FANUC > series
R-30*A CONTROLLER
MAINTENANCE MANUAL
(Additional information for C-flex)
B-82595EN-12/01
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PREFACE
B-82595EN-12/01
PREFACE
This manual describes the following models.
Model
FANUC C-flex 105 Positioner
FANUC C-flex 105S Positioner
FANUC C-flex 104 Positioner
p-1
Abbreviation
C-flex 105 Positioner
C-flex 105S Positioner
C-flex 104 Positioner
TABLE OF CONTENTS
B-82595EN-12/01
TABLE OF CONTENTS
PREFACE ....................................................................................................p-1
I. SAFETY PRECAUTIONS
1
SAFETY PRECAUTIONS....................................................................... iii
1.1
1.2
1.3
1.4
1.5
WORKING PERSON .....................................................................................iii
OPERATOR SAFETY.................................................................................... v
1.2.1
Operator Safety...................................................................................................... vii
1.2.2
Safety of the Teach Pendant Operator.................................................................. viii
1.2.3
Safety During Maintenance......................................................................................x
SAFETY OF THE TOOLS AND PERIPHERAL DEVICES............................ xi
1.3.1
Precautions in Programming ...................................................................................xi
1.3.2
Precautions for Mechanism .....................................................................................xi
SAFETY OF THE ROBOT MECHANISM .....................................................xii
1.4.1
Precautions in Operation ....................................................................................... xii
1.4.2
Precautions in Programming ................................................................................. xii
1.4.3
Precautions for Mechanisms.................................................................................. xii
SAFETY OF THE END EFFECTOR.............................................................xii
1.5.1
1.6
Precautions in Programming ................................................................................. xii
WARNING LABEL .......................................................................................xiii
II. MAINTENANCE
1
OVERVIEW ............................................................................................. 3
2
CONFIGURATION .................................................................................. 5
2.1
3
PRINTED CIRCUIT BOARDS ................................................................. 9
3.1
4
EXTERNAL VIEW OF THE CONTROLLER .................................................. 6
PHASE DETECTION INTERFACE (PDI) PRINTED CIRCUIT BOARD
（A20B-1008-0730） .................................................................................. 10
SERVO AMPLIFIERS ........................................................................... 11
4.1
4.2
OUTLINE DRAWINGS ................................................................................ 12
4.1.1
Common Power Supply (A06B-6115-H001).........................................................12
4.1.2
Servo Amplifier (A06B-6117-H205, A06B-6117-H302) ......................................13
LED DISPLAY OF THE SERVO AMPLIFIER .............................................. 14
4.2.1
LED Display of the Common Power Supply .........................................................14
c-1
TABLE OF CONTENTS
4.2.2
5
LED Display of the Servo Amplifier......................................................................15
SETTING THE POWER SUPPLY ......................................................... 16
5.1
5.2
6
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BLOCK DIAGRAM OF THE POWER SUPPLY ........................................... 17
TRANSFORMER ......................................................................................... 19
REPLACING A UNIT............................................................................. 22
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
REPLACING THE TRANSFORMER ........................................................... 23
REPLACING THE BREAKER UNIT ............................................................ 27
REPLACING THE BRAKE UNIT ................................................................. 28
REPLACING THE CELL INTERFACE PANEL ............................................ 29
REPLACING THE MATE AMPLIFIER BOX (MAB) TRANSIT CABLE PANEL
..................................................................................................................... 30
REPLACING THE SWITCHING HUB.......................................................... 31
REPLACING THE SERVO AMPLIFIER ...................................................... 32
REPLACING THE DOOR FAN UNIT AND HEAT EXCHANGER ................ 33
REPLACING THE INDICATOR ................................................................... 34
REPLACING THE CONNECTOR PANEL ................................................... 35
REPLACING THE FUSE ............................................................................. 36
6.11.1
Replacing the Fuse of the PDI Printed Circuit Board ............................................36
III. CONNECTION
1
GENERAL ............................................................................................. 39
2
BLOCK DIAGRAMS ............................................................................. 40
3
TRANSPORTATION AND INSTALLATION ......................................... 44
3.1
3.2
3.3
3.4
TRANSPORTATION.................................................................................... 44
INSTALLATION ........................................................................................... 46
OUTLINE DRAWING OF THE ROBOT CONTROLLER.............................. 47
INSTALLATION CONDITION ...................................................................... 50
APPENDIX
A
TOTAL CONNECTION DIAGRAM........................................................ 53
c-2
I. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B-82595EN-12/01
1
1.SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety
precautions when operating a robot and its peripheral devices installed
in a work cell.
For the safety precautions, see the “FANUC Robot Safety Manual
(B-80687EN)” .
1.1
WORKING PERSON
The personnel can be classified as follows.
Operator :
• Turns robot controller power ON/OFF
• Starts robot program from operator’s panel
Programmer or teaching operator :
• Operates the robot
• Teaches robot inside the safety fence
Maintenance engineer :
• Operates the robot
• Teaches robot inside the safety fence
• Maintenance (adjustment, replacement)
-
-
An operator cannot work inside the safety fence.
A programmer, teaching operator, and maintenance engineer can
work inside the safety fence. The working activities inside the
safety fence include lifting, setting, teaching, adjusting,
maintenace, etc..
To work inside the fence, the person must be trained on proper
robot operation.
Table 1 lists the normal working activities performed outside of the
safety fence. In this table, the symbol “{” identifies which activities
can be performed by the operator, the programmer or teaching
operator, and the maintenance engineer.
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1.SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B-82595EN-12/01
Table 1 List of workings performed outside the fence
Operator
Turns robot controller power ON/OFF
Select operating mode (AUTO, T1, T2)
Select Remote/Local mode
Select robot program with teach pendant
Select robot program with external device
Starts robot program from operator’s panel
Starts robot program from teach pendant
Reset alarm with operator’s panel
Reset alarm with teach pendant
Set data on the teach pendant
Teaching with teach pendant
Emergency stop with operator’s panel
Emergency stop with teach pendant
Emergency stop with safety fence open
Maintenance of operator’s panel
Maintenance of teach pendant
{
{
{
{
Programmer
or Teaching
operator
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
Maintenance
engineer
{
{
{
{
{
{
{
{
{
{
{
{
{
During the operation, programming, and maintenance of your robotic
system, the programmer, teaching operator, and maintenance engineer
should take additional care of their safety by using the following
safety precations.
•
•
•
Use adequate clothing or uniforms during system operation
Wear safety shoes
Use helmet
iv
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1.2
SAFETY PRECAUTIONS
1.SAFETY PRECAUTIONS
OPERATOR SAFETY
Operator safety is the primary safety consideration. Because it is
very dangerous to enter the operating space of the robot during
automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions.
Careful consideration must be made to ensure operator safety.
(1) Have the robot system operators attend the training courses held
by FANUC.
FANUC provides various training courses.
details.
Contact our sales office for
(2) Even when the robot is stationary, it is possible that the robot is
still in a ready to move state, and is waiting for a signal. In this
state, the robot is regarded as still in motion. To ensure
operator safety, provide the system with an alarm to indicate
visually or aurally that the robot is in motion.
(3) Install a safety fence with a gate so that no operator can enter the
work area without passing through the gate. 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.1.2(b).
(4) Provide the peripheral devices with appropriate grounding (Class
A, Class B, Class C, and Class D).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the
robot motion, including the tools such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an
interlock to a visual or aural alarm that stops the robot when an
operator enters the work area.
(8) If necessary, install a safety lock so that no one except the
operator in charge can turn on the power of the robot.
The circuit breaker installed in the controller is designed to disable anyone
from turning it on when it is locked with a padlock.
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1.SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
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(9) When adjusting each peripheral device independently, be sure to
turn off the power of the robot.
Interlock switch and safety plug to monitor the opening of the door.
Fig.1.2(a) Safety Fence and Safety Gate
Fig.1.2(b)
Connection Diagram for Safety Fence
NOTE
Terminals EAS1, EAS11, EAS2, and EAS21 are on
the PC board in the operator box or operator panel.
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SAFETY PRECAUTIONS
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1.2.1
1.SAFETY PRECAUTIONS
Operator Safety
The operator is a person who operates the robot system. In this sense,
a worker who operates the teach pendant is also an operator.
However, this section does not apply to teach pendant operators.
(1) If it is not necessary for the robot to operate, turn off the robot
controller power or press the EMERGENCY STOP button, and
then proceed with necessary work.
(2) Operate the robot system at a location outside of the safety fence
(3) Install a safety fence with a safety gate to prevent any worker,
other than the operator, from entering the work area
unexpectedly and also to prevent the worker from entering a
dangerous area.
(4) Install an EMERGENCY STOP button within the operator's
reach.
The robot controller is designed to be connected to an external
EMERGENCY STOP button. With this connection, the controller stops the
robot operation when the external EMERGENCY STOP button is pressed.
See the diagram fig.1.2.1 for connection.
NOTE
Connect to EES1 and EES11, EES2 and EES21.
Fig.1.2.1 Connection Diagram for External Emergency Stop Button
vii
1.SAFETY PRECAUTIONS
1.2.2
SAFETY PRECAUTIONS
B-82595EN-12/01
Safety of the Teach Pendant Operator
While teaching the robot, it is necessary for the operator to enter the
work area of the robot. It is particularly necessary to ensure the
safety of the teach pendant operator.
(1) Unless it is specifically necessary to enter the robot work area,
carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral
devices are all operating normally.
(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 teach pendant operator should pay careful attention so that
no other workers enter the robot work area.
The operator panel is provided with an emergency stop button and a key
switch (mode switch) for selecting the automatic operation mode (AUTO)
and the teach modes (T1 and T2). Before entering the inside of the safety
fence for the purpose of teaching, set the switch to a teach mode, remove
the key from the mode switch to prevent other people from changing the
operation mode carelessly, then open the safety gate. If the safety gate is
opened with the automatic operation mode set, the robot enters the
emergency stop state. After the switch is set to a teach mode, the safety
gate is disabled. The programmer should understand that the safety gate
is disabled and is responsible for keeping other people from entering the
inside of the safety fence.
The teach pendant is provided with a DEADMAN switch as well as an
emergency stop button. These button and switch function as follows:
(1) Emergency stop button: Causes an emergency stop when pressed.
(2) DEADMAN switch: Functions differently depending on the mode
switch setting status.
(a) Automatic operation mode: The DEADMAN switch is disabled.
(b) Teach mode: Causes an emergency stop when the operator
releases the DEADMAN switch or when the operator presses the
switch strongly.
Note) The DEADMAN switch is provided to place the robot in the
emergency stop state when the operator releases the teach
pendant or presses the pendant strongly due to an emergency.
The R-30iA employs a 3-position DEADMAN switch, which
allows the robot to operate when the 3-position DEADMAN
switch is pressed to its intermediate point. When the operator
releases the DEADMAN switch or presses the switch strongly,
the robot enters the emergency stop state.
The operator's intention of starting the teaching process is monitored by the
controller and determined by the dual operation of setting the teach pendant
enable/disable switch to the enable position and pressing the DEADMAN
switch. The operator should verify that the robot can operate in such
conditions and be responsible in carrying out tasks safely.
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SAFETY PRECAUTIONS
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1.SAFETY PRECAUTIONS
The teach pendant, operator panel, and peripheral device interface each
send a robot start signal. However, the validity of each signal changes
depending on the operator panels mode switch, the teach pendants enable
and DEADMAN switches, and the remote condition of the software.
Mode
Teach pendant
enable switch
On
AUTO mode
Off
On
T1, T2 mode
Off
Software
remote
condition
Teach pendant Operator panel
Peripheral
device
Local
Remote
Local
Remote
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Local
Remote
Local
Remote
Allowed to start
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
(5) To start the system using the operator's panel, make certain that
nobody is in the robot work area and that there are no abnormal
conditions in the robot work area.
(6) When a program is completed, be sure to carry out a test run
according to the procedure below.
(a) Run the program for at least one operation cycle in the
single step mode at low speed.
(b) Run the program for at least one operation cycle in the
continuous operation mode at low speed.
(c) Run the program for one operation cycle in the continuous
operation mode at the intermediate speed, and check that no
abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous
operation mode at the normal operating speed, and check
that the system operates automatically without trouble.
(e) After checking the completeness of the program through the
test run above, execute it in the automatic operation mode.
(7) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.
ix
1.SAFETY PRECAUTIONS
1.2.3
SAFETY PRECAUTIONS
B-82595EN-12/01
Safety During Maintenance
For the safety of maintenance personnel, pay utmost attention to the
following.
(1) During operation, never enter the robot work area.
(2) Except when specifically necessary, turn off the power of the
controller while carrying out maintenance. Lock the power
switch, if necessary, so that no other person can turn it on.
(3) If it becomes necessary to enter the robot operation range while
the power is on, press the emergency stop button on the operator
panel, or the teach pendant before entering the range. The
maintenance personnel must indicate that maintenance work is in
progress and be careful not to allow other people to operate the
robot carelessly.
(4) When disconnecting the pneumatic system, be sure to reduce the
supply pressure.
(5) Before the start of teaching, check that the robot and its
peripheral devices are all operating normally.
(6) Do not operate the robot in the automatic mode while anybody is
in the robot work area.
(7) When it is necessary to maintain the robot alongside a wall or
instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.
(8) When a tool is mounted on the robot, or when any moving device
other than the robot is installed, such as belt conveyor, pay
careful attention to its motion.
(9) If necessary, have a worker who is familiar with the robot system
stand beside the operator panel and observe the work being
performed. If any danger arises, the worker should be ready to
press the EMERGENCY STOP button at any time.
(10) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
(11) When handling each unit or printed circuit board in the controller
during inspection, turn off the circuit breaker to protect against
electric shock.
(12) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified
ratings. They may cause a fire or result in damage to the
components in the controller.
(13) When restarting the robot system after completing maintenance
work, make sure in advance that there is no person in the work
area and that the robot and the peripheral devices are not
abnormal.
x
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SAFETY PRECAUTIONS
1.SAFETY PRECAUTIONS
1.3
SAFETY OF THE TOOLS AND PERIPHERAL DEVICES
1.3.1
Precautions in Programming
(1) Use a limit switch or other sensor to detect a dangerous condition
and, if necessary, design the program to stop the robot when the
sensor signal is received.
(2) Design the program to stop the robot when an abnormal
condition occurs in any other robots or peripheral devices, even
though the robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in
synchronous motion, particular care must be taken in
programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral
devices so that the robot can detect the states of all devices in the
system and can be stopped according to the states.
1.3.2
Precautions for Mechanism
(1) Keep the component cells of the robot system clean, and operate
the robot in an environment free of grease, water, and dust.
(2) Employ a limit switch or mechanical stopper to limit the robot
motion so that the robot does not come into contact with its
peripheral devices or tools.
xi
1.SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
1.4
SAFETY OF THE ROBOT MECHANISM
1.4.1
Precautions in Operation
B-82595EN-12/01
(1) When operating the robot in the jog mode, set it at an appropriate
speed so that the operator can manage the robot in any
eventuality.
(2) Before pressing the jog key, be sure you know in advance what
motion the robot will perform in the jog mode.
1.4.2
Precautions in Programming
(1) When the work areas of robots overlap, make certain that the
motions of the robots do not interfere with each other.
(2) Be sure to specify the predetermined work origin in a motion
program for the robot, and program the motion so that it starts
from the origin and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance
that the robot motion has terminated.
1.4.3
Precautions for Mechanisms
(1) Keep the work area of the robot clean, and operate the robot in an
environment free of grease, water, and dust.
1.5
SAFETY OF THE END EFFECTOR
1.5.1
Precautions in Programming
(1) To control the pneumatic, hydraulic and electric actuators,
carefully consider the necessary time delay after issuing each
control command to the actual motion to ensure safe control.
(2) Provide an end effector with a limit switch, and control the robot
system by monitoring the state of the end effector.
xii
B-82595EN-12/01
1.6
SAFETY PRECAUTIONS
1.SAFETY PRECAUTIONS
WARNING LABEL
(1) Step-on prohibitive label
Fig.1.6 (a)
Step-on Prohibitive Label
Description
Do not step on or climb the robot or controller as it may
adversely affect the robot or controller and you may get hurt
if you lose your footing.
(2) High-temperature warning label
Fig.1.6 (b)
High-Temperature Warning Label
Description
Be cautious about a section where this label is affixed, as
the section generates heat. If you must touch such a
section when it is hot, use a protective provision such as
heat-resistant gloves.
xiii
1.SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B-82595EN-12/01
(3) High-voltage warning label
Fig.1.6 (c)
High-Voltage Warning Label
Description
A high voltage is applied to the places where this label is
attached.
Before starting maintenance, turn the power to the control
unit off, and turn the circuit breaker off to avoid electric
shock hazards. Take additional precautions with the servo
amplifier and other equipment, because high-voltage
remains in these units for a certain amounts of time
xiv
II. MAINTENANCE
MAINTENANCE
B-82595EN-12/01
1
1.OVERVIEW
OVERVIEW
This manual describes the maintenance and connection of the C-flex
robot controllers.
An R-30iA B-cabinet controller, or Main Controller (MC), is the
primary control source and power distribution center of the C-flex
System. A single Main Controller has the capacity of controlling up
to eighteen C-flex positioners. The second controller used in the
C-flex System is an R-30iA Mate Controller, or Mate Amplifier Box
(MAB). The function of the Mate Amplifier Box (MAB) is to
contain the required power supply module and servo amplifiers
necessary to drive a C-flex positioner. For every positioner there is
one Mate Amplifier Box.
Organization of Manual :
FANUC Robot series (RIA) R-30iA CONTROLLER
MAINTENNACE MANUAL B-82595EN-2
Maintenance Part :
Troubleshooting, and the setting, adjustment, and replacement of
units
Connection Part :
Connection of the C-flex 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.
Terminology
The C-flex controller has the FANUC servo
amplifier αi series (referred to below as the servo
amplifier αi).
The servo amplifier αi consists of the common
power supply (αiPSR) and servo amplifier (αiSV).
In this document, αiPSR and αiSV are called the
common power supply and servo amplifier,
respectively, and the servo amplifier αi, which
consists of the common power supply and servo
amplifier, is also called the servo amplifier.
-3-
1.OVERVIEW
MAINTENANCE
B-82595EN/01
NOTE
This manual is a supplement to the R-30iA
CONTROLLER MAINTENANCE MANUAL.
Therefore, information covering the Main Board,
the Power Supply Unit, the Emergency Stop Unit,
and trouble shooting information related to SRVO
error codes can be found there.
-4-
2.CONFIGURATION
2
MAINTENANCE
CONFIGURATION
-5-
B-82595EN-12/01
B-82595EN-12/01
2.1
2.CONFIGURATION
MAINTENANCE
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) shows the appearance of the Main controller (MC).
Fig. 2.1 (b) shows the mounting diagram of the internal components
of the Main controller (MC).
Fig. 2.1 (c) shows the appearance of the Mate Amplifier Box (MAB).
Fig. 2.1 (d) shows the mounting diagram of the internal components
of the Mate Amplifier Box (MAB).
Operator’s panel
Teach pendant
Fig. 2.1 (a) Appearance of the Main Controller (MC)
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2.CONFIGURATION
MAINTENANCE
B-82595EN-12/01
Fiber optic cable inlet
CPU2
Switching hub
Power supply unit #2
Brake unit
Power supply unit #3
CPU3
Breaker unit
E-stop unit with
Phase Detection
Interface (PDI)
Power supply unit #1
CPU1
Riser
Mate Amplifier Box (MAB)
transit cable panel
#1 and #2
Fig. 2.1 (b)
Cell interface panel
Mate Amplifier Box (MAB)
transit cable panel
#3 and #4
Mate Amplifier Box (MAB)
transit cable panel #5 and #6
Mounting diagram of the internal components of the main controller (MC)
-7-
2.CONFIGURATION
MAINTENANCE
B-82595EN-12/01
Indicator panel
Connector panel
Fan unit
Riser
Fig. 2.1 (c) Appearance of the Mate Amplifier Box (MAB)
Reinforcing metal bracket
Heat exchanger
Servo amplifier
(AMP1)
Servo amplifier
(AMP2)
Common power supply
Fig. 2.1 (d)
Mounting diagram of the internal components of the Mate Amplifier Box (MAB)
-8-
3.PRINTED CIRCUIT BOARDS
3
MAINTENANCE
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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.
-9-
B-82595EN-12/01
3.1
MAINTENANCE
3.PRINTED CIRCUIT BOARDS
PHASE DETECTION INTERFACE (PDI) PRINTED CIRCUIT
BOARD（A20B-1008-0730）
Fig. 3.1 (a) PDI printed circuit board
(1) PDF printed circuit board
Fig. 3.1(b) Status of LED display and input power supply
- 10 -
4.SERVO AMPLIFIERS
4
MAINTENANCE
B-82595EN-12/01
SERVO AMPLIFIERS
The servo amplifiers are factory-set for operation. Usually, you do
not need to set or adjust them.
This chapter describes the adjustment required if a defective servo
amplifier is replaced.
Table 4 Servo amplifier specifications
Common power
Servo amplifier (AMP1) Servo amplifier (AMP2)
supply
A06B-6115-H001
A06B-6117-H205
A06B-6117-H302
(αiPSR-1)
(αiSV 20/20)
(αiSV 10/10/10)
L
M
L
M
N
J1
J2
J3
J4
J5
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MAINTENANCE
B-82595EN-12/01
4.1
OUTLINE DRAWINGS
4.1.1
Common Power Supply (A06B-6115-H001)
Fig. 4.1.1
4.SERVO AMPLIFIERS
Outline drawing of the common power supply (A06B-6115-H001)
- 12 -
4.SERVO AMPLIFIERS
4.1.2
MAINTENANCE
B-82595EN-12/01
Servo Amplifier (A06B-6117-H205, A06B-6117-H302)
A06B-6117-H205
A06B-6117-H302
Fig. 4.1.2 Outline drawing of the servo amplifiers (A06B-6117-H205, A06B-6117-H302)
- 13 -
4.SERVO AMPLIFIERS
MAINTENANCE
B-82595EN-12/01
4.2
LED DISPLAY OF THE SERVO AMPLIFIER
4.2.1
LED Display of the Common Power Supply
The common power supply has a 7-segment LED display.
For the
measures against errors indicated by the LED display, see the alarm
indicated on the teach pendant.
7 segment LED
LED
indication
Description
The electromagnetic contactor controlled by the common
power supply remains off and the motor is not ready to be
driven.
The electromagnetic contactor controlled by the common
power supply is on and the motor is ready to be driven.
A voltage drop was found in the direct current section (DC link)
of the main circuit.
The main circuit could not be charged within a specified time
period.
A voltage drop was found in the control power supply.
A excessive voltage was found in the direct current section
(DC link) of the main circuit.
The amount of regeneration was too excess.
The regenerative resistor was overheated.
An open phase occurs in input power.
- 14 -
4.SERVO AMPLIFIERS
4.2.2
MAINTENANCE
B-82595EN-12/01
LED Display of the Servo Amplifier
The servo amplifier has a 7-segment LED display.
For the measures
against errors indicated by the LED display, see the alarm indicated
on the teach pendant.
7 segment LED
LED
indication
Description
The main circuit in the servo amplifier remains off and the
motor is not ready to be driven.
The main circuit in the servo amplifier is on and the motor is
ready to be driven.
The internal cooling fan stopped.
A voltage drop was found in the control power supply.
A voltage drop was found in the direct current section (DC link)
of the main circuit.
An error occurred during communication between servo
amplifiers.
a) The IPM alarm was detected in the servo amplifier.
b) The IPM alarm (overheat) was detected in the servo
amplifier.
The place where the alarm occurred is the L-axis for "8", the
M-axis for "9", or the N-axis for "A".
An error occurred while supplying a current to the servo motor.
The place where the alarm occurred is the L-axis for "b", the
M-axis for "c", or the N-axis for "d".
- 15 -
B-82595EN-12/01
5
MAINTENANCE
5.SETTING THE POWER SUPPLY
SETTING THE POWER SUPPLY
Setting and adjustment of the power supply is factory-set for operation.
Usually, you do not need to set or adjust it.
- 16 -
Fig. 5.1 (a)
- 17 -
AC POWER
INPUT
BREAKER
TRANS
TEACH
PENDANT PANEL BOARD
BATTERY
MAIN BOARD
EMERGENCY
STOP UNIT
FAN
POWER SUPPLY
SWITCHING
HUB
ERAL
DIVECE
BATT
ERY
PERIPH
PROCESS
I/O BOARD
BRAKE UNIT
MAIN BOARD
BACK
PLANE
BREAKER UNIT
POWER SUPPLY
BATT
ERY
MAIN BOARD
BACK
PLANE
(TO MAB)
POWER SUPPLY
5.1
BACK
PLANE
5.SETTING THE POWER SUPPLY
MAINTENANCE
B-82595EN-12/01
BLOCK DIAGRAM OF THE POWER SUPPLY
Block diagram of the power supply of the Main Controller (MC)
Fig. 5.1 (b)
ELECTROMAGNETIC
CONTACTER(MCC)
FAN
INDICATOR
PANEL
- 18 REGENERATION
RESISTOR
MAIN
CIRCUIT
DC LINK
POWER SUPPLY
MODULE
INVERTER
CIRCUIT
SERVO
AMPLIFIER
MODULE 1
INVERTER
CIRCUIT
SERVO
AMPLIFIER
MODULE 2
B-82595EN-12/01
MAINTENANCE
5.SETTING THE POWER SUPPLY
Block diagram of the power supply of the Mate Amplifier Box (MAB)
5.SETTING THE POWER SUPPLY
5.2
MAINTENANCE
B-82595EN-12/01
TRANSFORMER
The transformer to be used depends on the number of C-flex units to
be controlled. Select the transformer with the power supply voltage
that satisfies the following rated voltage.
Transformer specifications
Number of controlled units
Nominal
Rated
value
voltage
440 to 480V
380 to 415V
- 19 -
12
18
15.4KVA
19.2KVA
A80L-0028-0029 A80L-0028-0030
MAINTENANCE
B-82595EN-12/01
5.SETTING THE POWER SUPPLY
Transformer
Main controller B-cabinet (back)
Fig.5.2 (a)
Transformer mounting locations and structure
- 20 -
5.SETTING THE POWER SUPPLY
MAINTENANCE
1
440-480V
2
380-415V
B-82595EN-12/01
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.
Cabinet side connector
1. 440V-480V
Dummy plug
Dummy plug
Circuit
breaker
2. 380V-415V
Dummy plug
Dummy plug
Fig. 5.2(b)
Circuit
breaker
Setting the input voltage
- 21 -
B-82595EN-12/01
6
MAINTENANCE
6.REPLACING A UNIT
REPLACING A UNIT
This section explains how to replace each unit in the control section.
WARNING
Before you start to replace a unit, turn off the
control unit main power. Also keep all machines in
the area of the control unit switched.
- 22 -
6.REPLACING A UNIT
6.1
MAINTENANCE
B-82595EN-12/01
REPLACING THE TRANSFORMER
WARNING
The transformer is heavy. When replacing the
transformer, be careful not to cause injury. (The
transformer weighs 90 to 110 kg.)
(a) Remove the screws and detach the back panel.
- 23 -
B-82595EN-12/01
MAINTENANCE
6.REPLACING A UNIT
(b) Detach the connectors of LA, LB, LC, OUT, and CP1.
Remove the pin-type terminals inserted into XT2-1 to XT2-4 of
the brake unit and remove the connector of the CRM72, which is
connected to the emergency stop unit.
If a cable is fastened with nylon ties, cut them with a diagonal
cutter to release the cable. Be careful not to damage the cable.
Brake unit XT2-1 to XT2-4
Emergency stop unit
(c) Remove the retaining screws from the transformer terminal board
and remove the metal plate.
- 24 -
6.REPLACING A UNIT
MAINTENANCE
B-82595EN-12/01
A
Details of A
- 25 -
B-82595EN-12/01
MAINTENANCE
6.REPLACING A UNIT
(d) Remove the two retaining M6 screws from the transformer, then
remove the transformer.
(e) Install a replacement transformer by reversing procedure (a) to
(d).
- 26 -
6.REPLACING A UNIT
6.2
MAINTENANCE
B-82595EN-12/01
REPLACING THE BREAKER UNIT
(a) Turn off the breaker of the breaker unit.
(b) Remove the cables connected to the breaker unit.
(c) Remove the two upper screws of the four screws securing the
breaker unit and loosen the two lower screws, and replace the
breaker unit.
(d) Connect the removed cables to the original positions.
(e) Turn on the breaker.
Fig. 6.2 Replacing the breaker unit
- 27 -
B-82595EN-12/01
6.3
MAINTENANCE
6.REPLACING A UNIT
REPLACING THE BRAKE UNIT
(a) Turn off the circuit breaker of the brake unit.
(b) Remove the cables connected to the brake unit.
(c) Remove the two upper screws of the four screws securing the
brake unit and loosen the two lower screws, and replace the
brake unit.
(d) Connect the removed cables to the original positions.
(e) Turn on the circuit breaker.
Fig. 6.3 Replacing the brake unit
NOTE
If your system has multiple CPUs, you will need to
remove the additional 2-slot back planes (contain
CPU and power supply unit) before removing
Brake Unit.
- 28 -
6.REPLACING A UNIT
6.4
MAINTENANCE
B-82595EN-12/01
REPLACING THE CELL INTERFACE PANEL
(a) Remove the cables from the cell interface panel.
(b) Remove the six screws securing the cell interface panel and
replace the cell interface panel.
(c) Connect the removed cables to the original positions.
Fig. 6.4 Replacing the cell interface panel
- 29 -
B-82595EN-12/01
6.5
MAINTENANCE
6.REPLACING A UNIT
REPLACING THE MATE AMPLIFIER BOX (MAB) TRANSIT
CABLE PANEL
(a) Remove the cables from the Mate Amplifier Box (MAB) relay
panel to be replaced.
(b) Remove the four screws securing the Mate Amplifier Box
(MAB) relay panel and replace the Mate Amplifier Box (MAB)
relay panel.
(c) Connect the removed cables to the original positions.
Fig. 6.5 Replacing the Mate Amplifier Box (MAB) transit cable panel
- 30 -
6.REPLACING A UNIT
6.6
MAINTENANCE
B-82595EN-12/01
REPLACING THE SWITCHING HUB
(a) Remove the cables from the switching hub.
(b) Slide the switching hub on the rail.
(c) Connect the removed cables to the original positions.
Switching hub
Fig. 6.6 Replacing the switching hub
- 31 -
6.7
6.REPLACING A UNIT
MAINTENANCE
B-82595EN-12/01
REPLACING THE SERVO AMPLIFIER
WARNING
Before replacing the servo amplifier, turn off the
main power.
The procedure for replacing the common power supply and servo
amplifier is described below.
(a) Remove the cables connected to the servo amplifier. Remove
the short-circuit bar connecting DC links (L+, L-). Remove the
grounding cable connected to the heatsink.
(b) Remove the two nuts from the upper surface of the servo
amplifier.
(c) Install the replacing servo amplifier by reversing the order in step
(b).
(d) Attach the short-circuit bar connecting the connection cables and
DC links (L+, L-) to the original position.
Nuts
(2-M5)
Common power
supply
Fig. 6.7 Replacing the servo amplifier
- 32 -
Servo
amplifier
6.REPLACING A UNIT
6.8
MAINTENANCE
B-82595EN-12/01
REPLACING THE DOOR FAN UNIT AND HEAT
EXCHANGER
WARNING
Before replacement, turn off the main power of the
controller.
Keep your hands away from the rotating fan motor.
Door fan unit
(a) Remove the four setscrews (M4).
(b) Remove the cables connected to the fan unit.
(c) Attach a reserved fan unit by reversing the order of removal.
Heat exchanger
(a) Remove the cables connected to the heat exchanger.
(b) Remove the six setscrews (M4) and pull the heat exchanger.
(c) Remove the wiring for the door fan unit.
(d) Attach a reserved heat exchanger by reversing the order of
removal.
Fig. 6.8
Replacing the door fan unit and heat exchanger
- 33 -
B-82595EN-12/01
6.9
MAINTENANCE
6.REPLACING A UNIT
REPLACING THE INDICATOR
(a) Remove the grounding wire and connectors CRR97 and MCC (1,
3, 5) on the indicator panel.
(b) Remove the cables (CZ1, CX3, CXA2A) connected to the servo
amplifier.
(c) Remove the four screws (M3) securing the indicator panel and
remove the operator's panel.
(d) Attach a new indicator panel by reversing steps (a) to (c).
Fig. 6.9 Replacing the indicator panel
NOTE
The indicator panel includes the panel section and
the cables (CZ1, CX3, CXA2A) connected to the
servo amplifier.
- 34 -
6.REPLACING A UNIT
6.10
MAINTENANCE
B-82595EN-12/01
REPLACING THE CONNECTOR PANEL
(a) Remove the cables connected to the connector panel.
Note) The connector panel includes the cables connected to the
indicator panel and the servo amplifier.
(b) Remove the six screws securing the connector panel and remove
the connector panel.
(c) Remove the cables between the back of the connector panel and
the Mate Amplifier Box (MAB) and the grounding cable.
(d) Attach a new connector panel by reversing steps (a) to (c).
Fig. 6.10 Replacing the connector panel
- 35 -
MAINTENANCE
B-82595EN-12/01
6.11
6.REPLACING A UNIT
REPLACING THE FUSE
If the fuse blows, identify the cause, take an appropriate action, and
replace the fuse.
6.11.1
Replacing the Fuse of the PDI Printed Circuit Board
The PDI printed circuit board has the following fuse.
FU1:
Protection against 200 V output to peripheral equipment
(A60L-0001-0396#2.0A)
If this fuse blows, it is probable that wiring to peripheral
equipment is incorrect or a cable is broken.
FU1
- 36 -
III. CONNECTION
1.GENERAL
1
CONNECTION
B-82595EN-12/01
GENERAL
This section describes the electrical interface connections of the C-flex
System. It also includes installation information.
- 39 -
B-82595EN-12/01
2
CONNECTIONS
2.BLOCK DIAGRAMS
BLOCK DIAGRAMS
The block diagrams for C-flex electric interfacing are shown below.
1． When there are three CPUs (main boards)
2． When there are two CPUs (main boards)
3． When there is one CPU (main board)
- 40 -
2.BLOCK DIAGRAMS
CONNECTION
B-82595EN-12/01
Main Controller (MC)
End effecter
End effecter
Air
pressure
source
Mech.
unit
Servo box
Air
pressure
source
Servo box
Switching hub
End effecter
Servo box
Air
pressure
source
Servo box
Air
pressure
source
Air
pressure
source
Mech.
unit
End effecter
Air
pressure
source
Servo box
Fig. 2(a) Block diagram for three CPUs (main boards)
- 41 -
Mech.
unit
Servo box
End effecter
Servo box
Air
pressure
source
End effecter
Air
pressure
source
Mech.
unit
Servo box
Mech.
unit
Mech.
unit
Servo box
End effecter
End effecter
Air
pressure
source
End effecter
Air
pressure
source
Mech.
unit
Servo box
End effecter
Mech.
unit
Servo box
Air
pressure
source
Mech.
unit
Air
pressure
source
Mech.
unit
Servo box
Servo box
Air
pressure
source
End effecter
End effecter
End effecter
Mech.
unit
Servo box
Air
pressure
source
Mech.
unit
Air
pressure
source
Mech.
unit
Servo box
Mech.
unit
Air
pressure
source
End effecter
End effecter
End effecter
Mech.
unit
Servo box
End effecter
Mech.
unit
Air
pressure
source
Mech.
unit
Servo box
Servo box
End effecter
Mech.
unit
Air
pressure
source
2.BLOCK DIAGRAMS
CONNECTIONS
B-82595EN-12/01
Main Controller (MC)
End effecter
Air
pressure
source
Mech.
unit
Servo box
End effecter
Servo box
End effecter
Air
pressure
source
Mech.
unit
Servo box
Switching hub
Air
pressure
source
Servo box
Fig. 2(b)
End effecter
Air
pressure
source
Mech.
unit
Servo box
Mech.
unit
End effecter
Air
pressure
source
Mech.
unit
End effecter
Air
pressure
source
Servo box
Block diagram for two CPUs (main boards)
- 42 -
Mech.
unit
Servo box
Air
pressure
source
Servo box
Air
pressure
source
Mech.
unit
Servo box
End effecter
End effecter
Air
pressure
source
End effecter
Air
pressure
source
Mech.
unit
Servo box
End effecter
Mech.
unit
Servo box
End effecter
Mech.
unit
Air
pressure
source
Mech.
unit
Servo box
End effecter
Mech.
unit
Air
pressure
source
2.BLOCK DIAGRAMS
CONNECTION
B-82595EN-12/01
Main Controller (MC)
End effecter
Air
pressure
source
Mech.
unit
Servo box
End effecter
End effecter
Mech.
unit
Servo box
Fig. 2(c)
Air
pressure
source
Mech.
unit
Servo box
Mech.
unit
Air
pressure
source
Servo box
End effecter
Air
pressure
source
Servo box
End effecter
Air
pressure
source
Mech.
unit
Servo box
Block diagram for one CPU (main board)
- 43 -
End effecter
Mech.
unit
Air
pressure
source
B-82595EN-12/01
3
3.1
CONNECTIONS 3.TRANSPORTATION AND INSTALLATION
TRANSPORTATION AND INSTALLATION
TRANSPORTATION
The controller is transported by a crane. Attach a strap to eye bolts
at the top of the control unit.
Eye bolts (M12)
Transportation of the Main Controller (MC)
Crane capacity : Min.300kg
Sling capacity : Min.300kg
- 44 -
3.TRANSPORTATION AND INSTALLATION CONNECTIONS
B-82595EN-12/01
Eye bolts (M10)
Transportation of the Mate Amplifier Box (MAB)
- 45 -
CONNECTIONS 3.TRANSPORTATION AND INSTALLATION
B-82595EN-12/01
3.2
INSTALLATION
Leave the following clearance for maintenance during installation of
the controller.
Fig. 3.2 (a) Installation dimensions for the Main Controller (MC)
When multiple Mate Amplifier
Boxes (MAB) are installed
Fig. 3.2 (b) Installation dimensions for the Mate Amplifier Box (MAB)
- 46 -
3.TRANSPORTATION AND INSTALLATION CONNECTIONS
3.3
B-82595EN-12/01
OUTLINE DRAWING OF THE ROBOT CONTROLLER
Fig. 3.3 (a)
Outline drawing of the Main Controller (MC)
- 47 -
CONNECTIONS 3.TRANSPORTATION AND INSTALLATION
B-82595EN-12/01
Cable holder
Fig. 3.3 (b)
Outline drawing of the Mate Amplifier Box (MAB)
- 48 -
3.TRANSPORTATION AND INSTALLATION CONNECTIONS
B-82595EN-12/01
Fig. 3.3 (c) Outline drawing of stacked Mate Amplifier Boxes (MAB)
WARNING
A maximum of two Make Amplifier Boxes (MAB) can
be piled. When two boxes are stacked or the cable
holder is attached, the controller needs to be fixed.
- 49 -
CONNECTIONS 3.TRANSPORTATION AND INSTALLATION
B-82595EN-12/01
3.4
INSTALLATION CONDITION
Item
Rated Voltage
All models
Tolerant fluctuation
All models
Input power source capacity
Mate Amplifier Box (MAB)
12 machines
Mate Amplifier Box (MAB)
18 machines
Mate Amplifier Box (MAB)
12 machines
Mate Amplifier Box (MAB)
18 machines
All models
Average power consumption
Permissible ambient
temperature
Permissible ambient
humidity
Surrounding gas
Model
Specification/condition
Trans. Type E 380-415, 440-480, 500-575VAC
50/60Hz 3phases
Tolerant voltage fluctuation: +10% -15%
Tolerant frequency fluctuation: ±1Hz
19.2KVA
28.8KVA
4.8KW
7.2KW
0 to 45ºC during operation, and -20 to 60ºC during
shipment and storage with a temperature coefficient
of 1.1ºC/min
Relative humidity: 30% to 95%, non-condensing
All models
All models
An additional protective provision is necessary if the
machine is installed in an environment in which there
are relatively large amounts of contaminants (dust,
dielectric fluid, organic solvent, acid, corrosive gas,
and/of salt).
Installation category
All models
Installation category III, Pollution degree 3,
IEC60664-1 and IEC61010-1
Vibration
All models
0.5G or less. When using the robot in a location
subject to serious vibration, consult with your FANUC
sales representative.
Altitude
Common to all models
Not higher than 1,000m above sea level
Ionized
and
non-ionized Common to all models
A shielding provision is necessary if the machine is
radiation
installed in an environment in which it is exposed to
radiation (microwave, ultraviolet rays, laser beams,
and/or X-rays).
Mass of control unit
Main Controller (MC)
280kg
Mate Amplifier For one machine 30kg
Box (MAB)
- 50 -
APPENDIX
B-82595EN-12/01
A
A.TOTAL CONNECTION DIAGRAM
APPENDIX
TOTAL CONNECTION DIAGRAM
- 53 -
A.TOTAL CONNECTION DIAGRAM
APPENDIX
Fig. A (a) Total connection diagram
- 54 -
B-82595EN-12/01
B-82595EN-12/01
A.TOTAL CONNECTION DIAGRAM
APPENDIX
- 55 -
A.TOTAL CONNECTION DIAGRAM
APPENDIX
Fig. A (b) Total connection diagram
- 56 -
B-82595EN-12/01
B-82595EN-12/01
A.TOTAL CONNECTION DIAGRAM
APPENDIX
Fig. A (c) Total connection diagram
- 57 -
A.TOTAL CONNECTION DIAGRAM
APPENDIX
Fig. A (d) Total connection diagram
- 58 -
B-82595EN-12/01
A.TOTAL CONNECTION DIAGRAM
APPENDIX
B-82595EN-12/01
MATE
Fig. A (e) Total connection diagram
- 59 -
INDEX
B-82595EN-12/01
INDEX
REPLACING THE CONNECTOR PANEL .................. 35
<B>
REPLACING THE DOOR FAN UNIT AND HEAT
BLOCK DIAGRAM OF THE POWER SUPPLY .......... 17
EXCHANGER................................................................ 33
BLOCK DIAGRAMS ..................................................... 40
REPLACING THE FUSE............................................... 36
<C>
Replacing the Fuse of the PDI Printed Circuit Board ..... 36
Common Power Supply (A06B-6115-H001) .................. 12
REPLACING THE INDICATOR................................... 34
CONFIGURATION ..........................................................5
REPLACING THE MATE AMPLIFIER BOX (MAB)
TRANSIT CABLE PANEL............................................ 30
<E>
REPLACING THE SERVO AMPLIFIER...................... 32
EXTERNAL VIEW OF THE CONTROLLER ................6
REPLACING THE SWITCHING HUB......................... 31
<G>
REPLACING THE TRANSFORMER ........................... 23
GENERAL ...................................................................... 39
<S>
<I>
Safety During Maintenance .............................................. x
INSTALLATION............................................................ 46
SAFETY OF THE END EFFECTOR............................. xii
INSTALLATION CONDITION..................................... 50
SAFETY OF THE ROBOT MECHANISM ................... xii
Safety of the Teach Pendant Operator ...........................viii
<L>
SAFETY OF THE TOOLS AND PERIPHERAL DEVICES
LED Display of the Common Power Supply .................. 14
......................................................................................... xi
LED Display of the Servo Amplifier .............................. 15
SAFETY PRECAUTIONS ..............................................iii
LED DISPLAY OF THE SERVO AMPLIFIER............. 14
Servo Amplifier (A06B-6117-H205, A06B-6117-H302) 13
<O>
SERVO AMPLIFIERS ................................................... 11
SETTING THE POWER SUPPLY................................. 16
Operator Safety ...............................................................vii
OPERATOR SAFETY......................................................v
<T>
OUTLINE DRAWING OF THE ROBOT CONTROLLER
TOTAL CONNECTION DIAGRAM............................. 53
........................................................................................ 47
TRANSFORMER ........................................................... 19
OUTLINE DRAWINGS ................................................. 12
TRANSPORTATION..................................................... 44
OVERVIEW .....................................................................3
TRANSPORTATION AND INSTALLATION.............. 44
<P>
<W>
PHASE DETECTION INTERFACE (PDI) PRINTED
WARNING LABEL ......................................................xiii
CIRCUIT BOARD(A20B-1008-0730) ........................... 10
WORKING PERSON ......................................................iii
Precautions for Mechanism ..............................................xi
Precautions for Mechanisms ...........................................xii
Precautions in Operation .................................................xii
Precautions in Programming .......................................xi,xii
PREFACE ......................................................................p-1
PRINTED CIRCUIT BOARDS ........................................9
<R>
REPLACING A UNIT .................................................... 22
REPLACING THE BRAKE UNIT................................. 28
REPLACING THE BREAKER UNIT............................ 27
REPLACING THE CELL INTERFACE PANEL .......... 29
i-1
Nov., 2007
Date
01
Edition
Contents
Edition
Date
Contents
FANUC Robot series C-flex CONTROLLER MAINTENANCE MANUAL (B-82595EN-12)
Revision Record
B-82595EN-12/01
* B- 8 2 5 9 5 EN- 1 2 / 0 1 *