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FANUC Robotseries

(RIA R15.06-1999 COMPLIANT)


R-30iA CONTROLLER
MAINTENANCE MANUAL
MARMCRIA304071E REV. B
This publication contains proprietary information
of FANUC Robotics America, Inc. furnished for
customer use only. No other uses are authorized
without the express written permission of
FANUC Robotics America, Inc.
FANUC Robotics America, Inc.
3900 W. Hamlin Road
Rochester Hills, Michigan 483093253
B-82595EN-2/02
The descriptions and specifications contained in this manual were in
effect at the time this manual was approved for printing. FANUC
Robotics America, Inc, hereinafter referred to as FANUC Robotics,
reserves the right to discontinue models at any time or to change
specifications or design without notice and without incurring
obligations.
FANUC Robotics manuals present descriptions, specifications,
drawings, schematics, bills of material, parts, connections and/or
procedures for installing, disassembling, connecting, operating and
programming FANUC Robotics products and/or systems. Such
systems consist of robots, extended axes, robot controllers,
application software, the KAREL programming language,
INSIGHT vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been
trained in one or more approved FANUC Robotics Training
Course(s) be permitted to install, operate, use, perform procedures
on, repair, and/or maintain FANUC Robotics products and/or
systems and their respective components. Approved training
necessitates that the courses selected be relevant to the type of
system installed and application performed at the customer site.
WARNING
This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in accordance
with the instruction manual, may cause interference to radio
communications. As temporarily permitted by regulation, it
has not been tested for compliance with the limits for Class A
computing devices pursuant to subpart J of Part 15 of FCC
Rules, which are designed to provide reasonable protection
against such interference. Operation of the equipment in a
residential area is likely to cause interference, in which case
the user, at his own expense, will be required to take
whatever measure may be required to correct the
interference.
FANUC Robotics conducts courses on its systems and products on
a regularly scheduled basis at its headquarters in Rochester Hills,
Michigan. For additional information contact
FANUC Robotics America, Inc.
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com
!
Copyright 2007 by FANUC Robotics America, Inc.
All Rights Reserved
The information illustrated or contained herein is not to be
reproduced, copied, downloaded, translated into another language,
published in any physical or electronic format, including internet, or
transmitted in whole or in part in any way without the prior written
consent of FANUC Robotics America, Inc.
AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL,
KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks,
PalletTool, SOCKETS, SOFT PARTS SpotTool,
TorchMate, and YagTool are Registered Trademarks of FANUC
Robotics.
FANUC Robotics reserves all proprietary rights, including but not
limited to trademark and trade name rights, in the following names:
AccuAir AccuCal AccuChop AccuFlow AccuPath
AccuSeal ARC Mate ARC Mate Sr. ARC Mate System 1
ARC Mate System 2 ARC Mate System 3 ARC Mate System
4 ARC Mate System 5 ARCWorks Pro AssistTool
AutoNormal AutoTCP BellTool BODYWorks Cal Mate Cell
Finder Center Finder Clean Wall CollisionGuard
DispenseTool F-100 F-200i FabTool FANUC LASER
DRILL Flexibell FlexTool HandlingTool HandlingWorks
INSIGHT INSIGHT II IntelliTrak Integrated Process Solution
Intelligent Assist Device IPC -Integrated Pump Control IPD
Integral Pneumatic Dispenser ISA Integral Servo Applicator ISD
Integral Servo Dispenser Laser Mate System 3 Laser Mate
System 4 LaserPro LaserTool LR Tool MIG Eye
MotionParts NoBots Paint Stick PaintPro PaintTool 100
PAINTWorks PAINTWorks II PAINTWorks III PalletMate
PalletMate PC PalletTool PC PayloadID RecipTool
RemovalTool Robo Chop Robo Spray S-420i S-430i
ShapeGen SoftFloat SOF PARTS SpotTool+ SR Mate
SR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM R-
J3 Controller SYSTEM R-J3iB Controller TCP Mate
TurboMove TorchMate visLOC visPRO-3D visTRAC
WebServer WebTP YagTool
FANUC LTD 2007
No part of this manual may be reproduced in any form.
All specifications and designs are subject to change without notice.
This manual includes information essential to the safety of
personnel, equipment, software, and data. This information is
indicated by headings and boxes in the text.
WARNING
Information appearing under WARNING concerns the
protection of personnel. It is boxed and in bold type to set it
apart from other text.
CAUTION
Information appearing under CAUTION concerns the protection of
equipment, software, and data. It is boxed to set it apart from
other text.

NOTE Information appearing next to NOTE concerns related
information or useful hints.
Conventions
!
!














Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.

This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller
labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.

No part of this manual may be reproduced in any form.
All specifications and designs are subject to change without notice.

The products in this manual are controlled based on Japans Foreign Exchange and
Foreign Trade Law. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.

In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as impossible.

B-82595EN-2/02 PREFACE

p-1
PREFACE

This manual describes the following models (R-30iA controller).
Model Abbreviation
FANUC Robot R-2000iB/210F R-2000iB/210F
FANUC Robot R-2000iB/200R R-2000iB/200R
FANUC Robot R-2000iB/200EW R-2000iB/200EW
FANUC Robot R-2000iB/165R R-2000iB/165R
FANUC Robot R-2000iB/165F R-2000iB/165F
FANUC Robot R-2000iB/165EW R-2000iB/165EW
FANUC Robot R-2000iB/165CF R-2000iB/165CF
FANUC Robot R-2000iB/125L R-2000iB/125L
FANUC Robot R-2000iB/100P R-2000iB/100P
FANUC Robot R-2000iB/200T R-2000iB/200T
R-2000iB
FANUC Robot M-6iB M-6iB
FANUC Robot M-6iB/6T M-6iB/6T
FANUC Robot M-6iB/6S M-6iB/6S
FANUC Robot M-6iB/2HS M-6iB/2HS
FANUC Robot M-6iB/6C M-6iB/6C
M-6iB
FANUC Robot M-10iA M-10iA
FANUC Robot M-16iB/20 M-16iB/20
FANUC Robot M-16iB/10L M-16iB/10L
FANUC Robot M-16iB/20T M-16iB/20T
FANUC Robot M-16iB/10LT M-16iB/10LT
M-16iB
FANUC Robot ARC Mate 100iB ARC Mate 100iB
FANUC Robot ARC Mate 100iBe ARC Mate 100iBe
FANUC Robot ARC Mate 100iB/6S ARC Mate 100iB/6S
ARC Mate 100iB
FANUC Robot ARC Mate 100iC ARC Mate 100iC
FANUC Robot ARC Mate 120iB ARC Mate 120iB
FANUC Robot ARC Mate 120iBe ARC Mate 120iBe
FANUC Robot ARC Mate 120iB/10L ARC Mate 120iB/10L
FANUC Robot ARC Mate 120iB/20T ARC Mate 120iB/20T
FANUC Robot ARC Mate 120iB/10LT ARC Mate 120iB/10LT
ARC Mate 120iB
FANUC Robot M-710iC/70 M-710iC/70
FANUC Robot M-710iC/70T M-710iC/70T
FANUC Robot M-710iC/50 M-710iC/50
FANUC Robot M-710iC/50S M-710iC/50S
FANUC Robot M-710iC/50T M-710iC/50T
FANUC Robot M-710iC/20L M-710iC/20L
M-710iC
FANUC Robot M-410iB/160 M-410iB/160
FANUC Robot M-410iB/300 M-410iB/300
FANUC Robot M-410iB/450 M-410iB/450
M-410iB
FANUC Robot M-420iA M-420iA
FANUC Robot M-421iA M-421iA
FANUC Robot M-430iA/2F M-430iA/2F
FANUC Robot M-430iA/2P M-430iA/2P
M-430iA
FANUC Robot M-900iA/260L M-900iA/260L
FANUC Robot M-900iA/350 M-900iA/350
FANUC Robot M-900iA/600 M-900iA/600
M-900iA
FANUC Robot F-200iB F-200iB

B-82595EN-2/02 TABLE OF CONTENTS

c - 1
TABLE OF CONTENTS

PREFACE....................................................................................................... 1
I. SAFETY PRECAUTIONS
1 SAFETY PRECAUTIONS........................................................................ 3
1.1 WORKING PERSON..................................................................................... 3
1.2 WORKING PERSON SAFETY...................................................................... 5
1.2.1 General Person Safety ..............................................................................................7
1.2.2 Safety of the Teaching Operator ..............................................................................8
1.2.3 Safety During Maintenance....................................................................................10
1.3 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES........................... 11
1.3.1 Precautions in Programming ..................................................................................11
1.3.2 Precautions for Mechanism....................................................................................11
1.4 SAFETY OF THE ROBOT MECHANISM.................................................... 12
1.4.1 Precautions in Operation ........................................................................................12
1.4.2 Precautions in Programming ..................................................................................12
1.4.3 Precautions for Mechanisms...................................................................................12
1.5 SAFETY OF THE END EFFECTOR............................................................ 12
1.5.1 Precautions in Programming ..................................................................................12
1.6 WARNING LABEL ....................................................................................... 13

II. MAINTENANCE
1 OVERVIEW........................................................................................... 17
2 CONFIGURATION ................................................................................ 18
2.1 EXTERNAL VIEW OF THE CONTROLLER................................................ 19
2.2 COMPONENT FUNCTIONS........................................................................ 32
2.3 PREVENTIVE MAINTENANCE................................................................... 33
3 TROUBLESHOOTING.......................................................................... 34
3.1 POWER CANNOT BE TURNED ON........................................................... 35
3.2 ALARM OCCURRENCE SCREEN.............................................................. 39
3.3 SAFETY SIGNALS...................................................................................... 42
3.4 MASTERING............................................................................................... 43
3.5 TROUBLESHOOTING USING THE ERROR CODE................................... 45
TABLE OF CONTENTS B-82595EN-2/02

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3.6 FUSE-BASED TROUBLESHOOTING....................................................... 146
3.7 TROUBLESHOOTING BASED ON LED INDICATIONS ........................... 154
3.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE
POSITION (POSITIONING)....................................................................... 166
3.9 MANUAL OPERATION IMPOSSIBLE....................................................... 167
4 PRINTED CIRCUIT BOARDS............................................................. 169
4.1 MAIN BOARD (A16B-3200-0600, -0601) .................................................. 170
4.2 EMERGENCY STOP CONTROL BOARD (A20B-1008-0740) .................. 173
4.3 BACKPLANE BOARD ............................................................................... 174
4.4 PANEL BOARD (A20B-2101-0370)........................................................... 176
4.5 PROCESS I/O BOARD CA (A16B-2201-0470) ......................................... 177
4.6 PROCESS I/O BOARD EA (A16B-3200-0230).......................................... 180
4.7 PROCESS I/O BOARD EB (A16B-3200-0231).......................................... 183
4.8 PROCESS I/O BOARD FA (A16B-3200-0420).......................................... 185
4.9 PROCESS I/O BOARD GA (A16B-2203-0520) ......................................... 187
4.10 PROCESS I/O BOARD HA (A16B-2203-0760) ......................................... 189
4.11 PROCESS I/O BOARD JA (A16B-2204-0010) .......................................... 192
4.12 PROCESS I/O BOARD JB (A16B-2204-0011) .......................................... 194
4.13 PROCESS I/O BOARD KA (A16B-2204-0050).......................................... 196
4.14 PROCESS I/O BOARD KBA16B-2204-0051...................................... 199
4.15 PROCESS I/O BOARD KCA16B-2204-0052...................................... 202
5 SERVO AMPLIFIERS ......................................................................... 204
5.1 LED OF SERVO AMPLIFIER .................................................................... 206
5.2 SETTING OF SERVO AMPLIFIER............................................................ 207
6 SETTING THE POWER SUPPLY....................................................... 208
6.1 BLOCK DIAGRAM OF THE POWER SUPPLY......................................... 209
6.2 TRANSFORMER....................................................................................... 210
6.3 CHECKING THE POWER SUPPLY UNIT (A16B-2203-0910) .................. 214
7 REPLACING A UNIT........................................................................... 215
7.1 A-CABINET................................................................................................ 216
7.1.1 Replacing the A-cabinet Top Panel ......................................................................216
7.1.2 Replacing the A-cabinet Rear Panel.....................................................................217
7.1.3 Replacing the A-cabinet Louver...........................................................................218
7.1.4 Replacing the A-cabinet Door ..............................................................................219
7.2 REPLACING THE PRINTED-CIRCUIT BOARDS ..................................... 220
7.2.1 Replacing the Backplane Board (Unit).................................................................221
B-82595EN-2/02 TABLE OF CONTENTS

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7.2.2 Replacing the Power Unit and Printed-Circuit Boards on the Backplane Unit ....222
7.2.3 Replacing the Panel Board ...................................................................................224
7.2.4 Replacing the Process I/O Board EA,EB,FA,GA,KA,KB,KC (A-cabinet) .........226
7.3 REPLACING CARDS AND MODULES ON THE MAIN BOARD............... 227
7.4 REPLACING THE TRANSFORMER......................................................... 231
7.5 REPLACING THE REGENERATIVE RESISTOR UNIT ............................ 238
7.6 REPLACING THE E-STOP UNIT .............................................................. 241
7.7 REPLACING SERVO AMPLIFIERS.......................................................... 243
7.8 REPLACING I/O Unit-MODEL A................................................................ 250
7.8.1 Replacing the Base Unit of I/O Unit-MODEL A.................................................250
7.8.2 Replacing a Module..............................................................................................251
7.9 REPLACING THE TEACH PENDANT and i PENDANT............................ 252
7.10 REPLACING THE CONTROL SECTION FAN MOTOR............................ 253
7.11 REPLACING THE AC FAN MOTOR ......................................................... 254
7.11.1 Replacing the Heat Exchanger and Door Fan Unit (A-cabinet) ...........................254
7.11.2 Replacing External Air Fan Unit (A-cabinet) ......................................................255
7.11.3 Replacing External Air Fan Unit and Door Fan (B-cabinet)................................256
7.12 REPLACE THE MODE SWITCH............................................................... 258
7.13 REPLACING FUSES................................................................................. 260
7.13.1 Replacing Fuses in the Servo Amplifier...............................................................260
7.13.2 Replacing Fuses in the Power Unit ......................................................................261
7.13.3 Replacing Fuses in the Main board ......................................................................262
7.13.4 Replacing the Fuse on the Process I/O Boards.....................................................263
7.13.5 Replacing the Fuse on the Panel Board................................................................267
7.14 REPLACING RELAYS............................................................................... 268
7.14.1 Replacing Relays on the Panel Board ..................................................................268
7.15 REPLACING BATTERY ............................................................................ 269
7.15.1 Battery for Memory Backup (3 VDC)..................................................................269
8 HOW TO USE THE PLATE TO FIX THE COMPACT FLASH MEMORY
CARD .................................................................................................. 272

III. CONNECTIONS
1 GENERAL ........................................................................................... 277
2 BLOCK DIAGRAM.............................................................................. 278
TABLE OF CONTENTS B-82595EN-2/02

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3 ELECTRICAL CONNECTIONS........................................................... 280
3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS.................. 281
3.2 EXTERNAL CABLE WIRING DIAGRAM................................................... 283
3.2.1 Robot Connection Cables.....................................................................................283
3.2.2 Teach Pendant Cable............................................................................................297
3.2.3 Connecting the Input Power .................................................................................298
3.2.4 Connecting the External Power Supply ON/OFF Switch ....................................301
3.2.5 Connecting the External Emergency Stop............................................................303
3.2.6 Connecting the Non-Teaching Enabling (NTED) Signal (CRM65) ....................314
3.2.7 Connecting the Auxiliary Axis BrakeCRR65 A/B.......................................316
3.2.8 Connecting the Auxiliary Axis Over Travel (CRM68) ........................................317
3.2.9 Connecting the Operation Box.............................................................................318
4 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR
INTERFACES...................................................................................... 319
4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM.......................... 322
4.1.1 When Process I/O Board EA/EB/GA is Used (A-cabinet)...................................322
4.1.2 When Process I/O Board FA is Used (A-cabinet)................................................324
4.1.3 When Process I/O Board CA/HA is Used (B-cabinet).........................................325
4.1.4 When Process I/O Board JA is Used (B-cabinet).................................................327
4.1.5 When Process I/O Board KA is Used (A-Cabinet) ..............................................328
4.1.6 When I/O Unit-MODEL A is Used......................................................................329
4.1.6.1 In case of B-cabinet ......................................................................................... 329
4.1.7 When Two or more Process I/O Printed Circuit Boards and I/O Unit-MODEL A are
Used 330
4.1.7.1 In case of B-cabinet ......................................................................................... 330
4.2 PERIPHERAL DEVICE INTERFACE COMBINATION .............................. 331
4.2.1 In Case of A-cabinet.............................................................................................331
4.2.2 In Case of B-cabinet .............................................................................................332
4.3 PROCESS I/O BOARD SIGNALS............................................................. 333
4.4 INTERFACE FOR PERIPHERAL DEVICES.............................................. 336
4.4.1 Peripheral Device and Control Unit Connection (Source Type DO) .............336
4.4.2 Peripheral Device and Control Unit Connection (Sink Type DO)..............351
4.5 INTERFACE FOR WELDER...................................................................... 364
4.5.1 Connection Between the Control Unit and Welder ..............................................364
4.6 INTERFACE FOR END EFFECTOR......................................................... 374
4.6.1 Connection Between the Mechanical Unit and End Effector...............................374
4.7 DIGITAL I/O SIGNAL SPECIFICATIONS.................................................. 376
B-82595EN-2/02 TABLE OF CONTENTS

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4.7.1 Peripheral Device Interface A..............................................................................376
4.7.2 End Effector Control Interface .............................................................................380
4.7.3 I/O Signal Specifications for ARC-Welding Interface.........................................382
4.8 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES
AND WELDERS ........................................................................................ 386
4.8.1 Peripheral Device Interface A Cable (CRM2, CRMA5: Honda Tsushin, 50 pins)
386
4.8.2 Peripheral Device Interface B Cable (CRM4, CRMA6: Honda Tsushin, 20 pins)
386
4.8.3 ARC Weld Connection Cable (CRW1, CRW7:Honda Tsushin,34pins)..............387
4.8.4 ARC Weld Connection CableCRW10 : Honda Tsushin, 50 pins................387
4.9 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END
EFFECTORS, AND ARC WELDERS ........................................................ 388
4.9.1 Peripheral Device Connection Cable....................................................................388
4.9.2 Peripheral Device Cable Connector .....................................................................389
4.9.3 End Effector Cable Connector .............................................................................391
4.9.4 Recommended Cables ..........................................................................................392
4.10 CONNECTION OF HDI ............................................................................. 393
4.10.1 Connecting HDI ...................................................................................................393
4.10.2 Input Signal Rules for the High-speed Skip (HDI) ..............................................395
4.11 CONNECTING THE COMMUNICATION UNIT......................................... 396
4.11.1 RS-232-C Interface...............................................................................................396
4.11.1.1 Interface........................................................................................................... 396
4.11.1.2 RS-232-C interface signals .............................................................................. 397
4.11.1.3 Connection between RS-232-C interface and I/O device................................ 398
4.11.2 Ethernet Interface .................................................................................................400
4.11.2.1 Connection to Ethernet .................................................................................... 401
4.11.2.2 10/100 BASE-T connector (CD38) pin assignments....................................... 402
4.11.2.3 Cable connection ............................................................................................. 402
4.11.2.4 Lead materials.................................................................................................. 404
4.11.2.5 Connector specification ................................................................................... 406
4.11.2.6 Cable clamp and shielding............................................................................... 406
4.11.2.7 Grounding the network.................................................................................... 407
5 TRANSPORTATION AND INSTALLATION ....................................... 410
5.1 TRANSPORTATION.................................................................................. 411
5.2 INSTALLATION......................................................................................... 412
5.2.1 Installation Method...............................................................................................412
5.2.2 Assemble at Installation .......................................................................................418
TABLE OF CONTENTS B-82595EN-2/02

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5.3 INSTALLATION CONDITION.................................................................... 420
5.4 ADJUSTMENT AND CHECKS AT INSTALLATION.................................. 421
5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION
................................................................................................................... 422
5.5.1 Peripheral Device Interface Processing................................................................422
5.5.2 Resetting Overtravel.............................................................................................422
5.5.3 How to Disable/Enable HBK...............................................................................423
5.5.4 How to Disable/Enable Pneumatic Pressure Alarm (PPABN).............................423

APPENDIX
A TOTAL CONNECTION DIAGRAM...................................................... 427
B SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE............... 466
B.1 SIGNAL ..................................................................................................... 467
B.2 SETTING COMMON VOLTAGE................................................................ 469
B.3 I/O Signals ................................................................................................. 470
B.3.1 Input Signals.........................................................................................................470
B.3.2 Output Signals ......................................................................................................474
B.4 Specifications of Digital Input/Output ......................................................... 478
B.4.1 Overview..............................................................................................................478
B.4.2 Input/Output Hardware Usable in the R-30iA Controller ....................................478
B.4.3 Software Specifications........................................................................................478
C OPTICAL FIBER CABLE.................................................................... 479















I. SAFETY PRECAUTIONS
Safety
FANUCRoboticsisnotanddoesnotrepresentitself asanexpertinsafetysystems, safetyequipment, or
thespecificsafetyaspectsof your companyand/or itswork force. It istheresponsibilityof theowner,
employer, or user totakeall necessarystepstoguaranteethesafetyof all personnel intheworkplace.
Theappropriatelevel of safety for your applicationandinstallationcanbest bedeterminedby safety
systemprofessionals. FANUC Roboticstherefore, recommendsthat eachcustomer consult withsuch
professionalsinorder toprovideaworkplacethat allowsfor thesafeapplication, use, andoperationof
FANUC Robotic systems.
According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult the
standards to ensure compliance with its requests for Robotics Systemdesign, usability, operation,
maintenance, andservice. Additionally, astheowner, employer, or user of aroboticsystem, it isyour
responsibilitytoarrangefor thetrainingof theoperator of arobot systemtorecognizeandrespondto
known hazards associated with your robotic systemand to beawareof therecommended operating
proceduresfor your particular applicationandrobot installation.
FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair,
or otherwiseusetherobotics systembetrainedinanapprovedFANUC Robotics trainingcourseand
becomefamiliar with theproper operation of thesystem. Persons responsiblefor programming the
system-includingthedesign, implementation, anddebuggingof applicationprograms-mustbefamiliar
withtherecommendedprogrammingproceduresfor your applicationandrobot installation.
Thefollowingguidelinesareprovidedtoemphasizetheimportanceof safetyintheworkplace.
CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION
Safetyisessential whenever robotsareused. Keepinmindthefollowingfactorswithregardtosafety:
Thesafety of peopleandequipment
Useof safety enhancingdevices
Techniquesfor safeteachingandmanual operationof therobot(s)
Techniquesfor safeautomatic operationof therobot(s)
Regular scheduledinspectionof therobot andworkcell
Proper maintenanceof therobot
Keeping People and Equipment Safe
Thesafetyof peopleisalwaysof primaryimportanceinanysituation. However, equipment must be
kept safe, too. Whenprioritizinghowtoapplysafetytoyour roboticsystem, consider thefollowing:
i
Safety
People
External devices
Robot(s)
Tooling
Workpiece
Using Safety Enhancing Devices
Alwaysgiveappropriateattentiontothework areathat surroundstherobot. Thesafetyof thework
areacanbeenhancedbytheinstallationof someor all of thefollowingdevices:
Safety fences, barriers, or chains
Light curtains
Interlocks
Pressuremats
Floor markings
Warninglights
Mechanical stops
EMERGENCY STOP buttons
DEADMAN switches
Setting Up a Safe Workcell
A safeworkcell isessential toprotect peopleandequipment. Observethefollowingguidelinesto
ensurethat theworkcell isset upsafely. Thesesuggestionsareintendedtosupplementandnot replace
existingfederal, state, andlocal laws, regulations, andguidelinesthat pertaintosafety.
Sponsor your personnel for traininginapprovedFANUC Roboticstrainingcourse(s) relatedto
your application. Never permit untrainedpersonnel tooperatetherobots.
Install alockout devicethat usesanaccesscodetoprevent unauthorizedpersonsfromoperating
therobot.
Useanti-tie-downlogictoprevent theoperator frombypassingsafetymeasures.
Arrangetheworkcell sotheoperator facestheworkcell andcanseewhat isgoingoninsidethe
cell.
ii
Safety
Clearlyidentifythework envelopeof eachrobot inthesystemwithfloor markings, signs, and
special barriers. Thework envelopeistheareadefinedby themaximummotionrangeof the
robot, includinganytoolingattachedtothewrist flangethat extendthisrange.
Positionall controllersoutsidetherobot work envelope.
Never relyonsoftwareor firmwarebasedcontrollersastheprimarysafetyelement unlessthey
comply withapplicablecurrent robot safety standards.
Mount anadequatenumber of EMERGENCY STOP buttonsor switcheswithineasyreachof the
operator andat critical pointsinsideandaroundtheoutsideof theworkcell.
Install flashinglights and/or audiblewarningdevices that activatewhenever therobot is
operating, that is, whenever power isappliedtotheservodrivesystem. Audiblewarningdevices
shall exceedtheambient noiselevel at theend-useapplication.
Wherever possible, install safetyfencestoprotect against unauthorizedentrybypersonnel into
thework envelope.
Install special guardingthat preventstheoperator fromreachingintorestrictedareasof the
work envelope.
Useinterlocks.
Usepresenceor proximity sensingdevicessuchaslight curtains, mats, andcapacitanceand
visionsystemstoenhancesafety.
Periodicallycheck thesafetyjointsor safetyclutchesthat canbeoptionallyinstalledbetweenthe
robot wrist flangeandtooling. If thetoolingstrikesanobject, thesedevicesdislodge, remove
power fromthesystem, andhelptominimizedamagetothetoolingandrobot.
Makesureall external devicesareproperly filtered, grounded, shielded, andsuppressedto
prevent hazardousmotionduetotheeffects of electro-magnetic interference(EMI), radio
frequency interference(RFI), andelectro-static discharge(ESD).
Makeprovisionsfor power lockout/tagout at thecontroller.
Eliminatepinch points . Pinchpointsareareaswherepersonnel couldget trappedbetweena
movingrobot andother equipment.
Provideenoughroominsidetheworkcell topermit personnel toteachtherobot andperform
maintenancesafely.
Programtherobot toloadandunloadmaterial safely.
If highvoltageelectrostaticsarepresent, besuretoprovideappropriateinterlocks, warning, and
beacons.
If materialsarebeingappliedat dangerously highpressure, provideelectrical interlocksfor
lockout of material flowandpressure.
iii
Safety
Staying Safe While Teaching or Manually Operating the Robot
Adviseall personnel whomust teachtherobot or otherwisemanuallyoperatetherobot toobservethe
followingrules:
Never wear watches, rings, neckties, scarves, or looseclothingthat couldget caught inmoving
machinery.
Knowwhether or not youareusinganintrinsically safeteachpendant if youareworkingin
ahazardous environment.
Beforeteaching, visually inspect therobot andwork envelope tomakesurethat nopotentially
hazardousconditionsexist. Thework envelopeistheareadefinedbythemaximummotionrange
of therobot. Theseincludetoolingattachedtothewrist flangethat extendsthisrange.
Theareanear therobot must becleanandfreeof oil, water, or debris. Immediatelyreport unsafe
workingconditionstothesupervisor or safety department.
FANUCRoboticsrecommendsthatnooneenter theworkenvelopeof arobotthatison, exceptfor
robot teachingoperations. However, if youmust enter thework envelope, besureall safeguards
areinplace, check theteachpendant DEADMAN switchfor proper operation, andplacethe
robot inteachmode. Taketheteachpendant withyou, turnit on, andbepreparedtoreleasethe
DEADMAN switch. Onlythepersonwiththeteachpendant shouldbeinthework envelope.
Warning
Never bypass, strap, or otherwise deactivate a safety device, such as a
limit switch, for any operational convenience. Deactivating a safety
device is known to have resulted in serious injury and death.
Knowthepaththat canbeusedtoescapefromamovingrobot; makesuretheescapepathis
never blocked.
Isolatetherobot fromall remotecontrol signalsthat cancausemotionwhiledataisbeingtaught.
Test any programbeingrunfor thefirst timeinthefollowingmanner:
Warning
Stay outside the robot work envelope whenever a program is being
run. Failure to do so can result in injury.
Usingalowmotionspeed, singlesteptheprogramfor at least onefull cycle.
Usingalowmotionspeed, test runtheprogramcontinuouslyfor at least onefull cycle.
Usingtheprogrammedspeed, test runtheprogramcontinuouslyfor at least onefull cycle.
Makesureall personnel areoutsidethework envelopebeforerunningproduction.
iv
Safety
Staying Safe During Automatic Operation
Adviseall personnel whooperatetherobot duringproductiontoobservethefollowingrules:
Makesureall safety provisionsarepresent andactive.
Knowtheentireworkcell area. Theworkcell includestherobot anditswork envelope, plusthe
areaoccupiedbyall external devicesandother equipment withwhichtherobot interacts.
Understandthecompletetask therobot isprogrammedtoperformbeforeinitiatingautomatic
operation.
Makesureall personnel areoutsidethework envelopebeforeoperatingtherobot.
Never enter or allowotherstoenter thework envelopeduringautomaticoperationof therobot.
Knowthelocationandstatusof all switches, sensors, andcontrol signalsthat couldcausethe
robot to move.
KnowwheretheEMERGENCY STOP buttonsarelocatedonboththerobot control andexternal
control devices. Bepreparedtopressthesebuttonsinanemergency.
Never assumethat aprogramiscompleteif therobot isnot moving. Therobot couldbewaiting
for aninput signal that will permit it tocontinueactivity.
If therobot isrunninginapattern, donot assumeit will continuetoruninthesamepattern.
Never try tostoptherobot, or break itsmotion, withyour body. Theonly way tostoprobot
motionimmediatelyistopressanEMERGENCY STOP buttonlocatedonthecontroller panel,
teachpendant, or emergency stopstationsaroundtheworkcell.
Staying Safe During Inspection
Wheninspectingtherobot, besureto
Turnoff power at thecontroller.
Lock out andtagout thepower sourceat thecontroller accordingtothepoliciesof your plant.
Turnoff thecompressedair sourceandrelievetheair pressure.
If robot motionisnot neededfor inspectingtheelectrical circuits, presstheEMERGENCY
STOP buttonontheoperator panel.
Never wear watches, rings, neckties, scarves, or looseclothingthat couldget caught inmoving
machinery.
If power isneededtocheck therobot motionor electrical circuits, bepreparedtopressthe
EMERGENCY STOP button, inanemergency.
Beawarethat whenyouremoveaservomotor or brake, theassociatedrobot armwill fall if it is
not supportedor restingonahardstop. Support thearmonasolidsupport beforeyourelease
thebrake.
v
Safety
Staying Safe During Maintenance
Whenperformingmaintenanceonyour robot system, observethefollowingrules:
Never enter thework envelopewhiletherobot or aprogramisinoperation.
Beforeenteringthework envelope, visually inspect theworkcell tomakesurenopotentially
hazardous conditions exist.
Never wear watches, rings, neckties, scarves, or looseclothingthat couldget caught inmoving
machinery.
Consider all or any overlappingwork envelopesof adjoiningrobotswhenstandinginawork
envelope.
Test theteachpendant for proper operationbeforeenteringthework envelope.
If it isnecessaryfor youtoenter therobot work envelopewhilepower isturnedon, youmust be
surethat youareincontrol of therobot. Besuretotaketheteachpendant withyou, pressthe
DEADMANswitch, andturntheteachpendanton. BepreparedtoreleasetheDEADMANswitch
toturnoff servopower totherobot immediately.
Whenever possible, performmaintenancewiththepower turnedoff. Beforeyouopenthe
controller front panel or enter thework envelope, turnoff andlock out the3-phasepower source
at thecontroller.
Beawarethat anapplicator bell cupcancontinuetospinat averyhighspeedevenif therobot is
idle. Useprotectiveglovesor disablebearingair andturbineair beforeservicingtheseitems.
Beawarethat whenyouremoveaservomotor or brake, theassociatedrobot armwill fall if it is
not supportedor restingonahardstop. Support thearmonasolidsupport beforeyourelease
thebrake.
Warning
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to avoid
electrical shock.HIGH VOLTAGE IS PRESENT at the input side
whenever the controller is connected to a power source. Turning the
disconnect or circuit breaker to the OFF position removes power from
the output side of the device only.
Releaseor block all storedenergy. Beforeworkingonthepneumaticsystem, shut off thesystem
air supply andpurgetheair lines.
Isolatetherobot fromall remotecontrol signals. If maintenancemust bedonewhenthepower
ison, makesurethepersoninsidethework envelopehassolecontrol of therobot. Theteach
pendant must beheldby thisperson.
vi
Safety
Makesurepersonnel cannot get trappedbetweenthemovingrobot andother equipment. Know
thepaththat canbeusedtoescapefromamovingrobot. Makesuretheescaperouteisnever
blocked.
Useblocks, mechanical stops, andpinstoprevent hazardousmovement bytherobot. Makesure
that suchdevicesdonot createpinchpointsthat couldtrappersonnel.
Warning
Do not try to remove any mechanical component from the robot
before thoroughly reading and understanding the procedures in the
appropriate manual. Doing so can result in serious personal injury and
component destruction.
Beawarethat whenyouremoveaservomotor or brake, theassociatedrobot armwill fall if it is
not supportedor restingonahardstop. Support thearmonasolidsupport beforeyourelease
thebrake.
Whenreplacingor installingcomponents, makesuredirt anddebrisdonot enter thesystem.
Useonlyspecifiedpartsfor replacement. Toavoidfiresanddamagetopartsinthecontroller,
never usenonspecifiedfuses.
Beforerestartingarobot, makesurenooneisinsidetheworkenvelope; besurethat therobot and
all external devicesareoperatingnormally.
KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE
Certainprogrammingandmechanical measuresareuseful inkeepingthemachinetoolsandother
external devicessafe. Someof thesemeasuresareoutlinedbelow. Makesureyouknowall associated
measures for safeuseof suchdevices.
Programming Safety Precautions
Implement thefollowingprogrammingsafety measurestoprevent damagetomachinetoolsand
other external devices.
Back-check limit switchesintheworkcell tomakesuretheydonot fail.
Implement failureroutines inprogramsthat will provideappropriaterobot actionsif anexternal
deviceor another robot intheworkcell fails.
Usehandshaking protocol tosynchronizerobot andexternal deviceoperations.
Programtherobot tocheck theconditionof all external devicesduringanoperatingcycle.
vii
Safety
Mechanical Safety Precautions
Implement thefollowingmechanical safetymeasurestoprevent damagetomachinetoolsandother
external devices.
Makesuretheworkcell iscleanandfreeof oil, water, anddebris.
Usesoftwarelimits, limit switches, andmechanical hardstopstoprevent undesiredmovement of
therobot intothework areaof machinetoolsandexternal devices.
KEEPING THE ROBOT SAFE
Observethefollowingoperatingandprogrammingguidelinestoprevent damagetotherobot.
Operating Safety Precautions
Thefollowingmeasuresaredesignedtoprevent damagetotherobot duringoperation.
Usealowoverridespeedtoincreaseyour control over therobot whenjoggingtherobot.
Visualizethemovement therobot will makebeforeyoupressthejogkeysontheteachpendant.
Makesurethework envelopeiscleanandfreeof oil, water, or debris.
Usecircuit breakerstoguardagainst electrical overload.
Programming Safety Precautions
Thefollowingsafetymeasuresaredesignedtoprevent damagetotherobot duringprogramming:
Establishinterference zones toprevent collisionswhentwoor morerobotsshareawork area.
Makesurethat theprogramendswiththerobot near or at thehomeposition.
Beawareof signalsor other operations that couldtrigger operationof toolingresultingin
personal injury or equipment damage.
Indispensingapplications, beawareof all safety guidelineswithrespect tothedispensing
materials.
Note Anydeviationfromthemethodsandsafetypracticesdescribedinthismanual must conform
totheapprovedstandardsof your company. If youhavequestions, seeyour supervisor.
viii
Safety
ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT
INSTALLATIONS
Processtechniciansaresometimesrequiredtoenter thepaint booth, for example, duringdaily or
routinecalibrationor whileteachingnewpathstoarobot. Maintenancepersonal alsomust work
insidethepaint boothperiodically.
Whenever personnel areworkinginsidethepaint booth, ventilationequipment must beused.
Instructionontheproper useof ventilatingequipmentusuallyisprovidedbythepaintshopsupervisor.
Althoughpaint boothhazardshavebeenminimized, potential dangersstill exist. Therefore, todays
highlyautomatedpaint boothrequiresthat processandmaintenancepersonnel havefull awarenessof
thesystemanditscapabilities. Theymust understandtheinteractionthat occursbetweenthevehicle
movingalongtheconveyor andtherobot(s), hood/deck anddoor openingdevices, andhigh-voltage
electrostatic tools.
Paint robots areoperatedinthreemodes:
Teachor manual mode
Automatic mode, includingautomatic andexerciseoperation
Diagnostic mode
Duringbothteachandautomaticmodes, therobotsinthepaint boothwill followapredetermined
patternof movements. Inteachmode, theprocesstechnicianteaches(programs) paint pathsusing
theteachpendant.
Inautomatic mode, robot operationisinitiatedat theSystemOperator Console(SOC) or Manual
Control Panel (MCP), if available, andcanbemonitoredfromoutsidethepaint booth. All personnel
must remainoutsideof theboothor inadesignatedsafeareawithintheboothwhenever automatic
modeis initiatedat theSOC or MCP.
Inautomaticmode, therobotswill executethepathmovementstheyweretaught duringteachmode,
but generally at productionspeeds.
Whenprocessandmaintenancepersonnel rundiagnosticroutinesthat requirethemtoremaininthe
paint booth, they must stay inadesignatedsafearea.
Paint System Safety Features
Processtechniciansandmaintenancepersonnel must becometotallyfamiliar withtheequipment and
itscapabilities. Tominimizetherisk of injury whenworkingnear robotsandrelatedequipment,
personnel must comply strictly withtheproceduresinthemanuals.
ix
Safety
Thissectionprovidesinformationabout thesafetyfeaturesthat areincludedinthepaint systemand
alsoexplainsthewaytherobot interactswithother equipment inthesystem.
Thepaint systemincludesthefollowingsafety features:
Most paint boothshaveredwarningbeaconsthat illuminatewhentherobotsarearmedandready
topaint. Your boothmight haveother kindsof indicators. Learnwhat theseare.
Somepaint boothshaveabluebeaconthat, whenilluminated, indicatesthat theelectrostatic
devicesareenabled. Your boothmight haveother kindsof indicators. Learnwhat theseare.
EMERGENCY STOP buttonsarelocatedontherobot controller andteachpendant. Become
familiar withthelocationsof all E-STOP buttons.
Anintrinsicallysafeteachpendant isusedwhenteachinginhazardouspaint atmospheres.
A DEADMAN switchislocatedoneachteachpendant. Whenthisswitchisheldin, andthe
teachpendant ison, power isappliedtotherobot servosystem. If theengagedDEADMAN
switchisreleasedduringrobot operation, power isremovedfromtheservosystem, all axis
brakesareapplied, andtherobot comestoanEMERGENCY STOP. Safety interlockswithin
thesystemmight alsoE-STOP other robots.
Warning
An EMERGENCY STOP will occur if the DEADMAN switch is released
on a bypassed robot.
Overtravel byrobot axesispreventedbysoftwarelimits. All of themajor andminor axesare
governedbysoftwarelimits. Limit switchesandhardstopsalsolimit travel bythemajor axes.
EMERGENCY STOP limit switchesandphotoelectric eyesmight bepart of your system.
Limit switches, locatedontheentrance/exit doorsof eachbooth, will EMERGENCY STOP all
equipment intheboothif adoor isopenedwhilethesystemisoperatinginautomaticor manual
mode. For somesystems, signalstotheseswitchesareinactivewhentheswitchontheSCC is
inteachmode.Whenpresent, photoelectric eyesaresometimesusedtomonitor unauthorized
intrusionthroughtheentrance/exit silhouetteopenings.
Systemstatusismonitoredbycomputer. Severeconditionsresult inautomaticsystemshutdown.
Staying Safe While Operating the Paint Robot
Whenyouwork inor near thepaint booth, observethefollowingrules, inadditiontoall rulesfor
safeoperationthat apply toall robot systems.
Warning
Observe all safety rules and guidelines to avoid injury.
x
Safety
Warning
Never bypass, strap, or otherwise deactivate a safety device, such as a
limit switch, for any operational convenience. Deactivating a safety device
is known to have resulted in serious injury and death.
Warning
Enclosures shall not be opened unless the area is know to be
nonhazardous or all power has been removed from devices within the
enclosure. Power shall not be restored after the enclosure has been
opened until all combustible dusts have been removed from the interior
of the enclosure and the enclosure purged. Refer to the Purge chapter
for the required purge time.
Knowthework areaof theentirepaint station(workcell).
Knowthework envelopeof therobot andhood/deck anddoor openingdevices.
Beawareof overlappingwork envelopesof adjacent robots.
Knowwhereall red, mushroom-shapedEMERGENCY STOP buttonsarelocated.
Knowthelocationandstatusof all switches, sensors, and/or control signalsthat might causethe
robot, conveyor, andopeningdevicestomove.
Makesurethat thework areanear therobot iscleanandfreeof water, oil, anddebris. Report
unsafeconditionstoyour supervisor.
Becomefamiliar withthecompletetasktherobotwill performBEFORE startingautomaticmode.
Makesureall personnel areoutsidethepaint boothbeforeyouturnonpower totherobot
servo system.
Never enter theworkenvelopeor paint boothbeforeyouturnoff power totherobot servosystem.
Never enter theworkenvelopeduringautomaticoperationunlessasafeareahasbeendesignated.
Never wear watches, rings, neckties, scarves, or looseclothingthat couldget caught inmoving
machinery.
Removeall metallicobjects, suchasrings, watches, andbelts, beforeenteringaboothwhenthe
electrostatic devices areenabled.
Stay out of areaswhereyoumight get trappedbetweenamovingrobot, conveyor, or opening
deviceandanother object.
Beawareof signalsand/or operationsthat couldresult inthetriggeringof gunsor bells.
Beawareof all safetyprecautionswhendispensingof paint isrequired.
Followtheproceduresdescribedinthismanual.
xi
Safety
Special Precautions for Combustible Dusts (powder paint)
Whentherobot isusedinalocationwherecombustibledustsarefound, suchastheapplicationof
powder paint, thefollowingspecial precautionsarerequiredtoinsurethat therearenocombustible
dusts insidetherobot.
Purgemaintenanceair shouldbemaintainedat all times, evenwhentherobot power isoff. This
will insurethat dust cannot enter therobot.
A purgecyclewill not removeaccumulateddusts. Therefore, if therobot isexposedtodust
whenmaintenanceair isnot present, it will benecessarytoremovethecoversandcleanout any
accumulateddust. Donot energizetherobot until youhaveperformedthefollowingsteps.
1. Beforecoversareremoved, theexterior of therobot shouldbecleanedtoremoveaccumulated
dust.
2. Whencleaningandremovingaccumulateddust, either ontheoutsideor insideof therobot, be
suretousemethodsappropriatefor thetypeof dust that exists. Usuallylint freeragsdampened
withwater areacceptable. Donot useavacuumcleaner toremovedust asit cangeneratestatic
electricityandcauseanexplosionunlessspecial precautionsaretaken.
3. Thoroughlycleantheinterior of therobot withalint freeragtoremoveanyaccumulateddust.
4. Whenthedust hasbeenremoved, thecoversmust bereplacedimmediately.
5. Immediately after thecoversarereplaced, runacompletepurgecycle. Therobot cannow
beenergized.
Staying Safe While Operating Paint Application Equipment
Whenyouwork withpaint applicationequipment, observethefollowingrules, inadditiontoall rules
for safeoperationthat apply toall robot systems.
Warning
When working with electrostatic paint equipment, follow all national and
local codes as well as all safety guidelines within your organization.
Also reference the following standards: NFPA 33 Standards for Spray
Application Using Flammable or Combustible Materials , and NFPA 70
National Electrical Code .
Grounding : All electrically conductiveobjectsinthespray areamust begrounded. This
includesthespraybooth, robots, conveyors, workstations, part carriers, hooks, paintpressurepots,
aswell assolvent containers. Groundingisdefinedastheobject or objectsshall beelectrically
connectedtogroundwitharesistanceof not morethan1megohms.
xii
Safety
High Voltage : Highvoltageshouldonlybeonduringactual sprayoperations. Voltageshouldbe
off whenthepaintingprocessiscompleted. Never leavehighvoltageonduringacapcleaning
process.
Avoidany accumulationof combustiblevaporsor coatingmatter.
Followall manufacturer recommendedcleaningprocedures.
Makesureall interlocksareoperational.
No smoking.
Post all warningsigns regardingtheelectrostatic equipment andoperationof electrostatic
equipment accordingto NFPA 33Standardfor Spray ApplicationUsingFlammableor
CombustibleMaterial.
Disableall air andpaint pressuretobell.
Verify that thelinesarenot under pressure.
Staying Safe During Maintenance
Whenyouperformmaintenanceonthepainter system, observethefollowingrules, andall other
maintenancesafety rulesthat apply toall robot installations. Only qualified, trainedserviceor
maintenancepersonnel shouldperformrepair work onarobot.
Paint robotsoperateinapotentially explosiveenvironment. Usecautionwhenworkingwith
electric tools.
Whenamaintenancetechnicianisrepairingor adjustingarobot, theworkareaisunder thecontrol
of that technician. All personnel not participatinginthemaintenancemust stayout of thearea.
For somemaintenanceprocedures, stationasecondpersonat thecontrol panel withinreach
of theEMERGENCY STOP button. Thispersonmust understandtherobot andassociated
potential hazards.
Besureall coversandinspectionplatesareingoodrepair andinplace.
Alwaysreturntherobot tothehome positionbeforeyoudisarmit.
Never usemachinepower toaidinremovinganycomponent fromtherobot.
Duringrobot operations, beawareof therobotsmovements. Excessvibration, unusual sounds,
andsoforth, canalert youtopotential problems.
Whenever possible, turnoff themainelectrical disconnect beforeyoucleantherobot.
Whenusingvinyl resinobservethefollowing:
Wear eyeprotectionandprotectiveglovesduringapplicationandremoval
Adequateventilationisrequired. Overexposurecouldcausedrowsinessor skinandeye
irritation.
If thereiscontact withtheskin, washwithwater.
xiii
Safety
FollowtheOriginal Equipment ManufacturersMaterial SafetyDataSheets.
Whenusingpaint remover observethefollowing:
Eyeprotection, protectiverubber gloves, boots, andapronarerequiredduringboothcleaning.
Adequateventilationisrequired. Overexposurecouldcausedrowsiness.
If thereiscontact withtheskinor eyes, rinsewithwater for at least 15minutes. Then,
seek medical attentionassoonaspossible.
FollowtheOriginal Equipment ManufacturersMaterial SafetyDataSheets.
xiv
B-82595EN-2/02 1.SAFETY PRECAUTIONS

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1 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.

1.1 WORKING PERSON

The personnel can be classified as follows.

Operator :
Power ON/OFF for robot controller
Start of robot program with operators panel

Programmer or teaching operator :
Operate for Robot
Teaching inside safety fence

Maintenance engineer :
Operate for Robot
Teaching inside safety fence
Maintenance (adjustment, replacement)

- An operator cannot work inside the safety fence.
- A programmer, Teaching operator and maintenance engineer can
work inside the safety fence. The workings inside safety fence
are lifting, setting, teaching, adjusting, maintenance, etc..
- To work inside the fence, the person must be trained for the
robot.

Table 1 lists the workings of outside the fence. In this table, the
symbol means the working allowed to be carried out by the
personnel.



1.SAFETY PRECAUTIONS B-82595EN-2/02

- 4 -
Table 1 List of workings outside the fence

Operator Programmer
or Teaching
operator
Maintenance
engineer
Power ON/OFF for Robot controller
Select operating mode (AUTO, T1, T2)
Select Remote/Local mode
Select robot program with teach pendant
Select robot program with external device
Start robot program with operators panel
Start robot program with teach pendant
Reset alarm with operators panel
Reset alarm with teach pendant
Set data on the teach pendant
Teaching with teach pendant
Emergency stop with operators panel
Emergency stop with teach pendant
Emergency stop with safety fence open
Maintain for operators panel
Maintain for teach pendant

In operating, programming and maintenance, the programmer,
teaching operator and maintenance engineer take care of their safety
using the following safety protectors, for example.

Use adequate clothes, uniform, overall for operation
Put on the safety shoes
Use helmet

B-82595EN-2/02 1.SAFETY PRECAUTIONS

- 5 -
1.2 WORKING PERSON SAFETY

Working person safety is the primary safety consideration. Because
it is very dangerous to enter the operating space of the robot during
automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful
consideration must be made to ensure working person safety.

(1) Have the robot system working person attend the training courses
held by FANUC.

FANUC provides various training courses. Contact our sales office for
details.

(2) Even when the robot is stationary, it is possible that the robot is
still in a ready to move state, and is waiting for a signal. In this
state, the robot is regarded as still in motion. To ensure
working person safety, provide the system with an alarm to
indicate visually or aurally that the robot is in motion.

(3) Install a safety fence with a gate so that no working person can
enter the work area without passing through the gate. Install an
interlock switch, a safety plug, and so forth in the safety gate so
that the robot is stopped as the safety gate is opened.

The controller is designed to receive this interlock signal of the door switch.
When the gate is opened and this signal received, the controller stops the
robot in an emergency. For connection, see Fig.1.1.

(4) Provide the peripheral devices with appropriate grounding (Class
A, Class B, Class C, and Class D).

(5) Try to install the peripheral devices outside the work area.

(6) Draw an outline on the floor, clearly indicating the range of the
robot motion, including the tools such as a hand.

(7) Install a mat switch or photoelectric switch on the floor with an
interlock to a visual or aural alarm that stops the robot when an
working person enters the work area.

(8) If necessary, install a safety lock so that no one except the
working person in charge can turn on the power of the robot.

The circuit breaker installed in the controller is designed to disable anyone
from turning it on when it is locked with a padlock.

1.SAFETY PRECAUTIONS B-82595EN-2/02

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(9) When adjusting each peripheral device independently, be sure to
turn off the power of the robot.
Interlock switch and safety plug when the door is opening.
RI/RO, HBK, ROT

Fig.1.2 Safety fence and safety gate




NOTE
Terminals EAS1, EAS11, EAS2, and EAS21 are on
the PC board in the operator box or operator panel.

B-82595EN-2/02 1.SAFETY PRECAUTIONS

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1.2.1 General Person Safety

The general person is a person who operates the robot system. In
this sense, a worker who operates the teach pendant is also a general
person. However, this section does not apply to teaching 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 of the safety fence
(3) Install a safety fence with a safety gate to prevent any worker
other than the operator from entering the work area unexpectedly
and also to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the general
persons 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.




NOTE
Connect to EES1 and EES11, EES2 and EES21.

Fig.1.2.1 Connection diagram for external emergency stop button

1.SAFETY PRECAUTIONS B-82595EN-2/02

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1.2.2 Safety of the Teaching Operator

While teaching the robot, it is necessary for the operator to enter the
work area of the robot. It is particularly necessary to ensure the
safety of the teaching 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).
(4) The teaching operator should pay careful attention so that no
other workers enter the robot work area.

Our operator panel is provided with an emergency stop button and a key
switch (mode switch) for selecting the automatic operation mode (AUTO)
and the teach modes (T1 and T2). Before entering the inside of the safety
fence for the purpose of teaching, set the switch to a teach mode, remove
the key from the mode switch to prevent other people from changing the
operation mode carelessly, then open the safety gate. If the safety gate is
opened with the automatic operation mode set, the robot enters the
emergency stop state. After the switch is set to a teach mode, the safety
gate is disabled. The programmer should understand that the safety gate
is disabled and is responsible for keeping other people from entering the
inside of the safety fence.

Our teach pendant is provided with a DEADMAN switch as well as an
emergency stop button. These button and switch function as follows:
(1) Emergency stop button: Causes an emergency stop when pressed.
(2) DEADMAN switch: Functions differently depending on the mode
switch setting status.
(a) Automatic operation mode: The DEADMAN switch is disabled.
(b) Teach mode: Causes an emergency stop when the operator
releases the DEADMAN switch or when the operator presses the
switch strongly.
Note) The DEADMAN switch is provided to place the robot in the
emergency stop state when the operator releases the teach
pendant or presses the pendant strongly in case of
emergency. The R-30iA employs a 3-position DEADMAN
switch, which allows the robot to operate when the 3-position
DEADMAN switch is pressed to its intermediate point. When
the operator releases the DEADMAN switch or presses the
switch strongly, the robot enters the emergency stop state.

The operator's intention of starting teaching is determined by the control
unit through the dual operation of setting the teach pendant enable/disable
switch to the enable position and pressing the DEADMAN switch. The
operator should make sure that the robot can operate in such conditions
and be responsible in carrying out tasks safely.

B-82595EN-2/02 1.SAFETY PRECAUTIONS

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The teach pendant, operator panel, and peripheral device interface send
each robot start signal. However the validity of each signal changes as
follows depending on the mode switch of the operator panel DEADMAN
switch, the teach pendant enable switch and the remote condition on the
software.

Mode
Teach pendant
enable switch
Software
remote
condition
Teach pendant Operator panel
Peripheral
device
Local Not allowed Not allowed Not allowed
On
Remote Not allowed Not allowed Not allowed
Local Not allowed Allowed to start Not allowed
AUTO mode
Off
Remote Not allowed Not allowed Allowed to start
Local Allowed to start Not allowed Not allowed
On
Remote Allowed to start Not allowed Not allowed
Local Not allowed Not allowed Not allowed
T1, T2 mode
Off
Remote Not allowed Not allowed Not allowed

(5) To start the system using the operator's panel, make certain that
nobody is in the robot work area and that there are no abnormal
conditions in the robot work area.
(6) When a program is completed, be sure to carry out a test run
according to the procedure below.
(a) Run the program for at least one operation cycle in the
single step mode at low speed.
(b) Run the program for at least one operation cycle in the
continuous operation mode at low speed.
(c) Run the program for one operation cycle in the continuous
operation mode at the intermediate speed and check that no
abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous
operation mode at the normal operating speed and check
that the system operates automatically without trouble.
(e) After checking the completeness of the program through the
test run above, execute it in the automatic operation mode.
(7) While operating the system in the automatic operation mode, the
teaching operator should leave the robot work area.

1.SAFETY PRECAUTIONS B-82595EN-2/02

- 10 -
1.2.3 Safety During Maintenance

For the safety of maintenance personnel, pay utmost attention to the
following.

(1) During operation, never enter the robot work area.
(2) Except when specifically necessary, turn off the power of the
controller while carrying out maintenance. Lock the power
switch, if necessary, so that no other person can turn it on.
(3) If it becomes necessary to enter the robot operation range while
the power is on, press the emergency stop button on the operator
panel, or the teach pendant before entering the range. The
maintenance personnel must indicate that maintenance work is in
progress and be careful not to allow other people to operate the
robot carelessly.
(4) When disconnecting the pneumatic system, be sure to reduce the
supply pressure.
(5) Before the start of teaching, check that the robot and its
peripheral devices are all in the normal operating condition.
(6) Do not operate the robot in the automatic mode while anybody is
in the robot work area.
(7) When it is necessary to maintain the robot alongside a wall or
instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.
(8) When a tool is mounted on the robot, or when any moving device
other than the robot is installed, such as belt conveyor, pay
careful attention to its motion.
(9) If necessary, have a worker who is familiar with the robot system
stand beside the operator panel and observe the work being
performed. If any danger arises, the worker should be ready to
press the EMERGENCY STOP button at any time.
(10) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
(11) When handling each unit or printed circuit board in the controller
during inspection, turn off the circuit breaker to protect against
electric shock.
(12) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified
ratings. They may cause a fire or result in damage to the
components in the controller.
(13) When restarting the robot system after completing maintenance
work, make sure in advance that there is no person in the work
area and that the robot and the peripheral devices are not
abnormal.

B-82595EN-2/02 1.SAFETY PRECAUTIONS

- 11 -
1.3 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

1.3.1 Precautions in Programming

(1) Use a limit switch or other sensor to detect a dangerous condition
and, if necessary, design the program to stop the robot when the
sensor signal is received.
(2) Design the program to stop the robot when an abnormal
condition occurs in any other robots or peripheral devices, even
though the robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in
synchronous motion, particular care must be taken in
programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral
devices so that the robot can detect the states of all devices in the
system and can be stopped according to the states.

1.3.2 Precautions for Mechanism

(1) Keep the component cells of the robot system clean, and operate
the robot in an environment free of grease, water, and dust.
(2) Employ a limit switch or mechanical stopper to limit the robot
motion so that the robot does not come into contact with its
peripheral devices or tools.

1.SAFETY PRECAUTIONS B-82595EN-2/02

- 12 -
1.4 SAFETY OF THE ROBOT MECHANISM

1.4.1 Precautions in Operation

(1) When operating the robot in the jog mode, set it at an appropriate
speed so that the operator can manage the robot in any
eventuality.
(2) Before pressing the jog key, be sure you know in advance what
motion the robot will perform in the jog mode.

1.4.2 Precautions in Programming

(1) When the work areas of robots overlap, make certain that the
motions of the robots do not interfere with each other.
(2) Be sure to specify the predetermined work origin in a motion
program for the robot and program the motion so that it starts
from the origin and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance
that the robot motion has terminated.

1.4.3 Precautions for Mechanisms

(1) Keep the work area of the robot clean, and operate the robot in an
environment free of grease, water, and dust.

1.5 SAFETY OF THE END EFFECTOR

1.5.1 Precautions in Programming

(1) To control the pneumatic, hydraulic and electric actuators,
carefully consider the necessary time delay after issuing each
control command 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.

B-82595EN-2/02 1.SAFETY PRECAUTIONS

- 13 -
1.6 WARNING LABEL

(1) Step-on prohibitive label

Fig.1.6 (a) Step-on prohibitive label

Description
Do not step on or climb the robot or controller as it may
adversely affect the robot or controller and you may get hurt
if you lose your footing as well.

(2) High-temperature warning label

Fig.1.6 (b) High-temperature warning label

Description
Be cautious about a section where this label is affixed, as
the section generates heat. If you have to inevitably touch
such a section when it is hot, use a protective provision such
as heat-resistant gloves.

1.SAFETY PRECAUTIONS B-82595EN-2/02

- 14 -
(3) High-voltage warning label

Fig.1.6 (c) High-voltage warning label

Description
A high voltage is applied to the places where this label is
attached.
Before starting maintenance, turn the power to the control
unit off, 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.















II. MAINTENANCE

B-82595EN-2/02 MAINTENANCE 1.OVERVIEW

- 17 -
1 OVERVIEW

This manual describes the maintenance and connection of the R-30iA
robot controller (called the R-30iA).

Maintenance Part :
Troubleshooting, and the setting, adjustment, and replacement of
units
Connection Part :
Connection of the R-30iA controller to the robot mechanical unit
and peripheral devices, and installation of the controller

WARNING
Before you enter the robot working area, be sure to
turn off the power to the controller or press the
EMERGENCY STOP button on the operator's
panel or teach pendant.
Otherwise, you could injure personnel or damage
equipment.

- The RIA R15.06 - - 1999 compliant controller has safety circuit
performance compliant with 4.5.4 control reliable.
- For information on third party approvals, contact your FANUC
representative.
- The controller is designed to meet R15.06 - - 1999 American
standard for industrial robots and robot systems - - safety
requirements.

2.CONFIGURATION MAINTENANCE B-82595EN-2/02

- 18 -
2 CONFIGURATION

B-82595EN-2/02 MAINTENANCE 2.CONFIGURATION

- 19 -
2.1 EXTERNAL VIEW OF THE CONTROLLER

The appearance and components might slightly differ depending on
the controlled robot, application, and options used.
Fig.2.1 (a) to (c) shows the view of R-30iA.
Fig.2.1 (d) to (i) show the construction of the R-30iA controller.
Fig.2.1 (j) to (l) show the external view of the operators panel.
Fig.2.1 (m) and (n) show the block diagram of R-30iA.



Fig.2.1 (a) External view of the R-30iA controller (A-cabinet)


Fig.2.1 (b) External view of the R-30iA controller (Integrated operation box)

Teach pendant
Operation box
R-30iA
controller
Teach pendant
Integrated operation box
R-30iA
controller
2.CONFIGURATION MAINTENANCE B-82595EN-2/02

- 20 -

Operators panel
Teach pendant

Fig.2.1 (c) External view of the R-30iA controller (B-cabinet)

B-82595EN-2/02 MAINTENANCE 2.CONFIGURATION

- 21 -




















































Fig.2.1 (d) R-30iA A-cabinet interior




Regenerative
resistor unit
Teach pendant
Emergency stop
button
Enable switch
Emergency stop unit
Main board
Power supply unit
Fan unit
Servo amplifier
Transformer
Side fan type
Rear fan type
FANUNIT
2.CONFIGURATION MAINTENANCE B-82595EN-2/02

- 22 -

Fig.2.1 (e) R-30iA A-cabinet interior (M-430iA)

Emergency stop unit
Servo amplifier
Main board
Power supply unit
Fan unit
Heat exchanger
Teach pendant
Emergency stop button
Enable switch
2-axis servo amplifier(AMP2)-M-430iA/2F
3-axis servo amplifier(AMP2)-M-430iA/2P
B-82595EN-2/02 MAINTENANCE 2.CONFIGURATION

- 23 -




Fig.2.1 (f) R-30iA B-cabinet interior (Front)

3 mode switch
DC fan unit
Servo amplifier
Emergency stop
button
Panel board
Emergency stop
button
Enable switch
Teach pendant
Door fan Optional slot
Main board Power supply unit
Emergency stop unit
RCC I/F unit
(only M-900iA/260L,
M-900iA/350)
Back plane
Circuit
breaker
External air
fan unit
Battery
2.CONFIGURATION MAINTENANCE B-82595EN-2/02

- 24 -



Fig.2.1 (g) R-30iA B-cabinet interior (Front) (M-900 iA/600)























3 mode switch
DC fan unit
Emergency stop
button
Panel board
Enable switch
Teach pendant
Door fan Optional slot
Main board Power supply unit
Emergency stop unit
RCC I/F unit
Back plane
Circuit
breaker
External air
fan unit
Battery
6-servo amplifier (AMP1) 2-axis servo amplifier (AMP2) 1-axis Servo amplifier (AMP3)
Emergency stop
button
B-82595EN-2/02 MAINTENANCE 2.CONFIGURATION

- 25 -

Fig. 2.1 (h) R-30iA B-cabinet interiorFront(M-430iA)
Transformer
Regenerative
resistor unit

Fig.2.1 (i) R-30iA B-cabinet interior (Back)

Mode switch
DC fan unit
Emergency stop button
Panel board
Emergency stop button
Enable switch
Teach pendant
Door fan Option slot
Main board Power supply unit
Emergency stop unit
RCC I/F unit
Back plane
Circuit breaker
External air
fan unit
Battery
6-axis servo amplifierAMP1
2-axis servo amplifier(AMP2)-M-430iA/2F
3-axis servo amplifier(AMP2)-M-430iA/2P
2.CONFIGURATION MAINTENANCE B-82595EN-2/02

- 26 -
EMERGENCY STOP
FAULT
RESET
CYCLE
START
FAULT POWER

Fig.2.1 (j) R-30iA panel overview

2 mode switch 3 mode switch

Fig.2.1 (k) Mode switch operation

B-82595EN-2/02 MAINTENANCE 2.CONFIGURATION

- 27 -

Fig.2.1 (l) USB/RS-232-C interface overview


2.CONFIGURATION MAINTENANCE B-82595EN-2/02

- 28 -

Table 2.1 (a) Servo amplifier specification
REGENERATIVE REGISTOR
ROBOT SERVO AMPLIFIER
A-CABINET B-CABINET
M-900iA/600
A06B-6107-H001 (AMP1)
A06B-6117-H209 (AMP2)
A06B-6117-H105 (AMP3)
A05B-2502-C100
R-2000iB/200T
M-900iA/260L
M-900iA/350

M-410iB
A06B-6107-H001
A05B-2501-C102
A05B-2502-C100
R-2000iB
except /200T

M-710iC A05B-2501-C103
M-16iB
ARC Mate 120iB
(Except ARC Mate
120iBe.)
A05B-2501-C100
M-420iA, M-421iA
A06B-6107-H002
A05B-2501-C102
A05B-2502-C100
M-6iB
ARC Mate 100iB
ARC Mate 120iBe
A05B-2501-C101
F-200iB
A06B-6107-H003
A05B-2501-C105
A05B-2502-C101
ARC Mate 100iC
M-10iA
A06B-6107-H004 A05B-2501-C101 A05B-2502-C101
M-430iA/2F
A06B-6107-H007 (AMP 1)
A06B-6117-H201 (AMP 2)
M-430iA/2P
A06B-6107-H007 (AMP 1)
A06B-6117-H301 (AMP 2)
A05B-2501-C105 A05B-2502-C101

B-82595EN-2/02 MAINTENANCE 2.CONFIGURATION

- 29 -
Table 2.1(b) fan type list for A-cabinet

FAN TYPE
ROBOT
REAR FAN SIDE FAN
M-410iB
M-710iC
M-16iB
ARC Mate 120iB
M-420iA, M-421iA
M-6iB
ARC Mate 100iB
F-200iB
ARC Mate 100iC
M-430iA
M-10iA


2.CONFIGURATION MAINTENANCE B-82595EN-2/02

- 30 -


Fig.2.1 (m) Block diagram of the R-30iA (A-cabinet)

B-82595EN-2/02 MAINTENANCE 2.CONFIGURATION

- 31 -
B
a
c
k
p
l
a
n
e

P
r
i
n
t
e
d
-
c
i
r
c
u
i
t

b
o
a
r
d

P
o
w
e
r

s
u
p
p
l
y

u
n
i
t

M
a
i
n

b
o
a
r
d

P
r
o
c
e
s
s

I
/
O

I
/
O

U
n
i
t
-
M
O
D
E
L

A

F
a
n

T
r
a
n
s
f
o
r
m
e
r

Circuit
breaker
A
C

i
n
p
u
t




3


2
0
0


2
3
0

V
A
C

3
8
0


4
0
0

V
A
C

3
8
0


4
1
5

V
A
C

4
4
0


5
0
0

V
A
C

5
0
0


5
7
5

V
A
C

E

s
t
o
p

u
n
i
t

O
p
e
r
a
t
o
r
'
s

p
a
n
e
l

P
a
n
e
l

b
o
a
r
d

M
e
m
o
r
y

c
a
r
d

Battery
U
S
B

m
e
m
o
r
y

S
w
i
t
c
h

S
e
r
v
o

a
m
p
l
i
f
i
e
r

(
6

a
x
i
s

a
m
p
l
i
f
i
e
r
)

R
e
g
e
n
e
r
a
t
i
v
e

r
e
s
i
s
t
o
r

200 V, single-phase output
200 V, single-phase input
Servo signal (FSSB)
24VDC
Signals for I/O Link and Teach pendant
24VDC
EMG signal
2
0
0

V
,

3
-
p
h
a
s
e

T
r
a
n
s
f
o
r
m
e
r

o
v
e
r
h
e
a
t

s
i
g
n
a
l

2
0
0

V
,

3
-
p
h
a
s
e

E
M
G

s
i
g
n
a
l

P
u
l
s
e

c
o
d
e
r

s
i
g
n
a
l
s
,

R
o
b
o
t

D
I
/
D
O

s
i
g
n
a
l
s

M
o
t
o
r

p
o
w
e
r

s
u
p
p
l
y
,

B
r
a
k
e

p
o
w
e
r

s
u
p
p
l
y

P
e
r
i
p
h
e
r
a
l

d
e
v
i
c
e

(
S
e
r
i
a
l
)

P
e
r
i
p
h
e
r
a
l

d
e
v
i
c
e

(
S
e
r
i
a
l
)

P
e
r
i
p
h
e
r
a
l

d
e
v
i
c
e

(
E
t
h
e
r
n
e
t
)

T
e
a
c
h

p
e
n
d
a
n
t

E
x
t
e
r
n
a
l

E

s
t
o
p

E
x
t
e
r
n
a
l

o
n
/
o
f
f

R
o
b
o
t


Fig.2.1 (n) Block diagram of the R-30iA (B-cabinet)

2.CONFIGURATION MAINTENANCE B-82595EN-2/02

- 32 -
2.2 COMPONENT FUNCTIONS

Main board
The main board contains a microprocessor, its peripheral circuits,
memory, and operator's panel control circuit. The main CPU
controls servo mechanism positioning.
I/O printed circuit board, FANUC I/O Unit MODEL-A
Various types of printed circuit boards are provided for
applications including process I/O. The FANUC I/O unit
MODEL-A can also be installed. When it is used, various I/O
types can be selected. These are connected with FANUC I/O
Link.
E-stop unit and MCC unit
This unit controls the emergency stop system for both of the
magnetic contactor and the precharge of the servo amplifier.
Power supply unit
The power supply unit converts the AC power to various levels
of DC power.
Backplane printed circuit board
The various control printed circuit boards are mounted on the
backplane printed circuit board.
Teach pendant
All operations including robot programming are performed with
this unit. The controller status and data are indicated on the
liquid-crystal display (LCD) on the pendant.
Servo amplifier
The servo amplifier controls servomotor, pulse coder signal,
brake control, overtravel and hand broken.
Operator's panel
Buttons and LEDs on the operator's panel are used to start the
robot and to indicate the robot status. The panel has a port and
an USB interface for the serial interface to an external device and
an interface to connect the memory card for data backup. It also
controls the emergency stop control circuit.
Transformer
The supply voltage is converted to an AC voltage required for
the controller by the transformer.
Fan unit, heat exchanger
These components cool the inside of the controller.
Circuit breaker
If the electric system in the controller malfunctions, or if
abnormal input power causes high current in the system, the
input power is connected to the circuit breaker to protect the
equipment.
Regenerative resistor
To discharge the counter electromotive force from the
servomotor, connect a regenerative resistor to the servo
amplifier.

B-82595EN-2/02 MAINTENANCE 2.CONFIGURATION

- 33 -
2.3 PREVENTIVE MAINTENANCE

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.
(2) Check after one month
Check that the fan is rotating normally. If the fan has dirt and
dust built up, clean the fan according to step (d) described below
for inspection to be performed every 6 months.
(3) Periodic inspection performed every six months
Remove the top cover, louver, and back panel (if possible), then
remove any dirt and dust from the inside of the transformer
compartment. Wipe off dirt and dust from the fan and
transformer.
(4) Battery daily check
Replace the battery on the front panel of the main board every 4
years. Please refer to the section 7.14.
(5) Maintenance tools
The following maintenance tools are recommended:
(a) Measuring instruments
AC/DC voltmeter (A digital voltmeter is sometimes
required.)
Oscilloscope with a frequency range of 5 MHz or higher,
two channels
(b) Tools
Phillips screwdrivers : Large, medium, and small
Standard screwdrivers : Large, medium, and small
Nut driver set (Metric)
Pliers
Needle-nose pliers
Diagonal cutting pliers

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 34 -
3 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.

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 35 -
3.1 POWER CANNOT BE TURNED ON

Check and Corrective action Figure
(Check 1) Check that the circuit breaker is
on and has not tripped.
(Corrective
action)
Turn on the circuit breaker.

Circuit breaker

(Check 2) Check whether the LED (PIL:
green) on the power supply unit
is on.

(Corrective
action)
If the LED is not on, 200 VAC is
not supplied to the power supply
unit. It is likely that fuse F1 in
the power supply unit has blown.
- If 200 VAC is not supplied:
Find the cause by referencing
the general schematic
diagram presented in the
appendix.
- If 200 VAC is supplied:
Find the cause of the blown
fuse. Fuse F1 is in the power
supply unit. Before you start
troubleshooting, turn off the
circuit breaker.
a) If fuse F1 has blown:
- See Corrective action
(1).
b) If fuse F1 has not blown:
- Replace the power
supply unit.
DB1: Diode stack
F1(8.0A): Fuse for AC input
CP1: Connector for AC input
CP1A: Connector for AC output
CP2, CP3: Connector for AC output
F3(7.5A): Fuse for +24E
F4(7.5A): Fuse for +24V
PIL: LED (green)
CP5: Connector for +24E
CP6: Connector for +24V
ALM: LED (red)
CP4: Connector for control
VS1: Surge absorber
H1: Auxiliary power module
Circuit breaker
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 36 -
Check and Corrective action Figure
(Corrective
action(1))
Causes of blown fuses F1 and
corrective action
a) Check whether the unit and
printed-circuit board
connected to the connectors
CP2 and CP3 in the power
supply unit are abnormal, by
referencing the general
schematic diagram presented
in the appendix.
b) Short-circuit in the surge
absorber VS1
VS1 is inserted to absorb
surge voltage between input
lines.
If the surge voltage is
excessive or sustained,
excessively high voltage is
applied to VS1 and a failure
occurs in the short-circuit
mode, causing F1 to blow. If
a short-circuit occurs in VS1,
and there is not a spare part,
the system is permitted to
operate without VS1. In this
case, however, obtain and
install a new VS1 as soon as
possible.
VS1 ordering number:
A70L-0001-0015#20DK431
c) Short-circuit of diode stack
DB1
d) The secondary power supply
module is faulty :
If one of the causes (b) to (c)
above is detected, replace
the power supply unit with a
spare unit.
The ordering number. for F1
is : A60L-0001-0450#8RO

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 37 -
Check and Corrective action Figure
(Check 3) Check whether the EXON1 and
EXON2 signals, and the EXOFF1
and EXOFF2 signals are
connected on the terminal block
on the panel board.
(Corrective
action)
If the external ON/OFF function is
not used, connect terminal
EXON1 to EXON2 and terminal
EXOFF1 to EXOFF2. If the
external ON and OFF lines are
already used, check the mating
contacts and the cable.
Shortcircuit plate :
Between EXON1 and
-EXON2
Shortcircuit plate :
Between EXOFF1
and EXOFF2

(Check 4) Check whether the connector
(JRS15) on the main board or the
connector (JRS15) on the panel
board is connected properly.
Another probable cause is that
the cable connected to either of
these connectors is faulty.
Confirm that the 200VAC power
is supplied to connector CP1 by
reverifying Checks 1 - 3, and
verifying that the ON/OFF switch
is functioning properly.
If the red ALM (Alarm) LED on
the power supply unit is on, verify
that the +24V external connection
cable is connected to 0V or
ground.
If the problem still exists, check
the power supply unit using the
following procedure :
a) Check Fuse F4.
- If the fuse is blown, see
Corrective action 2.
b) Fuse F4 is not blown.
- A printed circuit board or
unit that uses a DC supply
(+2.5V, +3.3V, +5V, +24V,
or +15V) is faulty.
- Verify that 200VAC is
being supplied to
connector CP1. If the
power is supplied, replace
the power supply unit.
(Corrective
action)
If the power supply unit is not
faulty, replace the panel board
or operator panel.


DB1: Diode stack
F1(8.0A): Fuse for AC input
CP1: Connector for AC input
CP1A: Connector for AC output
CP2, CP3:Connector for AC output
F3(7.5A): Fuse for +24E
F4(7.5A): Fuse for +24V
PIL: LED (green)
CP5: Connector for +24E
CP6: Connector for +24V
ALM: LED (red)
CP4: Connector for control
VS1: Surge absorber
H1: Auxiliary power module

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 38 -
Check and Corrective action Figure
(Corrective
action(2))
Causes of blown fuse F4 and
corrective action
The device connected to
connector CP5 of the power
supply unit may be faulty. If no
device is connected to CP5 or
the connected device is normal,
the +24 V power used in a
printed circuit board connected to
the backplane is faulty.
The ordering number of F4 is
A60L-0001-0046#7.5 :


B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

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3.2 ALARM OCCURRENCE SCREEN

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.

Alarm history screen display
Press F3 [HIST]. Press F3 [ACTIVE].
Alarm occurrence screen display
Press the alarm key. Automatic alarm display
upon occurrence
Press the screen
selection key to select
[4 ALARM].

Fig.3.2 Alarm occurrence screen and alarm history screen display
procedure

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 40 -
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

MENUS
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



[ 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].

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
CLEAR HELP
F5


(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].

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.
CLEAR HELP
F4
SHIFT
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 41 -

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


3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 42 -
3.3 SAFETY SIGNALS

The safety signal screen indicates the state of signals related to safety.
To be specific, the screen indicates whether each safety signal is
currently on. On this screen, it is impossible to change the state of any
safety signal.

Table 3.3 Safety signals
Safety signal Description
Operators panel
emergency stop
This item indicates the state of the emergency stop button on the operators panel. If the
EMERGENCY STOP button 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 button 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 asserted, 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 correctly, the state is
indicated as TRUE. If the DEADMAN switch is released or is grasped tightly when the
teach pendant is operable, an alarm occurs, causing the servo power to be switched off.
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 JOINT 30%

SIGNAL NAME STATUS 1/11

1 SOP E-Stop: FALSE
2 TP E-stop: FALSE
3 Ext E-Stop: FALSE
4 Fence Open: FALSE
5 TP Deadman: TRUE
6 TP Enable: TRUE
7 Hand Broken: FALSE
8 Over Travel: FALSE
9 Low Air Alarm: FALSE

[TYPE]

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

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3.4 MASTERING

Mastering is needed if:
(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 fixture position mastering. (Zero-degree position
mastering is just for quick-fix purposes. After zero-degree position
mastering is used, fixture position mastering should be performed
later.)
The mastering procedure is described below. For details, refer to an
applicable maintenance manual of mechanical unit or operator's
manual of control unit.

Condition
System variable $MASTER_ENB must be set to 1 or 2.

SYSTEM Variables JOINT 10%
57/136
57 $MASTER_ENB 1


Step
(1) Press <MENUS>.
(2) Select SYSTEM.
(3) Press F1, TYPE.
(4) Select Master/Cal you will see a screen similar to the following.

F1
Master
/TYPE
SYSTEM Master/Cal JOINT 30%

1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE


Press 'ENTER' or number key to select.


[TYPE] LOAD RES_PCA DONE
5 POSITION
6 SYSTEM
7
MENUS
9
0 -- NEXT --


(5) Move the robot by jog feed to the mastering position. Release the
brake on the manual brake control screen if necessary.

NOTE
Mastering can not be performed until axis is rotated
enough to establish a pulse.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 44 -
(6) Select "1 FIXTURE POSITION MASTER" and press the F4 key
(yes). Mastering data is set.

F4
SYSTEM Master/Cal JOINT 30 %

1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <122000309> <2000319>


[ TYPE ] LOAD RES_PCA DONE

SYSTEM Master/Cal

1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
Master at master position?
[NO]
ENTER
Master at master position?
[ ] [ TYPE ] YES NO


(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.

F4
SYSTEM Master/Cal JOINT 30 %

1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<10.000> <-25.000> <40.000>
<5.000> <-15.000> <0.000>
[ TYPE ] LOAD RES_PCA DONE
5 SET QUICK MASTER REF
6 CALIBRATE
Calibrate? [NO]
ENTER
Calibrate? [NO]
[ TYPE ] YES


(8) Press F5 "DONE", after mastering.

F5
DONE


B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 45 -
3.5 TROUBLESHOOTING USING THE ERROR CODE

(1) SRVO-001 Operator panel E-stop
(Explanation) The emergency stop button on the operator's panel
is pressed.
(Action 1) Release the emergency stop button pressed on the
operator's panel.
(Action 2) Check the wires connecting between the
emergency stop button and the panel board
(CRT16) for continuity. If an open wire is found,
replace the entire harness.
(Action 3) Check the wires connecting between the teach
pendant and the panel board (CRS20) for
continuity. If an open wire is found, replace the
entire harness.
(Action 4) With the emergency stop in the released position,
check for continuity across the terminals of the
switch. If continuity is not found, the emergency
stop button is broken. Replace the switch unit or
the operator's panel.
(Action 5) Replace the teach pendant.
(Action 6) Replace the panel board.
Before executing the (Action 7), perform a complete controller
back-up to save all your programs and settings.
(Action 7) Replace the main board.

NOTE
If SRVO-001 is issued together with SRVO-213, a
fuse may have blown. Take the same actions as
for SRVO-213.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 46 -
Emergency stop
button

(A-cabinet) (B-cabinet)
Fig.3.5 (1) (a) SRVO-001 Operator panel E-stop



(Panel board)
Fig.3.5 (1) (b) SRVO-001 Operator panel E-stop

(Main board)
Fig.3.5 (1) (c) SRVO-001 Operator panel E-stop
CRS20
CRT16
Emergency stop
button
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 47 -
(2) SRVO-002 Teach pendant E-stop
(Explanation) The emergency stop button on the teach pendant
was pressed.
(Action 1) Release the emergency stop button on the teach
pendant.
(Action 2) Replace the teach pendant.

Emergency stop
button

Fig.3.5 (2) SRVO-002 Teach pendant E-stop

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 48 -
(3) SRVO-003 DEADMAN switch released
(Explanation) The teach pendant is enabled, but the DEADMAN
switch is not pressed. Alternatively, the
DEADMAN switch is pressed strongly.
(Action 1) Check the intermediate position of the
DEADMAN switch on the teach pendant.
(Action 2) Check that the mode switch on the operator's panel
and the enable switch on the teach pendant are at
the correct positions.
(Action 3) Replace the teach pendant.
(Action 4) Check the mode switch connection and operation.
If trouble is found, replace the mode switch.
(Action 5) Replace the panel board.


Enable switch
DEADMAN switch

Fig.3.5 (3) (a) SRVO-003 DEADMAN switch released

2 mode switch
3 mode switch

(Mode switch)
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 49 -


(Panel board)
Fig. 3.5 (3) (b) SRV0-003 Mode switch and panel board

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 50 -
(4) SRVO-004 Fence open
(Explanation) In the automatic operation mode, the safety fence
contact connected to EAS1-EAS11 or
EAS2-EAS21 of TBOP4 is open.
(Action 1) When a safety fence is connected, close the safety
fence.
(Action 2) Check the cables and switches connected between
EAS1 and EAS11 and between EAS2 and EAS21
of the terminal block TBOP4 on the panel board.
(Action 3) If the safety fence signal is not used, make a
connection between EAS1 and EAS11 and
between EAS2 and EAS21 of the terminal block
TBOP4 on the panel board.
(Action 4) Check the mode switch. If trouble is found,
replace the mode switch.
(Action 5) Replace the panel board.

NOTE
If SRVO-004 is issued together with SRVO-213, a
fuse may have blown. Take the same actions as
for SRVO-213.





EAS1
EAS11
EAS2
EAS22


(Panel board)

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 51 -
2 mode switch 3 mode switch

(Mode switch)
Fig. 3.5 (4) Panel board and mode switch

WARNING
In a system using the safety fence signal, it is very
dangerous to disable the signal when a connection
is made between EAS1 and EAS11 and between
EAS2 and EAS21 of TBOP4. Never make such
an attempt. If a temporary connection is needed
for operation, separate safety measures must be
taken.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 52 -
(5) SRVO-005 Robot overtravel
(Explanation) The robot has moved beyond a hardware limit
switch on the axes.
(Action 1)
1) Select [System OT release] on the overtravel
release screen to release each robot axis from
the overtravel state.
2) Hold down the shift key, and press the alarm
release button to reset the alarm condition.
3) Still hold down the shift key, and jog to bring
all axes into the movable range.
(Action 2) Replace the limit switch.

(Action 3) Check the FS2 fuse on the servo amplifier. If the
SRVO-214 Fuse blown alarm is also generated, the
FS2 fuse has blown.
(Action 4) Check the end effector connector.
(Action 5) Replace the servo amplifier.
(Action 6) Verify the following for connector RP1 at the base
of the robot :
1) There are no bent or dislocated pins in the male
or female connectors.
2) The connector is securely connected.
Then verify that connectors CRF8 and CRM68 on
the servo amplifier are securely connected. Also
verify that the RP1 cable is in good condition, and
there are no cuts or kinks visible. If no limit switch
is in use, jumper connector must be attached in the
mechanical unit. Check for the jumper connector.

NOTE
It is factory-placed in the overtravel state for
packing purposes.
If the Overtravel signal is not in use, it may have
been disabled by short-circuiting in the mechanical
unit.

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 53 -

Servo amplifier

Servo amplifier

(A-cabinet) (B-cabinet)



Connector (CRF8)
Connector (CRM68)
FS2

(Servo amplifier)
Fig. 3.5 (5) SRVO-005 Robot overtravel
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 54 -
(6) SRVO-006 Hand broken
(Explanation) The safety joint (if in use) might have been broken.
Alternatively, the HBK signal on the robot
connection cable might be a ground fault or a cable
disconnection.
(Action 1) Hold down the shift key, and press the alarm
release button to reset the alarm condition. Still
hold down the shift key, and jog the tool to the
work area.
1) Replace the safety joint.
2) Check the safety joint cable.
(Action 2) Replace the servo amplifier.
(Action 3) Verify the following for connector RP1 at the base
of the robot :
1) There are no bent or dislocated pins in the male
or female connectors.
2) The connector is securely connected.
Then verify that connector CRF8 on the servo
amplifier is securely connected.
Also verify that the RP1 cable is in good condition,
and there are no cuts or kinks visible. Check the
robot connection cable (RP1) for a ground fault or
a cable disconnection.

NOTE
If the Hand broken signal is not in use, it can be
disabled by software setting.
Refer to Subsection 5.5.3 How to Disable/Enable
HBK in Part III, "CONNECTIONS" of "Maintenance
Manual" to disable the Hand broken signal.


Servo amplifier

Servo amplifier

(A-cabinet) (B-cabinet)


B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 55 -

Connector (CRF8)
Connector (CRM68)
FS2

(Servo amplifier)
Fig. 3.5 (6) SRVO-006 Hand broken

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 56 -
(7) SRVO-007 External E-stop
(Explanation) On the terminal block TBOP4 of the panel board,
no connection of external emergency stop is made
between EES1 and EES11, EES2 and EES21.
(Action 1) If an external emergency stop switch is connected,
release the switch.
(Action 2) Check the switch and cable connected to
EES1-EES11 and EES2-EES21 on TBOP4.
(Action 3) When this signal is not used, make a connection
between EES1 and EES11, EES2 and EES21.
(Action 4) Replace the panel board.

NOTE
If SRVO-007 is issued together with SRVO-213, a
fuse may have blown. Take the same actions as
for SRVO-213.






(Panel board)
Fig.3.5 (7) SRVO-007 Panel board

WARNING
In a system using the external emergency stop
signal, it is very dangerous to disable the signal
when a connection is made between EES1 and
EES11 and between EES2 and EES21 of TBOP4.
Never make such an attempt. If a temporary
connection is needed for operation, separate safety
measures must be taken.

EES1
EES11
EES2
EES22
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 57 -
(8) SRVO-009 Pneumatic pressure abnormal
(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.
(Action 2) Check the end effector connector.
(Action 3) Check the robot connection cable (RP1) for a
ground fault or a cable disconnection. If a fault
or a disconnection is detected, replace the cable.
(Action 4) Replace the servo amplifier.
(Action 5) Replace the internal cables of the robot.

NOTE
Pneumatic pressure alarm input is on the end
effector. Please refer to the manual of your robot.


Servo amplifier

Servo amplifier

(A-cabinet) (B-cabinet)
Fig.3.5 (8) SRVO-009 Pneumatic pressure alarm

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 58 -
(9) SRVO-014 Fan motor abnormal
(Explanation) When a fan motor stops on backplane unit,
TP shows the following message.In one minutes
from occurring of alarm, robot stops and can not
be operated from TP. The robot can be
recovered by replacing a fan motor.Number in
the bracket indicateds which fan is abnormal.
(1): fan above the slot1 (2): fan above slot2
(3) : both fans
(Action 1) Check the fan motor and its cables. Replace them
if necessary.
(Action 2) Replace the backplane unit.
Before executing the (Action 3), perform a
complete controller back-up to save all your
programs and settings.
(Action 3) Replace the main board.


Fan motor
Main board

Fig. 3.5 (9) SRVO-014 Fan motor abnormal
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 59 -
(10) SRVO-015 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), cool down the ambient temperature.
(Action 2) If the fan motor is not running, check it and its
cables. Replace them if necessary.
Before executing the (Action 3), perform a
complete controller back-up to save all your
programs and settings.
(Action 3) Replace the main board. (The thermostat on the
main board may be faulty.)


Main board Heat exchanger
Fan unit

A-cabinet (Front)

Fan unit

Fan unit

A-cabinet (Side fan type) A-cabinet (Rear fan type)



3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 60 -

Servo amplifier
Main board
Door fan unit

B-cabinet (Front)

Amplifier fan

B-cabinet (Back)
Fig.3.5 (10) SRVO-015 SYSTEM OVER HEAT

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 61 -
(11) SRVO-018 Brake abnormal
(Explanation) An excessive brake current is detected. The ALM
LED on the servo amplifier is lit.
(Action 1) Check the robot connection cable (RM1) and
cables internal to the mechanical section for a
short-circuit and connection to the ground. If a
fault or a disconnection is detected, replace the
cable.
(Action 2) This alarm may occur if the brake connector is not
attached.
Make sure that connector CRM88 is securely
attached to the servo amplifier.
(Action 3) Replace the servo amplifier.


Servo amplifier

Servo amplifier

(A-cabinet) (B-cabinet)
Fig.3.5 (11) SRVO-018 Brake abnormal

CAUTION
This error can be caused by the optional brake
release unit if the on/off switch is left in on position
while the operator attempts to jog the robot. To
recover, turn the brake release unit off and cycle
the controller power.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 62 -
(12) SRVO-021 SRDY off (Group : i Axis : j)
(Explanation) The HRDY is on and the SRDY is off, although
there is no other cause of an alarm. (HRDY is a
signal with which the host detects the servo system
whether to turn on or off the servo amplifier
magnetic contactor. SRDY is a signal with which
the servo system informs the host whether the
magnetic contactor is turned on.)
If the servo amplifier magnetic contactor cannot be
turned on when directed so, it is most likely that a
servo amplifier alarm has occurred. If a servo
amplifier alarm has been detected, the host will not
issue this alarm (SRDY off). Therefore, this
alarm indicates that the magnetic contactor cannot
be turned on for an unknown reason.
(Action 1) Make sure that the emergency stop board
connectors CP2, CRM96, CNMC3, and servo
amplifier SRM96 are securely attached to the servo
amplifier.
(Action 2) It is possible that an instant disconnection of power
source causes this alarm. Check whether an instant
disconnection occurred.
(Action 3) Replace the E-stop unit.
(Action 4) Replace the servo amplifier.


Servo amplifier
Main board
E-stop unit


Servo amplifier
Main board
E-stop unit

(A-cabinet) (B-cabinet)
Fig.3.5 (12) SRVO-021 SRDY off

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 63 -
(13) SRVO-022 SRDY on (Group : i Axis : j)
(Explanation) When the HRDY is about to go on, the SRDY is
already on. (HRDY is a signal with which the
host directs the servo system whether to turn on or
off the servo amplifier magnetic contactor.
SRDY is a signal with which the servo system
informs the host whether the magnetic contactor is
turned on.)
(Action 1) Replace the servo amplifier as the alarm message.


Servo amplifier
Main board
E-stop unit


Servo amplifier
Main board
E-stop unit

(A-cabinet) (B-cabinet)
Fig.3.5 (13) SRVO-022 SRDY on

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 64 -
(14) SRVO-023 Stop error excess (Group : i Axis : j)
(Explanation) When the servo is at stop, the position error is
abnormally large.
Check whether the brake is released through the
clack sound of the brake or vibration.
In case that the brake is not released.
(Action 1) If the brake is not released, check the continuity of
the brake line in the robot connection cable and the
robot internal cable.
(Action 2) If the disconnection is not found, replace the servo
amplifier or the servo motor.
In case that the brake is released.
(Action 1) Check whether the obstacle disturbs the robot
motion.
(Action 2) Make sure that connectors CNJ1A-CNJ6 are
securely attached to the servo amplifier.
(Action 3) Check the continuity of the robot connection cable
and the internal robot power cable.
(Action 4) Check to see if the load is greater than the rating. If
greater, reduce it to within the rating. (If the load is
too great, the torque required for acceleration /
deceleration becomes higher than the capacity of
the motor.
As a result, the motor becomes unable to follow
the command, and an alarm is issued.)
(Action 5) Check the input voltage to the controller is within
the rated voltage and no phase is lack. And check
the setting of the transformer is correct.
Check each phase voltage of the CRR38A or
CRR38B connector of the three-phase power (200
VAC) input to the servo amplifier. If it is 210 VAC
or lower, check the line voltage. (If the voltage
input to the servo amplifier becomes low, the
torque output also becomes low. As a result, the
motor may become unable to follow the command,
hence possibly causing an alarm.).
(Action 6) Replace the servo amplifier.
(Action 7) Replace the motor of the alarm axis.

NOTE
Incorrect setting of the brake number causes this
alarm.

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

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Servo amplifier

Servo amplifier

(A-cabinet) (B-cabinet)

Fig.3.5 (14) SRVO-023 Stop error excess

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(15) SRVO-024 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) Take the same actions as SRVO-023.

(16) SRVO-027 Robot not mastered (Group : i)
(Explanation) An attempt was made to calibrate the robot, but
the necessary adjustment had not been completed.
(Action) Check whether the mastering is valid. If the
mastering is invalid, master the robot.

WARNING
If the position data is incorrect, the robot or
additional axis can operate abnormally, set the
position data correctly. Otherwise, you could injure
personnel or damage equipment.

(17) SRVO-030 Brake on hold (Group:i)
(Explanation) If the temporary halt alarm function is enabled
($SCR.$BRKHOLD ENB=1), SRVO-030 is issued
when a temporary halt occurs. When this
function is not used, disable the setting.
(Action) Disable [Servo-off in temporary halt] on the
general item setting screen [6 General Setting
Items].

(18) SRVO-033 Robot not calibrated (Group : i)
(Explanation) An attempt was made to set up a reference point
for 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.

(19) SRVO-034 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.

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(20) SRVO-036 Inpos time over (Group : i Axis : j)
(Explanation) The robot did not get to the effective area
($PARAM _ GROUP.$ STOPTOL) even after the
position check monitoring time ($PARAM _
GROUP. $INPOS _ TIME) elapsed.
(Action) Take the same actions as for SRVO-023 (large
position error at a stop).

(21) SRVO-037 IMSTP input (Group : i)
(Explanation) The *IMSTP signal for a peripheral device
interface was input.
(Action) Turn on the *IMSTP signal.

(22) SRVO-038 Pulse mismatch (Group : i Axis : j)
(Explanation) The pulse count obtained when power is turned off
does not match the pulse count obtained when
power is applied. This alarm is asserted after
exchange the pulsecoder or battery for back up of
the pulsecoder data or loading back up data to the
Main Board.
Check the alarm history.
(Action 1) If the brake number is set to the non-brake motors,
this alarm may occur. Check the software setting of
the brake number.
(Action 2) In case the robot has been moved by using the
brake release unit while the power is off or when
restoring the back-up data to the main board, this
alarm may occur. Remaster the robot.
(Action 3) If the robot has been moved because the brake
failed, this alarm may occur. Check the cause of
the brake trouble. Then remaster the robot.
(Action 4) Replace the pulsecoder and master the robot.


Main board

(A-cabinet)
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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Main board


Axis control card

(B-cabinet) (Main board)
Fig.3.5 (22) SRVO-038 Pulse mismatch

(23) SRVO-042 MCAL alarm (Group : i Axis : j)
(Explanation) This alarm means that the contacts of the magnetic
contactor have stuck to each other. The alarm
condition occurs if the magnetic contactor turns
out to be already on when an attempt is made to
turn it on. The alarm condition is detected between
the time contact sticking occurs and the time an
attempt is made to turn on the magnetic contactor.
(Action 1) Replace the E-stop unit.
(Action 2) Replace the servo amplifier.


Servo amplifier
E-stop unit
Magnetic contactor

(A-cabinet)

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Servo amplifier
E-stop unit
Magnetic contactor

(B-cabinet)
Fig.3.5 (23) SRVO-042 MCAL alarm

(24) SRVO-043 DCAL alarm (Group : i Axis : j)
(Explanation) The regenerative discharge energy was too high to
be dissipated as heat. (To run the robot, the servo
amplifier supplies energy to the robot. When
going down the vertical axis, the robot operates
from the potential energy. If a reduction in the
potential energy is higher than the energy needed
for acceleration, the servo amplifier receives
energy from the motor. A similar phenomenon
occurs even when no gravity is applied, for
example, at deceleration on a horizontal axis.
The energy that the servo amplifier receives from
the motor is called the regenerative energy. The
servo amplifier dissipates this energy as heat. If
the regenerative energy is higher than the energy
dissipated as heat, the difference is stored in the
servo amplifier, causing an alarm.)
(Action 1) This alarm may occur if the axis is subjected to
frequent acceleration/deceleration or if the axis is
vertical and generates a large amount of
regenerative energy.
If this alarm has occurred, relax the service
conditions.
(Action 2) Check fuse FS3 in the servo amplifier. If it has
blown, remove the cause, and replace the fuse. One
of the probable causes of a blown fuse is a ground
fault in the servo amplifier for the auxiliary axis.
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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(Action 3) The ambient temperature is excessively high. Or
the regenerative resistor can't be cooled effectively.
Check the fan unit, and replace it if it stops. Clean
up the fun unit, the regenerative resistor and the
louver if they are dirty.
(Action 4) Measure each inter-phase voltage of the input
power supply, and make sure that all measurements
satisfy the input voltage stipulation. If voltage is
wrong, check the power supply facility. If voltage
is correct, replace the E-stop unit.
(Action 5) Make sure that the servo amplifier CRR63A and
CRR63B connectors are connected tightly. Then
detach the cable from CRR63A and CRR63B
connectors on the Servo amplifier, and check for
continuity between pins 1 and 2 of the cable-end
connector. If there is no continuity between the
pins, replace the regenerative resistor.
(Action 6) Make sure that the servo amplifier CRR45A and
CRR45B are connected tightly, then detach the
cables from CRR45A and CRR45B on the servo
amplifier and check the resistance between pins 1
and 2 of each cable end connector. If the resistance
is not 9-16, replace the regenerative resistor.
CRR45B may not be used depending on the robot
model.
(Action 7) Replace the servo amplifier.


Servo amplifier
E-stop unit

A-cabinet (Front)

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Regenerative resistor unit
Transformer


Regenerative resistor unit
Transformer

Side fan type Rear fan type
A-cabinet (Back)

Servo amplifier
regenerative
resistor unit
Fan unit

B-cabinet (Front) B-cabinet (Back)
Fig.3.5 (24) SRVO-043 DCAL alarm

(25) SRVO-044 HVAL alarm (Group : i Axis : j)
(Explanation) The DC voltage (DC link voltage) of the main
circuit power supply is abnormally high.
(Action 1) Check the three-phase input voltage at the servo
amplifier. If it is 240 VAC or higher, check the
line voltage. (If the three-phase input voltage is
higher than 240 VAC, high
acceleration/deceleration can cause 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) Check that the CRR63A and CRR63B connectors
of the servo amplifier are attached firmly. Next,
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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detach the cables then check the continuity
between pins 1 and 2 of the cable-side connectors.
If a disconnection is found, replace the
regenerative resistor.
(Action 4) Replace the servo amplifier.


Servo amplifier


Servo amplifier

(A-cabinet) (B-cabinet)
Fig.3.5 (25) SRVO-044 HVAL alarm

(26) SRVO-045 HCAL alarm (Group : i Axis : j)
(Explanation) Abnormally high current flowed in the main circuit
of the servo amplifier.
(Action 1) Turn off the power, and disconnect the power
cable from the servo amplifier indicated by the
alarm message. (And disconnect the brake cable
(CRR88 on the servo amplifier) to avoid the axis
falling unexpectedly.) Supply power and see if the
alarm occurs again. If the alarm occurs again,
replace the servo amplifier.
(Action 2) Turn off the power and disconnect the power cable
from the servo amplifier indicated by the alarm
message, and check the insulation of their U, V, W
and the GND lines each other. If there is a
short-circuit, replace the power cable.
(Action 3) Turn off the power and disconnect the power cable
from the servo amplifier by the alarm message, and
measure the resistance between their U and V, V
and W and W and U with an ohmmeter that has a
very low resistance range. If the resistances at the
three places are different from each other, the
motor, the power cable is defective. Check each
item in detail and replace it if necessary.
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Servo amplifier


Servo amplifier


(A-cabinet) (B-cabinet)
Fig.3.5 (26) SRVO-045 HCAL alarm

(27) SRVO-046 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 condition for the robot and
relax the service condition if possible. If the load
or operating condition has exceeded the rating,
reduce the load or relax the operating condition to
meet the rating.
(Action 2) Check whether the voltage input to the controller is
within the rated voltage and also check whether the
voltage set for the transformer of the controller is
correct.
(Action 3) Check whether the brake of the corresponding axis
is released.
(Action 4) Check whether there is a factor that has increased
the mechanical load on the corresponding axis.
(Action 5) Replace the servo amplifier.
(Action 6) Replace the motor of the corresponding axis.
(Action 7) Replace the E-stop unit
(Action 8) Replace the motor power line (robot connection
cable) of the corresponding axis.
(Action 9) Replace the motor power line and brake line
(inside the mechanical section) of the
corresponding axis.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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Servo amplifier


Servo amplifier

(A-cabinet) (B-cabinet)
Fig.3.5 (27) SRVO-046 OVC alarm

Reference
Relationships among the OVC, OHAL, and HC alarms

- Overview
This section points out the differences among the OVC, OHAL, and
HC alarms and describes the purpose of each alarm.

- Alarm detection section
Abbreviation Designation Detection section
OVC Overcurrent alarm Servo software
OHAL Overheat alarm Thermal relay in the motor
Thermal relay in the servo amplifier
Thermal relay in the separate
regenerative discharge unit
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 OHAL alarms (overcurrent and overload alarms)
The OVC and OHAL alarms are intended to prevent overheat
that may lead to the burnout of the motor winding, the
breakdown of the servo amplifier transistor, and the separate
regenerative resistor.
The OHAL alarm occurs when each built-in thermal relay detects
a temperature higher than the rated value. However, this
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method is not necessarily perfect to prevent these failures. For
example, if the motor frequently repeats to start and stop, the
thermal time constant of the motor, which has a large mass,
becomes higher than the time constant of the thermal relay,
because these two components are different in material, structure,
and dimension. Therefore, if the motor continues to start and
stop within a short time as shown in Fig. 3.5 (a), 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 Start Start Stop Stop
Temperature at
which the winding
starts to burn
Thermal time constant of the
motor is high.
Thermal time constant of the
thermal relay is low.
Time

Fig.3.5 (a) 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.
To sum up, a double protection method is used; the OVC alarm is
used for protection from a short-time overcurrent, and the OHAL
alarm is used for protection from long-term overload. The
relationship between the OVC and OHAL alarms is shown in Fig.3.5
(b).

Current
Protection area for
the motor and servo
amplifier
Protection by the OHAL
Limit current
Protection by
the OVC
Rated continuous current
Time

Fig.3.5 (b) Relationship between the OVC and OHAL alarms
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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NOTE
The relationship shown in Fig.3.5 (b) 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.

(28) SRVO-047 LVAL alarm (Group : i Axis : j)
(Explanation) The control power supply voltage (+5 V, etc.)
supplied from the power supply circuit in the servo
amplifier is abnormally low.
(Action 1) Replace the servo amplifier.
(Action 2) Replace the power supply unit.


Servo amplifier Power supply unit


Servo amplifier
Power supply unit

(A-cabinet) (B-cabinet)
Fig.3.5 (28) SRVO-047 LVAL alarm

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(29) SRVO-049 OHAL1 alarm (Group : i Axis : j)
(Explanation) The thermostat in the transformer worked.
Alternatively, fuse F1 or F2 in the servo amplifier
has blown.
(Action 1) Check whether the fan is stopped and also check
whether the vent hole is clogged. If necessary,
clean or replace them.
(Action 2) If SRVO-049 is issued when the robot operating
condition is severe, check the robot operating
condition then relax the condition when possible.
(Action 3) Check that a connection is made between the
transformer connector CPOH and the emergency
stop unit CRM73.
(Action 4) Replace the servo.
(Action 5) Replace the transformer.


Servo amplifier
E-stop unit

A-cabinet (Front)


Regenerative resistor unit
Transformer


Regenerative resistor unit
Transformer

Side fan type Rear fan type
A-cabinet (Back)

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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Servo amplifier
E-stop unit
regenerative
resistor unit
Fan unit
Transformer

B-cabinet (Front) B-cabinet (Back)
Fig.3.5 (29) SRVO-049 OHAL1 alarm

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(30) SRVO-050 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 whether the robot has collided and also
check whether there is a factor that has increased
the mechanical load on the corresponding axis.
(Action 2) Check whether the load settings are valid.
(Action 3) Check whether the brake of the corresponding axis
is released.
(Action 4) If the load weight exceeds the rated range, decrease
it to within the limit.
(Action 5) Check whether the voltage input to the controller is
within the rated voltage and also check whether the
voltage set for the transformer of the controller is
correct.
(Action 6) Replace the servo amplifier.
(Action 7) Replace the motor of the corresponding axis.
(Action 8) Replace the E-stop unit.
(Action 9) Replace the motor power line (robot connection
cable) of the corresponding axis.
(Action 10) Replace the motor power line and brake line
(inside the mechanical section) of the
corresponding axis.


Servo amplifier


Servo amplifier

(A-cabinet) (B-cabinet)
Fig.3.5 (30) SRVO-050 CLALM alarm
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(31) SRVO-051 CUER alarm (Group : i Axis : j)
(Explanation) The offset of the current feedback value is
abnormally high.
(Action) Replace the servo amplifier.



Servo amplifier


Servo amplifier

(A-cabinet) (B-cabinet)
Fig.3.5 (31) SRVO-051 CUER alarm

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(32) SRVO-055 FSSB com error 1 (Group : i Axis : j)
(Explanation) A communication error has occurred between the
main board and servo amplifier.
(Action 1) Check the communication cable (optical fiber)
between the main board and servo amplifier.
Replace it if it is faulty.
(Action 2) Replace the axis control card on the main board.
(Action 3) Replace the servo amplifier.

Servo amplifier Main board

(A-cabinet)



Servo amplifier
Main board

Axis control card

(B-cabinet) (Main board)
Fig.3.5 (32) SRVO-055 FSSB com error 1

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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(33) SRVO-056 FSSB com error 2 (Group : i Axis : j)
(Explanation) A communication error has occurred between the
main board and servo amplifier.
(Action 1) Check the communication cable (optical fiber)
between the main board and servo amplifier.
Replace it if it is faulty.
(Action 2) Replace the axis control card on the main board.
(Action 3) Replace the servo amplifier.


Servo amplifier Main board

(A-cabinet)



Servo amplifier
Main board

Axis control card

(B-cabinet) (Main board)
Fig.3.5 (33) SRVO-056 FSSB com error 2

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(34) SRVO-057 FSSB disconnect (Group : i Axis : j)
(Explanation) Communication was interrupted between the
main board and servo amplifier.
(Action 1) Check whether fuse F4 in the power supply unit
has blown. If the fuse has blown, replace the
servo amplifier including the fuse.
(Action 2) Replace the optical cable between the axis
control card and servo amplifier.
(Action 3) Replace the axis control card on the main board.
(Action 4) Replace the servo amplifier.
(Action 5) Check for a point where the robot connection
cable RP1 or an internal cable running to each
pulse coder through the robot mechanical section
is grounded.
Before continuing to the next step, perform a complete controller
back-up to save all your programs and settings.
(Action 6) Replace the main board.
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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Servo amplifier Main board

(A-cabinet)



Servo amplifier
Main board

Axis control card

(B-cabinet) (Main board)
Fig.3.5 (34) SRVO-057 FSSB disconnect

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(35) SRVO-058 FSSB init error (Group : i Axis : j)
(Explanation) Communication was interrupted between the main
board and servo amplifier.
(Action 1) Check whether fuse F4 in the power supply unit
has blown. If the fuse has blown, check and
correct the cause then replace the fuse.
(Action 2) Check whether fuse FS1 on the servo amplifier has
blown. If the fuse has blown, replace the servo
amplifier including the fuse.
(Action 3) Turn off the power and disconnect the CRF8
connector on the servo amplifier. Then check
whether this alarm occurs again. (Ignore the alarm
SRVO-068 because of disconnecting the CRF8
connector.)
If this alarm does not occur, the RP1 cable of the
robot connection cable or the internal cable of the
robot may be short-circuited to the ground. Check
the cables and replace it if necessary.
(Action 4) Check whether the LED (P5V and P3.3V) on the
servo amplifier is lit. If they are not lit, the DC
power is not supplied to the servo amplifier.
Make sure the connector CRP24 and CRM96 on
the E-stop unit and the connector CRM96 on the
servo amplifier are connected tightly. If they are
connected tightly, replace the servo amplifier.
(Action 5) Check the communication cable (optical fiber)
between the axis control board and servo amplifier.
Replace it if it is faulty.
(Action 6) Replace the servo card on the main board.
(Action 7) Replace the servo amplifier.
(Action 8) If the other units (the servo amplifier for the
auxiliary axis and the line tracking interface) are
connected in the FSSB optical communication,
disconnect these units and connect only servo
amplifier for the robot. Then turn on the power. If
this alarm does not occur, search the failed unit and
replace it.
Before executing the (Action9), perform a
complete controller back-up to save all your
programs and settings.
(Action 9) Replace the main board.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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Servo amplifier Main board

(A-cabinet)


Servo amplifier
Main board

Axis control card

(B-cabinet) (Main board)

Fig.3.5 (35) SRVO-058 FSSB init error

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(36) SRVO-059 Servo amp init error
(Explanation) Servo amplifier initialization is failed.
(Action 1) Check the wiring of the servo amplifier.
(Action 2) Replace the servo amplifier.


Servo amplifier


Servo amplifier

(A-cabinet) (B-cabinet)
Fig.3.5 (36) SRVO-059 Servo amp init error

(37) SRVO-062 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 1) Replace the battery in the battery box of the robot
base.
(Action 2) Replace the pulse coder with which an alarm has
been issued.
(Action 3) Check whether the robot internal cable for feeding
power from the battery to the pulse coder is not
disconnected and grounded. If an abnormality is
found, replace the cable.

CAUTION
After correcting the cause of this alarm, set the
system variable (MCR.$SPC_RESET) to TRUE
then turn on the power again. Mastering is
needed.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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(38) SRVO-064 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.

(39) SRVO-065 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 power and replace
the battery as soon as possible. A delay in battery
replacement may result in the BZAL alarm being
detected. In this case, the position data will be lost.
Once the position data is lost, mastering will
become necessary.

(40) SRVO-067 OHAL2 alarm (Group : i Axis : j)
(Explanation) The temperature inside the pulse coder or motor is
abnormally high, and the built-in thermostat has
operated.
(Action 1) Check the robot operating conditions. If a
condition such as the duty cycle and load weight
has exceeded the rating, relax the robot load
condition to meet the allowable range.
(Action 2) When power is supplied to the motor after it has
become sufficiently cool, if the alarm still occurs,
replace the motor.

(41) SRVO-068 DTERR alarm (Group : i Axis : j)
(Explanation) The serial pulse coder does not return serial data in
response to a request signal.
(Action 1) Make sure that the RP1 connector of servo
amplifier (motor side) is connected tightly.
(Action 2) Check that the shielding of the RP1 cable is
grounded securely in the cabinet.
(Action 3) Replace the pulse coder.
(Action 4) Replace the servo amplifier.
(Action 5) Replace the RP1 cable.
(Action 6) Replace the robot interconnection cable (for the
pulse coder).

(42) SRVO-069 CRCERR alarm (Group : i Axis : j)
(Explanation) The serial data has disturbed during
communication.
- See actions on SRVO-070

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

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(43) SRVO-070 STBERR alarm (Group : i Axis : j)
(Explanation) The start and stop bits of the serial data are
abnormal.
(Action) Replace the RPI cable.


Servo amplifier


Servo amplifier

(A-cabinet) (B-cabinet)
Fig.3.5 (43) SRVO-070 STBERR alarm

(44) SRVO-071 SPHAL alarm (Group : i Axis : j)
(Explanation) The feedback speed is abnormally high.
(Action) Action as same as the SRVO-068.

NOTE
If this alarm occurs together with the PHAL alarm
(SRVO-064), this alarm does not correspond to the
major cause of the failure.

(45) SRVO-072 PMAL alarm (Group : i Axis : j)
(Explanation) It is likely that the pulse coder is abnormal.
(Action) Replace the pulse coder and remaster the robot.

(46) SRVO-073 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 1) Reinforce the earth of the motor flange.
(Action 2) Replace the pulse coder.

(47) SRVO-074 LDAL alarm (Group : i Axis : j)
(Explanation) The LED in the pulse coder is broken.
(Action) Replace the pulse coder, and remaster the robot.

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(48) SRVO-075 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.
(49) SRVO-076 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 has collided. Or check
whether the machinery load of the corresponding
axis is increased.
(Action 2) Check whether the load settings are valid.
(Action 3) Check whether the brake of the corresponding axis
is released.
(Action 4) Check whether the load weight is within the rated
range. If the weight exceeds the upper limit,
decrease it to the limit.
(Action 5) Check whether the voltage input to the controller is
within the rated voltage and also check whether the
voltage set for the transformer of the controller is
correct.
(Action 6) Replace the servo amplifier.
(Action 7) Replace the corresponding servo motor.
(Action 8) Replace the E-stop unit.
(Action 9) Replace the power cable of the robot connection
cable in which the corresponding axis is connected.
(Action 10) Replace the power cable of the robot
interconnection cable in which the corresponding
axis is connected.

Servo amplifier
E-stop unit


Servo amplifier
E-stop unit

(A-cabinet) (B-cabinet)
Fig.3.5 (49) SRVO-076 Tip Stick Detection
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 91 -
(50) SRVO-081 EROFL alarm (Track enc : i)
(Explanation) The pulse counter for line tracking has overflowed.
(Action 1) Check whether the condition of the line tracking
exceeds the limitation.
(Action 2) Replace the pulse coder.
(Action 3) Replace the line tracking interface board.

(51) SRVO-082 DAL alarm (Track ebc : i)
(Explanation) The line tracking pulse coder has not been
connected.
(Action 1) Check the connection cable at each end (the line
tracking interface board and the motor side)
(Action 2) Check whether the shielding of the connection
cable is connected securely to the grounding plate.
(Action 3) Replace the line tracking cable.
(Action 4) Replace the pulse coder.
(Action 5) Replace the line tracking interface board.

(52) SRVO-084 BZAL alarm (Track enc : i)
(Explanation) This alarm occurs if the backup battery for the
absolute position of the pulse coder has not been
connected. See the description about the BZAL
alarm (SRVO-062).

(53) SRVO-087 BLAL alarm (Track enc : i)
(Explanation) This alarm occurs if the voltage of the backup
battery for the absolute position of the pulse coder
is low. See the description about the BLAL alarm
(SRVO-065).

(54) SRVO-089 OHAL2 alarm (Track enc : i)
(Explanation) The motor has overheated. When power is
supplied to the pulse coder after it has become
sufficiently cool, if the alarm still occurs. See the
description about the OHAL2 alarm (SRVO-067).

(55) SRVO-090 DTERR alarm (Track ebc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
SRVO-068 DTERR alarm.
(Action 1) Check the connection cable at each end (the line
tracking interface board and the pulse coder)
(Action 2) Check whether the shielding of the connection
cable is connected securely to the grounding plate.
(Action 3) Replace the pulse coder.
(Action 4) Replace the line tracking cable.
(Action 5) Replace the line tracking interface board.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 92 -
(56) SRVO-091 CRCERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal.
(Action) Action as same as the SRVO-090.

(57) SRVO-092 STBERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal.
(Action) Action as same as the SRVO-090.

(58) SRVO-093 SPHAL alarm (Track enc : i)
(Explanation) This alarm occurs if the current position data from
the pulse coder is higher than the previous position
data.
(Action) Action as same as the SRVO-090.

(59) SRVO-094 PMAL alarm (Track enc : i)
(Explanation) It is likely that the pulse coder is abnormal. See
the description about the PMAL alarm
(SRVO-072).

(60) SRVO-095 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).
(Action 1) Reinforce the earth of the flange of the pulse coder.
(Action 2) Replace the pulse coder.

(61) SRVO-096 LDAL alarm (Track enc : i)
(Explanation) The LED in the pulse coder is broken. See the
description about the LDAL alarm (SRVO-074).

(62) SRVO-097 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.
(Action 1) Reset the alarm, and jog the axis on which the
alarm has occurred until the same alarm does not
occur again. (Jog one motor revolution)

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 93 -
(63) SRVO-105 Door open or E-stop
(Explanation) The cabinet door is open.
- When the door switch is mounted.
(Action 1) When the door is open, close it.
(Action 2) Check the door switch and door switch connection
cable. If the switch or cable is faulty, replace it.
- When the door switch is not mounted.
(Action 3) Check that the CRM72, CRM95, and CRM96
connectors on the E-STOP unit are connected
securely.
(Action 4) Replace the E-stop unit.
(Action 5) Replace the servo amplifier.
(Action 6) Replace the panel board.
(Action 7) Replace the connection cable between the panel
board and the E-stop unit.


(A-cabinet)
Fig.3.5 (63) SRVO-105 Door open or E-stop

Door switch
Servo amplifier Main board
E-stop unit
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 94 -
(64) SRVO-136 DCLVAL alarm (Group : i Axis : j)
(Explanation) The servo the DC current of amplifier (DC link
voltage) of the main power supply is abnormally
low.
- This alarm occurred during robot operation.
(Action 1) Check the input voltage to the controller is within
the rated voltage and no phase is lack. And check
the setting of the transformer is correct.
(Action 2) It is possible that an instant disconnection of power
source causes this alarm. Check whether an instant
disconnection occurred.
(Action 3) Modify the program in order that robot and the
auxiliary axis do not accelerate simultaneously in
the system with the auxiliary axis.
(Action 4) Replace the E-stop unit.
(Action 5) Replace the servo amplifier.
- If this alarm occurred before the magnetic contactor is
turned on:
(Action 1) Check whether the circuit breaker in the
emergency stop unit is OFF. If it is OFF, check the
servo amplifier and the wiring between the servo
amplifier and the emergency stop unit. If anything
is abnormal, replace it. Else turn on the breaker.
(Action 2) Check the input voltage to the controller is within
the rated voltage and no phase is lack. And check
the setting of the transformer is correct.
(Action 3) Replace the E-stop unit.
(Action 4) Replace the servo amplifier.

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 95 -


Servo amplifier
E-stop unit
Magnetic contactor

(A-cabinet)

Servo amplifier
E-stop unit
Magnetic contactor

(B-cabinet)

Fig.3.5 (64) SRVO-136 DCLVAL alarm

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 96 -
(65) SRVO-156 IPMAL alarm (Group : i Axis : j)
(Explanation) Abnormally high current flowed through the main
circuit of the servo amplifier.
(Action 1) Turn off the power, and disconnect the power
cable from the servo amplifier indicated by the
alarm message. (And disconnect the brake cable
(CRR88 on the servo amplifier) to avoid the axis
falling unexpectedly.) Supply power and see if the
alarm occurs again. If the alarm occurs again,
replace the servo amplifier.
(Action 2) Turn off the power and disconnect the power cable
from the servo amplifier indicated by the alarm
message, and check the insulation of their U, V, W
and the GND lines each other. If there is a
short-circuit, replace the power cable.
(Action 3) Turn off the power and disconnect the power cable
from the servo amplifier by the alarm message, and
measure the resistance between their U and V, V
and W and W and U with an ohmmeter that has a
very low resistance range. If the resistances at the
three places are different from each other, the
motor, the power cable is defective. Check each
item in detail and replace it if necessary.


Servo amplifier


Servo amplifier

(A-cabinet) (B-cabinet)

Fig.3.5 (65) SRVO-156 IPMAL alarm

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 97 -
(66) SRVO-157 CHGAL alarm (Group : i Axis : j)
(Explanation) The capacitor for the condenser voltage of the
servo amplifier was not charged within the
specified time when the servo power is on.
(Action 1) Replace the E-stop unit.
(Action 2) Replace the servo amplifier.
(Action 3) Replace the auxiliary amplifier for system of the
auxiliary axis.


Servo amplifier
E-stop unit


Servo amplifier
E-stop unit

(A-cabinet) (B-cabinet)

(B-cabinet)

Fig.3.5 (66) SRVO-157 CHGAL alarm

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 98 -
(67) SRVO-194 Servo disconnect
(Explanation) The external contact connected to SD4-SD41 or
SD5-SD51 of the terminal block TBOP3 on the
panel board is open.
(Action 1) If external circuitry is connected to SD4-SD41 or
SD5-SD51 of the terminal block TBOP3 on the
panel board, check the external circuitry.
(Action 2) If this signal is not used, make a connection
between SD4 and SD41 and between SD5 and
SD51 of the terminal block TBOP3 on the panel
board.
(Action 3) Replace the panel board.
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 99 -

(A-cabinet)


Panel board

(B-cabinet)
Fig.3.5 (67) SRVO-194 Servo disconnect

WARNING
In a system using the servo disconnect signal, it is
very dangerous to disable the signal when a
connection is made between SD4 and SD41 and
between SD5 and SD51 of the terminal block
TBOP3 on the panel board. Never make such an
attempt. If a temporary connection is needed for
operation, separate safety measures must be
taken.

Panel board
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 100 -
(68) SRVO-201 Panel E-stop or SVEMG abnormal
(Explanation) The EMERGENCY STOP button on the operators
panel was pressed, but the EMERGENCY STOP
line was not disconnected.
(Action 1) Replace the panel board.
(Action 2) Replace the E-stop unit.
(Action 3) Replace the servo amplifier.


Servo amplifier
E-stop unit

(A-cabinet)

Servo amplifier
E-stop unit
Panel board
EMERGENCY STOP button

(B-cabinet)
Fig.3.5 (68) SRVO-201 Panel E-stop or SVEMG abnormal
Panel board
Emergency
stop button
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 101 -
(69) SRVO-202 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) Replace the teach pendant.
(Action 2) Check the teach pendant cable. If this inferior,
replace the cable.
(Action 3) Replace the operator's panel.
(Action 4) Replace the E-stop unit.
(Action 5) Replace the servo amplifier.

NOTE
This alarm might occur if the EMERGENCY STOP
button is pressed slowly.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 102 -


Servo amplifier
E-stop unit

(A-cabinet)


Servo amplifier
E-stop unit
Panel board
Teach pendant

(B-cabinet)
Fig.3.5 (69) SRVO-202 TP E-stop or SVEMG abnormal

Panel board
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 103 -
(70) SRVO-204 External (SVEMG abnormal) E-stop
(Explanation) The switch connected across EES1 EES11 and
EES2 EES21 on the TBOP4 terminal board on
the panel board was pressed, but the
EMERGENCY STOP line was not disconnected.
In case that RDY LED (green) is lit.
(Action 1) Check the switch and cable connected to EES1
EES11 and EES2 EES21 on TBOP4 terminal
board. If the cable are abnormal replace it.
(Action 2) Replace the panel board.
(Action 3) Replace the E-stop unit.
(Action 4) Replace the servo amplifier.
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 104 -


Servo amplifier
E-stop unit

(A-cabinet)

Servo amplifier
E-stop unit
Panel board

(B-cabinet)
Panel board
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 105 -





(Panel board)

Fig.3.5 (70) SRVO-204 External (SVEMG abnormal) E-stop

EES1
EES11
EES2
EES22
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 106 -
(71) SRVO-205 Fence open (SVEMG abnormal)
(Explanation) The switch connected across EES1 EES11 and
EES2 EES21 on the TBOP4 terminal board on
the panel board was pressed, but the
EMERGENCY STOP line was not disconnected.
In case that RDY LED (green) is lit.
(Action 1) Check the switch and cable connected to EES1
EES11 and EES2 EES21. If the cable are
abnormal, replace it.
(Action 2) Replace the panel board.
(Action 3) Replace the E-stop unit.
(Action 4) Replace the servo amplifier.




Servo amplifier

(A-cabinet)



Servo amplifier
Panel board

(B-cabinet)
Panel board
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 107 -




(Panel board)
Fig.3.5 (71) SRVO-205 Fence open (SVEMG abnormal)

(72) SRVO-206 DEADMAN switch (SVEMG abnormal)
(Explanation) When the teach pendant was enabled, the
DEADMAN switch was released or pressed
strongly, but the emergency stop line was not
disconnected.
(Action 1) Replace the teach pendant.
(Action 2) Check the teach pendant cable. If it is inferior,
replace the cable.
(Action 3) Replace the panel board.
(Action 4) When the NTED signal is used, check whether the
cabling of the signal connected to CRM65 on the
panel board is correct.
(Action 5) Replace the E-stop unit.
(Action 6) Replace the servo amplifier.
EAS1
EAS11
EAS2
EAS22
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 108 -


Servo amplifier
E-stop unit

(A-cabinet)

Servo amplifier
E-stop unit
Panel board
Teach pendant

(B-cabinet)

Fig.3.5 (72) SRVO-206 DEADMAN switch (SVEMG abnormal)

Panel board
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 109 -
(73) SRVO-213 WARN Fuse blown (Panel PCB)
(Explanation) A fuse (FUSE1 or FUSE2) on the panel board has
blown, or no voltage is supplied to EXT24V.
(Action 1) Check whether the fuse (FUSE1) on the panel
board has blown. If the fuse has blown, +24EXT
may be short-circuited to 0EXT. Take Action 2. If
FUSE1 has not blown, take Action 3 and up.
(Action 2) Disconnect the connection destinations of +24EXT
that can cause grounding then check that FUSE1
does not blow. Disconnect the following on the
panel board then turn on the power:
- CRS20
- CRT16
- TBOP4: EES1, EES11, EAS1, EAS11, EGS1,
EGS11
- TBOP3: SD4, SD41
If FUSE1 does not blow in this state, +24EXT and
0EXT may be short-circuited at any of the
connection destinations above. Isolate the faulty
location then take action.
If FUSE1 blows even when the connection
destinations above are detached, replace the panel
board.
(Action 3) Check whether 24 V is applied to between
EXT24V and EXT0V of TBOP6. If not, check
the external power supply circuit.
If no external power supply is used, check whether
the terminals above are connected to the INT24V
and INT0V terminals, respectively.
(Action 4) Replace the panel board.
(Action 5) Replace the teach pendant cable.
(Action 6) Replace the teach pendant.

(panel board)



JRS15
LED (green)
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 110 -



(A-cabinet)
Main board
Panel board

(B-cabinet)
Connector JRS15

(Main board)

Fig.3.5 (73) SRVO-213 WARN Fuse blown (Panel PCB)

Panel board
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 111 -
(74) SRVO-214 Fuse blown (Servo amplifier)
(Explanation) A fuse in the servo amplifier has blown.
In case that FS1 is blown
(Action 1) Replace the servo amplifier.
In case that FS2 or FS3 is blown
(Action 1) A fuse is blown, eliminate the cause, then replace
the fuse. (See Section 3.6 in the Part II,
MAINTENANCE.)
(Action 2) Replace the servo amplifier.


Servo amplifier

(A-cabinet)

Servo amplifier

(B-cabinet)
Fig.3.5 (74) SRVO-214 Fuse blown (Panel PCB)
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 112 -
(75) SRVO-216 OVC (total) (Robot : i)
(Explanation) The current (total current for six axes) flowing
through the motor is too large.
(Action 1) Slow the motion of the robot where possible.
Check the robot operation conditions. If the robot
is used with a condition exceeding the duty or load
weight robot rating, reduce the load condition
value to the specification range.
(Action 2) Check the input voltage to the controller is within
the rated voltage and no phase is lack. And check
the setting of the transformer is correct.
(Action 3) Replace the servo amplifier.

Servo amplifier

Servo amplifier

(B-cabinet)

Fig.3.5 (75) SRVO-216 OVC (total) (Robot : i)
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 113 -
(76) SRVO-221 Lack of DSP (Group : i Axis : j)
(Explanation) A controlled axis card corresponding to the set
number of axes is not mounted.
(Action 1) Check whether the set number of axes is valid. If
the number is invalid, set the correct number.
(Action 2) Replace the axis control card with a card
corresponding to the set number of axes.


Servo amplifier Main board

(A-cabinet)


Main board

Axis control card

(B-cabinet) (Main board)

Fig.3.5 (76) SRVO-221 Lack of DSP (Group : i Axis : j)

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 114 -
(77) SRVO-223 DSP dry run(a b)
(Explanation) Servo system initialization was stopped because of
a hardware failure or improver software setting.
The controller has been started in the DSP dry run
mode.
(Action 1) When the value is 1, 5, or 6: An incorrect setting
is made. Check whether the dry run mode is set
and also check whether the setting of the hard start
axis is correct.
(Action 2) When the value is 2, 3, 4, or 7: Replace the servo
card.
(Action 3) When the value is 8 or 10: Take action for an
FSSB initialization error that has occurred at the
same time.
(Action 4) When the value is 9: Take the following action:
Check whether the servo amplifier is connected.
Replace the optical cable used for servo amplifier
connection.
Replace the servo amplifier


Servo amplifier

Servo amplifier

Fig.3.5 (77) SRVO-223 DSP dry run(a b)
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 115 -
(78) SRVO-230 Chain 1 (+24V) abnormal
SRVO-231 Chain 2 (0V) abnormal
(Explanation) A mismatch occurred between duplicate safety
signals.
SRVO-230 is issued if such a mismatch that a
contact connected on the chain 1 side (between
EES1 and EES11, between EAS1 and EAS11,
between EGS1 and EGS11, between SD4 and
SD41, and so forth) is closed, and a contact on the
chain 2 side (between EES2 and EES21, between
EAS2 and EAS21, between EGS2 and EGS21,
between SD5 and SD51, and so forth) is open
occurs. SRVO-231 is issued if such a mismatch
that a contact on the chain 1 side is open, and a
contact on the chain 2 side is closed occurs.
If a chain error is detected, correct the cause of the
alarm then reset the alarm according to the method
described later.
(Action) Check the alarms issued at the same time in order
to identify with which signal the mismatch
occurred.
SRVO-266 through SRVO-275 and SRVO-370
through SRVO-385 are issued at the same time.
Take the action(s) described for each item.
(Caution 1) After correcting the cause of the hardware chain
error according to the work described above, set
"YES" for chain error resetting on the system
setting screen. Finally, press the reset key on the
teach pendant. For details, see "Chain error reset
procedure" described later.
(Caution 2) If this alarm is issued, do not reset the chain error
alarm until the failure is identified and repaired.
If robot use is continued with one of the duplicate
circuits being faulty, safety may not be guaranteed
when the other circuit fails.


Servo amplifier
E-stop unit

(A-cabinet)
Panel board
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 116 -
Servo amplifier
E-stop unit
Panel board

(B-cabinet)
Fig.3.5 (78) SRVO-230 Chain 1 (+24V) abnormal / SRVO-231 Chain 2 (0V) abnormal

CAUTION
1 The state of this alarm is preserved by software.
After correcting the cause of the alarm, reset the
chain error alarm according to the chain error reset
procedure described later.
2 Until a chain error is reset, no ordinary reset
operation must be performed. If an ordinary reset
operation is performed before chain error resetting,
the message "SRVO-237 Chain error cannot be
reset" is displayed on the teach pendant.

Alarm history display method
1. Press the screen selection key on the teach pendant.
2. Select [4 ALARM] on the teach pendant.
3. Press F3 [HIST] on the teach pendant.

Chain error reset procedure
CAUTION
Do not perform this operation until the cause of the
alarm is corrected.

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 117 -
<Method 1>
1. Press the emergency stop button.
2. Press the screen selection key on the teach pendant.
3. Select [0 NEXT PAGE] on the teach pendant.
4. Press [6 SYSTEM] on the teach pendant.
5. Press [7 SYSTEM SETTING] on the teach pendant.
6. Find "28" Chain Error Reset Execution.
7. Press F3 on the teach pendant to reset "Chain Error".

<Method 2>
1. Press the screen selection key on the teach pendant.
2. Select [4 ALARM] on the teach pendant.
3. Press F4 [CHAIN RESET] on the teach pendant.

(79) SRVO-232 NTED input
(Explanation) In the teach mode, the NTED signal connected to
CRM65 on the panel board was placed in the open
state.
(Action 1) Check the operation of the device connected to
NTED.
(Action 2) Replace the teach pendant.
(Action 3) Replace the teach pendant cable.
(Action 4) Replace the panel board
(Action 5) Check the mode switch and its cable. Replace them
if a defect is found.


Servo amplifier

(A-cabinet)
Panel board
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 118 -
Servo amplifier
Panel board
Teach pendant

(B-cabinet)

Fig.3.5 (79) SRVO-232 NTED input

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 119 -
(80) SRVO-233 TP disabled in T1, T2/Door open
(Explanation) Teach pendant is disabled when the mode switch is
T1 or T2.
Or controller door is opened.
(Action 1) Enable the teach pendant in teaching operation. In
other case the mode switch should be AUTO
mode.
(Action 2) Close the controller door, if open.
(Action 3) Replace the teach pendant.
(Action 4) Replace the teach pendant cable.
(Action 5) Replace the mode switch.
(Action 6) Replace the panel board.
(Action 7) Replace the E-stop unit.
(Action 8) Replace the servo amplifier.






(A-cabinet)

Door switch
Mode switch Panel board
Servo amplifier
E-stop unit
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 120 -
Servo amplifier
E-stop unit
Panel board
Teach pendant
Mode switch
Enable switch

(B-cabinet)

Fig.3.5 (80) SRVO-233 TP disabled in T1, T2/Door open

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 121 -
(81) SRVO-235 Short term Chain abnormal
(Explanation) Short term single chain failure condition is
detected.
Cause of this alarm is ;
- Half release of DEADMAN switch
- Half operation of emergency stop switch.
(Action 1) Cause the same error to occur again, then perform
resetting.
(Action 2) Replace the panel board.
(Action 3) Replace the E-stop unit.
(Action 4) Replace the servo amplifier.


Servo amplifier
E-stop unit

(A-cabinet)

Servo amplifier
E-stop unit
Panel board

(B-cabinet)
Panel board
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 122 -
Enable switch Deadman switch

(Teach pendant)

Fig.3.5 (81) SRVO-235 Short term Chain abnormal

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 123 -
(82) SRVO-251 DB relay abnormal
(Explanation) An abnormality was detected in the internal relay
(DB relay) of the servo amplifier.
(Action) Replace the servo amplifier.

(83) SRVO-252 Current detect abnl
(Explanation) An abnormality was detected in the current
detection circuit inside the servo amplifier.
(Action) Replace the servo amplifier.

(84) SRVO-253 Amp internal over heat
(Explanation) An overheat was detected inside the servo
amplifier.
(Action) Replace the servo amplifier.

Servo amplifier

(A-cabinet)
Servo amplifier

(B-cabinet)

Fig.3.5 (82) SRVO-251 DB relay abnormal / SRVO-252 Current detect abnl / SRVO-253 Amp internal over heat

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 124 -
(85) SRVO-266 FENCE1 status abnormal a,b
SRVO-267 FENCE2 status abnormal a,b
(Explanation) A chain alarm was detected with the EAS
(FENCE) signal.
(Action 1) Check whether the circuitry connected to the dual
input signal (EAS) is faulty.
(Action 2) Check whether the timing of the dual input signal
(EAS) satisfies the timing specification
(See Section 3.2.5, Table 3.2.5 of Part III
CONNECTIONS).
(Action 3) Replace the panel board.

CAUTION
1 For the procedure of recovery from this alarm, see
the descriptions of SRVO-230 and SRVO-231.
2 If this alarm is issued, do not reset the chain error
alarm until the failure is checked and corrected. If
robot use is continued with one of the duplicate
circuits being faulty, safety may not be guaranteed
when the other circuit fails.



EAS1
EAS11
EAS2
EAS22

Fig.3.5 (85) SRVO-266 FENCE1 status abnormal a,b / SRVO-267 FENCE2 status abnormal a,b

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 125 -
(86) SRVO-268 SVOFF1 status abnormal a,b
SRVO-269 SVOFF2 status abnormal a,b
(Explanation) A chain alarm was detected with the EGS
(SVOFF) signal.
(Action 1) Check whether the circuitry connected to the dual
input signal (EGS) is faulty.
(Action 2) Check whether the timing of the dual input signal
(EGS) satisfies the timing specification
(See Section 3.2.5, Table 3.2.5 of Part III
CONNECTIONS).
(Action 3) Replace the panel board.

CAUTION
1 For the procedure of recovery from this alarm, see
the descriptions of SRVO-230 and SRVO-231.
2 If this alarm is issued, do not reset the chain error
alarm until the failure is checked and corrected. If
robot use is continued with one of the duplicate
circuits being faulty, safety may not be guaranteed
when the other circuit fails.






Fig.3.5 (86) SRVO-268 SVOFF1 status abnormal a,b / SRVO-269 SVOFF2 status abnormal a,b

EGS1
EGS11
EGS2
EGS22
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 126 -
(87) SRVO-270 EXEMG1 status abnormal a,b
SRVO-271 EXEMG2 status abnormal a,b
(Explanation) A chain alarm was detected with the EES
(EXEMG) signal.
(Action 1) Check whether the circuitry connected to the dual
input signal (EES) is faulty.
(Action 2) Check whether the timing of the dual input signal
(EES) satisfies the timing specification
(See Section 3.2.5, Table 3.2.5 of Part III
CONNECTIONS).
(Action 3) Replace the panel board.

CAUTION
1 For the procedure of recovery from this alarm, see
the descriptions of SRVO-230 and SRVO-231.
2 If this alarm is issued, do not reset the chain error
alarm until the failure is checked and corrected. If
robot use is continued with one of the duplicate
circuits being faulty, safety may not be guaranteed
when the other circuit fails.





Fig.3.5 (87) SRVO-270 EXEMG1 status abnormal a,b / SRVO-271 EXEMG2 status abnormal a,b

EES1
EES11
EES2
EES22
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 127 -
(88) SRVO-272 SVDISC1 status abnormal a,b
SRVO-273 SVDISC2 status abnormal a,b
(Explanation) A chain alarm was detected with the SD4 or SD5
(SVDISC) signal.
(Action 1) Check whether the circuitry connected to the dual
input signal (SD) is faulty.
(Action 2) Check whether the timing of the dual input signal
(SD) satisfies the timing specification
(See Section 3.2.5, Table 3.2.5 of Part III
CONNECTIONS).
(Action 3) Replace the panel board.

CAUTION
1 For the procedure of recovery from this alarm, see
the descriptions of SRVO-230 and SRVO-231.
2 If this alarm is issued, do not reset the chain error
alarm until the failure is checked and corrected. If
robot use is continued with one of the duplicate
circuits being faulty, safety may not be guaranteed
when the other circuit fails.


Fig.3.5 (88) SRVO-272 SVDISC1 status abnormal a,b / SRVO-273 SVDISC2 status abnormal a,b

SD4
SD41
SD5
SD51
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 128 -
(89) SRVO-274 NTED1 status abnormal a,b
SRVO-275 NTED2 status abnormal a,b
(Explanation) A chain alarm was detected with the NTED signal.
(Action 1) This alarm may be issued when the DEADMAN
switch is pressed to a proper position or is operated
very slowly. In such a case, release the
DEADMAN switch once completely then press the
DEADMAN switch again.
(Action 2) Check whether the circuitry connected to the dual
input signal (NTED) is faulty.
(Action 3) Check whether the timing of the dual input signal
(NTED) satisfies the timing specification
(See Section 3.2.5, Table 3.2.5 of Part III
CONNECTIONS).
(Action 4) Replace the panel board.
(Action 5) Replace the teach pendant cable.
(Action 6) Replace the teach pendant.
(Action 7) Replace the mode switch on the operator's panel.

CAUTION
1 For the procedure of recovery from this alarm, see
the descriptions of SRVO-230 and SRVO-231.
2 If this alarm is issued, do not reset the chain error
alarm until the failure is checked and corrected. If
robot use is continued with one of the duplicate
circuits being faulty, safety may not be guaranteed
when the other circuit fails.




Panel board

(A-cabinet) (B-cabinet)
Panel board
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 129 -

Enable switch Deadman switch







Fig.3.5 (89) SRVO-274 NTED1 status abnormal a,b / SRVO-275 NTED2 status abnormal a,b

CRM65
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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(90) SRVO-277 Panel E-stop(SVEMG abnormal)
(Explanation) The emergency stop line was not disconnected
although the emergency stop button on the
operator's panel was pressed.
(Action 1) Replace the panel board.
(Action 2) Replace the E-stop unit
(Action 3) Replace the servo amplifier.


Servo amplifier
E-stop unit

(A-cabinet)


Servo amplifier
E-stop unit
Panel board

(B-cabinet)


Fig.3.5 (90) SRVO-277 Panel E-stop(SVEMG abnormal)

Panel board
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 131 -
(91) SRVO-278 TP E-stop(SVEMG abnormal)
(Explanation) The emergency stop line was not disconnected
although the emergency stop button on the
operator's panel was pressed.
(Action 1) Replace the teach pendant.
(Action 2) Replace the teach pendant cable.
(Action 3) Replace the panel board.
(Action 4) Replace the E-stop unit
(Action 5) Replace the servo amplifier.

NOTE
This alarm may be issued if the emergency stop
button is pressed very slowly.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 132 -


Servo amplifier
E-stop unit

(A-cabinet)

Servo amplifier
E-stop unit
Panel board
EMERGENCY
STOP button
Teach pendant

Fig.3.5 (91) SRVO-278 TP E-stop(SVEMG abnormal)

Panel board
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

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(92) SRVO-280 SVOFF input
(Explanation) The external contact connected to EGS1-EGS11 or
EGS2-EGS21 of the terminal block TBOP4 on the
panel board is open.
(Action 1) If external circuitry is connected to EGS1-EGS11
or EGS2-EGS21 of the terminal block TBOP4 on
the panel board, check the external circuitry.
(Action 2) If this signal is not used, make a connection
between EGS1 and EGS11 and between EGS2 and
EGS21 of the terminal block TBOP4 on the panel
board.
(Action 3) Replace the panel board.


Panel board

(A-cabinet) (B-cabinet)

Panel board
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 134 -






Fig.3.5 (92) SRVO-280 SVOFF input

WARNING
In a system using the SVOFF signal, it is very
dangerous to disable the signal when a connection
is made between EGS1 and EGS11 and between
EGS2 and EGS21 of TBOP4. Never make such
an attempt. If a temporary connection is needed
for operation, separate safety measures must be
taken.

EGS1
EGS11
EGS2
EGS22
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 135 -
(93) SRVO-281 SVOFF input (SVEMG abnormal)
(Explanation) The emergency stop line was not disconnected
although the contact connected between EGS1 and
EGS11 or between EGS2 and EGS21 of the
terminal block TBOP4 on the panel board was
open. The emergency stop circuit is faulty.
(Action 1) Check the switch and cable connected to
EGS1-EGS11and EGS2-EGS21 on TBOP4. If
the cable are abnormal replace it.
(Action 2) Replace the panel board.
(Action 3) Replace the E-stop unit.
(Action 4) Replace the servo amplifier.
(Action 5) Replace the connection cable between the panel
board and the E-stop unit.


Servo amplifier
E-stop unit

(A-cabinet)

Servo amplifier
E-stop unit
Panel board

(B-cabinet)

Panel board
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 136 -







Fig.3.5 (93) SRVO-281 SVOFF input (SVEMG abnormal)

(94) SRVO-291 IPM over heat (G:i A:j)
(Explanation) IPM on the servo amplifier is overheated.
(Action 1) Check whether the fan for cabinet ventilation is
stopped and also check whether the vent hole is
clogged. If necessary, clean or replace them.
(Action 2) If SRVO-291 is issued when the robot operating
condition is severe, check the robot operating
condition then relax the condition when possible.
(Action 3) If SRVO-291 is issued frequently, replace the
servo amplifier.

EGS1
EGS11
EGS2
EGS22
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 137 -

Servo amplifier

A-cabinet (Front)


External air fan


External air fan

Side fan type Rear fan type
A-cabinet (Back)
Servo amplifier

External air fan

B-cabinet (Front) B-cabinet (Back)
Fig.3.5 (94) SRVO-291 IPM over heat (G:i A:j)
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 138 -
(95) SRVO-300 Hand broken/HBK disabled
SRVO-302 Set Hand broken to ENABLE
(Explanation) Although HBK was disabled, the HBK signal was
input.
(Action 1) Press RESET on the teach pendant to release the
alarm.
(Action 2) Check whether the hand broken signal is connected
to the robot. When the hand broken signal circuit
is connected, enable hand broken.
(See Subsection 5.5.3 in Part III,
CONNECTIONS.)


(96) SRVO-335 DCS OFFCHK alarm a,b
(Explanation) A failure was detected in the safety signal input
circuit.
(Action) Replace the panel board.


Panel board

(A-cabinet) (B-cabinet)

Fig.3.5 (96) SRVO-335 DCS OFFCHK alarm a,b

(97) SRVO-348 DCS MCC OFF alarm a,b
(Explanation) A command was issued to turn off the magnetic
contactor, but the magnetic contactor was not
turned off.
(Action 1) Replace the E-stop unit.
(Action 2) Replace the panel board.
(Action 3) If a signal is connected to the emergency stop unit
CRM72, check whether there is a problem in the
connection destination.

Panel board
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 139 -
(98) SRVO-349 DCS MCC ON alarm a,b
(Explanation) A command was issued to turn on the magnetic
contactor, but the magnetic contactor was not
turned on.
(Action 1) Replace the E-stop unit.
(Action 2) Replace the panel board.
(Action 3) Replace the servo amplifier.


Servo amplifier
E-stop unit

(A-cabinet)

Servo amplifier
E-stop unit
Panel board


Fig.3.5 (98) 348 DCS MCC OFF alarm a,b / 349 DCS MCC ON alarm a,b

Panel board
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 140 -
(99) SRVO-370 SVON1 status abnormal a,b
SRVO-371 SVON2 status abnormal a,b
(Explanation) A chain alarm was detected with the panel board
internal signal (SVON).
(Action) Replace the panel board.

CAUTION
1 For the procedure of recovery from this alarm, see
the descriptions of SRVO-230 and SRVO-231.
2 If this alarm is issued, do not reset the chain error
alarm until the failure is checked and corrected. If
robot use is continued with one of the duplicate
circuits being faulty, safety may not be guaranteed
when the other circuit fails.


Panel board

(A-cabinet) (B-cabinet)

Fig.3.5 (99) SRVO-370 SVON1 status abnormal a,b / SRVO-371 SVON2 status abnormal a,b

Panel board
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 141 -
(100)SRVO-372 OPEMG1 status abnormal a,b
(Explanation) A chain alarm was detected with the emergency
stop switch on the operator's panel.
(Action 1) Replace the panel board.
(Action 2) Replace the teach pendant cable.
(Action 3) Replace the teach pendant.
(Action 4) Replace the emergency stop button on the
operator's panel.

CAUTION
1 For the procedure of recovery from this alarm, see
the descriptions of SRVO-230 and SRVO-231.
2 If this alarm is issued, do not reset the chain error
alarm until the failure is checked and corrected. If
robot use is continued with one of the duplicate
circuits being faulty, safety may not be guaranteed
when the other circuit fails.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 142 -




(A-cabinet)


Panel board
EMERGENCY STOP button
Teach pendant
(B-cabinet)

Fig.3.5 (100) SRVO-372 OPEMG1 status abnormal a,b / SRVO-373 OPEMG2 status abnormal a,b

Panel board
Emergency
stop button
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 143 -
(101)SRVO-374 MODE11 status abnormal a,b
SRVO-375 MODE12 status abnormal a,b
SRVO-376 MODE21 status abnormal a,b
SRVO-377 MODE22 status abnormal a,b
(Explanation) A chain alarm was detected with the mode switch
signal.
(Action 1) Check the mode switch and its cable. Replace
them if a defect is found.
(Action 2) Replace the panel board.

CAUTION
1 For the procedure of recovery from this alarm, see
the descriptions of SRVO-230 and SRVO-231.
2 If this alarm is issued, do not reset the chain error
alarm until the failure is checked and corrected. If
robot use is continued with one of the duplicate
circuits being faulty, safety may not be guaranteed
when the other circuit fails.


3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 144 -



(A-cabinet)



Panel board
Mode switch

(B-cabinet)

Fig.3.5 (101) SRVO-374 MODE11 status abnormal a,b / SRVO-375 MODE12 status abnormal a,b /
SRVO-376 MODE21 status abnormal a,b / SRVO-377 MODE22 status abnormal a,b

Panel board Mode switch
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 145 -
(102)SRVO-378 OPSFTY11 status abnormal a,b
SRVO-379 OPSFTY12 status abnormal a,b
SRVO-380 OPSFTY21 status abnormal a,b
SRVO-381 OPSFTY22 status abnormal a,b
SRVO-382 OPSFTY31 status abnormal a,b
SRVO-383 OPSFTY32 status abnormal a,b
SRVO-384 OPSFTY41 status abnormal a,b
SRVO-385 OPSFTY42 status abnormal a,b
(Explanation) A chain alarm was detected with the OPSFTY
signal.
(Action 1) Check whether the circuitry connected to the dual
input signal (OPSFTY) is faulty.
(Action 2) Check whether the timing of the dual input signal
(OPSFTY) satisfies the timing specification
(See Section 3.2.5, Table 3.2.5 of Part III
CONNECTION).
(Action 3) Replace the panel board.

CAUTION
1 For the procedure of recovery from this alarm, see
the descriptions of SRVO-230 and SRVO-231.
2 If this alarm is issued, do not reset the chain error
alarm until the failure is checked and corrected. If
robot use is continued with one of the duplicate
circuits being faulty, safety may not be guaranteed
when the other circuit fails.



Fig.3.5 (102) SRVO-378 OPSFTY11 status abnormal a,b / SRVO-379 OPSFTY12 status abnormal a,b /
SRVO-380 OPSFTY21 status abnormal a,b / SRVO-381 OPSFTY22 status abnormal a,b /
SRVO-382 OPSFTY31 status abnormal a,b / SRVO-383 OPSFTY32 status abnormal a,b /
SRVO-384 OPSFTY41 status abnormal a,b / SRVO-385 OPSFTY42 status abnormal a,b
CRMA8
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 146 -
3.6 FUSE-BASED TROUBLESHOOTING

This section describes the alarms and symptoms generated and actions
required when the fuses installed on the printed circuit boards and
units have blown.

(1) When the fuses of the power supply unit have blown
F1: Fuse for AC input
F3: Fuse for +24 E
F4: Fuse for +24 V

Name Symptom observed when fuse has blown Action
F1 The LED (PIL: Green) of the power supply unit does
not light, and the power cannot be turned on.
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 power supply unit.
F3 If the fuse blows when the power supply is turned
on, an alarm such as for overtravel, hand breakage,
FSSB disconnect, LVAL is output on the teach
pendant.
If the fuse turns out to have already blown when the
power supply is turned on, the FSSB initialization
alarm is displayed on the teach pendant.
1 Check the printed circuit boards, units, servo
amplifier, and cables using +24 E according to the
power supply system diagram. Replace a faulty
printed circuit board, unit, servo amplifier or cable
if any.
2 Replace the power supply unit.
F4 The power, when turned on, is immediately turned
off. At this time, the LED (ALM: Red) lights.
1 Check the printed circuit boards, units, and cables
using +24 V according to the power supply system
diagram. Replace a faulty printed circuit board,
unit, or cable if any. The LED of ALM is turned
off by pressing the OFF button once.
2 Replace the power supply unit.

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 147 -



(A-cabinet)


Servo amplifier
Power supply unit

F3(7.5A): Fuse for +24E
F47.5A: Fuse for +24V
PIL: LED (green)
F1(8.0A): Fuse for AC input
ALM: LED (red)

(B-cabinet) (Power supply unit)

Servo amplifier
Power supply unit
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 148 -
(2) Main board fuse
FU1: For protection of the +12V output for the vision sensor
(This fuse is mounted on the mainboard of the total edition
06B after.)

Name Symptom observed when fuse has blown Action
FU1 +12V is not output. 1 Check +12V used by the vision sensor for a ground fault.
2 Check the vision sensor and the connection cable.
3 Replace the main board.



75173 (Receiver)
75172 (Driver)
CPU card
FROM/SRAM module
(Behind the axis control card)
Axis control card
FU1 Fuse(0.5A)
(Total edition 06B after)

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 149 -
(3) Servo amplifier fuse
FS1: For generation of the power to the amplifier control circuit
FS2: For protection of the 24V output to the end effector, ROT,
and HBK
FS3: For protection of the 24V output to the regenerative
resistance and the additional axis amplifier

Name Symptom observed when fuse has blown Action
FS1 All LEDs on the servo amplifier go out.
The FSSB disconnection or initialization
alarm is displayed on the teach pendant.
Replace the servo amplifier.
FS2 The Fuse Blown (Amp) alarm (SRVO-214),
Hand broken (SRVO-006), and ROBOT
OVER TRAVEL are displayed on the teach
pendant.
1 Check +24VF used by the end effector for a ground fault.
2 Check the robot connection cable and the robots internal
cable.
3 Replace the servo amplifier.
FS3 The Fuse Blown (Amp) alarm (SRVO-214)
and DCAL are displayed on the teach
pendant.
1 Check the regenerative resistance, and replace it if
required.
2 Check the additional axis amplifier and its wiring, and
replace them if required.
3 Replace the servo amplifier.


5A
3.2A
3.2A


CRR88
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 150 -
(4) Panel board fuses
FUSE1: For +24EXT line (emergency stop line) protection
FUSE2: For protection of the teach pendant emergency stop line

Name Symptom observed when fuse has blown Action
FUSE1 The teach pendant displays external
emergency stop, fence open, or SVOFF input
fuse blown (panel PCB).
1 If an alarm is issued when the fuse has not blown, check
the voltages of EXT24V and EXT0V (TBOP6). If
external 24V or 0V is not used, check the jumper pin
between EXT24V and INT24V or between EXT0V and
INT0V.
2 Check the +24EXT line (emergency stop line) for a short
circuit or connection to ground.
3 Replace the panel board.
FUSE2 The display on the teach pendant disappears. 1 Check the teach pendant cable for a fault, and replace it
if required.
2 Check the teach pendant for a fault, and replace it if
required.
3 Replace the panel board.



B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 151 -
(5) Fuse on the process I/O printed circuit board
FUSE1: Fuse for +24E

Name Symptom observed when fuse has blown Action
FUSE1 The LED (ALM-2 or FALM) on the process I/O
printed circuit board lights, and an alarm such as
IMSTP input is output on the teach pendant.
(The display data depends on state of peripheral
equipment connection.)
1 Check if the cables and peripheral equipment
connected to the process I/O printed circuit board are
normal.
2 Replace the process I/O printed circuit board.

Process I/O board CA


Process I/O board EA, EB
Fuse location is common to EA and EB.The following is figure of EA.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 152 -
Process I/O board FA

Process I/O board GA

Process I/O board HA


B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 153 -
Process I/O board JA, JB
Fuse location is common to JA and JB.The following is figure of JA.

Process I/O JA

Process I/O board KA, KB, KC
Fuse location is common to KA, KB and KC. The following is figure of KA.
FUSE1
LED

Process I/O KA


3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 154 -
3.7 TROUBLESHOOTING BASED ON LED INDICATIONS

The printed circuit boards and servo amplifier are provided with alarm
LEDs and status LEDs. The LED status and corresponding
troubleshooting procedures are described below.


Servo amplifier
Main board Power supply unit

(A-cabinet)

Servo amplifier
Panel board
Optional slot Main board Power supply unit

(B-cabinet)
Panel board
Process I/O
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 155 -
TROUBLESHOOTING USING THE LEDS ON THE MAIN BOARD
(1) Troubleshooting using the status display LED
To troubleshoot an alarm that arises before the teach pendant is
ready to display, check the status LEDs (green) on the main
board at power-on. After power-on, the LEDs light as
described in steps 1 to end, in the order described. If an alarm
is detected, the step in which the alarm occurred can be
determined from which LEDs are lit.

Step LED Action to be taken
1: After power-on, all
LEDs are lit.


[Action1] Replace the CPU card.
* [Action2] Replace the main board.
2: Software operation
start-up.

[Action1] Replace the CPU card.
* [Action2] Replace the main board.
3: The initialization of
dram on the CPU
card is completed.


[Action1] Replace the CPU card.
* [Action2] Replace the main board.
4: The initialization of
DPRAM on the
communication IC is
completed.


[Action1] Replace the CPU card.
* [Action2] Replace the main board.
* [Action3] Replace the FROM/SRAM module.
5: The initialization of
the communication IC
is completed.


[Action1] Replace the CPU card.
* [Action2] Replace the main board.
* [Action3] Replace the FROM/SRAM module.
6: The loading of the
basic software is
completed.


* [Action1] Replace the main board.
* [Action2] Replace the FROM/SRAM module.
7: Basic software
start-up.


* [Action1] Replace the main board.
* [Action2] Replace the FROM/SRAM module.
8: Start-up of
communication with
the teach pendant.


* [Action1] Replace the main board.
* [Action2] Replace the FROM/SRAM module.
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 156 -
Step LED Action to be taken
9: The loading of
optional software is
completed.


* [Action1] Replace the main board.
[Action2] Replace the process I/O board.
10: DI/DO initialization


* [Action1] Replace the FROM/SRAM module.
* [Action2] Replace the main board.
11: The preparation of
the SRAM module is
completed.


[Action1] Replace the axis control card.
* [Action2] Replace the main board.
[Action3] Replace the servo amplifier.
12: Axis control card
initialization


[Action1] Replace the axis control card.
* [Action2] Replace the main board.
[Action3] Replace the servo amplifier.
13: Calibration is
completed.


[Action1] Replace the axis control card.
* [Action2] Replace the main board.
[Action3] Replace the servo amplifier.
14: Start-up of power
application for the
servo system


* [Action1] Replace the main board.
15: Program execution


* [Action1] Replace the main board.
[Action2] Replace the process I/O board.
16: DI/DO output start-up.


* [Action1] Replace the main board.
17: Initialization is
terminated.


Initialization has ended normally.
18: Normal status


Status LEDs 1 and 2 blink when the system is operating
normally.
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 157 -
* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will
be lost. Before you replace the unit, therefore, make a backup copy of the data.
If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.

CPU card
FROM/SRAM module
Axis control card


3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 158 -
(2) TROUBLESHOOTING BY 7-SEGMENT LED INDICATOR

7-segment LED
indicator
Description


[Description] A parity alarm condition has occurred in DRAM on the CPU card installed on the
main board.
[Action1] Replace the CPU card.
* [Action2] Replace the main board.


[Description] A parity alarm condition has occurred in SRAM on the FROM/SRAM module
installed on the main board.
[Action1] Replace the FROM/SRAM module.
* [Action2] Replace the main board.


[Description] A bus error has occurred in the communication controller.
* [Action] Replace the main board.


[Description] A parity alarm condition has occurred in DRAM controlled by the communication
controller.
* [Action] Replace the main board.


[Description] A servo alarm condition has occurred on the main board.
[Action1] Replace the axis control card.
* [Action2] Replace the main board.


[Description] The SYSEMG alarm has occurred.
[Action1] Replace the axis control card.
[Action2] Replace the CPU card.
* [Action3] Replace the main board.


[Description] The SYSFAIL alarm has occurred.
[Action1] Replace the axis control card.
[Action2] Replace the CPU card.
* [Action3] Replace the main board.


[Description] 5V is supplied to Main board. Above alarms do not occur.

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified
data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.
If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.


B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

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Troubleshooting by LEDs on power supply unit

LED indication Failure description and required measure


[Description] When ALM LED (red) turned on, power supply alarm has occurred.
[Action1] Check fuse F4 (+24V) on the power supply unit, and replace it if it has
blown.
[Action2] Check the printed-circuit boards powered by the DC power supplies (+5V,
15V, and +24V), the relevant units, and cables, and replace them if
defective.
[Action3] Replace the power supply unit.


[Description] If the PIL LED (Green) does not light, the power supply unit has not been
supplied with 200 VAC.
[Action1] Check fuse F1 on the power supply unit, and replace it if it has blown.
For detailed causes of fuse blown out, please refer to section 3.6.
[Action2] Replace the power supply unit.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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F1 (8.0A) : Fuse for AC input
F3 (7.5A) : Fuse for +24E
F4 (7.5A) : Fuse for +24V
PIL : LED (green)
ALM :LED (red)

(Power supply unit)

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

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Troubleshooting by LED on the panel board
- A20B-2101-0370

LED indication Failure description and required measure
ALM1
ALM2
[Description] When the ALM1 and ALM2 (red) tourned on, communication with the main
board does not execute.
[Action1] Check the communication cable between the main and panel boards, and
replace it if necessary.
[Action2] Replace the main board.
[Action3] Replace the panel board.
5V [Description] When the LED does not light. The power supply inside the panel board
does not generate +5 V normally.
[Action1] Check the CRM96 connector and check that 24 V is supplied.
[Action2] Replace the panel board.

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified
data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.
If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.



(Panel board)

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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Troubleshooting by alarm LEDs on the process I/O printed circuit board

LED Description and action to be taken
Process I/O
CA/HA/JA/JB
Process I/O
EA/EB/FA/GA/KA/KB/KC

ALM0
FALM

[Description] A communication alarm occurred between the main
CPU PC board and process I/O PC board.
[Action1] Replace the process I/O PC board.
* [Action2] Replace the main CPU PC board.
[Action3] Replace the I/O link connection cable.
Process I/O
CA/HA/JA/JB
Process I/O
EA/EB/FA/GA/KA/KB/KC

ALM0
FALM

[Description] A fuse on the process I/O PC board is blown.
[Action1] Replace the blown fuse on the process I/O PC board.
[Action2] Examine the cables and peripheral devices connected
to the process I/O PC board.
Replace any failed components.
[Action3] Replace the process I/O PC board.


Fuse
Process I/O CA/HA
Fuse
Process I/O EA/EB/FA/GA/KA/KB/KC

Fuse specification: A60L-0001-0046#2.0



B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

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Process I/O JA/JB

Fuse specification: A60L-0001-0046#2.0

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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Troubleshooting by LEDs on servo amplifier
The servo amplifier has alarm LEDs. Troubleshoot the alarm
indicated by the LEDs, referring also to the alarm indication on the
teach pendant.

Check that the voltage is not higher than 50V.


CAUTION
Before touching the servo amplifier, check the DC
link voltage with the screws located above the LED
"D7". By using a DC voltage tester, check that the
voltage is 50 V or less.

LED Color Description
P5V Green Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V
normally.
If the LED does not light:
[Measure 1] Check the robot connection cable (RP1) to see if there is a ground fault in the
+5V wire.
[Measure 2] Replace the servo amplifier.
P3.3V Green Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V
normally.
If the LED does not light:
[Measure] Replace the servo amplifier.
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

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LED Color Description
SVEMG Red Lights when an emergency stop signal is input to the servo amplifier.
If the LED lights when the machine is not at an emergency stop:
[Measure] Replace the servo amplifier.
If the LED does light when the machine is at an emergency stop:
[Measure] Replace the servo amplifier.
ALM Red Lights when the servo amplifier detects an alarm.
If the LED lights when there is no alarm condition in the machine:
[Measure] Replace the servo amplifier.
If the LED does not light when there is an alarm condition in the machine:
[Measure] Replace the servo amplifier.
DRDY Green Lights when the servo amplifier is ready to drive the servo motor.
If the LED does not light when the motor is activated:
[Measure] Replace the servo amplifier.
OPEN Green Lights when the communication between the servo amplifier and the main board is normal.
If the LED does not light:
[Measure 1] Check for the connection of the FSSB optical cable.
[Measure 2] Replace the servo card.
[Measure 3] Replace the servo amplifier.
D7 Red Lights when the DCLINK circuit inside the servo amplifier is charged to reach the specified
voltage.
If the LED does not light after pre-charge is finished:
[Measure 1] It is likely that the DC Link may be short-circuited. Check for connection.
[Measure 2] It is likely that the charge current control resistor may be defective. Replace the
emergency stop unit.
[Measure 3] Replace the servo amplifier.

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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3.8 POSITION DEVIATION FOUND IN RETURN TO THE
REFERENCE POSITION (POSITIONING)

(Check 1) On the status screen, check the position deviation in the
stopped state. To display the position deviation, press the
screen selection key, and select STATUS from the menu.
Press F1, [TYPE], select AXIS from the menu, then press
the F4, PULSE.
(Corrective action)
Correct the parameters related to return to the reference
position (positioning).
(Check 2) Check whether the motor axis can be positioned normally.
(Corrective action)
If the motor axis can be positioned normally, check the
mechanical unit.
(Check 3) Check the mechanical unit for backlash.
(Corrective action)
Replace a faulty key of motor shaft or other faulty parts.
(Check 4) If checks 1 to 3 show normal results
(Corrective action)
Replace the pulse coder and main board.

* If the main board or FROM/SRAM module is replaced, the
contents of memory (parameters, specified data, etc.) will be lost.
Before you replace the unit, therefore, make a backup copy of the
data.
B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

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3.9 MANUAL OPERATION IMPOSSIBLE

The following explains checking and corrective action required if the
robot cannot be operated manually after the controller is turned on:

(1) Check and corrective action to be made if manual operation is
impossible
(Check 1) Check whether the teach pendant is enabled.
(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 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 (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.
3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

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(Check 2) Check whether the HOLD signal for the
peripheral-device control interface is on. Also check
whether the HOLD lamp on the teach pendant is on.
(Corrective action)
If the HOLD signal of the peripheral device control
interface is on, turn it off.
(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.

B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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4 PRINTED CIRCUIT BOARDS

The printed circuit boards are factory-set for operation. Usually, you
do not need to set or adjust them. This chapter describes the standard
settings and adjustment required if a defective printed circuit board is
replaced. It also describes the test pins and the LED indications.
The control unit printed circuit board includes the main unit printed
circuit board and one or more cards or modules installed horizontally
to the main-unit printed-circuit board.
These PC boards have interface connectors, LED indicators, and a
plastic panel at the front. At the rear, there is a backplane connector.

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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4.1 MAIN BOARD (A16B-3200-0600, -0601)


75173 (Receiver)
75172 (Driver)
CPU card
FROM/SRAM module
(Behind the axis control card)
Axis control card
FU1 Fuse(0.5A)
(Total edition 06B after)


Fig.4.1 Main board

Name Ordering Specification Board Specification Note
A05B-2500-H001 A16B-3200-0600 Main board
A05B-2500-H002 A16B-3200-0601 With force sensor I/F
CPU card A05B-2500-H020 A20B-3400-0020 SDRAM 32M
A05B-2500-H040 A20B-3300-0448 8-axis
A05B-2500-H041 A20B-3300-0447 12-axis
Axis control card
A05B-2500-H042 A20B-3300-0442 16-axis
A05B-2500-H060 A20B-3900-0163
A20B-3900-0223
FROM 32M/ SRAM 1M
A05B-2500-H061 A20B-3900-0164
A20B-3900-0224
FROM 32M/ SRAM 2M
A05B-2500-H062 A20B-3900-0165
A20B-3900-0225
FROM 32M/ SRAM 3M
A05B-2500-H063 A20B-3900-0166
A20B-3900-0226
FROM 64M/ SRAM 1M
FROM/SRAM module
A05B-2500-H064 A20B-3900-0167
A20B-3900-0227
FROM 64M/ SRAM 2M
B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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(1) Test pins

Name Use
GND1
GND2
GND3
CACHOFF
LOAD
For testing the printed circuit board

(2) LEDs

Seven segment
LED
Description


A parity alarm occurred in a DRAM of the CPU card on
the main board.


A parity alarm occurred in a SRAM of the FROM/SRAM
module on the main board.


Bus error occurred on the communication controller.


A parity alarm occurred in DRAM controlled by
communication controller.


A servo alarm occurred on the main board.


SYSEMG occurred.


SYSFAIL occurred.


5V is supplied to Mainboard.
Above 0-7 alarms do not occur.

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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Status LED Description
Operating status of the system.

ETHERNET LED Color Description
TX Green Flashes during data transmission.
L/RX
Green
Lights when a link is established, and blinks
when data is received.




(3) Communication IC
If the teach pendant cannot display anything because of, for
example, a broken wire in the teach pendant connection cable, it
is likely that the communication driver or receiver may be
defective.

Name Drawing number
75172 (Driver) A76L-0151-0098
75173 (Receiver) A76L-0151-0099

Please refer to Fig.4.1.

B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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4.2 EMERGENCY STOP CONTROL BOARD (A20B-1008-0740)


Fig.4.2 Emergency stop control board

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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4.3 BACKPLANE BOARD

(A20B-2003-0890)

Fig.4.3 (a) Backplane Board (A20B-2003-0890)

(1) Test pins

Name Use
HIGH
TEST
LOW
For testing the printed circuit board

B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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(A20B-2004-0040)

Fig.4.3 (b) Backplane board (A20B-2004-0040)

(1) Test pins

Name Use
HIGH
TEST
LOW
For testing the printed circuit board


4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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4.4 PANEL BOARD (A20B-2101-0370)


Fig.4.4 Panel Board

(1) Meanings of LEDs

Name Color Use
5V Green Lights when +5 V is output normally from the internal
power supply of the panel board.
ALM1
ALM2
Red Lights when communication with the main board is
interrupted.

B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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4.5 PROCESS I/O BOARD CA (A16B-2201-0470)


Fig. 4.6 Process I/O Board CA
(1) Test pins

Name Use
P24V
P5V
P15VC
M15VC
GND1
GND2
+24V
+5V
+15V
-15V
GND
GND
For measuring the DC supply voltage
P10V +10V
For measuring the reference voltage of the
digital/analog converter
P15VF
M15VF
GNDF
+15V
-15V
GND
Power for the digital/analog converter
AI1
AI2
AI3
AI4
AI5
AI6
Channel 1
Channel 2
Channel 3
Channel 4
Channel 5
Channel 6
For measuring the ovltage of the analog input
signal (analog/digital)
AOUT1
AOUT2
Channel 1
Channel 2
For measuring the voltage of the analog output
signal (digital/analog)

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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(2) Setting

Name Standard
setting
Description
ICOM1 UDI1 to UDI20
(Connector CRM2A)
ICOM2 UDI21 to UDI40
(Connector CRM2B)
ICOM3 WI01 to WI08
(Connector CRW1)
Side A Set this jumper according to the
common voltage of input
devices.
Side A : +24V common
SideB : 0V common
SP1 Channel 1
SP2 Channel 2
Open The polarity of the output
voltage is switched to:
Strapped: Negative (-)
Open : Positive (+)

(3) Adjustment

VR1: Adjust the gain of channel 1.
Execute a robot program and set AOUT[1] to 4095 on the teach
pendant. Connect a digital voltmeter to test pin AOUT1 and
rotate VR1 until the meter reads 12.0V.
Connect the negative (-) lead of the digital voltmeter to test pin
GNDF. (The GNDF test pin is different from the common GND
test pin.)
VR2: Adjust the gain of channel 2.
Execute a robot program and set AOUT[2] to 4095 on the teach
pendant. Connect the digital voltmeter to test pin AOUT2 and
rotate VR2 until the meter reads 12.0V.
Connect the negative (-) lead of the digital voltmeter to test pin
GNDF. (The GNDF test pin is different from the common GND
test pin.)
VR3: Adjust the reference supply voltage of the digital/analog
converter.
Connect the digital voltmeter to test pin P10V and rotate VR3
until the meter reads 10.00.1V.

(4) LEDs

Color Description

Red
A communication alarm
occurred between the main
CPU and process input/output.

Red
A fuse (FUSE 1) in the
process input/output blew.


B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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(5) Correspondence between driver IC and DO signals
Ordering code for the driver IC: A76L-0151-0062

Driver IC DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 DO01, DO02, DO03, DO04
DV7 DO05, DO06, DO07, DO08
DV8 DO09, DO10, DO11, DO12
DV9 DO13, DO14, DO15, DO16
DV10 DO17, DO18, DO19, DO20
DV11 WO01, WO02, WO03, WO04
DV12 WO05, WO06, WO07, WO08
RESERVED For replacement

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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4.6 PROCESS I/O BOARD EA (A16B-3200-0230)


Fig. 4.6 Process I/O Board EA

(1) Test pins

Name Use
P24V
P5V
P15VC
M15VC
GND1
GND2
+24V
+5V
+15V
-15V
GND
GND
For measuring the DC supply voltage
P10V +10V
For measuring the reference voltage of the
digital/analog converter
P15VF
M15VF
GNDF
+15V
-15V
GND
For measuring power for the digital/analog
converter
AI1
AI2
AI3
AI4
AI5
AI6
Channel 1
Channel 2
Channel 3
Channel 4
Channel 5
Channel 6
For measuring the ovltage of the analog input
signal (analog/digital)
AOUT1
AOUT2
Channel 1
Channel 2
For measuring the voltage of the analog output
signal (digital/analog)

B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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(2) Setting

Name Standard
setting
Description
ICOM1 UDI1 to UDI20
(Connector CRM2A)
ICOM2 UDI21 to UDI40
(Connector CRM2B)
ICOM3 WI01 to WI08
(Connector CRW1)
Side A Set this jumper according to the
common voltage of input
devices.
Side A : +24V common
SideB : 0V common
SP1 Channel 1
SP2 Channel 2
Open Output voltage is adjusted to:
Short : Output voltage minus (-)
Open : Output voltage plus(+)

(3) Adjustment

VR1: Adjust the gain of channel 1.
Execute a robot program and set AOUT[1] to 4095 on the teach
pendant. Connect a digital voltmeter to test pin AOUT1 and
rotate VR1 until the meter reads 12.0V.
Connect the negative (-) lead of the digital voltmeter to test pin
GNDF. (The GNDF test pin is different from the common GND
test pin.)
VR2: Adjust the gain of channel 2.
Execute a robot program and set AOUT[2] to 4095 on the teach
pendant. Connect the digital voltmeter to test pin AOUT2 and
rotate VR2 until the meter reads 12.0V.
Connect the negative (-) lead of the digital voltmeter to test pin
GNDF. (The GNDF test pin is different from the common GND
test pin.)
VR3: Adjust the standard voltage for the digital/analog converter.
Connect the digital voltmeter to test pin P10V and rotate VR3
until the meter reads 10.00.1V
VR4, VR5: Adjust the internal power supply
This volume is adjusting the internal power supplu.
Adjusting when shipping from the factory, so you need not to
adjust.

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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(4) LEDs

Color Description

Red
A communication alarm occurred
between the main CPU and process
I/O board.
Red
A fuse (FUSE 1) in the process I/O
board blew.


(5) Correspondence between driver IC and DO signals
Ordering code for the driver IC: A76L-0151-0062

Driver IC DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 DO01, DO02, DO03, DO04
DV7 DO05, DO06, DO07, DO08
DV8 DO09, DO10, DO11, DO12
DV9 DO13, DO14, DO15, DO16
DV10 DO17, DO18, DO19, DO20
DV11 WO01, WO02, WO03, WO04
DV12 WO05, WO06, WO07, WO08


B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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4.7 PROCESS I/O BOARD EB (A16B-3200-0231)


Fig. 4.7 PROCESS I/O BOARD EB (A16B-3200-0231)

(1) Test pins

Name Use
P24V
P5V
GND1
GND2
+24V
+5V
GND
GND
For measuring the DC supply voltage

(2) Setting

Name Standard
setting
Description
ICOM1 UDI1 to UDI20
(Connector CRM2A)
ICOM2 UDI21 to UDI40
(Connector CRM2B)
Side A Set this jumper according to the
common voltage of input
devices.
Side A : +24V common
SideB : 0V common

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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(3) LEDs

Color Description

Red
A communication alarm occurred
between the main CPU and
process I/O board.
Red
A fuse (FUSE 1) in the process
I/O board blew.

(4) Correspondence between driver IC and DO signals
Ordering code for the driver IC: A76L-0151-0062

Driver IC DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 DO01, DO02, DO03, DO04
DV7 DO05, DO06, DO07, DO08
DV8 DO09, DO10, DO11, DO12
DV9 DO13, DO14, DO15, DO16
DV10 DO17, DO18, DO19, DO20



B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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4.8 PROCESS I/O BOARD FA (A16B-3200-0420)


Fig. 4.8 Process I/O Board FA

(1) Test pins

Name Use
P24V
P5V
GND1
GND2
+24V
+5V
GND
GND
For measuring the DC supply voltage

(2) Setting

Name Standard
setting
Description
ICOM1 UDI1 to UDI20
(Connector CRM2A)
ICOM2 UDI21 to UDI40
(Connector CRM2B)
ICOM3 UDI41 to UDI60
(Connector CRM2C)
ICOM4 UDI61 to UDI80
(Connector CRM2D)
ICOM5 UDI81 to UDI88
(Connector CRM4A)
ICOM6 UDI89 to UDI96
(Connector CRM4B)
Side A
Set this jumper according to the
common voltage of input
devices.
Side A : +24V common
SideB : 0V common

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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(3) LEDs

Color Description

Red
A communication alarm occurred
between the main CPU and
process I/O board.
Red
A fuse (FUSE 1) in the process
I/O board blew.

(4) Correspondence between driver IC and DO signals
Ordering code for the driver IC: A76L-0151-0062

Driver IC DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 DO01, DO02, DO03, DO04
DV7 DO05, DO06, DO07, DO08
DV8 DO09, DO10, DO11, DO12
DV9 DO13, DO14, DO15, DO16
DV10 DO17, DO18, DO19, DO20
DV11 DO21, DO22, DO23, DO24
DV12 DO25, DO26, DO27, DO28
DV13 DO29, DO30, DO31, DO32
DV14 DO33, DO34, DO35, DO36
DV15 DO37, DO38, DO39, DO40
DV16 DO41, DO42, DO43, DO44
DV17 DO45, DO46, DO47, DO48
DV18 DO49, DO50, DO51, DO52
DV19 DO53, DO54, DO55, DO56
DV20 DO57, DO58, DO59, DO60
DV21 DO61, DO62, DO63, DO64
DV22 DO65, DO66, DO67, DO68
DV23 DO69, DO70, DO71, DO72
DV24 DO73, DO74, DO75, DO76




B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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4.9 PROCESS I/O BOARD GA (A16B-2203-0520)



(1) Test pins

Name Use
P24V
P5V
GND1
GND2
GND3
+24V
+5V
GND
GND
GND
For measuring the DC supply voltage
P24VF
P5VF
GNDF
+24V
+5V
GND
Power for the digital/analog converter
AOUT1
AOUT2
Channel 1
Channel 2
For measuring the voltage of the analog output
signal (digital/analog)

(2) Setting

Name Standard
setting
Description
ICOM1 UDI1 to UDI20
(Connector CRM2A)
ICOM2 UDI21 to UDI40
(Connector CRM2B)
ICOM3 WI01 to WI08
(Connector CRW7)
Side A Set this jumper according to the
common voltage of input
devices.
Side A : +24V common
SideB : 0V common

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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(3) Adjustment

VR1/VR2: Adjust the gain and the offset of channel 1.
Execute a robot program and set AOUT[1] to 3413 on the teach
pendant. Connect a digital voltmeter to test pin AOUT1 and
rotate VR1 or VR2 until the meter reads 15.0V.
Connect the negative (-) lead of the digital voltmeter to test pin
GNDF. (The GNDF test pin is different from the common GND
test pin.)
VR3/VR4: Adjust the gain and the offset of channel 2.
Execute a robot program and set AOUT[2] to 3413 on the teach
pendant. Connect the digital voltmeter to test pin AOUT2 and
rotate VR3 or VR4 until the meter reads 15.0V.
Connect the negative (-) lead of the digital voltmeter to test pin
GNDF. (The GNDF test pin is different from the common GND
test pin.)
(4) LEDs

Color Description

Red
A communication alarm occurred
between the main CPU and process
I/O board.
Red
A fuse (FUSE 1) in the process I/O
board blew.

(5) Correspondence between driver IC and DO signals
Ordering code for the driver IC: A76L-0151-0062

Driver IC DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 DO01, DO02, DO03, DO04
DV7 DO05, DO06, DO07, DO08
DV8 DO09, DO10, DO11, DO12
DV9 DO13, DO14, DO15, DO16
DV10 DO17, DO18, DO19, DO20

B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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4.10 PROCESS I/O BOARD HA (A16B-2203-0760)


Fig. 4.10 Process I/O Board HA

(1) Test pins

Name Use
P24V
P5V
GND1
GND2
GND3
+24V
+5V
GND
GND
GND
For measuring the DC supply voltage
P24VF
P5VF
GNDF
+24V
+5V
GND
Power for the digital/analog converter
AO1
AO2
Channel 1
Channel 2
For measuring the voltage of the analog output
signal (digital/analog)

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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(2) Setting

Name Standard
setting
Description
ICOM1 UDI1 to UDI20
(Connector CRM2A)
ICOM2 UDI21 to UDI40
(Connector CRM2B)
ICOM3 WI01 to WI08
(Connector CRW7)
Side A Set this jumper according to the
common voltage of input
devices.
Side A : +24V common
SideB : 0V common

(3) Adjustment

VR1/VR2: Adjust the gain and the offset of channel 1.
Execute a robot program and set AOUT[1] to 3413 on the teach
pendant. Connect a digital voltmeter to test pin AOUT1 and
rotate VR1 or VR2 until the meter reads 15.0V.
Connect the negative (-) lead of the digital voltmeter to test pin
GNDF. (The GNDF test pin is different from the common GND
test pin.)
VR3/VR4: Adjust the gain and the offset of channel 2.
Execute a robot program and set AOUT[2] to 3413 on the teach
pendant. Connect the digital voltmeter to test pin AOUT2 and
rotate VR3 or VR4 until the meter reads 15.0V.
Connect the negative (-) lead of the digital voltmeter to test pin
GNDF. (The GNDF test pin is different from the common GND
test pin.)

(4) LEDs

Color Description

Red
A communication alarm occurred
between the main CPU and process
I/O board.
Red
A fuse (FUSE 1) in the process I/O
board blew.


B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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(5) Correspondence between driver IC and DO signals
Ordering code for the driver IC: A76L-0151-0062

Driver IC DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 DO01, DO02, DO03, DO04
DV7 DO05, DO06, DO07, DO08
DV8 DO09, DO10, DO11, DO12
DV9 DO13, DO14, DO15, DO16
DV10 DO17, DO18, DO19, DO20


4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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4.11 PROCESS I/O BOARD JA (A16B-2204-0010)

ICOM1
ICOM5
GND1
ICOM2
ICOM6
ICOM3
ICOM4
FUSE (2A)
LED

CRMA6A

CRMA6B

TBSRC3

TBSRC1

CRMA5A

CRMA5B
CRMA5C

CRMA5D

TBSRC2

I/O-LK
JD1B

I/O-LK
JD1A
P24V
P5V
GND2

Fig.4.11 Process I/O Board JA

(1) Test pins

Name Use
P24V
P5V
GND1
GND2
+24V
+5V
GND
GND
For measuring the DC supply
voltage

B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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(2) Settings

Name Standard
setting
Description
ICOM1 UDI1 to 20
(Connector CRMA5A)
ICOM2 UDI21 to 40
(Connector CRMA5B)
ICOM3 UDI41 to 60
(Connector CRMA5C)
ICOM4 UDI61 to 80
(Connector CRMA5D)
ICOM5 UDI81 to 88
(Connector CRMA6A)
ICOM6 UDI89 to 96
(Connector CRMA6B)
Side A Set the common voltage
Side A : +24 V common
Side B : 0 V common

(3) LEDs

Color Description





Red
A communication alarm occurred between
the main CPU and process I/O.





Red A fuse (FUSE 1) in the process I/O blew.

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

- 194 -
4.12 PROCESS I/O BOARD JB (A16B-2204-0011)


ICOM1

ICOM2
LED

TBSRC1

CRMA5A

CRMA5B
I/O-LK
JD1B

I/O-LK
JD1A
FUSE (2A)




Fig.4.12 Process I/O Board JB

(1) Test pins

Name Use
P24V
P5V
GND1
GND2
+24V
+5V
GND
GND
For measuring the DC supply
voltage

P5V
P24V
GND1
GND2
B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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(2) Settings

Name Standard
setting
Description
ICOM1 UDI1 to 20
(Connector CRMA5A)
ICOM2 UDI21 to 40
(Connector CRMA5B)
Side A Set the common voltage
Side A : +24 V common
Side B : 0 V common

(3) LEDs

Color Description





Red
A communication alarm occurred between
the main CPU and process I/O.





Red A fuse (FUSE 1) in the process I/O blew.


4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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4.13 PROCESS I/O BOARD KA (A16B-2204-0050)


P24V
P5V
P15V
N15V
GND1
GND2 GND3
GND4
P5VF
P24VF
GNDF
AI1 AI2
VR5
VR6
VR4
VR3
VR2
VR1
AOUT1
AOUT2
AOUT3
ICOM1
ICOM2
ICOM3
LED
DV1
DRV1 DRV2



(1) Meanings of check pins
Name Use
P24V
P5V
P15V
N15V
GND1
GND2
GND3
GND4
24V
5V
15V
15V
GND
GND
GND
GND
For DC power measurement
P5VF
P24VF
GNDF
5V
+24V
GND
D/A converter power supply
AI1
AI2
Channel 1
Channel 2
For analog input signal (A/D) voltage
measurement
AOUT1
AOUT2
AOUT3
Channel 1
Channel 2
Channel 3
For analog output signal (D/A) voltage
measurement

Total edition
B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

- 197 -
(2) Setting
Name Standard
setting
Use
ICOM1 UDI120
connector CRMA5A
ICOM2 UDI2140
connector CRMA5B
ICOM3 WI0108
connector CRW10
Side A For common voltage setting
Side A: +24 V common
Side B: 0 V common

(3) Adjustment
VR1/VR2 Channel 1 gain and offset adjustment
Connect the "+" and "-" terminals of a digital voltmeter,
respectively, to the AOUT1 check pin and the GNDF check
pin (not a general ground point). From the teach pendant,
execute AOUT[1]=3413, using a robot program. While
observing the voltage at the AOUT1 check pin with the
digital voltmeter, adjust potentiometers VR1 and VR2 for
15.0 V.
VR3/VR4 Channel 2 gain and offset adjustment
Connect the "+" and "-" terminals of a digital voltmeter,
respectively, to the AOUT2 check pin and the GNDF check
pin (not a general ground point). From the teach pendant,
execute AOUT[2]=3413, using a robot program. While
observing the voltage at the AOUT2 check pin with the
digital voltmeter, adjust potentiometers VR3 and VR4 for
15.0 V.
VR5/VR6 Channel 3 gain and offset adjustment
Connect the "+" and "-" terminals of a digital voltmeter,
respectively, to the AOUT3 check pin and the GNDF check
pin (not a general ground point). From the teach pendant,
execute AOUT[3]=3413, using a robot program. While
observing the voltage at the AOUT3 check pin with the
digital voltmeter, adjust potentiometers VR5 and VR6 for
15.0 V.

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

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(4) Meaning of LEDs
Color Meaning

Red
A communication alarm occurred between the
main CPU and the process I/O board.

Red
The fuse (FUSE1) on the process I/O board
has blown.

(5) Correspondence between driver ICs and DO signals
Driver IC specification:DRV1, DRV2A76L-1151-0167
DV1A76L-1151-0070
Driver IC name DO signal name
DRV1 CMDENBLSYSRDYPROGRUNPAUSED
HELDFAULTATPERCHTPENBL
BATALMBUSYACK1/SNO1ACK2/SNO2
ACK3/SNO3ACK4/SNO4ACK5/SNO5ACK6/SNO6
DRV2 ACK7/SNO7ACK8/SNO8SNACKRESERVED
DO01 DO02 DO03 DO04
DO05 DO06 DO07 DO08
DO09 DO10 DO11 DO12
DV1 DO13 DO14 DO15 DO16
DO17 DO18 DO19 DO20

B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

- 199 -
4.14 PROCESS I/O BOARD KBA16B-2204-0051


P24V
P5V
GND1
GND2 GND3
GND4
P5VF
P24VF
GNDF
VR4
VR2
VR1
AOUT1
AOUT2
ICOM1
ICOM2
ICOM3
LED
DV1
DRV1 DRV2
VR3

(1) Meanings of check pins
Name Use
P24V
P5V
GND1
GND2
GND3
GND4
24V
5V
GND
GND
GND
GND
For DC power measurement
P5VF
P24VF
GNDF
5V
+24V
GND
D/A converter power supply
AOUT1
AOUT2
Channel 1
Channel 2
For analog output signal (D/A) voltage
measurement

Total edition
4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

- 200 -
(2) Setting
Name Standard
setting
Use
ICOM1 UDI120
(connector CRMA5A)
ICOM2 UDI2140
(connector CRMA5B)
ICOM3 WI0108
(connector CRW10)
Side A For common voltage setting
Side A: +24 V common
Side B: 0 V common

(3) Adjustment
VR1/VR2 Channel 1 gain and offset adjustment
Connect the "+" and "-" terminals of a digital voltmeter,
respectively, to the AOUT1 check pin and the GNDF check
pin (not a general ground point). From the teach pendant,
execute AOUT[1]=3413, using a robot program. While
observing the voltage at the AOUT1 check pin with the
digital voltmeter, adjust potentiometers VR1 and VR2 for
15.0 V.
VR3/VR4 Channel 2 gain and offset adjustment
Connect the "+" and "-" terminals of a digital voltmeter,
respectively, to the AOUT2 check pin and the GNDF check
pin (not a general ground point). From the teach pendant,
execute AOUT[2]=3413, using a robot program. While
observing the voltage at the AOUT2 check pin with the
digital voltmeter, adjust potentiometers VR3 and VR4 for
15.0 V.

B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

- 201 -
(4) Meaning of LEDs
Color Meaning

Red
A communication alarm occurred between the
main CPU and the process I/O board.

Red
The fuse (FUSE1) on the process I/O board
has blown.

(5) Correspondence between driver ICs and DO signals
Driver IC specification:DRV1, DRV2A76L-1151-0167
DV1A76L-1151-0070
Driver IC name DO signal name
DRV1 CMDENBLSYSRDYPROGRUNPAUSED
HELDFAULTATPERCHTPENBL
BATALMBUSYACK1/SNO1ACK2/SNO2
ACK3/SNO3ACK4/SNO4ACK5/SNO5ACK6/SNO6
DRV2 ACK7/SNO7ACK8/SNO8SNACKRESERVED
DO01 DO02 DO03 DO04
DO05 DO06 DO07 DO08
DO09 DO10 DO11 DO12
DV1 DO13 DO14 DO15 DO16
DO17 DO18 DO19 DO20

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

- 202 -
4.15 PROCESS I/O BOARD KCA16B-2204-0052


P24V
P5V
GND1
GND2 GND3
GND4
ICOM1
ICOM2
LED
DV1
DRV1 DRV2

(1) Meanings of check pins
Name Use
P24V
P5V
GND1
GND2
GND3
GND4
24V
5V
GND
GND
GND
GND
For DC power measurement

(2) Setting
Name Standard
setting
Use
ICOM1 UDI120
(connector CRMA5A)
ICOM2 UDI2140
(connector CRMA5B)
Side A For common voltage setting
Side A: +24 V common
Side B: 0 V common

Total edition
B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

- 203 -
(3) Meaning of LEDs
Color Meaning

Red
A communication alarm occurred between the
main CPU and the process I/O board.

Red
The fuse (FUSE1) on the process I/O board
has blown.

(4) Correspondence between driver ICs and DO signals
Driver IC specification:DRV1, DRV2A76L-1151-0167
DV1A76L-1151-0070
Driver IC name DO signal name
DRV1 CMDENBLSYSRDYPROGRUNPAUSED
HELDFAULTATPERCHTPENBL
BATALMBUSYACK1/SNO1ACK2/SNO2
ACK3/SNO3ACK4/SNO4ACK5/SNO5ACK6/SNO6
DRV2 ACK7/SNO7ACK8/SNO8SNACKRESERVED
DO01 DO02 DO03 DO04
DO05 DO06 DO07 DO08
DO09 DO10 DO11 DO12
DV1 DO13 DO14 DO15 DO16
DO17 DO18 DO19 DO20





5.SERVO AMPLIFIERS MAINTENANCE B-82595EN-2/02

- 204 -
5 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 specification
REGENERATIVE REGISTOR
ROBOT SERVO AMPLIFIER
A-CABINET B-CABINET
M-900iA/600
A06B-6107-H001 (AMP1)
A06B-6117-H209 (AMP2)
A06B-6117-H105 (AMP3)
A05B-2502-C100
R-2000iB/200T
M-900iA/260L
M-900iA/350

M-410iB
A06B-6107-H001
A05B-2501-C102
A05B-2502-C100
R-2000iB
except /200T

M-710iC A05B-2501-C103
M-16iB
ARC Mate 120iB
(Except ARC Mate
120iBe.)
A05B-2501-C100
M-420iA, M-421iA
A06B-6107-H002
A05B-2501-C102
A05B-2502-C100
M-6iB
ARC Mate 100iB
ARC Mate 120iBe
A05B-2501-C101
F-200iB
A06B-6107-H003
A05B-2501-C105
A05B-2502-C101
ARC Mate 100iC
M-10iA
A06B-6107-H004 A05B-2501-C101 A05B-2502-C101
M-430iA/2F
A06B-6107-H007 (AMP 1)
A06B-6117-H201 (AMP 2)
M-430iA/2P
A06B-6107-H007 (AMP 1)
A06B-6117-H301 (AMP 2)
A05B-2501-C105 A05B-2502-C101

B-82595EN-2/02 MAINTENANCE 5.SERVO AMPLIFIERS

- 205 -
Check that the voltage is not higher than 50V.


NOTE
Before touching the servo amplifier, for example,
for maintenance purposes, check the voltage at the
screw above the LED D7 with a DC voltage tester
to see if the remaining voltage is not higher than
50V.

5.SERVO AMPLIFIERS MAINTENANCE B-82595EN-2/02

- 206 -
5.1 LED OF SERVO AMPLIFIER



LED Color Description
P5V Green Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V
normally.
P3.3V Green Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V
normally.
SVEMG Red Lights when an emergency stop signal is input to the servo amplifier.
SVALM Red Lights when the servo amplifier detects an alarm.
DRDY Green Lights when the servo amplifier is ready to drive the servo motor.
OPEN Green Lights when the communication between the servo amplifier and the main board is normal.
D7 Red Lights when the DCLINK circuit inside the servo amplifier is charged to reach a specific voltage.

B-82595EN-2/02 MAINTENANCE 5.SERVO AMPLIFIERS

- 207 -
5.2 SETTING OF SERVO AMPLIFIER

Settings

Name Standard
setting
Description
COM1 Side A Robot Digital Input (RDI) device common voltage.
Side A: +24V common
Side B: 0V common



A side
B side
RI
RI

Circuit based on jumper pin location

6.SETTING THE POWER SUPPLY MAINTENANCE B-82595EN-2/02

- 208 -
6 SETTING THE POWER SUPPLY

Setting and adjustment of the power supply is factory-set for operation.
Usually, you do not need to set or adjust it.

B-82595EN-2/02 MAINTENANCE 6.SETTING THE POWER SUPPLY

- 209 -
6.1 BLOCK DIAGRAM OF THE POWER SUPPLY

Robot
AC power supply unit
AC 200 230 V
AC 380 400 V
AC 380 415 V
AC 440 500 V
AC 500 575 V
Transformer
Breaker
E-stop unit

210VAC
3
210VAC
Servo amplifier
(6-axis amplifier)

Backplane Power
supply
unit
CP1A
CP2
CP3
CP6
CP5
DC/DC
+5V, +3.3V
+2.5V,
+15V, -15V
+24V, +24E
Fan
+24E
+24V
CRP24
C
N
J
C
R
F
8
C
R
R
6
4
CRR38
CRM96 CRM96
CP2
+24V
Main board

JRS16
Battery
Process
I/O board
CRM2
CRM4
CRMA5
CRMA6
P
o
w
e
r
B
r
a
k
e
P
u
l
s
e

c
o
r
d
e
r
+
5
V

+
2
4
V
F
End effector
Motor








Panel board
+
2
4
E
C
R
M
9
5
C
R
M
9
5

DC/DC
+5V
CRS20
Teach pendant
+24T
Peripheral device
+24F
+
3
.
3
V
+
5
V

+
1
5
V

-
1
5
V

+
2
4
E

+
2
4
V

F1
F3
F4
FUSE2
+24E
DC/DC
+5V, +3.3V
+15V, -15V
FS1
FS3
Regenerative
res. aux. axis
FS2
Breaker
+24E
CP5A
FUSE1
CP8B
JD1A
JD17
E-stop
circuit
Power supply
I/O unit
CRS26
CA69A
RS-232-C
I/O LINK
RS-232-C/RS-485
FORCE SENSOR
SERVO CHECK I/F
200VAC

CP1
+
2
.
5
V
200VAC

(FU1)
JRL6
VIDEO INPUT
24V
12V

Fig. 6.1 Block diagram of the power supply

C
R
R
8
8
6.SETTING THE POWER SUPPLY MAINTENANCE B-82595EN-2/02

- 210 -
6.2 TRANSFORMER

Select a transformer and tap according to the supply voltage. Select
a transformer tap among the rated voltage.

A-cabinet
Transformer specification

Rated
voltage
13.0KVA 10.5KVA 7.5KVA 3KVA
500 to 575
440 to 500 TYPE E
380 to 415
A80L-0028-0024#A A80L-0026-0040#A A80L-0024-0028
200 to 230
TYPE D
380 to 400
A80L-0028-0027#A A80L-0026-0041#A A80L-0024-0029

B-cabinet
Transformer specification

Rated
voltage
13.0KVA 10.5KVA 7.5KVA 3KVA
500 to 575
440 to 500 TYPE E
380 to 415
A80L-0028-0025 A80L-0028-0024 A80L-0026-0040 A80L-0024-0028
200 to 230
TYPE D
380 to 400
A80L-0028-0028 A80L-0028-0027 A80L-0026-0041 A80L-0024-0029



Side fan type Rear fan type
A-cabinet (Back)
Transformer
B-82595EN-2/02 MAINTENANCE 6.SETTING THE POWER SUPPLY

- 211 -
Transformer

B-Cabinet (Back)

Fig.6.2 (a) Transformer mounting locations and structure




6.SETTING THE POWER SUPPLY MAINTENANCE B-82595EN-2/02

- 212 -

Cabinet side connector
1. TYPE E (500V-575V)
4. TYPE D (380V-400V)
2. TYPE E (440V-500V)
3. TYPE E (380V-415V)
5. TYPE D (200V-230V)
Circuit
breaker
Dummy plug
Dummy plug
Y connection
cable
Dummy plug
Dummy plug
Dummy plug
Dummy plug
Circuit
breaker
Circuit
breaker
Circuit
breaker
Circuit
breaker
connection
cable
(B-cabinet)
Y - connection
unit
Circuit
breaker
Y connection
cable
(A-cabinet)


Fig. 6.2(b) Setting the input voltage

B-82595EN-2/02 MAINTENANCE 6.SETTING THE POWER SUPPLY

- 213 -

1 Type E: 500V-575V Insert the connector connected to the circuit
breaker into connector LA and the dummy plug
into connectors LB and LC.
2 Type E: 440-500V Insert the connector connected to the circuit
breaker into connector LB and the dummy plug
into connectors LA and LC.
3 Type E: 380-415V Insert the connector connected to the circuit
breaker into connector LC and the dummy plug
into connectors LA and LB.
4 Type D: 380-400V Insert the Y connection cable connected to the
circuit breaker into connectors LA and LB.
5 Type D: 200-230V Insert the connection cable connected to
the circuit breaker into connectors LA and LB.



CAUTION
The secondary voltage of the transformer depneds
on the cable connection between a breaker and a
transformer. Be careful for the cable connection in
the mainternance.


6.SETTING THE POWER SUPPLY MAINTENANCE B-82595EN-2/02

- 214 -
6.3 CHECKING THE POWER SUPPLY UNIT (A16B-2203-0910)

The power supply unit need not be set or adjusted.

Table 6.3 Rating of the Power supply unit
Output Rated voltage Tolerance
+5V +5.1V 3%
+3.3V +3.3V 3%
+2.5V +2.5V 3%
+24V +24V 5%
+24E +24V 5%
+15V +15V 10%
-15V -15V 10%


DB1 : Diode stack
F1 (8.0A) : Fuse for AC input
VS1 : Surge absorber
H1 : Auxiliary power module
CP1 : Connector for AC input
CP1A : Connector for AC output
CP2, CP3 : Connector for AC output
F3 (7.5A) : Fuse for +24E
F4 (7.5A) : Fuse for +24V
PIL : LED (green)
CP5 : Connector for +24V
CP6 : Connector for +24E


ALM : LED (red)
CP4 : Connector for control


Fig.6.3 (a) Interface of the power supply unit

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7 REPLACING A UNIT

This section explains how to replace each unit in the control section.

WARNING
1 Before you start to replace a unit, turn off the
control unit main power. Also keep all machines in
the area of the control unit switched. Otherwise,
you could injure personnel or damage equipment.
2 Before replacing components, read the
maintenance manual to understand the
replacement procedure. Performing an incorrect
replacement procedure can lead to an
unpredictable accident, resulting in breakage in the
robot or personal injury.
3 When a heavy component or unit is to be handled,
support the workers with a crane or the like not to
apply excessive loads to the workers. Note that
incorrect handling can cause serious injury to the
workers.

CAUTION
Components in the control unit heat up, so care
should be taken. When you have to touch a
heated component, prepare a protector such as
heat-resistant gloves.

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7.1 A-CABINET
The following components of the A-cabinet can be removed.


7.1.1 Replacing the A-cabinet Top Panel

Remove three M4 screws from the upper edge of the rear surface.
Pull the top panel slightly backward, then lift it off.


Fig.7.1.1 Replacing the Top Panel


NOTE
In case of the Rear fan type, replace the Top panel
after remove the Rear louver.

M4 screws (3 places)
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7.1.2 Replacing the A-cabinet Rear Panel

Remove the retaining M4 screws and four M10 bolts from the rear
panel.


Fig.7.1.2 Replacing the Top Panel


NOTE
In case of the Rear fan type, replace the Rear
Panel after remove the Rear louver.




M4 screws (7 places)
M10 bolts (4 places)
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7.1.3 Replacing the A-cabinet Louver

(a) Side fan type
Loosen four retaining M4 screws from the louver, then remove the
louver.

Fig.7.1.3 (a) Replacing the Louver (Side fan type)

(b) Rear fan type
Loosen four retaining M4 screws from the louver (the louver is
fastened together with the rear panel), then remove the louver.

Fig.7.1.3 (b) Replacing the Louver (Rear fan type)


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7.1.4 Replacing the A-cabinet Door

Detach the cables from each unit (such as the fan unit) installed on the
door. Lift the door off its hinges to dismount it.


Fig.7.1.4 Replacing the Door


Lift up the door
to mount it.
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7.2 REPLACING THE PRINTED-CIRCUIT BOARDS

CAUTION
When you replace printed-circuit boards, observe
the following cautions:
1 Keep the controller power switched off.
2 When you remove a printed-circuit board, do not
touch the semiconductor devices on the board
with your hand or make them touch other
components.
3 Make sure that the replacement printed-circuit
board has been set up appropriately. (Setting
plug etc.)
4 After replacing a printed-circuit board, make
adjustments correctly if the board needs to be
adjusted.
5 If the backplane board, power supply unit, or
main board (including cards and modules) is
replaced, it is likely that robot parameters and
taught data are lost. Before you start to replace
these components, save a backup copy of the
robot parameters and taught data to an external
memory device.
6 Before you disconnect a cable, note its location.
If a cable is detached for replacement,
reconnect it exactly as before.

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7.2.1 Replacing the Backplane Board (Unit)

When replacing the backplane board, do so together with the plastic
rack.
(1) Detach the cables from the power unit and boards on the
backplane board.

CAUTION
When you remove the main PC Board, be sure that
the battery is good (3.1-3.3VDC) and it is installed
correctly. USE STATIC PROTECTION.

(2) Remove the power unit and boards from the rack. (See Section
7.2.2.)
(3) Detach the grounding cable from the backplane unit.
(4) Loosen the retaining screws in the upper section of the rack.
Remove the retaining screws from the lower section of the rack.
(5) Side rack up and out.
(6) To replace the backplane and rack, reverse steps (1) - (6).

CAUTION
There is a possibility of data loss when a
backplane- mounted printed circuit board is
replaced. Be sure to back up all program and setup
data on an external device such as a memory card
before proceeding.

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7.2.2 Replacing the Power Unit and Printed-Circuit Boards on the
Backplane Unit

The backplane unit incorporates the power unit, main board, and
option boards. There are two types of option boards: Full-size board
and mini-size board. A full-size board occupies one slot. A mini-size
board uses part of a full-size board.

CAUTION
Before starting replacement, turn off the control unit
main power. The main board is equipped with
battery-backed memory devices for holding robot
parameters and taught data, for example. When
the main board is replaced, the data in the memory
devices is lost.

(1) Detach the cable from the power supply unit or the
printed-circuit board, whichever is to be replaced.
(2) Pinch the barbed handles on the upper and lower sections of the
board to unlatch it, then pull it toward you.
(3) Place the replacement board on the rail in the appropriate slot of
the rack, then push it in gently by the handles until it is latched.
(4) There are two rails in the main board SLOT (slot 1). When
inserting the main board, align it to the right-side rail.
(5) There are two rails in slots 3 (slots for a full-size option board).
When you insert a full-size option board, align it to the left-side
rail.


Backplane board
Left rail
Right rail

Fig.7.2.2(a) Replacing the backplane board

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SLOT 3
SLOT 2
SLOT 1
Handles
PSU (Power supply SLOT)
Handles

SLOT 1

Fig.7.2.2(b) Replacing the power unit and printed-circuit boards on the backplane unit

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7.2.3 Replacing the Panel Board

The panel board is at the back of the operator panel.
(1) Detach all cables from the panel board. The terminal blocks
(TBOP3, TBOP4, and TBOP6) are of a connector type. Pull out
the upper terminal block sections.
(2) Remove four retaining screws from the panel board, and replace
the panel board.
(3) Remove two M3 screws from the fixing sheet metal of the panel
board, and remove the sheet metal.
(4) Attach the fixing sheet metal to a new panel board, and attach the
new panel board to the operator panel.


A-cabinet
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Details of section A

B-cabinet

Fig. 7.2.3 Panel board replacement


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7.2.4 Replacing the Process I/O Board EA,EB,FA,GA,KA,KB,KC
(A-cabinet)



Fig. 7.2.4 Replacing the Process I/O Board

M4 screws (4 places)
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7.3 REPLACING CARDS AND MODULES ON THE MAIN
BOARD

CAUTION
Before you start to replace a card or module, make
a backup copy of robot parameters and taught
data. If the FROM/SRAM module is replaced,
SRAM memory contents are lost.

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.
Be sure to hold this part
to pull out the card.

(2)
Card
Spacer
Connector

Fig. 7.3 (a) Demounting the card on the main board

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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.


(1)


Be sure to hold this part to push the card.
Spacer
Connector


Connector
Be sure to hold this part to
push the card.

Fig. 7.3 (b) Mounting the card on the main board

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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)

A
Details of section A

(b)
A
Details of section A

(c)

Fig.7.3 (c) Demounting/mounting a module
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Figure 7.3 (d) shows the locations of the cards and modules.


CPU card
FROM/SRAM module
(Behind the axis control card)
Axis control card

Fig.7.3 (d) Locations of cards and modules

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7.4 REPLACING THE TRANSFORMER

WARNING
The transformer is heavy. When replacing the
transformer, be careful not to cause injury. (The
transformer weighs 45 to 60 kg.)

In case of A-cabinet
Following (1) to (3) are not need for the remote type A-cabinet.
For the remote type A-cabinet, start from (4).
If the A-cabinet is connected to the robot, it will need to be separated.

Cabinet separation
(1) Disconnect the cable connectors and ground clamps coming from
the robot. These cables are generally at the following connectors
on the Servo amplifier: CRF8, CNJ1 to 6, and CNJGA to CNJGC,
and the ground cables.








Motor power cable
Pulse coder cable
Grounding cable
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(2) Remove the four M10 robot retaining bolts that hold the cabinet to
a robot.

(3) Being careful not to strain or break any cables, gently separate the
cabinet from the robot and its cables.

(4) Disconnect the power cable from the transformer input connector
panel. (The power cable comes from the opration box. )



(5) Remove three M4 screws from the upper edge of the rear surface.
(Refer to a Fig.7.1.1)
Remove the retaining M4 screws and four M10 bolts the rear panel.
(Refer to a Fig.7.1.2)

Robot retaining bolts
M10 (4 places)
Transformer input
connectors panel
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Following (6) to (7) are not need for the Rear fan type.

(6) Unscrew and Remove the regenerative resistor from the plate on
the top of the transformer. (Refer to a Fig.7.5)

(7) Unscrew and Remove the plate on the top of the transformer.

(8) Remove four screws from a metal plate of connectors panel, and
remove the metal plate.

A metal plate of
connectors panel

Screw
Washer
Screw
(M5)
3 places
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(9) Remove the two M6 screws holding the transformer in place and
remove the transformer.


Screws (2-M6)




(10) Install a replacement transformer by reversing steps 1 through 9.




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In case of B-cabinet
(1) Remove the screws and detach the back panel.



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(2) Detach the connectors of LA, LB, LC, OUT, and CPOH.
If a cable is fastened with nylon ties, cut them with a diagonal
cutter to release the cable. Be careful not to damage the cable.

In case of TYPE E
In case of TYPE D


(3) Remove the retaining screws from the transformer terminal board
and remove the metal plate.

A
Details of section A

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(4) Remove the two retaining M6 screws from the transformer, then
remove the transformer.





(5) Install a replacement transformer by reversing procedure (1) to
(4).

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7.5 REPLACING THE REGENERATIVE RESISTOR UNIT

WARNING
Before you start, turn off the controller main power.
Be careful not to get burned, because the
regenerative resistor unit is very hot immediately
after operation.

In case of A-cabinet
(a) Remove the top panel from the A-cabinet. Remove the Louver
plate and the lower plate on the right side of the cabinet.
(In case of the Rear fan type, remove the rear panel or fan unit.)

(b) Unplug connector CRR45 and CRR63 at the Servo amplifier.

(c) Unscrew the cord grip nut inside the transformer compartment and
pull the cables through, being careful not to damage the
connectors or cables.

(d) Unscrew the retaining screws on the regenerative resistor unit and
remove it.

(e) Install the replacement unit by reversing this procedure (a) to (d).











CRR45
CRR63
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(Side fan type)





(Rear fan type)

Screw
Washer
The type of the regenerative
resistor varies with the model of
the robot.
Transformer The cable is retained using a cord grip. Remove the
cord grip, and pull out the cable. The cord grip is
retained with nuts on the rear side. Remove the lower
right plate beforehand.
Screw
(M4)
2 places
The type of the regenerative
resistor varies with the model of
the robot.
Transformer
The cable is retained using a cord grip. Remove the
cord grip, and pull out the cable. The cord grip is
retained with nuts on the rear side. Remove the lower
right plate beforehand.
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In case of B-cabinet
(a) Remove the servo amplifier. (See Section 7.6)
(b) Remove the metal plate securing the cable of the regenerative
resistor unit.
If a cable is fastened with nylon ties, cut them with a diagonal
cutter to release the cable. Be careful not to damage the cable.


A
Details of section A

Fig. 7.5 (a) Cable part of the regenerative resister

(c) Of the two nuts fastening the regenerative resistor unit, remove
the upper nut, loosen the lower nut, then remove the regenerative
resistor unit.


A
Details of section A

Fig. 7.5 (b) Regenerative resistor unit

(d) Install a replacement regenerative resistor unit and a servo
amplifier by reversing the procedure (a) to (c).
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7.6 REPLACING THE E-STOP UNIT

In case of A-cabinet
NOTE
The magnetic contactor mounted in the emergency stop unit is turned on
when the conditions are satisfied. While the controller is turned on, do
not press the button on the magnetic contactor in any case. Otherwise,
the contactor may be damaged.





E-stop unit (A-cabinet)


(a) Detach the cables from the emergency stop unit.
(b) Remove retaining screws (M4 4 places) from the emergency stop
unit, and replace the emergency stop unit.
(c) Reconnect the cables.


E-stop unit
4-M4 screws
Note) Do not press this switch in any case.
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In case of B-cabinet
NOTE
The magnetic contactor mounted in the emergency stop unit is turned on
when the conditions are satisfied. While the controller is turned on, do
not press the button on the magnetic contactor in any case. Otherwise,
the contactor may be damaged.


E-stop unit (B-cabinet)

(a) Detach the cables from the emergency stop unit.
(b) Of the four screws fastening the emergency stop unit, remove the
upper two screws, loosen the lower two screws, then replace the
emergency stop unit.
(c) Reconnect the cables.

A
Details of section A


Fig.7.6 Replacing the emergency stop unit

Note) Do not press this switch in any case.
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7.7 REPLACING SERVO AMPLIFIERS

WARNING
Because the servo amplifier is heated immediately
after operation, leave the servo amplifier until it
cools down thoroughly, before replacing it.

In case of A-cabinet
A servo amplifier can be dismounted by pulling it out from the side,
using its rail. Only a flat-head screwdriver is required, provided that
servo amplifier SHIPPING screws have been removed. These screws
are intended to prevent damage to the servo amplifier during
shipment.

(a) Make sure that servo amplifier shipping screws (2 phillips head)
have been removed. Retain screws for shipping purposes.
(b) Check the voltage at the screw above the LED "D7" with a DC
voltage tester to see if the remaining voltage is not higher than
50V.

Check that the voltage is not higher than 50V.

(c) Detach the cables from the servo amplifier. Pull out the detected
cables away from the amplifier toward you so that they will not be
caught when it slides along the rail.


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(d) Unlock the servo amplifier by rotating the quarter-turn screws on
the outside surface of the plate using a coin or the like.


(e) Hold the upper and lower handles, and pull out the servo amplifier
slowly. Be sure that all cables are unplugged from the servo
amplifier before you try to remove the servo amplifier. After
pulling the servo amplifier a little, check again that it is all right to
continue to pull the servo amplifier. Be careful not to let the servo
amplifier slide off the rail.

(f) Place a replacement servo amplifier on the rail, slide it in gently
untill it is hooked on the guide pins.


(g) Rotate the quarter-turn screws on the outside surface of the plate
to lock the servo amplifier.

(h) Reconnect the cables.

Unlock Lock
Servo amplifier shipping screws
(M5, 2 places)
Quarter-turn screws
(4 places)
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Rail
Handles
Guide pin
Guide pin
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In case of B-cabinet

(a) Detach the amplifier cover, and pull out the cable.

Details of section A


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(b) Check the voltage at the screw above the LED "D7" with a DC
voltage tester to see if the remaining voltage is not higher than 50
V.

Check that the voltage is not higher than 50V.


7.REPLACING A UNIT MAINTENANCE B-82595EN-2/02

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(c) Turn the retaining pin at the top of the amplifier 90 degrees
counterclockwise. (At the middle of the top of the amplifier,
there is an M5 screw that fastens the amplifier during transport of
the cabinet. After the installation of the cabinet, remove the
screw.
This improves maintainability.)




Fixation screw
for transport
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(d) Holding the handles located at the top and bottom of the
amplifier, pull out the amplifier toward you.



(e) Pull the amplifier up while keeping it slanted.




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7.8 REPLACING I/O Unit-MODEL A

7.8.1 Replacing the Base Unit of I/O Unit-MODEL A

First dismount the modules from the base unit of I/O Unit-MODEL A.
The base unit is retained with 4 screws. Of these screws, loosen the
upper 2 screws and remove the lower 2 screws, then replace the base
unit.

Details of section A

Fig.7.8.1 Replacing the base unit of I/O unit model A

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7.8.2 Replacing a Module

An interface module and input/output module can be easily installed
in and removed from the base unit, as described below.

Installing a module
(a) Put the upper hook of the module into the upper hole of the base
unit.
(b) Fit the connectors of the module and the base unit to each other.
(c) Push the module until the lower stopper of the module is caught
in the lower hole of the base unit.

Removing a module
(a) Press the lever at the bottom of the module to release the stopper.
(b) Lift the module up.


Fig.7.8.2 Replacing the module

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7.9 REPLACING THE TEACH PENDANT and i PENDANT

The specifications of the teach pendant vary with its use. When you
replace the teach pendant, check its specifications carefully.
(1) Be sure that the power of a robot controller is off.
(2) Detach the cable from the teach pendant.
(3) Replace the teach pendant.

Detach or attach the cable by rotating the
connector retaining ring.

Fig.7.9 Replacing the teach pendant

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7.10 REPLACING THE CONTROL SECTION FAN MOTOR

The control section fan motor can be replaced without using a tool.
The fan motor is mounted on the fan unit rack.
(1) Be sure that the power of a robot controller is off.
(2) Put your finger in the dent in the upper section of the fan unit,
and pull the fan unit until it is unlatched.
(3) Lift the fan unit slightly, and dismount it from the rack.
(4) Place a replacement fan on the upper section of the rack, and
slide it gently until it is latched.


Fan motor
Pull the fan motor
unit toward you to
unlatch it.
Fan motor connector
Dent

Fig.7.10 Replacing the control section fan motor

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7.11 REPLACING THE AC FAN MOTOR

WARNING
Do not touch the fan motor when it is rotating, or
you could be injured.

7.11.1 Replacing the Heat Exchanger and Door Fan Unit (A-cabinet)

The heat exchanger of the A-cabinet is inside its door. To replace the
heat exchanger, it is necessary to remove the door fan unit in advance.

Door fan unit
(1) Remove retaining screws (M4, 4 places).
(2) Detach the cable from the heat exchanger.
(3) Mount the replacement fan unit by reversing the removal
procedure. Be careful not to let the cable get caught in the fan.

Heat exchanger
(1) Dismount the fan unit from the door. (See the above procedure.)
(2) Open the A-cabinet door, and detach cables.
(3) Remove retaining nuts (M5, 4 places), and dismount the unit.
(4) Mount the replacement heat exchanger by reversing the
dismounting procedure.




Door fan unit
Screws (4-M4)
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7.11.2 Replacing External Air Fan Unit (A-cabinet)

The external air fan unit has two fans mutually connected with a cable.
When the fan unit is replaced, the cable is replaced together with the
fan unit.

(1) Loosen the retaining screws of the louver, then remove it (see
Section 7.1.3)

(2) In case of the Side fan type, detach the fan unit. (The fan is
fastened together with the louver.)
In case of the Rear fan type, loosen four retaining M4 screws from
the Rear fan unit, and then detach the fan unit.

(3) Detach the fan unit lead-out cable and grounding wire. (The cable
is terminated with a connector. The grounding wire is fastened
with a screw.)

(4) Replace the fan unit with a new one.



(Side fan type)

Nuts (4-M5)
Heat Exchanger
The fan cable is
attached using an
in-line connector.
Screws (4-M4)
used to fasten both the
fan unit and louver.
7.REPLACING A UNIT MAINTENANCE B-82595EN-2/02

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(Rear fan type)

7.11.3 Replacing External Air Fan Unit and Door Fan (B-cabinet)

Door fan
(1) Detach the cable from the fan unit.
(2) Remove the retaining screws from the fan unit, then dismount it.
(3) Install a new fan unit by reversing the dismounting procedure.


(Replacing the Door Fan Unit)

Screws M4
(4 places)
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External Air fan unit
(1) Detach the cable connecting the fan unit.
(2) Remove the screws and pull out the fan unit toward you.
(3) Install a new fan unit by reversing the dismounting procedure.



(Replacing the Air Fan Unit)

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7.12 REPLACE THE MODE SWITCH

(a) Remove the cable from the mode switch.
(b) Remove the screws fastening the mode switch, and replace the
mode switch.

NOTE
1 When mounting the mode switch, do not
overtighten the screws. (Tightening torque: 0.3
Nm)
2 Tighten the screws evenly so that the mode switch
flat surface becomes parallel- to the sheet metal.


Fig. 7.12 (a) Replacing the mode switch (1/3)


Fig. 7.12 (b) Replacing the mode switch (2/3)

Mode switch
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A
Tightening torque:
0.3Nm
Details of section A
(Back plane of operators panel)

Fig. 7.12 (c) Replacing the mode switch (3/3)

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7.13 REPLACING FUSES

If a fuse in the control unit has blown, find the cause and take an
appropriate measure before replacing the fuse.

7.13.1 Replacing Fuses in the Servo Amplifier

The following fuses are in the servo amplifier.

FS1: For generation of the power to the amplifier control circuit
(A60L-0001-0290#LM32C)
FS2: For protection of the 24 V output to the end effector, ROT,
and HBK (A60L-0001-0290#LM32C)
FS3: For protection of the 24 V output to the regenerative
resistance and the additional axis amplifier
(A60L-0001-0290#LM50C)

5A
3.2A
3.2A
CRR88


Fig.7.13.1 Replacing fuses in the servo amplifier

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7.13.2 Replacing Fuses in the Power Unit

The following fuses are in the power unit.
F1: Fuse for the AC input, A60L-0001-0450#8RO
F3: Fuse for protecting the +24E output, A60L-0001-0046#7.5
F4: Fuse for protecting the +24V output, A60L-0001-0046#7.5


F1 8.0A
Fuse for AC input
F3 7.5A
Fuse for +24E
F4 7.5A
Fuse for +24V
Details of section A
Details of section B


Fig.7.13.2 Replacing fuses in the power unit
7.REPLACING A UNIT MAINTENANCE B-82595EN-2/02

- 262 -
7.13.3 Replacing Fuses in the Main board

The following fuses are in the power unit.
FU1: For protection of the +12V output for the vision sensor,
A60L-0001-0175#0.5A



75173 (Receiver)
75172 (Driver)
CPU card
FROM/SRAM module
(Behind the axis control card)
Axis control card
FU1 Fuse(0.5A)
(Total edition 06B after)


Fig.7.13.3 Replacing fuses in the main board

B-82595EN-2/02 MAINTENANCE 7.REPLACING A UNIT

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7.13.4 Replacing the Fuse on the Process I/O Boards

The following fuse is on each process I/O board.
FUSE1: Fuse for protecting the +24V output for peripheral
equipment interfaces.
A60L-0001-0046#2.0
Process I/O board CA

Fig. 7.13.4 (a) Process I/O board CA
Process I/O board EA, EB
Fuse location is common to EA and EB.The following is figure of EA.

Fig. 7.13.4 (b) Process I/O board EA, EB
7.REPLACING A UNIT MAINTENANCE B-82595EN-2/02

- 264 -
Process I/O board FA

Fig. 7.13.4 (c) Process I/O board FA

Process I/O board GA

Fig. 7.13.4 (d) Process I/O board GA
B-82595EN-2/02 MAINTENANCE 7.REPLACING A UNIT

- 265 -
Process I/O board HA

Fig. 7.13.4 (e) Process I/O board HA

Process I/O board JA, JB
Fuse location is common to JA and JB.The following is figure of JA.


FUSE (2A)

Fig. 7.13.4 (f) Replacing the fuse on the process I/O boards

7.REPLACING A UNIT MAINTENANCE B-82595EN-2/02

- 266 -
Process I/O board KA, KB, KC
Fuse location is common to KA, KB and KC. The following is figure of KA.

FUSE1
LED

Fig. 7.13.4 (g) Process I/O Board KA


B-82595EN-2/02 MAINTENANCE 7.REPLACING A UNIT

- 267 -
7.13.5 Replacing the Fuse on the Panel Board

The following fuse is on the panel board.
FUSE1 : For protection of the +24EXT line (emergency stop line)
FUSE2 : For protection of the teach pendant emergency stop line
A60L-0001-0046#1.0


(Panel board)

Fig.7.13.5 Replacing the fuse on the panel board

FUSE2 (1A) FUSE1 (1A)
7.REPLACING A UNIT MAINTENANCE B-82595EN-2/02

- 268 -
7.14 REPLACING RELAYS

Prolonged use of a relay might result in its contacts failing to make a
secure connection or sticking to each other permanently. If such a
failure occurs, replace the relay.

7.14.1 Replacing Relays on the Panel Board

KA21, KA22 : Relay for emergency stop circuit
A58L-0001-0192#1997R



Fig.7.14.1 Replacing relays on the panel board

KA22 KA21
B-82595EN-2/02 MAINTENANCE 7.REPLACING A UNIT

- 269 -
7.15 REPLACING BATTERY

7.15.1 Battery for Memory Backup (3 VDC)

The programs, and system variables are stored in the SRAM in the
main board. The power to the SRAM memory is backed up by a
lithium battery mounted on the front panel of the main board. The
above data is not lost even when the main power of controller is
turned off. A new battery can maintain the contents of memory for
about 4 years (Note).
When the voltage of the battery becomes low, the low-voltage battery
alarm (system-035) is displayed on the teach pendant. When this
alarm is displayed, replace the battery as soon as possible. In general,
the battery can be replaced within one or two weeks, however, this
depends on the system configuration.
If the battery voltage gets lower, it becomes impossible to back up the
content of the SRAM. Cycling power to the controller in this state
causes system not to start, and LED located on the main board
displays "1" because the contents of memory have been lost. Clear
the entire SRAM memory and reenter data after replacing the battery.
Important data should be saved to the memory card or other external
device beforehand in case of emergency.

NOTE
In a newly introduced robot, the battery is
factory-installed. Battery replacement may,
therefore, be needed within 4 years after the
introduction of the robot.

7.REPLACING A UNIT MAINTENANCE B-82595EN-2/02

- 270 -
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.

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.

(3) Turn the robot controller off.
(4) Remove the old battery from the top of the main board.
First unlatch the battery, remove it from the battery holder, and
detach its connector.

Battery connector
Lithium battery
Battery latch


(5) Remove the old battery, insert a new one into the battery holder,
and attach the connector. Confirm that the battery is latched
firmly.

B-82595EN-2/02 MAINTENANCE 7.REPLACING A UNIT

- 271 -
WARNING
Using other than the recommended battery may
result in the battery explosion.
Replace the battery only with the specified battery
(A02B-0200-K102).


Dispose of the replaced battery as an industrial waste, according to the
laws and other rules in the country 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.


8. HOW TO USE THE PLATE TO FIX THE
COMPACT FLASH MEMORY CARD

MAINTENANCE B-82595EN-2/02

- 272 -
8 HOW TO USE THE PLATE TO FIX THE
COMPACT FLASH MEMORY CARD

Optional plate to fix the compact flash memory card (CF card) can
make it possible to perform a back-up on fixing the CF card on the
mainboard.


Parts
Fixing plate
Adapter for CF card (made by fanuc)











2. Fixing plate
Main board
Compact flash memory card
(The card is not included.
It must be supplied by the customer.)
1. Adapter for CF card
(made by fanuc)
8. HOW TO USE THE PLATE TO FIX THE
COMPACT FLASH MEMORY CARD

B-82595EN-2/02 MAINTENANCE

- 273 -

Installation of the CF card






Removal of the CF card








1. Insert the CF card into the
Adapter.
2. Lock the latch, and drive the
screw.
1. Loosen the screw, and unlock
the latch.
2. Pull the CF card out of the
Adapter.















III. CONNECTIONS

B-82595EN-2/02 CONNECTIONS 1.GENERAL

- 277 -
1 GENERAL

This section describes the electrical interface connections in the
R-30iA. It also includes information about installation of the
R-30iA.

2.BLOCK DIAGRAM CONNECTIONS B-82595EN-2/02

- 278 -
2 BLOCK DIAGRAM

Fig.2 is a block diagram of electrical interface connections with the
R-30iA.

R-30iA
(A-cabinet)
Mechanical unit
Pneumatic
pressure source
End effector




Operation box
USB memory (Note2)
Teach pendant
RS-232-C (Note3)
Ethernet
Peripheral device
Weldi ng machi ne
AC power supply
Memory card
(PCMCIA)

Fig.2 (a) Block Diagram of Electrical Interface Connection (A-cabinet)

NOTE
1 : Indicates electrical connection.
-------- : Indicates mechanical connection.
2 In case the length of the connection cable between
A-cabinet and Operation box is 10m or longer,
there is the USB interface panel and RS-232-C
interface on the A-cabinet.
3 For more information, contact our service section.




B-82595EN-2/02 CONNECTIONS 2.BLOCK DIAGRAM

- 279 -
R-30iA
B-cabinet
Pneumatic
pressure source
Mechanical unit End effector
USB memory
Memory card
(PCMCIA)
RS-232-C
Teach pendant
Peripheral device
Ethernet
Welding machine
AC power supply

Fig.2 (b) Block Diagram of Electrical Interface Connection (B-cabinet)

NOTE
1 : Indicates electrical connection.
-------- : Indicates mechanical connection.
2 For more information, contact our service section.

3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 280 -
3 ELECTRICAL CONNECTIONS

B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 281 -
3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS




















Fig.3.1 (a) Mechanical connection diagram

NOTE
1 This cable is not included. It must be supplied by
the customer.

R-30iA



Robot


RP1
(Pulse coder, RI/RO
, HBK, ROT)


RM1
(Motor power/brake)

RM2
(Motor power)

Servo amplifier

CRF8
(Pulse coder, RI/RO,
HBK, ROT)

CNJx
(Motor power)
CNGx
(Ground)
CRR88
(Brake control)
(Note1)
RCC I/F UNIT
(M-900iA ONLY)
EE
End effector
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 282 -

Note 2
Note 2
Note 2
Note 2
Note 2
Note 2
R-30iA
(Panel board)
USB memory
(Process I/O)
Teach pendant
Peripheral device
Ethernet
(Main board)
Panel board
(TBOP3)
External power
ON/OFF switch
External device
Input power
External emergency
stop switch
Fence
Servo off switch
Port A
(Operator's panel)
(Main board)
Circuit breaker
Panel board
(TBOP4)
Panel board
(TBOP4)
Panel board
(TBOP4)

Fig.3.1 (b) Mechanical connection unit

NOTE
1 For detail of the peripheral device connection,
see the section of Peripheral device interface.
2 This cable is not included. It must be supplied by
the customer.

B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 283 -
3.2 EXTERNAL CABLE WIRING DIAGRAM

3.2.1 Robot Connection Cables

CAUTION
Before operating the robot, uncoil the
interconnection cables from their shipping position
to prevent excessive heat, which may damage the
cables.
(Coiled part should be shorter than 10 meter.)

There are two types of the robot connection cable;
Non-flex type: usage is restricted to fixed laying
Flex type: possible to use in the cable track

Specification of cable
Non-flex type Flex type
Robot
Diameter
(mm)
Weight
(kg/m)
Minimum
bending
radius
(mm)
Diameter
(mm)
Weight
(kg/m)
Minimum
bending
radius
(mm)
RP1 All models 15.7 0.45 200 20.5 0.71 200
Group 1 26.1 1.22 200 25.4 1.2 200
Group 2 20.0 0.7 200 18.4 0.7 200
Group 3 26.1 1.22 200 25.4 1.2 200
Group 4 26.1 1.22 200 25.4 1.2 200
Group 5 26.1 1.22 200 25.4 1.2 200
RM1
Group 6 20.0 0.7 200 - - -
Group 3 26.1 1.22 200 25.4 1.2 200
Group 4 26.1 1.22 200 25.4 1.2 200 RM2
Group 5 26.1 1.22 200 25.4 1.2 200
RP1 15.7 0.45 200 - - -
RM1
Group 7
20.0 0.7 200 - - -
RP1 14.2 0.31 200 20.5 0.71 200
RMP1
RM1
Group 8
20.0 0.7 200 18.4 0.7 200
EARTH All models 4.7 0.065 200 4.7 0.065 200

Group1 R-2000iB (except /200T), M-420iA, M-421iA M-710iC
Group2 ARC Mate 100iB, ARC Mate 120iB, M-6iB, M-16iB, F-200iB
Group3 R-2000iB/200T, M-410iB
Group4 M-900iA/260L,M-900iA/350
Group5 M-900iA/600
Group6 M-430iA/2F
Group7 M-430iA/2P
Group8 ARC Mate 100iC,M-10iA





3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 284 -
Using condition of flex type cable
(1) When routing cables in movable places, use a cable bearer.
(2) The bending radius (R) of the cable track is more than 200mm.
(3) The cable should be fixed to the cable track by using the clamp.
(e.g. rubber packing)
(4) The size of the hole to support a cable in the cable track should
be more than 110% of the cable size and should have the gap
more than 3mm.
(5) When cables are laid in the cable track, pay attention for the
cable not to be twisted.
Robot Model Group1:R-2000iB (expect /200T), M-420iA, M-421iA M-710iC
Group2:ARC Mate 100iB, ARC Mate 120iB, M-6iB, M-16iB, F-200iB
In case of A-cabinet
RI,RO,HBK,ROT

(Connection A-cabinet and Robot)
B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 285 -
In case of B-cabinet
RI,RO,HBK,ROT

(Connection B-cabinet and Robot)
- Detail of cable connection to servo amplifier.
















Fig. 3.2.1 (a) Robot connection cable (Group1, Group2)



R-30iA(Servo amplifier)





Robot






RP1
(Pulse coder, RI/RO, HBK, ROT)

RM1
Motor power/brake
(J1M, J2M, J3M, J4M, J5M, J6M, BK)
CNJ2A CNJ4 CNJ5 CNJ1A
CRR88 CNGA CNJ3A
CNGC
CRF8
CNJ6
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 286 -
Robot Model Group3:R-2000iB/200T, M-410iB
In case of A-cabinet
RI,RO,HBK,ROT

(Connection A-cabinet and Robot)
B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 287 -
In case of B-cabinet
RI,RO,HBK,ROT

(Connection B-cabinet and Robot)


- Detail of cable connection to servo amplifier.





















Fig. 3.2.1 (b) Robot connection cable (Group3)
R-30iA(Servo amplifier)





Robot






RP1
(Pulse coder, RI/RO, HBK, ROT)

RM1
Motor power/brake
(J1M, J2M, J3M, J4M, J5M, J6M, BK)

RM2
Motor power
(J1M, J2M, J3M)
CNJ2B CNJ1B
CNJ3B
CNJ1A
CRR88 CNGA CNJ3A
CNGC
CRF8
CNJ6
CNJ2A CNJ4 CNJ5
CNGB
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 288 -
Robot Model Group4:M-900iA/260L, M-900iA/350
In case of B-cabinet
RI,RO,HBK,ROT

(Connection B-cabinet and Robot)

- Detail of cable connection to servo amplifier.




















Fig. 3.2.1 (c) Robot connection cable (Group4)
R-30iA(Servo amplifier)





Robot






RP1
(Pulse coder, RI/RO, HBK, ROT)

RM1
Motor power/brake
(J1M, J2M, J3M, J4M, J5M, J6M, BK)

RM2
Motor power
(J1M, J2M, J3M)
CNJ1B CNJ2B
CNJ3B
CNJ1A
CRR88 CNGA CNJ3A
CNGC
CRF8
CNJ6
CNJ2A CNJ4 CNJ5
R
M
1
A

R
M
1
B

R
M
2
A

RCC I/F UNIT
CNGB
B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 289 -
Robot Model Group5:M-900iA/600
In case of B-cabinet
RI,RO,HBK,ROT

(Connection B-cabinet and Robot)

3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 290 -

- Detail of cable connection to servo amplifier.






























Fig. 3.2.1 (d) Robot connection cable (Group5)



















R-30iA

6-Axis Servo amplifier (AMP1)

















2-Axis Servo amplifier (AMP2)





1-Axis Servo amplifier (AMP3)


Robot






RP1
(Pulse coder, RI/RO, HBK, ROT)

RM1
Motor power/brake
(J1M, J2M, J3M, J4M, J5M, J6M, BK)

RM2
Motor power
(J1M, J2M, J3M, J4M, J5M, J6M)
CNJ3A
CNJ1A
CNJ1B
CRR88 CNGA
CNJ2A
CNJ2B
CNJ3B
R
M
1
A
R
M
1
B
R
M
2
A
RCC I/F UNIT
CRF8
CZ2 JF
CZ2L
CZ2M JF2
JF1
CNGB
B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 291 -
Robot Model Group6:M-430iA/2F
In case of A-cabinet
RI,RO,HBK,ROT

(Connection A-cabinet and Robot)






















3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 292 -
In case of B-cabinet
RI,RO,HBK,ROT

(Connection B-cabinet and Robot)

Detail of cable connection to servo amplifier.
























Fig. 3.2.1(e) Robot Connection CableGroup6
R-30iA(Servo amplifier)





Robot






RP1
(Pulse coder, RI/RO, HBK, ROT)

RM1
Motor power/brake
(J1MA, J1MB, J2MA, J2MB, J3MA,
J3MB, J4M,, J5M, J6M, BK)
CNJ2A CNJ4 CNJ5 CNJ1A
CRR88 CNGA CNJ3A
CNGC
CRF8
CNJ6
Servo amplifier
CZ2M
JF1
JF2
CZ2L
B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 293 -
Robot Model Group7:M-430iA/2P
In case of A-cabinet
RI,RO,HBK,ROT

(Connection A-cabinet and Robot)






















3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 294 -
In case of B-cabinet
RI,RO,HBK,ROT

(Connection B-cabinet and Robot)

Detail of cable connection to servo amplifier.























Fig. 3.2.1(f) Robot Connection CableGroup7
R-30iA(Servo amplifier)





Robot






RMP1
(Pulse coder, RI/RO, HBK, ROT)

Motor power/brake

CNJ5 CNJ1A
CRR88 CNGA CNJ3A
CRF8
Servo amplifier
CZ2M
JF2
JF3
CZ2L
CZ2N
JF1
B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 295 -
Robot Model Group8: ARC Mate 100iC,M-10iA
In case of A-cabinet
RI,RO,HBK,ROT

(Connection A-cabinet and Robot)






















3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 296 -
In case of B-cabinet
RI,RO,HBK,ROT

(Connection B-cabinet and Robot)

Detail of cable connection to servo amplifier.
















Fig. 3.2.1(g) Robot Connection CableGroup8
R-30iA(Servo amplifier)





Robot






RMP1
(Pulse coder, RI/RO, HBK, ROT)

Motor power/brake
CNJ2A CNJ4 CNJ5 CNJ1A
CRR88 CNGA CNJ3A
CRF8
CNJ6
B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 297 -
3.2.2 Teach Pendant Cable


(A-cabinet)

Panel board
Teach pendant
Teach pendant cable

(B-cabinet)

Fig.3.2.2 Teach pendant cable



Teach pendant
Panel board
Teach pendant cable
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 298 -
3.2.3 Connecting the Input Power

Considering the robot power capacity and the circuit breaker capacity,
connect the power supply whose voltage conforms to the installation
conditions to the terminal located above the circuit breaker.
Provide a class-D or better ground.


CAUTION
Disconnection of protective earth ground may
impair the protection provided by the system.
There shall be no switches or disconnects in the grounding conductor.

The resistance to the ground must not exceed 100.
Use a thick wire to withstand the maximum current used.
Selection of an input transformer tap is necessary depending on the
input voltage.
The tap is set to the specified voltage before shipment. However,
check it referring to section 6.2 in "Maintenance" before supplying
power (before the breaker switch is turned on).
The motor is driven by the PWM inverter system using a power
transistor bridge. If the servo amplifier is used without a transformer,
a high-frequency leakage current flows through the stray capacitance
between the ground and the motor coils, power cable, and amplifier.
This might cause the leakage-current circuit breaker or
leakage-protection relay installed in the path of the power supply to
cut out.
Use the following leakage current circuit breaker for inverters to
prevent incorrect operation.

Example of leakage current circuit breaker for inverters
Manufacture Type
Fuji Electric Co., Ltd. EG A series or later
SG A series or later
Hitachi, Ltd. ES100C type
ES225C type
Matsushita Electric
Works, Ltd.
Leakage current circuit breaker, C type
Leakage current circuit breaker, KC type

Fig.3.2.3 shows the cable connection.

B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 299 -

(A-cabinet)


(Note) Always replace the cover after completing
Input Power supply

(B-cabinet)
Fig.3.2.3 Input power supply connection (B-cabinet)

Input power supply cable
(Note) Always replace the
cover after completing
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 300 -
NOTE
On/off timing by the breaker
If the power supply is turned on, turned off, and then turned on again
repeatedly in a short time, the controller may not be started up. If the
power is turned off before the controller is completely started up (it takes
about 30 seconds), wait for at least 10 seconds before turning on the power
again.


OFF
ON
T
OFF-ON
10 sec T
ON-OFF
30 sec

The power is turned off within 30 seconds after it has been turned on.



B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 301 -
3.2.4 Connecting the External Power Supply ON/OFF Switch


(A-cabinet)


Panel board

(B-cabinet)
Fig.3.2.4 (a) Connection of the external power supply ON/OFF switch

Panel board
TBOP3
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 302 -

Contact specifications
Withstand voltage: 50VDC (across contacts)
Current: 100mA min. (min. load 2mA)
When using the external ON/OFF switch, remove
the short-circuit plate between EXOFF1 and
EXOFF2, and attach the cable to these terminals.
Shortcircuit plate :
between EXON1 and EXON2
EXON1
EXON2
EXOFF1
EXOFF2


Close
EXOFF1-2
POWER
OFF
ON
Open
T
OFF-ON
5 sec


NOTE
1 When the external power supply ON/OFF switch is
set to ON (closed), the controller can be turned on
and off by using the circuit breaker.
2 When the external power supply ON/OFF switch is
set to OFF (open), the controller cannot be turned
on and off by using the circuit breaker.

Fig.3.2.4 (b) Connection of the external power supply switch ON and OFF

B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 303 -
3.2.5 Connecting the External Emergency Stop


(A-cabinet)


Panel board

(B-cabinet)
Fig.3.2.5 (a) Connection of the external emergency stop

Panel board
TBOP3
TBOP4
TBOP6
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 304 -
External emergency stop output




Panel board

For the circuit, see Figure A (e) in Appendix A, "TOTAL
CONNECTION DIAGRAM".
The SVOFF input signal does not affect EMGOUT

Signal Description Current, voltage Min. load
ESPB1 ESPB11
ESPB2 ESPB21
ESPB3 ESPB31
ESPB4 ESPB41
Emergency stop output signals. The
contact is open if an emergency stop
occurs or the power is turned off. The
contact is closed during normal operation.
Rated contact:
250 VAC, 5-A resistor load
300 VDC, 5-A resistor load
(Reference value)
DC5V 10mA





E
S
P
B
1

E
S
P
B
1
1

E
S
P
B
2

E
S
P
B
2
1

E
S
P
B
3

E
S
P
B
3
1

E
S
P
B
4

E
S
P
B
4
1

B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 305 -





































ESPB1
ESPB11
ESPB2
ESPB21
ESPB3
ESPB31
ESPB4
ESPB41
Internal
circuit
+24EXT
0EXT
0EXT
+24EXT
TP emergency
stop button
KA21
KA22
Control
circuit
ESPB1
ESPB11
ESPB2
ESPB21
Example of the connection with the safety relay
Robot controller
Safety relay unit
Contact output signal ensured safety

WARNING
In case of using the contact of the
emergency stop output signal, be
sure to pair ESPB1 with ESPB2,
and ESPB3 with ESPB4.
Robot controller does not detect
the breakdown of the contact of
the emergency stop output signal.
Take countermeasures such as
inspecting the duplicated
contacts, or using a safety relay
circuit that can detect the
breakdown.
Operator panel
emergency stop button
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 306 -
External emergency stop input
External emergency stop switch
Fence
Servo ON/OFF
input switch
Servo disconnect
switch signal
These terminals are
factory-jumpered. When using
external emergency stop inputs,
remove the short-circuit plate.
E
G
S
2
1
E
G
S
2

E
G
S
1
1
E
G
S
1

E
A
S
2
1

E
A
S
2

E
A
S
1
1

E
A
S
1

E
E
S
2
1

E
E
S
2

E
E
S
1
1

E
E
S
1

SD4
SD41
SD5
SD51


Signal Description Current, voltage
EES1
EES11
EES2
EES21
Connect the contacts of the external emergency stop switch to these
terminals. When a contact is open, the servo power supply is turned off, and
the robot is immediately placed in the emergency stop state. When using
the contacts of a relay or contactor instead of the switch, connect a spark
killer to the coil of the relay or contactor, to suppress noise. When these
terminals are not used, jumper them.
Open and close of
24VDC 0.1A
(Note 1)
EAS1
EAS11
EAS2
EAS21
These signals are used to stop the robot safely when the safety fence gate is
opened during operation in the AUTO mode. When a contact is open, the
robot decelerates then stops, and the servo power supply is turned off.
In the T1 or T2 mode, the robot can be operated even when the safety fence
gate is open.
When using the contacts of a relay or contactor instead of the switch, connect
a spark killer to the coil of the relay or contactor, to suppress noise. When
these terminals are not used, jumper them.
Open and close of
24VDC 0.1A
(Note 1)
EGS1
EGS11
EGS2
EGS21
Connect the contacts of the servo-off input switch to these terminals. When
a contact is open, the robot decelerates then stops, and the servo power
supply is turned off. When using the contacts of a relay or contactor
instead of the switch, connect a spark killer to the coil of the relay or
contactor, to suppress noise. When these terminals are not used, jumper
them.
Open and close of
24VDC 0.1A
(Note 1)
B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 307 -
Signal Description Current, voltage
SD4
SD41
SD5
SD51
Connect the contacts of the servo disconnect switch to these terminals.
When a contact is open, the servo power supply is turned off, and the robot
stops immediately.
When using the contacts of a relay or contactor instead of the switch, connect
a spark killer to the coil of the relay or contactor, to suppress noise. When
these terminals are not used, jumper them.
Open and close of
24VDC 0.1A
(Note 1)

NOTE
1 Use a contact which minimum load is 5 mA less.


EES1
EES11
EES2
EES21
Examples of connection of duplicate safety signals
External emergency stop switch
EES1
EES11
EES2
EES21
External emergency stop switch
Correct connection
Discrepancy in duplicate inputs results in an alarm.
Wrong connection

Input timing of duplicate safety signals
Duplicate inputs are used for signals such as the external emergency
stop signal, safety fence signal, and servo off signal so that a response
is made even when a single failure occurs. The statuses of these
duplicate input signals must always be changed at the same timing
according to the timing specifications provided in this section. The
robot control unit always checks that the statuses of the duplicate
inputs are the same, and if the control unit finds a discrepancy, it
issues an alarm. If the timing specifications are not satisfied, an
alarm may be issued because of a signal discrepancy.

3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 308 -

Open
Close
EES1
EAS1
EGS1
SD4
EES2
EAS2
EGS2
SD5
T
DIF
T
OPEN
T
OPEN
T
DIF
T
DIF
(input time difference)< 200msec
Open
Close
T
OPEN
(input hold period) > 2sec

Fig. 3.2.5(b) Input timing of duplicate safety signals

B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 309 -
External power connection









The relays for emergency stop input and output can be separated from
controllers power.Please connect external +24V instead of internal
+24V,if emeregency stop output must not be effected controllers
power.

EXT24V
INT24V
INT0V
EXT0V
Example of the connection
In case of not using the external
power source
In case of using the external power source
EXT24V
INT24V
INT0V
EXT0V
24V
0V
External power source
+24V(10%)
more than 300mA
EXT0V EXT24V
External power source
+24V(10%)
more than 300mA

EXT
0V 24V
INT
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 310 -

Connecting external on/off and external emergency stop signal input/output
wires
FANUC's specification Manufacturer's
specification (WAGO)
Remark
8-pole terminal block
(TBOP3)
A63L-0001-0783#308 231-311/026-000 External emergency stop
12-pole terminal block
(TBOP4,6)
A63L-0001-0783#312 231-304/026-000 External ON/OFF
Jumper pin A63L-0001-0783#902 231-902
Operation lever A63L-0001-0783#131-M 231-131 2 pieces of 231-131 and operation
manual are included in FANUC's
specification

1. Detach the plug connector block from the panel board.
2. Insert the tip of a flat-blade screwdriver into the manipulation
slot and push down its handle.
3. Insert the end of the signal wire into the wire slot.
4. Pull out the screwdriver.
5. Attach the plug connector block to the panel board.

Do not insert a wire into the wire hole of a plug connector or pull
it out with the plug connector block mounted on the panel board;
otherwise, the panel board may be damaged.

FANUC recommonds the lever (A05B-2400-K030) for connecting the
signal wire to the plug connector block instead of Flat-blade
screwdriver.


Manipulation slot
Flat-blade
screwdriver
Signal wire
Details of section A

B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 311 -



(1) Pull down the lever.





(2) Push in the conductor while
holding the lever.



(3) Set the lever free.
* And pull the conductor softly to
check the clamping.


* Don't pull strongly.
Wiring
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 312 -


(1) Pull off the lever. Be careful not
to lose the lever.



(2) Hook the lever to the rectangle
hole.


(3) Push down the lever untill click in.




(1) Push in the connector to header.

* Be careful to fit the
shape of each other.



(2) Please check if the latch is hooked to header.








(1) Attach levers to connector.


(2) Hold down levers at the same time,
then put the jumper into connector.







* Please check the direction of the
jumper.
Replace the lever
Fit to header
Installation of "Jumper"
B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 313 -


- Without jumpers




* Max wire size 0 2.0mm
2
(AWG14)
(with "Ferrule")


- With jumper



- Additional wire is available under the
jumper.
* Max wire size 0 0.5mm
2
(AWG20)
(with "Ferrule")

- With two jumpers



- Additional wire is not available
under the jumper.



(1) Put the wire through the
hole of ferrules.
(2) Introduce wire with ferrule
into cramping station.
(3) Squeeze handles until
ratchet mechanism is
released.
(4) Please check if
the wire crimped
correctly.
Crimping Toole (Specification : WAGO Item-No.206-204)



WAGO
Item-No.
Wire size
mm
2
Color
Stripped
Length
(mm)
L L1 D
(mm)
D1 D2
Pack.-unit
pcs
216-301
216-302
216-201
216-202
216-203
216-204
216-205
0.25
0.34
0.5
0.75
1.0
1.5
2.0
light yellow
light green
white
gray
red
black
yellow
9.5
9.5
9.5
10.0
10.0
10.0
10.0
12.5
12.5
14.0
14.0
14.0
14.0
14.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
2.5
2.5
3.1
3.3
3.5
4.0
4.2
2.0
2.0
2.6
2.8
3.0
3.5
3.7
0.8
0.8
1.0
1.2
1.4
1.7
2.0
100
100
100
100
100
100
100

CAUTION Please make sure to use WAGO 206-204 to crimp the ferrules.



Availability of wires
Installation of "Ferrules"
Specifications of Ferrules
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 314 -
3.2.6 Connecting the Non-Teaching Enabling (NTED) Signal
(CRM65)



Fig. 3.2.6 Connecting the NTED Signal

NTED signal is the signal to be able to connect with the switch that is
same function as deadman switch on the teach pendant.In the auto
mode, robot moves without reference to the state of the switch
connected with NTED signal.
Refer to APPENDIX A,Total connection Diagram Fig.A(e) about
NTED circuit.
Input timing of NTED signal must comply with rules in the section
Input timing of duplicate safety signals.

NOTE
After connnecting NTED switch, be sure to check
the operation of those switches, the emergency stop
button on the operators panel/operation box, and
the emergency stop button on the teach pendant.


CRM65 (NTED)
B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 315 -













CRM65 connector
A1 NTED1 B1 NTED2
A2 NTED11 B2 NTED21
A3 B3
NTED signal connector manufactured by Tyco Electronics AMP k.k.
( Specification Rece-housing 1-1318119-3
Rece-contact 131807-1





NTED1
NTED11
NTED2
NTED21
Enabling Device
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 316 -
3.2.7 Connecting the Auxiliary Axis BrakeCRR65 A/B




Fig.3.2.7 6-axis servo amplifier

CRR65 A/B
A1 BKA1 B1 BKA2
A2 B2
A3 COMMON B3 COMMON
CRR65 A/B connector manufacutured by Tyco Electronics AMP k.k.
( Specification Rece-housing 1-178129-6
Rece-contact 175218-2



CRR65
B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 317 -
3.2.8 Connecting the Auxiliary Axis Over Travel (CRM68)




Fig.3.2.8 6-axis servo amplifier

CRM68
A1 AUXOT1
A2 AUXOT2
A3
CRM68 connector manufacutured by Tyco Electronics AMP k.k.
( Specification Rece-housing 1-1318120-3
Rece-contact 1318107-1




CRM68
3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 318 -
3.2.9 Connecting the Operation Box

The operation box is not connected to the controller in shipment in
some robot models. In this case connect the operation box connection
cable to the operation box as following drawings. Also connect the
input power cable and the teach pendant cable as described in section
3.2.2 and 3.2.3








JD1B
Signal Line
Power Line
Port (M4 NUT 3 Places)
JRS15
CRM95
Cable clamp
B-82595EN-2/02 CONNECTIONS
- 319 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4 PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES

R-30iA I/O peripheral device interfaces include printed circuit boards
and a unit selected according to the applications. Table 4 lists details
of the printed-circuit boards and units. Figure 4 shows the locations
of these boards and units.

Table 4 Peripheral Device Interface Types
Number of I/O points
No. Name
Drawing
number DI DO D/A A/D
Remarks
1 Process I/O board CA A05B-2500-J003 40 40 (sink type) 2 6 Installed in back plane
2 Process I/O board EA A05B-2500-J012 40 40 (sink type) 2 3 Installed in operation box
3 Process I/O board EB A05B-2500-J013 40 40 (sink type) 0 0 Installed in operation box
4 Process I/O board FA A05B-2500-J014 96 96 (sink type) 0 0 Installed in operation box
5 Process I/O board GA A05B-2500-J015 40 40 (sink type) 2 0 Installed in operation box
6 Process I/O board HA A05B-2500-J006 40 40 (sink type) 2 0 Installed in back plane
7 Process I/O board JA A05B-2500-J001 96 96
(source type)
0 0 Installed in back plane
8 Process I/O board JB A05B-2500-J002 40 40
(source type)
0 0 Installed in back plane
9 Process I/O board KA A05B-2500-J010 40 40
(source type)
3 2 Installed in operation box
10 Process I/O board KB A05B-2500-J011 40 40
(source type)
2 0 Installed in operation box
11 Process I/O board KC A05B-2500-J016 40 40
(source type)
0 0 Installed in operation box
12 I/O Unit-MODEL A A05B-2502-J090
(Base and
interface unit)
Depending on selected I/O module. Common to both A and
B-cabinet (five slots)

CONNECTIONS B-82595EN-2/02
- 320 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
NOTE
1 General purpose I/O (DI/DO) is a number which subtract an exclusive signal from
the table value.
Example : Process I/O board JB
Table value Exclusive DI General purpose DI
DI; 40 - 18 = 22 points
Table value Exclusive DO General purpose DO
DO; 40 - 20 = 20 points
2 When there are slave units on the I/O Link and the power for control to these slave
units is supplied from other than the robot control unit, the power to the controller
and the power to the slave units must be turned on and off at the following timings:
a) The power to the slave units must be turned on before or when the power to the
controller, which is the master of the I/O Link, is turned on.
b) If the power to a slave unit is turned off after the system has started up, an I/O
Link error occurs. To establish the I/O Link again, turn off the power to all units
including the control unit, then turn on the power to the units in the order
described in a).


B-82595EN-2/02 CONNECTIONS
- 321 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

(A-cabinet)


Optional slot
I/O Unit-MODEL A

(B-cabinet)
Fig.4 Locations of Peripheral Device Interfaces
Process I/O board
CONNECTIONS B-82595EN-2/02
- 322 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM

Following are a block diagram of the peripheral device interface and
the specifications.

4.1.1 When Process I/O Board EA/EB/GA is Used (A-cabinet)


A-cabinet Operation box
Main
board
JD1A JD1B
CP5
Process I/O
board
EA/EB/GA
CRM2A
CRM2B
CRW1
or CRW7
(NOTE 2)
CRW2
Panel board
Peripheral
device
(1)
(2)
(5)
(4)
(3)
CP5A

Fig.4.1.1 Block diagram of the process I/O board EA, EB and GA


NOTE
1 CRW1 and CRW2 are not provided for process I/O board EB
2 In case of process I/O board EA: CRW1
In case of process I/O board GA: CRW7

B-82595EN-2/02 CONNECTIONS
- 323 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Number Name Drawing number Remarks
A05B-2501-H460 Connected length : 5m
A05B-2501-H461 Connected length : 10m
(1) Operation box connection cable
A05B-2501-H462 Connected length : 2m
(2) Process I/O power supply cable A05B-2501-J150
A05B-2501-J203 Connected length : 10m (one)
A05B-2501-J204 Connected length : 20m (one)
(3) (4) Peripheral device connection cable
(Process I/O EA, EB, FA, GA)
A05B-2501-J205 Connected length : 30m (one)
A05B-2501-J279 Connected length : 10m (one) CRW1
A05B-2501-J280 Connected length : 20m (one) CRW1
Welding device connection cable
(Process I/O EA)
(Fanuc interface / elbow) A05B-2501-J281 Connected length : 30m (one) CRW1
A05B-2501-J229 Connected length : 10m (one) CRW1
A05B-2501-J230 Connected length : 20m (one) CRW1
Welding device connection cable
(Process I/O EA)
(Fanuc interface / straight) A05B-2501-J231 Connected length : 30m (one) CRW1
A05B-2501-J282 Connected length : 10m (one) CRW7
A05B-2501-J283 Connected length : 20m (one) CRW7
Welding device connection cable
(Process I/O GA)
(General-purpose interface / elbow) A05B-2501-J284 Connected length : 30m (one) CRW7
A05B-2501-J232 Connected length : 10m (one) CRW7
A05B-2501-J233 Connected length : 20m (one) CRW7
Welding device connection cable
(Process I/O GA)
(General-purpose interface / straight) A05B-2501-J234 Connected length : 30m (one) CRW7
A05B-2501-J285 Connected length : 10m (one) CRW7
A05B-2501-J286 Connected length : 20m (one) CRW7
Welding device connection cable
(Process I/O GA)
(Fanuc interface / elbow) A05B-2501-J287 Connected length : 30m (one) CRW7
A05B-2501-J235 Connected length : 10m (one) CRW7
A05B-2501-J236 Connected length : 20m (one) CRW7
(5)
Welding device connection cable
(Process I/O GA)
(Fanuc interface / straight) A05B-2501-J237 Connected length : 30m (one) CRW7

CONNECTIONS B-82595EN-2/02
- 324 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.1.2 When Process I/O Board FA is Used (A-cabinet)


A-cabinet Operation box
Main
board
JD1A JD1B
CP5
Process I/O
board
FA
Panel board
Peripheral
device
(1)
(2)
CRM2A
CRM2B
(4)
(3)
CP5A
CRM2C
CRM2D
(6)
(5)
CRM4A
CRM4B
(8)
(7)

Fig.4.1.2 Block diagram of the process I/O board FA

Number Name Drawing number Remarks
A05B-2501-H460 Connected length : 5m
A05B-2501-H461 Connected length : 10m
(1) Operation box connection cable
A05B-2501-H462 Connected length : 2m
(2) Process I/O power supply cable A05B-2501-J150
A05B-2501-J203 Connected length : 10m (one)
A05B-2501-J204 Connected length : 20m (one)
(3) (4)
(5) (6)
Peripheral device connection cable
A05B-2501-J205 Connected length : 30m (one)
A05B-2501-J253 Connected length : 10m (one)
A05B-2501-J254 Connected length : 20m (one)
(7)
(8)
Peripheral device connection cable
A05B-2501-J255 Connected length : 30m (one)

B-82595EN-2/02 CONNECTIONS
- 325 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.1.3 When Process I/O Board CA/HA is Used (B-cabinet)


Main
board
JD1A
JD1B
(JD4A)
Process I/O board
CA/HA
Process I/O board
CA/HA
Peripheral
device
(1)
(2)
(5)
(4)
(3)
CRM2A
CRM2B
CRW1
or CRW7
(NOTE)
CRW2
CRM2A
CRM2B
CRW1
or CRW7
(NOTE)
CRW2
JD1A
(JD4B)
JD1B
(JD4A)
JD1A
(JD4B)


Fig.4.1.3 Block diagram of the process I/O board CA/HA

NOTE
Process I/O board CA: CRW1
Process I/O board HA: CRW7


CONNECTIONS B-82595EN-2/02
- 326 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Number Name
Drawing
number
Remarks
(1) I/O Link cable A05B-2502-J130 Between main board and process I/O
(2) I/O Link cable A05B-2502-J131 Between process I/O and process I/O
A05B-2502-J170 Connected length : 10m (one)
A05B-2502-J171 Connected length : 20m (one)
(3) (4) Peripheral device connection cable
(Process I/O CA, HA)
A05B-2502-J172 Connected length : 30m (one)
A05B-2502-J200 Connected length : 10m (one) CRW1
A05B-2502-J201 Connected length : 20m (one) CRW1
Welding device connection cable
(Process I/O CA)
(Fanuc interface / elbow) A05B-2502-J202 Connected length : 30m (one) CRW1
A05B-2502-J203 Connected length : 10m (one) CRW1
A05B-2502-J204 Connected length : 20m (one) CRW1
Welding device connection cable
(Process I/O CA)
(Fanuc interface / straight) A05B-2502-J205 Connected length : 30m (one) CRW1
A05B-2502-J206 Connected length : 10m (one) CRW7
A05B-2502-J207 Connected length : 20m (one) CRW7
Welding device connection cable
(Process I/O HA)
(General-purpose interface / elbow) A05B-2502-J208 Connected length : 30m (one) CRW7
A05B-2502-J210 Connected length : 10m (one) CRW7
A05B-2502-J211 Connected length : 20m (one) CRW7
Welding device connection cable
(Process I/O HA)
(General-purpose interface / straight) A05B-2502-J212 Connected length : 30m (one) CRW7
A05B-2502-J213 Connected length : 10m (one) CRW7
A05B-2502-J214 Connected length : 20m (one) CRW7
Welding device connection cable
(Process I/O HA)
(Fanuc interface / elbow) A05B-2502-J215 Connected length : 30m (one) CRW7
A05B-2502-J216 Connected length : 10m (one) CRW7
A05B-2502-J217 Connected length : 20m (one) CRW7
(5)
Welding device connection cable
(Process I/O HA)
(Fanuc interface / straight) A05B-2502-J218 Connected length : 30m (one) CRW7

B-82595EN-2/02 CONNECTIONS
- 327 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.1.4 When Process I/O Board JA/JB is Used (B-cabinet)


Main
board
JD1A
JD1B
JD1A

JD1B
JD1A
Process I/O board
JA/JB
CRMA5A
CRMA5B
CRMA5C
CRMA6B
CRMA5D
CRMA6A
CRMA6B
CRMA5A
CRMA5B
CRMA5C
CRMA5D
CRMA6A
Process I/O board
JA/JB
Peripheral
device
(1)
(2)
(5)
(6)
(4)
(3)
(7)
(8)


Fig.4.1.4 Block diagram of the process I/O board JA/JB

NOTE
The process I/O board JB has none of CRMA5C,
CRMA5D, CRMA6A, and CRMA6B.

Number Name
Drawing
number
Remarks
(1) I/O Link cable A05B-2502-J130 Between main board and process I/O
(2) I/O Link cable A05B-2502-J131 Between process I/O and process I/O
A05B-2502-J160 Connected length : 10m (one)
A05B-2502-J161 Connected length : 20m (one)
(3) (4)
(5) (6)
Peripheral device connection cable
(Process I/O JA, JB)
A05B-2502-J162 Connected length : 30m (one)
A05B-2502-J180 Connected length : 10m (one)
A05B-2502-J181 Connected length : 20m (one)
(7)
(8)
Peripheral device connection cable
(Process I/O JA)
A05B-2502-J182 Connected length : 30m (one)

CONNECTIONS B-82595EN-2/02
- 328 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.1.5 When Process I/O Board KA/KB/KC is Used (A-Cabinet)


A-cabinet Operation box
Main board
JD1A
JD1B
CP5
Process I/O
board
KA/KB/KC
CRMA5A
CRMA5B
CRW10
Panel board
Peripheral
device
(1)
(2)
(5)
(4)
(3)
CP5A


Fig. 4.1.5 Block diagram of the process I/O board KA/KB/KC

NOTE
CRW10 is not provided for process I/O board KC.

Number Name Drawing number Remarks
A05B-2501-H450 Connection length of 4 m
A05B-2501-H451 Connection length of 10 m
(1) Operator panel box connection
cable
A05B-2501-H452 Connection length of 2 m
(2) Process I/O board power supply
cable
A05B-2501-J150
A05B-2501-J050 Connection length of 10 m (one)
A05B-2501-J051 Connection length of 20 m (one)
(3)
(4)
Peripheral device connection
cable
A05B-2501-J052 Connection length of 30 m (one)
A05B-2501-J053 Connection length of 3 m (one),
CRW10
A05B-2501-J054 Connection length of 7 m (one),
CRW10
Welding machine connection
cable
(for process I/O board KB)
(general interface/elbow type)
A05B-2501-J055 Connection length of 14 m (one),
CRW10
A05B-2501-J056 Connection length of 3 m (one),
CRW10
A05B-2501-J057 Connection length of 7 m (one),
CRW10
(5)
Welding machine connection
cable
(for process I/O board KA, KB)
(FANUC interface/elbow type)
A05B-2501-J058 Connection length of 14 m (one),
CRW10


B-82595EN-2/02 CONNECTIONS
- 329 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.1.6 When I/O Unit-MODEL A is Used

4.1.6.1 In case of B-cabinet



B-cabinet
Peripheral
device

Main
board


JD1A




Interface module






B
a
c
k

p
l
a
n
e

(
f
i
v
e
-
s
l
o
t
)

J
D
1
A

J
D
1
B

C
P
3
2






K25
K54
K54
K54
K54
K54
E-Stop
unit CP5A

CP5A

K26

Fig.4.1.6.1 Block diagram of I/O Unit-A (In case of B-cabinet)

Cable
number
Name
Drawing
number
Remarks
K25 I/O Link cable - Included in A05B-2502-J090
K26 I/O Link cable - Included in A05B-2502-J090
K54 Peripheral device
connection cable
-
Must be supplied by the
customer.
K54 Peripheral device
connection cable
-
Must be supplied by the
customer.

CONNECTIONS B-82595EN-2/02
- 330 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.1.7 When Two or more Process I/O Printed Circuit Boards and I/O
Unit-MODEL A are Used

4.1.7.1 In case of B-cabinet

When several units of the process I/O PCB, I/O Unit-A are used,
connect them as shown below.


B-cabinet
Back plane (five-slot)
I/O Unit-A
Interface module
JD1B
JD1A
CP32
Main
board


JD1A

Process I/O board

JD1B
JD1A
Process I/O board

JD1B
JD1A
A05B-2502-J130
A05B-2502-J131
Included in model A base
unit
A05B-2502-J090
DC power is supplied
from the back plane.
E-stop unit




CP5A


Fig.4.1.7.1 Block diagram of two or more process I/O printed circuit boards and I/O unit-MODEL A
(In case of B-cabinet)
B-82595EN-2/02 CONNECTIONS
- 331 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.2 PERIPHERAL DEVICE INTERFACE COMBINATION

Peripheral device interfaces can be used by using process I/O boards
and the I/O Unit-MODEL A.

4.2.1 In Case of A-cabinet

Only one of the following peripheral device interfaces can be used in
A-cabinet.
Process I/O board EA
Process I/O board EB
Process I/O board FA
Process I/O board GA
Process I/O board KA
Process I/O board KB
Process I/O board KC
I/O unit Model A (5 slots)
If you want to use more than one interface unit in combination in case
of A-cabinet, you need another box contact a FANUC sales
representative for details.

CONNECTIONS B-82595EN-2/02
- 332 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.2.2 In Case of B-cabinet
One board or one unit is used
Combination C Process I/O board CA/HA/JB (40 points/40 points)
Combination D Process I/O board JA (96 points/96 points)
Combination E I/O Unit-MODEL A

Two boards/units are used in combination
Combination CE
Process I/O board CA/HA/JB (40 points/40 points)
+
I/O Unit-MODEL A

Combination DC
Process I/O board JA (96 points/96 points)
+
Process I/O board CA/HA/JB (40 points/40 points)
Combination DD
Process I/O board JA (96 points/96 points)
+
Process I/O board JA (96 points/96 points)
Combination DE
Process I/O board JA (96 points/96 points)
+
I/O Unit-MODEL A

Three boards/units are used in combination
Combination DCE
Process I/O board JA (96 points/96 points)
+
Process I/O board CA/HA/JB (40 points/40 points)
+
I/O Unit-MODEL A
Combination DDE
Process I/O board JA (96 points/96 points)
+
Process I/O board JA (96 points/96 points)
+
I/O Unit-MODEL A
B-82595EN-2/02 CONNECTIONS
- 333 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.3 PROCESS I/O BOARD SIGNALS

There are 18 exclusive data inputs (DI) and 20 exclusive data outputs
(DO) for a process I/O board.
These signals are allocated to the process I/O board connected first
when two or more printed boards are combined. (General signals
DI/DO are allocated to the second and the following process I/O
boards.)
The common voltage of the DI signals input to pins 1 to 4 of
connector CRMA5A or CRM2A is clamped +24 V (common) in each
process I/O board.
Table 4.3 shows signals of a process I/O board.

Table 4.3 Process I/O Board Signals
Connector
number
Signal name Description Remarks
(DI signals)
CRMA5A- 1
(CRM2A is
similar to
CRMA5A)
*IMSTP Immediate stop Clamped at +24 V
common
CRMA5A- 2 *HOLD Temporary stop Clamped at +24 V
common
CRMA5A- 3 *SFSD Safe speed Clamped at +24 V
common
CRMA5A- 4 CSTOPI Cycle stop Clamped at +24 V
common
CRMA5A- 5 FAULT RESET External reset
CRMA5A- 6 START Start
CRMA5A- 7 HOME Return to home position
CRMA5A- 8 ENBL Operation enabled
CRMA5A- 9 RSR1 Robot service request
PNS1 Program number selection Option
CRMA5A-10 RSR2 Robot service request
PNS2 Program number selection Option
CRMA5A-11 RSR3 Robot service request
PNS3 Program number selection Option
CRMA5A-12 RSR4 Robot service request
PNS4 Program number selection Option
CRMA5A-13 RSR5 Robot service request
PNS5 Program number selection Option
CRMA5A-14 RSR6 Robot service request
PNS6 Program number selection Option
CRMA5A-15 RSR7 Robot service request
PNS7 Program number selection Option
CRMA5A-16 RSR8 Robot service request
PNS8 Program number selection Option
CRMA5A-29 PNSTROBE PNS strobe
CRMA5A-30 PROD START Start of automatic operation
CRMA5A-31 DI01 Peripheral device status General signal
CRMA5A-32 DI02 Peripheral device status General signal
CRMA5B- 1 DI03 Peripheral device status General signal
CONNECTIONS B-82595EN-2/02
- 334 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Connector
number
Signal name Description Remarks
CRMA5B- 2 DI04 Peripheral device status General signal
CRMA5B- 3 DI05 Peripheral device status General signal
CRMA5B- 4 DI06 Peripheral device status General signal
CRMA5B- 5 DI07 Peripheral device status General signal
CRMA5B- 6 DI08 Peripheral device status General signal
CRMA5B- 7 DI09 Peripheral device status General signal
CRMA5B- 8 DI10 Peripheral device status General signal
CRMA5B- 9 DI11 Peripheral device status General signal
CRMA5B-10 DI12 Peripheral device status General signal
CRMA5B-11 DI13 Peripheral device status General signal
CRMA5B-12 DI14 Peripheral device status General signal
CRMA5B-13 DI15 Peripheral device status General signal
CRMA5B-14 DI16 Peripheral device status General signal
CRMA5B-15 DI17 Peripheral device status General signal
CRMA5B-16 DI18 Peripheral device status General signal
CRMA5B-29 DI19 Peripheral device status General signal
CRMA5B-30 DI20 Peripheral device status General signal
CRMA5B-31 DI21 Peripheral device status General signal
CRMA5B-32 DI22 Peripheral device status General signal
(DO signals)
CRMA5A-33 CMDENBL During automatic operation
CRMA5A-34 SYSRDY Preparation completed
CRMA5A-35 PROGRUN Program running
CRMA5A-36 PAUSED Program being interrupted
CRMA5A-38 HELD During temporary stop
CRMA5A-39 FAULT Alarm
CRMA5A-40 ATPERCH Home position
CRMA5A-41 TPENBL Teach pendant enabled
CRMA5A-43 BATALM Battery voltage drop
CRMA5A-44 BUSY During operation
CRMA5A-45 ACK1 Robot service request acceptance
SNO1 Selected program number Option
CRMA5A-46 ACK2 Robot service request acceptance
SNO2 Selected program number Option
CRMA5A-19 ACK3 Robot service request acceptance
SNO3 Selected program number Option
CRMA5A-20 ACK4 Robot service request acceptance
SNO4 Selected program number Option
CRMA5A-21 ACK5 Robot service request acceptance
SNO5 Selected program number Option
CRMA5A-22 ACK6 Robot service request acceptance
SNO6 Selected program number Option
CRMA5A-24 ACK7 Robot service request acceptance
SNO7 Selected program number Option
CRMA5A-25 ACK8 Robot service request acceptance
SNO8 Selected program number Option
CRMA5A-26 SNACK Response signal to PNS
CRMA5A-27 RESERVED
CRMA5B-33 DO01 Peripheral device control signal General signal
CRMA5B-34 DO02 Peripheral device control signal General signal
CRMA5B-35 DO03 Peripheral device control signal General signal
B-82595EN-2/02 CONNECTIONS
- 335 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Connector
number
Signal name Description Remarks
CRMA5B-36 DO04 Peripheral device control signal General signal
CRMA5B-38 DO05 Peripheral device control signal General signal
CRMA5B-39 DO06 Peripheral device control signal General signal
CRMA5B-40 DO07 Peripheral device control signal General signal
CRMA5B-41 DO08 Peripheral device control signal General signal
CRMA5B-43 DO09 Peripheral device control signal General signal
CRMA5B-44 DO10 Peripheral device control signal General signal
CRMA5B-45 DO11 Peripheral device control signal General signal
CRMA5B-46 DO12 Peripheral device control signal General signal
CRMA5B-19 DO13 Peripheral device control signal General signal
CRMA5B-20 DO14 Peripheral device control signal General signal
CRMA5B-21 DO15 Peripheral device control signal General signal
CRMA5B-22 DO16 Peripheral device control signal General signal
CRMA5B-24 DO17 Peripheral device control signal General signal
CRMA5B-25 DO18 Peripheral device control signal General signal
CRMA5B-26 DO19 Peripheral device control signal General signal
CRMA5B-27 DO20 Peripheral device control signal General signal

CONNECTIONS B-82595EN-2/02
- 336 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.4 INTERFACE FOR PERIPHERAL DEVICES

4.4.1 Peripheral Device and Control Unit Connection
(Source Type DO)


Peripheral device control interface A1
(Source type DO)
CRMA5A
01 *IMSTP 33 CMDENBL
02 *HOLD 19 ACK3/SNO3 34 SYSRDY
03 *SFSPD 20 ACK4/SNO4 35 PROGRUN
04 CSTOPI 21 ACK5/SNO5 36 PAUSED
05 FAULT RESET 22 ACK6/SNO6 37 DOSRC1
06 START 23 DOSRC1 38 HELD
07 HOME 24 ACK7/SNO7 39 FAULT
08 ENBL 25 ACK8/SNO8 40 ATPERCH
09 RSR1/PNS1 26 SNACK 41 TPENBL
10 RSR2/PNS2 27 RESERVED 42 DOSRC1
11 RSR3/PNS3 28 DOSRC1 43 BATALM
12 RSR4/PNS4 29 PNSTROBE 44 BUSY
13 RSR5/PNS5 30 PROD START 45 ACK1/SNO1
14 RSR6/PNS6 31 DI01 46 ACK2/SNO2
15 RSR7/PNS7 32 DI02 47 DOSRC1
16 RSR8/PNS8 48
17 0V 49 +24E
18 0V

50 +24E
Peripheral device control interface A2
(Source type DO)
CRMA5B
01 DI03 33 DO01
02 DI04 19 DO13 34 DO02
03 DI05 20 DO14 35 DO03
04 DI06 21 DO15 36 DO04
05 DI07 22 DO16 37 DOSRC1
06 DI08 23 DOSRC1 38 DO05
07 DI09 24 DO17 39 DO06
08 DI10 25 DO18 40 DO07
09 DI11 26 DO19 41 DO08
10 DI12 27 DO20 42 DOSRC1
11 DI13 28 DOSRC1 43 DO09
12 DI14 29 DI19 44 DO10
13 DI15 30 DI20 45 DO11
14 DI16 31 DI21 46 DO12
15 DI17 32 DI22 47 DOSRC1
16 DI18 48
17 0V 49 +24E
18 0V

50 +24E
Terminal block
TBSRC1
1 DOSRC1
2 0V


Peripheral
device A1
Peripheral
device A2
Control
unit
B-82595EN-2/02 CONNECTIONS
- 337 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

NOTE
1 The peripheral device connection cables are
optional.
2 The DOSRC1 pins of the CRMA5A and CRMA5B
are pins for supplying power to drivers. (None of
these pins can be left open.)
3 When the level of the voltage applied to the load is
insufficient for a cause such as a too long
peripheral device connection cable, supply power
from the TBSRC1 terminal block.

Applicable process I/O board type
JA, JB, KA, KB, KC

CONNECTIONS B-82595EN-2/02
- 338 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Peripheral device control interface A3
(Source type DO)
CRMA5C
01 DI23 33 DO21
02 DI24 19 DO33 34 DO22
03 DI25 20 DO34 35 DO23
04 DI26 21 DO35 36 DO24
05 DI27 22 DO36 37 DOSRC2
06 DI28 23 DOSRC2 38 DO25
07 DI29 24 DO37 39 DO26
08 DI30 25 DO38 40 DO27
09 DI31 26 DO39 41 DO28
10 DI32 27 DO40 42 DOSRC2
11 DI33 28 DOSRC2 43 DO29
12 DI34 29 DI39 44 DO30
13 DI35 30 DI40 45 DO31
14 DI36 31 DI41 46 DO32
15 DI37 32 DI42 47 DOSRC2
16 DI38 48
17 0V 49 +24E
18 0V

50 +24E
Peripheral device control interface A4
(Source type DO)
CRMA5D
01 DI43 33 DO41
02 DI44 19 DO53 34 DO42
03 DI45 20 DO54 35 DO43
04 DI46 21 DO55 36 DO44
05 DI47 22 DO56 37 DOSRC2
06 DI48 23 DOSRC2 38 DO45
07 DI49 24 DO57 39 DO46
08 DI50 25 DO58 40 DO47
09 DI51 26 DO59 41 DO48
10 DI52 27 DO60 42 DOSRC2
11 DI53 28 DOSRC2 43 DO49
12 DI54 29 DI59 44 DO50
13 DI55 30 DI60 45 DO51
14 DI56 31 DI61 46 DO52
15 DI57 32 DI62 47 DOSRC2
16 DI58 48
17 0V 49 +24E
18 0V

50 +24E
Terminal block
TBSRC2
1 DOSRC2
2 0V


Peripheral
device A4
Peripheral
device A3
Control unit
B-82595EN-2/02 CONNECTIONS
- 339 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
NOTE
1 The peripheral device connection cables are
optional.
2 The DOSRC2 pins of the CRMA5C and CRMA5D
are pins for supplying power to drivers. (None of
these pins can be left open.)
3 When the level of the voltage applied to the load is
insufficient for a cause such as a too long
peripheral device connection cable, supply power
from the TBSRC2 terminal block.

Applicable process I/O board type
JA

CONNECTIONS B-82595EN-2/02
- 340 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit
Peripheral device control interface B1
(Source type DO)
CRMA6A
01 DI63 08 DO65 14 DO61
02 DI64 09 DO66 15 DO62
03 DI65 10 DO67 16 DO63
04 DI66 11 DO68 17 DO64
05 DI67 12 DOSRC3 18 DOSRC3
06 DI68 13 DI70 19 +24E
07 DI69 20 0V

Peripheral device control interface B2
(Source type DO)
CRMA6B
01 DI71 08 DO73 14 DO69
02 DI72 09 DO74 15 DO70
03 DI73 10 DO75 16 DO71
04 DI74 11 DO76 17 DO72
05 DI75 12 DOSRC3 18 DOSRC3
06 DI76 13 DI78 19 +24E
07 DI77 20 0V


Terminal block
TBSRC3
1 DOSRC3
2 0V



NOTE
1 The peripheral device connection cables are
optional.
2 The DOSRC3 pins of the CRMA6A and CRMA6B
are pins for supplying power to drivers. (None of
these pins can be left open.)
3 When the level of the voltage applied to the load is
insufficient for a cause such as a too long
peripheral device connection cable, supply power
from the TBSRC3 terminal block.

Applicable process I/O board type
JA

Peripheral
device B1
Peripheral
device B2
B-82595EN-2/02 CONNECTIONS
- 341 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Set this jumper according
to the common voltage of
input devices. (ICOM1)
Control unit (peripheral device control interface A1) Peripheral device
*IMSTP
CRMA5A (1)
CRMA5A (49,50)
Connector pin No. +24E
Receiver circuit
ENBL
CRMA5A (8)
DI02
CRMA5A (32)
COM-1 CRMA5A (17,18)
0V
*HOLD
CRMA5A (2)
*SFSPD
CRMA5A (3)
CSTOPI
CRMA5A (4)
FAULT RESET
CRMA5A (5)
START
CRMA5A (6)
HOME
CRMA5A (7)
RSR1/PNS1
CRMA5A (9)
CRMA5A (10)
CRMA5A (11)
CRMA5A (12)
CRMA5A (13)
CRMA5A (14)
CRMA5A (15)
CRMA5A (16)
PNSTROBE
CRMA5A (29)
PROD START
CRMA5A (30)
DI01
CRMA5A (31)
3.3k
+24E
0V
B A
Set this jumper according to the
common voltage of input devices.
(ICOM1)
0V
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RSR2/PNS2
RSR3/PNS3
RSR4/PNS4
RSR5/PNS5
RSR6/PNS6
RSR7/PNS7
RSR8/PNS8


NOTE
In this diagram, common voltage of input devices is
+24V.


CONNECTIONS B-82595EN-2/02
- 342 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit (peripheral device control interface A1)
Peripheral device
CMDENBL
CRMA5A (34)
CRMA5A (33)
Connector pin No.
Driver circuit
TPENBL
CRMA5A (43)
RESERVED
SYSRDY
CRMA5A (35)
PROGRUN
CRMA5A (36)
PAUSED
CRMA5A (38)
HELD
CRMA5A (39)
FAULT
CRMA5A (40)
ATPERCH
CRMA5A (41)
BATALM
CRMA5A (44)
BUSY
CRMA5A (45)
ACK1/SNO1
CRMA5A (46)
CRMA5A (19)
CRMA5A (20)
CRMA5A (21)
CRMA5A (22)
CRMA5A (24)
CRMA5A (25)
CRMA5A (26)
SNACK
CRMA5A (27)
DV
LOAD
RELAY
A maximum output current per DO point is 0.2 A.
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRMA5A (23,28,37,42,47)
DOSRC1

+24V 0V
+24V regulated
power supply
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
CRMA5A (17,18)
0V
DOSRC1(1)
TBSRC1(2)
ACK2/SNO2
ACK3/SNO3
ACK4/SNO4
ACK5/SNO5
ACK6/SNO6
ACK7/SNO7
ACK8/SNO8

B-82595EN-2/02 CONNECTIONS
- 343 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Control unit (peripheral device control interface A2) Peripheral device
DI03
CRMA5B (1)
CRMA5B (49,50)
Connector pin No.
+24E
Receiver circuit
DI10
CRMA5B (8)
DI22
CRMA5B (32)
COM-2 CRMA5B (17,18)
0V
DI04
CRMA5B (2)
DI05
CRMA5B (3)
DI06
CRMA5B (4)
DI07
CRMA5B (6)
DI08
CRMA5B (5)
DI09
CRMA5B (7)
DI11
CRMA5B (9)
CRMA5B (10)
CRMA5B (11)
CRMA5B (12)
CRMA5B (13)
CRMA5B (14)
CRMA5B (15)
CRMA5B (16)
DI19
CRMA5B (29)
DI20
CRMA5B (30)
DI21
CRMA5B (31)
3.3k
+24E
0V
B A
Set this jumper according to the
common voltage of input devices.
(ICOM2)
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
DI12
DI13
DI14
DI15
DI16
DI17
DI18


NOTE
In this diagram, common voltage of input devices is
+24V.

CONNECTIONS B-82595EN-2/02
- 344 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Control unit (peripheral device control interface A2) Peripheral device
DO01
CRMA5B (34)
CRMA5B (33)
Connector pin No.
Driver circuit
DO08
CRMA5B (43)
DO20
DO02
CRMA5B (35)
DO03
CRMA5B (36)
DO04
CRMA5B (38)
DO05
CRMA5B (39)
DO06
CRMA5B (40)
DO07
CRMA5B (41)
DO09
CRMA5B (44)
DO10
CRMA5B (45)
DO11
CRMA5B (46)
CRMA5B (19)
CRMA5B (20)
CRMA5B (21)
CRMA5B (22)
CRMA5B (24)
CRMA5B (25)
CRMA5B (26)
DO19
CRMA5B (27)
DV
LOAD
RELAY
A maximum output current per DO point is 0.2 A.
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRMA5B (23,28,37,42,47)
DOSRC1
+24V 0V
+24V regulated
power supply
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
CRMA5B (17,18)
0V
DOSRC1(1)
TBSRC1(2)
DO12
DO13
DO14
DO15
DO16
DO17
DO18

B-82595EN-2/02 CONNECTIONS
- 345 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Control unit (peripheral device control interface A3) Peripheral device
DI23
CRMA5C (1)
CRMA5C (49,50)
Connector pin No.
+24E
Receiver circuit
DI30
CRMA5C (8)
DI42
CRMA5C (32)
COM-3 CRMA5C (17,18)
0V
DI24
CRMA5C (2)
DI25
CRMA5C (3)
DI26
CRMA5C (4)
DI27
CRMA5C (6)
DI28
CRMA5C (5)
DI29
CRMA5C (7)
DI31
CRMA5C (9)
CRMA5C (10)
CRMA5C (11)
CRMA5C (12)
CRMA5C (13)
CRMA5C (14)
CRMA5C (15)
CRMA5C (16)
DI39
CRMA5C (29)
DI40
CRMA5C (30)
DI41
CRMA5C (31)
3.3k
+24E
0V
B A
Set this jumper according to
the common voltage of input
devices.(ICOM3)
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
DI32
DI33
DI34
DI35
DI36
DI37
DI38


NOTE
In this diagram, common voltage of input devices is
+24V.

CONNECTIONS B-82595EN-2/02
- 346 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Control unit (peripheral device control interface A2) Peripheral device
DO21
CRMA5C (34)
CRMA5C (33)
Connector pin No.
Driver circuit
DO28
CRMA5C (43)
DO40
DO22
CRMA5C (35)
DO23
CRMA5C (36)
DO24
CRMA5C (38)
DO25
CRMA5C (39)
DO26
CRMA5C (40)
DO27
CRMA5C (41)
DO29
CRMA5C (44)
DO30
CRMA5C (45)
DO31
CRMA5C (46)
CRMA5C (19)
CRMA5C (20)
CRMA5C (21)
CRMA5C (22)
CRMA5C (24)
CRMA5C (25)
CRMA5C (26)
DO39
CRMA5C (27)
DV
LOAD
RELAY
A maximum output current per DO point is 0.2 A.
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRMA5C (23,28,37,42,47)
DOSRC2
+24V 0V
+24V regulated
power supply
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
CRMA5C (17,18)
0V
TBSRC2(1)
TBSRC2(2)
DO32
DO33
DO34
DO35
DO36
DO37
DO38


B-82595EN-2/02 CONNECTIONS
- 347 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Control unit (peripheral device control interface A4) Peripheral device
DI43
CRMA5D (1)
CRMA5D (49,50)
+24E
DI50
CRMA5D (8)
DI62
CRMA5D (32)
COM-4 CRMA5D (17,18)
0V
DI44
CRMA5D (2)
DI45
CRMA5D (3)
DI46
CRMA5D (4)
DI47
CRMA5D (6)
DI48
CRMA5D (5)
DI49
CRMA5D (7)
DI51
CRMA5D (9)
CRMA5D (10)
CRMA5D (11)
CRMA5D (12)
CRMA5D (13)
CRMA5D (14)
CRMA5D (15)
CRMA5D (16)
DI59
CRMA5D (29)
DI60
CRMA5D (30)
DI61
CRMA5D (31)
3.3k
+24E
0V
B A
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
DI52
DI53
DI54
DI55
DI56
DI57
DI58
Connector pin No.
Receiver circuit
Set this jumper according to the
common voltage of input devices.
(ICOM4)


NOTE
In this diagram, common voltage of input devices is
+24V.

CONNECTIONS B-82595EN-2/02
- 348 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Control unit (peripheral device control interface A4) Peripheral device
DO41
CRMA5D (34)
CRMA5D (33)
Connector pin No.
Driver circuit
DO48
CRMA5D (43)
DO60
DO42
CRMA5D (35)
DO43
CRMA5D (36)
DO44
CRMA5D (38)
DO45
CRMA5D (39)
DO46
CRMA5D (40)
DO47
CRMA5D (41)
DO49
CRMA5D (44)
DO50
CRMA5D (45)
DO51
CRMA5D (46)
CRMA5D (19)
CRMA5D (20)
CRMA5D (21)
CRMA5D (22)
CRMA5D (24)
CRMA5D (25)
CRMA5D (26)
DO59
CRMA5D (27)
DV
LOAD
RELAY
A maximum output current per DO point is 0.2 A
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRMA5D (23,28,37,42,47)
DOSRC2

+24V 0V
+24V regulated
power supply
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
CRMA5D (17,18)
0V
DOSRC2(1)
TBSRC2(2)
DO52
DO53
DO54
DO55
DO56
DO57
DO58




B-82595EN-2/02 CONNECTIONS
- 349 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Control unit (peripheral device control interface B1)
Peripheral device
DI63
CRMA6A (1)
CRMA6A (19)
+24E
DI70
CRMA6A (13)
COM-5
DI64
CRMA6A (2)
DI65
CRMA6A (3)
DI66
CRMA6A (4)
DI67
CRMA6A (6)
DI68
CRMA6A (5)
DI69
CRMA6A (7)
3.3k
+24E
0V
B A
RV
RV
RV
RV
RV
RV
RV
RV
RV
DO61
CRMA6A (15)
CRMA6A (14)
DO68
DO62
CRMA6A (16)
DO63
CRMA6A (17)
DO64
CRMA6A (8)
DO65
CRMA6A (9)
DO66
CRMA6A (10)
DO67
CRMA6A (11)
DV
LOAD
RELAY
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRMA6A (12,18)
DOSRC3

+24V 0V
+24V regulated
power supply
DOSRC3(1)
CRMA6A (20)
0V
TBSRC3(2)
DV
DV
DV
DV
DV
DV
DV
Connector pin No.
Driver circuit
A maximum output current per DO point is 0.2 A.
Receiver circuit
Connector pin No.
Set this jumper according
to the common voltage of
input devices. (ICOM5)

NOTE
In this diagram, common voltage of input devices is
+24V.
CONNECTIONS B-82595EN-2/02
- 350 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Control unit (peripheral device control interface B2) Peripheral device
DI71
CRMA6B (1)
CRMA6B (19)
+24E
DI78
CRMA6B (13)
COM-6
DI72
CRMA6B (2)
DI73
CRMA6B (3)
DI74
CRMA6B (4)
DI75
CRMA6B(6)
DI76
CRMA6B (5)
DI77
CRMA6B (7)
3.3k
+24E
0V
B A
RV
RV
RV
RV
RV
RV
RV
RV
RV
DO69
CRMA6B (15)
CRMA6B (14)
DO76
DO70
CRMA6B (16)
DO71
CRMA6B (17)
DO72
CRMA6B (8)
DO73
CRMA6B (9)
DO74
CRMA6B (10)
DO75
CRMA6B (11)
DV
LOAD
RELAY
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRMA6B (12,18)
DOSRC3

+24V 0V
+24V regulated
power supply
DOSRC3(1)
CRMA6B (20)
0V
TBSRC3(2)
DV
DV
DV
DV
DV
DV
DV
Connector pin No.
Driver circuit
A maximum output current per DO point is 0.2 A.
Receiver circuit
Connector pin No.
Set this jumper according
to the common voltage of
input devices. (ICOM6)

NOTE
In this diagram, common voltage of input devices is
+24V.
B-82595EN-2/02 CONNECTIONS
- 351 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.4.2 Peripheral Device and Control Unit Connection
(Sink Type DO)


Peripheral
device A1
Peripheral
device A2
Peripheral device control interface A2 Sink type DO
0V
Control unit Peripheral device control interface A1 Sink type DO



NOTE
1 The peripheral device connection cables are optional.
2 All of COM- are connected to 0V.

Applicable process I/O board type
CA, EA, EB, FA, GA, HA
CONNECTIONS B-82595EN-2/02
- 352 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit Peripheral device control interface A3 Sink type DO
Peripheral device control interface A4 Sink type DO
Peripheral
device A3
Peripheral
device A4



NOTE
1 The peripheral device connection cables are optional.
2 All of COM- are connected to 0V.

Applicable process I/O board type
FA

B-82595EN-2/02 CONNECTIONS
- 353 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES


Control unit Peripheral device control interface B1 Sink type DO
Control unit Peripheral device control interface B2 Sink type DO
Peripheral
device B1
Peripheral
device B2


NOTE
1 The peripheral device connection cables are optional.
2 All of COM- are connected to 0V.

Applicable process I/O board type
FA


CONNECTIONS B-82595EN-2/02
- 354 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit (peripheral device interface A1)
Peripheral device
*IMSTP
CRM2A (1)
CRM2A (49,50)
Connector pin No.
+24E
Receiver circuit
ENBL
CRM2A (8)
DI02
CRM2A (32)
COM-1 CRM2A (17,18)
0V
*HOLD
CRM2A (2)
*SFSPD
CRM2A (3)
CSTOPI
CRM2A (4)
FAULT RESET
CRM2A (5)
START
CRM2A (6)
HOME
CRM2A (7)
RSR1/PNS1
CRM2A (9)
RSR2/PNS2
CRM2A (10)
RSR3/PNS3
CRM2A (11)
RSR4/PNS4
CRM2A (12)
RSR5/PNS5
CRM2A (13)
RSR6/PNS6
CRM2A (14)
RSR7/PNS7
CRM2A (15)
RSR8/PNS8
CRM2A (16)
PNSTROBE
CRM2A (29)
PROD START
CRM2A (30)
DI01
CRM2A (31)
3.3k
+24E
0V
B A
Set this jumper according to the
common voltage of input devices.
(ICOM1)
0V
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV


NOTE
In this diagram, common voltage of input devices is +24V.


B-82595EN-2/02 CONNECTIONS
- 355 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES


CONNECTIONS B-82595EN-2/02
- 356 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit (peripheral device interface A2) Peripheral device
DI03
CRM2B (1)
CRM2B (49,50)
Connector pin No.
+24E
Receiver circuit
DI10
CRM2B (8)
DI22
CRM2B (32)
COM-2 CRM2B (17,18)
0V
DI04
CRM2B (2)
DI05
CRM2B (3)
DI06
CRM2B (4)
DI07
CRM2B (5)
DI08
CRM2B (6)
DI09
CRM2B (7)
DI11
CRM2B (9)
DI12
CRM2B (10)
DI13
CRM2B (11)
DI14
CRM2B (12)
DI15
CRM2B (13)
DI16
CRM2B (14)
DI17
CRM2B (15)
DI18
CRM2B (16)
DI19
CRM2B (29)
DI20
CRM2B (30)
DI21
CRM2B (31)
3.3k
+24E
0V
B A
Set this jumper according to the
common voltage of input devices.
ICOM2
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV



NOTE
In this diagram, common voltage of input devices is +24V.

B-82595EN-2/02 CONNECTIONS
- 357 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit (peripheral device interface A2) Peripheral device
DO01
CRM2B (34)
CRM2B (33)
Connector pin No.
Driver circuit
DO08
CRM2B (43)
DO20
CRM2B (23,28,37,42,47)
0V
DO02
CRM2B (35)
DO03
CRM2B (36)
DO04
CRM2B (38)
DO05
CRM2B (39)
DO06
CRM2B (40)
DO07
CRM2B (41)
DO09
CRM2B (44)
DO10
CRM2B (45)
DO11
CRM2B (46)
DO12
CRM2B (19)
DO13
CRM2B (20)
DO14
CRM2B (21)
DO15
CRM2B (22)
DO16
CRM2B (24)
DO17
CRM2B (25)
DO18
CRM2B (26)
DO19
CRM2B (27)
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
LOAD
RELAY
0V +24V

A maximum output current per DO point is 0.2 A.
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
0V
+24 V regulated power supply


CONNECTIONS B-82595EN-2/02
- 358 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit (peripheral device interface A3) Peripheral device
DI23
CRM2C (1)
CRM2C (49,50)
Connector pin No.
+24E
Receiver circuit
DI30
CRM2C (8)
DI42
CRM2C (32)
COM-3 CRM2C (17,18)
0V
DI24
CRM2C (2)
DI25
CRM2C (3)
DI26
CRM2C (4)
DI27
CRM2C (5)
DI28
CRM2C (6)
DI29
CRM2C (7)
DI31
CRM2C (9)
DI32
CRM2C (10)
DI33
CRM2C (11)
DI34
CRM2C (12)
DI35
CRM2C (13)
DI36
CRM2C (14)
DI37
CRM2C (15)
DI38
CRM2C (16)
DI39
CRM2C (29)
DI40
CRM2C (30)
DI41
CRM2C (31)
3.3k
+24E
0V
B A
Set this jumper according to the
common voltage of input devices.
ICOM3
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV



NOTE
In this diagram, common voltage of input devices is +24V.

B-82595EN-2/02 CONNECTIONS
- 359 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit (peripheral device interface A3) Peripheral device
DO21
CRM2C (34)
CRM2C (33)
Connector pin No.
Driver circuit
DO28
CRM2C (43)
DO40
CRM2C (23,28,37,42,47)
0V
DO22
CRM2C (35)
DO23
CRM2C (36)
DO24
CRM2C (38)
DO25
CRM2C (39)
DO26
CRM2C (40)
DO27
CRM2C (41)
DO29
CRM2C (44)
DO30
CRM2C (45)
DO31
CRM2C (46)
DO32
CRM2C (19)
DO33
CRM2C (20)
DO34
CRM2C (21)
DO35
CRM2C (22)
DO36
CRM2C (24)
DO37
CRM2C (25)
DO38
CRM2C (26)
DO39
CRM2C (27)
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
LOAD
RELAY
0V +24V
A maximum output current per DO point is 0.2 A.
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
0V
+24 V regulated power
supply


CONNECTIONS B-82595EN-2/02
- 360 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit (peripheral device interface A4) Peripheral device
DI43
CRM2D (1)
CRM2D (49,50)
Connector pin No. +24E
Receiver circuit
DI50
CRM2D (8)
DI62
CRM2D (32)
COM-4 CRM2D (17,18)
0V
DI44
CRM2D (2)
DI45
CRM2D (3)
DI46
CRM2D (4)
DI47
CRM2D (5)
DI48
CRM2D (6)
DI49
CRM2D (7)
DI51
CRM2D (9)
DI52
CRM2D (10)
DI53
CRM2D (11)
DI54
CRM2D (12)
DI55
CRM2D (13)
DI56
CRM2D (14)
DI57
CRM2D (15)
DI58
CRM2D (16)
DI59
CRM2D (29)
DI60
CRM2D (30)
DI61
CRM2D (31)
3.3k
+24E
0V
B A
Set this jumper according to the common
voltage of input devices.
ICOM4
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV


NOTE
In this diagram, common voltage of input devices is +24V.


B-82595EN-2/02 CONNECTIONS
- 361 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit (peripheral device interface A4) Peripheral device
DO41
CRM2D (34)
CRM2D (33)
Connector pin No.
Driver circuit
DO48
CRM2D (43)
DO60
CRM2D (23,28,37,42,47)
0V
DO42
CRM2D (35)
DO43
CRM2D (36)
DO44
CRM2D (38)
DO45
CRM2D (39)
DO46
CRM2D (40)
DO47
CRM2D (41)
DO49
CRM2D (44)
DO50
CRM2D (45)
DO51
CRM2D (46)
DO52
CRM2D (19)
DO53
CRM2D (20)
DO54
CRM2D (21)
DO55
CRM2D (22)
DO56
CRM2D (24)
DO57
CRM2D (25)
DO58
CRM2D (26)
DO59
CRM2D (27)
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
DV
LOAD
RELAY
0V +24V

A maximum output current per DO point is 0.2 A.
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
0V
+24 V regulated power
supply


CONNECTIONS B-82595EN-2/02
- 362 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit (peripheral device interface B1)
Peripheral device
DI63
CRM4A (1)
CRM4A (19)
Connector pin No. +24E
Receiver circuit
DI70
CRM4A (13)
COM-5 CRM4A (20)
0V
DI64
CRM4A (2)
DI65
CRM4A (3)
DI66
CRM4A (4)
DI67
CRM4A (5)
DI68
CRM4A (6)
DI69
CRM4A (7)
3.3k
+24E
0V
B A
Set this jumper according to the
common voltage of input devices.
ICOM5
RV
RV
RV
RV
RV
RV
RV
RV
RV
DO68
CRM4A (12, 18)
0V
CRM4A (15)
DO62
CRM4A (16)
DO63
CRM4A (17)
DO64
CRM4A (8)
DO65
CRM4A (9)
DO66
CRM4A (10)
DO67
CRM4A (11)
DV
DV
DV
DV
DV
DV
DV
0V +24V

A maximum output current per DO point is 0.2 A.
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
DO61
CRM4A (14)
Connector pin No.
Driver circuit
DV
LOAD
RELAY
0V
+24 V regulated power
supply



NOTE
In this diagram, common voltage of input devices is +24V.

B-82595EN-2/02 CONNECTIONS
- 363 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit (peripheral device interface B2) Peripheral device
DI71
CRM4B (1)
CRM4B (19)
Connector pin No. +24E
Receiver circuit
DI78
CRM4B (13)
COM-6 CRM4B (20)
0V
DI72
CRM4B (2)
DI73
CRM4B (3)
DI74
CRM4B (4)
DI75
CRM4B (5)
DI76
CRM4B (6)
DI77
CRM4B (7)
3.3k
+24E
0V
B A
Set this jumper according to the
common voltage of input devices.
ICOM6
RV
RV
RV
RV
RV
RV
RV
RV
RV
DO76
CRM4B (12, 18)
0V
CRM4B (15)
DO70
CRM4B (16)
DO71
CRM4B (17)
DO72
CRM4B (8)
DO73
CRM4B (9)
DO74
CRM4B (10)
DO75
CRM4B (11)
DV
DV
DV
DV
DV
DV
DV
0V +24V
A maximum output current per DO point is 0.2 A.
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
DO69
CRM4B (14)
Connector pin No.
Driver circuit
DV
LOAD
RELAY
0V
+24 V regulated
power supply


NOTE
In this diagram, common voltage of input devices is +24V.

CONNECTIONS B-82595EN-2/02
- 364 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.5 INTERFACE FOR WELDER

4.5.1 Connection Between the Control Unit and Welder

Control unit Welding machine interface
Welding
machine
Peripheral
device
Analog input interface
WI1
WI2
WI3
WI4
WI5
WI6
WI7
WI8
WO1
WO2
WO3
WO4
WO5
WO6
WO7
WO8



NOTE
Welder and peripheral device connection cable are
optional.

Applicable process I/O board type
CA, EA

B-82595EN-2/02 CONNECTIONS
- 365 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES


CONNECTIONS B-82595EN-2/02
- 366 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Control unit (welding machine interface)
Process I/O boards CA and EA
Welding machine
WI01
CRW1 (5)
CRW1 (33,34)
Connector pin No.
+24V
Receiver circuit
WI08
CRW1 (12)
COM-3
CRW1 (21,22)
WI02
CRW1 (6)
WI03
CRW1 (7)
WI04
CRW1 (8)
WI05
CRW1 (9)
WI06
CRW1 (10)
WI07
CRW1 (11)
3.3k
+24E
0V
B A
Set this jumper according to the
common voltage of input devices.
ICOM3
RV
RV
RV
RV
RV
RV
RV
RV
RV
WO08
CRW1 (19,20)
0V
CRW1 (24)
WO02
CRW1 (25)
WO03
CRW1 (26)
WO04
CRW1 (27)
WO05
CRW1 (28)
WO06
CRW1 (29)
WO07
CRW1 (30)
DV
DV
DV
DV
DV
DV
DV

0V +24V
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
WO01
CRW1 (23)
Connector pin No.
Driver circuit
DV
LOAD
RELAY
0V
r
c
d
e
f
g
h
j
k
R
S
T
U
V
W
X
Z
a,m
b,n
Arc regeneration
detection signal
+24 V regulated
power
Out-of-gas
detection signal
Broken-wire
detection signal
Out-of-cooling-
water detection
signal
Abnormal-welding
power signal
Welding start signal
Gas signal
Wire inching (+)
signal
Wire inching (-)
signal
s
Welding machine frame ground
Cabinet ground (shield clamped)


NOTE
In this diagram, common voltage of input devices is +24V.
B-82595EN-2/02 CONNECTIONS
- 367 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
CRW2 connector analog connection (analog input)


(Relationships between process I/O points and analog inputs)
Analog inputs

Process I/O
points
ADCH1
COMAD1
ADCH2
COMAD2
ADCH3
COMAD3
ADCH4
COMAD4
ADCH5
COMAD5
ADCH6
COMAD6
Process I/O CA points
In CRW1 In CRW1

Process I/O EA points
In CRW1 In CRW1
Process I/O GB points

Process I/O HB points



CONNECTIONS B-82595EN-2/02
- 368 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES



Control unit Welding machine interface
Welding
machine
WI1
WI2
WI3
WI4
WI5
WI6
WI7
WI8
WO5
WO1
WO2
WO3
WO4


NOTE
Welder and peripheral device connection cable are
optional.

Applicable process I/O board type
GA, HA

B-82595EN-2/02 CONNECTIONS
- 369 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
General-purpose interface

Control unit (welding machine interface)
Process I/O boards GA, HA, and HB
Welding machine
DACH1
CRW7 (1)
Connector pin No.
R = 100 or
higher
COMDA1
CRW7 (2)
DACH2
CRW7 (3)
COMDA2
CRW7 (4)

Welding voltage
specification signal
Wire speed
specification signal
A
B
C
D
MS connector pin No.
WDI+
CRW1 (31)
WDI-
CRW1 (32)
Wire deposition
detection signal
M
N

Welding
power
WI02
CRW7 (6)
CRW7 (33,34)
Connector pin No.
Receiver circuit
COM-3
WI03
CRW7 (7)
WI04
CRW7 (8)
WI06
CRW7 (10)
3.3k
+24E
0V
B A
Set this jumper according to the
common voltage of input devices.
ICOM3
RV
RV
RV
RV
RV
E
P
T
S
R
Arc detection signal
Out-of-gas
detection signal
Broken-wire
detection signal
Arc-off detection
signal (power
supply abnormal)
CRW7 (23)
L
Welding start signal
WO01
Wire inching (+)
WCOM1
CRW7 (24)
K
CRW7 (29)
F WO04
WCOM4
CRW7 (30)
G
CRW7 (13)
H WO05
WCOM5
CRW7 (14)
J
Wire inching (-)

Welding machine frame ground


Cabinet ground (shield clamped)
+24E


NOTE
In this diagram, common voltage of input devices is +24V.

CONNECTIONS B-82595EN-2/02
- 370 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
FANUC interface

Control unit (welding machine interface)
Process I/O boards GA, HA, and HB
Welding machine
DACH1
CRW7 (1)
Connector pin No.
R = 100 or
higher
COMDA1
CRW7 (2)
DACH2
CRW7 (3)
COMDA2
CRW7 (4)

Welding voltage
specification signal
Wire speed
specification signal
A
B
E
F
MS connector pin No.
WDI+
CRW1 (31)
WDI-
CRW1 (32)
Wire deposition
detection signal
N
P

Welding
power
WI01
CRW7 (5)
CRW7 (33,34)
Connector pin No.
Receiver circuit
COM-3
WI02
CRW7 (6)
WI03
CRW7 (7)
WI04
CRW7 (8)
3.3k
+24E
0V
B A
Set this jumper according to the
common voltage of input devices.
ICOM3
RV
RV
RV
RV
RV
r
c
d
e
f
Arc detection signal
Out-of-gas
detection signal
Broken-wire
detection signal
Arc-off detection
signal (power
supply abnormal)
CRW7 (23)
R
Welding start signal
WO01
Wire inching (+)
WCOM1
CRW7 (24)
CRW7 (29)
U WO04
WCOM4
CRW7 (30)
CRW7 (13)
V WO05
WCOM5
CRW7 (14)
b
Wire inching (-)

WI05
CRW7 (9)
WI06
CRW7 (10)
WI07
CRW7 (11)
WI08
CRW7 (12)
RV
RV
RV
RV
h
j
k
g
+24E
Out-of-cooling-
water detection
CRW7 (19,20)
m
CRW7 (21,22)
n
0V
CRW7 (25)
S
Gas signal
WO02
WCOM2
CRW7 (26)
a
s
Welding machine frame ground
Cabinet ground (shield clamped)


NOTE
In this diagram, common voltage of input devices is +24V.
B-82595EN-2/02 CONNECTIONS
- 371 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Welding machine interface
CRW10
01 DACH1 33 WO1
02 COMDA1 19 ADCH1 34 WCOM1
03 DACH2 20 COMAD1 35 WO2
04 COMDA2 21 ADCH2 36 WCOM12
05 DACH3 22 COMAD2 37 WO3
06 COMDA3 23 38 WCOM3
07 WI1 24 39 WO4
08 WI2 25 WDI+ 40 WCOM4
09 WI3 26 WDI- 41 WO5
10 WI4 27 42 WCOM5
11 WI5 28 43 WO6
12 WI6 29 44 WCOM6
13 WI7 30 45 WO7
14 WI8 31 46 WCOM7
15 0V 32 47 WO8
16 0V 48 WCOM8
17 0V 49 +24E
18 0V

50 +24E


NOTE
The welding machine connection cables are options.

Applicable process I/O board types
KA



Control unit
Welding machine
CONNECTIONS B-82595EN-2/02
- 372 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Pin-to-pin connection between CRW10 connector and welding machine connector (general interface)
(analog output, welding wire deposition detection, WI/WO connection, for connections with +24 V common)

Control unitWelding machine interface
Process I/O board KB
Welding machine

DACH1
CRW10 (1)
Connector pin No.
R=100or
higher
COMDA1
CRW10 (2)
DACH2
CRW10 (3)
COMDA2
CRW10 (4)

Welding voltage
specification signal
Wire speed
specification signal
A
B
C
D
MS connector pin No.
WDI+
CRW10 (25)
WDI-
CRW10 (26)
Wire deposition
detection signal
M
N

Welding
power
WI02
CRW10 (8)
CRW10 (49,50)
Connector pin No.
Receiver circuit
COM-3
WI03
CRW10 (9)
WI04
CRW10 (10)
WI06
CRW10 (12)
3.3k
+24E
0V
B A
Set this jumper according to the
common voltage of input devices.
ICOM3
RV
RV
RV
RV
RV
E
P
S
T
R
Arc detection signal
Out-of-gas
detection signal
Broken-wire
detection signal
Arc-off detection
signal (power
supply abnormal)
CRW10 (33)
L
Welding start signal
WO01
Wire inching (+)
WCOM1
CRW10 (34)
K
CRW10 (39)
F WO04
WCOM4
CRW10 (40)
G
CRW10 (41)
H WO05
WCOM5
CRW10 (42)
J
Wire inching (-)

Welding machine frame ground


Cabinet ground (shield clamped)
+24E

NOTE
In this diagram, common voltage of input devices is
+24V.
B-82595EN-2/02 CONNECTIONS
- 373 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Pin-to-pin connection between CRW10 connector and welding machine connector: FANUC interface
(analog input/output, welding wire deposition detection, WI/WO connection, for connections with +24 V common)

Control unit (welding machine interface)
Process I/O boards KA, KB
Welding machine

DACH1
CRW10 (1)
Connector pin No.
COMDA1
CRW10 (2)
DACH2
CRW10 (3)
COMDA2
CRW10 (4)
Welding voltage
specification signal
Wire speed
specification signal
A
B
E
F
MS connector pin No.

r
c
d
e
f
WI08
WI01
COM-3
WI02
WI03
WI04
WI05
WI06
WI07
CRW10 (7)
Connector pin No.
CRW10 (8)
CRW10 (9)
CRW10 (10)
CRW10 (11)
CRW10 (12)
CRW10 (13)
CRW10 (14)
Receiver circuit
RV
RV
RV
RV
RV
RV
RV
RV
RV
h
j
k
g
Arc detection signal
Out-of-gas
detection signal
Broken-wire
detection signal
Arc-off detection
signal (power
supply abnormal)
Out-of-cooling-
water detection
A
0V
m
n
CRW10 (49,50)
+24E
CRW10 (15,16)
CRW10 (17,18)
0V
Welding machine frame ground
+24E B
Set this jumper according to the
common voltage of input devices.
ICOM3
3.3k
ADCH1
CRW10 (19)
COMAD1
CRW10 (20)
ADCH2
CRW10 (21)
COMAD2
CRW10 (22)
0V
s
Cabinet ground (shield clamped)

J
K
L
M
Ripples must
have been
removed
from the
output
signals.
Welding start signal

Wire inching (+)
Gas signal
WO01
WCOM1
WO03
WCOM3
WO04
WCOM4
WO02
WCOM2
CRW10 (33)
CRW10 (34)
CRW10 (37)
CRW10 (38)
CRW10 (39)
CRW10 (40)
CRW10 (35)
CRW10 (36)
Wire inching (-)



WO05
WCOM5
WO07
WCOM7
WO08
WCOM8
WO06
WCOM6
CRW10 (41)
CRW10 (42)
CRW10 (45)
CRW10 (46)
CRW10 (47)
CRW10 (48)
CRW10 (43)
CRW10 (44)
WDI+
CRW10 (25)
WDI-
CRW10 (26)
Wire deposition
detection signal
R = 100 or
higher

N
P

Welding
power
R
U
V

S
T
a
b
W
Z
X
Welding voltage
detection signal
Welding current
detection signal

CONNECTIONS B-82595EN-2/02
- 374 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.6 INTERFACE FOR END EFFECTOR

4.6.1 Connection Between the Mechanical Unit and End Effector



Mechanical unit
EE
1 2 3 4
RO1 RO2 RO3 RO4
5 6 7 8 9
RO5 RO6 *HBK 0V RI1
10 11 12 13 14 15
RI2 RI3 RI4 RI8 *PPABN RI5
16 17 18 19 20
RI6 +24VF +24VF +24VF +24VF
21 22 23 24
RO7 RO8 0V RI7






Fig.4.6.1 In case of the R-2000iB, M-710iC (For other robots, refer to the each operators manual.)

End effector
B-82595EN-2/02 CONNECTIONS
- 375 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

Mechanical unit (end-effector interface) Peripheral device
Wrist breakage *HBK
detection signal
EE (7)
EE(17,18,19,20)
Connector pin No.
+24VF
Receiver circuit
RI7
EE (24)
RI9
RI1
EE (9)
RI2
EE (10)
RI3
EE (11)
RI4
EE (15)
RI5
EE (12)
RI6
EE (16)
3.3k
+24E
0V
B A
Set this jumper according
to the common voltage of
input devices. (COM1)
RV
RV
RV
RV
RV
RV
RV
RV
RV
RO1
EE (2)
EE (1)
Driver circuit
RO8
RO2
EE (3)
RO3
EE (4)
RO4
EE (5)
RO5
EE (6)
RO6
EE (21)
RO7
EE (22)
DV
LOAD
RELAY
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
+24VF
A maximum output current per RO point is 0.2 A.
EE (8,23)
0V
DV
DV
DV
DV
DV
DV
DV
RI8
EE (13)
RV
(Pneumatic pressure *PPABN)
abnormal signal)
0V
EE (13)


NOTE
1 In this diagram, common voltage of input devices is +24V.
2 The common-level change-over setting pin (COM1) is in the 6-axis servo amplifier.
CONNECTIONS B-82595EN-2/02
- 376 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.7 DIGITAL I/O SIGNAL SPECIFICATIONS

This section describes the specifications of the digital I/O signals
interfaced with the peripheral device, end effector, and arc welder.

4.7.1 Peripheral Device Interface A

(1) Output signals in peripheral device interface A (Source type DO)

(a) Example of connection
Spark killer diode
0.2A or less


(b) Electrical specifications
Maximum load current when driver is on: 200 mA
(including momentary level)
Saturation voltage when driver is on: 1.0 V max.
Dielectric strength: 24 V 20% (including momentary
level)
Leakage current when driver is off: 100 A

(c) The external power supply to output signals must satisfy the
following:
Power supply voltage: +24 V 10%
Power supply current:
For each printed circuit board of this type
(Total sum of maximum load currents including
momentary levels + 100 mA or more)
Power-on timing:
At the same time when the control unit is turned on or
earlier
Power-off timing:
At the same time when the control unit is turned off or
later

(d) Spark killer diode
Rated peak reverse voltage : 100 V or more
Rated effective forward current : 1 A or more

(e) Driver for output signals
In the driver device, the current of each output signal is
monitored, and when an overcurrent is detected, the relevant
output is turned off. After an output has been turned off
by overcurrent, the overcurrent state is released because the
output is off, so the output on state is restored. Therefore,
B-82595EN-2/02 CONNECTIONS
- 377 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
in the ground fault or overcurrent state, the output is turned
on and off repeatedly. Such a condition is found also
when a load with a high surge current is connected.
The driver device also includes an overheat detection circuit,
which turns off all outputs of the device when the internal
temperature of the device has increased as a result of a
continued overcurrent state due to a ground fault of an
output and so on. The outputs are held off, but their
normal states can be restored by turning the power to the
controller on and off after the internal temperature of the
device has lowered.

(f) Note on use
When adding a relay, solenoid, or the like directly to the
circuit, connect a diode for counter electromotive voltage
protection in parallel to the load.

(g) Applicable signals
Output signals of process I/O board CRMA5 and CRMA6
CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD,
FAULT, ATPERCH, TPENBL, BATALM, BUSY,
ACK1 to ACK8, SNO1 to SNO8, SNACK, DO1 to DO76

(2) Output signals in peripheral device interface A (Sink type DO)

(a) Example of connection
0V
+24V
0.2A
or less
Spark killer diode


(b) Electrical specifications
Rated voltage :24VDC
Maximum applied voltage :30VDC
Maximum load current :0.2A
Transistor type :Open collector NPN
Saturation voltage at connection :1.0V (approx.)

(c) Spark killer diode
Rated peak reverse voltage :100V or more
Rated effective forward current :1A or more

(d) Note on use
CONNECTIONS B-82595EN-2/02
- 378 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Do not use the +24V power supply of the robot.
When adding a relay, solenoid, or the like directly to the
circuit, connect a diode for counter electromotive voltage
protection in parallel to the load.

(e) Applicable signals
Output signals of process I/O board CRM2 and CRM4
CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD,
FAULT, ATPERCH, TPENBL, BATALM, BUSY,
ACK1 to ACK8, SNO1 to SNO8, SNACK, DO1 to DO76


(2) Input signals in peripheral device interface A
(a) Example of connection
+24V
3.3k


+24V


(b) Electrical specifications of the receiver
Type : Grounded voltage receiver
Rated input voltage : Contact close
+20V to +28V
: Contact open
0V to +4V
Maximum applied input voltage : +28VDC
Input impedance : 3.3k(approx.)
Response time : 5ms to 20ms

(d) specifications of the peripheral device contact
Rated contact capacity : 30VDC, 50mA or more
Input signal width : 200ms or more (on/off)
Chattering time : 5ms or less
Closed circuit resistance : 100 or less
Opened circuit resistance : 100k or more
B-82595EN-2/02 CONNECTIONS
- 379 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
(Signal) (Signal)
TC TC
TB TB TB
Peripheral device
contact signal
Robot receiver signal
TB ; Chattering 5 ms or less
TC ; 5 to 20 ms


(e) 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.

(f) Applicable signals
Input signals of process I/O board CRM2, CRM4, CRMA5
and CRMA6
*IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET,
START, HOME, ENBL, RSR1 to RSR8, PNSTROBE,
PROD START, DI1 to DI78

CONNECTIONS B-82595EN-2/02
- 380 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.7.2 End Effector Control Interface

(1) Output signals in end effector interface

(a) Example of connection
0V
+24V
0.2A or less
Spark killer diode


(b) Electrical specifications
Maximum load current when driver is on: 200 mA
(including momentary level)
Saturation voltage when driver is on: 1.0 V max.
Dielectric strength: 24 V 20% (including momentary
level)
Leakage current when driver is off: 100 A

(c) Power supply to output signals
The +24 V power supply on the robot side can be used if the
total current level, including the current of the welding
interface, is 0.7 A or less.

(d) Driver for output signals
In the driver device, the current of each output signal is
monitored, and when an overcurrent is detected, the relevant
output is turned off. After an output has been turned off
by overcurrent, the overcurrent state is released because the
output is off, so the output on state is restored. Therefore,
in the ground fault or overcurrent state, the output is turned
on and off repeatedly. Such a condition is found also
when a load with a high surge current is connected.
The driver device also includes an overheat detection circuit,
which turns off all outputs of the device when the internal
temperature of the device has increased as a result of a
continued overcurrent state due to a ground fault of an
output and so on. The outputs are held off, but their
normal states can be restored by turning the power to the
control unit on and off after the internal temperature of the
device has lowered.

(e) Note on use
When adding a relay, solenoid, or the like directly to the
circuit, connect a diode for counter electromotive voltage
protection in parallel to the load.
B-82595EN-2/02 CONNECTIONS
- 381 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES

(f) Applicable signals
RO1 to RO8

(2) Input signal in peripheral device interface
The input signals are the same as those of other I/O boards.
(Refer to Subsection 4.5.1 in CONNECTIONS.)

(a) Applicable signals
RI1 to RI8, *HBN, *PPABN

CONNECTIONS B-82595EN-2/02
- 382 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.7.3 I/O Signal Specifications for ARC-Welding Interface

(1) Digital Output signals specifications for an arc welding interface
In case of process I/O CA,EA
(a) Example of connection
0V
+24V
0.2A
or less
Spark killer diode


(b) Electrical specifications
Rated voltage :24VDC
Maximum applied voltage :30VDC
Maximum load current :0.2A
Transistor type :Open collector NPN
Saturation voltage at connection :1.0V (approx.)

(c) Spark killer diode
Rated peak reverse voltage :100V or more
Rated effective forward current :1A or more

(d) Note on use
Do not use the +24V power supply of the robot.
When adding a relay, solenoid, or the like directly to the
circuit, connect a diode for counter electromotive voltage
protection in parallel to the load.

(e) Applicable signals
Output signals of process I/O board CRW1
WO1 to WO8
B-82595EN-2/02 CONNECTIONS
- 383 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
In case of process I/O GA,HA
(a) Example of connection
0V
+24V
0.3A
or less
Spark killer diode


(b) Electrical specifications
Rated voltage :24VDC
Maximum applied voltage :30VDC
Maximum load current :0.3A
Transistor type :Relay connect output

(c) Spark killer diode
Rated peak reverse voltage :100V or more
Rated effective forward current :1A or more

(d) Note on use
Do not use the +24V power supply of the robot.
When adding a relay, solenoid, or the like directly to the
circuit, connect a diode for counter electromotive voltage
protection in parallel to the load.

(e) Applicable signals
Output signals of process I/O board CRW7
WO1 to WO8


(2) Digital input signals specifications for an arc welding interface
The input signals are the same as those of other I/O boards.
(Refer to Subsection 4.5.1 in CONNECTIONS.)

(a) Applicable signals
Input signals of process I/O board CRW1, CRW7
WI1 to WI8
CONNECTIONS B-82595EN-2/02
- 384 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
(3) Analog output signal specifications for an arc welding interface
(Welding voltage command, wire-feed rate command)

(a) Example of connection

0V
Welder
Process I/O CA, EA: -10V to +10V
Process I/O GA, HA: 0V to +15V

(b) Note on use
Input impedance: 3.3k or more
Connect a high-pass filter

(2) Analog input signal specifications for an arc welding interface
(Welding-voltage detection , welding-current detection)

(a) Example of connection

0V
Welder
10V10V

(b) Note on use
Input impedance: 2k
The analog input signal should have no ripple for the circuit
to operate properly.


B-82595EN-2/02 CONNECTIONS
- 385 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
(Wire deposit detection: WDI+ and WDI-)

(a) Example of connection

Welder
max.
+15V 85mA
Welding electrode
+

(b) Note on use
Connect a resistor of 100 or more between the positive
and negative electrodes of the welder. Isolate the deposit
detection signals for TIG welding from the welding circuit,
which uses high-frequency components. The dielectric
withstand voltage of this circuit is 80V.


CONNECTIONS B-82595EN-2/02
- 386 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.8 SPECIFICATIONS OF THE CABLES USED FOR
PERIPHERAL DEVICES AND WELDERS

If the customer manufactures cables, make sure they conform to the
FANUC standard cables described in this section.
(See the description in "Peripheral Device Interface" in this manual for
the specifications of the FANUC standard cables.)

4.8.1 Peripheral Device Interface A Cable (CRM2, CRMA5: Honda
Tsushin, 50 pins)

Process I/O
Honda Tsushin
MR50RMA
Peripheral
device
Honda Tsushin
MR50LWF01
(MR50LF)
Honda Tsushin
MR50LM01
(MR50LM)
Honda Tsushin's MR50RF
Supplied with an ordered cable
CRMA5*


4.8.2 Peripheral Device Interface B Cable (CRM4, CRMA6: Honda
Tsushin, 20 pins)

Process I/O
Peripheral
device
Process I/O
Honda Tsushin
MR20RMA
Peripheral
device
Honda Tsushin
MR20LWF01
(MR20LF)
Honda Tsushin
MR20LM01
(MR20LM)
Honda Tsushin's MR20RF
Supplied with an ordered cable
CRMA6*


B-82595EN-2/02 CONNECTIONS
- 387 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.8.3 ARC Weld Connection Cable (CRW1, CRW7:Honda
Tsushin,34pins)
Be sure to use our cable to connect the welder.



4.8.4 ARC Weld Connection CableCRW10 : Honda Tsushin, 50
pins
Be sure to use our cable to connect the Welder.




CRW10

MRH-50RFD
MR-50LWMH
Process I/O
Honda Tsushin
Honda Tsushin
Japan Aviation Electronics
Industry Ltd.
ARC Welder
Japan Aviation Electronics
Industry Ltd.
Standard position of guide
key


CONNECTIONS B-82595EN-2/02
- 388 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.9 CABLE CONNECTION FOR THE PERIPHERAL DEVICES,
END EFFECTORS, AND ARC WELDERS

4.9.1 Peripheral Device Connection Cable

Fig.4.9.1 shows the connection of the peripheral device cable in the
cabinet.

(A-cabinet)

Shield plate
Metallic clamp
Optional board
CRMA5A CRMA5B

(B-cabinet)
For noise protection, cut part of the jacket of the peripheral device
cable to expose the shield sheath, and fasten this part to the shield
plate with the clamp.

Fig.4.9.1 Peripheral Device Cable Connection
Process I/O board
CRM2A or CRMA5A
CRM2B or CRMA5B
CRW1 or CRW7 or CRW10
B-82595EN-2/02 CONNECTIONS
- 389 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.9.2 Peripheral Device Cable Connector

(1) Fig.4.9.2 shows the connector for peripheral device cables A and
B.



Dimensions Connector
specifications
Applicable
interface A (B) C (D)
Remark
MR50LM CRMA5 67.9 73.5 44.8 18 Honda Tsushin Kogyo, 50 pins
MR20LM CRMA6 39.3 44.9 39.8 17 Honda Tsushin Kogyo, 20 pins

Symbol Name
1

Connector cover
2

Cable clamp screw
3

Connector clamp spring
4

Connector clamp screw
5

Connector 50 pins (male) MR50M
20 pins (male) MR20M

Fig.4.9.2 (a) Peripheral device cable connector (Honda Tsushin Kogyo)

CONNECTIONS B-82595EN-2/02
- 390 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
(2) Peripheral device connector





Dimensions Connector
specifications
Applicable
interface A B
Remark
MR50RF (CRM2)
(CRMA5)
61.4 56.4 Honda Tsushin Kogyo, 50 pins
MR20RF (CRM4)
(CRMA6)
39.3 44.9 Honda Tsushin Kogyo, 20 pins

Symbol Name
1

Connector clamp screw
2

Screw M2.6 8
3

Connector (MR50RF)
(MR20RF)

Fig.4.9.2 (b) Peripheral device connector (Honda Tsushin Kogyo)

B-82595EN-2/02 CONNECTIONS
- 391 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.9.3 End Effector Cable Connector

(1) Connector external view (For R-2000iB and M-710iC. Refer to
the each operators manual for other robots.)



A : M30#1
B : 63.0
C : 54.5
D : 9.6 to 15.0 (Inside diameter)
E : #33
F : 11.2
G : 24.7
Manufactured by Fujikura JMLP2524M

Fig.4.9.3 (a) Connector (Elbow Type)



A : M30#1
B : 54.1
C : 37.5
D : 9.6 to 15.0 (Inside diameter)
E : #33
F : 11.2
G : 24.7
Manufactured by Fujikura JMLP2524M

Fig.4.9.3 (b) Connector (Straight Type)

CONNECTIONS B-82595EN-2/02
- 392 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.9.4 Recommended Cables

(1) Peripheral device connection cable
Connect a peripheral device using a completely shielded, heavily
protected cable conforming to the specifications in Table 4.9.4
(a).
Allow an extra 50 cm for routing the cable in the control unit.
The maximum cable length is 30 m.

Table 4.9.4 (a) Recommended Cable (for Peripheral Device Connection)
Conductor Electrical characteristics
Number of wires
Wire specifications
(FANUC
specifications)
Diameter
(mm)
Configuration
Sheath
thickness
(mm)
Effective
outside
diameter
(mm)
Conductor
resistance
(/km)
Allowable
current (A)
50 A66L-0001-0042 1.05 7/0.18 AWG24 1.5 12.5 106 1.6A
20 A66L-0001-0041 1.05 7/0.18 AWG24 1.5 10.5 106 1.6A

(2) End effector connection cable
Connect an end effector using a heavily protected cable with a
movable wire conforming to the specifications in Table 4.9.4 (b).
The cable length is determined so that the cable will not interfere
with the end effector and the wrist can move through its full
stroke.

Table 4.9.4 (b) Recommended Cable (for End Effector Connection)
Conductor Electrical characteristics
Number of wires
Wire specifications
(FANUC
specifications)
Diameter
(mm)
Configuration
Sheath
thickness
(mm)
Effective
outside
diameter
(mm)
Conductor
resistance
(/km)
Allowable
current (A)
6 A66L-0001-0143 1.1 40/0.08 AWG24 1.0 5.3 91 3.7
20 A66L-0001-0144 1.1 40/0.08 AWG24 1.0 8.6 91 2.3
24 A66L-0001-0459 0.58 40/0.08 AWG24 1.0 8.3 93 2.3

B-82595EN-2/02 CONNECTIONS
- 393 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.10 CONNECTION OF HDI

4.10.1 Connecting HDI

The HDI signals are used in combination with special application
software. The HDI signals cannot be used as general-purpose DIs.




R-30iA











Main board
JRL5
1 HDI0 11 HDI1
2 0V 12 0V
3 HDI2 13 HI3
4 0V 14 0V
5 0V 15 HDI5
6 HDI4 16 0V
7 17 HDI6
8 18 0V
9 19 HDI7
10 20 0V



CONNECTIONS B-82595EN-2/02
- 394 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Cable connections
Recommended cable connector:
PCR-E20FA (Honda Tsushin Kogyo)
FI30-20S (Hirose Electric)
FCN-247J020-G/E (Fujitsu)
52622-2011 (Molex Japan)
HDI0
0V
HDI1
0V
HDI2
0V
HDI3
0V
HDI4
0V
HDI5
0V
HDI6
0V
HDI7
0V
1
2
11
12
3
4
13
14
6
5
or
10
15
16
17
18
19
20
7
8
9
10
JRL5
Shield
Ground plate


B-82595EN-2/02 CONNECTIONS
- 395 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.10.2 Input Signal Rules for the High-speed Skip (HDI)

Circuit configuration
R-30iA
VH/VL
DRIVER
SHIELD
FILTER liL/liH RECEIVER


Absolute maximum rating
Input voltage range Vin: -3.6 to +10 V
Input characteristics

Unit Symbol Specification Unit Remark
High level input voltage VH 3.6 to 7 V
Low level input voltage VL 0 to 1.0 V
2 max mA Vin=5 V High level input current liH
11 max mA Vin = 10 V
Low level input current liL -8.0 max mA Vin = 0 V
Input signal pulse
duration
20 min m s
Input signal delay or
variations
0.02(max) ms

NOTE
1 The plus (+) sign of IiH/IiL represents the direction
of flow into the receiver. The minus (-) sign of
IiH/IiL represents the direction of flow out of the
receiver.
2 The high-speed skip signal is assumed to be 1
when the input voltage is at the low level and 0
when it is at the high level.


CONNECTIONS B-82595EN-2/02
- 396 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.11 CONNECTING THE COMMUNICATION UNIT

4.11.1 RS-232-C Interface

4.11.1.1 Interface

This interface can be connected to a communication unit from
FANUC.





(A-cabinet)


RS-232-C port

(B-cabinet)
RS-232-C port
RS-232-C port
In case of the length of operation box
connection cable that is 10m or longer.
B-82595EN-2/02 CONNECTIONS
- 397 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
ER
+24V
14
16
15
17
19
18
20
22
21
23
25
24
SD
FG
RD
CS
RS
DR
SG
1
3
2
4
6
5
7
9
8
10
12
11
13
R-30iA
> <
Main board
Operator's panel
Connector
(DBM-25S)
>


NOTE
1 +24 V can be used as the power supply for FANUC
RS-232-C equipment.
2 Do not connect anything to those pins for which
signal names are not indicated.

4.11.1.2 RS-232-C interface signals

Generally signals as follows are used in RS-232-C interface.

R-30iA
SD (Send data)
RD (Receive data)
RS (Request to Send)
CS (Enable to send)
ER (Ready)
DR (Data set ready)
SG (Signal ground)
FG (Frame ground)
When CS is not used short
CS and RS.
When DR is not
used short DR and
ER.
Output
Input

Fig.4.11.1.2 RS-232-C interface

CONNECTIONS B-82595EN-2/02
- 398 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.11.1.3 Connection between RS-232-C interface and I/O device

The figure below shows a connection with the handshaking of the
ER/DR, RS/CS signals.

R-30iA I/O device side
SD
RD
RS
CS
ER
DR
CD
SG
FG
SD
RD
RS
CS
ER
DR
CD
SG
FG
FG (Frame ground)


B-82595EN-2/02 CONNECTIONS
- 399 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
The figure below shows a connection without the handshaking of
the RS/CS, ER/DR signals.

External device
side
SD
RD
RS
CS
ER
DR
SG
FG
SD
RD
RS
CS
ER
DR
CD
SG
FG
R-30iA
FG (Frame ground)


Cable connection
DR
R-30iA
Cable : twist 10 pairs 0.18mm
2
, with shield
SD
RD
RS
CS
SG
ER

Pair each signal with SG.

CONNECTIONS B-82595EN-2/02
- 400 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.11.2 Ethernet Interface

CAUTION
Before connecting or disconnecting cables to and
from the Ethernet board, cut the power supply of
R-30iA, and make sure that the power is off.

NOTE
Please ask each manufacturer about the network
construction of network or the condition of using
the equipment except the Ethernet board (hub,
transceiver, cable etc.). When configuring your
network, you must take other sources of electrical
noise into consideration to prevent your network
from being influenced by electrical noise. Make
sure that network wiring is sufficiently separated
from power lines and other sources of electrical
noise such as motors, and ground each of the
devices as necessary. Also, a high and insufficient
ground impedance may cause interference during
communications. After installing the machine,
conduct a communications test before you actually
start operating the machine.
We cannot ensure operation that is influenced by
network trouble caused by a device other than the
main board.

B-82595EN-2/02 CONNECTIONS
- 401 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.11.2.1 Connection to Ethernet

The main board is provided with a 10/100 BASE-T interface.
Prepare a hub for connecting the Ethernet board to the Ethernet trunk.
The following shows an example of a general connection.

R-30iA


Some devices (hub, transceiver, etc.) that are needed for building a
network do not come in a dust-proof construction. Using such devices
in an atmosphere where they are subjected to dust or oil mist will
interfere with communications or damage the Ethernet board. Be sure
to install such devices in a dust-proof cabinet.

CONNECTIONS B-82595EN-2/02
- 402 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.11.2.2 10/100 BASE-T connector (CD38) pin assignments

CD38
Pin No. Signal Name Description
1 TX+ Send +
2 TX- Send -
3 RX+ Receive +
4 Not used
5 Not used
6 RX- Receive -
7 Not used
8 Not used

4.11.2.3 Cable connection

The figure below shows the cable connection between the 10/100
BASE-T connector (CD38) of the main board and hub.
Ethernet board
RJ-45 modular connector

MAX.100m
Shielded cable


For details on shielding, see Subsection 4.7.1, "Peripheral Device
Connection Cable" in the Part III, CONNECTIONS.
Keep the total cable length to within 100 m. (FANUC
recommends the cable length to within 50 m for movable parts.)
Do not extend the cable longer than necessary.


B-82595EN-2/02 CONNECTIONS
- 403 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES


(For the A-cabinet)


Use any connector not in use
Clamp : A02B-0083-K301
The cable should be fixed on the shield plate.
CONNECTIONS B-82595EN-2/02
- 404 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.11.2.4 Lead materials

Unshielded cable (UTP cable) is commercially available as 10/100
BASE-T twisted-pair cable. However, be sure to use shielded
Category 5 twisted-pair cable (STP) to improve the resistance to
electrical noise in an FA environment. (For details on shielding, see
Subsection 4.7.1, "Peripheral Device Connection Cable" in the Part III,
CONNECTIONS.

Recommended Cable (For fixed parts)
Manufacturer Specification
Furukawa Electric Co., Ltd. DTS5087-4P
Nissei Electric Co., Ltd. F-4PFWMF

Inquiries
Manufacturer Contact Address
Furukawa Electric Co., Ltd.,
Sales Headquarters
Maru-no-uchi 2-6-1, Chiyoda-ku. Tokyo
100-8322
TEL: 03-3286-3126
Remarks
Nissei Electric Co., Ltd.,
Machida Branch
4F MS center Bldg., Minami-narise 1-2-2,
Machida City, Tokyo 194-0045
TEL: 0427-29-2531
FAX: 0427-29-3375
Overseas Sales Office IWATANI International Corporation
- Tokyo Head Office
21-8 NISHI-SHINBASHI 3-CHOME,
MINATO-KU, TOKYO, 105-8458, JAPAN
TEL:03-5405-5810
Telex : 2524256 IWATYO J
Remarks Cables with connectors at both ends can be
supplied.

NOTE
The recommended cables cannot be connected to
movable portions.

Recommended Cable (For movable parts)
Manufacturer Specification Remarks
Oki Electric Cable Co.,
Ltd.
AWG26 4P TPMC-C5-F(SB) FANUC-specific
cable

Cable specifications (FANUC-specific cable No connector)
Drawing number: A66L-0001-0453
Manufacturer: Oki Electric Cable Co., Ltd.
Nagano Sales Office TEL: 0266-27-1597

B-82595EN-2/02 CONNECTIONS
- 405 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Specifications
Electric characteristics: Conform to EIA/TIA 568A categories
3 and 5.
For reasons related to attenuation performance, the distance to
the hub must be 50 m or shorter.
Structure: Common shield cable (braided shield). Drain wire
provided.
The conductor is AWG26 annealed copper stranded wire. The
sheath thickness is 0.8 mm. The outside diameter is 6.70.3
mm.
Flame resistance: UL1581 VW-1
Oil resistance: Based on the FANUC standard.
(equivalent to the conventional oil-resistant electric cables)
Flexing resistance: 1 million times or more with 50 mm of a
bend radius (U-shape flexing test)
UL style No.: AWM 20276 (80n/30 V/VW-1)

NOTE
Always use connector TM21CP-88P(03)
manufactured by Hirose Electric for this cable.
Cable assembly
Oki Electric Cable Co., Ltd. also supplies cable
assemblies using connector TM21CP-88P(03)
manufactured by Hirose Electric. Make
arrangements directly with the manufacturer for
the specifications (length, outgoing inspection,
packing, and others) and purchase cable
assemblies.
Contact point:
Oki Electric Cable Co., Ltd.
Sales contact point) Nagano Sales Office
TEL: 0266-27-1597

CONNECTIONS B-82595EN-2/02
- 406 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.11.2.5 Connector specification

As a connector used with a twisted pair cable for Ethernet, an 8-bit
modular connector called RJ-45 is used. Use the following
connector or equivalent:

Specification Manufacturer Remarks
For solid wire 5-569530-3 Tyco Electronics AMP
For solid wire MS8-RSZT-EMC SK KOHKI Co., Ltd. Special tool
required
For twisted wire 5-569552-3 Tyco Electronics AMP
For twisted wire TM11AP-88P Hirose Electric Co., Ltd. Special tool
required


For movable parts Specification Manufacturer Remarks
For cable AWG26
4P TPMC-C5-F(SB)
TM21CP-88P(03) Hirose Electric Co., Ltd. (Note)

NOTE
TM21CP-88P(03)
Connector (manufacturer standard part)
Drawing number: A63L-0001-0823#P
Manufacturer: Hirose Electric Co., Ltd.
Manufacturer catalog number: TM21CP-88P(03)
Conforms to EIA/TIA 568A categories 3 and 5.
For how to assemble the connector and cable,
contact Hirose Electric.
(Hirose Electric technical document
"TM21CP-88P(03) Connection Procedure
Specifications" (technical specification No.
ATAD-E2367) is available.)

4.11.2.6 Cable clamp and shielding

Shield the cables as like as other cables are shielded. (See Subsection
4.7.1, "Peripheral Device Connection Cable" in the Part III,
CONNECTIONS.)

B-82595EN-2/02 CONNECTIONS
- 407 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
4.11.2.7 Grounding the network

Even if the grounding conditions on the machine are satisfied,
electrical noise from the machine sometimes enters the
communications line and causes communications interference
depending on the installation conditions and the peripheral
environment of the machine. To prevent the entry of such electrical
noise, separating and insulating the machine from the Ethernet trunk
cable and the personal computer effectively reduces the influence of
electrical noise.

The following figure shows an example of such a connection.

CONNECTIONS B-82595EN-2/02
- 408 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
Large-scale Network
Small-scale Network
Electrically separated
by 10/100 BASE-T
cable connection
Electrically separated
by 10/100 BASE-T
cable connection


B-82595EN-2/02 CONNECTIONS
- 409 -
4. PERIPHERAL DEVICE, ARC
WELDING, AND END
EFFECTOR INTERFACES
NOTE
1 The ground between the PC/Trunk line side and
machine system side must be separated. If it is
impossible to separate the ground because there is
only one grounding point, connect the ground cable
for each system to the grounding point
independently. (Refer Fig.4.9.2.7)
The resistance for grounding must be less than
100-ohm (Class 3).
The thickness of the ground cable is the same as
the thickness of AC power cable or more. At least
thickness of 5.5mm2 is necessary.
2 Please use the HUB that has unshielded interface
connector. FANUC recommends the HCN-7500
(Hitachi-Densen LTD) or equivalent.
3 There is the possibility that noise makes the
obstacle of communication even if the ground is
separated using the 10/100 BASE-T. In the case of
using the Ethernet board under the worst
environment, please separate between the
PC/Trunk line side and machine system side
completely using the 10/100 BASE-FL (Optical
fiber media).


Fig.4.11.2.7 Wiring on a single ground point

5.TRANSPORTATION AND INSTALLATION CONNECTIONS B-82595EN-2/02

- 410 -
5 TRANSPORTATION AND INSTALLATION

This chapter describes the transportation and installation for the
controller.
B-82595EN-2/02 CONNECTIONS 5.TRANSPORTATION AND INSTALLATION

- 411 -
5.1 TRANSPORTATION

The controller is transported by a crane. Attach a strap to eye bolts
at the top of the control unit.



(A-cabinet) (B-cabinet)

Fig. 5.1 Transportation

Eye bolt (M12)
Crane capacity : Minimum 300kg
Sling capacity : Minimum 300kg
Eye bolt (M12)
5.TRANSPORTATION AND INSTALLATION CONNECTIONS B-82595EN-2/02

- 412 -
5.2 INSTALLATION

5.2.1 Installation Method

Following is the installation method for cabinet.
When installing the controller, allow the space for maintenance shown
in the following figure.























Munsell Color
5GY3.5/0.5 Gray



Fig. 5.2.1 (a) External dimension (A-cabinet Rear fan type)
B-82595EN-2/02 CONNECTIONS 5.TRANSPORTATION AND INSTALLATION

- 413 -






















Munsell Color
5GY3.5/0.5 Gray



Fig. 5.2.1 (b) External dimension (A-cabinet Side fan type)



5.TRANSPORTATION AND INSTALLATION CONNECTIONS B-82595EN-2/02

- 414 -

Munsell Color
Body 5GY3.5/0.5 Gray
Door 3.0GY8.2/0.9 White
Op.panel N1.5 Black

Fig. 5.2.1 (c) External dimension (B-cabinet)




B-82595EN-2/02 CONNECTIONS 5.TRANSPORTATION AND INSTALLATION

- 415 -





Fig. 5.2.1 (d) Installtion dimension (A-cabinet)


5.TRANSPORTATION AND INSTALLATION CONNECTIONS B-82595EN-2/02

- 416 -

Controller Controller Controller
100
100


NOTE
Keep this area for maintenance and the radiation of
heat.

Fig. 5.2.1 (e) Installtion dimension (B-cabinet)
B-82595EN-2/02 CONNECTIONS 5.TRANSPORTATION AND INSTALLATION

- 417 -


Munsell Color
Body 5GY3.5/0.5 Gray
Door 3.0GY8.2/0.9 White



Fig. 5.2.1 (f) External dimension (A-cabinet operation box)


Munsell Color
Body 5GY3.5/0.5 Gray
Door 3.0GY8.2/0.9 White

Fig. 5.2.1 (g) External dimension (Integrated operation box)

5.TRANSPORTATION AND INSTALLATION CONNECTIONS B-82595EN-2/02

- 418 -
5.2.2 Assemble at Installation


Fig.5.2.2 (a) Assemble at installation (A-cabinet)



Fig.5.2.2 (b) Assemble at installation (Integrated operation box)


Peripheral device connection cable
Operation box
Teach pendant
Robot connection cable
R-30iA controller
Teach pendant
Integrated operation box
Peripheral device connection
cable
Robot connection cable
B-82595EN-2/02 CONNECTIONS 5.TRANSPORTATION AND INSTALLATION

- 419 -

Teach pendant
R-30iA controller
Robot connection cable
Peripheral device connection cable

Fig.5.2.2 (c) Assemble at installation (B-cabinet)

5.TRANSPORTATION AND INSTALLATION CONNECTIONS B-82595EN-2/02

- 420 -
5.3 INSTALLATION CONDITION
Item Model Specification/condition
Rated Voltage All models Trans. Type E 380-415, 440-500, 500-575VAC
Trans. Type D 380-400, 200-230VAC
50/60Hz 3phases
Tolerant fluctuation All models Tolerant voltage fluctuation: +10% -15%
Tolerant frequency fluctuation: 1Hz
M-900iA/600 18KVA
R-2000iB/200T,M-410iB,
M-900iA/260L,M-900iA/350
15KVA
R-2000iB(except /200T)
M-420iA /M-421iA,M-710iC
12KVA
F-200iB 5KVA
M-16iB,ARC Mate 120iB 3KVA
M-6iB,ARC Mate 100iB 2.5KVA
M-430iA/2F 3.5KVA
M-430iA/2P 3.5KVA
Input power source capacity
ARC Mate 100iC, M-10iA 2.0KVA
M-900iA/600 5KW
R-2000iB/200T,M-410iB,
M-900iA/260L,M-900iA/350
3KW
R-2000iB(except /200T)
M-420iA /M-421iA,M-710iC
2.5KW
M-6iB, M-16iB
ARC Mate100iB
ARC Mate120iB, F-200iB
1.0KW
M-430iA/2F 1.0KW
M-430iA/2P 1.0KW
Average power consumption
ARC Mate 100iC, M-10iA 1.0KW
Permissible ambient
temperature
All models 0 to 45C during operation, and -20 to 60C during
shipment and storage with a temperature coefficient
of 1.1C/min
Permissible ambient
humidity
All models Relative humidity: 30% to 95%, non-condensing
Surrounding gas All models An additional protective provision is necessary if the
machine is installed in an environment in which there
are relatively large amounts of contaminants (dust,
dielectric fluid, organic solvent, acid, corrosive gas,
and/of salt).
Installation category All models Installation category III, Pollution degree 3,
IEC60664-1 and IEC61010-1
Vibration All models 0.5G or less. When using the robot in a location
subject to serious vibration, consult with your FANUC
sales representative.
Altitude Common to all models Not higher than 1,000m above sea level
Ionized and non-ionized radiation Common to all models A shielding provision is necessary if the machine is
installed in an environment in which it is exposed to
radiation (microwave, ultraviolet rays, laser beams,
and/or X-rays).
All models
(except below
models)
Approx. 120kg A-cabinet
M-410iB Approx. 140kg
All models
(except below
models)
Approx. 180kg
Mass of control unit
B-cabinet
M-900iA,
M-410iB,
R-2000iB/200T
Approx. 200kg
B-82595EN-2/02 CONNECTIONS 5.TRANSPORTATION AND INSTALLATION

- 421 -

NOTE
The power rating indicated above is sufficient as the continuous rating. However, when
the robot is rapidly accelerating, the instantaneous requirement may increase to several
times the continuous rating.

5.4 ADJUSTMENT AND CHECKS AT INSTALLATION

Adjust the robot according to the following procedure at installation.

No. Description
1 Visually check the inside and outside of the control unit.
2 Check the screw terminals for proper connection.
3 Check that the connectors and printed circuit boards are firmly
connected.
4 Check transformer tap setting. (See II MAINTENANCE section 6.2)
5 The breaker off and connect the input power cable.
6 Check the input power voltage and transformer outputs.
7 Press the EMERGENCY STOP button on the operator panel and
turn on the control unit.
8 Check the interface signals between control unit and robot
mechanical unit.
9 Check the parameters. If necessary, set them.
10 Release the EMERGENCY STOP button on the operator panel.
Turn on the controller.
11 Check the movement along each axis in manual jog mode.
12 Check the end effector interface signals.
13 Check the peripheral device control interface signals.

5.TRANSPORTATION AND INSTALLATION CONNECTIONS B-82595EN-2/02

- 422 -
5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT
INSTALLATION

An overtravel and emergency stop occur when the robot is operated
for the first time after it is installed and the mechanical and control
units are wired. This section describes how to reset the overtravel
and emergency stop.
Remove the red plate fastening the swiveling axis beforehand.
The J2 and J3 axes are pressed against the hard stops at shipment.
Therefore, an overtravel alarm occurs when the power is turned on
after installation.
The robot can also be in an emergency stop state if the peripheral
device control interface is not connected.

5.5.1 Peripheral Device Interface Processing

Take the following actions if signals *IMSTP, *HOLD, *SFSD, and
ENBL are not used.

49, 50
+24F
1 *IMSTP
RV
2 *HOLD
RV
3 *SFSD
RV
4 ENBL
RV
CRM2A


5.5.2 Resetting Overtravel

1) Select [OT release] on the overtravel release screen to release
each robot axis from the overtravel state.
2) Hold down the shift key, and press the alarm release button to
reset the alarm condition.
3) Still hold down the shift key, and jog to bring all axes into the
movable range.

B-82595EN-2/02 CONNECTIONS 5.TRANSPORTATION AND INSTALLATION

- 423 -
5.5.3 How to Disable/Enable HBK

1) Press [MENUS] on the teach pendant.
2) Select [NEXT].
3) Select [SYSTEM].
4) Press "F1" (TYPE) on the teach pendant.
5) Select "Config" to disable/enable HBK.

Status
Hand Broken
enable/disable setting
HBK (*1) HBK detection Robot operation Message
1 Enable CLOSE Yes Possible None
2 Enable OPEN Yes Impossible SRVO-006
3 Disable CLOSE Yes(*2) Possible None
4 Disable OPEN No Possible At cold start, SRVO-300

NOTE
1 Robot end effector connector

24V
*HBK
24V
*HBK
CLOSE OPEN

2 The moment the HBK circuit is closed, HBK detection becomes enabled.
When the HBK circuit is opened again, alarm "Servo 300" or "Servo 302" occurs,
causing the robot to stop.
3 If the power is turned off and on again under the condition stated in *2, status 4 is
entered, so the alarm condition is removed.

5.5.4 How to Disable/Enable Pneumatic Pressure Alarm (PPABN)

1) Press [MENUS] on the teach pendant.
2) Select [NEXT].
3) Select [SYSTEM].
4) Press "F1" (TYPE) on the teach pendant.
5) Select "Config" to disable/enable PPABN.
















APPENDIX

B
-
8
2
5
9
5
E
N
-
2
/
0
2

A
P
P
E
N
D
I
X

A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M


-

4
2
7

-

A

T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M

CRMA8
VISION
RI/RO

F
i
g
.

A
(
a
)

S
y
s
t
e
m

b
l
o
c
k

d
i
a
g
r
a
m

(
A
-
c
a
b
i
n
e
t
)


System Block Diagram A-Cabinet
A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M

A
P
P
E
N
D
I
X

B
-
8
2
5
9
5
E
N
-
2
/
0
2


-

4
2
8

-

CRMA8
CRMA7
VISION
RI/RO


F
i
g
.

A
(
b
)

S
y
s
t
e
m

b
l
o
c
k

d
i
a
g
r
a
m

(
B
-
c
a
b
i
n
e
t
)


B
-
8
2
5
9
5
E
N
-
2
/
0
2

A
P
P
E
N
D
I
X

A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M


-

4
2
9

-

A1
A2
A3
: B1
: B2
: A1
: A2
: B1
: B2
A1
A2
A3
: B1
: B2
: B3


F
i
g
.

A
(
c
)

A
C

p
o
w
e
r

l
i
n
e

c
o
n
n
e
c
t
i
o
n

d
i
a
g
r
a
m

(
i
n

c
a
s
e

o
f

T
Y
P
E

E

t
r
a
n
s
f
o
r
m
e
r

/

A
-
c
a
b
i
n
e
t
)

A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M

A
P
P
E
N
D
I
X

B
-
8
2
5
9
5
E
N
-
2
/
0
2


-

4
3
0

-

: A1
: A2
: A3
: B1
: B2
: A1
: A2
: B1
: B2
A1
A2
A3
: B1
: B2
: B3


F
i
g
.

A
(
d
)

A
C

p
o
w
e
r

l
i
n
e

c
o
n
n
e
c
t
i
o
n

d
i
a
g
r
a
m

(
i
n

c
a
s
e

o
f

T
Y
P
E

E

t
r
a
n
s
f
o
r
m
e
r

/

B
-
c
a
b
i
n
e
t
)

B
-
8
2
5
9
5
E
N
-
2
/
0
2

A
P
P
E
N
D
I
X

A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M


-

4
3
1

-

CPOH



F
i
g
.

A

(
e
)

A
C

p
o
w
e
r

l
i
n
e

c
o
n
n
e
c
t
i
o
n

d
i
a
g
r
a
m

(
i
n

c
a
s
e

o
f

T
Y
P
E

D

l
i
n
e
f
i
l
t
e
r

t
r
a
n
s
f
o
r
m
e
r
)


A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M

A
P
P
E
N
D
I
X

B
-
8
2
5
9
5
E
N
-
2
/
0
2


-

4
3
2

-

: B2
: B1
: A2
: A1


F
i
g
.

A
(
f
)

D
C

p
o
w
e
r

l
i
n
e

c
o
n
n
e
c
t
i
o
n

d
i
a
g
r
a
m

(
A
-
c
a
b
i
n
e
t
)

B
-
8
2
5
9
5
E
N
-
2
/
0
2

A
P
P
E
N
D
I
X

A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M


-

4
3
3

-



RS-232-C
: B2
: B1
: A2
: A1


F
i
g
.

A
(
g
)

D
C

p
o
w
e
r

l
i
n
e

c
o
n
n
e
c
t
i
o
n

d
i
a
g
r
a
m

(
B
-
c
a
b
i
n
e
t
)


A.TOTAL CONNECTION DIAGRAM APPENDIX B-82595EN-2/02

- 434 -


CRMA8


Fig. A (h) E-STOP circuit connection diagram
B-82595EN-2/02 APPENDIX A.TOTAL CONNECTION DIAGRAM

- 435 -



A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M

A
P
P
E
N
D
I
X

B
-
8
2
5
9
5
E
N
-
2
/
0
2


-

4
3
6

-


F
i
g
.

A
(
i
)

E
m
e
r
g
e
n
c
y

s
t
o
p

b
o
a
r
d

c
o
n
n
e
c
t
o
r

t
a
b
l
e


B
-
8
2
5
9
5
E
N
-
2
/
0
2

A
P
P
E
N
D
I
X

A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M


-

4
3
7

-

CAMDI0
CAMDI1
12V


F
i
g
.

A
(
j
)

M
a
i
n

b
o
a
r
d

c
o
n
n
e
c
t
o
r

t
a
b
l
e


A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M

A
P
P
E
N
D
I
X

B
-
8
2
5
9
5
E
N
-
2
/
0
2


-

4
3
8

-


F
i
g
.

A
(
k
)

P
a
n
e
l

b
o
a
r
d

c
o
n
n
e
c
t
i
o
n

d
i
a
g
r
a
m

B
-
8
2
5
9
5
E
N
-
2
/
0
2

A
P
P
E
N
D
I
X

A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M


-

4
3
9

-


F
i
g
.

A
(
l
)

P
a
n
e
l

b
o
a
r
d

c
o
n
n
e
c
t
o
r

t
a
b
l
e


A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M

A
P
P
E
N
D
I
X

B
-
8
2
5
9
5
E
N
-
2
/
0
2


-

4
4
0

-



F
i
g
.

A
(
m
)

S
e
r
v
o

a
m
p
l
i
f
i
e
r

c
o
n
n
e
c
t
o
r

t
a
b
l
e


B
-
8
2
5
9
5
E
N
-
2
/
0
2

A
P
P
E
N
D
I
X

A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M


-

4
4
1

-


F
i
g
.

A
(
n
)

M
o
t
o
r

p
o
w
e
r

c
o
n
n
e
c
t
i
o
n

(
G
r
o
u
p
1
)


A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M

A
P
P
E
N
D
I
X

B
-
8
2
5
9
5
E
N
-
2
/
0
2


-

4
4
2

-


F
i
g
.

A
(
o
)

M
o
t
o
r

p
o
w
e
r

c
o
n
n
e
c
t
i
o
n

(
G
r
o
u
p
2
)



B
-
8
2
5
9
5
E
N
-
2
/
0
2

A
P
P
E
N
D
I
X

A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M


-

4
4
3

-


F
i
g
.

A
(
p
)

M
o
t
o
r

p
o
w
e
r

c
o
n
n
e
c
t
i
o
n

(
G
r
o
u
p
3
)



A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M

A
P
P
E
N
D
I
X

B
-
8
2
5
9
5
E
N
-
2
/
0
2


-

4
4
4

-


F
i
g
.

A
(
q
)

M
o
t
o
r

p
o
w
e
r

c
o
n
n
e
c
t
i
o
n

(
G
r
o
u
p
4
)



B
-
8
2
5
9
5
E
N
-
2
/
0
2

A
P
P
E
N
D
I
X

A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M


-

4
4
5

-



F
i
g
.

A
(
r
)

M
o
t
o
r

p
o
w
e
r

c
o
n
n
e
c
t
i
o
n

(
G
r
o
u
p
5
)


A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M

A
P
P
E
N
D
I
X

B
-
8
2
5
9
5
E
N
-
2
/
0
2


-

4
4
6

-


F
i
g
.

A
(
s
)

M
o
t
o
r

P
o
w
e
r

C
o
n
n
e
c
t
i
o
n
(
G
r
o
u
p

6
)


B
-
8
2
5
9
5
E
N
-
2
/
0
2

A
P
P
E
N
D
I
X

A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M


-

4
4
7

-


F
i
g
.

A
(
t
)

M
o
t
o
r

P
o
w
e
r

C
o
n
n
e
c
t
i
o
n
(
G
r
o
u
p

7
)


A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M

A
P
P
E
N
D
I
X

B
-
8
2
5
9
5
E
N
-
2
/
0
2


-

4
4
8

-


F
i
g
.

A
(
u
)

M
o
t
o
r

P
o
w
e
r

C
o
n
n
e
c
t
i
o
n
(
G
r
o
u
p

8
)


B-82595EN-2/02 APPENDIX A.TOTAL CONNECTION DIAGRAM

- 449 -


Fig. A (v) RI/RO connection diagram











A.TOTAL CONNECTION DIAGRAM APPENDIX B-82595EN-2/02

- 450 -

Fig. A (w) RI/RO Connection Diagram(Group6,Group7)

B-82595EN-2/02 APPENDIX A.TOTAL CONNECTION DIAGRAM

- 451 -

Fig. A (x) RI/RO Connection Diagram(Group8)

There are many type EE connector of mechanical unit.
The detail is shown on the mechanical unit manual.


A.TOTAL CONNECTION DIAGRAM APPENDIX B-82595EN-2/02

- 452 -



Fig. A (y) Pulse coder signal connection diagram















B-82595EN-2/02 APPENDIX A.TOTAL CONNECTION DIAGRAM

- 453 -

Fig.A (z) Pulse coder Signal Connection Diagram(Group5)

A.TOTAL CONNECTION DIAGRAM APPENDIX B-82595EN-2/02

- 454 -

Fig.A (aa) Pulse coder Signal Connection Diagram(Group6)

B-82595EN-2/02 APPENDIX A.TOTAL CONNECTION DIAGRAM

- 455 -

Fig.A (ab) Pulse coder Signal Connection Diagram(Group7)

A.TOTAL CONNECTION DIAGRAM APPENDIX B-82595EN-2/02

- 456 -

Fig.A (ac) Pulse coder Signal Connection Diagram(Group8)
B
-
8
2
5
9
5
E
N
-
2
/
0
2

A
P
P
E
N
D
I
X

A
.
T
O
T
A
L

C
O
N
N
E
C
T
I
O
N

D
I
A
G
R
A
M


-

4
5
7

-



F
i
g
.

A
(
a
d
)

M
e
c
h
a
n
i
c
a
l

u
n
i
t

i
n
t
e
r
f
a
c
e
(
G
r
o
u
p
1
,

G
r
o
u
p
2
)



A
.
T
O
T
A
L

C
O
N
N
E
C
T
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B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE APPENDIX B-82595EN-2/02

- 466 -
B SPECIFICATIONS OF PERIPHERAL
DEVICE INTERACE

B-82595EN-2/02 APPENDIX B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE

- 467 -
B.1 SIGNAL

The following table lists the I/O signals used for the peripheral device
interface in the R-30iA controller.

Input signals (Refer to B.3.1)
Signal Description
*IMSTP
*HOLD
*SFSPD
CSTOPI
FAULT_RESET
START
HOME
ENBL
RSR1/PNS1
RSR2/PNS2
RSR3/PNS3
RSR4/PNS4
RSR5/PNS5
RSR6/PNS6
RSR7/PNS7
RSR8/PNS8
PNSTROBE
PROD_START
DI01
DI02

DI03
DI04
DI05
DI06
DI07
DI08
DI09
DI10
DI11
DI12
DI13
DI14
DI15
DI16
DI17
DI18
DI19
DI20
DI21
DI22
Instantaneous stop signal
Hold signal
Safety speed signal
Cycle stop signal
Alarm release signal
Cycle start signal
Robot service request/program number select signal (*1)
Enabling signal
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
Robot service request/program number select signal (*1)
PNS strobe signal
Automatic operation start signal
General-purpose input signal
General-purpose input signal

General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal
General-purpose input signal

*1: RSR :Robot Service Request (RSR5 to RSR8 are optional)
PNS :Program Number Select Input (optional)
Whether RSR is used or PNS is used can be preset.

B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE APPENDIX B-82595EN-2/02

- 468 -

Output signals (Refer to B.3.2)
Signal Description
CMDENBL
SYSRDY
PROGRUN
PAUSED
HELD
FAULT
ATPERCH
TPENBL
BATALM
BUSY
ACK1/SNO1
ACK2/SNO2
ACK3/SNO3
ACK4/SNO4
ACK5/SNO5
ACK6/SNO6
ACK7/SNO7
ACK8/SNO8
SNACK
______

DO01
DO02
DO03
DO04
DO05
DO06
DO07
DO08
DO09
DO10
DO11
DO12
DO13
DO14
DO15
DO16
DO17
DO18
DO19
DO20
Command acceptance enabled signal
System ready signal
Program run signal
Program paused signal
Held signal
Alarm signal
Reference point signal
Teach pendant enabled signal
Battery alarm signal
Operating signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
RSR acknowledge/Selected program number signal
PNS acknowledge signal
Not used (for future expansion)

General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal
General-purpose output signal






B-82595EN-2/02 APPENDIX B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE

- 469 -
B.2 SETTING COMMON VOLTAGE

All process I/O printed boards have a jumper to set the common
voltage of input signals to 0 V or 24 V. The system automatically
adjusts the polarity by software according to the status of this pin.
Therefore, you can operate the system without being concerned about
the setting of the common voltage.

To ensure safety, the common reference voltage of the following four
signals, is remains at +24V.

*IMSTP
*HOLD
*SFSPD
CSTOPI
B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE APPENDIX B-82595EN-2/02

- 470 -
B.3 I/O Signals

B.3.1 Input Signals

This section describes the specifications of each input signal.
(1) Instantaneous stop signal (input) *IMSTP
Effective : At any time
Function : Use the normally-closed switch because it is a
reverse signal.
The system turns off power to the servo unit when
the *IMSTP is open (turned off). This signal has
the same effect as that of the emergency stop signal,
but it is controlled by software. For this reason,
use the emergency stop external interface on the
emergency stop control board for wiring of the
emergency stop signal.
Do not use *IMSTP.

(2) Alarm release signal (input) FAULT RESET
Effective : In the alarm status
Function : The FAULT RESET signal releases the alarm
status. If the servo unit has been turned off, it
also turns on the unit. At the same time, the
alarm display on the teach pendant (the top line)
is cleared.
Description: This signal releases only the alarm status.
It does not re-start execution of the program.
The robot will keep running if the signal is triggered
"ON" during operation.

(3) Hold signal (input) *HOLD
Effective:At any time
Function : Use the normally-closed switch because it is
a reverse signal.
The *HOLD signal has the same function as the
hold button on the teach pendant. It halts the
current program and stops the operation of the
robot. While this signal is being input, the held
signal (output) HELD is turned on and the robot
cannot be operated.

(4) Start signal (input) START
Effective : When the command acceptance enabled signal
(output) CMDENBL is turned on.
See the description of CMDENBL in Section
B.3.2 (1) for details.
Function : This input signal starts the selected program at the
falling edge when the signal is turned off after
being turned on. Its function differs according
to the setting of parameter
$SHELL_CFG.$CONT_ONLY.
B-82595EN-2/02 APPENDIX B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE

- 471 -
- If parameter $SHELL_CFG.$CONT_ONLY is set to
DISABLED, the START signal starts the program which
has been selected from the teach pendant. By default, the
program starts from the current cursor position.
- If parameter $SHELL_CFG.$CONT_ONLY is set to
ENABLED, the START signal only resumes the execution
of the temporarily held program. To execute an
inactivated program from the start, input the
PROD_START signal.

(5) Cycle stop signal (input) CSTOPI
Effective : At any time
Function :
- If parameter $SHELL_CFG.$USE_ABORT is set to
DISABLED, the CSTOPI signal releases the program from
the wait status caused by an RSR. It does not stop the
execution of the current program and allows it to continue
processing (by default).
- If parameter $SHELL_CFG.$USE_ABORT is set to
ENABLED, the CSTOPI signal immediately cancels the
execution of the current program. The program returns to
the status in which it was before execution, and the
information for the subprogram to return to the main
program is lost. At the same time, this signal also releases
the program from the wait status caused by RSR.

(6) Enabling signal (input) ENBL
Effective : At any time
Function : If the ENBL signal is turned off, the operation of
the robot or the activation of a program is
inhibited, and the execution of the current
program is suspended.

(7) Safety speed signal (input) *SFSPD
Effective : At any time
Function :
- Use the normally-closed switch because it is a reverse signal.
Usually this switch should be connected to safety fence. It
must be set normally on.
- Since the *SFSPD signal is counted as a remote condition,
such input signals as RSR and START to the peripheral
device interface cannot take effect unless this signal is
turned on.
- If this signal is turned from on to off during robot operation,
the execution of the current program is suspended. At the
same time, the overriding value is switched to a preset value
(parameter $SCR. $FENCEOVER.)
- As long as this signal is off, the overriding value cannot be
increased beyond the preset value ($SCR.$SFJOGOVLIM:
For jog, $SCR. $SFRUNOVLIM : For test execution.)

(8) Robot service request signal (input) RSR1/RSR2/RSR3/RSR4
B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE APPENDIX B-82595EN-2/02

- 472 -
Effective : When the command acceptance enabled signal
(output) CMDENBL is turned on.
See the description of CMDENBL in Section
B.3.2 (1) for details.
Function :
- The user can choose between RSR and PNS (optional),
although they cannot be used simultaneously.
- Four input signals, RSR1 to RSR4, are used.
- If a signal is input to an RSR input, a specified. program is
started. The program number can be set by a menu.
- If another program has already started processing, the newly
activated program enters the wait status. As soon as the
current program terminates, the waiting program starts
processing.
- By using an RSR instruction, each RSR in a program can be
enabled or disabled.
- A menu is provided to register the program number of a
specified program when each RSR is input. (Refer to the
application manual for details of the menu).


- When an RSR is input, the program whose program name
consists of the specified program number plus a base value
is started. For exam ple, if a signal is input to RSR2 when
program number 23 is registered in RSR2, the program to
be started is the one with the program name calculated from
the expression
RSR + (RSR2 program number + base number),
i.e., RSR0123.
The base number is stored in parameter
$SHELL_CFG.$JOB_BASE, and can be changed in a
program with a parameter instruction. (For example,
$SHELL_ CFG. $JOB_BASE =100). In this way, the
combination of programs which can be started by RSRs can
be changed.
- Whether the system should output an acknowledge signal to
an RSR can be selected from the menu. If so specified, a
pulse is output from the signal corresponding to the RSR,
one of signals ACK1 to ACK4, when the input of the
B-82595EN-2/02 APPENDIX B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE

- 473 -
RSR is accepted. From the same menu, the width of the
pulse can also be specified.
It is possible to accept other RSRs while outputting an
acknowledge signal.
- Input of a CSTOPIT signal can clear the program queue
waiting for execution after acceptance of RSRs.

(9) PNS/PNSTROBE (input)
Signal name : PNS: Program number select
PNSTROBE : Strobe input for PNS
Effective : When the command acceptance enabled signal
(output) CMDENBL is turned on.
See the description of CMDENBL in Section B.3.2 (1) for
details.
Function :
- The PNS/PNSTROBE signal selects whether the RSR
function is used or the PNS function (optional) is used. If
the PNS function is enabled, the RSR function cannot be
used.
- The eight signals PNS1 to PNS8 are used to specify a
program at the instant the strobe signal PNSTROBE rises.
- A menu is provided to specify the information about PNS.



If a number other than zero is entered to PNS input, a
program is selected whose program number is the entered
value plus the base number. For example, if the PNS
value is 23, the program to be started has the program name
calculated from the expression
PNS + (entered PNS value + base number),
i.e., PNS0123.
If zero is entered to PNS input, it is cleared as if no
selection has been made.
- A PNS signal, which can only select a program, cannot
execute the selected program. The execution of the
selected program can only be started after input of
automatic operation start signal PROD_START.

- For safety, the selected program cannot be changed from the
teach pendant unless PNSTROBE is turned off.
B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE APPENDIX B-82595EN-2/02

- 474 -
- If a program is selected by PNS, the program number is
output to selected program number signal (output) SNO,
and a pulse is output to program selection acknowledge
signal SNACK. Using these signals, peripheral devices
can confirm the correct program has been selected. For the
timing of these signals, see the sections describing SNO and
SNACK.
- The following operations are effective for the program
selected by PNS. You can:
- Start up a program by input of automatic operation start
signal PROD_START
- Restart the program that has been suspended.
Inputting the START signal restarts the program selected by
PNS when $SHELL_CFG.$CONT_ ONLY is set to
ENABLED.
- Input of CSTOPI cancels execution of the pro-grams
selected by PNS when $SHELL_CFG.$USE_ ABORT is
set to ENABLED.

(10) Automatic operation start signal (input) PROD_START

Effective : When the command acceptance enabled signal
(output) CMDENBL is turned on.
See the description of CMDENBL in Section
B.3.2 (1) for details.
Function : This input signal executes the selected program at
the falling edge when the signal is turned off after
being turned on.
B.3.2 Output Signals

This section describes the specifications of output signals for the
peripheral device interface.

(1) Command acceptance enabled signal (output) CMDENBL
Turned on :When the remote conditions are satisfied and the
system is not in the alarm status
Turned off:When the remote conditions are not
satisfied or the system is in the alarm status
The remote conditions are satisfied when all of
the following are satisfied.
- The teach pendant is in the DISABLED status.
- The remote/local setting is set to REMOTE.
- Parameter $RMT_MASTER is set to 0 (external interface).
- Signal *SFSPD is set to on, or in the normal status.

(2) System ready signal (output) SYSRDY
Turned on : When power is applied to the motor of the robot.
Turned off: When power is not applied to the motor of the robot.

(3) Program run signal (output) PROGRUN
Turned on: When the program is being executed.
Turned off: When the program is not being executed.
B-82595EN-2/02 APPENDIX B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE

- 475 -

(4) Held signal (output) HELD
This signal is used to check the status of the hold input.
Turned on : When the hold button on the teach pendant
(or input) is being pressed down (or turned on).
Turned off : When the hold button on the teach pendant
(or input) is not being pressed down
(or is turned off).

(5) Program paused signal (output) PAUSED
This signal is used together with output signal PROGRUN to
determine whether a program can be restarted while it is being
held.
Turned on: When a program is held and has not been
restarted yet. While this signal is on, the
program can be restarted and retains information
such as that to return from a subprogram to the
main program.
Turned off: When a program is being executed or is ready to
start. If signal PROGRUN is on, the program is
being executed. If signal PROGRUN is off, the
program has not been executed and can be started
from this status.

(6) Alarm status signal (output) FAULT
Turned on: When the system is in the alarm status (or an
alarm which can stop a program execution is
detected.) The indicator lamp does not go on in
warning.
Turned off :When the alarm status is released by an alarm
release operation.

(7) Reference point signal (output) ATPERCH
Turned on: When the robot is in the reference position
specified in the parameter. (the reference point
No.1 in reference point setup screen.)
Turned off: When the robot is not in the reference position
specified in the parameter. (the reference point
No.1 in reference point setup screen.)
Up to three reference positions can be specified,
but this signal is output when the robot is in the
first reference position. For the other two
reference positions, general-purpose signals can
be assigned to output as such. (They can be set
from the setup screen.)

(8) Teach pendant enabled signal (output) TPENBL
Turned on: When the teach pendant is enabled.
Turned off: When the teach pendant is disabled.

(9) Battery alarm signal (output) BATALM
Turned on: When the voltage of the battery for the CMOS
B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE APPENDIX B-82595EN-2/02

- 476 -
memory backup drops below the reference.
Turned off: When the voltage of the battery for the CMOS
memory backup is at the normal level.

(10) Operating signal (output) BUSY
Turned on: When a program is being executed or is being
processed from operation panels such as the teach
pendant. (This has the same function as that of
the BUSY lamp on the teach pendant.)
Turned off: When a program is not being executed nor is
being processed from operation panels such as
the teach pendant.

(11) RSR acknowledge signals (output) ACK1/ACK2/ACK3/ACK4
These signals are used together with the RSR function. They
can be specified to be enabled or disabled from the RSR setup
menu.
Turned on: When one of the signals from RSR1 to RSR4 is
input and accepted. A pulse whose width is
specified from the menu is output to acknowledge
the signal.
Turned off: Normally. Since these signals are always output
as pulses, they are normally in the off status.
The following chart shows the timing of the RSR input and ACK
output.

B-82595EN-2/02 APPENDIX B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE

- 477 -


* Other RSR signals can be accepted even when the ACK signal is
being output.

(12) PNS acknowledge signal (output) SNO/SNACK

These signals are used together with the PNS function.
Turned on: Whenever the PNS function is enabled.
The selected program number is displayed in
binary code (SN01 to SN08) on the teach
pendant.
If the number cannot be represented as an
eight-bit number, it becomes zero.
After selecting a program by PNS, a pulse is
output from signal SNACK as a part of the PNS
operation. The width of the pulse can be
specified from the menu.
See the timing chart below.



B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE APPENDIX B-82595EN-2/02

- 478 -
B.4 Specifications of Digital Input/Output

B.4.1 Overview

This section describes the external specifications of digital and analog
input/output in the R-30iA controller.

B.4.2 Input/Output Hardware Usable in the R-30iA Controller

The R-30iA controller can use up to 512 digital input and output
points or an equivalent number of analog input and output points.
One analog input/output point uses the resources equivalent to those
used by 16 digital I/O points.
The R-30iA can use a total of up to 512 I/O points.

The R-30iA controller can use the following I/O hardware.
- Process I/O printed circuit board
- I/O unit model A

The process I/O printed circuit board and the I/O unit model A can be
used together.

B.4.3 Software Specifications

(1) RI/RO
These are signals sent to the connector at the wrist of the robot.
They cannot be assigned (redefined) and are fixed.
The standard format is eight inputs and eight outputs. The
number of points that can be used for the connector at the wrist
depends on the individual robot.

(2) DI/DO
The signal No. that is determined at hardware can be changed by
software operation.

(3) Analog I/O
An analog I/O signal can access the analog I/O port (optional) on
the process I/O printed circuit board or the I/O port on the analog
I/O module (used together with the I/O unit model A).
It reads and writes the digital value converted from the analog
value of the I/O voltage. It means that the value does not
always represent the real I/O voltage.

(4) Group I/O
Group I/O is a function which can input or output multiple
DI/DO signals as binary codes. Any number of continuous
signals of up to 16 bits can be set for its use. It can be set in the
menu DETAILS on the group I/O screen.

B-82595EN-2/02 APPENDIX C.OPTICAL FIBER CABLE

- 479 -
C OPTICAL FIBER CABLE

The R-30iA uses fiber optic cables for communication between the
main board and servo amplifiers. Observe the following cautions
when handling these fiber optic cables. Handle fiber optic cables with
utmost care, especially when installing the unit.

(1) Protection during storage
When the electrical/optical conversion module (mounted on the
printed) circuit board and the fiber optic cable are not in use,
their mating surfaces must be protected with the lid and caps with
which they are supplied. If left uncovered, the mating surfaces
are likely to become dirty, possibly resulting in a poor cable
connection.


Fig.C (a) Protection of electrical/optical conversion module and fiber optic cable (when not in use)

(2) Fiber optic cable

- Although the reinforcing cover of the external optical cable has
sufficient mechanical strength, be careful not to drop heavy
objects on the cable.

C.OPTICAL FIBER CABLE APPENDIX B-82595EN-2/02

- 480 -
- 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 mm2 cords
Diameter of cable with reinforced cover : 7.6 mm
Tensile strength: Cable with reinforced cover :75 kg
Fiber optic cord :7 kg per cord
Between fiber optic cord and connector : 2 kg
Minimum bending radius of fiber optic cord :25 mm
Minimum bending radius of cable with reinforced cover :50 mm
Bending resistance (cable with reinforced cover) :
10 million bending cycles at room
temperature(when the bending radius is
100 mm)
Flame resistance: Equivalent to UL VW-1
Operating temperature: -20 to 705C


Fig.C (b) External dimensions of external optical cable Unit : mm

- After it is connected, the optical connector is automatically
locked by the lock levers on its top. To remove the connector,
release the lock levers and pull the connector.

- Although optical connectors cannot be connected in other than
the correct orientation, always take note of the connector's
orientation before making the connection.

- Take care to keep both parts of the optical connector (cable side
and PCB side) clean. If they become dirty, wipe them with tissue
paper or absorbent cotton to remove dirt. The tissue paper or
absorbent cotton may be moistened with ethyl alcohol. Do not
use any organic solvent other than ethyl alcohol.

- Fix the reinforcing cover by using a cable clamp, as shown in Fig.
C(c), to prevent the weight of the fiber optic cable from being
applied directly to the connecting part of the optical connector.


B-82595EN-2/02 APPENDIX C.OPTICAL FIBER CABLE

- 481 -


Fig.C (c) Fixing the cable with a clamp

- Any superfluous portion of the cable might be wound into a
loops. Should this prove necessary, make sure the diameter of
each loop is at least 150 mm (for an external cable). Winding
the cable into smaller loops can produce sharp curves that exceed
the specified bend radius limit. Such bending can result in
transmission loss, ultimately leading to a communication failure.

- When using a nylon band (cable tie) as a cable clamp, follow the
instructions given below. Also, take care not to apply a bending
force to one particular part of the cable when fixing it with a
clamp. Failing to clamp the cable correctly might cut or
damage it.

External cable :

Do not clamp the uncovered portion of the cable with a nylon band.
When clamping the cable by the reinforcing cover, the clamping force
is not an important factor to consider. However, ensure that the
clamping force is as small as possible to ensure that the reinforcing
cover is not deformed by the clamping.
If possible, the clamping force should be 5kg (111bs) or less.


B-82595EN-2/02 INDEX
i-1
INDEX
<Number>
10/100 BASE-T connector (CD38) pin assignments..... 402
<A>
A-CABINET................................................................. 216
ADJUSTMENT AND CHECKS AT
INSTALLATION......................................................... 421
ALARM OCCURRENCE SCREEN............................... 39
ARC Weld Connection Cable (CRW1, CRW7:Honda
Tsushin,34pins) ............................................................. 387
ARC Weld Connection CableCRW10 : Honda
Tsushin, 50 pins........................................................ 387
Assemble at Installation ................................................ 418
<B>
BACKPLANE BOARD................................................ 174
Battery for Memory Backup (3 VDC) .......................... 269
BLOCK DIAGRAM..................................................... 278
BLOCK DIAGRAM OF THE POWER SUPPLY........ 209
<C>
Cable clamp and shielding ............................................ 406
Cable connection........................................................... 402
CABLE CONNECTION FOR THE PERIPHERAL
DEVICES, END EFFECTORS, AND ARC WELDERS
...................................................................................... 388
CHECKING THE POWER SUPPLY UNIT
(A16B-2203-0910) ........................................................ 214
COMPONENT FUNCTIONS......................................... 32
CONFIGURATION........................................................ 18
Connecting HDI ............................................................ 393
Connecting the Auxiliary Axis BrakeCRR65 A/B316
Connecting the Auxiliary Axis Over Travel (CRM68) . 317
CONNECTING THE COMMUNICATION UNIT ...... 396
Connecting the External Emergency Stop..................... 303
Connecting the External Power Supply ON/OFF
Switch ........................................................................... 301
Connecting the Input Power .......................................... 298
Connecting the Non-Teaching Enabling (NTED)
Signal (CRM65) ............................................................ 314
Connecting the Operation Box...................................... 318
Connection between RS-232-C interface and I/O
device ............................................................................ 398
Connection Between the Control Unit and Welder....... 364
Connection Between the Mechanical Unit and End
Effector ........................................................................ 374
CONNECTION DIAGRAM BETWEEN
MECHANICAL UNITS ............................................... 281
CONNECTION OF HDI .............................................. 393
Connection to Ethernet ................................................. 401
Connector specification ................................................ 406
<D>
DIGITAL I/O SIGNAL SPECIFICATIONS................ 376
<E>
ELECTRICAL CONNECTIONS................................. 280
EMERGENCY STOP CONTROL BOARD
(A20B-1008-0740)........................................................ 173
End Effector Cable Connector ...................................... 391
End Effector Control Interface...................................... 380
Ethernet Interface.......................................................... 400
EXTERNAL CABLE WIRING DIAGRAM................ 283
EXTERNAL VIEW OF THE CONTROLLER.............. 19
<F>
FUSE-BASED TROUBLESHOOTING....................... 146
<G>
GENERAL.................................................................... 277
General Person Safety....................................................... 7
Grounding the network ................................................. 407
<H>
How to Disable/Enable HBK........................................ 423
How to Disable/Enable Pneumatic Pressure Alarm
(PPABN)....................................................................... 423
HOW TO USE THE PLATE TO FIX THE COMPACT
FLASH MEMORY CARD........................................... 272
<I>
I/O Signal Specifications for ARC-Welding Interface.. 382
I/O Signals .................................................................... 470
In Case of A-cabinet ..................................................... 331
In case of B-cabinet ............................................... 329,330
In Case of B-cabinet ..................................................... 332
Input Signal Rules for the High-speed Skip (HDI) ....... 395
Input Signals ................................................................. 470
INDEX B-82595EN-2/02
i-2
Input/Output Hardware Usable in the R-30iA
Controller ...................................................................... 478
INSTALLATION.......................................................... 412
INSTALLATION CONDITION................................... 420
Installation Method ....................................................... 412
Interface ........................................................................ 396
INTERFACE FOR END EFFECTOR.......................... 374
INTERFACE FOR PERIPHERAL DEVICES ............. 336
INTERFACE FOR WELDER....................................... 364
<L>
Lead materials ............................................................... 404
LED OF SERVO AMPLIFIER..................................... 206
<M>
MAIN BOARD (A16B-3200-0600, -0601) .................. 170
MANUAL OPERATION IMPOSSIBLE...................... 167
MASTERING ................................................................. 43
<O>
OPTICAL FIBER CABLE............................................ 479
Output Signals............................................................... 474
Overview....................................................................... 478
OVERVIEW................................................................... 17
<P>
PANEL BOARD (A20B-2101-0370) ........................... 176
Peripheral Device and Control Unit Connection
(Sink Type DO)............................................................ 351
Peripheral Device and Control Unit Connection
(Source Type DO) ........................................................ 336
Peripheral Device Cable Connector .............................. 389
Peripheral Device Connection Cable ............................ 388
Peripheral Device Interface A....................................... 376
Peripheral Device Interface A Cable (CRM2, CRMA5:
Honda Tsushin, 50 pins)................................................ 386
Peripheral Device Interface B Cable (CRM4, CRMA6:
Honda Tsushin, 20 pins)................................................ 386
PERIPHERAL DEVICE INTERFACE BLOCK
DIAGRAM.................................................................... 322
PERIPHERAL DEVICE INTERFACE
COMBINATION .......................................................... 331
Peripheral Device Interface Processing......................... 422
PERIPHERAL DEVICE, ARC WELDING, AND END
EFFECTOR INTERFACES.......................................... 319
POSITION DEVIATION FOUND IN RETURN TO
THE REFERENCE POSITION (POSITIONING) ....... 166
POWER CANNOT BE TURNED ON........................... 35
Precautions for Mechanism............................................. 11
Precautions for Mechanisms ........................................... 12
Precautions in Operation................................................. 12
Precautions in Programming...................................... 11,12
PREVENTIVE MAINTENANCE.................................. 33
PRINTED CIRCUIT BOARDS.................................... 169
PROCESS I/O BOARD CA (A16B-2201-0470) .......... 177
PROCESS I/O BOARD EA (A16B-3200-0230) .......... 180
PROCESS I/O BOARD EB (A16B-3200-0231) .......... 183
PROCESS I/O BOARD FA (A16B-3200-0420) .......... 185
PROCESS I/O BOARD GA (A16B-2203-0520).......... 187
PROCESS I/O BOARD HA (A16B-2203-0760).......... 189
PROCESS I/O BOARD JA (A16B-2204-0010) ........... 192
PROCESS I/O BOARD JB (A16B-2204-0011) ........... 194
PROCESS I/O BOARD KA (A16B-2204-0050).......... 196
PROCESS I/O BOARD KBA16B-2204-0051...... 199
PROCESS I/O BOARD KCA16B-2204-0052...... 202
PROCESS I/O BOARD SIGNALS .............................. 333
<R>
Recommended Cables................................................... 392
REPLACE THE MODE SWITCH............................... 258
Replacing a Module...................................................... 251
REPLACING A UNIT.................................................. 215
REPLACING BATTERY............................................. 269
REPLACING CARDS AND MODULES ON THE MAIN
BOARD........................................................................ 227
Replacing External Air Fan Unit (A-cabinet) ............... 255
Replacing External Air Fan Unit and Door Fan (B-cabinet)
...................................................................................... 256
REPLACING FUSES................................................... 260
Replacing Fuses in the Main board............................... 262
Replacing Fuses in the Power Unit ............................... 261
Replacing Fuses in the Servo Amplifier ....................... 260
REPLACING I/O Unit-MODEL A............................... 250
REPLACING RELAYS................................................ 268
Replacing Relays on the Panel Board........................... 268
REPLACING SERVO AMPLIFIERS.......................... 243
REPLACING THE AC FAN MOTOR......................... 254
Replacing the A-cabinet Door....................................... 219
Replacing the A-cabinet Louver ................................... 218
Replacing the A-cabinet Rear Panel ............................. 217
Replacing the A-cabinet Top Panel .............................. 216
B-82595EN-2/02 INDEX
i-3
Replacing the Backplane Board (Unit) ......................... 221
Replacing the Base Unit of I/O Unit-MODEL A.......... 250
REPLACING THE CONTROL SECTION FAN
MOTOR........................................................................ 253
REPLACING THE E-STOP UNIT............................... 241
Replacing the Fuse on the Panel Board......................... 267
Replacing the Fuse on the Process I/O Boards.............. 263
Replacing the Heat Exchanger and Door Fan Unit
(A-cabinet) .................................................................... 254
Replacing the Panel Board............................................ 224
Replacing the Power Unit and Printed-Circuit Boards
on the Backplane Unit .................................................. 222
REPLACING THE PRINTED-CIRCUIT BOARDS.... 220
Replacing the Process I/O Board
EA,EB,FA,GA,KA,KB,KC (A-cabinet)........................ 226
REPLACING THE REGENERATIVE RESISTOR
UNIT............................................................................. 238
REPLACING THE TEACH PENDANT and i
PENDANT.................................................................... 252
REPLACING THE TRANSFORMER ......................... 231
Resetting Overtravel...................................................... 422
RESETTING OVERTRAVEL AND EMERGENCY
STOP AT INSTALLATION......................................... 422
Robot Connection Cables.............................................. 283
RS-232-C Interface ....................................................... 396
RS-232-C interface signals............................................ 397
<S>
Safety During Maintenance............................................. 10
SAFETY OF THE END EFFECTOR............................. 12
SAFETY OF THE ROBOT MECHANISM................... 12
Safety of the Teaching Operator ....................................... 8
SAFETY OF THE TOOLS AND PERIPHERAL
DEVICES........................................................................ 11
SAFETY PRECAUTIONS ............................................... 3
SAFETY SIGNALS........................................................ 42
SERVO AMPLIFIERS ................................................. 204
SETTING COMMON VOLTAGE............................... 469
SETTING OF SERVO AMPLIFIER............................ 207
SETTING THE POWER SUPPLY............................... 208
SIGNAL........................................................................ 467
Software Specifications................................................. 478
Specifications of Digital Input/Output .......................... 478
SPECIFICATIONS OF PERIPHERAL DEVICE
INTERACE................................................................... 466
SPECIFICATIONS OF THE CABLES USED FOR
PERIPHERAL DEVICES AND WELDERS ............... 386
<T>
Teach Pendant Cable .................................................... 297
TOTAL CONNECTION DIAGRAM........................... 427
TRANSFORMER......................................................... 210
TRANSPORTATION................................................... 411
TRANSPORTATION AND INSTALLATION............ 410
TROUBLESHOOTING.................................................. 34
TROUBLESHOOTING BASED ON LED
INDICATIONS............................................................. 154
TROUBLESHOOTING USING THE ERROR CODE.. 45
<W>
WARNING LABEL ....................................................... 13
When I/O Unit-MODEL A is Used .............................. 329
When Process I/O Board CA/HA is Used (B-cabinet).. 325
When Process I/O Board EA/EB/GA is Used
(A-cabinet).................................................................... 322
When Process I/O Board FA is Used (A-cabinet)......... 324
When Process I/O Board JA is Used (B-cabinet).......... 327
When Process I/O Board KA is Used (A-Cabinet) ....... 328
When Two or more Process I/O Printed Circuit
Boards and I/O Unit-MODEL A are Used.................... 330
WORKING PERSON....................................................... 3
WORKING PERSON SAFETY....................................... 5



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