Controler Maintenance R30iA.pdf

FANUC Robot series

(RIA R15.06-1999 COMPLIANT) R-30iA CONTROLLER

MAINTENANCE MANUAL MARMCRIA304071E REV. B 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 Robotics America, Inc. 3900 W. Hamlin Road Rochester Hills, Michigan 48309–3253

B-82595EN-2/02

The descriptions and specifications contained in this manual were in effect at the time this manual 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’ 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 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 and if not installed and used in accordance with the instruction manual, may cause interference to radio communications. As temporarily permitted by regulation, it has not been tested for compliance with the limits for Class A computing devices pursuant to subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measure may be required to correct the 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 2007 by FANUC Robotics America, Inc. All Rights Reserved The information illustrated or contained herein is not to be reproduced, copied, downloaded, translated into another language, published in any physical or electronic format, including internet, 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 2007

• •

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 from other 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.

Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand the content. This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.

• No part of this manual may be reproduced in any form. • All specifications and designs are subject to change without notice. The products in this manual are controlled based on Japan’s “Foreign Exchange and Foreign Trade Law”. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. In this manual we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as ”impossible”.

PREFACE

B-82595EN-2/02

PREFACE This manual describes the following models (R-30iA controller). Model FANUC Robot R-2000iB/210F FANUC Robot R-2000iB/200R FANUC Robot R-2000iB/200EW FANUC Robot R-2000iB/165R FANUC Robot R-2000iB/165F FANUC Robot R-2000iB/165EW FANUC Robot R-2000iB/165CF FANUC Robot R-2000iB/125L FANUC Robot R-2000iB/100P FANUC Robot R-2000iB/200T FANUC Robot M-6iB FANUC Robot M-6iB/6T FANUC Robot M-6iB/6S FANUC Robot M-6iB/2HS FANUC Robot M-6iB/6C FANUC Robot M-10iA FANUC Robot M-16iB/20 FANUC Robot M-16iB/10L FANUC Robot M-16iB/20T FANUC Robot M-16iB/10LT FANUC Robot ARC Mate 100iB FANUC Robot ARC Mate 100iBe FANUC Robot ARC Mate 100iB/6S FANUC Robot ARC Mate 100iC FANUC Robot ARC Mate 120iB FANUC Robot ARC Mate 120iBe FANUC Robot ARC Mate 120iB/10L FANUC Robot ARC Mate 120iB/20T FANUC Robot ARC Mate 120iB/10LT FANUC Robot M-710iC/70 FANUC Robot M-710iC/70T FANUC Robot M-710iC/50 FANUC Robot M-710iC/50S FANUC Robot M-710iC/50T FANUC Robot M-710iC/20L FANUC Robot M-410iB/160 FANUC Robot M-410iB/300 FANUC Robot M-410iB/450 FANUC Robot M-420iA FANUC Robot M-421iA FANUC Robot M-430iA/2F FANUC Robot M-430iA/2P FANUC Robot M-900iA/260L FANUC Robot M-900iA/350 FANUC Robot M-900iA/600 FANUC Robot F-200iB

Abbreviation R-2000iB/210F R-2000iB/200R R-2000iB/200EW R-2000iB/165R R-2000iB/165F R-2000iB R-2000iB/165EW R-2000iB/165CF R-2000iB/125L R-2000iB/100P R-2000iB/200T M-6iB M-6iB/6T M-6iB M-6iB/6S M-6iB/2HS M-6iB/6C M-10iA M-16iB/20 M-16iB/10L M-16iB M-16iB/20T M-16iB/10LT ARC Mate 100iB ARC Mate 100iB ARC Mate 100iBe ARC Mate 100iB/6S ARC Mate 100iC ARC Mate 120iB ARC Mate 120iBe ARC Mate 120iB ARC Mate 120iB/10L ARC Mate 120iB/20T ARC Mate 120iB/10LT M-710iC/70 M-710iC/70T M-710iC/50 M-710iC M-710iC/50S M-710iC/50T M-710iC/20L M-410iB/160 M-410iB M-410iB/300 M-410iB/450 M-420iA M-421iA M-430iA/2F M-430iA M-430iA/2P M-900iA/260L M-900iA M-900iA/350 M-900iA/600 F-200iB

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TABLE OF CONTENTS

B-82595EN-2/02

TABLE OF CONTENTS PREFACE ....................................................................................................... 1 I. SAFETY PRECAUTIONS 1

SAFETY PRECAUTIONS........................................................................ 3 1.1 1.2

1.3

1.4

1.5

WORKING PERSON ..................................................................................... 3 WORKING PERSON SAFETY ...................................................................... 5 1.2.1

General Person Safety ..............................................................................................7

1.2.2

Safety of the Teaching Operator ..............................................................................8

1.2.3

Safety During Maintenance....................................................................................10

SAFETY OF THE TOOLS AND PERIPHERAL DEVICES........................... 11 1.3.1

Precautions in Programming ..................................................................................11

1.3.2

Precautions for Mechanism ....................................................................................11

SAFETY OF THE ROBOT MECHANISM .................................................... 12 1.4.1

Precautions in Operation ........................................................................................12

1.4.2


1.4.3

Precautions for Mechanisms...................................................................................12

SAFETY OF THE END EFFECTOR............................................................ 12 1.5.1

1.6


WARNING LABEL ....................................................................................... 13

II. MAINTENANCE 1

OVERVIEW ........................................................................................... 17

2

CONFIGURATION ................................................................................ 18 2.1 2.2 2.3

3

EXTERNAL VIEW OF THE CONTROLLER ................................................ 19 COMPONENT FUNCTIONS........................................................................ 32 PREVENTIVE MAINTENANCE ................................................................... 33

TROUBLESHOOTING .......................................................................... 34 3.1 3.2 3.3 3.4 3.5

POWER CANNOT BE TURNED ON ........................................................... 35 ALARM OCCURRENCE SCREEN.............................................................. 39 SAFETY SIGNALS ...................................................................................... 42 MASTERING ............................................................................................... 43 TROUBLESHOOTING USING THE ERROR CODE ................................... 45 c-1

TABLE OF CONTENTS 3.6 3.7 3.8 3.9

4

LED OF SERVO AMPLIFIER .................................................................... 206 SETTING OF SERVO AMPLIFIER............................................................ 207

SETTING THE POWER SUPPLY ....................................................... 208 6.1 6.2 6.3

7

MAIN BOARD (A16B-3200-0600, -0601) .................................................. 170 EMERGENCY STOP CONTROL BOARD (A20B-1008-0740) .................. 173 BACKPLANE BOARD ............................................................................... 174 PANEL BOARD (A20B-2101-0370)........................................................... 176 PROCESS I/O BOARD CA (A16B-2201-0470) ......................................... 177 PROCESS I/O BOARD EA (A16B-3200-0230).......................................... 180 PROCESS I/O BOARD EB (A16B-3200-0231).......................................... 183 PROCESS I/O BOARD FA (A16B-3200-0420).......................................... 185 PROCESS I/O BOARD GA (A16B-2203-0520) ......................................... 187 PROCESS I/O BOARD HA (A16B-2203-0760) ......................................... 189 PROCESS I/O BOARD JA (A16B-2204-0010) .......................................... 192 PROCESS I/O BOARD JB (A16B-2204-0011) .......................................... 194 PROCESS I/O BOARD KA (A16B-2204-0050).......................................... 196 PROCESS I/O BOARD KB（A16B-2204-0051）...................................... 199 PROCESS I/O BOARD KC（A16B-2204-0052）...................................... 202

SERVO AMPLIFIERS ......................................................................... 204 5.1 5.2

6

FUSE-BASED TROUBLESHOOTING ....................................................... 146 TROUBLESHOOTING BASED ON LED INDICATIONS ........................... 154 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING)....................................................................... 166 MANUAL OPERATION IMPOSSIBLE ....................................................... 167

PRINTED CIRCUIT BOARDS ............................................................. 169 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15

5

B-82595EN-2/02

BLOCK DIAGRAM OF THE POWER SUPPLY ......................................... 209 TRANSFORMER ....................................................................................... 210 CHECKING THE POWER SUPPLY UNIT (A16B-2203-0910) .................. 214

REPLACING A UNIT........................................................................... 215 7.1

7.2

A-CABINET................................................................................................ 216 7.1.1

Replacing the A-cabinet Top Panel......................................................................216

7.1.2

Replacing the A-cabinet Rear Panel.....................................................................217

7.1.3

Replacing the A-cabinet Louver...........................................................................218

7.1.4

Replacing the A-cabinet Door ..............................................................................219

REPLACING THE PRINTED-CIRCUIT BOARDS ..................................... 220 7.2.1

Replacing the Backplane Board (Unit).................................................................221 c-2

TABLE OF CONTENTS

B-82595EN-2/02

7.3 7.4 7.5 7.6 7.7 7.8

7.9 7.10 7.11

7.12 7.13

7.14

7.2.2

Replacing the Power Unit and Printed-Circuit Boards on the Backplane Unit....222

7.2.3

Replacing the Panel Board ...................................................................................224

7.2.4

Replacing the Process I/O Board EA,EB,FA,GA,KA,KB,KC (A-cabinet) .........226

REPLACING CARDS AND MODULES ON THE MAIN BOARD ............... 227 REPLACING THE TRANSFORMER ......................................................... 231 REPLACING THE REGENERATIVE RESISTOR UNIT ............................ 238 REPLACING THE E-STOP UNIT .............................................................. 241 REPLACING SERVO AMPLIFIERS .......................................................... 243 REPLACING I/O Unit-MODEL A................................................................ 250 7.8.1

Replacing the Base Unit of I/O Unit-MODEL A .................................................250

7.8.2

Replacing a Module..............................................................................................251

REPLACING THE TEACH PENDANT and i PENDANT ............................ 252 REPLACING THE CONTROL SECTION FAN MOTOR ............................ 253 REPLACING THE AC FAN MOTOR ......................................................... 254 7.11.1

Replacing the Heat Exchanger and Door Fan Unit (A-cabinet) ...........................254

7.11.2

Replacing External Air Fan Unit (A-cabinet) ......................................................255

7.11.3

Replacing External Air Fan Unit and Door Fan (B-cabinet)................................256

REPLACE THE MODE SWITCH ............................................................... 258 REPLACING FUSES ................................................................................. 260 7.13.1

Replacing Fuses in the Servo Amplifier...............................................................260

7.13.2

Replacing Fuses in the Power Unit ......................................................................261

7.13.3

Replacing Fuses in the Main board ......................................................................262

7.13.4

Replacing the Fuse on the Process I/O Boards.....................................................263

7.13.5

Replacing the Fuse on the Panel Board................................................................267

REPLACING RELAYS............................................................................... 268 7.14.1

7.15

REPLACING BATTERY ............................................................................ 269 7.15.1

8

Replacing Relays on the Panel Board ..................................................................268 Battery for Memory Backup (3 VDC)..................................................................269

HOW TO USE THE PLATE TO FIX THE COMPACT FLASH MEMORY CARD .................................................................................................. 272

III. CONNECTIONS 1

GENERAL ........................................................................................... 277

2

BLOCK DIAGRAM.............................................................................. 278 c-3

TABLE OF CONTENTS

3

ELECTRICAL CONNECTIONS........................................................... 280 3.1 3.2

4

B-82595EN-2/02

CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS .................. 281 EXTERNAL CABLE WIRING DIAGRAM ................................................... 283 3.2.1

Robot Connection Cables.....................................................................................283

3.2.2

Teach Pendant Cable ............................................................................................297

3.2.3

Connecting the Input Power .................................................................................298

3.2.4

Connecting the External Power Supply ON/OFF Switch ....................................301

3.2.5

Connecting the External Emergency Stop............................................................303

3.2.6

Connecting the Non-Teaching Enabling (NTED) Signal (CRM65) ....................314

3.2.7

Connecting the Auxiliary Axis Brake（CRR65 A/B）.......................................316

3.2.8

Connecting the Auxiliary Axis Over Travel (CRM68) ........................................317

3.2.9

Connecting the Operation Box .............................................................................318

PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES...................................................................................... 319 4.1

PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM.......................... 322 4.1.1

When Process I/O Board EA/EB/GA is Used (A-cabinet)...................................322

4.1.2

When Process I/O Board FA is Used (A-cabinet)................................................324

4.1.3

When Process I/O Board CA/HA is Used (B-cabinet).........................................325

4.1.4

When Process I/O Board JA is Used (B-cabinet).................................................327

4.1.5

When Process I/O Board KA is Used (A-Cabinet) ..............................................328

4.1.6

When I/O Unit-MODEL A is Used......................................................................329 4.1.6.1

4.1.7

In case of B-cabinet ......................................................................................... 329

When Two or more Process I/O Printed Circuit Boards and I/O Unit-MODEL A are Used 330 4.1.7.1

4.2

4.3 4.4

4.5

PERIPHERAL DEVICE INTERFACE COMBINATION .............................. 331 4.2.1

In Case of A-cabinet.............................................................................................331

4.2.2

In Case of B-cabinet .............................................................................................332

PROCESS I/O BOARD SIGNALS ............................................................. 333 INTERFACE FOR PERIPHERAL DEVICES.............................................. 336 4.4.1

Peripheral Device and Control Unit Connection

(Source Type DO) .............336

4.4.2


(Sink Type DO)..............351

INTERFACE FOR WELDER...................................................................... 364 4.5.1

4.6

Connection Between the Control Unit and Welder ..............................................364

INTERFACE FOR END EFFECTOR ......................................................... 374 4.6.1

4.7

In case of B-cabinet ......................................................................................... 330

Connection Between the Mechanical Unit and End Effector...............................374

DIGITAL I/O SIGNAL SPECIFICATIONS .................................................. 376 c-4

TABLE OF CONTENTS

B-82595EN-2/02

4.8

4.7.1

Peripheral Device Interface A ..............................................................................376

4.7.2

End Effector Control Interface .............................................................................380

4.7.3

I/O Signal Specifications for ARC-Welding Interface.........................................382

SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS ........................................................................................ 386 4.8.1

Peripheral Device Interface A Cable (CRM2, CRMA5: Honda Tsushin, 50 pins) 386

4.8.2

Peripheral Device Interface B Cable (CRM4, CRMA6: Honda Tsushin, 20 pins) 386

4.9

4.10

4.11

4.8.3

ARC Weld Connection Cable (CRW1, CRW7:Honda Tsushin,34pins)..............387

4.8.4

ARC Weld Connection Cable（CRW10 : Honda Tsushin, 50 pins） ................387

CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS, AND ARC WELDERS ........................................................ 388 4.9.1

Peripheral Device Connection Cable....................................................................388

4.9.2

Peripheral Device Cable Connector .....................................................................389

4.9.3

End Effector Cable Connector .............................................................................391

4.9.4

Recommended Cables ..........................................................................................392

CONNECTION OF HDI ............................................................................. 393 4.10.1

Connecting HDI ...................................................................................................393

4.10.2

Input Signal Rules for the High-speed Skip (HDI) ..............................................395

CONNECTING THE COMMUNICATION UNIT ......................................... 396 4.11.1

RS-232-C Interface...............................................................................................396 4.11.1.1 Interface ........................................................................................................... 396 4.11.1.2 RS-232-C interface signals .............................................................................. 397 4.11.1.3 Connection between RS-232-C interface and I/O device ................................ 398

4.11.2

Ethernet Interface .................................................................................................400 4.11.2.1 4.11.2.2 4.11.2.3 4.11.2.4 4.11.2.5 4.11.2.6 4.11.2.7

5

Connection to Ethernet .................................................................................... 401 10/100 BASE-T connector (CD38) pin assignments....................................... 402 Cable connection ............................................................................................. 402 Lead materials.................................................................................................. 404 Connector specification ................................................................................... 406 Cable clamp and shielding............................................................................... 406 Grounding the network.................................................................................... 407

TRANSPORTATION AND INSTALLATION ....................................... 410 5.1 5.2

TRANSPORTATION.................................................................................. 411 INSTALLATION ......................................................................................... 412 5.2.1

Installation Method...............................................................................................412

5.2.2

Assemble at Installation .......................................................................................418 c-5

TABLE OF CONTENTS 5.3 5.4 5.5

B-82595EN-2/02

INSTALLATION CONDITION .................................................................... 420 ADJUSTMENT AND CHECKS AT INSTALLATION .................................. 421 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION ................................................................................................................... 422 5.5.1

Peripheral Device Interface Processing................................................................422

5.5.2

Resetting Overtravel.............................................................................................422

5.5.3

How to Disable/Enable HBK ...............................................................................423

5.5.4

How to Disable/Enable Pneumatic Pressure Alarm (PPABN).............................423

APPENDIX A

TOTAL CONNECTION DIAGRAM...................................................... 427

B

SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE ............... 466 B.1 B.2 B.3

B.4

C

SIGNAL ..................................................................................................... 467 SETTING COMMON VOLTAGE................................................................ 469 I/O Signals ................................................................................................. 470 B.3.1

Input Signals.........................................................................................................470

B.3.2

Output Signals ......................................................................................................474

Specifications of Digital Input/Output ......................................................... 478 B.4.1

Overview ..............................................................................................................478

B.4.2

Input/Output Hardware Usable in the R-30iA Controller ....................................478

B.4.3

Software Specifications ........................................................................................478

OPTICAL FIBER CABLE .................................................................... 479

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I. SAFETY PRECAUTIONS

Safety 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.

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety:

• 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

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:

i

Safety • People • External devices • Robot(s) • Tooling • Workpiece

Using Safety Enhancing Devices 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:

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

Setting Up a Safe Workcell 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.

• 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.

ii

Safety • 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 or firmware based controllers as the primary safety element unless they comply with applicable current robot safety standards.

• 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.

• 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.

iii

Safety

Staying Safe While Teaching or Manually Operating the Robot 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. Warning Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury 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 outside the robot work envelope whenever a program is being run. Failure 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. — 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.

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Safety

Staying Safe During Automatic Operation 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. • 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.

Staying Safe During Inspection 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.


• 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.

v

Safety

Staying Safe During Maintenance When performing maintenance on your robot system, observe the following rules:

• 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 an applicator bell cup can continue to spin at a very high speed even if the robot is idle. Use protective gloves or disable bearing air and turbine air before servicing these items.

• 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 voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock.HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit breaker to the OFF position removes power from the 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.

• 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.

vi

Safety • 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 from the robot before thoroughly reading and understanding the procedures in the appropriate 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.

• 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.

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Safety

Mechanical Safety Precautions Implement the following mechanical safety measures to prevent 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.

• 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.

Programming Safety Precautions 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. • 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.

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Safety

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 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.

ix

Safety 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 will occur if the DEADMAN switch is released on a bypassed robot.

• 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.

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

Staying Safe While Operating the Paint Robot 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 injury.

x

Safety Warning Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death. Warning Enclosures shall not be opened unless the area is know to be nonhazardous or all power has been removed from devices within the enclosure. Power shall not be restored after the enclosure has been opened until all combustible dusts have been removed from the interior of the enclosure and the enclosure purged. Refer to the Purge chapter for the required purge time.

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

• 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.

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Safety

Special Precautions for Combustible Dusts (powder paint) When the robot is used in a location where combustible dusts are found, such as the application of powder paint, the following special precautions are required to insure that there are no combustible dusts inside the robot.

• Purge maintenance air should be maintained at all times, even when the robot power is off. This will insure that dust can not enter the robot.

• A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed to dust when maintenance air is not present, it will be necessary to remove the covers and clean out any accumulated dust. Do not energize the robot until you have performed the following steps. 1. Before covers are removed, the exterior of the robot should be cleaned to remove accumulated dust. 2. When cleaning and removing accumulated dust, either on the outside or inside of the robot, be sure to use methods appropriate for the type of dust that exists. Usually lint free rags dampened with water are acceptable. Do not use a vacuum cleaner to remove dust as it can generate static electricity and cause an explosion unless special precautions are taken. 3. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust. 4. When the dust has been removed, the covers must be replaced immediately. 5. Immediately after the covers are replaced, run a complete purge cycle. The robot can now be energized.

Staying Safe While Operating Paint Application Equipment 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 within your organization. Also reference the following standards: NFPA 33 Standards for Spray Application Using Flammable or Combustible Materials , and NFPA 70 National Electrical Code .

• 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.

xii

Safety • 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.

• 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.

Staying Safe During Maintenance 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.

• 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.

xiii

Safety — Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.

• 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. Then, seek medical attention as soon as possible. — Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.

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1.SAFETY PRECAUTIONS

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1

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

1.1

WORKING PERSON The personnel can be classified as follows.

Operator : • Power ON/OFF for robot controller • Start of robot program with operator’s panel Programmer or teaching operator : • Operate for Robot • Teaching inside safety fence Maintenance engineer : • Operate for Robot • Teaching inside safety fence • Maintenance (adjustment, replacement) -

An operator cannot work inside the safety fence. A programmer, Teaching operator and maintenance engineer can work inside the safety fence. The workings inside safety fence are lifting, setting, teaching, adjusting, maintenance, etc.. To work inside the fence, the person must be trained for the robot.

Table 1 lists the workings of outside the fence. In this table, the symbol “{” means the working allowed to be carried out by the personnel.

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Table 1 List of workings outside the fence Operator

Power ON/OFF for Robot controller Select operating mode (AUTO, T1, T2) Select Remote/Local mode Select robot program with teach pendant Select robot program with external device Start robot program with operator’s panel Start robot program with teach pendant Reset alarm with operator’s panel Reset alarm with teach pendant Set data on the teach pendant Teaching with teach pendant Emergency stop with operator’s panel Emergency stop with teach pendant Emergency stop with safety fence open Maintain for operator’s panel Maintain for teach pendant

{

{

{ {

Programmer or Teaching operator { { { { { { { { { { { { { { {

Maintenance engineer { { { { { { { { {

{ { { {

In operating, programming and maintenance, the programmer, teaching operator and maintenance engineer take care of their safety using the following safety protectors, for example. • • •

Use adequate clothes, uniform, overall for operation Put on the safety shoes Use helmet

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1.2

WORKING PERSON SAFETY Working person safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure working person safety. (1) Have the robot system working person attend the training courses held by FANUC. FANUC provides various training courses. details.

Contact our sales office for

(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working person safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. (3) Install a safety fence with a gate so that no working person can enter the work area without passing through the gate. Install an interlock switch, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened. The controller is designed to receive this interlock signal of the door switch. When the gate is opened and this signal received, the controller stops the robot in an emergency. For connection, see Fig.1.1.

(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D). (5) Try to install the peripheral devices outside the work area. (6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when an working person enters the work area. (8) If necessary, install a safety lock so that no one except the working person in charge can turn on the power of the robot. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.

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

RI/RO, HBK, ROT

Interlock switch and safety plug when the door is opening.

Fig.1.2 Safety fence and safety gate

NOTE Terminals EAS1, EAS11, EAS2, and EAS21 are on the PC board in the operator box or operator panel.

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1.2.1

General Person Safety The general person is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also a general person. However, this section does not apply to teaching operators. (1) If it is not necessary for the robot to operate, turn off the power of the robot controller or press the EMERGENCY STOP button, and then proceed with necessary work. (2) Operate the robot system at a location outside of the safety fence (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the work area unexpectedly and also to prevent the worker from entering a dangerous area. (4) Install an EMERGENCY STOP button within the general person’s reach. The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

NOTE Connect to EES1 and EES11, EES2 and EES21. Fig.1.2.1 Connection diagram for external emergency stop button

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1.2.2

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Safety of the Teaching Operator While teaching the robot, it is necessary for the operator to enter the work area of the robot. It is particularly necessary to ensure the safety of the teaching operator. (1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating condition. (3) When entering the robot work area and teaching the robot, be sure to check the location and condition of the safety devices (such as the EMERGENCY STOP button and the DEADMAN switch on the teach pendant). (4) The teaching operator should pay careful attention so that no other workers enter the robot work area. Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the automatic operation mode set, the robot enters the emergency stop state. After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety fence. Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and switch function as follows: (1) Emergency stop button: Causes an emergency stop when pressed. (2) DEADMAN switch: Functions differently depending on the mode switch setting status. (a) Automatic operation mode: The DEADMAN switch is disabled. (b) Teach mode: Causes an emergency stop when the operator releases the DEADMAN switch or when the operator presses the switch strongly. Note) The DEADMAN switch is provided to place the robot in the emergency stop state when the operator releases the teach pendant or presses the pendant strongly in case of emergency. The R-30iA employs a 3-position DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly, the robot enters the emergency stop state. The operator's intention of starting teaching is determined by the control unit through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should make sure that the robot can operate in such conditions and be responsible in carrying out tasks safely.

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The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode switch of the operator panel DEADMAN switch, the teach pendant enable switch and the remote condition on the software.

Mode

Teach pendant enable switch On

AUTO mode Off On T1, T2 mode Off

Software remote condition

Teach pendant Operator panel

Peripheral device

Local Remote Local Remote

Not allowed Not allowed Not allowed Not allowed

Not allowed Not allowed Allowed to start Not allowed

Not allowed Not allowed Not allowed Allowed to start

Local Remote Local Remote

Allowed to start Allowed to start Not allowed Not allowed



(5) To start the system using the operator's panel, make certain that nobody is in the robot work area and that there are no abnormal conditions in the robot work area. (6) When a program is completed, be sure to carry out a test run according to the procedure below. (a) Run the program for at least one operation cycle in the single step mode at low speed. (b) Run the program for at least one operation cycle in the continuous operation mode at low speed. (c) Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing. (d) Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble. (e) After checking the completeness of the program through the test run above, execute it in the automatic operation mode. (7) While operating the system in the automatic operation mode, the teaching operator should leave the robot work area.

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1.2.3

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Safety During Maintenance For the safety of maintenance personnel, pay utmost attention to the following. (1) During operation, never enter the robot work area. (2) Except when specifically necessary, turn off the power of the controller while carrying out maintenance. Lock the power switch, if necessary, so that no other person can turn it on. (3) If it becomes necessary to enter the robot operation range while the power is on, press the emergency stop button on the operator panel, or the teach pendant before entering the range. The maintenance personnel must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly. (4) When disconnecting the pneumatic system, be sure to reduce the supply pressure. (5) Before the start of teaching, check that the robot and its peripheral devices are all in the normal operating condition. (6) Do not operate the robot in the automatic mode while anybody is in the robot work area. (7) When it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers are working nearby, make certain that their escape path is not obstructed. (8) When a tool is mounted on the robot, or when any moving device other than the robot is installed, such as belt conveyor, pay careful attention to its motion. (9) If necessary, have a worker who is familiar with the robot system stand beside the operator panel and observe the work being performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time. (10) When replacing or reinstalling components, take care to prevent foreign matter from entering the system. (11) When handling each unit or printed circuit board in the controller during inspection, turn off the circuit breaker to protect against electric shock. (12) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of non-specified ratings. They may cause a fire or result in damage to the components in the controller. (13) When restarting the robot system after completing maintenance work, make sure in advance that there is no person in the work area and that the robot and the peripheral devices are not abnormal.

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1.3

SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

1.3.1

Precautions in Programming (1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received. (2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal. (3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other. (4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states.

1.3.2

Precautions for Mechanism (1) Keep the component cells of the robot system clean, and operate the robot in an environment free of grease, water, and dust. (2) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot does not come into contact with its peripheral devices or tools.

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1.4

SAFETY OF THE ROBOT MECHANISM

1.4.1

Precautions in Operation (1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality. (2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the jog mode.

1.4.2

Precautions in Programming (1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere with each other. (2) Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

1.4.3

Precautions for Mechanisms (1) Keep the work area of the robot clean, and operate the robot in an environment free of grease, water, and dust.

1.5

SAFETY OF THE END EFFECTOR

1.5.1

Precautions in Programming (1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control. (2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.

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1.6

WARNING LABEL (1) Step-on prohibitive label

Fig.1.6 (a)

Step-on prohibitive label

Description Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing as well. (2) High-temperature warning label

Fig.1.6 (b)

High-temperature warning label

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

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(3) High-voltage warning label

Fig.1.6 (c)

High-voltage warning label

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

- 14 -

II. MAINTENANCE

MAINTENANCE

B-82595EN-2/02

1

1.OVERVIEW

OVERVIEW This manual describes the maintenance and connection of the R-30iA robot controller (called the R-30iA). Maintenance Part : Troubleshooting, and the setting, adjustment, and replacement of units Connection Part : Connection of the R-30iA controller to the robot mechanical unit and peripheral devices, and installation of the controller

WARNING Before you enter the robot working area, be sure to turn off the power to the controller or press the EMERGENCY STOP button on the operator's panel or teach pendant. Otherwise, you could injure personnel or damage equipment. - The RIA R15.06 - - 1999 compliant controller has safety circuit performance compliant with 4.5.4 control reliable. - For information on third party approvals, contact your FANUC representative. - The controller is designed to meet R15.06 - - 1999 American standard for industrial robots and robot systems - - safety requirements.

- 17 -

2.CONFIGURATION

2

MAINTENANCE

CONFIGURATION

- 18 -

B-82595EN-2/02

2.1

2.CONFIGURATION

MAINTENANCE

B-82595EN-2/02

EXTERNAL VIEW OF THE CONTROLLER The appearance and components might slightly differ depending on the controlled robot, application, and options used. Fig.2.1 (a) to (c) shows the view of R-30iA. Fig.2.1 (d) to (i) show the construction of the R-30iA controller. Fig.2.1 (j) to (l) show the external view of the operator’s panel. Fig.2.1 (m) and (n) show the block diagram of R-30iA.

Operation box

R-30iA controller

Teach pendant

Fig.2.1 (a) External view of the R-30iA controller (A-cabinet) Integrated operation box

Teach pendant R-30iA controller

Fig.2.1 (b) External view of the R-30iA controller (Integrated operation box)

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2.CONFIGURATION

MAINTENANCE

B-82595EN-2/02

Operator’s panel

Teach pendant

Fig.2.1 (c) External view of the R-30iA controller (B-cabinet)

- 20 -

2.CONFIGURATION

MAINTENANCE

B-82595EN-2/02

Emergency stop button

Teach pendant Enable switch Power supply unit Main board Emergency stop unit

Fan unit

Servo amplifier

Regenerative resistor unit

Transformer FANUNIT Side fan type

Rear fan type Fig.2.1 (d)

R-30iA A-cabinet interior

- 21 -

2.CONFIGURATION

MAINTENANCE

B-82595EN-2/02


Enable switch

Teach pendant Power supply unit 2-axis servo amplifier(AMP2)-M-430iA/2F 3-axis servo amplifier(AMP2)-M-430iA/2P

Main board Fan unit

Emergency stop unit

Heat exchanger

Servo amplifier

Fig.2.1 (e)

R-30iA A-cabinet interior (M-430iA)

- 22 -

2.CONFIGURATION

MAINTENANCE

B-82595EN-2/02

DC fan unit

Servo amplifier

3 mode switch


External air fan unit

Panel board Circuit breaker

Battery Emergency stop button

Back plane

RCC I/F unit

(only M-900iA/260L, M-900iA/350)

Main board

Enable switch Teach pendant

Door fan

Fig.2.1 (f)

Power supply unit

Optional slot

R-30iA B-cabinet interior (Front)

- 23 -

Emergency stop unit

2.CONFIGURATION

MAINTENANCE

1-axis Servo amplifier (AMP3)

B-82595EN-2/02

2-axis servo amplifier (AMP2)

6-servo amplifier (AMP1)

3 mode switch DC fan unit Emergency stop button


Panel board Circuit breaker

Battery Emergency stop button

Back plane RCC I/F unit

Main board


Door fan

Fig.2.1 (g)

Power supply unit

Optional slot

R-30iA B-cabinet interior (Front) (M-900 iA/600)

- 24 -

Emergency stop unit

2.CONFIGURATION

MAINTENANCE

B-82595EN-2/02

2-axis servo amplifier(AMP2)-M-430iA/2F 3-axis servo amplifier(AMP2)-M-430iA/2P

6-axis servo amplifier（AMP1）

Mode switch DC fan unit Emergency stop button


Panel board Circuit breaker Battery Back plane


RCC I/F unit

Main board


Door fan

Fig. 2.1 (h)

Power supply unit

Option slot

R-30iA B-cabinet interior（Front）(M-430iA)


Transformer

Fig.2.1 (i)

R-30iA B-cabinet interior (Back)

- 25 -

Emergency stop unit

2.CONFIGURATION

MAINTENANCE

B-82595EN-2/02

FAULT RESET

CYCLE START

FAULT

EMERGENCY STOP

POWER

Fig.2.1 (j) R-30iA panel overview

2 mode switch

3 mode switch Fig.2.1 (k)

Mode switch operation

- 26 -

B-82595EN-2/02

MAINTENANCE

2.CONFIGURATION

Fig.2.1 (l) USB/RS-232-C interface overview

- 27 -

2.CONFIGURATION

MAINTENANCE

Table 2.1 (a) ROBOT M-900iA/600 R-2000iB/200T M-900iA/260L M-900iA/350 M-410iB R-2000iB （except /200T） M-710iC M-16iB ARC Mate 120iB (Except ARC Mate 120iBe.) M-420iA, M-421iA M-6iB ARC Mate 100iB ARC Mate 120iBe F-200iB ARC Mate 100iC M-10iA M-430iA/2F M-430iA/2P

SERVO AMPLIFIER

B-82595EN-2/02

Servo amplifier specification REGENERATIVE REGISTOR A-CABINET B-CABINET

A06B-6107-H001 (AMP1) A06B-6117-H209 (AMP2) A06B-6117-H105 (AMP3)

A05B-2502-C100

A06B-6107-H001

A05B-2502-C100 A05B-2501-C102

A05B-2501-C103 A06B-6107-H002

A05B-2502-C100 A05B-2501-C100 A05B-2501-C102

A06B-6107-H003

A05B-2501-C101

A05B-2502-C101

A05B-2501-C105 A06B-6107-H004

A05B-2501-C101

A05B-2502-C101

A06B-6107-H007 (AMP 1) A06B-6117-H201 (AMP 2) A06B-6107-H007 (AMP 1) A06B-6117-H301 (AMP 2)

A05B-2501-C105

A05B-2502-C101

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2.CONFIGURATION

MAINTENANCE

B-82595EN-2/02

Table 2.1(b) ROBOT

fan type list for A-cabinet FAN TYPE REAR FAN SIDE FAN

M-410iB

―

○

M-710iC

―

○

M-16iB

○

―

ARC Mate 120iB

○

―

M-420iA, M-421iA

―

○

M-6iB

○

―

ARC Mate 100iB

○

―

F-200iB

―

○

ARC Mate 100iC

○

―

M-430iA

○

―

M-10iA

○

―

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2.CONFIGURATION

MAINTENANCE

Fig.2.1 (m) Block diagram of the R-30iA (A-cabinet)

- 30 -

B-82595EN-2/02

Transformer

Fan

24VDC

200 V, single-phase input

200 V, single-phase output

- 31 24VDC EMG signal

Servo signal (FSSB) EMG signal

200 V, 3-phase

Regenerative resistor

Servo amplifier (6–axis amplifier)

Switch

USB memory

Memory card

Process I/O I/O Unit-MODEL A

Motor power supply, Brake power supply

Pulse coder signals, Robot DI/DO signals

Battery

Transformer overheat signal

200 V, 3-phase

Signals for I/O Link and Teach pendant

E–stop unit

Panel board

Operator's panel

Main board

Robot

External E–stop External on/off

Teach pendant

Peripheral device (Ethernet)

Peripheral device (Serial)

Peripheral device (Serial)

MAINTENANCE

Circuit breaker

Fig.2.1 (n) Block diagram of the R-30iA (B-cabinet)

AC input 3Φ 200 – 230 VAC 380 – 400 VAC 380 – 415 VAC 440 – 500 VAC 500 – 575 VAC

Power supply unit

Backplane Printed-circuit board

B-82595EN-2/02

2.CONFIGURATION

2.CONFIGURATION

2.2

MAINTENANCE

B-82595EN-2/02

COMPONENT FUNCTIONS •

•

• • • •

• •

• • •

•

Main board The main board contains a microprocessor, its peripheral circuits, memory, and operator's panel control circuit. The main CPU controls servo mechanism positioning. I/O printed circuit board, FANUC I/O Unit MODEL-A Various types of printed circuit boards are provided for applications including process I/O. The FANUC I/O unit MODEL-A can also be installed. When it is used, various I/O types can be selected. These are connected with FANUC I/O Link. E-stop unit and MCC unit This unit controls the emergency stop system for both of the magnetic contactor and the precharge of the servo amplifier. Power supply unit The power supply unit converts the AC power to various levels of DC power. Backplane printed circuit board The various control printed circuit boards are mounted on the backplane printed circuit board. Teach pendant All operations including robot programming are performed with this unit. The controller status and data are indicated on the liquid-crystal display (LCD) on the pendant. Servo amplifier The servo amplifier controls servomotor, pulse coder signal, brake control, overtravel and hand broken. Operator's panel Buttons and LEDs on the operator's panel are used to start the robot and to indicate the robot status. The panel has a port and an USB interface for the serial interface to an external device and an interface to connect the memory card for data backup. It also controls the emergency stop control circuit. Transformer The supply voltage is converted to an AC voltage required for the controller by the transformer. Fan unit, heat exchanger These components cool the inside of the controller. Circuit breaker If the electric system in the controller malfunctions, or if abnormal input power causes high current in the system, the input power is connected to the circuit breaker to protect the equipment. Regenerative resistor To discharge the counter electromotive force from the servomotor, connect a regenerative resistor to the servo amplifier.

- 32 -

B-82595EN-2/02

2.3

MAINTENANCE

2.CONFIGURATION

PREVENTIVE MAINTENANCE Daily maintenance and periodic maintenance/inspection ensure reliable robot performance for extended periods of time. (1) Daily maintenance Before operating the system each day, clean each part of the system and check the system parts for any damage or cracks. Also check the following: (a) Before service operation Check the cable connected to the teach pendant for excessive twisting. Check the controller and peripheral devices for abnormalities. (b) After service operation At the end of service operation, return the robot to the specified position, then turn off the controller. Clean each part, and check for any damage or cracks. If the ventilation port of the controller is dusty, clean it. (2) Check after one month Check that the fan is rotating normally. If the fan has dirt and dust built up, clean the fan according to step (d) described below for inspection to be performed every 6 months. (3) Periodic inspection performed every six months Remove the top cover, louver, and back panel (if possible), then remove any dirt and dust from the inside of the transformer compartment. Wipe off dirt and dust from the fan and transformer. (4) Battery daily check Replace the battery on the front panel of the main board every 4 years. Please refer to the section 7.14. (5) Maintenance tools The following maintenance tools are recommended: (a) Measuring instruments AC/DC voltmeter (A digital voltmeter is sometimes required.) Oscilloscope with a frequency range of 5 MHz or higher, two channels (b) Tools Phillips screwdrivers : Large, medium, and small Standard screwdrivers : Large, medium, and small Nut driver set (Metric) Pliers Needle-nose pliers Diagonal cutting pliers

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3.TROUBLESHOOTING

3

MAINTENANCE

B-82595EN-2/02

TROUBLESHOOTING This chapter describes the checking method and corrective action for each error code indicated if a hardware alarm occurs. Refer to the operator's manual to release program alarms.

- 34 -

3.1

3.TROUBLESHOOTING

MAINTENANCE

B-82595EN-2/02

POWER CANNOT BE TURNED ON Check and Corrective action

(Check 1) (Corrective action)

Figure

Check that the circuit breaker is on and has not tripped. Turn on the circuit breaker. Circuit breaker

Circuit breaker

(Check 2)

(Corrective action)

Check whether the LED (PIL: green) on the power supply unit is on. If the LED is not on, 200 VAC is not supplied to the power supply unit. It is likely that fuse F1 in the power supply unit has blown. - If 200 VAC is not supplied: Find the cause by referencing the general schematic diagram presented in the appendix. - If 200 VAC is supplied: Find the cause of the blown fuse. Fuse F1 is in the power supply unit. Before you start troubleshooting, turn off the circuit breaker. a) If fuse F1 has blown: - See Corrective action (1). b) If fuse F1 has not blown: - Replace the power supply unit.

DB1: Diode stack F1(8.0A): Fuse for AC input

VS1: Surge absorber H1: Auxiliary power module

CP1: Connector for AC input CP1A: Connector for AC output CP2, CP3: Connector for AC output F3(7.5A): Fuse for +24E F4(7.5A): Fuse for +24V PIL: LED (green) CP5: Connector for +24E CP6: Connector for +24V ALM: LED (red) CP4: Connector for control

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3.TROUBLESHOOTING

MAINTENANCE

Check and Corrective action (Corrective action(1))

B-82595EN-2/02

Figure

Causes of blown fuses F1 and corrective action a) Check whether the unit and printed-circuit board connected to the connectors CP2 and CP3 in the power supply unit are abnormal, by referencing the general schematic diagram presented in the appendix. b) Short-circuit in the surge absorber VS1 VS1 is inserted to absorb surge voltage between input lines. If the surge voltage is excessive or sustained, excessively high voltage is applied to VS1 and a failure occurs in the short-circuit mode, causing F1 to blow. If a short-circuit occurs in VS1, and there is not a spare part, the system is permitted to operate without VS1. In this case, however, obtain and install a new VS1 as soon as possible. VS1 ordering number: A70L-0001-0015#20DK431 c) Short-circuit of diode stack DB1 d) The secondary power supply module is faulty : If one of the causes (b) to (c) above is detected, replace the power supply unit with a spare unit. The ordering number. for F1 is : A60L-0001-0450#8RO

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MAINTENANCE

B-82595EN-2/02

Check and Corrective action (Check 3)

(Corrective action)

(Check 4)

(Corrective action)

Check whether the EXON1 and EXON2 signals, and the EXOFF1 and EXOFF2 signals are connected on the terminal block on the panel board. If the external ON/OFF function is not used, connect terminal EXON1 to EXON2 and terminal EXOFF1 to EXOFF2. If the external ON and OFF lines are already used, check the mating contacts and the cable. Check whether the connector (JRS15) on the main board or the connector (JRS15) on the panel board is connected properly. Another probable cause is that the cable connected to either of these connectors is faulty. Confirm that the 200VAC power is supplied to connector CP1 by reverifying Checks 1 - 3, and verifying that the ON/OFF switch is functioning properly. If the red ALM (Alarm) LED on the power supply unit is on, verify that the +24V external connection cable is connected to 0V or ground. If the problem still exists, check the power supply unit using the following procedure : a) Check Fuse F4. - If the fuse is blown, see Corrective action 2. b) Fuse F4 is not blown. - A printed circuit board or unit that uses a DC supply (+2.5V, +3.3V, +5V, +24V, or +15V) is faulty. - Verify that 200VAC is being supplied to connector CP1. If the power is supplied, replace the power supply unit.

3.TROUBLESHOOTING Figure Short–circuit plate : Between EXON1 and -EXON2 Short–circuit plate : Between EXOFF1 and EXOFF2

DB1: Diode stack F1(8.0A): Fuse for AC input CP1: Connector for AC input CP1A: Connector for AC output CP2, CP3:Connector for AC output

VS1: Surge absorber H1: Auxiliary power module

F3(7.5A): Fuse for +24E F4(7.5A): Fuse for +24V PIL: LED (green) CP5: Connector for +24E CP6: Connector for +24V ALM: LED (red) CP4: Connector for control

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

- 37 -

3.TROUBLESHOOTING

MAINTENANCE

Check and Corrective action (Corrective action(2))

B-82595EN-2/02

Figure

Causes of blown fuse F4 and corrective action The device connected to connector CP5 of the power supply unit may be faulty. If no device is connected to CP5 or the connected device is normal, the +24 V power used in a printed circuit board connected to the backplane is faulty. The ordering number of F4 is A60L-0001-0046#7.5 :

- 38 -

B-82595EN-2/02

3.2

3.TROUBLESHOOTING

MAINTENANCE

ALARM OCCURRENCE SCREEN The alarm occurrence screen displays only the alarm conditions that are currently active. If an alarm reset signal is input to reset the alarm conditions, the alarm occurrence screen displays the message "PAUSE or more serious alarm has not occurred." The alarm occurrence screen displays only the alarm conditions (if any) that occur after the most recently entered alarm reset signal. To erase all alarm displays from the alarm occurrence screen. Press the CLEAR key (+ shift) on the alarm history screen. The alarm occurrence screen is intended to display PAUSE or more serious alarms. It will not display WARN, NONE, or a reset. It is possible to disable PAUSE and some of more serious alarms from being displayed by setting the $ER_NOHIS system variable appropriately. If two or more alarms have occurred, the display begins with the most recent alarm. Up to 100 lines can be displayed. If an alarm has a cause code, it is displayed below the line indicating the alarm. Press the screen selection key to select [4 ALARM].

Press the alarm key.

Automatic alarm display upon occurrence

Alarm occurrence screen display

Press F3 [ACTIVE].

Press F3 [HIST].

Alarm history screen display

Fig.3.2 Alarm occurrence screen and alarm history screen display procedure

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3.TROUBLESHOOTING

MAINTENANCE

B-82595EN-2/02

Displaying the alarm history/alarm detail information

Step (1) Press the MENUS key to display the screen menu. (2) Select [ALARM]. You will see a screen similar to the following 3 4 ALARM 5 I/O

INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Specified line does not exist Alarm JOINT 30 % 1/25 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop 3 R E S E T 4 SRVO-027 Robot not mastered(Group:1) 5 SYST-026 System normal power up

MENUS

[ TYPE ]

CLEAR

HELP

NOTE The latest alarm is assigned number 1. To view messages that are currently not on the screen, press the F5, HELP, then press the right arrow key. (3) To display the alarm detail screen, press F5, [HELP]. CLEAR

HELP F5

INTP-224 (SAMPLE1, 7) Jump label is fail INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Specified line does not exist 30-MAY-44 07:15 STOP.L 00000110 Alarm 1/25 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop [ TYPE ]

CLEAR

HELP

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

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

SHIFT

F4

HELP

NOTE When system variable $ER_NOHIS = 1, NONE alarms or WARN alarms are not recorded. When $ER_NOHIS=2, resets are not recorded in the alarm history. When $ER_NOHIS=3, resets, WARN alarms, and NONE alarms are not recorded. - 40 -

B-82595EN-2/02

3.TROUBLESHOOTING

MAINTENANCE

The following map indicates teach pendant operations used to check an alarm. 4 ALARM F1 [TYPE] Alarm : Active F1 [TYPE] F3 HIST Alarm : HIST F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP DETAIL Alarm F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP

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3.TROUBLESHOOTING

3.3

MAINTENANCE

B-82595EN-2/02

SAFETY SIGNALS The safety signal screen indicates the state of signals related to safety. To be specific, the screen indicates whether each safety signal is currently on. On this screen, it is impossible to change the state of any safety signal. Table 3.3 Safety signals Description

Safety signal Operator’s panel emergency stop Teach pendant emergency stop External emergency stop Fence open DEADMAN switch

Teach pendant operable Hand broken

Robot overtravel

Abnormal air pressure

This item indicates the state of the emergency stop button on the operator’s panel. If the EMERGENCY STOP button is pressed, the state is indicated as “TRUE”. This item indicates the state of the emergency stop button on the teach pendant. If the EMERGENCY STOP button is pressed, the state is indicated as “TRUE”. This item indicates the state of the external emergency stop signal. If the EMERGENCY STOP signal is asserted, the state is indicated as “TRUE”. This item indicates the state of the safety fence. If the safety fence is open, the state is indicated as “TRUE”. This item indicates whether the DEADMAN switch on the teach pendant is grasped. If the teach pendant is operable, and the DEADMAN switch is grasped correctly, the state is indicated as “TRUE”. If the DEADMAN switch is released or is grasped tightly when the teach pendant is operable, an alarm occurs, causing the servo power to be switched off. This item indicates whether the teach pendant is operable. If the teach pendant is operable, the state is indicated as “TRUE”. This item indicates the state of the hand safety joint. If the hand interferes with a workpiece or anything like this, and the safety joint is opened, the state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be switched off. This item indicates whether the current position of the robot is out of the operation range. If any robot articulation goes out of the operation range beyond the overtravel switch, the state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be switched off. This item indicates the state of the air pressure. The abnormal air pressure signal is connected to the air pressure sensor. If the air pressure is not higher than the specified value, the state is indicated as “TRUE”.

Step (1) (2) (3) (4)

Press the MENUS key to display the screen menu. Select STATUS on the next page. Press F1, [TYPE] to display the screen switching menu. Select Safety Signal. You will see a screen similar to the following.

SYSTEM Safety

1 2 3 4 5 6 7 8 9

JOINT 30%

SIGNAL NAME

STATUS

SOP E-Stop: TP E-stop: Ext E-Stop: Fence Open: TP Deadman: TP Enable: Hand Broken: Over Travel: Low Air Alarm:

FALSE FALSE FALSE FALSE TRUE TRUE FALSE FALSE

[TYPE]

- 42 -

1/11

FALSE

3.4

3.TROUBLESHOOTING

MAINTENANCE

B-82595EN-2/02

MASTERING Mastering is needed if: (1) The SRVO-062 BZAL or SRVO-038 pulse mismatch alarm occurs, or (2) The pulse coder is replaced. Item (1) requires simplified mastering, while item (2) requires zero-degree or fixture position mastering. (Zero-degree position mastering is just for quick-fix purposes. After zero-degree position mastering is used, fixture position mastering should be performed later.) The mastering procedure is described below. For details, refer to an applicable maintenance manual of mechanical unit or operator's manual of control unit.

Condition System variable $MASTER_ENB must be set to 1 or 2. SYSTEM Variables 57 $MASTER_ENB

JOINT 10% 57/136 1

Step (1) (2) (3) (4) 9 0 -- NEXT --

MENUS 5 POSITION 6 SYSTEM 7

Press . Select SYSTEM. Press F1, TYPE. Select Master/Cal you will see a screen similar to the following. SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 30%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE

Press 'ENTER' or number key to select. Master /TYPE

[TYPE]

LOAD RES_PCA

DONE

F1

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

NOTE Mastering can not be performed until axis is rotated enough to establish a pulse. - 43 -

3.TROUBLESHOOTING

MAINTENANCE

B-82595EN-2/02

(6) Select "1 FIXTURE POSITION MASTER" and press the F4 key (yes). Mastering data is set. SYSTEM Master/Cal

SYSTEM Master/Cal

1 FIXTURE POSITION MASTER ENTER 2 ZERO POSITION MASTER Master at master position? [NO] Master at master position? ] YES [ TYPE ]

NO

JOINT

30 %

1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <122000309> <2000319>

F4 [ TYPE ]

LOAD

RES_PCA

DONE

(7) Select "6 CALIBRATE" and press the F4 key (yes). Calibration is performed. Alternatively, to perform positioning, turn the power off, then turn it on again. Calibration is performed whenever the power is turned on. 5 SET QUICK MASTER REF 6 CALIBRATE Calibrate? [NO] ENTER Calibrate? [NO] [ TYPE ]

SYSTEM Master/Cal

YES

F4

JOINT

30 %

1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <10.000> <-25.000> <40.000> <5.000> <-15.000> <0.000> [ TYPE ] LOAD RES_PCA DONE

(8) Press F5 "DONE", after mastering. DONE

F5

- 44 -

B-82595EN-2/02

3.5

MAINTENANCE

3.TROUBLESHOOTING

TROUBLESHOOTING USING THE ERROR CODE (1) SRVO-001 Operator panel E-stop (Explanation) The emergency stop button on the operator's panel is pressed. (Action 1) Release the emergency stop button pressed on the operator's panel. (Action 2) Check the wires connecting between the emergency stop button and the panel board (CRT16) for continuity. If an open wire is found, replace the entire harness. (Action 3) Check the wires connecting between the teach pendant and the panel board (CRS20) for continuity. If an open wire is found, replace the entire harness. (Action 4) With the emergency stop in the released position, check for continuity across the terminals of the switch. If continuity is not found, the emergency stop button is broken. Replace the switch unit or the operator's panel. (Action 5) Replace the teach pendant. (Action 6) Replace the panel board. Before executing the (Action 7), perform a complete controller back-up to save all your programs and settings. (Action 7) Replace the main board.

NOTE If SRVO-001 is issued together with SRVO-213, a fuse may have blown. Take the same actions as for SRVO-213.

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3.TROUBLESHOOTING

MAINTENANCE

B-82595EN-2/02



(A-cabinet)

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

CRS20

CRT16

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

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

- 46 -

B-82595EN-2/02

MAINTENANCE

3.TROUBLESHOOTING

(2) SRVO-002 Teach pendant E-stop (Explanation) The emergency stop button on the teach pendant was pressed. (Action 1) Release the emergency stop button on the teach pendant. (Action 2) Replace the teach pendant. Emergency stop button

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

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3.TROUBLESHOOTING

MAINTENANCE

B-82595EN-2/02

(3) SRVO-003 DEADMAN switch released (Explanation) The teach pendant is enabled, but the DEADMAN switch is not pressed. Alternatively, the DEADMAN switch is pressed strongly. (Action 1) Check the intermediate position of the DEADMAN switch on the teach pendant. (Action 2) Check that the mode switch on the operator's panel and the enable switch on the teach pendant are at the correct positions. (Action 3) Replace the teach pendant. (Action 4) Check the mode switch connection and operation. If trouble is found, replace the mode switch. (Action 5) Replace the panel board.

Enable switch

DEADMAN switch

Fig.3.5 (3) (a) SRVO-003 DEADMAN switch released

3 mode switch

2 mode switch (Mode switch)

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(Panel board) Fig. 3.5 (3) (b) SRV0-003 Mode switch and panel board

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(4) SRVO-004 Fence open (Explanation) In the automatic operation mode, the safety fence contact connected to EAS1-EAS11 or EAS2-EAS21 of TBOP4 is open. (Action 1) When a safety fence is connected, close the safety fence. (Action 2) Check the cables and switches connected between EAS1 and EAS11 and between EAS2 and EAS21 of the terminal block TBOP4 on the panel board. (Action 3) If the safety fence signal is not used, make a connection between EAS1 and EAS11 and between EAS2 and EAS21 of the terminal block TBOP4 on the panel board. (Action 4) Check the mode switch. If trouble is found, replace the mode switch. (Action 5) Replace the panel board.

NOTE If SRVO-004 is issued together with SRVO-213, a fuse may have blown. Take the same actions as for SRVO-213.

EAS1 EAS11 EAS2 EAS22

(Panel board)

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3 mode switch

2 mode switch

Fig. 3.5 (4)

3.TROUBLESHOOTING

(Mode switch) Panel board and mode switch

WARNING In a system using the safety fence signal, it is very dangerous to disable the signal when a connection is made between EAS1 and EAS11 and between EAS2 and EAS21 of TBOP4. Never make such an attempt. If a temporary connection is needed for operation, separate safety measures must be taken.

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(5) SRVO-005 Robot overtravel (Explanation) The robot has moved beyond a hardware limit switch on the axes. (Action 1) 1) Select [System OT release] on the overtravel release screen to release each robot axis from the overtravel state. 2) Hold down the shift key, and press the alarm release button to reset the alarm condition. 3) Still hold down the shift key, and jog to bring all axes into the movable range. (Action 2) Replace the limit switch. (Action 3) (Action 4) (Action 5) (Action 6)

Check the FS2 fuse on the servo amplifier. If the SRVO-214 Fuse blown alarm is also generated, the FS2 fuse has blown. Check the end effector connector. Replace the servo amplifier. Verify the following for connector RP1 at the base of the robot : 1) There are no bent or dislocated pins in the male or female connectors. 2) The connector is securely connected. Then verify that connectors CRF8 and CRM68 on the servo amplifier are securely connected. Also verify that the RP1 cable is in good condition, and there are no cuts or kinks visible. If no limit switch is in use, jumper connector must be attached in the mechanical unit. Check for the jumper connector.

NOTE It is factory-placed in the overtravel state for packing purposes. If the Overtravel signal is not in use, it may have been disabled by short-circuiting in the mechanical unit.

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3.TROUBLESHOOTING Servo amplifier

Servo amplifier

(A-cabinet)

(B-cabinet)

Connector (CRF8) Connector (CRM68) FS2

Fig. 3.5 (5)

(Servo amplifier) SRVO-005 Robot overtravel

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(6) SRVO-006 Hand broken (Explanation) The safety joint (if in use) might have been broken. Alternatively, the HBK signal on the robot connection cable might be a ground fault or a cable disconnection. (Action 1) Hold down the shift key, and press the alarm release button to reset the alarm condition. Still hold down the shift key, and jog the tool to the work area. 1) Replace the safety joint. 2) Check the safety joint cable. (Action 2) Replace the servo amplifier. (Action 3) Verify the following for connector RP1 at the base of the robot : 1) There are no bent or dislocated pins in the male or female connectors. 2) The connector is securely connected. Then verify that connector CRF8 on the servo amplifier is securely connected. Also verify that the RP1 cable is in good condition, and there are no cuts or kinks visible. Check the robot connection cable (RP1) for a ground fault or a cable disconnection.

NOTE If the Hand broken signal is not in use, it can be disabled by software setting. Refer to Subsection 5.5.3 How to Disable/Enable HBK in Part III, "CONNECTIONS" of "Maintenance Manual" to disable the Hand broken signal. Servo amplifier

Servo amplifier

(A-cabinet)

(B-cabinet)

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Connector (CRF8) Connector (CRM68) FS2

(Servo amplifier) Fig. 3.5 (6) SRVO-006 Hand broken

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(7) SRVO-007 External E-stop (Explanation) On the terminal block TBOP4 of the panel board, no connection of external emergency stop is made between EES1 and EES11, EES2 and EES21. (Action 1) If an external emergency stop switch is connected, release the switch. (Action 2) Check the switch and cable connected to EES1-EES11 and EES2-EES21 on TBOP4. (Action 3) When this signal is not used, make a connection between EES1 and EES11, EES2 and EES21. (Action 4) Replace the panel board.

NOTE If SRVO-007 is issued together with SRVO-213, a fuse may have blown. Take the same actions as for SRVO-213. EES1 EES11 EES2 EES22

(Panel board) Fig.3.5 (7) SRVO-007 Panel board

WARNING In a system using the external emergency stop signal, it is very dangerous to disable the signal when a connection is made between EES1 and EES11 and between EES2 and EES21 of TBOP4. Never make such an attempt. If a temporary connection is needed for operation, separate safety measures must be taken.

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(8) SRVO-009 Pneumatic pressure abnormal (Explanation) An abnormal air pressure was detected. The input signal is located on the end effector of the robot. Refer to the manual of your robot. (Action 1) If an abnormal air pressure is detected, check the cause. (Action 2) Check the end effector connector. (Action 3) Check the robot connection cable (RP1) for a ground fault or a cable disconnection. If a fault or a disconnection is detected, replace the cable. (Action 4) Replace the servo amplifier. (Action 5) Replace the internal cables of the robot.

NOTE Pneumatic pressure alarm input is on the end effector. Please refer to the manual of your robot. Servo amplifier

Servo amplifier

(A-cabinet)

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

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(9) SRVO-014 Fan motor abnormal (Explanation) When a fan motor stops on backplane unit, TP shows the following message.In one minutes from occurring of alarm, robot stops and can not be operated from TP. The robot can be recovered by replacing a fan motor.Number in the bracket indicateds which fan is abnormal. (1): fan above the slot1 (2): fan above slot2 (3) : both fans (Action 1) Check the fan motor and its cables. Replace them if necessary. (Action 2) Replace the backplane unit. Before executing the (Action 3), perform a complete controller back-up to save all your programs and settings. (Action 3) Replace the main board.

Fan motor

Main board

Fig. 3.5 (9)

SRVO-014 Fan motor abnormal

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(10) SRVO-015 SYSTEM OVER HEAT (Group : i Axis : j) (Explanation) The temperature in the control unit exceeds the specified value. (Action 1) If the ambient temperature is higher than specified (45℃), cool down the ambient temperature. (Action 2) If the fan motor is not running, check it and its cables. Replace them if necessary. Before executing the (Action 3), perform a complete controller back-up to save all your programs and settings. (Action 3) Replace the main board. (The thermostat on the main board may be faulty.) Fan unit

Main board

Heat exchanger

A-cabinet (Front) Fan unit

Fan unit

A-cabinet (Side fan type)

A-cabinet (Rear fan type)

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Servo amplifier

Main board

Door fan unit

B-cabinet (Front)

Amplifier fan

Fig.3.5 (10)

B-cabinet (Back) SRVO-015 SYSTEM OVER HEAT

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(11) SRVO-018 Brake abnormal (Explanation) An excessive brake current is detected. The ALM LED on the servo amplifier is lit. (Action 1) Check the robot connection cable (RM1) and cables internal to the mechanical section for a short-circuit and connection to the ground. If a fault or a disconnection is detected, replace the cable. (Action 2) This alarm may occur if the brake connector is not attached. Make sure that connector CRM88 is securely attached to the servo amplifier. (Action 3) Replace the servo amplifier. Servo amplifier

Servo amplifier

(A-cabinet)

(B-cabinet) Fig.3.5 (11) SRVO-018 Brake abnormal

CAUTION This error can be caused by the optional brake release unit if the on/off switch is left in on position while the operator attempts to jog the robot. To recover, turn the brake release unit off and cycle the controller power.

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(12) SRVO-021 SRDY off (Group : i Axis : j) (Explanation) The HRDY is on and the SRDY is off, although there is no other cause of an alarm. (HRDY is a signal 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 a servo amplifier alarm has occurred. If a servo 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 on for an unknown reason. (Action 1) Make sure that the emergency stop board connectors CP2, CRM96, CNMC3, and servo amplifier SRM96 are securely attached to the servo amplifier. (Action 2) It is possible that an instant disconnection of power source causes this alarm. Check whether an instant disconnection occurred. (Action 3) Replace the E-stop unit. (Action 4) Replace the servo amplifier. Servo amplifier

E-stop unit

Main board Servo amplifier

Main board

(A-cabinet)

(B-cabinet) Fig.3.5 (12) SRVO-021 SRDY off

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(13) SRVO-022 SRDY on (Group : i Axis : j) (Explanation) When the HRDY is about to go on, the SRDY is already on. (HRDY is a signal with which the host directs 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.) (Action 1) Replace the servo amplifier as the alarm message. Servo amplifier

E-stop unit

Main board Servo amplifier

Main board

(A-cabinet)

(B-cabinet) Fig.3.5 (13) SRVO-022 SRDY on

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(14) SRVO-023 Stop error excess (Group : i Axis : j) (Explanation) When the servo is at stop, the position error is abnormally large. Check whether the brake is released through the clack sound of the brake or vibration. In case that the brake is not released. (Action 1) If the brake is not released, check the continuity of the brake line in the robot connection cable and the robot internal cable. (Action 2) If the disconnection is not found, replace the servo amplifier or the servo motor. In case that the brake is released. (Action 1) Check whether the obstacle disturbs the robot motion. (Action 2) Make sure that connectors CNJ1A-CNJ6 are securely attached to the servo amplifier. (Action 3) Check the continuity of the robot connection cable and the internal robot power cable. (Action 4) 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.) (Action 5) Check the input voltage to the controller is within the rated voltage and no phase is lack. And check the setting of the transformer is correct. Check each phase voltage of the CRR38A or CRR38B connector of the three-phase power (200 VAC) input to the servo amplifier. If it is 210 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 causing an alarm.). (Action 6) Replace the servo amplifier. (Action 7) Replace the motor of the alarm axis.

NOTE Incorrect setting of the brake number causes this alarm.

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Servo amplifier

(A-cabinet)

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

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(15) SRVO-024 Move error excess (Group : i Axis : j) (Explanation) When the robot is running, its position error is greater than a specified value ($PARAM _ GROUP. $MOVER _ OFFST or $PARAM _ GROUP. $TRKERRLIM). It is likely that the robot cannot follow the speed specified by program. (Action 1) Take the same actions as SRVO-023. (16) SRVO-027 Robot not mastered (Group : i) (Explanation) An attempt was made to calibrate the robot, but the necessary adjustment had not been completed. (Action) Check whether the mastering is valid. If the mastering is invalid, master the robot.

WARNING If the position data is incorrect, the robot or additional axis can operate abnormally, set the position data correctly. Otherwise, you could injure personnel or damage equipment. (17) SRVO-030 Brake on hold (Group:i) (Explanation) If the temporary halt alarm function is enabled ($SCR.$BRKHOLD ENB=1), SRVO-030 is issued when a temporary halt occurs. When this function is not used, disable the setting. (Action) Disable [Servo-off in temporary halt] on the general item setting screen [6 General Setting Items]. (18) SRVO-033 Robot not calibrated (Group : i) (Explanation) An attempt was made to set up a reference point for simplified adjustment, but the robot had not been calibrated. (Action) Calibrate the robot. 1. Supply power. 2. Set up a simplified adjustment reference point using [Positioning] on the positioning menu. (19) SRVO-034 Ref pos not set (Group : i) (Explanation) An attempt was made to perform simplified adjustment, but the reference point had not been set up. (Action) Set up a simplified adjustment reference point on the positioning menu.

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(20) SRVO-036 Inpos time over (Group : i Axis : j) (Explanation) The robot did not get to the effective area ($PARAM _ GROUP.$ STOPTOL) even after the position check monitoring time ($PARAM _ GROUP. $INPOS _ TIME) elapsed. (Action) Take the same actions as for SRVO-023 (large position error at a stop). (21) SRVO-037 IMSTP input (Group : i) (Explanation) The *IMSTP signal for a peripheral device interface was input. (Action) Turn on the *IMSTP signal. (22) SRVO-038 Pulse mismatch (Group : i Axis : j) (Explanation) The pulse count obtained when power is turned off does not match the pulse count obtained when power is applied. 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. Check the alarm history. (Action 1) If the brake number is set to the non-brake motors, this alarm may occur. Check the software setting of the brake number. (Action 2) In case the robot has been moved by using the brake release unit while the power is off or when restoring the back-up data to the main board, this alarm may occur. Remaster the robot. (Action 3) If the robot has been moved because the brake failed, this alarm may occur. Check the cause of the brake trouble. Then remaster the robot. (Action 4) Replace the pulsecoder and master the robot.

Main board

(A-cabinet)

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Axis control card Main board

(B-cabinet) Fig.3.5 (22) SRVO-038 Pulse mismatch

(Main board)

(23) SRVO-042 MCAL alarm (Group : i Axis : j) (Explanation) This alarm means that the contacts of the magnetic contactor have stuck to each other. The alarm 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 an attempt is made to turn on the magnetic contactor. (Action 1) Replace the E-stop unit. (Action 2) Replace the servo amplifier. E-stop unit

Servo amplifier

Magnetic contactor

(A-cabinet)

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Servo amplifier

Magnetic contactor

E-stop unit (B-cabinet) Fig.3.5 (23) SRVO-042 MCAL alarm

(24) SRVO-043 DCAL alarm (Group : i Axis : j) (Explanation) 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.) (Action 1) This alarm may occur if the axis is subjected to frequent acceleration/deceleration or if the axis is vertical and generates a large amount of regenerative energy. If this alarm has occurred, relax the service conditions. (Action 2) Check fuse FS3 in the servo amplifier. If it has blown, remove the cause, and replace the fuse. One of the probable causes of a blown fuse is a ground fault in the servo amplifier for the auxiliary axis.

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(Action 3)

(Action 4)

(Action 5)

(Action 6)

(Action 7)

The ambient temperature is excessively high. Or the regenerative resistor can't be cooled effectively. Check the fan unit, and replace it if it stops. Clean up the fun unit, the regenerative resistor and the louver if they are dirty. Measure each inter-phase voltage of the input power supply, and make sure that all measurements satisfy the input voltage stipulation. If voltage is wrong, check the power supply facility. If voltage is correct, replace the E-stop unit. Make sure that the servo amplifier CRR63A and CRR63B connectors are connected tightly. Then detach the cable from CRR63A and CRR63B connectors on the Servo amplifier, and check for continuity between pins 1 and 2 of the cable-end connector. If there is no continuity between the pins, replace the regenerative resistor. Make sure that the servo amplifier CRR45A and CRR45B are connected tightly, then detach the cables from CRR45A and CRR45B on the servo amplifier and check the resistance between pins 1 and 2 of each cable end connector. If the resistance is not 9-16Ω, replace the regenerative resistor. CRR45B may not be used depending on the robot model. Replace the servo amplifier.

E-stop unit

Servo amplifier

A-cabinet (Front)

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3.TROUBLESHOOTING Regenerative resistor unit

Transformer

Transformer

Side fan type

Rear fan type A-cabinet (Back) Servo amplifier

regenerative resistor unit

Fan unit

B-cabinet (Front) B-cabinet (Back) Fig.3.5 (24) SRVO-043 DCAL alarm

(25) SRVO-044 HVAL alarm (Group : i Axis : j) (Explanation) The DC voltage (DC link voltage) of the main circuit power supply is abnormally high. (Action 1) Check the three-phase input voltage at the servo amplifier. If it is 240 VAC or higher, check the line voltage. (If the three-phase input voltage is higher than 240 VAC, high acceleration/deceleration can cause in this alarm.) (Action 2) 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.) (Action 3) Check that the CRR63A and CRR63B connectors of the servo amplifier are attached firmly. Next, - 71 -

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detach the cables then check the continuity between pins 1 and 2 of the cable-side connectors. If a disconnection is found, replace the regenerative resistor. Replace the servo amplifier. Servo amplifier

Servo amplifier

(A-cabinet)

(B-cabinet) Fig.3.5 (25) SRVO-044 HVAL alarm

(26) SRVO-045 HCAL alarm (Group : i Axis : j) (Explanation) Abnormally high current flowed in the main circuit of the servo amplifier. (Action 1) Turn off the power, and disconnect the power cable from the servo amplifier indicated by the alarm message. (And disconnect the brake cable (CRR88 on the servo amplifier) to avoid the axis falling unexpectedly.) Supply power and see if the alarm occurs again. If the alarm occurs again, replace the servo amplifier. (Action 2) Turn off the power and disconnect the power cable from the servo amplifier 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. (Action 3) Turn off the power and disconnect the power cable from the servo amplifier 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 is defective. Check each item in detail and replace it if necessary.

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Servo amplifier

(A-cabinet)

(B-cabinet) Fig.3.5 (26) SRVO-045 HCAL alarm

(27) SRVO-046 OVC alarm (Group : i Axis : j) (Explanation) This alarm is issued to prevent the motor from thermal damage that might occur when the root meant square current calculated within the servo system is out of the allowable range. (Action 1) Check the operating condition for the robot and relax the service condition if possible. If the load or operating condition has exceeded the rating, reduce the load or relax the operating condition to meet the rating. (Action 2) Check whether the voltage input to the controller is within the rated voltage and also check whether the voltage set for the transformer of the controller is correct. (Action 3) Check whether the brake of the corresponding axis is released. (Action 4) Check whether there is a factor that has increased the mechanical load on the corresponding axis. (Action 5) Replace the servo amplifier. (Action 6) Replace the motor of the corresponding axis. (Action 7) Replace the E-stop unit (Action 8) Replace the motor power line (robot connection cable) of the corresponding axis. (Action 9) Replace the motor power line and brake line (inside the mechanical section) of the corresponding axis.

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Servo amplifier

Servo amplifier

(A-cabinet)

(B-cabinet) Fig.3.5 (27) SRVO-046 OVC alarm

Reference Relationships among the OVC, OHAL, and HC alarms

- Overview This section points out the differences among the OVC, OHAL, and HC alarms and describes the purpose of each alarm.

- Alarm detection section Abbreviation

Designation

OVC OHAL

Overcurrent alarm Overheat alarm

HC

High current alarm

Detection section Servo software Thermal relay in the motor Thermal relay in the servo amplifier Thermal relay in the separate regenerative discharge unit Servo amplifier

- Purpose of each alarm 1)

2)

HC alarm (high current alarm) If high current flow in a power transistor momentarily due to abnormality or noise in the control circuit, the power transistor and rectifier diodes might be damaged, or the magnet of the motor might be degaussed. The HC alarm is intended to prevent such failures. OVC and OHAL alarms (overcurrent and overload alarms) The OVC and OHAL alarms are intended to prevent overheat that may lead to the burnout of the motor winding, the breakdown of the servo amplifier transistor, and the separate regenerative resistor. The OHAL alarm occurs when each built-in thermal relay detects a temperature higher than the rated value. However, this - 74 -

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method is not necessarily perfect to prevent these failures. For example, if the motor frequently repeats to start and stop, the thermal time constant of the motor, which has a large mass, becomes higher than the time constant of the thermal relay, because these two components are different in material, structure, and dimension. Therefore, if the motor continues to start and stop within a short time as shown in Fig. 3.5 (a), the temperature rise in the motor is steeper than that in the thermal relay, thus causing the motor to burn before the thermal relay detects an abnormally high temperature. Temperature Start

Stop

Start

Stop

Start Thermal time constant of the motor is high.

Temperature at which the winding starts to burn

Thermal time constant of the thermal relay is low.

Time

Fig.3.5 (a) Relationship between the temperatures of the motor and thermal relay on start/stop cycles

To prevent the above defects, software is used to monitor the current in the motor constantly in order to estimate the temperature of the motor. The OVC alarm is issued based on this estimated temperature. This method estimates the motor temperature with substantial accuracy, so it can prevent the failures described above. To sum up, a double protection method is used; the OVC alarm is used for protection from a short-time overcurrent, and the OHAL alarm is used for protection from long-term overload. The relationship between the OVC and OHAL alarms is shown in Fig.3.5 (b). Current Protection area for the motor and servo amplifier Protection by the OHAL Limit current

Protection by the OVC

Rated continuous current Time

Fig.3.5 (b)

Relationship between the OVC and OHAL alarms

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NOTE The relationship shown in Fig.3.5 (b) is taken into consideration for the OVC alarm. The motor might not be hot even if the OVC alarm has occurred. In this case, do not change the parameters to relax protection. (28) SRVO-047 LVAL alarm (Group : i Axis : j) (Explanation) The control power supply voltage (+5 V, etc.) supplied from the power supply circuit in the servo amplifier is abnormally low. (Action 1) Replace the servo amplifier. (Action 2) Replace the power supply unit. Servo amplifier

Servo amplifier

Power supply unit

Power supply unit

(A-cabinet)

(B-cabinet) Fig.3.5 (28) SRVO-047 LVAL alarm

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(29) SRVO-049 OHAL1 alarm (Group : i Axis : j) (Explanation) The thermostat in the transformer worked. Alternatively, fuse F1 or F2 in the servo amplifier has blown. (Action 1) Check whether the fan is stopped and also check whether the vent hole is clogged. If necessary, clean or replace them. (Action 2) If SRVO-049 is issued when the robot operating condition is severe, check the robot operating condition then relax the condition when possible. (Action 3) Check that a connection is made between the transformer connector CPOH and the emergency stop unit CRM73. (Action 4) Replace the servo. (Action 5) Replace the transformer. E-stop unit

Servo amplifier

A-cabinet (Front) Regenerative resistor unit


Transformer

Transformer

Side fan type

Rear fan type A-cabinet (Back)

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Servo amplifier

regenerative resistor unit

Fan unit Transformer

E-stop unit B-cabinet (Front) B-cabinet (Back) Fig.3.5 (29) SRVO-049 OHAL1 alarm

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(30) SRVO-050 CLALM alarm (Group : i Axis : j) (Explanation) The disturbance torque estimated by the servo software is abnormally high. (A collision has been detected.) (Action 1) Check whether the robot has collided and also check whether there is a factor that has increased the mechanical load on the corresponding axis. (Action 2) Check whether the load settings are valid. (Action 3) Check whether the brake of the corresponding axis is released. (Action 4) If the load weight exceeds the rated range, decrease it to within the limit. (Action 5) Check whether the voltage input to the controller is within the rated voltage and also check whether the voltage set for the transformer of the controller is correct. (Action 6) Replace the servo amplifier. (Action 7) Replace the motor of the corresponding axis. (Action 8) Replace the E-stop unit. (Action 9) Replace the motor power line (robot connection cable) of the corresponding axis. (Action 10) Replace the motor power line and brake line (inside the mechanical section) of the corresponding axis. Servo amplifier

Servo amplifier

(A-cabinet)

(B-cabinet) Fig.3.5 (30) SRVO-050 CLALM alarm

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(31) SRVO-051 CUER alarm (Group : i Axis : j) (Explanation) The offset of the current feedback value is abnormally high. (Action) Replace the servo amplifier.

Servo amplifier

Servo amplifier

(A-cabinet)

(B-cabinet) Fig.3.5 (31) SRVO-051 CUER alarm

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(32) SRVO-055 FSSB com error 1 (Group : i Axis : j) (Explanation) A communication error has occurred between the main board and servo amplifier. (Action 1) Check the communication cable (optical fiber) between the main board and servo amplifier. Replace it if it is faulty. (Action 2) Replace the axis control card on the main board. (Action 3) Replace the servo amplifier.

Servo amplifier

Main board

(A-cabinet)

Servo amplifier


(B-cabinet) Fig.3.5 (32) SRVO-055 FSSB com error 1

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(33) SRVO-056 FSSB com error 2 (Group : i Axis : j) (Explanation) A communication error has occurred between the main board and servo amplifier. (Action 1) Check the communication cable (optical fiber) between the main board and servo amplifier. Replace it if it is faulty. (Action 2) Replace the axis control card on the main board. (Action 3) Replace the servo amplifier.

Servo amplifier

Main board

(A-cabinet)

Servo amplifier


(B-cabinet) Fig.3.5 (33) SRVO-056 FSSB com error 2

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(34) SRVO-057 FSSB disconnect (Group : i Axis : j) (Explanation) Communication was interrupted between the main board and servo amplifier. (Action 1) Check whether fuse F4 in the power supply unit has blown. If the fuse has blown, replace the servo amplifier including the fuse. (Action 2) Replace the optical cable between the axis control card and servo amplifier. (Action 3) Replace the axis control card on the main board. (Action 4) Replace the servo amplifier. (Action 5) Check for a point where the robot connection cable RP1 or an internal cable running to each pulse coder through the robot mechanical section is grounded. Before continuing to the next step, perform a complete controller back-up to save all your programs and settings. (Action 6) Replace the main board.

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Servo amplifier

B-82595EN-2/02

Main board

(A-cabinet)

Servo amplifier


(B-cabinet) Fig.3.5 (34) SRVO-057 FSSB disconnect

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(35) SRVO-058 FSSB init error (Group : i Axis : j) (Explanation) Communication was interrupted between the main board and servo amplifier. (Action 1) Check whether fuse F4 in the power supply unit has blown. If the fuse has blown, check and correct the cause then replace the fuse. (Action 2) Check whether fuse FS1 on the servo amplifier has blown. If the fuse has blown, replace the servo amplifier including the fuse. (Action 3) Turn off the power and disconnect the CRF8 connector on the servo amplifier. Then check whether this alarm occurs again. (Ignore the alarm SRVO-068 because of disconnecting the CRF8 connector.) If this alarm does not occur, the RP1 cable of the robot connection cable or the internal cable of the robot may be short-circuited to the ground. Check the cables and replace it if necessary. (Action 4) Check whether the LED (P5V and P3.3V) on the servo amplifier is lit. If they are not lit, the DC power is not supplied to the servo amplifier. Make sure the connector CRP24 and CRM96 on the E-stop unit and the connector CRM96 on the servo amplifier are connected tightly. If they are connected tightly, replace the servo amplifier. (Action 5) Check the communication cable (optical fiber) between the axis control board and servo amplifier. Replace it if it is faulty. (Action 6) Replace the servo card on the main board. (Action 7) Replace the servo amplifier. (Action 8) If the other units (the servo amplifier for the auxiliary axis and the line tracking interface) are connected in the FSSB optical communication, disconnect these units and connect only servo amplifier for the robot. Then turn on the power. If this alarm does not occur, search the failed unit and replace it. Before executing the (Action9), perform a complete controller back-up to save all your programs and settings. (Action 9) Replace the main board.

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Servo amplifier

B-82595EN-2/02

Main board

(A-cabinet)

Servo amplifier


(B-cabinet) Fig.3.5 (35) SRVO-058 FSSB init error

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

Servo amplifier

(A-cabinet)

(B-cabinet) Fig.3.5 (36) SRVO-059 Servo amp init error

(37) SRVO-062 BZAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if battery for pulse coder absolute-position backup is empty. A probable cause is a broken battery cable or no batteries in the robot. (Action 1) Replace the battery in the battery box of the robot base. (Action 2) Replace the pulse coder with which an alarm has been issued. (Action 3) Check whether the robot internal cable for feeding power from the battery to the pulse coder is not disconnected and grounded. If an abnormality is found, replace the cable.

CAUTION After correcting the cause of this alarm, set the system variable (＄MCR.$SPC_RESET) to TRUE then turn on the power again. Mastering is needed.

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(38) SRVO-064 PHAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the phase of the pulses generated in the pulse coder is abnormal. (Action) Replace the pulse coder.

NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm. (39) SRVO-065 BLAL alarm (Group : i Axis : j) (Explanation) The battery voltage for the pulse coder is lower than the rating. (Action) Replace the battery. (If this alarm occurs, turn on the power and replace the battery as soon as possible. A delay in battery replacement may result in the BZAL alarm being detected. In this case, the position data will be lost. Once the position data is lost, mastering will become necessary. (40) SRVO-067 OHAL2 alarm (Group : i Axis : j) (Explanation) The temperature inside the pulse coder or motor is abnormally high, and the built-in thermostat has operated. (Action 1) Check the robot operating conditions. If a condition such as the duty cycle and load weight has exceeded the rating, relax the robot load condition to meet the allowable range. (Action 2) When power is supplied to the motor after it has become sufficiently cool, if the alarm still occurs, replace the motor. (41) SRVO-068 DTERR alarm (Group : i Axis : j) (Explanation) The serial pulse coder does not return serial data in response to a request signal. (Action 1) Make sure that the RP1 connector of servo amplifier (motor side) is connected tightly. (Action 2) Check that the shielding of the RP1 cable is grounded securely in the cabinet. (Action 3) Replace the pulse coder. (Action 4) Replace the servo amplifier. (Action 5) Replace the RP1 cable. (Action 6) Replace the robot interconnection cable (for the pulse coder). (42) SRVO-069 CRCERR alarm (Group : i Axis : j) (Explanation) The serial data has disturbed communication. - See actions on SRVO-070

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during

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(43) SRVO-070 STBERR alarm (Group : i Axis : j) (Explanation) The start and stop bits of the serial data are abnormal. (Action) Replace the RPI cable. Servo amplifier

Servo amplifier

(A-cabinet)

(B-cabinet) Fig.3.5 (43) SRVO-070 STBERR alarm

(44) SRVO-071 SPHAL alarm (Group : i Axis : j) (Explanation) The feedback speed is abnormally high. (Action) Action as same as the SRVO-068.

NOTE If this alarm occurs together with the PHAL alarm (SRVO-064), this alarm does not correspond to the major cause of the failure. (45) SRVO-072 PMAL alarm (Group : i Axis : j) (Explanation) It is likely that the pulse coder is abnormal. (Action) Replace the pulse coder and remaster the robot. (46) SRVO-073 CMAL alarm (Group : i Axis : j) (Explanation) It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. (Action 1) Reinforce the earth of the motor flange. (Action 2) Replace the pulse coder. (47) SRVO-074 LDAL alarm (Group : i Axis : j) (Explanation) The LED in the pulse coder is broken. (Action) Replace the pulse coder, and remaster the robot.

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(48) SRVO-075 Pulse not established (Group : i Axis : j) (Explanation) The absolute position of the pulse coder cannot be established. (Action) Reset the alarm, and jog the axis on which the alarm has occurred until the same alarm will not occur again. (49) SRVO-076 Tip Stick Detection (Group : i Axis : j) (Explanation) An excessive disturbance was assumed in servo software at the start of operation. (An abnormal load was detected. The cause may be welding.) (Action 1) Check whether the robot has collided. Or check whether the machinery load of the corresponding axis is increased. (Action 2) Check whether the load settings are valid. (Action 3) Check whether the brake of the corresponding axis is released. (Action 4) Check whether the load weight is within the rated range. If the weight exceeds the upper limit, decrease it to the limit. (Action 5) Check whether the voltage input to the controller is within the rated voltage and also check whether the voltage set for the transformer of the controller is correct. (Action 6) Replace the servo amplifier. (Action 7) Replace the corresponding servo motor. (Action 8) Replace the E-stop unit. (Action 9) Replace the power cable of the robot connection cable in which the corresponding axis is connected. (Action 10) Replace the power cable of the robot interconnection cable in which the corresponding axis is connected. Servo amplifier

E-stop unit

Servo amplifier

E-stop unit

(A-cabinet)

(B-cabinet) Fig.3.5 (49) SRVO-076 Tip Stick Detection

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(50) SRVO-081 EROFL alarm (Track enc : i) (Explanation) The pulse counter for line tracking has overflowed. (Action 1) Check whether the condition of the line tracking exceeds the limitation. (Action 2) Replace the pulse coder. (Action 3) Replace the line tracking interface board. (51) SRVO-082 DAL alarm (Track ebc : i) (Explanation) The line tracking pulse coder has not been connected. (Action 1) Check the connection cable at each end (the line tracking interface board and the motor side) (Action 2) Check whether the shielding of the connection cable is connected securely to the grounding plate. (Action 3) Replace the line tracking cable. (Action 4) Replace the pulse coder. (Action 5) Replace the line tracking interface board. (52) SRVO-084 BZAL alarm (Track enc : i) (Explanation) This alarm occurs if the backup battery for the absolute position of the pulse coder has not been connected. See the description about the BZAL alarm (SRVO-062). (53) SRVO-087 BLAL alarm (Track enc : i) (Explanation) This alarm occurs if the voltage of the backup battery for the absolute position of the pulse coder is low. See the description about the BLAL alarm (SRVO-065). (54) SRVO-089 OHAL2 alarm (Track enc : i) (Explanation) The motor has overheated. When power is supplied to the pulse coder after it has become sufficiently cool, if the alarm still occurs. See the description about the OHAL2 alarm (SRVO-067). (55) SRVO-090 DTERR alarm (Track ebc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the SRVO-068 DTERR alarm. (Action 1) Check the connection cable at each end (the line tracking interface board and the pulse coder) (Action 2) Check whether the shielding of the connection cable is connected securely to the grounding plate. (Action 3) Replace the pulse coder. (Action 4) Replace the line tracking cable. (Action 5) Replace the line tracking interface board.

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(56) SRVO-091 CRCERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. (Action) Action as same as the SRVO-090. (57) SRVO-092 STBERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. (Action) Action as same as the SRVO-090. (58) SRVO-093 SPHAL alarm (Track enc : i) (Explanation) This alarm occurs if the current position data from the pulse coder is higher than the previous position data. (Action) Action as same as the SRVO-090. (59) SRVO-094 PMAL alarm (Track enc : i) (Explanation) It is likely that the pulse coder is abnormal. See the description about the PMAL alarm (SRVO-072). (60) SRVO-095 CMAL alarm (Track enc : i) (Explanation) It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. See the description about the CMAL alarm (SRVO-073). (Action 1) Reinforce the earth of the flange of the pulse coder. (Action 2) Replace the pulse coder. (61) SRVO-096 LDAL alarm (Track enc : i) (Explanation) The LED in the pulse coder is broken. See the description about the LDAL alarm (SRVO-074). (62) SRVO-097 Pulse not established (enc : i) (Explanation) The absolute position of the pulse coder cannot be established. See the description about (SRVO-075). Pulse not established. (Action 1) Reset the alarm, and jog the axis on which the alarm has occurred until the same alarm does not occur again. (Jog one motor revolution)

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(63) SRVO-105 Door open or E-stop (Explanation) The cabinet door is open. When the door switch is mounted. (Action 1) When the door is open, close it. (Action 2) Check the door switch and door switch connection cable. If the switch or cable is faulty, replace it. When the door switch is not mounted. (Action 3) Check that the CRM72, CRM95, and CRM96 connectors on the E-STOP unit are connected securely. (Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier. (Action 6) Replace the panel board. (Action 7) Replace the connection cable between the panel board and the E-stop unit. E-stop unit

Servo amplifier

Main board

Door switch

(A-cabinet) Fig.3.5 (63) SRVO-105 Door open or E-stop

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(64) SRVO-136 DCLVAL alarm (Group : i Axis : j) (Explanation) The servo the DC current of amplifier (DC link voltage) of the main power supply is abnormally low. This alarm occurred during robot operation. (Action 1) Check the input voltage to the controller is within the rated voltage and no phase is lack. And check the setting of the transformer is correct. (Action 2) It is possible that an instant disconnection of power source causes this alarm. Check whether an instant disconnection occurred. (Action 3) Modify the program in order that robot and the auxiliary axis do not accelerate simultaneously in the system with the auxiliary axis. (Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier. If this alarm occurred before the magnetic contactor is turned on: (Action 1) Check whether the circuit breaker in the emergency stop unit is OFF. If it is OFF, check the servo amplifier and the wiring between the servo amplifier and the emergency stop unit. If anything is abnormal, replace it. Else turn on the breaker. (Action 2) Check the input voltage to the controller is within the rated voltage and no phase is lack. And check the setting of the transformer is correct. (Action 3) Replace the E-stop unit. (Action 4) Replace the servo amplifier.

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E-stop unit

Servo amplifier

Magnetic contactor

(A-cabinet) Servo amplifier

Magnetic contactor

E-stop unit (B-cabinet) Fig.3.5 (64) SRVO-136 DCLVAL alarm

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(65) SRVO-156 IPMAL alarm (Group : i Axis : j) (Explanation) Abnormally high current flowed through the main circuit of the servo amplifier. (Action 1) Turn off the power, and disconnect the power cable from the servo amplifier indicated by the alarm message. (And disconnect the brake cable (CRR88 on the servo amplifier) to avoid the axis falling unexpectedly.) Supply power and see if the alarm occurs again. If the alarm occurs again, replace the servo amplifier. (Action 2) Turn off the power and disconnect the power cable from the servo amplifier 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. (Action 3) Turn off the power and disconnect the power cable from the servo amplifier 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 is defective. Check each item in detail and replace it if necessary. Servo amplifier

Servo amplifier

(A-cabinet)

(B-cabinet) Fig.3.5 (65) SRVO-156 IPMAL alarm

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(66) SRVO-157 CHGAL alarm (Group : i Axis : j) (Explanation) The capacitor for the condenser voltage of the servo amplifier was not charged within the specified time when the servo power is on. (Action 1) Replace the E-stop unit. (Action 2) Replace the servo amplifier. (Action 3) Replace the auxiliary amplifier for system of the auxiliary axis. Servo amplifier

E-stop unit

Servo amplifier

E-stop unit

(A-cabinet)

(B-cabinet) (B-cabinet) Fig.3.5 (66) SRVO-157 CHGAL alarm

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(67) SRVO-194 Servo disconnect (Explanation) The external contact connected to SD4-SD41 or SD5-SD51 of the terminal block TBOP3 on the panel board is open. (Action 1) If external circuitry is connected to SD4-SD41 or SD5-SD51 of the terminal block TBOP3 on the panel board, check the external circuitry. (Action 2) If this signal is not used, make a connection between SD4 and SD41 and between SD5 and SD51 of the terminal block TBOP3 on the panel board. (Action 3) Replace the panel board.

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Panel board

(A-cabinet)

Panel board

Fig.3.5 (67)

(B-cabinet) SRVO-194 Servo disconnect

WARNING In a system using the servo disconnect signal, it is very dangerous to disable the signal when a connection is made between SD4 and SD41 and between SD5 and SD51 of the terminal block TBOP3 on the panel board. Never make such an attempt. If a temporary connection is needed for operation, separate safety measures must be taken.

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(68) SRVO-201 Panel E-stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator’s panel was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Replace the panel board. (Action 2) Replace the E-stop unit. (Action 3) Replace the servo amplifier. E-stop unit Emergency stop button

Panel board

Servo amplifier (A-cabinet) Servo amplifier

EMERGENCY STOP button Panel board

E-stop unit

Fig.3.5 (68)

(B-cabinet) SRVO-201 Panel E-stop or SVEMG abnormal

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(69) SRVO-202 TP E-stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator panel was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Replace the teach pendant. (Action 2) Check the teach pendant cable. If this inferior, replace the cable. (Action 3) Replace the operator's panel. (Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier.

NOTE This alarm might occur if the EMERGENCY STOP button is pressed slowly.

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E-stop unit Panel board

Servo amplifier (A-cabinet)

Servo amplifier Panel board

Teach pendant

E-stop unit

Fig.3.5 (69)

(B-cabinet) SRVO-202 TP E-stop or SVEMG abnormal

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(70) SRVO-204 External (SVEMG abnormal) E-stop (Explanation) The switch connected across EES1 – EES11 and EES2 – EES21 on the TBOP4 terminal board on the panel board was pressed, but the EMERGENCY STOP line was not disconnected. In case that RDY LED (green) is lit. (Action 1) Check the switch and cable connected to EES1 – EES11 and EES2 – EES21 on TBOP4 terminal board. If the cable are abnormal replace it. (Action 2) Replace the panel board. (Action 3) Replace the E-stop unit. (Action 4) Replace the servo amplifier.

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E-stop unit (B-cabinet)

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EES1 EES11 EES2 EES22

(Panel board) Fig.3.5 (70)

SRVO-204 External (SVEMG abnormal) E-stop

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(71) SRVO-205 Fence open (SVEMG abnormal) (Explanation) The switch connected across EES1 – EES11 and EES2 – EES21 on the TBOP4 terminal board on the panel board was pressed, but the EMERGENCY STOP line was not disconnected. In case that RDY LED (green) is lit. (Action 1) Check the switch and cable connected to EES1 – EES11 and EES2 – EES21. If the cable are abnormal, replace it. (Action 2) Replace the panel board. (Action 3) Replace the E-stop unit. (Action 4) Replace the servo amplifier.

Panel board



(B-cabinet)

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Fig.3.5 (71)

(Panel board) SRVO-205 Fence open (SVEMG abnormal)

(72) SRVO-206 DEADMAN switch (SVEMG abnormal) (Explanation) When the teach pendant was enabled, the DEADMAN switch was released or pressed strongly, but the emergency stop line was not disconnected. (Action 1) Replace the teach pendant. (Action 2) Check the teach pendant cable. If it is inferior, replace the cable. (Action 3) Replace the panel board. (Action 4) When the NTED signal is used, check whether the cabling of the signal connected to CRM65 on the panel board is correct. (Action 5) Replace the E-stop unit. (Action 6) Replace the servo amplifier.

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Teach pendant

E-stop unit (B-cabinet) Fig.3.5 (72)

SRVO-206 DEADMAN switch (SVEMG abnormal)

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(73) SRVO-213 WARN Fuse blown (Panel PCB) (Explanation) A fuse (FUSE1 or FUSE2) on the panel board has blown, or no voltage is supplied to EXT24V. (Action 1) Check whether the fuse (FUSE1) on the panel board has blown. If the fuse has blown, +24EXT may be short-circuited to 0EXT. Take Action 2. If FUSE1 has not blown, take Action 3 and up. (Action 2) Disconnect the connection destinations of +24EXT that can cause grounding then check that FUSE1 does not blow. Disconnect the following on the panel board then turn on the power: - CRS20 - CRT16 - TBOP4: EES1, EES11, EAS1, EAS11, EGS1, EGS11 - TBOP3: SD4, SD41 If FUSE1 does not blow in this state, +24EXT and 0EXT may be short-circuited at any of the connection destinations above. Isolate the faulty location then take action. If FUSE1 blows even when the connection destinations above are detached, replace the panel board. (Action 3) Check whether 24 V is applied to between EXT24V and EXT0V of TBOP6. If not, check the external power supply circuit. If no external power supply is used, check whether the terminals above are connected to the INT24V and INT0V terminals, respectively. (Action 4) Replace the panel board. (Action 5) Replace the teach pendant cable. (Action 6) Replace the teach pendant.

JRS15

LED (green)

(panel board)

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Panel board

(A-cabinet) Panel board

Main board

(B-cabinet) Connector JRS15

(Main board) Fig.3.5 (73) SRVO-213 WARN Fuse blown (Panel PCB)

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(74) SRVO-214 Fuse blown (Servo amplifier) (Explanation) A fuse in the servo amplifier has blown. In case that FS1 is blown (Action 1) Replace the servo amplifier. In case that FS2 or FS3 is blown (Action 1) A fuse is blown, eliminate the cause, then replace the fuse. (See Section 3.6 in the Part II, “MAINTENANCE”.) (Action 2) Replace the servo amplifier.


(B-cabinet) Fig.3.5 (74) SRVO-214 Fuse blown (Panel PCB)

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(75) SRVO-216 OVC (total) (Robot : i) (Explanation) The current (total current for six axes) flowing through the motor is too large. (Action 1) Slow the motion of the robot where possible. Check the robot operation conditions. If the robot is used with a condition exceeding the duty or load weight robot rating, reduce the load condition value to the specification range. (Action 2) Check the input voltage to the controller is within the rated voltage and no phase is lack. And check the setting of the transformer is correct. (Action 3) Replace the servo amplifier.

Servo amplifier Servo amplifier

(B-cabinet) Fig.3.5 (75)

SRVO-216 OVC (total) (Robot : i)

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(76) SRVO-221 Lack of DSP (Group : i Axis : j) (Explanation) A controlled axis card corresponding to the set number of axes is not mounted. (Action 1) Check whether the set number of axes is valid. If the number is invalid, set the correct number. (Action 2) Replace the axis control card with a card corresponding to the set number of axes.

Servo amplifier

Main board

(A-cabinet)

Axis control card Main board (B-cabinet) Fig.3.5 (76)

(Main board)

SRVO-221 Lack of DSP (Group : i

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(77) SRVO-223 DSP dry run(a b) (Explanation) Servo system initialization was stopped because of a hardware failure or improver software setting. The controller has been started in the DSP dry run mode. (Action 1) When the value is 1, 5, or 6: An incorrect setting is made. Check whether the dry run mode is set and also check whether the setting of the hard start axis is correct. (Action 2) When the value is 2, 3, 4, or 7: Replace the servo card. (Action 3) When the value is 8 or 10: Take action for an FSSB initialization error that has occurred at the same time. (Action 4) When the value is 9: Take the following action: Check whether the servo amplifier is connected. Replace the optical cable used for servo amplifier connection. Replace the servo amplifier Servo amplifier

Servo amplifier Fig.3.5 (77) SRVO-223 DSP dry run(a b)

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(78) SRVO-230 Chain 1 (+24V) abnormal SRVO-231 Chain 2 (0V) abnormal (Explanation) A mismatch occurred between duplicate safety signals. SRVO-230 is issued if such a mismatch that a contact connected on the chain 1 side (between EES1 and EES11, between EAS1 and EAS11, between EGS1 and EGS11, between SD4 and SD41, and so forth) is closed, and a contact on the chain 2 side (between EES2 and EES21, between EAS2 and EAS21, between EGS2 and EGS21, between SD5 and SD51, and so forth) is open occurs. SRVO-231 is issued if such a mismatch that a contact on the chain 1 side is open, and a contact on the chain 2 side is closed occurs. If a chain error is detected, correct the cause of the alarm then reset the alarm according to the method described later. (Action) Check the alarms issued at the same time in order to identify with which signal the mismatch occurred. SRVO-266 through SRVO-275 and SRVO-370 through SRVO-385 are issued at the same time. Take the action(s) described for each item. (Caution 1) After correcting the cause of the hardware chain error according to the work described above, set "YES" for chain error resetting on the system setting screen. Finally, press the reset key on the teach pendant. For details, see "Chain error reset procedure" described later. (Caution 2) If this alarm is issued, do not reset the chain error alarm until the failure is identified and repaired. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. E-stop unit Panel board


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E-stop unit (B-cabinet) Fig.3.5 (78) SRVO-230 Chain 1 (+24V) abnormal / SRVO-231 Chain 2 (0V) abnormal

CAUTION 1 The state of this alarm is preserved by software. After correcting the cause of the alarm, reset the chain error alarm according to the chain error reset procedure described later. 2 Until a chain error is reset, no ordinary reset operation must be performed. If an ordinary reset operation is performed before chain error resetting, the message "SRVO-237 Chain error cannot be reset" is displayed on the teach pendant.

Alarm history display method 1. 2. 3.

Press the screen selection key on the teach pendant. Select [4 ALARM] on the teach pendant. Press F3 [HIST] on the teach pendant.

Chain error reset procedure CAUTION Do not perform this operation until the cause of the alarm is corrected. - 116 -

MAINTENANCE

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3.TROUBLESHOOTING

1. Press the emergency stop button. 2. Press the screen selection key on the teach pendant. 3. Select [0 NEXT PAGE] on the teach pendant. 4. Press [6 SYSTEM] on the teach pendant. 5. Press [7 SYSTEM SETTING] on the teach pendant. 6. Find "28" Chain Error Reset Execution. 7. Press F3 on the teach pendant to reset "Chain Error". 1. Press the screen selection key on the teach pendant. 2. Select [4 ALARM] on the teach pendant. 3. Press F4 [CHAIN RESET] on the teach pendant. (79) SRVO-232 NTED input (Explanation) In the teach mode, the NTED signal connected to CRM65 on the panel board was placed in the open state. (Action 1) Check the operation of the device connected to NTED. (Action 2) Replace the teach pendant. (Action 3) Replace the teach pendant cable. (Action 4) Replace the panel board (Action 5) Check the mode switch and its cable. Replace them if a defect is found.

Panel board


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3.TROUBLESHOOTING

MAINTENANCE

B-82595EN-2/02


Teach pendant


SRVO-232 NTED input

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3.TROUBLESHOOTING

(80) SRVO-233 TP disabled in T1, T2/Door open (Explanation) Teach pendant is disabled when the mode switch is T1 or T2. Or controller door is opened. (Action 1) Enable the teach pendant in teaching operation. In other case the mode switch should be AUTO mode. (Action 2) Close the controller door, if open. (Action 3) Replace the teach pendant. (Action 4) Replace the teach pendant cable. (Action 5) Replace the mode switch. (Action 6) Replace the panel board. (Action 7) Replace the E-stop unit. (Action 8) Replace the servo amplifier.

E-stop unit

Panel board

Mode switch

Door switch (A-cabinet)

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Servo amplifier

3.TROUBLESHOOTING

MAINTENANCE

Mode switch

B-82595EN-2/02

Servo amplifier

Panel board

Teach pendant

E-stop unit

Enable switch (B-cabinet) Fig.3.5 (80) SRVO-233 TP disabled in T1, T2/Door open

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MAINTENANCE

B-82595EN-2/02

(81) SRVO-235 Short term Chain abnormal (Explanation) Short term single chain failure condition is detected. • Cause of this alarm is ; - Half release of DEADMAN switch - Half operation of emergency stop switch. (Action 1) Cause the same error to occur again, then perform resetting. (Action 2) Replace the panel board. (Action 3) Replace the E-stop unit. (Action 4) Replace the servo amplifier. E-stop unit Panel board

Servo amplifier (A-cabinet) Servo amplifier Panel board


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3.TROUBLESHOOTING

MAINTENANCE

Enable switch

B-82595EN-2/02

Deadman switch

(Teach pendant) Fig.3.5 (81)

SRVO-235 Short term Chain abnormal

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MAINTENANCE

(82) SRVO-251 DB relay abnormal (Explanation) An abnormality was detected in the internal relay (DB relay) of the servo amplifier. (Action) Replace the servo amplifier. (83) SRVO-252 Current detect abnl (Explanation) An abnormality was detected in the current detection circuit inside the servo amplifier. (Action) Replace the servo amplifier. (84) SRVO-253 Amp internal over heat (Explanation) An overheat was detected inside the servo amplifier. (Action) Replace the servo amplifier.


(B-cabinet) Fig.3.5 (82) SRVO-251 DB relay abnormal / SRVO-252 Current detect abnl / SRVO-253 Amp internal over heat

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MAINTENANCE

B-82595EN-2/02

(85) SRVO-266 FENCE1 status abnormal a,b SRVO-267 FENCE2 status abnormal a,b (Explanation) A chain alarm was detected with the EAS (FENCE) signal. (Action 1) Check whether the circuitry connected to the dual input signal (EAS) is faulty. (Action 2) Check whether the timing of the dual input signal (EAS) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS). (Action 3) Replace the panel board.

CAUTION 1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 and SRVO-231. 2 If this alarm is issued, do not reset the chain error alarm until the failure is checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.


Fig.3.5 (85) SRVO-266 FENCE1 status abnormal a,b / SRVO-267 FENCE2 status abnormal a,b

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MAINTENANCE

3.TROUBLESHOOTING

(86) SRVO-268 SVOFF1 status abnormal a,b SRVO-269 SVOFF2 status abnormal a,b (Explanation) A chain alarm was detected with the EGS (SVOFF) signal. (Action 1) Check whether the circuitry connected to the dual input signal (EGS) is faulty. (Action 2) Check whether the timing of the dual input signal (EGS) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS). (Action 3) Replace the panel board.

CAUTION 1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 and SRVO-231. 2 If this alarm is issued, do not reset the chain error alarm until the failure is checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. EGS1 EGS11 EGS2 EGS22

Fig.3.5 (86)

SRVO-268 SVOFF1 status abnormal a,b / SRVO-269 SVOFF2 status abnormal a,b

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(87) SRVO-270 EXEMG1 status abnormal a,b SRVO-271 EXEMG2 status abnormal a,b (Explanation) A chain alarm was detected with the EES (EXEMG) signal. (Action 1) Check whether the circuitry connected to the dual input signal (EES) is faulty. (Action 2) Check whether the timing of the dual input signal (EES) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS). (Action 3) Replace the panel board.

CAUTION 1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 and SRVO-231. 2 If this alarm is issued, do not reset the chain error alarm until the failure is checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. EES1 EES11 EES2 EES22

Fig.3.5 (87)

SRVO-270 EXEMG1 status abnormal a,b / SRVO-271 EXEMG2 status abnormal a,b

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MAINTENANCE

3.TROUBLESHOOTING

(88) SRVO-272 SVDISC1 status abnormal a,b SRVO-273 SVDISC2 status abnormal a,b (Explanation) A chain alarm was detected with the SD4 or SD5 (SVDISC) signal. (Action 1) Check whether the circuitry connected to the dual input signal (SD) is faulty. (Action 2) Check whether the timing of the dual input signal (SD) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS). (Action 3) Replace the panel board.


SD4 SD41 SD5 SD51

Fig.3.5 (88) SRVO-272 SVDISC1 status abnormal a,b / SRVO-273 SVDISC2 status abnormal a,b

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MAINTENANCE

B-82595EN-2/02

(89) SRVO-274 NTED1 status abnormal a,b SRVO-275 NTED2 status abnormal a,b (Explanation) A chain alarm was detected with the NTED signal. (Action 1) This alarm may be issued when the DEADMAN switch is pressed to a proper position or is operated very slowly. In such a case, release the DEADMAN switch once completely then press the DEADMAN switch again. (Action 2) Check whether the circuitry connected to the dual input signal (NTED) is faulty. (Action 3) Check whether the timing of the dual input signal (NTED) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS). (Action 4) Replace the panel board. (Action 5) Replace the teach pendant cable. (Action 6) Replace the teach pendant. (Action 7) Replace the mode switch on the operator's panel.


Panel board

Panel board

(A-cabinet)

(B-cabinet)

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MAINTENANCE

Enable switch

Deadman switch

CRM65

Fig.3.5 (89) SRVO-274 NTED1 status abnormal a,b / SRVO-275 NTED2 status abnormal a,b

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MAINTENANCE

B-82595EN-2/02

(90) SRVO-277 Panel E-stop(SVEMG abnormal) (Explanation) The emergency stop line was not disconnected although the emergency stop button on the operator's panel was pressed. (Action 1) Replace the panel board. (Action 2) Replace the E-stop unit (Action 3) Replace the servo amplifier. E-stop unit Panel board




Fig.3.5 (90)

SRVO-277 Panel E-stop(SVEMG abnormal)

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MAINTENANCE

3.TROUBLESHOOTING

(91) SRVO-278 TP E-stop(SVEMG abnormal) (Explanation) The emergency stop line was not disconnected although the emergency stop button on the operator's panel was pressed. (Action 1) Replace the teach pendant. (Action 2) Replace the teach pendant cable. (Action 3) Replace the panel board. (Action 4) Replace the E-stop unit (Action 5) Replace the servo amplifier.

NOTE This alarm may be issued if the emergency stop button is pressed very slowly.

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MAINTENANCE

B-82595EN-2/02



Teach pendant

EMERGENCY STOP button

E-stop unit

Fig.3.5 (91)

SRVO-278 TP E-stop(SVEMG abnormal)

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MAINTENANCE

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3.TROUBLESHOOTING

(92) SRVO-280 SVOFF input (Explanation) The external contact connected to EGS1-EGS11 or EGS2-EGS21 of the terminal block TBOP4 on the panel board is open. (Action 1) If external circuitry is connected to EGS1-EGS11 or EGS2-EGS21 of the terminal block TBOP4 on the panel board, check the external circuitry. (Action 2) If this signal is not used, make a connection between EGS1 and EGS11 and between EGS2 and EGS21 of the terminal block TBOP4 on the panel board. (Action 3) Replace the panel board.

Panel board

Panel board

(A-cabinet)

(B-cabinet)

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3.TROUBLESHOOTING

MAINTENANCE

B-82595EN-2/02

EGS1 EGS11 EGS2 EGS22

Fig.3.5 (92)

SRVO-280 SVOFF input

WARNING In a system using the SVOFF signal, it is very dangerous to disable the signal when a connection is made between EGS1 and EGS11 and between EGS2 and EGS21 of TBOP4. Never make such an attempt. If a temporary connection is needed for operation, separate safety measures must be taken.

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3.TROUBLESHOOTING

MAINTENANCE

B-82595EN-2/02

(93) SRVO-281 SVOFF input (SVEMG abnormal) (Explanation) The emergency stop line was not disconnected although the contact connected between EGS1 and EGS11 or between EGS2 and EGS21 of the terminal block TBOP4 on the panel board was open. The emergency stop circuit is faulty. (Action 1) Check the switch and cable connected to EGS1-EGS11and EGS2-EGS21 on TBOP4. If the cable are abnormal replace it. (Action 2) Replace the panel board. (Action 3) Replace the E-stop unit. (Action 4) Replace the servo amplifier. (Action 5) Replace the connection cable between the panel board and the E-stop unit. E-stop unit Panel board



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MAINTENANCE

B-82595EN-2/02


Fig.3.5 (93)

SRVO-281 SVOFF input (SVEMG abnormal)

(94) SRVO-291 IPM over heat (G:i A:j) (Explanation) IPM on the servo amplifier is overheated. (Action 1) Check whether the fan for cabinet ventilation is stopped and also check whether the vent hole is clogged. If necessary, clean or replace them. (Action 2) If SRVO-291 is issued when the robot operating condition is severe, check the robot operating condition then relax the condition when possible. (Action 3) If SRVO-291 is issued frequently, replace the servo amplifier.

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MAINTENANCE

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3.TROUBLESHOOTING

Servo amplifier

A-cabinet (Front) External air fan

External air fan

Side fan type


Servo amplifier

External air fan

B-cabinet (Front) B-cabinet (Back) Fig.3.5 (94) SRVO-291 IPM over heat (G:i A:j)

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MAINTENANCE

B-82595EN-2/02

(95) SRVO-300 Hand broken/HBK disabled SRVO-302 Set Hand broken to ENABLE (Explanation) Although HBK was disabled, the HBK signal was input. (Action 1) Press RESET on the teach pendant to release the alarm. (Action 2) Check whether the hand broken signal is connected to the robot. When the hand broken signal circuit is connected, enable hand broken. (See Subsection 5.5.3 in Part III, “CONNECTIONS”.) (96) SRVO-335 DCS OFFCHK alarm a,b (Explanation) A failure was detected in the safety signal input circuit. (Action) Replace the panel board.

Panel board

Panel board

(A-cabinet)

(B-cabinet)

Fig.3.5 (96)

SRVO-335 DCS OFFCHK alarm a,b

(97) SRVO-348 DCS MCC OFF alarm a,b (Explanation) A command was issued to turn off the magnetic contactor, but the magnetic contactor was not turned off. (Action 1) Replace the E-stop unit. (Action 2) Replace the panel board. (Action 3) If a signal is connected to the emergency stop unit CRM72, check whether there is a problem in the connection destination.

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3.TROUBLESHOOTING

MAINTENANCE

B-82595EN-2/02

(98) SRVO-349 DCS MCC ON alarm a,b (Explanation) A command was issued to turn on the magnetic contactor, but the magnetic contactor was not turned on. (Action 1) Replace the E-stop unit. (Action 2) Replace the panel board. (Action 3) Replace the servo amplifier. E-stop unit Panel board


E-stop unit Fig.3.5 (98) 348 DCS MCC OFF alarm a,b / 349 DCS MCC ON alarm a,b

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MAINTENANCE

B-82595EN-2/02

(99) SRVO-370 SVON1 status abnormal a,b SRVO-371 SVON2 status abnormal a,b (Explanation) A chain alarm was detected with the panel board internal signal (SVON). (Action) Replace the panel board.


Panel board

Panel board

(A-cabinet)

(B-cabinet)

Fig.3.5 (99) SRVO-370 SVON1 status abnormal a,b / SRVO-371 SVON2 status abnormal a,b

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MAINTENANCE

3.TROUBLESHOOTING

(100)SRVO-372 OPEMG1 status abnormal a,b (Explanation) A chain alarm was detected with the emergency stop switch on the operator's panel. (Action 1) Replace the panel board. (Action 2) Replace the teach pendant cable. (Action 3) Replace the teach pendant. (Action 4) Replace the emergency stop button on the operator's panel.


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3.TROUBLESHOOTING

MAINTENANCE


B-82595EN-2/02

Panel board

(A-cabinet)

EMERGENCY STOP button

Panel board

Teach pendant


SRVO-372 OPEMG1 status abnormal a,b / SRVO-373 OPEMG2 status abnormal a,b

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MAINTENANCE

3.TROUBLESHOOTING

(101)SRVO-374 MODE11 status abnormal a,b SRVO-375 MODE12 status abnormal a,b SRVO-376 MODE21 status abnormal a,b SRVO-377 MODE22 status abnormal a,b (Explanation) A chain alarm was detected with the mode switch signal. (Action 1) Check the mode switch and its cable. Replace them if a defect is found. (Action 2) Replace the panel board.


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3.TROUBLESHOOTING

MAINTENANCE

Panel board

B-82595EN-2/02

Mode switch

(A-cabinet)

Mode switch Panel board

(B-cabinet) Fig.3.5 (101) SRVO-374 MODE11 status abnormal a,b / SRVO-375 MODE12 status abnormal a,b / SRVO-376 MODE21 status abnormal a,b / SRVO-377 MODE22 status abnormal a,b

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MAINTENANCE

3.TROUBLESHOOTING

(102)SRVO-378 OPSFTY11 status abnormal a,b SRVO-379 OPSFTY12 status abnormal a,b SRVO-380 OPSFTY21 status abnormal a,b SRVO-381 OPSFTY22 status abnormal a,b SRVO-382 OPSFTY31 status abnormal a,b SRVO-383 OPSFTY32 status abnormal a,b SRVO-384 OPSFTY41 status abnormal a,b SRVO-385 OPSFTY42 status abnormal a,b (Explanation) A chain alarm was detected with the OPSFTY signal. (Action 1) Check whether the circuitry connected to the dual input signal (OPSFTY) is faulty. (Action 2) Check whether the timing of the dual input signal (OPSFTY) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTION). (Action 3) Replace the panel board.


CRMA8 Fig.3.5 (102) SRVO-378 OPSFTY11 status abnormal a,b / SRVO-379 OPSFTY12 status abnormal a,b / SRVO-380 OPSFTY21 status abnormal a,b / SRVO-381 OPSFTY22 status abnormal a,b / SRVO-382 OPSFTY31 status abnormal a,b / SRVO-383 OPSFTY32 status abnormal a,b / SRVO-384 OPSFTY41 status abnormal a,b / SRVO-385 OPSFTY42 status abnormal a,b

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3.TROUBLESHOOTING

3.6

MAINTENANCE

B-82595EN-2/02

FUSE-BASED TROUBLESHOOTING This section describes the alarms and symptoms generated and actions required when the fuses installed on the printed circuit boards and units have blown. (1) When the fuses of the power supply unit have blown F1: Fuse for AC input F3: Fuse for +24 E F4: Fuse for +24 V

Name

Symptom observed when fuse has blown

F1

The LED (PIL: Green) of the power supply unit does not light, and the power cannot be turned on.

F3

F4

If the fuse blows when the power supply is turned on, an alarm such as for overtravel, hand breakage, FSSB disconnect, LVAL is output on the teach pendant. If the fuse turns out to have already blown when the power supply is turned on, the FSSB initialization alarm is displayed on the teach pendant. The power, when turned on, is immediately turned off. At this time, the LED (ALM: Red) lights.

Action 1

2 1

2 1

2

- 146 -

Check the units (fans) and cables connected to the CP2 and CP3 connectors of the power supply unit to see if there is any short circuit. Replace the power supply unit. Check the printed circuit boards, units, servo amplifier, and cables using +24 E according to the power supply system diagram. Replace a faulty printed circuit board, unit, servo amplifier or cable if any. Replace the power supply unit. Check the printed circuit boards, units, and cables using +24 V according to the power supply system diagram. Replace a faulty printed circuit board, unit, or cable if any. The LED of ALM is turned off by pressing the OFF button once. Replace the power supply unit.

MAINTENANCE

B-82595EN-2/02

Servo amplifier

3.TROUBLESHOOTING

Power supply unit (A-cabinet)

Servo amplifier

F1(8.0A): Fuse for AC input

F3(7.5A): Fuse for +24E F4（7.5A）: Fuse for +24V PIL: LED (green)

ALM: LED (red)

Power supply unit (B-cabinet)

(Power supply unit)

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B-82595EN-2/02

(2) Main board fuse FU1:For protection of the +12V output for the vision sensor (This fuse is mounted on the mainboard of the total edition “06B” after.) Name FU1

Symptom observed when fuse has blown +12V is not output.

Action 1 2 3

Check +12V used by the vision sensor for a ground fault. Check the vision sensor and the connection cable. Replace the main board.

75173 (Receiver)

75172 (Driver)

CPU card

FROM/SRAM module (Behind the axis control card)

Axis control card

FU1

Fuse(0.5A)

(Total edition “06B” after)

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3.TROUBLESHOOTING

(3) Servo amplifier fuse FS1: For generation of the power to the amplifier control circuit FS2: For protection of the 24V output to the end effector, ROT, and HBK FS3: For protection of the 24V output to the regenerative resistance and the additional axis amplifier Name FS1

FS2

FS3

Symptom observed when fuse has blown All LEDs on the servo amplifier go out. The FSSB disconnection or initialization alarm is displayed on the teach pendant. The Fuse Blown (Amp) alarm (SRVO-214), Hand broken (SRVO-006), and ROBOT OVER TRAVEL are displayed on the teach pendant. The Fuse Blown (Amp) alarm (SRVO-214) and DCAL are displayed on the teach pendant.

Action Replace the servo amplifier.

1 2 3 1 2 3

Check +24VF used by the end effector for a ground fault. Check the robot connection cable and the robot’s internal cable. Replace the servo amplifier. Check the regenerative resistance, and replace it if required. Check the additional axis amplifier and its wiring, and replace them if required. Replace the servo amplifier.

CRR88

5A 3.2A 3.2A

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MAINTENANCE

B-82595EN-2/02

(4) Panel board fuses FUSE1: For +24EXT line (emergency stop line) protection FUSE2: For protection of the teach pendant emergency stop line Name


Action

FUSE1

The teach pendant displays external emergency stop, fence open, or SVOFF input fuse blown (panel PCB).

FUSE2

The display on the teach pendant disappears.

1 If an alarm is issued when the fuse has not blown, check the voltages of EXT24V and EXT0V (TBOP6). If external 24V or 0V is not used, check the jumper pin between EXT24V and INT24V or between EXT0V and INT0V. 2 Check the +24EXT line (emergency stop line) for a short circuit or connection to ground. 3 Replace the panel board. 1 Check the teach pendant cable for a fault, and replace it if required. 2 Check the teach pendant for a fault, and replace it if required. 3 Replace the panel board.

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MAINTENANCE

3.TROUBLESHOOTING

(5) Fuse on the process I/O printed circuit board FUSE1: Fuse for +24E Name


Action

FUSE1

The LED (ALM-2 or FALM) on the process I/O printed circuit board lights, and an alarm such as IMSTP input is output on the teach pendant. (The display data depends on state of peripheral equipment connection.)

1 Check if the cables and peripheral equipment connected to the process I/O printed circuit board are normal. 2 Replace the process I/O printed circuit board.

Process I/O board CA

Process I/O board EA, EB Fuse location is common to EA and EB.The following is figure of EA.

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3.TROUBLESHOOTING

MAINTENANCE

Process I/O board FA

Process I/O board GA

Process I/O board HA

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MAINTENANCE

3.TROUBLESHOOTING

Process I/O board JA, JB Fuse location is common to JA and JB.The following is figure of JA.

Process I/O JA

Process I/O board KA, KB, KC Fuse location is common to KA, KB and KC. The following is figure of KA.

LED

FUSE1

Process I/O KA

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3.TROUBLESHOOTING

3.7

MAINTENANCE

B-82595EN-2/02

TROUBLESHOOTING BASED ON LED INDICATIONS The printed circuit boards and servo amplifier are provided with alarm LEDs and status LEDs. The LED status and corresponding troubleshooting procedures are described below. Main board Process I/O

Power supply unit

Panel board


Optional slot

Main board

(B-cabinet)

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Power supply unit

MAINTENANCE

B-82595EN-2/02

3.TROUBLESHOOTING

TROUBLESHOOTING USING THE LEDS ON THE MAIN BOARD (1) Troubleshooting using the status display LED To troubleshoot an alarm that arises before the teach pendant is ready to display, check the status LEDs (green) on the main board at power-on. After power-on, the LEDs light as described in steps 1 to end, in the order described. If an alarm is detected, the step in which the alarm occurred can be determined from which LEDs are lit. Step

LED

Action to be taken

1: After power-on, all LEDs are lit.

[Action1] Replace the CPU card. * [Action2] Replace the main board.

2: Software operation start-up.


3: The initialization of dram on the CPU card is completed.


4: The initialization of DPRAM on the communication IC is completed.

[Action1] Replace the CPU card. * [Action2] Replace the main board. * [Action3] Replace the FROM/SRAM module.

5: The initialization of the communication IC is completed.

[Action1] Replace the CPU card. * [Action2] Replace the main board. * [Action3] Replace the FROM/SRAM module.

6: The loading of the basic software is completed.

* [Action1] Replace the main board. * [Action2] Replace the FROM/SRAM module.

7: Basic software start-up.


8: Start-up of communication with the teach pendant.


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3.TROUBLESHOOTING Step 9: The loading of optional software is completed.

MAINTENANCE LED

B-82595EN-2/02

Action to be taken * [Action1] Replace the main board. [Action2] Replace the process I/O board.

10: DI/DO initialization

* [Action1] Replace the FROM/SRAM module. * [Action2] Replace the main board.

11: The preparation of the SRAM module is completed.

[Action1] Replace the axis control card. * [Action2] Replace the main board. [Action3] Replace the servo amplifier.

12: Axis control card initialization


13: Calibration is completed.


14: Start-up of power application for the servo system

* [Action1] Replace the main board.

15: Program execution

* [Action1] Replace the main board. [Action2] Replace the process I/O board.

16: DI/DO output start-up.

* [Action1] Replace the main board.

17: Initialization is terminated.

Initialization has ended normally.

18: Normal status

Status LEDs 1 and 2 blink when the system is operating normally.

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*

MAINTENANCE

3.TROUBLESHOOTING

If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data. If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.

CPU card

FROM/SRAM module

Axis control card

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MAINTENANCE

B-82595EN-2/02

(2) TROUBLESHOOTING BY 7-SEGMENT LED INDICATOR 7-segment LED indicator

Description [Description] A parity alarm condition has occurred in DRAM on the CPU card installed on the main board. [Action1] Replace the CPU card. * [Action2] Replace the main board. [Description] A parity alarm condition has occurred in SRAM on the FROM/SRAM module installed on the main board. [Action1] Replace the FROM/SRAM module. * [Action2] Replace the main board. [Description] A bus error has occurred in the communication controller. * [Action] Replace the main board.

*

*

*

*

[Description] A parity alarm condition has occurred in DRAM controlled by the communication controller. [Action] Replace the main board. [Description] A servo alarm condition has occurred on the main board. [Action1] Replace the axis control card. [Action2] Replace the main board. [Description] The SYSEMG alarm has occurred. [Action1] Replace the axis control card. [Action2] Replace the CPU card. [Action3] Replace the main board. [Description] The SYSFAIL alarm has occurred. [Action1] Replace the axis control card. [Action2] Replace the CPU card. [Action3] Replace the main board. [Description] 5V is supplied to Main board. Above alarms do not occur.

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data. If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.

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MAINTENANCE

3.TROUBLESHOOTING

Troubleshooting by LEDs on power supply unit LED indication

Failure description and required measure [Description] When ALM LED (red) turned on, power supply alarm has occurred. [Action1] Check fuse F4 (+24V) on the power supply unit, and replace it if it has blown. [Action2] Check the printed-circuit boards powered by the DC power supplies (+5V, 15V, and +24V), the relevant units, and cables, and replace them if defective. [Action3] Replace the power supply unit.

[Description] If the PIL LED (Green) does not light, the power supply unit has not been supplied with 200 VAC. [Action1] Check fuse F1 on the power supply unit, and replace it if it has blown. For detailed causes of fuse blown out, please refer to section 3.6. [Action2] Replace the power supply unit.

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3.TROUBLESHOOTING

MAINTENANCE

F1 (8.0A) : Fuse for AC input

F3 (7.5A) : Fuse for +24E F4 (7.5A) : Fuse for +24V PIL : LED (green)

ALM :LED (red)

(Power supply unit)

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B-82595EN-2/02

MAINTENANCE

3.TROUBLESHOOTING

Troubleshooting by LED on the panel board - A20B-2101-0370 LED indication

Failure description and required measure

ALM1 ALM2

[Description] When the ALM1 and ALM2 (red) tourned on, communication with the main board does not execute. [Action1] Check the communication cable between the main and panel boards, and replace it if necessary. [Action2] Replace the main board. [Action3] Replace the panel board. [Description] When the LED does not light. The power supply inside the panel board does not generate +5 V normally. [Action1] Check the CRM96 connector and check that 24 V is supplied. [Action2] Replace the panel board.

5V

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data. If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.

(Panel board)

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3.TROUBLESHOOTING

MAINTENANCE

B-82595EN-2/02

Troubleshooting by alarm LEDs on the process I/O printed circuit board LED Process I/O CA/HA/JA/JB

Description and action to be taken Process I/O EA/EB/FA/GA/KA/KB/KC

ALM0

[Description] A communication alarm occurred between the main CPU PC board and process I/O PC board. [Action1] Replace the process I/O PC board. * [Action2] Replace the main CPU PC board. [Action3] Replace the I/O link connection cable.

FALM

Process I/O CA/HA/JA/JB

Process I/O EA/EB/FA/GA/KA/KB/KC

ALM0

[Description] A fuse on the process I/O PC board is blown. [Action1] Replace the blown fuse on the process I/O PC board. [Action2] Examine the cables and peripheral devices connected to the process I/O PC board. Replace any failed components. [Action3] Replace the process I/O PC board.

FALM

Process I/O CA/HA

Process I/O EA/EB/FA/GA/KA/KB/KC

Fuse

Fuse

Fuse specification: A60L-0001-0046#2.0

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MAINTENANCE

3.TROUBLESHOOTING

Process I/O JA/JB

Fuse specification: A60L-0001-0046#2.0

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3.TROUBLESHOOTING

MAINTENANCE

B-82595EN-2/02

Troubleshooting by LEDs on servo amplifier The servo amplifier has alarm LEDs. Troubleshoot the alarm indicated by the LEDs, referring also to the alarm indication on the teach pendant. Check that the voltage is not higher than 50V.

CAUTION Before touching the servo amplifier, check the DC link voltage with the screws located above the LED "D7". By using a DC voltage tester, check that the voltage is 50 V or less. LED

Color

P5V

Green

P3.3V

Green

Description Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally. If the LED does not light: [Measure 1] Check the robot connection cable (RP1) to see if there is a ground fault in the +5V wire. [Measure 2] Replace the servo amplifier. Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V normally. If the LED does not light: [Measure] Replace the servo amplifier.

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3.TROUBLESHOOTING

LED

Color

Description

SVEMG

Red

ALM

Red

DRDY

Green

OPEN

Green

D7

Red

Lights when an emergency stop signal is input to the servo amplifier. If the LED lights when the machine is not at an emergency stop: [Measure] Replace the servo amplifier. If the LED does light when the machine is at an emergency stop: [Measure] Replace the servo amplifier. Lights when the servo amplifier detects an alarm. If the LED lights when there is no alarm condition in the machine: [Measure] Replace the servo amplifier. If the LED does not light when there is an alarm condition in the machine: [Measure] Replace the servo amplifier. Lights when the servo amplifier is ready to drive the servo motor. If the LED does not light when the motor is activated: [Measure] Replace the servo amplifier. Lights when the communication between the servo amplifier and the main board is normal. If the LED does not light: [Measure 1] Check for the connection of the FSSB optical cable. [Measure 2] Replace the servo card. [Measure 3] Replace the servo amplifier. Lights when the DCLINK circuit inside the servo amplifier is charged to reach the specified voltage. If the LED does not light after pre-charge is finished: [Measure 1] It is likely that the DC Link may be short-circuited. Check for connection. [Measure 2] It is likely that the charge current control resistor may be defective. Replace the emergency stop unit. [Measure 3] Replace the servo amplifier.

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3.8

MAINTENANCE

B-82595EN-2/02

POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) (Check 1) On the status screen, check the position deviation in the stopped state. To display the position deviation, press the screen selection key, and select STATUS from the menu. Press F1, [TYPE], select AXIS from the menu, then press the F4, PULSE. (Corrective action) Correct the parameters related to return to the reference position (positioning). (Check 2) Check whether the motor axis can be positioned normally. (Corrective action) If the motor axis can be positioned normally, check the mechanical unit. (Check 3) Check the mechanical unit for backlash. (Corrective action) Replace a faulty key of motor shaft or other faulty parts. (Check 4) If checks 1 to 3 show normal results (Corrective action) Replace the pulse coder and main board. * If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.

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3.9

MAINTENANCE

3.TROUBLESHOOTING

MANUAL OPERATION IMPOSSIBLE The following explains checking and corrective action required if the robot cannot be operated manually after the controller is turned on: (1) Check and corrective action to be made if manual operation is impossible (Check 1) Check whether the teach pendant is enabled. (Corrective action) Turn on the teach pendant "enable". (Check 2) Check whether the teach pendant is handled correctly. (Corrective action) To move an axis by manual operation, press the axis selection key and shift key at the same time. Set the override for manual feed to a position other than the FINE and VFINE positions. (Check 3) Check whether the ENBL signal of the peripheral device control interface is set to 1. (Corrective action) Place the peripheral device control interface in the ENBL status. (Check 4) Check whether the HOLD signal of the peripheral device control interface (hold status). (Check whether the hold lamp on the teach pendant is on.) (Corrective action) Turn off the HOLD signal of the peripheral device control interface. (Check 5) Check whether the previous manual operation has been completed. (Corrective action) If the robot cannot be placed in the effective area because of the offset of the speed command voltage preventing the previous operation from being completed, check the position deviation on the status screen, and change the setting. (Check 6) Check whether the controller is in the alarm status. (Corrective action) Release the alarm. (2) Check and corrective action to be taken if the program cannot be executed (Check 1) Check whether the ENBL signal for the peripheral-device control interface is on. (Corrective action) Put the peripheral-device control interface in the ENBL state.

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MAINTENANCE

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(Check 2) Check whether the HOLD signal for the peripheral-device control interface is on. Also check whether the HOLD lamp on the teach pendant is on. (Corrective action) If the HOLD signal of the peripheral device control interface is on, turn it off. (Check 3) Check whether the previous manual operation has been completed. (Corrective action) If the robot cannot be placed in the effective area because of the offset of the speed command voltage, which prevents the previous operation from being completed, check the position deviation on the status screen, then change the setting. (Check 4) Check whether the controller is in the alarm status. (Corrective action) Release the alarm.

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4

MAINTENANCE

4.PRINTED CIRCUIT BOARDS

PRINTED CIRCUIT BOARDS The printed circuit boards are factory-set for operation. Usually, you do not need to set or adjust them. This chapter describes the standard settings and adjustment required if a defective printed circuit board is replaced. It also describes the test pins and the LED indications. The control unit printed circuit board includes the main unit printed circuit board and one or more cards or modules installed horizontally to the main-unit printed-circuit board. These PC boards have interface connectors, LED indicators, and a plastic panel at the front. At the rear, there is a backplane connector.

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4.1

MAINTENANCE

B-82595EN-2/02

MAIN BOARD (A16B-3200-0600, -0601) 75173 (Receiver)

75172 (Driver)

CPU card


Axis control card FU1

Fuse(0.5A)

(Total edition “06B” after) Fig.4.1 Main board Name Main board CPU card Axis control card

FROM/SRAM module

Ordering Specification

Board Specification

A05B-2500-H001 A05B-2500-H002 A05B-2500-H020 A05B-2500-H040 A05B-2500-H041 A05B-2500-H042 A05B-2500-H060

A16B-3200-0600 A16B-3200-0601 A20B-3400-0020 A20B-3300-0448 A20B-3300-0447 A20B-3300-0442 A20B-3900-0163 A20B-3900-0223 A20B-3900-0164 A20B-3900-0224 A20B-3900-0165 A20B-3900-0225 A20B-3900-0166 A20B-3900-0226 A20B-3900-0167 A20B-3900-0227

A05B-2500-H061 A05B-2500-H062 A05B-2500-H063 A05B-2500-H064

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Note With force sensor I/F SDRAM 32M 8-axis 12-axis 16-axis FROM 32M/ SRAM 1M FROM 32M/ SRAM 2M FROM 32M/ SRAM 3M FROM 64M/ SRAM 1M FROM 64M/ SRAM 2M

B-82595EN-2/02

MAINTENANCE


(1) Test pins Name

Use

GND1 GND2 GND3 CACHOFF LOAD

For testing the printed circuit board

(2) LEDs Seven segment LED

Description A parity alarm occurred in a DRAM of the CPU card on the main board. A parity alarm occurred in a SRAM of the FROM/SRAM module on the main board. Bus error occurred on the communication controller.

A parity alarm occurred in DRAM controlled by communication controller. A servo alarm occurred on the main board.

SYSEMG occurred.

SYSFAIL occurred.

5V is supplied to Mainboard. Above 0-7 alarms do not occur.

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MAINTENANCE

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Status LED

Description Operating status of the system.

ETHERNET LED

Color

Description

TX L/RX

Green

Flashes during data transmission. Lights when a link is established, and blinks when data is received.

Green

(3) Communication IC If the teach pendant cannot display anything because of, for example, a broken wire in the teach pendant connection cable, it is likely that the communication driver or receiver may be defective. Name

Drawing number

75172 (Driver) 75173 (Receiver)

A76L-0151-0098 A76L-0151-0099

Please refer to Fig.4.1.

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4.2

MAINTENANCE


EMERGENCY STOP CONTROL BOARD (A20B-1008-0740)

Fig.4.2 Emergency stop control board

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4.3

MAINTENANCE

B-82595EN-2/02

BACKPLANE BOARD (A20B-2003-0890)

Fig.4.3 (a) Backplane Board (A20B-2003-0890)

(1) Test pins Name

Use

HIGH TEST LOW


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MAINTENANCE


(A20B-2004-0040)

Fig.4.3 (b) Backplane board (A20B-2004-0040)

(1) Test pins Name

Use

HIGH TEST LOW


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4.4

MAINTENANCE

B-82595EN-2/02

PANEL BOARD (A20B-2101-0370)

Fig.4.4 Panel Board

(1) Meanings of LEDs Name

Color

Use

5V

Green

ALM1 ALM2

Red

Lights when +5 V is output normally from the internal power supply of the panel board. Lights when communication with the main board is interrupted.

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4.5


MAINTENANCE

B-82595EN-2/02

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

Fig. 4.6 Process I/O Board CA

(1) Test pins Name

Use

P24V P5V P15VC M15VC GND1 GND2

+24V +5V +15V -15V GND GND

For measuring the DC supply voltage

P10V

+10V

For measuring the reference voltage of the digital/analog converter

P15VF M15VF GNDF AI1 AI2 AI3 AI4 AI5 AI6 AOUT1 AOUT2

+15V -15V GND Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 1 Channel 2

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Power for the digital/analog converter

For measuring the ovltage of the analog input signal (analog/digital)

For measuring the voltage of the analog output signal (digital/analog)


MAINTENANCE

B-82595EN-2/02

(2) Setting Name ICOM1 ICOM2 ICOM3 SP1 SP2

UDI1 to UDI20 (Connector CRM2A) UDI21 to UDI40 (Connector CRM2B) WI01 to WI08 (Connector CRW1) Channel 1 Channel 2

Standard setting Side A

Open

Description Set this jumper according to the common voltage of input devices. Side A : +24V common SideB : 0V common The polarity of the output voltage is switched to: Strapped: Negative (-) Open : Positive (+)

(3) Adjustment VR1: Adjust the gain of channel 1. Execute a robot program and set AOUT[1] to 4095 on the teach pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 until the meter reads 12.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) VR2: Adjust the gain of channel 2. Execute a robot program and set AOUT[2] to 4095 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR2 until the meter reads 12.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) VR3: Adjust the reference supply voltage of the digital/analog converter. Connect the digital voltmeter to test pin P10V and rotate VR3 until the meter reads 10.0±0.1V. (4) LEDs Color

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Description

Red

A communication alarm occurred between the main CPU and process input/output.

Red

A fuse (FUSE 1) in the process input/output blew.

B-82595EN-2/02

MAINTENANCE


(5) Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062 Driver IC DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 DV11 DV12 RESERVED

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DO signal CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED DO01, DO02, DO03, DO04 DO05, DO06, DO07, DO08 DO09, DO10, DO11, DO12 DO13, DO14, DO15, DO16 DO17, DO18, DO19, DO20 WO01, WO02, WO03, WO04 WO05, WO06, WO07, WO08 For replacement


4.6

MAINTENANCE

B-82595EN-2/02

PROCESS I/O BOARD EA (A16B-3200-0230)

Fig. 4.6 Process I/O Board EA

(1) Test pins Name

Use

P24V P5V P15VC M15VC GND1 GND2

+24V +5V +15V -15V GND GND


P10V

+10V

For measuring the reference voltage of the digital/analog converter

P15VF M15VF GNDF AI1 AI2 AI3 AI4 AI5 AI6 AOUT1 AOUT2

+15V -15V GND Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 1 Channel 2

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For measuring power for the digital/analog converter

For measuring the ovltage of the analog input signal (analog/digital)

For measuring the voltage of the analog output signal (digital/analog)

MAINTENANCE

B-82595EN-2/02


(2) Setting Name ICOM1 ICOM2 ICOM3 SP1 SP2

UDI1 to UDI20 (Connector CRM2A) UDI21 to UDI40 (Connector CRM2B) WI01 to WI08 (Connector CRW1) Channel 1 Channel 2


Open

Description Set this jumper according to the common voltage of input devices. Side A : +24V common SideB : 0V common Output voltage is adjusted to: Short : Output voltage minus (-) Open : Output voltage plus(+)

(3) Adjustment VR1: Adjust the gain of channel 1. Execute a robot program and set AOUT[1] to 4095 on the teach pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 until the meter reads 12.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) VR2: Adjust the gain of channel 2. Execute a robot program and set AOUT[2] to 4095 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR2 until the meter reads 12.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) VR3: Adjust the standard voltage for the digital/analog converter. Connect the digital voltmeter to test pin P10V and rotate VR3 until the meter reads 10.0±0.1V VR4, VR5: Adjust the internal power supply This volume is adjusting the internal power supplu. Adjusting when shipping from the factory, so you need not to adjust.

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MAINTENANCE

B-82595EN-2/02

(4) LEDs Color

Description

Red

A communication alarm occurred between the main CPU and process I/O board.

Red

A fuse (FUSE 1) in the process I/O board blew.

(5) Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062 Driver IC DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 DV11 DV12

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DO signal CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED DO01, DO02, DO03, DO04 DO05, DO06, DO07, DO08 DO09, DO10, DO11, DO12 DO13, DO14, DO15, DO16 DO17, DO18, DO19, DO20 WO01, WO02, WO03, WO04 WO05, WO06, WO07, WO08

MAINTENANCE

B-82595EN-2/02

4.7


PROCESS I/O BOARD EB (A16B-3200-0231)

Fig. 4.7 PROCESS I/O BOARD EB (A16B-3200-0231)

(1) Test pins Name

Use +24V +5V GND GND

P24V P5V GND1 GND2


(2) Setting Name ICOM1 ICOM2

UDI1 to UDI20 (Connector CRM2A) UDI21 to UDI40 (Connector CRM2B)

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Description Set this jumper according to the common voltage of input devices. Side A : +24V common SideB : 0V common


MAINTENANCE

B-82595EN-2/02

(3) LEDs Color

Description

Red


Red


(4) Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062 Driver IC DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10

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DO signal CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED DO01, DO02, DO03, DO04 DO05, DO06, DO07, DO08 DO09, DO10, DO11, DO12 DO13, DO14, DO15, DO16 DO17, DO18, DO19, DO20

4.8


MAINTENANCE

B-82595EN-2/02

PROCESS I/O BOARD FA (A16B-3200-0420)

Fig. 4.8 Process I/O Board FA

(1) Test pins Name


P24V P5V GND1 GND2


(2) Setting Name ICOM1 ICOM2 ICOM3 ICOM4 ICOM5 ICOM6

UDI1 to UDI20 (Connector CRM2A) UDI21 to UDI40 (Connector CRM2B) UDI41 to UDI60 (Connector CRM2C) UDI61 to UDI80 (Connector CRM2D) UDI81 to UDI88 (Connector CRM4A) UDI89 to UDI96 (Connector CRM4B)

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Standard setting

Side A

Description

Set this jumper according to the common voltage of input devices. Side A : +24V common SideB : 0V common


MAINTENANCE

B-82595EN-2/02

(3) LEDs Color

Description

Red


Red


(4) Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062 Driver IC DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 DV11 DV12 DV13 DV14 DV15 DV16 DV17 DV18 DV19 DV20 DV21 DV22 DV23 DV24

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DO signal CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED DO01, DO02, DO03, DO04 DO05, DO06, DO07, DO08 DO09, DO10, DO11, DO12 DO13, DO14, DO15, DO16 DO17, DO18, DO19, DO20 DO21, DO22, DO23, DO24 DO25, DO26, DO27, DO28 DO29, DO30, DO31, DO32 DO33, DO34, DO35, DO36 DO37, DO38, DO39, DO40 DO41, DO42, DO43, DO44 DO45, DO46, DO47, DO48 DO49, DO50, DO51, DO52 DO53, DO54, DO55, DO56 DO57, DO58, DO59, DO60 DO61, DO62, DO63, DO64 DO65, DO66, DO67, DO68 DO69, DO70, DO71, DO72 DO73, DO74, DO75, DO76

MAINTENANCE

B-82595EN-2/02

4.9


PROCESS I/O BOARD GA (A16B-2203-0520)

(1) Test pins Name +24V +5V GND GND GND +24V +5V GND Channel 1 Channel 2

P24V P5V GND1 GND2 GND3 P24VF P5VF GNDF AOUT1 AOUT2

Use


Power for the digital/analog converter For measuring the voltage of the analog output signal (digital/analog)

(2) Setting Name ICOM1 ICOM2 ICOM3

UDI1 to UDI20 (Connector CRM2A) UDI21 to UDI40 (Connector CRM2B) WI01 to WI08 (Connector CRW7)

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MAINTENANCE

B-82595EN-2/02

(3) Adjustment VR1/VR2: Adjust the gain and the offset of channel 1. Execute a robot program and set AOUT[1] to 3413 on the teach pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 or VR2 until the meter reads 15.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) VR3/VR4: Adjust the gain and the offset of channel 2. Execute a robot program and set AOUT[2] to 3413 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR3 or VR4 until the meter reads 15.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) (4) LEDs Color

Description

Red


Red



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4.10


MAINTENANCE

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

Fig. 4.10 Process I/O Board HA

(1) Test pins Name P24V P5V GND1 GND2 GND3 P24VF P5VF GNDF AO1 AO2

+24V +5V GND GND GND +24V +5V GND Channel 1 Channel 2

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Use


Power for the digital/analog converter For measuring the voltage of the analog output signal (digital/analog)


MAINTENANCE

B-82595EN-2/02

(2) Setting Name ICOM1 ICOM2 ICOM3

UDI1 to UDI20 (Connector CRM2A) UDI21 to UDI40 (Connector CRM2B) WI01 to WI08 (Connector CRW7)



(3) Adjustment VR1/VR2: Adjust the gain and the offset of channel 1. Execute a robot program and set AOUT[1] to 3413 on the teach pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 or VR2 until the meter reads 15.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) VR3/VR4: Adjust the gain and the offset of channel 2. Execute a robot program and set AOUT[2] to 3413 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR3 or VR4 until the meter reads 15.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) (4) LEDs Color

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Description

Red


Red


B-82595EN-2/02

MAINTENANCE



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4.11

MAINTENANCE

B-82595EN-2/02

PROCESS I/O BOARD JA (A16B-2204-0010) P24V

GND1

ICOM1 ICOM5

P5V

LED CRMA6A

ICOM2

CRMA6B

ICOM6

TBSRC3 TBSRC1 CRMA5A GND2

CRMA5B

CRMA5C CRMA5D ICOM3

TBSRC2

ICOM4

I/O-LK JD1B I/O-LK JD1A FUSE (2A) Fig.4.11

Process I/O Board JA

(1) Test pins Name


P24V P5V GND1 GND2

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MAINTENANCE

B-82595EN-2/02

(2) Settings Name ICOM1 ICOM2 ICOM3 ICOM4 ICOM5 ICOM6

UDI1 to 20 (Connector CRMA5A) UDI21 to 40 (Connector CRMA5B) UDI41 to 60 (Connector CRMA5C) UDI61 to 80 (Connector CRMA5D) UDI81 to 88 (Connector CRMA6A) UDI89 to 96 (Connector CRMA6B)

Standard setting

Description

Side A

Set the common voltage Side A : +24 V common Side B : 0 V common

(3) LEDs Color

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Description

Red

A communication alarm occurred between the main CPU and process I/O.

Red

A fuse (FUSE 1) in the process I/O blew.


4.12

MAINTENANCE

B-82595EN-2/02

PROCESS I/O BOARD JB (A16B-2204-0011)

ICOM1 ICOM2

P5V P24V GND1 LED

GND2

TBSRC1 CRMA5A CRMA5B

I/O-LK JD1B FUSE (2A)

I/O-LK JD1A

Fig.4.12

Process I/O Board JB

(1) Test pins Name


P24V P5V GND1 GND2

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MAINTENANCE

B-82595EN-2/02

(2) Settings Name ICOM1 ICOM2

UDI1 to 20 (Connector CRMA5A) UDI21 to 40 (Connector CRMA5B)

Standard setting

Description

Side A

Set the common voltage Side A : +24 V common Side B : 0 V common

(3) LEDs Color

- 195 -

Description

Red

A communication alarm occurred between the main CPU and process I/O.

Red

A fuse (FUSE 1) in the process I/O blew.


4.13

MAINTENANCE

B-82595EN-2/02

PROCESS I/O BOARD KA (A16B-2204-0050) Total edition GND2

P24V

GND3

P5V

VR5 VR6

GNDF

VR4

GND1 DV1

P5VF

VR3 VR2

LED

AOUT3

VR1 AOUT2

P24VF N15V

GND4 ICOM2

AOUT1

P15V

DRV1

AI2

ICOM3

AI1

DRV2

ICOM1

(1) Meanings of check pins Name

Use

P24V

＋24V

P5V

＋5V

P15V

＋15V

N15V

－15V

GND1

GND

GND2

GND

GND3

GND

GND4

GND

P5VF

＋5V

P24VF

+24V

GNDF

GND

For DC power measurement

D/A converter power supply

AI1

Channel 1

For analog input signal (A/D) voltage

AI2

Channel 2

measurement

AOUT1

Channel 1 Channel 2 Channel 3

AOUT2 AOUT3

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For analog output signal (D/A) voltage measurement

MAINTENANCE

B-82595EN-2/02


(2) Setting Name ICOM1

UDI1～20 （connector CRMA5A）

ICOM2


Use For common voltage setting Side A: +24 V common Side B: 0 V common

UDI21～40 （connector CRMA5B）

ICOM3

WI01～08 （connector CRW10）

(3) Adjustment VR1/VR2 Channel 1 gain and offset adjustment Connect the "+" and "-" terminals of a digital voltmeter, respectively, to the AOUT1 check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT[1]=3413, using a robot program. While observing the voltage at the AOUT1 check pin with the digital voltmeter, adjust potentiometers VR1 and VR2 for 15.0 V. VR3/VR4 Channel 2 gain and offset adjustment Connect the "+" and "-" terminals of a digital voltmeter, respectively, to the AOUT2 check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT[2]=3413, using a robot program. While observing the voltage at the AOUT2 check pin with the digital voltmeter, adjust potentiometers VR3 and VR4 for 15.0 V. VR5/VR6 Channel 3 gain and offset adjustment Connect the "+" and "-" terminals of a digital voltmeter, respectively, to the AOUT3 check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT[3]=3413, using a robot program. While observing the voltage at the AOUT3 check pin with the digital voltmeter, adjust potentiometers VR5 and VR6 for 15.0 V.

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MAINTENANCE

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(4) Meaning of LEDs Color

Meaning

Red

A communication alarm occurred between the main CPU and the process I/O board.

Red

The fuse (FUSE1) on the process I/O board has blown.

(5) Correspondence between driver ICs and DO signals Driver IC specification:DRV1, DRV2：A76L-1151-0167 DV1：A76L-1151-0070 DO signal name

Driver IC name DRV1

CMDENBL，SYSRDY，PROGRUN，PAUSED HELD，FAULT，ATPERCH，TPENBL BATALM，BUSY，ACK1/SNO1，ACK2/SNO2 ACK3/SNO3，ACK4/SNO4，ACK5/SNO5，ACK6/SNO6

DRV2

ACK7/SNO7，ACK8/SNO8，SNACK，RESERVED DO01， DO02， DO03， DO04 DO05， DO06， DO07， DO08 DO09， DO10， DO11， DO12

DV1

DO13， DO14， DO15， DO16 DO17， DO18， DO19， DO20

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4.14


MAINTENANCE

B-82595EN-2/02

PROCESS I/O BOARD KB（A16B-2204-0051） Total edition GND2

P24V

GND3

P5V GNDF

VR4

GND1 DV1

P5VF

VR3

LED

VR2 VR1

P24VF

AOUT2

GND4 ICOM2

AOUT1

DRV1

DRV2

ICOM1

ICOM3


Use

P24V

＋24V

P5V

＋5V

GND1

GND

GND2

GND

GND3

GND

GND4

GND

P5VF

＋5V

P24VF

+24V

GNDF

GND


D/A converter power supply

AOUT1

Channel 1

For analog output signal (D/A) voltage

AOUT2

Channel 2

measurement

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MAINTENANCE

B-82595EN-2/02

(2) Setting

ICOM1

Name

Standard setting

UDI1～20

Side A

(connector CRMA5A) ICOM2

UDI21～40


(connector CRMA5B) ICOM3

WI01～08 (connector CRW10)

(3) Adjustment VR1/VR2 Channel 1 gain and offset adjustment Connect the "+" and "-" terminals of a digital voltmeter, respectively, to the AOUT1 check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT[1]=3413, using a robot program. While observing the voltage at the AOUT1 check pin with the digital voltmeter, adjust potentiometers VR1 and VR2 for 15.0 V. VR3/VR4 Channel 2 gain and offset adjustment Connect the "+" and "-" terminals of a digital voltmeter, respectively, to the AOUT2 check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT[2]=3413, using a robot program. While observing the voltage at the AOUT2 check pin with the digital voltmeter, adjust potentiometers VR3 and VR4 for 15.0 V.

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B-82595EN-2/02

MAINTENANCE



Meaning

Red


Red


(5) Correspondence between driver ICs and DO signals Driver IC specification:DRV1, DRV2：A76L-1151-0167 DV1：A76L-1151-0070 Driver IC name DRV1

DO signal name CMDENBL，SYSRDY，PROGRUN，PAUSED HELD，FAULT，ATPERCH，TPENBL BATALM，BUSY，ACK1/SNO1，ACK2/SNO2 ACK3/SNO3，ACK4/SNO4，ACK5/SNO5，ACK6/SNO6

DRV2


DV1


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4.15

MAINTENANCE

B-82595EN-2/02

PROCESS I/O BOARD KC（A16B-2204-0052） Total edition GND2

P24V

GND3

P5V

GND1 DV1

LED

GND4 ICOM2 DRV1

DRV2

ICOM1


Use

P24V

＋24V

P5V

＋5V

GND1

GND

GND2

GND

GND3

GND

GND4

GND


(2) Setting

ICOM1

Name

Standard setting

UDI1～20

Side A

(connector CRMA5A) ICOM2

UDI21～40 (connector CRMA5B)

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B-82595EN-2/02

MAINTENANCE



Meaning

Red


Red


(4) Correspondence between driver ICs and DO signals Driver IC specification:DRV1, DRV2：A76L-1151-0167 DV1：A76L-1151-0070 Driver IC name DRV1

DO signal name CMDENBL，SYSRDY，PROGRUN，PAUSED HELD，FAULT，ATPERCH，TPENBL BATALM，BUSY，ACK1/SNO1，ACK2/SNO2 ACK3/SNO3，ACK4/SNO4，ACK5/SNO5，ACK6/SNO6

DRV2


DV1


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5.SERVO AMPLIFIERS

5

MAINTENANCE

B-82595EN-2/02

SERVO AMPLIFIERS The servo amplifiers are factory-set for operation. Usually, you do not need to set or adjust them. This chapter describes the standard settings and adjustment required if a defective servo amplifier is replaced. It also describes the use of test pins and meanings of the LED indications. Table 5

ROBOT M-900iA/600 R-2000iB/200T M-900iA/260L M-900iA/350 M-410iB R-2000iB （except /200T） M-710iC M-16iB ARC Mate 120iB (Except ARC Mate 120iBe.) M-420iA, M-421iA M-6iB ARC Mate 100iB ARC Mate 120iBe F-200iB ARC Mate 100iC M-10iA M-430iA/2F M-430iA/2P

SERVO AMPLIFIER

Servo amplifier specification REGENERATIVE REGISTOR A-CABINET B-CABINET

A06B-6107-H001 (AMP1) A06B-6117-H209 (AMP2) A06B-6117-H105 (AMP3)

A05B-2502-C100

A06B-6107-H001

A05B-2502-C100 A05B-2501-C102

A05B-2501-C103 A06B-6107-H002

A05B-2502-C100 A05B-2501-C100 A05B-2501-C102

A06B-6107-H003

A05B-2501-C101

A05B-2502-C101

A05B-2501-C105 A06B-6107-H004

A05B-2501-C101

A05B-2502-C101

A06B-6107-H007 (AMP 1) A06B-6117-H201 (AMP 2) A06B-6107-H007 (AMP 1) A06B-6117-H301 (AMP 2)

A05B-2501-C105

A05B-2502-C101

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B-82595EN-2/02

MAINTENANCE

5.SERVO AMPLIFIERS

Check that the voltage is not higher than 50V.

NOTE Before touching the servo amplifier, for example, for maintenance purposes, check the voltage at the screw above the LED “D7” with a DC voltage tester to see if the remaining voltage is not higher than 50V.

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5.SERVO AMPLIFIERS

5.1

MAINTENANCE

B-82595EN-2/02

LED OF SERVO AMPLIFIER

LED

Color

Description

P5V

Green

P3.3V

Green

SVEMG SVALM DRDY OPEN D7

Red Red Green Green Red

Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally. Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V normally. Lights when an emergency stop signal is input to the servo amplifier. Lights when the servo amplifier detects an alarm. Lights when the servo amplifier is ready to drive the servo motor. Lights when the communication between the servo amplifier and the main board is normal. Lights when the DCLINK circuit inside the servo amplifier is charged to reach a specific voltage.

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MAINTENANCE

B-82595EN-2/02

5.2

5.SERVO AMPLIFIERS

SETTING OF SERVO AMPLIFIER Settings Name COM1


Description Robot Digital Input (RDI) device common voltage. Side A: +24V common Side B: 0V common

A side

RI

B side

RI

Circuit based on jumper pin location

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6.SETTING THE POWER SUPPLY

6

MAINTENANCE

B-82595EN-2/02

SETTING THE POWER SUPPLY Setting and adjustment of the power supply is factory-set for operation. Usually, you do not need to set or adjust it.

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6.1


MAINTENANCE

B-82595EN-2/02

BLOCK DIAGRAM OF THE POWER SUPPLY

Servo amplifier (6-axis amplifier)

E-stop unit Transformer

210VAC 3φ

Breaker

Regenerative res. aux. axis

210VAC

Breaker

CRR38 CRM96

+24V

DC/DC +5V, +3.3V +15V, -15V

FS1 CRM96 FS2

CRF8

CRR64 CRR88

CNJ

AC power supply unit AC 200 ～ 230 V AC 380 ～ 400 V AC 380 ～ 415 V AC 440 ～ 500 V AC 500 ～ 575 V

200VAC １φ

CP1

Robot

CP2

200VAC １φ

Fan CP2

Motor

CP3 DC/DC

F3

CP6

F4

CP5

CRP24

End effector

CP5A

+24V

+24E

Main board

+24E

CRM95

+5V, +3.3V +2.5V, +15V, -15V +24V, +24E

Pulse corder

CP1A

r e w o P

F1

Brake

Power supply unit

+24VF

+5V

Power supply I/O unit

Backplane

FS3

Battery CRM95

CP8B

+24E

CRS20

+24T

FUSE2

Teach pendant

DC/DC +5V

E-stop circuit JRS16 JD1A JD17 CRS26 CA69A 24V→ 12V

Panel board

RS-232-C I/O LINK RS-232-C/RS-485 FORCE SENSOR SERVO CHECK I/F

JRL6 VIDEO INPUT (FU1)

Process I/O board +24E

FUSE1

+24F

Peripheral device

+24V +24E -15V +15V +5V +3.3V +2.5V

CRM2 CRM4 CRMA5 CRMA6

Fig. 6.1

Block diagram of the power supply

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6.2

MAINTENANCE

B-82595EN-2/02

TRANSFORMER Select a transformer and tap according to the supply voltage. Select a transformer tap among the rated voltage.

A-cabinet Transformer specification

Rated voltage

13.0KVA

10.5KVA

7.5KVA

3KVA

A80L-0028-0024#A

A80L-0026-0040#A

A80L-0024-0028

A80L-0028-0027#A

A80L-0026-0041#A

A80L-0024-0029

500 to 575 TYPE E

440 to 500 380 to 415

TYPE D

200 to 230 380 to 400

B-cabinet Transformer specification

Rated voltage

13.0KVA

10.5KVA

7.5KVA

3KVA

500 to 575 TYPE E

440 to 500

A80L-0028-0025

A80L-0028-0024

A80L-0026-0040

A80L-0024-0028

A80L-0028-0028

A80L-0028-0027

A80L-0026-0041

A80L-0024-0029

380 to 415 TYPE D

200 to 230 380 to 400

Transformer

Side fan type


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MAINTENANCE

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Transformer

B-Cabinet (Back)

Fig.6.2 (a)

Transformer mounting locations and structure

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MAINTENANCE

B-82595EN-2/02

Cabinet side connector 4. TYPE D (380V-400V)

1. TYPE E (500V-575V)

Dummy plug Dummy plug

Circuit breaker Y connection cable

2. TYPE E (440V-500V)

Circuit breaker

5. TYPE D (200V-230V)

Dummy plug Dummy plug

Circuit breaker

∆ connection cable

Circuit breaker

(B-cabinet) 3. TYPE E (380V-415V) Dummy plug Dummy plug

Y - ∆ connection unit

Circuit breaker

(A-cabinet)

Fig. 6.2(b)

Setting the input voltage

- 212 -

Y connection cable

Circuit breaker

MAINTENANCE

B-82595EN-2/02

1

Type E: 500V-575V

2

Type E: 440-500V

3

Type E: 380-415V

4

Type D: 380-400V

5

Type D: 200-230V


Insert the connector connected to the circuit breaker into connector LA and the dummy plug into connectors LB and LC. Insert the connector connected to the circuit breaker into connector LB and the dummy plug into connectors LA and LC. Insert the connector connected to the circuit breaker into connector LC and the dummy plug into connectors LA and LB. Insert the Y connection cable connected to the circuit breaker into connectors LA and LB. Insert the Δ connection cable connected to the circuit breaker into connectors LA and LB.

CAUTION The secondary voltage of the transformer depneds on the cable connection between a breaker and a transformer. Be careful for the cable connection in the mainternance.

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6.3

MAINTENANCE

B-82595EN-2/02

CHECKING THE POWER SUPPLY UNIT (A16B-2203-0910) The power supply unit need not be set or adjusted. Table 6.3 Rating of the Power supply unit Output Rated voltage Tolerance +5V +3.3V +2.5V +24V +24E +15V -15V

+5.1V +3.3V +2.5V +24V +24V +15V -15V

DB1 : Diode stack F1 (8.0A) : Fuse for AC input CP1 : Connector for AC input CP1A : Connector for AC output CP2, CP3 : Connector for AC output VS1 : Surge absorber

F3 (7.5A) : Fuse for +24E F4 (7.5A) : Fuse for +24V PIL : LED (green)

H1 : Auxiliary power module CP5 : Connector for +24V CP6 : Connector for +24E ALM : LED (red) CP4 : Connector for control

Fig.6.3 (a)

Interface of the power supply unit

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±3% ±3% ±3% ±5% ±5% ±10% ±10%

B-82595EN-2/02

7

MAINTENANCE

7.REPLACING A UNIT

REPLACING A UNIT This section explains how to replace each unit in the control section.

WARNING 1 Before you start to replace a unit, turn off the control unit main power. Also keep all machines in the area of the control unit switched. Otherwise, you could injure personnel or damage equipment. 2 Before replacing components, read the maintenance manual to understand the replacement procedure. Performing an incorrect replacement procedure can lead to an unpredictable accident, resulting in breakage in the robot or personal injury. 3 When a heavy component or unit is to be handled, support the workers with a crane or the like not to apply excessive loads to the workers. Note that incorrect handling can cause serious injury to the workers. CAUTION Components in the control unit heat up, so care should be taken. When you have to touch a heated component, prepare a protector such as heat-resistant gloves.

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7.REPLACING A UNIT

7.1

MAINTENANCE

B-82595EN-2/02

A-CABINET The following components of the A-cabinet can be removed.

7.1.1

Replacing the A-cabinet Top Panel Remove three M4 screws from the upper edge of the rear surface. Pull the top panel slightly backward, then lift it off.

M4 screws (3 places)

Fig.7.1.1 Replacing the Top Panel

NOTE In case of the Rear fan type, replace the Top panel after remove the Rear louver.

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B-82595EN-2/02

7.1.2

MAINTENANCE

7.REPLACING A UNIT

Replacing the A-cabinet Rear Panel Remove the retaining M4 screws and four M10 bolts from the rear panel.


M10 bolts (4 places)

Fig.7.1.2 Replacing the Top Panel

NOTE In case of the Rear fan type, replace the Rear Panel after remove the Rear louver.

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7.REPLACING A UNIT

7.1.3

MAINTENANCE

B-82595EN-2/02

Replacing the A-cabinet Louver (a) Side fan type Loosen four retaining M4 screws from the louver, then remove the louver.

Fig.7.1.3 (a)

Replacing the Louver (Side fan type)

(b) Rear fan type Loosen four retaining M4 screws from the louver (the louver is fastened together with the rear panel), then remove the louver.

Fig.7.1.3 (b)

- 218 -

Replacing the Louver (Rear fan type)

B-82595EN-2/02

7.1.4

MAINTENANCE

7.REPLACING A UNIT

Replacing the A-cabinet Door Detach the cables from each unit (such as the fan unit) installed on the door. Lift the door off its hinges to dismount it.

Lift up the door to mount it.

Fig.7.1.4 Replacing the Door

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7.REPLACING A UNIT

7.2

MAINTENANCE

B-82595EN-2/02

REPLACING THE PRINTED-CIRCUIT BOARDS CAUTION When you replace printed-circuit boards, observe the following cautions: 1 Keep the controller power switched off. 2 When you remove a printed-circuit board, do not touch the semiconductor devices on the board with your hand or make them touch other components. 3 Make sure that the replacement printed-circuit board has been set up appropriately. (Setting plug etc.) 4 After replacing a printed-circuit board, make adjustments correctly if the board needs to be adjusted. 5 If the backplane board, power supply unit, or main board (including cards and modules) is replaced, it is likely that robot parameters and taught data are lost. Before you start to replace these components, save a backup copy of the robot parameters and taught data to an external memory device. 6 Before you disconnect a cable, note its location. If a cable is detached for replacement, reconnect it exactly as before.

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B-82595EN-2/02

7.2.1

MAINTENANCE

7.REPLACING A UNIT

Replacing the Backplane Board (Unit) When replacing the backplane board, do so together with the plastic rack. (1) Detach the cables from the power unit and boards on the backplane board.

CAUTION When you remove the main PC Board, be sure that the battery is good (3.1-3.3VDC) and it is installed correctly. USE STATIC PROTECTION. (2) Remove the power unit and boards from the rack. (See Section 7.2.2.) (3) Detach the grounding cable from the backplane unit. (4) Loosen the retaining screws in the upper section of the rack. Remove the retaining screws from the lower section of the rack. (5) Side rack up and out. (6) To replace the backplane and rack, reverse steps (1) - (6).

CAUTION There is a possibility of data loss when a backplane- mounted printed circuit board is replaced. Be sure to back up all program and setup data on an external device such as a memory card before proceeding.

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7.REPLACING A UNIT

7.2.2

MAINTENANCE

B-82595EN-2/02

Replacing the Power Unit and Printed-Circuit Boards on the Backplane Unit The backplane unit incorporates the power unit, main board, and option boards. There are two types of option boards: Full-size board and mini-size board. A full-size board occupies one slot. A mini-size board uses part of a full-size board.

CAUTION Before starting replacement, turn off the control unit main power. The main board is equipped with battery-backed memory devices for holding robot parameters and taught data, for example. When the main board is replaced, the data in the memory devices is lost. (1) Detach the cable from the power supply unit or the printed-circuit board, whichever is to be replaced. (2) Pinch the barbed handles on the upper and lower sections of the board to unlatch it, then pull it toward you. (3) Place the replacement board on the rail in the appropriate slot of the rack, then push it in gently by the handles until it is latched. (4) There are two rails in the main board SLOT (slot 1). When inserting the main board, align it to the right-side rail. (5) There are two rails in slots 3 (slots for a full-size option board). When you insert a full-size option board, align it to the left-side rail.

Backplane board Left rail

Fig.7.2.2(a) Replacing the backplane board

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Right rail

7.REPLACING A UNIT

MAINTENANCE

B-82595EN-2/02

SLOT 3

SLOT 1 SLOT 2 PSU (Power supply SLOT)

Handles

Handles

SLOT 1

Fig.7.2.2(b)

Replacing the power unit and printed-circuit boards on the backplane unit

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7.REPLACING A UNIT

7.2.3

MAINTENANCE

B-82595EN-2/02

Replacing the Panel Board The panel board is at the back of the operator panel. (1) Detach all cables from the panel board. The terminal blocks (TBOP3, TBOP4, and TBOP6) are of a connector type. Pull out the upper terminal block sections. (2) Remove four retaining screws from the panel board, and replace the panel board. (3) Remove two M3 screws from the fixing sheet metal of the panel board, and remove the sheet metal. (4) Attach the fixing sheet metal to a new panel board, and attach the new panel board to the operator panel.

A-cabinet

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B-82595EN-2/02

7.REPLACING A UNIT

MAINTENANCE

Details of section A B-cabinet Fig. 7.2.3 Panel board replacement

- 225 -

7.REPLACING A UNIT

7.2.4

MAINTENANCE

B-82595EN-2/02

Replacing the Process I/O Board EA,EB,FA,GA,KA,KB,KC (A-cabinet)


Fig. 7.2.4

Replacing the Process I/O Board

- 226 -

7.3

7.REPLACING A UNIT

MAINTENANCE

B-82595EN-2/02

REPLACING CARDS AND MODULES ON THE MAIN BOARD CAUTION Before you start to replace a card or module, make a backup copy of robot parameters and taught data. If the FROM/SRAM module is replaced, SRAM memory contents are lost.

Demounting a Card (1) Pull outward the clip of each of the two spacers used to secure the card PCB, then release each latch. (2) Extract the card upward.

Be sure to hold this part to pull out the card.

(2)

Card

Spacer Connector Fig. 7.3 (a)

- 227 -

Demounting the card on the main board

7.REPLACING A UNIT

MAINTENANCE

B-82595EN-2/02

Mounting a Card (1) Check that the clip of each of the two spacers is latched outward, then insert the card into the connector. (2) Push the clip of each spacer downward to secure the card PCB.

Be sure to hold this part to push the card.

(1)

Spacer

Connector

Be sure to hold this part to push the card. Connector Fig. 7.3 (b)

- 228 -

Mounting the card on the main board

B-82595EN-2/02

7.REPLACING A UNIT

MAINTENANCE

Demounting a module CAUTION When replacing the module, be careful not to touch the module contact. If you touch the contact inadvertently, wipe out dirt on the contact with a clean cloth. (1) Move the clip of the socket outward. (a) (2) Extract the module by raising it at a 30 degree slant and pulling outward.

Mounting a module (1) Insert the module at a 30 degree slant into the module socket, with side B facing upward. (b) (2) Push the module inward and downward until it is locked. (c) (a)

A

Details of section A

(b)

Details of section A A

(c)

Fig.7.3 (c)

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Demounting/mounting a module

7.REPLACING A UNIT

MAINTENANCE

B-82595EN-2/02

Figure 7.3 (d) shows the locations of the cards and modules.

CPU card


Axis control card

Fig.7.3 (d)

Locations of cards and modules

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B-82595EN-2/02

7.4

MAINTENANCE

7.REPLACING A UNIT

REPLACING THE TRANSFORMER WARNING The transformer is heavy. When replacing the transformer, be careful not to cause injury. (The transformer weighs 45 to 60 kg.) In case of A-cabinet Following (1) to (3) are not need for the remote type A-cabinet. For the remote type A-cabinet, start from (4). If the A-cabinet is connected to the robot, it will need to be separated. Cabinet separation (1) Disconnect the cable connectors and ground clamps coming from the robot. These cables are generally at the following connectors on the Servo amplifier: CRF8, CNJ1 to 6, and CNJGA to CNJGC, and the ground cables.

Motor power cable Pulse coder cable

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Grounding cable

7.REPLACING A UNIT

MAINTENANCE

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(2) Remove the four M10 robot retaining bolts that hold the cabinet to a robot.

Robot retaining bolts M10 (4 places)

(3) Being careful not to strain or break any cables, gently separate the cabinet from the robot and it’s cables. (4) Disconnect the power cable from the transformer input connector panel. (The power cable comes from the opration box. ) Transformer input connector’s panel

(5) Remove three M4 screws from the upper edge of the rear surface. (Refer to a Fig.7.1.1) Remove the retaining M4 screws and four M10 bolts the rear panel. (Refer to a Fig.7.1.2)

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MAINTENANCE

Following (6) to (7) are not need for the Rear fan type. (6) Unscrew and Remove the regenerative resistor from the plate on the top of the transformer. (Refer to a Fig.7.5) (7) Unscrew and Remove the plate on the top of the transformer. Screw Washer

Screw (M5) 3 places

(8) Remove four screws from a metal plate of connector’s panel, and remove the metal plate. A metal plate of connector’s panel

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MAINTENANCE

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(9) Remove the two M6 screws holding the transformer in place and remove the transformer.

Screws (2-M6)

(10) Install a replacement transformer by reversing steps 1 through 9.

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7.REPLACING A UNIT

In case of B-cabinet (1) Remove the screws and detach the back panel.

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(2) Detach the connectors of LA, LB, LC, OUT, and CPOH. If a cable is fastened with nylon ties, cut them with a diagonal cutter to release the cable. Be careful not to damage the cable. In case of TYPE E

In case of TYPE D

(3) Remove the retaining screws from the transformer terminal board and remove the metal plate.

A


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7.REPLACING A UNIT

(4) Remove the two retaining M6 screws from the transformer, then remove the transformer.

(5) Install a replacement transformer by reversing procedure (1) to (4).

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7.REPLACING A UNIT

7.5

MAINTENANCE

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REPLACING THE REGENERATIVE RESISTOR UNIT WARNING Before you start, turn off the controller main power. Be careful not to get burned, because the regenerative resistor unit is very hot immediately after operation. In case of A-cabinet (a) Remove the top panel from the A-cabinet. Remove the Louver plate and the lower plate on the right side of the cabinet. (In case of the Rear fan type, remove the rear panel or fan unit.) (b) Unplug connector CRR45 and CRR63 at the Servo amplifier. (c) Unscrew the cord grip nut inside the transformer compartment and pull the cables through, being careful not to damage the connectors or cables. (d) Unscrew the retaining screws on the regenerative resistor unit and remove it. (e) Install the replacement unit by reversing this procedure (a) to (d).

CRR63

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CRR45

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MAINTENANCE

Screw Washer The type of the regenerative resistor varies with the model of the robot.

The cable is retained using a cord grip. Remove the cord grip, and pull out the cable. The cord grip is retained with nuts on the rear side. Remove the lower right plate beforehand.

Transformer

(Side fan type)

The type of the regenerative resistor varies with the model of the robot.

Screw (M4) 2 places

Transformer

The cable is retained using a cord grip. Remove the cord grip, and pull out the cable. The cord grip is retained with nuts on the rear side. Remove the lower right plate beforehand. (Rear fan type)

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MAINTENANCE

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In case of B-cabinet (a) Remove the servo amplifier. (See Section 7.6) (b) Remove the metal plate securing the cable of the regenerative resistor unit. If a cable is fastened with nylon ties, cut them with a diagonal cutter to release the cable. Be careful not to damage the cable.

A


Fig. 7.5 (a)

Cable part of the regenerative resister

(c) Of the two nuts fastening the regenerative resistor unit, remove the upper nut, loosen the lower nut, then remove the regenerative resistor unit.

A


Fig. 7.5 (b)


(d) Install a replacement regenerative resistor unit and a servo amplifier by reversing the procedure (a) to (c). - 240 -

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7.6

MAINTENANCE

7.REPLACING A UNIT

REPLACING THE E-STOP UNIT In case of A-cabinet NOTE The magnetic contactor mounted in the emergency stop unit is turned on when the conditions are satisfied. While the controller is turned on, do not press the button on the magnetic contactor in any case. Otherwise, the contactor may be damaged.

Note) Do not press this switch in any case.

E-stop unit (A-cabinet)

(a) Detach the cables from the emergency stop unit. (b) Remove retaining screws (M4 4 places) from the emergency stop unit, and replace the emergency stop unit. (c) Reconnect the cables.

E-stop unit 4-M4 screws

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7.REPLACING A UNIT

MAINTENANCE

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In case of B-cabinet NOTE The magnetic contactor mounted in the emergency stop unit is turned on when the conditions are satisfied. While the controller is turned on, do not press the button on the magnetic contactor in any case. Otherwise, the contactor may be damaged.

Note) Do not press this switch in any case.


(a) Detach the cables from the emergency stop unit. (b) Of the four screws fastening the emergency stop unit, remove the upper two screws, loosen the lower two screws, then replace the emergency stop unit. (c) Reconnect the cables.

A


Fig.7.6 Replacing the emergency stop unit

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7.7

MAINTENANCE

7.REPLACING A UNIT

REPLACING SERVO AMPLIFIERS WARNING Because the servo amplifier is heated immediately after operation, leave the servo amplifier until it cools down thoroughly, before replacing it. In case of A-cabinet A servo amplifier can be dismounted by pulling it out from the side, using its rail. Only a flat-head screwdriver is required, provided that servo amplifier SHIPPING screws have been removed. These screws are intended to prevent damage to the servo amplifier during shipment. (a) Make sure that servo amplifier shipping screws (2 phillips head) have been removed. Retain screws for shipping purposes. (b) Check the voltage at the screw above the LED "D7" with a DC voltage tester to see if the remaining voltage is not higher than 50V. Check that the voltage is not higher than 50V.

(c) Detach the cables from the servo amplifier. Pull out the detected cables away from the amplifier toward you so that they will not be caught when it slides along the rail.

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(d) Unlock the servo amplifier by rotating the quarter-turn screws on the outside surface of the plate using a coin or the like.

Unlock

Servo amplifier shipping screws (M5, 2 places)

Lock

Quarter-turn screws (4 places)

(e) Hold the upper and lower handles, and pull out the servo amplifier slowly. Be sure that all cables are unplugged from the servo amplifier before you try to remove the servo amplifier. After pulling the servo amplifier a little, check again that it is all right to continue to pull the servo amplifier. Be careful not to let the servo amplifier slide off the rail. (f) Place a replacement servo amplifier on the rail, slide it in gently untill it is hooked on the guide pins. (g) Rotate the quarter-turn screws on the outside surface of the plate to lock the servo amplifier. (h) Reconnect the cables.

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7.REPLACING A UNIT

Guide pin

Guide pin Handles

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Rail

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In case of B-cabinet (a) Detach the amplifier cover, and pull out the cable.


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7.REPLACING A UNIT

(b) Check the voltage at the screw above the LED "D7" with a DC voltage tester to see if the remaining voltage is not higher than 50 V. Check that the voltage is not higher than 50V.

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(c) Turn the retaining pin at the top of the amplifier 90 degrees counterclockwise. (At the middle of the top of the amplifier, there is an M5 screw that fastens the amplifier during transport of the cabinet. After the installation of the cabinet, remove the screw. This improves maintainability.)

Fixation screw for transport

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MAINTENANCE

7.REPLACING A UNIT

(d) Holding the handles located at the top and bottom of the amplifier, pull out the amplifier toward you.

(e) Pull the amplifier up while keeping it slanted.

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7.REPLACING A UNIT

MAINTENANCE

7.8

REPLACING I/O Unit-MODEL A

7.8.1

Replacing the Base Unit of I/O Unit-MODEL A

B-82595EN-2/02

First dismount the modules from the base unit of I/O Unit-MODEL A. The base unit is retained with 4 screws. Of these screws, loosen the upper 2 screws and remove the lower 2 screws, then replace the base unit.

Details of section A Fig.7.8.1

Replacing the base unit of I/O unit model A

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MAINTENANCE

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7.8.2

7.REPLACING A UNIT

Replacing a Module An interface module and input/output module can be easily installed in and removed from the base unit, as described below.

Installing a module (a) Put the upper hook of the module into the upper hole of the base unit. (b) Fit the connectors of the module and the base unit to each other. (c) Push the module until the lower stopper of the module is caught in the lower hole of the base unit.

Removing a module (a) Press the lever at the bottom of the module to release the stopper. (b) Lift the module up.

Fig.7.8.2 Replacing the module

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7.REPLACING A UNIT

7.9

MAINTENANCE

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REPLACING THE TEACH PENDANT and i PENDANT The specifications of the teach pendant vary with its use. When you replace the teach pendant, check its specifications carefully. (1) Be sure that the power of a robot controller is off. (2) Detach the cable from the teach pendant. (3) Replace the teach pendant.

Detach or attach the cable by rotating the connector retaining ring.

Fig.7.9

Replacing the teach pendant

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7.10

7.REPLACING A UNIT

MAINTENANCE

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REPLACING THE CONTROL SECTION FAN MOTOR The control section fan motor can be replaced without using a tool. The fan motor is mounted on the fan unit rack. (1) Be sure that the power of a robot controller is off. (2) Put your finger in the dent in the upper section of the fan unit, and pull the fan unit until it is unlatched. (3) Lift the fan unit slightly, and dismount it from the rack. (4) Place a replacement fan on the upper section of the rack, and slide it gently until it is latched.

Fan motor Dent

Pull the fan motor unit toward you to unlatch it.

Fan motor connector

Fig.7.10 Replacing the control section fan motor

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7.REPLACING A UNIT

7.11

MAINTENANCE

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REPLACING THE AC FAN MOTOR WARNING Do not touch the fan motor when it is rotating, or you could be injured.

7.11.1

Replacing the Heat Exchanger and Door Fan Unit (A-cabinet) The heat exchanger of the A-cabinet is inside its door. To replace the heat exchanger, it is necessary to remove the door fan unit in advance. Door fan unit (1) Remove retaining screws (M4, 4 places). (2) Detach the cable from the heat exchanger. (3) Mount the replacement fan unit by reversing the removal procedure. Be careful not to let the cable get caught in the fan. Heat exchanger (1) Dismount the fan unit from the door. (See the above procedure.) (2) Open the A-cabinet door, and detach cables. (3) Remove retaining nuts (M5, 4 places), and dismount the unit. (4) Mount the replacement heat exchanger by reversing the dismounting procedure.

Door fan unit Screws (4-M4)

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7.REPLACING A UNIT

MAINTENANCE

Heat Exchanger

Nuts (4-M5)

7.11.2

Replacing External Air Fan Unit (A-cabinet) The external air fan unit has two fans mutually connected with a cable. When the fan unit is replaced, the cable is replaced together with the fan unit. (1) Loosen the retaining screws of the louver, then remove it (see Section 7.1.3) (2) In case of the Side fan type, detach the fan unit. (The fan is fastened together with the louver.) In case of the Rear fan type, loosen four retaining M4 screws from the Rear fan unit, and then detach the fan unit. (3) Detach the fan unit lead-out cable and grounding wire. (The cable is terminated with a connector. The grounding wire is fastened with a screw.) (4) Replace the fan unit with a new one. Screws (4-M4) used to fasten both the fan unit and louver.

(Side fan type)

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The fan cable is attached using an in-line connector.

7.REPLACING A UNIT

MAINTENANCE

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Screws M4 (4 places)

(Rear fan type)

7.11.3

Replacing External Air Fan Unit and Door Fan (B-cabinet)

Door fan (1) Detach the cable from the fan unit. (2) Remove the retaining screws from the fan unit, then dismount it. (3) Install a new fan unit by reversing the dismounting procedure.

(Replacing the Door Fan Unit)

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MAINTENANCE

7.REPLACING A UNIT

External Air fan unit (1) Detach the cable connecting the fan unit. (2) Remove the screws and pull out the fan unit toward you. (3) Install a new fan unit by reversing the dismounting procedure.

(Replacing the Air Fan Unit)

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7.REPLACING A UNIT

7.12

MAINTENANCE

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REPLACE THE MODE SWITCH (a) Remove the cable from the mode switch. (b) Remove the screws fastening the mode switch, and replace the mode switch.

NOTE 1 When mounting the mode switch, do not overtighten the screws. (Tightening torque: 0.3 N⋅m) 2 Tighten the screws evenly so that the mode switch flat surface becomes parallel- to the sheet metal.

Mode switch

Fig. 7.12 (a) Replacing the mode switch (1/3)

Fig. 7.12 (b) Replacing the mode switch (2/3)

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MAINTENANCE

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7.REPLACING A UNIT

A

(Back plane of operator’s panel)


Tightening torque: 0.3N⋅m

Fig. 7.12 (c) Replacing the mode switch (3/3)

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7.REPLACING A UNIT

7.13

MAINTENANCE

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REPLACING FUSES If a fuse in the control unit has blown, find the cause and take an appropriate measure before replacing the fuse.

7.13.1

Replacing Fuses in the Servo Amplifier The following fuses are in the servo amplifier. FS1: FS2: FS3:

For generation of the power to the amplifier control circuit (A60L-0001-0290#LM32C) For protection of the 24 V output to the end effector, ROT, and HBK (A60L-0001-0290#LM32C) For protection of the 24 V output to the regenerative resistance and the additional axis amplifier (A60L-0001-0290#LM50C)

CRR88

5A 3.2A 3.2A

Fig.7.13.1 Replacing fuses in the servo amplifier

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7.13.2

7.REPLACING A UNIT

MAINTENANCE

Replacing Fuses in the Power Unit The following fuses are in the power unit. F1: Fuse for the AC input, A60L-0001-0450#8RO F3: Fuse for protecting the +24E output, A60L-0001-0046#7.5 F4: Fuse for protecting the +24V output, A60L-0001-0046#7.5

F1 8.0A Fuse for AC input


F3 7.5A Fuse for +24E

F4 7.5A Fuse for +24V Details of section B

Fig.7.13.2 Replacing fuses in the power unit

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7.REPLACING A UNIT

7.13.3

MAINTENANCE

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Replacing Fuses in the Main board The following fuses are in the power unit. FU1: For protection of the +12V output for the vision sensor, A60L-0001-0175#0.5A

75173 (Receiver)

75172 (Driver)

CPU card


Axis control card

FU1

Fuse(0.5A)

(Total edition “06B” after)

Fig.7.13.3 Replacing fuses in the main board

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MAINTENANCE

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7.13.4

7.REPLACING A UNIT

Replacing the Fuse on the Process I/O Boards The following fuse is on each process I/O board. FUSE1: Fuse for protecting the +24V output for peripheral equipment interfaces. A60L-0001-0046#2.0

Process I/O board CA

Fig. 7.13.4 (a) Process I/O board CA

Process I/O board EA, EB Fuse location is common to EA and EB.The following is figure of EA.

Fig. 7.13.4 (b) Process I/O board EA, EB

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7.REPLACING A UNIT

MAINTENANCE

Process I/O board FA

Fig. 7.13.4 (c) Process I/O board FA

Process I/O board GA

Fig. 7.13.4 (d) Process I/O board GA

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MAINTENANCE

7.REPLACING A UNIT

Process I/O board HA

Fig. 7.13.4 (e) Process I/O board HA

Process I/O board JA, JB Fuse location is common to JA and JB.The following is figure of JA.

FUSE (2A)

Fig. 7.13.4 (f) Replacing the fuse on the process I/O boards

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7.REPLACING A UNIT

MAINTENANCE

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Process I/O board KA, KB, KC Fuse location is common to KA, KB and KC. The following is figure of KA.

LED

FUSE1

Fig. 7.13.4 (g)

Process I/O Board KA

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7.13.5

7.REPLACING A UNIT

MAINTENANCE

Replacing the Fuse on the Panel Board The following fuse is on the panel board. FUSE1 : For protection of the +24EXT line (emergency stop line) FUSE2 : For protection of the teach pendant emergency stop line A60L-0001-0046#1.0

(Panel board)

FUSE2 (1A)

Fig.7.13.5 Replacing the fuse on the panel board

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FUSE1 (1A)

7.REPLACING A UNIT

7.14

MAINTENANCE

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REPLACING RELAYS Prolonged use of a relay might result in its contacts failing to make a secure connection or sticking to each other permanently. If such a failure occurs, replace the relay.

7.14.1

Replacing Relays on the Panel Board KA21, KA22 : Relay for emergency stop circuit A58L-0001-0192#1997R

KA22 Fig.7.14.1 Replacing relays on the panel board

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KA21

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MAINTENANCE

7.15

REPLACING BATTERY

7.15.1

Battery for Memory Backup (3 VDC)

7.REPLACING A UNIT

The programs, and system variables are stored in the SRAM in the main board. The power to the SRAM memory is backed up by a lithium battery mounted on the front panel of the main board. The above data is not lost even when the main power of controller is turned off. A new battery can maintain the contents of memory for about 4 years (Note). When the voltage of the battery becomes low, the low-voltage battery alarm (system-035) is displayed on the teach pendant. When this alarm is displayed, replace the battery as soon as possible. In general, the battery can be replaced within one or two weeks, however, this depends on the system configuration. If the battery voltage gets lower, it becomes impossible to back up the content of the SRAM. Cycling power to the controller in this state causes system not to start, and LED located on the main board displays "1" because the contents of memory have been lost. Clear the entire SRAM memory and reenter data after replacing the battery. Important data should be saved to the memory card or other external device beforehand in case of emergency.

NOTE In a newly introduced robot, the battery is factory-installed. Battery replacement may, therefore, be needed within 4 years after the introduction of the robot.

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7.REPLACING A UNIT

MAINTENANCE

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Replacing the lithium battery (1) Prepare a new lithium battery (ordering drawing number: A02B-0200-K102). (2) Turn the robot controller on for about 30 seconds.

CAUTION Complete the steps (3) to (5) within 30 minutes. If the battery is left disconnected for a long time, the contents of memory will be lost. To prevent possible data loss, it is recommended that the robot data such as programs and system variables be backed up before battery replacement. (3) Turn the robot controller off. (4) Remove the old battery from the top of the main board. First unlatch the battery, remove it from the battery holder, and detach its connector.

Lithium battery

Battery connector

Battery latch

(5) Remove the old battery, insert a new one into the battery holder, and attach the connector. Confirm that the battery is latched firmly.

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MAINTENANCE

7.REPLACING A UNIT

WARNING Using other than the recommended battery may result in the battery explosion. Replace the battery only with the specified battery (A02B-0200-K102). Dispose of the replaced battery as an industrial waste, according to the laws and other rules in the country where the controller is installed and those established by the municipality and other organizations that have jurisdiction over the area where the controller is installed.

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8. HOW TO USE THE PLATE TO FIX THE COMPACT FLASH MEMORY CARD

8

MAINTENANCE

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HOW TO USE THE PLATE TO FIX THE COMPACT FLASH MEMORY CARD Optional plate to fix the compact flash memory card (CF card) can make it possible to perform a back-up on fixing the CF card on the mainboard. Parts ・ Fixing plate ・ Adapter for CF card (made by fanuc)

1. Adapter for CF card (made by fanuc)

Compact flash memory card (The card is not included. It must be supplied by the customer.)

2. Fixing plate

Main board

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MAINTENANCE

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8. HOW TO USE THE PLATE TO FIX THE COMPACT FLASH MEMORY CARD

Installation of the CF card 2.

1. Insert the CF card into the

Lock the latch, and drive the screw.

Adapter.

Removal of the CF card 1.

Loosen the screw, and unlock the latch.

2.

Pull the CF card out of the Adapter.

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III. CONNECTIONS

CONNECTIONS

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1

1.GENERAL

GENERAL This section describes the electrical interface connections in the R-30iA. It also includes information about installation of the R-30iA.

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2.BLOCK DIAGRAM

2

CONNECTIONS

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BLOCK DIAGRAM Fig.2 is a block diagram of electrical interface connections with the R-30iA. R-30iA (A-cabinet)

Pneumatic pressure source Mechanical unit

End effector USB memory (Note2) Teach pendant

Operation box

RS-232-C (Note3) Peripheral device Welding machine

Memory card (PCMCIA) Ethernet AC power supply Fig.2 (a)

Block Diagram of Electrical Interface Connection (A-cabinet)

NOTE 1 : Indicates electrical connection. -------- : Indicates mechanical connection. 2 In case the length of the connection cable between A-cabinet and Operation box is 10m or longer, there is the USB interface panel and RS-232-C interface on the A-cabinet. 3 For more information, contact our service section.

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CONNECTIONS

B-82595EN-2/02

R-30iA B-cabinet

2.BLOCK DIAGRAM

Pneumatic pressure source Mechanical unit

End effector

USB memory

Memory card (PCMCIA) Teach pendant

RS-232-C

Peripheral device

Welding machine

Ethernet

AC power supply

Fig.2 (b)

Block Diagram of Electrical Interface Connection (B-cabinet)

NOTE 1 : Indicates electrical connection. -------- : Indicates mechanical connection. 2 For more information, contact our service section.

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3.ELECTRICAL CONNECTIONS

3

CONNECTIONS

ELECTRICAL CONNECTIONS

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CONNECTIONS

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3.1


CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS

R-30iA Robot

Servo amplifier CRF8

RP1

(Pulse coder, RI/RO,

(Pulse coder, RI/RO , HBK, ROT)

HBK, ROT)

CNJx (Motor power)

CNGx (Ground)

RCC I/F UNIT (M-900iA ONLY)

RM1 (Motor power/brake)

RM2 (Motor power)

End effector

EE

CRR88

(Note1)

(Brake control)

Fig.3.1 (a) Mechanical connection diagram

NOTE 1 This cable is not included. It must be supplied by the customer.

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CONNECTIONS

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R-30iA Teach pendant

(Panel board)

Peripheral device

(Process I/O)

Port A (Operator's panel)

(Main board)

(Main board)

Note 2

External device

Note 2

Ethernet

Circuit breaker Input power

Panel board (TBOP3)

Panel board (TBOP4)

Panel board (TBOP4)

Panel board (TBOP4)

Note 2

Note 2

External power ON/OFF switch

External emergency stop switch

Note 2

Note 2

Fence

Servo off switch

USB memory

Fig.3.1 (b) Mechanical connection unit

NOTE 1 For detail of the peripheral device connection, see the section of Peripheral device interface. 2 This cable is not included. It must be supplied by the customer.

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CONNECTIONS

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3.2

EXTERNAL CABLE WIRING DIAGRAM

3.2.1

Robot Connection Cables CAUTION Before operating the robot, uncoil the interconnection cables from their shipping position to prevent excessive heat, which may damage the cables. (Coiled part should be shorter than 10 meter.) There are two types of the robot connection cable; Non-flex type: usage is restricted to fixed laying Flex type: possible to use in the cable track

Specification of cable Non-flex type

RP1

RM1

RM2 RP1 RM1 RMP1 RP1 RM1 EARTH Group1 Group2 Group3 Group4 Group5 Group6 Group7 Group8

Flex type

Robot

Diameter (mm)

Weight (kg/m)

Minimum bending radius (mm)

All models Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 3 Group 4 Group 5

15.7 26.1 20.0 26.1 26.1 26.1 20.0 26.1 26.1 26.1 15.7 20.0 14.2 20.0 4.7

0.45 1.22 0.7 1.22 1.22 1.22 0.7 1.22 1.22 1.22 0.45 0.7 0.31 0.7 0.065

200 200 200 200 200 200 200 200 200 200 200 200 200 200 200

Group 7 Group 8 All models

Diameter (mm)

Weight (kg/m)

Minimum bending radius (mm)

20.5 25.4 18.4 25.4 25.4 25.4 25.4 25.4 25.4 20.5 18.4 4.7

0.71 1.2 0.7 1.2 1.2 1.2 1.2 1.2 1.2 0.71 0.7 0.065

200 200 200 200 200 200 200 200 200 200 200 200

R-2000iB (except /200T), M-420iA, M-421iA M-710iC ARC Mate 100iB, ARC Mate 120iB, M-6iB, M-16iB, F-200iB R-2000iB/200T, M-410iB M-900iA/260L,M-900iA/350 M-900iA/600 M-430iA/2F M-430iA/2P ARC Mate 100iC,M-10iA

- 283 -


Robot Model

CONNECTIONS

B-82595EN-2/02

Using condition of flex type cable (1) When routing cables in movable places, use a cable bearer. (2) The bending radius (R) of the cable track is more than 200mm. (3) The cable should be fixed to the cable track by using the clamp. (e.g. rubber packing) (4) The size of the hole to support a cable in the cable track should be more than 110% of the cable size and should have the gap more than 3mm. (5) When cables are laid in the cable track, pay attention for the cable not to be twisted. Group1:R-2000iB (expect /200T), M-420iA, M-421iA M-710iC Group2:ARC Mate 100iB, ARC Mate 120iB, M-6iB, M-16iB, F-200iB

In case of A-cabinet

RI,RO,HBK,ROT

(Connection A-cabinet and Robot)

- 284 -

CONNECTIONS

B-82595EN-2/02


In case of B-cabinet

RI,RO,HBK,ROT (Connection B-cabinet and Robot)

- Detail of cable connection to servo amplifier. R-30iA(Servo amplifier)

CRR88

CNGA

Robot CNJ3A

CNJ6

CNGC

RP1

CRF8

(Pulse coder, RI/RO, HBK, ROT)

RM1 Motor power/brake (J1M, J2M, J3M, J4M, J5M, J6M, BK) CNJ1A

CNJ2A

CNJ4

Fig. 3.2.1 (a)

CNJ5

Robot connection cable (Group1, Group2)

- 285 -


CONNECTIONS

B-82595EN-2/02

Robot Model Group3:R-2000iB/200T, M-410iB In case of A-cabinet

RI,RO,HBK,ROT


- 286 -

CONNECTIONS

B-82595EN-2/02





CRR88

Robot

CNGA

CNJ3A

CNGC

CNJ3B

CNJ6

CNGB

RP1

CRF8


RM1 Motor power/brake (J1M, J2M, J3M, J4M, J5M, J6M, BK)

RM2 Motor power (J1M, J2M, J3M) CNJ1B

CNJ2B

CNJ1A

CNJ2A

CNJ4

Fig. 3.2.1 (b)

CNJ5

Robot connection cable (Group3)

- 287 -


CONNECTIONS

B-82595EN-2/02

Robot Model Group4:M-900iA/260L, M-900iA/350 In case of B-cabinet



CNGC

CNJ3B

RCC I/F UNIT

CNJ6

RM2A

CNJ3A

RM1B

CNGA

RM1A

CRR88

Robot

CNGB

RP1

CRF8



RM2 Motor power (J1M, J2M, J3M) CNJ1B

CNJ2B

CNJ1A

CNJ2A

CNJ4

Fig. 3.2.1 (c)

CNJ5


- 288 -

B-82595EN-2/02

CONNECTIONS


Robot Model Group5:M-900iA/600 In case of B-cabinet


- 289 -


CONNECTIONS

B-82595EN-2/02

- Detail of cable connection to servo amplifier. R-30iA Robot

6-Axis Servo amplifier (AMP1) CRR88

CNGA

CNJ3A CNJ3B

CNGB

RP1

CRF8



RM2 Motor power CNJ1B

CNJ2B

CNJ1A

CNJ2A

(J1M, J2M, J3M, J4M, J5M, J6M)

CZ2L

JF2

CZ2M

RM2A

JF1

RM1B

RM1A

2-Axis Servo amplifier (AMP2)

RCC I/F UNIT

1-Axis Servo amplifier (AMP3) JF

CZ2

Fig. 3.2.1 (d)


- 290 -

CONNECTIONS

B-82595EN-2/02


Robot Model Group6:M-430iA/2F In case of A-cabinet

RI,RO,HBK,ROT


- 291 -


CONNECTIONS

B-82595EN-2/02



Detail of cable connection to servo amplifier. R-30iA(Servo amplifier)

CRR88

CNGA

Robot CNJ3A

CNJ6

CNGC

RP1

CRF8


RM1 Motor power/brake CNJ1A

CNJ2A

CNJ4

CNJ5

(J1MA, J1MB, J2MA, J2MB, J3MA, J3MB, J4M,, J5M, J6M, BK)

Servo amplifier JF1 JF2 CZ2L CZ2M

Fig. 3.2.1(e) Robot Connection Cable（Group6）

- 292 -

CONNECTIONS

B-82595EN-2/02


Robot Model Group7:M-430iA/2P In case of A-cabinet

RI,RO,HBK,ROT


- 293 -


CONNECTIONS

B-82595EN-2/02


RI,RO,HBK,ROT

(Connection B-cabinet and Robot)


CRR88

CNGA

Robot CNJ3A

RMP1

CRF8


Motor power/brake

CNJ1A

CNJ5

Servo amplifier

JF1 JF2 JF3 CZ2L CZ2M CZ2N

Fig. 3.2.1(f) Robot Connection Cable（Group7）

- 294 -

B-82595EN-2/02

CONNECTIONS


Robot Model Group8: ARC Mate 100iC,M-10iA In case of A-cabinet

RI,RO,HBK,ROT


- 295 -


CONNECTIONS

B-82595EN-2/02


RI,RO,HBK,ROT

(Connection B-cabinet and Robot)


CRR88

CNGA

Robot CNJ3A

CNJ6

RMP1

CRF8


Motor power/brake

CNJ1A

CNJ2A

CNJ4

CNJ5

Fig. 3.2.1(g) Robot Connection Cable（Group8）

- 296 -

CONNECTIONS

B-82595EN-2/02

3.2.2


Teach Pendant Cable

Panel board

Teach pendant

Teach pendant cable

(A-cabinet) Teach pendant cable Panel board Teach pendant

(B-cabinet) Fig.3.2.2 Teach pendant cable

- 297 -


3.2.3

CONNECTIONS

B-82595EN-2/02

Connecting the Input Power Considering the robot power capacity and the circuit breaker capacity, connect the power supply whose voltage conforms to the installation conditions to the terminal located above the circuit breaker. Provide a class-D or better ground.

CAUTION Disconnection of protective earth ground may impair the protection provided by the system. There shall be no switches or disconnects in the grounding conductor. The resistance to the ground must not exceed 100Ω. Use a thick wire to withstand the maximum current used. Selection of an input transformer tap is necessary depending on the input voltage. The tap is set to the specified voltage before shipment. However, check it referring to section 6.2 in "Maintenance" before supplying power (before the breaker switch is turned on). The motor is driven by the PWM inverter system using a power transistor bridge. If the servo amplifier is used without a transformer, a high-frequency leakage current flows through the stray capacitance between the ground and the motor coils, power cable, and amplifier. This might cause the leakage-current circuit breaker or leakage-protection relay installed in the path of the power supply to cut out. Use the following leakage current circuit breaker for inverters to prevent incorrect operation. Example of leakage current circuit breaker for inverters Type

Manufacture

Fuji Electric Co., Ltd. Hitachi, Ltd. Matsushita Electric Works, Ltd.

EG A series or later SG A series or later ES100C type ES225C type Leakage current circuit breaker, C type Leakage current circuit breaker, KC type

Fig.3.2.3 shows the cable connection.

- 298 -

CONNECTIONS

B-82595EN-2/02


Input power supply cable

(Note)

Always replace the cover after completing (A-cabinet)

(Note) Always replace the cover after completing Input Power supply (B-cabinet) Fig.3.2.3 Input power supply connection (B-cabinet)

- 299 -


CONNECTIONS

B-82595EN-2/02

NOTE On/off timing by the breaker If the power supply is turned on, turned off, and then turned on again repeatedly in a short time, the controller may not be started up. If the power is turned off before the controller is completely started up (it takes about 30 seconds), wait for at least 10 seconds before turning on the power again.

TON-OFF ≦ 30 sec

TOFF-ON ≥ 10 sec

ON OFF

The power is turned off within 30 seconds after it has been turned on.

- 300 -

CONNECTIONS

B-82595EN-2/02

3.2.4


Connecting the External Power Supply ON/OFF Switch

Panel board

TBOP3

(A-cabinet) Panel board

Fig.3.2.4 (a)

(B-cabinet) Connection of the external power supply ON/OFF switch

- 301 -


CONNECTIONS

B-82595EN-2/02

Short–circuit plate : between EXON1 and EXON2 EXON1 EXON2 EXOFF1 EXOFF2

When using the external ON/OFF switch, remove the short-circuit plate between EXOFF1 and EXOFF2, and attach the cable to these terminals.

Contact specifications Withstand voltage: 50VDC (across contacts) Current: 100mA min. (min. load 2mA)

EXOFF1-2

Close Open

POWER

ON

TOFF-ON ≥ 5 sec

OFF

NOTE 1 When the external power supply ON/OFF switch is set to ON (closed), the controller can be turned on and off by using the circuit breaker. 2 When the external power supply ON/OFF switch is set to OFF (open), the controller cannot be turned on and off by using the circuit breaker. Fig.3.2.4 (b)

Connection of the external power supply switch ON and OFF

- 302 -

CONNECTIONS

B-82595EN-2/02

3.2.5


Connecting the External Emergency Stop

Panel board TBOP4

TBOP3

TBOP6

(A-cabinet)

Panel board

(B-cabinet) Fig.3.2.5 (a) Connection of the external emergency stop

- 303 -


CONNECTIONS

B-82595EN-2/02

External emergency stop output

ESPB1 ESPB11 ESPB2 ESPB21 ESPB3 ESPB31 ESPB4 ESPB41

Panel board

For the circuit, see Figure A (e) in Appendix A, "TOTAL CONNECTION DIAGRAM". The SVOFF input signal does not affect EMGOUT Signal

ESPB1 ESPB2 ESPB3 ESPB4


Description

Emergency stop output signals. The contact is open if an emergency stop occurs or the power is turned off. The contact is closed during normal operation.

- 304 -

Current, voltage

Min. load

Rated contact: 250 VAC, 5-A resistor load 300 VDC, 5-A resistor load

(Reference value) DC5V 10mA

CONNECTIONS

B-82595EN-2/02

Internal

TP emergency

Operator panel

circuit

stop button

emergency stop button

+24EXT


KA21

0EXT

KA22

0EXT

+24EXT

ESPB1 ESPB11

WARNING In case of using the contact of the emergency stop output signal, be sure to pair ESPB1 with ESPB2, and ESPB3 with ESPB4. Robot controller does not detect the breakdown of the contact of the emergency stop output signal. Take countermeasures such as inspecting the duplicated contacts, or using a safety relay circuit that can detect the breakdown.

ESPB2 ESPB21


Example of the connection with the safety relay Robot controller

Safety relay unit ESPB1 ESPB11

Control

ESPB2

circuit

ESPB21

Contact output signal ensured safety

- 305 -


CONNECTIONS

B-82595EN-2/02

External emergency stop input External emergency stop switch

Fence

These terminals are factory-jumpered. When using external emergency stop inputs, remove the short-circuit plate. Servo ON/OFF input switch

EGS21 EGS2 EGS11 EGS1 EAS21 EAS2 EAS11 EAS1 EES21 EES2 EES11 EES1

Servo disconnect switch signal SD4 SD41 SD5 SD51

Signal

EES1 EES11 EES2 EES21



Description

Connect the contacts of the external emergency stop switch to these terminals. When a contact is open, the servo power supply is turned off, and the robot is immediately placed in the emergency stop state. When using the contacts of a relay or contactor instead of the switch, connect a spark killer to the coil of the relay or contactor, to suppress noise. When these terminals are not used, jumper them. These signals are used to stop the robot safely when the safety fence gate is opened during operation in the AUTO mode. When a contact is open, the robot decelerates then stops, and the servo power supply is turned off. In the T1 or T2 mode, the robot can be operated even when the safety fence gate is open. When using the contacts of a relay or contactor instead of the switch, connect a spark killer to the coil of the relay or contactor, to suppress noise. When these terminals are not used, jumper them. Connect the contacts of the servo-off input switch to these terminals. When a contact is open, the robot decelerates then stops, and the servo power supply is turned off. When using the contacts of a relay or contactor instead of the switch, connect a spark killer to the coil of the relay or contactor, to suppress noise. When these terminals are not used, jumper them.

- 306 -

Current, voltage

Open and close of 24VDC 0.1A (Note 1)



CONNECTIONS

B-82595EN-2/02

Signal

SD4 SD41 SD5 SD51


Description

Current, voltage

Connect the contacts of the servo disconnect switch to these terminals. When a contact is open, the servo power supply is turned off, and the robot stops immediately. When using the contacts of a relay or contactor instead of the switch, connect a spark killer to the coil of the relay or contactor, to suppress noise. When these terminals are not used, jumper them.


NOTE 1 Use a contact which minimum load is 5 mA less. Examples of connection of duplicate safety signals

Correct connection

Wrong connection



EES1

EES1

EES11

EES11

EES2

EES2

EES21

EES21 Discrepancy in duplicate inputs results in an alarm.

Input timing of duplicate safety signals Duplicate inputs are used for signals such as the external emergency stop signal, safety fence signal, and servo off signal so that a response is made even when a single failure occurs. The statuses of these duplicate input signals must always be changed at the same timing according to the timing specifications provided in this section. The robot control unit always checks that the statuses of the duplicate inputs are the same, and if the control unit finds a discrepancy, it issues an alarm. If the timing specifications are not satisfied, an alarm may be issued because of a signal discrepancy.

- 307 -


EES1 EAS1 EGS1 SD4

Close

EES2 EAS2 EGS2 SD5

Close

CONNECTIONS

B-82595EN-2/02

Open

Open TDIF

TDIF TOPEN TOPEN

TDIF (input time difference)< 200msec TOPEN (input hold period) > 2sec

Fig. 3.2.5(b) Input timing of duplicate safety signals

- 308 -


CONNECTIONS

B-82595EN-2/02

External power connection

0V

24V

EXT0V

INT EXT

EXT24V External power source +24V(±10%) more than 300mA

The relays for emergency stop input and output can be separated from controller’s power.Please connect external +24V instead of internal +24V,if emeregency stop output must not be effected controller’s power. Example of the connection In case of not using the external

In case of using the external power source

power source External power source EXT24V

24V

EXT24V

INT24V

INT24V

INT0V

INT0V

EXT0V

0V +24V(±10%) more than 300mA

- 309 -

EXT0V


CONNECTIONS

B-82595EN-2/02

Connecting external on/off and external emergency stop signal input/output wires FANUC's specification

8-pole terminal block (TBOP3) 12-pole terminal block (TBOP4,6) Jumper pin Operation lever

Manufacturer's specification (WAGO)

Remark

A63L-0001-0783#308

231-311/026-000

External emergency stop

A63L-0001-0783#312

231-304/026-000

External ON/OFF

A63L-0001-0783#902 A63L-0001-0783#131-M

231-902 231-131

1. 2. 3. 4. 5.

2 pieces of 231-131 and operation manual are included in FANUC's specification

Detach the plug connector block from the panel board. Insert the tip of a flat-blade screwdriver into the manipulation slot and push down its handle. Insert the end of the signal wire into the wire slot. Pull out the screwdriver. Attach the plug connector block to the panel board. Do not insert a wire into the wire hole of a plug connector or pull it out with the plug connector block mounted on the panel board; otherwise, the panel board may be damaged.

FANUC recommonds the lever (A05B-2400-K030) for connecting the signal wire to the plug connector block instead of Flat-blade screwdriver.

Signal wire

Flat-blade screwdriver

Manipulation slot


- 310 -

B-82595EN-2/02

CONNECTIONS


Wiring (1) Pull down the lever.

(2) Push in the conductor while holding the lever.

(3) Set the lever free. * And pull the conductor softly to check the clamping.

* Don't pull strongly.

- 311 -


CONNECTIONS

B-82595EN-2/02

Replace the lever (1) Pull off the lever. Be careful not to lose the lever.

(2) Hook the lever to the rectangle hole.。

(3) Push down the lever untill click in.

Fit to header (2) Please check if the latch is hooked to header.

(1) Push in the connector to header.

* Be careful to fit the shape of each other.

Installation of "Jumper"

(1) Attach levers to connector.

(2) Hold down levers at the same time, then put the jumper into connector.

- 312 -

*

Please check the direction of the jumper.

CONNECTIONS

B-82595EN-2/02


Availability of wires -

-

Without jumpers

* Max wire size 0 2.0mm2 (AWG14) (with "Ferrule")

-

With jumper

- Additional wire is available under the jumper. * Max wire size 0 0.5mm2 (AWG20) (with "Ferrule")

With two jumpers

Additional wire is not available under the jumper.

Installation of "Ferrules" (3) Squeeze handles until ratchet mechanism is released. (1) Put the wire through the hole of ferrules.

(4) Please check if the wire crimped correctly.

(2) Introduce wire with ferrule into cramping station.

Crimping Toole (Specification : WAGO Item-No.206-204)

Specifications of Ferrules WAGO Item-No.

Wire size mm2

216-301 216-302 216-201 216-202 216-203 216-204 216-205

0.25 0.34 0.5 0.75 1.0 1.5 2.0

CAUTION

Color light yellow light green white gray red black yellow

Stripped Length (mm) 9.5 9.5 9.5 10.0 10.0 10.0 10.0

L

L1

D (mm)

D1

D2

12.5 12.5 14.0 14.0 14.0 14.0 14.0

8.0 8.0 8.0 8.0 8.0 8.0 8.0

2.5 2.5 3.1 3.3 3.5 4.0 4.2

2.0 2.0 2.6 2.8 3.0 3.5 3.7

0.8 0.8 1.0 1.2 1.4 1.7 2.0

Pack.-unit pcs 100 100 100 100 100 100 100

Please make sure to use WAGO 206-204 to crimp the ferrules.

- 313 -


3.2.6

CONNECTIONS

B-82595EN-2/02

Connecting the Non-Teaching Enabling (NTED) Signal (CRM65) CRM65 (NTED)

Fig. 3.2.6

Connecting the NTED Signal

NTED signal is the signal to be able to connect with the switch that is same function as deadman switch on the teach pendant.In the auto mode, robot moves without reference to the state of the switch connected with NTED signal. Refer to “APPENDIX A,Total connection Diagram Fig.A(e)” about NTED circuit. Input timing of NTED signal must comply with rules in the section “Input timing of duplicate safety signals”.

NOTE After connnecting NTED switch, be sure to check the operation of those switches, the emergency stop button on the operator’s panel/operation box, and the emergency stop button on the teach pendant.

- 314 -

B-82595EN-2/02

CONNECTIONS


Enabling Device NTED1 NTED11 NTED2 NTED21

CRM65 connector A1 NTED1 B1 NTED2 A2 NTED11 B2 NTED21 A3 B3 NTED signal connector manufactured by Tyco Electronics AMP k.k. ( Specification Rece-housing 1-1318119-3 Rece-contact 131807-1）

- 315 -


3.2.7

CONNECTIONS

B-82595EN-2/02

Connecting the Auxiliary Axis Brake（CRR65 A/B）

CRR65

Fig.3.2.7 6-axis servo amplifier

CRR65 A/B A1 BKA1 B1 BKA2 A2 B2 A3 COMMON B3 COMMON CRR65 A/B connector manufacutured by Tyco Electronics AMP k.k. ( Specification Rece-housing 1-178129-6 Rece-contact 175218-2）

- 316 -

B-82595EN-2/02

3.2.8

CONNECTIONS


Connecting the Auxiliary Axis Over Travel (CRM68)

CRM68

Fig.3.2.8 6-axis servo amplifier

CRM68 A1 AUXOT1 A2 AUXOT2 A3 CRM68 connector manufacutured by Tyco Electronics AMP k.k. ( Specification Rece-housing 1-1318120-3 Rece-contact 1318107-1）

- 317 -


3.2.9

CONNECTIONS

B-82595EN-2/02

Connecting the Operation Box The operation box is not connected to the controller in shipment in some robot models. In this case connect the operation box connection cable to the operation box as following drawings. Also connect the input power cable and the teach pendant cable as described in section 3.2.2 and 3.2.3 JD1B Port (M4 NUT 3 Places) JRS15 CRM95

Signal Line

Cable clamp

- 318 -

Power Line

CONNECTIONS

B-82595EN-2/02

4

4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES

PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES R-30iA I/O peripheral device interfaces include printed circuit boards and a unit selected according to the applications. Table 4 lists details of the printed-circuit boards and units. Figure 4 shows the locations of these boards and units. Table 4 Peripheral Device Interface Types Drawing Number of I/O points number DI DO D/A

No.

Name

1 2 3 4 5 6 7

Process I/O board CA Process I/O board EA Process I/O board EB Process I/O board FA Process I/O board GA Process I/O board HA Process I/O board JA

A05B-2500-J003 A05B-2500-J012 A05B-2500-J013 A05B-2500-J014 A05B-2500-J015 A05B-2500-J006 A05B-2500-J001

8

Process I/O board JB

A05B-2500-J002

9

Process I/O board KA

A05B-2500-J010

10

Process I/O board KB

A05B-2500-J011

11

Process I/O board KC

A05B-2500-J016

12

I/O Unit-MODEL A

A05B-2502-J090 (Base and interface unit)

40 40 40 96 40 40 96

A/D

40 (sink type) 2 6 40 (sink type) 2 3 40 (sink type) 0 0 96 (sink type) 0 0 40 (sink type) 2 0 40 (sink type) 2 0 96 0 0 (source type) 40 40 0 0 (source type) 40 40 3 2 (source type) 40 40 2 0 (source type) 40 40 0 0 (source type) Depending on selected I/O module.

- 319 -

Remarks Installed in back plane Installed in operation box Installed in operation box Installed in operation box Installed in operation box Installed in back plane Installed in back plane Installed in back plane Installed in operation box Installed in operation box Installed in operation box Common to both A and B-cabinet (five slots)


CONNECTIONS

B-82595EN-2/02

NOTE 1 General purpose I/O (DI/DO) is a number which subtract an exclusive signal from the table value. Example : Process I/O board JB Table value Exclusive DI General purpose DI DI; 40 18 = 22 points Table value Exclusive DO General purpose DO DO; 40 20 = 20 points 2 When there are slave units on the I/O Link and the power for control to these slave units is supplied from other than the robot control unit, the power to the controller and the power to the slave units must be turned on and off at the following timings: a) The power to the slave units must be turned on before or when the power to the controller, which is the master of the I/O Link, is turned on. b) If the power to a slave unit is turned off after the system has started up, an I/O Link error occurs. To establish the I/O Link again, turn off the power to all units including the control unit, then turn on the power to the units in the order described in a).

- 320 -

B-82595EN-2/02


CONNECTIONS

Process I/O board

(A-cabinet)

Optional slot

I/O Unit-MODEL A

(B-cabinet) Fig.4 Locations of Peripheral Device Interfaces

- 321 -


4.1

CONNECTIONS

B-82595EN-2/02

PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM Following are a block diagram of the peripheral device interface and the specifications.

4.1.1

When Process I/O Board EA/EB/GA is Used (A-cabinet)

A-cabinet

Operation box

Main board

(1)

JD1A

JD1B

Process I/O board EA/EB/GA CRM2A

Panel board CP5A

CRM2B (2) CP5

CRW1 or CRW7 (NOTE 2)

(3)

Peripheral device

(4)

(5)

CRW2

Fig.4.1.1

Block diagram of the process I/O board EA, EB and GA

NOTE 1 CRW1 and CRW2 are not provided for process I/O board EB 2 In case of process I/O board EA: CRW1 In case of process I/O board GA: CRW7

- 322 -

CONNECTIONS

B-82595EN-2/02

Number (1)

(2) (3) (4)

(5)

Name Operation box connection cable

Process I/O power supply cable Peripheral device connection cable (Process I/O EA, EB, FA, GA) Welding device connection cable (Process I/O EA) (Fanuc interface / elbow) Welding device connection cable (Process I/O EA) (Fanuc interface / straight) Welding device connection cable (Process I/O GA) (General-purpose interface / elbow) Welding device connection cable (Process I/O GA) (General-purpose interface / straight) Welding device connection cable (Process I/O GA) (Fanuc interface / elbow) Welding device connection cable (Process I/O GA) (Fanuc interface / straight)

Drawing number A05B-2501-H460 A05B-2501-H461 A05B-2501-H462 A05B-2501-J150 A05B-2501-J203 A05B-2501-J204 A05B-2501-J205 A05B-2501-J279 A05B-2501-J280 A05B-2501-J281 A05B-2501-J229 A05B-2501-J230 A05B-2501-J231 A05B-2501-J282 A05B-2501-J283 A05B-2501-J284 A05B-2501-J232 A05B-2501-J233 A05B-2501-J234 A05B-2501-J285 A05B-2501-J286 A05B-2501-J287 A05B-2501-J235 A05B-2501-J236 A05B-2501-J237

- 323 -


Remarks Connected length : 5m Connected length : 10m Connected length : 2m Connected length : 10m (one) Connected length : 20m (one) Connected length : 30m (one) Connected length : 10m (one) CRW1 Connected length : 20m (one) CRW1 Connected length : 30m (one) CRW1 Connected length : 10m (one) CRW1 Connected length : 20m (one) CRW1 Connected length : 30m (one) CRW1 Connected length : 10m (one) CRW7 Connected length : 20m (one) CRW7 Connected length : 30m (one) CRW7 Connected length : 10m (one) CRW7 Connected length : 20m (one) CRW7 Connected length : 30m (one) CRW7 Connected length : 10m (one) CRW7 Connected length : 20m (one) CRW7 Connected length : 30m (one) CRW7 Connected length : 10m (one) CRW7 Connected length : 20m (one) CRW7 Connected length : 30m (one) CRW7


4.1.2

CONNECTIONS

B-82595EN-2/02

When Process I/O Board FA is Used (A-cabinet)

A-cabinet

Operation box

Main board

(1)

JD1A

JD1B

Process I/O board FA CRM2A

Panel board

CRM2B (2)

CP5A

CRM2C CP5

CRM2D CRM4A CRM4B

(3)

Peripheral device

(4) (5) (6) (7) (8)

Fig.4.1.2 Block diagram of the process I/O board FA Number (1)

Name Operation box connection cable

(2) (3) (4) (5) (6)

Process I/O power supply cable Peripheral device connection cable

(7) (8)

Peripheral device connection cable

Drawing number A05B-2501-H460 A05B-2501-H461 A05B-2501-H462 A05B-2501-J150 A05B-2501-J203 A05B-2501-J204 A05B-2501-J205 A05B-2501-J253 A05B-2501-J254 A05B-2501-J255

- 324 -

Remarks Connected length : 5m Connected length : 10m Connected length : 2m Connected length : 10m (one) Connected length : 20m (one) Connected length : 30m (one) Connected length : 10m (one) Connected length : 20m (one) Connected length : 30m (one)

CONNECTIONS

B-82595EN-2/02

4.1.3


When Process I/O Board CA/HA is Used (B-cabinet)

Process I/O board CA/HA

Main board JD1A

(1)

JD1B (JD4A)

CRM2A CRM2B

JD1A (JD4B)

(2)

CRW1 or CRW7 (NOTE)

(3) (4) (5)

CRW2

JD1B

Process I/O board CA/HA

(JD4A)

CRM2A CRM2B JD1A (JD4B)

CRW1 or CRW7 (NOTE) CRW2

Fig.4.1.3 Block diagram of the process I/O board CA/HA

NOTE Process I/O board CA: CRW1 Process I/O board HA: CRW7

- 325 -

Peripheral device


Number (1) (2) (3) (4)

(5)

CONNECTIONS

Drawing number

Remarks

A05B-2502-J130 A05B-2502-J131 A05B-2502-J170 A05B-2502-J171 A05B-2502-J172 A05B-2502-J200 A05B-2502-J201 A05B-2502-J202 A05B-2502-J203 A05B-2502-J204 A05B-2502-J205 A05B-2502-J206 A05B-2502-J207 A05B-2502-J208 A05B-2502-J210 A05B-2502-J211 A05B-2502-J212 A05B-2502-J213 A05B-2502-J214 A05B-2502-J215 A05B-2502-J216 A05B-2502-J217 A05B-2502-J218

Between main board and process I/O Between process I/O and process I/O Connected length : 10m (one) Connected length : 20m (one) Connected length : 30m (one) Connected length : 10m (one) CRW1 Connected length : 20m (one) CRW1 Connected length : 30m (one) CRW1 Connected length : 10m (one) CRW1 Connected length : 20m (one) CRW1 Connected length : 30m (one) CRW1 Connected length : 10m (one) CRW7 Connected length : 20m (one) CRW7 Connected length : 30m (one) CRW7 Connected length : 10m (one) CRW7 Connected length : 20m (one) CRW7 Connected length : 30m (one) CRW7 Connected length : 10m (one) CRW7 Connected length : 20m (one) CRW7 Connected length : 30m (one) CRW7 Connected length : 10m (one) CRW7 Connected length : 20m (one) CRW7 Connected length : 30m (one) CRW7

Name I/O Link cable I/O Link cable Peripheral device connection cable (Process I/O CA, HA) Welding device connection cable (Process I/O CA) (Fanuc interface / elbow) Welding device connection cable (Process I/O CA) (Fanuc interface / straight) Welding device connection cable (Process I/O HA) (General-purpose interface / elbow) Welding device connection cable (Process I/O HA) (General-purpose interface / straight) Welding device connection cable (Process I/O HA) (Fanuc interface / elbow) Welding device connection cable (Process I/O HA) (Fanuc interface / straight)

B-82595EN-2/02

- 326 -

CONNECTIONS

B-82595EN-2/02

4.1.4


When Process I/O Board JA/JB is Used (B-cabinet)

Process I/O board JA/JB

Main board JD1A

(1)

JD1B

CRMA5A CRMA5B JD1A

CRMA5C CRMA5D CRMA6A

(2)

CRMA6B

(3)

Peripheral device

(4) (5) (6) (7) (8)

Process I/O board JA/JB JD1B

JD1A

CRMA5A CRMA5B CRMA5C CRMA5D CRMA6A CRMA6B

Fig.4.1.4 Block diagram of the process I/O board JA/JB

NOTE The process I/O board JB has none of CRMA5C, CRMA5D, CRMA6A, and CRMA6B. Number

Drawing number

Remarks

A05B-2502-J130 A05B-2502-J131 A05B-2502-J160 A05B-2502-J161 A05B-2502-J162 A05B-2502-J180 A05B-2502-J181 A05B-2502-J182

Between main board and process I/O Between process I/O and process I/O Connected length : 10m (one) Connected length : 20m (one) Connected length : 30m (one) Connected length : 10m (one) Connected length : 20m (one) Connected length : 30m (one)

Name

(1) (2) (3) (4) (5) (6)

I/O Link cable I/O Link cable Peripheral device connection cable (Process I/O JA, JB)

(7) (8)

Peripheral device connection cable (Process I/O JA)

- 327 -


4.1.5

CONNECTIONS

B-82595EN-2/02

When Process I/O Board KA/KB/KC is Used (A-Cabinet)

Operation box

A-cabinet

Main board

JD1A

(1)

JD1B

Process I/O board KA/KB/KC CRMA5A

Panel board

CRMA5B

(3)

device

(4)

(2)

CP5A

Fig. 4.1.5

Peripheral

CP5

CRW10

(5)

Block diagram of the process I/O board KA/KB/KC

NOTE CRW10 is not provided for process I/O board KC. Number (1)

(2) (3) (4) (5)

Name

Drawing number

Operator panel box connection cable

A05B-2501-H450 A05B-2501-H451 A05B-2501-H452 Process I/O board power supply A05B-2501-J150 cable Peripheral device connection A05B-2501-J050 cable A05B-2501-J051 A05B-2501-J052 Welding machine connection A05B-2501-J053 cable (for process I/O board KB) A05B-2501-J054 (general interface/elbow type) A05B-2501-J055 Welding machine connection cable (for process I/O board KA, KB) (FANUC interface/elbow type)

A05B-2501-J056 A05B-2501-J057 A05B-2501-J058

- 328 -

Remarks Connection length of 4 m Connection length of 10 m Connection length of 2 m

Connection length of 10 m (one) Connection length of 20 m (one) Connection length of 30 m (one) Connection length of 3 m (one), CRW10 Connection length of 7 m (one), CRW10 Connection length of 14 m (one), CRW10 Connection length of 3 m (one), CRW10 Connection length of 7 m (one), CRW10 Connection length of 14 m (one), CRW10


CONNECTIONS

B-82595EN-2/02

4.1.6

When I/O Unit-MODEL A is Used

4.1.6.1

In case of B-cabinet B-cabinet E-Stop unit CP5A CP5A

K26

Main board K25

JD1A

︱ Back plane (five-slot)

CP32

JD1B

JD1A

Peripheral device

Interface module K54 K54 K54 K54 K54

Fig.4.1.6.1

Block diagram of I/O Unit-A (In case of B-cabinet) Cable number K25 K26 K54 K54

Name I/O Link cable I/O Link cable Peripheral device connection cable Peripheral device connection cable

- 329 -

Drawing number -

Remarks Included in A05B-2502-J090 Included in A05B-2502-J090 Must be supplied by the customer. Must be supplied by the customer.


CONNECTIONS

B-82595EN-2/02

4.1.7

When Two or more Process I/O Printed Circuit Boards and I/O Unit-MODEL A are Used

4.1.7.1

In case of B-cabinet When several units of the process I/O PCB, I/O Unit-A are used, connect them as shown below.

B-cabinet

Main board

Process I/O board

A05B-2502-J130

JD1A

JD1B JD1A DC power is supplied from the back plane. Process I/O board

A05B-2502-J131 JD1B Included in model A base unit A05B-2502-J090 E-stop unit

JD1A I/O Unit-A Interface module

JD1B JD1A CP5A

CP32 Back plane (five-slot)

Fig.4.1.7.1

Block diagram of two or more process I/O printed circuit boards and I/O unit-MODEL A (In case of B-cabinet)

- 330 -

B-82595EN-2/02

4.2

CONNECTIONS


PERIPHERAL DEVICE INTERFACE COMBINATION Peripheral device interfaces can be used by using process I/O boards and the I/O Unit-MODEL A.

4.2.1

In Case of A-cabinet Only one of the following peripheral device interfaces can be used in A-cabinet. Process I/O board EA Process I/O board EB Process I/O board FA Process I/O board GA Process I/O board KA Process I/O board KB Process I/O board KC I/O unit Model A (5 slots) If you want to use more than one interface unit in combination in case of A-cabinet, you need another box contact a FANUC sales representative for details.

- 331 -


4.2.2

CONNECTIONS

B-82595EN-2/02

In Case of B-cabinet One board or one unit is used Combination C Combination D Combination E

Process I/O board CA/HA/JB (40 points/40 points) Process I/O board JA (96 points/96 points) I/O Unit-MODEL A

Two boards/units are used in combination Combination CE

Combination DC

Combination DD

Combination DE

Process I/O board CA/HA/JB (40 points/40 points) + I/O Unit-MODEL A Process I/O board JA (96 points/96 points) + Process I/O board CA/HA/JB (40 points/40 points) Process I/O board JA (96 points/96 points) + Process I/O board JA (96 points/96 points) Process I/O board JA (96 points/96 points) + I/O Unit-MODEL A

Three boards/units are used in combination

Combination DCE

Combination DDE

- 332 -

Process I/O board JA (96 points/96 points) + Process I/O board CA/HA/JB (40 points/40 points) + I/O Unit-MODEL A Process I/O board JA (96 points/96 points) + Process I/O board JA (96 points/96 points) + I/O Unit-MODEL A

CONNECTIONS

B-82595EN-2/02

4.3


PROCESS I/O BOARD SIGNALS There are 18 exclusive data inputs (DI) and 20 exclusive data outputs (DO) for a process I/O board. These signals are allocated to the process I/O board connected first when two or more printed boards are combined. (General signals DI/DO are allocated to the second and the following process I/O boards.) The common voltage of the DI signals input to pins 1 to 4 of connector CRMA5A or CRM2A is clamped +24 V (common) in each process I/O board. Table 4.3 shows signals of a process I/O board. Table 4.3 Connector number

Process I/O Board Signals

Signal name

Description

Remarks

(DI signals) CRMA5A- 1 (CRM2A is similar to CRMA5A) CRMA5A- 2

*IMSTP

Immediate stop

Clamped at +24 V common

*HOLD

Temporary stop

CRMA5A- 3

*SFSD

Safe speed

CRMA5A- 4

CSTOPI

Cycle stop

Clamped at +24 V common Clamped at +24 V common Clamped at +24 V common

CRMA5A- 5 CRMA5A- 6 CRMA5A- 7 CRMA5A- 8 CRMA5A- 9

FAULT RESET START HOME ENBL RSR1 PNS1 RSR2 PNS2 RSR3 PNS3 RSR4 PNS4 RSR5 PNS5 RSR6 PNS6 RSR7 PNS7 RSR8 PNS8 PNSTROBE PROD START DI01 DI02 DI03

External reset Start Return to home position Operation enabled Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection PNS strobe Start of automatic operation Peripheral device status Peripheral device status Peripheral device status

CRMA5A-10 CRMA5A-11 CRMA5A-12 CRMA5A-13 CRMA5A-14 CRMA5A-15 CRMA5A-16 CRMA5A-29 CRMA5A-30 CRMA5A-31 CRMA5A-32 CRMA5B- 1

- 333 -

Option Option Option Option Option Option Option Option

General signal General signal General signal


Connector number CRMA5B- 2 CRMA5B- 3 CRMA5B- 4 CRMA5B- 5 CRMA5B- 6 CRMA5B- 7 CRMA5B- 8 CRMA5B- 9 CRMA5B-10 CRMA5B-11 CRMA5B-12 CRMA5B-13 CRMA5B-14 CRMA5B-15 CRMA5B-16 CRMA5B-29 CRMA5B-30 CRMA5B-31 CRMA5B-32 (DO signals) CRMA5A-33 CRMA5A-34 CRMA5A-35 CRMA5A-36 CRMA5A-38 CRMA5A-39 CRMA5A-40 CRMA5A-41 CRMA5A-43 CRMA5A-44 CRMA5A-45 CRMA5A-46 CRMA5A-19 CRMA5A-20 CRMA5A-21 CRMA5A-22 CRMA5A-24 CRMA5A-25 CRMA5A-26 CRMA5A-27 CRMA5B-33 CRMA5B-34 CRMA5B-35

CONNECTIONS

Signal name

B-82595EN-2/02

Description

DI04 DI05 DI06 DI07 DI08 DI09 DI10 DI11 DI12 DI13 DI14 DI15 DI16 DI17 DI18 DI19 DI20 DI21 DI22

Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status

CMDENBL SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1 SNO1 ACK2 SNO2 ACK3 SNO3 ACK4 SNO4 ACK5 SNO5 ACK6 SNO6 ACK7 SNO7 ACK8 SNO8 SNACK RESERVED DO01 DO02 DO03

During automatic operation Preparation completed Program running Program being interrupted During temporary stop Alarm Home position Teach pendant enabled Battery voltage drop During operation Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Response signal to PNS Peripheral device control signal Peripheral device control signal Peripheral device control signal

- 334 -

Remarks General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal

Option Option Option Option Option Option Option Option

General signal General signal General signal


CONNECTIONS

B-82595EN-2/02

Connector number CRMA5B-36 CRMA5B-38 CRMA5B-39 CRMA5B-40 CRMA5B-41 CRMA5B-43 CRMA5B-44 CRMA5B-45 CRMA5B-46 CRMA5B-19 CRMA5B-20 CRMA5B-21 CRMA5B-22 CRMA5B-24 CRMA5B-25 CRMA5B-26 CRMA5B-27

Signal name DO04 DO05 DO06 DO07 DO08 DO09 DO10 DO11 DO12 DO13 DO14 DO15 DO16 DO17 DO18 DO19 DO20

Description Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal

- 335 -

Remarks General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal


CONNECTIONS

B-82595EN-2/02

4.4

INTERFACE FOR PERIPHERAL DEVICES

4.4.1

Peripheral Device and Control Unit Connection (Source Type DO) Peripheral device control interface A1

Control unit

(Source type DO) CRMA5A

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18

*IMSTP *HOLD *SFSPD CSTOPI FAULT RESET

START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 0V 0V

19 20 21 22 23 24 25 26 27 28 29 30 31 32

ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 DOSRC1 ACK7/SNO7 ACK8/SNO8 SNACK RESERVED DOSRC1 PNSTROBE PROD START DI01 DI02

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

CMDENBL SYSRDY PROGRUN PAUSED DOSRC1 HELD FAULT ATPERCH TPENBL DOSRC1 BATALM BUSY ACK1/SNO1 ACK2/SNO2 DOSRC1

Peripheral device A1

+24E +24E

Peripheral device control interface A2 (Source type DO) CRMA5B 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18

DI03 DI04 DI05 DI06 DI07 DI08 DI09 DI10 DI11 DI12 DI13 DI14 DI15 DI16 DI17 DI18 0V 0V

19 20 21 22 23 24 25 26 27 28 29 30 31 32

DO13 DO14 DO15 DO16 DOSRC1 DO17 DO18 DO19 DO20 DOSRC1 DI19 DI20 DI21 DI22

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

DO01 DO02 DO03 DO04 DOSRC1 DO05 DO06 DO07 DO08 DOSRC1 DO09 DO10 DO11 DO12 DOSRC1 +24E +24E

Terminal block

TBSRC1 1 2

DOSRC1 0V

- 336 -


B-82595EN-2/02

CONNECTIONS


NOTE 1 The peripheral device connection cables are optional. 2 The DOSRC1 pins of the CRMA5A and CRMA5B are pins for supplying power to drivers. (None of these pins can be left open.) 3 When the level of the voltage applied to the load is insufficient for a cause such as a too long peripheral device connection cable, supply power from the TBSRC1 terminal block. Applicable process I/O board type JA, JB, KA, KB, KC

- 337 -


CONNECTIONS

B-82595EN-2/02

Control unit

Peripheral device control interface A3 (Source type DO) CRMA5C 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18


19 20 21 22 23 24 25 26 27 28 29 30 31 32


33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

DO21 DO22 DO23 DO24 DOSRC2 DO25 DO26 DO27 DO28 DOSRC2 DO29 DO30 DO31 DO32 DOSRC2


+24E +24E

Peripheral device control interface A4 (Source type DO) CRMA5D 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18


19 20 21 22 23 24 25 26 27 28 29 30 31 32


33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

DO41 DO42 DO43 DO44 DOSRC2 DO45 DO46 DO47 DO48 DOSRC2 DO49 DO50 DO51 DO52 DOSRC2 +24E +24E

Terminal block

TBSRC2 1 2

DOSRC2 0V

- 338 -


B-82595EN-2/02

CONNECTIONS


NOTE 1 The peripheral device connection cables are optional. 2 The DOSRC2 pins of the CRMA5C and CRMA5D are pins for supplying power to drivers. (None of these pins can be left open.) 3 When the level of the voltage applied to the load is insufficient for a cause such as a too long peripheral device connection cable, supply power from the TBSRC2 terminal block. Applicable process I/O board type JA

- 339 -


CONNECTIONS

B-82595EN-2/02

Control unit

Peripheral device control interface B1 (Source type DO) CRMA6A 01 02 03 04 05 06 07

DI63 DI64 DI65 DI66 DI67 DI68 DI69

08 09 10 11 12 13

DO65 DO66 DO67 DO68 DOSRC3 DI70

14 15 16 17 18 19 20

DO61 DO62 DO63 DO64 DOSRC3 +24E 0V

Peripheral device B1

Peripheral device control interface B2 (Source type DO) CRMA6B 01 02 03 04 05 06 07

DI71 DI72 DI73 DI74 DI75 DI76 DI77

08 09 10 11 12 13

DO73 DO74 DO75 DO76 DOSRC3 DI78

14 15 16 17 18 19 20

DO69 DO70 DO71 DO72 DOSRC3 +24E 0V


Terminal block

TBSRC3 1 2

DOSRC3 0V

NOTE 1 The peripheral device connection cables are optional. 2 The DOSRC3 pins of the CRMA6A and CRMA6B are pins for supplying power to drivers. (None of these pins can be left open.) 3 When the level of the voltage applied to the load is insufficient for a cause such as a too long peripheral device connection cable, supply power from the TBSRC3 terminal block. Applicable process I/O board type JA

- 340 -

CONNECTIONS

B-82595EN-2/02

Control unit (peripheral device control interface A1)


Peripheral device

+24E Connector pin No. CRMA5A (49,50)

Receiver circuit *IMSTP

RV

*HOLD

RV

CRMA5A (1)

3.3k

CRMA5A (2) CRMA5A (3)

*SFSPD RV Set this jumper according to the common CSTOPI RV voltage of input devices. (ICOM1)

CRMA5A (4)

0V

CRMA5A (5)

FAULT RESET

RV

START

RV

HOME

RV

ENBL

RV

RSR1/PNS1

RV

RSR2/PNS2

RV

RSR3/PNS3

RV

RSR4/PNS4

RV

RSR5/PNS5

RV

RSR6/PNS6

RV

RSR7/PNS7

RV

RSR8/PNS8

RV

PNSTROBE

RV

PROD START

RV

DI01

RV

CRMA5A (31)

DI02

RV

CRMA5A (32)

COM-1

RV +24E

CRMA5A (6) CRMA5A (7) CRMA5A (8) CRMA5A (9) CRMA5A (10) CRMA5A (11) CRMA5A (12) CRMA5A (13) CRMA5A (14) CRMA5A (15) CRMA5A (16) CRMA5A (29) CRMA5A (30)

CRMA5A (17,18) B

A 0V

Set this jumper according to the common voltage of input devices. (ICOM1)

0V

NOTE In this diagram, common voltage of input devices is +24V.

- 341 -


CONNECTIONS

Control unit (peripheral device control interface A1) DOSRC1(1)

B-82595EN-2/02

Peripheral device

DOSRC1 Connector pin No. CRMA5A (23,28,37,42,47)

0V +24V +24V regulated power supply

Driver circuit DV

LOAD

CMDENBL CRMA5A (33)

SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK RESERVED

CRMA5A (34)

DV

CRMA5A (35)

DV

CRMA5A (36)

DV

CRMA5A (38)

DV

CRMA5A (39)

DV

CRMA5A (40)

DV

CRMA5A (41)

DV

CRMA5A (43)

DV

CRMA5A (44)

DV

CRMA5A (45)

DV

CRMA5A (46)

DV

CRMA5A (19)

DV

CRMA5A (20)

DV

CRMA5A (21)

DV

CRMA5A (22)

DV

CRMA5A (24)

DV

CRMA5A (25)

DV

CRMA5A (26)

DV

CRMA5A (27)

DV

CRMA5A (17,18) TBSRC1(2) 0V

A maximum output current per DO point is 0.2 A.

- 342 -

RELAY

LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD

CONNECTIONS

B-82595EN-2/02



Peripheral device

+24E Connector pin No. CRMA5B (49,50)

Receiver circuit

CRMA5B (1)

DI03

RV

DI04

RV

DI05

RV

DI06

RV

DI07

RV

DI08

RV

DI09

RV

DI10

RV

DI11

RV

DI12

RV

DI13

RV

DI14

RV

DI15

RV

DI16

RV

DI17

RV

DI18

RV

DI19

RV

DI20

RV

DI21

RV

CRMA5B (31)

DI22

RV

CRMA5B (32)

COM-2

RV +24E

3.3k

CRMA5B (2) CRMA5B (3) CRMA5B (4) CRMA5B (5) CRMA5B (6) CRMA5B (7) CRMA5B (8) CRMA5B (9) CRMA5B (10) CRMA5B (11) CRMA5B (12) CRMA5B (13) CRMA5B (14) CRMA5B (15) CRMA5B (16) CRMA5B (29) CRMA5B (30)

CRMA5B (17,18) B

A 0V


0V


- 343 -


CONNECTIONS


DOSRC1(1)

B-82595EN-2/02

Peripheral device

DOSRC1 Connector pin No. CRMA5B (23,28,37,42,47)

+24V 0V +24V regulated power supply

Driver circuit DV

LOAD

DO01 CRMA5B (33)

DO02 DO03 DO04 DO05 DO06 DO07 DO08 DO09 DO10 DO11 DO12 DO13 DO14 DO15 DO16 DO17 DO18 DO19 DO20

CRMA5B (34)

DV

CRMA5B (35)

DV

CRMA5B (36)

DV

CRMA5B (38)

DV

CRMA5B (39)

DV

CRMA5B (40)

DV

CRMA5B (41)

DV

CRMA5B (43)

DV

CRMA5B (44)

DV

CRMA5B (45)

DV

CRMA5B (46)

DV

CRMA5B (19)

DV

CRMA5B (20)

DV

CRMA5B (21)

DV

CRMA5B (22)

DV

CRMA5B (24)

DV

CRMA5B (25)

DV

CRMA5B (26)

DV

CRMA5B (27)

DV

CRMA5B (17,18) TBSRC1(2) 0V


- 344 -

RELAY


CONNECTIONS

B-82595EN-2/02



Peripheral device

+24E Connector pin No. CRMA5C (49,50) Receiver circuit

CRMA5C (1)

DI23

RV

DI24

RV

DI25

RV

DI26

RV

DI27

RV

DI28

RV

DI29

RV

DI30

RV

DI31

RV

DI32

RV

DI33

RV

DI34

RV

DI35

RV

DI36

RV

DI37

RV

DI38

RV

DI39

RV

DI40

RV

DI41

RV

CRMA5C (31)

DI42

RV

CRMA5C (32)

COM-3

RV +24E

3.3k

CRMA5C (2) CRMA5C (3) CRMA5C (4) CRMA5C (5) CRMA5C (6) CRMA5C (7) CRMA5C (8) CRMA5C (9) CRMA5C (10) CRMA5C (11) CRMA5C (12) CRMA5C (13) CRMA5C (14) CRMA5C (15) CRMA5C (16) CRMA5C (29) CRMA5C (30)

CRMA5C (17,18) B

A 0V

Set this jumper according to the common voltage of input devices.(ICOM3)

0V


- 345 -


CONNECTIONS


TBSRC2(1)

B-82595EN-2/02

Peripheral device

DOSRC2 Connector pin No. CRMA5C (23,28,37,42,47)


Driver circuit DV

LOAD

DO21 CRMA5C (33)


CRMA5C (34)

DV

CRMA5C (35)

DV

CRMA5C (36)

DV

CRMA5C (38)

DV

CRMA5C (39)

DV

CRMA5C (40)

DV

CRMA5C (41)

DV

CRMA5C (43)

DV

CRMA5C (44)

DV

CRMA5C (45)

DV

CRMA5C (46)

DV

CRMA5C (19)

DV

CRMA5C (20)

DV

CRMA5C (21)

DV

CRMA5C (22)

DV

CRMA5C (24)

DV

CRMA5C (25)

DV

CRMA5C (26)

DV

CRMA5C (27)

DV

CRMA5C (17,18) TBSRC2(2) 0V


- 346 -

RELAY


CONNECTIONS

B-82595EN-2/02



Peripheral device

+24E Connector pin No. CRMA5D (49,50)

Receiver circuit CRMA5D (1)

DI43

RV

DI44

RV

DI45

RV

DI46

RV

DI47

RV

DI48

RV

DI49

RV

DI50

RV

DI51

RV

DI52

RV

DI53

RV

DI54

RV

DI55

RV

DI56

RV

DI57

RV

DI58

RV

DI59

RV

DI60

RV

DI61

RV

CRMA5D (31)

DI62

RV

CRMA5D (32)

COM-4

RV +24E

3.3k

CRMA5D (2) CRMA5D (3) CRMA5D (4) CRMA5D (5) CRMA5D (6) CRMA5D (7) CRMA5D (8) CRMA5D (9) CRMA5D (10) CRMA5D (11) CRMA5D (12) CRMA5D (13) CRMA5D (14) CRMA5D (15) CRMA5D (16) CRMA5D (29) CRMA5D (30)

CRMA5D (17,18) B

A 0V


0V


- 347 -


CONNECTIONS

Control unit (peripheral device control interface A4) DOSRC2(1)

B-82595EN-2/02

Peripheral device

DOSRC2 Connector pin No. CRMA5D (23,28,37,42,47)


Driver circuit DV

LOAD

DO41 CRMA5D (33)


CRMA5D (34)

DV

CRMA5D (35)

DV

CRMA5D (36)

DV

CRMA5D (38)

DV

CRMA5D (39)

DV

CRMA5D (40)

DV

CRMA5D (41)

DV

CRMA5D (43)

DV

CRMA5D (44)

DV

CRMA5D (45)

DV

CRMA5D (46)

DV

CRMA5D (19)

DV

CRMA5D (20)

DV

CRMA5D (21)

DV

CRMA5D (22)

DV

CRMA5D (24)

DV

CRMA5D (25)

DV

CRMA5D (26)

DV

CRMA5D (27)

DV

CRMA5D (17,18) TBSRC2(2) 0V

A maximum output current per DO point is 0.2 A

- 348 -

RELAY


CONNECTIONS

B-82595EN-2/02

Control unit (peripheral device control interface B1)


Peripheral device

+24E Connector pin No. CRMA6A (19) Receiver circuit DI63

RV

DI64

RV

DI65

RV

DI66

RV

DI67

RV

DI68

RV

DI69

RV

DI70

RV

COM-5

RV +24E

CRMA6A (1)

3.3k

CRMA6A (2) CRMA6A (3) CRMA6A (4) CRMA6A (5) CRMA6A (6) CRMA6A (7) CRMA6A (13)

B

A


0V DOSRC3(1)

DOSRC3

Connector pin No. CRMA6A (12,18)


Driver circuit DV

LOAD

DO61 CRMA6A (14)

DO62 DO63 DO64 DO65 DO66 DO67 DO68

CRMA6A (15)

DV

CRMA6A (16)

DV

CRMA6A (17)

DV

CRMA6A (8)

DV

CRMA6A (9)

DV

CRMA6A (10)

DV

CRMA6A (11)

DV

RELAY

LOAD LOAD LOAD LOAD LOAD LOAD LOAD

CRMA6A (20) TBSRC3(2) 0V A maximum output current per DO point is 0.2 A.

NOTE In this diagram, common voltage of input devices is +24V. - 349 -


CONNECTIONS

Control unit (peripheral device control interface B2)

B-82595EN-2/02

Peripheral device

+24E Connector pin No. CRMA6B (19) Receiver circuit DI71

RV

DI72

RV

DI73

RV

DI74

RV

DI75

RV

DI76

RV

DI77

RV

DI78

RV

COM-6

RV +24E

CRMA6B (1)

3.3k

CRMA6B (2) CRMA6B (3) CRMA6B (4) CRMA6B (5) CRMA6B(6) CRMA6B (7) CRMA6B (13)

B

A


0V DOSRC3(1)

DOSRC3

Connector pin No. CRMA6B (12,18)

Driver circuit DV

LOAD

DO69 CRMA6B (14)



CRMA6B (15)

DV

CRMA6B (16)

DV

CRMA6B (17)

DV

CRMA6B (8)

DV

CRMA6B (9)

DV

CRMA6B (10)

DV

CRMA6B (11)

DV

RELAY


CRMA6B (20) TBSRC3(2) 0V A maximum output current per DO point is 0.2 A.


CONNECTIONS

B-82595EN-2/02

4.4.2


Peripheral Device and Control Unit Connection (Sink Type DO) Control unit Peripheral device control interface A1 Sink type DO


0V

Peripheral device control interface A2 Sink type DO


NOTE 1 The peripheral device connection cables are optional. 2 All of COM-∗∗ are connected to 0V. Applicable process I/O board type CA, EA, EB, FA, GA, HA

- 351 -


CONNECTIONS

B-82595EN-2/02

Control unit Peripheral device control interface A3 Sink type DO


Peripheral device control interface A4 Sink type DO


NOTE 1 The peripheral device connection cables are optional. 2 All of COM-∗∗ are connected to 0V. Applicable process I/O board type FA

- 352 -

B-82595EN-2/02

CONNECTIONS


Control unit Peripheral device control interface B1 Sink type DO


Control unit Peripheral device control interface B2 Sink type DO


NOTE 1 The peripheral device connection cables are optional. 2 All of COM-∗∗ are connected to 0V. Applicable process I/O board type FA

- 353 -


CONNECTIONS

Peripheral device

Control unit (peripheral device interface A1) +24E

B-82595EN-2/02

Connector pin No. CRM2A (49,50)

Receiver circuit *IMSTP

RV

*HOLD

RV

*SFSPD

RV

CSTOPI

RV

FAULT RESET

RV

START

RV

HOME

RV

ENBL

RV

RSR1/PNS1

RV

RSR2/PNS2

RV

RSR3/PNS3

RV

RSR4/PNS4

RV

RSR5/PNS5

RV

RSR6/PNS6

RV

RSR7/PNS7

RV

RSR8/PNS8

RV

PNSTROBE

RV

PROD START

RV

DI01

RV

DI02

RV

CRM2A (1)

3.3k

CRM2A (2) CRM2A (3) CRM2A (4)

0V

COM-1

RV +24E

CRM2A (5) CRM2A (6) CRM2A (7) CRM2A (8) CRM2A (9) CRM2A (10) CRM2A (11) CRM2A (12) CRM2A (13) CRM2A (14) CRM2A (15) CRM2A (16) CRM2A (29) CRM2A (30) CRM2A (31) CRM2A (32) CRM2A (17,18)

B

A 0V

Set this jumper according to the common voltage of input devices. 0V (ICOM1)


- 354 -

B-82595EN-2/02

CONNECTIONS

- 355 -



CONNECTIONS

Control unit (peripheral device interface A2)

B-82595EN-2/02

Peripheral device

+24E Connector pin No. CRM2B (49,50)

Receiver circuit DI03

RV

DI04

RV

DI05

RV

DI06

RV

DI07

RV

DI08

RV

DI09

RV

DI10

RV

DI11

RV

DI12

RV

DI13

RV

DI14

RV

DI15

RV

DI16

RV

DI17

RV

DI18

RV

DI19

RV

DI20

RV

DI21

RV

DI22

RV

COM-2

RV +24E

CRM2B (1)

3.3k

CRM2B (2) CRM2B (3) CRM2B (4) CRM2B (5) CRM2B (6) CRM2B (7) CRM2B (8) CRM2B (9) CRM2B (10) CRM2B (11) CRM2B (12) CRM2B (13) CRM2B (14) CRM2B (15) CRM2B (16) CRM2B (29) CRM2B (30) CRM2B (31) CRM2B (32) CRM2B (17,18)

B

A 0V

Set this jumper according to the common voltage of input devices. （ICOM2）

0V


- 356 -

CONNECTIONS

B-82595EN-2/02

Control unit (peripheral device interface A2) Driver circuit


Peripheral device

Connector pin No. CRM2B (33)

DV

LOAD

DO01

RELAY 0V


CRM2B (34)

DV

LOAD

CRM2B (35)

DV

LOAD

CRM2B (36)

DV

LOAD

CRM2B (38)

DV

LOAD

CRM2B (39)

DV

LOAD

CRM2B (40)

DV

LOAD

CRM2B (41)

DV

LOAD

CRM2B (43)

DV

LOAD

CRM2B (44)

DV

LOAD

CRM2B (45)

DV

LOAD

CRM2B (46)

DV

LOAD

CRM2B (19)

DV

LOAD

CRM2B (20)

DV

LOAD

CRM2B (21)

DV

LOAD

CRM2B (22)

DV

LOAD

CRM2B (24)

DV

LOAD

CRM2B (25)

DV

LOAD

CRM2B (26)

DV

LOAD

CRM2B (27)

DV

CRM2B (23,28,37,42,47)

LOAD

0V

+24V

0V


- 357 -

+24 V regulated power supply


CONNECTIONS


B-82595EN-2/02

Peripheral device

+24E Connector pin No. CRM2C (49,50)


RV

DI24

RV

DI25

RV

DI26

RV

DI27

RV

DI28

RV

DI29

RV

DI30

RV

DI31

RV

DI32

RV

DI33

RV

DI34

RV

DI35

RV

DI36

RV

DI37

RV

DI38

RV

DI39

RV

DI40

RV

DI41

RV

DI42

RV

COM-3

RV +24E

CRM2C (1)

3.3k

CRM2C (2) CRM2C (3) CRM2C (4) CRM2C (5) CRM2C (6) CRM2C (7) CRM2C (8) CRM2C (9) CRM2C (10) CRM2C (11) CRM2C (12) CRM2C (13) CRM2C (14) CRM2C (15) CRM2C (16) CRM2C (29) CRM2C (30) CRM2C (31) CRM2C (32) CRM2C (17,18)

B

A 0V


0V


- 358 -

CONNECTIONS

B-82595EN-2/02



Peripheral device

Connector pin No. CRM2C (33)

DV

LOAD

DO21

RELAY 0V


CRM2C (34)

DV

LOAD

CRM2C (35)

DV

LOAD

CRM2C (36)

DV

LOAD

CRM2C (38)

DV

LOAD

CRM2C (39)

DV

LOAD

CRM2C (40)

DV

LOAD

CRM2C (41)

DV

LOAD

CRM2C (43)

DV

LOAD

CRM2C (44)

DV

LOAD

CRM2C (45)

DV

LOAD

CRM2C (46)

DV

LOAD

CRM2C (19)

DV

LOAD

CRM2C (20)

DV

LOAD

CRM2C (21)

DV

LOAD

CRM2C (22)

DV

LOAD

CRM2C (24)

DV

LOAD

CRM2C (25)

DV

LOAD

CRM2C (26)

DV

LOAD

CRM2C (27)

DV

CRM2C (23,28,37,42,47)

LOAD

0V

+24V

0V


- 359 -



CONNECTIONS


B-82595EN-2/02

Peripheral device

+24E Connector pin No. CRM2D (49,50)


RV

DI44

RV

DI45

RV

DI46

RV

DI47

RV

DI48

RV

DI49

RV

DI50

RV

DI51

RV

DI52

RV

DI53

RV

DI54

RV

DI55

RV

DI56

RV

DI57

RV

DI58

RV

DI59

RV

DI60

RV

DI61

RV

DI62

RV

COM-4

RV +24E

CRM2D (1) 3.3k

CRM2D (2) CRM2D (3) CRM2D (4) CRM2D (5) CRM2D (6) CRM2D (7) CRM2D (8) CRM2D (9) CRM2D (10) CRM2D (11) CRM2D (12) CRM2D (13) CRM2D (14) CRM2D (15) CRM2D (16) CRM2D (29) CRM2D (30) CRM2D (31) CRM2D (32) CRM2D (17,18)

B

A 0V

Set this jumper according to the common voltage of input devices. 0V （ICOM4）


- 360 -

CONNECTIONS

B-82595EN-2/02


Peripheral device

Connector pin No. CRM2D (33)

DV


LOAD

DO41

RELAY 0V


CRM2D (34)

DV

LOAD

CRM2D (35)

DV

LOAD

CRM2D (36)

DV

LOAD

CRM2D (38)

DV

LOAD

CRM2D (39)

DV

LOAD

CRM2D (40)

DV

LOAD

CRM2D (41)

DV

LOAD

CRM2D (43)

DV

LOAD

CRM2D (44)

DV

LOAD

CRM2D (45)

DV

LOAD

CRM2D (46)

DV

LOAD

CRM2D (19)

DV

LOAD

CRM2D (20)

DV

LOAD

CRM2D (21)

DV

LOAD

CRM2D (22)

DV

LOAD

CRM2D (24)

DV

LOAD

CRM2D (25)

DV

LOAD

CRM2D (26)

DV

LOAD

CRM2D (27)

DV

CRM2D (23,28,37,42,47)

LOAD

0V

+24V

0V


- 361 -



CONNECTIONS

Peripheral device

Control unit (peripheral device interface B1) +24E

B-82595EN-2/02

Connector pin No. CRM4A (19)

DI63

Receiver circuit RV

DI64

RV

DI65

RV

DI66

RV

DI67

RV

DI68

RV

DI69

RV

DI70

RV

COM-5

CRM4A (1)

3.3k

CRM4A (2) CRM4A (3) CRM4A (4) CRM4A (5) CRM4A (6) CRM4A (7) CRM4A (13)

RV +24E

CRM4A (20) B

A 0V


Driver circuit

Connector pin No. CRM4A (14)

DV

LOAD

DO61

RELAY 0V


CRM4A (15)

DV

LOAD

CRM4A (16)

DV

LOAD

CRM4A (17)

DV

LOAD

CRM4A (8)

DV

LOAD

CRM4A (9)

DV

LOAD

CRM4A (10)

DV

LOAD

CRM4A (11)

DV

CRM4A (12, 18)

LOAD

0V

+24V

0V




CONNECTIONS

B-82595EN-2/02

Control unit (peripheral device interface B2)


Peripheral device

Connector pin No.

+24E

CRM4B (19)


RV

DI72

RV

DI73

RV

DI74

RV

DI75

RV

DI76

RV

DI77

RV

DI78

RV

COM-6

CRM4B (1)

3.3k

CRM4B (2) CRM4B (3) CRM4B (4) CRM4B (5) CRM4B (6) CRM4B (7) CRM4B (13)

RV +24E

CRM4B (20) B

A 0V


Connector pin No. Driver circuit

CRM4B (14)

DV

LOAD

DO69

RELAY 0V


CRM4B (15)

DV

LOAD

CRM4B (16)

DV

LOAD

CRM4B (17)

DV

LOAD

CRM4B (8)

DV

LOAD

CRM4B (9)

DV

LOAD

CRM4B (10)

DV

LOAD

CRM4B (11)

DV

CRM4B (12, 18)

LOAD

0V

+24V

0V




- 363 -


CONNECTIONS

B-82595EN-2/02

4.5

INTERFACE FOR WELDER

4.5.1

Connection Between the Control Unit and Welder

Control unit

Welding machine interface WO1 WO2 WO3 WO4

WI1

WO5

WI2

WO6

WI3

WO7

WI4

WO8

Welding machine

WI5 WI6 WI7 WI8

Analog input interface

Peripheral device

NOTE Welder and peripheral device connection cable are optional. Applicable process I/O board type CA, EA

- 364 -

B-82595EN-2/02

CONNECTIONS

- 365 -



CONNECTIONS

Welding machine

Control unit (welding machine interface) Process I/O boards CA and EA Connector pin No. CRW1 (23)

Driver circuit DV Welding start signal

B-82595EN-2/02

R

LOAD RELAY

WO01 0V

Gas signal

WO02 WO03

Wire inching (+) signal Wire inching (-) signal

WO04 WO05 WO06 WO07 WO08

DV DV DV DV DV DV DV

Receiver circuit WI01 RV Arc regeneration detection signal Out-of-gas detection signal Broken-wire detection signal Out-of-coolingwater detection signal Abnormal-welding power signal

WI02

RV

WI03

RV

WI04

RV

WI05

RV

WI06

RV

WI07

RV

WI08

RV

COM-3

RV +24E B

CRW1 (24)

S

CRW1 (25)

T

CRW1 (26)

U

CRW1 (27)

V

CRW1 (28)

W

CRW1 (29)

X

CRW1 (30)

Z

CRW1 (19,20)

a,m

CRW1 (21,22)

b,n

0V Connector pin No. 3.3k CRW1 (5)


0V

+24V

+24 V regulated power c

CRW1 (6)

d

CRW1 (7)

e

CRW1 (8)

f

CRW1 (9)

g

CRW1 (10)

h

CRW1 (11)

j

CRW1 (12)

k

CRW1 (33,34)

r

A

Set this jumper according to the common voltage of input devices. 0V （ICOM3） +24V

s Cabinet ground (shield clamped)）

Welding machine frame ground


- 366 -


CONNECTIONS

B-82595EN-2/02

CRW2 connector analog connection (analog input)

(Relationships between process I/O points and analog inputs) Analog inputs ADCH1 ADCH2 ADCH3 COMAD1 COMAD2 COMAD3 Process I/O points Process I/O CA points In CRW1 In CRW1 ○

Process I/O EA points

In CRW1

In CRW1

Process I/O GB points

○ ○

○ ○

Process I/O HB points

○ ○ ○

- 367 -

ADCH4 COMAD4

ADCH5 COMAD5

ADCH6 COMAD6

○ × ○ ○

○ × ○ ○

○ × ○ ○


Control unit

CONNECTIONS

B-82595EN-2/02

Welding machine interface WO1 WO5

WI1

WO2

WO3

WI2 WI3

Welding machine

WO4

WI4 WI5 WI6 WI7 WI8

NOTE Welder and peripheral device connection cable are optional. Applicable process I/O board type GA, HA

- 368 -

CONNECTIONS

B-82595EN-2/02


General-purpose interface

Control unit (welding machine interface) Process I/O boards GA, HA, and HB Welding voltage specification signal Wire speed specification signal

Arc detection signal Out-of-gas detection signal Broken-wire detection signal Arc-off detection signal (power supply abnormal)

Connector pin No. CRW7 (1)

DACH1

CRW7 (2)

COMDA1

CRW7 (3)

DACH2

CRW7 (4)

COMDA2 Receiver circuit WI02 RV WI03

RV

WI04

RV

WI06

RV

COM-3

RV +24E B

Welding start signal WCOM1 WO04 Wire inching (+) WCOM4 WO05 Wire inching (-) WCOM5

Wire deposition detection signal

WDI+ WDI-

A B C D

Connector pin No. 3.3k CRW7 (6)

P

CRW7 (7)

T

CRW7 (8)

S

CRW7 (10)

R

CRW7 (33,34)

E

+24E A


WO01

Welding machine MS connector pin No.

0V

CRW7 (23) CRW7 (24) CRW7 (29) CRW7 (30) CRW7 (13) CRW7 (14)

L K F G H J

R = 100 Ω or higher

CRW1 (31)

M

＋

CRW1 (32)

N

－

Cabinet ground (shield clamped)

＋－ Welding power Welding machine frame ground


- 369 -


CONNECTIONS

B-82595EN-2/02

FANUC interface

Control unit (welding machine interface) Process I/O boards GA, HA, and HB


DACH1

Welding voltage specification signal

CRW7 (2)

COMDA1

CRW7 (3)

DACH2

Wire speed specification signal

CRW7 (4)

COMDA2 Receiver circuit WI01 RV

Arc detection signal Out-of-gas detection signal Broken-wire detection signal

WI02

RV

WI03

RV

WI04

RV

WI05

RV

WI06

RV

WI07

RV

WI08

RV

COM-3

RV

Out-of-coolingwater detection Arc-off detection signal (power supply abnormal)

+24E

B


Welding start signal WCOM1 WO02 Gas signal WCOM2 WO04 Wire inching (+) WCOM4 WO05 Wire inching (-) WCOM5


WDI+ WDI-

B E F

c

CRW7 (6)

d

CRW7 (7)

e

CRW7 (8)

f

CRW7 (9)

g

CRW7 (10)

h

CRW7 (11)

j

CRW7 (12)

k

CRW7 (33,34)

r

CRW7 (19,20)

WO01

A

+24E

A


Welding machine MS connector pin No.

CRW7 (21,22)

0V 0V

CRW7 (23)

m n

R

CRW7 (24) CRW7 (25) CRW7 (26) CRW7 (29)

S a U

CRW7 (30) CRW7 (13) CRW7 (14)

V b


CRW1 (31)

N

＋

CRW1 (32)

P

－

s




CONNECTIONS

B-82595EN-2/02

Control unit


Welding machine interface CRW10

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18

DACH1 COMDA1 DACH2 COMDA2 DACH3 COMDA3 WI1 WI2 WI3 WI4 WI5 WI6 WI7 WI8 0V 0V 0V 0V

19 20 21 22 23 24 25 26 27 28 29 30 31 32

ADCH1 COMAD1 ADCH2 COMAD2

WDI+ WDI-

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

WO1 WCOM1 WO2 WCOM12 WO3 WCOM3 WO4 WCOM4 WO5 WCOM5 WO6 WCOM6 WO7 WCOM7 WO8 WCOM8 +24E +24E

Welding machine

NOTE The welding machine connection cables are options. Applicable process I/O board types KA

- 371 -


CONNECTIONS

B-82595EN-2/02

Pin-to-pin connection between CRW10 connector and welding machine connector (general interface) (analog output, welding wire deposition detection, WI/WO connection, for connections with +24 V common)

Control unit（Welding machine interface） Process I/O board KB




DACH1

CRW10 (2)

COMDA1

CRW10 (3)

DACH2

CRW10 (4)

COMDA2 Receiver circuit

Arc detection signal Out-of-gas detection signal Broken-wire detection signal Arc-off detection signal (power supply abnormal)

WI02

RV

WI03

RV

WI04

RV

WI06

RV

COM-3

RV +24E B

Welding machine MS connector pin No. A B C D


P

CRW10 (9)

S

CRW10 (10)

T

CRW10 (12)

R

+24E CRW10 (49,50)

E

3.3k

A


WO01 Welding start signal WCOM1 WO04 Wire inching (+) WCOM4 WO05 Wire inching (-) WCOM5


WDI+ WDI-

CRW10 (33) CRW10 (34) CRW10 (39) CRW10 (40) CRW10 (41) CRW10 (42)

L K F G H J

R=100Ωor higher

CRW10 (25)

M

＋

CRW10 (26)

N

－




CONNECTIONS

B-82595EN-2/02


Pin-to-pin connection between CRW10 connector and welding machine connector:

FANUC interface

(analog input/output, welding wire deposition detection, WI/WO connection, for connections with +24 V common) Control unit (welding machine interface) Process I/O boards KA, KB

Welding machine MS connector pin No. Connector pin No. CRW10 (1)

DACH1


CRW10 (2)

COMDA1

CRW10 (3)

DACH2


CRW10 (4)

COMDA2

Welding voltage detection signal

CRW10 (19)

ADCH1

CRW10 (20)

COMAD1 Welding current detection signal

CRW10 (21)

ADCH2

CRW10 (22)

COMAD2 0V Receiver circuit WI01 Arc detection signal

RV

WI02

Out-of-gas detection signal Broken-wire detection signal Out-of-coolingwater detection

RV

WI05

RV

WI06

RV

WI08

RV

COM-3 +24E

B

RV A

Welding start signal

WO01 WCOM1

Gas signal

WO02 WCOM2

－

WO03 WCOM3

Wire inching (+)

WO04 WCOM4

Wire inching (-)

WO05 WCOM5

－

WO06 WCOM6

－

WO07 WCOM7

－

WO08 WCOM8


WDI+ WDI-

J K L M

e f

CRW10 (11)

g

CRW10 (12)

h

CRW10 (13)

j

CRW10 (14)

k

+24E CRW10 (49,50)

r

CRW10 (17,18) 0V

CRW10 (33)

Ripples must have been removed from the output signals.

c

CRW10 (10)

CRW10 (15,16) Set this jumper according to the common voltage of input devices. 0V （ICOM3）

F

d

RV

WI07

E

CRW10 (9)

RV

WI04

B

CRW10 (8)

RV

WI03

Arc-off detection signal (power supply abnormal)


A

m n R

CRW10 (34) CRW10 (35)

S

CRW10 (36) CRW10 (37)

T

CRW10 (38) CRW10 (39) CRW10 (40) CRW10 (41)

U a V

CRW10 (42) CRW10 (43)

W

CRW10 (44) CRW10 (45)

X

CRW10 (46) CRW10 (47) CRW10 (48)

Z


CRW10 (25)

b N

＋

CRW10 (26)

P

－

s


- 373 -



CONNECTIONS

B-82595EN-2/02

4.6

INTERFACE FOR END EFFECTOR

4.6.1

Connection Between the Mechanical Unit and End Effector

Mechanical unit EE 1 RO1 5 RO5 10 RI2

6 RO6 11 RI3

16 RI6

2 RO2

7 *HBK 12 RI4

17 +24VF 21 RO7

3 RO3 8 0V 13 RI8

18 +24VF

22 RO8

4 RO4 9 RI1 14 *PPABN

19 +24VF 23 0V

15 RI5

20 +24VF

End effector

24 RI7

Fig.4.6.1 In case of the R-2000iB, M-710iC (For other robots, refer to the each operators manual.)

- 374 -


CONNECTIONS

B-82595EN-2/02

Peripheral device

Mechanical unit (end-effector interface) +24VF

Connector pin No.

EE(17,18,19,20) Wrist breakage *HBK detection signal

Receiver circuit RV 3.3k

RI1

RV

RI2

RV

RI3

RV

RI4

RV

RI5

RV

RI6

RV

RI7

RV

RI8

RV

RI9 RV ‘(Pneumatic pressure *PPABN) +24E abnormal signal)

EE (7)

0V

EE (9) EE (10) EE (11) EE (12) EE (15) EE (16) EE (24) EE (13) EE (13)

B

A

Set this jumper according to the common voltage of input devices. (COM1)

0V

+24VF Driver circuit DV

LOAD

RO1 EE (1)

RO2 RO3 RO4 RO5 RO6 RO7 RO8

EE (2)

DV

EE (3)

DV

EE (4)

DV

EE (5)

DV

EE (6)

DV

EE (21)

DV

EE (22)

DV

RELAY


EE (8,23) 0V A maximum output current per RO point is 0.2 A.

NOTE 1 In this diagram, common voltage of input devices is +24V. 2 The common-level change-over setting pin (COM1) is in the 6-axis servo amplifier.

- 375 -


4.7

CONNECTIONS

B-82595EN-2/02

DIGITAL I/O SIGNAL SPECIFICATIONS This section describes the specifications of the digital I/O signals interfaced with the peripheral device, end effector, and arc welder.

4.7.1

Peripheral Device Interface A (1) Output signals in peripheral device interface A (Source type DO) (a) Example of connection Spark killer diode

0.2A or less

(b) Electrical specifications Maximum load current when driver is on: 200 mA (including momentary level) Saturation voltage when driver is on: 1.0 V max. Dielectric strength: 24 V ±20% (including momentary level) Leakage current when driver is off: 100 µA (c) The external power supply to output signals must satisfy the following: Power supply voltage: +24 V ±10% Power supply current: For each printed circuit board of this type (Total sum of maximum load currents including momentary levels + 100 mA or more) Power-on timing: At the same time when the control unit is turned on or earlier Power-off timing: At the same time when the control unit is turned off or later (d) Spark killer diode Rated peak reverse voltage : 100 V or more Rated effective forward current : 1 A or more (e) Driver for output signals In the driver device, the current of each output signal is monitored, and when an overcurrent is detected, the relevant output is turned off. After an output has been turned off by overcurrent, the overcurrent state is released because the output is off, so the output on state is restored. Therefore, - 376 -

B-82595EN-2/02


CONNECTIONS

in the ground fault or overcurrent state, the output is turned on and off repeatedly. Such a condition is found also when a load with a high surge current is connected. The driver device also includes an overheat detection circuit, which turns off all outputs of the device when the internal temperature of the device has increased as a result of a continued overcurrent state due to a ground fault of an output and so on. The outputs are held off, but their normal states can be restored by turning the power to the controller on and off after the internal temperature of the device has lowered. (f)

Note on use When adding a relay, solenoid, or the like directly to the circuit, connect a diode for counter electromotive voltage protection in parallel to the load.

(g) Applicable signals Output signals of process I/O board CRMA5 and CRMA6 CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT, ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNO1 to SNO8, SNACK, DO1 to DO76 (2) Output signals in peripheral device interface A (Sink type DO) (a) Example of connection Spark killer diode

+24V 0.2A or less

0V (b) Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at connection

:24VDC :30VDC :0.2A :Open collector NPN :1.0V (approx.)

(c) Spark killer diode Rated peak reverse voltage Rated effective forward current

:100V or more :1A or more

(d) Note on use - 377 -


CONNECTIONS

B-82595EN-2/02

Do not use the +24V power supply of the robot. When adding a relay, solenoid, or the like directly to the circuit, connect a diode for counter electromotive voltage protection in parallel to the load. (e) Applicable signals Output signals of process I/O board CRM2 and CRM4 CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT, ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNO1 to SNO8, SNACK, DO1 to DO76 (2) Input signals in peripheral device interface A (a) Example of connection

+24V

ＲＶ 3.3kΩ

+24V ＢＡＩＣＯＭ

(b) Electrical specifications of the receiver Type : Grounded voltage receiver Rated input voltage : Contact close +20V to +28V : Contact open 0V to +4V Maximum applied input voltage : +28VDC Input impedance : 3.3kΩ(approx.) Response time : 5ms to 20ms (d) specifications of the peripheral device contact Rated contact capacity : 30VDC, 50mA or more Input signal width : 200ms or more (on/off) Chattering time : 5ms or less Closed circuit resistance : 100Ω or less Opened circuit resistance : 100kΩ or more

- 378 -


CONNECTIONS

B-82595EN-2/02

(Signal)

TB

TB

(Signal)

TB

Peripheral device contact signal

Robot receiver signal TC

TC

TB TC

; ;

Chattering 5 ms or less 5 to 20 ms

(e) Note on use Apply the +24 V power at the robot to the receiver. However, the above signal specifications must be satisfied at the robot receiver. (f)

Applicable signals Input signals of process I/O board CRM2, CRM4, CRMA5 and CRMA6 *IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET, START, HOME, ENBL, RSR1 to RSR8, PNSTROBE, PROD START, DI1 to DI78

- 379 -


4.7.2

CONNECTIONS

B-82595EN-2/02

End Effector Control Interface (1) Output signals in end effector interface (a) Example of connection Spark killer diode

+24V

0.2A or less

0V (b) Electrical specifications Maximum load current when driver is on: 200 mA (including momentary level) Saturation voltage when driver is on: 1.0 V max. Dielectric strength: 24 V ±20% (including momentary level) Leakage current when driver is off: 100 µA (c) Power supply to output signals The +24 V power supply on the robot side can be used if the total current level, including the current of the welding interface, is 0.7 A or less. (d) Driver for output signals In the driver device, the current of each output signal is monitored, and when an overcurrent is detected, the relevant output is turned off. After an output has been turned off by overcurrent, the overcurrent state is released because the output is off, so the output on state is restored. Therefore, in the ground fault or overcurrent state, the output is turned on and off repeatedly. Such a condition is found also when a load with a high surge current is connected. The driver device also includes an overheat detection circuit, which turns off all outputs of the device when the internal temperature of the device has increased as a result of a continued overcurrent state due to a ground fault of an output and so on. The outputs are held off, but their normal states can be restored by turning the power to the control unit on and off after the internal temperature of the device has lowered. (e) Note on use When adding a relay, solenoid, or the like directly to the circuit, connect a diode for counter electromotive voltage protection in parallel to the load. - 380 -

B-82595EN-2/02

CONNECTIONS

(f)


Applicable signals RO1 to RO8

(2) Input signal in peripheral device interface The input signals are the same as those of other I/O boards. (Refer to Subsection 4.5.1 in CONNECTIONS.) (a) Applicable signals RI1 to RI8, *HBN, *PPABN

- 381 -


4.7.3

CONNECTIONS

B-82595EN-2/02

I/O Signal Specifications for ARC-Welding Interface (1) Digital Output signals specifications for an arc welding interface In case of process I/O CA,EA (a) Example of connection Spark killer diode

+24V 0.2A or less

0V (b) Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at connection

:24VDC :30VDC :0.2A :Open collector NPN :1.0V (approx.)



(d) Note on use Do not use the +24V power supply of the robot. When adding a relay, solenoid, or the like directly to the circuit, connect a diode for counter electromotive voltage protection in parallel to the load. (e) Applicable signals Output signals of process I/O board CRW1 WO1 to WO8

- 382 -

B-82595EN-2/02


CONNECTIONS

In case of process I/O GA,HA (a) Example of connection Spark killer diode

+24V 0.3A or less

0V (b) Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type

:24VDC :30VDC :0.3A :Relay connect output



(d) Note on use Do not use the +24V power supply of the robot. When adding a relay, solenoid, or the like directly to the circuit, connect a diode for counter electromotive voltage protection in parallel to the load. (e) Applicable signals Output signals of process I/O board CRW7 WO1 to WO8 (2) Digital input signals specifications for an arc welding interface The input signals are the same as those of other I/O boards. (Refer to Subsection 4.5.1 in CONNECTIONS.) (a) Applicable signals Input signals of process I/O board CRW1, CRW7 WI1 to WI8

- 383 -


CONNECTIONS

B-82595EN-2/02

(3) Analog output signal specifications for an arc welding interface (Welding voltage command, wire-feed rate command) (a) Example of connection Welder Process I/O CA, EA: -10V to +10V Process I/O GA, HA:

0V to +15V

0V

(b) Note on use Input impedance: 3.3kΩ or more Connect a high-pass filter (2) Analog input signal specifications for an arc welding interface (Welding-voltage detection , welding-current detection) (a)

Example of connection Welder

－10V～＋10V

0V

(b) Note on use Input impedance: 2kΩ The analog input signal should have no ripple for the circuit to operate properly.

- 384 -

B-82595EN-2/02


CONNECTIONS

(Wire deposit detection: WDI+ and WDI-) (a)

Example of connection Welder

+ max. +15V

85mA

‐ Welding electrode

(b) Note on use Connect a resistor of 100Ω or more between the positive and negative electrodes of the welder. Isolate the deposit detection signals for TIG welding from the welding circuit, which uses high-frequency components. The dielectric withstand voltage of this circuit is 80V.

- 385 -


4.8

CONNECTIONS

B-82595EN-2/02

SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS If the customer manufactures cables, make sure they conform to the FANUC standard cables described in this section. (See the description in "Peripheral Device Interface" in this manual for the specifications of the FANUC standard cables.)

4.8.1

Peripheral Device Interface A Cable (CRM2, CRMA5: Tsushin, 50 pins) Honda Tsushin MR50LWF01 (MR50LF)

Honda

Honda Tsushin MR50LM01 (MR50LM) Peripheral device

Process I/O CRMA5*

Honda Tsushin MR50RMA

4.8.2

Honda Tsushin's MR50RF Supplied with an ordered cable

Peripheral Device Interface B Cable (CRM4, CRMA6: Tsushin, 20 pins) Honda Tsushin MR20LWF01 (MR20LF)

Honda Tsushin MR20LM01 (MR20LM) Peripheral Peripheral device device

Process Process I/O I/O CRMA6*

Honda Tsushin MR20RMA

Honda Tsushin's MR20RF Supplied with an ordered cable

- 386 -

Honda

CONNECTIONS

B-82595EN-2/02

4.8.3


ARC Weld Connection Cable (CRW1, CRW7:Honda Tsushin,34pins) Be sure to use our cable to connect the welder.

4.8.4

ARC Weld Connection Cable（CRW10 : Honda Tsushin, 50 pins） Be sure to use our cable to connect the Welder.

ARC Welder Honda Tsushin

MR-50LWMH Process I/O

CRW10

Japan Aviation Electronics Industry Ltd. Honda Tsushin

Japan Aviation Electronics Industry Ltd.

MRH-50RFD

- 387 -

Standard position of guide key


CONNECTIONS

B-82595EN-2/02

4.9

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

4.9.1

Peripheral Device Connection Cable Fig.4.9.1 shows the connection of the peripheral device cable in the cabinet. Process I/O board CRM2B or CRMA5B CRM2A or CRMA5A

CRW1 or CRW7 or CRW10

(A-cabinet)

Shield plate

CRMA5B

CRMA5A

Optional board

Metallic clamp

(B-cabinet)

For noise protection, cut part of the jacket of the peripheral device cable to expose the shield sheath, and fasten this part to the shield plate with the clamp. Fig.4.9.1 Peripheral Device Cable Connection

- 388 -

CONNECTIONS

B-82595EN-2/02

4.9.2


Peripheral Device Cable Connector (1) Fig.4.9.2 shows the connector for peripheral device cables A and B.

Connector specifications

Applicable interface

A

MR50LM MR20LM

CRMA5 CRMA6

67.9 39.3

(D)

73.5 44.9

18 17

Symbol

1 2 3 4 5 Fig.4.9.2 (a)

Remark

Dimensions (B) C

44.8 39.8

Honda Tsushin Kogyo, 50 pins Honda Tsushin Kogyo, 20 pins

Name

Connector cover Cable clamp screw Connector clamp spring Connector clamp screw Connector 50 pins (male) 20 pins (male)

MR50M MR20M

Peripheral device cable connector (Honda Tsushin Kogyo)

- 389 -


CONNECTIONS

B-82595EN-2/02

(2) Peripheral device connector ，

Connector specifications

Applicable interface

MR50RF

(CRM2) (CRMA5) (CRM4) (CRMA6)

MR20RF

61.4

56.4

Honda Tsushin Kogyo, 50 pins

39.3

44.9

Honda Tsushin Kogyo, 20 pins

Symbol

1 2 3 Fig.4.9.2 (b)

Remark

Dimensions A B

Name

Connector clamp screw Screw M2.6 8 Connector (MR50RF) (MR20RF)

Peripheral device connector (Honda Tsushin Kogyo)

- 390 -

B-82595EN-2/02

4.9.3

CONNECTIONS


End Effector Cable Connector (1) Connector external view (For R-2000iB and M-710iC. Refer to the each operators manual for other robots.)

A : M30#1 B : 63.0 C : 54.5 D : 9.6 to 15.0 (Inside diameter) E : #33 F : 11.2 G : 24.7 Manufactured by Fujikura JMLP2524M Fig.4.9.3 (a)

Connector (Elbow Type)

A : M30#1 B : 54.1 C : 37.5 D : 9.6 to 15.0 (Inside diameter) E : #33 F : 11.2 G : 24.7 Manufactured by Fujikura JMLP2524M Fig.4.9.3 (b)

Connector (Straight Type)

- 391 -


4.9.4

CONNECTIONS

B-82595EN-2/02

Recommended Cables (1) Peripheral device connection cable Connect a peripheral device using a completely shielded, heavily protected cable conforming to the specifications in Table 4.9.4 (a). Allow an extra 50 cm for routing the cable in the control unit. The maximum cable length is 30 m. Table 4.9.4 (a)

Recommended Cable (for Peripheral Device Connection) Conductor Effective Electrical characteristics Wire specifications Sheath outside Conductor Number of wires (FANUC thickness Diameter Allowable diameter resistance Configuration specifications) (mm) (mm) current (A) (mm) (Ω/km)

50 20

A66L-0001-0042 A66L-0001-0041

φ1.05 φ1.05

7/0.18 AWG24 7/0.18 AWG24

1.5 1.5

φ12.5 φ10.5

106 106

1.6A 1.6A

(2) End effector connection cable Connect an end effector using a heavily protected cable with a movable wire conforming to the specifications in Table 4.9.4 (b). The cable length is determined so that the cable will not interfere with the end effector and the wrist can move through its full stroke. Table 4.9.4 (b)

Recommended Cable (for End Effector Connection) Conductor Effective Electrical characteristics Wire specifications Sheath outside Conductor Number of wires (FANUC thickness Diameter Allowable diameter resistance Configuration specifications) (mm) (mm) current (A) (mm) (Ω/km)

6 20 24

A66L-0001-0143 A66L-0001-0144 A66L-0001-0459

φ1.1 φ1.1 φ0.58

40/0.08 AWG24 40/0.08 AWG24 40/0.08 AWG24

- 392 -

1.0 1.0 1.0

φ5.3 φ8.6 φ8.3

91 91 93

3.7 2.3 2.3


CONNECTIONS

B-82595EN-2/02

4.10

CONNECTION OF HDI

4.10.1

Connecting HDI The HDI signals are used in combination with special application software. The HDI signals cannot be used as general-purpose DIs.

R-30iA Main board JRL5 1

HDI0

11

2

0V

12

HDI1 0V

3

HDI2

13

HI3

4

0V

14

0V

5

0V

15

HDI5

6

HDI4

16

0V

7

17

HDI6

8

18

0V

9

19

HDI7

10

20

0V

- 393 -


CONNECTIONS

B-82595EN-2/02

Cable connections JRL5 HDI0 0V HDI1 0V HDI2 0V HDI3 0V HDI4 0V HDI5 0V HDI6 0V HDI7 0V

1 2 11 12 3 4 13 14 6 5 or 10 15 16 17 18 19 20 7 8 9 10 Shield

Ground plate Recommended cable connector: PCR-E20FA (Honda Tsushin Kogyo) FI30-20S (Hirose Electric) FCN-247J020-G/E (Fujitsu) 52622-2011 (Molex Japan)

- 394 -

CONNECTIONS

B-82595EN-2/02

4.10.2


Input Signal Rules for the High-speed Skip (HDI)

Circuit configuration

R-30iA liL/liH FILTER

DRIVER

RECEIVER

VH/VL SHIELD

Absolute maximum rating Input voltage range Vin: -3.6 to +10 V Input characteristics Unit

Symbol

High level input voltage Low level input voltage High level input current

VH VL liH

Low level input current Input signal pulse duration Input signal delay or variations

liL

Specification

Unit

3.6 to 7 0 to 1.0 2 max 11 max -8.0 max 20 min

V V mA mA mA ms

0.02(max)

ms

Remark

Vin=5 V Vin = 10 V Vin = 0 V

NOTE 1 The plus (+) sign of IiH/IiL represents the direction of flow into the receiver. The minus (-) sign of IiH/IiL represents the direction of flow out of the receiver. 2 The high-speed skip signal is assumed to be 1 when the input voltage is at the low level and 0 when it is at the high level.

- 395 -


CONNECTIONS

B-82595EN-2/02

4.11

CONNECTING THE COMMUNICATION UNIT

4.11.1

RS-232-C Interface

4.11.1.1 Interface This interface can be connected to a communication unit from FANUC. In case of the length of operation box connection cable that is 10m or longer. RS-232-C port

(A-cabinet)

RS-232-C port

RS-232-C port

(B-cabinet)

- 396 -

B-82595EN-2/02


CONNECTIONS

R-30iA Operator's panel Connector (DBM-25S)

Main board

>

>

<

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

FG SD RD RS CS DR SG

14 15 16 17 18 19 20 21 22 23 24 25

ER

+24V

NOTE 1 +24 V can be used as the power supply for FANUC RS-232-C equipment. 2 Do not connect anything to those pins for which signal names are not indicated.

4.11.1.2 RS-232-C interface signals Generally signals as follows are used in RS-232-C interface. R-30iA Output

SD (Send data)

Input

RD (Receive data) RS (Request to Send)

When CS is not used short CS and RS.

CS (Enable to send) ER (Ready)

DR (Data set ready) SG (Signal ground) FG (Frame ground)

Fig.4.11.1.2 RS-232-C interface

- 397 -

When DR is not used short DR and ER.


CONNECTIONS

B-82595EN-2/02

4.11.1.3 Connection between RS-232-C interface and I/O device The figure below shows a connection with the handshaking of the ER/DR, RS/CS signals.

R-30iA

I/O device side

- 398 -

SD

SD

RD

RD

RS

RS

CS

CS

ER

ER

DR

DR

CD

CD

SG

SG

FG (Frame ground) FG

FG


CONNECTIONS

B-82595EN-2/02

•

The figure below shows a connection without the handshaking of the RS/CS, ER/DR signals.

External device side

R-30iA SD

SD

RD

RD

RS

RS

CS

CS

ER

ER

DR

DR CD

SG

SG

FG (Frame ground) FG

FG

Cable connection R-30iA SD RD RS CS SG ER DR

Cable : twist 10 pairs

Pair each signal with SG.

- 399 -

2

0.18mm , with shield


4.11.2

CONNECTIONS

B-82595EN-2/02

Ethernet Interface CAUTION Before connecting or disconnecting cables to and from the Ethernet board, cut the power supply of R-30iA, and make sure that the power is off. NOTE Please ask each manufacturer about the network construction of network or the condition of using the equipment except the Ethernet board (hub, transceiver, cable etc.). When configuring your network, you must take other sources of electrical noise into consideration to prevent your network from being influenced by electrical noise. Make sure that network wiring is sufficiently separated from power lines and other sources of electrical noise such as motors, and ground each of the devices as necessary. Also, a high and insufficient ground impedance may cause interference during communications. After installing the machine, conduct a communications test before you actually start operating the machine. We cannot ensure operation that is influenced by network trouble caused by a device other than the main board.

- 400 -

B-82595EN-2/02

CONNECTIONS


4.11.2.1 Connection to Ethernet The main board is provided with a 10/100 BASE-T interface. Prepare a hub for connecting the Ethernet board to the Ethernet trunk. The following shows an example of a general connection.

R-30iA

Some devices (hub, transceiver, etc.) that are needed for building a network do not come in a dust-proof construction. Using such devices in an atmosphere where they are subjected to dust or oil mist will interfere with communications or damage the Ethernet board. Be sure to install such devices in a dust-proof cabinet.

- 401 -


CONNECTIONS

B-82595EN-2/02

4.11.2.2 10/100 BASE-T connector (CD38) pin assignments CD38 Pin No.

Signal Name

1 2 3 4 5 6 7 8

TX+ TXRX+

RX-

Description

Send + Send Receive + Not used Not used Receive Not used Not used

4.11.2.3 Cable connection The figure below shows the cable connection between the 10/100 BASE-T connector (CD38) of the main board and hub. Ethernet board

RJ-45 modular connector

MAX.100m

Shielded cable

• •

For details on shielding, see Subsection 4.7.1, "Peripheral Device Connection Cable" in the Part III, “CONNECTIONS”. Keep the total cable length to within 100 m. (FANUC recommends the cable length to within 50 m for movable parts.) Do not extend the cable longer than necessary.

- 402 -

B-82595EN-2/02

CONNECTIONS


(For the A-cabinet)

Use any connector not in use Clamp : A02B-0083-K301 The cable should be fixed on the shield plate.

- 403 -


CONNECTIONS

B-82595EN-2/02

4.11.2.4 Lead materials Unshielded cable (UTP cable) is commercially available as 10/100 BASE-T twisted-pair cable. However, be sure to use shielded Category 5 twisted-pair cable (STP) to improve the resistance to electrical noise in an FA environment. (For details on shielding, see Subsection 4.7.1, "Peripheral Device Connection Cable" in the Part III, “CONNECTIONS”. Recommended Cable (For fixed parts) Manufacturer

Specification

Furukawa Electric Co., Ltd. Nissei Electric Co., Ltd.

DTS5087-4P F-4PFWMF

Inquiries Manufacturer

Contact Address

Furukawa Electric Co., Ltd., Sales Headquarters Remarks Nissei Electric Co., Ltd., Machida Branch

Overseas Sales Office

Remarks

Maru-no-uchi 2-6-1, Chiyoda-ku. Tokyo 100-8322 TEL: 03-3286-3126 4F MS center Bldg., Minami-narise 1-2-2, Machida City, Tokyo 194-0045 TEL: 0427-29-2531 FAX: 0427-29-3375 IWATANI International Corporation Tokyo Head Office 21-8 NISHI-SHINBASHI 3-CHOME, MINATO-KU, TOKYO, 105-8458, JAPAN TEL:03-5405-5810 Telex : 2524256 IWATYO J Cables with connectors at both ends can be supplied.

NOTE The recommended cables cannot be connected to movable portions. Recommended Cable (For movable parts) Manufacturer

Oki Electric Cable Co., Ltd.

Specification

Remarks

AWG26 4P TPMC-C5-F(SB)

FANUC-specific cable

Cable specifications (FANUC-specific cable No connector) Drawing number: A66L-0001-0453 Manufacturer: Oki Electric Cable Co., Ltd. Nagano Sales Office TEL: 0266-27-1597

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CONNECTIONS


Specifications • Electric characteristics: Conform to EIA/TIA 568A categories 3 and 5. For reasons related to attenuation performance, the distance to the hub must be 50 m or shorter. • Structure: Common shield cable (braided shield). Drain wire provided. The conductor is AWG26 annealed copper stranded wire. The sheath thickness is 0.8 mm. The outside diameter is 6.7±0.3 mm. • Flame resistance: UL1581 VW-1 • Oil resistance: Based on the FANUC standard. (equivalent to the conventional oil-resistant electric cables) • Flexing resistance: 1 million times or more with 50 mm of a bend radius (U-shape flexing test) • UL style No.: AWM 20276 (80n/30 V/VW-1)

NOTE Always use connector TM21CP-88P(03) manufactured by Hirose Electric for this cable. Cable assembly Oki Electric Cable Co., Ltd. also supplies cable assemblies using connector TM21CP-88P(03) manufactured by Hirose Electric. Make arrangements directly with the manufacturer for the specifications (length, outgoing inspection, packing, and others) and purchase cable assemblies. Contact point: Oki Electric Cable Co., Ltd. Sales contact point) Nagano Sales Office TEL: 0266-27-1597

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CONNECTIONS

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4.11.2.5 Connector specification As a connector used with a twisted pair cable for Ethernet, an 8-bit modular connector called RJ-45 is used. Use the following connector or equivalent: Specification

Manufacturer

For solid wire For solid wire

5-569530-3 MS8-RSZT-EMC

Tyco Electronics AMP SK KOHKI Co., Ltd.

For twisted wire For twisted wire

5-569552-3 TM11AP-88P

Tyco Electronics AMP Hirose Electric Co., Ltd.

Remarks

Special tool required Special tool required

For movable parts

Specification

Manufacturer

For cable AWG26 4P TPMC-C5-F(SB)

TM21CP-88P(03)

Hirose Electric Co., Ltd.

Remarks

(Note)

NOTE TM21CP-88P(03) Connector (manufacturer standard part) Drawing number: A63L-0001-0823#P Manufacturer: Hirose Electric Co., Ltd. Manufacturer catalog number: TM21CP-88P(03) Conforms to EIA/TIA 568A categories 3 and 5. For how to assemble the connector and cable, contact Hirose Electric. (Hirose Electric technical document "TM21CP-88P(03) Connection Procedure Specifications" (technical specification No. ATAD-E2367) is available.)

4.11.2.6 Cable clamp and shielding Shield the cables as like as other cables are shielded. (See Subsection 4.7.1, "Peripheral Device Connection Cable" in the Part III, “CONNECTIONS”.)

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CONNECTIONS


4.11.2.7 Grounding the network Even if the grounding conditions on the machine are satisfied, electrical noise from the machine sometimes enters the communications line and causes communications interference depending on the installation conditions and the peripheral environment of the machine. To prevent the entry of such electrical noise, separating and insulating the machine from the Ethernet trunk cable and the personal computer effectively reduces the influence of electrical noise. The following figure shows an example of such a connection.

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CONNECTIONS

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Electrically separated by 10/100 BASE-T cable connection

Large-scale Network

Electrically separated by 10/100 BASE-T cable connection

Small-scale Network

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CONNECTIONS


NOTE 1 The ground between the PC/Trunk line side and machine system side must be separated. If it is impossible to separate the ground because there is only one grounding point, connect the ground cable for each system to the grounding point independently. (Refer Fig.4.9.2.7) The resistance for grounding must be less than 100-ohm (Class 3). The thickness of the ground cable is the same as the thickness of AC power cable or more. At least thickness of 5.5mm2 is necessary. 2 Please use the HUB that has unshielded interface connector. FANUC recommends the HCN-7500 (Hitachi-Densen LTD) or equivalent. 3 There is the possibility that noise makes the obstacle of communication even if the ground is separated using the 10/100 BASE-T. In the case of using the Ethernet board under the worst environment, please separate between the PC/Trunk line side and machine system side completely using the 10/100 BASE-FL (Optical fiber media).

Fig.4.11.2.7 Wiring on a single ground point

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5.TRANSPORTATION AND INSTALLATION CONNECTIONS

5

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TRANSPORTATION AND INSTALLATION This chapter describes the transportation and installation for the controller.

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CONNECTIONS 5.TRANSPORTATION AND INSTALLATION

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5.1

TRANSPORTATION The controller is transported by a crane. Attach a strap to eye bolts at the top of the control unit. Crane capacity : Minimum 300kg Sling capacity : Minimum 300kg Eye bolt (M12)

Eye bolt (M12)

(A-cabinet)

(B-cabinet) Fig. 5.1 Transportation

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5.2

INSTALLATION

5.2.1

Installation Method

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Following is the installation method for cabinet. When installing the controller, allow the space for maintenance shown in the following figure.

Munsell

Color

5GY3.5/0.5

Gray

Fig. 5.2.1 (a) External dimension (A-cabinet Rear fan type)

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Munsell

Color

5GY3.5/0.5

Gray

Fig. 5.2.1 (b)

External dimension (A-cabinet Side fan type)

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Body Door Op.panel

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Munsell 5GY3.5/0.5 3.0GY8.2/0.9 N1.5

Fig. 5.2.1 (c) External dimension (B-cabinet)

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Color Gray White Black

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Fig. 5.2.1 (d)

Installtion dimension (A-cabinet)

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100

Controller

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100

Controller

Controller

NOTE Keep this area for maintenance and the radiation of heat. Fig. 5.2.1 (e)

Installtion dimension (B-cabinet)

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Munsell

Color

Body

5GY3.5/0.5

Gray

Door

3.0GY8.2/0.9

White

Fig. 5.2.1 (f) External dimension (A-cabinet operation box)

Body Door

Munsell 5GY3.5/0.5 3.0GY8.2/0.9

Fig. 5.2.1 (g) External dimension (Integrated operation box)

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Color Gray White


5.2.2

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Assemble at Installation

Operation box R-30iA controller Robot connection cable

Teach pendant


Fig.5.2.2 (a) Assemble at installation (A-cabinet)

Integrated operation box Teach pendant


Robot connection cable Fig.5.2.2 (b) Assemble at installation (Integrated operation box)

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Teach pendant

R-30iA controller

Robot connection cable

Peripheral device connection cable Fig.5.2.2 (c) Assemble at installation (B-cabinet)

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5.3

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INSTALLATION CONDITION Item

Model

Rated Voltage

All models

Tolerant fluctuation

All models

Input power source capacity

M-900iA/600 R-2000iB/200T,M-410iB, M-900iA/260L,M-900iA/350 R-2000iB(except /200T) M-420iA /M-421iA,M-710iC F-200iB M-16iB,ARC Mate 120iB M-6iB,ARC Mate 100iB M-430iA/2F M-430iA/2P ARC Mate 100iC, M-10iA M-900iA/600 R-2000iB/200T,M-410iB, M-900iA/260L,M-900iA/350 R-2000iB(except /200T) M-420iA /M-421iA,M-710iC M-6iB, M-16iB ARC Mate100iB ARC Mate120iB, F-200iB M-430iA/2F M-430iA/2P ARC Mate 100iC, M-10iA All models

Average power consumption

Permissible ambient temperature Permissible ambient humidity Surrounding gas

All models

Installation category

All models

Vibration

All models

Altitude Ionized and non-ionized radiation

Common to all models Common to all models

Mass of control unit

A-cabinet

All models

All models (except below models)

M-410iB B-cabinet All models

(except models)

Specification/condition Trans. Type E 380-415, 440-500, 500-575VAC Trans. Type D 380-400, 200-230VAC 50/60Hz 3phases Tolerant voltage fluctuation: +10% -15% Tolerant frequency fluctuation: ±1Hz 18KVA 15KVA 12KVA 5KVA 3KVA 2.5KVA 3.5KVA 3.5KVA 2.0KVA 5KW 3KW 2.5KW 1.0KW

1.0KW 1.0KW 1.0KW 0 to 45ºC during operation, and -20 to 60ºC during shipment and storage with a temperature coefficient of 1.1ºC/min Relative humidity: 30% to 95%, non-condensing An additional protective provision is necessary if the machine is installed in an environment in which there are relatively large amounts of contaminants (dust, dielectric fluid, organic solvent, acid, corrosive gas, and/of salt). Installation category III, Pollution degree 3, IEC60664-1 and IEC61010-1 0.5G or less. When using the robot in a location subject to serious vibration, consult with your FANUC sales representative. Not higher than 1,000m above sea level A shielding provision is necessary if the machine is installed in an environment in which it is exposed to radiation (microwave, ultraviolet rays, laser beams, and/or X-rays). Approx. 120kg

Approx. 140kg Approx. 180kg

below

M-900iA, M-410iB, R-2000iB/200T

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Approx. 200kg

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NOTE The power rating indicated above is sufficient as the continuous rating. However, when the robot is rapidly accelerating, the instantaneous requirement may increase to several times the continuous rating.

5.4

ADJUSTMENT AND CHECKS AT INSTALLATION Adjust the robot according to the following procedure at installation. No.

Description

1 2 3

Visually check the inside and outside of the control unit. Check the screw terminals for proper connection. Check that the connectors and printed circuit boards are firmly connected. Check transformer tap setting. (See II MAINTENANCE section 6.2) The breaker off and connect the input power cable. Check the input power voltage and transformer outputs. Press the EMERGENCY STOP button on the operator panel and turn on the control unit. Check the interface signals between control unit and robot mechanical unit. Check the parameters. If necessary, set them. Release the EMERGENCY STOP button on the operator panel. Turn on the controller. Check the movement along each axis in manual jog mode. Check the end effector interface signals. Check the peripheral device control interface signals.

4 5 6 7 8 9 10 11 12 13

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5.5

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RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION An overtravel and emergency stop occur when the robot is operated for the first time after it is installed and the mechanical and control units are wired. This section describes how to reset the overtravel and emergency stop. Remove the red plate fastening the swiveling axis beforehand. The J2 and J3 axes are pressed against the hard stops at shipment. Therefore, an overtravel alarm occurs when the power is turned on after installation. The robot can also be in an emergency stop state if the peripheral device control interface is not connected.

5.5.1

Peripheral Device Interface Processing Take the following actions if signals *IMSTP, *HOLD, *SFSD, and ENBL are not used.

+24F

RV RV RV RV

5.5.2

CRM2A 49, 50

*IMSTP

1

*HOLD

2

*SFSD

3

ENBL

4

Resetting Overtravel 1) 2) 3)

Select [OT release] on the overtravel release screen to release each robot axis from the overtravel state. Hold down the shift key, and press the alarm release button to reset the alarm condition. Still hold down the shift key, and jog to bring all axes into the movable range.

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5.5.3

How to Disable/Enable HBK 1) 2) 3) 4) 5)

Press [MENUS] on the teach pendant. Select [NEXT]. Select [SYSTEM]. Press "F1" (TYPE) on the teach pendant. Select "Config" to disable/enable HBK.

Status

Hand Broken enable/disable setting

HBK (*1)

HBK detection

Robot operation

Message

1 2 3 4

Enable Enable Disable Disable

CLOSE OPEN CLOSE OPEN

Yes Yes Yes(*2) No

Possible Impossible Possible Possible

None SRVO-006 None At cold start, SRVO-300

NOTE 1 Robot end effector connector CLOSE

OPEN

24V

24V

*HBK

*HBK

2 The moment the HBK circuit is closed, HBK detection becomes enabled. When the HBK circuit is opened again, alarm "Servo 300" or "Servo 302" occurs, causing the robot to stop. 3 If the power is turned off and on again under the condition stated in *2, status 4 is entered, so the alarm condition is removed.

5.5.4

How to Disable/Enable Pneumatic Pressure Alarm (PPABN) 1) 2) 3) 4) 5)

Press [MENUS] on the teach pendant. Select [NEXT]. Select [SYSTEM]. Press "F1" (TYPE) on the teach pendant. Select "Config" to disable/enable PPABN.

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APPENDIX

APPENDIX

A.TOTAL CONNECTION DIAGRAM

RI/RO

TOTAL CONNECTION DIAGRAM

CRMA8

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Fig. A(a) System block diagram (A-cabinet)

VISION

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A

System Block Diagram A-Cabinet

A.TOTAL CONNECTION DIAGRAM APPENDIX

CRMA8

CRMA7

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Fig. A(b) System block diagram (B-cabinet)

VISION

RI/RO

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A2

: B2 A3

: A1

A1

: B1 : A2

A2

: B2 A3

: B3

: B2


: B1

APPENDIX

: B1

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Fig. A(c) AC power line connection diagram (in case of TYPE E transformer / A-cabinet)

A1


: B1 : A2

: A3

: B2

A1

: B1 : A2

A2

: B2 A3 : B1

: B3

: B2

APPENDIX

: A1

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Fig. A(d) AC power line connection diagram (in case of TYPE E transformer / B-cabinet)

: A1

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APPENDIX

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Fig. A (e) AC power line connection diagram (in case of TYPE D linefilter transformer)

CPOH

: B2

: A2

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APPENDIX

Fig. A(f) DC power line connection diagram (A-cabinet)

: A1


: B1

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: B1

: B2

: A2

APPENDIX

RS-232-C

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Fig. A(g) DC power line connection diagram (B-cabinet)

: A1


APPENDIX

CRMA8

Fig. A (h) E-STOP circuit connection diagram

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APPENDIX

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Fig. A(i) Emergency stop board connector table

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CAMDI1

CAMDI0 12V

APPENDIX


Fig. A(j) Main board connector table

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Fig. A(k) Panel board connection diagram

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APPENDIX


Fig. A(l) Panel board connector table

- 439 -


Fig. A(m) Servo amplifier connector table

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APPENDIX


Fig. A(n) Motor power connection (Group1)

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Fig. A(o) Motor power connection (Group2)

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APPENDIX


Fig. A(p) Motor power connection (Group3)

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Fig. A(q) Motor power connection (Group4)

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APPENDIX


Fig. A(r) Motor power connection (Group5)

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Fig. A(s) Motor Power Connection(Group 6)

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APPENDIX


Fig. A(t) Motor Power Connection(Group 7)

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Fig. A(u) Motor Power Connection(Group 8)

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APPENDIX

Fig. A (v) RI/RO connection diagram

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APPENDIX

Fig. A (w) RI/RO Connection Diagram(Group6,Group7)

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APPENDIX

Fig. A (x) RI/RO Connection Diagram(Group8)

There are many type EE connector of mechanical unit. The detail is shown on the mechanical unit manual.

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APPENDIX

Fig. A (y) Pulse coder signal connection diagram

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APPENDIX

Fig.A (z) Pulse coder Signal Connection Diagram(Group5)

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APPENDIX

Fig.A (aa) Pulse coder Signal Connection Diagram(Group6)

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APPENDIX

Fig.A (ab) Pulse coder Signal Connection Diagram(Group7)

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APPENDIX

Fig.A (ac) Pulse coder Signal Connection Diagram(Group8)

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APPENDIX


Fig. A(ad) Mechanical unit interface(Group1, Group2)

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Fig. A(ae) Mechanical unit interface(Group3, Group4)

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APPENDIX


Fig. A(af) Mechanical Unit Interface (Group5,Group6)

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Fig. A(ag) Mechanical Unit Interface (Group7,Group8)

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DI/DO

APPENDIX

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Fig. A(ah) I/O device connection diagram (A-cabinet)

WI / WO


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APPENDIX

Fig. A(ai) I/O device connection diagram (B-cabinet)

DI/DO

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APPENDIX


Fig. A(aj) Process I/O connector table (Process I/O JA, JB)

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Fig. A(ak) Process I/O connector table (Process I/O CA,EA,EB,FA)

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APPENDIX


Fig. A(al) Process I/O connector table (Process I/O KA, KB, KC)

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B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE APPENDIX

B

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SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE

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APPENDIX

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B.1

B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE

SIGNAL The following table lists the I/O signals used for the peripheral device interface in the R-30iA controller. Input signals (Refer to B.3.1) Signal *IMSTP *HOLD *SFSPD CSTOPI FAULT_RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSTROBE PROD_START DI01 DI02

Description Instantaneous stop signal Hold signal Safety speed signal Cycle stop signal Alarm release signal Cycle start signal Robot service request/program number select signal (*1) Enabling signal Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) PNS strobe signal Automatic operation start signal General-purpose input signal General-purpose input signal

DI03 DI04 DI05 DI06 DI07 DI08 DI09 DI10 DI11 DI12 DI13 DI14 DI15 DI16 DI17 DI18 DI19 DI20 DI21 DI22

General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal

*1: RSR :Robot Service Request (RSR5 to RSR8 are optional) PNS :Program Number Select Input (optional) Whether RSR is used or PNS is used can be preset.

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Output signals (Refer to B.3.2) Signal CMDENBL SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK ______

Description Command acceptance enabled signal System ready signal Program run signal Program paused signal Held signal Alarm signal Reference point signal Teach pendant enabled signal Battery alarm signal Operating signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal PNS acknowledge signal Not used (for future expansion)

DO01 DO02 DO03 DO04 DO05 DO06 DO07 DO08 DO09 DO10 DO11 DO12 DO13 DO14 DO15 DO16 DO17 DO18 DO19 DO20

General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal

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B.2

APPENDIX


SETTING COMMON VOLTAGE All process I/O printed boards have a jumper to set the common voltage of input signals to 0 V or 24 V. The system automatically adjusts the polarity by software according to the status of this pin. Therefore, you can operate the system without being concerned about the setting of the common voltage. To ensure safety, the common reference voltage of the following four signals, is remains at +24V. *IMSTP *HOLD *SFSPD CSTOPI

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B.3

I/O Signals

B.3.1

Input Signals

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This section describes the specifications of each input signal. (1) Instantaneous stop signal (input) *IMSTP Effective : At any time Function : Use the normally-closed switch because it is a reverse signal. The system turns off power to the servo unit when the *IMSTP is open (turned off). This signal has the same effect as that of the emergency stop signal, but it is controlled by software. For this reason, use the emergency stop external interface on the emergency stop control board for wiring of the emergency stop signal. Do not use *IMSTP. (2) Alarm release signal (input) FAULT RESET Effective : In the alarm status Function : The FAULT RESET signal releases the alarm status. If the servo unit has been turned off, it also turns on the unit. At the same time, the alarm display on the teach pendant (the top line) is cleared. Description: This signal releases only the alarm status. It does not re-start execution of the program. The robot will keep running if the signal is triggered "ON" during operation. (3) Hold signal (input) *HOLD Effective:At any time Function : Use the normally-closed switch because it is a reverse signal. The *HOLD signal has the same function as the hold button on the teach pendant. It halts the current program and stops the operation of the robot. While this signal is being input, the held signal (output) HELD is turned on and the robot cannot be operated. (4) Start signal (input) START Effective : When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details. Function : This input signal starts the selected program at the falling edge when the signal is turned off after being turned on. Its function differs according to the setting of parameter $SHELL_CFG.$CONT_ONLY. - 470 -

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APPENDIX

-

-


If parameter $SHELL_CFG.$CONT_ONLY is set to DISABLED, the START signal starts the program which has been selected from the teach pendant. By default, the program starts from the current cursor position. If parameter $SHELL_CFG.$CONT_ONLY is set to ENABLED, the START signal only resumes the execution of the temporarily held program. To execute an inactivated program from the start, input the PROD_START signal.

(5) Cycle stop signal (input) CSTOPI Effective : At any time Function : If parameter $SHELL_CFG.$USE_ABORT is set to DISABLED, the CSTOPI signal releases the program from the wait status caused by an RSR. It does not stop the execution of the current program and allows it to continue processing (by default). If parameter $SHELL_CFG.$USE_ABORT is set to ENABLED, the CSTOPI signal immediately cancels the execution of the current program. The program returns to the status in which it was before execution, and the information for the subprogram to return to the main program is lost. At the same time, this signal also releases the program from the wait status caused by RSR. (6) Enabling signal (input) ENBL Effective : At any time Function : If the ENBL signal is turned off, the operation of the robot or the activation of a program is inhibited, and the execution of the current program is suspended. (7) Safety speed signal (input) *SFSPD Effective : At any time Function : - Use the normally-closed switch because it is a reverse signal. Usually this switch should be connected to safety fence. It must be set normally on. Since the *SFSPD signal is counted as a remote condition, such input signals as RSR and START to the peripheral device interface cannot take effect unless this signal is turned on. If this signal is turned from on to off during robot operation, the execution of the current program is suspended. At the same time, the overriding value is switched to a preset value (parameter $SCR. $FENCEOVER.) As long as this signal is off, the overriding value cannot be increased beyond the preset value ($SCR.$SFJOGOVLIM: For jog, $SCR. $SFRUNOVLIM : For test execution.) (8) Robot service request signal (input) RSR1/RSR2/RSR3/RSR4 - 471 -


Effective :

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When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details.

Function : The user can choose between RSR and PNS (optional), although they cannot be used simultaneously. Four input signals, RSR1 to RSR4, are used. If a signal is input to an RSR input, a specified. program is started. The program number can be set by a menu. If another program has already started processing, the newly activated program enters the wait status. As soon as the current program terminates, the waiting program starts processing. By using an RSR instruction, each RSR in a program can be enabled or disabled. A menu is provided to register the program number of a specified program when each RSR is input. (Refer to the application manual for details of the menu).

-

-

When an RSR is input, the program whose program name consists of the specified program number plus a base value is started. For exam ple, if a signal is input to RSR2 when program number 23 is registered in RSR2, the program to be started is the one with the program name calculated from the expression RSR + (RSR2 program number + base number), i.e., RSR0123. The base number is stored in parameter $SHELL_CFG.$JOB_BASE, and can be changed in a program with a parameter instruction. (For example, $SHELL_ CFG. $JOB_BASE =100). In this way, the combination of programs which can be started by RSRs can be changed. Whether the system should output an acknowledge signal to an RSR can be selected from the menu. If so specified, a pulse is output from the signal corresponding to the RSR, one of signals ACK1 to ACK4, when the input of the - 472 -

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APPENDIX

-


RSR is accepted. From the same menu, the width of the pulse can also be specified. It is possible to accept other RSRs while outputting an acknowledge signal. Input of a CSTOPIT signal can clear the program queue waiting for execution after acceptance of RSRs.

(9) PNS/PNSTROBE (input) Signal name : PNS: Program number select PNSTROBE : Strobe input for PNS Effective : When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details. Function : The PNS/PNSTROBE signal selects whether the RSR function is used or the PNS function (optional) is used. If the PNS function is enabled, the RSR function cannot be used. The eight signals PNS1 to PNS8 are used to specify a program at the instant the strobe signal PNSTROBE rises. A menu is provided to specify the information about PNS.

-

-

If a number other than zero is entered to PNS input, a program is selected whose program number is the entered value plus the base number. For example, if the PNS value is 23, the program to be started has the program name calculated from the expression PNS + (entered PNS value + base number), i.e., PNS0123. If zero is entered to PNS input, it is cleared as if no selection has been made. A PNS signal, which can only select a program, cannot execute the selected program. The execution of the selected program can only be started after input of automatic operation start signal PROD_START. For safety, the selected program cannot be changed from the teach pendant unless PNSTROBE is turned off. - 473 -


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B-82595EN-2/02

If a program is selected by PNS, the program number is output to selected program number signal (output) SNO, and a pulse is output to program selection acknowledge signal SNACK. Using these signals, peripheral devices can confirm the correct program has been selected. For the timing of these signals, see the sections describing SNO and SNACK. The following operations are effective for the program selected by PNS. You can: Start up a program by input of automatic operation start signal PROD_START Restart the program that has been suspended. Inputting the START signal restarts the program selected by PNS when $SHELL_CFG.$CONT_ ONLY is set to ENABLED. Input of CSTOPI cancels execution of the pro-grams selected by PNS when $SHELL_CFG.$USE_ ABORT is set to ENABLED.

(10) Automatic operation start signal (input) PROD_START Effective :

Function :

B.3.2

Output Signals

When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details. This input signal executes the selected program at the falling edge when the signal is turned off after being turned on.

This section describes the specifications of output signals for the peripheral device interface. (1) Command acceptance enabled signal (output) CMDENBL Turned on :When the remote conditions are satisfied and the system is not in the alarm status Turned off:When the remote conditions are not satisfied or the system is in the alarm status The remote conditions are satisfied when all of the following are satisfied. The teach pendant is in the DISABLED status. The remote/local setting is set to REMOTE. Parameter $RMT_MASTER is set to 0 (external interface). Signal *SFSPD is set to on, or in the normal status. (2) System ready signal (output) SYSRDY Turned on : When power is applied to the motor of the robot. Turned off: When power is not applied to the motor of the robot. (3) Program run signal (output) PROGRUN Turned on: When the program is being executed. Turned off: When the program is not being executed. - 474 -

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APPENDIX


(4) Held signal (output) HELD This signal is used to check the status of the hold input. Turned on : When the hold button on the teach pendant (or input) is being pressed down (or turned on). Turned off : When the hold button on the teach pendant (or input) is not being pressed down (or is turned off). (5) Program paused signal (output) PAUSED This signal is used together with output signal PROGRUN to determine whether a program can be restarted while it is being held. Turned on: When a program is held and has not been restarted yet. While this signal is on, the program can be restarted and retains information such as that to return from a subprogram to the main program. Turned off: When a program is being executed or is ready to start. If signal PROGRUN is on, the program is being executed. If signal PROGRUN is off, the program has not been executed and can be started from this status. (6) Alarm status signal (output) FAULT Turned on: When the system is in the alarm status (or an alarm which can stop a program execution is detected.) The indicator lamp does not go on in warning. Turned off :When the alarm status is released by an alarm release operation. (7) Reference point signal (output) ATPERCH Turned on: When the robot is in the reference position specified in the parameter. (the reference point No.1 in reference point setup screen.) Turned off: When the robot is not in the reference position specified in the parameter. (the reference point No.1 in reference point setup screen.) Up to three reference positions can be specified, but this signal is output when the robot is in the first reference position. For the other two reference positions, general-purpose signals can be assigned to output as such. (They can be set from the setup screen.) (8) Teach pendant enabled signal (output) TPENBL Turned on: When the teach pendant is enabled. Turned off: When the teach pendant is disabled. (9) Battery alarm signal (output) BATALM Turned on: When the voltage of the battery for the CMOS - 475 -


Turned off:

B-82595EN-2/02

memory backup drops below the reference. When the voltage of the battery for the CMOS memory backup is at the normal level.

(10) Operating signal (output) BUSY Turned on: When a program is being executed or is being processed from operation panels such as the teach pendant. (This has the same function as that of the BUSY lamp on the teach pendant.) Turned off: When a program is not being executed nor is being processed from operation panels such as the teach pendant. (11) RSR acknowledge signals (output) ACK1/ACK2/ACK3/ACK4 These signals are used together with the RSR function. They can be specified to be enabled or disabled from the RSR setup menu. Turned on: When one of the signals from RSR1 to RSR4 is input and accepted. A pulse whose width is specified from the menu is output to acknowledge the signal. Turned off: Normally. Since these signals are always output as pulses, they are normally in the off status. The following chart shows the timing of the RSR input and ACK output.

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B-82595EN-2/02

APPENDIX


* Other RSR signals can be accepted even when the ACK signal is being output. (12)

PNS acknowledge signal (output) SNO/SNACK

These signals are used together with the PNS function. Turned on: Whenever the PNS function is enabled. The selected program number is displayed in binary code (SN01 to SN08) on the teach pendant. If the number cannot be represented as an eight-bit number, it becomes zero. After selecting a program by PNS, a pulse is output from signal SNACK as a part of the PNS operation. The width of the pulse can be specified from the menu. See the timing chart below.

- 477 -


B.4

Specifications of Digital Input/Output

B.4.1

Overview

B-82595EN-2/02

This section describes the external specifications of digital and analog input/output in the R-30iA controller.

B.4.2

Input/Output Hardware Usable in the R-30iA Controller The R-30iA controller can use up to 512 digital input and output points or an equivalent number of analog input and output points. One analog input/output point uses the resources equivalent to those used by 16 digital I/O points. The R-30iA can use a total of up to 512 I/O points. The R-30iA controller can use the following I/O hardware. Process I/O printed circuit board I/O unit model A The process I/O printed circuit board and the I/O unit model A can be used together.

B.4.3

Software Specifications (1) RI/RO These are signals sent to the connector at the wrist of the robot. They cannot be assigned (redefined) and are fixed. The standard format is eight inputs and eight outputs. The number of points that can be used for the connector at the wrist depends on the individual robot. (2) DI/DO The signal No. that is determined at hardware can be changed by software operation. (3) Analog I/O An analog I/O signal can access the analog I/O port (optional) on the process I/O printed circuit board or the I/O port on the analog I/O module (used together with the I/O unit model A). It reads and writes the digital value converted from the analog value of the I/O voltage. It means that the value does not always represent the real I/O voltage. (4) Group I/O Group I/O is a function which can input or output multiple DI/DO signals as binary codes. Any number of continuous signals of up to 16 bits can be set for its use. It can be set in the menu DETAILS on the group I/O screen.

- 478 -

APPENDIX

B-82595EN-2/02

C

C.OPTICAL FIBER CABLE

OPTICAL FIBER CABLE The R-30iA uses fiber optic cables for communication between the main board and servo amplifiers. Observe the following cautions when handling these fiber optic cables. Handle fiber optic cables with utmost care, especially when installing the unit. (1) Protection during storage When the electrical/optical conversion module (mounted on the printed) circuit board and the fiber optic cable are not in use, their mating surfaces must be protected with the lid and caps with which they are supplied. If left uncovered, the mating surfaces are likely to become dirty, possibly resulting in a poor cable connection.

Fig.C (a)

Protection of electrical/optical conversion module and fiber optic cable (when not in use)

(2) Fiber optic cable -

Although the reinforcing cover of the external optical cable has sufficient mechanical strength, be careful not to drop heavy objects on the cable.

- 479 -


APPENDIX

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B-82595EN-2/02

Grasp the optical connector firmly when connecting or disconnecting the cable. Do not pull on the fiber optic cord itself. (The maximum tensile strength between the fiber cord and connector is 2 kg. Applying greater force to the cord is likely to cause the connector to come off, making the cable unusable.) Fiber optic cord diameter:2.2 mm×2 cords Diameter of cable with reinforced cover : 7.6 mm Tensile strength: Cable with reinforced cover :75 kg Fiber optic cord :7 kg per cord Between fiber optic cord and connector : 2 kg Minimum bending radius of fiber optic cord :25 mm Minimum bending radius of cable with reinforced cover :50 mm Bending resistance (cable with reinforced cover) : 10 million bending cycles at room temperature(when the bending radius is 100 mm) Flame resistance: Equivalent to UL VW-1 Operating temperature: -20 to 705C

Fig.C (b)

External dimensions of external optical cable Unit : mm

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After it is connected, the optical connector is automatically locked by the lock levers on its top. To remove the connector, release the lock levers and pull the connector.

-

Although optical connectors cannot be connected in other than the correct orientation, always take note of the connector's orientation before making the connection.

-

Take care to keep both parts of the optical connector (cable side and PCB side) clean. If they become dirty, wipe them with tissue paper or absorbent cotton to remove dirt. The tissue paper or absorbent cotton may be moistened with ethyl alcohol. Do not use any organic solvent other than ethyl alcohol.

-

Fix the reinforcing cover by using a cable clamp, as shown in Fig. C(c), to prevent the weight of the fiber optic cable from being applied directly to the connecting part of the optical connector.

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APPENDIX

B-82595EN-2/02


Fig.C (c) Fixing the cable with a clamp

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Any superfluous portion of the cable might be wound into a loops. Should this prove necessary, make sure the diameter of each loop is at least 150 mm (for an external cable). Winding the cable into smaller loops can produce sharp curves that exceed the specified bend radius limit. Such bending can result in transmission loss, ultimately leading to a communication failure.

-

When using a nylon band (cable tie) as a cable clamp, follow the instructions given below. Also, take care not to apply a bending force to one particular part of the cable when fixing it with a clamp. Failing to clamp the cable correctly might cut or damage it.

External cable : Do not clamp the uncovered portion of the cable with a nylon band. When clamping the cable by the reinforcing cover, the clamping force is not an important factor to consider. However, ensure that the clamping force is as small as possible to ensure that the reinforcing cover is not deformed by the clamping. If possible, the clamping force should be 5kg (111bs) or less.

- 481 -

INDEX

B-82595EN-2/02

INDEX Connection Between the Control Unit and Welder....... 364

Connection Between the Mechanical Unit and End

10/100 BASE-T connector (CD38) pin assignments..... 402

Effector ........................................................................ 374

CONNECTION DIAGRAM BETWEEN

A-CABINET ................................................................. 216

MECHANICAL UNITS ............................................... 281

ADJUSTMENT AND CHECKS AT

CONNECTION OF HDI .............................................. 393

INSTALLATION......................................................... 421

Connection to Ethernet ................................................. 401

ALARM OCCURRENCE SCREEN............................... 39

Connector specification ................................................ 406

ARC Weld Connection Cable (CRW1, CRW7:Honda

Tsushin,34pins) ............................................................. 387

DIGITAL I/O SIGNAL SPECIFICATIONS ................ 376

ARC Weld Connection Cable（CRW10 : Honda

Tsushin, 50 pins） ........................................................ 387

ELECTRICAL CONNECTIONS ................................. 280

Assemble at Installation ................................................ 418

EMERGENCY STOP CONTROL BOARD

(A20B-1008-0740)........................................................ 173

BACKPLANE BOARD ................................................ 174

End Effector Cable Connector ...................................... 391

Battery for Memory Backup (3 VDC) .......................... 269

End Effector Control Interface...................................... 380

BLOCK DIAGRAM ..................................................... 278

Ethernet Interface.......................................................... 400

BLOCK DIAGRAM OF THE POWER SUPPLY ........ 209

EXTERNAL CABLE WIRING DIAGRAM................ 283

EXTERNAL VIEW OF THE CONTROLLER .............. 19

Cable clamp and shielding ............................................ 406

Cable connection........................................................... 402

FUSE-BASED TROUBLESHOOTING....................... 146

CABLE CONNECTION FOR THE PERIPHERAL

DEVICES, END EFFECTORS, AND ARC WELDERS ...................................................................................... 388

GENERAL.................................................................... 277

CHECKING THE POWER SUPPLY UNIT

General Person Safety....................................................... 7

(A16B-2203-0910) ........................................................ 214

Grounding the network ................................................. 407

COMPONENT FUNCTIONS......................................... 32

CONFIGURATION ........................................................ 18

How to Disable/Enable HBK........................................ 423

Connecting HDI ............................................................ 393

How to Disable/Enable Pneumatic Pressure Alarm

Connecting the Auxiliary Axis Brake（CRR65 A/B） 316

(PPABN)....................................................................... 423

Connecting the Auxiliary Axis Over Travel (CRM68) . 317

HOW TO USE THE PLATE TO FIX THE COMPACT

CONNECTING THE COMMUNICATION UNIT ...... 396

FLASH MEMORY CARD ........................................... 272

Connecting the External Emergency Stop..................... 303

Connecting the External Power Supply ON/OFF Switch ........................................................................... 301

I/O Signal Specifications for ARC-Welding Interface.. 382

Connecting the Input Power .......................................... 298

I/O Signals .................................................................... 470

Connecting the Non-Teaching Enabling (NTED)

In Case of A-cabinet ..................................................... 331

Signal (CRM65) ............................................................ 314

In case of B-cabinet ............................................... 329,330

Connecting the Operation Box ...................................... 318

In Case of B-cabinet ..................................................... 332

Connection between RS-232-C interface and I/O

Input Signal Rules for the High-speed Skip (HDI) ....... 395

device ............................................................................ 398

Input Signals ................................................................. 470

i-1

INDEX

B-82595EN-2/02

Input/Output Hardware Usable in the R-30iA

THE REFERENCE POSITION (POSITIONING) ....... 166

Controller ...................................................................... 478

POWER CANNOT BE TURNED ON ........................... 35

INSTALLATION.......................................................... 412

Precautions for Mechanism............................................. 11

INSTALLATION CONDITION................................... 420

Precautions for Mechanisms ........................................... 12

Installation Method ....................................................... 412

Precautions in Operation................................................. 12

Interface ........................................................................ 396

Precautions in Programming...................................... 11,12

INTERFACE FOR END EFFECTOR .......................... 374

PREVENTIVE MAINTENANCE.................................. 33

INTERFACE FOR PERIPHERAL DEVICES ............. 336

PRINTED CIRCUIT BOARDS.................................... 169

INTERFACE FOR WELDER....................................... 364

PROCESS I/O BOARD CA (A16B-2201-0470) .......... 177 PROCESS I/O BOARD EA (A16B-3200-0230) .......... 180

PROCESS I/O BOARD EB (A16B-3200-0231) .......... 183

Lead materials ............................................................... 404

PROCESS I/O BOARD FA (A16B-3200-0420) .......... 185

LED OF SERVO AMPLIFIER ..................................... 206

PROCESS I/O BOARD GA (A16B-2203-0520).......... 187

PROCESS I/O BOARD HA (A16B-2203-0760).......... 189

MAIN BOARD (A16B-3200-0600, -0601) .................. 170

PROCESS I/O BOARD JA (A16B-2204-0010) ........... 192

MANUAL OPERATION IMPOSSIBLE...................... 167

PROCESS I/O BOARD JB (A16B-2204-0011) ........... 194

MASTERING ................................................................. 43

PROCESS I/O BOARD KA (A16B-2204-0050).......... 196 PROCESS I/O BOARD KB（A16B-2204-0051）...... 199

PROCESS I/O BOARD KC（A16B-2204-0052）...... 202

OPTICAL FIBER CABLE............................................ 479

PROCESS I/O BOARD SIGNALS .............................. 333

Output Signals............................................................... 474

Overview....................................................................... 478

Recommended Cables................................................... 392

OVERVIEW ................................................................... 17

REPLACE THE MODE SWITCH ............................... 258

Replacing a Module ...................................................... 251

PANEL BOARD (A20B-2101-0370) ........................... 176

REPLACING A UNIT.................................................. 215


REPLACING BATTERY............................................. 269

(Sink Type DO)............................................................ 351

REPLACING CARDS AND MODULES ON THE MAIN


BOARD ........................................................................ 227

(Source Type DO) ........................................................ 336

Replacing External Air Fan Unit (A-cabinet) ............... 255

Peripheral Device Cable Connector .............................. 389

Replacing External Air Fan Unit and Door Fan (B-cabinet)

Peripheral Device Connection Cable ............................ 388

...................................................................................... 256

Peripheral Device Interface A ....................................... 376

REPLACING FUSES ................................................... 260

Peripheral Device Interface A Cable (CRM2, CRMA5:

Replacing Fuses in the Main board............................... 262

Honda Tsushin, 50 pins)................................................ 386

Replacing Fuses in the Power Unit ............................... 261

Peripheral Device Interface B Cable (CRM4, CRMA6:

Replacing Fuses in the Servo Amplifier ....................... 260

Honda Tsushin, 20 pins)................................................ 386

REPLACING I/O Unit-MODEL A............................... 250

PERIPHERAL DEVICE INTERFACE BLOCK

REPLACING RELAYS................................................ 268

DIAGRAM.................................................................... 322

Replacing Relays on the Panel Board ........................... 268

PERIPHERAL DEVICE INTERFACE

REPLACING SERVO AMPLIFIERS .......................... 243

COMBINATION .......................................................... 331

REPLACING THE AC FAN MOTOR......................... 254

Peripheral Device Interface Processing......................... 422

Replacing the A-cabinet Door....................................... 219

PERIPHERAL DEVICE, ARC WELDING, AND END

Replacing the A-cabinet Louver ................................... 218

EFFECTOR INTERFACES.......................................... 319

Replacing the A-cabinet Rear Panel ............................. 217

POSITION DEVIATION FOUND IN RETURN TO

Replacing the A-cabinet Top Panel .............................. 216

i-2

INDEX

B-82595EN-2/02

Replacing the Backplane Board (Unit) ......................... 221

SPECIFICATIONS OF THE CABLES USED FOR

Replacing the Base Unit of I/O Unit-MODEL A .......... 250

PERIPHERAL DEVICES AND WELDERS ............... 386

REPLACING THE CONTROL SECTION FAN

MOTOR ........................................................................ 253

Teach Pendant Cable .................................................... 297

REPLACING THE E-STOP UNIT............................... 241

TOTAL CONNECTION DIAGRAM........................... 427

Replacing the Fuse on the Panel Board......................... 267

TRANSFORMER ......................................................... 210

Replacing the Fuse on the Process I/O Boards.............. 263

TRANSPORTATION................................................... 411

Replacing the Heat Exchanger and Door Fan Unit

TRANSPORTATION AND INSTALLATION............ 410

(A-cabinet) .................................................................... 254

TROUBLESHOOTING.................................................. 34

Replacing the Panel Board ............................................ 224

TROUBLESHOOTING BASED ON LED

Replacing the Power Unit and Printed-Circuit Boards

INDICATIONS............................................................. 154

on the Backplane Unit.................................................. 222

TROUBLESHOOTING USING THE ERROR CODE .. 45

REPLACING THE PRINTED-CIRCUIT BOARDS.... 220

Replacing the Process I/O Board EA,EB,FA,GA,KA,KB,KC (A-cabinet)........................ 226

WARNING LABEL ....................................................... 13

REPLACING THE REGENERATIVE RESISTOR

When I/O Unit-MODEL A is Used .............................. 329

UNIT ............................................................................. 238

When Process I/O Board CA/HA is Used (B-cabinet).. 325

REPLACING THE TEACH PENDANT and i

When Process I/O Board EA/EB/GA is Used

PENDANT .................................................................... 252

(A-cabinet).................................................................... 322

REPLACING THE TRANSFORMER ......................... 231

When Process I/O Board FA is Used (A-cabinet)......... 324

Resetting Overtravel...................................................... 422

When Process I/O Board JA is Used (B-cabinet).......... 327

RESETTING OVERTRAVEL AND EMERGENCY

When Process I/O Board KA is Used (A-Cabinet) ....... 328

STOP AT INSTALLATION......................................... 422

When Two or more Process I/O Printed Circuit

Robot Connection Cables.............................................. 283

Boards and I/O Unit-MODEL A are Used.................... 330

RS-232-C Interface ....................................................... 396

WORKING PERSON ....................................................... 3

RS-232-C interface signals............................................ 397

WORKING PERSON SAFETY ....................................... 5

Safety During Maintenance............................................. 10 SAFETY OF THE END EFFECTOR ............................. 12 SAFETY OF THE ROBOT MECHANISM ................... 12 Safety of the Teaching Operator .......................................8 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES........................................................................ 11 SAFETY PRECAUTIONS ...............................................3 SAFETY SIGNALS........................................................ 42 SERVO AMPLIFIERS ................................................. 204 SETTING COMMON VOLTAGE ............................... 469 SETTING OF SERVO AMPLIFIER ............................ 207 SETTING THE POWER SUPPLY............................... 208 SIGNAL ........................................................................ 467 Software Specifications................................................. 478 Specifications of Digital Input/Output .......................... 478 SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE................................................................... 466

i-3

Aug, 2007

Mar., 2007

Date

02

01

Edition

Contents

M-430iA, ARC Mate 100iC, M-10iA

Addition of the following models;

Addition of descriptions about Process I/O KA, KB, KC.

Addition of descriptions about Integrated operation box.

Edition

Date

Contents

FANUC Robot series (RIA R15.06-1999 COMPLIANT) R-30iA CONTROLLER MAINTENANCE MANUAL (B-82595EN-2)

Revision Record

Controler Maintenance R30iA.pdf

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