FANUC R-J3iB - Maintenance Manual for Europe - B-81465EN-1-02

FANUC Robot seriesR--J3iB CONTROLLER FOR EUROPE MAINTENANCE MANUAL B--81465EN--1/02 B--81465EN--1/02 Table of Contents 1 3 4 6 7 9 PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p--1 I SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 OPERATOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.1 1.1.2 1.1.3 Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety of the Teach Pendant Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1 1.2.2 10 10 10 1.3 SAFETY OF THE ROBOT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.1 1.3.2 1.3.3 11 11 11 11 1.4 1.5 1.6 SAFETY OF THE END EFFECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.1 12 12 SAFETY IN MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 14 II MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 2.2 2.3 EXTERNAL VIEW OF THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 19 20 21 25 26 3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 POWER CANNOT BE TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALARM OCCURRENCE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING USING THE ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSED--BASED TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING BASED ON LED INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIBRATION OBSERVED DURING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MANUAL OPERATION IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 28 30 33 34 36 117 122 131 132 133 4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 4.1 4.2 4.3 MAIN BOARD (A16B--3200--0412, --0413) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMERGENCY STOP CONTROL PC BOARD (A20B--1007--0800) . . . . . . . . . . . . . . . . . . . . . . . . BACKPLANE PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 139 140 c--1 Table of Contents B--81465EN--1/02 4.4 4.5 4.6 4.7 4.8 4.9 PANEL BOARD (A20B--2100--0770) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCESS I/O BOARD CA (A16B--2201--0470) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCESS I/O BOARD CB (A16B--2201--0472) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCESS I/O BOARD DA (A16B--2201--0480) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCESS I/O BOARD HA (A16B--2203--0760) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL SWITCH BOARD (A20B--1007--0850) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 143 146 148 150 152 5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 5.1 5.2 5.3 LED OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SETTING OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVER CHIP FOR ROBOT DI/DO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 155 156 6. SETTING THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 6.1 6.2 6.3 BLOCK DIAGRAM OF THE MAIN POWER INCLUDING POWER SUPPLY . . . . . . . . . . . . . . SELECTING TRANSFORMER TAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 159 161 7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 7.1 REPLACING THE PRINTED--CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 7.1.2 7.1.3 Replacing the Backplane Board (Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Power Unit and Printed--Circuit Boards on the Backplane Unit . . . . . . . . . . . . . . . . . . . Replacing the Panel Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 165 166 168 7.2 7.3 7.4 7.5 7.6 7.7 REPLACING CARDS AND MODULES ON THE MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE REGENERATIVE RESISTOR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE E--STOP UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING I/O UNIT MODEL A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7.1 7.7.2 Replacing the Base Unit of I/O Unit Model A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 173 176 177 178 182 182 183 7.8 7.9 7.10 7.11 7.12 7.13 REPLACING THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE CONTROL SECTION FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE AC FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10.1 Replacing External Air Fan Unit and Door Fan (B--cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 185 186 186 REPLACING THE OPERATOR PANEL AND PANEL SWITCH BOARD . . . . . . . . . . . . . . . . . . REPLACE THE MODE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13.1 7.13.2 7.13.3 7.13.4 Replacing Fuses in the Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Fuses in the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Process I/O Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Panel Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Relays on the Panel Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery for Memory Backup (3 VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 189 190 190 191 192 194 7.14 7.15 REPLACING RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14.1 7.15.1 195 195 REPLACING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 196 c--2 B--81465EN--1/02 Table of Contents III CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 3. ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 3.1 3.2 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS . . . . . . . . . . . . . . . . . . . . . . . . . EXTERNAL CABLE WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 Robot Connection Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teach Pendant Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the External Power Supply ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the External Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 206 206 207 208 210 212 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 4.1.2 4.1.3 4.1.4 When Process I/O Board CA/CB/HA is Used (B--cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When Process I/O Board DA is Used (B--cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When I/O Unit--MODEL A is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3.1 In case of B--cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When Two or more Process I/O Boards and I/O Unit (Model A or Model B) are Used . . . . . . . . . . . . In Case of B--cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 221 223 224 224 225 4.2 4.3 4.4 PERIPHERAL DEVICE INTERFACE COMBINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 226 226 PROCESS I/O BOARD SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS . . . . . . . . . . 4.4.1 4.4.2 4.4.3 Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection Between the Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection Between the Control Unit and Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End Effector Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O Signal Specifications for ARC--Welding Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 231 232 245 247 4.5 DIGITAL I/O SIGNAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1 4.5.2 4.5.3 253 253 255 257 4.6 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.1 4.6.2 4.6.3 Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins) . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins) . . . . . . . . . . . . . . . . . . . . . . . . ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 261 261 262 4.7 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS, AND ARC WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.1 4.7.2 4.7.3 4.7.4 Peripheral Device Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End Effector Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting HDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Signal Rules for the High--speed Skip (HDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS--232--C Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9.1.1 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 263 264 266 267 4.8 CONNECTION OF HDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8.1 4.8.2 268 268 270 4.9 CONNECTING THE COMMUNICATION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9.1 271 271 271 c--3 Table of Contents B--81465EN--1/02 4.9.1.2 4.9.2 RS--232--C Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 273 275 276 277 277 278 279 280 281 4.9.1.3 Connection between RS--232--C Interface and External Device . . . . . . . . . . . . . . . . . . . . . . . . Ethernet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9.2.1 Connection to Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9.2.2 4.9.2.3 4.9.2.4 4.9.2.5 4.9.2.6 4.9.2.7 10/100 BASE--T Connector (CD38) Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lead Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connector Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Clamp and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding the Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 5.1 5.2 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 5.2.2 Installation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assemble at installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 285 285 287 5.3 5.4 5.5 INSTALLATION CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT AND CHECKS AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION . . . . . . . . . . . . . . 5.5.1 5.5.2 5.5.3 5.5.4 Peripheral Device Interface Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Disable/Enable HBK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Disable/Enable Pneumatic Pressure Alarm (PPABN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 289 290 290 290 291 292 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 A. TOTAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE . . . . . . . . . . . . . . . . . 316 B.1 B.2 B.3 SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SETTING COMMON VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.1 B.3.2 Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input/Output Hardware Usable in the R-J3iB Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 319 320 320 325 B.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.1 B.4.2 B.4.3 329 329 329 330 C. POWER DISTRIBUTION CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 D. OPTICAL FIBER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 E. CARD INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 c--4 B--81465EN--1/02 PREFACE PREFACE This manual describes the following models (R--J3iB controller). Model Abbreviation FANUC Robot R--2000iA/165F FANUC Robot R--2000iA/200F FANUC Robot R--2000iA/165R FANUC Robot R--2000iA/200R FANUC Robot R--2000iA/125L FANUC Robot M--6iB FANUC Robot ARC Mate 100iB R--2000iA/165F R--2000iA/200F R--2000iA/165R R--2000iA/200R R--2000iA/125L M--6iB ARC Mate 100iB R--2000iA R 2000iA FANUC Robot R--2000iA/165CF R--2000iA/165CF p--1 I SAFETY PRECAUTIONS . follow all safety precautions when operating a robot and its peripheral devices installed in a work cell. SAFETY PRECAUTIONS 1 SAFETY PRECAUTIONS For the safety of the operator and the system. 3 .B--81465EN--1/02 SAFETY PRECAUTIONS 1. clearly indicating the range of the robot motion. In this state. (1) Have the robot system operators attend the training courses held by FANUC. (3) Install a safety fence with a gate so that no operator can enter the work area without passing through the gate.1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B--81465EN--1/02 1. it is possible that the robot is still ready to move state and is waiting for a signal. For connection. Equip the gate with an interlock that stops the robot when the gate is opened. 4 . install a safety lock so that no one except the operator in charge can turn on the power of the robot. FANUC provides various training courses. adequate safety precautions must be observed. see Fig. or Class 3).1. To ensure operator safety. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock. (4) Provide the peripheral devices with appropriate grounding (Class 1. the controller stops the robot in an emergency. (5) Try to install the peripheral devices outside the work area.1. the robot is regarded as still in motion. including the tools such as a hand. Because it is very dangerous to enter the operating space of the robot during automatic operation. provide the system with an alarm to indicate visually or aurally that the robot is in motion. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when an operator enters the work area. (6) Draw an outline on the floor. The controller is designed to receive this interlock signal. Contact our sales office for details. (2) Even when the robot is stationary.1 OPERATOR SAFETY Operator safety is the primary safety consideration. When the gate is opened and this signal received. Careful consideration must be made to ensure operator safety. (8) If necessary. Class 2. The following lists the general safety precautions. 1 Safety Fence and Safety Gate 5 . SAFETY PRECAUTIONS (9) When adjusting each peripheral device independently. be sure to turn off the power of the robot. Fence circuit is a safety stop circuit.B--81465EN--1/02 SAFETY PRECAUTIONS 1. Limit switch for the safety gate Panel board EAS1 EAS11 EAS2 EAS21 Note) Terminals FENCE1 and FENCE2 are on the PC board in the operator panel. Fig.1. a worker who operates the teach pendant is also an operator. EES2 and EES21. In this sense.1. the controller stops the robot operation when the external EMERGENCY STOP button is pressed. (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the work area unexpectedly and also to prevent the worker from entering a dangerous area. With this connection. (4) Install an EMERGENCY STOP button within the operator’s reach. turn off the power of the robot controller or press the EMERGENCY STOP button. (1) If it is not necessary for the robot to operate. and then proceed with necessary work. See the diagram below for connection. External EMERGENCY STOP button Panel board EES1 EES11 EES2 EES21 Note) Connect to EES1 and EES11.1 Operator Safety The operator is a person who operates the robot system.1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B--81465EN--1/02 1. However. (2) Operate the robot system at a location outside the work area.1. this section does not apply to teach pendant operators. The robot controller is designed to be connected to an external EMERGENCY STOP button.1. Fig.1 Connection Diagram for External Emergency Stop Switch 6 . 1. It is particularly necessary to ensure the safety of the teach pendant operator.B--81465EN--1/02 SAFETY PRECAUTIONS 1. (2) Before teaching the robot. be sure to check the location and condition of the safety devices (such as the EMERGENCY STOP button and the deadman switch on the teach pendant).2 Safety of the Teach Pendant Operator While teaching the robot. (1) Unless it is specifically necessary to enter the robot work area. Pressing the 3--position deadman switch halfway makes the robot operable. irrespective to the condition of the teach pendant enable switch. The functions of each switch are as follows. NOTE The deadman switch is provided so that the robot operation can be stopped simply by releasing finger from the teach pendant or holding the deadman switch strongly in case of emergency.Releasing the finger from the dead man switch or holding the deadman switch strongly stops the robot in an emergency. check that the robot and its peripheral devices are all in the normal operating condition. When the enable switch is on -. Releasing the finger from the deadman switch or holding the deadman switch strongly causes the robot to enter the emergency stop state. EMERGENCY STOP button : Pressing this button stops the robot in an emergency. When the enable switch is off -. (3) When entering the robot work area and teaching the robot. SAFETY PRECAUTIONS 1. it is necessary for the operator to enter the work area of the robot. 7 . carry out all tasks outside the area.The deadman switch is ineffective. Deadman switch : The function depends on the state of the teach pendant enable switch. The R--J3iB has adopted a 3--position deadman switch as an RIA--specification teach pendant. The teach pendant supplied by FANUC is provided with a teach pendant enable switch and a deadman switch in addition to the EMERGENCY STOP button. operator panel. 8 . the emergency stop factor (normally the safety gate) connected to EAS1 and EAS11. EAS2 and EAS21 of the controller is invalidated. while the teach pendant enable switch is off. The teach pendant operator should be well aware that the safety gate is not functional under this condition and bear full responsibility to ensure that no one enters the fence during teaching. In particular. However the validity of each signal changes as follows depending on the mode of the teach pendant enable switch and the remote switch on the operator’s panel. By pressing the deadman switch while the enable switch is on. it is possible for an operator to enter the fence during teach operation without making the robot in the emergency stop condition. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B--81465EN--1/02 (4) The teach pendant operator should pay careful attention so that no other workers enter the robot work area.1. (5) When entering the robot work area. the teach pendant operator should enable the teach pendant whenever he or she enters the robot work area. the system understands that the combined operations of pressing the teach pendant enable switch and pressing the deadman switch indicates the start of teaching. (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. (b) Run the program for at least one operation cycle in the continuous operation mode at low speed. (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. the teach pendant enable switch and the deadman switch also have the following function. be sure to carry out a test run according to the procedure below. In this case. make certain that no start command is sent to the robot from any operator panel other than the teach pendant. (a) Run the program for at least one operation cycle in the single step mode at low speed. Teach pendant enable switch On Off Off Remote condition Independent Local Remote Teach pendant Allowed to start Not allowed Not allowed Operator panel Not allowed Allowed to start Not allowed Peripheral devices Not allowed Not allowed Allowed to start (6) To start the system using the operator panel. execute it in the automatic operation mode. make certain that nobody is in the robot work area and that there are no abnormal conditions in the robot work area. (7) When a program is completed. (e) After checking the completeness of the program through the test run above. NOTE In addition to the above. The teach pendant. and peripheral device interface send each robot start signal. In other words. They may cause a fire or result in damage to the components in the controller. (10) When handling each unit or printed circuit board in the controller during inspection. SAFETY PRECAUTIONS (8) While operating the system in the automatic operation mode. (5) Do not operate the robot in the automatic mode while anybody is in the robot work area. the worker should indicate that the machine is being serviced and make certain that no one starts the robot unexpectedly. 1.1. pay careful attention to its motion. (3) Before the start of teaching. if necessary. or when multiple workers are working nearby. (1) Except when specifically necessary. the teach pendant operator should leave the robot work area. turn off the power of the controller while carrying out maintenance. take care to prevent foreign matter from entering the system. pay utmost attention to the following. (4) If it is necessary to enter the robot work area for maintenance when the power is turned on. In particular. such as belt conveyor. Lock the power switch. (8) If necessary. be sure to reduce the supply pressure. the worker should be ready to press the EMERGENCY STOP button at any time. have a worker who is familiar with the robot system stand beside the operator panel and observe the work being performed. check that the robot and its peripheral devices are all in the normal operating condition.3 Safety During Maintenance For the safety of maintenance personnel. (6) When it is necessary to maintain the robot alongside a wall or instrument. (9) When replacing or reinstalling components. make certain that their escape path is not obstructed. or when any moving device other than the robot is installed. never use fuses or other parts of non-specified ratings. be sure to use those specified by FANUC. 9 . (7) When a tool is mounted on the robot. (11) When replacing parts. so that no other person can turn it on. (2) When disconnecting the pneumatic system. turn off the power of the controller and also turn off the circuit breaker to protect against electric shock. If any danger arises.B--81465EN--1/02 SAFETY PRECAUTIONS 1. 2. 1.1 Precautions in Programming (1) Use a limit switch or other sensor to detect a dangerous condition and. particular care must be taken in programming so that they do not interfere with each other. design the program to stop the robot when the sensor signal is received. water. (3) For a system in which the robot and its peripheral devices are in synchronous motion. if necessary.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 1.2 Precautions for Mechanism (1) Keep the component cells of the robot system clean. and operate the robot in an environment free of grease. and dust.1. 10 . SAFETY PRECAUTIONS SAFETY PRECAUTIONS B--81465EN--1/02 1.2. (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) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices. (2) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot does not come into contact with its peripheral devices or tools. even though the robot itself is normal. and operate the robot in an environment free of grease.3 Precautions for Mechanisms (1) Keep the work area of the robot clean. make certain that the motions of the robots do not interfere with each other. water.B--81465EN--1/02 SAFETY PRECAUTIONS 1.3. and dust.3.1 Precautions in Operation (1) When operating the robot in the jog mode.2 Precautions in Programming (1) When the work areas of robots overlap. be sure you know in advance what motion the robot will perform in the jog mode. (2) Before pressing the jog key. (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. 1. 11 . set it at an appropriate speed so that the operator can manage the robot in any eventuality. SAFETY PRECAUTIONS 1. 1. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.3 SAFETY OF THE ROBOT MECHANISM 1.3. hydraulic and electric actuators. carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control.1 Precautions in Programming (1) To control the pneumatic.1.4 SAFETY OF THE END EFFECTOR 1. and control the robot system by monitoring the state of the end effector. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B--81465EN--1/02 1. 12 .4. (2) Provide the end effector with a limit switch. When replacing the parts in the pneumatic system. be sure to reduce the pressure in the piping to zero by turning the pressure control on the air regulator. Turn off the power before entering the robot work area for inspection and maintenance. (4) When handling each unit or printed circuit board in the controller during inspection. take care to prevent foreign matter from entering the system. SAFETY PRECAUTIONS 1. never use fuses or other parts of non-specified ratings. In particular. be sure to check that no one is in the robot work area and that the robot and its peripheral devices are all in the normal operating state.5 SAFETY IN MAINTENANCE (1) Never enter the robot work area while the robot is operating. They may cause a fire or result in damage to the components in the controller. first press the EMERGENCY STOP button on the operator panel. (6) Before restarting the robot. (2) If it is necessary to enter the robot work area with the power turned on. (3) When replacing or reinstalling components. turn off the power of the controller and turn off the circuit breaker to protect against electric shock. be sure to use those specified by FANUC. 13 .B--81465EN--1/02 SAFETY PRECAUTIONS 1. (5) When replacing parts. Be careful with servo amplifier and other units because high--voltage places in these units may remain in the high--voltage state for a fixed time. Before starting maintenance. turn the power to the control unit off.1.6 (a) Step--on Prohibitive Label Description Be cautious about a section where this label is affixed. If you have to inevitably touch such a section when it is hot. (1) Step--on prohibitive label Fig. use a protective provision such as heat--resistant gloves. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B--81465EN--1/02 1. then turn the circuit breaker off to avoid electric shock hazards. as the section generates heat.6 (b) High--Temperature Warning Label Description A high voltage is applied to the places where this label is attached. (2) High--temperature warning label Fig.6 WARNING LABEL Description Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing as well.1.1. 14 . B--81465EN--1/02 SAFETY PRECAUTIONS 1. Before working on such a portion. In addition. 15 . SAFETY PRECAUTIONS (3) High--voltage warning label Fig. turn off the power to the controller and set its circuit breaker to the off position to avoid shock hazards. be careful about servo amplifiers and other electric circuits because a high voltage may remain in them for a certain period of time after the power is turned off.6 (c) High--Voltage Warning Label Description There may be a high voltage in a place with this label.1. II MAINTENANCE . For information on third party approvals. contact your FANUC representative. OVERVIEW 1 OVERVIEW This manual describes the maintenance and connection of the R--J3iB robot controller (called the R--J3iB). adjustment. be sure to turn off the power to the controller or press the EMERGENCY STOP button on the operator panel or teach pendant. and installation of the controller WARNING Before you enter the robot working area. 19 . and the setting. .B--81465EN--1/02 MAINTENANCE 1. Maintenance Part : Troubleshooting. Otherwise. and replacement of units Connection Part : Connection of the R--J3iB controller to the robot mechanical unit and peripheral devices. you could injure personnel or damage equipment. CONFIGURATION MAINTENANCE B--81465EN--1/02 2 CONFIGURATION 20 .2. 1 (b) and (c) show the R--J3iB consists of the R--J3iB controller.2. Fig.1 (a) shows the view of R--J3iB. Fig.2.1 EXTERNAL VIEW OF THE CONTROLLER The appearance and components might slightly differ depending on the controlled robot.1 (a) External View of the R--J3iB Controller (B--cabinet) 21 . Mode switch Teach pendant Operator panel Fig. and options used.B--81465EN--1/02 MAINTENANCE 2. application. CONFIGURATION 2.2. 2.2. CONFIGURATION MAINTENANCE B--81465EN--1/02 Fig.1 (b) R--J3iB B--cabinet interior (Front) 22 . 1 Servo amplifier and regenerative resistor unit Robot models R--2000iA M--6iB ARC Mate 100iB Servo amplifier A06B--6105--H002 A06B--6105--H003 Regenerative resistor unit A05B--2452--C200 (B--cabinet) A05B--2452--C201 ( (B--cabinet) ) 23 .2.B--81465EN--1/02 MAINTENANCE 2.1 (c) R--J3iB B--cabinet overview (Back) Table 2. CONFIGURATION Fig. Brake power supply Noise filter AC input 380 -.500 VAC 3φ Breaker Transformer overheat signal Regenerative resistor B--81465EN--1/02 . TP Signal Operator’s panel Panel board 210VAC Output 210VAC Input 24VDC MAINTENANCE Switch peripheral device (Ethernet) Teach pendant 24 Transformer 24VDC EMG signals E--stop unit Servo amplifier (6--axis amplifier) External E--stop External on/off Robot 210VAC 210VAC EMG signals Pulse coder signals. Robot DI/DO signals Motor power supply.2.2.1 (d) Block diagram of the R--J3iB (B--cabinet) Fan Servo Signal (FSSB) HSSB. CONFIGURATION Backplane Power supply unit Main board Battery Process I/O I/O unit MODEL A peripheral device (I/O) peripheral device (Serial) Memory card Fig.415 VAC 440 -. .E--stop unit This unit controls the emergency stop system with control reliable E--stop performance criteria for both of the magnetic contactor and the precharge of the servo amplifier. pulse coder. and operator panel control circuit. various I/O types can be selected. .Teach pendant All operations including robot programming are performed with this unit. . memory. .Regenerative resistor To discharge the counter electromotive force from the servomotor. . . The main CPU controls servo mechanism positioning and servo amplifier voltages.Servo amplifier The servo amplifier controls servomotor power. . overtravel and hand broken.Transformer The supply voltage is converted to an AC voltage required for the controller by the transformer.Battery retains main board memory when controller power is off. . or if abnormal input power causes high current in the system. the input power is connected to the circuit breaker to protect the equipment. 25 . These are connected with FANUC I/O Link.Backplane printed circuit board The various control printed circuit boards are mounted on the backplane printed circuit board. The panel has a port for the serial interface to an external device and an interface to connect the memory card for data backup. heat exchanger These components cool the inside of the control unit. its peripheral circuits. The FANUC I/O unit MODEL-A can also be installed. When it is used. CONFIGURATION 2. .B--81465EN--1/02 MAINTENANCE 2. The controller status and data are indicated on the liquid-crystal display (LCD) on the pendant.Fan unit.Circuit breaker If the electric system in the controller malfunctions.Operator panel Buttons and LEDs on the operator panel are used to start the robot and to indicate the robot status. connect a regenerative resistor to the servo amplifier. It also controls the emergency stop control circuit.Power supply unit The power supply unit converts the AC power to various levels of DC power. FANUC I/O Unit MODEL--A Various types of printed circuit boards are provided for applications including process I/O.I/O printed circuit board. brake control. . .Main board The main board contains a microprocessor. .2 COMPONENT FUNCTIONS -. If the fan has dirt and dust built up. (2) Maintenance tools The following maintenance tools are recommended: (a) Measuring instruments AC/DC voltmeter (A digital voltmeter is sometimes required. clean the fan according to step (d) described below for inspection to be performed every 6 months. Wipe off dirt and dust from the fan and transformer. and small Standard screwdrivers: Large. medium.2. Clean each part. If the ventilation port of the controller is dusty. (b) After service operation At the end of service operation. then remove any dirt and dust from the inside of the transformer compartment. (d) Periodic inspection performed every six months Remove the top cover. CONFIGURATION MAINTENANCE B--81465EN--1/02 2. louver. clean each part of the system and check the system parts for any damage or cracks. and check for any damage or cracks. clean it. Check the controller and peripheral devices for abnormalities. and small Nut driver set (Metric) Pliers Needle-nose pliers Diagonal cutting pliers 26 . Also check the following: (a) Before service operation Check the cable connected to the teach pendant for excessive twisting. and back panel (if possible). then turn off the controller. (1) Daily maintenance Before operating the system each day. (c) Check after one month Check that the fan is rotating normally. two channels (b) Tools Phillips screwdrivers : Large.3 PREVENTIVE MAINTENANCE Daily maintenance and periodic maintenance/inspection ensure reliable robot performance for extended periods of time. medium.) Oscilloscope with a frequency range of 5 MHz or higher. return the robot to the specified position. Refer to the operator’s manual to release program alarms.B--81465EN--1/02 MAINTENANCE 3. TROUBLESHOOTING 3 TROUBLESHOOTING This chapter describes the checking method and corrective action for each error code indicated if a hardware alarm occurs. 27 . 3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 3.1 POWER CANNOT BE TURNED ON Check and Corrective action (Check 1) (Corrective action) Check that the circuit breaker is on and has not tripped. Turn on the circuit breaker. Figure Breaker (Check 2) (Corrective action) Check whether the LED (PIL: green) on the power supply unit is on. If the LED is not on, 200 VAC is not supplied to the power supply unit. It is likely that fuse F1 in the power supply unit has blown. -- If 200 VAC is not supplied: Find the cause by referencing the general schematic diagram presented in the appendix. -- If 200 VAC is supplied: Find the cause of the blown fuse. Fuse F1 is in the power supply unit. Before you start troubleshooting, turn off the circuit breaker. a) If fuse F1 has blown: -- See Corrective action (1). b) If fuse F1 has not blown: -- Replace the power supply unit. Causes of blown fuses F1 and corrective action a) Check whether the unit and printed--circuit board connected to the connectors CP2 and CP3 in the power supply unit are abnormal, by referencing the general schematic diagram presented in the appendix. b) Short-circuit in the surge absorber VS1 VS1 is inserted to absorb surge voltage between input lines. If the surge voltage is excessive or sustained, excessively high voltage is applied to VS1 and a failure occurs in the short-circuit mode, causing F1 to blow. If a short-circuit occurs in VS1, and there is not a spare part, the system is permitted to operate without VS1. In this case, however, obtain and install a new VS1 as soon as possible. VS1 ordering number: A50L-2001-0122#G431k c) Short-circuit of diode stack DB1 d) The secondary power supply module is faulty : If one of the causes (b) to (c) above is detected, replace the power supply unit with a spare unit. The spec. for F1 is : A60L-0001-0396#8.0A Diode stack DB1 F1 8.0A Fuse for AC input CP1 connector Surge absorber VS1 Spare power supply module H1 F3 7.5A Fuse for +24E F4 7.5A Fuse for +24V PIL LED (green) for AC power supply display CP6 connector CP5 connector LED (red) for alarm display (Corrective action(1)) 28 B--81465EN--1/02 MAINTENANCE 3. TROUBLESHOOTING Check and Corrective action (Check 3) Check whether the EXON1 and EXON2 signals, and the EXOFF1 and EXOFF2 signals are connected on the terminal block on the panel board. If the external ON/OFF function is not used, connect the EXON1 and EXON2 the EXOFF1 and EXOFF2. If the external ON and OFF lines are already used, check the mating contacts and the cable. Short piece : Figure between 1 (EXON1) and 2 (EXON2) between 3 (EXOFF1) and 4 (EXOFF2) (Corrective action) Connector (JRS11) (Check 4) Check whether the connector (JRS11) on the main board or the connector (JRS11) on the panel board is connected properly. Another probable cause is that the cable connected to either of these connectors is faulty. Check 1 to 3 above confirm that 200 VAC power is supplied to connector CP1 of the power supply unit and that the ON/OFF switch functions normally. Therefore check the power supply unit using the following procedure: If the LED (ALM: red) on the power supply unit is on Check if the +24 V external connection cable is connected to 0 V or ground. a) Fuse F4 blown : See corrective action (2). b) None of the above fuses blown [d) is also probable] : A printed circuit board or unit that uses a DC supply voltage (+3.3V, +5V, +24V, or ±15V) is faulty. c) None of the above fuses blown : Check that 200 VAC is supplied to connector CP1. If it is supplied replace the power supply unit. If the power supply unit is not faulty, replace the panel board or operator panel. Causes of blown fuse F4 and corrective action The device connected to connector CP5 of the power supply unit may be faulty. If no device is connected to CP5 or the connected device is normal, the +24 V power used in a printed circuit board connected to the backplane is faulty. The code of F4 is A60L--0001--0046#7.5 : Diode stack DB1 F1 8.0A Fuse for AC input (Check 5) CP1 connector Surge absorber VS1 Spare power supply module H1 F3 7.5A Fuse for +24E F4 7.5A Fuse for +24V PIL LED (green) for AC power supply display CP6 connector CP5 connector LED (red) for alarm display (Corrective action) (Corrective action(2)) 29 3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 3.2 ALARM OCCURRENCE SCREEN The alarm occurrence screen displays only the alarm conditions that are currently active. If an alarm reset signal is input to reset the alarm conditions, the alarm occurrence screen displays the message “PAUSE or more serious alarm has not occurred.” The alarm occurrence screen displays only the alarm conditions (if any) that occur after the most recently entered alarm reset signal. To erase all alarm displays from the alarm occurrence screen. Press the CLEAR key (+ shift) on the alarm history screen. The alarm occurrence screen is intended to display PAUSE or more serious alarms. It will not display WARN, NONE, or a reset. It is possible to disable PAUSE and some of more serious alarms from being displayed by setting the $ER_NOHIS system variable appropriately. If two or more alarms have occurred, the display begins with the most recent alarm. Up to 100 lines can be displayed. If an alarm has a cause code, it is displayed below the line indicating the alarm. Press the screen selection key to select [4 ALARM]. Automatic alarm display upon occurrence Press the alarm key. Alarm occurrence screen display Press F3 [ACTIVE]. Press F3 [HIST]. Alarm history screen display Fig.3.2 Alarm Occurrence Screen and Alarm History Screen Display Procedure 30 B--81465EN--1/02 MAINTENANCE 3. TROUBLESHOOTING Displaying the alarm history/alarm detail information Step (1) Press the MENUS key to display the screen menu. (2) Select [ALARM]. You will see a screen similar to the following 3 4 ALARM 5 I/O MENUS INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Specified line does not exist Alarm JOINT 30 % 1/25 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop 3 R E S E T 4 SRVO-027 Robot not mastered(Group:1) 5 SYST-026 System normal power up [ TYPE ] CLEAR HELP NOTE The latest alarm is assigned number 1. To view messages that are currently not on the screen, press the F5, HELP, then press the right arrow key. (3) To display the alarm detail screen, press F5, [HELP]. CLEAR HELP F5 INTP-224 (SAMPLE1, 7) Jump label is fail INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Specified line does not exist 30-MAY-44 07:15 STOP.L 00000110 Alarm 1/25 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop [ TYPE ] CLEAR HELP (4) To return to the alarm history screen, press the PREV key. PREV (5) To delete all the alarm histories, press and hold down the SHIFT key, then press F4, [CLEAR]. CLEAR F4 HELP SHIFT NOTE When system variable $ER_NOHIS = 1, NONE alarms or WARN alarms are not recorded. When $ER_NOHIS=2, resets are not recorded in the alarm history. When $ER_NOHIS=3, resets, WARN alarms, and NONE alarms are not recorded. 31 3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 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 32 B--81465EN--1/02 MAINTENANCE 3. TROUBLESHOOTING 3.3 SAFETY SIGNALS Safety signal Operator panel emergency stop Teach pendant emergency stop External emergency stop Fence open Deadman switch The safety signal screen indicates the state of signals related to safety. To be specific, the screen indicates whether each safety signal is currently on. On this screen, it is impossible to change the state of any safety signal. Table 3.3 Safety Signals Description This item indicates the state of the emergency stop button on the operator panel. If the EMERGENCY STOP board is pressed, the state is indicated as “TRUE”. This item indicates the state of the emergency stop button on the teach pendant. If the EMERGENCY STOP board is pressed, the state is indicated as “TRUE”. This item indicates the state of the external emergency stop signal. If the EMERGENCY STOP signal is input, the state is indicated as “TRUE”. This item indicates the state of the safety fence. If the safety fence is open, the state is indicated as “TRUE”. This item indicates whether the DEADMAN switch on the teach pendant is grasped. If the teach pendant is operable, and the DEADMAN switch is grasped, the state is indicated as “TRUE”. If the deadman switch is released when the teach pendant is operable, an alarm occurs, causing the servo power to be switched off. This item indicates whether the teach pendant is operable. If the teach pendant is operable, the state is indicated as “TRUE”. This item indicates the state of the hand safety joint. If the hand interferes with a workpiece or anything like this, and the safety joint is opened, the state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be switched off. This item indicates whether the current position of the robot is out of the operation range. If any robot articulation goes out of the operation range beyond the overtravel switch, the state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be switched off. This item indicates the state of the air pressure. The abnormal air pressure signal is connected to the air pressure sensor. If the air pressure is not higher than the specified value, the state is indicated as “TRUE”. Teach pendant operable Hand broken Robot overtravel Abnormal air pressure Step (1) Press the MENUS key to display the screen menu. (2) Select STATUS on the next page. (3) Press F1, [TYPE] to display the screen switching menu. (4) Select Safety Signal. You will see a screen similar to the following. SYSTEM Safety SIGNAL NAME 1 2 3 4 5 6 7 8 9 SOP E-Stop: TP E-stop: Ext E-Stop: Fence Open: TP Deadman: TP Enable: Hand Broken: Over Travel: Low Air Alarm: JOINT 30% STATUS FALSE FALSE FALSE FALSE TRUE TRUE FALSE FALSE FALSE 1/11 [TYPE] 33 refer to an applicable maintenance manual of mechanical unit or operator’s manual of control unit. (Zero--degree position mastering is just for quick--fix purposes.NEXT -SYSTEM Master/Cal 1 MENUS JOINT 30% FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE 5 POSITION 6 SYSTEM 7 2 3 4 5 6 Master/Cal TYPE Press ’ENTER’ or number key to select. TYPE. 34 . NOTE Mastering can not be performed until axis is rotated enough to establish a pulse. Condition System variable $MASTER_ENB must be set to 1 or 2. SYSTEM Variables 57 $MASTER_ENB JOINT 10% 57/136 1 Step (1) Press <MENUS>. [TYPE] LOAD RES_PCA DONE F1 (5) Move the robot by jog feed to the mastering position. For details. Release the brake on the manual brake control screen if necessary. (3) Press F1. (2) Select SYSTEM.3.4 MASTERING Mastering is needed if: (1) The SRVO--062 BZAL or SRVO--038 pulse mismatch alarm occurs. while item (2) requires zero--degree or jig position mastering. Item (1) requires simplified mastering. After zero--degree position mastering is used. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 3.) The mastering procedure is described below. (4) Select Master/Cal you will see a screen similar to the following. 9 USER 0 -. jig position mastering should be performed later. or (2) The pulse coder is replaced. then turn it on again.000> [ TYPE ] LOAD RES_PCA DONE (8) Press F5 “DONE”. Mastering data is set. turn the power off. to perform positioning.000> <5. 5 SET QUICK MASTER REF 6 CALIBRATE ENTER Calibrate? [NO] Calibrate? [NO] [ TYPE ] SYSTEM Master/Cal JOINT 30 % YES NO F4 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <10. DONE F5 35 .000> <-15. TROUBLESHOOTING (6) Select “1 FIXTURE POSITION MASTER” and press the F4 key (yes). after mastering.000> <0. Calibration is performed whenever the power is turned on.000> <-25.B--81465EN--1/02 MAINTENANCE 3. Calibration is performed. Alternatively.000> <40. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER Master at master position? [NO] Master at master position? [NO] [ TYPE ] YES ENTER SYSTEM Master/Cal JOINT 30 % NO F4 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <122000309> <2000319> [ TYPE ] LOAD RES_PCA DONE (7) Select “6 CALIBRATE” and press the F4 key (yes). NOTE If the LED is turned off. Or. check for continuity across the terminals of the switch. SRVO--199 Control stop. SRVO--004 Fence open. perform a complete controller back--up to save all your programs and settings. replace the switch. the cable. or main board may be faulty.3. SRVO--213 Fuse blown (Panel PCB). (Action 4) Replace the Main Board. (Action 3) With the emergency stop in the released position. 36 . TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 3. The connectors of the cable between the main board and the panel board may be loose. SRVO--277 Panel E--stop (SVEMG abnormal). the following alarms are also generated.5 TROUBLESHOOTING USING THE ERROR CODE (1) SRVO--001 SVAL1 Operator panel E--stop (Explanation) The emergency stop button on the operation operator panel or is pressed. (Action 2) Check the wires connecting the emergency stop switch connector CRT8 for continuity. If continuity is found replace the operator panel PCB. (Note) (Action 1) Release the emergency stop button pressed on the operator panel. communication between the main board (JRS11) and the panel board (JRS11) is abnormal. panel board. If continuity is not found. If the SYST--067 (Panel HSSB disconnect) alarm is also generated. If an open wire is found replace the entire harness. SRVO--204 External (SVEMG abnormal) E--stop. SRVO--007 External emergency stop. SRVO--001 Operator panel E--stop. SRVO--280 SVOFF input Check the alarm history display on the teach pendant. or if the LED (green) on the panel board is turned off. Before executing the (Action 4). B--81465EN--1/02 MAINTENANCE 3. TROUBLESHOOTING Emergency stop button Fig.3.5 (1) (a) SRVO--001 SVAL1 Operator panel E--stop 37 . 3.5 (1) (c) SRVO--001 SVAL1 Operator panel E--stop 38 .3.3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 Connector (CRT8) LED (Green) Connector (JRS11) Panel board Fig.5 (1) (b) SRVO--001 SVAL1 Operator panel E--stop Connector (JRS11) Main board Fig. 3. (Action 2) Replace the teach pendant.5 (2) SRVO--002 SVAL1 Teach pendant E--stop (3) SRVO--003 SVAL1 Deadman switch released (Explanation) The teach pendant is enabled. Deadman switch is three position switch.3. Don’t press the switch to the second “open” position. but the deadman switch is not pressed. Switch is enabled in middle position only. Emergency stop button Fig. TROUBLESHOOTING (2) SRVO--002 SVAL1 Teach pendant E--stop (Explanation) The emergency stop button on the operator’s Teach Pendant was pressed. (Action 1) Press the deadman switch to run the robot.5 (3) SRVO--001 SVAL1 Deadman switch released 39 . Deadman switch Fig.B--81465EN--1/02 MAINTENANCE 3. (Action 1) Release the emergency stop button on the teach pendant. (Action 2) Replace Teach Pendant. (Action 3) When this signal is not used. (Note) (Action 1) If a safety fence is connected. “Maintenance. or main board may be faulty. remove the cause. the robot decelerates in a controlled manner and then stops. close the door. (Refer to Section 3. then replace the fuse. it is likely that FUSE1 on the panel board has blown. Check the fuse. (Action 2) Check the switch and cable connected to 5 (EAS1) and 6 (EAS11) or 7 (EAS2) and 8 (EAS21). SRVO--007 (External emergency stops).3. NOTE FENCE input (AUTO STOP) is a safety stop input when this input is opened. as it is very dangerous. If it is necessary to run the robot by short--circuiting the signal even temporarily.6 in Part II. the magnetic contactor opens after the robot stops.”) (Action 5) Replace the panel board. (Action 4) If SRVO--004 (Fence open). this signal in a system in which the Fence signal is in use. the cable. make a connection between 5 (EAS1) and 6 (EAS11) or between 7 (EAS2) and 8 (EAS21). 40 . the door of the safety fence is open. The connectors of the cable between the main board and the panel board may be loose. SRVO--213 (Fuse Blown (Panel PCB)). TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (4) SRVO--004 SVAL1 Fence open (Explanation) On the terminal block TBOP4 of the panel board. or disable. or if the LED (green) on the panel board is turned off. and SRVO--280 (SVOFF input) occur simultaneously. an additional safety provision must be provided. panel board. communication between the main board (JRS11) and the panel board (JRS11) is abnormal. If the SYST--067 (Panel HSSB disconnect) alarm is also generated. If it has blown. WARNING Do NOT short--circuit. no connection is made between 5 (EAS1) and 6 (EAS11) or between 7 (EAS2) and 8 (EAS21). Or.” of “Maintenance Manual. If a safety fence is connected between 5 (EAS1) and 6 (EAS11) or between 7 (EAS2) and 8 (EAS21). SRVO--199 Control stop. TROUBLESHOOTING NOTE If the LED is turned off. Short connection 5 (EAS1) and 6 (EAS11) Connector (CRT8) Short connection 7 (EAS2) and 8 (EAS21) LED (Green) Connector (JRS11) Panel board Fig. SRVO--280 SVOFF input Check the alarm history display on the teach pendant.5 (4) (a) SRVO--004 SVAL1 Fence open Connector (JRS11) Main board Fig.3. SRVO--277 Panel E--stop (SVEMG abnormal). SRVO--001 Operator panel E--stop. SRVO--007 External emergency stop. the following alarms are also generated.5 (4) (b) SRVO--004 SVAL1 Fence open 41 . SRVO--004 Fence open.3.B--81465EN--1/02 MAINTENANCE 3. SRVO--213 Fuse blown (Panel PCB). SRVO--204 External (SVEMG abnormal) E--stop. 2) Hold down the shift key. it may have been disabled by short--circuiting in the mechanical unit. 3) Still hold down the shift key. and press the alarm release button to reset the alarm condition. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (5) SRVO--005 SVAL1 Robot overtravel (Explanation) The robot has moved beyond a hardware limit switch on the axes. 42 . FS2 fuse have been blown. If the SRVO--214 Fuse blown alarm is also generated. Then verify that connectors CRF7 and CRM68 on the servo amplifier are securely connected. If no limit switch is in use. (Action 4) Replace the servo amplifier. (Action 1) 1) Select [System OT release] on the overtravel release screen to release each robot axis from the overtravel state. If the Overtravel signal is not in use. 2) The connector is securely connected. (Action 2) Check the FS2 fuse on the servo amplifier. (Action 3) Verify the following for connector RP1 at the base of the robot : 1) There are no bent or dislocated pins in the male or female connectors. a jumper connector must be attached in the mechanical unit. Check for the jumper connector.3. Also verify that the RP1 cable is in good condition. It is factory--placed in the overtravel state for packing purposes. and there are no cuts or kinks visible. and jog to bring all axes into the movable range. TROUBLESHOOTING Servo amplifier FS2 Connector (CRF7) Connector (CRM68) Servo amplifier Fig.5 (5) SRVO--005 SVAL1 Robot overtravel 43 .3.B--81465EN--1/02 MAINTENANCE 3. 5. and there are no cuts or kinks visible. (Action 4) Replace the servo amplifier. (Action 2) Check the FS2 fuse on the servo amplifier. the HBK signal on the robot connection cable might be a ground fault or a cable disconnection. 2) The connector is securely connected. Refer to Subsection 5. Then verify that connector CRF7 on the servo amplifier is securely connected. it can be disabled by software setting. and press the alarm release button to reset the alarm condition. FS2 fuse have been blown. “Connections. Also verify that the RP1 cable is in good condition.3. If the SRVO--214 Fuse blown alarm is also generated. Alternatively. 44 . TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (6) SRVO--006 SVAL1 Hand broken (Explanation) The safety joint (if in use) might have been broken. 1) Replace the safety joint. 2) Check the safety joint cable. (Action 1) Hold down the shift key. and jog the tool to the work area. (Action 3) Verify the following for connector RP1 at the base of the robot : 1) There are no bent or dislocated pins in the male or femail connectors.3 in Part III.” of “Maintenance Manual” for how to disable the Hand broken signal. Check the robot connection cable (RP1) for a ground fault or a cable disconnection. Still hold down the shift key. If the Hand broken signal is not in use. 3.B--81465EN--1/02 MAINTENANCE 3.5 (6) SRVO--006 SVAL1 Hand broken 45 . TROUBLESHOOTING Servo amplifier FS2 Connector (CRF7) Servo amplifier Fig. releases the switch. then replace the fuse. NOTE If the LED is turned off. SRVO--213 (Fuse blown (Panel PCB)). 46 . If it has blown. an additional safety provision must be provided. it is likely that FUSE1 on the panel board has blown. If the SYST--067 (Panel HSSB disconnect) alarm is also generated. The connectors of the cable between the main board and the panel board may be loose. (Action 4) If SRVO--004 (Fence open). WARNING Do NOT short--circuit. alarm is also generated. communication between the main board (JRS11) and the panel board (JRS11) is abnormal. make a connection between 1 (EES1) and 2 (EES11) or between 3 (EES2) and 4 (EES21). or disable. SRVO--004 (Fence open). the cable. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (7) SRVO--007 SVAL1 External E--stop (Explanation) On the terminal block TBOP4 of the panel board.3. SRVO--007 (External emergency stops). and SRVO--280 (SVOFF input) occur simultaneously. Or.”) (Action 5) Replace the panel board. If it is necessary to run the robot by short--circuiting the signal even temporarily. this signal in a system in which the External emergency stop input signal is in use. (Action 3) When this signal is not used. Check the alarm history display on the teach pendant. remove the cause. as it is very dangerous. the switch is pressed. no connection is made between 1 (EES1) and 2 (EES11) or between 3 (EES2) and 4 (EES21). or main board may be faulty.” of “Maintenance Manual. panel board.6 in Part II. the SRVO--001 (Operator panel E--stop). (Note) (Action 1) If an external emergency stop switch is connected. “Maintenance. or SRVO--280 (SVOFF input). Check the fuse. (Refer to Section 3. If an external emergency stop switch is connected between 1 (EES1) and 2 (EES11) or between 3 (EES2) and 4 (EES21). (Action 2) Check the switch and cable connected to 1 (EES1) and 2 (EES11) or 3 (EES2) and 4 (EES21). or if the LED (green) on the panel board is turned off. SRVO--007 (External emergency stops). B--81465EN--1/02 MAINTENANCE 3.5 (7) (b) SRVO--007 SVAL1 External E--stop 47 . TROUBLESHOOTING Short connection 1 (EES1) and 2 (EES11) Short connection 3 (EES2) and 4 (EES21) Panel board LED (Green) Connector (JRS11) Panel board Fig.3.3.5 (7) (a) SRVO--007 SVAL1 External E--stop Connector (JRS11) Main board Fig. (Action 1) If an abnormal air pressure is detected. The input signal is located on the end effector of the robot.5 (8) SRVO--009 SVAL1 Pneumatic pressure alarm Pneumatic pressure alarm input is disabled/enabled by software. check the robot cable and if the peripheral device are abnormal. Please refer to Subsection 5. Servo amplifier Fig.4. in Part III Connections of this Maintenance Manual. If the peripheral device are normal.5.3. (Action 2) Replace the servo amplifier.3. check the cause. replace the device. 48 . Refer to the manual of your robot. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (8) SRVO--009 SVAL1 Pneumatic pressure alarm (Explanation) An abnormal air pressure was detected. TROUBLESHOOTING (9) SRVO--014 WARN Fan motor abnormal (Explanation) A fan motor in the backplane unit is abnormal. Fan motor Fig. (Action) Check the fan motor and its cables.3.B--81465EN--1/02 MAINTENANCE 3. Replace them if necessary.5 (9) SRVO--014 WARN Fan motor abnormal 49 . (Action 1) If the ambient temperature is higher than specified (45°C). cool down ambient temperature.5 (10) SRVO--015 SVAL1 SYSTEM OVER HEAT 50 . External air Fan unit Door fan Floor fan unit Main board Fig.3. replace the main board. Replace them if necessary. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (10) SRVO--015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j) (Explanation) The temperature in the control unit exceeds the specified value. (Action 2) If the fan motor is not running. check it and its cables.3. (Action 3) If the thermostat on the main board is defective. The ALM LED on the servo amplifier is lit. (Action 2) This alarm may occur if the brake connector is not attached. Make sure that connector CRR64 is securely attached to the servo amplifier.3.5 (11) SRVO--018 SVAL1 Brake abnormal 51 .B--81465EN--1/02 MAINTENANCE 3. (Action 1) Check the robot connection cable (RM1) and cables internal to the mechanical section for a short--circuit and connection to the ground. (Action 3) Replace the servo amplifier. TROUBLESHOOTING (11) SRVO--018 SVAL1 Brake abnormal (Explanation) An excessive brake current is detected. Servo amplifier Fig. (Action 5) Replace the cable between the E--stop unit and the panel board. teach pendant enable/disable switch. If a servo amplifier alarm has been detected. (Action 4) Replace the E--stop unit. Therefore. servo--off input. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (12) SRVO--021 SVAL1 SRDY off (Group : i Axis : j) (Explanation) The HRDY is on and the SRDY is off. (Action 2) Check whether an outage has occurred on an emergency stop line (teach pendant emergency stop. or door switch). (HRDY is a signal with which the host detects the servo system whether to turn on or off the servo amplifier magnetic contactor. (Action 7) Replace axis control card on the main board.3. operator panel emergency stop. 52 . (Action 3) Replace the servo amplifier. it is most likely that a servo amplifier alarm has occurred. fence input. teach pendant deadman switch. although there is no other cause of an alarm. external emergency stop input. the host will not issue this alarm (SRDY off). this alarm indicates that the magnetic contactor cannot be turned on for an unknown reason. This alarm occurs if the alarm cause cannot be detected by software because of a short break and magnetic contactor off. (Action 6) Replace the cable between the E--stop unit and the servo amplifier. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on. (Action 1) Make sure that the CP2 and CRM73 of the E--stop unit and the servo amplifier CNMC2 and CNMC3 are connected tightly.) If the servo amplifier magnetic contactor cannot be turned on when directed so. 3. TROUBLESHOOTING Servo amplifier Main board Axis control card E--stop unit Main board Fig.B--81465EN--1/02 MAINTENANCE 3.5 (12) SRVO--021 SVAL1 SRDY off 53 . SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on. (Action 2) Replace the servo amplifier.5 (13) SRVO--022 SVAL1 SRDY on 54 . the SRDY is already on.3. (HRDY is a signal with which the host directs the servo system whether to turn on or off the servo amplifier magnetic contactor.3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (13) SRVO--022 SVAL1 SRDY on (Group : i Axis : j) (Explanation) When the HRDY is about to go on. (Action 1) Replace the axis control card on the main board. Servo amplifier Main board Axis control card E--stop unit Main board Fig. ) (Action 4) Check each phase voltage of the CRR38A or CRR38B connector of the three--phase power (200 VAC) input to the servo amplifier. the torque output also becomes low.B--81465EN--1/02 MAINTENANCE 3. (Action 6) Check disconnection of motor power cable (RM1. (Action 7) Replace the motor. (Action 3) Check to see if the load is greater than the rating.3. Servo amplifier Main board E--stop unit Fig. the position error is abnormally large. the motor becomes unable to follow the command. check the line voltage. (Action 1) Check whether the motor brake has been released. (If the voltage input to the servo amplifier becomes low. the torque required for acceleration / deceleration becomes higher than the capacity of the motor.5 (14) SRVO--023 SVAL1 Stop error excess 55 . RM2). (If the load is too greater. If it is 170 VAC or lower. As a result the motor may become unable to follow the command. hence possibly an alarm.) (Action 5) If the line voltage is 170 VAC or higher. As a result. reduce it to within the rating. TROUBLESHOOTING (14) SRVO--023 SVAL1 Stop error excess (Group : i Axis : j) (Explanation) When the servo is at stop. If greater. replace the servo amplifier. and an alarm is issued. (Action 2) Make sure that the servo amplifier CNJ1A to CNJ6 are connected tightly. The actual motor speed is clamped to the maximum speed.$JNTVELLIM) was specified. (25) SRVO--037 SVAL1 Imstp input (Group : i) (Explanation) The *IMSTP signal for a peripheral device interface was input. (Action) Master the robot.3.Supply power. but the reference point had not been set up.$ STOPTOL) even after the position check monitoring time ($PARAM _ GROUP. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (15) SRVO--024 SVAL1 Move error excess (Group : i Axis : j) (Explanation) When the robot is running. 2. $TRKERRLIM). (22) SRVO--034 WARN Ref pos not set (Group : i) (Explanation) An attempt was made to perform simplified adjustment. (Action) Take the same actions as for SRVO--23 (large position error at a stop). (16) SRVO--025 SVAL1 Motn dt overflow (Group : i Axis : j) (Explanation) The specified value is too great. $BRKHOLD _ ENB = 1). (Action) Calibrate the robot. $MOVER _ OFFST or $PARAM _ GROUP.Set up a simplified adjustment reference point using [Positioning] on the positioning menu. if the brake on hold function has been enabled ($SCR. Each actual axis speed is clamped to the maximum speed. (21) SRVO--033 WARN Robot not calibrated (Group : i) (Explanation) An attempt was made to set up a reference point for simplified adjustment. (23) SRVO--035 WARN2 Joint speed limit (Group : i Axis : j) (Explanation) A value higher than the maximum axis speed ($PARAM_GROUP. Disable the function if it is not necessary. (18) SRVO--027 WARN Robot not mastered (Group : i) (Explanation) An attempt was made to calibrate the robot. (17) SRVO--026 WARN2 Motor speed limit (Group : i Axis : j) (Explanation) A value higher than the maximum motor speed ($PARAM_GROUP. It is likely that the robot cannot follow the speed specified by program. (Action 2) Take the same actions as described for the above alarm. its position error is greater than a specified value ($PARAM _ GROUP.$MOT_SPD_LIM) was specified. but the necessary adjustment had not been completed. (20) SRVO--031 SVAL1 User servo alarm (Group : i) (Explanation) An user servo alarm occurred. 1. (19) SRVO--030 SVAL1 Brake on hold (Group : i) (Explanation) This alarm occurs when the robot pauses. (Action 1) Check the robot for binding axis. $INPOS _ TIME) elapsed. (Action) Set up a simplified adjustment reference point on the positioning menu. (Action) Turn on the *IMSTP signal. 56 . (Action) Disable [Servo--off during pause] on the general setting menu (Select Setting general). (24) SRVO--036 SVAL1 Inpos time over (Group : i Axis : j) (Explanation) The robot did not get to the effective area ($PARAM _ GROUP. but the robot had not been calibrated. If the contacts of the magnetic contactor have stuck to each other. (Action 2) Replace the E--stop unit. The fault condition should reset. 4. If the power is switched off without turning off the circuit breaker. PES--PCA. because the stuck contacts keep three--phase 200 V applied to the servo amplifier. Press F1 [TYPE]. (Action 1) Check the magnetic contactor. 57 . 3. 2. (28) SRVO--042 MCAL alarm (Group : i Axis : j) (Explanation) This alarm means that the contacts of the magnetic contactor have stuck to each other. If the controller is still faulted with additional servo--related errors. Press RESET. 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. Select SYSTEM. Select MASTER/CAL. (Action) Perform APC reset and remaster robot (RES--PCA) 1. cold start the controller. The alarm condition is detected between the time contact sticking occurs and the time an attempt is made to turn on the magnetic contactor. (Action 3) Replace the servo amplifier. (27) SRVO--041 SVAL2 MOFAL alarm (Group : i Axis : j) (Explanation) The servo value was too high. 6. Press F3. 5. Press MENUS. (Action) Cold start the controller. The alarm condition occurs if the magnetic contactor turns out to be already on when an attempt is made to turn it on.B--81465EN--1/02 MAINTENANCE 3. TROUBLESHOOTING (26) SRVO--038 SVAL2 Pulse mismatch (Group : i Axis : j) (Explanation) The pulse count obtained when power is turned off does not match the pulse count obtained when power is applied. It might be necessary to remaster the robot. the servo amplifier may get damaged. and replace it if necessary. turn off the circuit breaker. the robot operates from the potential energy. If this alarm has occurred. at deceleration on a horizontal axis. the servo amplifier receives energy from the motor. remove the cause. One of the probable causes of a blown fuse is a ground fault in the servo amplifier for auxiliary axis. If a reduction in the potential energy is higher than the energy needed for acceleration. If it has blown. A similar phenomenon occurs even when no gravity is applied. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 Servo amplifier Main board E--stop unit Fig. the difference is stored in the servo amplifier. causing an alarm. 58 . (Action 2) Check fuse FS3 in the servo amplifier. for example.5 (28) SRVO--042 MCAL alarm (29) SRVO--043 SVAL1 DCAL alarm (Group : i Axis : j) (Explanation) The regenerative discharge energy was too high to be dissipated as heat. The energy that the servo amplifier receives from the motor is called the regenerative energy. (Action 3) Make sure that the servo amplifier CRR63A. The servo amplifier dissipates this energy as heat.3.3. CRR63B and CRR63C are connected tightly. relax the service conditions. When going down the vertical axis. CRR63B and CRR63C connector on the emergency stop board. If the regenerative energy is higher than the energy dissipated as heat. the servo amplifier supplies energy to the robot.) (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. then detach the cable from CRR63A. and check for continuity between pins 1 and 2 of the cable--end connector. If there is no continuity between the pins. replace the regenerative resistance. (To run the robot. and replace the fuse. Replace the servo amplifier. If the resistance is not 9--16Ω.3. CRR45B and CRR45C are connected tightly then detach the cables from CRR45A. TROUBLESHOOTING (Action 4) (Action 5) Make sure that the servo amplifier CRR45A. Servo amplifier Regenerative resistor Fig.B--81465EN--1/02 MAINTENANCE 3. replace the regenerative resistor. CRR45B and CRR45C on the servo amplifier and check the resistance between pins 1 and 2 of each cable end connector.5 (29) SRVO--043 SVAL1 DCAL alarm 59 . check the line voltage. reduce it to within the rating. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (30) SRVO--044 SVAL1 HVAL alarm (Group : i Axis : j) (Explanation) The DC voltage (DC link voltage) of the main circuit power supply is abnormally high. Servo amplifier Fig. high acceleration/deceleration can result in this alarm. If it is 253 VAC or higher.5 (30) SRVO--044 SVAL1 HVAL alarm 60 .3. (Action 1) Check the three--phase input voltage at the servo amplifier. (Action 3) Replace the servo amplifier. (If the machine load is higher than the rating. the accumulation of regenerative energy might result in the HVAL alarm even when the three--phase input voltage is within the rating. (If the three--phase input voltage is higher than 253 VAC.) (Action 2) Check that the load weight is within the rating.3. If it is higher than the rating. or intra--robot cable is defective. (Action 3) Disconnect the Robot connection cable (Motor power) from the servo amplifier connector (CNJ**). TROUBLESHOOTING (31) SRVO--045 SVAL1 HCAL alarm (Group : i Axis : j) (Explanation) Abnormally high current flowed in the main circuit of the servo amplifier. and measure the resistance between the U and V. (Action 1) Disconnect the Robot connection cable (Motor power) from the servo amplifier. Servo amplifier Fig. or intra--robot cable is defective. Check each item in detail and replace it if necessary. V. robot interconnection cable. If there is a short--circuit.5 (31) SRVO--045 SVAL1 HCAL alarm 61 . If the resistances at these three places are different from each other. robot interconnection cable. Check them and replace them if necessary. the motor. V and W. and check the insulation of each Robot connection cable (Motor power) (U.B--81465EN--1/02 MAINTENANCE 3. and W and U with a ohmmeter with a very low resistance range.3. or W) and the GND line. (Action 2) Disconnect the Robot connection cable (Motor power) from the servo amplifier connector (CNJ**). the motor. (Action 4) Check the robot connection cable (RM1. (Action 5) Replace the motor. check the line voltage. Servo amplifier Fig. (Action 3) Replace the servo amplifier.3.3. If any problems are found in the cables. replace the cables. RM2). TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (32) SRVO--046 SVAL2 OVC alarm (Group : i Axis : j) (Explanation) This alarm is issued to prevent the motor from thermal damage that might occur when the root meant square current calculated within the servo system is out of the allowable range. If it is 170 VAC or lower.5 (32) SRVO--046 SVAL2 OVC alarm 62 . (Action 2) Check each phase voltage of the three--phase input power (200 VAC for the servo amplifier. (Action 1) Check the operating conditions for the robot and relax the service conditions. 2) OVC and OVL alarms (overcurrent and overload alarms) The OVC and OVL alarms are intended to prevent overheat that may lead to the burnout of the motor winding. so it can prevent the failures described above. Temperature at which the winding starts to burn Time Fig. which has a large mass. For example. 63 . and HC alarms Overview This section points out the differences among the OVC. Alarm detection section Abbreviation Designation Overcurrent alarm Overload alarm Detection section Servo software Thermal relay in the motor OHAL2 Thermal relay in the servo amplifier OHAL1 Thermal relay in the separate regenerative discharge unit DCAL Servo amplifier OVC OVL HC High current alarm Purpose of each alarm 1) HC alarm (high current alarm) If high current flow in a power transistor momentarily due to abnormality or noise in the control circuit. OVL. and dimension. software is used to monitor the current in the motor constantly in order to estimate the temperature of the motor. The HC alarm is intended to prevent such failures. However. this method is not necessarily perfect to prevent these failures.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles To prevent the above defects. the breakdown of the servo amplifier transistor. TROUBLESHOOTING Reference Relationships among the OVC. and the separate regenerative resistor. The OVC alarm is issued based on this estimated temperature. or the magnet of the motor might be degaussed. thus causing the motor to burn before the thermal relay detects an abnormally high temperature. 1. the thermal time constant of the motor. the power transistor and rectifier diodes might be damaged. This method estimates the motor temperature with substantial accuracy. Therefore. the temperature rise in the motor is steeper than that in the thermal relay. structure. OVL. if the motor frequently repeats to start and stop. because these two components are different in material. if the motor repeats to start and stop within a short time as shown in Fig. Temperature Start Stop Start Stop Start Thermal time constant of the motor is high. and HC alarms and describes the purpose of each alarm. Thermal time constant of the thermal relay is low. becomes higher than the time constant of the thermal relay. The OVL alarm occurs when each built--in thermal relay detects a temperature higher than the rated value.B--81465EN--1/02 MAINTENANCE 3. 2 Relationship between the OVC and OVL alarms NOTE The relationship shown in Fig.5 (33) SRVO--047 SVAL1 LVAL alarm 64 . a double protection method is used. The motor might not be hot even if the OVC alarm has occurred. etc. do not change the parameters to relax protection. the OVC alarm is used for protection from a short--time overcurrent. (Action 1) Replace the servo amplifier. In this case.3. (33) SRVO--047 SVAL1 LVAL alarm (Group : i Axis : j) (Explanation) The control power supply voltage (+5 V.) supplied from the power supply circuit in the servo amplifier is abnormally low. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 To sum up. Current Protection area for the motor and servo amplifier Protection by the OVL Limit current Protection by the OVC Rated continuous current Time Fig. The relationship between the OVC and OVL alarms is shown in Fig 2. Servo amplifier Fig. 2 is taken into consideration for the OVC alarm.3. and the OVL alarm is used for protection from long--term overload. Alternatively.) (Action 4) If the fan motor is not running. (Action 2) Check the operating conditions for the robot and relax the service conditions.6. Replace them if necessary.3. (Action 5) Replace the transformer. (Action 3) If fuses F1 and F2 have blown.(See II MAINTENANCE. (Action 1) Make sure that the CRM73 connector of the E--stop unit is connected tightly.5 (34) SRVO--049 SVAL1 OHAL1 alarm 65 . check it and its cables. Servo amplifier Transformer E--stop unit Fig. replace the servo amplifier. fuse F1 or F2 in the servo amplifier has blown.B--81465EN--1/02 MAINTENANCE 3. TROUBLESHOOTING (34) SRVO--049 SVAL1 OHAL1 alarm (Group : i Axis : j) (Explanation) The thermostat in the transformer worked. Section 3. (Action 5) Replace the servo amplifier. reduce it to within the rating.3. If it is higher than the rating.) (Action 1) Check that the robot has collided with anything. If it has. Servo amplifier Fig.3.5 (35) SRVO--050 SVAL1 CLALM alarm 66 . the estimated disturbance torque becomes abnormally high. If it is 170 VAC or lower. (A collision has been detected. check the line voltage. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (35) SRVO--050 SVAL1 CLALM alarm (Group : i Axis : j) (Explanation) The disturbance torque estimated by the servo software is abnormally high.) (Action 4) Check the phase voltage of the three--phase input power (200 VAC) to the servo amplifier. (Action 2) Make sure that the load setting is correct. reset the robot and jog--feed it to recover from the collision. (If the robot is used out of its usable range. possibly resulting in this alarm being detected. (Action 3) Check that the load weight is within the rating. (Action) Replace the servo amplifier.3. TROUBLESHOOTING (36) SRVO--051 SVAL2 CUER alarm (Group : i Axis : j) (Explanation) The offset of the current feedback value is abnormally high.B--81465EN--1/02 MAINTENANCE 3.5 (36) SRVO--051 SVAL2 CUER alarm 67 . Servo amplifier Fig. 3. Servo amplifier Main board Axis control card E--stop unit Main board Fig. (Action) Replace the axis control card on the main board.3.5 (37) SRVO--054 DSM Memory Error 68 . TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (37) SRVO--054 DSM Memory Error (Explanation) An access to the servo module memory fails. Before continuing to the next step. Failure to perform this could result in damage to equipment or lost data. (Action 3) Replace the servo amplifier. perform a complete controller back--up to save all your programs and settings.5 (38) SRVO--055 SVAL2 FSSB com error 1 69 . (from main board to servo amplifier.) (Action 1) Check the communication cable (optical fiber) between the main board and servo amplifier. (Action 4) Replace the main board.3. Replace it if it is faulty. (Action 2) Replace the axis control card on the main board.B--81465EN--1/02 MAINTENANCE 3. Servo amplifier Main board Axis control card E--stop unit Main board Fig. TROUBLESHOOTING (38) SRVO--055 SVAL2 FSSB com error 1 (Group : i Axis : j) (Explanation) A communication error has occurred between the main board and servo amplifier. ) (Action 1) Check the communication cable (optical fiber) between the main board and servo amplifier. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (39) SRVO--056 SVAL2 FSSB com error 2 (Group : i Axis : j) (Explanation) A communication error has occurred between the main board and servo amplifier. Servo amplifier Main board Axis control card E--stop unit Main board Fig. (Action 3) Replace the servo amplifier. perform a complete controller back--up to save all your programs and settings.3.5 (39) SRVO--056 SVAL2 FSSB com error 2 70 . (Action 4) Replace the main board.3. (from servo amplifier to main board. Before continuing to the next step. Failure to perform this could result in damage to equipment or lost data. Replace it if it is faulty. (Action 2) Replace the axis control card on the main board. (Action 6) Replace the main board. (+5V ground fault) Servo amplifier Main board Axis control card E--stop unit Main board Fig. (Action 2) Check whether fuse FS1 in the servo amplifier has blown.5 (40) SRVO--057 SVAL2 FSSB disconnect 71 . (Action 3) Check the communication cable (optical fiber) between the main board and servo amplifier. (Action 7) Check the RP1 cable of robot connection cable. TROUBLESHOOTING (40) SRVO--057 SVAL2 FSSB disconnect (Group : i Axis : j) (Explanation) Communication was interrupted between the main board and servo amplifier. perform a complete controller back--up to save all your programs and settings. Replace it if it is faulty. (Action 5) Replace the servo amplifier. Before continuing to the next step.B--81465EN--1/02 MAINTENANCE 3. Failure to perform this could result in damage to equipment or lost data. (Action 4) Replace the axis control card on the main board.3. (Action 1) Check whether fuse F3 in the power supply unit has blown. (Action 4) Check the communication cable (optical fiber) between the main board and servo amplifier. (Action 1) Check whether fuse F3 in the power supply unit and fuse FS1 in the servo amplifier have blown. Before continuing to the next step.5 (41) SRVO--058 SVAL2 FSSB init error 72 .” (Action 2) Check whether LEDs (P5V and P3.3V) on the servo amplifier are on. (Action 3) Check whether connectors CP6 and CRM67 on the emergency stop unit are securely connected to connector CP6 on the power supply unit and connector CRM67 on the servo amplifier. respectively. perform “Action 3” and all actions that follow it. If they have blown. Failure to perform this could result in damage to equipment or lost data. Servo amplifier Main board Axis control card E--stop unit Main board Fig. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (41) SRVO--058 SVAL2 FSSB init error (Group : i Axis : j) (Explanation) Communication was interrupted between the main board and servo amplifier. “Troubleshooting for Blown Fuse. (Action 5) Replace the axis control card on the main board.3. (Action 7) Replace the main board. (Action 6) Replace the servo amplifier. see Section 3. If they are not on. Replace it if it is faulty.3. perform a complete controller back--up to save all your programs and settings. perform “Action 4” and all actions that follow it. If they are on.6. B--81465EN--1/02 MAINTENANCE 3.3. CRCERR. (Action) Replace the pulse coder. Servo amplifier Fig. 73 . In this case. (Action 1) Check the wiring of the servo amplifier. (Action 5) Replace the backplane.$SPC_RESET to TRUE. mastering is required or follow SRVO--038 RECOVERY PROCEDURE. (44) SRVO--061 SVAL2 CKAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal count clock). (Action 2) Replace the servo amplifier. and replace the new battery. however. After this. (Action 3) Replace the additional axis amplifier. (Action 2) Replace the additional axis board. TROUBLESHOOTING (42) SRVO--059 SVAL2 Servo amp init error (Explanation) Servo amplifier initiazation is failed. (45) SRVO--062 SVAL2 BZAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if battery for pulse coder absolute-position backup is empty. there is no actual condition for this alarm. A probable cause is a broken battery cable or no batteries in the robot. or STBERR alarm. (Action) Check the battery and battery cable. Then set the system variable $MCR. then supply power again. NOTE This alarm might accompany the DTERR. (Action 1) Check whether the optical cable between the additional axis board and additional axis amplifier is connected securely.5 (42) SRVO--059 SVAL2 Servo amp init error (43) SRVO--60 FATL FSSB init error (Explanation) Communication between the additional axis board and additional axis amplifier was interrupted. (Action 4) Replace the main board. (49) SRVO--066 SVAL2 CSAL alarm (Group : i Axis : j) (Explanation) The ROM in the pulse coder is abnormal. there is no actual condition for this alarm. replace the motor. (Action) Replace the pulse coder. or STBERR alarm. (47) SRVO--064 SVAL2 PHAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the phase of the pulses generated in the pulse coder is abnormal. --See actions on SRVO--070 74 . CRCERR. In this case. NOTE This alarm might accompany the DTERR. (50) SRVO--067 SVAL2 OHAL2 alarm (Group : i Axis : j) (Explanation) The temperature inside the pulse coder or motor is abnormally high. NOTE This alarm might accompany the DTERR. the position data will be lost. (If this alarm occurs. (48) SRVO--065 WARN BLAL alarm (Group : i Axis : j) (Explanation) The battery voltage for the pulse coder is lower than the rating. or STBERR alarm. however. (Action 1) Check the operating conditions for the robot and relax the service conditions. (Action) Replace the battery. however. (Action) Replace the pulse coder. CRCERR. or STBERR alarm. turn on the AC power and replace the battery as soon as possible. In this case. Once the position data is lost. (Action 2) When power is supplied to the motor after it has become sufficiently cool. and the built--in thermostat has operated. if the alarm still occurs. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (46) SRVO--063 SVAL2 RCAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal counter). A delay in battery replacement may result in the BZAL alarm being detected.3. --See actions on SRVO--070 (52) SRVO--069 SVAL2 CRCERR alarm (Group : i Axis : j) (Explanation) The serial data has disturbed during communication. mastering will become necessary. In this case. there is no actual condition for this alarm. (51) SRVO--068 SVAL2 DTERR alarm (Group : i Axis : j) (Explanation) The serial pulse coder does not return serial data in response to a request signal. In this case. NOTE This alarm might accompany the DTERR. however. there is no actual condition for this alarm. CRCERR. (Action) Replace the pulse coder. (Action 3) Check that each unit is grounded securely. (58) SRVO--075 WARN Pulse not established (Group : i Axis : j) (Explanation) The absolute position of the pulse coder cannot be established. (Action 1) Make sure that the CRF7 connector of servo amplifire is connected tightly. this alarm does not correspond to the major cause of the failure. Servo amplifier Fig. (Action) Master the robot and enhance the shielding. TROUBLESHOOTING (53) SRVO--070 SVAL2 STBERR alarm (Group : i Axis : j) (Explanation) The start and stop bits of the serial data are abnormal. (Action 1) If this alarm occurs together with the PHAL alarm (No. (56) SRVO--073 SVAL2 CMAL alarm (Group : i Axis : j) (Explanation) It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. and remaster the robot. (Action 2) Check that the shielding of the robot interconnection cable (for the pulse coder) and the peripheral equipment cable is connected securely to the grounding plate. and jog the axis on which the alarm has occurred until the same alarm will not occur again.B--81465EN--1/02 MAINTENANCE 3. (57) SRVO--074 SVAL2 LDAL alarm (Group : i Axis : j) (Explanation) The LED in the pulse coder is broken. 064). (Action) Replace the pulse coder and remaster the robot.5 (53) SRVO--070 SVAL2 STBERR alarm (54) SRVO--071 SVAL2 SPHAL alarm (Group : i Axis : j) (Explanation) The feedback speed is abnormally high. (Action) Reset the alarm. (55) SRVO--072 SVAL2 PMAL alarm (Group : i Axis : j) (Explanation) It is likely that the pulse coder is abnormal. (Jog one motor revolution) 75 . (Action 5) Replace the pulse coder. (Action 6) Replace the robot interconnection cable (for the pulse coder).3. (Action) Replace the pulse coder. (Action 2) Replace the pulse coder. (Action 4) Replace the servo amplifier. (Action) See the description about the SRVO--061 CKAL alarm. resulting in this alarm. decrease it to the limit. If the weight exceeds the upper limit. check the input power supply voltage.3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (59) SRVO--076 SVAL1 Tip Stick Detection (Group : i Axis : j) (Explanation) An excessive disturbance was assumed in servo software at the start of operation. and replace it if necessary. (Action 3) Check whether the load weight is within the rated range. (Action 2) Check whether the load settings are valid. then switch it to the jog feed mode to avoid the collision. (Action 1) Check the pulse coder connection cable. (62) SRVO--083 WARN CKAL alarm (Track ebc : i) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal count clock).3. The cause may be welding. 76 .5 (60) SRVO--076 SVAL1 Tip Stick Detection (60) SRVO--081 WARN EROFL alarm (Track enc : i) (Explanation) The pulse counter for line tracking has overflowed. reset the system. (Action 2) Replace the pulse coder. Servo amplifier Fig. If a collision occurs. (Use of the robot with a load exceeding the limit applied may abnormally increase the assumed disturbance. If the voltage is 170 VAC or lower.) (Action 1) Check whether the robot comes into collision with foreign matter.) (Action 4) Check each inter--phase voltage of the three--phase input (200 VAC) to the servo amplifier. (Action 5) Replace the servo amplifier. (An abnormal load was detected. (61) SRVO--082 WARN DAL alarm (Track ebc : i) (Explanation) The line tracking pulse coder has not been connected. (68) SRVO--089 WARN OHAL2 alarm (Track enc : i) (Explanation) The motor has overheated. See the description about the CRCERR alarm (SRVO--069). See the description about the BZAL alarm (SRVO--062). (66) SRVO--087 WARN BLAL alarm (Track enc : i) (Explanation) This alarm occurs if the voltage of the backup battery for the absolute position of the pulse coder is low. See the description about the CMAL alarm (SRVO--073).B--81465EN--1/02 MAINTENANCE 3. (65) SRVO--086 WARN PHAL alarm (Track enc : i) (Explanation) This alarm occurs if the phase of pulses generated in the pulse coder is abnormal. See the description about the DTERR alarm (SRVO--068). (70) SRVO--091 WARN CRCERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. 77 . See the description about the OHAL2 alarm (SRVO--067). See the description about the STBERR alarm (SRVO--070). (Action) See the description about the SRVO--066 CSAL alarm. (71) SRVO--092 WARN STBERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the PHAL alarm (SRVO--064). (75) SRVO--096 WARN LDAL alarm (Track enc : i) (Explanation) The LED in the pulse coder is broken. See the description about the BLAL alarm (SRVO--065). (69) SRVO--090 WARN DTERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the PMAL alarm (SRVO--072). See the description about the LDAL alarm (SRVO--074). (64) SRVO--085 WARN RCAL alarm (Track ebc : i) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal counter). (67) SRVO--088 WARN CSAL alarm (Track ebc : i) (Explanation) The ROM in the pulse coder is abnormal. (73) SRVO--094 WARN PMAL alarm (Track enc : i) (Explanation) It is likely that the pulse coder is abnormal. (72) SRVO--093 WARN SPMAL alarm (Track enc : i) (Explanation) This alarm occurs if the current position data from the pulse coder is higher than the previous position data. See the description about the SPHAL alarm (SRVO--071). (Action) See the description about the SRVO--063 RCAL alarm. (74) SRVO--095 WARN CMAL alarm (Track enc : i) (Explanation) It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. TROUBLESHOOTING (63) SRVO--084 WARN BZAL alarm (Track enc : i) (Explanation) This alarm occurs if the backup battery for the absolute position of the pulse coder has not been connected. (77) SRVO--105 SVAL1 Door open or E--stop (Explanation) The cabinet door is open. If the switch or cable is faulty. --This alarm occured in the robot operation. go to [Action 3].3. Reference the total connection diagram in Appendix and check whether the emergency stop line is normal. (Action 2) Replace the servo amplifier. Pulse not established. (Action 5) Replace the servo amplifier.3. CRM71. If it is 170 VAC or lower. If anything is abnormal. check the line voltage. If no door switch is mounted. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (76) SRVO--097 WARN Palse not established (enc : i) (Explanation) The absolute position of the pulse coder cannot be established. (Action 3) Check that the CRM70. close it. Servo amplifier Electro magnetic contactor E--stop unit Fig. (Action 1) Check the phase voltage of the three--phase input power (200 VAC) to the servo amplifier. replace it. If it is OFF. check the servo amplifier and the wiring between the servo amplifier and the emergency stop unit.5 (79) SRVO--105 SVAL1 Door open or E--stop (78) SRVO--136 SVAL1 DCLVAL alarm (Group : i Axis : j) (Explanation) The servo the DC current of amplifier (DC link voltage) of the main power supply is abnormally low. 78 . (Action 2) Check the door switch and door switch connection cable. replace it. (Action 4) This alarm is also issued if software cannot determine the cause of disconnection of the emergency stop line. and CRM72 connectors on the E--STOP unit are connected securely. --If this alarm occurs before the magnetic contactor is turned on: (Action 1) Check whether the circuit breaker in the emergency stop unit is OFF. (Action 1) When the door is open. See the description about (SRVO--075). Replace the E--stop unit. TROUBLESHOOTING (Action 2) (Action 3) (Action 4) Check each phase--to--phase voltage of the three--phase input (200 VAC) on the primary side of the magnetic contactor. (Action 3) Replace the servo amplifier. Replace the servo amplifier. If the input is not higher than 170 VAC. (Action) If this problem occurs repeatedly. (Action 2) The charging current control resistor may be faulty. check the input power supply voltage. please make sure the cable shields are grounded. replase the pulse coder and master the robot. 79 . (Action) If the alarm disappeared by power OFF/ON. (Action 1) A short circuit may occur in the DC link. Or the inter polation circuit of the pulse coder is broken. (80) SRVO--153 SVAL1 CHGAL(CNV) alarm (Group : i Axis : j) (Explanation) The main circuit could not be charged within the specified time. Servo amplifier Main board E--stop unit Fig. Replace the E--STOP unit.B--81465EN--1/02 MAINTENANCE 3. Check the connection.5 (78) SRVO--136 SVAL1 DCLVAL alarm (79) SRVO--138 SDAL alarm(Group : i Axis : j) (Explanation) The feedback data from pulse coder was abnormal by noise on the pulse coder.3. or robot internal cable is likely be defective. Check each of them. then check to see if the alarm occurs again. (Action 3) Detach the motor power lines from the respective terminals on the servo amplifier. robot connection cable. V. robot connection cable. (Action 1) Detach the motor power lines from the respective terminals on the servo amplifier. the motor.5 (80) SRVO--153 SVAL1 CHGAL(CNV) alarm (81) SRVO--156 SVAL1 IPMAL alarm (Group : i Axis : j) (Explanation) Abnormally high current flowed through the main circuit of the servo amplifier. and check for isolation between each motor power line (U. the motor. 80 . TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 Servo amplifier Panel board E--stop unit Fig. or W) and a ground potential (GND). and replace it if necessary. and replace it if necessary. and switch on the power. If the alarm occurs. If the measured three resistances are different. If a motor power line is short--circuited to a ground. V and W. and check the resistance between each motor power line pair (U and V. or robot internal cable is likely to be defective.3. (Action 2) Detach the motor power lines from the respective terminals on the servo amplifier. or W and U) using a meter that is capable of measuring a very low resistance.3. Check each of them. replace the servo amplifier. 5 (82) SRVO--157 SVAL1 CHGAL alarm 81 . TROUBLESHOOTING Servo amplifier Fig. (Action 2) The charging current control resistor may be faulty. (Action 3) Replace the servo amplifier. Replace the E--STOP unit.5 (81) SRVO--156 SVAL1 IPMAL alarm (82) SRVO--157 SVAL1 CHGAL alarm (Group : i Axis : j) (Explanation) The capacitor for the DC link voltage of the servo amplifier was not charged within the specified time. Check the connection.3.3. (Action 1) A short circuit may occur in the DC link voltage. Servo amplifier Panel board E--stop unit Fig.B--81465EN--1/02 MAINTENANCE 3. Or. If the SYST--067 (Panel HSSB disconnect) alarm is also generated. SRVO--213 Fuse blown (Panel PCB). or main board may be faulty. no connection is made between 5 (SD4) and 6 (SD41) or between 7 (SD5) and 8 (SD51). The connectors of the cable between the main board and the panel board may be loose. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (83) SRVO--194 Servo disconnect (Explanation) On the terminal block TBOP3 of the panel board. the switch is pressed. make a connection between 5 (SD4) and 6 (SD41) or between 7 (SD5) and 8 (SD51). SRVO--199 Control stop. panel board. When this signal is not used. Check the switch and cable connected to 5 (SD4) and 6 (SD41) or 7 (SD5) and 8 (SD51). the cable. Replace the PC board. communication between the main board (JRS11) and the panel board (JRS11) is abnormal. (Note) (Action 1) (Action 2) (Action 3) (Action 4) If a servo disconnect switch is connected. If a servo disconnect switch is connected between 5 (SD4) and 6 (SD41) or between 7 (SD5) and 8 (SD51). 82 . releases the switch. SRVO--004 Fence open. or if the LED (green) on the panel board is turned off. SRVO--204 External (SVEMG abnormal) E--stop. NOTE If the LED is turned off. SRVO--007 External emergency stop. SRVO--277 Panel E--stop (SVEMG abnormal). SRVO--001 Operator panel E--stop.3. SRVO--280 SVOFF input Check the alarm history display on the teach pendant. the following alarms are also generated. 3.3.5 (83) (a) SRVO--194 Servo disconnect Connector (JRS11) Main board Fig. 83 . TROUBLESHOOTING Short connection 5 (SD4) and 6 (SD41) Panel board LED (Green) Connector (JRS11) Short connection 7 (SD5) and 8 (SD51) Panel board Fig.B--81465EN--1/02 MAINTENANCE 3.5 (83) (b) SRVO--194 Servo disconnect (84) SRVO--199 Control Stop (Explanation) This alarm is displayed together with a Fence open alarm or SVOFF input alarm. (Action 3) Replace the servo amplifier. (Action 2) Replace the panel board. NOTE This alarm might occur if the EMERGENCY STOP button is pressed slowly. (Action 1) Check the EMERGENCY STOP button on the operator panel. Servo amplifier Emergency stop button Panel board Fig.3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (85) SRVO--201 SVAL1 Panel E--stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator panel was pressed.3. and replace it if necessary. but the EMERGENCY STOP line was not disconnected.5 (85) SRVO--201 SVAL1 Panel E--stop or SVEMG abnormal 84 . (Action 3) Replace the panel board. TROUBLESHOOTING (86) SRVO--202 SVAL1 TP E--stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator panel was pressed. NOTE This alarm might occur if the EMERGENCY STOP button is pressed slowly. but the EMERGENCY STOP line was not disconnected. (Action 2) Replace the teach pendant. (Action 1) Check the teach pendant connection cable.3.5 (86) SRVO--202 SVAL1 TP E--stop or SVEMG abnormal 85 .B--81465EN--1/02 MAINTENANCE 3. (Action 4) Replace the servo amplifier. Servo amplifier Emergency stop button Panel board Fig. and replace it if necessary. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (87) SRVO--204 SVAL1 External (SVEMG abnormal) E--stop (Explanation) The switch connected across EES1 and EES11.3.5 (87) SRVO--204 SVAL1 External (SVEMG abnormal) E--stop 86 . (Action 2) Replace the servo amplifier.3. Servo amplifier Emergency stop button Panel board Fig. EES2 and EES21 on the TBOP4 terminal board on the panel board was pressed. but the EMERGENCY STOP line was not disconnected. (Action 1) Replace the panel board. B--81465EN--1/02 MAINTENANCE 3. TROUBLESHOOTING (88) SRVO--205 SVAL1 Fence open (SVEMG abnormal) (Explanation) The switch connected across EAS1 and EAS11, EAS2 and EAS21 on the TBOP4 terminal board on the panel board was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Replace the panel board. (Action 2) Replace the servo amplifier. Servo amplifier Emergency stop button Panel board Fig.3.5 (88) SRVO--205 SVAL1 Fence open (SVEMG abnormal) 87 3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (89) SRVO--206 SVAL1 Deadman switch (SVEMG abnormal) (Explanation) The DEADMAN switch was released when the teach pendant was operable, but the EMERGENCY STOP line was not disconnected. (Action 1) Check the teach pendant connection cable. Replace it if necessary. (Action 2) Replace the teach pendant. (Action 3) Replace the panel board. (Action 4) Replace the servo amplifier. Servo amplifier Emergency stop button Panel board Fig.3.5 (89) SRVO--206 SVAL1 Deadman switch (SVEMG abnormal) 88 B--81465EN--1/02 MAINTENANCE 3. TROUBLESHOOTING (90) SRVO--207 SVAL1 TP switch abnormal or door open (Explanation) The teach pendant is operable, and the deadman switch has been grasped, but the EMERGENCY STOP line is kept disconnected. (Action 1) Check the teach pendant connection cable, and replace it if necessary. (Action 2) Replace the teach pendant. (Action 3) Replace the panel board. (Action 4) Replace the servo amplifier. Servo amplifier Emergency stop button Panel board Fig.3.5 (90) SRVO--207 SVAL1 TP switch abnormal or door open 89 3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (91) SRVO--213 WARN Fuse blown (Panel PCB) (Explanation) A fuse on the panel board has blown. (Action 1) Check whether fuse FUSE1 on the panel board is blown. When the fuse is blown, eliminate the cause, then replace the fuse. (See II MAINTENANCE, Section 3.6.) (Action 2) Replace the panel board. Servo amplifier Panel board E--stop unit Fig.3.5 (91) SRVO--213 WARN Fuse blawon (Panel PCB) 90 B--81465EN--1/02 MAINTENANCE 3. TROUBLESHOOTING (92) SRVO--214 WARN Fuse blown (Panel PCB) (Explanation) A fuse in the servo amplifier has blown. (Action 1) Check whether fuse F1, F2, FS2, or FS3 in the servo amplifier is blown. When a fuse is blown, eliminate the cause, then replace the fuse. (See II MAINTENANCE, Section 3.6.) (Action 2) Replace the servo amplifier. Servo amplifier Panel board E--stop unit Fig.3.5 (92) SRVO--214 WARN Fuse blown (Panel PCB) 91 3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (93) SRVO--215 WARN Fuse blown (Aux axis) (Explanation) The fuse in the additional axis amplifier has blown. (Action 1) Check the cause and solve the problem, then replace the fuse. (94) SRVO--216 SVAL1 OVC (total) (Robot : i) (Explanation) The current (total current for six axes) flowing through the motor is too large. (Action 1) Slow the motion of the robot where possible. Check the robot operation conditions. If the robot is used with a condition exceeding the duty or load weight robot rating, reduce the load condition value to the specification range. (Action 2) Check each inter--phase voltage of the three--phase input (200 VAC) to the servo amplifier. If the voltage is 170 VAC or lower, check the input power supply voltage. (95) SRVO--221 SVAL1 Lack of DSP (Group : i Axis : j) (Explanation) A controlled axis card corresponding to the set number of axes is not mounted. (Action 1) Check whether the set number of axes is valid. If the number is invalid, set the correct number. (Action 2) Replace the controlled axis card with a card corresponding to the set number of axes. (Example) When six axes are set, a controlled axis card for six or eight axes is available. For how to replace the controlled axis card, see II MAINTENANCE, Section 7.2 in this manual. (96) SRVO--222 SVAL1 Lack of Amp (Amp : i) (Explanation) The FSSB has no SVM. (Action 1) Check that the optical cable is securely connected to the SVM. (Action 2) Replace the optical cable. (Action 3) Check whether power is properly supplied to the SVM. Check that there is no problem with each SVM input voltage. (Action 4) Replace the SVM. (97) SRVO--230 SVAL1 Chain 1 (+24V) abnormal SRVO--231 SVAL1 Chain 2 (0V) abnormal (Explanation) Single chain 1 (+24V)/chain 2 (0V) failure occured on emergency stop of operator panel or emergency stop of teach pendant or deadman switch or fence switch or external emergency stop or servo ON/OFF switch or NTED input or door switch. Please check history of alarm by Alarm Log. ¯ Single chain failure is ; One of emergency stop chain is emergency stop condition, and another chain is not emergency stop condition. ¯ Cause of this alarm is ; -- Weld of contact -- Wire broken or shorted -- Half release of deadman switch -- Half operation of emergency stop of operator panel and emergency stop of teach pendant 92 (Example of external emergency stop) [Displaying the Alarm Log] Please refer to “Setup and Operations Manual”. Select Alarm Log. Single chain 1 (+24V) failure is . 4.) The single chain failure occurred on the emergency stop switch of the operator panel. Press F1. if the RESET operation is issued before the special reset procedure is performed. 1. 3 If a successful operator panel emergency stop. Press “4” on the teach pendant. CAUTION 1 This alarm is controlled by the software and requires a special reset procedure. 2 The RESET operation is inhibited until the special reset procedure is performed. (Example of external emergency stop) Single chain 2 (0V) failure is . please issue the special reset procedure according to end of Explanations and Actions shown below. TROUBLESHOOTING -. Press “MENUS” on the teach pendant. the message of “SRVO--236 Chain failure is repaired” is displayed. or when the deadman switch is released after this alarm. Hold the alarm state for the duration that the alarm history is being checked. (Out of specified timing.Irregular input from external emergency stop and etc. The message of “SRVO--237 Cannot reset chain failure” is displayed. emergency stop switch of the teach pendant and the deadman switch. 3. 2. [TYPE]. or turning the power on again. 93 . This failure can be recovered by performing the correct stop operation. [4 ALARM]. The detecting circuit for the single chain failure is reset by either entering another stop cause.B--81465EN--1/02 MAINTENANCE 3. After resolving the cause of the alarm. or teach pendant emergency stop. 5 (98) SRVO--230 SVAL1 Chain 1 (+24V) abnormal 94 . TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (Example) (98) SRVO--230 SVAL1 Chain 1 (+24V) abnormal with SRVO--001 Operator panel E--stop SRVO--231 SVAL1 Chain 2 (0V) abnormal with SRVO--001 Operator panel E--stop (Action 1) Re--operate emergency stop of operator panel. Servo amplifier Panel board Mode switch Operator panel Teach pendant E--stop unit Fig.3. (Action 4) Replace the E--stop unit. (Action 5) Replace the servo amplifier. (Action 2) Replace the panel board. the message of “SRVO--236 Chain failure is repaired” is displayed.3. (Action 3) Replace the operator panel. If this alarm is reset. (Action 4) Replace the operator panel. (Action 6) Replace the servo amplifier. If this alarm is reset. Servo amplifier Panel board Mode switch Operator panel Teach pendant E--stop unit Fig. (Action 5) Replace the E--stop unit.3.5 (99) SRVO--230 SVAL1 Chain 1 (+24V) abnormal 95 . the message of “SRVO--236 Chain failure is repaired” is displayed.B--81465EN--1/02 MAINTENANCE 3. (Action 2) Check the teach pendant connection cable and replace it if necessary. TROUBLESHOOTING (99) SRVO--230 SVAL1 Chain 1 (+24V) abnormal with SRVO--002 Teach pendant E--stop SRVO--231 SVAL1 Chain 2 (0V) abnormal with SRVO--002 Teach pendant E--stop (Action 1) Re--operate emergency stop of teach pendant. (Action 3) Replace the panel board. (Action 4) Replace the teach pendant. (Action 7) Replace the mode switch.5 (100) SRVO--230 SVAL1 Chain 1 (+24V) abnormal 96 . Servo amplifier Panel board Mode switch Operator panel Teach pendant E--stop unit Fig. If this alarm is reset. (Action 6) Replace the servo amplifier. (Action 3) Replace the panel board. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (100) SRVO--230 SVAL1 Chain 1 (+24V) abnormal with SRVO--003 Deadman switch released SRVO--231 SVAL1 Chain 2 (0V) abnormal with SRVO--003 Deadman switch released (Action 1) Re--operate deadman switch. (Action 5) Replace the E--stop unit.3.3. (Action 2) Check the teach pendant connection cable and replace it if necessary. the message of “SRVO--236 Chain failure is repaired” is displayed. 5 (101) SRVO--240 Chain1 (FENCE) abnormal 97 . (Action 3) Replace the E--stop unit. or the 0V connection of safety fence (EAS2 -.3. (Action 4) Replace the servo amplifier. Servo amplifier Panel board Mode switch Operator panel Teach pendant E--stop unit Fig.B--81465EN--1/02 MAINTENANCE 3. TROUBLESHOOTING (101) SRVO--240 Chain1 (FENCE) abnormal with SRVO--230 SVAL1 Chain 1 (+24V) abnormal and SRVO--004 Fence open SRVO--241 Chain2 (FENCE) abnormal with SRVO--231 SVAL1 Chain 2 (0V) abnormal and SRVO--004 Fence open (Action 1) Check the +24V connection of safety fence (EAS1 -EAS11). (Action 5) Replace the mode switch.EAS21) (Action 2) Replace the panel board. EES11). (Action 3) Replace the E--stop unit.3. Servo amplifier Panel board Mode switch Operator panel Teach pendant E--stop unit Fig. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (102) SRVO--242 Chain1 (EXEMG) abnormal with SRVO--230 SVAL1 Chain 1 (+24V) abnormal and SRVO--007 External emergency stops SRVO--243 Chain2 (EXEMG) abnormal with SRVO--231 SVAL1 Chain 2 (0V) abnormal and SRVO--007 External emergency stops (Action 1) Check the +24V connection of external emergency stop (EES1 -.5 (102) SRVO--242 Chain1 (EXEMG) abnormal 98 . (Action 2) Replace the panel board.3.EES21). or the 0V connection of external emergency stop (EES2 -. (Action 4) Replace the servo amplifier. NTED21).3. (Action 5) Replace the mode switch. Servo amplifier Panel board Mode switch Operator panel Teach pendant E--stop unit Fig.B--81465EN--1/02 MAINTENANCE 3. (Action 3) Replace the E--stop unit.NTED11).5 (103) SRVO--230 SVAL1 Chain 1 (+24V) abnormal 99 . TROUBLESHOOTING (103) SRVO--230 SVAL1 Chain 1 (+24V) abnormal with SRVO--232 SVAL1 NTED input SRVO--231 SVAL1 Chain 2 (0V) abnormal with SRVO--232 SVAL1 NTED input (Action 1) Check the +24V connection of NTED input (NTED1 -. (Action 2) Replace the panel board. (Action 4) Replace the servo amplifier. or the 0V connection of NTED input (NTED2 -. Servo amplifier Panel board Mode switch Operator panel Teach pendant E--stop unit Fig. (Action 3) Replace the teach pendant. (Action 2) Replace the panel board. (Action 5) Replace the servo amplifier.3. T2/Door open (Action 1) Check the teach pendant connection cable and replace it if necessary. (Action 4) Replace the E--stop unit.3.5 (104) SRVO--230 SVAL1 Chain 1 (+24V) abnormal 100 . (Action 6) Replace the mode switch. T2/Door open SRVO--231 SVAL1 Chain 2 (0V) abnormal with SRVO--233 SVAL1 TP disabled in T1. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (104) SRVO--230 SVAL1 Chain 1 (+24V) abnormal with SRVO--233 SVAL1 TP disabled in T1. Press “6” on the teach pendant. Press F4. 7. 1. 4. 101 . [TRUE]. Search item 28. And few seconds later the display changes “FALSE” from “TRUE” again. [0 ---. Press “MENU” on the teach pendant. 8. Press “0” on the teach pendant. The display of “28 Reset CHAIN FAILURE detection : ” changes “TRUE” from “FALSE”. Press F1. 2. TROUBLESHOOTING [Special reset operation] CAUTION Do not issue this operation before resolving the cause of the alarm.B--81465EN--1/02 MAINTENANCE 3. 5.NEXT ----]. [TYPE]. 6. 3. [6 SYSTEM]. The RESET operation is allowed. Press E--stop button for correct emergency stop condition. 9. Select Config. (Action 2) Replace the panel board. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (105) SRVO--232 SVAL1 NTED input (Explanation) Non teacher enabling device is released. (Action 1) Check the connection of non teacher enabling device. (Action 3) Replace the mode switch. Servo amplifier Panel board Mode switch Operator panel Teach pendant E--stop unit Fig.3.5 (105) SRVO--232 SVAL1 NTED input 102 .3. TROUBLESHOOTING (106) SRVO--233 SVAL1 TP disabled in T1. Or controller door is opened.5 (106) SRVO--233 SVAL1 TP disabled in T1. and replace it if necessary. (Action 2) Check the door switch. (Action 3) Replace the panel board. T2/Door open 103 . (Action 4) Replace the teach pendant.3. Servo amplifier Panel board Mode switch Operator panel Teach pendant E--stop unit Fig. (Action 5) Replace the mode switch. (Action 1) Close the controller door. T2/Door open (Explanation) Teach pendant is disabled when the mode switch is T1 or T2.B--81465EN--1/02 MAINTENANCE 3. if open. See the explanation of SRVO--230 and SRVO--231. emergency stop of teach pendant and deadman switch are recoverable issuing correct stop operation. 104 . see the explanation of SRVO--230 and SRVO--231. (Action 1) To reset detecting circuit for single chain failure. CAUTION This alarm is an un--clear single chain failure condition. (108) SRVO--236 SVAL1 Chain failure is repaired (Explanation) A chain failure was repaired. If any cause of stop is issued for a short time. the message of “SRVO--236 Chain failure is repaired” is displayed. The above are operated by the operator. (109) SRVO--237 SVAL1 Not reset chain failure (Explanation) A chain failure could not be repaired. NOTE 1 This alarm may occur when an operator panel emergency stop.Half release of deadman switch -.Half operation of emergency stop of operator panel and emergency stop of teach pendant Short term single chain failures occured on emergency stop of operator panel. ¯ Short term single chain failure is . the messege of “SRVO--236 Chain failure is repaired” is displayed.3. (Action 1) Check the alarm history and see the explanation of the displayed alarm. ¯ Cause of this alarm is . In this case. re--operate emergency stop of operator panel or emergency stop of teach pendant or deadman switch according previous operation. 2 If correct action is issued after this alarm. For details. so this alarm is distinguished from “SRVO--230” and “SRVO--231”. -. This alarm is provided for un--clear and fast--repeated operation by the operator. cause of stop is not detected by software. The software waits for a correct operation response to reset the single chain failure condition. If another cause is issued. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (107) SRVO--235 Short term Chain abnormal (Explanation) Short term single chain failure condition is detected. detecting circuit for single chain failure detects as single chain failure depending on hardware specification. If this alarm is reset. teach pendant emergency stop or when the deadman switch is released. then the software detects the real single chain failure and displays “Chain 1 (+24V) abnormal” or “Chain 2 (0V) abnormal”. 5 (111) SRVO--241 SVAL1 Chain 2 (FENCE) abnormal 105 . (Action 4) Replace the servo amplifier. NOTE Eliminate the cause of the abnormal chain. (Action 3) Replace the E--STOP unit. Servo amplifier Panel board E--stop unit Fig.B--81465EN--1/02 MAINTENANCE 3.3. the emergency stop line was not disconnected. TROUBLESHOOTING (110) SRVO--240 SVAL1 Chain 1 (FENCE) abnormal (111) SRVO--241 SVAL1 Chain 2 (FENCE) abnormal (Explanation) Although the circuit connected between EAS11 and EAS1 or between EAS21 and EAS2 on the TBOP4 terminal block on the panel board was disconnected. (Action 1) Check the +24 V connection (between EAS11 and EAS1) and 0 V connection (between EAS21 and EAS2) for the fence. then execute “special reset operation” to release the alarm. (Action 2) Replace the panel board. The emergency stop circuit is faulty. (Action 2) Replace the panel board. (Action 4) Replace the servo amplifier. The emergency stop circuit is faulty. the emergency stop line was not disconnected.3. NOTE Eliminate the cause of the abnormal chain.5 (112) SRVO--242 SVAL1 Chain 1 (EXEMG) abnormal SRVO--243 SVAL1 Chain 2 (EXEMG) abnormal 106 . (Action 3) Replace the E--STOP unit. (Action 1) Check the +24 V connection (between EES11 and EES1) and 0 V connection (between EES21 and EES2) for the external emergency stop circuit. Servo amplifier Panel board E--stop unit Fig. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (112) SRVO--242 SVAL1 Chain 1 (EXEMG) abnormal SRVO--243 SVAL1 Chain 2 (EXEMG) abnormal (Explanation) Although the external emergency stop circuit was disconnected.3. then execute “special reset operation” to release the alarm. TROUBLESHOOTING (113) SRVO--260 SVAL1 Chain 1 (NTED) abnormal SRVO--261 SVAL1 Chain 2 (NTED) abnormal (Explanation) Although the non--teacher--enabling device disconnected the NTED circuit in the T1/T2 mode.3. (Action 1) Check the +24 V connection (between NTED11 and NTED1) and 0 V connection (between NTED21 and NTED2) for the NTED circuit. (Action 3) Replace the E--STOP unit. The emergency stop circuit is faulty.B--81465EN--1/02 MAINTENANCE 3. (Action 3) Replace the E--STOP unit. the emergency stop line was not disconnected. The emergency stop circuit is faulty. (Action 1) Check the +24 V connection (between SD41 and SD1) and 0 V connection (between SD51 and SD5) for the SVDCT circuit.5 (113) SRVO--260 SVAL1 Chain 1 (NTED) abnormal SRVO--261 SVAL1 Chain 2 (NTED) abnormal (114) SRVO--262 SVAL1 Chain 1 (SVDCT) abnormal SRVO--263 SVAL1 Chain 2 (SVDCT) abnormal (Explanation) Although the SVDCT circuit was disconnected. (Action 2) Replace the panel board. (Action 4) Replace the servo amplifier. (Action 4) Replace the servo amplifier. Servo amplifier Panel board E--stop unit Fig. the emergency stop line was not disconnected. 107 . (Action 2) Replace the panel board. 3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 Servo amplifier Panel board E--stop unit Fig. (Action 3) Replace the E--STOP unit. (Action 4) Replace the servo amplifier.3.STOP circuit abnormal 1” 108 .STOP circuit abnormal 1” (Explanation) An error occurred in the emergency stop circuit. (Action 1) Check whether the CRM67 and CRM72 connectors on the E--STOP unit are connected securely.5 (114) SRVO--262 SVAL1 Chain 1 (SVDCT) abnormal SRVO--263 SVAL1 Chain 2 (SVDCT) abnormal (115) SRVO--264 SVAL1 “E.5 (115) SRVO--264 SVAL1 “E. (Action 2) Check whether the circuits connected to CRM67 and CRM72 in the emergency stop circuit are normal.3. Servo amplifier E--stop unit Fig. If the SYST--067 (Panel HSSB disconnect) alarm is also generated. Check the fuse.B--81465EN--1/02 MAINTENANCE 3. Or. no connection is made between 9 (EGS1) and 10 (EGS11) or between 11 (EGS2) and 12 (EGS21). SRVO--007 (External emergency stops).3.” of “Maintenance Manual. panel board. it is likely that FUSE1 on the panel board has blown. (Action 4) If SRVO--004 (Fence open). The MON3 state is abnormal. remove the cause. or if the LED (green) on the panel board is turned off. If it has blown.STOP circuit abnormal 2 (117) SRVO--280 SVAL1 SVOFF input (Explanation) On the terminal block TBOP4 of the panel board. the cable. “Maintenance. (Action 1) If a switch is connected. communication between the main board (JRS11) and the panel board (JRS11) is abnormal. or main board may be faulty. MON3 was in the on state.”) 109 .STOP circuit abnormal 2 (Explanation) When the servo entered the activated state. TROUBLESHOOTING (116) SRVO--265 SVAL1 E. and SRVO--280 (SVOFF input) occur simultaneously. (Action 3) Replace the panel board. (Action 2) Replace the servo amplifier.5 (116) SRVO--265 SVAL1 E. If a switch is connected between 9 (EGS1) and 10 (EGS11) or between 11 (EGS2) and 12 (EGS21). then replace the fuse. the switch is pressed. SRVO--213 (Fuse blown (Panel PCB)). (Refer to Section 3. make a connection between 9 (EGS1) and 10 (EGS11) or between 11 (EGS2) and 12 (EGS21). The connectors of the cable between the main board and the panel board may be loose. (Action 1) Replace the E--STOP unit. releases the switch.6 in Part II. (Action 3) When this signal is not used. Servo amplifier Panel board E--stop unit Fig. (Note) (Action 2) Check the switch and cable connected to 9 (EGS1) and 10 (EGS11) or 11 (EGS2) and 12 (EGS21). TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (Action 5) (Action 6) Replace the panel board. or SRVO--280 (SVOFF input). alarm is also generated. SRVO--007 (External emergency stops). Before performing “Action 6. the following alarms are also generated. SRVO--280 SVOFF input Check the alarm history display on the teach pendant. SRVO--004 Fence open. The magnetic contactor opens after the robot stops. NOTE If the LED is turned off.3. When this input is opened. an additional safety provision must be provided. WARNING Do NOT short--circuit. 110 . NOTE If the LED is turned off. SRVO--001 Operator panel E--stop. the robot decelerates in a controlled manner and then stops.” make a backup copy of all programs and settings in the control unit. SRVO--004 (Fence open). If it is necessary to run the robot by short--circuiting the signal even temporarily. SRVO--277 Panel E--stop (SVEMG abnormal). as it is very dangerous. this signal in a system in which the Servo off emergency stop signal input is in use. the SRVO--001 (Operator panel E--stop). or disable. SRVO--007 External emergency stop. SRVO--199 Control stop. NOTE SVOFF input (GENERAL STOP) is a safety stop input. Replace the main board. SRVO--204 External (SVEMG abnormal) E--stop. SRVO--213 Fuse blown (Panel PCB). Check the alarm history display on the teach pendant. TROUBLESHOOTING Short connection 9 (EGS1) and 10 (EGS11) Short connection 11 (EGS2) and 12 (EGS21) LED (Green) Connector (JRS11) Panel board Fig. (Action 1) Check the +24 V connection (between EAS11 and EAS1) and 0 V connection (between EAS21 and EAS2) for the fence. NOTE Eliminate the cause of the abnormal chain. 111 .5 (117) (b) SRVO--280 SVAL1 SVON input (118) SRVO--266 SVAL1 FENCE1 status abnormal SRVO--267 SVAL1 FENCE2 status abnormal (Explanation) The fence circuit is abnormal.3.5 (117) (a) SRVO--280 SVAL1 SVON input Connector (JRS11) Main board Fig.B--81465EN--1/02 MAINTENANCE 3. (Action 3) Replace the panel board.3. (Action 2) Check the fence switch. then execute “special reset operation” to release the alarm. then execute “special reset operation” to release the alarm.3. NOTE Eliminate the cause of the abnormal chain. then execute “special reset operation” to release the alarm. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (119) SRVO--268 SVAL1 SVOFF1 status abnormal SRVO--269 SVAL1 SVOFF2 status abnormal (Explanation) The SVOFF circuit is abnormal. NOTE Eliminate the cause of the abnormal chain. (Action 1) Check the +24 V connection (between SD41 and SD4) and 0 V connection (between SD51 and SD5) for the SVDISC circuit. (Action 1) Check the +24 V connection (between EGS11 and EGS1) and 0 V connection (between EGS21 and EGS2) for the SVOFF circuit. (Action 2) Check the EXEMG switch. NOTE Eliminate the cause of the abnormal chain. NOTE Eliminate the cause of the abnormal chain. (Action 1) Check the +24 V connection (between ESPB11 and ESPB1) and 0 V connection (between ESPB21 and ESPB2) for the EXEMG circuit. (Action 3) Replace the panel board. (Action 1) Check the +24 V connection (between NTED11 and NTED1) and 0 V connection (between NTED21 and NTED2) for the NTED circuit. (120) SRVO--270 SVAL1 EXEMG1 status abnormal SRVO--271 SVAL1 EXEMG2 status abnormal (Explanation) The EXEMG circuit is abnormal. (Action 3) Replace the panel board. (121) SRVO--272 SVAL1 SVDISC1 status abnormal SRVO--273 SVAL1 SVDISC2 status abnormal (Explanation) The SVDISC circuit is abnormal. then execute “special reset operation” to release the alarm. (122) SRVO--274 SVAL1 NTED1 status abnormal SRVO--275 SVAL1 NTED2 status abnormal (Explanation) The NTED circuit is abnormal. then execute “special reset operation” to release the alarm. (Action 3) Replace the panel board. (Action 2) Check the NTED switch. 112 . (Action 2) Check the SVOFF switch. (Action 3) Replace the panel board. (Action 2) Check the SVDISC switch. (Action 1) Replace the panel board.B--81465EN--1/02 MAINTENANCE 3. Servo amplifier Panel board E--stop unit Fig. (Action 2) Replace the servo amplifier.3. The emergency stop circuit is faulty.5 (123) SRVO--281 SVAL1 SVOFF input (SVEMG abnormal) 113 . (Action 3) Replace the E--STOP unit. TROUBLESHOOTING (123) SRVO--281 SVAL1 SVOFF input (SVEMG abnormal) (Explanation) When the SVOFF signal was input. an SVEMG error was detected. or the 0V connection of servo ON/OFF switch (EGS2 -.3. (Action 2) Replace the panel board. The emergency stop circuit is faulty. (Action 3) Replace the E--stop unit. 114 . TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (124) SRVO--282 SVAL1 Chain1 (SVOFF) abnormal SRVO--283 SVAL1 Chain2 (SVOFF) abnormal (Explanation) Although the switch connected between EGS11 and EGS1 or between EGS21 and EGS2 on the TBOP4 terminal block on the panel board was pressed.EGS21).3.EGS11). the emergency stop line was not disconnected. (Action 1) Replace the panel board. (Action 4) Replace the servo amplifier.5 (124) SRVO--282 SVAL1 Chain1 (SVOFF) abnormal SRVO--283 SVAL1 Chain2 (SVOFF) abnormal (125) SRVO--282 Chain1 (SVOFF) abnormal with SRVO--230 SVAL1 Chain 1 (+24V) abnormal and SRVO--280 SVOFF input SRVO--283 Chain2 (SVOFF) abnormal with SRVO--231 SVAL1 Chain 2 (0V) abnormal and SRVO--280 SVOFF input (Action 1) Check the +24V connection of servo ON/OFF switch (EGS1 -. (Action 3) Replace the E--STOP unit. (Action 2) Replace the servo amplifier. Servo amplifier Panel board E--stop unit Fig. (Action 1) Check the three--phase input power supply. (Action 3) Replace the SVM. 115 . replace the amplifier. (Action 2) Reduce the override because the use condition is too hard. (128) SRVO--293 SVAL1 DClink (PSM) HCAL (Group : i Axis : j) (Explanation) The three--phase input power supply is abnormal or the PSM is faulty. (Action 1) Check whether the amplifier fan stops. (127) SRVO--292 SVAL1 EXT FAN alarm (Group : i A : j) (Explanation) The external fan for the αSVMi is faulty. (Action 2) Replace the PSM. TROUBLESHOOTING Servo amplifier Panel board Mode switch Operator panel Teach pendant E--stop unit Fig.5 (125) SRVO--282 Chain1 (SVOFF) abnormal (126) SRVO--291 SVAL1 “IPM over heat (Group : i Axis : j)” (Explanation) The IPM in the servo amplifier overheats. (129) SRVO--294 SVAL1 EXT FAN (PSM) alarm (Group : i Axis : j) (Explanation) The external fan for the αPSM and αPSMR is faulty. (Action 3) If this alarm is frequently issued. (Action 1) Replace the cable between the PSM and SVM.3. (131) SRVO--296 SVAL1 PSM DISCHG alarm (Group : i Axis : j) (Explanation) The use condition is too hard or the fan for cooling the regenerative resistance for the PSMR stops. (Action 2) Replace the PSM. (Action 1) Reduce the taught feedrate because the use condition is too hard. (Action 1) Replace the external fan. (Action 1) Replace the external fan for the SVM. (Action 2) Check whether the fan for cooling the regenerative resistance for the PSMR stops. (130) SRVO--295 SVAL1 PSM COM alarm (Group : i Axis : j) (Explanation) The cable between the PSM and SVM may be faulty or the PSM or SVM may be faulty.B--81465EN--1/02 MAINTENANCE 3. (Action 2) Check whether the hand broken signal is connected to the robot.3. (Action 3) Replace the SVM. (Action 1) Check the three--phase input power supply. (See III CONNECTION. (133) SRVO--300 SVAL1 Hand broken/HBK disabled SRVO--302 SVAL1 Set Hand broken to ENABLE (Explanation) Although HBK was disabled. Subsection 5. (Action 1) Press RESET on the teach pendant to release the alarm. (Action 2) Replace the PSM. enable hand broken. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (132) SRVO--297 SVAL1 PSM Low Volt alarm (Group : i Axis : j) (Explanation) The three--phase input voltage may drop or the PSM or SVM may be faulty.) 116 .3 in this manual. When the hand broken signal circuit is connected.5. the HBK signal was input. Replace a faulty printed circuit board. TROUBLESHOOTING 3. or cable if any. Replace a output on the teach pendant. servo amplifier or cable if any. and cables using +24 time. At this 1 Check the printed circuit boards. is immediately turned off. is turned on. the FSSB initialization alarm is displayed on the teach pendant. unit.5A Fuse for +24E F4 7. an alarm 1 Check the printed circuit boards. when turned on. and 1 Check the units (fans) and cables connected to the CP2 and the power cannot be turned on.5A Fuse for +24V PIL LED (green) for AC power supply display ALM LED (red) for alarm display 117 . the LED (ALM: Red) lights. 2 Replace the power supply unit.B--81465EN--1/02 MAINTENANCE 3. faulty printed circuit board. The power. and cables using +24 such as for overtravel. units. hand broken. LVAL is E according to the power supply system diagram. F3 F4 Power supply unit F1 8. unit.6 FUSED--BASED TROUBLESHOOTING Name F1 (1) When the fuses of the power supply unit have blown F1: Fuse for AC input F3: Fuse for +24 E F4: Fuse for +24 V Action Symptom observed when fuse has blown The LED (PIL: Green) of the power supply unit does not light. If the fuse turns out to have already blown when the power supply 2 Replace the power supply unit. 2 Replace the power supply unit. FSSB disconnect. V according to the power supply system diagram. If the fuse blows when the power supply is turned on. units. The LED of ALM is turned off by pressing the OFF button once.0A Fuse for AC input F3 7. CP3 connectors of the power supply unit to see if there is any short circuit. hand broken (SRVO--006). and replace it if required. 3 Replace the servo amplifier. and ROBOT OVER TRAVEL (SRVO--005) are displayed on the teach pendant. 3 Replace the servo amplifier. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (2) Servo amplifier fuse FS1 : For generation of the power to the amplifier control circuit FS2 : For protection of the 24V output to the end effector. Name FS1 Symptom observed when fuse has blown All LEDs on the servo amplifier go out. The blown fuse (Amp) alarm (SRVO--214) and DCAL (SRVO--043) are displayed on the teach pendant. 2 Check the robot connection cable and the robot’s internal cable. Servo amplifier Fuse F1 Fuse F2 Fuse FS1 Fuse FS3 Fuse FS2 118 . The fuse blown (Amp) alarm (SRVO--214). F2 : For protection of the circuit failure in the servo amplifier. 2 Check the additional axis amplifier and its wiring. The FSSB disconnection or initialization alarm is displayed on the teach pendant. 1 Check the regenerative resistance. 2 Replace the servo amplifier. Action FS2 1 Check +24E used by the end effector for a ground fault. FS3 F1 F2 The OHAL1 alarm is output on the teach pendant. ROT. and HBK FS3 : For protection of the 24V output to the regenerative resistance and the additional axis amplifier F1.3. Replace the servo amplifier. and replace them if required. 1 Check if the cables connected to three phase input of servo amplifier is defective. 3 Replace the panel board.B--81465EN--1/02 MAINTENANCE 3. 1 Check the teach pendant cable for a fault. and replace it if required. SVOFF input. TROUBLESHOOTING (3) Panel board fuses FUSE1: For protection of the +24EXT line (emergency stop line) FUSE2: For protection of the teach pendant emergency stop line Name FUSE1 Symptom observed when fuse has blown The external emergency stop. 2 Check the teach pendant for a fault. 2 Replace the panel board. open fence. and blown fuse (panel PCB) alarm are displayed on the teach pendant. The display on the teach pendant disappears. and replace it if required. Action 1 Check the +24EXT line (emergency stop line) for a short--circuit and ground fault. FUSE2 Panel board FUSE2 FUSE1 119 . the process I/O printed circuit board are normal.2 Replace the process I/O printed circuit board.3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (4) Fuse on the process I/O board FUSE1: Fuse for +24 E Name FUSE1 Symptom observed when fuse has blown Action The LED (ALM--2 or FALM) on the process I/O board lights. (The display data depends on state of peripheral equipment con.) Process I/O board CA. nection.CB FUSE1 Process I/O board DA FUSE1 120 . and 1 Check if the cables and peripheral equipment connected to an alarm such as IMSTP input is output on the teach pendant. B--81465EN--1/02 MAINTENANCE 3. TROUBLESHOOTING Process I/O board HA FUSE1 Total version 121 . 7 TROUBLESHOOTING BASED ON LED INDICATIONS The printed circuit boards and servo amplifier are provided with alarm LEDs and status LEDs. The LED status and corresponding troubleshooting procedures are described below. Servo amplifier Main board Power supply unit 122 . TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 3.3. * [Action2] Replace the FROM/SRAM module. 4: The initialization of SRAM and DPRAM is completed. 7: Basic software start--up.) will be lost. * [Action1] Replace the main board. * [Action1] Replace the main board. 5: The initialization of the communication IC is completed. 6: The loading of the basic software is completed. the step in which the alarm occurred can be determined from which LEDs are lit. 9: The loading of optional software is completed. therefore. Before you replace the unit. * [Action2] Replace the main board. in the order described. LED Action to be taken [Action1] Replace the CPU card * [Action2] Replace the main board. make a backup copy of the data. 123 .B--81465EN--1/02 MAINTENANCE 3. all LEDs are lit. * [Action3] Replace the FROM/SRAM module. [Action3] Replace the servo amplifier. 8: Start--up of communication with the teach pendant. * [Action1] Replace the main board. the contents of memory (parameters. * [Action1] Replace the main board. etc. * [Action2] Replace the FROM/SRAM module. 10:DI/DO initialization * [Action1] Replace the FROM/SRAM module. [Action1] Replace the CPU card * [Action2] Replace the main board. specified data. [Action2] Replace the process I/O board. 11: The preparation of the SRAM module is completed. * [Action2] Replace the FROM/SRAM module. * [Action1] Replace the main board. check the status LEDs (green) on the main board at power--on. the LEDs light as described in steps 1 to 17. [Action1] Replace the axis control card. [Action1] Replace the CPU card * [Action2] Replace the main board. 3: The initialization of dram on the CPU card is completed. * If the main board or FROM/SRAM module is replaced. After power--on. [Action1] Replace the CPU card * [Action2] Replace the main board. * [Action2] Replace the main board. * [Action2] Replace the FROM/SRAM module. Step 1: After power--on. If an alarm is detected. TROUBLESHOOTING (1) TROUBLESHOOTING USING THE LEDS ON THE MAIN BOARD To troubleshoot an alarm that arises before the teach pendant is ready to display. 2: Software operation start--up. * [Action1] Replace the main board. Main board FROM/SRAM module CPU card Axis control card 124 . 13:Calibration is completed. the contents of memory (parameters. 14:Start--up of power application for the servo system 15:Program execution * [Action1] Replace the main board. 16:DI/DO output start--up. [Action2] Replace the process I/O board. etc. [Action1] Replace the axis control card. * [Action2] Replace the main board. [Action3] Replace the servo amplifier. * [Action2] Replace the main board. make a backup copy of the data. 18:Normal status Status LEDs 1 and 2 blink when the system is operating normally.3. specified data. Initialization has ended normally. [Action3] Replace the servo amplifier. Before you replace the unit. 17: Initialization is terminated. * If the main board or FROM/SRAM module is replaced. therefore.) will be lost. * [Action1] Replace the main board. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 Step 12:Axis control card initialization LED Action to be taken [Action1] Replace the axis control card. * If the main board or FROM/SRAM module is replaced. [Action3] Replace the main board. [Action2] Replace the main board. [Action1] Check the communication cable (optical cable) between the main and panel boards. [Action3] Replace the main board. [Description] A parity alarm condition has occurred in DRAM controlled by the communication controller. [Description] A parity alarm condition has occurred in RAM on the FROM/SRAM module installed on the main board. and replace it if necessary. [Action1] Replace the axis control card. [Action1] Replace the axis control card. [Description] A communication error has occurred during communication with the panel board. [Action2] Replace the CPU card. make a backup copy of the data. therefore. [Description] The SYSFAIL alarm has occurred. [Action] Replace the main board. the contents of memory (parameters. [Action1] Replace the CPU card. [Action2] Replace the main board. [Action1] Replace the axis control card. etc. [Description] A bus error has occurred in the communication controller. [Description] A servo alarm condition has occurred on the main board. [Action2] Replace the main board. [Description] The SYSEMG alarm has occurred. specified data. TROUBLESHOOTING (2) TROUBLESHOOTING BY 7--SEGMENT LED INDICATOR 7--segment LED indicator Description [Description] A parity alarm condition has occurred in RAM on the CPU card installed on the main board. [Action] Replace the main board. [Action3] Replace the panel board.B--81465EN--1/02 MAINTENANCE 3. 125 . Before you replace the unit. [Action2] Replace the main board. [Action2] Replace the CPU card.) will be lost. [Action1] Replace the FROM/SRAM module. and replace them if defective. [Action1] Check fuse F4 (+24V) on the power supply unit. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 Troubleshooting by LEDs on power supply unit LED indication Failure description and required measure [Description] When ALM LED (red) turned on. [Description] If the PIL LED (Green) does not light.5A Fuse for +24E F4 7. For detailed causes of fuse blown out.3. the power supply unit has not been supplied with 200 VAC.0A Fuse for AC input F3 7. 15V. and +24V). [Action3] Replace the power supply unit. and replace it if it has blown. and replace it if it has blown. power supply alarm has occurred.1. Power supply unit F1 8. the relevant units. [Action1] Check fuse F1 on the power supply unit. and cables. [Action2] Replace the power supply unit.5A Fuse for +24V PIL LED (green) for AC power supply display ALM LED (red) for alarm display 126 . [Action2] Check the printed--circuit boards powered by the DC power supplies (+5V. please refer to section 3. Communication with the main board does not execute. TROUBLESHOOTING Troubleshooting by LED on the panel board LED indication RDY Failure description and required measure [Description] When the LED (green) does not light. [Description] When the LED does not light. The power supply inside the panel board does not generate +5 V normally. [Action1] Check the communication cable between the main and panel boards. [Action3] Replace the panel board. [Action2] Replace the panel board. [Action1] Check the CRM63 connector and check that 24 V is supplied. PON LED (Green) PON Panel board RDY LED (Green) 127 . [Action2] Replace the main board.B--81465EN--1/02 MAINTENANCE 3. and replace it if necessary. [Action1] Replace the process I/O board. Fuse For process I/O board CA/CB/DA/HA Specificalion : A60L--0001--0046#2. [Action2] Examine the cables and peripheral devices connected to the process I/O board. [Action3] Replace the I/O link connection cable.0 128 .3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 Troubleshooting by alarm LEDs on the process I/O printed circuit board LED Process I/O CA/CB/DA/HA Description and action to be taken [ [Description] A communication alarm occurred between the main CPU PC board and process p ] p I/O board. Replace any failed components. [Action3] Replace the process I/O board. p ] p / [Action1] Replace the blown fuse on the process I/O board. Process I/O CA/CB/DA/HA [ [Description] A fuse on the process I/O board is blown. * [Action2] Replace the main CPU board. Troubleshoot the alarm indicated by the LEDs. TROUBLESHOOTING Troubleshooting by LEDs on servo amplifier The servo amplifier has alarm LEDs. referring also to the alarm indication on the teach pendant.B--81465EN--1/02 MAINTENANCE 3. 129 . [Measure 3] Replace the CPU card. Lights when the servo amplifier detects an alarm. Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V normally. If the LED does not light when there is an alarm condition in the machine: [Measure] Replace the servo amplifier. Lights when the DCLINK circuit inside the servo amplifier is charged to reach the specified voltage. [Measure 3] Replace the servo amplifier. Lights when the communication between the servo amplifier and the main board is normal.3.3V Green SVEMG Red ALM Red RDY Green OPEN Green WD Red D7 Red 130 . If the LED lights when the machine is not at an emergency stop: [Measure] Replace the servo amplifier. [Measure 2] It is likely that the charge current control resistor may be defective. Lights when an emergency stop signal is input to the servo amplifier. [Measure 3] Replace the servo amplifier. If the LED lights when there is no alarm condition in the machine: [Measure] Replace the servo amplifier. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 LED P5V Color Green Description Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally. If the LED does not light: [Measure] Replace the servo amplifier. If the LED does not light when the motor is activated: [Measure] Replace the servo amplifier. [Measure 2] Replace the servo card. Replace the emergency stop unit. Lights when the servo amplifier is ready to drive the servo motor. Check for connection. If the LED does not light: [Measure 1] Check for the connection of the FSSB optical cable. If the LED does not light: [Measure 1] Check the robot connection cable (RP1) to see if there is a ground fault in the +5 v wire. [Measure 1] Replace the servo amplifier. [Measure 4] Replace the main board. P3. [Measure 2] Replace the servo amplifier. [Measure 2] Replace the servo card. If the LED does not light after pre--charge is finished: [Measure 1] It is likely that the DC Link may be short--circuited. If the LED does light when the machine is at an emergency stop: [Measure] Replace the servo amplifier. Lights when a watch dog alarm is detected in the servo amplifier. To display the position deviation. check the position deviation in the stopped state. (Corrective action) If the motor axis can be positioned normally. PULSE. select AXIS from the menu.B--81465EN--1/02 MAINTENANCE 3. Press F1. TROUBLESHOOTING 3. check the mechanical unit. press the screen selection key. (Check 2) Check whether the motor axis can be positioned normally. and select STATUS from the menu. (Corrective action) Replace a faulty key of motor shaft or other faulty parts. [TYPE].8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) (Check 1) On the status screen. (Check 3) Check the mechanical unit for backlash. (Check 4) If checks 1 to 3 show normal results (Corrective action) Replace the pulse coder and main board. 131 . then press the F4. (Corrective action) Correct the parameters related to return to the reference position (positioning). 9 VIBRATION OBSERVED DURING MOVEMENT (Check 1) Check the settings of parameters such as the position loop gain parameter. (Check 2) Check the mechanical unit for backlash. (Corrective action) Replace a faulty key of motor shaft or other faulty parts. (Corrective action) Correct parameters.3. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 3. 132 . 133 . (Check 2) Check whether the teach pendant is handled correctly. (Check 5) Check whether the previous manual operation has been completed. TROUBLESHOOTING 3. (Corrective action) Turn on the teach pendant “enable”. press the axis selection key and case shift key at the same time.) (Corrective action) If the HOLD signal is on. (Check whether the hold lamp on the teach pendant is on. (Corrective action) Release the alarm. (Check whether the HOLD lamp on the teach pendant is on. and change the setting.) (Corrective action) Turn off the HOLD signal of the peripheral device control interface or the HOLD switch on the operator’s panel. (2) Check and corrective action to be taken if the program cannot be executed (Check 1) Check whether the ENBL signal for the peripheral-device control interface is on. (Corrective action) To move an axis by manual operation. Set the override for manual feed to a position other than the FINE and VFINE positions. If the HOLD switch is on. (Check 6) Check whether the controller is in the alarm status.10 MANUAL OPERATION IMPOSSIBLE The following explains checking and corrective action required if the robot cannot be operated manually after the controller is turned on: (1) Check and corrective action to be made if manual operation is impossible (Check 1) Check whether the teach pendant is enabled. (Corrective action) 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. turn it off. (Check 2) Check whether the HOLD signal for the peripheral-device control interface is on.B--81465EN--1/02 MAINTENANCE 3. (Check 4) Check whether the HOLD signal of the peripheral device control interface or the HOLD switch on the operator’s panel is on (hold status). (Corrective action) Put the peripheral-device control interface in the ENBL state. Also check whether the HOLD switch on the operator’s panel is on. (Check 3) Check whether the ENBL signal of the peripheral device control interface is set to 1. turn it off. check the position deviation on the status screen. (Corrective action) Place the peripheral device control interface in the ENBL status. 3. check the position deviation on the status screen. then change the setting. which prevents the previous operation from being completed. 134 . (Corrective action) Release the alarm. (Check 4) Check whether the controller is in the alarm status. TROUBLESHOOTING MAINTENANCE B--81465EN--1/02 (Check 3) Check whether the previous manual operation has been completed. (Corrective action) If the robot cannot be placed in the effective area because of the offset of the speed command voltage. LED indicators. and a plastic panel at the front.B--81465EN--1/02 MAINTENANCE 4. This chapter describes the standard settings and adjustment required if a defective printed circuit board is replaced. PRINTED CIRCUIT BOARDS 4 PRINTED CIRCUIT BOARDS The printed circuit boards are factory-set for operation. Usually. you do not need to set or adjust them. It also describes the test pins and the LED indications. The standard printed circuit board includes the main unit printed circuit board and one or more cards or modules installed horizontally to the main--unit printed--circuit board. there is a backplane connector. 135 . These PC boards have interface connectors. At the rear. 4.1 Main board Name CPU card Ordering Specification A05B--2450--H010 A05B--2450--H011 Board Specification A20B--3300--0104 A20B--3300--0105 A20B--3300--0240 A20B--3300--0241 A20B--3300--0242 A20B--3900--0160 A20B--3900--0161 A20B--3900--0162 A20B--3900--0163 A20B--3900--0164 A20B--3900--0165 A16B--3200--0412 A16B--3200--0413 Note SDRAM 8M (Standard) SDRAM 16M 8--axis 6--axis (Standard) 4--axis FROM 16M. --0413) CPU card FROM/SRAM module Total version Axis control card TBDL exists in case of --0413 Fig. SRAM 2M FROM 16M. SRAM 1M FROM 32M. SRAM 1M FROM 16M. SRAM 3M FROM 32M.1 MAIN BOARD (A16B--3200--0412.4. SRAM 2M FROM 32M. SRAM 3M Standard With distributed link (Option) Axis control card A05B--2450--H021 A05B--2450--H020 TBD FROM/SRAM module A05B--2450--H031 A05B--2450--H032 A05B--2450--H033 A05B--2450--H035 A05B--2450--H036 A05B--2450--H037 Main board A05B--2450--H001 TBD 136 . PRINTED CIRCUIT BOARDS MAINTENANCE B--81465EN--1/02 4. A communication error occurred between panel boards and main board. SYSEMG occurred. A parity alarm occurred in a RAM of the SRAM module on the main board. 137 . PRINTED CIRCUIT BOARDS (1) Test pins Name GND1 GND2 GND3 CACHOFF LOAD MCBOOT CORE Use For testing the printed circuit board (2) LEDs Seven segment LED Description A parity alarm occurred in a RAM of the main CPU card on the main board. Bus error occurred on the communication controller. A servo alarm occurred on the main board.B--81465EN--1/02 MAINTENANCE 4. This number appears temporarily after the power is switched on. SYSFAIL occurred. A parity alarm occurred in DRAM controlled by communication controller. but it is not abnormal. 1 Main board. Lights during full duplex communication. a broken wire in the teach pendant connection cable. Name 75172 75173 Drawing number A76L--0151--0098 A76L--0151--0099 Please refer to Fig. 138 . for example. Lights during communication with 100BASE--T. it is likely that the communication driver or receiver may be defective. Lights during communication with 10BASE--T. STATUS LED ETHERNET LED TX RX L FDX COL BT BTX Color Green Green Yellow Green Red Green Green Description Flashes during data transmission. Lights when a connection to a network is made. Flashes during data reception. (3) Driver/receiver IC If the teach pendant cannot display anything because of.4.4. PRINTED CIRCUIT BOARDS MAINTENANCE B--81465EN--1/02 Status LED Description Operating status of the system. Lights if a COLLISION occurs during half duplex communication. 2 Emergency stop control PC board (1) LED Name LED1 Status of Relay KA1--1 ON Active OFF Inactive Status of KA2--1 ON Active OFF Inactive Status of KA3--1 ON Active OFF Inactive Use LED2 LED3 139 .2 EMERGENCY STOP CONTROL PC BOARD (A20B--1007--0800) LED 3 LED 2 LED 1 Total version Fig. PRINTED CIRCUIT BOARDS 4.B--81465EN--1/02 MAINTENANCE 4.4. 3 BACKPLANE PC BOARD (A20B--2002--0771) Total version Fig.4.4.3 (a) Backplane PC Board (1) Test pins Name HI1 TEST1 LOW1 Use For testing the printed circuit board 140 . PRINTED CIRCUIT BOARDS MAINTENANCE B--81465EN--1/02 4. B--81465EN--1/02 MAINTENANCE 4. PRINTED CIRCUIT BOARDS (A20B--2002--0761) Total version Test pins Fig.4.3 (b) Backplane PC Board (1) Test pins Name HI1 TEST1 LOW1 Use For testing the printed circuit board 141 4. PRINTED CIRCUIT BOARDS MAINTENANCE B--81465EN--1/02 4.4 PANEL BOARD (A20B--2100--0770) PON LED Total version RDY LED Fig.4.4 Panel Board (1) LED Name RDY PON Use Communication status with main board ON Normal OFF Communication error Lights when the internal power supply of the panel board outputs +5V normally. 142 B--81465EN--1/02 MAINTENANCE 4. PRINTED CIRCUIT BOARDS 4.5 PROCESS I/O BOARD CA (A16B--2201--0470) Total version Fig.4.8 Process I/O Board CA (1) Test pins Name P24V P5V P15VC M15VC GND1 GND2 P10V P15VF M15VF GNDF AI1 AI2 AI3 AI4 AI5 AI6 AOUT1 AOUT2 +24V +5V +15V --15V GND GND +10V +15V --15V GND Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 1 Channel 2 Use For measuring the DC supply voltage For measuring the reference voltage of the digital/analog converter Power for the digital/analog converter For measuring the voltage of the analog input signal (analog/digital) For measuring the voltage of the analog output signal (digital/analog) 143 4. PRINTED CIRCUIT BOARDS MAINTENANCE B--81465EN--1/02 (2) Settings Name ICOM1 UDI1 to UDI20 (Connector CRM2A) Side A Standard setting Description UDI21 to UDI40 ICOM2 (Connector CRM2B) ICOM3 SP1 SP2 WDI01 to WDI08 (Connector CRW1) Channel 1 The common voltage is adjusted to: Side A : +24 V common Side B : 0 V common The polarity of the output voltage is switched to: Strapped : Negative (--) Open : Positive (+) Open Channel 2 (3) Adjustment VR1: Adjusts the gain of channel 1. Execute a robot program and set AOUT[1] to 4095 on the teach pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 until the meter reads 12.0 V. Connect the negative (--) lead of the digital voltmeter to test pin GNDF. VR2: Adjusts the gain of channel 2. Execute a robot program and set AOUT[2] to 4095 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR2 until the meter reads 12.0 V. Connect the negative (--) lead of the digital voltmeter to test pin GNDF. (The 0VF test pin is different from the common 0V test pin.) VR3: Adjusts the reference supply voltage of the digital/analog converter. Connect the digital voltmeter to test pin P10V and rotate VR3 until the meter reads 10.0 0.1 V. (4) LEDs Color Description Red A communication alarm occurred between the main CPU and process input/output. Red A fuse (FUSE 1) in the process input/output blew. 144 B--81465EN--1/02 MAINTENANCE 4. PRINTED CIRCUIT BOARDS (5) Correspondence between driver chips and DO signals Ordering code for the driver chips: A76L-0151-0062 Driver chip DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 DV11 DV12 RESERVED DO signal CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED SDO01, SDO02, SDO03, SDO04 SDO05, SDO06, SDO07, SDO08 SDO09, SDO10, SDO11, SDO12 SDO13, SDO14, SDO15, SDO16 SDO17, SDO18, SDO19, SDO20 WDO01, WDO02, WDO03, WDO04 WDO05, WDO06, WDO07, WDO08 For replacement 145 4. PRINTED CIRCUIT BOARDS MAINTENANCE B--81465EN--1/02 4.6 PROCESS I/O BOARD CB (A16B--2201--0472) Test pins Total version Fig.4.9 Process I/O Board CB (1) Test pins Name P24V P5V P15VC M15VC GND1 GND2 +24V +5V +15V --15V GND GND For measuring the DC supply voltage Use (2) Settings Name ICOM1 ICOM2 UDI1 to UDI20 (Connector CRM2A) UDI21 to UDI40 (Connector CRM2B) Side A Standard setting Description The common voltage is adjusted to: Side A : +24 V common Side B : 0 V common 146 PAUSED HELD. SDO14. SDO12 SDO13. SDO15. (4) Correspondence between driver chips and DO signals Ordering code for the driver chips: A76L-0151-0062 Driver chip DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 RESERVED DO signal CMDENBL. FALT. ACK6/SNO6 ACK7/SNO7. ATPERCH. SDO02. SDO19. SDO18. SDO03. ACK1/SNO1. Red A fuse (FUSE 1) in the process input/output blew. SYSRDY. ACK2/SNO ACK3/SNO3. PROGRUN.B--81465EN--1/02 MAINTENANCE 4. SDO04 SDO05. ACK5/SNO5. ACK4/SNO4. RESERVED SDO01. SNACK. SDO08 SDO09. SDO16 SDO17. TPENBL BATALM. SDO20 For replacement 147 . PRINTED CIRCUIT BOARDS (3) LEDs Color Description Red A communication alarm occurred between the main CPU and process input/output. ACK8/SNO8. BUSY. SDO11. SDO07. SDO10. SDO06. 7 PROCESS I/O BOARD DA (A16B--2201--0480) Total version Test pins Fig. PRINTED CIRCUIT BOARDS MAINTENANCE B--81465EN--1/02 4.4.4.10 Process I/O Board DA (1) Test pins Name P24V P5V GND1 GND2 +24V +5V GND GND For measuring the DC supply voltage Description (2) Settings Name ICOM1 ICOM2 ICOM3 ICOM4 ICOM5 ICOM6 UDI01 to 20 (Connector CRM2A) UDI21 to 40 (Connector CRM2B) UDI41 to 60 (Connector CRM2C) UDI61 to 80 (Connector CRM2D) UDI81 to 88 (Connector CRM4A) UDI89 to 96 (Connector CRM4B) The common voltage is adjusted to: Side A : +24 V common Side B : 0 V common Standard setting Description Side A 148 . SDO04 SDO05. Red A fuse (FUSE 1) in the process input/output below. SDO10. BUSY. PAUSED HELD. SDO16 SDO17. SDO76 For replacement 149 . TPENBL BATALM. ACK5/SNO5. SDO47. SDO54. SDO02. SDO19. SDO38. ACK6/SNO6 ACK7/SNO7. SDO34. SDO66. SDO40 SDO41. SDO51. SDO07. SDO58. SDO46. SDO50. SDO48 SDO49. ACK8/SNO8. SDO68 SDO69. SDO42. SDO39. SDO55. SDO31. SDO11. SDO63. SDO14. SDO12 SDO13. SNACK. SDO24 SDO25. SDO62. ACK2/SNO2 ACK3/SNO3. SDO35. SDO64 SDO65. SDO26. SDO22. SDO30. SDO36 SDO37. SDO20 ADO21. SDO44 SDO45. SDO06. SDO75. SDO28 SDO29. ACK1/SNO1. SDO74. SDO56 SDO57. SDO52 SDO53. PROGRUN. RESERVED SDO01. SDO08 SDO09. SDO71. SDO15. SDO23. SDO32 SDO33. SDO70. SYSRDY. SDO60 SDO61.B--81465EN--1/02 MAINTENANCE 4. PRINTED CIRCUIT BOARDS (3) LEDs Color Description Red A communication alarm occurred between the main CPU and process input/output. SDO18. SDO43. SDO27. ACK4/SNO4. SDO67. FALT. SDO72 SDO73. (4) Correspondence between driver chips and DO signals Ordering code for the driver chips: A76L-0151-0062 Driver chip DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 DV11 DV12 DV13 DV14 DV15 DV16 DV17 DV18 DV19 DV20 DV21 DV22 DV23 DV24 RESERVED DO signal CMDENBL. SDO59. SDO03. ATPERCH. 4.4. PRINTED CIRCUIT BOARDS MAINTENANCE B--81465EN--1/02 4.8 PROCESS I/O BOARD HA (A16B--2203--0760) Total version Fig.11 Process I/O Board HA (1) Test pins Name P24V P5V GND1 GND2 GND3 P24VF P5VF GNDF AO1 AO2 +24V +5V GND GND GND +24V +5V GND Channel 1 Channel 2 Use For measuring the DC supply voltage Power for the digital/analog converter For measuring the voltage of the analog output signal (digital/analog) (2) Settings Name ICOM1 UDI1 to UDI20 (Connector CRM2A) Side A Standard setting Description UDI21 to UDI40 ICOM2 (Connector CRM2B) ICOM3 WDI01 to WDI08 (Connector CRW7) The common voltage is adjusted to: Side A : +24 V common Side Sid B : 0 V common 150 . SDO20 151 . RESERVED SDO01. ACK1/SNO1. PRINTED CIRCUIT BOARDS (3) Adjustment VR1/VR2: Adjusts the gain and the offset of channel 1.0 V.B--81465EN--1/02 MAINTENANCE 4. SDO15. SDO07. SDO04 SDO05. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 or VR2 until the meter reads 15. BUSY. SDO19. SDO03. Execute a robot program and set AOUT[1] to 3413 on the teach pendant. FALT. SDO16 SDO17. FALM (5) Correspondence between driver chips and DO signals Ordering code for the driver chips: A76L-0151-0062 Driver chip DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 DO signal CMDENBL. ACK8/SNO8. SDO08 SDO09. FALM ALMO Red A fuse (FUSE 1) in the process I/O board blew. ACK6/SNO6 ACK7/SNO7. SYSRDY. ACK4/SNO4. Connect the negative (--) lead of the digital voltmeter to test pin GNDF. VR3/VR4: Adjusts the gain and the offset of channel 2. ATPERCH. PAUSED HELD. SDO11. SDO02. SDO06. ACK5/SNO5. SDO18. Execute a robot program and set AOUT[2] to 3413 on the teach pendant. SDO10.) (4) LEDs Color Description ALMO Red A communication alarm occurred between the main CPU and process I/O board. SDO14. Connect the digital voltmeter to test pin AOUT2 and rotate VR3 or VR4 until the meter reads 15. PROGRUN.0 V. ACK2/SNO2 ACK3/SNO3. (The 0VF test pin is different from the common 0V test pin. SNACK. SDO12 SDO13. Connect the negative (--) lead of the digital voltmeter to test pin GNDF. TPENBL BATALM. 12 Panel Switch Board 152 .9 PANEL SWITCH BOARD (A20B--1007--0850) Total version Fig. PRINTED CIRCUIT BOARDS MAINTENANCE B--81465EN--1/02 4.4.4. Table 5 Servo amplifier specifications Robot models R--2000iA M--6iB ARC Mate 100iB Servo amplifier A06B--6105--H002 A06B--6105--H003 Regenerative resistor unit A05B--2452--C200 (B--cabinet) A05B--2452--C201 ( (B--cabinet) ) Check that the voltage is not higher than 50 V. check the voltage at the screw above the LED “D7” with a DC voltage tester to see if the remaining voltage is not higher than 50 V. Usually. It also describes the use of test pins and meanings of the LED indications. for maintenance purposes. NOTE Before touching the servo amplifier. you do not need to set or adjust them. This chapter describes the standard settings and adjustment required if a defective servo amplifier is replaced. for example.B--81465EN--1/02 MAINTENANCE 5. SERVO AMPLIFIERS 5 SERVO AMPLIFIERS The servo amplifiers are factory-set for operation. 153 . Lights when the servo amplifier is ready to drive the servo motor. Lights when the communication between the servo amplifier and the main board is normal.1 LED OF SERVO AMPLIFIER LED D7 LED P5V P3. Lights when the servo amplifier detects an alarm. Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3V SVEMG ALM RDY OPEN WD D7 Color Green Green Red Red Green Green Red Red Description Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally. Lights when a watch dog alarm is detected in the servo amplifier.5. SERVO AMPLIFIERS MAINTENANCE B--81465EN--1/02 5. Lights when the DCLINK circuit inside the servo amplifier is charged to reach a specific voltage.3 V normally. 154 . Lights when an emergency stop signal is input to the servo amplifier. 2 SETTING OF SERVO AMPLIFIER Settings Name COM1 Standard setting Side A Description This jumper sets the common voltage for the Robot digital Inputs (RDI) to: Side A : +24V common Side B : 0V common Fuse F1 Fuse F2 Fuse FS1 Fuse FS3 Fuse FS2 Set jumper 155 .B--81465EN--1/02 MAINTENANCE 5. SERVO AMPLIFIERS 5. RDO6. RDO8 XRESERVE. RDO3. XBRKRLS2. RDO4 RDO5. XBRKRLS1. XBRKRLS3 156 . RDO2. RDO7. SERVO AMPLIFIERS MAINTENANCE B--81465EN--1/02 5.5.3 DRIVER CHIP FOR ROBOT DI/DO DIO19 DIO18 DIO17 Correspondence between driver chips and DO signals Ordering code for the driver chips : A76L--0151--0062 Driver chip DIO17 DIO18 DIO19 DO signal RDO1. SETTING THE POWER SUPPLY 6 SETTING THE POWER SUPPLY The power supply is factory-set for operation. you do not need to set or adjust it.B--81465EN--1/02 MAINTENANCE 6. 157 . Usually. 6. +3.1 Block diagram of the power supply (B--cabinet) 158 . +24E CP5 CP6 +24V +24E CP5A CP6 CP5A CRM64 210VAC Power Brake FAN CP2 Motor Robot Pulsecoder End Effector +24V Main board BATTERY CRM64 CRM64 +24V CRS16 FUSE2 +24T CP8B Teach pendant DC/DC +5V +24EXT FUSE1 E--STOP CIRCUIT Panel board +24E +24E +24E JD5A JD5B JD17 Handy file etc. Process I/O board +24E FUSE1 CRM2 CRM4 +24E +24E +24V --15V +15V +5V +3. --15V F3 +24V.Axis DC/DC +5V. +3.1 BLOCK DIAGRAM OF THE MAIN POWER INCLUDING POWER SUPPLY AC input 380 -.3V +15V.500 VAC 3φ Transformer 210VAC E--stop unit Breaker 210VAC Servo amplifier (6--axis amplifier) FS3 Regenerative res. SETTING THE POWER SUPPLY MAINTENANCE B--81465EN--1/02 6. Aux. --15V Noise filter Breaker CRR38 CRM67 +24E FS1 CRM67 CRR64 CRF7 FS2 CNJ +5V +24VF 200VAC Backplane Power supply unit F1 CP1 CP2 CP3 DC/DC F4 +5V.6.415 VAC 440 -.3V +15V.3V +24F Peripheral device Fig. B--81465EN--1/02 MAINTENANCE 6. SETTING THE POWER SUPPLY 6.5KVA A80L--0026--0035 A80L 0026 0035 3KVA A80L--0024--0025 A80L 0024 0025 A80L--0026--0036 A80L 0026 0036 A80L--0024--0026 A80L 0024 0026 A80L--0026--0037 A80L 0026 0037 A80L--0024--0027 A80L 0024 0027 Structure of transformer Mounting locations of transformer (B--cabinet. back side) Transformer Fig. 2 Type I: 500--575 V Type II: 440--500 V 159 .2 SELECTING TRANSFORMER TAPS Select a transformer and tap according to the supply voltage.2 (a) Transformer mounting locations and structure 1 Type I:440--480 V Type II:380--415 V Insert the connector connected to the circuit breaker into connector LB and the dummy plug into connector LA. Select a transformer tap such that the rated voltage is +10% to --15% of the induced voltage.6. Rated Voltage 500-575 Type I 440-480 380-415 Type II 440-500 380-400 Type III 200-230 Transformer specification 7. Insert the connector connected to the circuit breaker into connector LA and the dummy plug into connector LB. Insert the connector connected to the circuit breaker into connector LA and use the Y connection cable for connector LB. SETTING THE POWER SUPPLY MAINTENANCE B--81465EN--1/02 3 4 Type III: 200--230 V Type III: 380--400 V Use the ∆ connection cable.6. Fig.6.2 (b) Setting a tap 160 . 3 CHECKING THE POWER SUPPLY UNIT The power supply unit need not be set or adjusted. Table 6.1V +3.3V +24V +24E +15V --15V Rated voltage +5.3V +24V +24E +15V --15V Tolerance 3% 3% 5% 5% 10% 10% 161 .3 Rating of the Power supply unit Output +5V +3. SETTING THE POWER SUPPLY 6.B--81465EN--1/02 MAINTENANCE 6. 5A fuse for +24V MAINTENANCE CP5 : +24V CP6 : +24E PIL LED for indicating the AC power supply status (Green) 162 ALM LED for indicating the alarm (Red) B--81465EN--1/02 .6.6.5A fuse for +24E Fig.0A Fuse for AC input F3 7. SETTING THE POWER SUPPLY F1 8.3 (a) Interface of the power supply unit F4 7. B--81465EN--1/02 R2 R1 S2 S1 G2 G1 P280 F1 R AC INPUT NF S P0 G +3.3VDC REGULATOR 0V A24 A12 P22 AUX P0 P280 P.1 +3.1VDC REGULATOR 0V +3.6.3V 0V 8A +5.5A +24E 7.3 (b) Block diagram of the power supply unit MAINTENANCE 163 6.S.3 +3. SETTING THE POWER SUPPLY ON COM OFF A24 HI LO P0 0V .1 +5. 0V P22 A24 A5 +15 +5.5A +24V 0V +5.3 +24 +15 --15 ALM CONTROL CIRCUIT +15V 15VDC REGULATOR 0V ENA EN5 FA FB --15 --15V +24VDC REGULATOR A5 +24 F3 F4 0V 7.1V AC OUTPUT Fig. Also keep all machines in the area of the control unit switched off.7. you could injure personnel or damage equipment. Otherwise. 164 . WARNING Before you start to replace a unit. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 7 REPLACING A UNIT This section explains how to replace each unit in the control section. turn off the control unit main power. (2) Remove the power unit and boards from the rack. (6) To replace the backplane and rack. floppy disk. If a cable is detached for replacement. 2 When you remove a printed--circuit board. 5 Before you disconnect a cable. reconnect it exactly as before.1. (1) Detach the cables from the power unit and boards on the backplane board. or main board (including cards and modules) is replaced. 165 . CAUTION There is a possibility of data loss when a backplane-mounted printed circuit board is replaced.) (3) Detach the grounding cable from the backplane unit. power supply unit.2.1 Replacing the Backplane Board (Unit) When replacing the backplane board. or any other external memory device. Be sure to back up all program and setup data on a floppy disk before proceeding.1--3.(6). 7. be sure that the battery is good (3. Remove the retaining screws from the lower section of the rack.3VDC) and it is installed correctly. (See Section 7. 3 Make sure that the replacement printed--circuit board has been set up appropriately.) 4 If the backplane board. (Setting plug etc. note its location. (5) Side rack up and out. REPLACING A UNIT 7. CAUTION When you remove the main board.1 REPLACING THE PRINTED--CIRCUIT BOARDS CAUTIONS When you replace printed--circuit boards. save a backup copy of the robot parameters and taught data to a memory card. do so together with the plastic rack.1. do not touch the semiconductor devices on the board with your hand or make them touch other components. (4) Loosen the retaining screws in the upper section of the rack. reverse steps (1) -. it is likely that robot parameters and taught data are lost.B--81465EN--1/02 MAINTENANCE 7. USE STATIC PROTECTION. Before you start to replace these components. observe the following cautions: 1 Keep the control unit power switched off. The main board is equipped with battery--backed memory devices for holding robot parameters and taught data. When you insert a full--size option board.7. When the main board is replaced. CAUTION Before starting replacement. A full--size board occupies one slot.7. When inserting the main board.1. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 Fig. (2) Pinch the barbed handles on the upper and lower sections of the board to unlatch it. (4) There are two rails in the main board SLOT (slot 1). align it to the left--side rail. then push it in gently by the handles until it is latched. for example. align it to the right--side rail. There are two types of option boards: Full--size board and mini--size board. then pull it toward you.2 Replacing the Power Unit and Printed--Circuit Boards on the Backplane Unit The backplane unit incorporates the power unit.1 Replacing the Backplane Board 7.1. turn off the control unit main power. and option boards. (5) There are two rails in slots 3 and 5 (slots for a full--size option board). A mini--size board uses part of a full--size board. whichever is to be replaced. the data in the memory devices is lost. 166 . main board. (3) Place the replacement board on the rail in the appropriate slot of the rack. (1) Detach the cable from the power supply unit or the printed--circuit board. 1.B--81465EN--1/02 MAINTENANCE 7.7.2 Replacing the Power Unit and Printed--Circuit Boards on the Backplane Unit 167 . REPLACING A UNIT SLOT 1 SLOT 2 SLOT 3 PSU (Power supply SLOT) Handles SLOT 1 SLOT 10 Handles SLOT 9 SLOT 8 Fig. Pull out the upper terminal block sections.3 Panel board replacement (3) Remove two retaining screws from the panel board. TBOP4 and TBOP6) are of a connector type. 168 . 2--M3 screws (4) Attach two plates to new panel board by two screws. and remove two plates. then attach the panel board to the oparator panel by four screws.1. 4--M3 screws B--cabinet Fig.7. (2) Remove four retaining screws from the panel board. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 7.7.1.3 Replacing the Panel Board The panel board is at the back of the operator panel. and remove the panel board. (1) Detach all cables from the panel board. The terminal blocks (TBOP3. If the FROM/SRAM module is replaced. (2) Extract the card upward. memory contents are lost. Card Card Card Card Spacer Connector Card Spacer Connector Fig. Demounting a Card (1) Pull outward the clip of each of the two spacers used to secure the card PCB.7.2(a) Demounting a card 169 . make a backup copy of robot parameters and taught data.2 REPLACING CARDS AND MODULES ON THE MAIN BOARD CAUTION Before you start to replace a card or module. then release each latch. REPLACING A UNIT 7.B--81465EN--1/02 MAINTENANCE 7. (2) Push the clip of each spacer downward to secure the card PCB. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 Mounting a Card (1) Check that the clip of each of the two spacers is latched outward. Card Spacer Connector Card Card Card Card Spacer Connector Fig. then insert the card into the connector.7.2(b) Mounting a card 170 .7. B--81465EN--1/02 MAINTENANCE 7. (b) (2) Push the module inward and downward until it is locked.7. (1) Move the clip of the socket outward. REPLACING A UNIT Demounting a module CAUTION When replacing the module. (c) (a) (b) (c) Fig.2(c) Demounting/Mounting a module 171 . be careful not to touch the module contact. If you touch the contact inadvertently. Mounting a module (1) Insert the module at a 30 degree slant into the module socket. (a) (2) Extract the module by raising it at a 30 degree slant and pulling outward. wipe out dirt on the contact with a clean cloth. with side B facing upward. 2(d) Locations of Cards and Modules 172 .7.2 (d) shows the locations of the cards and modules.7. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 Figure 7. Main board CPU card Axis control card FROM/SRAM module Fig. it weighs 45 to 60 kg. In case of B--cabinet (1) Remove the six M4 screws and detach the back panel. The transformer is quite heavy. 6--M4 screws 173 . turn off the main power to the control unit.3 REPLACING THE TRANSFORMER WARNING Before you start replacement procedure. REPLACING A UNIT 7.B--81465EN--1/02 MAINTENANCE 7. Be careful not to damage the cable. If a cable is fastened with nylon ties. LB. OUT.7. CP1. (3) Remove the retaining screws from the transformer terminal board and remove metal plate. and TOH. 174 . REPLACING A UNIT MAINTENANCE B--81465EN--1/02 (2) Detach the connectors of LA. cut them with a diagonal cutter to release the cable. then remove the transformer. REPLACING A UNIT (4) Remove the two retaining M6 screws from the transformer.B--81465EN--1/02 MAINTENANCE 7. Shape of the transformer 2--M6 screws (5) Install a replacement transformer by reversing procedure (1) to (4). 175 . (See “Replacing the servo amplifier. 176 . Be careful not to get burned.”) (2) Remove two M4 screws. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 7. turn off the control unit main power.7. because the regenerative resistor unit is very hot immediately after operation. 2--M5 nuts (4) Install a replacement regenerative resistor unit and a servo amplifier by reversing the procedure (1) to (3). 2--M4 screws (3) Remove the two retaining M5 nuts and lift away the regenerative resistor unit. then detach the housing that fastens cables. In case of B--cabinet (1) Remove the servo amplifier.4 REPLACING THE REGENERATIVE RESISTOR UNIT WARNING Before you start. B--cabinet (1) Detach the cables from the emergency stop unit. (3) Reconnect the cables.5 REPLACING THE E--STOP UNIT WARNING Before you start replacement.5 Replacing the Emergency Stop Unit 177 . turn off the control unit main power.7. and replace the emergency stop unit. (2) Remove retaining screws (4--M4) from the emergency stop unit. REPLACING A UNIT 7. E--stop unit 4--M4 screws B--cabinet Fig.B--81465EN--1/02 MAINTENANCE 7. 6 (a) Replacing the servo Amplifier (B--cabinet) 178 . detach the amplifier cover. and pull out the cable. turn off the control unit main power.7.7. Amplifier cover Fig. In case of B--cabinet (1) Turn the four screws. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 7.6 REPLACING SERVO AMPLIFIERS WARNING Before you start replacement. At the middle of the top of the amplifier. there is an M5 screw that fastens the amplifier during transport of the cabinet. Screw Fixation screw for transport (MS) Fig. After the installation of the cabinet. remove the screw. Check that the voltage is not higher than 50 V. (3) Remove the two screws located on the top of the amplifier.7.6 (b) Replacing the servo Amplifier (B--cabinet) 179 .B--81465EN--1/02 MAINTENANCE 7. REPLACING A UNIT (2) Check the voltage at the screw above the LED “D7” with a DC voltage tester to see if the remaining voltage is not higher than 50 V. This improves maintainability. pull out the amplifier toward you. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 (4) Holding the handles located at the top and bottom of the amplifier. such as capacitors. Fig. Be careful not to touch any components. be careful not to damage the cables that are routed under the servo amplifier when pulling it out.7.7. on the lower part of the servo amplifier printed--circuit board.7.6 (d) Replacing the servo Amplifier (B--cabinet) 180 .6 (c) Replacing the servo Amplifier (B--cabinet) (5) Pull out the lower part of the amplifier further toward you and slant the amplifier. Also. Fig. B--81465EN--1/02 MAINTENANCE 7.6 (e) Replacing the servo Amplifier (B--cabinet) (7) Install a replacement servo amplifier by reversing step (b).7. 181 . (8) Re--attach the cables. REPLACING A UNIT (6) Take the amplifier out while keeping it slanted. Fig. loosen the upper 2 screws and remove the lower 2 screws.7. 7.7.7 REPLACING I/O UNIT MODEL A WARNING Before you start replacement. turn off the control unit main power.1 Replacing the Base Unit of I/O Unit Model A First dismount the modules from the base unit of I/O unit model A. Of these screws. then replace the base unit.7. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 7.7. M4 screw (4 pieces) B--cabinet Fig. The base unit is retained with 4 screws.1 Replacing the Base Unit of I/O Unit Model A 182 . (b) Lift the module up.2 Replacing the module 183 . (b) Fit the connectors of the module and the base unit to each other.7. as described below.2 Replacing a Module Installing a module An interface module and input/output module can be easily installed in and removed from the base unit. Fig. (c) Push the module until the lower stopper of the module is caught in the lower hole of the base unit.B--81465EN--1/02 MAINTENANCE 7.7. REPLACING A UNIT 7.7. (a) Put the upper hook of the module into the upper hole of the base unit. Removing a module (a) Press the lever at the bottom of the module to release the stopper. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 7. Detach or attach the cable by rotating the connector retaining ring. check its specifications carefully. (3) Replace the teach pendant. (2) Detach the cable from the teach pendant. Fig. (1) Be sure that the power of a robot controller is off.7.8 Replacing the Teach Pendant 184 .8 REPLACING THE TEACH PENDANT The specifications of the teach pendant vary with its use.7. When you replace the teach pendant. (2) Put your finger in the dent in the upper section of the fan unit. (3) Lift the fan unit slightly.9 Replacing the Control Section Fan Motor 185 . and pull the fan unit until it is unlatched. (4) Place a replacement fan on the upper section of the rack.7. and dismount it from the rack. The fan motor is mounted on the fan unit rack. Fan motor connector Fan motor Pull the fan motor unit toward you to unlatch it. and slide it gently until it is latched.B--81465EN--1/02 MAINTENANCE 7. Fig. REPLACING A UNIT 7.9 REPLACING THE CONTROL SECTION FAN MOTOR The control section fan motor can be replaced without using a tool. (1) Be sure that the power of a robot controller is off. (3) Install a new fan unit by reversing the dismounting procedure. then dismount it. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 7. (3) Install a new fan unit by reversing the dismounting procedure. 7.10 REPLACING THE AC FAN MOTOR WARNING Before you start replacement.1 Replacing External Air Fan Unit and Door Fan (B--cabinet) Door fan (1) Detach the cable from the fan unit. (2) Remove the fan by unscrewing the two retaining M4 screws. (3) Reverse the procedure to mount a spare fan unit. or you could be injured.7. (2) Remove the two retaining M4 screws from the fan unit. Do not touch the fan motor when it is rotating. (2) Remove the six M4 screws and pull out the fan unit toward you. turn off the control unit main power. Screw (2--M4) Screw (6--M4) Floor fan unit (1) Remove the cable from the fan unit.10. 186 . External Air fan unit (1) Detach the cable. B--81465EN--1/02 MAINTENANCE 7. REPLACING A UNIT Floor fan unit Screw (2--M4) 187 . (4) Install a new panel switch board by reversing the dismounting procedure.11 Replacing the operator panel and Panel switch board 188 .11 REPLACING THE OPERATOR PANEL AND PANEL SWITCH BOARD (1) Detach the cable (CRT8. CRM51) (2) Straighten the 12 claws on the printed circuit board.7. Screw (6--M3) Fig. then remove the panel switch board. then remove the printed circuit board. (3) Remove the six (6--M3) screws.7. Straighten the claws. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 7. NOTE 1 When mounting the mode switch. and replace the mode switch.12 Replacing the Mode Switch 189 . (Tightening torque: 2. (b) Remove the screws fastening the mode switch. Door Screw Mode switch Fig.to the sheet metal.5 kg·cm) 2 Tighten the screws evenly so that the mode switch flat surface becomes parallel-. do not overtighten the screws.7.12 REPLACE THE MODE SWITCH (a) Remove the cable from the mode switch. REPLACING A UNIT 7.B--81465EN--1/02 MAINTENANCE 7. find the cause and take an appropriate measure before replacing the fuse.1 Replacing Fuses in the Servo Amplifier 190 . it is likely that the servo amplifier is defective.13. F2: Fuses for detection of the circuits failure in the servo amplifier. F1. (A60L--0001--0245#GP20) If either of these fuses has blown. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 7. ROT.1 Replacing Fuses in the Servo Amplifier If a fuse in the control unit has blown.7.13 REPLACING FUSES 7. and HBK (A60L--0001--0290#LM32C) FS3: For protection of the 24 V output to the regenerative resistance and the additional axis amplifier (A60L--0001--0290#LM50C) Fuse F1 Fuse F2 Fuse FS1 Fuse FS3 Fuse FS2 Fig.7. The following fuses are in the servo amplifier. FS1: For generation of the power to the amplifier control circuit (A60L--0001--0290#LM32C) FS2: For protection of the 24 V output to the end effector. Replace the servo amplifier.13. A60L--0001--0396#8.5 F1 8.7.B--81465EN--1/02 MAINTENANCE 7.13.5 F4: Fuse for protecting the +24V output. A60L--0001--0046#7.13. A60L--0001--0046#7.5A +24E fuse F4 7.0A F3: Fuse for protecting the +24E output.2 Replacing Fuses in the Power Unit The following fuses are in the power unit.2 Replacing Fuses in the Power Unit 191 .0A AC input fuse F3 7.5A +24V fuse Fig. REPLACING A UNIT 7. F1: Fuse for the AC input. 3 Replacing the Fuse on the Process I/O Boards The following fuse is on each process I/O board. A60L--0001--0046#2.0 Process I/O board CA. FUSE1:Fuse for protecting the +24V output for peripheral equipment interfaces.13.7.CB FUSE1 Total version Process I/O board DA FUSE1 Total version Fig. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 7.3 (c) Replacing the Fuse on the Process I/O Boards 192 .13.7. REPLACING A UNIT Process I/O board CA.CB FUSE1 Total version 193 .B--81465EN--1/02 MAINTENANCE 7. 0 Fuse 2 Fuse 1 Fig.13.13.7.7.4 Replacing the Fuse on the Panel Board The following fuse is on the panel board.4 Replacing the fuse on the panel board 194 . FUSE1 : For protection of the +24EXT line (emergency stop line) FUSE2 : For protection of the teach pendant emergency stop line A60L--0001--0046#1. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 7. 1 Replacing Relays on the Panel Board 195 .14.B--81465EN--1/02 MAINTENANCE 7.14. REPLACING A UNIT 7. If such a failure occurs. 7.7. replace the relay.1 Replacing Relays on the Panel Board KA21.14 REPLACING RELAYS Prolonged use of a relay might result in its contacts failing to make a secure connection or sticking to each other permanently. KA22: Relay for emergency stop circuit A58L--0001--0192#1509A KA22 KA21 Fig. When this alarm is displayed. Important data should be saved to the memory card or floppy disk beforehand in case of emergency. this depends on the system configuration. Clear the entire SRAM memory and reenter data after replacing the battery.15 REPLACING BATTERY 7. (2) Turn the robot controller on for about 30 seconds. the battery can be replaced within one or two weeks.7. If the battery voltage gets lower. replace the battery as soon as possible. (4) Remove the old battery from the top of the main board. In general. The above data is not lost even when the main battery goes dead. (3) Turn the robot controller off. and system variables are stored in the SRAM in the main board. it becomes impossible to back up the content of the SRAM. Replacing the lithium battery (1) Prepare a new lithium battery (ordering drawing number: A02B--0200--K102). however. be needed within 4 years after the introduction of the robot. remove it from the battery holder. When replacing the memory backup battery. do so while the robot controller is turned off in case of emergency. the low--voltage battery alarm (system--035) is displayed on the teach pendant. the battery is factory--installed.15. and detach its connector. First unlatch the battery. A new battery can maintain the contents of memory for about 4 years (Note). Battery replacement may. Turning on the power to the in this state causes system not to start and LED of seven segment on the main board to be displayed “1” because the contents of memory are lost. NOTE In a newly introduced robot. The power to the SRAM memory is backed up by a lithium battery mounted on the front panel of the main board. When the voltage of the battery becomes low. therefore.1 Battery for Memory Backup (3 VDC) The programs. REPLACING A UNIT MAINTENANCE B--81465EN--1/02 7. 196 . Confirm that the battery is latched firmly. Replace the battery only with the specified battery (A02B--0200--K102). Dispose of the replaced battery as an industrial waste. it is recommended that the robot data such as programs and system variables be backed up before battery replacement. insert a new one into the battery holder.B--81465EN--1/02 MAINTENANCE 7. CAUTION Complete the steps (3) to (5) within 30 minutes. REPLACING A UNIT Battery latch Lithium battery Battery connector (5) Remove the old battery. If the battery is left disconnected for a long time. To prevent possible data loss. 197 . the contents of memory will be lost. and attach the connector. 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. WARNING Using other than the recommended battery may result in the battery exploding. III CONNECTIONS . 201 . GENERAL 1 GENERAL This section describes the electrical interface connections in the R-J3iB. It also includes information about installation of the R-J3iB.B--81465EN--1/02 CONNECTIONS 1. 2. : Indicates mechanical connectin. 202 . contact our service section. BLOCK DIAGRAM CONNECTIONS B--81465EN--1/02 2 BLOCK DIAGRAM Fig. 2 For more information.2 Block Diagram of Electrical Interface Connection (In case of B--cabinet) NOTE 1 : Indicates electrical connection. 2 is a block diagram of electrical interface connections with the R-J3iB. Pneumatic pressure source R--J3iB (B--cabinet) Mechanical unit End effector Memory card (PCMCIA) Teach pendant RS--232--C (Note2) Peripheral device Welding machine Ethernet AC power supply Fig. ELECTRICAL CONNECTIONS 3 ELECTRICAL CONNECTIONS 203 .B--81465EN--1/02 CONNECTIONS 3. HBK) CNJ1A (J1 motor power) CNJ2A (J2 motor power) CNJ3A (J3 motor power) CNJ4A (J4 motor power) CNJ5A (J5 motor power) CNJ6A (J6 motor power) CNGA (J1--J3 ground) CNGB (J4--J6 ground) CRR64 (Brake control) RM1 (J1--J6 motor power. ELECTRICAL CONNECTIONS CONNECTIONS B--81465EN--1/02 3. RDI/RDO. Motor brake) EE (Note) End effector Fig. ROT.1 (a) Mechanical Connection Diagram NOTE This cable is not included. 204 .3. HBK) CRF7 (Pulsecoder signal.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS R-J3iB Robot RP1 (Pulsecoder signal RDI/RDO. ROT. It must be supplied by the customer.3. 3. 205 . see the section of Peripheral device interface. It must be supplied by the customer. CRM4 (Process I/O) (NOTE1) Peripheral device Port A (Operator panel) Handy File JD5B (Main board) (NOTE2) External device JD17 (Main board) (NOTE2) External device CD38 (Main board) L1 L2 Braker L3 G Panel board (TBOP3) ON1 ON2 OFF1 OFF2 EES1 EES11 EES2 EES21 EAS1 EAS11 EAS2 EAS21 EGS1 EGS11 EGS2 EGS21 (NOTE2) Ethernet Input power (NOTE2) External power ON/OFF switch Panel board (TBOP4) (NOTE2) External emergency stop switch Panel board (TBOP4) (NOTE2) Fence Panel board (TBOP4) (NOTE2) Servo off switch Fig.1 (b) Mechanical Connection Unit NOTE 1 For detail of the peripheral device connection.B--81465EN--1/02 CONNECTIONS 3. 2 This cable is not included. ELECTRICAL CONNECTIONS R-J3iB CRS16 (Panel board) Teach pendant CRM2. R--J3iB (Servo amplifier) CRR64 CNGA CNJ6 CNJ5 Robot CNGB CRF7 Pulse coder (Pulse coder. J2M.2.ROT) Motor power/brake (J1M.3.2 EXTERNAL CABLE WIRING DIAGRAM 3. J5M.RDI/RDO.1 Robot Connection Cables Robot Model R--2000iA M--6iB ARC Mate 100iB (B--Cabinet) D Detail of cable connection to servo amplifier.2.1 (a) Robot Connection Cable (B--cabinet) 206 .HBK.3. J3M. ELECTRICAL CONNECTIONS CONNECTIONS B--81465EN--1/02 3. J4M. J6M. BK) CNJ4 CNJ3A CNJ2A CNJ1A Fig. B--81465EN--1/02 CONNECTIONS 3. This figure applies to all robot models.2.2. ELECTRICAL CONNECTIONS 3.2 Teach Pendant Cable (1) Teach pendant cable The teach pendant connection cable is connected to the operator panel as follows. Teach pendant Teach pendant connection cable Fig.3.2 Teach Pendant Cable 207 . Ltd. Matsushita Electric Works. Ltd. KC type Type Fig. 3. Provide a class--D or better ground. Use the following leakage current circuit breaker for inverters to prevent incorrect operation. Ltd.2. This might cause the leakage-current circuit breaker or leakage-protection relay installed in the path of the power supply to cut out. Example of Leakage Current Circuit Breaker for Inverters Manufacture Fuji Electric Co. However. The tap is set to the specified voltage before shipment. and amplifier. Selection of an input transformer tap is necessary depending on the input voltage. C type Leakage current circuit breaker. 208 . check it referring to section 6. power cable. If the servo amplifier is used without a transformer. ELECTRICAL CONNECTIONS CONNECTIONS B--81465EN--1/02 3. The resistance to the ground must not exceed 100Ω.2 in “Maintenance” before supplying power (before the breaker switch is turned on). Hitachi.3.. Be sure to ground the work table or jig used by an arc welding robot or the like so that it can handle a large current. EG A series SG A series ES100C type ES225C type Leakage current circuit breaker. a high-frequency leakage current flows through the stray capacitance between the ground and the motor coils.3 shows the cable connection. Use a thick wire to withstand the maximum current used. connect the power supply whose voltage conforms to the installation conditions to the terminal located above the circuit breaker.3 Connecting the Input Power Considering the robot power capacity and the circuit breaker capacity. The motor is driven by the PWM inverter system using a power transistor bridge.2. 2.3 Input Power Supply Connection (B--cabinet) 209 . ELECTRICAL CONNECTIONS B--cabinet Input Power supply cable (Note) Always replace the cover after completing Fig.B--81465EN--1/02 CONNECTIONS 3.3. 4 (a) Connection of the external power supply ON/OFF switch 210 . ELECTRICAL CONNECTIONS CONNECTIONS B--81465EN--1/02 3.3.2.4 Connecting the External Power Supply ON/OFF Switch Panel board The External Power On/Off signal turns on and off the power supply from the outside of the control unit.3. and is connected as follows.2. TBOP3 Fig. Use a contact conforming to the following : Voltage rating : 50 VDC. Fig. Note3) When the external ON/OFF switch is turned OFF (Open). 100mA or more The power supply on/off timing chart is as follows ON/OFF SW on operator panel TOFF--ON EXOFF1--2 ON OFF Close Open ON Power OFF TOFF--ON ≧ 5 sec Note1) In case of using the external ON/OFF control.3. the ON/OFF switch on operator panel can not turn ON the controller. remove the short piece between EXOFF1 and EXOFF2. Note2) When the external ON/OFF switch is turned ON (Closed). In case of using external ON/OFF switch.B--81465EN--1/02 CONNECTIONS 3.4 (b) Connection of the external power supply switch ON and OFF 211 . then connect the wires. the ON/OFF switch on operator panel must be turned ON. ELECTRICAL CONNECTIONS Short piece between EXON1 and EXON2 External ON/OFF switch.2. the ON/OFF switch on operator panel can turn ON the controller. 3.5 Connecting the External Emergency Stop Fig.2. ELECTRICAL CONNECTIONS CONNECTIONS B--81465EN--1/02 3.5 (a) Connection of the external emergency stop 212 .2.3. B--81465EN--1/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS External emergency stop output . Signal ESPB1 ESPB11 ESPB2 ESPB21 ESPB3 ESPB31 ESPB4 ESPB41 Description Emergency stop output signals. These contacts are open if an emergency stop of teach pendant or operator panel occurs or the power is turned off. (Note 1) These contacts are closed during normal operation. Current, voltage Rated contact: 250 VAC, 5 A or 5-A 30 VDC, 5A resistor load Fig.3.2.5 (b) External emergency stop output NOTE 1 The relays for emergency stop output signals can be connected external power source. The power for relays are connected controller’s power at the factory, and please connect external power source if emergency stop output must not be effected controller’s power. Please refer to “External power connection”. 213 3. ELECTRICAL CONNECTIONS CONNECTIONS B--81465EN--1/02 External emergency stop input After connecting an external emergency stop switch and safety fence door switch, be sure to check the operations of those switches, the emergency stop switch on the operator’s panel, and the emergency stop switch on the teach pendant. Use a contact which minimum load is 5mA less. Signal EES1 EES11 EES2 EES21 EAS1 EAS11 EAS2 EAS21 EGS1 EGS11 EGS2 EGS21 SD4 SD41 SD5 SD51 Description Current, voltage Connect the contacts of the external emergency stop switch to these terminals. When using the contacts of a relay of contactor instead of the switch, Open and close of connect a spark killer to the coil of the relay or contactor, to suppress noise. 24VDC 10mA When these terminals are not used, jumper them. These signals are used to stop the robot when the door on the safety fence is open. While the deadman’s switch on the teach pendant is pressed and the teach Open and close of pendant enable switch is validated, these signals are ignored and an emer- 24VDC 10mA gency stop does not occur. If these signals are not used, short these terminals. Connect the contacts of the servo--on input switch to these terminals. When using the contacts of a relay or contactor instead of the switch, connect a Open and close of spark killer to the coil of the relay or contactor, to suppress noise. 24VDC 10mA When these terminals are not used, jumper them. Connect the contacts of the servo--disconnect input switch to these terminals. When using the contacts of a relay or contactor instead of the switch, Open and close of connect a spark killer to the coil of the relay or contactor, to suppress noise. 24VDC 10mA When these terminals are not used, jumper them. 214 B--81465EN--1/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS Input requirement for external emergency stop and etc. The emergency stop circuit is composed of a chain of contacts. D Please connect dual contacts, which work same time, for external emergency stop, safety fence switch, servo ON/OFF switch and servo disconnect switch. D Please observe following timing. If input requirements are not satisfied, it may occure single chain failure. l. CAUTION 1 Single chain failure will occure, if this input requirements are not satisfied. 2 Single chain failure can’t be reset until special reset operation even if controller power is OFF and ON. 215 3. ELECTRICAL CONNECTIONS CONNECTIONS B--81465EN--1/02 Extenal power connection The relays for emergency stop input and output can be separated from controller’s power. Please connect external +24V instead of internal +24V, if emergency stop output must not be effected controller’s power. 216 B--81465EN--1/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS Connecting external on/off and external emergency stop signal input/output wires Details of the signal wires are shown below: Bare wire length: 8 to 9 mm Compliant wire size: 0.08 to 2.5 mm2 If you want to use a rod terminal, select one that is suitable for the wire shown above. The following table lists recommended products (manufactured by Weissmuller). Wire (mm2) 0.5 0.75 1.0 1.5 2.5 Specification H0.5/14 H0.75/14 H1.0/14 H1.5/14 H2.5/14 Remark With insulation cover (Crimping tool : PZ3, PZ4, PZ6/5) How to attach signal wires to connectors Manipulation slot Flat--blade screwdriver Plug connector block Signal wire 1. 2. 3. 4. 5. Detach the plug connector block from the panel board. Insert the tip of a flat--blade screwdriver into the manipulation slot and push down its handle. Insert the end of the signal wire into the wire slot. Pull out the screwdriver. Attach the plug connector block to the panel board. Do not insert a wire into the wire hole of a plug connector or pull it out with the plug connector block mounted on the panel board; otherwise, the panel board may be damaged. 217 3. ELECTRICAL CONNECTIONS CONNECTIONS B--81465EN--1/02 FANUC recommonds the lever (A05B--2400--K030) for connecting the signal wire to the plug connector block instead of Flat--blade screwdriver. Wire stripping F Available wire size AWG 28--14 (0.08 to 2.5mm2) Handling of the Lever F Hold the connector, and push down the lever by finger F Don’t handle the lever after fit the connector into the PCB, otherwise PCB will be damaged by handling stress. F Please check the strip length carefully. F Please readjust the loose end. Wiring (1) Pull down the lever. (2) Push in the conductor with holding the lever. (3) Set the lever free. L And pull the conductor softly to check the clamping L Don’t pull strongly Replace the lever (1) Pull off the lever. (2) Hook the lever to the rectangle hole. (3) Push down the lever untill click in. Fit to header (1) Push in the connector to header. (2) Please check if the latch is hooked to header. L Be careful to fit the shape of each other. 218 L Max wire size … 0.34 (24) 0.0 8.0 14.5 9.1 3.0 3.4 1.0 L CAUTION Please make sure to use WAGO 206--204 to crimp the ferrules.0 4.0 8.--unit pcs 100 100 100 100 100 100 100 yellow green white gray red black yellow 12.25 (24) 0.5 (22) 0.0 2.0 8.5 10.8 3.5 14.0 8. (4) Please check if the wire crimped correctly.0 2.0 1.0 8. (2) Introduce wire with ferrule into cramping station.5 3. (1) Put the wire through the hole of ferrules.0mm2 (AWG14) (with “Ferrule”) F Additional wire is available under F Additional wire is the jumper.5 (16) 2.5 3.7 2. then put the jumper into connector.8 1. L Please check the direction of the jumper.0 8.5 2. NOT avairable under the jumper.5 4.6 2.B--81465EN--1/02 CONNECTIONS 3.0 10.206--204) Specifications of Ferrules WAGO Item--No.2 D1 D2 Pack.0 L L1 D (m) 2.0 2. Availability of wires F Without jumpers F With jumper F With two jumpers L Max wire size … 2.0 10. ELECTRICAL CONNECTIONS Installation of “Jumper” (1) Attach levers to connector.0 (18) 1. 219 .2 1.0 (14) Color Stripped Lengt (m) 9.5 9. (2) Hold down levers at the same time.7 0.0 10.3 3.75 (20) 1.0 14. Crimping Toole ( : WAGO Item--No.5 12.0 14. 216--301 216--302 216--201 216--202 216--203 216--204 216--205 Sleep for mm2 (AWG) 0.0 14.0 8.5mm2 (AWG20) (with “Ferrule”) Installation of “Ferrules” (3) Squeeze handles until ratchet mechanism is released.8 0. Example: Process I/O board CB Table value Exclusive DI General purpose DI DI. 40 -18 = 22 points Table value Exclusive DO General purpose DO DO. PERIPHERAL DEVICE. Figure 4 shows the locations of these boards and units. ARC WELDING. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 4 No. 40 -20 = 20 points Process I/O printed board I/O unit model A (5 slots) Fig. AND END EFFECTOR INTERFACES R-J3iB I/O peripheral device interfaces include printed circuit boards and a unit selected according to the applications. ARC WELDING. Table 4 lists details of the printed--circuit boards and units. Table 4 Peripheral Device Interface Types Drawing number A05B--2450--J001 A05B--2450--J002 A05B--2450--J003 A05B--2450--J004 A05B-2452-J100 (Base and interface unit) Number of I/O points DI 40 40 96 40 DO 40 40 96 40 D/A 2 0 0 2 A/D 6 0 0 0 Remarks Installed in backplane Installed in backplane Installed in backplane Installed in backplane Process I/O board CA Process I/O board CB Process I/O board DA Process I/O board HA I/O Unit--MODEL A (B--cabinet) Depending on selected I/O module NOTE General purpose I/O (SDI/SDO) is a number which subtract an exclusive signal from the table value. No 1 2 3 4 5 Name PERIPHERAL DEVICE.4.4 Locations of Peripheral Device Interfaces 220 . 1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM 4.1 Block diagram of the process I/O board CA/CB/HA 221 . B--cabinet Process I/O board CA/CB/HA 3 CRM2A 1 JD4A (JD1B) CRM2B JD4B (JD1A) CRW1 or CRW7 (NOTE2) CRW2 2 Process I/O board CA/CB/HA CRM2A JD4A (JD1B) CRM2B JD4B (JD1A) CRW1 or CRW7 (NOTE 2) CRW2 5 4 Peripheral device Main board JD1A (JD4) Fig.1.4.B--81465EN--1/02 CONNECTIONS 4.1 When Process I/O Board CA/CB/HA is Used (B--cabinet) Following are a block diagram of the peripheral device interface and the specifications. AND END EFFECTOR INTERFACES 4.1. PERIPHERAL DEVICE. ARC WELDING. ARC WELDING. PERIPHERAL DEVICE.4. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 NOTE 1 CRW1 and CRW2 are not provided for process I/O board CB 2 In case of process I/O CA : CRW1 In case of process I/O HA : CRW7 No. 1 2 3 4 5 Welding device connection cable g (Process I/O CA) (FANUC interface) Welding device connection cable g (Process I/O HA) (General interface) Welding device connection cable g (Process I/O HA) (FANUC interface) I/O link cable I/O link cable Peripheral device connection cable p Name Drawing number A05B--2452--J140 A05B--2452--J141 A05B--2452--J200 A05B--2452--J201 A05B--2452--J202 A05B--2452--J270 A05B--2452--J271 A05B--2452--J272 A05B--2452--J273 A05B--2452--J274 A05B--2452--J275 A05B--2452--J276 A05B--2452--J277 A05B--2452--J278 Remarks Between main board and process I/O Between process I/O and process I/O Cable length 10m (one cable) Cable length 20m (one cable) Cable length 30m (one cable) Cable length 3m (one cable) CRW1 Cable length 7m (one cable) CRW1 Cable length 14m (one cable) CRW1 Cable length 3m (one cable) CRW7 Cable length 7m (one cable) CRW7 Cable length 14m (one cable) CRW7 Cable length 3m (one cable) CRW7 Cable length 7m (one cable) CRW7 Cable length 14m (one cable) CRW7 222 . PERIPHERAL DEVICE.1. ARC WELDING.B--81465EN--1/02 CONNECTIONS 4. AND END EFFECTOR INTERFACES 4.2 When Process I/O Board DA is Used (B--cabinet) B--cabinet Main board Process I/O board DA Peripheral device JD1A 1 JD4A CRM2A JD4B CRM2B CRM2C CRM2D 3 4 5 6 7 8 CRM4B 2 CRM4A Process I/O board DA JD4A CRM2A JD4B CRM2B CRM2C CRM2D CRM4A CRM4B Fig.1.4.2 Block diagram of the process I/O board DA Cable number 1 2 3 5 7 8 4 6 Peripheral device connection cable p I/O link cable I/O link cable Peripheral device connection cable p Name Drawing number A05B--2452--J140 A05B--2452--J141 A05B--2452--J200 A05B--2452--J201 A05B--2452--J202 A05B--2452--J250 A05B--2452--J251 A05B--2452--J252 Remarks Between main board and process I/O Between process I/O and process I/O Connected length 10m (one cable) Connected length 20m (one cable) Connected length 30m (one cable) Connected length 10m (one cable) Connected length 20m (one cable) Connected length 30m (one cable) 223 . 1. 224 . AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 4. ARC WELDING.1.4. PERIPHERAL DEVICE.4.1.1 In case of B--cabinet E--Stop unit CP5A Main board JD1A 1 Peripheral device Interface module 2 2 2 2 2 Fig.3.3 When I/O Unit--MODEL A is Used 4.3.1 Block diagram of I/O Unit--A (In case of B--cabinet) Cable number 1 2 I/O link cable Peripheral device connection cable Name Drawing number — — Remarks Included in A05B--2452--J100 Must be supplied by the customer. ARC WELDING. Process I/O board A05B--2452--J141 JD4A E--stop unit JD4B CP5A Included in model A base unit I/O Unit--A Interface module JD1B JD1A CP32 Back plane (5--slot) 225 . I/O Unit--A are used. PERIPHERAL DEVICE. AND END EFFECTOR INTERFACES 4. Main board B--cabinet Process I/O board JD1A A05B--2452--J140 JD4A JD4B DC power is supplied from the back plane. connect them as shown below.B--81465EN--1/02 CONNECTIONS 4.1. When several units of the process I/O board.4 When Two or more Process I/O Boards and I/O Unit (Model A or Model B) are Used In case of B--cabinet. 4.1 In Case of B--cabinet One board or one unit is used Combination C Combination D Combination E Process I/O board CA/CB/HA (40 points) Process I/O board DA (96 points) I/O Unit--A Two boards/units are used in combination Combination CC Process I/O board CA/CB/HA (40 points) + Process I/O board CA/CB/HA (40 points) Process I/O board CA/CB/HA (40 points) + I/O Unit--A Process I/O board DA (96 points) + Process I/O board CA/CB/HA (40 points) Process I/O board DA (96 points) + Process I/O board DA (96 points) Process I/O board DA (96 points) + I/O Unit--A Combination CE Combination DC Combination DD Combination DE Three boards/units are used in combination Combination CCE Process I/O board CA/CB/HA (40 points) + Process I/O board CA/CB/HA (40 points) + I/O Unit--A Process I/O board DA (96 points) + Process I/O board CA/CB/HA (40 points) + I/O Unit--A Process I/O board DA (96 points) + Process I/O board DA (96 points) + I/O Unit--A Combination DCE Combination DDE 226 .2 PERIPHERAL DEVICE INTERFACE COMBINATION 4. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 4. ARC WELDING.2. PERIPHERAL DEVICE. 3 shows signals of a process I/O board. (General signals SDI/SDO are allocated to the second and the following process I/O boards. Table 4. These signals are allocated to the process I/O board connected first when two or more printed boards are combined. PERIPHERAL DEVICE.3 PROCESS I/O BOARD SIGNALS There are 18 exclusive data inputs (DI) and 20 exclusive data outputs (DO) for a process I/O board. AND END EFFECTOR INTERFACES 4. ARC WELDING.) The common voltage of the DI signals input to pins 1 to 4 of connector CRM2A is clamped +24 V (common) in each process I/O board.3 Process I/O Board Signals (1/4) (DI signals) Connector number CRM2A-1 CRM2A-2 CRM2A-3 CRM2A-4 CRM2A-5 CRM2A-6 CRM2A-7 CRM2A-8 CRM2A-9 Signal name *IMSTP *HOLD *SFSD Description Immediate stop Temporary stop Safe speed Cycle stop External reset Start Return to home position Operation enabled Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Remarks Clamped at +24 V common Clamped at +24 V common Clamped at +24 V common Clamped at +24 V common CSTOPI FAULT RESET START HOME ENBL RSR1 PNS1 Option CRM2A-10 RSR2 PNS2 Option CRM2A-11 RSR3 PNS3 Option CRM2A-12 RSR4 PNS4 Option CRM2A-13 RSR5 PNS5 Option CRM2A-14 RSR6 PNS6 Option CRM2A-15 RSR7 PNS7 Option CRM2A-16 RSR8 PNS8 Option 227 . Table 4.B--81465EN--1/02 CONNECTIONS 4. 3 Process I/O Board Signals (2/4) (DI signals) Connector number CRM2A-29 CRM2A-30 CRM2A-31 CRM2A-32 CRM2B-1 CRM2B-2 CRM2B-3 CRM2B-4 CRM2B-5 CRM2B-6 CRM2B-7 CRM2B-8 CRMSB-9 CRM2B-10 CRM2B-11 CRM2B-12 CRM2B-13 CRM2B-14 CRM2B-15 CRM2B-16 CRM2B-29 CRM2B-30 CRM2B-31 CRM2B-32 Signal name PNSTROBE PROD START SDI01 SDI02 SDI03 SDI04 SDI05 SDI06 SDI07 SDI08 SDI09 SDI10 SDI11 SDI12 SDI13 SDI14 SDI15 SDI16 SDI17 SDI18 SDI19 SDI20 SDI21 SDI22 Description PNS strobe Start of automatic operation Peripheral device p status General signal Remarks 228 . ARC WELDING. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 Table4. PERIPHERAL DEVICE.4. ARC WELDING. PERIPHERAL DEVICE.3 Process I/O Board Signals (3/4) (DO signals) Connector number CRM2A-33 CRM2A-34 CRM2A-35 CRM2A-36 CRM2A-38 CRM2A-39 CRM2A-40 CRM2A-41 CRM2A-43 CRM2A-44 CRM2A-45 Signal name CMDENBL SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1 SNO1 CRM2A-46 ACK2 SNO2 CRM2A-19 ACK3 SNO3 CRM2A-20 ACK4 SNO4 CRM2A-21 ACK5 SNO5 CRM2A-22 ACK6 SNO6 CRM2A-24 ACK7 SNO7 CRM2A-25 ACK8 SNO8 CRM2A-26 CRM2A-27 SNACK RESERVED Description During automatic operation Preparation completed Program running Program being interrupted During temporary stop Alarm Home position Teach pendant enabled Battery voltage drop During operation Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Response signal to PNS Option Option Option Option Option Option Option Option Remarks 229 . AND END EFFECTOR INTERFACES Table4.B--81465EN--1/02 CONNECTIONS 4. PERIPHERAL DEVICE.3 Process I/O Board Signals (4/4) (DO signals) Connector number CRM2B-33 CRM2B-34 CRM2B-35 CRM2B-36 CRM2B-38 CRM2B-39 CRM2B-40 CRM2B-41 CRM2B-43 CRM2B-44 CRMSB-45 CRM2B-46 CRM2B-19 CRM2B-20 CRM2B-21 CRM2B-22 CRM2B-24 CRM2B-25 CRM2B-26 CRM2B-27 Signal name SDO01 SDO02 SDO03 SDO04 SDO05 SDO06 SDO07 SDO08 SDO09 SDO10 SDO11 SDO12 SDO13 SDO14 SDO15 SDO16 SDO17 SDO18 SDO19 SDO20 Description Peripheral device p control signal Remarks General signal 230 .4. ARC WELDING. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 Table4. AND END EFFECTOR INTERFACES 4. AND WELDERS 231 .4 INTERFACE FOR PERIPHERAL DEVICES. PERIPHERAL DEVICE. END EFFECTORS.B--81465EN--1/02 CONNECTIONS 4. ARC WELDING. 4.1 Peripheral Device and Control Unit Connection Control unit Peripheral device control interface A1 CRM2A *IMSTP 33 34 *HOLD ACK3/SNO3 19 35 *SFSPD 20 ACK4/SNO4 36 CSTOPI ACK5/SNO5 21 FAULT RESET 37 ACK6/SNO6 22 38 START COM--A4 23 39 HOME 24 ACK7/SNO7 40 ENBL 25 ACK8/SNO8 RSR1/PNS1 41 26 SNACK RSR2/PNS2 42 27 RESERVED RSR3/PNS3 43 COM--A5 28 RSR4/PNS4 44 PNSTROBE 29 RSR5/PNS5 45 PROD START 30 46 RSR6/PNS6 31 SDI01 RSR7/PNS7 47 32 SDI02 RSR8/PNS8 48 49 0V 50 0V Peripheral device control interface A2 CRM2B SDI03 33 34 SDI04 SDO13 19 35 SDI05 20 SDO14 36 SDI06 21 SDO15 SDI07 37 SDO16 22 38 SDI08 COM--B4 23 39 SDI09 24 SDO17 40 SDI10 25 SDO18 SDI11 41 26 SDO19 SDI12 42 27 SDO20 SDI13 43 COM--B5 28 SDI14 44 SDI19 29 SDI15 45 SDI20 30 46 SDI16 SDI21 31 SDI17 47 32 SDI22 SDI18 48 49 0V 0V 50 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CMDENBL SYSRDY PROGRUN PAUSED COM--A1 HELD FAULT ATPERCH TPENBL COM--A2 BATALM BUSY ACK1/SNO1 ACK2/SNO2 COM--A3 +24E +24E Peripheral device A1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 SDO01 SDO02 SDO03 SDO04 COM--B1 SDO05 SDO06 SDO07 SDO08 COM--B2 SDO09 SDO10 SDO11 SDO12 COM--B3 +24E +24E Peripheral device A2 NOTE 1 The peripheral device connection cables are optional. PERIPHERAL DEVICE. ARC WELDING. 2 All of COM-** are connected to 0 V. Applicable process I/O board type CA. CB. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 4. DA.4. HA 232 . 2 All of COM-** are connected to 0 V. ARC WELDING. Applicable process I/O board type DA 233 . AND END EFFECTOR INTERFACES Control unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Peripheral device control interface A3 CRM2C SDI23 33 34 SDI24 19 SDO33 35 SDI25 20 SDO34 SDI26 36 21 SDO35 SDI27 37 22 SDO36 38 SDI28 COM--C4 23 39 SDI29 24 SDO37 40 SDI30 25 SDO38 SDI31 41 26 SDO39 SDI32 42 27 SDO40 SDI33 43 COM--C5 28 SDI34 44 SDI39 29 SDI35 45 SDI40 30 46 SDI36 SDI41 31 SDI37 47 32 SDI42 SDI38 48 49 0V 50 0V Peripheral device control interface A4 CRM2D SDI43 33 SDI44 SDI45 SDI46 SDI47 SDI48 SDI49 SDI54 SDI51 SDI52 SDI53 SDI54 SDI55 SDI56 SDI57 SDI58 0V 0V 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SDO53 SDO54 SDO55 SDO56 COM--D4 SDO57 SDO58 SDO59 SDO60 COM--D5 SDI59 SDI60 SDI61 SDI62 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 SDO21 SDO22 SDO23 SDO24 COM--C1 SDO25 SDO26 SDO27 SDO28 COM--C2 SDO29 SDO30 SDO31 SDO32 COM--C3 +24E +24E Pripheral device A3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 SDO41 SDO42 SDO43 SDO44 COM--D1 SDO45 SDO46 SDO47 SDO48 COM--D2 SDO49 SDO50 SDO51 SDO52 COM--D3 +24E +24E Pripheral device A4 NOTE 1 The peripheral device connection cables are optional. PERIPHERAL DEVICE.B--81465EN--1/02 CONNECTIONS 4. PERIPHERAL DEVICE. 2 All of COM--** are connected to 0V. Applicable process I/O board type DA 234 .4. ARC WELDING. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 Control unit Peripheral device control interface B1 CRM4A 01 02 03 04 05 06 07 SDI63 SDI64 SDI65 SDI66 SDI67 SDI68 SDI69 08 09 10 11 12 13 SDO65 SDO66 SDO67 SDO68 COM--E2 SDI70 14 15 16 17 18 19 20 SDO61 SDO62 SDO63 SDO64 COM--E1 +24 0V Peripheral device B1 Control unit Peripheral device control interface B1 CRM4B 01 02 03 04 05 06 07 SDI71 SDI72 SDI73 SDI74 SDI75 SDI76 SDI77 08 09 10 11 12 13 SDO73 SDO74 SDO75 SDO76 COM--F2 SDI78 14 15 16 17 18 19 20 SDO69 SDO70 SDO71 SDO72 COM--F1 +24 0V Peripheral device B2 NOTE 1 The peripheral device connection cables are optional. B--81465EN--1/02 CONNECTIONS 4. ARC WELDING. AND END EFFECTOR INTERFACES Control unit (peripheral device control interface A1) Connector pin No. 235 . +24E CRM2A (49.50) Receiver circuit CRM2A (1) CRM2A (2) CRM2A (3) CRM2A (4) Peripheral device *IMSTP *HOLD *SFSPD CSTOPI RV RV RV RV FAULT RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSROBE PROD START SDI01 SDI02 RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV +24E B CRM2A (5) CRM2A (6) CRM2A (7) CRM2A (8) CRM2A (9) CRM2A (10) CRM2A (11) CRM2A (12) CRM2A (13) CRM2A (14) CRM2A (15) CRM2A (16) CRM2A (29) CRM2A (30) CRM2A (31) CRM2A (32) A Common setting pin (ICOM1) NOTE This is a connection diagram for +24v common. PERIPHERAL DEVICE. PERIPHERAL DEVICE.4. 42.37. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 Control unit (peripheral device control interface A1) Connector pin No.28. Peripheral device Receiver circuit DV CMDENBL CRM2A (33) LOAD RELAY SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK RESERVED DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV CRM2A (34) CRM2A (35) CRM2A (36) CRM2A (38) CRM2A (39) CRM2A (40) CRM2A (41) CRM2A (43) CRM2A (44) CRM2A (45) CRM2A (46) CRM2A (19) CRM2A (20) CRM2A (21) CRM2A (22) CRM2A (24) CRM2A (25) CRM2A (26) CRM2A (27) LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD CRM2A(23. ARC WELDING.47) 0V +24V +24 V regulated power supply 236 . PERIPHERAL DEVICE. ARC WELDING.B--81465EN--1/02 CONNECTIONS 4. AND END EFFECTOR INTERFACES Control unit (peripheral device control interface A2) Connector pin No. +24E CRM2B (49. 237 .50) Peripheral device Receiver circuit SDI03 SDI04 SDI05 SDI06 SDI07 SDI08 SDI09 SDI10 SDI11 SDI12 SDI13 SDI14 SDI15 SDI16 SDI17 SDI18 SDI19 SDI20 SDI21 SDI22 RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV +24E B A CRM2B (1) CRM2B (2) CRM2B (3) CRM2B (4) CRM2B (5) CRM2B (6) CRM2B (7) CRM2B (8) CRM2B (9) CRM2B (10) CRM2B (11) CRM2B (12) CRM2B (13) CRM2B (14) CRM2B (15) CRM2B (16) CRM2B (29) CRM2B (30) CRM2B (31) CRM2B (32) Common setting pin (ICOM2) NOTE This is a connection diagram for +24V common. 47) 0V +24V +24 V regulated power supply 238 . PERIPHERAL DEVICE.4. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 Control unit (peripheral device control interface A2) Peripheral device Connector pin No. SDO01 DV CRM2B (33) LOAD RELAY SDO02 SDO03 SDO04 SDO05 SDO06 SDO07 SDO08 SDO09 SDO10 SDO11 SDO12 SDO13 SDO14 SDO15 SDO16 SDO17 SDO18 SDO19 SDO20 DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV CRM2B (34) CRM2B (35) CRM2B (36) CRM2B (38) CRM2B (39) CRM2B (40) CRM2B (41) CRM2B (43) CRM2B (44) CRM2B (45) CRM2B (46) CRM2B (19) CRM2B (20) CRM2B (21) CRM2B (22) CRM2B (24) CRM2B (25) CRM2B (26) CRM2B (27) LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD CRM2A(23. 42. ARC WELDING.37.28. 50) Peripheral device Receiver circuit SDI23 SDI24 SDI25 SDI26 SDI27 SDI28 SDI29 SDI30 SDI31 SDI32 SDI33 SDI34 SDI35 SDI36 SDI37 SDI38 SDI39 SDI40 SDI41 SDI42 RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV +24E B A CRM2C (1) CRM2C (2) CRM2C (3) CRM2C (4) CRM2C (5) CRM2C (6) CRM2C (7) CRM2C (8) CRM2C (9) CRM2C (10) CRM2C (11) CRM2C (12) CRM2C (13) CRM2C (14) CRM2C (15) CRM2C (16) CRM2C (29) CRM2C (30) CRM2C (31) CRM2C (32) Common setting pin (ICOM3) NOTE This is a connection diagram for +24V common. 239 .B--81465EN--1/02 CONNECTIONS 4. PERIPHERAL DEVICE. AND END EFFECTOR INTERFACES Control unit (peripheral device control interface A3) Connector pin No. +24E CRM2C (49. ARC WELDING. PERIPHERAL DEVICE.47) 0V +24V +24 V regulated power supply 240 . ARC WELDING. SDO21 DV CRM2C (33) LOAD RELAY SDO22 SDO23 SDO24 SDO25 SDO26 SDO27 SDO28 SDO29 SDO30 SDO31 SDO32 SDO33 SDO34 SDO35 SDO36 SDO37 SDO38 SDO39 SDO40 DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV CRM2C (34) CRM2C (35) CRM2C (36) CRM2C (38) CRM2C (39) CRM2C (40) CRM2C (41) CRM2C (43) CRM2C (44) CRM2C (45) CRM2C (46) CRM2C (19) CRM2C (20) CRM2C (21) CRM2C (22) CRM2C (24) CRM2C (25) CRM2C (26) CRM2C (27) LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD CRM2C(23.4.28. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 Control unit (peripheral device control interface A3) Peripheral device Connector pin No. 42.37. 50) Peripheral device Receiver circuit SDI43 SDI44 SDI45 SDI46 SDI47 SDI48 SDI49 SDI50 SDI51 SDI52 SDI53 SDI54 SDI55 SDI56 SDI57 SDI58 SDI59 SDI60 SDI61 SDI62 RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV +24E B A CRM2D (1) CRM2D (2) CRM2D (3) CRM2D (4) CRM2D (5) CRM2D (6) CRM2D (7) CRM2D (8) CRM2D (9) CRM2D (10) CRM2D (11) CRM2D (12) CRM2D (13) CRM2D (14) CRM2D (15) CRM2D (16) CRM2D (29) CRM2D (30) CRM2D (31) CRM2D (32) Common setting pin (ICOM4) NOTE This is a connection diagram for +24V common.B--81465EN--1/02 CONNECTIONS 4. ARC WELDING. 241 . PERIPHERAL DEVICE. AND END EFFECTOR INTERFACES Control unit (peripheral device control interface A4) Connector pin No. +24E CRM2D (49. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 Control unit (peripheral device control interface A4) Peripheral device Connector pin No. PERIPHERAL DEVICE. ARC WELDING. 42.28.37. SDO41 DV CRM2D (33) LOAD RELAY SDO42 SDO43 SDO44 SDO45 SDO46 SDO47 SDO48 SDO49 SDO50 SDO51 SDO52 SDO53 SDO54 SDO55 SDO56 SDO57 SDO58 SDO59 SDO60 DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV CRM2D (34) CRM2D (35) CRM2D (36) CRM2D (38) CRM2D (39) CRM2D (40) CRM2D (41) CRM2D (43) CRM2D (44) CRM2D (45) CRM2D (46) CRM2D (19) CRM2D (20) CRM2D (21) CRM2D (22) CRM2D (24) CRM2D (25) CRM2D (26) CRM2D (27) LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD CRM2D(23.47) 0V +24V +24 V regulated power supply 242 .4. PERIPHERAL DEVICE. ARC WELDING. 243 .B--81465EN--1/02 CONNECTIONS 4. SDO61 DV CRM4A (14) LOAD RELAY SDO62 SDO63 SDO64 SDO65 SDO66 SDO67 SDO68 DV DV DV DV DV DV DV CRM4A (15) CRM4A (16) CRM4A (17) CRM4A (8) CRM4A (9) CRM4A (10) CRM4A (11) LOAD LOAD LOAD LOAD LOAD LOAD LOAD CRM4A (20) 0V +24V +24 V regulated power supply NOTE This is a connection diagram for +24V common. AND END EFFECTOR INTERFACES Control unit (peripheral device control interface B1) Connector pin No. +24E CRM4A (19) Peripheral device Receiver circuit SDI63 SDI64 SDI65 SDI66 SDI67 SDI68 SDI69 SDI70 RV RV RV RV RV RV RV RV +24E B CRM4A (1) CRM4A (2) CRM4A (3) CRM4A (4) CRM4A (5) CRM4A (6) CRM4A (7) CRM4A (13) A Common setting pin (ICOM5) Connector pin No. 244 . PERIPHERAL DEVICE. +24E CRM4B (19) Peripheral device Receiver circuit SDI71 SDI72 SDI73 SDI74 SDI75 SDI76 SDI77 SDI78 RV RV RV RV RV RV RV RV +24E B CRM4B (1) CRM4B (2) CRM4B (3) CRM4B (4) CRM4B (5) CRM4B (6) CRM4B (7) CRM4B (13) A Common setting pin (ICOM5) Connector pin No. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 Control unit (peripheral device control interface B2) Connector pin No. SDO69 DV CRM4B (14) LOAD RELAY SDO70 SDO71 SDO72 SDO73 SDO74 SDO75 SDO76 DV DV DV DV DV DV DV CRM4B (15) CRM4B (16) CRM4B (17) CRM4B (8) CRM4B (9) CRM4B (10) CRM4B (11) LOAD LOAD LOAD LOAD LOAD LOAD LOAD CRM4B (20) 0V +24V +24 V regulated power supply NOTE This is a connection diagram for +24V common.4. ARC WELDING. 2 Connection Between the Mechanical Unit and End Effector EE Fig. AND END EFFECTOR INTERFACES 4. ARC WELDING.4.) 245 . PERIPHERAL DEVICE.B--81465EN--1/02 CONNECTIONS 4.2 In case of the R--2000i (For other robots.4.4. referto the each maintenance manual. 4. 246 . PERIPHERAL DEVICE. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 RDI9 (Pneumatic pressure abnormal signal) (COM1) NOTE 1 This is a connection diagram for +24V common. ARC WELDING. 2 The common--level change--over setting pin (COM1) is in the 6--axis servo amplifier. 4. Applicable process I/O board type CA 247 . PERIPHERAL DEVICE. AND END EFFECTOR INTERFACES 4. ARC WELDING.3 Connection Between the Control Unit and Welder Control unit Welder interface CRW1 Welder Analog input interface CRW2 Peripheral device NOTE Welder and peripheral device connection cable are optional.B--81465EN--1/02 CONNECTIONS 4. 3kΩ high--pass filter shall be provided. Welding current detector signal COMAD2 R=100Ω or more Wire stick detection signal Welding power supply 248 . PERIPHERAL DEVICE. ARC WELDING.4. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 Control unit (Welding interface) Process I/O CA Welder Connector pin number MS connector pin number Welding voltage command signal COMDA1 The input impedance shall be more than 3. Wire speed command signal COMDA2 Welding voltage detection signal COMAD1 Output signals without ripples. n +24V regulated power supply Receiver circuit WDI1 Arc detection signal Gas shortage detection signal Wire cut detection signal CRWI (5) c WDI2 WDI3 WDI4 Cooling water WDI5 shortage detection signal WDI6 Welding power supplu abnomality signal WDI7 WDI8 CRWI (11) CRWI (12) j k Common switching set pin CRWI (33. ARC WELDING.B--81465EN--1/02 CONNECTIONS 4. AND END EFFECTOR INTERFACES Control unit (Welding interface) Process I/O CA Welding start signal Welder WD01 Gas signal WD02 WD03 CRWI (25) T Wire inching (positive) signal Wire inching (negative) signal WD04 WD05 WD06 WD07 WD08 CRWI (28) CRWI (29) CRWI (30) W X Z a.34) FG (cabinet ground) Shield NOTE This is the connection for +24V. 249 . PERIPHERAL DEVICE. m b. COMAD5 COMAD6 250 . PERIPHERAL DEVICE.4. ARC WELDING. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 Control unit (Analog input interface) Process I/O CA Peripheral device COMAD3 COMAD4 Output signals without ripples. ARC WELDING. AND END EFFECTOR INTERFACES Control unit Welder interface CRW7 Welder NOTE Welder and peripheral device connection cable is option. Applicable process I/O board type HA 251 . PERIPHERAL DEVICE.B--81465EN--1/02 CONNECTIONS 4. 34) T S E Welding start signal DO common Wire inching (+) DO common Wire inching (--) DO common WDO (1) WCOM (1) WDO (4) WCOM (4) WDO (5) WCOM (5) CRW7 (23) CRW7 (24) CRW7 (29) CRW7 (30) CRW7 (13) CRW7 (14) L K F G H J M N WDI + Wire stick detection signal WDI -- CRW7 (31) CRW7 (32) + -- NOTE This is the connection for +24V.4. PERIPHERAL DEVICE. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 Control unit (welding interface) Process I/O HA Connector pin numbers Welding voltage command signal 0 V for analog output DACH (1) COMDA CRW7 (1) CRW7 (2) CRW7 (3) CRW7 (4) RV RV +24V B A CRW7 (6) CRW7 (10) Welding machine MS connector pin numbers A B C D P R Wire speed command DACH (2) signal 0 V for analog output Arc No arc (power supply error) COMDA WDI (2) WDI (6) No gas No wire WDI (3) WDI (4) +24V CRW7 (7) CRW7 (8) CRW7 (33. ARC WELDING. 252 . ARC WELDING. PERIPHERAL DEVICE.5 DIGITAL I/O SIGNAL SPECIFICATIONS 4. HELD. Applicable signals Output signals of process I/O board CRM2 and CRM4 CMDENBL.2 A or less 0V +24V Lamp 0. SYSRDY. (1) Output signals in peripheral device interface A Example of connection Spark killer diode +24V 0. solenoid. ATPERCH.2 A or less 0V Protective resistance Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at connection Spark killer diode Rated peak reverse voltage Rated effective forward current : : : : : 24 VDC 30 VDC 0. SNACK. If a load is connected causing a surge current when a lamp is turned on. PROGRUN. SNO1 to SNO8. AND END EFFECTOR INTERFACES 4. SDO1 to SDO76 253 . and arc welder. end effector. and so on directly. ACK1 to ACK8. connect them in parallel with diodes to prevent back electromotive force.5.1 Peripheral Device Interface This section describes the specifications of the digital I/O signals interfaced with the peripheral device.) : 100 V or more : 1 A or more NOTE Do not use the +24 V power supply of the robot.0 V (approx. BUSY. PAUSED. BATALM. FAULT.2 A Open collector NPN 1. use a protective resistance. When you load a relay.B--81465EN--1/02 CONNECTIONS 4. TPENBL. *HOLD. Chattering 5 ms or less 5 to 20 ms NOTE Apply the +24 V power at the robot to the receiver. PROD START. However. ENBL. TC . AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 (2) Input signals in peripheral device interface A Example of connection +24V RV 3. FAULT RESET. PERIPHERAL DEVICE. CSTOPI. the above signal specifications must be satisfied at the robot receiver.3 kΩ +24V B A ICOM Electrical specifications of the receiver Type : Grounded voltage receiver Rated input voltage : Contact close : +20 V to +28 V Contact open : 0 V to +4 V Maximum applied input voltage : +28 VDC Input impedance : 3.) Response time : 5 ms to 20 ms Specifications of the peripheral device contact Rated contact capacity : 30 VDC. SDI1 to SDI78 254 . Applicable signals Input signals of process I/O board CRM2 and CRM4 *IMSTP. PNSTROBE. *SFSD.3 kΩ (approx. 50 mA or more Input signal width : 200 ms or more (on/off) Chattering time : 5 ms or less Closed circuit resistance : 100 Ω or less Opened circuit resistance : 100 kΩ or more TB (Signal) TB (Signal) TB Peripheral device contact signal Robot receiver signal TC TC TB . ARC WELDING. START. HOME. PNS1 to PNS8.4. RSR1 to RSR8. solenoid.2 A or less 0V Protective resistance Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at connection Spark killer diode Rated peak reverse voltage Rated effective forward current : : : : : 24 VDC 30 VDC 0. connect them in parallel with diodes to prevent back electromotive force.0 V (approx. AND END EFFECTOR INTERFACES 4. and so on directly. use a protective resistance.2 A or less 0V +24V Lamp 0.B--81465EN--1/02 CONNECTIONS 4.2 A Open collector NPN 1. PERIPHERAL DEVICE. Applicable signals Output signals of the end effector control interface RDO1 to RDO8 255 . ARC WELDING. When you load a relay.7 A or less.) : 100 V or more : 1 A or more NOTE The +24 V power supply at the robot can be used when the total current of the welding interface and end effector interface is 0.2 End Effector Control Interface (1) Output signals Example of connection Spark killer diode +24V 0.5. If a load is connected causing a surge current when a lamp is turned on. *PPABN 256 . 50 mA or more Input signal width : 200 ms or more (on/off) Chattering time : 5 ms or less Closed circuit resistance : 100 Ω or less Opened circuit resistance : 100 kΩ or more TB (Signal) TB (Signal) TB Peripheral device contact signal Robot receiver signal TC TC TB . ARC WELDING. However.4.3 kΩ +24V B A COM1 Electrical specifications of the receiver Type : Rated input voltage : Contact close : Contact open : Maximum applied input voltage : Input impedance : Response time : Grounded voltage receiver +20 V to +28 V 0 V to +4 V +28 VDC 3. *HBK. Applicable signals Input signals of the end effector control interface RDI1 to RDI8. the above signal specifications must be satisfied at the robot receiver.3 kΩ (approx. TC .) 5 ms to 20 ms Specifications of peripheral device contact Rated contact capacity : 30 VDC. PERIPHERAL DEVICE. Chattering 5 ms or less 5 to 20 ms NOTE Apply the +24 V power at the robot to the receiver. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 (2) Input signal Example of connection +24V RV 3. 7 A. connect a protective resistor.WDO1 to WDO8 257 .5.Output signals on the arc--welding interface -.2 A or less Electrical characteristics Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at on : : : : : 24 VDC 30 VDC 0.2 A Open--collector NPN About 1. To drive a relay or solenoid directly. AND END EFFECTOR INTERFACES 4. To connect a load which generates an inrush current when you turn on the control unit. This limit applies to the sum of the currents flowing through the arc--welding and end--effector control interfaces.0 V Spark killer diode Rated peak reverse voltage : 100 V or more Rated effective forward current : 1 A or more NOTE A power voltage of +24 V.B--81465EN--1/02 CONNECTIONS 4. can be used for interface signals of up to 0. ARC WELDING. connect a diode preventing back electromotive force to the load in parallel. provided for the robot.3 I/O Signal Specifications for ARC--Welding Interface (1) Digital output signal specifications for an arc welding interface In case of process I/O CA Example connection Spark killer diode 0. Applicable signals -. PERIPHERAL DEVICE. When you load a relay. solenoid.3 A Relay connect output Spark killer diode Rated peak reverse voltage : 100 V or more Rated effective forward current : 1 A or more NOTE Do not use the +24 V power supply of the robot.WDO1 to WDO4 258 . Applicable signals -. PERIPHERAL DEVICE. If a load is connected causing a surge current when a lamp is turned on.4. use a protective resistance. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 In case of process I/O HA Example connection Spark killer diode 0.Output signals on the arc--welding interface -. connect them in parallel with diodes for preventing back electromotive force.3 A or less Electrical characteristics Rated voltage Maximum applied voltage Maximum load current Output type : : : : 24 VDC 30 VDC 0. ARC WELDING. and so on directly. 50 mA or more Input signal width : 200 ms or more for on and off states Chattering period : 5 ms or less Closed--circuit resistance : 100 or less Open--circuit resistance : 100 k or more (Signal) Contact signal for peripheral (Signal) Receiver signal for robot TB: Chattering of 5 ms or less TC: 5 to 20 ms NOTE Supply the +24 V power.WDI1 to WDI8 259 . AND END EFFECTOR INTERFACES (2) Digital input signal specifications for arc welding interface Example connection Electrical characteristics of receivers Type: Grounded voltage receiver Rated input voltage : +20 to +28 V with contacts closed 0 to +4 V when open Maximum input voltage : +28 VDC Input impedance : About 3. ARC WELDING.Input signals for arc welding interface -. Applicable signals -.3 k Response time : 5 to 20 ms Contact specifications for peripherals Rated contact capacity : 30 VDC. to the receivers. The receiver signal on the robot must satisfy the signal timing specified above. provided for the robot.B--81465EN--1/02 CONNECTIONS 4. PERIPHERAL DEVICE. Isolate the deposit detection signals for TIG welding from the welding circuit.3 kΩ or more Connect a high--pass filter. PERIPHERAL DEVICE. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 (3) Analog output signal specifications for arc welding interface (Welding voltage command. 260 . (Wire deposit detection: WDI+ and WDI--) Example connection Welder Welding electrode NOTE Connect a resistor of 100Ω or more between the positive and negative electrodes of the welder. ARC WELDING. which uses high--frequency components.4. The dielectric withstand voltage of this circuit is 80 V. EA : --10V to +10V Process I/O GA. HA : 0V to +15V 0V NOTE Input impedance: 3. wire--feed rate command) Example connection Welder Process I/O CA. (4) Analog input signal specifications for arc welding interface (Welding--voltage detection. welding--current detection) Example connection Welder --10V to +10V 0V NOTE The analog input signal should have no ripple for the circuit to operate properly. 2 Peripheral Device Interface B Cable (CRM4: Honda Tsushin. conform to the FANUC standard cables described in this section. (See the description in “Peripheral Device Interface” in this manual for the specifications of the FANUC standard cables. 50 pins) If the customer manufactures cables.) Honda Tsushin MR50LWF01 (MR50LF) Process I/O Honda Tsushin MR50LM01 (MR50LM) Peripheral device Honda Tsushin MR50RMA Honda Tsushin’s MR50RF Supplied with an ordered cable 4. PERIPHERAL DEVICE.6.B--81465EN--1/02 CONNECTIONS 4.6 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS 4. 20 pins) Honda Tsushin MR20LWF01 (MR20LF) Process I/O CRM4* Honda Tsushin MR20LM01 (MR20LM) Peripheral device Honda Tsushin MR20RMA Honda Tsushin’s MR20RF Supplied with an ordered cable 261 . ARC WELDING.1 Peripheral Device Interface A Cable (CRM2: Honda Tsushin.6. AND END EFFECTOR INTERFACES 4. 3 ARC Weld Connection Cable (CRW1: Honda Tsushin. PERIPHERAL DEVICE. 34 pins) Be sure to use our cable to connect the welder. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 4. MS3108B28--21P MS3057--16 Japan Aviation Electronics Industry Ltd.6. ARC WELDING. ARC welder Honda Tsushin Process I/O CRW1 or CRW7 Honda Tsushin MR34RFA Japan Aviation Electronics Industry Ltd. MS3102A28--21S Standard position of guide key 262 .4. 7. Metallic clamp External shield To peripheral device Process I/O CRW1 or CRW7 Shield plate Noise protection: Remove a part of the sheath of a peripheral cable to expose the outside shield.4. END EFFECTORS. AND ARC WELDERS 4.7 CABLE CONNECTION FOR THE PERIPHERAL DEVICES. 4. PERIPHERAL DEVICE. Secure the cable to the shield plate with the metallic clamp at the exposed position.7. AND END EFFECTOR INTERFACES 4.1 shows the connection of the peripheral device cable in the cabinet.1 Peripheral Device Cable Connection 263 . Fig. ARC WELDING.7.1 Peripheral Device Connection Cable B cabinet CRM2A CRM2B Fig.B--81465EN--1/02 CONNECTIONS 4. Connector specifications MR50LM MR20LM Applicable interface CRM2 CRM4 Dimensions A 67.2 shows the connector for peripheral device cables A and B.2 Peripheral Device Cable Connector (1) Fig.7.4. 50 pins Honda Tsushin Kogyo. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 4. PERIPHERAL DEVICE. 4.9 39.7.2 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo) 264 .8 (D) 18 17 Remark Honda Tsushin Kogyo.4.8 39.7.3 (B) 73. 20 pins Symbol ¡ © ¢ £ ¤ Connector cover Cable clamp screw Name Connector clamp spring Connector clamp screw Connector 50 pins (male) MR50M 20 pins (male) MR20M Fig.9 C 44. ARC WELDING.5 44. 4 39.B--81465EN--1/02 CONNECTIONS 4. ARC WELDING.6×8 Connector (MR50RF) (MR20RF) Fig.2 (b) Peripheral Device Connector (Honda Tsushin Kogyo) 265 .7. 50 pins Honda Tsushin Kogyo. AND END EFFECTOR INTERFACES (2) Peripheral device connector Connector specifications MR50RF MR20RF Applicable interface (CRM2) (CRM4) Dimensions A 61.4. PERIPHERAL DEVICE.4 44.9 Remark Honda Tsushin Kogyo. 20 pins Symbol ¡ © ¢ Name Connector clamp screw Screw M2.3 B 56. 7.1 F : 11.7 D : 9.4.2 C : 54.7.0 (Inside diameter) Manufactured by Daiichi Denshi Kogyo JMLP2524M Fig. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 4.0 (Inside diameter) Manufactured by Daiichi Denshi Kogyo JMLP2524M Fig.) A : M30¢1 E : ø33 B : 63.5 G : 24.6 to 15.7 D : 9.4.5 G : 24.2 C : 37.3 End Effector Cable Connector (1) Connector external view (For R--2000iA. ARC WELDING.4.3 (b) Connector (Straight Type) 266 .0 F : 11. Refer to the each maintenance manual for other robots.7.3 (a) Connector (Elbow Type) A : M30¢1 E : ø33 B : 54.6 to 15. PERIPHERAL DEVICE. 4 (a) Recommended Cable (for Peripheral Device Connection) Conductor Number of wires 50 20 Wire specifications (FANUC specifications) A66L-0001-0042 A66L-0001-0041 Diameter (mm) ø1.5 Effective outside diameter (mm) ø12.1 ø1.0 Effective outside diameter (mm) ø5.7 2.08 AWG24 Sheath thickness (mm) 1.7. Table 4.7.7.0 1.1 Configuration 40/0. Allow an extra 50 cm for routing the cable in the control unit.18 AWG24 Sheath thickness (mm) 1.05 ø1.3 ø8. 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. PERIPHERAL DEVICE.05 Configuration 7/0. heavily protected cable conforming to the specifications in Table 4.4 (b) Recommended Cable (for End Effector Connection) Conductor Number of wires 6 20 Wire specifications (FANUC specifications) A66L-0001-0143 A66L-0001-0144 Diameter (mm) ø1. Table 4.B--81465EN--1/02 CONNECTIONS 4.5 Electrical characteristics Conductor resistance (Ω/km) 106 106 Allowable current (A) 1. AND END EFFECTOR INTERFACES 4. ARC WELDING.08 AWG24 40/0.4 Recommended Cables (1) Peripheral device connection cable Connect a peripheral device using a completely shielded.6 (2) End effector connection cable Connect an end effector using a heavily protected cable with a movable wire conforming to the specifications in Table 4.5 1.7. The maximum cable length is 30 m.3 267 .4 (a).5 ø10.6 Electrical characteristics Conductor resistance (Ω/km) 91 91 Allowable current (A) 3.6 1.7.18 AWG24 7/0.4 (b). The HDI signals cannot be used as general--purpose DIs.8 CONNECTION OF HDI 4. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 4.1 Connecting HDI The HDI signals are used in combination with special application software. PERIPHERAL DEVICE. ARC WELDING.4.8. Main board JRL5 R--J3iB Main board JRL5 1 2 3 4 5 6 7 8 9 10 HDI0 0V HDI2 0V 0V HDI4 11 12 13 14 15 16 17 18 19 20 HDI1 0V HI3 0V HDI5 0V HDI6 0V HDI7 0V 268 . B--81465EN--1/02 CONNECTIONS 4. PERIPHERAL DEVICE. ARC WELDING. AND END EFFECTOR INTERFACES Cable connections JRL5 HDI0 0V HDI1 0V HDI2 0V HDI3 0V HDI4 0V HDI5 0V HDI6 0V HDI7 0V 1 2 11 12 3 4 13 14 6 5 or 10 15 16 17 18 19 20 7 8 9 10 Shield Ground plate Recommended cable connector: PCR--E20FA (Honda Tsushin Kogyo) FI30--20S (Hirose Electric) FCN--247J020--G/E (Fujitsu) 52622--2011 (Molex Japan) 269 . 270 .4. 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.0 max 20 min 0. PERIPHERAL DEVICE. The minus (--) sign of IiH/IiL represents the direction of flow out of the receiver. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 4. ARC WELDING.2 Input Signal Rules for the High--speed Skip (HDI) Circuit configuration R--J3iB DRIVER liL/liH FILTER VH/VL SHIELD RECEIVER Absolute maximum rating Input voltage range Vin: --3.6 to 7 0 to 1.6 to +10.02(max) Unit V V mA mA mA μs ms Vin=5 V Vin = 10 V Vin = 0 V Remark NOTE 1 The plus (+) sign of IiH/IiL represents the direction of flow into the receiver.8.0 V Input characteristics Unit High level input voltage Low level input voltage High level input current Symbol VH VL liH Specification 3.0 2 max 11 max Low level input current Input signal pulse duration Input signal delay or variations liL --8. AND END EFFECTOR INTERFACES 4. ARC WELDING. RS--232--C port 271 .1.9 CONNECTING THE COMMUNICATION UNIT 4.9. PERIPHERAL DEVICE.9.1 RS--232--C Interface 4.1 Interface This interface can be connected to a handy file or another communication unit from FANUC.B--81465EN--1/02 CONNECTIONS 4. R--J3iB Output Input RD (Recieve data) RS (Request to Send) CS (Enable to send) ER (Ready) DR (Data set ready) SG (Signal ground) FG (Frame ground) When DR is not used short DR and ER.1.9. SD (Send data) When CS is not used short CS and RS.2 RS--232--C interface 272 . 2 Do not connect anything to those pins for which signal names are not indicated. ARC WELDING.4. 4.2 RS--232--C Interface Signals Generally signals as follows are used in RS--232--C interface.4. Fig. PERIPHERAL DEVICE.1. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 R--J3iB Main board Operator’s panel connector (DBM--25S) 1 2 3 4 5 6 7 8 9 10 11 12 13 FG SD RD RS CS DR SG 14 15 16 17 18 19 20 ER 21 22 23 24 25 +24V i i h NOTE 1 +24 V can be used as the power supply for FANUC RS--232--C equipment.9. ARC WELDING. PERIPHERAL DEVICE.3 Connection between RS--232--C Interface and External Device The figure below shows a connection with the handshaking of the ER and DB signals.9. R--J3iB SD SD External device side RD RD RS RS CS CS ER ER DR DR CD CD SG SG FG FG 273 .1. AND END EFFECTOR INTERFACES 4.B--81465EN--1/02 CONNECTIONS 4. PERIPHERAL DEVICE.18mm2. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 D The figure below shows a connection without the handshaking of the ER and DB signals. ARC WELDING. R--J3iB SD SD External device side RD RD RS RS CS CS ER ER DR DR CD SG SG FG FG Prepare the cable as follows : R--J3iB SD RD RS CS SG ER DR Cable : twist 10 pairs × 0.4. with shield 274 . When configuring your network. 275 . PERIPHERAL DEVICE.9. and ground each of the devices as necessary. transceiver. you must take other sources of electrical noise into consideration to prevent your network from being influenced by electrical noise. cable etc. Also.B--81465EN--1/02 CONNECTIONS 4. Make sure that network wiring is sufficiently separated from power lines and other sources of electrical noise such as motors. and make sure that the power is off. NOTE Please inqure of each manufacturer about the network construction or the condition of using the equipment except the Ethernet board (hub. After installing the machine. AND END EFFECTOR INTERFACES 4. conduct a communications test before you actually start operating the machine. ARC WELDING. a high and insufficient ground impedance may cause interference during communications. cut the power supply of R--J3iB.).2 Ethernet Interface CAUTION Before connecting or disconnecting cables to and from the Ethernet board. We cannot ensure operation that is influenced by network trouble caused by a device other than the main board. Using such devices in an atmosphere where they are subjected to dust or oil mist will interfere with communications or damage the Ethernet board. PERIPHERAL DEVICE. Prepare a hub for connecting the Ethernet board to the Ethernet trunk.2. S S S R--J3iB Some devices (hub. transceiver.) that are needed for building a network do not come in a dust--proof construction. etc. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 4.4.9. The following shows an example of a general connection. Be sure to install such devices in a dust--proof cabinet.1 Connection to Ethernet The main board is provided with a 10/100 BASE--T interface. 276 . ARC WELDING. 1 2 3 4 5 6 7 8 RX-Signal Name TX+ TX-RX+ Send + Send -Receive + Not used Not used Receive -Not used Not used Description 4.9.9.9. see “4.2 10/100 BASE--T Connector (CD38) Pin Assignments CD38 Pin No. AND END EFFECTOR INTERFACES 4. PERIPHERAL DEVICE. Do not extend the cable longer than necessary.2.2.2.B--81465EN--1/02 CONNECTIONS 4. 277 .3 Cable Connection The figure below shows the cable connection between the 10/100 BASE--T connector (CD38) of the main board and hub. ARC WELDING. D Keep the total cable length to within 100 m. 10/100BASE--T connector D For details on shielding.6 Cable clamp and shielding”. . Ltd. Minami--narise 1--9--1.. Ltd... However. Tokyo 194--0045 TEL: 0427--29--2153 FAX: 0427--29--3375 Overseas Sales Office NISSEI ELECTRIC CO.9. NOTE The recommended cables cannot be connected to movable portions.2.. DTS5087 F--4PFWMF Specification Inquiries Manufacturer Furukawa Electric Co. Nissei Electric Co. Nagano Sales Office TEL: 0266--27--1597 278 . Ltd.6 Cable clamp and shielding. Tokyo 100--8322 TEL: 03--3286--3126 FAX: 03--3286--3979 Remarks Nissei Electric Co. be sure to use shielded Category 5 twisted--pair cable (STP) to improve the resistance to electrical noise in an FA environment. ARC WELDING. Recommended Cable (For movable parts) Manufacturer Oki Electric Cable Co. (For details on shielding. LTD 1509 Okubo--cho...jp Remarks Cables with connectors at both ends can be supplied. 432--8006 Japan TEL: 053--485--4114 FAX: 053--485--6908 E--mail: [email protected]. Machida Branch 3F MU Bldg. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 4. see “4..4 Lead Materials Unshielded cable (UTP cable) is commercially available as 10/100 BASE--T twisted--pair cable.. Ltd. Specification AWG26 4P TPMC--C5--F(SB) Remarks FANUC--specific cable Cable specifications (FANUC--specific cable No connector) Drawing number: A66L--0001--0453 Manufacturer: Oki Electric Cable Co. Machida City.or. Ltd. Hamamatsu--shi Shizuoka--ken.. Ltd.4. Sales Headquarters Contact Address Maru--no--uchi 2--6--1. Chiyoda--ku.” Recommended Cable Manufacturer Furukawa Electric Co. PERIPHERAL DEVICE. Remarks (Note) 279 . For reasons related to attenuation performance. The conductor is AWG26 annealed copper stranded wire. Cable assembly Oki Electric Cable Co. Ltd. PERIPHERAL DEVICE. Ltd. Ltd. an 8--bit modular connector called RJ--45 is used.9. Contact point: Oki Electric Cable Co. also supplies cable assemblies using connector TM21CP--88P(03) manufactured by Hirose Electric.B--81465EN--1/02 CONNECTIONS 4.8 mm. packing. The sheath thickness is 0.. the distance to the hub must be 50 m or shorter. (equivalent to the conventional oil--resistant electric cables) D Flexing resistance: 1 million times or more with 50 mm of a bend radius (U--shape flexing test) D UL style No. outgoing inspection.2. D Structure: Common shield cable (braided shield). AND END EFFECTOR INTERFACES Specifications D Electric characteristics: Conform to EIA/TIA 568A categories 3 and 5. AMP Japan. ARC WELDING. Ltd. Ltd.. The outside diameter is 6.. Use the following connector or equivalent: Specification For solid wire For solid wire For twisted wire For twisted wire 5--569530--3 MS8--RSZT--EMC 5--569552--3 TM11AP--88P Manufacturer AMP Japan. Remarks Special tool required Special tool required For movable parts For cable AWG26 4P TPMC--C5--F(SB) Specification TM21CP--88P(03) Manufacturer Hirose Electric Co..70.: AWM 20276 (80°C/30 V/VW--1) NOTE Always use connector TM21CP--88P(03) manufactured by Hirose Electric for this cable. Make arrangements directly with the manufacturer for the specifications (length. D Flame resistance: UL1581 VW--1 D Oil resistance: Based on the FANUC standard. Sales contact point) Nagano Sales Office TEL: 0266--27--1597 4. SK KOHKI Co. Ltd.. Drain wire provided. Hirose Electric Co. and others) and purchase cable assemblies. Ltd.5 Connector Specification As a connector used with a twisted pair cable for Ethernet.3 mm. 9.4. ARC WELDING. (See 4. (Hirose Electric technical document “TM21CP--88P(03) Connection Procedure Specifications” (technical specification No.2..6 Cable Clamp and Shielding Shield the cables as like as other cables are shielded. Manufacturer catalog number: TM21CP--88P(03) Conforms to EIA/TIA 568A categories 3 and 5. Ltd. For how to assemble the connector and cable.1) 280 . PERIPHERAL DEVICE. ATAD--E2367) is available.7. AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 NOTE TM21CP--88P(03) Connector (manufacturer standard part) Drawing number: A63L--0001--0823#P Manufacturer: Hirose Electric Co. contact Hirose Electric.) 4. 2. ARC WELDING. Electrically separated by 10/100 BASE--T cable connection Large--scale Network Electrically separated by 10/100 BASE--T cable connection Small--scale Network 281 .B--81465EN--1/02 CONNECTIONS 4. AND END EFFECTOR INTERFACES 4. electrical noise from the machine sometimes enters the communications line and causes communications interference depending on the installation conditions and the peripheral environment of the machine. The following figure shows an example of such a connection. To prevent the entry of such electrical noise.7 Grounding the Network Even if the grounding conditions on the machine are satisfied. PERIPHERAL DEVICE.9. separating and insulating the machine from the Ethernet trunk cable and the personal computer effectively reduces the influence of electrical noise. 4. (Refer Fig. Fig. connect the ground cable for each system to the grounding point independently.9.7 Wiring on a Single Ground Point 282 .5mm2 is necessary. PERIPHERAL DEVICE. please separate between the PC/Trunk line side and machine system side completely using the 10/100 BASE--FL (Optical fiber media).2. In the case of using the Ethernet board under the worst environment. At least thickness of 5. FANUC recommends the HCN--7500 (Hitachi--Densen LTD) or equivalent. 3 There is the possibility that noise makes the obstacle of communication even if the ground is separated using the 10/100 BASE--T. ARC WELDING. The thickness of the ground cable is the same as the thickness of AC power cable or more.1) The resistance for grounding must be less than 100--ohm (Class 3). AND END EFFECTOR INTERFACES CONNECTIONS B--81465EN--1/02 NOTE 1 The ground between the PC/Trunk line side and machine system side must be separated.4. 2 Please use the HUB that has unshielded interface connector. If it is impossible to separate the ground because there is only one grounding point. B--81465EN--1/02 CONNECTIONS 5. TRANSPORTATION AND INSTALLATION 5 TRANSPORTATION AND INSTALLATION 283 . The control unit is transported by a crane. Attach a strap to eye bolts at the top of the control unit.5.1 Transportation 284 .1 TRANSPORTATION This section describes the transportation and installation for the control unit. B--cabinet Fig.5. TRANSPORTATION AND INSTALLATION CONNECTIONS B--81465EN--1/02 5. 1 (a) External dimension 285 .5. Fig.2 INSTALLATION 5.2. When installing the control unit.B--81465EN--1/02 CONNECTIONS 5.1 Installation Method Following is the installation method for B--cabinet. allow the space for maintenance shown in the following figure. TRANSPORTATION AND INSTALLATION 5.2. 1 (b) Installation Method (B--cabinet) 286 .5. TRANSPORTATION AND INSTALLATION CONNECTIONS B--81465EN--1/02 300 100 Controller 740 Controller 550 100 Controller 100 1000 Fig.5.2. B--81465EN--1/02 CONNECTIONS 5.5.2.2 Assemble at installation Teach pendant R--3iB controller Input power connection cable Peripheral device connection cable Robot connection cable Fig.2 (a) Assemble at Installation (B--cabinet) 287 . TRANSPORTATION AND INSTALLATION 5.2. 0. Not higher than 1. and --20 to 60ºC during shipment and storage with a temperature coefficient of 1. organic solvent.0KW 0 to 45 ºC during operation. robot power draw can be several times the continuous rating value. 180kg Input p p power source capacity p y R--2000iA M--6iB ARC Mate100iB Average power consumption g p p R--2000iA M--6iB ARC Mate100iB Permissible ambient temperature Permissible ambient humidity Surrounding gas All models All models All models Vibration All models Altitude Ionized and nonionized radiation Common to all models Common to all models Mass of control unit A--cabinet B--cabinet NOTE During rapid acceleration.5KVA 2.5. non--condensing An additional protective provision is necessary if the machine is installed in an environment in which there are relatively large amounts of contaminants (dust. consult with your FANUC sales representative.3 INSTALLATION CONDITION Item Transformer Model All models Specifications/condition I 440--480. ultraviolet rays. acid. TRANSPORTATION AND INSTALLATION CONNECTIONS B--81465EN--1/02 5.1ºC/min Relative humidity: 30% to 95%. 440--500 VAC (+10%--15%) III 200--230. 288 . 380--400 VAC (+10%--15%) 50/60Hz1Hz 3phases 12KVA 2.5KW 1. Approx. and/or X-rays). 120kg Approx. When using the robot in a location subject to serious vibration.5G or less. laser beams.000m above sea level A shielding provision is necessary if the machine is installed in an environment in which it is exposed to radiation (microwave. 500--575 VAC (+10%--15%) II 380--415. corrosive gas. dielectric fluid. and/of salt). Release the EMERGENCY STOP button on the operator panel. (See II MAINTENANCE section 6. TRANSPORTATION AND INSTALLATION 5. Check the screw terminals for proper connection. Check the movement along each axis in manual jog mode. Turn on the controller. Check the peripheral device control interface signals. set them. Check transformer tap setting. Check the end effector interface signals. If necessary. Check that the connectors and printed circuit boards are firmly connected. Check the parameters. 1 2 3 4 5 6 7 8 9 10 11 12 13 Description Visually check the inside and outside of the control unit. Check the interface signals between control unit and robot mechanical unit.B--81465EN--1/02 CONNECTIONS 5.2) The breaker off and connect the input power cable. 289 . Press the EMERGENCY STOP button on the operator panel and turn on the control unit.4 ADJUSTMENT AND CHECKS AT INSTALLATION Adjust the robot according to the following procedure at installation. Check the input power voltage and transformer outputs. No. 290 . and press the alarm release button to reset the alarm condition. Therefore.1 Peripheral Device Interface Processing Take the following actions if signals *IMSTP.5. *SFSD. and jog to bring all axes into the movable range. The robot can also be in an emergency stop state if the peripheral device control interface is not connected. CRM2A +24F 49. The J2 and J3 axes are pressed against the hard stops at shipment. an overtravel alarm occurs when the power is turned on after installation.5. *HOLD. 5.5. 2) Hold down the shift key. 50 *IMSTP 1 RV *HOLD 2 RV *SFSD 3 RV ENBL RV 4 5. and ENBL are not used.2 Resetting Overtravel 1) Select [OT release] on the overtravel release screen to release each robot axis from the overtravel state. This section describes how to reset the overtravel and emergency stop. TRANSPORTATION AND INSTALLATION CONNECTIONS B--81465EN--1/02 5. Remove the red plate fastening the swiveling axis beforehand.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION An overtravel and emergency stop occur when the robot is operated for the first time after it is installed and the mechanical and control units are wired. 3) Still hold down the shift key. Select “Config” to disable/enable HBK. 3 If the power is turned off and on again under the condition stated in *2. HBK detection Yes Yes Yes(*2) No Robot operation Possible Impossible Possible Possible Message None SRVO--006 None At cold start. so the alarm condition is removed. causing the robot to stop. alarm “Servo 300” or “Servo 302” occurs. Select [SYSTEM]. status 4 is entered. HBK detection becomes enabled.3 How to Disable/Enable HBK Hand Broken enable/ disable setting Enable Enable Disable Disable 1) 2) 3) 4) 5) Press [MENUS] on the teach pendant.B--81465EN--1/02 CONNECTIONS 5.5. SRVO--300 Status 1 2 3 4 HBK (*1) CLOSE OPEN CLOSE OPEN Notes 1 Robot end effector connector CLOSE 24V 24V OPEN *HBK *HBK 2 The moment the HBK circuit is closed. Press “F1” (TYPE) on the teach pendant. 291 . Select [NEXT]. TRANSPORTATION AND INSTALLATION 5. When the HBK circuit is opened again. Press “F1” (TYPE) on the teach pendant.5. TRANSPORTATION AND INSTALLATION CONNECTIONS B--81465EN--1/02 5. Select [NEXT]. Select [SYSTEM]. Select “Config” to disable/enable PPABN.5. 292 .4 How to Disable/Enable Pneumatic Pressure Alarm (PPABN) 1) 2) 3) 4) 5) Press [MENU] on the teach pendant. APPENDIX . B--81465EN--1/02 APPENDIX A. TOTAL CONNECTION DIAGRAM A TOTAL CONNECTION DIAGRAM 295 . A.A (a) Total connection diagram (B--cabinet) 296 . TOTAL CONNECTION DIAGRAM APPENDIX B--81465EN--1/02 Fig. TOTAL CONNECTION DIAGRAM 297 .B--81465EN--1/02 APPENDIX A. A. TOTAL CONNECTION DIAGRAM APPENDIX B--81465EN--1/02 Fig.A (b) Transformer type I (B--cabinet) (1/3) 298 . A (b) Transformer type II (B--cabinet) (2/3) 299 . TOTAL CONNECTION DIAGRAM Fig.B--81465EN--1/02 APPENDIX A. A (b) Transformer type III (B--cabinet) (3/3) 300 . TOTAL CONNECTION DIAGRAM APPENDIX B--81465EN--1/02 Fig.A. B--81465EN--1/02 APPENDIX A. TOTAL CONNECTION DIAGRAM Fig.A (c) Power supply unit 301 . A.A (d) Main CPU 302 . TOTAL CONNECTION DIAGRAM APPENDIX B--81465EN--1/02 Fig. B--81465EN--1/02 APPENDIX A. 1/2) 303 .A (e) E--stop unit (B--cabinet. TOTAL CONNECTION DIAGRAM Fig. A (e) E--stop unit (B--cabinet.A. TOTAL CONNECTION DIAGRAM APPENDIX B--81465EN--1/02 Fig. 2/2) 304 . A (f) 6--axis servo amplifier (1/2) 305 . TOTAL CONNECTION DIAGRAM Fig.B--81465EN--1/02 APPENDIX A. TOTAL CONNECTION DIAGRAM APPENDIX B--81465EN--1/02 Fig.A.A (f) 6--axis servo amplifier (2/2) 306 . A (g) Motor power connection (R--2000iA) 307 . TOTAL CONNECTION DIAGRAM Fig.B--81465EN--1/02 APPENDIX A. A.A (h) Motor power connection (M-6iB. TOTAL CONNECTION DIAGRAM APPENDIX B--81465EN--1/02 Fig. ARC Mate 100iB) 308 . B--81465EN--1/02 APPENDIX A. TOTAL CONNECTION DIAGRAM Fig.A (i) Operator panel (without E--stop) 309 . TOTAL CONNECTION DIAGRAM APPENDIX B--81465EN--1/02 Fig.A (j) Operator panel (B--cabinet) 310 .A. TOTAL CONNECTION DIAGRAM Fig.A (k) Mechanical interface 311 .B--81465EN--1/02 APPENDIX A. TOTAL CONNECTION DIAGRAM APPENDIX B--81465EN--1/02 Fig.A (l) I/O device (B--cabinet) (1/2) 312 .A. A (l) I/O device (interface) (2/2) 313 . TOTAL CONNECTION DIAGRAM Fig.B--81465EN--1/02 APPENDIX A. A (m) Emergency stop circuit of B--cabinet 314 .A. TOTAL CONNECTION DIAGRAM APPENDIX B--81465EN--1/02 Fig. B--81465EN--1/02 APPENDIX A. TOTAL CONNECTION DIAGRAM 315 . SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE APPENDIX B--81465EN--1/02 B SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE 316 .B. 317 . Input signals (Refer to B.1 SIGNALS The following table lists the I/O signals used for the peripheral device interface in the R-J3iB controller.B--81465EN--1/02 APPENDIX B.3. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE B.1) Signal *IMSTP *HOLD *SFSPD CSTOPI FAULT_RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSTROBE PROD_START SDI01 SDI02 SDI03 SDI04 SDI05 SDI06 SDI07 SDI08 SDI09 SDI10 SDI11 SDI12 SDI13 SDI14 SDI15 SDI16 SDI17 SDI18 SDI19 SDI20 SDI21 SDI22 Description Instantaneous stop signal Hold signal Safety speed signal Cycle stop signal Alarm release signal Cycle start signal Robot service request/program number select signal (*1) Enabling signal Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) PNS strobe signal Automatic operation start signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal *1: RSR : Robot Service Request (RSR5 to RSR8 are optional) PNS : Program Number Select Input (optional) Whether RSR is used or PNS is used can be preset. B.3.2) Signal CMDENBL SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK ______ SDO01 SDO02 SDO03 SDO04 SDO05 SDO06 SDO07 SDO08 SDO09 SDO10 SDO11 SDO12 SDO13 SDO14 SDO15 SDO16 SDO17 SDO18 SDO19 SDO20 Description Command acceptance enabled signal System ready signal Program run signal Program paused signal Held signal Alarm signal Reference point signal Teach pendant enabled signal Battery alarm signal Operating signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal PNS acknowledge signal Not used (for future expansion) General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal 318 . SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE APPENDIX B--81465EN--1/02 Output signals (Refer to B. Therefore.2 SETTING COMMON VOLTAGE All process I/O printed boards have a jumper to set the common voltage of input signals to 0 V or 24 V. you can operate the system without being concerned about the setting of the common voltage.B--81465EN--1/02 APPENDIX B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE B. To ensure safety. The system automatically adjusts the polarity by software according to the status of this pin. the common reference voltage of the following four signals. *IMSTP *HOLD *SFSPD CSTOPI 319 . is remains at +24V. 1 Input Signals This section describes the specifications of each input signal. : At any time : Use the normally-closed switch because it is a reverse signal. Do not use *IMSTP. the alarm display on the teach pendant (the top line) is cleared. use the emergency stop external interface on the emergency stop control board for wiring of the emergency stop signal. The *HOLD signal has the same function as the hold button on the operator panel. (2) Alarm release signal (input) FAULT RESET Effective Function : In the alarm status : The FAULT RESET signal releases the alarm status. It does not re-start execution of the program. This signal has the same effect as that of the emergency stop signal. it also turns on the unit. Description : This signal releases only the alarm status. It halts the current program and stops the operation of the robot. While this signal is being input.3 I/O SIGNALS B.3. The system turns off power to the servo unit when the *IMSTP is open (turned off).B. At the same time. (1) Instantaneous stop signal (input) *IMSTP Effective Function : At any time : Use the normally-closed switch because it is a reverse signal. For this reason. but it is controlled by software. The robot will keep running if the signal is triggered “ON” during operation. If the servo unit has been turned off. the held signal (output) HELD is turned on and the robot cannot be operated. (3) Hold signal (input) *HOLD Effective Function 320 . SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE APPENDIX B--81465EN--1/02 B. $CONT_ONLY is set to DISABLED.If parameter $SHELL_CFG. and the execution of the current program is suspended. the START signal only resumes the execution of the temporarily held program. To execute an inactivated program from the start. and the information for the subprogram to return to the main program is lost. . the operation of the robot or the activation of a program is inhibited. : This input signal starts the selected program at the falling edge when the signal is turned off after being turned on. Its function differs according to the setting of parameter $SHELL_CFG. .If parameter $SHELL_CFG. : At any time : .$CONT_ONLY.$USE_ABORT is set to DISABLED. See the description of CMDENBL in Section B. At the same time.3. the CSTOPI signal releases the program from the wait status caused by an RSR. this signal also releases the program from the wait status caused by RSR. . By default. input the PROD_START signal.$USE_ABORT is set to ENABLED. It does not stop the execution of the current program and allows it to continue processing (by default).$CONT_ONLY is set to ENABLED. : At any time : If the ENBL signal is turned off. Function (5) Cycle stop signal (input) CSTOPI Effective Function (6) Enabling signal (input) ENBL Effective Function 321 .If parameter $SHELL_CFG. the START signal starts the program which has been selected from the teach pendant. The program returns to the status in which it was before execution. the CSTOPI signal immediately cancels the execution of the current program. the program starts from the current cursor position. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE (4) Start signal (input) START Effective : When the command acceptance enabled signal (output) CMDENBL is turned on.2 (1) for details.B--81465EN--1/02 APPENDIX B.If parameter $SHELL_CFG. although they cannot be used simultaneously.As long as this signal is off. . the newly activated program enters the wait status. . .$SFJOGOVLIM: For jog.If a signal is input to an RSR input.3. program is started. .Since the *SFSPD signal is counted as a remote condition.) .B. . The program number can be set by a menu. the waiting program starts processing. See the description of CMDENBL in Section B. the overriding value is switched to a preset value (parameter $SCR.Use the normally-closed switch because it is a reverse signal.A menu is provided to register the program number of a specified program when each RSR is input. $SCR. each RSR in a program can be enabled or disabled. Usually this switch should be connected to safety fence. (Refer to the application manual for details of the menu).If another program has already started processing. It must be set normally on. Function 322 . are used. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE APPENDIX B--81465EN--1/02 (7) Safety speed signal (input) *SFSPD Effective Function : At any time : .Four input signals. .The user can choose between RSR and PNS (optional). a specified. such input signals as RSR and START to the peripheral device interface cannot take effect unless this signal is turned on. As soon as the current program terminates. $FENCEOVER.If this signal is turned from on to off during robot operation. At the same time.2 (1) for details. the overriding value cannot be increased beyond the preset value ($SCR. the execution of the current program is suspended.) (8) Robot service request signal (input) RSR1/RSR2/RSR3/RSR4 Effective : When the command acceptance enabled signal (output) CMDENBL is turned on. : .By using an RSR instruction. RSR1 to RSR4. $SFRUNOVLIM : For test execution. . i. a pulse is output from the signal corresponding to the RSR. If the PNS function is enabled. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE .The eight signals PNS1 to PNS8 are used to specify a program at the instant the strobe signal PNSTROBE rises. the RSR function cannot be used. the program to be started is the one with the program name calculated from the expression RSR + (RSR2 program number + base number).When an RSR is input.A menu is provided to specify the information about PNS. . The base number is stored in parameter $SHELL_CFG. the combination of programs which can be started by RSRs can be changed. one of signals ACK1 to ACK4. If so specified.$JOB_BASE. 323 . For exam ple.Whether the system should output an acknowledge signal to an RSR can be selected from the menu.3. It is possible to accept other RSRs while outputting an acknowledge signal. . the program whose program name consists of the specified program number plus a base value is started.The PNS/PNSTROBE signal selects whether the RSR function is used or the PNS function (optional) is used. when the input of the RSR is accepted. if a signal is input to RSR2 when program number 23 is registered in RSR2. (For example. $SHELL_ CFG. Function : .2 (1) for details. In this way. . . From the same menu. the width of the pulse can also be specified.. See the description of CMDENBL in Section B. (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.e.B--81465EN--1/02 APPENDIX B. $JOB_BASE =100).Input of a CSTOPIT signal can clear the program queue waiting for execution after acceptance of RSRs. and can be changed in a program with a parameter instruction. RSR0123. Using these signals. it is cleared as if no selection has been made.. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE APPENDIX B--81465EN--1/02 If a number other than zero is entered to PNS input. See the description of CMDENBL in Section B. The execution of the selected program can only be started after input of automatic operation start signal PROD_START. . . peripheral devices can confirm the correct program has been selected.3.$USE_ ABORT is set to ENABLED.A PNS signal.e. if the PNS value is 23. For example. .2 (1) for details. Inputting the START signal restarts the program selected by PNS when $SHELL_CFG.B.$CONT_ ONLY is set to ENABLED. · Input of CSTOPI cancels execution of the pro-grams selected by PNS when $SHELL_CFG. If zero is entered to PNS input. Function 324 . which can only select a program. You can: · Start up a program by input of automatic operation start signal PROD_START · Restart the program that has been suspended. : This input signal executes the selected program at the falling edge when the signal is turned off after being turned on. the selected program cannot be changed from the teach pendant unless PNSTROBE is turned off. i. (10) Automatic operation start signal (input) PROD_START Effective : When the command acceptance enabled signal (output) CMDENBL is turned on. PNS0123. the program number is output to selected program number signal (output) SNO. cannot execute the selected program.If a program is selected by PNS. and a pulse is output to program selection acknowledge signal SNACK. a program is selected whose program number is the entered value plus the base number. see the sections describing SNO and SNACK. the program to be started has the program name calculated from the expression PNS + (entered PNS value + base number).The following operations are effective for the program selected by PNS. For the timing of these signals.For safety. . If signal PROGRUN is off. (4) Held signal (output) HELD This signal is used to check the status of the hold input. Turned off : When the program is not being executed. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE B. .B--81465EN--1/02 APPENDIX B. Turned off : When the hold button (or input) is not being pressed down (or is turned off).2 Output Signals This section describes the specifications of output signals for the peripheral device interface. 325 . the program is being executed.Parameter $RMT_MASTER is set to 0 (external interface). or in the normal status. (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. (1) Command acceptance enabled signal (output) CMDENBL Turned on : When the remote conditions are satisfied and the system is not in the alarm status Turned off : When the remote conditions are not satisfied or the system is in the alarm status The remote conditions are satisfied when all of the following are satisfied.The teach pendant is in the DISABLED status. Turned on : When the hold button (or input) is being pressed down (or turned on). . Turned on : When a program is held and has not been restarted yet. Turned off : When the alarm status is released by an alarm release operation. While this signal is on.) The indicator lamp does not go on in warning. If signal PROGRUN is on. the program has not been executed and can be started from this status. Turned off : When power is not applied to the motor of the robot. Turned off : When a program is being executed or is ready to start. . (3) Program run signal (output) PROGRUN Turned on : When the program is being executed. . (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.Signal *SFSPD is set to on.The remote switch on the operator’s panel is set to REMOTE side. the program can be restarted and retains information such as that to return from a subprogram to the main program.3. (2) System ready signal (output) SYSRDY Turned on : When power is applied to the motor of the robot. B. (the reference point No. For the other two reference positions. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE APPENDIX B--81465EN--1/02 (7) Reference point signal (output) ATPERCH Turned on : When the robot is in the reference position specified in the parameter. Turned off : When the teach pendant is disabled. general-purpose signals can be assigned to output as such. (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. Turned off : When the voltage of the battery for the CMOS memory backup is at the normal level.) Turned off : When a program is not being executed nor is being processed from operation panels such as the teach pendant. (They can be set from the setup screen. (This has the same function as that of the BUSY lamp on the teach pendant.) Turned off : When the robot is not in the reference position specified in the parameter.1 in reference point setup screen.) Up to three reference positions can be specified. but this signal is output when the robot is in the first reference position. (9) Battery alarm signal (output) BATALM Turned on : When the voltage of the battery for the CMOS memory backup drops below the reference.) (8) Teach pendant enabled signal (output) TPENBL Turned on : When the teach pendant is enabled. 326 .1 in reference point setup screen. (the reference point No. Turned on : When one of the signals from RSR1 to RSR4 is input and accepted. They can be specified to be enabled or disabled from the RSR setup menu.) RSR2 (I) ACK2 (O) RSR3 (I) ACK3 (O) RSR4 (I) ACK4 (O) * Other RSR signals can be accepted even when the ACK signal is being output. CMDENBL (O) (The remote conditions need to be satisfied. Turned off : Normally. 327 . ACK1 (O) (The width of the pulse is set in the parameter. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE (11) RSR acknowledge signals (output) ACK1/ACK2/ACK3/ACK4 These signals are used together with the RSR function. Since these signals are always output as pulses. they are normally in the off status. The following chart shows the timing of the RSR input and ACK output.B--81465EN--1/02 APPENDIX B.) RSR1 (I) The maximum delay is 32 msec. A pulse whose width is specified from the menu is output to acknowledge the signal. The selected program number is displayed in binary code (SN01 to SN08) on the teach pendant. CMDENBL (O) (The remote conditions need to be satisfied.) PNSTROBE (I) Detection and processing of PNSTROBE by software. (A strobe is input for PNS. If the number cannot be represented as an eight-bit number.) SNO1-8 (O) SNACK (O) PROD_START (I) (Program execution starts within 32 msec. it becomes zero. a pulse is output from signal SNACK as a part of the PNS operation.) PROGRUN (O) 328 . Turned on : Whenever the PNS function is enabled. The width of the pulse can be specified from the menu. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE APPENDIX B--81465EN--1/02 (12) PNS acknowledge signal (output) SNO/SNACK These signals are used together with the PNS function. After selecting a program by PNS.B.) (PNS is read within a maximum of 32 msec after PNSTROBE is turned on.) PNS1-8 (I) (A value is input. See the timing chart below. B--81465EN--1/02 APPENDIX B.Process I/O printed circuit board . SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE B. 329 . B.2 Input/Output Hardware Usable in the R-J3iB Controller The R--J3iB controller can use up to 512 digital input and output points or an equivalent number of analog input and output points. One analog input/output point uses the resources equivalent to those used by 16 digital I/O points. The R--J3iB controller can use the following I/O hardware. The R--J3iB can use a total of up to 512 I/O points.4.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT B.4. .1 Overview This section describes the external specifications of digital and analog input/output in the R--J3iB controller.I/O unit model A The process I/O printed circuit board and the I/O unit model A can be used together. The number of points that can be used for the connector at the wrist depends on the individual robot. (2) SDI/SDO The signal No. (3) Analog I/O An analog I/O signal can access the analog I/O port (optional) on the process I/O printed circuit board or the I/O port on the analog I/O module (used together with the I/O unit model A). Any number of continuous signals of up to 16 bits can be set for its use. that is determined at hardware can be changed by software operation.4. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE APPENDIX B--81465EN--1/02 B. They cannot be assigned (redefined) and are fixed. 330 .3 Software Specifications (1) RDI/RDO These are signals sent to the connector at the wrist of the robot. It means that the value does not always represent the real I/O voltage. It can be set in the menu DETAILS on the group I/O screen. (4) Group I/O Group I/O is a function which can input or output multiple DI/DO signals as binary codes. It reads and writes the digital value converted from the analog value of the I/O voltage. The standard format is eight inputs and eight outputs.B. B--81465EN--1/02 APPENDIX C. POWER DISTRIBUTION CIRCUIT DIAGRAM C POWER DISTRIBUTION CIRCUIT DIAGRAM 331 . C. POWER DISTRIBUTION CIRCUIT DIAGRAM APPENDIX B--81465EN--1/02 Fig.C (a) 200VAC Power supply Circuit Diagram (B--cabinet) 332 . POWER DISTRIBUTION CIRCUIT DIAGRAM 333 .B--81465EN--1/02 APPENDIX C. 3V. --15V Power Supply Circuit Diagram (B--cabinet) 334 . +15V. +3.C (b) +5V.C. POWER DISTRIBUTION CIRCUIT DIAGRAM APPENDIX B--81465EN--1/02 Fig. B--81465EN--1/02 APPENDIX C.C (c) Robot Mechanical Unit +5V Power Supply Circuit Diagram 335 . POWER DISTRIBUTION CIRCUIT DIAGRAM Fig. C (d) +24V Power Supply Circuit Diagram (B--cabinet) 336 . POWER DISTRIBUTION CIRCUIT DIAGRAM APPENDIX B--81465EN--1/02 Fig.C. POWER DISTRIBUTION CIRCUIT DIAGRAM Fig.B--81465EN--1/02 APPENDIX C.C (e) Robot Mechanical Unit +24V Power Supply Circuit Diagram 337 . D. Electrical/optical conversion module Lid Fiber optic cable Fiber optic cable caps Fig. their mating surfaces must be protected with the lid and caps with which they are supplied. If left uncovered. the mating surfaces are likely to become dirty. Handle fiber optic cables with utmost care. especially when installing the unit.D(a) Protection of electrical/optical conversion module and fiber optic cable (when not in use) 338 . possibly resulting in a poor cable connection. Observe the following cautions when handling these fiber optic cables. OPTICAL FIBER CABLE APPENDIX B--81465EN--1/02 D OPTICAL FIBER CABLE The R--J3iB uses fiber optic cables for communication between the main board and servo amplifiers. (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. D Grasp the optical connector firmly when connecting or disconnecting the cable. The tissue paper or absorbent cotton may be moistened with ethyl alcohol. Applying greater force to the cord is likely to cause the connector to come off. D Although optical connectors cannot be connected in other than the correct orientation.D(b) External dimensions of external optical cable Unit : mm D Afler it is connected.B--81465EN--1/02 APPENDIX D. 21 Code Bush Reinforced cover Fig.7 19 max. always take note of the connector’s orientation before making the connection. as shown in Fig. Do not use any organic solvent other than ethyl alcohol. (The maximum tensile strength between the fiber cord and connector is 2 kg. release the lock levers and pull the connector. D Fix the reinforcing cover by using a cable clamp.2 mm × 2 cords Diameter of cable with reinforced cover : 7. To remove the connector.2 6. OPTICAL FIBER CABLE (2) Fiber optic cable D Although the reinforcing cover of the external optical cable has sufficient mechanical strength. D Take care to keep both parts of the optical connector (cable side and PCB side) clean. D(c). Do not pull on the fiber optic cord itself. 60 max. 35typ. the optical connector is automatically locked by the lock levers on its top. wipe them with tissue paper or absorbent cotton to remove dirt.) Fiber optic cord diameter : 2.6 mm Tensile strength : Cable with reinforced cover :75 kg Fiber optic cord :7 kg per cord Between fiber optic cord and connector : 2 kg Minimum bending radius of fiber optic cord :25 mm Minimum bending radius of cable with reinforced cover : 50 mm Bending resistance (cable with reinforced cover) : 10 million bending cycles at room temperature (when the bending radius is 100 mm) Flame resistance : Equivalent to UL VW--1 Operating temperature : --20 to 70°C 8. to prevent the weight of the fiber optic cable from being applied directly to the connecting part of the optical connector. be careful not to drop heavy objects on the cable. making the cable unusable. If they become dirty. 339 . Failing to clamp the cable correctly might cut or damage it. 340 . When clamping the cable by the reinforcing cover. ensure that the clamping force is as small as possible to ensure that the reinforcing cover is not deformed by the clamping. OPTICAL FIBER CABLE APPENDIX B--81465EN--1/02 Optical connector Part of optical fiber cord Part of reinforcing cover Bending radius of 25 mm or more (Make the bending radius as large as possible. If possible. Winding the cable into smaller loops can produce sharp curves that exceed the specified bend radius limit.) Fig. External cable : Do not clamp the uncovered portion of the cable with a nylon band.D(c) Fixing the cable with a clamp D Any superfluous portion of the cable might be wound into a loops. make sure the diameter of each loop is at least 150 mm (for an external cable). Should this prove necessary.D. take care not to apply a bending force to one particular part of the cable when fixing it with a clamp. the clamping force is not an important factor to consider. However.) Cable clamp (Don’t clamp tight) Bending radius of 50 mm or more (Make the bending radius as large as possible. the clamping force should be 5kg (111bs) or less. Such bending can result in transmission loss. D When using a nylon band (cable tie) as a cable clamp. follow the instructions given below. ultimately leading to a communication failure. Also. B--81465EN--1/02 APPENDIX E.E Precautions for card interface 341 . CARD INTERFACE E CARD INTERFACE Connector for card Card Card Fig. 224 In Case of B--cabinet. 245 Connection Diagram Between Mechanical Units. 285 Interface. 255 Ethernet Interface. 206 External View of the Controller. 226 Input Signals. end Effectors. 156 10/100 BASE--T Connector (CD38) Pin Assignments. 285 Installation Condition. 276 Connector Specification. 341 Checking the Power Supply Unit. 263 Card Interface. 139 End Effector Cable Connector. 208 Connection between RS--232--C Interface and External Device. 202 Block Diagram of the Main Power Including Power Supply.B--81465EN--1/02 Index [Numbers] [D] Digital I/O Signal Specifications. 320 Input/Output Hardware Usable in the R--J3iB Controller. and Welders. 280 Cable Connection. 196 Block Diagram. 273 Connection Between the Control Unit and Welder. 21 [B] Backplane PC Board. 278 i--1 [H] How to Disable/Enable Pneumatic Pressure Alarm (PPABN). 117 [G] Grounding the Network. 25 Configuration. 210 Connecting the Input Power . 212 Connecting the External Power Supply ON/OFF Switch. 262 Assemble at installation. 281 [C] Cable Clamp and Shielding. 257 I/O Signals. 253 Driver Chip for Robot DI/DO. 34 pins). End Effectors. 203 Emergency Stop Control PC Board (A20B--1007--0800). 20 Connecting the Communication Unit. 292 [I] I/O Signal Specifications for Arc--Welding Interface. 277 [A] Adjustment and Checks at Installation. 277 Cable Connection for the Peripheral Devices. 320 In Case of B--Cabinet. 158 [F] Fused--Based Troubleshooting. 247 Connection Between the Mechanical Unit and End Effector. 288 Installation Method. 287 [E] Electrical Connections. 329 Installation. 204 Connection to Ethernet. 231 [L] . 271 Connecting the External Emergency Stop. 289 Alarm Occurrence Screen. 161 Component Functions. and ARC Welders. 266 End Effector Control Interface. 279 Lead Materials. 30 ARC Weld Connection Cable (CRW1: Honda Tsushin. 271 Interface for Peripheral Devices. 275 External Cable Wiring Diagram. 140 Battery for memory backup (3 VDC). 263 Peripheral Device Interface. 261 Peripheral Device Interface Block Diagram. 290 Peripheral Device. 168 Replacing the Power Unit and Printed--Circuit Boards on the Backplane Unit. 165 Replacing the Base Unit of I/O Unit Model A. 184 Replacing the Transformer. 26 Printed Circuit Boards. 253 Peripheral Device Interface A Cable (CRM2: Honda Tsushin. 192 Replacing the Operator Panel and Panel Switch Board. 10. 186 Replacing Fuses. 271 RS--232--C Interface Signals. 182 [O] Operator Safety. 177 Replacing the Regenerative Resistor Unit. 12 Preventive Maintenance. 143 Process I/O Board CB (A16B--2201--0472). and End Effector Interfaces. 152 Peripheral Device and Control Unit Connection. 166 Replacing the Printed--Circuit Boards. 11. 169 Replacing External Air Fan Unit and Door Fan Unit (B--cabinet). 146 Process I/O Board DA (A16B--2201--0480). 272 [S] Safety During Maintenance. 226 Peripheral Device Interface Processing. 191 Replacing Fuses in the Servo Amplifier. 34 [R] Recommended Cables. 135 Process I/O Board CA (A16B--2201--0470). 176 Replacing the Teach Pendant. 142 Panel Switch Board (A20B--9002--0310). 195 Replacing Servo Amplifiers. 232 Peripheral Device Cable Connector. 190 Replacing I/O Unit Model A. 267 Replace the Mode Switch. 154 [M] Main Board (A16B--3200--0412. 9 Safety in Maintenance. 6 Optical Fiber Cable. 220 Position Deviation Found in Return to the Reference Position (Positioning). 13 . 10 Precautions for Mechanisms. 338 Output Signals.Index B--81465EN--1/02 LED of Servo Amplifier. 221 Peripheral Device Interface Combination. 136 Manual Operation Impossible. 165 Replacing the Redundant E--stop Unit. 148 Process I/O Board Signals. 190 Replacing Fuses in the Power Unit. 11 Precautions in Programming. --0331). 261 Peripheral Device Interface B Cable (CRM4: Honda Tsushin. 196 Replacing Cards and Modules on the Main Board. 28 Power Distribution Circuit Diagram. 20 pins). 325 [P] Panel Board (A20B--2100--0770). 164 Replacing Battery. 290 Robot Connection Cables. 189 Replacing a Module. 178 Replacing the AC Fan Motor. 50 pins). 185 Replacing the Fuse on the Panel Board. 331 Precautions for Mechanism. 227 i--2 Replacing Relays. 264 Peripheral Device Connection Cable. 188 Replacing the Panel Board. 11 Precautions in Operation. 133 Mastering. 291 Resetting Overtravel and Emergency Stop at Installation. 173 Resetting Overtravel. 4. 183 Replacing a Unit. 195 Replacing Relays on the Panel Board. 290. ARC Welding. 182 Replacing the Control Section Fan Motor. 186 Replacing the Backplane Board (Unit). 194 Replacing the Fuse on the Process I/O Boards. 206 RS--232--C Interface. 131 Power Cannot be Turned On. 261 Total Connection Diagram.B--81465EN--1/02 Index Safety of the End Effector. 319 Setting of Servo Amplifier. 36 [V] Vibration Observed During Movement. 330 Specifications of Digital Input/Output. 157 Signals. 153 Setting Common Voltage. 132 [W] Warning Label. 10 Safety Precautions. 283 Troubleshooting. 224 When Process I/O Board CA/CB/HA is Used (B--cabinet). 316 Specifications of the Cables Used for Peripheral Devices and Welders. 317 Software Specifications. 7 Safety of the Tools and Peripheral Devices. 33 Selecting Transformer Taps. 122 Troubleshooting Using the Error Code. 329 Specifications of Peripheral Device Interface. 284 Transportation and Installation. 27 Troubleshooting Based on LED Indications. 3 Safety Signals. 207 i--3 . 14 When I/O Unit--MODEL A is Used. 225 [T] Teach Pendant Cable. 155 Setting the Power Supply. 12 Safety of the Robot Mechanism. 223 When Two or more Process I/O Boards and I/O Unit (Model A or Model B) are Used. 159 Servo Amplifiers. 295 Transportation. 221 When Process I/O Board DA is Used (B--cabinet). 11 Safety of the Teach Pendant Operator. M--6iB and ARC Mate100iB 01 Mar.Revision Record FANUC Robot series R--J3iB CONTROLLER FOR EUROPE MAINTENANCE MANUAL (B--81465EN--1) 02 Oct.. 2001 Addition of R--2000iA/165F/200F/165R/200R/125L/CF. 2001 Edition Date Contents Edition Date Contents ..