 3..........1 3................. 111 REPLACING THE AC FAN MOTOR ..2......................... ....................2 4.......2..........1 4.................................194 c-3 ....................TABLE OF CONTENTS B-83525EN/01 4...............................6......2 5.2.....2....................................................... 183 Check Items at Installation ....... AND ARC WELDERS ................. 175 4.....................10....... 179 Twisted-pair Cable Specification...................5.......................................................................................................2......4 4..................................1 4........................................................................3 4..............1 4............................................ 188 5..9...... END EFFECTORS..............188 Assemble at Installation .................166 Peripheral Device Interface A2 Cable (CRMA16: Tyco Electronics AMP........................................ 30 pin)...........10.....................................1.................... 191 ADJUSTMENT AND CHECKS AT INSTALLATION .....................................................6 Installation Method........................9............................3 5................178 4........ 176 4....................................... Tyco Electronics AMP.................................................... 175 4..............................................................................................159 EE Interface.7 4............. 159 4..................158 Connecting HDI ..............................................................10............ 158 4.................172 CONNECTION OF HDI ...........................8.............6....162 I/O Signal Specifications for ARC-Welding Interface (A-cabinet/Process I/O Board MB) ... 179 100BASE-TX Connector (CD38A..................10..........................4 Peripheral Device Connection Cable.............. 193 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION....8................1 5..1 Interface ...........................................................................6................163 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS ...................6.................2 Ethernet Interface ..............2 4........1 4.....3 4.6 5 Connection to Ethernet ......194 How to Disable/Enable HBK .....4 Peripheral Device Interface Processing.....................................6 DIGITAL I/O SIGNAL SPECIFICATIONS ............................................................................................................ 178 Routing of the Ethernet Cable ....................................................194 How to Disable/Enable Pneumatic Pressure Alarm (PPABN).............1 4............10.......................10........ 168 4..1 4............ 187 5..........10..........................................7...........1 RS-232-C Interface...2......10.. 173 4............................. 186 TRANSPORTATION AND INSTALLATION ......................................................................8 Connection between the LR Mate 200iD and End Effector.2................................. 20 pin) ......................................7.............................7.........................2 4...6.................6..................................................................................169 Recommended Cables ................... 176 4................193 Resetting Overtravel...................................................1 5.................................................. 190 INSTALLATION CONDITION ...................10.....................1 5..............................................................3 4........ 180 Electrical Noise Countermeasures ..........................168 Peripheral Device Cable Connector ... 40 pins) .3 Connection between RS-232-C interface and I/O device ... 193 5...............................2 4..5 5......6......................2..................10 Peripheral Device Interface A1 Cable (CRMA15: Tyco Electronics AMP......................10..174 CONNECTING THE COMMUNICATION UNIT ...............................................7.....173 Input Signal Rules for the High-speed Skip (HDI) .....2 TRANSPORTATION... CD38B) Pin Assignments................10.......................2 RS-232-C interface signals .167 CABLE CONNECTION FOR THE PERIPHERAL DEVICES..................3 5................9 Peripheral Device Interface A ...................................................................166 Peripheral Device Interface B1 and B2 Cables (CRMA52..........189 INSTALLATION OF TEACH PENDANT HOOK (Option).......................................8.............................................................................................2 4.........................5 INTERFACE FOR END EFFECTOR ..2................1......................... 187 INSTALLATION ..........................2 5.....................167 ARC Weld Connection Cables (CRW11..175 4.1.......... Tyco Electronics AMP....................................3 4..................... 40 pins) ...... 166 4..5 4....4 5.................. ...............................................4 Input Signals.215 Output Signals ..2............5 D.................3.........................................................................................1 E...1 B.................3 Overview ........................2 D..................... 236 c-4 ...................................................... 213 B.......................................... 213 SETTING COMMON VOLTAGE............................................................................................................................. 232 SPECIFICATIONS.........................2................................... 223 D BRAKE RELEASE UNIT..................................221 Software Specifications .........................1 D.................2 B.......................... 226 CONFIRMATIONS BEFORE OPERATION . 215 B...221 Input/Output Hardware Usable in the R-30iB Mate Controller .................................................... 227 D........................................................................................1 D....................................... 230 DIMENSION .. 234 E...............229 Teach Pendant Disconnect .. 234 PROCEDURE OF TEACH PENDANT DISCONNECT ..3 SAFETY PRECAUTIONS .................234 Teach Pendant Connect ...................6 D...............4.....................................1 E........................................................................... 221 B..............................................................................3 SIGNAL ..................................... 231 FUSE .............................4.................. 226 OPERATION.............4..........................2 F In case of operating to the robot .........4 D.......................................2 B............................................................................................................................................... 197 B SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE............3........................TABLE OF CONTENTS B-83525EN/01 APPENDIX A TOTAL CONNECTION DIAGRAM....3.... 215 I/O SIGNALS .................. 234 E.................. 226 D...............................................................................7 E HOW TO CONNECT THE PLUG TO THE POWER CABLE (IN CASE OF NO POWER PLUG) ....................................235 INSTRUCTION FOR TERMINAL BLOCK .........................................................................................227 In case of operating to the auxiliary Axis..................................222 C OPTICAL FIBER CABLE .......................................................................................................2 B......................1 B.......................3..................................2 D.......218 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT.................................................... 233 TEACH PENDANT DISCONNECT FUNCTION (Option) .........2 CONFIGURATION................................................................................1 B........... MAINTENANCE .I. . R-30iB Mate has three variations depending on the required standards. and the setting. EMC parts. Low voltage Directive. Breakers). And the specific descriptions of CE and NRTL controller have notifications in this manual. Otherwise. and replacement of units ･Connection Part: Connection of R-30iB Mate to the robot mechanical unit and peripheral devices.OVERVIEW MAINTENANCE B-83525EN/01 OVERVIEW This manual is applied to R-30iB Mate controller (called R-30iB Mate). Applied standards Common Standard Basic controller CE controller NRTL controller ISO 10218-1 ISO 13849-1 IEC 60204-1 IEC 61508 EMC Standard UL/CSA Standard - - Safety Standard General electrical requirement - CE Marking •Europe •Noise filter •EMC Cabinet •Shielded cable UL standard CSA standard •USA and Canada •UL listed main breaker EN 55011 EN 61000-6-2 EN 61000-6-4 - UL1740 CAN/CSA Z434 NFPA79 Requirement Difference - This manual describes the maintenance and connection of R-30iB Mate. Basic controller: CE controller: NRTL controller: To meet Safety Standard and General electrical requirement To meet Machinery Directive. and installation of the controller WARNING Before you enter the robot working area. be sure to turn off the power to the controller or press the EMERGENCY STOP button on the operator's panel or teach pendant.1 1. The difference of NRTL and CE controller from Basic controller is small as shown in Table 1 (ex. adjustment. EMC Directive to cover the requirement of CE mark To meet UL/CSA standard This manual covers these three variations of R-30iB Mate. Table 1. ･Maintenance Part: Troubleshooting. -3- . you could injure personnel or damage equipment. 1 (a) shows the view of R-30iB Mate. application.1 EXTERNAL VIEW OF THE CONTROLLER The appearance and components might slightly differ depending on the controlled robot. Fig. Teach pendant hook (Option) Operator’s panel Breaker Teach pendant (iPendant) USB port (Option) Fig.2. Fig.1 (b) to (d) show the construction of the R-30iB Mate controller. and options used. Fig.CONFIGURATION MAINTENANCE B-83525EN/01 2 CONFIGURATION 2.1 (e) to (g) show the external view of the operator’s panel and teach pendant.2.2.2.2.1 (a) External view of the R-30iB Mate controller -4- . 2.1 (b) R-30iB Mate cabinet interior (Front-1) Noise Filter (EMC Option) Power supply unit Process I/O board (Option) Fig.1 (c) R-30iB Mate cabinet interior (Front-2) -5- .CONFIGURATION MAINTENANCE B-83525EN/01 Emergency stop button Main board Battery Back plane unit mode switch Heat exchanger Breaker 6-Axis Servo amplifier E-stop unit Fig.2.2. 2.1 (d) R-30iB Mate cabinet interior (Rear) Mode switch (In case of 3-mode switch) Emergency Stop button CYCLE START button with LED(Green) Fig.2.1 (f) Mode switch -6- .CONFIGURATION MAINTENANCE B-83525EN/01 Regenerative resistor 6-Axis Servo amplifier (Rear side) Fig.1 (e) R-30iB Mate operator’s panel 2 mode switch 3 mode switch Fig.2.2. MAINTENANCE B-83525EN/01 2.2.1 (g) Teach pendant (iPendant) -7- .CONFIGURATION Enable/disable switch Emergency Stop button USB port Deadman switch Fig. CONFIGURATION 2.2 Block diagram of the R-30iB Mate -8- B-83525EN/01 .2.2 MAINTENANCE COMPONENT FUNCTIONS Fig.2. Clean each part. the input power is connected to the circuit breaker to protect the equipment. (2) Check after one month Check that the fan is rotating normally. Please refer to the Section 7. heat exchanger These components cool the inside of the controller. PREVENTIVE MAINTENANCE Daily maintenance and periodic maintenance/inspection ensure reliable robot performance for extended periods of time. Also.3 MAINTENANCE 2.CONFIGURATION Main board The main board contains a microprocessor. It also has user interface terminals of safety relevant signals. and operator's panel control circuit. Power supply unit The power supply unit converts the AC power to various levels of DC power. its peripheral circuits. clean the fan according to step (d) described below for inspection to be performed every 6 months. The controller status and data are indicated on the liquid-crystal display (LCD) on the pendant. Regenerative resistor To discharge the counter electromotive force from the servomotor. Circuit breaker If the electric system in the controller malfunctions.B-83525EN/01 - - - - - - - 2. and then turn off the controller. I/O printed circuit board Various types of printed circuit boards are provided for applications including process I/O board. overtravel and hand broken. The main CPU controls servo mechanism positioning. Backplane printed circuit board The various control printed circuit boards are mounted on the backplane printed circuit board.11. or if abnormal input power causes high current in the system. Operator's panel Buttons and LEDs on the operator's panel are used to start the robot and to indicate the robot status. 6-Axis Servo amplifier The servo amplifier controls servomotor. (4) Maintenance tools The following maintenance tools are recommended: (a) Measuring instruments -9- . If the fan has dirt and dust built up. Fan unit. These are connected with FANUC I/O Link. external on/off signals etc. If the ventilation port of the controller is dusty. check the following: (a) Before operation Check the cable connected to the teach pendant for excessive twisting. E-stop unit This unit controls the emergency stop system of the robot controller. clean each part of the system and check the system parts for any damage or cracks. Check the controller and peripheral devices for abnormalities. return the robot to the specified position. Teach pendant All operations including robot programming are performed with this unit. brake control. memory. (3) Battery daily check Replace the battery on the front panel of the main board every 4 years. clean it. connect a regenerative resistor to the servo amplifier. Pulsecoder signal. (b) After operation At the end of operation. (1) Daily maintenance Before operating the system each day. and check for any damage or cracks. medium.10 - B-83525EN/01 . and small Nut driver set (Metric) Pliers Needle-nose pliers Diagonal cutting pliers .) Oscilloscope with a frequency range of 5 MHz or higher.CONFIGURATION MAINTENANCE AC/DC voltmeter (A digital voltmeter is sometimes required.2. two channels (b) Tools Phillips screwdrivers: Large. and small Standard screwdrivers: Large. medium. carry out action 2. find the cause by referencing the total connection diagram presented in the appendix. replace the emergency stop unit. When the LED on the main board lights. 3. b) If the circuit breaker has tripped. When fuse (FUSE3) is blown. carry out action 1 and replace the fuse. a) If circuit breaker is OFF.1 Figure Check that the circuit breaker is on and has not tripped. When it is blown.MAINTENANCE B-83525EN/01 3 3. Teach pendant (Inspection 2) When fuse (FUSE3) is not blown. carry out action 1. Refer to the operator's manual to release program alarms. (c) Replace the emergency stop board. Circuit Breaker When the Teach Pendant Cannot be Powered on Inspection and action Illustration (Inspection 1) Confirm that fuse (FUSE3) on the emergency stop board is not blown. Turn on the circuit breaker. (b) Check the teach pendant for failure and replace it as necessary.1. LED (Red) FUSE3 (Action 2) When the LED on the main board does not light. (Action 1) (a) Check the cable of the teach pendant for failure and replace it as necessary. . the LED on the emergency stop board lights in red.11 - .TROUBLESHOOTING TROUBLESHOOTING This chapter describes the checking method and corrective action for each error code indicated if a hardware alarm occurs.1 POWER CANNOT BE TURNED ON Check and Corrective action (Check 1) (Corrective action) 3. replace the option board. FUSE1 Back plane . check if fuse (FUSE1) on the main board is blown.1. (c) Replace the boards indicated in action 1. (a) Replace the emergency stop unit. (Action 1) (Action 2) (a) Replace the backplane board. (b) When fuse (FUSE1) is not blown See action 2.2 MAINTENANCE B-83525EN/01 When the Teach Pendant Does not Change from the Initial Screen Inspection and action Illustration (Inspection 1) Check that the status display LED and 7-segment LED on the main board operate normally. (b) Replace the main board. (a) When fuse (FUSE1) is blown See action 1. (b) Replace the cable between the main board and the emergency stop unit. (Action) Carry out an action according to the LED status. see "TROUBLESHOOTING USING THE LEDS ON THE MAIN BOARD". (c) When an option board is installed in the mini slot.12 - Mini slot (2slot) .3.TROUBLESHOOTING 3. For details. 7 Segment LED RLED1 (Red) LEDG1 LEDG2 LEDG3 LEDG4 (Green) (Inspection 2) When the LED on the main board does not light in inspection 1. To erase all alarm displays from the alarm occurrence screen. INTP-224 (TEST1. If an alarm reset signal is input to reset the alarm conditions. If two or more alarms have occurred. the alarm screen appears automatically. Press the alarm key. Press the CLEAR key (+ shift) on the alarm history screen. Alarm history screen display Fig. the alarm occurrence screen displays the message "PAUSE or more serious alarm has not occurred. or a reset. If an alarm has a cause code. NONE. the display begins with the most recent alarm. (2) Select [ALARM]. Press the screen selection key to select [4 ALARM]. You will see a screen similar to the following. 6) Jump label faile MEMO-027 Specified line does not exi [ TYPE ] [ VIEW ] HIST RES_1CH .3.3. If an alarm has occurred. 6)Jump label failed MEMO-027 Specified line does not exis JOINT 30% Alarm : Active 1/2 1 INTP-224 (TEST1. It will not display WARN.TROUBLESHOOTING MAINTENANCE B-83525EN/01 ALARM OCCURRENCE SCREEN The alarm occurrence screen displays only the alarm conditions that are currently active. Press F3 [HIST].13 - Alarm detail code . It is possible to disable PAUSE and some of more serious alarms from being displayed by setting the $ER_NOHIS system variable appropriately. however. Up to 100 lines can be displayed. it is displayed below the line indicating the alarm. Automatic alarm display upon occurrence Alarm occurrence screen display Press F3 [ACTIVE].2 Alarm occurrence screen and alarm history screen display procedure Displaying the alarm history/alarm detail information Step (1) Press the MENUS key to display the screen menu." The alarm occurrence screen displays only the alarm conditions (if any) that occur after the most recently entered alarm reset signal. The alarm occurrence screen is intended to display PAUSE or alarms that are more serious.2 3. TROUBLESHOOTING MAINTENANCE B-83525EN/01 (3) To display the alarm history screen. When $ER_NOHIS=2. press and hold down the SHIFT key. [HIST]. WARN alarms. and NONE alarms are not recorded.14 - . When $ER_NOHIS=3. press F3. (6) To delete all the alarm histories. press the PREV key.3. and then press the right arrow key. then press F4. press F5. [CLEAR]. HELP.L 21-NOV-11 12:16 Alarm : Hist 1 INTP-224 (TEST1. [HELP]. 6) Jump label faile R E S E T SRVO-007 External emergency stop SRVO-001 Operator panel E-stop R E S E T SRVO-001 Operator panel E-stop SRVO-012 Power failure recovery INTP-127 Power fail detected SRVO-047 LVAL alarm (Group:1 Axis:5) SRVO-047 LVAL alarm (Group:1 Axis:4) SRVO-002 Teach pendant E-stop [ TYPE ] [ VIEW ] ACTIVE CLEAR DETAIL NOTE The latest alarm is assigned number 1. . 6) Jump label faile 2 R E S E T 3 SRVO-007 External emergency stop 4 SRVO-001 Operator panel E-stop 5 R E S E T 6 SRVO-001 Operator panel E-stop 7 SRVO-012 Power failure recovery [ TYPE ] [ VIEW ] ACTIVE CLEAR DETAIL (5) To return to the alarm history screen. Press F3 [ACTIVE] again. 6) Jump label failed MEMO-027 Specified line does not exist STOP. resets are not recorded in the alarm history. Alarm : Hist 1 2 3 4 5 6 7 8 9 10 11 1/25 INTP-224 (TEST1. resets. press the F5. the alarm screen appears. Alarm : Hist DETAIL Alarm INTP-224 (TEST1. NOTE When system variable $ER_NOHIS = 1. (4) To display the alarm detail screen. To view messages that are currently not on the screen. NONE alarms or WARN alarms are not recorded. B-83525EN/01 3.TROUBLESHOOTING MAINTENANCE The following map indicates teach pendant operations used to check an alarm. 4 ALARM F1 [TYPE] Alarm : Active F1 [TYPE] F3 HIST Alarm : HIST F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP DETAIL Alarm F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP .15 - . causing the servo power to be switched off. If any robot articulation goes out of the operation range beyond the overtravel switch. the state is indicated as “TRUE”.16 - FALSE FALSE FALSE FALSE TRUE TRUE FALSE FALSE FALSE FALSE FALSE FALSE 1/12 .TROUBLESHOOTING 3. the state is indicated as “TRUE”. If the DEADMAN switch is released or is grasped tightly when the teach pendant is operable. This item indicates the state of the air pressure. To be specific. Dev.3. the screen indicates whether each stop signal is currently on. the state is indicated as “TRUE”. If the hand interferes with a workpiece or anything like this. This item indicates the state of the hand safety joint. the state is indicated as “TRUE”. Select STATUS on the next page. an alarm occurs. In this case. Press F1. and the DEADMAN switch is grasped correctly. the state is indicated as “TRUE”. This item indicates the state of the safety fence. Select Stop Signal. If the EMERGENCY STOP button is pressed. This item indicates whether the DEADMAN switch on the teach pendant is grasped. If the teach pendant is operable. the state is indicated as “TRUE”. This item indicates whether the current position of the robot is out of the operation range. If the EMERGENCY STOP signal is asserted. an alarm occurs. STATUS Stop Signal SIGNAL NAME 1 2 3 4 5 6 7 8 9 10 11 12 STATUS SOP E-Stop: TP E-STOP: EXT E-STOP: Fence Open: TP Deadman: TP Enable: Hand Broken: Overtravel: Low Air Alarm: Belt Broken: SVOFF Input: Non Teacher Enb. Step (1) (2) (3) (4) Press the MENUS key to display the screen menu. If the teach pendant is operable. the state is indicated as “TRUE”. [TYPE] to display the screen switching menu. The abnormal air pressure signal is connected to the air pressure sensor. If the air pressure is not higher than the specified value. causing the servo power to be switched off. If the EMERGENCY STOP button is pressed. the state is indicated as “TRUE”. causing the servo power to be switched off. In this case. On this screen. Table 3.3 Stop signals Description Stop signal Operator’s panel emergency stop Teach pendant emergency stop External emergency stop Fence open DEADMAN switch Teach pendant operable Hand broken Robot overtravel Abnormal air pressure This item indicates the state of the emergency stop button on the operator’s panel. You will see a screen similar to the following. and the safety joint is opened. This item indicates the state of the external emergency stop signal.: [ TYPE ] . it is impossible to change the state of any stop signal.3 MAINTENANCE B-83525EN/01 STOP SIGNALS The stop signal screen indicates the state of signals related to stop. the state is indicated as “TRUE”. If the safety fence is open. This item indicates the state of the emergency stop button on the teach pendant. an alarm occurs. This item indicates whether the teach pendant is operable. 3. Item (1) requires quick mastering. Press F1. SYSTEM Master/Cal 1 2 3 4 5 6 TORQUE = [ON ] FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ‘ENTER’ or number key to select. Release the brake on the manual brake control screen if necessary. (Single axis mastering is just for quick-fix purposes. fixture position mastering should be performed later. refer to an applicable maintenance manual of mechanical unit or operator's manual of controller.) The mastering procedure is described below. Move the robot by jog feed to the mastering position. Select Master/Cal you will see a screen similar to the following. [ TYPE ] LOAD RES_PCA DONE NOTE Mastering cannot be performed until axis is rotated enough to establish a pulse.TROUBLESHOOTING MAINTENANCE B-83525EN/01 MASTERING Mastering is needed if: (1) The SRVO-062 BZAL or SRVO-038 pulse mismatch alarm occurs. . Condition System variable $MASTER_ENB must be set to 1 or 2.4 3. For details. TYPE. or (2) The Pulsecoder is replaced. Select SYSTEM. SYSTEM Variables 272 $MASTER_ENB 1 Step (1) (2) (3) (4) (5) Press <MENUS>.17 - . After single axis mastering is used. while item (2) requires single axis or fixture position mastering. (9) Restore the brake condition to its original condition.18 - DONE .2241> < 0. and then turn it on again.3. Calibration is performed. .0000> < 24.7759> < 0. Alternatively.TROUBLESHOOTING MAINTENANCE B-83525EN/01 (6) Select "1 FIXTURE POSITION MASTER" and press the F4 key (yes). SYSTEM Master/Cal TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <-3105333> <-13216881> <22995280> <-1354153> <0> <0> [ TYPE ] LOAD RES_PCA DONE (7) Select "6 CALIBRATE" and press the F4 key (yes).0000> [ TYPE ] LOAD RES_PCA (8) Press F5 "DONE". SYSTEM Master/Cal TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): < 0. Mastering data is set.0000> < -85. Calibration is performed whenever the power is turned on.6528> < -94. to perform positioning. turn the power off. after mastering. If an open wire is found. a fuse may have blown. (Action 1) Release the emergency stop button pressed on the operator's panel. If an open wire is found.5 3.19 - . NOTE If SRVO-001 is issued together with SRVO-213. Emergency stop button CRT30 CRS36 Fig. (Action 3) Check the wires connecting between the teach pendant and the emergency stop board (CRS36) for continuity. (Action 5) Replace the teach pendant. Replace the emergency stop button or the operator's panel. (Action 7) Replace the main board.TROUBLESHOOTING TROUBLESHOOTING USING THE ERROR CODE SRVO-001 Operator panel E-stop (Explanation) The emergency stop button on the operator's panel is pressed.3. check for continuity across the terminals of the switch. If continuity is not found. the emergency stop button is broken. (Action 4) With the emergency stop in the released position. (Action 2) Check the wires connecting between the emergency stop button and the emergency stop board (CRT30) for continuity. perform a complete controller back-up to save all your programs and settings. replace the entire harness. Before executing the (Action 7). Take the same actions as for SRVO-213. (Action 6) Replace the emergency stop board.5 (a) SRVO-001 Operator panel E-stop . replace the entire harness.MAINTENANCE B-83525EN/01 3. 5 (b) SRVO-002 Teach pendant E-stop SRV0-003 Mode switch and emergency stop board .3. If trouble is found. (Action 4) Check the mode switch connection and operation. (Action 2) Check that the mode switch on the operator's panel and the enable/disable switch on the teach pendant are at the correct positions. but the DEADMAN switch is not pressed. (Action 5) Replace the emergency stop board. (Action 2) Replace the teach pendant. SRVO-003 DEADMAN switch released (Explanation) The teach pendant is enabled. Enable/disable Emergency stop button Deadman switch (Teach pendant) 2 mode switch 3 mode switch (Mode switch) Emergency stop board Fig. (Action 3) Replace the teach pendant.3. Alternatively. (Action 1) Check the intermediate position of the DEADMAN switch on the teach pendant. the DEADMAN switch is pressed strongly.TROUBLESHOOTING SRVO-002 MAINTENANCE B-83525EN/01 Teach pendant E-stop (Explanation) The emergency stop button on the teach pendant was pressed. (Action 1) Release the emergency stop button on the teach pendant. replace the mode switch.20 - . NOTE If SRVO-004 is issued together with SRVO-213. it is very dangerous to disable the signal when a connection is made between EAS1 and EAS11 and between EAS2 and EAS21. a fuse may have blown. Name 12 E-STOP (ESPB) 11 10 9 8 FENCE (EAS) 7 6 5 4 EMGIN (EES) 3 2 1 21 2 11 1 21 2 11 1 21 2 11 1 Fig.5 (c) SRVO-004 Fence open WARNING In a system using the safety fence signal.TROUBLESHOOTING MAINTENANCE B-83525EN/01 Fence open (Explanation) In the automatic operation mode. make a connection between EAS1 and EAS11 and between EAS2 and EAS21 of the terminal block TBOP20 on the emergency stop board.21 - . SRVO-005 Robot overtravel (Explanation) The robot has moved beyond a hardware limit switch on the axes. (Action 2) Check the cables and switches connected between EAS1 and EAS11 and between EAS2 and EAS21 of the terminal block TBOP20 on the emergency stop board. Never make such an attempt. Take the same actions as for SRVO-213. (Action 5) Replace the emergency stop board. If trouble is found.3. (Action 4) Check the mode switch. replace the mode switch. 3 mode switch 2 mode switch (Mode switch) TBOP20 No. (Action 1) When a safety fence is connected. If a temporary connection is needed for operation. close the safety fence. . (Action 3) If the safety fence signal is not used. the safety fence contact connected to EAS1-EAS11 or EAS2-EAS21 of TBOP20 is open. separate safety measures must be taken.SRVO-004 3. the FS2 fuse has blown. Alternatively. Check the internal cable of the robot for a short circuit or connection to ground. verify that the robot connection cable (RMP1) is in good condition. SRVO-006 Hand broken (Explanation) The safety joint (if in use) might have been broken. (Action 2) Replace the 6-Axis servo amplifier. 2) The connector is securely connected. Then verify that connectors CRF8 and CRM68 on the servo amplifier are securely connected. the HBK signal on the robot connection cable might be a ground fault or a cable disconnection. and press the alarm release button to reset the alarm condition. and there are no cuts or kinks visible. and jog to bring all axes into the movable range. Refer to Subsection 5.22 - . and press the alarm release button to reset the alarm condition. it may have been disabled by short-circuiting in the mechanical unit. and jog the tool to the work area. Check the FS2 fuse on the servo amplifier. verify that the robot connection cable (RMP1) is in good condition.6. NOTE If the Hand broken signal is not in use. Still hold down the shift key. Also. If the Overtravel signal is not in use. 2) Check the safety joint cable. Replace the limit switch. Then verify that connectors CRF8 and CRM68 on the servo amplifier are securely connected. (Action 3) Verify the following for connector RMP1 at the base of the robot: 1) There are no bent or dislocated pins in the male or female connectors.3. Replace the 6-Axis servo amplifier.TROUBLESHOOTING (Action 1) (Action 2) (Action 3) (Action 4) (Action 5) (Action 6) MAINTENANCE B-83525EN/01 1) Select [System OT release] on the overtravel release screen to release each robot axis from the overtravel state. (Action 1) Hold down the shift key. 2) The connector is securely connected. Check the internal cable of the robot for a short circuit or connection to ground. 3) Still hold down the shift key. and there are no cuts or kinks visible.3 in CONNECTIONS to disable the Hand broken signal. If the SRVO-214 fuse blown alarm is also generated. Verify the following for connector RMP1 at the base of the robot: 1) There are no bent or dislocated pins in the male or female connectors. 1) Replace the safety joint. . 2) Hold down the shift key. NOTE It is factory-placed in the overtravel state for packing purposes. it can be disabled by software setting. Also. Check the EE connector. 3.TROUBLESHOOTING MAINTENANCE B-83525EN/01 6-Axis servo amplifier Connector(CRM68) Connector(CRF8) FS2 (3.23 - .5 (d) SRVO-005 Robot overtravel SRVO-006 Hand broken .3.2A) (6-Axis servo amplifier) Fig. TROUBLESHOOTING SRVO-007 MAINTENANCE B-83525EN/01 External E-stop (Explanation) On the terminal block TBOP20 of the emergency stop board. EES2 and EES21.24 - . it is very dangerous to disable the signal when a connection is made between EES1 and EES11 and between EES2 and EES21. make a connection between EES1 and EES11. release the switch. a fuse may have blown. separate safety measures must be taken. no connection of external emergency stop is made between EES1 and EES11. Name 12 E-STOP (ESPB) 11 10 9 8 FENCE (EAS) 7 6 5 4 EMGIN (EES) 3 2 1 21 2 11 1 21 2 11 1 21 2 11 1 Fig. (Action 2) Check the switch and cable connected to EES1-EES11 and EES2-EES21 on TBOP20 of the emergency stop board. If a temporary connection is needed for operation.3. (Action 4) Replace the emergency stop board. Take the same actions as for SRVO-213.3. TBOP20 No. (Action 1) If an external emergency stop switch is connected. .5 (e) SRVO-007 External E-stop WARNING In a system using the external emergency stop signal. EES2 and EES21. Never make such an attempt. (Action 3) When this signal is not used. NOTE If SRVO-007 is issued together with SRVO-213. Please refer to the 6-Axis servo amplifier Fig.5 (f) SRVO-009 Pneumatic pressure alarm . check the cause. Refer to the manual of your robot.25 - . (Action 4) Replace the 6-Axis servo amplifier. If a fault or a disconnection is detected. The input signal is located on the end EE interface of the robot. replace the cable. (Action 1) If an abnormal air pressure is detected. (Action 5) Replace the internal cables of the robot.MAINTENANCE B-83525EN/01 SRVO-009 3. (Action 2) Check the EE connector.TROUBLESHOOTING Pneumatic pressure abnormal (Explanation) An abnormal air pressure was detected. NOTE Pneumatic pressure alarm input is on the EE interface.3. (Action 3) Check the robot connection cable (RMP1) and the internal cable of the robot for a ground fault or a cable disconnection. manual of your robot. Replace them if necessary. The robot can be recovered by replacing a fan motor. robot stops and cannot be operated from TP. (1): FAN0 (2): FAN1 (3): both fans (Action 1) Check the fan motor and its cables. (Action 3) Replace the main board. Fan motor (FAN0) Fan motor (FAN1) Main board Fig.TROUBLESHOOTING SRVO-014 MAINTENANCE B-83525EN/01 Fan motor abnormal (Explanation) When a fan motor stops on backplane unit. Teach pendant shows the following message. Number in the bracket indicates which fan is abnormal. perform a complete controller back up to save all your programs and settings. Before executing the (Action 3). In one minutes from occurring of alarm.5 (g) SRVO-014 Fan motor abnormal . (Action 2) Replace the fan board.26 - .3.3. ) Door fan Fan motor Main board Heat exchanger Fig.3.5 (h) SRVO-015 SYSTEM OVER HEAT .27 - .MAINTENANCE B-83525EN/01 SRVO-015 3. Before executing the (Action 3). robot stops and cannot be operated from TP. (Action 2) If the fan motor is not running. (The thermostat on the main board may be faulty. Replace them if necessary. cool down the ambient temperature.TROUBLESHOOTING System over heat (Explanation) The temperature in the controller exceeds the specified value. (Action 1) If the ambient temperature is higher than specified (45°C). perform a complete controller backup to save all your programs and settings. In one minutes from occurring of alarm. check it and its cables. (Action 3) Replace the main board. (Action 2) It is possible that an instant disconnection of power source causes this alarm.) (Action 1) Replace the servo amplifier as the alarm message. the host will not issue this alarm (SRDY off). CRR65B connector on the 6-Axis servo amplifier. In case that the brake is not released.TROUBLESHOOTING SRVO-018 MAINTENANCE B-83525EN/01 Brake abnormal (Explanation) An excessive brake current is detected. If a short-circuit or grounding fault is found. Check whether the brake is released through the clack sound of the brake or vibration. (Action 1) Check the robot connection cable (RMP1) and the internal cable of the robot and motor brakes connected to CRR88 connector on the 6-Axis servo amplifier. (Action 1) Make sure that the emergency stop board connectors CP5A. (Action 3) Replace the 6-Axis servo amplifier. CAUTION This error can be caused by the optional brake release unit if the on/off switch is left in on position while the operator attempts to jog the robot. replace the failed part.28 - . replace the failed part. (Action 1) If the brake is not released. (Action 4) Replace the servo amplifier. The ALM LED (SVALM) on the 6-Axis servo amplifier is lit. (Action 3) Replace the E-stop unit. replace the 6-Axis servo amplifier or the servo motor. SRVO-023 Stop error excess (G:i A:j) (Explanation) When the servo is at stop. (HRDY is a signal with which the host directs the servo system whether to turn on or off the servo amplifier magnetic contactor. the SRDY is already on. . CRMB22. CRMA92. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on. and 6-Axis servo amplifier CRMA91 are securely attached to the servo amplifier.3. (Action 2) If the disconnection is not found. To recover. Therefore. In case that the brake is released.) If the servo amplifier magnetic contactor cannot be turned on when directed so. (Action 1) Check whether the obstacle disturbs the robot motion. (HRDY is a signal with which the host detects the servo system whether to turn on or off the servo amplifier magnetic contactor. Check whether an instant disconnection occurred. (Action 2) Make sure that connectors CNJ1A-CNJ6 are securely attached to the 6-Axis servo amplifier. check the continuity of the brake line in the robot connection cable and the robot internal cable. If a short-circuit or grounding fault is found. although there is no other cause of an alarm. If a servo amplifier alarm has been detected. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on. the position error is abnormally large. SRVO-021 SRDY off (Group: i Axis: j) (Explanation) The HRDY is on and the SRDY is off. turn the brake release unit off and cycle the controller power. this alarm indicates that the magnetic contactor cannot be turned on for an unknown reason. it is most likely that a servo amplifier alarm has occurred. (Action 2) Check the cables and motor brakes connected to CRR65A. SRVO-022 SRDY on (Group: i Axis: j) (Explanation) When the HRDY is about to go on. ) Check the input voltage to the controller is within the rated voltage and no phase is lack. reduce it to within the rating.MAINTENANCE B-83525EN/01 (Action 3) (Action 4) (Action 5) (Action 6) (Action 7) 3. the motor may become unable to follow the command. and an alarm is issued. (If the voltage input to the 6-Axis servo amplifier becomes low.). hence possibly causing an alarm. the torque required for acceleration / deceleration becomes higher than the capacity of the motor. Replace the servo amplifier. Check each phase voltage of the CRR68A or CRR68B connector of the three-phase power (200 VAC) input to the 6-Axis servo amplifier. Replace the motor of the alarm axis.5 (i) SRVO-018 Brake abnormal SRVO-021 SRDY off SRVO-022 SRDY on SRVO-023 Stop error excess .3. If greater. the torque output also becomes low. If it is 210 VAC or lower. As a result. (If the load is too great. As a result. NOTE Incorrect setting of the brake number causes this alarm.29 - . check the line voltage. the motor becomes unable to follow the command. Check to see if the load is greater than the rating.TROUBLESHOOTING Check the continuity of the robot connection cable and the internal robot power cable. 6-Axis servo amplifier Fig. If the mastering is invalid. SRVO-030 is issued when a temporary halt occurs. SRVO-037 IMSTP input (Group: i) (Explanation) The *IMSTP signal for a peripheral device interface was input. but the reference point had not been set up. SRVO-030 Brake on hold (Group: i) (Explanation) If the temporary halt alarm function is enabled ($SCR. but the necessary adjustment had not been completed. .TROUBLESHOOTING SRVO-024 MAINTENANCE B-83525EN/01 Move error excess (G:i A:j) (Explanation) When the robot is running. $MOVER _ OFFST). WARNING If the position data is incorrect. (Action) Set up a quick mastering reference point on the positioning menu. master the robot. (Action 1) Take the same actions as SRVO-023. (Action) Calibrate the robot.$ STOPTOL) even after the position check monitoring time ($PARAM _ GROUP. SRVO-036 Inpos time over (G:i A:j) (Explanation) The robot did not get to the effective area ($PARAM _ GROUP. When this function is not used. SRVO-027 Robot not mastered (Group: i) (Explanation) An attempt was made to calibrate the robot. disable the setting. Otherwise. its position error is greater than a specified value ($PARAM _ GROUP. the robot or additional axis can operate abnormally. but the robot had not been calibrated.3. 1. SRVO-034 Ref pos not set (Group: i) (Explanation) An attempt was made to perform quick mastering. (Action) Take the same actions as for SRVO-023 (large position error at a stop). (Action) Check whether the mastering is valid.30 - . This alarm is asserted after exchange the Pulsecoder or battery for back up of the Pulsecoder data or loading back up data to the Main Board. $INPOS _ TIME) elapsed. Supply power. (Action) Disable [Servo-off in temporary halt] on the general item setting screen [6 General Setting Items]. you could injure personnel or damage equipment. SRVO-033 Robot not calibrated (Group: i) (Explanation) An attempt was made to set up a reference point for quick mastering. Check the alarm history. Set up a quick mastering reference point using [Positioning] on the positioning menu. 2. It is likely that the robot cannot follow the speed specified by program. set the position data correctly. SRVO-038 Pulse mismatch (Group: i Axis: j) (Explanation) The pulse count obtained when power is turned off does not match the pulse count obtained when power is applied. (Action) Turn on the *IMSTP signal.$BRKHOLD ENB=1). Check the software setting of the brake number. (Action 6) Replace the 6-Axis servo amplifier. (Action 2) Check fuse (FS3) in the 6-Axis servo amplifier. then detach the cables from CRRA11A and CRRA11B on the 6-Axis servo amplifier and check the resistance between pins 1 and 3 of each cable end connector. The servo amplifier dissipates this energy as heat. Remaster the robot. (Action 3) The ambient temperature is excessively high. Clean up the fun unit. A similar phenomenon occurs even when no gravity is applied. relax the service conditions. causing an alarm. In case the robot has been moved by using the brake release unit while the power is off or when restoring the back-up data to the main board. this alarm may occur.5Ω.) (Action 1) This alarm may occur if the axis is subjected to frequent acceleration/deceleration or if the axis is vertical and generates a large amount of regenerative energy. the servo amplifier receives energy from the motor.MAINTENANCE B-83525EN/01 (Action 1) (Action 2) (Action 3) (Action 4) SRVO-043 3. Check the cause of the brake trouble. If it has blown. If the resistance is not 6. the servo amplifier supplies energy to the robot. replace the regenerative resistor. (Action 5) Make sure that the 6-Axis servo amplifier CRRA11A and CRRA11B are connected tightly. If there is no continuity between the pins. and check for continuity between pins 1 and 2 of the cable-end connector.3. Or the regenerative resistor can't be cooled effectively. this alarm may occur. If the regenerative energy is higher than the energy dissipated as heat. this alarm may occur. (To run the robot.5 (j) E-stop unit SRVO-043 DCAL alarm . and replace the fuse. Replace the Pulsecoder and master the robot. replace the regenerative resistor. the robot operates from the potential energy.31 - Regenarative resistor . If this alarm has occurred.TROUBLESHOOTING If the brake number is set to the non-brake motors. remove the cause. Check the external fan unit. the difference is stored in the servo amplifier. When going down the vertical axis. If the robot has been moved because the brake failed. Then remaster the robot. for example. the regenerative resistor and the louver if they are dirty. CRRA11B may not be used depending on the robot model. DCAL alarm (Group: i Axis: j) (Explanation) The regenerative discharge energy was too high to be dissipated as heat. at deceleration on a horizontal axis. and replace it if it stops. Then detach the cable from CRR63A and CRR63B connectors on the 6-Axis servo amplifier. If a reduction in the potential energy is higher than the energy needed for acceleration. 6-Axis servo amplifier Fig. The energy that the servo amplifier receives from the motor is called the regenerative energy. (Action 4) Make sure that the 6-Axis servo amplifier CRR63A and CRR63B connectors are connected tightly. (Action 5) Replace the 6-Axis servo amplifier.5Ω. and measure the resistance between their U and V. If it is 240 VAC or higher. W and the GND lines each other. (Action 3) Turn off the power and disconnect the power cable from the servo amplifier by the alarm message. and check the insulation of their U. (If the machine load is higher than the rating. the power cable is defective.32 - . If the resistances at the three places are different from each other. (Action 1) Turn off the power.TROUBLESHOOTING SRVO-044 MAINTENANCE B-83525EN/01 DCHVAL%s alarm (G:%d A:%d) (Explanation) The DC voltage (DC link voltage) of the main circuit power supply is abnormally high. And check the setting of the transformer is correct. (Action 2) Turn off the power and disconnect the power cable from the servo amplifier indicated by the alarm message. Next. check the line voltage.) Supply power and see if the alarm occurs again. CRRA11B may not be used depending on the robot model. replace the servo amplifier. Check each item in detail and replace it if necessary.3.) (Action 4) Check that the CRRA11A and CRRA11B connectors of the 6-Axis servo amplifier are attached firmly. V. (If the three-phase input voltage is higher than 240 VAC. replace the power cable. If it is higher than the rating. high acceleration/deceleration can cause in this alarm. replace the regenerative resistor. (And disconnect the brake cable (CRR88 on the 6-Axis servo amplifier) to avoid the axis falling unexpectedly. and disconnect the power cable from the servo amplifier indicated by the alarm message. the motor. (Action 2) Check the three-phase input voltage at the 6-Axis servo amplifier. detach the cables then check the continuity between pins. If the alarm occurs again. the accumulation of regenerative energy might result in the HVAL alarm even when the three-phase input voltage is within the rating. (Action 1) Check the input voltage to the controller is within the rated voltage. V and W and W and U with an ohmmeter that has a very low resistance range. If the resistance is not 6.) (Action 3) Check that the load weight is within the rating. SRVO-045 HCAL alarm (Group: i Axis: j) (Explanation) Abnormally high current flowed in the main circuit of the servo amplifier. . If there is a short-circuit. reduce it to within the rating. 3. (Action 3) Check whether the brake of the corresponding axis is released. (Action 7) Replace the E-stop unit (Action 8) Replace the motor power line (robot connection cable) of the corresponding axis. (Action 5) Replace the servo amplifier. (Action 6) Replace the motor of the corresponding axis. reduce the load or relax the operating condition to meet the rating. (Action 2) Check whether the voltage input to the controller is within the rated voltage. (Action 1) Check the operating condition for the robot and relax the service condition if possible. (Action 9) Replace the motor power line and brake line (internal cable of the robot) of the corresponding axis.33 - .MAINTENANCE B-83525EN/01 SRVO-046 3.5(k) SRVO-044 HVAL alarm SRVO-045 HCAL alarm SRVO-046 OVC alarm . 6-Axis servo amplifier Fig. If the load or operating condition has exceeded the rating. (Action 4) Check whether there is a factor that has increased the mechanical load on the corresponding axis.TROUBLESHOOTING OVC alarm (Group: i Axis: j) (Explanation) This alarm is issued to prevent the motor from thermal damage that might occur when the root meant square current calculated within the servo system is out of the allowable range. 2) Temperature Start Stop Start Stop Start Thermal time constant of the motor is high. This method estimates the motor temperature with substantial accuracy.5 (p). The HC alarm is intended to prevent such failures. The OVC alarm is issued based on this estimated temperature. if the motor continues to start and stop within a short time as shown in Fig. Time Fig. if the motor frequently repeats to start and stop. OHAL. OVC and OHAL alarms (overcurrent and overload alarms) The OVC and OHAL alarms are intended to prevent overheat that may lead to the burnout of the motor winding. and HC alarms - Overview This section points out the differences among the OVC.3.TROUBLESHOOTING MAINTENANCE B-83525EN/01 Reference Relationships among the OVC. so it can prevent the failures described above. - Alarm detection section Abbreviation Designation OVC OHAL Overcurrent alarm Overheat alarm HC High current alarm Detection section Servo software Thermal relay in the motor Thermal relay in the servo amplifier Thermal relay in the separate regenerative resister Servo amplifier - Purpose of each alarm 1) HC alarm (high current alarm) If high current flow in a power transistor momentarily due to abnormality or noise in the control circuit. and HC alarms and describes the purpose of each alarm. this method is not necessarily perfect to prevent these failures. the thermal time constant of the motor. 3. Temperature at which the winding starts to burn Thermal time constant of the thermal relay is low. .5 (l) Relationship between the temperatures of the motor and thermal relay on start/stop cycles To prevent the above defects. For example. thus causing the motor to burn before the thermal relay detects an abnormally high temperature. However.3. the power transistor and rectifier diodes might be damaged. or the magnet of the motor might be degaussed. software is used to monitor the current in the motor constantly in order to estimate the temperature of the motor. and the separate regenerative resistor. which has a large mass. Therefore. The OHAL alarm occurs when each built-in thermal relay detects a temperature higher than the rated value. OHAL. the breakdown of the servo amplifier transistor. becomes higher than the time constant of the thermal relay. because these two components are different in material. the temperature rise in the motor is steeper than that in the thermal relay. and dimension.34 - . structure. 5 (q) is taken into consideration for the OVC alarm. In this case. the OVC alarm is used for protection from a short-time overcurrent.3.3. and the OHAL alarm is used for protection from long-term overload.5 (m) Relationship between the OVC and OHAL alarms NOTE The relationship shown in Fig. do not change the parameters to relax protection.TROUBLESHOOTING To sum up. The relationship between the OVC and OHAL alarms is shown in Fig.5 (q). The motor might not be hot even if the OVC alarm has occurred.35 - .3.MAINTENANCE B-83525EN/01 3. a double protection method is used. . Current Protection area for the motor and servo amplifier Protection by the OHAL Limit current Protection by the OVC Rated continuous current Time Fig. 3. etc.3.TROUBLESHOOTING SRVO-047 MAINTENANCE B-83525EN/01 LVAL alarm (Group: i Axis: j) (Explanation) The control power supply voltage (+5 V. 6-Axis servo amplifier Power supply unit Fig. (Action 2) Replace the power supply unit. (Action 1) Replace the servo amplifier.36 - .5 (n) SRVO-047 LVAL alarm .) supplied from the power supply circuit in the servo amplifier is abnormally low. ) (Action 1) Check whether the robot has collided and also check whether there is a factor that has increased the mechanical load on the corresponding axis. 6-Axis servo amplifier Fig.TROUBLESHOOTING OHAL1 alarm (G: i A: j) (Explanation) The 6-Axis servo amplifier detects transformer overheat signal. (Action 2) Replace the 6-Axis servo amplifier. (Action 5) Check whether the voltage input to the controller is within the rated voltage. SRVO-050 Collision Detect alarm (Grp:i Ax:j) (Explanation) The disturbance torque estimated by the servo software is abnormally high.MAINTENANCE B-83525EN/01 SRVO-049 3. (Action 2) Check whether the load settings are valid. SRVO-051 CUER alarm (Group: i Axis: j) (Explanation) The offset of the current feedback value is abnormally high. (Action 6) Replace the servo amplifier. (Action 4) If the load weight exceeds the rated range. (Action 10) Replace the motor power line and brake line (internal cable of the robot) of the corresponding axis.5 (o) SRVO-049 OHAL1 alarm SRVO-050 CLALM alarm SRVO-051 CUER alarm . decrease it to within the limit. (Action 8) Replace the E-stop unit. (Action 3) Check whether the brake of the corresponding axis is released. (A collision has been detected. (Action 7) Replace the motor of the corresponding axis.3.37 - E-stop unit . (Action 9) Replace the motor power line (robot connection cable) of the corresponding axis. (Action) Replace the servo amplifier. (Action 1) Check that a connection is made between the 6-Axis servo amplifier CRMA91. (Action 6) Replace the 6-Axis servo amplifier. search the failed unit and replace it. . (Action 2) Replace the axis control card on the main board. replace the 6-Axis servo amplifier including the fuse. If the fuse has blown.3. the DC power is not supplied to the 6-Axis servo amplifier. If the fuse has blown.38 - .3V) on the 6-Axis servo amplifier is lit. SRVO-057 FSSB disconnect (G:i A: j) (Explanation) Communication was interrupted between the main board and servo amplifier. (Ignore the alarm SRVO-068 because of disconnecting the CRF8 connector. (Action 2) Replace the axis control card on the main board. If they are connected tightly. (Action 1) Check the optical fiber cable between the axis control card and servo amplifier. Replace it if it is faulty. Before continuing to the next step. (Action 5) Check for a point where the robot connection cable (RMP1) or an internal cable running to each Pulsecoder through the robot mechanical section is grounded. (Action 4) Replace the servo amplifier. (Action 1) Check the optical fiber cable between the axis control card and servo amplifier. replace the 6-Axis servo amplifier. If this alarm does not occur. SRVO-056 FSSB com error 2 (G: i A: j) (Explanation) A communication error has occurred between the main board and servo amplifier. Replace it if it is faulty. (Action 1) Check whether fuse (FS1) on the 6-Axis servo amplifier has blown. Make sure the connector CP5 on the power supply unit and the connector CXA2B on the 6-Axis servo amplifier are connected tightly. the robot connection cable (RMP1) or the internal cable of the robot may be short-circuited to the ground. If they are not lit. Check the cables and replace it if necessary. (Action 2) Turn off the power and disconnect the CRF8 connector on the 6-Axis servo amplifier. replace the 6-Axis servo amplifier including the fuse. (Action 1) Check whether fuse (FS1) on the 6-Axis servo amplifier has blown. SRVO-058 FSSB xx init error (yy) (Explanation) Communication was interrupted between the main board and servo amplifier. (Action 2) Check the optical fiber cable between the axis control card and servo amplifier. Replace it if it is faulty. (Action 7) If the other units (the servo amplifier for the auxiliary axis and the line tracking interface) are connected in the FSSB optical communication.TROUBLESHOOTING SRVO-055 MAINTENANCE B-83525EN/01 FSSB com error 1 (G: i A: j) (Explanation) A communication error has occurred between the main board and servo amplifier. (Action 6) Replace the main board. disconnect these units and connect only 6-Axis servo amplifier for the robot.) If this alarm does not occur. (Action 4) Check the optical fiber cable between the axis control card and servo amplifier. (Action 3) Replace the servo amplifier. Then turn on the power. (Action 3) Replace the servo amplifier. Then check whether this alarm occurs again. (Action 3) Check whether the LED (P5V and P3. perform a complete controller back up to save all your programs and settings. Replace it if it is faulty. (Action 5) Replace the axis control card on the main board. (Action 3) Replace the axis control card on the main board. 6-Axis servo amplifier Main board Axis control card (Main board) Fig.TROUBLESHOOTING MAINTENANCE B-83525EN/01 Before executing the (Action 8).39 - .5 (p) SRVO-055 FSSB com error 1 SRVO-056 FSSB com error 2 SRVO-057 FSSB disconnect SRVO-058 FSSB init error .3. (Action 8) Replace the main board. perform a complete controller back up to save all your programs and settings.3. (Action) Replace the Pulsecoder with which an alarm has been issued. (Action 3) Check whether the robot internal cable for feeding power from the battery to the Pulsecoder is not disconnected and grounded. . set the system variable ($MCR. replace the cable. however. CRCERR. (Action 2) Replace the Pulsecoder with which an alarm has been issued. CAUTION After correcting the cause of this alarm. Check the wiring of the servo amplifier. (Action 1) Replace the battery in the battery box of the robot base. If an abnormality is found. (Action 1) Check the robot operating conditions. NOTE This alarm might accompany the DTERR. and the built-in thermostat has operated. SRVO-064 PHAL alarm (Group: i Axis: j) (Explanation) This alarm occurs if the phase of the pulses generated in the Pulsecoder is abnormal. SRVO-067 OHAL2 alarm (Grp:i Ax:j) (Explanation) The temperature inside the Pulsecoder or motor is abnormally high.$SPC_RESET) to TRUE then turn on the power again. In this case. Replace the line tracking board. If a condition such as the duty cycle and load weight has exceeded the rating.40 - . Mastering is needed. Once the position data is lost. A delay in battery replacement may result in the BZAL alarm being detected.3. SRVO-065 BLAL alarm (Group: i Axis: j) (Explanation) The battery voltage for the Pulsecoder is lower than the rating. (If installed) BZAL alarm (Group: i Axis: j) (Explanation) This alarm occurs if battery for Pulsecoder absolute-position backup is empty. Replace the servo amplifier. relax the robot load condition to meet the allowable range.TROUBLESHOOTING SRVO-059 B-83525EN/01 Servo amp init error (Explanation) (Action 1) (Action 2) (Action 3) SRVO-062 MAINTENANCE Servo amplifier initialization is failed. if the alarm still occurs. (If this alarm occurs. (Action) Replace the battery. the position data will be lost. turn on the power and replace the battery as soon as possible. there is no actual condition for this alarm. In this case. replace the motor. mastering will become necessary. or STBERR alarm. A probable cause is a broken battery cable or no batteries in the robot. (Action 2) When power is supplied to the motor after it has become sufficiently cool. 3. (Action) See actions on SRVO-068 6-Axis servo amplifier Fig. (Action 4) Replace the servo amplifier.TROUBLESHOOTING DTERR alarm (Grp:i Ax:j) (Explanation) The serial Pulsecoder does not return serial data in response to a request signal. (Action 2) Check that the shielding of the robot connection cable (RMP1) is grounded securely in the cabinet.5 (q) SRVO-059 Servo amp init error SRVO-070 STBERR alarm . (Action 3) Replace the Pulsecoder. (Action 1) Make sure that the robot connection cable (RMP1) connector (CRF8) of 6-Axis servo amplifier and the connector (motor side) are connected tightly. SRVO-069 CRCERR alarm (Grp:i Ax:j) (Explanation) The serial data has disturbed during communication. (Action) See actions on SRVO-068 SRVO-070 STBERR alarm (Grp:i Ax:j) (Explanation) The start and stop bits of the serial data are abnormal. (Action 6) Replace the internal cable of the robot (for the Pulsecoder).MAINTENANCE B-83525EN/01 SRVO-068 3.41 - . (Action 5) Replace the robot connection cable (RMP1). (Action 10) Replace the internal cable of the robot (power/brake) in which the corresponding axis is connected.) (Action 1) Check whether the robot has collided. NOTE If this alarm occurs together with the PHAL alarm (SRVO-064). (Action 4) Check whether the load weight is within the rated range. (Action) Replace the Pulsecoder. and jog the axis on which the alarm has occurred until the same alarm will not occur again. If the weight exceeds the upper limit. and remaster the robot. this alarm does not correspond to the major cause of the failure. .42 - . (In case of Auxiliary axis) (Action 3) Replace the Pulsecoder. (Action) Reset the alarm. (Action) Replace the Pulsecoder and remaster the robot. SRVO-073 CMAL alarm (Group: i Axis: j) (Explanation) It is likely that the Pulsecoder is abnormal or the Pulsecoder has malfunctioned due to noise. Or check whether the machinery load of the corresponding axis is increased.3. SRVO-074 LDAL alarm (Group: i Axis: j) (Explanation) The LED in the Pulsecoder is broken. (Action 5) Check whether the voltage input to the controller is within the rated voltage. (Action 6) Replace the servo amplifier. (Action) Action as same as the SRVO-068. SRVO-072 PMAL alarm (Group: i Axis: j) (Explanation) It is likely that the Pulsecoder is abnormal.TROUBLESHOOTING SRVO-071 MAINTENANCE B-83525EN/01 SPHAL alarm (Grp:i Ax:j) (Explanation) The feedback speed is abnormally high. Check the earth cable connection between controller and robot connection cables are connected securely to the grounding plate. (Action 1) Check whether the connection of the controller earth is good. (Action 9) Replace the power cable of the robot connection cable in which the corresponding axis is connected. (Action 7) Replace the corresponding servo motor. (Action 3) Check whether the brake of the corresponding axis is released. (Action 8) Replace the E-stop unit. decrease it to the limit. The cause may be welding. SRVO-075 Pulse not established (G: i A: j) (Explanation) The absolute position of the Pulsecoder cannot be established. (Action 2) Check whether the load settings are valid. (Action 2) Reinforce the earth of the motor flange. (An abnormal load was detected. SRVO-076 Tip Stick Detection (G: i A: j) (Explanation) An excessive disturbance was assumed in servo software at the start of operation. 5 (r) SRVO-081 E-stop unit SRVO-076 Tip stick detection EROFL alarm (Track enc: i) (Explanation) (Action 1) (Action 2) (Action 3) SRVO-082 3. . if the alarm still occurs.6-Axis servo amplifier Fig. See the description about the BZAL alarm (SRVO-062). When power is supplied to the Pulsecoder after it has become sufficiently cool. (Action 5) Replace the line tracking board. See the description about the OHAL2 alarm (SRVO-067).TROUBLESHOOTING MAINTENANCE B-83525EN/01 The pulse counter for line tracking has overflowed. Replace the Pulsecoder. (Action 3) Replace the line tracking cable. (Action 1) Check the connection cable at each end (the line tracking board and the motor side) (Action 2) Check whether the shielding of the connection cable is connected securely to the grounding plate. Check whether the condition of the line tracking exceeds the limitation.43 - .3. See the description about the BLAL alarm (SRVO-065). DAL alarm (Track encoder: i) (Explanation) The line tracking Pulsecoder has not been connected. SRVO-087 BLAL alarm (Track enc: i) (Explanation) This alarm occurs if the voltage of the backup battery for the absolute position of the Pulsecoder is low. Replace the line tracking board. SRVO-089 OHAL2 alarm (Track enc: i) (Explanation) The motor has overheated. (Action 4) Replace the Pulsecoder. SRVO-084 BZAL alarm (Track enc: i) (Explanation) This alarm occurs if the backup battery for the absolute position of the Pulsecoder has not been connected. SRVO-095 See the description about the PMAL CMAL alarm (Track enc: i) (Explanation) It is likely that the Pulsecoder is abnormal or the Pulsecoder has malfunctioned due to noise. and jog the axis on which the alarm has occurred until the same alarm does not occur again. (Action 1) Reset the alarm. SRVO-096 LDAL alarm (Track enc: i) (Explanation) The LED in the Pulsecoder is broken. alarm (SRVO-072). SRVO-094 PMAL alarm (Track enc: i) (Explanation) It is likely that the Pulsecoder is abnormal. See the description about (SRVO-075). (Action 2) Replace the Pulsecoder. See the description about the CMAL alarm (SRVO-073). (Jog one motor revolution) . (Action) Action as same as the SRVO-090.TROUBLESHOOTING SRVO-090 MAINTENANCE B-83525EN/01 DTERR alarm (Track enc: i) (Explanation) Communication between the Pulsecoder and line tracking board is abnormal. (Action 4) Replace the line tracking cable. SRVO-093 SPHAL alarm (Track enc: i) (Explanation) This alarm occurs if the current position data from the Pulsecoder is higher than the previous position data. SRVO-097 See the description about the LDAL alarm Pulse not established (enc: i) (Explanation) The absolute position of the Pulsecoder cannot be established. SRVO-092 STBERR alarm (Track enc: i) (Explanation) Communication between the Pulsecoder and line tracking board is abnormal. (Action 1) Reinforce the earth of the flange of the Pulsecoder.3. Pulse not established. (Action) Action as same as the SRVO-090. (Action 3) Replace the Pulsecoder. (Action) Action as same as the SRVO-090. (Action 5) Replace the line tracking board. SRVO-091 CRCERR alarm (Track enc: i) (Explanation) Communication between the Pulsecoder and line tracking board is abnormal.44 - . See the SRVO-068 DTERR alarm. (SRVO-074). (Action 1) Check the connection cable at each end (the line tracking board and the Pulsecoder) (Action 2) Check whether the shielding of the connection cable is connected securely to the grounding plate. .45 - .When the door switch is not mounted skip Action 1 and 2 and start from Action 3 (Action 1) When the door is open. 6-Axis servo amplifier Fig. close it.3.SRVO-105 3. (Action 5) Replace the 6. If the switch or cable is faulty.TROUBLESHOOTING MAINTENANCE B-83525EN/01 Door open or E. replace it. (Action 2) Check the door switch and door switch connection cable. (Action 4) Replace the emergency stop board.5 (s) E-stop unit (Emergency stop board) SRVO-105 Door open or E-stop .Stop (Explanation) The cabinet door is open. CRMB8 connectors on the E-STOP unit and CRMA91 on the 6-Axis servo amplifier are connected securely. (Action 3) Check that the CRMA92.Axis servo amplifier. (Action 2) Check the input voltage to the controller is within the rated voltage. Fan motor Main board Fig. (Action 3) Replace the main board.3.46 - . (Action 3) Modify the program in order that robot and the auxiliary axis do not accelerate simultaneously in the system with the auxiliary axis. (Action 4) Replace the E-stop unit. perform a complete controller back up to save all your programs and settings. .3.TROUBLESHOOTING SRVO-123 MAINTENANCE B-83525EN/01 Fan motor rev slow down(%d) (Explanation) The rotation speed of fan motor is slow down. Replace them if necessary. (Action 2) Replace the backplane unit. (Action 1) Check the fan motor and its cables. Before executing the (Action 3). Check whether an instant disconnection occurred.5 (t) SRVO-134 SRVO-123 Fan motor rev slow down(%d) DCLVAL alarm (G:%d A:%d) (Explanation) The DC voltage (DC link voltage) of the main circuit power supply for the servo amplifier is abnormally low. (Action 5) Replace the servo amplifier. (Action 1) It is possible that an instant disconnection of power source causes this alarm. V and W and W and U with an ohmmeter that has a very low resistance range. If there is a short-circuit. (And disconnect the brake cable (CRR88 on the servo amplifier) to avoid the axis falling unexpectedly.3. (Action 2) Make sure that the 6-axis servo amplifier CRRA12 and emergency stop board CRRA12 connector are connected tightly. (Action 3) Turn off the power and disconnect the power cable from the servo amplifier by the alarm message. If the resistances at the three places are different from each other. (Action 4) Replace the E-stop unit. replace the servo amplifier. (Action 1) Turn off the power.TROUBLESHOOTING IPMAL alarm (G: i A: j) (Explanation) Abnormally high current flowed through the main circuit of the servo amplifier. and measure the resistance between their U and V. Check each item in detail and replace it if necessary. 6-Axis servo amplifier Fig. replace the power cable. the power cable is defective.MAINTENANCE B-83525EN/01 SRVO-156 3. SRVO-157 CHGAL alarm (G: i A: j) (Explanation) The capacitor on the servo amplifier was not charged properly within the specified time when the servo power is on. (Action 1) Check the input voltage to the controller is within the rated voltage. W and the GND lines each other. and disconnect the power cable from the servo amplifier indicated by the alarm message. (Action 3) Replace the 6-axis servo amplifier. and check the insulation of their U. V. the motor.) Turn on the power.5 (u) SRVO-156 IPMAL alarm SRVO-157 CHGAL alarm . (Action 2) Turn off the power and disconnect the power cable from the servo amplifier indicated by the alarm message. and if the alarm occurs again.47 - E-stop unit (Emergency stop board) . replace it. Before executing the (Action 2).3. (Action 1) Check the switch and cable connected to EES1 – EES11 and EES2 – EES21 on the TBOP20.48 - . (Action 4) Replace the 6-Axis servo amplifier. (Action 2) Replace the main board. perform a complete controller back up to save all your programs and settings. (Action 3) Replace the emergency stop board.5 (v) SRVO-204 External (SVEMG abnormal) E-stop . If the cable is abnormal. but the EMERGENCY STOP line was not disconnected. Name 12 E-STOP (ESPB) 11 10 9 8 FENCE (EAS) 7 6 5 4 EMGIN (EES) 3 2 1 E-stop unit (Emergency stop board) 21 2 11 1 21 2 11 1 21 2 11 1 (Emergency stop board) Fig.TROUBLESHOOTING SRVO-204 MAINTENANCE B-83525EN/01 External (SVEMG abnormal) E-stop (Explanation) The switch connected across EES1 – EES11 and EES2 – EES21 on the TBOP20 on the emergency stop board was pressed.3. 6-Axis servo amplifier TBOP20 No. 6-Axis servo amplifier TBOP20 No. Before executing the (Action 2). (Action 3) Replace the emergency stop board.TROUBLESHOOTING Fence open (SVEMG abnormal) (Explanation) The switch connected across EAS1 – EAS11 and EAS2 – EAS21 on the TBOP20 on the emergency stop board was opened. (Action 4) Replace the 6-Axis servo amplifier.49 - .MAINTENANCE B-83525EN/01 SRVO-205 3. Name 12 E-STOP (ESPB) 11 10 9 8 FENCE (EAS) 7 6 5 4 EMGIN (EES) 3 2 1 E-stop unit (Emergency stop board) 21 2 11 1 21 2 11 1 21 2 11 1 (Emergency stop board) Fig. but the EMERGENCY STOP line was not disconnected.3. If the cable is abnormal. (Action 2) Replace the main board.5 (w) SRVO-205 Fence open (SVEMG abnormal) . replace it. (Action 1) Check the switch and cable connected to EAS1 – EAS11 and EAS2 – EAS21 on the TBOP20. perform a complete controller back up to save all your programs and settings. replace the emergency stop board. (Action 4) Replace the emergency stop board. take Action 3 and up.CRS36 . (Action 2) Disconnect the connection destinations of 24EXT that can cause grounding then check that the fuse (FUSE2) does not blow. Before executing the (Action 2). If the fuse has blown. If not. replace the cable. Take Action 2. (Action 4) Replace the 6-Axis servo amplifier. or no voltage is supplied to EXT24V.CRT30 . SRVO-213 E-STOP Board FUSE2 blown (Explanation) A fuse (FUSE2) on the emergency stop board has blown.TBOP20: EES1. 24EXT and 0EXT may be short-circuited at any of the connection destinations above.50 - . (Action 1) Replace the teach pendant. (Action 6) Replace the teach pendant. (Action 2) Check the teach pendant cable. (Action 5) Replace the teach pendant cable. 24EXT may be short-circuited to 0EXT. EAS1. (Action 3) Replace the emergency stop board. but the emergency stop line was not disconnected. . (Action 3) Check whether 24 V is applied to between EXT24V and EXT0V of TBOP19.3. EAS11 If the fuse (FUSE2) does not blow in this state. If the fuse (FUSE2) blows even when the connection destinations above are detached. Isolate the faulty location then take action. Disconnect the following on the emergency stop board then turn on the power: . perform a complete controller back up to save all your programs and settings. (Action 7) Replace the operator’s panel cable (CRT30). (Action 1) Check whether the fuse (FUSE2) on the emergency stop board has blown.TROUBLESHOOTING SRVO-206 MAINTENANCE B-83525EN/01 Deadman switch (SVEMG abnormal) (Explanation) When the teach pendant was enabled. respectively. the DEADMAN switch was released or pressed strongly. EES11. If it is inferior. check the external power supply circuit. (Action 2) Replace the main board. check whether the terminals above are connected to the INT24V and INT0V terminals. If FUSE2 has not blown. If no external power supply is used. 51 - . 4 3 2 1 Name EXT0V INT0V INT24V EXT24V TBOP20 No.3. Name 12 E-STOP 11 (ESPB) 10 9 8 FENCE (EAS) 7 6 5 EMGIN 4 (EES) 3 2 1 CRT30 21 2 11 1 21 2 11 1 21 2 11 1 CRS36 (Emergency stop board) 6-Axis servo amplifier Fig.5 (x) E-stop unit (Emergency stop board) SRVO-206 DEADMAN switch (SVEMG abnormal) SRVO-213 E-STOP Board FUSE2 blown .TROUBLESHOOTING FUSE2 TBOP19 No.MAINTENANCE B-83525EN/01 3. Software axis config (FSSB line number. Execute aux axis setting to add axis at controlled start. (Action 1) Check whether the set number of axes is valid.3. SRVO-221 Lack of DSP (G: i A: j) (Explanation) A controlled axis card corresponding to the set number of axes is not mounted. 13. If the robot is used with a condition exceeding the duty or load weight robot rating.15: Document the events that led to the error. SRVO-216 OVC (total) (Robot: i) (Explanation) The current (total current for six axes) flowing through the motor is too large. (Action 1) Slow the motion of the robot where possible. •Check whether the servo amplifier power is supplied.6) (Action 2) Replace the 6-Axis servo amplifier.10: SRVO-058 (FSSB init error) occurs simultaneously. Non-existing axis number is specified.4. the software entered DSP dry run mode.3. eliminate the cause. •Replace the servo amplifier 11: Invalid axisorder setting. 9: There is no amplifier that is connected to the servo card.7: Replace a servo card. •Check whether the fuse on the servo amplifier has blown.TROUBLESHOOTING SRVO-214 MAINTENANCE B-83525EN/01 6ch amplifier fuse blown (R: i) (Explanation) A fuse (FS2 or FS3) in the 6-Axis servo amplifier has blown. 2. 6: SRVO-180 occurs simultaneously. •Replace the optical fiber cable.$startup_cnd=12. •Check the optical fiber cable. If the number is invalid. •Check the hardware connection. .52 - . Check the robot operation conditions. Software axis config (FSSB line number) might be wrong or auxiliary axis board is necessary. 12: SRVO-059 (Servo amp init error) occurs simultaneously. (Action) Perform an action according to the first number that is displayed in the alarm message. 8. (Action 2) Replace the axis control card with a card corresponding to the set number of axes.%d) (Explanation) A servo DSP initialization failure occurred due to hardware failure or wrong software setting. amplifier axis number) might be wrong. Then. (Action 2) Check the input voltage to the controller is within the rated voltage. 1: This is a warning due to $scr. reduce the load condition value to the specification range.14. 5: Invalid ATR setting. and contact your FANUC technical representative. The second number is extra information. SRVO-223 DSP dry run (%d. (Action 3) Replace the 6-Axis servo amplifier. Follow the remedy of SRVO-058. (See Section 3. (Action 1) A fuse (FS2 or FS3) is blown. set the correct number. and then replace the fuse. Follow the remedy of SRVO-059. Controllable axis does not exist on any group. The first number indicates the cause of the failure. MAINTENANCE B-83525EN/01 3.TROUBLESHOOTING 6-Axis servo amplifier Main board Axis control card (Main board) Fig.%d) .53 - .3.5 (y) SRVO-214 6ch amplifier fuse blown (Panel PCB) SRVO-216 OVC (total) SRVO-221 Lack of DSP SRVO-223 DSP dry run (%d. b . (Action) Check the alarms issued at the same time in order to identify with which signal the mismatch occurred. reset the chain error alarm according to the chain error reset procedure described later. SRVO-266 through SRVO-275 and SRVO-370 through SRVO-385 are issued at the same time. CAUTION 1 The state of this alarm is preserved by software. If a chain error is detected. 2 Until a chain error is reset.54 - . If robot use is continued with one of the duplicate circuits being faulty. b Chain 2 abnormal a.3. 6-Axis servo amplifier Fig. SRVO-231 is issued if such a mismatch that a contact on the chain 1 side is open. and a contact on the chain 2 side is closed occurs. between EAS2 and EAS21. WARNING If this alarm is issued. b (Explanation) A mismatch occurred between duplicate safety signals. correct the cause of the alarm then reset the alarm according to the method described later. SRVO-230 is issued if such a mismatch that a contact connected on the chain 1 side (between EES1 and EES11. b SRVO-231 Chain 2 (0V) abnormal a. and so forth) is open occurs.5 (z) E-stop unit (Emergency stop board) SRVO-230 Chain 1 (+24V) abnormal a. no ordinary reset operation must be performed. Take the action(s) described for each item. safety may not be guaranteed when the other circuit fails. and so forth) is closed. do not reset the chain error alarm until the failure is identified and repaired.3.TROUBLESHOOTING SRVO-230 SRVO-231 MAINTENANCE B-83525EN/01 Chain 1 abnormal a. After correcting the cause of the alarm. the message "SRVO-237 Chain error cannot be reset" is displayed on the teach pendant. If an ordinary reset operation is performed before chain error resetting. between EAS1 and EAS11. and a contact on the chain 2 side (between EES2 and EES21. 55 - .TROUBLESHOOTING Alarm history display method 1. Select [4 ALARM] on the teach pendant. 3. Press the emergency stop button. 3. Select [4 ALARM] on the teach pendant. Press F3 [HIST] on the teach pendant. 5. Press the screen selection key on the teach pendant. 3. Press the screen selection key on the teach pendant. <Method 1> 1. Press [7 SYSTEM SETTING] on the teach pendant. <Method 2> 1. 2.B-83525EN/01 MAINTENANCE 3. Select [0 NEXT PAGE] on the teach pendant. 4. Press [6 SYSTEM] on the teach pendant. 2. 7. 6. Find "28" Chain Error Reset Execution. Press F4 [CHAIN RESET] on the teach pendant. Chain error reset procedure CAUTION Do not perform this operation until the cause of the alarm is corrected. 2. . Press F3 on the teach pendant to reset "Chain Error". Press the screen selection key on the teach pendant. SRVO-235 Short term Chain abnormal (Explanation) Short term single chain failure condition is detected.56 - . (Action 3) Replace the 6-Axis servo amplifier. SRVO-251 DB relay abnormal (G: i A: j) (Explanation) An abnormality was detected in the internal relay (DB relay) of the servo amplifier. (Action 1) Enable the teach pendant in teaching operation. (Action 1) Cause the same error to occur again. (Action 2) Replace the emergency stop board. and then perform resetting. (Action 3) Replace the teach pendant. (Action 5) Replace the mode switch. • Cause of this alarm is. In other case the mode switch should be AUTO mode. . (Action 7) Replace the 6-Axis servo amplifier. Or controller door is opened. SRVO-253 Amp internal over heat (G: i A: j) (Explanation) An overheat was detected inside the servo amplifier. (Action) Replace the servo amplifier. (Action) Replace the servo amplifier.TROUBLESHOOTING SRVO-233 MAINTENANCE B-83525EN/01 TP disabled in T1. if open. T2/Door open (Explanation) Teach pendant is disabled when the mode switch is T1 or T2. (Action 4) Replace the teach pendant cable. (Action 2) Close the controller door. SRVO-252 Current detect abnl (G: i A: j) (Explanation) An abnormality was detected in the current detection circuit inside the servo amplifier. (Action) Replace the servo amplifier.3. (Action 6) Replace the emergency stop board.Half operation of emergency stop switch.Half release of DEADMAN switch . . 5 (aa) SRVO-233 TP disabled in T1.TROUBLESHOOTING E-stop unit (Emergency stop board) 3 mode switch 2 mode switch (Mode switch) Fig.57 - .MAINTENANCE B-83525EN/01 6-Axis servo amplifier 3.3. T2/Door open SRVO-235 Short term Chain abnormal SRVO-251 DB relay abnormal SRVO-252 Current detect abnl SRVO-253 Amp internal over heat . Name 12 E-STOP (ESPB) 11 10 9 FENCE 8 (EAS) 7 6 5 4 EMGIN (EES) 3 2 1 21 2 11 1 21 2 11 1 21 2 11 1 (Emergency stop board) Fig.5 (ab) SRVO-266 FENCE1 status abnormal SRVO-267 FENCE2 status abnormal .5. see the descriptions of SRVO-230 and SRVO-231. perform a complete controller back up to save all your programs and settings. do not reset the chain error alarm until the failure is identified and repaired. TBOP20 No. (Action 1) Check whether the circuitry connected to the dual input signal (EAS) is faulty.3.5 in CONNECTIONS). (Action 2) Check whether the timing of the dual input signal (EAS) satisfies the timing specification (See Subsection 3.TROUBLESHOOTING SRVO-266 SRVO-267 MAINTENANCE B-83525EN/01 FENCE1 status abnormal FENCE2 status abnormal (Explanation) A chain alarm was detected with the EAS (FENCE) signal. (Action 4) Replace the emergency stop board.2. Table 3.58 - .2. NOTE For the procedure of recovery from this alarm. Before executing the (Action 3). (Action 3) Replace the main board. WARNING If this alarm is issued.3. safety may not be guaranteed when the other circuit fails. If robot use is continued with one of the duplicate circuits being faulty. perform a complete controller back up to save all your programs and settings.5. safety may not be guaranteed when the other circuit fails.MAINTENANCE B-83525EN/01 SRVO-270 SRVO-271 3. (Action 3) Replace the main board.3. WARNING If this alarm is issued. Before executing the (Action 3). If robot use is continued with one of the duplicate circuits being faulty.2. (Action 1) Check whether the circuitry connected to the dual input signal (EES) is faulty. see the descriptions of SRVO-230 and SRVO-231.5(c) in CONNECTIONS). Fig 3. NOTE For the procedure of recovery from this alarm.5 (ac) SRVO-270 EXEMG1 status abnormal SRVO-271 EXEMG2 status abnormal . TBOP20 No. Name 12 E-STOP (ESPB) 11 10 9 8 FENCE (EAS) 7 6 5 EMGIN 4 (EES) 3 2 1 21 2 11 1 21 2 11 1 21 2 11 1 (Emergency stop board) Fig.TROUBLESHOOTING EXEMG1 status abnormal EXEMG2 status abnormal (Explanation) A chain alarm was detected with the EES (EXEMG) signal. (Action 4) Replace the emergency stop board. (Action 2) Check whether the timing of the dual input signal (EES) satisfies the timing specification (See Subsection 3.2.59 - . do not reset the chain error alarm until the failure is identified and repaired. Before executing the (Action 8).2. (Action 8) Replace the main board. Before executing the (Action 1). (Action 1) Replace the main board.5(c) in CONNECTIONS).5. SRVO-277 Panel E-stop (SVEMG abnormal) (Explanation) The emergency stop line was not disconnected although the emergency stop button on the operator's panel was pressed.60 - . perform a complete controller back up to save all your programs and settings. (Action 3) Check whether the timing of the dual input signal (NTED) satisfies the timing specification (See Subsection 3. (Action 3) Replace the 6-Axis servo amplifier. do not reset the chain error alarm until the failure is identified and repaired. (Action 6) Replace the emergency stop board.TROUBLESHOOTING SRVO-274 SRVO-275 MAINTENANCE B-83525EN/01 NTED1 status abnormal NTED2 status abnormal (Explanation) A chain alarm was detected with the NTED signal. Fig 3.3.2. (Action 2) Check whether the circuitry connected to the dual input signal (NTED) is faulty. (Action 4) Replace the teach pendant cable. In such a case. . NOTE For the procedure of recovery from this alarm. (Action 5) Replace the teach pendant. (Action 1) This alarm may be issued when the DEADMAN switch is pressed to a proper position or is operated very slowly. release the DEADMAN switch once completely then press the DEADMAN switch again. If robot use is continued with one of the duplicate circuits being faulty. (Action 7) Replace the mode switch on the operator's panel. WARNING If this alarm is issued. (Action 2) Replace the emergency stop board. perform a complete controller back up to save all your programs and settings. see the descriptions of SRVO-230 and SRVO-231. safety may not be guaranteed when the other circuit fails. (Action 1) Replace the teach pendant. (Action 2) Replace the teach pendant cable. (Action 3) Replace the main board. (Action 5) Replace the 6-Axis servo amplifier. NOTE This alarm may be issued if the emergency stop button is pressed very slowly. E-stop unit (Emergency stop board) 3 mode switch 2 mode switch (Mode switch) Fig.3. (Action 4) Replace the emergency stop board.TROUBLESHOOTING TP E-stop (SVEMG abnormal) (Explanation) The emergency stop line was not disconnected although the emergency stop button on the teach pendant was pressed.5 (ad) SRVO-274 NTED1 status abnormal SRVO-275 NTED2 status abnormal SRVO-277 Panel E-stop (SVEMG abnormal) SRVO-278 TP E-stop (SVEMG abnormal) . Before executing the (Action 3).MAINTENANCE B-83525EN/01 SRVO-278 3. perform a complete controller back up to save all your programs and settings.61 - . check whether there is a problem in the connection destination. SRVO-348 DCS MCC OFF alarm a. (Action 1) Replace the main board. (Action 3) If SRVO-291 is issued frequently.62 - . (Action 2) Replace the E-stop unit. perform a complete controller back up to save all your programs and settings. the HBK signal was input. replace the servo amplifier. (Action 2) Measure the secondary voltage between each phase at the main breaker. (Action 4) Replace the 6-Axis servo amplifier. .3. (Action 1) Press RESET on the teach pendant to release the alarm. clean them. broken signal circuit is connected. perform a complete controller back up to save all your programs and settings. Before executing the (Action 1). (Action 3) Replace the main board. (Action 2) Check whether the hand broken signal is connected to the robot. enable hand broken. SRVO.6. b (Explanation) A failure was detected in the safety signal input circuit. (Action 2) Replace the main board. Before executing the (Action 3). SRVO-349 DCS MCC ON alarm a. (Action 3) Replace the E-stop unit. (Action 4) Replace the 6-axis servo amplifier.TROUBLESHOOTING SRVO-291 MAINTENANCE B-83525EN/01 IPM over heat (G:i A:j) (Explanation) IPM on the servo amplifier is overheated. (Action 1) Replace the 6-axis servo amplifier. b (Explanation) A command was issued to turn on the magnetic contactor. b (Explanation) A command was issued to turn off the magnetic contactor. (See Subsection 5. (Action 1) If a signal is connected to the E-stop unit CRMB8. If necessary. SRVO-300 SRVO-302 Hand broken/HBK disabled Set Hand broken to ENABLE (Explanation) Although HBK was disabled.297 Improper input power (G:%d A:%d) (Explanation) The 6-axis servo amplifier has detected the input voltage phase lack. (Action 1) Replace the E-stop unit. (Action 2) If SRVO-291 is issued when the robot operating condition is severe. Before executing the (Action 2). replace the main breaker. SRVO. (Action 1) Check whether the vent hole is clogged. but the magnetic contactor was not turned off.3 in CONNECTIONS) SRVO-335 When the hand DCS OFFCHK alarm a. check the robot operating condition then relax the condition when possible. perform a complete controller back up to save all your programs and settings. but the magnetic contactor was not turned on.295 SVM COM alarm(G:%d A:%d) (Explanation) A communication error occurred in the 6-axis servo amplifier. if phase lack is detected. (Action 1) Check the input voltage of the controller whether phase is not lack. NOTE For the procedure of recovery from this alarm. b . see the descriptions of SRVO-230 and SRVO-231. WARNING If this alarm is issued. safety may not be guaranteed when the other circuit fails.MAINTENANCE B-83525EN/01 (Action 3) SRVO-370 SRVO-371 3.3. do not reset the chain error alarm until the failure is identified and repaired. (Action 2) Replace the 6-Axis servo amplifier. b SRVO-348 DCS MCC OFF alarm a.63 - . Before executing the (Action 1). perform a complete controller back up to save all your programs and settings. b SRVO-370 SVON1 status abnormal a. (Action 3) Replace the emergency stop board. b SRVO-349 DCS MCC ON alarm a. SVON1 status abnormal SVON2 status abnormal (Explanation) A chain alarm was detected with the main board internal signal (SVON).TROUBLESHOOTING Replace the 6-Axis servo amplifier. b SRVO-371 SVON2 status abnormal a. 6-Axis servo amplifir Main board Fig. If robot use is continued with one of the duplicate circuits being faulty.5 (ae) E-stop unit (Emergency stop board) SRVO-291 IPM over heat SRVO-295 SVM COM alarm SRVO-297 Improper input power SRVO-335 DCS OFFCHK alarm a. (Action 1) Replace the main board. NOTE For the procedure of recovery from this alarm. (Action 2) Replace the emergency stop board. Before executing the (Action 5). WARNING If this alarm is issued. Before executing the (Action 3). If robot use is continued with one of the duplicate circuits being faulty. WARNING If this alarm is issued. (Action 3) Replace the main board.64 - .3. If robot use is continued with one of the duplicate circuits being faulty. do not reset the chain error alarm until the failure is identified and repaired. see the descriptions of SRVO-230 and SRVO-231. (Action 1) Check the mode switch and its cable. (Action 5) Replace the main board. perform a complete controller back up to save all your programs and settings. Replace them if a defect is found. perform a complete controller back up to save all your programs and settings. SRVO-374 SRVO-375 SRVO-376 SRVO-377 MODE11 status abnormal MODE12 status abnormal MODE21 status abnormal MODE22 status abnormal (Explanation) A chain alarm was detected with the mode switch signal. Replace the emergency stop button on the operator's panel. Replace the emergency stop board. Replace the teach pendant. NOTE For the procedure of recovery from this alarm. safety may not be guaranteed when the other circuit fails. do not reset the chain error alarm until the failure is identified and repaired. see the descriptions of SRVO-230 and SRVO-231.TROUBLESHOOTING SRVO-372 SRVO-373 MAINTENANCE B-83525EN/01 OPEMG1 status abnormal OPEMG2 status abnormal (Explanation) (Action 1) (Action 2) (Action 3) (Action 4) A chain alarm was detected with the emergency stop button on the operator's panel. safety may not be guaranteed when the other circuit fails. Replace the teach pendant cable. . b SRVO-377 MODE22 status abnormal a. b SRVO-376 MODE21 status abnormal a. b SRVO-373 OPEMG2 status abnormal a. b SRVO-375 MODE12 status abnormal a.3.65 - .TROUBLESHOOTING MAINTENANCE B-83525EN/01 E-stop unit (Emergency stop board) 3 mode switch 2 mode switch (Mode switch) (Red) (Yellow) (Emergency stop button) Fig. b SRVO-374 MODE11 status abnormal a. b .3.5 (af) SRVO-372 OPEMG1 status abnormal a. If robot use is continued with one of the duplicate circuits being faulty.3.3. . do not reset the chain error alarm until the failure is identified and repaired.4. Fig 3. SRVO-453 Low volt driver(G:%d A:%d) (Explanation) Driver supply voltage in the servo amplifier is low. (Action 1) (Action 2) SRVO-451 Check the line of the two drive off inputs.5 (ag) SRVO-450 SRVO-378 SFDIxx status abnormal Drvoff circuit fail(G:%d A:%d) (Explanation) The two drive off inputs are not in the same status. WARNING If this alarm is issued. Replace the servo amplifier.4(c) in CONNECTIONS).66 - . (See Subsection 3. (Action 1) Replace the servo amplifier. xx shows signal name. (Action 1) Replace the servo amplifier. ROM data failure(G:%d A:%d) (Explanation) An error is found in the ROM data in the servo amplifier. E-stop unit (Emergency stop board) Fig. Internal S-BUS fail(G:%d A:%d) (Explanation) (Action 1) SRVO-452 An error is found in the serial bus communication in the servo amplifier.3.3. Replace the servo amplifier.TROUBLESHOOTING SRVO-378 MAINTENANCE B-83525EN/01 SFDIxx status abnormal (Explanation) A chain alarm was detected with the SFDI signal. (Action 1) Replace the servo amplifier. see the descriptions of SRVO-230 and SRVO-231. (Action 1) Check whether the circuitry connected to the dual input signal (SFDI) is faulty. safety may not be guaranteed when the other circuit fails. SRVO-454 CPU BUS failure(G:%d A:%d) (Explanation) An error was found in CPU bus data in the amplifier. (Action 2) Check whether the timing of the dual input signal (SFDI) satisfies the timing specification. NOTE For the procedure of recovery from this alarm. B-83525EN/01 SRVO-455 MAINTENANCE 3.TROUBLESHOOTING CPU watch dog(G:%d A:%d) (Explanation) An error occurred in CPU operation in the amplifier. (Action 1) Replace the servo amplifier. SRVO-456 Ground fault (G:%d A:%d) (Explanation) An error is found in the motor current detection data in the servo amplifier. (Action 1) Replace the servo amplifier. SRVO-459 Excess regeneration2%s (G:%d A:%d) (Explanation) An error is found in the discharge circuit in the servo amplifier. (Action 1) Replace the servo amplifier. SRVO-460 Illegal parameter%s (G:%d A:%d) (Explanation) An error is found in the setting of the parameters in the servo amplifier. (Action 1) Replace the servo amplifier. SRVO-461 Hardware error%s (G:%d A:%d) (Explanation) An error is found in the circuit in the servo amplifier. (Action 1) Replace the servo amplifier. - 67 - 3.TROUBLESHOOTING 3.6 MAINTENANCE B-83525EN/01 FUSE-BASED TROUBLESHOOTING This section describes the alarms and symptoms generated and actions required when the fuses installed on the printed circuit boards and units have blown. (1) Fuses on the main board FUSE1: For protecting the +24 V output of the peripheral device interface (A60L-0001-0290#LM10C) Name Symptom observed when fuse has blown Action FUSE1 An alarm (SRVO-220) is displayed on the teach pendant. 1. 24SDI and 0 V may be short-circuited. Check the peripheral device cable for any abnormality, and replace it if necessary. 2. Disconnect CRS40. If fuse (FUSE3) still blows, replace the main board. 3. Replace the cable between the emergency stop unit and the servo amplifier. 4. Replace the cable between the main board and the emergency stop unit. 5. Replace the emergency stop unit. 6. Replace the servo amplifier. FUSE1 (1.0A) CRS40 Fig.3.6(a) Fuse on the main board - 68 - B-83525EN/01 MAINTENANCE 3.TROUBLESHOOTING (2) Servo amplifier fuse FS1: For generation of the power to the amplifier control circuit (A60L-0001-0290#LM32C) FS2: For protection of the 24V output to the end effector, XROT, and XHBK (A60L-0001-0290#LM32C) FS3: For protection of the 24V output to the regenerative resister (A60L-0001-0290#LM32C) Name FS1 FS2 FS3 Symptom observed when fuse has blown All LEDs on the servo amplifier go out. The FSSB disconnection alarm (SRVO-057) or FSSB initialization alarm (SRVO-058) is displayed on the teach pendant. The 6-Axis servo amplifier fuse blown (SRVO-214), Hand broken (SRVO-006), and Robot overtravel (SRVO-005) are displayed on the teach pendant. The 6-Axis servo amplifier fuse blown (SRVO-214), DCAL alarm (SRVO-043) are displayed on the teach pendant. Action Replace the 6-Axis servo amplifier. 1 2 3 4 1 2 Check +24VF used by the end effector for a ground fault. Check the robot connection cable and the robot’s internal cable. Replace the 6-Axis servo amplifier. In case of M-3iA, check the fan motor inside the robot (option). Check the regenerative resister, and replace it if required. Replace the 6-Axis servo amplifier. FS1 (3.2A) FS3 (3.2A) FS2 (3.2A) Fig.3.6(b) Fuse on the servo amplifier - 69 - 3.TROUBLESHOOTING MAINTENANCE (3) Emergency stop board fuses FUSE2: For emergency stop circuit FUSE3: For teach pendant power supply circuit FUSE4: For +24V protection FUSE5: For +24V of mainboard protection FUSE6,FUSE7: For AC200V of door fan protection Name Symptom observed when fuse has blown FUSE2 Alarm (SRVO-007) is displayed on the teach pendant, and the red LED (24EXT) on the emergency stop board lights. FUSE3 The display on the teach pendant disappears, and the red LED (24T) on the emergency stop board lights. FUSE4 An alarm relating to an input signal that causes an emergency stop is issued, and the red LED (24V2) on the emergency stop board lights. FUSE5 The teach pendant can not be operated and the red LED (24V3) on the emergency stop board lights. FUSE6 FUSE7 The fan stops. * B-83525EN/01 (A60L-0001-0290#LM10C) (A60L-0001-0290#LM10C) (A60L-0001-0290#LM20C) (A60L-0001-0290#LM50C) (A60L-0001-0175#3.2A) Action 1. Check the voltage between EXT24V and EXT0V (TBOP19). If no external power supply is used, check the jumper pin between EXT24V and INT24V or between EXT0V and INT0V. 2. Check the 24EXT (emergency stop line) for a short circuit or connection to ground. 3. Replace the emergency stop board. 2. Check the teach pendant and replace it if necessary. 1. Check the teach pendant cable and replace it if necessary. 2. Check the cable between the emergency stop board (CRS40) and the main board (CRS40) , and replace it if necessary. 3. Check the teach pendant and replace it if necessary. 4. Replace the emergency stop board. 5. Replace the main board. (*) 1. Check the connection on TROP20. 2. Check the cable between the emergency stop board (CRS40) and the main board (CRS40), and replace it if necessary. 3. Check the cable between the emergency stop board (CRMA92) and the 6-Axis servo amplifier (CRMA91), and replace it if necessary. 4. If the cable between the emergency stop board (CRMB22) and the 6-Axis servo amplifier (CRMB16) exist. Check this cable and replace it if necessary. 5. Replace the emergency stop board. 6. Replace the E-stop unit. 7. Replace the main board. (*) 8. Replace the 6-Axis servo amplifier. 1. Check the cable between the emergency stop board (CRS40) and the main board (CRS40), and replace it if necessary. 2. Check the cable between the emergency stop board (CRMA92) and the 6-Axis servo amplifier (CRMA91), and replace it if necessary. 3. Replace the back plane board. 4. Replace the main board. (*) 5. Replace the emergency stop board. 6. Replace the 6-Axis servo amplifier. 1. Check the fan cable and replace it if necessary. 2. Replace the fan unit. 3. Replace the emergency stop board. If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data. If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely. - 70 - 3.TROUBLESHOOTING MAINTENANCE B-83525EN/01 FUSE2 (1A) FUSE4 (2A) FUSE5 (5A) LED:24V2(Red) LED:24V3(Red) LED:24EXT(Red) TBOP19 LED:24T（Red） FUSE6 (3.2A) TBOP20 FUSE7 (3.2A) FUSE3 (1A) Fig.3.6 (c) Fuse on the emergency stop board (4) Fuse on the process I/O MA,MB FUSE1: Fuse for +24E Name FUSE1 (A60L-0001-0046#1.0) Symptom observed when fuse has blown Action The LED (ALM1 or FALM) the process I/O board lights. 1. Check if the cables and peripheral devices connected to the process I/O board are normal. 2. Replace the process I/O board. LED:FALM（Red） LED:ALM1（Red） FUSE1 (1A) Fig.3.6 (d) Fuse on the process I/O board MA - 71 - Main board 6-Axis servo amplifier Fig.72 - Emergency stop board The .7 Troubleshooting based on LED indication .7 TROUBLESHOOTING BASED ON LED INDICATIONS The printed circuit boards and servo amplifier are provided with alarm LEDs and status LEDs.3. LED status and corresponding troubleshooting procedures are described below.TROUBLESHOOTING MAINTENANCE B-83525EN/01 LED:FALM (Red) LED:ALM1 (Red) FUSE1 (1A) Fig.3.3.6 (e) Fuse on the process I/O board MB 3. 73 - . 3: The initialization of dram on the CPU card is completed.TROUBLESHOOTING MAINTENANCE B-83525EN/01 Troubleshooting Using the LEDS On the Main Board (1) Troubleshooting using the status display LED To troubleshoot an alarm that arises before the teach pendant is ready to display.1 3.1 Step RLED1 (Red) LEDG1 LEDG2 LEDG3 LEDG4 (Green) Troubleshooting Using the LEDS On the Main Board LED Action to be taken 1: After power-on. 4: The initialization of DPRAM on the communication IC is completed.3. LEDG1 LEDG2 LEDG3 LEDG4 [Action 1] Replace the CPU card. LEDG1 LEDG2 LEDG3 LEDG4 [Action 1] Replace the CPU card. the step in which the alarm occurred can be determined from which LEDs are lit. * [Action 2] Replace the main board. the LEDs light as described in steps 1 to end. * [Action 3] Replace the FROM/SRAM module. * [Action 2] Replace the main board.7. 2: Software operation start-up. LEDG1 LEDG2 LEDG3 LEDG4 [Action 1] Replace the CPU card. in the order described. . all LEDs are lit. LEDG1 LEDG2 LEDG3 LEDG4 [Action 1] Replace the CPU card. If an alarm is detected. After power-on. 3. check the status LEDs (green) on the main board at power-on. * [Action 2] Replace the main board. * [Action 2] Replace the main board.7. 7-segment LED Fig. LEDG1 LEDG2 LEDG3 LEDG4 * [Action 1] Replace the main board. * [Action 2] Replace the main board. LEDG1 LEDG2 LEDG3 LEDG4 [Action 1] Replace the CPU card. * [Action 3] Replace the FROM/SRAM module. 13: Calibration is completed. * [Action 2] Replace the main board. [Action 3] Replace the servo amplifier. [Action 2] Replace the process I/O board. LEDG1 LEDG2 LEDG3 LEDG4 [Action 1] Replace the axis control card. LEDG1 LEDG2 LEDG3 LEDG4 [Action 1] Replace the axis control card. * [Action 2] Replace the main board. LEDG1 LEDG2 LEDG3 LEDG4 * [Action 1] Replace the main board. . [Action 3] Replace the servo amplifier.TROUBLESHOOTING Step MAINTENANCE LED B-83525EN/01 Action to be taken 5: The initialization of the communication IC is completed. LEDG1 LEDG2 LEDG3 LEDG4 * [Action 1] Replace the main board. [Action 2] Replace the FROM/SRAM module. [Action 2] Replace the main board.74 - . * [Action 2] Replace the FROM/SRAM module. 11: The preparation of the SRAM module is completed. 6: The loading of the basic software is completed. * [Action 2] Replace the main board. * [Action 2] Replace the FROM/SRAM module. 8: Start-up of communication with the teach pendant. LEDG1 LEDG2 LEDG3 LEDG4 * [Action 1] Replace the main board. 10: DI/DO initialization LEDG1 LEDG2 LEDG3 LEDG4 [Action 1] Replace the FROM/SRAM module.3. 14: Start-up of power application for the servo system LEDG1 LEDG2 LEDG3 LEDG4 * [Action 1] Replace the main board. 9: The loading of optional software is completed. 12: Axis control card initialization LEDG1 LEDG2 LEDG3 LEDG4 [Action 1] Replace the axis control card. 7: Basic software start-up. [Action 3] Replace the servo amplifier. 7 * [Action2] Replace the main board. Replace the main board. 16: DI/DO output start-up. .75 - . [Description] A bus error has occurred in the communication controller. [Action 2] Replace the process I/O board. [Description] A parity alarm condition has occurred in SRAM on the FROM/SRAM module installed on the main board. Before you replace the unit.TROUBLESHOOTING MAINTENANCE B-83525EN/01 Step LED Action to be taken 15: Program execution LEDG1 LEDG2 LEDG3 LEDG4 * [Action 1] Replace the main board. Replace the CPU card. Replace the axis control card. Replace the main board. replace the option board. Replace the axis control card. (2) TROUBLESHOOTING BY 7-SEGMENT LED INDICATOR 7-segment LED indicator Description [Description] A parity alarm condition has occurred in DRAM on the CPU card installed on the main board. So.) will be lost. etc. 17: Initialization is terminated. If an alarm is issued. therefore. back up the contents of memory routinely. the contents of memory (parameters. [Action1] Replace the FROM/SRAM module. [Action1] Replace the CPU card. 18: Normal status LEDG1 LEDG2 LEDG3 LEDG4 Status LEDs 1 and 2 blink when the system is operating normally. make a backup copy of the data. * [Action] Replace the main board.3.3. * [Action] Replace the main board. [Description] A parity alarm condition has occurred in DRAM controlled by the communication controller. * If the main board or FROM/SRAM module is replaced. LEDG1 LEDG2 LEDG3 LEDG4 * [Action 1] Replace the main board. [Action 1] Replace the CPU card. * [Action2] Replace the main board. If an option board is installed. data backup may be disabled. The SYSEMG alarm has occurred. LED indication RLED1 (Red) Description [Description] CPU card is not working. LEDG1 LEDG2 LEDG3 LEDG4 Initialization has ended normally. specified data. [Description] [Action1] * [Action2] [Action3] [Description] [Action1] [Action2] * [Action3] A servo alarm condition has occurred on the main board. If an option board is installed. referring also to the alarm indication on the teach pendant. back up the contents of memory routinely. check that the voltage is 50 V or less. make a backup copy of the data. LED: V4 (R) LED: SVALM (R) SVEMG (R) DRDY (G) OPEN (G) P5V (G) P3. Before you replace the unit. check the DC link voltage with the screws located above the LED "V4".76 - . Check that the voltage is not higher than 50V. 3. therefore.3V(G) Fig. 5V is supplied to Main board. . Above alarms do not occur.TROUBLESHOOTING MAINTENANCE 7-segment LED indicator Description [Description] [Action1] [Action2] * [Action3] [Action4] [Description] * B-83525EN/01 The SYSFAIL alarm has occurred. So.2 Troubleshooting by LEDs on the 6-Axis Servo Amplifier The 6-Axis servo amplifier has alarm LEDs. Replace the axis control card. replace the option board.3. the contents of memory (parameters. data backup may be disabled. Troubleshoot the alarm indicated by the LEDs. etc.7. Replace the main board.) will be lost. By using a DC voltage tester.3. If an alarm is issued. If the main board or FROM/SRAM module is replaced.7. Replace the CPU card.2 LEDs on the 6-Axis servo amplifier WARNING Before touching the 6-Axis servo amplifier. specified data. Lights when an emergency stop signal is input to the servo amplifier. Lights when the communication between the servo amplifier and the main board is normal. [Action 3] Replace the servo amplifier. If the LED lights when the machine is not at an emergency stop: [Action] Replace the servo amplifier. If the LED does not light when there is an alarm condition in the machine: [Action] Replace the servo amplifier.TROUBLESHOOTING LED Color Description V4 Red ALM Red SVEMG Red DRDY Green OPEN Green P5V Green P3. If the LED does not light: [Action 1] Check the robot connection cable (RP1/RMP1) to see if there is a ground fault in the +5V wire. Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally. If the LED does light when the machine is at an emergency stop: [Action] Replace the servo amplifier. [Action 2] Replace the servo amplifier. Lights when the servo amplifier is ready to drive the servo motor. Replace the emergency stop unit. If the LED does not light when the motor is activated: [Action] Replace the servo amplifier.3V Green Lights when the DCLINK circuit inside the servo amplifier is charged to reach the specified voltage.MAINTENANCE B-83525EN/01 3. If the LED does not light: [Action 1] Check for the connection of the FSSB optical cable.3 V normally. If the LED lights when there is no alarm condition in the machine: [Action] Replace the servo amplifier. If the LED does not light after pre-charge is finished: [Action 1] The DC Link may be short-circuited. . [Action 2] The charge current control resistor may be defective. [Action 3] Replace the servo amplifier. [Action 2] Replace the servo card. Lights when the servo amplifier detects an alarm. If the LED does not light: [Action] Replace the servo amplifier. Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.77 - . Check for connection. Replace the emergency stop board. Replace the main board. If no external power supply is used. and replace it if necessary. Check this cable and replace it if necessary. Check the cable between the emergency stop board (CRS40) and the main board (CRS40). 24EXT for the emergency stop circuit is not supplied. Replace the main board. 24T for the teach pendant is not supplied. and replace it if required. and replace it if necessary. Check the connection of TBOP20. When the LED (red) turned on. When the LED (red) turned on. Check the cable between the emergency stop board (CRS40) and the main board (CRS40). the fuse (FUSE2) is brown. Replace the main board.TROUBLESHOOTING 3. Check the cable between the emergency stop board (CRS40) and the main board (CRS40). the fuse (FUSE4) is brown. Check the cable between the emergency stop board (CRMA92) and the 6-Axis servo amplifier (CRMA91). and replace it if necessary.3. Replace the 6-Axis servo amplifier. Replace the E-stop unit. Check the teach pendant.78 - . the servo amplifier is ready to energize. check the jumper pin between EXT24V and INT24V or between EXT0V and INT0V. When the LED (red) turned on. Replace the 6-Axis servo amplifier. If the fuse (FUSE2) has not brown in this state. Check the cable between the emergency stop board (CRMA92) and the 6-Axis servo amplifier (CRMA91). When the SVON1 and SVON2 (green) turned on. 24V-3 for the main board is not supplied. These LEDs (green) indicate the status of SVON1/SVON2 signals from the emergency stop board to the servo amplifier. If the cable between the emergency stop board (CRMB22) and the 6-Axis servo amplifier (CRMB16) exist. and replace it if necessary. Check the teach pendant. Replace the backplane board. Replace the emergency stop board. Check the 24EXT (emergency stop line) for a short circuit or connection to ground. Replace the emergency stop board. and replace it if required. the fuse (FUSE3) is brown. . check the voltage between EXT24V and EXT0V (TBOP19). the fuse (FUSE5) is brown. Check the teach pendant cable (CRS36). and replace it if required. and replace it if necessary.7. Replace the emergency stop board. 24V-2 for the emergency stop input signal is not supplied.3 MAINTENANCE B-83525EN/01 Troubleshooting by LED on the Emergency Stop Board LED indication Failure description and required measure [Description] [Action 1] 24EXT (Red) [Action 2] [Action 3] [Action 4] [Description] 24T (Red) [Action 1] [Action 2] [Action 3] [Action 4] *[Action 5] [Description] [Action 1] [Action 2] [Action 3] 24V2 (Red) [Action 4] [Action 5] [Action 6] *[Action 7] [Action 8] [Description] [Action 1] 24V3 (Red) [Action 2] [Action 3] *[Action 4] [Action 5] [Action 6] [Description] SVON1/SVON2 (Green) When the LED (red) turned on. 2A) FUSE3 (1A) Fig.3 LEDs on the emergency stop board .79 - .MAINTENANCE B-83525EN/01 FUSE2 (1A) FUSE4 (2A) 3.7.TROUBLESHOOTING FUSE5 (5A) LED:24V2(Red) LED:24V3(Red) LED:24EXT(Red) TBOP19 LED:24T（Red） FUSE6 (3.3.2A) TBOP20 FUSE7 (3. Check the cables and peripheral units connected to the process I/O board and replace the defective units.MB LED Color Description [Description] ALM1 Red FALM Red [Action 1] [Action 2] [Action 3] [Description] [Action1] [Action2] [Action3] An alarm was issued during communication between the main board and the process I/O board.3. Replace the fuse on the process I/O board.4 (c) LEDs on the process I/O board MB . Replace the process I/O board.7.7. LED:FALM（Red） LED:ALM1（Red） FUSE1 (1A) Fig.TROUBLESHOOTING 3. Replace the process I/O board.7. Replace the main board.4 MAINTENANCE B-83525EN/01 Troubleshooting by Alarm LEDs on the Process I/O Board Process I/O MA.4 (b) LEDs on the process I/O board MA LED:FALM (Red) LED:ALM1 (Red) FUSE1 (1A) Fig.3. The fuse on the process I/O board was blown. Replace the I/O link connection cable.80 - .3. (Check 5) Check whether the previous manual operation has been completed. press the axis selection key and shift key at the same time. (2) Check and corrective action to be taken if the program cannot be executed (Check 1) Check whether the ENBL signal for the peripheral-device control interface is on. turn it off. (Corrective action) Release the alarm. which prevents the previous operation from being completed. Also check whether the HOLD lamp on the teach pendant is on. (Check whether the hold lamp on the teach pendant is on.8 MAINTENANCE 3. . (Check 3) Check whether the ENBL signal of the peripheral device control interface is set to on. (Corrective action) Release the alarm.) (Corrective action) Turn off the HOLD signal of the peripheral device control interface. (Check 3) Check whether the previous manual operation has been completed. check the position deviation on the status screen. (Corrective action) To move an axis by manual operation. check the position deviation on the status screen. (Check 4) Check whether the HOLD signal of the peripheral device control interface (hold status). (Check 2) Check whether the HOLD signal for the peripheral-device control interface is on.B-83525EN/01 3. (Check 4) Check whether the controller is in the alarm status. (Check 6) Check whether the controller is in the alarm status. (Corrective action) Turn on the teach pendant "enable".TROUBLESHOOTING MANUAL OPERATION IMPOSSIBLE The following explains checking and corrective action required if the robot cannot be operated manually after the controller is turned on: (1) Check and corrective action to be made if manual operation is impossible (Check 1) Check whether the teach pendant is enabled. (Corrective action) If the HOLD signal of the peripheral device control interface is on. Set the override for manual feed to a position other than the FINE and VFINE positions. (Check 2) Check whether the teach pendant is handled correctly. (Corrective action) Put the peripheral-device control interface in the ENBL state. then change the setting. (Corrective action) If the robot cannot be placed in the effective area because of the offset of the speed command voltage preventing the previous operation from being completed. (Corrective action) Place the peripheral device control interface in the ENBL status.81 - . (Corrective action) If the robot cannot be placed in the effective area because of the offset of the speed command voltage. and change the setting. 0. OFF = approx.5 sec ON = approx. Operation mode LED state OFF ON Common I/O Link I/O Link i Meaning Fault location and action Power OFF Power ON (before communication start) Blink (1:1 at high speed) Communication at halt Blink (1:3) Communication in progress Blink (1:1) Communication in progress Communication in progress (Dual check safety in use) Blink (3:1) . 1.TROUBLESHOOTING MAINTENANCE B-83525EN/01 3.82 - Communication is at halt because of an alarm. 0.5 sec ON = approx.5 sec ON = approx. The following table lists the ON/OFF states of the LEDs and their meanings. These LEDs indicate the states of the units. “ALM” (red). OFF = approx. OFF = approx.9.3.25 sec.9 LEDS ON UNITS SUPPORTING I/O LINK i 3. .5 sec. 0.1 Meanings of LEDs on Units Supporting I/O Link i The standard I/O Link i incorporates three LEDs.5 sec. and “FUSE” (red) for each unit separately. LED ON/OFF state Steadily OFF Steadily ON Blink (1:1) Blink (3:1) Blink (1:3) Blink (1:1 at high speed) ON and OFF duration ON = approx.5 sec. Identify the cause according to the states of the red LED stated below or information displayed on the CNC screen. “LINK” (green). 1. 0. OFF = approx.25 sec LED「LINK」(green) The “LINK” (green) LED indicates the state of communication. 0. The following table lists the meanings of LED states. 0. it is likely that there may be noise. Check to see if there is noise around the cable.83 - It is likely that the hardware may be defective. I/O Link i .MAINTENANCE B-83525EN/01 3. such as a DO ground fault. It is likely that the hardware may be defective. The following table lists the meanings of LED states. Operation mode LED state Meaning Fault location and action Common OFF Normal state or power OFF I/O Link ON Alarm ON Alarm Blink (1:1) Broken wire between the unit of interest and a unit subsequent to it Blink (3:1) Power failure (including instantaneous power failure) in a unit subsequent to the unit of interest Identify and remove the cause of a power failure in a unit subsequent to the unit of interest. . Check for a defective cable or a poor cable connection between JD1A on the unit of interest and JD1B on a unit subsequent to that unit. Replace the unit. Identify and remove the cause of the alarm.TROUBLESHOOTING LED「ALM」(red) The “ALM” (red) LED indicates an alarm in the unit of interest or a unit subsequent to it. has occurred. Replace the unit. Blink (1:3) Status alarm A status alarm. Alternatively. 84 - .PRINTED CIRCUIT BOARDS 4 MAINTENANCE B-83525EN/01 PRINTED CIRCUIT BOARDS The printed circuit boards are factory-set for operation.4. The controller printed circuit board includes the main unit printed circuit board and one or more cards or modules installed horizontally to the main-unit printed-circuit board. LED indicators. This chapter describes the standard settings and adjustment required if a defective printed circuit board is replaced. you do not need to set or adjust them. It also describes the test pins and the LED indications. Usually. there is a backplane connector. At the rear. and a plastic panel at the front. These PC boards have interface connectors. . 4.PRINTED CIRCUIT BOARDS MAINTENANCE B-83525EN/01 4.1 MAIN BOARD Card and Modules Axis control card CPU card FROM/SRAM module Fig.4.1 Main board Name Main board CPU card Axis control card FROM/SRAM module Fan board Ordering Specification Board Specification Note A05B-2650-H001 A20B-8200-0790 A05B-2650-H002 A20B-8200-0791 A05B-2650-H003 A20B-8200-0792 A05B-2600-H020 A05B-2600-H021 A05B-2600-H022 A05B-2600-H040 A05B-2600-H041 A05B-2600-H042 A05B-2600-H043 A05B-2600-H060 A05B-2600-H061 A05B-2600-H062 A05B-2600-H063 A05B-2600-H064 A05B-2600-H065 A05B-2600-H066 A05B-2600-H067 A05B-2600-H068 A05B-2650-H001 A05B-2650-H002 A05B-2650-H003 A20B-3300-0686 A20B-3300-0687 A20B-3300-0688 A20B-3300-0664 A20B-3300-0663 A20B-3300-0662 A20B-3300-0661 A20B-3900-0283 A20B-3900-0284 A20B-3900-0285 A20B-3900-0286 A20B-3900-0287 A20B-3900-0288 A20B-3900-0280 A20B-3900-0281 A20B-3900-0282 A20B-8200-0669 Standard Ethernet:1ch Ethernet:2ch With Vision I/F, Force sensor I/F Ethernet:2ch With Vision I/F, Force sensor I/F, PMC, HDI Standard / SDRAM 32Mbyte Standard / SDRAM 64Mbyte Standard / SDRAM 128Mbyte 6-axis 12-axis 18-axis 24-axis FROM 32M/ SRAM 1M FROM 32M/ SRAM 2M FROM 32M/ SRAM 3M FROM 64M/ SRAM 1M FROM 64M/ SRAM 2M FROM 64M/ SRAM 3M FROM 128M/ SRAM 1M FROM 128M/ SRAM 2M FROM 128M/ SRAM 3M - 85 - 4.PRINTED CIRCUIT BOARDS MAINTENANCE B-83525EN/01 7segments LED RLED1 (Red) LEDG1 LEDG2 LEDG3 LEDG4 (Green) CD38B LEDB2(LINK) LEDB1(RX/TX) CD38A LEDA2(LINK) LEDA1(RX/TX) CAMERA LEDD2(LINK) LEDD1(RX/TX) TP LEDC2(LINK) LEDC1(RX/TX) LEDs CD38A Seven segment LED CD38B Description When the alarm condition has occurred in the main board, this LED is turned on. Please see the Section 3.7.TROUBLESHOOTING BASED ON LED INDICATIONS. ALARM LED Color Description RLED1 Red When the alarm condition has occurred in the CPU card, this LED is turned on. Please see the Section 3.7.TROUBLESHOOTING BASED ON LED INDICATIONS. STATUS LED Color Description LEDG1 LEDG2 LEDG3 LEDG4 Green Green Green Green These LEDs show the operating status of the system. Please see the Section 3.7.TROUBLESHOOTING BASED ON LED INDICATIONS. ETHERNET LED Color RX/TX LINK Green Green Description Blink during data transmission of Ethernet TP Light when a link of Ethernet is established Note. TP:For Ethernet TP, CAMERA: For camera - 86 - 4.2 4.PRINTED CIRCUIT BOARDS MAINTENANCE B-83525EN/01 EMERGENCY STOP BOARD:A20B-2005-0150 FUSE2 (1A) FUSE4 (2A) FUSE5 (5A) LED:24V2(Red) LED:24V3(Red) LED:24EXT(Red) TBOP19 LED:24T（Red） FUSE6 (3.2A) TBOP20 FUSE7 (3.2A) FUSE3 (1A) Fig.4.2 Emergency stop board 4.3 BACKPLANE Backplane Mini slot(2slot) Fig.4.3 Backplane Name 2 slot backplane Ordering Specification Parts number Board specification A05B-2650-H080 A05B-2650-C040 A20B-8200-0680 - 87 - 4.PRINTED CIRCUIT BOARDS 4.4 MAINTENANCE B-83525EN/01 PROCESS I/O BOARD MA (A20B-2004-0381) JD1B JD1A CRMA52A ICOM1 ICOM2 P24V LED:FALM(Red) LED:ALM1(Red) CRMA52B GND FUSE1 (1A) P5V Fig.4.4 Process I/O board MA (1) Test pins Name Use +24V +5V GND P24V P5V GND For measuring the DC supply voltage (2) Settings Name ICOM1 Standard setting UDI1- 10 (Connector CRMA52A) UDI11- 20 (Connector CRMA52B) ICOM2 Side A Description For common voltage setting Side A: +24V common Side B: 0V common (3) LEDs Name Color ALM1 Red FALM Red Description A communication alarm occurred between the main board and process I/O board. The fuse (FUSE1) on the process I/O board has blown. - 88 - 4.5 4.PRINTED CIRCUIT BOARDS MAINTENANCE B-83525EN/01 PROCESS I/O BOARD MB (A20B-2101-0731) LED:FALM (Red) LED:ALM1 (Red) VR2 CRW11 24V VR3 VR4 VR1 5V AOUT1 P24VF JD1B JD1A GND GNDF P5VF FUSE1 (1A) AOUT2 Fig.4.5 Process I/O board MB (1) Test pins and pads Name Use 24V 5V GND +24V +5V GND P24VF P5VF GNDF AOUT1 AOUT2 +24V +5V GND Channel 1 Channel 2 For measuring the DC supply voltage D/A converter power supply For analog output signal (D/A) voltage measurement (2) Adjustment VR1/VR2 Channel 1 gain and offset adjustment Connect the “+” and “-” terminals of a digital voltmeter, respectively, to the AOUT1 check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT[1]=3413, using a robot program. While observing the voltage at the AOUT1 check pin with the digital voltmeter, adjust potentiometers VR1 and VR2 for 15.0V. VR3/VR4 Channel 2 gain and offset adjustment Connect the “+” and “-” terminals of a digital voltmeter, respectively, to the AOUT2 check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT[2]=3413, using a robot program. While observing the voltage at the AOUT2 check pin with the digital voltmeter, adjust potentiometers VR3 and VR4 for 15.0V. (3) LEDs Name Color ALM1 Red FALM Red Description A communication alarm occurred between the main CPU and process I/O board. The fuse (FUSE1) on the process I/O board has blown. - 89 - 6 MAINTENANCE B-83525EN/01 I/O CONNECTOR CONVERTER BOARD (A20B-2004-0411) CRMA58 CRMA59 (I/O connector converter board) .4.PRINTED CIRCUIT BOARDS 4.90 - . SERVO AMPLIFIERS SERVO AMPLIFIERS The servo amplifiers are factory-set for operation.91 - . Usually.MAINTENANCE B-83525EN/01 5 5. This chapter describes the standard settings and adjustment required if a defective servo amplifier is replaced. It also describes the use of test pins and meanings of the LED indications. LED：V4（red） WARNING Before touching the servo amplifier. check the voltage at the screw above the LED “V4” with a DC voltage tester to see if the remaining voltage is not higher than 50V. for maintenance purposes. Table 5(b) Servo amplifier specification (Power supply regeneration) REGENERATIVE RESISTOR ROBOT SERVO AMPLIFIER LR Mate 200iD A06B-6400-H005 A05B-2650-C100 Check that the voltage is not higher than 50V. . you do not need to set or adjust them. for example. Lights when the communication between the servo amplifier and the main board is normal. Lights when the servo amplifier detects an alarm.3V Green Description Lights when the DCLINK circuit inside the servo amplifier is charged to reach a specific voltage. Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3. Lights when an emergency stop signal is input to the servo amplifier.3V(G) LED Color V4 Red SVALM SVEMG DRDY OPEN P5V Red Red Green Green Green P3.5.SERVO AMPLIFIERS 5. Lights when the servo amplifier is ready to drive the servo motor. .1 MAINTENANCE B-83525EN/01 LEDS OF SERVO AMPLIFIER LED: V4 (R) LED: SVALM (R) SVEMG (R) DRDY (G) OPEN (G) P5V (G) P3. Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally.92 - .3 V normally. 2 Settings Name Standard setting COM1 Side A Description Robot Digital Input (RI) device common voltage.2 5.5.MAINTENANCE B-83525EN/01 5.93 - .SERVO AMPLIFIERS SETTING OF SERVO AMPLIFIER Table 5.2 Circuit based on jumper pin location or setting of switch . Side A: +24V common Side B: 0V common COM A B A side RI B side RI Fig. 5Arms CURRENT：J3 20Ap / 6.5Arms 80Ap / 23.6Arms CURRENT：J3 20Ap / 3. 50/60Hz.4Arms 40Ap / 13.0Arms 80Ap / 23.4Arms TOTAL CURRENT 125Arms 90Arms 90Arms A06B-6400-H003 A06B-6400-H004 INPUT VOLTAGE RATINGS POWER CAPACITY OUTPUT MAXIMUM OUTPUT AC200~AC240V ( +10% / -15% ).5Arms 20Ap / 6.5Arms TOTAL CURRENT 52. 50/60Hz. 3phase 2. 50/60Hz.0Arms CURRENT：J3 160Ap / 36.0Arms 80Ap / 23.6Arms CURRENT：J4 20Ap / 3.0KVA 240V ~ CURRENT：J1 40Ap / 13.5Arms CURRENT：J6 20Ap / 6.4Arms CURRENT：J5 40Ap / 13.1KVA 240V ~ 160Ap / 36.7KVA 2.4Arms CURRENT：J6 40Ap / 13.4Arms 40Ap / 13.6Arms CURRENT：J2 20Ap / 3.SERVO AMPLIFIERS 5. 3phase 5.3 MAINTENANCE B-83525EN/01 6-AXIS SERVO AMPLIFIER SPECIFICATIONS SPECIFICATIONS TABLE：（A06B-6400-H***） UNIT INPUT VOLTAGE RATINGS POWER CAPACITY OUTPUT MAXIMUM OUTPUT RATINGS A06B-6400-H102 AC200~AC240V ( +10% / -15% ).3/1.5Arms 20Ap / 6.6Arms CURRENT：J5 10Ap / 2.4Arms 40Ap / 13.0Arms CURRENT：J6 10Ap / 2.0Arms CURRENT：J2 160Ap / 36.5Arms 20Ap / 6.0Arms TOTAL CURRENT 18.0Arms 80Ap / 23.0Arms CURRENT：J4 40Ap / 13.6KVA 5.5Arms 80Ap / 23.5Arms CURRENT：J5 20Ap / 6.4 ( 3/1phase ) OUTPUT MAXIMUM OUTPUT 240V ~ CURRENT：J1 20Ap / 3.4Arms 20Ap / 6.5.5Arms 80Ap / 23.8Arms 39Arms UNIT A06B-6400-H005 INPUT VOLTAGE AC200~AC240V ( +10% / -15% ).4Arms 40Ap / 13.4Arms 40Ap / 13.94 - .1KVA 5.5Arms CURRENT：J2 40Ap / 13.4Arms RATINGS A06B-6400-H002 CURRENT：J1 UNIT RATINGS A06B-6400-H101 .5Arms CURRENT：J4 20Ap / 6. 3/1phase RATINGS POWER CAPACITY 1.4Arms 20Ap / 6.5Arms 20Ap / 6.4Arms 40Ap / 13. or adjust it.POWER SUPPLY MAINTENANCE B-83525EN/01 POWER SUPPLY Setting and adjustment of the power supply is factory-set for operation.5V No fuse is existed in the grounding line(Neutral of 200VAC. +3.6. 1φ and 0V).3V +2. you do not need to set BLOCK DIAGRAM OF THE POWER SUPPLY 6-Axis servo amplifier MCC FS3 200VAC Breaker CRR38A +24V Emergency stop board CNMC6 CP1 FS2 CNJ 200VAC DC/DC +5V.1 Block diagram of the power supply .1 Usually.3V +15V. 6.+3.3V +2. Fig.6 6.95 - .5V +15V.-15V Main board Pulsecoder FUSE3 CRS36 Power FUSE5 CRT30 +24VF Fan CP1A FUSE7 CP5A Motor EE CRMB23 +24T Teach pendant JRS26 I/O LINK (1ch) JD44A I/O LINK i (2ch) FUSE1 CRMA15 Peripheral device CRMA16 JRS27 CRS41 24V→ JRL7 12V Peripheral device RS-232-C/ETHERNET CAMERA FORCE/3D SENSOR. LVC VISION Battery Fan board CA131 +24V Fan CA130 Fan +24V -15V +15V +5V +3. -15V CRF8 AC Input AC 200 ～ 230 V Single phase Three phase FS1 CXA2B Regenerative resistor FUSE6 +5V PSU AC/DC +24V Backplane Robot DC/DC (IN+24V) +5V. 6 Before you disconnect a cable. make adjustments correctly if the board needs to be adjusted. note its location. power supply unit. Before you start to replace these components. it is likely that robot parameters and taught data are lost. turn off the controller main power. do not touch the semiconductor devices on the board with your hand or make them touch other components. so care should be taken. WARNING When a heavy component or unit is to be handled. 3 Make sure that the replacement printed-circuit board has been set up appropriately. 2 When you remove a printed-circuit board. or main board (including cards and modules) is replaced.1 REPLACING THE PRINTED-CIRCUIT BOARDS CAUTION When you replace printed-circuit boards. you could injure personnel or damage equipment. Also keep all machines in the area of the controller switched. read the maintenance manual to understand the replacement procedure. reconnect it exactly as before. Note that incorrect handling can cause serious injury to the workers. WARNING Before replacing components. When you have to touch a heated component. prepare a protector such as heat-resistant gloves. resulting in breakage in the robot or personal injury. Otherwise. save a backup copy of the robot parameters and taught data to an external memory device. support the workers with a crane or the like not to apply excessive loads to the workers. WARNING Before you start to replace a unit. 5 If the backplane board. If a cable is detached for replacement. . 7. (Setting plug etc.96 - .REPLACING UNITS 7 MAINTENANCE B-83525EN/01 REPLACING UNITS This section explains how to replace each unit in the control section.7.) 4 After replacing a printed-circuit board. Performing an incorrect replacement procedure can lead to an unpredictable accident. CAUTION Components in the controller heat up. observe the following cautions: 1 Keep the controller power switched off. (2) (2) (1)Remove the (2) screws (3) Replace the backplane unit with a new one. When the case is attached. When setting the case.) CAUTION When you remove the backplane unit. (1) Remove the (2) screws fastening the case. and battery installed in the case.1-3. tighten the (2) screws of the case. and pull out the case. (If the cables of option boards have been detached.1. and be careful not to apply excessive force.) (2) Release the latches in the upper part on each side of the case from the base metal plate.1 7.97 - .REPLACING UNITS Replacing the Backplane Board (Unit) Replace the backplane board together with the plastic case.3VDC) and it is installed correctly. (5) After confirming that the case is surely latched. The case can be pulled out with the backplane board. and pull out the case. and make sure that the connectors are connected securely. check that the connectors are connected properly. connect the cables again. (4) Confirm that the screw and latch positions of the case are in place. . detach the cables. (When cables are connected to option boards. and slowly set the case. fan. (2) Unlatche. the backplane board installed in the case is connected to the main board with the connectors. USE STATIC PROTECTION. Lightly press the fan and battery. be sure that the battery is good (3.MAINTENANCE B-83525EN/01 7. ) (2) Detach cables from the connectors on the main board. Detach the main board by sliding the main board downward. The main board is equipped with battery-backed memory devices for holding robot parameters and taught data. turn off the main power of the controller.1. (See Subsection 7. and remove the (3) screws fastening the main board. When the main board is replaced.7. CAUTION Before starting replacement. the memory contents are lost.2 MAINTENANCE B-83525EN/01 Replacing the Main Board The backplane unit incorporates the backplane board. (1) Remove the case. (4) Install the case.REPLACING UNITS 7. The main board and fan board are connected directly with connector CA132.98 - . CA132 (2)Remove screws (3) Replace the main board with a new one. main board.1.1.1.1.) . (See Subsection 7. and option boards. Pull up the spacer metal fitting. If the FROM/SRAM module is replaced.99 - .7.7. make a backup copy of robot parameters and programs. 7. but push back the card softly. This completes the extraction of the card board. do not fully extract the card board. 4. When one side of the card board is raised slightly by pulling up. 7. When the card board is pushed back to be parallel with the main board. (Fig.2 (a)) 2. hold the neighborhood of the main board on the opposite side with the other hand whenever possible. pinch two sides of the card board and pull up the card board.2 (b) (Note: At this time. A force of 7 to 8 kgf is required for extraction. Insert a finger into the rear of the card and pull up the card slowly in the arrow direction.2 7. SRAM memory contents are lost. Card PCB Card PCB Spacer Card PCB Fig. Demounting a Card 1.2 (a) Demounting a card .REPLACING UNITS MAINTENANCE B-83525EN/01 REPLACING CARDS AND MODULES ON THE MAIN BOARD CAUTION Before you start to replace a card or module. (Fig.) 3. 3.) While aligning the board with the spacers.2 (b) Demounting a card Mounting a Card 1. Otherwise. Step 2 Step 3 Side view Fig. The force required for connector insertion is about 10 kgf.7.7.2 (d)) (do not press until aligned. (Fig. 2. 7. touch the spacer end faces of the board with the spacer.2 (d)) At this time. insert a finger into the rear of this point.7. re-check the alignment of the connector to prevent damaging the connector(s). (Fig. 4.7.) The mating position can be determined more easily by moving the card back and forth until the alignment “nubs” and “holes” are aligned on the connectors.2 (e)) Push in the spacer metal fitting to lock the board in place. (Fig. Spacer side Connector side 160-pin connector on the back Push back the card softly. (Fig.REPLACING UNITS MAINTENANCE B-83525EN/01 For extraction. The board must be turned to view the board connectors on the side. push on the back of the board over the connector. the board is touching the spacers only.2 (d)) (At this time.2 (f)) . 6.7. If the connector will not insert easily.7.7. do not press the radiation fin installed on the CPU and LSI chip. lower the connector side slowly until the connectors touch each other. the CPU or LSI chip can be damaged.100 - . (Fig. 5.2 (c)) To align the board insertion position. (Fig. then pull up the card in the arrow direction. Check that the metal fittings of the spacers are raised. In case that CPU CARD is standard. 2 (d) Mounting a card .REPLACING UNITS MAINTENANCE B-83525EN/01 Card PCB Fig.7.101 - .7.7.2 (c) Mounting a card Spacer Spacer fixing end face Spacer side Connector side 160-pin connector on the back Spacer Fig. 7.7.102 - .2 (e) Mounting a card Card PCB Card PCB Spacer Card PCB Fig. (Standard) Fig.REPLACING UNITS MAINTENANCE B-83525EN/01 Press here only for insertion.7.2 (f) Mounting a card . (b) (2) Push the module inward and downward until it is locked. (1) Move the clip of the socket outward. Mounting a module (1) Insert the module at a 30 degree slant into the module socket.REPLACING UNITS MAINTENANCE B-83525EN/01 Demounting a module CAUTION When replacing the module. wipe out dirt on the contact with a clean cloth.7. If you touch the contact inadvertently. with side B facing upward.2 (g) Demounting/mounting a module . be careful not to touch the module contact. (a) (2) Extract the module by raising it at a 30 degree slant and pulling outward.103 - .7. (c) (a) A Details of section A (b) Details of section A A (c) Fig. REPLACING UNITS MAINTENANCE B-83525EN/01 Figure 7. (3) Reconnect the cables. Axis control card CPU card FROM/SRAM module Fig. .3 (d) shows the locations of the cards and modules.2 (h) Locations of cards and modules 7.3 REPLACING THE E-STOP UNIT (1) Detach the cables from the E-stop unit.7.7. and replace the E-stop unit. (2) Remove (4) screws.104 - . (2) Unlock the nylon latches (4 places) holding the board.B-83525EN/01 7.REPLACING UNITS REPLACING THE EMERGENCY STOP BOARD (1) Detach the cables from the emergency stop board unit.4 MAINTENANCE 7. and replace the board. . (3) Reconnect the cables.105 - . 106 - .REPLACING UNITS 7. (3) Install a replacement power supply unit by reversing above steps.5 MAINTENANCE B-83525EN/01 REPLACING THE POWER SUPPLY UNIT (1) Detach the cable from the power supply unit.7. and remove the power supply unit. (2) Remove the (2) screws. (2) Screws Power supply unit Connector for cable . B-83525EN/01 7. because the regenerative resistor unit is very hot immediately after operation.107 - . and remove the rear plate. Install the replacement unit by reversing above steps.6 Regenerative resister (LR Mate 200iD) . 7. Remove the (4) screws on the regenerative resistor unit and remove it. (1) (2) (3) (4) Remove the (4) screws fastening the rear plate of the cabinet. 6-Axis servo amplifier Rear plate Regenerative resistor Fig.REPLACING UNITS REPLACING THE REGENERATIVE RESISTOR UNIT WARNING Before you start. Unplug connector CRR63 and CRR11 at the 6-Axis servo amplifier. turn off the controller main power. Be careful not to get burned.6 MAINTENANCE 7. LED：V4（red） . check the voltage at the screw above the LED “V4” with a DC voltage tester to see if the remaining voltage is not higher than 50V. Check that the voltage is not higher than 50V.108 - . for example. CAUTION Because the 6-Axis servo amplifier is heated immediately after operation.7. leave the 6-Axis servo amplifier until it cools down thoroughly.7 MAINTENANCE B-83525EN/01 REPLACING THE 6-AXIS SERVO AMPLIFIER WARNING Before touching the 6-Axis servo amplifier. (1) Check the voltage at the screw above the LED "V4" with a DC voltage tester to see if the remaining voltage is not higher than 50V.REPLACING A UNIT 7. before replacing it. for maintenance purposes. REPLACING A UNIT (3) Detach the cables from the 6-Axis servo amplifier. (6) Install a replacement amplifier by reversing above procedure. the controller falls down when the 6-Axis servo amplifier is removed. (4) Remove (2) screws fastening the 6-Axis servo amplifier.109 - . (2) Screws Fig. CAUTION If the controller is not fixed on the floor.MAINTENANCE B-83525EN/01 7.7 Replacing the servo amplifier (5) Hold the handle at the upper side of the amplifier and remove 6-Axis servo amplifier.7. . (2) Detach the cable from the teach pendant.110 - .REPLACING A UNIT 7. (1) Be sure that the power of a robot controller is off.7. check its specifications carefully. When you replace the teach pendant.8 MAINTENANCE B-83525EN/01 REPLACING THE TEACH PENDANT The specifications of the teach pendant vary with its use. (3) Replace the teach pendant.7. Detach or attach the cable by rotating the connector retaining ring. Fig.8 Replacing the teach pendant . (2) Pull out the fan motor to be replaced. Fig.9 Replacing the control section fan motor .111 - . (3) Install a new fan unit.B-83525EN/01 7. (1) Be sure that the power to the robot controller is turned off.7. The fan motor is mounted on the backplane unit.) Insert the unit until the latch snaps into the case.9 7. and unlatch the unit from the case. (Insert the unit until the latch of the unit snaps into the case. hold the latch of the fan unit.REPLACING A UNIT MAINTENANCE REPLACING THE CONTROL SECTION FAN MOTOR The control section fan motor can be replaced without using a tool.) Hold this part and pull out the motor. (When pulling out the fan motor. ) Open the cabinet door. or you could be injured. To replace the heat exchanger.10. Remove retaining (4) M5 nuts.1 Replacing the Heat Exchanger and Door Fan Unit (A-cabinet) The heat exchanger of the A-cabinet is inside its door. Mount the replacement unit by reversing above procedure.112 - . (2) Disconnect the connector at the FAN. and detach cables. Be careful not to let the cable get caught in the fan. 7. (3) Mount the replacement fan unit by reversing above procedure. Door fan unit (1) Remove (4) M4 screws.7. Heat exchanger (1) (2) (3) (4) Dismount the door fan unit.REPLACING A UNIT 7. it is necessary to remove the door fan unit in advance. (See the above procedure.10.10 MAINTENANCE B-83525EN/01 REPLACING THE AC FAN MOTOR WARNING Do not touch the fan motor when it is rotating. Door fan unit (M4 Screws(4)) Heat exchanger (M5 Nuts(4)) Fig.1 Replacing the heat exchanger and door fan unit .7. and dismount the unit. and the seven segment LED located on the main board displays “1” because the contents of memory have been lost. Turn the robot controller on for about 30 seconds. replace the battery as soon as possible. The above data is not lost even when the main power of controller is turned off. Battery replacement may. Turn the robot controller off. In general. When the voltage of the battery becomes low. . this depends on the system configuration.11. NOTE In a newly introduced robot. A new battery can maintain the contents of memory for about 4 years (Note). Important data should be saved to the memory card or other external device beforehand in case of emergency. and pull out the unit. the battery is factory-installed. If the battery voltage gets lower.7. Clear the entire SRAM memory and reenter data after replacing the battery. therefore. be needed within 4 years after the introduction of the robot. the battery can be replaced within one or two weeks. (Hold the latch of the battery unit. unlatch the battery unit from the case. When this alarm is displayed.1 Battery for Memory Backup (3 VDC) The programs and system variables are stored in the SRAM in the main board.113 - . it becomes impossible to back up the content of the SRAM. The power to the SRAM memory is backed up by a lithium battery mounted on the front panel of the main board. the low-voltage battery alarm (system-035) is displayed on the teach pendant.11 REPLACING THE BATTERY 7.). Pull out the battery unit located in the lower right part of the backplane unit. Hold this part and pull out the battery unit.REPLACING A UNIT MAINTENANCE B-83525EN/01 7. Cycling power to the controller in this state causes the system not to start. however. Replacing the lithium battery (1) (2) (3) (4) Prepare a new lithium battery (ordering drawing number: A05B-2650-K030). you should make a backup copy of the robot programs and system variables before replacing the battery.7. Note that keeping the control unit unconnected to a battery for a long period of time may result in the memory contents being lost. (Insert the battery unit until the latch of the unit snaps into the case. WARNING Using other than the recommended battery may result in the battery explosion. For a rainy day.) Check that the battery unit is latched securely. (5) Install a new battery unit.REPLACING A UNIT MAINTENANCE B-83525EN/01 Insert the unit until the latch snaps into the case. Dispose of the replaced battery as an industrial waste. . CAUTION Execute steps (3) to (5) within 30 minutes. Replace the battery only with the specified battery (A05B-2650-K030). according to the laws and other rules in the country where the controller is installed and those established by the municipality and other organizations that have jurisdiction over the area where the controller is installed.114 - . CONNECTIONS .II. . GENERAL GENERAL This section describes the electrical interface connections in the R-30iB Mate.CONNECTIONS B-83525EN/01 1 1. .117 - . It also includes information about installation of the R-30iB Mate. : Indicates mechanical connection.118 - . R-30iB Mate Pneumatic pressure source Mechanical unit End effector USB memory Teach pendant RS-232-C Peripheral device Welding machine Ethernet AC power supply NOTE : Indicates electrical connection.2 Block diagram of electrical interface connection . -------. Fig.BLOCK DIAGRAM 2 CONNECTIONS B-83525EN/01 BLOCK DIAGRAM Fig.2.2 is a block diagram of electrical interface connections with the R-30iB Mate. XROT) CNJx (Motor power/brake) (Motor power) CNGx End effector EE (Ground) (Note1) CRR88 (Brake control) Fig. RI/RO . It must be supplied by the customer. RI/RO.CONNECTIONS B-83525EN/01 3. XHBK.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS R-30iB Mate Robot Servo amplifier CRF8 RMP (Pulsecoder. (Pulsecoder.1 (a) Mechanical connection diagram NOTE 1 This cable is not included. .119 - . XROT) XHBK.ELECTRICAL CONNECTIONS 3 ELECTRICAL CONNECTIONS 3.3. 3.ELECTRICAL CONNECTIONS CONNECTIONS B-83525EN/01 R-30iB Mate Circuit breaker L1 L2 L3 PE Main board JRS27 CD38A,CD38B CRMA15,CRMA16 Input power (Note 2) (Note 2) (Note 1) External device Ethernet Peripheral device JRS26 Process I/O(Master setting) CNC, etc. (Slave setting) JD44A Process I/O, etc. (Slave setting) CRS36 Teach pendant Emergency stop board TBOP20 EES1 EES11 EES2 EES21 EAS1 EAS11 EAS2 EAS21 (Note 2) (Note 2) External emergency stop switch Fence NOTE 1 For detail of the peripheral device connection, see the section of Peripheral device interface. 2 This cable is not included. It must be supplied by the customer. Fig.3.1 (b) Unit-to-unit connection diagram - 120 - 3.ELECTRICAL CONNECTIONS CONNECTIONS B-83525EN/01 3.2 FANUC I/O LINK 3.2.1 Connection of I/O Link The connection of I/O links in the R-30iB Mate is shown below. 1. When the R-30iB Mate controller is used as the I/O link master (default) (When the R-30iB Mate controller controls the process I/O board etc.) To another I/O link JRS26 JD1B JD1A Process I/O board etc. R-30iB Mate 2. When the R-30iB Mate controller is connected to a CNC etc. via the I/O link JRS26 JD1B JD1B1 JD1A1 FANUC I/O link connection unit R-30iB Mate JD1B2 FANUC I/O Unit etc. JD1A2 JD1A JD1B FANUC I/O Unit etc. CNC 3. When the R-30iB Mate controller is used as an I/O link slave (When a CNC is the I/O link master) To another I/O link JD1A CNC JD1B JD1A JRS26 R-30iB Mate FANUC I/O Unit etc. Fig.3.2.1 Connection of I/O links - 121 - 3.ELECTRICAL CONNECTIONS 3.2.2 CONNECTIONS B-83525EN/01 Connection of the I/O Link Cable Cable cramp Main board To another I/O Link JRS26 JD44A(OPTION) Earth plate I/O Link cable Fig.3.2.2 (a) Path of the I/O link cable 1. 2. Connect the cable according to the system. Before connection turn off the power. Be sure to perform shielding. NOTE For connection with the CNC with I/O links, turn on or off the power of the CNC and the robot controller at the following timing. a) Slave units and the master must be powered on at the same time. b) If the CNC or robot controller is powered off after startup of the system, an I/O link error occurs. To successfully make connection with I/O links again, power off all of the units and then power them on at the timing indicated in a). 11 12 13 14 15 16 17 18 19 20 JRS26 interface 0V 01 0V 02 0V 03 0V 04 0V 05 0V 06 07 (+5V) 08 (24V) 09 (+5V) 10 RXSLC1 *RXSLC1 TXSLC1 *TXSLC1 RXSLC2 *RXSLC2 TXSLC2 *TXSLC2 (+5V) (24V) 11 12 13 14 15 16 17 18 19 20 Note: +5V is connected when the optical I/O link adapter is used. JD44A（Option） interface 0V 01 0V 02 0V 03 0V 04 0V 05 0V 06 07 (+5V) 08 (24V) 09 (+5V) 10 (Reserve) (Reserve) (Reserve) (Reserve) RXSLCS *RXSLCS TXSLCS *TXSLCS (+5V) (24V) Note: +5V is connected when the optical I/O link adapter is used. (1) Use a twisted-pair cable in which wires 1 and 2 are paired and wires 3 and 4 are paired. (2) Shield the cable collectively and ground the shield on the CNC side. - 122 - 3.ELECTRICAL CONNECTIONS CONNECTIONS B-83525EN/01 ・JRS26 JRS26 can be used as master interface or slave interface. Cable cramp Main board To another I/O Link JRS26 JD44A(OPTION) I/O Link cable When used as master interface JRS26 interface 11 12 13 14 15 16 17 18 19 20 0V 0V 0V 0V 0V 0V (+5V) (24V) (+5V) 01 02 03 04 05 06 07 08 09 10 RXSLC1 *RXSLC1 TXSLC1 *TXSLC1 RXSLC2 *RXSLC2 TXSLC2 *TXSLC2 (+5V) (24V) Note: +5V is connected when the optical I/O link adapter is used. 11 12 13 14 15 16 17 18 19 20 Master interface Earth plate When used as slave interface JRS26 Interface Refer to item 3 of Fig. 3.2.1 0V 01 RXSLC1 0V 02 *RXSLC1 0V 03 TXSLC1 0V 04 *TXSLC1 0V 05 RXSLC2 0V 06 *RXSLC2 07 TXSLC2 (+5V) 08 *TXSLC2 (24V) 09 (+5V) (+5V) 10 (24V) Note: +5V is connected when the optical I/O link adapter is used. - 123 - From Master controller To the next I/O link device 3.ELECTRICAL CONNECTIONS CONNECTIONS B-83525EN/01 ・JD44A JD44A is used to connect the Additional safety I/O board (Mini slot) Additional safety I/O board (Mini slot) Main board JD44A(Option) 11 12 13 14 15 16 17 18 19 20 0V 0V 0V 0V 0V 0V (+5V) (24V) (+5V) JD44A Interface 01 02 03 04 05 06 07 08 09 10 (Reserve) (Reserve) (Reserve) (Reserve) RXSLCS *RXSLCS TXSLCS *TXSLCS (+5V) (24V) Note: +5V is connected when the optical I/O link adapter is used. Example JD44A CRS38B R-30iB Mate CRS38A Additional safety I/O board （Mini slot） - 124 - uncoil the interconnection cables from their shipping position to prevent excessive heat. Non-flex type: usage is restricted to fixed laying Flex type: possible to use in the cable track . R-30iB Mate JD1A JRS26 [RX] SIN (1) [XRX] XSIN (2) (1) RXSLC1 (2) XRXSLC1 [TX] SOUT (3) (3) TXSLC1 [XTX] XSOUT (4) (4) XTXSLC1 0V (11) (11) 0V 0V (12) 0V (13) (12) 0V (13) 0V 0V (14) (14) 0V 0V (15) (15) 0V 0V (16) (16) 0V Fig.3.125 - .1 Robot Connection Cables CAUTION Before operating the robot. which may damage the cables.) There are two types of the robot connection cable.CONNECTIONS B-83525EN/01 3.3 EXTERNAL CABLE WIRING DIAGRAM 3. (Coiled part should be shorter than 10 meter.2.3.2 (b) Connection diagram of I/O Link cable 3.ELECTRICAL CONNECTIONS Cable connection diagram Master configuration I/Ounit etc. R-30iB Mate JRS26 JD1B RXSLC1 (1) XRXSLC1 (2) (1) SIN [RX] (2) XSIN [XRX] TXSLC1 (3) (3) SOUT [TX] XTXSLC1 (4) (4) XSOUT [XTX] 0V (11) (11) 0V 0V (12) 0V (13) (12) 0V (13) 0V 0V (14) (14) 0V 0V (15) (15) 0V 0V (16) (16) 0V Slave configuration CNC、PLC etc. Cable Route 6-Axis Servo amplifier Earth wire (Fix at the right side of the cabinet) RMP cable Earth plate Earth terminal Cable clamp CAUTION Signal cable should be clamped to Earth plate by cable clamp.g. (3) The cable should be fixed to the cable track by using the clamp.5 0.31 200 20.065 200 4.5 0.49 200 4. (e. (5) When cables are laid in the cable track. Power/Brake cable should be clamped to Earth plate by cable clamp.3 200 15.065 200 Using condition of flex type cable (1) When routing cables in movable places. .7 0.126 - .2 0. In case of CE controller. pay attention for the cable not to be twisted.3. use a cable bearer.ELECTRICAL CONNECTIONS CONNECTIONS B-83525EN/01 Specification of cable Robot RMP Signal Power Earth All models All models Diameter (mm) Non-flex type Weight Minimum (kg/m) bending radius (mm) Diameter (mm) Flex type Weight (kg/m) Minimum bending radius (mm) 14. (2) The bending radius (R) of the cable track is more than 200mm.7 0.71 200 15.5 0. rubber packing) (4) The size of the hole to support a cable in the cable track should be more than 110% of the cable size and should have the gap more than 3mm. BK) C NJ1A CN J2A CN J4 CNJ5 Fig.127 - .3. ROT) Motor power/brake (J1M. HBK.3. J4M. J5M.CONNECTIONS B-83525EN/01 3. R I/RO.2.ELECTRICAL CONNECTIONS Robot Model LR Mate 200iD Detail of cable connection to servo amplifier R-30iB Mate (Servo amplifier) CRR88 CN GA Robot CNJ3A CNJ6 CRF 8 RMP (Pulsecoder.3. J6M.1 Robot connection cable 3. J3M.3.2 Teach Pendant Cable Teach pendant Teach pendant cable Emergency stop board Fig.2 Teach pendant cable . J2M. 3.1 CONNECTIONS B-83525EN/01 Connecting the Input Power Connecting the input power cable (1) Fig3.3.3 3. However.3.1.3. Fig.3) Conductor size of AC Power supply cable 200V All models AWG14 to AWG10 (Note 1) Terminal size of AC power supply cable M5 Terminal Conductor size of earth size of earth cable cable WARNING 2 M5 WARNING 1 The input power cable according to the breaker or the fuse of the input power supply (power distribution panel) connected to the robot controller must be used.3.2.3. (2) Use the input power cable according to the following Table 3.3. Note）The cover should be replaced after completing Input power supply cable Earth cable (M5) Note）The cover should be replaced after completing WARNING The cover for primly terminal of main breaker should be replaced after completing.1 Conductor size and terminal size of AC power supply Input Voltage Input power source capacity (Refer to CONNECTIONS 5. the input power cable according to the breaker or the fuse of the input power supply (power distribution panel) connected to the robot controller must be used. Table 3. 2 Use conductor of earth cable size is as well as the AC power supply cable size.1 Connecting the input power cable .3.3. (3) Provide a class-D or better ground. 3 Disconnection of protective earth ground may impair the protection provided by the system.3. The resistance to the ground must not exceed 100Ω.128 - .3. Use a thick wire to withstand the maximum current used. There shall be no switches or disconnects in the grounding conductor.ELECTRICAL CONNECTIONS 3.1 shows the method of connecting the input power supply cable.2. .CONNECTIONS B-83525EN/01 3. (2) Leakage breaker using robot controller has sensitive electric current of 30mA.2 Example of leakage current circuit breaker for inverters Manufacture Type Fuji Electric Co. Matsushita Electric Works. Ltd. C type or later Leakage current circuit breaker. and amplifier.4 EG A series or later SG A series or later ES100C type or later ES225C type or later Leakage current circuit breaker.129 - . the shielded cable is recommended for the connection cable. Use the following leakage current circuit breaker for inverters to prevent incorrect operation. A high-frequency leakage current flows through the stray capacitance between the ground and the motor coils. Table 3.3. Ltd. Ltd.3. TBOP19 Emergency stop board TBOP20 Fig. KC type or later Connecting the External Emergency Stop After connecting the safety signals like external emergency stop signal and/or safety fence signal. power cable. Hitachi.3. verify that. ･All safety signals stop the robot as intended. and fasten this part to the earth plate with the cable clamp.3.2 3.3. ･There is no mistake in connection of safety signals.3..4 (a) Connecting the external emergency stop NOTE For protection against the noise. This might cause the leakage-current circuit breaker or leakage-protection relay installed in the path of the power supply to cut out.3.ELECTRICAL CONNECTIONS Leakage breaker (1) The motor is driven by the PWM inverter system using a power transistor bridge. Cut part of the jacket of the cable to expose the shield . 3. voltage Min. and fasten this part to the earth plate with the cable clamp. see Fig. load The contact is open when one of the TP emergency stop button or the Operator panel emergency stop button is pressed. 5 A resistor load (Reference value) DC5V 10mA NOTE For protection against the noise.ELECTRICAL CONNECTIONS CONNECTIONS B-83525EN/01 External emergency stop output TBOP20 No. Cut part of the jacket of the cable to expose the shield .3. Rated contact: 30 VDC. By connecting external power supply to the emergency stop circuit.3. the shielded cable is recommended for the connection cable.4 (b) Emergency stop board For the circuit. A (e) in Appendix A. "TOTAL CONNECTION DIAGRAM".130 - . Name 12 E-STOP (ESPB) 11 10 9 8 FENCE (EAS) 7 6 5 4 EMGIN (EES) 3 2 1 21 2 11 1 21 2 11 1 21 2 11 1 Fig. the contact works even while the robot controller is powered off. . Signal ESPB1 ESPB2 ESPB11 ESPB21 Description Current. (See “External power connection” of this section) The contact is closed during normal operation. The contact is also open while the controller is powered off regardless of status of emergency stop buttons.3. 3. or using a safety relay circuit that can detect the breakdown.ELECTRICAL CONNECTIONS CONNECTIONS B-83525EN/01 Internal circuit TP emergency stop button Operator panel emergency stop button +24EXT KA21 KA22 +24EXT 0EXT 0EXT ESPB1 ESPB11 WARNING Robot controller does not detect the breakdown of the contact of the emergency stop output signal.131 - . ESPB2 ESPB21 Example of the connection with the safety relay unit Robot controller Safety relay unit ESPB1 ESPB11 Control ESPB2 circuit ESPB21 Contact output signal ensured safety . Take countermeasures such as inspecting the duplicated contacts. . Cut part of the jacket of the cable to expose the shield .ELECTRICAL CONNECTIONS CONNECTIONS B-83525EN/01 External power connection TBOP19 No.3. if emergency stop output must not be effected controller’s power. and fasten this part to the earth plate with the cable clamp. Example of the connection In case of not using the external In case of using the external power source power source External power source EXT24V 24V EXT24V INT24V INT24V INT0V INT0V EXT0V 0V EXT0V +24V(±10%) more than 300mA NOTE For protection against the noise. Please connect external +24V instead of internal +24V. 4 3 2 1 Name EXT0V INT0V INT24V EXT24V External power source z +24V(±10%) z More than 300mA z EMC Compliant(CE mark controller) Emergency stop board The relays for emergency stop input and output can be separated from controller’s power. the shielded cable is recommended for the connection cable.132 - . 133 - . Use a contact which minimum load is 5 mA less. jumper them. When using the contacts of a relay or contactor instead of the switch. connect a spark killer to the coil of the relay or contactor. jumper them. Current. and fasten this part to the earth plate with the cable clamp. the shielded cable is recommended for the connection cable. See Chapter 7 in SAFETY PRECAUTIONS. These signals are used to stop the robot safely when the safety fence gate is opened during operation in the AUTO mode. the robot can be operated even when the safety fence gate is open. 2. voltage Open and close of 24VDC 0. (Note 2) In the T1 or T2 mode and the DEADMAN switch is held correct position. the robot stops according to predetermined stop pattern. When these terminals are not used.ELECTRICAL CONNECTIONS External emergency stop input TBOP19 No. Emergency stop board Signal EES1 EES11 EES2 EES21 EAS1 EAS11 EAS2 EAS21 Emergency stop board (B-cabinet) Description Connect the contacts of the external emergency stop switch to these terminals. NOTE For protection against the noise.1A (Note 1) NOTE 1. When the contacts are open. to suppress noise.CONNECTIONS B-83525EN/01 3. 4 3 2 1 Safety fence External emergency switch Name EXT0V INT0V INT24V EXT24V TBOP20 No. . the robot stops according to predetermined stop pattern. When these terminals are not used. remove the short-circuit plate. Name 12 E-STOP (ESPB) 11 10 9 FENCE 8 (EAS) 7 6 5 4 EMGIN (EES) 3 2 1 21 2 11 1 21 2 11 1 21 2 11 1 These terminals are factory-jumpered.1A (Note 1) Open and close of 24VDC 0. When using external emergency stop inputs. Cut part of the jacket of the cable to expose the shield . When the contacts are open in the AUTO mode. to suppress noise. (Note 2) When using the contacts of a relay or contactor instead of the switch. connect a spark killer to the coil of the relay or contactor. 4(c) Input timing of duplicate safety signals . The statuses of these duplicate input signals must always be changed at the same timing according to the timing specifications provided in this section. The robot controller always checks that the statuses of the duplicate inputs are the same. EES1 EAS1 Close Open EES2 EAS2 Close Open TDIF TDIF TOPEN TOPEN TDIF (input time difference)< 200msec TOPEN (input hold period) > 2sec Fig. safety fence signal. and if the controller finds a discrepancy.ELECTRICAL CONNECTIONS CONNECTIONS B-83525EN/01 Examples of connection of duplicate safety signals Correct connection Wrong connection External emergency stop switch External emergency stop switch EES1 EES1 EES11 EES11 EES2 EES2 EES21 EES21 Discrepancy in duplicate inputs results in an alarm.3. If the timing specifications are not satisfied. an alarm may be issued because of a signal discrepancy. and servo off signal so that a response is made even when a single failure occurs.3. Input timing of duplicate safety signals Duplicate inputs are used for signals such as the external emergency stop signal.3. it issues an alarm.134 - . CONNECTIONS B-83525EN/01 3. FANUC recommends the lever (A05B-2600-K030) for connecting the signal wire to the plug connector block instead of Flat-blade screwdriver. 4. Attach the plug connector block to the emergency stop board. FANUC's specification Manufacturer's specification (WAGO) A63L-0002-0154#104 734-104 A63L-0002-0154#112 734-112 A63L-0002-0154#402F A63L-0002-0154#230-M 734-402F 734-230 Remark 2 pieces of 734-230 and operation manual are included in FANUC's specification Detach the plug connector block from the emergency stop board. the emergency stop board may be damaged. Pull out the screwdriver. 5.ELECTRICAL CONNECTIONS Connecting external on/off and external emergency stop signal input/output wires 4-pole terminal block (TBOP19) 12-pole terminal block (TBOP20) Jumper pin Operation lever 1. . Insert the tip of a flat-blade screwdriver into the manipulation slot and push down its handle.135 - . 3. Insert the end of the signal wire into the wire slot. CAUTION Do not insert a wire into the wire hole of a plug connector or pull it out with the plug connector block mounted on the emergency stop board. 2. otherwise. 3.3.ELECTRICAL CONNECTIONS 3.136 - .3.3.5 6-axis servo amplifier CRR65 A/B A1 A2 A3 BKA1 B1 B2 B3 COMMON Specification TE Connectivity Specification Rece-housing Rece-contact 1-178128-3 175218-2 BKA2 COMMON FANUC Specification A63L-0001-0460#032KSX A63L-0001-0456#ASL .5 CONNECTIONS B-83525EN/01 Connecting the Auxiliary Axis Brake (CRR65 A/B) CRR65A/B Fig. CONNECTIONS B-83525EN/01 3.6 3.3.3.6 6-axis servo amplifier CRM68 A1 A2 A3 AUXOT1 AUXOT2 Specification TE Connectivity Specification Rece-housing Rece-contact 1-1318120-3 1318107-1 FANUC Specification A63L-0001-0812#R03SX A63L-0001-0812#CRM .3.ELECTRICAL CONNECTIONS Connecting the Auxiliary Axis Over Travel (CRM68) CRM68 Fig.137 - . 138 - . Figure 4 shows the locations of these boards and units. ARC WELDING. AND EE INTERFACES R-30iB Mate I/O peripheral device interfaces include printed circuit boards and a unit selected according to the applications..4(a) Connecting the peripheral device cable (CRMA15. No. AND EE INTERFACES 4 CONNECTIONS B-83525EN/01 PERIPHERAL DEVICE. Force sensor I/F Vision. ARC WELDING. HDI Peripheral device interface CRMA52A CRMA52B DI DO DI A05B-2650-J060 10 8 (Source) 10 Drawing number Peripheral device interface CRW11 WI WO D/A A/D A05B-2650-J061 Remarks 5 4(Sink) 2 Remarks DO 8 Option (Source) 0 Remarks Option Drawing number Remarks A05B-2650-J070 This option board converts peripheral device interfaces CRMA15 and CRMA16 of the main board to the MR connector manufactured by Honda Tsushin Kogyo Co. Force sensor I/F PMC.4. Name Drawing number 2 Process I/O board MA No. Table 4 lists details of the printed-circuit boards and units. LTD. 4 Name Connector converter board DO 8 (Source) 8 (Source) 8 (Source) DI 8 8 8 DO 16 (Source) 16 (Source) 16 (Source) Standard Vision. Name 3 Process I/O board MB No. Table 4 Peripheral device interface types Peripheral device interface Drawing number CRMA15 CRMA16 Name DI 1a Main board A A05B-2650-H001 20 1b Main board B A05B-2650-H002 20 1c Main board C A05B-2650-H003 20 No. PERIPHERAL DEVICE. Cable clamp Main board CRMA15 To Peripheral device CRMA16 Peripheral device cable Earth plate Fig. CRMA16) . AND EE INTERFACES CONNECTIONS B-83525EN/01 Process I/O board Connector converter board Cable clamp To Peripheral device Earth plate Peripheral device cable Process I/O MA CRMA52A CRMA52B Process I/O MB CRW11 I/O connector converter board CRMA58 CRMA59 Fig.139 - .4(b) Connecting the peripheral device cable (Process I/O board MA/MB) . PERIPHERAL DEVICE.4. ARC WELDING. 4. ARC WELDING. AND EE INTERFACES 4.1.4.140 - . Fig.4.1 In Case of Main Board (CRMA15.1.2 Block diagram of the process I/O MA .1 Block diagram of connecting peripheral device cable Name Drawing number 4.2 Length: 10m (CRMA15) Length: 10m (CRMA16) Length: 20m (CRMA15) Length: 20m (CRMA16) A05B-2650-J100 Peripheral device connection cable (For main board) Remarks A05B-2650-J101 In the Case of the Process I/O Board MA Main board Note) JRS26 (1) Process I/O Peripheral board MA device JD1B CRMA52A CRMA52B (2) (2) (Note) The connection depends on whether the R-30iB Mate is the I/O link master or an I/O link slave. PERIPHERAL DEVICE.1 CONNECTIONS B-83525EN/01 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM Following are a block diagram of the peripheral device interface and the specifications.1.1. CRMA16) Main board Peripheral Device CRMA15 CRMA16 Fig. For details.2. 4. see Section 3.1. 3 Remark - A05B-2650-J151 In the Case of the Process I/O Board MB Main board Note) JRS26 (1) Process I/O Welding board MB machine JD1B CRW11 (2) (Note) The connection depends on whether the R-30iBMate is the I/O link master or an I/O link slave.3 Block diagram of the process I/O MB Component (1) I/O link cable (2) Welding machine connection cable (For process I/O MB) (FANUC interface/elbow type) Drawing number Remark A05B-2650-J160 Included in the process I/O board MB Connection length 3m (one): CRW11 A05B-2650-J161 A05B-2650-J162 Connection length 7m (one): CRW11 Connection length 14m (one): CRW11 . ARC WELDING.1.4.2.141 - . For details.4. AND EE INTERFACES CONNECTIONS B-83525EN/01 Component Drawing number (1) I/O link cable Included in the process I/O board MA Connection length 10m (one): CRMA52 Connection length 20m (one): CRMA52 A05B-2650-J150 (2) Peripheral device cable (For process I/O MA) 4.1. Fig.1. see Section 3. PERIPHERAL DEVICE. 1. Fig. For details on the connection method. - .1.4. see "Connection between the peripheral devices and the controller".4 Connection diagram of the connector conversion board Component Drawing number Remark (1) Connection cable Included in the I/O connector conversion board. ARC WELDING.4. PERIPHERAL DEVICE.4 CONNECTIONS B-83525EN/01 In the Case of the Connector Conversion Board Main board (1) Connector conversion board device (Note) CRMA58 CRMA15 (1) CRMA16 Peripheral (Note) CRMA59 NOTE This component is not provided by FANUC. AND EE INTERFACES 4. The customer needs to obtain it.142 - . 143 - Remarks General signal .2 I/O SIGNALS OF MAIN BOARD There are 28 data inputs (DI) and 24 data outputs (DO) on main board. Table 4. AND EE INTERFACES CONNECTIONS B-83525EN/01 4. PERIPHERAL DEVICE. ARC WELDING.4. Table 4.2 I/O Signals of main board (1/2) Connector number CRMA15-A5 CRMA15-B5 CRMA15-A6 CRMA15-B6 CRMA15-A7 CRMA15-B7 CRMA15-A8 CRMA15-B8 CRMA15-A9 CRMA15-B9 CRMA15-A10 CRMA15-B10 CRMA15-A11 CRMA15-B11 CRMA15-A12 CRMA15-B12 CRMA15-A13 CRMA15-B13 CRMA15-A14 CRMA15-B14 CRMA16-A5 CRMA16-B5 CRMA16-A6 CRMA16-B6 CRMA16-A7 CRMA16-B7 CRMA16-A8 CRMA16-B8 Signal name DI101 DI102 DI103 DI104 DI105 DI106 DI107 DI108 DI109 DI110 DI111 DI112 DI113 DI114 DI115 DI116 DI117 DI118 DI119 DI120 XHOLD RESET START ENBL PNS1 PNS2 PNS3 PNS4 Description Peripheral device status Temporary stop External reset Start Operation enabled Program number .2 shows I/O signals of main board. ARC WELDING.4.144 - Remarks General signal .2 I/O Signals of main board (1/2) Connector number CRMA15-A15 CRMA15-B15 CRMA15-A16 CRMA15-B16 CRMA15-A17 CRMA15-B17 CRMA15-A18 CRMA15-B18 CRMA16-A10 CRMA16-B10 CRMA16-A11 CRMA16-B11 CRMA16-A12 CRMA16-B12 CRMA16-A13 CRMA16-B13 CRMA16-A14 CRMA16-B14 CRMA16-A15 CRMA16-B15 CRMA16-A16 CRMA16-B16 CRMA16-A17 CRMA16-B17 Signal name DO101 DO102 DO103 DO104 DO105 DO106 DO107 DO108 DO109 DO110 DO111 DO112 DO113 DO114 DO115 DO116 DO117 DO118 DO119 DO120 CMDENBL FAULT BATALM BUSY Description Peripheral device status During automatic operation Alarm Battery voltage drop During operation . PERIPHERAL DEVICE. AND EE INTERFACES CONNECTIONS B-83525EN/01 Table 4. AND EE INTERFACES CONNECTIONS B-83525EN/01 4. SDICOM2 → Selects a common for DI109～DI120. connect to 0V. When +24F common is used. .1 Connection between the Main Board (CRMA15.145 - . When 0V common is used. SDICOM1 → Selects a common for DI101～DI108. ARC WELDING.4. CRMA16) and Peripheral Devices Peripheral device control interface A1 (source type DO) CRMA15 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 A 24F 24F SDICOM1 0V DI101 DI103 DI105 DI107 DI109 DI111 DI113 DI115 DI117 DI119 DO101 DO103 DO105 DO107 0V DOSRC1 B 24F 24F SDICOM2 0V DI102 DI104 DI106 DI108 DI110 DI112 DI114 DI116 DI118 DI120 DO102 DO104 DO106 DO108 0V DOSRC1 Peripheral device A1 Peripheral device control interface A2 (source type DO) CRMA16 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 A 24F 24F SDICOM3 0V XHOLD START PNS1 PNS3 B 24F 24F 0V RESET ENBL PNS2 PNS4 DO109 DO111 DO113 DO115 DO117 DO119 CMDENBL BATALM DO110 DO112 DO114 DO116 DO118 DO120 FAULT BUSY 0V DOSRC2 0V DOSRC2 Peripheral device A2 SDICOM1～3 signal are common selection signal for SDI.3. PERIPHERAL DEVICE.3 INTERFACE FOR PERIPHERAL DEVICES 4. connect to +24F. B4.4. 2 The DOSRC1 and DOSRC2 pins of the CRMA15 and CRMA16 are pins for supplying power to drivers. AND EE INTERFACES CONNECTIONS B-83525EN/01 SDICOM3 → Selects a common for XHOLD、RESET、START、ENBL、PNS1～PNS4. (None of these pins can be left open. .3k CRMA15 (B5) DI102 RV Set this jumper according to the common DI103 RV voltage of input devices.) Controller (peripheral device control interface A1) +24E Peripheral device Connector pin No. common voltage of input devices is +24V.A19.A2. (ICOM1) DI104 RV CRMA15 (A6) CRMA15 (B6) CRMA15 (A7) DI105 RV DI106 RV DI107 RV DI108 RV SDICOM1 RV DI109 RV DI110 RV DI111 RV DI112 RV DI113 RV DI114 RV DI115 RV DI116 RV DI117 RV DI118 RV CRMA15 (B13) DI119 RV CRMA15 (A14) DI120 RV SDICOM2 RV CRMA15 (B7) CRMA15 (A8) CRMA15 (B8) CRMA15 (A3) CRMA15 (A9) CRMA15 (B9) CRMA15 (A10) CRMA15 (B10) CRMA15 (A11) CRMA15 (B11) CRMA15 (A12) CRMA15 (B12) CRMA15 (A13) CRMA15 (B14) CRMA15 (B3) CRMA15 (A4.146 - . NOTE 1 The peripheral device connection cables are optional. ARC WELDING. CRMA15 (A1.B1. PERIPHERAL DEVICE.B2) +24F FUSE3 Receiver circuit DI101 RV CRMA15 (A5) 3.B19) 0V NOTE In this diagram. B19) 0V A maximum output current per DO point is 0.4. PERIPHERAL DEVICE.147 - RELAY LOAD LOAD LOAD LOAD LOAD LOAD LOAD .B20) +24V 0V +24V regulated power supply Driver circuit DV LOAD DO101 CRMA15 (A15) DO102 DV DO103 DV DO104 DO105 DO106 DO107 DO108 DV DV DV DV DV CRMA15 (B15) CRMA15 (A16) CRMA15 (B16) CRMA15 (A17) CRMA15 (B17) CRMA15 (A18) CRMA15 (B18) CRMA15 (A4. CRMA15 (A20.2 A. AND EE INTERFACES CONNECTIONS B-83525EN/01 Controller (peripheral device control interface A1) Peripheral device DOSRC1 Connector pin No.B4. ARC WELDING.A19. . (ICOM1) ENBL RV PNS1 RV PNS2 RV PNS3 RV PNS4 RV SDICOM3 RV CRMA16 (A6) CRMA16 (B6) CRMA16 (A7) CRMA16 (B7) CRMA16 (A8) CRMA16 (B8) CRMA16 (A3) CRMA16 (A4.B4. ARC WELDING. CRMA16 (A1. common voltage of input devices is +24V.B2) Peripheral device +24F FUSE3 Receiver circuit XHOLD RV CRMA16 (A5) 3. PERIPHERAL DEVICE.A19.4.148 - .A2. AND EE INTERFACES CONNECTIONS B-83525EN/01 Controller (peripheral device control interface A2) +24E Connector pin No.B19) 0V NOTE In this diagram.B1.3k CRMA16 (B5) RESET RV Set this jumper according to the common START RV voltage of input devices. . B19) 0V A maximum output current per DO point is 0. PERIPHERAL DEVICE.B4.A19. ARC WELDING.149 - RELAY LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD . AND EE INTERFACES CONNECTIONS B-83525EN/01 Peripheral device Controller (peripheral device control interface A2) DOSRC2 Connector pin No.4. CRMA16 (A20.B20) +24V 0V +24V regulated power supply Driver circuit DV LOAD DO109 CRMA16 (A10) DO110 DO111 DO112 DO113 DO114 DO115 DO116 DO117 DO118 DO119 DO120 CMDENBL FAULT BATALM BUSY DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV CRMA16 (B10) CRMA16 (A11) CRMA16 (B11) CRMA16 (A12) CRMA16 (B12) CRMA16 (A13) CRMA16 (B13) CRMA16 (A14) CRMA16 (B14) CRMA16 (A15) CRMA16 (B15) CRMA16 (A16) CRMA16 (B16) CRMA16 (A17) CRMA16 (B17) CRMA16 (A4. .2 A. AND EE INTERFACES CONNECTIONS B-83525EN/01 The following shows the connector interface of the optional peripheral device cables on the peripheral device side. PERIPHERAL DEVICE. ARC WELDING.150 - 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SDICOM3 DO120 DO117 DO118 DO119 0V 0V DOSRC2 DOSRC2 DO109 DO110 DO111 DO112 DO113 DO114 DO115 DO116 24F 24F . Peripheral device A1 Controller CRMA15 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 DI101 DI102 DI103 DI104 DI105 DI106 DI107 DI108 DI109 DI110 DI111 DI112 DI113 DI114 DI115 DI116 0V 0V 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SDICOM1 SDICOM2 DI117 DI118 DI119 DI120 0V 0V DOSRC1 DOSRC1 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 DO101 DO102 DO103 DO104 DO105 DO106 DO107 DO108 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 CMDENBL FAULT BATALM BUSY 24F 24F Peripheral device A2 CRMA16 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 XHOLD RESET START ENBL PNS1 PNS2 PNS3 PNS4 0V 0V .4. AND EE INTERFACES CONNECTIONS B-83525EN/01 4. ARC WELDING. PERIPHERAL DEVICE.151 - Peripheral deviceC2 .3. see Section 4.2 Connection between the Connector Conversion Board and Peripheral Devices The connector interface of the optional connector conversion board is shown below. For electrical Controller Peripheral device control interface C1 (Honda Tsushin Kogyo MR-50RFD) CRMA58 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 DI101 DI102 DI103 DI104 DI105 DI106 DI107 DI108 DI109 DI110 DI111 DI112 DI113 DI114 DI115 DI116 0V 0V 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SDICOM1 SDICOM2 DI117 DI118 DI119 DI120 0V 0V DOSRC1 DOSRC1 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 DO101 DO102 DO103 DO104 DO105 DO106 DO107 DO108 Peripheral deviceC1 24F 24F Peripheral device control interface C2 (Honda Tsushin Kogyo MR-50RFD) CRMA59 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 XHOLD RESET START ENBL PNS1 PNS2 PNS3 PNS4 0V 0V 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SDICOM3 DO120 DO117 DO118 DO119 0V 0V DOSRC2 DOSRC2 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 CMDENBL FAULT BATALM BUSY DO109 DO110 DO111 DO112 DO113 DO114 DO115 DO116 24F 24F . connection.4.3.1. 2 The DOSRC3 pin of CRMA52A and CRMA52B supply power to the drivers (connect all pins).4.3 Controller CONNECTIONS B-83525EN/01 Connection between the Process I/O Board MA and Peripheral Devices Peripheral device control interface B1 (source type DO) CRMA52A 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 A 24F DI121 DI123 DI125 DI127 DI129 B 24F DI122 DI124 DI126 DI128 DI130 DO121 DO123 DO125 DO127 DO122 DO124 DO126 DO128 0V 0V DOSRC3 0V 0V DOSRC3 周辺機器 B1 Peripheral device control interface B2 (source type DO) CRMA52B 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 A 24F DI131 DI133 DI135 DI137 DI139 B 24F DI132 DI134 DI136 DI138 DI140 DO129 DO131 DO133 DO135 DO130 DO132 DO134 DO136 0V 0V DOSRC3 0V 0V DOSRC3 周辺機器 B2 NOTE 1 The peripheral device connection cable is optional. . AND EE INTERFACES 4. PERIPHERAL DEVICE.3. ARC WELDING.152 - . AND EE INTERFACES CONNECTIONS B-83525EN/01 +24E Connector pin N o.B1) Controller （Peripheral device control interface:B1） DI121 RV DI122 RV DI123 RV DI124 RV DI125 RV DI126 RV DI127 RV DI128 RV DI129 RV DI130 RV COM1 Peripheral device FUSE1 CRMA52A (A2) CRMA52A (B2) CRMA52A (A3) CRMA52A (B3) CRMA52A (A4) CRMA52A (B4) CRMA52A (A5) CRMA52A (B5) CRMA52A (A6) CRMA52A (B6) CRMA52A (A13. common voltage of input device is 24V.B13) RV +24E +24F B A 0V Common-level change-over setting pin (ICOM1) (This common voltage is for 24V. ARC WELDING.4. . PERIPHERAL DEVICE.B 15) +24V 0V +24V regulated power supply Driver circuit DV LOAD DO121 CRMA52A (A8) DO122 DO123 DO124 DO125 DO126 DO127 DO128 DV DV DV DV DV DV DV CRMA52A (B8) CRMA52A (A9) CRMA52A (B9) CRMA52A (A10) CRMA52A (B10) CRMA52A (A11) CRMA52A (B11) RELAY LOAD LOAD LOAD LOAD LOAD LOAD LOAD CRMA52A (A14. CRMA52A (A15. CRMA52A (A1.153 - .B14) 0V EXT0V NOTE In this diagram.) 0V EXT24V DOSRC3 Connector pin No. CRMA52B (A1.4.154 - .) 0V EXT24V DOSRC3 Connector pin No. ARC WELDING. AND EE INTERFACES CONNECTIONS +24E Connector pin N o.B1) Controller （Peripheral device control interface:B2） RV DI 132 RV DI 133 RV DI 134 RV DI 135 RV DI 136 RV DI137 RV DI138 RV DI139 RV CRMA52B (A6) DI140 RV CRMA52B (B6) Peripheral device CRMA52B (B2) CRMA52B (A3) CRMA52B (B3) CRMA52B (A4) CRMA52B (B4) CRMA52B (A5) CRMA52B (B5) RV +24E +24F FUSE1 CRMA52B (A2) DI 131 COM1 B-83525EN/01 CRMA52B (A13. CRMA52B (A15.B 14) 0V EXT0V NOTE In this diagram. .B15) +24V 0V +24V regulated power supply Driver circuit DV LOAD DO129 CRMA52B (A8) DO130 DO131 DO132 DO133 DO134 DO135 DO136 DV DV DV DV DV DV DV CRMA52B (B 8) CRMA52B (A9) CRMA52B (B9) CRMA52B (A 10) CRMA52B (B 10) CRMA52B (A11) CRMA52B (B11) RELAY LOAD LOAD LOAD LOAD LOAD LOAD LOAD CRMA52B (A14. PERIPHERAL DEVICE. common voltage of input device is 24V.B13) B A 0V Common-level change-over setting pin (ICOM2) (This common voltage is for 24V. AND EE INTERFACES CONNECTIONS B-83525EN/01 The following shows the connector interface of the optional peripheral device cables on the peripheral device side. ARC WELDING. Peripheral device A3 I/O board CRMA52A 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 DI121 DI122 DI123 DI124 DI125 DI126 DI127 DI128 DI129 DI130 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 DI131 DI132 DI133 DI134 DI135 DI136 DI137 DI138 DI139 DI140 19 20 21 22 23 24 25 26 27 28 29 30 31 32 0V 0V DOSRC3 DOSRC3 0V 0V 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 DO121 DO122 DO123 DO124 DO125 DO126 DO127 DO128 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 DO129 DO130 DO131 DO132 DO133 DO134 DO135 DO136 +24F +24F Peripheral device A4 CRMA52B 0V 0V . PERIPHERAL DEVICE.155 - 19 20 21 22 23 24 25 26 27 28 29 30 31 32 0V 0V DOSRC3 DOSRC3 +24F +24F .4. AND EE INTERFACES CONNECTIONS B-83525EN/01 4. . PERIPHERAL DEVICE. ARC WELDING.4 INTERFACE FOR WELDING MACHINES 4.4.156 - .4.1 Connection between the Process I/O Board MB and Welding Machines Controller Welding machine interface CRW11 01 02 03 04 05 06 07 08 09 10 A WI02 WI03 WI04 WI05 WI06 WO01 WO02 WO04 WO05 B 24F 24F 0V 0V WDI+ WDIDACH1 COMDA DACH2 COMDA Welding machine NOTE 1 The welding machine connection cable is optional. ARC WELDING. AND EE INTERFACES CONNECTIONS B-83525EN/01 Welding machine MS connector pin No.157 - .0k RV WI03 RV WI04 RV WI05 RV WI06 RV A B E F r +24F CRW11 (A1) d CRW11 (A2) e CRW11 (A3) f CRW11 (A4) g CRW11 (A5) h CRW11 (B3. WI/WO connection) . welding wire deposition detection. Controller（welding machine interface） Process I/O board MB Welding voltage specification signal Wire speed specification signal Connector pin No. CRW11 (B7) DACH1 CRW11 (B8) COMDA CRW11 (B9) DACH2 CRW11 (B10) COMDA +24E Arc detection signal Out-of-gus detection signal Broken-wire detection signal Out-of-coolingwater detection signal Arc-off detection signal (power supply abnormal) Connector pin No. CRW11 (B1.0A) 3.B4) m Receiver circuit (Photocoupler) 0V CRW11 (A6) DV Welding start signal 0V R WO01 0V Gas signal WO02 DV Wire inching (+) WO04 DV Wire inching (-) WO05 DV Wire deposition detection signal WDI+ WDI- CRW11 (A7) CRW11 (A8) CRW11 (A9) S U V R=100Ω or higher CRW11 (B5) N ＋ CRW11 (B6) P － ＋ － Welding power Cabinet ground (shield clamped) Welding machine frame ground Pin-to-pin connection between CRW11 connector and welding machine connector (FANUC interface) (analog output.4. PERIPHERAL DEVICE.B2) WI02 FUSE(1. 4. PERIPHERAL DEVICE, ARC WELDING, AND EE INTERFACES CONNECTIONS B-83525EN/01 4.5 INTERFACE FOR END EFFECTOR 4.5.1 Connection between the LR Mate 200iD and End Effector Example of the EE interface of the robot Fig.4.5.1 End effector interface NOTE RDO1 to RDO6 are used as the on/off signals of the solenoid valve option. For details, refer to the operator’s manual of the mechanical unit. NOTE For EE interface figures other than the above, refer to the operator's manual of each robot. - 158 - 4. PERIPHERAL DEVICE, ARC WELDING, AND EE INTERFACES CONNECTIONS B-83525EN/01 Mechanical unit (end effector interface) Peripheral device Connector pin No. +24VF EE(9,10) Receiver circuit RV RI1 RI2 0V RV RI3 RV RI4 RV RI5 RV RI6 (Pneumatic pressure abnormal signal XPPABN) EE (1) 3.3k EE (2) EE (3) EE (4) EE (5) EE (6) RV +24E B A Set this jumper or switch according to the common voltage of input devices. (COM1) 0V +24VF Driver circuit DV LOAD RO7 EE (7) RO8 EE (8) DV RELAY LOAD EE (11,12) 0V A maximum output current per RO point is 0.2A. NOTE 1 In this diagram, common voltage of input devices is +24V. 2 The common-level change-over setting pin or switch (COM1) is in the 6-axis servo amplifier. 4.6 DIGITAL I/O SIGNAL SPECIFICATIONS This section describes the specifications of the digital I/O signals interfaced with the peripheral device, end effector, and arc welder. 4.6.1 Peripheral Device Interface A (1) Output signals in peripheral device interface A (Source type DO) (a) Example of connection - 159 - 4. PERIPHERAL DEVICE, ARC WELDING, AND EE INTERFACES CONNECTIONS B-83525EN/01 Spark killer diode 0.2A or less (b) Electrical specifications Maximum load current when driver is on: Saturation voltage when driver is on: Dielectric strength: Leakage current when driver is off: 200mA (including momentary level) 1.0V max. 24V ±20% (including momentary level) 100μA (c) The external power supply to output signals must satisfy the following: Power supply voltage: +24V ±10% Power supply current: For each printed circuit board of this type (Total sum of maximum load currents including momentary levels + 100mA or more) Power-on timing: At the same time when the controller is turned on or earlier Power-off timing: At the same time when the controller unit is turned off or later (d) Spark killer diode Rated peak reverse voltage: Rated effective forward current: 100V or more 1A or more (e) Driver for output signals In the driver device, the current of each output signal is monitored, and when an overcurrent is detected, the relevant output is turned off. After an output has been turned off by overcurrent, the overcurrent state is released because the output is off, so the output on state is restored. Therefore, in the ground fault or overcurrent state, the output is turned on and off repeatedly. Such a condition is found also when a load with a high surge current is connected. The driver device also includes an overheat detection circuit, which turns off all outputs of the device when the internal temperature of the device has increased as a result of a continued overcurrent state due to a ground fault of an output and so on. The outputs are held off, but their normal states can be restored by turning the power to the controller on and off after the internal temperature of the device has lowered. (f) Note on use Do not use the +24V power supply of the robot. When adding a relay, solenoid, or the like directly to the circuit, connect a diode for counter electromotive voltage protection in parallel to the load. When using a load, such as a lamp, that generates surge current when it is turned on, install a protection resistor. (g) Applicable signals Output signals of main board I/O board CRMA15 and CRMA16 CMDENBL, FAULT, BATALM, BUSY, DO101 to DO120 Output signals of Process I/O board CRMA52A and CRMA52B DO01 to DO16 - 160 - 4. PERIPHERAL DEVICE, ARC WELDING, AND EE INTERFACES CONNECTIONS B-83525EN/01 (2) Input signals in peripheral device interface A (a) Example of connection +24V ＲＶ 3.3kΩ +24V Ｂ Ａ ＩＣＯＭ (b) Electrical specifications of the receiver Type: Grounded voltage receiver Rated input voltage: Contact close : +20V to +28V Contact open : 0V to +4V Maximum applied input voltage: +28VDC Input impedance: 3.3kΩ(approx.) Response time: 5ms to 20ms (c) Specifications of the peripheral device contact Voltage and Current: DC24V, 0.1A (Use a contact which minimum load is 5mA or less.) Input signal width: 200ms or more (on/off) Chattering time: 5ms or less Closed circuit resistance: 100Ω or less Opened circuit resistance: 100kΩ or more TB (Signal) TB (Signal) TB Peripheral device contact signal Robot receiver signal TC TC TB TC ; ; Chattering 5 ms or less 5 to 20 ms (d) Note on use Apply the +24 V power at the robot to the receiver. However, the above signal specifications must be satisfied at the robot receiver. (e) Applicable signals Input signals of main board CRMA15 and CRMA16 XHOLD, FAULT RESET, START, HOME, ENBL DI101 to DI120 Input signals of Process I/O board CRMA52A and CRMA52B - 161 - 4. PERIPHERAL DEVICE, ARC WELDING, AND EE INTERFACES CONNECTIONS B-83525EN/01 DI01 to DI20 4.6.2 EE Interface (1) Output signals in EE interface (a) Example of connection Spark killer diode +24V 0.2A or less 0V (b) Electrical specifications Maximum load current when driver is on: Saturation voltage when driver is on: Dielectric strength: Leakage current when driver is off : 200mA (including momentary level) 1.0V max. 24V ±20% (including momentary level) 100μA (c) Power supply to output signals The +24V power supply on the robot side can be used if the total current level, including the current of the welding interface, is 0.7A or less. (d) Driver for output signals In the driver device, the current of each output signal is monitored, and when an overcurrent is detected, the relevant output is turned off. After an output has been turned off by overcurrent, the overcurrent state is released because the output is off, so the output on state is restored. Therefore, in the ground fault or overcurrent state, the output is turned on and off repeatedly. Such a condition is found also when a load with a high surge current is connected. The driver device also includes an overheat detection circuit, which turns off all outputs of the device when the internal temperature of the device has increased as a result of a continued overcurrent state due to a ground fault of an output and so on. The outputs are held off, but their normal states can be restored by turning the power to the controller on and off after the internal temperature of the device has lowered. (e) Note on use When adding a relay, solenoid, or the like directly to the circuit, connect a diode for counter electromotive voltage protection in parallel to the load. When using a load, such as a lamp, that generates surge current when it is turned on, install a protection resistor. (f) Applicable signals RO1 to RO8 (2) Input signal in peripheral device interface The input signals are the same as those of other I/O boards. CONNECTIONS.) (a) Applicable signals RI1 to RI8, XHBK, XPPABN - 162 - (Refer to Subsection 4.5.1 in AND EE INTERFACES CONNECTIONS I/O Signal Specifications for ARC-Welding Interface (A-cabinet/Process I/O Board MB) (1) Specification for arc welding machine interface digital output signals (a) Example of connection スパークキラーダイオード Spark killer diode +24V 0.0V (c) Spark killer diode Rated peak-to-peak reverse withstand voltage: Rated effective forward current: 100V or higher 1A or more (d) Caution for use The arc welding machine interface can use the +24V power supply of the robot unless the sum of its sink current and that of the EE interface exceeds 0. connect the load and a back electromotive force voltage prevention diode in parallel. 2. PERIPHERAL DEVICE.2A 0. install a protection resistor. such as a lamp. When using a relay or solenoid directly as a load.6.2 A or less 以下 0V (b) Electrical specifications Rated voltage: Maximum applicable voltage: Maximum load current: Transistor type: Saturation voltage when the circuit is on: 24VDC 30VDC 200mA (including momentary level) Open-collector NPN Approximately 1. When using a load.7A.4.5] .3 4.B-83525EN/01 4. ARC WELDING.163 - . that generates surge current when it is turned on. (e) Applicable signals Arc welding machine interface output signals [WO1. ) Input signal width: 200ms or more (on/off) Chattering time: 5ms or less Closed circuit resistance:100Ω or less Opened circuit resistance: 100kΩ or more TB (Signal) TB (Signal) TB Peripheral device contact signal Robot receiver signal TC TC TB TC .4. (e) Applicable signals Arc welding machine interface input signals [WI2～6] . the above signal specifications must be satisfied at the robot receiver.) Response time: 5ms to 20ms (c) Specifications of the peripheral device contact Voltage and Current: DC24V. Chattering 5 ms or less 5 to 20 ms (d) Note on use Apply the +24 V power at the robot to the receiver.164 - .0kΩ(approx. However. PERIPHERAL DEVICE. AND EE INTERFACES CONNECTIONS B-83525EN/01 (2) Specification for arc welding machine interface digital input signals (a) Example of connection +24E RV 0V (b) Electrical specifications of the receiver Type: Grounded voltage receiver Rated input voltage: Contact close +20V to +28V Contact open 0V to +4V Maximum applied input voltage: +28VDC Input impedance: 3.1A (Use a contact which minimum load is 5mA less. . 0. ARC WELDING. The TIG welding deposition detection circuit must be isolated from the welding circuit (high frequency). This circuit can withstand up to 80 V. .165 - .3kΩ or higher Install a high-frequency filter.terminals of the welding machine must be 100 Ω or higher.4. WDI-) (b) Caution for use The resistance between the + and . ARC WELDING. AND EE INTERFACES CONNECTIONS B-83525EN/01 (3) Specification for arc welding machine interface analog output signals (welding voltage and wire feed speed specification signals) (a) Example of connection Welding machine 溶接機側 0V～＋15V 0V (b) Caution for use Input impedance: 3. +15V 85mA ‐ 溶接電極 Welding electrode (Wire deposition detection: WDI+. (Wire deposit detection: WDI+ and WDI-) (a) Example of connection 溶接機側 Welding machine + max. PERIPHERAL DEVICE. 40 pins) Tyco Electronics AMP 1-1827863-0(Housing) 1939991-2(Contact) Main board Honda Tsushin MR50LF01 (Connector) MRP-F112 (Contact) Peripheral device CRMA15 Tyco Electronics AMP 1-1939995-0 4.7.7 CONNECTIONS B-83525EN/01 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS If the customer manufactures cables.1 Peripheral Device Interface A1 Cable (CRMA15: Tyco Electronics AMP.166 - Peripheral device . make sure they conform to the FANUC standard cables described in this section.) 4. (See the description in "Peripheral Device Interface" in this manual for the specifications of the FANUC standard cables. PERIPHERAL DEVICE. AND EE INTERFACES 4. 40 pins) Main board Tyco Electronics AMP 2-1827863-0(Housing) 1939991-2(Contact) Honda Tsushin MR50LF01 (Connector) MRP-F112 (Contact) CRMA16 Tyco Electronics AMP 2-1939995-0 Honda Tsushin MR50RMH .2 Honda Tsushin MR50RMH Peripheral Device Interface A2 Cable (CRMA16: Tyco Electronics AMP.4. ARC WELDING.7. AND EE INTERFACES CONNECTIONS B-83525EN/01 4. Tyco Electronics AMP. PERIPHERAL DEVICE. 30 pin) Tyco Electronics AMP 1-1827863-5(connector) 1939991-2(contact) Process I/O board MA Peripheral device Honda Tsushin Kogyo MR50LF01 (connector) MRP-F112 (contact) CRMA52 Tyco Electronics AMP D-1100 series 30 pin X key 4.167 - Standard position of guide key . Tyco Electronics AMP D-2100 series 20pin X key Japan Aviation Electronics Industry Ltd. . ARC WELDING.7.3 Peripheral Device Interface B1 and B2 Cables (CRMA52.4. Tyco Electronics AMP.7.4 Honda Tsushin Kogyo MR50RMH ARC Weld Connection Cables (CRW11. 20 pin) ARC Welder Tyco Electronics AMP 1-1318118-9(connector) 1318106-1(contact) Process I/O CRW11 Japan Aviation Electronics Industry Ltd. AND ARC WELDERS 4. END EFFECTORS. Fig.8 CABLE CONNECTION FOR THE PERIPHERAL DEVICES.1 Peripheral Device Connection Cable Fig.8. and fasten this part to the earth plate with the cable clamp.8.168 - .1 shows the connection of the peripheral device cable in the cabinet. Cable clamp Main board CRMA15 To Peripheral device CRMA16 Peripheral device cable Earth plate Earth plate Cable Cable clamp Earth plate Shield Jacket NOTE For protection against the noise. cut part of the jacket of the connection cable to expose the shield.4. AND EE INTERFACES CONNECTIONS B-83525EN/01 4.4. ARC WELDING.8. PERIPHERAL DEVICE.4.1 Peripheral Device Cable Connection . 2 (a) Peripheral device cable connector .8 20.8.169 - .4.Y-key) CRMA16 1939991-2 (Contact) - Maintenance tool Hand tool (for crimping contact) Extraction tool A B 12.8. AND EE INTERFACES CONNECTIONS B-83525EN/01 4.9 E 32. ARC WELDING. PERIPHERAL DEVICE. Connector specifications Applicable interface 1-1827863-5 (Housing.6 Remark Tyco Electronics AMP D-1000 series 30pin Tyco Electronics AMP 1762846-1:A05B-2550-K060 1891526-1:A05B-2550-K061 Fig.4 Dimensions C D 28.2 Peripheral Device Cable Connector (1) The connector for peripheral device cables (Robot controller side).X-key) CRMA15 CRMA52 2-1827863-5 (Housing.4.0 30. 170 - . 50 pins Honda Tsushin Kogyo.4.2 (b) Peripheral device cable connector . AND EE INTERFACES CONNECTIONS B-83525EN/01 (2) The connector for peripheral device cables (Peripheral device side).8 Symbol 1 2 3 4 5 Remark Dimensions (B) C Honda Tsushin Kogyo.9 39. PERIPHERAL DEVICE.4. Connector specifications Applicable interface A MR50LM MR20LM - 67.5 44.8. 20 pins Name Connector cover Cable clamp screw Connector clamp spring Connector clamp screw Connector 50 pins (male) 20 pins (male) MR50M MR20M Fig.9 18 17 44. ARC WELDING.3 (D) 73.8 39. 9 Honda Tsushin Kogyo.4 39.4.171 - .6 x 8 Connector (MR50RF) (MR20RF) Fig. 20 pins Name Connector clamp screw Screw M2. 50 pins Honda Tsushin Kogyo. AND EE INTERFACES CONNECTIONS B-83525EN/01 (3) Peripheral device connector ， Connector specifications Applicable interface MR50RF MR20RF - 61.8.4.2 (c) Peripheral device connector .3 Symbol (1) (2) (3) Remark Dimensions A B 56. ARC WELDING.4 44. PERIPHERAL DEVICE. 4.1 φ0.18 AWG24 7/0.6 φ8. Table 4.5 1.172 - .5 φ10.0 1.3 (a). Table 4.58 40/0.7 2. Allow an extra 50 cm for routing the cable in the controller. PERIPHERAL DEVICE.6A (2) End effector connection cable Connect an end effector using a heavily protected cable with a movable wire conforming to the specifications in Table 4. AND EE INTERFACES 4.6A 1. and fasten this part to the earth plate with the cable clamp.08 AWG24 40/0. cut part of the jacket of the connection cable to expose the shield. heavily protected cable conforming to the specifications in Table 4.08 AWG24 1.3 CONNECTIONS B-83525EN/01 Recommended Cables (1) Peripheral device connection cable Connect a peripheral device using a completely shielded. . ARC WELDING.3 φ8. The maximum cable length is 30 m. The cable length is determined so that the cable will not interfere with the end effector and the wrist can move through its full stroke.8.5 φ12.5 106 106 1.3 (b).3 NOTE For protection against the noise.8.0 φ5.05 φ1.0 1.3 91 91 93 3.05 7/0.3 (a) Recommended Cable (for Peripheral Device Connection) Conductor Effective Electrical characteristics Wire specifications Sheath outside Conductor Number of wires (FANUC thicknes Diameter Allowable Configuration s (mm) diameter resistance specifications) (mm) current (A) (mm) (Ω/km) 50 20 A66L-0001-0042 A66L-0001-0041 φ1.18 AWG24 1.3 (b) Recommended Cable (for End Effector Connection) Conductor Effective Electrical characteristics Wire specifications Sheath outside Conductor Number of wires (FANUC thicknes Diameter Allowable diameter resistance Configuration specifications) s (mm) (mm) current (A) (mm) (Ω/km) 6 20 24 A66L-0001-0143 A66L-0001-0144 A66L-0001-0459 φ1.08 AWG24 40/0.3 2.8.8.8.1 φ1. 9 CONNECTION OF HDI 4. ARC WELDING.4.173 - .9. PERIPHERAL DEVICE. and fasten this part to the earth plate with the cable clamp. cut part of the jacket of the connection cable to expose the shield.1 Connecting HDI The HDI signals are used in combination with special application software. The HDI signals cannot be CRL3 R-30iB Mate Main board CRL3 1 HDI0 2 HDI1 3 0V 4 0V Cable connections CRL3 HDI0 0V HDI1 0V 1 3 2 4 Shield Ground plate Recommended cable connector: DF11-4DS-2C (Hirose Electric) NOTE For protection against the noise. . used as general-purpose DIs. AND EE INTERFACES CONNECTIONS B-83525EN/01 4. 9.6 0 to 1. AND EE INTERFACES 4.2 CONNECTIONS B-83525EN/01 Input Signal Rules for the High-speed Skip (HDI) Circuit configuration R-30iB Mate liL/liH FILTER DRIVER RECEIVER VH/VL SHIELD Absolute maximum rating Input voltage range Vin: -3.6 to 11.0 2 (max) 11 (max) -8. 2 The high-speed skip signal is assumed to be 1 when the input voltage is at the low level and 0 when it is at the high level. ARC WELDING.0 (max) 20 (min) 20 (max) Unit V V mA mA mA μs μs Remark Vin=5 V Vin = 10 V Vin = 0 V NOTE 1 The plus (+) sign of IiH/IiL represents the direction of flow into the receiver. PERIPHERAL DEVICE. .174 - .6 to +10 V Input characteristics Unit Symbol High level input voltage Low level input voltage High level input current VH VL liH Low level input current Input signal pulse duration Input signal delay or variations liL Specification 3. The minus (-) sign of IiH/IiL represents the direction of flow out of the receiver.4. AND EE INTERFACES CONNECTIONS B-83525EN/01 4.1 Interface JRS27 JRS27 1 2 3 4 5 6 7 8 9 10 RD (RXDA) SG (0V) DR (DSRA) SG (0V) CS (CTSA) SG (0V) +24V (24V-3) 11 12 13 14 15 16 17 18 19 20 SD (TXDA) SG (0V) ER (DTRA) SG (0V) RS (RTSA) SG (0V) Honda Tsushin Kogyo CONNECTOR: PCR-E20FS COVER: PCR-V20LA. or compatible connector +24V (24V-3) NOTE 1 +24 V can be used as the power supply for FANUC RS-232-C equipment. PERIPHERAL DEVICE.10.1 RS-232-C Interface 4. .175 - .10 CONNECTING THE COMMUNICATION UNIT 4. ARC WELDING.1. 2 Do not connect anything to those pins for which signal names are not indicated.4.10. 1. AND EE INTERFACES CONNECTIONS B-83525EN/01 4. RS/CS signals.1.3 Connection between RS-232-C interface and I/O device The figure below shows a connection with the handshaking of the ER/DR. R-30iB Mate I/O device side SD SD RD RD RS RS CS CS ER ER DR DR CD SG SG FG (Frame ground) FG FG . PERIPHERAL DEVICE.10.2 RS-232-C interface 4.10. R-30iB Mate Output SD (Send data) Input RD (Receive data) RS (Request to Send) When CS is not used short CS and RS. CS (Enable to send) When DR is not used short DR and ER. ER (Ready) DR (Data set ready) SG (Signal ground) FG (Frame ground) Fig.176 - .1.2 RS-232-C interface signals Generally signals as follows are used in RS-232-C interface.4.10.4. ARC WELDING. ARC WELDING. with shield Pair each signal with SG.4. PERIPHERAL DEVICE. ER/DR signals.18mm2. and fasten this part to the earth plate with the cable clamp. . cut part of the jacket of the connection cable to expose the shield.177 - . AND EE INTERFACES CONNECTIONS B-83525EN/01 • The figure below shows a connection without the handshaking of the RS/CS. NOTE For protection against the noise. R-30iB Mate SD SD RD RD RS RS CS CS ER ER DR DR External device side CD SG SG FG (Frame ground) FG FG Cable connection R-30iB Mate SD RD RS CS SG ER DR Cable : twist 10 pairs 0. Some devices (hub. In addition. Prepare a hub for connecting the controller to the Ethernet trunk. cable etc. PERIPHERAL DEVICE. etc. ARC WELDING. 100m .1 Connection to Ethernet The robot controller is provided with a 100BASE-TX interface.) that are needed for building a network do not come in a dust-proof construction. 2 Please inquire of each manufacturer (of hub.2 CONNECTIONS B-83525EN/01 Ethernet Interface This section describes information relating to the physical Ethernet connection. When configuring your network. Using such devices in an atmosphere where they are subjected to dust or oil mist will interfere with communications or damage the robot controller. CAUTION 1 Before connecting or disconnecting the Ethernet cable. make sure that the power to the robot controller is turned off.) about the construction of network or the condition of using the equipment. transceiver. After installing the robot.10. HUB : : : Twisted pair cable Robot controller Max. Be sure to install such devices in a dust-proof cabinet.10.4.2.178 - . We cannot ensure operation that is influenced by network trouble caused by a device other than the robot controller. you must take other sources of electrical noise into consideration to prevent your network from being influenced by electrical noise. and ground each of the devices as necessary. Make sure that network wiring is sufficiently separated from power lines and other sources of electrical noise such as motors. high and insufficient ground impedance may cause interference during communications. The following shows an example of a general connection. 4. AND EE INTERFACES 4. conduct a communications test before you actually start operating the robot. transceiver. 10.2. CD38B) Pin Assignments Pin No.2.3 100BASE-TX Connector (CD38A.179 - .4. Signal name 1 2 3 4 5 6 7 8 TX+ TXRX+ CD38A.CD38B Description Send + Send Receive + Not used Not used Receive Not used Not used RX- . ARC WELDING.10. This clamp is also used to ground the cable shield. PERIPHERAL DEVICE. 4. AND EE INTERFACES CONNECTIONS B-83525EN/01 4.2 Routing of the Ethernet Cable Ethernet cable Cable clamp Earth plate (Bending radius > 70mm) The Ethernet cable must be fastened by a cable clamp to prevent tension being applied to the modular connector (RJ-45) that connects the cable to the controller even if the Ethernet cable is pulled directly. 6 .2 3 RX+ RX+ 3 6 RX- RX. PERIPHERAL DEVICE.CD38B 1 2 3 4 5 6 7 8 TX+ TXRX+ HUB RJ-45 modular connector RXMAX. "X" is usually indicated at the port of the hub to signify that cables are crossed in the hub. The figure above shows the cable connection when cables are crossed in the hub.180 - .4 Twisted-pair Cable Specification Cable Connection The cable used for connection between the 100BASE-TX interface. AND EE INTERFACES CONNECTIONS B-83525EN/01 4. ARC WELDING. CD38.4.100m 1 2 3 4 5 6 7 8 TX+ TXRX+ RX- TX+ (1) (1) TX+ TX- (2) (2) TX- RX+ (3) (3) RX+ RX- (6) (6) RX- Shielded cable • • Keep the total cable length within 100 m. “X”: cross-connection inside the hub HUB R-30iB Mate 1 TX+ X TX+ 1 2 TX- TX.10. Do not extend the cable more than is necessary.2. of the controller and the hub is connected as follows: R-30iB Mate CD38A. PERIPHERAL DEVICE. LTD. NISSEI ELECTRIC CO. Ltd. 105-8458. Contact address Nagano Sales Office TEL:0266-27-1597 Tokyo Sales Office TEL:03-3492-0073 Specification • Electric characteristics: Conforms to EIA/TIA 568A Category 3 and Category 5. Remarks DTS5087C-4P F-4PFWMF Twisted-pair cable Single-conductor cable Inquiries Manufacturer Contact address FURUKAWA ELECTRIC CO. Shinko Electric Industrial Co.. Sales Headquarters NISSEI ELECTRIC CO.7 mm ±0. Recommended cable (Flexible cable) Manufacturer Oki Electric Cable Co. NOTE The recommended cables cannot be used for moving parts. Minato-ku. Chiyoda-ku. Ltd. Tokyo 194-0045 TEL: 0427-29-2531 FAX: 0427-29-3375 IWATANI International Corporation Tokyo Head Office 21-8 Nishi-shinbashi 3-chome. use shielded Category 5 twisted-pair cable (STP cable) to improve the resistance to electrical noise in an FA environment.. ARC WELDING. with a sheath thickness of 0. Tokyo 100-8322 TEL: 03-3286-3126 FAX: 03-3286-3979 3F MU Bldg..8 mm and an outer diameter of 6. Machida Branch Overseas Sales Office Remarks 2-6-1 Marunouchi. LTD..4.. • Fire retardancy UL1581 VW-1 • Oil resistance . however. • Structure: Group shielded (braided shield). From the viewpoint of attenuation performance... The conductor is an AWG26 annealed copper twisted wire. Specification AWG26 4P TPMC-C5-F (SB) FNC-118 Remarks Dedicated to FANUC Inquiries Manufacturer Oki Electric Cable Co. TOKYO.3 mm. AND EE INTERFACES CONNECTIONS B-83525EN/01 (1) Cable Materials CAUTION Unshielded cable (UTP cable) is commercially available as 100BASE-TX twisted-pair cable: You should. Ltd..181 - .. LTD. JAPAN TEL: 03-5405-5810 FAX: 03-5405-5666 Telex: 2524256 IWATYO J A finished cable with connectors at both ends can be offered. Ltd. LTD. Shinko Electric Industrial Co. Machida City. 1-9-1 Minami-narise. Recommended Cables (Non-flexible cable) Manufacturer Specification FURUKAWA ELECTRIC CO. ensure that the length to the hub is 50 m or less. A drain wire is available. 000.) ..182 - ... LTD. PERIPHERAL DEVICE. directly. AWM 20276 (80°C/30V/VW-1) NOTE Be sure to use the connector TM21CP-88P (03) manufactured by HIROSE ELECTRIC CO. LTD.. For assembly with a cable.000 times or more with a bending radius of 50 mm (U-shaped flex test) • UL style No... Ltd. "TM21CP-88P (03) Connection Procedure Manual (Technical Specification No. (From HIROSE ELECTRIC CO. ARC WELDING. LTD. Manufacturer type number: TM21CP-88P (03) Conforms to EIA/TIA 568A Category 3 and Category 5. LTD. • Flexing resistance: 1. Flex For cable AWG26 4P TPMC-C5-F (SB) or FNC-118 Specification TM21CP-88P (03) Manufacturer HIROSE ELECTRIC CO. Cable assembly Oki Electric Cable Co. packing. for this cable. contact HIROSE ELECTRIC CO. Non-Flex Specification Manufacturer Solid wire 5-569530-3 TE Connectivity Solid wire MS8-RSZT-EMC SK KOHKI CO. The following connectors or equivalents must be used. LTD. factory test. AND EE INTERFACES CONNECTIONS B-83525EN/01 Conforms to the FANUC internal standards (equivalent to the conventional oil-resistant electric cables). Remarks Special tools required Special tools required Remarks Note NOTE Information about TM21CP-88P (03): Connector (standard product of the manufacturer) Drawing number: A63L-0001-0823#P Manufacturer: HIROSE ELECTRIC CO... LTD. can also supply the cable assembly mentioned above.4.. LTD. ATAD-E2367)" is available as a technical document. Contact Oki Electric directly to determine the specifications (length. and so forth) for purchase. (2) Connector Specification Use an 8-pin modular connector (RJ-45) with the twisted-pair cable for the Ethernet connection. Twisted-pair cable 5-569552-3 TE Connectivity Twisted-pair cable TM11AP-88P HIROSE ELECTRIC CO. necessary to provide more noise resistance than that provided by general Ethernet wiring work. therefore. PERIPHERAL DEVICE. FL-net communication is not provided with a retransmission process at intervals of several seconds.2. Peel off part of the jacket as shown in the figure to expose the outer coating of the shield.B-83525EN/01 4. and press this outer coating against the earth plate with the cable clamp.183 - .5 Electrical Noise Countermeasures Clamping and Shielding Cables Clamp an Ethernet twisted pair cable according to the method described below. Never overlook cable clamping. conduct satisfactory communication tests not only before system operation but after system operation from the viewpoint of noise prevention measures. ARC WELDING. Clamping cables provides support and shielding and is extremely important to the safe operation of the system. as with cables that need to be shielded. 2 After the laying of cables. AND EE INTERFACES CONNECTIONS 4. clamp and shield the cables. The machine manufacturer must prepare the ground plate and install it as follows: Earth plate Cable Cable clamp Earth plate Shield Jacket NOTE To ensure the safe operation of the system.10. It is. unlike normal Ethernet communication. . NOTE 1 To secure fast response. Personal computer Switching HUB Note 2 Note 1 Hub power supply Note 2 Personal computer / HUB side Note 2 HUB Electrically separated by 100BASE-TX cable connection HUB STP cable STP cable Machine system Machine Ethernet Note 1 Note 1 Machine Note 1 Machine Note 1 Note 1 Note 1 Large-Scale Network Personal computer Hub power supply Note 2 HUB Note 1 Note 1 Personal computer/Ethernet trunk side Electrically separated by 100BASE-TX cable connection STP cable Machine system Ethernet Note 1 Machine Note 1 Small-Scale Network . the machine should be separated and insulated from the Ethernet trunk cable and personal computer. PERIPHERAL DEVICE. thus resulting in a communication error. Examples of connection are given below. the communication line can pick up noise from the machine.4.184 - . depending on the machine installation condition and environment. AND EE INTERFACES CONNECTIONS B-83525EN/01 Grounding the Network Even if the grounding condition on the machine side is satisfied. ARC WELDING. To protect against such noise. If it is impossible to separate the ground because there is only one grounding point. At least thickness of 5. FG Note 2 HUB Ground wire on personal computer and trunk sides Ground wire on machine system FG Ground wire on machine system Ground point Wiring on a single ground point .) The resistance for grounding must be less than 100-ohm (Class D). ARC WELDING.5mm2 is necessary. (See figure below.185 - . PERIPHERAL DEVICE.4. 2 Note that the number of allowable hub-to-hub connections depends on the type of hub. In the case of using the FAST Ethernet/FAST Data Server under the worst environment. connect the ground cable for each system to the grounding point independently. please separate between the PC/Trunk line side and machine system side completely using the 100BASE-FX (Optical fiber media). The thickness of the ground cable is the same as the thickness of AC power cable or more. 3 There is possibility that noise makes the obstacle of communication even if the ground is separated using the 100BASE-TX. AND EE INTERFACES CONNECTIONS B-83525EN/01 NOTE 1 The ground between PC/HUB side and machine system side must be separated. HUB Use conditions Grounding Cabinet Vibration Bending radius The "cautions on use" of the hub shall be observed (A terminating resistor shall be mounted properly if required).4. Any cable connector shall not be pulled (to prevent poor contact of the connector). For a twisted-pair cable.186 - Check .2. The bending radius shall be at least four times as long as the diameter of the cable. and others 2) Group B: Current DC (24 VDC) and others For a shielded cable.6 Check Items at Installation The following table lists check items at installation. 6 (RX-) The Ethernet cables shall be bound separately from the following cables or covered with an electromagnetic shield: 1) Group A: AC power lines. 1 (TX+) – pin No. 3 (RX+) – pin No. AND EE INTERFACES CONNECTIONS B-83525EN/01 4. . ARC WELDING. The hub shall be grounded.10. the following pins shall be paired: 1) Pin No. No cable shall be laid under a heavy object. The hub shall be installed so that it is not affected by vibration. Check item Description Ethernet cable Type Length Connection Separation Shielding Clamping Connectors Wiring Bending radius For movable part Use cables which satisfies all the following conditions: 1) With shielding 2) Twisted-pair cable 3) Category 5 The cable length shall be within 100 m (50 m for a movable cable recommended by FANUC). For a movable part. The bending radius shall be at least four times as long as the diameter of the cable. The ground plate shall be located as nearest to the CNC as possible (to make the cable between the ground plate and CNC hard to be affected by noise). the part of which outer coating is peeled off and exposed shall be fixed to the ground plate with a clamp fixture. 2 (TX-) 2) Pin No. a cable for a movable part shall be used. The hub shall be installed in an enclosed cabinet. PERIPHERAL DEVICE. power lines for motors. 5.5.CONNECTIONS B-83525EN/01 5 5.1 TRANSPORTATION The controller is transported by a crane. Crane capacity: Minimum 150kg Sling capacity: Minimum 150kg Eyebolt (M10) Fig.TRANSPORTATION AND INSTALLATION TRANSPORTATION AND INSTALLATION This chapter describes the transportation and installation for the controller. Attach a strap to eyebolts at the top of the controller.1 Transportation .187 - . 5.0GY8.2.TRANSPORTATION AND INSTALLATION CONNECTIONS 5.5 Gray Door 3.5/0.5.2 INSTALLATION 5.188 - 322 . panel N1.1 Installation Method B-83525EN/01 Following is the installation method for cabinet. When installing the controller.5 Black 400 Munsell 40 17 52 55 10 470 77 190 Fixing bolt (5)-M10 12 446 12 Fig. allow the space for maintenance shown in the following figure.1(a) External dimension . Color Body 5GY3.2.2/0.9 White Op. 2.5.2. 5.TRANSPORTATION AND INSTALLATION 100 CONNECTIONS B-83525EN/01 100 100 322 470 ° 480 120 Fig.2.2 Assemble at Installation Teach pendant (Hook is an option) R-30iB Mate controller Robot connection cable Peripheral device connection cable Fig.189 - .5.2 Assemble at installation .1 (b) Installation dimension NOTE Keep this area for maintenance and the radiation of heat.5. 5.5.190 - . Screw(M3) Mounting hole Teach Pendant HOOK Mounting plate for Teach Pendant (Provided by customer.3 CONNECTIONS B-83525EN/01 INSTALLATION OF TEACH PENDANT HOOK (Option) Following is external dimension for Teach Pendant HOOK (Ordering specification: A05B-2650-K050).3 External dimension of Teach Pendant HOOK .) Teach Pendant Fig.TRANSPORTATION AND INSTALLATION 5. Installation Category Ⅲ.4 5. Move error excess alarm. laser beams. the extreme current may flow to the robot controller instantaneously and the input voltage of robot controller will drop. Power supply alarm. 40kg IP54 NOTE The power rating indicated above is sufficient as the continuous rating.). In this case. Transport -20°C to 60°C Temperature change 0. ultraviolet rays. Operating: Up to 1000m Non-operating: Up to 12000m A shielding provision is necessary if the machine is installed in an environment in which it is exposed to radiation (microwave. However. and/or X-rays). etc.5G or less When using the robot in a location subject to serious vibration.191 - . no condensation An additional protective provision is necessary if the machine is installed in an environment in which there are relatively large amounts of contaminants (dust. . Pollution Degree 3.CONNECTIONS B-83525EN/01 5. acid. no condensation Short period (less than 1 month): 95%RH or less.TRANSPORTATION AND INSTALLATION INSTALLATION CONDITION Item Rated Voltage Model Specification/condition All models 200-230VAC 50/60Hz Single phase Tolerant fluctuation All models 200-230VAC 50/60Hz 3 phase Tolerant voltage fluctuation: +10% -15% Tolerant frequency fluctuation: ±1Hz Input power source capacity Average power consumption Permissible ambient temperature LR Mate 200iD LR Mate 200iD All models Permissible ambient humidity All models Surrounding gas All models Installation Category All models Vibration All models Altitude All models Ionized and non-ionized radiation All models Mass of controller Degree of protection All models All models 1.5kW Operating 0℃ to 45°C Storage. organic solvent. If the acceleration/deceleration override (ACC) greater than 100% is set in the robot program. when the robot is rapidly accelerating. corrosive gas. consult with your FANUC sales representative. dielectric fluid. DCLV alarm of servo amplifier may occur. IEC60664-1 and IEC61010-1 0. salt. if the supply voltage is decreased 10% or more per rated voltage. the instantaneous requirement may increase to several times the continuous rating.2kVA 0.3°C/minute or less Normal: 75%RH or less. in the form of electromagnetic radiation.192 - .TRANSPORTATION AND INSTALLATION CONNECTIONS B-83525EN/01 NOTE In case of CE controller R-30iB Mate controller is a group 1. class A product according to IEC55011. due to conducted as well as radiated disturbances. . inductive and/or capacitive coupling. This means that this product does not generate and/or use intentionally radio-frequency energy.5. This product may cause interference if used in residential areas. This product must not be used in residual areas. Such use must be avoided unless the user takes special measures to reduce electromagnetic emissions to prevent interference to the reception of radio and television broadcasts. for the treatment of material or inspection / analysis purpose and that it is suitable for use in all establishments other than domestic and those directly connected to a low voltage power supply network which supplies buildings used for domestic purposes. There may be potential difficulties in ensuring electromagnetic compatibility in environments other than industrial. 5. The breaker off and connect the input power cable.A2. Therefore. Press the EMERGENCY STOP button on the operator panel and turn on the controller. Check the movement along each axis in manual jog mode.6. 1 2 3 4 5 6 7 8 9 10 11 12 13 5.6 Description Visually check the inside and outside of the controller. Check the screw terminals for proper connection.B2 +24F XHOLD A5 ENBL B6 RV RV . This section describes how to reset the overtravel and emergency stop. If necessary. Check the parameters. Check the input power voltage. connect these signals as follows.5 5.B1. No.TRANSPORTATION AND INSTALLATION ADJUSTMENT AND CHECKS AT INSTALLATION Adjust the robot according to the following procedure at installation. RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION An overtravel and emergency stop occur when the robot is operated for the first time after it is installed and the mechanical and controllers are wired. Connect controller and mechanical unit cables. Check that the connectors and printed circuit boards are firmly connected. Check the peripheral device control interface signals. an overtravel alarm occurs when the power is turned on after installation. CRMA16 A1.CONNECTIONS B-83525EN/01 5.1 Peripheral Device Interface Processing If signals XHOLD and ENBL are not used. Release the EMERGENCY STOP button on the operator panel. set them. Check the interface signals between controller and robot mechanical unit. The robot can also be in an emergency stop state if the peripheral device control interface is not connected. Remove the red plate fastening the swiveling axis beforehand.193 - . The J2 and J3 axes are pressed against the hard stops at shipment. Check the signals of EE interface. alarm "Servo 300" or "Servo 302" occurs. SRVO-300 NOTE 1 Robot EE connector CLOSE OPEN 24V 24V XHBK XHBK 2 The moment the HBK circuit is closed. Select "Config" to disable/enable PPABN.TRANSPORTATION AND INSTALLATION 5. 5.3 1) 2) 3) 4) 5) How to Disable/Enable HBK Press [MENUS] on the teach pendant. and jog to bring all axes into the movable range.194 - . Press "F1" (TYPE) on the teach pendant. Hold down the shift key.2 1) CONNECTIONS B-83525EN/01 Resetting Overtravel Select [OT release] on the overtravel release screen to release each robot axis from the overtravel state. 2) 3) 5. When the HBK circuit is opened again. Select "Config" to disable/enable HBK. and press the alarm release button to reset the alarm condition.4 1) 2) 3) 4) 5) How to Disable/Enable Pneumatic Pressure Alarm (PPABN) Press [MENUS] on the teach pendant. Select [NEXT]. Still hold down the shift key. . causing the robot to stop. Select [NEXT]. 3 If the power is turned off and on again under the condition stated in *2. status 4 is entered.6. Select [SYSTEM].5. HBK detection becomes enabled. Press "F1" (TYPE) on the teach pendant.6. Select [SYSTEM]. Status Hand Broken enable/disable setting HBK (*1) HBK detection Robot operation Message 1 2 3 4 Enable Enable Disable Disable CLOSE OPEN CLOSE OPEN Yes Yes Yes (*2) No Possible Impossible Possible Possible None SRVO-006 None At cold start. so the alarm condition is removed.6. APPENDIX . . 197 - .TOTAL CONNECTION DIAGRAM TOTAL CONNECTION DIAGRAM .B-83525EN/01 A APPENDIX A. In case of three phase input.A(b)) .A.198 - .TOTAL CONNECTION DIAGRAM APPENDIX B-83525EN/01 Fig. See the Fig.A (a) System block diagram (This diagram shows the single phase input circuit. A(b) AC power line connection diagram (in case of three phase input) .TOTAL CONNECTION DIAGRAM Fig.199 - .B-83525EN/01 APPENDIX A. A(c) AC power line connection diagram (in case of single phase input) .200 - B-83525EN/01 .TOTAL CONNECTION DIAGRAM APPENDIX Fig.A. 201 - .B-83525EN/01 APPENDIX A.A (d) DC power line connection diagram .TOTAL CONNECTION DIAGRAM Fig. 202 - .A.TOTAL CONNECTION DIAGRAM APPENDIX B-83525EN/01 Fig.A(b)) .A (e) Emergency stop circuit connection diagram (This diagram shows the single phase input circuit. See the Fig. In case of three phase input. TOTAL CONNECTION DIAGRAM .B-83525EN/01 APPENDIX .203 - A. A.TOTAL CONNECTION DIAGRAM APPENDIX Fig.204 - B-83525EN/01 .A (f) Emergency stop board connector table . B-83525EN/01 APPENDIX A.205 - .TOTAL CONNECTION DIAGRAM Fig.A (g) Main board connector table . TOTAL CONNECTION DIAGRAM APPENDIX Fig.206 - B-83525EN/01 .A (h) Operator’s panel connection diagram .A. 207 - .A (i) Operator’s panel/Teach pendant connector table .B-83525EN/01 APPENDIX A.TOTAL CONNECTION DIAGRAM Fig. 208 - B-83525EN/01 .TOTAL CONNECTION DIAGRAM APPENDIX Fig.A (j) 6-Axis Servo amplifier connector table .A. B-83525EN/01 APPENDIX A.209 - .TOTAL CONNECTION DIAGRAM Fig.A (k) Motor power connection LR Mate 200iD (6-Axis) . 210 - .TOTAL CONNECTION DIAGRAM APPENDIX B-83525EN/01 Fig.A. The detail is shown on the mechanical unit manual.A (l) RI/RO connection diagram (There are many type EE connector of mechanical unit.) . B-83525EN/01 APPENDIX A.211 - .A (m) Pulsecoder signal connection diagram .TOTAL CONNECTION DIAGRAM Fig. A (n) Mechanical unit interface .A.TOTAL CONNECTION DIAGRAM APPENDIX Fig.212 - B-83525EN/01 . 1) Description Instantaneous stop signal Hold signal Safety speed signal Cycle stop signal Alarm release signal Cycle start signal Robot service request/program number select signal (*1) Enabling signal Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) PNS strobe signal Automatic operation start signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal .213 - .1 B.APPENDIX B-83525EN/01 B B.3.SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE SIGNAL The following table lists the I/O signals used for the peripheral device interface in the R-30iB Mate controller. Signal *IMSTP *HOLD *SFSPD CSTOPI FAULT_RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSTROBE PROD_START DI01 DI02 DI03 DI04 DI05 DI06 DI07 DI08 DI09 DI10 DI11 DI12 DI13 DI14 DI15 DI16 DI17 DI18 DI19 DI20 DI21 DI22 Input signals (Refer to B. 3.SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE NOTE *1: RSR: PNS: *1: RSR: PNS: APPENDIX Robot Service Request (RSR5 to RSR8 are optional) Program Number Select Input (optional) Whether RSR is used or PNS is used can be preset.B.2) Description Command acceptance enabled signal System ready signal Program run signal Program paused signal Held signal Alarm signal Reference point signal Teach pendant enabled signal Battery alarm signal Operating signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal PNS acknowledge signal Not used (for future expansion) DO01 DO02 DO03 DO04 DO05 DO06 DO07 DO08 DO09 DO10 DO11 DO12 DO13 DO14 DO15 DO16 DO17 DO18 DO19 DO20 General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal Signal . Robot Service Request (RSR5 to RSR8 are optional) Program Number Select Input (optional) Whether RSR is used or PNS is used can be preset. CMDENBL SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK ______ Output signals (Refer to B.214 - B-83525EN/01 . 3.3 I/O SIGNALS B. the alarm display on the teach pendant (the top line) is cleared. use the external emergency stop signal. . is remains at +24V. See the description of CMDENBL in Section B.$CONT_ONLY is set to ENABLED. The system automatically adjusts the polarity by software according to the status of this pin. the program starts from the current cursor position. To execute an inactivated program from the start. the START signal only resumes the execution of the temporarily held program. the START signal starts the program which has been selected from the teach pendant. Do not use *IMSTP as safety relevant signal. it also turns on the unit.3. If the servo unit has been turned off. Description: This signal releases only the alarm status. Therefore.If parameter $SHELL_CFG. *IMSTP *HOLD *SFSPD CSTOPI B. The system turns off power to the servo unit when the *IMSTP is open (turned off).2 B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE SETTING COMMON VOLTAGE All process I/O boards have a jumper to set the common voltage of input signals to 0 V or 24 V. To ensure safety. $CONT_ONLY.$CONT_ONLY is set to DISABLED.APPENDIX B-83525EN/01 B. Its function differs according to the setting of parameter $SHELL_CFG. you can operate the system without being concerned about the setting of the common voltage. By default. The *HOLD signal has the same function as the hold button on the teach pendant. (1) Instantaneous stop signal (input) *IMSTP Effective: At any time Function: Use the normally closed switch because it is a reverse signal. input the PROD_START signal. the held signal (output) HELD is turned on and the robot cannot be operated.If parameter $SHELL_CFG. For safety purpose. The robot will keep running if the signal is triggered "ON" during operation. At the same time. the common reference voltage of the following four signals.2 (1) for details. It does not re-start execution of the program. While this signal is being input. Function: This input signal starts the selected program at the falling edge when the signal is turned off after being turned on. It halts the current program and stops the operation of the robot. (3) Hold signal (input) *HOLD Effective: At any time Function: Use the normally-closed switch because it is a reverse signal.1 Input Signals This section describes the specifications of each input signal. . (2) Alarm release signal (input) FAULT RESET Effective: In the alarm status Function: The FAULT RESET signal releases the alarm status.215 - . . (4) Start signal (input) START Effective: When the command acceptance enabled signal (output) CMDENBL is turned on. .) .216 - . . are used.The user can choose between RSR and PNS (optional). RSR1 to RSR4. (7) Safety speed signal (input) *SFSPD Effective: At any time Function: . See the description of CMDENBL in Section B. the overriding value is switched to a preset value (parameter $SCR. and the execution of the current program is suspended. . $SFRUNOVLIM : For test execution.If parameter $SHELL_CFG.Use the normally-closed switch because it is a reverse signal. a specified program is started. (Refer to the application manual for details of the menu). . It does not stop the execution of the current program and allows it to continue processing (by default).$USE_ABORT is set to ENABLED. the newly activated program enters the wait status. . .By using an RSR instruction. although they cannot be used simultaneously.Since the *SFSPD signal is counted as a remote condition. . and the information for the subprogram to return to the main program is lost. this signal also releases the program from the wait status caused by RSR.3. .2 (1) for details. $SCR. such input signals as RSR and START to the peripheral device interface cannot take effect unless this signal is turned on.$SFJOGOVLIM: For jog. Usually this switch should be connected to safety fence. Function: .SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE APPENDIX B-83525EN/01 (5) Cycle stop signal (input) CSTOPI Effective: At any time Function: . It must be set normally on.As long as this signal is off.$USE_ABORT is set to DISABLED.If parameter $SHELL_CFG.If this signal is turned from on to off during robot operation. . each RSR in a program can be enabled or disabled.If a signal is input to an RSR input.) (8) Robot service request signal (input) RSR1/RSR2/RSR3/RSR4 Effective: When the command acceptance enabled signal (output) CMDENBL is turned on. The program number can be set by a menu. $FENCEOVER. (6) Enabling signal (input) ENBL Effective: At any time Function: If the ENBL signal is turned off. At the same time. the operation of the robot or the activation of a program is inhibited. the CSTOPI signal immediately cancels the execution of the current program. The program returns to the status in which it was before execution. the CSTOPI signal releases the program from the wait status caused by an RSR. the waiting program starts processing.If another program has already started processing. As soon as the current program terminates.Four input signals. the overriding value cannot be increased beyond the preset value ($SCR. At the same time.B. the execution of the current program is suspended.A menu is provided to register the program number of a specified program when each RSR is input. See the description of CMDENBL in Section B. Function: .. . the width of the pulse can also be specified.A menu is provided to specify the information about PNS.217 - . Input of a CSTOPIT signal can clear the program queue waiting for execution after acceptance of RSRs.2 (1) for details. the program whose program name consists of the specified program number plus a base value is started.e. (9) PNS/PNSTROBE (input) Signal name: PNS: Program number select PNSTROBE: Strobe input for PNS Effective: When the command acceptance enabled signal (output) CMDENBL is turned on. $SHELL_ CFG. . If the PNS function is enabled. . the RSR function cannot be used. if a signal is input to RSR2 when program number 23 is registered in RSR2. (For example. If so specified. a pulse is output from the signal corresponding to the RSR.APPENDIX B-83525EN/01 - - - B. For example.3.The eight signals PNS1 to PNS8 are used to specify a program at the instant the strobe signal PNSTROBE rises. From the same menu.The PNS/PNSTROBE signal selects whether the RSR function is used or the PNS function (optional) is used.$JOB_BASE. In this way. RSR0123. when the input of the RSR is accepted. Whether the system should output an acknowledge signal to an RSR can be selected from the menu. $JOB_BASE =100). and can be changed in a program with a parameter instruction. the program to be started is the one with the program name calculated from the expression RSR + (RSR2 program number + base number). The base number is stored in parameter $SHELL_CFG. It is possible to accept other RSRs while outputting an acknowledge signal. the combination of programs which can be started by RSRs can be changed. one of signals ACK1 to ACK4. i.SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE When an RSR is input. . Using these signals. i. if the PNS value is 23. For safety. B. A PNS signal. See the description of CMDENBL in Section B.$USE_ ABORT is set to ENABLED. the program to be started has the program name calculated from the expression PNS + (entered PNS value + base number).3.The teach pendant is in the DISABLED status. The remote conditions are satisfied when all of the following are satisfied. PNS0123.$CONT_ ONLY is set to ENABLED. a program is selected whose program number is the entered value plus the base number. peripheral devices can confirm the correct program has been selected. For example. see the sections describing SNO and SNACK. . Turned off: When the remote conditions are not satisfied or the system is in the alarm status.2 (1) for details. You can: Start up a program by input of automatic operation start signal PROD_START Restart the program that has been suspended. . The execution of the selected program can only be started after input of automatic operation start signal PROD_START. If zero is entered to PNS input.Parameter $RMT_MASTER is set to 0 (external interface).3. the selected program cannot be changed from the teach pendant unless PNSTROBE is turned off. the program number is output to selected program number signal (output) SNO.The remote/local setting is set to REMOTE. which can only select a program.e. cannot execute the selected program. The following operations are effective for the program selected by PNS.2 Output Signals This section describes the specifications of output signals for the peripheral device interface. . Function: This input signal executes the selected program at the falling edge when the signal is turned off after being turned on.B. and a pulse is output to program selection acknowledge signal SNACK. Input of CSTOPI cancels execution of the pro-grams selected by PNS when $SHELL_CFG.218 - . (1) Command acceptance enabled signal (output) CMDENBL Turned on: When the remote conditions are satisfied and the system is not in the alarm status. Inputting the START signal restarts the program selected by PNS when $SHELL_CFG. If a program is selected by PNS. (10) Automatic operation start signal (input) PROD_START Effective: When the command acceptance enabled signal (output) CMDENBL is turned on. it is cleared as if no selection has been made.SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE - - - - APPENDIX B-83525EN/01 If a number other than zero is entered to PNS input. For the timing of these signals.. 219 - . Turned off: When the hold button on the teach pendant (or input) is not being pressed down (or is turned off).) (8) Teach pendant enabled signal (output) TPENBL Turned on: When the teach pendant is enabled. (2) System ready signal (output) SYSRDY Turned on: When power is applied to the motor of the robot. but this signal is output when the robot is in the first reference position.) The indicator lamp does not go on in warning. (5) Program paused signal (output) PAUSED This signal is used together with output signal PROGRUN to determine whether a program can be restarted while it is being held.) Up to three reference positions can be specified.1 in reference point setup screen. (The reference point No.) . Turned off: When the program is not being executed. the program has not been executed and can be started from this status. (This has the same function as that of the BUSY lamp on the teach pendant. general-purpose signals can be assigned to output as such. While this signal is on. (The reference point No. Turned off: When the voltage of the battery for the CMOS memory backup is at the normal level.SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE Signal *SFSPD is set to on. For the other two reference positions. the program can be restarted and retains information such as that to return from a subprogram to the main program. (4) Held signal (output) HELD This signal is used to check the status of the hold input. Turned off: When the teach pendant is disabled. (7) Reference point signal (output) ATPERCH Turned on: When the robot is in the reference position specified in the parameter. (3) Program run signal (output) PROGRUN Turned on: When the program is being executed. Turned on: When the hold button on the teach pendant (or input) is being pressed down (or turned on). If signal PROGRUN is off.) Turned off: When the robot is not in the reference position specified in the parameter. Turned on: When a program is held and has not been restarted yet. Turned off: When power is not applied to the motor of the robot. (6) Alarm status signal (output) FAULT Turned on: When the system is in the alarm status (or an alarm which can stop a program execution is detected. (They can be set from the setup screen.1 in reference point setup screen. If signal PROGRUN is on. Turned off: When a program is being executed or is ready to start. or in the normal status. (10) Operating signal (output) BUSY Turned on: When a program is being executed or is being processed from operation panels such as the teach pendant. the program is being executed.APPENDIX B-83525EN/01 - B. (9) Battery alarm signal (output) BATALM Turned on: When the voltage of the battery for the CMOS memory backup drops below the reference. Turned off: When the alarm status is released by an alarm release operation. Turned off: Normally. A pulse whose width is specified from the menu is output to acknowledge the signal. The following chart shows the timing of the RSR input and ACK output. they are normally in the off status. Since these signals are always output as pulses. (11) RSR acknowledge signals (output) ACK1/ACK2/ACK3/ACK4 These signals are used together with the RSR function. They can be specified to be enabled or disabled from the RSR setup menu.B. .220 - . Turned on: When one of the signals from RSR1 to RSR4 is input and accepted.SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE Turned off: APPENDIX B-83525EN/01 When a program is not being executed nor is being processed from operation panels such as the teach pendant. * Other RSR signals can be accepted even when the ACK signal is being output. a pulse is output from signal SNACK as a part of the PNS operation. The R-30iB can use a total of up to 512 I/O points. If the number cannot be represented as an eight-bit number. See the timing chart below. The width of the pulse can be specified from the menu. The selected program number is displayed in binary code (SN01 to SN08) on the teach pendant. B. One analog input/output point uses the resources equivalent to those used by 16 digital I/O points. B.2 Input/Output Hardware Usable in the R-30iB Mate Controller The R-30iB Mate controller can use up to 512 digital input and output points or an equivalent number of analog input and output points.1 Overview This section describes the external specifications of digital and analog input/output in the R-30iB controller.APPENDIX B-83525EN/01 B. The R-30iB controller can use the following I/O hardware.4.SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE (12) PNS acknowledge signal (output) SNO/SNACK These signals are used together with the PNS function. Process I/O printed board I/O unit model A . Turned on: Whenever the PNS function is enabled.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT B.221 - . it becomes zero. After selecting a program by PNS.4. (2) DI/DO The signal No. (4) Group I/O Group I/O is a function. They cannot be assigned (redefined) and are fixed. (3) Analog I/O An analog I/O signal can access the analog I/O port (optional) on the process I/O board or the I/O port on the analog I/O module (used together with the I/O unit model A). which can input or output multiple DI/DO signals as binary codes. It means that the value does not always represent the real I/O voltage. The standard format is eight inputs and eight outputs.4. that is determined at hardware can be changed by software operation. The number of points that can be used for the connector at the wrist depends on the individual robot. B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE APPENDIX B-83525EN/01 The process I/O board and the I/O unit model A can be used together. It can be set in the menu DETAILS on the group I/O screen. .B.3 Software Specifications (1) RI/RO These are signals sent to the connector at the wrist of the robot. It reads and writes the digital value converted from the analog value of the I/O voltage. Any number of continuous signals of up to 16 bits can be set for its use.222 - . APPENDIX B-83525EN/01 C C.OPTICAL FIBER CABLE OPTICAL FIBER CABLE The R-30iB Mate uses fiber optic cables for communication between the main board and servo amplifiers. especially when installing the unit. (1) Protection during storage When the electrical/optical conversion module (mounted on the printed) circuit board and the fiber optic cable are not in use. the mating surfaces are likely to become dirty. their mating surfaces must be protected with the lid and caps with which they are supplied.2 mm×2 cords φ7. Observe the following cautions when handling these fiber optic cables. Handle fiber optic cables with utmost care. possibly resulting in a poor cable connection.223 - φ2.C (a) Protection of electrical/optical conversion module and fiber optic cable (when not in use) (2) Fiber optic cable External type Fiber optic cord diameter: Diameter of cable with reinforced cover: Tensile strength: Cable with reinforced cover: Fiber optic cord: Between fiber optic cord and connector: Minimum bending radius of fiber optic cord: Minimum bending radius of cable with reinforced cover: Bending resistance (cable with reinforced cover): Flame resistance: Operating temperature: . If left uncovered. Fig.6 mm 75 kg 7 kg per cord 2 kg 25 mm 50 mm 10 million bending cycles at room temperature (when the bending radius is 100 mm) Equivalent to UL VW-1 -20 to 70ºC . Take care to keep both parts of the optical connector (cable side and PCB side) clean.C (c) External dimensions of internal optical cable Unit: mm - - - - After it is connected. as shown in Fig. 100 typ. to prevent the weight of the fiber optic cable from being applied directly to the connecting part of the optical connector. wipe them with tissue paper or absorbent cotton to remove dirt. Two cords are bound together.) Although optical connectors cannot be connected in other than the correct orientation. always take note of the connector's orientation before making the connection. To remove the connector. 21 Code Fig. 100 typ.7 14 max.7 14 max. Although the reinforcing cover of the external optical cable has sufficient mechanical strength.OPTICAL FIBER CABLE APPENDIX B-83525EN/01 Unit: mm 7 6.C (b) External dimensions of external optical cable Unit: mm Internal type Fiber optic cord diameter: Tensile strength: Fiber optic cord: Between fiber optic cord and connector: Minimum bending radius of fiber optic cord: Flame resistance: Operating temperature: φ2. Do not use any organic solvent other than ethyl alcohol.224 - . The tissue paper or absorbent cotton may be moistened with ethyl alcohol. If they become dirty. release the lock levers and pull the connector. the optical connector is automatically locked by the lock levers on its top. (Do not pull on the fiber optic cord itself. 21 Code Fig.2 mm×2 cords 7 kg per cord 2 kg 25 mm Equivalent to UL VW-1 -20 to 70ºC Unit: mm 7 6. C(d). Fix the reinforcing cover by using a cable clamp.C. be careful not to drop heavy objects on the cable. Two cords are bound together. . follow the instructions given below. the clamping force should be 5kg (111bs) or less. Also. ensure that the clamping force is as small as possible to ensure that the reinforcing cover is not deformed by the clamping.B-83525EN/01 APPENDIX C.OPTICAL FIBER CABLE Fig. Winding the cable into smaller loops can produce sharp curves that exceed the specified bend radius limit. Failing to clamp the cable correctly might cut or damage it.C (d) Fixing the cable with a clamp - - Any superfluous portion of the cable might be wound into loops. take care not to apply a bending force to one particular part of the cable when fixing it with a clamp. However. . Should this prove necessary. When clamping the cable by the reinforcing cover. make sure the diameter of each loop is at least 150 mm (for an external cable).225 - . Such bending can result in transmission loss. External cable: Do not clamp the uncovered portion of the cable with a nylon band. Desirable clamping force is 1 to 2 kg (make sure that no force is applied to the cable). If possible. ultimately leading to a communication failure. Internal cable: Lightly clamp the optical cable with a nylon band so that the cable shield is not deformed. the clamping force is not an important factor to consider. When using a nylon band (cable tie) as a cable clamp. 2 Brake release unit connection cable . Before using the brake release unit.2 CONFIRMATIONS BEFORE OPERATION Confirm the followings before operation.1 SAFETY PRECAUTIONS WARNING Support the robot arm by mechanical means to prevent it from falling down or rising up when brake is released. Table D. (2) Confirm that the power supply of the robot controller is disconnected. Do not use it when there are damages in the unit and the cable.2 (a).226 - . read the Operator’s manual of the robot that tries to release the brake. Confirm the cable specification corresponding to the robot referring to Table D. (1) Confirm the exterior of the brake release unit and the power cable. (3) There are Two types of brake release units according to the input voltage as shown in Table D. (4) Confirm that the voltage of power supply before connecting the power supply to the brake release unit. Confirm that the robot is fixed tightly to the floor to prevent the falling down and unexpected movement of robot. Confirm that the outlet with earth is used for the power supply of brake release unit and earth of brake release unit is surely connected to earth of power supply. There is danger of getting an electric shock if earth is not connected.D. single phase Input voltage AC200-240V.4). Robot Brake release unit side(CRR56A) Robot side RM1(RMP) Cable specification Auxiliary Axis The applicable robot types are shown.D.BRAKE RELEASE UNIT APPENDIX B-83525EN/01 D BRAKE RELEASE UNIT D. There is possibility to give the damaging to the brake or the brake release unit when the incorrect power supply is connected to the unit. Confirm the input voltage of the unit to refer to the input voltage label put to the unit (Fig. D.D. Inside robot controller (CRR65A/B) Brake release unit side(CRR56A) Fig.2 (b). single phase (5) The brake release unit connection cable is different in each robot.2 (a) Specification of Brake release unit Brake release unit Remarks Brake release unit (AC 100V) Brake release unit (AC 200V) Input voltage AC100-115V. D. and connect the Brake Release Unit connection cable to the Robot.’6’ according to the axis that tries to release the brake. (3) Disconnect the RM1 connector from Robot. Refer to the Operator’s manual for each robot.3. then brake will be released.3.2 for the auxiliary axis.3. (5) Press and hold the deadman switch in the middle position. .1) Two axes or more cannot be operated at the same time.1 In case of operating to the robot Operate the brake release unit according to the following procedures.3 OPERATION D.D. (6) Press the brake switch ‘1’.3.BRAKE RELEASE UNIT APPENDIX B-83525EN/01 Table D.1 (a) Brake Release Unit Table D.1 The relation between brake switch and robot axis Brake Unit Button Robot Type 1 2 3 4 LR Mate 200iD (6-Axis) J1 J2 J3 J4 In case of the auxiliary Axis J1 - - Refer to Fig. Axis R-30iB Mate A660-2006-T474 A660-2005-T711 D.D. Deadman switch Brake Release Unit 1 2 3 4 5 6 Brake switch Power cable Brake Release Unit connection cable Fig. (4) Connect the power cable of Brake release unit to power supply.3. Keep the connection of Robot connection cable except RM1 cable.. (Refer to Table D. (1) Support the robot arm by mechanical means to prevent it from falling down or rising up when brake is released.227 - 5 6 J5 - J6 - .2 (b) Specification of brake release unit connection cable Controller Applicable robot types Specification of cable LR Mate 200iD Aux. (2) Connect the Brake Release Unit connection cable to Brake Release Unit. BRAKE RELEASE UNIT APPENDIX B-83525EN/01 Remove RM1(RMP) connector Robot controller RM1(RMP) Robot Brake Release Unit connection cable Power Cable Brake Release Unit Fig.1 (b) How to connect Brake Release Unit .D.D.228 - .3. (4) Connect the power cable of Brake release unit to power supply. (2) Connect the Brake Release Unit connection cable to Brake Release Unit. then brake will be released. Pulsecoder. Keep the connection of all cables of aux.2 D.3. Axis) .2 How to connect Brake Release Unit (In case of operating to the Aux.BRAKE RELEASE UNIT APPENDIX B-83525EN/01 In case of operating to the auxiliary Axis Operate the brake release unit according to the following procedures. axis brake connector (CRR65A/B).3. axis motor (power. (5) Press and hold the deadman switch in the middle position. (3) Disconnect the aux. Axis Do not disconnect motor cables. and connect the CRR65A/B connector to the Brake Release Unit connection cable.D. Robot controller Disconnect the brake connection cable(CRR65A/B) Brake cable for Aux. brake). (1) Support the auxiliary Axis by mechanical means to prevent it from falling down or rising up when the brake is released. Axis Brake Release Unit connection cable Power cable Break Release Unit Fig.D. (6) Press the brake switch‘1’.229 - . Motor for Aux. . In the EU area. Terminal (M4 Size) 1(R) 2(S) PE Earth(Yellow/Green spiral） Power plug （Provided by customer） AC200-240V 1(R) +10%/-15% or Cable (Provided by FANUC) Brake Release Unit 2(S) AC100-115V +10%/-15% PE Outlet Fig. Do not install the plugs without protective earth pin. only plug complying with the relevant European product standard can be used.D.4 How to connect the plug to the power cable WARNING Only a specialist having the relevant expertise knowledge is permitted to connect the plug to the power cable.D.4 APPENDIX B-83525EN/01 HOW TO CONNECT THE PLUG TO THE POWER CABLE (IN CASE OF NO POWER PLUG) Connect the plug to the power cable as follows.230 - .BRAKE RELEASE UNIT D. This plug is provided by customer. 5 (a) Dimension of Brake Release Unit (Front view) .5 D.APPENDIX B-83525EN/01 D.D.231 - .BRAKE RELEASE UNIT DIMENSION Warning label Input voltage label Brake switch Pilot lamp Deadman switch Caution label Belt The connector(CRR56A) for Brake Power cable Release Unit connection cable Fig. 5 (b) Dimension of Brake Release Unit (Rear view) D.D. Specification: P420H Rating: 2A WARNING When the fuse is replaced. exchange the fuse after finding the root cause of failure.6 FUSE The fuses are mounted inside this unit. When the fuse is blown.D. Please check the fuse when the pilot lamp doesn't light even if deadman switch is pressed. and taking the appropriate countermeasures.232 - . Manufacturer: Daito Communication Co. .BRAKE RELEASE UNIT APPENDIX B-83525EN/01 Instructions for use Fig. the power cable of brake release unit must be disconnected. 50/60Hz±1Hz. single phase.5 kg .7 SPECIFICATIONS Input power supply AC100-115V. 50/60Hz±1Hz. +10%/-15%.6 The location of fuses D. +10%/-15%.APPENDIX B-83525EN/01 FU011 D. 1A AC200-240V.233 - . single phase.BRAKE RELEASE UNIT FU012 FU001 Fig. 1A Weight Brake Release Unit (AC 100V): Brake Release Unit (AC 200V): 2.D.3 kg 3. (2) Turn the disconnect switch to “Connect/Disconnect” position.E.TEACH PENDANT DISCONNECT FUNCTION (Option) E APPENDIX B-83525EN/01 TEACH PENDANT DISCONNECT FUNCTION (Option) This appendix shows an instruction for Teach pendant disconnect function (Option).2. (6) Administrator should store the teach pendant and the teach pendant cable in the storage in order to avoid incorrect operation.E.1 Teach pendant disconnect switch Teach pendant disconnect function E. E.234 - . (4) Connect the jumper connector.2 PROCEDURE OF TEACH PENDANT DISCONNECT E.1 Teach Pendant Disconnect (1) Set AUTO mode. . (5) Turn the disconnect switch to “Normal” position. (Robot stops because Operator’s panel E-stop Alarm occurs and Power LED of the teach pendant is OFF.1 CONFIGURATION Operator’s panel with teach pendant disconnect Jumper connector Connector for teach pendant disconnect Fig.) (3) Disconnect the teach pendant cable. (4) Connect the teach pendant cable with the teach pendant. This teach pendant is not connected to robot controller and emergency stop button of the teach pendant is not inactive. When the LED (POWER) on the teach pendant turned off. Emergency stop button Teach pendant POWER LED .2 E.2.235 - . (Robot stops because Operator’s panel E-stop Alarm occurs.TEACH PENDANT DISCONNECT FUNCTION (Option) Teach Pendant Connect (1) Set AUTO mode.) (3) Disconnect the jumper connector. this teach pendant is connected to the robot controller and emergency stop button of the teach pendant is active. (2) Turn the disconnect switch to “Connect/Disconnect” position. (5) Turn the disconnect switch to “Normal” position.APPENDIX B-83525EN/01 E. WARNING When the LED (POWER) on the teach pendant turned on. 2.Please readjust a loose end. otherwise PCB will be damaged by handling stress. 3. and push down the lever by finger.Release an operating tool.F.Pull of the lever.1.Hold the connector.236 - . 3.Please check a strip length carefully. 2 Available wire size AWG 28 -14 (0.Push in the connector to the header. Don’t pull strongly. 1. Push down the lever. . Fit to header 2. Pull a wire slightly to check if connecting has been done completely. .Don’t handle the lever after fit the connector into PCB.5mm ) .Hook the lever to the rectangle hole. 734-230 Wiring 1. Be careful to fit the shape of each other. 7mm Operating Lever .Push down the lever until click in. Stripping of Wire Handling of the lever .Please check if the latch is hooked to header.Insert a wire into the wire hole with holding the lever.08 . 2. Item No.INSTRUCTION FOR TERMINAL BLOCK F APPENDIX B-83525EN/01 INSTRUCTION FOR TERMINAL BLOCK This appendix shows an instruction for external on/off and external emergency stop signal input/output terminal block. Replace the lever 1. 1.INSTRUCTION FOR TERMINAL BLOCK APPENDIX B-83525EN/01 Installation of Jumper 2.3 216-203 1.5 (22) White 9.5 8.25 (24) Yellow 9.0 0.Squeeze handles until ratchet mechanism is released.0 1. 2.Put a wire through the hole of ferrules.0 14.0 14.0 (18) Red 10.5 2.8 1.5 8.1 216-202 0.5 Please make sure to use WAGO 206-204 to crimp the ferrules. Availability of wires With jumpers Without jumpers 2 Max wire size 1.5 13.75 (20) Gray 10. CAUTION! Sleeve for 2 mm (AWG) Color Stripped length(mm) L (mm) L1 D D1 D2 216-301 0. Specifications of Ferrules WAGO Item No. when attached the jumper.5 12.8 216-201 0. 1.0 0.5 8. 4.0 3. then put the jumper into the connector.34 (24) Turquoise 9.0 2. Installation of Ferrules 3.0 3.237 - Pack-unit 100 .0 2.Please check if the wire crimped correctly.5 8. .5 2. Please confirm that the jumper is fully inserted.0 3.F.0 2.3 2.5 1.Hold down levers at the same time.0mm (AWG18) (with Ferrule) The wire cannot connect. Attach two levers to the connector.6 3.5 12.Introduce a wire with ferrules into the cramping station.0 8.8 216-302 0. . ...................186 COMPONENT FUNCTIONS......163 ADJUSTMENT AND CHECKS AT INSTALLATION193 ALARM OCCURRENCE SCREEN.......142 In the Case of the Process I/O Board MA .................................125 EXTERNAL VIEW OF THE CONTROLLER .................121 FUSE.....128 Connection between RS-232-C interface and I/O device ..................119 Electrical Noise Countermeasures ........................194 How to Disable/Enable Pneumatic Pressure Alarm (PPABN) ..................90 I/O SIGNALS ............128 Connecting the input power cable ..............................94 DIGITAL I/O SIGNAL SPECIFICATIONS .....INDEX B-83525EN/01 INDEX <Number> <D> 100BASE-TX Connector (CD38A........................................193 <F> <B> FANUC I/O LINK ..........230 How to Disable/Enable HBK ...178 <I> I/O CONNECTOR CONVERTER BOARD (A20B-2004-0411) .....................................188 INSTALLATION CONDITION....................................................95 BRAKE RELEASE UNIT ...............87 Ethernet Interface...................................................................156 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS...............................................................................191 Installation Method .............................................140 In case of operating to the auxiliary Axis ......................118 BLOCK DIAGRAM OF THE POWER SUPPLY .......................................145 Connection between the Process I/O Board MA and Peripheral Devices....129 Connecting the Input Power.................................................................................................173 Connecting the Auxiliary Axis Brake (CRR65 A/B) ......................... Tyco Electronics AMP......................................................................87 Battery for Memory Backup (3 VDC) ......................226 <G> GENERAL.........145 INTERFACE FOR WELDING MACHINES ..................................................................117 <H> <C> HOW TO CONNECT THE PLUG TO THE POWER CABLE (IN CASE OF NO POWER PLUG) .......................156 i-1 ...........................................................................................174 Input Signals .............................................................. END EFFECTORS.................................189 AT INSTALLATION .............................188 INSTALLATION OF TEACH PENDANT HOOK (Option) ......................................158 INTERFACE FOR PERIPHERAL DEVICES ..................................................................113 BLOCK DIAGRAM ........163 In Case of Main Board (CRMA15..............................234 CONFIRMATIONS BEFORE OPERATION...........236 Interface ................162 ELECTRICAL CONNECTIONS .........................232 FUSE-BASED TROUBLESHOOTING .............................................................................................................................................................................................................................................121 Connection of the I/O Link Cable .....................231 <E> <A> EE Interface ...... CRMA16) and Peripheral Devices ....119 CONNECTION OF HDI............................141 Input Signal Rules for the High-speed Skip (HDI) ...168 Check Items at Installation.....................................173 Connection of I/O Link .............................143 I/O Signal Specifications for ARC-Welding Interface (A-cabinet/Process I/O Board MB) ........................229 In case of operating to the robot.......................... CD38B) Pin Assignments ....................................................... CRMA16) ..............176 Connection between the Connector Conversion Board and Peripheral Devices .........68 BACKPLANE..............................122 Connection to Ethernet. AND ARC WELDERS .....................................................151 Connection between the LR Mate 200iD and End Effector..............................................136 Connecting the Auxiliary Axis Over Travel (CRM68) 137 CONNECTING THE COMMUNICATION UNIT .............227 In the Case of the Connector Conversion Board .167 Assemble at Installation ...................215 I/O SIGNALS OF MAIN BOARD .....................................175 Connecting the External Emergency Stop.......................................................................226 Connecting HDI ...........................152 Connection between the Process I/O Board MB and Welding Machines..........................13 ARC Weld Connection Cables (CRW11...................................................................................194 CABLE CONNECTION FOR THE PERIPHERAL DEVICES....................................................................158 Connection between the Main Board (CRMA15...........................179 6-AXIS SERVO AMPLIFIER SPECIFICATIONS..........................8 CONFIGURATION ..............................221 INSTALLATION.........4 (A-cabinet/Process I/O Board MB) .............................................................215 Input/Output Hardware Usable in the R-30iB Mate Controller .... 20 pin) ...............................................................................4.....................................183 EMERGENCY STOP BOARD:A20B-2005-0150 ....................................................................................................159 DIMENSION ..............178 EXTERNAL CABLE WIRING DIAGRAM ..............140 In the Case of the Process I/O Board MB .......................190 INSTRUCTION FOR TERMINAL BLOCK....................................175 INTERFACE FOR END EFFECTOR ........................................ ........76 TROUBLESHOOTING USING THE ERROR CODE .................................................193 PERIPHERAL DEVICE..........11 When the Teach Pendant Does not Change from the Initial Screen ......................125 Routing of the Ethernet Cable...........112 Replacing the Main Board............................................11 POWER SUPPLY ...........213 Software Specifications......................................................................... ARC WELDING...................................................................................................215 SETTING OF SERVO AMPLIFIER ................................97 REPLACING THE BATTERY .........80 Troubleshooting by LED on the Emergency Stop Board ...........................................176 Leakage breaker ...........166 STOP SIGNALS ........................................................................ 30 pin)....................85 MANUAL OPERATION IMPOSSIBLE.........233 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT..................................................................89 <T> Teach Pendant Cable........................................194 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION ........................................................92 LEDS ON UNITS SUPPORTING I/O LINK i ............................................221 <S> SAFETY PRECAUTIONS ........................................................168 Peripheral Device Interface A ...................................................................................19 Troubleshooting Using the LEDS On the Main Board .........................................................112 Replacing the Backplane Board (Unit) ...........234 TEACH PENDANT DISCONNECT FUNCTION (Option) ..............................................91 SETTING COMMON VOLTAGE ....................................................221 SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE....................105 REPLACING THE E-STOP UNIT...........3...82 <O> OPERATION .............................98 <W> When the Teach Pendant Cannot be Powered on.................................................111 REPLACING THE EMERGENCY STOP BOARD...........................................223 Output Signals..............187 TROUBLESHOOTING ........................................................166 Peripheral Device Interface B1 and B2 Cables (CRMA52.....................................................................................................11 TROUBLESHOOTING BASED ON LED INDICATIONS ............................................193 Robot Connection Cables......................213 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS..............................................179 RS-232-C Interface ............................96 REPLACING THE REGENERATIVE RESISTOR UNIT ................................................................................................... 40 pins)............................................ s-1....106 REPLACING THE PRINTED-CIRCUIT BOARDS.......................9 PRINTED CIRCUIT BOARDS ...81 MASTERING ........................88 PROCESS I/O BOARD MB (A20B-2101-0731).....93 SIGNAL....110 REPLACING UNITS............95 PREFACE ...............................................................................................138 Peripheral Devices ..96 Resetting Overtravel ..................172 REPLACING CARDS AND MODULES ON THE MAIN BOARD .........234 PROCESS I/O BOARD MA (A20B-2004-0381) ...187 TRANSPORTATION AND INSTALLATION..........................................180 <R> Recommended Cables ...........................................140 Peripheral Device Interface Processing..............................................................127 Teach Pendant Connect........................................129 LEDS OF SERVO AMPLIFIER.................113 REPLACING THE CONTROL SECTION FAN MOTOR ..INDEX B-83525EN/01 <L> REPLACING THE POWER SUPPLY UNIT....16 <P> Peripheral Device Cable Connector ...............................................................167 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM..................................166 Peripheral Device Interface A2 Cable (CRMA16: Tyco Electronics AMP..............................197 TRANSPORTATION ... p-1 PREVENTIVE MAINTENANCE .................. Tyco Electronics AMP...........104 Replacing the Heat Exchanger and Door Fan Unit (A-cabinet) ....................................234 TOTAL CONNECTION DIAGRAM.....................................................................................................................................................................................................................................................................................................145 POWER CANNOT BE TURNED ON ............................78 Troubleshooting by LEDs on the 6-Axis Servo Amplifier ..99 REPLACING THE 6-AXIS SERVO AMPLIFIER ...............................................................................159 Peripheral Device Interface A1 Cable (CRMA15: Tyco Electronics AMP..................... AND EE INTERFACES.....................................107 REPLACING THE TEACH PENDANT .............235 Teach Pendant Disconnect .................................................222 SPECIFICATIONS ....................................................218 OVERVIEW .72 Troubleshooting by Alarm LEDs on the Process I/O Board .........................84 PROCEDURE OF TEACH PENDANT DISCONNECT ................................73 Twisted-pair Cable Specification ................227 OPTICAL FIBER CABLE....108 REPLACING THE AC FAN MOTOR ......................................169 Peripheral Device Connection Cable ................................12 i-2 . 40 pins)......................175 RS-232-C interface signals ......82 <M> MAIN BOARD ......................226 SERVO AMPLIFIERS .....................................17 Meanings of LEDs on Units Supporting I/O Link i ............................................................................................................................................................................................ .REVISION RECORD B-83525EN/01 REVISION RECORD Edition Date 01 Dec.2012 Contents r-1 . 8 3 5 2 5 E N / 0 1 * .B-83525EN/01 * B .
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