Aux Axis Manual Fanuc

FANUC Robotics R-J3iB R-J3iB and R-J3iB R-J3iB Mate Mate Contro llers Aux Au x i l i ary ar y Ax A x i s and an d L o c al Stop St op Options Connection and Maint Maint enance enance Manual MAREIBAUX11011E REV. E A-82377 and A-83110

This publication contains proprietary information of FANUC Robotics America, Inc. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics America, Inc. FANUC FANUC Robot Robot ics Americ a, Inc. Inc. 3900 W. Hamlin Road Rochester Hills , Mich igan 48309 48309–32 –3253 53

The descriptions and specifications contained in this manual were in effect at the time this manual was was approved for printing. FANUC Robotics America, Inc, hereinafter referred to as FANUC Robotics, reserves the right to discontinue models at any time or to change specifications or design without notice and without incurring obligations. FANUC Robotics manuals present descriptions, specifications, drawings, schematics, bills of material, parts, connections and/or procedures for installing, disassembling, connecting, operating and programming FANUC Robotics’ Robotics’ products and/or systems. Such systems consist of robots, extended axes, robot controllers, application software, the KAREL® programming language, INSIGHT® vision equipment, and special tools. FANUC Robotics recommends that only persons who have been trained in one or more approved FANUC Robotics Training Course(s) be permitted to install, operate, use, perform procedures on, repair, and/or maintain FANUC Robotics’ products and/or systems and their respective respective components. Approved training necessitates that the courses selected be relevant to the type of system installed and application performed at the customer site.

WARNING This equipment generates, uses, and can radiate radio frequency energy energy and if not i nstalled and used in accordance wi th the instr ucti on manual, may may cause interference to radio communications. As temporarily permitted by regulation, it has not been been tested for compl iance with the lim its f or Class A comput ing devices purs uant to subpart J of Part 15 of FCC Rules, which are designed to provide reasonable reasonable protection against against such interference. interference. Operation Operation of the equipment in a residential area is l ikely to cause interference, interference, in whi ch case the user, at at his own expense, expense, will be required to take whatever whatever m easure easure may be required t o co rrect t he interference.

FANUC Robotics conducts courses on its systems and products on a regularly scheduled basis at its headquarters in Rochester Hills, Michigan. For additional information contact FANUC Robotics America, Inc. Training Department 3900 W. Hamlin Road Rochester Hills, Michigan 48309-3253 www.fanucrobotics.com Send your comments and suggestions about this manual to: [email protected]

Copyright ©2004 2004 by FANUC FANUC Robotic s Ameri ca, Inc. All Rig ht s Reserv Res erved ed The information illustrated or contained herein is not to be reproduced, copied, translated into another language, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics America, Inc. AccuStat®, ArcTool®, DispenseTool®, FANUC LASER DRILL®, KAREL®, INSIGHT®, INSIGHT II ®, PaintTool®, PaintWorks®, PalletTool®, SOCKETS®, SOFT PARTS® SpotTool®, TorchMate®, and YagTool® are Registered Trademarks of FANUC Robotics. FANUC Robotics reserves all proprietary rights, including but not limited to trademark and trade name rights, in the following names: AccuAir ™ AccuCal™ AccuChop™ AccuFlow™ AccuPath™ AccuSeal™ ARC Mate™ ARC Mate Sr. ™ ARC Mate System 1™ ARC Mate System 2™ ARC Mate System 3™ ARC Mate System 4™ ARC Mate System 5™ ARCWorks Pro™ AssistTool™ AutoNormal™ AutoTCP™ BellTool™ BODYWorks™ Cal Mate™ Cell Finder ™ Center Finder ™ Clean Wall™ CollisionGuard™ DispenseTool™ F-100™ F-200i™ FabTool™ FANUC LASER DRILL™ Flexibell™ FlexTool™ HandlingTool™ HandlingWorks™ INSIGHT™ INSIGHT II ™ IntelliTrak™ Integrated Process Solution™ Intelligent Assist Device™ IPC -Integrated Pump Control™ IPD Integral Pneumatic Dispenser ™ ISA Integral Servo Applicator ™ ISD Integral Servo Dispenser ™ Laser Mate System 3™ Laser Mate System 4™ LaserPro™ LaserTool™ LR Tool™ MIG Eye™ MotionParts™ NoBots™ Paint Stick ™ PaintPro™ PaintTool 100™ PAINTWorks™ PAINTWorks II ™ PAINTWorks III ™ PalletMate™ PalletMate PC™ PalletTool PC™ PayloadID™ RecipTool™ RemovalTool™ Robo Chop™ Robo Spray™ S-420i™ S-430i™ ShapeGen™ SoftFloat™ SOF™ PARTS™ SpotTool+™ SR Mate™ SR ShotTool™ SureWeld™ SYSTEM R-J2 Controller ™ SYSTEM RJ3 Controller ™ SYSTEM R-J3iB Controller ™ TCP Mate™ TurboMove™ TorchMate™ visLOC™ visPRO-3D™ visTRAC™ WebServer ™ WebTP™ YagTool™ © FANUC • •

LTD L TD 2004

No part of this manual may be reproduced in any form. All specifications and designs are subject to change without notice.

Conventions

This manual includes information essential to the safety of personnel, equipment, software, and data. This information is indicated by headings and boxes in the text. WARNING Information appearing under WARNING concerns the protection of personnel. It is boxed and in bold type to set it apart f rom ot her text.

CAUTION Information appearing under CAUTION concerns the protection of equipment, software, and data. It is boxed to set it apart from other text.

NOTE Information appearing next to NOTE concerns related information

or useful hints.

MAREIBAUX11011E REV E

Contents-1

Chapter 1 R-J3 I B CONTROLLER - ALPHA I SERIES MOTOR / AMPLIFIER AUXILIARY AXIS OPTION

1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.1 B -Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.2 A-Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

2.3 Auxiliary Axis Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Brake Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 3

3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

3.1 Troubleshooting Using the Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

3.2 Troubleshooting Based on LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

4 REPLACING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

4.1 Replacing the Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

4.2 Replacing the Servo Amplifier Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

4.3 Replacing the Brake Unit Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

4.4 Replacing the Servo Amplifier Internal Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Replacing the Servo Amplifier External Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 22 23

5 CABLE CONNETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 For B-Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 25

5.2 For A-Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

6 TOTAL CONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

7 SETTING THE BRAKE NUMBER FOR THE AUXILIARY AXIS . . . . . . . . . . . . . . . . . . . . . .

38

Chapter 2 R-J3 I B B- CABINET CONTROLLER - ALPHA SERIES MOTOR / AMPLIFIER AUXILIARY AXIS OPTION

1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

2 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

2.1 B -Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Brake Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 42

3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Troubleshooting Using the Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 44

3.2 Troubleshooting Based on LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

4 REPLACING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

4.1 Replacing the Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

Contents-2

MAREIBAUX11011E REV E

4.2 Replacing the Servo Amplifier Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Replacing the Brake Unit Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 59

4.4 Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

5 CABLE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

6 TOTAL CONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62

Chapter 3 LOCAL STOP HARDWARE

3.1 LOCAL STOP OPTION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3.2 LOCAL STOP KIT ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5

3.3 CONNECTION AND HARDWARE MOUNTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . .

3-8

3.4 ARC WELDING APPLICATION CONNECTION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . .

3-14

3.5 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-21

Chapter 4 R-J3IB MATE CONTROLLER - AUXILIARY AXIS OPTION

1 CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MOTOR CONNECTION CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TOTAL CONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Safety-1 FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner, employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace. The appropriate level of safety for your application and installation can best be determined by safety system professionals. FANUC Robotics therefore, recommends that each customer consult with such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC Robotic systems. According to the industry standard ANSI/RIA R15.06, the owner or user is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to recognize and respond to known hazards associated with your robotic system and to be aware of the recommended operating procedures for your particular application and robot installation. FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use the robotics system be trained in an approved FANUC Robotics training course and become familiar with the proper operation of the system. Persons responsible for programming the system–including the design, implementation, and debugging of application programs– must be familiar with the recommended programming procedures for your application and robot installation. The following guidelines are provided to emphasize the importance of safety in the workplace.

Safety-2

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION

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

• • •

Keeping People and Equipment Safe

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

Using Safety Enhancing Devices

People External devices Robot(s) Tooling Workpiece

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

Setti ng Up a Safe Workcell

The safety of people and equipment Use of safety enhancing devices Techniques for safe teaching and manual operation of the robot(s) Techniques for safe automatic operation of the robot(s) Regular scheduled inspection of the robot and workcell Proper maintenance of the robot

Safety fences, barriers, or chains Light curtains Interlocks Pressure mats Floor markings Warning lights Mechanical stops EMERGENCY STOP buttons DEADMAN switches

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

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

Safety-3

•

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

•

Use anti–tie–down logic to prevent the operator from bypassing safety measures.

•

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

•

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

•

Position all controllers outside the robot work envelope.

•

Never rely on software as the primary safety element.

•

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

•

Install flashing lights and/or audible warning devices that activate whenever the robot is operating, that is, whenever power is applied to the servo drive system. Audible warning devices shall exceed the ambient noise level at the end–use application.

•

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

•

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

•

Use interlocks.

•

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

•

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

Safety-4

Staying Safe While Teaching or Manually Operating t he Robot

•

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

•

Make provisions for power lockout/tagout at the controller.

•

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

•

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

•

Program the robot to load and unload material safely.

•

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

•

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

Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules: •

•

•

•

•

Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment. Before teaching, visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These include tooling attached to the wrist flange that extends this range. The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe working conditions to the supervisor or safety department. FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except for robot teaching operations. However, if you must enter the work envelope, be sure all safeguards are in place, check the teach pendant DEADMAN switch for proper operation, and place the robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the DEADMAN switch. Only the person with the teach pendant should be in the work envelope.

Safety-5

WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit swi tch, for any operational convenience. Deactivating a safety device is know n to have resulted i n serious inj ury and death.

•

•

•

Know the path that can be used to escape from a moving robot; make sure the escape path is never blocked. Isolate the robot from all remote control signals that can cause motion while data is being taught. Test any program being run for the first time in the following manner: WARNING Stay outsi de the robot work envelope whenever a program is being run. Failur e to do so can result in injury.

-

Using a low motion speed, single step the program for at least one full cycle.

-

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

•

Staying Safe Durin g Auto mat ic Oper ati on

Using the programmed speed, test run the program continuously for at least one full cycle. Make sure all personnel are outside the work envelope before running production.

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

Make sure all safety provisions are present and active.

•

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

•

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

•

Make sure all personnel are outside the work envelope before operating the robot.

Safety-6

Staying Safe Durin g Inspection

Staying Safe Durin g Maintenance

•

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

•

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

•

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

•

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

•

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

•

Never try to stop the robot, or break its motion, with your body. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel, teach pendant, or emergency stop stations around the workcell.

When inspecting the robot, be sure to •

Turn off power at the controller.

•

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

•

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

•

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

•

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

•

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

•

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

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

Safety-7

•

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

•

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

•


•

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

•

Test the teach pendant for proper operation before entering the work envelope.

•

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

•

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

•

Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake. WARNING Lethal vol tage is pr esent in t he cont rol ler WHENEVER IT IS CONNECTED to a power sour ce. Be extr emely careful to avoid electri cal shock. HIGH VOLTAGE IS PRESENT at the input side whenever the contro ller is connected to a power source. Turning the discon nect or cir cuit b reaker to the OFF position r emoves power from t he output side of the device only.

•

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

Safety-8 •

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

•

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

•

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

WARNING Do not try to remove any mechanical component f rom t he robot before thoro ughly reading and understanding the procedures in the appropri ate manual. Doing so can result in serious personal injury and component destruction. •

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

•

When replacing or installing components, make sure dirt and debris do not enter the system.

•

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

•

Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot and all external devices are operating normally.

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. Some of these measures are outlined below. Make sure you know all associated measures for safe use of such devices.

Programming Safety Precautions

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

Safety-9

Mechanical Safety Precautions

•

Back–check limit switches in the workcell to make sure they do not fail.

•

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

•

Use handshaking protocol to synchronize robot and external device operations.

•

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

Implement the following mechanical safety measures to pr event damage to machine tools and other external devices. •

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

•

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

KEEPING THE ROBOT SAFE

Observe the following operating and programming guidelines to prevent damage to the robot.

Operating Safety Precautions

The following measures are designed to prevent damage to the robot during operation.

Programming Safety Precautions

•

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

•

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

•

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

•

Use circuit breakers to guard against electrical overload.

The following safety measures are designed to prevent damage to the robot during programming: •

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

Safety-10 •

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

•

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

•

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

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

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS

Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personal also must work inside the paint booth periodically. Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor. Although paint booth hazards have been minimized, potential dangers still exist. Therefore, today’s highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its capabilities. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools. Paint robots are operated in three modes: Teach or manual mode Automatic mode, including automatic and exercise operation • Diagnostic mode • During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant. •

In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth or in a designated safe

Safety-11 area within the booth whenever automatic mode is initiated at the SOC or MCP. In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds. When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.

Paint System Safety Features

Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment, personnel must comply strictly with the procedures in the manuals. This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system. The paint system includes the following safety features: •

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

•

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

•

EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become familiar with the locations of all E– STOP buttons.

•

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

•

A DEADMAN switch is located on each teach pendant. When this switch is held in, and the teach pendant is on, power is applied to the robot servo system. If the engaged DEADMAN switch is released during robot operation, power is removed from the servo system, all axis brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within the system might also E–STOP other robots. WARNING An EMERGENCY STOP wil l o cc ur if th e DEADMAN sw it ch is released on a bypassed robot.

Safety-12 •

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

•

EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all equipment in the booth if a door is opened while the system is operating in automatic or manual mode. For some systems, signals to these switches are inactive when the switch on the SCC is in teach mode. When present, photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit silhouette openings.

•

Staying Safe While Operating the Paint Robot

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

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

WARNING Observe all safety rules and guidelines to avoid in jury.

WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit swi tch, for any operational convenience. Deactivating a safety device is know n to have resulted i n serious inj ury and death.

•

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

•

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

•

Be aware of overlapping work envelopes of adjacent robots.

•

Know where all red, mushroom–shaped EMERGENCY STOP buttons are located.

Safety-13

Staying Safe Whil e Operating Paint Appli cat io n Eq uip men t

•

Know the location and status of all switches, sensors, and/or control signals that might cause the robot, conveyor, and opening devices to move.

•

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

•

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

•

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

•

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

•

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

•


•

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

•

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

•

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

•

Be aware of all safety precautions when dispensing of paint is required.

•

Follow the procedures described in this manual.

When you work with paint application equipment, observe the following rules, in addition to all rules for safe operation that apply to all robot systems. WARNING When working with electrostatic paint equipment, follow all national and local codes as well as all safety guidelines wi thin your organization. Also reference the foll owi ng standards: NFPA 33 Standards for Spray Application Using Flammable or Combustible Materials, and NFPA 70 National Electri cal Code.

Safety-14

•

Grounding: All electrically conductive objects in the spray area must be grounded. This includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots, as well as solvent containers. Grounding is defined as the object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms.

•

High Voltage: High voltage should only be on during actual spray operations. Voltage should be off when the painting process is completed. Never leave high voltage on during a cap cleaning process.

•

Staying Safe Durin g Maintenance

Avoid any accumulation of combustible vapors or coating matter.

•

Follow all manufacturer recommended cleaning procedures.

•

Make sure all interlocks are operational.

•

No smoking.

•

Post all warning signs regarding the electrostatic equipment and operation of electrostatic equipment according to NFPA 33 Standard for Spray Application Using Flammable or Combustible Material.

•

Disable all air and paint pressure to bell.

•

Verify that the lines are not under pressure.

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

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

•

When a maintenance technician is repairing or adjusting a robot, the work area is under the control of that technician. All personnel not participating in the maintenance must stay out of the area.

•

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

Safety-15

•

•

Be sure all covers and inspection plates are in good repair and in place. Always return the robot to the ‘‘home’’ position before you disarm it.

•

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

•

During robot operations, be aware of the robot’s movements. Excess vibration, unusual sounds, and so forth, can alert you to potential problems.

•

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

•

When using vinyl resin observe the following:

•

-

Wear eye protection and protective gloves during application and removal

-

Adequate ventilation is required. Overexposure could cause drowsiness or skin and eye irritation.

-

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

When using paint remover observe the following:

-

Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning.

-

Adequate ventilation is required. Overexposure could cause drowsiness.

-

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

Chapter 1

R-J3iB Auxiliary Axis Option Maintenance Manual (Alpha-i series motor/amplifier) 1. Scope This manual is supplement for Auxiliary Axis Option (Alpha-i series motor/amplifier) of the R-J3iB controller (Standard, RIA and CE). Refer to the R-J3iB maintenance manual for general maintenance description.

2. Assembly 2.1 B-cabinet

Fig.2.1 B-cabinet

1

2.2 A-cabinet

EMERGENCY STOP UNIT (E-STOP UNIT)

Fig.2.2 A-cabinet 2.3 Auxiliary axis cabinet

Fig.2.3 Auxiliary Axis Cabinet

2

2 .4 B r a k e U n i t

3

F i g .2 .4 .1 B r a k e U n i t ( w i t h c o n t a c t o r )

4

F i g 2 .4 .2 B r a k e U n i t

5

F i g 2 .4 .2 B r a k e U n i t ( w i t h 2 c o n t a c t o r s )

3. Troubleshooting 3.1 Troubleshooting using the error code SRVO-021 SRDY off (Group:i Axis:j) [Explanation]

When HDRY is on, SRDY is off even though no other alarm or emergency stop condition is present. This alarm can also occur when HRDY is off and the servo amplifier MCC is ON. HRDY is the signal sent from the host (Main board) to the servo system to specify whether to turn the servo amplifier MCC (located on E-Stop Unit) on or off. SRDY is the signal sent from the servo system to the host to indicate whether the servo amplifier MCC is on or off. If the servo amplifier MCC cannot be turned on when directed so, it is likely that a servo amplifier alarm has occurred. The host does not issue this alarm (SRDY off) if an alarm for the servo amplifier is detected. Therefore, this alarm indicates that the MCC cannot be turned on for an unknown reason. Check the alarm history and investigate the factor of this alarm as follows. If this alarm occurs on the 6-axis servo amplifier and the auxiliary axis servo amplifiers at the same time, [Action 1] It is likely that the supply voltage stops instantaneously. Check the power supply. [Action 2] Replace the E-stop unit. [Action 3] Replace the 6-axis servo amplifier. If this alarm occurs with other alarms, [Action 1] In case other alarms occurs at the same time in the alarm history, check the troubleshooting of other alarms. [Action 2] In case with “SRVO-214 Fuse Blown (Amp)”, replace the fuse of the 6-axis servo amplifier. [Action 3] In case with “SRVO-222 Lack of Amp (Amp:i)”, see the troubleshooting of SRVO-222. If this alarm occurs on only the auxiliary axis servo amplifiers, [Action 1] Make sure that connector JX5 of the servo amplifier is connected tightly. [Action 2] Replace the auxiliary axis servo amplifier that is indicated by the alarm massage. [Action 3] Replace the 6-axis servo amplifier. A SRDY off may occur when the software setting is incorrect. <1> If the parameter of the auxiliary axis is wrong, SRDY off occurs. <2> If the machine lock is set to the 6-axis servo amplifier, SRDY off occurs on the auxiliary axis that is subordinate to the 6-axis servo amplifier. <3> If the machine lock is set to one axis of the 2-axis and 3-axis servo amplifier, SRDY off occurs on the other auxiliary axis.

SRVO-022 SRDY on (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

After inputting the reset signal, the ready signal from the servo amplifier was on before outputting the signal that let the amplifier to be re ady. Replace the servo card or the auxiliary axis board indicated by the alarm message. Replace the servo amplifier that is indicated by the alarm massage.

6

SRVO-023 Stop error excess (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

[Action 3] [Action 4]

[Action 5]

[Action 6] [Action 7] [Action 8]

The position error becomes abnormally large, when the servo is at stop, Check whether the robot or the auxiliary axis has collided with anything. Check whether the motor brake has been released. <1> Check the continuity of the brake circuit (cable, coil) at the CRR65*. <2> Make sure that the brake cable has no ground fault. <3> In case the brake unit is mounted, check to see if the fuse FUSE1 of the brake unit is blown.(If this fuse is blown, it may be caused by some defect of the brake cable.) Make sure that CZ2 connector at the servo amplifier and the power connector at the motor are connected tightly and check the continuity of the servo power circuit at CZ2. Check to see if the load is greater than the rating. If greater, reduce it to within the rating. (If the load is too great, the torque required for acceleration / deceleration becomes higher than the capacity of the motor. As a result, the motor becomes unable to follow the command, and an alarm is issued. Check to see if the input voltage of the R-J3iB controller is within its rated voltage and the voltage setting of the transformer is right. (If the voltage input to the servo amplifier becomes low, the torque output also becomes low. As a result the motor may become unable to follow the command, hence possibly an alarm.) Replace the servo amplifier indicated by the alarm message. Replace the brake unit. Replace the motor.

SRVO-024 Move error excess (Group:i Axis:j) [Explanation] [Action]

When the robot is running, its position error is greater than a specified value ($PARAM_GROUP. $MOVER_OFFST or $PARAM_GROUP.$TRKERRLIM). It is likely that the robot cannot follow the speed specified by program. Take the same actions as for SRVO-023.

SRVO-036 Inpos time over (Group:i Axis:j) [Explanation] [Action]

The robot did not get to the specified area ($PARAM_GROUP_$INPOS TIME) even after the position check monitoring time ($PARAM_GROUP.$STOPTOL) elapsed. Take the same actions as for SRVO-023.

7

SRVO-038 Pulse mismatch (Group:i Axis:j) [Explanation]

The pulse count stored when power was turned off does not match the count obtained when the power is turned on. This alarm will be asserted after changing the pulsecoder, changing the back up battery for the pulse coder data or after loading back up data into the main board. Check the alarm history and investigate the factor of this alarm as follows. [Action 1] In case with “SRVO-222 Lack of Amp (Amp:i)”, see the troubleshooting of SRVO-222. [Action 2] If the brake number is set to the non-brake motors, this alarm may occur. Check the software setting of the brake number. [Action 3] In case the robot or the auxiliary axis motors have been moved using the brake release unit while the power is off or when restoring the back-up data to the main board, this alarm may occur. Remaster the robot and the auxiliary axis motors. [Action 4] If the robot or the auxiliary axis motors have been moved because the brake failed, this alarm may occur. Remove the factors and remaster the robot and the auxiliary axis motors. [Action 5] Replace the pulse coder and remaster the group axis that is indicated by the alarm message.

SRVO-045 HCAL alarm (Group:i Axis:j) [Explanation] [Action 1]


Abnormally high current flowed in the main circuit of the servo amplifier. Turn off the power, and disconnect the power cable for the auxiliary axis motor from the servo amplifier indicated by the alarm message.(and disconnect the brake cable to avoid the axis falling unexpectedly.) Supply power and see if the alarm occurs again. If the alarm occurs again, replace the servo amplifier. Turn off the power and disconnect the power cable for the auxiliary axis(CZ2*) indicated by the alarm message, and check the insulation of their U, V, W and the GND lines each other. If there is a short-circuit, replace the power cable. Turn off the power and disconnect the power cable for the auxiliary axis (CZ2*) indicated by the alarm message, and measure the resistance between their U and V,V and W and W and U with an ohmmeter that has a very low resistance range. If the resistances at the three places are different from each other, the motor, the power cable for auxiliary axis is defective. Check each item in detail and replace it if necessary.

SRVO-046 OVC alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

This alarm is issued to prevent the motor from thermal damage that might occur when the root mean square current calculated within the servo system is out of the allowable range. Check the operating conditions for the robot and relax the service conditions if it is possible. Take the same actions as for SRVO-023.

SRVO-47 LVAL alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

The control power supply voltage(+24V) supplied to servo amplifier is abnormally low. Replace the servo amplifier that is indicated by the alarm message. Replace the power supply unit.

8

SRVO-50 Collision Detect alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

The disturbance torque estimated by the servo software is abnormally high. (A collision has been detected.) Check the software setting for this option. Take the same actions as for SRVO-023.

SRVO-51 CUER alarm (Group:i Axis:j) [Explanation] [Action 1]

The offset of the current feedback value is abnormally high. Replace the servo amplifier that is indicated by the alarm message.

SRVO-55 FSSB com error 1 (Group:i Axis:j) [Explanation] [Action 1] [Action 2] [Action 3] [Action 4]

A communication error has been detected by the servo amplifier. Replace the communication cable (Optical fiber) on the COP10B side of the servo amplifier indicated by the alarm message. Replace the servo amplifier that is indicated by the alarm message. Replace the servo amplifier between main board and the indicated servo amplifier. Replace the servo card or the auxiliary axis board.

SRVO-56 FSSB com error 2 (Group:i Axis:j) [Explanation] [Action ]

A communication error has been detected by the servo software. Take the same actions as described for the above alarm.

SRVO-57 FSSB disconnect (Group:i Axis:j) [Explanation] [Action 1] [Action 2] [Action 3] [Action 4] [Action 5] [Action 6]

Communication was broken between the main board and the servo amplifier. Check whether fuse F3 in the power supply unit has blown. Check whether fuse FS1 in the servo amplifier has blown. Check the communication cable (Optical fiber) between the main board and the 6-axis servo amplifier and between the 6-axis amplifier and the auxiliary axis servo amplifier. Replace it if it is faulty. Replace the servo card or the auxiliary axis. Replace the 6-Axis amplifier and the auxiliary amplifier. Check the robot connection cable RP1 and the pulse coder cable of the auxiliary axis (+5V ground fault).

Caution

Before continuing to the next step, perform a complete controller back up to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data.

[Action 7]

Replace the main board.

9

SRVO-061 CKAL alarm (Group:i Axis:j) SRVO-062 BZAL alarm (Group:i Axis:j) SRVO-063 RCAL alarm (Group:i Axis:j) SRVO-064 PHAL alarm (Group:i Axis:j) SRVO-065 BLAL alarm (Group:i Axis:j) SRVO-066 CSAL alarm (Group:i Axis:j) SRVO-067 OHAL2 alarm (Group:i Axis:j) SRVO-068 DTERR alarm (Group:i Axis:j) SRVO-069 CRCERR alarm (Group:i Axis:j) SRVO-070 STBERR alarm (Group:i Axis:j) SRVO-071 SPHAL alarm (Group:i Axis:j) SRVO-072 PMAL alarm (Group:i Axis:j) Refer to the R-J3iB control unit maintenance manual. SRVO-073 CMAL alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. Reinforce the earth of the flange of the motor that is indicated by the alarm message. Replace the pulse coder that is indicated by the alarm message.

SRVO-074 LDAL alarm (Group:i Axis:j) Refer to the R-J3iB control unit maintenance manual. SRVO-135 FSAL alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

Faulty internal fan motor of the auxiliary axis servo amplifier. Replace the internal fan motor of the auxiliary servo amplifier that is indicated by the alarm message. Replace the auxiliary servo amplifier that is indicated by the alarm message.

SRVO-136 DCLVAL alarm (Group:i Axis:j) [Explanation] The DC link voltage is abnormally low. -In case this alarm occurred during robot operation: [Action 1] Check to see if the input voltage of the R-J3iB controller is within its rated voltage and the voltage setting of the transformer is right. [Action 2] It is likely that the supply voltage stops instantaneously. Check the power supply. [Action 3] Replace the E-STOP unit. [Action 4] Replace the servo amplifier. -In case this alarm occurs while the power up sequence or right after inputting reset signal: [Action 1] Check whether the circuit breaker in the emergency stop unit is off. If it is off, check the servo amplifier and the wiring between the servo amplifier and the emergency stop unit. If anything is abnormal, replace it. [Action 2] Check to see if the input voltage of the R-J3iB controller is within its rated voltage and the voltage setting of the transformer is right. [Action 3] Replace the E-stop unit. [Action 4] Replace the servo amplifier that is indicated by the alarm message. -In case this alarm occurs right after pushing emergency stop button. [Action 1] This alarm will occur in case the servo amplifier primary power is removed before an emergency stop. Check whether the auxiliary axis unit is installed correctly.

10

SRVO-156 IPMAL alarm (Group:i Axis:j) [Explanation] [Action]

Abnormally high current flowed through the main circuit of the servo power. Take the same actions as for SRVO-045.

SRVO-215 Fuse blown (Aux. Axis) [Explanation] [Action]

The fuse FUSE1 on the brake unit is blown. Replace this fuse after replacing the brake cable because it may be defective. (If this fuse is blown, it may be caused by some defect of the brake cable.)

SRVO-222 Lack of Amp (Amp:i) [Explanation] [Action 1]

[Action 2] [Action 3] [Action 4] [Action 5]

The servo amplifiers were not found at the power up sequence. Turn off the controller, disconnect the pulse coder cable JF1,JF2 from the servo amplifier and turn on the controller again. If this alarm dose not occur, the pulse coder cable may have +5V ground fault.(The LED of the servo amplifier may display blinking “-“ when the pulse coder cable has +5V g round fault.) Replace the servo amplifier for auxiliary axis. Replace the 6-Axis servo amplifier. Replace the optical fiber cable. Replace the servo card or the auxiliary axis servo card.

SRVO-290 DC link HC alarm (Group:i Axis:j) [Explanation] [Action]

The DC link current of the servo amplifier is abnormal Take the same actions as for SRVO-045.

SRVO-291 IPM over heat (Group:i Axis:j) [Explanation] [Action 1] [Action 2] [Action 3]

The IPM in the servo amplifier overheated Check the operating conditions for the robot and relax the service conditions if it is possible. Check whether the amplifier fan has stopped. If this alarm is frequency issued, replace the servo amplifier.

SRVO-292 EXT.FAN alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

The external fan of the auxiliary axis servo amplifier is faulty. Replace the external fan of the auxiliary axis servo amplifier. Replace the servo amplifier.

11

3.2 Troubleshooting based on LED indication.

LED indication

Description [Explanation] [Action 1 ］


Internal cooling fan is stopped. Check whether there is any foreign material in the fan. Check that the fan connector is attached correctly. Replace the fan. Replace the servo amplifier.

[Explanation] [Action 1 ］

Control power supply undervoltage Replace the servo amplifier.

[Explanation] [Action 1 ］

DC link undervoltage Check that the screws for the DC link connection cable (bar) are tight. If DC link low voltage alarm occurs in only one servo amplifier, replace that servo amplifier.

[Action 2]

[Action 2] [Explanation] [Action 1 ］ [Action 2] [Action 3] [Action 4] [Explanation] [Action 1 ］ [Action 2] [Action 3] [Action 4] [Explanation]

[Action 1 ］ [Action 2]

12

Overheat Check that the motor is being used at or below its continuous rating. Check that cooling capacity of the cabinet is sufficient (inspect the fans and filters). Check that the ambient temperature is not too high. Replace the servo amplifier. Cooling fan stopped of the radiator Check whether there is any foreign material in the fan. Check that the fan connector is attached correctly. Replace the fan. Replace the servo amplifier. There are no communications between the servo amplifiers in the auxiliary axis option of R-J3iB. If this alarm occurs, take the actions as follows Check the short-connector JX5. Replace the servo amplifier.

LED indication

Description [Explanation]

DC Link current alarm

[Action 1]

Disconnect the motor power leads from the servo amplifier (, disconnect the brake cable to prevent the axis from falling), and release the servo amplifier from an emergency stop condition. <1> If no abnormal DC link current alarm condition has occurred. →Go to [Action 2].

<2> If an abnormal DC link current alarm condition has occurred. →Replace the servo amplifier.

[Action 2]

Disconnect the motor power leads from the servo amplifier , and check the insulation between PE and the motor power lead U,V, and W. <1> If the insulation is deteriorated →Go to [Action 3]

<2> If the insulation is normal →Replace the servo amplifier.

[Action 3]

Disconnect the motor from its power leads, and check whether insulation of the motor or power leads is deteriorated. <1> If the insulation deteriorated.

of

the

motor

is

→Replace the motor.

<2> If the insulation of any power lead is deteriorated. →Replace the power lead.

13

LED indication

Description [Explanation 1] [Action 1 ］

IPM Alarm. Disconnect the motor power leads from the servo amplifier (, disconnect the brake cable to prevent the axis from falling), and release the servo amplifier from an emergency stop condition. <1> If no IPM alarm condition has occurred →Go to [Action 2]. <2> If an IPM alarm condition has occurred →Replace the servo amplifier.

[Action 2]

Disconnect the motor power leads from the servo amplifier, and check the insulation between PE and the motor power lead U,V, and W <1> If the insulation is deteriorated →Go to [Action 4]. <2> If the insulation is normal →Replace the servo amplifier

[Action 3]

Disconnect the motor from its power lead, and check whether the insulation of motor or power lead is deteriorated. <1> If the insulation of the motor is deteriorated →Replace the motor. <2> If the insulation of any power lead is deteriorated →Replace the power lead.

[Explanation 1]

IPM Alarm (OH).

[Action 1]

Check that the heat sink cooling fan is running.

[Action 2]

Check that the motor is being used at or below its continuous rating.

[Action 3]

Check that the cooling capacity of the cabinet is sufficient (inspect the fans and filters).

[Action 4]

Check that the ambient temperature is not too high.

[Action 5]

Replace the servo amplifier.

LED “8.” means that this alarm occurs in the L-Axis. LED “9.” means that this alarm occurs in the M-Axis. LED “A.” means that this alarm occurs in the N-Axis.

14

LED indication

Description [Explanation] [Action 1 ］

[Action 2]

[Action 3]

Abnormal motor current. Check whether the servo parameter has default values. Alternatively, if an abnormal motor current alarm condition occurs only on rapid acceleration/deceleration, it is likely that the motor is being used under too harsh a condition. Increase the acceleration/deceleration time constant, and see what will occur. Disconnect the motor power leads from the servo amplifier (, disconnect the brake cable to prevent the axis from falling), and release the servo amplifier from an emergency stop condition. <1> If no abnormal motor current occurs →Go to [Action 3]. <2> If an abnormal motor current occurs →Replace the servo amplifier. Disconnect the motor power leads from the servo amplifier, and check the insulation between PE and the motor power lead U,V, and W <1> If the insulation is deteriorated →Go to [Action 4]. <2> If the insulation is normal →Replace the servo amplifier

[Action 4]

Disconnect the motor from its power lead, and check whether the insulation of motor or power lead is deteriorated. <1> If the insulation of the motor is deteriorated →Replace the motor. <2>If the insulation of any power lead is deteriorated →Replace the power lead.

LED “b” means that this alarm occurs in the L-Axis. LED “c” means that this alarm occurs in the M-Axis. LED “d” means that this alarm occurs in the N-Axis.

15

LED indication


Abnormal Control Power Supply

[Action 1 ］

Disconnect the pulse coder cable(JF*) from the servo amplifier, and then s witch on the power. <1> If blinking continues Replace the servo amplifier. <2> If blinking stops Go to [Action 2]

（Blinking）

[Action 2 ］

Disconnect the pulse coder cable(JF*) from the pulse coder, and then switch on the power.(Keep the cable on the servo amplifier side connected.) <1> If blinking continues Replace the cable. <2> If blinking stops Replace the motor.

[Explanation]

FSSB communication error.

[Action 1 ］

Replace the optical cable(COP10B) that is the nearest to the main board on which “U” is displayed.(In Fig 3.1,the cable between UNIT2 and UNIT 3.)

[Action 2 ］

Replace the servo amplifier that is the nearest to the main board on which “U” is displayed.(In Fig 3.1, UNIT 3)

[Action 3 ］

Replace the servo amplifier that is the farthest to the main board on which “L” is displayed.(In Fig 3.1, UNIT 3)

[Action 4 ］

Replace the servo card or the auxiliary axis servo card that is indicated by the alarm.

Alarm “U” means FSSB communication error of COP10B side. Alarm “L” means FSSB communication error of COP10A side. Note: When the robot controller is turn on, “U” blinks momentarily, and then “-“ steadily lights. This is normal.

Fig. 3.1 LED indication “U”,”L”

16

4. Replacing Unit 4.1 Replacing the servo amplifier (a) Detach the cable from the servo amplifier (b) Remove retaining screws and replace the servo amplifier (c) Reconnect the cables.

Fig. 4.1.1 Replacing the servo amplifier of B-cabinet

17

Fig.4.1.2 Replace the servo amplifier of Auxiliary axis cabinet

18

4.2 Replacing the fuse of the servo amplifier There is one fuse on the servo amplifier printed-circuit board. Fuse specification FU1: A60L-0001-0290/LM32C

Fig. 4.2 Replacing the fuse of the servo amplifier

Caution: In case this fuse is blown, replace the amplifier because it is likely that this servo amplifier has some defect.

19

4.3 Replacing the fuse on the brake unit There is one fuse to protect brake circuit on the brake unit. Fuse specification FUSE1: A60L-0001-0101/P420H

FUSE1

Fig. 4.3.1 Replacing the fuse on the brake unit

This fuse has a window to indicate whether the fuse is blown or not. When the fuse is blown, a white metal piece appears on the window.

2

A

Alarm Window Normal: semitransparent Fuse blown: a white metal piece appears

250V

Fig. 4.3.2 Alarm window of the brake fuse. Caution: If this fuse is blown, brake circuit (brake cable for example) may have some defect. So, replace the fuse after repairing the failure.

20

4.4 Replacing the internal fan motor of the servo amplifier (a) Holding the two lugs on the fan unit, lift the fan unit in the direction of the arrow (toward the right in the figure). When replacing the fan motor, pay attention to its orientation and the orientation of the connector.

Fig.4.4. Replace the internal fan motor of the servo amplifier

21

4.5 Replacing the external fan of the servo amplifier (a) Remove the fan motor mounting screws (two for one fan motor and four for two fan motors. (b) Remove the connector mounting screws (two)

Fig.4.5 Replacing the external fan of the servo amplifier

22

4.6 Replacing the battery (a) Remove the top panel. (b) Do not make a mistake on polarity when replace the battery. (c) Close the battery unit panel (Note 1) Before you replace the batteries, turn on the controller power and press an emergency stop switch. If you replace the batteries with controller power off, the current motor position will be lost. (Note 2) Change batteries (Size D battery 4) every 18 months. (Note 3) The auxiliary axis battery box location shown might be different depending upon your application.

. Figure 4.6.1 Replacing the battery of B-cabinet

23

Fig.4.6.2 Replacing the battery of Aux. Axis cabinet

24

5 5 .1 . C F o o n r n B e - c t C i a o b n i n C e a t b l e .

2 5

2 6

2 7

5 .2 F o r A - C a b i n e t

2 8

2 9

3 0

(Note)

(Note) Battery at the mechanical unit is used in case ARP/ARM cable is used.

6 6 .1 . T T o o t a t a l l c o c o n n n n e e c c t i t i o n o n d d a i i g a g r r a a m m o f B - c a b i n e t ( w i t h o u t B r a k e U n i t )

(Note)

3 1


6 .2 ( w T i o t t h a l B c r o a n k n e e U c t i n o i t n d ( A i 0 a 5 g r B a - 2 m 4 8 o 5 f - B J - 4 c 0 a b 0 i / A n 0 e 5 t B - 2 4 5 2 - C 2 6 0 ) )

(Note)

3 2


6 . 3 ( w T i o t t h a l B c r o a n k n e e U c t i n o i t n d ( A i 0 a 5 g r B a - 2 m 4 8 o 5 f - B J - 4 c 0 a b 1 i / A n 0 e 5 t B - 2 4 5 2 - C 2 6 1 ) )

(Note)

3 3


6 .4 ( w T i o t t h a l B c r o a n k n e e U c t i n o i t n d ( A i 0 a 5 g r B a - 2 m 4 8 o 5 f - B J - 4 c 0 a b 2 i / A n 0 e 5 t B - 2 4 5 2 - C 2 6 2 ) )

6 . 5 T o t a l c o n n e c t i o n d i a g r a m o f A - c a b i n e t 3 4

(Note)


6 . 6 T o t a l c o n n e c t i o n d i a g r a m o f B r a k e U n i t （ 3 5

A 0 5 B - 2 4 8 5 - J 4 0 0 / A 0 5 B - 2 4 5 2 - C 2 6 0

）


A 0 5 B - 2 4 8 5 - J 4 0 1 / A 0 5 B - 2 4 5 2 - C 2 6 1

）


A 0 5 B - 2 4 8 5 - J 4 0 2 / A 0 5 B - 2 4 5 2 - C 2 6 2

）

7.Setting the brake number of the auxiliary axis. The auxiliary axis brake has a number that is set by the software as follows. Brake Number 1 2 3 4

Connector Note CRR65A/CRR65B on the 6-axis servo Same brake timing as the robot. amplifier Use this group for the axis with CRR65C on the brake unit. (2 circuits) gun-change function. CRR65D on the brake unit. (2 circuits) Reserve

Table 7. Setting the brake number of the auxiliary axis.

38

Chapter 2

R-J3iB/B-cabinet Auxiliary Axis Option with alpha Motor/Amplifier Maintenance Manual 1. Application This manual is supplement for Auxiliary Axis Option of R-J3iB/B-cabinet. Refer to the R-J3iB maintenance manual (B-81465 or B-81505) for general maintenance description. 2. Assembly 2.1 B-cabinet

Fig.2.1 B-cabinet

41

2 .2 B r a k e U n i t

4 2

F i g .2 .2 B r a k e U n i t ( f o r t h e g u n c h a n g e s y s t e m )

BRAKE UNIT FOR THE GUN CHANGE SYSTEM (A05B-2452-C250)

4 3

F i g .2 . 3 B r a k e U n i t

BRAKE UNIT (A05B-2452-C251)

3. Troubleshooting 3.1 Troubleshooting using error code SRVO-21 SVAL1 SRDY Off (Group:i Axis:j) [Explanation]


[Action 3] [Action 4] [Action 5] [Action 6] [Action 7] [Action 8] [Action 9]

The HRDY is on and the SRDY is off, although there is no other cause of an alarm. (HRDY is a signal with which the host detects the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on.) If the servo amplifier magnetic contactor cannot be turned on when directed so, it is most likely that an amplifier alarm has been detected, the host will not issue this alarm (SRDY off). Therefore, this alarm indicates that the magnetic contactor cannot be turned for an unknown reason. Make sure the all cable connections to the all servo amplifier are connected tightly. Especially check the optical fiber cables. And make sure that the CP2, CRM73, CNMC2 and CNMC3 of the E-stop unit are connected tightly. Check whether an outage has occurred on an emergency stop line (teach pendant emergency stop, teach pendant enable/disable switch, external emergency stop input, fence input, servo off – input, or door switch). This alarm occurs if the alarm cause cannot be detected by the software because of a short break and magnetic contactor off. Check the RP1 cable of robot connection cable and the pulse coder cable for the auxiliary axis (+5V ground fault). Replace the servo amplifier indicated in the alarm massage. Replace the E-stop unit. Replace the cable between the E-stop unit and the panel board. Replace the cable between the E-stop unit and the servo amplifier. Replace the axis control card on the main board or the auxiliary axis board in the backplane indicated in the alarm message. Replace the brake unit.

SRVO-22 SVAL1 SRDY On (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

When the HRDY is about go on, the SRDY is already on. Replace the servo card indicated in the alarm message. Replace the servo amplifier that indicated in the alarm massage.

44

SRVO-23 SVAL1 Stop error excess (Group:i Axis:j) [Explanation] [Action 1]

When the servo is stopped, the position error is abnormally large. Check whether the motor brake has been released. If the motor brake of the auxiliary axis is not released, Check the continuity of the brake power cable and brake coil. Check if there is no short circuit or grounding fault on the brake power cable. Check if FUSE1 on the brake unit is not brown. ( If it was brown, brake cable may be faulty) Make sure that the servo amplifier CNJ1A to CNJ6 are connected tightly. Check to see if the load is greater than the rating. If greater, reduce it to within the rating. (If the load is too greater, the torque required for acceleration / deceleration becomes higher than the capacity of the motor. As a result, the motor becomes unable to follow the command, and an alarm is issued. Check each phase voltage of the CRR38A or CRR38B connector of the three-phase power (200VAC) input to the servo amplifier. If it is 170 VAC or lower, check the line voltage. (If the voltage input to the servo amplifier becomes low, the torque output also becomes low. As a result the motor may become unable to follow the command, hence possibly an alarm.) If the line voltage is 170VAC or higher, replace the servo amplifier that indicated by the alarm message. Check the disconnection of motor power cable (RM1, RM2 or power cable of auxiliary axis cable). Replace the brake unit. Replace the servo amplifier indicated in the alarm massage. Replace the motor. • • •


[Action 4]

[Action 5] [Action 6] [Action 7] [Action 8] [Action 9]

SRVO-24 SVAL1 Move error excess (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

When the robot is running, its position error is greater than a specified value ($PARAM_GROUP. $MOVER_OFFST or $PARAM_GROUP.$TRKERRLIM).It is likely that the robot cannot follow the speed specified by program. Check the robot for blind axis. Take the same actions as SRVO-23 alarm.

SRVO-36 SVAL1 Inpos time over (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

The robot did not get to the effective area ($PARAM_GROUP_$INPOS TIME) even after the position check monitoring time ($PARAM_GROUP.$STOPTOL) elapsed. Check the robot for blind axis. Take the same actions as for SRVO-23 (large position error at a stop) .

45

SRVO-38 SVAL2 Pulse count mismatch (Group:i Axis:j) [Explanation] [Action]

The pulse count obtained when power is turned off does not match the count obtained when the power is applied. 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. Perform APC reset and remaster robot (RES-PCA) 1. Press MENUS 2. Select SYSTEM 3. Press F1 [TYPE] 4. Select MASTER/CAL 5. Press F3, PES-PCA 6. Press RESET The fault condition should reset. If the controller is still faulted with additional servorelated errors , cold start the controller . It might be necessary to remaster the robot.

SRVO-42 SVAL1 MCAL alarm (Group:i Axis:j) [Explanation]

[Action 1]


This alarm means that the contacts of the magnetic contactor have stuck each other. The alarm condition occurs if the magnetic contactor turns out to be already on when an attempt is made to turn it on. The alarm condition is detected between the time contact sticking occurs and the time attempt is made to turn on the magnetic contactor. Check the magnetic contactor , and replace it if necessary . If the contacts of magnetic contactor have stuck to each other, turn off the circuit breaker. If the power switched off without turning off the circuit breaker, the servo amplifier may get damaged, because the stuck contacts keep three-phase 200VAC applied to the servo amplifier. Replace the E-stop unit. Replace the servo amplifier indicated in the alarm message.

46

SRVO-43 SVAL1 DCAL alarm (Group:i Axis:j) [Explanation]

[Action 1]


[Action 5]

[Action 6]

The regenerative discharge energy was too high to be dissipated as heat. (To run the robot, the servo amplifier supplies energy to the robot . When going down the vertical axis, the robot operates from the potential energy. If a reduction in the potential energy is higher than the energy needed for acceleration, the servo amplifier receives energy from the motor. A similar phenomenon occurs even when no gravity is applied, for example, at deceleration on a horizontal axis. The energy that the servo amplifier receives from the motor is called the regenerative energy. The servo amplifier dissipates this energy as heat. If the regenerative energy is higher than the energy dissipated as heat, the difference is stored in the servo amplifier, causing an alarm.) "8" is display on the servo segment LED of the servo amplifier. Check the magnetic contactor , and replace it if necessary . If the contacts of magnetic contactor have stuck to each other, turn off the circuit breaker. If the power switched off without turning off the circuit breaker, the servo amplifier may get damaged, because the stuck contacts keep three-phase 200V applied to the servo amplifier. Check FS3 in the servo amplifier. If it has brown, remove the cause, and replace the fuse. One of the probable causes of a blown fuse is a ground fault in the servo amplifier for auxiliary axis. Check the fan unit under the 6-ch servo amplifier, and replace it if necessary. Make sure that the servo amplifier CRR63A, CRR63B and CRR63C are connected tightly, then detach the cable from CRR63A, CRR63B and CRR63C connector on the emergency stop board, and check for continuity between pins 1 and 2 of cable-end connector. If there is no continuity between the pins, replace the regenerative resistor. Make sure that the 6-ch servo amplifier CRR45A, CRR45B and CRR45C are connected tightly then detach the cables from CRR45A, CRR45B and CRR45C on the servo amplifier, and the check the resistance between pins 1 and 2 of each cable-end connector. If the resistance is not 9-16 Ω, replace the regenerative resistor. Replace the servo amplifier indicated in the alarm message.

47

SRVO-44 SVAL1 HVAL alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

[Action 3]

The DC voltage (DC link voltage) of main circuit power supply is abnormally high. Check the three-phase input voltage at the servo amplifier. If it is 253 VAC or higher, check the line voltage. (If the three-phase input voltage is higher than 253 VAC , high acceleration/deceleration can result in this alarm.) Check that the load weight is within the rating. If it is higher than the rating, reduce it to within the rating. (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.) Replace the servo amplifier indicated by the alarm message.

SRVO-45 SVAL1 HCAL alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

[Action 3]

Abnormally high current flowed in the main circuit of the servo amplifier. Disconnect the robot connection cable (RM1, RM2) and power cable of auxiliary axis motor cable from servo amplifier. Supply power and see if the alarm occurs again. If alarm occurs , replace the servo amplifier indicated by the alarm message. Disconnect the robot connection cable (motor power) from the servo amplifier connector (CNJ**) and power cable of auxiliary axis cable, and check insulation of their U, V or W and the GND line. If there is a short-circuit, the motor, robot connection cable, intra-robot cable or power cable of auxiliary axis cable is defective. Check them and replace them if necessary. Disconnect the robot connection cable (motor power) from the servo amplifier connector (CNJ**) and power cable of auxiliary axis cable, and measure the resistance between their U and V, V and W, and W and U with a ohmmeter with a very low resistance range. If the resistances at the three places are different from each other, the motor , robot connection cable, intra-robot cable or power cable of auxiliary axis cable is defective. Check each item in detail and replace it if necessary.

SRVO-46 SVAL1 OVC alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2] [Action 3]

This alarm is issued to prevent the motor from thermal damage that might occur when the root mean square current calculated within the servo system is out of the allowable range. Check the operating conditions for the robot and relax the service conditions. Check each phase voltage of the three-phase input power (200VAC for the servo amplifier. If it is 170VAC or lower, check the line voltage. Check whether the motor brake has been released. If the motor brake of the auxiliary axis is not released, Check the continuity of the brake power cable and brake coil. Check if there is no short circuit or grounding fault on the brake power cable. Check if FUSE1 on the brake unit is not brown. ( If it was brown, brake cable may be faulty) Replace the servo amplifier indicated in the alarm message. Check the robot connection cable (RM1, RM2) and power cable of auxiliary axis cable. If any problems are found in the cables, replace the cables. Replace the motor. • • •


48

SRVO-47 SVAL1 LVAL alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

The control power supply voltage (+5V, etc) supplied from the power supply circuit in the servo amplifier is abnormally low. Replace the servo amplifier indicated in the alarm message. Replace the power supply unit.

SRVO-49 SVAL1 OHAL1 alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2] [Action 3] [Action 4] [Action 5] [Action 6] [Action 7]

The thermostat in the transformer worked. Alternatively, fuse F1 or F2 in the servo amplifier has blown. Make sure that the CRM73 connector of the E-stop unit is connected tightly. Check the operating conditions for the robot and relax the service conditions. If fuses F1 and F2 have blown, replace the servo amplifier. If the fan motor in the cabinet is not running, check it and its cables. Replace it if necessary. Check the fan motor of the auxiliary axis servo amplifier. Replace it if necessary. Replace the auxiliary axis servo amplifier. Replace the transformer.

SRVO-50 SVAL1 CLALM alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2] [Action 3]

[Action 4]

The disturbance torque estimated by the servo software is abnormally high. (A collision has been detected.) Check that the robot has collided with anything. If it has, reset the robot and jog-feed it to recover from the collision Make sure that the load setting is correct. Check that the load weight is within the rating. If it is higher than the rating . reduce it to within the rating. (If the robot is used out of its usable range, the estimated disturbance torque becomes abnormally high, possibly resulting in this alarm being detected.) Check whether the motor brake has been released. If the motor brake of the auxiliary axis is not released, Check the continuity of the brake power cable and brake coil. Check if there is no short circuit or grounding fault on the brake power cable. Check if FUSE1 on the brake unit is not brown. ( If it was brown, brake cable may be faulty) Check the phase voltage of the three-phase input power (200VAC) to the servo amplifier. If it is 170 VAC or lower, check the line voltage. Replace the servo amplifier Replace the motor. • • •

[Action 5] [Action 6] [Action 7].

SRVO-51 SVAL2 CUER alarm (Group:i Axis:j) [Explanation] [Action 1]

The offset of the current feedback value is abnormally high. Replace the servo amplifier indicated in the alarm message.

49

SRVO-55 SVAL2 FSSB com error 1 (Group:i Axis:j) [Explanation] [Action 1] [Action 2] [Action 3]

A communication error has occurred between the main board and servo amplifier (from main board to servo amplifier). Check the communication cable (optical fiber) between the main board and the servo amplifier. Replace it if it is faulty. Replace the axis control card on the main board or the auxiliary axis board in the backplane indicated in the alarm message. Replace the servo amplifier indicated in the alarm message. Before continuing the next step, perform a complete controller back up to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data.

[Action 4]


SRVO-56 SVAL2 FSSB com error 2 (Group:i Axis:j) [Explanation] [Action ]

A communication error has occurred between the main board and servo amplifier (From servo amplifier to main board). Take the same actions as SRVO-55 alarm.

SRVO-57 SVAL2 FSSB disconnect (Group:i Axis:j) [Explanation] [Action 1] [Action 2] [Action 3] [Action 4] [Action 5]

Communication was interrupted between the main board and servo amplifier. Check whether fuse F3 in the power supply unit has blown. Check whether fuse FS1 in the servo amplifier has blown. Check the communication cable (optical fiber) between the main board and the servo amplifier. Replace it if it is faulty. Replace the axis control card on the main board or the auxiliary axis board in the backplane indicated in the alarm message. Replace the servo amplifier indicated by the alarm message. Before continuing the next step, perform a complete controller back up to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data.


Replace the main board. Check the RP1 cable of robot connection cable and the pulse coder cable for the auxiliary axis (+5V ground fault).

50

SRVO-58 SVAL2 FSSB init error (Group:i Axis:j) [Explanation] [Action 1] [Action 2] [Action 3] [Action 4] [Action 5] [Action 6]

Communication was interrupted between the main board and servo amplifier. Check whether fuse F3 in the power supply and fuse FS1 in the servo amplifier has blown, see Section 3.6 ,”Troubleshooting for Blown fuse “ of the R-J3iB control unit maintenance manual. Check whether LEDs (P5V and P3.3V) on the servo amplifier are on. If they are on, perform “Action 4” and all actions that follow it. If they are not on , perform “Action 3” and all actions that follow it. 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. Check the communication cable (optical fiber) between the main board and the servo amplifier. Replace it if it is faulty. Replace the axis control card on the main board or the auxiliary axis board in the backplane indicated in the alarm message. Replace the servo amplifier indicated by the alarm message. Before continuing the next step, perform a complete controller back up to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data.

[Action 7]


SRVO-061 SVAL2 OKAL alarm (Group:i Axis:j) SRVO-062 SVAL2 BZAL alarm (Group:i Axis:j) SRVO-063 SVAL2 RCAL alarm (Group:i Axis:j) SRVO-064 SVAL2 PAHL alarm (Group:i Axis:j) SRVO-065 WARN BLAL alarm (Group:i Axis:j) SRVO-066 SVAL2 CSAL alarm (Group:i Axis:j) SRVO-067 SVAL2 OHAL2 alarm (Group:i Axis:j) SRVO-068 SVAL2 DTERR alarm (Group:i Axis:j) SRVO-069 SVAL2 CRCERR alarm (Group:i Axis:j) SRVO-070 SVAL2 STBERR alarm (Group:i Axis:j) SRVO-071 SVAL2 SPHAL alarm (Group:i Axis:j) SRVO-072 SVAL2 PMAL alarm (Group:i Axis:j) SRVO-073 SVAL2 CMAL alarm (Group:i Axis:j) SRVO-074 SVAL2 LDAL alarm (Group:i Axis:j) Refer to the R-J3iB controller maintenance manual.

51

SRVO-135 SVAL2 FSAL alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

Faulty of the internal fan motor of the auxiliary axis servo amplifier. Replace the internal fan motor of the auxiliary servo amplifier indicated by the alarm message. Replace the auxiliary servo amplifier indicated by the alarm message.

SRVO-136 SVAL1 DCLVAL alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2] [Action 1] [Action 2] [Action 3] [Action 4]

The servo the DC current of amplifier (DC link voltage) of the main power supply is abnormally low. -This alarm occurred in the robot operation: Check the phase voltage of the three-phase input power (200VAC) to the servo amplifier. If it is 170 VAC or lower, check the line voltage. Replace the servo amplifier. -This alarm occurs before the magnetic contactor is turn on: Check whether the circuit breaker in the emergency stop unit is OFF. If it is OFF, check the servo amplifier and the wiring between the servo amplifier and the emergency stop unit. If anything is abnormal, replace it. Check each phase-to-phase voltage of the three-phase input (200 VAC) on the primary side of the magnetic contactor. If the input is not higher than 170VAC, check the input power supply voltage. Replace the E-stop unit. Replace the servo amplifier indicated by the alarm message.

SRVO-156 SVAL1 IPMAL alarm (Group:i Axis:j) [Explanation] [Action 1]

[Action 2]

[Action 3]

Abnormally high current flowed through the main circuit of the servo amplifier. Disconnect the robot connection cable (RM1, RM2) and power cable of auxiliary axis motor cable from servo amplifier. Switch on the power, and then check to see if the alarm occurs again. If alarm occurs, replace the servo amplifier indicated in the alarm message. Disconnect the robot connection cable (motor power) from the servo amplifier connector (CNJ**) and power cable of auxiliary axis cable, and check for insulation between each motor power line (U, V, or W) and ground potential (GND). If there is a short-circuit, the motor , robot connection cable, intra-robot cable or power cable of auxiliary axis cable is defective. Check them and replace them if necessary. Disconnect the robot connection cable (motor power) from the servo amplifier connector (CNJ**) and power cable of auxiliary axis cable, and measure the resistance between their U and V, V and W and W and V with an ohmmeter with a very low resistance range. If these resistances are different from each other, the motor, robot connection cable, intra-robot cable or power cable of auxiliary axis cable is defective. Check each item in detail and replace it if necessary.

52

SRVO-290 DC LINK HC alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2]

[Action 3]

DC link current of the servo amplifier is abnormal Disconnect the robot connection cable (RM1, RM2) and power cable of auxiliary axis motor cable from servo amplifier. Supply power and see if the alarm occurs again. If alarm occurs , replace the servo amplifier indicated by the alarm message. Disconnect the robot connection cable (motor power) from the servo amplifier connector (CNJ**) and power cable of auxiliary axis cable, and check insulation of their U, V or W and the GND line. If there is a short-circuit, the motor, robot connection cable, intra-robot cable or power cable of auxiliary axis cable is defective. Check them and replace them if necessary. Disconnect the robot connection cable (motor power) from the servo amplifier connector (CNJ**) and power cable of auxiliary axis cable, and measure the resistance between their U and V, V and W and W and V with an ohmmeter with a very low resistance range. If these resistances are different from each other, the motor, robot connection cable, intra-robot cable or power cable of auxiliary axis cable is defective. Check each item in detail and replace it if necessary. Before continuing the next step, perform a complete controller back up to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data.

[Action 4]


SRVO-291 SVAL1 IMP over heat alarm (Group:i Axis:j) [Explanation] [Action 1] [Action 2] [Action 3]

The IPM in the servo amplifier overheats Check whether the amplifier fan stops. Reduce the override because the use condition is too hard. If this alarm is frequency issued, replace the servo amplifier.

SRVO-292 SVAL1 EXT fan alarm (Group:i Axis:j) [Explanation] [Action 1]

The external fan of the auxiliary axis servo amplifier amplifier is faulty. Replace the external fan of the auxiliary axis servo amplifier.

53

3.2 Troubleshooting based on LED indication.

７ segment LED

LED indication

Description [Explanation] [Explanation]

Internal cooling fan is stopped.

[Action 1 ］

Check whether there is any foreign material in the fan

[Action 2]

Check that the fan connector is attached correctly.

[Action 3]

Replace the fan.

[Action 4]


[Explanation]

Control power supply undervoltage undervoltage

[Action 1 ］

Check the three-phase input voltage of the amplifier (the voltage shall not be lower than 85% of the rated input voltage)

[Action 2]

Check the 24V power supply voltage output from the 6-ch servo amplifier (The voltage shall normally not lower than 22.8V).

[Action 3]

Check the connector and cable (CXA2A/B).

[Action 4]


[Explanation]

DC link undervoltage undervoltage

[Action 1]

Check that the screws for the DC link connection cable (bar) are tight.

[Action 2]

If DC link low voltage alarm occurs in both 6-ch servo amplifier and the auxiliary axis servo amplifier, replace the 6-ch servo amplifier.

[Action 3]

If DC link low voltage alarm occurs in only one servo amplifier, replace that servo amplifier.

54

LED indication

Description

[Explanation] [Explanatio n]

Abnormal Current Alarms

[Action 1]

Remove the power line wires form terminals, and release an emergency stop state. <1> If an abnormal current alarm is issued, the servo amplifier needs to be replaced. <2> If not, go to [Action 2].

[Action 2]

Check for the insulation insulatio n between PE and each of the removed power wires U, V and W. If the insulation is not perfect, disconnect the power wires from the motor connector. Then check for insulation between PE and each of the U, V and W terminals on the motor. <1> If there is a short-circuit between PE and U, V and W of the motor, replace the motor. <2> If the insulation of the motor is perfect, replace the power wires.

55

LED indication


IPM Alarms (Note that these codes simultaneously with a period)

[Action 1]

are

displayed

Wait for about 10 minutes. Then release the emergency stop state. If IPM alarm still occurs, go to [Action 2] If the cause is IPM overheat, the IPM alarm will not recur. IPM overheat can occur if the ambient temperature is high or the motor is overloaded. Check the operating condition.

[Action 2]

Remove the power wires from the amplifier terminals, and release an emergency stop state. If the IPM alarm does not recur, go to [Action 3]. If the IPM alarm recurs, the probable cause is the operation of the IPM protective function (for overcurrent or power failure). Replace the amplifier, and if the IPM alarm does not recur, go to [Action 3].

[Action 3]

Check for the insulation between PE and each of the removed power wires U, V and W. If the insulation is not perfect, disconnect the power wires from the motor connector. Then check for insulation between PE and each of the U, V and W terminals on the motor. <1> If there is a short-circuit between PE and U, V and W of the motor, replace the motor. <2> If the insulation of the motor is perfect, replace the power wires.

56

4. Replacing Unit 4.1 Replacing the servo amplifier (d) Detach the cable from the servo amplifier (e) Remove retaining screws and replace the servo amplifier (f) Reconnect the cables.

Fig. 4.1. Replacing the servo amplifier

57

4.2 Replacing the fuse on the servo amplifier There is one fuse for the 24V control power on the servo amplifier printed-circuit board. Fuse specification FU1: A60L-0001-0290/LM32C

Fig. 4.2 Replacing the fuse on the servo amplifier

58

4.3 Replacing the fuse on the brake unit There is one fuse to protect brake circuit on the brake unit. Fuse specification FUSE1: A60L-0001-0101/P420H FUSE1

Fig. 4.3 Replacing the fuse on the brake unit This fuse has a window to indicate whether the fuse is blown or not. When the fuse is blown, a white metal piece appears on the window. 2

A

250V

Alarm Window Normal: semitransparent Fuse blown: a white metal piece appears

Fig. 4.4 Alarm window of the brake fuse

59

4.4 Replacing the battery 1. Remove the top panel. 2. Do not make a mistake on the polarity when replace the battery. 3. Close the battery unit panel (Note 1) When replacing the battery, turning on the control unit and the emergency switch. If replacing the battery in turning off the power , the current positions of the motors are lost. (Note 2) Change to new battery annually.

Fig 4.5 Replace the battery.

60

5. Connection Cable

61

6 . T o t a l C i r c u i t

6 2

In case of A05B-2487-J402

6 3


6 4


Chapter 3

Chapter 3 The Local Stop Option

Contents

Ch ap ter 3 3.1 3.2 3.3 3.4 3.5

............................................................................ L oc al St op Op ti on Ov er vi ew ...................................................................... L ocal St op K it A ssem bl ies ......................................................................... Co nn ec t io n an d Cab i net Mo un ti n g Di ag r am s ............................................ A rc Wel di n g A pp l ic at i on Co nn ec ti o n Dr aw i ng s ......................................... Parts List ................................................................................................... Th e L oc al St op Op ti on

3– 1 3– 2 3– 5 3– 8 3–14 3–21

3–1

3. Th e L oc al St op Op ti on

This chapter provides hardware information on the optional FANUC Robotics Local Stop Printed Circuit Board (PCB). Images of the Local Stop PCB and circuit diagrams are provided. For information on how to set up your Local Stop hardware refer to the Setting Up Local Stop Software Procedure in the FANUC Robotics SYSTEM R-J3iB Controller Software Installation Manual.

3.1 Local Stop Option Overview The Local Stop Option allows you to stop an auxiliary axis without shutting down the controller. This function can be performed while maintaining compliance to the ANSI/RIA R15.06 — 1999 standard. See Figure 3– 1.

Fi gu re 3–1. L oc al St op Pr in ted Ci rc ui t B oar d

Figure 3–2. illustrates an Arc Welding System with one robot and two headstock positioners. Each positioner uses a single auxiliary axis motor and is controlled by separate motion groups. In this

3–2


application, an operator is loading or unloading a part on one headstock positioner while the robot and other positioner continue to run. The Local Stop Unit protects the operator by disconnecting the motor power from the desired headstock positioner and preventing accidental movement. By using the Local Stop Unit to only deactivate the required motion group, the robot and the other auxiliary axis can continue to run production. This facilitates the safe loading and unloading of parts in your robotic system. The Light Curtain on the load/unload side of the positioner is bypassed when the Local Stop Unit is activated. This allows the operator to enter the work cell and manipulate the work piece. All other safety signals are active and independent of the Local Stop Unit. Each auxiliary axis motion group is required to have a Local Stop Unit if an operator will be interacting with that motion group during production. A Local Stop Unit can only control one motion group, but that motion group can control up to two axis. Up to three auxiliary axis motion groups can be added to a robot system. If an auxiliary axis motor is in a system and has no interaction with an operator during production, it might not require a Local Stop Unit.

Ex am pl es o f t hi s t yp e o f s ys tem i nc lu de:

• Robot rails or booms that use zone switches in conjunction with light curtains • Headstock positioners that are robotically loaded or unloaded and only require operator interaction during maintenance when the entire system can be locked out

3–3

3. Th e L oc al St op Op ti on Fi gu re 3–2. Ty pi cal A rc Wel di ng Ro bo ti c Sy st em

3–4


3.2 L ocal St op K it A ssem bl ies There are four Local Stop Kits that can be combined for different applications. The type of kit required is based upon how many auxiliary amplifiers your system is using, the number of axes (channels) you plan to drive in each motion group, the number of motion groups in the robot system and the type of connector (XX or XY) you require. The XX connector is for channel one on a single or dual channel amplifier and the XY connector is for channel two of a dual channel amplifier. Refer to Table 3–1 for more information and Figure 3–3 for an illustration. Figure 3–4 contains a generic connection block diagram of the Local Stop PCB. Tab le 3–1. L oc al St op K it s Part Number

Type For Configuration

EE-4707–020

(1) Auxiliary Amplifier, (1) Channel and (1) XX Connection

EE-4707–021

(2) Auxiliary Amplifier, (1) Channel each and (2) XX Connections

EE-4707–022

(1) Auxiliary Amplifier, (2) Channels and (1) XX and (1) XY Connection

EE-4707–023

(1) Auxiliary Amplifier, (2) Channels and (1) XY Connection

3–5

3. Th e L oc al St op Op ti on Fi gu re 3–3. L oc al St op PCB Il lu st rat io n EE-4707-006 1

1 7 2 7 1 1 7 1 2 P O S .

1

S O 1 P N C 3 P Y M E A

T B 1

2 6 3 1 8 7 1 2

K Y

1

S O 2 P N 3 C P M Y A E

1

2 6 3 1 8 7 1 2

K Y

1 7 2 7 1 1 7 1 2 P O S .

T B 2

1

2 P 3 M 1 3 N A 3 8 C 7 1 Y 1 E K - y X

1 1 7 2 7 0 9 4 1 0 P O S .

T B 3

3 9 0 0 W . H a m l i n R d . R o c h e s t e r H i l l s , M I 4 8 3 0 9

X -K

-1 7 8 1 3 6 -2

A E M Y P 3 C -P N 5 O S 1

1

F S A

E E M - a 3 2 d 8 e 5 I - n 8 0 U 0 S - A 1 5 8

S

E S R S I ’ Y A R L N N O J O : 1 3 i A B :

4 O P N C 3 P Y M E A

M L P O / 2 C n d A L C S H T N O L P X U Y N O I T P # T I O R N

K X

E X E X -4 X 7 X 0 X 7 X 0 X 0 X 6 X X X X X

1 7 3 0 4 2 1

4 B T 1

E V :

1

MADE IN USA

LC1D2501 CONTACTOR W/LA1DN04 AUX. CONTACT

P M A

S 7 G

B N 2 A O 2 - B R A 1 S A M 7 3 O G A

S 7 G

B N 2 A O 2 - B R A 1 S A M 7 3 O G A

S 7 G 7 1 1 7 2 7 1

SIDE VIEW

3–6

F R O N T 1 7 3 0 4 2 1

5 B T

B N 2 A O 2 - B R A 1 S A M 7 3 O G A

2 6 3 1 8 7 1 1

F R O N T

R-J3iB LOCAL STOP UNIT 1 AMP-2nd CHNL XY OPTION DIN RAIL SUB-ASS’Y

3. Th e L oc al St op Op ti on Fi gu re 3–4. L oc al St op PCB — Co nn ec ti on B lo ck Di ag ram

Local Stop PCB Connection Block Diagram (Refer to the Connection Diagrams portion of the manual for detailed drawings)

100VAC Transformer

R-J3iB Local Stop PCB E-Stop PCB TB8

CP2

CN1

CN4

Brake

200VAC (200VAC for additional Local Stop PCBs)

CP5A

(Brakes for additional motors)

CN2

CN5

CN3 100VAC (Aux. Contact Required)

TB3

MCC

Operator Panel PCB

(Daisy Chain for additional Local Stop PCBs)

TBOB4

TB1

TB1

(External E-Stop Customer Inputs) (Local Stop Customer Inputs)

6 Channel Servo Amplifier CRM39

TB2

TB7

(To additional Local Stop PCBs)

CRF7

Contactor KA4

SVMi Amplifier DC Link

CXA2A

CXA2B

XX

XX

Power

JF1 Encoder Motor

3–7


3.3 Connection and Cabinet Mounting Diagrams This section provides standard configuration illustrations of the Local Stop Option.

3–8

ESTOP PC BD

EE-4707-016-001

EE-4707-017-001

*

CP2

EE-4707-020

RJ3iB LOCAL STOP PBD

*

CN1

XX UNIT PC BOARD ROADMAP FOR SINGLE MOTOR DRIVE

KA1

200VAC IN

KA1

CN1 CP5A

EE-4707-012-001 CN2

TO MOTOR BRAKE CONN

CN4

BRK+

TB8

#

2

* AUX. CONTACT REQUIRED

7

MCC

1

1

EES1

2

EES11

3

EES2

3

4

EES21

4

EE-4707-009-001

CRM39

EE-4707-013-001

*BRKRLS3 0V

EES2

BEES2

7

EES21

BEES21

8

LS1

9

LS11

10

LS2

11

LS21

12

KA3

EES OUT TB

} }

EXTERNAL E-STOP* CUSTOMER INPUTS

*-JUMPER WHEN NOT IN USE LOCAL STOP* CUSTOMER INPUTS

24V

4

A3

5

B1

6 7 4

6

2 3

CUSTOMER SUPPLIED LOCAL STOP REQUEST INPUT

A2

5

1

SAFE TO ENTER

*

A1

BEES1 BEES11

TB2

#

#

6 CHANNEL AMP

*BRKRLS2

TB1

EES1 EES11

EE-4707-010-001

*BRKRLS1

TB1

2

24V

0V

24V

2

DAISY CHAIN TO TB3 PIN 2 OF ALL SUBSEQUENTLOCAL STOP PCBUNITS (PART OF EE-4707-012-001)

10

1

DI

DI

BRK-

TB3

9 TBOP4

BRK+

D4

~ -

EE-4707-014-001

8

PANEL BD

CN5

KA3

CN3

5

100VAC

KA2 ~ +

IN 100B

6

XFMR

DB3

IN 100A

4

200VAC

FU1 2A

CN3

3

A80L-0010-0071 1/CONTROLLER

BRK-

CN2 EE-4707-008-001

1

24V KA1 24V

1 8 TB7 D6 R6

0V

0V

*BRKRLS1

9

D2

KA2

BRK REL

0V

KA1

LOCAL STOP PCB #2 LOCAL STOP PCB #3

CRF7 38 RDO6 22 RDI4 21 RDI3 39 RDO7 24

1

LOCAL STOP REQUEST

3

MOTOR(S) DISCONNECTED

2

MOTOR ON COMMAND

1

LOCAL STOP REQUEST

3


2

MOTOR ON COMMAND

1

10

26

LOCAL STOP REQUEST

3

11

25


2

12

RDI8

EE-4707-011-001

*

CXA2A 0V A2,B2 *ESP

A4

LOCAL STOP PCB #2

D5 R5 D1

KA1

MTR ON

MOTOR DISCONNECTED

KA2 DB1

SVMi AMPLIFIER EE-4707-015-001

#

HV

24V A1,B1

LOCAL STOP PCB #3

40

RDI5

DC LINK

} }

23

RDI6

RDO8

RDI7

MOTOR ON COMMAND

7 R 7 D

D3

KA3

CXA2B

MOV1

R1

R8

R2

C1

0V

0 9 1

3

TB3

4

1

5

TB3

2

3

4

5

6

TB4

7

1

8

TB3

2

3

4

5

TB5

A1,B1 24V A2,B2 A4

0V *ESP

XX

KEY CXA2A A1,B1 24V A2,B2 A4

KA4

0V *ESP

# - LOCAL STOP XX UNIT STANDARD WIRING SET KIT EE-4707-020

JF1

EE-4707-006-001

62

61

72

71

82

81

1 3

2 4

5

6

A1

*

- CONTROLLER HOOKUP KIT 1/CONTROLLER EE-4707-030 - USED WITH MULTIPLE LOCAL STOPS IN 1 CONTROLLER

A2

XX MOTOR 1 MTR ENC

3 – 9

F i g u r e 3 – 5 . S i n g l e M o t o r a n d A m p l i f i e r — X X C o n n e c t o r

BRK

3 . T h e L o c a l S t o p O p t i o n

3 – 1 0 ESTOP PC BD

EE-4707-016-001

EE-4707-017-001

*

CP2


*

KA1

EE-4707-012-001 CN2

TB8

#

- LOCAL STOP 2XX UNIT STANDARD WIRING SET KIT EE-4707-021

*

- CONTROLLER HOOKUP KIT 1/CONTROLLER EE-4707-030

CN3

2

*

6

XFMR

MCC

0V

1

EES1

BEES1

5

2

EES11

BEES11

6

3

EES2

3

EES2

BEES2

7

4

EES21

4

EES21

BEES21

8

LS1

9

CRM39

EE-4707-009-001 #

TB2 1

EE-4707-013-001

2 3


A2 A3

10

LS2

11

LS21

12

EES OUT TB

} }



24V

4 5

B1

24V

6 7 4

LS11 KA3

SAFE TO ENTER

*

A1

0V

TB1

EES1

6 CHANNEL AMP

*BRKRLS3

TB1

EES11

#

*BRKRLS2

24V

2


10

EE-4707-010-001

*BRKRLS1

BRK-

2

DI

TO MOTOR BRAKE CONN

D4

1

DI 24V

BRK+

~ -

1

9 TBOP4

CN5

KA3

TB3

8

PANEL BD

KA2 ~ +

EE-4707-014-001

AUX. CONTACT REQUIRED

7

100VAC

DB3

CN3

5

TO MOTOR BRAKE CONN

BRKFU1 2A

IN 100B

4

200VAC

BRK+

IN 100A

3


DRIVE USING 2 SINGLE AXIS AMPS

CN4

- USED WITH MULTIPLE LOCAL STOPS IN 1 CONTROLLER

CN2 EE-4707-008-001 #

1

R-J3iB LOCAL ESTOP 2XX UNIT PC BOARD ROADMAP FOR DUAL MOTOR

KA1

CN1 CP5A

EE-4707-021

KEY

CN1

200VAC IN

KA1 24V

1 8 TB7 D6 R6

0V

0V

*BRKRLS1

9

D2

KA2

BRK REL

0V

KA1


CRF7 38

MOTOR ON COMMAND

1

22

LOCAL STOP REQUEST

3

21


2

39

MOTOR ON COMMAND

1

24

LOCAL STOP REQUEST

3

23


2

40

MOTOR ON COMMAND

1

10

LOCAL STOP REQUEST

3

11


2

12

RDO6 RDI4 RDI3 RDO7 RDI6 RDI5 RDO8

26

RDI8 25 RDI7

EE-4707-011-001

*

DC LINK

CXA2A 24V A1,B1 0V A2,B2 *ESP A4

} }

LOCAL STOP PCB #3

LOCAL STOP PCB #2

D5 R5 D1

KA1

MTR ON

MOTOR DISCONNECTED

KA2 DB1

DB2

SVMi AMPLIFIER 7 R 7 D

EE-4707-015-001

#

HV

D3

KA3

R1

R8

R2

R3

R4

C1

0V

CXA2B

MOV1

0 9 1

3

TB3

4

5

1

TB3

2

3

4

5

6

7

1 2

8

TB4

TB3

3

4

5

TB5

A1,B1 24V A2,B2 0V A4 *ESP

XX

CXA2A A1,B1 24V A2,B2 A4

KA4

0V *ESP

KA5

JF1

SVMi AMPLIFIER

EE-4707-006-001

HV

62

61

62

61

72

71

72

71

82

81

82

81

1 3

2 4

1 3

2 4

5

6

5

6

A1

A2

A1

XX

A2

MOTOR 2 MTR

BRK

ENC

CXA2B A1,B1 24V A2,B2 A4

0V *ESP

XX

EE-4707-006-002

XX MOTOR 1 MTR

CXA2A

ENC

A1,B1 24V A2,B2 A4

0V *ESP

JF1

BRK

F i g u r e 3 – 6 . D u a l M o t o r a n d A m p l i f i e r — X X C o n n e c t o r


ESTOP PC BD

EE-4707-016-001

EE-4707-017-001

*

CP2

EE-4707-022


*

CN1 KA1

200VAC IN

R-J3iB LOCAL ESTOP XX/XY UNIT PC BOARD ROADMAP FOR DUAL MOTOR DRIVE WITH DUAL AXIS AMP.

KA1

CN1 CP5A

EE-4707-012-001 CN2

CN4

TO MOTOR BRAKE CONN

BRK+

TB8

EE-4707-008-001

1

#

2

KA2 ~ +

CN5

KA3

BRK+

*

6

BRK-

EE-4707-014-001


7

TO MOTOR BRAKE CONN

D4

~ -

CN3

5

100VAC

DB3

IN 100B

4

XFMR

FU1 2A

CN3

IN 100A

3

200VAC

BRK-

CN2

TB3

MCC

1 8

24V

2 9

PANEL BD

10

TBOP4 1

DI

2

24V

3

DI

4

0V

DAISY CHAIN TO TB3 PIN 2 OF ALL SUBSEQUENTLOCAL STOPPCB UNITS (PARTOF EE-4707-012-001)

TB1

TB1

EES1

1

EES1

BEES1 5

EES11

2

EES11

BEES11 6

EES2

3

EES2

BEES2 7

EES21

4

EES21

BEES21 8 LS1 9

EE-4707-009-001

EE-4707-010-001

6 CHANNEL AMP

CRM39

EE-4707-013-001

SAFE TO ENTER

*BRKRLS2

A3

*BRKRLS3

LS21 12



24V

5

24V

6 7 4

} }

4

B1

0V

LS2 11

KA3

2 3


A2

LS11 10

1

*

A1

*BRKRLS1

TB2

#

#

EES OUT TB

KEY

KA1 24V

#

1 8 TB7 D6 R6

0V

0V

*BRKRLS1

9

D2

KA2

BRK REL

*

0V

KA1

LOCAL STOP PCB #2

38

MOTOR ON COMMAND

1

22

LOCAL STOP REQUEST

3

21


2

MOTOR ON COMMAND

1

LOCAL STOP REQUEST

3


2

MOTOR ON COMMAND

1

10

LOCAL STOP REQUEST

3

11


2

12

RDI4 RDI3 39 RDO7 24 RDI6 23 RDI5 40 RDO8 26 RDI8 25 RDI7

EE-4707-011-001

*

DC LINK

0V A2,B2 A4

LOCAL STOP PCB #3

LOCAL STOP PCB #2

D5 R5 D1

KA1

MTR ON

MOTOR DISCONNECTED

KA2 DB1

DB2


#

HV

CXA2A 24V A1,B1 *ESP

} }

7 R 7 D

D3

KA3

MOV1

R1

R8

R2

R3

R4

C1

0V

CXA2B

9

0 1

1 2

TB3

TB3

3

4

6

5

7

1

8

TB4

TB3

2

3

4

5

TB5

A1,B1 24V A2,B2 A4

0V *ESP

XX


KA4

0V *ESP

KA5

JF1

EE-4707-006-001

62

61

62

61

72

71

72

71

82

81

82

81

1

2

3

4

5

6

A1

A2

1

2

3

4

5

6

A1

XX

A2

MOTOR 2 MTR

BRK

ENC

XY

EE-4707-007-001

XX MOTOR 1 MTR ENC

JF2

3 – 1 1


LOCAL STOP PCB #3

CRF7

RDO6

- LOCAL STOP XX/XY STANDARD WIRING SET KIT EE-4707-023

BRK

F i g u r e 3 – 7 . D u a l M o t o r a n d S i n g l e A m p l i f i e r — X X a n d X Y C o n n e c t o r s



EE-4707-016-001

EE-4707-017-001

*

CP2

EE-4707-023


*

CN1 KA1

200VAC IN

XY UNIT PC BOARD ROADMAP FOR SINGLE MOTOR DRIVE

KA1

CN1 CP5A

EE-4707-012-001 CN2

TO MOTOR BRAKE CONN

CN4

BRK+

TB8

BRK-

CN2 EE-4707-008-001

1

#

2

FU1 2A

CN3

DB3

KA2 ~ +

IN 100A


XFMR

200VAC

CN3

5

*

6 7

100VAC


MCC

TB3 1

TB1

TB1

EES1

1

EES1

BEES1

5

2

EES11

2

EES11

BEES11

6

3

EES2

3

EES2

BEES2

7

4

EES21

4

EES21

BEES21

8

LS1

9

DI 0V

DAISY CHAIN TO TB3 PIN 2 OF ALL SUBSEQUENT LOCAL STOPPCB UNITS (PARTOF EE-4707-012-001)

10

1

DI 24V

24V

2

9 TBOP4

BRK-

EE-4707-014-001

8

PANEL BD

BRK+

~ -

IN 100B 4

CN5

KA3 D4

3

EE-4707-009-001

EE-4707-010-001

6 CHANNEL AMP

EE-4707-013-001 A1

A3

*BRKRLS3

10

LS2

11

LS21

12



24V

5

24V

6 7 4

LS11

} }

4

B1

0V

KA3

2 3


A2

*BRKRLS2

1

SAFE TO ENTER

*

CRM39

*BRKRLS1

TB2

#

#

EES OUT TB

1

KA1 24V

8 TB7 D6 R6

0V

0V

*BRKRLS1

9

D2

KA2

BRK REL

0V

KA1

KEY


CRF7 38 RDO6 22 RDI4 21 RDI3 39 RDO7 24 RDI6 23 RDI5 40 RDO8 26 RDI8 25 RDI7

MOTOR ON COMMAND

1

LOCAL STOP REQUEST

3


1

LOCAL STOP REQUEST

3 2 1

10

LOCAL STOP REQUEST

3

11


2

12

*ESP

A4

MTR ON

MOTOR DISCONNECTED

KA2 DB1

SVMi AMPLIFIER 7 R 7 D

EE-4707-015-001

#

HV

CXA2A

D1

KA1

D3

KA3

MOV1

R1

R8

R2

C1

0V

CXA2B

0 9 1

3

TB3

4

1 2

5

TB3

3

4

5

6

TB4

7

8

1

TB3

2

3

4

5

TB5

A1,B1 24V A2,B2 0V A4

*ESP

XX

CXA2A A1,B1 24V A2,B2 0V A4

*ESP

KA4 JF1

EE-4707-007-002

62

61

72

71

82

81

1

2

3

4

5

6

A1

XY

A2

XX MOTOR 1 MTR ENC

JF2

#

- LOCAL STOP XY UNIT STANDARD WIRING SET KIT EE-4707-023

*


D5 R5

MOTOR ON COMMAND

*

24V A1,B1 0V A2,B2

LOCAL STOP PCB #2


EE-4707-011-001

DC LINK

} }

2

MOTOR ON COMMAND

LOCAL STOP PCB #3

BRK

F i g u r e 3 – 8 . S i n g l e M o t o r a n d A m p l i f i e r — X Y C o n n e c t o r


EE-4707-040

NOTE: THIS MAY OR MAY NOT REFLECT YOUR CONFIGURATION

3 – 1 3

F i g u r e 3 – 9 . C o n t r o l l e r C a b i n e t H a r d w a r e M o u n t i n g D i a g r a m



3.4 Arc Welding Application Connection Drawings This section provides illustrations specific to the ARC Application.

Figure 3–10. Positioners

Ferris Wheel Positioner

Headstock Positioner

3–14

ESTOP PC BD

EE-4707-016-001

EE-4707-017-001

*

CP2

FE-4830-011


*

CN1

HEADSTOCK POSITIONER

KA1

200VAC IN

KA1

CN1 CP5A CN2

TO MOTOR BRAKE CONN

CN4

BRK+

BRK-

TB8

EE-4707-008-001

1

#

2

5

*

MCC

1

1

EES1

2

EES11

3

EES2

3

4

EES21

4

EE-4707-009-001

CRM39

EE-4707-013-001

5

BEES2

7

BEES21

8

LS1

9

LS11

10

LS2

11

LS21

12

KA3

7 4

} }


*-JUMPER WHEN NOT IN USE LOCAL STOP* CUSTOMER INPUTS (i.e. Light Curtain)

24V

24V

6

B1

0V

EES2 EES21

EES OUT TB

4

A3

*BRKRLS3

6

2 3


A2

5

1

SAFE TO ENTER SIGNAL OUT

*

A1

BEES1 BEES11

TB2

#

#

6 CHANNEL AMP

*BRKRLS2

TB1

EES1 EES11

EE-4707-010-001

*BRKRLS1

TB1

2

24V

0V


10

1

DI

DI

24V

2

9 TBOP4

BRK-

TB3

8

PANEL BD

BRK+

D4

~ -

EE-4707-014-001


7

100VAC

CN5

KA3

CN3

6

XFMR

KA2 ~ +

IN 100B

4

200VAC

DB3

IN 100A

3


FU1 2A

CN3

KA1 24V

1

F i g u r e 3 – 1 1 . S i n g l e H e a d s t o c k P o s i t i o n e r

8 TB7 D6 R6

0V

0V

*BRKRLS1

9

D2

KA2

BRK REL

0V

KA1


CRF7 38 RDO6 22 RDI4 21 RDI3 39 RDO7 24

1

LOCAL STOP REQUEST

3


2

MOTOR ON COMMAND

1

LOCAL STOP REQUEST

3


2

MOTOR ON COMMAND

1

10

26

LOCAL STOP REQUEST

3

11

25


2

12

RDI8

EE-4707-011-001

*

CXA2A 0V A2,B2 *ESP

A4

LOCAL STOP PCB #2

D5 R5 D1

KA1

MTR ON

MOTOR DISCONNECTED

KA2 DB1


#

HV

24V A1,B1

LOCAL STOP PCB #3

40

RDI5

DC LINK

} }

23

RDI6

RDO8

RDI7

MOTOR ON COMMAND

7 R 7 D

D3

KA3

CXA2B

MOV1

R1

R8

R2

C1

0V

0 9 1

3

TB3

4

1

5

TB3

2

3

4

5

6

TB4

7

1

8

TB3

2

3

4

5

TB5

A1,B1 24V A2,B2 A4

0V *ESP

XX

KEY CXA2A A1,B1 24V A2,B2 A4

KA4

0V *ESP

# - LOCAL STOP XX UNIT STANDARD WIRING SET KIT EE-4707-020

JF1

EE-4707-006-001

62

61

72

71

82

81

1 3

2 4

5

6

A1

*


A2

XX MOTOR 1 MTR ENC

3 – 1 5

BRK



EE-4707-016-001

EE-4707-017-001

*

CP2

FE-4830-012


*

CN1 KA1

200VAC IN

TILT / ROTATE OR DROP-CENTER POSITIONER

KA1

CN1 CP5A CN2

CN4

TO MOTOR BRAKE CONN

BRK+

BRK-

TB8

EE-4707-008-001

1

#

2

*

6

CN5

KA3

BRK+

TO MOTOR BRAKE CONN

D4

~ -

BRK-

EE-4707-014-001


7

100VAC

KA2 ~ +

CN3

5

XFMR

DB3

IN 100B

4

200VAC

FU1 2A

CN3

IN 100A

3

TB3

MCC

1 8

24V

2 9

PANEL BD

10

TBOP4 1

DI

2

24V

3

DI

4

0V

DAISY CHAIN TO TB3 PIN 2 OF ALL SUBSEQUENTLOCAL STOPPCB UNITS (PARTOF EE-4707-012-001)

TB1

TB1

EES1

1

EES1

BEES1 5

EES11

2

EES11

BEES11 6

EES2

3

EES2

BEES2 7

EES21

4

EES21

BEES21 8 LS1 9

EE-4707-009-001

EE-4707-010-001

6 CHANNEL AMP

CRM39

EE-4707-013-001

SAFE TO ENTER SIGNAL OUT

*BRKRLS2

A3

*BRKRLS3

LS21 12


*-JUMPER WHEN NOT IN USE LOCAL STOP* CUSTOMER INPUTS (i.e. Light Curtain)

24V

5

24V

6 7 4

} }

4

B1

0V

LS2 11

KA3

2 3


A2

LS11 10

1

*

A1

*BRKRLS1

TB2

#

#

EES OUT TB

KEY

KA1 24V

#

1 8 TB7 D6 R6

0V

0V

*BRKRLS1

9

D2

KA2

BRK REL

*

0V

KA1

LOCAL STOP PCB #2

38

MOTOR ON COMMAND

1

22

LOCAL STOP REQUEST

3

21


2

MOTOR ON COMMAND

1

LOCAL STOP REQUEST

3


2

MOTOR ON COMMAND

1

10

LOCAL STOP REQUEST

3

11


2

12

RDI4 RDI3 39 RDO7 24 RDI6 23 RDI5 40 RDO8 26 RDI8 25 RDI7

EE-4707-011-001

*

DC LINK

0V A2,B2 A4

LOCAL STOP PCB #3

LOCAL STOP PCB #2

D5 R5 D1

KA1

MTR ON

MOTOR DISCONNECTED

KA2 DB1

DB2


#

HV

CXA2A 24V A1,B1 *ESP

} }

7 R 7 D

D3

KA3

MOV1

R1

R8

R2

R3

R4

C1

0V

CXA2B

9

0 1

1 2

TB3

TB3

3

4

6

5

7

1

8

TB4

TB3

2

3

4

5

TB5

A1,B1 24V A2,B2 A4

0V *ESP

XX


KA4

0V *ESP

KA5

JF1 62

61

62

61

72

71

72

71

81

82

81

82

EE-4707-006-001

1

2

1

2

3

4

3

4

5

6

5

6

A1

A2

A1

XX

A2

MOTOR 2 MTR

BRK

ENC

XY

EE-4707-007-001

XX MOTOR 1 MTR ENC

JF2


LOCAL STOP PCB #3

CRF7

RDO6

- LOCAL STOP XX/XY STANDARD WIRING SET KIT EE-4707-023

BRK

F i g u r e 3 – 1 2 . T i l t / R o t a t e o r D r o p C e n t e r P o s i t i o n e r


F i g u r e 3 – 1 3 . T w o H e a d s t o c k P o s i t i o n e r s

FE-4830-021 TWO HEADSTOCK POSITIONERS

KEY - LOCAL STOP XX UNIT STANDARD WIRING SET KIT EE-4707-020

#

*


EE-4707-012-001

ESTOP PC BD

EE-4707-016-001

EE-4707-017-001

*

CP2

RJ3iB LOCAL STOP PBD #1

*

CP5A

EE-4707-020PACKAGE

RJ3iB LOCAL STOP PBD #2

CN1

EE-4707-023PACKAGE

CN1 KA1

200VACIN

EE-4707-012-001

KA1 200VACIN

KA1

CN1

KA1

CN1 CN2

TOMOTOR BRAKECONN

CN4

CN2

CN4 BRK+

BRK+

TOMOTOR BRAKECONN TB8

CN2

1

#

2

4

XFMR

10 0VAC

IN 100A

KA2 ~ +

IN 100B

~ -

D4

CN3

BRK-

TB3

TB3 1

24V

1

24V

2

2 DAISYCHAINTOTB3PIN2OF ALLSUBSEQUENTLOCAL STOPPCBUNITS (PARTOF EE-4707-012-001)

TB1

TB1

TB1

TB1

EESOUTTB 5

1

EES1

BEES1

5

1

EES1

BEES1

2

EES11

2

EES11

BEES11

6

2

EES11

BEES11

6

3

EES2

3

EES2

BEES2

7

3

EES2

BEES2

7

EES21

BEES21

8

EES21

6 CHANNEL AMP

4

EE-4707-013-001

EE-4707-009-001

#

#

A1

2 3

CUSTOMERSUPPLIED LOCALSTOP REQUEST INPUT

A3

BEES21

9 10

LS2

11

LS21

12

}

EE-4707-009-001 LOCALSTOP* CUSTOMER INPUTS

5

24V

7

#

2 3

CUSTOMERSUPPLIED LOCALSTOP REQUEST

5

24V

7 TOCP5 ONE-STOPPCB

*BRKRLS1

9

D2

11 12

*-JUMPERWHEN NOTINUSE LOCALSTOP* CUSTOMER INPUTS (i.e. Light Curtain)

24V KA1 24V

8

D6R6

0V

0V

LS2 LS21

EXTERNALE-STOP* CUSTOMERINPUTS

24V

6

8

9 10

} }

4

KA1

TB7

LS1 LS11 KA3

1 SAFETOENTER SIGNALOUT

24V

6 1

TB2

(i.e. Light Curtain)

4

B1 4

4

8

LS1 LS11 KA3

1 SAFETOENTER SIGNALOUT

A2

0V

EES21

TB2

*

CRM39

*BRKRLS3

~ -

BRK+

EES1

EE-4707-010-001

*BRKRLS2

IN 100B

CN5

KA3

1

4

*BRKRLS1

IN 100A

KA2 ~ +

#

MCC

9

0V

DB3

D4

EE-4707-014-001

AUX.CONTACT REQUIRED

8

24V

FU1 2A

CN3

EE-4707-008-001

10

TBOP4

DI

CN5

KA3

CN3

*

7

PANEL BD

DI

DB3

5 6

200VAC

FU1 2A

CN3

3


BRK-

BRK-

EE-4707-008-001

D6R6

BRKREL

0V

0V

KA1

KA2

*BRKRLS2

9

D2

KA2

BRKREL

0V

KA1

*BRKRLS2 LOCALSTOPPCB#3

CRF7 38 22

MOTORON COMMAND

1

LOCALSTOP REQUEST

3

21

MOTOR(S)DISCONNECTED

2

39

MOTORON COMMAND

1

24

LOCALSTOP REQUEST

3


2

RDO6 RDI4 RDI3 RDO7 RDI6 23 RDI5

D5R5

40

MOTORON COMMAND

1

10

LOCALSTOP REQUEST

3

11

RDI8 25

2

MOTOR(S)DISCONNECTED EE-4707-011-001

*

DCLINK

12

7 R 7 D

EE-4707-015-001

#

MOTORON COMMAND

10

LOCALSTOP REQUEST

11


KA2

A1,B1 A2,B2 A4

D3

KA3

MOV1

R1

R8

12

D1

KA1

MTRON

MOTORDISCONNECTED

KA2 DB1

R2 EE-4707-015-001

C1

7 R 7 D

D3

KA3

MOV1

R1

R8

R2

C1

# 0V

CXA2B

0V A2,B2 A4

D5R5

MTRON

DB1

HV

CXA2A

D1

KA1

MOTORDISCONNECTED

SVMi AMPLIFIER

24V A1,B1 *ESP

LOCALSTOPPCB#3

26

RDO8

RDI7

}

0V

9

0 1

3

TB3

4

1 2

5

TB3

3

4

5

6

TB4

7

8

1

TB3

2

3

4

0V

5

TB5

0 9 1

3

TB3

4

5

1 2

TB3

3

4

5

6

TB4

7

1

8

TB3

2

3

4

5

TB5

24V 0V *ESP

XX

CXA2A A1,B1 A2,B2 A4

24V

KA4

0V *ESP

KA4

JF1

EE-4707-006-001

62

61

62

61

72

71

72

71

82

81

82

81

1

2

3

4

5

6

A1

1 3 5

A2

A1

2 4 6 A2

XY

XX

XX MOTOR1

JF2

MOTOR2 BRK

MTR

ENC

ENC

EE-4707-007-002

0V LOCALSTOPPCB#2 MOTORON COMMAND LOCALSTOP REQUEST MOTOR(S)DISCONNECTED

3 – 1 7

BRK



3.5 Parts List Tab le 3–2. L oc al St op Un it Par ts L is t Description

Part Number

Remarks

L oc al St op Ki ts Local Stop Kit

EE-4707–020

For use with: (1) Auxiliary

Kit Contents: EE-4707–001 (Din Rail Sub-Assembly)

Amplifier, (1) Channel and

EE-4707–008–001

(1) XX Connection

EE-4707–009–001 EE-4707–010 –001 EE-4707–015–001

Local Stop Kit

EE-4707–021



Amplifier, (1) Channel each

EE-4707–008–001

and (2) XX Connection

EE-4707–009–001 EE-4707–010–001 EE-4707–015–001

Local Stop Kit

EE-4707–022



Amplifier , (2) Channels

EE-4707–008–001

and (1) XX and (1) XY

EE-4707–009–001

Connection

EE-4707–010–001 EE-4707–015–001

Local Stop Kit

EE-4707–023



Amplifier, (2) Channels and

EE-4707–008–001

(1) XY Connection

EE-4707–009–001 EE-4707–010–001 EE-4707–015–001

Brake Transformer Harness

EE-4707– 008–001

24V Panel Board Harness

EE-4707–009–001

24V E-Stop Board Harness

EE-4707–010–001

Data Signal Harness

EE-4707–015–001

Part of Local Stop Kit Assembly

Din Rail Sub-Assembly Din Rail Sub-Assembly

EE-4707–001

Sub-Assembly Contents:

For use with:

EE-4707–004

EE-4707–020

EE-4707–006–001

3–21


Tab le 3–2. L oc al St op Un it Par ts L is t (Co nt ’d ) Description Din Rail Sub-AssemblyFor

Part Number EE-4707–002

Remarks Sub-Assembly Contents:

use with:

EE-4707–005

EE-4707–021

EE-4707–006–001 EE-4707–006–002

Din Rail Sub-AssemblyFor

EE-4707–003


use with:

EE-4707–005

EE-4707–022

EE-4707–006–001 EE-4707–007 –001

Din Rail Sub-AssemblyFor

EE-4707–006


use with:

EE-4707–004

EE-4707–023

EE-4707–007–002

Local Stop PCB (Single

EE-4707–004

Board with all components

EE-4707–005

Board with all components

EE-4707–006–001

Part of Din Rail Sub-Assembly

Channel) Local Stop PCB (Dual Channel) Contactor Harness - Single Channel Amplifier (XX Key & K4 Tag) Contactor Harness - Single

EE-4707–006–002

Channel Amplifier (XX Key & K5 Tag) Contactor Harness - Single

EE-4707–007–001

or Dual Channel Amplifier (XY Key & K5 Tag) Contactor Harness - Single

EE-4707–007–002

or Dual Channel Amplifier (XY Key & K4 Tag) Controller Hookup Kit Controller Hookup Kit

EE-4707–030

Kit Contents: EE-4707–011–001 EE-4707–013–001 EE-4707–014–001 EE-4707–016–001 EE-4707–017–001

3–22


Tab le 3–2. L oc al St op Un it Par ts L is t (Co nt ’d ) Description 6 Channel Amplifier Local

Part Number EE-4707–011–001

Remarks Part of Controller Hookup Kit Assembly

Stop Control Harness Brake Signal Harness

EE-4707–013–001

Auxiliary Contact Harness

EE-4707–014–001

200V Transformer Power

EE-4707–016–001

Input Harness with Din Rail TB-8 200V IN to Local Stop Unit

EE-4707–017–001

#1 Harness Miscellaneous Controller and Application Items 100V Brake Transformer

A80L-0010–0071

200V Jumper Harness

EE-4707–012–001

Required for Local Stop Units 2 and 3

RLAYLC1D2501M6

TELEMEC.

AC 3 Pole Contactor

3–23

Chapter 4

This manual is a supplement for the R-J3iB Mate Co ntroller Auxiliary Axis Option. Refer to the R-J3iB Mate maintenance manual for general maintenance descriptions. Note: Local Stop functionality is not available for R-J3iB Mate Auxiliary Axis packages.

Auxiliary Auxil iary servo servo amplifi amplifi e (in case case of B 20)

P ower wer supply unit uni t

E mer mer gency gency stopunit uni t F an

Operator panel

N oise filt fi lter( er(opti option) on)

Brake Br ake relay relay unit(o unit (op ption) ti on)

M ai n cabi net

MCC MC C

Br akeI /F

Auxi l i ar y axi s cabi ne

Battery Battery unit uni t

BRAKE

A1 A2 A3

BKP

1

BKM

4

2 BKP 3 BKM

POWER

B2 A2

W G

B1 A1

U V

1 U 4 G

2 V 3 W

PULSECODER

01 02 03 04 05 06 07 08 09 10

SD XSD

REQ XREQ

+5V-1

11 12 13 14 15 16 17 18 19 20

0V-1

1 2 3

0V-2

0V-2

+5V-2

+6V

XSD SD DRAIN

4 5 6 7

+6V XREQ

REQ 0V-1

8 9 10

+5V-1 +5V-2

0V-2

A1 A2 A3

BKP 6 BKM

BKM

5 BKP

4 G

3 W

2 V

POWER/BRAKE

B2 A2

W G

B1 A1

U V

PULSECODER

01 02 03 04 05 06 07 08 09 10

SD XSD

REQ XREQ

+5V-1

11 12 13 14 15 16 17 18 19 20

0V-1

1 2 3

0V-2

0V-2

+5V-2

+6V

XSD SD DRAIN

4 5 6 7

+6V XREQ

REQ 0V-1

8 9 10

+5V-1 +5V-2

0V-2

1 U

BRAKE

A

C

BKM

A1 A2 A3

B

BKP

BKP

BKM

POWER

B2 A2

W G

B1 A1

A D U G B C V W

U V

PULSECODER

01 02 03 04 05 06 07 08 09 10

SD XSD

REQ XREQ

+5V-1

11 12 13 14 15 16 17 18 19 20

0V-1

1 2 3

0V-2

0V-2

+5V-2

+6V

XSD SD DRAIN

4 5 6 7

+6V XREQ

REQ 0V-1

8 9 10

+5V-1 +5V-2

0V-2

BRAKE A

C

BKM

B A1 A2 A3

BKP

BKP BKM

POWER

B2 A2

W G

B1 A1

A D U G B C V W

U V

PULSECODER

01 02 03 04 05 06 07 08 09 10

SD XSD

REQ XREQ

+5V-1

11 12 13 14 15 16 17 18 19 20

0V-1

1 2 3

0V-2

0V-2 +6V

+5V-2

XSD SD DRAIN

4 5 6 7

+6V XREQ

REQ 0V-1

8 9 10

+5V-1 +5V-2

0V-2

This section contains a list of spare parts used within an R-J3iB Mate Auxiliary Axis system. Table 1, Table 2 and Table 3 provide part number information for the servo motors and amplifiers available for use in an R-J3iB Mate Auxiliary Axis system. Table 1. Alpha i Servo Motors A06B-aaaa-B b c d Model [aaaa] Shaft/Brake [b] 0202: Alpha 1/5000i 0205: Alpha 2/5000i 0223: Alpha 4/4000i 0227: Alpha 8/3000i 0243: Alpha 12/3000i 0247: Alpha 22/3000i 0212: Alpha M2/5000i 0215: Alpha M3/5000i 0235: Alpha M8/4000i 0238: Alpha M12/4000i

Fan [c]

0: Taper Shaft 1: Straight shaft 2: Straight shaft with keyway 6: Taper shaft with Brake (DC90V) 7: Straight shaft with Brake (DC90V) 8: Straight shaft with Brake (DC90V) and keyway

Table 2. Beta M Servo Motors A06B-aaaa-B b cc # dddd Model [aaaa] Shaft/Brake [b] 0114: Beta M0.4/4000 0115: Beta M0.5/4000 0116: Beta M1/4000

0: Standard = without Fan Pulsecoder [d] 5: Alpha A64i

Modification [dddd]

0: Straight shaft 2: Straight shaft with Brake (DC90V) Pulsecoder [cc]

0000: Standard 0008: with keyway

75: Beta A64B Table 3. Servo Amplifiers and Compatible Servo Motors Servo Amplifier Compatible Servo Part Number (Communication) Motor Beta M0.4/4000 Beta M0.5/4000 Beta M1/4000 Beta SVU-20 A06B-6093-H112 Alpha 1/5000i (FSSB I/F) Alpha 2/5000i Alpha M2/5000i Alpha M3/5000i "4/4000i Beta SVU-40 A06B-6093-H113 "8/3000i (FSSB I/F)

Note

Regeneration resistance (30!/20W) is mounted separately A06B-6093-H401 Amplifier includes 70W discharge resistor

"12/3000i

Beta SVU-80 (FSSB I/F)

"22/3000i

A06B-6093-H114

"M8/4000i "M12/4000i

Amplifier includes 70W discharge resistor

Table 4 provides the part number for the auxiliary axis connection cable. This cable provides the DC signal, AC power and FSSB communication to the auxiliary axis cabinet. Table 4. Interconnection cable (Mate Controller to Auxiliary Axis Cabinet) Description Part Number Note Length = 3m Connection cable A05B-2448-J070 STD/RIA

Table 5 provides part numbers for a single and three phase noise filter. If your system is using a SVU-40 or 80 Beta amplifier, you are required to use a noise filter. Table 5. Noise Filter Description

R-J3iB Mate Power spec.

Part Number

Noise filter unit A

3 phase

A05B-2448-J090

Note

STD/RIA Noise filter unit B

1 phase

A05B-2448-J091

Note: The use of Beta SVU-40 or 80 amplifiers requires the use of a noise filter.

Table 6 provides a list of motor connection cables. The cables come in 7, 14 and 20 meter lengths. Table 6. Motor Connection Cables (Flex Type) Servo Motor Spec. Beta M0.4/4000 Beta M0.5/4000 Beta M1/4000 Alpha 1/5000i Alpha 2/5000i Alpha M2/5000i Alpha M3/5000i Alpha 4/4000i Alpha 8/3000i Alpha M8/4000i Alpha M12/4000i Alpha 12/3000i Alpha 22/3000i

STD RIA

STD RIA

STD RIA STD RIA

Length 7m 14m

Part Number A05B-2448-D200 A05B-2448- D201

20m

A05B-2448- D202

7m 14m

A05B-2448- D220 A05B-2448-D221

20m

A05B-2448-D222

7m 14m

A05B-2448-D240 A05B-2448-D241

20m

A05B-2448-D242

7m 14m 20m

A05B-2448-D260 A05B-2448-D261 A05B-2448-D262

Table 7. Servo Card Description Part Number 6 Axes Servo Card A05B-2440-H020 8 Axes Servo Card

A05B-2440-H021

Note For LR Mate100iB + 1 Auxiliary Axis For LR Mate100iB + 2 Auxiliary Axes For LR Mate200iB + 1 or 2 Auxiliary Axes

Table 8. MCC / Brake Interface and Power Supply Unit Description Part Number MCC and Brake Interface A05B-2448-C001

Note STD/RIA

Table 9. Brake Relay Cable Description Part Number Note Brake relay cable A05B-2448-J080 STD/RIA Note: For LR Mate 100iB, the following cable is required for auxiliary axis brakes. Table 10. Replacement Battery Description Part Number Battery A06B-6050-K061

Note Alkaline dry battery

Aux Axis Manual Fanuc

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