FANUC Robot series
R--J3iB CONTROLLER
FOR EUROPE
MAINTENANCE MANUAL
B--81465EN--1/02
B--81465EN--1/02
Table of Contents
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p--1
I SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1.1
OPERATOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.1
1.1.2
1.1.3
1.2
SAFETY OF THE TOOLS AND PERIPHERAL DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.1
1.2.2
1.3
Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY OF THE ROBOT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1
1.3.2
1.3.3
1.4
Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety of the Teach Pendant Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions in Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY OF THE END EFFECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.1
Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
6
7
9
10
10
10
11
11
11
11
12
12
1.5
SAFETY IN MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
1.6
WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
II MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
2. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
2.1
EXTERNAL VIEW OF THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
2.2
COMPONENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
2.3
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
3.1
POWER CANNOT BE TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
3.2
ALARM OCCURRENCE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
3.3
SAFETY SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
3.4
MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
3.5
TROUBLESHOOTING USING THE ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
3.6
FUSED--BASED TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
117
3.7
TROUBLESHOOTING BASED ON LED INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
122
3.8
POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION
(POSITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
131
3.9
VIBRATION OBSERVED DURING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
132
3.10
MANUAL OPERATION IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
133
4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.1
MAIN BOARD (A16B--3200--0412, --0413) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
136
4.2
EMERGENCY STOP CONTROL PC BOARD (A20B--1007--0800) . . . . . . . . . . . . . . . . . . . . . . . .
139
4.3
BACKPLANE PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
140
c--1
Table of Contents
B--81465EN--1/02
4.4
PANEL BOARD (A20B--2100--0770) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
142
4.5
PROCESS I/O BOARD CA (A16B--2201--0470) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
143
4.6
PROCESS I/O BOARD CB (A16B--2201--0472) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
146
4.7
PROCESS I/O BOARD DA (A16B--2201--0480) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
148
4.8
PROCESS I/O BOARD HA (A16B--2203--0760) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
150
4.9
PANEL SWITCH BOARD (A20B--1007--0850) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
152
5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.1
LED OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
154
5.2
SETTING OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
155
5.3
DRIVER CHIP FOR ROBOT DI/DO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
156
6. SETTING THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
6.1
BLOCK DIAGRAM OF THE MAIN POWER INCLUDING POWER SUPPLY . . . . . . . . . . . . . .
158
6.2
SELECTING TRANSFORMER TAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
159
6.3
CHECKING THE POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
161
7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.1
REPLACING THE PRINTED--CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1
7.1.2
7.1.3
Replacing the Backplane Board (Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Power Unit and Printed--Circuit Boards on the Backplane Unit . . . . . . . . . . . . . . . . . . .
Replacing the Panel Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
165
165
166
168
7.2
REPLACING CARDS AND MODULES ON THE MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . .
169
7.3
REPLACING THE TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
173
7.4
REPLACING THE REGENERATIVE RESISTOR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
176
7.5
REPLACING THE E--STOP UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
177
7.6
REPLACING SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
178
7.7
REPLACING I/O UNIT MODEL A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
182
7.7.1
7.7.2
Replacing the Base Unit of I/O Unit Model A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
182
183
7.8
REPLACING THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
184
7.9
REPLACING THE CONTROL SECTION FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
185
REPLACING THE AC FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
186
7.10
7.10.1
Replacing External Air Fan Unit and Door Fan (B--cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
186
7.11
REPLACING THE OPERATOR PANEL AND PANEL SWITCH BOARD . . . . . . . . . . . . . . . . . .
188
7.12
REPLACE THE MODE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
189
REPLACING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
190
7.13
7.13.1
7.13.2
7.13.3
7.13.4
7.14
REPLACING RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.14.1
7.15
Replacing Fuses in the Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Fuses in the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fuse on the Process I/O Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fuse on the Panel Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Relays on the Panel Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.15.1
Battery for Memory Backup (3 VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c--2
190
191
192
194
195
195
196
196
B--81465EN--1/02
Table of Contents
III CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3.1
CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS . . . . . . . . . . . . . . . . . . . . . . . . .
204
3.2
EXTERNAL CABLE WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
Robot Connection Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Teach Pendant Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the External Power Supply ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the External Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206
207
208
210
212
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4.1
4.2
PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1
4.1.2
4.1.3
When Process I/O Board CA/CB/HA is Used (B--cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
When Process I/O Board DA is Used (B--cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
When I/O Unit--MODEL A is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3.1 In case of B--cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.4
When Two or more Process I/O Boards and I/O Unit (Model A or Model B) are Used . . . . . . . . . . . .
PERIPHERAL DEVICE INTERFACE COMBINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1
In Case of B--cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
221
221
223
224
224
225
226
226
4.3
PROCESS I/O BOARD SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
227
4.4
INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS . . . . . . . . . .
231
4.4.1
4.4.2
4.4.3
4.5
DIGITAL I/O SIGNAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1
4.5.2
4.5.3
4.6
Peripheral Device Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Effector Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION OF HDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.1
4.8.2
4.9
Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins) . . . . . . . . . . . . . . . . . . . . . . . .
Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins) . . . . . . . . . . . . . . . . . . . . . . . .
ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS,
AND ARC WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.1
4.7.2
4.7.3
4.7.4
4.8
Peripheral Device Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Effector Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Signal Specifications for ARC--Welding Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES
AND WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1
4.6.2
4.6.3
4.7
Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection Between the Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection Between the Control Unit and Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting HDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Signal Rules for the High--speed Skip (HDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING THE COMMUNICATION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.1
RS--232--C Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.1.1 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c--3
232
245
247
253
253
255
257
261
261
261
262
263
263
264
266
267
268
268
270
271
271
271
Table of Contents
4.9.1.2
4.9.2
B--81465EN--1/02
RS--232--C Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
272
4.9.1.3 Connection between RS--232--C Interface and External Device . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.2.1 Connection to Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
273
275
276
4.9.2.2
10/100 BASE--T Connector (CD38) Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
277
4.9.2.3
Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
277
4.9.2.4
Lead Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
278
4.9.2.5
Connector Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
279
4.9.2.6
Cable Clamp and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
280
4.9.2.7
Grounding the Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
281
5. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
5.1
TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
284
5.2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
285
5.2.1
5.2.2
Installation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assemble at installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
285
287
5.3
INSTALLATION CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
288
5.4
ADJUSTMENT AND CHECKS AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
289
RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION . . . . . . . . . . . . . .
290
5.5
5.5.1
5.5.2
5.5.3
5.5.4
Peripheral Device Interface Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Disable/Enable HBK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Disable/Enable Pneumatic Pressure Alarm (PPABN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
290
290
291
292
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
A. TOTAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE . . . . . . . . . . . . . . . . . 316
B.1
SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
317
B.2
SETTING COMMON VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
319
B.3
I/O SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
320
B.3.1
B.3.2
B.4
Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS OF DIGITAL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.4.1
B.4.2
B.4.3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input/Output Hardware Usable in the R-J3iB Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
320
325
329
329
329
330
C. POWER DISTRIBUTION CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
D. OPTICAL FIBER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
E. CARD INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
c--4
B--81465EN--1/02
PREFACE
PREFACE
This manual describes the following models (R--J3iB controller).
Model
Abbreviation
FANUC Robot R--2000iA/165F
R--2000iA/165F
FANUC Robot R--2000iA/200F
R--2000iA/200F
FANUC Robot R--2000iA/165R
R--2000iA/165R
FANUC Robot R--2000iA/200R
R--2000iA/200R
FANUC Robot R--2000iA/125L
R--2000iA/125L
FANUC Robot R--2000iA/165CF R--2000iA/165CF
FANUC Robot M--6iB
FANUC Robot ARC Mate 100iB
p--1
M--6iB
ARC Mate 100iB
R 2000iA
R--2000iA
I SAFETY PRECAUTIONS
B--81465EN--1/02
1
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety precautions
when operating a robot and its peripheral devices installed in a work cell.
3
1. SAFETY PRECAUTIONS
1.1
OPERATOR SAFETY
SAFETY PRECAUTIONS
B--81465EN--1/02
Operator safety is the primary safety consideration. Because it is very
dangerous to enter the operating space of the robot during automatic
operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration
must be made to ensure operator safety.
(1) Have the robot system operators attend the training courses held by
FANUC.
FANUC provides various training courses. Contact our sales office for details.
(2) Even when the robot is stationary, it is possible that the robot is still
ready to move state and is waiting for a signal. In this state, the robot
is regarded as still in motion. To ensure operator safety, provide the
system with an alarm to indicate visually or aurally that the robot is
in motion.
(3) Install a safety fence with a gate so that no operator can enter the work
area without passing through the gate. Equip the gate with an
interlock that stops the robot when the gate is opened.
The controller is designed to receive this interlock signal. When the gate is
opened and this signal received, the controller stops the robot in an emergency.
For connection, see Fig.1.1.
(4) Provide the peripheral devices with appropriate grounding (Class 1,
Class 2, or Class 3).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot
motion, including the tools such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an
interlock to a visual or aural alarm that stops the robot when an
operator enters the work area.
(8) If necessary, install a safety lock so that no one except the operator
in charge can turn on the power of the robot.
The circuit breaker installed in the controller is designed to disable anyone from
turning it on when it is locked with a padlock.
4
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B--81465EN--1/02
(9) When adjusting each peripheral device independently, be sure to turn
off the power of the robot.
Limit switch for
the safety gate
Panel board
EAS1
EAS11
EAS2
EAS21
Note)
Fig.1.1 Safety Fence and Safety Gate
5
Terminals FENCE1 and FENCE2 are
on the PC board in the operator panel.
Fence circuit is a safety stop circuit.
1. SAFETY PRECAUTIONS
1.1.1
Operator Safety
SAFETY PRECAUTIONS
B--81465EN--1/02
The operator is a person who operates the robot system. In this sense, a
worker who operates the teach pendant is also an operator. However, this
section does not apply to teach pendant operators.
(1) If it is not necessary for the robot to operate, turn off the power of the
robot controller or press the EMERGENCY STOP button, and then
proceed with necessary work.
(2) Operate the robot system at a location outside the work area.
(3) Install a safety fence with a safety gate to prevent any worker other
than the operator from entering the work area unexpectedly and also
to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator’s reach.
The robot controller is designed to be connected to an external EMERGENCY
STOP button. With this connection, the controller stops the robot operation
when the external EMERGENCY STOP button is pressed. See the diagram
below for connection.
External EMERGENCY STOP button
Panel board
EES1
EES11
EES2
EES21
Note)
Connect to EES1 and EES11, EES2 and EES21.
Fig.1.1.1 Connection Diagram for External Emergency Stop Switch
6
B--81465EN--1/02
1.1.2
Safety of the Teach
Pendant Operator
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
While teaching the robot, it is necessary for the operator to enter the work
area of the robot. It is particularly necessary to ensure the safety of the
teach pendant operator.
(1) Unless it is specifically necessary to enter the robot work area, carry
out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral
devices are all in the normal operating condition.
(3) When entering the robot work area and teaching the robot, be sure to
check the location and condition of the safety devices (such as the
EMERGENCY STOP button and the deadman switch on the teach
pendant).
The teach pendant supplied by FANUC is provided with a teach pendant enable switch and a deadman switch in addition to the EMERGENCY STOP button. The functions of each switch are as follows.
EMERGENCY STOP button : Pressing this button stops the robot in an
emergency, irrespective to the condition of
the teach pendant enable switch.
Deadman switch
: The function depends on the state of the
teach pendant enable switch.
When the enable switch is on -- Releasing the finger from the dead man
switch or holding the deadman switch
strongly stops the robot in an emergency.
When the enable switch is off -- The deadman switch is ineffective.
NOTE
The deadman switch is provided so that the robot operation can
be stopped simply by releasing finger from the teach pendant or
holding the deadman switch strongly in case of emergency.
The R--J3iB has adopted a 3--position deadman switch as
an RIA--specification teach pendant.
Pressing the
3--position deadman switch halfway makes the robot
operable. Releasing the finger from the deadman switch or
holding the deadman switch strongly causes the robot to
enter the emergency stop state.
7
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B--81465EN--1/02
(4) The teach pendant operator should pay careful attention so that no
other workers enter the robot work area.
NOTE
In addition to the above, the teach pendant enable switch and the
deadman switch also have the following function.
By pressing the deadman switch while the enable switch is on, the
emergency stop factor (normally the safety gate) connected to
EAS1 and EAS11, EAS2 and EAS21 of the controller is
invalidated. In this case, it is possible for an operator to enter the
fence during teach operation without making the robot in the
emergency stop condition. In other words, the system understands
that the combined operations of pressing the teach pendant
enable switch and pressing the deadman switch indicates the start
of teaching. The teach pendant operator should be well aware that
the safety gate is not functional under this condition and bear full
responsibility to ensure that no one enters the fence during teaching.
(5) When entering the robot work area, the teach pendant operator should
enable the teach pendant whenever he or she enters the robot work
area. In particular, while the teach pendant enable switch is off, make
certain that no start command is sent to the robot from any operator
panel other than the teach pendant.
The teach pendant, operator panel, and peripheral device interface send each
robot start signal. However the validity of each signal changes as follows depending on the mode of the teach pendant enable switch and the remote switch
on the operator’s panel.
Teach pendant enable
switch
Remote
condition
Teach
pendant
Operator
panel
Peripheral
devices
On
Independent
Allowed to
start
Not allowed
Not allowed
Off
Local
Not allowed
Allowed to
start
Not allowed
Off
Remote
Not allowed
Not allowed
Allowed to
start
(6) To start the system using the operator panel, make certain that nobody
is in the robot work area and that there are no abnormal conditions in
the robot work area.
(7) When a program is completed, be sure to carry out a test run according
to the procedure below.
(a) Run the program for at least one operation cycle in the single step
mode at low speed.
(b) Run the program for at least one operation cycle in the continuous
operation mode at low speed.
(c) Run the program for one operation cycle in the continuous
operation mode at the intermediate speed and check that no
abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous
operation mode at the normal operating speed and check that the
system operates automatically without trouble.
(e) After checking the completeness of the program through the test
run above, execute it in the automatic operation mode.
8
B--81465EN--1/02
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
(8) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.
1.1.3
Safety During
Maintenance
For the safety of maintenance personnel, pay utmost attention to the
following.
(1) Except when specifically necessary, turn off the power of the
controller while carrying out maintenance. Lock the power switch,
if necessary, so that no other person can turn it on.
(2) When disconnecting the pneumatic system, be sure to reduce the
supply pressure.
(3) Before the start of teaching, check that the robot and its peripheral
devices are all in the normal operating condition.
(4) If it is necessary to enter the robot work area for maintenance when
the power is turned on, the worker should indicate that the machine
is being serviced and make certain that no one starts the robot
unexpectedly.
(5) Do not operate the robot in the automatic mode while anybody is in
the robot work area.
(6) When it is necessary to maintain the robot alongside a wall or
instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.
(7) When a tool is mounted on the robot, or when any moving device
other than the robot is installed, such as belt conveyor, pay careful
attention to its motion.
(8) If necessary, have a worker who is familiar with the robot system
stand beside the operator panel and observe the work being
performed. If any danger arises, the worker should be ready to press
the EMERGENCY STOP button at any time.
(9) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
(10) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and also turn
off the circuit breaker to protect against electric shock.
(11) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified ratings.
They may cause a fire or result in damage to the components in the
controller.
9
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B--81465EN--1/02
1.2
SAFETY OF THE
TOOLS AND
PERIPHERAL
DEVICES
1.2.1
Precautions in
Programming
(1) Use a limit switch or other sensor to detect a dangerous condition and,
if necessary, design the program to stop the robot when the sensor
signal is received.
(2) Design the program to stop the robot when an abnormal condition
occurs in any other robots or peripheral devices, even though the
robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in
synchronous motion, particular care must be taken in programming
so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral
devices so that the robot can detect the states of all devices in the
system and can be stopped according to the states.
1.2.2
Precautions for
Mechanism
(1) Keep the component cells of the robot system clean, and operate the
robot in an environment free of grease, water, and dust.
(2) Employ a limit switch or mechanical stopper to limit the robot motion
so that the robot does not come into contact with its peripheral devices
or tools.
10
B--81465EN--1/02
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
1.3
SAFETY OF THE
ROBOT MECHANISM
1.3.1
Precautions in
Operation
1.3.2
Precautions in
Programming
1.3.3
Precautions for
Mechanisms
(1) When operating the robot in the jog mode, set it at an appropriate
speed so that the operator can manage the robot in any eventuality.
(2) Before pressing the jog key, be sure you know in advance what
motion the robot will perform in the jog mode.
(1) When the work areas of robots overlap, make certain that the motions
of the robots do not interfere with each other.
(2) Be sure to specify the predetermined work origin in a motion program
for the robot and program the motion so that it starts from the origin
and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance that
the robot motion has terminated.
(1) Keep the work area of the robot clean, and operate the robot in an
environment free of grease, water, and dust.
11
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B--81465EN--1/02
1.4
SAFETY OF THE END
EFFECTOR
1.4.1
Precautions in
Programming
(1) To control the pneumatic, hydraulic and electric actuators, carefully
consider the necessary time delay after issuing each control command
up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot
system by monitoring the state of the end effector.
12
B--81465EN--1/02
1.5
SAFETY IN
MAINTENANCE
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
(1) Never enter the robot work area while the robot is operating. Turn off
the power before entering the robot work area for inspection and
maintenance.
(2) If it is necessary to enter the robot work area with the power turned
on, first press the EMERGENCY STOP button on the operator panel.
(3) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
When replacing the parts in the pneumatic system, be sure to reduce
the pressure in the piping to zero by turning the pressure control on
the air regulator.
(4) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and turn off the
circuit breaker to protect against electric shock.
(5) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified ratings.
They may cause a fire or result in damage to the components in the
controller.
(6) Before restarting the robot, be sure to check that no one is in the robot
work area and that the robot and its peripheral devices are all in the
normal operating state.
13
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B--81465EN--1/02
1.6
WARNING LABEL
Description
Do not step on or climb the robot or controller as it may adversely affect
the robot or controller and you may get hurt if you lose your footing as
well.
(1) Step--on prohibitive label
Fig.1.6 (a) Step--on Prohibitive Label
Description
Be cautious about a section where this label is affixed, as the section
generates heat. If you have to inevitably touch such a section when it is
hot, use a protective provision such as heat--resistant gloves.
(2) High--temperature warning label
Fig.1.6 (b) High--Temperature Warning Label
Description
A high voltage is applied to the places where this label is attached.
Before starting maintenance, turn the power to the control unit off, then
turn the circuit breaker off to avoid electric shock hazards. Be careful with
servo amplifier and other units because high--voltage places in these units
may remain in the high--voltage state for a fixed time.
14
B--81465EN--1/02
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
(3) High--voltage warning label
Fig.1.6 (c) High--Voltage Warning Label
Description
There may be a high voltage in a place with this label. Before working
on such a portion, turn off the power to the controller and set its circuit
breaker to the off position to avoid shock hazards.
In addition, be careful about servo amplifiers and other electric circuits
because a high voltage may remain in them for a certain period of time
after the power is turned off.
15
II MAINTENANCE
MAINTENANCE
B--81465EN--1/02
1
1. OVERVIEW
OVERVIEW
This manual describes the maintenance and connection of the R--J3iB
robot controller (called the R--J3iB).
Maintenance Part : Troubleshooting, and the setting, adjustment,
and replacement of units
Connection Part : Connection of the R--J3iB controller to the robot
mechanical unit and peripheral devices, and
installation of the controller
WARNING
Before you enter the robot working area, be sure to turn off
the power to the controller or press the EMERGENCY
STOP button on the operator panel or teach pendant.
Otherwise, you could injure personnel or damage
equipment.
- For information on third party approvals, contact your FANUC
representative.
19
2. CONFIGURATION
2
MAINTENANCE
CONFIGURATION
20
B--81465EN--1/02
B--81465EN--1/02
2.1
EXTERNAL VIEW OF
THE CONTROLLER
2. CONFIGURATION
MAINTENANCE
The appearance and components might slightly differ depending on the
controlled robot, application, and options used.
Fig.2.1 (a) shows the view of R--J3iB.
Fig.2.1 (b) and (c) show the R--J3iB consists of the R--J3iB controller.
Mode switch
Teach pendant
Operator panel
Fig.2.1 (a) External View of the R--J3iB Controller (B--cabinet)
21
2. CONFIGURATION
MAINTENANCE
Fig.2.1 (b) R--J3iB B--cabinet interior (Front)
22
B--81465EN--1/02
B--81465EN--1/02
MAINTENANCE
2. CONFIGURATION
Fig.2.1 (c) R--J3iB B--cabinet overview (Back)
Table 2.1 Servo amplifier and regenerative resistor unit
Robot models
Servo amplifier
Regenerative resistor unit
R--2000iA
A06B--6105--H002
A05B--2452--C200 (B--cabinet)
M--6iB
A06B--6105--H003
A05B--2452--C201 ((B--cabinet))
ARC Mate 100iB
23
2. CONFIGURATION
Backplane
Power
supply
unit
Main
board
Process
I/O
peripheral
device
(I/O)
Fan
Operator’s panel
peripheral
device
(Serial)
Panel
board
Memory card
peripheral
device
(Ethernet)
Switch
Teach
pendant
Transformer
210VAC
24VDC
EMG signals
E--stop unit
Servo amplifier
(6--axis amplifier)
MAINTENANCE
HSSB, TP Signal
Servo Signal (FSSB)
24VDC
210VAC Input
210VAC Output
24
Breaker
Fig.2.1 (d) Block diagram of the R--J3iB (B--cabinet)
Battery
I/O unit
MODEL A
External E--stop
External on/off
210VAC
Pulse coder signals, Robot DI/DO signals
EMG signals
Motor power supply, Brake power supply
Robot
Transformer overheat signal
Noise filter
B--81465EN--1/02
AC input
380 -- 415 VAC
440 -- 500 VAC
3φ
Regenerative
resistor
B--81465EN--1/02
2.2
COMPONENT
FUNCTIONS
MAINTENANCE
2. CONFIGURATION
-- Main board
The main board contains a microprocessor, its peripheral circuits,
memory, and operator panel control circuit. The main CPU controls
servo mechanism positioning and servo amplifier voltages.
- Battery retains main board memory when controller power is off.
- I/O printed circuit board, FANUC I/O Unit MODEL--A
Various types of printed circuit boards are provided for applications
including process I/O. The FANUC I/O unit MODEL-A can also be
installed. When it is used, various I/O types can be selected. These
are connected with FANUC I/O Link.
- E--stop unit
This unit controls the emergency stop system with control reliable
E--stop performance criteria for both of the magnetic contactor and
the precharge of the servo amplifier.
- Power supply unit
The power supply unit converts the AC power to various levels of DC
power.
- Backplane printed circuit board
The various control printed circuit boards are mounted on the
backplane printed circuit board.
- Teach pendant
All operations including robot programming are performed with this
unit. The controller status and data are indicated on the liquid-crystal
display (LCD) on the pendant.
- Servo amplifier
The servo amplifier controls servomotor power, pulse coder, brake
control, overtravel and hand broken.
- Operator panel
Buttons and LEDs on the operator panel are used to start the robot and
to indicate the robot status. The panel has a port for the serial interface
to an external device and an interface to connect the memory card for
data backup. It also controls the emergency stop control circuit.
- Transformer
The supply voltage is converted to an AC voltage required for the
controller by the transformer.
- Fan unit, heat exchanger
These components cool the inside of the control unit.
- Circuit breaker
If the electric system in the controller malfunctions, or if abnormal
input power causes high current in the system, the input power is
connected to the circuit breaker to protect the equipment.
- Regenerative resistor
To discharge the counter electromotive force from the servomotor,
connect a regenerative resistor to the servo amplifier.
25
2. CONFIGURATION
2.3
PREVENTIVE
MAINTENANCE
MAINTENANCE
B--81465EN--1/02
Daily maintenance and periodic maintenance/inspection ensure reliable
robot performance for extended periods of time.
(1) Daily maintenance
Before operating the system each day, clean each part of the system
and check the system parts for any damage or cracks. Also check the
following:
(a) Before service operation
Check the cable connected to the teach pendant for excessive
twisting. Check the controller and peripheral devices for
abnormalities.
(b) After service operation
At the end of service operation, return the robot to the specified
position, then turn off the controller. Clean each part, and check
for any damage or cracks. If the ventilation port of the controller
is dusty, clean it.
(c) Check after one month
Check that the fan is rotating normally. If the fan has dirt and dust
built up, clean the fan according to step (d) described below for
inspection to be performed every 6 months.
(d) Periodic inspection performed every six months
Remove the top cover, louver, and back panel (if possible), then
remove any dirt and dust from the inside of the transformer
compartment. Wipe off dirt and dust from the fan and
transformer.
(2) Maintenance tools
The following maintenance tools are recommended:
(a) Measuring instruments
AC/DC voltmeter (A digital voltmeter is sometimes required.)
Oscilloscope with a frequency range of 5 MHz or higher, two
channels
(b) Tools
Phillips screwdrivers : Large, medium, and small
Standard screwdrivers: Large, medium, and small
Nut driver set (Metric)
Pliers
Needle-nose pliers
Diagonal cutting pliers
26
B--81465EN--1/02
3
MAINTENANCE
3. TROUBLESHOOTING
TROUBLESHOOTING
This chapter describes the checking method and corrective action for each
error code indicated if a hardware alarm occurs. Refer to the operator’s
manual to release program alarms.
27
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
3.1
POWER CANNOT BE
TURNED ON
Check and Corrective action
Figure
(Check 1)
Check that the circuit breaker is on and has not tripped.
(Corrective
action)
Turn on the circuit breaker.
Breaker
(Check 2)
Check whether the LED (PIL: green) on the power supply unit
is on.
(Corrective
action)
If the LED is not on, 200 VAC is not supplied to the power supply
unit. It is likely that fuse F1 in the power supply unit has blown.
-- If 200 VAC is not supplied:
Find the cause by referencing the general schematic diagram
presented in the appendix.
-- If 200 VAC is supplied:
Find the cause of the blown fuse. Fuse F1 is in the power supply unit. Before you start troubleshooting, turn off the circuit
breaker.
a) If fuse F1 has blown:
-- See Corrective action (1).
b) If fuse F1 has not blown:
-- Replace the power supply unit.
(Corrective
action(1))
Causes of blown fuses F1 and corrective action
a) Check whether the unit and printed--circuit board connected
to the connectors CP2 and CP3 in the power supply unit are
abnormal, by referencing the general schematic diagram
presented in the appendix.
b) Short-circuit in the surge absorber VS1
VS1 is inserted to absorb surge voltage between input lines.
If the surge voltage is excessive or sustained, excessively
high voltage is applied to VS1 and a failure occurs in the
short-circuit mode, causing F1 to blow. If a short-circuit occurs in VS1, and there is not a spare part, the system is permitted to operate without VS1. In this case, however, obtain
and install a new VS1 as soon as possible.
VS1 ordering number: A50L-2001-0122#G431k
c) Short-circuit of diode stack DB1
d) The secondary power supply module is faulty :
If one of the causes (b) to (c) above is detected, replace the
power supply unit with a spare unit.
The spec. for F1 is : A60L-0001-0396#8.0A
28
Diode stack
DB1
F1 8.0A
Fuse for AC input
CP1 connector
Surge absorber
VS1
Spare power
supply module
H1
F3 7.5A
Fuse for +24E
F4 7.5A
Fuse for +24V
PIL
LED (green)
for AC power
supply display
CP6 connector
CP5 connector
LED (red) for
alarm display
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
Check and Corrective action
(Check 3)
(Corrective
action)
Figure
Check whether the EXON1 and EXON2 signals, and the
EXOFF1 and EXOFF2 signals are connected on the terminal
block on the panel board.
Short piece :
between 1 (EXON1) and 2 (EXON2)
between 3 (EXOFF1) and 4 (EXOFF2)
If the external ON/OFF function is not used, connect the EXON1
and EXON2 the EXOFF1 and EXOFF2. If the external ON and
OFF lines are already used, check the mating contacts and the
cable.
Connector (JRS11)
(Check 4)
Check whether the connector (JRS11) on the main board or the
connector (JRS11) on the panel board is connected properly.
Another probable cause is that the cable connected to either of
these connectors is faulty.
(Check 5)
Check 1 to 3 above confirm that 200 VAC power is supplied to
connector CP1 of the power supply unit and that the ON/OFF
switch functions normally. Therefore check the power supply
unit using the following procedure:
If the LED (ALM: red) on the power supply unit is on
Check if the +24 V external connection cable is connected to 0
V or ground.
a) Fuse F4 blown :
See corrective action (2).
b) None of the above fuses blown [d) is also probable] :
A printed circuit board or unit that uses a DC supply voltage (+3.3V, +5V, +24V, or ±15V) is faulty.
c) None of the above fuses blown :
Check that 200 VAC is supplied to connector CP1. If it
is supplied replace the power supply unit.
(Corrective
action)
If the power supply unit is not faulty, replace the panel board or
operator panel.
(Corrective
action(2))
Causes of blown fuse F4 and corrective action
The device connected to connector CP5 of the power supply unit
may be faulty. If no device is connected to CP5 or the connected
device is normal, the +24 V power used in a printed circuit board
connected to the backplane is faulty.
The code of F4 is A60L--0001--0046#7.5 :
29
Diode stack
DB1
F1 8.0A
Fuse for AC input
CP1 connector
Surge absorber
VS1
Spare power
supply module
H1
F3 7.5A
Fuse for +24E
F4 7.5A
Fuse for +24V
PIL
LED (green)
for AC power
supply display
CP6 connector
CP5 connector
LED (red) for
alarm display
3. TROUBLESHOOTING
3.2
ALARM
OCCURRENCE
SCREEN
MAINTENANCE
B--81465EN--1/02
The alarm occurrence screen displays only the alarm conditions that are
currently active. If an alarm reset signal is input to reset the alarm
conditions, the alarm occurrence screen displays the message “PAUSE or
more serious alarm has not occurred.”
The alarm occurrence screen displays only the alarm conditions (if any)
that occur after the most recently entered alarm reset signal. To erase all
alarm displays from the alarm occurrence screen. Press the CLEAR key
(+ shift) on the alarm history screen.
The alarm occurrence screen is intended to display PAUSE or more
serious alarms. It will not display WARN, NONE, or a reset. It is possible
to disable PAUSE and some of more serious alarms from being displayed
by setting the $ER_NOHIS system variable appropriately.
If two or more alarms have occurred, the display begins with the most
recent alarm.
Up to 100 lines can be displayed.
If an alarm has a cause code, it is displayed below the line indicating the
alarm.
Press the screen
selection key to select
[4 ALARM].
Press the alarm key.
Automatic alarm display
upon occurrence
Alarm occurrence screen display
Press F3 [ACTIVE].
Press F3 [HIST].
Alarm history screen display
Fig.3.2 Alarm Occurrence Screen and Alarm History Screen Display
Procedure
30
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
Displaying the alarm history/alarm detail information
Step
(1) Press the MENUS key to display the screen menu.
(2) Select [ALARM].
You will see a screen similar to the following
3
4 ALARM
5 I/O
INTP-224 (SAMPLE1, 7) Jump label is fail
MEMO-027 Specified line does not exist
Alarm
JOINT 30 %
1/25
1 INTP-224 (SAMPLE1, 7) Jump label is
2 SRVO-002 Teach pendant E-stop
3 R E S E T
4 SRVO-027 Robot not mastered(Group:1)
5 SYST-026 System normal power up
MENUS
[ TYPE ]
CLEAR
HELP
NOTE
The latest alarm is assigned number 1. To view messages
that are currently not on the screen, press the F5, HELP,
then press the right arrow key.
(3) To display the alarm detail screen, press F5, [HELP].
CLEAR
HELP
F5
INTP-224 (SAMPLE1, 7) Jump label is fail
INTP-224 (SAMPLE1, 7) Jump label is fail
MEMO-027 Specified line does not exist
30-MAY-44 07:15
STOP.L
00000110
Alarm
1/25
1 INTP-224 (SAMPLE1, 7) Jump label is
2 SRVO-002 Teach pendant E-stop
[ TYPE ]
CLEAR
HELP
(4) To return to the alarm history screen, press the PREV key.
PREV
(5) To delete all the alarm histories, press and hold down the SHIFT key,
then press F4, [CLEAR].
CLEAR
SHIFT
F4
HELP
NOTE
When system variable $ER_NOHIS = 1, NONE alarms or
WARN alarms are not recorded. When $ER_NOHIS=2,
resets are not recorded in the alarm history. When
$ER_NOHIS=3, resets, WARN alarms, and NONE alarms
are not recorded.
31
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
The following map indicates teach pendant operations used to check an
alarm.
4 ALARM
F1 [TYPE]
Alarm : Active
F1 [TYPE]
F3 HIST
Alarm : HIST
F1 [TYPE]
F3 [ACTIVE]
F4 CLEAR
F5 HELP
DETAIL Alarm
F1 [TYPE]
F3 [ACTIVE]
F4 CLEAR
F5 HELP
32
3.3
SAFETY SIGNALS
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
The safety signal screen indicates the state of signals related to safety. To
be specific, the screen indicates whether each safety signal is currently on.
On this screen, it is impossible to change the state of any safety signal.
Table 3.3 Safety Signals
Description
Safety signal
Operator panel emergency stop
This item indicates the state of the emergency stop button on the operator panel. If the
EMERGENCY STOP board is pressed, the state is indicated as “TRUE”.
Teach pendant emergency stop
This item indicates the state of the emergency stop button on the teach pendant. If the
EMERGENCY STOP board is pressed, the state is indicated as “TRUE”.
External emergency stop
This item indicates the state of the external emergency stop signal. If the EMERGENCY
STOP signal is input, the state is indicated as “TRUE”.
Fence open
This item indicates the state of the safety fence. If the safety fence is open, the state is
indicated as “TRUE”.
Deadman switch
This item indicates whether the DEADMAN switch on the teach pendant is grasped. If
the teach pendant is operable, and the DEADMAN switch is grasped, the state is indicated as “TRUE”. If the deadman switch is released when the teach pendant is operable,
an alarm occurs, causing the servo power to be switched off.
Teach pendant operable
This item indicates whether the teach pendant is operable. If the teach pendant is operable, the state is indicated as “TRUE”.
Hand broken
This item indicates the state of the hand safety joint. If the hand interferes with a workpiece or anything like this, and the safety joint is opened, the state is indicated as
“TRUE”. In this case, an alarm occurs, causing the servo power to be switched off.
Robot overtravel
This item indicates whether the current position of the robot is out of the operation range.
If any robot articulation goes out of the operation range beyond the overtravel switch, the
state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be
switched off.
Abnormal air pressure
This item indicates the state of the air pressure. The abnormal air pressure signal is connected to the air pressure sensor. If the air pressure is not higher than the specified
value, the state is indicated as “TRUE”.
Step
(1) Press the MENUS key to display the screen menu.
(2) Select STATUS on the next page.
(3) Press F1, [TYPE] to display the screen switching menu.
(4) Select Safety Signal. You will see a screen similar to the following.
SYSTEM Safety
1
2
3
4
5
6
7
8
9
JOINT 30%
SIGNAL NAME
STATUS
SOP E-Stop:
TP E-stop:
Ext E-Stop:
Fence Open:
TP Deadman:
TP Enable:
Hand Broken:
Over Travel:
Low Air Alarm:
FALSE
FALSE
FALSE
FALSE
TRUE
TRUE
FALSE
FALSE
FALSE
[TYPE]
33
1/11
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
3.4
Mastering is needed if:
MASTERING
(1) The SRVO--062 BZAL or SRVO--038 pulse mismatch alarm occurs,
or
(2) The pulse coder is replaced.
Item (1) requires simplified mastering, while item (2) requires
zero--degree or jig position mastering. (Zero--degree position mastering
is just for quick--fix purposes. After zero--degree position mastering is
used, jig position mastering should be performed later.)
The mastering procedure is described below. For details, refer to an
applicable maintenance manual of mechanical unit or operator’s manual
of control unit.
Condition
System variable $MASTER_ENB must be set to 1 or 2.
SYSTEM Variables
57 $MASTER_ENB
Step
JOINT 10%
57/136
1
(1) Press <MENUS>.
(2) Select SYSTEM.
(3) Press F1, TYPE.
(4) Select Master/Cal you will see a screen similar to the following.
9 USER
0 -- NEXT --
MENUS
5 POSITION
6 SYSTEM
7
Master/Cal
TYPE
SYSTEM Master/Cal
1
FIXTURE POSITION MASTER
2
3
4
5
6
ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
JOINT 30%
Press ’ENTER’ or number key to select.
[TYPE]
LOAD RES_PCA
DONE
F1
(5) Move the robot by jog feed to the mastering position. Release the
brake on the manual brake control screen if necessary.
NOTE
Mastering can not be performed until axis is rotated enough
to establish a pulse.
34
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
(6) Select “1 FIXTURE POSITION MASTER” and press the F4 key
(yes). Mastering data is set.
SYSTEM Master/Cal
SYSTEM Master/Cal
ENTER
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
Master at master position? [NO]
Master at master position? [NO]
[ TYPE ]
YES
NO
F4
JOINT
30 %
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <122000309> <2000319>
[ TYPE ]
LOAD
RES_PCA
DONE
(7) Select “6 CALIBRATE” and press the F4 key (yes). Calibration is
performed.
Alternatively, to perform positioning, turn the power off, then turn it
on again. Calibration is performed whenever the power is turned on.
5 SET QUICK MASTER REF
6 CALIBRATE
ENTER
Calibrate? [NO]
Calibrate? [NO]
[ TYPE ]
SYSTEM Master/Cal
YES
F4
NO
JOINT
30 %
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<10.000> <-25.000> <40.000>
<5.000> <-15.000> <0.000>
[ TYPE ] LOAD RES_PCA
DONE
(8) Press F5 “DONE”, after mastering.
DONE
F5
35
3. TROUBLESHOOTING
3.5
TROUBLESHOOTING
USING THE ERROR
CODE
MAINTENANCE
B--81465EN--1/02
(1) SRVO--001 SVAL1 Operator panel E--stop
(Explanation) The emergency stop button on the operation operator
panel or is pressed.
If the SYST--067 (Panel HSSB disconnect) alarm is
also generated, or if the LED (green) on the panel
board is turned off, communication between the main
board (JRS11) and the panel board (JRS11) is
abnormal. The connectors of the cable between the
main board and the panel board may be loose. Or, the
cable, panel board, or main board may be faulty.
(Note)
(Action 1)
Release the emergency stop button pressed on the
operator panel.
(Action 2)
Check the wires connecting the emergency stop
switch connector CRT8 for continuity. If an open wire
is found replace the entire harness.
(Action 3)
With the emergency stop in the released position,
check for continuity across the terminals of the
switch. If continuity is not found, replace the switch.
If continuity is found replace the operator panel PCB.
Before executing the (Action 4), perform a complete
controller back--up to save all your programs and
settings.
(Action 4)
Replace the Main Board.
NOTE
If the LED is turned off, the following alarms are also
generated.
SRVO--001 Operator panel E--stop.
SRVO--004 Fence open.
SRVO--007 External emergency stop.
SRVO--199 Control stop.
SRVO--204 External (SVEMG abnormal) E--stop.
SRVO--213 Fuse blown (Panel PCB).
SRVO--277 Panel E--stop (SVEMG abnormal).
SRVO--280 SVOFF input
Check the alarm history display on the teach pendant.
36
B--81465EN--1/02
3. TROUBLESHOOTING
MAINTENANCE
Emergency stop button
Fig.3.5 (1) (a) SRVO--001 SVAL1 Operator panel E--stop
37
3. TROUBLESHOOTING
MAINTENANCE
Connector (CRT8)
LED (Green)
Connector (JRS11)
Panel board
Fig.3.5 (1) (b) SRVO--001 SVAL1 Operator panel E--stop
Connector (JRS11)
Main board
Fig.3.5 (1) (c) SRVO--001 SVAL1 Operator panel E--stop
38
B--81465EN--1/02
B--81465EN--1/02
MAINTENANCE
3. TROUBLESHOOTING
(2) SRVO--002 SVAL1 Teach pendant E--stop
(Explanation) The emergency stop button on the operator’s Teach
Pendant was pressed.
(Action 1)
Release the emergency stop button on the teach
pendant.
(Action 2)
Replace Teach Pendant.
Emergency stop button
Fig.3.5 (2) SRVO--002 SVAL1 Teach pendant E--stop
(3) SRVO--003 SVAL1 Deadman switch released
(Explanation) The teach pendant is enabled, but the deadman switch
is not pressed.
Deadman switch is three position switch.
Don’t press the switch to the second “open” position.
Switch is enabled in middle position only.
(Action 1)
Press the deadman switch to run the robot.
(Action 2)
Replace the teach pendant.
Deadman switch
Fig.3.5 (3) SRVO--001 SVAL1 Deadman switch released
39
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
(4) SRVO--004 SVAL1 Fence open
(Explanation) On the terminal block TBOP4 of the panel board, no
connection is made between 5 (EAS1) and 6 (EAS11)
or between 7 (EAS2) and 8 (EAS21). If a safety fence
is connected between 5 (EAS1) and 6 (EAS11) or
between 7 (EAS2) and 8 (EAS21), the door of the
safety fence is open.
If the SYST--067 (Panel HSSB disconnect) alarm is
also generated, or if the LED (green) on the panel
board is turned off, communication between the main
board (JRS11) and the panel board (JRS11) is
abnormal. The connectors of the cable between the
main board and the panel board may be loose. Or, the
cable, panel board, or main board may be faulty.
(Note)
(Action 1)
If a safety fence is connected, close the door.
(Action 2)
Check the switch and cable connected to 5 (EAS1)
and 6 (EAS11) or 7 (EAS2) and 8 (EAS21).
(Action 3)
When this signal is not used, make a connection
between 5 (EAS1) and 6 (EAS11) or between 7
(EAS2) and 8 (EAS21).
(Action 4)
If SRVO--004 (Fence open), SRVO--007 (External
emergency stops), SRVO--213 (Fuse Blown (Panel
PCB)), and SRVO--280 (SVOFF input) occur
simultaneously, it is likely that FUSE1 on the panel
board has blown. Check the fuse. If it has blown,
remove the cause, then replace the fuse.
(Refer to Section 3.6 in Part II, “Maintenance,” of
“Maintenance Manual.”)
(Action 5)
Replace the panel board.
NOTE
FENCE input (AUTO STOP) is a safety stop input when this
input is opened, the robot decelerates in a controlled
manner and then stops, the magnetic contactor opens after
the robot stops.
WARNING
Do NOT short--circuit, or disable, this signal in a system in
which the Fence signal is in use, as it is very dangerous. If
it is necessary to run the robot by short--circuiting the signal
even temporarily, an additional safety provision must be
provided.
40
B--81465EN--1/02
3. TROUBLESHOOTING
MAINTENANCE
NOTE
If the LED is turned off, the following alarms are also
generated.
SRVO--001 Operator panel E--stop.
SRVO--004 Fence open.
SRVO--007 External emergency stop.
SRVO--199 Control stop.
SRVO--204 External (SVEMG abnormal) E--stop.
SRVO--213 Fuse blown (Panel PCB).
SRVO--277 Panel E--stop (SVEMG abnormal).
SRVO--280 SVOFF input
Check the alarm history display on the teach pendant.
Short connection
5 (EAS1) and 6 (EAS11)
Short connection
7 (EAS2) and 8 (EAS21)
Connector (CRT8)
LED (Green)
Connector (JRS11)
Panel board
Fig.3.5 (4) (a) SRVO--004 SVAL1 Fence open
Connector (JRS11)
Main board
Fig.3.5 (4) (b) SRVO--004 SVAL1 Fence open
41
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
(5) SRVO--005 SVAL1 Robot overtravel
(Explanation) The robot has moved beyond a hardware limit switch
on the axes. It is factory--placed in the overtravel state
for packing purposes.
If the Overtravel signal is not in use, it may have been
disabled by short--circuiting in the mechanical unit.
(Action 1)
1) Select [System OT release] on the overtravel
release screen to release each robot axis from the
overtravel state.
2) Hold down the shift key, and press the alarm
release button to reset the alarm condition.
3) Still hold down the shift key, and jog to bring all
axes into the movable range.
(Action 2)
Check the FS2 fuse on the servo amplifier.
If the SRVO--214 Fuse blown alarm is also generated,
FS2 fuse have been blown.
(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 connectors CRF7 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,
a jumper connector must be attached in the
mechanical unit. Check for the jumper connector.
(Action 4)
Replace the servo amplifier.
42
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
Servo amplifier
FS2
Connector (CRF7)
Connector (CRM68)
Servo amplifier
Fig.3.5 (5) SRVO--005 SVAL1 Robot overtravel
43
3. TROUBLESHOOTING
MAINTENANCE
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(6) SRVO--006 SVAL1 Hand broken
(Explanation) The safety joint (if in use) might have been broken.
Alternatively, the HBK signal on the robot
connection cable might be a ground fault or a cable
disconnection.
If the Hand broken signal is not in use, it can be
disabled by software setting.
Refer to Subsection 5.5.3 in Part III, “Connections,”
of “Maintenance Manual” for how to disable the
Hand broken signal.
(Action 1)
Hold down the shift key, and press the alarm release
button to reset the alarm condition. Still hold down
the shift key, and jog the tool to the work area.
1) Replace the safety joint.
2) Check the safety joint cable.
(Action 2)
Check the FS2 fuse on the servo amplifier. If the
SRVO--214 Fuse blown alarm is also generated, FS2
fuse have been blown.
(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 femail connectors.
2) The connector is securely connected.
Then verify that connector CRF7 on the servo
amplifier is securely connected. Also verify that the
RP1 cable is in good condition, and there are no cuts
or kinks visible. Check the robot connection cable
(RP1) for a ground fault or a cable disconnection.
(Action 4)
Replace the servo amplifier.
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Servo amplifier
FS2
Connector (CRF7)
Servo amplifier
Fig.3.5 (6) SRVO--006 SVAL1 Hand broken
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(7) SRVO--007 SVAL1 External E--stop
(Explanation) On the terminal block TBOP4 of the panel board, no
connection is made between 1 (EES1) and 2 (EES11)
or between 3 (EES2) and 4 (EES21). If an external
emergency stop switch is connected between 1
(EES1) and 2 (EES11) or between 3 (EES2) and 4
(EES21), the switch is pressed.
If the SYST--067 (Panel HSSB disconnect) alarm is
also generated, or if the LED (green) on the panel
board is turned off, communication between the main
board (JRS11) and the panel board (JRS11) is
abnormal. The connectors of the cable between the
main board and the panel board may be loose. Or, the
cable, panel board, or main board may be faulty.
(Note)
(Action 1)
If an external emergency stop switch is connected,
releases the switch.
(Action 2)
Check the switch and cable connected to 1 (EES1)
and 2 (EES11) or 3 (EES2) and 4 (EES21).
(Action 3)
When this signal is not used, make a connection
between 1 (EES1) and 2 (EES11) or between 3
(EES2) and 4 (EES21).
(Action 4)
If SRVO--004 (Fence open), SRVO--007 (External
emergency stops), SRVO--213 (Fuse blown (Panel
PCB)), and SRVO--280 (SVOFF input) occur
simultaneously, it is likely that FUSE1 on the panel
board has blown. Check the fuse. If it has blown,
remove the cause, then replace the fuse.
(Refer to Section 3.6 in Part II, “Maintenance,” of
“Maintenance Manual.”)
(Action 5)
Replace the panel board.
WARNING
Do NOT short--circuit, or disable, this signal in a system in
which the External emergency stop input signal is in use, as
it is very dangerous. If it is necessary to run the robot by
short--circuiting the signal even temporarily, an additional
safety provision must be provided.
NOTE
If the LED is turned off, the SRVO--001 (Operator panel
E--stop), SRVO--004 (Fence open), SRVO--007 (External
emergency stops), or SRVO--280 (SVOFF input), alarm is
also generated. Check the alarm history display on the teach
pendant.
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Short connection
1 (EES1) and 2 (EES11)
Short connection
3 (EES2) and 4 (EES21)
Panel board
LED (Green)
Connector (JRS11)
Panel board
Fig.3.5 (7) (a) SRVO--007 SVAL1 External E--stop
Connector (JRS11)
Main board
Fig.3.5 (7) (b) SRVO--007 SVAL1 External E--stop
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(8) SRVO--009 SVAL1 Pneumatic pressure alarm
(Explanation) An abnormal air pressure was detected. The input
signal is located on the end effector of the robot.
Refer to the manual of your robot.
(Action 1)
If an abnormal air pressure is detected, check the cause.
If the peripheral device are normal, check the robot
cable and if the peripheral device are abnormal,
replace the device.
(Action 2)
Replace the servo amplifier.
Servo amplifier
Fig.3.5 (8) SRVO--009 SVAL1 Pneumatic pressure alarm
Pneumatic pressure alarm input is disabled/enabled by software. Please
refer to Subsection 5.5.4. in Part III Connections of this Maintenance
Manual.
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3. TROUBLESHOOTING
(9) SRVO--014 WARN Fan motor abnormal
(Explanation) A fan motor in the backplane unit is abnormal.
(Action)
Check the fan motor and its cables. Replace them if
necessary.
Fan motor
Fig.3.5 (9) SRVO--014 WARN Fan motor abnormal
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(10) SRVO--015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j)
(Explanation) The temperature in the control unit exceeds the
specified value.
(Action 1)
If the ambient temperature is higher than specified
(45°C), cool down ambient temperature.
(Action 2)
If the fan motor is not running, check it and its cables.
Replace them if necessary.
(Action 3)
If the thermostat on the main board is defective,
replace the main board.
External air Fan unit
Door fan
Floor fan unit
Main board
Fig.3.5 (10) SRVO--015 SVAL1 SYSTEM OVER HEAT
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(11) SRVO--018 SVAL1 Brake abnormal
(Explanation) An excessive brake current is detected. The ALM
LED on the servo amplifier is lit.
(Action 1)
Check the robot connection cable (RM1) and cables
internal to the mechanical section for a short--circuit
and connection to the ground.
(Action 2)
This alarm may occur if the brake connector is not
attached.
Make sure that connector CRR64 is securely attached
to the servo amplifier.
(Action 3)
Replace the servo amplifier.
Servo amplifier
Fig.3.5 (11) SRVO--018 SVAL1 Brake abnormal
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(12) SRVO--021 SVAL1 SRDY off (Group : i Axis : j)
(Explanation) The HRDY is on and the SRDY is off, although there
is no other cause of an alarm. (HRDY is a signal with
which the host detects the servo system whether to
turn on or off the servo amplifier magnetic contactor.
SRDY is a signal with which the servo system
informs the host whether the magnetic contactor is
turned on.)
If the servo amplifier magnetic contactor cannot be
turned on when directed so, it is most likely that a
servo amplifier alarm has occurred. If a servo
amplifier alarm has been detected, the host will not
issue this alarm (SRDY off). Therefore, this alarm
indicates that the magnetic contactor cannot be turned
on for an unknown reason.
(Action 1)
Make sure that the CP2 and CRM73 of the E--stop
unit and the servo amplifier CNMC2 and CNMC3 are
connected tightly.
(Action 2)
Check whether an outage has occurred on an
emergency stop line (teach pendant emergency stop,
teach pendant enable/disable switch, teach pendant
deadman switch, operator panel emergency stop,
external emergency stop input, fence input, servo--off
input, or door switch). This alarm occurs if the alarm
cause cannot be detected by software because of a
short break and magnetic contactor off.
(Action 3)
Replace the servo amplifier.
(Action 4)
Replace the E--stop unit.
(Action 5)
Replace the cable between the E--stop unit and the
panel board.
(Action 6)
Replace the cable between the E--stop unit and the
servo amplifier.
(Action 7)
Replace axis control card on the main board.
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Servo amplifier
Main board
Axis control card
E--stop unit
Main board
Fig.3.5 (12) SRVO--021 SVAL1 SRDY off
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(13) SRVO--022 SVAL1 SRDY on (Group : i Axis : j)
(Explanation) When the HRDY is about to go on, the SRDY is already
on. (HRDY is a signal with which the host directs the
servo system whether to turn on or off the servo
amplifier magnetic contactor. SRDY is a signal with
which the servo system informs the host whether the
magnetic contactor is turned on.
(Action 1)
Replace the axis control card on the main board.
(Action 2)
Replace the servo amplifier.
Servo amplifier
Main board
E--stop unit
Axis control card
Main board
Fig.3.5 (13) SRVO--022 SVAL1 SRDY on
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(14) SRVO--023 SVAL1 Stop error excess (Group : i Axis : j)
(Explanation) When the servo is at stop, the position error is
abnormally large.
(Action 1)
Check whether the motor brake has been released.
(Action 2)
Make sure that the servo amplifier CNJ1A to CNJ6
are connected tightly.
(Action 3)
Check to see if the load is greater than the rating. If
greater, reduce it to within the rating. (If the load is
too greater, the torque required for acceleration /
deceleration becomes higher than the capacity of the
motor. As a result, the motor becomes unable to
follow the command, and an alarm is issued.)
(Action 4)
Check each phase voltage of the CRR38A or CRR38B
connector of the three--phase power (200 VAC) input to
the servo amplifier. If it is 170 VAC or lower, check the
line voltage. (If the voltage input to the servo amplifier
becomes low, the torque output also becomes low. As
a result the motor may become unable to follow the
command, hence possibly an alarm.)
(Action 5)
If the line voltage is 170 VAC or higher, replace the
servo amplifier.
(Action 6)
Check disconnection of motor power cable (RM1,
RM2).
(Action 7)
Replace the motor.
Servo amplifier
Main board
E--stop unit
Fig.3.5 (14) SRVO--023 SVAL1 Stop error excess
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(15) SRVO--024 SVAL1 Move error excess (Group : i Axis : j)
(Explanation) When the robot is running, its position error is greater
than a specified value ($PARAM _ GROUP.
$MOVER _ OFFST or $PARAM _ GROUP.
$TRKERRLIM). It is likely that the robot cannot
follow the speed specified by program.
(Action 1)
Check the robot for binding axis.
(Action 2)
Take the same actions as described for the above
alarm.
(16) SRVO--025 SVAL1 Motn dt overflow (Group : i Axis : j)
(Explanation) The specified value is too great.
(17) SRVO--026 WARN2 Motor speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum motor speed
($PARAM_GROUP.$MOT_SPD_LIM)
was
specified. The actual motor speed is clamped to the
maximum speed.
(18) SRVO--027 WARN Robot not mastered (Group : i)
(Explanation) An attempt was made to calibrate the robot, but the
necessary adjustment had not been completed.
(Action)
Master the robot.
(19) SRVO--030 SVAL1 Brake on hold (Group : i)
(Explanation) This alarm occurs when the robot pauses, if the brake
on hold function has been enabled ($SCR.
$BRKHOLD _ ENB = 1). Disable the function if it is
not necessary.
(Action)
Disable [Servo--off during pause] on the general
setting menu (Select Setting general).
(20) SRVO--031 SVAL1 User servo alarm (Group : i)
(Explanation) An user servo alarm occurred.
(21) SRVO--033 WARN Robot not calibrated (Group : i)
(Explanation) An attempt was made to set up a reference point for
simplified adjustment, but the robot had not been
calibrated.
(Action)
Calibrate the robot.
1.Supply power.
2.Set up a simplified adjustment reference point
using [Positioning] on the positioning menu.
(22) SRVO--034 WARN Ref pos not set (Group : i)
(Explanation) An attempt was made to perform simplified adjustment,
but the reference point had not been set up.
(Action)
Set up a simplified adjustment reference point on the
positioning menu.
(23) SRVO--035 WARN2 Joint speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum axis speed
($PARAM_GROUP.$JNTVELLIM) was specified.
Each actual axis speed is clamped to the maximum
speed.
(24) SRVO--036 SVAL1 Inpos time over (Group : i Axis : j)
(Explanation) The robot did not get to the effective area ($PARAM _
GROUP.$ STOPTOL) even after the position check
monitoring time ($PARAM _ GROUP. $INPOS _
TIME) elapsed.
(Action)
Take the same actions as for SRVO--23 (large position
error at a stop).
(25) SRVO--037 SVAL1 Imstp input (Group : i)
(Explanation) The *IMSTP signal for a peripheral device interface
was input.
(Action)
Turn on the *IMSTP signal.
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(26) SRVO--038 SVAL2 Pulse mismatch (Group : i Axis : j)
(Explanation) The pulse count obtained when power is turned off
does not match the pulse count obtained when power
is applied. This alarm is asserted after exchange the
pulsecoder or battery for back up of the pulsecoder
data or loading back up data to the Main Board.
(Action)
Perform APC reset and remaster robot (RES--PCA)
1. Press MENUS.
2. Select SYSTEM.
3. Press F1 [TYPE].
4. Select MASTER/CAL.
5. Press F3, PES--PCA.
6. Press RESET.
The fault condition should reset. If the controller
is still faulted with additional servo--related errors,
cold start the controller.
It might be necessary to remaster the robot.
(27) SRVO--041 SVAL2 MOFAL alarm (Group : i Axis : j)
(Explanation) The servo value was too high.
(Action)
Cold start the controller.
(28) 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 an attempt is made to turn it on. The alarm
condition is detected between the time contact sticking
occurs and the time an attempt is made to turn on the
magnetic contactor.
(Action 1)
Check the magnetic contactor, and replace it if
necessary.
If the contacts of the magnetic contactor have stuck
to each other, turn off the circuit breaker. If the power
is switched off without turning off the circuit breaker,
the servo amplifier may get damaged, because the
stuck contacts keep three--phase 200 V applied to the
servo amplifier.
(Action 2)
Replace the E--stop unit.
(Action 3)
Replace the servo amplifier.
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Servo amplifier
Main board
E--stop unit
Fig.3.5 (28) SRVO--042 MCAL alarm
(29) SRVO--043 SVAL1 DCAL alarm (Group : i Axis : j)
(Explanation) The regenerative discharge energy was too high to be
dissipated as heat. (To run the robot, the servo
amplifier supplies energy to the robot. When going
down the vertical axis, the robot operates from the
potential energy. If a reduction in the potential energy
is higher than the energy needed for acceleration, the
servo amplifier receives energy from the motor. A
similar phenomenon occurs even when no gravity is
applied, for example, at deceleration on a horizontal
axis. The energy that the servo amplifier receives
from the motor is called the regenerative energy. The
servo amplifier dissipates this energy as heat. If the
regenerative energy is higher than the energy
dissipated as heat, the difference is stored in the servo
amplifier, causing an alarm.)
(Action 1)
This alarm may occur if the axis is subjected to frequent
acceleration/deceleration or if the axis is vertical and
generates a large amount of regenerative energy. If this
alarm has occurred, relax the service conditions.
(Action 2)
Check fuse FS3 in the servo amplifier. If it has blown,
remove the cause, and replace the fuse. One of the
probable causes of a blown fuse is a ground fault in
the servo amplifier for auxiliary axis.
(Action 3)
Make sure that the servo amplifier CRR63A,
CRR63B and CRR63C are connected tightly, then
detach the cable from CRR63A, CRR63B and
CRR63C connector on the emergency stop board, and
check for continuity between pins 1 and 2 of the
cable--end connector. If there is no continuity between
the pins, replace the regenerative resistance.
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(Action 4)
3. TROUBLESHOOTING
Make sure that the servo amplifier CRR45A,
CRR45B and CRR45C are connected tightly then
detach the cables from CRR45A, CRR45B and
CRR45C on the servo amplifier and check the
resistance between pins 1 and 2 of each cable end
connector. If the resistance is not 9--16Ω, replace the
regenerative resistor.
Replace the servo amplifier.
(Action 5)
Servo amplifier
Regenerative resistor
Fig.3.5 (29) SRVO--043 SVAL1 DCAL alarm
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(30) SRVO--044 SVAL1 HVAL alarm (Group : i Axis : j)
(Explanation) The DC voltage (DC link voltage) of the main circuit
power supply is abnormally high.
(Action 1)
Check the three--phase input voltage at the servo
amplifier. If it is 253 VAC or higher, check the line
voltage. (If the three--phase input voltage is higher
than 253 VAC, high acceleration/deceleration can
result in this alarm.)
(Action 2)
Check that the load weight is within the rating. If it
is higher than the rating, reduce it to within the rating.
(If the machine load is higher than the rating, the
accumulation of regenerative energy might result in
the HVAL alarm even when the three--phase input
voltage is within the rating.
(Action 3)
Replace the servo amplifier.
Servo amplifier
Fig.3.5 (30) SRVO--044 SVAL1 HVAL alarm
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(31) SRVO--045 SVAL1 HCAL alarm (Group : i Axis : j)
(Explanation) Abnormally high current flowed in the main circuit of
the servo amplifier.
(Action 1)
Disconnect the Robot connection cable (Motor power)
from the servo amplifier.
(Action 2)
Disconnect the Robot connection cable (Motor power)
from the servo amplifier connector (CNJ**), and
check the insulation of each Robot connection cable
(Motor power) (U, V, or W) and the GND line. If there
is a short--circuit, the motor, robot interconnection
cable, or intra--robot cable is defective. Check them
and replace them if necessary.
(Action 3)
Disconnect the Robot connection cable (Motor power)
from the servo amplifier connector (CNJ**), and
measure the resistance between the U and V, V and W,
and W and U with a ohmmeter with a very low
resistance range. If the resistances at these three
places are different from each other, the motor, robot
interconnection cable, or intra--robot cable is
defective. Check each item in detail and replace it if
necessary.
Servo amplifier
Fig.3.5 (31) SRVO--045 SVAL1 HCAL alarm
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(32) SRVO--046 SVAL2 OVC alarm (Group : i Axis : j)
(Explanation) This alarm is issued to prevent the motor from
thermal damage that might occur when the root meant
square current calculated within the servo system is
out of the allowable range.
(Action 1)
Check the operating conditions for the robot and relax
the service conditions.
(Action 2)
Check each phase voltage of the three--phase input
power (200 VAC for the servo amplifier. If it is 170
VAC or lower, check the line voltage.
(Action 3)
Replace the servo amplifier.
(Action 4)
Check the robot connection cable (RM1, RM2). If any
problems are found in the cables, replace the cables.
(Action 5)
Replace the motor.
Servo amplifier
Fig.3.5 (32) SRVO--046 SVAL2 OVC alarm
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Reference
Relationships among the OVC, OVL, and HC alarms
Overview
This section points out the differences among the OVC, OVL, and HC
alarms and describes the purpose of each alarm.
Alarm detection section
Abbreviation
Designation
OVC
Overcurrent alarm
Servo software
Detection section
OVL
Overload alarm
Thermal relay in the motor OHAL2
Thermal relay in the servo amplifier OHAL1
Thermal relay in the separate regenerative discharge unit DCAL
HC
High current alarm
Servo amplifier
Purpose of each alarm
1) HC alarm (high current alarm)
If high current flow in a power transistor momentarily due to
abnormality or noise in the control circuit, the power transistor and
rectifier diodes might be damaged, or the magnet of the motor might
be degaussed. The HC alarm is intended to prevent such failures.
2) OVC and OVL alarms (overcurrent and overload alarms)
The OVC and OVL alarms are intended to prevent overheat that may
lead to the burnout of the motor winding, the breakdown of the servo
amplifier transistor, and the separate regenerative resistor.
The OVL alarm occurs when each built--in thermal relay detects a
temperature higher than the rated value. However, this method is not
necessarily perfect to prevent these failures. For example, if the
motor frequently repeats to start and stop, the thermal time constant
of the motor, which has a large mass, becomes higher than the time
constant of the thermal relay, because these two components are
different in material, structure, and dimension. Therefore, if the
motor repeats to start and stop within a short time as shown in Fig.
1, the temperature rise in the motor is steeper than that in the thermal
relay, thus causing the motor to burn before the thermal relay detects
an abnormally high temperature.
Temperature
Start
Stop
Start
Stop
Start
Thermal time constant
of the motor is high.
Temperature at
which the winding
starts to burn
Thermal time constant
of the thermal relay is
low.
Time
Fig.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles
To prevent the above defects, software is used to monitor the current
in the motor constantly in order to estimate the temperature of the
motor. The OVC alarm is issued based on this estimated temperature.
This method estimates the motor temperature with substantial
accuracy, so it can prevent the failures described above.
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To sum up, a double protection method is used; the OVC alarm is used
for protection from a short--time overcurrent, and the OVL alarm is
used for protection from long--term overload. The relationship
between the OVC and OVL alarms is shown in Fig 2.
Current
Protection area for
the motor and
servo amplifier
Protection by the OVL
Limit current
Protection by
the OVC
Rated continuous current
Time
Fig.2 Relationship between the OVC and OVL alarms
NOTE
The relationship shown in Fig. 2 is taken into consideration
for the OVC alarm. The motor might not be hot even if the
OVC alarm has occurred. In this case, do not change the
parameters to relax protection.
(33) SRVO--047 SVAL1 LVAL alarm (Group : i Axis : j)
(Explanation) The control power supply voltage (+5 V, etc.) supplied
from the power supply circuit in the servo amplifier
is abnormally low.
(Action 1)
Replace the servo amplifier.
Servo amplifier
Fig.3.5 (33) SRVO--047 SVAL1 LVAL alarm
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(34) SRVO--049 SVAL1 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)
Make sure that the CRM73 connector of the E--stop
unit is connected tightly.
(Action 2)
Check the operating conditions for the robot and relax
the service conditions.
(Action 3)
If fuses F1 and F2 have blown, replace the servo
amplifier.(See II MAINTENANCE, Section 3.6.)
(Action 4)
If the fan motor is not running, check it and its cables.
Replace them if necessary.
(Action 5)
Replace the transformer.
Servo amplifier
Transformer
E--stop unit
Fig.3.5 (34) SRVO--049 SVAL1 OHAL1 alarm
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(35) SRVO--050 SVAL1 CLALM alarm (Group : i Axis : j)
(Explanation) The disturbance torque estimated by the servo software
is abnormally high. (A collision has been detected.)
(Action 1)
Check that the robot has collided with anything. If it
has, reset the robot and jog--feed it to recover from the
collision.
(Action 2)
Make sure that the load setting is correct.
(Action 3)
Check that the load weight is within the rating. If it
is higher than the rating, reduce it to within the rating.
(If the robot is used out of its usable range, the
estimated disturbance torque becomes abnormally
high, possibly resulting in this alarm being detected.)
(Action 4)
Check the phase voltage of the three--phase input
power (200 VAC) to the servo amplifier. If it is 170
VAC or lower, check the line voltage.
(Action 5)
Replace the servo amplifier.
Servo amplifier
Fig.3.5 (35) SRVO--050 SVAL1 CLALM alarm
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(36) SRVO--051 SVAL2 CUER alarm (Group : i Axis : j)
(Explanation) The offset of the current feedback value is abnormally
high.
(Action)
Replace the servo amplifier.
Servo amplifier
Fig.3.5 (36) SRVO--051 SVAL2 CUER alarm
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(37) SRVO--054 DSM Memory Error
(Explanation) An access to the servo module memory fails.
(Action)
Replace the axis control card on the main board.
Servo amplifier
Main board
Axis control card
E--stop unit
Main board
Fig.3.5 (37) SRVO--054 DSM Memory Error
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(38) SRVO--055 SVAL2 FSSB com error 1 (Group : i Axis : j)
(Explanation) A communication error has occurred between the
main board and servo amplifier. (from main board to
servo amplifier.)
(Action 1)
Check the communication cable (optical fiber)
between the main board and servo amplifier. Replace
it if it is faulty.
(Action 2)
Replace the axis control card on the main board.
(Action 3)
Replace the servo amplifier.
Before continuing to the next step, perform a
complete controller back--up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.
(Action 4)
Replace the main board.
Servo amplifier
Main board
Axis control card
E--stop unit
Main board
Fig.3.5 (38) SRVO--055 SVAL2 FSSB com error 1
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(39) SRVO--056 SVAL2 FSSB com error 2 (Group : i Axis : j)
(Explanation) A communication error has occurred between the
main board and servo amplifier. (from servo amplifier
to main board.)
(Action 1)
Check the communication cable (optical fiber)
between the main board and servo amplifier. Replace
it if it is faulty.
(Action 2)
Replace the axis control card on the main board.
(Action 3)
Replace the servo amplifier.
Before continuing to the next step, perform a
complete controller back--up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.
(Action 4)
Replace the main board.
Servo amplifier
Main board
Axis control card
E--stop unit
Main board
Fig.3.5 (39) SRVO--056 SVAL2 FSSB com error 2
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(40) SRVO--057 SVAL2 FSSB disconnect (Group : i Axis : j)
(Explanation) Communication was interrupted between the main
board and servo amplifier.
(Action 1)
Check whether fuse F3 in the power supply unit has
blown.
(Action 2)
Check whether fuse FS1 in the servo amplifier has
blown.
(Action 3)
Check the communication cable (optical fiber)
between the main board and servo amplifier. Replace
it if it is faulty.
(Action 4)
Replace the axis control card on the main board.
(Action 5)
Replace the servo amplifier.
Before continuing to the next step, perform a
complete controller back--up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.
(Action 6)
Replace the main board.
(Action 7)
Check the RP1 cable of robot connection cable.
(+5V ground fault)
Servo amplifier
Main board
Axis control card
E--stop unit
Main board
Fig.3.5 (40) SRVO--057 SVAL2 FSSB disconnect
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(41) SRVO--058 SVAL2 FSSB init error (Group : i Axis : j)
(Explanation) Communication was interrupted between the main
board and servo amplifier.
(Action 1)
Check whether fuse F3 in the power supply unit and
fuse FS1 in the servo amplifier have blown.
If they have blown, see Section 3.6, “Troubleshooting
for Blown Fuse.”
(Action 2)
Check whether LEDs (P5V and P3.3V) on the servo
amplifier are on.
If they are on, perform “Action 4” and all actions that
follow it. If they are not on, perform “Action 3” and
all actions that follow it.
(Action 3)
Check whether connectors CP6 and CRM67 on the
emergency stop unit are securely connected to
connector CP6 on the power supply unit and connector
CRM67 on the servo amplifier, respectively.
(Action 4)
Check the communication cable (optical fiber)
between the main board and servo amplifier. Replace
it if it is faulty.
(Action 5)
Replace the axis control card on the main board.
(Action 6)
Replace the servo amplifier.
Before continuing to the next step, perform a
complete controller back--up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.
(Action 7)
Replace the main board.
Servo amplifier
Main board
Axis control card
E--stop unit
Main board
Fig.3.5 (41) SRVO--058 SVAL2 FSSB init error
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(42) SRVO--059 SVAL2 Servo amp init error
(Explanation) Servo amplifier initiazation is failed.
(Action 1)
Check the wiring of the servo amplifier.
(Action 2)
Replace the servo amplifier.
Servo amplifier
Fig.3.5 (42) SRVO--059 SVAL2 Servo amp init error
(43) SRVO--60 FATL FSSB init error
(Explanation) Communication between the additional axis board
and additional axis amplifier was interrupted.
(Action 1)
Check whether the optical cable between the
additional axis board and additional axis amplifier is
connected securely.
(Action 2)
Replace the additional axis board.
(Action 3)
Replace the additional axis amplifier.
(Action 4)
Replace the main board.
(Action 5)
Replace the backplane.
(44) SRVO--061 SVAL2 CKAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if the rotation speed count in the
pulse coder is abnormal (abnormal count clock).
(Action)
Replace the pulse coder.
NOTE
This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.
(45) SRVO--062 SVAL2 BZAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if battery for pulse coder
absolute-position backup is empty.
A probable cause is a broken battery cable or no
batteries in the robot.
(Action)
Check the battery and battery cable, and replace the
new battery.
Then set the system variable $MCR.$SPC_RESET
to TRUE, then supply power again.
After this, mastering is required or follow SRVO--038
RECOVERY PROCEDURE.
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(46) SRVO--063 SVAL2 RCAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if the rotation speed count in the
pulse coder is abnormal (abnormal counter).
(Action)
Replace the pulse coder.
NOTE
This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.
(47) SRVO--064 SVAL2 PHAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if the phase of the pulses generated
in the pulse coder is abnormal.
(Action)
Replace the pulse coder.
NOTE
This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.
(48) SRVO--065 WARN BLAL alarm (Group : i Axis : j)
(Explanation) The battery voltage for the pulse coder is lower than
the rating.
(Action)
Replace the battery.
(If this alarm occurs, turn on the AC power and
replace the battery as soon as possible. A delay in
battery replacement may result in the BZAL alarm
being detected. In this case, the position data will be
lost. Once the position data is lost, mastering will
become necessary.
(49) SRVO--066 SVAL2 CSAL alarm (Group : i Axis : j)
(Explanation) The ROM in the pulse coder is abnormal.
(Action)
Replace the pulse coder.
NOTE
This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.
(50) SRVO--067 SVAL2 OHAL2 alarm (Group : i Axis : j)
(Explanation) The temperature inside the pulse coder or motor is
abnormally high, and the built--in thermostat has
operated.
(Action 1)
Check the operating conditions for the robot and relax
the service conditions.
(Action 2)
When power is supplied to the motor after it has
become sufficiently cool, if the alarm still occurs,
replace the motor.
(51) SRVO--068 SVAL2 DTERR alarm (Group : i Axis : j)
(Explanation) The serial pulse coder does not return serial data in
response to a request signal.
--See actions on SRVO--070
(52) SRVO--069 SVAL2 CRCERR alarm (Group : i Axis : j)
(Explanation) The serial data has disturbed during communication.
--See actions on SRVO--070
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(53) SRVO--070 SVAL2 STBERR alarm (Group : i Axis : j)
(Explanation) The start and stop bits of the serial data are abnormal.
(Action 1)
Make sure that the CRF7 connector of servo amplifire
is connected tightly.
(Action 2)
Check that the shielding of the robot interconnection
cable (for the pulse coder) and the peripheral equipment
cable is connected securely to the grounding plate.
(Action 3)
Check that each unit is grounded securely.
(Action 4)
Replace the servo amplifier.
(Action 5)
Replace the pulse coder.
(Action 6)
Replace the robot interconnection cable (for the pulse
coder).
Servo amplifier
Fig.3.5 (53) SRVO--070 SVAL2 STBERR alarm
(54) SRVO--071 SVAL2 SPHAL alarm (Group : i Axis : j)
(Explanation) The feedback speed is abnormally high.
(Action 1)
If this alarm occurs together with the PHAL alarm
(No. 064), this alarm does not correspond to the major
cause of the failure.
(Action 2)
Replace the pulse coder.
(55) SRVO--072 SVAL2 PMAL alarm (Group : i Axis : j)
(Explanation) It is likely that the pulse coder is abnormal.
(Action)
Replace the pulse coder and remaster the robot.
(56) SRVO--073 SVAL2 CMAL alarm (Group : i Axis : j)
(Explanation) It is likely that the pulse coder is abnormal or the pulse
coder has malfunctioned due to noise.
(Action)
Master the robot and enhance the shielding.
(57) SRVO--074 SVAL2 LDAL alarm (Group : i Axis : j)
(Explanation) The LED in the pulse coder is broken.
(Action)
Replace the pulse coder, and remaster the robot.
(58) SRVO--075 WARN Pulse not established (Group : i Axis : j)
(Explanation) The absolute position of the pulse coder cannot be
established.
(Action)
Reset the alarm, and jog the axis on which the alarm
has occurred until the same alarm will not occur
again. (Jog one motor revolution)
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(59) SRVO--076 SVAL1 Tip Stick Detection (Group : i Axis : j)
(Explanation) An excessive disturbance was assumed in servo
software at the start of operation. (An abnormal load
was detected. The cause may be welding.)
(Action 1)
Check whether the robot comes into collision with
foreign matter. If a collision occurs, reset the system,
then switch it to the jog feed mode to avoid the
collision.
(Action 2)
Check whether the load settings are valid.
(Action 3)
Check whether the load weight is within the rated
range. If the weight exceeds the upper limit, decrease
it to the limit.
(Use of the robot with a load exceeding the limit
applied may abnormally increase the assumed
disturbance, resulting in this alarm.)
(Action 4)
Check each inter--phase voltage of the three--phase
input (200 VAC) to the servo amplifier. If the voltage
is 170 VAC or lower, check the input power supply
voltage.
(Action 5)
Replace the servo amplifier.
Servo amplifier
Fig.3.5 (60) SRVO--076 SVAL1 Tip Stick Detection
(60) SRVO--081 WARN EROFL alarm (Track enc : i)
(Explanation) The pulse counter for line tracking has overflowed.
(61) SRVO--082 WARN DAL alarm (Track ebc : i)
(Explanation) The line tracking pulse coder has not been connected.
(Action 1)
Check the pulse coder connection cable, and replace
it if necessary.
(Action 2)
Replace the pulse coder.
(62) SRVO--083 WARN CKAL alarm (Track ebc : i)
(Explanation) This alarm occurs if the rotation speed count in the
pulse coder is abnormal (abnormal count clock).
(Action)
See the description about the SRVO--061 CKAL
alarm.
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(63) SRVO--084 WARN BZAL alarm (Track enc : i)
(Explanation) This alarm occurs if the backup battery for the absolute
position of the pulse coder has not been connected. See
the description about the BZAL alarm (SRVO--062).
(64) SRVO--085 WARN RCAL alarm (Track ebc : i)
(Explanation) This alarm occurs if the rotation speed count in the
pulse coder is abnormal (abnormal counter).
(Action)
See the description about the SRVO--063 RCAL
alarm.
(65) SRVO--086 WARN PHAL alarm (Track enc : i)
(Explanation) This alarm occurs if the phase of pulses generated in
the pulse coder is abnormal. See the description
about the PHAL alarm (SRVO--064).
(66) SRVO--087 WARN BLAL alarm (Track enc : i)
(Explanation) This alarm occurs if the voltage of the backup battery
for the absolute position of the pulse coder is low. See
the description about the BLAL alarm (SRVO--065).
(67) SRVO--088 WARN CSAL alarm (Track ebc : i)
(Explanation) The ROM in the pulse coder is abnormal.
(Action)
See the description about the SRVO--066 CSAL
alarm.
(68) SRVO--089 WARN OHAL2 alarm (Track enc : i)
(Explanation) The motor has overheated. See the description about
the OHAL2 alarm (SRVO--067).
(69) SRVO--090 WARN DTERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
description about the DTERR alarm (SRVO--068).
(70) SRVO--091 WARN CRCERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
description about the CRCERR alarm (SRVO--069).
(71) SRVO--092 WARN STBERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
description about the STBERR alarm (SRVO--070).
(72) SRVO--093 WARN SPMAL alarm (Track enc : i)
(Explanation) This alarm occurs if the current position data from the
pulse coder is higher than the previous position data.
See the description about the SPHAL alarm
(SRVO--071).
(73) SRVO--094 WARN PMAL alarm (Track enc : i)
(Explanation) It is likely that the pulse coder is abnormal. See the
description about the PMAL alarm (SRVO--072).
(74) SRVO--095 WARN CMAL alarm (Track enc : i)
(Explanation) It is likely that the pulse coder is abnormal or the pulse
coder has malfunctioned due to noise. See the
description about the CMAL alarm (SRVO--073).
(75) SRVO--096 WARN LDAL alarm (Track enc : i)
(Explanation) The LED in the pulse coder is broken. See the
description about the LDAL alarm (SRVO--074).
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(76) SRVO--097 WARN Palse not established (enc : i)
(Explanation) The absolute position of the pulse coder cannot be
established. See the description about (SRVO--075).
Pulse not established.
(77) SRVO--105 SVAL1 Door open or E--stop
(Explanation) The cabinet door is open.
(Action 1)
When the door is open, close it. If no door switch is
mounted, go to [Action 3].
(Action 2)
Check the door switch and door switch connection
cable. If the switch or cable is faulty, replace it.
(Action 3)
Check that the CRM70, CRM71, and CRM72
connectors on the E--STOP unit are connected
securely.
(Action 4)
This alarm is also issued if software cannot determine
the cause of disconnection of the emergency stop line.
Reference the total connection diagram in Appendix
and check whether the emergency stop line is normal.
(Action 5)
Replace the servo amplifier.
Servo amplifier
Electro
magnetic
contactor
E--stop unit
Fig.3.5 (79) SRVO--105 SVAL1 Door open or E--stop
(78) SRVO--136 SVAL1 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.
--This alarm occured in the robot operation.
(Action 1)
Check the phase voltage of the three--phase input
power (200 VAC) to the servo amplifier. If it is 170
VAC or lower, check the line voltage.
(Action 2)
Replace the servo amplifier.
--If this alarm occurs before the magnetic contactor is turned on:
(Action 1)
Check whether the circuit breaker in the emergency
stop unit is OFF. If it is OFF, check the servo
amplifier and the wiring between the servo amplifier
and the emergency stop unit. If anything is abnormal,
replace it.
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(Action 2)
Check each phase--to--phase voltage of the
three--phase input (200 VAC) on the primary side of
the magnetic contactor. If the input is not higher than
170 VAC, check the input power supply voltage.
Replace the E--stop unit.
Replace the servo amplifier.
(Action 3)
(Action 4)
Servo amplifier
Main board
E--stop unit
Fig.3.5 (78) SRVO--136 SVAL1 DCLVAL alarm
(79) SRVO--138 SDAL alarm(Group : i Axis : j)
(Explanation) The feedback data from pulse coder was abnormal by
noise on the pulse coder.
Or the inter polation circuit of the pulse coder is
broken.
(Action)
If the alarm disappeared by power OFF/ON, please
make sure the cable shields are grounded.
(Action)
If this problem occurs repeatedly, replase the pulse
coder and master the robot.
(80) SRVO--153 SVAL1 CHGAL(CNV) alarm (Group : i Axis : j)
(Explanation) The main circuit could not be charged within the
specified time.
(Action 1)
A short circuit may occur in the DC link. Check the
connection.
(Action 2)
The charging current control resistor may be faulty.
Replace the E--STOP unit.
(Action 3)
Replace the servo amplifier.
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Servo amplifier
Panel board
E--stop unit
Fig.3.5 (80) SRVO--153 SVAL1 CHGAL(CNV) alarm
(81) SRVO--156 SVAL1 IPMAL alarm (Group : i Axis : j)
(Explanation) Abnormally high current flowed through the main
circuit of the servo amplifier.
(Action 1)
Detach the motor power lines from the respective
terminals on the servo amplifier, and switch on the
power, then check to see if the alarm occurs again. If
the alarm occurs, replace the servo amplifier.
(Action 2)
Detach the motor power lines from the respective
terminals on the servo amplifier, and check for isolation
between each motor power line (U, V, or W) and a
ground potential (GND). If a motor power line is
short--circuited to a ground, the motor, robot connection
cable, or robot internal cable is likely to be defective.
Check each of them, and replace it if necessary.
(Action 3)
Detach the motor power lines from the respective
terminals on the servo amplifier, and check the
resistance between each motor power line pair (U and
V, V and W, or W and U) using a meter that is capable
of measuring a very low resistance. If the measured
three resistances are different, the motor, robot
connection cable, or robot internal cable is likely be
defective. Check each of them, and replace it if
necessary.
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Servo amplifier
Fig.3.5 (81) SRVO--156 SVAL1 IPMAL alarm
(82) SRVO--157 SVAL1 CHGAL alarm (Group : i Axis : j)
(Explanation) The capacitor for the DC link voltage of the servo
amplifier was not charged within the specified time.
(Action 1)
A short circuit may occur in the DC link voltage.
Check the connection.
(Action 2)
The charging current control resistor may be faulty.
Replace the E--STOP unit.
(Action 3)
Replace the servo amplifier.
Servo amplifier
Panel board
E--stop unit
Fig.3.5 (82) SRVO--157 SVAL1 CHGAL alarm
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(83) SRVO--194 Servo disconnect
(Explanation) On the terminal block TBOP3 of the panel board, no
connection is made between 5 (SD4) and 6 (SD41) or
between 7 (SD5) and 8 (SD51). If a servo disconnect
switch is connected between 5 (SD4) and 6 (SD41) or
between 7 (SD5) and 8 (SD51), the switch is pressed.
If the SYST--067 (Panel HSSB disconnect) alarm is
also generated, or if the LED (green) on the panel
board is turned off, communication between the main
board (JRS11) and the panel board (JRS11) is
abnormal. The connectors of the cable between the
main board and the panel board may be loose. Or, the
cable, panel board, or main board may be faulty.
(Note)
(Action 1)
If a servo disconnect switch is connected, releases the
switch.
Check the switch and cable connected to 5 (SD4) and
6 (SD41) or 7 (SD5) and 8 (SD51).
When this signal is not used, make a connection
between 5 (SD4) and 6 (SD41) or between 7 (SD5)
and 8 (SD51).
Replace the PC board.
(Action 2)
(Action 3)
(Action 4)
NOTE
If the LED is turned off, the following alarms are also
generated.
SRVO--001 Operator panel E--stop.
SRVO--004 Fence open.
SRVO--007 External emergency stop.
SRVO--199 Control stop.
SRVO--204 External (SVEMG abnormal) E--stop.
SRVO--213 Fuse blown (Panel PCB).
SRVO--277 Panel E--stop (SVEMG abnormal).
SRVO--280 SVOFF input
Check the alarm history display on the teach pendant.
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Short connection
5 (SD4) and 6 (SD41)
Panel board
Connector (JRS11)
LED (Green)
Short connection
7 (SD5) and 8 (SD51)
Panel board
Fig.3.5 (83) (a) SRVO--194 Servo disconnect
Connector (JRS11)
Main board
Fig.3.5 (83) (b) SRVO--194 Servo disconnect
(84) SRVO--199 Control Stop
(Explanation) This alarm is displayed together with a Fence open
alarm or SVOFF input alarm.
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(85) SRVO--201 SVAL1 Panel E--stop or SVEMG abnormal
(Explanation) The EMERGENCY STOP button on the operator
panel was pressed, but the EMERGENCY STOP line
was not disconnected.
(Action 1)
Check the EMERGENCY STOP button on the
operator panel, and replace it if necessary.
(Action 2)
Replace the panel board.
(Action 3)
Replace the servo amplifier.
NOTE
This alarm might occur if the EMERGENCY STOP button
is pressed slowly.
Servo amplifier
Emergency stop button
Panel board
Fig.3.5 (85) SRVO--201 SVAL1 Panel E--stop or SVEMG abnormal
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(86) SRVO--202 SVAL1 TP E--stop or SVEMG abnormal
(Explanation) The EMERGENCY STOP button on the operator
panel was pressed, but the EMERGENCY STOP line
was not disconnected.
(Action 1)
Check the teach pendant connection cable, and
replace it if necessary.
(Action 2)
Replace the teach pendant.
(Action 3)
Replace the panel board.
(Action 4)
Replace the servo amplifier.
NOTE
This alarm might occur if the EMERGENCY STOP button
is pressed slowly.
Servo amplifier
Emergency stop button
Panel board
Fig.3.5 (86) SRVO--202 SVAL1 TP E--stop or SVEMG abnormal
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(87) SRVO--204 SVAL1 External (SVEMG abnormal) E--stop
(Explanation) The switch connected across EES1 and EES11, EES2
and EES21 on the TBOP4 terminal board on the panel
board was pressed, but the EMERGENCY STOP line
was not disconnected.
(Action 1)
Replace the panel board.
(Action 2)
Replace the servo amplifier.
Servo amplifier
Emergency stop button
Panel board
Fig.3.5 (87) SRVO--204 SVAL1 External (SVEMG abnormal) E--stop
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(88) SRVO--205 SVAL1 Fence open (SVEMG abnormal)
(Explanation) The switch connected across EAS1 and EAS11,
EAS2 and EAS21 on the TBOP4 terminal board on
the panel board was pressed, but the EMERGENCY
STOP line was not disconnected.
(Action 1)
Replace the panel board.
(Action 2)
Replace the servo amplifier.
Servo amplifier
Emergency stop button
Panel board
Fig.3.5 (88) SRVO--205 SVAL1 Fence open (SVEMG abnormal)
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(89) SRVO--206 SVAL1 Deadman switch (SVEMG abnormal)
(Explanation) The DEADMAN switch was released when the teach
pendant was operable, but the EMERGENCY STOP
line was not disconnected.
(Action 1)
Check the teach pendant connection cable. Replace it
if necessary.
(Action 2)
Replace the teach pendant.
(Action 3)
Replace the panel board.
(Action 4)
Replace the servo amplifier.
Servo amplifier
Emergency stop button
Panel board
Fig.3.5 (89) SRVO--206 SVAL1 Deadman switch (SVEMG abnormal)
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(90) SRVO--207 SVAL1 TP switch abnormal or door open
(Explanation) The teach pendant is operable, and the deadman
switch has been grasped, but the EMERGENCY
STOP line is kept disconnected.
(Action 1)
Check the teach pendant connection cable, and
replace it if necessary.
(Action 2)
Replace the teach pendant.
(Action 3)
Replace the panel board.
(Action 4)
Replace the servo amplifier.
Servo amplifier
Emergency stop button
Panel board
Fig.3.5 (90) SRVO--207 SVAL1 TP switch abnormal or door open
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(91) SRVO--213 WARN Fuse blown (Panel PCB)
(Explanation) A fuse on the panel board has blown.
(Action 1)
Check whether fuse FUSE1 on the panel board is
blown.
When the fuse is blown, eliminate the cause, then
replace the fuse.
(See II MAINTENANCE, Section 3.6.)
(Action 2)
Replace the panel board.
Servo amplifier
Panel board
E--stop unit
Fig.3.5 (91) SRVO--213 WARN Fuse blawon (Panel PCB)
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(92) SRVO--214 WARN Fuse blown (Panel PCB)
(Explanation) A fuse in the servo amplifier has blown.
(Action 1)
Check whether fuse F1, F2, FS2, or FS3 in the servo
amplifier is blown.
When a fuse is blown, eliminate the cause, then
replace the fuse.
(See II MAINTENANCE, Section 3.6.)
(Action 2)
Replace the servo amplifier.
Servo amplifier
Panel board
E--stop unit
Fig.3.5 (92) SRVO--214 WARN Fuse blown (Panel PCB)
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(93) SRVO--215 WARN Fuse blown (Aux axis)
(Explanation) The fuse in the additional axis amplifier has blown.
(Action 1)
Check the cause and solve the problem, then replace
the fuse.
(94) SRVO--216 SVAL1 OVC (total) (Robot : i)
(Explanation) The current (total current for six axes) flowing
through the motor is too large.
(Action 1)
Slow the motion of the robot where possible. Check
the robot operation conditions. If the robot is used
with a condition exceeding the duty or load weight
robot rating, reduce the load condition value to the
specification range.
(Action 2)
Check each inter--phase voltage of the three--phase
input (200 VAC) to the servo amplifier. If the voltage
is 170 VAC or lower, check the input power supply
voltage.
(95) SRVO--221 SVAL1 Lack of DSP (Group : i Axis : j)
(Explanation) A controlled axis card corresponding to the set
number of axes is not mounted.
(Action 1)
Check whether the set number of axes is valid. If the
number is invalid, set the correct number.
(Action 2)
Replace the controlled axis card with a card
corresponding to the set number of axes.
(Example)
When six axes are set, a controlled axis card for six
or eight axes is available. For how to replace the
controlled axis card, see II MAINTENANCE,
Section 7.2 in this manual.
(96) SRVO--222 SVAL1 Lack of Amp (Amp : i)
(Explanation) The FSSB has no SVM.
(Action 1)
Check that the optical cable is securely connected to
the SVM.
(Action 2)
Replace the optical cable.
(Action 3)
Check whether power is properly supplied to the
SVM.
Check that there is no problem with each SVM input
voltage.
(Action 4)
Replace the SVM.
(97) SRVO--230 SVAL1 Chain 1 (+24V) abnormal
SRVO--231 SVAL1 Chain 2 (0V) abnormal
(Explanation) Single chain 1 (+24V)/chain 2 (0V) failure occured
on emergency stop of operator panel or emergency
stop of teach pendant or deadman switch or fence
switch or external emergency stop or servo ON/OFF
switch or NTED input or door switch.
Please check history of alarm by Alarm Log.
¯ Single chain failure is ;
One of emergency stop chain is emergency stop
condition, and another chain is not emergency stop
condition.
¯ Cause of this alarm is ;
-- Weld of contact
-- Wire broken or shorted
-- Half release of deadman switch
-- Half operation of emergency stop of operator
panel and emergency stop of teach pendant
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-- Irregular input from external emergency stop
and etc. (Out of specified timing.)
The single chain failure occurred on the emergency
stop switch of the operator panel, emergency stop
switch of the teach pendant and the deadman switch.
This failure can be recovered by performing the
correct stop operation.
The detecting circuit for the single chain failure is
reset by either entering another stop cause, or turning
the power on again. Hold the alarm state for the
duration that the alarm history is being checked.
CAUTION
1 This alarm is controlled by the software and requires a
special reset procedure.
After resolving the cause of the alarm, please issue the
special reset procedure according to end of Explanations
and Actions shown below.
2 The RESET operation is inhibited until the special reset
procedure is performed.
The message of “SRVO--237 Cannot reset chain failure” is
displayed, if the RESET operation is issued before the
special reset procedure is performed.
3 If a successful operator panel emergency stop, or teach
pendant emergency stop, or when the deadman switch is
released after this alarm, the message of “SRVO--236
Chain failure is repaired” is displayed.
Single chain 1 (+24V) failure is ;
(Example of external emergency stop)
Single chain 2 (0V) failure is ;
(Example of external emergency stop)
[Displaying the Alarm Log]
Please refer to “Setup and Operations Manual”.
1. Press “MENUS” on the teach pendant.
2. Press “4” on the teach pendant. [4 ALARM].
3. Press F1, [TYPE].
4. Select Alarm Log.
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(Example)
(98) SRVO--230 SVAL1 Chain 1 (+24V) abnormal
with SRVO--001 Operator panel E--stop
SRVO--231 SVAL1 Chain 2 (0V) abnormal
with SRVO--001 Operator panel E--stop
(Action 1)
Re--operate emergency stop of operator panel.
If this alarm is reset, the message of “SRVO--236
Chain failure is repaired” is displayed.
(Action 2)
Replace the panel board.
(Action 3)
Replace the operator panel.
(Action 4)
Replace the E--stop unit.
(Action 5)
Replace the servo amplifier.
Servo amplifier
Teach pendant
Panel board
Mode switch
Operator panel
E--stop unit
Fig.3.5 (98) SRVO--230 SVAL1 Chain 1 (+24V) abnormal
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(99) SRVO--230 SVAL1 Chain 1 (+24V) abnormal
with SRVO--002 Teach pendant E--stop
SRVO--231 SVAL1 Chain 2 (0V) abnormal
with SRVO--002 Teach pendant E--stop
(Action 1)
Re--operate emergency stop of teach pendant.
If this alarm is reset, the message of “SRVO--236
Chain failure is repaired” is displayed.
(Action 2)
Check the teach pendant connection cable and replace
it if necessary.
(Action 3)
Replace the panel board.
(Action 4)
Replace the operator panel.
(Action 5)
Replace the E--stop unit.
(Action 6)
Replace the servo amplifier.
Servo amplifier
Teach pendant
Panel board
Mode switch
Operator panel
E--stop unit
Fig.3.5 (99) SRVO--230 SVAL1 Chain 1 (+24V) abnormal
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(100) SRVO--230 SVAL1 Chain 1 (+24V) abnormal
with SRVO--003 Deadman switch released
SRVO--231 SVAL1 Chain 2 (0V) abnormal
with SRVO--003 Deadman switch released
(Action 1)
Re--operate deadman switch. If this alarm is reset. the
message of “SRVO--236 Chain failure is repaired” is
displayed.
(Action 2)
Check the teach pendant connection cable and replace
it if necessary.
(Action 3)
Replace the panel board.
(Action 4)
Replace the teach pendant.
(Action 5)
Replace the E--stop unit.
(Action 6)
Replace the servo amplifier.
(Action 7)
Replace the mode switch.
Servo amplifier
Teach pendant
Panel board
Mode switch
Operator panel
E--stop unit
Fig.3.5 (100) SRVO--230 SVAL1 Chain 1 (+24V) abnormal
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(101) SRVO--240 Chain1 (FENCE) abnormal
with SRVO--230 SVAL1 Chain 1 (+24V) abnormal
and SRVO--004 Fence open
SRVO--241 Chain2 (FENCE) abnormal
with SRVO--231 SVAL1 Chain 2 (0V) abnormal
and SRVO--004 Fence open
(Action 1)
Check the +24V connection of safety fence (EAS1 -EAS11), or the 0V connection of safety fence (EAS2
-- EAS21)
(Action 2)
Replace the panel board.
(Action 3)
Replace the E--stop unit.
(Action 4)
Replace the servo amplifier.
(Action 5)
Replace the mode switch.
Servo amplifier
Teach pendant
Panel board
Mode switch
Operator panel
E--stop unit
Fig.3.5 (101) SRVO--240 Chain1 (FENCE) abnormal
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(102) SRVO--242 Chain1 (EXEMG) abnormal
with SRVO--230 SVAL1 Chain 1 (+24V) abnormal
and SRVO--007 External emergency stops
SRVO--243 Chain2 (EXEMG) abnormal
with SRVO--231 SVAL1 Chain 2 (0V) abnormal
and SRVO--007 External emergency stops
(Action 1)
Check the +24V connection of external emergency
stop (EES1 -- EES11), or the 0V connection of
external emergency stop (EES2 -- EES21).
(Action 2)
Replace the panel board.
(Action 3)
Replace the E--stop unit.
(Action 4)
Replace the servo amplifier.
Servo amplifier
Teach pendant
Panel board
Mode switch
Operator panel
E--stop unit
Fig.3.5 (102) SRVO--242 Chain1 (EXEMG) abnormal
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(103) SRVO--230 SVAL1 Chain 1 (+24V) abnormal
with SRVO--232 SVAL1 NTED input
SRVO--231 SVAL1 Chain 2 (0V) abnormal
with SRVO--232 SVAL1 NTED input
(Action 1)
Check the +24V connection of NTED input (NTED1
-- NTED11), or the 0V connection of NTED input
(NTED2 -- NTED21).
(Action 2)
Replace the panel board.
(Action 3)
Replace the E--stop unit.
(Action 4)
Replace the servo amplifier.
(Action 5)
Replace the mode switch.
Servo amplifier
Teach pendant
Panel board
Mode switch
Operator panel
E--stop unit
Fig.3.5 (103) SRVO--230 SVAL1 Chain 1 (+24V) abnormal
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(104) SRVO--230 SVAL1 Chain 1 (+24V) abnormal
with SRVO--233 SVAL1 TP disabled in T1, T2/Door open
SRVO--231 SVAL1 Chain 2 (0V) abnormal
with SRVO--233 SVAL1 TP disabled in T1, T2/Door open
(Action 1)
Check the teach pendant connection cable and replace
it if necessary.
(Action 2)
Replace the panel board.
(Action 3)
Replace the teach pendant.
(Action 4)
Replace the E--stop unit.
(Action 5)
Replace the servo amplifier.
(Action 6)
Replace the mode switch.
Servo amplifier
Teach pendant
Panel board
Mode switch
Operator panel
E--stop unit
Fig.3.5 (104) SRVO--230 SVAL1 Chain 1 (+24V) abnormal
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[Special reset operation]
CAUTION
Do not issue this operation before resolving the cause of the
alarm.
1.
2.
3.
4.
5.
6.
7.
8.
Press E--stop button for correct emergency stop condition.
Press “MENU” on the teach pendant.
Press “0” on the teach pendant, [0 ---- NEXT ----].
Press “6” on the teach pendant, [6 SYSTEM].
Press F1, [TYPE].
Select Config.
Search item 28.
Press F4, [TRUE].
The display of “28 Reset CHAIN FAILURE detection : ”
changes “TRUE” from “FALSE”.
And few seconds later the display changes “FALSE” from
“TRUE” again.
9. The RESET operation is allowed.
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(105) SRVO--232 SVAL1 NTED input
(Explanation) Non teacher enabling device is released.
(Action 1)
Check the connection of non teacher enabling device.
(Action 2)
Replace the panel board.
(Action 3)
Replace the mode switch.
Servo amplifier
Panel board
Mode switch
Operator panel
E--stop unit
Fig.3.5 (105) SRVO--232 SVAL1 NTED input
102
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(106) SRVO--233 SVAL1 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)
Close the controller door, if open.
(Action 2)
Check the door switch, and replace it if necessary.
(Action 3)
Replace the panel board.
(Action 4)
Replace the teach pendant.
(Action 5)
Replace the mode switch.
Servo amplifier
Teach pendant
Panel board
Mode switch
Operator panel
E--stop unit
Fig.3.5 (106) SRVO--233 SVAL1 TP disabled in T1, T2/Door open
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(107) SRVO--235 Short term Chain abnormal
(Explanation) Short term single chain failure condition is detected.
¯ Short term single chain failure is ;
If any cause of stop is issued for a short time,
detecting circuit for single chain failure detects as
single chain failure depending on hardware
specification.
In this case, cause of stop is not detected by
software, so this alarm is distinguished from
“SRVO--230” and “SRVO--231”.
¯ Cause of this alarm is ;
-- Half release of deadman switch
-- Half operation of emergency stop of operator
panel and emergency stop of teach pendant
Short term single chain failures occured on
emergency stop of operator panel, emergency stop of
teach pendant and deadman switch are recoverable
issuing correct stop operation.
(Action 1)
To reset detecting circuit for single chain failure,
re--operate emergency stop of operator panel or
emergency stop of teach pendant or deadman switch
according previous operation.
If this alarm is reset, the message of “SRVO--236
Chain failure is repaired” is displayed.
CAUTION
This alarm is an un--clear single chain failure condition.
The software waits for a correct operation response to reset
the single chain failure condition.
If another cause is issued, then the software detects the real
single chain failure and displays “Chain 1 (+24V) abnormal”
or “Chain 2 (0V) abnormal”.
NOTE
1 This alarm may occur when an operator panel emergency
stop, teach pendant emergency stop or when the deadman
switch is released.
The above are operated by the operator.
This alarm is provided for un--clear and fast--repeated
operation by the operator.
2 If correct action is issued after this alarm, the messege of
“SRVO--236 Chain failure is repaired” is displayed.
(108) SRVO--236 SVAL1 Chain failure is repaired
(Explanation) A chain failure was repaired. For details, see the
explanation of SRVO--230 and SRVO--231.
(109) SRVO--237 SVAL1 Not reset chain failure
(Explanation) A chain failure could not be repaired. See the
explanation of SRVO--230 and SRVO--231.
(Action 1)
Check the alarm history and see the explanation of the
displayed alarm.
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(110) SRVO--240 SVAL1 Chain 1 (FENCE) abnormal
(111) SRVO--241 SVAL1 Chain 2 (FENCE) abnormal
(Explanation) Although the circuit connected between EAS11 and
EAS1 or between EAS21 and EAS2 on the TBOP4
terminal block on the panel board was disconnected,
the emergency stop line was not disconnected. The
emergency stop circuit is faulty.
(Action 1)
Check the +24 V connection (between EAS11 and
EAS1) and 0 V connection (between EAS21 and
EAS2) for the fence.
(Action 2)
Replace the panel board.
(Action 3)
Replace the E--STOP unit.
(Action 4)
Replace the servo amplifier.
NOTE
Eliminate the cause of the abnormal chain, then execute
“special reset operation” to release the alarm.
Servo amplifier
Panel board
E--stop unit
Fig.3.5 (111) SRVO--241 SVAL1 Chain 2 (FENCE) abnormal
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(112) SRVO--242 SVAL1 Chain 1 (EXEMG) abnormal
SRVO--243 SVAL1 Chain 2 (EXEMG) abnormal
(Explanation) Although the external emergency stop circuit was
disconnected, the emergency stop line was not
disconnected. The emergency stop circuit is faulty.
(Action 1)
Check the +24 V connection (between EES11 and
EES1) and 0 V connection (between EES21 and
EES2) for the external emergency stop circuit.
(Action 2)
Replace the panel board.
(Action 3)
Replace the E--STOP unit.
(Action 4)
Replace the servo amplifier.
NOTE
Eliminate the cause of the abnormal chain, then execute
“special reset operation” to release the alarm.
Servo amplifier
Panel board
E--stop unit
Fig.3.5 (112) SRVO--242 SVAL1 Chain 1 (EXEMG) abnormal
SRVO--243 SVAL1 Chain 2 (EXEMG) abnormal
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(113) SRVO--260 SVAL1 Chain 1 (NTED) abnormal
SRVO--261 SVAL1 Chain 2 (NTED) abnormal
(Explanation) Although the non--teacher--enabling device
disconnected the NTED circuit in the T1/T2 mode,
the emergency stop line was not disconnected. The
emergency stop circuit is faulty.
(Action 1)
Check the +24 V connection (between NTED11 and
NTED1) and 0 V connection (between NTED21 and
NTED2) for the NTED circuit.
(Action 2)
Replace the panel board.
(Action 3)
Replace the E--STOP unit.
(Action 4)
Replace the servo amplifier.
Servo amplifier
Panel board
E--stop unit
Fig.3.5 (113) SRVO--260 SVAL1 Chain 1 (NTED) abnormal
SRVO--261 SVAL1 Chain 2 (NTED) abnormal
(114) SRVO--262 SVAL1 Chain 1 (SVDCT) abnormal
SRVO--263 SVAL1 Chain 2 (SVDCT) abnormal
(Explanation) Although the SVDCT circuit was disconnected, the
emergency stop line was not disconnected. The
emergency stop circuit is faulty.
(Action 1)
Check the +24 V connection (between SD41 and
SD1) and 0 V connection (between SD51 and SD5)
for the SVDCT circuit.
(Action 2)
Replace the panel board.
(Action 3)
Replace the E--STOP unit.
(Action 4)
Replace the servo amplifier.
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Servo amplifier
Panel board
E--stop unit
Fig.3.5 (114) SRVO--262 SVAL1 Chain 1 (SVDCT) abnormal
SRVO--263 SVAL1 Chain 2 (SVDCT) abnormal
(115) SRVO--264 SVAL1 “E.STOP circuit abnormal 1”
(Explanation) An error occurred in the emergency stop circuit.
(Action 1)
Check whether the CRM67 and CRM72 connectors
on the E--STOP unit are connected securely.
(Action 2)
Check whether the circuits connected to CRM67 and
CRM72 in the emergency stop circuit are normal.
(Action 3)
Replace the E--STOP unit.
(Action 4)
Replace the servo amplifier.
Servo amplifier
E--stop unit
Fig.3.5 (115) SRVO--264 SVAL1 “E.STOP circuit abnormal 1”
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(116) SRVO--265 SVAL1 E.STOP circuit abnormal 2
(Explanation) When the servo entered the activated state, MON3
was in the on state. The MON3 state is abnormal.
(Action 1)
Replace the E--STOP unit.
(Action 2)
Replace the servo amplifier.
(Action 3)
Replace the panel board.
Servo amplifier
Panel board
E--stop unit
Fig.3.5 (116) SRVO--265 SVAL1 E.STOP circuit abnormal 2
(117) SRVO--280 SVAL1 SVOFF input
(Explanation) On the terminal block TBOP4 of the panel board, no
connection is made between 9 (EGS1) and 10
(EGS11) or between 11 (EGS2) and 12 (EGS21). If
a switch is connected between 9 (EGS1) and 10
(EGS11) or between 11 (EGS2) and 12 (EGS21), the
switch is pressed.
(Action 1)
If a switch is connected, releases the switch.
If the SYST--067 (Panel HSSB disconnect) alarm is
also generated, or if the LED (green) on the panel
board is turned off, communication between the main
board (JRS11) and the panel board (JRS11) is
abnormal. The connectors of the cable between the
main board and the panel board may be loose. Or, the
cable, panel board, or main board may be faulty.
(Note)
(Action 2)
Check the switch and cable connected to 9 (EGS1)
and 10 (EGS11) or 11 (EGS2) and 12 (EGS21).
(Action 3)
When this signal is not used, make a connection
between 9 (EGS1) and 10 (EGS11) or between 11
(EGS2) and 12 (EGS21).
(Action 4)
If SRVO--004 (Fence open), SRVO--007 (External
emergency stops), SRVO--213 (Fuse blown (Panel
PCB)), and SRVO--280 (SVOFF input) occur
simultaneously, it is likely that FUSE1 on the panel
board has blown. Check the fuse. If it has blown,
remove the cause, then replace the fuse. (Refer to
Section 3.6 in Part II, “Maintenance,” of
“Maintenance Manual.”)
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(Action 5)
(Action 6)
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Replace the panel board.
Before performing “Action 6,” make a backup copy
of all programs and settings in the control unit.
Replace the main board.
NOTE
SVOFF input (GENERAL STOP) is a safety stop input.
When this input is opened, the robot decelerates in a
controlled manner and then stops. The magnetic contactor
opens after the robot stops.
WARNING
Do NOT short--circuit, or disable, this signal in a system in
which the Servo off emergency stop signal input is in use,
as it is very dangerous. If it is necessary to run the robot by
short--circuiting the signal even temporarily, an additional
safety provision must be provided.
NOTE
If the LED is turned off, the SRVO--001 (Operator panel
E--stop), SRVO--004 (Fence open), SRVO--007 (External
emergency stops), or SRVO--280 (SVOFF input), alarm is
also generated. Check the alarm history display on the teach
pendant.
NOTE
If the LED is turned off, the following alarms are also
generated.
SRVO--001 Operator panel E--stop.
SRVO--004 Fence open.
SRVO--007 External emergency stop.
SRVO--199 Control stop.
SRVO--204 External (SVEMG abnormal) E--stop.
SRVO--213 Fuse blown (Panel PCB).
SRVO--277 Panel E--stop (SVEMG abnormal).
SRVO--280 SVOFF input
Check the alarm history display on the teach pendant.
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Short connection
9 (EGS1) and 10 (EGS11)
LED (Green)
3. TROUBLESHOOTING
Short connection
11 (EGS2) and 12 (EGS21)
Connector (JRS11)
Panel board
Fig.3.5 (117) (a) SRVO--280 SVAL1 SVON input
Connector (JRS11)
Main board
Fig.3.5 (117) (b) SRVO--280 SVAL1 SVON input
(118) SRVO--266 SVAL1 FENCE1 status abnormal
SRVO--267 SVAL1 FENCE2 status abnormal
(Explanation) The fence circuit is abnormal.
(Action 1)
Check the +24 V connection (between EAS11 and
EAS1) and 0 V connection (between EAS21 and
EAS2) for the fence.
(Action 2)
Check the fence switch.
(Action 3)
Replace the panel board.
NOTE
Eliminate the cause of the abnormal chain, then execute
“special reset operation” to release the alarm.
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(119) SRVO--268 SVAL1 SVOFF1 status abnormal
SRVO--269 SVAL1 SVOFF2 status abnormal
(Explanation) The SVOFF circuit is abnormal.
(Action 1)
Check the +24 V connection (between EGS11 and
EGS1) and 0 V connection (between EGS21 and
EGS2) for the SVOFF circuit.
(Action 2)
Check the SVOFF switch.
(Action 3)
Replace the panel board.
NOTE
Eliminate the cause of the abnormal chain, then execute
“special reset operation” to release the alarm.
(120) SRVO--270 SVAL1 EXEMG1 status abnormal
SRVO--271 SVAL1 EXEMG2 status abnormal
(Explanation) The EXEMG circuit is abnormal.
(Action 1)
Check the +24 V connection (between ESPB11 and
ESPB1) and 0 V connection (between ESPB21 and
ESPB2) for the EXEMG circuit.
(Action 2)
Check the EXEMG switch.
(Action 3)
Replace the panel board.
NOTE
Eliminate the cause of the abnormal chain, then execute
“special reset operation” to release the alarm.
(121) SRVO--272 SVAL1 SVDISC1 status abnormal
SRVO--273 SVAL1 SVDISC2 status abnormal
(Explanation) The SVDISC circuit is abnormal.
(Action 1)
Check the +24 V connection (between SD41 and
SD4) and 0 V connection (between SD51 and SD5)
for the SVDISC circuit.
(Action 2)
Check the SVDISC switch.
(Action 3)
Replace the panel board.
NOTE
Eliminate the cause of the abnormal chain, then execute
“special reset operation” to release the alarm.
(122) SRVO--274 SVAL1 NTED1 status abnormal
SRVO--275 SVAL1 NTED2 status abnormal
(Explanation) The NTED circuit is abnormal.
(Action 1)
Check the +24 V connection (between NTED11 and
NTED1) and 0 V connection (between NTED21 and
NTED2) for the NTED circuit.
(Action 2)
Check the NTED switch.
(Action 3)
Replace the panel board.
NOTE
Eliminate the cause of the abnormal chain, then execute
“special reset operation” to release the alarm.
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(123) SRVO--281 SVAL1 SVOFF input (SVEMG abnormal)
(Explanation) When the SVOFF signal was input, an SVEMG error
was detected. The emergency stop circuit is faulty.
(Action 1)
Replace the panel board.
(Action 2)
Replace the servo amplifier.
(Action 3)
Replace the E--STOP unit.
Servo amplifier
Panel board
E--stop unit
Fig.3.5 (123) SRVO--281 SVAL1 SVOFF input (SVEMG abnormal)
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(124) SRVO--282 SVAL1 Chain1 (SVOFF) abnormal
SRVO--283 SVAL1 Chain2 (SVOFF) abnormal
(Explanation) Although the switch connected between EGS11 and
EGS1 or between EGS21 and EGS2 on the TBOP4
terminal block on the panel board was pressed, the
emergency stop line was not disconnected. The
emergency stop circuit is faulty.
(Action 1)
Replace the panel board.
(Action 2)
Replace the servo amplifier.
(Action 3)
Replace the E--STOP unit.
Servo amplifier
Panel board
E--stop unit
Fig.3.5 (124) SRVO--282 SVAL1 Chain1 (SVOFF) abnormal
SRVO--283 SVAL1 Chain2 (SVOFF) abnormal
(125) SRVO--282 Chain1 (SVOFF) abnormal
with SRVO--230 SVAL1 Chain 1 (+24V) abnormal
and SRVO--280 SVOFF input
SRVO--283 Chain2 (SVOFF) abnormal
with SRVO--231 SVAL1 Chain 2 (0V) abnormal
and SRVO--280 SVOFF input
(Action 1)
Check the +24V connection of servo ON/OFF switch
(EGS1 -- EGS11), or the 0V connection of servo
ON/OFF switch (EGS2 -- EGS21).
(Action 2)
Replace the panel board.
(Action 3)
Replace the E--stop unit.
(Action 4)
Replace the servo amplifier.
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Servo amplifier
Teach pendant
Panel board
Mode switch
Operator panel
E--stop unit
Fig.3.5 (125) SRVO--282 Chain1 (SVOFF) abnormal
(126) SRVO--291 SVAL1 “IPM over heat (Group : i Axis : j)”
(Explanation) The IPM in the servo amplifier overheats.
(Action 1)
Check whether the amplifier fan stops.
(Action 2)
Reduce the override because the use condition is too
hard.
(Action 3)
If this alarm is frequently issued, replace the
amplifier.
(127) SRVO--292 SVAL1 EXT FAN alarm (Group : i A : j)
(Explanation) The external fan for the αSVMi is faulty.
(Action 1)
Replace the external fan for the SVM.
(128) SRVO--293 SVAL1 DClink (PSM) HCAL (Group : i Axis : j)
(Explanation) The three--phase input power supply is abnormal or
the PSM is faulty.
(Action 1)
Check the three--phase input power supply.
(Action 2)
Replace the PSM.
(129) SRVO--294 SVAL1 EXT FAN (PSM) alarm (Group : i Axis : j)
(Explanation) The external fan for the αPSM and αPSMR is faulty.
(Action 1)
Replace the external fan.
(130) SRVO--295 SVAL1 PSM COM alarm (Group : i Axis : j)
(Explanation) The cable between the PSM and SVM may be faulty
or the PSM or SVM may be faulty.
(Action 1)
Replace the cable between the PSM and SVM.
(Action 2)
Replace the PSM.
(Action 3)
Replace the SVM.
(131) SRVO--296 SVAL1 PSM DISCHG alarm (Group : i Axis : j)
(Explanation) The use condition is too hard or the fan for cooling the
regenerative resistance for the PSMR stops.
(Action 1)
Reduce the taught feedrate because the use condition
is too hard.
(Action 2)
Check whether the fan for cooling the regenerative
resistance for the PSMR stops.
115
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
(132) SRVO--297 SVAL1 PSM Low Volt alarm (Group : i Axis : j)
(Explanation) The three--phase input voltage may drop or the PSM
or SVM may be faulty.
(Action 1)
Check the three--phase input power supply.
(Action 2)
Replace the PSM.
(Action 3)
Replace the SVM.
(133) SRVO--300 SVAL1 Hand broken/HBK disabled
SRVO--302 SVAL1 Set Hand broken to ENABLE
(Explanation) Although HBK was disabled, the HBK signal was
input.
(Action 1)
Press RESET on the teach pendant to release the
alarm.
(Action 2)
Check whether the hand broken signal is connected to
the robot. When the hand broken signal circuit is
connected, enable hand broken.
(See III
CONNECTION, Subsection 5.5.3 in this manual.)
116
MAINTENANCE
B--81465EN--1/02
3.6
FUSED--BASED
TROUBLESHOOTING
Name
3. TROUBLESHOOTING
(1) When the fuses of the power supply unit have blown
F1: Fuse for AC input
F3: Fuse for +24 E
F4: Fuse for +24 V
Symptom observed when fuse has blown
Action
F1
The LED (PIL: Green) of the power supply unit does not light, and 1 Check the units (fans) and cables connected to the CP2 and
the power cannot be turned on.
CP3 connectors of the power supply unit to see if there is any
short circuit.
2 Replace the power supply unit.
F3
If the fuse blows when the power supply is turned on, an alarm 1 Check the printed circuit boards, units, and cables using +24
such as for overtravel, hand broken, FSSB disconnect, LVAL is
E according to the power supply system diagram. Replace a
output on the teach pendant.
faulty printed circuit board, unit, servo amplifier or cable if any.
If the fuse turns out to have already blown when the power supply 2 Replace the power supply unit.
is turned on, the FSSB initialization alarm is displayed on the
teach pendant.
F4
The power, when turned on, is immediately turned off. At this 1 Check the printed circuit boards, units, and cables using +24
time, the LED (ALM: Red) lights.
V according to the power supply system diagram. Replace a
faulty printed circuit board, unit, or cable if any. The LED of
ALM is turned off by pressing the OFF button once.
2 Replace the power supply unit.
Power supply unit
F1 8.0A
Fuse for AC input
F3 7.5A
Fuse for +24E
F4 7.5A
Fuse for +24V
PIL
LED (green) for AC power
supply display
ALM
LED (red) for alarm display
117
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
(2) Servo amplifier fuse
FS1 : For generation of the power to the amplifier control circuit
FS2 : For protection of the 24V output to the end effector, ROT,
and HBK
FS3 : For protection of the 24V output to the regenerative
resistance and the additional axis amplifier
F1, F2 : For protection of the circuit failure in the servo amplifier.
Name
Symptom observed when fuse has blown
FS1
All LEDs on the servo amplifier go out.
The FSSB disconnection or initialization alarm is displayed on the teach pendant.
Replace the servo amplifier.
FS2
The fuse blown (Amp) alarm (SRVO--214), hand broken (SRVO--006), and ROBOT OVER TRAVEL
(SRVO--005) are displayed on the teach pendant.
1 Check +24E used by the end effector for a ground fault.
2 Check the robot connection cable and the robot’s internal cable.
3 Replace the servo amplifier.
FS3
The blown fuse (Amp) alarm (SRVO--214) and DCAL
(SRVO--043) are displayed on the teach pendant.
1 Check the regenerative resistance, and replace it if required.
2 Check the additional axis amplifier and its wiring, and replace them if required.
3 Replace the servo amplifier.
The OHAL1 alarm is output on the teach pendant.
1 Check if the cables connected to three phase input of servo amplifier is
defective.
2 Replace the servo amplifier.
F1
F2
Servo amplifier
Action
Fuse F1
Fuse F2
Fuse FS1
Fuse FS3
Fuse FS2
118
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
(3) Panel board fuses
FUSE1: For protection of the +24EXT line (emergency stop line)
FUSE2: For protection of the teach pendant emergency stop line
Name
Symptom observed when fuse has blown
Action
FUSE1
The external emergency stop, open fence, SVOFF input, and blown fuse (panel PCB) alarm are displayed
on the teach pendant.
1 Check the +24EXT line (emergency stop line) for a short--circuit and
ground fault.
2 Replace the panel board.
FUSE2
The display on the teach pendant disappears.
1 Check the teach pendant cable for a fault, and replace it if required.
2 Check the teach pendant for a fault, and replace it if required.
3 Replace the panel board.
Panel board
FUSE2
FUSE1
119
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
(4) Fuse on the process I/O board
FUSE1: Fuse for +24 E
Name
FUSE1
Symptom observed when fuse has blown
Action
The LED (ALM--2 or FALM) on the process I/O board lights, and 1 Check if the cables and peripheral equipment connected to
an alarm such as IMSTP input is output on the teach pendant.
the process I/O printed circuit board are normal.
(The display data depends on state of peripheral equipment con- 2 Replace the process I/O printed circuit board.
nection.)
Process I/O board CA,CB
FUSE1
Process I/O board DA
FUSE1
120
MAINTENANCE
B--81465EN--1/02
3. TROUBLESHOOTING
Process I/O board HA
FUSE1
Total version
121
3. TROUBLESHOOTING
3.7
TROUBLESHOOTING
BASED ON LED
INDICATIONS
MAINTENANCE
B--81465EN--1/02
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.
Servo amplifier
Main board
Power supply unit
122
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
(1) TROUBLESHOOTING USING THE LEDS ON THE MAIN
BOARD
To troubleshoot an alarm that arises before the teach pendant is ready
to display, check the status LEDs (green) on the main board at
power--on.
After power--on, the LEDs light as described in steps 1 to 17, in the
order described. If an alarm is detected, the step in which the alarm
occurred can be determined from which LEDs are lit.
Step
LED
Action to be taken
1: After power--on, all LEDs are
lit.
[Action1] Replace the CPU card
* [Action2] Replace the main board.
2: Software operation start--up.
[Action1] Replace the CPU card
* [Action2] Replace the main board.
3: The initialization of dram on
the CPU card is completed.
[Action1] Replace the CPU card
* [Action2] Replace the main board.
4: The initialization of SRAM
and DPRAM is completed.
[Action1] Replace the CPU card
* [Action2] Replace the main board.
* [Action3] Replace the FROM/SRAM module.
5: The initialization of the communication IC is completed.
* [Action1] Replace the main board.
* [Action2] Replace the FROM/SRAM module.
6: The loading of the basic software is completed.
* [Action1] Replace the main board.
* [Action2] Replace the FROM/SRAM module.
7: Basic software start--up.
* [Action1] Replace the main board.
* [Action2] Replace the FROM/SRAM module.
8: Start--up of communication
with the teach pendant.
* [Action1] Replace the main board.
* [Action2] Replace the FROM/SRAM module.
9: The loading of optional software is completed.
* [Action1] Replace the main board.
[Action2] Replace the process I/O board.
10:DI/DO initialization
* [Action1] Replace the FROM/SRAM module.
* [Action2] Replace the main board.
11: The preparation of the SRAM
module is completed.
[Action1] Replace the axis control card.
* [Action2] Replace the main board.
[Action3] Replace the servo amplifier.
* 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.
123
3. TROUBLESHOOTING
Step
MAINTENANCE
LED
B--81465EN--1/02
Action to be taken
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 servo system
* [Action1] Replace the main board.
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.
17: Initialization is terminated.
Initialization has ended normally.
18:Normal status
Status LEDs 1 and 2 blink when the system is operating normally.
* 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.
Main board
FROM/SRAM module
Axis control card
124
CPU card
B--81465EN--1/02
MAINTENANCE
3. TROUBLESHOOTING
(2) TROUBLESHOOTING BY 7--SEGMENT LED INDICATOR
7--segment LED
indicator
Description
[Description] A parity alarm condition has occurred in RAM on the CPU card installed on the main
board.
[Action1]
Replace the CPU card.
[Action2]
Replace the main board.
[Description] A parity alarm condition has occurred in RAM on the FROM/SRAM module installed
on the main board.
[Action1]
Replace the FROM/SRAM module.
[Action2]
Replace the main board.
[Description] A bus error has occurred in the communication controller.
[Action]
Replace the main board.
[Description] A parity alarm condition has occurred in DRAM controlled by the communication controller.
[Action]
Replace the main board.
[Description] A communication error has occurred during communication with the panel board.
[Action1]
Check the communication cable (optical cable) between the main and panel boards,
and replace it if necessary.
[Action2]
Replace the main board.
[Action3]
Replace the panel board.
[Description] A servo alarm condition has occurred on the main board.
[Action1]
Replace the axis control card.
[Action2]
Replace the main board.
[Description] The SYSEMG alarm has occurred.
[Action1]
Replace the axis control card.
[Action2]
Replace the CPU card.
[Action3]
Replace the main board.
[Description] The SYSFAIL alarm has occurred.
[Action1]
Replace the axis control card.
[Action2]
Replace the CPU card.
[Action3]
Replace the main board.
* 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.
125
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
Troubleshooting by LEDs on power supply unit
LED indication
Failure description and required measure
[Description] When ALM LED (red) turned on, power supply alarm has occurred.
[Action1]
Check fuse F4 (+24V) on the power supply unit, and replace it if it has blown.
[Action2]
Check the printed--circuit boards powered by the DC power supplies (+5V, 15V,
and +24V), the relevant units, and cables, and replace them if defective.
[Action3]
Replace the power supply unit.
[Description] If the PIL LED (Green) does not light, the power supply unit has not been supplied with 200 VAC.
[Action1]
Check fuse F1 on the power supply unit, and replace it if it has blown.
For detailed causes of fuse blown out, please refer to section 3.1.
[Action2]
Replace the power supply unit.
Power supply unit
F3 7.5A
Fuse for +24E
F1 8.0A
Fuse for AC input
F4 7.5A
Fuse for +24V
PIL
LED (green) for AC power
supply display
ALM
LED (red) for alarm display
126
B--81465EN--1/02
MAINTENANCE
3. TROUBLESHOOTING
Troubleshooting by LED on the panel board
LED indication
Failure description and required measure
RDY
[Description] When the LED (green) does not light. 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.
[Action3]
Replace the panel board.
PON
[Description] When the LED does not light. The power supply inside the panel board does
not generate +5 V normally.
[Action1]
Check the CRM63 connector and check that 24 V is supplied.
[Action2]
Replace the panel board.
Panel board
PON LED (Green)
RDY LED (Green)
127
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
Troubleshooting by alarm LEDs on the process I/O printed circuit board
LED
Description and action to be taken
Process I/O CA/CB/DA/HA
[[Description]
p
] A communication alarm occurred between the main CPU PC board and process
p
I/O board.
[Action1]
Replace the process I/O board.
* [Action2]
Replace the main CPU board.
[Action3]
Replace the I/O link connection cable.
Process I/O CA/CB/DA/HA
[
[Description]
p
] A fuse on the process
p
I/O
/ board is blown.
[Action1]
Replace the blown fuse on the process I/O board.
[Action2]
Examine the cables and peripheral devices connected to the process I/O board.
Replace any failed components.
[Action3]
Replace the process I/O board.
Fuse
For process I/O board CA/CB/DA/HA
Specificalion : A60L--0001--0046#2.0
128
B--81465EN--1/02
Troubleshooting by
LEDs on servo amplifier
MAINTENANCE
3. TROUBLESHOOTING
The servo amplifier has alarm LEDs. Troubleshoot the alarm indicated
by the LEDs, referring also to the alarm indication on the teach pendant.
129
3. TROUBLESHOOTING
LED
MAINTENANCE
B--81465EN--1/02
Color
Description
P5V
Green
Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally.
If the LED does not light:
[Measure 1] Check the robot connection cable (RP1) to see if there is a ground fault in the +5 v wire.
[Measure 2] Replace the servo amplifier.
P3.3V
Green
Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V normally.
If the LED does not light:
[Measure] Replace the servo amplifier.
Red
Lights when an emergency stop signal is input to the servo amplifier.
If the LED lights when the machine is not at an emergency stop:
[Measure] Replace the servo amplifier.
If the LED does light when the machine is at an emergency stop:
[Measure] Replace the servo amplifier.
ALM
Red
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.
RDY
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.
Green
Lights when the communication between the servo amplifier and the main board is normal.
If the LED does not light:
[Measure 1] Check for the connection of the FSSB optical cable.
[Measure 2] Replace the servo card.
[Measure 3] Replace the servo amplifier.
SVEMG
OPEN
WD
D7
Red
Lights when a watch dog alarm is detected in the servo amplifier.
[Measure 1] Replace the servo amplifier.
[Measure 2] Replace the servo card.
[Measure 3] Replace the CPU card.
[Measure 4] Replace the main board.
Red
Lights when the DCLINK circuit inside the servo amplifier is charged to reach the specified voltage.
If the LED does not light after pre--charge is finished:
[Measure 1] It is likely that the DC Link may be short--circuited. Check for connection.
[Measure 2] It is likely that the charge current control resistor may be defective. Replace the emergency stop unit.
[Measure 3] Replace the servo amplifier.
130
B--81465EN--1/02
3.8
POSITION DEVIATION
FOUND IN RETURN
TO THE REFERENCE
POSITION
(POSITIONING)
MAINTENANCE
3. TROUBLESHOOTING
(Check 1) On the status screen, check the position deviation in the
stopped state. To display the position deviation, press the
screen selection key, and select STATUS from the menu.
Press F1, [TYPE], select AXIS from the menu, then press
the F4, PULSE.
(Corrective action)
Correct the parameters related to return to the reference
position (positioning).
(Check 2) Check whether the motor axis can be positioned normally.
(Corrective action)
If the motor axis can be positioned normally, check the
mechanical unit.
(Check 3) Check the mechanical unit for backlash.
(Corrective action)
Replace a faulty key of motor shaft or other faulty parts.
(Check 4) If checks 1 to 3 show normal results
(Corrective action)
Replace the pulse coder and main board.
131
3. TROUBLESHOOTING
3.9
VIBRATION
OBSERVED DURING
MOVEMENT
MAINTENANCE
B--81465EN--1/02
(Check 1) Check the settings of parameters such as the position loop
gain parameter.
(Corrective action)
Correct parameters.
(Check 2) Check the mechanical unit for backlash.
(Corrective action)
Replace a faulty key of motor shaft or other faulty parts.
132
B--81465EN--1/02
3.10
MANUAL
OPERATION
IMPOSSIBLE
MAINTENANCE
3. TROUBLESHOOTING
The following explains checking and corrective action required if the
robot cannot be operated manually after the controller is turned on:
(1) Check and corrective action to be made if manual operation is
impossible
(Check 1) Check whether the teach pendant is enabled.
(Corrective action)
Turn on the teach pendant “enable”.
(Check 2) Check whether the teach pendant is handled correctly.
(Corrective action)
To move an axis by manual operation, press the axis
selection key and case shift key at the same time.
Set the override for manual feed to a position other than the
FINE and VFINE positions.
(Check 3) Check whether the ENBL signal of the peripheral device
control interface is set to 1.
(Corrective action)
Place the peripheral device control interface in the ENBL
status.
(Check 4) Check whether the HOLD signal of the peripheral device
control interface or the HOLD switch on the operator’s panel
is on (hold status). (Check whether the hold lamp on the
teach pendant is on.)
(Corrective action)
Turn off the HOLD signal of the peripheral device control
interface or the HOLD switch on the operator’s panel.
(Check 5) Check whether the previous manual operation has been
completed.
(Corrective action)
If the robot cannot be placed in the effective area because of
the offset of the speed command voltage preventing the
previous operation from being completed, check the position
deviation on the status screen, and change the setting.
(Check 6) Check whether the controller is in the alarm status.
(Corrective action)
Release the alarm.
(2) Check and corrective action to be taken if the program cannot be
executed
(Check 1) Check whether the ENBL signal for the peripheral-device
control interface is on.
(Corrective action)
Put the peripheral-device control interface in the ENBL state.
(Check 2) Check whether the HOLD signal for the peripheral-device
control interface is on. Also check whether the HOLD
switch on the operator’s panel is on. (Check whether the
HOLD lamp on the teach pendant is on.)
(Corrective action)
If the HOLD signal is on, turn it off. If the HOLD switch
is on, turn it off.
133
3. TROUBLESHOOTING
MAINTENANCE
B--81465EN--1/02
(Check 3) Check whether the previous manual operation has been
completed.
(Corrective action)
If the robot cannot be placed in the effective area because of
the offset of the speed command voltage, which prevents the
previous operation from being completed, check the position
deviation on the status screen, then change the setting.
(Check 4) Check whether the controller is in the alarm status.
(Corrective action)
Release the alarm.
134
B--81465EN--1/02
4
MAINTENANCE
4. PRINTED CIRCUIT BOARDS
PRINTED CIRCUIT BOARDS
The printed circuit boards are factory-set for operation. Usually, you do
not need to set or adjust them. This chapter describes the standard settings
and adjustment required if a defective printed circuit board is replaced.
It also describes the test pins and the LED indications.
The standard printed circuit board includes the main unit printed circuit
board and one or more cards or modules installed horizontally to the
main--unit printed--circuit board.
These PC boards have interface connectors, LED indicators, and a plastic
panel at the front. At the rear, there is a backplane connector.
135
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81465EN--1/02
4.1
MAIN BOARD
(A16B--3200--0412,
--0413)
CPU card
Total version
FROM/SRAM module
Axis control card
TBDL exists in case of --0413
Fig.4.1 Main board
Name
CPU card
Axis control card
FROM/SRAM module
Main board
Ordering Specification
Board Specification
A05B--2450--H010
A20B--3300--0104
SDRAM 8M (Standard)
A05B--2450--H011
A20B--3300--0105
SDRAM 16M
A05B--2450--H021
A20B--3300--0240
8--axis
A05B--2450--H020
A20B--3300--0241
6--axis (Standard)
TBD
A20B--3300--0242
4--axis
A05B--2450--H031
A20B--3900--0160
FROM 16M, SRAM 1M
A05B--2450--H032
A20B--3900--0161
FROM 16M, SRAM 2M
A05B--2450--H033
A20B--3900--0162
FROM 16M, SRAM 3M
A05B--2450--H035
A20B--3900--0163
FROM 32M, SRAM 1M
A05B--2450--H036
A20B--3900--0164
FROM 32M, SRAM 2M
A05B--2450--H037
A20B--3900--0165
FROM 32M, SRAM 3M
A05B--2450--H001
A16B--3200--0412
Standard
TBD
A16B--3200--0413
With distributed link (Option)
136
Note
B--81465EN--1/02
MAINTENANCE
4. PRINTED CIRCUIT BOARDS
(1) Test pins
Name
Use
GND1
GND2
GND3
CACHOFF
LOAD
MCBOOT
CORE
For testing the printed circuit board
(2) LEDs
Seven segment LED
Description
A parity alarm occurred in a RAM of the main CPU
card on the main board.
A parity alarm occurred in a RAM of the SRAM module on the main board.
Bus error occurred on the communication controller.
A parity alarm occurred in DRAM controlled by communication controller.
A communication error occurred between panel
boards and main board.
A servo alarm occurred on the main board.
SYSEMG occurred.
SYSFAIL occurred.
This number appears temporarily after the power is
switched on, but it is not abnormal.
137
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81465EN--1/02
Status LED
Description
Operating status of the system.
STATUS
LED
ETHERNET LED
Color
Description
TX
Green
Flashes during data transmission.
RX
Green
Flashes during data reception.
L
Yellow
Lights when a connection to a network is made.
FDX
Green
Lights during full duplex communication.
COL
Red
BT
Green
Lights during communication with 10BASE--T.
BTX
Green
Lights during communication with 100BASE--T.
Lights if a COLLISION occurs during half duplex
communication.
(3) Driver/receiver IC
If the teach pendant cannot display anything because of, for example,
a broken wire in the teach pendant connection cable, it is likely that
the communication driver or receiver may be defective.
Name
Drawing number
75172
A76L--0151--0098
75173
A76L--0151--0099
Please refer to Fig.4.1 Main board.
138
B--81465EN--1/02
MAINTENANCE
4. PRINTED CIRCUIT BOARDS
4.2
EMERGENCY STOP
CONTROL PC
BOARD
(A20B--1007--0800)
LED 3
LED 2
LED 1
Total version
Fig.4.2 Emergency stop control PC board
(1) LED
Name
Use
LED1
Status of Relay KA1--1
ON
Active
OFF
Inactive
LED2
Status of KA2--1
ON
Active
OFF
Inactive
LED3
Status of KA3--1
ON
Active
OFF
Inactive
139
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81465EN--1/02
4.3
BACKPLANE PC
BOARD
(A20B--2002--0771)
Total version
Fig.4.3 (a) Backplane PC Board
(1) Test pins
Name
Use
HI1
TEST1
LOW1
For testing the printed circuit board
140
B--81465EN--1/02
MAINTENANCE
4. PRINTED CIRCUIT BOARDS
(A20B--2002--0761)
Total
version
Test pins
Fig.4.3 (b) Backplane PC Board
(1) Test pins
Name
Use
HI1
TEST1
LOW1
For testing the printed circuit board
141
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81465EN--1/02
4.4
PANEL BOARD
(A20B--2100--0770)
PON LED
RDY LED
Total version
Fig.4.4 Panel Board
(1) LED
Name
Use
RDY
Communication status with main board
ON
Normal
OFF
Communication error
PON
Lights when the internal power supply of the panel board outputs +5V normally.
142
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81465EN--1/02
4.5
PROCESS I/O
BOARD CA
(A16B--2201--0470)
Total
version
Fig.4.8 Process I/O Board CA
(1) Test pins
Name
Use
P24V
P5V
P15VC
M15VC
GND1
GND2
+24V
+5V
+15V
--15V
GND
GND
For measuring the DC supply voltage
P10V
+10V
For measuring the reference voltage of the
digital/analog converter
P15VF
M15VF
GNDF
+15V
--15V
GND
Power for the digital/analog converter
AI1
AI2
AI3
AI4
AI5
AI6
Channel 1
Channel 2
Channel 3
Channel 4
Channel 5
Channel 6
For measuring the voltage of the analog input
signal (analog/digital)
AOUT1
AOUT2
Channel 1
Channel 2
For measuring the voltage of the analog output
signal (digital/analog)
143
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81465EN--1/02
(2) Settings
Standard
setting
Name
ICOM1
UDI1 to UDI20
(Connector CRM2A)
UDI21 to UDI40
ICOM2
(Connector CRM2B)
ICOM3
WDI01 to WDI08
(Connector CRW1)
SP1
Channel 1
SP2
Channel 2
Description
Side A
The common voltage is
adjusted to:
Side A : +24 V common
Side B : 0 V common
Open
The polarity of the output voltage
is switched to:
Strapped : Negative (--)
Open
: Positive (+)
(3) Adjustment
VR1: Adjusts the gain of channel 1.
Execute a robot program and set AOUT[1] to 4095 on the teach
pendant. Connect a digital voltmeter to test pin AOUT1 and
rotate VR1 until the meter reads 12.0 V.
Connect the negative (--) lead of the digital voltmeter to test pin
GNDF.
VR2: Adjusts the gain of channel 2.
Execute a robot program and set AOUT[2] to 4095 on the teach
pendant. Connect the digital voltmeter to test pin AOUT2 and
rotate VR2 until the meter reads 12.0 V.
Connect the negative (--) lead of the digital voltmeter to test pin
GNDF. (The 0VF test pin is different from the common 0V test
pin.)
VR3: Adjusts the reference supply voltage of the digital/analog
converter.
Connect the digital voltmeter to test pin P10V and rotate VR3
until the meter reads 10.0 0.1 V.
(4) LEDs
Color
144
Description
Red
A communication alarm occurred between
the main CPU and process input/output.
Red
A fuse (FUSE 1) in the process input/output
blew.
B--81465EN--1/02
MAINTENANCE
4. PRINTED CIRCUIT BOARDS
(5) Correspondence between driver chips and DO signals
Ordering code for the driver chips: A76L-0151-0062
Driver chip
DO signal
DV1
CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2
HELD, FALT, ATPERCH, TPENBL
DV3
BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4
ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5
ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6
SDO01, SDO02, SDO03, SDO04
DV7
SDO05, SDO06, SDO07, SDO08
DV8
SDO09, SDO10, SDO11, SDO12
DV9
SDO13, SDO14, SDO15, SDO16
DV10
SDO17, SDO18, SDO19, SDO20
DV11
WDO01, WDO02, WDO03, WDO04
DV12
WDO05, WDO06, WDO07, WDO08
RESERVED
For replacement
145
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81465EN--1/02
4.6
PROCESS I/O
BOARD CB
(A16B--2201--0472)
Test pins
Total
version
Fig.4.9 Process I/O Board CB
(1) Test pins
Name
Use
P24V
+24V
P5V
+5V
P15VC
+15V
M15VC
--15V
GND1
GND
GND2
GND
For measuring the DC supply voltage
(2) Settings
Name
ICOM1
UDI1 to UDI20
(Connector CRM2A)
ICOM2
UDI21 to UDI40
(Connector CRM2B)
146
Standard
setting
Side A
Description
The common voltage is
adjusted to:
Side A : +24 V common
Side B : 0 V common
B--81465EN--1/02
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
(3) LEDs
Color
Description
Red
A communication alarm occurred between
the main CPU and process input/output.
Red
A fuse (FUSE 1) in the process input/output
blew.
(4) Correspondence between driver chips and DO signals
Ordering code for the driver chips: A76L-0151-0062
Driver chip
DO signal
DV1
CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2
HELD, FALT, ATPERCH, TPENBL
DV3
BATALM, BUSY, ACK1/SNO1, ACK2/SNO
DV4
ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5
ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6
SDO01, SDO02, SDO03, SDO04
DV7
SDO05, SDO06, SDO07, SDO08
DV8
SDO09, SDO10, SDO11, SDO12
DV9
SDO13, SDO14, SDO15, SDO16
DV10
SDO17, SDO18, SDO19, SDO20
RESERVED
For replacement
147
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81465EN--1/02
4.7
PROCESS I/O
BOARD DA
(A16B--2201--0480)
Total version
Test pins
Fig.4.10 Process I/O Board DA
(1) Test pins
Name
Description
P24V
+24V
P5V
+5V
GND1
GND
GND2
GND
For measuring the DC supply voltage
(2) Settings
Name
ICOM1
UDI01 to 20
(Connector CRM2A)
ICOM2
UDI21 to 40
(Connector CRM2B)
ICOM3
UDI41 to 60
(Connector CRM2C)
ICOM4
UDI61 to 80
(Connector CRM2D)
ICOM5
UDI81 to 88
(Connector CRM4A)
ICOM6
UDI89 to 96
(Connector CRM4B)
148
Standard
setting
Side A
Description
The common voltage is
adjusted to:
Side A : +24 V common
Side B : 0 V common
B--81465EN--1/02
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
(3) LEDs
Color
Description
Red
A communication alarm occurred between
the main CPU and process input/output.
Red
A fuse (FUSE 1) in the process input/output
below.
(4) Correspondence between driver chips and DO signals
Ordering code for the driver chips: A76L-0151-0062
Driver chip
DO signal
DV1
CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2
HELD, FALT, ATPERCH, TPENBL
DV3
BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4
ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5
ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6
SDO01, SDO02, SDO03, SDO04
DV7
SDO05, SDO06, SDO07, SDO08
DV8
SDO09, SDO10, SDO11, SDO12
DV9
SDO13, SDO14, SDO15, SDO16
DV10
SDO17, SDO18, SDO19, SDO20
DV11
ADO21, SDO22, SDO23, SDO24
DV12
SDO25, SDO26, SDO27, SDO28
DV13
SDO29, SDO30, SDO31, SDO32
DV14
SDO33, SDO34, SDO35, SDO36
DV15
SDO37, SDO38, SDO39, SDO40
DV16
SDO41, SDO42, SDO43, SDO44
DV17
SDO45, SDO46, SDO47, SDO48
DV18
SDO49, SDO50, SDO51, SDO52
DV19
SDO53, SDO54, SDO55, SDO56
DV20
SDO57, SDO58, SDO59, SDO60
DV21
SDO61, SDO62, SDO63, SDO64
DV22
SDO65, SDO66, SDO67, SDO68
DV23
SDO69, SDO70, SDO71, SDO72
DV24
SDO73, SDO74, SDO75, SDO76
RESERVED
For replacement
149
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81465EN--1/02
4.8
PROCESS I/O
BOARD HA
(A16B--2203--0760)
Total version
Fig.4.11 Process I/O Board HA
(1) Test pins
Name
Use
P24V
P5V
GND1
GND2
GND3
+24V
+5V
GND
GND
GND
For measuring the DC supply voltage
P24VF
P5VF
GNDF
+24V
+5V
GND
Power for the digital/analog converter
AO1
AO2
Channel 1
Channel 2
For measuring the voltage of the analog output signal (digital/analog)
(2) Settings
Name
ICOM1
UDI1 to UDI20
(Connector CRM2A)
UDI21 to UDI40
ICOM2
(Connector CRM2B)
ICOM3
Standard
setting
WDI01 to WDI08
(Connector CRW7)
150
Side A
Description
The common voltage is
adjusted to:
Side A : +24 V common
Sid B : 0 V common
Side
B--81465EN--1/02
MAINTENANCE
4. PRINTED CIRCUIT BOARDS
(3) Adjustment
VR1/VR2: Adjusts the gain and the offset of channel 1.
Execute a robot program and set AOUT[1] to 3413 on the teach
pendant. Connect a digital voltmeter to test pin AOUT1 and
rotate VR1 or VR2 until the meter reads 15.0 V.
Connect the negative (--) lead of the digital voltmeter to test pin
GNDF.
VR3/VR4: Adjusts the gain and the offset of channel 2.
Execute a robot program and set AOUT[2] to 3413 on the teach
pendant. Connect the digital voltmeter to test pin AOUT2 and
rotate VR3 or VR4 until the meter reads 15.0 V.
Connect the negative (--) lead of the digital voltmeter to test pin
GNDF. (The 0VF test pin is different from the common 0V test
pin.)
(4) LEDs
ALMO
Color
Description
Red
A communication alarm occurred between
the main CPU and process I/O board.
Red
A fuse (FUSE 1) in the process I/O board
blew.
FALM
ALMO
FALM
(5) Correspondence between driver chips and DO signals
Ordering code for the driver chips: A76L-0151-0062
Driver chip
DV1
DV2
DV3
DV4
DV5
DV6
DV7
DV8
DV9
DV10
DO signal
CMDENBL, SYSRDY, PROGRUN, PAUSED
HELD, FALT, ATPERCH, TPENBL
BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
SDO01, SDO02, SDO03, SDO04
SDO05, SDO06, SDO07, SDO08
SDO09, SDO10, SDO11, SDO12
SDO13, SDO14, SDO15, SDO16
SDO17, SDO18, SDO19, SDO20
151
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81465EN--1/02
4.9
PANEL SWITCH
BOARD
(A20B--1007--0850)
Total version
Fig.4.12 Panel Switch Board
152
5
5. SERVO AMPLIFIERS
MAINTENANCE
B--81465EN--1/02
SERVO AMPLIFIERS
The servo amplifiers are factory-set for operation. Usually, you do not
need to set or adjust them.
This chapter describes the standard settings and adjustment required if a
defective servo amplifier is replaced. It also describes the use of test pins
and meanings of the LED indications.
Table 5 Servo amplifier specifications
Robot models
Servo amplifier
Regenerative resistor unit
R--2000iA
A06B--6105--H002
A05B--2452--C200 (B--cabinet)
M--6iB
A06B--6105--H003
A05B--2452--C201 ((B--cabinet))
ARC Mate 100iB
Check that the voltage is not higher than 50 V.
NOTE
Before touching the servo amplifier, for example, for
maintenance purposes, check the voltage at the screw
above the LED “D7” with a DC voltage tester to see if the
remaining voltage is not higher than 50 V.
153
5. SERVO AMPLIFIERS
MAINTENANCE
B--81465EN--1/02
5.1
LED OF SERVO
AMPLIFIER
LED D7
LED
Color
Description
P5V
Green
Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V normally.
P3.3V
Green
Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V normally.
SVEMG
Red
Lights when an emergency stop signal is input to the servo amplifier.
ALM
Red
Lights when the servo amplifier detects an alarm.
RDY
Green
Lights when the servo amplifier is ready to drive the servo motor.
OPEN
Green
Lights when the communication between the servo amplifier and the main board is normal.
WD
Red
Lights when a watch dog alarm is detected in the servo amplifier.
D7
Red
Lights when the DCLINK circuit inside the servo amplifier is charged to reach a specific voltage.
154
MAINTENANCE
B--81465EN--1/02
5.2
5. SERVO AMPLIFIERS
Settings
SETTING OF SERVO
AMPLIFIER
Name
Standard
setting
COM1
Side A
Description
This jumper sets the common voltage for the
Robot digital Inputs (RDI) to:
Side A : +24V common
Side B : 0V common
Fuse F1
Fuse F2
Fuse FS1
Fuse FS3
Fuse FS2
Set
jumper
155
5. SERVO AMPLIFIERS
MAINTENANCE
B--81465EN--1/02
5.3
DRIVER CHIP FOR
ROBOT DI/DO
DIO19 DIO18 DIO17
Correspondence between driver chips and DO signals
Ordering code for the driver chips : A76L--0151--0062
Driver chip
DO signal
DIO17
RDO1, RDO2, RDO3, RDO4
DIO18
RDO5, RDO6, RDO7, RDO8
DIO19
XRESERVE, XBRKRLS1, XBRKRLS2, XBRKRLS3
156
B--81465EN--1/02
6
MAINTENANCE
6. SETTING THE POWER SUPPLY
SETTING THE POWER SUPPLY
The power supply is factory-set for operation. Usually, you do not need
to set or adjust it.
157
6. SETTING THE POWER SUPPLY
MAINTENANCE
B--81465EN--1/02
6.1
BLOCK DIAGRAM OF
THE MAIN POWER
INCLUDING POWER
SUPPLY
AC input
380 -- 415 VAC
440 -- 500 VAC
3φ
Transformer
210VAC
Noise filter
Breaker
Servo amplifier
(6--axis amplifier)
E--stop unit
Regenerative res.
Aux.Axis
210VAC
CRR38
CRM67
+24E
FS1
CRM67
Motor
CP3
CP6
+24V
CP5A
+24E
CP6
End Effector
CP5A
+24V
Main board
CP5
CRM64
DC/DC
F4
+5V, +3.3V
+15V, --15V F3
+24V, +24E
+24VF
CP2
Pulsecoder
FAN
210VAC
Brake
CP1
CP2
DC/DC
+5V, +3.3V
+15V, --15V
Robot
Power
F1
CRF7
Power supply
unit
FS2
+5V
CRR64
CNJ
200VAC
Backplane
FS3
Breaker
BATTERY
CRM64
CRM64
CP8B
+24V
CRS16
+24T
FUSE2
Teach pendant
DC/DC
+5V
+24EXT
FUSE1
E--STOP
CIRCUIT
Panel board
+24E
JD5A
+24E
JD5B
+24E
JD17
Handy file etc.
Process I/O
board
+24E FUSE1
+24F
Peripheral device
CRM2
CRM4
+24E
+24E
+24V
--15V
+15V
+5V
+3.3V
Fig.6.1 Block diagram of the power supply (B--cabinet)
158
MAINTENANCE
B--81465EN--1/02
6.2
6. SETTING THE POWER SUPPLY
Select a transformer and tap according to the supply voltage. Select a
transformer tap such that the rated voltage is +10% to --15% of the induced
voltage.
SELECTING
TRANSFORMER
TAPS
Rated
Voltage
Transformer specification
7.5KVA
3KVA
500-575
Type I
440-480
A80L 0026 0035
A80L--0026--0035
A80L 0024 0025
A80L--0024--0025
A80L 0026 0036
A80L--0026--0036
A80L 0024 0026
A80L--0024--0026
A80L 0026 0037
A80L--0026--0037
A80L 0024 0027
A80L--0024--0027
380-415
Type II
440-500
380-400
Type III
200-230
Structure of transformer
Mounting locations of transformer
(B--cabinet, back side)
Transformer
Fig.6.2 (a) Transformer mounting locations and structure
1
Type I:440--480 V
Type II:380--415 V
Insert the connector connected to the circuit
breaker into connector LB and the dummy
plug into connector LA.
2
Type I: 500--575 V
Type II: 440--500 V
Insert the connector connected to the circuit
breaker into connector LA and the dummy
plug into connector LB.
159
6. SETTING THE POWER SUPPLY
MAINTENANCE
B--81465EN--1/02
3
Type III: 200--230 V
Use the ∆ connection cable.
4
Type III: 380--400 V
Insert the connector connected to the circuit
breaker into connector LA and use the Y connection cable for connector LB.
Fig.6.2 (b) Setting a tap
160
B--81465EN--1/02
6.3
CHECKING THE
POWER SUPPLY
UNIT
MAINTENANCE
6. SETTING THE POWER SUPPLY
The power supply unit need not be set or adjusted.
Table 6.3 Rating of the Power supply unit
Output
Rated voltage
Tolerance
+5V
+5.1V
3%
+3.3V
+3.3V
3%
+24V
+24V
5%
+24E
+24E
5%
+15V
+15V
10%
--15V
--15V
10%
161
6. SETTING THE POWER SUPPLY
F4 7.5A
fuse for +24V
CP5 : +24V
PIL
LED for indicating the
AC power supply
status (Green)
CP6 : +24E
MAINTENANCE
162
Fig.6.3 (a) Interface of the power supply unit
F3 7.5A
fuse for +24E
F1 8.0A
Fuse for AC input
ALM
LED for indicating
the alarm (Red)
B--81465EN--1/02
B--81465EN--1/02
R2
R1
AC
S2
OUTPUT
S1
G2
G1
P280
F1
+5.1
8A
+5.1V
R
NF
S
0V
+5.1VDC REGULATOR
0V
P0
+3.3
G
+3.3VDC
+3.3V
REGULATOR
0V
A24
A12
P22
F3
+24E
A5
AUX
0V
7.5A
+24
F4
7.5A
+24V
P.S.
0V
P0
P280
P22
0V
+24VDC REGULATOR
A24
MAINTENANCE
163
A5
+15
+15V
+5.1
+3.3
ON
15VDC
+24
+15
COM
OFF
--15
ALM
CONTROL
CIRCUIT
REGULATOR
--15
--15V
0V
ENA
EN5
A24
HI
LO
FA
FB
P0
0V
6. SETTING THE POWER SUPPLY
Fig.6.3 (b) Block diagram of the power supply unit
AC INPUT
7. REPLACING A UNIT
7
MAINTENANCE
B--81465EN--1/02
REPLACING A UNIT
This section explains how to replace each unit in the control section.
WARNING
Before you start to replace a unit, turn off the control unit
main power. Also keep all machines in the area of the control
unit switched off. Otherwise, you could injure personnel or
damage equipment.
164
B--81465EN--1/02
MAINTENANCE
7. REPLACING A UNIT
7.1
REPLACING THE
PRINTED--CIRCUIT
BOARDS
7.1.1
Replacing the
Backplane Board (Unit)
CAUTIONS
When you replace printed--circuit boards, observe the
following cautions:
1 Keep the control unit power switched off.
2 When you remove a printed--circuit board, do not touch the
semiconductor devices on the board with your hand or
make them touch other components.
3 Make sure that the replacement printed--circuit board has
been set up appropriately. (Setting plug etc.)
4 If the backplane board, power supply unit, or main board
(including cards and modules) is replaced, it is likely that
robot parameters and taught data are lost. Before you start
to replace these components, save a backup copy of the
robot parameters and taught data to a memory card, floppy
disk, or any other external memory device.
5 Before you disconnect a cable, note its location. If a cable
is detached for replacement, reconnect it exactly as before.
When replacing the backplane board, do so together with the plastic rack.
(1) Detach the cables from the power unit and boards on the backplane
board.
CAUTION
When you remove the main board, be sure that the battery
is good (3.1--3.3VDC) and it is installed correctly. USE
STATIC PROTECTION.
(2) Remove the power unit and boards from the rack. (See Section 7.1.2.)
(3) Detach the grounding cable from the backplane unit.
(4) Loosen the retaining screws in the upper section of the rack. Remove
the retaining screws from the lower section of the rack.
(5) Side rack up and out.
(6) To replace the backplane and rack, reverse steps (1) -- (6).
CAUTION
There is a possibility of data loss when a backplane-mounted printed circuit board is replaced. Be sure to back
up all program and setup data on a floppy disk before
proceeding.
165
7. REPLACING A UNIT
MAINTENANCE
B--81465EN--1/02
Fig.7.1.1 Replacing the Backplane Board
7.1.2
Replacing the Power
Unit and
Printed--Circuit Boards
on the Backplane Unit
The backplane unit incorporates the power unit, main board, and option
boards. There are two types of option boards: Full--size board and
mini--size board. A full--size board occupies one slot. A mini--size board
uses part of a full--size board.
CAUTION
Before starting replacement, turn off the control unit main
power. The main board is equipped with battery--backed
memory devices for holding robot parameters and taught
data, for example. When the main board is replaced, the
data in the memory devices is lost.
(1) Detach the cable from the power supply unit or the printed--circuit
board, whichever is to be replaced.
(2) Pinch the barbed handles on the upper and lower sections of the board
to unlatch it, then pull it toward you.
(3) Place the replacement board on the rail in the appropriate slot of the
rack, then push it in gently by the handles until it is latched.
(4) There are two rails in the main board SLOT (slot 1). When inserting
the main board, align it to the right--side rail.
(5) There are two rails in slots 3 and 5 (slots for a full--size option board).
When you insert a full--size option board, align it to the left--side rail.
166
B--81465EN--1/02
7. REPLACING A UNIT
MAINTENANCE
SLOT 1
PSU
(Power supply
SLOT)
SLOT 2
SLOT 3
Handles
SLOT 1
SLOT 10
Handles
SLOT 9
SLOT 8
Fig.7.1.2 Replacing the Power Unit and Printed--Circuit Boards
on the Backplane Unit
167
7. REPLACING A UNIT
MAINTENANCE
B--81465EN--1/02
7.1.3
The panel board is at the back of the operator panel.
Replacing the Panel
Board
(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 remove the
panel board.
4--M3
screws
B--cabinet
Fig.7.1.3 Panel board replacement
(3) Remove two retaining screws from the panel board, and remove two
plates.
2--M3 screws
(4) Attach two plates to new panel board by two screws, then attach the
panel board to the oparator panel by four screws.
168
B--81465EN--1/02
7. REPLACING A UNIT
MAINTENANCE
7.2
REPLACING CARDS
AND MODULES ON
THE MAIN BOARD
CAUTION
Before you start to replace a card or module, make a backup
copy of robot parameters and taught data. If the FROM/SRAM
module is replaced, memory contents are lost.
Demounting a Card
(1) Pull outward the clip of each of the two spacers used to secure the card
PCB, then release each latch.
(2) Extract the card upward.
Card
Card
Card
Card
Spacer
Connector
Card
Spacer
Connector
Fig.7.2(a) Demounting a card
169
7. REPLACING A UNIT
MAINTENANCE
B--81465EN--1/02
Mounting a Card
(1) Check that the clip of each of the two spacers is latched outward, then
insert the card into the connector.
(2) Push the clip of each spacer downward to secure the card PCB.
Card
Spacer
Connector
Card
Card
Card
Card
Spacer
Connector
Fig.7.2(b) Mounting a card
170
MAINTENANCE
B--81465EN--1/02
7. REPLACING A UNIT
Demounting a module
CAUTION
When replacing the module, be careful not to touch the
module contact. If you touch the contact inadvertently, wipe
out dirt on the contact with a clean cloth.
(1) Move the clip of the socket outward. (a)
(2) Extract the module by raising it at a 30 degree slant and pulling
outward.
Mounting a module
(1) Insert the module at a 30 degree slant into the module socket, with
side B facing upward. (b)
(2) Push the module inward and downward until it is locked. (c)
(a)
(b)
(c)
Fig.7.2(c) Demounting/Mounting a module
171
7. REPLACING A UNIT
MAINTENANCE
B--81465EN--1/02
Figure 7.2 (d) shows the locations of the cards and modules.
Main board
CPU card
Axis control card
FROM/SRAM module
Fig.7.2(d) Locations of Cards and Modules
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MAINTENANCE
7. REPLACING A UNIT
7.3
REPLACING THE
TRANSFORMER
WARNING
Before you start replacement procedure, turn off the main
power to the control unit. The transformer is quite heavy; it
weighs 45 to 60 kg.
In case of B--cabinet
(1) Remove the six M4 screws and detach the back panel.
6--M4 screws
173
7. REPLACING A UNIT
MAINTENANCE
B--81465EN--1/02
(2) Detach the connectors of LA, LB, OUT, CP1, and TOH.
If a cable is fastened with nylon ties, cut them with a diagonal cutter
to release the cable. Be careful not to damage the cable.
(3) Remove the retaining screws from the transformer terminal board and
remove metal plate.
174
MAINTENANCE
B--81465EN--1/02
7. REPLACING A UNIT
(4) Remove the two retaining M6 screws from the transformer, then
remove the transformer.
Shape of the transformer
2--M6 screws
(5) Install a replacement transformer by reversing procedure (1) to (4).
175
7. REPLACING A UNIT
MAINTENANCE
B--81465EN--1/02
7.4
REPLACING THE
REGENERATIVE
RESISTOR UNIT
WARNING
Before you start, turn off the control unit main power.
Be careful not to get burned, because the regenerative
resistor unit is very hot immediately after operation.
In case of B--cabinet
(1) Remove the servo amplifier. (See “Replacing the servo amplifier.”)
(2) Remove two M4 screws, then detach the housing that fastens cables.
2--M4 screws
(3) Remove the two retaining M5 nuts and lift away the regenerative
resistor unit.
2--M5 nuts
(4) Install a replacement regenerative resistor unit and a servo amplifier
by reversing the procedure (1) to (3).
176
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7. REPLACING A UNIT
MAINTENANCE
7.5
REPLACING THE
E--STOP UNIT
WARNING
Before you start replacement, turn off the control unit main
power.
B--cabinet
(1) Detach the cables from the emergency stop unit.
(2) Remove retaining screws (4--M4) from the emergency stop unit, and
replace the emergency stop unit.
(3) Reconnect the cables.
E--stop unit
4--M4 screws
B--cabinet
Fig.7.5 Replacing the Emergency Stop Unit
177
7. REPLACING A UNIT
MAINTENANCE
B--81465EN--1/02
7.6
REPLACING SERVO
AMPLIFIERS
WARNING
Before you start replacement, turn off the control unit main
power.
In case of B--cabinet
(1) Turn the four screws, detach the amplifier cover, and pull out the
cable.
Amplifier cover
Fig.7.6 (a) Replacing the servo Amplifier (B--cabinet)
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MAINTENANCE
7. REPLACING A UNIT
(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 50 V.
(3) Remove the two screws located on the top of the amplifier.
At the middle of the top of the amplifier, there is an M5 screw that
fastens the amplifier during transport of the cabinet. After the
installation of the cabinet, remove the screw.
This improves maintainability.
Screw
Fixation screw for
transport (MS)
Fig.7.6 (b) Replacing the servo Amplifier (B--cabinet)
179
7. REPLACING A UNIT
MAINTENANCE
B--81465EN--1/02
(4) Holding the handles located at the top and bottom of the amplifier,
pull out the amplifier toward you.
Be careful not to touch any components, such as capacitors, on the
lower part of the servo amplifier printed--circuit board. Also, be
careful not to damage the cables that are routed under the servo
amplifier when pulling it out.
Fig.7.6 (c) Replacing the servo Amplifier (B--cabinet)
(5) Pull out the lower part of the amplifier further toward you and slant
the amplifier.
Fig.7.6 (d) Replacing the servo Amplifier (B--cabinet)
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MAINTENANCE
7. REPLACING A UNIT
(6) Take the amplifier out while keeping it slanted.
Fig.7.6 (e) Replacing the servo Amplifier (B--cabinet)
(7) Install a replacement servo amplifier by reversing step (b).
(8) Re--attach the cables.
181
7. REPLACING A UNIT
MAINTENANCE
B--81465EN--1/02
7.7
REPLACING I/O UNIT
MODEL A
7.7.1
Replacing the Base
Unit of I/O Unit Model A
WARNING
Before you start replacement, turn off the control unit main
power.
First dismount the modules from the base unit of I/O unit model A. The
base unit is retained with 4 screws. Of these screws, loosen the upper 2
screws and remove the lower 2 screws, then replace the base unit.
M4 screw (4 pieces)
B--cabinet
Fig.7.7.1 Replacing the Base Unit of I/O Unit Model A
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7.7.2
Replacing a Module
Installing a module
MAINTENANCE
7. REPLACING A UNIT
An interface module and input/output module can be easily installed in
and removed from the base unit, as described below.
(a) Put the upper hook of the module into the upper hole of the base unit.
(b) Fit the connectors of the module and the base unit to each other.
(c) Push the module until the lower stopper of the module is caught in the
lower hole of the base unit.
Removing a module
(a) Press the lever at the bottom of the module to release the stopper.
(b) Lift the module up.
Fig.7.7.2 Replacing the module
183
7. REPLACING A UNIT
7.8
REPLACING THE
TEACH PENDANT
MAINTENANCE
B--81465EN--1/02
The specifications of the teach pendant vary with its use. When you
replace the teach pendant, check its specifications carefully.
(1) Be sure that the power of a robot controller is off.
(2) Detach the cable from the teach pendant.
(3) Replace the teach pendant.
Detach or attach the cable by rotating
the connector retaining ring.
Fig.7.8 Replacing the Teach Pendant
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B--81465EN--1/02
7.9
REPLACING THE
CONTROL SECTION
FAN MOTOR
MAINTENANCE
7. REPLACING A UNIT
The control section fan motor can be replaced without using a tool. The
fan motor is mounted on the fan unit rack.
(1) Be sure that the power of a robot controller is off.
(2) Put your finger in the dent in the upper section of the fan unit, and pull
the fan unit until it is unlatched.
(3) Lift the fan unit slightly, and dismount it from the rack.
(4) Place a replacement fan on the upper section of the rack, and slide it
gently until it is latched.
Fan motor connector
Fan motor
Pull the fan motor unit
toward you to unlatch it.
Fig.7.9 Replacing the Control Section Fan Motor
185
7. REPLACING A UNIT
MAINTENANCE
B--81465EN--1/02
7.10
REPLACING THE AC
FAN MOTOR
WARNING
Before you start replacement, turn off the control unit main
power. Do not touch the fan motor when it is rotating, or you
could be injured.
7.10.1
Door fan
Replacing External Air
Fan Unit and Door Fan
(B--cabinet)
(1) Detach the cable from the fan unit.
(2) Remove the two retaining M4 screws from the fan unit, then dismount
it.
(3) Install a new fan unit by reversing the dismounting procedure.
External Air fan unit
(1) Detach the cable.
(2) Remove the six M4 screws and pull out the fan unit toward you.
(3) Install a new fan unit by reversing the dismounting procedure.
Screw (2--M4)
Screw (6--M4)
Floor fan unit
(1) Remove the cable from the fan unit.
(2) Remove the fan by unscrewing the two retaining M4 screws.
(3) Reverse the procedure to mount a spare fan unit.
186
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MAINTENANCE
7. REPLACING A UNIT
Floor fan unit
187
Screw (2--M4)
7. REPLACING A UNIT
7.11
REPLACING THE
OPERATOR PANEL
AND PANEL SWITCH
BOARD
MAINTENANCE
B--81465EN--1/02
(1) Detach the cable (CRT8, CRM51)
(2) Straighten the 12 claws on the printed circuit board, then remove the
printed circuit board.
(3) Remove the six (6--M3) screws, then remove the panel switch board.
(4) Install a new panel switch board by reversing the dismounting
procedure.
Straighten the claws.
Screw (6--M3)
Fig.7.11 Replacing the operator panel and Panel switch board
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B--81465EN--1/02
7.12
REPLACE THE MODE
SWITCH
MAINTENANCE
7. REPLACING A UNIT
(a) Remove the cable from the mode switch.
(b) Remove the screws fastening the mode switch, and replace the mode
switch.
NOTE
1 When mounting the mode switch, do not overtighten the
screws. (Tightening torque: 2.5 kg·cm)
2 Tighten the screws evenly so that the mode switch flat
surface becomes parallel-- to the sheet metal.
Door
Screw
Mode switch
Fig.7.12 Replacing the Mode Switch
189
7. REPLACING A UNIT
7.13
REPLACING FUSES
7.13.1
Replacing Fuses in the
Servo Amplifier
MAINTENANCE
B--81465EN--1/02
If a fuse in the control unit has blown, find the cause and take an
appropriate measure before replacing the fuse.
The following fuses are in the servo amplifier.
F1, F2:
Fuses for detection of the circuits failure in the servo amplifier,
(A60L--0001--0245#GP20)
If either of these fuses has blown, it is likely that the servo amplifier
is defective. Replace the servo amplifier.
FS1: For generation of the power to the amplifier control circuit
(A60L--0001--0290#LM32C)
FS2: For protection of the 24 V output to the end effector, ROT, and HBK
(A60L--0001--0290#LM32C)
FS3: For protection of the 24 V output to the regenerative resistance and
the additional axis amplifier (A60L--0001--0290#LM50C)
Fuse F1
Fuse F2
Fuse FS1
Fuse FS3
Fuse
FS2
Fig.7.13.1 Replacing Fuses in the Servo Amplifier
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7.13.2
Replacing Fuses in the
Power Unit
MAINTENANCE
7. REPLACING A UNIT
The following fuses are in the power unit.
F1: Fuse for the AC input, A60L--0001--0396#8.0A
F3: Fuse for protecting the +24E output, A60L--0001--0046#7.5
F4: Fuse for protecting the +24V output, A60L--0001--0046#7.5
F1 8.0A
AC input fuse
F3 7.5A
+24E fuse
F4 7.5A
+24V fuse
Fig.7.13.2 Replacing Fuses in the Power Unit
191
7. REPLACING A UNIT
MAINTENANCE
7.13.3
Replacing the Fuse on
the Process I/O Boards
B--81465EN--1/02
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,CB
FUSE1
Total version
Process I/O board DA
FUSE1
Total version
Fig.7.13.3 (c) Replacing the Fuse on the Process I/O Boards
192
MAINTENANCE
B--81465EN--1/02
7. REPLACING A UNIT
Process I/O board CA,CB
FUSE1
Total version
193
7. REPLACING A UNIT
MAINTENANCE
7.13.4
Replacing the Fuse on
the Panel Board
B--81465EN--1/02
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
Fuse 2
Fuse 1
Fig.7.13.4 Replacing the fuse on the panel board
194
MAINTENANCE
B--81465EN--1/02
7.14
REPLACING RELAYS
7.14.1
Replacing Relays on
the Panel Board
7. REPLACING A UNIT
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.
KA21, KA22: Relay for emergency stop circuit
A58L--0001--0192#1509A
KA22
Fig.7.14.1 Replacing Relays on the Panel Board
195
KA21
7. REPLACING A UNIT
MAINTENANCE
B--81465EN--1/02
7.15
REPLACING
BATTERY
7.15.1
Battery for Memory
Backup (3 VDC)
The programs, and system variables are stored in the SRAM in the main
board. The power to the SRAM memory is backed up by a lithium battery
mounted on the front panel of the main board. The above data is not lost
even when the main battery goes dead. A new battery can maintain the
contents of memory for about 4 years (Note).
When the voltage of the battery becomes low, the low--voltage battery
alarm (system--035) is displayed on the teach pendant. When this alarm
is displayed, replace the battery as soon as possible. In general, the battery
can be replaced within one or two weeks, however, this depends on the
system configuration.
If the battery voltage gets lower, it becomes impossible to back up the
content of the SRAM. Turning on the power to the in this state causes
system not to start and LED of seven segment on the main board to be
displayed “1” because the contents of memory are lost. Clear the entire
SRAM memory and reenter data after replacing the battery. Important
data should be saved to the memory card or floppy disk beforehand in case
of emergency.
When replacing the memory backup battery, do so while the robot
controller is turned off in case of emergency.
NOTE
In a newly introduced robot, the battery is factory--installed.
Battery replacement may, therefore, be needed within 4
years after the introduction of the robot.
Replacing the lithium
battery
(1) Prepare a new lithium battery (ordering drawing number:
A02B--0200--K102).
(2) Turn the robot controller on for about 30 seconds.
(3) Turn the robot controller off.
(4) Remove the old battery from the top of the main board.
First unlatch the battery, remove it from the battery holder, and detach
its connector.
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MAINTENANCE
7. REPLACING A UNIT
Battery latch
Lithium battery
Battery
connector
(5) Remove the old battery, insert a new one into the battery holder, and
attach the connector. Confirm that the battery is latched firmly.
WARNING
Using other than the recommended battery may result in the
battery exploding.
Replace the battery only with the specified battery
(A02B--0200--K102).
CAUTION
Complete the steps (3) to (5) within 30 minutes.
If the battery is left disconnected for a long time, the
contents of memory will be lost.
To prevent possible data loss, it is recommended that the
robot data such as programs and system variables be
backed up before battery replacement.
Dispose of the replaced battery as an industrial waste, according to the
laws and other rules in the country where the controller is installed and
those established by the municipality and other organizations that have
jurisdiction over the area where the controller is installed.
197
III CONNECTIONS
CONNECTIONS
B--81465EN--1/02
1
1. GENERAL
GENERAL
This section describes the electrical interface connections in the R-J3iB.
It also includes information about installation of the R-J3iB.
201
2. BLOCK DIAGRAM
2
CONNECTIONS
B--81465EN--1/02
BLOCK DIAGRAM
Fig. 2 is a block diagram of electrical interface connections with the
R-J3iB.
Pneumatic
pressure source
R--J3iB
(B--cabinet)
Mechanical unit
End effector
Memory card
(PCMCIA)
Teach pendant
RS--232--C
(Note2)
Peripheral device
Welding machine
Ethernet
AC power supply
Fig.2 Block Diagram of Electrical Interface Connection (In case of B--cabinet)
NOTE
1
: Indicates electrical connection.
: Indicates mechanical connectin.
2 For more information, contact our service section.
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3
CONNECTIONS
ELECTRICAL CONNECTIONS
203
3. ELECTRICAL CONNECTIONS
3. ELECTRICAL CONNECTIONS
CONNECTIONS
B--81465EN--1/02
3.1
CONNECTION
DIAGRAM BETWEEN
MECHANICAL UNITS
R-J3iB
CRF7
(Pulsecoder signal,
RDI/RDO, ROT,
HBK)
CNJ1A
(J1 motor power)
Robot
RP1
(Pulsecoder signal
RDI/RDO, ROT, HBK)
RM1
(J1--J6 motor power,
Motor brake)
CNJ2A
(J2 motor power)
EE
CNJ3A
(J3 motor power)
End effector
(Note)
CNJ4A
(J4 motor power)
CNJ5A
(J5 motor power)
CNJ6A
(J6 motor power)
CNGA
(J1--J3 ground)
CNGB
(J4--J6 ground)
CRR64
(Brake control)
Fig.3.1 (a) Mechanical Connection Diagram
NOTE
This cable is not included. It must be supplied by the customer.
204
CONNECTIONS
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3. ELECTRICAL CONNECTIONS
R-J3iB
CRS16
(Panel board)
CRM2, CRM4
(Process I/O)
Teach pendant
(NOTE1)
Port A
(Operator panel)
Peripheral device
Handy File
JD5B
(Main board)
(NOTE2)
External device
JD17
(Main board)
(NOTE2)
External device
CD38
(Main board)
(NOTE2)
Ethernet
L1
L2
Braker
L3
G
Panel board
(TBOP3)
ON1
ON2
OFF1
OFF2
Input power
(NOTE2)
Panel board
(TBOP4)
EES1
EES11
EES2
EES21
(NOTE2)
Panel board
(TBOP4)
EAS1
EAS11
EAS2
EAS21
(NOTE2)
Panel board
(TBOP4)
EGS1
EGS11
EGS2
EGS21
(NOTE2)
External power
ON/OFF switch
External emergency
stop switch
Fence
Servo off switch
Fig.3.1 (b) Mechanical Connection Unit
NOTE
1 For detail of the peripheral device connection, see the section of Peripheral device interface.
2 This cable is not included. It must be supplied by the customer.
205
3. ELECTRICAL CONNECTIONS
CONNECTIONS
B--81465EN--1/02
3.2
EXTERNAL CABLE
WIRING DIAGRAM
3.2.1
Robot Connection
Cables
Robot Model
R--2000iA
M--6iB
ARC Mate 100iB
(B--Cabinet)
D Detail of cable connection to servo amplifier.
Robot
R--J3iB (Servo amplifier)
CRR64
CNGA
CNJ6
CNJ5
CNGB
CRF7
Pulse coder
(Pulse coder,RDI/RDO,HBK,ROT)
Motor power/brake
(J1M, J2M, J3M, J4M, J5M, J6M, BK)
CNJ4
CNJ3A
CNJ2A
CNJ1A
Fig.3.2.1 (a) Robot Connection Cable (B--cabinet)
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3.2.2
Teach Pendant Cable
CONNECTIONS
3. ELECTRICAL CONNECTIONS
(1) Teach pendant cable
The teach pendant connection cable is connected to the operator panel
as follows. This figure applies to all robot models.
Teach pendant
Teach pendant
connection cable
Fig.3.2.2 Teach Pendant Cable
207
3. ELECTRICAL CONNECTIONS
3.2.3
Connecting the Input
Power
CONNECTIONS
B--81465EN--1/02
Considering the robot power capacity and the circuit breaker capacity,
connect the power supply whose voltage conforms to the installation
conditions to the terminal located above the circuit breaker.
Provide a class--D or better ground.
The resistance to the ground must not exceed 100Ω.
Be sure to ground the work table or jig used by an arc welding robot or
the like so that it can handle a large current.
Use a thick wire to withstand the maximum current used.
Selection of an input transformer tap is necessary depending on the input
voltage.
The tap is set to the specified voltage before shipment. However, check
it referring to section 6.2 in “Maintenance” before supplying power
(before the breaker switch is turned on).
The motor is driven by the PWM inverter system using a power transistor
bridge. If the servo amplifier is used without a transformer, a
high-frequency leakage current flows through the stray capacitance
between the ground and the motor coils, power cable, and amplifier. This
might cause the leakage-current circuit breaker or leakage-protection
relay installed in the path of the power supply to cut out.
Use the following leakage current circuit breaker for inverters to prevent
incorrect operation.
Example of Leakage Current Circuit Breaker for Inverters
Manufacture
Type
Fuji Electric Co., Ltd.
EG A series
SG A series
Hitachi, Ltd.
ES100C type
ES225C type
Matsushita Electric
Works, Ltd.
Leakage current circuit breaker, C type
Leakage current circuit breaker, KC type
Fig. 3.2.3 shows the cable connection.
208
B--81465EN--1/02
CONNECTIONS
3. ELECTRICAL CONNECTIONS
B--cabinet
Input Power supply
cable
(Note) Always replace the cover
after completing
Fig.3.2.3 Input Power Supply Connection (B--cabinet)
209
3. ELECTRICAL CONNECTIONS
3.2.4
CONNECTIONS
B--81465EN--1/02
The External Power On/Off signal turns on and off the power supply from
the outside of the control unit, and is connected as follows.
Connecting the
External Power Supply
ON/OFF Switch
Panel board
TBOP3
Fig.3.2.4 (a) Connection of the external power supply ON/OFF switch
210
CONNECTIONS
B--81465EN--1/02
3. ELECTRICAL CONNECTIONS
Short piece between EXON1 and EXON2
External ON/OFF switch.
In case of using external
ON/OFF switch, remove
the short piece between EXOFF1
and EXOFF2, then connect
the wires.
Use a contact conforming to the following : Voltage rating : 50 VDC, 100mA or more
The power supply on/off timing chart is as follows
ON
ON/OFF SW
on operator panel
OFF
TOFF--ON
Close
EXOFF1--2
Open
ON
Power
OFF
TOFF--ON ≧ 5 sec
Note1) In case of using the external ON/OFF control, the ON/OFF switch on operator panel must be turned ON.
Note2) When the external ON/OFF switch is turned ON (Closed), the ON/OFF switch on operator panel can turn ON the
controller.
Note3) When the external ON/OFF switch is turned OFF (Open), the ON/OFF switch on operator panel can not turn ON
the controller.
Fig.3.2.4 (b) Connection of the external power supply switch ON and OFF
211
3. ELECTRICAL CONNECTIONS
CONNECTIONS
3.2.5
Connecting the
External Emergency
Stop
Fig.3.2.5 (a) Connection of the external emergency stop
212
B--81465EN--1/02
CONNECTIONS
B--81465EN--1/02
3. ELECTRICAL CONNECTIONS
External emergency stop output
.
Signal
ESPB1
ESPB11
ESPB2
ESPB21
ESPB3
ESPB31
ESPB4
ESPB41
Description
Emergency stop output signals.
These contacts are open if an
emergency stop of teach pendant
or operator panel occurs or the
power is turned off. (Note 1)
These contacts are closed during
normal operation.
Current, voltage
Rated contact:
5-A
250 VAC, 5
A or
30 VDC, 5A resistor load
Fig.3.2.5 (b) External emergency stop output
NOTE
1 The relays for emergency stop output signals can be connected external power source.
The power for relays are connected controller’s power at the factory, and please connect
external power source if emergency stop output must not be effected controller’s power.
Please refer to “External power connection”.
213
3. ELECTRICAL CONNECTIONS
CONNECTIONS
B--81465EN--1/02
External emergency stop input
After connecting an external emergency stop switch and safety fence door switch, be sure to check the operations of those
switches, the emergency stop switch on the operator’s panel, and the emergency stop switch on the teach pendant.
Use a contact which minimum load is 5mA less.
Signal
EES1
EES11
EES2
EES21
EAS1
EAS11
EAS2
EAS21
EGS1
EGS11
EGS2
EGS21
SD4
SD41
SD5
SD51
Description
Current, voltage
Connect the contacts of the external emergency stop switch to these terminals. When using the contacts of a relay of contactor instead of the switch, Open and close of
connect a spark killer to the coil of the relay or contactor, to suppress noise. 24VDC 10mA
When these terminals are not used, jumper them.
These signals are used to stop the robot when the door on the safety fence
is open.
While the deadman’s switch on the teach pendant is pressed and the teach Open and close of
pendant enable switch is validated, these signals are ignored and an emer- 24VDC 10mA
gency stop does not occur.
If these signals are not used, short these terminals.
Connect the contacts of the servo--on input switch to these terminals. When
using the contacts of a relay or contactor instead of the switch, connect a Open and close of
spark killer to the coil of the relay or contactor, to suppress noise.
24VDC 10mA
When these terminals are not used, jumper them.
Connect the contacts of the servo--disconnect input switch to these terminals. When using the contacts of a relay or contactor instead of the switch, Open and close of
connect a spark killer to the coil of the relay or contactor, to suppress noise. 24VDC 10mA
When these terminals are not used, jumper them.
214
B--81465EN--1/02
CONNECTIONS
3. ELECTRICAL CONNECTIONS
Input requirement for external emergency stop and etc.
The emergency stop circuit is composed of a chain of contacts.
D Please connect dual contacts, which work same time, for external emergency stop, safety fence switch, servo ON/OFF
switch and servo disconnect switch.
D Please observe following timing.
If input requirements are not satisfied, it may occure single chain failure.
l.
CAUTION
1 Single chain failure will occure, if this input requirements are
not satisfied.
2 Single chain failure can’t be reset until special reset
operation even if controller power is OFF and ON.
215
3. ELECTRICAL CONNECTIONS
CONNECTIONS
B--81465EN--1/02
Extenal power connection
The relays for emergency stop input and output can be separated from controller’s power.
Please connect external +24V instead of internal +24V, if emergency stop output must not be effected controller’s power.
216
CONNECTIONS
B--81465EN--1/02
3. ELECTRICAL CONNECTIONS
Connecting external on/off and external emergency stop signal input/output wires
Details of the signal wires are shown below:
Bare wire length: 8 to 9 mm
Compliant wire size: 0.08 to 2.5 mm2
If you want to use a rod terminal, select one that is suitable for the wire shown above.
The following table lists recommended products (manufactured by Weissmuller).
Wire (mm2)
0.5
0.75
1.0
1.5
2.5
Specification
H0.5/14
H0.75/14
H1.0/14
H1.5/14
H2.5/14
Remark
With
insulation
cover
(Crimping tool : PZ3, PZ4, PZ6/5)
How to attach signal wires to connectors
Manipulation slot
Flat--blade screwdriver
Plug connector block
Signal wire
1.
2.
3.
4.
5.
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.
217
3. ELECTRICAL CONNECTIONS
CONNECTIONS
B--81465EN--1/02
FANUC recommonds the lever (A05B--2400--K030) for connecting the
signal wire to the plug connector block instead of Flat--blade screwdriver.
Wire stripping
Handling of the Lever
F Available wire size AWG 28--14 (0.08 to 2.5mm2)
F Hold the connector, and
push down the lever by
finger
F Don’t handle the lever
after fit the connector
into the PCB, otherwise
PCB will be damaged by
handling stress.
F Please check the strip length carefully.
F Please readjust the loose end.
Wiring
(1) Pull down the lever.
(2) Push in the conductor
with holding the lever.
(3) Set the lever free.
L And pull the conductor
softly to check the clamping
L Don’t pull strongly
Replace the lever
(1) Pull off the
lever.
(2) Hook the lever
to the rectangle
hole.
(3) Push down the lever untill
click in.
Fit to header
(1) Push in the connector to header.
(2) Please check if the
latch is hooked to header.
L Be careful to fit the
shape of each other.
218
3. ELECTRICAL CONNECTIONS
CONNECTIONS
B--81465EN--1/02
Installation of “Jumper”
(1) Attach levers to connector.
L Please check the direction
of the jumper.
(2) Hold down levers at the same
time, then put the jumper into
connector.
Availability of wires
F Without jumpers
F With jumper
F With two jumpers
L Max wire size … 2.0mm2 (AWG14)
(with “Ferrule”)
F Additional wire is available under F Additional wire is
the jumper.
NOT avairable under
the jumper.
L Max wire size … 0.5mm2 (AWG20)
(with “Ferrule”)
Installation of “Ferrules”
(3) Squeeze handles until
ratchet mechanism is
released.
(1) Put the wire through the
hole of ferrules.
(2) Introduce wire
with ferrule into
cramping station.
(4) Please check if
the wire crimped
correctly.
Crimping Toole ( : WAGO Item--No.206--204)
Specifications of Ferrules
WAGO
Item--No.
Sleep for
mm2 (AWG)
Color
Stripped
Lengt (m)
L
L1
D
(m)
D1
D2
Pack.--unit
pcs
216--301
216--302
0.25 (24)
0.34 (24)
yellow
green
9.5
9.5
12.5
12.5
8.0
8.0
2.5
2.5
2.0
2.0
0.8
0.8
100
100
216--201
216--202
216--203
0.5 (22)
0.75 (20)
1.0 (18)
white
gray
red
9.5
10.0
10.0
14.0
14.0
14.0
8.0
8.0
8.0
3.1
3.3
3.5
2.6
2.8
3.0
1.0
1.2
1.4
100
100
100
216--204
216--205
1.5 (16)
2.0 (14)
black
yellow
10.0
10.0
14.0
14.0
8.0
8.0
4.0
4.2
3.5
3.7
1.7
2.0
100
100
L CAUTION Please make sure to use WAGO 206--204 to crimp the ferrules.
219
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR
INTERFACES
4
R-J3iB I/O peripheral device interfaces include printed circuit boards and
a unit selected according to the applications. Table 4 lists details of the
printed--circuit boards and units. Figure 4 shows the locations of these boards
and units.
Table 4 Peripheral Device Interface Types
No
No.
Name
1
Process I/O board CA
2
Process I/O board CB
3
Drawing number
Number of I/O points
Remarks
DI
DO
D/A
A/D
A05B--2450--J001
40
40
2
6
Installed in backplane
A05B--2450--J002
40
40
0
0
Installed in backplane
Process I/O board DA
A05B--2450--J003
96
96
0
0
Installed in backplane
4
Process I/O board HA
A05B--2450--J004
40
40
2
0
Installed in backplane
5
I/O Unit--MODEL A
(B--cabinet)
A05B-2452-J100
(Base and interface unit)
Depending on selected I/O module
NOTE
General purpose I/O (SDI/SDO) is a number which subtract an exclusive signal from the table
value.
Example: Process I/O board CB
Table value Exclusive DI General purpose DI
DI;
40
-18
=
22 points
Table value Exclusive DO General purpose DO
DO; 40
-20
=
20 points
Process I/O
printed board
I/O unit model A
(5 slots)
Fig.4 Locations of Peripheral Device Interfaces
220
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
4.1
PERIPHERAL
DEVICE INTERFACE
BLOCK DIAGRAM
Following are a block diagram of the peripheral device interface and the
specifications.
4.1.1
When Process I/O
Board CA/CB/HA is
Used (B--cabinet)
B--cabinet
Process I/O
board
CA/CB/HA
Main
board
JD1A
(JD4)
Peripheral
device
3
CRM2A
1
JD4A
(JD1B)
CRM2B
4
JD4B
(JD1A)
CRW1
or CRW7
(NOTE2)
CRW2
2
Process I/O
board
CA/CB/HA
CRM2A
JD4A
(JD1B)
CRM2B
JD4B
(JD1A)
CRW1
or CRW7
(NOTE 2)
CRW2
Fig.4.1.1 Block diagram of the process I/O board CA/CB/HA
221
5
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
NOTE
1 CRW1 and CRW2 are not provided for process I/O board
CB
2 In case of process I/O CA : CRW1
In case of process I/O HA : CRW7
No.
Name
Drawing number
Remarks
1
I/O link cable
A05B--2452--J140
Between main board and process I/O
2
I/O link cable
A05B--2452--J141
Between process I/O and process I/O
3
Peripheral
p
device connection cable
A05B--2452--J200
Cable length 10m (one cable)
A05B--2452--J201
Cable length 20m (one cable)
A05B--2452--J202
Cable length 30m (one cable)
Welding
g device connection cable
(Process I/O CA)
(FANUC interface)
A05B--2452--J270
Cable length 3m (one cable) CRW1
A05B--2452--J271
Cable length 7m (one cable) CRW1
A05B--2452--J272
Cable length 14m (one cable) CRW1
Welding
g device connection cable
(Process I/O HA)
(General interface)
A05B--2452--J273
Cable length 3m (one cable) CRW7
A05B--2452--J274
Cable length 7m (one cable) CRW7
A05B--2452--J275
Cable length 14m (one cable) CRW7
Welding
g device connection cable
(Process I/O HA)
(FANUC interface)
A05B--2452--J276
Cable length 3m (one cable) CRW7
A05B--2452--J277
Cable length 7m (one cable) CRW7
A05B--2452--J278
Cable length 14m (one cable) CRW7
4
5
222
CONNECTIONS
B--81465EN--1/02
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
4.1.2
When Process I/O
Board DA is Used
(B--cabinet)
B--cabinet
Main board
Process I/O
board DA
1
JD1A
JD4A
Peripheral
device
3
CRM2A
JD4B
CRM2B
CRM2C
CRM2D
2
CRM4A
4
5
6
7
8
CRM4B
Process I/O
board DA
JD4A
CRM2A
JD4B
CRM2B
CRM2C
CRM2D
CRM4A
CRM4B
Fig.4.1.2 Block diagram of the process I/O board DA
Cable
number
1
2
3
4
5
6
7
8
Name
Drawing number
Remarks
I/O link cable
A05B--2452--J140
Between main board and process I/O
I/O link cable
A05B--2452--J141
Between process I/O and process I/O
Peripheral
p
device connection cable
A05B--2452--J200
Connected length 10m (one cable)
A05B--2452--J201
Connected length 20m (one cable)
A05B--2452--J202
Connected length 30m (one cable)
A05B--2452--J250
Connected length 10m (one cable)
A05B--2452--J251
Connected length 20m (one cable)
A05B--2452--J252
Connected length 30m (one cable)
Peripheral
p
device connection cable
223
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
4.1.3
When I/O Unit--MODEL
A is Used
4.1.3.1
In case of B--cabinet
E--Stop unit
CP5A
Main board
1
JD1A
Peripheral
device
Interface module
2
2
2
2
2
Fig.4.1.3.1 Block diagram of I/O Unit--A (In case of B--cabinet)
Cable
number
Name
Drawing number
Remarks
1
I/O link cable
—
Included in A05B--2452--J100
2
Peripheral device connection cable
—
Must be supplied by the customer.
224
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
4.1.4
When Two or more
Process I/O Boards
and I/O Unit (Model A
or Model B) are Used
In case of B--cabinet.
When several units of the process I/O board, I/O Unit--A are used, connect
them as shown below.
B--cabinet
Main board
Process
I/O board
JD1A
A05B--2452--J140
DC power is supplied
from the back plane.
JD4A
JD4B
Process
I/O board
A05B--2452--J141
JD4A
E--stop unit
JD4B
CP5A
I/O Unit--A
Interface module
Included in model
A base unit
JD1B
JD1A
CP32
Back plane (5--slot)
225
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
4.2
PERIPHERAL
DEVICE INTERFACE
COMBINATION
4.2.1
In Case of B--cabinet
One board or one unit is used
Combination C
Process I/O board CA/CB/HA (40 points)
Combination D
Process I/O board DA
(96 points)
Combination E
I/O Unit--A
Two boards/units are used in combination
Combination CC
Process I/O board CA/CB/HA (40 points)
+
Process I/O board CA/CB/HA (40 points)
Combination CE
Process I/O board CA/CB/HA (40 points)
+
I/O Unit--A
Combination DC
Process I/O board DA (96 points)
+
Process I/O board CA/CB/HA (40 points)
Combination DD
Process I/O board DA (96 points)
+
Process I/O board DA (96 points)
Combination DE
Process I/O board DA (96 points)
+
I/O Unit--A
Three boards/units are used in combination
Combination CCE
Process I/O board CA/CB/HA (40 points)
+
Process I/O board CA/CB/HA (40 points)
+
I/O Unit--A
Combination DCE
Process I/O board DA (96 points)
+
Process I/O board CA/CB/HA (40 points)
+
I/O Unit--A
Combination DDE
Process I/O board DA (96 points)
+
Process I/O board DA (96 points)
+
I/O Unit--A
226
B--81465EN--1/02
4.3
PROCESS I/O
BOARD SIGNALS
CONNECTIONS
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
There are 18 exclusive data inputs (DI) and 20 exclusive data outputs
(DO) for a process I/O board.
These signals are allocated to the process I/O board connected first when
two or more printed boards are combined. (General signals SDI/SDO are
allocated to the second and the following process I/O boards.)
The common voltage of the DI signals input to pins 1 to 4 of connector
CRM2A is clamped +24 V (common) in each process I/O board.
Table 4.3 shows signals of a process I/O board.
Table 4.3 Process I/O Board Signals (1/4)
(DI signals)
Connector
number
Signal name
Description
Remarks
CRM2A-1
*IMSTP
Immediate stop
Clamped at +24 V
common
CRM2A-2
*HOLD
Temporary stop
Clamped at +24 V
common
CRM2A-3
*SFSD
Safe speed
Clamped at +24 V
common
CRM2A-4
CSTOPI
Cycle stop
Clamped at +24 V
common
CRM2A-5
FAULT RESET
External reset
CRM2A-6
START
Start
CRM2A-7
HOME
Return to home
position
CRM2A-8
ENBL
Operation enabled
CRM2A-9
RSR1
Robot service request
PNS1
Program number
selection
RSR2
Robot service request
PNS2
Program number
selection
RSR3
Robot service request
PNS3
Program number
selection
RSR4
Robot service request
PNS4
Program number
selection
RSR5
Robot service request
PNS5
Program number
selection
RSR6
Robot service request
PNS6
Program number
selection
RSR7
Robot service request
PNS7
Program number
selection
RSR8
Robot service request
PNS8
Program number
selection
CRM2A-10
CRM2A-11
CRM2A-12
CRM2A-13
CRM2A-14
CRM2A-15
CRM2A-16
227
Option
Option
Option
Option
Option
Option
Option
Option
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
Table4.3 Process I/O Board Signals (2/4)
(DI signals)
Connector
number
Signal name
Description
CRM2A-29
PNSTROBE
PNS strobe
CRM2A-30
PROD START
Start of automatic
operation
CRM2A-31
SDI01
CRM2A-32
SDI02
Peripheral
p
device
status
CRM2B-1
SDI03
CRM2B-2
SDI04
CRM2B-3
SDI05
CRM2B-4
SDI06
CRM2B-5
SDI07
CRM2B-6
SDI08
CRM2B-7
SDI09
CRM2B-8
SDI10
CRMSB-9
SDI11
CRM2B-10
SDI12
CRM2B-11
SDI13
CRM2B-12
SDI14
CRM2B-13
SDI15
CRM2B-14
SDI16
CRM2B-15
SDI17
CRM2B-16
SDI18
CRM2B-29
SDI19
CRM2B-30
SDI20
CRM2B-31
SDI21
CRM2B-32
SDI22
228
Remarks
General signal
B--81465EN--1/02
CONNECTIONS
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
Table4.3 Process I/O Board Signals (3/4)
(DO signals)
Connector
number
Signal name
Description
CRM2A-33
CMDENBL
During automatic
operation
CRM2A-34
SYSRDY
Preparation
completed
CRM2A-35
PROGRUN
Program running
CRM2A-36
PAUSED
Program being
interrupted
CRM2A-38
HELD
During temporary stop
CRM2A-39
FAULT
Alarm
CRM2A-40
ATPERCH
Home position
CRM2A-41
TPENBL
Teach pendant
enabled
CRM2A-43
BATALM
Battery voltage drop
CRM2A-44
BUSY
During operation
CRM2A-45
ACK1
Robot service request
acceptance
SNO1
Selected program
number
ACK2
Robot service request
acceptance
SNO2
Selected program
number
ACK3
Robot service request
acceptance
SNO3
Selected program
number
ACK4
Robot service request
acceptance
SNO4
Selected program
number
ACK5
Robot service request
acceptance
SNO5
Selected program
number
ACK6
Robot service request
acceptance
SNO6
Selected program
number
ACK7
Robot service request
acceptance
SNO7
Selected program
number
ACK8
Robot service request
acceptance
SNO8
Selected program
number
CRM2A-26
SNACK
Response signal to
PNS
CRM2A-27
RESERVED
CRM2A-46
CRM2A-19
CRM2A-20
CRM2A-21
CRM2A-22
CRM2A-24
CRM2A-25
229
Remarks
Option
Option
Option
Option
Option
Option
Option
Option
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
Table4.3 Process I/O Board Signals (4/4)
(DO signals)
Connector
number
Signal name
CRM2B-33
SDO01
CRM2B-34
SDO02
CRM2B-35
SDO03
CRM2B-36
SDO04
CRM2B-38
SDO05
CRM2B-39
SDO06
CRM2B-40
SDO07
CRM2B-41
SDO08
CRM2B-43
SDO09
CRM2B-44
SDO10
CRMSB-45
SDO11
CRM2B-46
SDO12
CRM2B-19
SDO13
CRM2B-20
SDO14
CRM2B-21
SDO15
CRM2B-22
SDO16
CRM2B-24
SDO17
CRM2B-25
SDO18
CRM2B-26
SDO19
CRM2B-27
SDO20
230
Description
Remarks
Peripheral
p
device
control signal
General signal
B--81465EN--1/02
CONNECTIONS
4.4
INTERFACE FOR
PERIPHERAL
DEVICES, END
EFFECTORS, AND
WELDERS
231
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
4.4.1
Peripheral Device and
Control Unit
Connection
Control unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Peripheral device control interface A1
CRM2A
*IMSTP
33
34
*HOLD
ACK3/SNO3
19
35
*SFSPD
20
ACK4/SNO4
36
CSTOPI
ACK5/SNO5
21
FAULT RESET
37
ACK6/SNO6
22
38
START
COM--A4
23
39
HOME
24
ACK7/SNO7
40
ENBL
25
ACK8/SNO8
RSR1/PNS1
41
26
SNACK
RSR2/PNS2
42
27
RESERVED
RSR3/PNS3
43
COM--A5
28
RSR4/PNS4
44
PNSTROBE
29
RSR5/PNS5
45
PROD START
30
46
RSR6/PNS6
31
SDI01
RSR7/PNS7
47
32
SDI02
RSR8/PNS8
48
49
0V
50
0V
Peripheral device control interface A2
CRM2B
SDI03
33
34
SDI04
SDO13
19
35
SDI05
20
SDO14
36
SDI06
21
SDO15
SDI07
37
SDO16
22
38
SDI08
COM--B4
23
39
SDI09
24
SDO17
40
SDI10
25
SDO18
SDI11
41
26
SDO19
SDI12
42
27
SDO20
SDI13
43
COM--B5
28
SDI14
44
SDI19
29
SDI15
45
SDI20
30
46
SDI16
SDI21
31
SDI17
47
32
SDI22
SDI18
48
49
0V
0V
50
CMDENBL
SYSRDY
PROGRUN
PAUSED
COM--A1
HELD
FAULT
ATPERCH
TPENBL
COM--A2
BATALM
BUSY
ACK1/SNO1
ACK2/SNO2
COM--A3
Peripheral
device A1
+24E
+24E
SDO01
SDO02
SDO03
SDO04
COM--B1
SDO05
SDO06
SDO07
SDO08
COM--B2
SDO09
SDO10
SDO11
SDO12
COM--B3
Peripheral
device A2
+24E
+24E
NOTE
1 The peripheral device connection cables are optional.
2 All of COM-** are connected to 0 V.
Applicable process I/O board type
CA, CB, DA, HA
232
CONNECTIONS
B--81465EN--1/02
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
Control unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Peripheral device control interface A3
CRM2C
SDI23
33
34
SDI24
19
SDO33
35
SDI25
20
SDO34
SDI26
36
21
SDO35
SDI27
37
22
SDO36
38
SDI28
COM--C4
23
39
SDI29
24
SDO37
40
SDI30
25
SDO38
SDI31
41
26
SDO39
SDI32
42
27
SDO40
SDI33
43
COM--C5
28
SDI34
44
SDI39
29
SDI35
45
SDI40
30
46
SDI36
SDI41
31
SDI37
47
32
SDI42
SDI38
48
49
0V
50
0V
Peripheral device control interface A4
CRM2D
SDI43
33
SDI44
SDI45
SDI46
SDI47
SDI48
SDI49
SDI54
SDI51
SDI52
SDI53
SDI54
SDI55
SDI56
SDI57
SDI58
0V
0V
19
20
21
22
23
24
25
26
27
28
29
30
31
32
SDO53
SDO54
SDO55
SDO56
COM--D4
SDO57
SDO58
SDO59
SDO60
COM--D5
SDI59
SDI60
SDI61
SDI62
34
35
36
37
38
39
40
41
42
43
44
45
46
47
SDO21
SDO22
SDO23
SDO24
COM--C1
SDO25
SDO26
SDO27
SDO28
COM--C2
SDO29
SDO30
SDO31
SDO32
COM--C3
Pripheral
device A3
+24E
+24E
SDO41
SDO42
SDO43
SDO44
COM--D1
SDO45
SDO46
SDO47
SDO48
COM--D2
SDO49
SDO50
SDO51
SDO52
COM--D3
48
49
Pripheral
device A4
+24E
+24E
50
NOTE
1 The peripheral device connection cables are optional.
2 All of COM-** are connected to 0 V.
Applicable process I/O board type
DA
233
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
Control unit
Peripheral device control interface B1
CRM4A
01
02
03
04
05
SDI63
SDI64
SDI65
SDI66
SDI67
06
07
SDI68
SDI69
08
09
10
11
12
13
SDO65
SDO66
SDO67
SDO68
COM--E2
SDI70
14
15
16
17
18
SDO61
SDO62
SDO63
SDO64
COM--E1
19
20
+24
0V
Peripheral
device B1
Control unit
Peripheral device control interface B1
CRM4B
01
02
03
04
05
06
07
SDI71
SDI72
SDI73
SDI74
SDI75
SDI76
SDI77
08
09
10
11
12
13
SDO73
SDO74
SDO75
SDO76
COM--F2
SDI78
14
15
16
17
18
19
20
SDO69
SDO70
SDO71
SDO72
COM--F1
Peripheral
device B2
+24
0V
NOTE
1 The peripheral device connection cables are optional.
2 All of COM--** are connected to 0V.
Applicable process I/O board type
DA
234
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
Control unit
(peripheral device control interface A1)
Connector pin No.
Peripheral device
+24E
CRM2A (49,50)
Receiver circuit
*IMSTP
RV
*HOLD
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
RSR7/PNS7
RV
RSR8/PNS8
RV
PNSROBE
RV
PROD START
RV
SDI01
RV
SDI02
RV
CRM2A (1)
CRM2A (2)
CRM2A (3)
CRM2A (4)
CRM2A (5)
CRM2A (6)
CRM2A (7)
CRM2A (8)
CRM2A (9)
CRM2A (10)
CRM2A (11)
CRM2A (12)
CRM2A (13)
CRM2A (14)
CRM2A (15)
CRM2A (16)
CRM2A (29)
CRM2A (30)
CRM2A (31)
CRM2A (32)
+24E
B
A
Common setting
pin (ICOM1)
NOTE
This is a connection diagram for +24v common.
235
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
Control unit
(peripheral device control interface A1)
B--81465EN--1/02
Connector pin No.
Peripheral device
LOAD
Receiver circuit
CRM2A (33)
DV
RELAY
CMDENBL
SYSRDY
DV
PROGRUN
DV
PAUSED
DV
HELD
DV
FAULT
DV
ATPERCH
TPENBL
BATALM
BUSY
CRM2A (34)
CRM2A (35)
ACK3/SNO3
DV
ACK4/SNO4
DV
ACK5/SNO5
DV
ACK6/SNO6
DV
ACK7/SNO7
DV
ACK8/SNO8
DV
SNACK
DV
RESERVED
DV
LOAD
CRM2A (40)
LOAD
CRM2A (41)
LOAD
CRM2A (43)
LOAD
CRM2A (44)
DV
DV
LOAD
CRM2A (39)
DV
ACK2/SNO2
LOAD
CRM2A (38)
DV
DV
LOAD
CRM2A (36)
DV
ACK1/SNO1
LOAD
LOAD
CRM2A (45)
LOAD
CRM2A (46)
LOAD
CRM2A (19)
LOAD
CRM2A (20)
LOAD
CRM2A (21)
LOAD
CRM2A (22)
LOAD
CRM2A (24)
LOAD
CRM2A (25)
LOAD
CRM2A (26)
LOAD
CRM2A (27)
LOAD
CRM2A(23,28,37,
42,47)
0V
+24V
+24 V regulated
power supply
236
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
Control unit
(peripheral device control interface A2)
Connector pin No.
Peripheral device
+24E
CRM2B (49,50)
Receiver circuit
SDI03
RV
SDI04
RV
SDI05
RV
SDI06
RV
SDI07
RV
SDI08
RV
SDI09
RV
SDI10
RV
SDI11
RV
SDI12
RV
SDI13
RV
SDI14
RV
SDI15
RV
SDI16
RV
SDI17
RV
SDI18
RV
SDI19
RV
SDI20
RV
SDI21
RV
SDI22
RV
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)
CRM2B (14)
CRM2B (15)
CRM2B (16)
CRM2B (29)
CRM2B (30)
CRM2B (31)
CRM2B (32)
+24E
B
A
Common setting
pin (ICOM2)
NOTE
This is a connection diagram for +24V common.
237
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
Control unit
(peripheral device control interface A2)
Peripheral device
Connector pin No.
SDO01
DV
SDO02
DV
SDO03
DV
SDO04
DV
SDO05
DV
SDO06
DV
SDO07
SDO08
SDO09
SDO10
CRM2B (33)
RELAY
CRM2B (34)
SDO13
DV
SDO14
DV
SDO15
DV
SDO16
DV
SDO17
DV
SDO18
DV
SDO19
DV
SDO20
DV
LOAD
CRM2B (39)
LOAD
CRM2B (40)
LOAD
CRM2B (41)
LOAD
CRM2B (43)
LOAD
CRM2B (44)
DV
DV
LOAD
CRM2B (38)
DV
SDO12
LOAD
CRM2B (36)
DV
DV
LOAD
CRM2B (35)
DV
SDO11
LOAD
LOAD
CRM2B (45)
LOAD
CRM2B (46)
LOAD
CRM2B (19)
LOAD
CRM2B (20)
LOAD
CRM2B (21)
LOAD
CRM2B (22)
LOAD
CRM2B (24)
LOAD
CRM2B (25)
LOAD
CRM2B (26)
LOAD
CRM2B (27)
LOAD
CRM2A(23,28,37,
42,47)
0V
+24V
+24 V regulated
power supply
238
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
Control unit
(peripheral device control interface A3)
Connector pin No.
+24E
Peripheral device
CRM2C (49,50)
Receiver circuit
SDI23
RV
SDI24
RV
SDI25
RV
SDI26
RV
SDI27
RV
SDI28
RV
SDI29
RV
SDI30
RV
SDI31
RV
SDI32
RV
SDI33
RV
SDI34
RV
SDI35
RV
SDI36
RV
SDI37
RV
SDI38
RV
SDI39
RV
SDI40
RV
SDI41
RV
SDI42
RV
CRM2C (1)
CRM2C (2)
CRM2C (3)
CRM2C (4)
CRM2C (5)
CRM2C (6)
CRM2C (7)
CRM2C (8)
CRM2C (9)
CRM2C (10)
CRM2C (11)
CRM2C (12)
CRM2C (13)
CRM2C (14)
CRM2C (15)
CRM2C (16)
CRM2C (29)
CRM2C (30)
CRM2C (31)
CRM2C (32)
+24E
B
A
Common setting
pin (ICOM3)
NOTE
This is a connection diagram for +24V common.
239
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
Control unit
(peripheral device control interface A3)
Peripheral device
Connector pin No.
SDO21
DV
SDO22
DV
SDO23
DV
SDO24
DV
SDO25
DV
SDO26
DV
SDO27
SDO28
SDO29
SDO30
CRM2C (33)
RELAY
CRM2C (34)
SDO33
DV
SDO34
DV
SDO35
DV
SDO36
DV
SDO37
DV
SDO38
DV
SDO39
DV
SDO40
DV
LOAD
CRM2C (39)
LOAD
CRM2C (40)
LOAD
CRM2C (41)
LOAD
CRM2C (43)
LOAD
CRM2C (44)
DV
DV
LOAD
CRM2C (38)
DV
SDO32
LOAD
CRM2C (36)
DV
DV
LOAD
CRM2C (35)
DV
SDO31
LOAD
LOAD
CRM2C (45)
LOAD
CRM2C (46)
LOAD
CRM2C (19)
LOAD
CRM2C (20)
LOAD
CRM2C (21)
LOAD
CRM2C (22)
LOAD
CRM2C (24)
LOAD
CRM2C (25)
LOAD
CRM2C (26)
LOAD
CRM2C (27)
LOAD
CRM2C(23,28,37,
42,47)
0V
+24V
+24 V regulated
power supply
240
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
Control unit
(peripheral device control interface A4)
Connector pin No.
+24E
Peripheral device
CRM2D (49,50)
Receiver circuit
SDI43
RV
SDI44
RV
SDI45
RV
SDI46
RV
SDI47
RV
SDI48
RV
SDI49
RV
SDI50
RV
SDI51
RV
SDI52
RV
SDI53
RV
SDI54
RV
SDI55
RV
SDI56
RV
SDI57
RV
SDI58
RV
SDI59
RV
SDI60
RV
SDI61
RV
SDI62
RV
CRM2D (1)
CRM2D (2)
CRM2D (3)
CRM2D (4)
CRM2D (5)
CRM2D (6)
CRM2D (7)
CRM2D (8)
CRM2D (9)
CRM2D (10)
CRM2D (11)
CRM2D (12)
CRM2D (13)
CRM2D (14)
CRM2D (15)
CRM2D (16)
CRM2D (29)
CRM2D (30)
CRM2D (31)
CRM2D (32)
+24E
B
A
Common setting
pin (ICOM4)
NOTE
This is a connection diagram for +24V common.
241
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
Control unit
(peripheral device control interface A4)
Peripheral device
Connector pin No.
SDO41
DV
SDO42
DV
SDO43
DV
SDO44
DV
SDO45
DV
SDO46
DV
SDO47
SDO48
SDO49
SDO50
CRM2D (33)
RELAY
CRM2D (34)
CRM2D (35)
CRM2D (36)
CRM2D (38)
CRM2D (39)
CRM2D (40)
DV
CRM2D (41)
DV
CRM2D (43)
DV
CRM2D (44)
DV
SDO51
DV
SDO52
DV
SDO53
DV
SDO54
DV
SDO55
DV
SDO56
DV
SDO57
DV
SDO58
DV
SDO59
DV
SDO60
DV
LOAD
CRM2D (45)
CRM2D (46)
CRM2D (19)
CRM2D (20)
CRM2D (21)
CRM2D (22)
CRM2D (24)
CRM2D (25)
CRM2D (26)
CRM2D (27)
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRM2D(23,28,37,
42,47)
0V
+24V
+24 V regulated
power supply
242
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
Control unit
(peripheral device control interface B1)
Connector pin No.
+24E
Peripheral device
CRM4A (19)
Receiver circuit
SDI63
RV
SDI64
RV
SDI65
RV
SDI66
RV
SDI67
RV
SDI68
RV
SDI69
RV
SDI70
RV
+24E
CRM4A (1)
CRM4A (2)
CRM4A (3)
CRM4A (4)
CRM4A (5)
CRM4A (6)
CRM4A (7)
CRM4A (13)
B
A
Common setting
pin (ICOM5)
Connector pin No.
SDO61
DV
SDO62
DV
SDO63
DV
SDO64
DV
SDO65
DV
SDO66
DV
SDO67
SDO68
LOAD
CRM4A (14)
RELAY
CRM4A (15)
CRM4A (16)
CRM4A (17)
CRM4A (8)
CRM4A (9)
CRM4A (10)
DV
CRM4A (11)
DV
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRM4A (20)
0V
+24V
+24 V regulated
power supply
NOTE
This is a connection diagram for +24V common.
243
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
Control unit
(peripheral device control interface B2)
B--81465EN--1/02
Connector pin No.
+24E
Peripheral device
CRM4B (19)
Receiver circuit
SDI71
RV
SDI72
RV
SDI73
RV
SDI74
RV
SDI75
RV
SDI76
RV
SDI77
RV
SDI78
RV
+24E
CRM4B (1)
CRM4B (2)
CRM4B (3)
CRM4B (4)
CRM4B (5)
CRM4B (6)
CRM4B (7)
CRM4B (13)
B
A
Common setting
pin (ICOM5)
Connector pin No.
SDO69
DV
SDO70
DV
SDO71
DV
SDO72
DV
SDO73
DV
SDO74
DV
SDO75
DV
SDO76
DV
LOAD
CRM4B (14)
RELAY
CRM4B (15)
CRM4B (16)
CRM4B (17)
CRM4B (8)
CRM4B (9)
CRM4B (10)
CRM4B (11)
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRM4B (20)
0V
+24V
+24 V regulated
power supply
NOTE
This is a connection diagram for +24V common.
244
CONNECTIONS
B--81465EN--1/02
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
4.4.2
Connection Between
the Mechanical Unit
and End Effector
EE
Fig.4.4.2 In case of the R--2000i (For other robots, referto the each maintenance manual.)
245
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
RDI9
(Pneumatic pressure
abnormal signal)
(COM1)
NOTE
1 This is a connection diagram for +24V common.
2 The common--level change--over setting pin (COM1) is in
the 6--axis servo amplifier.
246
CONNECTIONS
B--81465EN--1/02
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
4.4.3
Connection Between
the Control Unit and
Welder
Control unit
Welder interface
CRW1
Welder
Analog input interface
CRW2
Peripheral device
NOTE
Welder and peripheral device connection cable are optional.
Applicable process I/O board type
CA
247
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
Wire speed
command signal
Welding voltage
detection signal
B--81465EN--1/02
Welder
Control unit
(Welding interface)
Process I/O CA
Welding voltage
command signal
CONNECTIONS
Connector pin number
COMDA1
MS connector pin number
The input impedance
shall be more than 3.3kΩ
high--pass filter shall be
provided.
COMDA2
COMAD1
Output signals
without ripples.
Welding current
detector signal
COMAD2
R=100Ω or more
Wire stick
detection signal
Welding power supply
248
CONNECTIONS
B--81465EN--1/02
Control unit
(Welding interface)
Process I/O CA
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
Welder
Welding start
signal
WD01
Gas signal
WD02
CRWI (25)
T
WD06
CRWI (28)
W
WD07
CRWI (29)
X
WD08
CRWI (30)
Z
WD03
Wire inching
(positive) signal
WD04
Wire inching
(negative) signal
WD05
a, m
b, n
+24V regulated
power supply
Receiver circuit
WDI1
Arc detection
signal
WDI2
Gas shortage
detection signal
WDI3
Wire cut
detection signal
WDI4
CRWI (5)
c
CRWI (11)
j
CRWI (12)
k
Cooling water
WDI5
shortage detection
signal
WDI6
Welding power
supplu abnomality
signal
WDI7
WDI8
Common switching
set pin
CRWI (33,34)
FG (cabinet ground)
Shield
NOTE
This is the connection for +24V.
249
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
Peripheral device
Control unit
(Analog input interface)
Process I/O CA
COMAD3
COMAD4
Output signals without
ripples.
COMAD5
COMAD6
250
CONNECTIONS
B--81465EN--1/02
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
Control unit
Welder interface
CRW7
Welder
NOTE
Welder and peripheral device connection cable is option.
Applicable process I/O board type
HA
251
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
Control unit (welding interface)
Process I/O HA
B--81465EN--1/02
Welding machine
MS connector pin numbers
Connector pin numbers
Welding voltage
command signal
0 V for analog output
CRW7 (1)
DACH (1)
CRW7 (2)
COMDA
Wire speed command
DACH (2)
signal
0 V for analog output
CRW7 (3)
CRW7 (4)
COMDA
Arc
WDI (2)
RV
No arc
(power supply error)
WDI (6)
RV
A
B
C
D
CRW7 (6)
P
CRW7 (10)
R
+24V
B
No gas
WDI (3)
No wire
WDI (4)
+24V
Welding start signal
DO common
Wire inching (+)
DO common
Wire inching (--)
DO common
WDO (1)
WCOM (1)
WDO (4)
WCOM (4)
WDO (5)
WCOM (5)
WDI +
Wire stick
detection signal
WDI --
A
CRW7 (7)
T
CRW7 (8)
S
CRW7 (33, 34)
E
CRW7 (23)
CRW7 (24)
CRW7 (29)
CRW7 (30)
CRW7 (13)
CRW7 (14)
L
K
F
G
H
J
CRW7 (31)
M
CRW7 (32)
N
NOTE
This is the connection for +24V.
252
+
--
B--81465EN--1/02
4.5
DIGITAL I/O SIGNAL
SPECIFICATIONS
4.5.1
Peripheral Device
Interface
CONNECTIONS
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
This section describes the specifications of the digital I/O signals
interfaced with the peripheral device, end effector, and arc welder.
(1) Output signals in peripheral device interface A
Example of connection
Spark killer diode
+24V
0.2 A
or less
0V
+24V
Lamp
0.2 A
or less
0V
Protective resistance
Electrical specifications
Rated voltage
Maximum applied voltage
Maximum load current
Transistor type
Saturation voltage at connection
:
:
:
:
:
Spark killer diode
Rated peak reverse voltage
Rated effective forward current
: 100 V or more
: 1 A or more
24 VDC
30 VDC
0.2 A
Open collector NPN
1.0 V (approx.)
NOTE
Do not use the +24 V power supply of the robot.
When you load a relay, solenoid, and so on directly, connect
them in parallel with diodes to prevent back electromotive
force.
If a load is connected causing a surge current when a lamp
is turned on, use a protective resistance.
Applicable signals
Output signals of process I/O board CRM2 and CRM4
CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT,
ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNO1 to
SNO8, SNACK, SDO1 to SDO76
253
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
(2) Input signals in peripheral device interface A
Example of connection
+24V
RV
3.3 kΩ
+24V
B
A
ICOM
Electrical specifications of the receiver
Type
: Grounded voltage receiver
Rated input voltage
: Contact close
: +20 V to +28 V
Contact open
: 0 V to +4 V
Maximum applied input voltage : +28 VDC
Input impedance
: 3.3 kΩ (approx.)
Response time
: 5 ms to 20 ms
Specifications of the peripheral device contact
Rated contact capacity
: 30 VDC, 50 mA or more
Input signal width
: 200 ms or more (on/off)
Chattering time
: 5 ms or less
Closed circuit resistance
: 100 Ω or less
Opened circuit resistance
: 100 kΩ or more
TB
(Signal)
TB
(Signal)
TB
Peripheral device
contact signal
Robot receiver signal
TC
TC
TB ;
TC ;
Chattering 5 ms or less
5 to 20 ms
NOTE
Apply the +24 V power at the robot to the receiver.
However, the above signal specifications must be satisfied
at the robot receiver.
Applicable signals
Input signals of process I/O board CRM2 and CRM4
*IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET, START,
HOME, ENBL, RSR1 to RSR8, PNS1 to PNS8, PNSTROBE,
PROD START, SDI1 to SDI78
254
B--81465EN--1/02
CONNECTIONS
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
4.5.2
End Effector Control
Interface
(1) Output signals
Example of connection
Spark killer diode
+24V
0.2 A
or less
0V
+24V
Lamp
0.2 A
or less
0V
Protective resistance
Electrical specifications
Rated voltage
Maximum applied voltage
Maximum load current
Transistor type
Saturation voltage at connection
:
:
:
:
:
Spark killer diode
Rated peak reverse voltage
Rated effective forward current
: 100 V or more
: 1 A or more
24 VDC
30 VDC
0.2 A
Open collector NPN
1.0 V (approx.)
NOTE
The +24 V power supply at the robot can be used when the
total current of the welding interface and end effector
interface is 0.7 A or less.
When you load a relay, solenoid, and so on directly, connect
them in parallel with diodes to prevent back electromotive
force.
If a load is connected causing a surge current when a lamp
is turned on, use a protective resistance.
Applicable signals
Output signals of the end effector control interface RDO1 to RDO8
255
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
(2) Input signal
Example of connection
+24V
RV
3.3 kΩ
+24V
B
A
COM1
Electrical specifications of the receiver
Type
:
Rated input voltage : Contact close :
Contact open
:
Maximum applied input voltage
:
Input impedance
:
Response time
:
Grounded voltage receiver
+20 V to +28 V
0 V to +4 V
+28 VDC
3.3 kΩ (approx.)
5 ms to 20 ms
Specifications of peripheral device contact
Rated contact capacity
: 30 VDC, 50 mA or more
Input signal width
: 200 ms or more (on/off)
Chattering time
: 5 ms or less
Closed circuit resistance
: 100 Ω or less
Opened circuit resistance
: 100 kΩ or more
TB
(Signal)
TB
(Signal)
TB
Peripheral device
contact signal
Robot receiver signal
TC
TC
TB ;
TC ;
Chattering 5 ms or less
5 to 20 ms
NOTE
Apply the +24 V power at the robot to the receiver.
However, the above signal specifications must be satisfied
at the robot receiver.
Applicable signals
Input signals of the end effector control interface
RDI1 to RDI8, *HBK, *PPABN
256
B--81465EN--1/02
CONNECTIONS
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
4.5.3
I/O Signal
Specifications for
ARC--Welding Interface
(1) Digital output signal specifications for an arc welding interface
In case of process I/O CA
Example connection
Spark killer diode
0.2 A or
less
Electrical characteristics
Rated voltage
Maximum applied voltage
Maximum load current
Transistor type
Saturation voltage at on
:
:
:
:
:
24 VDC
30 VDC
0.2 A
Open--collector NPN
About 1.0 V
Spark killer diode
Rated peak reverse voltage
: 100 V or more
Rated effective forward current : 1 A or more
NOTE
A power voltage of +24 V, provided for the robot, can be
used for interface signals of up to 0.7 A. This limit applies
to the sum of the currents flowing through the arc--welding
and end--effector control interfaces. To drive a relay or
solenoid directly, connect a diode preventing back
electromotive force to the load in parallel. To connect a load
which generates an inrush current when you turn on the
control unit, connect a protective resistor.
Applicable signals
-- Output signals on the arc--welding interface
-- WDO1 to WDO8
257
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
In case of process I/O HA
Example connection
Spark killer diode
0.3 A or
less
Electrical characteristics
Rated voltage
Maximum applied voltage
Maximum load current
Output type
:
:
:
:
24 VDC
30 VDC
0.3 A
Relay connect output
Spark killer diode
Rated peak reverse voltage
: 100 V or more
Rated effective forward current : 1 A or more
NOTE
Do not use the +24 V power supply of the robot.
When you load a relay, solenoid, and so on directly, connect
them in parallel with diodes for preventing back
electromotive force.
If a load is connected causing a surge current when a lamp
is turned on, use a protective resistance.
Applicable signals
-- Output signals on the arc--welding interface
-- WDO1 to WDO4
258
B--81465EN--1/02
CONNECTIONS
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
(2) Digital input signal specifications for arc welding interface
Example connection
Electrical characteristics of receivers
Type: Grounded voltage receiver
Rated input voltage
: +20 to +28 V with contacts closed
0 to +4 V when open
Maximum input voltage : +28 VDC
Input impedance
: About 3.3 k
Response time
: 5 to 20 ms
Contact specifications for peripherals
Rated contact capacity
: 30 VDC, 50 mA or more
Input signal width
: 200 ms or more for on and off states
Chattering period
: 5 ms or less
Closed--circuit resistance : 100 or less
Open--circuit resistance : 100 k or more
(Signal)
(Signal)
Contact signal
for peripheral
Receiver
signal for robot
TB: Chattering of 5 ms or less
TC: 5 to 20 ms
NOTE
Supply the +24 V power, provided for the robot, to the
receivers. The receiver signal on the robot must satisfy the
signal timing specified above.
Applicable signals
-- Input signals for arc welding interface
-- WDI1 to WDI8
259
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
(3) Analog output signal specifications for arc welding interface
(Welding voltage command, wire--feed rate command)
Example connection
Welder
Process I/O CA, EA : --10V to +10V
Process I/O GA, HA : 0V to +15V
0V
NOTE
Input impedance: 3.3 kΩ or more
Connect a high--pass filter.
(4) Analog input signal specifications for arc welding interface
(Welding--voltage detection, welding--current detection)
Example connection
Welder
--10V to +10V
0V
NOTE
The analog input signal should have no ripple for the circuit
to operate properly.
(Wire deposit detection: WDI+ and WDI--)
Example connection
Welder
Welding electrode
NOTE
Connect a resistor of 100Ω or more between the positive
and negative electrodes of the welder. Isolate the deposit
detection signals for TIG welding from the welding circuit,
which uses high--frequency components. The dielectric
withstand voltage of this circuit is 80 V.
260
CONNECTIONS
B--81465EN--1/02
4.6
SPECIFICATIONS OF
THE CABLES USED
FOR PERIPHERAL
DEVICES AND
WELDERS
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
If the customer manufactures cables, conform to the FANUC standard
cables described in this section.
(See the description in “Peripheral Device Interface” in this manual for
the specifications of the FANUC standard cables.)
4.6.1
Peripheral Device
Interface A Cable
(CRM2: Honda
Tsushin, 50 pins)
Honda Tsushin
MR50LM01
(MR50LM)
Honda Tsushin
MR50LWF01
(MR50LF)
Peripheral
device
Process I/O
Honda Tsushin
MR50RMA
Honda Tsushin’s MR50RF
Supplied with an ordered cable
4.6.2
Peripheral Device
Interface B Cable
(CRM4: Honda
Tsushin, 20 pins)
Honda Tsushin
MR20LM01
(MR20LM)
Honda Tsushin
MR20LWF01
(MR20LF)
Peripheral
device
Process I/O
CRM4*
Honda Tsushin
MR20RMA
Honda Tsushin’s MR20RF
Supplied with an ordered cable
261
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
4.6.3
CONNECTIONS
B--81465EN--1/02
Be sure to use our cable to connect the welder.
ARC Weld Connection
Cable (CRW1: Honda
Tsushin, 34 pins)
ARC welder
Honda Tsushin
Process I/O
CRW1
or
CRW7
Honda Tsushin
MR34RFA
Japan Aviation Electronics
Industry Ltd.
MS3108B28--21P
MS3057--16
262
Japan Aviation Electronics
Industry Ltd.
MS3102A28--21S
Standard position of guide key
CONNECTIONS
B--81465EN--1/02
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
4.7
CABLE
CONNECTION FOR
THE PERIPHERAL
DEVICES, END
EFFECTORS, AND
ARC WELDERS
4.7.1
Peripheral Device
Connection Cable
Fig. 4.7.1 shows the connection of the peripheral device cable in the
cabinet.
B cabinet
CRM2A
CRM2B
Metallic clamp
External shield
To peripheral
device
Process I/O
CRW1 or CRW7
Shield plate
Noise protection: Remove a part of the sheath of a peripheral cable to expose the outside shield.
Secure the cable to the shield plate with the metallic clamp at the exposed position.
Fig.4.7.1 Peripheral Device Cable Connection
263
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
4.7.2
Peripheral Device
Cable Connector
(1) Fig. 4.7.2 shows the connector for peripheral device cables A and B.
Connector
specifications
Applicable
interface
MR50LM
MR20LM
Dimensions
Remark
A
(B)
C
CRM2
67.9
73.5
44.8
18
Honda Tsushin Kogyo,
50 pins
CRM4
39.3
44.9
39.8
17
Honda Tsushin Kogyo,
20 pins
Symbol
(D)
Name
¡
Connector cover
©
Cable clamp screw
¢
Connector clamp spring
£
Connector clamp screw
¤
Connector
50 pins (male) MR50M
20 pins (male) MR20M
Fig.4.7.2 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo)
264
CONNECTIONS
B--81465EN--1/02
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
(2) Peripheral device connector
Connector
specifications
Applicable
interface
MR50RF
MR20RF
Dimensions
Remark
A
B
(CRM2)
61.4
56.4
Honda Tsushin Kogyo,
50 pins
(CRM4)
39.3
44.9
Honda Tsushin Kogyo,
20 pins
Symbol
Name
¡
Connector clamp screw
©
Screw M2.6×8
¢
Connector
(MR50RF)
(MR20RF)
Fig.4.7.2 (b) Peripheral Device Connector (Honda Tsushin Kogyo)
265
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
4.7.3
End Effector Cable
Connector
(1) Connector external view (For R--2000iA. Refer to the each maintenance
manual for other robots.)
A :
M30¢1
E :
ø33
B :
63.0
F :
11.2
C :
54.5
G :
24.7
D :
9.6 to 15.0 (Inside diameter)
Manufactured by Daiichi Denshi Kogyo JMLP2524M
Fig.4.7.3 (a) Connector (Elbow Type)
A :
M30¢1
E :
ø33
B :
54.1
F :
11.2
C :
37.5
G :
24.7
D :
9.6 to 15.0 (Inside diameter)
Manufactured by Daiichi Denshi Kogyo JMLP2524M
Fig.4.7.3 (b) Connector (Straight Type)
266
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
4.7.4
Recommended Cables
(1) Peripheral device connection cable
Connect a peripheral device using a completely shielded, heavily
protected cable conforming to the specifications in Table 4.7.4 (a).
Allow an extra 50 cm for routing the cable in the control unit.
The maximum cable length is 30 m.
Table 4.7.4 (a) Recommended Cable (for Peripheral Device Connection)
Conductor
Number
of wires
Wire specifications
(FANUC specifications)
Diameter
(mm)
Configuration
Sheath
thickness
(mm)
Electrical characteristics
Effective
outside
diameter
(mm)
Conductor
resistance
(Ω/km)
Allowable
current
(A)
50
A66L-0001-0042
ø1.05
7/0.18
AWG24
1.5
ø12.5
106
1.6
20
A66L-0001-0041
ø1.05
7/0.18
AWG24
1.5
ø10.5
106
1.6
(2) End effector connection cable
Connect an end effector using a heavily protected cable with a
movable wire conforming to the specifications in Table 4.7.4 (b).
The cable length is determined so that the cable will not interfere with
the end effector and the wrist can move through its full stroke.
Table 4.7.4 (b) Recommended Cable (for End Effector Connection)
Conductor
Number
of wires
Wire specifications
(FANUC specifications)
Diameter
(mm)
Configuration
Sheath
thickness
(mm)
Effective
outside
diameter
(mm)
Electrical characteristics
Conductor
resistance
(Ω/km)
Allowable
current
(A)
6
A66L-0001-0143
ø1.1
40/0.08
AWG24
1.0
ø5.3
91
3.7
20
A66L-0001-0144
ø1.1
40/0.08
AWG24
1.0
ø8.6
91
2.3
267
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
4.8
CONNECTION OF HDI
4.8.1
Connecting HDI
The HDI signals are used in combination with special application
software. The HDI signals cannot be used as general--purpose DIs.
Main board
JRL5
R--J3iB
Main board
JRL5
1
HDI0
11
2
0V
12
HDI1
0V
3
HDI2
13
HI3
4
0V
14
0V
5
0V
15
HDI5
6
HDI4
16
0V
7
17
HDI6
8
18
0V
9
19
HDI7
10
20
0V
268
B--81465EN--1/02
CONNECTIONS
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
Cable connections
JRL5
HDI0
0V
HDI1
0V
HDI2
0V
HDI3
0V
HDI4
0V
HDI5
0V
HDI6
0V
HDI7
0V
1
2
11
12
3
4
13
14
6
5 or 10
15
16
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)
269
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
4.8.2
Input Signal Rules for
the High--speed Skip
(HDI)
Circuit configuration
R--J3iB
liL/liH FILTER
DRIVER
RECEIVER
VH/VL
SHIELD
Absolute maximum rating
Input voltage range Vin: --3.6 to +10.0 V
Input characteristics
Unit
Symbol
Specification
High level input voltage
VH
3.6 to 7
V
Low level input voltage
VL
0 to 1.0
V
High level input current
liH
2 max
mA
Vin=5 V
11 max
mA
Vin = 10 V
--8.0 max
mA
Vin = 0 V
Input signal pulse duration
20 min
μs
Input signal delay or variations
0.02(max)
ms
Low level input current
liL
Unit
Remark
NOTE
1 The plus (+) sign of IiH/IiL represents the direction of flow
into the receiver. The minus (--) sign of IiH/IiL represents the
direction of flow out of the receiver.
2 The high--speed skip signal is assumed to be 1 when the
input voltage is at the low level and 0 when it is at the high
level.
270
B--81465EN--1/02
CONNECTIONS
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
4.9
CONNECTING THE
COMMUNICATION
UNIT
4.9.1
RS--232--C Interface
4.9.1.1
Interface
This interface can be connected to a handy file or another communication
unit from FANUC.
RS--232--C port
271
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
R--J3iB
Operator’s panel
connector
(DBM--25S)
Main board
i
i
h
1
2
3
4
5
6
7
8
9
10
11
12
13
FG
SD
RD
RS
CS
DR
SG
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.
4.9.1.2
RS--232--C Interface
Signals
Generally signals as follows are used in RS--232--C interface.
R--J3iB
Output
SD (Send data)
Input
RD (Recieve data)
RS (Request to Send)
When CS is not used
short CS and RS.
CS (Enable to send)
ER (Ready)
DR (Data set ready)
SG (Signal ground)
FG (Frame ground)
Fig.4.9.1.2 RS--232--C interface
272
When DR is not
used short DR
and ER.
B--81465EN--1/02
4.9.1.3
Connection between
RS--232--C Interface and
External Device
CONNECTIONS
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
The figure below shows a connection with the handshaking of the ER and
DB signals.
R--J3iB
273
SD
SD
RD
RD
RS
RS
CS
CS
ER
ER
DR
DR
CD
CD
SG
SG
FG
FG
External device
side
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
D The figure below shows a connection without the handshaking of the
ER and DB signals.
R--J3iB
SD
SD
RD
RD
RS
RS
CS
CS
ER
ER
DR
DR
External device
side
CD
SG
SG
FG
FG
Prepare the cable as follows :
R--J3iB
SD
RD
RS
CS
SG
ER
DR
Cable : twist 10 pairs
274
× 0.18mm2, with shield
B--81465EN--1/02
CONNECTIONS
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
4.9.2
Ethernet Interface
CAUTION
Before connecting or disconnecting cables to and from the
Ethernet board, cut the power supply of R--J3iB, and make
sure that the power is off.
NOTE
Please inqure of each manufacturer about the network
construction or the condition of using the equipment except
the Ethernet board (hub, transceiver, cable etc.). When
configuring your network, you must take other sources of
electrical noise into consideration to prevent your network
from being influenced by electrical noise. Make sure that
network wiring is sufficiently separated from power lines
and other sources of electrical noise such as motors, and
ground each of the devices as necessary. Also, a high and
insufficient ground impedance may cause interference
during communications. After installing the machine,
conduct a communications test before you actually start
operating the machine.
We cannot ensure operation that is influenced by network
trouble caused by a device other than the main board.
275
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
4.9.2.1
Connection to Ethernet
CONNECTIONS
B--81465EN--1/02
The main board is provided with a 10/100 BASE--T interface.
Prepare a hub for connecting the Ethernet board to the Ethernet trunk.
The following shows an example of a general connection.
S
S
S
R--J3iB
Some devices (hub, transceiver, etc.) that are needed for building a
network do not come in a dust--proof construction. Using such devices in
an atmosphere where they are subjected to dust or oil mist will interfere
with communications or damage the Ethernet board. Be sure to install
such devices in a dust--proof cabinet.
276
CONNECTIONS
B--81465EN--1/02
4.9.2.2
10/100 BASE--T
Connector (CD38) Pin
Assignments
CD38
Pin No.
Signal Name
1
TX+
Send +
2
TX--
Send --
3
Cable Connection
Description
RX+
Receive +
4
Not used
5
Not used
6
4.9.2.3
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
RX--
Receive --
7
Not used
8
Not used
The figure below shows the cable connection between the 10/100
BASE--T connector (CD38) of the main board and hub.
10/100BASE--T connector
D For details on shielding, see “4.9.2.6 Cable clamp and shielding”.
D Keep the total cable length to within 100 m.
Do not extend the cable longer than necessary.
277
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
4.9.2.4
Lead Materials
CONNECTIONS
B--81465EN--1/02
Unshielded cable (UTP cable) is commercially available as 10/100
BASE--T twisted--pair cable. However, be sure to use shielded Category
5 twisted--pair cable (STP) to improve the resistance to electrical noise in
an FA environment. (For details on shielding, see “4.9.2.6 Cable clamp
and shielding.”
Recommended Cable
Manufacturer
Specification
Furukawa Electric Co., Ltd.
DTS5087
Nissei Electric Co., Ltd.
F--4PFWMF
Inquiries
Manufacturer
Contact Address
Furukawa Electric Co., Ltd.,
Sales Headquarters
Maru--no--uchi 2--6--1, Chiyoda--ku.
Tokyo 100--8322
TEL: 03--3286--3126
FAX: 03--3286--3979
Remarks
Nissei Electric Co., Ltd.,
Machida Branch
3F MU Bldg., Minami--narise 1--9--1,
Machida City, Tokyo 194--0045
TEL: 0427--29--2153
FAX: 0427--29--3375
Overseas Sales Office NISSEI ELECTRIC CO., LTD
1509 Okubo--cho, Hamamatsu--shi
Shizuoka--ken, 432--8006 Japan
TEL: 053--485--4114
FAX: 053--485--6908
E--mail: KYH05470@niftyserve.or.jp
Remarks Cables with connectors at both ends
can be supplied.
NOTE
The recommended cables cannot be connected to movable
portions.
Recommended Cable (For movable parts)
Manufacturer
Specification
Remarks
Oki Electric Cable Co., Ltd.
AWG26 4P TPMC--C5--F(SB)
FANUC--specific
cable
Cable specifications (FANUC--specific cable No connector)
Drawing number: A66L--0001--0453
Manufacturer: Oki Electric Cable Co., Ltd.
Nagano Sales Office TEL: 0266--27--1597
278
B--81465EN--1/02
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
Specifications
D Electric characteristics: Conform to EIA/TIA 568A categories 3 and 5.
For reasons related to attenuation performance, the distance to the hub
must be 50 m or shorter.
D Structure: Common shield cable (braided shield). Drain wire provided.
The conductor is AWG26 annealed copper stranded wire. The sheath
thickness is 0.8 mm. The outside diameter is 6.70.3 mm.
D Flame resistance: UL1581 VW--1
D Oil resistance: Based on the FANUC standard.
(equivalent to the conventional oil--resistant electric cables)
D Flexing resistance: 1 million times or more with 50 mm of a bend
radius (U--shape flexing test)
D UL style No.: AWM 20276 (80°C/30 V/VW--1)
NOTE
Always use connector TM21CP--88P(03) manufactured by
Hirose Electric for this cable.
Cable assembly
Oki Electric Cable Co., Ltd. also supplies cable
assemblies
using
connector
TM21CP--88P(03)
manufactured by Hirose Electric. Make arrangements
directly with the manufacturer for the specifications
(length, outgoing inspection, packing, and others) and
purchase cable assemblies.
Contact point: Oki Electric Cable Co., Ltd.
Sales contact point) Nagano Sales Office
TEL: 0266--27--1597
4.9.2.5
Connector Specification
As a connector used with a twisted pair cable for Ethernet, an 8--bit
modular connector called RJ--45 is used. Use the following connector or
equivalent:
Specification
Manufacturer
For solid wire
5--569530--3
AMP Japan, Ltd.
For solid wire
MS8--RSZT--EMC
SK KOHKI Co., Ltd.
For twisted wire
5--569552--3
AMP Japan, Ltd.
For twisted wire
TM11AP--88P
Hirose Electric Co., Ltd.
For movable parts
For cable AWG26 4P
TPMC--C5--F(SB)
279
Specification
TM21CP--88P(03)
Remarks
Special tool required
Special tool required
Manufacturer
Hirose Electric Co., Ltd.
Remarks
(Note)
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
NOTE
TM21CP--88P(03)
Connector (manufacturer standard part)
Drawing number: A63L--0001--0823#P
Manufacturer: Hirose Electric Co., Ltd.
Manufacturer catalog number: TM21CP--88P(03)
Conforms to EIA/TIA 568A categories 3 and 5.
For how to assemble the connector and cable, contact
Hirose Electric.
(Hirose Electric technical document “TM21CP--88P(03)
Connection Procedure Specifications”
(technical specification No. ATAD--E2367) is available.)
4.9.2.6
Shield the cables as like as other cables are shielded. (See 4.7.1)
Cable Clamp and
Shielding
280
B--81465EN--1/02
4.9.2.7
Grounding the Network
CONNECTIONS
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
Even if the grounding conditions on the machine are satisfied, electrical
noise from the machine sometimes enters the communications line and
causes communications interference depending on the installation
conditions and the peripheral environment of the machine. To prevent the
entry of such electrical noise, separating and insulating the machine from
the Ethernet trunk cable and the personal computer effectively reduces the
influence of electrical noise.
The following figure shows an example of such a connection.
Electrically separated
by 10/100 BASE--T
cable connection
Large--scale Network
Electrically separated
by 10/100 BASE--T
cable connection
Small--scale Network
281
4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES
CONNECTIONS
B--81465EN--1/02
NOTE
1 The ground between the PC/Trunk line side and machine
system side must be separated. If it is impossible to
separate the ground because there is only one grounding
point, connect the ground cable for each system to the
grounding point independently. (Refer Fig.1)
The resistance for grounding must be less than 100--ohm
(Class 3).
The thickness of the ground cable is the same as the
thickness of AC power cable or more. At least thickness of
5.5mm2 is necessary.
2 Please use the HUB that has unshielded interface
connector. FANUC recommends the HCN--7500
(Hitachi--Densen LTD) or equivalent.
3 There is the possibility that noise makes the obstacle of
communication even if the ground is separated using the
10/100 BASE--T. In the case of using the Ethernet board
under the worst environment, please separate between the
PC/Trunk line side and machine system side completely
using the 10/100 BASE--FL (Optical fiber media).
Fig.4.9.2.7 Wiring on a Single Ground Point
282
B--81465EN--1/02
5
CONNECTIONS
5. TRANSPORTATION AND
INSTALLATION
TRANSPORTATION AND INSTALLATION
283
5. TRANSPORTATION AND
INSTALLATION
5.1
TRANSPORTATION
CONNECTIONS
B--81465EN--1/02
This section describes the transportation and installation for the control
unit.
The control unit is transported by a crane. Attach a strap to eye bolts at
the top of the control unit.
B--cabinet
Fig.5.1 Transportation
284
B--81465EN--1/02
CONNECTIONS
5. TRANSPORTATION AND
INSTALLATION
5.2
INSTALLATION
5.2.1
Installation Method
Following is the installation method for B--cabinet.
When installing the control unit, allow the space for maintenance shown
in the following figure.
Fig.5.2.1 (a) External dimension
285
5. TRANSPORTATION AND
INSTALLATION
CONNECTIONS
B--81465EN--1/02
300
100
Controller
740
100
Controller
Controller
550
100
1000
Fig.5.2.1 (b) Installation Method (B--cabinet)
286
B--81465EN--1/02
5. TRANSPORTATION AND
INSTALLATION
CONNECTIONS
5.2.2
Assemble at
installation
Teach pendant
R--3iB controller
Input power connection cable
Peripheral device connection cable
Robot connection cable
Fig.5.2.2 (a) Assemble at Installation (B--cabinet)
287
5. TRANSPORTATION AND
INSTALLATION
CONNECTIONS
B--81465EN--1/02
5.3
INSTALLATION
CONDITION
Item
Model
Specifications/condition
Transformer
All models
I 440--480, 500--575 VAC (+10%--15%)
II 380--415, 440--500 VAC (+10%--15%)
III 200--230, 380--400 VAC (+10%--15%)
50/60Hz1Hz 3phases
Input
p p
power source capacity
p
y
R--2000iA
12KVA
M--6iB
ARC Mate100iB
2.5KVA
R--2000iA
2.5KW
M--6iB
ARC Mate100iB
1.0KW
Permissible ambient
temperature
All models
0 to 45 ºC during operation, and --20 to 60ºC during shipment and storage with a temperature coefficient of
1.1ºC/min
Permissible ambient
humidity
All models
Relative humidity: 30% to 95%, non--condensing
Surrounding gas
All models
An additional protective provision is necessary if the machine is installed in an environment in which there are relatively large amounts of contaminants (dust, dielectric fluid,
organic solvent, acid, corrosive gas, and/of salt).
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 nonionized radiation
Common to all 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).
Mass of control unit
A--cabinet
Approx. 120kg
B--cabinet
Approx. 180kg
Average
g power
p
consumption
p
NOTE
During rapid acceleration, robot power draw can be several
times the continuous rating value.
288
CONNECTIONS
B--81465EN--1/02
5.4
ADJUSTMENT AND
CHECKS AT
INSTALLATION
5. TRANSPORTATION AND
INSTALLATION
Adjust the robot according to the following procedure at installation.
No.
Description
1
Visually check the inside and outside of the control unit.
2
Check the screw terminals for proper connection.
3
Check that the connectors and printed circuit boards are firmly connected.
4
Check transformer tap setting. (See II MAINTENANCE section 6.2)
5
The breaker off and connect the input power cable.
6
Check the input power voltage and transformer outputs.
7
Press the EMERGENCY STOP button on the operator panel and turn on
the control unit.
8
Check the interface signals between control unit and robot mechanical
unit.
9
Check the parameters. If necessary, set them.
10
Release the EMERGENCY STOP button on the operator panel. Turn on
the controller.
11
Check the movement along each axis in manual jog mode.
12
Check the end effector interface signals.
13
Check the peripheral device control interface signals.
289
5. TRANSPORTATION AND
INSTALLATION
5.5
RESETTING
OVERTRAVEL AND
EMERGENCY STOP
AT INSTALLATION
5.5.1
Peripheral Device
Interface Processing
CONNECTIONS
B--81465EN--1/02
An overtravel and emergency stop occur when the robot is operated for
the first time after it is installed and the mechanical and control units are
wired. This section describes how to reset the 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.
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 Overtravel
1) Select [OT release] on the overtravel release screen to release each
robot axis from the overtravel state.
2) Hold down the shift key, and press the alarm release button to reset
the alarm condition.
3) Still hold down the shift key, and jog to bring all axes into the movable
range.
290
5. TRANSPORTATION AND
INSTALLATION
CONNECTIONS
B--81465EN--1/02
5.5.3
1)
2)
3)
4)
5)
How to Disable/Enable
HBK
Press [MENUS] on the teach pendant.
Select [NEXT].
Select [SYSTEM].
Press “F1” (TYPE) on the teach pendant.
Select “Config” to disable/enable HBK.
Status
Hand Broken enable/
disable setting
HBK (*1)
HBK detection
Robot operation
Message
1
Enable
CLOSE
Yes
Possible
None
2
Enable
OPEN
Yes
Impossible
SRVO--006
3
Disable
CLOSE
Yes(*2)
Possible
None
4
Disable
OPEN
No
Possible
At cold start, SRVO--300
Notes
1 Robot end effector connector
CLOSE
OPEN
24V
24V
*HBK
*HBK
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.
291
5. TRANSPORTATION AND
INSTALLATION
5.5.4
How to Disable/Enable
Pneumatic Pressure
Alarm (PPABN)
CONNECTIONS
1)
2)
3)
4)
5)
Press [MENU] on the teach pendant.
Select [NEXT].
Select [SYSTEM].
Press “F1” (TYPE) on the teach pendant.
Select “Config” to disable/enable PPABN.
292
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APPENDIX
B--81465EN--1/02
A
APPENDIX
TOTAL CONNECTION DIAGRAM
295
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (a) Total connection diagram (B--cabinet)
296
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B--81465EN--1/02
APPENDIX
297
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (b) Transformer type I (B--cabinet) (1/3)
298
B--81465EN--1/02
B--81465EN--1/02
APPENDIX
A. TOTAL CONNECTION DIAGRAM
Fig.A (b) Transformer type II (B--cabinet) (2/3)
299
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (b) Transformer type III (B--cabinet) (3/3)
300
B--81465EN--1/02
B--81465EN--1/02
APPENDIX
Fig.A (c) Power supply unit
301
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (d) Main CPU
302
B--81465EN--1/02
B--81465EN--1/02
APPENDIX
A. TOTAL CONNECTION DIAGRAM
Fig.A (e) E--stop unit (B--cabinet, 1/2)
303
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (e) E--stop unit (B--cabinet, 2/2)
304
B--81465EN--1/02
B--81465EN--1/02
APPENDIX
A. TOTAL CONNECTION DIAGRAM
Fig.A (f) 6--axis servo amplifier (1/2)
305
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (f) 6--axis servo amplifier (2/2)
306
B--81465EN--1/02
B--81465EN--1/02
APPENDIX
A. TOTAL CONNECTION DIAGRAM
Fig.A (g) Motor power connection (R--2000iA)
307
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (h) Motor power connection (M-6iB, ARC Mate 100iB)
308
B--81465EN--1/02
B--81465EN--1/02
APPENDIX
A. TOTAL CONNECTION DIAGRAM
Fig.A (i) Operator panel (without E--stop)
309
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (j) Operator panel (B--cabinet)
310
B--81465EN--1/02
B--81465EN--1/02
APPENDIX
Fig.A (k) Mechanical interface
311
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (l) I/O device (B--cabinet) (1/2)
312
B--81465EN--1/02
B--81465EN--1/02
APPENDIX
Fig.A (l) I/O device (interface) (2/2)
313
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (m) Emergency stop circuit of B--cabinet
314
B--81465EN--1/02
B--81465EN--1/02
APPENDIX
315
A. TOTAL CONNECTION DIAGRAM
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
B
APPENDIX
B--81465EN--1/02
SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE
316
APPENDIX
B--81465EN--1/02
B.1
SIGNALS
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
The following table lists the I/O signals used for the peripheral device
interface in the R-J3iB controller.
Input signals (Refer to B.3.1)
Description
Signal
*IMSTP
*HOLD
*SFSPD
CSTOPI
FAULT_RESET
START
HOME
ENBL
RSR1/PNS1
RSR2/PNS2
RSR3/PNS3
RSR4/PNS4
RSR5/PNS5
RSR6/PNS6
RSR7/PNS7
RSR8/PNS8
PNSTROBE
PROD_START
SDI01
SDI02
Instantaneous stop signal
Hold signal
Safety speed signal
Cycle stop signal
Alarm release signal
Cycle start signal
Robot service request/program number select signal (*1)
Enabling signal
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
PNS strobe signal
Automatic operation start signal
General-purpose input signal
General-purpose input signal
SDI03
SDI04
SDI05
SDI06
SDI07
SDI08
SDI09
SDI10
SDI11
SDI12
SDI13
SDI14
SDI15
SDI16
SDI17
SDI18
SDI19
SDI20
SDI21
SDI22
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
*1: RSR : Robot Service Request (RSR5 to RSR8 are optional)
PNS : Program Number Select Input (optional)
Whether RSR is used or PNS is used can be preset.
317
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
APPENDIX
B--81465EN--1/02
Output signals (Refer to B.3.2)
Signal
Description
CMDENBL
SYSRDY
PROGRUN
PAUSED
HELD
FAULT
ATPERCH
TPENBL
BATALM
BUSY
ACK1/SNO1
ACK2/SNO2
ACK3/SNO3
ACK4/SNO4
ACK5/SNO5
ACK6/SNO6
ACK7/SNO7
ACK8/SNO8
SNACK
______
Command acceptance enabled signal
System ready signal
Program run signal
Program paused signal
Held signal
Alarm signal
Reference point signal
Teach pendant enabled signal
Battery alarm signal
Operating signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
PNS acknowledge signal
Not used (for future expansion)
SDO01
SDO02
SDO03
SDO04
SDO05
SDO06
SDO07
SDO08
SDO09
SDO10
SDO11
SDO12
SDO13
SDO14
SDO15
SDO16
SDO17
SDO18
SDO19
SDO20
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
318
B--81465EN--1/02
B.2
SETTING COMMON
VOLTAGE
APPENDIX
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
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
319
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
APPENDIX
B--81465EN--1/02
B.3
I/O SIGNALS
B.3.1
This section describes the specifications of each input signal.
Input Signals
(1) Instantaneous stop signal (input) *IMSTP
Effective
Function
: At any time
: Use the normally-closed switch because it is a reverse
signal.
The system turns off power to the servo unit when the
*IMSTP is open (turned off). This signal has the same
effect as that of the emergency stop signal, but it is controlled by software. For this reason, use the emergency
stop external interface on the emergency stop control
board for wiring of the emergency stop signal.
Do not use *IMSTP.
(2) Alarm release signal (input) FAULT RESET
Effective
Function
: In the alarm status
: 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
Function
: At any time
: Use the normally-closed switch because it is a reverse
signal.
The *HOLD signal has the same function as the hold
button on the operator panel. It halts the current program and stops the operation of the robot. While this
signal is being input, the held signal (output) HELD is
turned on and the robot cannot be operated.
320
APPENDIX
B--81465EN--1/02
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
(4) Start signal (input) START
Effective
Function
: When the command acceptance enabled signal (output)
CMDENBL is turned on.
See the description of CMDENBL in Section B.3.2 (1)
for details.
: This input signal starts the selected program at the falling edge when the signal is turned off after being turned
on. Its function differs according to the setting of parameter $SHELL_CFG.$CONT_ONLY.
- If parameter $SHELL_CFG.$CONT_ONLY is set to
DISABLED, the START signal starts the program
which has been selected from the teach pendant. By
default, the program starts from the current cursor
position.
- If parameter $SHELL_CFG.$CONT_ONLY is set to
ENABLED, the START signal only resumes the
execution of the temporarily held program. To
execute an inactivated program from the start, input
the PROD_START signal.
(5) Cycle stop signal (input) CSTOPI
Effective
Function
: 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
Function
: At any time
: 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.
321
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
APPENDIX
B--81465EN--1/02
(7) Safety speed signal (input) *SFSPD
Effective
Function
: At any time
: - Use the normally-closed switch because it is a reverse
signal. Usually this switch should be connected to
safety fence. It must be set normally on.
- Since the *SFSPD signal is counted as a remote condition, such input signals as RSR and START to the peripheral device interface cannot take effect unless this
signal is turned on.
- If this signal is turned from on to off during robot operation, the execution of the current program is suspended. At the same time, the overriding value is
switched to a preset value (parameter $SCR.
$FENCEOVER.)
- As long as this signal is off, the overriding value cannot be increased beyond the preset value
($SCR.$SFJOGOVLIM: For jog, $SCR. $SFRUNOVLIM : For test execution.)
(8) Robot service request signal (input) RSR1/RSR2/RSR3/RSR4
Effective
Function
: When the command acceptance enabled signal (output)
CMDENBL is turned on.
See the description of CMDENBL in Section B.3.2 (1)
for details.
: - 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).
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APPENDIX
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
- When an RSR is input, the program whose program
name consists of the specified program number plus a
base value is started. For exam ple, if a signal is input
to RSR2 when program number 23 is registered in
RSR2, the program to be started is the one with the program name calculated from the expression
RSR + (RSR2 program number + base
number),
i.e., RSR0123.
The base number is stored in parameter
$SHELL_CFG.$JOB_BASE, and can be changed in
a program with a parameter instruction. (For example,
$SHELL_ CFG. $JOB_BASE =100). In this way, the
combination of programs which can be started by
RSRs can be changed.
- Whether the system should output an acknowledge signal to an RSR can be selected from the menu. If so specified, a pulse is output from the signal corresponding
to the RSR, one of signals ACK1 to ACK4, when the
input of the RSR is accepted. From the same menu, the
width of the pulse can also be specified.
It is possible to accept other RSRs while outputting an
acknowledge signal.
- Input of a CSTOPIT signal can clear the program queue
waiting for execution after acceptance of RSRs.
(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.
323
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
APPENDIX
B--81465EN--1/02
If a number other than zero is entered to PNS input, a
program is selected whose program number is the entered value plus the base number. For example, if the
PNS value is 23, the program to be started has the program name calculated from the expression
PNS + (entered PNS value + base number),
i.e., PNS0123.
If zero is entered to PNS input, it is cleared as if no selection has been made.
- A PNS signal, which can only select a program, cannot execute the selected program. The execution of
the selected program can only be started after input of
automatic operation start signal PROD_START.
- For safety, the selected program cannot be changed
from the teach pendant unless PNSTROBE is turned
off.
- If a program is selected by PNS, the program number
is output to selected program number signal (output)
SNO, and a pulse is output to program selection acknowledge signal SNACK. Using these signals, peripheral devices can confirm the correct program has
been selected. For the timing of these signals, see the
sections describing SNO and SNACK.
- The following operations are effective for the program
selected by PNS. You can:
· Start up a program by input of automatic operation
start signal PROD_START
· Restart the program that has been suspended.
Inputting the START signal restarts the program
selected by PNS when $SHELL_CFG.$CONT_
ONLY is set to ENABLED.
· Input of CSTOPI cancels execution of the pro-grams
selected by PNS when $SHELL_CFG.$USE_
ABORT is set to ENABLED.
(10) Automatic operation start signal (input) PROD_START
Effective
Function
: When the command acceptance enabled signal (output)
CMDENBL is turned on.
See the description of CMDENBL in Section B.3.2 (1)
for details.
: This input signal executes the selected program at the
falling edge when the signal is turned off after being
turned on.
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B.3.2
Output Signals
APPENDIX
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
This section describes the specifications of output signals for the
peripheral device interface.
(1) Command acceptance enabled signal (output) CMDENBL
Turned on : When the remote conditions are satisfied and the system
is not in the alarm status
Turned off : When the remote conditions are not satisfied or the system is in the alarm status
The remote conditions are satisfied when all of the following are satisfied.
- The teach pendant is in the DISABLED status.
- The remote switch on the operator’s panel is set to REMOTE side.
- Parameter $RMT_MASTER is set to 0 (external interface).
- Signal *SFSPD is set to on, or in the normal status.
(2) System ready signal (output) SYSRDY
Turned on : When power is applied to the motor of the robot.
Turned off : When power is not applied to the motor of the robot.
(3) Program run signal (output) PROGRUN
Turned on : When the program is being executed.
Turned off : When the program is not being executed.
(4) Held signal (output) HELD
This signal is used to check the status of the hold input.
Turned on : When the hold button (or input) is being pressed down
(or turned on).
Turned off : When the hold button (or input) is not being pressed
down (or is turned off).
(5) Program paused signal (output) PAUSED
This signal is used together with output signal PROGRUN to determine
whether a program can be restarted while it is being held.
Turned on : When a program is held and has not been restarted yet.
While this signal is on, the program can be restarted and
retains information such as that to return from a subprogram to the main program.
Turned off : When a program is being executed or is ready to start.
If signal PROGRUN is on, the program is being
executed. If signal PROGRUN is off, the program has
not been executed and can be started from this status.
(6) Alarm status signal (output) FAULT
Turned on : When the system is in the alarm status (or an alarm
which can stop a program execution is detected.) The
indicator lamp does not go on in warning.
Turned off : When the alarm status is released by an alarm release operation.
325
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
APPENDIX
B--81465EN--1/02
(7) Reference point signal (output) ATPERCH
Turned on : When the robot is in the reference position specified in
the parameter. (the reference point No.1 in reference
point setup screen.)
Turned off : When the robot is not in the reference position specified
in the parameter. (the reference point No.1 in reference
point setup screen.)
Up to three reference positions can be specified, but this signal is output
when the robot is in the first reference position. For the other two reference positions, general-purpose signals can be assigned to output as
such. (They can be set from the setup screen.)
(8) Teach pendant enabled signal (output) TPENBL
Turned on : When the teach pendant is enabled.
Turned off : When the teach pendant is disabled.
(9) Battery alarm signal (output) BATALM
Turned on : When the voltage of the battery for the CMOS memory
backup drops below the reference.
Turned off : When the voltage of the battery for the CMOS memory
backup is at the normal level.
(10) Operating signal (output) BUSY
Turned on : When a program is being executed or is being processed
from operation panels such as the teach pendant. (This
has the same function as that of the BUSY lamp on the
teach pendant.)
Turned off : When a program is not being executed nor is being processed from operation panels such as the teach pendant.
326
B--81465EN--1/02
APPENDIX
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
(11) RSR acknowledge signals (output) ACK1/ACK2/ACK3/ACK4
These signals are used together with the RSR function. They can be
specified to be enabled or disabled from the RSR setup menu.
Turned on : When one of the signals from RSR1 to RSR4 is input
and accepted. A pulse whose width is specified from the
menu is output to acknowledge the signal.
Turned off : Normally. Since these signals are always output as
pulses, they are normally in the off status.
The following chart shows the timing of the RSR input and ACK output.
CMDENBL (O)
(The remote conditions need to be satisfied.)
RSR1 (I)
The maximum delay is 32 msec.
ACK1 (O)
(The width of the pulse is set in the parameter.)
RSR2 (I)
ACK2 (O)
RSR3 (I)
ACK3 (O)
RSR4 (I)
ACK4 (O)
* Other RSR signals can be accepted even when the ACK signal is being output.
327
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
APPENDIX
B--81465EN--1/02
(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.
CMDENBL (O)
(The remote conditions need to be satisfied.)
PNS1-8 (I)
PNSTROBE (I)
Detection and
processing of
PNSTROBE by
software.
(A value is input.)
(A strobe is input for PNS.)
(PNS is read within a maximum of 32 msec after PNSTROBE is turned
on.)
SNO1-8 (O)
SNACK (O)
PROD_START (I)
(Program execution
starts within 32 msec.)
PROGRUN (O)
328
B--81465EN--1/02
APPENDIX
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
B.4
SPECIFICATIONS OF
DIGITAL
INPUT/OUTPUT
B.4.1
Overview
B.4.2
Input/Output Hardware
Usable in the R-J3iB
Controller
This section describes the external specifications of digital and analog
input/output in the R--J3iB controller.
The R--J3iB controller can use up to 512 digital input and output points
or an equivalent number of analog input and output points. One analog
input/output point uses the resources equivalent to those used by 16
digital I/O points. The R--J3iB can use a total of up to 512 I/O points.
The R--J3iB controller can use the following I/O hardware.
- Process I/O printed circuit board
- I/O unit model A
The process I/O printed circuit board and the I/O unit model A can be used
together.
329
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE
APPENDIX
B--81465EN--1/02
B.4.3
Software
Specifications
(1) RDI/RDO
These are signals sent to the connector at the wrist of the robot.
They cannot be assigned (redefined) and are fixed.
The standard format is eight inputs and eight outputs. The number of
points that can be used for the connector at the wrist depends on the
individual robot.
(2) SDI/SDO
The signal No. that is determined at hardware can be changed by
software operation.
(3) Analog I/O
An analog I/O signal can access the analog I/O port (optional) on the
process I/O printed circuit board or the I/O port on the analog I/O
module (used together with the I/O unit model A).
It reads and writes the digital value converted from the analog value
of the I/O voltage. It means that the value does not always represent
the real I/O voltage.
(4) Group I/O
Group I/O is a function which can input or output multiple DI/DO
signals as binary codes.
Any number of continuous signals of up to 16 bits can be set for its
use.
It can be set in the menu DETAILS on the group I/O screen.
330
B--81465EN--1/02
C
APPENDIX
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM
POWER DISTRIBUTION CIRCUIT DIAGRAM
331
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM
APPENDIX
Fig.C (a) 200VAC Power supply Circuit Diagram (B--cabinet)
332
B--81465EN--1/02
B--81465EN--1/02
APPENDIX
333
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM
APPENDIX
Fig.C (b) +5V, +3.3V, +15V, --15V Power Supply Circuit Diagram (B--cabinet)
334
B--81465EN--1/02
B--81465EN--1/02
APPENDIX
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM
Fig.C (c) Robot Mechanical Unit +5V Power Supply Circuit Diagram
335
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM
APPENDIX
Fig.C (d) +24V Power Supply Circuit Diagram (B--cabinet)
336
B--81465EN--1/02
B--81465EN--1/02
APPENDIX
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM
Fig.C (e) Robot Mechanical Unit +24V Power Supply Circuit Diagram
337
D. OPTICAL FIBER CABLE
D
APPENDIX
B--81465EN--1/02
OPTICAL FIBER CABLE
The R--J3iB uses fiber optic cables for communication between the main
board and servo amplifiers. Observe the following cautions when
handling these fiber optic cables. Handle fiber optic cables with utmost
care, especially when installing the unit.
(1) Protection during storage
When the electrical/optical conversion module (mounted on the
printed) circuit board and the fiber optic cable are not in use, their
mating surfaces must be protected with the lid and caps with which
they are supplied. If left uncovered, the mating surfaces are likely to
become dirty, possibly resulting in a poor cable connection.
Electrical/optical conversion module
Fiber optic cable
Lid
Fiber optic
cable caps
Fig.D(a) Protection of electrical/optical conversion module and fiber
optic cable (when not in use)
338
D. OPTICAL FIBER CABLE
APPENDIX
B--81465EN--1/02
(2) Fiber optic cable
D Although the reinforcing cover of the external optical cable has
sufficient mechanical strength, be careful not to drop heavy objects
on the cable.
D Grasp the optical connector firmly when connecting or
disconnecting the cable. Do not pull on the fiber optic cord itself.
(The maximum tensile strength between the fiber cord and
connector is 2 kg. Applying greater force to the cord is likely to
cause the connector to come off, making the cable unusable.)
Fiber optic cord diameter : 2.2 mm × 2 cords
Diameter of cable with reinforced cover : 7.6 mm
Tensile strength : Cable with reinforced cover :75 kg
Fiber optic cord
:7 kg per cord
Between fiber optic cord and connector : 2 kg
Minimum bending radius of fiber optic cord
:25 mm
Minimum bending radius of cable with reinforced cover : 50 mm
Bending resistance (cable with reinforced cover) :
10 million bending cycles at room temperature
(when the bending radius is 100 mm)
Flame resistance
: Equivalent to UL VW--1
Operating temperature
: --20 to 70°C
8.2
6.7
19 max.
60 max.
35typ.
21
Bush
Code
Reinforced cover
Fig.D(b) External dimensions of external optical cable Unit : mm
D Afler it is connected, the optical connector is automatically locked
by the lock levers on its top. To remove the connector, release the
lock levers and pull the connector.
D Although optical connectors cannot be connected in other than the
correct orientation, always take note of the connector’s orientation
before making the connection.
D Take care to keep both parts of the optical connector (cable side and
PCB side) clean. If they become dirty, wipe them with tissue paper
or absorbent cotton to remove dirt. The tissue paper or absorbent
cotton may be moistened with ethyl alcohol. Do not use any
organic solvent other than ethyl alcohol.
D Fix the reinforcing cover by using a cable clamp, as shown in Fig.
D(c), to prevent the weight of the fiber optic cable from being
applied directly to the connecting part of the optical connector.
339
D. OPTICAL FIBER CABLE
Optical connector
APPENDIX
Part of optical fiber cord
B--81465EN--1/02
Part of reinforcing cover
Bending radius of 25 mm or more
(Make the bending radius as large as
possible.)
Cable clamp
(Don’t clamp tight)
Bending radius of 50 mm or more
(Make the bending radius as large as possible.)
Fig.D(c) Fixing the cable with a clamp
D Any superfluous portion of the cable might be wound into a loops.
Should this prove necessary, make sure the diameter of each loop
is at least 150 mm (for an external cable). Winding the cable into
smaller loops can produce sharp curves that exceed the specified
bend radius limit. Such bending can result in transmission loss,
ultimately leading to a communication failure.
D When using a nylon band (cable tie) as a cable clamp, follow the
instructions given below. Also, take care not to apply a bending
force to one particular part of the cable when fixing it with a clamp.
Failing to clamp the cable correctly might cut or damage it.
External cable :
Do not clamp the uncovered portion of the cable with a nylon
band. When clamping the cable by the reinforcing cover, the
clamping force is not an important factor to consider. However,
ensure that the clamping force is as small as possible to ensure
that the reinforcing cover is not deformed by the clamping. If
possible, the clamping force should be 5kg (111bs) or less.
340
E
E. CARD INTERFACE
APPENDIX
B--81465EN--1/02
CARD INTERFACE
Connector for card
Card
Card
Fig.E Precautions for card interface
341
Index
B--81465EN--1/02
[Numbers]
[D]
Digital I/O Signal Specifications, 253
Driver Chip for Robot DI/DO, 156
10/100 BASE--T Connector (CD38) Pin Assignments,
277
[E]
[A]
Electrical Connections, 203
Emergency Stop Control PC Board
(A20B--1007--0800), 139
End Effector Cable Connector, 266
End Effector Control Interface, 255
Ethernet Interface, 275
External Cable Wiring Diagram, 206
External View of the Controller, 21
Adjustment and Checks at Installation, 289
Alarm Occurrence Screen, 30
ARC Weld Connection Cable (CRW1: Honda Tsushin,
34 pins), 262
Assemble at installation, 287
[B]
Backplane PC Board, 140
[F]
Battery for memory backup (3 VDC), 196
Fused--Based Troubleshooting, 117
Block Diagram, 202
Block Diagram of the Main Power Including Power
Supply, 158
[G]
Grounding the Network, 281
[C]
[H]
Cable Clamp and Shielding, 280
Cable Connection, 277
How to Disable/Enable Pneumatic Pressure Alarm
(PPABN), 292
Cable Connection for the Peripheral Devices, end Effectors, and ARC Welders, 263
Card Interface, 341
[I]
Checking the Power Supply Unit, 161
I/O Signal Specifications for Arc--Welding Interface,
257
I/O Signals, 320
In Case of B--Cabinet, 224
In Case of B--cabinet, 226
Input Signals, 320
Input/Output Hardware Usable in the R--J3iB Controller, 329
Installation, 285
Installation Condition, 288
Installation Method, 285
Interface, 271
Interface for Peripheral Devices, End Effectors, and
Welders, 231
Component Functions, 25
Configuration, 20
Connecting the Communication Unit, 271
Connecting the External Emergency Stop, 212
Connecting the External Power Supply ON/OFF
Switch, 210
Connecting the Input Power , 208
Connection between RS--232--C Interface and External Device, 273
Connection Between the Control Unit and Welder,
247
Connection Between the Mechanical Unit and End
Effector, 245
Connection Diagram Between Mechanical Units, 204
Connection to Ethernet, 276
[L]
Connector Specification, 279
Lead Materials, 278
i--1
Index
B--81465EN--1/02
LED of Servo Amplifier, 154
[R]
[M]
Recommended Cables, 267
Main Board (A16B--3200--0412, --0331), 136
Replace the Mode Switch, 189
Manual Operation Impossible, 133
Replacing a Module, 183
Mastering, 34
Replacing a Unit, 164
Replacing Battery, 196
Replacing Cards and Modules on the Main Board, 169
[O]
Operator Safety, 4, 6
Replacing External Air Fan Unit and Door Fan Unit
(B--cabinet), 186
Optical Fiber Cable, 338
Replacing Fuses, 190
Output Signals, 325
Replacing Fuses in the Power Unit, 191
Replacing Fuses in the Servo Amplifier, 190
Replacing I/O Unit Model A, 182
[P]
Replacing Relays, 195
Panel Board (A20B--2100--0770), 142
Replacing Relays on the Panel Board, 195
Panel Switch Board (A20B--9002--0310), 152
Replacing Servo Amplifiers, 178
Peripheral Device and Control Unit Connection, 232
Replacing the AC Fan Motor, 186
Peripheral Device Cable Connector, 264
Replacing the Backplane Board (Unit), 165
Peripheral Device Connection Cable, 263
Replacing the Base Unit of I/O Unit Model A, 182
Peripheral Device Interface, 253
Replacing the Control Section Fan Motor, 185
Peripheral Device Interface A Cable (CRM2: Honda
Tsushin, 50 pins), 261
Replacing the Fuse on the Panel Board, 194
Peripheral Device Interface B Cable (CRM4: Honda
Tsushin, 20 pins), 261
Replacing the Operator Panel and Panel Switch
Board, 188
Peripheral Device Interface Block Diagram, 221
Replacing the Panel Board, 168
Peripheral Device Interface Combination, 226
Replacing the Power Unit and Printed--Circuit Boards
on the Backplane Unit, 166
Replacing the Fuse on the Process I/O Boards, 192
Peripheral Device Interface Processing, 290
Peripheral Device, ARC Welding, and End Effector
Interfaces, 220
Replacing the Printed--Circuit Boards, 165
Position Deviation Found in Return to the Reference
Position (Positioning), 131
Replacing the Regenerative Resistor Unit, 176
Replacing the Redundant E--stop Unit, 177
Replacing the Teach Pendant, 184
Power Cannot be Turned On, 28
Replacing the Transformer, 173
Power Distribution Circuit Diagram, 331
Resetting Overtravel, 290, 291
Precautions for Mechanism, 10
Precautions for Mechanisms, 11
Resetting Overtravel and Emergency Stop at Installation, 290
Precautions in Operation, 11
Robot Connection Cables, 206
Precautions in Programming, 10, 11, 12
RS--232--C Interface, 271
Preventive Maintenance, 26
RS--232--C Interface Signals, 272
Printed Circuit Boards, 135
Process I/O Board CA (A16B--2201--0470), 143
[S]
Process I/O Board CB (A16B--2201--0472), 146
Process I/O Board DA (A16B--2201--0480), 148
Safety During Maintenance, 9
Process I/O Board Signals, 227
Safety in Maintenance, 13
i--2
Index
B--81465EN--1/02
Safety of the End Effector, 12
Total Connection Diagram, 295
Safety of the Robot Mechanism, 11
Transportation, 284
Safety of the Teach Pendant Operator, 7
Transportation and Installation, 283
Safety of the Tools and Peripheral Devices, 10
Troubleshooting, 27
Safety Precautions, 3
Troubleshooting Based on LED Indications, 122
Safety Signals, 33
Troubleshooting Using the Error Code, 36
Selecting Transformer Taps, 159
Servo Amplifiers, 153
[V]
Setting Common Voltage, 319
Setting of Servo Amplifier, 155
Vibration Observed During Movement, 132
Setting the Power Supply, 157
Signals, 317
Software Specifications, 330
[W]
Specifications of Digital Input/Output, 329
Warning Label, 14
Specifications of Peripheral Device Interface, 316
When I/O Unit--MODEL A is Used, 224
Specifications of the Cables Used for Peripheral Devices and Welders, 261
When Process I/O Board CA/CB/HA is Used (B--cabinet), 221
When Process I/O Board DA is Used (B--cabinet), 223
[T]
When Two or more Process I/O Boards and I/O Unit
(Model A or Model B) are Used, 225
Teach Pendant Cable, 207
i--3
Revision Record
FANUC Robot series R--J3iB CONTROLLER FOR EUROPE MAINTENANCE MANUAL (B--81465EN--1)
02
Oct., 2001
01
Mar., 2001
Edition
Date
Addition of R--2000iA/165F/200F/165R/200R/125L/CF,
M--6iB and ARC Mate100iB
Contents
Edition
Date
Contents