7/17/2019 MANUTENÇÃO ROBO FANUC.pdf FANUC Robotseries RIA R15.06-1999 COMPLIANT R-30iA CONTROLLER MAINTENANCE MANUAL MARMCRIA304071E REV. D This publication contains proprietary information of FANUC Robotics America, Inc. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics America, Inc. FANUC Robo tics Americ a, Inc. 3900 W. Hamlin Road Rochester Hills, Mich igan 48309–3253 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 1/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. FANUC Robotics America, hereinafter referred to astime FANUC reserves the right toInc, discontinue models at any or to Robotics, 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 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf FANUC Robotics America, Inc. 2/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Copyright 2009 by FANUC Robotics America, Inc. All Rights Reserved The information illustrated or contained herein is not to be reproduced, copied, downloaded, translated into another language, published in any physical or electronic format, including internet, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics America, Inc. AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL, KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks, PalletTool SOFT PARTS SpotTool , of FANUC TorchMate , ,SOCKETS and YagTool, are Registered Trademarks 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 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf FANUC LTD 2009 3/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Conventions This manual includes information essential to the safety of personnel, software, data. indicated byequipment, headings and boxesand in the text.This information is 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. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 4/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand the content. This manual can be used with controllers labeled R-30 iA or R-J3iC. If you have a controller labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual. • No part of this manual may be reproduced in any form. • All specifications and designs are subject to change without notice. The products in this manual are controlled based on Japan’s “Foreign Exchange and Foreign Trade Law”. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of http://slidepdf.com/reader/full/manutencao-robo-fanucpdf the country from where the product is re-exported. Furthermore, the product may also be 5/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 6/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf TABLE OF CONTENTS B-82595EN-2/04 TABLE OF CONTENTS PREFACE ....................................................................................................p-1 I SAFETY PRECAUTIONS 1 SAFETY PRECAUTIONS........................................................................ 3 1.1 1.2 WORKING PERSON ..................................................................................... 3 WORKING PERSON SAFETY ...................................................................... 4 1.2.1 1.2.2 1.2.3 1.3 General Person Safety ..............................................................................................5 Safety of the Teaching Operator...............................................................................6 Safety during Maintenance.......................................................................................7 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES............................. 8 1.3.1 1.3.2 Precautions in Programming ....................................................................................8 Precautions for Mechanism ......................................................................................8 1.4 SAFETY OF THE ROBOT MECHANISM ...................................................... 8 1.5 SAFETY OF THE END EFFECTOR.............................................................. 9 1.4.1 1.4.2 1.4.3 1.5.1 1.6 Precautions in Operation ..........................................................................................8 Precautions in Programming ....................................................................................9 Precautions for Mechanisms.....................................................................................9 Precautions in Programming ....................................................................................9 WARNING LABEL .........................................................................................9 II MAINTENANCE 1 OVERVIEW ...........................................................................................13 2 CONFIGURATION ................................................................................ 14 3 2.1 2.2 EXTERNAL VIEW OF THE CONTROLLER ................................................ 14 COMPONENT FUNCTIONS........................................................................ 26 2.3 PREVENTIVE MAINTENANCE ................................................................... 27 TROUBLESHOOTING ..........................................................................28 3.1 POWER CANNOT BE TURNED ON ........................................................... 28 3.2 ALARM OCCURRENCE SCREEN.............................................................. 31 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 3.3 SAFETY SIGNALS ......................................................................................34 7/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf TABLE OF CONTENTS 5 4.5 PROCESS I/O BOARD CA (A16B-2201-0470) ......................................... 129 4.6 4.7 4.8 4.9 4.10 4.11 4.12 PROCESS I/O BOARD EA (A16B-3200-0230).......................................... 131 PROCESS I/O BOARD EB (A16B-3200-0231).......................................... 133 PROCESS I/O BOARD FA (A16B-3200-0420).......................................... 135 PROCESS I/O BOARD GA (A16B-2203-0520) ......................................... 137 PROCESS I/O BOARD HA (A16B-2203-0760) ......................................... 139 PROCESS I/O BOARD JA (A16B-2204-0010) .......................................... 141 PROCESS I/O BOARD JB (A16B-2204-0011) .......................................... 143 4.13 4.14 4.15 PROCESS I/O BOARD KA (A16B-2204-0050, A20B-2101-0560)............. 144 PROCESS I/O BOARD KB (A16B-2204-0051, A20B-2101-0561)............. 147 PROCESS I/O BOARD KC (A16B-2204-0052, A20B-2101-0562) ............ 150 SERVO AMPLIFIERS .........................................................................152 5.1 5.2 6 LED OF SERVO AMPLIFIER .................................................................... 154 SETTING OF SERVO AMPLIFIER............................................................ 155 SETTING THE POWER SUPPLY ....................................................... 156 6.1 6.2 6.3 7 B-82595EN-2/04 BLOCK DIAGRAM OF THE POWER SUPPLY ......................................... 156 TRANSFORMER .......................................................................................157 CHECKING THE POWER SUPPLY UNIT (A16B-2203-0910) .................. 160 REPLA CING A UNIT........................................................................... 161 7.1 A-CABINET................................................................................................ 162 7.1.1 7.1.2 7.1.3 7.1.4 7.2 Replacing the A-cabinet Top Panel ......................................................................162 Replacing the A-cabinet Rear Panel.....................................................................163 Replacing the A-cabinet Louver...........................................................................163 Replacing the A-cabinet Door ..............................................................................164 REPLACING THE PRINTED-CIRCUIT BOARDS ..................................... 165 7.2.1 7.2.2 7.2.3 Replacing the Backplane Board (Unit).................................................................165 Replacing the Power Unit and Printed-Circuit Boards on the Backplane Unit ....166 Replacing the Panel Board ...................................................................................168 7.2.4 Replacing the Process I/O Board EA, EB, FA, GA, KA, KB, KC (A-cabinet) ...169 7.3 REPLACING CARDS AND MODULES ON THE MAIN BOARD ............... 169 7.4 REPLACING THE TRANSFORMER ......................................................... 173 7.5 REPLACING THE REGENERATIVE RESISTOR UNIT ............................ 180 7.6 REPLACING THE E-STOP UNIT .............................................................. 183 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 77 REPLACING SERVO AMPLIFIERS 185 8/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf TABLE OF CONTENTS B-82595EN-2/04 7.14 7.13.3 Replacing Fuses in the Main board ......................................................................201 7.13.4 7.13.5 Replacing the Fuse on the Process I/O Boards.....................................................202 Replacing the Fuse on the Panel Board................................................................206 REPLACING RELAYS............................................................................... 206 7.14.1 7.15 REPLACING BATTERY ............................................................................207 7.15.1 8 Replacing Relays on the Panel Board ..................................................................206 Battery for Memory Backup (3 VDC)..................................................................207 HOW TO USE THE PLATE TO FIX THE COMPACT FLA SH MEMORY CARD .................................................................................................. 209 III CONNECTIONS 1 GENERAL ...........................................................................................213 2 BLOCK DIAGRAM .............................................................................. 214 3 ELECTRICAL CONNECTIONS...........................................................216 3.1 3.2 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS .................. 216 EXTERNAL CABLE WIRING DIAGRAM ................................................... 218 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 4 Robot Connection Cables.....................................................................................218 Teach Pendant Cable ............................................................................................231 Connecting the Input Power .................................................................................233 3.2.3.1 3.2.3.2 Connecting the input power cable ................................................................... 233 Leakage breaker............................................................................................... 235 3.2.3.3 3.2.3.4 Check input voltage ......................................................................................... 235 On/off timing by the breaker ........................................................................... 235 Connecting the External Power Supply ON/OFF Switch ....................................236 Connecting the External Emergency Stop............................................................239 Connecting the Non-Teaching Enabling (NTED) Signal (CRM65) ....................249 Connecting the Auxiliary Axis Brake (CRR65 A/B) ...........................................250 Connecting the Auxiliary Axis Over Travel (CRM68) ........................................251 Connecting the Operation Box .............................................................................252 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES ......................................................................................253 4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM.......................... 255 4.1.1 When Process I/O Board EA/EB/GA is Used (A-cabinet)...................................255 FA is Used (A-cabinet) ................................................256 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 4.1.2 When Process I/O Board 9/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf TABLE OF CONTENTS 4.4.2 B-82595EN-2/04 Peripheral Device and Control Unit Connection (Sink Type DO) .......................279 4.5 INTERFACE FOR WELDER...................................................................... 292 4.6 INTERFACE FOR END EFFECTOR ......................................................... 302 4.5.1 4.6.1 4.7 4.8.2 4.8.3 4.8.4 Peripheral Device Connection Cable....................................................................313 Peripheral Device Cable Connector .....................................................................314 End Effector Cable Connector..............................................................................316 Recommended Cables ..........................................................................................317 CONNECTION OFHDI HDI .............................................................................318 4.10.1 Connecting ...................................................................................................318 4.10.2 4.11 Peripheral Device Interface A Cable (CRM2, CRMA5: Honda Tsushin, 50 pins) ..............................................................................................................................311 Peripheral Device Interface B Cable (CRM4, CRMA6: Honda Tsushin, 20 pins) ..............................................................................................................................311 ARC Weld Connection Cable (CRW1, CRW7: Honda Tsushin, 34pins)............312 ARC Weld Connection Cable (CRW10: Honda Tsushin, 50 pins) ......................................................................312 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS, AND ARC WELDERS ........................................................ 313 4.9.1 4.9.2 4.9.3 4.9.4 4.10 Peripheral Device Interface A ..............................................................................304 End Effector Control Interface .............................................................................307 I/O Signal Specifications for ARC-Welding Interface.........................................308 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS ........................................................................................ 311 4.8.1 4.9 Connection between the Mechanical Unit and End Effector ...............................302 DIGITAL I/O SIGNAL SPECIFICATIONS .................................................. 304 4.7.1 4.7.2 4.7.3 4.8 Connection between the Control Unit and Welder...............................................292 Input Signal Rules for the High-speed Skip (HDI) ..............................................320 CONNECTING THE COMMUNICATION UNIT ......................................... 321 4.11.1 RS-232-C Interface...............................................................................................321 4.11.1.1 4.11.1.2 4.11.1.3 4.11.2 Interface........................................................................................................... 321 RS-232-C interface signals .............................................................................. 322 Connection between RS-232-C interface and I/O device ................................ 323 Ethernet Interface .................................................................................................324 4.11.2.1 Connection to Ethernet .................................................................................... 324 4.11.2.2 Leading out the Ethernet Cable ....................................................................... 325 4.11.2.3 100BASE-TX Connector (CD38R) Pin Assignments ..................................... 326 4.11.2.4 Twisted-pair Cable Specification..................................................................... 326 4.11.2.5 Electrical Noise Countermeasures................................................................... 329 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 4.11.2.6 Check Items at Installation .............................................................................. 333 10/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf TABLE OF CONTENTS B-82595EN-2/04 APPENDIX A TOTAL CONNECTION DIAGRAM......................................................349 B SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE ...............391 B.1 B.2 B.3 SIGNAL .....................................................................................................391 SETTING COMMON VOLTAGE................................................................ 393 I/O SIGNALS ............................................................................................. 393 B.3.1 B.3.2 B.4 Input Signals.........................................................................................................393 Output Signals ......................................................................................................397 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT..................................... 400 B.4.1 B.4.2 B.4.3 Overview ..............................................................................................................400 Input/Output Hardware Usable in the R-30iA Controller ....................................400 Software Specifications ........................................................................................400 C OPTICAL FIBER CABL E .................................................................... 401 D BRAKE RELEASE UNIT.....................................................................404 D.1 D.2 D.3 D.4 D.5 D.6 D.7 E SAFETY PRECAUTIONS.......................................................................... 404 CONFIRMATIONS BEFORE OPERATION............................................... 404 OPERATION.............................................................................................. 406 HOW TO CONNECT THE PLUG TO THE POWER CABLE (IN CASE OF NO POWER PLUG) .........................................................................................410 DIMENSION .............................................................................................. 411 FUSE ......................................................................................................... 413 SPECIFICATIONS..................................................................................... 413 THE CONTROLLER FOR M-900iA/200P, M-2000iA .........................414 E.1 E.2 CONFIGURATION..................................................................................... 414 TROUBLESHOOTING USING THE ERROR CODE ................................. 416 E.2.1 E.2.2 E.2.3 Troubleshooting using the error code...................................................................416 Alarms detected by servo amplifier......................................................................417 Relationship of axis ..............................................................................................418 E.3 INSTALLING THE CONNECTION CABLE BETWEEN CABINETS .......... 419 E.4 ROBOT CONNECTION CABLE ................................................................ 420 E.5 CONNECTING THE INPUT POWER CABLE............................................ 424 E.6 CONFIRMATIONS OF ON/OFF BY THE BREAKER FOR M-900iA/200P AND http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 11/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 12/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf PREFACE B-82595EN-2/04 PREFACE This manual describes the following models (R-30iA controller). Model Abbreviation FANUC Robot R-2000iB/210F R-2000iB/210F FANUC Robot R-2000iB/200R R-2000iB/200R FANUC Robot R-2000iB/200EW R-2000iB/200EW FANUC Robot R-2000iB/150U FANUC Robot R-2000iB/165R R-2000iB/150U R-2000iB/165R FANUC Robot R-2000iB/165F R-2000iB/165F FANUC Robot R-2000iB/165EW R-2000iB/165EW FANUC Robot R-2000iB/165CF R-2000iB/165CF FANUC Robot R-2000iB/170CF R-2000iB/170CF FANUC Robot R-2000iB/175L R-2000iB/175L FANUC Robot R-2000iB/125L R-2000iB/125L FANUC Robot R-2000iB/100P FANUC Robot R-2000iB/100H R-2000iB/100P R-2000iB/100H FANUC Robot R-2000iB/200T R-2000iB/200T FANUC Robot R-1000iA/80F R-1000iA/80F FANUC Robot M-6iB M-6iB FANUC Robot M-6iB/6T M-6iB/6T FANUC Robot M-6iB/6S M-6iB/6S FANUC Robot M-6iB/2HS M-6iB/2HS FANUC Robot M-6iB/6C M-6iB/6C FANUC Robot M-10iA M-10iA FANUC Robot M-10iA/6L M-10iA/6L FANUC Robot M-16iB/20 M-16iB/20 FANUC Robot M-16iB/10L M-16iB/10L FANUC Robot M-16iB/20T M-16iB/20T FANUC Robot M-16iB/10LT M-16iB/10LT FANUC Robot M-20iA M-20iA FANUC Robot M-20iA/10L M-20iA/10L FANUC Robot M-20iA/20T M-20iA/20T FANUC Robot ARC Mate 100iB ARC Mate 100iB FANUC Robot ARC Mate 100iBe ARC Mate 100iBe FANUC Robot ARC Mate 100iB/6S ARC Mate 100iB/6S http://slidepdf.com/reader/full/manutencao-robo-fanucpdf FANUC Robot ARC Mate 100iC ARC Mate 100iC R-2000iB R-1000iA M-6iB M-10iA M-16iB M-20iA ARC Mate 100iB 13/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf PREFACE B-82595EN-2/04 Model Abbreviation FANUC Robot M-710iC/70 FANUC Robot M-710iC/70T M-710iC/70 M-710iC/70T FANUC Robot M-710iC/70W M-710iC/70W FANUC Robot M-710iC/50 M-710iC/50 FANUC Robot M-710iC/50S M-710iC/50S FANUC Robot M-710iC/50T M-710iC/50T FANUC Robot M-710iC/50E M-710iC/50E FANUC Robot M-710iC/20L M-710iC/20L FANUC Robot M-410iB/160 M-410iB/160 FANUC Robot M-410iB/300 M-410iB/300 FANUC Robot M-410iB/450 M-410iB/450 FANUC Robot M-410iB/700 M-410iB/700 FANUC Robot M-420iA M-420iA FANUC Robot M-421iA M-421iA FANUC Robot M-430iA/2F M-710iC M-410iB M-430iA/2F FANUC Robot M-430iA/2FH FANUC Robot M-430iA/2P M-430iA/2P M-430iA FANUC Robot M-430iA/2PH FANUC Robot M-430iA/4FH M-430iA/4FH FANUC Robot M-900iA/200P M-900iA/200P FANUC Robot M-900iA/260L M-900iA/260L FANUC Robot M-900iA/350 M-900iA/350 FANUC Robot M-900iA/400L M-900iA/400L FANUC Robot M-900iA/600 M-900iA/600 FANUC Robot M-2000iA/900L M-2000iA/900L FANUC Robot M-2000iA/1200 M-2000iA/1200 FANUC Robot F-200iB F-200iB http://slidepdf.com/reader/full/manutencao-robo-fanucpdf M-900iA M-2000iA 14/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Safety FANUC Robotics not andofdoes represent itselfits as work an expert in safety safety equipment, or the specific safetyis aspects yournot company and/or force. It is thesystems, 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. Ensure that the robot being used is appropriate for the application. Robots used in classified (hazardous) locations must be certified for this use. FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use the robotics system be trained in an approved FANUC Robotics training course and become familiar with the proper operation of the system. Persons responsible for programming the system-including the design, implementation, and debugging of application programs-must be familiar with the recommended programming procedures for your application and robot installation. The following guidelines are provided to emphasize the importance of safety in the workplace. CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety: • The safety of people and equipment • Use of safety enhancing devices • Techniques for safe teaching and manual operation of the robot(s) • Techniques for safe automatic operation of the robot(s) • Regular scheduled inspection of the robot and workcell http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 15/483 Safety 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 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: • People • External devices • Robot(s) • Tooling • Workpiece Using Safety Enhancing Devices Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the installation of some or all of the following devices: • Safety fences, barriers, or chains • Light curtains • Interlocks • Pressure mats • Floor markings • Warning lights • Mechanical stops • EMERGENCY STOP buttons • DEADMAN switches Setting Up a Safe Workcell A safe workcell is essential to protect people and equipment. Observe the following guidelines to ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace existing federal, state, and local laws, regulations, and guidelines that pertain to safety. • Sponsor your personnel for training http://slidepdf.com/reader/full/manutencao-robo-fanucpdf in approved FANUC Robotics training course(s) related to 16/483 Safety MANUTENÇÃO ROBO FANUC.pdf 7/17/2019 • 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 or firmware based controllers as the primary safety element unless they comply with applicable current robot safety standards. • Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the operator and at critical points inside and around the outside of the workcell. • Install flashing lights and/or audible warning devices that activate whenever the robot is operating, that is, whenever power is applied to the servo drive system. Audible warning devices shall exceed the ambient noise level at the end-use application. • Wherever possible, install safety fences to protect against unauthorized entry by personnel into the work envelope. • Install special guarding that prevents the operator from reaching into restricted areas of the work envelope. • Use interlocks. • Use presence or proximity sensing devices such as light curtains, mats, and capacitance and vision systems to enhance safety. • Periodically check the safety joints or safety clutches that can be optionally installed between the robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove power from the system, and help to minimize damage to the tooling and robot. • Make sure all external devices are properly filtered, grounded, shielded, and suppressed to prevent hazardous motion due to the effects of electro-magnetic interference (EMI), radio frequency interference (RFI), and electro-static discharge (ESD). • Make provisions for power lockout/tagout at the controller. • Eliminate pinch points . Pinch points are areas where personnel could get trapped between a moving robot and other equipment. • Provide enough room inside the workcell to permit personnel to teach the robot and perform maintenance safely. • Program the robot to load and unload material safely. • If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and beacons. • If materials are being applied at dangerously high pressure provide electrical interlocks for http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 17/483 Safety 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Staying Safe While Teaching or Manually Operating the Robot Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules: • Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. • Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment. • Before teaching, visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These include tooling attached to the wrist flange that extends this range. • The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe working conditions to the supervisor or safety department. • FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except for robot teaching operations. However, if you must enter the work envelope, be sure all safeguards are in place, check the teach pendant DEADMAN switch for proper operation, and place the robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the DEADMAN switch. Only the person with the teach pendant should be in the work envelope. Warning Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death. • Know the path that can be used to escape from a moving robot; make sure the escape path is never blocked. • Isolate the robot from all remote control signals that can cause motion while data is being taught. • Test any program being run for the first time in the following manner: Warning Stay outside the robot work envelope whenever a program is being run. Failure to do so can result in injury. — Using a low motion speed, single step the program for at least one full cycle. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 18/483 Safety 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Staying Safe During Automatic Operation Advise all personnel who operate the robot during production to observe the following rules: • Make sure all safety provisions are present and active. • Know the entire workcell area. The workcell includes the robot and its work envelope, plus the area occupied by all external devices and other equipment with which the robot interacts. • Understand the complete task the robot is programmed to perform before initiating automatic operation. • Make sure all personnel are outside the work envelope before operating the robot. • Never enter or allow others to enter the work envelope during automatic operation of the robot. • Know the location and status of all switches, sensors, and control signals that could cause the robot to move. • Know where the EMERGENCY STOP buttons are located on both the robot control and external control devices. Be prepared to press these buttons in an emergency. • Never assume that a program is complete if the robot is not moving. The robot could be waiting for an input signal that will permit it to continue activity. • If the robot is running in a pattern, do not assume it will continue to run in the same pattern. • Never try to stop the robot, or break its motion, with your body. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel, teach pendant, or emergency stop stations around the workcell. Staying Safe During Inspection When inspecting the robot, be sure to • Turn off power at the controller. • Lock out and tag out the power source at the controller according to the policies of your plant. • Turn off the compressed air source and relieve the air pressure. • If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY STOP button on the operator panel. • Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 19/483 Safety 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Staying Safe During Maintenance When performing maintenance on your robot system, observe the following rules: • Never enter the work envelope while the robot or a program is in operation. • Before entering the work envelope, visually inspect the workcell to make sure no potentially hazardous conditions exist. • 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 an applicator bell cup can continue to spin at a very high speed even if the robot is idle. Use protective gloves or disable bearing air and turbine air before servicing these items. • Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake. Warning Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit to the OFF position removes power from the output side of thebreaker 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. I l t th b tf ll t http://slidepdf.com/reader/full/manutencao-robo-fanucpdf t l i l If i t tb d h th 20/483 Safety 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf • Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked. • Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure that such devices do not create pinch points that could trap personnel. Warning Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Doing so can result in serious personal injury and component destruction. • Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake. • When replacing or installing components, make sure dirt and debris do not enter the system. • Use only specified parts for replacement. To avoid fires and damage to parts in the controller, never use nonspecified fuses. • Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot and all external devices are operating normally. KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. Some of these measures are outlined below. Make sure you know all associated measures for safe use of such devices. Programming Safety Precautions Implement the following programming safety measures to prevent damage to machine tools and other external devices. • Back-check limit switches in the workcell to make sure they do not fail. • Implement “failure routines” in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 21/483 Safety 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Mechanical Safety Precautions Implement the following mechanical safety measures to prevent damage to machine tools and other external devices. • Make sure the workcell is clean and free of oil, water, and debris. • Use software limits, limit switches, and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices. KEEPING THE ROBOT SAFE Observe the following operating and programming guidelines to prevent damage to the robot. Operating Safety Precautions The following measures are designed to prevent damage to the robot during operation. • Use a low override speed to increase your control over the robot when jogging the robot. • Visualize the movement the robot will make before you press the jog keys on the teach pendant. • Make sure the work envelope is clean and free of oil, water, or debris. • Use circuit breakers to guard against electrical overload. Programming Safety Precautions The following safety measures are designed to prevent damage to the robot during programming: • Establish interference zones to prevent collisions when two or more robots share a work area. • Make sure that the program ends with the robot near or at the home position. • Be aware of signals or other operations that could trigger operation of tooling resulting in personal injury or equipment damage. • In dispensing applications, be aware of all safety guidelines with respect to the dispensing materials. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 22/483 Safety 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 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. Caution Ensure that all ground cables remain connected. Never operate the paint robot with ground provisions disconnected. Otherwise, you could injure personnel or damage equipment. Paint robots are operated in three modes: • Teach or manual mode • Automatic mode, including automatic and exercise operation • Diagnostic mode During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant. In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth or in a designated safe area within the booth whenever automatic mode is initiated at the SOC or MCP. In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 23/483 Safety 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 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. • Overtravel by robot axes is prevented by software limits. All of the major and minor axes are governed by software limits. Limit switches and hardstops also limit travel by the major axes. • EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all equipment in the booth if a door is opened while the system is operating in automatic or manual mode. For some systems, signals to these switches are inactive when the switch on the SCC is in teach mode.When present, photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit silhouette openings. • System status is monitored by computer. Severe conditions result in automatic system shutdown. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 24/483 Safety 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Staying Safe While Operating the Paint Robot When you work in or near the paint booth, observe the following rules, in addition to all rules for safe operation that apply to all robot systems. Warning Observe all safety rules and guidelines to avoid injury. Warning Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death. Warning Enclosures shall not be opened unless the area is know to be nonhazardous or all power has been removed from devices within the enclosure. Power shall not be restored after the enclosure has been opened until all combustible dusts have been removed from the interior of the enclosure and the enclosure purged. Refer to the Purge chapter for the required purge time. • Know the work area of the entire paint station (workcell). • Know the work envelope of the robot and hood/deck and door opening devices. • Be aware of overlapping work envelopes of adjacent robots. • Know where all red, mushroom-shaped EMERGENCY STOP buttons are located. • Know the location and status of all switches, sensors, and/or control signals that might cause the robot, conveyor, and opening devices to move. • Make sure that the work area near the robot is clean and free of water, oil, and debris. Report unsafe conditions to your supervisor. • Become familiar with the complete task the robot will perform BEFORE starting automatic mode. • Make sure all personnel are outside the paint booth before you turn on power to the robot servo system. • Never enter the work envelope or paint booth before you turn off power to the robot servo system. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 25/483 Safety 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf • 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. Special Precautions for Combustible Dusts (powder paint) When the robot is used in a location where combustible dusts are found, such as the application of powder paint, the following special precautions are required to insure that there are no combustible dusts inside the robot. • Purge maintenance air should be maintained at all times, even when the robot power is off. This will insure that dust can not enter the robot. • A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed to dust when maintenance air is not present, it will be necessary to remove the covers and clean out any accumulated dust. Do not energize the robot until you have performed the following steps. 1. Before covers are removed, the exterior of the robot should be cleaned to remove accumulated dust. 2. When cleaning and removing accumulated dust, either on the outside or inside of the robot, be sure to use methods appropriate for the type of dust that exists. Usually lint free rags dampened with water are acceptable. Do not use a vacuum cleaner to remove dust as it can generate static electricity and cause an explosion unless special precautions are taken. 3. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust. 4. When the dust has been removed, the covers must be replaced immediately. 5. Immediately after the covers are replaced, run a complete purge cycle. The robot can now be energized. Staying Safe While Operating Paint Application Equipment h k ih i li http://slidepdf.com/reader/full/manutencao-robo-fanucpdf i i b h f ll i l i ddi i ll l 26/483 Safety 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 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 St andar ds f or Spr ay A p p l i c a ti o n U s i n g F l am m a b l e o r C o m b u s t i b l e M a t er i a ls , and NFPA 70 Nat i onal El ec t r i c al Code . • Grounding: All electrically conductive objects in the spray area must be grounded. This includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots, as well as solvent containers. Grounding is defined as the object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms. • High Voltage: High voltage should only be on during actual spray operations. Voltage should be off when the painting process is completed. Never leave high voltage on during a cap cleaning process. • Avoid any accumulation of combustible vapors or coating matter. • Follow all manufacturer recommended cleaning procedures. • Make sure all interlocks are operational. • No smoking. • Post all warning signs regarding the electrostatic equipment and operation of electrostatic equipment according to NFPA 33 Standard for Spray Application Using Flammable or Combustible Material. • Disable all air and paint pressure to bell. • Verify that the lines are not under pressure. Staying Safe During Maintenance When you perform maintenance on the painter system, observe the following rules, and all other maintenance safety rules that apply to all robot installations. Only qualified, trained service or maintenance personnel should perform repair work on a robot. • Paint robots operate in a potentially explosive environment. Use caution when working with electric tools. • When a maintenance technician is repairing or adjusting a robot, the work area is under the control of that technician. All personnel not participating in the maintenance must stay out of the area. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 27/483 Safety 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf • 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. — Follow the Original Equipment Manufacturer’s Material Safety Data Sheets. • When using paint remover observe the following: — Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning. — Adequate ventilation is required. Overexposure could cause drowsiness. — If there is contact with the skin or eyes, rinse with water for at least 15 minutes. Then, seek medical attention as soon as possible. — Follow the Original Equipment Manufacturer’s Material Safety Data Sheets. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 28/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf I. SAFETY PRECAUTIONS http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 29/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 30/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 1.SAFETY PRECAUTIONS B-82595EN-2/04 1 SAFETY PRECAUTIONS 1.1 WORKING PERSON 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. The personnel can be classified as follows. Operator: Power ON/OFF for robot controller Start of robot program with operator’s panel Programmer or teaching operator: Operate for Robot • • • • Teaching inside safety fence Maint enance engi neer: Operate for Robot Teaching inside safety fence Maintenance (adjustment, replacement) • • • - An operator cannot work inside the safety fence. A programmer, Teaching operator and maintenance engineer can work inside the safety fence. workings inside safety fence are lifting, setting, teaching, adjusting, maintenance, etc.. To work inside the fence, the person must be trained for the robot. The Table 1 lists the workings of outside the fence. In this table, the symbol “ “ means the working allowed to be carried out by the personnel. Table 1 List of working s outside th e fence Operator Power ON/OFF for Robot controller Select operating mode (AUTO, T1, T2) Select Remote/Local mode Select robot program with teach pendant Select robot program with external device http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Programmer or Maintenance Teaching operator engineer 31/483 7/17/2019 1.SAFETY PRECAUTIONS • • • 1.2 MANUTENÇÃO ROBO FANUC.pdf B-82595EN-2/04 Use adequate clothes, uniform, overall for operation Put on the safety shoes Use helmet WORKING PERSON SAFETY Working person safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure working person safety. (1) Have the robot system working person attend the training courses held by FANUC. FANUC provides various training courses. Contact our sales office for details. (2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working person safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. (3) Install a safety fence with a gate so that no working person can enter the work area without passing through the gate. Install an interlock switch, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened. The controller is designed to receive this interlock signal of the door switch. When the gate is opened and this signal received, the controller stops the robot in an emergency. For connection, see Fig.1.1. (4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D). (5) Try to install the peripheral devices outside the work area. (6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when a working person enters the work area. (8) If necessary, install a safety lock so that no one except the working person in charge can turn on the power of the robot. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 32/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf 1.SAFETY PRECAUTIONS (9) When adjusting each peripheral device independently, be sure to turn off the power of the robot. RP1 Pulsecoder RI/RO,XHBK,XROT RM1 Motor power/brake EARTH Safety fence Interlock switch and safety plug that are activated if the gate is opened. Fig.1.2 Safety fence and safety gate NOTE Terminals EAS1 EAS11 EAS2 and EAS21 are on the PC board in the operator http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 33/483 7/17/2019 1.SAFETY PRECAUTIONS MANUTENÇÃO ROBO FANUC.pdf B-82595EN-2/04 The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection. NOTE Connect to EES1 and EES11, EES2 and EES21. Fig.1.2.1 Connection diagram for external emergency stop button 1.2.2 Safety of t he Teaching Operator While teaching the robot, it is necessary for the operator to enter the work area of the robot. particularly necessary to ensure the safety of the teaching operator. It is (1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating condition. (3) When entering the robot work area and teaching the robot, be sure to check the location and condition of the safety devices (such as the EMERGENCY STOP button and the DEADMAN switch on the teach pendant). (4) The teaching operator should pay careful attention so that no other workers enter the robot work area. Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the automatic operation mode set, the robot enters the emergency stop state. After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand that the safety gate is disabled and http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 34/483 MANUTENÇÃO ROBO FANUC.pdf 1.SAFETY PRECAUTIONS 7/17/2019 B-82595EN-2/04 The operator's intention of starting teaching is determined by the control unit through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should make sure that the robot can operate in such conditions and be responsible in carrying out tasks safely. The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode switch of the operator panel DEADMAN switch, the teach pendant enable switch and the remote condition on the software. Mode Teach pendant enable/disable Software remote Teach pendant Operator panel Peripheral device switch condition Local Remote Local Remote Local Remote Local Not allowed Not allowed Not allowed Not allowed Allowed to start Allowed to start Not allowed Not allowed Not allowed Allowed to start Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Allowed to start Not allowed Not allowed Not allowed Remote Not allowed Not allowed Not allowed On AUTO mode Off On T1, T2 mode Off (5) To start the system using the operator's panel, make certain that nobody is in the robot work area and that there are no abnormal conditions in the robot work area. (6) When a program is completed, be sure to carry out a test run according to the procedure below. (a) Run the program for at least one operation cycle in the single step mode at low speed. (b) Run the program for at least one operation cycle in the continuous operation mode at low speed. (c) Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing. (d) Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble. (e) After checking the completeness of the program through the test run above, execute it in the automatic operation mode. (7) While operating the system in the automatic operation mode, the teaching operator should leave the robot work area. 1.2.3 Safety durin g Maintenance For the safety of maintenance personnel, pay utmost attention to the following. (1) During operation, never enter the robot work area. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 35/483 1.SAFETY PRECAUTIONS 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf (9) If necessary, have a worker who is familiar with the robot system stand beside the operator panel and observe the work being performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time. (10) When replacing or reinstalling components, take care to prevent foreign matter from entering the system. (11) When handling each unit or printed circuit board in the controller during inspection, turn off the circuit breaker to protect against electric shock. In case of M-900iA/200P and M-2000iA, turn off both MAIN MACHINE DISCONNECT-1 (Breaker of main controller) and MAIN MACHINE DISCONNECT-2 (Breaker of 2nd controller) before servicing. (12) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of non-specified ratings. They may cause a fire or result in damage to the components in the controller. (13) When restarting the robot system after completing maintenance work, make sure in advance that there is no person in the work area and that the robot and the peripheral devices are not abnormal. 1.3 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 1.3.1 Precautions in Programming (1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received. (2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal. (3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other. (4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states. 1.3.2 Precautions for Mechanism (1) Keep the component cells of the robot system clean, and operate the robot in an environment free of grease, water, and dust. (2) Use mechanical unit cable that have required user interface. Please do not obstruct the movement of the mechanical unit cable when cables are added. (Please never do the nylon band stop etc. of an external cable to the mechanical unit cable.) Moreover, please do not interfere with the mechanical unit cable when equipment is installed in the robot. If these precautions are not observed there is a possibility that the mechanical unit cable is disconnected and the trouble not anticipated occurs http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 36/483 1.SAFETY PRECAUTIONS MANUTENÇÃO ROBO FANUC.pdf B-82595EN-2/04 7/17/2019 1.4.2 Precautions in Programming (1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere with each other. (2) Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated. 1.4.3 Precautions for Mechanisms (1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water, and dust. 1.5 SAFETY OF THE END EFFECTOR 1.5.1 Precautions in Programming (1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control. (2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector. 1.6 WARNING LABEL (1) Step-on prohibitive label http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 37/483 1.SAFETY PRECAUTIONS B-82595EN-2/04 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (2) High-temperature warning label Fig.1.6 (b) High -temperature warnin g 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. (3) High-voltage warning label Fig.1.6 (c) High-vol tage warnin g 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, and then turn the circuit breaker to avoid electric careful with servo amplifier anda fixed other time. units because off high-voltage places inshock these hazards. units may Be remain in the high-voltage state for http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 38/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf II. MAINTENANCE http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 39/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 40/483 MAINTENANCE B-82595EN-2/04 7/17/2019 1 1.OVERVIEW MANUTENÇÃO ROBO FANUC.pdf OVERVIEW This manual describes the maintenance and connection of the R-30iA robot controller (called the R-30iA). Maintenance Part: Troubleshooting, and the setting, adjustment, and replacement of units Connection Part: Connection of the R-30iA controller to the robot mechanical unit and peripheral devices, and installation of the controller WARNING Before you enter the robot working area, be sure to turn off the power to the controller or press the EMERGENCY STOP button on the operator's panel or teach pendant. Otherwise, you could injure personnel or damage equipment. - The RIA R15.06 - 1999 compliant controller has safety circuit performance compliant with 4.5.4 control reliable. For information on third party approvals, contact your FANUC representative. The controller is designed to meet R15.06 - 1999 American standard for industrial robots and robot systems - safety requirements. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 41/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 42/483 2.CONFIGURATION MAINTENANCE 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf 2 2.1 CONFIGURATION EXTERNAL VIEW OF THE CONTROLLER The appearance and components might slightly differ depending on the controlled robot, application, and options used. Fig.2.1 (a) to (c) shows the view of R-30 iA. Fig.2.1 (d) to (i) show the construction of the R-30 iA controller. Fig.2.1 (j) to (l) show the external view of the operator’s panel. Fig.2.1 (m) and (n) show the block diagram of R-30iA. Operation box R-30iA controller Teach pendant Fig.2.1 (a) External view o f th e R-30iA co nt ro ll er (A-c abi net ) Integrated operation box http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 43/483 MAINTENANCE B-82595EN-2/04 7/17/2019 2.CONFIGURATION MANUTENÇÃO ROBO FANUC.pdf Operator’s panel Teach pendant Fig.2.1 (c) External view of the R-30iA co nt ro ll er (B -cabin et) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 44/483 2.CONFIGURATION MAINTENANCE 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf Emergency stop button Teach pendant Enable/disable switch Power supply unit Main board Emergency stop unit Heat exchanger Servo amplifier Regenerative resistor http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Rear fan unit 45/483 2.CONFIGURATION MAINTENANCE B-82595EN-2/04 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Emergency stop button Enable/disable switch Teach pendant Power supply unit 2-axis servo amplifier (AMP2)-M-430iA/2F Main board 3-axis servo amplifier (AMP2)-M-430iA/2P Emergency stop unit Heat exchanger Servo amplifier Fig.2.1 (e) R-30iA A-cabi net in ter io r (M-430iA) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 46/483 2.CONFIGURATION 7/17/2019 MAINTENANCE B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf Fan motor Servo amplifier 3 mode switch External fan unit Emergency stop Panel board Breaker Battery Back plane Emergency stop RCC I/F unit (Only M-900iA/260L, M-900iA/350) Main board Enable/disable switch Teach pendant Door fan Power supply unit Optional slot E-stop unit Fig.2.1 (f) R-30iA B-c abi net in ter io r (Fr on t) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 47/483 7/17/2019 2.CONFIGURATION MAINTENANCE B-82595EN-2/04 1-axis servo amplifier（AMP 3） 2-axis servo amplifier （AMP 2） MANUTENÇÃO ROBO FANUC.pdf 6-axis servo amplifier（AMP1） Mode switch Fan motor Emergency stop button External fan unit Panel board Breaker Battery Back plane Emergency stop button RCC I/F unit Teach pendant Main board Enable/disable switch Door fan Power su l unit Option slot E-stop unit Fig. 2.1 (g) R-30iA (B-c abi net ) in ter io r (Fr on t)(M-900iA/400L, M-900iA/600) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 48/483 2.CONFIGURATION MAINTENANCE 7/17/2019 B 82595EN 2/04 MANUTENÇÃO ROBO FANUC.pdf 2-axis servo amplifier (AMP2)-M-430iA/2F 3-axis servo amplifier (AMP2)-M-430iA/2P 6-axis servo amplifier（AMP1） Mode switch Fan motor External fan unit Emergency stop button Panel board Breaker Battery Back plane Emergency stop button RCC I/F unit Main board Enable/disable switch Door fan Teach pendant Power su Option slot l unit E-stop unit Fig. 2.1 (h) R-30iA B-c abi net in ter io r (Fr on t)(M-430iA) Regenerative resistor http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 49/483 MAINTENANCE 2.CONFIGURATION 7/17/2019 FAULT RESET CYCLE MANUTENÇÃO ROBO FANUC.pdf EMERGENCY STOP START FAULT POWER Fig.2.1 (j) R-30iA pan el o verview 2 mode switch 3 mode switch Fig.2.1 (k) Mode swi tch o peration http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 2.CONFIGURATION 50/483 MAINTENANCE B-82595EN-2/04 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 51/483 MAINTENANCE 2.CONFIGURATION Table 2.1 (a) Servo ampli fier sp ecificati onsMANUTENÇÃO ROBO FANUC.pdf 7/17/2019 ROBOT REGENERATIVE REGISTOR SERVO AMPLIFIER A-CAB INET M-900iA/400L A06B-6107-H001 (AMP1) A05B-2502-C100 A06B-6117-H209 (AMP2) M-900iA/600 B-CAB INET A06B-6117-H105 (AMP3) R-2000iB/200T M-900iA/260L M-900iA/350 A06B-6107-H001 A05B-2502-C100 M-410iB A05B-2501-C102 R-2000iB (Except /200T) R-1000iA/80F M-710iC A05B-2501-C103 M-16iB M-20iA A06B-6107-H002 A05B-2502-C100 A05B-2501-C100 ARC Mate 120iB (Except ARC Mate 120iBe.) ARC Mate 120iC M-420iA, M-421iA A05B-2501-C102 M-6iB ARC Mate 100iB ARC Mate 120iBe A05B-2501-C101 A06B-6107-H003 F-200iB A05B-2502-C101 A05B-2501-C105 ARC Mate 100iC M-10iA M-430iA/2F M-430iA/2P M-900iA/200P A06B-6107-H004 A05B-2501-C101 A05B-2502-C101 A05B-2501-C105 A05B-2502-C101 A06B-6107-H007 (AMP 1) A06B-6117-H201 (AMP 2) A06B-6107-H007 (AMP 1) A06B-6117-H301 (AMP 2) A06B-6107-H001 (Main, AMP 1) A05B-2502-C100 A06B-6107-H001 (2nd, AMP 1) A05B-2502-C100 A06B-6107-H001 (Main, AMP 1) A06B-6117-H105 (Main, AMP 2) M-2000iA A06B-6107-H001 (2nd, AMP 1) A06B-6117-H105 (2nd, AMP 2) Table 2.1(b) fan type list f or A-cabinet ROBOT FAN TYPE REAR FAN SIDE FAN ― ○ ― ○ M-410iB M-710iC http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 2.CONFIGURATION 52/483 MAINTENANCE B-82595EN-2/04 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 MAINTENANCE 2.CONFIGURATION 53/483 7/17/2019 l ra e h p ir e P )l ia r e S ( e c i v e d l ra e h p ir e P p o t s – e c i v e d l ra e h ip r e P )l ia r e S ( e c i v e d )t e rn e th E ( h c a e T t n a d n e p l E a n r te x E ff o / n lo a n r te x E A L E D O M -t i n O /I U Battery y r o m e m B S U d r a c ry o m e M rd a o b in a M h c it r e fii l p m )r e if il p m a a o v r e S is x a – (6 w S l e n a p 's r o t ra e p O rd a o b l e n a P Signals for I/O Link and Teach pendant Servo signal (FSSB) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 24VDC EMG signal y l p p u s r e w o p e k a r B , y l p p u s r e w o p r to o M e iv t ra e n e r o t is g s e R e r e s a h p 3 , V 0 0 2 l a n g i s G M E t i n u p to s – E e s a y 2.CONFIGURATION t o b o R ls a n ig s O D /I D t o b o R , s l a n g i s r e d o c e ls u P O I/ s s e c o r P rd a o b ti u c ir c d e t n ir P e n a l p k c a B MANUTENÇÃO ROBO FANUC.pdf MAINTENANCE 54/483 B-82595EN-2/04 2.2 7/17/2019 • • • • • • • • • • • • COMPONENT FUNCTIONS MANUTENÇÃO ROBO FANUC.pdf Main board The main board contains a microprocessor, its peripheral circuits, memory, and operator's panel control circuit. The main CPU controls servo mechanism positioning. I/O printed circuit board, FANUC I/O Unit MODEL-A Various types of printed circuit boards are provided for applications including process I/O. The FANUC I/O unit MODEL-A can also be installed. When it is used, various I/O types can be selected. These are connected with FANUC I/O Link. E-stop unit and MCC unit This unit controls the emergency stop system for both of the magnetic contactor and the precharge of the servo amplifier. Power supply unit The power supply unit converts the AC power to various levels of DC power. Backplane printed circuit board The various control printed circuit boards are mounted on the backplane printed circuit board. Teach pendant All including robot programming performed this unit. The controller status and dataoperations are indicated on the liquid-crystal displayare (LCD) on thewith pendant. Servo amplifier The servo amplifier controls servomotor, pulsecoder signal, brake control, overtravel and hand broken. Operator's panel Buttons and LEDs on the operator's panel are used to start the robot and to indicate the robot status. The panel has a port and an USB interface for the serial interface to an external device and an interface circuit. to connect the memory card for data backup. It also controls the emergency stop control Transformer The supply voltage is converted to an AC voltage required for the controller by the transformer. Fan unit, heat exchanger These components cool the inside of the controller. Circuit breaker If the electric system in the controller malfunctions, or if abnormal input power causes high current in the system, the input power is connected to the circuit breaker to protect the equipment. Regenerative resistor To discharge the counter electromotive force from the servomotor, connect a regenerative resistor to the servo amplifier. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 MAINTENANCE 2.CONFIGURATION 55/483 2.3 PREVENTIVE MAINTENANCE 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 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 operation Check the cable connected to the teach pendant for excessive twisting. Check the controller and peripheral devices for abnormalities. (b) After operation At the end of operation, return the robot to the specified position, and then turn off the controller. Clean each part, and check for any damage or cracks. If the ventilation port of the controller is dusty, clean it. (2) Check after one month Check that the fan is rotating normally. If the fan has dirt and dust built up, clean the fan according to step (d) described below for inspection to be performed every 6 months. (3) Periodic inspection performed every six months Remove the top cover, louver, and back panel (if possible), and then remove any dirt and dust from the inside of the transformer compartment. Wipe off dirt and dust from the fan and transformer. (4) Battery daily check Replace the battery on the front panel of the main board every 4 years. Please refer to the section 7.15. (5) Maintenance tools The following maintenance tools are recommended: (a) Measuring instruments AC/DC voltmeter (A digital voltmeter is sometimes required.) Oscilloscope with a frequency range of 5 MHz or higher, two channels (b) Tools Phillips screwdrivers: Large, medium, and small Standard screwdrivers: Nut driver set (Metric) Pliers Needle-nose pliers Diagonal cutting pliers Large, medium, and small http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 56/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 3 TROUBLESHOOTING 3.1 POWER CANNOT BE TURNED ON 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. Check and Corrective action (Check 1) Check that the circuit breaker is on and has not tripped. (Corrective Turn on the circuit breaker. action) Figure Circuit breaker Circuit breaker (Check 2) (Corrective action) Check whether the LED (PIL: green) on the power supply unit is on. If the LED is not on, 200 VAC is not supplied to the power supply unit. It is likely that fuse F1 in the power supply unit has blown. - If 200 VAC is not supplied: Find the cause by referencing the general schematic diagram presented in the DB1: Diode stack F1(8.0A): Fuse for AC input CP1: Connector for AC input CP1A: Connector for AC output VS1: Surge absorber H1: Auxiliary power module http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 MAINTENANCE CP2, CP3: Connector for AC output F3(7.5A): Fuse for +24E F4(7.5A): Fuse for +24V PIL: LED (green) CP5: Connector for +24E CP6: Connector for +24V 3.TROUBLESHOOTING 57/483 7/17/2019 Check and Corrective action (Corrective Causes of blown fuses F1 action (1)) (Check 3) (Corrective action) Figure MANUTENÇÃO ROBO FANUC.pdf and corrective action a) Check the units (fans), printed-circuit board and cables connected to the CP2 and CP3 connectors of the power supply unit to see if there is any short circuit. b) Replace the power supply unit. Check whether the EXON1 and EXON2 signals and the EXOFF1 and EXOFF2 signals are connected on the terminal block on the panel board. If the external ON/OFF Short–circuit plate : Between EXON1 and -EXON2 Short–circuit plate : Between EXOFF1 and EXOFF2 function not used, connect terminal is EXON1 to EXON2 and terminal EXOFF1 to EXOFF2. If the external ON and OFF lines are already used, check the mating contacts and the cable. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 58/483 7/17/2019 Check and Corrective action (Check 4) Check whether the connector (JRS15) on the main board or the connector (JRS15) on the panel board is connected properly. Another probable cause is that the cable connected to either of these connectors is faulty. Confirm that the 200VAC power is supplied to connector CP1 by reverifying Checks 1 - 3, and verifying that the ON/OFF switch is functioning properly. If the red ALM (Alarm) LED on the power supply unit is on, verify that the +24V external connection cable is connected to 0V or ground. If the problem still exists, check the power supply unit using the following procedure: a) Check Fuse F4. - If the fuse is blown, see Corrective action Figure MANUTENÇÃO ROBO FANUC.pdf DB1: Diode stack F1(8.0A): Fuse for AC input CP1: Connector for AC input CP1A: Connector for AC output CP2, CP3:Connector for AC output VS1: Surge absorber H1: Auxiliary power module F3(7.5A): Fuse for +24E F4(7.5A): Fuse for +24V PIL: LED (green) CP5: Connector for +24E CP6: Connector for +24V ALM: LED (red) CP4: Connector for control 2. b) Fuse F4 is not blown. - A printed circuit board or unit that uses a DC supply (+2.5V, +3.3V, +5V, +24V, or +15V) is faulty. - Verify that 200VAC is being supplied to connector CP1. If the power is supplied, replace the power supply unit. (Corrective If the power supply unit is http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING 59/483 3.2 7/17/2019 ALARM OCCURRENCE SCREEN MANUTENÇÃO ROBO FANUC.pdf 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 alarms that are more serious. 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 alarm key. Press the screen selection key to select [4 ALARM]. 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 3.TROUBLESHOOTING http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE B-82595EN-2/04 60/483 Displaying 7/17/2019 the alarm histor y/alarm detail info rmation MANUTENÇÃO ROBO FANUC.pdf Step (1) Press the MENUS key to display the screen menu. (2) Select [ALARM]. You will see a screen similar to the following. If an alarm has occurred, however, the alarm screen appears automatically. 3 4 ALARM INTP-224 (SAMPLE1, 7) Jump label is fail 5 I/O Alarm MENUS JOINT 30 % 1/1 MEMO-027 Specified line does not exist [ TYPE ] ALARM detail code HIST (3) To display the alarm history screen, press F3, [HIST]. Press F3 [ACTIVE] again, the alarm screen appears. 3 4 ALARM 5 I/O MENUS 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 3 4 5 SRVO-002 Teach pendant E-stop R E S E T SRVO-027 Robot not mastered(Group:1) SYST-026 System normal power up [ 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, and then press the right arrow key. (4) To display the alarm detail screen, press F5, [HELP]. B-82595EN-2/04 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE 3.TROUBLESHOOTING 61/483 (5) To return to the alarm history screen, press the PREV key. 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf PREV (6) To delete all the alarm histories, press and hold down the SHIFT key, then press F4, [CLEAR]. CLEAR SHIFT HELP F4 NOTE When system variable $ER_NOHIS = 1, NONE alarms or WARN alarms are not recorded. When $ER_NOHIS=2, resets are not recorded in the alarm history. When $ER_NOHIS=3, resets, WARN alarms, and NONE alarms are not recorded. The following map indicates teach pendant operations used to check an alarm. 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] 3.TROUBLESHOOTING http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE B-82595EN-2/04 62/483 3.3 SAFETY SIGNALS 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 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 sig nals Safety signal Description Operator’s panel emergency stop Teach pendant emergency stop External emergency stop This item indicates the state of the emergency stop button on the operator’s panel. If the EMERGENCY STOP button is pressed, the state is indicated as “TRUE”. This item indicates the state of the emergency stop button on the teach pendant. If the EMERGENCY STOP button is pressed, the state is indicated as “TRUE”. This item indicates the state of the external emergency stop signal. If the EMERGENCY STOP signal is asserted, the state is indicated as “TRUE”. This item indicates the state of the safety fence. If the safety fence is open, the state is indicated as “TRUE”. This item indicates whether the DEADMAN switch on the teach pendant is grasped. If the teach pendant is operable, and the DEADMAN switch is grasped correctly, the Fence open DEADMAN switch Teach pendant operable Hand broken Robot overtravel Abnormal air pressure state is indicated as “TRUE”. If the DEADMAN switch is released or is grasped tightly when the teach pendant is operable, an alarm occurs, causing the servo power to be switched off. This item indicates whether the teach pendant is operable. If the teach pendant is operable, the state is indicated as “TRUE”. This item indicates the state of the hand safety joint. If the hand interferes with a workpiece or anything like this, and the safety joint is opened, the state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be switched off. This item indicates whether the current position of the robot is out of the operation range. If any robot articulation goes out of the operation range beyond the overtravel switch, the state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be switched off. This item indicates the state of the air pressure. The abnormal air pressure signal is connected to the air pressure sensor. If the air pressure is not higher than the specified value, the state is indicated as “TRUE”. Step (1) (2) (3) (4) Press the MENUS key to display the screen menu. Select STATUS on the next page. Press F1, [TYPE] to display the screen switching menu. Select Safety Signal. You will see a screen similar to the following. B-82595EN-2/04 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE 3.TROUBLESHOOTING 63/483 3.4 MASTERING 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Mastering is needed if: (1) The SRVO-062 BZAL or SRVO-038 pulse mismatch alarm occurs, or (2) The Pulsecoder is replaced. Item (1) requires quick mastering, while item (2) requires zero-degree or fixture position mastering. (Zero-degree position mastering is just for quick-fix purposes. After zero-degree position mastering is used, fixture position mastering should be performed later.) The mastering procedure is described below. For details, refer to an applicable maintenance manual of mechanical unit or operator's manual of control unit. Condition System variable $MASTER_ENB must be set to 1 or 2. SYSTEM Variables JOINT 10% 57/136 1 57 $MASTER_ENB Step (1) (2) (3) (4) Press <MENUS>. Select SYSTEM. Press F1, TYPE. Select Master/Cal you will see a screen similar to the following. 9 0 -- NEXT -- MENUS 5 POSITION 6 SYSTEM 7 SYSTEM Master/Cal 1 2 3 4 5 6 JOINT 30% FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press 'ENTER' or number key to select. Master TYPE [TYPE] LOAD RES_PCA DONE F1 3.TROUBLESHOOTING http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE B-82595EN-2/04 (6) Select "1 FIXTURE POSITION MASTER" and press the F4 key (yes). Mastering data is set. 64/483 (6) Select 1 FIXTURE POSITION MASTER and press the F4 key (yes). Mastering data is set. 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf SYSTEM Master/Cal SYSTEM Master/Cal 1 FIXTURE POSITION MASTER ENTER 2 ZERO POSITION MASTER Master at master position? Master at master position? [ TYPE ] YES 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> NO F4 [ TYPE ] LOAD RES_PCA DONE (7) Select "6 CALIBRATE" and press the F4 key (yes). Calibration is performed. Alternatively, to perform positioning, turn the power off, and then turn it on again. Calibration is performed whenever the power is turned on. 5 SET QUICK MASTER REF 6 CALIBRATE Calibrate? [NO] ENTER Calibrate? [NO] [ TYPE ] SYSTEM Master/Cal 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 YES F4 (8) Press F5 "DONE", after mastering. DONE F5 B-82595EN-2/04 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE 3.TROUBLESHOOTING 65/483 3.5 TROUBLESHOOTING USING THE ERROR CODE 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (1) SRVO-001 Operator panel E-stop (Explanation) The emergency stop button on the operator's panel is pressed. (Action 1) Release the emergency stop button pressed on the operator's panel. (Action 2) Check the wires connecting between the emergency stop button and the panel board (CRT16) for continuity. If an open wire is found, replace the entire harness. (Action 3) Check the wires connecting between the teach pendant and the panel board (CRS20) for continuity. If an open wire is found, replace the entire harness. (Action 4) With the emergency stop in the released position, check for continuity across the terminals of the switch. If continuity is not found, the emergency stop button is broken. Replace the switch unit or the operator's panel. (Action 5) Replace the teach pendant. (Action 6) Replace the panel board. Before executing the (Action 7), perform a complete controller back-up to save all your programs and settings. (Action 7) Replace the main board. NOTE If SRVO-001 is issued together with SRVO-213, a fuse may have blown. Take the same actions as for SRVO-213. Emergency stop button Emergency stop button 3.TROUBLESHOOTING http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE B-82595EN-2/04 66/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CRS20 CRT16 (Panel b oard) Fig.3.5 (b) SRVO-001 Operator panel E-stop (2) SRVO-002 Teach pendant E-stop (Explanation) The emergency stop button on the teach pendant was pressed. (Action 1) Release the emergency stop button on the teach pendant. (Action 2) Replace the teach pendant. Emergency stop button Fig.3.5 (c) SRVO-002 Teach pendant E-stop (3) SRVO-003 DEADMAN switch released (Explanation) The teach pendant is enabled, but the DEADMAN switch is not pressed. Alternatively, the DEADMAN switch is pressed strongly. (Action 1) Check the intermediate position of the DEADMAN switch on the teach pendant. (Action 2) (Action 3) (Action 4) Check that the mode on thepositions. operator's panel and the enable/disable switch on the teach pendant are switch at the correct Replace the teach pendant. Check the mode switch connection and operation. If trouble is found, replace the mode switch. B-82595EN-2/04 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (4) SRVO-004 Fence open MAINTENANCE 3.TROUBLESHOOTING 67/483 (Explanation) In the automatic operation mode, the safety fence contact connected to EAS1-EAS11 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (Action 1) (Action 2) (Action 3) (Action 4) (Action 5) or EAS2-EAS21 of TBOP4 is open. When a safety fence is connected, close the safety fence. Check the cables and switches connected between EAS1 and EAS11 and between EAS2 and EAS21 of the terminal block TBOP4 on the panel board. If the safety fence signal is not used, make a connection between EAS1 and EAS11 and between EAS2 and EAS21 of the terminal block TBOP4 on the panel board. Check the mode switch. If trouble is found, replace the mode switch. Replace the panel board. NOTE If SRVO-004 is issued together with SRVO-213, a fuse may have blown. Take the same actions as for SRVO-213. EAS1 EAS11 EAS2 EAS22 (Panel b oard) 3.TROUBLESHOOTING http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (5) SRVO-005 Robot overtravel MAINTENANCE B-82595EN-2/04 68/483 (Explanation) The robot has moved beyond a hardware limit switch on the axes. 7/17/2019 (Action 1) (Action 2) (Action 3) (Action 4) (Action 5) (Action 6) MANUTENÇÃO ROBO FANUC.pdf 1) Select OT release] axis from [System the overtravel state. on the overtravel release screen to release each robot 2) Hold down the shift key, and press the alarm release button to reset the alarm condition. 3) Still hold down the shift key, and jog to bring all axes into the movable range. Replace the limit switch. Check the FS2 fuse on the servo amplifier. If the SRVO-214 fuse blown alarm is also generated, the FS2 fuse has blown. Check the end effector connector. Replace the servo amplifier. Verify the following for connector RP1 at the base of the robot: 1) There are no bent or dislocated pins in the male or female connectors. 2) The connector is securely connected. Then verify that connectors CRF8 and CRM68 on the servo amplifier are securely connected. Also verify that the RP1 cable is in good condition, and there are no cuts or kinks visible. If no limit switch is in use, jumper connector must be attached in the mechanical unit. Check for the jumper connector. NOTE It is factory-placed in the overtravel state for packing purposes. If the Overtravel signal is not in use, it may have been disabled by short-circuiting in the mechanical unit. (6) SRVO-006 Hand broken (Explanation) The safetyconnection joint (if incable use) might been broken. the HBK signal on the robot might have be a ground fault orAlternatively, a cable disconnection. (Action 1) Hold down the shift key, and press the alarm release button to reset the alarm condition. Still hold down the shift key, and jog the tool to the work area. 1) Replace the safety joint. 2) Check the safety joint cable. (Action 2) Replace the servo amplifier. (Action 3) Verify the following for connector RP1 at the base of the robot: 1) There are no bent or dislocated pins in the male or female connectors. 2) The connector is securely connected. Then verify that connector CRF8 on the servo amplifier is securely connected. Also verify that the RP1 cable is in good condition, and there are no cuts or kinks visible. Check the robot connection cable (RP1) for a ground fault or a cable disconnection B-82595EN-2/04 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE 3.TROUBLESHOOTING Servo amplifier 69/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Servo amplifier (A-cabinet) (B-cabinet) Connector (CRF8) Connector (CRM68) FS2 (Servo ampli fier) Fig. 3.5 (f) SRVO-005 Robot overtravel SRVO-006 Hand broken 3.TROUBLESHOOTING http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (7) SRVO-007 External E-stop MAINTENANCE B-82595EN-2/04 70/483 (Explanation) On the terminal block TBOP4 of the panel board, no connection of external 7/17/2019 (Action 1) (Action 2) (Action 3) (Action 4) MANUTENÇÃO ROBO FANUC.pdf emergency stop is made between EES1 and EES11,release EES2 and EES21. If an external emergency stop switch is connected, the switch. Check the switch and cable connected to EES1-EES11 and EES2-EES21 on TBOP4. When this signal is not used, make a connection between EES1 and EES11, EES2 and EES21. Replace the panel board. NOTE If SRVO-007 is issued with SRVO-213, a fuse may have blown. Take the same actions as fortogether SRVO-213. EES1 EES11 EES2 EES22 (Panel b oard) Fig.3.5 (g) SRVO-007 External E-stop WARNING In a system using the external emergency stop signal, it is very dangerous to disable the signal when a connection is made between EES1 and EES11 and B-82595EN-2/04 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE (8) SRVO-009 Pneumatic pressure abnormal 3.TROUBLESHOOTING 71/483 (Explanation) An abnormal air pressure was detected. 7/17/2019 (Action 1) (Action 2) (Action 3) (Action 4) (Action 5) The input signal is located on the end MANUTENÇÃO ROBO FANUC.pdf effector of the robot. Refer the manual of the your robot. If an abnormal air pressure is to detected, check cause. Check the end effector connector. Check the robot connection cable (RP1) for a ground fault or a cable disconnection. If a fault or a disconnection is detected, replace the cable. Replace the servo amplifier. Replace the internal cables of the robot. NOTE Pneumatic pressure alarm input is on the end effector. Please refer to the manual of your robot. Servo amplifier Servo amplifier (A-cabinet) (B-cabinet) Fig.3.5 (h) SRVO-009 Pneumatic pressure alarm 3.TROUBLESHOOTING http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (9) SRVO-014 Fan motor abnormal MAINTENANCE B-82595EN-2/04 72/483 7/17/2019 (Explanation) When a fan motor stops on backplane unit, TP shows the following message. In one minutes from occurring of alarm, robot stops and cannot be operated from TP. The MANUTENÇÃO ROBO FANUC.pdf robot can be recovered by replacing a fan motor. Number in the bracket indicates which fan is abnormal. (1): fan above the slot1 (2): fan above slot2 (3): both fans (Action 1) Check the fan motor and its cables. Replace them if necessary. (Action 2) Replace the backplane unit. Before executing the (Action 3), perform a complete controller back-up to save all your programs and settings. (Action 3) Replace the main board. Fan motor Main board B-82595EN-2/04 MAINTENANCE http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (10) SRVO-015 SYSTEM OVER HEAT (Group: 3.TROUBLESHOOTING i Axis: j) (Explanation) The temperature in the control unit exceeds the specified value. 73/483 7/17/2019 (Action 1) (Action 2) ° If the ambient temperature is higher than specifiedMANUTENÇÃO (45 C), coolROBO downFANUC.pdf the ambient temperature. If the fan motor is not running, check it and its cables. Replace them if necessary. Before executing the (Action 3), perform a complete controller back-up to save all your programs and settings. (Action 3) Replace the main board. (The thermostat on the main board may be faulty.) Fan motor Fan Main board Heat exchanger A-cab in et (Fron t) Rear fan unit Side fan unit 3.TROUBLESHOOTING MAINTENANCE http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Fan motor Servo amplifier B-82595EN-2/04 74/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Main board Door fan B-cabinet (Front) External fan unit B-cabinet (Rear) Fig.3.5 (j) SRVO-015 SYSTEM OVER HEAT B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING (11) SRVO-018 Brake abnormal http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Explanation) An excessive brake current is detected. 75/483 The ALM LED on the servo amplifier is lit. (Action 1) 7/17/2019 (Action 2) (Action 3) Check the robot connection cable (RM1) and cables internal to the mechanical section for a short-circuit and connection to the ground. If a faultROBO or a disconnection MANUTENÇÃO FANUC.pdf is detected, replace the cable. This alarm may occur if the brake connector is not attached. Make sure that connector CRM88 is securely attached to the servo amplifier. Replace the servo amplifier. CAUTION This can be caused the optional brake if theTo on/off switch is left inerror on position while thebyoperator attempts torelease jog the unit robot. recover, turn the brake release unit off and cycle the controller power. (12) SRVO-021 SRDY off (Group: i Axis: j) (Explanation) The HRDY is on and the SRDY is off, although there is no other cause of an alarm. (HRDY is a signal with which the host detects the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo (Action 1) (Action 2) (Action 3) (Action 4) system informs the host whethercontactor the magnetic contactor is turned on.)directed so, it is If the servo amplifier magnetic cannot be turned on when 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. Make sure that the emergency stop board connectors CP2, CRM96, CNMC3, and servo amplifier SRM96 are securely attached to the servo amplifier. It is possible that an instant disconnection of power source causes this alarm. Check whether an instant disconnection occurred. Replace the E-stop unit. Replace the servo amplifier. (13) SRVO-022 SRDY on (Group: i Axis: j) (Explanation) When the HRDY is about to go on, the SRDY is already on. (HRDY is a signal with which the host directs the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on.) (Action 1) Replace the servo amplifier as the alarm message. 3.TROUBLESHOOTING (14) SRVO-023 Stop error excess (Group: http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE i Axis: j) (Explanation) When the servo is at stop, the position error is abnormally large. B-82595EN-2/04 76/483 Check whether the brake is released through the clack sound of the brake or vibration. MANUTENÇÃO ROBO FANUC.pdf 7/17/2019 In case that the brake is not released. (Action 1) If the brake is not released, check the continuity of the brake line in the robot connection cable and the robot internal cable. (Action 2) If the disconnection is not found, replace the servo amplifier or the servo motor. In case that the brake is released. (Action 1) Check whether the obstacle disturbs the robot motion. (Action 2) Make sure that connectors CNJ1A-CNJ6 are securely attached to the servo amplifier. (Action 3) Check the continuity of the robot connection cable and the internal robot power cable. (Action 4) Check to see if the load is greater than the rating. If greater, reduce it to within the rating. (If the load is too great, the torque required for acceleration / deceleration becomes higher than the capacity of the motor. As a result, the motor becomes unable to follow the command, and an alarm is (Action 5) (Action 6) (Action 7) issued.) Check the input voltage to the controller is within the rated voltage and no phase is lack. And check the setting of the transformer is correct. Check each phase voltage of the CRR38A or CRR38B connector of the three-phase power (200 VAC) input to the servo amplifier. If it is 210 VAC or lower, check the line voltage. (If the voltage input to the servo amplifier becomes low, the torque output also becomes low. As a result, the motor may become unable to follow the command, hence possibly causing an alarm.). Replace the servo amplifier. Replace the motor of the alarm axis. NOTE Incorrect setting of the brake number causes this alarm. Servo amplifier B-82595EN-2/04 MAINTENANCE (15) SRVO-024 Move error excess (Group: http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 3.TROUBLESHOOTING i Axis: j) (Explanation) When the robot is running, its position error is greater than a specified value 77/483 7/17/2019 (Action 1) ($PARAM_GROUP. $MOVER _ OFFST ). the speed specified by program. Take the same actions as SRVO-023. It is likely that the robot cannot follow MANUTENÇÃO ROBO FANUC.pdf (16) SRVO-027 Robot not mastered (Group: i) (Explanation) An attempt was made to calibrate the robot, but the necessary adjustment had not been completed. (Action) Check whether the mastering is valid. If the mastering is invalid, master the robot. WARNING If the position data is incorrect, the robot or additional axis can operate abnormally, set the position data correctly. Otherwise, you could injure personnel or damage equipment. (17) SRVO-030 Brake on hold (Group:i) (Explanation) If the temporary halt alarm function is enabled ($SCR.$BRKHOLD ENB=1), (Action) SRVO-030 is issued when a temporary halt occurs. When this function is not used, disable the setting. Disable [Servo-off in temporary halt] on the general item setting screen [6 General Setting Items]. (18) SRVO-033 Robot not calibrated (Group: i) (Explanation) An attempt was made to set up a reference point for quick mastering, but the robot had not been calibrated. (Action) Calibrate the robot. 1. Supply power. 2. Set up a quick mastering reference point using [Positioning] on the positioning menu. (19) SRVO-034 Ref pos not set (Group: i) (Explanation) An attempt was made to perform quick mastering, but the reference point had not been set up. (Action) Set up a quick mastering reference point on the positioning menu. (20) SRVO-036 Inpos time over (Group: i Axis: j) (Explanation) The robot did not get to the effective area ($PARAM _ GROUP.$ STOPTOL) even after the position check monitoring time ($PARAM _ GROUP. $INPOS _ TIME) elapsed. (Action) Take the same actions as for SRVO 023 (large position error at a stop) 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (22) SRVO-038 Pulse mismatch (Group: i Axis: j) (Explanation) The pulse count obtained when power is turned off does not match the pulse count http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 78/483 obtained when power is applied. This alarm is asserted after exchange the Pulsecoder or battery for back up of the PulsecoderMANUTENÇÃO data or loading back up data to ROBO FANUC.pdf the Main Board. 7/17/2019 Check the alarm history. (Action 1) If the brake number is set to the non-brake motors, this alarm may occur. Check the software setting of the brake number. (Action 2) In case the robot has been moved by using the brake release unit while the power is off or when restoring the back-up data to the main board, this alarm may occur. Remaster the robot. (Action 3) If the robot has been moved because the brake failed, this alarm may occur. Check the cause of the brake trouble. Then remaster the robot. (Action 4) Replace the Pulsecoder and master the robot. (23) SRVO-042 MCAL alarm (Group: i Axis: j) (Explanation) This alarm means that the contacts of the magnetic contactor have stuck to each other. The alarm condition occurs if the magnetic contactor turns out to be already on when (Action 1) (Action 2) an attempt is made to turn it on. The alarm condition is detected between the time contact sticking occurs and the time an attempt is made to turn on the magnetic contactor. Replace the E-stop unit. Replace the servo amplifier. Servo amplifier E-stop unit Magnetic con B-82595EN-2/04 (24) MAINTENANCE 3.TROUBLESHOOTING SRVO-043 DCAL alarm (Group: i Axis: j) (Explanation) The regenerative discharge energy was too high to be dissipated as heat. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (To run 79/483 7/17/2019 (Action 1) (Action 2) (Action 3) (Action 4) (Action 5) (Action 6) the robot, the servo amplifier supplies energy to the robot. When going down the vertical axis, the robot operates from the potential energy. If a reduction in the MANUTENÇÃO ROBO FANUC.pdf potential energy is higher than the energy needed for acceleration, the servo amplifier receives energy from the motor. A similar phenomenon occurs even when no gravity is applied, for example, at deceleration on a horizontal axis. The energy that the servo amplifier receives from the motor is called the regenerative energy. The servo amplifier dissipates this energy as heat. If the regenerative energy is higher than the energy dissipated as heat, the difference is stored in the servo amplifier, causing an alarm.) This alarm may occur if the axis is subjected to frequent acceleration/deceleration or if the axis is vertical and generates a large amount of regenerative energy. If this alarm has occurred, relax the service conditions. Check fuse FS3 in the servo amplifier. If it has blown, remove the cause, and replace the fuse. One of the probable causes of a blown fuse is a ground fault in the servo amplifier for the auxiliary axis. The ambient temperature is excessively high. Or the regenerative resistor can't be cooled effectively. Check the external fan unit, and replace it if it stops. Clean up the fun unit, the regenerative resistor and the louver if they are dirty. Measure the input voltage between each phase at the main breaker, and make sure that each voltage satisfy the input voltage rating. If each voltage does not satisfy the input voltage rating, check the power supply facility. Measure the secondary voltage of transformer at breaker terminal of E-stop unit, and make sure that the measured voltage is approximately 210V. If phase loss is detected, replace the transformer. Replace the E-stop unit. (Action 7) Make that the servo amplifier tightly.sure Then detach the cable fromCRR63A CRR63Aand andCRR63B CRR63Bconnectors connectorsare on connected the Servo amplifier, and check for continuity between pins 1 and 2 of the cable-end connector. If there is no continuity between the pins, replace the regenerative resistor. Make sure that the servo amplifier CRR45A and CRR45B are connected tightly, then detach the cables from CRR45A and CRR45B on the servo amplifier and check the resistance between pins 1 and 2 of each cable end connector. If the resistance is not 9-16Ω, replace the regenerative resistor. CRR45B may not be used depending on (Action 8) the robotthe model. Replace servo amplifier. 3.TROUBLESHOOTING E-stop unit http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE B-82595EN-2/04 80/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Servo amplifier A-cab in et (Fr on t) egenera ve res s or Regenerative resistor Transformer Transformer Side fan type Rear fan type A-cab in et (Rear) Servo amplifier Regenerative B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING (25) SRVO-044 HVAL alarm (Group: i Axis: j) link voltage) of the main circuit power supply is abnormally high. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Explanation) The DC voltage (DC 81/483 7/17/2019 (Action 3) high. Check the three-phase input voltage at the servo amplifier. If it is 240 VAC or FANUC.pdf higher, check the line voltage. (If the three-phase MANUTENÇÃO input voltageROBO is higher than 240 VAC, high acceleration/deceleration can cause in this alarm.) Check that the load weight is within the rating. If it is higher than the rating, reduce it to within the rating. (If the machine load is higher than the rating, the accumulation of regenerative energy might result in the HVAL alarm even when the three-phase input voltage is within the rating.) Check that the CRR63A and CRR63B connectors of the servo amplifier are attached (Action 4) firmly. Next, detach the cables then check the continuity between pins 1 and 2 of the cable-side connectors. If a disconnection is found, replace the regenerative resistor. Replace the servo amplifier. (Action 1) (Action 2) (26) SRVO-045 HCAL alarm (Group: i Axis: j) (Explanation) Abnormally high current flowed in the main circuit of the servo amplifier. (Action 1) Turn off the power, and disconnect the power cable from the servo amplifier (Action 2) (Action 3) indicated by the alarm message. (And disconnect the brake cable (CRR88 on the servo amplifier) to avoid the axis falling unexpectedly.) Supply power and see if the alarm occurs again. If the alarm occurs again, replace the servo amplifier. Turn off the power and disconnect the power cable from the servo amplifier indicated by the alarm message, and check the insulation of their U, V, W and the GND lines each other. If there is a short-circuit, replace the power cable. Turn off the power and disconnect the power cable from the servo amplifier by the alarm message, and measure the resistance between their U and V, V and W and W and with anare ohmmeter haseach a very lowthe resistance If thecable resistances at the threeUplaces differentthat from other, motor, range. the power is defective. Check each item in detail and replace it if necessary. 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (27) SRVO-046 OVC alarm (Group: i Axis: j) 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 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Explanation) This alarm is issued 82/483 7/17/2019 (Action 1) (Action 2) (Action 3) (Action 4) (Action 5) (Action 6) (Action 7) (Action 8) (Action 9) allowable range. ROBO FANUC.pdf Check the operating condition for the robot and relaxMANUTENÇÃO the service condition if possible. If the load or operating condition has exceeded the rating, reduce the load or relax the operating condition to meet the rating. Check whether the voltage input to the controller is within the rated voltage and also check whether the voltage set for the transformer of the controller is correct. Check whether the brake of the corresponding axis is released. Check whether there is a factor that has increased the mechanical load on the corresponding axis. Replace the servo amplifier. Replace the motor of the corresponding axis. Replace the E-stop unit Replace the motor power line (robot connection cable) of the corresponding axis. Replace the motor power line and brake line (inside the mechanical section) of the corresponding axis. Servo amplifier Servo amplifier (A-cabinet) (B-cabinet) Fig.3.5 (n) SRVO-044 HVAL alarm B-82595EN-2/04 MAINTENANCE Reference http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Relationships among the OVC, OHAL, and HC alarms 3.TROUBLESHOOTING 83/483 7/17/2019 - Overview - Alarm detection section ROBO FANUC.pdf This section points out the differences among the OVC, OHAL, and HC MANUTENÇÃO alarms and describes the purpose of each alarm. Abb revi ati on Design ati on Detect io n s ect io n OVC Overcurrent alarm Servo software OHAL Overheat alarm HC High current alarm Thermal the servo motor amplifier Thermal relay relay in in the Thermal relay in the separate regenerative discharge unit 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. OVC and OHAL alarms (overcurrent and overload alarms) The OVC and OHAL alarms are intended to prevent overheat that may lead to the burnout of the motor winding, the breakdown of the servo amplifier transistor, and the separate regenerative resistor. The OHAL alarm occurs when each built-in thermal relay detects a temperature higher than the rated value. However, this method is not necessarily perfect to prevent these failures. For example, if the motor frequently repeats to start and stop, the thermal time constant of the motor, which has a large mass, becomes higher than the time constant of the thermal relay, because these two components are different in material, structure, and dimension. Therefore, if the motor continues to start and stop within a short time as shown in Fig. 3.5 (o), 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. 2) Temperature Start Stop Start Start Thermal time constant of the motor is high. Temperature at 3.TROUBLESHOOTING Stop MAINTENANCE B-82595EN-2/04 To sum up, a double protection method is used; the OVC alarm is used for protection from a short-time for protection from long-term overload. The relationship between the OVC and OHAL alarms is shown in Fig.3.5 (p). overcurrent, and the OHAL alarm is used http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 84/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Current Protection area for the motor and servo amplifier Protection by the OHAL Limit current Protection by the OVC Rated continuous current Time Fig.3.5 (p) Relationshi p betw een the OVC and OHAL alarms NOTE The relationship shown in Fig.3.5 (p) 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. B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING (28) SRVO-047 LVAL alarm (Group: i Axis: j) (Explanation) The control power supply voltage (+5 V, etc.) supplied from the power supply circuit http://slidepdf.com/reader/full/manutencao-robo-fanucpdf in the servo amplifier is abnormally low. 85/483 7/17/2019 (Action 1) (Action 2) Replace the servo amplifier. Replace the power supply unit. MANUTENÇÃO ROBO FANUC.pdf Servo amplifier Servo amplifier Power supply unit Power supply unit (A-cabinet) (B-cabinet) Fig.3.5 (q) SRVO-047 LVAL al arm (29) SRVO-049 OHAL1 alarm (Group: i Axis: j) (Explanation) The thermostat in the transformer worked. Alternatively, fuse F1 or F2 in the servo amplifier has blown. (Action 1) Check whether the fan is stopped and also check whether the vent hole is clogged. If necessary, clean or replace them. (Action 2) If SRVO-049 is issued when the robot operating condition is severe, check the robot operating condition then relax the condition when possible. (Action 3) Check that a connection is made between the transformer connector CPOH and the E-stop CRM73. (Action 4) Replace the servo. (Action 5) Replace the transformer. 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 E-stop unit http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 86/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Servo amplifier A-cab in et (Fron t) egenera ve res s or Regenerative resistor Transformer Transformer Side fan type Rear fan type A-cab in et (Rear) Servo amplifier regenerative resistor unit B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING (30) SRVO-050 CLALM alarm (Group: i Axis: j) (Explanation) The disturbance torque estimated by the servo software is abnormally high. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf collision has been detected.) (A 87/483 (Action 1) 7/17/2019 (Action 2) (Action 3) (Action 4) (Action 5) (Action 6) (Action 7) (Action 8) (Action 9) (Action 10) Check whether the robot has collided and also check whether there is a factor that has increased the mechanical load on the corresponding axis. MANUTENÇÃO ROBO FANUC.pdf Check whether the load settings are valid. Check whether the brake of the corresponding axis is released. If the load weight exceeds the rated range, decrease it to within the limit. Check whether the voltage input to the controller is within the rated voltage and also check whether the voltage set for the transformer of the controller is correct. Replace the servo amplifier. Replace the motor of the corresponding axis. Replace the E-stop unit. Replace the motor power line (robot connection cable) of the corresponding axis. Replace the motor power line and brake line (inside the mechanical section) of the corresponding axis. (31)SRVO-051 CUER alarm (Group: i Axis: j) (Explanation) The offset of the current feedback value is abnormally high. (Action) Replace the servo amplifier. Servo amplifier Servo amplifier 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (33) SRVO-056 FSSB com error 2 (Group: i Axis: j) (Explanation) A communication error has occurred between the main board and servo amplifier. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 1) Check the communication cable (optical fiber) between the main board and servo 88/483 7/17/2019 (Action 2) (Action 3) amplifier. Replace it if it is faulty. Replace the axis control card on the main board. Replace the servo amplifier. MANUTENÇÃO ROBO FANUC.pdf (34) SRVO-057 FSSB disconnect (Group: i Axis: j) (Explanation) Communication was interrupted between the main board and servo amplifier. (Action 1) Check whether fuse F4 in the power supply unit has blown. If the fuse has blown, replace the servo amplifier including the fuse. (Action 2) (Action 3) (Action 4) (Action 5) Replace the optical cable between the axis control card and servo amplifier. Replace the axis control card on the main board. Replace the servo amplifier. Check for a point where the robot connection cable RP1 or an internal cable running to each Pulsecoder through the robot mechanical section is grounded. Before continuing to the next step, perform a complete controller back-up to save all your programs and settings. (Action 6) Replace the main board. (35) SRVO-058 FSSB init error (Group: i Axis: j) (Explanation) Communication was interrupted between the main board and servo amplifier. (Action 1) Check whether fuse F4 in the power supply unit has blown. If the fuse has blown, check and correct the cause then replace the fuse. (Action 2) Check whether fuse FS1 on the servo amplifier has blown. If the fuse has blown, replace the servo amplifier including the fuse. (Action 3) (Action 4) (Action 5) Turn off the power disconnect the CRF8 connector on the servo amplifier. Then check whether this and alarm occurs again. (Ignore the alarm SRVO-068 because of disconnecting the CRF8 connector.) If this alarm does not occur, the RP1 cable of the robot connection cable or the internal cable of the robot may be short-circuited to the ground. Check the cables and replace it if necessary. Check whether the LED (P5V and P3.3V) on the servo amplifier is lit. If they are not lit, the DC power is not supplied to the servo amplifier. Make sure the connector CRP24 and CRM96 on the E-stop unit and the connector CRM96 on the servo amplifier are connected tightly. If they are connected tightly, replace the servo amplifier. Check the communication cable (optical fiber) between the axis control board and servo amplifier. Replace it if it is faulty. B-82595EN-2/04 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE 3.TROUBLESHOOTING 89/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Servo amplifier Main board (A-cabinet) Servo amplifier Axis control card Main board (B-cabinet) (Main board) Fig.3.5 (t) SRVO-055 FSSB com er ror 1 3.TROUBLESHOOTING MAINTENANCE (36) SRVO-059 Servo amp init error (Explanation) Servo amplifier initialization is failed. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 1) Check the wiring of the servo amplifier. B-82595EN-2/04 90/483 (Action 2) 7/17/2019 Replace the servo amplifier. MANUTENÇÃO ROBO FANUC.pdf (37) SRVO-062 BZAL alarm (Group: i Axis: j) (Explanation) This alarm occurs if battery for Pulsecoder absolute-position backup is empty. A probable cause is a broken battery cable or no batteries in the robot. (Action 1) Replace the battery in the battery box of the robot base. (Action 2) Replace the Pulsecoder with which an alarm has been issued. (Action 3) Check whether the robot internal cable for feeding power from the battery to the Pulsecoder is not disconnected and grounded. the cable. If an abnormality is found, replace CAUTION After correcting the cause of this alarm, set the system variable ($MCR.$SPC_RESET) to TRUE then turn on the power again. Mastering is needed. (38) SRVO-064 PHAL alarm (Group: i Axis: j) (Explanation) This alarm occurs if the phase of the pulses generated in the Pulsecoder is abnormal. (Action) Replace the Pulsecoder. NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm. (39) SRVO-065 BLAL alarm (Group: i Axis: j) (Explanation) The battery voltage for the Pulsecoder is lower than the rating. (Action) Replace the battery. (If this alarm occurs, turn on the power and replace the battery as soon as possible. A delay in battery replacement may result in the BZAL alarm being detected. In this case, the position data will be lost. Once the position data is lost, mastering will become necessary. (40) SRVO-067 OHAL2 alarm (Group: i Axis: j) (Explanation) The temperature inside the Pulsecoder or motor is abnormally high, and the built-in thermostat has operated. (Action 1) Check the robot operating conditions. If a condition such as the duty cycle and load B-82595EN-2/04 MAINTENANCE (42) SRVO-069 CRCERR alarm (Group: i Axis: j) (Explanation) The serial data has disturbed during communication. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action) See actions on SRVO-068 3.TROUBLESHOOTING 91/483 7/17/2019 (43) SRVO-070 STBERR alarm (Group: i Axis: j) MANUTENÇÃO ROBO FANUC.pdf (Explanation) The start and stop bits of the serial data are abnormal. (Action) See actions on SRVO-068 Servo amplifier Servo amplifier (A-cabinet) (B-cabinet) Fig.3.5 (u) SRVO-059 Servo amp init error SRVO-070 STBERR alarm (44) SRVO-071 SPHAL alarm (Group: i Axis: j) (Explanation) The feedback speed is abnormally high. (Action) Action as same as the SRVO-068. NOTE If this alarm occurs together with the PHAL alarm (SRVO-064), this alarm does not correspond to the major cause of the failure. (45) SRVO-072 PMAL Axis: j) is abnormal. (Explanation) It is alarm likely (Group: that the iPulsecoder (Action) Replace the Pulsecoder and remaster the robot. (46) SRVO-073 CMAL alarm (Group: i Axis: j) 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (48) SRVO-075 Pulse not established (Group: i Axis: j) (Explanation) The absolute position of the Pulsecoder cannot be established. (Action) Reset the alarm, and jog the axis on which the alarm has occurred until the same http://slidepdf.com/reader/full/manutencao-robo-fanucpdf alarm will not occur again. 92/483 7/17/2019 (49) SRVO-076 Tip Stick Detection (Group: i Axis: j) MANUTENÇÃO ROBO FANUC.pdf (Explanation) An excessive disturbance was assumed in servo software at the start of operation. (An abnormal load was detected. The cause may be welding.) (Action 1) Check whether the robot has collided. Or check whether the machinery load of the corresponding axis is increased. (Action 2) Check whether the load settings are valid. (Action 3) (Action 4) (Action 5) (Action 6) (Action 7) (Action 8) (Action 9) (Action 10) Check whether the brake of the corresponding axis is released. Check whether the load weight is within the rated range. If the weight exceeds the upper limit, decrease it to the limit. Check whether the voltage input to the controller is within the rated voltage and also check whether the voltage set for the transformer of the controller is correct. Replace the servo amplifier. Replace the corresponding servo motor. Replace the E-stop unit. Replace the power cable of the robot connection cable in which the corresponding axis is connected. Replace the power cable of the robot interconnection cable in which the corresponding axis is connected. Servo amplifier E-stop unit B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING (50) SRVO-081 EROFL alarm (Track enc: i) (Explanation) The pulse counter for line tracking has overflowed. (Action 1) Check whether the condition of the line tracking exceeds the limitation. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 2) Replace the Pulsecoder. 93/483 (Action 3) Replace the line tracking interface board. 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (51) SRVO-082 DAL alarm (Track ebc: i) (Explanation) The line tracking Pulsecoder has not been connected. (Action 1) Check the connection cable at each end (the line tracking interface board and the motor side) (Action 2) Check whether the shielding of the connection cable is connected securely to the (Action 3) (Action 4) (Action 5) grounding plate. Replace the line tracking cable. Replace the Pulsecoder. Replace the line tracking interface board. (52) SRVO-084 BZAL alarm (Track enc: i) (Explanation) This alarm occurs if the backup battery for the absolute position of the Pulsecoder has not been connected. See the description about the BZAL alarm (SRVO-062). (53) SRVO-087 BLAL alarm (Track enc: i) (Explanation) This alarm occurs if the voltage of the backup battery for the absolute position of the Pulsecoder is low. See the description about the BLAL alarm (SRVO-065). (54) SRVO-089 OHAL2 alarm (Track enc: i) (Explanation) The motor has overheated. When power is supplied to the Pulsecoder after it has become sufficiently cool, if the alarm still occurs. See the description about the OHAL2 alarm (SRVO-067). (55) SRVO-090 DTERR alarm (Track ebc: i) (Explanation) Communication between the Pulsecoder and line tracking interface board is abnormal. See the SRVO-068 DTERR alarm. (Action 1) Check the connection cable at each end (the line tracking interface board and the Pulsecoder) (Action 2) Check whether the shielding of the connection cable is connected securely to the grounding plate. (Action 3) Replace the Pulsecoder. (Action 4) Replace the line tracking cable. (Action 5) Replace the line tracking interface board. 3.TROUBLESHOOTING MAINTENANCE (59) SRVO-094 PMAL alarm (Track enc: i) (Explanation) It is likely that the Pulsecoder is abnormal. alarm (SRVO-072). http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 See the description about the PMAL 94/483 7/17/2019 (60) SRVO-095 CMAL alarm (Track enc: i) (Explanation) It is likely that the Pulsecoder is abnormal or the Pulsecoder hasROBO malfunctioned MANUTENÇÃO FANUC.pdf due to noise. See the description about the CMAL alarm (SRVO-073). (Action 1) Reinforce the earth of the flange of the Pulsecoder. (Action 2) Replace the Pulsecoder. (61) SRVO-096 LDAL alarm (Track enc: i) (Explanation) The LED in the Pulsecoder is broken. (SRVO-074). See the description about the LDAL alarm (62) SRVO-097 Pulse not established (enc: i) (Explanation) The absolute position of the Pulsecoder cannot be established. See the description about (SRVO-075). Pulse not established. (Action 1) Reset the alarm, and jog the axis on which the alarm has occurred until the same alarm does not occur again. (Jog one motor revolution) B-82595EN-2/04 MAINTENANCE (63) SRVO-105 Door open or E-stop (Explanation) The cabinet door is open. When the door switch is mounted. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 1) When the door is open, close it. 3.TROUBLESHOOTING 95/483 (Action 2) (Action 4) (Action 5) Check the door switch and door switch connection cable. If the switch or cable is faulty, replace it. MANUTENÇÃO ROBO FANUC.pdf When the door switch is not mounted. Check that the CRM72, CRM95, and CRM96 connectors on the E-STOP unit are connected securely. Replace the E-stop unit. Replace the servo amplifier. (Action 6) (Action 7) Replace the panel board. Replace the connection cable between the panel board and the E-stop unit. 7/17/2019 (Action 3) E-stop unit Servo amplifier Main board Door switch (A-cabinet) Fig.3.5 (w) SRVO-105 Door open or E-stop 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (64) SRVO-136 DCLVAL alarm (Group: i Axis: j) (Explanation) The servo the DC current of amplifier (DC link voltage) of the main power supply is abnormally low. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf - This alarm occurred during robot operation. 96/483 (Action 1) 7/17/2019 Check the input voltage to the controller is within the rated voltage and no phase is lack. And check the setting of the transformer is correct. MANUTENÇÃO ROBO FANUC.pdf It is possible that an instant disconnection of power source causes this alarm. Check whether an instant disconnection occurred. Modify the program in order that robot and the auxiliary axis do not accelerate simultaneously in the system with the auxiliary axis. Replace the E-stop unit. (Action 2) (Action 3) (Action 4) (Action 5) (Action 3) Replace the servo amplifier. If this alarm occurred before the magnetic contactor is turned on: Check whether the circuit breaker in the E-stop unit is OFF. If it is OFF, check the servo amplifier and the wiring between the servo amplifier and the E-stop unit. If anything is abnormal, replace it. Else, turn on the breaker. Check the input voltage to the controller is within the rated voltage and no phase is lack. And check the setting of the transformer is correct. Replace the E-stop unit. (Action 4) Replace the servo amplifier. (Action 1) (Action 2) - (65) SRVO-156 IPMAL alarm (Group: i Axis: j) (Explanation) Abnormally high current flowed through the main circuit of the servo amplifier. (Action 1) Turn off the power, and disconnect the power cable from the servo amplifier indicated by the alarm message. (And disconnect the brake cable (CRR88 on the servo amplifier) to avoid the axis falling unexpectedly.) Turn on the power, and if the alarm occurs again, replace the servo amplifier. (Action 2) Turn off the power and disconnect the power cable from the servo amplifier indicated by the alarm message, and check the insulation of their U, V, W and the GND lines each other. If there is a short-circuit, replace the power cable. (Action 3) Turn off the power and disconnect the power cable from the servo amplifier by the alarm message, and measure the resistance between their U and V, V and W and W and U with an ohmmeter that has a very low resistance range. If the resistances at the three places are different from each other, the motor, the power cable is defective. Check each item in detail and replace it if necessary. MAINTENANCE B-82595EN-2/04 3.TROUBLESHOOTING (66) SRVO-157 CHGAL alarm (Group: i Axis: j) (Explanation) The capacitor for the condenser voltage of the servo amplifier was not charged within the specified time when the servo power is on. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 1) Replace the E-stop unit. 97/483 7/17/2019 (Action 2) (Action 3) Replace the servo amplifier. Replace the auxiliary amplifier for system of the auxiliary axis. MANUTENÇÃO ROBO FANUC.pdf Servo amplifier E-stop unit Servo amplifier E-stop unit (A-cabinet) (B-cabinet) Fig.3.5 (x) SRVO-136 DCLVAL alar m SRVO-156 IPMAL alar m SRVO-157 CHGAL alarm 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (67) SRVO-194 Servo disconnect (Explanation) The external contact connected to SD4-SD41 or SD5-SD51 of the terminal block TBOP3 on the panel board is open. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 1) If external circuitry is connected to SD4-SD41 or SD5-SD51 of the terminal block TBOP3 on the panel board, check the external circuitry. 98/483 7/17/2019 (Action 2) (Action 3) TBOP3 on the panel board, check the external circuitry. If this signal is not used, make a connection between SD4 and SD41 and between MANUTENÇÃO SD5 and SD51 of the terminal block TBOP3 on the panel board. ROBO FANUC.pdf Replace the panel board. Panel board Panel board (A-cabinet) (B-cabinet) Fig.3.5 (y) SRVO-194 Servo disconnect WARNING In a system using the servo disconnect signal, it is very dangerous to disable the signal when a connection is made between SD4 and SD41 and between SD5 and SD51 of the terminal block TBOP3 on the panel board. Never make such an attempt. If a temporary connection is needed for operation, separate safety measures must be taken. MAINTENANCE B-82595EN-2/04 3.TROUBLESHOOTING (68) SRVO-201 Panel E-stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator’s panel was pressed, but the EMERGENCY STOP line was not disconnected. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 1) (Action 2) Replace the panel board. Replace the E-stop unit. 99/483 (Action 3) Replace the servo amplifier. 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (69) SRVO-202 TP E-stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the teach pendant was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Replace the teach pendant. (Action 2) (Action 3) (Action 4) (Action 5) Check the teach pendant cable. Replace the operator's panel. Replace the E-stop unit. Replace the servo amplifier. If this inferior, replace the cable. NOTE This alarm might occur if the EMERGENCY STOP button is pressed slowly. (70) SRVO-204 External (SVEMG abnormal) E-stop (Explanation) The switch connected across EES1 – EES11 and EES2 – EES21 on the TBOP4 terminal board on the panel board was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Check the switch and cable connected to EES1 – EES11 and EES2 – EES21 on TBOP4 terminal board. If the cable is abnormal, replace it. (Action 2) Replace the panel board. (Action 3) Replace the E-stop unit. (Action 4) Replace the servo amplifier. Panel board 3.TROUBLESHOOTING E-stop unit MAINTENANCE http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Panel board B-82595EN-2/04 Servo amplifier 100/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Teach pendant E-stop unit (B-cabinet) EES1 EES11 EES2 EES21 MAINTENANCE B-82595EN-2/04 3.TROUBLESHOOTING (71) SRVO-205 Fence open (SVEMG abnormal) (Explanation) The switch connected across EES1 – EES11 and EES2 – EES21 on the TBOP4 terminal board on the panel board was pressed, but the EMERGENCY STOP line http://slidepdf.com/reader/full/manutencao-robo-fanucpdf was not disconnected. (Action 1) Check the switch and cable connected to EES1 – EES11 and EES2 – EES21. 101/483 If the 7/17/2019 (Action 2) (Action 3) (Action 4) cable is abnormal, replace it. Replace the panel board. Replace the E-stop unit. Replace the servo amplifier. MANUTENÇÃO ROBO FANUC.pdf Panel board Servo amplifier (A-cabinet) Servo amplifier Panel board (B-cabinet) EAS1 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (72) SRVO-206 DEADMAN switch (SVEMG abnormal) (Explanation) When the teach pendant was enabled, the DEADMAN switch was released or pressed strongly, but the emergency stop line was not disconnected. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 1) Replace the teach pendant. (Action 2) Check the teach pendant cable. 102/483 If it is inferior, replace the cable. 7/17/2019 (Action 3) (Action 4) (Action 5) (Action 6) Replace the panel board. When the NTED signal is used, check whether the cabling of the ROBO signalFANUC.pdf connected to MANUTENÇÃO CRM65 on the panel board is correct. Replace the E-stop unit. Replace the servo amplifier. E-stop unit Panel board Servo amplifier (A-cabinet) Servo amplifier Panel board Teach pendant B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING (73) SRVO-213 Fuse blown (Panel PCB) (Explanation) A fuse (FUSE1 or FUSE2) on the panel board has blown, or no voltage is supplied to EXT24V. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 1) Check whether the fuse (FUSE1) on the panel board has blown. If the fuse has blown, +24EXT may be short-circuited to 0EXT. Take Action 2. If FUSE1 has not 103/483 7/17/2019 (Action 2) (Action 3) (Action 4) (Action 5) (Action 6) blown, take Action 3 and up. Disconnect the connection destinations of +24EXTMANUTENÇÃO that can cause grounding then ROBO FANUC.pdf check that FUSE1 does not blow. Disconnect the following on the panel board then turn on the power: - CRS20 - CRT16 -- TBOP4: EES1, EES11, EAS1, EAS11, EGS1, EGS11 TBOP3: SD4, SD41 If FUSE1 does not blow in this state, +24EXT and 0EXT may be short-circuited at any of the connection destinations above. Isolate the faulty location then take action. If FUSE1 blows even when the connection destinations above are detached, replace the panel board. Check whether 24 V is applied to between EXT24V and EXT0V of TBOP6. If not, check the external power supply circuit. If no external power supply is used, check whether the terminals above are connected to the INT24V and INT0V terminals, respectively. Replace the panel board. Replace the teach pendant cable. Replace the teach pendant. JRS15 LED (green) 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 Panel board http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 104/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (A-cabinet) Panel board M i b d MAINTENANCE B-82595EN-2/04 3.TROUBLESHOOTING (74) SRVO-214 Fuse blown (Servo amplifier) (Explanation) A fuse in the servo amplifier has blown. In case that FS1 is blown http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 1) Replace the servo amplifier. 105/483 7/17/2019 In case that FS2 or FS3 is blown MANUTENÇÃO ROBO FANUC.pdf (Action 1) A fuse is blown, eliminate the cause, and then replace the fuse. (See Section 3.6 in the Part II, “MAINTENANCE”.) (Action 2) Replace the servo amplifier. (75) SRVO-216 OVC (total) (Robot: (Explanation) The current (totali)current for six axes) flowing through the motor is too large. (Action 1) Slow the motion of the robot where possible. Check the robot operation conditions. If the robot is used with a condition exceeding the duty or load weight robot rating, reduce the load condition value to the specification range. (Action 2) Check the input voltage to the controller is within the rated voltage and no phase is lack. And check the setting of the transformer is correct. (Action 3) Replace the servo amplifier. (76) SRVO-221 Lack of DSP (Group: i Axis: j) (Explanation) A controlled axis card corresponding to the set number of axes is not mounted. (Action 1) Check whether the set number of axes is valid. If the number is invalid, set the correct number. (Action 2) Replace the axis control card with a card corresponding to the set number of axes. (77) SRVO-223 DSP dry run (a b) (Explanation) Servo system initialization was stopped because of a hardware failure or improver software setting. The controller has been started in the DSP dry run mode. (Action 1) When the value is 1, 5, or 6: An incorrect setting is made. Check whether the dry run mode is set and also check whether the setting of the hard start axis is correct. (Action 2) When the value is 2, 3, 4, or 7: Replace the servo card. (Action 3) When the value is 8 or 10: Take action for an FSSB initialization error that has occurred at the same time. (Action 4) When the value is 9: Take the following action: Check whether the servo amplifier is connected. Replace the optical cable used for servo amplifier connection. Replace the servo amplifier 3.TROUBLESHOOTING http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE B-82595EN-2/04 106/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Servo amplifier Main board (A-cabinet) A is control card B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING (78) SRVO-230 Chain 1 (+24V) abnormal SRVO-231 Chain 2 (0V) abnormal (Explanation) A mismatch occurred between duplicate safety signals. SRVO-230 is issued if such http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (between EES1 and EES11, a mismatch that a contact connected on the chain 1 side between EAS1 and EAS11, between EGS1 and EGS11, between SD4 and SD41, and so forth) is closed, and a contact on the chain 2 side 107/483 (between EES2 and EES21, between EAS2 and EAS21, between EGS2 and EGS21, MANUTENÇÃO ROBO FANUC.pdf between SD5 and SD51, and so forth) is open occurs. SRVO-231 is issued if such a mismatch that a contact on the chain 1 side is open, and a contact on the chain 2 sides is closed occurs. If a chain error is detected, correct the cause of the alarm then reset the alarm 7/17/2019 (Action) (Caution 1) (Caution 2) according the method later. Check the to alarms issued described at the same time in order to identify with which signal the mismatch occurred. SRVO-266 through SRVO-275 and SRVO-370 through SRVO-385 are issued at the same time. Take the action(s) described for each item. After correcting the cause of the hardware chain error according to the work described above, set "YES" for chain error resetting on the system setting screen. Finally, press the reset key on the teach pendant. For details, see "Chain error reset procedure" described later. If this alarm is issued, do not reset the chain error alarm until the failure is identified and repaired. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. Panel board E-stop unit Servo amplifier (A-cabinet) 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 Servo amplifier Panel board http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 108/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf E-stop unit (B-cabinet) Fig.3.5 (ae) SRVO-230 Chain 1 (+24V) abno rmal / SRVO-231 Chain 2 (0V) abno rmal CAUTION 1 The state of this alarm is preserved by software. After correcting the cause of the alarm, reset the chain error alarm according to the chain error reset procedure described later. 2 Until a chain error is reset, no ordinary reset operation must be performed. If an ordinary reset operation is performed before chain error resetting, the message "SRVO-237 Chain error cannot be reset" is displayed on the teach pendant. B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING Al arm his tor y d ispl ay m etho d 1. 2. Press the screen selection key on the teach pendant. Select [4 ALARM] on the teach pendant. 3. Press F3 [HIST] on the teach pendant. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 109/483 Chain error reset procedure 7/17/2019 CAUTION MANUTENÇÃO ROBO FANUC.pdf Do not perform this operation until the cause of the alarm is corrected. <Method 1> 1. Press the emergency stop button. 2. Press the screen selection key on the teach pendant. 3. Select [0 NEXT PAGE] on the teach pendant. 4. Press [6 SYSTEM] on the teach pendant. 5. Press [7 SYSTEM SETTING] on the teach pendant. 6. Find "28" Chain Error Reset Execution. 7. Press F3 on the teach pendant to reset "Chain Error". <Method 2> 1. Press the screen selection key on the teach pendant. 2. Select [4 ALARM] on the teach pendant. 3. Press F4 [CHAIN RESET] on the teach pendant. 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (79) SRVO-232 NTED input (Explanation) In the teach mode, the NTED signal connected to CRM65 on the panel board was placed in the open state. (Action 1) Check the operation of the device connected to NTED. (Action 3) Replace the teach pendant cable. (Action 2) Replace the teach pendant. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 110/483 7/17/2019 (Action 4) (Action 5) Replace the panel board Check the mode switch and its cable. Replace them if a defect is found. MANUTENÇÃO ROBO FANUC.pdf (80) SRVO-233 TP disabled in T1, T2/Door open (Explanation) Teach pendant is disabled when the mode switch is T1 or T2. Or controller door is opened. (Action 1) Enable the teach pendant in teaching operation. In other case the mode switch should be AUTO mode. (Action 2) Close the controller door, if open. (Action 3) Replace the teach pendant. (Action 4) Replace the teach pendant cable. (Action 5) Replace the mode switch. (Action 6) Replace the panel board. (Action 7) Replace the E-stop unit. (Action 8) Replace the servo amplifier. (81) SRVO-235 Short term Chain abnormal (Explanation) Short term single chain failure condition is detected. Cause of this alarm is; - Half release of DEADMAN switch - Half operation of emergency stop switch. (Action 1) Cause the same error to occur again, and then perform resetting. (Action 2) (Action 3) (Action 3) Replace the panel board. Replace the E-stop unit. Replace the servo amplifier. (82) SRVO-251 DB relay abnormal (Explanation) An abnormality was detected in the internal relay (DB relay) of the servo amplifier. (Action) Replace the servo amplifier. (83) SRVO-252 Current detect abnl (Explanation) An abnormality was detected in the current detection circuit inside the servo amplifier. (Action) Replace the servo amplifier. B-82595EN-2/04 Panel board http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 3.TROUBLESHOOTING MAINTENANCE E-stop unit 111/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Servo amplifier (A-cabinet) Servo amplifier Panel board E-stop unit (B-cabinet) 3.TROUBLESHOOTING Enable/disable switch Deadman switch (Teach pendant) MAINTENANCE B-82595EN-2/04 (85) SRVO-266 FENCE1 status abnormal a, b SRVO-267 FENCE2 status abnormal a, b (Explanation) A chain alarm was detected with the EAS (FENCE) signal. (Action (Action 1) 2) Check to the dual signal input signal is faulty. Check whether whetherthe thecircuitry timing connected of the dual input (EAS)(EAS) satisfies the timing specification http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 112/483 7/17/2019 (Action 3) (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS). Replace the panel board. MANUTENÇÃO ROBO FANUC.pdf CAUTION 1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 and SRVO-231. 2 If this alarm is issued, do not reset the chain error alarm until the failure is checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. EAS1 EAS11 EAS2 EAS21 Fig.3.5 (ag) SRVO-266 FENCE1 statu s abn orm al a, b / SRVO-267 FENCE2 stat us ab no rmal a, b MAINTENANCE B-82595EN-2/04 3.TROUBLESHOOTING (86) SRVO-268 SVOFF1 status abnormal a, b SRVO-269 SVOFF2 status abnormal a, b (Explanation) A chain alarm was detected with the EGS (SVOFF) signal. (Action (Action 1) 2) Check to the dual signal input signal is faulty. Check whether whetherthe thecircuitry timing connected of the dual input (EGS)(EGS) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS). http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 113/483 (Action 3) 7/17/2019 Replace the panel board. MANUTENÇÃO ROBO FANUC.pdf CAUTION 1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 and SRVO-231. 2 If this alarm is issued, do not reset the chain error alarm until the failure is checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. EGS1 EGS11 EGS2 EGS21 Fig.3.5 (ah) SRVO-268 SVOFF1 statu s abn orm al a, b / SRVO-269 SVOFF2 stat us ab nor mal a, b 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (87) SRVO-270 EXEMG1 status abnormal a, b SRVO-271 EXEMG2 status abnormal a, b (Explanation) A chain alarm was detected with the EES (EXEMG) signal. (Action (Action 1) 2) Check to the dual signal input signal is faulty. Check whether whetherthe thecircuitry timing connected of the dual input (EES)(EES) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS). http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 114/483 (Action 3) 7/17/2019 Replace the panel board. MANUTENÇÃO ROBO FANUC.pdf CAUTION 1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 and SRVO-231. 2 If this alarm is issued, do not reset the chain error alarm until the failure is checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. EES1 EES11 EES2 EES21 Fig.3.5 (ai) SRVO-270 EXEMG1 statu s abn orm al a, b / SRVO-271 EXEMG2 statu s abn orm al a, b B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING (88) SRVO-272 SVDISC1 status abnormal a, b SRVO-273 SVDISC2 status abnormal a, b (Explanation) A chain alarm was detected with the SD4 or SD5 (SVDISC) signal. (Action (Action 1) 2) Check circuitry to theinput dual input is faulty. Check whether whetherthethe timingconnected of the dual signalsignal (SD)(SD) satisfies the timing 3.2.5, Table 3.2.5 of Part III CONNECTIONS). Replace the panel board. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf specification (See Section (Action 3) 115/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CAUTION 1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 and SRVO-231. 2 If this alarm is issued, do not reset the chain error alarm until the failure is checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. SD4 SD41 SD5 SD51 Fig.3.5 (aj) SRVO-272 SVDISC1 status abno rmal a, b / SRVO-273 SVDISC2 statu s abn orm al a, b 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (89) SRVO-274 NTED1 status abnormal a, b SRVO-275 NTED2 status abnormal a, b (Explanation) A chain alarm was detected with the NTED signal. (Action 1) This alarm be issued when theInDEADMAN switch the is pressed to a switch proper position or ismay operated very slowly. such a case, release DEADMAN http://slidepdf.com/reader/full/manutencao-robo-fanucpdf once completely then press the DEADMAN switch again. (Action 2) Check whether the circuitry connected to the dual input signal (NTED) is faulty. 116/483 (Action 3) 7/17/2019 (Action 4) (Action 5) (Action 6) (Action 7) Check whether the timing of the dual input signal (NTED) satisfies the timing MANUTENÇÃO ROBO FANUC.pdf specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS). Replace the panel board. Replace the teach pendant cable. Replace the teach pendant. Replace the mode switch on the operator's panel. CAUTION 1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 and SRVO-231. 2 If this alarm is issued, do not reset the chain error alarm until the failure is checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. Panel board Panel board B-82595EN-2/04 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE 3.TROUBLESHOOTING 117/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Enable/disable switch Deadman switch CRM65 Fig.3.5 (ak) SRVO-274 NTED1 statu s abn orm al a, b / SRVO-275 NTED2 status abno rmal a, b 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (90) SRVO-277 Panel E-stop (SVEMG abnormal) (Explanation) The emergency stop line was not disconnected although the emergency stop button on the operator's panel was pressed. (Action Replace (Action 1) 2) Replace the the panel E-stopboard. unit (Action 3) Replace the servo amplifier. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 118/483 E-stop unit 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Panel board Servo amplifier (A-cabinet) Servo amplifier Panel board B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING (91) SRVO-278 TP E-stop (SVEMG abnormal) (Explanation) The emergency stop line was not disconnected although the emergency stop button on the teach pendant was pressed. (Action 2) 1) Replace the the teach teach pendant pendant.cable. (Action Replace (Action 3) Replace the panel board. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 4) Replace the E-stop unit 119/483 (Action 5) Replace the servo amplifier. 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf NOTE This alarm may be issued if the emergency stop button is pressed very slowly. (92) SRVO-280 SVOFF input (Explanation) The external contact connected to EGS1-EGS11 or EGS2-EGS21 of the terminal block TBOP4 on the panel board is open. (Action 1) If external circuitry is connected to EGS1-EGS11 or EGS2-EGS21 of the terminal block TBOP4 on the panel board, check the external circuitry. (Action 2) If this signal is not used, make a connection between EGS1 and EGS11 and between EGS2 and EGS21 of the terminal block TBOP4 on the panel board. (Action 3) Replace the panel board. WARNING In a system using the SVOFF signal, it is very dangerous to disable the signal when a connection is made between EGS1 and EGS11 and between EGS2 and EGS21 of TBOP4. Never make such an attempt. If a temporary connection is needed for operation, separate safety measures must be taken. 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (93) SRVO-281 SVOFF input (SVEMG abnormal) (Explanation) The emergency stop line was not disconnected although the contact connected between EGS1 and EGS11 or between EGS2 and EGS21 of the terminal block TBOP4 on the panel board was open. The emergency stop circuit is faulty. (Action 1) Check the switch and cable connected to EGS1-EGS11and EGS2-EGS21 on TBOP4. If the cable is abnormal, replace it. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 2) Replace the panel board. 120/483 7/17/2019 (Action 3) (Action 4) (Action 5) Replace the E-stop unit. Replace the servo amplifier. MANUTENÇÃO ROBO FANUC.pdf Replace the connection cable between the panel board and the E-stop unit. E-stop unit Panel board Servo amplifier (A-cabinet) Servo amplifier Panel board B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING EGS1 EGS11 EGS2 EGS21 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 121/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig.3.5 (am) SRVO-278 TP E-stop (SVEMG abno rmal ) SRVO-280 SVOFF inp ut SRVO-281 SVOFF inpu t (SVEMG abno rmal ) 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (94) SRVO-291 IPM over heat (G:i A:j) (Explanation) IPM on the servo amplifier is overheated. (Action 1) Check whether the fan for cabinet ventilation is stopped and also check whether the vent hole is clogged. If necessary, clean or replace them. (Action 2) If SRVO-291 is issued when the robot operating condition is severe, check the robot operating condition then relax the condition when possible. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 3) If SRVO-291 is issued frequently, replace the servo amplifier. 122/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Servo amplifier A-cab in et (Fron t) Side fan unit Rear fan unit Side fan type Rear fan type A-cab in et (Rear) MAINTENANCE B-82595EN-2/04 3.TROUBLESHOOTING Servo amplifier http://slidepdf.com/reader/full/manutencao-robo-fanucpdf External fan unit 123/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf B-cabinet (Front) B-cabinet (Rear) Fig.3.5 (an) SRVO-291 IPM over heat (G: i A: j ) (95) SRVO-300 Hand broken/HBK disabled SRVO-302 Set Hand broken to ENABLE (Explanation) Although HBK was disabled, the HBK signal was input. (Action 1) Press RESET on the teach pendant to release the alarm. (Action 2) Check whether the hand broken signal is connected to the robot. When the hand broken signal circuit is connected, enable hand broken. (See Subsection 5.5.3 in Part III, “CONNECTIONS”.) (96) SRVO-335 DCS OFFCHK alarm a, b (Explanation) A failure was detected in the safety signal input circuit. (Action) Replace the panel board. (97) SRVO-348 DCS MCC OFF alarm a, b (Explanation) A command was issued to turn off the magnetic contactor, but the magnetic contactor was not turned off. (Action 1) Replace the E-stop unit. (Action 2) Replace the panel board. (Action 3) If a signal is connected to the E-stop unit CRM72, check whether there is a problem 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (99) SRVO-370 SVON1 status abnormal a, b SRVO-371 SVON2 status abnormal a, b (Explanation) A chain alarm was detected with the panel board internal signal (SVON). (Action) Replace the panel board. CAUTION 1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 124/483 7/17/2019 and SRVO-231. 2 If this alarm is issued, do not reset the chain error alarmMANUTENÇÃO until the failure is ROBO FANUC.pdf checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. E-stop unit Panel board Servo amplifier (A-cabinet) Servo amplifier Panel board B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING (100)SRVO-372 OPEMG1 status abnormal a, b SRVO-373 OPEMG2 status abnormal a, b (Explanation) A chain alarm was detected with the emergency stop switch on the operator's panel. (Action 1) Replace the panel board. (Action 2) Replace the teach pendant cable. (Action 3) Replace the teach pendant. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Action 4) Replace the emergency stop button on the operator's panel. 125/483 7/17/2019 CAUTION MANUTENÇÃO ROBO FANUC.pdf 1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 and SRVO-231. 2 If this alarm issued, do not resetuse theischain error alarm until is checked andiscorrected. If robot continued with one ofthe thefailure duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. (101)SRVO-374 MODE11 status abnormal a, b SRVO-375 MODE12 status abnormal a, b SRVO-376 MODE21 status abnormal a, b SRVO-377 MODE22 status abnormal a, b (Explanation) A chain alarm was detected with the mode switch signal. (Action 1) Check the mode switch and its cable. Replace them if a defect is found. (Action 2) Replace the panel board. CAUTION 1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 and SRVO-231. 2 If this alarm is issued, do not reset the chain error alarm until the failure is checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. Emergency stop button Panel board Mode s witch 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 Mode switch EMERGENCY STOP button http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 126/483 Panel board 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Teach pendant (B-cabinet) Fig.3.5 (ap) SRVO-372 OPEMG1 status abno rmal a, b / SRVO-373 OPEMG2 statu s abn orm al a, b SRVO-374 MODE11 statu s abn orm al a, b / SRVO-375 MODE12 statu s abn orm al a, b SRVO-376 MODE21 statu s abn orm al a, b / SRVO-377 MODE22 statu s abn orm al a, b B-82595EN-2/04 MAINTENANCE (102)SRVO-378 OPSFTY11 status abnormal a, b SRVO-379 OPSFTY12 status abnormal a, b SRVO-380 OPSFTY21 status abnormal a, b SRVO-381 OPSFTY22 status abnormal a, b SRVO-382 OPSFTY31 status abnormal a, b SRVO-383 OPSFTY32 status abnormal a, b SRVO-384 OPSFTY41 status abnormal a, b http://slidepdf.com/reader/full/manutencao-robo-fanucpdf SRVO-385 OPSFTY42 status abnormal a, b 3.TROUBLESHOOTING 127/483 (Explanation) A chain alarm was detected with the OPSFTY signal. (Action 1) Check whether the circuitry connected to the dual input signal (OPSFTY) is faulty. MANUTENÇÃO ROBO FANUC.pdf (Action 2) Check whether the timing of the dual input signal (OPSFTY) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTION). (Action 3) Replace the panel board. 7/17/2019 CAUTION 1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 and SRVO-231. 2 If this alarm is issued, do not reset the chain error alarm until the failure is checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. CRMA8 3.TROUBLESHOOTING 3.6 MAINTENANCE B-82595EN-2/04 FUSE-BASED TROUBLESHOOTING This section describes the alarms and symptoms generated and actions required when the fuses installed on the printed circuit boards and units have blown. (1) When the fuses of the power supply unit have blown F1: Fuse for AC input http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 128/483 7/17/2019 F3: Fuse for +24 E F4: Fuse for +24 V MANUTENÇÃO ROBO FANUC.pdf Name Symptom observed when fuse has blown F1 The LED (PIL: Green) of the power supply unit does not light, and the power cannot be turned on. Action 1 2 1 F3 The teach pendant is turned off. F4 The power, when turned on, is immediately turned off. At this time, the LED (ALM: Red) lights. 2 1 2 B-82595EN-2/04 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE Check the units (fans) , printed-circuit board and cables connected to the CP2 and CP3 connectors of the power supply unit to see if there is any short circuit. Replace the power supply unit. Check the printed circuit boards, units, servo amplifier, and cables using +24 E according to the power supply system diagram. Replace a faulty printed circuit board, unit, servo amplifier or cable if any. Replace the power supply unit. Check the printed circuit boards, units, and cables using +24 V according to the power supply system diagram. Replace a faulty printed circuit board, unit, or cable if any. The LED of ALM is turned off by pressing the OFF button once. Replace the power supply unit. 3.TROUBLESHOOTING 129/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Servo amplifier Power supply unit (A-cabinet) Servo amplifier F1(8.0A): Fuse for AC input F3(7.5A): Fuse for +24E F4（7.5A）: Fuse for +24V PIL: LED (green) ALM: LED (red) Power supply unit (B-cabinet) 3.TROUBLESHOOTING (Power supp ly uni t) MAINTENANCE B-82595EN-2/04 (2) Main board fuse FU1:For protection of the +12V output for the vision sensor (This fuse is mounted on the main board of the total edition “06B” or later.) Name FU1 Symptom observed when fuse has blown +12V is not output. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Act io n 1 2 Check +12V used by the vision sensor for a ground fault. Check the vision sensor and the connection cable. 130/483 3 Replace the main board. 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 75173 (Receiver) Total edition 09B or earlier 75172 (Driver) Total edition 09B or earlier CPU card FROM/SRAM module (Behind the axis control card) Axis control card FU1 Fuse(0.5A) (Total edition “06B” or later) 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (3) Servo amplifier fuse FS1: For generation of the power to the amplifier control circuit FS2: For protection of the 24V output to the end effector, XROT, and XHBK FS3: For protection of the 24V output to the regenerative resistance and the additional axis amplifier Name Symptom observed when fuse has blown http://slidepdf.com/reader/full/manutencao-robo-fanucpdf FS1 All LEDs on the servo amplifier go out. Act io n Replace the servo amplifier. 131/483 7/17/2019 The FSSB disconnection or initialization alarm is displayed on the teach pendant. The Fuse Blown (Amp) alarm (SRVO-214), Hand broken (SRVO-006), FS2 and ROBOT OVER TRAVEL are displayed on the teach pendant. The Fuse Blown (Amp) alarm (SRVO-214) and DCAL are displayed on the teach pendant. FS3 1 2 3 1 2 3 ROBO FANUC.pdf Check +24VF used byMANUTENÇÃO the end effector for a ground fault. Check the robot connection cable and the robot’s internal cable. Replace the servo amplifier. Check the regenerative resistance, and replace it if required. Check the additional axis amplifier and it’s wiring, and replace them if required. Replace the servo amplifier. CRR88 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 (4) Panel board fuses FUSE1: For +24EXT line (emergency stop line) protection FUSE2: For protection of the teach pendant emergency stop line Name FUSE1 Symptom observed when fuse has blown The teach pendant displays external http://slidepdf.com/reader/full/manutencao-robo-fanucpdf emergency stop, fence open, or SVOFF input fuse blown (panel PCB). Act io n 1 If an alarm is issued when the fuse has not blown, check the voltages of EXT24V and EXT0V (TBOP6). If external 24V or 0V is not used, check the jumper pin 132/483 between EXT24V and INT24V or between EXT0V and MANUTENÇÃO ROBO FANUC.pdf INT0V. 2 Check the +24EXT line (emergency stop line) for a 7/17/2019 FUSE2 B-82595EN-2/04 short circuit or connection to ground. 3 Replace the panel board. 1 Check the teach pendant cable for a fault, and replace it if required. 2 Check the teach pendant for a fault, and replace it if required. 3 Replace the panel board. The display on the teach pendant disappears. MAINTENANCE 3.TROUBLESHOOTING (5) Fuse on the process I/O printed circuit board FUSE1: Fuse for +24E Name FUSE1 Symptom observed when fuse has blown The LED (ALM-2 or FALM) on the process I/O printed circuit board lights, and an alarm such as IMSTP input is output on the teach pendant. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (The display data depends on state of peripheral equipment connection.) Action 1 Check if the cables and peripheral equipment connected to the process I/O printed circuit board are normal. 2 Replace the process I/O printed circuit board. 133/483 7/17/2019 Process MANUTENÇÃO ROBO FANUC.pdf I/O board CA Process I/O board EA, EB Fuse location is common to EA and EB. The following is figure of EA. 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 Process I/O board FA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 134/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Process I/O board GA Process I/O board HA B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING Process I/O board JA , JB Fuse location is common to JA and JB. The following is figure of JA. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 135/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Process I/O board K A, KB, KC Fuse location is common to KA, KB and KC. The following is figure of KA. LED FUSE A16B-2204-0050 3.TROUBLESHOOTING 3.7 MAINTENANCE B-82595EN-2/04 TROUBLESHOOTING BASED ON LED INDICATIONS The printed circuit boards and servo amplifier are provided with alarm LEDs and status LEDs. The LED status and corresponding troubleshooting procedures are described below. Process I/O Panel http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Main board board Power supply unit 136/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Servo amplifier (A-cabinet) Servo amplifier Panel board B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING TROUBLESHOOTING USING THE LEDS ON THE MAIN BOARD (Total edition 09B or earlier) (1) Troubleshooting using the status display LED To troubleshoot arises before theAfter teachpower-on, pendant isthe ready to light display, check theinstatus LEDs (green) on an thealarm main that board at power-on. LEDs as described steps 1 to end, in the order described. If an alarm is detected, the step in which the alarm occurred can be determined from which LEDs are lit. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 137/483 ●：Turn on ○：Turn off ☆：Blink 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Step LED Action to be taken 1: After power-on, all LEDs are lit. [Action1] Replace the CPU card. * [Action2] Replace the main board. 2: Software operation start-up. [Action1] Replace the CPU card. * [Action2] Replace the main board. 3: The initialization of dram on the CPU card is completed. [Action1] Replace the CPU card. * [Action2] Replace the main board. 4: The initialization of [Action1] Replace the CPU card. DPRAM on the communication IC is completed. * [Action2] Replace the main board. * [Action3] Replace the FROM/SRAM module. 5: The initialization of the communication IC is completed. [Action1] Replace the CPU card. * [Action2] Replace the main board. * [Action3] Replace the FROM/SRAM module. 6: The loading of the basic software is completed * [Action1] Replace the main board. * [Action2] Replace the FROM/SRAM module. 3.TROUBLESHOOTING Step 9: MAINTENANCE LED The loading of optional software is completed. 10: DI/DO initialization http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 Action to be taken * [Action1] Replace the main board. [Action2] Replace the process I/O board. * [Action1] Replace the FROM/SRAM module. * [Action2] Replace the main board. 138/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 11: The preparation of the SRAM module is completed. [Action1] Replace the axis control card. * [Action2] Replace the main board. [Action3] Replace the servo amplifier. 12: Axis control card initialization [Action1] Replace the axis control card. * [Action2] Replace the main board. [Action3] Replace the servo amplifier. 13: Calibration is completed. [Action1] Replace the axis control card. * [Action2] Replace the main board. [Action3] Replace the servo amplifier. 14: Start-up of power application for the * [Action1] Replace the main board. servo system 15: Program execution * [Action1] Replace the main board. [Action2] Replace the process I/O board. 16: DI/DO output start-up. * [Action1] Replace the main board. B-82595EN-2/04 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MAINTENANCE 3.TROUBLESHOOTING 139/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CPU card FROM/SRAM module Axis control card (Total edition 09B or earlier) 3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/04 TROUBLESHOOTING USING THE LEDS ON THE MAIN BOARD (Total edition 10B or later) (1) Troubleshooting using the status display LED To troubleshoot an alarm that arises before the teach pendant is ready to display, check the status LEDs (green) on the main board at power-on. After power-on, the LEDs light as described in steps 1 to end, in the order described. If an alarm is detected, the step in which the alarm occurred can be determined from which LEDs are lit. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf ●：Turn on ○：Turn off ☆：Blink 140/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Step 1: LED After power-on, all LEDs are lit. Action to be taken D1 D2 [Action1] Replace the CPU card. * [Action2] Replace the main board. D3 D4 2: Software operation start-up. D1 D2 [Action1] Replace the CPU card. * [Action2] Replace the main board. D3 D4 3: The initialization of dram on the CPU card is completed. D1 D2 [Action1] Replace the CPU card. * [Action2] Replace the main board. D3 D4 4: The initialization of DPRAM on the D1 D2 communication IC is completed. D3 [Action1] Replace the CPU card. * [Action2] Replace the main board. * [Action3] Replace the FROM/SRAM module. D4 5: The initialization of the communication IC is completed. D1 D2 D3 [Action1] Replace the CPU card. * [Action2] Replace the main board. * [Action3] Replace the FROM/SRAM module. D4 D1 6: The of the basicloading software is completed. D2 D3 MAINTENANCE B-82595EN-2/04 Step 9: The loading of optional software is completed. * [Action1] Replace board. module. * [Action2] Replace the the main FROM/SRAM LED 3.TROUBLESHOOTING Action to be taken D1 D2 * [Action1] Replace the main board. [Action2] Replace the process I/O board. D3 D4 10: DI/DO initialization D1 D2 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf D3 * [Action1] Replace the FROM/SRAM module. * [Action2] Replace the main board. 141/483 D4 7/17/2019 11: The preparation of the SRAM module is completed. D1 D2 D3 [Action1] Replace theMANUTENÇÃO axis control card. ROBO FANUC.pdf * [Action2] Replace the main board. [Action3] Replace the servo amplifier. D4 12: Axis control card initialization D1 D2 D3 [Action1] Replace the axis control card. * [Action2] Replace the main board. [Action3] Replace the servo amplifier. D4 13: Calibration is completed. D1 D2 D3 [Action1] Replace the axis control card. * [Action2] Replace the main board. [Action3] Replace the servo amplifier. D4 14: Start-up of power application for the servo system D1 * [Action1] Replace the main board. D2 D3 D4 15: Program execution D1 D2 * [Action1] Replace the main board. [Action2] Replace the process I/O board. D3 D4 16: DI/DO output start-up. D1 * [Action1] Replace the main board. D2 D3 D4 17: Initialization is D1 3.TROUBLESHOOTING http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Initialization has ended normally MAINTENANCE B-82595EN-2/04 142/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf D1 D2 Status LEDs D3 D4 (Total Edition 10B or later) (2) TROUBLESHOOTING BY 7-SEGMENT LED INDICATOR 7-segment LED indicator Description [Description] A parity alarm condition has occurred in DRAM on the CPU card installed on the main board. [Action1] Replace the CPU card. * [Action2] Replace the main board. [Description] A parity alarm condition has occurred in SRAM on the FROM/SRAM module installed on the main board. [Action1] Replace the FROM/SRAM module. Replace the main board. * [Action2] MAINTENANCE B-82595EN-2/04 7-segment LED indicator 3.TROUBLESHOOTING Description [Description] The SYSFAIL alarm has occurred. [Action1] Replace the axis control card. [Action2] Replace the CPU card. Replace the main board. [Description] 5V is supplied to Main board. Above alarms do not occur. * [Action3] http://slidepdf.com/reader/full/manutencao-robo-fanucpdf * If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, 143/483 7/17/2019 specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data. ROBO FANUC.pdf If an alarm is issued, data backup may be disabled. So, back up theMANUTENÇÃO contents of memory routinely. Troubleshooting b y LEDs on pow er supply unit LED indication Failure description and required measure [Description] When ALM LED (red) turned on, power supply alarm has occurred. [Action1] Check fuse F4 (+24V) on the power supply unit, and replace it if it has blown. [Action2] Check the printed-circuit boards powered by the DC power supplies (+5V, 15V, and +24V), the relevant units, and cables, and replace them if defective. [Action3] Replace the power supply unit. 3.TROUBLESHOOTING MAINTENANCE LED indication B-82595EN-2/04 Failure description and required measure [Description] If the PIL LED (Green) does not light, the power supply unit has not been supplied with 200 VAC. [Action1] Check fuse F1 on the power supply unit, and replace it if it has blown. [Action2] For detailed causes of fuse blown out, please refer to section 3.6. Replace the power supply unit. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 144/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf F1 (8.0A) : Fuse for AC input F3 (7.5A) : Fuse for +24E F4 (7.5A) : Fuse for +24V PIL : LED (green) ALM :LED (red) B-82595EN-2/04 MAINTENANCE 3.TROUBLESHOOTING Troubleshoo ting b y LED on th e panel board - A20B-2101-0370 LED indication Failure description and required measure ALM1 ALM2 [Description] When the ALM1 and ALM2 (red) turned on, communication with the main board does not execute. [Action1] Check the communication cable between the main and panel boards, and replace it if necessary. [Action2] Replace the main board. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf [Action3] Replace the panel board. 145/483 5V [Description] When the LED does not light. The power supply inside the panel board does not generate +5 V normally. MANUTENÇÃO ROBO FANUC.pdf 7/17/2019 [Action1] [Action2] * Check the CRM96 connector and check that 24 V is supplied. Replace the panel board. If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data. If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely. (Panel b oard) Troubleshoo ting b y alarm LEDs on the proc ess I/O prin ted circui t board 3.TROUBLESHOOTING MAINTENANCE LED [Action2] ALM0 [Action3] B-82595EN-2/04 Descripti on and action to be taken Examine the cables and peripheral devices connected to the process I/O PC board. Replace any failed components. Replace the process I/O PC board. FALM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 146/483 Process I/O CA/HA Process I/O EA/EB/FA/GA/KA/KB/KC 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fuse Fuse Fuse specification: A60L-0001-0046#2.0 Process I/O JA/JB MAINTENANCE B-82595EN-2/04 3.TROUBLESHOOTING Troubleshoot ing by LEDs on servo amplifier The servo amplifier has alarm LEDs. Troubleshoot the alarm indicated by the LEDs, referring also to the alarm indication on the teach pendant. Check that the voltage is not higher than 50V. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 147/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CAUTION Before touching the servo amplifier, check the DC link voltage with the screws located above the LED "D7". By using a DC voltage tester, check that the voltage is 50 V or less. LED Color P5V Green Description Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally. If the LED does not light: 3.TROUBLESHOOTING LED Color ALM Red MAINTENANCE B-82595EN-2/04 Description Lights when the servo amplifier detects an alarm. If the LED lights when there is no alarm condition in the machine: [Measure] Replace the servo amplifier. If the LED does not light when there is an alarm condition in the machine: [Measure] Replace the servo amplifier. DRDY Green Lights when the servo amplifier is ready to drive the servo motor. If the LED does not light when the motor is activated: [Measure] Replace the servo amplifier. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf OPEN Green Lights when the communication between the servo amplifier and the main board is normal. If the LED does not light: 148/483 7/17/2019 D7 3.8 (Check 1) (Check 2) (Check 3) (Check 4) Red [Measure 1] Check for the connection of the FSSB optical cable. [Measure 2] Replace the servo card. MANUTENÇÃO ROBO FANUC.pdf [Measure 3] Replace the servo amplifier. Lights when the DCLINK circuit inside the servo amplifier is charged to reach the specified voltage. If the LED does not light after pre-charge is finished: [Measure 1] It is likely that the DC Link may be short-circuited. Check for connection. [Measure 2] It is likely that the charge current control resistor may be defective. Replace the E-stop unit. [Measure 3] Replace the servo amplifier. POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) 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 whether the motor axis can be positioned normally. (Corrective action) If the motor axis can be positioned normally, check the mechanical unit. Check the mechanical unit for backlash. (Corrective action) Replace a faulty key of motor shaft or other faulty parts. If checks 1 to 3 show normal results (Corrective action) Replace the Pulsecoder and main board. MAINTENANCE B-82595EN-2/04 3.9 3.TROUBLESHOOTING MANUAL OPERATION IMPOSSIBLE The following explains checking and corrective action required if the robot cannot be operated manually after the controller is turned on: (1) Check and corrective action to be made if manual operation is impossible (Check 1) Check whether the teach pendant is enabled. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Corrective action) Turn on the teach pendant "enable". 149/483 (Check 2) 7/17/2019 (Check 3) (Check 4) (Check 5) (Check 6) Check whether the teach pendant is handled correctly. MANUTENÇÃO ROBO FANUC.pdf (Corrective action) To move an axis by manual operation, press the axis selection key and shift key at the same time. Set the override for manual feed to a position other than the FINE and VFINE positions. Check whether the ENBL signal of the peripheral device control interface is set to on. (Corrective action) Place the peripheral device control interface in the ENBL status. Check whether the HOLD signal of the peripheral device control interface (hold status). (Check whether the hold lamp on the teach pendant is on.) (Corrective action) Turn off the HOLD signal of the peripheral device control interface. Check 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 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. (Check 2) (Corrective action) Put the peripheral-device control interface in the ENBL state. Check whether the HOLD signal for the peripheral-device control interface is on. Al h k h h h HOLD l h h d i 4.PRINTED CIRCUIT BOARDS 4 MAINTENANCE B-82595EN-2/04 PRINTED CIRCUIT BOARDS The printed circuit boards are factory-set for operation. Usually, you do not need to set or adjust them. This chapter describes the standard settings and adjustment required if a defective printed circuit board is replaced. It also describes the test pins and the LED indications. The control unit printed circuit board includes the main unit printed circuit board and one or more cards or modules installed horizontally to the main-unit printed-circuit board. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf These PC boards have interface connectors, LED indicators, and a plastic panel at the front. At the rear, there is a backplane connector. 150/483 7/17/2019 4.1 MANUTENÇÃO ROBO FANUC.pdf MAIN BOARD (A16B-3200-0600, -0601) 75173 (receiver) * Total edition 09B or earlier 75172 (driver) * Total edition 09B or earlier CPU card FROM/SRAM module (under the axis control card) Axis control card Fuse (0.5 A) * Total edition 06B or later Fig 4 1 Main b oard B-82595EN-2/04 Name FROM/SRAM module MAINTENANCE 4.PRINTED CIRCUIT BOARDS Ordering Specificati on Board Specificatio n A05B-2500-H060 A20B-3900-0163 A20B-3900-0223 A20B-3900-0164 A05B-2500-H061 A05B-2500-H062 A05B-2500-H063 A05B-2500-H064 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A20B-3900-0224 A20B-3900-0165 A20B-3900-0225 A20B-3900-0166 A20B-3900-0226 A20B-3900-0167 A20B-3900-0227 Note FROM 32M/ SRAM 1M FROM 32M/ SRAM 2M FROM 32M/ SRAM 3M FROM 64M/ SRAM 1M FROM 64M/ SRAM 2M 151/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (1) Test pins Name Use GND1 GND2 GND3 CACHOFF LOAD For testing the printed circuit board (2) LEDs Seven segment LED Descriptio n A parity alarm occurred in a DRAM of the CPU card on the main board. A parity alarm occurred in a SRAM of the FROM/SRAM module on the main board. Bus error occurred on the communication controller. A parity alarm occurred in DRAM controlled by communication controller. A servo alarm occurred on the main board. 4.PRINTED CIRCUIT BOARDS MAINTENANCE Status LED B-82595EN-2/04 Descripti on Operating status of the system. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 152/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf ETHERNET LED Color Descriptio n TX L/RX Green Green Flashes during data transmission. Lights when a link is established and blinks when data is received. (3) Communication IC If the teach pendant cannot display anything because of, for example, a broken wire in the teach pendant connection cable, it is likely that the communication driver or receiver may be defective. Name Drawing number 75172 (Driver) 75173 (Receiver) A76L-0151-0098 A76L-0151-0099 MAINTENANCE B-82595EN-2/04 4.2 4.PRINTED CIRCUIT BOARDS EMERGENCY STOP CONTROL B OARD (A20B-1008-0740) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 153/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig.4.2 Emergency stop control board 4.PRINTED CIRCUIT BOARDS 4.3 MAINTENANCE B-82595EN-2/04 BACKPLANE BOARD (A20B-2003-0890) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 154/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf MAINTENANCE 4.PRINTED CIRCUIT BOARDS (A20B-2004-0040) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 155/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 4.PRINTED CIRCUIT BOARDS 4.4 MAINTENANCE B-82595EN-2/04 PANEL BOARD (A20B-2101-0370) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 156/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig.4.4 Panel Board (1) Meanings of LEDs Name Colo r 5V Green ALM1 ALM2 Red Use Lights when +5 V is output normally from the internal power supply of the panel board. Lights when communication with the main board is interrupted. MAINTENANCE B-82595EN-2/04 4.5 4.PRINTED CIRCUIT BOARDS PROCESS I/O BOARD CA (A16B-2201-0470) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 157/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig. 4.5 Process I/O Board CA (1) Test pins Name Use +24V +5V +15V -15V GND GND +10V +15V P24V P5V P15VC M15VC GND1 GND2 P10V P15VF 4.PRINTED CIRCUIT BOARDS For measuring the DC supply voltage For measuring the reference voltage of the digital/analog converter MAINTENANCE B-82595EN-2/04 (2) Setting Name ICOM1 UDI1 to UDI20 (Connector CRM2A) ICOM2 UDI21 to UDI40 (Connector CRM2B) ICOM3 WI01 to WI08 (Connector CRW1) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf SP1 Channel 1 SP2 Channel 2 Standard setting Description Side A Set this jumper according to the common voltage of input devices. Side A: +24V common Side: 0V common Open The polarity of the output voltage is switched to: Strapped: Negative (-) 158/483 Open: Positive (+) 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (3) Adjustment VR1: Adjust the gain of channel 1. Execute a robot program and set AOUT [1] to 4095 on the teach pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 until the meter reads 12.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) VR2: Adjust the gain of channel 2. Execute a robot program and set AOUT [2] to 4095 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR2 until the meter reads 12.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) VR3: Adjust the reference supply voltage of the digital/analog converter. Connect the digital voltmeter to test pin P10V and rotate VR3 until the meter reads 10.0±0.1V. (4) LEDs Color Description Red A communication alarm occurred between the main CPU and process input/output. MAINTENANCE B-82595EN-2/04 Driver IC DV6 DV7 DV8 DV9 DV10 DV11 DV12 RESERVED DO sign al DO01, DO02, DO03, DO04 DO05, DO06, DO07, DO08 DO09, DO10, DO11, DO12 DO13, DO14, DO15, DO16 DO17, DO18, DO19, DO20 WO01, WO02, WO03, WO04 WO05, WO06, WO07, WO08 For replacement http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 4.6 4.PRINTED CIRCUIT BOARDS PROCESS I/O BOARD EA (A16B-3200-0230) 159/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig. 4.6 Process I/O Board EA (1) Test pins Name P24V P5V P15VC M15VC GND1 GND2 Use +24V +5V +15V -15V GND GND 4.PRINTED CIRCUIT BOARDS For measuring the DC supply voltage MAINTENANCE B-82595EN-2/04 (2) Setting Name ICOM1 UDI1 to UDI20 (Connector CRM2A) ICOM2 UDI21 to UDI40 (Connector CRM2B) ICOM3 WI01 to WI08 (Connector CRW1) SP1 Channel 1 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf SP2 Channel 2 Standard setting Description Side A Set this jumper according to the common voltage of input devices. Side A: +24V common Side: 0V common Open Output voltage is adjusted to: Short: Output voltage minus (-) 160/483 Open: Output voltage plus (+) 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (3) Adjustment VR1: Adjust the gain of channel 1. Execute a robot program and set AOUT [1] to 4095 on the teach pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 until the meter reads 12.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) VR2: Adjust the gain of channel 2. Execute a robot program and set AOUT [2] to 4095 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR2 until the meter reads 12.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) VR3: Adjust the standard voltage for the digital/analog converter. Connect the digital voltmeter to test pin P10V and rotate VR3 until the meter reads 10.0±0.1V VR4, VR5: Adjust the internal power supply This volume is adjusting the internal power supply. Adjusting when shipping from the factory, so you need not to adjust. (4) LEDs B-82595EN-2/04 Color Description Red A communication alarm occurred between the main CPU and process I/O board. MAINTENANCE 4.PRINTED CIRCUIT BOARDS (5) Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062 Driver IC DO sign al DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED DV2 HELD, FALT, ATPERCH, TPENBL DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED DV6 DO01, DO02, DO03, DO04 DV7 DO05, DO06, DO07, DO08 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf DV8 DO09, DO10, DO11, DO12 161/483 DV9 DV10 DV11 DV12 7/17/2019 4.7 DO13, DO14, DO15, DO16 DO17, DO18, DO19, DO20 WO01, WO02, WO03, WO04 WO05, WO06, WO07, WO08 MANUTENÇÃO ROBO FANUC.pdf PROCESS I/O BOARD EB (A16B-3200-0231) Fig. 4.7 PROCESS I/O BOARD EB (A16B-3200-0231) (1) Test pins 4.PRINTED CIRCUIT BOARDS MAINTENANCE Name ICOM2 Standard setting UDI21 to UDI40 (Connector CRM2B) B-82595EN-2/04 Description Side A: +24V common Side B: 0V common (3) LEDs Color Description http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 162/483 A communication alarm occurred between the main Red CPU and process I/O board. 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Red A fuse (FUSE 1) in the process I/O board blew. (4) Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062 Driver IC DO sign al DV1 DV2 DV3 DV4 DV5 DV6 DV7 CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED DO01, DO02, DO03, DO04 DO05, DO06, DO07, DO08 DV8 DV9 DV10 DO09, DO10, DO11, DO12 DO13, DO14, DO15, DO16 DO17, DO18, DO19, DO20 MAINTENANCE B-82595EN-2/04 4.8 4.PRINTED CIRCUIT BOARDS PROCESS I/O BOARD FA (A16B-3200-0420) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 163/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig. 4.8 Process I/O Board FA (1) Test pins Name P24V P5V GND1 GND2 Use +24V +5V GND GND For measuring the DC supply voltage (2) Setting Name ICOM1 ICOM2 ICOM3 Standard setting Description UDI1 to UDI20 (Connector CRM2A) UDI21 to UDI40 (Connector CRM2B) UDI41 to UDI60 (Connector CRM2C) 4.PRINTED CIRCUIT BOARDS Set this jumper according to the common voltage of input devices. Side A MAINTENANCE B-82595EN-2/04 (3) LEDs http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Color Description Red A communication alarm occurred between the main CPU and process I/O board. 164/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Red A fuse (FUSE 1) in the process I/O board blew. (4) Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062 Driver IC DO sign al DV1 DV2 DV3 DV4 CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 DV5 DV6 DV7 DV8 DV9 DV10 DV11 DV12 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED DO01, DO02, DO03, DO04 DO05, DO06, DO07, DO08 DO09, DO10, DO11, DO12 DO13, DO14, DO15, DO16 DO17, DO18, DO19, DO20 DO21, DO22, DO23, DO24 DO25, DO26, DO27, DO28 DV13 DV14 DV15 DO29, DO30, DO31, DO32 DO33, DO34, DO35, DO36 DO37, DO38, DO39, DO40 MAINTENANCE B-82595EN-2/04 4.9 4.PRINTED CIRCUIT BOARDS PROCESS I/O BOARD GA (A16B-2203-0520) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 165/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (1) Test pins Name Use P24V P5V GND1 +24V +5V GND GND2 GND3 P24VF P5VF GNDF AOUT1 AOUT2 GND GND +24V +5V GND Channel 1 Channel 2 For measuring the DC supply voltage Power for the digital/analog converter For measuring the voltage of the analog output signal (digital/analog) (2) Setting Name Standard 4.PRINTED CIRCUIT BOARDS Description MAINTENANCE B-82595EN-2/04 Execute a robot program and set AOUT [2] to 3413 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR3 or VR4 until the meter reads 15.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) (4) LEDs Color http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Red Description A communication alarm occurred between the main CPU and process I/O board. 166/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Red A fuse (FUSE 1) in the process I/O board blew. (5) Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062 Driver IC DO sign al DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED DO01, DO02, DO03, DO04 DO05, DO06, DO07, DO08 DO09, DO10, DO11, DO12 DV9 DV10 DO13, DO14, DO15, DO16 DO17, DO18, DO19, DO20 MAINTENANCE B-82595EN-2/04 4.10 4.PRINTED CIRCUIT BOARDS PROCESS I/O BOARD HA (A16B-2203-0760) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 167/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig. 4.10 Process I/O Board HA (1) Test pins Name P24V P5V GND1 GND2 GND3 P24VF P5VF Use +24V +5V GND GND GND +24V +5V 4.PRINTED CIRCUIT BOARDS For measuring the DC supply voltage Power for the digital/analog converter MAINTENANCE B-82595EN-2/04 (3) Adjustment VR1/VR2: Adjust the gain and the offset of channel 1. Execute a robot program and set AOUT [1] to 3413 on the teach pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 or VR2 until the meter reads 15.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) VR3/VR4: Adjust the gain and the offset of channel 2. Execute a robot program and set AOUT [2] to 3413 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR3 or VR4 until the meter reads 15.0V. Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (4) LEDs 168/483 7/17/2019 MANUTENÇÃO Description ROBO FANUC.pdf Color Red A communication alarm occurred between the main CPU and process I/O board. Red A fuse (FUSE 1) in the process I/O board blew. (5) Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062 Driver IC DV1 DV2 DV3 DV4 DO sign al CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FALT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 4.11 4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/04 PROCESS I/O BOARD JA (A16B-2204-0010) P24V P5V ICOM2 GND1 ICOM1 ICOM5 LED CRMA6A CRMA6B ICOM6 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf TBSRC3 TBSRC1 169/483 CRMA5A 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf GND2 CRMA5B CRMA5C CRMA5D ICOM3 TBSRC2 ICOM4 I/O-LK JD1B I/O-LK JD1A FUSE (2A) Fig.4.11 Process I/O Board JA (1) Test pins Name P24V P5V GND1 GND2 Use +24V +5V GND GND 4.PRINTED CIRCUIT BOARDS For measuring the DC supply voltage MAINTENANCE B-82595EN-2/04 (2) Settings Name ICOM1 UDI1 to 20 CRMA5A) (Connector ICOM2 UDI21 to 40 (Connector CRMA5B) ICOM3 UDI41 to 60 (Connector CRMA5C) ICOM4 UDI61 to 80 (Connector CRMA5D) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf ICOM5 UDI81 to 88 Standard setting Side A Description Set the A: common voltage Side +24 V common Side B: 0 V common 170/483 7/17/2019 ICOM6 (Connector CRMA6A) UDI89 to 96 (Connector CRMA6B) MANUTENÇÃO ROBO FANUC.pdf (3) LEDs Color Description Red A communication alarm occurred between the main CPU and process I/O. Red A fuse (FUSE 1) in the process I/O blew. MAINTENANCE B-82595EN-2/04 4.12 4.PRINTED CIRCUIT BOARDS PROCESS I/O BOARD JB (A16B-2204-0011) ICOM1 ICOM2 P5V P24V GND1 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf LED 171/483 GND2 7/17/2019 TBSRC1 MANUTENÇÃO ROBO FANUC.pdf CRMA5A CRMA5B I/O-LK JD1B FUSE (2A) I/O-LK JD1A Fig.4.12 Process I/O Board JB (1) Test pins Name Use P24V +24V P5V GND1 GND2 +5V GND GND For measuring the DC supply voltage 4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/04 (3) LEDs Color Description Red A communication alarm occurred between the main CPU and process I/O. Red A fuse (FUSE 1) in the process I/O blew. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 172/483 4.13 7/17/2019 PROCESS I/O BOARD KA (A16B-2204-0050, A20B-2101-0560) MANUTENÇÃO ROBO FANUC.pdf Total edition GND2 GND3 P24V P5V VR5 VR6 GNDF GND1 VR4 DV1 P5VF VR3 VR2 LED AOUT3 VR1 AOUT2 P24VF N15V GND4 ICOM2 AOUT1 DRV1 P15V AI2 AI1 DRV2 ICOM1 ICOM3 MAINTENANCE B-82595EN-2/04 P24V GND4 GNDF 4.PRINTED CIRCUIT BOARDS P5VF P24VF VR5 VR6 VR4 VR3 GND1 VR2 VR1 LED P5V DV1 P15V http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 173/483 N15V DRV1 7/17/2019 AOUT3 DRV2 MANUTENÇÃO ROBO FANUC.pdf GND3 AI1 AI2 AOUT1 AOUT2 GND2 ICOM3 ICOM2 ICOM1 Total edition A20B-2101-0560 (1) Meanings of check pins Name Use P24V +24V P5V P15V N15V GND1 GND2 GND3 GND4 P5VF P24VF +5V +15V -15V GND GND GND GND +5V +24V GNDF AI1 AI2 GND Channel 1 Channel 2 4.PRINTED CIRCUIT BOARDS For DC power measurement D/A converter power supply For analog input signal (A/D) voltage measurement MAINTENANCE B-82595EN-2/04 (3) Adjustment VR1/VR2: Channel 1 gain and offset adjustment Connect the "+" and "-" terminals of a digital voltmeter, respectively, to the AOUT1 check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT [1]=3413, using a robot program. While observing the voltage at the AOUT1 check pin with the digital voltmeter, adjust potentiometers VR1 and VR2 for 15.0 V. VR3/VR4: Channel 2 gain and offset adjustment Connect the "+" and "-" terminals of a digital voltmeter, respectively, to the AOUT2 check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT [2]=3413, using a robot program. While observing the voltage at the AOUT2 check pin with the digital voltmeter, adjust potentiometers VR3 and VR4 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf for 15.0 V. 174/483 7/17/2019 VR5/VR6: Channel 3 gain and offset adjustment Connect the "+" and "-" terminals of a digital voltmeter, respectively, to the AOUT3 MANUTENÇÃO ROBO FANUC.pdf check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT [3]=3413, using a robot program. While observing the voltage at the AOUT3 check pin with the digital voltmeter, adjust potentiometers VR5 and VR6 for 15.0 V. (4) Meaning of LEDs Color Meaning Red A communication alarm occurred between the main CPU and the process I/O board. Red The fuse (FUSE1) on the process I/O board has blown. (5) Correspondence between driver ICs and DO signals Driver IC specification: DRV1, DRV2: A76L-1151-0167 DV1 A76L 1151 0070 MAINTENANCE B-82595EN-2/04 4.14 4.PRINTED CIRCUIT BOARDS PROCESS I/O BOARD KB (A16B-2204-0051, A20B-2101-0561) Total edition GND2 GND3 P24V P5V GNDF http://slidepdf.com/reader/full/manutencao-robo-fanucpdf VR4 VR3 GND1 175/483 DV1 P5VF LED VR2 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf VR1 AOUT2 P24VF GND4 ICOM2 AOUT1 DRV1 DRV2 ICOM1 ICOM3 A16B-2204-0051 P24V GND4 GNDF P5VF P24VF VR4 VR3 GND1 VR2 LED VR1 P5V DV1 P15V 4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/04 (1) Meanings of check pins Name P24V P5V GND1 GND2 GND3 GND4 P5VF P24VF GNDF Use +24V +5V GND GND GND GND +5V +24V GND For DC power measurement D/A converter power supply http://slidepdf.com/reader/full/manutencao-robo-fanucpdf AOUT1 Channel 1 For analog output signal (D/A) voltage AOUT2 Channel 2 measurement 176/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (2) Setting Name ICOM1 ICOM2 ICOM3 Standard setting UDI1 20 (Connector CRMA5A) UDI21 40 (Connector CRMA5B) WI01 08 (Connector CRW10) Side A ～ ～ Use For common voltage setting Side A: +24 V common Side B: 0 V common ～ (3) Adjustment VR1/VR2: Channel 1 gain and offset adjustment Connect the "+" and "-" terminals of a digital voltmeter, respectively, to the AOUT1 check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT [1]=3413, using a robot program. While observing the voltage at the AOUT1 check pin with the digital voltmeter, adjust potentiometers VR1 and VR2 for 15.0 V. VR3/VR4: Channel 2 gain and offset adjustment Connect the "+" and "-" terminals of a digital voltmeter, respectively, to the AOUT2 check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT [2]=3413, using a robot program. While observing the voltage at the AOUT2 check pin with the digital voltmeter, adjust potentiometers VR3 and VR4 for 15.0 V. MAINTENANCE B-82595EN-2/04 4.PRINTED CIRCUIT BOARDS Color Red Meaning The fuse (FUSE1) on the process I/O board has blown. (5) Correspondence between driver ICs and DO signals Driver IC specification: DRV1, DRV2: A76L-1151-0167 DV1: A76L-1151-0070 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Driver IC name 177/483 DO sign al name 7/17/2019 DRV1 DRV2 DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED MANUTENÇÃO ROBO FANUC.pdf HELD, FAULT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED DO01, DO02, DO03, DO04 DO05, DO06, DO07, DO08 DO09, DO10, DO11, DO12 DO13, DO14, DO15, DO16 DO17, DO18, DO19, DO20 4.PRINTED CIRCUIT BOARDS 4.15 MAINTENANCE B-82595EN-2/04 PROCESS I/O BOARD KC (A16B-2204-0052, A20B-2101-0562) Total edition GND2 GND3 P24V P5V GND1 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf DV1 LED 178/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf GND4 ICOM2 DRV1 DRV2 ICOM1 A16B-2204-0052 P24V GND4 GND1 LED P5V DV1 P15V DRV MAINTENANCE B-82595EN-2/04 DRV 4.PRINTED CIRCUIT BOARDS (1) Meanings of check pins Name P24V P5V GND1 GND2 GND3 GND4 Use +24V +5V GND GND GND GND For DC power measurement (2) Setting Name http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Standard setting Use 179/483 UDI1 20 (Connector CRMA5A) UDI21 40 (Connector CRMA5B) ICOM1 Side A ～ 7/17/2019 ICOM2 ～ For common voltage setting Side A: MANUTENÇÃO +24 V commonROBO FANUC.pdf Side B: 0 V common (3) Meaning of LEDs Color Meaning Red A communication alarm occurred between the main CPU and the process I/O board. Red The fuse (FUSE1) on the process I/O board has blown. (4) Correspondence between driver ICs and DO signals Driver IC specification: DRV1, DRV2: A76L-1151-0167 DV1: A76L-1151-0070 5.SERVO AMPLIFIERS 5 MAINTENANCE B-82595EN-2/04 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 SERVO AMPLIFIER A06B-6107-H001 (AMP1) M-900iA/400L A06B-6117-H209 (AMP2) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf M-900iA/600 A06B-6117-H105 (AMP3) REGENERATIVE REGISTOR A-CABINET B-CAB INET A05B-2502-C100 180/483 7/17/2019 R-2000iB/200T M-900iA/260L M-900iA/350 M-410iB R-2000iB (Except /200T) MANUTENÇÃO ROBO FANUC.pdf A05B-2502-C100 A06B-6107-H001 A05B-2501-C102 R-1000iA/80F i M-710 C M-16iB M-20iA ARC Mate 120iB (Except ARC Mate 120iBe.) ARC Mate 120iC M-420iA, M-421iA M-6iB ARC Mate 100iB ARC Mate 120iBe F-200iB ARC Mate 100iC M-10iA A05B-2501-C103 A06B-6107-H002 A05B-2502-C100 A05B-2501-C100 A05B-2501-C102 A05B-2501-C101 A06B-6107-H003 A05B-2501-C105 A06B-6107-H004 A06B-6107-H007 (AMP 1) A06B-6117-H201 (AMP 2) M-430iA/2F A06B-6107-H007 (AMP 1) M-430iA/2P A05B-2502-C101 A05B-2501-C101 A05B-2502-C101 A05B-2501-C105 A05B-2502-C101 A06B-6117-H301 (AMP 2) M-900iA/200P A06B-6107-H001 (Main, AMP 1) A06B-6107-H001 (2nd AMP 1) MAINTENANCE B-82595EN-2/04 A05B-2502-C100 5.SERVO AMPLIFIERS Check that the voltage is not higher than 50V. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 181/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf NOTE Before touching the servo amplifier, for example, for maintenance purposes, check theremaining voltage at voltage the screw above the than LED 50V. “D7” with a DC voltage tester to see if the is not higher 5.SERVO AMPLIFIERS 5.1 MAINTENANCE B-82595EN-2/04 LED OF SERVO AMPLIFIER http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 182/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig.5.1 LED of servo ampli fier LED Color P5V Green P3.3V Green SVEM G SVALM Red Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally. Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V normally. Lights when an emergency stop signal is input to the servo amplifier. Descriptio n Red Lights when the servo amplifier detects an alarm. DRDY OPEN D7 Green Green Red Lights when the servo amplifier is ready to drive the servo motor. Lights when the communication between the servo amplifier and the main board is normal. Lights when the DCLINK circuit inside the servo amplifier is charged to reach a specific 5.2 5.SERVO AMPLIFIERS MAINTENANCE B-82595EN-2/04 SETTING OF SERVO AMPLIFIER Table 5.2 Settin gs Name COM1 Standard setting Side A Descripti on Robot Digital Input (RDI) device common voltage. Side A: +24V common Side B: 0V common Total edition of servo amplifier control board When total edition of servo amplifier http://slidepdf.com/reader/full/manutencao-robo-fanucpdf control board is 11E or earlier 183/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf COM1 A B When total edition of servo amplifier control board is 12F or later A si de RI 6.SETTING THE POWER SUPPLY 6 MAINTENANCE B-82595EN-2/04 SETTING THE POWER SUPPLY Setting and adjustment of the power supply is factory-set for operation. or adjust it. 6.1 Usually, you do not need to set BLOCK DIAGRAM OF THE POWER SUPPLY http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 210VAC Transformer 3φ E-stop unit Servo amplifier Breaker (6-axis amplifier) 210VAC FS3 Regenerative res. aux. axis 184/483 Breaker CRR38 DC/DC FS1 7/17/2019 AC AC AC AC AC AC +24V CRM96 power supply unit 200 ～ 230 V 380 ～ 400 V 380 ～ 415 V 440 ～ 500 V 500 ～ 575 V +15V, -15V MANUTENÇÃO ROBO FANUC.pdf C R R 6 4 C N J FS2 C R F 8 200VAC １φ + 5 V Power supply Backplane +5V, +3.3V CRM96 Power supply unit F1 + 2 4 V F I/O unit CP1 CP1A P o w e r Fan 200VAC １φ CP2 CP2 B ra k e P u ls e c o rd e r Robot Motor CP3 DC/DC F3 CP6 F4 CP5 +5V, +3.3V +2.5V, +15V, -15V +24E CRP24 End effector CP5A C R M 9 5 +24V +24V, +24E Main board + 2 4 E Battery CP8B C R M 9 5 CRS20 +24E +24T Teach pendant FUSE2 DC/DC +5V E-stop circuit JRS16 RS-232-C JD1A MAINTENANCE B-82595EN-2/04 6.2 Panel board I/O LINK 6.SETTING THE POWER SUPPLY TRANSFORMER Select a transformer and tap according to the supply voltage. voltage. Select a transformer tap among the rated A-cab in et Rated voltage Transformer specification 13.0KVA 10.5KVA 7.5KVA 3KVA A80L-0028-0024#A A80L-0026-0040# A A80L-0024-0028 500 to 575 TYPE E 440 to 500 380 to 415 TYPE D 200 to 230 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 380 to 400 A80L-0028-0027#A A80L-0026-0041# A A80L-0024-0029 185/483 B-cabinet 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Transformer specification Rated voltage 13.0KVA 10.5KVA 7.5KVA 3KVA 500 to 575 TYPE E 440 to 500 A80L-0028-0025 A80L-0028-0024 A80L-0026-0040 A80L-0024-0028 A80L-0028-0028 A80L-0028-0027 A80L-0026-0041 A80L-0024-0029 380 to 415 TYPE D 200 to 230 380 to 400 Transformer Side fan type Rear fan type A-cab in et (Rear) 6.SETTING THE POWER SUPPLY http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Transformer MAINTENANCE B-82595EN-2/04 186/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf B-cabinet (Rear) MAINTENANCE B-82595EN-2/04 6.SETTING THE POWER SUPPLY Cabinet side connector 4. TYPE D (380V-400V) 1. TYPE E (500V-575V) Circuit Dummy plug Dummy plug breaker 2. TYPE E (440V-500V) Y connection cable Circuit breaker 5. TYPE D (200V-230V) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Dummy plug Circuit 187/483 Circuit breaker Dummy plug breaker connection cable Δ 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (B-cabinet) 3. TYPE E (380V-415V) Dummy plug Dummy plug Y - Δ connection unit Circuit breaker Circuit breaker Operation box Connection cable (A-cabinet) Fig. 6.2(b) Setting the input voltage 1 Type E: 500V-575V 2 Type E: 440-500V 3 Type E: 380-415V 4 T pe D 380 400V Insert the connector connected to the circuit breaker into connector LA and the dummy plug into connectors LB and LC. Insert the connector connected to the circuit breaker into connector LB and the dummy plug into connectors LA and LC. Insert the connector connected to the circuit breaker into connector LC and the dummy plug into connectors LA and LB. Insert the Y connection cable connected to the circ it breaker into 6.SETTING THE POWER SUPPLY 6.3 MAINTENANCE B-82595EN-2/04 CHECKING THE POWER SUPPLY UNIT (A16B-2203-0910) The power supply unit need not be set or adjusted. Output Table 6.3 Rating of the Power supply unit Rated voltage +5V +3.3V +2.5V +24V +24E +15V +5.1V +3.3V +2.5V +24V +24V +15V -15V http://slidepdf.com/reader/full/manutencao-robo-fanucpdf -15V Tolerance ±3% ±3% ±3% ±5% ±5% ±10% ± 10% 188/483 DB1 : Diode stack 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf F1 (8.0A) : Fuse for AC input CP1 : Connector for AC input CP1A : Connector for AC output CP2, CP3 : Connector for AC output VS1 : Surge absorber F3 (7.5A) : Fuse for +24E F4 (7.5A) : Fuse for +24V PIL : LED (green) H1 : Auxiliary power module CP5 : Connector for +24V CP6 : Connector for +24E ALM : LED (red) CP4 : Connector for control http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 189/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf B-82595EN-2/04 7 MAINTENANCE 7.REPLACING A UNIT REPLACING A UNIT This section explains how to replace each unit in the control section. WARNING 1 Before you start to replace a unit, turn off the control unit main power. Also, keep all machines in the area of the control unit switched. Otherwise, you could injure personnel or damage equipment. 2 Before replacing components, read the maintenance manual to understand the replacement procedure. Performing an incorrect replacement procedure can lead to an unpredictable accident, http://slidepdf.com/reader/full/manutencao-robo-fanucpdf injury. resulting in breakage in the robot or personal 3 When a heavy component or unit is to be handled, support the workers with a 190/483 7/17/2019 3 When a heavy component or unit is to be handled, support the workers with a crane or the like not to apply excessive loads to the workers. Note that MANUTENÇÃO ROBO FANUC.pdf incorrect handling can cause serious injury to the workers. CAUTION Components in the control unit heat up, so care should be taken. When you have to touch a heated component, prepare a protector such as heat-resistant gloves. 7.REPLACING A UNIT 7.1 MAINTENANCE B-82595EN-2/04 A-CABINET The following components of the A-cabinet can be removed. 7.1.1 Replacing the A-cabinet Top Panel Remove three M4 screws from the upper edge of the rear surface. Pull the top panel slightly backward, and then lift it off. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 191/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf M4 screws (3 places) Fig.7.1.1 Replacin g t he Top Panel NOTE In case of the Rear fan type, replace the Top panel after remove the Rear louver. B-82595EN-2/04 7.1.2 MAINTENANCE 7.REPLACING A UNIT Replaci ng t he A-cabinet Rear Panel Remove the retaining M4 screws and four M10 bolts from the rear panel. M4 screws (7 places) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 192/483 7/17/2019 M10 bolts (4 places) MANUTENÇÃO ROBO FANUC.pdf Fig.7.1.2 Replacin g t he Top Panel NOTE In case of the Rear fan type, replace the Rear Panel after remove the Rear louver. 7.1.3 Replacing the A-cabinet Louver (a) Side fan type Loosen four retaining M4 screws from the louver, and then remove the louver. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 193/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf B-82595EN-2/04 7.2 MAINTENANCE 7.REPLACING A UNIT REPLACING THE PRINTED-CIRCUIT BOARDS CAUTION When you replace printed-circuit boards, observe the following cautions: 1 Keep the controller power switched off. 2 When you remove a printed-circuit board, do not touch the semiconductor devices on the board with your hand or make them touch other components. 3 Make sure that the replacement printed-circuit board has been set up appropriately. (Setting plug etc.) 4 After replacing a printed-circuit board, make adjustments correctly if the board needs to be adjusted. 5 If the backplane board, power supply unit,parameters or main board cards that robot and(including taught data areand lost. Before you start to replace these components, save a backup copy of the modules) is replaced, it is likely http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 194/483 robot parameters and taught data to an external memory device. ROBO FANUC.pdf 6 Before you disconnect a cable, note its location. If a MANUTENÇÃO cable is detached for replacement, reconnect it exactly as before. 7/17/2019 Replacing the Backpl ane Board (Unit) 7.2.1 When replacing the backplane board, do so together with the plastic rack. (1) Detach the cables from the power unit and boards on the backplane board. CAUTION When you remove the main PC Board, be sure that the battery is good (3.1-3.3VDC) and it is installed correctly. USE STATIC PROTECTION. (2) Remove the power unit and boards from the rack. (See Section 7.2.2.) (3) Detach the grounding cable from the backplane unit. (4) Loosen the retaining screws in the upper section of the rack. Remove the retaining screws from the lower section of the rack. (5) Side rack up and out. (6) To replace the backplane and rack, reverse steps (1) - (6). CAUTION There is a possibility of data loss when a backplane- mounted printed circuit 7.REPLACING A UNIT 7.2.2 MAINTENANCE B-82595EN-2/04 Replacing the Power Unit and Printed-Circuit B oards on the Backplane Unit The backplane unit incorporates the power unit, main board, and option boards. There are two types of option boards: Full-size board and mini-size board. A full-size board occupies one slot. A mini-size board uses part of a full-size board. CAUTION Before starting replacement, turn off the control unit main power. The main board is equipped with battery-backed memory devices for holding robot parameters and taught data, for example. When the main board is replaced, the data in the memory devices is lost. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (1) Detach the cable from the power supply replaced. unit or the printed-circuit board, whichever is to be 195/483 7/17/2019 (2) Pinch the barbed handles on the upper and lower sections of the board to unlatch it, and then pull it MANUTENÇÃO ROBO FANUC.pdf toward you. (3) Place the replacement board on the rail in the appropriate slot of the rack, then push it in gently by the handles until it is latched. (4) There are two rails in the main board SLOT (slot 1). When inserting the main board, align it to the right-side rail. (5) There are two rails in slots 3 (slots for a full-size option board). When you insert a full-size option board, align it to the left-side rail. Backplane board Left rail 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 Right rail SLOT 1 SLOT 3 SLOT 2 PSU (Power su ppl y SLOT) Handles http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 196/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Handles SLOT 1 7.REPLACING A UNIT 7.2.3 MAINTENANCE B-82595EN-2/04 Replacing the Panel B oard The panel board is at the back of the operator panel. (1) Detach all cables from the panel board. The terminal blocks (TBOP3, TBOP4, and TBOP6) are of a connector type. Pull out the upper terminal block sections. (2) Remove four retaining screws from the panel board, and replace the panel board. (3) Remove two M3 screws from the fixing sheet metal of the panel board, and remove the sheet metal. (4) Attach the fixing sheet metal to a new panel board, and attach the new panel board to the operator panel. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 197/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf A-cab in et MAINTENANCE B-82595EN-2/04 7.2.4 7.REPLACING A UNIT Replaci ng t he Process I/O Board EA, EB, FA, GA, KA, KB , KC (A-cabinet) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 198/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf M4 screws (4 places) Fig. 7.2.4 Replacing t he Process I/O Board 7.3 REPLACING CARDS AND MODULES ON THE MAIN BOARD CAUTION Before you start to replace a card or module, make a backup copy of robot parameters and taught data. If the FROM/SRAM module is replaced, SRAM memory contents are lost. Demoun ting a Card (1) Pull outward the clip of each of the two spacers used to secure the card PCB, and then release each latch. (2) Extract the card upward. 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 (2) Card http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 199/483 Spacer 7/17/2019 Connector MANUTENÇÃO ROBO FANUC.pdf Fig. 7.3 (a) Demount ing t he card on the main bo ard Mounting a Card (1) Check that the clip of each of the two spacers is latched outward, then insert the card into the connector. (2) Push the clip of each spacer downward to secure the card PCB. Be sure to hold this part to push the card. MAINTENANCE B-82595EN-2/04 7.REPLACING A UNIT Be sure to hold this part to push the card. Connector http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Fig. 7.3 (b) Mount ing t he card on the main bo ard 200/483 Demoun ting 7/17/2019 a modul e MANUTENÇÃO ROBO FANUC.pdf CAUTION When replacing the module, be careful not to touch the module contact. If you touch the contact inadvertently, wipe out dirt on the contact with a clean cloth. (1) Move the clip of the socket outward. (a) (2) Extract the module by raising it at a 30 degree slant and pulling outward. Mounting a module (1) Insert the module at a 30 degree slant into the module socket, with side B facing upward. (b) (2) Push the module inward and downward until it is locked. (c) (a) A Details of section A 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 (c) Fig.7.3 (c) Demounting/mounting a module Figure 7.3 (d) shows the locations of the cards and modules. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 201/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CPU card FROM/SRAM module (Behind the axis control card) MAINTENANCE B-82595EN-2/04 7.4 7.REPLACING A UNIT REPLACING THE TRANSFORMER WARNING The transformer is heavy. cause injury. When replacing the transformer, be careful not to (The transformer weighs 45 to 60 kg.) In case of A-cabinet Following (1) to (3) are not necessary for the remote type A-cabinet. For the remote type A-cabinet, start from (4). If the A-cabinet is connected to the robot, it will need to be separated. Cabinet separation (1) Disconnect the cable connectors and ground clamps coming from the robot. These cables are generally at the following connectors on the Servo amplifier: CRF8, CNJ1 to 6, and CNJGA to http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CNJGC, and the ground cables. 202/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Motor power cable Grounding cable Pulsecoder cable 7.REPLACING A UNIT Cable clamp MAINTENANCE B-82595EN-2/04 (2) Remove the four M10 robot retaining bolts that hold the cabinet to a robot. Robot retaining bolts M10 (4 places) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 203/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (3) Being careful not to strain or break any cables, gently separate the cabinet from the robot and it’s cables. (4) Disconnect the power cable from the transformer input connector panel. (The power cable comes from the operation box.) Transformer input connector’s panel B-82595EN-2/04 MAINTENANCE 7.REPLACING A UNIT (7) Unscrew and Remove the plate on the top of the transformer. Screw Washer Screw (M5) 3 places http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 204/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (8) Remove four screws from a metal plate of connector’s panel, and remove the metal plate. A metal plate of connector’s panel 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 (9) Remove the two M6 screws holding the transformer in place and remove the transformer. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 205/483 Screws (2-M6) 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (10) Install a replacement transformer by reversing steps 1 through 9. B-82595EN-2/04 MAINTENANCE 7.REPLACING A UNIT In case of B-cabinet (1) Remove the screws and detach the back panel. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 206/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 (2) Detach the connectors of LA, LB, LC, OUT, and CPOH. If a cable is fastened with nylon ties, cut them with a diagonal cutter to release the cable. careful not to damage the cable. Be In case of TYPE E http://slidepdf.com/reader/full/manutencao-robo-fanucpdf In case of TYPE D 207/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (3) Remove the retaining screws from the transformer terminal board and remove the metal plate. B-82595EN-2/04 MAINTENANCE 7.REPLACING A UNIT (4) Remove the two retaining M6 screws from the transformer, then remove the transformer. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 208/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 7.REPLACING A UNIT 7.5 MAINTENANCE B-82595EN-2/04 REPLACING THE REGENERATIVE RESISTOR UNIT WARNING Before you start, turn off the controller main power. Be careful not to get burned, because the regenerative resistor unit is very hot immediately after operation. In case of A-cabinet (1) Remove the top panel from the A-cabinet. Remove the Louver plate and the lower plate on the right side of the cabinet. (In case of the Rear fan type, remove the rear panel or fan unit.) (2) Unplug connector CRR45 and CRR63 at the Servo amplifier. (3) Unscrew the cord grip nut inside the transformer compartment and pull the cables through, being careful not to damage the connectors or cables. (4) Unscrew the retaining screws on the regenerative resistor unit and remove it. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (5) Install the replacement unit by reversing this procedure (1) to (4). 209/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CRR45 CRR63 B-82595EN-2/04 7.REPLACING A UNIT MAINTENANCE The type of the regenerative resistor varies with the model of the robot. The cable is retained using a cord grip. Remove the http://slidepdf.com/reader/full/manutencao-robo-fanucpdf cord grip, and pull out the cable. The cord grip is retained with nuts on the rear side. Remove the lower Transformer 210/483 right plate beforehand. 7/17/2019 (Side fan type) MANUTENÇÃO ROBO FANUC.pdf The type of the regenerative resistor varies with the model of the robot. Screw (M4) 2 places Transformer The cable is retained using a cord grip. Remove the cord grip, and pullonout The cord is retained with nuts the the rearcable. side. Remove thegrip lower right plate beforehand. 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 In case of B-cabinet (1) Remove the servo amplifier. (See Section 7.6) (2) Remove the metal plate securing the cable of the regenerative resistor. If a cable is fastened with nylon ties, cut them with a diagonal cutter to release the cable. careful not to damage the cable. Be A http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 211/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Details of section A Fig. 7.5 (a) Cable part o f th e regenerative resister (3) Of the two nuts fastening the regenerative resistor, remove the upper nut, loosen the lower nut, and then remove the regenerative resistor. A MAINTENANCE B-82595EN-2/04 7.6 7.REPLACING A UNIT REPLACING THE E-STOP UNIT In case of A-cabinet NOTE The magnetic contactor mounted in the E-stop unit is turned on when the conditions are satisfied. While the controller is turned on, do not press the button on the magnetic contactor in any case. Otherwise, the contactor may be damaged. Note) Do not press this switch in any case. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 212/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf E-stop unit (A-cabinet) (1) Detach the cables from the E-stop unit. (2) Remove retaining screws (M4 4 places) from the E-stop unit, and replace the E-stop unit. (3) Reconnect the cables. 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 In case of B-cabinet NOTE The magnetic contactor mounted in the E-stop unit is turned on when the conditions are satisfied. While the controller is turned on, do not press the button on the magnetic contactor in any case. Otherwise, the contactor may be damaged. Note) Do not press this switch in any case. Note) Do not press this switch in any case. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 213/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf E-stop unit (B-cabinet) (1) Detach the cables from the E-stop unit. (2) Of the four screws fastening the E-stop unit, remove the upper two screws, loosen the lower two screws, then replace the E-stop unit. (3) Reconnect the cables. MAINTENANCE B-82595EN-2/04 7.7 7.REPLACING A UNIT REPLACING SERVO AMPLIFIERS WARNING Because the servo amplifier is heated immediately after operation, leave the servo amplifier until it cools down thoroughly, before replacing it. In case of A-cabinet A servo amplifier can be dismounted by pulling it out from the side, using its rail. Only a flat-head screwdriver is required, provided that servo amplifier SHIPPING screws have been removed. These screws are intended to prevent damage to the servo amplifier during shipment. (1) Make sure that servo amplifier shipping screws (2 phillips head) have been removed. Retain screws for shipping purposes. (2) Check the voltage at the screw above the LED "D7" with a DC voltage tester to see if the remaining voltage is not higher than 50V. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Check that the voltage is not higher than 50V. 214/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 (4) Unlock the servo amplifier by rotating the quarter-turn screws on the outside surface of the plate using a coin or the like. Unlock http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Lock 215/483 7/17/2019 Servo amplifier shipping screws (M5, 2 places) MANUTENÇÃO ROBO FANUC.pdf Quarter-turn screws (4 places) (5) Hold the upper and lower handles, and pull out the servo amplifier slowly. Be sure that all cables are unplugged from the servo amplifier before you try to remove the servo amplifier. After pulling the servo amplifier a little, check again that it is all right to continue to pull the servo amplifier. Be careful not to let the servo amplifier slide off the rail. (6) Place a replacement servo amplifier on the rail, slide it in gently until it is hooked on the guide pins. (7) Rotate the quarter-turn screws on the outside surface of the plate to lock the servo amplifier. (8) Reconnect the cables. Guide pin B-82595EN-2/04 MAINTENANCE 7.REPLACING A UNIT In case of B-cabinet (1) Detach the amplifier cover, and pull out the cable. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 216/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Details of section A (2) Check the voltage at the screw above the LED "D7" with a DC voltage tester to see if the remaining voltage is not higher than 50 V. Check that the voltage is not higher than 50V. 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 (3) Turn the retaining pin at the top of the amplifier 90 degrees counterclockwise. (At the middle of the top of the amplifier, there is an M5 screw that fastens the amplifier during transport of the cabinet. After the installation of the cabinet, remove the screw. This improves maintainability.) Fixation screw for transport http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 217/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (4) Holding the handles located at the top and bottom of the amplifier, pull out the amplifier toward you. B-82595EN-2/04 MAINTENANCE 7.REPLACING A UNIT (5) Pull the amplifier up while keeping it slanted. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 218/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 7.REPLACING A UNIT MAINTENANCE 7.8 REPLACING I/O UNIT-MODEL A 7.8.1 Replaci ng the Base Unit of I/O Unit-MODEL A B-82595EN-2/04 First, dismount modules from base2unit of I/O A. The base unit retainedthe with 4 screws. Of thesethe screws, loosen thethe upper screws andUnit-MODEL remove the lower 2 screws, thenisreplace base unit. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 219/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Details of section A Fig.7.8.1 Replacing the base unit of I/O unit mo del A MAINTENANCE B-82595EN-2/04 7.8.2 7.REPLACING A UNIT Replacing a Module An interface module and input/output module can be easily installed in and removed from the base unit, as described below. Installing a module (1) Put the upper hook of the module into the upper hole of the base unit. (2) Fit the connectors of the module and the base unit to each other. (3) Push the module until the lower stopper of the module is caught in the lower hole of the base unit. Remov ing a modul e (1) Press the lever at the bottom of the module to release the stopper. (2) Lift the module up. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 220/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 7.REPLACING A UNIT 7.9 MAINTENANCE B-82595EN-2/04 REPLACING THE TEACH PENDANT AND i PENDANT The specifications of the teach pendant vary with its use. When you replace the teach pendant, check its specifications carefully. (1) Be sure that the power of a robot controller is off. (2) Detach the cable from the teach pendant. (3) Replace the teach pendant. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 221/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Detach or attach the cable by rotating the connector retaining ring. Fig.7.9 Replacing th e teach pendant 7.10 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 REPLACING THE CONTROL SECTION FAN MOTOR The control section fan motor can be replaced without using a tool. The fan motor is mounted on the fan unit rack. (1) Be sure that the power of a robot controller is off. (2) Put your finger in the dent in the upper section of the fan unit, and pull the fan unit until it is unlatched. (3) Lift the fan unit slightly, and dismount it from the rack. (4) Place a replacement fan on the upper section of the rack, and slide it gently until it is latched. Fan motor Dent http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 222/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Pull the fan motor unit toward you to unlatch it. Fan motor connector Fig.7.10 Replacing t he control section fan motor 7.REPLACING A UNIT 7.11 MAINTENANCE B-82595EN-2/04 REPLACING THE AC FAN MOTOR WARNING Do not touch the fan motor when it is rotating, or you could be injured. 7.11.1 Replacing the Heat Exchanger and Door Fan Unit (A-cabinet) The heat exchanger of the A-cabinet is inside its door. To replace the heat exchanger, it is necessary to remove the door fan unit in advance. Door fan unit (1) Remove retaining screws (M4, 4 places). (2) Detach the cable from the heat exchanger. (3) Mount the replacement fan unit by reversing the removal procedure. Be careful not to let the cable get caught in the fan. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Heat exchanger 223/483 (1) Dismount the fan unit from the door. (See the above procedure.) (2) Open the A-cabinet door, and detach cables. 7/17/2019 (3) Remove retaining nuts (M5, 4 places), and dismount the unit. MANUTENÇÃO ROBO FANUC.pdf (4) Mount the replacement heat exchanger by reversing the dismounting procedure. Door fan Screws (4-M4) 7.11.2 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 Replacing External Air Fan Unit (A-cabinet) The external air fan unit has two fans mutually connected with a cable. When the fan unit is replaced, the cable is replaced together with the fan unit. (1) thethe retaining of the louver, (see Section 7.1.3) with the louver.) (2) Loosen In case of Side fanscrews type, detach the fan then unit.remove (The fanit is fastened together In case of the Rear fan type, loosen four retaining M4 screws from the Rear fan unit, and then detach the fan unit. (3) Detach the fan unit lead-out cable and grounding wire. (The cable is terminated with a connector. The grounding wire is fastened with a screw.) (4) Replace the fan unit with a new one. Screws (4-M4) used to fasten both the fan unit and louver. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 224/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf The fan cable is attached using an in-line connector. (Side fan type) Screws M4 (4 places) 7.REPLACING A UNIT 7.11.3 MAINTENANCE B-82595EN-2/04 Replacing External Fan Unit and Door Fan (B-cabinet) Door fan (1) Detach the cable from the fan unit. (2) Remove the retaining screws from the fan unit, then dismount it. (3) Install a new fan unit by reversing the dismounting procedure. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 225/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (Replacin g the Door Fan Unit ) External fan uni t (1) Detach the cable connecting the fan unit. (2) Remove the screws and pull out the fan unit toward you. (3) Install a new fan unit by reversing the dismounting procedure. MAINTENANCE B-82595EN-2/04 7.12 7.REPLACING A UNIT REPLACE THE MODE SWITCH (1) Remove the cable from the mode switch. (2) Remove the screws fastening the mode switch, and replace the mode switch. NOTE 1 When mounting the mode switch, do not overtighten the screws. (Tightening torque: 0.3 N⋅m) 2 Tighten the screws evenly so that the mode switch flat surface becomes parallelto the sheet metal. Mode switch http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 226/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig. 7.12 (a) Replacin g t he mod e swit ch (1/3) 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 A (Back plane of operator’s panel) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 227/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Details of section A Tightening torque: 0.3N⋅m Fig. 7.12 (b) Replacin g th e mode sw itch (2/3) MAINTENANCE B-82595EN-2/04 7.13 7.REPLACING A UNIT REPLACING FUSES If a fuse in the control unit has blown, find the cause and take an appropriate measure before replacing the fuse. 7.13.1 Replacing Fuses in the Servo A mpli fier The following fuses are in the servo amplifier. FS1: For generation of the power to the amplifier control circuit (A60L-0001-0290#LM32C) FS2: For protection of the 24 V output to the end effector, XROT, and XHBK (A60L-0001-0290#LM32C) FS3: For protection of the 24 V output to the regenerative resistance and the additional axis amplifier (A60L-0001-0290#LM50C) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 228/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CRR88 5A 3 2A 3 2A 7.REPLACING A UNIT 7.13.2 MAINTENANCE B-82595EN-2/04 Replacing Fuses in t he Power Unit The following fuses are in the power unit. F1: Fuse for the AC input, A60L-0001-0450#8RO F3: Fuse for protecting the +24E output, A60L-0001-0046#7.5 F4: Fuse for protecting the +24V output, A60L-0001-0046#7.5 F1 8.0A Fuse for AC input Details of section A F3 7.5A Fuse for +24E http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 229/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf F4 7.5A Fuse for +24V Details of section B Fig.7.13.2 Replacing fuses in the power unit MAINTENANCE B-82595EN-2/04 7.13.3 7.REPLACING A UNIT Replacing Fuses in t he Main board The following fuses are in the power unit. FU1: For protection of the +12V output for the vision sensor, A60L-0001-0175#0.5A 75173 (receiver) * Total edition 09B or earlier 75172 (driver) * Total edition 09B or earlier CPU card http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 230/483 7/17/2019 FROM/SRAM module MANUTENÇÃO ROBO FANUC.pdf (under the axis control card) Axis control card Fuse (0.5 A) * Total edition 06B or later Fig.7.13.3 Replacing fu ses in the main bo ard 7.REPLACING A UNIT 7.13.4 MAINTENANCE B-82595EN-2/04 Replacing the Fuse on t he Process I/O Boards The following fuse is on each process I/O board. FUSE1: Fuse for protecting the +24V output for peripheral equipment interfaces. A60L-0001-0046#2.0 Process I/O board CA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 231/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig. 7.13.4 (a) Process I/O board CA Process I/O board EA, EB Fuse location is common to EA and EB. The following is figure of EA. MAINTENANCE B-82595EN-2/04 7.REPLACING A UNIT Process I/O board FA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Fig. 7.13.4 (c) Process I/O board FA 232/483 7/17/2019 Process I/O board GA 7.REPLACING A UNIT MANUTENÇÃO ROBO FANUC.pdf MAINTENANCE B-82595EN-2/04 Process I/O board HA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Fig. 7.13.4 (e) Process I/O board HA 233/483 Process I/O board JA , JB 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fuse location is common to JA and JB. The following is figure of JA. B-82595EN-2/04 MAINTENANCE 7.REPLACING A UNIT Process I/O board K A, KB, KC Fuse location is common to KA, KB and KC. The following is figure of KA. LED FUSE1 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 234/483 Fig. 7.13.4 (g) Proc ess I/O Bo ard K A (A16B-2204-0050) MANUTENÇÃO ROBO FANUC.pdf 7/17/2019 LED FUSE1 7.REPLACING A UNIT 7.13.5 MAINTENANCE B-82595EN-2/04 Replacing the Fuse on t he Panel Board The following fuse is on the panel board. FUSE1: For protection of the +24EXT line (emergency stop line) FUSE2: For protection of the teach pendant emergency stop line A60L-0001-0046#1.0 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 235/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf FUSE2 (1A) FUSE1 (1A) (Panel b oard) Fig.7.13.5 Replacing th e fuse on t he panel board 7.14 REPLA CING RELAYS Prolonged use of a relay might result in its contacts failing to make a secure connection or sticking to each other permanently. If such a failure occurs, replace the relay. 7.14.1 Replacing Relays on the Panel Board KA21, KA22: Relay for emergency stop circuit A58L-0001-0192#1997R 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 KA22 Fig.7.14.1 Replacing relays o n the panel b oard http://slidepdf.com/reader/full/manutencao-robo-fanucpdf KA21 236/483 7.15 REPLA CING B ATTERY 7.15.1 Battery f or Memory Backu p (3 VDC) 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf The programs and system variables are stored in the SRAM in the main board. The power to the SRAM memory is backed up by a lithium battery mounted on the front panel of the main board. The above data is not lost even when the main power of controller is turned off. A new battery can maintain the contents of memory for about 4 years (Note). When the voltage of the battery becomes low, the low-voltage battery alarm (system-035) is displayed on the teach pendant. When this alarm is displayed, replace the battery as soon as possible. In general, the battery can be replaced within one or two weeks, however, this depends on the system configuration. If the battery voltage gets lower, it becomes impossible to back up the content of the SRAM. Cycling power to the controller in this state causes system not to start, and LED located on the main board displays "1" because the contents of memory have been lost. Clear the entire SRAM memory and reenter data after replacing the battery. Important data should be saved to the memory card or other external device beforehand in case of emergency. NOTE In a newly introduced robot the battery is factory installed Battery replacement 7.REPLACING A UNIT MAINTENANCE B-82595EN-2/04 (3) Turn the robot controller off. (4) Remove the old battery from the top of the main board. First, unlatch the battery, remove it from the battery holder, and detach its connector. Lithium battery Battery connector Battery latch http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 237/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (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 explosion. Replace the battery only with the specified battery (A02B-0200-K102). Dispose of the replaced battery as an industrial waste, according to the laws and other rules in the country wherejurisdiction the controller installed and the those established by the municipality and other organizations that have overisthe area where controller is installed B-82595EN-2/04 8 MAINTENANCE 8.HOW TO USE THE PLATE TO FIX THE COMPACT FLASH MEMORY CARD HOW TO USE THE PLATE TO FIX THE COMPACT FLASH MEMORY CARD Optional plate to fix the compact flash memory card (CF card) can make it possible to perform a back-up on fixing the CF card on the main board. Parts Fixing plate Adapter for CF card (made by Fanuc) 1. Adapter for CF card (Made by Fanuc) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 238/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Compact flash memory card (The card is not included. It must be supplied by the customer.) 2. Fixing plate Main board 8.HOW TO USE THE PLATE CARD TO FIX THE COMPACT FLASH MEMORY MAINTENANCE B-82595EN-2/04 - Install ation of the CF card 1. Insert the CF card into the Adapter. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 2. Lock the latch, and drive the screw. 239/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf - Removal of the CF card 1. Loosen the screw, and unlock the latch. 2. Pull the CF card out of the Adapter. III. CONNECTIONS http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 240/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 241/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CONNECTIONS B-82595EN-2/04 1 1.GENERAL GENERAL This section describes the electrical interface connections in the R-30iA. It also includes information about installation of the R-30 iA. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 242/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 243/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 2.BLOCK DIAGRAM 2 CONNECTIONS B-82595EN-2/04 BLOCK DIAGRAM Fig.2 is a block diagram of electrical interface connections with the R-30 iA. R-30i A (A-cabinet) Pneumatic pressure source Mechanical unit End effect or USB memory (Note2) Teach pendant Operation box http://slidepdf.com/reader/full/manutencao-robo-fanucpdf RS-232-C (Note3) Peripheral device 244/483 Welding machine MANUTENÇÃO ROBO FANUC.pdf 7/17/2019 Memory card (PCMCIA) Ethernet AC power supply Fig.2 (a) Block Diagram of Electrical Int erface Conn ection (A-cabinet) NOTE 1 : Indicates electrical connection. -------- : Indicates mechanical connection. 2 In case the length of the connection cable between A-cabinet and Operation box is 10m or longer, there is the USB interface panel and RS-232-C interface on the CONNECTIONS B-82595EN-2/04 R-30iA (B-cabinet) 2.BLOCK DIAGRAM Pneumatic pressure source Mechanical unit End effector USB memory Memory card (PCMCIA) Teach pendant RS-232-C Peripheral device http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 245/483 Welding machine 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Ethernet AC power supply Fig.2 (b) Block Diagram of Electr ical Interface Connectio n (B-cabinet) NOTE 1 : Indicates electrical connection. -------- : Indicates mechanical connection. 2 For more information, contact our service section. 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 3 ELECTRICAL CONNECTIONS 3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS R-30iA Robot Servo amplifier CRF8 RP1 (Pulsecoder, RI/RO, (Pulsecoder, RI/RO , XHBK, XROT) XHBK, XROT) RCC I/F UNIT (M-900iA,M-2000iA ONLY) CNJx (Motor power) CNGx http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (Ground) RM1 (Motor power/brake) RM2 (Motor power) End effector EE (Note1) 246/483 CRR88 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig.3.1 (a) Mechanical conn ection diagram NOTE 1 This cable is not included. It must be supplied by the customer. CONNECTIONS B-82595EN-2/04 3.ELECTRICAL CONNECTIONS R-30iA Teach pendant (Panel board) Peripheral device (Process I/O) Port A (Operator's panel) Note 2 (Main board) Note 2 (Main board) External device Ethernet Circuit breaker Input power http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Panel board 247/483 Note 2 External power External power (TBOP3) ON/OFF switch 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Note 2 Panel board (TBOP4) External emergency stop switch Note 2 Panel board (TBOP4) Note 2 Panel board (TBOP4) Fence Servo off switch USB memory 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 3.2 EXTERNAL CABLE WIRING DIAGRAM 3.2.1 Robot Connectio n Cables CAUTION Before operating the robot, uncoil the interconnection cables from their shipping position to prevent excessive heat, which may damage the cables. (Coiled part should be shorter than 10 meter.) There are two types of the robot connection cable; Non-flex type: usage is restricted to fixed laying Flex type: possible to use in the cable track Specif ication of c able Non-flex type Robot Diameter (mm) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Weight (kg/m) Flex type Minimum bending radius (mm) Diameter (mm) Weight (kg/m) Minimum bending radius (mm) 248/483 RP1 7/17/2019 RM1 RM2 RP1 RM1 RMP1 RP1 RM1 EARTH All models Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 3 Group 4 15.7 26.1 20.0 26.1 26.1 26.1 20.0 26.1 26.1 0.45 1.22 0.7 1.22 1.22 1.22 0.7 1.22 1.22 200 200 200 200 200 200 200 200 200 20.5 0.71 200 25.4 1.2 200 MANUTENÇÃO ROBO FANUC.pdf 18.4 0.7 200 25.4 1.2 200 25.4 1.2 200 25.4 1.2 200 25.4 1.2 200 25.4 1.2 200 Group 5 26.1 15.7 20.0 14.2 20.0 4.7 1.22 0.45 0.7 0.31 0.7 0.065 200 200 200 200 200 200 25.4 20.5 18.4 4.7 Group 7 Group 8 All models 1.2 0.71 0.7 0.065 Group1 R-2000iB (except /200T), M-420iA, M-421iA, M-710iC, R-1000iA Group2 G 3 ARC Mate 100iB, ARC Mate 120iB, M-6iB, M-16iB, F-200iB R 2000iB/200T M 410iB B-82595EN-2/04 CONNECTIONS 200 200 200 200 3.ELECTRICAL CONNECTIONS Robot Model Group1: R-2000iB (expect /200T), M-420iA, M-421iA, M-710iC, R-1000iA Robot Model Group2: ARC Mat e 100iB, ARC Mate 120iB, M-6iB, M-16iB, F-200iB In case of A-cabinet http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 249/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf RI/RO,XHBK,XROT (Connection A-cabinet and Robot) 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 In case of B-cabinet http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 250/483 RI/RO,XHBK,XROT 7/17/2019 (Connection B-cabinet and Robot) R-30iA (Servo amplifier) CRR88 CNGA MANUTENÇÃO ROBO FANUC.pdf Robot CNJ3A CNJ6 CNGC RP1 CRF8 (Pulsecoder, RI/RO, XHBK, XROT) RM1 Motor power/brake (J1M, J2M, J3M, J4M, J5M, J6M, BK) CNJ1A CNJ2A CNJ4 B-82595EN-2/04 CNJ5 CONNECTIONS 3.ELECTRICAL CONNECTIONS Robot Model Group 3: R-2000iB/200T, M-410iB In case of A-cabinet http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 251/483 RI/RO,XHBK,XROT 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (Connection A-cabinet and Robot) 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 In case of B-cabinet http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 252/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf RI/RO,XHBK,XROT (Connection B-cabinet and Robot) R-30iA (Servo amplifier) CRR88 Robot CNGA CNJ3A CNGC CNJ3B CNJ6 CNGB RP1 CRF8 (Pulsecoder, RI/RO, XHBK, XROT) RM1 Motor power/brake (J1M, J2M, J3M, J4M, J5M, J6M, BK) B-82595EN-2/04 CONNECTIONS 3.ELECTRICAL CONNECTIONS Robot Model Group 4: M-900iA/260L, M-900iA/350 In case of B-cabinet http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 253/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf RI/RO,XHBK,XROT (Connection B-cabinet and Robot) R-30iA (Servo amplifier) CRR88 Robot CNGA CNJ3A CNGC CNJ3B CNJ6 RCC I/F UNIT A 1 M R B 1 M R A 2 M R B 2 M R CNGB RP1 CRF8 (Pulsecoder, RI/RO, XHBK, XROT) RM1 Motor power/brake 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 Robot Model Group 5: M-900iA/400L, M-900iA/600 In case of B-cabinet http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 254/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf RI/RO,XHBK,XROT (Connection B-cabinet and Robot) 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 R-30iA Robot 6-Axis Servo amplifier (AMP1) CRR88 CNGA CNJ3A CNJ3B CNGB RP1 CRF8 (Pulsecoder, RI/RO, XHBK, XROT) RM1 Motor power/brake (J1M, J2M, J3M, J4M, J5M, J6M, BK) RM2 Motor power CNJ1B CNJ2B CNJ1A CNJ2A (J1M, J2M, J3M, J4M, J5M, J6M) 2-Axis Servo amplifier (AMP2) JF1 CZ2L http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A 1 M R B 1 M R A 2 M R B 2 M R 255/483 JF2 RCC I/F UNIT CZ2M 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 1-Axis Servo amplifier (AMP3) JF CZ2 (Detail of cable connection to servo amplifier) Fig. 3.2.1 (d) Robot co nnecti on cabl e (Group 5) 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 Robot Model Group 6: M-430iA/2F In case of A-cabinet RI/RO,XHBK,XROT http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 256/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (Connection A-cabinet and Robot) B-82595EN-2/04 CONNECTIONS 3.ELECTRICAL CONNECTIONS In case of B-cabinet RI/RO,XHBK,XROT http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 257/483 (Connection B-cabinet and Robot) 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf R-30iA (Servo amplifier) CRR88 CNGA Robot CNJ3A CNJ6 CNGC CRF8 RP1 (Pulsecoder, RI/RO, XHBK, XROT) RM1 Motor power/brake CNJ1A CNJ2A CNJ4 CNJ5 J1MA J1MB J2MA J2MB J3MA Servo amplifier 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 Robot Model Group 7: M-430iA/2P In case of A-cabinet http://slidepdf.com/reader/full/manutencao-robo-fanucpdf RI/RO,XHBK,XROT 258/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (Connection A-cabinet and Robot) In case of B-cabinet CONNECTIONS B-82595EN-2/04 3.ELECTRICAL CONNECTIONS Detail of cable connection to s ervo amplifier R-30iA (Servo amplifier) CRR88 CNGA Robot CNJ3A RMP1 CRF8 (Pulsecoder, RI/RO, XHBK, XROT) Motor power/brake CNJ1A CNJ5 Servo amplifier JF1 JF2 JF3 CZ2L CZ2M http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CZ2N 259/483 CZ2N 7/17/2019 ROBO FANUC.pdf Fig. 3.2.1(f) Robot Conn ection Cable (GroupMANUTENÇÃO 7) Robot Model Group 8: ARC Mate 100iC, ARC Mate 120iC, M-10iA, M-20iA In case of A-cabinet 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 In case of B-cabinet http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 260/483 RI/RO,XHBK,XROT 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (Connection B-cabinet and Robot) R-30iA (Servo amplifier) Robot CRR88 CNGA CNJ3A CNJ6 RMP1 CRF8 (Pulsecoder, RI/RO, XHBK, XROT) Motor power/brake CONNECTIONS B-82595EN-2/04 3.2.2 3.ELECTRICAL CONNECTIONS Teach Pendant Cable Panel board Teach pendant Teach pendant cable Operator panel box typ eB (A-cabinet) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 261/483 Panel board 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Teach pendant Teach pendant cable 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 Teach pendant cable Panel board Teach pendant http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 262/483 (B-cabinet) 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig.3.2.2 Teach p endant c able CONNECTIONS B-82595EN-2/04 3.2.3 Connecting t he Input Power 3.2.3.1 Connecting the input power cable 3.ELECTRICAL CONNECTIONS (1) Fig3.2.3 shows the method of connecting the input power supply cable. (2) Use the input power cable according to the following Table 3.2.3.1. However, the input power cable according to the breaker or the fuse of the input power supply (power distribution panel) connected to the robot controller must be used. (3) Provide a class-D or better ground. There shall be no switches or disconnects in the grounding conductor. The resistance to the ground must not exceed 100 Ω. Use a thick wire to withstand the maximum current used. Table 3.2.3.1 Condu ctor size and Terminal size of AC power su ppl y Input Voltage Input power source capacity (Refer t o CONNECTIONS 5.3) Conductor size of AC Power supply cable Terminal size of AC po wer supp ly cable Conductor size of earth cable Terminal size of earth cable All robot AWG10 or more (Note 1) M5 Note 2 M5 15KVAor more AWG8 or more (Note 1) M8 Note 2 M5 12KVAmore less AWG10 or more (Note 1) M5 Note 2 M5 400V 200V http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 200V 263/483 12KVAmore less 7/17/2019 more (Note 1) M5 Note 2 M5 MANUTENÇÃO ROBO FANUC.pdf WARNING 1 The input power cable according to the breaker or the fuse of the input power supply (power distribution panel) connected to the robot controller must be used. 2 Use conductor of earth cable size is as well as the AC power supply cable size. 3 Disconnection of protective earth ground may impair the protection provided by the system. 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 Need to Code grip. (hole sizeφ35) Input power cable Main Breaker Earth cable (M5) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Note）Always replace the cover after completing. 264/483 Fig3.2.3 (b) Integrated o peration box (A-cabinet) 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fix the cable. I CONNECTIONS B-82595EN-2/04 3.2.3.2 t bl 3.ELECTRICAL CONNECTIONS Leakage breaker (1) The motor is driven by the PWM inverter system using a power transistor bridge. A high-frequency leakage current flows through the stray capacitance between the ground and the motor coils, power cable, and amplifier. This might cause the leakage-current circuit breaker or leakage-protection relay installed in the path of the power supply to cut out. the following leakage current circuit breaker for electric inverterscurrent to prevent incorrect operation. (2) Use Leakage breaker using robot controller has sensitive of 30mA. Table 3.2.3.2 Example of l eakage current circu it br eaker for inverters Manufacture Fuji Electric Co., Ltd. Hitachi, Ltd. Matsushita Electric Works, Ltd. 3.2.3.3 Type EG A series or later SG A series or later ES100C type ES225C type Leakage current circuit breaker, C type Leakage current circuit breaker, KC type Check input voltage Setting of transformer tap is necessary depending on the input voltage. The tap is set to the specified voltage before shipment. However, check it referring to section 6.2 in "Maintenance" before supplying power (before the breaker switch is turned on). http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 265/483 3.2.3.4 7/17/2019 On/off t iming by the breaker MANUTENÇÃO ROBO FANUC.pdf If the power supply is turned on, turned off, and then turned on again repeatedly in a short time, the controller may not be started up. If the power is turned off before the controller is completely started up (it takes about 30 seconds), wait for at least 10 seconds before turning on the power again. TON-OFF ≦ 30 sec TOFF-ON ≥ 10 sec ON OFF Fig.3.2.3.4 The power is turned off within 30 seconds after it has been turned on 3.ELECTRICAL CONNECTIONS 3.2.4 CONNECTIONS B-82595EN-2/04 Connecting the External Power Suppl y ON/OFF Switch Panel board TBOP3 Operator panel box typeB (A-cabinet) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 266/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Panel board TBOP3 CONNECTIONS B-82595EN-2/04 3.ELECTRICAL CONNECTIONS Panel board http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 267/483 (B-cabinet) MANUTENÇÃO Fig.3.2.4 (a) Connecti on o f the external p ower su ppl y ON/OFF swi tch ROBO FANUC.pdf 7/17/2019 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 Dual-check speci ficati on (panel bo ard A20B-2101-0370) Short–circuit plate : between EXON1 and EXON2 EXON1 EXON2 EXOFF1 EXOFF2 When using the external ON/OFF switch, remove the short-circuit plate between EXOFF1 and EXOFF2, and attach the cable to these terminals. Contact specifications Withstand voltage: 50VDC (across contacts) Current: 100mA min. (min. load 2mA) EXOFF1-2 Close Open POWER ON http://slidepdf.com/reader/full/manutencao-robo-fanucpdf TOFF-ON ≥ 5 sec OFF 268/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf NOTE 1 When the external power supply ON/OFF switch is set to ON (closed), the controller can be turned on and off by using the circuit breaker. 2 When the external power supply ON/OFF switch is set to OFF (open), the controller cannot be turned on and off by using the circuit breaker. Fig.3.2.4 (b) Connectio n of th e external power sup ply sw itch ON and OFF 3.2.5 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 Connecting the External Emergency Stop Panel board TBOP4 TBOP3 TBOP6 Operator panel box typeB (A-cabinet) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 269/483 Panel boardMANUTENÇÃO ROBO FANUC.pdf 7/17/2019 TBOP4 TBOP3 TBOP6 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 Panel board (B-cabinet) Fig.3.2.5 (a) Conn ection of th e external emergency stop External emergency stop output Dual-check specification (panel board A20B-2101-0370) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 270/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf E S P B 4 1 D l h i fi ti ( lb TP emergency stop button E S P B 3 1 E S P B 3 E S P B 2 1 E S P B 2 E S P B 1 1 E S P B 1 d A20B 2101 0370) 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 Internal circuit k E S P B 4 Operator panel emergency stop button +24EXT KA21 0EXT 0EXT WARNING KA22 +24EXT ESPB1 ESPB11 ESPB2 In case of using contact of the emergency stop the output signal, be sure to pair ESPB1 with ESPB2, and ESPB3 with ESPB4. Robot controller does not detect the breakdown of the contact of the emergency stop output signal. Take countermeasures such as ESPB21 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf inspecting the duplicated ESPB41 contacts, or using a safety relay ESPB3 ESPB31 ESPB4 271/483 7/17/2019 circuit that breakdown. can detect the MANUTENÇÃO ROBO FANUC.pdf Example of the connection with the safety relay unit Robot controller Safety relay unit ESPB1 ESPB11 Control ESPB2 circuit ESPB21 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 External emergency sto p input External emergency stop switch Fence These terminals are factory-jumpered. When using external emergency stop inputs, remove the short-circuit plate. Servo ON/OFF input switch E E S 1 E E S 1 1 E E S 2 E E S 2 1 E A S 1 E A S 1 1 E A S 2 E A S 2 1 E G S 1 E G S 1 1 E G S 2 Servo disconnect switch signal E G S 2 1 SD4 SD41 SD5 SD51 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 272/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Signal Descripti on Current, voltage EES1 EES11 EES2 EES21 Connect the contacts of the external emergency stop switch to these terminals. When a contact is open, the servo power supply is turned off, and the robot is immediately placed in the emergency stop state. When using the contacts of a relay or contactor instead of the switch, connect a spark killer to the coil of the relay or contactor, to suppress noise. When these terminals are not used, jumper them. Open and close of 24VDC 0.1A (Note 1) EAS1 Th O i l dt t th f l h th Signal f t f t d l f 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 SD4 SD41 SD5 SD51 b t Descripti on Current, voltage Connect the contacts of the servo disconnect switch to these terminals. When a contact is open, the servo power supply is turned off, and the robot stops immediately. When using the contacts of a relay or contactor instead of the switch, connect a spark killer to the coil of the relay or contactor, to suppress noise. When these terminals are not used, jumper them. Open and close of 24VDC 0.1A (Note 1) NOTE 1 Use a contact which minimum load is 5 mA less. Examples of connection of duplicate safety signals Correct connection Wrong connection External emergency stop switch EES1 EES11 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf EES2 External emergency stop switch EES1 EES11 EES2 273/483 EES21 7/17/2019 EES21 MANUTENÇÃO ROBO FANUC.pdf Discrepancy in duplicate inputs results in an alarm. 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 Input timing of dup licate safety signals Duplicate inputs are used for signals such as the external emergency stop signal, safety fence signal, and servo off signal so that a response is made even when a single failure occurs. The statuses of these duplicate input signals must always be changed at the same timing according to the timing specifications provided in this section. The robot control unit always checks that the statuses of the duplicate inputs are the same, and if the control unit finds a discrepancy, it issues an alarm. If the timing specifications are not satisfied, an alarm may be issued because of a signal discrepancy. EES1 EAS1 EGS1 SD4 Close EES2 EAS2 EGS2 SD5 Close Open Open TDIF TDIF TOPEN http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 274/483 TOPEN 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf TDIF (input time difference)< 200msec TOPEN (input hold period) > 2sec Fig. 3.2.5(b) Input timing of duplicate safety signals CONNECTIONS B-82595EN-2/04 3.ELECTRICAL CONNECTIONS External power connection 0V 24V INT EXT0V EXT24V EXT http://slidepdf.com/reader/full/manutencao-robo-fanucpdf External power source +24V(±10%) more than 300mA EMC Compliant The relays for emergency stop input and output can be separated from controller’s power. Please connect 275/483 external +24V instead of internal +24V,if emergency stop output must not be effected controller’s power. 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Example of the connection In case of using the external power source In case of not using the external power source External power source EXT24V EXT24V 24V INT24V INT24V INT0V INT0V 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 Connecting external on/off and external emergency st op sign al input/outpu t wires 8-pole terminal block (TBOP3) 12-pole terminal block (TBOP4, 6) Jumper pin Operation lever 1. 2. 3. 4. 5. FANUC' s sp ec if icat io n Man uf ac tu rer 's specification (WAGO) Remark A63L-0001-0783#308 231-311/026-000 External emergency stop A63L-0001-0783#312 231-304/026-000 External ON/OFF A63L-0001-0783#902 A63L-0001-0783#131-M 231-902 231-131 2 pieces of 231-131 and operation manual are included in FANUC's specification Detach the plug connector block from the panel board. Insert the tip of a flat-blade screwdriver into the manipulation slot and push down its handle. Insert the end of the signal wire into the wire slot. Pull out the screwdriver. Attach the plug connector block to the panel board. Do not insert a wire into the wire hole of a plug connector or pull it out with the plug connector block mounted on the panel board; otherwise, the panel board may be damaged. FANUC recommends the lever (A05B-2400-K030) for connecting the signal wire to the plug connector block instead of Flat-blade screwdriver. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 276/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Signal wire CONNECTIONS B-82595EN-2/04 3.ELECTRICAL CONNECTIONS Wiring (1) Pull down the lever. (2) Push in the conductor while holding the lever. (3) Set the lever free. * And pull the conductor softly to check the clamping. * Don't pull strongly. Re lace the lever (1) Pull off the lever. to lose the lever. Be careful not (2) Hook the lever to the rectangle hole. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (3) Push down the lever until click in. 277/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fit to header (1) Push in the connector to header. (2) Please check if the latch is hooked to header. * Be careful to fit the 3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/04 Installation of "Jum er" (1) Attach levers to connector. (2) Hold down levers at the same time, then put the jumper into connector. * Please check the direction of the jumper. - - With two jumpers Availabilit of wires - Without jumpers * Max wire size 0 2.0mm2 (AWG14) (with "Ferrule") With jumper - Additional wire is available under the http://slidepdf.com/reader/full/manutencao-robo-fanucpdf jumper. Additional wire is not available under the jumper. 278/483 2 * Max wire size 0 0.5mm (AWG20) (with "Ferrule") 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Installation of "Ferrules" (3) Squeeze handles until ratchet mechanism is released. (1) Put the wire through the hole of ferrules. (4) Please check if the wire crimped correctly. (2) Introduce wire with ferrule into cramping station. CONNECTIONS B-82595EN-2/04 3.2.6 3.ELECTRICAL CONNECTIONS Connecting the Non-Teaching Enabling (NTED) Signal (CRM65) CRM65 (NTED) Fig. 3.2.6 Connectin g t he NTED Signal NTED signal is the signal to be able to connect with the switch that is same function as deadman switch on the teach pendant. In the auto mode, robot moves without reference to the state of the switch connected with NTED signal. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Refer to “APPENDIX A, Total connection Diagram Fig.A (e)” about NTED circuit. Input timing of NTED signal must comply with rules in the section “Input timing of duplicate safety 279/483 signals”. 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf NOTE After connecting NTED switch, be sure to check the operation of those switches, the emergency stop button on the operator’s panel/operation box, and the emergency stop button on the teach pendant. Enabling Device NTED1 NTED11 NTED2 3.ELECTRICAL CONNECTIONS 3.2.7 CONNECTIONS B-82595EN-2/04 Connecting the Aux iliary A xis Brake (CRR65 A/B) CRR65 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Fig.3.2.7 6-axis servo amplif ier 280/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CRR65 A/B A1 A2 A3 BKA1 B1 B2 B3 COMMON BKA2 COMMON CRR65 A/B connector manufactured by Tyco Electronics AMP k.k. (Specification Rece-housing 1-178129-6, Rece-contact 175218-2) Specification Tyco Electroni cs AMP Rece-housing Rece-contact 1-178129-6 175218-2 FANUC A63L-0001-0460#032KSX A63L-0001-0456#ASL B-82595EN-2/04 CONNECTIONS 3.2.8 3.ELECTRICAL CONNECTIONS Connecting the A uxil iary A xis Over Travel (CRM68) CRM68 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Fig.3.2.8 6-axis servo amplif ier 281/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CRM68 A1 A2 A3 AUXOT1 AUXOT2 CRM68 connector manufactured by Tyco Electronics AMP k.k. Specification Tyco Electroni cs AMP Rece-housing Rece-contact FANUC 1-1318120-3 1318107-1 A63L-0001-0812#R03SX A63L-0001-0812#CRM CONNECTIONS B-82595EN-2/04 3.ELECTRICAL CONNECTIONS 3.2.9 Connecting t he Operation Box The operation box is not connected to the controller in shipment in some robot models. In this case, connect the operation box connection cable to the operation box as following drawings. Also connect the input power cable and the teach pendant cable as described in section 3.2.2 and 3.2.3. JD1B Port (M4 NUT 3 Places) JRS15 CRM95 Signal Line http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Cable clamp Power Line 282/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 283/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 4. CONNECTIONS B-82595EN-2/04 4 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES R-30iA I/O peripheral device interfaces include printed circuit boards and a unit selected according to the applications. Table 4 lists details of the printed-circuit boards and units. of these boards and units. Figure 4 shows the locations Table 4 Peripheral Device Interface Types No . Name Drawing number DI Number of I/O points DO D/A 1 2 Process I/O board CA Process I/O board EA A05B-2500-J003 A05B-2500-J012 40 40 40 (sink type) 40 (sink type) 3 4 5 6 7 8 9 10 11 12 Process I/O board EB Process I/O board FA Process I/O board GA Process I/O board HA Process I/O board JA Process I/O board JB Process I/O board KA Process I/O board KB Process I/O board KC I/O Unit-MODEL A A05B-2500-J013 A05B-2500-J014 A05B-2500-J015 A05B-2500-J006 A05B-2500-J001 A05B-2500-J002 A05B-2500-J010 A05B-2500-J011 A05B-2500-J016 A05B-2502-J090 (Base and http://slidepdf.com/reader/full/manutencao-robo-fanucpdf interface unit) 2 2 A/D 6 3 40 40 (sink type) 0 0 96 96 (sink type) 0 0 40 40 (sink type) 2 0 40 40 (sink type) 2 0 96 96 (source type) 0 0 40 40 (source type) 0 0 40 40 (source type) 3 2 40 40 (source type) 2 0 40 40 (source type) 0 0 Depending on selected I/O module. Remarks Installed in back plane Installed in operation box Installed in operation box Installed in operation box Installed in operation box Installed in back plane Installed in back plane Installed in back plane Installed in operation box Installed in operation box Installed in operation box Common to both A and B-cabinet (five slots) 284/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf NOTE 1 General purpose I/O (DI/DO) is a number which subtract an exclusive signal from the table value. Example: Process I/ODI; board40 JB(Table value) – 18 (Exclusive DI)= 22 points General purpose General purpose DO; 40 (Table value) – 20 (Exclusive DO) = 20 points 2 When there are slave units on the I/O Link and the power for control to these slave units is supplied from other than the robot control unit, the power to the controller and the power to the slave units must be turned on and off at the following timings: a) The power to the slave units must be turned on before or when the power to 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS B-82595EN-2/04 Process I/O board (A-cabinet) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 285/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 4. CONNECTIONS B-82595EN-2/04 4.1 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM Following are a block diagram of the peripheral device interface and the specifications. 4.1.1 When Process I/O Board EA/EB/GA is Used (A-cabinet) A-cabinet Operation box Main Process I/O board board (1) JD1A JD1B EA/EB/GA CRM2A Panel board CP5A http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CRM2B (3) Peripheral device (4) (2) CP5 CRW1 or CRW7 (NOTE 2) CRW2 (5) 286/483 7/17/2019 Fig.4.1.1 Block di agram of th e process I/O board EA,MANUTENÇÃO EB and GA ROBO FANUC.pdf NOTE 1 CRW1 and CRW2 are not provided for process I/O board EB 2 In case of process I/O board EA: CRW1 In case of process I/O board GA: CRW7 Number (1) 4. Name Operation box connection cable PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Number (5) Remarks A05B-2501-H460 A05B-2501-H461 A05B-2501-H462 Connected length: 5m Connected length: 10m Connected length: 2m CONNECTIONS Name Welding device connection cable (Process I/O EA) (Fanuc interface / elbow) B-82595EN-2/04 Drawing number Remarks A05B-2501-J279 A05B-2501-J280 A05B-2501-J281 A05B-2501-J229 A05B-2501-J230 A05B-2501-J231 Connected length: 10m (one) CRW1 Connected length: 20m (one) CRW1 Connected length: 30m (one) CRW1 Connected length: 10m (one) CRW1 Connected length: 20m (one) CRW1 Connected length: 30m (one) CRW1 Welding device connection cable (Process I/O GA) A05B-2501-J282 A05B-2501-J283 A05B-2501-J284 A05B-2501-J232 A05B-2501-J233 A05B-2501-J234 A05B-2501-J285 A05B-2501-J286 Connected length: 10m (one) CRW7 Connected length: 20m (one) CRW7 Connected length: 30m (one) CRW7 Connected length: 10m (one) CRW7 Connected length: 20m (one) CRW7 Connected length: 30m (one) CRW7 Connected length: 10m (one) CRW7 Connected length: 20m (one) CRW7 (Fanuc interface / elbow) Welding device connection cable (Process I/O GA) (Fanuc interface / straight) A05B-2501-J287 A05B-2501-J235 A05B-2501-J236 A05B-2501-J237 Connected length: 30m (one) CRW7 Connected length: 10m (one) CRW7 Connected length: 20m (one) CRW7 Connected length: 30m (one) CRW7 Welding device connection cable (Process I/O EA) (Fanuc interface / straight) Welding device connection cable (Process I/O GA) (General-purpose interface / elbow) Welding device connection cable (Process I/O GA) (General-purpose interface / straight) 4.1.2 Drawing number When Process I/O Board FA is Used (A-cabinet) A-cabinet Operation box http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 287/483 Main 7/17/2019 board (1) JD1A JD1B Process I/O board FA MANUTENÇÃO ROBO FANUC.pdf Peripheral device CRM2A Panel board CRM2B (2) CP5A CRM2C CP5 CRM2D CRM4A 4. CONNECTIONS B-82595EN-2/04 Number (3) (4) (5) (6) Name Peripheral device connection cable (7) (8) Peripheral device connection cable 4.1.3 Drawing number A05B-2501-J203 A05B-2501-J204 A05B-2501-J205 A05B-2501-J253 A05B-2501-J254 A05B-2501-J255 (3) (4) (5) (6) (7) (8) PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Remarks Connected length: 10m (one) Connected length: 20m (one) Connected length: 30m (one) Connected length: 10m (one) Connected length: 20m (one) Connected length: 30m (one) When Process I/O Board CA/HA is Used (B-cabinet) Process I/O board CA/HA Main board JD1A (1) Peripheral JD1B (JD4A) CRM2A CRM2B JD1A (JD4B) (2) CRW1 or CRW7 (NOTE) (3) device (4) (5) CRW2 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Process I/O board CA/HA 288/483 JD1B (JD4A) 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CRM2A CRM2B JD1A (JD4B) CRW1 or CRW7 (NOTE) CRW2 Fig.4.1.3 Block d iagram of the pro cess I/O board CA/HA 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Number (5) CONNECTIONS Name Welding device connection cable (Process I/O CA) (Fanuc interface / elbow) Welding device connection cable (Process I/O CA) (Fanuc interface / straight) Welding device connection cable (Process I/O HA) (General-purpose interface / elbow) Welding device connection cable (Process I/O HA) (General-purpose interface / straight) Welding device connection cable (Process I/O HA)/ elbow) (Fanuc interface Welding device connection cable (Process I/O HA) (Fanuc interface / straight) 4.1.4 Drawing number B-82595EN-2/04 Remarks A05B-2502-J200 A05B-2502-J201 A05B-2502-J202 A05B-2502-J203 A05B-2502-J204 Connected length: 10m (one) CRW1 Connected length: 20m (one) CRW1 Connected length: 30m (one) CRW1 Connected length: 10m (one) CRW1 Connected length: 20m (one) CRW1 A05B-2502-J205 A05B-2502-J206 A05B-2502-J207 A05B-2502-J208 A05B-2502-J210 A05B-2502-J211 A05B-2502-J212 A05B-2502-J213 Connected length: 30m (one) CRW1 Connected length: 10m (one) CRW7 Connected length: 20m (one) CRW7 Connected length: 30m (one) CRW7 Connected length: 10m (one) CRW7 Connected length: 20m (one) CRW7 Connected length: 30m (one) CRW7 Connected length: 10m (one) CRW7 A05B-2502-J214 A05B-2502-J215 A05B-2502-J216 A05B-2502-J217 A05B-2502-J218 Connected length: 20m (one) CRW7 Connected length: 30m (one) CRW7 Connected length: 10m (one) CRW7 Connected length: 20m (one) CRW7 Connected length: 30m (one) CRW7 When Process I/O Board JA/JB i s Used (B-cabinet) Process I/O board Main http://slidepdf.com/reader/full/manutencao-robo-fanucpdf board JA/JB 289/483 JD1A (1) Peripheral device JD1B 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (3) CRMA5A (4) CRMA5B JD1A (5) (6) CRMA5C CRMA5D (7) CRMA6A (2) (8) CRMA6B Process I/O board JA/JB 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES NOTE The process I/O board JB has none of CRMA5C, CRMA5D, CRMA6A, and CRMA6B. Number (1) Name Drawing number Remarks I/O Link cable A05B-2502-J130 Between main board and process I/O (2) (3) (4) (5) (6) I/O Link cable Peripheral device connection cable (Process I/O JA, JB) (7) (8) Peripheral device connection cable (Process I/O JA) A05B-2502-J131 A05B-2502-J160 A05B-2502-J161 A05B-2502-J162 A05B-2502-J180 A05B-2502-J181 A05B-2502-J182 Between process I/O and process I/O Connected length: 10m (one) Connected length: 20m (one) Connected length: 30m (one) Connected length: 10m (one) Connected length: 20m (one) Connected length: 30m (one) 4.1.5 When Process I/O Board KA/KB/KC is Used (A-cabinet) A-cabinet Operation box Main board JD1A (1) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf JD1B Process I/O board KA/KB/KC Peripheral (3) device 290/483 CRMA5A (4) MANUTENÇÃO ROBO FANUC.pdf CRMA5B 7/17/2019 Panel board (2) CP5A (5) CP5 CRW10 Fig. 4.1.5 Block di agram of th e process I/O board KA/KB/KC 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Number CONNECTIONS Name Drawing number (3) (4) Peripheral device connection cable (5) B-82595EN-2/04 Remarks Welding machine connection cable (For process I/O board KB) (General interface/elbow type) A05B-2501-J050 A05B-2501-J051 A05B-2501-J052 A05B-2501-J053 A05B-2501-J054 A05B-2501-J055 Connection length of 10 m (one) Connection length of 20 m (one) Connection length of 30 m (one) Connection length of 3 m (one), CRW10 Connection length of 7 m (one), CRW10 Connection length of 14 m (one), CRW10 Welding machine connection cable (For process I/O board KA, KB) (FANUC interface/elbow type) A05B-2501-J056 A05B-2501-J057 A05B-2501-J058 Connection length of 3 m (one), CRW10 Connection length of 7 m (one), CRW10 Connection length of 14 m (one), CRW10 Integrated type Number Name Drawing number Remarks (1) Operator panel box connection cable A05B-2501-H481 (2) (3) (4) Process I/O board supply cable Peripheral device connection cable (5) Welding machine connection cable (For process I/O board KB) (General interface/elbow type) Welding machine connection cable A05B-2501-J151 A05B-2501-J080 A05B-2501-J081 A05B-2501-J082 A05B-2501-J083 A05B-2501-J084 A05B-2501-J085 A05B-2501-J086 Connection length of 10 m (one) Connection length of 20 m (one) Connection length of 30 m (one) Connection length of 3 m (one), CRW10 Connection length of 7 m (one), CRW10 Connection length of 14 m (one), CRW10 Connection length of 3 m (one), CRW10 (For process I/O board KA, KB) (FANUC interface/elbow type) A05B-2501-J087 A05B-2501-J088 Connection length of 7 m (one), CRW10 Connection length of 14 m (one), CRW10 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 291/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 4. CONNECTIONS B-82595EN-2/04 4.1.6 When I/O Unit -MODEL A is Used 4.1.6.1 In case of B-cabinet PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES B-cabinet E-Stop unit CP5A CP5A K26 Main board JD1A K25 J D 1 A B a c k p la n e (f iv e -l s o t) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf J D 1 B C P 3 2 Peripheral device Interface module K54 K54 K54 K54 292/483 K54 MANUTENÇÃO ROBO FANUC.pdf 7/17/2019 Fig.4.1.6.1 Block diagram o f I/O Unit -A (In case of B-cabinet) Cable numb er K25 K26 K54 4. Drawing number Name I/O Link cable I/O Link cable Peripheral device connection cable PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES - Remarks Included in A05B-2502-J090 Included in A05B-2502-J090 Must be supplied by the customer. - CONNECTIONS B-82595EN-2/04 B-cabinet Main board Process I/O board A05B-2502-J130 JD1A JD1B JD1A DC power is supplied from the back plane. Process I/O board A05B-2502-J131 JD1B Included in model A base unit A05B-2502-J090 E-stop unit JD1A I/O Unit-A Interface module JD1B JD1A CP5A CP32 Back plane (five-slot) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Fig.4.1.7.1 Block di agram of tw o or mo re process I/O printed cir cuit boards and I/O unit-MODEL A 293/483 (In case of B cabinet) 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 4.2 PERIPHERAL DEVICE INTERFACE COMBINATION Peripheral device interfaces can be used by using process I/O boards and the I/O Unit-MODEL A. 4.2.1 In Case of A-cabinet Only one of the following peripheral device interfaces can be used in A-cabinet. - Process I/O board EA Process I/O board EB 4. CONNECTIONS B-82595EN-2/04 4.2.2 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES In Case of B-cabinet One board or o ne unit is u sed Combination C Combination D Combination E Process I/O board CA/HA/JB (40 points/40 points) Process I/O board JA (96 points/96 points) I/O Unit-MODEL A Two boards/units are used in comb ination Combination CE Process I/O board CA/HA/JB (40 points/40 points) + I/O Unit-MODEL A Combination DC Process I/O board JA (96 points/96 points) + Process I/O board CA/HA/JB (40 points/40 points) Combination DD Combination DE Process I/O board JA (96 points/96 points) + Process I/O board JA (96 points/96 points) Process I/O board JA (96 points/96 points) + I/O Unit-MODEL A Three boards/units are used in combination Process I/O board JA (96 points/96 points) + Combination DCE Process I/O board CA/HA/JB (40 points/40 points) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf + I/O Unit-MODEL A 294/483 Process I/O board JA (96 points/96 points) + Process I/O board JA (96 points/96 points) + 7/17/2019 Combination DDE MANUTENÇÃO ROBO FANUC.pdf I/O Unit-MODEL A 4.3 PROCESS I/O BOARD SIGNALS There are 18 exclusive data inputs (DI) and 20 exclusive data outputs (DO) for a process I/O board. These signals are allocated to the process I/O board connected first when two or more printed boards are combined. (General signals DI/DO are allocated to the second and the following process I/O boards.) 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Connector numb er CRMA5A- 7 CRMA5A- 8 CRMA5A- 9 CRMA5A-10 CRMA5A-11 CRMA5A-12 CRMA5A-13 CRMA5A-14 CRMA5A-15 CRMA5A-16 CRMA5A-29 CRMA5A-30 CRMA5A-31 CRMA5A-32 CRMA5B- 1 CONNECTIONS Signal name B-82595EN-2/04 Descriptio n Remarks HOME ENBL RSR1 PNS1 RSR2 PNS2 Return to home position Operation enabled Robot service request Program number selection Robot service request Program number selection RSR3 PNS3 RSR4 PNS4 RSR5 PNS5 RSR6 PNS6 Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection Robot service request Program number selection RSR7 PNS7 RSR8 PNS8 PNSTROBE PROD START DI01 DI02 DI03 Robot service request Program number selection Robot service request Program number selection PNS strobe Start of automatic operation Peripheral device status Peripheral device status Peripheral device status Option Peripheral device status Peripheral device status Peripheral device status Peripheral device status General signal General signal General signal General signal CRMA5B- 2 DI04 CRMA5B- 3 DI05 CRMA5B- 4 DI06 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CRMA5B- 5 DI07 Option Option Option Option Option Option Option General signal General signal General signal 295/483 CRMA5B- 6 CRMA5B- 7 7/17/2019 CRMA5B- 8 CRMA5B- 9 CRMA5B-10 CRMA5B-11 CRMA5B-12 CRMA5B-13 CRMA5B-14 CRMA5B-15 CRMA5B-16 CRMA5B-29 CRMA5B-30 DI08 DI09 DI10 DI11 Peripheral device status Peripheral device status Peripheral device status Peripheral device status DI12 DI13 DI14 DI15 DI16 DI17 DI18 DI19 DI20 Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status Peripheral device status General signal General signal MANUTENÇÃO ROBO FANUC.pdf General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal General signal 4. CONNECTIONS B-82595EN-2/04 Connector numb er CRMA5A-46 CRMA5A-19 CRMA5A-20 CRMA5A-21 CRMA5A-22 CRMA5A-24 CRMA5A-25 CRMA5A-26 CRMA5A-27 CRMA5B-33 CRMA5B-34 CRMA5B-35 CRMA5B-36 CRMA5B-38 CRMA5B-39 Signal name PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Descriptio n Remarks SNO1 ACK2 SNO2 ACK3 SNO3 ACK4 Selected program number Option Robot service request acceptance Selected program number Option Robot service request acceptance Selected program number Option Robot service request acceptance SNO4 ACK5 SNO5 ACK6 SNO6 ACK7 SNO7 ACK8 SNO8 SNACK RESERVED DO01 DO02 DO03 DO04 DO05 DO06 Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Robot service request acceptance Selected program number Response signal to PNS Option Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal General signal General signal General signal General signal General signal General signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal General signal General signal General signal General signal CRMA5B-40 DO07 CRMA5B-41 DO08 CRMA5B-43 DO09 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CRMA5B-44 DO10 Option Option Option Option 296/483 CRMA5B-45 CRMA5B-46 7/17/2019 CRMA5B-19 CRMA5B-20 DO11 DO12 DO13 DO14 Peripheral device control signal General signal Peripheral device control signal General signal MANUTENÇÃO ROBO FANUC.pdf Peripheral device control signal General signal Peripheral device control signal General signal CRMA5B-21 CRMA5B-22 CRMA5B-24 CRMA5B-25 CRMA5B-26 CRMA5B-27 DO15 DO16 DO17 DO18 DO19 DO20 Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal Peripheral device control signal 4.4 4. INTERFACE FOR PERIPHERAL DEVICES PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Control unit General signal General signal General signal General signal General signal General signal CONNECTIONS B-82595EN-2/04 Peripheral device control interface A1 (Source type DO) CRMA5A 01 02 XIMSTP XHOLD 03 04 05 06 07 08 09 10 11 12 XSFSPD CSTOPI 13 14 15 16 17 18 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 0V 0V FAULT RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 19 ACK3/SNO3 33 34 CMDENBL SYSRDY 20 21 22 23 24 25 26 27 28 29 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 DOSRC1 ACK7/SNO7 ACK8/SNO8 SNACK RESERVED DOSRC1 PNSTROBE 35 36 37 38 39 40 41 42 43 44 PROGRUN PAUSED DOSRC1 HELD FAULT ATPERCH TPENBL DOSRC1 BATALM BUSY 30 31 32 PROD START DI01 DI02 45 46 47 48 49 50 ACK1/SNO1 ACK2/SNO2 DOSRC1 Peripheral device A1 +24E +24E Peripheral device control interface A2 (Source type DO) CRMA5B 01 DI03 02 DI04 19 DO13 03 DI05 20 DO14 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 04 DI06 21 DO15 05 DI07 22 DO16 33 34 35 36 37 DO01 DO02 DO03 DO04 DOSRC1 297/483 7/17/2019 06 07 08 09 DI08 DI09 DI10 DI11 23 24 25 26 DOSRC1 DO17 DO18 DO19 38 39 40 41 DO05 DO06 DO07 DO08 10 11 12 13 14 15 16 17 18 DI12 DI13 DI14 DI15 DI16 DI17 DI18 0V 0V 27 28 29 30 31 32 DO20 DOSRC1 DI19 DI20 DI21 DI22 42 43 44 45 46 47 48 49 50 DOSRC1 DO09 DO10 DO11 DO12 DOSRC1 MANUTENÇÃO ROBO FANUC.pdf Peripheral device A2 +24E +24E 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Control unit Peripheral device control interface A3 (Source type DO) CRMA5C 01 02 DI23 DI24 19 DO33 33 34 DO21 DO22 03 04 05 06 07 08 09 10 11 12 DI25 DI26 DI27 DI28 DI29 DI30 DI31 DI32 DI33 DI34 20 21 22 23 24 25 26 27 28 29 DO34 DO35 DO36 DOSRC2 DO37 DO38 DO39 DO40 DOSRC2 DI39 35 36 37 38 39 40 41 42 43 44 DO23 DO24 DOSRC2 DO25 DO26 DO27 DO28 DOSRC2 DO29 DO30 13 14 15 16 17 18 DI35 DI36 DI37 DI38 0V 0V 30 31 32 DI40 DI41 DI42 45 46 47 48 49 50 DO31 DO32 DOSRC2 Peripheral device A3 +24E +24E Peripheral device control interface A4 (Source type DO) CRMA5D 01 DI43 02 DI44 19 DO53 03 DI45 20 DO54 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 04 DI46 21 DO55 33 34 35 36 DO41 DO42 DO43 DO44 298/483 7/17/2019 4. 05 06 07 08 09 10 11 12 13 14 15 16 17 18 DI47 DI48 DI49 DI50 DI51 DI52 DI53 DI54 DI55 DI56 DI57 DI58 0V 0V 22 23 24 25 26 27 28 29 30 31 32 DO56 DOSRC2 DO57 DO58 DO59 DO60 DOSRC2 DI59 DI60 DI61 DI62 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 37 38 39 40 41 42 43 44 45 46 47 48 49 50 DOSRC2 DO45 DO46 DO47 DO48 DOSRC2 DO49 DO50 DO51 DO52 DOSRC2 MANUTENÇÃO ROBO FANUC.pdf Peripheral device A4 +24E +24E CONNECTIONS B-82595EN-2/04 Control unit Peripheral device control interface B1 (Source type DO) CRMA6A 01 02 DI63 DI64 08 09 DO65 DO66 14 15 DO61 DO62 03 04 05 06 07 DI65 DI66 DI67 DI68 DI69 10 11 12 13 DO67 DO68 DOSRC3 DI70 16 17 18 19 20 DO63 DO64 DOSRC3 +24E 0V Peripheral device B1 Peripheral device control interface B2 (Source type DO) CRMA6B 01 02 03 04 05 06 07 DI71 DI72 DI73 DI74 DI75 DI76 DI77 Terminal block 08 09 10 11 12 13 DO73 DO74 DO75 DO76 DOSRC3 DI78 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf TBSRC3 14 15 16 17 18 19 20 DO69 DO70 DO71 DO72 DOSRC3 +24E 0V Peripheral device B2 299/483 1 2 7/17/2019 DOSRC3 0V MANUTENÇÃO ROBO FANUC.pdf NOTE 1 The peripheral device connection cables are optional. 2 The DOSRC3 pins of the CRMA6A and CRMA6B are pins for supplying power to drivers. (None of these pins can be left open.) 3 When the level of the voltage applied to the load is insufficient for a cause such as a too long peripheral device connection cable, supply power from the 4. CONNECTIONS B-82595EN-2/04 Control unit (peripheral device control interface A1) PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Peripheral device +24E Connector pin No. CRMA5A (49,50) Receiver circuit RV 3.3k *HOLD RV *IMSTP *SFSPD 0V RV START RV HOME RV ENBL RV RSR1/PNS1 RV RSR2/PNS2 RV RSR3/PNS3 RV RV RSR4/PNS4 RSR5/PNS5 RV RSR6/PNS6 RV RSR7/PNS7 RV CRMA5A (2) CRMA5A (3) RV Set this jumper according to the common CSTOPI RV voltage of input devices. (ICOM1) FAULT RESET CRMA5A (1) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CRMA5A (4) CRMA5A (5) CRMA5A (6) CRMA5A (7) CRMA5A (8) CRMA5A (9) CRMA5A (10) CRMA5A (11) CRMA5A (12) CRMA5A (13) CRMA5A (14) CRMA5A (15) 300/483 7/17/2019 CRMA5A (16) RSR8/PNS8 RV PNSTROBE RV PROD START DI01 RV RV CRMA5A (31) DI02 RV CRMA5A (32) CRMA5A (29) MANUTENÇÃO ROBO FANUC.pdf CRMA5A (30) COM-1 RV +24E CRMA5A (17,18) B A 0V Set this jumper according to the 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS Control unit (peripheral device control interface A1) DOSRC1(1) B-82595EN-2/04 Peripheral device DOSRC1 Connector pin No. CRMA5A (23,28,37,42,47) +24V 0V +24V regulated power supply Driver circuit DV LOAD CMDENBL CRMA5A (33) SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL DV DV DV DV DV DV DV DV BATALM BUSY DV ACK1/SNO1 DV ACK2/SNO2 DV CRMA5A (34) CRMA5A (35) CRMA5A (36) CRMA5A (38) CRMA5A (39) CRMA5A (40) CRMA5A (41) CRMA5A (43) CRMA5A (44) CRMA5A (45) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CRMA5A (46) RELAY LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD 301/483 ACK3/SNO3 7/17/2019 ACK4/SNO4 DV DV CRMA5A (19) CRMA5A (20) LOAD MANUTENÇÃO ROBO FANUC.pdf LOAD CRMA5A (21) ACK5/SNO5 ACK6/SNO6 DV DV ACK7/SNO7 DV ACK8/SNO8 SNACK RESERVED DV DV DV LOAD LOAD CRMA5A (22) CRMA5A (24) LOAD CRMA5A (25) LOAD CRMA5A (26) LOAD CRMA5A (27) LOAD 4. CONNECTIONS B-82595EN-2/04 Control unit (peripheral device control interface A2) PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Peripheral device +24E Connector pin No. CRMA5B (49,50) Receiver circuit DI03 RV 3.3k DI04 RV DI05 RV DI06 RV DI07 RV DI08 RV DI09 RV DI10 RV DI11 RV DI12 RV DI13 RV DI14 RV RV DI15 DI16 RV RV DI17 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf RV DI18 CRMA5B (1) CRMA5B (2) CRMA5B (3) CRMA5B (4) CRMA5B (5) CRMA5B (6) CRMA5B (7) CRMA5B (8) CRMA5B (9) CRMA5B (10) CRMA5B (11) CRMA5B (12) CRMA5B (13) CRMA5B (14) CRMA5B (15) CRMA5B (16) 302/483 7/17/2019 DI19 RV DI20 RV DI21 DI22 RV RV CRMA5B (29) CRMA5B (30) MANUTENÇÃO ROBO FANUC.pdf CRMA5B (31) COM-2 CRMA5B (32) RV +24E CRMA5B (17,18) B A 0V Set this jumper according to the common voltage of input devices. (ICOM2) 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 0V CONNECTIONS Control unit (peripheral device control interface A2) DOSRC1(1) B-82595EN-2/04 Peripheral device DOSRC1 Connector pin No. CRMA5B (23,28,37,42,47) +24V 0V +24V regulated power supply Driver circuit DV LOAD DO01 CRMA5B (33) DO02 DO03 DO04 DO05 DO06 DO07 DO08 DV DV DV DV DV DV DV DV DO09 DO10 DO11 DV DV http://slidepdf.com/reader/full/manutencao-robo-fanucpdf DO12 DV CRMA5B (34) CRMA5B (35) CRMA5B (36) CRMA5B (38) CRMA5B (39) CRMA5B (40) CRMA5B (41) CRMA5B (43) CRMA5B (44) CRMA5B (45) CRMA5B (46) RELAY LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD 303/483 DO13 7/17/2019 CRMA5B (19) DV DO14 DV DO15 DO16 DV DV DO17 DV CRMA5B (20) LOAD MANUTENÇÃO ROBO FANUC.pdf LOAD CRMA5B (21) DO18 DO19 DO20 LOAD LOAD CRMA5B (22) CRMA5B (24) LOAD CRMA5B (25) DV LOAD CRMA5B (26) DV LOAD CRMA5B (27) DV LOAD 4. CONNECTIONS B-82595EN-2/04 Control unit (peripheral device control interface A3) PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Peripheral device +24E Connector pin No. CRMA5C (49,50) Receiver circuit DI23 RV DI24 RV DI25 RV DI26 RV DI27 RV DI28 RV DI29 RV DI30 RV DI31 RV DI32 RV DI33 RV DI34 RV DI35 RV DI36 RV CRMA5C (1) 3.3k RV DI37 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf RV DI38 CRMA5C (2) CRMA5C (3) CRMA5C (4) CRMA5C (5) CRMA5C (6) CRMA5C (7) CRMA5C (8) CRMA5C (9) CRMA5C (10) CRMA5C (11) CRMA5C (12) CRMA5C (13) CRMA5C (14) CRMA5C (15) CRMA5C (16) CRMA5C (29) 304/483 7/17/2019 DI39 RV DI40 RV DI41 DI42 RV RV CRMA5C (29) CRMA5C (30) MANUTENÇÃO ROBO FANUC.pdf CRMA5C (31) COM-3 RV +24E CRMA5C (32) CRMA5C (17,18) B A 0V Set this jumper according to the common voltage of input d i (ICOM3) 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 0V CONNECTIONS Control unit (peripheral device control interface A2) TBSRC2(1) B-82595EN-2/04 Peripheral device DOSRC2 Connector pin No. CRMA5C (23,28,37,42,47) +24V 0V +24V regulated power supply Driver circuit DV LOAD DO21 CRMA5C (33) DO22 DV DO23 DV DO24 DV DO25 DO26 DO27 DO28 DO29 DO30 DO31 DV DV DV DV DV DV DV CRMA5C (34) CRMA5C (35) CRMA5C (36) CRMA5C (38) CRMA5C (39) CRMA5C (40) CRMA5C (41) CRMA5C (43) CRMA5C (44) CRMA5C (45) CRMA5C (46) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf DV DO32 CRMA5C (19) RELAY LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD 305/483 DO33 7/17/2019 DO34 DV LOAD CRMA5C (20) DV MANUTENÇÃO ROBO FANUC.pdf LOAD CRMA5C (21) DO35 DO36 DV DV DO37 DV DO38 DO39 DO40 LOAD LOAD CRMA5C (22) CRMA5C (24) LOAD CRMA5C (25) DV LOAD CRMA5C (26) DV LOAD CRMA5C (27) DV LOAD 4. CONNECTIONS B-82595EN-2/04 Control unit (peripheral device control interface A4) PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Peripheral device +24E Connector pin No. CRMA5D (49,50) Receiver circuit DI43 RV DI44 RV DI45 RV DI46 RV DI47 RV DI48 RV DI49 RV DI50 RV DI51 RV DI52 RV DI53 RV DI54 RV DI55 RV DI56 RV DI57 RV CRMA5D (1) 3.3k http://slidepdf.com/reader/full/manutencao-robo-fanucpdf RV DI58 CRMA5D (2) CRMA5D (3) CRMA5D (4) CRMA5D (5) CRMA5D (6) CRMA5D (7) CRMA5D (8) CRMA5D (9) CRMA5D (10) CRMA5D (11) CRMA5D (12) CRMA5D (13) CRMA5D (14) CRMA5D (15) CRMA5D (16) CRMA5D (29) 306/483 7/17/2019 DI59 RV DI60 RV CRMA5D (30) MANUTENÇÃO ROBO FANUC.pdf CRMA5D (31) DI61 DI62 COM-4 RV RV CRMA5D (32) RV +24E CRMA5D (17,18) B A 0V Set this jumper according to the common voltage of input devices. (ICOM4) 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 0V CONNECTIONS Control unit (peripheral device control interface A4) DOSRC2(1) B-82595EN-2/04 Peripheral device DOSRC2 Connector pin No. CRMA5D (23,28,37,42,47) +24V 0V +24V regulated power supply Driver circuit DV LOAD DO41 CRMA5D (33) DO42 DO43 DO44 DO45 DO46 DO47 DO48 DO49 DO50 DO51 DV DV DV DV DV DV DV DV DV DV DV http://slidepdf.com/reader/full/manutencao-robo-fanucpdf DO52 CRMA5D (34) CRMA5D (35) CRMA5D (36) CRMA5D (38) CRMA5D (39) CRMA5D (40) CRMA5D (41) CRMA5D (43) CRMA5D (44) CRMA5D (45) CRMA5D (46) CRMA5D (19) RELAY LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD 307/483 DV DO53 DV DO54 7/17/2019 LOAD CRMA5D (20) LOAD ROBO FANUC.pdf MANUTENÇÃO CRMA5D (21) DO55 DO56 DV DV DO57 DV CRMA5D (24) DO59 LOAD CRMA5D (26) DV DO60 LOAD CRMA5D (25) DV DO58 LOAD LOAD CRMA5D (22) LOAD CRMA5D (27) DV LOAD 4. CONNECTIONS B-82595EN-2/04 Control unit (peripheral device control interface B1) PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Peripheral device +24E Connector pin No. CRMA6A (19) Receiver circuit DI63 RV DI64 RV DI65 RV DI66 RV DI67 RV DI68 RV DI69 RV DI70 RV COM-5 RV +24E CRMA6A (1) 3.3k CRMA6A (2) CRMA6A (3) CRMA6A (4) CRMA6A (5) CRMA6A (6) CRMA6A (7) CRMA6A (13) B A Set this jumper according to the common voltage of input devices. (ICOM5) 0V DOSRC3(1) DOSRC3 Connector pin No. CRMA6A (12,18) +24V 0V +24V regulated ower su l Driver circuit DV LOAD DO61 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CRMA6A (14) RELAY 308/483 7/17/2019 CRMA6A (15) DO62 DO63 DV DV DO64 DV DO65 LOAD CRMA6A (8) LOAD CRMA6A (9) LOAD CRMA6A (10) DV DO68 4. CRMA6A (17) DV DO67 LOAD LOAD CRMA6A (16) DV DO66 MANUTENÇÃO ROBO FANUC.pdf LOAD CRMA6A (11) DV PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES LOAD CONNECTIONS Control unit (peripheral device control interface B2) B-82595EN-2/04 Peripheral device +24E Connector pin No. CRMA6B (19) Receiver circuit DI71 RV DI72 RV DI73 RV DI74 RV DI75 RV DI76 RV DI77 RV DI78 RV COM-6 RV +24E CRMA6B (1) 3.3k CRMA6B (2) CRMA6B (3) CRMA6B (4) CRMA6B (5) CRMA6B(6) CRMA6B (7) CRMA6B (13) B A Set this jumper according to the common voltage of input devices. (ICOM6) 0V DOSRC3(1) DOSRC3 Connector pin No. CRMA6B (12,18) +24V 0V +24V regulated ower su Driver circuit l DV DO69 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf LOAD CRMA6B (14) RELAY 309/483 7/17/2019 CRMA6B (15) DO70 DO71 DV DV DO72 DV DO73 DV DO74 DV DO75 DV DO76 DV MANUTENÇÃO ROBO FANUC.pdf LOAD LOAD CRMA6B (16) CRMA6B (17) LOAD CRMA6B (8) LOAD CRMA6B (9) LOAD CRMA6B (10) LOAD CRMA6B (11) LOAD 4. CONNECTIONS B-82595EN-2/04 4.4.2 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Peripheral Device and Contr ol Unit Connection (Sink Type DO) Control unit Peripheral device control interface A1 Sink type DO Peripheral device A1 0V Peripheral device control interface A2 Sink type DO http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 310/483 Peripheral 7/17/2019 4. MANUTENÇÃO device A2 ROBO FANUC.pdf PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS B-82595EN-2/04 Control unit Peripheral device control interface A3 Sink type DO Peripheral device A3 Peripheral device control interface A4 Sink type DO http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 311/483 Peripheral 7/17/2019 MANUTENÇÃO FANUC.pdf device ROBO A4 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Control unit Peripheral device control interface B1 Sink type DO Peripheral device B1 Control unit Peripheral device control interface B2 Sink type DO Peripheral device B2 NOTE 1 The peripheral device connection cables are optional. 2 All of COM-∗∗ are connected to 0V. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf App li cab le p ro cess I/O boar d t ype FA 312/483 7/17/2019 4. MANUTENÇÃO ROBO FANUC.pdf PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS Peripheral device Control unit (peripheral device interface A1) +24E B-82595EN-2/04 Connector pin No. CRM2A (49,50) Receiver circuit *IMSTP *HOLD RV RV *SFSPD RV CSTOPI RV FAULT RESET RV START RV HOME RV ENBL RV RSR1/PNS1 RV RSR2/PNS2 RV RSR3/PNS3 RV RSR4/PNS4 RV RSR5/PNS5 RV RSR6/PNS6 RV 3.3k CRM2A (1) CRM2A (2) CRM2A (3) CRM2A (4) 0V CRM2A (5) CRM2A (6) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf RV RSR7/PNS7 CRM2A (7) CRM2A (8) CRM2A (9) CRM2A (10) CRM2A (11) CRM2A (12) CRM2A (13) CRM2A (14) CRM2A (15) CRM2A (16) 313/483 7/17/2019 RSR8/PNS8 RV PNSTROBE RV PROD START RV DI01 RV DI02 RV COM-1 CRM2A (29) CRM2A (31) CRM2A (32) RV +24E MANUTENÇÃO ROBO FANUC.pdf CRM2A (30) CRM2A (17,18) B A 0V 4. B-82595EN-2/04 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CONNECTIONS PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 314/483 7/17/2019 4. MANUTENÇÃO ROBO FANUC.pdf PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS Control unit (peripheral device interface A2) B-82595EN-2/04 Peripheral device +24E Connector pin No. CRM2B (49,50) Receiver circuit DI03 RV 3.3k DI04 RV DI05 RV DI06 RV DI07 RV DI08 RV DI09 RV DI10 RV DI11 RV DI12 RV DI13 RV DI14 RV DI15 RV DI16 RV DI17 RV CRM2B (1) CRM2B (2) CRM2B (3) CRM2B (4) CRM2B (5) CRM2B (6) CRM2B (7) CRM2B (8) CRM2B (9) CRM2B (10) CRM2B (11) CRM2B (12) CRM2B (13) RV DI18 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf RV CRM2B (14) CRM2B (15) CRM2B (16) CRM2B (29) 315/483 DI19 7/17/2019 DI20 RV DI21 RV DI22 RV COM-2 CRM2B (30) MANUTENÇÃO ROBO FANUC.pdf CRM2B (31) CRM2B (32) CRM2B (17,18) RV +24E B A 0V Set this jumper according to the common voltage of input devices. 0V 4. CONNECTIONS B-82595EN-2/04 Control unit (peripheral device interface A2) Driver circuit PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Peripheral device Connector pin No. DV CRM2B (33) DO01 LOAD RELAY 0V DO02 DO03 DO04 DO05 DV DV DV DV CRM2B (34) CRM2B (35) CRM2B (36) CRM2B (38) LOAD LOAD LOAD LOAD CRM2B (39) DO06 DV DO07 DV DO08 DO09 DO10 DO11 DV DV DV DV CRM2B (40) CRM2B (41) CRM2B (43) CRM2B (44) CRM2B (45) LOAD LOAD LOAD LOAD LOAD LOAD CRM2B (46) DO12 DO13 DO14 DV DV DV DV DO15 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf DO16 DV LOAD CRM2B (19) CRM2B (20) CRM2B (21) CRM2B (22) LOAD LOAD LOAD LOAD 316/483 7/17/2019 DO17 DV DO18 DV DO19 CRM2B (24) CRM2B (25) LOAD CRM2B (26) DV DO20 LOAD MANUTENÇÃO ROBO FANUC.pdf LOAD CRM2B (27) DV CRM2B (23,28,37,42,47) LOAD 0V +24V 0V 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS Control unit (peripheral device interface A3) B-82595EN-2/04 Peripheral device +24E Connector pin No. CRM2C (49,50) Receiver circuit DI23 RV DI24 RV DI25 RV DI26 RV DI27 RV DI28 RV DI29 RV DI30 RV DI31 RV DI32 RV DI33 RV DI34 RV DI35 RV DI36 RV DI37 RV 3.3k CRM2C (1) CRM2C (2) CRM2C (3) CRM2C (4) CRM2C (5) CRM2C (6) CRM2C (7) RV DI38 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf DI39 RV CRM2C (8) CRM2C (9) CRM2C (10) CRM2C (11) CRM2C (12) CRM2C (13) CRM2C (14) CRM2C (15) CRM2C (16) CRM2C (29) 317/483 7/17/2019 DI40 RV DI41 RV DI42 RV COM-3 CRM2C (30) MANUTENÇÃO ROBO FANUC.pdf CRM2C (31) CRM2C (32) RV CRM2C (17,18) +24E B A 0V Set this jumper according to the common voltage of input devices. 0V 4. CONNECTIONS B-82595EN-2/04 Control unit (peripheral device interface A3) Driver circuit PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Peripheral device Connector pin No. DV CRM2C (33) DO21 LOAD RELAY 0V DO22 DO23 DO24 DO25 DV DV DV DV CRM2C (34) CRM2C (35) CRM2C (36) CRM2C (38) LOAD LOAD LOAD LOAD CRM2C (39) DO26 DV DO27 DV DO28 DO29 DO30 DO31 DV DV DV DV CRM2C (40) CRM2C (41) CRM2C (43) CRM2C (44) CRM2C (45) LOAD LOAD LOAD LOAD LOAD LOAD CRM2C (46) DO32 DO33 DO34 DO35 DV DV DV DV http://slidepdf.com/reader/full/manutencao-robo-fanucpdf DO36 DV LOAD CRM2C (19) CRM2C (20) CRM2C (21) CRM2C (22) LOAD LOAD LOAD LOAD 318/483 7/17/2019 DO37 DV DO38 DV DO39 CRM2C (24) CRM2C (25) LOAD CRM2C (26) DV DO40 LOAD MANUTENÇÃO ROBO FANUC.pdf LOAD CRM2C (27) DV LOAD CRM2C (23,28,37,42,47) 0V +24V 0V 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS Control unit (peripheral device interface A4) B-82595EN-2/04 Peripheral device +24E Connector pin No. CRM2D (49,50) Receiver circuit DI43 CRM2D (1) RV 3.3k DI44 RV DI45 RV DI46 RV DI47 RV DI48 RV DI49 RV DI50 RV DI51 RV DI52 RV DI53 RV DI54 RV DI55 RV DI56 RV DI57 RV DI58 RV DI59 RV CRM2D (2) CRM2D (3) CRM2D (4) CRM2D (5) CRM2D (6) CRM2D (7) CRM2D (8) CRM2D (9) CRM2D (10) CRM2D (11) CRM2D (12) CRM2D (13) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CRM2D (14) CRM2D (15) CRM2D (16) CRM2D (29) 319/483 7/17/2019 DI60 RV DI61 RV DI62 RV COM-4 CRM2D (30) CRM2D (31) MANUTENÇÃO ROBO FANUC.pdf CRM2D (32) CRM2D (17,18) RV +24E B A 0V Set this jumper according to the common voltage of input devices. 0V 4. CONNECTIONS B-82595EN-2/04 Control unit (peripheral device interface A4) Driver circuit PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Peripheral device Connector pin No. DV CRM2D (33) DO41 LOAD RELAY 0V DO42 DO43 DO44 DO45 DV DV DV DV CRM2D (34) CRM2D (35) CRM2D (36) CRM2D (38) LOAD LOAD LOAD LOAD CRM2D (39) DO46 DV DO47 DV DO48 DO49 DO50 DO51 DV DV DV DV CRM2D (40) CRM2D (41) CRM2D (43) CRM2D (44) CRM2D (45) LOAD LOAD LOAD LOAD LOAD LOAD CRM2D (46) DO52 DO53 DO54 DO55 DV DV DV DV http://slidepdf.com/reader/full/manutencao-robo-fanucpdf DO56 DV LOAD CRM2D (19) CRM2D (20) CRM2D (21) CRM2D (22) LOAD LOAD LOAD 320/483 LOAD 7/17/2019 CRM2D (24) DV DO57 CRM2D (25) DV DO58 DO59 LOAD CRM2D (26) DV DO60 LOAD MANUTENÇÃO ROBO FANUC.pdf LOAD CRM2D (27) DV CRM2D (23,28,37,42,47) LOAD 0V +24V 0V 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS Peripheral device Control unit (peripheral device interface B1) +24E B-82595EN-2/04 Connector pin No. CRM4A (19) Receiver circuit DI63 RV DI64 RV DI65 RV DI66 RV DI67 RV DI68 RV CRM4A (1) 3.3k CRM4A (2) CRM4A (3) CRM4A (4) CRM4A (5) CRM4A (6) CRM4A (7) DI69 RV DI70 RV COM-5 CRM4A (13) RV CRM4A (20) +24E B A 0V Set this jumper according to the common voltage of input devices. 0V （ICOM5） Driver circuit Connector pin No. DV CRM4A (14) DO61 LOAD RELAY 0V http://slidepdf.com/reader/full/manutencao-robo-fanucpdf DO62 DV CRM4A (15) 321/483 LOAD CRM4A (16) DV DO63 7/17/2019 CRM4A (17) DV DO64 DO67 LOAD CRM4A (10) DV DO68 LOAD CRM4A (9) DV DO66 LOAD CRM4A (8) DV DO65 LOAD MANUTENÇÃO ROBO FANUC.pdf LOAD CRM4A (11) DV LOAD 4. CONNECTIONS B-82595EN-2/04 Control unit (peripheral device interface B2) PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Peripheral device Connector pin No. +24E CRM4B (19) Receiver circuit DI71 RV DI72 RV DI73 RV DI74 RV DI75 RV DI76 RV DI77 RV DI78 RV CRM4B (1) 3.3k CRM4B (2) CRM4B (3) CRM4B (4) CRM4B (5) CRM4B (6) CRM4B (7) COM-6 CRM4B (13) CRM4B (20) RV +24E B A 0V Set this jumper according to the common voltage of input devices. 0V （ICOM6） Driver circuit Connector pin No. DV CRM4B (14) DO69 LOAD RELAY 0V http://slidepdf.com/reader/full/manutencao-robo-fanucpdf DO70 DV CRM4B (15) 322/483 LOAD 7/17/2019 CRM4B (17) DV DO72 CRM4B (8) DV DO73 CRM4B (9) DV DO74 DO75 CRM4B (10) DV DO76 4. CRM4B (16) DV DO71 CRM4B (11) DV PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES LOAD MANUTENÇÃO ROBO FANUC.pdf LOAD LOAD LOAD LOAD LOAD CONNECTIONS B-82595EN-2/04 4.5 INTERFACE FOR WELDER 4.5.1 Connection between the Cont rol Unit and Welder Control unit Welding machine interface WO1 WO2 WO3 WO4 WI1 WI2 WO5 WO6 WI3 WI4 WO7 Welding machine WO8 WI5 WI6 WI7 WI8 Analog input interface http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Peripheral device 323/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf NOTE 4. B-82595EN-2/04 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CONNECTIONS PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 324/483 7/17/2019 4. MANUTENÇÃO ROBO FANUC.pdf PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS Welding machine Control unit (welding machine interface) Process I/O boards CA and EA Driver circuit DV Welding start signal B-82595EN-2/04 Connector pin No. CRW1 (23) R WO01 LOAD RELAY 0V Gas signal WO02 WO03 Wire inching (+) signal Wire inching (-) signal WO04 WO05 WO06 DV DV DV DV DV WO07 DV WO08 DV Receiver circuit WI01 RV Arc regeneration WI02 RV detection signal Out-of-gas WI03 RV detection signal Broken-wire WI04 RV detection signal Out-of-coolingWI05 RV water detection http://slidepdf.com/reader/full/manutencao-robo-fanucpdf signal WI06 RV Abnormal-welding CRW1 (24) S CRW1 (25) T CRW1 (26) U CRW1 (27) V CRW1 (28) W CRW1 (29) X CRW1 (30) Z CRW1 (19,20) a,m CRW1 (21,22) b,n LOAD LOAD LOAD LOAD LOAD LOAD 0V +24V +24 V regulated power 0V Connector pin No. 3.3k LOAD CRW1 (5) c CRW1 (6) d CRW1 (7) e CRW1 (8) f CRW1 (9) g CRW1 (10) h 325/483 power signal 7/17/2019 WI07 RV WI08 RV COM-3 CRW1 (11) j CRW1 (12) k MANUTENÇÃO ROBO FANUC.pdf RV +24E B A Set this jumper according to the common voltage of input devices. 0V （ICOM3） +24V 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CRW2 connector analog connection (analog in put) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 326/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (Relationships between process I/O points and analog inp uts) Anal og in pu ts P 4. ADCH1 COMAD1 I/O ADCH2 COMAD2 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Control unit ADCH3 COMAD3 ADCH4 COMAD4 CONNECTIONS ADCH5 COMAD5 ADCH6 COMAD6 B-82595EN-2/04 Welding machine interface WO1 WO5 WO2 WI1 WI2 WI3 Welding machine XWST WO4 WI4 WI5 WI6 WI7 WI8 NOTE Welder and peripheral device connection cable are optional. App li cab le p ro cess I/O boar d t ype GA, HA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 327/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES General-purpose interface Welding machine MS connector pin No. Control unit (welding machine interface) Process I/O boards GA, HA, and HB Connector pin No. CRW7 (1) DACH1 Welding voltage specification signal Wire speed specification signal Arc detection signal Out-of-gas detection signal Broken-wire detection signal Arc-off detection signal (power supply abnormal) CRW7 (2) COMDA1 CRW7 (3) DACH2 CRW7 (4) COMDA2 Receiver circuit WI02 RV WI03 RV WI04 RV WI06 RV COM-3 Welding start signal WCOM1 CRW7 (7) T CRW7 (8) S CRW7 (10) R CRW7 (33,34) E A 0V CRW7 (23) CRW7 (24) CRW7 (29) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf WCOM4 D +24E B WO01 Wire inching (+) C P Set this jumper according to the common voltage of input devices. （ICOM3） WO04 B Connector pin No. 3.3k CRW7 (6) RV +24E A CRW7 (30) L K F G 328/483 WCOM4 7/17/2019 G CRW7 (13) WO05 Wire inching (-) CRW7 (14) WCOM5 WDI+ Wire deposition detection signal 4. MANUTENÇÃO ROBO FANUC.pdf H WDI- PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES J R = 100 Ω or higher CRW1 (31) M ＋ CRW1 (32) N － CONNECTIONS B-82595EN-2/04 FANUC interface Control unit (welding machine interface) Process I/O boards GA, HA, and HB Welding machine MS connector pin No. Connector pin No. CRW7 (1) DACH1 Welding voltage specification signal CRW7 (2) COMDA1 CRW7 (3) DACH2 Wire speed specification signal CRW7 (4) COMDA2 Receiver circuit WI01 RV Arc detection signal WI02 RV WI03 RV WI04 RV WI05 RV WI06 RV WI07 RV WI08 RV COM-3 RV Out-of-gas detection signal Broken-wire detection signal Out-of-coolingwater detection Arc-off detection signal (power su l abnormal +24E B A B E F Connector pin No. 3.3k CRW7 (5) c CRW7 (6) d CRW7 (7) e CRW7 (8) f CRW7 (9) g CRW7 (10) h CRW7 (11) j CRW7 (12) k CRW7 (33,34) r CRW7 (19,20) m +24E A Set this jumper according to the common voltage of input devices. （ICOM3） CRW7 (21,22) 0V WO01 Welding start signal WCOM1 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf WO02 0V CRW7 (23) n R CRW7 (24) CRW7 (25) 329/483 S Gas signal CRW7 (26) WCOM2 7/17/2019 a CRW7 (29) WO04 Wire inching (+) MANUTENÇÃO ROBO FANUC.pdf U CRW7 (30) WCOM4 CRW7 (13) WO05 Wire inching (-) V CRW7 (14) WCOM5 b 4. CONNECTIONS B-82595EN-2/04 Control unit R = 100 Ω or higher PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Welding machine interface CRW10 01 02 03 04 05 06 07 08 09 10 11 12 13 14 DACH1 COMDA1 DACH2 COMDA2 DACH3 COMDA3 WI1 WI2 WI3 WI4 WI5 WI6 WI7 WI8 15 16 17 18 0V 0V 0V 0V 19 20 21 22 23 24 25 26 27 28 29 30 31 ADCH1 COMAD1 ADCH2 COMAD2 WDI+ WDI- 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 WO1 WCOM1 WO2 WCOM12 WO3 WCOM3 WO4 WCOM4 WO5 WCOM5 WO6 WCOM6 WO7 WCOM7 47 48 49 50 WO8 WCOM8 +24E +24E Welding machine NOTE The welding machine connection cables are options. App li cab le p ro cess I/O boar d t ype KA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 330/483 7/17/2019 4. MANUTENÇÃO ROBO FANUC.pdf PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS B-82595EN-2/04 Pin-to-pin connection between CRW10 connector and welding machine connector (general interface) (Analog ou tput, welding wire deposition detection, WI/WO connection, for connections wi th +24 V common) Welding machine MS connector pin No. Control unit（Welding machine interface） Process I/O board KB Connector pin No. CRW10 (1) DACH1 Welding voltage A CRW10 (2) specification signal COMDA1 B CRW10 (3) DACH2 Wire speed specification signal CRW10 (4) COMDA2 WI02 RV Out-of-gas detection signal WI03 RV WI04 RV WI06 RV Broken-wire detection signal Arc-off detection signal (power supply abnormal) COM-3 3.3k RV +24E D Connector pin No. Receiver circuit Arc detection signal C CRW10 (8) P CRW10 (9) S CRW10 (10) T CRW10 (12) R CRW10 (49,50) E +24E B A Set this jumper according to the common voltage of input devices. 0V （ICOM3） WO01 Welding start signal WCOM1 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf WO04 Wire inching (+) CRW10 (33) CRW10 (34) CRW10 (39) L K F 331/483 CRW10 (40) WCOM4 7/17/2019 G CRW10 (41) WO05 Wire inching (-) H CRW10 (42) WCOM5 Wire deposition MANUTENÇÃO ROBO FANUC.pdf J CRW10 (25) WDI+ M 4. ＋ PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS B-82595EN-2/04 R=100Ωor higher Pin-to-pin connection between CRW10 connector and welding machine connector: FANUC interface (Analog i nput/output, w elding w ire deposition detection, WI/WO connection, for connections w ith +24 V common) Control unit (welding machine interface) Process I/O boards KA, KB Welding machine MS connector pin No. Connector pin No. CRW10 (1) DACH1 Welding voltage specification signal CRW10 (2) COMDA1 CRW10 (3) DACH2 Wire speed specification signal CRW10 (4) COMDA2 Welding voltage detection signal CRW10 (19) ADCH1 CRW10 (20) COMAD1 Welding current CRW10 (21) ADCH2 detection signal 0V Receiver circuit Arc detection signal RV WI02 Out-of-gas detection signal Broken-wire detection signal Out-of-coolingwater detection WI03 RV WI04 RV RV WI06 Arc-off detection signal (power supply abnormal) RV WI08 RV COM-3 RV B F J K L Ripples must have been removed from the output signals. CRW10 (7) c CRW10 (8) d CRW10 (9) e CRW10 (10) f CRW10 (11) g CRW10 (12) h CRW10 (13) j CRW10 (14) k CRW10 (49,50) r RV WI07 +24E E Connector pin No. 3.3k RV WI05 B CRW10 (22) COMAD2 WI01 A +24E A CRW10 (15,16) Set this jumper according to the http://slidepdf.com/reader/full/manutencao-robo-fanucpdf common voltage of input devices. 0V （ICOM3） CRW10 (17,18) 0V CRW10 (33) m n 332/483 WO01 Welding start signal 7/17/2019 R CRW10 (34) WCOM1 CRW10 (35) WO02 Gas signal CRW10 (37) WO03 CRW10 (39) WO04 CRW10 (40) WCOM4 4. T CRW10 (38) WCOM3 Wire inching (+) S CRW10 (36) WCOM2 － MANUTENÇÃO ROBO FANUC.pdf PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS U a B-82595EN-2/04 4.6 INTERFACE FOR END EFFECTOR 4.6.1 Connection between th e Mechanical Unit and End Effector Mechanical unit EE 1 RO1 5 RO5 10 RI2 2 RO2 6 RO6 7 XHBK 11 RI3 16 RI6 3 RO3 12 RI4 17 24VF 21 RO7 8 0V 13 RI8 18 24VF 22 RO8 4 RO4 9 RI1 14 R19(XPPABN) 19 24VF 23 0V 15 RI5 End effector 20 24VF 24 RI7 Fig.4.6.1 In case of the R-2000 iB, M-710iC (For other ro bots , refer to the each operators manual.) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 333/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Peripheral device Mechanical unit (end-effector interface) +24VF Connector pin No. EE(17,18,19,20) Receiver circuit Wrist breakage XHBK detection signal RV RI1 RV RI2 RV RI3 RV RI4 RV RI5 RV RI6 RV RI7 RV RI8 RV EE (7) 3.3k 0V EE (9) EE (10) EE (11) EE (12) EE (15) EE (16) EE (24) EE (13) RI9 RV ‘(Pneumatic pressure XPPABN) +24E abnormal signal) EE (14) B Set this jumper or switch according to the common voltage of input devices. (COM1) A 0V +24VF Driver circuit DV LOAD RO1 EE (1) RO2 DV http://slidepdf.com/reader/full/manutencao-robo-fanucpdf RO3 DV EE (2) EE (3) RELAY LOAD LOAD 334/483 EE (4) 7/17/2019 RO4 DV RO5 DV RO6 DV RO7 RO8 LOAD EE (5) MANUTENÇÃO LOAD ROBO FANUC.pdf EE (6) EE (21) DV EE (22) DV LOAD LOAD LOAD EE (8,23) 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 4.7 CONNECTIONS B-82595EN-2/04 DIGITAL I/O SIGNAL SPECIFICATIONS This section describes the specifications of the digital I/O signals interfaced with the peripheral device, end effector, and arc welder. 4.7.1 Peripheral Device Interface A (1) Output signals in peripheral device interface A (Source type DO) (a) Example of connection Spark killer diode 0.2A or less (b) Electrical specifications Maximum load current when driver is on: Saturation voltage when driver is on: Dielectric strength: Leakage current when driver is off: 200 mA (including momentary level) 1.0 V max. 24 V ±20% (including momentary level) 100 μA (c) The external power supply to output signals must satisfy the following: Power supply voltage: +24 V ±10% Power supply current: For each printed circuit board of this type (Total sum of maximum load currents including momentary levels + 100 mA or more) Power-on timing: At the same time when the control unit is turned on http://slidepdf.com/reader/full/manutencao-robo-fanucpdf or earlier Power-off timing: At the same time when the control unit is turned 335/483 off or later 7/17/2019 (d) Spark killer diode Rated peak reverse voltage: Rated effective forward current: (e) MANUTENÇÃO ROBO FANUC.pdf 100 V or more 1 A or more Driver for output signals 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES (g) Applicable signals Output signals of process I/O board CRMA5 and CRMA6 CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT, ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNO1 to SNO8, SNACK, DO1 to DO76 (2) Output signals in peripheral device interface A (Sink type DO) (a) Example of connection Spark killer diode +24V 0.2A or le ss 0V (b) Electrical specifications Rated voltage: Maximum applied voltage: Maximum load current: Transistor type: Saturation voltage at connection: (c) 24VDC 30VDC 0.2A Open collector NPN 1.0V (approx.) Spark killer diode Rated peak reverse voltage: http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Rated effective forward current: 100V or more 1A or more 336/483 7/17/2019 (d) Note on use MANUTENÇÃO ROBO FANUC.pdf Do not use the +24V power supply of the robot. When adding a relay, solenoid, or the like directly to the circuit, connect a diode for counter electromotive voltage protection in parallel to the load. (e) 4. Applicable signals O i l f I/O b PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES d CRM2 d CRM4 CONNECTIONS B-82595EN-2/04 (3) Input signals in peripheral device interface A (a) Example of connection +24V ＲＶ 3.3kΩ +24V Ｂ Ａ ＩＣＯＭ (b) Electrical specifications of the receiver Type: Grounded voltage receiver Rated input voltage: Contact close +20V to +28V Contact open 0V to +4V Maximum applied input voltage: +28VDC Input impedance: 3.3kΩ(approx.) Response time: 5ms to 20ms (c) Specifications of the peripheral device contact Voltage and Current: DC24V, 0.1A (Use a contact which minimum load is 5mA less.) Input signal width: 200ms or more (on/off) Chattering time: 5ms or less Closed circuit resistance:100Ω or less Opened circuit resistance: 100kΩ or more http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 337/483 (Signal) TB TB (Signal) 7/17/2019 TB MANUTENÇÃO ROBO FANUC.pdf Peripheral device contact signal 4. CONNECTIONS B-82595EN-2/04 4.7.2 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES End Effecto r Control Interface (1) Output signals in end effector interface (a) Example of connection Spark killer diode +24V 0.2A or less 0V (b) Electrical specifications Maximum load current when driver is on: Saturation voltage when driver is on: Dielectric strength: Leakage current when driver is off: (c) 200 mA (including momentary level) 1.0 V max. 24 V ±20% (including momentary level) 100 μA Power supply to output signals The +24 V power supply on the robot side can be used if the total current level, including the current of the welding interface, is 0.7 A or less. (d) Driver for output signals In the driver device, the current of each output signal is monitored, and when an overcurrent is detected, the relevant output is turned off. After an output has been turned off by overcurrent, the overcurrent state is released because the output is off, so the output on state is restored. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Therefore, in the ground fault or overcurrent state, the output is turned on and off repeatedly. 338/483 Such a condition found also when a load with a high circuit, surge current connected. The driver deviceisalso includes an overheat detection which is turns off all outputs of the MANUTENÇÃO ROBO device when the internal temperature of the device has increased as a result ofFANUC.pdf a continued overcurrent state due to a ground fault of an output and so on. The outputs are held off, but their normal states can be restored by turning the power to the control unit on and off after the internal temperature of the device has lowered. 7/17/2019 (e) 4. Note on use PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 4.7.3 CONNECTIONS B-82595EN-2/04 I/O Signal Specification s for ARC-Welding Interface (1) Digital Output signals specifications for an arc welding interface In case of proc ess I/O CA, EA (a) Example of connection Spark killer diode +24V 0.2A or le ss 0V (b) Electrical specifications Rated voltage: Maximum applied voltage: 24VDC 30VDC Maximum load current: 0.2A Transistor type: Open collector NPN Saturation voltage at connection: 1.0V (approx.) (c) Spark killer diode Rated peak reverse voltage: Rated effective forward current: http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 100V or more 1A or more 339/483 7/17/2019 (d) Note onuse usethe +24V power supply of the robot. Do not MANUTENÇÃO FANUC.pdf When adding a relay, solenoid, or the like directly to the circuit, connect aROBO diode for counter electromotive voltage protection in parallel to the load. (e) Applicable signals Output signals of process I/O board CRW1 WO1 to WO8 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Spark killer diode +24V 0.3A or less 0V (b) Electrical specifications Rated voltage: Maximum applied voltage: (c) 24VDC 30VDC Maximum load current: Transistor type: 0.3A Relay connect output Spark killer diode Rated peak reverse voltage: Rated effective forward current: 100V or more 1A or more (d) Note on use Do not use the +24V power supply of the robot. When adding a relay, solenoid, or the like directly to the circuit, connect a diode for counter electromotive voltage protection in parallel to the load. (e) Applicable signals Output signals of process I/O board CRW7 WO1, WO2, WO 4 and WO 5 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 340/483 (2) Digital inputsignals signalsare specifications an arc of welding The input the same for as those other interface I/O boards. (Refer to Subsection 4.5.1 in CONNECTIONS.) 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (a) Applicable signals Input signals of process I/O board CRW1, CRW7 WI1 to WI8 (3) Analog output signal specifications for an arc welding interface 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS B-82595EN-2/04 (b) Note on use Input impedance: 3.3kΩ or more Connect a high-pass filter (2) Analog input signal specifications for an arc welding interface (Welding-voltage detection, welding-current detection) (a) Example of connection Welder －10V～＋10V 0V (b) Note on use Input impedance: 2kΩ The analog input signal should have no ripple for the circuit to operate properly. (Wire deposit detection: WDI+ and WDI-) (a) Example of connection Welder http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 341/483 + max. 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf +15V 85mA ‐ 4. CONNECTIONS B-82595EN-2/04 4.8 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS If the customer manufactures cables, make sure they conform to the FANUC standard cables described in this section. (See the description in "Peripheral Device Interface" in this manual for the specifications of the FANUC standard cables.) 4.8.1 Peripheral Device Int erface A Cable (CRM2, CRMA5: Honda Tsushin , 50 pins) Honda Tsushin MR50LWF01 (MR50LF) Honda Tsushin MR50LM01 (MR50LM) Peripheral device Process I/O CRMA5* Honda Tsushin MR50RMA Honda Tsushin's MR50RF Supplied with an ordered cable 4.8.2 Peripheral Device Int erface B Cable (CRM4, CRMA6: Honda Tsushin , 20 pins) Honda Tsushin http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MR20LWF01 Honda Tsushin MR20LM01 342/483 (MR20LF) 7/17/2019 (MR20LM) Peripheral MANUTENÇÃO ROBO FANUC.pdf Process I/O device CRMA6* 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 4.8.3 CONNECTIONS B-82595EN-2/04 ARC Weld Con nectio n Cable (CRW1, CRW7: Ho nd a Tsushin , 34pins) Be sure to use our cable to connect the welder. 4.8.4 ARC Weld Con nectio n Cabl e (CRW10: Honda Tsushin , 50 pin s) Be sure to use our cable to connect the Welder. ARC Welder Honda Tsushin MR-50LWMH Process I/O http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 343/483 CRW10 Japan Aviation Electronics Industry Ltd. 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Japan Aviation Electronics Industry Ltd. Honda Tsushin MRH-50RFD 4. CONNECTIONS B-82595EN-2/04 Standard position of guide key PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 4.9 CAB LE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS, AND ARC WELDERS 4.9.1 Peripheral Device Connection Cable Fig.4.9.1 shows the connection of the peripheral device cable in the cabinet. CRW1, CRW7, or CRW10 Process I/O board CRM2B or CRMA5B CRM2A or CRMA5A Process I/O board CRM2B or CRMA5B CRM2A or CRMA5A CRW1, CRW7, or CRW10 Operation box typeA (A-cabinet) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Integrated operatio n box (A-cabinet) 344/483 7/17/2019 4. MANUTENÇÃO ROBO FANUC.pdf PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 4.9.2 CONNECTIONS B-82595EN-2/04 Peripheral Device Cable Connector (1) Fig.4.9.2 shows the connector for peripheral device cables A and B. Connector specifications App li cab le interface A MR50LM CRMA5 67.9 MR20LM CRMA6 39.3 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Dimensions (B) C (D) 73.5 44.9 18 17 44.8 39.8 Remark Honda Tsushin Kogyo, 50 pins Honda Tsushin Kogyo, 20 pins 345/483 Symbol 7/17/2019 1 2 3 4 5 Name MANUTENÇÃO ROBO FANUC.pdf Connector cover Cable clamp screw Connector clamp spring Connector clamp screw Connector 50 pins (male) MR50M 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES (2) Peripheral device connector ， Connector specifications App li cab le interface MR50RF (CRM2) (CRMA5) 61.4 56.4 Honda Tsushin Kogyo, 50 pins MR20RF (CRM4) (CRMA6) 39.3 44.9 Honda Tsushin Kogyo, 20 pins Symbol 1 2 3 Dimensions A B Remark Name Connector clamp screw Screw M2.6 x 8 Connector (MR50RF) (MR20RF) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 346/483 Fig.4.9.2 (b) Perip heral device connecto r (Honda Tsushin Ko gyo) 7/17/2019 4. MANUTENÇÃO ROBO FANUC.pdf PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 4.9.3 CONNECTIONS B-82595EN-2/04 End Effector Cable Connecto r (1) Connector external view (For R-2000iB and M-710iC. Refer to the each operators manual for other robots.) A: B: C: D: E: F: G: M30 x 1 63.0 54.5 9.6 to 15.0 (Inside diameter) φ33 11.2 24.7 Manufactured by Fujikura JMLP2524M Fig.4.9.3 (a) Connecto r (Elbo w Type) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 347/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf A: M30 x 1 4. CONNECTIONS B-82595EN-2/04 4.9.4 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Recommended Cables (1) Peripheral device connection cable Connect a peripheral device using a completely shielded, heavily protected cable conforming to the specifications in Table 4.9.4 (a). Allow an extra 50 cm for routing the cable in the control unit. The maximum cable length is 30 m. Table 4.9.4 (a) Recommended Cable (for Peripheral Device Connecti on) Conductor Effective Electrical characteristics Wire specifications Sheath outside Conductor Number of wires (FANUC thicknes Diameter All ow abl e diameter resistance Configuration specifications) s (mm) (mm) current (A) (mm) ( /km) 50 20 A66L-0001-0042 A66L-0001-0041 φ1.05 φ1.05 7/0.18 AWG24 7/0.18 AWG24 1.5 1.5 φ12.5 φ10.5 106 106 1.6A 1.6A (2) End effector connection Connect an end effectorcable using a heavily protected cable with a movable wire conforming to the specifications in Table 4.9.4 (b). The cable length is determined so that the cable will not interfere with the end effector and the wrist can move through its full stroke. Table 4.9.4 (b) Recommended Cable (for End Effector Connectio n) Conductor Effective Electrical characteristics Wire specifications Sheath outside Conductor Number of wires (FANUC thicknes Diameter Configuration diameter resistance current All ow abl e specifications) s (mm) (mm) (A) (mm) ( /km) 6 20 24 A66L-0001-0143 A66L-0001-0144 A66L-0001-0459 φ1.1 φ1.1 φ0.58 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 40/0.08 AWG24 40/0.08 AWG24 40/0.08 AWG24 1.0 1.0 1.0 φ5.3 φ8.6 φ8.3 91 91 93 3.7 2.3 2.3 348/483 7/17/2019 4. MANUTENÇÃO ROBO FANUC.pdf PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS 4.10 CONNECTION OF HDI 4.10.1 Connecting HDI The HDI signals are used in combination with special application software. used as general-purpose DIs. B-82595EN-2/04 The HDI signals cannot be R-30iA Main board http://slidepdf.com/reader/full/manutencao-robo-fanucpdf JRL5 349/483 7/17/2019 1 HDI0 11 2 0V 12 HDI1 0V 3 HDI2 13 HI3 4 0V 14 0V HDI5 5 0V 15 6 HDI4 16 0V 17 HDI6 7 MANUTENÇÃO ROBO FANUC.pdf 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Cable connections JRL5 HDI0 0V HDI1 0V 1 2 11 12 3 HDI2 0V HDI3 0V HDI4 0V HDI5 4 13 14 6 5 or 10 15 16 0V HDI6 0V HDI7 0V 17 18 19 20 7 8 9 10 Shield Ground plate Recommended cable connector: PCR-E20FA (Honda Tsushin Kogyo) FI30-20S (Hirose Electric) FCN-247J020-G/E (Fujitsu) 52622-2011 (Molex Japan) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 350/483 7/17/2019 4. MANUTENÇÃO ROBO FANUC.pdf PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 4.10.2 CONNECTIONS B-82595EN-2/04 Input Signal Rules for the High-speed Skip (HDI) Circuit configuration R-30iA liL/liH FILTER RECEIVER DRIVER VH/VL SHIELD Absolute maximum rating -3.6 to +10 V Input voltage range Vin: Input characteristics Unit Symbol High level input voltage Low level input voltage High level input current VH VL liH Low level input current Input signal pulse duration Input signal delay or variations liL Specificatio n 3.6 to 7 0 to 1.0 2 max 11 max -8.0 max 20 min 0.02(max) Unit V V mA mA mA m s ms Remark Vin=5 V Vin = 10 V Vin = 0 V NOTE 1 The plus (+) sign of IiH/IiL represents the direction of flow into the receiver. minus (-) sign of IiH/IiL represents the direction of flow out of the receiver. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf The 2 The high-speed skip signal is assumed to be 1 when the input voltage is at the low level and 0 when it is at the high level. 351/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 4.11 CONNECTING THE COMMUNICATION UNIT 4.11.1 RS-232-C Interface 4.11.1.1 Interface This interface can be connected to a communication unit from FANUC. In case of the length of operation box connection cable that is 10m or longer. RS-232-C port RS-232-C port (A-cabinet) RS-232-C port http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 352/483 7/17/2019 4. MANUTENÇÃO ROBO FANUC.pdf PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS B-82595EN-2/04 R-30iA Operator's panel Connector (DBM-25S) Main board > > < 1 2 3 4 FG 5 6 7 8 9 10 11 12 13 CS DR SG SD RD RS 14 15 16 17 18 19 20 ER 21 22 23 24 25 +24V NOTE 1 +24 V can be used as the power supply for FANUC RS-232-C equipment. 2 Do not connect anything to those pins for which signal names are not indicated. 4.11.1.2 RS-232-C interface si gnals Generally signals as follows are used in RS-232-C interface. R-30iA Output Input SD (Send data) RD (Receive data) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf RS (Request to Send) 353/483 7/17/2019 CS (Enable to send) When CS is not used short CS and RS. MANUTENÇÃO ROBO FANUC.pdf When DR is not used short DR and ER. ER (Ready) 4. CONNECTIONS B-82595EN-2/04 4.11.1.3 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Connect ion between RS-232-C interface and I/O device The figure below shows a connection with the handshaking of the ER/DR, RS/CS signals. R-30iA • I/O device side SD SD RD RD RS RS CS CS ER ER DR DR CD CD SG SG FG (Frame ground) FG FG The figure below shows a connection without the handshaking of the RS/CS, ER/DR signals. R-30iA SD http://slidepdf.com/reader/full/manutencao-robo-fanucpdf RD SD RD External device side 354/483 7/17/2019 4. RS RS CS CS ER ER PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES MANUTENÇÃO ROBO FANUC.pdf CONNECTIONS B-82595EN-2/04 R-30iA SD RD RS CS SG ER DR Cable : twist 10 pairs 2 0.18mm , with shield Pair each signal with SG. 4.11.2 Ethernet Interf ace This section describes information relating to the physical Ethernet connection. CAUTION 1 Before connecting or disconnecting the cable to or from the FAST Ethernet/FAST Data Server, make sure that the power to the CNC is turned off. 2 Please inquire of each manufacturer about the construction of network or the condition of using the equipment except the FAST Ethernet/FAST Data Server (hub, transceiver, cable etc.). When configuring your network, you must take other sources of electrical noise into consideration to prevent your network from being influenced by electrical noise. Make sure that network wiring is sufficiently separated from power lines and other sources of electrical noise such as motors, and ground each of the devices as necessary. In addition, high and insufficient ground impedance may cause interference during communications. After http://slidepdf.com/reader/full/manutencao-robo-fanucpdf installing the machine, conduct operating the machine. a communications test before you actually start 355/483 7/17/2019 We cannot ensure operation that is influenced by network trouble caused by a MANUTENÇÃO ROBO FANUC.pdf device other than the FAST Ethernet or FAST Data Server. 4.11.2.1 Connection to Ethernet 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES HUB : : : Twisted pair cable CNC FAST Ethernet or FAST Data Server Max. 100m 4.11.2.2 Leading out the Ethernet Cable For this type of control unit, the cable is drawn out only from the front of the control unit. See the outline drawing of each type of board for the location of the connector. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 356/483 7/17/2019 4. MANUTENÇÃO ROBO FANUC.pdf The radius of the cable must be 70 mm or more. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 4.11.2.3 CONNECTIONS B-82595EN-2/04 100BASE-TX Connect or (CD38R) Pin Assignm ents CD38R Pin No. Signal name Descripti on 1 2 3 4 TX+ TXRX+ Send + Send Receive + Not used 5 6 7 8 4.11.2.4 Not used Receive Not used Not used RX- Twisted-pair Cable Specification (1) Cable Connection The cable used for connection between the 100BASE-TX interface, CD38R, of the Ethernet board/Data Server board and the hub is connected as follows: Ethernet board / Data Server board CD38 1 TX+ 2 TX3 RX+ 4 5 6 7 8 TX+ HUB RJ-45 modular connector RXMAX.100m (1) TX(2) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf RX+ (3) 1 2 3 TX+ TXRX+ 4 5 6 7 8 RX- (1) TX+ (2) TX- (3) RX+ 357/483 RX- (6) (6) 7/17/2019 RXMANUTENÇÃO ROBO FANUC.pdf Shielded cable 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES (2) Cable Materials CAUTION Unshielded cable (UTP cable) is commercially available as 100BASE-TX twisted-pair cable: You should, however, use shielded Category 5 twisted-pair cable (STP cable) to improve the resistance to electrical noise in an FA environment. Recommended Cables Manufacturer Specificatio n FURUKAWA ELECTRIC CO., LTD. NISSEI ELECTRIC CO., LTD. DTS5087C-4P F-4PFWMF Remarks Twisted-pair cable Single-conductor cable Inquiries Manufacturer Contact address FURUKAWA ELECTRIC CO., LTD. Sales Headquarters Remarks 2-6-1 Marunouchi, Chiyoda-ku. Tokyo 100-8322 TEL: 03-3286-3126 FAX: 03-3286-3979 NISSEI ELECTRIC CO., LTD. Machida Branch Overseas Sales Office 3F MU Bldg., 1-9-1 Minami-narise, Machida City, Tokyo 194-0045 TEL: 0427-29-2531 FAX: 0427-29-3375 IWATANI International Corporation Tokyo Head Office 21-8 Nishi-shinbashi 3-chome, Minato-ku, TOKYO, 105-8458, JAPAN TEL: 03-5405-5810 FAX: 03-5405-5666 Telex: 2524256 IWATYO J A finished cable with connectors at both ends can be offered. Remarks NOTE The recommended cables cannot be connected to moving parts. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Recommended cable (for movable parts) 358/483 Manufacturer 7/17/2019 Specificatio n Oki Electric Cable Co., Ltd. Shinko Electric Industrial Co., Ltd. Remarks AWG26 4P TPMC-C5-F (SB) Dedicated to MANUTENÇÃO ROBO FANUC.pdf FANUC FNC-118 Specification 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES • CONNECTIONS B-82595EN-2/04 UL style No. AWM 20276 (80°C/30V/VW-1) NOTE Be sure to use the connector TM21CP-88P (03) manufactured by HIROSE ELECTRIC CO., LTD. for this cable. Inquiries Manufacturer Oki Electric Cable Co., Ltd. Remarks Contact address Nagano Sales Office TEL:0266-27-1597 Shinko Electric Industrial Co., Ltd. Remarks Tokyo Sales Office TEL:03-3492-0073 Cable assembly Oki Electric Cable Co., Ltd. can also supply the cable assembly mentioned above. Contact Oki Electric directly to determine the specifications (length, factory test, packing, and so forth) for purchase. (3) Connector Specification Use an 8-pin modular connector (RJ-45) with the twisted-pair cable for the Ethernet connection. The following connectors or equivalents must be used. For general use Specificatio n Manufact urer Solid wire 5-569530-3 Tyco Electronics AMP K.K.. Solid wire MS8-RSZT-EMC SK KOHKI CO., LTD. Twisted-pair cable 5-569552-3 Tyco Electronics AMP K.K.. Twisted-pair cable TM11AP-88P HIROSE ELECTRIC CO., LTD. For movable parts For cable AWG26 4P TPMC-C5-F Specificatio n TM21CP-88P (03) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf (SB) or FNC-118 Remarks Special tools required Special tools required Manufacturer HIROSE ELECTRIC CO., LTD. Remarks Note 359/483 7/17/2019 NOTE Information about TM21CP-88P (03): Connector (standard product of the manufacturer) Drawing number: A63L-0001-0823#P MANUTENÇÃO ROBO FANUC.pdf 4. CONNECTIONS B-82595EN-2/04 4.11.2.5 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Electr ical Noise Countermeasures (1) Separating Signal Lines For signal line separation, refer to the description of noise protection in the Connection Manual (Hardware) (B-63943EN) of CNC. The wiring for the Ethernet cable is of group C. (2) Clamping and Shielding Cables Clamp an Ethernet twisted pair cable according to the method described below, as with cables that need to be shielded. Clamping and shielding and is extremely important to the safe operation of the system.cables Neverprovides overlooksupport cable clamping. Peel off part of the jacket as shown in the figure to expose the outer coating of the shield, and press this outer coating against the ground plate with the clamp fixture. The machine manufacturer must prepare the ground plate and install it as follows: Ground plate Cable Cable clamp Ground plate http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Shield 360/483 Peel off jacket 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf NOTE To ensure the safe operation of the system, clamp and shield the cables. 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS B-82595EN-2/04 A-c abi net B-cabinet http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 361/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 4. CONNECTIONS B-82595EN-2/04 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES (3) Grounding the Network Even if the grounding condition on the machine side is satisfied, the communication line can pick up noise from the machine, depending on the machine installation condition and environment, thus resulting in a communication error. To protect against such noise, the machine should be separated and insulated from the Ethernet trunk cable and personal computer. Examples of connection are given below. Personal computer Switching HUB Note 2 Note 1 Hub power supply Note 2 Personal computer / Note 2 HUB HUB HUB side Electrically separated by 100BASE-TX cable connection STP cable STP cable Machine system Machine Ethernet Note 1 Note 1 Machine Note 1 Machine Note 1 Note 1 Note 1 Large-Scale Network Personal computer Hub power supply Note 2 HUB Note 1 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Personal computer/Ethernet trunk side Note 1 362/483 7/17/2019 Electrically separated by 100BASE-TX cable connection STP cable MANUTENÇÃO ROBO FANUC.pdf Machine system Ethernet 4. PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES CONNECTIONS B-82595EN-2/04 NOTE 1 The ground between PC/HUB side and machine system side must be separated. If it is impossible to separate the ground because there is only one grounding point, connect the ground cable for each system to the grounding point independently. (See figure below.) The resistance for grounding must be less than 100-ohm (Class D). The thickness of the ground cable is the same as the thickness of AC power cable or more. At least thickness of 5.5mm2 is necessary. 2 Note that the number of allowable hub-to-hub connections depends on the type of hub. 3 There is possibility that noise makes the obstacle of communication even if the ground is separated using the 100BASE-TX. In the case of using the FAST Ethernet/FAST Data Server under the worst environment, please separate between the PC/Trunk line side and machine system side completely using the 100BASE-FX (Optical fiber media). FG Note 2 HUB Ground wire on personal computer and trunk sides Ground wire on machine system Ground wire on machine system http://slidepdf.com/reader/full/manutencao-robo-fanucpdf FG 363/483 Ground point 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Wiring on a single ground point 4. CONNECTIONS B-82595EN-2/04 4.11.2.6 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES Check Items at Installation The following table lists check items at installation. Check item Descriptio n Check Ethernet cable Use cables which satisfies all the following conditions: 1) With shielding Type 2) Twisted-pair cable 3) Category 5 The cable length shall be within 100 m (50 m for a movable cable recommended by FANUC). Length Connection Separation Shielding Clamping For a twisted-pair cable, the following pins shall be paired: 1) Pin No. 1 (TX+) – pin No. 2 (TX-) 2) Pin No. 3 (RX+) – pin No. 6 (RX-) The Ethernet cables shall be bound separately from the following cables or covered with an electromagnetic shield: 1) Group A: AC power lines, power lines for motors, and others 2) Group B: Current DC (24 VDC) and others For a shielded cable, the part of which outer coating is peeled off and exposed shall be fixed to the ground plate with a clamp fixture. The ground plate shall be located as nearest to the CNC as possible (to make the cable between the ground plate and CNC hard to be affected by noise). Connectors Wiring Any cable connector shall not be pulled (to prevent poor contact of the connector). No cable shall be laid under a heavy object. Bending radius The bending radius shall be at least four times as long as the diameter of the cable. For part For a movable part, a cable for a movable part shall be used. movable CNC and cabinet Ground plate The CNC ground (frame ground) shall be connected properly and the length of the ground wire shall be within 300 mm. The ground plate shall be connected to the AC ground of the cabinet with wire. Mounting The Ethernet board shall be inserted in a CNC slot properly. CNC grounding HUB http://slidepdf.com/reader/full/manutencao-robo-fanucpdf The "cautions on use" of the hub shall be observed (A terminating resistor shall be 364/483 Use conditions 7/17/2019 Grounding Cabinet mounted properly if required). The hub shall be grounded. The hub shall be installed in an enclosed cabinet. Vibration The hub shall be installed so that it is not affected by vibration. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 365/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 5.TRANSPORTATION AND INSTALLATION 5 CONNECTIONS B-82595EN-2/04 TRANSPORTATION AND INSTALLATION This chapter describes the transportation and installation for the controller. 5.1 TRANSPORTATION The controller is transported by a crane. Attach a strap to eye bolts at the top of the control unit. Crane capacity: Minimum 300kg Sling capacity: Minimum 300kg Eye bolt (M12) Eye bolt (M10) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 366/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (A-cabinet) B-82595EN-2/04 CONNECTIONS 5.2 INSTALLATION 5.2.1 Installation Method (B-cabinet) 5.TRANSPORTATION AND INSTALLATION Following is the installation method for cabinet. When installing the controller, allow the space for maintenance shown in the following figure. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 367/483 7/17/2019 Munsell Color 5GY3.5/0.5 Gray 5.TRANSPORTATION AND INSTALLATION Munsell Color 5GY3.5/0.5 Gray http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf CONNECTIONS B-82595EN-2/04 368/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CONNECTIONS B-82595EN-2/04 Body Door Op.panel 5.TRANSPORTATION AND INSTALLATION Munsell Color 5GY3.5/0.5 3.0GY8.2/0.9 N1.5 Gray White Black Fig. 5.2.1 (c) External d imensio n (B-cabinet) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 369/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 5.TRANSPORTATION AND INSTALLATION CONNECTIONS B-82595EN-2/04 Fixing bolt location Bolt specification The A-cabinet uses M10 x 16 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 370/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf CONNECTIONS B-82595EN-2/04 100 Controller 5.TRANSPORTATION AND INSTALLATION 100 Controller Controller NOTE Keep this area for maintenance and the radiation of heat. Fig. 5.2.1 (e) Install ation d imensio n (B-cabinet) Munsell Color Body 5GY3.5/0.5 Gray Door 3.0GY8.2/0.9 White http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 371/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 5.TRANSPORTATION AND INSTALLATION CONNECTIONS B-82595EN-2/04 Munsell Color Body 5GY3.5/0.5 Gray Door 3.0GY8.2/0.9 White Fig. 5.2.1 (g) External di mension (Integrated operation b ox) 5.2.2 Assemb le at Install ation Operation box R-30 iA co ntr oll er Robot connection cable Teach pendant http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 372/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Peripheral device connection cable B-82595EN-2/04 CONNECTIONS 5.TRANSPORTATION AND INSTALLATION Integrated operation box Teach pendant Peripheral device connection cable Robot connection cable Fig.5.2.2 (b) Assemble at installation (Integrated operation box) Teach pendant http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 373/483 R-30iA controller 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 5.TRANSPORTATION AND INSTALLATION 5.3 CONNECTIONS B-82595EN-2/04 INSTALLATION CONDITION Item Model Specification/conditio n Rated Voltage All models Trans. Type E 380-415, 440-500, 500-575VAC Trans. Type D 380-400, 200-230VAC 50/60Hz 3phases Tolerant fluctuation All models Tolerant voltage fluctuation: +10% -15% Tolerant frequency fluctuation: ±1Hz Input power source capacity M-900iA/400L, M-900iA/600 M-900iA/200P, M-2000iA R-2000iB/200T,M-410iB, M-900iA/260L,M-900iA/350 R-2000iB (except /200T), R-1000iA M-420iA /M-421iA, M-710iC F-200iB M-16iB, M-20iA ARC Mate 120iB, ARC Mate 120iC M-6iB, ARC Mate 100iB M-430iA/2F, M-430iA/2FH, M-430iA/2PH,M-430iA/4FH M-430iA/2P ARC Mate 100iC, M-10iA M-900iA/400L, M-900iA/600 M-900iA/200P M-2000iA 18KVA 30KVA 15KVA R-2000iB/200T,M-410iB, M-900iA/260L,M-900iA/350 R-2000iB (except /200T), R-1000iA M-420iA /M-421iA, M-710iC M-6iB, M-16iB, M-20iA ARC Mate100iB, ARC Mate120iB ARC Mate120iC, F-200iB M-430iA/2F, M-430iA/2FH, M-430iA/2PH,M-430iA/4FH M-430iA/2P ARC Mate 100iC, M-10iA 3KW Average power consumption http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Permissible ambient All models 12KVA 5KVA 3KVA 2.5KVA 3.5KVA 3.5KVA 2.0KVA 5KW 10KW 8KW 2.5KW 1.0KW 1.0KW 1.0KW 1.0KW Operating C to 45 C ° ° 374/483 temperature 7/17/2019 Storage, Transport -20 C to 60 C Temperature change 0.3 C/minute or less MANUTENÇÃO ROBO FANUC.pdf Normal: 75%RH or less, d ti ° Permissible ambient h idit All models CONNECTIONS B-82595EN-2/04 Item 5.TRANSPORTATION AND INSTALLATION Model Ionized and non-ionized radiation Common to all models Mass of control unit A-cabinet operator box A-cabinet B-cabinet Specification/conditio n TYPE B Integrated type All models (Except below models) A shielding provision is necessary if the machine is installed in an environment in which it is exposed to radiation (microwave, ultraviolet rays, laser beams, and/or X-rays). 25kg 20kg 120kg M-410iB 140kg All models (Except 180kg below models) M-900iA, M-410iB, 200kg R-2000iB/200T, M-900iA/200P, M-2000iA NOTE The power rating indicated above is sufficient as the continuous rating. However, when the robot is rapidly accelerating, the instantaneous requirement may increase to several times the continuous rating. If the acceleration/deceleration override(ACC) greater than 100% is set in the robot program, the extreme current may flow to the robot controller instantaneously and the input voltage of robot controller will drop. In this case, if the supply voltage is decreased 10% or more per rated voltage, Power supply alarm, Move error excess alarm, DCLV alarm of servo amplifier may occur. 5.4 ADJUSTMENT AND CHECK S AT INSTALLATION Adjust the robot according to the following procedure at installation. No. 1 Description Visually check the inside and outside of the control unit. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 2 Check the screw terminals for proper connection. 3 Check that the connectors and printed circuit boards are firmly connected. 375/483 4 5 6 7/17/2019 Check transformer tap setting. (See II MAINTENANCE section 6.2) MANUTENÇÃO ROBO FANUC.pdf The breaker off and connect the input power cable. Check the input power voltage and transformer outputs 5.TRANSPORTATION AND INSTALLATION CONNECTIONS B-82595EN-2/04 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION 5.5 An overtravel and emergency stop occur when the robot is operated for the first time after it is installed and the mechanical and control units are wired. This section describes how to reset the overtravel and emergency stop. Remove the red plate fastening the swiveling axis beforehand. The J2 and J3 axes are pressed against the hard stops at shipment. Therefore, an overtravel alarm occurs when the power is turned on after installation. The robot can also be in an emergency stop state if the peripheral device control interface is not connected. 5.5.1 Peripheral Device Interf ace Processing Take the following actions if signals *IMSTP, *HOLD, *SFSD, and ENBL are not used. CRM2A +24F 49, 50 *IMSTP 1 *HOLD 2 *SFSD 3 ENBL 4 RV RV RV RV 5.5.2 Resetting Overtr avel http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 1) Select [OT release] on the overtravel release screen to release each robot axis from the overtravel 376/483 2) 7/17/2019 3) state. Hold down the shift key, and press the alarm release button to reset the alarm condition. MANUTENÇÃO ROBO FANUC.pdf Still hold down the shift key, and jog to bring all axes into the movable range. CONNECTIONS B-82595EN-2/04 5.TRANSPORTATION AND INSTALLATION Status Hand Broken enable/disable setting HBK (*1) HBK detection Robot operatio n Message 1 2 3 4 Enable Enable Disable Disable CLOSE OPEN CLOSE OPEN Yes Yes Yes (*2) No Possible Impossible Possible Possible None SRVO-006 None At cold start, SRVO-300 NOTE 1 Robot end effector connector CLOSE OPEN 24V 24V XHBK XHBK 2 The moment the HBK circuit is closed, HBK detection becomes enabled. When the HBK circuit is opened again, alarm "Servo 300" or "Servo 302" occurs, causing the robot to stop. 3 If the power is turned off and on again under the condition stated in *2, status 4 is entered, so the alarm condition is removed. 5.5.4 1) 2) 3) 4) 5) How to Disable/Enable Pneumatic Pressure Alarm (PPABN) Press [MENUS] on the teach pendant. Select [NEXT]. Select [SYSTEM]. Press "F1" (TYPE) on the teach pendant. Select "Config" to disable/enable PPABN. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 377/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 378/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 379/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 380/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 381/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf A A.TOTAL CONNECTION DIAGRAM APPENDIX B-82595EN-2/04 TOTAL CONNECTION DIAGRAM O /R I R N IO S I V t i b a e http://slidepdf.com/reader/full/manutencao-robo-fanucpdf n 382/483 8 A M 7/17/2019 M R C C A m MANUTENÇÃO ROBO FANUC.pdf A.TOTAL CONNECTION DIAGRAM APPENDIX B-82595EN-2/04 O R I/ R N IO IS V http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 8 A M R C 7 A M R C 383/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf A.TOTAL CONNECTION DIAGRAM APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 1 B : 2 B : 1 A 2 3 A A 1 B : 2 B : 3 B : 1 A 2 A 3 A 1 A : 2 A : 1 B : 2 B : 384/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf APPENDIX 1 B : 2 B : 1 A : 2 3 A A : : 1 B : 2 B : 3 B : 1 A 2 A 3 A 1 A : 2 A : 1 B : B-82595EN-2/04 2 B : 385/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 A.TOTAL CONNECTION DIAGRAM H O P C http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 386/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 387/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf C 2 3 2 A.TOTAL CONNECTION DIAGRAM 388/483 S R 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 389/483 CRMA8 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 390/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 391/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 392/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 393/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 394/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 395/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 396/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 397/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 398/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 399/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 400/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 401/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 402/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 403/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 404/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 405/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 406/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 407/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX A.TOTAL CONNECTION DIAGRAM Fig. A (z) RI/RO Connection Diagram (Group8; ARC Mate 100iC, ARC Mate 120iC) There are many type EE conn ector of m echanical uni t. The detail is sho wn o n the mechanical unit manual. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 408/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf A.TOTAL CONNECTION DIAGRAM APPENDIX B-82595EN-2/04 Fig. A (aa) Pulsecoder sig nal connection d iagram http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 409/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX A.TOTAL CONNECTION DIAGRAM Fig. A (ab) Pulsecod er Signal Connecti on Diagram (Group5; M-900iA/600) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 410/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 411/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 412/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 413/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf B-82595EN-2/04 APPENDIX A.TOTAL CONNECTION DIAGRAM Fig. A (af) Pulsecoder Signal Con nectio n Diagram (Group8; ARC Mate 100iC, ARC Mate 120iC) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 414/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 415/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 416/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 417/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 418/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf A.TOTAL CONNECTION DIAGRAM APPENDIX B-82595EN-2/04 O W / I W O /D I D http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 419/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 A.TOTAL CONNECTION DIAGRAM O D I/ D http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 420/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 421/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf A.TOTAL CONNECTION DIAGRAM 422/483 7/17/2019 A.TOTAL CONNECTION DIAGRAM http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 423/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE B SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE B.1 SIGNAL The following table lists the I/O signals used for the peripheral device interface in the R-30 iA controller. Table B.1 (a) Input sign als (Refer to B .3.1) Signal Description *IMSTP *HOLD *SFSPD CSTOPI FAULT_RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 Instantaneous stop signal Hold signal Safety speed signal Cycle stop signal Alarm release signal Cycle start signal Robot service request/program number select signal (*1) Enabling signal Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) RSR7/PNS7 RSR8/PNS8 PNSTROBE PROD_START DI01 DI02 Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) PNS strobe signal Automatic operation start signal General-purpose input signal General-purpose input signal DI03 DI04 General-purpose input signal General-purpose input signal DI05 DI06 DI07 DI08 DI09 DI10 General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 424/483 7/17/2019 B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 Table B.1 (b) Outp ut si gnals (Refer to B.3.2) Signal Description CMDENBL SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL Command acceptance enabled signal System ready signal Program run signal Program paused signal Held signal Alarm signal Reference point signal Teach pendant enabled signal BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 Battery alarm signal Operating signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal ACK8/SNO8 SNACK ______ RSR acknowledge/Selected program number signal PNS acknowledge signal Not used (for future expansion) DO01 DO02 DO03 DO04 DO05 DO06 DO07 DO08 DO09 DO10 DO11 DO12 DO13 General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal DO14 DO15 DO16 DO17 DO18 DO19 General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 425/483 7/17/2019 B-82595EN-2/04 B.2 APPENDIX MANUTENÇÃO ROBO FANUC.pdf B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE SETTING COMMON VOLTAGE All process I/O printed boards have a jumper to set the common voltage of input signals to 0 V or 24 V. The system automatically adjusts the polarity by software according to the status of this pin. Therefore, you can operate the system without being concerned about the setting of the common voltage. To ensure safety, the common reference voltage of the following four signals, is remains at +24V. *IMSTP *HOLD *SFSPD CSTOPI B.3 I/O SIGNALS B.3.1 Input Signals This section describes the specifications of each input signal. (1) Instantaneous stop signal (input) *IMSTP Effective: At any time Function: Use the normally closed switch because it is a reverse signal. The system turns off power to the servo unit when the *IMSTP is open (turned off). This signal has the same effect as that of the emergency stop signal, but it is controlled by software. For this reason, use the emergency stop external interface on the emergency stop control boardFAULT for wiring of the emergency stop signal. Do not use *IMSTP. (2) Alarm release signal (input) RESET Effective: In the alarm status Function: The FAULT RESET signal releases the alarm status. If the servo unit has been turned off, it also turns on the unit. At the same time, the alarm display on the teach pendant (the top line) is cleared. Description: This signal releases only the alarm status. It does not re-start execution of the program. The robot will keep running if the signal is triggered "ON" during operation. (3) Hold signal (input) *HOLD Effective: At any time Function: Use the normally closed switch because it is a reverse signal. The *HOLD signal has the same function as the hold button on the teach pendant. It halts the current program and stops the operation of the robot. While this signal is being input, the http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 426/483 7/17/2019 B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE Effective: Function: MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 At any time - If parameter $SHELL_CFG.$USE_ABORT is set to DISABLED, the CSTOPI signal releases the program from the wait status caused by an RSR. It does not stop the execution of the current program and allows it to continue processing (by default). - If parameter $SHELL_CFG.$USE_ABORT is set to ENABLED, the CSTOPI signal immediately cancels the execution of the current program. The program returns to the status in which it was before execution, and the information for the subprogram to return to the main program is lost. At the same time, this signal also releases the program from the wait status caused by RSR. (6) Enabling signal (input) ENBL Effective: At any time Function: If the ENBL signal is turned off, the operation of the robot or the activation of a program is inhibited, and the execution of the current program is suspended. (7) Safety speed signal (input) *SFSPD Effective: At any time Function: - - - Use the normally closed switch because it is a reverse signal. Usually this switch should be connected to safety fence. It must be set normally on. Since the *SFSPD signal is counted as a remote condition, such input signals as RSR and START to the peripheral device interface cannot take effect unless this signal is turned on. If this signal is turned from on to off during robot operation, the execution of the current program is suspended. At the same time, the overriding value is switched to a preset value (parameter $SCR. $FENCEOVER.) As long as this signal is off, the overriding value cannot be increased beyond the preset value ($SCR.$SFJOGOVLIM: For jog, $SCR. $SFRUNOVLIM : For test execution.) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 427/483 7/17/2019 B-82595EN-2/04 APPENDIX MANUTENÇÃO ROBO INTERACE FANUC.pdf B.SPECIFICATIONS OF PERIPHERAL DEVICE (8) Robot service request signal (input) RSR1/RSR2/RSR3/RSR4 Effective: When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details. Function: - The user can choose between RSR and PNS (optional), although they cannot be used simultaneously. - Four input signals, RSR1 to RSR4, are used. - If a signal is input to an RSR input, a specified program is started. The program number can be set by a menu. - If another program has already started processing, the newly activated program enters the wait status. As soon as the current program terminates, the waiting program starts processing. - By using an RSR instruction, each RSR in a program can be enabled or disabled. - A menu is provided to register the program number of a specified program when each RSR is input. (Refer to the application manual for details of the menu). - When an RSR is input, the program whose program name consists of the specified program number plus a base value is started. For example, if a signal is input to RSR2 when program number 23 is registered in RSR2, the program to be started is the one with the program name calculated from the expression RSR + (RSR2 program number + base number), i.e., RSR0123. The base number is stored in parameter $SHELL_CFG.$JOB_BASE, and can be changed in a program with a parameter instruction. (For example, $SHELL_ CFG. $JOB_BASE =100). In this way, the combination of programs which can be started by RSRs can be changed. Wh th th t h ld t t k l d i lt RSR b l t d http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 428/483 7/17/2019 B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE MANUTENÇÃO B-82595EN-2/04 APPENDIX ROBO FANUC.pdf (9) PNS/PNSTROBE (input) Signal name: PNS: Program number select PNSTROBE: Strobe input for PNS Effective: When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details. Function: - The PNS/PNSTROBE signal selects whether the RSR function is used or the PNS function (optional) is used. If the PNS function is enabled, the RSR function cannot be used. - The eight signals PNS1 to PNS8 are used to specify a program at the instant the - - - strobe signal PNSTROBE rises. A menu is provided to specify the information about PNS. If a number other than zero is entered to PNS input, a program is selected whose program number is the entered value plus the base number. For example, if the PNS value is 23, the program to be started has the program name calculated from the expression PNS + (entered PNS value + base number), i.e., PNS0123. If zero is entered to PNS input, it is cleared as if no selection has been made. A PNS signal, which can only select a program, cannot execute the selected program. The execution of the selected program can only be started after input of automatic operation start signal PROD_START. For safety, the selected program cannot be changed from the teach pendant unless PNSTROBE is turned off. If a program is selected by PNS, the program number is output to selected program number signal (output) SNO, and a pulse is output to program selection acknowledge signal SNACK. Using these signals, peripheral devices can confirm the correct h b l t d F th ti i f th i l th ti http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 429/483 7/17/2019 B-82595EN-2/04 B.3.2 APPENDIX MANUTENÇÃO ROBO INTERACE FANUC.pdf B.SPECIFICATIONS OF PERIPHERAL DEVICE Output Signals This section describes the specifications of output signals for the peripheral device interface. (1) Command acceptance enabled signal (output) CMDENBL Turned on: When the remote conditions are satisfied and the system is not in the alarm status Turned off: When the remote conditions are not satisfied or the system is in the alarm status the remote conditions are satisfied when all of the following are satisfied. (2) (3) (4) (5) - The teach pendant is in the DISABLED status. - The remote/local setting is set to REMOTE. - Parameter $RMT_MASTER is set to 0 (external interface). - Signal *SFSPD is set to on, or in the normal status. System ready signal (output) SYSRDY Turned on: When power is applied to the motor of the robot. Turned off: When power is not applied to the motor of the robot. Program run signal (output) PROGRUN Turned on: When the program is being executed. Turned off: When the program is not being executed. Held signal (output) HELD This signal is used to check the status of the hold input. Turned on: When the hold button on the teach pendant (or input) is being pressed down (or turned on). Turned off: When the hold button on the teach pendant (or input) is not being pressed down (or is turned off). Program paused signal (output) PAUSED This signal is used together with output signal PROGRUN to determine whether a program can be restarted while it is being held. Turned on: When a program is held and has not been restarted yet. While this signal is on, the program can be restarted and retains information such as that to return from a subprogram to the main program. Turned off: When a program is being executed or is ready to start. If signal PROGRUN is on, the program is being executed. If signal PROGRUN is off, the program has not been executed and can be started from this status. (6) Alarm status signal (output) FAULT Turned on: When the system is in the alarm status (or an alarm which can stop a program execution is detected.) The indicator lamp does not go on in warning. Turned off: When the alarm status is released by an alarm release operation. (7) Reference point signal (output) ATPERCH Turned on: When the robot is in the reference position specified in the parameter. (The reference http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 430/483 B.SPECIFICATIONS 7/17/2019 OF PERIPHERAL DEVICE INTERACE B-82595EN-2/04 APPENDIX ROBO FANUC.pdf MANUTENÇÃO Turned on: When a program is being executed or is being processed from operation panels such as the teach pendant. (This has the same function as that of the BUSY lamp on the teach pendant.) Turned off: When a program is not being executed nor is being processed from operation panels such as the teach pendant. (11) RSR acknowledge signals (output) ACK1/ACK2/ACK3/ACK4 These signals are used together with the RSR function. They can be specified to be enabled or disabled from the RSR setup menu. Turned on: When one of the signals from RSR1 to RSR4 is input and accepted. A pulse whose width is specified from the menu is output to acknowledge the signal. Turned off: Normally. off status. Since these signals are always output as pulses, they are normally in the The following chart shows the timing of the RSR input and ACK output. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 431/483 B-82595EN-2/04 7/17/2019 APPENDIX B.SPECIFICATIONS OF PERIPHERAL DEVICE MANUTENÇÃO ROBO INTERACE FANUC.pdf (12) PNS acknowledge signal (output) SNO/SNACK These signals are used together with the PNS function. Turned on: Whenever the PNS function is enabled. The selected program number is displayed in binary code (SN01 to SN08) on the teach pendant. If the number cannot be represented as an eight-bit number, it becomes zero. After selecting a program by PNS, a pulse is output from signal SNACK as a part of the PNS operation. The width of the pulse can be specified from the menu. See the timing chart below. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 432/483 B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE 7/17/2019 APPENDIX B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf B.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT B.4.1 Overview This section describes the external specifications of digital and analog input/output in the R-30 iA controller. B.4.2 Input/Output Hardware Usable in the R-30iA Con trol ler The R-30iA controller can use up to 512 digital input and output points or an equivalent number of analog input and output points. One analog input/output point uses the resources equivalent to those used by 16 digital I/O points. The R-30iA can use a total of up to 512 I/O points. The R-30iA controller can use the following I/O hardware. Process I/O printed circuit board - I/O unit model A The process I/O printed circuit board and the I/O unit model A can be used together. B.4.3 Software Specifications (1) RI/RO These are signals sent to the connector at the wrist of the robot. They cannot be assigned (redefined) andeight are fixed. The standard format is eight inputs and outputs. The number of points that can be used for the connector at the wrist depends on the individual robot. (2) DI/DO The signal No. that is determined at hardware can be changed by software operation. (3) Analog I/O An analog I/O signal can access the analog I/O port (optional) on the process I/O printed circuit board or the I/O port on the analog I/O module (used together with the I/O unit model A). It reads and writes the digital value converted from the analog value of the I/O voltage. It means that the value does not always represent the real I/O voltage. (4) Group I/O Group I/O is a function, which can input or output multiple DI/DO signals as binary codes. Any number of continuous signals of up to 16 bits can be set for its use. It can be set in the menu DETAILS on the group I/O screen. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 433/483 APPENDIX B-82595EN-2/04 7/17/2019 C C.OPTICAL FIBER CABLE MANUTENÇÃO ROBO FANUC.pdf OPTICAL FIBER CABLE The R-30iA uses fiber optic cables for communication between the main board and servo amplifiers. Observe the following cautions when handling these fiber optic cables. Handle fiber optic cables with utmost care, especially when installing the unit. (1) Protection during storage When the electrical/optical conversion module (mounted on the printed) circuit board and the fiber optic cable are not in use, their mating surfaces must be protected with the lid and caps with which they are supplied. If left uncovered, the mating surfaces are likely to become dirty, possibly resulting in a poor cable connection. Fig.C (a) Protection o f electrical/optical conversion module and fiber opt ic cable (when not in u se) (2) Fiber optic cable http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 434/483 C.OPTICAL FIBER CABLE 7/17/2019 APPENDIX B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf Minimum bending radius of cable with reinforced cover: 50 mm Bending resistance (cable with reinforced cover): 10 million bending cycles at room temperature (when the bending radius is 100 mm) Flame resistance: Equivalent to UL VW-1 Operating temperature: -20 to 70ºC Fig.C (b) External dimensions of external optical cable Unit: mm - - After it is connected, the optical connector is automatically locked by the lock levers on its top. To remove the connector, release the lock levers and pull the connector. Although optical connectors cannot be connected in other than the correct orientation, always take note of the connector's orientation before making the connection. Take care to keep both parts of the optical connector (cable side and PCB side) clean. If they become dirty, wipe them with tissue paper or absorbent cotton to remove dirt. The tissue paper or absorbent cotton may be moistened with ethyl alcohol. Do not use any organic solvent other than ethyl alcohol. Fix the reinforcing cover by using a cable clamp, as shown in Fig. C(c), to prevent the weight of the fiber optic cable from being applied directly to the connecting part of the optical connector. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 435/483 B-82595EN-2/04 7/17/2019 APPENDIX C.OPTICAL FIBER CABLE MANUTENÇÃO ROBO FANUC.pdf External cable: Do not clamp the uncovered portion of the cable with a nylon band. When clamping the cable by the reinforcing cover, the clamping force is not an important factor to consider. However, ensure that the clamping force is as small as possible to ensure that the reinforcing cover is not deformed by the clamping. If possible, the clamping force should be 5kg (111bs) or less. http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 436/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 437/483 D.BRAKE RELEASE UNIT APPENDIX B-82595EN-2/04 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf D D.1 BRAKE RELEASE UNIT SAFETY PRECAUTIONS WARNING Support the robot arm by mechanical means to prevent it from falling down or rising up when brake is released. Before using the brake release unit, read the Operator’s manual of the robot that tries to release the brake. Confirm that the robot is fixed tightly to the floor to prevent the falling down and unexpected movement of robot. Confirm that the outlet with earth is used for the power supply of brake release unit and earth of brake release unit is surely connected to earth of power supply. There is danger of getting an electric shock if earth is not connected. D.2 CONFIRMATIONS BEFORE OPERATION Confirm the followings before operation. (1) Confirm the exterior of the brake release unit and the power cable. Do not use it when there are damages in the unit and the cable. (2) Confirm that the power supply of the robot controller is disconnected. (3) There are Two types of brake release units according to the input voltage as shown in Table D.2 (a). Confirm the input voltage of the unit to refer to the input voltage label put to the unit (Fig.D.4). (4) Confirm that the voltage of power supply before connecting the power supply to the brake release unit. There is possibility to give the damaging to the brake or the brake release unit when the incorrect power supply is connected to the unit. Table D.2 (a) Specificati on o f Br ake release uni t Brake release uni t Remarks Brake release unit (AC 100V) Brake release unit (AC 200V) Input voltage AC100-115V, single phase Input voltage AC200-240V, single phase http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 438/483 D.BRAKE RELEASE UNIT APPENDIX B-82595EN-2/04 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf (5) The brake release unit connection cable is different in each robot. Confirm the cable specification corresponding to the robot referring to Table D.2 (b). Robot Brake release unit side(CRR56A) Robot side RM1 Auxiliary Axis The applicable robot types are shown. Cable specification Inside robot controller (CRR65A/B) Brake release unit side(CRR56A) Fig.D.2 Brake release unit connection cable Table D.2 (b) Specification of brake release unit connection cable Controller R-30iA Stand alone type Applicable robot types Specification of cable R-2000iB, R-2000iB/200T, M-710iC, M-410iB, M-420iA, M-421iA, M-900iA/350, M900iA/400L, M900iA/600, M-900iA/200P,M-2000iA, R-1000iA M-6iB, M-16iB, ARC Mate 100iB, ARC Mate 120iB, F-200iB M-10iA, M-20iA, ARC Mate 100iC, ARC Mate 120iC i i i A660-2005-T559 A660-2005-T871 A660-2006-T881 i M-430 A/2F, M-430 A/2FH, M-430 A/2PH,M-430 A/4FH M-430iA/2P R-30iA Integrated type C-flex, F-100iA Aux. Axis A660-2006-T888 A660-2006-T887 A660-2006-T474 A660-2005-T711 M-410iB A660-2006-T803 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 439/483 D.BRAKE RELEASE UNIT APPENDIX B-82595EN-2/04 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf D.3 OPERATION In case of operating t o the robot Operate the brake release unit according to the following procedures. (1) Support the robot arm by mechanical means to prevent it from falling down or rising up when brake is released. Refer to the Operator’s manual for each robot. (2) Connect the Brake Release Unit connection cable to Brake Release Unit. (3) Disconnect the RM1 connector from Robot, and connect the Brake Release Unit connection cable to the Robot. Keep the connection of Robot connection cable except RM1 cable. (4) Connect the power cable of Brake release unit to power supply. (5) Press and hold the deadman switch in the middle position. (6) Press the brake switch ‘1’..’6’ according to the axis that tries to release the brake, then brake will be released. (Refer to Table D.3) Two axes or more cannot be operated at the same time. Deadman switch Brake Release Unit 1 2 3 4 5 6 Brake switch Power cable Brake Release Unit connection cable Fig.D.3 (a) Brake Release Unit Table D.3 The relation b etween brake switc h and rob ot axis http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 440/483 APPENDIX B-82595EN-2/04 7/17/2019 Except M-410iB (Integrated r obot ) D.BRAKE RELEASE UNIT MANUTENÇÃO ROBO FANUC.pdf Remove RM1 connector Robot controller ＲＭ1 Robot Brake Release Unit connection cable Power Cable Brake Release Unit Fig.D.3 (b) How to conn ect Brake Release Unit (In case of except M-410iB) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 441/483 D.BRAKE RELEASE UNIT APPENDIX 7/17/2019 In case of M-410iB (Integrated ro bot) B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf Connect Brake release unit cable to servo motor brake connector. Only J1 switch is available. Servo motor brake corrector Robot Controller Brake Release Unit connection cable Power Cable Brake Release Unit (Press the brake switch‘1’, then brake will be released) Fig.D.3 (c) How t o co nnect Brake Release Unit (In case of M-410iB) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 442/483 D.BRAKE RELEASE UNIT APPENDIX B-82595EN-2/04 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf In case of operating t o the auxiliary Axis Operate the brake release unit according to the following procedures. (1) Support the auxiliary Axis by mechanical means to prevent it from falling down or rising up when the brake is released. (2) Connect the Brake Release Unit connection cable to Brake Release Unit. (3) Disconnect the aux. axis brake connector (CRR65A/B), and connect the CRR65A/B connector to the Brake Release Unit connection cable. Keep the connection of all cables of aux. axis motor (power, Pulsecoder, brake). (4) Connect the power cable of Brake release unit to power supply. (5) Press and hold the deadman switch in the middle position. (6) Press the brake switch‘1’, then brake will be released. Robot controller Disconnect the brake connection cable(CRR65A/B) Brake cable for Aux. Axis Do not disconnect motor cables. Motor for Aux. Axis Brake Release Unit connection cable Power cable Break Release Unit Fig.D.3 (d) How t o con nect Brake Release Unit (In case of operati ng to the Aux. Axis) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 443/483 D.BRAKE RELEASE UNIT 7/17/2019 APPENDIX B 82595EN 2/04 MANUTENÇÃO ROBO FANUC.pdf D.4 HOW TO CONNECT THE PLUG TO THE POWER CABLE (IN CASE OF NO POWER PLUG) Connect the plug to the power cable as follows. This plug is provided by customer. Terminal (M4 Size) 1(R) 2(S) PE Earth(Yellow/Green spiral） Power plug （Provided by customer） AC200-240V Cable (Provided by FANUC) 1(R) +10%/-15% Brake Release Unit or 2(S) AC100-115V +10%/-15% PE Outlet Fig.D.4 How t o connect th e plug to the power cable WARNING Only a specialist having the relevant expertise knowledge is permitted to connect the plug to the power cable. In the EU area, only plug complying with the relevant European product standard can be used. Do not install the plugs without protective earth pin http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 444/483 APPENDIX D.BRAKE RELEASE UNIT 7/17/2019 D.5 MANUTENÇÃO ROBO FANUC.pdf DIMENSION Warning label Input voltage label Brake switch Pilot lamp Deadman switch Caution label Belt http://slidepdf.com/reader/full/manutencao-robo-fanucpdf D.BRAKE RELEASE UNIT 445/483 APPENDIX B-82595EN-2/04 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Instructions for use Fig.D.5 (b) Dimensio n o f Br ake Release Unit (Rear view ) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 446/483 APPENDIX D.BRAKE RELEASE UNIT D.6 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf FUSE The fuses are mounted inside this unit. Please check the fuse when the pilot lamp doesn't light even if deadman switch is pressed. When the fuse is blown, exchange the fuse after finding the root cause of failure, and taking the appropriate countermeasures. Manufacturer: Daito Communication Co. Specification: P420H Rating: 2A WARNING When the fuse is replaced, the power cable of brake release unit must be disconnected. FU011 FU012 FU001 Fig.D.6 The location of fuses D.7 I t SPECIFICATIONS l http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 447/483 APPENDIX B-82595EN-2/04 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf E THE CONTROLLER FOR M-900iA/200P, M-2000iA Additional document of the controller for M-900iA/200P and M-2000iA. E.1 CONFIGURATION E-STOP transit unit Operator’s panel 6-servo amplifier(AMP1） DC fan motor Mode switch Emergency stop External Panel board Breaker/Noise Filter unit Battery Emergency stop button Back plane RCC I/F unit E-stop unit Door fan Teach pendant Enable switch Main board Power supply unit Floor fan Optional slot Fig. E (a) M-900iA/200P, MAIN CONTRLLER 6-servo amplifier (AMP1) DC fan motor External fan unit http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 APPENDIX E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 448/483 7/17/2019 E-STOP transit unit Operator’s panel Aux.Axis amplifier (AMP2) MANUTENÇÃO ROBO FANUC.pdf 6-servo amplifier (AMP1) DC fan motor Mode switch Emergency stop External Panel board Breaker/Noise Battery Filter unit Back plane Emergency stop button RCC I/F unit E-stop unit Door fan Enable switch Teach endant Main board Optional slot Power supply unit Floor fan Fig. E(c) M-2000iA, MAIN CONTROLLER Aux.Axis amplifier (AMP2) DC fan motor 6-servo amplifier (AMP1) External fan unit Breaker/Noise Filter unit Back plane RCC I/F unit http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA APPENDIX B-82595EN-2/04 449/483 E.2 MANUTENÇÃO ROBO FANUC.pdf TROUBLESHOOTING USING THE ERROR CODE E.2.1 Troubleshootin g using t he error c ode 7/17/2019 (1) SRVO-101 Robot overtravel (Explanation) The robot has moved beyond a hardware limit switch on the axes. (Action) Take the same actions as SRVO-005. NOTE It is factory-placed in the overtravel state for packing purposes. If the Overtravel signal is not in use, it may have been disabled by short-circuiting in the mechanical unit. (2) SRVO-102 Hand broken (Explanation) The safety joint (if in use) might have been broken. Alternatively, the HBK signal on the robot connection cable might be a ground fault or a cable disconnection. (Action) Take the same actions as SRVO-006. NOTE If the Hand broken signal is not in use, it can be disabled by software setting. Refer to Subsection 5.5.3 How to Disable/Enable HBK in Part III, "CONNECTIONS" of "Maintenance Manual" to disable the Hand broken signal. (3) SRVO-103 Pneumatic pressure abnormal (Explanation) An abnormal air pressure detected. effector of the robot. Referwas to the manual ofThe yourinput robot.signal is located on the end (Action) Take the same actions as SRVO-009. NOTE Pneumatic pressure alarm input is on the end effector. manual of your robot. Please refer to the (4) SRVO-106 Door open or E-stop (Explanation) The cabinet door is open. - When the door switch is mounted. (Action) Take the same actions as SRVO-105 (5) SRVO 244 Ch i 1 (+24V) b http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 APPENDIX l E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 450/483 7/17/2019 (6) SRVO-301 Hand broken/HBK disabled SRVO-303 Set Hand broken to ENABLE MANUTENÇÃO ROBO FANUC.pdf (Explanation) Although HBK was disabled, the HBK signal was input. (Action) Take the same actions as SRVO-300, 302. Main controller 2nd controller Servo amplifier Panel board Servo amplifier E-stop unit E-stop unit Fig. E (e) B-cabinet (In case of M-900 iA/200P,M-2000iA) E.2.2 Alarms det ected by servo amp lif ier The following alarms are detected by servo amplifier. If the alarms in the following table are caused, find the controller, which the alarm is caused according to the table of relationship of axis. (E2.3) And find the cause and take an appropriate measure according to the troubleshooting in maintenance Chapter 3. Table E (a) Alarms detected by servo ampli fier Alarm SRVO - 018 Brake abnormal (Group:i Axis:j) SRVO - 043 DCAL alarm (Group:i Axis:j) SRVO - 044 HVAL alarm (Group:i Axis:j) SRVO - 047 LVAL alarm (Group:i Axis:j) SRVO - 049 OHAL1 alarm (Group:i Axis:j) SRVO 136 DCLVAL l (G i A i j) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA APPENDIX B-82595EN-2/04 451/483 E.2.3 7/17/2019 Relationship of axis MANUTENÇÃO ROBO FANUC.pdf The following table is shown the relation ship of each axes (Axis (j) displayed in the teach pendant, motor number, Controller, Connector of AMP) for M-900iA/200P, M-2000iA and M-430iA. If the alarm is occurred, find the motor number, the connector of AMP and the controller (which the alarm is caused) according to the relationship of the axis and the alarm displayed in the teach pendant (Axis (j)), and find the cause of alarm according to the trouble shooing. ALARM disp layed i n t he t each pen dan t. SRVO - *** ALARM (Group:i Axis:j) Table E (b) Relation of axis (In case of M-900iA/200P) M-900iA/200P Without Aux. Axis AMP M-900iA/200P In case of 1 Aux. Axis amplifier Axi s (j ) Motor number Controller Connector of AMP 1 2 3 4 J1A J2 J3 J4 2nd controller 2nd controller Main controller 2nd controller 6 axis amplifier (AMP1): CNJ1 6 axis amplifier (AMP1): CNJ2 6 axis amplifier (AMP1): CNJ2 6 axis amplifier (AMP1): CNJ4 5 6 7 1 2 3 4 5 6 7 8 J5 J6 J1B J1A J2 J3 J4 J5 J6 2nd controller Main controller Main controller 2nd controller 2nd controller Main controller 2nd controller 2nd controller Main controller Main controller Main controller 6 axis amplifier (AMP1): CNJ5 6 axis amplifier (AMP1): CNJ3 6 axis amplifier (AMP1): CNJ1 6 axis amplifier (AMP1): CNJ1 6 axis amplifier (AMP1): CNJ2 6 axis amplifier (AMP1): CNJ2 6 axis amplifier (AMP1): CNJ4 6 axis amplifier (AMP1): CNJ5 6 axis amplifier (AMP1): CNJ3 6 axis amplifier (AMP1): CNJ4 6 axis amplifier (AMP1): CNJ1 J7 (Aux. axis) J1B Table E (c) Relation of axis (In case of M-2000iA) M-2000iA No Aux. Axis AMP Axi s (j ) Motor number Controller Connector of AMP 1 2 3 4 5 6 7 J1 J2A J3A J4 J5 J6 J2B Main controller Main controller Main controller Main controller 2nd controller 2nd controller 2nd controller 6 axis amplifier (AMP1): CNJ1 6 axis amplifier (AMP1): CNJ2 6 axis amplifier (AMP1): CNJ3 Aux. axis amplifier (AMP2): CNJ1 6 axis amplifier (AMP1): CNJ1 Aux. axis amplifier (AMP2): CNJ1 6 axis amplifier (AMP1): CNJ2 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf B-82595EN-2/04 APPENDIX E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 452/483 E.3 7/17/2019 INSTALLING THE CONNECTION CABLE BETWEEN MANUTENÇÃO ROBO FANUC.pdf CABINETS The connection cable between cabinets (emergency stop cable, optical cable, and earth cable) is disconnected from the main controller at shipment. Install the connection cable between cabinets as shown in the following Fig. E (f). E-stop transit unit CRMA13A AMP2 COP10A Main controller controller Main 2ndcontroller controller 2nd Earth cable: Fix the screw (M5) Earth cable: Fix the nylon band The connection cable between cabinets. (length 50cm/1m) Optical cable(FSSB) Emergency stop signal cable Earth cable ・ Optical: Fix the nylon band ・ Cable for E-stop (CRMA13A): Fix the nylon band ・ Remove jumper connector, and Cable for E-stop attach CRMA13A connector. Fig. E (f ) Installing the con nection cable between cabinets http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA APPENDIX B-82595EN-2/04 453/483 E.4 7/17/2019 ROBOT CONNECTION CABLE MANUTENÇÃO ROBO FANUC.pdf Following is the installation method of robot connection cable for M-900 iA/200P,M-2000iA at installing. Teach pendant Robot connection cable (RM) Robot connection cable (RM) Main controller 2nd controller Robot connection cable (RP) Cabinet connection cable Robot connection cable (RP) Fig. E (g) Assemble at i nstallatio n (In case of M-900iA/200P,M-2000iA) Motor power RM1, RM2, RM3, RM4 EARTH B-82595EN-2/04 APPENDIX E.THE http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CONTROLLER FOR M-900iA/200P, M-2000iA 454/483 There are two types of the robot connection cable; Non-flex type: usage is restricted to fixed laying 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Flex type: possible to use in the cable track Table E (e) Specifi cation of cabl e Non-flex type Robot RP1 RP1, 2 RM1, 2,3,4 RP1, 2 RM1, 2,3,4 EARTH All models M-900iA/200P M-2000iA All models Flex type Diameter (mm) Weight (kg/m) Minimum bending radius (mm) Diameter (mm) Weight (kg/m) Minimum bending radius (mm) 15.7 14.2 26.1 14.2 26.1 4.7 0.45 0.31 1.22 0.31 1.22 0.065 200 200 200 200 200 200 20.5 4.7 0.71 0.065 200 200 CAUTION Before operating the robot, uncoil the interconnection cables from their shipping position to prevent excessive heat, which may damage the cables. (Coiled part should be shorter than 10 meter.) E.THE CONTROLLER FOR M-900iA/200P, http://slidepdf.com/reader/full/manutencao-robo-fanucpdf M-2000iA APPENDIX B-82595EN-2/04 455/483 - Detail of cable connection to servo amplifier 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf R-30iA (Main controller) Robot 6-Axis Servo amplifier (AMP1) CRR88 CNGA CNJ3A CNJ3B CNGB CRF8 RP2 (Pulsecoder, RI/RO, XHBK, XROT) RM3 Motor power (J1BM, J3M, J6M, J7M) RM4 Motor power CNJ1B CNJ2B CNJ1A CNJ2A JF (J1BM, J3M, J6M, J7M) A 1 M R CZ2 B 1 M R A 2 M R B 2 M R RCC I/F UNIT R-30iA (2nd controller) 6-Axis Servo amplifier (AMP1) CRR88 CNGA CNJ3A CNJ3B CNGB CRF8 RP1 (Pulsecoder, RI/RO, XHBK, XROT) RM1 Motor power/brake (J1AM, J2M, J4M, J5M, BK) B-82595EN-2/04 APPENDIX E.THE http://slidepdf.com/reader/full/manutencao-robo-fanucpdf CONTROLLER FOR M-900iA/200P, M-2000iA 456/483 - Detail of cable connection to servo amplifier 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf R-30iA (Main controller) Robot 6-Axis Servo amplifier (AMP1) CRR88 CNGA CNJ3A CNJ3B CNGB RP1 CRF8 (Pulsecoder, RI/RO, XHBK, XROT) RM1 Motor power/brake (J1M, J2AM, J3AM, J4, BK) RM2 Motor power CNJ1B CNJ2B CNJ1A CNJ2A (J1M, J2AM, J3AM, J4) 1-Axis Servo amplifier (AMP2) JF CZ2L A M R B M R RCC I/F UNIT i R-30 A (2nd controller) 6-Axis Servo amplifier (AMP1) CRR88 CNGA CNJ3A CNJ3B CNGB CRF8 RP2 (Pulsecoder, RI/RO, XHBK, XROT) RM3 Motor power (J5M, J2BM, J3BM, J6M) E.THE CONTROLLER FOR M-900iA/200P, M-2000iA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf APPENDIX B-82595EN-2/04 457/483 E.5 7/17/2019 CONNECTING THE INPUT POWER CABLE MANUTENÇÃO ROBO FANUC.pdf M-900iA/200P and M-2000iA are composed of two B cabinets, and need to connect the power supply with each main breaker as shown in figure E (k). Refer to Chapter 3.2 for the method of connecting the power supply with each main breaker. Main controller Main breaker 2nd controller Main breaker Fix power supply cable Input power supply Input power supply Earth cable (M5) (Note) Be sure to put the cover back in place after wiring. Fig. E (k) B-cabinet (In case o f M-900iA/200P,M-2000iA) B-82595EN-2/04 APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 458/483 E.6 7/17/2019 CONFIRMATIONS OF ON/OFF BY THE BREAKER FOR MANUTENÇÃO ROBO FANUC.pdf M-900iA/200P AND M-2000iA (1) In case of turn on power supply, turn on MAIN MACHINE DISCONNECT-1 (Breaker of main controller) after turn on MAIN MACHINE DISCONNECT-2 (Breaker of 2nd controller) every turn on power supply. (2) Turn off MAIN MACHINE DISCONNECT-2 (Breaker of 2nd controller) after turn off MAIN MACHINE DISCONNECT-1 (Breaker of main controller), when the power off or servicing. WARNING Turn off both MAIN MACHINE DISCONNECT-1 (Breaker of main controller) and MAIN MACHINE DISCONNECT-2 (Breaker of 2nd controller) before servicing. Main controller 2nd controller Breaker of MAIN CONTROLLER (MAIN MACHINE DISCONNECT-1) E.THE CONTROLLER FOR M-900iA/200P, M-2000iA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Breaker of 2nd CONTROLLER (MAIN MACHINE DISCONNECT-2) APPENDIX B-82595EN-2/04 459/483 E.7 TOTAL CONNECTION DIAGRAM 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 460/483 7/17/2019 E.THE CONTROLLER FOR M-900iA/200P, M-2000iA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 461/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 462/483 7/17/2019 E.THE CONTROLLER FOR M-900iA/200P, M-2000iA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 463/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 464/483 7/17/2019 E.THE CONTROLLER FOR M-900iA/200P, M-2000iA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 465/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 466/483 7/17/2019 E.THE CONTROLLER FOR M-900iA/200P, M-2000iA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 467/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 468/483 7/17/2019 E.THE CONTROLLER FOR M-900iA/200P, M-2000iA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 469/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 470/483 7/17/2019 E.THE CONTROLLER FOR M-900iA/200P, M-2000iA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 471/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 472/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig. A (y) Pulsecod er Signal Connecti on Diagram (grou p9; M-900iA/200P,Main co nt ro ll er) E.THE CONTROLLER FOR M-900iA/200P, M-2000iA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf APPENDIX B-82595EN-2/04 473/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Fig. A (aa) Pulsecoder Sign al Connecti on Diagram (gro up10; M-2000iA, Main co nt ro ll er) B-82595EN-2/04 APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 474/483 7/17/2019 E.THE CONTROLLER FOR M-900iA/200P, M-2000iA http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf APPENDIX B-82595EN-2/04 475/483 7/17/2019 B-82595EN-2/04 MANUTENÇÃO ROBO FANUC.pdf APPENDIX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf E.THE CONTROLLER FOR M-900iA/200P, M-2000iA 476/483 7/17/2019 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf 477/483 7/17/2019 B-82595EN-2/04 INDEX http://slidepdf.com/reader/full/manutencao-robo-fanucpdf MANUTENÇÃO ROBO FANUC.pdf INDEX 478/483 <Number> 7/17/2019 100BASE-TX Connector (CD38R) Pin Assignments.. 326 <A> A-CABINET................................................................ 162 ADJUSTMENT AND CHECKS AT INSTALLATION343 ALARM OCCURRENCE SCREEN.............................. 31 Alarms detected by servo amplifier..............................417 ARC Weld Connection Cable (CRW1, CRW7: Honda Tsushin, 34pins)...........................................................312 ARC Weld Connection Cable (CRW10: Honda Tsushin, 50 pins).............................................................................. 312 Assemble at Installation ............................................... 340 <B> BACKPLANE BOARD...............................................126 Battery for Memory Backup (3 VDC) .........................207 BLOCK DIAGRAM ....................................................214 BLOCK DIAGRAM OF THE POWER SUPPLY.......156 BRAKE RELEASE UNIT ........................................... 404 <C> CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS, AND ARC WELDERS .....................................................................................313 Check input voltage......................................................235 Check Items at Installation...........................................333 CHECKING THE POWER SUPPLY UNIT (A16B-2203-0910).......................................................160 COMPONENT FUNCTIONS........................................26 CONFIGURATION................................................14,414 CONFIRMATIONS BEFORE OPERATION..............404 CONFIRMATIONS OF ON/OFF BY THE BREAKER FOR M-900iA/200P AND M-2000iA..........................425 Connecting HDI ........................................................... 318 Connecting the Auxiliary Axis Brake (CRR65 A/B) ...250 Connecting the Auxiliary Axis Over Travel (CRM68) 251 CONNECTING THE COMMUNICATION UNIT .....321 Connecting the External Emergency Stop....................239 INDEX Leakage breaker ...........................................................235 LED OF SERVO AMPLIFIER....................................154 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf <D> MANUTENÇÃO ROBO FANUC.pdf DIGITAL I/O SIGNAL SPECIFICATIONS ............... 304 DIMENSION...............................................................411 <E> ELECTRICAL CONNECTIONS ................................ 216 Electrical Noise Countermeasures ............................... 329 EMERGENCY STOP CONTROL BOARD (A20B-1008-0740)....................................................... 125 End Effector Cable Connector..................................... 316 End Effector Control Interface..................................... 307 Ethernet Interface.........................................................324 EXTERNAL CABLE WIRING DIAGRAM...............218 EXTERNAL VIEW OF THE CONTROLLER ............. 14 <F> FUSE ........................................................................... 413 FUSE-BASED TROUBLESHOOTING......................100 <G> GENERAL...................................................................213 General Person Safety......................................................5 <H> HOW TO CONNECT THE PLUG TO THE POWER CABLE (IN CASE OF NO POWER PLUG)............... 410 How to Disable/Enable HBK.......................................344 How to Disable/Enable Pneumatic Pressure Alarm (PPABN)......................................................................345 HOW TO USE THE PLATE TO FIX THE COMPACT FLASH MEMORY CARD..........................................209 <I> I/O Signal Specifications for ARC-Welding Interface.308 I/O SIGNALS .............................................................. 393 In Case of A-cabinet .................................................... 262 In case of B-cabinet ..................................................... 261 In Case of B-cabinet .................................................... 263 Input Signal Rules for the High-speed Skip (HDI)...... 320 B-82595EN-2/04 PROCESS I/O BOARD KC (A16B-2204-0052, A20B-2101-0562)........................................................ 150 PROCESS I/O BOARD SIGNALS ............................. 263 479/483 <M> MAIN BOARD (A16B-3200-0600, -0601) ................. 122 MANUAL OPERATION IMPOSSIBLE..................... 121 MASTERING ................................................................ 35 7/17/2019 <O> On/off timing by the breaker........................................235 OPERATION...............................................................406 OPTICAL FIBER CABLE...........................................401 Output Signals..............................................................397 Overview......................................................................400 OVERVIEW .................................................................. 13 <P> PANEL BOARD (A20B-2101-0370) ..........................128 Peripheral Device and Control Unit Connection (Sink Type DO) ..............................................................................279 Peripheral Device and Control Unit Connection (Source Type DO) .....................................................................265 Peripheral Device Cable Connector .............................314 Peripheral Device Connection Cable ...........................313 Peripheral Device Interface A......................................304 Peripheral Device Interface A Cable (CRM2, CRMA5: Honda Tsushin, 50 pins)...............................................311 Peripheral Device Interface B Cable (CRM4, CRMA6: Honda Tsushin, 20 pins)...............................................311 <R> MANUTENÇÃO ROBO FANUC.pdf Recommended Cables..................................................317 Relationship of axis ..................................................... 418 REPLACE THE MODE SWITCH .............................. 197 Replacing a Module..................................................... 191 REPLACING A UNIT................................................. 161 REPLACING BATTERY............................................207 REPLACING CARDS AND MODULES ON THE MAIN BOARD ....................................................................... 169 Replacing External Air Fan Unit (A-cabinet) .............. 195 Replacing External Fan Unit and Door Fan (B-cabinet)196 REPLACING FUSES .................................................. 199 Replacing Fuses in the Main board..............................201 Replacing Fuses in the Power Unit.............................. 200 Replacing Fuses in the Servo Amplifier ...................... 199 REPLACING I/O UNIT-MODEL A ........................... 190 REPLACING RELAYS...............................................206 Replacing Relays on the Panel Board.......................... 206 REPLACING SERVO AMPLIFIERS......................... 185 REPLACING THE AC FAN MOTOR........................ 194 Replacing the A-cabinet Door...................................... 164 Replacing the A-cabinet Louver .................................. 163 Replacing the A-cabinet Rear Panel ............................ 163 Replacing the A-cabinet Top Panel ............................. 162 Replacing the Backplane Board (Unit) ........................ 165 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM...................................................................255 PERIPHERAL DEVICE INTERFACE COMBINATION .....................................................................................262 Peripheral Device Interface Processing........................344 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES.........................................253 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) ...............120 Replacing the Base Unit of I/O Unit-MODEL A......... 190 REPLACING THE CONTROL SECTION FAN MOTOR ..................................................................................... 193 REPLACING THE E-STOP UNIT.............................. 183 Replacing the Fuse on the Panel Board........................ 206 Replacing the Fuse on the Process I/O Boards ............ 202 Replacing the Heat Exchanger and Door Fan Unit (A-cabinet)................................................................... 194 Replacing the Panel Board........................................... 168 POWER CANNOT BE TURNED ON ..........................28 Precautions for Mechanism..............................................8 Precautions for Mechanisms ............................................ 9 Precautions in Operation ..................................................8 Precautions in Programming ......................................... 8,9 Replacing the Power Unit and Printed-Circuit Boards on the Backplane Unit ............................................................ 166 REPLACING THE PRINTED-CIRCUIT BOARDS... 165 Replacing the Process I/O Board EA, EB, FA, GA, KA, KB, KC (A-cabinet) 169 B-82595EN-2/04 SAFETY OF THE END EFFECTOR..............................9 SAFETY OF THE ROBOT MECHANISM .................... 8 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Safety of the Teaching Operator ......................................6 INDEX 480/483 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES .........................................................................................8 7/17/2019 SAFETY PRECAUTIONS ....................................... 3,404 SAFETY SIGNALS.......................................................34 SERVO AMPLIFIERS ................................................ 152 SETTING COMMON VOLTAGE ..............................393 SETTING OF SERVO AMPLIFIER ...........................155 SETTING THE POWER SUPPLY..............................156 SIGNAL.......................................................................391 Software Specifications................................................400 SPECIFICATIONS ......................................................413 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT.. 400 SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE..................................................................391 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS...............311 MANUTENÇÃO ROBO FANUC.pdf <T> Teach Pendant Cable....................................................231 THE CONTROLLER FOR M-900iA/200P, M-2000iA414 TOTAL CONNECTION DIAGRAM...................349,426 TRANSFORMER ........................................................157 TRANSPORTATION ..................................................334 TRANSPORTATION AND INSTALLATION........... 334 TROUBLESHOOTING.................................................28 TROUBLESHOOTING BASED ON LED INDICATIONS .....................................................................................108 Troubleshooting using the error code...........................416 TROUBLESHOOTING USING THE ERROR CODE ................................................................................37,416 Twisted-pair Cable Specification .................................326 <W> WARNING LABEL.........................................................9 When I/O Unit-MODEL A is Used..............................261 When Process I/O Board CA/HA is Used (B-cabinet) .257 When Process I/O Board EA/EB/GA is Used (A-cabinet) .....................................................................................255 When Process I/O Board FA is Used (A-cabinet)........256 When Process I/O Board JA/JB is Used (B-cabinet) 258 http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 481/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf Revision Record FANUC Robot series (RIA R15.06-1999 COMPLIANT) R-30iA CONTROLLER MAINTENANCE MANUAL (B-82595EN-2) http://slidepdf.com/reader/full/manutencao-robo-fanucpdf 482/483 7/17/2019 MANUTENÇÃO ROBO FANUC.pdf 04 Apr., 2009 - Addition of the following models; M-900/200P, M-2000iA, ARC Mate 120iC, M-20iA R-1000iA 03 Sep., 2008 - Addition of descriptions about Integrated operation box. - Addition of descriptions about Process I/O KA, KB, KC. 02 Aug., 2007 - Addition of descriptions about Integrated operation box. - Addition of descriptions about Process I/O KA, KB, - KC. Addition of the following models; M-430iA, ARC Mate 100iC, M-10iA 01 Mar., 2007 Edition Date http://slidepdf.com/reader/full/manutencao-robo-fanucpdf Contents Edition Date Contents 483/483
