[536]R J3iB Controller

FANUC Robotics R-J3iBMate Controller (RIA R15.06 – 1999 Compliant) Maintenance Manual

MARMIBRIA01021E REV. B

B-81535EN/02

This publication contains proprietary information of FANUC Robotics

North America, Inc. furnished for customer use only. No other uses

are authorized without the express written permission of FANUC

Robotics North America, Inc.

FANUC Robotics North America, Inc.

3900 W. Hamlin Road

Rochester Hills, Michigan 48309–3253

The descriptions and specifications contained in this manual were in

effect at the time this manual was approved for printing. FANUC

Robotics North America, Inc, hereinafter referred to as FANUC

Robotics, reserves the right to discontinue models at any time or to

change specifications or design without notice and without incurring

obligations.

FANUC Robotics manuals present descriptions, specifications,

drawings, schematics, bills of material, parts, connections and/or

procedures for installing, disassembling, connecting, operating and

programming FANUC Robotics’ products and/or systems. Such

systems consist of robots, extended axes, robot controllers,

application software, the KAREL!!!! programming language,

INSIGHT!!!! vision equipment, and special tools.

FANUC Robotics recommends that only persons who have been

trained in one or more approved FANUC Robotics Training

Course(s) be permitted to install, operate, use, perform procedures

on, repair, and/or maintain FANUC Robotics’ products and/or

systems and their respective components. Approved training

necessitates that the courses selected be relevant to the type of

system installed and application performed at the customer site.

WARNING This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual, may cause interference to radio communications. As temporarily permitted by regulation, it has not been tested for compliance with the limits for Class A computing devices pursuant to subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measure may be required to correct the interference.

FANUC Robotics conducts courses on its systems and products on

a regularly scheduled basis at its headquarters in Rochester Hills,

Michigan. For additional information contact


Training Department

3900 W. Hamlin Road

Rochester Hills, Michigan 48309-3253

www.fanucrobotics.com

Send your comments and suggestions about this manual to:

[email protected]

Copyright "2002 by FANUC Robotics North America, Inc.

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


AccuStat!, ArcTool!, DispenseTool!, FANUC LASER DRILL!,

KAREL!, INSIGHT!, INSIGHT II!, PaintTool!, PaintWorks!,

PalletTool!, SOCKETS!, SOFT PARTS! SpotTool!,

TorchMate!, and YagTool! are Registered Trademarks of FANUC

Robotics.

FANUC Robotics reserves all proprietary rights, including but not

limited to trademark and trade name rights, in the following names:

AccuAir AccuCal AccuChop AccuFlow AccuPath

AccuSeal ARC Mate ARC Mate Sr. ARC Mate System 1

ARC Mate System 2 ARC Mate System 3 ARC Mate System

4 ARC Mate System 5 ARCWorks Pro AssistTool

AutoNormal AutoTCP BellTool BODYWorks Cal Mate Cell

Finder Center Finder Clean Wall CollisionGuard

DispenseTool F-100 F-200i FabTool FANUC LASER

DRILL Flexibell FlexTool HandlingTool HandlingWorks

INSIGHT INSIGHT II IntelliTrak Integrated Process Solution

Intelligent Assist Device IPC -Integrated Pump Control IPD

Integral Pneumatic Dispenser ISA Integral Servo Applicator ISD

Integral Servo Dispenser Laser Mate System 3 Laser Mate

System 4 LaserPro LaserTool LR Tool MIG Eye

MotionParts NoBots Paint Stick PaintPro PaintTool 100

PAINTWorks PAINTWorks II PAINTWorks III PalletMate

PalletMate PC PalletTool PC PayloadID RecipTool

RemovalTool Robo Chop Robo Spray S-420i S-430i

ShapeGen SoftFloat SOF PARTS SpotTool+ SR Mate

SR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM R-

J3 Controller SYSTEM R-J3iB Controller TCP Mate

TurboMove TorchMate visLOC visPRO-3D visTRAC

WebServer WebTP YagTool

This manual includes information essential to the safety of

personnel, equipment, software, and data. This information is

indicated by headings and boxes in the text.

WARNING

Information appearing under WARNING concerns the protection of personnel. It is boxed and in bold type to set it apart from other text.

Conventions

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.

SafetySafety-1

FANUC Robotics is not and does not represent itself as an expert in

safety systems, safety equipment, or the specific safety aspects of

your company and/or its work force. It is the responsibility of the

owner, employer, or user to take all necessary steps to guarantee

the safety of all personnel in the workplace.

The appropriate level of safety for your application and installation

can best be determined by safety system professionals. FANUC

Robotics therefore, recommends that each customer consult with

such professionals in order to provide a workplace that allows for

the safe application, use, and operation of FANUC Robotic systems.

According to the industry standard ANSI/RIA R15.06, the owner or

user is advised to consult the standards to ensure compliance with

its requests for Robotics System design, usability, operation,

maintenance, and service. Additionally, as the owner, employer, or

user of a robotic system, it is your responsibility to arrange for the

training of the operator of a robot system to recognize and respond

to known hazards associated with your robotic system and to be

aware of the recommended operating procedures for your particular

application and robot installation.

FANUC Robotics therefore, recommends that all personnel who

intend to operate, program, repair, or otherwise use the robotics

system be trained in an approved FANUC Robotics training course

and become familiar with the proper operation of the system.

Persons responsible for programming the system–including the

design, implementation, and debugging of application programs–

must be familiar with the recommended programming procedures

for your application and robot installation.

The following guidelines are provided to emphasize the importance

of safety in the workplace.

Safety-2

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

• The safety of people and equipment

• Use of safety enhancing devices

• Techniques for safe teaching and manual operation of the

robot(s)

• Techniques for safe automatic operation of the robot(s)

• Regular scheduled inspection of the robot and workcell

• Proper maintenance of the robot

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

• People

• External devices

• Robot(s)

• Tooling

• Workpiece

Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the

installation of some or all of the following devices:

• Safety fences, barriers, or chains

• Light curtains

• Interlocks

• Pressure mats

• Floor markings

• Warning lights

• Mechanical stops

• EMERGENCY STOP buttons

• DEADMAN switches

A safe workcell is essential to protect people and equipment. Observe the following guidelines to ensure that the workcell is set up safely. These suggestions are intended to supplement and not

replace existing federal, state, and local laws, regulations, and

guidelines that pertain to safety.

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

CONSIDERING SAFETY FOR YOUR ROBOT

INSTALLATION

Keeping People and

Equipment Safe

Using Safety

Enhancing Devices

Setting Up a Safe

Workcell

Safety-3

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

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

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

• Clearly identify the work envelope of each robot in the system with floor markings, signs, and special barriers. The work

envelope is the area defined by the maximum motion range of the robot, including any tooling attached to the wrist flange that

extend this range.

• Position all controllers outside the robot work envelope.

• Never rely on software as the primary safety element.

• Mount an adequate number of EMERGENCY STOP buttons or

switches within easy reach of the operator and at critical points inside and around the outside of the workcell.

• Install flashing lights and/or audible warning devices that activate whenever the robot is operating, that is, whenever

power is applied to the servo drive system. Audible warning devices shall exceed the ambient noise level at the end–use application.

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

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

• Use interlocks.

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

• Periodically check the safety joints or safety clutches that can be optionally installed between the robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove

power from the system, and help to minimize damage to the tooling and robot.

Safety-4

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

(ESD).

• Make provisions for power lockout/tagout at the controller.

• Eliminate pinch points. Pinch points are areas where personnel

could get trapped between a moving robot and other equipment.

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

• Program the robot to load and unload material safely.

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

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

pressure.

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

• Never wear watches, rings, neckties, scarves, or loose clothing

that could get caught in moving machinery.

• Know whether or not you are using an intrinsically safe teach

pendant if you are working in a hazardous environment.

• Before teaching, visually inspect the robot and work envelope to

make sure that no potentially hazardous conditions exist. The

work envelope is the area defined by the maximum motion

range of the robot. These include tooling attached to the wrist

flange that extends this range.

• The area near the robot must be clean and free of oil, water, or

debris. Immediately report unsafe working conditions to the

supervisor or safety department.

• FANUC Robotics recommends that no one enter the work

envelope of a robot that is on, except for robot teaching

operations. However, if you must enter the work envelope, be

sure all safeguards are in place, check the teach pendant

DEADMAN switch for proper operation, and place the robot in

teach mode. Take the teach pendant with you, turn it on, and be

prepared to release the DEADMAN switch. Only the person

with the teach pendant should be in the work envelope.

Staying Safe While Teaching or Manually

Operating the Robot

Safety-5

WARNING

Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.

• Know the path that can be used to escape from a moving robot;

make sure the escape path is never blocked.

• Isolate the robot from all remote control signals that can cause

motion while data is being taught.

• Test any program being run for the first time in the following

manner: WARNING

Stay outside the robot work envelope whenever a program is being run. Failure to do so can result in injury.

- Using a low motion speed, single step the program for at

least one full cycle.

- Using a low motion speed, test run the program continuously

for at least one full cycle.

- Using the programmed speed, test run the program

continuously for at least one full cycle.

• Make sure all personnel are outside the work envelope before

running production.

Advise all personnel who operate the robot during production to

observe the following rules:

• Make sure all safety provisions are present and active.

• Know the entire workcell area. The workcell includes the robot and its work envelope, plus the area occupied by all external

devices and other equipment with which the robot interacts.

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

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

Staying Safe During

Automatic Operation

Safety-6

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

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

• Know where the EMERGENCY STOP buttons are located on both the robot control and external control devices. Be prepared

to press these buttons in an emergency.

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

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

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

teach pendant, or emergency stop stations around the workcell.

When inspecting the robot, be sure to

• Turn off power at the controller.

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

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

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

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

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

• Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a

hard stop. Support the arm on a solid support before you release the brake.

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

Staying Safe During

Inspection

Staying Safe During

Maintenance

Safety-7

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

operation.

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


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

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

• If it is necessary for you to enter the robot work envelope while power is turned on, you must be sure that you are in control of the robot. Be sure to take the teach pendant with you, press the

DEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switch to turn off servo power to the

robot immediately.

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

controller.

• Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a

hard stop. Support the arm on a solid support before you release the brake.

WARNING

Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to

avoid electrical shock.

HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit breaker to the OFF position removes

power from the output side of the device only.

• Release or block all stored energy. Before working on the

pneumatic system, shut off the system air supply and purge the air lines.

Safety-8

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

• Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to

escape from a moving robot. Make sure the escape route is never blocked.

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

WARNING

Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Doing so can result in serious personal injury and component destruction.

• Be aware that when you remove a servomotor or brake, the

associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you

release the brake.

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

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

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

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

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

KEEPING MACHINE TOOLS AND EXTERNAL

DEVICES SAFE

Programming Safety

Precautions

Safety-9

• Back–check limit switches in the workcell to make sure they do

not fail.

• Implement ‘‘failure routines” in programs that will provide appropriate robot actions if an external device or another robot

in the workcell fails.

• Use handshaking protocol to synchronize robot and external

device operations.

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

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

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

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

Observe the following operating and programming guidelines to

prevent damage to the robot.

The following measures are designed to prevent damage to the

robot during operation.

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

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

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

• Use circuit breakers to guard against electrical overload.

The following safety measures are designed to prevent damage to

the robot during programming:

• Establish interference zones to prevent collisions when two or

more robots share a work area.

Mechanical Safety

Precautions

KEEPING THE

ROBOT SAFE

Operating Safety

Precautions

Programming Safety

Precautions

Safety-10

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

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

damage.

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

NOTE Any deviation from the methods and safety practices

described in this manual must conform to the approved standards of

your company. If you have questions, see your supervisor.

Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personal also must

work inside the paint booth periodically.

Whenever personnel are working inside the paint booth, ventilation

equipment must be used. Instruction on the proper use of

ventilating equipment usually is provided by the paint shop

supervisor.

Although paint booth hazards have been minimized, potential

dangers still exist. Therefore, today’s highly automated paint booth

requires that process and maintenance personnel have full

awareness of the system and its capabilities. They must

understand the interaction that occurs between the vehicle moving

along the conveyor and the robot(s), hood/deck and door opening

devices, and high–voltage electrostatic tools.

Paint robots are operated in three modes:

• Teach or manual mode

• Automatic mode, including automatic and exercise operation

• Diagnostic mode

During both teach and automatic modes, the robots in the paint

booth will follow a predetermined pattern of movements. In teach

mode, the process technician teaches (programs) paint paths using

the teach pendant.

In automatic mode, robot operation is initiated at the System

Operator Console (SOC) or Manual Control Panel (MCP), if

available, and can be monitored from outside the paint booth. All

personnel must remain outside of the booth or in a designated safe

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS

Safety-11

area within the booth whenever automatic mode is initiated at the

SOC or MCP.

In automatic mode, the robots will execute the path movements they

were taught during teach mode, but generally at production speeds.

When process and maintenance personnel run diagnostic routines

that require them to remain in the paint booth, they must stay in a

designated safe area.

Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment,

personnel must comply strictly with the procedures in the manuals.

This section provides information about the safety features that are

included in the paint system and also explains the way the robot

interacts with other equipment in the system.

The paint system includes the following safety features:

• Most paint booths have red warning beacons that illuminate when the robots are armed and ready to paint. Your booth

might have other kinds of indicators. Learn what these are.

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

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

STOP buttons.

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

• A DEADMAN switch is located on each teach pendant. When this

switch is held in, and the teach pendant is on, power is applied to the

robot servo system. If the engaged DEADMAN switch is released

during robot operation, power is removed from the servo system, all

axis brakes are applied, and the robot comes to an EMERGENCY

STOP. Safety interlocks within the system might also E–STOP other

robots.

WARNING

An EMERGENCY STOP will occur if the DEADMAN switch is

released on a bypassed robot.

Paint System Safety

Features

Safety-12

• Overtravel by robot axes is prevented by software limits. All of

the major and minor axes are governed by software limits. Limit switches and hardstops also limit travel by the major axes.

• EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all

equipment in the booth if a door is opened while the system is operating in automatic or manual mode. For some systems,

signals to these switches are inactive when the switch on the SCC is in teach mode.

When present, photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit

silhouette openings.

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

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

systems.

WARNING

Observe all safety rules and guidelines to avoid injury.

WARNING

Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.

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

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

• Be aware of overlapping work envelopes of adjacent robots.

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

Staying Safe While Operating the Paint

Robot

Safety-13

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

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

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

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

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

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


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

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

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

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

• Follow the procedures described in this manual.

When you work with paint application equipment, observe the

following rules, in addition to all rules for safe operation that apply to all robot systems.

WARNING

When working with electrostatic paint equipment, follow all national and local codes as well as all safety guidelines

within your organization. Also reference the following standards: NFPA 33 Standards for Spray Application Using Flammable or Combustible Materials, and NFPA 70 National

Electrical Code.

Staying Safe While Operating Paint

Application Equipment

Safety-14

• Grounding: All electrically conductive objects in the spray area must be grounded. This includes the spray booth, robots,

conveyors, workstations, part carriers, hooks, paint pressure pots, as well as solvent containers. Grounding is defined as the

object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms.

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

cleaning process.

• Avoid any accumulation of combustible vapors or coating matter.

• Follow all manufacturer recommended cleaning procedures.

• Make sure all interlocks are operational.

• No smoking.

• Post all warning signs regarding the electrostatic equipment and operation of electrostatic equipment according to NFPA 33

Standard for Spray Application Using Flammable or Combustible Material.

• Disable all air and paint pressure to bell.

• Verify that the lines are not under pressure.

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

personnel should perform repair work on a robot.

• Paint robots operate in a potentially explosive environment. Use

caution when working with electric tools.

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

the area.

• For some maintenance procedures, station a second person at the control panel within reach of the EMERGENCY STOP

button. This person must understand the robot and associated potential hazards.

Staying Safe During

Maintenance

Safety-15

• Be sure all covers and inspection plates are in good repair and in place.

• Always return the robot to the ‘‘home’’ position before you disarm it.

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

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

potential problems.

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

• When using vinyl resin observe the following:

- Wear eye protection and protective gloves during application

and removal

- Adequate ventilation is required. Overexposure could cause

drowsiness or skin and eye irritation.

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

• When using paint remover observe the following:

- Eye protection, protective rubber gloves, boots, and apron

are required during booth cleaning.

- Adequate ventilation is required. Overexposure could cause

drowsiness.

- If there is contact with the skin or eyes, rinse with water for

at least 15 minutes.

Update SectionSingle Phase Power Option

B–81535EN/02 Table of Contents

c–1

PREFACE p–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 OPERATOR SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.1 Operator Safety 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2 Safety of the Teach Pendant Operator 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.3 Safety During Maintenance 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1 Precautions in Programming 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.2 Precautions for Mechanism 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SAFETY OF THE ROBOT MECHANISM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.1 Precautions in Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.2 Precautions in Programming 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.3 Precautions for Mechanisms 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 SAFETY OF THE END EFFECTOR 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.1 Precautions in Programming 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 SAFETY IN MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 WARNING LABEL 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II MAINTENANCE

1. OVERVIEW 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. CONFIGURATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 EXTERNAL VIEW OF THE CONTROLLER 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 COMPONENT FUNCTIONS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PREVENTIVE MAINTENANCE 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. TROUBLESHOOTING 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 POWER CANNOT BE TURNED ON 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1 Teach Pendant Cannot be Turned On 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2 Initial Screen Remains on the Teach Pendant 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 ALARM OCCURRENCE SCREEN 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 SAFETY SIGNALS 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 MASTERING 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 TROUBLESHOOTING USING THE ERROR CODE 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 TROUBLESHOOTING USING FUSES 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 TROUBLESHOOTING BASED ON LED INDICATIONS 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 VIBRATION OBSERVED DURING MOVEMENT 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 MANUAL OPERATION IMPOSSIBLE 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4. PRINTED CIRCUIT BOARDS 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 ROBOT CONTROL BOARD (A16B–3200–0450) 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 EMERGENCY STOP BOARD (A20B–1008–0010, –0011) 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 BACKPLANE BOARD (A20B–2003–0330) 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 PROCESS I/O BOARD HE (A16B–2203–0764), HF (A16B–2203–0765) 118. . . . . . . . . . . . . . . . . . .

5. SERVO AMPLIFIERS 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 OUTLINE DRAWINGS 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Power Supply Module PSM (A06B–6115–H001) 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Servo Amplifier Module (A06B–6114–H205, A06B–6114–H302) 122. . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 LED OF SERVO AMPLIFIER 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 LED of Power Supply Module 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.2 LED of Servo Amplifier Module 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. SETTING THE POWER SUPPLY 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 BLOCK DIAGRAMS OF THE POWER SUPPLY 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 CHECKING THE POWER SUPPLY UNIT 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 CHECKING THE POWER SUPPLY MODULE 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. REPLACING A UNIT 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 REPLACING THE PRINTED–CIRCUIT BOARDS 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Replacing the Backplane Board (Unit) 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit 131. . . . . . . . . . . 7.1.3 Replacing the Emergency Stop Board 132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 REPLACING CARDS AND MODULES ON THE ROBOT CONTROL BOARD 133. . . . . . . . . . . . . 7.3 REPLACING THE TRANSFORMER 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.1 Replacing the Brake Power Transformer 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 REPLACING THE EMERGENCY STOP UNIT 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 REPLACING THE MAGNETIC CONTACTOR 139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 REPLACING SERVO AMPLIFIERS 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 REPLACING THE TEACH PENDANT 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 REPLACING THE CONTROL SECTION FAN MOTOR 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 REPLACING THE FAN MOTOR OF THE SERVO AMPLIFIER CONTROL UNIT 143. . . . . . . . . . 7.10 REPLACING THE DOOR FAN UNIT AND HEAT EXCHANGER 144. . . . . . . . . . . . . . . . . . . . . . . . 7.11 REPLACING THE OPERATOR PANEL 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 REPLACING THE POWER SUPPLY UNIT 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13 REPLACING A FUSE 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13.1 Replacing a Fuse on the Robot Control Board 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13.2 Replacing a Fuse on the Emergency Stop Board 148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13.3 Replacing the Fuse on the Door 149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13.4 Replacing the Fuse on the Power Supply Module 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13.5 Replacing the Fuse on the Servo Amplifier Module 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13.6 Replacing the Fuse on the Process I/O Boards 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14 REPLACING A RELAY 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14.1 Replacing a Relay on the Emergency Stop Board 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15 REPLACING BATTERY 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15.1 Battery for Memory Backup (3 VDC) 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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III CONNECTION

1. GENERAL 159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. BLOCK DIAGRAM 160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. CONNECTION DETAILS 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 CONNECTION OF POWER SUPPLY CABLE 162. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 FANUC I/O LINK 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 CONNECTION OF I/O LINK CABLE 165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 EMERGENCY STOP CIRCUIT 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.1 Circuit Diagram of Emergency Stop 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.2 External Emergency Stop Input 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.3 External Emergency Stop Output 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.4 External 24 V Input 170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 COONECTION OF SERVO AMPLIFIER 171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 CONNECTION OF ROBOT 172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 CONNECTION OF TEACH PENDANT CABLE 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 CONNECTION OF CABLE FOR RS–232–C/RS–422 174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 CONNECTING A CABLE TO A PERIPHERAL DEVICE 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.1 Peripheral Device Interfaces CRM79 and CRM81 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.2 When the Robot is Connected to the CNC by a Peripheral Device Cable 176. . . . . . . . . . . . . . . . . . . . . . . 3.9.3 Digital I/O Signal Specifications 193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.3.1 Peripheral device interface CRM 79 and CRM 81 193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.4 Peripheral Device Cable Connector 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.5 Recommended Cables 196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 END EFFECTOR INTERFACE 197. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.1 Connecting the Mechanical Unit and End Effector 197. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.2 Digital I/O Signal Specifications of End Effector Control Interface 199. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 TREATMENT FOR THE SHIELDED CABLE 200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 PERIPHERAL DEVICE, ARC WELDING, INTERFACES 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.1 Peripheral Device Interface Types 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.2 Peripheral Device Interface Block Diagram and Specifications 202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.3 Peripheral Device and Control Unit Connection 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.4 Connection Between the Control Unit and Welder 208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.5 Digital I/O Signal Specifications of Peripheral Device Interface A 214. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.6 I/O Signal Specifications for ARC–Welding Interface 216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.7 Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin, 50 pins) 219. . . . . . 3.12.8 ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins) 219. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.9 Peripheral Device Cable Connector 220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.10 Recommended Cables 221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. TRANSPORTATION AND INSTALLATION 222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 TRANSPORTATION 223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 INSTALLATION 223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 EXTERNAL CONTROLLER DIMENSIONS 224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 INSTALLATION CONDITION 225. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ADJUSTMENT AND CHECKS AT INSTALLATION 225. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 NOTE AT INSTALLATION 226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.7 DISABLING HAND BREAK 226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX

A. TOTAL CONNECTION DIAGRAM 229. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B. PERIPHERAL INTERFACE 238. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.1 SIGNAL TYPES 239. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2 I/O SIGNALS 240. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.1 Input Signals 240. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.2 Output Signals 241. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT 242. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.1 Overview 242. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.2 Input/Output Hardware Usable in the R-J3iB Mate Controller 242. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.3 Software Specifications 243. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C. OPTICAL FIBER CABLE 244. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B–81535EN/02 PREFACE

p–1

PREFACE

This manual describes the following models.Model Abbreviation

FANUC Robot LR Mate 100iB LR Mate 100iBFANUC Robot LR Mate 200iB LR Mate 200iBFANUC Robot ARC Mate 50iB ARC Mate 50iB

I SAFETY PRECAUTIONS

B–81535EN/02 1. SAFETY PRECAUTIONSSAFETY PRECAUTIONS

3

1SAFETY PRECAUTIONS

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

1. SAFETY PRECAUTIONS B–81535EN/02SAFETY PRECAUTIONS

4

Operator safety is the primary safety consideration. Because it is verydangerous to enter the operating space of the robot during automaticoperation, adequate safety precautions must be observed.The following lists the general safety precautions. Careful considerationmust be made to ensure operator safety.(1) Have the robot system operators attend the training courses held byFANUC.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 stillready to move state and is waiting for a signal. In this state, the robotis regarded as still in motion. To ensure operator safety, provide thesystem with an alarm to indicate visually or aurally that the robot isin motion.(3) Install a safety fence with a gate so that no operator can enter the workarea without passing through the gate. Equip the gate with aninterlock that stops the robot when the gate is opened.The controller is designed to receive this interlock signal. When the gate isopened 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 robotmotion, including the tools such as a hand.(7) Install a mat switch or photoelectric switch on the floor with aninterlock to a visual or aural alarm that stops the robot when anoperator enters the work area.(8) If necessary, install a safety lock so that no one except the operatorin charge can turn on the power of the robot.The circuit breaker installed in the controller is designed to disable anyone fromturning it on when it is locked with a padlock.

1.1OPERATOR SAFETY


5

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

Safety gate which executes with opening the door.

Fig.1.1 Safety Fence and Safety Gate


6

The operator is a person who operates the robot system. In this sense, aworker who operates the teach pendant is also an operator. However, thissection does not apply to teach pendant operators.(1) If it is not necessary for the robot to operate, turn off the power of therobot controller or press the EMERGENCY STOP button, and thenproceed 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 otherthan the operator from entering the work area unexpectedly and alsoto 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 EMERGENCYSTOP button. With this connection, the controller stops the robot operationwhen the external EMERGENCY STOP button is pressed. See the diagrambelow for connection.

EMGIN11

Emergency stop board

Note) Connect between EMGIN1 and EMGIN2 and between EMGIN21 and EMGIN22.

EMGIN11, EMGIN12, EMGIN21 and EMGIN22 are on the emergency stop

board.

External EMERGENCY STOP button

EMGIN12EMGIN21EMGIN22

Fig.1.1.1 Connection Diagram for External Emergency Stop Switch

1.1.1Operator Safety


7

While teaching the robot, it is necessary for the operator to enter the workarea of the robot. It is particularly necessary to ensure the safety of theteach pendant operator.(1) Unless it is specifically necessary to enter the robot work area, carryout all tasks outside the area.(2) Before teaching the robot, check that the robot and its peripheraldevices are all in the normal operating condition.(3) When entering the robot work area and teaching the robot, be sure tocheck the location and condition of the safety devices (such as theEMERGENCY STOP button and the deadman switch on the teachpendant).FANUC’s teach pendant has a switch for enabling or disabling the robot opera-tion from the teach pendant and a deadman switch in addition to the EMER-GENCY STOP button. The switches function as follows.

EMERGENCY STOP button : Pressing this button always brings the robotto an emergency stop, irrespective of thestate of the enable/disable switch and themode switch of operator panel.

Deadman switch : The function of this switch depends on thestate of the enable/disable switch and themode switch of operator panel.

When the mode switch is in the AUTO position– The enable/disable switch and deadman

switch are disabled.

When the mode switch is in the TI position and the enable/disable switch isin the enable position

– Releasing the deadman switch brings therobot to an emergency stop.

When the mode switch is in the TI position and the enable/disable switch isin the disable position

– The robot is brought to an emergency stopregardless of the operation of the deadmanswitch.

Note)The deadman switch is provided to bring the robot to an emergencystop when the operator releases the teach pendant in an emergency.

(4) The teach pendant operator should pay careful attention so that noother workers enter the robot work area.NOTE

In addition to the above, the teach pendant enable switch and the

deadman switch also have the following function.

By pressing the deadman switch while the enable switch is on, the

emergency stop factor (normally the safety gate) connected to

FENCE11 and FENCE12 of the controller is invalidated. In this

case, it is possible for an operator to enter the fence during teach

operation without making the robot in the emergency stop

condition. In other words, the system understands that the

combined operations of pressing the teach pendant enable switch

and pressing the deadman 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.

1.1.2Safety of the Teach

Pendant Operator


8

(5) When entering the robot work area, the teach pendant operator shouldenable the teach pendant whenever he or she enters the robot workarea. In particular, while the teach pendant enable switch is off, makecertain that no start command is sent to the robot from any operatorpanel other than the teach pendant.The teach pendant, operator panel, and peripheral device interface send eachrobot start signal. However the validity of each signal changes as follows de-pending on the mode of the teach pendant enable switch and the mode switchthe remote switch on the operator panel.

Operator panelmode switch

Teach pendantenable switch

Remotecondition

Teach pendant

Operator panelPeripheral

devices

T1 On Independent Allowed to start Not allowed Not allowed

AUTO Off Local Not allowed Allowed to start Not allowed

AUTO Off Remote Not allowed Not allowed Allowed to start

(6) When a program is completed, be sure to carry out a test run accordingto the procedure below.(a) Run the program for at least one operation cycle in the single stepmode at low speed.(b) Run the program for at least one operation cycle in the continuousoperation mode at low speed.(c) Run the program for one operation cycle in the continuousoperation mode at the intermediate speed and check that noabnormalities occur due to a delay in timing.(d) Run the program for one operation cycle in the continuousoperation mode at the normal operating speed and check that thesystem operates automatically without trouble.(e) After checking the completeness of the program through the testrun above, execute it in the automatic operation mode.(7) While operating the system in the automatic operation mode, theteach pendant operator should leave the robot work area.


9

For the safety of maintenance personnel, pay utmost attention to thefollowing.(1) Except when specifically necessary, turn off the power of thecontroller 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 thesupply pressure.(3) Before the start of teaching, check that the robot and its peripheraldevices are all in the normal operating condition.(4) If it is necessary to enter the robot work area for maintenance whenthe power is turned on, the worker should indicate that the machineis being serviced and make certain that no one starts the robotunexpectedly.(5) Do not operate the robot in the automatic mode while anybody is inthe robot work area.(6) When it is necessary to maintain the robot alongside a wall orinstrument, or when multiple workers are working nearby, makecertain that their escape path is not obstructed.(7) When a tool is mounted on the robot, or when any moving deviceother than the robot is installed, such as belt conveyor, pay carefulattention to its motion.(8) If necessary, have a worker who is familiar with the robot systemstand beside the operator panel and observe the work beingperformed. If any danger arises, the worker should be ready to pressthe EMERGENCY STOP button at any time.(9) When replacing or reinstalling components, take care to preventforeign matter from entering the system.(10)When handling each unit or printed circuit board in the controllerduring inspection, turn off the power of the controller and also turnoff 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 thecontroller.

1.1.3Safety During

Maintenance


10

(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 sensorsignal is received.(2) Design the program to stop the robot when an abnormal conditionoccurs in any other robots or peripheral devices, even though therobot itself is normal.(3) For a system in which the robot and its peripheral devices are insynchronous motion, particular care must be taken in programmingso that they do not interfere with each other.(4) Provide a suitable interface between the robot and its peripheraldevices so that the robot can detect the states of all devices in thesystem and can be stopped according to the states.(1) Keep the component cells of the robot system clean, and operate therobot in an environment free of grease, water, and dust.(2) Employ a limit switch or mechanical stopper to limit the robot motionso that the robot does not come into contact with its peripheral devicesor tools.

1.2SAFETY OF THE

TOOLS AND

PERIPHERAL

DEVICES

1.2.1Precautions in

Programming

1.2.2Precautions for

Mechanism


11

(1) When operating the robot in the jog mode, set it at an appropriatespeed so that the operator can manage the robot in any eventuality.(2) Before pressing the jog key, be sure you know in advance whatmotion the robot will perform in the jog mode.(1) When the work areas of robots overlap, make certain that the motionsof the robots do not interfere with each other.(2) Be sure to specify the predetermined work origin in a motion programfor the robot and program the motion so that it starts from the originand terminates at the origin.Make it possible for the operator to easily distinguish at a glance thatthe robot motion has terminated.(1) Keep the work area of the robot clean, and operate the robot in anenvironment free of grease, water, and dust.

1.3SAFETY OF THE

ROBOT MECHANISM

1.3.1Precautions in

Operation

1.3.2Precautions in

Programming

1.3.3Precautions for

Mechanisms


12

(1) To control the pneumatic, hydraulic and electric actuators, carefullyconsider the necessary time delay after issuing each control commandup to actual motion and ensure safe control.(2) Provide the end effector with a limit switch, and control the robotsystem by monitoring the state of the end effector.

1.4SAFETY OF THE END

EFFECTOR

1.4.1Precautions inProgramming


13

(1) Never enter the robot work area while the robot is operating. Turn offthe power before entering the robot work area for inspection andmaintenance.(2) If it is necessary to enter the robot work area with the power turnedon, first press the EMERGENCY STOP button on the operator panel.(3) When replacing or reinstalling components, take care to preventforeign matter from entering the system.When replacing the parts in the pneumatic system, be sure to reducethe pressure in the piping to zero by turning the pressure control onthe air regulator.(4) When handling each unit or printed circuit board in the controllerduring inspection, turn off the power of the controller and turn off thecircuit 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 thecontroller.(6) Before restarting the robot, be sure to check that no one is in the robotwork area and that the robot and its peripheral devices are all in thenormal operating state.

1.5SAFETY IN

MAINTENANCE


14

Do not step on or climb the robot or controller as it may adversely affectthe robot or controller and you may get hurt if you lose your footing aswell.(1) Step–on prohibitive label

Fig.1.6 (a) Step–on Prohibitive Label

Be cautious about a section where this label is affixed, as the sectiongenerates heat. If you have to inevitably touch such a section when it ishot, use a protective provision such as heat–resistant gloves.(2) High–temperature warning label

Fig.1.6 (b) High–Temperature Warning Label

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

1.6WARNING LABEL

Description

Description

Description


15

(3) High–voltage warning label

Fig.1.6 (c) High–Voltage Warning Label

There may be a high voltage in a place with this label. Before workingon such a portion, turn off the power to the controller and set its circuitbreaker to the off position to avoid shock hazards.In addition, be careful about servo amplifiers and other electric circuitsbecause a high voltage may remain in them for a certain period of timeafter the power is turned off.

Description

II MAINTENANCE

B–81535EN/02 1. OVERVIEWMAINTENANCE

19

1OVERVIEW

This manual describes the maintenance and connection of the R–J3iBMate robot controller (called the R–J3iB Mate).Maintenance Part : Troubleshooting, and the setting, adjustment,and replacement of unitsConnection Part : Connection of the R–J3iB Mate controller to therobot mechanical unit and peripheral devices,and installation of the controller

WARNINGBefore you enter the robot working area, be sure to turn offthe power to the controller or press the EMERGENCYSTOP button on the operator panel or teach pendant.Otherwise, you could injure personnel or damageequipment.

TERM

The R–J3iB Mate robot controller uses the FANUC servoamplifier α i series (called the servo amplifier (i).The servo amplifier α i comprises a power supply module(PSM) and a servo amplifier module (SVM).In this manual, the terms “power supply module” and “servoamplifier module” refer to the individual modules. The term“servo amplifier” refers to the combination of the powersupply module and servo amplifier module.

2. CONFIGURATION B–81535EN/02MAINTENANCE

20

2CONFIGURATION

B–81535EN/02 2. CONFIGURATIONMAINTENANCE

21

The appearance and components might slightly differ depending on thecontrolled robot, application, and options used.Fig.2.1 (a) shows the view of R–J3iB Mate.Fig.2.1 (b) shows the R–J3iB Mate consists of the R–J3iB Mate controller.Teach pendant

Operator

panel

R–J3iB Mate controller

Teach pendant cable

Fan unit

Fig.2.1 (a) External View of the R–J3iB Mate Controller

2.1EXTERNAL VIEW OF

THE CONTROLLER


22

Robot control board

Option slot (Process I/O board)

Back plane board

Servo amplifier module2 (AMP2)

Servo amplifier module1 (AMP1)Power supply module (PSM)

Fuse

MCC

Teach pendantEnable/disable switch Emergency stop

button

Power supply transformer for brake

Power supply unit

Emergency stop unit


Heat exchange

Circuit protector

Emergency stop button

Modeswitch

Fig.2.1 (b) R–J3iB Mate interior (Front)

Table 2.1 Servo amplifier specifications

Robot Power supply module Servo amplifier module1 Servo amplifier module2

A06B–6115–H001(αPSMR–1i) A06B–6114–H205

(αSVM–20/20i) A06B–6114–H302(αSVM–10/10/10i)

LR Mate 100iBL M L M N

J1 J2 J3 J4 J5

LR Mate 200iB A06B–6115–H001(αPSMR–1i) A06B–6114–H302

(αSVM–10/10/10i) A06B–6114–H302(αSVM–10/10/10i)LR Mate 200iB

ARC Mate 50iB L M N L M NARC Mate 50iBJ1 J2 J3 J4 J5 J6

B–81535EN/02 2. CONFIGURATIONMAINTENANCE

23

– Robot control printed circuit boardThis board is equipped with a microprocessor and its peripheralcircuitry, memory, and operator panel control circuit. A servo controlcircuit is also included.– Emergency stop unit, emergency stop printed circuit boardThis unit controls the emergency stop system, magnetic contactor(MCC) of the servo amplifier, and brake. The unit contains the powersupply unit for converting the AC power to the DC power.– Backplane boardVarious control boards are mounted on the backplane board.– Teach pendantThis unit is used to carry out all operations including robotprogramming. The liquid crystal display (LCD) of this unit displaysthe status of the control unit, data, and the like.– Servo amplifierThe servo amplifier amplifies the power of the servo amplifier andcontrols the pulse coder.– MCCThe MCC controls the main power of the servo amplifier.– Operator panelThe operator panel has a port for the serial interface to an externaldevice. The panel also has an EMERGENCY STOP button.– Fan unit, heat exchangerThese components are used to cool the inside of the control unit.– Circuit protectorThis component turns on or off the power.The input power is connected to the circuit protector in order toprotect the equipment from a large current that could result from aproblem in the electric system of the control unit or an abnormal inputpower.

2.2COMPONENT

FUNCTIONS


24

Daily maintenance and periodic maintenance/inspection ensure reliablerobot performance for extended periods of time.(1) Daily maintenanceBefore operating the system each day, clean each part of the systemand check the system parts for any damage or cracks. Also check thefollowing:(a) Before service operationCheck the cable connected to the teach pendant for excessivetwisting. Check the controller and peripheral devices forabnormalities.(b) After service operationAt the end of service operation, return the robot to the specifiedposition, then turn off the controller. Clean each part, and checkfor any damage or cracks. If the ventilation port of the controlleris dusty, clean it.(c) Check after one monthCheck that the fan is rotating normally. If the fan has dirt and dustbuilt up, clean the fan according to step (d) described below forinspection to be performed every 6 months.(d) Periodic inspection performed every six monthsRemove the top cover, louver, and back panel (if possible), thenremove any dirt and dust from the inside of the transformercompartment. Wipe off dirt and dust from the fan andtransformer.(2) Maintenance toolsThe following maintenance tools are recommended:(a) Measuring instrumentsAC/DC voltmeter (A digital voltmeter is sometimes required.)Oscilloscope with a frequency range of 5 MHz or higher, twochannels(b) ToolsPhillips screwdrivers : Large, medium, and smallStandard screwdrivers: Large, medium, and smallNut driver set (Metric)PliersNeedle-nose pliersDiagonal cutting pliers

2.3PREVENTIVE

MAINTENANCE

B–81535EN/02 3. TROUBLESHOOTINGMAINTENANCE

25

3TROUBLESHOOTING

This chapter describes the checking method and corrective action for eacherror code indicated if a hardware alarm occurs. Refer to the operator’smanual to release program alarms.

3. TROUBLESHOOTING B–81535EN/02MAINTENANCE

26

Check and Corrective action Figure

(Check 1) Check that the circuit protector is on andhas not tripped.

(Correctiveaction)

Turn on the circuit protector.Circuit protector (on/off switch)

(Check 2) Check that the door fan unit and the fanmotor of the heat exchanger are rotatingand that the LED indication on the powersupply module is “–”.

Circuit protector

Heat exchange for fan unit (door face)

LED of the power supply module

(Correctiveaction)

If the fan motor is not rotating or if theLED of the power supply module is notglowing, the fuse on the back of the doormay have been blown.

– Check the fuse on the back of thedoor.If the fuse on the back of the door hasbeen blown, replace the fuse.

Fuse

Secondary side of the circuit protector

fan unit (door face)

3.1POWER CANNOT BE

TURNED ON


27


(Check 1) Check the LCD display and LED indica-tion on the teach pendant. Teach pendant

(Correctiveaction)

Check the LCD display and LED indica-tion on the teach pendant to see whetherthe emergency stop unit is faulty.

– Check whether the fuse FUS4 on theemergency stop board is blown. If thefuse is blown, the FALM LED glows.Replace the blown fuse.

– If the fuse FUS4 on the emergencystop board is not blown, the emergen-cy stop unit may be faulty. Replacethe emergency stop unit.


Fuse FUS4

FALM LED

Emergency stop unit

3.1.1Teach Pendant Cannot

be Turned On


28


(Check 1) Check that the “.” portion of the seven–segment LED glows on the robot controlboard.

(Correctiveaction)

If the “.” portion is not glowing, the fuseFUS1 on the robot control board may beblown. Alternatively, the DC/DC con-verter module may be damaged.If the FUSE ALARM LED is glowing, thefuse FUS1 may be blown.The fuse FUS1 is provided on the robotcontrol board. Before checking the fuse,turn off the circuit protector.a) If the fuse FUS1 has been blown

– See Corrective action (1).b) If the fuse FUS1 is not blown

– See Corrective action (2).

+24V input connectorCP5

(Correctiveaction(1))

Cause of the blowing of the fuse FUS1and corrective actiona) Check whether the device which is

connected to the RS–232–C/RS–422 port and requires the powersupply of +24 V is sound.

b) Problem in the DC/DC convertermoduleIf the DC/DC converter module getsfaulty in the short–circuit mode,FUS1 is blown.Replace the DC/DC converter mod-ule.

DC/DC converter module

dot part of sevensegment LED

(Correctiveaction(2)) a) Problem in the DC/DC converter

moduleReplace the DC/DC converter mod-ule.

b) Problem in the robot control boardReplace the robot control board.(For the LED indications, see Section3.7, “TROUBLESHOOTING USINGLEDS.”)

FUS1 7.5ADC24V input fuse

3.1.2Initial Screen Remains

on the Teach Pendant


29

The alarm occurrence screen displays only the alarm conditions that arecurrently active. If an alarm reset signal is input to reset the alarmconditions, the alarm occurrence screen displays the message “PAUSE ormore 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 allalarm 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 moreserious alarms. It will not display WARN, NONE, or a reset. It is possibleto disable PAUSE and some of more serious alarms from being displayedby setting the $ER_NOHIS system variable appropriately.If two or more alarms have occurred, the display begins with the mostrecent alarm.Up to 100 lines can be displayed.If an alarm has a cause code, it is displayed below the line indicating thealarm.

Press the screenselection key to select[4 ALARM]. Press the alarm key.

Automatic alarm displayupon occurrence

Alarm occurrence screen display

Press F3 [ACTIVE]. Press F3 [HIST].

Alarm history screen display

Fig.3.2 Alarm Occurrence Screen and Alarm History Screen DisplayProcedure

3.2ALARM

OCCURRENCE

SCREEN


30

Displaying the alarm history/alarm detail information

(1) Press the MENUS key to display the screen menu.(2) Select [ALARM]. You will see a screen similar to the following

MENUS

34 ALARM5 I/O

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

[ TYPE ] CLEAR HELP

NOTEThe latest alarm is assigned number 1. To view messagesthat are currently not on the screen, press the F5, HELP,then press the right arrow key.

(3) To display the alarm detail screen, press F5, [HELP]. CLEAR HELP

F5

INTP–224 (SAMPLE1, 7) Jump label is fail

INTP–224 (SAMPLE1, 7) Jump label is failMEMO–027 Specified line does not exist30–MAY–44 07:15STOP.L 00000110Alarm 1/25 1 INTP–224 (SAMPLE1, 7) Jump label is 2 SRVO–002 Teach pendant E–stop

[ TYPE ] CLEAR HELP

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

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

When system variable $ER_NOHIS = 1, NONE alarms orWARN 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 alarmsare not recorded.

CLEAR HELP

F4SHIFT

Step


31

The following map indicates teach pendant operations used to check analarm.4 ALARM

F1 [TYPE]Alarm : Active

F1 [TYPE]F3 HIST

Alarm : HISTF1 [TYPE]F3 [ACTIVE]F4 CLEARF5 HELP

DETAIL AlarmF1 [TYPE]F3 [ACTIVE]F4 CLEARF5 HELP


32

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

Safety signal Description

Operator panel emergency stop This item indicates the state of the emergency stop button on the operator panel. If theEMERGENCY 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 theEMERGENCY 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 EMERGENCYSTOP 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 isindicated as “TRUE”.

Deadman switch This item indicates whether the DEADMAN switch on the teach pendant is grasped. Ifthe teach pendant is operable, and the DEADMAN switch is grasped, the state is indi-cated 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 oper-able, the state is indicated as “TRUE”.

Hand broken This item indicates the state of the hand safety joint. If the hand interferes with a work-piece 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, thestate is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to beswitched off.

Abnormal air pressure This item indicates the state of the air pressure. The abnormal air pressure signal is con-nected to the air pressure sensor. If the air pressure is not higher than the specifiedvalue, the state is indicated as “TRUE”.

(1) Press the MENUS key to display the screen menu.(2) Select STATUS on the next page.(3) Press F1, [TYPE] to display the screen switching menu.(4) Select Safety Signal. You will see a screen similar to the following. SYSTEM Safety JOINT 30%

SIGNAL NAME STATUS 1/11

1 SOP E–Stop: FALSE 2 TP E–stop: FALSE 3 Ext E–Stop: FALSE 4 Fence Open: FALSE 5 TP Deadman: TRUE 6 TP Enable: TRUE 7 Hand Broken: FALSE 8 Over Travel: FALSE 9 Low Air Alarm: FALSE

[TYPE]

3.3SAFETY SIGNALS

Step


33

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) requireszero–degree or jig position mastering. (Zero–degree position masteringis just for quick–fix purposes. After zero–degree position mastering isused, jig position mastering should be performed later.)The mastering procedure is described below. For details, refer to anapplicable maintenance manual of mechanical unit or operator’s manualof control unit.System variable $MASTER_ENB must be set to 1 or 2. SYSTEM Variables JOINT 10% 57/136 57 $MASTER_ENB 1

(1) Press <MENUS>.(2) Select SYSTEM.(3) Press F1, TYPE.(4) Select Master/Cal you will see a screen similar to the following.

F1

Master/Cal

TYPE

SYSTEM Master/Cal JOINT 30%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE

Press ’ENTER’ or number key to select.

[TYPE] LOAD RES_PCA DONE

5 POSITION6 SYSTEM7

MENUS

9 USER0 –– NEXT ––

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

Mastering can not be performed until axis is rotated enoughto establish a pulse.

3.4MASTERING

Condition

Step


34

(6) Select “1 FIXTURE POSITION MASTER” and press the F4 key(yes). Mastering data is set.

F4

SYSTEM Master/Cal

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

ENTER

Master at master position? [NO][ TYPE ] YES NO

SYSTEM Master/Cal JOINT 30 %

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

[ TYPE ] LOAD RES_PCA DONE

(7) Select “6 CALIBRATE” and press the F4 key (yes). Calibration isperformed.Alternatively, to perform positioning, turn the power off, then turn iton again. Calibration is performed whenever the power is turned on.

F4

5 SET QUICK MASTER REF 6 CALIBRATE Calibrate? [NO] ENTER

Calibrate? [NO][ TYPE ] YES NO

SYSTEM Master/Cal JOINT 30 %

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

(8) Press F5 “DONE”, after mastering.

F5

DONE


35

(1) SRVO–001 SVAL1 Operator panel E–stop(Explanation) The EMERGENCY STOP button on the operatorpanel is pressed.(Action 1) Release the emergency stop button pressed on theoperator panel.(Action 2) Release the EMERGENCY STOP button on theoperator panel.(Action 3) Replace the emergency stop unit.Before taking (Action 4), make a backup copy of allthe programs and settings of the control unit.(Action 4) Replace the robot control board.


Emergency stop unit

Robot control board

Operatorpanel

Fig.3.5 (1) (a) SRVO–001 SVAL1 Operator panel E–stop

3.5TROUBLESHOOTING

USING THE ERROR

CODE


36

(2) SRVO–002 SVAL1 Teach pendant E–stop(Explanation) The emergency stop button on the operator’s TeachPendant was pressed.(Action 1) Release the emergency stop button on the teachpendant.(Action 2) Replace Teach Pendant.Emergency stop button

Fig.3.5 (2) SRVO–002 SVAL1 Teach pendant E–stop

(3) SRVO–003 SVAL1 Deadman switch released(Explanation) The teach pendant is enabled, but the deadman switchis not pressed.(Action 1) Press the deadman switch to run the robot.(Action 2) Replace the teach pendant.

Deadman switch

Fig.3.5 (3) SRVO–001 SVAL1 Deadman switch released


37

(4) SRVO–004 SVAL1 Fence open(Explanation) In AUTO mode, there is no short circuit betweenFENCE11 and FENCE12 and between FENCE21and FENCE22 on the terminal block TBEB5 of theemergency stop board.If the safety fence is connected between FENCE11and FENCE12 and between FENCE21 andFENCE22, the door of the safety fence is open.(Action 1) When the safety fence is connected, close the door.(Action 2) Check the cables and switches connected toFENCE11, FENCE12, FENCE21 and FENCE22.(Action 3) When this signal is not used, short–circuit betweenFENCE11 and FENCE12 and between FENCE21and FENCE22.NOTE

In the system that uses the fence signal, do not short–circuit

this signal to disable it because the operation is dangerous.

When this signal must be temporarily short–circuited, make

safety provisions separately.

(Action 4) When AUTO mode is not entered even though themode switch is set to AUTO, the mode switch may befaulty. Replace the operator panel.(Action 5) Replace the emergency stop unit.Before taking (Action 6), make a backup copy of allthe programs and settings of the control unit.(Action 6) Replace the robot control board.

Emergency stop unit

Short connection boards:two positions (terminal blocks located on the right when viewing from the front)

Fig.3.5 (4) SRVO–004 SVAL1 Fence open


38

(5) SRVO–005 SVAL1 Robot overtravel(Explanation) This alarm should not occur because no overtravelinput signal is provided. However, this alarm can becaused by an abnormal overtravel input signal acrossthe robot interconnection cable and robot controlboard.(Action 1) Check the robot interconnection cable (RMP) for thefollowing.1) The male and female connection pins are not twisted or are not loose.2) The connector is securely connected.3) The cable is free from a break and ground fault.Next, check that the connector CRM82 of the robotcontrol board is securely connected. In addition,check that the RMP cable is sound and free from abreak or visible twist.Before taking (Action 2), make a backup copy of allthe programs and settings of the control unit.(Action 2) Replace the robot control board.

Robot control board

Fig.3.5 (5) SRVO–005 SVAL1 Robot overtravel


39

(6) SRVO–006 SVAL1 Hand broken(Explanation) The safety joint, if any, is broken. If no joint isbroken, the HBK signal line of the robotinterconnection cable has a break or ground fault.(Action 1) Holding down the shift key, press the alarm releasebutton. This releases the alarm. Keeping on holdingdown the shift key, carry out jog feed to move the toolto the work area.1) Replace the safety joint.2) Examine the cable.(Action 2) Check the robot interconnection cable (RMP) for thefollowing.1) The male and female connection pins are not twisted or are not loose.2) The connector is securely connected.3) The cable is free from a break and ground fault.Next, check that the connector CRM82 of the robotcontrol board is securely connected. In addition,check that the RMP cable is sound and free from abreak or visible twist.Before taking (Action 3), make a backup copy of allthe programs and settings of the control unit.(Action 3) Replace the robot control board.

Robot control board

Fig.3.5 (6) SRVO–006 SVAL1 Hand broken


40

(7) SRVO–007 SVAL1 External E–stop(Explanation) EMGIN11 and EMGIN12/EMGIN21 and EMGIN22on the terminal block TBEB5 of the emergency stopboard are not short–circuited. If an external emergencystop switch is connected across EMGIN11 andEMGIN12/EMGIN21 and EMGIN22, the switch hasbeen pressed.(Action 1) If an external emergency stop switch is connected,releases the switch.(Action 2) Check the switch and cable connected to EMGIN11and EMGIN12 and to EMGIN21 and EMGIN22.(Action 3) When this signal is not used, make a connectionbetween EMGIN11 and EMGIN12 and a connectionbetween EMGIN21 and EMGIN22. (WARNING)(Action 4) Replace the emergency stop unit.WARNING

Do NOT short–circuit, or disable, this signal in a system inwhich the External emergency stop input signal is in use, asit is very dangerous. If it is necessary to run the robot byshort–circuiting the signal even temporarily, an additionalsafety provision must be provided.

Emergency stop unit

Short connection boards:two positions (terminal blocks located on the left when viewing from the front)

Fig.3.5 (7) SRVO–007 SVAL1 External E–stop


41

(8) SRVO–009 SVAL1 Pneumatic pressure alarm(Explanation) An abnormal air pressure was detected. The inputsignal 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.If the peripheral device are normal, check the robotconnection cable.Before taking (Action 2), make a backup copy of allthe programs and settings of the control unit.(Action 2) Replace the robot control board.

Robot control board

Fig.3.5 (8) SRVO–009 SVAL1 Pneumatic pressure alarm


42

(9) SRVO–014 WARN Fan motor abnormal(Explanation) A fan motor in the backplane unit is abnormal.(Action) Check the fan motor and its cables. Replace them ifnecessary.Fan motor

Fig.3.5 (9) SRVO–014 WARN Fan motor abnormal


43

(10)SRVO–015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j)(Explanation) The temperature in the control unit exceeds thespecified value.(Action 1) If the ambient temperature is higher than specified(45°C), cool down ambient temperature.(Action 2) If the fan motor is not running, check it and its cables.Replace them if necessary.(Action 3) If the thermostat on the robot control board isdefective, replace the robot control board.

Fan motor (on the heat exchange)

Fan motor (door face) Robot control board

Fig.3.5 (10) SRVO–015 SVAL1 SYSTEM OVER HEAT


44

(11) SRVO–021 SVAL1 SRDY off (Group : i Axis : j)(Explanation) The HRDY is on and the SRDY is off, although thereis no other cause of an alarm. (HRDY is a signal withwhich the host detects the servo system whether toturn on or off the servo amplifier magnetic contactor.SRDY is a signal with which the servo systeminforms the host whether the magnetic contactor isturned on.)If the servo amplifier magnetic contactor cannot beturned on when directed so, it is most likely that aservo amplifier alarm has occurred. If a servoamplifier alarm has been detected, the host will notissue this alarm (SRDY off). Therefore, this alarmindicates that the magnetic contactor cannot be turnedon for an unknown reason.(Action 1) Measure the voltage of the 200–VAC input to thepower supply module. If the voltage is 170 VAC orlower, adjust the input voltage.(Action 2) Check that CRR78 of the emergency stop board andCX3 and CX4 of the power supply module aresecurely connected. Check the cables of theemergency stop board and power supply module fora break.(Action 3) Check the EMERGENCY STOP line (teach pendantemergency stop, teach pendant enable/disable switch,teach pendant deadman switch, operator panelemergency stop, external emergency stop input, fenceinput) for a possibility of an instantaneousinterruption. If the software cannot judge the causeof the alarm at an instantaneous interruption of theEMERGENCY STOP line, this alarm occurs.(Action 4) Replace the emergency stop unit.(Action 5) If an alarm occurs on all axes, the power supplymodule may be faulty. Replace the power supplymodule.(Action 6) If an alarm occurs on a particular axis, the servoamplifier module may be faulty. Replace the servoamplifier module controlling the axis.(Action 7) Replace the axis control card on the robot controlboard.


45

Robot control board

Servo amplifier modulePower supply module

Emergency stop unit

Axis control card

Fig.3.5 (11) SRVO–021 SVAL1 SRDY off


46

(12)SRVO–022 SVAL1 SRDY on (Group : i Axis : j)(Explanation) When the HRDY is about to go on, the SRDY is alreadyon. (HRDY is a signal with which the host directs theservo system whether to turn on or off the servoamplifier magnetic contactor. SRDY is a signal withwhich the servo system informs the host whether themagnetic contactor is turned on.(Action 1) Replace the axis control card on the robot controlboard.(Action 2) If an alarm occurs on all axes, the power supplymodule may be faulty. Replace the power supplymodule.(Action 3) If an alarm occurs on a particular axis, the servoamplifier module may be faulty. Replace the servoamplifier module controlling the axis.

Robot control board


Axis control card

Fig.3.5 (12) SRVO–022 SVAL1 SRDY on


47

(13)SRVO–023 SVAL1 Stop error excess (Group : i Axis : j)(Explanation) When the servo is at stop, the position error isabnormally large.(Action 1) Check whether the motor brake has been released.(Action 2) Make sure that the servo amplifier CZ2L to N areconnected tightly.(Action 3) Check to see if the load is greater than the rating. Ifgreater, reduce it to within the rating. (If the load istoo greater, the torque required for acceleration /deceleration becomes higher than the capacity of themotor. As a result, the motor becomes unable tofollow the command, and an alarm is issued.)(Action 4) Check each phase voltage of the CZ1 connector of thethree–phase power (200 VAC) input to the servoamplifier. If it is 170 VAC or lower, check the linevoltage. (If the voltage input to the servo amplifierbecomes low, the torque output also becomes low. Asa result the motor may become unable to follow thecommand, hence possibly an alarm.)(Action 5) If the line voltage is 170 VAC or higher, replace thepower supply module or servo amplifier module.(Action 6) Check disconnection of robot connection cable(RMP).(Action 7) Replace the motor.


Fig.3.5 (13) SRVO–023 SVAL1 Stop error excess


48

(14)SRVO–024 SVAL1 Move error excess (Group : i Axis : j)(Explanation) When the robot is running, its position error is greaterthan a specified value ($PARAM _ GROUP.$MOVER _ OFFST or $PARAM _ GROUP.$TRKERRLIM). It is likely that the robot cannotfollow the speed specified by program.(Action 1) Check the robot for binding axis.(Action 2) Take the same actions as described for the abovealarm.(15)SRVO–025 SVAL1 Motn dt overflow (Group : i Axis : j)(Explanation) The specified value is too great.(16)SRVO–026 WARN2 Motor speed limit (Group : i Axis : j)(Explanation) A value higher than the maximum motor speed($PARAM_GROUP.$MOT_SPD_LIM) wasspecified. The actual motor speed is clamped to themaximum speed.(17)SRVO–027 WARN Robot not mastered (Group : i)(Explanation) An attempt was made to calibrate the robot, but thenecessary adjustment had not been completed.(Action) Master the robot.(18)SRVO–030 SVAL1 Brake on hold (Group : i)(Explanation) This alarm occurs when the robot pauses, if the brakeon hold function has been enabled ($SCR.$BRKHOLD _ ENB = 1). Disable the function if it isnot necessary.(Action) Disable [Servo–off during pause] on the generalsetting menu (Select Setting general).(19)SRVO–031 SVAL1 User servo alarm (Group : i)(Explanation) An user servo alarm occurred.(20)SRVO–033 WARN Robot not calibrated (Group : i)(Explanation) An attempt was made to set up a reference point forsimplified adjustment, but the robot had not beencalibrated.(Action) Calibrate the robot.1.Supply power.2.Set up a simplified adjustment reference point using [Positioning] on the positioning menu.(21)SRVO–034 WARN Ref pos not set (Group : i)(Explanation) An attempt was made to perform simplified adjustment,but the reference point had not been set up.(Action) Set up a simplified adjustment reference point on thepositioning menu.(22)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 maximumspeed.(23)SRVO–036 SVAL1 Inpos time over (Group : i Axis : j)(Explanation) The robot did not get to the effective area ($PARAM _GROUP.$ STOPTOL) even after the position checkmonitoring time ($PARAM _ GROUP. $INPOS _TIME) elapsed.(Action) Take the same actions as for SRVO–23 (large positionerror at a stop).(24)SRVO–037 SVAL1 Imstp input (Group : i)(Explanation) The *IMSTP signal for a peripheral device interfacewas input.(Action) Turn on the *IMSTP signal.


49

(25)SRVO–038 SVAL2 Pulse mismatch (Group : i Axis : j)(Explanation) The pulse count obtained when power is turned offdoes not match the pulse count obtained when poweris applied. This alarm is asserted after exchange thepulsecoder or battery for back up of the pulsecoderdata or loading back up data to the Robot controlboard.(Action) Perform Absolute Pulse Coder reset and remasterrobot (RES–PCA)1. Press MENUS.2. Select SYSTEM.3. Press F1 [TYPE].4. Select MASTER/CAL.5. Press F3, PES–PCA and YES.6. Execute mastering.7. Press RESET.The fault condition should reset. If the controlleris still faulted with additional servo–related errors,cold start the controller.It might be necessary to remaster the robot.(26)SRVO–041 SVAL2 MOFAL alarm (Group : i Axis : j)(Explanation) The servo value was too high.(Action) Cold start the controller.


50

(27)SRVO–044 SVAL1 HVAL alarm (Group : i Axis : j)(Explanation) The DC voltage (DC link voltage) of the main circuitpower supply is abnormally high.The LED indication on the power supply module is“7” (HVAL).(Action 1) Check the three–phase input voltage at the powersupply module. If it is 253 VAC or higher, check theline voltage. (If the three–phase input voltage ishigher than 253 VAC, high acceleration/decelerationcan result in this alarm.)(Action 2) Check that the load weight is within the rating. If itis higher than the rating, reduce it to within the rating.(If the machine load is higher than the rating, theaccumulation of regenerative energy might result inthe HVAL alarm even when the three–phase inputvoltage is within the rating.(Action 3) Replace the power supply module.

Power supply module

Fig.3.5 (27) SRVO–044 SVAL1 HVAL alarm


51

(28)SRVO–045 SVAL1 HCAL alarm (Group : i Axis : j)(Explanation) Abnormally high current flowed in the main circuit ofthe servo amplifier module.The LED indications on the servo amplifier modulesare “b”, “C”, and “d”.(Action 1) Disconnect the Robot connection cable (Motor power)from the connector CZ2 of the servo amplifiermodule. If error occurs, replace the servo amplifier.(Action 2) Disconnect the Robot connection cable (Motor power)from the servo amplifier module connector (CZ2),and check the insulation of each Robot connectioncable (Motor power) (U, V, or W) and the GND line.If there is a short–circuit, the motor, robotinterconnection cable, or intra–robot cable isdefective. Check them and replace them if necessary.(Action 3) Disconnect the Robot connection cable (Motor power)from the servo amplifier module connector (CZ2),and measure the resistance between the U and V, Vand W, and W and U with a ohmmeter with a very lowresistance range. If the resistances at these threeplaces are different from each other, the motor, robotinterconnection cable, or intra–robot cable isdefective. Check each item in detail. Before taking (Action 4), make a backup copy of allthe programs and settings of the control unit.(Action 4) Replace the robot control board.

Robot control board

Servo amplifier module

Fig.3.5 (28) SRVO–045 SVAL1 HCAL alarm


52

(29)SRVO–046 SVAL2 OVC alarm (Group : i Axis : j)(Explanation) This alarm is issued to prevent the motor fromthermal damage that might occur when the root meantsquare current calculated within the servo system isout of the allowable range.(Action 1) Check the operating conditions for the robot and relaxthe service conditions.(Action 2) Check each phase voltage of the three–phase inputpower (200 VAC for the power supply module. If itis 170 VAC or lower, check the line voltage.(Action 3) Replace the power supply module and servoamplifier module.(Action 4) Check the robot connection cable (RMP).(Action 5) Replace the motor.


Fig.3.5 (29) SRVO–046 SVAL2 OVC alarm


53

Relationships among the OVC, OVL, and HC alarmsOverviewThis section points out the differences among the OVC, OVL, and HCalarms and describes the purpose of each alarm.Alarm detection section

Abbreviation Designation Detection section

OVC Overcurrent alarm Servo software

OVL Overload alarm Thermal relay in the motor OHAL2Thermal relay in the servo amplifier OHAL1Thermal relay in the separate regenerative dis-charge unit DCAL

HC High current alarm Servo amplifier

Purpose of each alarm1) HC alarm (high current alarm)If high current flow in a power transistor momentarily due toabnormality or noise in the control circuit, the power transistor andrectifier diodes might be damaged, or the magnet of the motor mightbe degaussed. The HC alarm is intended to prevent such failures.2) OVC and OVL alarms (overcurrent and overload alarms)The OVC and OVL alarms are intended to prevent overheat that maylead to the burnout of the motor winding, the breakdown of the servoamplifier transistor, and the separate regenerative resistor.The OVL alarm occurs when each built–in thermal relay detects atemperature higher than the rated value. However, this method is notnecessarily perfect to prevent these failures. For example, if themotor frequently repeats to start and stop, the thermal time constantof the motor, which has a large mass, becomes higher than the timeconstant of the thermal relay, because these two components aredifferent in material, structure, and dimension. Therefore, if themotor 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 thermalrelay, thus causing the motor to burn before the thermal relay detectsan abnormally high temperature.

Temperature

Start StartStartStop Stop

Temperature at which the winding starts to burn

Thermal time constant

of the motor is high.

Thermal time constant

of the thermal relay is

low.

Time

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 currentin the motor constantly in order to estimate the temperature of themotor. The OVC alarm is issued based on this estimated temperature.This method estimates the motor temperature with substantialaccuracy, so it can prevent the failures described above.

Reference


54

To sum up, a double protection method is used; the OVC alarm is usedfor protection from a short–time overcurrent, and the OVL alarm isused for protection from long–term overload. The relationshipbetween the OVC and OVL alarms is shown in Fig 2.Current

Protection area for

the motor and

servo amplifier

Protection by the OVLLimit current

Protection by

the OVC

Rated continuous current

Time

Fig.2 Relationship between the OVC and OVL alarms

NOTE

The relationship shown in Fig. 2 is taken into considerationfor the OVC alarm. The motor might not be hot even if theOVC alarm has occurred. In this case, do not change theparameters to relax protection.

(30)SRVO–047 SVAL1 LVAL alarm (Group : i Axis : j)(Explanation) The control power voltage (+5 V, etc.) on the servoamplifier module is too low. The LED indication onthe servo amplifier module is “2” (LVAL).(Action 1) Replace the servo amplifier module.


Fig.3.5 (30) SRVO–047 SVAL1 LVAL alarm


55

(31)SRVO–049 SVAL1 OHAL1 alarm (Group : i Axis : j)(Explanation) This alarm does not occur when the power supplymodule and serve amplifier modules used with theR–J3iB Mate are under normal conditions.This alarm indicates that any of the power supplymodule and servo amplifier modules is faulty.(Action 1) If this alarm occurs in relation to all axes, replace thepower supply module.(Action 2) If this alarm occurs in relation to a specific axis,replace the servo amplifier module that controls theaxis.


Fig.3.5 (31) SRVO–049 SVAL1 OHAL1 alarm


56

(32)SRVO–050 SVAL1 CLALM alarm (Group : i Axis : j)(Explanation) The disturbance torque estimated by the servo softwareis abnormally high. (A collision has been detected.)(Action 1) Check that the robot has collided with anything. If ithas, reset the robot and jog–feed it to recover from thecollision.(Action 2) Make sure that the load setting is correct.(Action 3) Check that the load weight is within the rating. If itis higher than the rating, reduce it to within the rating.(If the robot is used out of its usable range, theestimated disturbance torque becomes abnormallyhigh, possibly resulting in this alarm being detected.)(Action 4) Check the phase voltage of the three–phase inputpower (200 VAC) to the power supply module. If itis 170 VAC or lower, check the line voltage.(Action 5) Replace the power supply module and the servoamplifier module.


Fig.3.5 (32) SRVO–050 SVAL1 CLALM alarm


57

(33)SRVO–051 SVAL2 CUER alarm (Group : i Axis : j)(Explanation) The offset of the current feedback value is abnormallyhigh.(Action) Replace the servo amplifier module.


Fig.3.5 (33) SRVO–051 SVAL2 CUER alarm


58

(34)SRVO–054 DSM Memory Error(Explanation) An access to the axis control card on the robot controlboard memory fails.(Action) Replace the axis control card.

Robot control board


Axis control card

Fig.3.5 (34) SRVO–054 DSM Memory Error


59

(35)SRVO–055 SVAL2 FSSB com error 1 (Group : i Axis : j)(Explanation) A communication error has occurred between therobot control board and servo amplifier.(Action 1) Check the communication cable (optical fiber)between the robot control board and servo amplifier.Replace it if it is faulty.(Action 2) Replace the axis control card on the robot controlboard.(Action 3) Replace the servo amplifier module.Before continuing to the next step, perform acomplete controller back–up to save all yourprograms and settings. Failure to perform this couldresult in damage to equipment or lost data.(Action 4) Replace the robot control board.

Robot control board


Axis control card

Fig.3.5 (35) SRVO–055 SVAL2 FSSB com error 1


60

(36)SRVO–056 SVAL2 FSSB com error 2 (Group : i Axis : j)(Explanation) A communication error has occurred between therobot control board and servo amplifier.(Action 1) Check the communication cable (optical fiber)between the robot control board and servo amplifier.Replace it if it is faulty.(Action 2) Replace the axis control card on the robot controlboard.(Action 3) Replace the servo amplifier module.Before continuing to the next step, perform acomplete controller back–up to save all yourprograms and settings. Failure to perform this couldresult in damage to equipment or lost data.(Action 4) Replace the robot control board.

Robot control board


Axis control card

Fig.3.5 (36) SRVO–056 SVAL2 FSSB com error 2


61

(37)SRVO–057 SVAL2 FSSB disconnect (Group : i Axis : j)(Explanation) Communication was interrupted between the robotcontrol board and servo amplifier.(Action 1) Check whether fuse FU1 in the power supply moduleunit has blown.(Action 2) Check whether fuse FU1 in the servo amplifiermodule has blown.(Action 3) Check the communication cable (optical fiber)between the robot control board and servo amplifier.Replace it if it is faulty.(Action 4) Replace the axis control card on the robot controlboard.(Action 5) Replace the power supply module and the servoamplifier module.Before continuing to the next step, perform acomplete controller back–up to save all yourprograms and settings. Failure to perform this couldresult in damage to equipment or lost data.(Action 6) Replace the robot control board.(Action 7) Check the RMP cable of robot connection cable.(+5V ground fault)

Robot control board


Axis control card

Fig.3.5 (37) SRVO–057 SVAL2 FSSB disconnect


62

(38)SRVO–058 SVAL2 FSSB init error (Group : i Axis : j)(Explanation) Communication was interrupted between the robotcontrol board and servo amplifier module.(Action 1) Check whether fuse FU1 in the power supply modulehave blown.If they have blown, see Section 3.6, “Troubleshootingfor Blown Fuse.”(Action 2) Check whether seven segment LEDs on the servoamplifier module are on.If they are on, perform “Action 4” and all actions thatfollow it. If they are not on, perform “Action 3” andall actions that follow it.(Action 3) Check whether connector CX1 on the power supplymodule is securely connected.(Action 4) Check the communication cable (optical fiber)between the robot control board and servo amplifiermodule. Replace it if it is faulty.(Action 5) Replace the axis control card on the robot controlboard.(Action 6) If the seven–segment LED on the servo amplifiermodule is glowing, replace the servo amplifiermodule. If the seven–segment LED on the servoamplifier module is not glowing, replace the powersupply module.Before continuing to the next step, perform acomplete controller back–up to save all yourprograms and settings. Failure to perform this couldresult in damage to equipment or lost data.(Action 7) Replace the robot control board.

Robot controll board


Axis control card

Fig.3.5 (38) SRVO–058 SVAL2 FSSB init error


63

(39)SRVO–059 SVAL2 Servo amp init error(Explanation) Servo amplifier initialzation is failed.(Action 1) Check all connectors on the PSM and SVM. Makesure they are installed correctly.(Action 2) Replace the power supply module and the servoamplifier module.


Fig.3.5 (39) SRVO–059 SVAL2 Servo amp init error

(40)SRVO–061 SVAL2 CKAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if the rotation speed count in thepulse coder is abnormal (abnormal count clock).(Action) Replace the pulse coder.NOTE

In this case, perform actions associated with DTERR,CRCERR, or STBERR first.

(41)SRVO–062 SVAL2 BZAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if battery for pulse coderabsolute-position backup is empty.A probable cause is a broken battery cable or nobatteries in the robot.(Action) Remove the cause of the alarm, set the systemvariable ($MCR.$SPC RESET) to TRUE, then turnthe power off and on again. Mastering is required.(42)SRVO–063 SVAL2 RCAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if the rotation speed count in thepulse coder is abnormal (abnormal counter).(Action) Replace the pulse coder.NOTE

In this case, perform actions associated with DTERR,CRCERR, or STBERR first.


64

(43)SRVO–064 SVAL2 PHAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if the phase of the pulses generatedin the pulse coder is abnormal.(Action) Replace the pulse coder.NOTE

This alarm might accompany the DTERR, CRCERR, orSTBERR alarm. In this case, however, there is no actualcondition for this alarm.

(44)SRVO–065 WARN BLAL alarm (Group : i Axis : j)(Explanation) The battery voltage for the pulse coder is lower thanthe rating.(Action) Replace the battery.(If this alarm occurs, turn on the AC power andreplace the battery as soon as possible. A delay inbattery replacement may result in the BZAL alarmbeing detected. In this case, the position data will belost. Once the position data is lost, mastering willbecome necessary.(45)SRVO–066 SVAL2 CSAL alarm (Group : i Axis : j)(Explanation) The ROM in the pulse coder is abnormal.(Action) Replace the pulse coder.NOTE

This alarm might accompany the DTERR, CRCERR, orSTBERR alarm. In this case, however, there is no actualcondition for this alarm.

(46)SRVO–067 SVAL2 OHAL2 alarm (Group : i Axis : j)(Explanation) The temperature inside the pulse coder or motor isabnormally high, and the built–in thermostat hasoperated.(Action 1) Check the operating conditions for the robot and relaxthe service conditions.(Action 2) When power is supplied to the motor after it hasbecome sufficiently cool, if the alarm still occurs,replace the motor.(47)SRVO–068 SVAL2 DTERR alarm (Group : i Axis : j)(Explanation) The serial pulse coder does not return serial data inresponse to a request signal.–See actions on SRVO–070(48)SRVO–069 SVAL2 CRCERR alarm (Group : i Axis : j)(Explanation) The serial data has disturbed during communication.–See actions on SRVO–070


65

(49)SRVO–070 SVAL2 STBERR alarm (Group : i Axis : j)(Explanation) The start and stop bits of the serial data are abnormal.(Action 1) Make sure that the JF1 to JF3 connector of servoamplifire module is connected tightly.(Action 2) Check that the shielding of the robot interconnectioncable (for the pulse coder) and the peripheral equipmentcable is connected securely to the grounding plate.(Action 3) Check that each unit is grounded securely.(Action 4) Replace the servo amplifier module.(Action 5) Replace the pulse coder.(Action 6) Replace the robot interconnection cable (RMP).


Fig.3.5 (49) SRVO–070 SVAL2 STBERR alarm

(50)SRVO–071 SVAL2 SPHAL alarm (Group : i Axis : j)(Explanation) The feedback speed is abnormally high.(Action 1) If this alarm occurs together with the PHAL alarm(No. 064), this alarm does not correspond to the majorcause of the failure.(Action 2) Replace the pulse coder.(51)SRVO–072 SVAL2 PMAL alarm (Group : i Axis : j)(Explanation) It is likely that the pulse coder is abnormal.(Action) Replace the pulse coder and remaster the robot.(52)SRVO–073 SVAL2 CMAL alarm (Group : i Axis : j)(Explanation) It is likely that the pulse coder is abnormal or the pulsecoder has malfunctioned due to noise.(Action) Master the robot and enhance the shielding.(53)SRVO–074 SVAL2 LDAL alarm (Group : i Axis : j)(Explanation) The LED in the pulse coder is broken.(Action) Replace the pulse coder, and remaster the robot.(54)SRVO–075 WARN Pulse not established (Group : i Axis : j)(Explanation) The absolute position of the pulse coder cannot beestablished.(Action) Reset the alarm, and jog the axis on which the alarmhas occurred until the same alarm will not occuragain. (Jog one motor revolution)


66

(55)SRVO–076 SVAL1 Tip Stick Detection (Group : i Axis : j)(Explanation) An excessive disturbance was assumed in servosoftware at the start of operation. (An abnormal loadwas detected. The cause may be welding.)(Action 1) Check whether the robot comes into collision withforeign matter. If a collision occurs, reset the system,then switch it to the jog feed mode to avoid thecollision.(Action 2) Check whether the load settings are valid.(Action 3) Check whether the load weight is within the ratedrange. If the weight exceeds the upper limit, decreaseit to the limit.(Use of the robot with a load exceeding the limitapplied may abnormally increase the assumeddisturbance, resulting in this alarm.)(Action 4) Check each inter–phase voltage of the three–phaseinput (200 VAC) to the power supply module. If thevoltage is 170 VAC or lower, check the input powersupply voltage.(Action 5) Replace the power supply module and the servoamplifier module.


Fig.3.5 (60) SRVO–076 SVAL1 Tip Stick Detection

(56)SRVO–081 WARN EROFL alarm (Track enc : i)(Explanation) The pulse counter for line tracking has overflowed.(57)SRVO–082 WARN DAL alarm (Track ebc : i)(Explanation) The line tracking pulse coder has not been connected.(Action 1) Check the pulse coder connection cable, and replaceit if necessary.(Action 2) Replace the pulse coder.(58)SRVO–083 WARN CKAL alarm (Track ebc : i)(Explanation) This alarm occurs if the rotation speed count in thepulse coder is abnormal (abnormal count clock).(Action) See the description about the SRVO–061 CKALalarm.


67

(59)SRVO–084 WARN BZAL alarm (Track enc : i)(Explanation) This alarm occurs if the backup battery for the absoluteposition of the pulse coder has not been connected. Seethe description about the BZAL alarm (SRVO–062).(60)SRVO–085 WARN RCAL alarm (Track ebc : i)(Explanation) This alarm occurs if the rotation speed count in thepulse coder is abnormal (abnormal counter).(Action) See the description about the SRVO–063 RCALalarm.(61)SRVO–086 WARN PHAL alarm (Track enc : i)(Explanation) This alarm occurs if the phase of pulses generated inthe pulse coder is abnormal. See the descriptionabout the PHAL alarm (SRVO–064).(62)SRVO–087 WARN BLAL alarm (Track enc : i)(Explanation) This alarm occurs if the voltage of the backup batteryfor the absolute position of the pulse coder is low. Seethe description about the BLAL alarm (SRVO–065).(63)SRVO–088 WARN CSAL alarm (Track ebc : i)(Explanation) The ROM in the pulse coder is abnormal.(Action) See the description about the SRVO–066 CSALalarm.(64)SRVO–089 WARN OHAL2 alarm (Track enc : i)(Explanation) The motor has overheated. See the description aboutthe OHAL2 alarm (SRVO–067).(65)SRVO–090 WARN DTERR alarm (Track enc : i)(Explanation) Communication between the pulse coder and linetracking interface board is abnormal. See thedescription about the DTERR alarm (SRVO–068).(66)SRVO–091 WARN CRCERR alarm (Track enc : i)(Explanation) Communication between the pulse coder and linetracking interface board is abnormal. See thedescription about the CRCERR alarm (SRVO–069).(67)SRVO–092 WARN STBERR alarm (Track enc : i)(Explanation) Communication between the pulse coder and linetracking interface board is abnormal. See thedescription about the STBERR alarm (SRVO–070).(68)SRVO–093 WARN SPMAL alarm (Track enc : i)(Explanation) This alarm occurs if the current position data from thepulse coder is higher than the previous position data.See the description about the SPHAL alarm(SRVO–071).(69)SRVO–094 WARN PMAL alarm (Track enc : i)(Explanation) It is likely that the pulse coder is abnormal. See thedescription about the PMAL alarm (SRVO–072).(70)SRVO–095 WARN CMAL alarm (Track enc : i)(Explanation) It is likely that the pulse coder is abnormal or the pulsecoder has malfunctioned due to noise. See thedescription about the CMAL alarm (SRVO–073).(71)SRVO–096 WARN LDAL alarm (Track enc : i)(Explanation) The LED in the pulse coder is broken. See thedescription about the LDAL alarm (SRVO–074).


68

(72)SRVO–097 WARN Pulse not established (enc : i)(Explanation) The absolute position of the pulse coder cannot beestablished. See the description about (SRVO–075).Pulse not established.(73)SRVO–131 SVAL1 LVAL (PSM) alarm (Group : i Axis : j)(Explanation) The control power supply voltage (for example, +5V) on the power supply module is abnormally low.The LED indication on the power supply module is“6” (LVAL).(Action 1) Replace the power supply module.

Power supply module

Fig.3.5 (73) SRVO–131 SVAL1 LVAL(PSM) alarm


69

(74)SRVO–134 SVAL1 DCLVAL (PSM) alarm (Group : i Axis : j)(Explanation) The DC voltage (DC link voltage) of the main circuitpower supply on the power supply module isabnormally low. The LED indication on the powersupply module is “4.”–If this alarm occurs during robot operation:(Action 1) Check the phase voltage of the three–phase input (200VAC) to the power supply module. If it is 170 VACor lower, check the input power supply voltage.(Action 2) Replace the power supply module.–If this alarm occurs before the magnetic contactor (MCC) is turnedon:(Action 1) Check the emergency stop board and the wiringbetween the power supply module and magneticcontactor (MCC) for an abnormal condition.(Action 2) Replace the magnetic contactor (MCC).(Action 3) Replace the emergency stop unit.(Action 4) Replace the power supply module.

Emergency stop unit


Magnetic contactor

Fig.3.5 (74) SRVO–134 SVAL1 DCLVAL (PSM) alarm


70

(75)SRVO–135 SVAL FSAL alarm (Group : i Axis : j)(Explanation) The internal cooling fan(s) of the servo amplifiermodule(s) is abnormal. The LED indication on therelevant servo amplifier module is “1.”(Action 1) Replace the fan motor of the servo amplifier module.(Action 2) Replace the servo amplifier module.

Servo amplifier module Servo amplifier module

Fan

Fig.3.5 (75) SRVO–135 SVAL FSAL alarm


71

(76)SRVO–136 SVAL1 DCLVAL alarm (Group : i Axis : j)(Explanation) The servo the DC current of servo amplifier module(DC link voltage) of the main power supply isabnormally low.The LED indication on the servo amplifier modulebecomes “5”.–This alarm occured in the robot operation.(Action 1) Check the phase voltage of the three–phase inputpower (200 VAC) to the power supply module. If itis 170 VAC or lower, check the line voltage.(Action 2) Replace the power supply module and the servoamplifier module.–If this alarm occurs before the magnetic contactor is turned on:(Action 1) Check the emergency stop board and the wiringbetween the power supply module and electromagneticcontactor (MCC) for an abnormal condition.(Action 2) Replace the magnetic contactor.(Action 3) Replace the E–stop unit.(Action 4) Replace the servo amplifier module.

Robot control board


Magnetic contactor

Fig.3.5 (76) SRVO–136 SVAL1 DCLVAL alarm


72

(77)SRVO–156 SVAL1 IPMAL alarm (Group : i Axis : j)(Explanation) Abnormally high current flowed through the maincircuit of the servo amplifier.The LED indications on the servo amplifier modulesare “8.”, “9.”, and “A.”.(Action 1) Detach the motor power lines from the connectorsCZ2 of the servo amplifier modules, then turn on thepower. If this operation causes the error to recur,replace the servo amplifier module.(Action 2) Detach the motor power lines from the connectorsCZ2 of the servo amplifier modules, then check theinsulation between GND and each of the motor powerlines U, V, and W individually. If a short–circuit isfound, the motor, robot interconnection cable, orintra–robot cable may be faulty. Examine each ofthem for any problem.(Action 3) Detach the motor power lines from the connectorsCZ2 of the servo amplifier modules, then measure theresistance between the motor power lines U and V, Vand W, and W and U, using an ohmmeter with a verylow resistance range. If the three resistances aredifferent, the motor, robot connection cable, orintra–robot cable may be faulty. Examine each ofthem for any problem.Before taking (Action 4), make a backup copy of allthe programs and settings of the control unit.(Action 4) Replace the robot control board.

Robot control board


Fig.3.5 (77) SRVO–156 SVAL1 IPMAL alarm


73

(78)SRVO–157 SVAL1 CHGAL alarm (Group : i Axis : j)(Explanation) The capacitor for the DC link voltage of the servoamplifier module was not charged within thespecified time.(Action 1) A short circuit may occur in the DC link voltage.Check the connection.(Action 2) Replace the servo amplifier module.(Action 3) Replace the power supply module.


Fig.3.5 (78) SRVO–157 SVAL1 CHGAL alarm


74

(79)SRVO–201 SVAL1 Panel E–stop or SVEMG abnormal(Explanation) The EMERGENCY STOP button on the operatorpanel was pressed, but the EMERGENCY STOP linewas not disconnected.(Action 1) Check the EMERGENCY STOP button on theoperator panel, and replace it if necessary.(Action 2) Replace the emergency stop unit.(Action 3) Replace the power supply module.NOTE

This alarm might occur if the EMERGENCY STOP buttonis pressed slowly.

Power supply module

emergency stop button

Emergency stop unit

Fig.3.5 (79) SRVO–201 SVAL1 Panel E–stop or SVEMG abnormal


75

(80)SRVO–202 SVAL1 TP E–stop or SVEMG abnormal(Explanation) The EMERGENCY STOP button on the operatorpanel was pressed, but the EMERGENCY STOP linewas not disconnected.(Action 1) Check the teach pendant connection cable.(Action 2) Replace the teach pendant.(Action 3) Replace the emergency stop unit.(Action 4) Replace the power supply module.NOTE

This alarm might occur if the EMERGENCY STOP buttonis pressed slowly.

Power supply module

Emergency stop unit

Teach pendant

teach pendant cable

emergency stop button

Fig.3.5 (80) SRVO–202 SVAL1 TP E–stop or SVEMG abnormal


76

(81)SRVO–204 SVAL1 External (SVEMG abnormal) E–stop(Explanation) Although the switch connected across EMGIN11 andEMGIN12/EMGIN21 and EMGIN22 on the terminalblock TBEB1 of the emergency stop board waspressed, the EMERGENCY STOP line was notdisconnected.(Action 1) Check whether there is a large difference in operationtime between the switch connected across EMGIN11and EMGIN12 and the switch connected acrossEMGIN21 and EMGIN22. If the switch connectedacross EMGIN11 and EMGIN12 operates with alarge delay, this alarm may be issued.(Action 2) Replace the emergency stop unit.(Action 3) Replace the power supply module.

Power supply module

Emergency stop unit

Fig.3.5 (81) SRVO–204 SVAL1 External (SVEMG abnormal) E–stop


77

(82)SRVO–205 SVAL1 Fence open (SVEMG abnormal)(Explanation) The EMERGENCY STOP line was not disconnectedeven though the switch connected between FENCE11and FENCE12 and between FENCE21 and FENCE22on the terminal block TBEB2 of the emergency stopboard was open.(Action 1) Check whether there is a large difference in operationtime between the switch connected across EMGIN11and EMGIN12 and the switch connected acrossEMGIN21 and EMGIN22. If the switch connectedacross EMGIN11 and EMGIN12 operates with alarge delay, this alarm may be issued.(Action 2) Replace the emergency stop unit.(Action 3) Replace the power supply module.

Power supply module

Emergency stop unit

Fig.3.5 (82) SRVO–205 SVAL1 Fence open (SVEMG abnormal)


78

(83)SRVO–206 SVAL1 Deadman switch (SVEMG abnormal)(Explanation) The DEADMAN switch was released when the teachpendant was operable, but the EMERGENCY STOPline was not disconnected.(Action 1) The mode switch may be faulty. Replace the operatorpanel.(Action 2) Replace the teach pendant.(Action 3) Replace the emergency stop unit.(Action 4) Replace the power supply module.

Power supply module

Emergency stop unit

Fig.3.5 (83) SRVO–206 SVAL1 Deadman switch (SVEMG abnormal)


79

(84)SRVO–207 SVAL1 TP switch abnormal or door open(Explanation) The teach pendant is operable, and the deadmanswitch has been grasped, but the EMERGENCYSTOP line is kept disconnected.(Action 1) Check the teach pendant connection cable.(Action 2) Replace the teach pendant.(Action 3) Replace the emergency stop unit.

Emergency stop unit

Teach pendant

Teach pendant cable

Fig.3.5 (84) SRVO–207 SVAL1 TP switch abnormal or door open


80

(85)SRVO–215 WARN Fuse blown (Aux axis)(Explanation) The fuse in the additional axis amplifier has blown.(Action 1) Check the cause and solve the problem, then replacethe fuse.(86)SRVO–216 SVAL1 OVC (total) (Robot : i)(Explanation) The current (total current for five axes or six axes)flowing through the motor is too large.(Action 1) Slow the motion of the robot where possible. Checkthe robot operation conditions. If the robot is usedwith a condition exceeding the duty or load weightrobot rating, reduce the load condition value to thespecification range.(Action 2) Check each inter–phase voltage of the three–phaseinput (200 VAC) to the power supply module. If thevoltage is 170 VAC or lower, check the input powersupply voltage.

Power supply module

Fig.3.5 (86) SRVO–215 WARN Fuse blown (Aux axis)


81

(87)SRVO–221 SVAL1 Lack of DSP (Group : i Axis : j)(Explanation) A controlled axis card corresponding to the setnumber of axes is not mounted.(Action 1) Check whether the set number of axes is valid. If thenumber is invalid, set the correct number.(Action 2) Replace the controlled axis card with a cardcorresponding to the set number of axes.(Example)When six axes are set, a controlled axis card for sixor eight axes is available. For how to replace thecontrolled axis card, see II MAINTENANCE,Section 7.2 in this manual.

Robot control board


Axis control card

Fig.3.5 (87) SRVO–221 SVAL1 Lack of DSP (Group : i Axis : j)


82

(88)SRVO–222 SVAL1 Lack of Amp (Amp : i)(Explanation) The FSSB has no SVM.(Action 1) Check that the optical cable is securely connected tothe servo amplifier module.(Action 2) Replace the optical cable.(Action 3) Check whether power is properly supplied to theservo amplifier module.


Fig.3.5 (88) SRVO–222 SVAL1 Lack of Amp (Amp : i)


83

(89)SRVO–233 SVAL1 TP disabled in T1, T2/Door open(Explanation) The teach pendant is disabled when the mode switchis in the T1 mode position.(Action 1) During teaching operation, set the enable switch ofthe teach pendant to Enable. Otherwise, set the modeswitch to AUTO mode.(Action 2) Replace the emergency stop unit.(Action 3) Replace the teach pendant.(Action 4) The mode switch may be faulty. Replace the operatorpanel.

Emergency stop unit

Teach pendant


FUS3

Mode switch

Fig.3.5 (89) SRVO–233 SVAL1 TP disabled in T1, T2/Door open


84

(90)SRVO–264 SVAL1 “E.STOP circuit abnormal 1”(Explanation) An error occurred in the emergency stop circuit.(Action 1) Check whether the CRR78 connectors on theE–STOP unit and the CX3 connector of the powersupply module are connected securely.(Action 2) Replace the emergency stop unit.(Action 3) Replace the power supply module.

Power supply module

Emergency stop unit

Fig.3.5 (90) SRVO–264 SVAL1 “E.STOP circuit abnormal 1”

(91)SRVO–265 SVAL1 E.STOP circuit abnormal 2(Explanation) When the servo amplifier is excited, the monitorcontact of the magnetic contactor (MCC) becomesfaulty.(Action 1) Replace the magnetic contactor (MCC).(Action 2) Replace the emergency stop unit.(Action 3) Replace the power supply module.

Magnetic contactor (MCC)

Power supply module

Emergency stop unit

Fig.3.5 (91) SRVO–265 SVAL1 E.STOP circuit abnormal 2


85

(92)SRVO–290 SVAL1 DClink HC alarm (Group : i Axis : j)(Explanation) The DC link current in the servo amplifier module(s)is abnormal. The LED indication on the relevantservo amplifier module is “8.”(Action 1) Detach the motor power lines from connector CZ2 ofthe servo amplifier module, then turn the power on.If this alarm persists, replace the servo amplifiermodule.(Action 2) Detach the motor power lines from connector CZ2 ofthe servo amplifier module, then check the insulationbetween GND and each of U, V, and W of the motorpower lines. If a short circuit is detected, the motor,robot connection cable, or internal robot cable may bedefective. Check them for an abnormal condition.(Action 3) Detach the motor power lines from connector CZ2 ofthe servo amplifier module, then use a high–precisionohmmeter to measure U–V, V–W, and W–Uresistances of the motor power lines. If the threeresistances differ, the motor, robot connection cable,or internal robot cable may be defective. Check themfor an abnormal condition.Before proceeding with (Action 4), back up allprograms and settings for the control unit.(Action 4) Replace the robot control board.

Robot control board


Fig.3.5 (92) SRVO–290 SVAL1 DClink HC alarm

(93)SRVO–291 SVAL1 “IPM over heat (Group : i Axis : j)”(Explanation) The IPM in the servo amplifier overheats.The LED indications on the servo amplifier modulesare “8.”, “9.”, and “A.”.(Action 1) Check whether the servo amplifier module fan stops.(Action 2) Reduce the override because the use condition is toohard.(Action 3) If this alarm is frequently issued, replace the amplifiermodule.


86

(94)SRVO–295 SVAL1 SVM COM alarm (Group : i Axis : j)(Explanation) Communication between the servo amplifiermodules is abnormal. The LED indications on theservo amplifier modules are “P.”(Action 1) If “SRVO – 047 LVAL alarm” and “SRVO – 131LVAL (PSM) alarm” also occur, the control powersupply voltage is low. Take measures against thesealarms.(Action 2) Check the servo amplifier modules and cables forconnectors CX2A and CX2B of the power supplymodule, as well as their connection.(Action 3) Replace the axis control card on the robot controlboard.(Action 4) Replace the servo amplifier modules.Before proceeding with (Action 5), back up allprograms and settings for the control unit.(Action 5) Replace the robot control board.

Robot control board


Axis control card

Fig.3.5 (94) SRVO–295 SVAL1 SVM COM alarm


87

(95)SRVO–296 SVAL1 DCAL alarm (Group : i Axis : j)(Explanation) The regenerative discharge energy is too high to bedissipated as heat. (To move the robot, the servoamplifier supplies energy to the robot. When goingdown, the robot moves along the vertical axis as thepotential energy reduces. If a reduction in thepotential energy is larger than the amount ofacceleration energy, the servo amplifier receivesenergy from the motor. This also occurs atdeceleration even when no gravity is applied. Theenergy that the servo amplifier receives from themotor is called regenerative energy. The servoamplifier dissipates this energy as heat. If the amountof the regenerative energy dissipated as heat issmaller than was received, the remainder is stored inthe servo amplifier, causing this alarm.) The LEDindication on the power supply module is “8”(DCAL: regenerative energy adder detection).(Action 1) This alarm may occur if the robot is subjected tofrequent acceleration/deceleration or if the verticalaxis generates a large amount of regenerative energy.In this case, relax the service conditions.(Action 2) Replace the power supply module.

Power supply module

Fig.3.5 (95) SRVO–296 SVAL1 DCAL alarm


88

(96)SRVO–297 SVAL1 DCLVAL alarm (Group : i Axis : j)(Explanation) An open–phase condition has occurred in the inputpower supply to the main circuit on the power supplymodule. The LED indications on the power supplymodule is “E.”(Action 1) Check the phase voltage of the three–phase input (200VAC) to the power supply module. If an open–phasecondition is detected, check the input power supply.(Action 2) Replace the power supply module.

Power supply module

Fig.3.5 (96) SRVO–297 SVAL1 DCLVAL alarm


89

(97)SRVO–300 SVAL1 Hand broken/HBK disabledSRVO–302 SVAL1 Set Hand broken to ENABLE(Explanation) Although HBK was disabled, the HBK signal wasinput.(Action 1) Press RESET on the teach pendant to release thealarm.(Action 2) Check whether the hand broken signal is connected tothe robot. When the hand broken signal circuit isconnected, enable hand broken. (See IICONNECTION, Section 3.8 in this manual.)

Robot control board

Fig.3.5 (97) SRVO–300 SVAL1 Hand broken/HBK disabledSRVO–302 SVAL1 Set Hand broken to ENABLE


90

(98)SRVO–320 SVAL1 E.STOP(Explanation) Although there is no cause for an emergency stop, anemergency stop state was detected on the power supply module.(Action 1) Check external emergency stops and the safety fence.(Action 2) Check the connections of the CRR78 connector onthe emergency stop emergency stop board and the CX4 connector on thepower supply module.(Action 3) Replace the emergency stop unit.(Action 4) Replace the power supply module.

Power supply module

Emergency stop unit

Fig.3.5 (98) SRVO–320 SVAL1 E.STOP


91

(99)SRVO–321 SVAL1 TP SW/Deadman abnormal(Explanation) The ENABLE/DISABLE switch or Deadman switchon the teaching pendant is abnormal.(Action 1) Replace the teaching pendant cable.(Action 2) Replace the teaching pendant.(Action 3) Replace the emergency stop unit.Before taking (Action 4), make a backup copy of allthe programs and settings of the control unit.(Action 4) Replace the robot control board.

Emergency stop unit

Teach pendant

teach pendant cable

Deadman switch (Back side)

Robot control board

ENABLE/DISABLEswitch

Fig.3.5 (98) SRVO–321 SVAL1 TP SW/Deadman abnormal


92

This section describes alarms that can occur when a fuse mounted on aboard or unit is blown and corresponding corrective actions.(1) Fuses on the robot control boardFUS1 : For generating power to the control circuitFUS2 : For protecting +24E output to peripheral device digitalinput/output, end effector, ROT, and HBK

Name Problem caused by blown fuse Action

FUS1 The control power of the robot control board is shut off.The teach pendant displays the initial screen.

1 Check the units (fans) and cables connected to the CP2 andCP3 connectors of the power supply unit to see if there is anyshort circuit.

2 Replace the DC/DC converter module.3 Replace the robot control board.

FUS2 The teach pendant screen displays alarm information such asHand broken (SERVO – 006) or Robot overtravel (SERVO –005).

1 Check that +24E used by the peripheral device is free from aground fault.

2 Examine the peripheral device connection cable.3 Check that +24E used by the end effector is free from a ground

fault.4 Examine the robot interconnection cable and intra–robot

cable.

FUS1 FUS2

3.6TROUBLESHOOTING

USING FUSES


93

(2) Fuses on the emergency stop boardFUS3 : For monitoring the emergency stop circuitFUS4 : For controlling the emergency stop circuit and teach pendantFUS5 : For the brake circuitName Problem caused by blown fuse Action

FUS3 The teach pendant screen displays SVAL1 TP dis-abled in T1, T2/Door open (SRVO–233) and so forth.

Replace the emergency stop unit.

FUS4 The power supply to the teach pendant stops, thescreen display of the teach pendant disappears, andthe system enters the emergency stop state.

1 Examine the teach pendant cable for any problem.2 Examine the teach pendant for any problem.3 Check that the external emergency stop input and servo off input are

free from a ground fault and any other fault.

FUS5 Replace the emergency stop unit.The robot motor brake cannot be released, and alarminformation such as Large error in travel (SERVO –024), Large error at rest (SERVO – 023), Positioningtime over (SERVO – 036), or CLALM alarm (SERVO– 050) is displayed.

1 Check that the robot interconnection cable (RMP) and intra–mechani-cal–unit cable are free from faults such as a ground fault and short–cir-cuit.

2 If an additional axis is used, check that the brake connection cable isfree from a ground fault, short–circuit, and any other fault.

3 If a brake power transformer is used, note that a faulty brake powertransformer can cause a too large current to flow. Replace the brakepower transformer.

4 Replace the emergency stop unit.

FUS3

FUS4

FUS5



94

(3) Blown fuse on the doorName Problem caused by blown fuse Action

FUS6 The power supply unit on the emergency stop unit doesnot work, and the power cannot be turned on.

1 Check that the fan unit or cable is not short–circuited.2 Replace the power supply unit.

FUS6


95

(4) Fuse on the power supply moduleFU1 : For protecting 200 VAC input to generate power to thecontrol circuit


FU1 ALL LEDs of the servo amplifiers go out.The teach pendant screen displays the FSSB disconnectionalarm or FSSB initialization alarm.

1 Replace the fuse (5 A) on the control board of the power sup-ply module.

2 Replace the power supply module.

FU1

Remove the face plate


96

(5) Fuse on the servo amplifier moduleFU1 : For protecting +24 V input to generate power to the controlcircuit


FU1 ALL LEDs of the servo amplifier modules go out.The teach pendant screen displays the FSSB disconnectionalarm or FSSB initialization alarm.

1 Replace the fuse (3.2 A) on the control board of the servo am-plifier module.

2 Replace the servo amplifier module.

FU1

Remove the control board


97

The printed circuit boards and servo amplifier are provided with alarmLEDs and status LEDs. The LED status and corresponding troubleshootingprocedures are described below.


Power supply module (PSM)


Robot control board


3.7TROUBLESHOOTING

BASED ON LED

INDICATIONS


98

(1) TROUBLESHOOTING USING THE LEDS ON THE robot controlboardTo troubleshoot an alarm that arises before the teach pendant is readyto display, check the status LEDs (green) on the robot control boardat power–on. After power–on, the LEDs light as described in steps 1 to 18, in theorder described. If an alarm is detected, the step in which the alarmoccurred can be determined from which LEDs are lit.Step LED Action to be taken

1: After power–on, all LEDs arelit.

[Action1] Replace the CPU card* [Action2] Replace the robot control board.

2: Software operation start–up. [Action1] Replace the CPU card* [Action2] Replace the robot control board.

3: The initialization of dram onthe CPU card is completed.

[Action1] Replace the CPU card* [Action2] Replace the robot control board.

4: The initialization of SRAMand DPRAM is completed.

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

5: The initialization of the com-munication IC is completed.

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

6: The loading of the basic soft-ware is completed.

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

7: Basic software start–up. * [Action1] Replace the robot control board.* [Action2] Replace the FROM/SRAM module.

8: Start–up of communicationwith the teach pendant.

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

9: The loading of optional soft-ware is completed.

* [Action1] Replace the robot control board.

10:DI/DO initialization * [Action1] Replace the FROM/SRAM module.* [Action2] Replace the robot control board.

11:The preparation of the SRAMmodule is completed.

[Action1] Replace the axis control card.* [Action2] Replace the robot control board.

[Action3] Replace the servo amplifier.

* If the robot control board or FROM/SRAM module is replaced, the contents of memory (parameters, specifieddata, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.


99

Step Action to be takenLED

12:Axis control card initialization [Action1] Replace the axis control card.* [Action2] Replace the robot control board.


13:Calibration is completed. [Action1] Replace the axis control card.* [Action2] Replace the robot control board.


14:Start–up of power applicationfor the servo system

* [Action1] Replace the robot control board.

15:Program execution * [Action1] Replace the robot control board.

16:DI/DO output start–up. * [Action1] Replace the robot control board.

17: Initialization is terminated. Initialization has ended normally.

18:Normal status Status LED 2 blink when the system is operating normally.


Axis control card FROM/SRAM module(under the CPU card)

CPU card


100

(2) TROUBLESHOOTING BY 7–SEGMENT LED INDICATOR7–segment LED

indicatorDescription

[Description]A parity alarm condition has occurred in RAM on the CPU card installed on the robotcontrol board.

[Action1] Replace the CPU card.[Action2] Replace the robot control board.

[Description]A parity alarm condition has occurred in RAM on the FROM/SRAM module installedon the robot control board.

[Action1] Replace the FROM/SRAM module.[Action2] Replace the robot control board.

“2”, “3”, and “4” are not displayed.

[Description]A servo alarm condition has occurred on the robot control board.[Action1] Replace the axis control card.[Action2] Replace the robot control board.

[Description]The SYSEMG alarm has occurred.[Action1] Replace the axis control card.[Action2] Replace the CPU card.[Action3] Replace the robot control board.

[Description]The SYSFAIL alarm has occurred.[Action1] Replace the axis control card.[Action2] Replace the CPU card.[Action3] Replace the robot control board.



101

(3) Troubleshooting using a fuse alarm LEDLED indication Failure description and required measure

[Description]A fuse (FUS1 or FUS2) is blown.

Cause of the blowing of FUS1 and corrective actions

[Action1] Check whether the device which is connected to the RS–232–C/RS–422 portand requires the power supply of +24 V is sound.

[Action2] Faulty DC/DC converter moduleReplace the DC/DC converter module.

[Action3] Short–circuited surge absorber PVS1The system can be operated temporarily without PVS1. However, obtain andmount a new one at the earliest possible time.

[Action4] Faulty robot control boardReplace the robot control board.


[Action1] Check that +24E used by the peripheral device is free from a ground fault.[Action2] Examine the peripheral device connection cable.[Action3] Check that +24E used by the end effector is free from a ground fault.[Action4] Examine the robot interconnection cable and intra–robot cable.


102

Troubleshooting using an LED on the emergency stop board

LED indication Problem and corrective action

[Description]The fuse (FUS3, FUS4, or FUS5) is blown.

Cause of the blowing of FUS3 and corrective action

[Action] The emergency stop board is faulty. Replace the emergency stop unit.


[Action1] Check that the teach pendant cable is sound.[Action2] Check that the teach pendant is sound.[Action3] Check that the external emergency stop input and servo off input are free from

a ground fault and any other fault.[Action4] The emergency stop board is faulty. Replace the emergency stop unit.


[Action1] Check that the robot interconnection cable (RMP) and intra–mechanical–unitcable are free from a ground fault, short–circuit, and any other fault.

[Action2] If an additional axis is used, check that the brake connection cable is free froma ground fault, short–circuit, and any other fault.

[Action3] If a brake power transformer is used, note that a faulty brake power transformercan cause a too large current to flow. Replace the brake power transformer.

[Action4] The emergency stop board is faulty. Replace the emergency stop unit.

Fuse FUS4

Fuse FUS3

Fuse FUS5


Emergency stop unit

FALM LED


103

Troubleshooting using the LED of the power supply module

The power supply module has a seven–segment LED. When takinga corrective action corresponding to the LED indication, see the alarmdisplayed on the teach pendant screen.LED indication Problem and corrective action

[Description]The voltage of the DC link of the main circuit is low.[Action1] The input power was instantaneously interrupted.

Check the power supply.[Action2] The input supply voltage is low. Check the power re-

quirements.[Action3] The power to the main circuit was shut off in the emer-

gency stop release state. Check the emergency stop cir-cuit (emergency stop board, magnetic contactor, exter-nal emergency stop input, etc.).

[Description]The main circuit could not be charged within a predeter-mined period.

[Action1] The DC link is short–circuited. Check the connection.[Action2] The charge current controlling resistor is faulty. Replace

the power supply module.

[Description]The control power voltage is low.[Action] The input power is low. Check the power supply.

[Description]The voltage of the DC link of the main circuit is too high.[Action1] The regenerative power is too large. Change the operat-

ing conditions.[Action2] The regenerative resistor is faulty. Replace the power

supply module.

[Description]The regeneration amount is too large.[Action] Change the operating conditions. For instance, lower

the frequency of acceleration/deceleration.

[Description]The regenerative resistor was heated.[Action] Change the operating conditions. For instance, lower

the frequency of acceleration/deceleration.

[Description]The input power is in the open–phase state.[Action] Check the power supply.

dot part of seven segment LED


104

Troubleshooting using the LED of the servo amplifier module

The servo amplifier module has a seven–segment LED. When takinga corrective action corresponding to the LED indication, see the alarmdisplayed on the teach pendant screen.LED indication Problem and corrective action

[Description]The internal cooling fan stopped.[Action1] Check that the fan is not blocked with a foreign sub-

stance.[Action2] Check that the fan connector is correctly connected.[Action3] The fan is faulty. Replace the fan.[Action4] Replace the servo amplifier module.

[Description]The control supply voltage is low.[Action1] Check the three–phase input voltage. (The voltage must

be the rated input voltage multiplied by 0.85 at least.)[Action2] Measure the voltage of 24–V power supplied from the

power supply module. (Normal: 22.8 V or higher)[Action3] Check the CXA2A/B connector and the cable.[Action4] Replace the servo amplifier module.

[Description]The voltage of the DC link of the main circuit is low.[Action1] Check that the DC link connection cable (bar) is securely

screwed.[Action2] If this alarm occurs in multiple servo amplifier modules,

take the action for alarm code 4 of the power supply mod-ule.

[Action3] Replace the servo amplifier module.

[Description]The communication among servo amplifiers cannot benormally performed.

[Action1] Check the CXA2A/B connector and the cable.[Action2] Replace the control board of the servo amplifier module.[Action3] Replace the servo amplifier module.



105


[Description1] The IPM alarm was detected in the servo amplifier mod-ule.

[Action1] Detach the motor power lines from the connectors CZ2of the servo amplifier modules, and turn the power on.

a) If this alarm does not occur, go to Action 2.

b) If this alarm occurs, replace the servo amplifiermodule.

[Action2] Detach the motor power lines from the connectors CZ2of the servo amplifier modules, and check the insulationbetween PE and each of the motor power lines U, V, andW.

a) If the insulation is deteriorated, go to Action 3.

b) If the insulation is normal, replace the servo amplifi-er module.

[Action3] Separate the motor and power line, then check whetherthe motor or power line has deteriorated insulation.

a) If the motor insulation is deteriorated, replace themotor.

b) If the power line insulation is deteriorated, examinethe robot interconnection cable or intra–robot cable.

“8.”, “9.”, and “A.” represent that an alarm occurs on the L–axis, M–axis, and N–axis respectively.

[Description2] The IPM alarm (overheat) was detected in the servoamplifier module.

[Action1] Check that the internal cooling fan does not stop.[Action2] Check that the motor is operated at its continuous rating

or lower.[Action3] Check that the cooling capability of the cabinet is not low-

ered. (Check the fan unit and heat exchanger.)[Action4] Check that the ambient temperature is not high.[Action5] Replace the servo amplifier module.



106


[Description]An abnormal current is flowing to the servo motor.[Action1] Check that the servo parameters are set to default val-

ues. If this alarm occurs only at a sudden accelerationor deceleration, the motor operating conditions may betoo harsh. Increase the acceleration/deceleration timeconstant and observe the operation.

[Action2] Detach the motor power lines from the connectors CZ2of the servo amplifier modules, then turn on the power.

a) If this alarm does not occur, go to Action 2.

b) If this alarm occurs, replace the servo amplifiermodule.

[Action3] Detach the motor power lines from the connectors CZ2of the servo amplifier modules, then check the insulationbetween PE and each of the power lines U, V, and W.

a) If the insulation is deteriorated, go to Action 3.

b) If the insulation is normal, replace the servo amplifi-er.

[Action4] Separate the motor and power line, then check whetherthe motor or power line has deteriorated insulation.

a) If the motor insulation is deteriorated, replace themotor.

b) If the power line insulation is deteriorated, examinethe robot interconnection cable and intra–robotcable.

“b”, “C”, and “d” represent that an alarm occurs on the L–axis, M–axis,and N–axis respectively.


107

(Check 1) On the status screen, check the position deviation in thestopped state. To display the position deviation, press thescreen selection key, and select STATUS from the menu.Press F1, [TYPE], select AXIS from the menu, then pressthe F4, PULSE.(Corrective action)Correct the parameters related to return to the referenceposition (positioning).(Check 2) Check whether the motor axis can be positioned normally.(Corrective action)If the motor axis can be positioned normally, check themechanical 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 robot control board.

3.8POSITION DEVIATION

FOUND IN RETURN

TO THE REFERENCE

POSITION

(POSITIONING)


108

(Check 1) Check the settings of parameters such as the position loopgain 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.

3.9VIBRATION

OBSERVED DURING

MOVEMENT


109

The following explains checking and corrective action required if therobot cannot be operated manually after the controller is turned on:(1) Check and corrective action to be made if manual operation isimpossible(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 axisselection key and case shift key at the same time.Set the override for manual feed to a position other than theFINE and VFINE positions.(Check 3) Check whether the ENBL signal of the peripheral devicecontrol interface is set to 1.(Corrective action)Place the peripheral device control interface in the ENBLstatus.(Check 4) Check whether the HOLD signal of the peripheral devicecontrol interface or the HOLD switch on the operator’s panelis on (hold status). (Check whether the hold lamp on theteach pendant is on.)(Corrective action)Turn off the HOLD signal of the peripheral device controlinterface or the HOLD switch on the operator’s panel.(Check 5) Check whether the previous manual operation has beencompleted.(Corrective action)If the robot cannot be placed in the effective area because ofthe offset of the speed command voltage preventing theprevious operation from being completed, check the positiondeviation on the status screen, and change the setting.(Check 6) Check whether the controller is in the alarm status.(Corrective action)Release the alarm.(2) Check and corrective action to be taken if the program cannot beexecuted(Check 1) Check whether the ENBL signal for the peripheral-devicecontrol 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-devicecontrol interface is on. (Check whether the HOLD lamp onthe teach pendant is on.)(Corrective action)If the HOLD signal is on, turn it off. If the HOLD switchis on, turn it off.

3.10MANUAL

OPERATION

IMPOSSIBLE


110

(Check 3) Check whether the previous manual operation has beencompleted.(Corrective action)If the robot cannot be placed in the effective area because ofthe offset of the speed command voltage, which prevents theprevious operation from being completed, check the positiondeviation on the status screen, then change the setting.(Check 4) Check whether the controller is in the alarm status.(Corrective action)Release the alarm.

B–81535EN/02 4. PRINTED CIRCUIT BOARDSMAINTENANCE

111

4PRINTED CIRCUIT BOARDS

The printed circuit boards are factory-set for operation. Usually, you donot need to set or adjust them. This chapter describes the standard settingsand 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 circuitboard and one or more cards or modules installed horizontally to themain–unit printed–circuit board.These boards have interface connectors, LED indicators, and a plasticpanel at the front. At the rear, there is a backplane connector.

4. PRINTED CIRCUIT BOARDS B–81535EN/02MAINTENANCE

112

CPU card

Total version

Axis control card

FROM/SRAM moduleunder the CPU card DC/DC converter module

Fig.4.1 Robot control board

Name Board Specification Note

Robot control boardA16B–3200–0450

I/O Link master/slave switche-able, SDI/SDO = 28/24

DC/DC convert module A20B–8100–0721

CPU card A20B–3300–0106 SDRAM 8M (Standard)

A20B–3300–0107 SDRAM 16M

Axis control card A20B–3300–0241 6–axis

FROM/SRAM moduleA20B–3900–0181

FROM 16M, SRAM 0.5M :Standard

A20B–3900–0160 FROM 16M, SRAM 1MB

A20B–3900–0161 FROM 16M, SRAM 2MB

A20B–3900–0162 FROM 16M, SRAM 3MB

4.1ROBOT CONTROL

BOARD

(A16B–3200–0450)


113

(1) LEDsSeven segment LED Description

A parity alarm occurred in a RAM of the main CPUcard on the Robot control board.

A parity alarm occurred in a RAM of the FROM/SRAM module on the Robot control board.

“2”, “3”, and “4” are not displayed.

A servo alarm occurred on the Robot control board.

SYSEMG occurred.

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


114

Status LED Description

STATUSLED

Indicates the system operating status.

Status LED Description

FUSEALARMLED

A fuse (FUS1 or FUS2) was blown.


115

(2) Correspondence between driver ICs and DODriver IC specification: A76L–0151–0062Driver IC name DO signal name

H9 SDO101, SDO102, SDO103, SDO104

G9 SDO105, SDO106, SDO107, SDO108

K9 SDO109, SDO110, SDO111, SDO112

J9 SDO113, SDO114, SDO115, SDO116

J13 SDO119, SDO120, SDO81, Brake control (internal circuit)

H13 SDO82, SDO83, SDO84, Reserved

J6 RDO1, RDO2, RDO3, RDO4

J4 RDO5, RDO6, SDO117, SDO118

(3) Communication ICIf the teach pendant displays nothing because of a damaged teachpendant connection cable or another reason, the followingcommunication driver or receiver may be damaged.IC name Name and usage Drawing number

G17 75172, driver A76L–0151–0098

G16 75173, receiver A76L–0151–0099


116

Total version

Fig.4.2 Emergency stop board

4.2EMERGENCY STOP

BOARD

(A20B–1008–0010,

–0011)


117

Total version

4.3BACKPLANE BOARD

(A20B–2003–0330)


118

Total edition

Test pins

Fig.4.4 Process I/O Board HA

(1) Test pinsName Use

P24VP5V

GND1GND2GND3

+24V+5VGNDGNDGND

For measuring the DC supply voltage

P24VFP5VFGNDF

+24V+5VGND

Power for the digital/analog converter

AO1AO2

Channel 1Channel 2

For measuring the voltage of the analog output sig-nal (digital/analog)

(2) SettingsName

Standardsetting

Description

ICOM1 UDI1 to UDI20(Connector CRM2A)

ICOM2 UDI21 to UDI40(Connector CRM2B)

Side A

The common voltage is adjusted to:

Side A : +24 V common

ICOM3 WDI01 to WDI08(Connector CRW7)

Side B : 0 V common

4.4PROCESS I/O

BOARD HE

(A16B–2203–0764),

HF (A16B–2203–0765)


119

(3) AdjustmentVR1/VR2: Adjusts the gain and the offset of channel 1.Execute a robot program and set AOUT[1] to 3413 on the teachpendant. Connect a digital voltmeter to test pin AOUT1 androtate VR1 or VR2 until the meter reads 15.0 V.Connect the negative (–) lead of the digital voltmeter to test pinGNDF. (GNDF test pin is different from the 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 teachpendant. Connect the digital voltmeter to test pin AOUT2 androtate VR3 or VR4 until the meter reads 15.0 V.Connect the negative (–) lead of the digital voltmeter to test pinGNDF. (The 0VF test pin is different from the common GNDtest pin.)(4) LEDs

Color Description

RedA communication alarm occurred betweenthe main CPU and process input/output.

RedA fuse (FUSE 1) in the process input/outputbelow.

(5) Correspondence between driver chips and DO signalsOrdering code for the driver chips: A76L-0151-0062Driver chip DO signal

DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED

DV2 HELD, FAULT, 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





5. SERVO AMPLIFIERS B–81535EN/02MAINTENANCE

120

5SERVO AMPLIFIERS

The servo amplifiers are factory-set for operation. Usually, you do notneed to set or adjust them.This chapter describes the standard settings and adjustment required if adefective servo amplifier is replaced. It also describes the use of test pinsand meanings of the LED indications.Table 5 Servo amplifier specifications

Robot Power supply module Servo amplifier module1 Servo amplifier module2

A06B–6115–H001(αPSMR–1i) A06B–6114–H205

(αSVM–20/20i) A06B–6114–H302(αSVM–10/10/10i)

LR Mate 100iBL M L M N

J1 J2 J3 J4 J5

LR Mate 200iB A06B–6115–H001(αPSMR–1i) A06B–6114–H302

(αSVM–10/10/10i) A06B–6114–H302(αSVM–10/10/10i)LR Mate 200iB

ARC Mate 50iB L M N L M NARC Mate 50iBJ1 J2 J3 J4 J5 J6

B–81535EN/02 5. SERVO AMPLIFIERSMAINTENANCE

121

380 360

60 172

Fig.5.1.1 Outline drawing of power supply module PSM (A06B–6115–H001)

5.1OUTLINE DRAWINGS

5.1.1Power Supply Module

PSM (A06B–6115–H001)


122

380 360

60 172

A06B–6114–H205 A06B–6114–H302

Fig.5.1.2 Outline drawing of servo amplifier modules (A06B–6114–H205, A06B–6114–H302)

5.1.2Servo Amplifier Module

(A06B–6114–H205,A06B–6114–H302)

B–81535EN/02 5. SERVO AMPLIFIERSMAINTENANCE

123

The power supply module has a seven–segment LED. When taking acorrective action corresponding to the LED indication, see the alarmdisplayed on the teach pendant screen.LED indication Description

The magnetic contactor controlled by the power supply module is inthe off state and is not ready for driving the motor.

The magnetic contactor controlled by the power supply module is inthe on state and is ready for driving the motor.

The voltage of the DC link of the main circuit is low.

The main circuit cannot be charged within a predetermined period.

The control power voltage is low.

The voltage of the DC link of the main circuit is too high.

The regeneration amount is too large.

The regenerative resistor was heated.

The input power is in the open–phase state.

5.2LED OF SERVO

AMPLIFIER

5.2.1LED of Power Supply

Module



124

The servo amplifier module has a seven–segment LED. When taking acorrective action corresponding to the LED indication, see the alarmdisplayed on the teach pendant screen.LED indication Description

The main circuit in the servo amplifier module is in the off state and isnot ready for driving the motor.

The main circuit in the servo amplifier module is in the on state and isready for driving the motor.

The internal cooling fan stopped.

The control power voltage is low.

The voltage of the DC link of the main circuit is low.

The communication among servo amplifier modules cannot be normal-ly performed.

a) The IPM alarm was detected in the servo amplifier module.

b) The IPM alarm (overheat) was detected in the servo amplifier mod-ule.


An abnormal current is flowing to the servo motor.

“b”, “C”, and “d” represent that an alarm occurs on the L–axis, M–axis,and N–axis respectively.

5.2.2LED of Servo Amplifier

Module


B–81535EN/02 MAINTENANCE 6. SETTING THE POWER SUPPLY

125

6SETTING THE POWER SUPPLY

The power supply is factory-set for operation. Usually, you do not needto set or adjust it.

B–81535EN/02MAINTENANCE6. SETTING THE POWER SUPPLY

126

+24E

+24V

–15V

+15V

+5V

+3.3

V

Backplane

AC input

200 – 220 VAC3φ

Process I/O

CRM2CRM4

+24F+24E FUSE1

board

+24V

JD17

+24E

+24E

+24E

CRM81

CRM79

CRM82

FUS2

FUS1 CP5

CP8B

BATTERYDC/DC convertermodule+5V, +3.3V+15V, –15V

FAN

Powersupplyunit

AC/DC

+24V

CN1

FUS3 FUS4 FUS5

FU1CX1

CZ1

Power supply module

Servo amplifier

Motor

End Effector

Motor powersupply

Motor brake

Pulsecoder

Robot

Peripheral device (option)

Handy file etc.

Peripheral device

Teach pendant

+24T

CP5B CRS1

Monitor circuit

Brake

circuit

Emergency stopunit

Circuit protector

200VAC

FUS6

3φ

2φ 200VAC 2φ

200VAC

Magneticcontactor(MCC)

Main circuitDC link

AC/DC

+24V

DC/DC

+5V

Inverter

circuit

CXA2A L+, L–

CXA2B

JF1–3

L+, L–

CZ2 L–N

Emergen-cy stopcircuit

Servo amplifiermodule

Emergency stop print board

Robot controlboard

+24V

+24E


TBEB3

CP5A CRR77

regenerativeresistor

Fig.6.1 Block diagram of the power supply

6.1BLOCK DIAGRAMS

OF THE POWER

SUPPLY

B–81535EN/02 MAINTENANCE 6. SETTING THE POWER SUPPLY

127

The power supply unit need not be set or adjusted.Table 6.2 Rating of the Power supply unit

Output Rated voltage Tolerance

+24V +24V +23V to +25V

The power supply module need not be set or adjusted.Table 6.3 Rating of the Power supply module

Output Rated voltage Tolerance

+5V +5.1V ±3%

+3.3V +3.3V ±3%

+15V +15V ±10%

–15V –15V ±10%

6.2CHECKING THE

POWER SUPPLY

UNIT

6.3CHECKING THE

POWER SUPPLY

MODULE

7. REPLACING A UNIT B–81535EN/02MAINTENANCE

128

7REPLACING 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 unitmain power. Also keep all machines in the area of the controlunit switched. Otherwise, you could injure personnel ordamage equipment.

B–81535EN/02 7. REPLACING A UNITMAINTENANCE

129

CAUTIONSWhen you replace printed–circuit boards, observe thefollowing 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 ormake them touch other components.

3 Make sure that the replacement printed–circuit board hasbeen set up appropriately. (Setting plug etc.)

4 If the backplane board, power supply unit, or Robot controlboard (including cards and modules) is replaced, it is likelythat robot parameters and taught data are lost. Before youstart to replace these components, save a backup copy ofthe 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 cableis detached for replacement, reconnect it exactly as before.

7.1REPLACING THE

PRINTED–CIRCUIT

BOARDS


130

When replacing the backplane board, do so together with the plastic rack.(1) Detach the cables from the robot control board and boards on thebackplane board.CAUTION

When you remove the main robot control Board, be surethat the battery is good (3.1–3.3VDC) and it is installedcorrectly. USE STATIC PROTECTION.

(2) Remove the robot control board and boards from the rack. (SeeSection 7.1.2.)(3) Detach the grounding cable from the backplane unit.(4) Loosen the retaining screws in the upper section of the rack. Removethe 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 boardis replaced. Be sure to back up all program and setup dataon a floppy disk before proceeding.

M5 nut (2 places)

Backplane board

Fig.7.1.1 Replacing the Backplane Board

7.1.1Replacing the

Backplane Board (Unit)


131

The backplane unit incorporates the power unit, Robot control board, andoption boards. There are two types of option boards: Full–size board andmini–size board. A full–size board occupies one slot. A mini–size boarduses part of a full–size board.CAUTION

Before starting replacement, turn off the control unit mainpower. The robot control board is equipped withbattery–backed memory devices for holding robotparameters and taught data, for example. When the Robotcontrol board is replaced, the data in the memory devicesis lost.

(1) Detach the cable from the printed–circuit board, whichever is to bereplaced.(2) Pinch the barbed handles on the upper and lower sections of the boardto unlatch it, then pull it toward you.(3) Place the replacement board on the rail in the appropriate slot of therack, then push it in gently by the handles until it is latched.(4) There are two rails in the robot control board SLOT (slot 1). Wheninserting the robot control board, align it to the right–side rail.

Slot 1

Slot 2

Slot 1

Slot 10

Slot 9Rail

(Left)

Rail

(Right)

Barbedhandles

Barbedhandles

Option slot

zoom

Fig.7.1.2 Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit

7.1.2Replacing the Robot

Control Board andPrinted–Circuit Boardson the Backplane Unit


132

The board is at the emergency stop unit.(1) Detach all cables from the emergency stop unit consists of theemergency stop board and the power supply unit. The terminal blocks(TBEB1 and TBEB2) are of a connector type. Pull out the upperterminal block sections.(2) Remove four retaining nuts from the emergency stop unit (1, 2), andreplace the emergency stop unit.(3) Remove six retaining screws from the emergency stop board (3), andreplace the emergency stop board.

2 Remove the back nuts (2–M5)

1 Remove the front nuts

(2–M5)

3 Remove the

screws (6–M3)

Fig.7.1.3 Emergency stop board replacement

7.1.3Replacing the

Emergency Stop Board


133

CAUTION

Before you start to replace a card or module, make a backupcopy of robot parameters and taught data. If the FROM/SRAMmodule is replaced, memory contents are lost.

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

Card Card

Card

Card

Spacer

Spacer

Connector

Connector

Card

Fig.7.2 (a) Demounting a card

7.2REPLACING CARDS

AND MODULES ON

THE ROBOT

CONTROL BOARD


134

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

Card

CardCard

Card

Spacer

Spacer

Connector

Connector

CardCard

Fig.7.2 (b) Mounting a card


135

Demounting a moduleCAUTION

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

(a)

(b)

(c)

Fig.7.2 (c) Demounting/Mounting a module


136

Removing the DC/DC converter module(1) Unscrew the screws (3–M3).(2) Pull out the module.Mounting the module(1) Insert the module to the connector.(2) Screw the screws (3–M3).

DC/DC converter module

screws(3–M3)

Fig.7.2 (d) Mounting and removing the DC/DC converter module

Figure 7.2 (e) shows the locations of the cards and modules.

CPU card

Total version

Axis control card

FROM/SRAM moduleunder the CPU card DC/DC converter module

Fig.7.2 (e) Locations of Cards and Modules


137

WARNING

Before you start replacement procedure, turn off the mainpower to the control unit.

(1) Detach the cable from the transformer.(2) Remove the two nuts (M5) securing the transformer, then replace thetransformer.(3) Re–connect the cable.

Remore the nuts (2–M5)

Fig.7.3.1 Replacing the brake power transformer

7.3REPLACING THE

TRANSFORMER

7.3.1Replacing the Brake

Power Transformer


138

WARNINGBefore you start replacement, turn off the control unit mainpower.

(1) Detach the cables from the emergency stop unit.(2) Remove retaining screws (4–M5) from the emergency stop unit, andreplace the emergency stop unit.(3) Reconnect the cables.

2 Remove the back nuts (2–M5) screws

1 Remove the front nuts (2–M5) screws

Nut (4–M5)

Fig.7.4 Replacing the Emergency Stop Unit

7.4REPLACING THE

EMERGENCY STOP

UNIT


139

WARNING

Before starting the replacement, turn off the control unitmain power.

(1) Detach the cable from the magnetic contactor (MCC).(2) Holding down the magnetic contactor (MCC) a little, remove theMCC from the DIN rail.(3) Mount a new magnetic contactor (MCC) on the DIN rail.(4) Re–connect the cable.

Magnetic contactor (MCC)

Fig.7.5 Replacing the magnetic contactor

7.5REPLACING THE

MAGNETIC

CONTACTOR


140

WARNINGBefore you start replacement, turn off the control unit mainpower.

The following is the procedure for replacing the power supply module andservo amplifier module.(1) Detach the cable from the servo amplifier. Remove the jumperconnecting the DC link (L+ and L–).(2) Remove the two nuts from the top of the servo amplifier.(3) Mount a new servo amplifier, reversing the removal step of (2).(4) Re–connect the cable and re–mount the jumper connecting the DClink (L+ and L–).

Nut (2–M5)

Power supplymodule

servo amplifiermodule

Fig.7.6 Replacing the servo Amplifier

7.6REPLACING SERVO

AMPLIFIERS


141

The specifications of the teach pendant vary with its use. When youreplace the teach pendant, check its specifications carefully.(1) Be sure that the power of a robot controller is off.(2) Detach the cable from the teach pendant.(3) Replace the teach pendant.

Detach or attach the cable by rotatingthe connector retaining ring.

Fig.7.7 Replacing the Teach Pendant

7.7REPLACING THE

TEACH PENDANT


142

The control section fan motor can be replaced without using a tool. Thefan 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 pullthe fan unit until it is unlatched.(3) Lift the fan unit slightly, and dismount it from the rack.(4) Place a replacement fan on the upper section of the rack, and slide itgently until it is latched.

Fan motor connector

Fan motor

Pull the fan motor unittoward you to unlatch it.

Fig.7.8 Replacing the Control Section Fan Motor

7.8REPLACING THE

CONTROL SECTION

FAN MOTOR


143

The fan motor of the servo amplifier control unit can be replaced withoutusing tools. The fan unit is mounted at the top of the servo amplifier.(1) Check that the robot controller is turned off.(2) Holding the two lugs, pull up the fan unit in the direction of the arrow.(3) Place a new fan unit at the top of the servo amplifier, and slightly pressit in.

Holding the two lugs, pull up thefan unit in the direction of the arrow(rightward in the figure).

When mounting the fan motor, notethe orientation of the fan motor andconnector.

Lug

WhiteBlackRed

Note the orientationof the connector key.

Fan unit (for width of 60 mm)

Fig.7.9 Replacing the fan motor of the servo amplifier control unit

7.9REPLACING THE

FAN MOTOR OF THE

SERVO AMPLIFIER

CONTROL UNIT


144

WARNING

Before starting the replacement, turn off the control unitmain power. Never touch the fan motor while it is rotating.

Door fan unit(1) Unscrew the four fastening screws (M4).(2) Detach the cable from the fan unit.(3) Mount a spare fan unit, reversing the removal procedure.Heat exchanger(1) Detach the cable from the heat exchanger.(2) Remove the six fastening nuts (M4), and pull the heat exchangertoward you.(3) Detach the wiring from the door fan unit.(4) Mount a spare heat exchanger, reversing the removal procedure.

Screws (4–M4)Nut (4–M5)

Door fan unit

Heat exchange

Fig.7.10 Replacing the door fan unit and heat exchanger

7.10REPLACING THE

DOOR FAN UNIT AND

HEAT EXCHANGER


145

(1) Detach the cable from the circuit protector on the operator panel andthe grounding line from the door.(2) Detach the cable (JD17) from the robot control board and the cable(CRT11) from the emergency stop board.(3) Unscrew the four screws (M3) fastening the operator panel, andremove the operator panel.(4) Mount a new operator panel, reversing the removal steps of (1) to (3).

Screw (4–M3)

Fig.7.11 Replacing the operator panel

NOTEThe operator panel comprises the panel itself and thecables connected to the robot control board and emergencystop board.

7.11REPLACING THE

OPERATOR PANEL


146

The power supply unit is mounted on the emergency stop unit.(1) Detach all the cables from the emergency stop unit (emergency stopboard and power supply unit).(2) Pull out the connector–type terminal block (TBEB1, TBEB2) at thetop.(3) Remove the four nuts (1 and 2) fastening the emergency stop unit, andremove the emergency stop unit.(4) Unscrew the four screws fastening the power supply unit, and replacethe power supply unit.

1 Remove the front nuts

(2–M5)

3 Remove the screws (4–M3)

2 Remove the back nuts (2–M5)

Fig.7.12 Replacing the power supply unit

7.12REPLACING THE

POWER SUPPLY

UNIT


147

If a fuse of the control unit is blown, find out the cause, take an appropriateaction, then replace the fuse.

The robot control board has the following fuses.FUS1: For detecting a problem in the circuit on the robot control board:A60L–0001–0046#7.5If this fuse is blown, the DC/DC converter module or a deviceconnected to the RS–232–C/RS–422 port may be faulty. If thedevice connected to the RS–232–C/RS–422 port is not faulty,replace the DC/DC converter module.FUS2: For protecting the 24V output to the peripheral device:A60L–0001–0046#7.5If this fuse is blown, the wiring to the peripheral device and a cablemay be incorrect or damaged.

FUS1 FUS2

Fig.7.13.1 Replacing a fuse on the robot control board

7.13REPLACING A FUSE

7.13.1Replacing a Fuse on

the Robot ControlBoard


148

The emergency stop board has the following fuses.FUS3: For monitoring the emergency stop circuit: A60L–0001–0046#1.0If this fuse is blown, the emergency stop board may be faulty.Replace the emergency stop board.FUS4: For protecting the 24V output to the emergency stop circuit andteach pendant: A60L–0001–0046#1.0If this fuse is blown, the emergency stop circuit may be incorrectlyrouted, or the teach pendant or teach pendant cable may be faulty.Check the routing of the emergency stop circuit, and replace theteach pendant and teach pendant cable.FUS5: For monitoring the emergency stop circuit: A60L–0001–0245#GP20If the fuse is blown, the brake circuit may be faulty. Examine thebrake, robot, and robot interconnection cable. Alternatively,replace the emergency stop board.

FUS3

FUS4

FUS5


Fig.7.13.2 Replacing a fuse on the emergency stop board

7.13.2Replacing a Fuse on

the Emergency StopBoard


149

The door has the following fuse.FUS6: For protecting the 200VAC control output: A60L–0001–0101#P475HIf this fuse is blown, the power supply unit on the emergency stopunit or the cooling fan unit may be faulty. Replace the powersupply unit or cooling fan unit.

FUS6

Fig.7.13.3 Replacing a fuse on the emergency stop board

7.13.3Replacing the Fuse on

the Door


150

The power supply module has the following fuse.FU1: For protecting the 200VAC input for generating power to thecontrol circuit: A60L–0001–0359If the fuse is blown, the power supply module may be faulty.Replace the power supply module.

FU1

Remove the face plate

Fig.7.13.4 Replacing the fuse on the power supply module


the Power SupplyModule


151

The servo amplifier module has the following fuse.FU1: For protecting the +24 V input for generating power to the controlunit: A60L–0001–0290#LM32CIf this fuse is blown, the servo amplifier module may be faulty.Replace the servo amplifier module.

FU1

Remove the control board

Fig.7.13.5 Replacing the fuse on the servo amplifier module


the Servo AmplifierModule


152

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

FUSE1

Process I/O board HE, HF

Totaledition


the Process I/O Boards


153

Prolonged use of a relay might result in its contacts failing to make asecure connection or in them sticking to each other permanently. If sucha failure occurs, replace the relay.

The emergency stop board has the following relays.KA6: For external emergency stop output: A58L–0001–0192#1509AKA7: For brake control: A58L–0001–0192#1997R

KA6

KA7


Fig.7.14.1 Replacing a relay on the emergency stop board

7.14REPLACING A

RELAY

7.14.1Replacing a Relay on

the Emergency StopBoard


154

The programs, and system variables are stored in the SRAM in the Robotcontrol board. The power to the SRAM memory is backed up by a lithiumbattery mounted on the front panel of the Robot control board. The abovedata is not lost even when the main battery goes dead. A new battery canmaintain the contents of memory for about 4 years (Note).When the voltage of the battery becomes low, the battery alarm LED onthe operator panel is lit, and the low–voltage battery alarm (system–035)is displayed on the teach pendant. When this alarm is displayed, replacethe battery as soon as possible. In general, the battery can be replacedwithin one or two weeks, however, this depends on the systemconfiguration.If the battery voltage gets lower, it becomes impossible to back up thecontent of the SRAM. Turning on the power to the in this state causessystem not to start and LED of seven segment on the Robot control boardto be displayed “1” because the contents of memory are lost. Clear theentire SRAM memory and reenter data after replacing the battery.Important data should be saved to the memory card or floppy diskbeforehand in case of emergency.When replacing the memory backup battery, do so while the robotcontroller 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 4years after the introduction of the robot.

(1)Prepare a new lithium battery (ordering drawing number:A02B–0200–K102).(2)Turn the robot controller on for about 30 seconds.(3)Turn the robot controller off.(4)Remove the old battery from the top of the Robot control board.First unlatch the battery, remove it from the battery holder, and detachits connector.

7.15REPLACING

BATTERY

7.15.1Battery for Memory

Backup (3 VDC)

Replacing the lithiumbattery


155

Battery latch

Lithium battery

Batteryconnector

(5)Remove the old battery, insert a new one into the battery holder, andattach 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).

CAUTIONComplete 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 thelaws and other rules in the country where the controller is installed andthose established by the municipality and other organizations that havejurisdiction over the area where the controller is installed.

III CONNECTION

B–81535EN/02 1. GENERALCONNECTIONS

159

1GENERAL

This chapter describes the connection and the installation of the electricalinterface.

2. BLOCK DIAGRAM B–81535EN/02CONNECTIONS

160

2BLOCK DIAGRAM

Following are the block diagrams of the electrical interface connection forR–J3iB Mate.

R–J3iB Mate controller

Robotcontrolboard Operation

panel

Peripheral device

RS–232–CRS–422/485

Teach pendant

Emergency stop

Emergencystop unit

Powersupplyunit

Emergency stopboard

(Note2)

Transformer

Fan

Fuse

Circuit protector

MCCServoamplifier

(Brake)

(RDI/RDO)

Power

Pulse coder

Robot

NOTE

Tranceformer is installed when the robot is for 6–axes brakespecification.

B–81535EN/02 3. CONNECTION DETAILSCONNECTIONS

161

3CONNECTION DETAILS

Emergencystop circuit

CP8B

CP5

JRS12

PCMCIA

COP10A

CRM82

JD17

JD1A

JD1B

CRM79

CRM81

PCMCIA

EMGIN11, 12, 21, 22

FENCE11, 12, 21, 22CP5B

CRS24EMGOUT1, 2

EXT24V, 0V

CRS16

RS–232–C or RS–422/485

Robot controlboard

Battery

Emergencystop unit

Teach pendant

Servo amplifier

Mechanical unit

I/O Link (master)

I/O Link (slave : option)

Peripheral device


3. CONNECTION DETAILS B–81535EN/02CONNECTIONS

162

When the stand–alone controller is used, an optional power cable can be specified.

A grounding stud is providedbeside the circuit protector.Connect the primary powerground wire to this stud. Usean M4 crimp terminal.

Circuit protector Terminal is M4.

By using cable straps, securethe primary power cable to thescrews used to fasten the fan.

To primary power supply3Φ200VAC

Use the cable holders areprovided at these locations.

NOTEConnect the primary power cable to the circuit protector. After connection, insulatethe protector terminal by fitting the provided terminal cover. Connect the primarypower ground wire to the grounding stud, located beside the circuit protector.

You can specify the power supply cables as the option.

3.1CONNECTION OF

POWER SUPPLY

CABLE


163

Table 3.2 Types of FANUC I/O Links

I/O LinkNo. Name Drawing number

Master SlaveRemarks

1 Robot control board A16B–3200–0450 (*) (*) Standard

NOTEThe I/O Link of the robot control board is in the master modeby default. The I/O Link can be used in the slave mode bychanging the software parameter setting.

Refer to the operator’s manual for setting slave mode.

3.2FANUC I/O LINK


164

*Note that the connector name differs from that of the standard FANUC I/O link.

ÏÏÏÏ

When the R–J3iB Mate control unit is used as the master of an I/O link (when R–J3iB Mate control the process I/O printed board)

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

R–J3iB Mate

ÏÏJD1A ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏJD4*

Process I/O printed boord etc.

to other I/O link

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏJD1AÏÏJD1B

When the R–J3iB Mate control unit is used as a slave of the I/O link (when a CNC or PLC is used as the master of the I/O link)

CNC, PLC

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ


ÏÏÏÏ ÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏJD1B

FANUC I/O Unit etc.

When the R–J3iB Mate control unit is used as the master and a slave of an I/O link


ÏÏJD1B

FANUC I/O Unit etc.


ÏÏÏÏJD1A

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏ ÏÏ

JD1B2

ÏÏ ÏÏ

JD1B1 JD1A1

JD1A2

FANUC I/O Link connection unit

to other I/O link

JD4*

JD1A

R–J3iB Mate

JD1A

R–J3iB Matemaster

CNC, PLC

ÏÏÏÏ

ÏÏÏ

*NoteRobot control board is required./Switch by the software


165

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

Peel off the sheath of the shieldedcable, then ground the shield here.

1. Customer should be prepare this cable.2. Power off when it is connected.

When making a connection with a CNC via an I/O link, apply the following timing to turnthe power to the CNC and robot controller on/off:

a) Turn on the power to the slave units when or before turning on the master power.

b) If the power to the CNC or robot controller is turned off after the system has beenstarted, an I/O link error will occur. To reestablish normal connection via the I/O link,turn off the power to all units, then turn on the power as explained in a) above.

JD1A interface


JD4(JD1B) interface

Note) When using an optical I/O link adaptor, use +5V.

Note) When using an optical I/O link adaptor, use +5V.

Cable connections should be made ac-cording to the system. The customer isrequested to ground the shield.

For other I/O link

JD1A

Robot control board

Earth plate

JD1B

I/O Link cable connection

11 0V 01 RXSLC1

12 0V 02 *RXSLC1

13 0V 03 TXSLC1

14 0V 04 *TXSLC1

15 0V 05

16 0V 06

17 07

18 (+5V) 08

19 09 (+5V)

20 (+5V) 10

11 0V 01 RXSLC2

12 0V 02 *RXSLC2

13 0V 03 TXSLC2

14 0V 04 *TXSLC2

15 0V 05

16 0V 06

17 07

18 (+5V) 08

19 09 (+5V)

20 (+5V) 10

(1)Twisted–pair cables should be used for pin pairs 1 and 2, and 3 and 4.(2)Use unified shielding, and ground the shield on the CNC side.

3.3CONNECTION OF I/O

LINK CABLE


166

Cable connection

Master

Robot control boardJD1A

RXSLC1 (1)

*RXSLC1 (2)

TXSLC1 (3)

*TXSLC1 (4)

0V (11)

0V (12)

0V (13)

0V (14)

0V (15)

0V (16)

I/O unit, etc

JD1B

(1) SIN [RX]

(2) *SIN [*RX]

(3) SOUT [TX]

(4) *SOUT [*TX]

(11) 0V

(12) 0V

(13) 0V

(14) 0V

(15) 0V

(16) 0V

Slave

CNC, PLC etc

JD1A

[RX] SIN (1)

[*RX] *SIN (2)

[TX] SOUT (3)

[*TX] *SOUT (4)

0V (11)

0V (12)

0V (13)

0V (14)

0V (15)

0V (16)

Robot control boardJD1B

(1) RXSLC2

(2) *RXSLC2

(3) TXSLC2

(4) *TXSLC2

(11) 0V

(12) 0V

(13) 0V

(14) 0V

(15) 0V

(16) 0V


167

SR2–3 CLOSE OPEN

SR2–2 OPEN CLOSE

SR2–1 CLOSE OPEN

AUTO T1

Teach pendant Emergency stop board Operation panelmode switch

Emergencystop button

Enable/Disable switch

Dead man switch

+24T

+24T

0V

Robot control board

MODE1

MODE2

OP–EMG

FENCE

EX–EMG

MCCMON

Mode switch

(From CP5A)

24VIN +24EXT +24V+24EXT +24V

FUS4 FUS3

+24V

+24EXT

+24EXT

+24V

+24V

0V

JRS12 CRS24

CRM83

0V

0VEXT

0VEXT

0VEXT

0VEXT

0V

KA1–3 KA2–2 KA3–2

KA1–1

KA3–1

KA2–1

+

KA6–1

KA6–2

MCC(KM1)

KM1–1

KM1–5

KM1–4

KM1–3

KM1–2

CRS16CRT11

CRR78

EMGOUT1

EMGOUT1

FENCE22

FENCE21

FENCE12

FENCE11

EMGIN22

EMGIN21

EMGIN12

EMGIN11

EXT0V

INT0V

EXT24V

INT24VTBEB1

TBEB2

CX3

CX4

CZ1

AUTO T1


SR2–1

SR2–2

SR2–3

External

emergency stop

Safety fence

24V external power supply

Servo amplifier (α PSMR–1i)MCCOFF3

MCCOFF4

+24V

ESP

+24V

ESP

RL1

3φ200VAC

3.4EMERGENCY STOP

CIRCUIT

3.4.1Circuit Diagram of

Emergency Stop


168

When the robot is shipped, EMGIN11 and EMGIN12/EMGIN21 and EMGIN22, FENCE11 and FENCE12/FENCE21 and FENCE22 are short–connected. Toenable external emergency stop input and fenceinput, first disconnect these jumper wires, then makethe necessary connections.External emergency stop input is reflected in theexternal emergency stop output, but fence input isnot reflected in the external emergency stop output.Confirm the operation of emergency stop switches onthe teach pendant and on the front panel, after youwired the external emergency stop input and theservo off input.

ÏÏÏÏ

ÏÏÏÏ

ÏÏÏÏ

ÏÏÏÏ

EMGIN11EMGIN12EMGIN21

EMGIN22 EMGIN2

EMGIN1

SVOFF2

SVOFF1

FENCE21

FENCE22

EMGOUT1

EMGOUT2

TBEB2

Customer should prepare this cable

Cable holder

Emergency stop boardServo off input

External emergencystop input

FENCE11FENCE12FENCE21

FENCE22

FENCE11

FENCE12

EMGIN21

EMGIN22

EXT24V

INT24V

INT0V

EXT0V

TBEB1EMGIN11

EMGIN12

NOTE

The contact between EMGIN11 and EMGIN12 or betweenFENCE11 and FENCE12 opens or closes the emergencystop circuit. The contact between EMGIN21 and EMGIN22or between FENCE21 and FENCE22 monitors the inputstate. (Single–channel with monitoring safety circuit)When using external emergency stop input and fence input,prepare the contact for opening and closing the emergencystop circuit and the contact for monitoring.

3.4.2External Emergency

Stop Input


169

Customer should prepare this cable.

Cable holder


ÏÏÏÏÏÏÏÏ

ÏÏÏÏ

ÏÏÏÏ

Emergency stop from the teach pendant andemergency stop from the operator panel arereflected to the external emergency stop out-puts, EMGOUT1 and EMGOUT2.

EMGOUT1EMGOUT2

EMGOUT11

EMGOUT12

TPEmergencystop

OPEmergencystop

To peripheral con-trol sequencer etc.

FENCE21

FENCE22

EMGOUT1

EMGOUT2

TBEB2FENCE11

FENCE12

EMGIN21

EMGIN22

EXT24V

INT24V

INT0V

EXT0V

TBEB1EMGIN11

EMGIN12

3.4.3External Emergency

Stop Output


170

Customer should prepare this cable.

Cable holder


ÏÏÏÏÏÏÏÏ

ÏÏÏÏ

ÏÏÏÏ

When 24 V is applied externally, the externalemergency stop outputs, EMGOUT1 andEMGOUT2, are always output regardless ofthe power state of the robot control unit.

EXT24VEXT0V

FENCE21

FENCE22

EMGOUT1

EMGOUT2

TBEB2FENCE11

FENCE12

EMGIN21

EMGIN22

EXT24V

INT24V

INT0V

EXT0V

TBEB1EMGIN11

EMGIN12

A short connection board isinserted at the factory. Be-fore using external 24 V, re-move this short connectionboard.

24 V power supply

+24V

0V

EXT24V

EXT0V

INT24V

INT0V

NOTE

Connect a minus ground power supply for externallyconnected +24V. The circuit will not function properly if aplus ground power supply is connected.

3.4.4External 24 V Input


171

LR Mate 100iB

CXA2A

JF1 (L)

JF2 (M)

CZ2 L

CZ2 M

COP10B COP10A

CXA2B CXA2A

JF1 (L)

JF2 (M)

JF3 (N)

CZ2 L

CZ2 M

CZ2 N

CZ1

CX1A CXA2A

CX3

CX4

COP10B

CXA2B CXA2A

PSM AMP1 AMP2

TB1

L+

L–

TB1

L+

L–

TB1

L+

L–

POWER SUPPLYMODULE

(αPSMR–1i)A06B–6115–H001

SERVO AMPLIFIERMODULE

(αSVM2–20/20i)A06B–6114–H205


(αSVM3–10/10/10i)A06B–6114–H302

from MCC

from circuit protector

from emergency stop board

from robot controlboard

to robot

Pulse coder

Motor power

LR Mate 200iB/ARC Mate 50iB

CXA2A

JF1 (L)

JF2 (M)

CZ2 L

CZ2 M

COP10B COP10A

CXA2B CXA2A

JF1 (L)

JF2 (M)

JF3 (N)

CZ2 L

CZ2 M

CZ2 N

CZ1

CX1A CXA2A

CX3

CX4

COP10B

CXA2B CXA2A

PSM AMP1 AMP2

TB1

L+

L–

TB1

L+

L–

TB1

L+

L–

POWER SUPPLYMODULE

(αPSMR–1i)A06B–6115–H001


(αSVM3–10/10/10i)A06B–6114–H302

from MCC

from circuit protector

from emergency stop board

from robot controlboard

to robot

Pulse coder

Motor power

JF3 (N)

CZ2 N


(αSVM3–10/10/10i)A06B–6114–H302

3.5COONECTION OF

SERVO AMPLIFIER


172

CRM82

JF1–3

Power cable to RMP

Signal cable

TBEB3 CZ2 L, M, N

Ground cable

3.6CONNECTION OF

ROBOT


173

Emergency stop unit

CRS16

To teach pendant

Earth plate

Fig.3.7 Teach pendant cable

3.7CONNECTION OF

TEACH PENDANT

CABLE


174

Selection of RS–232–C or RS–422 (option) interface need setting ofsoftware.

ÏÏ

Ï

Communication port

Flopply, handy file etc.

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

01 FG

02 TXD

03 RXD

04 RTS

05 CTS

06 DSR

07 0 V

08

09

10

11

12

13

14 (TX)

15 (*TX)

16 (RX)

17 (*RX)

18

19

20 DTR

21

22

23

24

25 +24E

Signals whose names are enclosed inparentheses are assigned to use theRS–422 (option) interface. The num-bers of the interface differ from thoseof the standard RS–422 (option) inter-face. Take the caution when design-ing the interface.

3.8CONNECTION OF

CABLE FOR

RS–232–C/RS–422


175

Table 3.9.1 Types of FANUC I/O Links

Peripheral device interface

No. Name Drawing number CRM79 CRM81 Remarks

DI DO DI DO

1 Robot control board A A16B–3200–0450 20 20 8 4 Standard

NOTEThe DI and DO signals of CRM79 and CRM81 includespecial signals.

Connecting a peripheral device (CRM79 or CRM81)

Grounding plateStrip off the sheathing of the shield cable andconnect the cable to the grounding plate.

CRM81

to peripheral device

CRM79

Robot control board

Fig.3.9.1 Connecting the peripheral device cable

3.9CONNECTING A

CABLE TO A

PERIPHERAL

DEVICE

3.9.1Peripheral Device

Interfaces CRM79 andCRM81


176

NOTESee the operator’s MANUAL for the detail information.

Turn off the controller when connecting the cable.

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

Robotcontrol board

ÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

CNC

CRM79

ÏÏÏÏÏÏ

ÏÏÏÏ

ÏÏÏÏÏÏ

CRM81


ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ


CRM79 interface (Specified signals are not allocated and the Robotis connected to CNC and PLC by a FANUC I/O Link cable.)

SDI101

SDI102

SDI103

SDI104

SDI105

SDI106

SDI107

SDI108

SDI109

SDI110

SDI111

SDI112

SDI113

SDI114

SDI115

SDI116

0 V

0 V

SDICOM1

SDICOM2

SDI117

SDI118

SDI119

SDI120

0 V

0 V

+24E

+24E

SDO101

SDO102

SDO103

SDO104

SDO105

SDO106

SDO107

SDO108

SDO109

SDO110

SDO111

SDO112

SDO113

SDO114

SDO115

SDO116

+24E

+24E

Connector in cable sideHONDA TSUSHIN CO.,LTDConnector MR–50LMH(Male)

SDICOM1 and SDICOM2 are the signals used for selecting a common for SDI signals.To use the +24V common, connect SDICOM1 and SDICOM2 to 0V.To use the 0V common, connect SDICOM1 and SDICOM2 to +24V.SDICOM1→Selects a common for SDI101 to SDI108.SDICOM2→Selects a common for SDI109 to SDI120.

(Note) Maximum output current per one SDO signal is 70mA.

01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

SDO120

SDO117

SDO118

SDO119

3.9.2When the Robot is

Connected to the CNCby a Peripheral DeviceCable


177

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ


ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

CRM79 interface (standard allocation of specified signals andthe Robot is connected to the CNC and PLCby a peripheral device cable.)

01 SDI101

02 SDI102

03 SDI103

04 SDI104

05 SDI105

06 SDI106

07 SDI107

08 SDI108

09 *HOLD

10 RESET

11 START

12 ENBL

13 PNS1

14 PNS2

15 PNS3

16 PNS4

17 0 V

18 0 V

19 SDICOM1

20 SDICOM2

21

22 SDI117

23 SDI118

24 SDI119

25 SDI120

26

27

28

29 0 V

30 0 V

31 +24E

32 +24E

33 SDO101

34 SDO102

35 SDO103

36 SDO104

37 SDO105

38 SDO106

39 SDO107

40 SDO108

41 SDO109

42 SDO110

43 SDO111

44 SDO112

45 CMDENBL

46 FAULT

47 BATALM

48 BUSY

49 +24E

50 +24E

Connector in cable sideHONDA TSUUSHIN CO.,LTDConnector MR–50LMH (Male)

SDICOM1 and SDICOM2 signal are common selection signal for SDI.When 24 V common is used, connect to 0V.When 0V common is used, connect to +24V

SDICOM1”Selects a common for SDI101 to SDI108.SDICOM2”Selects a common for *HOLD, RESET,

START, ENBL, PNS1 to PNS4, and SDI117 to SDI120.

SDO120

SDO117

SDO118

SDO119

NOTE1 Maximum output current for one SDO signal is 70mA.2 The common (selected with SDICOM2) for a dedicated

signal should ideally be the +24V common, but the 0Vcommon can also be used.

3 Allocation of the specified signals can be changed from theteach pendant.


178

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ


ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

CRM79 interface (standard allocation of specified signals andthe Robot is connected to the CNC and PLCby a peripheral device cable.)

01 *IMSTP

02 *HOLD

03 *SFSPD

04 CSTOPI

05 RESET

06 START

07 HOME

08 ENBL

09 RSR1/PNS1

10 RSR2/PNS2

11 RSR3/PNS3

12 RSR4/PNS4

13 RSR5/PNS5

14 RSR6/PNS6

15 RSR7/PNS7

15 RSR8/PNS8

17 0V

18 0V

19 SDICOM1

20 SDICOM2

21

22 PNSTROBE

23 PROD_START

24 SDI119

25 SDI120

26

27

28

29 0V

30 0V

31 +24E

32 +24E

33 CMDENBL

34 SYSRDY

35 PROGRUN

36 PAUSED

37 HELD

38 FAULT

39 ATPERCH

40 TPENBL

41 BATALM

42 BUSY

43 ACK1/SNO1

44 ACK2/SNO2

45 ACK3/SNO3

46 ACK4/SNO4

47 ACK5/SNO5

48 ACK6/SNO6

49 +24E

50 +24E

Connector in cable sideHONDA TSUUSHIN CO.,LTDConnector MR–50LMH (Male)

SDICOM1 and SDICOM2 signal are common selection signal for SDI.When 24 V common is used, connect to 0V.When 0V common is used, connect to +24V

SDICOM1 → Selects a common for *IMSTP, *HOLD, *SFSPD, CSTOPI, RESET, START, HOME, ENBL.

SDICOM2 → Selects a common for RSR1/PNS1, RSR2/PNS2, RSR3/PNS3, RSR4/PNS4, RSR5/PNS5, RSR6/PNS6, RSR7/PNS7, RSR8/PNS8, PNSTROBE, PROD_START.

reserve

ACK7/SNO7

ACK8/SNO8

SNACK

NOTE1 Maximum output current for one SDO signal is 70mA.2 The common (selected with SDICOM1 and 2) for a

dedicated signal should ideally be the +24V common, butthe 0V common can also be used.

3 Allocation of the specified signals can be changed from theteach pendant.


179

In case +24V common at the peripheral device side. (Specified signals are not allocated)

Control unit (peripheral device interface : CRM79) Peripheral device

SDI101 RVCRM79 (1)

CRM79 (31,32,49,50)

Connector pin No+24E

SDICOM1CRM79 (19)

SDI120CRM79 (25)

SDICOM2CRM79 (20)

CRM79 (17,18,29,30)

0V

SDI102CRM79 (2)

SDI103CRM79 (3)

SDI104CRM79 (4)

SDI105CRM79 (5)

SDI106CRM79 (6)

SDI107CRM79 (7)

SDI108CRM79 (8)

SDI109CRM79 (9)

SDI110CRM79 (10)

SDI111CRM79 (11)

SDI112CRM79 (12)

SDI113CRM79 (13)

SDI114CRM79 (14)

SDI115CRM79 (15)

SDI116CRM79 (16)

SDI117CRM79 (22)

SDI118CRM79 (23)

SDI119CRM79 (24)

3.3kRV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

receiver circuit

Fig.3.9.2 (a) Peripheral device control interface : CRM79 (Input signal, +24V common)


180

In case 0V common at the peripheral device side. (Specified signals are not allocated)

SDI101 RVCRM79 (1)

SDICOM1CRM79 (19)

SDI120CRM79 (25)

SDICOM2CRM79 (20)

CRM79 (17,18,29,30)

0V

SDI102CRM79 (2)

SDI103CRM79 (3)

SDI104CRM79 (4)

SDI105CRM79 (5)

SDI106CRM79 (6)

SDI107CRM79 (7)

SDI108CRM79 (8)

SDI109CRM79 (9)

SDI110CRM79 (10)

SDI111CRM79 (11)

SDI112CRM79 (12)

SDI113CRM79 (13)

SDI114CRM79 (14)

SDI115CRM79 (15)

SDI116CRM79 (16)

SDI117CRM79 (22)

SDI118CRM79 (23)

SDI119CRM79 (24)

3.3k


CRM79 (31,32,49,50)


receiver circuit

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

Fig.3.9.2 (b) Peripheral device control interface : CRM79 (Input signal, 0V common)


181

(Specified signals are not allocated)

SDO101 DVCRM79 (33)

CRM79 (17,18,29,30)

0V

LOAD

RELAY

SDO102 LOADCRM79 (34)

SDO103CRM79 (35)

SDO104CRM79 (36)

SDO105CRM79 (37)

SDO106CRM79 (38)

SDO107CRM79 (39)

SDO108CRM79 (40)

SDO109CRM79 (41)

SDO110CRM79 (42)

SDO111CRM79 (43)

SDO112CRM79 (44)

SDO113CRM79 (45)

SDO114CRM79 (46)

SDO115CRM79 (47)

SDO116CRM79 (48)

SDO117CRM79 (26)

SDO118CRM79 (27)

SDO119CRM79 (28)

SDO120CRM79 (21)

0V +24V+24V regurated power supply


Connector pin NoDriver circuit

Max. current per SDO is 70mA.

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

Fig.3.9.2 (c) Peripheral device control interface : CRM79 (Output signal)


182

In case +24V common at the peripheral device side. (Specified signals are allocated)


SDI101 RVCRM79 (1)

CRM79 (31,32,49,50)


SDICOM1CRM79 (19)

SDI120CRM79 (25)

SDICOM2CRM79 (20)

CRM79 (17,18,29,30)

0V

SDI102CRM79 (2)

SDI103CRM79 (3)

SDI104CRM79 (4)

SDI105CRM79 (5)

SDI106CRM79 (6)

SDI107CRM79 (7)

SDI108CRM79 (8)

SDI109CRM79 (9)

SDI110CRM79 (10)

SDI111CRM79 (11)

SDI112CRM79 (12)

SDI113CRM79 (13)

SDI114CRM79 (14)

SDI115CRM79 (15)

SDI116CRM79 (16)

SDI117CRM79 (22)

SDI118CRM79 (23)

SDI119CRM79 (24)

3.3kRV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

receiver circuit

Fig.3.9.2 (d) Peripheral device control interface : CRM79 (Input signal, +24V common)


183

In case 0V common at the peripheral device side. (Specified signals are allocated)

SDI101 RVCRM79 (1)

SDICOM1CRM79 (19)

SDI120CRM79 (25)

SDICOM2CRM79 (20)

CRM79 (17,18,29,30)

0V

SDI102CRM79 (2)

SDI103CRM79 (3)

SDI104CRM79 (4)

SDI105CRM79 (5)

SDI106CRM79 (6)

SDI107CRM79 (7)

SDI108CRM79 (8)

SDI109CRM79 (9)

SDI110CRM79 (10)

SDI111CRM79 (11)

SDI112CRM79 (12)

SDI113CRM79 (13)

SDI114CRM79 (14)

SDI115CRM79 (15)

SDI116CRM79 (16)

SDI117CRM79 (22)

SDI118CRM79 (23)

SDI119CRM79 (24)

3.3k


CRM79 (31,32,49,50)


receiver circuit

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

Fig.3.9.2 (e) Peripheral device control interface : CRM79 (Input signal, 0V common)


184

(Specified signals are allocated)

SDO101 DVCRM79 (33)

CRM79 (17,18,29,30)

0V

LOAD

RELAY

SDO102 LOADCRM79 (34)

SDO103CRM79 (35)

SDO104CRM79 (36)

SDO105CRM79 (37)

SDO106CRM79 (38)

SDO107CRM79 (39)

SDO108CRM79 (40)

SDO109CRM79 (41)

SDO110CRM79 (42)

SDO111CRM79 (43)

SDO112CRM79 (44)

SDO113CRM79 (45)

SDO114CRM79 (46)

SDO115CRM79 (47)

SDO116CRM79 (48)

SDO117CRM79 (26)

SDO118CRM79 (27)

SDO119CRM79 (28)

SDO120CRM79 (21)

0V +24V+24V regurated power supply




DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

Fig.3.9.2 (f) Peripheral device control interface : CRM79 (Output signal)


185

In case +24V common at the peripheral device side. (Specified signals are allocated quickly)

*IMSTP RVCRM79 (1)

CRM79 (31,32,49,50)

+24E

SDICOM1 RVCRM79 (19)

SDI120 RVCRM79 (25)


CRM79 (17,18,29,30)

0V

*HOLD RVCRM79 (2)

*SFSPD RVCRM79 (3)

CSTOPI RVCRM79 (4)

RESET RVCRM79 (5)

SRART RVCRM79 (6)

HOME RVCRM79 (7)

ENBL RVCRM79 (8)

RSR1/PNS1 RVCRM79 (9)








PNSTROBE RVCRM79 (22)

PROD_START RVCRM79 (23)

SDI119 RVCRM79 (24)

3.3k


Connector pin No

receiver circuit

Fig.3.9.2 (g) Peripheral device control interface : CRM79 (Input signal, +24V common)


186

In case 0V common at the peripheral device side. (Specified signals are allocated quickly)

*IMSTP RVCRM79 (1)

CRM79 (31,32,49,50)

+24E


SDI120 RVCRM79 (25)


CRM79 (17,18,29,30)

0V

*HOLD RVCRM79 (2)

*SFSPD RVCRM79 (3)

CSTOPI RVCRM79 (4)

RESET RVCRM79 (5)

START RVCRM79 (6)

HOME RVCRM79 (7)

ENBL RVCRM79 (8)









PNSTROBE RVCRM79 (22)

PROD_START RVCRM79 (23)

SDI119 RVCRM79 (24)

3.3k


Connector pin No

receiver circuit

Fig.3.9.2 (h) Peripheral device control interface : CRM79 (Input signal, 0V common)


187

(Specified signals are allocated quickly)

CMDENBL DVCRM79 (33)

CRM79 (17,18,29,30)

0V

LOAD

RELAY

SYSRDY LOADDVCRM79 (34)

PROGRUN LOADDVCRM79 (35)

PAUSED LOADDVCRM79 (36)

HELD LOADDVCRM79 (37)

FAULT LOADDVCRM79 (38)

ATPERCH LOADDVCRM79 (39)

TPENBL LOADDVCRM79 (40)

BATALM LOADDVCRM79 (41)

BUSY LOADDVCRM79 (42)

ACK1/SNO1 LOADDVCRM79 (43)








SNACK LOADDVCRM79 (28)

reserve LOADDVCRM79 (21)

0V +24V+24V reguratedpower supply




Fig.3.9.2 (i) Peripheral device control interface : CRM79 (Output signal)


188

CRM81 interface(When a special signal is not allocated; when CNC and PLC are connectedby an I/O Link cable)A B

01 SDI81 SDI82

02 SDI83 SDI84

03 SDI85 SDI86

04 SDI87 SDI88

05 SDICOM

06

07 SDO81 SDO82

08 SDO83 SDO84

09 0V

10 +24V 0V

CRM81 interface(When a special signal is allocated; when CNC and PLC are connectedby a peripheral device cable)A B

01 *HOLD RESET

02 START ENBL

03 PNS1 PNS2

04 PNS3 PNS4

05 SDICOM

06

07 CMDENBL FAULT

08 BATALM BUSY

09 0V

10 +24E 0V

SDICOM1 is a common signal that can be used either as an SDI or specialsignal.+24 V common: Connected to 0 V0 V common: Connected to +24 VSDICOM Selects a common for SDI81 to SDI88.

CAUTIONThe maximum output current of each SDO or special signalis 70 mA.

Cable–side connectorYAMAICHI ELECTRICITY

ConnectorHousing – UFS–20B–04Contact – Contact 66 type

(UFS contact)

Cable–side connectorYAMAICHI ELECTRICITY

ConnectorHousing – UFS–20B–04Contact – Contact 66 type

(UFS contact)


189

In case +24V common at the peripheral device side. (Specified signal is not allocated.)

SDI81CRM81 (A1)

CRM81 (A10)

SDICOMCRM81 (A5)

SDI88CRM81 (B5)

CRM81 (B9,B10)

0V

SDI82CRM81 (B1)

SDI83CRM81 (A2)

SDI84CRM81 (B2)

SDI85CRM81 (A3)

SDI86CRM81 (B3)

SDI87CRM81 (A4)



RV3.3k

receiver circuit

RV

RV

RV

RV

RV

RV

RV

RV

Fig.3.9.2 (j) Peripheral device control interface : CRM81 (Input signal, +24V common)


190

In case 0V common at the peripheral device side. (Specified signal is not allocated.)

SDI81CRM81 (A1)

CRM81 (A10)

SDICOMCRM81 (A5)

SDI88CRM81 (B5)

CRM81 (B9,B10)

0V

SDI82CRM81 (B1)

SDI83CRM81 (A2)

SDI84CRM81 (B2)

SDI85CRM81 (A3)

SDI86CRM81 (B3)

SDI87CRM81 (A4)



receiver circuit

RV3.3k

RV

RV

RV

RV

RV

RV

RV

RV

Fig.3.9.2 (k) Peripheral device control interface : CRM81 (Input signal, 0V common)

(Specified signal is not allocated.)

SDO81

CRM81 (A7)

CRM81 (B9,B10)

SDO82 LOADCRM81 (B7)

SDO83CRM81 (A8)

SDO84CRM81 (B8)

0V +24V

DVRELAY


Connector pin NoDriver circuit LOAD

DV

DV

DV

LOAD

LOAD

0V

+24V regurated power supply


Fig.3.9.2 (l) Peripheral device control interface : CRM81 (Output signal)


191

In case +24V common at the peripheral device side. (Specified signal is allocated quickly)

*HOLD RVCRM81 (A1)

CRM81 (A10)

+24E

SDICOM RVCRM81 (A5)

PNS4 RVCRM81 (B5)

CRM81 (B9 ,B10)

0V

RESET RVCRM81 (B1)

START RVCRM81 (A2)

ENBL RVCRM81 (B2)

PNS1 RVCRM81 (A3)

PNS2 RVCRM81 (B3)

PNS3 RVCRM81 (A4)

3.3k


Connector pin No

receiver circuit

Fig.3.9.2 (m) Peripheral device control interface : CRM81 (Input signal, +24V common)


192

In case 0V common at the peripheral device side. (Specified signal is allocated quickly)

*HOLD RVCRM81 (A1)

CRM81 (A10)

+24E

SDICOM RVCRM81 (A5)

PNS4 RVCRM81 (B5)

CRM81 (B9 ,B10)

0V

RESET RVCRM81 (B1)

START RVCRM81 (A2)

ENBL RVCRM81 (B2)

PNS1 RVCRM81 (A3)

PNS2 RVCRM81 (B3)

PNS3 RVCRM81 (A4)

3.3k


Connector pin No

receiver circuit

Fig.3.9.2 (n) Peripheral device interface : CRM81 (Input signal, 0V common)

(Specified signal is allocated quickly)

CMDENBL DVCRM81 (A7)

CRM81 (B9 ,B10)

0V

LOAD

RELAY

FAULT LOADDVCRM81 (B7)

BATALM LOADDVCRM81 (A8)

BUSY LOADDVCRM81 (B8)

0V +24V


Connector pin Nodriver circuit

+24V regurated power supply


Fig.3.9.2 (o) Peripheral device control interface : CRM81 (Output signal)


193

This section describes the specifications of the digital I/O signalsinterfaced with the peripheral device and end effector.

Example of connection

Protective resistance

Lamp

70 mA or less

0V

+24V

70 mA or less

0V

+24V

Spark killer diode

0V

0V

Electrical specificationsRated voltage : 24 VDCMaximum applied voltage : 30 VDCMaximum load current : 70.mATransistor type : Open collector NPNSaturation voltage at connection : 1.0 V (approx.) Spark killer diodeRated peak reverse voltage : 100 V or moreRated effective forward current : 1 A or more Notes on useDo not use the +24 V power supply of the robot.When loading a relay, solenoid, and so on directly, connect them inparallel with diodes for preventing back electromotive force.If a load causing a surge current such as turning on LED is connected,use a protective resistance. Applicable signalOutput signal of peripheral device interface CRM79, CRM81 : SDI101 to SDI120 (CRM79)SDI81 to SDI88 (CRM81)

3.9.3Digital I/O Signal

Specifications

3.9.3.1Peripheral device

interface CRM 79 andCRM 81

Output signal regulation


194


3.3 kΩ

RV

SDICOM

+24V

0V

RV

SDI n

Example of +24V common connection

Electrical specifications of the receiverType : Grounded voltage receiverRated input voltage : Contact close :+20 V to +28 VContact open :0 V to +4 VMaximum applied input voltage : +28 VDCInput impedance : 3.3 kΩ (approx.)Response time : 5 ms to 20 ms Specifications of the peripheral device contactRated contact capacity : 30 VDC, 50 mA or moreInput signal width : 200 ms or more (on/off)Chattering time : 5 ms or lessClosed circuit resistance : 100Ω or lessOpened circuit resistance : 100 kΩ or more

(Signal)(Signal)

TCTC

TBTBTB

Peripheral device contact signal

Robot receiver signal

TB ; Chattering 5 ms or lessTC ; 5 to 20 ms

Note on useApply the +24 V power of the robot to the receiver.However, the above signal regulations must be satisfied at therobot receiver. Applicable signalInput signal of peripheral device interface CRM79, CRM81 : SDO101 to SDO120 (CRM79)SDO81 to SDO84 (CRM81)

Input signal regulation


195

The figure below shows the connector for peripheral device cable.

Symbol Name

1 Connector cover

2 Connector 50 pins (male)

Connector ApplicableDimensions Remark

Connectorspecification

Applicableinterface A (B) C (D) Honda Tsushin

φMR50LWM CRM79 67.9 73.5 66.1 20

Kogyo E φ16 50pins

Fig.3.9.4 (a) Peripheral Device Cable Connector (CRM79 : Honda Tsushin Kogyo)


Cable Connector


196

Connector Applicable DimensionsConnectorspecification

Applicableinterface A C

Remark

UFS–20B–04 29.98 22.86YAMAICHI ELECTRONICS

(Housing)

Contact 66 type

CRM81YAMAICHI ELECTRONICS

(Contact)

Applicable cable : AWG#28 (7/0.12), AWG#26 (19/0.1), AWG#24 (19/0.12), (7/0.18)

Fig.3.9.4 (b) Peripheral Device Cable Connector (CRM81 : YAMAICHI ELECTRONICS)

Connect a peripheral device using a completely shielded, heavilyprotected cable conforming to the specifications in Table 3.9.5.Allow an extra 1.5m for routing the cable in the control unit.The maximum cable length is 30m.Table 3.9.5 Recommended cable (For peripheral device connection)

Conductor Effective Electrical characteristics

Number ofwires

Wire specifications(FANUC

specifications)Diameter

(mm)Configura-

tion

Sheaththickness

(mm)

Effectiveoutside

diameter(mm)

Conductorresistance

(Ω/km)

Allowablecurrent (A)

50 A66L–0001–0042 φ1.05 7/0.18AWG24

1.5 φ12.5 106 1.6

20 A66L–0001–0041 φ1.05 7/0.18AWG24

1.5 φ10.5 106 1.6

3.9.5Recommended Cables

3.56

2.54

A

B

2.54

6.0

14.314.5


197

Table 3.10.1 Types of end effector interfaces

End effector interfaceNo. Name Drawing number

DI DORemarks

1 Robot control board A A16B–3200–0450 6 6 Standard

NOTE

Either RDI6 or *PPABN is selected by software.

1 RDI1 7 *HBK

2 RDI2 8 +24E

3 RDI3 9 +24E

4 RDI4 10 +24E

5 RDI5 11 0V

6 RDI6(*PPABN)

12 RDICOM

EE

Mechanical unit

End effecter

NOTERDO1 to RDO6 are used as the signals to turn on or offsolenoid valves. The end effector can use the RDI signalsand *HBK signal. For RDO signals, refer to themaintenance manual of the mechanical unit.

3.10END EFFECTOR

INTERFACE

3.10.1Connecting the

Mechanical Unit andEnd Effector


198

End effecter

RDI1 RVEE (1)

EE (8,8,10)Connector pin No.

+24E

Receiver circuit

RDICOMEE (12)

EE (11)

0V

RDI2EE (2)

RDI3EE (3)

RDI4EE (4)

RDI5EE (5)

RDI6(*PPABN)

EE (6)

3.3k

Mechanical unit (end effector interface)

RV

RV

RV

RV

RV

RV

Fig.3.10.1 (a) End effector interface (+24V common)

End effecter

RDI1 RVEE (1)

EE (8,8,10)Connector pin No.

+24E

Receiver circuit

RDICOMEE (12)

EE (11)

0V

RDI2EE (2)

RDI3EE (3)

RDI4EE (4)

RDI5EE (5)

RDI6(*PPABN)

EE (6)

3.3k

Mechanical unit (end effector interface)

RV

RV

RV

RV

RV

RV

Fig.3.10.1 (b) End effector interface (0V common)


199


3.3 kΩ

RV

RDICOM

+24V

0V

RV

RDI n

Example of +24V common connection

Electrical specifications of the receiverType : Grounded voltage receiverRated input voltage : Contact close: +20 V to +28 VContact open: 0 V to +4 VMaximum applied input voltage : +28 VDCInput impedance : 3.3 kΩ (approx.)Response time : 5 ms to 20 msSpecifications of the peripheral device contactRated contact capacity : 30 VDC, 50 mA or moreInput signal width : 200 ms or more (on/off)Chattering time : 5 ms or lessClosed circuit resistance : 100 Ω or lessOpened circuit resistance : 100 kΩ or more

(Signal)(Signal)

TCTC

TBTBTB

Peripheral device

contact signal


TB ; Chattering 5 ms or less

TC ; 5 to 20 ms

Note on useApply the +24 V power at the robot to the receiver.However, the above signal specifications must be satisfied at therobot receiver.Applicable signalsInput signals of end effector control interfaceAdditional I/O PCB CRW6 input signal WDI1 to WDI8RDI 1 to 6, *HBK, *PPABN (Switch RDI6 by software)


Specifications of EndEffector ControlInterface


200

In this manual the treatment for the shielded cable is shown on severalpages. Partly cut off the shielded cable to expose the shield jacket, andfasten the jacket to the shield plate with a clamp to protect against noise.(In case of stand–alone type a shield plate is installed in the controller.)

Fig.2.12 Shielded cable treatment

3.11TREATMENT FOR

THE SHIELDED

CABLE


201

Connection to the peripheral device and the arc welding is available to usethe process I/O board for R–J3iB Mate.

Number of I/O pointsNo. Name Drawing number

DI DO D/A A/DRemarks

1 Process I/O board HE A05B–2440–J002 40 40 2 6

2 Process I/O board HF A05B–2440–J003 40 40 0 0

NOTEGeneral purpose I/O (SDI/SDO) is a number which subtract an exclusive signal from the tablevalue.

3.12PERIPHERAL

DEVICE, ARC

WELDING,

INTERFACES


Interface Types


202

Main board

Process I/O

board

HE/HF

Peripheral

device

JD1A

(JD4)

CRM2A

JD4A

(JD1B)

CRM2B

CRW7

(NOTE 1)

CRW2

(NOTE1)

JD4B

(JD1A)

Fig.3.12.2 Block diagram of the process I/O board HE and HF

NOTE

1 CRW2 and CRW7 are not provided for process I/O boardHF.


Interface BlockDiagram andSpecifications


203

The connection is for the allocated specified signal.For detail of the allocation, refer to the OPERATOR’S MANUAL.

1 *IMSTP

*HOLD

3 *SFSPD

CSTOPI

5 FAULT RESET

7

9

2

4

6

8

10

12

14

16

11

13

15

18

17

Peripheral device control interface A1

CRM2A

START

HOME

ENBL

RSR8/PNS8

0V

0V

RSR7/PNS7

RSR6/PNS6

RSR5/PNS5

RSR4/PNS4

RSR3/PNS3

RSR2/PNS2

RSR1/PNS1SNACK

SDI01

PROD START

PNSTROBE

COM–A5

RESERVED

SDI02

ACK6/SNO6

ACK5/SNO5

ACK4/SNO4

ACK3/SNO3

COM–A4

ACK8/SNO8

ACK7/SNO7ATPERCH

FAULT

HELD

COM–A1

PAUSED

PROGRUN

SYSRDY

CMDENBL

COM–A3

ACK2/SNO2

ACK1/SNO1

BUSY

BATALM

COM–A2

TPENBL

+24E

+24E

Control unit

33

35

37

39

41

34

36

38

40

42

44

46

48

43

45

47

50

49

19

21

23

25

27

20

22

24

26

28

30

32

29

31

Peripheraldevice A1

1 SDI03

SDI04

3

SDI06

5

7

9

2

4

6

8

10

12

14

16

11

13

15

18

17

Peripheral device control interface A2

CRM2B

SDI08

SDI09

SDI10

SDI18

0V

0V

SDI17

SDI16

SDI15

SDI14

SDI13

SDI12

SDI11

33

35

37

39

41

34

36

38

40

42

44

46

48

43

45

47

50

49

19

21

23

25

27

20

22

24

26

28

30

32

29

31

Peripheraldevice A2

SDI07

SDI05

SDO01

SDO02

SDO04

SDO05

SDO06

SDO07

+24E

+24E

COM–B3

SDO12

SDO11

SDO10

SDO09

COM–B2

SDO08

COM–B1

SDO03SDO13

SDO14

SDO16

SDO17

SDO18

SDO19

SDI22

SDI21

SDI20

SDI19

COM–B5

SDO20

COM–B4

SDO15

NOTE

1 Peripheral device connection cable are optional.2 All COM-** are connected to the 0V.

Applicable process I/O board typeHE, HF

3.12.3Peripheral Device and

Control Unit Connection


204

*IMSTPCRM2A (1)

CRM2A (49,50)

+24E

ENBLCRM2A (8)

SDI02CRM2A (32)

COM–1 CRM2A (17,18)

0V

*HOLDCRM2A (2)

*SFSPDCRM2A (3)

CSTOPICRM2A (4)

FAULT RESETCRM2A (5)

STARTCRM2A (6)

HOMECRM2A (7)

RSR1/PNS1CRM2A (9)

RSR2/PNS2CRM2A (10)

RSR3/PNS3CRM2A (11)

RSR4/PNS4CRM2A (12)

RSR5/PNS5CRM2A (13)

RSR6/PNS6CRM2A (14)

RSR7/PNS7CRM2A (15)

RSR8/PNS8CRM2A (16)

PNSTROBECRM2A (29)

PROD STARTCRM2A (30)

SDI01CRM2A (31)

3.3k

+24E

0V

B A

0V

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

Control unit

(peripheral device control interface A1)

Receiver circuit

Common setting

pin (ICOM1)

Connector pin No.

Peripheral device

NOTE

This is a connection diagram for +24V common.


205

CMDENBL

CRM2A (34)

CRM2A (33)

TPENBL

CRM2A (43)

RESERVED

CRM2A (23,28,37,42,47)

0V

SYSRDY

CRM2A (35)PROGRUN

CRM2A (36)PAUSED

CRM2A (38)HELD

CRM2A (39)FAULT

CRM2A (40)ATPERCH

CRM2A (41)

BATALM

CRM2A (44)BUSY

CRM2A (45)ACK1/SNO1

CRM2A (46)ACK2/SNO2

CRM2A (19)ACK3/SNO3

CRM2A (20)ACK4/SNO4

CRM2A (21)ACK5/SNO5

CRM2A (22)ACK6/SNO6

CRM2A (24)ACK7/SNO7

CRM2A (25)ACK8/SNO8

CRM2A (26)SNACK

CRM2A (27)

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

LOAD

RELAY

0V +24V+24V reguratedpower supply

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

0V

Control unit


Driver circuit

Max. current per UDO is 70mA

Connector pin No.

Peripheral device


206

SDI03CRM2B (1)

CRM2B (49,50)

+24E

SDI10CRM2B (8)

SDI22CRM2B (32)

COM–2 CRM2B (17,18)

0V

SDI04CRM2B (2)

SDI05CRM2B (3)

SDI06CRM2B (4)

SDI07CRM2B (5)

SDI08CRM2B (6)

SDI09CRM2B (7)

SDI11CRM2B (9)

SDI12CRM2B (10)

SDI13CRM2B (11)

SDI14CRM2B (12)

SDI15CRM2B (13)

SDI16CRM2B (14)

SDI17CRM2B (15)

SDI18CRM2B (16)

SDI19CRM2B (29)

SDI20CRM2B (30)

SDI21CRM2B (31)

3.3k

+24E

0V

B A

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

Control unit


Receiver circuit

Common setting

pin (ICOM2)

Connector pin No.

Peripheral device

NOTE

This is a connection diagram for +24V common.


207

SDO01

CRM2B (34)

CRM2B (33)

SDO08

CRM2B (43)

SDO20

CRM2B (23,28,37,42,47)

0V

SDO02

CRM2B (35)SDO03

CRM2B (36)SDO04

CRM2B (38)SDO05

CRM2B (39)SDO06

CRM2B (40)SDO07

CRM2B (41)

SDO09

CRM2B (44)SDO10

CRM2B (45)SDO11

CRM2B (46)SDO12

CRM2B (19)SDO13

CRM2B (20)SDO14

CRM2B (21)SDO15

CRM2B (22)SDO16

CRM2B (24)SDO17

CRM2B (25)SDO18

CRM2B (26)SDO19

CRM2B (27)

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

LOAD

RELAY

0V +24V

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

0V

Control unit


Driver circuit

Max. current per DO is 70mA

Connector pin No.

Peripheral device

+24V reguratedpower supply


208

Control unit

Peripheral device

Analog input interface

CRW2

NOTE

Welder and peripheral device connection cable are optional.

Applicable process I/O board typeHE

3.12.4Connection Between

the Control Unit andWelder


209

Analog connection of CRW2 connector (Analog input)

ADCH1CRW2 (10)

COMAD1CRW2 (11)

ADCH2CRW2 (12)

COMAD2CRW2 (13)

0V

ADCH5CRW2 (18)

COMAD5CRW2 (19)

ADCH6CRW2 (8)

COMAD6CRW2 (9)

ADCH3CRW2 (14)

COMAD3CRW2 (15)

ADCH4CRW2 (16)

COMAD4CRW2 (17)

Connector pin number

Control unit

(Analog input interface)

Process I/O HE

Peripheral device

Output signals without

ripples.


210

Control unit

Welder interface

CRW7

Welder

NOTE

Welder and peripheral device connection cable is option.

Applicable process I/O board typeHE


211

Attaching the CRW7 connector to the welding machine: FANUC interface(Analog output, welding wire deposition detected, and WDI/WDO connection: Connected to the +24 V commonline)

DACH1CRW7 (1)

COMDA1CRW7 (2)

DACH2CRW7 (3)

COMDA2CRW7 (4)

+

A

B

C

D

WDI+ CRW1 (31)

WDI– CRW1 (32)

M

N

–

WDI02CRW7 (6)

CRW7 (33,34)

COM–3

WDI03CRW7 (7)

WDI04CRW7 (8)

WDI06CRW7 (10)

3.3k

+24E

0V

B A

RV

RV

RV

RV

RV

E

P

T

S

R

CRW7 (23) LWDO01

WCOM1 CRW7 (24) K

CRW7 (29) FWDO04

WCOM4 CRW7 (30) G

CRW7 (13) HWDO05

WCOM5 CRW7 (14) J

+–

+24E

R=100 Ω or more

Welding power supply

Receiver circuit

Common setting pin

(ICOM3)

Welding machine frame ground

Cabinet ground

(shield clamp)

Control unit (welding interface)

Process I/O HEConnector pin No.

Connector pin No.

Welding voltage

command signal

Wire speed command

signal

Arc detected signal

Gas outage detectedsignal

Broken–wire detectedsignal

Welding start signal

Wire inching (+)

Wire inching (–)

Welding machine

MS connector

pin No.

Wire deposition

detected signal

Arc turn–off detectedsignal (power supplyfailure)


212

NOTE

This is the connection for +24V.


213

Attaching the CRW7 connector to the welding machine: FANUC interface(Analog output, welding wire deposition detected, and WDI/WDO connection: Connected to the +24 V commonline)

DACH1CRW7 (1)

COMDA1CRW7 (2)

DACH2CRW7 (3)

COMDA2CRW7 (4)

+

A

B

E

F

WDI+CRW1 (31)

WDI–CRW1 (32)

N

P

–

WDI01CRW7 (5)

CRW7 (33,34)

COM–3

WDI02CRW7 (6)

WDI03CRW7 (7)

WDI04CRW7 (8)

3.3k

+24E

0V

B A

RV

RV

RV

RV

RV

r

c

d

e

f

CRW7 (23)RWDO01

WCOM1CRW7 (24)

CRW7 (29)UWDO04

WCOM4CRW7 (30)

CRW7 (13)VWDO05

WCOM5CRW7 (14)

b

+–

WDI05CRW7 (9)

WDI06CRW7 (10)

WDI07CRW7 (11)

WDI08CRW7 (12)

RV

RV

RV

RV

h

j

k

g

+24E

CRW7 (19,20)m

CRW7 (21,22)n

0V

CRW7 (23)SWDO02

WCOM2CRW7 (24)

a

s

R=100 Ω or more

Welding power supply

Receiver circuit

Common setting pin

(ICOM3)

Welding machine frame ground

Cabinet ground

(shield clamp)

Control unit (welding interface)

Process I/O HEConnector pin No.

Connector pin No.

Welding voltage

command signal

Wire speed command

signal

Arc detected signal

Gas outage detectedsignalBroken–wire detectedsignalCooling water outagesignal

Welding start signal

Wire inching (+)

Wire inching (–)

Welding machine

MS connector

pin No.

Wire deposition

detected signal

Arc turn–off detectedsignal (power supplyfailure)

Gas signal


214

(1) Output signals in peripheral device interface AExample of connection

Protective resistance

Lamp

70 mA

or less

0V

+24V

Spark killer diode

70 mA

or less

0V

+24V

Electrical specificationsRated voltage : 24 VDCMaximum applied voltage : 30 VDCMaximum load current : 70 mATransistor type : Open collector NPNSaturation voltage at connection : 1.0 V (approx.)Spark killer diodeRated peak reverse voltage : 100 V or moreRated effective forward current : 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, connectthem in parallel with diodes to prevent back electromotiveforce.If a load is connected causing a surge current when a lampis turned on, use a protective resistance.

Applicable signalsOutput signals of process I/O board CRM2 CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT,ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNACK,SDO1 to SDO76


Specifications ofPeripheral DeviceInterface A


215

(2) Input signals in peripheral device interface AExample of connection

AB

3.3 k

+24V

RV

+24V

ICOM

Electrical specifications of the receiverType : Grounded voltage receiverRated input voltage : Contact close: +20 V to +28 VContact open: 0 V to +4 VMaximum applied input voltage : +28 VDCInput impedance : 3.3 kΩ (approx.)Response time : 5 ms to 20 msSpecifications of the peripheral device contactRated contact capacity : 30 VDC, 50 mA or moreInput signal width : 200 ms or more (on/off)Chattering time : 5 ms or lessClosed circuit resistance : 100 Ω or lessOpened circuit resistance : 100 kΩ or more

(Signal)(Signal)

TCTC

TBTBTB

Peripheral device

contact signal


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 satisfiedat the robot receiver.

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


216

(1) Digital output signal specifications for an arc welding interfaceIn case of process I/O HE

0.3 A or

less

Example connection

Spark killer diode

Electrical characteristicsRated voltage : 24 VDCMaximum applied voltage : 30 VDCMaximum load current : 0.3 AOutput type : Relay connection outputSpark killer diodeRated peak reverse voltage : 100 V or moreRated effective forward current : 1 A or moreNOTE

A power voltage of +24 V, provided for the robot, can beused for interface signals of up to 0.7 A. This limit appliesto the sum of the currents flowing through the arc–weldingand end–effector control interfaces. To drive a relay orsolenoid directly, connect a diode preventing backelectromotive force to the load in parallel. To connect a loadwhich generates an inrush current when you turn on thecontrol unit, connect a protective resistor.

Applicable signals– Output signals on the arc–welding interface– WDO1 to WDO4

3.12.6I/O Signal

Specifications forARC–Welding Interface


217

(2) Digital input signal specifications for arc welding interfaceExample connection

Electrical characteristics of receiversType: Grounded voltage receiverRated input voltage : +20 to +28 V with contacts closed0 to +4 V when openMaximum input voltage : +28 VDCInput impedance : About 3.3 kResponse time : 5 to 20 msContact specifications for peripheralsRated contact capacity : 30 VDC, 50 mA or moreInput signal width : 200 ms or more for on and off statesChattering period : 5 ms or lessClosed–circuit resistance : 100 Ω or lessOpen–circuit resistance : 100 kΩ or more

Contact signal

for peripheral

Receiver

signal for robot

(Signal) (Signal)

TB: Chattering of 5 ms or less

TC: 5 to 20 ms

NOTESupply the +24 V power, provided for the robot, to thereceivers. The receiver signal on the robot must satisfy thesignal timing specified above.

Applicable signals– Input signals for arc welding interface– WDI1 to WDI8


218

(3) Analog output signal specifications for arc welding interface(Welding voltage command, wire–feed rate command)Welder

Example connection

0V

Process I/O CA, EA : –10V to +10V

Process I/O GA, HA : 0V to +15V

NOTEInput impedance: 3.3 kΩ or moreConnect a high–pass filter.

(4) Analog input signal specifications for arc welding interface(Welding–voltage detection, welding–current detection)

–10V to +10V

Welder

Example connection

0V

NOTEThe analog input signal should have no ripple for the circuitto operate properly.

(Wire deposit detection: WDI+ and WDI–)

Welding electrode

WelderExample connection

NOTEConnect a resistor of 100Ω or more between the positiveand negative electrodes of the welder. Isolate the depositdetection signals for TIG welding from the welding circuit,which uses high–frequency components. The dielectricwithstand voltage of this circuit is 80 V.


219

If the customer manufactures cables, make sure they conform to theFANUC standard cables described in this section. (See the description in“Peripheral Device Interface” in this manual for the specifications of theFANUC standard cables.)

Process I/O

Honda Tsushin

MR50RMA

Peripheral

device

Honda Tsushin

MR50LWF01

(MR50LF)

Honda Tsushin

MR50LM01

(MR50LM)

Honda Tsushin’s MR50RF

Supplied with an ordered cable

Be sure to use the FANUC cable to connect the welder.

Process I/O

Honda TsushinMR34RFA

ARC welder

Honda Tsushin

Japan Aviation ElectronicsIndustry Ltd.MS3108B28–21PMS3057–16

Japan Aviation ElectronicsIndustry Ltd.MS3102A28–21SStandard position of guide key

CRW1

or

CRW7

3.12.7Specifications of the

Cables used forPeripheral Devices A(CRM2: HondaTsushin, 50 pins)

3.12.8ARC Weld Connection

Cable (CRW1: HondaTsushin, 34 pins)


220

(1) Fig. 3.12.9 shows the connector for peripheral device cables A andB. (The connector is used for a peripheral device)

Connector Applicable DimensionsConnectorspecifications

Applicableinterface A (B) C (D)

Remark

MR50LM CRM2 67.9 73.5 44.8 18 Honda Tsushin Kogyo,50 pins

Symbol Name

Connector cover

Cable clamp screw

Connector clamp spring

Connector clamp screw

Connector 50 pins (male) MR50M

Fig.3.12.9 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo)


Cable Connector


221

(2) Peripheral device connector

Connector ApplicableDimen-sions Remark

specifications interfaceA B

Remark

MR50RF (CRM2) 61.4 56.4 Honda Tsushin Kogyo,50 pins

Symbol Name

Connector clamp screw

Screw M2.68

Connector (MR50RF)

Fig.3.12.9 (b) Peripheral Device Connector (Honda Tsushin Kogyo)

(1) Peripheral device connection cableConnect a peripheral device using a completely shielded, heavilyprotected cable conforming to the specifications in Table 3.12.10 (a).Allow an extra 50 cm for routing the cable in the control unit.The maximum cable length is 30 m.Table 3.12.10 Recommended Cable (for Peripheral Device Connection)

Conductor Effective Electrical characteristics

Numberof wires

Wire specifications (FANUC specifications) Diameter

(mm)Configura-

tion

Sheaththickness

(mm)

Effectiveoutside

diameter(mm)

Conductorresistance

(Ω/km)

Allowablecurrent

(A)

50 A66L-0001-0042 ø1.05 7/0.18AWG24

1.5 ø12.5 106 1.6

3.12.10Recommended Cables

CONNECTION4. TRANSPORTATION AND

INSTALLATION B–81535EN/02

222

4TRANSPORTATION AND INSTALLATION

CONNECTIONB–81535EN/024. TRANSPORTATION AND

INSTALLATION

223

The control unit should be transported by a crane. Attach a sling to eyebolts at the top of the control unit.

Fig.4.1 Transportation

Installation areaWhen the control unit is installed, allow the space for maintenance shownin the following figure.

Contrpl unit Contrpl unitContrpl unit

When the pluralcontroller isinstalled.

Fig.4.2 Installation

4.1TRANSPORTATION

4.2INSTALLATION



224

Four M10 weld nutsThe unit is shipped with the M10 boltsscrewed to the weld nuts as 10–mm feet.After the M10 bolts are removed, theseweld nuts can be used to secure the control unit.

Fig.4.3 External drawing of robot controller

4.3EXTERNAL

CONTROLLER

DIMENSIONS

CONNECTIONB–81535EN/024. TRANSPORTATION AND

INSTALLATION

225

Item Specifications/condition

Input power supply 50Hz; 200VAC, +10%, –15%60Hz; 200VAC to 220 VAC, +10%, –15%50/60 Hz1Hz, 3–phase

Input power supply capacity 1 kVA (LR Mate 100iB)1.2 kVA (LR Mate 200iB/ARC Mate 50iB)

Average power consumption 0.4 kW (LR Mate 100iB)0.5 kW (LR Mate 200iB/ARC Mate 50iB)

Permissible ambient temper-ature

0 to 45C during operation, and –20 to 60 Cduring shipment and storage with a tempera-ture coefficient of 1.1C/min.

Permissible ambient humid-ity

Relative humidity: 30% to 95%, non–condens-ing.

Surrounding gas An additional protective provision is neces-sary if the machine is installed in an environ-ment in which there are relatively largeamounts of contaminants (dust, dielectricfluid, organic solvent, acid, corrosive gas,and/or salt).

Vibration 0.5 G or less. When using the robot in a loca-tion subject to serious vibration, consult withyour FANUC sales representative.

Altitude Not higher than 1,000 m above sea level

Ionized and nonionized radi-ations

A shielding provision is necessary if themachine is installed in an environment inwhich it is exposed to radiations (microwave,ultraviolet rays, laser beams, and/or X–rays).

Weight of control unit Approx. 35kg

Adjust and check according to following procedure at installation.No. Description

1 Visually check the inside and outside of the control unit.

2 Check if the screwed terminal is connected properly.

3 Check that the connectors and printed circuit boards are inserted cor-rectly.

4 Connect control unit and mechanical unit cables.

5 Turn the breaker off and connect the input power cable.

6 Check the input power voltagage.

7 Press the EMERGENCY STOP button on the operator’s panel andturn the power on. Check the output voltage.

8 Check the interface signals between control unit and robot mechanicalunit.

9 Check the parameters. If necessary, set them.

10 Release the EMERGENCY STOP button on the operator’s panel.Turn the power on.

11 Check the movement along each axis in the manual jog mode.

12 Check the end effector interface signals.

13 Check the peripheral device control interface signals.

4.4INSTALLATION

CONDITION

4.5ADJUSTMENT AND

CHECKS AT

INSTALLATION



226

An overtravel and emergency stop occur when the robot is operated forthe first time after it is installed and the mechanical and control units arewired. This section describes how to reset the overtrvel and emergencystop.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 afterinstallation.

(1) Press the [MENUS] key on the teach pendant.(2) Select [Next].(3) Select [SETUP].(4) Press F1 [TYPE].(5) Select [Config] to disable or enable Hand Break.

Hand break

State Hand break HBK (*1) HBK detection Robot operation Message

1 Enabled CLOSE Detected Possible Not provided

2 Enabled OPEN Detected Impossible SERVO 6

3 Disabled CLOSE Detected (*2) Possible Not provided

4 Disabled OPEN Not detected Possible SERVO 300 at cold start

NOTE

1 Robot end effector connector

2 When the HBK circuit is closed, the HBK detection isenabled.If the HBK state changes from close to open, the SERVO300 or SERVO 302 alarm occurs, stopping the robot.

3 If the power is turned off and on in the state describedabove, the system enters state 4, releasing the alarm.

CLOSE OPEN

24V

*HBK

24V

*HBK

4.6NOTE AT

INSTALLATION

4.7DISABLING HAND

BREAK

APPENDIX

B–81535EN/02 A. TOTAL CONNECTION DIAGRAMAPPENDIX

229

ATOTAL CONNECTION DIAGRAM

A. TOTAL CONNECTION DIAGRAM B–81535EN/02APPENDIX

230

Fig.A (a) Total connection diagram


231


232

Fig.A (b) Emergency stop circuit diagram


233


234

Fig.A (c) Emergency stop circuit diagram


235


236Fig.A (d) Robot control board, Emergency stop board connector interface


237Fig.A (e) Servo amplifier robot mechanical unit connector interface

B–81535EN/02APPENDIXB. PERIPHERAL INTERFACE

238

BPERIPHERAL INTERFACE

Peripheral I/O (UI/UO) are a group of specialized signals whose usage isdecided by the system. These signals are connected with a remotecontroller and the peripheral devices via the following interfaces and I/Olinks and they are used to control the robot from the outside. The JD1A interface (The process I/O board, the I/O Unit MODEL Aand the MODEL B are connected as the slave of I/O link to R–J3iBMate.) (on master mode) The JD1B interface (CNC and PLC are connected as a master of I/Olink to R–J3iB Mate.) (on slave mode) CRM9 interfaceRefer to the operator’s MANUAL for detail informations.

B–81535EN/02 APPENDIX B. PERIPHERAL INTERFACE

239

The tables below list the special signals of the R–J3iB Mate robotcontroller.Input signals (See Subsection B.2.1.)

Signal Description

*HOLD

RESET

START

ENBL

PNS1

PNS2

PNS3

PNS4

Temporary stop

Alarm release

Cycle start

Enable

Program select (*1)

Program select (*1)

Program select (*1)

Program select (*1)

NOTEPNS (program select input) (optional)

Output signals (See Subsection B.2.1.)

Signal Description

CMDENBL

FAULT

BATALM

BUSY

Input acceptable

Alarm

Battery alarm

Busy

B.1SIGNAL TYPES


240

Fellowing is each input signal.

The remote controller uses the hold signal to halt the robot. Because*HOLD input signal is a inverted signal, normally set the signal on. Whenthe signal goes off, the following is executed: The robot is decelerated until its stops, then the program execution ishalted. If ENABLED is specified at “Break on hold” on the general itemsetting screen, the robot is stopped, an alarm is generated, and theservo power is turned off. (Standard setting: DISABLED)The RESET signal cancels an alarm. If the servo power is off, the RESETsignal turns on the servo power. The alarm output is not canceled until theservo power is turned on. The alarm is canceled at the instant this signalfalls in default setting. If TRUE is specified at “CSTOPI for ABORT” on the systemconfiguration screen, the RESET signal resets an alarm and aborts thecurrently selected program. (Standard setting: FALSE) To have alarms reset the instant the RESET signal rises, it is necessaryto specify RISE at “Detect FAULT RESET signal” on the systemconfiguration screen. (Standard setting: FALL)The START signal has two functions. It can select or collate a programand start the program. When the START signal goes high, PNS1 to PNS4 are read and thecorresponding program is selected or collated. Whether is program isselected or collated is specified by the setting of system variable$SHELL_CFG.$NUM_RSR [1]. (See the description of signalsPNS1 to PNS4.) When the START signal goes low, the current program is started fromthe line at which the cursor is placed (current line). If TRUE is specified at “START for CONTINUE only” on the systemconfiguration screen, only a program on hold can be started. (Standardsetting: FALSE)The ENBL signal allows the robot to be moved and places the robot in theready state. When the ENBL signal is off, the system inhibits a jog feedof the robot and activation of a program including a motion (group). Aprogram which is being executed is halted when the ENBL signal is setoff.NOTE

When the ENBL signal is not monitored, strap the signalwith the ground.

B.2I/O SIGNALS

B.2.1Input Signals

Hold input signals, *HOLD, UI [ 1 ]

Fault reset input signal,RESET, UI [ 2 ]

Start input signal,START, UI [ 3 ] (validatedin the remote state)

Enable input signal,ENBL, UI [ 4 ]


241

A program number selection signal has two functions.When the START signal goes on, PNS1 to PNS4 are read and thecorresponding program is selected or collated. Whether the program isselected or collated is specified by the setting of system variable$SHELL_CFG.$NUM_RSR [1]. In the program end state, a program is selected or collated accordingto the state (0 or 1) of the PNS signals. The current line of the selectedor collated program is set to 1.

Type 1 (when $SHELL_CFG.$NUM_RSR [1] is set to 0)The program specified by the PNS signals is selected. Type 2 (when $SHELL_CFG.$NUM_RSR [1] is set to 1)The program specified by the PNS signals is collated with thecurrent program. If the programs do not agree with each other, anerror occurs.

If all PNS signals are low in the program end state, the current programis executed from the current line. If no programs are selected, an erroroccurs. A halted program can be resumed only when all PNS signals are setoff. Otherwise, an error occurs. While a program is being executed, the PNS signals are ignored.

Fellowing are peripheral device interface output signals.

The CMDENBL signal is output when the following conditions aresatisfied. The CMDENBL signal indicates that the remote controller canstart a program including a motion (group). The remote conditions are satisfied. The ready conditions are satisfied. The continuous operation mode is selected (the single step mode isdisabled).The FAULT signal is output when an alarm occurs in the system. TheRESET signal cancels the alarm. If a warning (WARN alarm) occurs, theFAULT signal is not output.The BATALM signal indicates that the voltage of the battery forsupporting the memory has dropped. Replace the battery while keepingthe power of the controller on.To have the BATALM signal generated also when the BZAL/BLAL alarmoccurs, it is necessary to set the $BLAL_OUT.$BATALM_OR systemvariable. It is also possible to have the specified SDO output when theBZAL/BLAL alarm occurs.The BUSY signal is output while a program is being executed. The BUSYsignal is not output while a program is being halted.

Program numberselection signals, PNS1to PNS4, UI [ 5 to 8 ](validated in the remotestate)

B.2.2Output Signals

Command enable outputsignal, CMDENBL, UO [ 1 ]

Fault output signal,FAULT, UO [ 2 ]

Battery alarm outputsignal, BATALM, UO [ 3 ]

Busy output signal,BUSY, UO [ 4 ]


242

This section describes the external specifications of digital and analoginput/output in the R–J3iB Mate controller.

The R–J3iB Mate controller can use up to 512 digital input and outputpoints or an equivalent number of analog input and output points. Oneanalog input/output point uses the resources equivalent to those used by16 digital I/O points. The R–J3iB Mate can use a total of up to 512 I/Opoints.The R–J3iB Mate controller can use the following I/O hardware.- Process I/O printed circuit board- I/O unit model AThe process I/O printed circuit board and the I/O unit model A can be usedtogether.

B.3SPECIFICATIONS OF

DIGITAL

INPUT/OUTPUT

B.3.1Overview

B.3.2Input/Output Hardware

Usable in the R-J3iBMate Controller


243

(1) RDI/RDOThese are signals sent to the connector at the wrist of the robot.They cannot be assigned (redefined) and are fixed.The standard format is six inputs and six outputs. The number ofpoints that can be used for the connector at the wrist depends on theindividual robot.(2) SDI/SDOThe signal No. that is determined at hardware can be changed bysoftware operation.(3) Analog I/OAn analog I/O signal can access the analog I/O port (optional) on theprocess I/O printed circuit board or the I/O port on the analog I/Omodule (used together with the I/O unit model A).It reads and writes the digital value converted from the analog valueof the I/O voltage. It means that the value does not always representthe real I/O voltage.(4) Group I/OGroup I/O is a function which can input or output multiple DI/DOsignals as binary codes.Any number of continuous signals of up to 16 bits can be set for itsuse.It can be set in the menu DETAILS on the group I/O screen.

B.3.3Software

Specifications

C. OPTICAL FIBER CABLE B–81535EN/02APPENDIX

244

COPTICAL FIBER CABLE

The R–J3iB Mate uses fiber optic cables for communication between therobot control board and servo amplifier module and between the servoamplifier module and servo amplifier module. Observe the followingcautions when handling these fiber optic cables.(1) Protection during storageWhen the electrical/optical conversion module (mounted on theprinted) circuit board and the fiber optic cable are not in use, theirmating surfaces must be protected with the lid and caps with whichthey are supplied. If left uncovered, the mating surfaces are likely tobecome dirty, possibly resulting in a poor cable connection.

Electrical/optical conversion module Lid

Fiber optic cable Fiber opticcable caps

Fig.C (a) Protection of electrical/optical conversion module and fiberoptic cable (when not in use)

B–81535EN/02 C. OPTICAL FIBER CABLEAPPENDIX

245

(2) Fiber optic cable Grasp the optical connector firmly when connecting ordisconnecting the cable. Do not pull on the fiber optic cord itself.(The maximum tensile strength between the fiber cord andconnector is 2 kg. Applying greater force to the cord is likely tocause the connector to come off, making the cable unusable.)Fiber optic cord diameter : 2.2 mm 2 cordsTensile strength : Fiber optic cord :7 kg per cordBetween fiber optic cord and connector : 2 kgMinimum bending radius of fiber optic cord :25 mmFlame resistance : Equivalent to UL VW–1Operating temperature : –20 to 70°C

60 max.

8.2

21

6.7 19 max. 35typ.

Code Bush Reinforced cover

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

Afler it is connected, the optical connector is automatically lockedby the lock levers on its top. To remove the connector, release thelock levers and pull the connector. Although optical connectors cannot be connected in other than thecorrect orientation, always take note of the connector’s orientationbefore making the connection. Take care to keep both parts of the optical connector (cable side andPCB side) clean. If they become dirty, wipe them with tissue paperor absorbent cotton to remove dirt. The tissue paper or absorbentcotton may be moistened with ethyl alcohol. Do not use anyorganic solvent other than ethyl alcohol. Do not clamp the uncovered portion of the cable with a nylon band.

IndexB–81535EN/02

i–1

[A]

Adjustment and Checks at Installation, 225Alarm Occurrence Screen, 29ARC Weld Connection Cable (CRW1: Honda Tsushin,34 pins), 219

[B]

Backplane Board (A20B–2003–0330), 117Battery for Memory Backup (3 VDC), 154Block Diagram, 160Block Diagrams of the Power Supply, 126

[C]

Checking the Power Supply Module, 127Checking the Power Supply Unit, 127Circuit Diagram of Emergency Stop, 167Component Functions, 23Configuration, 20Connecting a Cable to a Peripheral Device, 175Connecting the Mechanical Unit and End Effector,197Connection Between the Control Unit and Welder,208Connection Details, 161Connection of Cable for RS–232–C/RS–422, 174Connection of I/O Link Cable, 165Connection of Power Supply Cable, 162Connection of Robot, 172Connection of Teach Pendant Cable, 173Coonection of Servo Amplifier, 171

[D]

Digital I/O Signal Specifications, 193Digital I/O Signal Specifications of End Effector Con-trol Interface, 199Digital I/O Signal Specifications of Peripheral DeviceInterface A, 214Disabling Hand Break, 226

[E]Emergency Stop Board (A20B–1008–0010, –0011),116Emergency Stop Circuit, 167End Effector Interface, 197External Controller Dimensions, 224External Emergency Stop Input, 168External Emergency Stop Output, 169External View of the Controller, 21

[F]FANUC I/O Link, 163

[I]I/O Signal Specifications for Arc–Welding Interface,216I/O Signals, 240Initial Screen Remains on the Teach Pendant, 28Input Signals, 240Input/Output Hardware Usable in the R–J3iB MateController, 242Installation, 223Installation Condition, 225

[L]LED of Power Supply Module, 123LED of Servo Amplifier, 123LED of Servo Amplifier Module, 124

[M]Manual Operation Impossible, 109Mastering, 33

[N]Note at Installation, 226

[O]Operator Safety, 4, 6Optical Fiber Cable, 244

Index B–81535EN/02

i–2

Outline Drawings, 121Output Signals, 241

[P]Peripheral Device and Control Unit Connection, 203Peripheral Device Cable Connector, 195, 220Peripheral Device Interface Block Diagram and Speci-fications, 202Peripheral device interface CRM 79 and CRM 81, 193Peripheral Device Interface Types, 201Peripheral Device Interfaces CRM79 and CRM81,175Peripheral Device, ARC Welding, Interfaces, 201Peripheral interface, 238Position Deviation Found in Return to the ReferencePosition (Positioning), 107Power Cannot be Turned On, 26Power Supply Module PSM (A06B–6115–H001), 121Precautions for Mechanism, 10Precautions for Mechanisms, 11Precautions in Operation, 11Precautions in Programming, 10, 11, 12Preventive Maintenance, 24Printed Circuit Boards, 111Process I/O Board HE (A16B–2203–0764), HF(A16B–2203–0765), 118

[R]Recommended Cables, 196, 221Replacing a Fuse, 147Replacing a Fuse on the Emergency Stop Board, 148Replacing a Fuse on the Robot Control Board, 147Replacing a Relay, 153Replacing a Relay on the Emergency Stop Board, 153Replacing a Unit, 128Replacing Battery, 154Replacing Cards and Modules on the Robot ControlBoard, 133Replacing Servo Amplifiers, 140Replacing the Backplane Board (Unit), 130Replacing the Brake Power Transformer, 137Replacing the Control Section Fan Motor, 142Replacing the Door Fan Unit and Heat Exchanger,144

Replacing the Emergency Stop Board, 132Replacing the Emergency Stop Unit, 138Replacing the Fan Motor of the Servo Amplifier Con-trol Unit, 143Replacing the Fuse on the Door, 149Replacing the Fuse on the Power Supply Module, 150Replacing the Fuse on the Process I/O Boards, 152Replacing the Fuse on the Servo Amplifier Module,151Replacing the Magnetic Contactor, 139Replacing the Operator Panel, 145Replacing the Power Supply Unit, 146Replacing the Printed–Circuit Boards, 129Replacing the Robot Control Board and Printed–Cir-cuit Boards on the Backplane Unit, 131Replacing the Teach Pendant, 141Replacing the Transformer, 137Robot Control Board (A16B–3200–0450), 112

[S]Safety During Maintenance, 9Safety in Maintenance, 13Safety of the End Effector, 12Safety of the Robot Mechanism, 11Safety of the Teach Pendant Operator, 7Safety of the Tools and Peripheral Devices, 10Safety Precautions, 3Safety Signals, 32Servo Amplifier Module (A06B–6114–H205,A06B–6114–H302), 122Servo Amplifiers, 120Setting the Power Supply, 125Signal Types, 239Software Specifications, 243Specifications of Digital Input/Output, 242Specifications of the Cables used for Peripheral De-vices A (CRM2: Honda Tsushin, 50 pins), 219

[T]Teach Pendant Cannot be Turned On, 27Total Connection Diagram, 229Transportation, 223Transportation and Installation, 222Treatment for the Shielded Cable, 200

B–81535EN/02 Index

i–3

Troubleshooting, 25Troubleshooting Based on LED Indications, 97Troubleshooting Using Fuses, 92Troubleshooting Using the Error Code, 35

[V]Vibration Observed During Movement, 108

[W]

Warning Label, 14When the Robot is Connected to the CNC by a Pe-ripheral Device Cable, 176

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Documents

[536]R J3iB Controller