RJ3iB Controller for Europe

FANUC Robotics R-J3iB CONTROLLER FOR EUROPE MAINTENANCE MANUAL

PROJECT DOCUMENTATION

B-81465EN-1/05 ©FANUC, 2003

FANUC Robotics R-J3iB CONTROLLER for Europe Maintenance Manual B-81465EN-1/05

This publication contains proprietary information of FANUC Robotics Europe S.A. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics Europe S.A.

FANUC Robotics Europe S.A. Zone Industrielle 6466 Echternach Luxemburg Phone: +(352) 72 7777-1 Fax: +(352) 72 7777-403 website: www.fanucrobotics.lu

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The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. FANUC Robotics Europe S.A., 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.

Copyright ©2003 by FANUC Robotics Europe S.A. All Rights Reserved The information illustrated or contained herein is not to be reproduced, copied, translated into another language, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics.

Conventions Used in this Manual 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 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.

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TABLE OF CONTENTS

B-81465EN-1/05

PREFACE .............................................................................................................. 13 1 SAFETY PRECAUTIONS ................................................................................ 15 1.1 OPERATOR SAFETY ................................................................................................. 15

1.1.1 Operator Safety ...................................................................................................................17 1.1.2 Safety of the Teach Pendant Operator ................................................................................18 1.1.3 Safety During Maintenance ................................................................................................20

1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES ...................................... 21 1.2.1 Precautions in Programming ..............................................................................................21 1.2.2 Precautions for Mechanism ................................................................................................21

1.3 SAFETY OF THE ROBOT MECHANISM ................................................................ 22 1.3.1 Precautions in Operation ....................................................................................................22 1.3.2 Precautions in Programming ..............................................................................................22 1.3.3 Precautions for Mechanisms ...............................................................................................22

1.4 SAFETY OF THE END EFFECTOR .......................................................................... 23 1.4.1 Precautions in Programming ..............................................................................................23

1.5 SAFETY IN MAINTENANCE .................................................................................... 24 1.6 WARNING LABEL ..................................................................................................... 25

I. MAINTENANCE 1 OVERVIEW ....................................................................................................... 27 2 CONFIGURATION ........................................................................................... 29 2.1 EXTERNAL VIEW OF THE CONTROLLER ........................................................... 29 2.2 COMPONENT FUNCTIONS ...................................................................................... 38 2.3 PREVENTIVE MAINTENANCE ............................................................................... 40

3 TROUBLESHOOTING ..................................................................................... 41 3.1 3.2 3.3 3.4 3.5

POWER CANNOT BE TURNED ON ........................................................................ 41 ALARM OCCURRENCE SCREEN ............................................................................ 45 SAFETY SIGNALS ..................................................................................................... 48 MASTERING ............................................................................................................... 50 TROUBLESHOOTING USING THE ERROR CODE ............................................... 53

3.5.1 SRVO-001 Operator panel E-stop ......................................................................................53 3.5.2 SRVO-002 Teach pendant E-stop ......................................................................................56 3.5.3 SRVO-003 Deadman switch released ................................................................................57 3.5.4 SRVO-004 Fence open .......................................................................................................58 3.5.5 SRVO-005 Robot overtravel ..............................................................................................61 3.5.6 SRVO-006 Hand broken ....................................................................................................63 3.5.7 SRVO-007 External E-stop ................................................................................................65 3.5.8 SRVO-009 Pneumatic pressure alarm ................................................................................69 3.5.9 SRVO-014 Fan motor abnormal ........................................................................................70 3.5.10 SRVO-015 SYSTEM OVER HEAT (Group : i Axis : j) ................................................71 3.5.11 SRVO-018 Brake abnormal .............................................................................................73 3.5.12 SRVO-021 SRDY off (Group : i Axis : j) .......................................................................74 3.5.13 SRVO-022 SRDY on (Group : i Axis : j) ........................................................................76 -5-

TABLE OF CONTENTS

B-81465EN-1/05

3.5.14 3.5.15 3.5.16 3.5.17 3.5.18 3.5.19 3.5.20 3.5.21 3.5.22 3.5.23 3.5.24 3.5.25 3.5.26 3.5.27 3.5.28 3.5.29 3.5.30 3.5.31 3.5.32 3.5.33 3.5.34 3.5.35 3.5.36 3.5.37 3.5.38 3.5.39 3.5.40 3.5.41 3.5.42 3.5.43 3.5.44 3.5.45 3.5.46 3.5.47 3.5.48 3.5.49 3.5.50 3.5.51 3.8.52 3.5.53 3.5.54 3.5.55 3.5.56 3.5.57 3.5.58 3.5.59 3.5.60 3.5.61 3.5.62 3.5.63 3.5.64 3.5.65

SRVO-023 Stop error excess (Group : i Axis : j) ........................................................... 77 SRVO-024 Move error excess (Group : i Axis : j) ......................................................... 79 SRVO-027 Robot not mastered (Group : i) ..................................................................... 79 SRVO-033 Robot not calibrated (Group : i) .................................................................... 79 SRVO-034 Ref pos not set (Group : i) ............................................................................ 79 SRVO-035 WARN2 Joint speed limit (Group : i Axis : j) ............................................. 79 SRVO-036 Inpos time over (Group : i Axis : j) ............................................................. 79 SRVO-037 Imstp input (Group : i) .................................................................................. 80 SRVO-038 Pulse mismatch (Group : i Axis : j) ............................................................. 80 SRVO-042 MCAL alarm (Group : i Axis : j) ................................................................ 81 SRVO-043 DCAL alarm (Group : i Axis : j) ................................................................. 82 SRVO-044 HVAL alarm (Group : i Axis : j) ................................................................. 85 SRVO-045 HCAL alarm (Group : i Axis : j) ................................................................. 86 SRVO-046 OVC alarm (Group : i Axis : j) .................................................................... 87 SRVO-047 LVAL alarm (Group : i Axis : j) .................................................................. 91 SRVO-049 OHAL1 alarm (Group : i Axis : j) ............................................................... 92 SRVO-050 CLALM alarm (Group : i Axis : j) .............................................................. 94 SRVO-051 CUER alarm (Group : i Axis : j) .................................................................. 95 SRVO-054 DSM Memory Error ..................................................................................... 96 SRVO-055 FSSB com error 1 (Group : i Axis : j) .......................................................... 97 SRVO-056 FSSB com error 2 (Group : i Axis : j) .......................................................... 98 SRVO-057 FSSB disconnect (Group : i Axis : j) ............................................................ 98 SRVO-058 FSSB init error (Group : i Axis : j) ............................................................. 100 SRVO-059 Servo amp init error .................................................................................... 102 SRVO-060 FATL FSSN init error ................................................................................. 103 SRVO-062 BZAL alarm (Group : i Axis : j) ................................................................ 103 SRVO-064 PHAL alarm (Group : i Axis : j) ................................................................ 103 SRVO-065 BLAL alarm (Group : i Axis : j) ................................................................ 104 SRVO-067 OHAL2 alarm (Group : i Axis : j) ............................................................. 104 SRVO-068 DTERR alarm (Group : i Axis : j) ............................................................. 104 SRVO-069 CRCERR alarm (Group : i Axis : j) ........................................................... 104 SRVO-070 STBERR alarm (Group : i Axis : j) ........................................................... 105 SRVO-071 SPHAL alarm (Group : i Axis : j) .............................................................. 106 SRVO-072 PMAL alarm (Group : i Axis : j) ............................................................... 106 SRVO-073 CMAL alarm (Group : i Axis : j) ............................................................... 106 SRVO-074 LDAL alarm (Group : i Axis : j) ................................................................ 106 SRVO-075 Pulse not established (Group : i Axis : j) ................................................... 106 SRVO-076 Tip Stick Detection (Group : i Axis : j) ..................................................... 107 SRVO-081 EROFL alarm (Track enc : i) ...................................................................... 108 SRVO-082 DAL alarm (Track ebc : i) .......................................................................... 109 SRVO-084 BZAL alarm (Track enc : i) ........................................................................ 109 SRVO-087 BLAL alarm (Track enc : i) ........................................................................ 109 SRVO-089 OHAL2 alarm (Track enc : i) ..................................................................... 109 SRVO-091 CRCERR alarm (Track enc : i) ................................................................... 110 SRVO-092 STBERR alarm (Track enc : i) ................................................................... 110 SRVO-093 SPMAL alarm (Track enc : i) ..................................................................... 110 SRVO-094 PMAL alarm (Track enc : i) ....................................................................... 111 SRVO-095 CMAL alarm (Track enc : i) ....................................................................... 111 SRVO-096 LDAL alarm (Track enc : i) ........................................................................ 111 SRVO-097 Pulse not established (enc : i) ..................................................................... 111 SRVO-105 Door open or E-stop .................................................................................... 112 SRVO-136 DCLVAL alarm (Group : i Axis : j) .......................................................... 114 -6-

TABLE OF CONTENTS

3.5.66 3.5.67 3.5.68 3.5.69 3.5.70 3.5.71 3.5.72 3.5.73 3.5.74 3.5.75 3.5.76 3.5.77 3.5.78 3.5.79 3.5.80 3.5.81

3.5.82

3.5.83

3.5.84

3.5.85

3.5.86

3.5.87

3.5.88 3.5.89 3.5.90 3.5.91

B-81465EN-1/05

SRVO-138 SDAL alarm (Group : i Axis : j) .................................................................116 SRVO-153 CHGAL(CNV) alarm (Group : i Axis : j) ..................................................116 SRVO-156 IPMAL alarm (Group : i Axis : j) ...............................................................117 SRVO-194 Servo disconnect ..........................................................................................118 SRVO-199 Control Stop .................................................................................................120 SRVO-201 Panel E-stop or SVEMG abnormal .............................................................121 SRVO-202 TP E-stop or SVEMG abnormal ..................................................................123 SRVO-204 External (SVEMG abnormal) E-STOP .......................................................125 SRVO-205 SVAL1 Fence open (SVEMG abnormal) ....................................................128 SRVO-206 Deadman switch (SVEMG abnormal) .........................................................131 SRVO-213 Fuse blown (Panel PCB) .............................................................................133 SRVO-214 Fuse blown (Amp) ....................................................................................... 137 SRVO-216 OVC (total) (Robot : i) ................................................................................138 SRVO-221 Lack of DSP (Group : i Axis : j) .................................................................138 SRVO-230 SVAL1 Chain 1 (+24V) abnormal SRVO-231 SVAL1 Chain 2 (0V) abnormal .................................................................. 139 SRVO-230 Chain 1 (+24V) abnormal with SRVO-001 Operator ´s panel E-stop SRVO-231 Chain 2 (0V) abnormal with SRVO-001 Operator´s panel E-stop ...............................................................................141 SRVO-230 Chain 1 (+24V) abnormal with SRVO-002 Teach pendant E-stop SRVO-231 Chain 2 (0V) abnormal with SRVO-002 Teach pendant E-stop ..................................................................................143 SRVO-230 Chain 1 (+24V) abnormal with SRVO-003 Deadman switch released SRVO-231 Chain 2 (0V) abnormal with SRVO-003 Deadman switch released ............................................................................ 145 SRVO-240 Chain1 (FENCE) abnormal with SRVO-230 Chain1 (+24V) abnormal and SRVO-004 Fence open SRVO-241 Chain2 (FENCE) abnormal with SRVO-231 Chain2 (0V) abnormal and SRVO-004 Fence open ...................................................................................................147 SRVO-242 Chain1 (EXEMG) abnormal with SRVO-230 Chain 1 (+24V) abnormal and SRVO-007 External emergency stops SRVO-243 Chain 2 (EXEMG) abnormal with SRVO-231 Chain 2 (0V) abnormal and SRVO-007 External emergency stops............................................................................ 150 SRVO-230 Chain 1 (+24V) abnormal with SRVO-232 NTED input SRVO-231 Chain 2 (0V) abnormal with SRVO-232 NTED input .................................................................................................153 SRVO-230 Chain 1 (+24V) abnormal with SRVO-233 TP disabled in T1, T2/Door open SRVO-231 Chain 2 (0V) abnormal with SRVO-233 TP disabled in T1, T2/Door open ................................................................157 SRVO-232 NTED input .................................................................................................160 SRVO-233 TP disabled in T1, T2/Door open .................................................................162 SRVO-235 Short term Chain abnormal .........................................................................164 SRVO-236 Chain failure is repaired ..............................................................................165 -7-

TABLE OF CONTENTS

B-81465EN-1/05

3.5.92 3.5.93 3.5.94 3.5.95

SRVO-237 Not reset chain failure ................................................................................. 165 SRVO-240 Chain 1 (FENCE) abnormal ....................................................................... 165 SRVO-241 Chain 2 (FENCE) abnormal ....................................................................... 165 SRVO-242 Chain 1 (EXEMG) abnormal SRVO-243 Chain 2 (EXEMG) abnormal ..................................................................... 169 3.5.96 SRVO-260 Chain 1 (NTED) abnormal SRVO-261 Chain 2 (NTED) abnormal ......................................................................... 172 3.5.97 SRVO-262 Chain 1 (SVDCT) abnormal SRVO-263 Chain 2 (SVDCT) abnormal ....................................................................... 175 3.5.98 SRVO-264 "E.STOP circuit abnormal 1" ...................................................................... 178 3.5.99 SRVO-265 E.STOP circuit abnormal 2 ......................................................................... 180 3.5.100 SRVO-266 FENCE1 status abnormal SRVO-267 FENCE2 status abnormal ......................................................................... 182 3.5.101 SRVO-268 SVOFF1 status abnormal SRVO-269 SVOFF2 status abnormal .......................................................................... 182 3.5.102 SRVO-270 EXEMG1 status abnormal SRVO-271 EXEMG2 status abnormal........................................................................ 183 3.5.103 SRVO-272 SVDISC1 status abnormal SRVO-273 SVDISC2 status abnormal ........................................................................ 183 3.5.104 SRVO-274 NTED1 status abnormal SRVO-275 NTED2 status abnormal ........................................................................... 184 3.5.105 SRVO-280 SVOFF input ............................................................................................. 184 3.5.106 SRVO-281 SVOFF input (SVEMG abnormal) ........................................................... 187 3.5.107 SRVO-282 Chain1 (SVOFF) abnormal SRVO-283 Chain2 (SVOFF) abnormal ....................................................................... 190 3.5.108 SRVO-282 Chain1 (SVOFF) abnormal with SRVO-230 Chain 1 (+24V) abnormal and SRVO-280 SVOFF input SRVO-283 Chain2 (SVOFF) abnormal with SRVO-231 Chain 2 (0V) abnormal and SRVO-280 SVOFF input ............................................................................................. 193 3.5.109 SRVO-291 "IPM over heat (Group : i Axis : j)" ........................................................ 196 3.5.110 SRVO-292 EXT FAN alarm (Group : i A : j) ............................................................ 196 3.5.111 SRVO-293 DClink (PSM) HCAL (Group : i Axis : j) ............................................... 196 3.5.112 SRVO-294 EXT FAN (PSM) alarm (Group : i Axis : j) ............................................ 196 3.5.113 SRVO-295 PSM COM alarm (Group : i Axis : j) ...................................................... 196 3.5.114 SRVO-296 PSM DISCHG alarm (Group : i Axis : j) ................................................ 197 3.5.115 SRVO-297 PSM Low Volt alarm (Group : i Axis : j) ................................................ 197 3.5.116 SRVO-300 Hand broken/HBK disabled SRVO-302 Set Hand broken to ENABLE ................................................................... 197

3.6 FUSED-BASED TROUBLESHOOTING ..................................................................199 3.7 TROUBLESHOOTING BASED ON LED INDICATIONS .....................................211 3.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) ............................................................226 3.9 VIBRATION OBSERVED DURING MOVEMENT ................................................ 226 3.10 MANUAL OPERATION IMPOSSIBLE .................................................................227

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TABLE OF CONTENTS

B-81465EN-1/05

4 PRINTED CIRCUIT BOARDS ....................................................................... 229 4.1 MAIN BOARD (A16B-3200-0412, -0413) ............................................................... 230 4.2 EMERGENCY STOP CONTROL BOARD (A20B-1007-0800) .............................. 235 4.3 BACKPLANE BOARD ............................................................................................. 236 4.4 PANEL BOARD (A20B-2100-0770) ........................................................................ 238 4.5 PANEL BOARD (A20B-2100-0771) ........................................................................ 240 4.6 PROCESS I/O BOARD CA (A16B-2201-0470) ....................................................... 241 4.7 PROCESS I/O BOARD CB (A16B-2201-0472) ....................................................... 245 4.8 PROCESS I/O BOARD DA (A16B-2201-0480) ....................................................... 247 4.9 PROCESS I/O BOARD EA (A16B-3200-0230) ....................................................... 250 4.10 PROCESS I/O BOARD EB (A16B-3200-0231)...................................................... 255 4.11 PROCESS I/O BOARD FA (A16B-2203-0420)...................................................... 257 4.12 PROCESS I/O BOARD GA (A16B-2203-0520)..................................................... 260 4.13 PROCESS I/O BOARD HA (A16B-2203-0760)..................................................... 263 4.14 PANEL SWITCH BOARD (A20B-1007-0850) ...................................................... 266

5 SERVO AMPLIFIERS .................................................................................... 267 5.1 LED OF SERVO AMPLIFIER .................................................................................. 269 5.2 SETTING OF SERVO AMPLIFIER ......................................................................... 271 5.3 DRIVER IC FOR ROBOT DI/DO 272

6 SETTING THE POWER SUPPLY .................................................................. 273

6.1 BLOCK DIAGRAM OF THE MAIN POWER INCLUDING POWER SUPPLY..................................................................................................... 273 6.2 SELECTING TRANSFORMER TAPS ...................................................................... 276 6.3 CHECKING THE POWER SUPPLY UNIT (A16B-2203-0370) ............................. 281

7 REPLACING A UNIT ..................................................................................... 285

7.1 A-CABINET ............................................................................................................... 285 7.1.1 7.1.2 7.1.3 7.1.4

Replacing the A-cabinet Top Panel ..................................................................................285 Replacing the A-cabinet Rear Panel .................................................................................286 Replacing the A-cabinet Louver .......................................................................................287 Replacing the A-cabinet Door ..........................................................................................288

7.2 REPLACING THE PRINTED-CIRCUIT BOARDS ................................................. 288 7.2.1 Replacing the Backplane Board (Unit) .............................................................................289 7.2.2 Replacing the Power Unit and Printed-Circuit Boards on the Backplane Unit .................................................................................................................290 7.2.3 Replacing the Process I/O Board EA, EB, FA,GA (A-cabinet) .......................................292 7.2.4 Replacing the Panel Board ...............................................................................................293

7.3 7.4 7.5 7.6 7.7 7.8

REPLACING CARDS AND MODULES ON THE MAIN BOARD ....................... 295 REPLACING THE TRANSFORMER ...................................................................... 301 REPLACING THE REGENERATIVE RESISTOR UNIT ....................................... 308 REPLACING THE E-STOP UNIT ............................................................................ 311 REPLACING THE POWER DISTRIBUTING UNIT .............................................. 313 REPLACING SERVO AMPLIFIERS ....................................................................... 314

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TABLE OF CONTENTS

B-81465EN-1/05

7.9 REPLACING I/O UNIT MODEL A ..........................................................................323 7.9.1 Replacing the Base Unit of I/O Unit Model A ................................................................ 323 7.9.2 Replacing a Module ......................................................................................................... 324

7.10 REPLACING THE TEACH PENDANT ..................................................................325 7.11 REPLACING THE CONTROL SECTION FAN MOTOR .....................................327 7.12 REPLACING THE AC FAN MOTOR .....................................................................328 7.12.1 Replacing the Heat Exchanger and Door Fan Unit (A-cabinet) .................................... 328 7.12.2 Replacing the Rear Fan Unit (A-cabinet) ...................................................................... 330 7.12.3 Replacing External Air Fan Unit and Door Fan (B-cabinet) ......................................... 331

7.13 REPLACING THE OPERATOR´S PANEL AND PANEL SWITCH BOARD .....333 7.14 REPLACE THE MODE SWITCH ...........................................................................336 7.15 REPLACING FUSES ...............................................................................................337 7.15.1 7.15.2 7.15.3 7.15.4 7.15.5

Replacing Fuses in the Servo Amplifier ........................................................................ 337 Replacing Fuses in the Power Unit ................................................................................ 338 Replacing the Fuse on the Process I/O Boards .............................................................. 339 Replacing the Fuse on the Panel Board ......................................................................... 343 Replacing the Fuses of the Power Distributing Unit ..................................................... 344

7.16 REPLACING RELAYS ..............................................................................................45 7.16.1 Replacing Relays on the Panel Board ............................................................................ 345

7.17 REPLACING BATTERY .........................................................................................346 7.17.1 Battery for Memory Backup (3 VDC) ........................................................................... 346

II.

CONNECTION

1 GENERAL ........................................................................................................ 349 2 BLOCK DIAGRAM ......................................................................................... 351 3 ELECTRICAL CONNECTIONS ..................................................................... 355

3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS ..........................355 3.2 EXTERNAL CABLE WIRING DIAGRAM ..............................................................358 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9

Robot Connection Cables ................................................................................................ 358 Teach Pendant Cable ....................................................................................................... 365 Connecting the Input Power ............................................................................................ 366 Connecting the External Power Supply ON/OFF Switch ................................................ 368 Connecting the External Emergency Stop ....................................................................... 371 Connecting the Operation Box ........................................................................................ 383 Connecting the NTED Signal (CRM65) .......................................................................... 386 Connecting the Auxiliary Axis Brake (CRR65 A/B) ...................................................... 387 Connecting the Auxiliary Axis Over Travel (CRM68) ................................................... 388

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TABLE OF CONTENTS

B-81465EN-1/05

4 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES .................................................................. 389 4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM ................................... 392 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5

When Process I/O Board EA/EB/GA is used (A-cabinet) ...............................................392 When Process I/O Board FA is Used (A-cabinet) ............................................................394 When Process I/O Board CA/CB/HA is Used (B-cabinet) ..............................................395 When Process I/O Board DA is Used (B-cabinet) ...........................................................397 When I/O Unit-MODEL A is Used ..................................................................................399

4.1.5.1 In case of B-cabinet ................................................................................................................ 399

4.1.6 When Two or more Process I/O Boards and I/O Unit-Model A are Used .......................400

4.2 PERIPHERAL DEVICE INTERFACE COMBINATION ........................................ 401 4.2.1 In Case of A-cabinet .........................................................................................................401 4.2.2 In Case of B-cabinet .........................................................................................................401

4.3 PROCESS I/O BOARD SIGNALS ............................................................................ 403 4.4 INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS ..................................................................... 409 4.4.1 Peripheral Device and Control Unit Connection ..............................................................409 4.4.2 Connection Between the Mechanical Unit and End Effector ...........................................429 4.4.3 Connection Between the Control Unit and Welder ..........................................................432

4.5 DIGITAL I/O SIGNAL SPECIFICATIONS ............................................................. 443 4.5.1 Peripheral Device Interface ..............................................................................................443 4.5.2 End Effector Control Interface .........................................................................................446 4.5.3 I/O Signal Specifications for ARC-Welding Interface .....................................................448

4.6 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS ........................................................... 453 4.6.1 Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins) ........................453 4.6.2 Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins) ........................454 4.6.3 ARC Weld Connection Cable (CRW1, CRW7: Honda Tsushin, 34 pins) ......................454

4.7 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS, AND ARC WELDERS ........................................................... 455 4.7.1 4.7.2 4.7.3 4.7.4

Peripheral Device Connection Cable ................................................................................455 Peripheral Device Cable Connector .................................................................................456 End Effector Cable Connector ..........................................................................................459 Recommended Cables ......................................................................................................460

4.8 CONNECTION OF HDI ............................................................................................ 461 4.8.1 Connecting HDI ................................................................................................................461 4.8.2 Input Signal Rules for the High-speed Skip (HDI) ..........................................................464

4.9 CONNECTING THE COMMUNICATION UNIT ................................................... 465 4.9.1 RS-232-C Interface ...........................................................................................................465 4.9.1.1 Interface .................................................................................................................................. 465 4.9.1.2 RS-232-C Interface signals..................................................................................................... 467 4.9.1.3 Connection between RS-232-C interface and external device ............................................... 468

4.9.2 Ethernet Interface .............................................................................................................471 4.9.2.1 4.9.2.2 4.9.2.3 4.9.2.4 4.9.2.5 4.9.2.5 4.9.2.6 4.9.2.7

Connection to ethernet ............................................................................................................ 472 10/100 BASE-T connector (CD38) pin assignments .............................................................. 473 Cable connection ..................................................................................................................... 473 Lead materials ......................................................................................................................... 475 Connector specification .......................................................................................................... 476 Cable clamp and shielding ...................................................................................................... 478 Cable clamp and shielding ...................................................................................................... 478 Grounding the network ........................................................................................................... 478 -11-

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B-81465EN-1/05

5 TRANSPORTATION AND INSTALLATION .............................................. 481

5.1 TRANSPORTATION .................................................................................................481 5.2 INSTALLATION ........................................................................................................482 5.2.1 Installation Method .......................................................................................................... 482 5.2.2 Assemble at Installation ................................................................................................... 487

5.3 INSTALLATION CONDITION ................................................................................491 5.4 ADJUSTMENT AND CHECKS AT INSTALLATION ............................................493 5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION .494 5.5.1 5.5.2 5.5.3 5.5.4

Peripheral Device Interface Processing ........................................................................... 494 Resetting Overtravel ........................................................................................................ 494 How to Disable/Enable HBK ........................................................................................... 495 How to Disable/Enable Pneumatic Pressure Alarm (PPABN) ........................................ 496

III. APPENDIX A TOTAL CONNECTION DIAGRAM ............................................................. 497 B SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE .................... 527

B.1 SIGNALS ...................................................................................................................527 B.2 SETTING COMMON VOLTAGE ............................................................................530 B.3 I/O SIGNALS .............................................................................................................531 B.3.1 Input Signals ................................................................................................................... 531 B.3.2 Output Signals ................................................................................................................. 537

B.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT ..............................................541 B.4.1 Overview ......................................................................................................................... 541 B.4.2 Input/Output Hardware Usable In the R-j3iB Controller ................................................ 541 B.4.3 Software Specifications ................................................................................................... 541

C POWER DISTRIBUTATION CIRCUIT DIAGRAM .................................... 543 D OPTICAL FIBER CABLE .............................................................................. 551 E CARD INTERFACE ........................................................................................ 555

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PREFACE

B-81465EN-1/05

PREFACE This manual describes the following models (R-J3iB controller). Model

Abbreviation

FANUC Robot R- 2000iA/165F

R-2000iA/165F

R-2000iA

FANUC Robot R- 2000i /200F

R-2000iA/200F

R-2000iA

FANUC Robot R-2000iA/200FO

R-2000iA/200FO

R-2000iA

FANUC Robot R-2000iA/165EA

R-2000iA/165EA

R-2000iA

FANUC Robot R-2000iA/165EW

R-2000iA/165EW

R-2000iA

FANUC Robot R- 2000i /165R

R-2000iA/165R

R-2000iA

FANUC Robot R- 2000i /200R

R-2000iA/200R

R-2000iA

FANUC Robot R- 2000i /125L

R-2000iA/125L

R-2000iA

FANUC Robot R- 2000i /165CF

R-2000iA/165CF

R-2000iA

FANUC Robot R-2000iA/200T

R-2000iA/200T

R-2000iA

FANUC Robot M-6iB

M-6iB

M-6iB

FANUC Robot M-6iB/6C

M-6iB/6C

M-6iB

FANUC Robot M-16iB/20

M-16iB/20

M-16iB

FANUC Robot M-16iB/10L

M-16iB/10L

M-16iB

FANUC Robot M-16iB/20T

M-16iB/20T

M-16iB

FANUC Robot M-16iB/10LT

M-16iB/10LT

M-16iB

FANUC Robot ARC Mate 100iB

ARC Mate 100iB

ARC Mate 120iB

FANUC Robot ARC Mate 120iB

ARC Mate 120iB

ARC Mate 120iB

FANUC Robot ARC Mate 120iB/10L

ARC Mate 120iB/10L

ARC Mate 120iB

FANUC Robot ARC Mate 120iB/20T

ARC Mate 120iB/20T

ARC Mate 120iB

FANUC Robot ARC Mate 120iB/10LT

ARC Mate 120iB/10LT

ARC Mate 120iB


M-710iB/45

M-710iB

FANUC Robot M-710iB/45E

M-710iB/45E

M-710iB


M-710iB/45T

M-710iB


M-710iB/70

M-710iB


M-710iB/70T

M-710iB


M-410iB/160

M-410iB


M-410iB/300

M-410iB

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PREFACE

B-81465EN-1/05

Model

Abbreviation


M-410iB/450

M-410iB

FANUC Robot M-420iA

M-420iA

M-420iA

FANUC Robot M-421iA

M-421iA

M-421iA

FANUC Robot F-200iB

F-200iB

F-200iB

FANUC Robot S-500iB

S-500iB

S-500iB

FANUC Robot S-900iB/400

S-900iB/400

S-900iB

FANUC Robot S-900iB/200

S-900iB/200

S-900iB

FANUC Robot S-900iB/220L

S-900iB/220L

S-900iB

FANUC Robot LR Mate 200iB

LR Mate 200iB

LR Mate 200iB

FANUC Robot LR Mate 200iB/3L

LR Mate 200iB/3L

LR Mate 200iB

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1. SAFETY PRECAUTIONS

B-81465EN-1/05

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 OPERATOR SAFETY Operator 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 operator safety. 1. Have the robot system operators attend the training courses held by FANUC. FANUC provides various training courses. Contact our sales office for details. 2. Even when the robot is stationary, it is possible that the robot is still ready to move state and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure operator 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 operator can enter the work area without passing through the gate. Equip the gate with an interlock that stops the robot when the gate is opened. The controller is designed to receive this interlock signal. 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 1, Class 2, or Class 3). 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 operator enters the work area. 8. If necessary, install a safety lock so that no one except the operator 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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B-81465EN-1/05

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

1

Limit switch for the safety gate

2

Fig. 1.1 Safety Fence and Safety Gate

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Note: Terminals FENCE 1 and FENCE 2 are on the PC board in the operator’s panel. Fence circuit is a safety stop circuit.


B-81465EN-1/05

1.1.1 Operator Safety The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant 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 the work area. 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 operator'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.

1

External EMERGENCY STOP button

2

Panel board

3

Note: Connect to EES1 and EES11, EES2 and EES21.

Fig. 1.1.1 Connection Diagram for External Emergency Stop Switch

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B-81465EN-1/05

1.1.2 Safety of the Teach Pendant 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 teach pendant 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's switch on the teach pendant).

NOTE The teach pendant supplied by FANUC is provided with a teach pendant enable switch and a deadman's switch in addition to the EMERGENCY STOP button. The functions of each switch are as follows. EMERGENCY STOP button: • Pressing this button stops the robot in an emergency, irrespective to the condition of the teach pendant enable switch. Deadman's switch: • The function depends on the state of the teach pendant enable switch. When the enable switch is on: • Releasing the finger from the deadman switch or holding the deadman switch strongly stops the robot in an emergency. When the enable switch is off: • The deadman's switch is ineffective.

NOTE The deadman switch is provided so that the robot operation can be stopped simply by releasing finger from the teach pendant or holding the deadman switch strongly in case of emergency. The R-J3iB has adopted a 3-position deadman switch as an RIA-specification teach pendant. Pressing the 3-position deadman switch halfway makes the robot operable. Releasing the finger from the deadman switch or holding the deadman switch strongly causes the robot to enter the emergency stop state. 4. The teach pendant operator should pay careful attention so that no other workers enter the robot work area.

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B-81465EN-1/05

NOTE In addition to the above, the teach pendant enable switch and the deadman's switch also have the following function. By pressing the deadman's switch while the enable switch is on, the emergency stop factor (normally the safety gate) connected to EAS1 and EAS11, EAS2 and EAS21 of the controller is invalidated. In this case, it is possible for an operator to enter the fence during teach operation without pressing the EMERGENCY STOP button. In other words, the system understands that the combined operations of pressing the teach pendant enable switch and pressing the deadman's switch indicates the start of teaching. The teach pendant operator should be well aware that the safety gate is not functional under this condition and bear full responsibility to ensure that no one enters the fence during teaching. 5. When entering the robot work area, the teach pendant operator should enable the teach pendant whenever he or she enters the robot work area. In particular, while the teach pendant enable switch is off, make certain that no start command is sent to the robot from any operator's panel other than the teach pendant. The teach pendant, operator's panel/operation box, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode of the teach pendant enable switch and the remote condition. Teach pendant enable switch

Remote condition

Teach pendant

Operators panel/ operation box

Peripheral devices

On

Independent

Allowed to start

Not allowed

Not allowed

Off

Local

Not allowed

Allowed to start

Not allowed

Off

Remote

Not allowed

Not allowed

Allowed to start

6. To start the system using the operator's panel/operation box, make certain that nobody is in the robot work area and that there are no abnormal conditions in the robot work area. 7. When a program is completed, 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. 8. While operating the system in the automatic operation mode, the teach pendant operator should leave the robot work area.

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B-81465EN-1/05

1.1.3 Safety During Maintenance For the safety of maintenance personnel, pay utmost attention to the following. 1. 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. 2. When disconnecting the pneumatic system, be sure to reduce the supply pressure. 3. Before the start of teaching, check that the robot and its peripheral devices are all in the normal operating condition. 4. If it is necessary to enter the robot work area for maintenance when the power is turned on, the worker should indicate that the machine is being serviced and make certain that no one starts the robot unexpectedly. 5. Do not operate the robot in the automatic mode while anybody is in the robot work area. 6. 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. 7. 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. 8. If necessary, have a worker who is familiar with the robot system stand beside the operator's 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. 9. When replacing or reinstalling components, take care to prevent foreign matter from entering the system 10.When handling each unit or printed circuit board in the controller during inspection, turn off the power of the controller and also turn off the circuit breaker to protect against electric shock. 11.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.

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B-81465EN-1/05

1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 1.2.1 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 insynchronous motion, particular care must be taken in programming so that they donot 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.

1.2.2 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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B-81465EN-1/05

1.3 SAFETY OF THE ROBOT MECHANISM 1.3.1 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.

1.3.2 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.

1.3.3 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.

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B-81465EN-1/05

1.4 SAFETY OF THE END EFFECTOR 1.4.1 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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B-81465EN-1/05

1.5 SAFETY IN MAINTENANCE 1. Never enter the robot work area while the robot is operating. Turn off the power before entering the robot work area for inspection and maintenance. 2. If it is necessary to enter the robot work area with the power turned on, first press the EMERGENCY STOP button on the operator's panel. 3. When replacing or reinstalling components, take care to prevent foreign matter from entering the system. When replacing the parts in the pneumatic system, be sure to reduce the pressure in the piping to zero by turning the pressure control on the air regulator. 4. When handling each unit or printed circuit board in the controller during inspection, turn off the power of the controller and turn off the circuit breaker to protect against electric shock. 5. 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. 6. Before restarting the robot, be sure to check that no one is in the robot work area and that the robot and its peripheral devices are all in the normal operating state.

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B-81465EN-1/05

1.6 WARNING LABEL Description Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing as well. 1. Step-on prohibitive label

Fig. 1.6 (a) Step-on Prohibitive 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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B-81465EN-1/05

2. High-temperature warning label

Fig. 1.6. (b) High-Temperature 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. 3. High-voltage warning label

Fig. 1.6 (c) High-Voltage Warning Label

Description There may be a high voltage in a place with this label. Before working on such a portion, turn off the power to the controller and set its circuit breaker to the off position to avoid shock hazards. In addition, be careful about servo amplifiers and other electric circuits because a high voltage may remain in them for a certain period of time after the power is turned off.

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1. OVERVIEW

MAINTENANCE

B-81465EN-1/05

1 OVERVIEW This manual describes the maintenance and connection of the R-J3iB robot controller (called the R-J3iB). Maintenance Part : Troubleshooting, and the setting, adjustment, and replacement of units Connection Part : Connection of the R-J3iB 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/operation box or teach pendant. Otherwise, you could injure personnel or damage equipment. - For information on third party approvals, contact your FANUC representative.

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B-81465EN-1/05

MAINTENANCE

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1. OVERVIEW

2. CONFIGURATION

MAINTENANCE

B-81465EN-1/05

2 CONFIGURATION 2.1 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), (b), (c), (d) and (e) show external and internal views of the R-J3iB A-cabinet and B-cabinet controllers. Fig. 2.1 (f), (g) and (h) show the MODE SELECT switch, the operator panel and the operator panel interface. Fig. 2.1 (i) and (j) show the block diagram of R-J3iB.

1

Operation box

2

Teach pendant

3

R-J3iB controller

Fig. 2.1 (a) External View of the R-J3iB Controller (A-cabinet)

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B-81465EN-1/05

1

Mode switch

2

Teach pendant

MAINTENANCE

3

Operator´s panel

Fig. 2.1 (b) External View of the R-J3iB Controller (B-cabinet)

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2. CONFIGURATION

2. CONFIGURATION

MAINTENANCE

B-81465EN-1/05

1

Teach pendant

5

Power supply unit

2

E-stop unit

6

Fan unit

3

Servo amplifier

7

Regenerative resistor

4

Main board

8

Transformer

Fig. 2.1 (c) R-J3iB A-cabinet interior

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B-81465EN-1/05

2. CONFIGURATION

MAINTENANCE

1

Servo Amplifier

11

Backplane

2

External air Fan Unit

12

E-Stop Unit

3

Emergency Stop Button

13

Main Board

4

Battery

14

Breaker

5

DC Fan Unit

15

Power supply Unit

6

Panel Board

16

Floor Fan Unit

7

Operator Panel

17

Enable switch

8

MODE Switch

18

Teach Pendant

9

Door Fan

19

Emergency Stop Button

10

Process I/O Board

Fig. 2.1 (d) R-J3iB B-cabinet interior (Front) -32-

2. CONFIGURATION

1

MAINTENANCE

Regenerative Resistor Unit

2

Fig. 2.1 (e) R-J3i B-cabinet overview (Back)

Fig. 2.1 (f) R-J3iB mode switch overview

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B-81465EN-1/05

Transformer

B-81465EN-1/05

MAINTENANCE

Fig. 2.1 (g) R-J3iB panel overview

Fig. 2.1 (h) R-J3iB interface overview

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2. CONFIGURATION

2. CONFIGURATION

MAINTENANCE

B-81465EN-1/05

Tab. 2.1 Servo amplifier and regenerative resistor unit Robot models

Servo amplifier

Regenerative resistor A-CABINET

Regenerative resistor B-CABINET

R-2000iA/200T

A06B-6105-H001

-----

A05B-2452-C200

S-900iB

A06B-6105-H001

A05B-2451-C204

A05B-2452-C200

M-410iB

A06B-6105-H001

A05B-2451-C204

A05B-2452-C200

R-2000iA (except/200T)

A06B-6105-H002

A05B-2451-C202

A05B-2452-C200

S-500iB

A06B-6105-H002

A05B-2451-C202

A05B-2452-C200

M-710iB

A06B-6105-H002

A05B-2451-C202

A05B-2452-C200

M-16iB

A06B-6105-H002

A05B-2451-C202

A05B-2452-C200

ARC Mate 120iB

A06B-6105-H002

A05B-2451-C202

A05B-2452-C200

M-420iA, M-421iA

A06B-6105-H002

A05B-2451-C204

A05B-2452-C200

M-6iB

A06B-6105-H003

A05B-2451-C201

A05B-2452-C201

ARC Mate 100iB

A06B-6105-H003

A05B-2451-C201

A05B-2452-C201

F-200iB

A06B-6105-H003

A05B-2451-C201

A05B-2452-C201

LR Mate 200iB

A06B-6105-H003

-----

A05B-2452-C201

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B-81465EN-1/05

MAINTENANCE

Fig. 2.1 (i) Block diagram of the R-J3iB (A-cabinet)

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2. CONFIGURATION

2. CONFIGURATION

MAINTENANCE

Fig. 2.1 (j) Block diagram of the R-J3iB (B-cabinet)

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B-81465EN-1/05

B-81465EN-1/05

MAINTENANCE

2. CONFIGURATION

2.2 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 and servo amplifier voltages. - Battery retains main board memory when controller power is off. - I/O printed circuit board and 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 This unit controls the emergency stop system with control reliable E-stop performance criteria for both of the magnetic contactor and the precharge of the servo amplifier. - 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 power, pulse coder, brake control, overtravel and hand broken. - Operator´s panel/operation box Buttons and LEDs on the operator´s panel/operation box are used to start the robot and to indicate the robot status. The panel has a port 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.

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2. CONFIGURATION

MAINTENANCE

B-81465EN-1/05

- 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 control unit. - 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.

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B-81465EN-1/05

MAINTENANCE

2. CONFIGURATION

2.3 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. c. 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. d. 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. e. Replacing battery Replace the lithium battery on the front panel of the main board every 4 years. Please refer to the section 7.17. 2. 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

MAINTENANCE

B-81465EN-1/05

3 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.

3.1 POWER CANNOT BE TURNED ON Check and Corrective action

Figure

(Check 1) Check that the circuit breaker is on and has not tripped. (Corrective action) Turn on the circuit breaker.

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MAINTENANCE

B-81465EN-1/05

Check and Corrective action

3. TROUBLESHOOTING

Figure

(Check 2) Check whether the LED (PIL: green) on the power supply unit is on. (Corrective action) 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. (Corrective action(1)) Causes of blown fuses F1 and corrective action a) Check whether the unit and printed-circuit board connected to the connectors CP2 and CP3 in the power supply unit are abnormal, by referencing the general schematic diagram presented in the appendix. b) Short-circuit in the surge absorber VS1 VS1 is inserted to absorb surge voltage between input lines.If the surge voltage is excessive or sustained, excessively high voltage is applied to VS1 and a failure occurs in the short-circuit mode, causing F1 to blow. If a short-circuit occurs in VS1, and there is not a spare part, the system is permitted to operate without VS1. In this case, however, obtain and install a new VS1 as soon as possible. VS1 ordering number: A50L-2001-0122#G431k c) Short-circuit of diode stack DB1 d) The secondary power supply module is faulty : If one of the causes (b) to (c) above is detected, replace the power supply unit with a spare unit. The spec. for F1 is : A60L-0001-0396#8.0A

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3. TROUBLESHOOTING

MAINTENANCE


B-81465EN-1/05

Figure

(Check 3) Check whether the EXON1 and EXON2 signals, and the EXOFF1 and EXOFF2 signals are connected on the terminal block on the panel board. (Corrective action) If the external ON/OFF function is not used, connect the EXON1 and EXON2 the EXOFF1 and EXOFF2. If the external ON and OFF lines are already used, check the mating contacts and the cable.

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B-81465EN-1/05

MAINTENANCE


3. TROUBLESHOOTING

Figure

(Check 4) Check whether the connector (JRS11) on the main board or the connector (JRS11) on the panel board is connected properly. Another probable cause is that the cable connected to either of these connectors is faulty. (Check 5) Check 1 to 3 above confirm that 200 VAC power is supplied to connector CP1 of the power supply unit and that the ON/OFF switch functions normally. Therefore check the power supply unit using the following procedure: If the LED (ALM: red) on the power supply unit is on Check if the +24 V external connection cable is connected to 0 V or ground. a) Fuse F4 blown : See corrective action (2). b) None of the above fuses blown [d) is also probable] : A printed circuit board or unit that uses a DC supply voltage (+3.3V, +5V, +24V, or +/-15V) is faulty. c) None of the above fuses blown : Check that 200 VAC is supplied to connector CP1. If it is supplied replace the power supply unit. (Corrective action) If the power supply unit is not faulty, replace the panel board or operator‘’s panel. (Corrective action (2)) Causes of blown fuse F4 and corrective action The device connected to connector CP5 of the power supply unit may be faulty. If no device is connected to CP5 or the connected device is normal, the +24 V power used in a printed circuit board connected to the backplane is faulty. The code of F4 is A60L-0001-0046#7.5 :

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

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

1

Press the screen selection key to select [4 ALARM]

5

Press F3 [ACTIVE]

2

Press the alarm key

6

Press F3 [HIST]

3

Automatic alarm display upon occurrence

7

Alarm history screen display

4

Alarm occurrence screen display

Fig. 3.2 Alarm Occurrence Screen and Alarm History Screen Display Procedure

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B-81465EN-1/05

MAINTENANCE

3. TROUBLESHOOTING

Displaying the alarm history/alarm detail information Step 1. Press the MENUS key to display the screen menu. 2. Select [ALARM]. You will see a screen similar to the following

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].

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

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

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. The following map indicates teach pendant operations used to check an alarm.

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3.3 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. Tab. 3.3 Safety Signals Safety signal

Description

Operator´s panel/operation box emergency stop

This item indicates the state of the emergency stop button on the operator´s panel or operation box. If the EMERGENCY STOP board is pressed, the state is indicated as "TRUE".

Teach pendant emergency stop

This item indicates the state of the emergency stop button on the teach pendant. If the EMERGENCY STOP board is pressed, the state is indicated as "TRUE".

External emergency stop

This item indicates the state of the external emergency stop signal. If the EMERGENCY STOP signal is input, the state is indicated as "TRUE".

Fence open

This item indicates the state of the safety fence. If the safety fence is open, the state is indicated as "TRUE".

Deadman switch

This item indicates whether the DEADMAN switch on the teach pendant is grasped. If the teach pendant is operable, and the DEADMAN switch is grasped, the state is indicated as "TRUE". If the deadman switch is released when the teach pendant is operable, an alarm occurs, causing the servo power to be switched off.

Teach pendant operable

This item indicates whether the teach pendant is operable. If the teach pendant is operable, the state is indicated as "TRUE".

Hand broken

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.

Robot overtravel

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.

Abnormal air pressure

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".

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Step 1. Press the MENUS key to display the screen menu. 2. Select STATUS on the next page. 3. Press F1, [TYPE] to display the screen switching menu. 4. Select Safety Signal. You will see a screen similar to the following.

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3.4 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 jig position mastering. (Zero-degree position mastering is just for quick-fix purposes. After zero-degree position mastering is used, jig position mastering should be performed later.) The mastering procedure is described below. For details, refer to an applicable maintenance manual of the mechanical unit or operator's manual of control unit. Condition System variable $MASTER_ENB must be set to 1 or 2.

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

5. Jog the robot to the mastering position. Release the brake on the manual brake control screen if necessary.

NOTE Mastering cannot be performed until axis is rotated enough to establish a pulse. 6. Select "1 FIXTURE POSITION MASTER" and press the F4 key (yes). Mastering data is set.

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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.

8. Press F5 "DONE", after mastering.

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3.5 TROUBLESHOOTING USING THE ERROR CODE 3.5.1 SRVO-001 Operator panel E-stop (Explanation) The emergency stop button on the operator's panel or operation box is pressed. If the SYST-067 (Panel HSSB disconnect) alarm is also generated, or if the LED (green) on the panel board is turned off, communication between the main board (JRS11) and the panel board (JRS11) is abnormal. The connectors of the cable between the main board and the panel board may be loose. Or, the cable, panel board, or main board may be faulty. (Note) (Action 1) Release the emergency stop button pressed on the operator's panel/operation box. (Action 2) Check the wires connecting between the emergency stop button and the connector (CRM51) on panel switch board for continuity. If an open wire is found replace the entire harness. (Action 3) 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/operation box. (Action 4) Replace the panel board. (Action 5) Replace the cable connecting between the main board (JRS11) and the panel board (JRS11). Before executing the (Action6), perform a complete controller back-up to save all your programs and settings. (Action 6) Replace the main board.

NOTE If SYST-067 Panel HSSB disconnect alarm occurs simultaneously or the RDY LED is turned off, the following alarms are also generated. SRVO-001 Operator's panel E-stop. SRVO-004 Fence open. SRVO-007 External emergency stop. SRVO-204 External (SVEMG abnormal) E-stop. SRVO-213 Fuse blown (Panel PCB). SRVO-280 SVOFF input Check the alarm history display on the teach pendant.

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1

Emergency stop button

3

A-cabinet

2

Breaker

4

B-cabinet

Fig. 3.5.1 (a) SRVO-001 Operator´s panel E-stop

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1

Connector (CRT 8)

3

Connector (JRS11)

2

LED (Green)

4

Panel board

2

Main board

Fig. 3.5.1 (b) SRVO-001 Operator´s panel E-stop

1

Connector (JRS11)

Fig. 3.5.1 (c) SRVO-001 Operator´s panel E-stop

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3.5.2 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 Teach Pendant.

1


Fig. 3.5.2 SRVO-002 Teach pendant E-stop

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3.5.3 SRVO-003 Deadman switch released (Explanation) The teach pendant is enabled, but the deadman switch is not pressed. Deadman switch is three position switch. Don´t press the switch to the second „open“ position. Switch is enabled in middle position only. (Action 1) Press the deadman switch to run the robot. (Action 2) Replace the teach pendant.

1

Deadman switch

Fig. 3.5.3 SRVO-001 Deadman switch released

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3.5.4 SRVO-004 Fence open (Explanation) On the terminal block TBOP4 of the panel board, no connection is made between 5 (EAS1) and 6 (EAS11) or between 7 (EAS2) and 8 (EAS21). If a safety fence is connected between 5 (EAS1) and 6 (EAS11) or between 7 (EAS2) and 8 (EAS21), the door of the safety fence is open. If the SYST-067 (Panel HSSB disconnect) alarm is also generated, or if the LED (green) on the panel board is turned off, communication between the main board (JRS11) and the panel board (JRC11) is abnormal. The connectors of the cable between the main board and the panel board may be loose. Or, the cable, panel board, or main board may be faulty. (Note) In case that RDY LED (green) is lit. (Action 1) If a safety fence is connected, close the door. (Action 2) Check the switch and cable connected to 5 (EAS1) and 6 (EAS11) or 7 (EAS2) and 8 (EAS21) on TBOP4. (Action 3) When this signal is not used, make a connection between 5 (EAS1) and 6 (EAS11) or between 7 (EAS2) and 8 (EAS21). (Action 4) Replace the panel board. In case that RDY LED (green) is not lit. (Action 1) Check whether FUSE1 on the panel board is blown. If FUSE1 is blown, replace FUSE1 after removing the cause. Else if, check the voltage of EXT24V and EXT0V (TBOP6). If external 24V, 0V is not used check the jumper pins between EXT24V and INT24V, EXT0V and INT 0V (TBOP6). (Action 2) Replace the panel board. (Action 3) Replace the cable connecting between the main board (JRS11) and the panel board (JRS11). Before executing the (Action4), perform a complete controller back-up to save all your programs and settings. (Action 4) Replace the main board.

NOTE FENCE input (AUTO STOP) is a safety stop input. When this input is opened, the robot decelerates in a controlled manner and then stops. The magnetic contactor opens after the robot stops.

WARNING Do NOT short-circuit, or disable, this signal in a system in which the Fence signal is in use, as it is very dangerous. If it is necessary to run the robot by short-circuiting the signal even temporarily, an additional safety provision must be provided.

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NOTE If the external 24V is not supplied adequately to TBOP6 (EXT24V, EXT0V), the following alarms are also generated. SRVO-004 Fence open. SRVO-007 SVALI External E-stop. SRVO-213 Fuse blown (Panel PCB). SRVO-280 SVOFF input


1

Short connection 5 (EAS1) and 6 (EAS11)

5

Connector (JRS11)

2

Short connection 7 (EAS2) and 8 (EAS21)

6

Panel board

3

Connector (CRT 8)

7

TB0P6

4

LED (Green)

Fig. 3.5.4 (a) SRVO-004 Fence open

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1

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Connector (JRS11)

2

Fig. 3.5.4 (b) SRVO-004 Fence open

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3.5.5 SRVO-005 Robot overtravel (Explanation) The robot has moved beyond a hardware limit switch on the axes. 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. (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) Check the FS2 fuse on the servo amplifier. If the SRVO-214 Fuse blown alarm is also generated, FS2 fuse has blown. (Action 4) Check the end effector connector. (Action 5) Replace the servo amplifier. (Action 6) 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 CRF7 and CRM68 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. If no limit switch is in use, a jumper connector must be attached in the mechanical unit. Check for the jumper connector.

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1

Servo amplifier

4

Connector (CRF7)

2

A-cabinet

5

Connector (CRM68)

3

B-cabinet

Fig. 3.5.5 SRVO-005 Robot overtravel -62-

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3.5.6 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. If the Hand broken signal is not in use, it can be disabled by software setting. Refer to Subsection 5.5.3 in Part III, "Connections," of "Maintenance Manual" for how to disable the Hand broken signal. (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) Check the FS2 fuse on the servo amplifier. If the SRVO-214 Fuse alarm is also generated, FS2 fuse has blown. (Action 3) Replace the servo amplifier. (Action 4) 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 CRM7 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.

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1

Servo amplifier

3

(B-cabinet)

2

(A-cabinet)

4

Connector (CRF7)

Fig. 3.5.6 SRVO-006 Hand broken -64-

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3.5.7 SRVO-007 External E-stop (Explanation) On the terminal block TBOP4 of the panel board, no connection is made between 1 (EES1) and 2 (EES11) or between 3 (EES2) and 4 (EES21). If an external emergency stop switch is connected between 1 (EES1) and 2 (EES11) or between 3 (EES2) and 4 (EES21), the switch is pressed. If the SYST-067 (Panel HSSB disconnect) alarm is also generated, or if the LED (green) on the panel board is turned off, communication between the main board (JRS11) and the panel board (JRS11) is abnormal. The connectors of the cable between the main board and the panel board may be loose. Or, the cable, panel board, or main board may be faulty. (Note) In case that RDY LED (green) is lit. (Action 1) If an external emergency stop switch is connected, releases the switch. (Action 2) Check the switch and cable connected to 1 (EES1) and 2 (EES11) or 3 (EES2) and 4 (EES21) on TBOP4. (Action 3) When this signal is not used, make a connection between 1 (EES1) and 2 (EES11) or between 3 (EES2) and 4 (EES21). (Action 4) Replace the panel board. In case that RDY LED (green) is not lit. (Action 1) Check whether FUSE1 on the panel board is blown. If FUSE1 is blown, replace FUSE1 after removing the cause. Else if, check the voltage of EXT24V and EXT0V (TBOP6). If external 24V, 0V is not used check the jumper pins between EXT24V and INT24V, EXT0V and INT 0V (TBOP6). (Action 2) Replace the panel board. (Action 3) Replace the cable connecting between the main board (JRS11) and the panel board (JRS11). Before executing the (Action4), perform a complete controller back-up to save all your programs and settings. (Action 4) Replace the main board.

WARNING Do NOT short-circuit, or disable, this signal in a system in which the External emergency stop input signal is in use, as it is very dangerous. If it is necessary to run the robot by short-circuiting the signal even temporarily, an additional safety provision must be provided.

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NOTE If the external 24 V is not supplied adequately to TB0P6 (EXT24V, EXT0V), the following alarms are also generated. SRVO-004 Fence open. SRVO-007 SVALI External E-stop. SRVO-213 Fuse blown (Panel PCB). SRVO-280 SVOFF input.

1

Short connection 1 (EES1) and 2 (EES11)

4

LED (Green)

2

Short connection 3 (EES2) and 4 (EES21)

5

Connector (JRS11)

3

Panel board

6

TBOP6

Fig. 3.5.7 (a) SRVO-007 External E-stop -66-

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MAINTENANCE

Connector (JRS11)

2

Fig. 3.5.7 (b) SRVO-007 External E-stop

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3.5.8 SRVO-009 Pneumatic pressure alarm (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) 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 CRF7 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. (Action 4) Replace the servo amplifier. (Action 5) Replace the internal cables of the robot.

1

Servo amplifier

2

(A-cabinet)

3

(B-cabinet)

Fig. 3.5.8 SRVO-009 Pneumatic pressure alarm

Pneumatic pressure alarm input is disabled/enabled by software. Please refer to Subsection 5.5.4. in Part III Connections of this Maintenance Manual.

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3.5.9 SRVO-014 Fan motor abnormal (Explanation) A fan motor in the backplane unit is abnormal. (Action 1) Check the fan motor and its cables. Replace them if necessary. (Action 2) Replace the backplane unit.

1

Fan motor

Fig. 3.5.9 SRVO-014 Fan motor abnormal

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3.5.10 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°C), 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 (Action3), perform a complete controller back-up to save all your programs and settings. (Action 3) Replace the main board.

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1

Door switch

6

B-cabinet

2

Main board

7

Door fan

3

Heat exchanger

8

Floor fan unit

4

Fan unit

9

External air Fan unit

5

A-cabinet

Fig. 3.5.10 SRVO-015 System Over Heat

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3.5.11 SRVO-018 Brake abnormal (Explanation) An excessive brake current is detected. The ALM LED on the servo amplifier 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. (Action 2) This alarm may occur if the brake connector is not attached. Make sure that connector CRR64 is securely attached to the servo amplifier. (Action 3) Replace the servo amplifier.

1

Servo amplifier

2

A-cabinet

3

Fig. 3.5.11 SRVO-018 Brake abnormal

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3.5.12 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 connector CP2, CRM64 and CNMC3 are securely attached to the E-stop unit and connector CRM64 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 servo amplifier. (Action 4) Replace the E-stop unit.

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1

Door switch

5

Power supply unit

2

Servo amplifier

6

A-cabinet

3

Main board

7

Axis control card

4

E-stop unit

8

B-cabinet

Fig. 3.5.12 SRVO-021 SRDY off

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3.5.13 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.

1

Door switch

5

Power supply unit

2

Servo amplifier

6

A-cabinet

3

Main board

7

Axis control card

4

E-stop unit

8

B-cabinet

Fig. 3.5.13 SRVO-022 SRDY on

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3.5.14 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 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 power cable in the robot connection 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 servo motor according to the alarm message.

NOTE Incorrect setting of the brake number causes this alarm.

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1

Servo amplifier

4

E-stop unit

2

A-cabinet

5

B-cabinet

3

Main board

Fig. 3.5.14 SRVO-023 Stop error excess

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3.5.15 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 action as SRVO-23.

3.5.16 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 1) Master the robot.

3.5.17 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 1) Calibrate the robot. 1. Supply power. 2. Set up a simplified adjustment reference point using [Positioning] on the positioning menu.

3.5.18 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 1) Set up a simplified adjustment reference point on the positioning menu.

3.5.19 SRVO-035 WARN2 Joint speed limit (Group : i Axis : j) (Explanation) A value higher than the maximum axis speed ($PARAM_GROUP. $JNTVELLIM) was specified. Each actual axis speed is clamped to the maximum speed.

3.5.20 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 1) Take the same actions as for SRVO-23 (large position error at a stop).

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3.5.21 SRVO-037 Imstp input (Group : i) (Explanation) The *IMSTP signal for a peripheral device interface was input. (Action 1) Turn on the *IMSTP signal.

3.5.22 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 pulse coder or battery for back up of the pulse coder data or loading back up data to the Main Board. Check the alarm history. (Action 1) In case with "SRVO-222 Lack of Amp (Amp : i)", see the troubleshooting of SRVO-222. (Action 2) If the brake number is set to the non-brake motors, this alarm may occur. Check the software setting of the brake number. (Action 3) In case the robot 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 4) 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 5) Replace the pulsecoder and master the robot.

NOTE Reseting this alarm. 1. Press MENUS. 2. Select SYSTEM. 3. Press F1, [TYPE]. 4. Select MASTER/CAL. 5. Press F3, RES-PCA. 6. Press RESET. The fault condition should reset. If the controller is still faulted with additional servo-related errors, cold start the controller. It might be necessary to remaster the robot.

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3.5.23 SRVO-042 MCAL alarm (Group : i Axis : j) (Explanation) This alarm means that the contacts of the magnetic contactor have stuck together. 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) Check the magnetic contactor, and replace it if necessary. If the contacts of the magnetic contactor have stuck to each other, turn off the circuit breaker. If the power is switched off without turning off the circuit breaker, the servo amplifier may get damaged, because the stuck contacts keep three-phase 200 VAC applied to the servo amplifier. (Action 2) Replace the E-stop unit. (Action 3) Replace the servo amplifier.

1

Door switch

5

A-cabinet

2

Servo amplifier

6

Power supply unit

3

Main board

7

B-cabinet

4

E-stop unit

Fig. 3.5.23 SRVO-042 MCAL alarm

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3.5.24 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 auxiliary axis. (Action 3) 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 dirt. (Action 4) Make sure that the servo amplifier CRR63A, CRR63B and CRR63C are connected tightly, then detach the cable from CRR63A, CRR63B and CRR63C connector on the emergency stop board, and check for continuity between pins 1 and 2 of the cable-end connector. If there is no continuity between the pins, replace the regenerative resistance. (Action 5) Make sure that the servo amplifier CRR45A, CRR45B and CRR45C are connected tightly then detach the cables from CRR45A, CRR45B and CRR45C on the servo amplifier and check the resistance between pins 1 and 2 of each cable end connector. If the resistance is not 9-16 Ohm, replace the regenerative resistor. CRR45B and CRR45C may not be used depending on the robot model. (Action 6) Replace the servo amplifier.

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MAINTENANCE

B-81465EN-1/05

1

Servo amplifier

4


2

E-stop unit

5

Transformer

3

A-cabinet (front view)

6

A-cabinet (rear view)

1

Servo amplifier

3


2

B-cabinet (front view)

4

B-cabinet (rear view)

Fig. 3.5.24 SRVO-043 DCAL alarm -83-

B-81465EN-1/05

MAINTENANCE

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3. TROUBLESHOOTING

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B-81465EN-1/05

3.5.25 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 result 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) Replace the servo amplifier.

1

Servo amplifier

2

A-cabinet

3

Fig. 3.5.25 SRVO-044 SVAL1 HVAL alarm

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3.5.26 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 (CRR64 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 shortcircuit, 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.

1

Servo amplifier

2

A-cabinet

3

Fig. 3.5.26 SRVO-045 HCAL alarm

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B-cabinet

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MAINTENANCE

B-81465EN-1/05

3.5.27 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 conditions for the robot and relax the service condition if possible. (Action 2) Take the same actions as SRVO-023.

1

Servo amplifier

2

A-cabinet

3

Fig. 3.5.27 SRVO-046 OVC alarm

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3. TROUBLESHOOTING

Reference Relationships among the OVC, OHAL, and HC alarms are described in this section. 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 OVC OHAL

HC

Designation

Detection section

Overcurrent alarm

Servo software

Overheat alarm

Thermal relay in the motor OHAL2 Thermal relay in the servo amplifier OHAL1 Thermal relay in the separate regenerative discharge unit DCAL

High current alarm

Servo amplifier

Purpose of each alarm 1. HC alarm (high current alarm) If high current flows 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. 2. 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 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 repeats to start and stop within a short time as shown in Fig. 1, 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.

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B-81465EN-1/05

1

Temperature

5

Temperature at which the winding starts to burn

2

Start

6

Thermal time constant of the thermal relay is low

3

Stop

7

Time

4

Thermal time constant of the motor is high

Fig. 1 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 2.

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1

Current

5

Protection by the OVC

2

Protection area for the motor and servo amplifier

6

Rated continuous current

3

Protection by the OHAL

7

Time

4

Limit current

Fig. 2 Relationship between the OVC and OHAL alarms

NOTE The relationship shown in Fig. 2 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.

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MAINTENANCE

B-81465EN-1/05

3.5.28 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 according to the alarm message. (Action 2) Replace the power supply unit.

1

Servo amplifier

3

B-cabinet

2

A-cabinet

4

Power sopply unit

Fig. 3.5.28 SRVO-047 LVAL alarm

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3.5.29 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 the operating condition for the robot and relax the service condition if possible. And check the fan unit, and replace it if it stops. Clean up the fun unit, the regenerative resistor and the louver if they are dirt. (Action 2) Check SRVO-214 Fuse blown (Amp) occurs simultaneously in the alarm history. If it occurs, replace the servo amplifier. Replacing the fuse F1 and F2 on the servo amplifier does not solve problem. (Action 3) Make sure that the CRM73 connector on the E-stop unit and TOH connector on the transformer is connected tightly. (Action 4) Replace the servo. (Action 5) Replace the transformer.

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

1

Servo amplifier

4


2

E-stop unit

5

Transformer

3

A-cabinet (front view)

6

A-cabinet (rear view)

-93-

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MAINTENANCE

1

Servo amplifier

4

Transformer

2

E-stop unit

5

B-cabinet (rear view)

3

B-cabinet (front view)

Fig. 3.5.29 SRVO-049 OHAL1 alarm

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MAINTENANCE

B-81465EN-1/05

3.5.30 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 the software setting for this option. (Action 2) Take the same actions as SRVO-023.

1

Servo amplifier

2

A-cabinet

3

Fig. 3.5.30 SRVO-050 CLALM alarm

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B-cabinet

B-81465EN-1/05

MAINTENANCE

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3. TROUBLESHOOTING

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.31 SRVO-051 CUER alarm (Group : i Axis : j) (Explanation) The offset of the current feedback value is abnormally high. (Action 1) Replace the servo amplifier.

1

Servo amplifier

2

A-cabinet

3

Fig. 3.5.31 SRVO-051 CUER alarm

-95-

B-cabinet

B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

3.5.32 SRVO-054 DSM Memory Error (Explanation) An access to the servo module memory fails. (Action 1) Replace the axis control card on the main board.

1

Door switch

5

Power supply unit

2

Servo amplifier

6

A-cabinet

3

Main board

7

B-cabinet

4

E-stop unit

8

Axis control card

Fig. 3.5.32 SRVO-054 DSM Memory Error

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B-81465EN-1/05

3.5.33 SRVO-055 FSSB com error 1 (Group : i Axis : j) (Explanation) A communication error has occurred between the main board and servo amplifier from main board to 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.

1

Power supply unit

5

A-cabinet

2

Servo amplifier

6

B-cabinet

3

Main board

7

Axis control card

4

E-stop unit

Fig. 3.5.33 SRVO-055 FSSB com error 1

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3.5.34 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) Take the same action as SRVO-055.

3.5.35 SRVO-057 FSSB disconnect (Group : i Axis : j) (Explanation) Communication was interrupted between the main board and servo amplifier. (Action 1) Check whether fuse F3 in the power supply unit has blown. (Action 2) Check whether fuse FS1 in the servo amplifier has blown. (Action 3) Check the communication cable (optical fiber) between the main board and servo amplifier. Replace it if it is faulty. (Action 4) Replace the axis control card on the main board. (Action 5) Replace the servo amplifier. (Action 6) Check the robot connection cable RP1 (+5V ground fault). Before executing the (Action7), perform a complete controller back-up to save all your programs and settings. (Action 7) Replace the main board.

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

1

Power supply unit

5

A-cabinet

2

Servo amplifier

6

B-cabinet

3

Main board

7

Axis control card

4

E-stop unit

Fig. 3.5.35 SRVO-057 FSSB disconnect

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MAINTENANCE

3. TROUBLESHOOTING

3.5.36 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 F3 in the power supply unit has blown. (Action 2) Turn off the power and disconnect the CRF7 connector on the servo amplifier. Then turn on the power and check whether this alarm occurs again. (Ignore the alarm SRVO-068 because of disconnecting the CRF7 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 3) 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 CP6 and CRM67 on the E-stop unit and the connector CRM67 on the servo amplifier are connected tightly. If they are connected tightly, replace the servo amplifier. (Action 4) Check the communication cable (optical fiber) between the main board and servo amplifier. Replace it if it is faulty. (Action 5) Replace the axis control card on the main board. (Action 6) Replace the servo amplifier.. (Action 7) If the other units (the servo amplifier for the auxiliary axis and the line tracking interface) are connected in the FSSB optical communication, disconnect these units and connect only the 6-channel 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 (Action 8), perform a complete controller back-up to save all your programs and settings. (Action 8) Replace the main board.

-100-

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

1

Door switch

5

Power supply unit

2

Servo amplifier

6

A-cabinet

3

Main board

7

B-cabinet

4

E-stop unit

8

Axis control card

Fig. 3.5.36 SRVO-058 FSSB init error

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MAINTENANCE

3.5.37 SRVO-059 Servo amp init error (Explanation) Servo amplifier initiazation is failed. (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 servo amplifier.

1

Servo amplifier

2

A-cabinet

3

Fig. 3.5.37 SRVO-059 Servo amp init error

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B-cabinet

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.38 SRVO-060 FATL FSSN init error (Explanation) Communication between the additional axis board and additional axis amplifier was interrupted. (Action 1) Check whether the optical cable between the additional axis board and additional axis amplifier is connected securely. (Action 2) Replace the additional axis board. (Action 3) Replace the additional axis amplifier. (Action 4) Replace the main board. (Action 5) Replace the backplane.

3.5.39 SRVO-062 BZAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the battery for the pulse coder absolute-position backup is empty. A probable cause is a broken battery cable or no batteries in the robot. (Action 1) Check the battery and battery cable, and replace the battery. Then set the system variable $MCR.$SPC_RESET to TRUE, and then supply power again. After this, master the robot or follow SRVO-038 RECOVERY PROCEDURE.

3.5.40 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 1) 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.

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MAINTENANCE

3. TROUBLESHOOTING

3.5.41 SRVO-065 BLAL alarm (Group : i Axis : j) (Explanation) The battery voltage for the pulse coder is lower than the rating. (Action 1) Replace the battery. (If this alarm occurs, turn on the AC 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.)

3.5.42 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 operating conditions for the robot and relax the service conditions. (Action 2) When power is supplied to the motor after it has become sufficiently cool, if the alarm still occurs, replace the motor.

3.5.43 SRVO-068 DTERR alarm (Group : i Axis : j) (Explanation) The serial pulse coder does not return serial data in response to a request signal. • See actions on SRVO-070

3.5.44 SRVO-069 CRCERR alarm (Group : i Axis : j) (Explanation) The serial data has disturbed during communication • See actions on SRVO-070

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.45 SRVO-070 STBERR alarm (Group : i Axis : j) (Explanation) The start and stop bits of the serial data are abnormal. (Action 1) Make sure that the CRF7 connector on the servo amplifier is connected tightly. (Action 2) Check that the shielding of the robot interconnection cable (for the pulse coder) and the peripheral equipment cable are connected securely to the grounding plate. (Action 3) Check that each unit is grounded securely. (Action 4) Replace the servo amplifier. (Action 5) Replace the pulse coder. (Action 6) Replace the robot interconnection cable (for the pulse coder).

1

Servo amplifier

2

A-cabinet

3

Fig. 3.5.45 SRVO-070 STBERR alarm

-105-

B-cabinet

B-81465EN-1/05

MAINTENANCE

3. TROUBLESHOOTING

3.5.46 SRVO-071 SPHAL alarm (Group : i Axis : j) (Explanation) The feedback speed is abnormally high. (Action 1) If this alarm occurs together with the PHAL alarm (SRVO-064), this alarm does not correspond to the major cause of the failure. (Action 2) Replace the pulse coder.

3.5.47 SRVO-072 PMAL alarm (Group : i Axis : j) (Explanation) It is likely that the pulse coder is abnormal. (Action 1) Replace the pulse coder and remaster the robot.

3.5.48 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 flange of the motor according to the alarm message. (Action 2) Replace the pulse coder and master the robot.

3.5.49 SRVO-074 LDAL alarm (Group : i Axis : j) (Explanation) The LED in the pulse coder is broken. (Action 1) Replace the pulse coder, and remaster the robot.

3.5.50 SRVO-075 Pulse not established (Group : i Axis : j) (Explanation) The absolute position of the pulse coder cannot be established. (Action 1) Reset the alarm, and jog the axis on which the alarm has occurred until the same alarm will not occur again (Jog one motor revolution).

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MAINTENANCE

B-81465EN-1/05

3.5.51 SRVO-076 Tip Stick Detection (Group : i Axis : j) (Explanation) An excessive disturbance was assumed in the 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 with foreign matter. If a collision has occured, reset the system, then jog the robot to avoid the collision. 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. (Use of the robot with a load exceeding the limit applied may abnormally increase the assumed disturbance, resulting in this alarm.) (Action 5) Check each inter-phase voltage of the three-phase input (200 VAC) to the servo amplifier. And check the setting of the transformer. (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.

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B-81465EN-1/05

1

Servo amplifier

2

A-cabinet

3. TROUBLESHOOTING

MAINTENANCE

3

B-cabinet

Fig. 3.5.51 SRVO-076 Tip Stick Detection

3.8.52 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 I/F board.

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MAINTENANCE

B-81465EN-1/05

3.5.53 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 I/F 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 line tracking cable. (Action 4) Replace the pulse coder. (Action 5) Replace the line tracking I/F board.

3.5.54 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 of the BZAL alarm (SRVO-062). (Action 1) Check the battery and battery cable, and replace the battery. Then set the system variable $MCR.$SPC_ RESET to TRUE, and supply power again. After this, master the pulse coder.

3.5.55 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). (Action 1) Replace the battery. (If this alarm occurs, turn on the AC 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.)

3.5.56 SRVO-089 OHAL2 alarm (Track enc : i) (Explanation) The motor has overheated. See the description about the OHAL2 alarm (SRVO-067). (Action 1) Check the operating conditions for the pulse coder. (Action 2) When power is supplied to the pulse coder after it has become sufficiently cool, if the alarm still occurs, replace the pulse coder.

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3. TROUBLESHOOTING

3.5.57 SRVO-091 CRCERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the CRCERR alarm (SRVO-092).

3.5.58 SRVO-092 STBERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. (Action 1) Check the connection cable at each end (the line tracking I/F 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 line tracking cable. (Action 4) Replace the pulse coder. (Action 5) Replace the line tracking I/F board.

3.5.59 SRVO-093 SPMAL alarm (Track enc : i) (Explanation) This alarm occurs if the current position data from the pulse coder is higher than the previous position data. (Action 1) If this alarm occurs together with the PHAL alarm (SRVO-086), this alarm does not correspond to the major cause of the failure. (Action 2) Replace the pulse coder. (Action 3) Check the connection cable at each end (the line tracking I/F board and the pulse coder). (Action 4) Check whether the shielding of the connection cable is connected securely to the grounding plate. (Action 5) Replace the line tracking cable. (Action 6) Replace the pulse coder. (Action 7) Replace the line tracking I/F board.

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MAINTENANCE

B-81465EN-1/05

3.5.60 SRVO-094 PMAL alarm (Track enc : i) (Explanation) It is likely that the pulse coder is abnormal. (Action 1) Replace the pulse coder.

3.5.61 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. (Action 1) Reinforce the earth of the flange of the motor according to the alarm message. (Action 2) Replace the pulse coder and master the robot.

3.5.62 SRVO-096 LDAL alarm (Track enc : i) (Explanation) The LED in the pulse coder is broken. (Action 1) Replace the pulse coder.

3.5.63 SRVO-097 Pulse not established (enc : i) (Explanation) The absolute position of the pulse coder cannot be 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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3. TROUBLESHOOTING

3.5.64 SRVO-105 Door open or E-stop (Explanation) The cabinet door is open. (Action 1) When the door is open, close it. If no door switch is mounted, go to [Action 3]. (Action 2) Check the door switch and door switch connection cable. If the switch or cable is faulty, replace it. (Action 3) Check that the CRM67, CRM70, and CRM71 connectors on the E-STOP unit are connected securely. (Action 4) Replace the teach pendant. (Action 5) Replace the teach pendant cable. (Action 6) Replace the mode switch on the operator's panel/ operation box. Or replace the operator's panel/ operation box. (Action 7) Replace the panel switch unit on the operator's panel/ operation box. Or replace the operator's panel/ operation box. (Action 8) Replace the panel board. (Action 9) Replace the E-stop unit. (Action 10) Replace the servo amplifier. (Action 11) Replace the connection cable between the panel board and the E-stop unit.

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

1

Door switch

5

Power supply unit

2

Servo amplifier

6

A-cabinet

3

Main board

7

B-cabinet

4

E-stop unit

8

Electro magnetic contactor

Fig. 3.5.64 SRVO-105 Door open or E-stop

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3. TROUBLESHOOTING

3.5.65 SRVO-136 DCLVAL alarm (Group : i Axis : j) (Explanation) The servo amplifier DC current (DC link voltage) is abnormally low. This alarm occured 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 other 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 occured 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.

-114-

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MAINTENANCE

B-81465EN-1/05

1

Power supply unit

4

E-stop unit

2

Servo amplifier

5

A-cabinet

3

Main board

6

B-cabinet

Fig. 3.5.65 SRVO-136 DCLVAL alarm

-115-

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MAINTENANCE

3.5.66 SRVO-138 SDAL alarm (Group : i Axis : j) (Explanation) The feedback data from the pulse coder was abnormal caused by noise on the pulse coder. Or the interpolation circuit of the pulse coder is broken. (Action 1) If the alarm disappears by turning power off and then on make sure the cable shields are grounded. (Action 2) If this problem occurs repeatedly, replace the pulse coder and master the robot.

3.5.67 SRVO-153 CHGAL(CNV) alarm (Group : i Axis : j) (Explanation) The main circuit could not be charged within the specified time. (Action 1) A short circuit may occur in the DC link. Check the connection. (Action 2) The charging current control resistor may be faulty. Replace the E-STOP unit. (Action 3) Replace the servo amplifier.

1

Servo amplifier

3

A-cabinet

2

E-stop unit

4

B-cabinet

Fig. 3.5.67 SRVO-153 CHGAL(CNV) alarm

-116-

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MAINTENANCE

B-81465EN-1/05

3.5.68 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 (CRR64 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.

1

Servo amplifier

2

A-cabinet

3

Fig. 3.5.68 SRVO-156 IPMAL alarm

-117-

B-cabinet

B-81465EN-1/05

MAINTENANCE

3. TROUBLESHOOTING

3.5.69 SRVO-194 Servo disconnect (Explanation) On the terminal block TBOP3 of the panel board, no connection is made between 5 (SD4) and 6 (SD41) or between 7 (SD5) and 8 (SD51). If a servo disconnect switch is connected between 5 (SD4) and 6 (SD41) or between 7 (SD5) and 8 (SD51), the switch is pressed. If the SYST-067 (Panel HSSB disconnect) alarm is also generated, or if the LED (green) on the panel board is turned off, communication between the main board (JRS11) and the panel board (JRS11) is abnormal. The connectors of the cable between the main board and the panel board may be loose. Or, the cable, panel board, or main board may be faulty. (Note) In case that RDY LED (green) is lit. (Action 1) If a servo disconnect switch is connected, release the switch. (Action 2) Check the switch and cable connected to 5 (SD4) - 6 (SD41), 7 (SD5) - 8 (SD51) on TBOP3. (Action 3) When this signal is not used, make a connection between 5 (SD4) and 6 (SD41) or 7 (SD5) and 8 (SD51). (Action 4) Replace the PC board. In case that RDY LED (green) is not lit. (Action 1) Check whether FUSE1 on the panel board is blown. If FUSE1 is blown, replace FUSE1 after removing the cause. Else if, check the voltage of EXT24V and EXT0V (TBOP6). If external 24V, 0V is not used check the jumper pins between EXT24V and INT24V, EXT0V and INT 0V (TBOP6). (Action 2) Replace the panel board. (Action 3) Replace the cable connecting between the main board (JRS11) and the panel board (JRS11). Before executing the (Action4), perform a complete controller back-up to save all your programs and settings. (Action 4) Replace the main board.

WARNING Do NOT short-circuit, or disable, this signal in a system in which the External emergency stop input signal is in use, as it is very dangerous. If it is necessary to run the robot by short-circuiting the signal even temporarily, an additional safety provision must be provided.

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B-81465EN-1/05


1

Panel board

4

Connector (JRS11)

2

Short connection 5 (SD4) and 6 (SD41)

5

Short connection 7 (SD5) and 8 (SD51)

3

LED (Green)

2

Main board

Fig. 3.5.69 (a) SRVO-194 Servo disconnect

1

Connector (JRS11)

Fig. 3.5.69 (b) SRVO-194 Servo disconnect

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MAINTENANCE

3. TROUBLESHOOTING

3.5.70 SRVO-199 Control Stop (Explanation) This alarm is displayed together with a Fence open alarm or SVOFF input alarm.

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.71 SRVO-201 Panel E-stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator´s panel or operation box was pressed, but the EMERGENCY STOP line was not disconnected. In case that RDY LED (green) is lit. (Action 1) Don't press slowly the emergency stop on the operator's panel/operation box. (Action 2) Check the emergency stop on the operator's panel/operation box. If the switch has any problem, replace the switch unit or the operator's panel/operation box. (Action 3) Replace the panel board. (Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier. In case that RDY LED (green) is not lit. (Action 1) Replace the cable connecting between the main board (JRS11) and the panel board (JRS11). (Action 2) Replace the panel board. Before executing the (Action3), perform a complete controller back-up to save all your programs and settings. (Action 3) Replace the main board.

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


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MAINTENANCE

1


4

E-stop unit

2

Panel board

5

A-cabinet

3

Servo amplifier

6

B-cabinet

Fig. 3.5.71 SRVO-201 Panel E-stop or SVEMG abnormal

-122-

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.72 SRVO-202 TP E-stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator´s panel or operation box was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Don't press slowly the emergency stop on the teach pendant. (Action 2) Replace the teach pendant. (Action 3) Replace the teach pendant cable. (Action 4) Replace the operator's panel/operation box. (Action 5) Replace the E-stop unit. (Action 6) Replace the servo amplifier.

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

-123-

B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

1


6

Servo amplifier

2

Panel board

7

E-stop unit

3

Mode switch

8

A-cabinet

4

Teach pendant

9

B-cabinet

5

Door switch

Fig. 3.5.72 SRVO-202 TP E-stop or SVEMG abnormal

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.73 SRVO-204 External (SVEMG abnormal) E-STOP (Explanation) The switch connected across EES1 and EES11, EES2 and 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 1 (EES1)-2 (EES11), 3 (EES2)-4 (EES21) on TBOP4. (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 E-stop unit and the panel board. In case that RDY LED (green) is not lit. (Action 1) Replace the cable connecting between the main board (JRS11) and the panel board (JRS11). (Action 2) Replace the panel board. Before executing the (Action3), perform a complete controller back-up to save all your programs and settings. (Action 3) Replace the main board.


-125-

B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

1


5

E-stop unit

2

Panel board

6

A-cabinet

3

TBOP6

7

B-cabinet

4

Servo amplifier

Fig. 3.5.73 (a) SRVO-204 External (SVEMG abnormal) E-stop

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3. TROUBLESHOOTING

1

MAINTENANCE

EXEMG signals

2

Fig. 3.5.73 (b) External E-stop signals connection

-127-

B-81465EN-1/05

Panel board

B-81465EN-1/05

MAINTENANCE

3. TROUBLESHOOTING

3.5.74 SRVO-205 SVAL1 Fence open (SVEMG abnormal) (Explanation) The switch connected across EAS1 and EAS11, EAS2 and EAS21 on the TBOP4 terminal board on the panel board was pressed, but the EMERGENCY STOP line was not disconnected. In case that RDY LED (green) is lit. (Action 1) Check the switch and cable connected to 5 (EAS1) and 6 (EAS11) or 7 (EAS2) and 8 (EAS21) on TBOP4. (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 E-stop unit and the panel board. In case that RDY LED (green) is not lit. (Action 1) Replace the cable connecting between the main board (JRS11) and the panel board (JRS11). (Action 2) Replace the panel board. Before executing the (Action3), perform a complete controller back-up to save all your programs and settings. (Action 3) Replace the main board.


-128-

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

1


4

E-stop unit

2

Panel board

5

A-cabinet

3

Servo amplifier

6

B-cabinet

Fig. 3.5.74 (a) SRVO-205 Fence open (SVEMG abnormal)

-129-

B-81465EN-1/05

1

3. TROUBLESHOOTING

MAINTENANCE

Fence signals

2

Fig. 3.5.74 (b) Fence open signal connection

-130-

Panel board

3. TROUBLESHOOTING

MAINTENANCE

3.5.75 SRVO-206 Deadman switch (SVEMG abnormal) (Explanation) The DEADMAN switch was released when the teach pendant was operable, but the EMERGENCY STOP line was not disconnected. (Action 1) Replace the teach pendant. (Action 2) Replace the teach pendant cable. (Action 3) Replace the operator's panel/operation box. (Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier.

-131-

B-81465EN-1/05

B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

1


6

Servo amplifier

2

Panel board

7

E-stop unit

3

Mode switch

8

A-cabinet

4

Teach pendant

9

B-cabinet

5

Door switch

Fig. 3.5.75 SRVO-206 Deadman switch (SVEMG abnormal)

-132-

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.76 SRVO-213 Fuse blown (Panel PCB) (Explanation) A fuse on the panel board has blown. (Action 1) Check whether FUSE1 on the panel board is blown. If FUSE1 is blown, replace FUSE1 after removing the cause. Else if, check the voltage of EXT24V and EXT0V (TBOP6). If external 24V, 0V is not used check the jumper pins between EXT24V and INT24V, EXT0V and INT0V (TBOP6). (Action 2) Replace the cable connecting between the main board (JRS11) and the panel board (JRS11). (Action 3) Replace the panel board. Before executing the (Action3), perform a complete controller back-up to save all your programs and settings. (Action 4) Replace the main board.

-133-

B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

1

A-cabinet

3

TBOP6

2

Panel board

4

B-cabinet

Fig. 3.5.76 SRVO-213 Fuse blown (Panel PCB)

-134-

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05


-135-

B-81465EN-1/05

MAINTENANCE

-136-

3. TROUBLESHOOTING

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.77 SRVO-214 Fuse blown (Amp) (Explanation) A fuse in the servo amplifier has blown. In case that F1 or F2 is blown. (Action 1) Replace the servo amplifier. In case that F2 or F3 is blown. (Action 1) A fuse is blown, eliminate the cause, then replace the fuse. (See II MAINTENANCE, Section 3.6.) (Action 2) Replace the servo amplifier.

1

Servo amplifier

3

B-cabinet

2

A-cabinet

4

E-stop unit

Fig. 3.5.77 SRVO-214 Fuse blown (Panel PCB)

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B-81465EN-1/05

MAINTENANCE

3. TROUBLESHOOTING

3.5.78 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.

3.5.79 SRVO-221 Lack of DSP (Group : i Axis : j) (Explanation) An axis control 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 it to the correct number. (Action 2) Replace the axis control card with a card corresponding to the set number of axes. (Example) When six axes are set, an axis control card for six or eight axes is available. For how to replace the axis control card, see II MAINTENANCE, Section 7.2 in this manual.

-138-

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.80 SRVO-230 SVAL1 Chain 1 (+24V) abnormal SRVO-231 SVAL1 Chain 2 (0V) abnormal (Explanation) A single chain 1 (+24V)/chain 2 (0V) failure occured on emergency stop of the operator´s panel/ operation box or on the emergency stop of the teach pendant or deadman switch or fence switch or external emergency stop or servo ON/OFF switch or NTED input or door switch. Please check history of alarm on the Alarm Log. • Single chain failure is : One of emergency stop chain is emergency stop condition, and another chain is not emergency stop condition. • Cause of this alarm is : - Weld of contact - Wire broken or shorted - Half release of deadman switch - Half operation of emergency stop of operator’s panel and emergency stop of teach pendant - Irregular input from external emergency stop and etc. (Out of specified timing.) The single chain failure occurred on the emergency stop switch of the operator’s panel/operation box, emergency stop switch of the teach pendant and the deadman switch. This failure can be recovered by performing the correct stop operation. The detecting circuit for the single chain failure is reset by either entering another stop cause, or turning the power on again. Hold the alarm state for the duration that the alarm history is being checked.

CAUTION 1. This alarm is controlled by the software and requires a special reset procedure. After resolving the cause of the alarm, please issue the special reset procedure according to end of Explanations and Actions shown below. 2. The RESET operation is inhibited until the special reset procedure is performed. The message of "SRVO-237 Cannot reset chain failure" is displayed, if the RESET operation is issued before the special reset procedure is performed. 3. If a successful operator panel emergency stop, or teach pendant emergency stop, or when the deadman switch is released after this alarm, the message of "SRVO-236 Chain failure is repaired" is displayed.

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MAINTENANCE

3. TROUBLESHOOTING

Single chain 1 (+24V) failure is : (Example of external emergency stop)

1

EES1 is kept +24EXT even if issued external emergency stop.

2

E-stop circuit

3

One case, the contact of SB3-1 is welded.

Single chain 2 (0V) failure is : (Example of external emergency stop)

1

E-stop circuit

3

2

EES2 is kept 0EXT even if issued external emergency stop.

[Displaying the Alarm Log] Please refer to "Setup and Operations Manual". 1. Press "MENUS" on the teach pendant. 2. Press "4" on the teach pendant. [4 ALARM]. 3. Press F1, [TYPE]. 4. Select Alarm Log. (Example)

-140-

One case, the contact of SB3-2 is welded.

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.81 SRVO-230 Chain 1 (+24V) abnormal with SRVO-001 Operator ´s panel E-stop SRVO-231 Chain 2 (0V) abnormal with SRVO-001 Operator´s panel E-stop (Action 1) Re-operate emergency stop of operator´s panel/operation box. If this alarm is reset, the message of "SRVO-236 Chain failure is repaired" is displayed. (Action 2) Replace the panel board. (Action 3) Replace the operator´s panel/operation box. (Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier. (Action 6) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM67).

-141-

B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

1


6

E-stop unit

2

Panel board

7

Teach pendant

3

Mode switch

8

A-cabinet

4

Door switch

9

Operator´s panel

5

Servo amplifier

10

B-cabinet

3.5.81 SRVO-230 Chain 1 (+24V) abnormal

-142-

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.82 SRVO-230 Chain 1 (+24V) abnormal with SRVO-002 Teach pendant E-stop SRVO-231 Chain 2 (0V) abnormal with SRVO-002 Teach pendant E-stop (Action 1) Re-operate emergency stop of teach pendant. If this alarm is reset, the message of "SRVO-236 Chain failure is repaired" is displayed. (Action 2) Replace the teach pendant. (Action 3) Replace the teach pendant cable. (Action 4) Replace the panel board. (Action 5) Replace the E-stop unit. (Action 6) Replace the servo amplifier. (Action 7) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM67).

-143-

B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

1


6

E-stop unit

2

Panel board

7

Teach pendant

3

Mode switch

8

A-cabinet

4

Door switch

9

Operator´s panel

5

Servo amplifier

10

B-cabinet

Fig. 3.5.82 SRVO-230 Chain 1 (+24V) abnormal

-144-

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.83 SRVO-230 Chain 1 (+24V) abnormal with SRVO-003 Deadman switch released SRVO-231 Chain 2 (0V) abnormal with SRVO-003 Deadman switch released (Action 1) Re-operate deadman switch. If this alarm is reset. the message of "SRVO-236 Chain failure is repaired" is displayed. (Action 2) Replace the teach pendant. (Action 3) Replace the teach pendant cable. (Action 4) Replace the panel board. (Action 5) Replace the E-stop unit. (Action 6) Replace the servo amplifier. (Action 7) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM67).

-145-

B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

1


6

E-stop unit

2

Panel board

7

Teach pendant

3

Mode switch

8

A-cabinet

4

Door switch

9

Operator´s panel

5

Servo amplifier

10

B-cabinet


-146-

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.84 SRVO-240 Chain1 (FENCE) abnormal with SRVO-230 Chain1 (+24V) abnormal and SRVO-004 Fence open SRVO-241 Chain2 (FENCE) abnormal with SRVO-231 Chain2 (0V) abnormal and SRVO-004 Fence open (Action 1) Check the +24V connection of safety fence (EAS1 - EAS11), or the 0V connection of safety fence (EAS2 - EAS21) (Action 2) Replace the panel board. (Action 3) Replace the E-stop unit. (Action 4) Replace the servo amplifier (Action 5) Replace the mode switch.

-147-

B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

1


6

E-stop unit

2

Panel board

7

Teach pendant

3

Mode switch

8

A-cabinet

4

Door switch

9

Operator´s panel

5

Servo amplifier

10

B-cabinet

Fig. 3.5.84 (a) SRVO-240 Chain 1 (FENCE) abnormal

-148-

3. TROUBLESHOOTING

1

MAINTENANCE

Fence signals

2

Fig. 3.5.84 (b) Fence signals connectionl

-149-

B-81465EN-1/05

Panel board

B-81465EN-1/05

MAINTENANCE

3. TROUBLESHOOTING

3.5.85 SRVO-242 Chain1 (EXEMG) abnormal with SRVO-230 Chain 1 (+24V) abnormal and SRVO-007 External emergency stops SRVO-243 Chain 2 (EXEMG) abnormal with SRVO-231 Chain 2 (0V) abnormal and SRVO-007 External emergency stops (Action 1) Check the +24V connection of the external emergency stop (EES1 - EES11), or the 0V connection of the external emergeny stop (EES2 - EES21). (Action 2) Replace the panel board. (Action 3) Replace the E-stop unit. (Action 4) Replace the servo amplifier.

-150-

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

1


6

E-stop unit

2

Panel board

7

Teach pendant

3

Mode switch

8

A-cabinet

4

Door switch

9

Operator´s panel

5

Servo amplifier

10

B-cabinet

Fig. 3.5.85 (a) SRVO-242 Chain 1 (EXEMG) abnormal

-151-

B-81465EN-1/05

1

3. TROUBLESHOOTING

MAINTENANCE

EXEMG signals

2

Fig. 3.5.85 (b) EXEMG signals connection

-152-

Panel board

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.86 SRVO-230 Chain 1 (+24V) abnormal with SRVO-232 NTED input SRVO-231 Chain 2 (0V) abnormal with SRVO-232 NTED input (Action 1) Check the +24V connection of the NTED input (NTED1 - NTED11), or the 0V connection of the NTED input (NTED2 - NTED21). (Action 2) Replace the mode switch. (Action 3) Replace the panel board. (Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier. (Action 6) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM67).

-153-

B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

1


6

E-stop unit

2

Panel board

7

Teach pendant

3

Mode switch

8

A-cabinet

4

Door switch

9

Operator´s panel

5

Servo amplifier

10

B-cabinet

Fig. 3.5.86 (a) SRVO-230 Chain 1 (+24V) abnormal

-154-

3. TROUBLESHOOTING

1

MAINTENANCE

Panel board

Fig. 3.5.86 (b) NTED signal connection

-155-

B-81465EN-1/05

B-81465EN-1/05

MAINTENANCE

-156-

3. TROUBLESHOOTING

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.87 SRVO-230 Chain 1 (+24V) abnormal with SRVO-233 TP disabled in T1, T2/Door open SRVO-231 Chain 2 (0V) abnormal with SRVO-233 TP disabled in T1, T2/Door open (Action 1) Replace the teach pendant. (Action 2) Replace the teach pendant cable. (Action 3) Replace the mode switch. (Action 4) Replace the panel board. (Action 5) Replace the E-stop unit. (Action 6) Replace the servo amplifier. (Action 7) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM67).

-157-

B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

1


6

E-stop unit

2

Panel board

7

Teach pendant

3

Mode switch

8

A-cabinet

4

Door switch

9

Operator´s panel

5

Servo amplifier

10

B-cabinet


-158-

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

[Special reset operation]

CAUTION Do not issue this operation before resolving the cause of the alarm. 1. Press E-stop button for the correct emergency stop condition. 2. Press "MENU" on the teach pendant. 3. Press "0" on the teach pendant, [0 -- NEXT --]. 4. Press "6" on the teach pendant, [6 SYSTEM]. 5. Press F1, [TYPE]. 6. Select Config. 7. Search item 28. 8. Press F4, [TRUE]. The display of "28 Reset CHAIN FAILURE detection : " changes "TRUE" from "FALSE". And few seconds later the display changes "FALSE" from "TRUE" again. 9. The RESET operation is allowed.

1. Press "MENU" on the teach pendant. 2. Press "4" on the teach pendant, [4 -- ALARM --]. 3. Press "F4" on the teach pendant, [F4 -- RES_1CH --].

-159-

B-81465EN-1/05

MAINTENANCE

3. TROUBLESHOOTING

3.5.88 SRVO-232 NTED input (Explanation) Non teacher enabling device is released. (Action 1) Grasp the NTED. (Action 2) Replace the mode switch. (Action 3) Replace the panel board. (Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier. (Action 6) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM67).

-160-

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

1


6

E-stop unit

2

Panel board

7

Teach pendant

3

Mode switch

8

A-cabinet

4

Door switch

9

Operator´s panel

5

Servo amplifier

10

B-cabinet

Fig. 3.5.88 SRVO-232 NTED input

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3. TROUBLESHOOTING

3.5.89 SRVO-233 TP disabled in T1, T2/Door open (Explanation) The teach pendant is disabled when the mode switch is T1 or T2. Or the 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. Or check the door switch, and replace it if necessary. (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. (Action 9) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM67).

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1


6

E-stop unit

2

Panel board

7

Teach pendant

3

Mode switch

8

A-cabinet

4

Door switch

9

Operator´s panel

5

Servo amplifier

10

B-cabinet

Fig. 3.5.89 SRVO-233 TP disabled in T1, T2/Door open

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3. TROUBLESHOOTING

3.5.90 SRVO-235 Short term Chain abnormal (Explanation) A short term single chain failure condition is detected. • A short term single chain failure is : If any cause of stop is issued for a short time, the detecting circuit for the single chain failure detects a single chain failure depending on hardware specification. In this case, cause of stop is not detected by software, so this alarm is distinguished from "SRVO-230" and "SRVO-231". • Cause of this alarm is : • Half release of deadman switch • Half operation of emergency stop of operator´s panel/operation box and emergency stop of teach pendant Short term single chain failures occured on emergency stop of operator´s panel/operation box, emergency stop of teach pendant and deadman switch are recoverable issuing a correct stop operation. (Action 1) To reset detecting circuit for single chain failure, re-operate the emergency stop of the operator´s panel or emergency stop of teach pendant or deadman switch according previous operation. If this alarm is reset, the message of "SRVO-236 Chain failure is repaired" is displayed. (Action 2) Check the input requirement for external emergency stop. (Action 3) Replace the panel board. (Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier. (Action 6) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM 67).

CAUTION This alarm is an un-clear single chain failure condition. The software waits for a correct operation response to reset the single chain failure condition. If another cause is issued, then the software detects the real single chain failure and displays "Chain 1 (+24V) abnormal" or "Chain 2 (0V) abnormal".

NOTE 1. This alarm may occur when an operator panel/operation box emergency stop button a teach pendant emergency stop button is pushed or when the deadman switch is released. The above are operated by the operator. This alarm is provided for un-clear and fast-repeated operation by the operator. 2. If correct action is issued after this alarm, the messege of "SRVO-236 Chain failure is repaired" is displayed.

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3.5.91 SRVO-236 Chain failure is repaired (Explanation) A chain failure was repaired. For details, see the explanation of SRVO-230 and SRVO-231.

3.5.92 SRVO-237 Not reset chain failure (Explanation) A chain failure could not be repaired. See the explanation of SRVO-230 and SRVO-231. (Action 1) Check the alarm history and see the explanation of the displayed alarm.

3.5.93 SRVO-240 Chain 1 (FENCE) abnormal 3.5.94 SRVO-241 Chain 2 (FENCE) abnormal (Explanation) Although the circuit connected between EAS11 and EAS1 or between EAS21 and EAS2 on the TBOP4 terminal block on the panel board was disconnected, the emergency stop line was not disconnected. The emergency stop circuit is faulty. (Action 1) Replace the panel board. (Action 2) Replace the E-STOP unit. (Action 3) Replace the servo amplifier. (Action 4) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM67).

NOTE Eliminate the cause of the abnormal chain, then execute "special reset operation" to release the alarm.

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MAINTENANCE

1


4

E- stop unit

2

Panel board

5

A-cabinet

3

Servo amplifier

6

B- cabinet

Fig. 3.5.94 (a) SRVO-241 Chain 2 (FENCE) abnormal

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1

MAINTENANCE

Fence signals

2

Fig. 3.5.94 (b) FENCE signal connection

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Panel board

B-81465EN-1/05

MAINTENANCE

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3. TROUBLESHOOTING

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B-81465EN-1/05

3.5.95 SRVO-242 Chain 1 (EXEMG) abnormal SRVO-243 Chain 2 (EXEMG) abnormal (Explanation) Although the external emergency stop circuit was disconnected, the emergency stop line was not disconnected. The emergency stop circuit is faulty. (Action 1) Replace the panel board. (Action 2) Replace the E-STOP unit. (Action 3) Replace the servo amplifier. (Action 4) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM67).


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MAINTENANCE

1


4

E-stop unit

2

Panel board

5

A-cabinet

3

Servo amplifier

6

B-cabinet

Fig. 3.5.95 (a) SRVO-242 Chain 1 (EXEMG) abnormal / SRVO-243 Chain 2 (EXEMG) abnormal

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1

MAINTENANCE

EXEMG singals

2

Fig. 3.5.95 (b) EXEMG signals connection

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Panel board

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MAINTENANCE

3. TROUBLESHOOTING

3.5.96 SRVO-260 Chain 1 (NTED) abnormal SRVO-261 Chain 2 (NTED) abnormal (Explanation) Although the non-teacher-enabling device disconnected the NTED circuit in the T1/T2 mode, the emergency stop line was not disconnected. The emergency stop circuit is faulty. (Action 1) Replace the panel board. (Action 2) Replace the E-STOP unit. (Action 3) Replace the servo amplifier. (Action 4) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM67).

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MAINTENANCE

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1


4

E-stop unit

2

Panel board

5

A-cabinet

3

Servo amplifier

6

B-cabinet

Fig. 3.5.96 (a) SRVO-260 Chain 1 (NTED) abnormal / SRVO-261 Chain 2 (NTED) abnormal

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1

MAINTENANCE

Panel board

Fig. 3.5.96 (b) NTED signal connection

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3. TROUBLESHOOTING

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3.5.97 SRVO-262 Chain 1 (SVDCT) abnormal SRVO-263 Chain 2 (SVDCT) abnormal (Explanation) Although the SVDCT circuit was disconnected, the emergency stop line was not disconnected. The emergency stop circuit is faulty. (Action 1) Replace the panel board. (Action 2) Replace the E-STOP unit. (Action 3) Replace the servo amplifier. (Action 4) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM67).

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MAINTENANCE

1


4

E-stop unit

2

Panel board

5

A-cabinet

3

Servo amplifier

6

B-cabinet

Fig. 3.5.97 (a) SRVO-262 Chain 1 (SVDCT) abnormal / SRVO-263 Chain 2 (SVDCT) abnormal

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1

MAINTENANCE

Panel board

Fig. 3.5.97 (b) SVDCT signals connection

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3.5.98 SRVO-264 "E.STOP circuit abnormal 1" (Explanation) An error occurred in the emergency stop circuit. (Action 1) Check whether the CRM67 and CRM72 connectors on the E-STOP unit are connected securely. (Action 2) Check whether the circuits connected to CRM67 and CRM72 in the emergency stop circuit are normal. (Action 3) Replace the E-STOP unit. (Action 4) Replace the servo amplifier.

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MAINTENANCE

B-81465EN-1/05

1


4

E-stop unit

2

Panel board

5

A-cabinet

3

Servo amplifier

6

B-cabinet

Fig. 3.5.98 SRVO-264 "E.STOP circuit abnormal 1"

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3.5.99 SRVO-265 E.STOP circuit abnormal 2 (Explanation) When the servo entered the activated state, MON3 was in the on state. The MON3 state is abnormal. (Action 1) Replace the E-STOP unit. (Action 2) Replace the servo amplifier.

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

1


4

E-stop unit

2

Panel board

5

A-cabinet

3

Servo amplifier

6

B-cabinet

Fig. 3.5.99 SRVO-265 E.STOP circuit abnormal 2

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3. TROUBLESHOOTING

3.5.100 SRVO-266 FENCE1 status abnormal SRVO-267 FENCE2 status abnormal (Explanation) The fence circuit is abnormal. (Action 1) Check the +24 V connection (between EAS11 and EAS1) and 0 V connection (between EAS21 and EAS2) for the fence. (Action 2) Check the fence switch. (Action 3) Replace the panel board.


3.5.101 SRVO-268 SVOFF1 status abnormal SRVO-269 SVOFF2 status abnormal (Explanation) The SVOFF circuit is abnormal. (Action 1) Check the +24 V connection (between EGS11 and EGS1) and 0 V connection (between EGS21 and EGS2) for the SVOFF circuit. (Action 2) Check the SVOFF switch. (Action 3) Replace the panel board.


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MAINTENANCE

B-81465EN-1/05

3.5.102 SRVO-270 EXEMG1 status abnormal SRVO-271 EXEMG2 status abnormal (Explanation) The EXEMG circuit is abnormal. (Action 1) Check the +24 V connection (between ESPB11 and ESPB1) and 0 V connection (between ESPB21 and ESPB2) for the EXEMG circuit. (Action 2) Check the EXEMG switch. (Action 3) Replace the panel board.


3.5.103 SRVO-272 SVDISC1 status abnormal SRVO-273 SVDISC2 status abnormal (Explanation) The SVDISC circuit is abnormal. (Action 1) Check the +24 V connection (between SD41 and SD4) and 0 V connection (between SD51 and SD5) for the SVDISC circuit. (Action 2) Check the SVDISC switch. (Action 3) Replace the panel board.


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3. TROUBLESHOOTING

3.5.104 SRVO-274 NTED1 status abnormal SRVO-275 NTED2 status abnormal (Explanation) The NTED circuit is abnormal. (Action 1) Check the +24 V connection (between NTED11 and NTED1) and 0 V connection (between NTED21 and NTED2) for the NTED circuit. (Action 2) Check the NTED switch. (Action 3) Replace the panel board.


3.5.105 SRVO-280 SVOFF input (Explanation) On the terminal block TBOP4 of the panel board, no connection is made between 9 (EGS1) and 10 (EGS11) or between 11 (EGS2) and 12 (EGS21). If a switch is connected between 9 (EGS1) and 10 (EGS11) or between 11 (EGS2) and 12 (EGS21), the switch is pressed. In case that RDY LED (green) is lit. (Action 1) If a switch is connected, releases the switch. (Action 2) Check the switch and cable connected to 9 (EGS1) and 10 (EGS11) or 11 (EGS2) and 12 (EGS21) on TBOP4. (Action 3) When this signal is not used, make a connection between 9 (EGS1) and 10 (EGS11) or between 11 (EGS2) and 12 (EGS21). (Action 4) Replace the panel board. In case that RDY LED (green) is not lit. (Action 1) Check whether FUSE1 on the panel board is blown. If FUSE1 is blown, replace FUSE1 after removing the cause. Else if, check the voltage of 9 (EXT24V) and 12 (EXT0V) (TBOP6). If external 24V, 0V is not used check the jumper pins between 9 (EXT24V) and 10 (INT24V), 12 (EXT0V) and 11 (INT 0V) (TBOP6). (Action 2) Replace the panel board. (Action 3) Replace the cable connecting between the main board (JRS11) and the panel board (JRS11).

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Before executing the (Action4), perform a complete controller back-up to save all your programs and settings. (Action 4) Replace the main board.

CAUTION Before performing "Action 6," make a backup copy of all programs and settings in the control unit.

NOTE SVOFF input (GENERAL STOP) is a safety stop input. When this input is opened, the robot decelerates in a controlled manner and then stops. The magnetic contactor opens after the robot stops.


WARNING Do NOT short-circuit, or disable, this signal in a system in which the Servo off emergency stop signal input is in use, as it is very dangerous. If it is necessary to run the robot by short-circuiting the signal even temporarily, an additional safety provision must be provided.


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MAINTENANCE

1

Short connection 9 (EGS1) and 10 (EGS11)

4

Connector (JRS11)

2

Short connection 11 (EGS2) and 12 (EGS21)

5

Panel Board

3

LED (Green)

2

Main board

Fig. 3.5.105 (a) SRVO-280 SVON input

1

Connector (JRS11)

Fig. 3.5.105 (b) SRVO-280 SVAL1 SVON input

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B-81465EN-1/05

3.5.106 SRVO-281 SVOFF input (SVEMG abnormal) (Explanation) When the SVOFF signal was input, an SVEMG error was detected. The emergency stop circuit is faulty. In case that RDY LED (green) is lit. (Action 1) Check the switch and cable connected to 9 (EGS1) and 10 (EGS11) or 11 (EGS2) and 12 (EGS21) on TBOP4. (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 E-STOP unit and the panel board. In case that RDY LED (green) is not lit. (Action 1) Replace the cable connecting between the main board (JRS11) and the panel board (JRS11). (Action 2) Replace the panel board. Before executing the (Action3), perform a complete controller back-up to save all your programs and settings. (Action 3) Replace the main board.


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3. TROUBLESHOOTING

MAINTENANCE

1


4

E-stop unit

2

Panel board

5

A-cabinet

3

Servo amplifier

6

B-cabinet

Fig. 3.5.106 (a) SRVO-281 SVOFF input (SVEMG abnormal)

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3. TROUBLESHOOTING

1

MAINTENANCE

SVOFF signals

2

Fig. 3.5.106 (b) SVOFF signals connection

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Panel board

B-81465EN-1/05

MAINTENANCE

3. TROUBLESHOOTING

3.5.107 SRVO-282 Chain1 (SVOFF) abnormal SRVO-283 Chain2 (SVOFF) abnormal (Explanation) Although the switch connected between EGS11 and EGS1 or between EGS21 and EGS2 on the TBOP4 terminal block on the panel board was pressed, the emergency stop line was not disconnected. The emergency stop circuit is faulty. (Action 1) Replace the panel board. (Action 2) Replace the E-STOP unit. (Action 3) Replace the servo amplifier. (Action 4) Replace the connection cable between the panel board and the E-stop unit (CRM64), or between the E-stop unit and the servo amplifier (CRM67).

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

1


4

E-stop unit

2

Panel board

5

A-cabinet

3

Servo amplifier

6

B-cabinet

Fig. 3.5.107 (a) SRVO-282 Chain1 (SVOFF) abnormal / SRVO-283 Chain2 (SVOFF) abnormal

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B-81465EN-1/05

1

3. TROUBLESHOOTING

MAINTENANCE

SVOFF signals

2


-192-

Panel board

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.5.108 SRVO-282 Chain1 (SVOFF) abnormal with SRVO-230 Chain 1 (+24V) abnormal and SRVO-280 SVOFF input SRVO-283 Chain2 (SVOFF) abnormal with SRVO-231 Chain 2 (0V) abnormal and SRVO-280 SVOFF input (Action 1) Check the +24V connection of servo ON/OFF switch (EGS1 - EGS11), or the 0V connection of servo ON/OFF switch (EGS2 - EGS21). (Action 2) Replace the panel board. (Action 3) Replace the E-STOP unit. (Action 4) Replace the servo amplifier.

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3. TROUBLESHOOTING

MAINTENANCE

1


6

Mode switch

2

Panel board

7

Operator’s panel

3

Servo amplifier

8

Teach pendant

4

E-stop unit

9

B-cabinet

5

A-cabinet

Fig. 3.5.108 (a) SRVO-282 Chain1 (SVOFF) abnormal

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3. TROUBLESHOOTING

1

MAINTENANCE

SVOFF signals

2


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B-81465EN-1/05

Panel board

B-81465EN-1/05

MAINTENANCE

3. TROUBLESHOOTING

3.5.109 SRVO-291 "IPM over heat (Group : i Axis : j)" (Explanation) The IPM in the servo amplifier overheats. (Action 1) Check whether the amplifier fan stops. (Action 2) Reduce the override because the use condition is too hard. (Action 3) If this alarm is frequently issued, replace the amplifier.

3.5.110 SRVO-292 EXT FAN alarm (Group : i A : j) (Explanation) The external fan for the alphaSVMi is faulty. (Action 1) Replace the external fan for the SVM.

3.5.111 SRVO-293 DClink (PSM) HCAL (Group : i Axis : j) (Explanation) The three-phase input power supply is abnormal or the PSM is faulty. (Action 1) Check the three-phase input power supply. (Action 2) Replace the PSM.

3.5.112 SRVO-294 EXT FAN (PSM) alarm (Group : i Axis : j) (Explanation) The external fan for the alphaPSM and alphaPSMR is faulty (Action 1) Replace the external fan.

3.5.113 SRVO-295 PSM COM alarm (Group : i Axis : j) (Explanation) The cable between the PSM and SVM may be faulty or the PSM or SVM may be faulty. (Action 1) Replace the cable between the PSM and SVM. (Action 2) Replace the PSM. (Action 3) Replace the SVM.

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B-81465EN-1/05

3.5.114 SRVO-296 PSM DISCHG alarm (Group : i Axis : j) (Explanation) The use condition is too hard or the fan for cooling the regenerative resistance for the PSMR stops. (Action 1) Reduce the taught feedrate because the use condition is too hard. (Action 2) Check whether the fan for cooling the regenerative resistance for the PSMR stops.

3.5.115 SRVO-297 PSM Low Volt alarm (Group : i Axis : j) (Explanation) The three-phase input voltage may drop or the PSM or SVM may be faulty. (Action 1) Check the three-phase input power supply. (Action 2) Replace the PSM. (Action 3) Replace the SVM.

3.5.116 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 III CONNECTION, Subsection 5.5.3 in this manual.)

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.6 FUSED-BASED TROUBLESHOOTING 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

Action

F1

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

1 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. 2 Replace the power supply unit.

F3

F4

If the fuse blows when the power supply is turned on, an alarm such as for overtravel, hand broken, FSSB disconnect or 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.

1 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, servo amplifier or cable if any.

The power, when turned on, is immediately turned off. At this time, the LED (ALM: Red) lights.

1 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.

2 Replace the power supply unit.

2 Replace the power supply unit.

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1

Servo amplifier

6

(Parts mounting side)

2

Power supply unit

7

F3 7.5A Fuse for +24E

3

A-cabinet

8

F4 7.5A Fuse for +24V

4

B-cabinet

9

PIL LED (green) for AC power supply display

5

F1 8.0A Fuse for AC input

10

ALM LED (red) for alarm display

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2. Servo amplifier fuse FS1: For generation of the power to the amplifier control circuit FS2: For protection of the 24V output to the end effector, ROT, and HBK FS3: For protection of the 24V output to the regenerative resistors and the additional axis amplifier F1, F2: For protection of the circuit failure in the servo amplifier.

Name


Action

FS1

All LEDs on the servo amplifier go out. The FSSB disconnection or initialization alarm is displayed on the teach pendant.

Replace the servo amplifier.

FS2

The fuse blown (Amp) alarm (SRVO- 214), hand breakage (SRVO- 006), and ROBOT OVER TRAVEL (SRVO- 005) are displayed on the teach pendant.

1 Check +24E used by the end effector for a ground fault. 2 Check the robot connection cable and the robot's internal cable. 3 Replace the servo amplifier.

FS3

The blown fuse (Amp) alarm (SRVO-214) and DCAL (SRVO-043) are displayed on the teach pendant.

1 Check the regenerative resistor, and replace it if required. 2 Check the additional axis amplifier and its wiring, and replace them if required. 3 Replace the servo amplifier.

F1 F2

The OHAL1 alarm is output on the teach pendant.

1 Check if the cables connected to three phase input of servo amplifier is defective. 2 Replace the servo amplifier.

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1

Servo amplifier

4

Fuse FS1

2

Fuse F1

5

Fuse FS3

3

Fuse F2

6

Fuse FS2

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

Symptom observed when fuse has blown The external emergency stop, open fence, SVOFF input, and blown fuse (panel PCB) alarm are displayed on the teach pendent.

Action 1 If the following alarms are displayed without fuse blown, check the voltage of EXT24V, EXT0V (TBOP6) If external 24V, 0V isn't used, check the jumper pins between EXT24V and INT24V, EXT0V and INT0V (TBOP6) 2 Check the +24EXT line (emergency stop line) for a short-circuit and ground fault. 3 Replace the panel board.

FUSE2

The display on the teach pendant disappears.

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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3. TROUBLESHOOTING

1

FUSE 2

2

Total edition

MAINTENANCE

3

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Panel board

MAINTENANCE

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3. TROUBLESHOOTING

4. Fuse on the process I/O board FUSE1: Fuse for +24 V Name


Action

FUSE1

The LED (ALM-2 or FALM) on the process I/O 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.

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2 Replace the process I/O printed circuit board.

3. TROUBLESHOOTING

1

Process I/O board CA, CB

2

FUSE 1

MAINTENANCE

3

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Process I/O board DA

B-81465EN-1/05

MAINTENANCE

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3. TROUBLESHOOTING

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1

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

3

Process I/O board FA

2

Total edition

4

Process I/O board GA

1

Process I/O board HA

2

Total edtion

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3.7 TROUBLESHOOTING BASED ON LED INDICATIONS The printed circuit boards and servo amplifier are provided with alarm LEDs and status LEDs. The LED status and corresponding troubleshooting procedures are described below.

1

E-stop button

5

A-cabinet

2

Panel board

6

Main board

3

Servo amplifier

7

Power supply unit

4

E-stop unit

8

B cabinet

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3. TROUBLESHOOTING

1. TROUBLESHOOTING USING THE LEDS ON THE MAIN BOARD 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 17, 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.

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

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

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

4: The initialization of SRAM and DPRAM 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 main board. [Action2]* Replace the FROM/SRAM module.

6: The loading of the basic software is completed.


7: Basic software start-up.


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3. TROUBLESHOOTING

Step

MAINTENANCE

LED

B-81465EN-1/05

Action to be taken

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


9: The loading of optional software is completed.

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

10: DI/DO initialization

[Action1]* Replace 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.

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

Step

LED

Action to be taken

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.

CAUTION 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.

1

Main board

3

CPU card

2

FROM/SRAM module

4

Axis control card

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

2. TROUBLESHOOTING BY 7-SEGMENT LED INDICATOR 7-segment LED indicator

Description [Description] A parity alarm condition has occurred in RAM on the CPU card installed on the main board. [Action1] Replace the CPU card. [Action2] Replace the main board. [Description] A parity alarm condition has occurred in RAM 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 communication error has occurred during communication with the panel board. [Action1] Check the communication cable (optical cable) between the main and panel boards, and replace it if necessary. [Action2] Replace the main board. [Action3] Replace the panel board. [Description] A servo alarm condition has occurred on the main board. [Action1] Replace the axis control card. [Action2] Replace the main board.

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MAINTENANCE

B-81465EN-1/05

7-segment LED indicator

3. TROUBLESHOOTING

Description [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 are not occured.


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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

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 3.1. [Action2] Replace the power supply unit.

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B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

1

Power supply unit

5

F4 7.5A Fuse for +24V

2

F1 8.0A Fuse for AC input

6

PIL LED (green) for AC power supply display

3


7

ALM LED (red) for alarm display

4

F3 7.5A Fuse for +24E

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

Troubleshooting by LED on the panel board LED indication

Failure description and required measure

RDY

[Description] When the LED (green) cloes not light. Communication with the main board does not execute. [Action1] Check the communication cable (optical cable) between the main and panel boards, and replace it if necessary. [Action2] Replace the main board. [Action3] Replace the panel board.

PON

[Description] When the LED (green) does not light. The power supply inside the panel board does not generate +5 V normally. [Action1] Check the CRM63 connector and check that 24 V is supplied. [Action2 ] Replace the panel board

D1 D2

[Description]

When the LED does not light, emergency stop factor exists on the teach pendant and panel board. D1 correspondents to SVON2 D2 correspondents to SVON1 Refer to the Emergency stop circuit.

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B-81465EN-1/05

3. TROUBLESHOOTING

MAINTENANCE

1

PON LED (Green)

3

RDY LED (Green)

2

Total edition

4

Panel board (A20B-2100-0770) (Total edition before 03C)


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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

1

PON LED (Green)

3

Total edition

2

D1 LED (Green)

4

Panel board (A20B-2100-0770) (Total edition after 04D)

-221-

MAINTENANCE

B-81465EN-1/05

3. TROUBLESHOOTING

Troubleshooting by alarm LEDs on the process I/O printed circuit board LED indication

Description and action to be taken

Process I/O CA/CB/DA/HA

Process I/O EA/EB/FA/GA

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

Process I/O CA/CB/DA/HA

Process I/O EA/EB/FA/GA

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

1

Fuse

2

For process I/O printed circuit board CA/CB/DA/HA Specification : A60I-0001-0046#2.0

3

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For process I/O printed circuit board EA/EB/FA/GA Specification : A60L-0001-0046#2.0

3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

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.

1

Check that the voltage is not higher than 50V.

CAUTION Check the screw above LED "D7" with a DC voltage to see if the remaining voltage is not higher than 50V.

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MAINTENANCE

B-81465EN-1/05

LED

Color

P5V

Green

P3.3V

Green

SVEMG

Red

ALM

Red

RDY

Green

OPEN

Green

3. TROUBLESHOOTING

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 +5 V 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. 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.

-224-

3. TROUBLESHOOTING

LED

MAINTENANCE

Color

WD

Red

D7

Red

B-81465EN-1/05

Description Lights when a watch dog alarm is detected in the servo amplifier. [Measure 1] Replace the servo amplifier. [Measure 2] Replace the servo card. [Measure 3] Replace the CPU card. [Measure 4] Replace the main board. 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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B-81465EN-1/05

MAINTENANCE

3. TROUBLESHOOTING

3.8 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.

3.9 VIBRATION OBSERVED DURING MOVEMENT (Check 1) Check the settings of parameters such as the position loop gain parameter. (Corrective action) Correct parameters. (Check 2) Check the mechanical unit for backlash. (Corrective action) Replace a faulty key of motor shaft or other faulty parts.

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3. TROUBLESHOOTING

MAINTENANCE

B-81465EN-1/05

3.10 MANUAL OPERATION IMPOSSIBLE The following explains checking and corrective action required if the robot cannot be operated manually after the controller is turned on: 1. Check and corrective action to be made if manual operation is impossible (Check 1) Check whether the teach pendant is enabled. (Corrective action) 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 case 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 is on (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.

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B-81465EN-1/05

MAINTENANCE

3. TROUBLESHOOTING

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. (Check 2) Check whether the HOLD signal for the peripheral-device control interface is on. Also check whether the HOLD switch on the teach pendant is on. (Corrective action) If the HOLD signal 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. PRINTED CIRCUIT BOARDS

MAINTENANCE

B-81465EN-1/05

4 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 standard printed circuit board includes the main unit printed circuit board and one or more cards or modules installed horizontally to the main 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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B-81465EN-1/05

MAINTENANCE


4.1 MAIN BOARD (A16B-3200-0412, -0413)

1

FROM/SRAM module

4

Axis control card

2

CPU card

5

TBDL exists in case of -0413

3

Total version

Fig. 4.1 Main board

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Name

Ordering Specification

MAINTENANCE

B-81465EN-1/05

Board Specification

Note

CPU card

A05B-2450-H010

A20B-3300-0104

SDRAM 8M (Standard)

CPU card

A05B-2450-H011

A20B-3300-0105

SDRAM 16M

Axis control card

A05B-2450-H021

A20B-3300-0240

8-axis

Axis control card

A05B-2450-H021

A20B-3300-0390

8-axis

Axis control card

A05B-2450-H020

A20B-3300-0241

6-axis (standard)

Axis control card

A05B-2450-H020

A20B-3300-0391

6-axis (standard)

Axis control card

TBD

A20B-3300-0242

4-axis

FROM/SRAM module

A05B-2450-H031

A20B-3900-0160

FROM 16M, SRAM 1M

FROM/SRAM module

A05B-2450-H032

A20B-3900-0161

FROM 16M, SRAM 2M

FROM/SRAM module

A05B-2450-H033

A20B-3900-0162

FROM 16M, SRAM 3M

FROM/SRAM module

A05B-2450-H035

A20B-3900-0163

FROM 32M, SRAM 1M

FROM/SRAM module

A05B-2450-H036

A20B-3900-0164

FROM 32M, SRAM 2M

FROM/SRAM module

A05B-2450-H037

A20B-3900-0165

FROM 32M, SRAM 3M

Main board

A05B-2450-H001

A16B-3200-0412

Standard

(1) Test pins Name

Use

GND1 GND2 GND3 CACHOFF LOAD MCBOOT CORE

For testing the printed circuit board

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MAINTENANCE

B-81465EN-1/05


(2) LEDs Seven segment LED

Description A parity alarm occurred in a RAM of the main CPU card on the main board.

A parity alarm occurred in a RAM of the SRAM module on the main board.

Bus error occurred on the communication controller.

A parity alarm occurred in DRAM controlled by communication controller.

A communication error occurred between panel boards and main board.

A servo alarm occurred on the main board.

SYSEMG occurred.

SYSFAIL occurred. This number appears temporarily after the power is switched on, but it is not abnormal.

5V is supplied to Mainboard. Above 0-7 alarms are not occurred.

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MAINTENANCE

Status LED

B-81465EN-1/05

Description

Operating status of the system.

ETHERNET LED

Color

Description

TX

Green

Flashes during data transmission.

RX

Green

Flashes during data reception.

L

Yellow

Lights when a connection to a network is made.

FDX

Green

Lights during full duplex communication.

COL

Red

Lights if a COLLISION occurs during half duplex communication.

BT

Green

Lights during communication with 10BASE-T.

BTX

Green

Lights during communication with 100BASE-T.

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MAINTENANCE

B-81465EN-1/05


(3) Driver/receiver 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)

A76L-0151-0098

75173 (Driver)

A76L-0151-0099

Please refer to Fig. 4.1 Main board.

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MAINTENANCE

B-81465EN-1/05

4.2 EMERGENCY STOP CONTROL BOARD (A20B-1007-0800)

1

LED 3

3

LED 1

2

LED 2

4

Total edition

Fig. 4.2 Emergency stop control board

(1) LED Name

Use

LED1

Status of Relay KA1-1 ON Active OFF Inactive

LED2

Status of KA2-1 ON Active OFF Inactive

LED3

Status of KA3-1 ON Active OFF Inactive

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B-81465EN-1/05


MAINTENANCE

4.3 BACKPLANE BOARD

1

A20B-2002-0771

2

Total edition

Fig. 4.3 (a) Backplane Board

(1) Test pins Name

Use

HI1 TEST1 LOW1


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1

(A20B-2002-0761)

2

Total edition

MAINTENANCE

3

B-81465EN-1/05

Test pins

Fig. 4.3 (b) Backplane Board

(1) Test pins Name

Use

HI1 TEST1 LOW1


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B-81465EN-1/05


MAINTENANCE

4.4 PANEL BOARD (A20B-2100-0770)

1

PON LED (Green)

6

D1 LED (Green)

2

Total edition

7

D2 LED (Green)

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MAINTENANCE

B-81465EN-1/05

3

RDY LED (Green)

8

RDY LED (Green)

4

(Total edition before 03C)

9

(Total edition after 04D)

5

PON LED (Green)

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B-81465EN-1/05


MAINTENANCE

4.5 PANEL BOARD (A20B-2100-0771)

1

PON LED (Green)

4

Total edition

2

D1 LED (Green)

5

RDY LED (Green)

3

D2 LED (Green)

(1) LED Name

Use

RDY

LED shows communication status with main board ON Normal OFF Communication error

PON

Lights when the internal power supply of the panel board outputs +5V normally

D1 D2

LED shows no emergency stop factor exists on the teach pendant and panel board. D1 Corresponds to SVON1 D2 Corresponds to SVON2

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MAINTENANCE

B-81465EN-1/05

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

1

Total edition

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

+15V -15V GND

Power for the digital/analog converter

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MAINTENANCE

B-81465EN-1/05

Name

Use

AI1 AI2 AI3 AI4 AI5 AI6

Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6

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

AOUT1 AOUT2

Channel 1 Channel 2

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

(2) Settings Name

Standard setting

Description

ICOM 1

UDI1 to UDI20 (Connector CRM2A)

Side A

The common voltage is adjusted to: Side A: +24 V common Side B: 0 V common

ICOM 2

UDI21 to UDI40 (Connector CRM2B)

Side A


ICOM 3

WDI01 to WDI08 (Connector CRW1)

Side A


SP1

Channel 1

Open

The polarity of the output voltage is switched to: Strapped: Negative (-) Open: Positive (+)

SP2

Channel 2

Open

The polarity of the output voltage is switched to: Strapped: Negative (-) Open: Positive (+)

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MAINTENANCE

B-81465EN-1/05

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

Description

Red

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

Red

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

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MAINTENANCE

B-81465EN-1/05


(5) Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062 Driver IC

DO signal

DV1

CMDENBL, SYSRDY, PROGRUN, PAUSED

DV2

HELD, FALT, ATPERCH, TPENBL

DV3

BATALM, BUSY, ACK1/SNO1, ACK2/SNO2

DV4

ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6

DV5

ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED

DV6

SDO01, SDO02, SDO03, SDO04

DV7


DV8


DV9


DV10


DV11

WDO01, WDO02, WDO03, WDO04

DV12


RESERVED

For replacement

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MAINTENANCE

B-81465EN-1/05

4.7 PROCESS I/O BOARD CB (A16B-2201-0472)

1

Test pins

2

Total edition

Fig. 4.7 Process I/O Board CB

(1) Test pins Name P24V P5V P15VC M15VC GND1 GND2

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


-245-


MAINTENANCE

B-81465EN-1/05

(2) Settings Name

Standard setting

Description

ICOM1


Side A


ICOM2


Side A


(3) LEDs Color

Description

Red


Red

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


DO signal

DV1


DV2


DV3

BATALM, BUSY, ACK1/SNO1, ACK2/SNO

DV4


DV5


DV6


DV7


DV8


DV9


DV10


RESERVED

For replacement -246-


MAINTENANCE

B-81465EN-1/05

4.8 PROCESS I/O BOARD DA (A16B-2201-0480)

1

Total edition

2

Test pins

Fig. 4.8 Process I/O Board DA

(1) Test pins Name P24V P5V GND1 GND2

Use +24V +5V GND GND


-247-

MAINTENANCE

B-81465EN-1/05


(2) Settings Name

Standard setting

Description

ICOM1

UDI01 to 20 (Connector CRM2A)

Side A


ICOM2

UDI21 to 40 (Connector CRM2B)

Side A


ICOM3

UDI41 to 60 (Connector CRM2C)

Side A


ICOM4

UDI61 to 80 (Connector CRM2D)

Side A


ICOM5

UDI81 to 88 (Connector CRM4A)

Side A


ICOM6

UDI89 to 96 (Connector CRM4B)

Side A


(3) LEDs Color

Description

Red


Red


-248-


MAINTENANCE


DO signal

DV1


DV2


DV3


DV4


DV5


DV6


DV7


DV8


DV9


DV10


DV11

ADO21, SDO22, SDO23, SDO24

DV12


DV13


DV14


DV15


DV16


DV17


DV18


DV19


DV20


DV21


DV22


DV23


DV24


RESERVED

For replacement

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B-81465EN-1/05


MAINTENANCE

B-81465EN-1/05

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

Fig, 4.9 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

+15V -15V GND

For measuring power for the digital /analog converter

Al1 Al2 Al3 Al4 Al5 Al6

Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6

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

AOUT1 AOUT2

Channel 1 Channel 2


-250-


MAINTENANCE

B-81465EN-1/05

(2) Settings Name

Standard setting

Description

ICOM1

UDI1 to UDl20 (Connector CRM2A)

Side A


ICOM2

UDI21 to UDl40 (Connector CRM2B)

Side A


ICOM3

WDl01 to WDl08 (Connector CRW1)

Side A


SP1

Channel 1

Open

Output voltage is adjusted to: Short: Output voltage minus (-) Open: Output voltage plus (+)

SP2

Channel 2

Open

Output voltage is adjusted to: Short: Output voltage minus (-) Open: Output voltage plus (+)

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

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MAINTENANCE

B-81465EN-1/05


(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.

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MAINTENANCE


DO signal

DV1


DV2


DV3


DV4


DV5


DV6


DV7


DV8


DV9


DV10


DV11


DV12


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-254-



MAINTENANCE

B-81465EN-1/05

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

1

Total edition

Fig. 4.10 Process I/O Board EB




(2) Settings Name

Standard setting

Description

ICOM1


Side A


ICOM2


Side A


-255-

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B-81465EN-1/05


(3) LEDs Color

Description

Red


Red



DO signal

DV1


DV2


DV3


DV4


DV5


DV6


DV7


DV8


DV9


DV10


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B-81465EN-1/05

4.11 PROCESS I/O BOARD FA (A16B-2203-0420)

1

Total edition

Fig. 4.11 Process I/O Board FA




-257-

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(2) Settings Name

Standard setting

Description

ICOM1


Side A


ICOM2


Side A


ICOM3

UDI41 to UDI60 (Connector CRM2C)

Side A


ICOM4

UDI61 to UDI80 (Connector CRM2D)

Side A


ICOM5


Side A


ICOM6


Side A


(3) LEDs Color

Description

Red

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

Red


-258-


MAINTENANCE


DO signal

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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B-81465EN-1/05

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

1

Total edition

Fig. 4.12 Process I/O Board GA

(1) Test pins Name

Use

P24V P5V GND1 GND2 GND3

+24V +5V GND GND GND


P24VF P5VF GNDF

+24V +5V GND


AOUT1 AOUT2

Channel 1 Channel 2


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B-81465EN-1/05

(2) Settings Name

Standard setting

Description

ICOM1


Side A


ICOM2


Side A


ICOM3


Side A


(3) Adjustment VR1/VR2: Adjusts 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 15.0 V. 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: Adjusts 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 15.0 V. 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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DO signal

DV1


DV2


DV3


DV4


DV5


DV6


DV7


DV8


DV9


DV10


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B-81465EN-1/05

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

1

Total version

Fig. 4.13 Process I/O Board HA

(1) Test pins Name

Use

P24V P5V GND1 GND2 GND3

+24V +5V GND GND GND


P24VF P5VF GNDF

+24V +5V GND


AO1 AO2

Channel 1 Channel 2


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(2) Settings Name

Standard setting

Description

ICOM1


Side A


ICOM2


Side A


ICOM3


Side A


(3) Adjustment VR1/VR2: Adjusts 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 15.0 V. 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: Adjusts 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 15.0 V. 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


-264-


MAINTENANCE


DO signal

DV1


DV2


DV3


DV4


DV5


DV6


DV7


DV8


DV9


DV10


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B-81465EN-1/05


4.14 PANEL SWITCH BOARD (A20B-1007-0850)

1

Total version

Fig. 4.14 Panel Switch Board

-266-

5. SERVO AMPLIFIERS

MAINTENANCE

B-81465EN-1/05

5 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. Tab. 5 Servo amplifier specifications Servo amplifier

Regenerative resistor unit A-CABINET

Regenerative resistor unit B-CABINET

R-2000iA/200T

A06B-6105-H001

-----

A05B-2452-C200

S-900iB

A06B-6105-H001

A05B-2451-C204

A05B-2452-C200

M-410iB

A06B-6105-H001

A05B-2451-C204

A05B-2452-C200

R-2000iA (except/200T)

A06B-6105-H002

A05B-2451-C202

A05B-2452-C200

S-500iB

A06B-6105-H002

A05B-2451-C202

A05B-2452-C200

M-710iB

A06B-6105-H002

A05B-2451-C202

A05B-2452-C200

M-16iB

A06B-6105-H002

A05B-2451-C202

A05B-2452-C200

ARC Mate 120iB

A06B-6105-H002

A05B-2451-C202

A05B-2452-C200

M-420iA/M-421iA

A06B-6105-H002

A05B-2451-C204

A05B-2452-C200

M-6iB

A06B-6105-H003

A05B-2451-C201

A05B-2452-C201

ARC Mate 100iB

A06B-6105-H003

A05B-2451-C201

A05B-2452-C201

F-200iB

A06B-6105-H003

A05B-2451-C201

A05B-2452-C201

LR Mate 200iB

A06B-6105-H003

-----

A05B-2452-C201

Robot models

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B-81465EN-1/05

1

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 50 V.

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5. SERVO AMPLIFIERS

MAINTENANCE

5.1 LED OF SERVO AMPLIFIER

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B-81465EN-1/05

LED

5. SERVO AMPLIFIERS

MAINTENANCE

B-81465EN-1/05

Color

Description

P5V

Green

Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally.

P3.3V

Green

Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V normally.

SVEMG

Red

Lights when an emergency stop signal is input to the servo amplifier.

ALM

Red

Lights when the servo amplifier detects an alarm.

RDY

Green

Lights when the servo amplifier is ready to drive the servo motor.

OPEN

Green

Lights when the communication between the servo amplifier and the main board is normal.

WD

Red

Lights when a watch dog alarm is detected in the servo amplifier.

D7

Red

Lights when the DCLINK circuit inside the servo amplifier is charged to reach a specific voltage.

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5. SERVO AMPLIFIERS

MAINTENANCE

B-81465EN-1/05

5.2 SETTING OF SERVO AMPLIFIER Settings Name

Standard setting

COM1

Side A

Description This jumper sets the common voltage for the Robot digital Inputs (RDI) to: Side A : +24V common Side B : 0V common

1

Fuse F1

4

Fuse FS3

2

Fuse F2

5

Fuse FS2

3

Fuse FS1

6

Set jumper

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5.3 DRIVER IC FOR ROBOT DI/DO

Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062 Driver IC

DO signal

DIO17

RDO1, RDO2, RDO3, RDO4

DIO18

RDO5, RDO6, RDO7, RDO8

DIO19

XRESERVE, XBRKRLS1, XBRKRLS2, XBRKRLS3

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5. SERVO AMPLIFIERS

6. SETTING THE POWER SUPPLY

MAINTENANCE

B-81465EN-1/05

6 SETTING THE POWER SUPPLY The power supply is factory-set for operation. Usually, you do not need to set or adjust it.

6.1 BLOCK DIAGRAM OF THE MAIN POWER INCLUDING POWER SUPPLY

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MAINTENANCE

1

Breaker

8

Robot

2

Noise filter

9

Main board

3

Transformer

10

Teach pendant

4

E-stop unit

11

Panel board

5

Breaker

12

Handy file etc.

6

Backplane

13

Process I/O board

7

Power supply unit

14

Peripheral device

Fig. 6.1 Block diagram of the power supply

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6.2 SELECTING TRANSFORMER TAPS Select a transformer and tap according to the supply voltage. Select a transformer tap such that the rated voltage is +10% to -15% of the induced voltage.

1

Mounting locations of transformer (A-cabinet, back side)

3

Mounting locations of transformer (B-cabinet, back side)

2

Transformer

4

Structure of transformer

Fig. 6.2 (a) Transformer mounting locations and structure

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Rated Voltage

Transformer specification 10.5KVA

Transformer specification 7.5KVA

Transformer specification 3KVA

Type I

500 to 575

A80L-0028-0017

A80L-0026-0035

A80L-0024-0025

Type I

440 to 480

A80L-0028-0017

A80L-0026-0035

A80L-0024-0025

Type II

380 to 415

A80L-0028-0018

A80L-0026-0036

A80L-0024-0026

Type II

440 to 500

A80L-0028-0018

A80L-0026-0036

A80L-0024-0026

Type III

380 to 400

A80L-0028-0019

A80L-0026-0037

A80L-0024-0027

Type III

200 to 230

A80L-0028-0019

A80L-0026-0037

A80L-0024-0027

For A-cabinet 1

Type I: 440-480 V Type II: 380-415 V

Insert the connector connected to the operation box connection cable into connector LB and the dummy plug into connector LA.

2

Type I: 500-575 V Type II: 440-500 V

Insert the connector connected to the operation box connection cable into connector LA and the dummy plug into connector LB.

3

Type III: 200-230 V

Use the connection unit (delta-connection).

4

Type III: 380-400 V

Insert the connector connected to the operation box connection cable into connector LA and short cable for Y connection into connector LB.

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B-81465EN-1/05

1

Connector

4

Connection Unit

2

Dummy Plag

5

Short cable for Y connection

3

Operation box connection cable

6

Connection unit

Fig. 6.2 (b) Setting a tap

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For B-cabinet 1

Type I: 440-480 V Type II: 380-415 V

Insert the connector connected to the circuit breaker into connector LB and the dummy plug into connector LA.

2

Type I: 500-575 V Type II: 440-500 V

Insert the connector connected to the circuit breaker into connector LA and the dummy plug into connector LB.

3

Type III: 200-230 V

Use the connection cable (delta-connection).

4

Type III: 380-400 V

Insert the connector connected to the circuit breaker into connector LA and use the Y connection cable for connector LB.

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B-81465EN-1/05

1

Connector

3

Breaker

2

Dummy Plag

4

Connection cable

Fig. 6.2 (c) Setting a tap

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6.3 CHECKING THE POWER SUPPLY UNIT (A16B-2203-0370) The power supply unit need not be set or adjusted. Tab. 6.3 Rating of the Power supply unit Output

Rated voltage

Tolerance

+ 5V

+5.1V

+/- 3%

+ 3.3V

+3.3V

+/- 3%

+24V

+24V

+/- 5%

+24E

+24E

+/- 5%

+15V

+15V

+/- 10%

-15V

-15V

+/- 10%

-280-


MAINTENANCE

Fig. 6.3 (a) Interface of the power supply unit -281-

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Fig. 6.3 (b) Block diagram of the power supply unit

-282-


7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

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

WARNING 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 off. Otherwise, you could injure personnel or damage equipment.

7.1 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.

1

Top panel

2

Fig. 7.1.1 Replacing the Top Panel

-285-

M4 screws (3 places)

B-81465EN-1/05

7. REPLACING A UNIT

MAINTENANCE

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

1


2

Fig. 7.1.2 Replacing the Rear Panel

-286-

M10 bolts (4 places)

7. REPLACING A UNIT

MAINTENANCE

7.1.3 Replacing the A-cabinet Louver Loosen four retaining M4 screws from the louver, then remove the louver.

1

Louver

Fig. 7.1.3 Replacing the Louver

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7. REPLACING A UNIT

7.1.4 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.

1

Lift up the door to dismount it

Fig. 7.1.4 Replacing the Door

7.2 REPLACING THE PRINTED-CIRCUIT BOARDS CAUTION When you replace printed-circuit boards, observe the following cautions: 1. Keep the control unit 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. 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 a memory card, floppy disk, or any other external memory device. 5. Before you disconnect a cable, note its location. If a cable is detached for replacement, reconnect it exactly as before.

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.2.1 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 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 a floppy disk before proceeding.

1

Backplane board

3

Right Rail

2

Left Rail

4


Fig. 7.2.1 Replacing the Backplane Board

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MAINTENANCE

7. REPLACING A UNIT

7.2.2 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 and 5 (slots for a full-size option board). When you insert a full-size option board, align it to the left-side rail.

-290-

7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

1

SLOT 1

5

Handles

2

SLOT 2

6

SLOT 10

3

SLOT 3

7

SLOT 9

4

PSU (Power supply SLOT)

8

SLOT 8

Fig. 7.2.2 Replacing the Power Unit and Printed-Circuit Boards on the Backplane Unit

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7. REPLACING A UNIT

MAINTENANCE

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

1

Process I/O Board

2

Fig. 7.2.3 Replacing the Process I/O Board

-292-

4-M4 screws

7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.2.4 Replacing the Panel Board The panel board is at the back of the operator´s panel/operation box. 1. Detach all cables from the panel board. The terminal boards (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 remove the panel board.

1

A-cabinet

3

Panel board

2

B-cabinet

4

4-M3 screws

Fig. 7.2.4 Panel board replacement

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MAINTENANCE

7. REPLACING A UNIT

3. Remove two retaining screws from the panel board, and remove two plates.

1

2-M3 screws

4. Attach two plates to the new panel board using two screws, then attach the panel board to the operator's panel/operation box using four screws.

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.3 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, memory contents are lost. Demounting a Card 1. Pull outward the clip of each of the four spacers used to secure the card PCB, then release each latch. 2. Extract the card upward.

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B-81465EN-1/05

1

Card

2

Spacer

7. REPLACING A UNIT

MAINTENANCE

3

Fig. 7.3 (a) Demounting a card

-296-

Connector

7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

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 secur the card PCB.

1

Card

2

Spacer

3

Fig. 7.3 (b) Mounting a card -297-

Connector

B-81465EN-1/05

MAINTENANCE

7. REPLACING A UNIT

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)

Fig. 7.3 (c) Demounting/Mounting a module

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

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

1

Main board

3

Axis control card

2

CPU card

4

FROM/SRAM module

Fig. 7.3 (d) Locations of Cards and Module

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B-81465EN-1/05

MAINTENANCE

-300-

7. REPLACING A UNIT

7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.4 REPLACING THE TRANSFORMER WARNING Before you start replacement procedure, turn off the main power to the control unit. The transformer is quite heavy; it 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: CRF7, CNJ1 to 6, and CNJGA to CNJGC, and the ground cables.

1

Motor power cable

3

Grounding cable

2

Pulse coder cable

4

A-cabinet

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7. REPLACING A UNIT

MAINTENANCE

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

1

Rear view of the A-cabinet

2

Robot retaining bolts (4-M10)

3. Being careful not to strain or breake any cables, gently separate the cabinet from the robot and it's cables. 4. At the transformer input connector panel disconnect the power cable coming from the operation box.

1

Power line from the operation box

2

-302-

A-cabinet

7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

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 from the rear panel (Refer to a Fig. 7.1.2). Remove four screws from a metal plate of connector's panel, and remove the metal plate.

1

A metal plate of connector's panel

2

A-cabinet

6. Unscrew and remove the regenerative resistor unit from the top of the transformer.

1

Screw Washer

3

Transformer

2

Regenerative resistor unit cable

4

A-cabinet

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B-81465EN-1/05

7. REPLACING A UNIT

MAINTENANCE

7. Remove the two M6 screws holding the transformer in place and remove the transformer.

1

A-cabinet

2

Screw (2-M6)

3

Shape of the transformer

8. Install a replacement transformer by reversing steps 1 through 7.

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

In case of B-cabinet 1. Remove the six M4 screws and detach the back panel.

1

6 -M4 screws

2

-305-

B-cabinet

B-81465EN-1/05

7. REPLACING A UNIT

MAINTENANCE

2. Detach the connectors of LA,LB, OUT, CP1, and TOH. 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.

1

Connector Panel

2

B-cabinet

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

1

B-cabinet

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

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

1

Shape of the transformer

2

2-M6 screws

3

B-cabinet

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

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MAINTENANCE

7. REPLACING A UNIT

7.5 REPLACING THE REGENERATIVE RESISTOR UNIT WARNING Before you start, turn off the control unit main power. Be careful not to get burned, because the regenerative resistor unit is very hot immediately after operation. In case of A-cabinet 1. Remove the top panel from the A-cabinet. Remove the Louver plate and the lower plate on the right side of the cabinet. 2. Unplug connector CRR45A at the servo amplifier and connector CRR43A at the emergency stop unit. 3. Unscrew the cord grip nut inside the transformer compartment and pull the cables through, being careful not to damage the connectors or cables. 4. Unscrew the four retaining screws on the regenerative feedback resistance unit and remove it. 5. Install the replacement unit by reversing this procedure.

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

1

Screw Washer

5

Transformer

2

Regenerative resistor cable

6

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.

3

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

4

Regenerative resistance unit cable

7

Fig. 7.5 (a) Replacing the Regenerative Resistance Unit

-309-

(A-cabinet)

B-81465EN-1/05

7. REPLACING A UNIT

MAINTENANCE

In case of B-cabinet 1. Remove the servo amplifier. (See "Replacing the servo amplifier.") 2. Remove two M4 screws, then detach the housing that fastens cables.

1

2-M4 screws

2

B-cabinet

3. Remove the two retaining M5 nuts and lift away the regenerative resistor unit.

1

2-M5 nuts

2

B-cabinet

4. Install a replacement regenerative resistor unit and a servo amplifier by reversing the procedure (1) to (3).

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.6 REPLACING THE E-STOP UNIT WARNING Before you start replacement, turn off the control unit main power. A-cabinet 1. Detach the cables from the emergency stop unit. 2. Remove retaining screws (M4 4 places) from the emergency stop unit, and replace the emergency stop unit. 3. Reconnect the cables.

1

E-stop unit

2

4-M4 screws

3

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A-cabinet

B-81465EN-1/05

7. REPLACING A UNIT

MAINTENANCE

B-cabinet 1. Detach the cables from the emergency stop unit. 2. Remove retaining screws (4-M4) from the emergency stop unit, and replace the emergency stop unit. 3. Reconnect the cables.

1

E-stop unit

2

4-M4 screws

3

Fig. 7.6 Replacing the Emergency Stop Unit

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B-cabinet

7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.7 REPLACING THE POWER DISTRIBUTING UNIT a. The power distributing unit is provided with a cable. Remove the connected cable from the connector panel of the transformer. b. Remove the two bolts (M4) fastening the emergency stop unit and power distributing unit together, then replace the power distributing unit. c. Connect the cable of the power distributing unit to the connector panel.

1

Connector panel

3

Power distributing unit

2

Emergency stop unit

4

Bolt (2-M4)

Fig. 7.7 Replacing the power distibuting unit

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MAINTENANCE

7. REPLACING A UNIT

7.8 REPLACING SERVO AMPLIFIERS WARNING Before you start replacement, turn off the control unit main power. 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. 1. Make sure that servo amplifier shipping screws (2 phillips head) have been removed. Retain screws for shipping purposes. 2. Open the door, and check the voltage at the screws above the LED "D7" with a DC voltage tester to see if the remaining voltage is not higher than 50V.

1

Use a DC voltage tester to check that the voltage is 50 V or lower

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

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

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

1

Quater-turn screws, (4 places)

4

Servo amplifier

2

Unlock Lock

5

Detach the cable from the servo amplifier, and pull them out toward you.

3

Servo amplifier shipping screws (M5, 2 places)

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7. REPLACING A UNIT

MAINTENANCE

5. 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. 6. Place a replacement servo amplifier on the rail, slide it in gently until it is hooked on the guide pins. 7. Rotate the quarter-turn screws on the outside surface of the plate to lock the servo amplifier. 8. Reconnect the cables.

1

Rail

2

-316-

Handles

7. REPLACING A UNIT

MAINTENANCE

In case of B-cabinet 1. Turn the four screws, detach the amplifier cover, and pull out the cable.

1

Servo Amplifier cover

Fig. 7.8 (a) Replacing the servo amplifier (B-cabinet)

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MAINTENANCE

7. REPLACING A UNIT

2. Check the voltage at the screws above the LED "D7" with a DC voltage tester to see if the remaining voltage is not higher than 50 V.

1

Check that the voltage is not higher than 50V

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

3. Remove the two screws located on the top of the amplifier. 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.

1

Screw

2

Fig. 7.8 (b) Replacing the servo amplifier (B-cabinet)

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Fixation screw for transport (M5)

B-81465EN-1/05

MAINTENANCE

7. REPLACING A UNIT

4. Holding the handles located at the top and bottom of the amplifier, pull out the amplifier toward you. Be careful not to touch any components, such as capacitors, on the lower part of he servo amplifier printed-circuit board. Also, be careful not to damage the cables that are routed under the servo amplifier when pulling it out.

Fig. 7.8 (c) Replacing the servo amplifier (B-cabinet)

5. Pull out the lower part of the amplifier further toward you and slant the amplifier.

Fig. 7.8 (d) Replacing the servo amplifier (B-cabinet)

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7. REPLACING A UNIT

MAINTENANCE

6. Take the amplifier out while keeping it slanted.

Fig. 7.8 (e) Replacing the servo amplifier (B-cabinet)

7. Install a replacement servo amplifier by reversing step (b). 8. Re-attach the cables.

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B-81465EN-1/05

MAINTENANCE

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7. REPLACING A UNIT

7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.9 REPLACING I/O UNIT MODEL A WARNING Before you start replacement, turn off the control unit main power.

7.9.1 Replacing the Base Unit of I/O Unit Model A First dismount the modules from the base unit of I/O unit model A. 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.

1

M4 screw (4 pieces)

2

Fig. 7.9.1 Replacing the Base Unit of I/O Unit Model A

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B-cabinet

B-81465EN-1/05

MAINTENANCE

7. REPLACING A UNIT

7.9.2 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. 7.9.2 Replacing the module

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.10 REPLACING THE TEACH 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.

1

Detach or attach the cable by rotating the connector retaining ring

Fig. 7.10 (a) Replacing the Teach Pendant

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B-81465EN-1/05

1

MAINTENANCE

Detach or attach the cable by rotating the connector retaining ring

Fig. 7.10 (b) Replacing the iPendant

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7. REPLACING A UNIT

7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.11 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, and pull the fan 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.

1

Fan motor connector

2

Fan motor

3

Fig. 7.11 Replacing the Control Section Fan Motor

-327-

Pull the fan motor unit toward you to unlatch it.

B-81465EN-1/05

MAINTENANCE

7. REPLACING A UNIT

7.12 REPLACING THE AC FAN MOTOR WARNING Before you start replacement, turn off the control unit main power. Do not touch the fan motor when it is rotating, or you could be injured.

7.12.1 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.

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

1

Screw (4-M4)

3

A cabinet

2

Door fan unit

4

Nuts (4-M5)

Fig. 7.12.1 Replacing the Heat Exchanger and Door Fan Unit

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B-81465EN-1/05

7. REPLACING A UNIT

MAINTENANCE

7.12.2 Replacing the Rear Fan Unit (A-cabinet) A fan unit for cooling air is at the right rear of the A-cabinet. This rear fan unit has two fans mutually connected with a cable. When the rear 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. Detach the fan unit (The fan unit is fastened together with the louver). 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.

1

Fan unit Screws (4-M4) Used to fasten both the fan unit and louver

3

A-cabinet

2

Fig. 7.12.2 (b) Replacing the Rear Fan Unit

-330-

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

7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.12.3 Replacing External Air Fan Unit and Door Fan (B-cabinet) Door fan 1. Detach the cable from the fan unit. 2. Remove the two retaining M4 screws from the fan unit, then dismount it. 3. Install a new fan unit by reversing the dismounting procedure. External Air fan unit 1. Detach the cable. 2. Remove the six M4 screws and pull out the fan unit toward you. 3. Install a new fan unit by reversing the dismounting procedure.

1

Screw (2-M4)

2

Screw (6-M4)

3

-331-

B-cabinet

B-81465EN-1/05

7. REPLACING A UNIT

MAINTENANCE

Floor fan unit 1. Remove the cable from the fan unit. 2. Remove the fan by unscrewing the two retaining M4 screws. 3. Reverse the procedure to mount a spare fan unit.

1

Floor fan unit

2

Screw (2-M4)

3

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B-cabinet

7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.13 REPLACING THE OPERATOR´S PANEL AND PANEL SWITCH BOARD 1. 2. 3. 4.

Detach the cable (CRT8, CRM51) Straighten the 12 claws on the printed circuit board, then remove the printed circuit board. Remove the six (6-M3) screws, then remove the panel switch board. Install a new panel switch board by reversing the dismounting procedure.

-333-

B-81465EN-1/05

MAINTENANCE

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7. REPLACING A UNIT

7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

1

Straighten the claws

3

A-cabinet

2

Screw (6-M3)

4

B-cabinet

Fig. 7.13 Replacing the operator´s panel and Panel switch board

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B-81465EN-1/05

7. REPLACING A UNIT

MAINTENANCE

7.14 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: 2.5 kgcm) 2. Tighten the screws evenly so that the mode switch flat surface becomes parallel to the sheet metal.

1

Door

4

A-Cabinet

2

Screw

5

B-Cabinet

3

Mode switch

Fig. 7.14 Replacing the Mode Switch

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

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

7.15.1 Replacing Fuses in the Servo Amplifier The following fuses are in the servo amplifier. F1, F2: These fuses detect circuit failures in the servo amplifier, (A60L-0001-0245#GP20) If either of these fuses has blown, it is likely that the servo amplifier is defective. Replace the servo amplifier. FS1: For generation of the power to the amplifier control circuit (A60L-0001-0290#LM32C) FS2: For protection of the 24 V output to the end effector, ROT, and HBK (A60L-0001-0290#LM32C) FS3: For protection of the 24 V output to the regenerative resistance and the additional axis amplifier (A60L-0001-0290#LM50C)

1

Fuse F1

4

Fuse FS3

2

Fuse F2

5

Fuse FS2

3

Fuse FS1

Fig. 7.15.1 Replacing Fuses in the Servo Amplifier

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B-81465EN-1/05

7. REPLACING A UNIT

MAINTENANCE

7.15.2 Replacing Fuses in the Power Unit The following fuses are in the power unit. F1: Fuse for the AC input, A60L-0001-0396#8.0A F3: Fuse for protecting the +24E output, A60L-0001-0046#7.5 F4: Fuse for protecting the +24V output, A60L-0001-0046#7.5

1

F1 8.0A AC input fuse

3

F3 7.5A +24E fuse

2


4

F4 7.5A +24V fuse

Fig. 7.15.2 Replacing Fuses in the Power Unit

-338-

7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.15.3 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

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B-81465EN-1/05

7. REPLACING A UNIT

MAINTENANCE

1

Process I/O board CA, CB

3

Total edition

2

FUSE 1

4


Fig. 7.15.3 (c) Replacing the Fuse on the Process I/O Boards

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7. REPLACING A UNIT

MAINTENANCE

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B-81465EN-1/05

B-81465EN-1/05

7. REPLACING A UNIT

MAINTENANCE

1

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

3


2

Total edition

4


1


2

Total edition

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

7.15.4 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

1

Fuse 2

2

Fig. 7.15.4 Replacing the fuses on the panel board

-343-

Fuse 1

B-81465EN-1/05

MAINTENANCE

7. REPLACING A UNIT

7.15.5 Replacing the Fuses of the Power Distributing Unit The power distributing unit has a fuse shown below. FU001: For 200-VAC output protection A60L-0001_0101#P475H

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7. REPLACING A UNIT

MAINTENANCE

B-81465EN-1/05

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

7.16.1 Replacing Relays on the Panel Board KA21, KA22: Relay for emergency stop circuit A58L-0001-0192#1509A

Fig. 7.16.1 Replacing Relays on the Panel Board

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MAINTENANCE

7. REPLACING A UNIT

7.17 REPLACING BATTERY 7.17.1 Battery for Memory Backup (3 VDC) 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 battery goes dead. 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. Turning on the power to the robot controller in this state causes the system not to start and the seven segment LED on the main board to be displayed "1" because the contents of memory are lost. Clear the entire SRAM memory and reenter data after replacing the battery. Important data should be saved to the memory card or floppy disk beforehand in case of emergency. When replacing the memory backup battery, do so while the robot controller is turned off in case of emergency..

NOTE In a newly introduced robot, the battery is factory-installed. Battery replacement may, therefore, be needed within 4 year after the introduction of the robot. Replacing the lithium battery 1. 2. 3. 4.

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

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7. REPLACING A UNIT

1

Battery latch

2

Lithium battery

MAINTENANCE

3

B-81465EN-1/05

Battery connector

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

WARNING Using other than the recommended battery may result in the battery exploding. Replace the battery only with the specified battery (A02B-0200-K102).

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. 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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MAINTENANCE

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7. REPLACING A UNIT

1. GENERAL

CONNECTIONS

1 GENERAL This section describes the electrical interface connections in the R-J3iB. It also includes information about installation of the R-J3iB.

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CONNECTIONS

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1. GENERAL

2. BLOCK DIAGRAM

CONNECTIONS

B-81465EN-1/05

2 BLOCK DIAGRAM Fig. 2 is a block diagram of electrical interface connections with the R-J3iB.

1

Operation box

7

RS-232-C (Note2)

2

Mechanical unit

8

Peripheral device

3

Pneumatic pressure source

9

Welding machine

4

End effector

10

Ethernet

5

Memory card

11

AC power supply

6

Teach pendant

Fig. 2 (a) Block Diagram of Electrical Interface Connection (A-cabinet)

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CONNECTIONS

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

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2. BLOCK DIAGRAM

2. BLOCK DIAGRAM

CONNECTIONS

B-81465EN-1/05

1

Pneumatic pressure source

6

RS-232-C (Note2)

2

Mechanical unit

7

Peripheral device

3

End effector

8

Welding machine

4

Memory card (PCMCIA)

9

Ethernet

5

Teach pendant

10

AC power supply

Fig. 2 (b) Block Diagram of Electrical Interface Connection (B-cabinet)

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B-81465EN-1/05

CONNECTIONS

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

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2. BLOCK DIAGRAM

3. ELECTRICAL CONNECTIONS

CONNECTIONS

B-81465EN-1/05

3 ELECTRICAL CONNECTIONS 3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS

1

Servo amplifier

7

RCC I/F Unit (S-900iB only)

2

(Pulse coder, RDI/RDO, HBK, ROT)

8

Robot

3

Motor power

9

(Motor power / brake)

4

(Ground)

10

End effector

5

(Brake control)

11

Note

6

Process I/O

12

Welding machine

Fig. 3.1 (a) Mechanical Connection Diagram

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

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B-81465EN-1/05


CONNECTIONS

1

Teach pendant

6

Input power

2

Peripheral device

7

External power ON/OFF switch

3

Handy File

8

External emergency stop switch

4

External device

9

Fence

5

Ethernet

10

Servo off switch

Fig. 3.1 (b) Mechanical Connection Unit -356-


CONNECTIONS

B-81465EN-1/05

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.

-357-

CONNECTIONS

B-81465EN-1/05


3.2 EXTERNAL CABLE WIRING DIAGRAM 3.2.1 Robot Connection Cables CAUTION If robot connection cables are laid close together, the power cable may become hot and the signal cable may become sensitive to the noise. So if robot connection cables have surplus length, lay cables as stretched and sparsely as possible. 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 Tab. 3.2.1 Specification of cable - Non-flex type Robot

Diameter (mm)

Weight (kg/m)

Minimum bending radius (mm)

RP1

All models

15.7

0.45

200

RM1

Group 1

26.1

1.22

200

RM1

Group 2

20.0

0.7

200

RM1

Group 3

26.1

1.22

200

RM1

Group 4

26.1

1.22

200

RM1

Group 5

20.0

0.7

200

RM2

Group 3

26.1

1.22

200

RM2

Group 4

26.1

1.22

200

EARTH

All models

4.7

0.065

200

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CONNECTIONS

B-81465EN-1/05

Tab. 3.2.1 Specification of cable - Flex type Robot

Diameter (mm)

Weight (kg/m)

Minimum bending radius (mm)

RP1

All models

20.5

0.71

200

RM1

Group 1

25.4

1.2

200

RM1

Group 2

18.4

0.7

200

RM1

Group 3

-----

-----

-----

RM1

Group 4

25.4

1.2

200

RM1

Group 5

-----

-----

-----

RM2

Group 3

-----

-----

-----

RM2

Group 4

25.4

1.2

200

EARTH

All models

4.7

0.065

200

Group 1

R-2000iA (except /200T), M-420iA, M-421iA, S-500iB, M-710iB

Group 2

ARC Mate 100iB, ARC Mate 120iB, M-6iB, M-16iB, F-200iB

Group 3

S-900iB

Group 4

R-2000iA/200T, M-410iB

Group 5

LR Mate 200iB

Using condition of flex type cable 1. The bending radius (R) of the cable track is more than 200mm. 2. The cable should be fixed to the cable track by using the clamp. (e.g. rubber packing) 3. 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. 4. When cables are laid in the cable track, pay attention for the cable not to be twisted.

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B-81465EN-1/05

CONNECTIONS

In case of A-cabinet

-360-



CONNECTIONS

In case of B-cabinet

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B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

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CONNECTIONS

B-81465EN-1/05

• Detail of cable connection to servo amplifier.

Fig. 3.2.1 (a) Robot Connection Cable (R-2000iA(except /200T), M-6iB, M-16iB, ARC Mate 100iB, ARC Mate 120iB, M-710iB, F-200iB, S-500iB, M-420iA, M-421iA)

Fig. 3.2.1 (b) Robot Connection Cable (R-2000iA/200T, M-410iB)

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B-81465EN-1/05

CONNECTIONS

Fig. 3.2.1 (c) Robot Connection Cable (S-900iB)

Fig. 3.2.1 (d) Robot Connection Cable (LR Mate 200iB)

-364-



CONNECTIONS

B-81465EN-1/05

3.2.2 Teach Pendant Cable (1) Teach pendant cable The teach pendant connection cable is connected to the operator´s panel as follows. This figure applies to all robot models.

1

(A-cabinet)

4

(B-cabinet)

2

Teach pendant

5

Teach pendant connection cable

3

Teach pendant cable

Fig. 3.2.2 Teach Pendant Cable -365-


CONNECTIONS

B-81465EN-1/05

3.2.3 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. The resistance to the ground must not exceed 100 Ohm. Be sure to ground the work table or jig used by an arc welding robot or the like so that it can handle a large current. 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 Manufacture

Type

Fuji Electric Co., Ltd.

EG A series or later SG A series or later

Hitachi, Ltd.

ES100C type ES225C type

Matsushita Electric Works, Ltd.

Leakage current circuit breaker, C type Leakage current circuit breaker, KC type

Fig. 3.2.3 shows the cable connection.

-366-


CONNECTIONS

B-81465EN-1/05

1

A-cabinet

3

Input Power supply cable

2

(Note) Always replace the cover after completing

4

B-cabinet

Fig. 3.2.3 Input Power Supply Connection (B-cabinet) -367-

B-81465EN-1/05


CONNECTIONS

3.2.4 Connecting the External Power Supply ON/OFF Switch The External Power On/Off signal turns on and off the power supply from the outside of the control unit, and is connected as follows.

1

Panel board

3

A-cabinet

2

TBOP3

4

B-cabinet

Fig. 3.2.4 (a) Connection of the external power supply ON/OFF switch

-368-


CONNECTIONS

B-81465EN-1/05

1

Short piece between EXON1 and EXON2

2

External ON/OFF switch

3

In case of using external ON/OFF switch, remove the short piece between EXOFF1 and EXOFF2, then connect the wires.

4

Use a contact conforming to the following : Voltage rating : 50 VDC, 100mA or more. The power supply on/off timing chart is as follows

5

ON/OFF SW on operator´s panel

6

ON

7

OFF

8

Close

9

Open

10

Power

11

Note1) In case of using the external ON/OFF control, the ON/OFF swith on operator‘s panel must be turned ON. Note2) When the external ON/OFF switch is turned ON (Closed), the ON/OFF switch on operator panel can turn ON the controller. Note3) When the external ON/OFF switch is turned OFF (Open), the ON/OFF switch on operator panel can not turn ON the controller.

Fig. 3.2.4 (b) Connection of the external power supply switch ON and OFF

-369-

B-81465EN-1/05

CONNECTIONS

-370-



CONNECTIONS

B-81465EN-1/05

3.2.5 Connecting the External Emergency Stop

1

Panel board

4

(A-cabinet)

2

TBOP4

5

TBOP6

3

TBOP3

6

(B-cabinet)

Fig. 3.2.5 (a) Connection of the external emergency stop -371-

CONNECTIONS

B-81465EN-1/05

1


External emergency stop output

Fig. 3.2.5 (b) External emergency stop output

Signal ESPB1 ESPB11

]

ESPB2 ESPB21

]

Description Emergency stop output signals. These contacts are open if an emergency stop of teach pendant or operator´s panel occurs or the power is turned off. (Note 1) These contacts are closed during normal operation.

Current,voltage Rated contact: 250 VAC, 5-A or 30 VDC, 5A resistor load

ESPB3 ESPB31

]

ESPB4 ESPB41

]

NOTE 1. The relays for emergency stop output signals can be connected external power source. The power for relays are connected controller's power at the factory, and please connect external power source if emergency stop output must not be effected controller's power. Please refer to "External power connection".

-372-


CONNECTIONS

B-81465EN-1/05

1

External emergency stop input After connecting an external emergency stop switch and safety fence door switch, be sure to check the operations of those switches, the emergency stop switch on the operator‘s panel, and the emergency stop switch on the teach pendant.

4

Servo ON/OFF input switch

2

External emergency stop switch

5

Servo disconnect input switch

3

Fence

6

Use a contact which minimum load is 5mA less.

-373-

B-81465EN-1/05

Signal EES1 EES11 ]

EES2

]

EES21

EAS1 EAS11

]

EAS2 EAS21

]

EGS1 EGS11 ]

EGS2 EGS21

SD4 SD41

]

SD5 SD51

]

]

CONNECTIONS


Description

Current, voltage

Connect the contacts of the external emergency stop switch to these terminals. When using the contacts of a relay of contactor instead of the switch, connect a spark killer to the coil of the relay or contactor, to suppress noise. When these terminals are not used, jumper them.

Open and close of 24VDC 10mA

These signals are used to stop the robot when the door on the safety fence is open. While the deadman's switch on the teach pendant is pressed and the teach pendant enable switch is validated, these signals are ignored and an emergency stop does not occur. If these signals are not used, short these terminals.


Connect the contacts of the servo-on input switch to these terminals. When using the contacts of a relay or contactor instead of the switch, connect a 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-disconnect input switch to these terminals. 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.


-374-


CONNECTIONS

B-81465EN-1/05

1

Input requirement for external emergency stop and etc. The emergency stop circuit is composed of a chain of contacts. - Please connect dual contacts, which work same time, for external emergencystop, safety fence switch, servo ON/OFF switchand servo disconnect switch. - Please observe following timing. If input requirements are not satisfied, it may occuresingle chain failure.

7

Don‘t care

2

Input time for external emergency stop and servo disconnect.

8

Emergency stop condition

3

Contact for +24V chain

9

One of contacts is opened.

4

Contact for OV chain

10

Both of contacts are closed.

5

Close

11

Input timing for safety fence and servo ON/OFF.

6

Open

12

About 1 sec.

13

Control stop

-375-

B-81465EN-1/05

CONNECTIONS


CAUTION 1. Single chain failure will occure, if this input requirements are not satisfied. 2. Single chain failure can't be reset until special reset operation even if controller power is OFF and ON.

1

External power connection The relays for emergency stop input and output can be separated from controller‘s power. Please connect external +24V instead of internal +24V, if emergency stop output must not be effected controller‘s power.

-376-


CONNECTIONS

B-81465EN-1/05

Connecting external on/off and external emergency stop signal input/output. Specification of the terminal block FANUCs specification

Manufacturer‘s specification

8-pole terminal block (TBOP3)

A63L-0001-0783#301

231-308/026-000

12-pole terminal block (TBOP4,6)

A63L-0001-0783#312

231-312/026-000

Jumper pin

A63L-0001-0783#902

231-902

Operation lever

A63L-0001-0783#131-M

231-131

1

Details of the signal wires are shown below:

6

Specification

2

Bare wire length: 8 to 9 mm

7

Remark

2

Remark

2 pieces of 231-131 and operation manual are included in FANUCs specification

3

Compliant wire size: 0.08 to 2.5 mm

8

With insulation cover

4

If you want to use a rod terminal, select one that is suitable for the wire shown abve. The following table lists recommend ed products (manufactured by Weissmuller).

9

(Crimping tool: PZ3, PZ4, PZ6/5)

5

Wire (mm2)

-377-

B-81465EN-1/05


CONNECTIONS

1

How to attach signal wires to connectors

5

Signal wire

2

Manipulation slot

6

1. Detach the plug connector block from the panel board. 2. Insert the tip of a flat-blade screwdriver into the manipulation slot and push down its handle. 3. Insert the end of the signal wire into the wire slot. 4. Pull out the screwdriver. 5. Attach the plug connector block to the panel board.

3

Flat-blade screwdriver

7

Do not insert a wire into the wire hole of a plug connector or pult it out with the plug connector block mounted on the panel board; otherwise, the panel board may be damaged.

4

Plug connector block

-378-


CONNECTIONS

B-81465EN-1/05

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

A

Wire stripping

B

Handling of the Lever

1

Available wiresizeAWG 28-14 (0.08 to 2.5mm2)

4

Hold the connector, and push down thelever by finger.

2

Please check the strip length carefully.

5

Don‘t handle the lever after fit theconnector into the PCB, otherwise PCB will be damaged by handling stress.

3

Please readjust the loose end.

A

Wiring

2

Push in the conductor with holding the lever.

1

Pull down the lever.

3

Set the lever free. * And pull the conductor softly to check the clamping. * Don‘t pull strongly.

-379-

B-81465EN-1/05

CONNECTIONS


A

Replace the lever

2

Hook the lever to the rectangle hole.

1

Pull off the lever.

3

Push down the lever until click in.

A

Fit to header

2

Please check if the latch is hooked to header.

1

Push in the connector to header.

3

Be careful to fit the shape of each other.

-380-


CONNECTIONS

B-81465EN-1/05

A

Installation of "Jumper"

2

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

1

Attach levers to connector.

3

Please check the direction of the jumper.

A

Availability of wires

2

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

1

Without jumpers * Max. wire size ...2.0mm2 (AWG14) (with "Ferrule")

3

With two jumpers Additional wire is NOT available under the jumper.

-381-

B-81465EN-1/05

CONNECTIONS


A

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 ferrules into cramping station.

5

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

A

Specifications of Ferrules

2

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

-382-


CONNECTIONS

B-81465EN-1/05

3.2.6 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. Operation box type A

1

Line Filter Connect the cable to the secondary terminal of the breaker when the line filter is not used.

4

port M4 nut (3 pieces)

2

signal line

5

cable clamp

3

power line

-383-

B-81465EN-1/05


CONNECTIONS

Operation box type B

1

signal line

3


2

power line

4

cable clamp

-384-


CONNECTIONS

B-81465EN-1/05

Operation box type C

1


4

power line

2

cable clamp

5

noise filter

3

signal line

-385-


CONNECTIONS

B-81465EN-1/05

3.2.7 Connecting the NTED Signal (CRM65)

1

Panel board

Fig. 3.2.7 Connecting the NTED Signal

Refer to APPENDIX A. Total connection Diagram Fig. A (a) about NTED circuit.

NOTE After connecting 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 switch on the teach pendant. 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 1318107-1)

-386-


CONNECTIONS

B-81465EN-1/05

3.2.8 Connecting the Auxiliary Axis Brake (CRR65 A/B)

Fig. 3.2.8 6-Axis. Servo Amplifier

CRR65 A/B A1

BKA1

B1

A2 A3

BKA2

B2 COMMON

B3

CRR65 A/B connector manufactured by Tyco Electronics AMP k.k. (specification Rece-housing 1-178129-6 Rece-contact 175218-2)

-387-

COMMON

CONNECTIONS

B-81465EN-1/05


3.2.9 Connecting the Auxiliary Axis Over Travel (CRM68)

Fig. 3.2.9 6-Axis. Servo Amplifier

CRM68 A1

AUX0T1

A2

AUX0T2

A3

CRM68 connector manufactured by Tyco Electronics AMP k.k. (specification Rece-housing 1-1318120-3 Rece-contact 1318107-1)

-388-

4. PERIPHERIE DEVICE

CONNECTIONS

B-81465EN-1/05

4 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES R-J3iB 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

Number of I/O points DI

Number of I/O points DO

Number of I/O points D/A

Number of I/O points A/D

No.

Name

1

Process I/O board CA

A05B-2450-J001

40

40

2

6

Installed in backplane

2

Process I/O board CB

A05B-2450-J002

40

40

0

0


3


A05B-2450-J003

96

96

0

0


4

Process I/O board EA

A05B-2450-J010

40

40

2

3

Installed in operation box

5

Process I/O board EB

A05B-2450-J011

40

40

0

0


6


A05B-2450-J012

96

96

2

0


7


A05B-2450-J013

40

40

2

0


8


A05B-2450-J004

40

40

2

0


I/O UnitMODEL A

A05B-2452-J100 (Base and interface unit)

Depending on selected I/O module.



9

-389-


Remarks

Common to both A- and B-cabinet

B-81465EN-1/05

CONNECTIONS

.


NOTE The number of general purpose I/O (SDI/SDO) is a number which subtract an exclusive signal from the table value. Example: Process I/O board CB Table value Exclusive DI General purpose DI DI; 40 18 = 22 points Table value Exclusive DO General purpose DO DO; 40 20 = 20 points

1

Process I/O board

2

-390-

(A-cabinet)


1

Process I/O board

2

I/O unit model A (5 slots)

CONNECTIONS

3

Fig. 4 Locations of Peripheral Device Interfaces

-391-

(B-cabinet)

B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

.


4.1 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)

1

A-cabinet

4

Panel board

2

Main board

5

Process I/O board

3

Operation box

6

Peripheral device

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

-392-


Number

CONNECTIONS

Name

Drawing number

B-81465EN-1/05

Remarks

1


A05B-2451-H350

Connected length : 5m

1


A05B-2451-H351


1


A05B-2451-H352


2

Process I/O power supply cable

A05B-2451-J150

3, 4

Peripheral device connection cable

A05B-2451-J200

Connected length : 10m (one)

3, 4


A05B-2451-J201


3, 4


A05B-2451-J202


5

Welding device connection cable (Process I/O EA) (Fanuc interface)

A05B-2451-J270

Connected length : 3m (one) CRW1

5


A05B-2451-J271


5


A05B-2451-J272


5

Welding device connection cable (Process I/O GA) (General-purpose interface)

A05B-2451-J273


5


A05B-2451-J274


5


A05B-2451-J275


5

Welding device connection cable (Process I/O GA) (Fanuc interface)

A05B-2451-J276


5


A05B-2451-J277


5


A05B-2451-J278

Connected length :14m (one) CRW7

-393-

CONNECTIONS

B-81465EN-1/05

.


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

1

A-cabinet

4

Panel board

2

Main board

5

Process I/O board

3

Operation box

6

Peripheral device

Fig. 4.1.2 Block diagram of the process I/O board FA Number

Name

Drawing number

1


A05B-2451-H350


1


A05B-2451-H351


1


A05B-2451-H352


2

Process I/O power supply cable

A05B-2451-J150

3, 4 5, 6


A05B-2451-J200


3, 4 5, 6


A05B-2451-J201


3, 4 5, 6


A05B-2451-J202


7, 8


A05B-2451-J250


7, 8


A05B-2451-J251


7, 8


A05B-2451-J252


-394-

Remarks


CONNECTIONS

B-81465EN-1/05

4.1.3 When Process I/O Board CA/CB/HA is Used (B-cabinet)

1

B-cabinet

3

Process I/O board

2

Main board

4

Peripheral device

Fig. 4.1.3 Block diagram of the process I/O board CA/CB/HA

-395-

CONNECTIONS

B-81465EN-1/05

.


NOTE 1. CRW1 and CRW2 are not provided for process I/O board CB 2. In case of process I/O CA : CRW1 In case of process I/O HA : CRW7 Number

Name

Drawing number

Remarks

1

I/O link cable

A05B-2452-J140

Between main board and process I/O

2

I/O link cable

A05B-2452-J141

Between process I/O and process I/O

3, 4


A05B-2452-J200

Cable length 10m (one cable)

3, 4


A05B-2452-J201


3, 4


A05B-2452-J202


5

Welding device connection cable (Process I/O CA) (FANUC interface)

A05B-2452-J270

Cable length 3m (one cable) CRW1

5


A05B-2452-J271


5


A05B-2452-J272


5

Welding device connection cable (Process I/O HA) (General interface)

A05B-2452-J273


5


A05B-2452-J274


5


A05B-2452-J275


5

Welding device connection cable (Process I/O HA) (FANUC interface)

A05B-2452-J276


5


A05B-2452-J277


5


A05B-2452-J278


-396-


CONNECTIONS

4.1.4 When Process I/O Board DA is Used (B-cabinet)

1

Main board

3

Process I/O board

2

B-cabinet

4

Peripheral device

Fig. 4.1.4 Block diagram of the process I/O board DA

-397-

B-81465EN-1/05

CONNECTIONS

B-81465EN-1/05

Cable number

Name

.

Drawing number


Remarks

1

I/O link cable

A05B-2452-J140

Between main board and process I/O

2

I/O link cable

A05B-2452-J141

Between process I/O and process I/O

3, 4 5, 6


A05B-2452-J200

Connected length 10m (one cable)

3, 4 5, 6


A05B-2452-J201


3, 4 5, 6


A05B-2452-J202


7, 8


A05B-2452-J250


7, 8


A05B-2452-J251


7, 8


A05B-2452-J252


-398-


CONNECTIONS

B-81465EN-1/05

4.1.5 When I/O Unit-MODEL A is Used 4.1.5.1 In case of B-cabinet

1

E-Stop unit CP5A

4

Interface module

2

Main board

5

Peripheral device

3

Backplane (5-slot)

Fig. 4.1.5.1 Block diagram of I/O Unit-A (In case of B-cabinet) Cable number

Name

Drawing number

Remarks

1

I/O link cable

-----

Included in A05B-2452-J100

2


-----

Must be supplied by the customer.

-399-

B-81465EN-1/05

CONNECTIONS

.


4.1.6 When Two or more Process I/O Boards and I/O Unit-Model A are Used In case of B-cabinet. When several units of the process I/O board, I/O Unit-A are used, connect them as shown below.

1

B-cabinet

6

E-stop unit

2

Main board

7

Included in model A base unit

3

Process I/O board

8

I/O Unit-A Interface module

4

DC power is supplied from the back plane

9

Backplane (5-slot)

5

Process I/O board

-400-


CONNECTIONS

B-81465EN-1/05

4.2 PERIPHERAL DEVICE INTERFACE COMBINATION 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 • 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.

4.2.2 In Case of B-cabinet One board or one unit is used Combination C

Process I/O board CA/CB/HA (40 points)

Combination D

Process I/O board DA (96 points)

Combination E

I/O Unit-A

Two boards/units are used in combination Combination CC

Process I/O board CA/CB/HA (40 points) + Process I/O board CA/CB/HA (40 points)

Combination CE

Process I/O board CA/CB/HA (40 points) + I/O Unit-A

Combination DC

Process I/O board DA (96 points) + Process I/O board CA/CB/HA (40 points)

Combination DD

Process I/O board DA (96 points) + Process I/O board DA (96 points)

Combination DE

Process I/O board DA (96 points) + I/O Unit-A

-401-

B-81465EN-1/05

CONNECTIONS

.


Three boards/units are used in combination Combination CCE

Process I/O board CA/CB/HA (40 points) + Process I/O board CA/CB/HA (40 points) + I/O Unit-A

Combination DCE

Process I/O board DA (96 points) + Process I/O board CA/CB/HA (40 points) + I/O Unit-A

Combination DDE

Process I/O board DA (96 points) + Process I/O board DA (96 points) + I/O Unit-A

-402-


CONNECTIONS

B-81465EN-1/05

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 SDI/SDO 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 CRM2A is clamped +24 V (common) in each process I/O board. Table 4.3 shows signals of a process I/O board.

-403-

CONNECTIONS

B-81465EN-1/05

.


Tab. 4.3 Process I/O Board Signals (1/4) (DI signals) Connector number

Signal name

Description

Remarks

CRM2A-1

*IMSTP

Immediate stop

Clamped at +24 V common

CRM2A-2

*HOLD

Temporary stop


CRM2A-3

*SFSD

Safe speed


CRM2A-4

CSTOPI

Cycle stop


CRM2A-5

FAULT RESET

External reset

CRM2A-6

START

Start

CRM2A-7

HOME

Return to home position

CRM2A-8

ENBL

Operation enabled

CRM2A-9

RSR1

Robot service request

CRM2A-9

PNS1

Program number selection

CRM2A-10

RSR2


CRM2A-10

PNS2


CRM2A-11

RSR3


CRM2A-11

PNS3


CRM2A-12

RSR4


CRM2A-12

PNS4


CRM2A-13

RSR5


CRM2A-13

PNS5


CRM2A-14

RSR6


CRM2A-14

PNS6


CRM2A-15

RSR7


CRM2A-15

PNS7


CRM2A-16

RSR8


CRM2A-16

PNS8


-404-

Option

Option

Option

Option

Option

Option

Option

Option


CONNECTIONS

B-81465EN-1/05

Tab. 4.3 Process I/O Board Signals (2/4) (DI signals) Connector number

Signal name

Description

Remarks

CRM2A-29

PNSTROBE

PNS strobe

CRM2A-30

PROD START

Start of automatic operation

CRM2A-31

SDI01

Peripheral device status

General signal

CRM2A-32

SDI02


General signal

CRM2B-1

SDI03


General signal

CRM2B-2

SDI04


General signal

CRM2B-3

SDI05


General signal

CRM2B-4

SDI06


General signal

CRM2B-5

SDI07


General signal

CRM2B-6

SDI08


General signal

CRM2B-7

SDI09


General signal

CRM2B-8

SDI10


General signal

CRM2B-9

SDI11


General signal

CRM2B-10

SDI12


General signal

CRM2B-11

SDI13


General signal

CRM2B-12

SDI14


General signal

CRM2B-13

SDI15


General signal

CRM2B-14

SDI16


General signal

CRM2B-15

SDI17


General signal

CRM2B-16

SDI18


General signal

CRM2B-29

SDI19


General signal

CRM2B-30

SDI20


General signal

CRM2B-31

SDI21


General signal

CRM2B-32

SDI22


General signal

-405-

CONNECTIONS

B-81465EN-1/05

.


Tab. 4.3 Process I/O Board Signals (3/4) (DO signals) Connector number

Signal name

Description

CRM2A-33

CMDENBL

During automatic operation

CRM2A-34

SYSRDY

Preparation completed

CRM2A-35

PROGRUN

Program running

CRM2A-36

PAUSED

Program being interrupted

CRM2A-38

HELD

During temporary stop

CRM2A-39

FAULT

Alarm

CRM2A-40

ATPERCH

Home position

CRM2A-41

TPENBL

Teach pendant enabled

CRM2A-43

BATALM

Battery voltage drop

CRM2A-44

BUSY

During operation

CRM2A-45

ACK1

Robot service request acceptance

CRM2A-45

SNO1

Selected program number

CRM2A-46

ACK2


CRM2A-46

SNO2


CRM2A-19

ACK3


CRM2A-19

SNO3


CRM2A-20

ACK4


CRM2A-20

SNO4


CRM2A-21

ACK5


CRM2A-21

SNO5


CRM2A-22

ACK6


CRM2A-22

SNO6


CRM2A-24

ACK7


CRM2A-24

SNO7


CRM2A-25

ACK8


CRM2A-25

SNO8


CRM2A-26

SNACK

Response signal to PNS

CRM2A-27

RESERVED

-406-

Remarks

Option

Option

Option

Option

Option

Option

Option

Option


CONNECTIONS

B-81465EN-1/05

Tab. 4.3 Process I/O Board Signals (4/4) (DO signals) Connector number

Signal name

Description

Remarks

CRM2B-33

SDO01

Peripheral device control signal

General signal

CRM2B-34

SDO02


General signal

CRM2B-35

SDO03


General signal

CRM2B-36

SDO04


General signal

CRM2B-38

SDO05


General signal

CRM2B-39

SDO06


General signal

CRM2B-40

SDO07


General signal

CRM2B-41

SDO08


General signal

CRM2B-43

SDO09


General signal

CRM2B-44

SDO10


General signal

CRM2B-45

SDO11


General signal

CRM2B-46

SDO12


General signal

CRM2B-19

SDO13


General signal

CRM2B-20

SDO14


General signal

CRM2B-21

SDO15


General signal

CRM2B-22

SDO16


General signal

CRM2B-24

SDO17


General signal

CRM2B-25

SDO18


General signal

CRM2B-26

SDO19


General signal

CRM2B-27

SDO20


General signal

-407-

B-81465EN-1/05

CONNECTIONS

.

-408-



CONNECTIONS

4.4 INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS 4.4.1 Peripheral Device and Control Unit Connection

1

Control unit

4

Peripheral device control interface A2

2


5

Peripheral device A2

3


-409-

B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

.

NOTE 1. The peripheral device connection cables are optional. 2. All of COM-** are connected to 0 V. Applicable process I/O board type CA, CB, DA, EA, EB, FA, GA, HA

-410-



CONNECTIONS

1

Control unit

4


2


5


3


NOTE 1. The peripheral device connection cables are optional. 2. All of COM-** are connected to 0 V. Applicable process I/O board type DA, FA -411-

B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

.


1

Control unit

4

Peripheral device control interface B2

2

Peripheral device control interface B1

5

Peripheral device B2

3

Peripheral device B1

NOTE 1. The peripheral device connection cables are optional. 2. All of COM-** are connected to 0 V. Applicable process I/O board type DA, FA

-412-


CONNECTIONS

1

Control unit (peripheral device control interface A1)

4

Receiver circuit

2

Connector pin No.

5

Common setting pin (ICOM1)

3

Peripheral device

-413-

B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

.

NOTE This is a connection diagram for +24V common.

-414-



CONNECTIONS

B-81465EN-1/05

1


4

Receiver circuit

2

Connector pin No.

5

+24 V regulated power supply

3

Peripheral device

6

A maximum output current per UDO point is 0.2 A.

-415-

B-81465EN-1/05

CONNECTIONS

.


1


4

Receiver circuit

2

Connector pin No.

5


3

Peripheral device

-416-


CONNECTIONS


-417-

B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

.


1


4

Receiver circuit

2

Connector pin No.

5


3

Peripheral device

6

A maximum output current per DO point is 0.2 A.

-418-


CONNECTIONS

1


4

Receiver circuit

2

Connector pin No.

5


3

Peripheral device

-419-

B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

.


-420-



CONNECTIONS

B-81465EN-1/05

1


4

Receiver circuit

2

Connector pin No.

5


3

Peripheral device

6

A miximum output current per UDO point is 0.2 A.

-421-

B-81465EN-1/05

CONNECTIONS

.


1


4

Receiver circuit

2

Connector pin No.

5


3

Peripheral device

-422-


CONNECTIONS


-423-

B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

.


1


4

Receiver circuit

2

Connector pin No.

5


3

Peripheral device

6


-424-


CONNECTIONS

1

Control unit (peripheral device control interface B1)

5


2

Connector pin No.

6


-425-

B-81465EN-1/05

B-81465EN-1/05

3

Peripheral device

4

Receiver circuit

CONNECTIONS

.


7


-426-



CONNECTIONS

1

Control unit (peripheral device control interface B2)

5


2

Connector pin No.

6


-427-

B-81465EN-1/05

B-81465EN-1/05

3

Peripheral device

4

Receiver circuit

CONNECTIONS

.


7


-428-



CONNECTIONS

B-81465EN-1/05

4.4.2 Connection Between the Mechanical Unit and End Effector

1

Mechanical unit

2

End effector

Fig. 4.4.2 In case of the R-2000i (For other robots, refer to the each maintenance manual.)

-429-

B-81465EN-1/05

CONNECTIONS

.


1

Mechanical unit (end-effector interfae)

5

Input signals indicating the states of the end effector

2

Connector pin No.

6

RDI9 (Pneumatic pressure abnormal signal)

3

End effector

7

Pin for switching the common signals (COM1)

4

Wrist breakage detection signal

8

Signals for controlling the end effector

-430-


CONNECTIONS

NOTE 1. This is a connection diagram for +24V common. 2. The common-level change-over setting pin (COM1) is in the 6-axis servo amplifier.

-431-

B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

.


4.4.3 Connection Between the Control Unit and Welder

1

Control unit

4

Analog input interface

2

Welder interface

5

Peripheral device

3

Welder

NOTE Welder and peripheral device connection cable are optional. Applicable process I/O board type CA, EA

-432-


CONNECTIONS

1

Control unit (Welding interface) Process I/O CA, EA

8

Welding voltage detection signal

2

Welder

9

Output signals without ripples

3

Connector pin number

10

Welding current detector signal

4

MS connector pin number

11

R=100Ohm or more

5

Welding voltage command signal

12

Wire soldering detector signal

6

The input impedance shall be more than 3.3kOhm high-pass filter shall be provided.

13

Welding power supply

7

Wire speed command signal

-433-

B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

.


FANUC interface

1

Control unit (Welding interface) Process I/O CA, EA

9

Arc detection signal

2

Welder

10

Gas shortage detection signal

-434-


CONNECTIONS

B-81465EN-1/05

3

Welding start signal

11

Wire cut detection signal

4

Gas signal

12

Cooling water shortage detection signal

5

Wire inching (positive) signal

13

Welding power supply abnormality signal

6

Wire inching (negative) signal

14

Common switching set pin

7

+24V regulated power supply

15

Welding machine frame ground

8

Receiver circuit

16

Cabinet ground (shielding clamp)

NOTE This is the connection for +24V.

-435-

B-81465EN-1/05

.

CONNECTIONS


CRW2 connector analog connection (analog input)

1

Control unit (Analog input interfae) Process I/O CA, EA, GB, HB

3

Peripheral device

2

Connector pin No.

4

Output signals without ripples

-436-


CONNECTIONS

B-81465EN-1/05

(Relationships between process I/O points and analog inputs) analog input ADCH1 COMAD1

analog input ADCH2 COMAD2





process I/0 CA points

In CRW1

In CRW1

o

o

o

o

process I/0 EA points

In CRW1

In CRW1

o

process I/0 GB points

o

o

o

o

o

o

process I/0 HB points

o

o

o

o

o

o

1

Control unit

2

Welding interface

3

Welder

NOTE Welder and peripheral device connection cable is option. Applicable process I/O board type GA, HA

-437-

B-81465EN-1/05

CONNECTIONS

.


General-purpose interface

1

Control unit (welding interface) Process I/O GA, HA; HB

10

-438-

No gas


CONNECTIONS

2

Welding machine MS connector pin numbers

11

No wire

3

Connector pin numbers

12


4


13

Wire inching

5

Receiver circuit

14


6


15


7

Common switching set pin (ICOM3)

16


8

Arc

17


9

No arc (power supply error)

18

R= 100Ohm or more


-439-

B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

.


FANUC interface

1

Control unit (welding interface) Process I/O GA, HA, HB

10

-440-

No arc (power supply error)


CONNECTIONS

2

Welding machine MS connector pin numbers

11

No wire

3

Connector pin numbers

12


4


13

Gas signal

5


14

Wire inching

6

Receiver circuit

15


7

Arc

16


8

No gas

17


9

Cooling water shortage detection signal

18



-441-

B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

.

-442-



CONNECTIONS

B-81465EN-1/05

4.5 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.

4.5.1 Peripheral Device Interface 1. Output signals in peripheral device interface A Example of connection

1

Spark killer diode

3

Lamp

2

0.2 A or less

4

Protective resistance

Electrical specifications Rated voltage: Maximum applied voltage: Maximum load current: Transistor type: Saturation voltage at connection:

24 VDC 30 VDC 0.2 A Open collector NPN 1.0 V (approx.)

Spark killer diode Rated peak reverse voltage: Rated effective forward current:

100 V or more 1 A or more

NOTE Do not use the +24 V power supply of the robot. When you load a relay, solenoid, and so on directly, connect them in parallel with diodes to prevent back electromotive force. If a load is connected causing a surge current when a lamp is turned on, use a protective resistance. 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, SDO1 to SDO76 -443-

B-81465EN-1/05

.

CONNECTIONS


2. Input signals in peripheral device interface A Example of connection

Electrical specifications of the receiver Type: Grounded voltage receiver Rated input voltage: Contact close: +20 V to +28 V Contact open 0 V to +4 V Maximum applied input voltage: +28 VDC Input impedance: 3.3 kΟhm (approx.) Response time: 5 ms to 20 ms Specifications of the peripheral device contact Rated contact capacity: 30 VDC, 50 mA or more Input signal width: 200 ms or more (on/off) Chattering time: 5 ms or less Closed circuit resistance: 100 Ohm or less Opened circuit resistance: 100 kΟhm or more:

1

(Signal)

3

Robot receiver signal

2

Peripheral device contact signal

4

TB ; Chattering 5 ms or less TC ; 5 to 20 ms

NOTE Apply the +24 V power at the robot to the receiver. However, the above signal specifications must be satisfied at the robot receiver.

-444-


CONNECTIONS

B-81465EN-1/05

Applicable signals Input signals of process I/O board CRM2 and CRM4 *IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET, START, HOME, ENBL, RSR1 to RSR8, PNS1 to PNS8, PNSTROBE, PROD START, SDI1 to SDI78

-445-

B-81465EN-1/05

CONNECTIONS

.


4.5.2 End Effector Control Interface 1. Output signals Example of connection

1

Spark killer diode

3

Lamp

2

0.2 A or less

4

Protective resistance

Electrical specifications Rated voltage: Maximum applied voltage: Maximum load current: Transistor type: Saturation voltage at connection:

24 VDC 30 VDC 0.2 A Open collector NPN 1.0 V (approx.)



NOTE The +24 V power supply at the robot can be used when the total current of the welding interface and end effector interface is 0.7 A or less. When you load a relay, solenoid, and so on directly, connect them in parallel with diodes to prevent back electromotive force. If a load is connected causing a surge current when a lamp is turned on, use a protective resistance. Applicable signals Output signals of the end effector control interface RDO1 to RDO8

-446-


CONNECTIONS

2. Input signals Example of connection

Electrical specifications of the receiver Type: Rated input voltage: Contact close: Contact open: Maximum applied input voltage: Input impedance: Response time:

Grounded voltage receiver +20 V to +28 V 0 V to +4 V +28 VDC 3.3 kOhm (approx.) 5 ms to 20 ms

Specifications of the peripheral device contact Rated contact capacity: Input signal width: Chattering time: Closed circuit resistance: Opened circuit resistance:

30 VDC, 50 mA or more 200 ms or more (on/off) 5 ms or less 100 Ohm or less 100 kOhm or more:

1

(Signal)

3

Robot receiver signal

2

Peripheral device contact signal

4


NOTE Apply the +24 V power at the robot to the receiver. However, the above signal specifications must be satisfied at the robot receiver. Applicable signals Input signals of the end effector control interface RDI1 to RDI8, *HBK, *PPABN -447-

B-81465EN-1/05

B-81465EN-1/05

CONNECTIONS

.


4.5.3 I/O Signal Specifications for ARC-Welding Interface 1. Digital output signal specifications for an arc welding interface In case of process I/O CA, EA

1

Example connection

3

2

Spark killer diode

4

0.2 A or less

Electrical characteristics Rated voltage: Maximum applied voltage: Maximum load current: Transistor type: Saturation voltage at connection:

24 VDC 30 VDC 0.2 A Open-collector NPN about 1.0 V



NOTE A power voltage of +24 V, provided for the robot, can be used for interface signals of up to 0.7 A. This limit applies to the sum of the currents flowing through the arc-welding and end-effector control interfaces. To drive a relay or solenoid directly, connect a diode preventing back electromotive force to the load in parallel. To connect a load which generates an inrush current when you turn on the control unit, connect a protective resistor. Applicable signals - Output signals on the arc-welding interface - WDO1 to WDO8

-448-


CONNECTIONS

B-81465EN-1/05

In case of process I/O GA, HA

1

Example connection

3

2

Spark killer diode

4

0.3 A or less

Electrical characteristics Rated voltage: Maximum applied voltage: Maximum load current: Output type:

24 VDC 30 VDC 0.3 A Relay connect output



NOTE Do not use the +24 V power supply of the robot. When you load a relay, solenoid, and so on directly, connect them in parallel with diodes for preventing back electromotive force. If a load is connected causing a surge current when a lamp is turned on, use a protective resistance. Applicable signals - Output signals on the arc-welding interface - WDO1 to WDO4

-449-

CONNECTIONS

B-81465EN-1/05

.


2. Digital input signal specifications for arc welding interface

1

Example connection

Electrical characteristics of receivers Type: Rated input voltage: 0 V to +4 V when open Maximum input voltage: Input impedance: Response time: Contact specifications for peripherals Rated contact capacity: Input signal width: Chattering period: Closed circuit resistance: Opened circuit resistance:

Grounded voltage receiver +20 V to +28 V with contacts closed +28 VDC About 3.3 kOhm 5 ms to 20 ms 30 VDC, 50 mA or more 200 ms or more for on and off states 5 ms or less 100 Ohm or less 100 kOhm or more:

1

(Signal)

3

Receiver signal for robot

2

Contact signal for peripheral

4


NOTE Supply the +24 V power, provided for the robot, to the receivers. The receiver signal on the robot must satisfy the signal timing specified above.

-450-


CONNECTIONS

Applicable signals - Input signals for arc welding interface - WDI1 to WDI8 3. Analog output signal specifications for arc welding interface (Welding voltage command, wire-feed rate command)

1

Example connection

2

Welder

3

Process I/O CA, EA: -10V to +10V Process I/O GA, HA: 0V to +15V

NOTE Input impedance: 3.3 kΩ or more. Connect a high-pass filter. 4. Analog input signal specifications for arc welding interface (Welding-voltage detection, welding-current detection)

1

Example connection

2

Welder

NOTE Input impedance: 2kW The analog input signal should have no ripple for the circuit to operate properly. (Wire deposit detection: WDI+ and WDI-)

-451-

B-81465EN-1/05

B-81465EN-1/05

1

Example connection

2

Welder

CONNECTIONS

.


3

Welding electrode

NOTE Connect a resistor of 100 Ohm 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 80 V.

-452-


CONNECTIONS

B-81465EN-1/05

4.6 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS If the customer manufactures cables, 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.)

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

1

Honda Tsushin MR50LWF01 (MR50LF)

4

Peripheral device

2

Honda Tsushin MR50LM01 (MR50LM)

5

Honda Tsushin MR50RMA

3

Process I/O CRM2*

6

Honda Tsushin’s MR50RF Supplied with an ordered cable

-453-

B-81465EN-1/05

CONNECTIONS

.


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

1

Honda Tsushin MR20LWF01 (MR20LF)

4

Peripheral device

2

Honda Tsushin MR20LM01 (MR20LM)

5

Honda Tsushin MR20RMA

3

Process I/O CRM4*

6

Honda Tsushin’s MR20RF Supplied with an ordered cable

4.6.3 ARC Weld Connection Cable (CRW1, CRW7: Honda Tsushin, 34 pins) Be sure to use our cable to connect the welder.

1

ARC welder

4

Japan Aviation Electronics Industry Ltd. MS3102A28-21S Standard position of guide key

2

Honda Tsushin MRP34LWM01

5

Honda Tsushin MR34RFA

3

Process I/O CRW1 or CRW7

6

Japan Aviation Electronics Industry Ltd. MS3108B28-21P MS3057-16

-454-


CONNECTIONS

B-81465EN-1/05

4.7 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS, AND ARC WELDERS 4.7.1 Peripheral Device Connection Cable Fig. 4.7.1 shows the connection of the peripheral device cable in the cabinet.

1

Process I/O board

5

Metallic clamp

2

To peripheral device

6

External shield

3

A cabinet

7

Shield plate

4

B cabinet

8

Noise protection: Remove a part of the sheath of a peripheral cable to expose the outside shield. Secure the cable to the shield plate with the metallic clamp at the exposed position.

Fig. 4.7.1 Peripheral Device Cable Connection -455-

CONNECTIONS

B-81465EN-1/05

.


4.7.2 Peripheral Device Cable Connector 1. Fig. 4.7.2 shows the connector for peripheral device cables A and B.

Fig. 4.7.2 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo)

Connector specifications

Applicable interface

Dimensions A

Dimensions (B)

Dimensions C

Dimensions (D)

Remark

MR50LM

(CRM2)

67.9

73.5

44.8

18

Honda Tsushin Kogyo, 50 pins

MR20LM

(CRM2)

39.3

44.9

39.8

17


-456-


CONNECTIONS

Symbol

Name

Connector cover

Connector clamp screw

Connector clamp spring

Connector clamp screw Connector 50 pins(male) MR50M Connector 20 pins (male) MR20M

-457-

B-81465EN-1/05

.

CONNECTIONS

B-81465EN-1/05


2. Peripheral device connector

Fig. 4.7.2 (b) Peripheral Device Connector (Honda Tsushin Kogyo)

Connector specifications

Applicable interface

Dimensions A

Dimensions B

Remark

MR50RF

(CRM2)

61.4

56.4


MR20RF

(CRM4)

39.3

44.9


Symbol

Name

Connector clamp screw

Screw M2.6 x 8

Connector (MR50RF) Connector (MR20RF)

-458-


CONNECTIONS

B-81465EN-1/05

4.7.3 End Effector Cable Connector 1. Connector external view (For R-2000iA. Refer to the each maintenance manual for other robots.)

1

Inside diameter

2

Manufactured by Daiichi Denshi Kogyo JMLP2524M

2

Manufactured by Daiichi Denshi Kogyo JMLP2524M

Fig. 4.7.3 (a) Connector (Elbow Type)

1

Inside diameter

Fig. 4.7.3 (b) Connector (Straight Type)

-459-

.

CONNECTIONS

B-81465EN-1/05


4.7.4 Recommended Cables 1. Peripheral device connection cable Connect a peripheral device using a completely shielded, heavily protected cable conforming to the specifications in Table 4.7.4 (a). Allow an extra 50 cm for routing the cable in the control unit. The maximum cable length is 30 m. Tab. 4.4.7 (a) Recommended Cable (for Peripheral Device Connection) Conductor

Number of wires

Wire specifications (FANUC specifications)

50

A66L-0001-0042

φ1.05

20

A66L-0001-0041

φ1.05

Diameter (mm)

Conductor

Electrical characteristics


Conductor resistance (W/km)

Allowable current (A)

Sheath thickness (mm)

Effective outside diameter (mm)

7/0.18 AWG24

1.5

φ12.5

106

1.6

7/0.18 AWG24

1.5

φ10.5

106

1.6

Configuration

2. End effector connection cable Connect an end effector using a heavily protected cable with a movable wire conforming to the specifications in Table 4.7.4 (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. Tab. 4.7.4 (b) Recommended Cable (for End Effector Connection) Conductor

Number of wires

Wire specifications (FANUC specifications)

6

A66L-0001-0143

φ1.1

20

A66L-0001-0144

φ1.1

Diameter (mm)

Conductor



Conductor resistance (W/km)

Allowable current (A)

Sheath thickness (mm)

Effective outside diameter (mm)

40/0.08 AWG24

1.0

φ5.3

91

3.7

40/0.08 AWG24

1.0

φ8.6

91

2.3

Configuration

-460-


CONNECTIONS

B-81465EN-1/05

4.8 CONNECTION OF HDI 4.8.1 Connecting HDI The HDI signals are used in combination with special application software. The HDI signals cannot be used as general-purpose DIs.

1

Main board

-461-

CONNECTIONS

B-81465EN-1/05

1

.

Main board

-462-



CONNECTIONS

Cable connections

1

Recommended cable connector

-463-

B-81465EN-1/05

CONNECTIONS

B-81465EN-1/05

.


4.8.2 Input Signal Rules for the High-speed Skip (HDI) Circuit Configuration

1

Driver

3

Filter

2

Shield

4

Receiver

Absolute maximum rating Input voltage range Vin: -3.6 to +10.0 V Input characteristics Unit

Symbol

Specification

Unit

Remark

High level input voltage

VH

3.6 to 7

V

Low level input voltage

VL

0 to 1.0

V

High level input current

liH

2 max

mA

Vin = 5 V

High level input current

liH

11 max

mA

Vin = 10 V

Low level input current

liL

-8.0 max

mA

Vin = 0 V

Input signal pulse duration

20 min

s

Input signal delay or variations

0.02(max)

ms

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.

-464-


CONNECTIONS

B-81465EN-1/05

4.9 CONNECTING THE COMMUNICATION UNIT 4.9.1 RS-232-C Interface 4.9.1.1 Interface This interface can be connected to a handy file or another communication unit from FANUC.

1

A-cabinet

2

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B-cabinet

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B-81465EN-1/05

1

1

.


R-J3iB interface overview

Main board

2

Operator’s panel connector

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.

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CONNECTIONS

4.9.1.2 RS-232-C Interface signals Generally signals as follows are used in RS-232-C interface.

1

Output

7

Enable to send

2

Send data

8

Ready

3

Input

9

When DR is not used short DR and ER

4

Receive data

10

Data set ready

5

Request to send

11

Signal ground

6

When CS is not used short CS and RS

12

Frame ground

Fig. 4.9.1.2 RS-232-C interface

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4.9.1.3 Connection between RS-232-C interface and external device The figure below shows a connection with the handshaking of the ER and DB signals.

1

External device side

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• The figure below shows a connection without the handshaking of the ER and DB signals.

1

External device side

Prepare the cable as follows :

1

Cable : twist 10 pairs x 0.18mm², with shield

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.

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CONNECTIONS

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4.9.2 Ethernet Interface CAUTION Before connecting or disconnecting cables to and from the Ethernet board, cut the power supply of R-J3iB, and make sure that the power is off.

NOTE Please inqure of each manufacturer about the network construction or the condition of using the equipment except the Ethernet board (hub, 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.

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4.9.2.1 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.

1

Personal computer

5

Transceiver

2

Transceiver cable

6

Main board

3

Hub

7

10BASE -5 trunk cable

4

Twisted -pair cable

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.

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4.9.2.2 10/100 BASE-T connector (CD38) pin assignments CD38 Pin No.

Signal Name

Description

1

TX+

Send +

2

TX-

Send -

3

RX+

Receive +

4

Not used

5

Not used

6

RX-

Receive -

7

Not used

8

Not used

4.9.2.3 Cable connection The figure below shows the cable connection between the 10/100 BASE-T connector (CD38) of the main board and hub.

1

10/100BASE-T connector CD38

3

RJ-45 modular connector

2

HUB

4

Shielded cable

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.

CONNECTIONS


• For details on shielding, see "4.9.2.6 Cable clamp and shielding". • Keep the total cable length to within 100 m. Do not extend the cable longer than necessary.

1

Example cable connected to the A-cabinet

5

For the A-cabinet

2

Partially peel the sheath to expose the shield

6

Use any connector not in use

3

to the HUB

7

Clamp: A02B-0083_K301 The cable shuld be fixed on the shield plate

4

Cord grip Diameter of the installation hole on the plate: Ø38.0mm

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4.9.2.4 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 "4.9.2.6 Cable clamp and shielding." Recommended Cable Manufacturer

Specification

Furukawa Electric Co., Ltd.

DTS5087

Nissei Electric Co., Ltd.

F-4PFWMF

Inquiries Contact Address

Manufacturer Furukawa Electric Co., Ltd., Sales Headquarters

Maru-no-uchi 2-6-1, Chiyoda-ku. Tokyo 100-8322 TEL: 03-3286-3126 FAX: 03-3286-3979

Remarks Nissei Electric Co., Ltd., Machida Branch

3F MU Bldg., Minami-narise 1-9-1, Machida City, Tokyo 194-0045 TEL: 0427-29-2153 FAX: 0427-29-3375

Overseas Sales Office

NISSEI ELECTRIC CO., LTD 1509 Okubo-cho, Hamamatsu-shi Shizuoka-ken, 432-8006 Japan TEL: 053-485-4114 FAX: 053-485-6908 E-mail: [email protected]

Remarks

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 AWG26 4P TPMC-C5-F(SB)

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Remarks FANUC-specific cable

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CONNECTIONS

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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 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 (805C/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

4.9.2.5 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

5-569530-3

AMP Japan, Ltd.

For solid wire

MS8-RSZT-EMC

SK KOHKI Co., Ltd.

For twisted wire

5-569552-3

AMP Japan, Ltd.

For twisted wire

TM11AP-88P

Hirose Electric Co., Ltd.

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Remarks

Special tool required

Special tool required


For movable parts For cable AWG26 4P TPMC-C5-F(SB)

CONNECTIONS

Specification TM21CP-88P(03)

B-81465EN-1/05

Manufacturer 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.)

4.9.2.6 Cable clamp and shielding Shield the cables as like as other cables are shielded. (See 4.7.1)

4.9.2.7 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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A

Large-scale Network

B

Small-scale Network

1

Personal computer

7

Personal computer/Ethernet trunk side

2

Note 1

8

Electrically separated by 10/100 BASE-T cable connection

3

10BASE-5 Ethernet trunk cable

9

STP cable

4

Note 2

10

Machine system

5

Hub power supply

11

Ethernet

6

HUB

12

Machine

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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.1) 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).

1

Shield

5

Ground wire on personal computer/trunk

2

Trunk cable

6

Ground wire on machine system

3

Note 2

7

Ground point

4

HUB

Fig. 4.9.2.7 Wiring on a Single Ground Point

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5. TRANSPORTATION/INSTALLATION

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5 TRANSPORTATION AND INSTALLATION 5.1 TRANSPORTATION This section describes the transportation and installation for the control unit. The control unit is transported by a crane. Attach a strap to eye bolts at the top of the control unit.

1

A-cabinet

2

Fig. 5.1 Transportation

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B-cabinet

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5.2 INSTALLATION 5.2.1 Installation Method Following is the installation method for A-cabinet/B-cabinet. When installing the control unit, allow the space for maintenance shown in the following figure.

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1

A-cabinet

3

B-cabinet

2

View from the A

4

Front

Fig. 5.2.1 (a) External dimension

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Fig. 5.2.1 (b) External dimension (A-cabinet operation box)

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1

Maintenance space

3

Top view

2

Space for replacing amplifier

4

For fixing bolts. Bolt spec. M10 M10x12 is used in A-cabinet

Fig. 5.2.1 (c) Installation Method (A-cabinet) (1/2)

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1

Controller

Fig. 5.2.1 (c) Installation Method (B-cabinet) (2/2)

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5.2.2 Assemble at Installation

1

Operation box

4

R-J3iB controller

2

Teach pendant

5


3

Input power cable

Fig. 5.2.2 (a) Assemble at Installation (A-cabinet integrated type) (1/3)

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CONNECTIONS


1

Operation box

4

R-J3iB controller

2

Teach pendant

5


3

Input power cable

6

Robot connection cable

Fig. 5.2.2 (a) Assemble at Installation (A-cabinet remote type) (2/3)

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CONNECTIONS

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1

Teach pendant

4


2

R-J3iB controller

5

Robot connection cable

3

Input power connection cable

Fig. 5.2.2 (b) Assemble at Installation (B-cabinet) (3/3)

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5.3 INSTALLATION CONDITION Item

Model

Specifications/condition

Rated Voltage

All models

Trans. I 440-480, 500-575 VAC Trans. II 380-415, 440-500 VAC Trans. III 200-230, 380-400 VAC 50/60Hz 3phases

Tolerant fluctuation

All models

Tolerant voltage fluctuation: +10% -15% Tolerant voltage fluctuation: +/-1 Hz

Input power source capacity

S-900iB R2000iA/200T M-410iB

15 kVA


R-2000iA (except/200T) M-420iA/M-421iA M-710iB

12 kVA


S-500iB

7.kVA


F-200iB

5 kVA


M-16iB ARC Mate 120iB

3 kVA


M-6iB ARC Mate 100iB

2.5 kVA


LR Mate 200iB

1.2 kVA

Average power consumption

S-900iB R2000iA/200T

3 KW


R-2000iA (except/200T) M-420iA/M-421iA M-710iB

2.5 KW


S-500iB

1.7KW


M-16iB M-6iB ARC Mate 100iB ARC Mate 120iB F-200iB

1.0KW


LR Mate 200iB

0.5KW

Permissible ambient temperature

All models

0°C to 45°C during operation, and -20°C to 60°C during shipment and storage with a temperture coefficient of 1.1°C/min.

Permissible ambient humidity

All models

Relative humidity: 30% to 95%, non-condensing.

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Item

Model


Specifications/condition

Surrounding gas

All models

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/or salt).

Vibration

All models

0.5 G or less. When using the robot in a location subject to serious vibration, consult with your FANUC sales representative.

Altitude

Common to all models

Not higher than 1,000m above sea level

Ionized and nonionized radiation

Common to all models

A shielding provision is necessary if the machine is installed in an environment in which ift is exposed to radiations (microwave, ultraviolet rayr , laser beams , and/or X-rays)

Mass of control unit

A-cabinet

Approx. 120 kg

Mass of control unit

B-cabinet

Approx. 180 kg

NOTE During rapid acceleration, robot power draw can be several times the continuous rating value.

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5.4 ADJUSTMENT AND CHECKS AT INSTALLATION Adjust the robot according to the following procedure at installation. No.

Description

1

Visually check the inside and outside of the control unit.

2

Check the screw terminals for proper connection.

3

Check that the connectors and printed circuit boards are firmly connected.

4

Check transformer tap setting. (See II MAINTENANCE section 6.2)

5

The breaker off and connect the input power cable.

6

Check the input power voltage and transformer outputs.

7

Press the EMERGENCY STOP button on the operator panel and turn on the control unit.

8

Check the interface signals between control and robot mechanical unit.

9

Check the parameters. If necessary, set them.

10

Release the EMERGENCY STOP button on the operator panel. Turn on the controller.

11

Check the movement along each axis in manual jog mode.

12

Check the end effector interface signals.

13

Check the peripheral device control interface signals

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CONNECTIONS


5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION An overtravel and emergency stop occur when the robot is operated for the first time after it is installed and the mechanical and control units are wired. 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.

5.5.2 Resetting Overtravel 1. Select [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.

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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)

Robot operation

HBK detection

Message

1

Enable

CLOSE

Yes

Possible

None

2

Enable

OPEN

Yes

Impossible

SRVO-006

3

Disable

CLOSE

Yes (*2)

Possible

None

4

Disable

OPEN

No

Possible

At cold start, SRVO-300

1

Robot end effector connector

2

CLOSE

3

OPEN

NOTE 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.

NOTE 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.

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CONNECTIONS


5.5.4 How to Disable/Enable Pneumatic Pressure Alarm (PPABN) 1. 2. 3. 4. 5.

Press [MENU] 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 A

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A TOTAL CONNECTION DIAGRAM

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APPENDIX A

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Fig. A (a) Total connection diagram (A-cabinet) (1/2)

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APPENDIX A

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Fig. A (a) Total connection diagram (B-cabinet) (2/2)

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Fig. A (b) Transformer type I (1/3)

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Fig. A (b) Transformer type II (2/3)

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Fig. A (b) Transformer type III (3/3)

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Fig. A (c) Power supply unit

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APPENDIX A

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Fig. A (d) Main CPU

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APPENDIX A

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Fig. A (e) E-stop unit (1/2)

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APPENDIX A

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Fig. A (e) E-stop unit (2/2)

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Fig. A (f) 6-axis servo amplifier (1/2)

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Fig. A (f) 6-axis servo amplifier (2/2)

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Fig. A (g) Motor power connection (R-2000iA, M-710iB, M-420iA, M-421iA, S-500iB)

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Fig. A (h) Motor power connection (M-6iB, M-16iB ARC Mate 100iB, ARC Mate 120iB, F-200iB)

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APPENDIX A

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Fig. A (i) Motor power connection (R-2000iA/200T, M-410iB)

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APPENDIX A

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Fig. A (j) Motor power connection (S-900iB)

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APPENDIX A

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Fig. A (k) Motor power connection (LR Mate 200iB)

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Fig. A (l) Operation´s panel/operation box (without E-stop)

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Fig. A (m) Operator’s panel/operation box

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Fig. A (n) Mechanical interface (R-2000iA, M-420iA, M-6iB, ARC Mate 100iB, F-200iB)

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Fig. A (o) Mechanical interface (S-900iB, R-2000iA/200T)

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Fig. A (p) Mechanical interface (LR Mate 200iB)

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Fig. A (q) I/O device (A-cabinet) (1/3)

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Fig. A (q) I/O device (B-cabinet) (2/3)

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Fig. A (q) I/O device (B-cabinet) (3/3)

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Fig. A (r) Emergency stop circuit

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APPENDIX A

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APPENDIX B

B-81465EN-1/05

B SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE B.1 SIGNALS The following table lists the I/O signals used for the peripheral device interface in the R-J3iB controller.

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APPENDIX B

B-81465EN-1/05

Input signals (Refer to B.3.1) Signal

Description

*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 SDIO1 SDIO2

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

SDIO3 SDIO4 SDIO5 SDIO6 SDIO7 SDIO8 SDIO9 SDIO10 SDIO12 SDIO13 SDIO14 SDIO15 SDIO16 SDIO17 SDIO18 SDIO19 SDIO20 SDIO21 SDIO22

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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APPENDIX B

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Output signals (Refer to B.3.2) Signal

Description

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 --------

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)

SDO01 SDO02 SDO03 SDO04 SDO05 SDO06 SDO07 SDO08 SDO09 SDO10 SDO11 SDO12 SDO13 SDO14 SDO15 SDO16 SDO17 SDO18 SDO19 SDO20

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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APPENDIX B

B-81465EN-1/05

B.2 SETTING COMMON VOLTAGE All process I/O printed boards have a jumper to set the common voltage of input signals to 0V or 24V. 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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APPENDIX B

B-81465EN-1/05

B.3 I/O SIGNALS B.3.1 Input Signals 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 operator panel. 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. • 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.

-531-

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B-81465EN-1/05

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 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 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.

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• 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 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.

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APPENDIX B

B-81465EN-1/05

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. • 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.

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APPENDIX B

B-81465EN-1/05

• The following operations are effective for the program selected by PNS. You can: a.Start up a program by input of automatic operation start signal PROD_START b.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. c.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 : 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 executes the selected program at the falling edge when the signal is turned off after being turned on.

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APPENDIX B

B-81465EN-1/05

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APPENDIX B

B-81465EN-1/05

B.3.2 Output Signals 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 switch on the operator's panel is set to REMOTE side. • 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. 4. Held signal (output) HELD This signal is used to check the status of the hold input. Turned on : When the hold button (or input) is being pressed down (or turned on). Turned off : When the hold button (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. -537-

APPENDIX B

B-81465EN-1/05

9. Battery alarm signal (output) BATALM Turned on : When the voltage of the battery for the CMOS memory backup drops below the reference. Turned off : When the 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.

1

(The remote conditions need to be satisfied.)

2

The maximum delay is 32 msec.

3

(The width of the pulse is set in the parameter.)

* Other RSR signals can be accepted even when the ACK signal is being output. -538-

APPENDIX B

B-81465EN-1/05

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.

1

(The remote conditions need to be satisfied.)

4

Detection and processing of PNSTROBE by software.

2

(A value is input.)

5

(PNS is read within a maximum of 32 msec after PNSTROBE is turned on.)

3

(A strobe is input for PNS.)

6

(Program execution starts within 32 msec.)

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B-81465EN-1/05

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APPENDIX B

B-81465EN-1/05

B.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT B.4.1 Overview This section describes the external specifications of digital and analog input/output in the R-J3iB controller.

B.4.2 Input/Output Hardware Usable In the R-j3iB Controller The R-J3iB controller can use up to 512 digital input and output points or an equivalent number of analog input and output points. One analog input/output point uses the resources equivalent to those used by 16 digital I/O points. The R-J3iB can use a total of up to 512 I/O points. The R-J3iB 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. RDI/RDO 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. SDI/SDO 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.

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APPENDIX B

B-81465EN-1/05

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APPENDIX C

B-81465EN-1/05

C POWER DISTRIBUTATION CIRCUIT DIAGRAM

-543-

APPENDIX C

B-81465EN-1/05

Fig. C (a) 200VAC Power supply Circuit Diagram

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APPENDIX C

B-81465EN-1/05

-545-

APPENDIX C

B-81465EN-1/05

Fig. C (b) +5V, +3.3V, +15V, -15V Power Supply Circuit Diagram

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APPENDIX C

B-81465EN-1/05

Fig. C (c) Robot Mechanical Unit +5V Power Supply Circuit Diagram

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APPENDIX C

B-81465EN-1/05

Fig. C (d) +24V Power Supply Circuit Diagram (A-cabinet) (1/2)

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APPENDIX C

B-81465EN-1/05

Fig. C (d) +24V Power Supply Circuit Diagram (B-cabinet) (2/2)

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APPENDIX C

B-81465EN-1/05

Fig. C (e) Robot Mechanical Unit +24V Power Supply Circuit Diagram

-550-

APPENDIX D

B-81465EN-1/05

D OPTICAL FIBER CABLE The R-J3iB 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.

1

Electrical/optical conversion module

3

Fiber optic cable

2

Lid

4

Fiber optic cable caps

Fig. D (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. • 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 x 2 cords Diameter of cable with reinforced cover: 7.6 mm Tensile strength: Cable with reinforced cover: Fiber optic cord: Between fiber optic cord and connector: Minimum bending radius of fiber optic cord:

75 kg 7 kg per cord 2 kg 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) -551-

APPENDIX D

B-81465EN-1/05

Flame resistance: Operating temperature:

1

Code

2

Bush

Equivalent to UL VW-1 -20 to 70°C

3

Reinforced cover

Fig. D (b) External dimensions of external optical cable Unit : mm

• 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. D (c), to prevent the weight of the fiber optic cable from being applied directly to the connecting part of the optical connector.

1

Optical connector

4

Bending radius of 25 mm or more (Make the bending radius as large as possible)

2

Part of optical fiber cord

5

Cable clamp (Don’t clamp tight)

3

Part of reinforcing cover

6

Bending radius of 50 mm or more (Make the bending radius as large as possible.)

Fig. D (c) Fixing the cable with a clamp

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APPENDIX D

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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.

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APPENDIX D

B-81465EN-1/05

-554-

APPENDIX E

B-81465EN-1/05

E CARD INTERFACE

1

Card interface

3

Card

2

Connector for card

4

Card should be inserted straight for the connector

Fig. E Precautions for card interface -555-

APPENDIX E

B-81465EN-1/05

-556-

NUMERICS 10/100 BASE-T CONNECTOR (CD38) PIN ASSIGNMENTS 473

A ADJUSTMENT AND CHECKS AT INSTALLATION 493 ALARM OCCURRENCE SCREEN 45 ARC WELD CONNECTION CABLE (CRW1 HONDA TSUSHIN, 34 PINS) 454 ASSEMBLE AT INSTALLATION 487

B BACKPLANE BOARD 236 BATTERY FOR MEMORY BACKUP (3 VDC) 346 BLOCK DIAGRAM 273, 351, 355

C CABLE CLAMP AND SHIELDING 478 CABLE CONNECTION 473 CARD INTERFACE 555 CHECKING THE POWER SUPPLY UNIT 281 COMPONENT FUNCTIONS 38 CONFIGURATION 29 CONNECTING THE COMMUNICATION UNIT 461, 465 CONNECTING THE EXTERNAL POWER SUPPLY ON/OFF SWITCH 368, 371, 386, 387, 388 CONNECTING THE INPUT POWER 366 CONNECTING THE OPERATION BOX 383 CONNECTION BETWEEN RS-232-C INTERFACE AND EXTERNAL DEVICE 468 CONNECTION BETWEEN THE CONTROL UNIT AND WELDER 432 CONNECTION BETWEEN THE MECHANICAL UNIT AND END EFFECTOR 429 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS 355 CONNECTION TO ETHERNET 472 CONNECTOR SPECIFICATION 476

D DIAGRAMM VOM SPANNUNGS-VERTEILERSCHALTKREIS 543 DIGITAL I/O SIGNAL SPECIFICATIONS 443

E EMERGENCY STOP CONTROL BOARD (A20B-1007-0800) 235 END EFFECTOR CABLE CONNECTOR 459 END EFFECTOR CONTROL INTERFACE 446 ETHERNET INTERFACE 471 EXTERNAL CABLE WIRING DIAGRAM 358 EXTERNAL VIEW OF THE CONTROLLER 29

F FUSED-BASED TROUBLESHOOTING 199

G GESAMTANSCHLUSSDIAGRAMM 497 GROUNDING THE NETWORK 478

H HOW TO DISABLE/ENABLE HBK 495 HOW TO DISABLE/ENABLE PNEUMATIC PRESSURE ALARM (PPABN) 496

I I/O SIGNAL SPECIFICATIONS FOR ARC-WELDING INTERFACE 448 I/O SIGNALS 531 INPUT SIGNALS 531 INPUT/OUTPUT HARGWARE USABLE IN THE R-J3I MODEL B CONTROLLER 541 INSTALLATION 482 INSTALLATION CONDITION 491 INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS 409

L LEAD MATERIALS 475 LED OF SERVO AMPLIFIER 269

M MAIN BOARD 230 MANUAL OPERATION IMPOSSIBLE 227 MASTERING 50

O OPERATOR SAFETY 15 OPTICAL FIBER CABLE 551 OUTPUT SIGNALS 537

P PANEL BOARD (A20B-2100-0470) 238, 240 PANEL SWITCH BOARD 245, 247, 250, 257, 260, 263 PANEL SWITCH BOARD (A20B-1007-0850) 266 PERIPHERAL DEVICE AND CONTROL UNIT CONNECTION 409 PERIPHERAL DEVICE AND END EFFECTOR INTERFACES 389 PERIPHERAL DEVICE CABLE CONNECTOR 456 PERIPHERAL DEVICE CONNECTION CABLE 455 PERIPHERAL DEVICE INTERFACE 443 PERIPHERAL DEVICE INTERFACE A CABLE (CRM2 HONDA TSUSHIN, 50 PINS) 453 PERIPHERAL DEVICE INTERFACE B CABLE (CRM4 HONDA TSUSHIN, 20 PINS) 454

PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM 392 PERIPHERAL DEVICE INTERFACE COMBINATION 401 PERIPHERAL DEVICE INTERFACE PROCESSING 494 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION 226 POWER CANNOT BE TURNED ON 41 PRECAUTIONS FOR MECHANISM 21 PRECAUTIONS IN PROGRAMMING 21 PREVENTIVE MAINTENANCE 40 PRINTED CIRCUIT BOARDS 229 PROCESS I/O BOARD CA (A16B-2201-0470) 241, 255 PROCESS I/O BOARD SIGNALS 403

R RECOMMENDED CABLES 460 REPLACE THE MODE SWITCH 336 REPLACING A MODULE 324 REPLACING A UNIT 285 REPLACING BATTERY 346 REPLACING CARDS AND MODULES ON THE MAIN BOARD 295 REPLACING EXTERNAL AIR FAN UNIT AND DOOR FAN (B-CABINET) 328, 330, 331 REPLACING FUSES 337 REPLACING FUSES IN THE POWER UNIT 338 REPLACING FUSES IN THE SERVO AMPLIFIER 337 REPLACING I/O UNIT MODEL A 323 REPLACING RELAYS 345 REPLACING RELAYS ON THE PANEL BOARD 345 REPLACING SERVO AMPLIFIERS 314 REPLACING THE AC FAN MOTOR 328 REPLACING THE A-CABINET TOP PANEL 285 REPLACING THE BACKPLANE BOARD (UNIT) 289 REPLACING THE BASE UNIT OF I/O UNIT MODEL A 323 REPLACING THE CONTROL SECTION FAN MOTOR 327 REPLACING THE FUSE ON THE PANEL BOARD 343 REPLACING THE FUSE ON THE PROCESS I/O BOARDS 339 REPLACING THE OPERATOR´S PANEL AND PANEL SWITCH BOARD 333 REPLACING THE PANEL BOARD 287, 288, 292, 293 REPLACING THE POWER DISTRIBUTING UNIT 313 REPLACING THE PRINTED-CIRCUIT BOARDS 285, 288 REPLACING THE REDUNDANT E-STOP UNIT 311 REPLACING THE REGENERATIVE RESISTANCE UNIT 308 REPLACING THE TEACH PENDANT 325 REPLACING THE TRANSFORMER 301 RESETTING OVERTRAVEL 494 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION 494 ROBOT CONNECTION CABLES 358 RS-232-C INTERFACE 461, 464, 465 RS-232-C INTERFACE SIGNALS 467

S SAFETY DURING MAINTENANCE 20 SAFETY IN MAINTENANCE 24 SAFETY OF THE END EFFECTOR 23 SAFETY OF THE ROBOT MECHANISM 22 SAFETY OF THE TEACH PENDANT OPERATOR 18 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 21 SAFETY PRECAUTIONS 15 SAFETY SIGNALS 48 SELECTING TRANSFORMER TAPS 276 SERVO AMPLIFIERS 267 SETTING AND ADJUSTING THE POWER SUPPLY 273 SETTING COMMON VOLTAGE 530 SETTING OF SERVO AMPLIFIER 271, 272 SIGNALS 527 SPECIFICATIONS OF DIGITAL DIGITAL INPUT/OUTPUT 541 SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE 527 SRVO-001 OPERATOR PANEL E-STOP 53 SRVO-002 TEACH PENDANT E-STOP 56 SRVO-003 DEADMAN SWITCH RELEASED 57 SRVO-004 FENCE OPEN 58 SRVO-005 ROBOT OVERTRAVEL 61 SRVO-006 HAND BROKEN 63 SRVO-007 EXTERNAL E-STOP 65 SRVO-009 PNEUMATIC PRESSURE ALARM 69 SRVO-014 FAN MOTOR ABNORMAL 70 SRVO-015 SYSTEM OVER HEAT (GROUP I AXIS J) 71 SRVO-018 BRAKE ABNORMAL 73 SRVO-021 SRDY OFF (GROUP I AXIS J) 74 SRVO-022 SRDY ON (GROUP I AXIS J) 76 SRVO-023 STOP ERROR EXCESS (GROUP I AXIS J) 77 SRVO-024 MOVE ERROR EXCESS (GROUP I AXIS J) 79 SRVO-027 ROBOT NOT MASTERED (GROUP I) 79 SRVO-033 ROBOT NOT CALIBRATED (GROUP I) 79 SRVO-034 REF POS NOT SET (GROUP I) 79 SRVO-035 WARN2 JOINT SPEED LIMIT (GROUP I AXIS J) 79 SRVO-036 INPOS TIME OVER (GROUP I AXIS J) 79 SRVO-037 IMSTP INPUT (GROUP I) 80 SRVO-038 PULSE MISMATCH (GROUP I AXIS J) 80 SRVO-042 MCAL ALARM (GROUP I AXIS J) 81 SRVO-043 DCAL ALARM (GROUP I AXIS J) 82 SRVO-044 HVAL ALARM (GROUP I AXIS J) 85 SRVO-045 HCAL ALARM (GROUP I AXIS J) 86 SRVO-046 OVC ALARM (GROUP I AXIS J) 87 SRVO-047 LVAL ALARM (GROUP I AXIS J) 91 SRVO-049 OHAL1 ALARM (GROUP I AXIS J) 92 SRVO-050 CLALM ALARM (GROUP I AXIS J) 94 SRVO-051 CUER ALARM (GROUP I AXIS J) 95

SRVO-054 DSM MEMORY ERROR 96 SRVO-055 FSSB COM ERROR 1 (GROUP I AXIS J) 97 SRVO-056 FSSB COM ERROR 2 (GROUP I AXIS J) 98 SRVO-057 FSSB DISCONNECT (GROUP I AXIS J) 98 SRVO-058 FSSB INIT ERROR (GROUP I AXIS J) 100 SRVO-059 SERVO AMP INIT ERROR 102 SRVO-060 FATL FSSN INIT ERROR 103 SRVO-062 BZAL ALARM (GROUP I AXIS J) 103 SRVO-064 PHAL ALARM (GROUP I AXIS J) 103 SRVO-065 BLAL ALARM (GROUP I AXIS J) 104 SRVO-067 OHAL2 ALARM (GROUP I AXIS J) 104 SRVO-068 DTERR ALARM (GROUP I AXIS J) 104 SRVO-069 CRCERR ALARM (GROUP I AXIS J) 104 SRVO-070 STBERR ALARM (GROUP I AXIS J) 105 SRVO-071 SPHAL ALARM (GROUP I AXIS J) 106 SRVO-072 PMAL ALARM (GROUP I AXIS J) 106 SRVO-073 CMAL ALARM (GROUP I AXIS J) 106 SRVO-074 LDAL ALARM (GROUP I AXIS J) 106 SRVO-075 PULSE NOT ESTABLISHED (GROUP I AXIS J) 106 SRVO-076 TIP STICK DETECTION (GROUP I AXIS J) 107 SRVO-081 EROFL ALARM (TRACK ENC I) 108 SRVO-082 DAL ALARM (TRACK EBC I) 109 SRVO-084 BZAL ALARM (TRACK ENC I) 109 SRVO-087 BLAL ALARM (TRACK ENC I) 109 SRVO-091 CRCERR ALARM (TRACK ENC I) 110 SRVO-092 STBERR ALARM (TRACK ENC I) 110 SRVO-093 SPMAL ALARM (TRACK ENC I) 110 SRVO-094 PMAL ALARM (TRACK ENC I) 111 SRVO-095 CMAL ALARM (TRACK ENC I) 111 SRVO-096 LDAL ALARM (TRACK ENC I) 111 SRVO-105 DOOR OPEN OR E-STOP 112 SRVO-136 DCLVAL ALARM (GROUP I AXIS J) 114 SRVO-138 SDAL ALARM (GROUP I AXIS J) 116 SRVO-153 SDAL1 CHGAL(CNV) ALARM (GROUP I AXIS J) 116 SRVO-156 IPMAL ALARM (GROUP I AXIS J) 117 SRVO-194 SERVO DISCONNECT 118 SRVO-199 CONTROL STOP 120 SRVO-201 PANEL E-STOP OR SVEMG ABNORMAL 121 SRVO-202 SVAL1 TP E-STOP OR SVEMG ABNORMAL 123 SRVO-204 SVAL1 SVON INPUT (SVEMG ABNORMAL) E-STOP 125 SRVO-205 SVAL1 FENCE OPEN (SVEMG ABNORMAL) 128 SRVO-206 DEADMAN SWITCH (SVEMG ABNORMAL) 131 SRVO-213 WARN FUSE BLOWN (PANEL PCB) 133 SRVO-214 FUSE BLOWN (AMP) 137 SRVO-216 OVC (TOTAL) (ROBOT I) 138 SRVO-221 LACK OF DSP (GROUP I AXIS J) 138 SRVO-230 CHAIN 1 (+24V) ABNORMAL WITH SRVO-002 TEACH PENDANT E-STOP 143 SRVO-230 CHAIN 1 (+24V) ABNORMAL WITH SRVO-232 NTED INPUT 153

SRVO-231 CHAIN 2 (0V) ABNORMAL WITH SRVO-001 OPERATOR´S PANEL E-STOP 141 SRVO-231 CHAIN 2 (0V) ABNORMAL WITH SRVO-002 TEACH PENDANT E-STOP 143 SRVO-231 CHAIN 2 (0V) ABNORMAL WITH SRVO-232 NTED INPUT 153 SRVO-232 NTED INPUT 160 SRVO-233 TP DISABLED IN T1, T2/DOOR OPEN 162 SRVO-235 SHORT TERM CHAIN ABNORMAL 164 SRVO-236 CHAIN FAILURE IS REPAIRED 165 SRVO-237 NOT RESET CHAIN FAILURE 165 SRVO-240 CHAIN 1 (FENCE) ABNORMAL 165 SRVO-241 CHAIN 2 (FENCE) ABNORMAL 165 SRVO-242 CHAIN 1 (EXEMG) ABNORMAL 169 SRVO-260 CHAIN 1 (NTED) ABNORMAL 172 SRVO-261 CHAIN 2 (NTED) ABNORMAL 172 SRVO-262 CHAIN 1 (SVDCT) ABNORMAL 175 SRVO-263 CHAIN 2 (SVDCT) ABNORMAL 175 SRVO-264 "E.STOP CIRCUIT ABNORMAL 1" 178 SRVO-265 E.STOP CIRCUIT ABNORMAL 2 180 SRVO-266 FENCE1 STATUS ABNORMAL 182 SRVO-267 FENCE2 STATUS ABNORMAL 182 SRVO-268 SVOFF1 STATUS ABNORMA 182 SRVO-269 SVOFF2 STATUS ABNORMAL 182 SRVO-270 EXEMG1 STATUS ABNORMAL 183 SRVO-271 EXEMG2 STATUS ABNORMAL 183 SRVO-272 SVDISC1 STATUS ABNORMAL 183 SRVO-273 SVDISC2 STATUS ABNORMAL 183 SRVO-274 NTED1 STATUS ABNORMA 184 SRVO-275 NTED2 STATUS ABNORMAL 184 SRVO-280 SVOFF INPUT 184 SRVO-281 SVOFF INPUT (SVEMG ABNORMAL) 187 SRVO-282 CHAIN1 (SVOFF) ABNORMAL 190 SRVO-283 CHAIN2 (SVOFF) ABNORMAL 190 SRVO-291 "IPM OVER HEAT (GROUP I AXIS J)" 196 SRVO-292 EXT FAN ALARM (GROUP I A J) 196 SRVO-293 DCLINK (PSM) HCAL (GROUP I AXIS J) 196 SRVO-294 EXT FAN (PSM) ALARM (GROUP I AXIS J) 196 SRVO-295 PSM COM ALARM (GROUP I AXIS J) 196 SRVO-296 PSM DISCHG ALARM (GROUP I AXIS J) 197 SRVO-297 PSM LOW VOLT ALARM (GROUP I AXIS J) 197 SRVO-300 HAND BROKEN/HBK DISABLED 197 SRVO-302 SET HAND BROKEN TO ENABLE 197

T TEACH PENDANT CABLE 365 TRANSPORTATION 481 TRANSPORTATION AND INSTALLATION 481 TROUBLESHOOTING 41 TROUBLESHOOTING BASED ON LED INDICATIONS 211 TROUBLESHOOTING USING THE ERROR CODE 53

V VIBRATION OBSERVED DURING MOVEMENT 226

W WARNING LABEL 25 WHEN I/O UNIT-MODEL A IS USED 399 WHEN PROCESS I/O BOARD CA/CB/HA IS USED (B-CABINET) 395 WHEN PROCESS I/O BOARD DA IS USED (B-CABINET) 397 WHEN PROCESS I/O BOARD FA IS USED (A-CABINET) 394

B-81465EN-1/05 ©FANUC, 2003

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