FANUC Robot series
R--J3iB Mate CONTROLLER
For Europe
MAINTENANCE MANUAL
B--81525EN--1/01
Table of Contents
B--81525EN--1/01
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p--1
I SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
OPERATOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.1
1.1.2
1.1.3
1.2
SAFETY OF THE TOOLS AND PERIPHERAL DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.1
1.2.2
1.3
Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY OF THE ROBOT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1
1.3.2
1.3.3
1.4
Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety of the Teach Pendant Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions in Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions for Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY OF THE END EFFECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.1
Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
6
7
9
10
10
10
11
11
11
11
12
12
1.5
SAFETY IN MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
1.6
WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
II MAINTENANCE
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
2. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
2.1
EXTERNAL VIEW OF THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
2.2
COMPONENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
2.3
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
3.1
POWER CANNOT BE TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1
3.1.2
Teach Pendant Cannot be Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Screen Remains on the Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
28
29
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
TROUBLESHOOTING USING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
3.7
TROUBLESHOOTING BASED ON LED INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96
3.8
POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION
(POSITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106
3.9
VIBRATION OBSERVED DURING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107
3.10
MANUAL OPERATION IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108
c--1
Table of Contents
B--81525EN--1/01
4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.1
ROBOT CONTROLLER PC BOARD (A16B--3200--0450) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
4.2
EMERGENCY STOP PC BOARD (A20B--1008--0022, --0023) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115
4.3
BACKPLANE PC BOARD (A20B--2003--0330) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
116
5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.1
OUTLINE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1
5.1.2
5.2
Power Supply Module PSM (A06B--6115--H001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servo Amplifier Module (A06B--6114--H205, A06B--6114--H302) . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1
5.2.2
LED of Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED of Servo Amplifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118
118
119
120
120
121
6. SETTING THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.1
BLOCK DIAGRAMS OF THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
123
6.2
CHECKING THE POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
124
6.3
CHECKING THE POWER SUPPLY MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
124
6.4
SELECTING THE TRANSFORMER CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
125
7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.1
REPLACING THE PRINTED--CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1
7.1.2
7.1.3
Replacing the Backplane Board (Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Robot Controller PC Board and Printed--Circuit Boards on the Backplane Unit . . . . . .
Replacing the Emergency Stop PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
127
128
129
130
7.2
REPLACING CARDS AND MODULES ON THE ROBOT CONTROLLER PC BOARD . . . . . .
131
7.3
REPLACING THE TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
135
7.3.1
7.3.2
Replacing the Brake Power Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Power Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
135
136
7.4
REPLACING THE EMERGENCY STOP UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
137
7.5
REPLACING THE MAGNETIC CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
138
7.6
REPLACING SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
139
7.7
REPLACING THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
140
7.8
REPLACING THE CONTROL SECTION FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
141
7.9
REPLACING THE FAN MOTOR OF THE SERVO AMPLIFIER CONTROL UNIT . . . . . . . . . .
142
7.10
REPLACING THE DOOR FAN UNIT AND HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . .
143
7.11
REPLACING THE OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
144
7.12
REPLACING THE POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
145
REPLACING A FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
146
7.13
7.13.1
7.13.2
7.13.3
7.13.4
7.14
REPLACING A RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.14.1
7.15
Replacing a Fuse on the Robot Controller PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Fuse on the Emergency Stop PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fuse on the Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fuse on the Servo Amplifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Relay on the Emergency Stop PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.15.1
Battery for Memory Backup (3 VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c--2
146
147
148
149
150
150
151
151
Table of Contents
B--81525EN--1/01
III CONNECTION
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3. CONNECTION DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.1
CONNECTING THE POWER SUPPLY CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
158
3.2
FANUC I/O LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
159
3.3
CONNECTING THE I/O LINK CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
161
EMERGENCY STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
163
3.4
3.4.1
3.4.2
3.4.3
Emergency Stop Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Emergency Stop Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Emergency Stop Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
163
164
165
3.5
CONNECTION OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
166
3.6
CONNECTION OF ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
167
3.7
CONNECTION OF TEACH PENDANT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
168
3.8
CONNECTION OF CABLE FOR RS--232--C/RS--422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
169
3.9
CONNECTING A CABLE TO A PERIPHERAL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
170
3.10
3.9.1
3.9.2
3.9.3
Peripheral Device Interfaces CRM79 and CRM81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
When the Robot is Connected to the CNC by a Peripheral Device Cable . . . . . . . . . . . . . . . . . . . . . . .
Digital I/O Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9.3.1 Peripheral device interface CRM 79 and CRM 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
170
171
182
182
3.9.4
3.9.5
Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
184
185
END EFFECTOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.1
3.10.2
3.11
Connecting the Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital I/O Signal Specifications of End Effecter Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . .
TREATMENT FOR THE SHIELDED CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
186
186
188
189
4. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4.1
TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
191
4.2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
191
4.3
EXTERNAL CONTROLLER DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
192
4.4
INSTALLATION CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
193
4.5
ADJUSTMENT AND CHECKS AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
193
4.6
NOTE AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
194
4.7
DISABLING HAND BREAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
194
APPENDIX
A. TOTAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
B. PERIPHERAL INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
B.1
SIGNAL TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c--3
209
Table of Contents
B.2
I/O SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.2.1
B.2.2
B.3
B--81525EN--1/01
Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS OF DIGITAL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.3.1
B.3.2
B.3.3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input/Output Hardware Usable in the R-J3iB Mate Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
210
210
211
212
212
212
213
C. OPTICAL FIBER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
c--4
B--81525EN--1/01
PREFACE
PREFACE
This manual describes the following models.
Model
Abbreviation
FANUC Robot LR Mate 100iB
LR Mate100iB
FANUC Robot LR Mate 200iB
LR Mate200iB
p--1
I SAFETY PRECAUTIONS
B--81525EN--1/01
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--81525EN--1/01
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
B--81525EN--1/01
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
(9) When adjusting each peripheral device independently, be sure to turn
off the power of the robot.
Safety gate which executes with opening the door.
Fig.1.1 Safety Fence and Safety Gate
5
1. SAFETY PRECAUTIONS
1.1.1
Operator Safety
SAFETY PRECAUTIONS
B--81525EN--1/01
The operator is a person who operates the robot system. In this sense, a
worker who operates the teach pendant is also an operator. However, this
section does not apply to teach pendant operators.
(1) If it is not necessary for the robot to operate, turn off the power of the
robot controller or press the EMERGENCY STOP button, and then
proceed with necessary work.
(2) Operate the robot system at a location outside the work area.
(3) Install a safety fence with a safety gate to prevent any worker other
than the operator from entering the work area unexpectedly and also
to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator’s reach.
The robot controller is designed to be connected to an external EMERGENCY
STOP button. With this connection, the controller stops the robot operation
when the external EMERGENCY STOP button is pressed. See the diagram
below for connection.
External EMERGENCY STOP button
Emergency stop P.C. board
EMGIN1
EMGIN2
Note)
Connect to EMGIN1 and EMGIN2 are on the emergency stop P.C. board
Fig.1.1.1 Connection Diagram for External Emergency Stop Switch
6
B--81525EN--1/01
1.1.2
Safety of the Teach
Pendant Operator
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
While teaching the robot, it is necessary for the operator to enter the work
area of the robot. It is particularly necessary to ensure the safety of the
teach pendant operator.
(1) Unless it is specifically necessary to enter the robot work area, carry
out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral
devices are all in the normal operating condition.
(3) When entering the robot work area and teaching the robot, be sure to
check the location and condition of the safety devices (such as the
EMERGENCY STOP button and the deadman switch on the teach
pendant).
FANUC’s teach pendant has a switch for enabling or disabling the robot operation from the teach pendant and a deadman switch in addition to the EMERGENCY STOP button. The switches function as follows.
EMERGENCY STOP button : Pressing this button always brings the robot
to an emergency stop, irrespective of the
state of the enable/disable switch.
Deadman switch
: The function of this switch depends on the
state of the enable/disable switch.
In the enable position
-- Releasing the deadman switch brings the
robot to an emergency stop.
In the disable position
-- The deadman switch is disabled.
Note)The deadman switch is provided to bring the robot to an emergency
stop when the operator releases the teach pendant in an emergency.
(4) The teach pendant operator should pay careful attention so that no
other workers enter the robot work area.
NOTE
In addition to the above, the teach pendant enable switch and the
deadman switch also have the following function.
By pressing the deadman switch while the enable switch is on, the
emergency stop factor (normally the safety gate) connected to
FENCE1 and FENCE2 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, the three mode
switch and the remote switch on the operator’s panel.
7
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B--81525EN--1/01
Operator panel
three mode switch
Teach pendant
enable switch
Remote
condition
Teach
pendant
Peripheral
devices
T1/T2/AUTO
On
Independent
Allowed to start
Not allowed
AUTO
Off
Local
Not allowed
Not allowed
AUTO
Off
Remote
Not allowed
Allowed to start
(6) When a program is completed, be sure to carry out a test run according
to the procedure below.
(a) Run the program for at least one operation cycle in the single step
mode at low speed.
(b) Run the program for at least one operation cycle in the continuous
operation mode at low speed.
(c) Run the program for one operation cycle in the continuous
operation mode at the intermediate speed and check that no
abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous
operation mode at the normal operating speed and check that the
system operates automatically without trouble.
(e) After checking the completeness of the program through the test
run above, execute it in the automatic operation mode.
(7) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.
8
B--81525EN--1/01
1.1.3
Safety During
Maintenance
SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS
For the safety of maintenance personnel, pay utmost attention to the
following.
(1) Except when specifically necessary, turn off the power of the
controller while carrying out maintenance. Lock the power switch,
if necessary, so that no other person can turn it on.
(2) When disconnecting the pneumatic system, be sure to reduce the
supply pressure.
(3) Before the start of teaching, check that the robot and its peripheral
devices are all in the normal operating condition.
(4) If it is necessary to enter the robot work area for maintenance when
the power is turned on, the worker should indicate that the machine
is being serviced and make certain that no one starts the robot
unexpectedly.
(5) Do not operate the robot in the automatic mode while anybody is in
the robot work area.
(6) When it is necessary to maintain the robot alongside a wall or
instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.
(7) When a tool is mounted on the robot, or when any moving device
other than the robot is installed, such as belt conveyor, pay careful
attention to its motion.
(8) If necessary, have a worker who is familiar with the robot system
stand beside the operator panel and observe the work being
performed. If any danger arises, the worker should be ready to press
the EMERGENCY STOP button at any time.
(9) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
(10) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and also turn
off the circuit breaker to protect against electric shock.
(11) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified ratings.
They may cause a fire or result in damage to the components in the
controller.
9
1. SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
B--81525EN--1/01
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--81525EN--1/01
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--81525EN--1/01
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--81525EN--1/01
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--81525EN--1/01
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--81525EN--1/01
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--81525EN--1/01
1
1. OVERVIEW
OVERVIEW
This manual describes the maintenance and connection of the R--J3iB
Mate robot controller (called the R--J3iB Mate).
Maintenance Part : Troubleshooting, and the setting, adjustment,
and replacement of units
Connection Part : Connection of the R--J3iB Mate controller to the
robot mechanical unit and peripheral devices,
and installation of the controller
WARNING
Before you enter the robot working area, be sure to turn off
the power to the controller or press the EMERGENCY
STOP button on the operator panel or teach pendant.
Otherwise, you could injure personnel or damage
equipment.
TERM
The R--J3iB Mate robot controller uses the FANUC servo
amplifier α i series (called the servo amplifier (i).
The servo amplifier α i comprises a power supply module
(PSM) and a servo amplifier module (SVM).
In this manual, the terms “power supply module” and “servo
amplifier module” refer to the individual modules. The term
“servo amplifier” refers to the combination of the power
supply module and servo amplifier module.
19
2. CONFIGURATION
2
MAINTENANCE
CONFIGURATION
20
B--81525EN--1/01
B--81525EN--1/01
2.1
EXTERNAL VIEW OF
THE CONTROLLER
2. CONFIGURATION
MAINTENANCE
The appearance and components might slightly differ depending on the
controlled robot, application, and options used.
Fig.2.1 (a) shows the view of R--J3iB Mate.
Fig.2.1 (b) shows the R--J3iB Mate consists of the R--J3iB Mate controller.
Teach pendant
R--J3iB Mate controller
ON/OFF handle
Operator
panel
Teach pendant
cable
Fan unit
Fig.2.1 (a) External View of the R--J3iB Mate Controller
21
2. CONFIGURATION
MAINTENANCE
B--81525EN--1/01
Power supply transformer
for brake
Teach pendant
Enable/disable switch
Emergency stop
button
Emergency stop unit
Power supply unit
Emergency stop P.C.board
Emergency stop
button
Heat exchange
Mode switch
Back plane
Option slot
Robot controller P.C. board
Servo amplifier module2 (AMP2)
Servo amplifier module1 (AMP1)
Power supply module (PSM)
AC reactle
Fig.2.1 (b) R--J3iB Mate interior (Front)
Circut protector
(on/off switch)
Noise filter
Circuit protector
MCC
Transformer
Fig.2.1 (c) R--J3iB Mate interior (Side)
22
B--81525EN--1/01
MAINTENANCE
2. CONFIGURATION
Table 2.1 Servo amplifier specifications
Robot
LR Mate 100iB
LR Mate 200iB
Power supply module
A06B--6115--H001
(αPSMR--1i)
Servo amplifier module1
A06B--6114--H205
(αSVM--20/20i)
L
M
J1
J2
A06B--6114--H302
(αSVM--10/10/10i)
L
M
N
J1
J2
J3
A06B--6115--H001
(αPSMR--1i)
23
Servo amplifier module2
A06B--6114--H302
(αSVM--10/10/10i)
L
M
N
J3
J4
J5
A06B--6114--H302
(αSVM--10/10/10i)
L
M
N
J4
J5
J6
2. CONFIGURATION
2.2
COMPONENT
FUNCTIONS
MAINTENANCE
B--81525EN--1/01
-- Robot control printed circuit board
This board is equipped with a microprocessor and its peripheral
circuitry, memory, and operator panel control circuit. A servo control
circuit is also included.
-- Emergency stop unit, emergency stop printed circuit board
This unit controls the emergency stop system, magnetic contactor
(MCC) of the servo amplifier, and brake. The unit contains the power
supply unit for converting the AC power to the DC power.
-- Backplane printed circuit board
Various control boards are mounted on the backplane PC board.
-- Teach pendant
This unit is used to carry out all operations including robot
programming. The liquid crystal display (LCD) of this unit displays
the status of the control unit, data, and the like.
-- Servo amplifier
The servo amplifier amplifies the power of the servo amplifier and
controls the pulse coder.
-- MCC
The MCC controls the main power of the servo amplifier.
-- Operator panel
The operator panel has a port for the serial interface to an external
device. The panel also has an EMERGENCY STOP button.
-- Transformer
The transformer converts the input power into the AC voltage
required for the control unit.
-- Fan unit, heat exchanger
These components are used to cool the inside of the control unit.
-- Circuit protector
This component turns on or off the power.
The input power is connected to the circuit protector in order to
protect the equipment from a large current that could result from a
problem in the electric system of the control unit or an abnormal input
power.
24
B--81525EN--1/01
2.3
PREVENTIVE
MAINTENANCE
MAINTENANCE
2. CONFIGURATION
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
25
3. TROUBLESHOOTING
3
MAINTENANCE
B--81525EN--1/01
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.
26
B--81525EN--1/01
3. TROUBLESHOOTING
MAINTENANCE
3.1
POWER CANNOT BE
TURNED ON
Check and Corrective action
(Check 1)
Check that the circuit protector is on and
has not tripped.
(Corrective
action)
Turn on the circuit protector.
(Check 2)
Check that the door fan unit and the fan
motor of the heat exchanger are rotating
and that the LED indication on the power
supply module is “--”.
(Corrective
action)
Figure
Circuit protector
(on/off switch)
LED of the power supply module
Heat exchange for
fan unit (door face)
If the fan motor is not rotating or if the
LED of the power supply module is not
glowing, the fuse on the back of the door
may have been blown.
-- Check the fuse on the back of the
door.
If the fuse on the back of the door has
been blown, replace the fuse.
Transformer unit
Circuit protector
27
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
3.1.1
Teach Pendant Cannot
be Turned On
Check and Corrective action
(Check 1)
Check the LCD display and LED indication on the teach pendant.
(Corrective
action)
Check the LCD display and LED indication on the teach pendant to see whether
the emergency stop unit is faulty.
-- Check whether the fuse FUS4 on the
emergency stop PC board is blown.
If the fuse is blown, the FALM LED
glows. Replace the blown fuse.
-- If the fuse FUS4 on the emergency
stop PC board is not blown, the emergency stop unit may be faulty. Replace the emergency stop unit.
Figure
Teach pendant
p
Emergency stop P.C.board
FALM LED
Fuse FUS4
Emergency stop unit
28
B--81525EN--1/01
3. TROUBLESHOOTING
MAINTENANCE
3.1.2
Initial Screen Remains
on the Teach Pendant
Check and Corrective action
(Check 1)
Check that the “.” portion of the seven-segment LED glows on the robot controller PC board.
(Corrective
action)
If the “.” portion is not glowing, the fuse
FUS1 on the robot controller PC board
may be blown. Alternatively, the DC/DC
converter module may be damaged.
If the FUSE ALARM LED is glowing, the
fuse FUS1 may be blown.
The fuse FUS1 is provided on the robot
controller PC board. Before checking
the fuse, turn off the circuit protector.
a) If the fuse FUS1 has been blown
-- See Corrective action (1).
b) If the fuse FUS1 is not blown
-- See Corrective action (2).
(Corrective
action(1))
(Corrective
action(2))
Figure
+24V input
connector
CP5
Cause of the blowing of the fuse FUS1
and corrective action
a) Check whether the device which is
connected to the RS--232--C/
RS--422 port and requires the power
supply of +24 V is sound.
b) Problem in the DC/DC converter
module
If the DC/DC converter module gets
faulty in the short--circuit mode,
FUS1 is blown.
Replace the DC/DC converter module.
DC/DC converter
module
dot part of seven
segment LED
a) Problem in the DC/DC converter
module
Replace the DC/DC converter module.
b) Problem in the robot controller PC
board
Replace the robot controller PC
board. (For the LED indications, see
Section 3.7, “TROUBLESHOOTING
USING LEDS.”)
FUS1 7.5A
DC24V input fuse
29
3. TROUBLESHOOTING
3.2
ALARM
OCCURRENCE
SCREEN
MAINTENANCE
B--81525EN--1/01
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--81525EN--1/01
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--81525EN--1/01
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--81525EN--1/01
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
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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 the axis is rotated
enough to establish a pulse.
34
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(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
MAINTENANCE
3.5
TROUBLESHOOTING
USING THE ERROR
CODE
B--81525EN--1/01
(1) SRVO--001 SVAL1 Operator panel E--stop
(Explanation) The EMERGENCY STOP button on the operator
panel is pressed.
(Action 1)
Release the emergency stop button pressed on the
operator panel.
(Action 2)
Release the EMERGENCY STOP button on the
operator panel.
(Action 3)
Replace the emergency stop unit.
Before taking (Action 4), make a backup copy of all
the programs and settings of the control unit.
(Action 4)
Replace the robot controller PC board.
Emergency stop button
Operator
panel
Robot controller P.C. board
Emergency stop unit
Fig.3.5 (1) (a) SRVO--001 SVAL1 Operator panel E--stop
36
B--81525EN--1/01
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.
(Action 1)
Press the deadman switch to run the robot.
(Action 2)
Replace the teach pendant.
Deadman switch
Fig.3.5 (3) SRVO--001 SVAL1 Deadman switch released
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3. TROUBLESHOOTING
MAINTENANCE
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(4) SRVO--004 SVAL1 Fence open
(Explanation) In AUTO mode, there is no short circuit between
FENCE1 and FENCE2 on the terminal block TBEB5
of the emergency stop PC board.
If the safety fence is connected between FENCE1 and
FENCE2, the door of the safety fence is open.
(Action 1)
When the safety fence is connected, close the door.
(Action 2)
Check the cables and switches connected to FENCE1
and FENCE2.
(Action 3)
When this signal is not used, short--circuit between
FENCE1 and FENCE2.
NOTE
In the system that uses the fence signal, do not short--circuit
this signal to disable it because the operation is dangerous.
When this signal must be temporarily short--circuited, make
safety provisions separately.
(Action 4)
When AUTO mode is not entered even though the
mode switch is set to AUTO, the mode switch may be
faulty. Replace the operator panel.
Replace the teach pendant cable.
Replace the teach pendant.
Replace the emergency stop unit.
Before taking (Action 8), make a backup copy of all
the programs and settings of the control unit.
Replace the robot controller PC board.
(Action 5)
(Action 6)
(Action 7)
(Action 8)
Short
connection
board
Emergency stop unit
Fig.3.5 (4) SRVO--004 SVAL1 Fence open
38
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MAINTENANCE
3. TROUBLESHOOTING
(5) SRVO--005 SVAL1 Robot overtravel
(Explanation) This alarm should not occur because no overtravel
input signal is provided. However, this alarm can be
caused by an abnormal overtravel input signal across
the robot interconnection cable and robot controller
PC board.
(Action 1)
Check the robot interconnection cable (RMP) for the
following.
1) The male and female connection pins are not
twisted or are not loose.
2) The connector is securely connected.
3) The cable is free from a break and ground fault.
Next, check that the connector CRM82 of the robot
controller PC board is securely connected. In
addition, check that the RMP cable is sound and free
from a break or visible twist.
Before taking (Action 2), make a backup copy of all
the programs and settings of the control unit.
(Action 2)
Replace the robot controller PC board.
Robot controller P.C. board
Fig.3.5 (5) SRVO--005 SVAL1 Robot overtravel
39
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(6) SRVO--006 SVAL1 Hand broken
(Explanation) The safety joint, if any, is broken. If no joint is
broken, the HBK signal line of the robot
interconnection cable has a break or ground fault.
(Action 1)
Holding down the shift key, press the alarm release
button. This releases the alarm. Keeping on holding
down the shift key, carry out jog feed to move the tool
to the work area.
1) Replace the safety joint.
2) Examine the cable.
(Action 2)
Check the robot interconnection cable (RMP) for the
following.
1) The male and female connection pins are not
twisted or are not loose.
2) The connector is securely connected.
3) The cable is free from a break and ground fault.
Next, check that the connector CRM82 of the robot
controller PC board is securely connected. In
addition, check that the RMP cable is sound and free
from a break or visible twist.
Before taking (Action 3), make a backup copy of all
the programs and settings of the control unit.
(Action 3)
Replace the robot controller PC board.
Robot controller P.C. board
Fig.3.5 (6) SRVO--006 SVAL1 Hand broken
40
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MAINTENANCE
3. TROUBLESHOOTING
(7) SRVO--007 SVAL1 External E--stop
(Explanation) EMGIN1 and EMGIN2 on the terminal block TBEB5
of the emergency stop PC board are not
short--circuited. If an external emergency stop switch
is connected across EMGIN1 and EMGIN2, the
switch has been pressed.
(Action 1)
If an external emergency stop switch is connected,
releases the switch.
(Action 2)
Check the switch and cable connected to EMGIN1
and EMGIN2.
(Action 3)
When this signal is not used, make a connection
between EMGIN1 and EMGIN2. (WARNING)
(Action 4)
Replace the emergency stop unit.
WARNING
Do NOT short--circuit, or disable, this signal in a system in
which the External emergency stop input signal is in use, as
it is very dangerous. If it is necessary to run the robot by
short--circuiting the signal even temporarily, an additional
safety provision must be provided.
Short
connection
board
Emergency stop unit
Fig.3.5 (7) SRVO--007 SVAL1 External E--stop
41
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(8) SRVO--009 SVAL1 Pneumatic pressure alarm
(Explanation) An abnormal air pressure was detected. The input
signal is located on the end effector of the robot.
Refer to the manual of your robot.
(Action 1)
If an abnormal air pressure is detected, check the cause.
If the peripheral device are normal, check the robot
connection cable.
Before taking (Action 2), make a backup copy of all
the programs and settings of the control unit.
(Action 2)
Replace the robot controller PC board.
Robot controller P.C. board
Fig.3.5 (8) SRVO--009 SVAL1 Pneumatic pressure alarm
42
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MAINTENANCE
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
43
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(10) SRVO--015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j)
(Explanation) The temperature in the control unit exceeds the
specified value.
(Action 1)
If the ambient temperature is higher than specified
(45°C), cool down ambient temperature.
(Action 2)
If the fan motor is not running, check it and its cables.
Replace them if necessary.
(Action 3)
If the thermostat on the robot controller PC board is
defective, replace the robot controller PC board.
Fan motor
(on the heat exchange)
Fan motor (door face)
Robot controller P.C. board
Fig.3.5 (10) SRVO--015 SVAL1 SYSTEM OVER HEAT
44
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MAINTENANCE
3. TROUBLESHOOTING
(11) SRVO--021 SVAL1 SRDY off (Group : i Axis : j)
(Explanation) The HRDY is on and the SRDY is off, although there
is no other cause of an alarm. (HRDY is a signal with
which the host 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.)
If the servo amplifier magnetic contactor cannot be
turned on when directed so, it is most likely that a
servo amplifier alarm has occurred. If a servo
amplifier alarm has been detected, the host will not
issue this alarm (SRDY off). Therefore, this alarm
indicates that the magnetic contactor cannot be turned
on for an unknown reason.
(Action 1)
Measure the voltage of the 200--VAC input to the
power supply module. If the voltage is 170 VAC or
lower, adjust the input voltage.
(Action 2)
Check that CRR78 of the emergency stop PC board
and CX3 and CX4 of the power supply module are
securely connected. Check the cables of the
emergency stop PC board and power supply module
for a break.
(Action 3)
Check the EMERGENCY STOP line (teach pendant
emergency stop, teach pendant enable/disable switch,
teach pendant deadman switch, operator panel
emergency stop, external emergency stop input, fence
input, servo off--input) for a possibility of an
instantaneous interruption. If the software cannot
judge the cause of the alarm at an instantaneous
interruption of the EMERGENCY STOP line, this
alarm occurs.
(Action 4)
Replace the emergency stop unit.
(Action 5)
If an alarm occurs on all axes, the power supply
module may be faulty. Replace the power supply
module.
(Action 6)
If an alarm occurs on a particular axis, the servo
amplifier module may be faulty. Replace the servo
amplifier module controlling the axis.
(Action 7)
Replace the axis control card on the robot controller
PC board.
45
3. TROUBLESHOOTING
MAINTENANCE
Emergency stop unit
B--81525EN--1/01
Robot controller P.C. board
Servo amplifier module
Power supply module
Axis control card
Fig.3.5 (11) SRVO--021 SVAL1 SRDY off
46
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MAINTENANCE
3. TROUBLESHOOTING
(12) SRVO--022 SVAL1 SRDY on (Group : i Axis : j)
(Explanation) When the HRDY is about to go on, the SRDY is already
on. (HRDY is a signal with which the host directs the
servo system whether to turn on or off the servo
amplifier magnetic contactor. SRDY is a signal with
which the servo system informs the host whether the
magnetic contactor is turned on.
(Action 1)
Replace the axis control card on the robot controller
PC board.
(Action 2)
If an alarm occurs on all axes, the power supply
module may be faulty. Replace the power supply
module.
(Action 3)
If an alarm occurs on a particular axis, the servo
amplifier module may be faulty. Replace the servo
amplifier module controlling the axis.
Robot controller P.C. board
Servo amplifier module
Power supply module
Axis control card
Fig.3.5 (12) SRVO--022 SVAL1 SRDY on
47
3. TROUBLESHOOTING
MAINTENANCE
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(13) SRVO--023 SVAL1 Stop error excess (Group : i Axis : j)
(Explanation) When the servo is at stop, the position error is
abnormally large.
(Action 1)
Check whether the motor brake has been released.
(Action 2)
Make sure that the servo amplifier CZ2L to N are
connected tightly.
(Action 3)
Check to see if the load is greater than the rating. If
greater, reduce it to within the rating. (If the load is
too greater, the torque required for acceleration /
deceleration becomes higher than the capacity of the
motor. As a result, the motor becomes unable to
follow the command, and an alarm is issued.)
(Action 4)
Check each phase voltage of the CZ1 connector of the
three--phase power (200 VAC) input to the servo
amplifier. If it is 170 VAC or lower, check the line
voltage. (If the voltage input to the servo amplifier
becomes low, the torque output also becomes low. As
a result the motor may become unable to follow the
command, hence possibly an alarm.)
(Action 5)
If the line voltage is 170 VAC or higher, replace the
power supply module or servo amplifier module.
(Action 6)
Check disconnection of robot connection cable
(RMP).
(Action 7)
Replace the motor.
Servo amplifier module
Power supply module
Fig.3.5 (13) SRVO--023 SVAL1 Stop error excess
48
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MAINTENANCE
3. TROUBLESHOOTING
(14) SRVO--024 SVAL1 Move error excess (Group : i Axis : j)
(Explanation) When the robot is running, its position error is greater
than a specified value ($PARAM _ GROUP.
$MOVER _ OFFST or $PARAM _ GROUP.
$TRKERRLIM). It is likely that the robot cannot
follow the speed specified by program.
(Action 1)
Check the robot for binding axis.
(Action 2)
Take the same actions as described for the above
alarm.
(15) SRVO--025 SVAL1 Motn dt overflow (Group : i Axis : j)
(Explanation) The specified value is too great.
(16) SRVO--026 WARN2 Motor speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum motor speed
($PARAM_GROUP.$MOT_SPD_LIM)
was
specified. The actual motor speed is clamped to the
maximum speed.
(17) SRVO--027 WARN Robot not mastered (Group : i)
(Explanation) An attempt was made to calibrate the robot, but the
necessary adjustment had not been completed.
(Action)
Master the robot.
(18) SRVO--030 SVAL1 Brake on hold (Group : i)
(Explanation) This alarm occurs when the robot pauses, if the brake
on hold function has been enabled ($SCR.
$BRKHOLD _ ENB = 1). Disable the function if it is
not necessary.
(Action)
Disable [Servo--off during pause] on the general
setting menu (Select Setting general).
(19) SRVO--031 SVAL1 User servo alarm (Group : i)
(Explanation) An user servo alarm occurred.
(20) SRVO--033 WARN Robot not calibrated (Group : i)
(Explanation) An attempt was made to set up a reference point for
simplified adjustment, but the robot had not been
calibrated.
(Action)
Calibrate the robot.
1.Supply power.
2.Set up a simplified adjustment reference point
using [Positioning] on the positioning menu.
(21) SRVO--034 WARN Ref pos not set (Group : i)
(Explanation) An attempt was made to perform simplified adjustment,
but the reference point had not been set up.
(Action)
Set up a simplified adjustment reference point on the
positioning menu.
(22) SRVO--035 WARN2 Joint speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum axis speed
($PARAM_GROUP.$JNTVELLIM) was specified.
Each actual axis speed is clamped to the maximum
speed.
(23) SRVO--036 SVAL1 Inpos time over (Group : i Axis : j)
(Explanation) The robot did not get to the effective area ($PARAM _
GROUP.$ STOPTOL) even after the position check
monitoring time ($PARAM _ GROUP. $INPOS _
TIME) elapsed.
(Action)
Take the same actions as for SRVO--23 (large position
error at a stop).
(24) SRVO--037 SVAL1 Imstp input (Group : i)
(Explanation) The *IMSTP signal for a peripheral device interface
was input.
(Action)
Turn on the *IMSTP signal.
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3. TROUBLESHOOTING
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(25) SRVO--038 SVAL2 Pulse mismatch (Group : i Axis : j)
(Explanation) The pulse count obtained when power is turned off
does not match the pulse count obtained when power
is applied. This alarm is asserted after exchange the
pulsecoder or battery for back up of the pulsecoder
data or loading back up data to the Robot controller
PC board.
(Action)
Perform Absolute Pulse Coder reset and remaster
robot (RES--PCA)
1. Press MENUS.
2. Select SYSTEM.
3. Press F1 [TYPE].
4. Select MASTER/CAL.
5. Press F3, PES--PCA and YES.
6. Execute machining.
7. Press RESET.
The fault condition should reset. If the controller
is still faulted with additional servo--related errors,
cold start the controller.
It might be necessary to remaster the robot.
(26) SRVO--041 SVAL2 MOFAL alarm (Group : i Axis : j)
(Explanation) The servo value was too high.
(Action)
Cold start the controller.
50
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MAINTENANCE
3. TROUBLESHOOTING
(27) SRVO--044 SVAL1 HVAL alarm (Group : i Axis : j)
(Explanation) The DC voltage (DC link voltage) of the main circuit
power supply is abnormally high.
The LED indication on the power supply module is
“7” (HVAL).
(Action 1)
Check the three--phase input voltage at the power
supply module. If it is 253 VAC or higher, check the
line voltage. (If the three--phase input voltage is
higher than 253 VAC, high acceleration/deceleration
can result in this alarm.)
(Action 2)
Check that the load weight is within the rating. If it
is higher than the rating, reduce it to within the rating.
(If the machine load is higher than the rating, the
accumulation of regenerative energy might result in
the HVAL alarm even when the three--phase input
voltage is within the rating.
(Action 3)
Replace the power supply module.
Power supply module
Fig.3.5 (27) SRVO--044 SVAL1 HVAL alarm
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3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(28) SRVO--045 SVAL1 HCAL alarm (Group : i Axis : j)
(Explanation) Abnormally high current flowed in the main circuit of
the servo amplifier module.
The LED indications on the servo amplifier modules
are “b”, “C”, and “d”.
(Action 1)
Disconnect the Robot connection cable (Motor power)
from the connector CZ2 of the servo amplifier
module. If error occurs, replace the servo amplifier.
(Action 2)
Disconnect the Robot connection cable (Motor power)
from the servo amplifier module connector (CZ2),
and check the insulation of each Robot connection
cable (Motor power) (U, V, or W) and the GND line.
If there is a short--circuit, the motor, robot
interconnection cable, or intra--robot cable is
defective. Check them and replace them if necessary.
(Action 3)
Disconnect the Robot connection cable (Motor power)
from the servo amplifier module connector (CZ2),
and measure the resistance between the U and V, V
and W, and W and U with a ohmmeter with a very low
resistance range. If the resistances at these three
places are different from each other, the motor, robot
interconnection cable, or intra--robot cable is
defective. Check each item in detail.
Before taking (Action 4), make a backup copy of all
the programs and settings of the control unit.
(Action 4)
Replace the robot controller PC board.
Robot controller P.C. board
Servo amplifier module
Fig.3.5 (28) SRVO--045 SVAL1 HCAL alarm
52
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MAINTENANCE
3. TROUBLESHOOTING
(29) SRVO--046 SVAL2 OVC alarm (Group : i Axis : j)
(Explanation) This alarm is issued to prevent the motor from
thermal damage that might occur when the root meant
square current calculated within the servo system is
out of the allowable range.
(Action 1)
Check the operating conditions for the robot and relax
the service conditions.
(Action 2)
Check each phase voltage of the three--phase input
power (200 VAC for the power supply module. If it
is 170 VAC or lower, check the line voltage.
(Action 3)
Replace the power supply module and servo
amplifier module.
(Action 4)
Check the robot connection cable (RMP).
(Action 5)
Replace the motor.
Servo amplifier module
Power supply module
Fig.3.5 (29) SRVO--046 SVAL2 OVC alarm
53
3. TROUBLESHOOTING
MAINTENANCE
Reference
B--81525EN--1/01
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.
(30) SRVO--047 SVAL1 LVAL alarm (Group : i Axis : j)
(Explanation) The control power voltage (+5 V, etc.) on the servo
amplifier module is too low. The LED indication on
the servo amplifier module is “2” (LVAL).
(Action 1)
Replace the servo amplifier module.
Servo amplifier module
Fig.3.5 (30) SRVO--047 SVAL1 LVAL alarm
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(31) SRVO--049 SVAL1 OHAL1 alarm (Group : i Axis : j)
(Explanation) This alarm does not occur when the power supply
module and serve amplifier modules used with the
R--J3iB Mate are under normal conditions.
This alarm indicates that any of the power supply
module and servo amplifier modules is faulty.
(Action 1)
If this alarm occurs in relation to all axes, replace the
power supply module.
(Action 2)
If this alarm occurs in relation to a specific axis,
replace the servo amplifier module that controls the
axis.
Servo amplifier module
Power supply module
Fig.3.5 (31) SRVO--049 SVAL1 OHAL1 alarm
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(32) SRVO--050 SVAL1 CLALM alarm (Group : i Axis : j)
(Explanation) The disturbance torque estimated by the servo software
is abnormally high. (A collision has been detected.)
(Action 1)
Check that the robot has collided with anything. If it
has, reset the robot and jog--feed it to recover from the
collision.
(Action 2)
Make sure that the load setting is correct.
(Action 3)
Check that the load weight is within the rating. If it
is higher than the rating, reduce it to within the rating.
(If the robot is used out of its usable range, the
estimated disturbance torque becomes abnormally
high, possibly resulting in this alarm being detected.)
(Action 4)
Check the phase voltage of the three--phase input
power (200 VAC) to the power supply module. If it
is 170 VAC or lower, check the line voltage.
(Action 5)
Replace the power supply module and the servo
amplifier module.
Servo amplifier module
Power supply module
Fig.3.5 (32) SRVO--050 SVAL1 CLALM alarm
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(33) SRVO--051 SVAL2 CUER alarm (Group : i Axis : j)
(Explanation) The offset of the current feedback value is abnormally
high.
(Action)
Replace the servo amplifier module.
Servo amplifier module
Fig.3.5 (33) SRVO--051 SVAL2 CUER alarm
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(34) SRVO--054 DSM Memory Error
(Explanation) An access to the axis control card on the robot
controller PC board memory fails.
(Action)
Replace the axis control card.
Robot controller P.C. board
Servo amplifier module
Axis control card
Fig.3.5 (34) SRVO--054 DSM Memory Error
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(35) SRVO--055 SVAL2 FSSB com error 1 (Group : i Axis : j)
(Explanation) A communication error has occurred between the
robot controller PC board and servo amplifier.
(Action 1)
Check the communication cable (optical fiber)
between the robot controller PC board and servo
amplifier. Replace it if it is faulty.
(Action 2)
Replace the axis control card on the robot controller
PC board.
(Action 3)
Replace the servo amplifier module.
Before continuing to the next step, perform a
complete controller back--up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.
(Action 4)
Replace the robot controller PC board.
Robot controller P.C. board
Servo amplifier module
Axis control card
Fig.3.5 (35) SRVO--055 SVAL2 FSSB com error 1
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(36) SRVO--056 SVAL2 FSSB com error 2 (Group : i Axis : j)
(Explanation) A communication error has occurred between the
robot controller PC board and servo amplifier.
(Action 1)
Check the communication cable (optical fiber)
between the robot controller PC board and servo
amplifier. Replace it if it is faulty.
(Action 2)
Replace the axis control card on the robot controller
PC board.
(Action 3)
Replace the servo amplifier module.
Before continuing to the next step, perform a
complete controller back--up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.
(Action 4)
Replace the robot controller PC board.
Robot controller P.C. board
Servo amplifier module
Axis control card
Fig.3.5 (36) SRVO--056 SVAL2 FSSB com error 2
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(37) SRVO--057 SVAL2 FSSB disconnect (Group : i Axis : j)
(Explanation) Communication was interrupted between the robot
controller PC board and servo amplifier.
(Action 1)
Check whether fuse FU1 in the power supply module
unit has blown.
(Action 2)
Check whether fuse FU1 in the servo amplifier
module has blown.
(Action 3)
Check the communication cable (optical fiber)
between the robot controller PC board and servo
amplifier. Replace it if it is faulty.
(Action 4)
Replace the axis control card on the robot controller
PC board.
(Action 5)
Replace the power supply module and the servo
amplifier module.
Before continuing to the next step, perform a
complete controller back--up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.
(Action 6)
Replace the robot controller PC board.
(Action 7)
Check the RMP cable of robot connection cable.
(+5V ground fault)
Robot controller P.C. board
Servo amplifier module
Power supply module
Axis control card
Fig.3.5 (37) SRVO--057 SVAL2 FSSB disconnect
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(38) SRVO--058 SVAL2 FSSB init error (Group : i Axis : j)
(Explanation) Communication was interrupted between the robot
controller PC board and servo amplifier module.
(Action 1)
Check whether fuse FU1 in the power supply module
have blown.
If they have blown, see Section 3.6, “Troubleshooting
for Blown Fuse.”
(Action 2)
Check whether seven segment LEDs on the servo
amplifier module are on.
If they are on, perform “Action 4” and all actions that
follow it. If they are not on, perform “Action 3” and
all actions that follow it.
(Action 3)
Check whether connector CX1 on the power supply
module is securely connected.
(Action 4)
Check the communication cable (optical fiber)
between the robot controller PC board and servo
amplifier module. Replace it if it is faulty.
(Action 5)
Replace the axis control card on the robot controller
PC board.
(Action 6)
If the seven--segment LED on the servo amplifier
module is glowing, replace the servo amplifier
module. If the seven--segment LED on the servo
amplifier module is not glowing, replace the power
supply module.
Before continuing to the next step, perform a
complete controller back--up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.
(Action 7)
Replace the robot controller PC board.
Robot controller P.C. board
Servo amplifier module
Power supply module
Axis control card
Fig.3.5 (38) SRVO--058 SVAL2 FSSB init error
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(39) SRVO--059 SVAL2 Servo amp init error
(Explanation) Servo amplifier initialization is failed.
(Action 1)
Check all connectors on the PSM and SVM. Make
sure they are installed correctly.
(Action 2)
Replace the power supply module and the servo
amplifier module.
Servo amplifier module
Power supply module
Fig.3.5 (39) SRVO--059 SVAL2 Servo amp init error
(40) SRVO--061 SVAL2 CKAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if the rotation speed count in the
pulse coder is abnormal (abnormal count clock).
(Action)
Replace the pulse coder.
NOTE
In this case, perform actions associated with DTERR,
CRCERR, or STBERR first.
(41) SRVO--062 SVAL2 BZAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if battery for pulse coder
absolute-position backup is empty.
A probable cause is a broken battery cable or no
batteries in the robot.
(Action)
Remove the cause of the alarm, set the system
variable ($MCR.$SPC RESET) to TRUE, then turn
the power off and on again. Mastering is required.
(42) SRVO--063 SVAL2 RCAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if the rotation speed count in the
pulse coder is abnormal (abnormal counter).
(Action)
Replace the pulse coder.
NOTE
In this case, perform actions associated with DTERR,
CRCERR, or STBERR first.
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(43) SRVO--064 SVAL2 PHAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if the phase of the pulses generated
in the pulse coder is abnormal.
(Action)
Replace the pulse coder.
NOTE
This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.
(44) SRVO--065 WARN BLAL alarm (Group : i Axis : j)
(Explanation) The battery voltage for the pulse coder is lower than
the rating.
(Action)
Replace the battery.
(If this alarm occurs, turn on the AC power and
replace the battery as soon as possible. A delay in
battery replacement may result in the BZAL alarm
being detected. In this case, the position data will be
lost. Once the position data is lost, mastering will
become necessary.
(45) SRVO--066 SVAL2 CSAL alarm (Group : i Axis : j)
(Explanation) The ROM in the pulse coder is abnormal.
(Action)
Replace the pulse coder.
NOTE
This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.
(46) SRVO--067 SVAL2 OHAL2 alarm (Group : i Axis : j)
(Explanation) The temperature inside the pulse coder or motor is
abnormally high, and the built--in thermostat has
operated.
(Action 1)
Check the operating conditions for the robot and relax
the service conditions.
(Action 2)
When power is supplied to the motor after it has
become sufficiently cool, if the alarm still occurs,
replace the motor.
(47) SRVO--068 SVAL2 DTERR alarm (Group : i Axis : j)
(Explanation) The serial pulse coder does not return serial data in
response to a request signal.
--See actions on SRVO--070
(48) SRVO--069 SVAL2 CRCERR alarm (Group : i Axis : j)
(Explanation) The serial data has disturbed during communication.
--See actions on SRVO--070
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(49) SRVO--070 SVAL2 STBERR alarm (Group : i Axis : j)
(Explanation) The start and stop bits of the serial data are abnormal.
(Action 1)
Make sure that the JF1 to JF3 connector of servo
amplifire module is connected tightly.
(Action 2)
Check that the shielding of the robot interconnection
cable (for the pulse coder) and the peripheral equipment
cable is connected securely to the grounding plate.
(Action 3)
Check that each unit is grounded securely.
(Action 4)
Replace the servo amplifier module.
(Action 5)
Replace the pulse coder.
(Action 6)
Replace the robot interconnection cable (RMP).
Servo amplifier module
Fig.3.5 (49) SRVO--070 SVAL2 STBERR alarm
(50) SRVO--071 SVAL2 SPHAL alarm (Group : i Axis : j)
(Explanation) The feedback speed is abnormally high.
(Action 1)
If this alarm occurs together with the PHAL alarm
(No. 064), this alarm does not correspond to the major
cause of the failure.
(Action 2)
Replace the pulse coder.
(51) SRVO--072 SVAL2 PMAL alarm (Group : i Axis : j)
(Explanation) It is likely that the pulse coder is abnormal.
(Action)
Replace the pulse coder and remaster the robot.
(52) SRVO--073 SVAL2 CMAL alarm (Group : i Axis : j)
(Explanation) It is likely that the pulse coder is abnormal or the pulse
coder has malfunctioned due to noise.
(Action)
Master the robot and enhance the shielding.
(53) SRVO--074 SVAL2 LDAL alarm (Group : i Axis : j)
(Explanation) The LED in the pulse coder is broken.
(Action)
Replace the pulse coder, and remaster the robot.
(54) SRVO--075 WARN Pulse not established (Group : i Axis : j)
(Explanation) The absolute position of the pulse coder cannot be
established.
(Action)
Reset the alarm, and jog the axis on which the alarm
has occurred until the same alarm will not occur
again. (Jog one motor revolution)
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(55) SRVO--076 SVAL1 Tip Stick Detection (Group : i Axis : j)
(Explanation) An excessive disturbance was assumed in servo
software at the start of operation. (An abnormal load
was detected. The cause may be welding.)
(Action 1)
Check whether the robot comes into collision with
foreign matter. If a collision occurs, reset the system,
then switch it to the jog feed mode to avoid the
collision.
(Action 2)
Check whether the load settings are valid.
(Action 3)
Check whether the load weight is within the rated
range. If the weight exceeds the upper limit, decrease
it to the limit.
(Use of the robot with a load exceeding the limit
applied may abnormally increase the assumed
disturbance, resulting in this alarm.)
(Action 4)
Check each inter--phase voltage of the three--phase
input (200 VAC) to the power supply module. If the
voltage is 170 VAC or lower, check the input power
supply voltage.
(Action 5)
Replace the power supply module and the servo
amplifier module.
Servo amplifier module
Power supply module
Fig.3.5 (60) SRVO--076 SVAL1 Tip Stick Detection
(56) SRVO--081 WARN EROFL alarm (Track enc : i)
(Explanation) The pulse counter for line tracking has overflowed.
(57) SRVO--082 WARN DAL alarm (Track ebc : i)
(Explanation) The line tracking pulse coder has not been connected.
(Action 1)
Check the pulse coder connection cable, and replace
it if necessary.
(Action 2)
Replace the pulse coder.
(58) SRVO--083 WARN CKAL alarm (Track ebc : i)
(Explanation) This alarm occurs if the rotation speed count in the
pulse coder is abnormal (abnormal count clock).
(Action)
See the description about the SRVO--061 CKAL
alarm.
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(59) SRVO--084 WARN BZAL alarm (Track enc : i)
(Explanation) This alarm occurs if the backup battery for the absolute
position of the pulse coder has not been connected. See
the description about the BZAL alarm (SRVO--062).
(60) SRVO--085 WARN RCAL alarm (Track ebc : i)
(Explanation) This alarm occurs if the rotation speed count in the
pulse coder is abnormal (abnormal counter).
(Action)
See the description about the SRVO--063 RCAL
alarm.
(61) SRVO--086 WARN PHAL alarm (Track enc : i)
(Explanation) This alarm occurs if the phase of pulses generated in
the pulse coder is abnormal. See the description
about the PHAL alarm (SRVO--064).
(62) SRVO--087 WARN BLAL alarm (Track enc : i)
(Explanation) This alarm occurs if the voltage of the backup battery
for the absolute position of the pulse coder is low. See
the description about the BLAL alarm (SRVO--065).
(63) SRVO--088 WARN CSAL alarm (Track ebc : i)
(Explanation) The ROM in the pulse coder is abnormal.
(Action)
See the description about the SRVO--066 CSAL
alarm.
(64) SRVO--089 WARN OHAL2 alarm (Track enc : i)
(Explanation) The motor has overheated. See the description about
the OHAL2 alarm (SRVO--067).
(65) SRVO--090 WARN DTERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
description about the DTERR alarm (SRVO--068).
(66) SRVO--091 WARN CRCERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
description about the CRCERR alarm (SRVO--069).
(67) SRVO--092 WARN STBERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
description about the STBERR alarm (SRVO--070).
(68) SRVO--093 WARN SPMAL alarm (Track enc : i)
(Explanation) This alarm occurs if the current position data from the
pulse coder is higher than the previous position data.
See the description about the SPHAL alarm
(SRVO--071).
(69) SRVO--094 WARN PMAL alarm (Track enc : i)
(Explanation) It is likely that the pulse coder is abnormal. See the
description about the PMAL alarm (SRVO--072).
(70) SRVO--095 WARN CMAL alarm (Track enc : i)
(Explanation) It is likely that the pulse coder is abnormal or the pulse
coder has malfunctioned due to noise. See the
description about the CMAL alarm (SRVO--073).
(71) SRVO--096 WARN LDAL alarm (Track enc : i)
(Explanation) The LED in the pulse coder is broken. See the
description about the LDAL alarm (SRVO--074).
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(72) SRVO--097 WARN Pulse not established (enc : i)
(Explanation) The absolute position of the pulse coder cannot be
established. See the description about (SRVO--075).
Pulse not established.
(73) SRVO--131 SVAL1 LVAL (PSM) alarm (Group : i Axis : j)
(Explanation) The control power supply voltage (for example, +5
V) on the power supply module is abnormally low.
The LED indication on the power supply module is
“6” (LVAL).
(Action 1)
Replace the power supply module.
Power supply module
Fig.3.5 (73) SRVO--131 SVAL1 LVAL(PSM) alarm
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(74) SRVO--134 SVAL1 DCLVAL (PSM) alarm (Group : i Axis : j)
(Explanation) The DC voltage (DC link voltage) of the main circuit
power supply on the power supply module is
abnormally low. The LED indication on the power
supply module is “4.”
--If this alarm occurs during robot operation:
(Action 1)
Check the phase voltage of the three--phase input (200
VAC) to the power supply module. If it is 170 VAC
or lower, check the input power supply voltage.
(Action 2)
Replace the power supply module.
--If this alarm occurs before the magnetic contactor (MCC) is turned
on:
(Action 1)
Check the emergency stop PC board and the wiring
between the power supply module and magnetic
contactor (MCC) for an abnormal condition.
(Action 2)
Replace the magnetic contactor (MCC).
(Action 3)
Replace the emergency stop unit.
(Action 4)
Replace the power supply module.
Servo amplifier module
Power supply module
Emergency stop unit
Magnetic contactor
Fig.3.5 (74) SRVO--134 SVAL1 DCLVAL (PSM) alarm
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(75) SRVO--135 SVAL FSAL alarm (Group : i Axis : j)
(Explanation) The internal cooling fan (s) of the servo amplifier
module (s) is abnormal. The LED indication on the
relevant servo amplifier module is “1.”
(Action 1)
Replace the fan motor of the servo amplifier module.
(Action 2)
Replace the servo amplifier module.
Fan
Servo amplifier module
Servo amplifier module
Fig.3.5 (75) SRVO--135 SVAL FSAL alarm
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(76) SRVO--136 SVAL1 DCLVAL alarm (Group : i Axis : j)
(Explanation) The servo the DC current of amplifier (DC link
voltage) of the main power supply is abnormally low.
The LED indication on the power supply module
becomes “4”, and the LED indication on the servo
amplifier module becomes “5”.
--This alarm occured in the robot operation.
(Action 1)
Check the phase voltage of the three--phase input
power (200 VAC) to the power supply module. If it
is 170 VAC or lower, check the line voltage.
(Action 2)
Replace the power supply module and the servo
amplifier module.
--If this alarm occurs before the magnetic contactor is turned on:
(Action 1)
Check the emergency stop PC board and the wiring
between the power supply module and electromagnetic
contactor (MCC) for an abnormal condition.
(Action 2)
Replace the magnetic contactor.
(Action 3)
Replace the E--stop unit.
(Action 4)
Replace the power supply module.
Magnetic contactor
Robot controller P.C. board
Servo amplifier module
Power supply module
Fig.3.5 (76) SRVO--136 SVAL1 DCLVAL alarm
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(77) SRVO--156 SVAL1 IPMAL alarm (Group : i Axis : j)
(Explanation) Abnormally high current flowed through the main
circuit of the servo amplifier.
The LED indications on the servo amplifier modules
are “8.”, “9.”, and “A.”.
(Action 1)
Detach the motor power lines from the connectors
CZ2 of the servo amplifier modules, then turn on the
power. If this operation causes the error to recur,
replace the servo amplifier module.
(Action 2)
Detach the motor power lines from the connectors
CZ2 of the servo amplifier modules, then check the
insulation between GND and each of the motor power
lines U, V, and W individually. If a short--circuit is
found, the motor, robot interconnection cable, or
intra--robot cable may be faulty. Examine each of
them for any problem.
(Action 3)
Detach the motor power lines from the connectors
CZ2 of the servo amplifier modules, then measure the
resistance between the motor power lines U and V, V
and W, and W and U, using an ohmmeter with a very
low resistance range. If the three resistances are
different, the motor, robot connection cable, or
intra--robot cable may be faulty. Examine each of
them for any problem.
Before taking (Action 4), make a backup copy of all
the programs and settings of the control unit.
(Action 4)
Replace the robot controller PC board.
Robot controller P.C. board
Servo amplifier module
Fig.3.5 (77) SRVO--156 SVAL1 IPMAL alarm
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(78) SRVO--157 SVAL1 CHGAL alarm (Group : i Axis : j)
(Explanation) The capacitor for the DC link voltage of the servo
amplifier module was not charged within the
specified time.
(Action 1)
A short circuit may occur in the DC link voltage.
Check the connection.
(Action 2)
Replace the servo amplifier module.
(Action 3)
Replace the power supply module.
Servo amplifier module
Power supply module
Fig.3.5 (78) SRVO--157 SVAL1 CHGAL alarm
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(79) SRVO--201 SVAL1 Panel E--stop or SVEMG abnormal
(Explanation) The EMERGENCY STOP button on the operator
panel was pressed, but the EMERGENCY STOP line
was not disconnected.
(Action 1)
Check the EMERGENCY STOP button on the
operator panel, and replace it if necessary.
(Action 2)
Check whether fuse FUS3 on the emergency stop PC
board is blown. Replace if it is blown.
(Action 3)
Check whether +24 V is connected to EMGIN2 on the
terminal block TBEB5 of the emergency stop PC
board by mistake. Correct any wrong wiring.
(Action 4)
Replace the emergency stop unit.
(Action 5)
Replace the power supply module.
NOTE
This alarm might occur if the EMERGENCY STOP button
is pressed slowly.
emergency stop button
Power supply module
Emergency stop unit
Fig.3.5 (79) SRVO--201 SVAL1 Panel E--stop or SVEMG abnormal
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(80) SRVO--202 SVAL1 TP E--stop or SVEMG abnormal
(Explanation) The EMERGENCY STOP button on the operator
panel was pressed, but the EMERGENCY STOP line
was not disconnected.
(Action 1)
Check the teach pendant connection cable.
(Action 2)
Replace the teach pendant.
(Action 3)
Check whether +24 V is incorrectly connected to
FENCE2 on the terminal block TBEB5 of the
emergency stop PC board. If it is incorrectly
connected, connect it again.
(Action 4)
Replace the emergency stop unit.
(Action 5)
Replace the power supply module.
NOTE
This alarm might occur if the EMERGENCY STOP button
is pressed slowly.
Teach pendant
Teach pendant cable
Emergency
stop button
FENCE2 terminal
Power supply module
Emergency stop unit
Emergency stop P.C. board
Fig.3.5 (80) SRVO--202 SVAL1 TP E--stop or SVEMG abnormal
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(81) SRVO--204 SVAL1 External (SVEMG abnormal) E--stop
(Explanation) Although the switch connected across EMGIN1 and
EMGIN2 on the terminal block TBEB5 of the
emergency stop PC board was pressed, the
EMERGENCY STOP line was not disconnected.
(Action 1)
Check whether +24 V is connected to SVOFF2 on the
terminal block TBEB5 of the emergency stop PC
board by mistake. Correct any wrong wiring.
(Action 2)
Replace the emergency stop unit.
(Action 3)
Replace the power supply module.
Power supply module
Emergency stop unit
Fig.3.5 (81) SRVO--204 SVAL1 External (SVEMG abnormal) E--stop
77
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(82) SRVO--205 SVAL1 Fence open (SVEMG abnormal)
(Explanation) The EMERGENCY STOP line was not disconnected
even though the switch connected between FENCE1
and FENCE2 on the terminal block TBEB5 of the
emergency stop PC board was open.
(Action 1)
Check whether +24 V is connected to EMGIN2 on the
terminal block TBEB5 of the emergency stop PC
board by mistake. Correct any incorrect wiring.
(Action 2)
Replace the emergency stop unit.
(Action 3)
Replace the power supply module.
Power supply module
Emergency stop unit
Fig.3.5 (82) SRVO--205 SVAL1 Fence open (SVEMG abnormal)
78
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3. TROUBLESHOOTING
MAINTENANCE
(83) SRVO--206 SVAL1 Deadman switch (SVEMG abnormal)
(Explanation) The DEADMAN switch was released when the teach
pendant was operable, but the EMERGENCY STOP
line was not disconnected.
(Action 1)
Check whether +24 V is incorrectly connected to
FENCE1 or FENCE2 on the terminal block TBEB5
of the emergency stop PC board. If it is incorrectly
connected, connect it again.
(Action 2)
Replace the teach pendant.
(Action 3)
Replace the emergency stop unit.
(Action 4)
Replace the power supply module.
Power supply module
Emergency stop unit
Fig.3.5 (83) SRVO--206 SVAL1 Deadman switch (SVEMG abnormal)
79
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(84) SRVO--207 SVAL1 TP switch abnormal or door open
(Explanation) The teach pendant is operable, and the deadman
switch has been grasped, but the EMERGENCY
STOP line is kept disconnected.
(Action 1)
Check the teach pendant connection cable.
(Action 2)
Replace the teach pendant.
(Action 3)
Replace the emergency stop unit.
Teach pendant
teach pendant cable
Emergency stop unit
Fig.3.5 (84) SRVO--207 SVAL1 TP switch abnormal or door open
80
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MAINTENANCE
3. TROUBLESHOOTING
(85) SRVO--215 WARN Fuse blown (Aux axis)
(Explanation) The fuse in the additional axis amplifier has blown.
(Action 1)
Check the cause and solve the problem, then replace
the fuse.
(86) SRVO--216 SVAL1 OVC (total) (Robot : i)
(Explanation) The current (total current for five axes or six axes)
flowing through the motor is too large.
(Action 1)
Slow the motion of the robot where possible. Check
the robot operation conditions. If the robot is used
with a condition exceeding the duty or load weight
robot rating, reduce the load condition value to the
specification range.
(Action 2)
Check each inter--phase voltage of the three--phase
input (200 VAC) to the power supply module. If the
voltage is 170 VAC or lower, check the input power
supply voltage.
Power supply module
Fig.3.5 (86) SRVO--215 WARN Fuse blown (Aux axis)
81
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(87) SRVO--221 SVAL1 Lack of DSP (Group : i Axis : j)
(Explanation) A controlled axis card corresponding to the set
number of axes is not mounted.
(Action 1)
Check whether the set number of axes is valid. If the
number is invalid, set the correct number.
(Action 2)
Replace the controlled axis card with a card
corresponding to the set number of axes.
(Example)
When six axes are set, a controlled axis card for six
or eight axes is available. For how to replace the
controlled axis card, see II MAINTENANCE,
Section 7.2 in this manual.
Robot controller P.C. board
Servo amplifier module
Power supply module
Axis control card
Fig.3.5 (87) SRVO--221 SVAL1 Lack of DSP (Group : i Axis : j)
82
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MAINTENANCE
3. TROUBLESHOOTING
(88) SRVO--222 SVAL1 Lack of Amp (Amp : i)
(Explanation) The FSSB has no SVM.
(Action 1)
Check that the optical cable is securely connected to
the servo amplifier module.
(Action 2)
Replace the optical cable.
(Action 3)
Check whether power is properly supplied to the
servo amplifier module.
Servo amplifier module
Fig.3.5 (88) SRVO--222 SVAL1 Lack of Amp (Amp : i)
83
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(89) SRVO--233 SVAL1 TP disabled in T1, T2/Door open
(Explanation) The teach pendant is disabled when the mode switch
is in the T1 mode or T2 mode position.
(Action 1)
During teaching operation, set the enable switch of
the teach pendant to Enable. Otherwise, set the mode
switch to AUTO mode.
(Action 2)
Replace the emergency stop unit.
(Action 3)
Replace the teach pendant.
(Action 4)
The mode switch may be faulty. Replace the operator
panel.
Teach pendant
Mode switch
FUS3
Emergency stop P.C. board
Emergency stop unit
Fig.3.5 (89) SRVO--233 SVAL1 TP disabled in T1, T2/Door open
84
B--81525EN--1/01
3. TROUBLESHOOTING
MAINTENANCE
(90) SRVO--264 SVAL1 “E.STOP circuit abnormal 1”
(Explanation) An error occurred in the emergency stop circuit.
(Action 1)
Check whether the CRR78 connectors on the
E--STOP unit and the CX3 connector of the power
supply module are connected securely.
(Action 2)
Replace the emergency stop unit.
(Action 3)
Replace the power supply module.
Power supply module
Emergency stop unit
Fig.3.5 (90) SRVO--264 SVAL1 “E.STOP circuit abnormal 1”
85
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(91) SRVO--265 SVAL1 E.STOP circuit abnormal 2
(Explanation) When the servo amplifier is excited, the monitor
contact of the magnetic contactor (MCC) becomes
faulty.
(Action 1)
Replace the magnetic contactor (MCC).
(Action 2)
Replace the emergency stop unit.
(Action 3)
Replace the power supply module.
Power supply module
Emergency stop unit
Magnetic contactor
Fig.3.5 (91) SRVO--265 SVAL1 E.STOP circuit abnormal 2
86
B--81525EN--1/01
MAINTENANCE
3. TROUBLESHOOTING
(92) SRVO--290 SVAL1 DClink HC alarm (Group : i Axis : j)
(Explanation) The DC link current in the servo amplifier module(s)
is abnormal. The LED indication on the relevant
servo amplifier module is “8.”
(Action 1)
Detach the motor power lines from connector CZ2 of
the servo amplifier module, then turn the power on.
If this alarm persists, replace the servo amplifier
module.
(Action 2)
Detach the motor power lines from connector CZ2 of
the servo amplifier module, then check the insulation
between GND and each of U, V, and W of the motor
power lines. If a short circuit is detected, the motor,
robot connection cable, or internal robot cable may be
defective. Check them for an abnormal condition.
(Action 3)
Detach the motor power lines from connector CZ2 of
the servo amplifier module, then use a high--precision
ohmmeter to measure U--V, V--W, and W--U
resistances of the motor power lines. If the three
resistances differ, the motor, robot connection cable,
or internal robot cable may be defective. Check them
for an abnormal condition.
Before proceeding with (Action 4), back up all
programs and settings for the control unit.
(Action 4)
Replace the robot control PC board.
Robot controller P.C. board
Servo amplifier module
Fig.3.5 (92) SRVO--290 SVAL1 DClink HC alarm
87
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(93) SRVO--291 SVAL1 “IPM over heat (Group : i Axis : j)”
(Explanation) The IPM in the servo amplifier overheats.
The LED indications on the servo amplifier modules
are “8.”, “9.”, and “A.”.
(Action 1)
Check whether the servo amplifier module fan stops.
(Action 2)
Reduce the override because the use condition is too
hard.
(Action 3)
If this alarm is frequently issued, replace the amplifier
module.
(94) SRVO--295 SVAL1 SVM COM alarm (Group : i Axis : j)
(Explanation) Communication between the servo amplifier
modules is abnormal. The LED indications on the
servo amplifier modules are “P.”
(Action 1)
If “SRVO -- 047 LVAL alarm” and “SRVO -- 131
LVAL (PSM) alarm” also occur, the control power
supply voltage is low. Take measures against these
alarms.
(Action 2)
Check the servo amplifier modules and cables for
connectors CX2A and CX2B of the power supply
module, as well as their connection.
(Action 3)
Replace the axis control card on the robot control PC
board.
(Action 4)
Replace the servo amplifier modules.
Before proceeding with (Action 5), back up all
programs and settings for the control unit.
(Action 5)
Replace the robot control PC board.
Robot controller P.C. board
Servo amplifier module
Power supply module
Axis control card
Fig.3.5 (94) SRVO--295 SVAL1 SVM COM alarm
88
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MAINTENANCE
3. TROUBLESHOOTING
(95) SRVO--296 SVAL1 DCAL alarm (Group : i Axis : j)
(Explanation) The regenerative discharge energy is too high to be
dissipated as heat. (To move the robot, the servo
amplifier supplies energy to the robot. When going
down, the robot moves along the vertical axis as the
potential energy reduces. If a reduction in the
potential energy is larger than the amount of
acceleration energy, the servo amplifier receives
energy from the motor. This also occurs at
deceleration even when no gravity is applied. The
energy that the servo amplifier receives from the
motor is called regenerative energy. The servo
amplifier dissipates this energy as heat. If the amount
of the regenerative energy dissipated as heat is
smaller than was received, the remainder is stored in
the servo amplifier, causing this alarm.) The LED
indication on the power supply module is “8”
(DCAL: regenerative energy adder detection).
(Action 1)
This alarm may occur if the robot is subjected to
frequent acceleration/deceleration or if the vertical
axis generates a large amount of regenerative energy.
In this case, relax the service conditions.
(Action 2)
Replace the power supply module.
Power supply module
Fig.3.5 (95) SRVO--296 SVAL1 DCAL alarm
89
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(96) SRVO--297 SVAL1 DCLVAL alarm (Group : i Axis : j)
(Explanation) An open--phase condition has occurred in the input
power supply to the main circuit on the power supply
module. The LED indications on the power supply
module is “E.”
(Action 1)
Check the phase voltage of the three--phase input (200
VAC) to the power supply module. If an open--phase
condition is detected, check the input power supply.
(Action 2)
Replace the power supply module.
Power supply module
Fig.3.5 (96) SRVO--297 SVAL1 DCLVAL alarm
(97) SRVO--300 SVAL1 Hand broken/HBK disabled
SRVO--302 SVAL1 Set Hand broken to ENABLE
(Explanation) Although HBK was disabled, the HBK signal was
input.
(Action 1)
Press RESET on the teach pendant to release the
alarm.
(Action 2)
Check whether the hand broken signal is connected to
the robot. When the hand broken signal circuit is
connected, enable hand broken.
(See II
CONNECTION, Section 3.8 in this manual.)
Robot controller P.C. board
Fig.3.5 (97)
90
SRVO--300 SVAL1 Hand broken/HBK disabled
SRVO--302 SVAL1 Set Hand broken to ENABLE
B--81525EN--1/01
MAINTENANCE
3. TROUBLESHOOTING
(98) SRVO--322 SVOFF input/E.STOP
(Explanation) SVOFF1 and SVOFF2 on the terminal block TBEB5
of the emergency stop PC board are not
short--circuited. If a servo off input signal line is
connected across SVOFF1 and SVOFF2, the servo
off input signal contact is open.
(Action 1)
If the servo off input signal line is connected, close the
servo off input signal contact.
(Action 2)
Examine the cables and switches connected to
SVOFF1 and SVOFF2.
(Action 3)
If this signal is not used, short--circuit SVOFF1 and
SVOFF2.
NOTE
If the system uses the servo off input signal, avoid
short--circuiting and disabling this signal. It is very
dangerous. If the system has to be operated with the signal
short--circuited temporarily, a corresponding safety
provision must be taken.
(Action 4)
Replace the emergency stop unit.
Before taking (Action 5), make a backup copy of all
the programs and settings of the control unit.
Replace the robot controller PC board.
(Action 5)
Short
connection
board
Robot controller P.C. board
Emergency stop unit
Fig.3.5 (98) SRVO--322 SVOFF input/E.STOP
91
3. TROUBLESHOOTING
MAINTENANCE
3.6
This section describes alarms that can occur when a fuse mounted on a PC
board or unit is blown and corresponding corrective actions.
TROUBLESHOOTING
USING FUSES
Name
B--81525EN--1/01
(1) Fuses on the robot controller PC board
FUS1 : For generating power to the control circuit
FUS2 : For protecting +24E output to peripheral device digital
input/output, end effector, ROT, and HBK
Problem caused by blown fuse
Action
FUS1
The control power of the robot controller PC board is shut off.
The teach pendant displays the initial screen.
FUS2
The teach pendant screen displays alarm information such as 1 Check that +24E used by the peripheral device is free from a
Hand broken (SERVO -- 006) or Robot overtravel (SERVO -ground fault.
005).
2 Examine the peripheral device connection cable.
3 Check that +24E used by the end effector is free from a ground
fault.
4 Examine the robot interconnection cable and intra--robot
cable.
FUS1
FUS2
92
1 Check the units (fans) and cables connected to the CP2 and
CP3 connectors of the power supply unit to see if there is any
short circuit.
2 Replace the DC/DC converter module.
3 Replace the robot controller PC board.
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(2) Fuses on the emergency stop PC board
FUS3 : For monitoring the emergency stop circuit
FUS4 : For controlling the emergency stop circuit and teach pendant
FUS5 : For the brake circuit
Name
Problem caused by blown fuse
Action
FUS3
The teach pendant screen displays SVAL1 TP disabled in T1, T2/Door open (SERVO -- 233) and so forth.
Replace the emergency stop unit.
FUS4
The power supply to the teach pendant stops, the
screen display of the teach pendant disappears, and
the system enters the emergency stop state.
1 Examine the teach pendant cable for any problem.
2 Examine the teach pendant for any problem.
3 Check that the external emergency stop input and servo off input are
free from a ground fault and any other fault.
FUS5
Replace the emergency stop unit.
The robot motor brake cannot be released, and alarm
information such as Large error in travel (SERVO -024), Large error at rest (SERVO -- 023), Positioning
time over (SERVO -- 036), or CLALM alarm (SERVO
-- 050) is displayed.
1 Check that the robot interconnection cable (RMP) and intra--mechanical--unit cable are free from faults such as a ground fault and short--circuit.
2 If an additional axis is used, check that the brake connection cable is
free from a ground fault, short--circuit, and any other fault.
3 If a brake power transformer is used, note that a faulty brake power
transformer can cause a too large current to flow. Replace the brake
power transformer.
4 Replace the emergency stop unit.
FUS4
FUS3
FUS5
Emergency stop P.C.board
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3. TROUBLESHOOTING
MAINTENANCE
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(3) Fuse on the power supply module
FU1 : For protecting 200 VAC input to generate power to the
control circuit
Name
FU1
Problem caused by blown fuse
Action
ALL LEDs of the servo amplifiers go out.
1 Replace the fuse (5 A) on the control PC board of the power
The teach pendant screen displays the FSSB disconnection
supply module.
alarm or FSSB initialization alarm.
2 Replace the power supply module.
FU1
Remove the face plate
94
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MAINTENANCE
3. TROUBLESHOOTING
(4) Fuse on the servo amplifier module
FU1 : For protecting +24 V input to generate power to the control
circuit
Name
FU1
Problem caused by blown fuse
Action
ALL LEDs of the servo amplifier modules go out.
1 Replace the fuse (3.2 A) on the control PC board of the servo
The teach pendant screen displays the FSSB disconnection
amplifier module.
alarm or FSSB initialization alarm.
2 Replace the servo amplifier module.
FU1
Remove the control P.C. board
95
3. TROUBLESHOOTING
3.7
TROUBLESHOOTING
BASED ON LED
INDICATIONS
MAINTENANCE
B--81525EN--1/01
The printed circuit boards and servo amplifier are provided with alarm
LEDs and status LEDs.
The LED status and corresponding
troubleshooting procedures are described below.
Robot controller P.C. board
Emergency stop P.C.board
96
Servo amplifier module2 (AMP2)
Servo amplifier module1 (AMP1)
Power supply module (PSM)
MAINTENANCE
B--81525EN--1/01
3. TROUBLESHOOTING
(1) TROUBLESHOOTING USING THE LEDS ON THE robot
controller PC board
To troubleshoot an alarm that arises before the teach pendant is ready
to display, check the status LEDs (green) on the robot controller PC
board at power--on.
After power--on, the LEDs light as described in steps 1 to 18, in the
order described. If an alarm is detected, the step in which the alarm
occurred can be determined from which LEDs are lit.
Step
LED
Action to be taken
1: After power--on, all LEDs are
lit.
[Action1] Replace the CPU card
* [Action2] Replace the robot controller PC board.
2: Software operation start--up.
[Action1] Replace the CPU card
* [Action2] Replace the robot controller PC board.
3: The initialization of dram on
the CPU card is completed.
[Action1] Replace the CPU card
* [Action2] Replace the robot controller PC board.
4: The initialization of SRAM
and DPRAM is completed.
[Action1] Replace the CPU card
* [Action2] Replace the robot controller PC board.
* [Action3] Replace the FROM/SRAM module.
5: The initialization of the communication IC is completed.
[Action1] Replace the CPU card
* [Action2] Replace the robot controller PC board.
* [Action3] Replace the FROM/SRAM module.
6: The loading of the basic software is completed.
* [Action1] Replace the robot controller PC board.
* [Action2] Replace the FROM/SRAM module.
7: Basic software start--up.
* [Action1] Replace the robot controller PC board.
* [Action2] Replace the FROM/SRAM module.
8: Start--up of communication
with the teach pendant.
* [Action1] Replace the robot controller PC board.
* [Action2] Replace the FROM/SRAM module.
9: The loading of optional software is completed.
* [Action1] Replace the robot controller PC board.
10:DI/DO initialization
* [Action1] Replace the FROM/SRAM module.
* [Action2] Replace the robot controller PC board.
11: The preparation of the SRAM
module is completed.
[Action1] Replace the axis control card.
* [Action2] Replace the robot controller PC board.
[Action3] Replace the servo amplifier.
* If the robot controller PC 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.
97
3. TROUBLESHOOTING
Step
MAINTENANCE
LED
B--81525EN--1/01
Action to be taken
12:Axis control card initialization
[Action1] Replace the axis control card.
* [Action2] Replace the robot controller PC board.
[Action3] Replace the servo amplifier.
13:Calibration is completed.
[Action1] Replace the axis control card.
* [Action2] Replace the robot controller PC board.
[Action3] Replace the servo amplifier.
14:Start--up of power application
for the servo system
* [Action1] Replace the robot controller PC board.
15:Program execution
* [Action1] Replace the robot controller PC board.
16:DI/DO output start--up.
* [Action1] Replace the robot controller PC 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 robot controller PC board or FROM/SRAM module is replaced, the contents of memory (parameters,
specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.
Axis control card
FROM/SRAM module
(under the CPU card)
98
CPU card
MAINTENANCE
B--81525EN--1/01
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 robot
controller PC board.
[Action1]
Replace the CPU card.
[Action2]
Replace the robot controller PC board.
[Description] A parity alarm condition has occurred in RAM on the FROM/SRAM module installed
on the robot controller PC board.
[Action1]
Replace the FROM/SRAM module.
[Action2]
Replace the robot controller PC board.
“2”, “3”, and “4” are not displayed.
[Description] A servo alarm condition has occurred on the robot controller PC board.
[Action1]
Replace the axis control card.
[Action2]
Replace the robot controller PC board.
[Description] The SYSEMG alarm has occurred.
[Action1]
Replace the axis control card.
[Action2]
Replace the CPU card.
[Action3]
Replace the robot controller PC board.
[Description] The SYSFAIL alarm has occurred.
[Action1]
Replace the axis control card.
[Action2]
Replace the CPU card.
[Action3]
Replace the robot controller PC board.
* If the robot controller PC 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.
99
3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
(3) Troubleshooting using a fuse alarm LED
LED indication
Failure description and required measure
[Description] A fuse (FUS1 or FUS2) is blown.
Cause of the blowing of FUS1 and corrective actions
[Action1]
Check whether the device which is connected to the RS--232--C/RS--422 port
and requires the power supply of +24 V is sound.
[Action2]
Faulty DC/DC converter module
Replace the DC/DC converter module.
[Action3]
Short--circuited surge absorber PVS1
The system can be operated temporarily without PVS1. However, obtain and
mount a new one at the earliest possible time.
[Action4]
Faulty robot controller PC board
Replace the robot controller PC board.
Cause of the blowing of FUS2 and corrective actions
[Action1]
Check that +24E used by the peripheral device is free from a ground fault.
[Action2]
Examine the peripheral device connection cable.
[Action3]
Check that +24E used by the end effector is free from a ground fault.
[Action4]
Examine the robot interconnection cable and intra--robot cable.
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MAINTENANCE
3. TROUBLESHOOTING
Troubleshooting using an LED on the emergency stop PC board
LED indication
Problem and corrective action
[Description] The fuse (FUS3, FUS4, or FUS5) is blown.
Cause of the blowing of FUS3 and corrective action
[Action]
The emergency stop PC board is faulty. Replace the emergency stop unit.
Cause of the blowing of FUS4 and corrective actions
[Action1]
Check that the teach pendant cable is sound.
[Action2]
Check that the teach pendant is sound.
[Action3]
Check that the external emergency stop input and servo off input are free from
a ground fault and any other fault.
[Action4]
The emergency stop PC board is faulty. Replace the emergency stop unit.
Cause of the blowing of FUS5 and corrective actions
[Action1]
Check that the robot interconnection cable (RMP) and intra--mechanical--unit
cable are free from a ground fault, short--circuit, and any other fault.
[Action2]
If an additional axis is used, check that the brake connection cable is free from
a ground fault, short--circuit, and any other fault.
[Action3]
If a brake power transformer is used, note that a faulty brake power transformer
can cause a too large current to flow. Replace the brake power transformer.
[Action4]
The emergency stop PC board is faulty. Replace the emergency stop unit.
FALM LED
Fuse FUS4
Fuse FUS3
Fuse FUS5
Emergency stop P.C.board
Emergency stop unit
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3. TROUBLESHOOTING
MAINTENANCE
B--81525EN--1/01
Troubleshooting using the LED of the power supply module
The power supply module has a seven--segment LED. When taking
a corrective action corresponding to the LED indication, see the alarm
displayed on the teach pendant screen.
dot part of
seven segment LED
LED indication
Problem and corrective action
[Description] The voltage of the DC link of the main circuit is low.
[Action1]
The input power was instantaneously interrupted.
Check the power supply.
[Action2]
The input supply voltage is low. Check the power requirements.
[Action3]
The power to the main circuit was shut off in the emergency stop release state. Check the emergency stop circuit (emergency stop PC board, magnetic contactor, external emergency stop input, etc.).
[Description] The main circuit could not be charged within a predetermined period.
[Action1]
The DC link is short--circuited. Check the connection.
[Action2]
The charge current controlling resistor is faulty. Replace
the power supply module.
[Description] The control power voltage is low.
[Action]
The input power is low. Check the power supply.
[Description] The voltage of the DC link of the main circuit is too high.
[Action1]
The regenerative power is too large. Change the operating conditions.
[Action2]
The regenerative resistor is faulty. Replace the power
supply module.
[Description] The regeneration amount is too large.
[Action]
Change the operating conditions. For instance, lower
the frequency of acceleration/deceleration.
[Description] The regenerative resistor was heated.
[Action]
Change the operating conditions. For instance, lower
the frequency of acceleration/deceleration.
[Description] The input power is in the open--phase state.
[Action]
Check the power supply.
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3. TROUBLESHOOTING
MAINTENANCE
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Troubleshooting using the LED of the servo amplifier module
The servo amplifier module has a seven--segment LED. When taking
a corrective action corresponding to the LED indication, see the alarm
displayed on the teach pendant screen.
dot part of
seven segment LED
LED indication
Problem and corrective action
[Description] The internal cooling fan stopped.
[Action1]
Check that the fan is not blocked with a foreign substance.
[Action2]
Check that the fan connector is correctly connected.
[Action3]
The fan is faulty. Replace the fan.
[Action4]
Replace the servo amplifier module.
[Description] The control supply voltage is low.
[Action1]
Check the three--phase input voltage. (The voltage must
be the rated input voltage multiplied by 0.85 at least.)
[Action2]
Measure the voltage of 24--V power supplied from the
power supply module. (Normal: 22.8 V or higher)
[Action3]
Check the CXA2A/B connector and the cable.
[Action4]
Replace the servo amplifier module.
[Description] The voltage of the DC link of the main circuit is low.
[Action1]
Check that the DC link connection cable (bar) is securely
screwed.
[Action2]
If this alarm occurs in multiple servo amplifier modules,
take the action for alarm code 4 of the power supply module.
[Action3]
Replace the servo amplifier module.
[Description] The communication among servo amplifiers cannot be
normally performed.
[Action1]
Check the CXA2A/B connector and the cable.
[Action2]
Replace the control PC board of the servo amplifier module.
[Action3]
Replace the servo amplifier module.
103
3. TROUBLESHOOTING
MAINTENANCE
LED indication
B--81525EN--1/01
Problem and corrective action
[Description1] The IPM alarm was detected in the servo amplifier module.
[Action1]
Detach the motor power lines from the connectors CZ2
of the servo amplifier modules, and turn the power on.
a) If this alarm does not occur, go to Action 2.
[Action2]
[Action3]
b) If this alarm occurs, replace the servo amplifier
module.
Detach the motor power lines from the connectors CZ2
of the servo amplifier modules, and check the insulation
between PE and each of the motor power lines U, V, and
W.
a) If the insulation is deteriorated, go to Action 3.
b) If the insulation is normal, replace the servo amplifier module.
Separate the motor and power line, then check whether
the motor or power line has deteriorated insulation.
a) If the motor insulation is deteriorated, replace the
motor.
b) If the power line insulation is deteriorated, examine
the robot interconnection cable or intra--robot cable.
“8.”, “9.”, and “A.” represent that an alarm occurs on the L--axis, M-axis, and N--axis respectively.
[Description2] The IPM alarm (overheat) was detected in the servo
amplifier module.
[Action1]
Check that the internal cooling fan does not stop.
[Action2]
Check that the motor is operated at its continuous rating
or lower.
[Action3]
Check that the cooling capability of the cabinet is not lowered. (Check the fan unit and heat exchanger.)
[Action4]
Check that the ambient temperature is not high.
[Action5]
Replace the servo amplifier module.
“8.”, “9.”, and “A.” represent that an alarm occurs on the L--axis, M-axis, and N--axis respectively.
104
MAINTENANCE
B--81525EN--1/01
LED indication
3. TROUBLESHOOTING
Problem and corrective action
[Description] An abnormal current is flowing to the servo motor.
[Action1]
Check that the servo parameters are set to default values. If this alarm occurs only at a sudden acceleration
or deceleration, the motor operating conditions may be
too harsh. Increase the acceleration/deceleration time
constant and observe the operation.
[Action2]
Detach the motor power lines from the connectors CZ2
of the servo amplifier modules, then turn on the power.
a) If this alarm does not occur, go to Action 2.
[Action3]
[Action4]
b) If this alarm occurs, replace the servo amplifier
module.
Detach the motor power lines from the connectors CZ2
of the servo amplifier modules, then check the insulation
between PE and each of the power lines U, V, and W.
a) If the insulation is deteriorated, go to Action 3.
b) If the insulation is normal, replace the servo amplifier.
Separate the motor and power line, then check whether
the motor or power line has deteriorated insulation.
a) If the motor insulation is deteriorated, replace the
motor.
b) If the power line insulation is deteriorated, examine
the robot interconnection cable and intra--robot
cable.
“b”, “C”, and “d” represent that an alarm occurs on the L--axis, M--axis,
and N--axis respectively.
105
3. TROUBLESHOOTING
3.8
POSITION DEVIATION
FOUND IN RETURN
TO THE REFERENCE
POSITION
(POSITIONING)
MAINTENANCE
B--81525EN--1/01
(Check 1) On the status screen, check the position deviation in the
stopped state. To display the position deviation, press the
screen selection key, and select STATUS from the menu.
Press F1, [TYPE], select AXIS from the menu, then press
the F4, PULSE.
(Corrective action)
Correct the parameters related to return to the reference
position (positioning).
(Check 2) Check whether the motor axis can be positioned normally.
(Corrective action)
If the motor axis can be positioned normally, check the
mechanical unit.
(Check 3) Check the mechanical unit for backlash.
(Corrective action)
Replace a faulty key of motor shaft or other faulty parts.
(Check 4) If checks 1 to 3 show normal results
(Corrective action)
Replace the pulse coder and robot controller PC board.
106
B--81525EN--1/01
3.9
VIBRATION
OBSERVED DURING
MOVEMENT
MAINTENANCE
3. TROUBLESHOOTING
(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.
107
3. TROUBLESHOOTING
3.10
MANUAL
OPERATION
IMPOSSIBLE
MAINTENANCE
B--81525EN--1/01
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 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.
(Check 5) Check whether the previous manual operation has been
completed.
(Corrective action)
If the robot cannot be placed in the effective area because of
the offset of the speed command voltage preventing the
previous operation from being completed, check the position
deviation on the status screen, and change the setting.
(Check 6) Check whether the controller is in the alarm status.
(Corrective action)
Release the alarm.
(2) Check and corrective action to be taken if the program cannot be
executed
(Check 1) Check whether the ENBL signal for the peripheral-device
control interface is on.
(Corrective action)
Put the peripheral-device control interface in the ENBL state.
(Check 2) Check whether the HOLD signal for the peripheral-device
control interface is on. (Check whether the HOLD lamp on
the teach pendant is on.)
(Corrective action)
If the HOLD signal is on, turn it off.
108
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MAINTENANCE
3. TROUBLESHOOTING
(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.
109
4. PRINTED CIRCUIT BOARDS
4
MAINTENANCE
B--81525EN--1/01
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.
110
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81525EN--1/01
4.1
ROBOT CONTROLLER
PC BOARD
(A16B--3200--0450)
FROM/SRAM module
under the CPU card
CPU card
DC/DC converter module
Total version
Axis control card
Fig.4.1 Robot controller PC board
Name
Board Specification
Note
Robot controller PC
board
A16B--3200--0450
I/O Link master/slave switcheable, SDI/SDO = 28/24
DC/DC convert module
A20B--8100--0721
CPU card
A20B--3300--0106
SDRAM 8M (Standard)
A20B--3300--0107
SDRAM 16M
A20B--3300--0241
6--axis
A20B--3900--0181
FROM 16M, SRAM 0.5M :
Standard
A20B--3900--0160
FROM 16M, SRAM 1MB
A20B--3900--0161
FROM 16M, SRAM 2MB
A20B--3900--0162
FROM 32M, SRAM 3MB
Axis control card
FROM/SRAM module
111
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81525EN--1/01
(1) LEDs
Seven segment LED
Description
A parity alarm occurred in a RAM of the main CPU
card on the Robot controller PC board.
A parity alarm occurred in a RAM of the FROM/
SRAM module on the Robot controller PC board.
“2”, “3”, and “4” are not displayed.
A servo alarm occurred on the Robot controller PC
board.
SYSEMG occurred.
SYSFAIL occurred.
This number appears temporarily after the power is
switched on, but it is not abnormal.
112
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MAINTENANCE
Status LED
4. PRINTED CIRCUIT BOARDS
Description
STATUS
LED
Indicates the system operating status.
Status LED
FUSE
ALARM
LED
113
Description
A fuse (FUS1 or FUS2) was blown.
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
B--81525EN--1/01
(2) Correspondence between driver ICs and DO
Driver IC specification: A76L--0151--0062
Driver IC name
DO signal name
H9
SDO101, SDO102, SDO103, SDO104
G9
SDO105, SDO106, SDO107, SDO108
K9
SDO109, SDO110, SDO111, SDO112
J9
SDO113, SDO114, SDO115, SDO116
J13
SDO119, SDO120, SDO81, Brake control (internal circuit)
H13
SDO82, SDO83, SDO84, Reserved
J6
RDO1, RDO2, RDO3, RDO4
J4
RDO5, RDO6, SDO117, SDO118
(3) Communication IC
If the teach pendant displays nothing because of a damaged teach
pendant connection cable or another reason, the following
communication driver or receiver may be damaged.
IC name
Name and usage
Drawing number
G17
75172, driver
A76L--0151--0098
G16
75173, receiver
A76L--0151--0099
114
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MAINTENANCE
4. PRINTED CIRCUIT BOARDS
4.2
EMERGENCY STOP
PC BOARD
(A20B--1008--0022,
--0023)
Total version
Fig.4.2 Emergency stop control PC board
115
4. PRINTED CIRCUIT BOARDS
MAINTENANCE
4.3
BACKPLANE PC
BOARD
(A20B--2003--0330)
Total version
Fig.4.3 Backplane PC Board
116
B--81525EN--1/01
B--81525EN--1/01
5
MAINTENANCE
5. SERVO AMPLIFIERS
SERVO AMPLIFIERS
The servo amplifiers are factory-set for operation. Usually, you do not
need to set or adjust them.
This chapter describes the standard settings and adjustment required if a
defective servo amplifier is replaced. It also describes the use of test pins
and meanings of the LED indications.
Table 5 Servo amplifier specifications
Robot
LR Mate 100iB
LR Mate 200iB
Power supply module
A06B--6115--H001
(αPSMR--1i)
Servo amplifier module1
A06B--6114--H205
(αSVM--20/20i)
L
M
J1
J2
A06B--6114--H302
(αSVM--10/10/10i)
L
M
N
J1
J2
J3
A06B--6115--H001
(αPSMR--1i)
117
Servo amplifier module2
A06B--6114--H302
(αSVM--10/10/10i)
L
M
N
J3
J4
J5
A06B--6114--H302
(αSVM--10/10/10i)
L
M
N
J4
J5
J6
5. SERVO AMPLIFIERS
MAINTENANCE
B--81525EN--1/01
5.1
OUTLINE DRAWINGS
5.1.1
Power Supply Module
PSM (A06B--6115--H001)
380
360
60
172
Fig.5.1.1 Outline drawing of power supply module PSM (A06B--6115--H001)
118
MAINTENANCE
B--81525EN--1/01
5. SERVO AMPLIFIERS
5.1.2
Servo Amplifier Module
(A06B--6114--H205,
A06B--6114--H302)
380
360
60
172
Fig.5.1.2 Outline drawing of servo amplifier modules (A06B--6114--H205, A06B--6114--H302)
119
5. SERVO AMPLIFIERS
MAINTENANCE
B--81525EN--1/01
5.2
LED OF SERVO
AMPLIFIER
5.2.1
LED of Power Supply
Module
dot part of
seven segment LED
The power supply module has a seven--segment LED. When taking a
corrective action corresponding to the LED indication, see the alarm
displayed on the teach pendant screen.
LED indication
Description
The magnetic contactor controlled by the power supply module is in
the off state and is not ready for driving the motor.
The magnetic contactor controlled by the power supply module is in
the on state and is ready for driving the motor.
The voltage of the DC link of the main circuit is low.
The main circuit cannot be charged within a predetermined period.
The control power voltage is low.
The voltage of the DC link of the main circuit is too high.
The regeneration amount is too large.
The regenerative resistor was heated.
The input power is in the open--phase state.
120
5.2.2
LED of Servo Amplifier
Module
dot part of
seven segment LED
5. SERVO AMPLIFIERS
MAINTENANCE
B--81525EN--1/01
The servo amplifier module has a seven--segment LED. When taking a
corrective action corresponding to the LED indication, see the alarm
displayed on the teach pendant screen.
LED indication
Description
The main circuit in the servo amplifier module is in the off state and is
not ready for driving the motor.
The main circuit in the servo amplifier module is in the on state and is
ready for driving the motor.
The internal cooling fan stopped.
The control power voltage is low.
The voltage of the DC link of the main circuit is low.
The communication among servo amplifier modules cannot be normally performed.
a) The IPM alarm was detected in the servo amplifier module.
b) The IPM alarm (overheat) was detected in the servo amplifier module.
“8.”, “9.”, and “A.” represent that an alarm occurs on the L--axis, M-axis, and N--axis respectively.
An abnormal current is flowing to the servo motor.
“b”, “C”, and “d” represent that an alarm occurs on the L--axis, M--axis,
and N--axis respectively.
121
6. SETTING THE POWER SUPPLY
6
MAINTENANCE
B--81525EN--1/01
SETTING THE POWER SUPPLY
The power supply is factory-set for operation. Usually, you do not need
to set or adjust it.
122
6. SETTING THE POWER SUPPLY
MAINTENANCE
B--81525EN--1/01
6.1
BLOCK DIAGRAMS
OF THE POWER
SUPPLY
AC input
Servo amplifier
220, 380, 415,
440, 500 VAC
3φ
Circuit
protector
Power supply module
Magnetic
contactor
(MCC)
Transformer
Circuit
protector
200VAC
200VAC
CZ1
Main circuit
DC link
3φ
2φ
200VAC
2φ
CX1
FU1
regenerative
resistor
FAN
AC/DC
+24V
Emergency stop
unit
Power
supply
unit
CN1
AC/DC
+24V
Emergency stop
print board
FUS3
Servo
amplifier
module
CP5A
FUS4
Monitor circuit
CP5B
CRR77
CXA2A
L+, L--
CXA2B
L+, L-Inverter
circuit
DC/DC
+5V
JF1--3
CZ2 L--N
EmergenFUS5
cy stop
circuit
Brake
circuit
CRS1
TBEB3
+24T
Backplane
Robot controller
P.C. board
DC/DC
converter
module
+5V, +3.3V
+15V, --15V CP8B
+24V
FUS1 CP5
Motor brake
Motor powersupply
BATTERY
Robot
Pulsecoder
Motor
End Effector
+24E
FUS2
+24E
CRM82
Teach pendant
+24E
CRM79
Peripheral device
+24E
Peripheral device
(option)
CRM81
+24V
JD17
Handy file etc.
Process I/O board
+24E FUSE1
+24F
Peripheral device
(option)
CRM2
CRM4
+24E
+24V
--15V
+15V
+5V
+3.3V
Fig. 6.1 Block diagram of the power supply
123
6. SETTING THE POWER SUPPLY
6.2
CHECKING THE
POWER SUPPLY
UNIT
6.3
CHECKING THE
POWER SUPPLY
MODULE
MAINTENANCE
B--81525EN--1/01
The power supply unit need not be set or adjusted.
Table 6.2 Rating of the Power supply unit
Output
Rated voltage
Tolerance
+24V
+24V
+23V to +25V
The power supply module need not be set or adjusted.
Table 6.3 Rating of the Power supply module
Output
Rated voltage
Tolerance
+5V
+5.1V
3%
+3.3V
+3.3V
3%
+15V
+15V
10%
--15V
--15V
10%
124
6. SETTING THE POWER SUPPLY
MAINTENANCE
B--81525EN--1/01
6.4
SELECTING THE
TRANSFORMER
CONNECTION
One of the transformer connections is selected according to the power
voltage.
Rated voltage
Transformer specification
220, 380, 415,
440, 500V
A80L--0022--0009
Teminal arrangement
Transformer
Fig.6.4 Transformer Installation Position and Terminal Block
Table 6.4 Transformer Tap Selection
Power
voltage
Primary side tap connection
L1
L2
L3
220V
4
9
14
380V
4
9
14
415V
3
8
13
440V
2
7
12
500V
1
6
11
Connection line
4-15
9-5
5 10 15
5-10-15
125
ConnecConnec
tion type
14-10
Delta n
Star Y
7. REPLACING A UNIT
7
MAINTENANCE
B--81525EN--1/01
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.
126
B--81525EN--1/01
MAINTENANCE
7. REPLACING A UNIT
7.1
REPLACING THE
PRINTED--CIRCUIT
BOARDS
CAUTIONS
When you replace printed--circuit boards, observe the
following cautions:
1 Keep the control unit power switched off.
2 When you remove a printed--circuit board, do not touch the
semiconductor devices on the board with your hand or
make them touch other components.
3 Make sure that the replacement printed--circuit board has
been set up appropriately. (Setting plug etc.)
4 If the backplane board, power supply unit, or Robot
controller PC 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.
127
7. REPLACING A UNIT
7.1.1
Replacing the
Backplane Board (Unit)
MAINTENANCE
B--81525EN--1/01
When replacing the backplane board, do so together with the plastic rack.
(1) Detach the cables from the robot controller PC board and boards on
the backplane board.
CAUTION
When you remove the main robot controller PC Board, be
sure that the battery is good (3.1--3.3VDC) and it is installed
correctly. USE STATIC PROTECTION.
(2) Remove the robot controller PC board and boards from the rack. (See
Section 7.1.2.)
(3) Detach the grounding cable from the backplane unit.
(4) Loosen the retaining screws in the upper section of the rack. Remove
the retaining screws from the lower section of the rack.
(5) Side rack up and out.
(6) To replace the backplane and rack, reverse steps (1) -- (6).
CAUTION
There is a possibility of data loss when a backplane-mounted printed circuit board is replaced. Be sure to back
up all program and setup data on a floppy disk before
proceeding.
Backplane board
M5 nut (2 places)
Fig.7.1.1 Replacing the Backplane Board
128
7.1.2
Replacing the Robot
Controller PC Board
and Printed--Circuit
Boards on the
Backplane Unit
7. REPLACING A UNIT
MAINTENANCE
B--81525EN--1/01
The backplane unit incorporates the power unit, Robot controller PC
board, and option boards. There are two types of option boards: Full--size
board and mini--size board. A full--size board occupies one slot. A
mini--size board uses part of a full--size board.
CAUTION
Before starting replacement, turn off the control unit main
power. The robot controller PC board is equipped with
battery--backed memory devices for holding robot
parameters and taught data, for example. When the Robot
controller PC board is replaced, the data in the memory
devices is lost.
(1) Detach the cable from the printed--circuit board, whichever is to be
replaced.
(2) Pinch the barbed handles on the upper and lower sections of the board
to unlatch it, then pull it toward you.
(3) Place the replacement board on the rail in the appropriate slot of the
rack, then push it in gently by the handles until it is latched.
(4) There are two rails in the robot controller PC board SLOT (slot 1).
When inserting the robot controller PC board, align it to the
right--side rail.
Slot 1
Option slot
Slot 1
Slot 10
Barbed
handles
Slot 2
Rail
(Left)
Slot 9
Rail
(Right)
zoom
Barbed
handles
Fig.7.1.2 Replacing the Robot Controller PC Board and Printed--Circuit
Boards on the Backplane Unit
129
7. REPLACING A UNIT
MAINTENANCE
B--81525EN--1/01
7.1.3
The board is at the emergency stop unit.
Replacing the
Emergency Stop PC
Board
(1) Detach all cables from the emergency stop unit consists of the
emergency stop PC board and the power supply unit. The terminal
blocks (TBEB5) are of a connector type. Pull out the upper terminal
block sections.
(2) Remove four retaining nuts from the emergency stop unit (1, 2), and
replace the emergency stop unit.
(3) Remove six retaining screws from the emergency stop PC board (3),
and replace the emergency stop PC board.
1 Remove the front nuts
(2--M5)
2 Remove the back nuts (2--M5)
3 Remove the
screws (6--M3)
Fig.7.1.3 Emergency stop PC board replacement
130
B--81525EN--1/01
7. REPLACING A UNIT
MAINTENANCE
7.2
REPLACING CARDS
AND MODULES ON
THE ROBOT
CONTROLLER PC
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
131
7. REPLACING A UNIT
MAINTENANCE
B--81525EN--1/01
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
132
MAINTENANCE
B--81525EN--1/01
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
133
7. REPLACING A UNIT
MAINTENANCE
B--81525EN--1/01
Removing the DC/DC converter module
(1) Unscrew the screws (3--M3).
(2) Pull out the module.
Mounting the module
(1) Insert the module to the connector.
(2) Screw the screws (3--M3).
DC/DC converter module
screws
(3--M3)
Fig.7.2 (d) Mounting and removing the DC/DC converter module
Figure 7.2 (e) shows the locations of the cards and modules.
FROM/SRAM module
under the CPU card
CPU card
DC/DC converter module
Total version
Axis control card
Fig.7.2 (e) Locations of Cards and Modules
134
B--81525EN--1/01
7. REPLACING A UNIT
MAINTENANCE
7.3
REPLACING THE
TRANSFORMER
WARNING
Before you start replacement procedure, turn off the main
power to the control unit. Otherwise you could injure
personnel or damage equipment.
7.3.1
Replacing the Brake
Power Transformer
(1) Detach the cable from the transformer.
(2) Remove the two nuts (M5) securing the transformer, then replace the
transformer.
(3) Re--connect the cable.
Remore the nuts (2--M5)
Fig.7.3.1 Replacing the brake power transformer
135
7. REPLACING A UNIT
MAINTENANCE
B--81525EN--1/01
7.3.2
Replacing the Power
Transformer
(1) Detach the cables from the transformer.
(2) Remove the two screws (M5) securing the transformer and then
replace the transformer.
(3) Connect the detached cables to the transformer.
Remove two screws (M5)
Fig.7.3.2 Replacing the Power Transformer
136
MAINTENANCE
B--81525EN--1/01
7. REPLACING A UNIT
7.4
REPLACING THE
EMERGENCY 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.
Nut (4--M5)
2 Remove the back nuts
(2--M5) screws
1 Remove the front nuts
(2--M5) screws
Fig.7.4 Replacing the Emergency Stop Unit
137
7. REPLACING A UNIT
MAINTENANCE
B--81525EN--1/01
7.5
REPLACING THE
MAGNETIC
CONTACTOR
WARNING
Before starting the replacement, turn off the control unit
main power. Otherwise you could injure personnel or
damage equipment.
(1) Detach the cable from the magnetic contactor (MCC).
(2) Holding down the magnetic contactor (MCC) a little, remove the
MCC from the DIN rail.
(3) Mount a new magnetic contactor (MCC) on the DIN rail.
(4) Re--connect the cable.
Magnetic contactor (MCC)
Fig.7.5 Replacing the magnetic contactor
138
B--81525EN--1/01
MAINTENANCE
7. REPLACING A UNIT
7.6
REPLACING SERVO
AMPLIFIERS
WARNING
Before you start replacement, turn off the control unit main
power. Otherwise you could injure personnel or damage
equipment.
The following is the procedure for replacing the power supply module and
servo amplifier module.
(1) Detach the cable from the servo amplifier. Remove the jumper
connecting the DC link (L+ and L--).
(2) Remove the two nuts from the top of the servo amplifier.
(3) Mount a new servo amplifier, reversing the removal step of (2).
(4) Re--connect the cable and re--mount the jumper connecting the DC
link (L+ and L--).
Nut
(2--M5)
Power supply
module
servo amplifier
module
Fig.7.6 Replacing the servo Amplifier
139
7. REPLACING A UNIT
7.7
REPLACING THE
TEACH PENDANT
MAINTENANCE
B--81525EN--1/01
The specifications of the teach pendant vary with its use. When you
replace the teach pendant, check its specifications carefully.
(1) Be sure that the power of a robot controller is off.
(2) Detach the cable from the teach pendant.
(3) Replace the teach pendant.
Detach or attach the cable by rotating
the connector retaining ring.
Fig.7.7 Replacing the Teach Pendant
140
B--81525EN--1/01
7.8
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.7.8 Replacing the Control Section Fan Motor
141
7. REPLACING A UNIT
7.9
REPLACING THE
FAN MOTOR OF THE
SERVO AMPLIFIER
CONTROL UNIT
MAINTENANCE
B--81525EN--1/01
The fan motor of the servo amplifier control unit can be replaced without
using tools. The fan unit is mounted at the top of the servo amplifier.
(1) Check that the robot controller is turned off.
(2) Holding the two lugs, pull up the fan unit in the direction of the arrow.
(3) Place a new fan unit at the top of the servo amplifier, and slightly press
it in.
Holding the two lugs, pull up the
fan unit in the direction of the arrow
(rightward in the figure).
When mounting the fan motor, note
the orientation of the fan motor and
connector.
Lug
White
Black
Red
Note the orientation
of the connector key.
Fan unit (for width of 60 mm)
Fig.7.9 Replacing the fan motor of the servo amplifier control unit
142
7. REPLACING A UNIT
MAINTENANCE
B--81525EN--1/01
7.10
REPLACING THE
DOOR FAN UNIT AND
HEAT EXCHANGER
WARNING
Before starting the replacement, turn off the control unit
main power. Never touch the fan motor while it is rotating.
Door fan unit
(1) Unscrew the four fastening screws (M4).
(2) Detach the cable from the fan unit.
(3) Mount a spare fan unit, reversing the removal procedure.
Heat exchanger
(1) Detach the cable from the heat exchanger.
(2) Remove the six fastening nuts (M4), and pull the heat exchanger
toward you.
(3) Detach the wiring from the door fan unit.
(4) Mount a spare heat exchanger, reversing the removal procedure.
Heat exchange
Door fan unit
Screws (4--M4)
Nut (4--M5)
Fig.7.10 Replacing the door fan unit and heat exchanger
143
7. REPLACING A UNIT
MAINTENANCE
B--81525EN--1/01
7.11
REPLACING THE
OPERATOR PANEL
(1) Detach the cable from the circuit protector on the operator panel and
the grounding line from the door.
(2) Detach the cable (JD17) from the robot controller PC board and the
cable (CRT12) from the emergency stop PC board.
(3) Unscrew the four screws (M3) fastening the operator panel, and
remove the operator panel.
(4) Mount a new operator panel, reversing the removal steps of (1) to (3).
Screw (4--M3)
Fig.7.11 Replacing the operator panel
NOTE
The operator panel comprises the panel itself and the
cables connected to the robot controller PC board and
emergency stop PC board.
144
B--81525EN--1/01
7. REPLACING A UNIT
MAINTENANCE
7.12
The power supply unit is mounted on the emergency stop unit.
REPLACING THE
POWER SUPPLY
UNIT
(1) Detach all the cables from the emergency stop unit (emergency stop
PC board and power supply unit).
(2) Pull out the connector--type terminal block (TBEB5) at the top.
(3) Remove the four nuts (1 and 2) fastening the emergency stop unit, and
remove the emergency stop unit.
(4) Unscrew the four screws fastening the power supply unit, and replace
the power supply unit.
1 Remove the front nuts
(2--M5)
2 Remove the back nuts (2--M5)
3 Remove the screws (4--M3)
Fig.7.12 Replacing the power supply unit
145
7. REPLACING A UNIT
MAINTENANCE
7.13
If a fuse of the control unit is blown, find out the cause, take an appropriate
action, then replace the fuse.
REPLACING A FUSE
7.13.1
The robot controller PC board has the following fuses.
FUS1: For detecting a problem in the circuit on the robot controller PC
board: A60L--0001--0046#7.5
If this fuse is blown, the DC/DC converter module or a device
connected to the RS--232--C/RS--422 port may be faulty. If the
device connected to the RS--232--C/RS--422 port is not faulty,
replace the DC/DC converter module.
FUS2: For protecting the 24V output to the peripheral device:
A60L--0001--0046#7.5
If this fuse is blown, the wiring to the peripheral device and a cable
may be incorrect or damaged.
Replacing a Fuse on
the Robot Controller
PC Board
FUS1
B--81525EN--1/01
FUS2
Fig.7.13.1 Replacing a fuse on the robot controller PC board
146
B--81525EN--1/01
7.13.2
Replacing a Fuse on
the Emergency Stop
PC Board
7. REPLACING A UNIT
MAINTENANCE
The emergency stop PC board has the following fuses.
FUS3: For monitoring the emergency stop circuit: A60L--0001--0046#1.0
If this fuse is blown, the emergency stop PC board may be faulty.
Replace the emergency stop PC board.
FUS4: For protecting the 24V output to the emergency stop circuit and
teach pendant: A60L--0001--0046#1.0
If this fuse is blown, the emergency stop circuit may be incorrectly
routed, or the teach pendant or teach pendant cable may be faulty.
Check the routing of the emergency stop circuit, and replace the
teach pendant and teach pendant cable.
FUS5: For monitoring the emergency stop circuit: A60L--0001--0245
#GP20
If the fuse is blown, the brake circuit may be faulty. Examine the
brake, robot, and robot interconnection cable. Alternatively,
replace the emergency stop PC board.
FUS4
FUS3
FUS5
Emergency stop P.C.board
Fig.7.13.2 Replacing a fuse on the emergency stop PC board
147
7. REPLACING A UNIT
7.13.3
Replacing the Fuse on
the Power Supply
Module
MAINTENANCE
B--81525EN--1/01
The power supply module has the following fuse.
FU1: For protecting the 200VAC input for generating power to the
control circuit: A60L--0001--0359
If the fuse is blown, the power supply module may be faulty.
Replace the power supply module.
FU1
Remove the face plate
Fig.7.13.3 Replacing the fuse on the power supply module
148
B--81525EN--1/01
7.13.4
Replacing the Fuse on
the Servo Amplifier
Module
7. REPLACING A UNIT
MAINTENANCE
The servo amplifier module has the following fuse.
FU1: For protecting the +24 V input for generating power to the control
unit: A60L--0001--0290#LM32C
If this fuse is blown, the servo amplifier module may be faulty.
Replace the servo amplifier module.
FU1
Remove the control P.C. board
Fig.7.13.4 Replacing the fuse on the servo amplifier module
149
7. REPLACING A UNIT
7.14
REPLACING A
RELAY
MAINTENANCE
B--81525EN--1/01
A relay may have a poor contact or deposition after long hours of use. If
any of these problems occur, replace the relay.
7.14.1
The emergency stop PC board has the following relays.
Replacing a Relay on
the Emergency Stop
PC Board
KA6: For external emergency stop output: A58L--0001--0192#1509A
KA7: For brake control: A58L--0001--0192#1997R
KA6
KA7
Emergency stop P.C.board
Fig.7.14.1 Replacing a relay on the emergency stop PC board
150
B--81525EN--1/01
MAINTENANCE
7. REPLACING A UNIT
7.15
REPLACING
BATTERY
7.15.1
Battery for Memory
Backup (3 VDC)
The programs, and system variables are stored in the SRAM in the Robot
controller PC board. The power to the SRAM memory is backed up by
a lithium battery mounted on the front panel of the Robot controller PC
board. The above data is not lost even when the main battery goes dead.
A new battery can maintain the contents of memory for about 4 years
(Note).
When the voltage of the battery becomes low, the battery alarm LED on
the operator panel is lit, and the low--voltage battery alarm (system--035)
is displayed on the teach pendant. When this alarm is displayed, replace
the battery as soon as possible. In general, the battery can be replaced
within one or two weeks, however, this depends on the system
configuration.
If the battery voltage gets lower, it becomes impossible to back up the
content of the SRAM. Turning on the power to the in this state causes
system not to start and LED of seven segment on the Robot controller PC
board to be displayed “1” because the contents of memory are lost. Clear
the entire SRAM memory and reenter data after replacing the battery.
Important data should be saved to the memory card or floppy disk
beforehand in case of emergency.
When replacing the memory backup battery, do so while the robot
controller is turned off in case of emergency.
NOTE
In a newly introduced robot, the battery is factory--installed.
Battery replacement may, therefore, be needed within 4
years after the introduction of the robot.
Replacing the lithium
battery
(1) Prepare a new lithium battery (ordering drawing number:
A02B--0200--K102).
(2) Turn the robot controller on for about 30 seconds.
(3) Turn the robot controller off.
(4) Remove the old battery from the top of the Robot controller PC board.
First unlatch the battery, remove it from the battery holder, and detach
its connector.
151
7. REPLACING A UNIT
MAINTENANCE
Battery latch
B--81525EN--1/01
Battery
connector
Lithium battery
(5) Remove the old battery, insert a new one into the battery holder, and
attach the connector. Confirm that the battery is latched firmly.
WARNING
Using other than the recommended battery may result in the
battery exploding.
Replace the battery only with the specified battery
(A02B--0200--K102).
CAUTION
Complete the steps (3) to (5) within 30 minutes.
If the battery is left disconnected for a long time, the
contents of memory will be lost.
To prevent possible data loss, it is recommended that the
robot data such as programs and system variables be
backed up before battery replacement.
Dispose of the replaced battery as an industrial waste, according to the
laws and other rules in the country where the controller is installed and
those established by the municipality and other organizations that have
jurisdiction over the area where the controller is installed.
152
III CONNECTION
CONNECTIONS
B--81525EN--1/01
1
1. GENERAL
GENERAL
This chapter describes the connection and the installation of the electrical
interface.
155
2. BLOCK DIAGRAM
2
CONNECTIONS
B--81525EN--1/01
BLOCK DIAGRAM
Following are the block diagrams of the electrical interface connection for
R--J3iB Mate.
R--J3iB Mate controller
Peripheral device
Robot
control
P.C. board
Operation
panel
(RDI/RDO)
RS--232--C
RS--422/485
Teach pendant
Emergency
stop unit
Power
supply
unit
Emergency stop
P.C.board
(Note2)
Emergency stop
(Brake)
Transformer
Robot
Fan
Circuit
protector
Transformer
Fuse
220, 380,
415, 440,
500VAC
Circuit
protector
Pulse coder
MCC
Servo
amplifier
Power
NOTE
Tranceformer is installed when the robot is for 6--axes brake
specification.
156
3
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
CONNECTION DETAILS
Robot controller
PC board
CP8B
Emergency
stop unit
EMGIN1, 2
SVOFF1, 2
Battery
CP5B
CP5
FENCE1, 2
CRS24
EMGOUT11, 12
JRS12
Emergency
stop circuit
EMGOUT21, 22
CRS1
PCMCIA
Teach pendant
PCMCIA
COP10A
Servo amplifier
CRM82
Mechanical unit
JD17
RS--232--C or RS--422/485
JD1A
I/O Link (master)
JD1B
I/O Link (slave : option)
CRM79
Peripheral device
CRM81
Peripheral device (option)
157
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
3.1
CONNECTING THE
POWER SUPPLY
CABLE
When the stand--alone controller is used, an optional power cable can be specified.
Circuit protector
A grounding stud is provided
beside the circuit protector.
Connect the primary power
ground wire to this stud. Use
an M4 crimp terminal.
Terminal is M4.
Use the cable holders are
provided at these locations.
(3 locations)
To primary power supply
3Φ220/380/415/440/500
VAC
NOTE
Connect the primary power cable to the circuit protector. Connect the primary
power ground wire to the grounding stud, located beside the circuit protector.
The power supply cables are optional.
158
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
3.2
FANUC I/O LINK
Table 3.2 Types of FANUC I/O Links
I/O Link
No
No.
1
Name
Robot controller PC board
Drawing number
A16B--3200--0450
Master
Slave
f(*)
f(*)
Remarks
Standard
NOTE
The I/O Link of the robot controller PC board is in the master
mode by default. The I/O Link can be used in the slave
mode by changing the software parameter setting.
Refer to the operator’s manual for setting slave mode.
159
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
When the R--J3iB Mate control unit is used as the master of an I/O link
(when R--J3iB Mate control the process I/O printed board)
to other I/O link
JD4*
JD4*
Process I/O
printed boord etc.
JD1A
R--J3iB Mate
*Note that the connector name differs from
that of the standard FANUC I/O link.
When the R--J3iB Mate control unit is used as the master and a slave of an I/O link
JD1B
JD1A
FANUC I/O
Unit etc.
R--J3iB Mate
JD1B1
JD1A1
FANUC I/O Link c
onnection unit
JD1B2
JD1A2
JD1A
JD1B
FANUC I/O
Unit etc.
CNC, PLC
When the R--J3iB Mate control unit is used as a slave of the I/O link
(when a CNC or PLC is used as the master of the I/O link)
to other I/O link
JD1B
JD1A
JD1A
R--J3iB Mate
CNC, PLC
*Note Switch by the software.
160
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
3.3
CONNECTING THE
I/O LINK CABLE
Cable connections should be made according to the system. The customer is
requested to ground the shield.
JD1A
JD1B
Control printed board
For other I/O link
Earth plate
Peel off the sheath of the shielded
cable, then ground the shield here.
I/O Link cable connection
1. Customer should be prepare this cable.
2. Power off when it is connected.
When making a connection with a CNC via an I/O link, apply the following timing to turn
the power to the CNC and robot controller on/off:
a) Turn on the power to the slave units when or before turning on the master power.
b) If the power to the CNC or robot controller is turned off after the system has been
started, an I/O link error will occur. To reestablish normal connection via the I/O link,
turn off the power to all units, then turn on the power as explained in a) above.
JD1A interface
JD4(JD1B) interface
11
0V
01 RXSLC1
11
0V
01 RXSLC2
12
0V
02 *RXSLC1
12
0V
02 *RXSLC2
13
0V
03 TXSLC1
13
0V
03 TXSLC2
14
0V
04 *TXSLC1
14
0V
04 *TXSLC2
15
0V
05
15
0V
05
16
0V
06
16
0V
06
07
17
08
18
17
18
(+5V)
19
20
09
(+5V)
07
(+5V)
19
(+5V)
20
10
Note) When using an optical
I/O link adaptor, use +5V.
08
09
(+5V)
(+5V)
10
Note) When using an optical I/O link
adaptor, use +5V.
(1) Twisted--pair cables should be used for pin pairs 1 and 2, and 3 and 4.
(2) Use unified shielding, and ground the shield on the CNC side.
161
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
Cable connection
Master
I/O unit, etc
JD1B
Robot controller PCB
JD1A
RXSLC1 (1)
(1) SIN [RX]
*RXSLC1 (2)
(2) *SIN [*RX]
TXSLC1 (3)
(3) SOUT [TX]
(4) *SOUT [*TX]
*TXSLC1 (4)
0V (11)
(11) 0V
0V (12)
(12) 0V
0V (13)
(13) 0V
0V (14)
(14) 0V
0V (15)
(15) 0V
0V (16)
(16) 0V
Slave
CNC, PLC etc
JD1A
Robot controller PCB
JD1B
[RX] SIN (1)
(1) RXSLC2
[*RX] *SIN (2)
(2) *RXSLC2
[TX] SOUT (3)
(3) TXSLC2
(4) *TXSLC2
[*TX] *SOUT (4)
0V (11)
(11) 0V
0V (12)
(12) 0V
0V (13)
(13) 0V
0V (14)
(14) 0V
0V (15)
(15) 0V
0V (16)
(16) 0V
162
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
3.4
EMERGENCY STOP
CIRCUIT
3.4.1
Emergency Stop
Circuit Diagram
Teach pendant
Emergency stop button
Emergency stop P.C. board
(From CP5A)
24IN
CRS1
FUS4
+24V
FUS3
+24V
Operation panel
mode switch
T1
CRT12
AUTO
T2
SR2--1
Dead man switch
SR2--2
(Right)
(Left)
SR2--3
Enable/Disable switch
Robot controller
P.C. board
JRS12
Emergency stop
button
KA3--1
0V
CRS24
+24V
MODE1
KA3--2
MODE2
+24V
FENCE
KA4--2
OP--EMG
EMGIN1
0V
KA4--1
+24V
KA2--2
External
emergency stop
TBEB5
EMGIN2
safety net
FENCE1
FENCE2
EX--EMG
KA2--1
SVOFF
SVOFF1
MCCMON
SVOFF2
KA6--1
Mode switch
AUTO
T1
T2
SR2--1 OPEN CLOSE CLOSE
SR2--2 CLOSE CLOSE OPEN
SR2--3 CLOSE OPEN OPEN CRM83
EMGOUT11
0V
KA6--2
EMGOUT12
EMGOUT21
+24V
KA5--1
EMGOUT22
CRR78
CX3
Servo amplifier
(αPSMR--1i)
MCCOFF3
0V
RL1
MCCOFF4
KA5--2
0V
+24V
CX4
+24V
ESP
MCC
(KM1)
KM1--1
CZ1
KM1--2
3φ200VAC
KM1--3
KM1--4
KM1--5
163
ESP
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
3.4.2
External Emergency
Stop Input
Customer should prepare this cable
TBEB5
Cable holder
FENCE1
FENCE2
EMGIN1
EMGIN2
SVOFF1
SVOFF2
Emergency stop P.C. board
When the robot is shipped, EMGIN1, and EMGIN2/SVOFF1 and SVOFF2/FENCE1 and FENCE2
are connected by jumper wires. To enable external
emergency stop input, servo off input and fence input
first disconnect these jumper wires, then make the
necessary connections.
External emergency stop input and fence input are
reflected in the external emergency stop output, but
servo off input is not reflected in the external emergency stop output..
In order to prevent any problem caused by a wrong
connection, check the operation of the emergency
stop switches on the teach pendant and operator
panel after connecting the external emergency stop
input, servo off input and fence input.
EMGIN1
EMGIN2
SVOFF1
External emergency
stop input
SVOFF2
FENCE1
FENCE1
FENCE2
EMGIN1
EMGIN2
SVOFF1
SVOFF2
EMGOUT11
EMGOUT12
EMGOUT21
EMGOUT22
Servo off input
FENCE2
Fence input
164
CONNECTIONS
B--81525EN--1/01
3. CONNECTION DETAILS
3.4.3
External Emergency
Stop Output
Customer should prepare this cable
Cable holder
An emergency stop button on the teach pendant, deadman’s switch an emergency stop
button on the control unit door, and external
emergency stop input #1 are reflected in the
external emergency stop output.
TBEB5
TP
Emergency
stop
OP
Emergency
stop
External
emergency stop
EMGOUT11
EMGOUT12
EMGOUT21
EMGOUT22
EMGOUT11
EMGOUT12
Emergency stop P.C. board
EMGOUT21
EMGOUT22
circuit
165
FENCE1
FENCE2
EMGIN1
EMGIN2
SVOFF1
SVOFF2
EMGOUT11
EMGOUT12
EMGOUT21
EMGOUT22
Sequencer etc. for
peripheral device
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
3.5
CONNECTION OF
SERVO AMPLIFIER
LR Mate 100iB
PSM
AMP1
AMP2
POWER SUPPLY
MODULE
(αPSMR--1i)
A06B--6115--H001
SERVO AMPLIFIER
MODULE
(αSVM2--20/20i)
A06B--6114--H205
SERVO AMPLIFIER
MODULE
(αSVM3--10/10/10i)
A06B--6114--H302
TB1
TB1
TB1
from MCC
CZ1
L+
L+
L+
L--
L-L--
from circuit
protector
from emergency
stop P.C.board
COP10B
CX1A
CXA2A
COP10B
CXA2B
CXA2A
CX3
COP10A
CXA2B
CXA2A
JF1 (L)
JF1 (L)
JF2 (M)
JF2 (M)
CX4
JF3 (N)
from robot control
P.C. board
CZ2 L
CZ2 L
CZ2 M
CZ2 M
CZ2 N
to robot
Pulse coder
Motor power
LR Mate 200iB
PSM
AMP1
AMP2
POWER SUPPLY
MODULE
(αPSMR--1i)
A06B--6115--H001
SERVO AMPLIFIER
MODULE
(αSVM3--10/10/10i)
A06B--6114--H302
SERVO AMPLIFIER
MODULE
(αSVM3--10/10/10i)
A06B--6114--H302
TB1
TB1
TB1
from MCC
CZ1
L+
L+
L+
L--
L-L--
from circuit
protector
from emergency
stop P.C.board
COP10B
CX1A
CXA2A
CXA2B
COP10B
CXA2A
CX3
CXA2B
COP10A
CXA2A
JF1 (L)
JF1 (L)
JF2 (M)
JF2 (M)
CX4
JF3 (N)
JF3 (N)
from robot control
P.C. board
CZ2 L
CZ2 L
CZ2 M
CZ2 M
CZ2 N
CZ2 N
to robot
Pulse coder
Motor power
166
CONNECTIONS
B--81525EN--1/01
3. CONNECTION DETAILS
3.6
CONNECTION OF
ROBOT
CRM82
JF1--3
Power cable
to RMP
Signal cable
TBEB3
CZ2 L, M, N
167
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
3.7
CONNECTION OF
TEACH PENDANT
CABLE
Emergency stop unit
CRS1
To teach pendant
Earth plate
Fig.3.7 Teach pendant cable
168
CONNECTIONS
B--81525EN--1/01
3.8
CONNECTION OF
CABLE FOR
RS--232--C/RS--422
3. CONNECTION DETAILS
Selection of RS--232--C or RS--422 interface need setting of software.
Refer to the operator’s manual for details.
Communication port
Peripheral device
01
FG
02
TXD
03
RXD
04
RTS
05
CTS
06
DSR
07
0V
08
09
10
11
12
13
14
(TX)
15
(*TX)
16
(RX)
17
(*RX)
18
19
20
DTR
21
22
23
24
25
169
+24E
Signals whose names are enclosed in
parentheses are assigned to use the
RS--422 interface. The numbers of
the interface differ from those of the
standard RS--422 interface. Take the
caution when designing the interface.
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
3.9
CONNECTING A
CABLE TO A
PERIPHERAL
DEVICE
3.9.1
Peripheral Device
Interfaces CRM79 and
CRM81
Table 3.9.1 Types of FANUC I/O Links
Peripheral device interface
No.
1
Name
Robot controller PC board A
Drawing
g number
A16B--3200--0450
CRM79
CRM81
DI
DO
DI
DO
20
20
8
4
Remarks
Standard
NOTE
The DI and DO signals of CRM79 and CRM81 include
special signals.
Connecting a peripheral device (CRM79 or CRM81)
Robot controller P.C. board
CRM81
CRM79
to peripheral device
Grounding plate
Strip off the sheathing of the shield cable and
connect the cable to the grounding plate.
Fig.3.9.1 Connecting the peripheral device cable
170
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
3.9.2
When the Robot is
Connected to the CNC
by a Peripheral Device
Cable
NOTE
See the operator’s MANUAL for the detail information.
Turn off the controller when connecting the cable.
CRM79
Robot
controller
PCB
CNC
CRM81
CRM79 interface (Specified signals are not allocated and the Robot
is connected to CNC and PLC by a FANUC I/O Link cable.)
01
SDI101
33
SDO101
02
SDI102
34
SDO102
35
SDO103
36
SDO104
37
SDO105
38
SDO106
39
SDO107
03
SDI103
04
SDI104
05
SDI105
06
SDI106
07
SDI107
08
SDI108
09
SDI109
10
SDI110
11
SDI111
12
SDI112
13
SDI113
14
SDI114
19
SDICOM1
20
SDICOM2
21
SDO120
22
SDI117
23
SDI118
24
SDI119
40
25
SDI120
SDO108
41
26
SDO117
42
SDO109
SDO110
27
SDO118
43
SDO111
28
44
SDO112
29
SDO119
0V
30
0V
45
SDO113
31
+24E
46
SDO114
32
+24E
47
SDO115
48
SDO116
15
SDI115
16
SDI116
17
0V
49
+24E
18
0V
50
+24E
Connector in cable side
HONDA TSUSHIN CO.,LTD
Connector MR--50LMH(Male)
SDICOM1 and SDICOM2 are the signals used for selecting a common for SDI signals.
To use the +24V common, connect SDICOM1 and SDICOM2 to 0V.
To use the 0V common, connect SDICOM1 and SDICOM2 to +24V.
SDICOM1→Selects a common for SDI101 to SDI108.
SDICOM2→Selects a common for SDI109 to SDI120.
(Note) Maximum output current per one SDO signal is 70mA.
171
3. CONNECTION DETAILS
CONNECTIONS
CRM79 interface
(standard allocation of specified signals and
the Robot is connected to the CNC and PLC
by a peripheral device cable.)
B--81525EN--1/01
Connector in cable side
HONDA TSUUSHIN CO.,LTD
Connector MR--50LMH (Male)
01
SDI101
33
SDO101
02
SDI102
SDI103
04
SDI104
05
SDI105
06
SDI106
07
SDI107
08
SDI108
09
*HOLD
10
RESET
11
START
12
ENBL
13
PNS1
14
PNS2
15
PNS3
16
PNS4
34
19 SDICOM1
35
20 SDICOM2
36
21 SDO120
37
22 SDI117
38
23 SDI118
39
24 SDI119
40
25 SDI120
41
26 SDO117
42
27 SDO118
43
28 SDO119
44
29
0V
45
30
0V
46
31
+24E
47
32
+24E
48
SDO102
03
17
0V
49
+24E
18
0V
50
+24E
SDO103
SDO104
SDO105
SDO106
SDO107
SDO108
SDO109
SDO110
SDO111
SDO112
CMDENBL
FAULT
BATALM
BUSY
SDICOM1 and SDICOM2 signal are common selection signal for SDI.
When 24 V common is used, connect to 0V.
When 0V common is used, connect to +24V
SDICOM1”Selects a common for SDI101 to SDI108.
SDICOM2”Selects a common for *HOLD, RESET,
START, ENBL, PNS1 to PNS4, and SDI117 to SDI120.
NOTE
1 Maximum output current for one SDO signal is 70mA.
2 The common (selected with SDICOM2) for a dedicated
signal should ideally be the +24V common, but the 0V
common can also be used.
3 Allocation of the specified signals can be changed from the
teach pendant.
172
CONNECTIONS
B--81525EN--1/01
3. CONNECTION DETAILS
In case +24V common at the peripheral device side. (Specified signals are not allocated)
Control unit (peripheral device interface : CRM79)
+24E
Peripheral device
Connector pin No
CRM79 (31,32,49,50)
receiver circuit
SDI101
RV
SDI102
RV
SDI103
RV
SDI104
RV
SDI105
RV
SDI106
RV
SDI107
RV
SDI108
RV
SDICOM1
RV
SDI109
RV
SDI110
RV
SDI111
RV
SDI112
RV
SDI113
RV
SDI114
RV
SDI115
RV
SDI116
RV
SDI117
RV
SDI118
RV
SDI119
RV
SDI120
RV
SDICOM2
RV
CRM79 (1)
3.3k
CRM79 (2)
CRM79 (3)
CRM79 (4)
CRM79 (5)
CRM79 (6)
CRM79 (7)
CRM79 (8)
CRM79 (19)
CRM79 (9)
CRM79 (10)
CRM79 (11)
CRM79 (12)
CRM79 (13)
CRM79 (14)
CRM79 (15)
CRM79 (16)
CRM79 (22)
CRM79 (23)
CRM79 (24)
CRM79 (25)
CRM79 (20)
CRM79 (17,18,29,30)
0V
Fig.3.9.2 (a) Peripheral device control interface : CRM79 (Input signal, +24V common)
173
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
In case 0V common at the peripheral device side. (Specified signals are not allocated)
Control unit (peripheral device interface : CRM79)
+24E
Peripheral device
Connector pin No
CRM79 (31,32,49,50)
receiver circuit
SDI101
RV
SDI102
RV
SDI103
RV
SDI104
RV
SDI105
RV
SDI106
RV
SDI107
RV
SDI108
RV
SDICOM1
RV
SDI109
RV
SDI110
RV
SDI111
RV
SDI112
RV
SDI113
RV
SDI114
RV
SDI115
RV
SDI116
RV
SDI117
RV
SDI118
RV
SDI119
RV
SDI120
RV
SDICOM2
RV
CRM79 (1)
3.3k
CRM79 (2)
CRM79 (3)
CRM79 (4)
CRM79 (5)
CRM79 (6)
CRM79 (7)
CRM79 (8)
CRM79 (19)
CRM79 (9)
CRM79 (10)
CRM79 (11)
CRM79 (12)
CRM79 (13)
CRM79 (14)
CRM79 (15)
CRM79 (16)
CRM79 (22)
CRM79 (23)
CRM79 (24)
CRM79 (25)
CRM79 (20)
CRM79 (17,18,29,30)
0V
Fig.3.9.2 (b) Peripheral device control interface : CRM79 (Input signal, 0V common)
174
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
(Specified signals are not allocated)
Control unit (peripheral device interface : CRM79)
Connector pin No
Driver circuit
SDO101
SDO102
SDO103
SDO104
SDO105
SDO106
SDO107
SDO108
SDO109
SDO110
SDO111
SDO112
SDO113
SDO114
SDO115
SDO116
SDO117
SDO118
SDO119
SDO120
Peripheral device
LOAD
CRM79 (33)
DV
RELAY
CRM79 (34)
DV
LOAD
CRM79 (35)
DV
LOAD
CRM79 (36)
LOAD
DV
CRM79 (37)
DV
LOAD
CRM79 (38)
DV
LOAD
CRM79 (39)
DV
LOAD
CRM79 (40)
DV
LOAD
CRM79 (41)
DV
LOAD
CRM79 (42)
DV
LOAD
CRM79 (43)
DV
LOAD
CRM79 (44)
DV
LOAD
CRM79 (45)
DV
LOAD
CRM79 (46)
DV
LOAD
CRM79 (47)
DV
LOAD
CRM79 (48)
DV
LOAD
CRM79 (26)
DV
LOAD
CRM79 (27)
DV
LOAD
CRM79 (28)
DV
LOAD
CRM79 (21)
DV
LOAD
CRM79 (17,18,29,30)
0V
0V
+24V
+24V regurated
power supply
Max. current per SDO is 70mA.
Fig.3.9.2 (c) Peripheral device control interface : CRM79 (Output signal)
175
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
In case +24V common at the peripheral device side. (Specified signals are allocated)
Control unit (peripheral device interface : CRM79)
+24E
Peripheral device
Connector pin No
CRM79 (31,32,49,50)
receiver circuit
SDI101
RV
SDI102
RV
SDI103
RV
SDI104
RV
SDI105
RV
SDI106
RV
SDI107
RV
SDI108
RV
SDICOM1
RV
SDI109
RV
SDI110
RV
SDI111
RV
SDI112
RV
SDI113
RV
SDI114
RV
SDI115
RV
SDI116
RV
SDI117
RV
SDI118
RV
SDI119
RV
SDI120
RV
SDICOM2
RV
CRM79 (1)
3.3k
CRM79 (2)
CRM79 (3)
CRM79 (4)
CRM79 (5)
CRM79 (6)
CRM79 (7)
CRM79 (8)
CRM79 (19)
CRM79 (9)
CRM79 (10)
CRM79 (11)
CRM79 (12)
CRM79 (13)
CRM79 (14)
CRM79 (15)
CRM79 (16)
CRM79 (22)
CRM79 (23)
CRM79 (24)
CRM79 (25)
CRM79 (20)
CRM79 (17,18,29,30)
0V
Fig.3.9.2 (d) Peripheral device control interface : CRM79 (Input signal, +24V common)
176
CONNECTIONS
B--81525EN--1/01
3. CONNECTION DETAILS
In case 0V common at the peripheral device side. (Specified signals are allocated)
Control unit (peripheral device interface : CRM79)
+24E
Peripheral device
Connector pin No
CRM79 (31,32,49,50)
receiver circuit
SDI101
RV
SDI102
RV
SDI103
RV
SDI104
RV
SDI105
RV
SDI106
RV
SDI107
RV
SDI108
RV
SDICOM1
RV
SDI109
RV
SDI110
RV
SDI111
RV
SDI112
RV
SDI113
RV
SDI114
RV
SDI115
RV
SDI116
RV
SDI117
RV
SDI118
RV
SDI119
RV
SDI120
RV
SDICOM2
RV
CRM79 (1)
3.3k
CRM79 (2)
CRM79 (3)
CRM79 (4)
CRM79 (5)
CRM79 (6)
CRM79 (7)
CRM79 (8)
CRM79 (19)
CRM79 (9)
CRM79 (10)
CRM79 (11)
CRM79 (12)
CRM79 (13)
CRM79 (14)
CRM79 (15)
CRM79 (16)
CRM79 (22)
CRM79 (23)
CRM79 (24)
CRM79 (25)
CRM79 (20)
CRM79 (17,18,29,30)
0V
Fig.3.9.2 (e) Peripheral device control interface : CRM79 (Input signal, 0V common)
177
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
(Specified signals are allocated)
Control unit (peripheral device interface : CRM79)
Connector pin No
Driver circuit
SDO101
SDO102
SDO103
SDO104
SDO105
SDO106
SDO107
SDO108
SDO109
SDO110
SDO111
SDO112
SDO113
SDO114
SDO115
SDO116
SDO117
SDO118
SDO119
SDO120
Peripheral device
LOAD
CRM79 (33)
DV
RELAY
CRM79 (34)
DV
LOAD
CRM79 (35)
DV
LOAD
CRM79 (36)
LOAD
DV
CRM79 (37)
DV
LOAD
CRM79 (38)
DV
LOAD
CRM79 (39)
DV
LOAD
CRM79 (40)
DV
LOAD
CRM79 (41)
DV
LOAD
CRM79 (42)
DV
LOAD
CRM79 (43)
DV
LOAD
CRM79 (44)
DV
LOAD
CRM79 (45)
DV
LOAD
CRM79 (46)
DV
LOAD
CRM79 (47)
DV
LOAD
CRM79 (48)
DV
LOAD
CRM79 (26)
DV
LOAD
CRM79 (27)
DV
LOAD
CRM79 (28)
DV
LOAD
CRM79 (21)
DV
LOAD
CRM79 (17,18,29,30)
0V
0V
+24V
+24V regurated
power supply
Max. current per SDO is 70mA.
Fig.3.9.2 (f) Peripheral device control interface : CRM79 (Output signal)
178
CONNECTIONS
B--81525EN--1/01
3. CONNECTION DETAILS
CRM81 interface
(When a special signal is not allocated; when CNC and PLC are connected
by an I/O Link cable)
A
B
01
SDI81
SDI82
02
SDI83
SDI84
03
SDI85
SDI86
04
SDI87
SDI88
05
SDICOM
06
07
SDO81
SDO82
08
SDO83
SDO84
09
10
Cable--side connector
YAMAICHI ELECTRICITY
Connector
Housing -- UFS--20B--04
Contact -- Contact 66 type
(UFS contact)
0V
+24V
0V
SDICOM1 is a common signal that can be used either as an SDI or special
signal.
+24 V common: Connected to 0 V
0 V common: Connected to +24 V
SDICOM → Selects a common for SDI81 to SDI88.
CAUTION
The maximum output current of each SDO or special signal
is 70 mA.
179
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
In case +24V common at the peripheral device side.
Control unit (peripheral device interface : CRM81)
+24E
Peripheral device
Connector pin No
CRM81 (A10)
receiver circuit
SDI81
RV
SDI82
RV
SDI83
RV
SDI84
RV
SDI85
RV
SDI86
RV
SDI87
RV
SDI88
RV
SDICOM
RV
CRM81 (A1)
3.3k
CRM81 (B1)
CRM81 (A2)
CRM81 (B2)
CRM81 (A3)
CRM81 (B3)
CRM81 (A4)
CRM81 (B5)
CRM81 (A5)
CRM81 (B9,B10)
0V
Fig.3.9.2 (g) Peripheral device control interface : CRM81 (Input signal, +24V common)
180
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
In case 0V common at the peripheral device side.
Control unit (peripheral device interface : CRM81)
+24E
Peripheral device
Connector pin No
CRM81 (A10)
receiver circuit
SDI81
RV
SDI82
RV
SDI83
RV
SDI84
RV
SDI85
RV
SDI86
RV
SDI87
RV
SDI88
RV
SDICOM
RV
CRM81 (A1)
3.3k
CRM81 (B1)
CRM81 (A2)
CRM81 (B2)
CRM81 (A3)
CRM81 (B3)
CRM81 (A4)
CRM81 (B5)
CRM81 (A5)
CRM81 (B9,B10)
0V
Fig.3.9.2 (h) Peripheral device control interface : CRM81 (Input signal, 0V common)
Control unit (peripheral device interface : CRM81)
Connector pin No
Driver circuit
SDO8
1
DV
SDO82
DV
SDO83
SDO84
Peripheral device
LOAD
CRM81 (A7)
RELAY
CRM81 (B7)
LOAD
CRM81 (A8)
DV
LOAD
CRM81 (B8)
DV
LOAD
CRM81 (B9,B10)
0V
0V
+24V
+24V regurated
power supply
Max. current per SDO is 70mA.
Fig.3.9.2 (i) Peripheral device control interface : CRM81 (Output signal)
181
3. CONNECTION DETAILS
3.9.3
Digital I/O Signal
Specifications
CONNECTIONS
B--81525EN--1/01
This section describes the specifications of the digital I/O signals
interfaced with the peripheral device and end effector.
3.9.3.1
Peripheral device
interface CRM 79 and
CRM 81
D Output signal regulation
Connection example
Spark killer diode
+24V
70 mA
or less
0V
0V
+24V
Lamp
70 mA
or less
0V
Protective resistance
D Electrical specifications
Rated voltage
Maximum applied voltage
Maximum load current
Transistor type
Saturation voltage at connection
:
:
:
:
:
D Spark killer diode
Rated peak reverse voltage
Rated effective forward current
: 100 V or more
: 1 A or more
0V
24 VDC
30 VDC
70.mA
Open collector NPN
1.0 V (approx.)
D Notes on use
Do not use the +24 V power supply of the robot.
When loading a relay, solenoid, and so on directly, connect them in
parallel with diodes for preventing back electromotive force.
If a load causing a surge current such as turning on LED is connected,
use a protective resistance.
D Applicable signal
Output signal of peripheral device interface CRM79, CRM81 :
SDO101 to SDO120 (CRM79)
SDO81 to SDO84 (CRM81)
182
D Input signal regulation
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
Connection example
+24V
SDI n
RV
3.3 kΩ
SDICOM
RV
Example of
+24V common connection
0V
D Electrical specifications of the receiver
Type
: Grounded voltage receiver
Rated input voltage
: Contact close :+20 V to +28 V
Contact open :0 V to +4 V
Maximum applied input voltage: +28 VDC
Input impedance
: 3.3 kΩ (approx.)
Response time
: 5 ms to 20 ms
D Specifications of the peripheral device contact
Rated contact capacity
: 30 VDC, 50 mA or more
Input signal width
: 200 ms or more (on/off)
Chattering time
: 5 ms or less
Closed circuit resistance
: 100Ω or less
Opened circuit resistance
: 100 kΩ or more
TB
(Signal)
TB
(Signal)
TB
Peripheral device
contact signal
Robot receiver signal
TC
TC
TB ;
TC ;
Chattering 5 ms or less
5 to 20 ms
D Note on use
Apply the +24 V power of the robot to the receiver.
However, the above signal regulations must be satisfied at the
robot receiver.
D Applicable signal
Input signal of peripheral device interface CRM79, CRM81 :
SDO101 to SDO120 (CRM79)
SDO81 to SDO84 (CRM81)
183
3. CONNECTION DETAILS
3.9.4
CONNECTIONS
B--81525EN--1/01
The figure below shows the connector for peripheral device cable.
Peripheral Device
Cable Connector
Symbol
Name
1
Connector cover
2
Cable clamp screw
3
Connector clamp spring
4
Connector clamp screw
5
Connector 50 pins (male) MR50MH
Dimensions
Remark
Connector
specification
Applicable
interface
A
(B)
C
(D)
MR50LMH
CRM79
67.9
73.5
44.8
18
Honda Tsushin
Kogyo 50 pins
Fig.3.9.4 (a) Peripheral Device Cable Connector (CRM79 : Honda Tsushin Kogyo)
184
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
A
B
3.56
2.54
2.54
6.0
14.3
14.5
Connector
specification
Dimensions
Applicable
interface
UFS--20B--04
Remark
A
C
29.98
22.86
CRM81
YAMAICHI ELECTRONICS
(Housing)
YAMAICHI ELECTRONICS
(Contact)
Contact 66 type
Applicable cable : AWG#28 (7/0.12), AWG#26 (19/0.1), AWG#24 (19/0.12), (7/0.18)
Fig.3.9.4 (b) Peripheral Device Cable Connector (CRM81 : YAMAICHI ELECTRONICS)
3.9.5
Recommended Cables
Connect a peripheral device using a completely shielded, heavily
protected cable conforming to the specifications in Table 3.9.5.
Allow an extra 1.5m for routing the cable in the control unit.
The maximum cable length is 30m.
Table 3.9.5 Recommended cable (For peripheral device connection)
Conductor
Electrical characteristics
Sheath
thickness
(mm)
Effective
outside
diameter
(mm)
Conductor
resistance
(Ω/km)
Allowable
current (A)
7/0.18
AWG24
1.5
φ12.5
106
1.6
7/0.18
AWG24
1.5
φ10.5
106
1.6
Number of
wires
Wire specifications
(FANUC
specifications)
Diameter
(mm)
Configuration
50
A66L--0001--0042
φ1.05
20
A66L--0001--0041
φ1.05
185
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
3.10
END EFFECTOR
INTERFACE
3.10.1
Connecting the
Mechanical Unit and
End Effector
Table 3.10.1 Types of end effector interfaces
End effector interface
No
No.
1
Name
Drawing number
A16B--3200--0450
Robot controller PC board A
DI
DO
6
6
Remarks
Standard
NOTE
Either RDI6 or *PPABN is selected in the software.
Mechanical unit
EE
1
2
3
4
5
RDI1
RDI2
RDI3
RDI4
RDI5
7
8
9
10
11
*HBK
+24E
+24E
+24E
0V
6
RDI6
(*PPABN)
12
RDICOM
End effecter
NOTE
RDO1 to RDO6 are used as the signals to turn on or off
solenoid valves. The end effector can use the RDI signals
and *HBK signal.
For RDO signals, refer to the
maintenance manual of the mechanical unit.
186
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
Mechanical unit (end effector interface)
+24E
End effector
Connector pin No.
EE (8,8,10)
Receiver circuit
RDI1
RV
RDI2
RV
RDI3
RV
RDI4
RV
RDI5
RV
RDI6
(*PPABN)
RV
RDICOM
RV
EE (1)
3.3k
EE (2)
EE (3)
EE (4)
EE (5)
EE (6)
EE (12)
EE (11)
0V
Fig.3.10.1 (a) End effector interface (+24V common)
Mechanical unit (end effector interface)
+24E
End effector
Connector pin No.
EE (8,8,10)
Receiver circuit
RDI1
RV
RDI2
RV
RDI3
RV
RDI4
RV
RDI5
RV
RDI6
(*PPABN)
RV
RDICOM
RV
EE (1)
3.3k
EE (2)
EE (3)
EE (4)
EE (5)
EE (6)
EE (12)
EE (11)
0V
Fig.3.10.1 (b) End effector interface (0V common)
187
3. CONNECTION DETAILS
CONNECTIONS
B--81525EN--1/01
3.10.2
Digital I/O Signal
Specifications of End
Effecter Control
Interface
Connection example
+24V
RDI n
RV
3.3 kΩ
RDICOM
RV
+24V common
connection example
0V
Electrical specifications of the receiver
Type
Rated input voltage
: Grounded voltage receiver
: Contact close
: +20 V to +28 V
Contact open
: 0 V to +4 V
Maximum applied input voltage : +28 VDC
Input impedance
: 3.3 kΩ (approx.)
Response time
: 5 ms to 20 ms
Specifications of the peripheral device contact
Rated contact capacity
Input signal width
Chattering time
Closed circuit resistance
Opened circuit resistance
TB
(Signal)
TB
(Signal)
:
:
:
:
:
30 VDC, 50 mA or more
200 ms or more (on/off)
5 ms or less
100 Ω or less
100 kΩ or more
TB
Peripheral device
contact signal
Robot receiver signal
TC
TC
TB ;
TC ;
Chattering 5 ms or less
5 to 20 ms
Note on use
Apply the +24 V power at the robot to the receiver.
However, the above signal specifications must be satisfied at the
robot receiver.
Applicable signals
Input signals of end effecter control interface
Additional I/O PCB CRW6 input signal WDI1 to WDI8
RDI 1 to 6, *HBK, *PPABN (Switch RDI6 by software)
188
B--81525EN--1/01
3.11
TREATMENT FOR
THE SHIELDED
CABLE
CONNECTIONS
3. CONNECTION DETAILS
In this manual the treatment for the shielded cable is shown on several
pages. Partly cut off the shielded cable to expose the shield jacket, and
fasten the jacket to the shield plate with a clamp to protect against noise.
(In case of stand--alone type a shield plate is installed in the controller.)
Fig.3.11 Shielded cable treatment
189
4. TRANSPORTATION AND
INSTALLATION
4
CONNECTION
TRANSPORTATION AND INSTALLATION
190
B--81525EN--1/01
B--81525EN--1/01
4.1
TRANSPORTATION
4. TRANSPORTATION AND
INSTALLATION
CONNECTION
The control unit should be transported by a crane. Attach a sling to eye
bolts at the top of the control unit.
Fig.4.1 Transportation
4.2
INSTALLATION
Control unit
Installation area
When the control unit is installed, allow the space for maintenance shown
in the following figure.
Control unit
Control unit
When the plural
controller is
installed.
Fig.4.2 Installation
191
4. TRANSPORTATION AND
INSTALLATION
CONNECTION
4.3
EXTERNAL
CONTROLLER
DIMENSIONS
Four M10 weld nuts (4 pcs)
The unit is shipped with the M10 bolts
screwed to the weld nuts as 10--mm feet.
After the M10 bolts are removed, these
weld nuts can be used to secure the
control unit.
Fig.4.3 External drawing of robot controller
192
B--81525EN--1/01
4. TRANSPORTATION AND
INSTALLATION
CONNECTION
B--81525EN--1/01
4.4
INSTALLATION
CONDITION
Item
50Hz/60Hz; 220/380/415/440/500VAC,
+10%, --15%
50/60Hz ± 1Hz, 3--phase
Input power supply capacity
1 kVA (LR Mate 100iB)
1.2 kVA (LR Mate 200iB)
0.4 kW (LR Mate 100iB)
0.5 kW (LR Mate 200iB)
0 to 45_C during operation, and --20 to 60 C
during shipment and storage with a temperature coefficient of 1.1_C/min.
Average power consumption
Permissible ambient temperature
4.5
ADJUSTMENT AND
CHECKS AT
INSTALLATION
Specifications/condition
Transformer
Permissible ambient humidity
Surrounding gas
Relative humidity: 30% to 95%, non--condensing.
An additional protective provision is necessary if the machine is installed in an environment in which there are relatively large
amounts of contaminants (dust, dielectric
fluid, organic solvent, acid, corrosive gas,
and/or salt).
Vibration
0.5 G or less. When using the robot in a location subject to serious vibration, consult with
your FANUC sales representative.
Altitude
Not higher than 1,000 m above sea level
Ionized and nonionized radiations
A shielding provision is necessary if the
machine is installed in an environment in
which it is exposed to radiations (microwave,
ultraviolet rays, laser beams, and/or X--rays).
Weight of control unit
Approx. 55kg
Adjust and check according to following procedure at installation.
No.
Description
1
Visually check the inside and outside of the control unit.
2
Check if the screwed terminal is connected properly.
3
4
Check that the connectors and printed circuit boards are inserted correctly.
Connect control unit and mechanical unit cables.
5
Turn the breaker off and connect the input power cable.
6
Check the input power voltagage.
7
Press the EMERGENCY STOP button on the operator’s panel and
turn the power on. Check the output voltage.
Check the interface signals between control unit and robot mechanical
unit.
Check the parameters. If necessary, set them.
8
9
10
11
Release the EMERGENCY STOP button on the operator’s panel.
Turn the power on.
Check the movement along each axis in the manual jog mode.
12
Check the end effector interface signals.
13
Check the peripheral device control interface signals.
193
4. TRANSPORTATION AND
INSTALLATION
CONNECTION
4.6
B--81525EN--1/01
An overtravel and emergency stop occur when the robot is operated for
the first time after it is installed and the mechanical and control units are
wired. This section describes how to reset the overtrvel and emergency
stop.
Remove the red plate fastening the swiveling axis beforehand.
The J2 and J3 axes are pressed against the hard stops at shipment.
Therefore, an overtravel alarm occurs when the power is turned on after
installation.
NOTE AT
INSTALLATION
4.7
DISABLING HAND
BREAK
(1) Press the [MENUS] key on the teach pendant.
(2) Select [Next].
(3) Select [SETUP].
(4) Press F1 [TYPE].
(5) Select [Config] to disable or enable Hand Break.
Hand break
State
Hand break
HBK (*1)
HBK detection
Robot operation
Message
1
Enabled
CLOSE
2
Enabled
OPEN
Detected
Possible
Not provided
Detected
Impossible
SERVO 6
3
Disabled
4
Disabled
CLOSE
Detected (*2)
Possible
Not provided
OPEN
Not detected
Possible
SERVO 300 at cold start
NOTE
1 Robot end effector connector
CLOSE
OPEN
24V
24V
*HBK
*HBK
2 When the HBK circuit is closed, the HBK detection is
enabled.
If the HBK state changes from close to open, the SERVO
300 or SERVO 302 alarm occurs, stopping the robot.
3 If the power is turned off and on in the state described
above, the system enters state 4, releasing the alarm.
194
APPENDIX
B--81525EN--1/01
A
APPENDIX
TOTAL CONNECTION DIAGRAM
197
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (a) Total connection diagram
198
B--81525EN--1/01
B--81525EN--1/01
APPENDIX
199
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (b) Transformer
200
B--81525EN--1/01
B--81525EN--1/01
APPENDIX
201
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (c) Emergency stop circuit diagram (LR Mate 100iB)
202
B--81525EN--1/01
B--81525EN--1/01
APPENDIX
203
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
Fig.A (d) Emergency stop circuit diagram (LR Mate 200iB)
204
B--81525EN--1/01
B--81525EN--1/01
APPENDIX
205
A. TOTAL CONNECTION DIAGRAM
A. TOTAL CONNECTION DIAGRAM
APPENDIX
B--81525EN--1/01
Fig.A (e) Robot controller P.C. board, emergency stop P.C. board connector interface
206
B--81525EN--1/01
APPENDIX
A. TOTAL CONNECTION DIAGRAM
Fig.A (f) Servo amplifier, robot mechanical unit connector interface
207
B. PERIPHERAL INTERFACE
B
APPENDIX
B--81525EN--1/01
PERIPHERAL INTERFACE
Peripheral I/O (UI/UO) are a group of specialized signals whose usage is
decided by the system. These signals are connected with a remote
controller and the peripheral devices via the following interfaces and I/O
links and they are used to control the robot from the outside.
D The JD1A interface (The process I/O PC board, the I/O Unit MODEL
A and the MODEL B are connected as the slave of I/O link to R--J3iB
Mate.) (on master mode)
D The JD1B interface (CNC and PLC are connected as a master of I/O
link to R--J3iB Mate.) (on slave mode)
D CRM9 interface
Refer to the operator’s MANUAL for detail informations.
208
APPENDIX
B--81525EN--1/01
B.1
SIGNAL TYPES
B. PERIPHERAL INTERFACE
The tables below list the special signals of the R--J3iB Mate robot
controller.
Input signals (See Subsection B.2.1.)
Description
Signal
*HOLD
RESET
START
ENBL
PNS1
PNS2
PNS3
PNS4
Temporary stop
Alarm release
Cycle start
Enable
Program select (*1)
Program select (*1)
Program select (*1)
Program select (*1)
NOTE
PNS (program select input) (optional)
Output signals (See Subsection B.2.1.)
Signal
Description
CMDENBL
FAULT
BATALM
BUSY
Input acceptable
Alarm
Battery alarm
Busy
209
B. PERIPHERAL INTERFACE
APPENDIX
B--81525EN--1/01
B.2
I/O SIGNALS
B.2.1
Fellowing is each input signal.
Input Signals
Hold input signals,
*HOLD, UI [ 1 ]
The remote controller uses the hold signal to halt the robot. Because
*HOLD input signal is a inverted signal, normally set the signal on. When
the signal goes off, the following is executed:
D The robot is decelerated until its stops, then the program execution is
halted.
D If ENABLED is specified at “Break on hold” on the general item
setting screen, the robot is stopped, an alarm is generated, and the
servo power is turned off. (Standard setting: DISABLED)
Fault reset input signal,
RESET, UI [ 2 ]
The RESET signal cancels an alarm. If the servo power is off, the RESET
signal turns on the servo power. The alarm output is not canceled until the
servo power is turned on. The alarm is canceled at the instant this signal
falls in default setting.
D If TRUE is specified at “CSTOPI for ABORT” on the system
configuration screen, the RESET signal resets an alarm and aborts the
currently selected program. (Standard setting: FALSE)
D To have alarms reset the instant the RESET signal rises, it is necessary
to specify RISE at “Detect FAULT RESET signal” on the system
configuration screen. (Standard setting: FALL)
Start input signal,
START, UI [ 3 ] (validated
in the remote state)
The START signal has two functions. It can select or collate a program
and start the program.
D When the START signal goes high, PNS1 to PNS4 are read and the
corresponding program is selected or collated. Whether is program is
selected or collated is specified by the setting of system variable
$SHELL_CFG.$NUM_RSR [1]. (See the description of signals
PNS1 to PNS4.)
D When the START signal goes low, the current program is started from
the line at which the cursor is placed (current line).
D If TRUE is specified at “START for CONTINUE only” on the system
configuration screen, only a program on hold can be started. (Standard
setting: FALSE)
Enable input signal,
ENBL, UI [ 4 ]
The ENBL signal allows the robot to be moved and places the robot in the
ready state. When the ENBL signal is off, the system inhibits a jog feed
of the robot and activation of a program including a motion (group). A
program which is being executed is halted when the ENBL signal is set
off.
NOTE
When the ENBL signal is not monitored, strap the signal
with the ground.
210
B--81525EN--1/01
Program number
selection signals, PNS1
to PNS4, UI [ 5 to 8 ]
(validated in the remote
state)
APPENDIX
B. PERIPHERAL INTERFACE
A program number selection signal has two functions.
When the START signal goes on, PNS1 to PNS4 are read and the
corresponding program is selected or collated. Whether the program is
selected or collated is specified by the setting of system variable
$SHELL_CFG.$NUM_RSR [1].
D In the program end state, a program is selected or collated according
to the state (0 or 1) of the PNS signals. The current line of the selected
or collated program is set to 1.
- Type 1 (when $SHELL_CFG.$NUM_RSR [1] is set to 0)
The program specified by the PNS signals is selected.
- Type 2 (when $SHELL_CFG.$NUM_RSR [1] is set to 1)
The program specified by the PNS signals is collated with the
current program. If the programs do not agree with each other, an
error occurs.
D If all PNS signals are low in the program end state, the current program
is executed from the current line. If no programs are selected, an error
occurs.
D A halted program can be resumed only when all PNS signals are set
off. Otherwise, an error occurs.
D While a program is being executed, the PNS signals are ignored.
B.2.2
Fellowing are peripheral device interface output signals.
Output signals
Command enable output
signal, CMDENBL,
UO [ 1 ]
The CMDENBL signal is output when the following conditions are
satisfied. The CMDENBL signal indicates that the remote controller can
start a program including a motion (group).
D The remote conditions are satisfied.
D The ready conditions are satisfied.
D The continuous operation mode is selected (the single step mode is
disabled).
Fault output signal,
FAULT, UO [ 2 ]
The FAULT signal is output when an alarm occurs in the system. The
RESET signal cancels the alarm. If a warning (WARN alarm) occurs, the
FAULT signal is not output.
Battery alarm output
signal, BATALM, UO [ 3 ]
The BATALM signal indicates that the voltage of the battery for
supporting the memory has dropped. Replace the battery while keeping
the power of the controller on.
To have the BATALM signal generated also when the BZAL/BLAL alarm
occurs, it is necessary to set the $BLAL_OUT.$BATALM_OR system
variable. It is also possible to have the specified SDO output when the
BZAL/BLAL alarm occurs.
Busy output signal,
BUSY, UO [ 4 ]
The BUSY signal is output while a program is being executed. The BUSY
signal is not output while a program is being halted.
211
B. PERIPHERAL INTERFACE
APPENDIX
B--81525EN--1/01
B.3
SPECIFICATIONS OF
DIGITAL
INPUT/OUTPUT
B.3.1
Overview
B.3.2
Input/Output Hardware
Usable in the R-J3iB
Mate Controller
This section describes the external specifications of digital and analog
input/output in the R--J3iB Mate controller.
The R--J3iB Mate controller can use up to 512 digital input and output
points or an equivalent number of analog input and output points. One
analog input/output point uses the resources equivalent to those used by
16 digital I/O points. The R--J3iB Mate can use a total of up to 512 I/O
points.
The R--J3iB Mate controller can use the following I/O hardware.
- Process I/O printed circuit board
- I/O unit model A
The process I/O printed circuit board and the I/O unit model A can be used
together.
212
B--81525EN--1/01
APPENDIX
B. PERIPHERAL INTERFACE
B.3.3
Software
Specifications
(1) RDI/RDO
These are signals sent to the connector at the wrist of the robot.
They cannot be assigned (redefined) and are fixed.
The standard format is six inputs and six outputs. The number of
points that can be used for the connector at the wrist depends on the
individual robot.
(2) SDI/SDO
The signal No. that is determined at hardware can be changed by
software operation.
(3) Analog I/O
An analog I/O signal can access the analog I/O port (optional) on the
process I/O printed circuit board or the I/O port on the analog I/O
module (used together with the I/O unit model A).
It reads and writes the digital value converted from the analog value
of the I/O voltage. It means that the value does not always represent
the real I/O voltage.
(4) Group I/O
Group I/O is a function which can input or output multiple DI/DO
signals as binary codes.
Any number of continuous signals of up to 16 bits can be set for its
use.
It can be set in the menu DETAILS on the group I/O screen.
213
C. OPTICAL FIBER CABLE
C
APPENDIX
B--81525EN--1/01
OPTICAL FIBER CABLE
The R--J3iB Mate uses fiber optic cables for communication between the
robot controller PC board and servo amplifier module and between the
servo amplifier module and servo amplifier module. Observe the
following cautions when handling these fiber optic cables.
(1) Protection during storage
When the electrical/optical conversion module (mounted on the
printed) circuit board and the fiber optic cable are not in use, their
mating surfaces must be protected with the lid and caps with which
they are supplied. If left uncovered, the mating surfaces are likely to
become dirty, possibly resulting in a poor cable connection.
Electrical/optical conversion module
Fiber optic cable
Lid
Fiber optic
cable caps
Fig.C (a) Protection of electrical/optical conversion module and fiber
optic cable (when not in use)
214
C. OPTICAL FIBER CABLE
APPENDIX
B--81525EN--1/01
(2) Fiber optic cable
D Grasp the optical connector firmly when connecting or
disconnecting the cable. Do not pull on the fiber optic cord itself.
(The maximum tensile strength between the fiber cord and
connector is 2 kg. Applying greater force to the cord is likely to
cause the connector to come off, making the cable unusable.)
Fiber optic cord diameter : 2.2 mm × 2 cords
Tensile strength : Fiber optic cord
:7 kg per cord
Between fiber optic cord and connector : 2 kg
Minimum bending radius of fiber optic cord
:25 mm
Flame resistance
: Equivalent to UL VW--1
Operating temperature
: --20 to 70°C
8.2
6.7
19 max.
60 max.
35typ.
21
Bush
Code
Reinforced cover
Fig.C (b) External dimensions of external optical cable Unit : mm
D Afler it is connected, the optical connector is automatically locked
by the lock levers on its top. To remove the connector, release the
lock levers and pull the connector.
D Although optical connectors cannot be connected in other than the
correct orientation, always take note of the connector’s orientation
before making the connection.
D Take care to keep both parts of the optical connector (cable side and
PCB side) clean. If they become dirty, wipe them with tissue paper
or absorbent cotton to remove dirt. The tissue paper or absorbent
cotton may be moistened with ethyl alcohol. Do not use any
organic solvent other than ethyl alcohol.
D Do not clamp the uncovered portion of the cable with a nylon band.
215
Index
B--81525EN--1/01
[A]
External Emergency Stop Output, 165
External View of the Controller, 21
Adjustment and Checks at Installation, 193
Alarm Occurrence Screen, 30
[F]
FANUC I/O Link, 159
[B]
Backplane PC Board (A20B--2003--0330), 116
Battery for Memory Backup (3 VDC), 151
[I]
Block Diagram, 156
I/O Signals, 210
Block Diagrams of the Power Supply, 123
Initial Screen Remains on the Teach Pendant, 29
Input Signals, 210
Input/Output Hardware Usable in the R--J3iB Mate
Controller, 212
[C]
Checking the Power Supply Module, 124
Installation, 191
Checking the Power Supply Unit, 124
Installation Condition, 193
Circuit Diagram of Emergency Stop, 163
Component Functions, 24
[L]
Configuration, 20
Connecting a Cable to a Peripheral Device, 170
LED of Power Supply Module, 120
Connecting the Mechanical Unit and End Effector,
186
LED of Servo Amplifier, 120
LED of Servo Amplifier Module, 121
Connection Details, 157
Connection of Cable for RS--232--C/RS--422, 169
[M]
Connection of I/O Link Cable, 161
Connection of Power Supply Cable, 158
Manual Operation Impossible, 108
Connection of Robot, 167
Mastering, 34
Connection of Teach Pendant Cable, 168
Coonection of Servo Amplifier, 166
[N]
Note at Installation, 194
[D]
Digital I/O Signal Specifications, 182
[O]
Digital I/O Signal Specifications of End Effecter Control Interface, 188
Operator Safety, 4, 6
Disabling Hand Break, 194
Optical Fiber Cable, 214
Outline Drawings, 118
Output signals, 211
[E]
Emergency Stop Circuit, 163
[P]
Emergency Stop PC Board (A20B--1008--0022,
--0023), 115
Peripheral Device Cable Connector, 184
End Effector Interface, 186
Peripheral device interface CRM 79 and CRM 81, 182
External Controller Dimensions, 192
Peripheral Device Interfaces CRM79 and CRM81,
170
External Emergency Stop Input, 164
i--1
Index
B--81525EN--1/01
Peripheral interface, 208
Replacing the Teach Pendant, 140
Position Deviation Found in Return to the Reference
Position (Positioning), 106
Replacing the Transformer, 135
Robot Controller PC Board (A16B--3200--0450), 111
Power Cannot be Turned On, 27
Power Supply Module PSM (A06B--6115--H001), 118
[S]
Precautions for Mechanism, 10
Precautions for Mechanisms, 11
Safety During Maintenance, 9
Precautions in Operation, 11
Safety in Maintenance, 13
Precautions in Programming, 10, 11, 12
Safety of the End Effector, 12
Preventive Maintenance, 25
Safety of the Robot Mechanism, 11
Printed Circuit Boards, 110
Safety of the Teach Pendant Operator, 7
Safety of the Tools and Peripheral Devices, 10
Safety Precautions, 3
[R]
Safety Signals, 33
Recommended Cables, 185
Servo Amplifier Module (A06B--6114--H205,
A06B--6114--H302), 119
Replacing a Fuse, 146
Servo Amplifiers, 117
Replacing a Fuse on the Emergency Stop PC Board,
147
Setting the Power Supply, 122
Replacing a Fuse on the Robot Controller PC Board,
146
Signal Types, 209
Replacing a Relay, 150
Software Specifications, 213
Replacing a Relay on the Emergency Stop PC Board,
150
Specifications of Digital Input/Output, 212
Replacing a Unit, 126
[T]
Replacing Battery, 151
Replacing Cards and Modules on the Robot Controller
PC Board, 131
Teach Pendant Cannot be Turned On, 28
Total Connection Diagram, 197
Replacing Servo Amplifiers, 139
Transportation, 191
Replacing the Backplane Board (Unit), 128
Transportation and Installation, 190
Replacing the Brake Power Transformer, 135
Treatment for the Shielded Cable, 189
Replacing the Control Section Fan Motor, 141
Troubleshooting, 26
Replacing the Door Fan Unit and Heat Exchanger,
143
Troubleshooting Based on LED Indications, 96
Replacing the Emergency Stop PC Board, 130
Troubleshooting Using Fuses, 92
Replacing the Emergency Stop Unit, 137
Troubleshooting Using the Error Code, 36
Replacing the Fan Motor of the Servo Amplifier Control Unit, 142
[V]
Replacing the Fuse on the Power Supply Module, 148
Replacing the Fuse on the Servo Amplifier Module,
149
Vibration Observed During Movement, 107
Replacing the Magnetic Contactor, 138
Replacing the Operator Panel, 144
[W]
Replacing the Power Supply Unit, 145
Warning Label, 14
Replacing the Printed--Circuit Boards, 127
When the Robot is Connected to the CNC by a Peripheral Device Cable, 171
Replacing the Robot Controller PC Board and
Printed--Circuit Boards on the Backplane Unit, 129
i--2
Revision Record
FANUC Robot series R--J3iB Mate CONTROLLER For Europe MAINTENANCE MANUAL (B--81525EN--1)
01
Oct., 2001
Edition
Date
Contents
Edition
Date
Contents