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
FANUC Robotics North America, Inc.
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com
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
FANUC Robotics North America, Inc.
AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL,
KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks,
PalletTool, SOCKETS, SOFT PARTS SpotTool,
TorchMate, and YagTool are Registered Trademarks of FANUC
Robotics.
FANUC Robotics reserves all proprietary rights, including but not
limited to trademark and trade name rights, in the following names:
AccuAir AccuCal AccuChop AccuFlow AccuPath
AccuSeal ARC Mate ARC Mate Sr.  ARC Mate System 1
ARC Mate System 2 ARC Mate System 3 ARC Mate System
4 ARC Mate System 5 ARCWorks Pro AssistTool
AutoNormal AutoTCP BellTool BODYWorks Cal Mate Cell
Finder Center Finder Clean Wall CollisionGuard
DispenseTool F-100 F-200i FabTool FANUC LASER
DRILL Flexibell FlexTool HandlingTool HandlingWorks
INSIGHT INSIGHT II IntelliTrak Integrated Process Solution
Intelligent Assist Device IPC -Integrated Pump Control IPD
Integral Pneumatic Dispenser ISA Integral Servo Applicator ISD
Integral Servo Dispenser Laser Mate System 3 Laser Mate
System 4 LaserPro LaserTool LR Tool MIG Eye
MotionParts NoBots Paint Stick PaintPro PaintTool 100
PAINTWorks PAINTWorks II PAINTWorks III PalletMate
PalletMate PC PalletTool PC PayloadID RecipTool
RemovalTool Robo Chop Robo Spray S-420i S-430i
ShapeGen SoftFloat SOF PARTS SpotTool+ SR Mate
SR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM RJ3 Controller SYSTEM R-J3iB Controller TCP Mate
TurboMove TorchMate visLOC visPRO-3D visTRAC
WebServer WebTP YagTool
Conventions
This manual includes information essential to the safety of
personnel, equipment, software, and data. This information is
indicated by headings and boxes in the text.
WARNING
Information appearing under WARNING concerns the
protection of personnel. It is boxed and in bold type to set it
apart from other text.
CAUTION
Information appearing under CAUTION concerns the protection of
equipment, software, and data. It is boxed to set it apart from
other text.
NOTE Information appearing next to NOTE concerns related information
or useful hints.
Safety
Safety-1
FANUC Robotics is not and does not represent itself as an expert in
safety systems, safety equipment, or the specific safety aspects of
your company and/or its work force. It is the responsibility of the
owner, employer, or user to take all necessary steps to guarantee
the safety of all personnel in the workplace.
The appropriate level of safety for your application and installation
can best be determined by safety system professionals. FANUC
Robotics therefore, recommends that each customer consult with
such professionals in order to provide a workplace that allows for
the safe application, use, and operation of FANUC Robotic systems.
According to the industry standard ANSI/RIA R15.06, the owner or
user is advised to consult the standards to ensure compliance with
its requests for Robotics System design, usability, operation,
maintenance, and service. Additionally, as the owner, employer, or
user of a robotic system, it is your responsibility to arrange for the
training of the operator of a robot system to recognize and respond
to known hazards associated with your robotic system and to be
aware of the recommended operating procedures for your particular
application and robot installation.
FANUC Robotics therefore, recommends that all personnel who
intend to operate, program, repair, or otherwise use the robotics
system be trained in an approved FANUC Robotics training course
and become familiar with the proper operation of the system.
Persons responsible for programming the system–including the
design, implementation, and debugging of application programs–
must be familiar with the recommended programming procedures
for your application and robot installation.
The following guidelines are provided to emphasize the importance
of safety in the workplace.
Safety-2
CONSIDERING
SAFETY FOR YOUR
ROBOT
INSTALLATION
Safety is essential whenever robots are used. Keep in mind the
following factors with regard to safety:
•
•
•
•
•
•
Keeping People and
Equipment Safe
The safety of people is always of primary importance in any
situation. However, equipment must be kept safe, too. When
prioritizing how to apply safety to your robotic system, consider the
following:
•
•
•
•
•
Using Safety
Enhancing Devices
People
External devices
Robot(s)
Tooling
Workpiece
Always give appropriate attention to the work area that surrounds
the robot. The safety of the work area can be enhanced by the
installation of some or all of the following devices:
•
•
•
•
•
•
•
•
•
Setting Up a Safe
Workcell
The safety of people and equipment
Use of safety enhancing devices
Techniques for safe teaching and manual operation of the
robot(s)
Techniques for safe automatic operation of the robot(s)
Regular scheduled inspection of the robot and workcell
Proper maintenance of the robot
Safety fences, barriers, or chains
Light curtains
Interlocks
Pressure mats
Floor markings
Warning lights
Mechanical stops
EMERGENCY STOP buttons
DEADMAN switches
A safe workcell is essential to protect people and equipment.
Observe the following guidelines to ensure that the workcell is set
up safely. These suggestions are intended to supplement and not
replace existing federal, state, and local laws, regulations, and
guidelines that pertain to safety.
•
Sponsor your personnel for training in approved FANUC
Robotics training course(s) related to your application. Never
permit untrained personnel to operate the robots.
Safety-3
•
Install a lockout device that uses an access code to prevent
unauthorized persons from operating the robot.
•
Use anti–tie–down logic to prevent the operator from bypassing
safety measures.
•
Arrange the workcell so the operator faces the workcell and can
see what is going on inside the cell.
•
Clearly identify the work envelope of each robot in the system
with floor markings, signs, and special barriers. The work
envelope is the area defined by the maximum motion range of
the robot, including any tooling attached to the wrist flange that
extend this range.
•
Position all controllers outside the robot work envelope.
•
Never rely on software as the primary safety element.
•
Mount an adequate number of EMERGENCY STOP buttons or
switches within easy reach of the operator and at critical points
inside and around the outside of the workcell.
•
Install flashing lights and/or audible warning devices that
activate whenever the robot is operating, that is, whenever
power is applied to the servo drive system. Audible warning
devices shall exceed the ambient noise level at the end–use
application.
•
Wherever possible, install safety fences to protect against
unauthorized entry by personnel into the work envelope.
•
Install special guarding that prevents the operator from reaching
into restricted areas of the work envelope.
•
Use interlocks.
•
Use presence or proximity sensing devices such as light
curtains, mats, and capacitance and vision systems to enhance
safety.
•
Periodically check the safety joints or safety clutches that can be
optionally installed between the robot wrist flange and tooling. If
the tooling strikes an object, these devices dislodge, remove
power from the system, and help to minimize damage to the
tooling and robot.
Safety-4
Staying Safe While
Teaching or Manually
Operating the Robot
•
Make sure all external devices are properly filtered, grounded,
shielded, and suppressed to prevent hazardous motion due to
the effects of electro–magnetic interference (EMI), radio
frequency interference (RFI), and electro–static discharge
(ESD).
•
Make provisions for power lockout/tagout at the controller.
•
Eliminate pinch points. Pinch points are areas where personnel
could get trapped between a moving robot and other equipment.
•
Provide enough room inside the workcell to permit personnel to
teach the robot and perform maintenance safely.
•
Program the robot to load and unload material safely.
•
If high voltage electrostatics are present, be sure to provide
appropriate interlocks, warning, and beacons.
•
If materials are being applied at dangerously high pressure,
provide electrical interlocks for lockout of material flow and
pressure.
Advise all personnel who must teach the robot or otherwise
manually operate the robot to observe the following rules:
•
•
•
•
•
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
Know whether or not you are using an intrinsically safe teach
pendant if you are working in a hazardous environment.
Before teaching, visually inspect the robot and work envelope to
make sure that no potentially hazardous conditions exist. The
work envelope is the area defined by the maximum motion
range of the robot. These include tooling attached to the wrist
flange that extends this range.
The area near the robot must be clean and free of oil, water, or
debris. Immediately report unsafe working conditions to the
supervisor or safety department.
FANUC Robotics recommends that no one enter the work
envelope of a robot that is on, except for robot teaching
operations. However, if you must enter the work envelope, be
sure all safeguards are in place, check the teach pendant
DEADMAN switch for proper operation, and place the robot in
teach mode. Take the teach pendant with you, turn it on, and be
prepared to release the DEADMAN switch. Only the person
with the teach pendant should be in the work envelope.
Safety-5
WARNING
Never bypass, strap, or otherwise deactivate a safety device,
such as a limit 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.
-
•
Staying Safe During
Automatic Operation
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.
Safety-6
Staying Safe During
Inspection
Staying Safe During
Maintenance
•
Never enter or allow others to enter the work envelope during
automatic operation of the robot.
•
Know the location and status of all switches, sensors, and
control signals that could cause the robot to move.
•
Know where the EMERGENCY STOP buttons are located on
both the robot control and external control devices. Be prepared
to press these buttons in an emergency.
•
Never assume that a program is complete if the robot is not
moving. The robot could be waiting for an input signal that will
permit it to continue activity.
•
If the robot is running in a pattern, do not assume it will continue
to run in the same pattern.
•
Never try to stop the robot, or break its motion, with your body.
The only way to stop robot motion immediately is to press an
EMERGENCY STOP button located on the controller panel,
teach pendant, or emergency stop stations around the workcell.
When inspecting the robot, be sure to
•
Turn off power at the controller.
•
Lock out and tag out the power source at the controller
according to the policies of your plant.
•
Turn off the compressed air source and relieve the air pressure.
•
If robot motion is not needed for inspecting the electrical circuits,
press the EMERGENCY STOP button on the operator panel.
•
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
•
If power is needed to check the robot motion or electrical
circuits, be prepared to press the EMERGENCY STOP button,
in an emergency.
•
Be aware that when you remove a servomotor or brake, the
associated robot arm will fall if it is not supported or resting on a
hard stop. Support the arm on a solid support before you
release the brake.
When performing maintenance on your robot system, observe the
following rules:
Safety-7
•
Never enter the work envelope while the robot or a program is in
operation.
•
Before entering the work envelope, visually inspect the workcell
to make sure no potentially hazardous conditions exist.
•
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
•
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.
KEEPING MACHINE
TOOLS AND
EXTERNAL
DEVICES SAFE
Certain programming and mechanical measures are useful in
keeping the machine tools and other external devices safe. Some
of these measures are outlined below. Make sure you know all
associated measures for safe use of such devices.
Programming Safety
Precautions
Implement the following programming safety measures to prevent
damage to machine tools and other external devices.
Safety-9
Mechanical Safety
Precautions
•
Back–check limit switches in the workcell to make sure they do
not fail.
•
Implement ‘‘failure routines” in programs that will provide
appropriate robot actions if an external device or another robot
in the workcell fails.
•
Use handshaking protocol to synchronize robot and external
device operations.
•
Program the robot to check the condition of all external devices
during an operating cycle.
Implement the following mechanical safety measures to prevent
damage to machine tools and other external devices.
•
Make sure the workcell is clean and free of oil, water, and
debris.
•
Use software limits, limit switches, and mechanical hardstops to
prevent undesired movement of the robot into the work area of
machine tools and external devices.
KEEPING THE
ROBOT SAFE
Observe the following operating and programming guidelines to
prevent damage to the robot.
Operating Safety
Precautions
The following measures are designed to prevent damage to the
robot during operation.
Programming Safety
Precautions
•
Use a low override speed to increase your control over the robot
when jogging the robot.
•
Visualize the movement the robot will make before you press
the jog keys on the teach pendant.
•
Make sure the work envelope is clean and free of oil, water, or
debris.
•
Use circuit breakers to guard against electrical overload.
The following safety measures are designed to prevent damage to
the robot during programming:
•
Establish interference zones to prevent collisions when two or
more robots share a work area.
Safety-10
•
Make sure that the program ends with the robot near or at the
home position.
•
Be aware of signals or other operations that could trigger
operation of tooling resulting in personal injury or equipment
damage.
•
In dispensing applications, be aware of all safety guidelines with
respect to the dispensing materials.
NOTE Any deviation from the methods and safety practices
described in this manual must conform to the approved standards of
your company. If you have questions, see your supervisor.
ADDITIONAL
SAFETY
CONSIDERATIONS
FOR PAINT ROBOT
INSTALLATIONS
Process technicians are sometimes required to enter the paint
booth, for example, during daily or routine calibration or while
teaching new paths to a robot. Maintenance personal also must
work inside the paint booth periodically.
Whenever personnel are working inside the paint booth, ventilation
equipment must be used. Instruction on the proper use of
ventilating equipment usually is provided by the paint shop
supervisor.
Although paint booth hazards have been minimized, potential
dangers still exist. Therefore, today’s highly automated paint booth
requires that process and maintenance personnel have full
awareness of the system and its capabilities. They must
understand the interaction that occurs between the vehicle moving
along the conveyor and the robot(s), hood/deck and door opening
devices, and high–voltage electrostatic tools.
Paint robots are operated in three modes:
• Teach or manual mode
• Automatic mode, including automatic and exercise operation
• Diagnostic mode
During both teach and automatic modes, the robots in the paint
booth will follow a predetermined pattern of movements. In teach
mode, the process technician teaches (programs) paint paths using
the teach pendant.
In automatic mode, robot operation is initiated at the System
Operator Console (SOC) or Manual Control Panel (MCP), if
available, and can be monitored from outside the paint booth. All
personnel must remain outside of the booth or in a designated safe
Safety-11
area within the booth whenever automatic mode is initiated at the
SOC or MCP.
In automatic mode, the robots will execute the path movements they
were taught during teach mode, but generally at production speeds.
When process and maintenance personnel run diagnostic routines
that require them to remain in the paint booth, they must stay in a
designated safe area.
Paint System Safety
Features
Process technicians and maintenance personnel must become
totally familiar with the equipment and its capabilities. To minimize
the risk of injury when working near robots and related equipment,
personnel must comply strictly with the procedures in the manuals.
This section provides information about the safety features that are
included in the paint system and also explains the way the robot
interacts with other equipment in the system.
The paint system includes the following safety features:
•
Most paint booths have red warning beacons that illuminate
when the robots are armed and ready to paint. Your booth
might have other kinds of indicators. Learn what these are.
•
Some paint booths have a blue beacon that, when illuminated,
indicates that the electrostatic devices are enabled. Your booth
might have other kinds of indicators. Learn what these are.
•
EMERGENCY STOP buttons are located on the robot controller
and teach pendant. Become familiar with the locations of all E–
STOP buttons.
•
An intrinsically safe teach pendant is used when teaching in
hazardous paint atmospheres.
•
A DEADMAN switch is located on each teach pendant. When this
switch is held in, and the teach pendant is on, power is applied to the
robot servo system. If the engaged DEADMAN switch is released
during robot operation, power is removed from the servo system, all
axis brakes are applied, and the robot comes to an EMERGENCY
STOP. Safety interlocks within the system might also E–STOP other
robots.
WARNING
An EMERGENCY STOP will occur if the DEADMAN switch is
released on a bypassed robot.
Safety-12
•
Overtravel by robot axes is prevented by software limits. All of
the major and minor axes are governed by software limits. Limit
switches and hardstops also limit travel by the major axes.
•
EMERGENCY STOP limit switches and photoelectric eyes
might be part of your system. Limit switches, located on the
entrance/exit doors of each booth, will EMERGENCY STOP all
equipment in the booth if a door is opened while the system is
operating in automatic or manual mode. For some systems,
signals to these switches are inactive when the switch on the
SCC is in teach mode.
When present, photoelectric eyes are sometimes used to
monitor unauthorized intrusion through the entrance/exit
silhouette openings.
•
Staying Safe While
Operating the Paint
Robot
System status is monitored by computer. Severe conditions
result in automatic system shutdown.
When you work in or near the paint booth, observe the following
rules, in addition to all rules for safe operation that apply to all robot
systems.
WARNING
Observe all safety rules and guidelines to avoid 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.
Safety-13
Staying Safe While
Operating Paint
Application Equipment
•
Know the location and status of all switches, sensors, and/or
control signals that might cause the robot, conveyor, and
opening devices to move.
•
Make sure that the work area near the robot is clean and free of
water, oil, and debris. Report unsafe conditions to your
supervisor.
•
Become familiar with the complete task the robot will perform
BEFORE starting automatic mode.
•
Make sure all personnel are outside the paint booth before you
turn on power to the robot servo system.
•
Never enter the work envelope or paint booth before you turn off
power to the robot servo system.
•
Never enter the work envelope during automatic operation
unless a safe area has been designated.
•
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
•
Remove all metallic objects, such as rings, watches, and belts,
before entering a booth when the electrostatic devices are
enabled.
•
Stay out of areas where you might get trapped between a
moving robot, conveyor, or opening device and another object.
•
Be aware of signals and/or operations that could result in the
triggering of guns or bells.
•
Be aware of all safety precautions when dispensing of paint is
required.
•
Follow the procedures described in this manual.
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.
Safety-14
Staying Safe During
Maintenance
•
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.
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 Section
Single Phase Power Option
Table of Contents
B–81535EN/02
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p–1
I SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
OPERATOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.1
1.1.2
1.1.3
1.2
SAFETY OF THE TOOLS AND PERIPHERAL DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.1
1.2.2
1.3
Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY OF THE ROBOT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1
1.3.2
1.3.3
1.4
Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety of the Teach Pendant Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions in Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY OF THE END EFFECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.1
Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
6
7
9
10
10
10
11
11
11
11
12
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1
3.1.2
3.2
Teach Pendant Cannot be Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Screen Remains on the Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALARM OCCURRENCE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
27
28
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
c–1
Table of Contents
B–81535EN/02
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1
5.1.2
5.2
Power Supply Module PSM (A06B–6115–H001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servo Amplifier Module (A06B–6114–H205, A06B–6114–H302) . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1
5.2.2
LED of Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED of Servo Amplifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
121
121
122
123
123
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1
7.1.2
7.1.3
Replacing the Backplane Board (Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit . . . . . . . . . . .
Replacing the Emergency Stop Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
130
131
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
7.13.2
7.13.3
7.13.4
7.13.5
7.13.6
7.14
REPLACING A RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.14.1
7.15
Replacing a Fuse on the Robot Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Fuse on the Emergency Stop Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fuse on the Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fuse on the Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fuse on the Servo Amplifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fuse on the Process I/O Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Relay on the Emergency Stop Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.15.1
Battery for Memory Backup (3 VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c–2
147
148
149
150
151
152
153
153
154
154
Table of Contents
B–81535EN/02
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
3.4.2
3.4.3
3.4.4
Circuit Diagram of Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Emergency Stop Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Emergency Stop Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External 24 V Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
167
168
169
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
CONNECTING A CABLE TO A PERIPHERAL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
175
3.9
3.9.1
3.9.2
3.9.3
3.9.4
3.9.5
3.10
END EFFECTOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.1
3.10.2
3.11
3.12
Peripheral Device Interfaces CRM79 and CRM81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
When the Robot is Connected to the CNC by a Peripheral Device Cable . . . . . . . . . . . . . . . . . . . . . . .
Digital I/O Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9.3.1 Peripheral device interface CRM 79 and CRM 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital I/O Signal Specifications of End Effector Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . .
175
176
193
193
195
196
197
197
199
TREATMENT FOR THE SHIELDED CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
200
PERIPHERAL DEVICE, ARC WELDING, INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201
3.12.1
3.12.2
3.12.3
3.12.4
3.12.5
3.12.6
3.12.7
3.12.8
3.12.9
3.12.10
Peripheral Device Interface Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Peripheral Device Interface Block Diagram and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection Between the Control Unit and Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital I/O Signal Specifications of Peripheral Device Interface A . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Signal Specifications for ARC–Welding Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin, 50 pins) . . . . . .
ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201
202
203
208
214
216
219
219
220
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
c–3
Table of Contents
4.7
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DISABLING HAND BREAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
226
APPENDIX
A. TOTAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
B. PERIPHERAL INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
B.1
B.2
SIGNAL TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
239
I/O SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
240
B.2.1
B.2.2
B.3
Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS OF DIGITAL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.3.1
B.3.2
B.3.3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input/Output Hardware Usable in the R-J3iB Mate Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
240
241
242
242
242
243
C. OPTICAL FIBER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
c–4
B–81535EN/02
PREFACE
PREFACE
This manual describes the following models.
Model
Abbreviation
FANUC Robot LR Mate 100iB
LR Mate 100iB
FANUC Robot LR Mate 200iB
LR Mate 200iB
FANUC Robot ARC Mate 50iB
ARC Mate 50iB
p–1
I SAFETY PRECAUTIONS
B–81535EN/02
1
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety precautions
when operating a robot and its peripheral devices installed in a work cell.
3
1. SAFETY PRECAUTIONS
1.1
OPERATOR SAFETY
SAFETY PRECAUTIONS
B–81535EN/02
Operator safety is the primary safety consideration. Because it is very
dangerous to enter the operating space of the robot during automatic
operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration
must be made to ensure operator safety.
(1) Have the robot system operators attend the training courses held by
FANUC.
FANUC provides various training courses. Contact our sales office for details.
(2) Even when the robot is stationary, it is possible that the robot is still
ready to move state and is waiting for a signal. In this state, the robot
is regarded as still in motion. To ensure operator safety, provide the
system with an alarm to indicate visually or aurally that the robot is
in motion.
(3) Install a safety fence with a gate so that no operator can enter the work
area without passing through the gate. Equip the gate with an
interlock that stops the robot when the gate is opened.
The controller is designed to receive this interlock signal. When the gate is
opened and this signal received, the controller stops the robot in an emergency.
For connection, see Fig.1.1.
(4) Provide the peripheral devices with appropriate grounding (Class 1,
Class 2, or Class 3).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot
motion, including the tools such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an
interlock to a visual or aural alarm that stops the robot when an
operator enters the work area.
(8) If necessary, install a safety lock so that no one except the operator
in charge can turn on the power of the robot.
The circuit breaker installed in the controller is designed to disable anyone from
turning it on when it is locked with a padlock.
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SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
(9) When adjusting each peripheral device independently, be sure to turn
off the power of the robot.
Safety gate which executes with opening the door.
Fig.1.1 Safety Fence and Safety Gate
5
1. SAFETY PRECAUTIONS
1.1.1
Operator Safety
SAFETY PRECAUTIONS
B–81535EN/02
The operator is a person who operates the robot system. In this sense, a
worker who operates the teach pendant is also an operator. However, this
section does not apply to teach pendant operators.
(1) If it is not necessary for the robot to operate, turn off the power of the
robot controller or press the EMERGENCY STOP button, and then
proceed with necessary work.
(2) Operate the robot system at a location outside the work area.
(3) Install a safety fence with a safety gate to prevent any worker other
than the operator from entering the work area unexpectedly and also
to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator’s reach.
The robot controller is designed to be connected to an external EMERGENCY
STOP button. With this connection, the controller stops the robot operation
when the external EMERGENCY STOP button is pressed. See the diagram
below for connection.
External EMERGENCY STOP button
Emergency stop board
EMGIN11
EMGIN12
EMGIN21
EMGIN22
Note)
Connect between EMGIN1 and EMGIN2 and between EMGIN21 and EMGIN22.
EMGIN11, EMGIN12, EMGIN21 and EMGIN22 are on the emergency stop
board.
Fig.1.1.1 Connection Diagram for External Emergency Stop Switch
6
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1.1.2
Safety of the Teach
Pendant Operator
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
While teaching the robot, it is necessary for the operator to enter the work
area of the robot. It is particularly necessary to ensure the safety of the
teach pendant operator.
(1) Unless it is specifically necessary to enter the robot work area, carry
out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral
devices are all in the normal operating condition.
(3) When entering the robot work area and teaching the robot, be sure to
check the location and condition of the safety devices (such as the
EMERGENCY STOP button and the deadman switch on the teach
pendant).
FANUC’s teach pendant has a switch for enabling or disabling the robot operation from the teach pendant and a deadman switch in addition to the EMERGENCY STOP button. The switches function as follows.
EMERGENCY STOP button : Pressing this button always brings the robot
to an emergency stop, irrespective of the
state of the enable/disable switch and the
mode switch of operator panel.
Deadman switch
: The function of this switch depends on the
state of the enable/disable switch and the
mode 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 is
in the enable position
– Releasing the deadman switch brings the
robot to an emergency stop.
When the mode switch is in the TI position and the enable/disable switch is
in the disable position
– The robot is brought to an emergency stop
regardless of the operation of the deadman
switch.
Note)The deadman switch is provided to bring the robot to an emergency
stop when the operator releases the teach pendant in an emergency.
(4) The teach pendant operator should pay careful attention so that no
other 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.
7
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B–81535EN/02
(5) When entering the robot work area, the teach pendant operator should
enable the teach pendant whenever he or she enters the robot work
area. In particular, while the teach pendant enable switch is off, make
certain that no start command is sent to the robot from any operator
panel other than the teach pendant.
The teach pendant, operator panel, and peripheral device interface send each
robot start signal. However the validity of each signal changes as follows depending on the mode of the teach pendant enable switch and the mode switch
the remote switch on the operator panel.
Operator panel
mode switch
Teach pendant
enable switch
Remote
condition
Teach
pendant
Operator panel
Peripheral
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 according
to the procedure below.
(a) Run the program for at least one operation cycle in the single step
mode at low speed.
(b) Run the program for at least one operation cycle in the continuous
operation mode at low speed.
(c) Run the program for one operation cycle in the continuous
operation mode at the intermediate speed and check that no
abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous
operation mode at the normal operating speed and check that the
system operates automatically without trouble.
(e) After checking the completeness of the program through the test
run above, execute it in the automatic operation mode.
(7) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.
8
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1.1.3
Safety During
Maintenance
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
For the safety of maintenance personnel, pay utmost attention to the
following.
(1) Except when specifically necessary, turn off the power of the
controller while carrying out maintenance. Lock the power switch,
if necessary, so that no other person can turn it on.
(2) When disconnecting the pneumatic system, be sure to reduce the
supply pressure.
(3) Before the start of teaching, check that the robot and its peripheral
devices are all in the normal operating condition.
(4) If it is necessary to enter the robot work area for maintenance when
the power is turned on, the worker should indicate that the machine
is being serviced and make certain that no one starts the robot
unexpectedly.
(5) Do not operate the robot in the automatic mode while anybody is in
the robot work area.
(6) When it is necessary to maintain the robot alongside a wall or
instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.
(7) When a tool is mounted on the robot, or when any moving device
other than the robot is installed, such as belt conveyor, pay careful
attention to its motion.
(8) If necessary, have a worker who is familiar with the robot system
stand beside the operator panel and observe the work being
performed. If any danger arises, the worker should be ready to press
the EMERGENCY STOP button at any time.
(9) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
(10) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and also turn
off the circuit breaker to protect against electric shock.
(11) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified ratings.
They may cause a fire or result in damage to the components in the
controller.
9
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B–81535EN/02
1.2
SAFETY OF THE
TOOLS AND
PERIPHERAL
DEVICES
1.2.1
Precautions in
Programming
(1) Use a limit switch or other sensor to detect a dangerous condition and,
if necessary, design the program to stop the robot when the sensor
signal is received.
(2) Design the program to stop the robot when an abnormal condition
occurs in any other robots or peripheral devices, even though the
robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in
synchronous motion, particular care must be taken in programming
so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral
devices so that the robot can detect the states of all devices in the
system and can be stopped according to the states.
1.2.2
Precautions for
Mechanism
(1) Keep the component cells of the robot system clean, and operate the
robot in an environment free of grease, water, and dust.
(2) Employ a limit switch or mechanical stopper to limit the robot motion
so that the robot does not come into contact with its peripheral devices
or tools.
10
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SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
1.3
SAFETY OF THE
ROBOT MECHANISM
1.3.1
Precautions in
Operation
1.3.2
Precautions in
Programming
1.3.3
Precautions for
Mechanisms
(1) When operating the robot in the jog mode, set it at an appropriate
speed so that the operator can manage the robot in any eventuality.
(2) Before pressing the jog key, be sure you know in advance what
motion the robot will perform in the jog mode.
(1) When the work areas of robots overlap, make certain that the motions
of the robots do not interfere with each other.
(2) Be sure to specify the predetermined work origin in a motion program
for the robot and program the motion so that it starts from the origin
and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance that
the robot motion has terminated.
(1) Keep the work area of the robot clean, and operate the robot in an
environment free of grease, water, and dust.
11
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B–81535EN/02
1.4
SAFETY OF THE END
EFFECTOR
1.4.1
Precautions in
Programming
(1) To control the pneumatic, hydraulic and electric actuators, carefully
consider the necessary time delay after issuing each control command
up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot
system by monitoring the state of the end effector.
12
B–81535EN/02
1.5
SAFETY IN
MAINTENANCE
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
(1) Never enter the robot work area while the robot is operating. Turn off
the power before entering the robot work area for inspection and
maintenance.
(2) If it is necessary to enter the robot work area with the power turned
on, first press the EMERGENCY STOP button on the operator panel.
(3) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
When replacing the parts in the pneumatic system, be sure to reduce
the pressure in the piping to zero by turning the pressure control on
the air regulator.
(4) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and turn off the
circuit breaker to protect against electric shock.
(5) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified ratings.
They may cause a fire or result in damage to the components in the
controller.
(6) Before restarting the robot, be sure to check that no one is in the robot
work area and that the robot and its peripheral devices are all in the
normal operating state.
13
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B–81535EN/02
1.6
WARNING LABEL
Description
Do not step on or climb the robot or controller as it may adversely affect
the robot or controller and you may get hurt if you lose your footing as
well.
(1) Step–on prohibitive label
Fig.1.6 (a) Step–on Prohibitive Label
Description
Be cautious about a section where this label is affixed, as the section
generates heat. If you have to inevitably touch such a section when it is
hot, use a protective provision such as heat–resistant gloves.
(2) High–temperature warning label
Fig.1.6 (b) High–Temperature Warning Label
Description
A high voltage is applied to the places where this label is attached.
Before starting maintenance, turn the power to the control unit off, then
turn the circuit breaker off to avoid electric shock hazards. Be careful with
servo amplifier and other units because high–voltage places in these units
may remain in the high–voltage state for a fixed time.
14
B–81535EN/02
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
(3) High–voltage warning label
Fig.1.6 (c) High–Voltage Warning Label
Description
There may be a high voltage in a place with this label. Before working
on such a portion, turn off the power to the controller and set its circuit
breaker to the off position to avoid shock hazards.
In addition, be careful about servo amplifiers and other electric circuits
because a high voltage may remain in them for a certain period of time
after the power is turned off.
15
II MAINTENANCE
MAINTENANCE
B–81535EN/02
1
1. OVERVIEW
OVERVIEW
This manual describes the maintenance and connection of the R–J3iB
Mate robot controller (called the R–J3iB Mate).
Maintenance Part : Troubleshooting, and the setting, adjustment,
and replacement of units
Connection Part : Connection of the R–J3iB Mate controller to the
robot mechanical unit and peripheral devices,
and installation of the controller
WARNING
Before you enter the robot working area, be sure to turn off
the power to the controller or press the EMERGENCY
STOP button on the operator panel or teach pendant.
Otherwise, you could injure personnel or damage
equipment.
TERM
The R–J3iB Mate robot controller uses the FANUC servo
amplifier 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 “servo
amplifier module” refer to the individual modules. The term
“servo amplifier” refers to the combination of the power
supply module and servo amplifier module.
19
2. CONFIGURATION
2
MAINTENANCE
CONFIGURATION
20
B–81535EN/02
B–81535EN/02
2.1
EXTERNAL VIEW OF
THE CONTROLLER
2. CONFIGURATION
MAINTENANCE
The appearance and components might slightly differ depending on the
controlled 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
R–J3iB Mate controller
Operator
panel
Teach pendant cable
Fan unit
Fig.2.1 (a) External View of the R–J3iB Mate Controller
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2. CONFIGURATION
MAINTENANCE
B–81535EN/02
Teach pendant
Power supply transformer
Enable/disable switch
Emergency stop
for brake
button
Emergency stop unit
Power supply unit
Emergency stop board
Circuit protector
Emergency stop
button
Heat exchange
Mode
switch
Back plane board
Option slot (Process I/O board)
Robot control board
Servo amplifier module2 (AMP2)
Servo amplifier module1 (AMP1)
Power supply module (PSM)
Fuse
MCC
Fig.2.1 (b) R–J3iB Mate interior (Front)
Table 2.1 Servo amplifier specifications
Robot
LR Mate 100iB
LR Mate 200iB
ARC Mate 50iB
Power supply module
A06B–6115–H001
(αPSMR–1i)
Servo amplifier module1
A06B–6114–H205
(αSVM–20/20i)
L
M
J1
J2
A06B–6114–H302
(αSVM–10/10/10i)
L
M
N
J1
J2
J3
A06B–6115–H001
(αPSMR–1i)
22
Servo amplifier module2
A06B–6114–H302
(αSVM–10/10/10i)
L
M
N
J3
J4
J5
A06B–6114–H302
(αSVM–10/10/10i)
L
M
N
J4
J5
J6
MAINTENANCE
B–81535EN/02
2.2
COMPONENT
FUNCTIONS
2. CONFIGURATION
– Robot control printed circuit board
This board is equipped with a microprocessor and its peripheral
circuitry, memory, and operator panel control circuit. A servo control
circuit is also included.
– Emergency stop unit, emergency stop printed circuit board
This unit controls the emergency stop system, magnetic contactor
(MCC) of the servo amplifier, and brake. The unit contains the power
supply unit for converting the AC power to the DC power.
– Backplane board
–
–
–
–
–
–
Various control boards are mounted on the backplane board.
Teach pendant
This unit is used to carry out all operations including robot
programming. The liquid crystal display (LCD) of this unit displays
the status of the control unit, data, and the like.
Servo amplifier
The servo amplifier amplifies the power of the servo amplifier and
controls the pulse coder.
MCC
The MCC controls the main power of the servo amplifier.
Operator panel
The operator panel has a port for the serial interface to an external
device. The panel also has an EMERGENCY STOP button.
Fan unit, heat exchanger
These components are used to cool the inside of the control unit.
Circuit protector
This component turns on or off the power.
The input power is connected to the circuit protector in order to
protect the equipment from a large current that could result from a
problem in the electric system of the control unit or an abnormal input
power.
23
2. CONFIGURATION
2.3
PREVENTIVE
MAINTENANCE
MAINTENANCE
B–81535EN/02
Daily maintenance and periodic maintenance/inspection ensure reliable
robot performance for extended periods of time.
(1) Daily maintenance
Before operating the system each day, clean each part of the system
and check the system parts for any damage or cracks. Also check the
following:
(a) Before service operation
Check the cable connected to the teach pendant for excessive
twisting. Check the controller and peripheral devices for
abnormalities.
(b) After service operation
At the end of service operation, return the robot to the specified
position, then turn off the controller. Clean each part, and check
for any damage or cracks. If the ventilation port of the controller
is dusty, clean it.
(c) Check after one month
Check that the fan is rotating normally. If the fan has dirt and dust
built up, clean the fan according to step (d) described below for
inspection to be performed every 6 months.
(d) Periodic inspection performed every six months
Remove the top cover, louver, and back panel (if possible), then
remove any dirt and dust from the inside of the transformer
compartment. Wipe off dirt and dust from the fan and
transformer.
(2) Maintenance tools
The following maintenance tools are recommended:
(a) Measuring instruments
AC/DC voltmeter (A digital voltmeter is sometimes required.)
Oscilloscope with a frequency range of 5 MHz or higher, two
channels
(b) Tools
Phillips screwdrivers : Large, medium, and small
Standard screwdrivers: Large, medium, and small
Nut driver set (Metric)
Pliers
Needle-nose pliers
Diagonal cutting pliers
24
MAINTENANCE
B–81535EN/02
3
3. TROUBLESHOOTING
TROUBLESHOOTING
This chapter describes the checking method and corrective action for each
error code indicated if a hardware alarm occurs. Refer to the operator’s
manual to release program alarms.
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3. TROUBLESHOOTING
MAINTENANCE
B–81535EN/02
3.1
POWER CANNOT BE
TURNED ON
Check and Corrective action
(Check 1)
Check that the circuit protector is on and
has not tripped.
(Corrective
action)
Turn on the circuit protector.
(Check 2)
Check that the door fan unit and the fan
motor of the heat exchanger are rotating
and that the LED indication on the power
supply module is “–”.
(Corrective
action)
If the fan motor is not rotating or if the
LED of the power supply module is not
glowing, the fuse on the back of the door
may have been blown.
– Check the fuse on the back of the
door.
If the fuse on the back of the door has
been blown, replace the fuse.
Figure
Circuit protector
(on/off switch)
LED of the power supply module
Circuit protector
Heat exchange for
fan unit (door face)
Secondary side of the circuit protector
Fuse
26
B–81535EN/02
3. TROUBLESHOOTING
MAINTENANCE
3.1.1
Teach Pendant Cannot
be Turned On
Check and Corrective action
(Check 1)
Check the LCD display and LED indication on the teach pendant.
(Corrective
action)
Check the LCD display and LED indication on the teach pendant to see whether
the emergency stop unit is faulty.
– Check whether the fuse FUS4 on the
emergency stop board is blown. If the
fuse is blown, the FALM LED glows.
Replace the blown fuse.
– If the fuse FUS4 on the emergency
stop board is not blown, the emergency stop unit may be faulty. Replace
the emergency stop unit.
Figure
Teach pendant
Emergency stop board
FALM LED
Fuse FUS4
Emergency stop unit
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3. TROUBLESHOOTING
MAINTENANCE
B–81535EN/02
3.1.2
Initial Screen Remains
on the Teach Pendant
Check and Corrective action
(Check 1)
Check that the “.” portion of the seven–
segment LED glows on the robot control
board.
(Corrective
action)
If the “.” portion is not glowing, the fuse
FUS1 on the robot control board may be
blown. Alternatively, the DC/DC converter module may be damaged.
If the FUSE ALARM LED is glowing, the
fuse FUS1 may be blown.
The fuse FUS1 is provided on the robot
control 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).
(Corrective
action(1))
(Corrective
action(2))
Figure
+24V input
connector
CP5
Cause of the blowing of the fuse FUS1
and corrective action
a) Check whether the device which is
connected to the RS–232–C/
RS–422 port and requires the power
supply of +24 V is sound.
b) Problem in the DC/DC converter
module
If the DC/DC converter module gets
faulty in the short–circuit mode,
FUS1 is blown.
Replace the DC/DC converter module.
DC/DC converter
module
dot part of seven
segment LED
a) Problem in the DC/DC converter
module
Replace the DC/DC converter module.
b) Problem in the robot control board
Replace the robot control board.
(For the LED indications, see Section
3.7, “TROUBLESHOOTING USING
LEDS.”)
FUS1 7.5A
DC24V input fuse
28
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3.2
ALARM
OCCURRENCE
SCREEN
3. TROUBLESHOOTING
MAINTENANCE
The alarm occurrence screen displays only the alarm conditions that are
currently active. If an alarm reset signal is input to reset the alarm
conditions, the alarm occurrence screen displays the message “PAUSE or
more serious alarm has not occurred.”
The alarm occurrence screen displays only the alarm conditions (if any)
that occur after the most recently entered alarm reset signal. To erase all
alarm displays from the alarm occurrence screen. Press the CLEAR key
(+ shift) on the alarm history screen.
The alarm occurrence screen is intended to display PAUSE or more
serious alarms. It will not display WARN, NONE, or a reset. It is possible
to disable PAUSE and some of more serious alarms from being displayed
by setting the $ER_NOHIS system variable appropriately.
If two or more alarms have occurred, the display begins with the most
recent alarm.
Up to 100 lines can be displayed.
If an alarm has a cause code, it is displayed below the line indicating the
alarm.
Press the screen
selection key to select
[4 ALARM].
Press the alarm key.
Automatic alarm display
upon occurrence
Alarm occurrence screen display
Press F3 [ACTIVE].
Press F3 [HIST].
Alarm history screen display
Fig.3.2 Alarm Occurrence Screen and Alarm History Screen Display
Procedure
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3. TROUBLESHOOTING
MAINTENANCE
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Displaying the alarm history/alarm detail information
Step
(1) Press the MENUS key to display the screen menu.
(2) Select [ALARM].
You will see a screen similar to the following
3
4 ALARM
5 I/O
INTP–224 (SAMPLE1, 7) Jump label is fail
MEMO–027 Specified line does not exist
Alarm
JOINT 30 %
1/25
1 INTP–224 (SAMPLE1, 7) Jump label is
2 SRVO–002 Teach pendant E–stop
3 R E S E T
4 SRVO–027 Robot not mastered(Group:1)
5 SYST–026 System normal power up
MENUS
[ TYPE ]
CLEAR
HELP
NOTE
The latest alarm is assigned number 1. To view messages
that are currently not on the screen, press the F5, HELP,
then press the right arrow key.
(3) To display the alarm detail screen, press F5, [HELP].
CLEAR
HELP
F5
INTP–224 (SAMPLE1, 7) Jump label is fail
INTP–224 (SAMPLE1, 7) Jump label is fail
MEMO–027 Specified line does not exist
30–MAY–44 07:15
STOP.L
00000110
Alarm
1/25
1 INTP–224 (SAMPLE1, 7) Jump label is
2 SRVO–002 Teach pendant E–stop
[ TYPE ]
CLEAR
HELP
(4) To return to the alarm history screen, press the PREV key.
PREV
(5) To delete all the alarm histories, press and hold down the SHIFT key,
then press F4, [CLEAR].
CLEAR
SHIFT
F4
HELP
NOTE
When system variable $ER_NOHIS = 1, NONE alarms or
WARN alarms are not recorded. When $ER_NOHIS=2,
resets are not recorded in the alarm history. When
$ER_NOHIS=3, resets, WARN alarms, and NONE alarms
are not recorded.
30
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3. TROUBLESHOOTING
MAINTENANCE
The following map indicates teach pendant operations used to check an
alarm.
4 ALARM
F1 [TYPE]
Alarm : Active
F1 [TYPE]
F3 HIST
Alarm : HIST
F1 [TYPE]
F3 [ACTIVE]
F4 CLEAR
F5 HELP
DETAIL Alarm
F1 [TYPE]
F3 [ACTIVE]
F4 CLEAR
F5 HELP
31
3. TROUBLESHOOTING
3.3
SAFETY SIGNALS
MAINTENANCE
B–81535EN/02
The safety signal screen indicates the state of signals related to safety. To
be specific, the screen indicates whether each safety signal is currently on.
On this screen, it is impossible to change the state of any safety signal.
Table 3.3 Safety Signals
Safety signal
Description
Operator panel emergency stop
This item indicates the state of the emergency stop button on the operator panel. If the
EMERGENCY STOP board is pressed, the state is indicated as “TRUE”.
Teach pendant emergency stop
This item indicates the state of the emergency stop button on the teach pendant. If the
EMERGENCY STOP board is pressed, the state is indicated as “TRUE”.
External emergency stop
This item indicates the state of the external emergency stop signal. If the EMERGENCY
STOP signal is input, the state is indicated as “TRUE”.
Fence open
This item indicates the state of the safety fence. If the safety fence is open, the state is
indicated as “TRUE”.
Deadman switch
This item indicates whether the DEADMAN switch on the teach pendant is grasped. If
the teach pendant is operable, and the DEADMAN switch is grasped, the state is indicated as “TRUE”. If the deadman switch is released when the teach pendant is operable,
an alarm occurs, causing the servo power to be switched off.
Teach pendant operable
This item indicates whether the teach pendant is operable. If the teach pendant is operable, the state is indicated as “TRUE”.
Hand broken
This item indicates the state of the hand safety joint. If the hand interferes with a workpiece or anything like this, and the safety joint is opened, the state is indicated as
“TRUE”. In this case, an alarm occurs, causing the servo power to be switched off.
Robot overtravel
This item indicates whether the current position of the robot is out of the operation range.
If any robot articulation goes out of the operation range beyond the overtravel switch, the
state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be
switched off.
Abnormal air pressure
This item indicates the state of the air pressure. The abnormal air pressure signal is connected to the air pressure sensor. If the air pressure is not higher than the specified
value, the state is indicated as “TRUE”.
Step
(1) Press the MENUS key to display the screen menu.
(2) Select STATUS on the next page.
(3) Press F1, [TYPE] to display the screen switching menu.
(4) Select Safety Signal. You will see a screen similar to the following.
SYSTEM Safety
1
2
3
4
5
6
7
8
9
JOINT 30%
SIGNAL NAME
STATUS
SOP E–Stop:
TP E–stop:
Ext E–Stop:
Fence Open:
TP Deadman:
TP Enable:
Hand Broken:
Over Travel:
Low Air Alarm:
FALSE
FALSE
FALSE
FALSE
TRUE
TRUE
FALSE
FALSE
FALSE
[TYPE]
32
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3. TROUBLESHOOTING
MAINTENANCE
B–81535EN/02
3.4
Mastering is needed if:
MASTERING
(1) The SRVO 062 BZAL or SRVO 038 pulse mismatch alarm occurs,
or
(2) The pulse coder is replaced.
Item (1) requires simplified mastering, while item (2) requires
zero–degree or jig position mastering. (Zero–degree position mastering
is just for quick–fix purposes. After zero–degree position mastering is
used, jig position mastering should be performed later.)
The mastering procedure is described below. For details, refer to an
applicable maintenance manual of mechanical unit or operator’s manual
of control unit.
Condition
System variable $MASTER_ENB must be set to 1 or 2.
SYSTEM Variables
57 $MASTER_ENB
Step
JOINT 10%
57/136
1
(1) Press <MENUS>.
(2) Select SYSTEM.
(3) Press F1, TYPE.
(4) Select Master/Cal you will see a screen similar to the following.
9 USER
0 –– NEXT ––
MENUS
5 POSITION
6 SYSTEM
7
Master/Cal
TYPE
SYSTEM Master/Cal
1
FIXTURE POSITION MASTER
2
3
4
5
6
ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
JOINT 30%
Press ’ENTER’ or number key to select.
[TYPE]
LOAD RES_PCA
DONE
F1
(5) Move the robot by jog feed to the mastering position. Release the
brake on the manual brake control screen if necessary.
NOTE
Mastering can not be performed until axis is rotated enough
to establish a pulse.
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3. TROUBLESHOOTING
MAINTENANCE
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(6) Select “1 FIXTURE POSITION MASTER” and press the F4 key
(yes). Mastering data is set.
SYSTEM Master/Cal
SYSTEM Master/Cal
ENTER
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
Master at master position? [NO]
Master at master position? [NO]
[ TYPE ]
YES
NO
F4
JOINT
30 %
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot 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 is
performed.
Alternatively, to perform positioning, turn the power off, then turn it
on again. Calibration is performed whenever the power is turned on.
5 SET QUICK MASTER REF
6 CALIBRATE
ENTER
Calibrate? [NO]
Calibrate? [NO]
[ TYPE ]
SYSTEM Master/Cal
YES
F4
NO
JOINT
30 %
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<10.000> <–25.000> <40.000>
<5.000> <–15.000> <0.000>
[ TYPE ] LOAD RES_PCA
DONE
(8) Press F5 “DONE”, after mastering.
DONE
F5
34
3. TROUBLESHOOTING
MAINTENANCE
B–81535EN/02
3.5
TROUBLESHOOTING
USING THE ERROR
CODE
(1) SRVO–001 SVAL1 Operator panel E–stop
(Explanation) The EMERGENCY STOP button on the operator
panel is pressed.
(Action 1)
Release the emergency stop button pressed on the
operator panel.
(Action 2)
Release the EMERGENCY STOP button on the
operator panel.
(Action 3)
Replace the emergency stop unit.
Before taking (Action 4), make a backup copy of all
the programs and settings of the control unit.
(Action 4)
Replace the robot control board.
Emergency stop button
Operator
panel
Robot control board
Emergency stop unit
Fig.3.5 (1) (a) SRVO–001 SVAL1 Operator panel E–stop
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3. TROUBLESHOOTING
MAINTENANCE
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(2) SRVO–002 SVAL1 Teach pendant E–stop
(Explanation) The emergency stop button on the operator’s Teach
Pendant was pressed.
(Action 1)
Release the emergency stop button on the teach
pendant.
(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 switch
is 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
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MAINTENANCE
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3. TROUBLESHOOTING
(4) SRVO–004 SVAL1 Fence open
(Explanation) In AUTO mode, there is no short circuit between
FENCE11 and FENCE12 and between FENCE21
and FENCE22 on the terminal block TBEB5 of the
emergency stop board.
If the safety fence is connected between FENCE11
and FENCE12 and between FENCE21 and
FENCE22, 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 to
FENCE11, FENCE12, FENCE21 and FENCE22.
(Action 3)
When this signal is not used, short–circuit between
FENCE11 and FENCE12 and between FENCE21
and 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 the
mode switch is set to AUTO, the mode switch may be
faulty. Replace the operator panel.
Replace the emergency stop unit.
Before taking (Action 6), make a backup copy of all
the programs and settings of the control unit.
Replace the robot control board.
(Action 5)
(Action 6)
Short connection boards:
two positions (terminal blocks
located on the right when
viewing from the front)
Emergency stop unit
Fig.3.5 (4) SRVO–004 SVAL1 Fence open
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3. TROUBLESHOOTING
MAINTENANCE
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(5) SRVO–005 SVAL1 Robot overtravel
(Explanation) This alarm should not occur because no overtravel
input signal is provided. However, this alarm can be
caused by an abnormal overtravel input signal across
the robot interconnection cable and robot control
board.
(Action 1)
Check the robot interconnection cable (RMP) for the
following.
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 robot
control board is securely connected. In addition,
check that the RMP cable is sound and free from a
break or visible twist.
Before taking (Action 2), make a backup copy of all
the 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
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MAINTENANCE
3. TROUBLESHOOTING
(6) SRVO–006 SVAL1 Hand broken
(Explanation) The safety joint, if any, is broken. If no joint is
broken, the HBK signal line of the robot
interconnection cable has a break or ground fault.
(Action 1)
Holding down the shift key, press the alarm release
button. This releases the alarm. Keeping on holding
down the shift key, carry out jog feed to move the tool
to the work area.
1) Replace the safety joint.
2) Examine the cable.
(Action 2)
Check the robot interconnection cable (RMP) for the
following.
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 robot
control board is securely connected. In addition,
check that the RMP cable is sound and free from a
break or visible twist.
Before taking (Action 3), make a backup copy of all
the 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
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3. TROUBLESHOOTING
MAINTENANCE
B–81535EN/02
(7) SRVO–007 SVAL1 External E–stop
(Explanation) EMGIN11 and EMGIN12/EMGIN21 and EMGIN22
on the terminal block TBEB5 of the emergency stop
board are not short–circuited. If an external emergency
stop switch is connected across EMGIN11 and
EMGIN12/EMGIN21 and EMGIN22, the switch has
been pressed.
(Action 1)
If an external emergency stop switch is connected,
releases the switch.
(Action 2)
Check the switch and cable connected to EMGIN11
and EMGIN12 and to EMGIN21 and EMGIN22.
(Action 3)
When this signal is not used, make a connection
between EMGIN11 and EMGIN12 and a connection
between EMGIN21 and EMGIN22. (WARNING)
(Action 4)
Replace the emergency stop unit.
WARNING
Do NOT short–circuit, or disable, this signal in a system in
which the External emergency stop input signal is in use, as
it is very dangerous. If it is necessary to run the robot by
short–circuiting the signal even temporarily, an additional
safety provision must be provided.
Short connection boards:
two positions (terminal blocks
located on the left when
viewing from the front)
Emergency stop unit
Fig.3.5 (7) SRVO–007 SVAL1 External E–stop
40
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MAINTENANCE
3. TROUBLESHOOTING
(8) SRVO–009 SVAL1 Pneumatic pressure alarm
(Explanation) An abnormal air pressure was detected. The input
signal is located on the end effector of the robot.
Refer to the manual of your robot.
(Action 1)
If an abnormal air pressure is detected, check the cause.
If the peripheral device are normal, check the robot
connection cable.
Before taking (Action 2), make a backup copy of all
the 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
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3. TROUBLESHOOTING
MAINTENANCE
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(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 if
necessary.
Fan motor
Fig.3.5 (9) SRVO–014 WARN Fan motor abnormal
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MAINTENANCE
3. TROUBLESHOOTING
(10) SRVO–015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j)
(Explanation) The temperature in the control unit exceeds the
specified value.
(Action 1)
If the ambient temperature is higher than specified
(45°C), cool down 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 is
defective, 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
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3. TROUBLESHOOTING
MAINTENANCE
B–81535EN/02
(11) SRVO–021 SVAL1 SRDY off (Group : i Axis : j)
(Explanation) The HRDY is on and the SRDY is off, although there
is no other cause of an alarm. (HRDY is a signal with
which the host detects the servo system whether to
turn on or off the servo amplifier magnetic contactor.
SRDY is a signal with which the servo system
informs the host whether the magnetic contactor is
turned on.)
If the servo amplifier magnetic contactor cannot be
turned on when directed so, it is most likely that a
servo amplifier alarm has occurred. If a servo
amplifier alarm has been detected, the host will not
issue this alarm (SRDY off). Therefore, this alarm
indicates that the magnetic contactor cannot be turned
on for an unknown reason.
(Action 1)
Measure the voltage of the 200–VAC input to the
power supply module. If the voltage is 170 VAC or
lower, adjust the input voltage.
(Action 2)
Check that CRR78 of the emergency stop board and
CX3 and CX4 of the power supply module are
securely connected. Check the cables of the
emergency stop board and power supply module for
a break.
(Action 3)
Check the EMERGENCY STOP line (teach pendant
emergency stop, teach pendant enable/disable switch,
teach pendant deadman switch, operator panel
emergency stop, external emergency stop input, fence
input) for a possibility of an instantaneous
interruption. If the software cannot judge the cause
of the alarm at an instantaneous interruption of the
EMERGENCY STOP line, this alarm occurs.
(Action 4)
Replace the emergency stop unit.
(Action 5)
If an alarm occurs on all axes, the power supply
module may be faulty. Replace the power supply
module.
(Action 6)
If an alarm occurs on a particular axis, the servo
amplifier module may be faulty. Replace the servo
amplifier module controlling the axis.
(Action 7)
Replace the axis control card on the robot control
board.
44
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MAINTENANCE
Emergency stop unit
3. TROUBLESHOOTING
Robot control board
Servo amplifier module
Power supply module
Axis control card
Fig.3.5 (11) SRVO–021 SVAL1 SRDY off
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3. TROUBLESHOOTING
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(12) SRVO–022 SVAL1 SRDY on (Group : i Axis : j)
(Explanation) When the HRDY is about to go on, the SRDY is already
on. (HRDY is a signal with which the host directs the
servo system whether to turn on or off the servo
amplifier magnetic contactor. SRDY is a signal with
which the servo system informs the host whether the
magnetic contactor is turned on.
(Action 1)
Replace the axis control card on the robot control
board.
(Action 2)
If an alarm occurs on all axes, the power supply
module may be faulty. Replace the power supply
module.
(Action 3)
If an alarm occurs on a particular axis, the servo
amplifier module may be faulty. Replace the servo
amplifier module controlling the axis.
Robot control board
Servo amplifier module
Power supply module
Axis control card
Fig.3.5 (12) SRVO–022 SVAL1 SRDY on
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MAINTENANCE
3. TROUBLESHOOTING
(13) SRVO–023 SVAL1 Stop error excess (Group : i Axis : j)
(Explanation) When the servo is at stop, the position error is
abnormally large.
(Action 1)
Check whether the motor brake has been released.
(Action 2)
Make sure that the servo amplifier CZ2L to N are
connected tightly.
(Action 3)
Check to see if the load is greater than the rating. If
greater, reduce it to within the rating. (If the load is
too greater, the torque required for acceleration /
deceleration becomes higher than the capacity of the
motor. As a result, the motor becomes unable to
follow the command, and an alarm is issued.)
(Action 4)
Check each phase voltage of the CZ1 connector of the
three–phase power (200 VAC) input to the servo
amplifier. If it is 170 VAC or lower, check the line
voltage. (If the voltage input to the servo amplifier
becomes low, the torque output also becomes low. As
a result the motor may become unable to follow the
command, hence possibly an alarm.)
(Action 5)
If the line voltage is 170 VAC or higher, replace the
power supply module or servo amplifier module.
(Action 6)
Check disconnection of robot connection cable
(RMP).
(Action 7)
Replace the motor.
Servo amplifier module
Power supply module
Fig.3.5 (13) SRVO–023 SVAL1 Stop error excess
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3. TROUBLESHOOTING
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(14) SRVO–024 SVAL1 Move error excess (Group : i Axis : j)
(Explanation) When the robot is running, its position error is greater
than a specified value ($PARAM _ GROUP.
$MOVER _ OFFST or $PARAM _ GROUP.
$TRKERRLIM). It is likely that the robot cannot
follow the speed specified by program.
(Action 1)
Check the robot for binding axis.
(Action 2)
Take the same actions as described for the above
alarm.
(15) SRVO–025 SVAL1 Motn dt overflow (Group : i Axis : j)
(Explanation) The specified value is too great.
(16) SRVO–026 WARN2 Motor speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum motor speed
($PARAM_GROUP.$MOT_SPD_LIM)
was
specified. The actual motor speed is clamped to the
maximum speed.
(17) SRVO–027 WARN Robot not mastered (Group : i)
(Explanation) An attempt was made to calibrate the robot, but the
necessary adjustment had not been completed.
(Action)
Master the robot.
(18) SRVO–030 SVAL1 Brake on hold (Group : i)
(Explanation) This alarm occurs when the robot pauses, if the brake
on hold function has been enabled ($SCR.
$BRKHOLD _ ENB = 1). Disable the function if it is
not necessary.
(Action)
Disable [Servo–off during pause] on the general
setting menu (Select Setting general).
(19) SRVO–031 SVAL1 User servo alarm (Group : i)
(Explanation) An user servo alarm occurred.
(20) SRVO–033 WARN Robot not calibrated (Group : i)
(Explanation) An attempt was made to set up a reference point for
simplified adjustment, but the robot had not been
calibrated.
(Action)
Calibrate the robot.
1.Supply power.
2.Set up a simplified adjustment reference point
using [Positioning] on the positioning menu.
(21) SRVO–034 WARN Ref pos not set (Group : i)
(Explanation) An attempt was made to perform simplified adjustment,
but the reference point had not been set up.
(Action)
Set up a simplified adjustment reference point on the
positioning menu.
(22) SRVO–035 WARN2 Joint speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum axis speed
($PARAM_GROUP.$JNTVELLIM) was specified.
Each actual axis speed is clamped to the maximum
speed.
(23) SRVO–036 SVAL1 Inpos time over (Group : i Axis : j)
(Explanation) The robot did not get to the effective area ($PARAM _
GROUP.$ STOPTOL) even after the position check
monitoring time ($PARAM _ GROUP. $INPOS _
TIME) elapsed.
(Action)
Take the same actions as for SRVO–23 (large position
error at a stop).
(24) SRVO–037 SVAL1 Imstp input (Group : i)
(Explanation) The *IMSTP signal for a peripheral device interface
was input.
(Action)
Turn on the *IMSTP signal.
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3. TROUBLESHOOTING
(25) SRVO–038 SVAL2 Pulse mismatch (Group : i Axis : j)
(Explanation) The pulse count obtained when power is turned off
does not match the pulse count obtained when power
is applied. This alarm is asserted after exchange the
pulsecoder or battery for back up of the pulsecoder
data or loading back up data to the Robot control
board.
(Action)
Perform Absolute Pulse Coder reset and remaster
robot (RES–PCA)
1. Press MENUS.
2. Select SYSTEM.
3. Press F1 [TYPE].
4. Select MASTER/CAL.
5. Press F3, PES–PCA and YES.
6. Execute mastering.
7. Press RESET.
The fault condition should reset. If the controller
is still faulted with additional servo–related errors,
cold start the controller.
It might be necessary to remaster the robot.
(26) SRVO–041 SVAL2 MOFAL alarm (Group : i Axis : j)
(Explanation) The servo value was too high.
(Action)
Cold start the controller.
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(27) SRVO–044 SVAL1 HVAL alarm (Group : i Axis : j)
(Explanation) The DC voltage (DC link voltage) of the main circuit
power supply is abnormally high.
The LED indication on the power supply module is
“7” (HVAL).
(Action 1)
Check the three–phase input voltage at the power
supply module. If it is 253 VAC or higher, check the
line voltage. (If the three–phase input voltage is
higher than 253 VAC, high acceleration/deceleration
can result in this alarm.)
(Action 2)
Check that the load weight is within the rating. If it
is higher than the rating, reduce it to within the rating.
(If the machine load is higher than the rating, the
accumulation of regenerative energy might result in
the HVAL alarm even when the three–phase input
voltage is within the rating.
(Action 3)
Replace the power supply module.
Power supply module
Fig.3.5 (27) SRVO–044 SVAL1 HVAL alarm
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(28) SRVO–045 SVAL1 HCAL alarm (Group : i Axis : j)
(Explanation) Abnormally high current flowed in the main circuit of
the servo amplifier module.
The LED indications on the servo amplifier modules
are “b”, “C”, and “d”.
(Action 1)
Disconnect the Robot connection cable (Motor power)
from the connector CZ2 of the servo amplifier
module. 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 connection
cable (Motor power) (U, V, or W) and the GND line.
If there is a short–circuit, the motor, robot
interconnection cable, or intra–robot cable is
defective. 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, V
and W, and W and U with a ohmmeter with a very low
resistance range. If the resistances at these three
places are different from each other, the motor, robot
interconnection cable, or intra–robot cable is
defective. Check each item in detail.
Before taking (Action 4), make a backup copy of all
the 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
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(29) SRVO–046 SVAL2 OVC alarm (Group : i Axis : j)
(Explanation) This alarm is issued to prevent the motor from
thermal damage that might occur when the root meant
square current calculated within the servo system is
out of the allowable range.
(Action 1)
Check the operating conditions for the robot and relax
the service conditions.
(Action 2)
Check each phase voltage of the three–phase input
power (200 VAC for the power supply module. If it
is 170 VAC or lower, check the line voltage.
(Action 3)
Replace the power supply module and servo
amplifier module.
(Action 4)
Check the robot connection cable (RMP).
(Action 5)
Replace the motor.
Servo amplifier module
Power supply module
Fig.3.5 (29) SRVO–046 SVAL2 OVC alarm
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Reference
Relationships among the OVC, OVL, and HC alarms
Overview
This section points out the differences among the OVC, OVL, and HC
alarms 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 OHAL2
Thermal relay in the servo amplifier OHAL1
Thermal relay in the separate regenerative discharge unit DCAL
HC
High current alarm
Servo amplifier
Purpose of each alarm
1) HC alarm (high current alarm)
If high current flow in a power transistor momentarily due to
abnormality or noise in the control circuit, the power transistor and
rectifier diodes might be damaged, or the magnet of the motor might
be degaussed. The HC alarm is intended to prevent such failures.
2) OVC and OVL alarms (overcurrent and overload alarms)
The OVC and OVL alarms are intended to prevent overheat that may
lead to the burnout of the motor winding, the breakdown of the servo
amplifier transistor, and the separate regenerative resistor.
The OVL alarm occurs when each built–in thermal relay detects a
temperature higher than the rated value. However, this method is not
necessarily perfect to prevent these failures. For example, if the
motor frequently repeats to start and stop, the thermal time constant
of the motor, which has a large mass, becomes higher than the time
constant of the thermal relay, because these two components are
different in material, structure, and dimension. Therefore, if the
motor repeats to start and stop within a short time as shown in Fig.
1, the temperature rise in the motor is steeper than that in the thermal
relay, thus causing the motor to burn before the thermal relay detects
an abnormally high temperature.
Temperature
Start
Stop
Start
Stop
Start
Thermal time constant
of the motor is high.
Temperature at
which the winding
starts to burn
Thermal time constant
of the thermal relay is
low.
Time
Fig.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles
To prevent the above defects, software is used to monitor the current
in the motor constantly in order to estimate the temperature of the
motor. The OVC alarm is issued based on this estimated temperature.
This method estimates the motor temperature with substantial
accuracy, so it can prevent the failures described above.
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To sum up, a double protection method is used; the OVC alarm is used
for protection from a short–time overcurrent, and the OVL alarm is
used for protection from long–term overload. The relationship
between the OVC and OVL alarms is shown in Fig 2.
Current
Protection area for
the motor and
servo amplifier
Protection by the OVL
Limit 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 consideration
for the OVC alarm. The motor might not be hot even if the
OVC alarm has occurred. In this case, do not change the
parameters to relax protection.
(30) SRVO–047 SVAL1 LVAL alarm (Group : i Axis : j)
(Explanation) The control power voltage (+5 V, etc.) on the servo
amplifier module is too low. The LED indication on
the servo amplifier module is “2” (LVAL).
(Action 1)
Replace the servo amplifier module.
Servo amplifier module
Fig.3.5 (30) SRVO–047 SVAL1 LVAL alarm
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(31) SRVO–049 SVAL1 OHAL1 alarm (Group : i Axis : j)
(Explanation) This alarm does not occur when the power supply
module and serve amplifier modules used with the
R–J3iB Mate are under normal conditions.
This alarm indicates that any of the power supply
module and servo amplifier modules is faulty.
(Action 1)
If this alarm occurs in relation to all axes, replace the
power supply module.
(Action 2)
If this alarm occurs in relation to a specific axis,
replace the servo amplifier module that controls the
axis.
Servo amplifier module
Power supply module
Fig.3.5 (31) SRVO–049 SVAL1 OHAL1 alarm
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(32) SRVO–050 SVAL1 CLALM alarm (Group : i Axis : j)
(Explanation) The disturbance torque estimated by the servo software
is abnormally high. (A collision has been detected.)
(Action 1)
Check that the robot has collided with anything. If it
has, reset the robot and jog–feed it to recover from the
collision.
(Action 2)
Make sure that the load setting is correct.
(Action 3)
Check that the load weight is within the rating. If it
is higher than the rating, reduce it to within the rating.
(If the robot is used out of its usable range, the
estimated disturbance torque becomes abnormally
high, possibly resulting in this alarm being detected.)
(Action 4)
Check the phase voltage of the three–phase input
power (200 VAC) to the power supply module. If it
is 170 VAC or lower, check the line voltage.
(Action 5)
Replace the power supply module and the servo
amplifier module.
Servo amplifier module
Power supply module
Fig.3.5 (32) SRVO–050 SVAL1 CLALM alarm
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(33) SRVO–051 SVAL2 CUER alarm (Group : i Axis : j)
(Explanation) The offset of the current feedback value is abnormally
high.
(Action)
Replace the servo amplifier module.
Servo amplifier module
Fig.3.5 (33) SRVO–051 SVAL2 CUER alarm
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(34) SRVO–054 DSM Memory Error
(Explanation) An access to the axis control card on the robot control
board memory fails.
(Action)
Replace the axis control card.
Robot control board
Servo amplifier module
Axis control card
Fig.3.5 (34) SRVO–054 DSM Memory Error
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(35) SRVO–055 SVAL2 FSSB com error 1 (Group : i Axis : j)
(Explanation) A communication error has occurred between the
robot 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 control
board.
(Action 3)
Replace the servo amplifier module.
Before continuing to the next step, perform a
complete controller back–up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.
(Action 4)
Replace the robot control board.
Robot control board
Servo amplifier module
Axis control card
Fig.3.5 (35) SRVO–055 SVAL2 FSSB com error 1
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(36) SRVO–056 SVAL2 FSSB com error 2 (Group : i Axis : j)
(Explanation) A communication error has occurred between the
robot 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 control
board.
(Action 3)
Replace the servo amplifier module.
Before continuing to the next step, perform a
complete controller back–up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.
(Action 4)
Replace the robot control board.
Robot control board
Servo amplifier module
Axis control card
Fig.3.5 (36) SRVO–056 SVAL2 FSSB com error 2
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(37) SRVO–057 SVAL2 FSSB disconnect (Group : i Axis : j)
(Explanation) Communication was interrupted between the robot
control board and servo amplifier.
(Action 1)
Check whether fuse FU1 in the power supply module
unit has blown.
(Action 2)
Check whether fuse FU1 in the servo amplifier
module 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 control
board.
(Action 5)
Replace the power supply module and the servo
amplifier module.
Before continuing to the next step, perform a
complete controller back–up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.
(Action 6)
Replace the robot control board.
(Action 7)
Check the RMP cable of robot connection cable.
(+5V ground fault)
Robot control board
Servo amplifier module
Power supply module
Axis control card
Fig.3.5 (37) SRVO–057 SVAL2 FSSB disconnect
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(38) SRVO–058 SVAL2 FSSB init error (Group : i Axis : j)
(Explanation) Communication was interrupted between the robot
control board and servo amplifier module.
(Action 1)
Check whether fuse FU1 in the power supply module
have blown.
If they have blown, see Section 3.6, “Troubleshooting
for Blown Fuse.”
(Action 2)
Check whether seven segment LEDs on the servo
amplifier module are on.
If they are on, perform “Action 4” and all actions that
follow it. If they are not on, perform “Action 3” and
all actions that follow it.
(Action 3)
Check whether connector CX1 on the power supply
module is securely connected.
(Action 4)
Check the communication cable (optical fiber)
between the robot control board and servo amplifier
module. Replace it if it is faulty.
(Action 5)
Replace the axis control card on the robot control
board.
(Action 6)
If the seven–segment LED on the servo amplifier
module is glowing, replace the servo amplifier
module. If the seven–segment LED on the servo
amplifier module is not glowing, replace the power
supply module.
Before continuing to the next step, perform a
complete controller back–up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.
(Action 7)
Replace the robot control board.
Robot controll board
Servo amplifier module
Power supply module
Axis control card
Fig.3.5 (38) SRVO–058 SVAL2 FSSB init error
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(39) SRVO–059 SVAL2 Servo amp init error
(Explanation) Servo amplifier initialzation is failed.
(Action 1)
Check all connectors on the PSM and SVM. Make
sure they are installed correctly.
(Action 2)
Replace the power supply module and the servo
amplifier module.
Servo amplifier module
Power supply 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 the
pulse 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 coder
absolute-position backup is empty.
A probable cause is a broken battery cable or no
batteries in the robot.
(Action)
Remove the cause of the alarm, set the system
variable ($MCR.$SPC RESET) to TRUE, then turn
the 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 the
pulse coder is abnormal (abnormal counter).
(Action)
Replace the pulse coder.
NOTE
In this case, perform actions associated with DTERR,
CRCERR, or STBERR first.
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(43) SRVO–064 SVAL2 PHAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if the phase of the pulses generated
in the pulse coder is abnormal.
(Action)
Replace the pulse coder.
NOTE
This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.
(44) SRVO–065 WARN BLAL alarm (Group : i Axis : j)
(Explanation) The battery voltage for the pulse coder is lower than
the rating.
(Action)
Replace the battery.
(If this alarm occurs, turn on the AC power and
replace the battery as soon as possible. A delay in
battery replacement may result in the BZAL alarm
being detected. In this case, the position data will be
lost. Once the position data is lost, mastering will
become necessary.
(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, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.
(46) SRVO–067 SVAL2 OHAL2 alarm (Group : i Axis : j)
(Explanation) The temperature inside the pulse coder or motor is
abnormally high, and the built–in thermostat has
operated.
(Action 1)
Check the operating conditions for the robot and relax
the service conditions.
(Action 2)
When power is supplied to the motor after it has
become sufficiently cool, if the alarm still occurs,
replace the motor.
(47) SRVO–068 SVAL2 DTERR alarm (Group : i Axis : j)
(Explanation) The serial pulse coder does not return serial data in
response to a request signal.
–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
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(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 servo
amplifire module is connected tightly.
(Action 2)
Check that the shielding of the robot interconnection
cable (for the pulse coder) and the peripheral equipment
cable is connected securely to the grounding plate.
(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).
Servo amplifier module
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 major
cause 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 pulse
coder 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 be
established.
(Action)
Reset the alarm, and jog the axis on which the alarm
has occurred until the same alarm will not occur
again. (Jog one motor revolution)
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(55) SRVO–076 SVAL1 Tip Stick Detection (Group : i Axis : j)
(Explanation) An excessive disturbance was assumed in servo
software at the start of operation. (An abnormal load
was detected. The cause may be welding.)
(Action 1)
Check whether the robot comes into collision with
foreign matter. If a collision occurs, reset the system,
then switch it to the jog feed mode to avoid the
collision.
(Action 2)
Check whether the load settings are valid.
(Action 3)
Check whether the load weight is within the rated
range. If the weight exceeds the upper limit, decrease
it to the limit.
(Use of the robot with a load exceeding the limit
applied may abnormally increase the assumed
disturbance, resulting in this alarm.)
(Action 4)
Check each inter–phase voltage of the three–phase
input (200 VAC) to the power supply module. If the
voltage is 170 VAC or lower, check the input power
supply voltage.
(Action 5)
Replace the power supply module and the servo
amplifier module.
Servo amplifier module
Power supply 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 replace
it 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 the
pulse coder is abnormal (abnormal count clock).
(Action)
See the description about the SRVO–061 CKAL
alarm.
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(59) SRVO–084 WARN BZAL alarm (Track enc : i)
(Explanation) This alarm occurs if the backup battery for the absolute
position of the pulse coder has not been connected. See
the 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 the
pulse coder is abnormal (abnormal counter).
(Action)
See the description about the SRVO–063 RCAL
alarm.
(61) SRVO–086 WARN PHAL alarm (Track enc : i)
(Explanation) This alarm occurs if the phase of pulses generated in
the pulse coder is abnormal. See the description
about the PHAL alarm (SRVO–064).
(62) SRVO–087 WARN BLAL alarm (Track enc : i)
(Explanation) This alarm occurs if the voltage of the backup battery
for the absolute position of the pulse coder is low. See
the description about the 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 CSAL
alarm.
(64) SRVO–089 WARN OHAL2 alarm (Track enc : i)
(Explanation) The motor has overheated. See the description about
the OHAL2 alarm (SRVO–067).
(65) SRVO–090 WARN DTERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
description about the DTERR alarm (SRVO–068).
(66) SRVO–091 WARN CRCERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
description about the CRCERR alarm (SRVO–069).
(67) SRVO–092 WARN STBERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
description about the STBERR alarm (SRVO–070).
(68) SRVO–093 WARN SPMAL alarm (Track enc : i)
(Explanation) This alarm occurs if the current position data from the
pulse coder is higher than the previous position data.
See the description about the SPHAL alarm
(SRVO–071).
(69) SRVO–094 WARN PMAL alarm (Track enc : i)
(Explanation) It is likely that the pulse coder is abnormal. See the
description 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 pulse
coder has malfunctioned due to noise. See the
description 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 the
description about the LDAL alarm (SRVO–074).
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(72) SRVO–097 WARN Pulse not established (enc : i)
(Explanation) The absolute position of the pulse coder cannot be
established. See the description about (SRVO–075).
Pulse not established.
(73) SRVO–131 SVAL1 LVAL (PSM) alarm (Group : i Axis : j)
(Explanation) The control power supply voltage (for example, +5
V) 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
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(74) SRVO–134 SVAL1 DCLVAL (PSM) alarm (Group : i Axis : j)
(Explanation) The DC voltage (DC link voltage) of the main circuit
power supply on the power supply module is
abnormally low. The LED indication on the power
supply module is “4.”
–If this alarm occurs during robot operation:
(Action 1)
Check the phase voltage of the three–phase input (200
VAC) to the power supply module. If it is 170 VAC
or lower, check the input power supply voltage.
(Action 2)
Replace the power supply module.
–If this alarm occurs before the magnetic contactor (MCC) is turned
on:
(Action 1)
Check the emergency stop board and the wiring
between the power supply module and magnetic
contactor (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.
Magnetic contactor
Servo amplifier module
Power supply module
Emergency stop unit
Fig.3.5 (74) SRVO–134 SVAL1 DCLVAL (PSM) alarm
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(75) SRVO–135 SVAL FSAL alarm (Group : i Axis : j)
(Explanation) The internal cooling fan(s) of the servo amplifier
module(s) is abnormal. The LED indication on the
relevant servo amplifier module is “1.”
(Action 1)
Replace the fan motor of the servo amplifier module.
(Action 2)
Replace the servo amplifier module.
Fan
Servo amplifier module
Servo amplifier module
Fig.3.5 (75) SRVO–135 SVAL FSAL alarm
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(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 is
abnormally low.
The LED indication on the servo amplifier module
becomes “5”.
–This alarm occured in the robot operation.
(Action 1)
Check the phase voltage of the three–phase input
power (200 VAC) to the power supply module. If it
is 170 VAC or lower, check the line voltage.
(Action 2)
Replace the power supply module and the servo
amplifier module.
–If this alarm occurs before the magnetic contactor is turned on:
(Action 1)
Check the emergency stop board and the wiring
between the power supply module and electromagnetic
contactor (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.
Magnetic contactor
Robot control board
Servo amplifier module
Power supply module
Fig.3.5 (76) SRVO–136 SVAL1 DCLVAL alarm
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(77) SRVO–156 SVAL1 IPMAL alarm (Group : i Axis : j)
(Explanation) Abnormally high current flowed through the main
circuit of the servo amplifier.
The LED indications on the servo amplifier modules
are “8.”, “9.”, and “A.”.
(Action 1)
Detach the motor power lines from the connectors
CZ2 of the servo amplifier modules, then turn on the
power. If this operation causes the error to recur,
replace the servo amplifier module.
(Action 2)
Detach the motor power lines from the connectors
CZ2 of the servo amplifier modules, then check the
insulation between GND and each of the motor power
lines U, V, and W individually. If a short–circuit is
found, the motor, robot interconnection cable, or
intra–robot cable may be faulty. Examine each of
them for any problem.
(Action 3)
Detach the motor power lines from the connectors
CZ2 of the servo amplifier modules, then measure the
resistance between the motor power lines U and V, V
and W, and W and U, using an ohmmeter with a very
low resistance range. If the three resistances are
different, the motor, robot connection cable, or
intra–robot cable may be faulty. Examine each of
them for any problem.
Before taking (Action 4), make a backup copy of all
the programs and settings of the control unit.
(Action 4)
Replace the robot control board.
Robot control board
Servo amplifier module
Fig.3.5 (77) SRVO–156 SVAL1 IPMAL alarm
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3. TROUBLESHOOTING
(78) SRVO–157 SVAL1 CHGAL alarm (Group : i Axis : j)
(Explanation) The capacitor for the DC link voltage of the servo
amplifier module was not charged within the
specified 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.
Servo amplifier module
Power supply module
Fig.3.5 (78) SRVO–157 SVAL1 CHGAL alarm
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3. TROUBLESHOOTING
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(79) SRVO–201 SVAL1 Panel E–stop or SVEMG abnormal
(Explanation) The EMERGENCY STOP button on the operator
panel was pressed, but the EMERGENCY STOP line
was not disconnected.
(Action 1)
Check the EMERGENCY STOP button on the
operator 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 button
is pressed slowly.
emergency stop button
Power supply module
Emergency stop unit
Fig.3.5 (79) SRVO–201 SVAL1 Panel E–stop or SVEMG abnormal
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3. TROUBLESHOOTING
(80) SRVO–202 SVAL1 TP E–stop or SVEMG abnormal
(Explanation) The EMERGENCY STOP button on the operator
panel was pressed, but the EMERGENCY STOP line
was not disconnected.
(Action 1)
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 button
is pressed slowly.
Teach pendant
teach pendant cable
emergency stop button
Power supply module
Emergency stop unit
Fig.3.5 (80) SRVO–202 SVAL1 TP E–stop or SVEMG abnormal
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(81) SRVO–204 SVAL1 External (SVEMG abnormal) E–stop
(Explanation) Although the switch connected across EMGIN11 and
EMGIN12/EMGIN21 and EMGIN22 on the terminal
block TBEB1 of the emergency stop board was
pressed, the EMERGENCY STOP line was not
disconnected.
(Action 1)
Check whether there is a large difference in operation
time between the switch connected across EMGIN11
and EMGIN12 and the switch connected across
EMGIN21 and EMGIN22. If the switch connected
across EMGIN11 and EMGIN12 operates with a
large 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
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(82) SRVO–205 SVAL1 Fence open (SVEMG abnormal)
(Explanation) The EMERGENCY STOP line was not disconnected
even though the switch connected between FENCE11
and FENCE12 and between FENCE21 and FENCE22
on the terminal block TBEB2 of the emergency stop
board was open.
(Action 1)
Check whether there is a large difference in operation
time between the switch connected across EMGIN11
and EMGIN12 and the switch connected across
EMGIN21 and EMGIN22. If the switch connected
across EMGIN11 and EMGIN12 operates with a
large 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)
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(83) SRVO–206 SVAL1 Deadman switch (SVEMG abnormal)
(Explanation) The DEADMAN switch was released when the teach
pendant was operable, but the EMERGENCY STOP
line was not disconnected.
(Action 1)
The mode switch may be faulty. Replace the operator
panel.
(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)
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(84) SRVO–207 SVAL1 TP switch abnormal or door open
(Explanation) The teach pendant is operable, and the deadman
switch has been grasped, but the EMERGENCY
STOP line is kept disconnected.
(Action 1)
Check the teach pendant connection cable.
(Action 2)
Replace the teach pendant.
(Action 3)
Replace the emergency stop unit.
Teach pendant
Teach pendant cable
Emergency stop unit
Fig.3.5 (84) SRVO–207 SVAL1 TP switch abnormal or door open
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3. TROUBLESHOOTING
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(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 replace
the 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. Check
the robot operation conditions. If the robot is used
with a condition exceeding the duty or load weight
robot rating, reduce the load condition value to the
specification range.
(Action 2)
Check each inter–phase voltage of the three–phase
input (200 VAC) to the power supply module. If the
voltage is 170 VAC or lower, check the input power
supply voltage.
Power supply module
Fig.3.5 (86) SRVO–215 WARN Fuse blown (Aux axis)
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3. TROUBLESHOOTING
(87) SRVO–221 SVAL1 Lack of DSP (Group : i Axis : j)
(Explanation) A controlled axis card corresponding to the set
number of axes is not mounted.
(Action 1)
Check whether the set number of axes is valid. If the
number is invalid, set the correct number.
(Action 2)
Replace the controlled axis card with a card
corresponding to the set number of axes.
(Example)
When six axes are set, a controlled axis card for six
or eight axes is available. For how to replace the
controlled axis card, see II MAINTENANCE,
Section 7.2 in this manual.
Robot control board
Servo amplifier module
Power supply module
Axis control card
Fig.3.5 (87) SRVO–221 SVAL1 Lack of DSP (Group : i Axis : j)
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3. TROUBLESHOOTING
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(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 to
the servo amplifier module.
(Action 2)
Replace the optical cable.
(Action 3)
Check whether power is properly supplied to the
servo amplifier module.
Servo amplifier module
Fig.3.5 (88) SRVO–222 SVAL1 Lack of Amp (Amp : i)
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(89) SRVO–233 SVAL1 TP disabled in T1, T2/Door open
(Explanation) The teach pendant is disabled when the mode switch
is in the T1 mode position.
(Action 1)
During teaching operation, set the enable switch of
the teach pendant to Enable. Otherwise, set the mode
switch 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 operator
panel.
Teach pendant
Mode switch
FUS3
Emergency stop unit
Emergency stop board
Fig.3.5 (89) SRVO–233 SVAL1 TP disabled in T1, T2/Door open
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3. TROUBLESHOOTING
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(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 the
E–STOP unit and the CX3 connector of the power
supply 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 monitor
contact of the magnetic contactor (MCC) becomes
faulty.
(Action 1)
Replace the magnetic contactor (MCC).
(Action 2)
Replace the emergency stop unit.
(Action 3)
Replace the power supply module.
Power supply module
Emergency stop unit
Magnetic contactor (MCC)
Fig.3.5 (91) SRVO–265 SVAL1 E.STOP circuit abnormal 2
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3. TROUBLESHOOTING
(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 relevant
servo amplifier module is “8.”
(Action 1)
Detach the motor power lines from connector CZ2 of
the servo amplifier module, then turn the power on.
If this alarm persists, replace the servo amplifier
module.
(Action 2)
Detach the motor power lines from connector CZ2 of
the servo amplifier module, then check the insulation
between GND and each of U, V, and W of the motor
power lines. If a short circuit is detected, the motor,
robot connection cable, or internal robot cable may be
defective. Check them for an abnormal condition.
(Action 3)
Detach the motor power lines from connector CZ2 of
the servo amplifier module, then use a high–precision
ohmmeter to measure U–V, V–W, and W–U
resistances of the motor power lines. If the three
resistances differ, the motor, robot connection cable,
or internal robot cable may be defective. Check them
for an abnormal condition.
Before proceeding with (Action 4), back up all
programs and settings for the control unit.
(Action 4)
Replace the robot control board.
Robot control board
Servo amplifier module
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 modules
are “8.”, “9.”, and “A.”.
(Action 1)
Check whether the servo amplifier module fan stops.
(Action 2)
Reduce the override because the use condition is too
hard.
(Action 3)
If this alarm is frequently issued, replace the amplifier
module.
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(94) SRVO–295 SVAL1 SVM COM alarm (Group : i Axis : j)
(Explanation) Communication between the servo amplifier
modules is abnormal. The LED indications on the
servo amplifier modules are “P.”
(Action 1)
If “SRVO – 047 LVAL alarm” and “SRVO – 131
LVAL (PSM) alarm” also occur, the control power
supply voltage is low. Take measures against these
alarms.
(Action 2)
Check the servo amplifier modules and cables for
connectors CX2A and CX2B of the power supply
module, as well as their connection.
(Action 3)
Replace the axis control card on the robot control
board.
(Action 4)
Replace the servo amplifier modules.
Before proceeding with (Action 5), back up all
programs and settings for the control unit.
(Action 5)
Replace the robot control board.
Robot control board
Servo amplifier module
Power supply module
Axis control card
Fig.3.5 (94) SRVO–295 SVAL1 SVM COM alarm
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3. TROUBLESHOOTING
(95) SRVO–296 SVAL1 DCAL alarm (Group : i Axis : j)
(Explanation) The regenerative discharge energy is too high to be
dissipated as heat. (To move the robot, the servo
amplifier supplies energy to the robot. When going
down, the robot moves along the vertical axis as the
potential energy reduces. If a reduction in the
potential energy is larger than the amount of
acceleration energy, the servo amplifier receives
energy from the motor. This also occurs at
deceleration even when no gravity is applied. The
energy that the servo amplifier receives from the
motor is called regenerative energy. The servo
amplifier dissipates this energy as heat. If the amount
of the regenerative energy dissipated as heat is
smaller than was received, the remainder is stored in
the servo amplifier, causing this alarm.) The LED
indication on the power supply module is “8”
(DCAL: regenerative energy adder detection).
(Action 1)
This alarm may occur if the robot is subjected to
frequent acceleration/deceleration or if the vertical
axis 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
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(96) SRVO–297 SVAL1 DCLVAL alarm (Group : i Axis : j)
(Explanation) An open–phase condition has occurred in the input
power supply to the main circuit on the power supply
module. The LED indications on the power supply
module is “E.”
(Action 1)
Check the phase voltage of the three–phase input (200
VAC) to the power supply module. If an open–phase
condition 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
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3. TROUBLESHOOTING
(97) SRVO–300 SVAL1 Hand broken/HBK disabled
SRVO–302 SVAL1 Set Hand broken to ENABLE
(Explanation) Although HBK was disabled, the HBK signal was
input.
(Action 1)
Press RESET on the teach pendant to release the
alarm.
(Action 2)
Check whether the hand broken signal is connected to
the robot. When the hand broken signal circuit is
connected, enable hand broken.
(See II
CONNECTION, Section 3.8 in this manual.)
Robot control board
Fig.3.5 (97)
SRVO–300 SVAL1 Hand broken/HBK disabled
SRVO–302 SVAL1 Set Hand broken to ENABLE
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(98) SRVO–320 SVAL1 E.STOP
(Explanation) Although there is no cause for an emergency stop, an
emergency 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 on
the emergency stop
emergency stop board and the CX4 connector on the
power 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
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MAINTENANCE
(99) SRVO–321 SVAL1 TP SW/Deadman abnormal
(Explanation) The ENABLE/DISABLE switch or Deadman switch
on 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 all
the programs and settings of the control unit.
(Action 4)
Replace the robot control board.
Teach pendant
teach pendant cable
ENABLE/DISABLE
switch
Deadman switch
(Back side)
Robot control board
Emergency stop unit
Fig.3.5 (98) SRVO–321 SVAL1 TP SW/Deadman abnormal
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3. TROUBLESHOOTING
MAINTENANCE
3.6
This section describes alarms that can occur when a fuse mounted on a
board or unit is blown and corresponding corrective actions.
TROUBLESHOOTING
USING FUSES
Name
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(1) Fuses on the robot control board
FUS1 : For generating power to the control circuit
FUS2 : For protecting +24E output to peripheral device digital
input/output, end effector, ROT, and HBK
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.
FUS2
The teach pendant screen displays alarm information such as 1 Check that +24E used by the peripheral device is free from a
Hand broken (SERVO – 006) or Robot overtravel (SERVO –
ground fault.
005).
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
1 Check the units (fans) and cables connected to the CP2 and
CP3 connectors of the power supply unit to see if there is any
short circuit.
2 Replace the DC/DC converter module.
3 Replace the robot control board.
FUS2
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(2) Fuses on the emergency stop board
FUS3 : For monitoring the emergency stop circuit
FUS4 : For controlling the emergency stop circuit and teach pendant
FUS5 : For the brake circuit
Name
Problem caused by blown fuse
Action
FUS3
The teach pendant screen displays SVAL1 TP disabled in T1, T2/Door open (SRVO–233) and so forth.
Replace the emergency stop unit.
FUS4
The power supply to the teach pendant stops, the
screen display of the teach pendant disappears, and
the 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 alarm
information such as Large error in travel (SERVO –
024), Large error at rest (SERVO – 023), Positioning
time over (SERVO – 036), or CLALM alarm (SERVO
– 050) is displayed.
1 Check that the robot interconnection cable (RMP) and intra–mechanical–unit cable are free from faults such as a ground fault and short–circuit.
2 If an additional axis is used, check that the brake connection cable is
free from a ground fault, short–circuit, and any other fault.
3 If a brake power transformer is used, note that a faulty brake power
transformer can cause a too large current to flow. Replace the brake
power transformer.
4 Replace the emergency stop unit.
FUS4
FUS3
FUS5
Emergency stop board
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(3) Blown fuse on the door
Name
Problem caused by blown fuse
FUS6
The power supply unit on the emergency stop unit does
not work, and the power cannot be turned on.
Action
1 Check that the fan unit or cable is not short–circuited.
2 Replace the power supply unit.
FUS6
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(4) Fuse on the power supply module
FU1
Name
FU1
: For protecting 200 VAC input to generate power to the
control circuit
Problem caused by blown fuse
Action
ALL LEDs of the servo amplifiers go out.
1 Replace the fuse (5 A) on the control board of the power supThe teach pendant screen displays the FSSB disconnection
ply module.
alarm or FSSB initialization alarm.
2 Replace the power supply module.
FU1
Remove the face plate
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(5) Fuse on the servo amplifier module
FU1
Name
FU1
: For protecting +24 V input to generate power to the control
circuit
Problem caused by blown fuse
Action
ALL LEDs of the servo amplifier modules go out.
1 Replace the fuse (3.2 A) on the control board of the servo amThe teach pendant screen displays the FSSB disconnection
plifier module.
alarm or FSSB initialization alarm.
2 Replace the servo amplifier module.
FU1
Remove the control board
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3.7
TROUBLESHOOTING
BASED ON LED
INDICATIONS
MAINTENANCE
3. TROUBLESHOOTING
The printed circuit boards and servo amplifier are provided with alarm
LEDs and status LEDs. The LED status and corresponding troubleshooting
procedures are described below.
Robot control board
Emergency stop board
97
Servo amplifier module2 (AMP2)
Servo amplifier module1 (AMP1)
Power supply module (PSM)
3. TROUBLESHOOTING
MAINTENANCE
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(1) TROUBLESHOOTING USING THE LEDS ON THE robot control
board
To troubleshoot an alarm that arises before the teach pendant is ready
to display, check the status LEDs (green) on the robot control board
at power–on.
After power–on, the LEDs light as described in steps 1 to 18, in the
order described. If an alarm is detected, the step in which the alarm
occurred can be determined from which LEDs are lit.
Step
LED
Action to be taken
1: After power–on, all LEDs are
lit.
[Action1] Replace the CPU card
* [Action2] Replace the robot control board.
2: Software operation start–up.
[Action1] Replace the CPU card
* [Action2] Replace the robot control board.
3: The initialization of dram on
the CPU card is completed.
[Action1] Replace the CPU card
* [Action2] Replace the robot control board.
4: The initialization of SRAM
and 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 communication 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 software 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 communication
with the teach pendant.
* [Action1] Replace the robot control board.
* [Action2] Replace the FROM/SRAM module.
9: The loading of optional software 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 SRAM
module 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, specified
data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.
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Step
LED
Action to be taken
12:Axis control card initialization
[Action1] Replace the axis control card.
* [Action2] Replace the robot control board.
[Action3] Replace the servo amplifier.
13:Calibration is completed.
[Action1] Replace the axis control card.
* [Action2] Replace the robot control board.
[Action3] Replace the servo amplifier.
14:Start–up of power application
for 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.
* If the robot control board or FROM/SRAM module is replaced, the contents of memory (parameters, specified
data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.
Axis control card
FROM/SRAM module
(under the CPU card)
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CPU card
3. TROUBLESHOOTING
MAINTENANCE
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(2) TROUBLESHOOTING BY 7–SEGMENT LED INDICATOR
7–segment LED
indicator
Description
[Description] A parity alarm condition has occurred in RAM on the CPU card installed on the robot
control 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 installed
on 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.
* If the robot control board or FROM/SRAM module is replaced, the contents of memory (parameters, specified
data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.
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3. TROUBLESHOOTING
(3) Troubleshooting using a fuse alarm LED
LED 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 port
and requires the power supply of +24 V is sound.
[Action2]
Faulty DC/DC converter module
Replace the DC/DC converter module.
[Action3]
Short–circuited surge absorber PVS1
The system can be operated temporarily without PVS1. However, obtain and
mount a new one at the earliest possible time.
[Action4]
Faulty robot control board
Replace the robot control board.
Cause of the blowing of FUS2 and corrective actions
[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.
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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.
Cause of the blowing of FUS4 and corrective actions
[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.
Cause of the blowing of FUS5 and corrective actions
[Action1]
Check that the robot interconnection cable (RMP) and intra–mechanical–unit
cable 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 from
a ground fault, short–circuit, and any other fault.
[Action3]
If a brake power transformer is used, note that a faulty brake power transformer
can cause a too large current to flow. Replace the brake power transformer.
[Action4]
The emergency stop board is faulty. Replace the emergency stop unit.
FALM LED
Fuse FUS4
Fuse FUS3
Fuse FUS5
Emergency stop board
Emergency stop unit
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3. TROUBLESHOOTING
MAINTENANCE
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Troubleshooting using the LED of the power supply module
The power supply module has a seven–segment LED. When taking
a corrective action corresponding to the LED indication, see the alarm
displayed on the teach pendant screen.
dot part of
seven segment LED
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 requirements.
[Action3]
The power to the main circuit was shut off in the emergency stop release state. Check the emergency stop circuit (emergency stop board, magnetic contactor, external emergency stop input, etc.).
[Description] The main circuit could not be charged within a predetermined 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 operating 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.
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3. TROUBLESHOOTING
MAINTENANCE
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Troubleshooting using the LED of the servo amplifier module
The servo amplifier module has a seven–segment LED. When taking
a corrective action corresponding to the LED indication, see the alarm
displayed on the teach pendant screen.
dot part of
seven segment LED
LED indication
Problem and corrective action
[Description] The internal cooling fan stopped.
[Action1]
Check that the fan is not blocked with a foreign substance.
[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 module.
[Action3]
Replace the servo amplifier module.
[Description] The communication among servo amplifiers cannot be
normally 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.
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MAINTENANCE
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LED indication
3. TROUBLESHOOTING
Problem and corrective action
[Description1] The IPM alarm was detected in the servo amplifier module.
[Action1]
Detach the motor power lines from the connectors CZ2
of the servo amplifier modules, and turn the power on.
a) If this alarm does not occur, go to Action 2.
[Action2]
[Action3]
b) If this alarm occurs, replace the servo amplifier
module.
Detach the motor power lines from the connectors CZ2
of the servo amplifier modules, and check the insulation
between PE and each of the motor 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 amplifier module.
Separate the motor and power line, then check whether
the motor or power line has deteriorated insulation.
a) If the motor insulation is deteriorated, replace the
motor.
b) If the power line insulation is deteriorated, examine
the 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 servo
amplifier 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 lowered. (Check the fan unit and heat exchanger.)
[Action4]
Check that the ambient temperature is not high.
[Action5]
Replace the servo amplifier module.
“8.”, “9.”, and “A.” represent that an alarm occurs on the L–axis, M–
axis, and N–axis respectively.
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3. TROUBLESHOOTING
MAINTENANCE
LED indication
B–81535EN/02
Problem and corrective action
[Description] An abnormal current is flowing to the servo motor.
[Action1]
Check that the servo parameters are set to default values. If this alarm occurs only at a sudden acceleration
or deceleration, the motor operating conditions may be
too harsh. Increase the acceleration/deceleration time
constant and observe the operation.
[Action2]
Detach the motor power lines from the connectors CZ2
of the servo amplifier modules, then turn on the power.
a) If this alarm does not occur, go to Action 2.
[Action3]
[Action4]
b) If this alarm occurs, replace the servo amplifier
module.
Detach the motor power lines from the connectors CZ2
of the servo amplifier modules, then check the insulation
between 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 amplifier.
Separate the motor and power line, then check whether
the motor or power line has deteriorated insulation.
a) If the motor insulation is deteriorated, replace the
motor.
b) If the power line insulation is deteriorated, examine
the robot interconnection cable and intra–robot
cable.
“b”, “C”, and “d” represent that an alarm occurs on the L–axis, M–axis,
and N–axis respectively.
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3.8
POSITION DEVIATION
FOUND IN RETURN
TO THE REFERENCE
POSITION
(POSITIONING)
MAINTENANCE
3. TROUBLESHOOTING
(Check 1)
On the status screen, check the position deviation in the
stopped state. To display the position deviation, press the
screen selection key, and select STATUS from the menu.
Press F1, [TYPE], select AXIS from the menu, then press
the F4, PULSE.
(Corrective action)
Correct the parameters related to return to the reference
position (positioning).
(Check 2)
Check whether the motor axis can be positioned normally.
(Corrective action)
If the motor axis can be positioned normally, check the
mechanical unit.
(Check 3)
Check the mechanical unit for backlash.
(Corrective action)
Replace a faulty key of motor shaft or other faulty parts.
(Check 4)
If checks 1 to 3 show normal results
(Corrective action)
Replace the pulse coder and robot control board.
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3. TROUBLESHOOTING
3.9
VIBRATION
OBSERVED DURING
MOVEMENT
MAINTENANCE
B–81535EN/02
(Check 1)
Check the settings of parameters such as the position loop
gain parameter.
(Corrective action)
Correct parameters.
(Check 2)
Check the mechanical unit for backlash.
(Corrective action)
Replace a faulty key of motor shaft or other faulty parts.
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3.10
MANUAL
OPERATION
IMPOSSIBLE
MAINTENANCE
3. TROUBLESHOOTING
The following explains checking and corrective action required if the
robot cannot be operated manually after the controller is turned on:
(1) Check and corrective action to be made if manual operation is
impossible
(Check 1)
Check whether the teach pendant is enabled.
(Corrective action)
Turn on the teach pendant “enable”.
(Check 2)
Check whether the teach pendant is handled correctly.
(Corrective action)
To move an axis by manual operation, press the axis
selection key and case shift key at the same time.
Set the override for manual feed to a position other than the
FINE and VFINE positions.
(Check 3)
Check whether the ENBL signal of the peripheral device
control interface is set to 1.
(Corrective action)
Place the peripheral device control interface in the ENBL
status.
(Check 4)
Check whether the HOLD signal of the peripheral device
control interface or the HOLD switch on the operator’s panel
is on (hold status). (Check whether the hold lamp on the
teach pendant is on.)
(Corrective action)
Turn off the HOLD signal of the peripheral device control
interface or the HOLD switch on the operator’s panel.
(Check 5)
Check whether the previous manual operation has been
completed.
(Corrective action)
If the robot cannot be placed in the effective area because of
the offset of the speed command voltage preventing the
previous operation from being completed, check the position
deviation on the status screen, and change the setting.
(Check 6)
Check whether the controller is in the alarm status.
(Corrective action)
Release the alarm.
(2) Check and corrective action to be taken if the program cannot be
executed
(Check 1)
Check whether the ENBL signal for the peripheral-device
control interface is on.
(Corrective action)
Put the peripheral-device control interface in the ENBL state.
(Check 2)
Check whether the HOLD signal for the peripheral-device
control interface is on. (Check whether the HOLD lamp on
the teach pendant is on.)
(Corrective action)
If the HOLD signal is on, turn it off. If the HOLD switch
is on, turn it off.
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3. TROUBLESHOOTING
MAINTENANCE
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(Check 3)
Check whether the previous manual operation has been
completed.
(Corrective action)
If the robot cannot be placed in the effective area because of
the offset of the speed command voltage, which prevents the
previous operation from being completed, check the position
deviation on the status screen, then change the setting.
(Check 4)
Check whether the controller is in the alarm status.
(Corrective action)
Release the alarm.
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4
MAINTENANCE
4. PRINTED CIRCUIT BOARDS
PRINTED CIRCUIT BOARDS
The printed circuit boards are factory-set for operation. Usually, you do
not need to set or adjust them. This chapter describes the standard settings
and adjustment required if a defective printed circuit board is replaced.
It also describes the test pins and the LED indications.
The standard printed circuit board includes the main unit printed circuit
board and one or more cards or modules installed horizontally to the
main–unit printed–circuit board.
These boards have interface connectors, LED indicators, and a plastic
panel at the front. At the rear, there is a backplane connector.
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4. PRINTED CIRCUIT BOARDS
MAINTENANCE
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4.1
ROBOT CONTROL
BOARD
(A16B–3200–0450)
FROM/SRAM module
under the CPU card
CPU card
DC/DC converter module
Total version
Axis control card
Fig.4.1 Robot control board
Name
Robot control board
Board Specification
Note
A16B–3200–0450
I/O Link master/slave switcheable, SDI/SDO = 28/24
DC/DC convert module
A20B–8100–0721
CPU card
A20B–3300–0106
SDRAM 8M (Standard)
A20B–3300–0107
SDRAM 16M
A20B–3300–0241
6–axis
A20B–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
Axis control card
FROM/SRAM module
112
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MAINTENANCE
4. PRINTED CIRCUIT BOARDS
(1) LEDs
Seven segment LED
Description
A parity alarm occurred in a RAM of the main CPU
card 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 is
switched on, but it is not abnormal.
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4. PRINTED CIRCUIT BOARDS
MAINTENANCE
Status LED
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Description
STATUS
LED
Indicates the system operating status.
Status LED
FUSE
ALARM
LED
114
Description
A fuse (FUS1 or FUS2) was blown.
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4. PRINTED CIRCUIT BOARDS
MAINTENANCE
(2) Correspondence between driver ICs and DO
Driver IC specification: A76L–0151–0062
Driver 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 IC
If the teach pendant displays nothing because of a damaged teach
pendant connection cable or another reason, the following
communication 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
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4. PRINTED CIRCUIT BOARDS
MAINTENANCE
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4.2
EMERGENCY STOP
BOARD
(A20B–1008–0010,
–0011)
Total version
Fig.4.2 Emergency stop board
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MAINTENANCE
4.3
BACKPLANE BOARD
(A20B–2003–0330)
Total version
117
4. PRINTED CIRCUIT BOARDS
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B–81535EN/02
4.4
PROCESS I/O
BOARD HE
(A16B–2203–0764),
HF (A16B–2203–0765)
Total edition
Test pins
Fig.4.4 Process I/O Board HA
(1) Test pins
Name
Use
P24V
P5V
GND1
GND2
GND3
+24V
+5V
GND
GND
GND
For measuring the DC supply voltage
P24VF
P5VF
GNDF
+24V
+5V
GND
Power for the digital/analog converter
AO1
AO2
Channel 1
Channel 2
For measuring the voltage of the analog output signal (digital/analog)
(2) Settings
Name
ICOM1
UDI1 to UDI20
(Connector CRM2A)
UDI21 to UDI40
ICOM2
(Connector CRM2B)
ICOM3
Standard
setting
WDI01 to WDI08
(Connector CRW7)
118
Side A
Description
The common voltage is
adjusted to:
Side A : +24 V common
Side B : 0 V common
B–81535EN/02
MAINTENANCE
4. PRINTED CIRCUIT BOARDS
(3) Adjustment
VR1/VR2: Adjusts the gain and the offset of channel 1.
Execute a robot program and set AOUT[1] to 3413 on the teach
pendant. Connect a digital voltmeter to test pin AOUT1 and
rotate VR1 or VR2 until the meter reads 15.0 V.
Connect the negative (–) lead of the digital voltmeter to test pin
GNDF. (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 teach
pendant. Connect the digital voltmeter to test pin AOUT2 and
rotate VR3 or VR4 until the meter reads 15.0 V.
Connect the negative (–) lead of the digital voltmeter to test pin
GNDF. (The 0VF test pin is different from the common GND
test pin.)
(4) LEDs
Color
Description
Red
A communication alarm occurred between
the main CPU and process input/output.
Red
A fuse (FUSE 1) in the process input/output
below.
(5) Correspondence between driver chips and DO signals
Ordering code for the driver chips: A76L-0151-0062
Driver chip
DV1
DV2
DV3
DV4
DV5
DV6
DV7
DV8
DV9
DV10
DO signal
CMDENBL, SYSRDY, PROGRUN, PAUSED
HELD, FAULT, ATPERCH, TPENBL
BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
SDO01, SDO02, SDO03, SDO04
SDO05, SDO06, SDO07, SDO08
SDO09, SDO10, SDO11, SDO12
SDO13, SDO14, SDO15, SDO16
SDO17, SDO18, SDO19, SDO20
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5. SERVO AMPLIFIERS
5
MAINTENANCE
B–81535EN/02
SERVO AMPLIFIERS
The servo amplifiers are factory-set for operation. Usually, you do not
need to set or adjust them.
This chapter describes the standard settings and adjustment required if a
defective servo amplifier is replaced. It also describes the use of test pins
and meanings of the LED indications.
Table 5 Servo amplifier specifications
Robot
LR Mate 100iB
LR Mate 200iB
ARC Mate 50iB
Power supply module
A06B–6115–H001
(αPSMR–1i)
A06B–6115–H001
(αPSMR–1i)
Servo amplifier module1
A06B–6114–H205
(αSVM–20/20i)
L
M
J1
J2
A06B–6114–H302
(αSVM–10/10/10i)
L
M
N
J1
J2
J3
120
Servo amplifier module2
A06B–6114–H302
(αSVM–10/10/10i)
L
M
N
J3
J4
J5
A06B–6114–H302
(αSVM–10/10/10i)
L
M
N
J4
J5
J6
5. SERVO AMPLIFIERS
MAINTENANCE
B–81535EN/02
5.1
OUTLINE DRAWINGS
5.1.1
Power Supply Module
PSM (A06B–6115–H001)
380
360
60
172
Fig.5.1.1 Outline drawing of power supply module PSM (A06B–6115–H001)
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5. SERVO AMPLIFIERS
MAINTENANCE
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5.1.2
Servo Amplifier Module
(A06B–6114–H205,
A06B–6114–H302)
A06B–6114–H205
A06B–6114–H302
380
360
60
172
Fig.5.1.2 Outline drawing of servo amplifier modules (A06B–6114–H205, A06B–6114–H302)
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5. SERVO AMPLIFIERS
MAINTENANCE
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5.2
LED OF SERVO
AMPLIFIER
5.2.1
LED of Power Supply
Module
dot part of
seven segment LED
The power supply module has a seven–segment LED. When taking a
corrective action corresponding to the LED indication, see the alarm
displayed on the teach pendant screen.
LED indication
Description
The magnetic contactor controlled by the power supply module is in
the off state and is not ready for driving the motor.
The magnetic contactor controlled by the power supply module is in
the 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.
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5. SERVO AMPLIFIERS
MAINTENANCE
5.2.2
LED of Servo Amplifier
Module
dot part of
seven segment LED
B–81535EN/02
The servo amplifier module has a seven–segment LED. When taking a
corrective action corresponding to the LED indication, see the alarm
displayed on the teach pendant screen.
LED indication
Description
The main circuit in the servo amplifier module is in the off state and is
not ready for driving the motor.
The main circuit in the servo amplifier module is in the on state and is
ready 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 normally performed.
a) The IPM alarm was detected in the servo amplifier module.
b) The IPM alarm (overheat) was detected in the servo amplifier module.
“8.”, “9.”, and “A.” represent that an alarm occurs on the L–axis, M–
axis, and N–axis respectively.
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.
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6
MAINTENANCE
6. SETTING THE POWER SUPPLY
SETTING THE POWER SUPPLY
The power supply is factory-set for operation. Usually, you do not need
to set or adjust it.
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6. SETTING THE POWER SUPPLY
MAINTENANCE
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6.1
BLOCK DIAGRAMS
OF THE POWER
SUPPLY
AC input
200 – 220 VAC
3φ
Servo amplifier
Power supply module
Magnetic
contactor
(MCC)
Circuit
protector
200VAC
2φ
200VAC
3φ
FUS6
200VAC
CZ1
2φ
CX1
Main circuit
DC link
FU1
regenerative
resistor
FAN
AC/DC
+24V
Emergency stop
unit
Power
supply
unit
CN1
AC/DC
+24V
Emergency stop
print board
FUS3
Servo
amplifier
module
CP5A
FUS4
Monitor circuit
CP5B
CRR77
CXA2A
L+, L–
CXA2B
L+, L–
Inverter
circuit
DC/DC
+5V
JF1–3
CZ2 L–N
EmergenFUS5
cy stop
circuit
Brake
circuit
CRS1
TBEB3
+24T
Backplane
Robot control
board
DC/DC
converter
module
+5V, +3.3V
+15V, –15V CP8B
+24V
FUS1 CP5
Motor brake
Motor powersupply
BATTERY
Robot
Pulsecoder
Motor
End Effector
+24E
FUS2
+24E
CRM82
Teach pendant
+24E
CRM79
Peripheral device
+24E
Peripheral device
(option)
CRM81
+24V
JD17
Handy file etc.
Process I/O board
+24E FUSE1
+24F
Peripheral device
(option)
CRM2
CRM4
+24E
+24V
–15V
+15V
+5V
+3.3V
Fig.6.1 Block diagram of the power supply
126
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6.2
CHECKING THE
POWER SUPPLY
UNIT
6.3
CHECKING THE
POWER SUPPLY
MODULE
MAINTENANCE
6. SETTING THE POWER SUPPLY
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%
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7. REPLACING A UNIT
7
MAINTENANCE
B–81535EN/02
REPLACING A UNIT
This section explains how to replace each unit in the control section.
WARNING
Before you start to replace a unit, turn off the control unit
main power. Also keep all machines in the area of the control
unit switched. Otherwise, you could injure personnel or
damage equipment.
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MAINTENANCE
7. REPLACING A UNIT
7.1
REPLACING THE
PRINTED–CIRCUIT
BOARDS
CAUTIONS
When you replace printed–circuit boards, observe the
following cautions:
1 Keep the control unit power switched off.
2 When you remove a printed–circuit board, do not touch the
semiconductor devices on the board with your hand or
make them touch other components.
3 Make sure that the replacement printed–circuit board has
been set up appropriately. (Setting plug etc.)
4 If the backplane board, power supply unit, or Robot control
board (including cards and modules) is replaced, it is likely
that robot parameters and taught data are lost. Before you
start to replace these components, save a backup copy of
the robot parameters and taught data to a memory card,
floppy disk, or any other external memory device.
5 Before you disconnect a cable, note its location. If a cable
is detached for replacement, reconnect it exactly as before.
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7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
7.1.1
When replacing the backplane board, do so together with the plastic rack.
Replacing the
Backplane Board (Unit)
(1) Detach the cables from the robot control board and boards on the
backplane board.
CAUTION
When you remove the main robot control Board, be sure
that the battery is good (3.1–3.3VDC) and it is installed
correctly. USE STATIC PROTECTION.
(2) Remove the robot control board and boards from the rack. (See
Section 7.1.2.)
(3) Detach the grounding cable from the backplane unit.
(4) Loosen the retaining screws in the upper section of the rack. Remove
the retaining screws from the lower section of the rack.
(5) Side rack up and out.
(6) To replace the backplane and rack, reverse steps (1) – (6).
CAUTION
There is a possibility of data loss when a backplane board
is replaced. Be sure to back up all program and setup data
on a floppy disk before proceeding.
Backplane board
M5 nut (2 places)
Fig.7.1.1 Replacing the Backplane Board
130
7.1.2
Replacing the Robot
Control Board and
Printed–Circuit Boards
on the Backplane Unit
7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
The backplane unit incorporates the power unit, Robot control board, and
option boards. There are two types of option boards: Full–size board and
mini–size board. A full–size board occupies one slot. A mini–size board
uses part of a full–size board.
CAUTION
Before starting replacement, turn off the control unit main
power. The robot control board is equipped with
battery–backed memory devices for holding robot
parameters and taught data, for example. When the Robot
control board is replaced, the data in the memory devices
is lost.
(1) Detach the cable from the printed–circuit board, whichever is to be
replaced.
(2) Pinch the barbed handles on the upper and lower sections of the board
to unlatch it, then pull it toward you.
(3) Place the replacement board on the rail in the appropriate slot of the
rack, then push it in gently by the handles until it is latched.
(4) There are two rails in the robot control board SLOT (slot 1). When
inserting the robot control board, align it to the right–side rail.
Slot 1
Option slot
Slot 1
Slot 10
Barbed
handles
Slot 2
Rail
(Left)
Slot 9
Rail
(Right)
zoom
Barbed
handles
Fig.7.1.2 Replacing the Robot Control Board and Printed–Circuit Boards
on the Backplane Unit
131
7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
7.1.3
The board is at the emergency stop unit.
Replacing the
Emergency Stop Board
(1) Detach all cables from the emergency stop unit consists of the
emergency stop board and the power supply unit. The terminal blocks
(TBEB1 and TBEB2) are of a connector type. Pull out the upper
terminal block sections.
(2) Remove four retaining nuts from the emergency stop unit (1, 2), and
replace the emergency stop unit.
(3) Remove six retaining screws from the emergency stop board (3), and
replace the emergency stop board.
1 Remove the front nuts
(2–M5)
2 Remove the back nuts (2–M5)
3 Remove the
screws (6–M3)
Fig.7.1.3 Emergency stop board replacement
132
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7. REPLACING A UNIT
MAINTENANCE
7.2
REPLACING CARDS
AND MODULES ON
THE ROBOT
CONTROL BOARD
CAUTION
Before you start to replace a card or module, make a backup
copy of robot parameters and taught data. If the FROM/SRAM
module is replaced, memory contents are lost.
Demounting a Card
(1) Pull outward the clip of each of the two spacers used to secure the card
PCB, then release each latch.
(2) Extract the card upward.
Card
Card
Card
Card
Spacer
Connector
Card
Spacer
Connector
Fig.7.2 (a) Demounting a card
133
7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
Mounting a Card
(1) Check that the clip of each of the two spacers is latched outward, then
insert the card into the connector.
(2) Push the clip of each spacer downward to secure the card PCB.
Card
Spacer
Connector
Card
Card
Card
Card
Spacer
Connector
Fig.7.2 (b) Mounting a card
134
MAINTENANCE
B–81535EN/02
7. REPLACING A UNIT
Demounting a module
CAUTION
When replacing the module, be careful not to touch the
module contact. If you touch the contact inadvertently, wipe
out dirt on the contact with a clean cloth.
(1) Move the clip of the socket outward. (a)
(2) Extract the module by raising it at a 30 degree slant and pulling
outward.
Mounting a module
(1) Insert the module at a 30 degree slant into the module socket, with
side B facing upward. (b)
(2) Push the module inward and downward until it is locked. (c)
(a)
(b)
(c)
Fig.7.2 (c) Demounting/Mounting a module
135
7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
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.
FROM/SRAM module
under the CPU card
CPU card
DC/DC converter module
Total version
Axis control card
Fig.7.2 (e) Locations of Cards and Modules
136
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7. REPLACING A UNIT
MAINTENANCE
7.3
REPLACING THE
TRANSFORMER
WARNING
Before you start replacement procedure, turn off the main
power to the control unit.
7.3.1
Replacing the Brake
Power Transformer
(1) Detach the cable from the transformer.
(2) Remove the two nuts (M5) securing the transformer, then replace the
transformer.
(3) Re–connect the cable.
Remore the nuts (2–M5)
Fig.7.3.1 Replacing the brake power transformer
137
7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
7.4
REPLACING THE
EMERGENCY STOP
UNIT
WARNING
Before you start replacement, turn off the control unit main
power.
(1) Detach the cables from the emergency stop unit.
(2) Remove retaining screws (4–M5) from the emergency stop unit, and
replace the emergency stop unit.
(3) Reconnect the cables.
Nut (4–M5)
2 Remove the back nuts
(2–M5) screws
1 Remove the front nuts
(2–M5) screws
Fig.7.4 Replacing the Emergency Stop Unit
138
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MAINTENANCE
7. REPLACING A UNIT
7.5
REPLACING THE
MAGNETIC
CONTACTOR
WARNING
Before starting the replacement, turn off the control unit
main power.
(1) Detach the cable from the magnetic contactor (MCC).
(2) Holding down the magnetic contactor (MCC) a little, remove the
MCC 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
139
7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
7.6
REPLACING SERVO
AMPLIFIERS
WARNING
Before you start replacement, turn off the control unit main
power.
The following is the procedure for replacing the power supply module and
servo amplifier module.
(1) Detach the cable from the servo amplifier. Remove the jumper
connecting 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 DC
link (L+ and L–).
Nut
(2–M5)
Power supply
module
servo amplifier
module
Fig.7.6 Replacing the servo Amplifier
140
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7.7
REPLACING THE
TEACH PENDANT
7. REPLACING A UNIT
MAINTENANCE
The specifications of the teach pendant vary with its use. When you
replace the teach pendant, check its specifications carefully.
(1) Be sure that the power of a robot controller is off.
(2) Detach the cable from the teach pendant.
(3) Replace the teach pendant.
Detach or attach the cable by rotating
the connector retaining ring.
Fig.7.7 Replacing the Teach Pendant
141
7. REPLACING A UNIT
7.8
REPLACING THE
CONTROL SECTION
FAN MOTOR
MAINTENANCE
B–81535EN/02
The control section fan motor can be replaced without using a tool. The
fan motor is mounted on the fan unit rack.
(1) Be sure that the power of a robot controller is off.
(2) Put your finger in the dent in the upper section of the fan unit, and pull
the fan unit until it is unlatched.
(3) Lift the fan unit slightly, and dismount it from the rack.
(4) Place a replacement fan on the upper section of the rack, and slide it
gently until it is latched.
Fan motor connector
Fan motor
Pull the fan motor unit
toward you to unlatch it.
Fig.7.8 Replacing the Control Section Fan Motor
142
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7.9
REPLACING THE
FAN MOTOR OF THE
SERVO AMPLIFIER
CONTROL UNIT
MAINTENANCE
7. REPLACING A UNIT
The fan motor of the servo amplifier control unit can be replaced without
using 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 press
it in.
Holding the two lugs, pull up the
fan unit in the direction of the arrow
(rightward in the figure).
When mounting the fan motor, note
the orientation of the fan motor and
connector.
Lug
White
Black
Red
Note the orientation
of the connector key.
Fan unit (for width of 60 mm)
Fig.7.9 Replacing the fan motor of the servo amplifier control unit
143
7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
7.10
REPLACING THE
DOOR FAN UNIT AND
HEAT EXCHANGER
WARNING
Before starting the replacement, turn off the control unit
main 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 exchanger
toward you.
(3) Detach the wiring from the door fan unit.
(4) Mount a spare heat exchanger, reversing the removal procedure.
Heat exchange
Door fan unit
Screws (4–M4)
Nut (4–M5)
Fig.7.10 Replacing the door fan unit and heat exchanger
144
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MAINTENANCE
7. REPLACING A UNIT
7.11
REPLACING THE
OPERATOR PANEL
(1) Detach the cable from the circuit protector on the operator panel and
the 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, and
remove 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
NOTE
The operator panel comprises the panel itself and the
cables connected to the robot control board and emergency
stop board.
145
7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
7.12
The power supply unit is mounted on the emergency stop unit.
REPLACING THE
POWER SUPPLY
UNIT
(1) Detach all the cables from the emergency stop unit (emergency stop
board and power supply unit).
(2) Pull out the connector–type terminal block (TBEB1, TBEB2) at the
top.
(3) Remove the four nuts (1 and 2) fastening the emergency stop unit, and
remove the emergency stop unit.
(4) Unscrew the four screws fastening the power supply unit, and replace
the power supply unit.
1 Remove the front nuts
(2–M5)
2 Remove the back nuts (2–M5)
3 Remove the screws (4–M3)
Fig.7.12 Replacing the power supply unit
146
MAINTENANCE
B–81535EN/02
7.13
7. REPLACING A UNIT
If a fuse of the control unit is blown, find out the cause, take an appropriate
action, then replace the fuse.
REPLACING A FUSE
7.13.1
The robot control board has the following fuses.
Replacing a Fuse on
the Robot Control
Board
FUS1: For detecting a problem in the circuit on the robot control board:
A60L–0001–0046#7.5
If this fuse is blown, the DC/DC converter module or a device
connected to the RS–232–C/RS–422 port may be faulty. If the
device 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#7.5
If this fuse is blown, the wiring to the peripheral device and a cable
may be incorrect or damaged.
FUS1
FUS2
Fig.7.13.1 Replacing a fuse on the robot control board
147
7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
7.13.2
The emergency stop board has the following fuses.
Replacing a Fuse on
the Emergency Stop
Board
FUS3: For monitoring the emergency stop circuit: A60L–0001–0046#1.0
If 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 and
teach pendant: A60L–0001–0046#1.0
If this fuse is blown, the emergency stop circuit may be incorrectly
routed, or the teach pendant or teach pendant cable may be faulty.
Check the routing of the emergency stop circuit, and replace the
teach pendant and teach pendant cable.
FUS5: For monitoring the emergency stop circuit: A60L–0001–0245
#GP20
If the fuse is blown, the brake circuit may be faulty. Examine the
brake, robot, and robot interconnection cable. Alternatively,
replace the emergency stop board.
FUS4
FUS3
FUS5
Emergency stop board
Fig.7.13.2 Replacing a fuse on the emergency stop board
148
B–81535EN/02
MAINTENANCE
7. REPLACING A UNIT
7.13.3
The door has the following fuse.
Replacing the Fuse on
the Door
FUS6: For protecting the 200VAC control output: A60L–0001–0101#
P475H
If this fuse is blown, the power supply unit on the emergency stop
unit or the cooling fan unit may be faulty. Replace the power
supply unit or cooling fan unit.
FUS6
Fig.7.13.3 Replacing a fuse on the emergency stop board
149
7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
7.13.4
The power supply module has the following fuse.
Replacing the Fuse on
the Power Supply
Module
FU1: For protecting the 200VAC input for generating power to the
control circuit: A60L–0001–0359
If 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
150
B–81535EN/02
7. REPLACING A UNIT
MAINTENANCE
7.13.5
The servo amplifier module has the following fuse.
Replacing the Fuse on
the Servo Amplifier
Module
FU1: For protecting the +24 V input for generating power to the control
unit: A60L–0001–0290#LM32C
If 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
151
7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
7.13.6
The following fuse is on each process I/O board.
Replacing the Fuse on
the Process I/O Boards
FUSE1:Fuse for protecting the +24V output for peripheral equipment
interfaces.
A60L–0001–0046#2.0
Process I/O board HE, HF
FUSE1
Total
edition
152
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7.14
REPLACING A
RELAY
7. REPLACING A UNIT
MAINTENANCE
Prolonged use of a relay might result in its contacts failing to make a
secure connection or in them sticking to each other permanently. If such
a failure occurs, replace the relay.
7.14.1
The emergency stop board has the following relays.
Replacing a Relay on
the Emergency Stop
Board
KA6: For external emergency stop output: A58L–0001–0192#1509A
KA7: For brake control: A58L–0001–0192#1997R
KA6
KA7
Emergency stop board
Fig.7.14.1 Replacing a relay on the emergency stop board
153
7. REPLACING A UNIT
MAINTENANCE
B–81535EN/02
7.15
REPLACING
BATTERY
7.15.1
Battery for Memory
Backup (3 VDC)
The programs, and system variables are stored in the SRAM in the Robot
control board. The power to the SRAM memory is backed up by a lithium
battery mounted on the front panel of the Robot control board. The above
data is not lost even when the main battery goes dead. A new battery can
maintain the contents of memory for about 4 years (Note).
When the voltage of the battery becomes low, the battery alarm LED on
the operator panel is lit, and the low–voltage battery alarm (system–035)
is displayed on the teach pendant. When this alarm is displayed, replace
the battery as soon as possible. In general, the battery can be replaced
within one or two weeks, however, this depends on the system
configuration.
If the battery voltage gets lower, it becomes impossible to back up the
content of the SRAM. Turning on the power to the in this state causes
system not to start and LED of seven segment on the Robot control board
to be displayed “1” because the contents of memory are lost. Clear the
entire SRAM memory and reenter data after replacing the battery.
Important data should be saved to the memory card or floppy disk
beforehand in case of emergency.
When replacing the memory backup battery, do so while the robot
controller is turned off in case of emergency.
NOTE
In a newly introduced robot, the battery is factory–installed.
Battery replacement may, therefore, be needed within 4
years after the introduction of the robot.
Replacing the lithium
battery
(1) Prepare a new lithium battery (ordering drawing number:
A02B–0200–K102).
(2) Turn the robot controller on for about 30 seconds.
(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 detach
its connector.
154
B–81535EN/02
MAINTENANCE
Battery latch
7. REPLACING A UNIT
Battery
connector
Lithium battery
(5) Remove the old battery, insert a new one into the battery holder, and
attach the connector. Confirm that the battery is latched firmly.
WARNING
Using other than the recommended battery may result in the
battery exploding.
Replace the battery only with the specified battery
(A02B–0200–K102).
CAUTION
Complete the steps (3) to (5) within 30 minutes.
If the battery is left disconnected for a long time, the
contents of memory will be lost.
To prevent possible data loss, it is recommended that the
robot data such as programs and system variables be
backed up before battery replacement.
Dispose of the replaced battery as an industrial waste, according to the
laws and other rules in the country where the controller is installed and
those established by the municipality and other organizations that have
jurisdiction over the area where the controller is installed.
155
III CONNECTION
CONNECTIONS
B–81535EN/02
1
1. GENERAL
GENERAL
This chapter describes the connection and the installation of the electrical
interface.
159
2. BLOCK DIAGRAM
2
CONNECTIONS
B–81535EN/02
BLOCK DIAGRAM
Following are the block diagrams of the electrical interface connection for
R–J3iB Mate.
R–J3iB Mate controller
Peripheral device
Robot
control
board
Operation
panel
(RDI/RDO)
RS–232–C
RS–422/485
Teach pendant
Emergency
stop unit
Power
supply
unit
Emergency stop
board
(Note2)
Emergency stop
(Brake)
Transformer
Robot
Fan
Fuse
Pulse coder
Circuit
protector
MCC
Servo
amplifier
Power
NOTE
Tranceformer is installed when the robot is for 6–axes brake
specification.
160
3
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
CONNECTION DETAILS
Robot control
board
Emergency
stop unit
CP8B
EMGIN11, 12, 21, 22
FENCE11, 12, 21, 22
CP5B
Battery
CP5
Emergency
stop circuit
CRS24
JRS12
EMGOUT1, 2
EXT24V, 0V
CRS16
PCMCIA
Teach pendant
PCMCIA
COP10A
Servo amplifier
CRM82
Mechanical unit
JD17
RS–232–C or RS–422/485
JD1A
I/O Link (master)
JD1B
I/O Link (slave : option)
CRM79
Peripheral device
CRM81
Peripheral device (option)
161
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.1
CONNECTION OF
POWER SUPPLY
CABLE
When the stand–alone controller is used, an optional power cable can be specified.
A grounding stud is provided
beside the circuit protector.
Connect the primary power
ground wire to this stud. Use
an M4 crimp terminal.
Use the cable holders are
provided at these locations.
Circuit protector
To primary power supply
3Φ200VAC
Terminal is M4.
By using cable straps, secure
the primary power cable to the
screws used to fasten the fan.
NOTE
Connect the primary power cable to the circuit protector. After connection, insulate
the protector terminal by fitting the provided terminal cover. Connect the primary
power ground wire to the grounding stud, located beside the circuit protector.
You can specify the power supply cables as the option.
162
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.2
FANUC I/O LINK
Table 3.2 Types of FANUC I/O Links
I/O Link
No.
1
Name
Robot control board
Drawing number
A16B–3200–0450
Master
Slave
f(*)
f(*)
Remarks
Standard
NOTE
The I/O Link of the robot control board is in the master mode
by default. The I/O Link can be used in the slave mode by
changing the software parameter setting.
Refer to the operator’s manual for setting slave mode.
163
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
ÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
ÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏ
ÏÏÏ
ÏÏ
ÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
ÏÏ
ÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏ
ÏÏ
ÏÏ
ÏÏ
ÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
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)
to other I/O link
JD4*
JD4*
Process I/O
printed boord etc.
JD1A
R–J3iB Mate
*Note that the connector name differs from
that of the standard FANUC I/O link.
When the R–J3iB Mate control unit is used as the master and a slave of an I/O link
JD1B
JD1A
FANUC I/O
Unit etc.
R–J3iB Mate
master
JD1B1
JD1A1
FANUC I/O Link
connection unit
JD1A2
JD1B2
JD1A
JD1B
FANUC I/O
Unit etc.
CNC, PLC
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)
ÏÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏÏ
ÏÏÏÏÏÏ
ÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏ
ÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏ
JD1B
JD1A
CNC, PLC
to other I/O link
JD1A
R–J3iB Mate
*Note
Robot control board is required./Switch by the software
164
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.3
CONNECTION OF I/O
LINK CABLE
Cable connections should be made according to the system. The customer is
requested to ground the shield.
JD1A
JD1B
Robot control board
For other I/O link
Earth plate
Peel off the sheath of the shielded
cable, then ground the shield here.
I/O Link cable connection
1. Customer should be prepare this cable.
2. Power off when it is connected.
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏ
When making a connection with a CNC via an I/O link, apply the following timing to turn
the 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 been
started, 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
11
0V
01 RXSLC1
11
0V
01 RXSLC2
12
0V
02 *RXSLC1
12
0V
02 *RXSLC2
0V
03 TXSLC2
13
0V
03 TXSLC1
13
14
0V
04 *TXSLC1
14
0V
04 *TXSLC2
0V
05
0V
15
0V
05
15
16
0V
06
16
07
17
08
18
09 (+5V)
19
10
20
17
18
(+5V)
19
20
(+5V)
Note) When using an optical
I/O link adaptor, use +5V.
06
07
(+5V)
08
09 (+5V)
(+5V)
10
Note) When using an optical I/O link
adaptor, use +5V.
(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.
165
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
Cable connection
Master
I/O unit, etc
JD1B
Robot control board
JD1A
RXSLC1 (1)
*RXSLC1 (2)
TXSLC1 (3)
*TXSLC1 (4)
0V (11)
0V (12)
0V (13)
0V (14)
0V (15)
0V (16)
(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
Robot control board
JD1B
[RX] SIN (1)
[*RX] *SIN (2)
[TX] SOUT (3)
[*TX] *SOUT (4)
0V (11)
0V (12)
0V (13)
0V (14)
0V (15)
0V (16)
(1) RXSLC2
(2) *RXSLC2
(3) TXSLC2
(4) *TXSLC2
(11) 0V
(12) 0V
(13) 0V
(14) 0V
(15) 0V
(16) 0V
166
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.4
EMERGENCY STOP
CIRCUIT
3.4.1
Circuit Diagram of
Emergency Stop
Teach pendant
Emergency
stop button
Emergency stop board
+24T
(From CP5A)
24VIN +24EXT
CRS16
FUS4
+24V
FUS3
Operation panel
mode switch
+24EXT +24V
CRT11
AUTO
T1
SR2–1
SR2–2
Enable/Disable switch
+24T
SR2–3
+24EXT
KA1–3 KA2–2 KA3–2
0V
Emergency stop button
+24V
Dead man switch
KA1–1
+24EXT
Robot control
board
JRS12
+24V
0VEXT
CRS24
TBEB1
INT24V
MODE1
EXT24V
MODE2
INT0V
24V external
power supply
EXT0V
OP–EMG
External
emergency stop
0V
0VEXT
EMGIN11
EMGIN12
FENCE
0VEXT
EMGIN21
KA2–1
EMGIN22
EX–EMG
+
MCCMON
FENCE11
TBEB2
Safety fence
FENCE12
Mode switch
SR2–1
SR2–2
SR2–3
AUTO
CLOSE
OPEN
CLOSE
T1
OPEN
CLOSE
OPEN
KA3–1
0VEXT
FENCE21
FENCE22
EMGOUT1
CRM83 +24V
Servo amplifier
(α PSMR–1i)
EMGOUT1
KA6–1
CRR78
CX3
MCCOFF3
0V
MCCOFF4
0V
RL1
KA6–2
+24V
CX4
+24V
ESP
MCC
(KM1)
KM1–1
KM1–2
KM1–3
3φ200VAC
KM1–4
KM1–5
167
CZ1
ESP
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.4.2
External Emergency
Stop Input
Customer should prepare this cable
TBEB1
EMGIN11
EMGIN12
EMGIN21
EMGIN22
Cable holder
ÏÏ
ÏÏ
EMGIN11
EMGIN12
EMGIN21
EMGIN22
FENCE11
FENCE12
FENCE21
FENCE22
EMGIN1
EMGIN2
SVOFF1
External emergency
stop input
Servo off input
ÏÏ
ÏÏ
When the robot is shipped, EMGIN11 and EMGIN12/
EMGIN21 and EMGIN22, FENCE11 and FENCE12/
FENCE21 and FENCE22 are short–connected. To
enable external emergency stop input and fence
input, first disconnect these jumper wires, then make
the necessary connections.
External emergency stop input is reflected in the
external emergency stop output, but fence input is
not reflected in the external emergency stop output.
Confirm the operation of emergency stop switches on
the teach pendant and on the front panel, after you
wired the external emergency stop input and the
servo off input.
ÏÏ
ÏÏ
SVOFF2
Emergency stop board
EXT24V
INT24V
INT0V
EXT0V
TBEB2
FENCE11
FENCE12
FENCE21
FENCE22
EMGOUT1
EMGOUT2
ÏÏ
ÏÏ
NOTE
The contact between EMGIN11 and EMGIN12 or between
FENCE11 and FENCE12 opens or closes the emergency
stop circuit. The contact between EMGIN21 and EMGIN22
or between FENCE21 and FENCE22 monitors the input
state. (Single–channel with monitoring safety circuit)
When using external emergency stop input and fence input,
prepare the contact for opening and closing the emergency
stop circuit and the contact for monitoring.
168
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.4.3
External Emergency
Stop Output
Customer should prepare this cable.
ÏÏ
ÏÏ
ÏÏ
ÏÏ
Cable holder
EMGOUT1
EMGOUT2
TP
Emergency
stop
ÏÏ
ÏÏ
ÏÏ
ÏÏ
Emergency stop from the teach pendant and
emergency stop from the operator panel are
reflected to the external emergency stop outputs, EMGOUT1 and EMGOUT2.
OP
Emergency
stop
TBEB1
EMGIN11
EMGIN12
EMGIN21
EMGIN22
TBEB2
FENCE11
FENCE12
FENCE21
FENCE22
EMGOUT1
EMGOUT2
EXT24V
INT24V
INT0V
EXT0V
Emergency stop board
EMGOUT11
EMGOUT12
169
To peripheral control sequencer etc.
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.4.4
External 24 V Input
Customer should prepare this cable.
ÏÏ
ÏÏ
ÏÏ
ÏÏ
Cable holder
EXT24V
EXT0V
Emergency stop board
A short connection board is
inserted at the factory. Before using external 24 V, remove this short connection
board.
24 V
power
supply
+24V
ÏÏ
ÏÏ
ÏÏ
ÏÏ
When 24 V is applied externally, the external
emergency stop outputs, EMGOUT1 and
EMGOUT2, are always output regardless of
the power state of the robot control unit.
TBEB1
EMGIN11
EMGIN12
EMGIN21
EMGIN22
TBEB2
FENCE11
FENCE12
FENCE21
FENCE22
EMGOUT1
EMGOUT2
EXT24V
INT24V
INT0V
EXT0V
EXT24V
INT24V
INT0V
EXT0V
0V
NOTE
Connect a minus ground power supply for externally
connected +24V. The circuit will not function properly if a
plus ground power supply is connected.
170
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.5
COONECTION OF
SERVO AMPLIFIER
LR Mate 100iB
PSM
AMP1
AMP2
POWER SUPPLY
MODULE
(αPSMR–1i)
A06B–6115–H001
SERVO AMPLIFIER
MODULE
(αSVM2–20/20i)
A06B–6114–H205
SERVO AMPLIFIER
MODULE
(αSVM3–10/10/10i)
A06B–6114–H302
TB1
TB1
TB1
from MCC
CZ1
L+
L+
L+
L–
L–
L–
from circuit
protector
from emergency
stop board
COP10B
CX1A
CXA2A
COP10B
CXA2B
CXA2A
CX3
COP10A
CXA2B
CXA2A
JF1 (L)
JF1 (L)
JF2 (M)
JF2 (M)
CX4
JF3 (N)
from robot control
board
CZ2 L
CZ2 L
CZ2 M
CZ2 M
CZ2 N
to robot
Pulse coder
Motor power
LR Mate 200iB/ARC Mate 50iB
PSM
AMP1
AMP2
POWER SUPPLY
MODULE
(αPSMR–1i)
A06B–6115–H001
SERVO AMPLIFIER
MODULE
(αSVM3–10/10/10i)
A06B–6114–H302
SERVO AMPLIFIER
MODULE
(αSVM3–10/10/10i)
A06B–6114–H302
TB1
TB1
TB1
from MCC
CZ1
L+
L+
L+
L–
L–
L–
from circuit
protector
from emergency
stop board
COP10B
CX1A
CXA2A
CXA2B
COP10B
CXA2A
CX3
CXA2B
COP10A
CXA2A
JF1 (L)
JF1 (L)
JF2 (M)
JF2 (M)
CX4
JF3 (N)
JF3 (N)
from robot control
board
CZ2 L
CZ2 L
CZ2 M
CZ2 M
CZ2 N
CZ2 N
to robot
Pulse coder
Motor power
171
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.6
CONNECTION OF
ROBOT
CRM82
JF1–3
Power cable to RMP
Signal cable
Ground cable
TBEB3
172
CZ2 L, M, N
B–81535EN/02
CONNECTIONS
3. CONNECTION DETAILS
3.7
CONNECTION OF
TEACH PENDANT
CABLE
Emergency stop unit
CRS16
To teach pendant
Earth plate
Fig.3.7 Teach pendant cable
173
3. CONNECTION DETAILS
3.8
CONNECTION OF
CABLE FOR
RS–232–C/RS–422
CONNECTIONS
B–81535EN/02
Selection of RS–232–C or RS–422 (option) interface need setting of
software.
Communication port
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01
FG
02
TXD
03
RXD
04
RTS
05
CTS
06
DSR
07
0V
08
09
10
11
12
13
14
(TX)
15
(*TX)
16
(RX)
17
(*RX)
18
19
20
DTR
21
22
23
24
25
174
+24E
Flopply, handy file etc.
Signals whose names are enclosed in
parentheses are assigned to use the
RS–422 (option) interface. The numbers of the interface differ from those
of the standard RS–422 (option) interface. Take the caution when designing the interface.
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.9
CONNECTING A
CABLE TO A
PERIPHERAL
DEVICE
3.9.1
Peripheral Device
Interfaces CRM79 and
CRM81
Table 3.9.1 Types of FANUC I/O Links
Peripheral device interface
No.
1
Name
Robot control board A
Drawing number
A16B–3200–0450
CRM79
CRM81
DI
DO
DI
DO
20
20
8
4
Remarks
Standard
NOTE
The DI and DO signals of CRM79 and CRM81 include
special signals.
Connecting a peripheral device (CRM79 or CRM81)
Robot control board
CRM81
CRM79
to peripheral device
Grounding plate
Strip off the sheathing of the shield cable and
connect the cable to the grounding plate.
Fig.3.9.1 Connecting the peripheral device cable
175
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.9.2
When the Robot is
Connected to the CNC
by a Peripheral Device
Cable
NOTE
See the operator’s MANUAL for the detail information.
Turn off the controller when connecting the cable.
ÏÏÏÏ
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ÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏ
ÏÏ
ÏÏÏÏÏ
ÏÏ
CRM79
Robot
control
board
CNC
CRM81
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ÏÏÏÏÏ
ÏÏÏÏÏ
ÏÏÏÏÏ
ÏÏÏÏÏ
CRM79 interface (Specified signals are not allocated and the Robot
is connected to CNC and PLC by a FANUC I/O Link cable.)
01
SDI101
33
SDO101
02
SDI102
34
SDO102
03
SDI103
35
SDO103
36
SDO104
37
SDO105
38
SDO106
39
SDO107
04
SDI104
05
SDI105
06
SDI106
07
SDI107
08
SDI108
09
SDI109
10
SDI110
11
12
SDI111
SDI112
13
SDI113
14
SDI114
19
SDICOM1
20
SDICOM2
21
SDO120
22
SDI117
23
SDI118
24
SDI119
40
25
SDI120
41
26
SDO117
42
27
SDO118
43
SDO108
SDO109
SDO110
SDO111
28
44
SDO112
29
SDO119
0V
30
0V
45
SDO113
31
+24E
46
SDO114
32
+24E
47
SDO115
48
SDO116
15
SDI115
16
SDI116
17
0V
49
+24E
18
0V
50
+24E
Connector in cable side
HONDA TSUSHIN CO.,LTD
Connector 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.
176
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
CRM79 interface
(standard allocation of specified signals and
the Robot is connected to the CNC and PLC
by a peripheral device cable.)
Connector in cable side
HONDA TSUUSHIN CO.,LTD
Connector MR–50LMH (Male)
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ÏÏÏÏÏÏ
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
0V
49
+24E
18
0V
50
+24E
33
SDO101
34 SDO102
19 SDICOM1
35 SDO103
20 SDICOM2
36 SDO104
21 SDO120
37 SDO105
22 SDI117
38 SDO106
23 SDI118
39 SDO107
24 SDI119
40 SDO108
25 SDI120
41 SDO109
26 SDO117
42 SDO110
27 SDO118
43 SDO111
28 SDO119
44 SDO112
29
0V
45 CMDENBL
30
0V
46
FAULT
31
+24E
47 BATALM
32
+24E
48
BUSY
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.
NOTE
1 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 0V
common can also be used.
3 Allocation of the specified signals can be changed from the
teach pendant.
177
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
CRM79 interface
(standard allocation of specified signals and
the Robot is connected to the CNC and PLC
by a peripheral device cable.)
Connector in cable side
HONDA TSUUSHIN CO.,LTD
Connector MR–50LMH (Male)
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ÏÏÏÏÏÏ
ÏÏÏÏÏ
ÏÏÏÏÏÏ
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
33 CMDENBL
34
19 SDICOM1
35
20 SDICOM2
36
reserve
21
37
22 PNSTROBE
38
23 PROD_START
39
24 SDI119
40
25 SDI120
41
26 ACK7/SNO7
42
27 ACK8/SNO8
43
28
SNACK
44
29
0V
45
30
0V
46
31
+24E
47
32
+24E
48
SYSRDY
PROGRUN
PAUSED
HELD
FAULT
ATPERCH
TPENBL
BATALM
BUSY
ACK1/SNO1
ACK2/SNO2
ACK3/SNO3
ACK4/SNO4
ACK5/SNO5
ACK6/SNO6
17
0V
49
+24E
18
0V
50
+24E
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.
NOTE
1 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, but
the 0V common can also be used.
3 Allocation of the specified signals can be changed from the
teach pendant.
178
CONNECTIONS
B–81535EN/02
3. CONNECTION DETAILS
In case +24V common at the peripheral device side. (Specified signals are not allocated)
Control unit (peripheral device interface : CRM79)
+24E
Peripheral device
Connector pin No
CRM79 (31,32,49,50)
receiver circuit
SDI101
RV
SDI102
RV
SDI103
RV
SDI104
RV
SDI105
RV
SDI106
RV
SDI107
RV
SDI108
RV
SDICOM1
RV
SDI109
RV
SDI110
RV
SDI111
RV
SDI112
RV
SDI113
RV
SDI114
RV
SDI115
RV
SDI116
RV
SDI117
RV
SDI118
RV
SDI119
RV
SDI120
RV
SDICOM2
RV
CRM79 (1)
3.3k
CRM79 (2)
CRM79 (3)
CRM79 (4)
CRM79 (5)
CRM79 (6)
CRM79 (7)
CRM79 (8)
CRM79 (19)
CRM79 (9)
CRM79 (10)
CRM79 (11)
CRM79 (12)
CRM79 (13)
CRM79 (14)
CRM79 (15)
CRM79 (16)
CRM79 (22)
CRM79 (23)
CRM79 (24)
CRM79 (25)
CRM79 (20)
CRM79 (17,18,29,30)
0V
Fig.3.9.2 (a) Peripheral device control interface : CRM79 (Input signal, +24V common)
179
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
In case 0V common at the peripheral device side. (Specified signals are not allocated)
Control unit (peripheral device interface : CRM79)
+24E
Peripheral device
Connector pin No
CRM79 (31,32,49,50)
receiver circuit
SDI101
RV
SDI102
RV
SDI103
RV
SDI104
RV
SDI105
RV
SDI106
RV
SDI107
RV
SDI108
RV
SDICOM1
RV
SDI109
RV
SDI110
RV
SDI111
RV
SDI112
RV
SDI113
RV
SDI114
RV
SDI115
RV
SDI116
RV
SDI117
RV
SDI118
RV
SDI119
RV
SDI120
RV
SDICOM2
RV
CRM79 (1)
3.3k
CRM79 (2)
CRM79 (3)
CRM79 (4)
CRM79 (5)
CRM79 (6)
CRM79 (7)
CRM79 (8)
CRM79 (19)
CRM79 (9)
CRM79 (10)
CRM79 (11)
CRM79 (12)
CRM79 (13)
CRM79 (14)
CRM79 (15)
CRM79 (16)
CRM79 (22)
CRM79 (23)
CRM79 (24)
CRM79 (25)
CRM79 (20)
CRM79 (17,18,29,30)
0V
Fig.3.9.2 (b) Peripheral device control interface : CRM79 (Input signal, 0V common)
180
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
(Specified signals are not allocated)
Control unit (peripheral device interface : CRM79)
Connector pin No
Driver circuit
SDO101
SDO102
SDO103
SDO104
SDO105
SDO106
SDO107
SDO108
SDO109
SDO110
SDO111
SDO112
SDO113
SDO114
SDO115
SDO116
SDO117
SDO118
SDO119
SDO120
Peripheral device
LOAD
CRM79 (33)
DV
RELAY
CRM79 (34)
DV
LOAD
CRM79 (35)
DV
LOAD
CRM79 (36)
LOAD
DV
CRM79 (37)
DV
LOAD
CRM79 (38)
DV
LOAD
CRM79 (39)
DV
LOAD
CRM79 (40)
DV
LOAD
CRM79 (41)
DV
LOAD
CRM79 (42)
DV
LOAD
CRM79 (43)
DV
LOAD
CRM79 (44)
DV
LOAD
CRM79 (45)
DV
LOAD
CRM79 (46)
DV
LOAD
CRM79 (47)
DV
LOAD
CRM79 (48)
DV
LOAD
CRM79 (26)
DV
LOAD
CRM79 (27)
DV
LOAD
CRM79 (28)
DV
LOAD
CRM79 (21)
DV
LOAD
CRM79 (17,18,29,30)
0V
0V
+24V
+24V regurated
power supply
Max. current per SDO is 70mA.
Fig.3.9.2 (c) Peripheral device control interface : CRM79 (Output signal)
181
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
In case +24V common at the peripheral device side. (Specified signals are allocated)
Control unit (peripheral device interface : CRM79)
+24E
Peripheral device
Connector pin No
CRM79 (31,32,49,50)
receiver circuit
SDI101
RV
SDI102
RV
SDI103
RV
SDI104
RV
SDI105
RV
SDI106
RV
SDI107
RV
SDI108
RV
SDICOM1
RV
SDI109
RV
SDI110
RV
SDI111
RV
SDI112
RV
SDI113
RV
SDI114
RV
SDI115
RV
SDI116
RV
SDI117
RV
SDI118
RV
SDI119
RV
SDI120
RV
SDICOM2
RV
CRM79 (1)
3.3k
CRM79 (2)
CRM79 (3)
CRM79 (4)
CRM79 (5)
CRM79 (6)
CRM79 (7)
CRM79 (8)
CRM79 (19)
CRM79 (9)
CRM79 (10)
CRM79 (11)
CRM79 (12)
CRM79 (13)
CRM79 (14)
CRM79 (15)
CRM79 (16)
CRM79 (22)
CRM79 (23)
CRM79 (24)
CRM79 (25)
CRM79 (20)
CRM79 (17,18,29,30)
0V
Fig.3.9.2 (d) Peripheral device control interface : CRM79 (Input signal, +24V common)
182
CONNECTIONS
B–81535EN/02
3. CONNECTION DETAILS
In case 0V common at the peripheral device side. (Specified signals are allocated)
Control unit (peripheral device interface : CRM79)
+24E
Peripheral device
Connector pin No
CRM79 (31,32,49,50)
receiver circuit
SDI101
RV
SDI102
RV
SDI103
RV
SDI104
RV
SDI105
RV
SDI106
RV
SDI107
RV
SDI108
RV
SDICOM1
RV
SDI109
RV
SDI110
RV
SDI111
RV
SDI112
RV
SDI113
RV
SDI114
RV
SDI115
RV
SDI116
RV
SDI117
RV
SDI118
RV
SDI119
RV
SDI120
RV
SDICOM2
RV
CRM79 (1)
3.3k
CRM79 (2)
CRM79 (3)
CRM79 (4)
CRM79 (5)
CRM79 (6)
CRM79 (7)
CRM79 (8)
CRM79 (19)
CRM79 (9)
CRM79 (10)
CRM79 (11)
CRM79 (12)
CRM79 (13)
CRM79 (14)
CRM79 (15)
CRM79 (16)
CRM79 (22)
CRM79 (23)
CRM79 (24)
CRM79 (25)
CRM79 (20)
CRM79 (17,18,29,30)
0V
Fig.3.9.2 (e) Peripheral device control interface : CRM79 (Input signal, 0V common)
183
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
(Specified signals are allocated)
Control unit (peripheral device interface : CRM79)
Connector pin No
Driver circuit
SDO101
SDO102
SDO103
SDO104
SDO105
SDO106
SDO107
SDO108
SDO109
SDO110
SDO111
SDO112
SDO113
SDO114
SDO115
SDO116
SDO117
SDO118
SDO119
SDO120
Peripheral device
LOAD
CRM79 (33)
DV
RELAY
CRM79 (34)
DV
LOAD
CRM79 (35)
DV
LOAD
CRM79 (36)
LOAD
DV
CRM79 (37)
DV
LOAD
CRM79 (38)
DV
LOAD
CRM79 (39)
DV
LOAD
CRM79 (40)
DV
LOAD
CRM79 (41)
DV
LOAD
CRM79 (42)
DV
LOAD
CRM79 (43)
DV
LOAD
CRM79 (44)
DV
LOAD
CRM79 (45)
DV
LOAD
CRM79 (46)
DV
LOAD
CRM79 (47)
DV
LOAD
CRM79 (48)
DV
LOAD
CRM79 (26)
DV
LOAD
CRM79 (27)
DV
LOAD
CRM79 (28)
DV
LOAD
CRM79 (21)
DV
LOAD
CRM79 (17,18,29,30)
0V
0V
+24V
+24V regurated
power supply
Max. current per SDO is 70mA.
Fig.3.9.2 (f) Peripheral device control interface : CRM79 (Output signal)
184
CONNECTIONS
B–81535EN/02
3. CONNECTION DETAILS
In case +24V common at the peripheral device side. (Specified signals are allocated quickly)
Control unit (peripheral device interface : CRM79)
+24E
Peripheral device
Connector pin No
CRM79 (31,32,49,50)
receiver circuit
*IMSTP
RV
*HOLD
RV
*SFSPD
RV
CSTOPI
RV
RESET
RV
SRART
RV
HOME
RV
ENBL
RV
SDICOM1
RV
RSR1/PNS1
RV
RSR2/PNS2
RV
RSR3/PNS3
RV
RSR4/PNS4
RV
RSR5/PNS5
RV
RSR6/PNS6
RV
RSR7/PNS7
RV
RSR8/PNS8
RV
PNSTROBE
RV
PROD_START
RV
SDI119
RV
SDI120
RV
SDICOM2
RV
CRM79 (1)
3.3k
CRM79 (2)
CRM79 (3)
CRM79 (4)
CRM79 (5)
CRM79 (6)
CRM79 (7)
CRM79 (8)
CRM79 (19)
CRM79 (9)
CRM79 (10)
CRM79 (11)
CRM79 (12)
CRM79 (13)
CRM79 (14)
CRM79 (15)
CRM79 (16)
CRM79 (22)
CRM79 (23)
CRM79 (24)
CRM79 (25)
CRM79 (20)
CRM79 (17,18,29,30)
0V
Fig.3.9.2 (g) Peripheral device control interface : CRM79 (Input signal, +24V common)
185
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
In case 0V common at the peripheral device side. (Specified signals are allocated quickly)
Control unit (peripheral device interface : CRM79)
Peripheral device
Connector pin No
+24E
CRM79 (31,32,49,50)
receiver circuit
*IMSTP
RV
*HOLD
RV
*SFSPD
RV
CSTOPI
RV
RESET
RV
START
RV
HOME
RV
ENBL
RV
SDICOM1
RV
RSR1/PNS1
RV
RSR2/PNS2
RV
RSR3/PNS3
RV
RSR4/PNS4
RV
RSR5/PNS5
RV
RSR6/PNS6
RV
RSR7/PNS7
RV
RSR8/PNS8
RV
PNSTROBE
RV
PROD_START
RV
SDI119
RV
SDI120
RV
SDICOM2
RV
CRM79 (1)
3.3k
CRM79 (2)
CRM79 (3)
CRM79 (4)
CRM79 (5)
CRM79 (6)
CRM79 (7)
CRM79 (8)
CRM79 (19)
CRM79 (9)
CRM79 (10)
CRM79 (11)
CRM79 (12)
CRM79 (13)
CRM79 (14)
CRM79 (15)
CRM79 (16)
CRM79 (22)
CRM79 (23)
CRM79 (24)
CRM79 (25)
CRM79 (20)
CRM79 (17,18,29,30)
0V
Fig.3.9.2 (h) Peripheral device control interface : CRM79 (Input signal, 0V common)
186
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
(Specified signals are allocated quickly)
Control unit (peripheral device interface : CRM79)
Driver circuit
CMDENBL
SYSRDY
PROGRUN
PAUSED
HELD
FAULT
ATPERCH
TPENBL
BATALM
BUSY
ACK1/SNO1
ACK2/SNO2
ACK3/SNO3
ACK4/SNO4
ACK5/SNO5
ACK6/SNO6
ACK7/SNO7
ACK8/SNO8
SNACK
reserve
Connector pin No
Peripheral device
LOAD
CRM79 (33)
DV
RELAY
CRM79 (34)
DV
LOAD
CRM79 (35)
DV
LOAD
CRM79 (36)
DV
LOAD
CRM79 (37)
DV
LOAD
CRM79 (38)
DV
LOAD
CRM79 (39)
DV
LOAD
CRM79 (40)
DV
LOAD
CRM79 (41)
DV
LOAD
CRM79 (42)
DV
LOAD
CRM79 (43)
DV
LOAD
CRM79 (44)
DV
LOAD
CRM79 (45)
DV
LOAD
CRM79 (46)
DV
LOAD
CRM79 (47)
DV
LOAD
CRM79 (48)
DV
LOAD
CRM79 (26)
DV
LOAD
CRM79 (27)
DV
LOAD
CRM79 (28)
DV
LOAD
CRM79 (21)
DV
CRM79 (17,18,29,30)
0V
LOAD
0V
+24V
+24V regurated
power supply
Max. current per SDO is 70mA.
Fig.3.9.2 (i) Peripheral device control interface : CRM79 (Output signal)
187
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
CRM81 interface
(When a special signal is not allocated; when CNC and PLC are connected
by 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
10
Cable–side connector
YAMAICHI ELECTRICITY
Connector
Housing – UFS–20B–04
Contact – Contact 66 type
(UFS contact)
0V
+24V
0V
CRM81 interface
(When a special signal is allocated; when CNC and PLC are connected
by 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
10
Cable–side connector
YAMAICHI ELECTRICITY
Connector
Housing – UFS–20B–04
Contact – Contact 66 type
(UFS contact)
0V
+24E
0V
SDICOM1 is a common signal that can be used either as an SDI or special
signal.
+24 V common: Connected to 0 V
0 V common: Connected to +24 V
SDICOM ³ Selects a common for SDI81 to SDI88.
CAUTION
The maximum output current of each SDO or special signal
is 70 mA.
188
CONNECTIONS
B–81535EN/02
3. CONNECTION DETAILS
In case +24V common at the peripheral device side. (Specified signal is not allocated.)
Control unit (peripheral device interface : CRM81)
+24E
Peripheral device
Connector pin No
CRM81 (A10)
receiver circuit
SDI81
RV
SDI82
RV
SDI83
RV
SDI84
RV
SDI85
RV
SDI86
RV
SDI87
RV
SDI88
RV
SDICOM
RV
CRM81 (A1)
3.3k
CRM81 (B1)
CRM81 (A2)
CRM81 (B2)
CRM81 (A3)
CRM81 (B3)
CRM81 (A4)
CRM81 (B5)
CRM81 (A5)
CRM81 (B9,B10)
0V
Fig.3.9.2 (j) Peripheral device control interface : CRM81 (Input signal, +24V common)
189
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
In case 0V common at the peripheral device side. (Specified signal is not allocated.)
Control unit (peripheral device interface : CRM81)
+24E
Peripheral device
Connector pin No
CRM81 (A10)
receiver circuit
SDI81
RV
SDI82
RV
SDI83
RV
SDI84
RV
SDI85
RV
SDI86
RV
SDI87
RV
SDI88
RV
SDICOM
RV
CRM81 (A1)
3.3k
CRM81 (B1)
CRM81 (A2)
CRM81 (B2)
CRM81 (A3)
CRM81 (B3)
CRM81 (A4)
CRM81 (B5)
CRM81 (A5)
CRM81 (B9,B10)
0V
Fig.3.9.2 (k) Peripheral device control interface : CRM81 (Input signal, 0V common)
(Specified signal is not allocated.)
Control unit (peripheral device interface : CRM81)
Connector pin No
Driver circuit
SDO8
1
DV
SDO82
DV
SDO83
SDO84
Peripheral device
LOAD
CRM81 (A7)
RELAY
CRM81 (B7)
LOAD
CRM81 (A8)
DV
LOAD
CRM81 (B8)
DV
LOAD
CRM81 (B9,B10)
0V
0V
+24V
+24V regurated
power supply
Max. current per SDO is 70mA.
Fig.3.9.2 (l) Peripheral device control interface : CRM81 (Output signal)
190
CONNECTIONS
B–81535EN/02
3. CONNECTION DETAILS
In case +24V common at the peripheral device side. (Specified signal is allocated quickly)
Control unit (peripheral device interface : CRM81)
+24E
Peripheral device
Connector pin No
CRM81 (A10)
*HOLD
RESET
receiver circuit
RV
3.3k
RV
START
RV
ENBL
RV
PNS1
RV
PNS2
RV
PNS3
RV
PNS4
RV
SDICOM
RV
CRM81 (A1)
CRM81 (B1)
CRM81 (A2)
CRM81 (B2)
CRM81 (A3)
CRM81 (B3)
CRM81 (A4)
CRM81 (B5)
CRM81 (A5)
CRM81 (B9 ,B10)
0V
Fig.3.9.2 (m) Peripheral device control interface : CRM81 (Input signal, +24V common)
191
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
In case 0V common at the peripheral device side. (Specified signal is allocated quickly)
Control unit (peripheral device interface : CRM81)
+24E
Peripheral device
Connector pin No
CRM81 (A10)
receiver circuit
*HOLD
RV
RESET
RV
START
RV
ENBL
RV
PNS1
RV
PNS2
RV
PNS3
RV
PNS4
RV
SDICOM
RV
CRM81 (A1)
3.3k
CRM81 (B1)
CRM81 (A2)
CRM81 (B2)
CRM81 (A3)
CRM81 (B3)
CRM81 (A4)
CRM81 (B5)
CRM81 (A5)
CRM81 (B9 ,B10)
0V
Fig.3.9.2 (n) Peripheral device interface : CRM81 (Input signal, 0V common)
(Specified signal is allocated quickly)
Control unit (peripheral device interface : CRM81)
Peripheral device
Connector pin No
LOAD
driver circuit
CMDENBL
DV
FAULT
DV
BATALM
BUSY
CRM81 (A7)
RELAY
CRM81 (B7)
LOAD
CRM81 (A8)
DV
LOAD
CRM81 (B8)
DV
LOAD
CRM81 (B9 ,B10)
0V
0V
+24V
+24V regurated
power supply
Max. current per SDO is 70mA.
Fig.3.9.2 (o) Peripheral device control interface : CRM81 (Output signal)
192
B–81535EN/02
3.9.3
Digital I/O Signal
Specifications
3. CONNECTION DETAILS
CONNECTIONS
This section describes the specifications of the digital I/O signals
interfaced with the peripheral device and end effector.
3.9.3.1
Peripheral device
interface CRM 79 and
CRM 81
D Output signal regulation
Example of connection
Spark killer diode
+24V
70 mA
or less
0V
0V
+24V
Lamp
70 mA
or less
0V
Protective resistance
D Electrical specifications
Rated voltage
Maximum applied voltage
Maximum load current
Transistor type
Saturation voltage at connection
:
:
:
:
:
D Spark killer diode
Rated peak reverse voltage
Rated effective forward current
: 100 V or more
: 1 A or more
0V
24 VDC
30 VDC
70.mA
Open collector NPN
1.0 V (approx.)
D Notes on use
Do not use the +24 V power supply of the robot.
When loading a relay, solenoid, and so on directly, connect them in
parallel 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.
D Applicable signal
Output signal of peripheral device interface CRM79, CRM81 :
SDI101 to SDI120 (CRM79)
SDI81 to SDI88 (CRM81)
193
3. CONNECTION DETAILS
D Input signal regulation
CONNECTIONS
B–81535EN/02
Example of connection
+24V
SDI n
RV
3.3 kΩ
SDICOM
RV
Example of
+24V common connection
0V
D Electrical specifications of the receiver
Type
: Grounded voltage receiver
Rated input voltage
: Contact close :+20 V to +28 V
Contact open :0 V to +4 V
Maximum applied input voltage : +28 VDC
Input impedance
: 3.3 kΩ (approx.)
Response time
: 5 ms to 20 ms
D Specifications of the peripheral device contact
Rated contact capacity
: 30 VDC, 50 mA or more
Input signal width
: 200 ms or more (on/off)
Chattering time
: 5 ms or less
Closed circuit resistance
: 100Ω or less
Opened circuit resistance
: 100 kΩ or more
TB
(Signal)
TB
(Signal)
TB
Peripheral device
contact signal
Robot receiver signal
TC
TC
TB ;
TC ;
Chattering 5 ms or less
5 to 20 ms
D Note on use
Apply the +24 V power of the robot to the receiver.
However, the above signal regulations must be satisfied at the
robot receiver.
D Applicable signal
Input signal of peripheral device interface CRM79, CRM81 :
SDO101 to SDO120 (CRM79)
SDO81 to SDO84 (CRM81)
194
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.9.4
The figure below shows the connector for peripheral device cable.
Peripheral Device
Cable Connector
Symbol
Name
1
Connector cover
2
Connector 50 pins (male)
Dimensions
Remark
Connector
specification
Applicable
interface
A
(B)
C
(D)
MR50LWM
CRM79
67.9
73.5
66.1
20
Honda Tsushin
Kogyo E φ16
φ 50
pins
Fig.3.9.4 (a) Peripheral Device Cable Connector (CRM79 : Honda Tsushin Kogyo)
195
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
A
B
3.56
2.54
2.54
6.0
14.3
14.5
Connector
specification
Dimensions
Applicable
interface
UFS–20B–04
Remark
A
C
29.98
22.86
CRM81
YAMAICHI ELECTRONICS
(Housing)
YAMAICHI ELECTRONICS
(Contact)
Contact 66 type
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)
3.9.5
Recommended Cables
Connect a peripheral device using a completely shielded, heavily
protected 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
Electrical characteristics
Sheath
thickness
(mm)
Effective
outside
diameter
(mm)
Conductor
resistance
(Ω/km)
Allowable
current (A)
7/0.18
AWG24
1.5
φ12.5
106
1.6
7/0.18
AWG24
1.5
φ10.5
106
1.6
Number of
wires
Wire specifications
(FANUC
specifications)
Diameter
(mm)
Configuration
50
A66L–0001–0042
φ1.05
20
A66L–0001–0041
φ1.05
196
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.10
END EFFECTOR
INTERFACE
3.10.1
Connecting the
Mechanical Unit and
End Effector
Table 3.10.1 Types of end effector interfaces
End effector interface
No.
1
Name
Drawing number
A16B–3200–0450
Robot control board A
DI
DO
6
6
Remarks
Standard
NOTE
Either RDI6 or *PPABN is selected by software.
Mechanical unit
EE
1
2
3
4
5
RDI1
RDI2
RDI3
RDI4
RDI5
7
8
9
10
11
*HBK
+24E
+24E
+24E
0V
6
RDI6
(*PPABN)
12
RDICOM
End effecter
NOTE
RDO1 to RDO6 are used as the signals to turn on or off
solenoid valves. The end effector can use the RDI signals
and *HBK signal.
For RDO signals, refer to the
maintenance manual of the mechanical unit.
197
3. CONNECTION DETAILS
CONNECTIONS
End effecter
Mechanical unit (end effector interface)
+24E
Connector pin No.
EE (8,8,10)
Receiver circuit
RDI1
RV
RDI2
RV
RDI3
RV
RDI4
RV
RDI5
RV
RDI6
(*PPABN)
RV
RDICOM
RV
B–81535EN/02
EE (1)
3.3k
EE (2)
EE (3)
EE (4)
EE (5)
EE (6)
EE (12)
EE (11)
0V
Fig.3.10.1 (a) End effector interface (+24V common)
End effecter
Mechanical unit (end effector interface)
+24E
Connector pin No.
EE (8,8,10)
Receiver circuit
RDI1
RV
RDI2
RV
RDI3
RV
RDI4
RV
RDI5
RV
RDI6
(*PPABN)
RV
RDICOM
RV
EE (1)
3.3k
EE (2)
EE (3)
EE (4)
EE (5)
EE (6)
EE (12)
EE (11)
0V
Fig.3.10.1 (b) End effector interface (0V common)
198
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.10.2
Digital I/O Signal
Specifications of End
Effector Control
Interface
Example of connection
+24V
RDI n
RV
3.3 kΩ
RDICOM
RV
Example of
+24V common connection
0V
Electrical specifications of the receiver
Type
Rated input voltage
: Grounded voltage receiver
: Contact close
: +20 V to +28 V
Contact open
: 0 V to +4 V
Maximum applied input voltage : +28 VDC
Input impedance
: 3.3 kΩ (approx.)
Response time
: 5 ms to 20 ms
Specifications of the peripheral device contact
Rated contact capacity
Input signal width
Chattering time
Closed circuit resistance
Opened circuit resistance
TB
(Signal)
TB
(Signal)
:
:
:
:
:
30 VDC, 50 mA or more
200 ms or more (on/off)
5 ms or less
100 Ω or less
100 kΩ or more
TB
Peripheral device
contact signal
Robot receiver signal
TC
TC
TB ;
TC ;
Chattering 5 ms or less
5 to 20 ms
Note on use
Apply the +24 V power at the robot to the receiver.
However, the above signal specifications must be satisfied at the
robot receiver.
Applicable signals
Input signals of end effector control interface
Additional I/O PCB CRW6 input signal WDI1 to WDI8
RDI 1 to 6, *HBK, *PPABN (Switch RDI6 by software)
199
3. CONNECTION DETAILS
3.11
TREATMENT FOR
THE SHIELDED
CABLE
CONNECTIONS
B–81535EN/02
In this manual the treatment for the shielded cable is shown on several
pages. Partly cut off the shielded cable to expose the shield jacket, and
fasten 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
200
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.12
Connection to the peripheral device and the arc welding is available to use
the process I/O board for R–J3iB Mate.
PERIPHERAL
DEVICE, ARC
WELDING,
INTERFACES
3.12.1
Peripheral Device
Interface Types
No.
Name
1
Process I/O board HE
2
Process I/O board HF
Drawing number
Number of I/O points
DI
DO
D/A
A/D
A05B–2440–J002
40
40
2
6
A05B–2440–J003
40
40
0
0
Remarks
NOTE
General purpose I/O (SDI/SDO) is a number which subtract an exclusive signal from the table
value.
201
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.12.2
Peripheral Device
Interface Block
Diagram and
Specifications
Process I/O
board
HE/HF
Peripheral
device
Main
board
CRM2A
JD4A
(JD1B)
JD1A
(JD4)
CRM2B
JD4B
(JD1A)
CRW7
(NOTE 1)
CRW2
(NOTE1)
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 board
HF.
202
CONNECTIONS
B–81535EN/02
3.12.3
Peripheral Device and
Control Unit Connection
Control unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
3. CONNECTION DETAILS
The connection is for the allocated specified signal.
For detail of the allocation, refer to the OPERATOR’S MANUAL.
Peripheral device control interface A1
CMDENBL
CRM2A
33
*IMSTP
*HOLD
*SFSPD
CSTOPI
FAULT RESET
START
HOME
ENBL
RSR1/PNS1
RSR2/PNS2
RSR3/PNS3
RSR4/PNS4
RSR5/PNS5
RSR6/PNS6
RSR7/PNS7
RSR8/PNS8
0V
0V
19
20
21
22
23
24
25
26
27
28
29
30
31
32
ACK3/SNO3
ACK4/SNO4
ACK5/SNO5
ACK6/SNO6
COM–A4
ACK7/SNO7
ACK8/SNO8
SNACK
RESERVED
COM–A5
PNSTROBE
PROD START
SDI01
SDI02
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
SYSRDY
PROGRUN
PAUSED
COM–A1
HELD
FAULT
ATPERCH
TPENBL
COM–A2
BATALM
BUSY
ACK1/SNO1
ACK2/SNO2
COM–A3
Peripheral
device A1
+24E
+24E
Peripheral device control interface A2
SDO01
CRM2B
33
SDI03
SDI04
SDI05
SDI06
SDI07
SDI08
SDI09
SDI10
SDI11
SDI12
SDI13
SDI14
SDI15
SDI16
SDI17
SDI18
0V
0V
19
20
21
22
23
24
25
26
27
28
29
30
31
32
SDO13
SDO14
SDO15
SDO16
COM–B4
SDO17
SDO18
SDO19
SDO20
COM–B5
SDI19
SDI20
SDI21
SDI22
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
SDO02
SDO03
SDO04
COM–B1
SDO05
SDO06
SDO07
SDO08
COM–B2
SDO09
SDO10
SDO11
SDO12
COM–B3
Peripheral
device A2
+24E
+24E
NOTE
1 Peripheral device connection cable are optional.
2 All COM-** are connected to the 0V.
Applicable process I/O board type
HE, HF
203
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
Peripheral device
Control unit
(peripheral device control interface A1)
+24E Connector pin No.
CRM2A (49,50)
Receiver circuit
*IMSTP
RV
*HOLD
RV
*SFSPD
RV
CSTOPI
RV
CRM2A (1)
3.3k
CRM2A (2)
CRM2A (3)
CRM2A (4)
0V
FAULT RESET
RV
START
RV
HOME
RV
ENBL
RV
RSR1/PNS1
RV
RSR2/PNS2
RV
RSR3/PNS3
RV
RSR4/PNS4
RV
RSR5/PNS5
RV
RSR6/PNS6
RV
RSR7/PNS7
RV
RSR8/PNS8
RV
PNSTROBE
RV
PROD START
RV
SDI01
RV
SDI02
RV
COM–1
CRM2A (5)
CRM2A (6)
CRM2A (7)
CRM2A (8)
CRM2A (9)
CRM2A (10)
CRM2A (11)
CRM2A (12)
CRM2A (13)
CRM2A (14)
CRM2A (15)
CRM2A (16)
CRM2A (29)
CRM2A (30)
CRM2A (31)
CRM2A (32)
RV
+24E
CRM2A (17,18)
B
A
0V
Common setting
pin (ICOM1)
0V
NOTE
This is a connection diagram for +24V common.
204
CONNECTIONS
B–81535EN/02
3. CONNECTION DETAILS
Peripheral device
Control unit
(peripheral device control interface A1)
Connector pin No.
Driver circuit
CRM2A (33)
DV
LOAD
RELAY
CMDENBL
0V
SYSRDY
DV
PROGRUN
DV
PAUSED
HELD
FAULT
ATPERCH
TPENBL
BATALM
BUSY
ACK1/SNO1
ACK2/SNO2
ACK3/SNO3
ACK4/SNO4
ACK5/SNO5
ACK6/SNO6
ACK7/SNO7
ACK8/SNO8
CRM2A (34)
CRM2A (35)
CRM2A (36)
DV
CRM2A (38)
DV
CRM2A (39)
DV
CRM2A (40)
DV
CRM2A (41)
DV
CRM2A (43)
DV
CRM2A (44)
DV
CRM2A (45)
DV
CRM2A (46)
DV
CRM2A (19)
DV
CRM2A (20)
DV
CRM2A (21)
DV
CRM2A (22)
DV
CRM2A (24)
DV
CRM2A (25)
DV
SNACK
DV
RESERVED
DV
CRM2A (26)
CRM2A (27)
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRM2A (23,28,37,42,47)
0V
+24V
+24V regurated
power supply
0V
Max. current per UDO is 70mA
205
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
Peripheral device
Control unit
(peripheral device control interface A2)
+24E
Connector pin No.
CRM2B (49,50)
Receiver circuit
SDI03
RV
SDI04
RV
SDI05
RV
SDI06
RV
SDI07
RV
SDI08
RV
SDI09
RV
SDI10
RV
SDI11
RV
SDI12
RV
SDI13
RV
SDI14
RV
SDI15
RV
SDI16
RV
SDI17
RV
SDI18
RV
SDI19
RV
SDI20
RV
SDI21
RV
SDI22
RV
COM–2
RV
CRM2B (1)
3.3k
CRM2B (2)
CRM2B (3)
CRM2B (4)
CRM2B (5)
CRM2B (6)
CRM2B (7)
CRM2B (8)
CRM2B (9)
CRM2B (10)
CRM2B (11)
CRM2B (12)
CRM2B (13)
CRM2B (14)
CRM2B (15)
CRM2B (16)
CRM2B (29)
CRM2B (30)
CRM2B (31)
CRM2B (32)
CRM2B (17,18)
+24E
B
A
0V
Common setting
pin (ICOM2)
0V
NOTE
This is a connection diagram for +24V common.
206
CONNECTIONS
B–81535EN/02
3. CONNECTION DETAILS
Peripheral device
Control unit
(peripheral device control interface A2)
Connector pin No.
Driver circuit
CRM2B (33)
DV
LOAD
RELAY
SDO01
0V
CRM2B (34)
SDO02
DV
SDO03
DV
SDO04
DV
SDO05
DV
SDO06
DV
SDO07
DV
SDO08
DV
SDO09
DV
CRM2B (35)
CRM2B (36)
CRM2B (38)
CRM2B (39)
CRM2B (40)
CRM2B (41)
CRM2B (43)
CRM2B (44)
SDO10
DV
CRM2B (45)
SDO11
DV
CRM2B (46)
SDO12
DV
CRM2B (19)
SDO13
DV
CRM2B (20)
SDO14
DV
CRM2B (21)
SDO15
DV
CRM2B (22)
SDO16
DV
CRM2B (24)
SDO17
DV
CRM2B (25)
SDO18
SDO19
SDO20
DV
CRM2B (26)
DV
CRM2B (27)
DV
CRM2B (23,28,37,42,47)
0V
Max. current per DO is 70mA
207
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
0V
+24V
+24V regurated
power supply
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.12.4
Connection Between
the Control Unit and
Welder
Control unit
Analog input interface
CRW2
Peripheral device
NOTE
Welder and peripheral device connection cable are optional.
Applicable process I/O board type
HE
208
CONNECTIONS
B–81535EN/02
3. CONNECTION DETAILS
Analog connection of CRW2 connector (Analog input)
Control unit
(Analog input interface)
Process I/O HE
Peripheral device
Connector pin number
CRW2 (10)
ADCH1
CRW2 (11)
COMAD1
CRW2 (12)
ADCH2
CRW2 (13)
COMAD2
CRW2 (14)
ADCH3
CRW2 (15)
COMAD3
Output signals without
ripples.
CRW2 (16)
ADCH4
CRW2 (17)
COMAD4
CRW2 (18)
ADCH5
CRW2 (19)
COMAD5
CRW2 (8)
ADCH6
CRW2 (9)
COMAD6
0V
209
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
Control unit
Welder interface
CRW7
Welder
NOTE
Welder and peripheral device connection cable is option.
Applicable process I/O board type
HE
210
CONNECTIONS
B–81535EN/02
3. CONNECTION DETAILS
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 common
line)
Control unit (welding interface)
Process I/O HE
Welding voltage
command signal
Wire speed command
signal
CRW7 (1)
Welding machine
MS connector
pin No.
A
CRW7 (2)
B
CRW7 (3)
C
CRW7 (4)
D
Connector pin No.
DACH1
COMDA1
DACH2
COMDA2
Connector pin No.
Receiver circuit
Arc detected signal
WDI02
RV
Gas outage detected
signal
WDI03
RV
Broken–wire detected
signal
Arc turn–off detected
signal (power supply
failure)
WDI04
RV
WDI06
RV
COM–3
RV
+24E
3.3k
CRW7 (6)
P
CRW7 (7)
T
CRW7 (8)
S
CRW7 (10)
R
+24E
B
A
CRW7 (33,34)
E
Common setting pin
0V
(ICOM3)
WDO01
CRW7 (23)
L
WCOM1
CRW7 (24)
K
WDO04
CRW7 (29)
F
WCOM4
CRW7 (30)
G
WDO05
CRW7 (13)
H
WCOM5
CRW7 (14)
J
Welding start signal
Wire inching (+)
Wire inching (–)
R=100 Ω or more
Wire deposition
detected signal
WDI+
CRW1 (31)
M
+
WDI–
CRW1 (32)
N
–
+
Cabinet ground
(shield clamp)
211
–
Welding power supply
Welding machine frame ground
3. CONNECTION DETAILS
CONNECTIONS
NOTE
This is the connection for +24V.
212
B–81535EN/02
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
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 common
line)
Control unit (welding interface)
Process I/O HE
Connector pin No.
CRW7 (1)
DACH1
Welding voltage
command signal
CRW7 (2)
COMDA1
CRW7 (3)
DACH2
Wire speed command
signal
CRW7 (4)
COMDA2
Receiver circuit
WDI01
RV
Arc detected signal
WDI02
RV
Gas outage detected
signal
Broken–wire detected
signal
Cooling water outage
signal
Arc turn–off detected
signal (power supply
failure)
WDI03
RV
WDI04
RV
WDI05
RV
WDI06
RV
WDI07
RV
WDI08
RV
COM–3
RV
+24E
B
Connector pin No.
3.3k
CRW7 (5)
Welding machine
MS connector
pin No.
A
B
E
F
c
CRW7 (6)
d
CRW7 (7)
e
CRW7 (8)
f
CRW7 (9)
g
CRW7 (10)
h
CRW7 (11)
j
CRW7 (12)
k
CRW7 (33,34)
r
+24E
A
CRW7 (19,20)
Common setting pin
0V
(ICOM3)
CRW7 (21,22)
m
n
0V
WDO01
Welding start signal
WCOM1
WDO02
Gas signal
WCOM2
WDO04
Wire inching (+)
WCOM4
WDO05
CRW7 (23)
R
CRW7 (24)
CRW7 (23)
CRW7 (24)
CRW7 (29)
S
a
U
CRW7 (30)
CRW7 (13)
V
Wire inching (–)
WCOM5
Wire deposition
detected signal
WDI+
WDI–
CRW7 (14)
b R=100 Ω or more
CRW1 (31)
N
+
CRW1 (32)
P
–
Cabinet ground
(shield clamp)
213
s
+
–
Welding power supply
Welding machine frame ground
3. CONNECTION DETAILS
3.12.5
Digital I/O Signal
Specifications of
Peripheral Device
Interface A
CONNECTIONS
B–81535EN/02
(1) Output signals in peripheral device interface A
Example of connection
Spark killer diode
+24V
70 mA
or less
0V
+24V
Lamp
70 mA
or less
0V
Protective resistance
Electrical specifications
Rated voltage
Maximum applied voltage
Maximum load current
Transistor type
Saturation voltage at connection
:
:
:
:
:
Spark killer diode
Rated peak reverse voltage
Rated effective forward current
: 100 V or more
: 1 A or more
24 VDC
30 VDC
70 mA
Open collector NPN
1.0 V (approx.)
NOTE
Do not use the +24 V power supply of the robot.
When you load a relay, solenoid, and so on directly, connect
them in parallel with diodes to prevent back electromotive
force.
If a load is connected causing a surge current when a lamp
is turned on, use a protective resistance.
Applicable signals
Output signals of process I/O board CRM2
CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT,
ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNACK,
SDO1 to SDO76
214
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
(2) Input signals in peripheral device interface A
Example of connection
+24V
RV
3.3 kW
+24V
B
A
ICOM
Electrical specifications of the receiver
Type
: Grounded voltage receiver
Rated input voltage
: Contact close
: +20 V to +28 V
Contact open
: 0 V to +4 V
Maximum applied input voltage : +28 VDC
Input impedance
: 3.3 kΩ (approx.)
Response time
: 5 ms to 20 ms
Specifications of the peripheral device contact
Rated contact capacity
: 30 VDC, 50 mA or more
Input signal width
: 200 ms or more (on/off)
Chattering time
: 5 ms or less
Closed circuit resistance
: 100 Ω or less
Opened circuit resistance
: 100 kΩ or more
TB
(Signal)
TB
(Signal)
TB
Peripheral device
contact signal
Robot receiver signal
TC
TC
TB ;
TC ;
Chattering 5 ms or less
5 to 20 ms
NOTE
Apply the +24 V power at the robot to the receiver.
However, the above signal specifications must be satisfied
at the robot receiver.
Applicable signals
Input 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
215
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.12.6
I/O Signal
Specifications for
ARC–Welding Interface
(1) Digital output signal specifications for an arc welding interface
In case of process I/O HE
Example connection
Spark killer diode
0.3 A or
less
Electrical characteristics
Rated voltage
Maximum applied voltage
Maximum load current
Output type
:
:
:
:
24 VDC
30 VDC
0.3 A
Relay connection output
Spark killer diode
Rated peak reverse voltage
: 100 V or more
Rated effective forward current : 1 A or more
NOTE
A power voltage of +24 V, provided for the robot, can be
used for interface signals of up to 0.7 A. This limit applies
to the sum of the currents flowing through the arc–welding
and end–effector control interfaces. To drive a relay or
solenoid directly, connect a diode preventing back
electromotive force to the load in parallel. To connect a load
which generates an inrush current when you turn on the
control unit, connect a protective resistor.
Applicable signals
– Output signals on the arc–welding interface
– WDO1 to WDO4
216
B–81535EN/02
3. CONNECTION DETAILS
CONNECTIONS
(2) Digital input signal specifications for arc welding interface
Example connection
Electrical characteristics of receivers
Type: Grounded voltage receiver
Rated input voltage
: +20 to +28 V with contacts closed
0 to +4 V when open
Maximum input voltage : +28 VDC
Input impedance
: About 3.3 k
Response time
: 5 to 20 ms
Contact specifications for peripherals
Rated contact capacity
: 30 VDC, 50 mA or more
Input signal width
: 200 ms or more for on and off states
Chattering period
: 5 ms or less
Closed–circuit resistance : 100 Ω or less
Open–circuit resistance : 100 kΩ or more
(Signal)
(Signal)
Contact signal
for peripheral
Receiver
signal for robot
TB: Chattering of 5 ms or less
TC: 5 to 20 ms
NOTE
Supply the +24 V power, provided for the robot, to the
receivers. The receiver signal on the robot must satisfy the
signal timing specified above.
Applicable signals
– Input signals for arc welding interface
– WDI1 to WDI8
217
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
(3) Analog output signal specifications for arc welding interface
(Welding voltage command, wire–feed rate command)
Example connection
Welder
Process I/O CA, EA : –10V to +10V
Process I/O GA, HA : 0V to +15V
0V
NOTE
Input impedance: 3.3 kΩ or more
Connect a high–pass filter.
(4) Analog input signal specifications for arc welding interface
(Welding–voltage detection, welding–current detection)
Example connection
Welder
–10V to +10V
0V
NOTE
The analog input signal should have no ripple for the circuit
to operate properly.
(Wire deposit detection: WDI+ and WDI–)
Example connection
Welder
Welding electrode
NOTE
Connect a resistor of 100Ω or more between the positive
and negative electrodes of the welder. Isolate the deposit
detection signals for TIG welding from the welding circuit,
which uses high–frequency components. The dielectric
withstand voltage of this circuit is 80 V.
218
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.12.7
If the customer manufactures cables, make sure they conform to the
FANUC standard cables described in this section. (See the description in
“Peripheral Device Interface” in this manual for the specifications of the
FANUC standard cables.)
Specifications of the
Cables used for
Peripheral Devices A
(CRM2: Honda
Tsushin, 50 pins)
Honda Tsushin
MR50LWF01
(MR50LF)
Honda Tsushin
MR50LM01
(MR50LM)
Peripheral
device
Process I/O
Honda Tsushin
MR50RMA
3.12.8
Honda Tsushin’s MR50RF
Supplied with an ordered cable
Be sure to use the FANUC cable to connect the welder.
ARC Weld Connection
Cable (CRW1: Honda
Tsushin, 34 pins)
ARC welder
Honda Tsushin
Process I/O
CRW1
or
CRW7
Honda Tsushin
MR34RFA
Japan Aviation Electronics
Industry Ltd.
MS3108B28–21P
MS3057–16
219
Japan Aviation Electronics
Industry Ltd.
MS3102A28–21S
Standard position of guide key
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
3.12.9
Peripheral Device
Cable Connector
(1) Fig. 3.12.9 shows the connector for peripheral device cables A and
B. (The connector is used for a peripheral device)
Connector
specifications
Applicable
interface
MR50LM
CRM2
Dimensions
A
(B)
C
67.9
73.5
44.8
Symbol
Remark
(D)
18
Honda Tsushin Kogyo,
50 pins
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)
220
3. CONNECTION DETAILS
CONNECTIONS
B–81535EN/02
(2) Peripheral device connector
Connector
specifications
Applicable
interface
MR50RF
(CRM2)
Dimensions
Remark
A
B
61.4
56.4
Symbol
Honda Tsushin Kogyo,
50 pins
Name
Connector clamp screw
Screw M2.6 8
Connector
(MR50RF)
Fig.3.12.9 (b) Peripheral Device Connector (Honda Tsushin Kogyo)
3.12.10
Recommended Cables
(1) Peripheral device connection cable
Connect a peripheral device using a completely shielded, heavily
protected 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
Number
of wires
50
Wire specifications
(FANUC specifications)
A66L-0001-0042
Diameter
(mm)
ø1.05
Configuration
7/0.18
AWG24
221
Sheath
thickness
(mm)
1.5
Effective
outside
diameter
(mm)
ø12.5
Electrical characteristics
Conductor
resistance
(Ω/km)
106
Allowable
current
(A)
1.6
4. TRANSPORTATION AND
INSTALLATION
4
CONNECTION
TRANSPORTATION AND INSTALLATION
222
B–81535EN/02
4. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81535EN/02
4.1
TRANSPORTATION
The control unit should be transported by a crane. Attach a sling to eye
bolts at the top of the control unit.
Fig.4.1 Transportation
4.2
INSTALLATION
Contrpl unit
Installation area
When the control unit is installed, allow the space for maintenance shown
in the following figure.
Contrpl unit
Contrpl unit
When the plural
controller is
installed.
Fig.4.2 Installation
223
4. TRANSPORTATION AND
INSTALLATION
CONNECTION
4.3
EXTERNAL
CONTROLLER
DIMENSIONS
Four M10 weld nuts
The unit is shipped with the M10 bolts
screwed to the weld nuts as 10–mm feet.
After the M10 bolts are removed, these
weld nuts can be used to secure the
control unit.
Fig.4.3 External drawing of robot controller
224
B–81535EN/02
CONNECTION
B–81535EN/02
4. TRANSPORTATION AND
INSTALLATION
4.4
INSTALLATION
CONDITION
Item
Input power supply
Input power supply capacity
Average power consumption
Permissible ambient temperature
Permissible ambient humidity
Surrounding gas
Vibration
Altitude
Ionized and nonionized radiations
Weight of control unit
4.5
ADJUSTMENT AND
CHECKS AT
INSTALLATION
Specifications/condition
50Hz; 200VAC, +10%, –15%
60Hz; 200VAC to 220 VAC, +10%, –15%
50/60 Hz"1Hz, 3–phase
1 kVA (LR Mate 100iB)
1.2 kVA (LR Mate 200iB/ARC Mate 50iB)
0.4 kW (LR Mate 100iB)
0.5 kW (LR Mate 200iB/ARC Mate 50iB)
0 to 45_C during operation, and –20 to 60 C
during shipment and storage with a temperature coefficient of 1.1_C/min.
Relative humidity: 30% to 95%, non–condensing.
An additional protective provision is necessary if the machine is installed in an environment in which there are relatively large
amounts of contaminants (dust, dielectric
fluid, organic solvent, acid, corrosive gas,
and/or salt).
0.5 G or less. When using the robot in a location subject to serious vibration, consult with
your FANUC sales representative.
Not higher than 1,000 m above sea level
A shielding provision is necessary if the
machine is installed in an environment in
which it is exposed to radiations (microwave,
ultraviolet rays, laser beams, and/or X–rays).
Approx. 35kg
Adjust and check according to following procedure at installation.
No.
Description
1
2
3
Visually check the inside and outside of the control unit.
Check if the screwed terminal is connected properly.
Check that the connectors and printed circuit boards are inserted correctly.
Connect control unit and mechanical unit cables.
4
5
6
7
11
Turn the breaker off and connect the input power cable.
Check the input power voltagage.
Press the EMERGENCY STOP button on the operator’s panel and
turn the power on. Check the output voltage.
Check the interface signals between control unit and robot mechanical
unit.
Check the parameters. If necessary, set them.
Release the EMERGENCY STOP button on the operator’s panel.
Turn the power on.
Check the movement along each axis in the manual jog mode.
12
13
Check the end effector interface signals.
Check the peripheral device control interface signals.
8
9
10
225
4. TRANSPORTATION AND
INSTALLATION
CONNECTION
4.6
B–81535EN/02
An overtravel and emergency stop occur when the robot is operated for
the first time after it is installed and the mechanical and control units are
wired. This section describes how to reset the overtrvel and emergency
stop.
Remove the red plate fastening the swiveling axis beforehand.
The J2 and J3 axes are pressed against the hard stops at shipment.
Therefore, an overtravel alarm occurs when the power is turned on after
installation.
NOTE AT
INSTALLATION
4.7
DISABLING HAND
BREAK
(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
2
Enabled
Enabled
CLOSE
OPEN
Detected
Detected
Possible
Impossible
Not provided
SERVO 6
3
4
Disabled
Disabled
CLOSE
OPEN
Detected (*2)
Not detected
Possible
Possible
Not provided
SERVO 300 at cold start
NOTE
1 Robot end effector connector
CLOSE
OPEN
24V
24V
*HBK
*HBK
2 When the HBK circuit is closed, the HBK detection is
enabled.
If the HBK state changes from close to open, the SERVO
300 or SERVO 302 alarm occurs, stopping the robot.
3 If the power is turned off and on in the state described
above, the system enters state 4, releasing the alarm.
226
APPENDIX
B–81535EN/02
A
APPENDIX
TOTAL CONNECTION DIAGRAM
229
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (a) Total connection diagram
230
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B–81535EN/02
APPENDIX
231
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (b) Emergency stop circuit diagram
232
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B–81535EN/02
APPENDIX
233
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (c) Emergency stop circuit diagram
234
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B–81535EN/02
APPENDIX
235
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (d) Robot control board, Emergency stop board connector interface
236
B–81535EN/02
B–81535EN/02
APPENDIX
A. TOTAL CONNECTION DIAGRAM
Fig.A (e) Servo amplifier robot mechanical unit connector interface
237
B. PERIPHERAL INTERFACE
B
APPENDIX
B–81535EN/02
PERIPHERAL INTERFACE
Peripheral I/O (UI/UO) are a group of specialized signals whose usage is
decided by the system. These signals are connected with a remote
controller and the peripheral devices via the following interfaces and I/O
links and they are used to control the robot from the outside.
D The JD1A interface (The process I/O board, the I/O Unit MODEL A
and the MODEL B are connected as the slave of I/O link to R–J3iB
Mate.) (on master mode)
D The JD1B interface (CNC and PLC are connected as a master of I/O
link to R–J3iB Mate.) (on slave mode)
D CRM9 interface
Refer to the operator’s MANUAL for detail informations.
238
APPENDIX
B–81535EN/02
B.1
SIGNAL TYPES
B. PERIPHERAL INTERFACE
The tables below list the special signals of the R–J3iB Mate robot
controller.
Input signals (See Subsection B.2.1.)
Signal
*HOLD
RESET
START
ENBL
PNS1
PNS2
PNS3
PNS4
Description
Temporary stop
Alarm release
Cycle start
Enable
Program select (*1)
Program select (*1)
Program select (*1)
Program select (*1)
NOTE
PNS (program select input) (optional)
Output signals (See Subsection B.2.1.)
Signal
Description
CMDENBL
FAULT
BATALM
BUSY
Input acceptable
Alarm
Battery alarm
Busy
239
B. PERIPHERAL INTERFACE
APPENDIX
B–81535EN/02
B.2
I/O SIGNALS
B.2.1
Fellowing is each input signal.
Input Signals
Hold input signals,
*HOLD, UI [ 1 ]
The remote controller uses the hold signal to halt the robot. Because
*HOLD input signal is a inverted signal, normally set the signal on. When
the signal goes off, the following is executed:
D The robot is decelerated until its stops, then the program execution is
halted.
D If ENABLED is specified at “Break on hold” on the general item
setting screen, the robot is stopped, an alarm is generated, and the
servo power is turned off. (Standard setting: DISABLED)
Fault reset input signal,
RESET, UI [ 2 ]
The RESET signal cancels an alarm. If the servo power is off, the RESET
signal turns on the servo power. The alarm output is not canceled until the
servo power is turned on. The alarm is canceled at the instant this signal
falls in default setting.
D If TRUE is specified at “CSTOPI for ABORT” on the system
configuration screen, the RESET signal resets an alarm and aborts the
currently selected program. (Standard setting: FALSE)
D To have alarms reset the instant the RESET signal rises, it is necessary
to specify RISE at “Detect FAULT RESET signal” on the system
configuration screen. (Standard setting: FALL)
Start input signal,
START, UI [ 3 ] (validated
in the remote state)
The START signal has two functions. It can select or collate a program
and start the program.
D When the START signal goes high, PNS1 to PNS4 are read and the
corresponding program is selected or collated. Whether is program is
selected or collated is specified by the setting of system variable
$SHELL_CFG.$NUM_RSR [1]. (See the description of signals
PNS1 to PNS4.)
D When the START signal goes low, the current program is started from
the line at which the cursor is placed (current line).
D If TRUE is specified at “START for CONTINUE only” on the system
configuration screen, only a program on hold can be started. (Standard
setting: FALSE)
Enable input signal,
ENBL, UI [ 4 ]
The ENBL signal allows the robot to be moved and places the robot in the
ready state. When the ENBL signal is off, the system inhibits a jog feed
of the robot and activation of a program including a motion (group). A
program which is being executed is halted when the ENBL signal is set
off.
NOTE
When the ENBL signal is not monitored, strap the signal
with the ground.
240
B–81535EN/02
APPENDIX
B. PERIPHERAL INTERFACE
Program number
selection signals, PNS1
to PNS4, UI [ 5 to 8 ]
(validated in the remote
state)
A program number selection signal has two functions.
When the START signal goes on, PNS1 to PNS4 are read and the
corresponding program is selected or collated. Whether the program is
selected or collated is specified by the setting of system variable
$SHELL_CFG.$NUM_RSR [1].
B.2.2
Fellowing are peripheral device interface output signals.
D In the program end state, a program is selected or collated according
to the state (0 or 1) of the PNS signals. The current line of the selected
or 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 the
current program. If the programs do not agree with each other, an
error occurs.
D If all PNS signals are low in the program end state, the current program
is executed from the current line. If no programs are selected, an error
occurs.
D A halted program can be resumed only when all PNS signals are set
off. Otherwise, an error occurs.
D While a program is being executed, the PNS signals are ignored.
Output Signals
Command enable output
signal, CMDENBL,
UO [ 1 ]
The CMDENBL signal is output when the following conditions are
satisfied. The CMDENBL signal indicates that the remote controller can
start a program including a motion (group).
D The remote conditions are satisfied.
D The ready conditions are satisfied.
D The continuous operation mode is selected (the single step mode is
disabled).
Fault output signal,
FAULT, UO [ 2 ]
The FAULT signal is output when an alarm occurs in the system. The
RESET signal cancels the alarm. If a warning (WARN alarm) occurs, the
FAULT signal is not output.
Battery alarm output
signal, BATALM, UO [ 3 ]
The BATALM signal indicates that the voltage of the battery for
supporting the memory has dropped. Replace the battery while keeping
the power of the controller on.
To have the BATALM signal generated also when the BZAL/BLAL alarm
occurs, it is necessary to set the $BLAL_OUT.$BATALM_OR system
variable. It is also possible to have the specified SDO output when the
BZAL/BLAL alarm occurs.
Busy output signal,
BUSY, UO [ 4 ]
The BUSY signal is output while a program is being executed. The BUSY
signal is not output while a program is being halted.
241
B. PERIPHERAL INTERFACE
APPENDIX
B–81535EN/02
B.3
SPECIFICATIONS OF
DIGITAL
INPUT/OUTPUT
B.3.1
Overview
B.3.2
Input/Output Hardware
Usable in the R-J3iB
Mate Controller
This section describes the external specifications of digital and analog
input/output in the R–J3iB Mate controller.
The R–J3iB Mate controller can use up to 512 digital input and output
points or an equivalent number of analog input and output points. One
analog input/output point uses the resources equivalent to those used by
16 digital I/O points. The R–J3iB Mate can use a total of up to 512 I/O
points.
The R–J3iB Mate controller can use the following I/O hardware.
- Process I/O printed circuit board
- I/O unit model A
The process I/O printed circuit board and the I/O unit model A can be used
together.
242
B–81535EN/02
APPENDIX
B. PERIPHERAL INTERFACE
B.3.3
Software
Specifications
(1) RDI/RDO
These are signals sent to the connector at the wrist of the robot.
They cannot be assigned (redefined) and are fixed.
The standard format is six inputs and six outputs. The number of
points that can be used for the connector at the wrist depends on the
individual robot.
(2) SDI/SDO
The signal No. that is determined at hardware can be changed by
software operation.
(3) Analog I/O
An analog I/O signal can access the analog I/O port (optional) on the
process I/O printed circuit board or the I/O port on the analog I/O
module (used together with the I/O unit model A).
It reads and writes the digital value converted from the analog value
of the I/O voltage. It means that the value does not always represent
the real I/O voltage.
(4) Group I/O
Group I/O is a function which can input or output multiple DI/DO
signals as binary codes.
Any number of continuous signals of up to 16 bits can be set for its
use.
It can be set in the menu DETAILS on the group I/O screen.
243
C. OPTICAL FIBER CABLE
C
APPENDIX
B–81535EN/02
OPTICAL FIBER CABLE
The R–J3iB Mate uses fiber optic cables for communication between the
robot control board and servo amplifier module and between the servo
amplifier module and servo amplifier module. Observe the following
cautions when handling these fiber optic cables.
(1) Protection during storage
When the electrical/optical conversion module (mounted on the
printed) circuit board and the fiber optic cable are not in use, their
mating surfaces must be protected with the lid and caps with which
they are supplied. If left uncovered, the mating surfaces are likely to
become dirty, possibly resulting in a poor cable connection.
Electrical/optical conversion module
Fiber optic cable
Lid
Fiber optic
cable caps
Fig.C (a) Protection of electrical/optical conversion module and fiber
optic cable (when not in use)
244
C. OPTICAL FIBER CABLE
APPENDIX
B–81535EN/02
(2) Fiber optic cable
D Grasp the optical connector firmly when connecting or
disconnecting the cable. Do not pull on the fiber optic cord itself.
(The maximum tensile strength between the fiber cord and
connector is 2 kg. Applying greater force to the cord is likely to
cause the connector to come off, making the cable unusable.)
Fiber optic cord diameter : 2.2 mm
2 cords
Tensile strength : Fiber optic cord
:7 kg per cord
Between fiber optic cord and connector : 2 kg
Minimum bending radius of fiber optic cord
:25 mm
Flame resistance
: Equivalent to UL VW–1
Operating temperature
: –20 to 70°C
8.2
6.7
19 max.
60 max.
35typ.
21
Bush
Code
Reinforced cover
Fig.C (b) External dimensions of external optical cable Unit : mm
D Afler it is connected, the optical connector is automatically locked
by the lock levers on its top. To remove the connector, release the
lock levers and pull the connector.
D Although optical connectors cannot be connected in other than the
correct orientation, always take note of the connector’s orientation
before making the connection.
D Take care to keep both parts of the optical connector (cable side and
PCB side) clean. If they become dirty, wipe them with tissue paper
or absorbent cotton to remove dirt. The tissue paper or absorbent
cotton may be moistened with ethyl alcohol. Do not use any
organic solvent other than ethyl alcohol.
D Do not clamp the uncovered portion of the cable with a nylon band.
245
Index
B–81535EN/02
[A]
[E]
Emergency Stop Board (A20B–1008–0010, –0011),
116
Adjustment and Checks at Installation, 225
Alarm Occurrence Screen, 29
Emergency Stop Circuit, 167
ARC Weld Connection Cable (CRW1: Honda Tsushin,
34 pins), 219
End Effector Interface, 197
External Controller Dimensions, 224
External Emergency Stop Input, 168
External Emergency Stop Output, 169
[B]
External View of the Controller, 21
Backplane Board (A20B–2003–0330), 117
Battery for Memory Backup (3 VDC), 154
[F]
Block Diagram, 160
FANUC I/O Link, 163
Block Diagrams of the Power Supply, 126
[I]
[C]
Checking the Power Supply Module, 127
I/O Signal Specifications for Arc–Welding Interface,
216
Checking the Power Supply Unit, 127
I/O Signals, 240
Circuit Diagram of Emergency Stop, 167
Initial Screen Remains on the Teach Pendant, 28
Component Functions, 23
Input Signals, 240
Configuration, 20
Input/Output Hardware Usable in the R–J3iB Mate
Controller, 242
Connecting a Cable to a Peripheral Device, 175
Installation, 223
Connecting the Mechanical Unit and End Effector,
197
Installation Condition, 225
Connection Between the Control Unit and Welder,
208
[L]
Connection Details, 161
LED of Power Supply Module, 123
Connection of Cable for RS–232–C/RS–422, 174
LED of Servo Amplifier, 123
Connection of I/O Link Cable, 165
LED of Servo Amplifier Module, 124
Connection of Power Supply Cable, 162
Connection of Robot, 172
[M]
Connection of Teach Pendant Cable, 173
Manual Operation Impossible, 109
Coonection of Servo Amplifier, 171
Mastering, 33
[D]
[N]
Digital I/O Signal Specifications, 193
Note at Installation, 226
Digital I/O Signal Specifications of End Effector Control Interface, 199
[O]
Digital I/O Signal Specifications of Peripheral Device
Interface A, 214
Operator Safety, 4, 6
Disabling Hand Break, 226
Optical Fiber Cable, 244
i–1
Index
B–81535EN/02
Outline Drawings, 121
Replacing the Emergency Stop Board, 132
Output Signals, 241
Replacing the Emergency Stop Unit, 138
Replacing the Fan Motor of the Servo Amplifier Control Unit, 143
[P]
Replacing the Fuse on the Door, 149
Replacing the Fuse on the Power Supply Module, 150
Peripheral Device and Control Unit Connection, 203
Replacing the Fuse on the Process I/O Boards, 152
Peripheral Device Cable Connector, 195, 220
Replacing the Fuse on the Servo Amplifier Module,
151
Peripheral Device Interface Block Diagram and Specifications, 202
Replacing the Magnetic Contactor, 139
Peripheral device interface CRM 79 and CRM 81, 193
Replacing the Operator Panel, 145
Peripheral Device Interface Types, 201
Replacing the Power Supply Unit, 146
Peripheral Device Interfaces CRM79 and CRM81,
175
Replacing the Printed–Circuit Boards, 129
Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit, 131
Peripheral Device, ARC Welding, Interfaces, 201
Peripheral interface, 238
Replacing the Teach Pendant, 141
Position Deviation Found in Return to the Reference
Position (Positioning), 107
Replacing the Transformer, 137
Robot Control Board (A16B–3200–0450), 112
Power Cannot be Turned On, 26
Power Supply Module PSM (A06B–6115–H001), 121
Precautions for Mechanism, 10
[S]
Precautions for Mechanisms, 11
Precautions in Operation, 11
Safety During Maintenance, 9
Precautions in Programming, 10, 11, 12
Safety in Maintenance, 13
Preventive Maintenance, 24
Safety of the End Effector, 12
Printed Circuit Boards, 111
Safety of the Robot Mechanism, 11
Process I/O Board HE (A16B–2203–0764), HF
(A16B–2203–0765), 118
Safety of the Teach Pendant Operator, 7
Safety of the Tools and Peripheral Devices, 10
Safety Precautions, 3
Safety Signals, 32
[R]
Recommended Cables, 196, 221
Servo Amplifier Module (A06B–6114–H205,
A06B–6114–H302), 122
Replacing a Fuse, 147
Servo Amplifiers, 120
Replacing a Fuse on the Emergency Stop Board, 148
Setting the Power Supply, 125
Replacing a Fuse on the Robot Control Board, 147
Signal Types, 239
Replacing a Relay, 153
Software Specifications, 243
Replacing a Relay on the Emergency Stop Board, 153
Specifications of Digital Input/Output, 242
Replacing a Unit, 128
Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin, 50 pins), 219
Replacing Battery, 154
Replacing Cards and Modules on the Robot Control
Board, 133
[T]
Replacing Servo Amplifiers, 140
Teach Pendant Cannot be Turned On, 27
Replacing the Backplane Board (Unit), 130
Total Connection Diagram, 229
Replacing the Brake Power Transformer, 137
Transportation, 223
Replacing the Control Section Fan Motor, 142
Transportation and Installation, 222
Replacing the Door Fan Unit and Heat Exchanger,
144
Treatment for the Shielded Cable, 200
i–2
Index
B–81535EN/02
Troubleshooting, 25
Troubleshooting Based on LED Indications, 97
Troubleshooting Using Fuses, 92
[W]
Troubleshooting Using the Error Code, 35
Warning Label, 14
[V]
When the Robot is Connected to the CNC by a Peripheral Device Cable, 176
Vibration Observed During Movement, 108
i–3
Revision Record
FANUC Robot series R–J3iB Mate CONTROLLER for (RIA R15.06--1999 COMPLIANT) MAINTENANCE MANUAL (B–81535EN)
02
Oct., 2002
01
Oct., 2001
Edition
Date
Addition of ARC Mate 50iB
Contents
Edition
Date
Contents