R-J2 Controller Maintenance FANUC

MXXXXXXXXXXXXXE REV A 1
FANUC Robotics
SYSTEM R-J2 Controller
Maintenance Manual
MAREG2AMS03503E REV B
B–80525EN/04
This publication contains proprietary information of FANUC Robotics
North America, Inc. furnished for customer use only. No other uses are
authorized without the express written permission of FANUC Robotics
North America, Inc.
FANUC Robotics North America, Inc.
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
2 MXXXXXXXXXXXXXE REV A
The descriptions and specifications contained in this manual were in effect

at the time this manual was approved for printing. FANUC Robotics
North 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 North America, Inc.
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
web site: www.fanucrobotics.com
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com
MXXXXXXXXXXXXXE REV A 3
Copyright 2000 by FANUC Robotics North America, Inc.

All Rights Reserved
The information illustrated or contained herein is not to be reproduced,

copied, translated into another language, or transmitted in whole or in part
in any way without the prior written consent of FANUC Robotics North
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:
AccuFlow
ARC Mate
ARC Mate Sr.
IntelliTrak
LaserTool
MotionParts
PaintWorks II
PalletMate
SureWeld
TurboMove
Conventions Used in This manual includes information essential to the safety of personnel,
this Manual 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.
R–J2 B–SIZE CONTROLLER CABINET
DIMENSION UPDATE
MAREG2AMS03503E REV B Updates–1
This section lists the updates that have been made to the FANUC Robotics
SYSTEM R–J2 Controller Maintenance Manual in the following areas:
Page
R–J2 B–Size Controller Cabinet Dimensions Updates–1

Update
R–J2 B–Size Controller Cabinet Dimensions
B–Size Controller This update was created to provide dimensional information on the B–Size
Cabinet Dimensions Controller Cabinet height. See note on Figure 1.
Figure 1. B–Size Controller Cabinet Dimensions
Control unit Control unit Control unit
Note: Height of cabinet is

1100mm. Add 200mm if optional
riser is used. (Dimensions in mm)
B–80525E/04 PREFACE
PREFACE
This manual covers the following models.
Model Abbreviation
FANUC Robot ARC Mate 100 ARC Mate 100
FANUC Robot ARC Mate 120 ARC Mate 120
FANUC Robot ARC Mate 100i ARC Mate 100i
FANUC Robot ARC Mate 120i ARC Mate 120i
FANUC Robot S–6 S–6
FANUC Robot M–6i M–6i
FANUC Robot S–420i F/iW/iS/iL/iR S–420 iF/iW/iS/iL/iR
FANUC Robot S–450L/S/U S–450
FANUC Robot M–410 iW/iWX M–410 iW/iWX
FANUC Robot M–500 M–500
FANUC Robot A–520i A–520i
(Note) When a description is common to all the types of S–420 i, it simply refers to S–420 i.
When a description is common to all the type of M–410 i, it simply refers to M–410 i.
FANUC Robotics Hotline
For a PRODUCTION robot that is DOWN

call 24 hours a day, 7 days a week
810-377-7159
For all other Troubleshooting and Technical Support

contact your local distributor or call the Hotline
Monday – Friday, 8:00 A.M. – 5:00 P.M. Eastern Time
BEFORE YOU CALL please have your Maintenance and Troubleshooting manual, and the
following information, ready.
INFORMATION DETAILS
Customer Information Include
your company’s name
caller’s name
phone number where caller can be reached, including
area code and extension
Robot type On the arm of the robot.
(A, L, M, P, or S, & 3-digit number)
Controller style Ask your supervisor.
(RA, RB, RC, RF, RG, RG2, RH, RJ, RJ2)
F Number On the identification tag on the robot and controller, near the
cable connection.
Robot serial number On the identification tag located near the cable connection.
(if no F Number is available)
Controller serial number On the controller tag located on the doors.
(if no F Number is available)
Software edition and revision numbers Shown on the CRT or teach pendant status screen during the
power-up sequence.
List of error messages Include
error message number
message following error message number
any numbers following error message
List of diagnostic LEDs Note the PCB where the LED is located and the LED name or
designation.
History of problem Description of events leading up to the problem.
Application software List
any application software running the system
the line number where the program halted
a description of what is happening on that line
B–80525E/04 Table of Contents
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p–1
I SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 OPERATOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2 Safety of the Teach Pendant Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.3 Safety During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.1 Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.2 Precautions for Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 SAFETY OF THE ROBOT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.1 Precautions in Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.3 Precautions for Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 SAFETY OF THE END EFFECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 SAFETY IN MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
II MAINTENANCE
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 EXTERNAL VIEW OF THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 COMPONENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1 POWER CANNOT BE TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 TROUBLESHOOTING USING THE ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION
(POSITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.4 VIBRATION OBSERVED DURING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.5 MANUAL OPERATION IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

4.1 MAIN CPU PC BOARDS (A16B–3200–0040) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.2 EMERGENCY STOP CONTROL PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.3 BACKPLANE PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.4 PROCESS INPUT/OUTPUT PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.4.1 Process Input/Output PC Board CA (A16B–2201–0470) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.4.2 Process Input/Output PC Board CB (A16B–2201–0472) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.4.3 Process Input/Output PC Board DA (A16B–2201–0480) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4.4.4 Process I/O Printed Board EA (A16B–3200–0230) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.4.5 Additional Axis Control Printed Board (A16B–2200–0820) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1
Table of contents B–80525E/04
5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

5.1 SERVO AMPLIFIER FOR (ARC MATE 100, ARC MATE 120, ARC MATE 100i,
ARC MATE 120i, S–6, S–12, M–6, M–16i, S–420i, S–500, S–700, M–400i, M–710i, A–520i) . . . 220
5.2 POWER SUPPLY IMODULE (PSM) (A06B–6087–H115) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.3 SERVO AMPLIFIER MODULE (SVM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5.4 SERVO AMPLIFIER (A06B–6066–H006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
5.5 SERVO AMPLIFIER UNIT (A06B–6089–H106) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
6. SETTING AND ADJUSTING THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . 248

6.1 BLOCK DIAGRAM OF THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
6.2 SELECTING TRANSFORMER TAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
6.3 CHECKING THE LINE FILTER UNIT AND TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . 255
6.4 CHECKING THE POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

7.1 REPLACING A PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
7.1.1 Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
7.1.2 Replacing the Power Supply Unit or a Printed Circuit Board on the
Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
7.1.3 Replacing the process I/O EA printed circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
7.2 REPLACING A MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
7.3 REPLACING THE I/O UNIT MODEL B INTERFACE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
7.4 REPLACING THE INPUT/OUTPUT UNIT OF MODEL A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
7.4.1 Replacing the Base Unit of the Input/Output Unit of Model A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
7.4.2 Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7.5 MOUNTING I/O UNIT MODEL B ON THE DIN RAIL
(USE A RAIL THAT IS 3.5MM WIDE AND 7.5MM HIGH.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
7.5.1 The DIN Rail is in the Operator’s Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
7.6 REPLACING THE TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
7.7 REPLACING A SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
7.8 REPLACING THE OPERATOR’S BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
7.9 REPLACING THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
7.10 REPLACING THE FAN MOTOR OF THE CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
7.11 REPLACEMENT OF FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
7.11.1 Transformer, line filter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
7.11.2 Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
7.11.3 Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
7.11.4 Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
7.11.5 Process Input/Output Printed Circuit Boards CA, CB, DA and EA . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
7.12 REPLACING A RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
7.13 REPLACING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
2
B–80525E/04 Table of contents
III CONNECTIONS
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
3. ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS . . . . . . . . . . . . . . . . . . . . . . . . . 305
3.2 EXTERNAL CABLE WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3.2.1 Robot Connection Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3.2.2 Teach Pendant Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
3.2.3 Connecting the Input Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3.2.4 Connecting the External Power Supply ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
3.2.5 Connecting the External Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
4. PERIPHERAL DEVICE, ARC WELDING,

AND END EFFECTOR INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
4.1.1 When Process I/O Printed Circuit Board CA, CB or EA is used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
4.1.2 When Process I/O Printed Cricuit Board DA is used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
4.1.3 When I/O Unit Model A is used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
4.1.4 When I/O Unit Model B is used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
4.1.5 When Two or more Process I/O Printed Circuit Boards and I/O Unit
(Model A or Model B) are used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
4.2 PERIPHERAL DEVICE INTERFACE COMBINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
4.3 PROCESS I/O PRINTED CIRCUIT BOARD SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
4.4 INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS . . . . . . . . . . 368
4.4.1 Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
4.4.2 Connection Between the Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
4.4.3 Connection Between the Control Unit and Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
4.5 DIGITAL I/O SIGNAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
4.5.1 Peripheral Device Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
4.5.2 End Effector Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
4.5.3 I/O Signal Specifications for ARC–Welding Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
4.6 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES
AND WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
4.6.1 Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins) . . . . . . . . . . . . . . . . . . . . . . . . 392
4.6.2 Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins) . . . . . . . . . . . . . . . . . . . . . . . . 392
4.6.3 ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
4.7 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS,
AND ARC WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
4.7.1 Peripheral Device Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
4.7.2 Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
4.7.3 End Effector Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
4.7.4 Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
4.8 QUICK CHANGE (I–CABINET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
4.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
4.8.2 Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
4.8.3 Replacement front cabinet unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
4.8.4 Hardware items required for quick change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
4.8.5 Notes on quick change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
4.8.6 Faulty unit replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
3
Table of contents B–80525E/04
5. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418

5.1 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
5.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
5.2.1 Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
5.2.2 Connecting Cables at Installation (Combined Type of i Cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
5.2.3 Separate–Type Control Unit of i Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
5.3 INSTALLATION CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
5.4 ADJUSTMENT AND CHECKS AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION . . . . . . . . . . . . . . 428
5.5.1 Peripheral Device Interface Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
5.5.2 Resetting Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
APPENDIX
A. TOTAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A.1 I–CABINET (ARC MATE 100, ARC MATE 120, ARC MATE 100i, ARC MATE 120i, S–6,
S–12, M–6i, M–16i, S–420i, S–500, S–700, M–400i, M–710i, A–520i) . . . . . . . . . . . . . . . . . . . . . 431
A.2 B–CABINET (ARC MATE 100, ARC MATE 120, ARC MATE 100i, ARC MATE 120i, S–6,
S–12, M–6i, M–16i, S–420i, S–500, S–700, M–400i, M–710i, A–520i) . . . . . . . . . . . . . . . . . . . . . 453
A.3 CABINET OF S–800/M–500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
A.4 CABINET OF M–410i AND S–450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
A.5 B–CABINET OF S–900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE . . . . . . . . . . . . . . . . . 542

B.1 SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
B.2 SETTING COMMON VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
B.3 I/O SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
B.3.1 Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
B.3.2 Output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
B.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
B.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
B.4.2 Input/Output Hardware Usable in the R-J2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
B.4.3 Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
C. DIAGRAM OF POWER SUPPLY PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
4
I SAFETY PRECAUTIONS
B–80525E/04 SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS
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 Operator safety is the primary safety consideration. Because it is very

dangerous to enter the operating space of the robot during automatic
OPERATOR SAFETY operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration
must be made to ensure operator safety.
(1) Have the robot system operators attend the training courses held by
FANUC.
FANUC provides various training courses. Contact our sales office for details.
(2) Even when the robot is stationary, it is possible that the robot is still
ready to move state and is waiting for a signal. In this state, the robot
is regarded as still in motion. To ensure operator safety, provide the
system with an alarm to indicate visually or aurally that the robot is
in motion.
(3) Install a safety fence with a gate so that no operator can enter the work
area without passing through the gate. Equip the gate with an
interlock that stops the robot when the gate is opened.
The controller is designed to receive this interlock signal. When the gate is
opened and this signal received, the controller stops the robot in an emergen-
cy. For connection, see Fig. 1.1 (a).
(4) Provide the peripheral devices with appropriate grounding (Class 1,

Class 2, or Class 3).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot
motion, including the tools such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an
interlock to a visual or aural alarm that stops the robot when an
operator enters the work area.
(8) If necessary, install a safety lock so that no one except the operator
in charge can turn on the power of the robot.
The circuit breaker installed in the controller is designed to disable anyone

from turning it on when it is locked with a padlock.
3
1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–80525E/04
(9) When adjusting each peripheral device independently, be sure to turn

off the power of the robot.
Limit switch which operates

when the gate is opened.
Limit switch for

the safety gate
Printed circuit board for
operator’s box
Note) Terminals FENCE1 and FENCE2 are

on the PC board in the operator’s box.
Fig.1.1 (a) Safety Fence and Safety Gate
4
1.1.1 The operator is a person who operates the robot system. In this sense, a
Operator Safety worker who operates the teach pendant is also an operator. However, this
section does not apply to teach pendant operators.
(1) If it is not necessary for the robot to operate, turn off the power of the
robot controller or press the EMERGENCY STOP button, and then
proceed with necessary work.
(2) Operate the robot system at a location outside the work area.
(3) Install a safety fence with a safety gate to prevent any worker other
than the operator from entering the work area unexpectedly and also
to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator’s reach.
The robot controller is designed to be connected to an external EMER-

GENCY STOP button. With this connection, the controller stops the robot
operation when the external EMERGENCY STOP button is pressed. See the
diagram below for connection.
External EMERGENCY STOP button

operator’s box
EMGIN1
EMGIN2
Note) Connect to EMGIN1 and EMGIN2.

Terminals EMGIN1 and EMGIN2 are on the PC board in the
operator’s box.
Fig.1.1 (b) Connection Diagram for External Emergency Stop Switch
5
1.1.2 While teaching the robot, it is necessary for the operator to enter the work
Safety of the Teach area of the robot. It is particularly necessary to ensure the safety of the
teach pendant operator.
Pendant Operator
(1) Unless it is specifically necessary to enter the robot work area, carry
out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral
devices are all in the normal operating condition.
(3) When entering the robot work area and teaching the robot, be sure to
check the location and condition of the safety devices (such as the
EMERGENCY STOP button and the deadman’s switch on the teach
pendant).
The teach pendant supplied by FANUC is provided with a teach pendant en-
able switch and a deadman’s switch in addition to the EMERGENCY STOP
button. The functions of each switch are as follows.
EMERGENCY STOP button : Pressing this button stops the robot in an
emergency, irrespective to the condition of
the teach pendant enable switch.
Deadman’s switch : The function depends on the state of the
teach pendant enable switch.
When the enable switch is on – Releasing the finger from the dead
man’s switch stops the robot in an
emergency.
When the enable switch is off – The deadman’s switch is ineffective.
NOTE
The deadman’s switch is provided so that the robot operation can
be stopped simply by releasing finger from the teach pendant in
case of emergency.
(4) The teach pendant operator should pay careful attention so that no
other workers enter the robot work area.
NOTE
In addition to the above, the teach pendant enable switch and the
deadman’s switch also have the following function.
By pressing the deadman’s switch while the enable switch is on,
the emergency stop factor (normally the safety gate) connected
to FENCE1 and FENCE2 of the controller is invalidated. In this
case, it is possible for an operator to enter the fence during teach
operation without pressing the EMERGENCY STOP button. In
other words, the system understands that the combined
operations of pressing the teach pendant enable switch and
pressing the deadman’s switch indicates the start of teaching. The
teach pendant operator should be well aware that the safety gate
is not functional under this condition and bear full responsibility to
ensure that no one enters the fence during teaching.
6
(5) When entering the robot work area, the teach pendant operator should
enable the teach pendant whenever he or she enters the robot work
area. In particular, while the teach pendant enable switch is off, make
certain that no start command is sent to the robot from any operator’s
panel other than the teach pendant.
The teach pendant, operator’s box, and peripheral device interface send
each robot start signal. However the validity of each signal changes as fol-
lows depending on the mode of the teach pendant enable switch and the re-
mote switch on the operator’s panel.
Teach pen-
dant enable Remote Teach Operator’s Peripheral
switch switch pendant panel devices
On Independent Allowed to Not allowed Not allowed

start
Off Remote OFF Not allowed Allowed to Not allowed
start
Off Remote ON Not allowed Not allowed Allowed to
start
(6) To start the system using the operator’s box, make certain that nobody
is in the robot work area and that there are no abnormal conditions in
the robot work area.
(7) When a program is completed, be sure to carry out a test run according
to the procedure below.
(a) Run the program for at least one operation cycle in the single step
mode at low speed.
(b) Run the program for at least one operation cycle in the continuous
operation mode at low speed.
(c) Run the program for one operation cycle in the continuous opera-
tion mode at the intermediate speed and check that no abnormali-
ties occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous opera-
tion mode at the normal operating speed and check that the sys-
tem operates automatically without trouble.
(e) After checking the completeness of the program through the test
run above, execute it in the automatic operation mode.
(8) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.
1.1.3 For the safety of maintenance personnel, pay utmost attention to the
following.
Safety During
Maintenance (1) Except when specifically necessary, turn off the power of the
controller while carrying out maintenance. Lock the power switch,
if necessary, so that no other person can turn it on.
(2) When disconnecting the pneumatic system, be sure to reduce the
supply pressure.
(3) Before the start of teaching, check that the robot and its peripheral
devices are all in the normal operating condition.
7
(4) If it is necessary to enter the robot work area for maintenance when
the power is turned on, the worker should indicate that the machine
is being serviced and make certain that no one starts the robot
unexpectedly.
(5) Do not operate the robot in the automatic mode while anybody is in
the robot work area.
(6) When it is necessary to maintain the robot alongside a wall or
instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.
(7) When a tool is mounted on the robot, or when any moving device
other than the robot is installed, such as belt conveyor, pay careful
attention to its motion.
(8) If necessary, have a worker who is familiar with the robot system
stand beside the operator’s panel and observe the work being
performed. If any danger arises, the worker should be ready to press
the EMERGENCY STOP button at any time.
(9) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
(10) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and also turn
off the circuit breaker to protect against electric shock.
(11)When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified ratings.
They may cause a fire or result in damage to the components in the
controller.
8
1.2
SAFETY OF THE
TOOLS AND
PERIPHERAL
DEVICES
1.2.1
Precautions in (1) Use a limit switch or other sensor to detect a dangerous condition and,
Programming if necessary, design the program to stop the robot when the sensor
signal is received.
(2) Design the program to stop the robot when an abnormal condition
occurs in any other robots or peripheral devices, even though the
robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in
synchronous motion, particular care must be taken in programming
so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral
devices so that the robot can detect the states of all devices in the
system and can be stopped according to the states.
1.2.2
Precautions for (1) Keep the component cells of the robot system clean, and operate the
Mechanism 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.
9
1.3
SAFETY OF THE
ROBOT MECHANISM
1.3.1
Precautions in (1) When operating the robot in the jog mode, set it at an appropriate
Operation 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.
1.3.2
Precautions in (1) When the work areas of robots overlap, make certain that the motions
Programming 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.
1.3.3
Precautions for (1) Keep the work area of the robot clean, and operate the robot in an
Mechanisms environment free of grease, water, and dust.
10
1.4
SAFETY OF THE END
EFFECTOR
1.4.1
Precautions in (1) To control the pneumatic, hydraulic and electric actuators, carefully
Programming 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.
11
1.5
SAFETY IN (1) Never enter the robot work area while the robot is operating. Turn off
the power before entering the robot work area for inspection and
MAINTENANCE
maintenance.
(2) If it is necessary to enter the robot work area with the power turned
on, first press the EMERGENCY STOP button on the operator’s box.
(3) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
When replacing the parts in the pneumatic system, be sure to reduce
the pressure in the piping to zero by turning the pressure control on
the air regulator.
(4) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and turn off the
circuit breaker to protect against electric shock.
(5) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified ratings.
They may cause a fire or result in damage to the components in the
controller.
(6) Before restarting the robot, be sure to check that no one is in the robot
work area and that the robot and its peripheral devices are all in the
normal operating state.
12
II MAINTENANCE
B–80525E/04 MAINTENANCE 1. OVERVIEW
1 OVERVIEW
This manual describes the maintenance and connection of the R-J2 robot
controller (called the R-J2).
Maintenance Part : Troubleshooting, and the setting, adjustment,
and replacement of units
Connection Part: Connection of the R-J2 controller to the robot
mechanical unit and peripheral devices, and
installation of the controller
NOTE
Before entering the robot working area, be sure to turn off the
power to the controller or press the emergency stop button on the
operator’s box or teach pendant.
15
2. CONFIGURATION MAINTENANCE B–80525E/04
2 CONFIGURATION
2.1 Fig. 2.1 (a) to (d) show the R-J2.

EXTERNAL VIEW OF
THE CONTROLLER
Operator’s box
(option)
Teach pendant
R–J2 controller
Integrated type ARC Mate 100i, M–6i, S420i, A520i, M–710i

Remote mount type ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i
S6, S–12, M–6i, M–16i, S–420i, S–500, S–700, M–400i, M–710i, A520i
Fig.2.1 (a) External View of the R-J2 Controller (i cabinet)
16
B–80525E/04 MAINTENANCE 2. CONFIGURATION
Teach pendant
Operator’s pendant
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i
S–420i, S–450, S–500, S–700, S–800, M–500, M–410i, M–710i, A–520i)
Fig.2.1 (b) External View of the R-J2 controller (B–Cabinet)
17
Fig.2.1 (c) External View of the R-J2 controller (B–Cabinet) (S–900)
18
Operator’s box
(option)
R–J2 Control unit Teach pendant
Cabinet for M–410i is

installed in robot’s frame.
Fig.2.1 (d) External View of the R-J2 controller (Cabinet for M–410i) (M410i)
19
The R-J2 consists of the units shown in Fig. 2.1 (e) to (l).
The appearance and components may slightly differ depending on the
controlled robot, application, and options used.
Operator’s box Circuit breaker

(option)
Operator’s panel
FANUC Handy File Teach pendant
Main CPU printed

Servo amplifier for 6 axes circuit board
PC board for
operator’s box
Cooling unit
Power supply unit
Fan unit
(Optional printed circuit board)
Back plane
Regenerative discharge registance
Fan unit
Circuit breaker
Louver
Printed circuit board for emergecy stop
control Transformer
Magnetic
contactor (MCC)
Fig.2.1 (e) R-J2 Controller Interior (i Cabinet)

20
Fan 1
Printed board for emergecy stop
Servo amplifier control
Main CPU printed board

Operator’s panel
Power supply unit
Optional printed board
I/O unit model A or model B
Braker
Fan 2
Line filter or transformer
Fan 3
Fig.2.1 (f) R-J2 Controller Interior (ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12,
M–6i, M–16i, S–420i, S–500, S–700, M–400i, A–520i)
21
FANUC Handy File

Teach pendant
Servo amplifier 5 Fan 1

Printed board for emergecy stop
Servo amplifier 4
control
Operator’s panel Main CPU printed board
Power supply unit
Braker
Fan 3 Fan 2
transformer or Line filter
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Fig.2.1 (g) R-J2 Controller Interior (B–Cabinet) (S–800)
22
Regenerative discharge unit

Fan 1
Servo amplifier 4
Servo amplifier 3
Additional cabinet
Operator’s panel Conversion printed board

Power supply unit
Printed board for emergecy

stop control
Braker
Fan 2
Servo amplifier 2
Fan 3 Servo amplifier 1
Servo amplifier 6
Teach pendant
Servo amplifier 5
Additional contactor
FANUC Handy File
Fan 4
Fan 5
(Additional cabinet interior)
Fig.2.1 (h) R-J2 Controller Interior (B–Cabinet) (S–900)
23
Servo module 1
Power supply module 1
Servo module 2
Servo module 3
Servo module 4
Fan 1
MCC
Battery unit AC reactor
Trans tap
I/O unit model B
Braker
I/O unit model A or B
transformer for brake

Power supply unit
Fan 2 Printed board for emergecy stop control
Fig.2.1 (i) R-J2 Controller Interior (Cabinet for M–410i)
24
Servo module 1
Servo module 2 Fan 1
Servo module 3
Emergency stop control

printed board
Power supply unit
I/O unit model A

or
I/O unit model B
Braker
Fan 2
Line filter
or
Transformer
Fan 3
Servo module 4
Power supply module
Fig.2.1 (j) R-J2 Controller Interior (B–Cabinet) (M–410i)
25

Fan 1
Servo amplifier 2
Servo amplifier 1 Conversion printed board

Operator’s panel
Power supply unit
Braker
Fan 2
Servo amplifier 4
Fan 3
Servo amplifier 3
Fig.2.1 (k) R–J2 Controller Interior (B–cabinet) (M–500)
26
Servo module 2
Servo module 3 Fan 1

Servo module 1
Servo module 4

printed board
Power supply unit
Additional axis control

printed board
I/O unit model A

or
I/O unit model B
Braker
Fan 2
Line filter
or
Transformer
Fan 3
Power supply module
Fig.2.1 (l) R-J2 Controller Interior (B–Cabinet) (S–450)
27
Robots and servo amplifier

J1 J2 J3 J4 J5 J6 J7
ARC Mate 100 A06B–6076–H005 (6–axis AMP) or A06B–6076–H105
ARC Mate 120i
ARC Mate A06B–6076–H105 (6–axis amplifier)
100i/M–6i
S–6 A06B–6076–H005 (6–axis AMP) or A06B–6076–H105
S–12, M–16i A06B–6076–H004 (6–axis AMP) or A06B–6076–H104
S–420i A06B–6076–H001 (6–axis AMP) or A06B–6076–H101
S–450 A06B–6077–H111 (PSM)
AMP1/L AMP1/M AMP2/M AMP2/L AMP3/L AMP3/M AMP4
A06B A06B A06B A06B A06B A06B S–450S:
–6079 –6079 –6079 –6079 –6079 –6079 A06B–6079
–H206 –H206 –H207 –H207 –H206 –H206 –H104
S–450L:
A06B–6079
–H101
A–520i
M–400i
S–800 AMP1 AMP2 AMP3 AMP4/M AMP4/M AMP5
A06B A06B A06B A06B A06B A06B
–6089 –6089 –6089 –6089 –6089 –6089
–H105 –H105 –H105 –H208 –H208 –H105
S–900 AMP1 AMP3 AMP5 AMP2 AMP4 AMP6
–6066 –6066 –6066 –6066 –6066 –6066
–H008 –H008 –H008 –H006 –H006 –H006
AMP1 AMP3 AMP5 AMP2 AMP4 AMP6
–6089 –6089 –6089 –6089 –6089 –6089
–H106 –H106 –H106 –H105 –H105 –H105
M410i A06B–6087–H115 (PSM)
AMP1 AMP2 AMP3 AMP4
A06B A06B A06B A06B
–6079 –6079 –6079 –6079
–H106 –H106 –H106 –H103
M–500 AMP1 AMP3/M AMP2 AMP3/L AMP4
A06B A06B A06B A06B A06B
–6089 –6089 –6089 –6089 –6089
–H106 –H206 –H105 –H206 –H104
M–710i A06B–6076–H106 (6–axis amplifier)
28
The 2.1 (m) to (q) show the block diagram of the R–J2.
Peripheral Handy File External

Teach device emergency
Sensor CRT/KB Stop
pendant External
computer Printer on/off
Robot Peripheral
Operator’s
device
box
Pulse coder signal

Process I/O
or
I/O unit
model A
model B
I/O signal (FANUC I/O Link)
Motor power supply
Brake power supply
Robot RDI/RDO signal
Back planeprinted circuit board
Pulse coder signal

Printed
circuit board
Servo signal for emergency
stop control
servo amplifier
Servo amplifier
Power supply unit
(6–axis amplifier)
precharge
Transformer
(Servo power
Battery over heat signal

210VAC
supply)
Fan
200-550 VAC
breaker
Transformer
AC input
Fig.2.1 (m) Block Diagram of the R-J2 (i–Cabinet) (ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate
120i, S–6, S–12, M–6i, M–16i, S–420i, S–500, S–700, M–400i, M–710i, A–520i)
29
Peripheral External
Teach device Handy File emergency Robot Peripheral
pendant Sensor CRT/KB Stop
device
External
Pulse coder signal

Operator’s
Process I/O
or
panel
I/O unit
model A
model B

Brake power supply

Motor power supply
Pulse coder signal
Printed
circuit board
stop control
servo amplifier
Servo amplifier
(6–axis amplifier)
Power supply unit
precharge
(Servo power
Transformer
Battery over heat signal
210VAC
supply)
Fan
200-550 VAC
breaker
Transformer or
AC input
line filter unit

3
Fig.2.1 (n) Block Diagram of the R-J2 (B–Cabinet) (ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC
Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500, S–700, M–400i, M–710i, A–520i)
30
Peripheral External
Teach device Handy File emergency
Sensor CRT/KB Stop
pendant External
Robot Peripheral
device
Motor power supply

Operator’s
Brake power supply

Pulse coder signal
Process I/O
or
panel
I/O unit
model A
model B
Pulse coder signal

Printed servo amplifier

circuit board
stop control
Emergency
stop signal
Power supply unit
Transformer over heat signal
210VAC
Battery (Servo power
supply)
200-550 VAC
Fan
breaker
Transformer or
AC input
AC reactor
3
Fig.2.1 (o) Block Diagram of the R-J2 (B–Cabinet) (S–800, S–900, M–500)
31

Robot Peripheral
Sensor CRT/KB Stop
pendant External device
Pulse coder signal

Operator’s
Process I/O
or
panel
I/O unit
model A
model B

Robot RDI/RDO signal for emergency
Pulse coder signal

circuit board
stop control
Brake power supply

Motor power supply

Printed
Conversion
Servo signal
printed
board
servo amplifier
(C series)
Power supply unit
Transformer
over heat signal
Battery 210VAC
(Servo power supply)
200-550 VAC
Fan
breaker
Transformer or
AC input
line filter unit

3
Fig.2.1 (p) Block Diagram of the R-J2 (B–Cabinet) (S–900)
32

CRT/KB Stop
pendant Sensor External
Robot Peripheral
device
Operator’s
box
Pulse coder signal
Motor power supply

Process I/O
Brake power supply

or
I/O unit
model A
model B

Pulse coder signal

Printed
circuit board Servo module
stop control
Power supply module

Power supply unit
Energency
stop signal
(Servo power
210VAC
supply)
Transformer
Battery
MMC unit
200-550 VAC
Transformer or
Fan
Transformer
breaker
AC reactor
AC input
Fig.2.1 (q) Block Diagram of the R-J2 (Cabinet) (S–450, M–410i)
33
2.2 – Main CPU PC board

COMPONENT The main CPU PC board contains a microprocessor, its peripheral
circuits, memory, a serial interface to connect a unit such as a teach
FUNCTIONS pendant, and operator’s panel control circuit. The main CPU controls
servo mechanism positioning and servo amplifier voltages.
- I/O printed circuit board, FANUC I/O Unit MODEL–A and MODEL B
Various types of printed circuit boards are provided forapplications
including process I/O. The FANUC I/O unit MODEL-A or MODEL
B can also be installed. When it is used, various I/O types can be
selected. These are connected with FANUC I/O Link.
- Printed circuit board for emergency stop control
This printed circuit board controls the emergency stop system
(including overtravel and Wrist breakdown).
- Power supply unit
The power supply unit converts the AC power to various levels of DC
power. It contains batteries to back up data memory.
- Backplane printed circuit board
The 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 servo motor power amplification.
- Operator’s box/operator’s panel
Buttons and LEDs on the operator’s box are used to start the robot and
to indicate the robot status. The box has a port for the serial interface
to an external device. 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. The transformer accepts a line voltage
from 200 to 575 VAC according to tap setting.
- Fan unit
The fan unit cools 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 discharge registance
This unit is connected to a servo amplifier to discharge the back
electromotive force generated in the servo motor.
34
2.3 Daily maintenance and periodic maintenance/inspection ensure reliable

robot performance for extended periods of time.
PREVENTIVE
(1) Daily maintenance
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 turned off the controller. Clean each part, and
check for any damage or cracks. If the ventilation port of the
controller is dusty, clean it.
(c) Check after one month
Check that the fan is rotating normally. If the fan has dirt and dust
built up, clean the fan according to step (d) described below for
inspection to be performed every 60 days.
When a B–cabinet is used, clean the filter installed at the air inlet
on the side of the control unit. When an i–cabinet is used, clean
the louver on the back of the control unit.
(d) Periodic inspection performed every six months
i–cabinet: Remove the top cover, louver, and back panel (if
possible), then remove any dirt and dust from the
inside of the transformer room. Wipe off dirt and
dust from the fan and transformer.
B–cabinet: Remove the back panel, then remove any dirt and
dust from the inside. Wipe off dirt and dust from the
fan and transformer.
(2) Maintenance tools
It is recommended that the following maintenance tools be prepared:
(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
Pliers
Long-nose pliers
Cutting pliers
35
3. TROUBLESHOOTING MAINTENANCE B–80525E/04
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 for releasing program alarms.
36
B–80525E/04 MAINTENANCE 3. TROUBLESHOOTING
3.1
POWER CANNOT BE
TURNED ON
Check1 Check that the circuit breaker is on and has not tripped.
Corrective action: Turn on the circuit breaker.
Check2 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. Find the cause. Investigate the cause
according to the overall circuit diagram in Appendix.
Check3 Check whether the OFF and COM signals are connected on the terminal
block on the panel printed circuit board.
Corrective action: If OFF and COM are not connected : If the external
ON/OFF function is not used, connect the external ON
and OFF lines. If the external ON and OFF lines are
already connected, check the mating contacts and the
cable.
Check4 Checks 1 to 3 above confirm that 200 VAC power is supplied to connector
CP1 of the power supply unit and that the ON/OFF switch functions
normally. So check the power supply unit using the following procedure:
If the LED (PIL: green) on the power supply unit is not on
a) Fuses F1 is blown : See corrective action (1).
b) None of the above fuses blown : Check that 200 VAC is supplied
to connector CP1 again.
If it is supplied, replace the power
supply unit.
If the LED (ALM: red) on the power supply unit is on
Check if the +24 V external connection cable is connected to 0 V or
ground.
a) Fuse F3 blown : See corrective action (2).
b) Fuse F4 blown : See corrective action (3).
c) None of the above fuses blown [d) is also probable] :
A printed circuit board or unit that
uses a DC supply voltage (+5 V,
+24 V, or +15 V) is faulty.
d) None of the above fuses blown : Check that 200 VAC is supplied
to connector CP1. If it is supplied
replace the power supply unit.
Corrective action: If the power supply unit is not
faulty, replace the operator’s box or
operater’s panel.
37
Corrective action 1 Causes of blown fuses F1 and corrective action

(a) Short-circuit in the surge absorber VS11
VS11 is inserted to absorb surge voltage between input lines.
If the surge voltage is excessive or sustained, excessively high
voltage is applied to VS11 and a failure occurs in the short-circuit
mode, causing F1 to blow. If a short-circuit occurs in VS11, and
there is not spare part, the system is permitted to operate without
VS11. In this case, however, obtain and install a new VS11 as
soon as possible.
VS11 ordering number: A50L-2001-0122#G431k
(b) Short-circuit of diode stack DB11
(c) Short-circuit between D and S in switching transistors Q21 and
Q22
(d) Short-circuit between diodes D31 and D32
(e) The secondary power supply module is faulty :
If one of the causes (b) to (e) above is detected, replace the power
supply unit with a spare unit.
The codes for F1 is : A60L-0001-0245#GP75
Corrective action 2 Causes of blown fuse F3 and corrective action

The device connected to connector CP5 of the power supply unit may be
faulty. If no device is connected to CP5 or the connected device is normal,
the +24 V power used in a printed circuit board connected to the backplane
is faulty.
The code of F3 is A60L–0001–0075#5.0 :
Corrective action 3 Causes of blown fuse F4 and corrective action

The device connected to connector CP6 of the power supply unit may be
faulty. If no device is connected to CP6 or the connected device is normal,
the +24E used in a printed circuit board connected to the backplane is
faulty.
The code of F4 is A60L-0001-0046#5.0.
38
3.2
TROUBLESHOOTING (1) SRVO–001 SVAL1 Operator panel E–stop
(Explanation) The emergency stop button on the operator’s box or
USING THE ERROR operator’s panel is pressed.
CODE (Action) Release the emergency stop button pressed on the
operator’s box or operator’s panel.
Operator’s box
Operator’s panel
Emergency stop (B–cabinet)
button
Emergency stop
button
(2) SRVO–002 SVAL1 Teach pendant E–stop

(Explanation) The emergency stop button on the operator’s panel
was pressed.
(Action) Release the emergency stop button on the teach
pendant.
Emergency stop button
39
(3) SRVO–003 SVAL1 Deadman switch released

(Explanation) The teach pendant is valid, but the deadman’s switch
is not pressed.
(Action) Press the deadman switch to run the robot.
Deadman switch
(4) SRVO–004 SVAL1 Fence open

(Explanation) On the terminal block of the panel printed circuit
board, no connection is made between FENCE1 and
FENCE2. If a safety fence is connected between
FENCE1 and FENCE2, the door of the safety fence
is open.
(Action 1) If a safety fence is connected, close the door.
(Action 2) Check the switch and cable connected to FENCE1
and FENCE2.
(Action 3) Make a connection between FENCE1 and FENCE2.
Panel printed circuit board
FENCE 1 FENCE 2
40
(5) SRVO–005 SVAL1 Robot overtravel

(Explanation) The robot has gone beyond an axis/direction hardware
limit switch. The robot is designed so that normally it
will neither go out of each axial movable range
(software limit) nor reach any hardware limit. It is
however factory–set in an overtravel state for
convenience of packing.
(Action 1) 1) Release axes from overtravel using the overtravel
release screen [OT_RELEASE].
2) Hold down the shift key and press the RESET
button to reset the alarm condition.
3) While still holding down the shift key, jog–feed
the robot until its overtraveled axes return within
the movable range.
(Action 2) Check fuse F4 of the power supply unit. If the fuse
has blown, replace it with a new one.
(Action 3) When a B–cabinet is used, check fuse F2 of the
emergency stop control printed circuit board. If the
fuse has blown, replace it with a new one.
(Action 4) Check the overtravel connection cable (i–cabinet
integration type) or robot connection cable (RP1) for
a connection to the ground.
(Action 5) Replace the emergency stop control printed circuit
board.
(6) SRVO–006 SVAL1 Hand broken
(Explanation) If a safety joint is used, it is broken. If the joint is not
broken, the voltage of the HBK signal in the robot
connection cable is 0 V for some reason.
(Action 1) 1.Hold down the shift key and press the alarm reset
button to reset the alarm condition.
(Action 2) While still holding down the shift key, jog–feed the
robot until the tool moves to the working area.
1) Exchange the safety joint.
2) Check the cables.
(7) SRVO–007 SVAL1 External E–stop
board, no connection is made between EMGIN1 and
EMGIN2. If an external emergency stop switch is
connected between EMGIN1 and EMGIN2, the
switch is pressed.
(Action 1) If an external emergency stop switch is connected,
releases the switch.
(Action 2) Check the switch and cable connected to EMGIN1
and EMGIN2.
(Action 3) Make a connection between EMGIN1 and EMGIN2.
41
EMGIN 1 EMGIN 2
(8) SRVO–009 SVAL1 Pneumatic pressure alarm

(Explanation) While checking the air pressure, an abnormal air
pressure was detected. If the air pressure is normal,
the PPABN signal in the robot connection cable
became abnormal for some reason.
(Action) If the pneumatic pressure is normal, check the cables.
(9) SRVO–014 WARN Fan motor abnormal
(Explanation) A fan motor in the backplane is abnormal.
(Action) Check the fan motor and its cables. Replace them if
necessary.
Fan motor
42
(10) SRVO–015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j)

(Explanation) The temperature in the control unit exceeds the
specified value.
(Action 1) If the ambient temperature is higher than specified
(45°C), cool down using the air conditioner.
(Action 2) If the fan motor is not running, check it and its cables.
Replace them if necessary.
(Action 3) If the thermostat on the backplane PC board is
defective, replace the backplane unit.
Fan motor
Fan motor
i cabinet
43
Fan motor
Fan motor
Fan motor B–Cabinet

(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12i, M–6i, M–16i, S–420i, S–500, S–700i,
M–400i, A–520)
44
Fan motor
Fan motor
(S–800)
Fan motor
Fan motor
Fan motor
(M–500)
Fan motor
45
Fan motor
Additional cabinet
Fan motor
Fan motor
Fan motor
Fan motor
B–Cabinet/S–900
46
Fan motor
Fan motor
Cabinet for M–410i
47
(11)SRVO–018 SVAL1 Brake abnormal

(Explanation) An excessive break current is detected. When the
ARC Mate 100, ARC Mate 120, ARC Mate 100i,
ARC Mate 120i, S–6. S–12, M–6i, M–16i, S–420i,
S–500, S–700, M–400i, M–710i or A–520i is used,
the seven–segment LED on the servo amplifier
indicates 1. When the S–800, M–410i, M–500 or
S–450 is used, the LED (red) on the emergency stop
control printed circuit board lights. When the S–900
is used, the LED (red) on the conversion printed
circuit board or the emergency stop control printed
circuit board lights.
(Action 1) Check the robot connection cable (RM1) and cables
internal to the mechanical section for a short–circuit
and connection to the ground.
(Action 2) Replace the servo amplifier (when the ARC Mate
100, ARC Mate 120, ARC Mate 100i, ARC Mate
120i, S–6. S–12, M–6i, M–16i, S–420i, S–500,
S–700, M–400i, M–710i or A–520i is used), the
emergency stop control printed circuit board (when
the S–450, S–800, M–410i, or M–500 is used), or the
conversion printed circuit board or the emergency
stop control printed circuit board (the conversion
printed circuit board is not installed.) (when the
S–900 is used).
Servo amplifier
i–Cabinet
48
Servo amplifier
B–Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500, S–700, M–400i,
M–710i, A–520i)
49
S–800

printed board
M–500
50

printed board
(M–410i)
Conversion printed board
(S–900)
51

printed board
S–450, M–410i (B–Cabinet)
52
(12) SRVO–019 SVAL1 SVON input

board, no connection is made between SVON1 and
SVON2. If a switch is connected between SVON1
and SVON2, the switch is pressed.
(Action 1) If a switch is connected, releases the switch.
(Action 2) Check the switch and cable connected to SVON1 and
SVON2.
(Action 3) Make a connection between SVON1 and SVON2.
SVON 1 SVON 2
53
(13) SRVO–021 SVAL1 SRDY off (Group : i Axis : j)

(Explanation) The HRDY is on and the SRDY is off, although there
is no other cause of an alarm. (HRDY is a signal with
which the host directs the servo system whether to
turn on or off the servo amplifier MCC. SRDY is a
signal with which the servo system informs the host
whether the MCC is turned on.)
If the servo amplifier MCC 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). To sum up, this alarm indicates that the
MCC cannot be turned on for an unknown reason.
(Action 1) Check that the door is completely closed. Check that
the door switch operates normally. (In case of
i–cabinet)
(Action 2) Check the input voltage (200 VAC) to the servo
amplifier. If it is 170 VAC or lower, check the line
voltage.
(Action 3) Replace the emergency stop control PC board.
(Action 4) Replace the main CPU PC board.
(Action 5) Check the cable between the servo amplifier and the
CPU PC board, and replace it if necessary.
(Action 6) Replace the servo amplifier.
Servo amplifier Main CPU
Door switch

emergency stop control
54
Emergency stop control Main CPU

printed board
Servo amplifier
B–Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500, S–700, M–400i, M–710i,
A–520i)
55

printed board Main CPU
Servo amplifier 5
Servo amplifier 4
Servo amplifier 3
S–800 Servo amplifier 2
Servo amplifier 1

printed board
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
M–500
Servo amplifier 3
56
Servo amplifier 4
Servo amplifier 3
Additional cabinet

printed board
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
57
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Emergency stop control printed board
58
Servo module 3
Emergency control printed board
Servo module 2 Main CPU printed board
Servo module 1
Power supply module Servo module 4
M–410i (B–Cabinet)
59
Servo module 4
Servo module 3 Emergency stop control printed board
Servo module 2
Servo module 1
Power supply module
S–450
60
(14) SRVO–022 SVAL1 SRDY on (Group : i Axis : j)

(Explanation) When the HRDY is about to go on, the SRDY is
already on. (HRDY is a signal with which the host
directs the servo system whether to turn on or off the
servo amplifier MCC. SRDY is a signal with which
the servo system informs the host whether the MCC
is turned on.
(Action 3) Check the cable between the servo amplifier and the
CPU PC board, and replace it if necessary.
Servo amplifier
Main CPU

61

printed board
Servo amplifier
B–Cabinet
A–520i)
62

Servo amplifier 5
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
S–800

printed board
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
Servo amplifier 3
M–500
63
Servo amplifier 4
Servo amplifier 3
Additional cabinet

printed board
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
64
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
65
Servo module 3
Servo module 1
66
Servo module 4
Servo module 2
Servo module 1
Power supply module
S–450
67
(15) SRVO–023 SVAL1 Stop error excess (Group : i Axis : j)

(Explanation) When the servo is at stop, the position error is
abnormally large.
(Action 1) Check to see if the load is greater than the rating. If
greater, reduce it to within the rating. (If the load is
too greater, the torque required for
acceleration/deceleration becomes higher than the
capacity of the motor. As a result, the motor becomes
unable to follow the command, and an alarm is
issued.)
(Action 2) Check each phase voltage of the three–phase power
(200 VAC) input to the servo amplifier. If it is 170
VAC or lower, check the line voltage. (If the voltage
input to the servo amplifier becomes low, the torque
output also becomes low. As a result the motor may
become unable to follow the command, hence
possibly an alarm.)
(Action 3) If the line voltage is 170 VAC or higher, replace the
servo amplifier.
(Action 4) Check continuity of motor power cables.
(Action 5) Replace the motor.
Servo amplifier
Main CPU

68

printed board
Servo amplifier
B–Cabinet
A–520i)
69

Servo amplifier 5
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
S–800

printed board
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
Servo amplifier 3
M–500
70
Servo amplifier 4
Servo amplifier 3
Additional cabinet

printed board
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
71
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
72
Servo module 3
Servo module 1
73
Servo module 4
Servo module 2
Servo module 1
Power supply module
S–450
(16) SRVO–024 SVAL1 Move error excess (Group : i Axis : j)

(Explanation) When the robot is running, its position error is greater
than a specified value ($PARAM _ GROOP.
$MOVER _ OFFST or $PARAM _ GROUP.
$TRKERRLIM). It is likely that the robot cannot
follow the speed specified by program.
(Action) Take the same actions as described for the above
alarm.
(17) SRVO–025 SVAL1 Motn dt overflow (Group : i Axis : j)
(Explanation) The specified value is too great.
74
(18) SRVO–026 WARN2 Motor speed limit (Group : i Axis : j)

(Explanation) A value higher than the maximum motor speed
($PARAM_GROUP.$MOT_SPD_LIM) was
specified. The actual motor speed is clamped to the
maximum speed.
(19) SRVO–027 WARN Robot not mastered (Group : i)
(Explanation) An attempt was made to calibrate the robot, but the
necessary adjustment had not been completed.
(Action) Make the adjustment on the positioning menu [6
System.positioning].
(20) SRVO–030 SVAL1 Brake on hold (Group : i)
(Explanation) This alarm occurs when the robot pauses, if the brake
on hold function has been enabled ($SCR.
$BRKHOLD _ ENB = 1). Disable the function if it is
not necessary.
(Action) Disable [Servo–off during pause] on the general
setting menu [6 Setting.general].
(21) SRVO–031 SVAL1 User servo alarm (Group : i)
(Explanation) A user servo alarm occurred.
(22) SRVO–033 WARN Robot not calibrated (Group : i)
(Explanation) An attempt was made to set up a reference point for
simplified adjustment, but the robot had not been
calibrated.
(Action) Calibrate the robot.
1.Supply power.
2.Set up a simplified adjustment reference point
using [Positioning] on the positioning menu.
(23) SRVO–034 WARN Ref pos not set (Group : i)
(Explanation) An attempt was made to perform simplified
adjustment, but the reference point had not been set
up.
(Action) Set up a simplified adjustment reference point on the
positioning menu.
(24) SRVO–035 WARN2 Joint speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum axis speed
($PARAM_GROUP.$JNTVELLIM) was specified.
Each actual axis speed is clamped to the maximum
speed.
(25) SRVO–036 SVAL1 Inpos time over (Group : i Axis : j)
(Explanation) The robot did not get to the effective area ($PARAM _
GROUP.$ STOPTOL) even after the position check
monitoring time ($PARAM _ GROUP. $INPOS _
TIME) elapsed.
(Action) Take the same actions as for SRVO–23 (large position
error at a stop).
(26) SRVO–037 SVAL1 Imstp input (Group : i j)
(Explanation) The *IMSTP signal for a peripheral device interface
was input.
(Action) Turn on the *IMSTP signal.
75
(27) SRVO–038 SVAL2 Pulse mismatch (Group : i Axis : j)

(Explanation) The pulse count obtained when power is turned off
does not match the pulse count obtained when power
is applied.
(Action) Perform APC reset and remaster robot (RES–PCA)
1. Press MENUS.
2. Select SYSTEM.
3. Press F1 [TYPE].
4. Select system variables.
5. Move the cursor to $MCR.
6. Press ENTER.
7. Move the cursor to $SPC_RESET.
8. Press F4, TRUE. The display will reset to false.
This is normal.
9. Press RESET.
The fault condition should reset. If the controller
is still faulted with additional servo–related errors,
cold start the controller.
It might be recessary to remaster the robot.
(28) SRVO–039 SVAL1 Motor speed excess (Group : i Axis : j)
(Explanation) The motor speed was too high to be used in vector
acceleration/deceleration control.
(Action) Specify a lower speed with the teach pendant.
(29) SRVO–041 SVAL2 MOFAL alarm (Group : i Axis : j)
(Explanation) The command value was too high.
(Action 1) Exchange axis module.
(Action 2) Exchange Main CPU.
(30) SRVO–042 MCAL alarm (Group : i Axis : j)
(Explanation) This alarm indicates that a deposit has been detected
in the magnetic contactor, which is built into the servo
amplifier. When an attempt was made to close the
contactor, a contact was already closed. A deposit can
be detected when an attempt is made to close a
contactor on which a deposit has been formed. ‘2’
(ARC Mate 100, ARC Mate 120, ARC Mate 100i,
ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i,
S–500, S–700, M–400i, M–710i, A–520i) or ‘7’
(S–900) is displayed on the servo amplifier LED
display.
(Action 1) Check fuses F1, F2, and F3 of the line filter unit (or
transformer). If they have blown, replace them.
(When F1, F2, and F3 blow, alarms OHAL1, and
MCAL are displayed on the teach pendant when the
control unit is turned on.)
(Action 2) Check the cable between the servo amplifier and
Main CPU printed circuit board. If it is defective,
replace it. (When the connection is broken, alarms
OHAL1 and MCAL are displayed on the teach
pendant at the same time.)
(Action 4) Replace the Main CPU printed circuit board.
76
Servo amplifier
i–Cabinet
Servo amplifier
B–Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500, S–700, M–400i, M–710i, A–520i)
77
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
78
(31) SRVO–043 SVAL1 DCAL alarm (Group : i Axis : j)

(Explanation) The regenerative discharge energy was too high to be
dissipated as heat. (To run the robot, the servo amplifier
supplies energy to the robot. When going down the
vertical axis, the robot operates from the potential
energy. If a reduction in the potential energy is higher
than the energy needed for acceleration, the servo
amplifier receives energy from the motor. A similar
phenomenon occurs even when no gravity is applied,
for example, at deceleration on a horizontal axis. The
energy that the servo amplifier receives from the motor
is called the regenerative energy. The servo amplifier
dissipates this energy as heat. If the regenerative energy
is higher than the energy dissipated as heat, the
difference is stored in the servo amplifier, causing an
alarm.) In case of ARC Mate 100, ARC Mate 120,
ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i,
M–16i, S–420i, S–500, S–700, M–400i, M–710i and
A520i.
(Action) If the servo amplifier LED indicates ”8” (DCOH
alarm): (This alarm occurs when a thermostat detects
that the regenerative resistor is overheated.)
–This alarm is likely to occur when the regenerative
discharge energy is high because of frequent
acceleration /deceleration or a vertical axis being used.
In this case, ease the conditions under which the robot
is used.
–Disconnect the cable from connector CN8A of the
servo amplifier, then check the continuity between
pins 1 and 2 of the cable, If a non–contimity is
detected, replace the regenerative resistor.
–Disconnect the cable from terminals R1 and R2 of
the servo amplifier, then measure the resistance of
the cable. If it is other than 4W, replace the
regenerative resistor.
–Replace the servo amplifier.
For S–800, S–900 and M–500
(Action1) When number 4 (DCSW alarm) is displayed on the
servo amplifier display (the DCSW alarm is issued
when the regenerative transistor holds the on state for
one second or more),
–The short–period (about one second) regenerative
energy may be excessive due to a large load being
applied to the robot. Reduce the load so that it does
not exceed the rated value.
(Action2) When number 5 (DCOH alarm) is displayed on the
servo amplifier display (the DCOH alarm is issued
when the thermostat detects overheating of the
regenerative resistor),
79
–Frequent acceleration/deceleration or large

regenerative energy at the gravity axis may cause
this alarm to be issued. Ease the use conditions.
–When a transformer is not being used, check that
TH1 and TH2 of the servo amplifier are
short–circuited.
–When a transformer is being used, check the wiring
of the thermostat.
–A phase of the power supplied to the servo amplifier
may be missed. Check the wiring.
Servo amplifier
Regenerative registance
i cabinet (ARC Mate 100, ARC Mate 120,

ARC Mate 100i, ARC Mate 120i, S–6, S–12,
M–6i, M–16i, S–420i, S–500, S–700,
M–400i, M–710i, A–520i)
80
Servo amplifier
Regenerative
registance
B–Cabinet
A–520i)
81
Servo amplifier 5
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
S–800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
Servo amplifier 3
M–500
82
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
83
(32) SRVO–044 SVAL1 HVAL alarm (Group : i Axis : j)

SRVO–154 SVAL1 HVAL alarm (Group : i Axis : j)
(Explanation) The DC voltage (DC link voltage) of the main circuit
power supply is abnormally high. The servo amplifier
LED indicates ”7”. (ARC Mate 100, ARC Mate 120,
M–16i, S–420i, S–450, S–500, S–700, M–410i,
M–400i, M–710i) or ‘1’(S–800, S–900 and M–500).
(Action 1) Check the three–phase input voltage at the servo
amplifier. If it is 253 VAC or higher, check the line
voltage. (If the three–phase input voltage is higher than
253 VAC, high acceleration/deceleration can result in
this alarm.)
(Action 2) Check that the load weight is within the rating. If it
is higher than the rating, reduce it to within the rating.
(If the machine load is higher than the rating, the
accumulation of regenerative energy may result in the
HVAL alarm even when the three–phase input
voltage is within the rating.
Servo amplifier
i–Cabinet
84
Servo amplifier
B–Cabinet
A–520i)
85
Servo amplifier 5
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
S–800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
Servo amplifier 3
M–500
86
Regenerafive discharge unit

Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
87
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
88
Servo module 3
Servo module 2
Servo module 1
89
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S–450
90
(33) SRVO–045 SVAL1 HCAL alarm (Group : i Axis : j)

SRVO–149 SVAL1 HCAL alarm (Group : i Axis : j)
SRVO–152 SVAL1 IPMAL alarm (Group : i Axis : j)
(Explanation) Abnormally high current flowed in the main circuit of
the servo amplifier. The servo amplifier 7–segment
LED indicates ”–”. At the same time, a red LED
(HC1 to HC6) corresponding to the HCAL alarm
above the 7–segment LED (For ARC Mate 100, ARC
Mate 120, ARC Mate 100i, ARC Mate 120i, S–6,
S–12, M–6i, M–16i, S–420i, S–500, S–700, A–520i)
or Servo amplifier one of ‘1’ ‘8’ ‘9’ ‘6’ of LED (For
S–800, S–900, M–410i, M–500, M–400i, M–710i)
lights.
(Action 1) Disconnect the motor power lines from the servo
amplifier terminals, supply power, and see if the
alarm occurs again. If the alarm occurs, replace the
servo amplifier.
amplifier terminals, and check the insulation of each
motor power line (U, V, or W) and the GND line. If
there is a short–circuit, the motor, robot
interconnection cable, or intra–robot cable is
defective. Check them and replace them if necessary.
amplifier terminals, and measure the resistance
between the U and V, V and W, and W and U with a
ohmmeter with a very low resistance range. If the
resistances at these three places are different from
each other, the motor, robot interconnection cable, or
intra–robot cable is defective. Check each item in
detail and replace it if necessary.
Servo amplifier
i–Cabinet
91
Servo amplifier
B–Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500, S–700, M–400i,
M–710i, A–520i)
92
Servo amplifier 5
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
S–800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
Servo amplifier 3
M–500
93
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
94
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
95
Servo module 3
Servo module 2
Servo module 1
96
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S–450
97
(34) SRVO–046 SVAL2 OVC alarm (Group : i Axis : j)

(Explanation) This alarm is issued to prevent the motor from
thermal damage that may occur when the root meant
square current calculated within the servo system is
out of the allowable range.
(Action 1) Check the operating conditions for the robot. If the
technical data of the robot such as duty cycle or load
weight is higher than the rating, reduce it to within the
rating.
(Action 2) Check each phase voltage of the three–phase input
power (200 VAC for the servo amplifier. If it is 170
VAC or lower, check the line voltage.
(Action 5) Replace the motor.
i–Cabinet
98
Servo amplifier
Main CPU
B–Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500, S–700,
M–400i, M–710i, A–520i)
99
Servo amplifier 5
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
S–800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
Servo amplifier 3
M–500
100
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
101
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
102
Servo module 3
Servo module 2
Servo module 1
103
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S–450
104
Reference Relationships among the OVC, OVL, and HC alarms

Overview
This section points out the differences among the OVC, OVL, and HC
alarms and describes the purpose of each alarm.
Alarm detection section
Abbreviation Designation Detection section
OVC Overcurrent alarm Servo software
OVL Overload alarm Thermal relay in the motor OHAL2
Thermal relay in the servo amplifier OHAL1
Thermal relay in the separate regenerative dis-
charge unit DCAL
HCAL 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 may be damaged, or the magnet of the motor may be
degaussed. The HC alarm is intended to prevent such failures.
2) OVC and OVL alarms (overcurrent and overload alarms)
The OVC and OVL alarms are intended to prevent overheat that may
lead to the burnout of the motor winding, the breakdown of the servo
amplifier transistor, and the separate regenerative resistor.
The OVL alarm occurs when each built–in thermal relay detects a
temperature higher than the rated value. However, this method is not
necessarily perfect to prevent these failures. For example, if the motor
frequently repeats to start and stop, the thermal time constant of the
motor, which has a large mass, becomes higher than the time constant
of the thermal relay, because these two components are different in
material, structure, and dimension. Therefore, if the motor repeats to
start and stop within a short time as shown in Fig. 1, the temperature rise
in the motor is steeper than that in the thermal relay, thus causing the
motor to burn before the thermal relay detects an abnormally high
temperature.
Temperature
Start Stop Start Stop Start
Thermal time constant

Temperature at of the motor is high.
which the winding
starts to burn
Thermal time constant
of the thermal relay is
low.
Time
Fig.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles
105
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 OVL alarm is
used for protection from long–term overload. The relationship
between the OVC and OVL alarms is shown in Fig 2.
Current
Protection area for
the motor and
servo amplifier
Protection by the OVL
Limit current
Protection by
the OVC
Rated continuous current
Time
Fig.2 Relationship between the OVC and OVL alarms
NOTE
The relationship shown in Fig. 2 is taken into consideration
for the OVC alarm. The motor may not be hot even if the
OVC alarm has occurred. In this case, do not change the
parameters to relax protection.
106
(35) SRVO–047 SVAL1 LVAL alarm (Group : i Axis : j)

SRVO–144 SVAL1 LVAL alarm (Group : i Axis : j)
(Explanation) When the external magnetic contactor for the servo
amplifier is turned on, the DC voltage (DC link
voltage) of the main power supply is abnormally low,
or the control power supply voltage (+5 V, etc.) is
abnormally low.
(Action 1) If the servo amplifier LED indicates ”6” (For ARC
Mate 100, ARC Mate 120, ARC Mate 100i, ARC
Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500,
S–700, M–400i, M–710i, A–520i) or indicates ”2”
(For S–450, S–800, S–900, M–410i, M–500) :
(This alarm occurs if the control power supply
voltage (+5 V etc.) is abnormally low.)
–Check the phase voltage of the three–phase input
power (200 VAC) to the servo amplifier. If it is 170
(Action 2) If the servo amplifier LED indicates ”3” (For S–900)
(This alarm occurs when the DC voltage (DC link
voltage) of the main circuit power supply is
abnormally low.)
(Action 3) If the servo amplifier LED indicates ”7” (For S–900)
–This alarm indicates that a deposit has been detected
in the magnetic contactor.
See (30)SRVO–042 MCAL alarm.
Servo amplifier
i–Cabinet
107
Servo amplifier
B–Cabinet
M–400i, M–710i, A–520i)
108
Servo amplifier 5
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
S–800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
Servo amplifier 3
M–500
109
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
110
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
111
Servo module 3
Servo module 2
Servo module 1
112
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S–450
113
(36) SRVO–049 SVAL1 OHAL1 alarm (Group : i Axis : j)

SRVO–141 SVAL1 OHAL1 alarm (Group : i Axis : j)
(Explanation) The thermostat in the servo amplifier or transformer
worked. Alternatively, fuse F1 or F2 in the servo
amplifier has blown (ARC Mate 100, ARC Mate 120,
M–16i, S–420i, S–450, S–500, S–700, M–400i,
M–710i and A–520i). The servo amplifier LED
indicates ”3”.(For ARC Mate 100, ARC Mate 120,
M–16i, S–420i, S–450, S–500, S–700, M–410i,
M–400i, M–710i, A–520i) or indicates ”6” (For
S–900) :
rating.
(Action 2) Clean fans, louver (i–cabinet) or filter (B–cabinet).
(Action 3) When fuses F1, F2, and F3 of the line filter unit (or
transformer) have blown (for the B cabinet), replace
them. (When they blow, alarms OH AL1, and MCAL
are displayed on the teach pendant when the control
unit is turned on.)
(Action 4) Investigate the cable connected to the threephase
input of the servo anplifier. If an error is found,
eliminate the causa, then replace fuses F1 and F2 of
the servo amplifier.
(Action 6) Replace the trans former.
Servo amplifier
i–Cabinet
114
Servo amplifier
B–Cabinet
M–400i, M–710i, A–520i)
115
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
116
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
117
Servo module 3
Servo module 2
Servo module 1
118
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S–450
119
(37) SRVO–050 SVAL1 CLALM alarm (Group : i Axis : j)

(Explanation) The disturbance torque estimated by the servo software
is abnormally high. (A collision has been detected.)
(Action 1) Check that the robot has collided with anything. If it
has, reset the robot and jog–feed it to recover from the
collision.
(Action 2) Check that the load weight is within the rating. If it
is higher than the rating, reduce it to within the rating.
(If the robot is used out of its usable range, the
estimated disturbance torque becomes abnormally
high, possibly resulting in this alarm being detected.)
(Action 3) Check the phase voltage of the three–phase input
(Action 4) Check motor power cables, replace if necessary.
Servo amplifier
i–Cabinet
120
Servo amplifier
B–Cabinet
M–400i, M–710i, A–520i)
121
Servo amplifier 5
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
S–800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
M–500 Servo amplifier 3
122
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
123
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
124
Servo module 3
Servo module 2
Servo module 1
125
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S–450
(38) SRVO–051 SVAL2 CUER alarm (Group : i Axis : j)

(Explanation) The offset of the current feedback value is abnormally
high.
126
Servo amplifier
Main CPU
i–Cabinet
B–Cabinet
M–400i, M–710i, A–520i)
127
Servo amplifier 5
Servo amplifier 4
Main CPU
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
S–800
Servo amplifier 2
Servo amplifier 1
Main CPU
Servo amplifier 4
Servo amplifier 3
M–500
128
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
129
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
130
Servo module 3
Servo module 2
Servo module 1
131
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S–450
(39) SRVO–053 ER_WARN Disturbance Excess

(Explanation) The estimated external disturbance exceed the
maximum allowable value.
This error may occur if acute
acceleration/deceleration is applied while
acceleration override is specified, or if an excessive
load is applied.
If the high–sensitivity collision detection option or
smart and easy package option is being used, this
error indicates that the load setting may be invalid.
(Action) Check that an excessive load is not being applied, and
that the load setting is correct.
If a lower detection sensitivity load is acceptable
when acceleration override is being used, increase the
setting for the maximum allowable value on the
status/disturbance display.
132
(40) SRVO–054 DSM Memory Error

(Explanation) An access to the servo module memory fails.
(Action) Replace the servo module.
(41) SRVO–062 SVAL2 BZAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if no battery for pulse coder
absolute-position backup is connected.
A probable cause is a broken battery cable in the robot.
(Action) Remove the cause of the alarm, and set the system
variable $MCR.$SPC_RESET to TRUE, then supply
power again. After this, adjustment is required.
(42) SRVO–064 SVAL2 PHAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if the phase of the pulses generated
in the pulse coder is abnormal.
(Action) Replace the pulse coder.
Note) The DTERR, CRCERR, or STBERR alarm
may trigger the PHAL alarm. In this case, there is no
actual cause for the PHAL alarm.
(43) SRVO–065 WARN BLAL alarm (Group : i Axis : j)
(Explanation) The battery voltage for the pulse coder is lower than
the rating.
(Action) Replace the battery.
(If this alarm occurs, turn on the AC power and
replace the battery as soon as possible. A delay in
battery replacement may result in the BZAL alarm
being detected. In this case, the position data will be
lost. Once the position data is lost, mastering will
become necessary.
(44) SRVO–067 SVAL2 OHAL2 alarm (Group : i Axis : j)
(Explanation) The temperature inside the pulse coder or motor is
abnormally high, and the built–in thermostat has
operated.
rating.
(Action 2) When power is supplied to the motor after it has
become sufficiently cool, if the alarm still occurs,
replace the motor.
(45) SRVO–068 SVAL2 DTERR alarm (Group : i Axis : j)
(Explanation) The serial pulse coder does not return serial data in
response to a request signal.
–See actions on SRVO–070
(46) SRVO–069 SVAL2 CRCERR alarm (Group : i Axis : j)
(Explanation) The serial data has changed during communication.
–See actions on SRVO–070
133
(47) SRVO–070 SVAL2 STBERR alarm (Group : i Axis : j)

(Explanation) The start and stop bits of the serial data are abnormal.
(Action 1) Check that the shielding of the robot interconnection
cable (for the pulse coder) and the peripheral equipment
cable is connected securely to the grounding plate.
(Action 2) Check that each unit is grounded securely.
(Action 4) Replace the cable between the emergency stop
control PC board and main CPU.
(Action 6) Replace the pulse coder.
(Action 7) Replace the robot interconnection cable (for the pulse
coder).

134

printed board
Servo amplifier
B–Cabinet
M–400i, M–710i, A–520i)
135
Servo amplifier 5
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
S–800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
Servo amplifier 3
M–500
136
Servo amplifier 4
Servo amplifier 3

printed board
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
137
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module

138
Servo module 3
Servo module 1
139
Servo module 4
Servo module 2
Servo module 1
Power supply module
S–450
(48) SRVO–071 SVAL2 SPHAL alarm (Group : i Axis : j)

(Explanation) The feedback speed is abnormally high (3750 rpm or
higher ).
(Action 1) If this alarm occurs together with the PHAL alarm
(No. 064), this alarm does not correspond to the major
cause of the failure.
(Action 2) If the load weight of the robot is higher than the rating,
reduce it to within the working range. (The torque
command may have encountered saturation in an area
where the maximum speed is higher than 3200 rpm.)
(Action 3) Replace the pulse coder.
(49) SRVO–072 SVAL2 PMAL alarm (Group : i Axis : j)
(Explanation) It is likely that the pulse coder is abnormal.
(Action) Replace the pulse coder and remaster.
(50) SRVO–073 SVAL2 CMAL alarm (Group : i Axis : j)
(Explanation) It is likely that the pulse coder is abnormal or the pulse
coder has malfunctioned due to noise.
140
(Action) Make a simplified adjustment and enhance the

shielding.
(51) SRVO–074 SVAL2 LDAL alarm (Group : i Axis : j)
(Explanation) The LED in the pulse coder is broken.
(Action) Replace the pulse coder, and make the remaster.
(52) SRVO–075 WARN Pulse not established (Group : i Axis : j)
(Explanation) The absolute position of the pulse coder cannot be
established.
(Action) Reset the alarm, and jog–feed the robot along the axis
on which the alarm has occurred until the same alarm
will not occur again. (Jog one motor revolution)
(53) SRVO–081 WARN EROFL alarm (Track enc : i)
(Explanation) The pulse counter for line tracking has overflowed.
(Action) Contact the FANUC service center.
(54) SRVO–084 WARN BZAL alarm (Track enc : i)
(Explanation) This alarm occurs if the backup battery for the absolute
position of the pulse coder has not been connected. See
the description about the BZAL alarm (SRVO–062).
(55) SRVO–086 WARN PHAL alarm (Track enc : i)
(Explanation) This alarm occurs if the phase of pulses generated in
the pulse coder is abnormal. See the description
about the PHAL alarm (SRVO–064).
(56) SRVO–087 WARN BLAL alarm (Track enc : i)
(Explanation) This alarm occurs if the voltage of the backup battery
for the absolute position of the pulse coder is low. See
the description about the BLAL alarm (SRVO–065).
(57) SRVO–089 WARN OHAL2 alarm (Track enc : i)
(Explanation) The motor has overheated. See the description about
the OHAL2 alarm (SRVO–067).
(58) SRVO–090 WARN DTERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and main
CPU PC board is abnormal. See the description about
the DTERR alarm (SRVO–068).
(59) SRVO–091 WARN CRCERR alarm (Track enc : i)
the CRCERR alarm (SRVO–069).
(60) SRVO–092 WARN STBERR alarm (Track enc : i)
the STBERR alarm (SRVO–070).
(61) SRVO–093 WARN SPMAL alarm (Track enc : i)
(Explanation) This alarm occurs if the current position data from the
pulse coder is higher than the previous position data.
See the description about the SPHAL alarm
(SRVO–071).
(62) SRVO–094 WARN PMAL alarm (Track enc : i)
(Explanation) It is likely that the pulse coder is abnormal. See the
description about the PMAL alarm (SRVO–072).
(63) SRVO–095 WARN CMAL alarm (Track enc : i)
141
(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).
(64) SRVO–096 WARN LDAL alarm (Track enc : i)
(Explanation) The LED in the pulse coder is broken. See the
description about the LDAL alarm (SRVO–074).
(65) SRVO–097 WARN Palse not established (enc : i)
(Explanation) The absolute position of the pulse coder cannot be
established. See the description about (SRVO–075).
Pulse not established.
(66) SRVO–145 SVAL1 LVAL alarm (Group : i Axis : j)
(Explanation) When the external magnetic contactor for the servo
amplifier is turned on, the DC current (DC link
voltage) of the main power supply is abnormally low.
(Action) If the servo amplifier LED indicates ”4” or ”5” (For
ARC Mate100, ARC Mate120, ARC Mate 100i,
ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i,
S–450, S–500, S–700, M–410i, M–400i, M–710i,
A–520i), ”2” or ”3” (For M–500) (This alarm occurs
when the DC current (DC link voltage) of the main
circuit power supply is abnormally low.)
Servo amplifier
i–Cabinet
142
Servo amplifier
B–Cabinet
M–400i, M–710i, A–520i)
143
(67) SRVO–150 SVAL1 FSAL alarm (Group : i Axis : j)

(Explanation) The cooling fan of power supply module stopped
rotating. Number ‘2’ is displayed on the LED display.
(Action) Replace the power supply module.
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
144
Servo module 3
Servo module 2
Servo module 1
145
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S–450
146
(68) SRVO–152 SVAL1 IPMAL alarm (Group : i Axis : j)

(Explanation) An error was detected in the IPM of a servo amplifier.
Servo amplifier LED indicates one of ’8.’, ’9.’, ’b.’.
(Action) Replace the servo amplifier.
Servo module 4
Servo module 3
Servo module 2
Servo module 1
M–410i
147
Servo amplifier 5
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
S–800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
Servo amplifier 3
M–500
148
(69) SRVO–153 SVAL1 CHGAL alarm (Group : i Axis : j)

(Explanation) The main circuit of the power supply module could
not be charged within the specified time. Number ‘5’
is displayed on the LED display.
(Action) Replace the power supply module.
(70) SRVO–164, –166, –167
(Explanation) A digital servo module (DSM) which does not match
the currently loaded servo parameters is mounted.
(Action) Replace the axis module, or initialize the robot by
means of control start.
Initializing the robot will load the appropriate servo
parameters for the DSM. Note, however, that the new
parameters may cause the robot’s performance or
paths to differ from those obtained with the previous
parameters.
(71) SRVO–165 Panel (SVON Abnormal) E–stop
(Explanation) An invalid +24V is connected to SVON or EXGEX
in the operator’s panel.
(Action) Turn off the power, then correct the wiring of SVON
or EXGEM in the operator’s panel.
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
149
Servo module 3
Servo module 2
Servo module 1
150
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S–450
151
Fused–based troubleshooting
The alarms issued and symptoms observed when the fuses mounted on
printed circuit boards and units have blown are described below together
with corrective actions required.
(1) When the fuses of the power supply unit have blown
F1: Fuse for AC input
F3: Fuse for +24 V
F4: Fuse for +24 E
Name Symptom observed when fuse has blown Action
F1 The LED (PIL: Green) of the power supply unit does not 1 Check the units (fans) and cables connected to the
light, and the power cannot be turned on. CP2 and CP3 connectors of the power supply unit to
see if there is any short circuit.
2 Replace the power supply unit.
F3 The power, when turned on, is immediately turned off. 1 Check the printed circuit boards, units, and cables
At this time, the LED (ALM: Red) lights. 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.
F4 An alarm such as for overtravel, hand breakage, IMSTP 1 Check the printed circuit boards, units, and cables
input (depending on the peripheral equipment interface using +24 E according to the power supply system
state) is output on the teach pendant. diagram. Replace a faulty printed circuit board, unit,
or cable if any.
152
F1
7.5A
Fuse for
AC Input
Power supply unit
LED : PIL
LED : ALM
F3 5AS
(Slow blow)
Fuse for +24V
F4 5A
Fuse for +24E
153
(2) Servo amplifier fuse (ARC Mate 100, ARC Mate 120, ARC Mate
100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500,
S–700, M–400i, M–710i, A–520i)
FUSE1: For transformer and regenerative resistance thermostat
detection
F1, F2 :For protection of servo amplifier internal circuit
FUSE1 The OHAL1 alarm is output on the teach pendant, and 1 Check if the cables connected to the CN7B, CN8A,
the seven–segment LED on the servo amplifier indi- and CN8B connectors of the servo amplifier are con-
cates 3. nected to the ground.
2 Replace the regenerative resistance.
3 Replace the transformer.
4 Replace the servo amplifier.
F1 The OHAL1 alarm is output on the teach pendant, and 1 Check if the cables connected to three phase input
F2 the seven–segment LED on the servo amplifier indicate of servo amplifier is defective.
3. 2 Replace the servo amplifier.
FUSE 1
Servo amplifier
FUSE
F1, F2
i–Cabinet
154
FUSE 1
Servo amplifier
FUSE
F1, F2
B–Cabinet
155
FUSE1
FUSE FUSE
F1 F2
156
(3) Servo amplifier fuses (S–450, S–800, S–900, M–410i, M–500)

F1: Fuse for power supply module control (S–450, M–410i)
F2: Fuse for servo module control (S–450, M–410i)
FUSE: Fuse for servo amplifier control (S–900, S–800, M–500)
F1 The seven–segment LED does not light. 1 Replace the power supply module, servo module, or
F2 servo amplifier.
FUSE1
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
157
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
S–900
158
Servo amplifier 5
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
S–800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
M–500 Servo amplifier 3
159
Servo module 3
Servo module 2
Servo module 1
160
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S–450
161
LED
Fuse
F2
Fuse
Note See 7.12.1

for the location of fuse.
Power supply module Servo module Servo amplifier
162
(4) Fuses on the emergency stop control printed circuit board (B–cabinet)
F1: Fuse for brake control
F2: Fuse for +24 E
F1 The LED (red) on the emergency stop control printed 1 Check if the robot connection cable (RM1) and
circuit board lights.(*1) cables internal to the mechanical section are con-
nected to the ground or are short–circuited.
2 Replace the emergency stop control printed circuit
board.
F2 The LED (red) on the emergency stop control printed 1 Check if the robot connection cable (RP1) and
circuit board lights, and the overtravel alarm is output on cables internal to the mechanical section are con-
the teach pendant. nected to the ground or are short–circuited.
board.
*1 If no additional axis is used with the ARC mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i,
S–500, S–700, M–400i, M–710i or A–520i the brake control circuit on the emergency stop control printed circuit board is not used: the F1
fuse does not blow.

printed board
B–Cabinet
M–400i, M–710i, A–520i)
163

printed board
S–800

printed board
M–500
164

printed board
165
Servo module 3
Servo module 2
Servo module 1
166
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S–450
167
FUSE
F2
ALARM LED
100 VAC for

FUSE
BRAKE
F1
Emergercy stop control printed board
168
(5) Fuse on the process I/O printed circuit board

FUSE1: Fuse for +24 E
FUSE The LED (ALM–2 or FALM) on the process I/O printed 1 Check if the cables and peripheral equipment con-
circuit board lights, and an alarm such as IMSTP input nected to the process I/O printed circuit board are
is output on the teach pendant. (The display data de- normal.
pends on state of peripheral equipment connection.) 2 Replace the process I/O printed circuit board.
LED : ALM–2
CA
DA
CB
169
Process I/O EA LED : FALM

FUSE1
(6) Fuse on the conversion printed circuit board (S–900)

FUSE: Fuse for brake control
FUSE The LED (red) on the emergency stop control printed 1 Check if the robot connection cable (RM1) and
circuit board lights. cables internal to the mechanical section are con-
nected to the ground or are short–circuited.
board.
Conversion PCB
170
FUSE
(7) Transformer/line filter fuses

F1, F2, F3: Fuses for servo three–phase input voltage
F4, F5: Fuses for 100 VAC
171

F1 or The LVAL (DCLK) alarm is output on the teach pendant, 1 Check if the cables and units connected to the three–
F3 and the seven–segment LED on the servo amplifier in- phase input voltage source are normal.
dicates 4.
F2 only The DCAL alarm is output on the teach pendant, and 1 Check if the cables and units connected to the three–
the seven–segment LED on the servo amplifier indi- phase input voltage source are normal.
cates 8.
F1, F2 The LVAL (DCLK) alarm is output on the teach pendant, 1 Check if the cables and units connected to the three–
F1, F3 and the seven–segment LED on the servo amplifier in- phase input voltage source are normal.
F2, F3 dicates 4.
F1F3
F4 or The LED (green) on the emergency stop control printed 1 Check if the transformer/line filter, emergency stop
F5 circuit board does not light, and the motor brake cannot control printed circuit board, and connection cables
be released.(*1) are normal.
NOTE
If no additional axis is used with models such as ARC Mate 100, ARC Mate 120, ARC Mate 100i,
ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500, S–700, M–400i, M–710i or A–520i
which do not use a sixth–axis servo amplifier, the brake control circuit on the emergency stop
control printed circuit board is not used. This means that even if the F4 or F5 fuse blows, the
robot operates normally.
172
(B cabinet for ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500, S–700,
S–800, S–900, M–400i, M–710i, A–520i)
Fuses Fuses Fuses
Fuses
Transformer Line filter
(B cabinet for S–450, M–410i)
Fuses Fuses Fuses Fuses
Transformer AC reactor
NOTE
Check that the PIL lamp on the power unit is not lit. Then,
replace the blown fuse.
173
TROUBLESHOOTING The printed circuit boards and servo amplifier are provided with alarm
BASED ON LED INDICATIONS LEDs and status LEDs. The LED statuses and corresponding
troubleshooting procedures are described below.
Main CPU printed circuit board
Power supply unit
Process I/O printed circuit

board CA/CB/DA
Servo amplifier
i–Cabinet
Servo amplifier
Power supply unit
Rocess I/O printed

board CA/CB/DA
B–Cabinet
174
Servo module 1
Power supply unit
Process I/O printed board
CA/CB/DA
Power supply module
Servo module 4
M–410i ( B–Cabinet)
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module

printed board
Rocess I/O printed board CA/CB/DA

Power supply unit
175
Servo amplifier 4
Servo amplifier 3
Additional cabinet

Power supply unit
Process I/O printed board
CA/CB/DA
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B–Cabinet/S–900
176
Servo module 4
Servo module 3
Power supply unit

Servo module 2
Servo module 1
Process I/O printed

board CA/CB/DA
Power supply module
S–450
Process I/O printed board EA
Operator’s box
177
(1) TROUBLESHOOTING USING THE LEDS ON THE MAIN CPU

PRINTED CIRCUIT BOARD
To troubleshoot an alarm that arises before the teach pendant is ready
to display, check the status LEDs (green) on the main CPU PC board
at power–on. If the robot’s status is normal, all the status LEDs will
be lit.
After power–on, the LEDs light as described in steps 1 to 11, 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 * [Action1]Replace the flash ROM module.
LEDs are lit. * [Action2]Replace the SRAM module.
[Action3]Replace the corresponding axis module.
[Action4]Replace the main CPU PC board.
2: Each printed circuit * [Action]Replace the main CPU PC board.

board is initialized.
3: The timer is initialized. * [Action]Replace the main CPU PC board.
4: The communication * [Action1]Replace the main CPU PC board.

port is initialized.
5: The software is initial- * [Action1]Replace the main CPU PC board.

ized. * [Action2]Replace the flash ROM module.
* If the main CPU PC board or SRAM module is replaced, the contents of memory (parameters, specified data,
etc.) will be lost. Prior toreplacing the unit, therefore, make a backup copy of the data. Similarly, make a
backup copy of the current data when replacing the flash ROM module with one of a later software edition.
178
SRAM module
Flash ROM module DRAM module
Axis module (J1, J2)
Step LED Action to be taken

6: The software is initial- * [Action1]Replace the SRAM module.
ized. * [Action2]Replace the main CPU PC board.

* [Action3]Replace the flash ROM module.
8: The software is initial- [Action]Replace the flash ROM module.

ized.
9: The software is initial- [Action]Replace the axis module.

ized.

11: Communication with the [Action1]Replace the teach pendant.

teach pendant is [Action2]Replace the cable of the teach pendant.
executed. * [Action3]Replace the main CPU PC board.
etc.) will be lost. Prior to replacing the unit, therefore, make a backup copy of the data. Similarly, make a
179
SRAM module
180
LED Color Description

[Description] A parity alarm occurred in the RAM of the main CPU PC board.
[Action1] Replace the DRAM module.
Red
* [Action2] Replace the SRAM module.
* [Action3] Replace the main CPU PC board.
[Description] An NMI occurred in the LSI chip (ABC) on the main CPU PC board.
[Action1] Replace the axis module.
Red * [Action2] Replace the main CPU PC board.
[Description] A servo alarm occurred on the main CPU PC board.

[Action1] Replace the corresponding axis module.
Red
[Description] An NMI occurred in the LSI chip (SLC2) of the main CPU PC board.
* [Action] Replace the main CPU PC board.
Red
[Description] A SYSFAIL occurred.

[Action1] Replace the corresponding axis module.
Red
[Description] The battery voltage has fallen to below the prescribed level.
* [Action] Replace the battery on the power supply unit.
Red
Note) To prevent data loss, before replacing the battery, turn the control
unit on.
etc.) will be lost. Prior to replacing the unit, therefore, make a backup copy of the data. Similarly, make a
SRAM module
Battery
Battery cover
[Battery replacement]
(1) Turn on the control unit.
(2) Remove the battery cover from the power supply unit, by
grasping both the top and bottom of the battery cover.
(3) Disconnect the cable and remove the battery.
(4) Connect a new battery and replace the battery cover.
(5) Turn the control unit off.
Battery
181
* LEDs on power supply unit

LED Description and action to be taken
[Description] A power supply alarm occurred.
[Action1] Check whether fuse F3 (+24 V) or F4 (+24 E) on the power supply unit
has blown.
Replace if necessary.
[Action2] Check the printed circuit boards, units, and cables using the DC power
supply (+5 V, ±15 V, +24 V, +24 E). Replace any failed components.
* [Action3] Replace the power supply unit.
[Description] If the LED is not lit, the power supply unit is not connected to the 200
VAC supply.
[Action1] Check whether fuse F1 on the power supply unit has blown. Replace if
necessary.
* [Action2] Replace the power supply unit.
* Power supply replacement must be completed within 30 minutes. (The power supply unit contains the backup
battery for the SRAM module of the main CPU PC board.)
182
LEDs on the emergency–stop PCB

LED indication Phenomena and countermeasures
[Description] The brake fuse (F1) or +24 V fuse (F2) has blown, or the brake
over–current alarm has been issued.
[Action1] Check whether fuse F1 or F2 on the emergency–stop PCB has blown.
If it has blown, replace it.
[Action2] Check whether the robot cable and mechanical unit cable are
short–circuited to ground or any metal object.
[Action3] Replace the emergency–stop PCB.
[Description] If the LED does not light, 100 VAC power is probably not being supplied
to the brake.
[Action1] If the system is in the emergency–stop state, release it.
[Action2] Check that 100 VAC is being output to the terminal box of the transformer or
line filter.
[Description] If the LED does not light, the brake has not yet been released.
[Action2] Replace the main CPU PCB.
183
LEDs on the conversion PCB

LED indication Phenomena and countermeasures
[Description] The brake fuse has blown, or the brake over–current alarm has been
issued.
[Action1] Check whether the fuse on the conversion PCB has blown. If it has blown,
replace it.
[Action2] Check whether the robot cable and mechanical unit cable are
short–circuited to ground or any metal object.
[Action3] Replace the conversion PCB.
[Description] If the LED does not light, 100 VAC power is probably not being supplied
to the brake.
[Action1] If the system is in the emergency–stop state, release it.
[Action2] Check that 100 VAC is being output to the terminal box for the transformer
or line filter.
[Description] If the LED does not light, the brake has not yet been released.
[Action2] Replace the main CPU PCB.
FUSE
184
(2) ALARM LEDS ON THE PROCESS I/O PRINTED CIRCUIT

BOARD
Alarm LED Description and action to be taken
Process I/O CA/CB/DA Process I/O EA [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.
[Action3] Replace the I/O link connection cable.
ALMO
FALM
Process I/O CA/CB/DA Process I/O EA [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.
ALMO
FALM
Fuse
Fuse
For process I/O printed circuit board CA/CB/DA

Specificalion : A60l–0001–0046#2.0
Process input/output PC board EA
185
* LEDs on servo amplifier (For ARC Mate 100, ARC Mate 120, ARC
Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500,
S–700, M–400i, M–710i, A–520i)
The servo amplifier has alarm LEDs and a seven–segment LED.
Troubleshoot the alarm indicated by the LEDs, referring also to the
alarm indication on the teach pendant.
Name LED Description

Brake failure The brake control circuit in the servo amplifier is defective.
Corresponding alarm
Servo–018 Brake failure
Electromagnetic contactor This alarm is issued when a contact of the electromagnetic contactor
melt alarm melts.
The corresponding alarm is:

Servo–042 MCAL Alarm
Servo amplifier overheat The thermostat in the servo amplifier or transformer tripped or the
fuses F1, F2 in the servo amplifier blow.
Corresponding alarm
Servo–049 OHAL1 Alarm
Insufficient DC link voltage The DC voltage being supplied to the main circuit is too low.
Corresponding alarm
Servo–047 LVAL Alarm
Insufficient control supply The voltage being supplied to the control circuit (+5 V) is too low.
voltage
Corresponding alarm
186

Excessive voltage The DC voltage being supplied to the main circuit is too high.
Corresponding alarm
Servo–044 HVAL Alarm
Excessive regenerative dis- The regenerative discharge energy is too high.

charge
Corresponding alarm
Servo–043 DCAL Alarm
Servo amplifier not ready The electromagnetic contactor for the main power supply is open. The
amplifier is not ready to drive the motor.
Servo amplifier ready The electromagnetic contactor for the main power supply is closed.
The amplifier is ready to drive the motor. (Normal operating status.)
HC1 to HC6
[Description] An excessive current was detected in the main circuit
of the servo amplifier.
The 7–segment LED on the servo amplifier displays
a hyphen (–). Of LEDs HC1 to HC6, above the
7–segment LED, the LED corresponding to the axis
on which HCAL occurred lights (red).
WD (LED8)
[Description] A watch–dog alarm occurred on the servo amplifier
control PC board.
The WD LED (LED8) on the servo amplifier is lit.
187
* LED on power supply included (PSM) (M410i)
LED
Weight 10.7Kg
188
When an alarm is issued, the red LED lights, and the corresponding alarm
number is displayed on the seven–segment LED display on the front panel
of the power supply module.
Input overcurrent An over–current was detected in the input circuit.
SRVO–148 HCAL alarm
Fan alarm The cooling fan, built into the power supply module, is defective.
SRVO–150 FSAL alarm
Overload alarm The temperature of the semiconductor heat sink is too high.
SRVO–141 OHAL alarm
Low voltage alarm for DC link The DC voltage of the main circuit is too low.
SRVO–145 LVAL alarm
In sufficieat charge alarm for The DC voltage of the main circuit has not reached the required level (insufficient
DC link pre–charge).
SRVO–153 CHGAL alarm
Input power missing phase A phase of the input power is missing.

alarm
SRVO–143 PSFLAL alarm
Overvoltage alarm for DC link The DC voltage of the main circuit is too high.
SRVO–154 HVAL alarm
Hardware error alarm The control circuit is defective.
The following messages do not indicate alarm states. They indicate

normal operation modes.
NOT READY The motor is not ready to operate.
READY The required DC voltage has been reached. The motor is ready to run.
189
* LED on servo amplifier module (SVM)
LED
190
An alarm is indicated at the seven–segment LED display on the front

panel of the servo amplifier module.
Low voltage alarm for control The control–power voltage (+5 V) is too low. Alternatively, the clock is erro-
power neous.
(LV5V)
Low voltage alarm for DC link The DC voltage of the main–circuit power supply is too low.
(LCDC)
Overcarrent alarm An excessive over–current was detected in the motor of the one–axis amplifier
(HCL) or in the L–axis motor of the two–axis amplifier.
SRVO–149 HLAL alarm
Overcarrent alarm An excessive over–current was detected in the M–axis motor of the two–axis
(HCM) amplifier.
Overcarrent alarm An excessive over–current was detected in the L– and M–axis motors of the
(HCLM) two–axis motor.
IPM alarm An error was detected in the IPM of a 1–axis amplifier or the L–axis IPM of a
(HCL) 2–axis or 3–axis amplifier.
SRVO–152 IPMAL alarm
IPM alarm An error was detected in the M–axis IPM of a 2–axis or 3–axis amplifier.
(HCM)
IPM alarm An error was detected in the L–axis and M–axis IPMs of a 2–axis or 3–axis am-
(HCLM) plifier.

Amp The motor is not ready to operate.
NOT READY
Amp The required DC voltage has been reached. The motor is ready to run.
READY
191
* LED on servo amplifier unit (S–800, S–900 and M–500)

The servo amplifier has a seven–segment LED display. If an alarm
is issued, take appropriate action according to the message displayed
on the teach pendant.
LED

Overvoltage alarm The DC voltage of the main–circuit power supply is too high.
(HV)
Alarm message: Servo – 044 HVAL alarm
Low voltage alarm for control The power voltage (+5 V) supplied to the control circuit is too low.
power
(LCDC) Alarm message: Servo – 047 LVAL alarm
(LVDC)
Alarm message: Servo – 047 LVAL alarm
Regenerative control circuit The short–period regenerative discharge energy is high.

alarm
(DCSW) Alarm message: Servo – 043 DCAL alarm
Over regenerative discharge The average regenerative discharge energy is high.

alarm
(DCOH) Alarm message: Servo – 043 DCAL alarm
Amplifier over heating The thermostat in the servo amplifier unit tripped.
(OH)
Alarm message: Servo – 049 OHALI alarm
192

Deposition of magnetic contac- A deposit was detected on the contact of the magnetic contactor. Any deposit on
tor the contact is detected immediately after the magnetic contactor activation com-
(MCC) mand is specified.
Alarm message: Servo – 042 MCAL alarm
Overcarrent alarm An excessively high current was detected in the main circuit of the one–axis
(HCL) amplifier or the L–axis main circuit of the two–axis amplifier.
Alarm message: Servo – 045 HCAL alarm
Overcarrent alarm An excessively high current was detected in the M–axis main circuit of the two–
(HCM) axis amplifier.
Overcarrent alarm An excessively high current was detected in the L– and M–axis main circuits of
(HCLM) the two–axis amplifier.
Amplifier NOT READY The magnetic contactor in the servo amplifier unit is open. The motor is not
ready to operate.
Amplifier READY The magnetic contactor in the servo amplifier unit is closed. The motor is ready
to run. (This state is the normal operation state.)
L–axis IPM alarm (IPML) This alarm is issued when the intelligent power module (IPM) of the L–axis de-
tects an alarm.
The corresponding alarm is: Servo – 152 IPMAL alarm
M–axis IPM alarm (IPMM) This alarm is issued when the intelligent power module (IPM) of the M–axis de-
tects an alarm.
L/M–axis IPM alarm (IPMLM) This alarm is issued when the intelligent power modules (IPMs) of the L–axis and
M–axis detect an alarm.
Circuit breaker The circuit breaker is When an abnormal current exceeding the operating current of the circuit breaker
set to off. flows, the circuit breaker trips.
NOTE
When the circuit breaker of the servo amplifier unit is set to off, the DC link
undervoltage alarm (LVDC) is issued.
193
3.3
POSITION DEVIATION (Check 1) On the status screen, check the position deviation in the
FOUND IN RETURN stopped state. To display the position deviation, press the
screen selection key, and select STATUS from the menu.
TO THE REFERENCE
Press the TYPE (F1) key, select AXIS from the menu, then
POSITION press the PULSE (F4) key.
(POSITIONING) (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 or other faulty parts.
(Check 4) If checks 1 to 3 show normal results
(Corrective action)
Replace the pulse coder and main CPU printed circuit board.
3.4
VIBRATION (Check 1) Check the settings of parameters such as the position loop
gain parameter.
OBSERVED DURING (Corrective action)
MOVEMENT Correct parameters.
(Check 2) Check the mechanical unit for backlash.
(Corrective action)
Replace a faulty key or other faulty parts.
3.5 The following explains checking and corrective action required if the
robot cannot be operated manually after the controller is turned on:
MANUAL
(1) Check and corrective action to be made if manual operation is
OPERATION impossible
IMPOSSIBLE
(Check 1) Check whether the teach pendant is on.
(Corrective action)
Turn on the teach pendant.
(Check 2) Check whether the teach pendant is handled correctly.
(Corrective action)
To move an axis by manual operation, press the axis
selection key and case shift key at the same time.
Set the override for manual feed to a position other than the
FINE and VFINE positions.
(Check 3) Check whether the ENBL signal of the peripheral device
control interface is set to 1.
(Corrective action)
Place the peripheral device control interface in the ENBL
status.
194
(Check 4) Check whether the HOLD signal of the peripheral device

control interface or the HOLD switch on the operator’s panel
is on (hold status). (Check whether the hold lamp on the
teach pendant is on.)
(Corrective action)
Turn off the HOLD signal of the peripheral device control
interface or the HOLD switch on the operator’s panel.
(Check 5) Check whether the previous manual operation has been
completed.
(Corrective action)
If the robot cannot be placed in the effective area because of
the offset of the speed command voltage preventing the
previous operation from being completed, check the
position deviation on the status screen, and change the
setting.
(Check 6) Check whether the controller is in the alarm status.
(Corrective action)
Release the alarm.
(2) Check and corrective action to be taken if the program cannot be
executed
(Check 1) Check whether the ENBL signal for the peripheral-device
control interface is on.
(Corrective action)
Put the peripheral-device control interface in the ENBL
state.
(Check 2) Check whether the HOLD signal for the peripheral-device
control interface is on. Also check whether the HOLD
switch on the operator’s panel is on. (Check whether the
HOLD lamp on the teach pendant is on.)
(Corrective action)
If the HOLD signal is on, turn it off. If the HOLD switch
is on, turn it off.
(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.
195
4. PRINTED CIRCUIT BOARDS MAINTENANCE B–80525E/04
4 PRINTED CIRCUIT BOARDS
The printed circuit boards are factory-set for operation. Usually, the user
need not 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 use of the test pins and meanings of the LED
indications.
Fig. 4 shows the printed circuit board of the control unit. The control unit
PC board consists of a main printed circuit board and some modules
installed perpendicular to the main PC board.
The control unit PC board has interface connectors, LED indicators, and
a plastic panel at the front. At the rear, there is a backplane connector.
The module is a small PC board in which components are
surface-mounted on both sides. On one edge, it has a connector electrode
which fits into a module socket on the main PC board of the control unit.
This connection enable the module to be replaced easily. Different
modules are available for different functions. The signal array of the
module connector depends on the function. The function of the module
determines the socket to which the module is installed on the main PC
board of the control unit. If the module is installed to the wrong socket,
it will not work. It may cause failure.
Ï LED indicator
Module
Ï
Ï
Ï Edge
connector Interface connector
Backplane connector
Main PC board of the control unit
Front panel
Fig.4 Configuration of the the Control Unit PC Board
196
B–80525E/04 MAINTENANCE 4. PRINTED CIRCUIT BOARDS
4.1
MAIN CPU PC
BOARDS
(A16B–3200–0040)
Total version
CMOS RAM module
Fig.4.1 Main CPU printed circuit board
(1) Test pins

Name Use
GND
P5V
P15V
M15V For testing the printed circuit board
P24V
P24E
LOAD
(2) Set pin

Name Use
SP1 Only for testing the printed circuit board
Note) If the set pin is removed, the RAM on the PC board is
disconnected from the backup circuit. Because no
power is supplied, therefore, the data stored in RAM
may be lost. Always connect the set pin.
197
(3) LEDs
Color Description
A parity alarm occurred in a CMOS RAM module or

Red
DRAM module on the main CPU board.
NMI occurred in the LSI(ABC) on the main CPU

Red
printed circuit board.
Servo alarm occurred on the main CPU printed

Red
circuit board.
NMI occurred in the LSI(SLC2) on the main CPU

Red
board.
Red SYSTEM FAIL occurred.
The battery voltage is insufficient.

Red
Replace the battery.
Green Indicates the operating status of the system.
(4) Relationship between driver chips and DO signals

Driver chip order code: A76L–0151–0062
Driver chip DO signal
DV1 RDO1, RDO2, RDO3, RDO4
DV2 RDO5, RDO6, RDO7, RDO8
198
4.2 A20B–1006–0300
EMERGENCY STOP
CONTROL PC
BOARD
Fig.4.2 (a) Emergency stop control PC board
199
A16B–1212–0930
Total version
Fig.4.2 (b) Emergency stop control PC board
200
A16B–1212–0931
Total version
Fig.4.2 (c) Emergency stop control PC board
201
(1) Settings
Symbol Standard Description
setting
COM A Common–voltage setting
A: +24 V
B: 0 V
HBK B *HBK signal enabled/disabled
A: Disabled
B: Enabled
SBK1 Open
SBK2 Brake–sensitivity adjustment
(note)
Notes
NOTE
Not provided for A20B–1006–0300.
(2) LED indication

LED Description
A brake fuse alarm or brake over–current alarm

Red has been issued.
Green 100 VAC power is supplied to the brake.
Brake state (when the brake is released, the

Green LED lights.)
202
Conversion PCB (S–900) A16B–1212–0910
Total version
Fig.4.2 (d) Conversion PCB
(1) LED indication

LED Description
A brake fuse alarm or brake over–current alarm

Red has been issued.
Green 100 VAC power is supplied to the brake.
Brake state (when the brake is released, the

Green LED lights.)
203
4.3 (A20B-2001-0670)
3 slot back plane
BACKPLANE PC A20B–2001–0670
Total version
BOARD
Fig.4.3 (a) Backplane PC Board

(A20B–2001–0860)
2 slot back plane Total version
A20B–2001–0860
Fig.4.3 (b) Backplane PC Board

(A20B–2001–0990)
5 slot back plane
Total version
A20B–2001–0990
Fig.4.3 (c) Backplane PC Board

204
4.4
PROCESS
INPUT/OUTPUT PC
BOARD
4.4.1
Process Input/Output
PC Board CA
(A16B–2201–0470)
Fig.4.4.1 Process Input/Output PC Board CA
205
(1) Test pins

Name Use
P24V +24V
P5V +5V
P15VC +15V
For measuring the DC supply voltage
M15VC –15V
GND1 GND
GND2 GND
For measuring the reference voltage of the
P10V +10V
digital/analog converter
P15VF +15V
M15VF –15V Power for the digital/analog converter
GNDF GND
AI1 Channel 1
AI2 Channel 2
AI3 Channel 3 For measuring the voltage of the analog input
AI4 Channel 4 signal (analog/digital)
AI5 Channel 5
AI6 Channel 6
AOUT1 Channel 1 For measuring the voltage of the analog output
AOUT2 Channel 2 signal (digital/analog)
(2) Settings
Name Standard Description
setting
UDI1 to UDI20
ICOM1
(Connector CRM2A)
The common voltage is
UDI21 to UDI40 adjusted to:
ICOM2 Side A
(Connector CRM2B) Side A : +24 V common
WDI01 to WDI08 Side B : 0 V common
ICOM3
(Connector CRW1)
SP1 Channel 1 The polarity of the output voltage

is switched to:
Open
Strapped : Negative (–)
SP2 Channel 2
Open : Positive (+)
206
(3) Adjustment
VR1: Adjusts the gain of channel 1.
Execute a robot program and set AOUT[1] to 4095 on the teach
pendant. Connect a digital voltmeter to test pin AOUT1 and
rotate VR1 until the meter reads 12.0 V.
Connect the negative (–) lead of the digital voltmeter to test pin
GNDF.
pendant. Connect the digital voltmeter to test pin AOUT2 and
GNDF. (The 0VF test pin is different from the common 0V test
pin.)
VR3: Adjusts the reference supply voltage of the digital/analog
converter.
Connect the digital voltmeter to test pin P10V and rotate VR3
until the meter reads 10.0 "0.1 V.
(4) LEDs
Color Description
A communication alarm occurred between

Red
the main CPU and process input/output.
A fuse (FUSE 1) in the process input/output

Red
blew.
207
(5) Correspondence between driver chips and DO signals

Ordering code for the driver chips: A76L-0151-0062
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 SDO01, SDO02, SDO03, SDO04
DV11 WDO01, WDO02, WDO03, WDO04
RESERVED For replacement
208
4.4.2
PC Board CB
(A16B–2201–0472)
Fig.4.4.2 Process Input/Output PC Board CB
(1) Test pins

Name Use
P24V +24V
P5V +5V
P15VC +15V
M15VC –15V
GND1 GND
GND2 GND
(2) Settings
setting
UDI1 to UDI20 The common voltage is
ICOM1
(Connector CRM2A) adjusted to:
Side A
UDI21 to UDI40 Side A : +24 V common
ICOM2 Side B : 0 V common
(Connector CRM2B)
209
(3) LEDs
Color Description

Red

Red
blew.

DV3 2BATALM, BUSY, ACK1/SNO1, ACK2/SNO
210
4.4.3
PC Board DA
(A16B–2201–0480)
Total version
Fig.4.4.3 Process I/O PC board DA
(1) Test pins

Name Description
P24V +24V
P5V +5V
GND1 GND
GND2 GND
(2) Settings
setting
UDI01 to 20
ICOM1
(Connector CRM2A)
UDI21 to 40 The common voltage is
ICOM2
(Connector CRM2B) adjusted to:
Side A
UDI41 to 60 Side A : +24 V common
ICOM3 Side B : 0 V common
(Connector CRM2C)
UDI61 to 80
ICOM4
(Connector CRM2D)
211
(3) LEDs
Color Description

Red

Red
below.

DV11 ADO21, SDO22, SDO23, SDO24
212
4.4.4
Process I/O Printed
Board EA
(A16B–3200–0230)
213
(1) Test pins

Name Use
P24V +24V
P5V +5V
P15VC +15V
M15VC –15V
GND1 GND
GND2 GND
For measuring the reference voltage of the
P10V +10V
digital/analog converter
P15VF +15V
M15VF –15V Power for the digital/analog converter
GNDF GND
AI1 Channel 1
AI2 Channel 2
AI3 Channel 3 For measuring the voltage of the analog input
AI4 Channel 4 signal (analog/digital)
AI5 Channel 5
AI6 Channel 6
AOUT1 Channel 1 For measuring the voltage of the analog output
AOUT2 Channel 2 signal (digital/analog)
(2) Settings
setting
UDI1 to UDI20
ICOM1
(Connector CRM2A)
The common voltage is
UDI21 to UDI40 adjusted to:
ICOM2 Side A
(Connector CRM2B) Side A : +24 V common
WDI01 to WDI08 Side B : 0 V common
ICOM3
(Connector CRW1)
SP1 Channel 1 The polarity of the output voltage

is switched to:
Open
Strapped : Negative (–)
SP2 Channel 2
Open : Positive (+)
214
(3) Adjustment
pendant. Connect a digital voltmeter to test pin AOUT1 and
GNDF.
pendant. Connect the digital voltmeter to test pin AOUT2 and
GNDF. (The 0VF test pin is different from the common 0V test
pin.)
VR3: Adjusts the reference supply voltage of the digital/analog
converter.
Connect the digital voltmeter to test pin P10V and rotate VR3
until the meter reads 10.0"0.1 V.
VR4, VR5: Internal power supply adjustment
These VRs are used to adjust the internal supply voltage for the
printed circuit board. They are set at the factory and need not
be adjusted by the user.
(4) LEDs
Color Description
ALMO A communication alarm occurred between

Red
FALM
ALMO A fuse (FUSE 1) in the process input/output

Red
blew.
FALM
215

216
4.4.5
Additional Axis Control
Printed Board
(A16B–2200–0820)
Total version
Axis module (Additional 1–, 2–axis)
Fig.4.4.5 Additional axis printed board
(1) Checking pins

Name Description
GND
P5V
P15V For checking the printed board
M15V
P24E
217
5. SERVO AMPLIFIERS MAINTENANCE B–80525E/04
5 SERVO AMPLIFIERS
The servo amplifiers are factory-set for operation. Usually, the user need
not 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.
218
B–80525E/04 MAINTENANCE 5. SERVO AMPLIFIERS
Robots and servo amplifier

J1 J2 J3 J4 J5 J6 J7
ARC Mate 120i
ARC Mate A06B–6076–H105 (6–axis amplifier)
100i/M–6i
S–12, M–16i A06B–6076–H004 (6–axis AMP) or A06B–6076–H104
S–420i A06B–6076–H001 (6–axis AMP) or A06B–6076–H101
S–450 A06B–6077–H111 (PSM)
AMP1/L AMP1/M AMP2/M AMP2/L AMP3/L AMP3/M AMP4
A06B A06B A06B A06B A06B A06B S–450S:
–6079 –6079 –6079 –6079 –6079 –6079 A06B–6079
–H206 –H206 –H207 –H207 –H206 –H206 –H104
S–450L:
A06B–6079
–H101
A–520i
M–400i
S–800 AMP1 AMP2 AMP3 AMP4/M AMP4/M AMP5
–6089 –6089 –6089 –6089 –6089 –6089
–H105 –H105 –H105 –H208 –H208 –H105
S–900 AMP1 AMP3 AMP5 AMP2 AMP4 AMP6
–6066 –6066 –6066 –6066 –6066 –6066
–H008 –H008 –H008 –H006 –H006 –H006
AMP1 AMP3 AMP5 AMP2 AMP4 AMP6
–6089 –6089 –6089 –6089 –6089 –6089
–H106 –H106 –H106 –H105 –H105 –H105
M410i A06B–6087–H115 (PSM)
AMP1 AMP2 AMP3 AMP4
A06B A06B A06B A06B
–6079 –6079 –6079 –6079
–H106 –H106 –H106 –H103
M–500 AMP1 AMP3/M AMP2 AMP3/L AMP4
A06B A06B A06B A06B A06B
–6089 –6089 –6089 –6089 –6089
–H106 –H206 –H105 –H206 –H104
M–710i A06B–6076–H106 (6–axis amplifier)
219
5.1
SERVO AMPLIFIER Machine Specification
ARC Mate100, S–6 A06B–6076–H005 or A06B–6076–H105
FOR (ARC Mate 100,
ARC Mate120, ARC Mate 120i,
ARC Mate 120, ARC S–12, M–16i
A06B–6076–H004 or A06B–6076–H104
Mate 100i, ARC Mate ARC Mate100i, M–6i A06B–6076–H105

S–420i A06B–6076–H001 or A06B–6076–H101
120i, S–6, S–12, M–6, S–500, A–520i, M–400i A06B–6076–H002 or A06B–6076–H102
M–16i, S–420i, S–500, S–700 A06B–6076–H003 or A06B–6076–H103
S–700, M–400i, M–710i A06B–6076–H106
M–710i, A–520i)
Fig.5.1 (a) Outline Drawings
220
Fig. 5.1 (b) shows the terminal boards of servo amplifiers.
J5–axis
output
J6–axis
output
J3–axis
output
J4–axis
output
J1–axis
output
J2–axis
output
Regenerative
resistance
connection
terminal
GND terminal AC input

(200VAC to 230VAC)
Fig.5.1 (b) Terminal Boards of Servo Amplifiers
221
The servo amplifier has alarm LEDs and a seven–segment LED.

Troubleshoot the alarm indicated by the LEDs, referring also to the alarm
indication on the teach pendant.

Brake failure The brake control circuit in the servo amplifier is defective.
Electromagnetic contactor This alarm is issued when a contact of the electromagnetic contactor
melt alarm melts.
The corresponding alarm is: Servo 042 – MCAL alarm
Servo amplifier overheat The thermostat in the servo amplifier or transformer tripped or the
fuses F1, F2 in the servo amplifier blow.
Corresponding alarm
Servo–049 OHAL1 Alarm
Insufficient DC link voltage The DC voltage being supplied to the main circuit is too low.
(LVDC)
Corresponding alarm
Insufficient control supply The voltage being supplied to the control circuit (+5 V) is too low.
voltage
(LV5V) Corresponding alarm
222

Excessive voltage The DC voltage being supplied to the main circuit is too high.
(HV)
Corresponding alarm
Servo–044 HVAL Alarm
Excessive regenerative dis- The regenerative discharge energy is too high.

charge
Corresponding alarm
Servo–043 DCAL Alarm
Servo amplifier not ready The electromagnetic contactor for the main power supply is open. The amplifier
is not ready to drive the motor.
Servo amplifier ready The electromagnetic contactor for the main power supply is closed. The amplifi-
er is ready to drive the motor. (Normal operating status.)
HC1 to HC6
[Description] An excessive current was detected in the main circuit
of the servo amplifier.
The 7–segment LED on the servo amplifier displays
a hyphen (–). Of LEDs HC1 to HC6, above the
7–segment LED, the LED corresponding to the axis
on which HCAL occurred lights (red).
WD (LED8)
[Description] A watch–dog alarm occurred on the servo amplifier
control PC board.
The WD LED (LED8) on the servo amplifier is lit.
223
5.2
POWER SUPPLY
IMODULE (PSM)
(A06B–6087–H115)
LED
Fig.(For M–410i)
224
Positions of test points
IR
IS
+24V
+5V
0V
Fig. Test Points
Test point Description

IR L1 phase (R phase) current
IS L2 phase (S phase) current
+24V,
+5V, Control power
0V
225
Position of the status LED display
Position of the STATUS LEDs
STATUS
PIL
ALM
Status indication
On ª
No. Off ª Description
A lit LED is indicated by –.

PIL, power–on indication, does not light.
1. PIL
Control power not turned on
ALM
PSM not ready.

PIL
Power is not being supplied to the main cir-
2. ALM
cuit.
Emergency stop state
PSM ready.
PIL
3. Power is being supplied to the main circuit.
ALM
The PSM is ready to operate.
Alarm.
PIL
The PSM is not ready to run.
ALM
4.
Alarm codes are indi-
cated with numbers
starting from 01.
226
LED display indicating alarms

When an alarm is issued, the red LED lights, and the corresponding
alarm number is displayed by the seven–segment LED display on the
front panel of the power supply module.
Input overcurrent An over–current was detected in the input circuit.
Fan alarm The cooling fan, built into the power supply module, is defective.
Overload alarm The temperature of the semiconductor heat sink is too high.
Low voltage alarm for DC link The DC voltage of the main circuit is too low.
In sufficieat charge alarm for The DC voltage of the main circuit has not reached the required level (insufficient
DC link pre–charge).
Input power missing phase A phase of the input power is missing.

alarm
Overvoltage alarm for DC link The DC voltage of the main circuit is too high.
Hardware error alarm The control circuit is defective.

NOT READY The motor is not ready to operate.
READY The required DC voltage has been reached. The motor is ready to run.
227
5.3
SERVO AMPLIFIER Servo amplifier module (SVM) (A06B–6079–H103) for M–410i
(A06B–6079–H104) for S–450
MODULE (SVM)
(A06B–6079–H206) for S–450
228
Servo amplifier module (SVM) (A06B–6079–H101)
229
Servo amplifier module (SVM) (A06B–6079–H106)
230
Servo amplifier module (SVM) (A06B–6079–H208, H207)
231
(1) Setting
To make a setting, remove the jumper plug

using a tool such as a pair of long–nosed
pliers.
Name Setting Description

S1 Open These setting pin are used for internal circuit.
These setting pin must not be changed.
S2 Short
232
An alarm is indicated at the seven–segment LED display on the front

panel of the servo amplifier module.
Fan alarm The fan built into the servo amplifier module is defective.
(FAL)
Low voltage alarm for control The control–power voltage (+5 V) is too low. Alternatively, the clock is erro-
power neous.
(LV5V)
(LCDC)
Overcarrent alarm An excessive over–current was detected in the motor of the one–axis amplifier
(HCL) or in the L–axis motor of the two–axis amplifier.
Overcarrent alarm An excessive over–current was detected in the M–axis motor of the two–axis
(HCM) amplifier.
Overcarrent alarm An excessive over–current was detected in the L– and M–axis motors of the
(HCLM) two–axis motor.
IPM alarm An error was detected in the IPM of a 1−axis amplifier or the L−axis IPM of a
(HCL) 2−axis amplifier.
IPM alarm An error was detected in the M−axis IPM of a 2−axis amplifier.
(HCM)
IPM alarm An error was detected in the L−axis and M−axis IPMs of a 2−axis amplifier.
(HCLM)

Amp The motor is not ready to operate.
NOT READY
Amp The required DC voltage has been reached. The motor is ready to run.
READY
233
Interface of supply module and servo amplifier module terminal unit
234
5.4
SERVO AMPLIFIER
(A06B–6066–H006)
Servo amplifier (A06B–6066–H006)
No fuse braker Terminal unit TI
235
Servo amplifier (A06B–6066–H008)
No fuse braker
Terminal unit TI
236
Interface of the Servo–Amplifier Terminal Block

The following figure shows the terminal box of the servo amplifier.
(A06B–6066–H006)
One–axis servo amplifier
Fig.5.2 Servo–Amplifier Terminal Block
237
Interface of the Servo–Amplifier Terminal Block

The following table lists the interface signals of the terminal box of
the servo amplifier.
Terminal No. Symbol Description Remarks
1 PE (G) Amplifier ground
2 L1 (R) AC power input
(200 to 230 VAC)
3 L2 (S)
4 L3 (T)
5 100A Emergency–stop input
(100 VAC)
6 100B
7 MC1 Magnetic contactor break con- (Note 4)
firmation signal
8 MC2
9 U Outputs to an AC motor
10 V
11 W
12 G Motor ground
13 L1C Control power inputs L1 (R) and L1C, and L2 (S) and L2C are usually connected(note 1).
(200 to 230 VAC)
14 L2C
15 TH1 Thermostat input signals Usually connected(note 2).
16 TH2
17 RC For a regenerative resistor RC and RI are usually connected(note 3).
18 RI
19 RE
20 UL Output to an AC motor These terminals are not prepared for 1 axis servo amplifier unit.
21 VL
22 WL
23 GL Motor ground
24 FAN1 Power for the cooling fan in Provided only for A06B–6066–H008(note 5).
the separate regenerative dis-
25 FAN2 charge unit
NOTE
1. These terminals are used to input the power for controlling the servo amplifier. L2 (S) and L1C, as well
as L3 (T) and L2C are usually connected. To conform to the European standard, the European–version
R–J controller controls the control and power sections separately.
2. To use a transformer or a separate regenerative discharge unit, remove the jumper plate, then connect
the transformer or the overheat signal of the separate regenerative discharge unit between the TH1 and
TH2 terminals of the servo amplifier.
3. To use a separate regenerative discharge unit, connect it between the RC and RE terminals. For the
S–900, connect the regenerative discharge resistor of the regenerative discharge unit between the
terminals. Keep the RC and RI terminals connected.
4. These terminals output the state signal of the contact used for checking whether power is supplied to the
servo amplifier. The output signal is the contact–b signal of the magnetic contactor, which controls the
power supplied to the main circuit of the servo amplifier. When power is not supplied to the main circuit,
the on signal is output.
Rating: 24 VDC, current between 10 mA and 0.3 A inclusive.
5. To use a separate regenerative discharge unit, connect the power pins of the cooling fan of the unit to these
terminals.
238
Alarm LED Display

An alarm is displayed on a seven–segment LED display.
Overvoltage alarm The DC power voltage of the main circuit of the servo amplifier is too high.
(HV)
Alarm message: Error code – 044
Low voltage alarm for The control power voltage (+5 V) of the servo amplifier is too low.
control power
(LV5V) Alarm message: Error code – 047
Low voltage alarm for The DC power voltage of the main circuit of the servo amplifier is too low.
DC link
(LVDC) Alarm message: Error code – 047
Regenerafive control The short–period regenerative discharge energy is high. This occurs when the regenera-
circuit alarm tive discharge circuit is defective.
(DCSW)
Over regenerafive dis- The average regenerative discharge energy is high. This occurs when acceleration/de-
charge alarm celeration is applied frequently.
(DCOH) When the overheat signal of the transformer is connected, this alarm is issued if the
transformer overheats.
For the A06B–6066–H008, if the fuse for the fan blows, this alarm is issued.
Amplifier over heating The thermostat of the servo amplifier was activated.
(OH)
Deposition of magnet- A deposit is present on a contact of the magnetic contactor of the servo amplifier.
ic contactor
(MCC) Alarm message: Error code – 042
Overcarrent alarm An excessively high current was detected in the main circuit of the one–axis servo ampli-
(HCL) fier or the L–axis main circuit of the two–axis servo amplifier.
Overcarrent alarm An excessively high current was detected in the M–axis main circuit of the two–axis ser-
(HCM) vo amplifier.
Overcarrent alarm An excessively high current was detected in the L– and M–axis main circuits of the two–
(HCLM) axis servo amplifier.
Amplifier The magnetic contactor of the servo amplifier is open. The motor is not ready to operate.
NOT READY
Amplifier READY The magnetic contactor of the servo amplifier is closed. The motor is ready to run.
Circuit Breaker
The circuit breaker opens if a current exceeding the rated operation
current of the breaker is detected in the servo amplifier. When the
circuit breaker is open, close it.
239
5.5
SERVO AMPLIFIER
Servo amplifier unit (A06B–6089–H106)
UNIT
(A06B–6089–H106)
LED
No fuse braker
Terminal unit TI
240
Servo amplifier unit (A06B–6089–H104, H105)
No fuse braker
Terminal unit TI
LED
241
Servo amplifier unit (A06B–6089–H206, H208)
No fuse braker
Terminal unit TI
LED
242
Setting
OFF ON
Switch
4
3
2
1
→ON
Set the switch as follows

1 ON
2 OFF
3 ON (In case of A06B–6089–H106, set switch OFF)
4 ON (In case of A06B–6089–H106, set switch OFF)
243
Interface of the Servo–Amplifier Unit Terminal Block

The following table lists the interface signals of the terminal box of
the servo amplifier unit.
Terminal No. Symbol Description Remarks
1 PE (G) Amplifier ground

2 L1 (R) AC power input
(200 to 230 VAC)
3 L2 (S)
4 L3 (T)
7 RL1 Point of contact relay for
8 RL2 dynamic brake.
9 U Outputs to an AC motor
10 V
11 W
12 G Motor ground
13 L1C Control power inputs L1 (R) and L1C, and L2 (S) and L2C are usually con-
14 L2C (200 to 230 VAC) nected(Note 1).
15 TH1 Thermostat input signals Usually connected(Note 2).

16 TH2
17 RC For a regenerative resistor RC and RI are usually connected(Note 3).
18 RI
19 RE
20 UL Output to an AC motor These terminals are not prepared for 1 axis servo amplifier
21 VL unit.
22 WL
23 GL Motor ground
24 FAN1 Power for the cooling fan in Provided only for A06B–6089–H106(Note 4).
the separate regenerative dis-
25 FAN2 charge unit
NOTE
1 These terminals are used to input the power for controlling the servo amplifier. L2 (S) and L1C, as well
as L3 (T) and L2C are usually connected. R–J controller controls the control and power sections
separately.
2 To use a transformer or a separate regenerative discharge unit, remove the jumper plate, then connect
the transformer or the overheat signal of the separate regenerative discharge unit between the TH1 and
TH2 terminals of the servo amplifier.
3 To use a separate regenerative discharge unit, connect it between the RC and RE terminals.
4 To use a separate regenerative discharge unit, connect the power pins of the cooling fan of the unit to these
terminals.
Type LED indication Description

Overvoltage alarm This alarm is issued when the DC voltage of the main circuit power supply unit is abnor-
(HV) mally high.
244
Control power supply This alarm is issued when the control power supply voltage is abnormally low.
undervoltage alarm
(LV)
DC link undervoltage This alarm is issued when the DC voltage of the main circuit power supply unit is abnor-
alarm (LVDC) mally low. This alarm is also issued when the circuit breaker has tripped.
Regenerative control This alarm is issued in any of the following cases:

circuit abnormality – When a very high regenerative discharge energy is output in a short time
alarm (DCSW) – When the regenerative discharge circuit is faulty
Excessive regenera- This alarm is issued in any of the following cases:

tive discharge alarm – When the average regenerative discharge energy is too high (for example, when the
(DCOH) frequency of acceleration/deceleration is too high)
– When a connected transformer is overheated
Dynamic brake circuit This alarm is issued when the relay contact for the dynamic brake has melted.
abnormality alarm
(DBRLY)
245

L–axis overcurrent This alarm is issued when an abnormally high current flows through the motor of the
alarm (HCL) L–axis.
M–axis overcurrent This alarm is issued when an abnormally high current flows through the motor of the
alarm (HCM) M–axis.
L/M–axis overcurrent This alarm is issued when an abnormally high current flows through the motors of the
alarm (HCLM) L–axis and M–axis.
L–axis IPM alarm This alarm is issued when the intelligent power module (IPM) of the L–axis detects an
(IPML) alarm.(*1)
M–axis IPM alarm This alarm is issued when the intelligent power module (IPM) of the M–axis detects an
(IPMM) alarm.(*1)
L/M–axis IPM alarm This alarm is issued when the intelligent power modules (IPMs) of the L–axis and M–axis
(IPMLM) detect an alarm.(*1)
Circuit breaker The circuit breaker is When an abnormal current exceeding the operating current of the circuit breaker flows,
set to off. the circuit breaker trips.
NOTE
1 The alarms detected by the IPM include:
– Overcurrent
– Overheat
– Decrease in IPM control power supply voltage
2 When the circuit breaker of the servo amplifier unit is set to
off, the DC link undervoltage alarm (LVDC) is issued.
246
In the normal operating mode, the seven–segment LED on the front of the
servo amplifier provides the indications below.
Amplifier not ready This indicates that the servo amplifier unit is not ready to drive the motor.
Amplifier ready This indicates that the servo amplifier unit is ready to drive the motor.
247
6. SETTING AND ADJUSTING
THE POWER SUPPLY MAINTENANCE B–80525E/04
6 SETTING AND ADJUSTING THE POWER SUPPLY
The power supply is factory-set for operation. Usually, the user need not
set or adjust it.
This chapter describes settings and adjustment required if a defective
power supply unit is replaced.
248
B–80525E/04 MAINTENANCE THE POWER SUPPLY
6.1
BLOCK DIAGRAM OF
THE POWER SUPPLY
Trans former Servo amplifier

210VAC Amplifier
Power input of Circuit
200 to 575VAC breaker 210VAC
Supply voltage to the transformer:

200 to 575 VAC
Power supply unit Robot
Fan
Motor
Brake
Pulse
Battery
coder

PC board
End
effector
Main CPU PC board
Process input/output
PC board
Teach pendant
Operator’s panel
Fig.6.1 (a) Block Diagram of the Power Supply (i cabinet)
249
Trans former Servo amplifier

200 to 575VAC breaker

200 to 575 VAC
Fan
Power supply unit

Robot
Motor
Brake
Pulse
Battery coder
End
PC board effector
Main CPU PC board
PC board
Teach pendant
Operator’s panel
Fig.6.1 (b) Block Diagram of the Power Supply (B–Cabinet)
250
Servo amplifier
Trans former Amplifier

200 to 575VAC breaker

200 to 575 VAC
Power supply unit

Robot
Fan
Motor
Brake
Pulse
coder
Emergency stop control End

PC board effector
Conversion printed
board
Main CPU PC board
PC board
Teach pendant
Operator’s panel
Fig.6.1 (c) Block Diagram of the Power Supply (S–900)
251
6.2 (i cabinet)
Select a transformer and tap according to the supply voltage. Select a
SELECTING transformer tap such that the supply voltage is +10% to –15% of the
TRANSFORMER induced voltage.
TAPS Supply voltage Specification Transformer specification
500 to 575 A80L–0026–0016
A05B–2350–H260
440 to 480 A80L–0024–0015
380 to 415 A80L–0026–0014
A05B–2350–H261
220 to 240 A80L–0024–0013
380 to 400 A80L–0026–0015
A05B–2350–H262
200 to 220 A80L–0024–0014
Transformer
Mounting locations of transformer
Voltage setting tap Core
Structure of transformer
252
Connect the tap according to the supply voltage.
(1) H260
Input voltage: 500–575V

Connect the cable from the circuit breaker to side A.
Input voltage: 440–480V
Connect the cable from the circuit breaker to side B.
(2) H261
Input voltage: 220–240

G1–L2, G2–L3, G3–L1
G1–G2–G3
(3) H262

G1–L2, G2–L3, G3–L1
G1–G2–G3
253
(B–cabinet)
Connect taps so that the supply voltage ranges from –15% to +10%,
relative to the tap voltage.
Transformer
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, S–6i,
M–16i, S–420, S–500, S–700, S–800, S–900, M–500i, M–400i, M–710i, A–520)
(S–450, M–410i)
Connection of taps on the primary coil Connectio

Supply voltage
L1 L2 L3 Connection line n type
220 7 15 23 7–24, 15–8, 23–16
240 6 14 22 6–24, 14–8, 22–16
380 7 15 23
415 6 14 22
460 5 13 21
Y
480 4 12 20 8–16–24
500 3 11 19
550 2 10 18
575 1 9 17
254
6.3 (a) Checking fuses F1 to F5

CHECKING THE LINE Check that the ratings of fuses F1 to F5 are as specified.
(b) Checking voltages
FILTER UNIT AND
When the line filter unit or transformer is replaced, check the
TRANSFORMER following voltages at the locations shown below. A high voltage is
applied to the line filter unit and transformer. Be careful not to touch
them when checking the voltages.
Voltages between terminals 1 and 3, 1 and 5, and 3 and 5 of
magnetic contactor ALC (voltages: 210 VAC, supplied to the
servo amplifier)
Voltage between terminals 43 and 44 of the terminal block
(voltage: 220 VAC, supplied to the control unit)
Voltage between terminals 41 and 42 of the terminal block
(voltage: 100 VAC, supplied to the servo amplifier)
Line filter unit

Transformer

255
Fig.6.3 (a) B–cabinet : ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i,
M–16i, S–420i, S–500, S–700, S–800, S–900, M–500, M–400i, M–710i, A–520i
(B–Cabinet : S–450, M–410i)
Transformer

AC reactor

Fig.6.3 (b) Checking the line unit and transformer
256
6.4 The power supply unit need not be set or adjusted.

CHECKING THE
Table 6.4 Rating of the Power Supply Unit
POWER SUPPLY
Maximum
UNIT Output Rated voltage Tolerance
rated current
Remarks
+5V +5V "3% 25.6A
+15V +15V "5% 0.5A
–15V –15V "5% 0.7A
+24V +24V "10% 2.0A
+24E +24E "10% 2.5A

Power supply unit : A16B–1212–0871
Figs. 6.4(a) and 6.4(b) show the interface and block diagram of the power
supply unit respectively.
257
THE POWER SUPPLY
F1 :
7.5A fuse for
Fig.6.4(a) Interface of the Power Supply Unit
AC input
MAINTENANCE
Battery cover
Battery
258
PIL :
Green LED for
indicating the AC
power supply status
ALM :
Red LED for
indicating an alarm
F4 :
5A fuse for +24E
F3 :
fuse for +24V
5A
(Slow blow) (After the battery
cover is removed)
B–80525E/04
Fig.6.4(b) Block Diagram of the Power Supply Unit
259
7. REPLACING A UNIT MAINTENANCE B–80525E/04
7 REPLACING A UNIT
In the case of the i–cabinet, the top covers can be removed from the
cabinet. Removing the top covers facilitates the replacement of units
during maintenance. The top covers are removed as follows:
Front top cover

Loosen the screws and remove the side brackets which secure the top
covers.
Open the door, then loosen the screws which secure the front top
cover (these screws are only finger–tight and do not require the use of
a tool to remove them).
Remove the front top cover.

260
B–80525E/04 MAINTENANCE 7. REPLACING A UNIT
Rear top cover

Loosen the screws and remove the side brackets which secure the top
covers.
Loosen the knurled screws and remove the rear louver.
Loosen the three knurled screws which secure the rear top cover.
Remove the rear top cover.
261
7.1 When replacing a printed circuit board, take the following precautions:
REPLACING A (a) Before starting replacement, check that the power of the control-
ler is locked and tagged out.
PRINTED CIRCUIT
(b) When removing the printed circuit board, do not touch semicon-
BOARD ductor components on it and do not let the components touch oth-
er components.
(c) Check that the printed circuit board to be installed is correctly set
and adjusted.
(d) If required, correctly adjust the printed circuit board after replace-
ment.
(e) When replacing the backplane printed circuit board, power sup-
ply unit, or main CPU printed circuit board (including the mod-
ules), the parameters and data specified for the robot may be lost.
Before starting replacement, store the data in a storage device
such as the FANUC Handy File.
(f) Connect the cables removed for replacement to the original posi-
tions. If the markings are complicated, write them down before
removing the cables.
CAUTION
There is a possibility of data loss when a backplane–mounted
printed circuit board is replaced. Be sure to back up all program
and setup data on a floppy disk before proceeding.
CAUTION
When either the power supply or main CPU printed circuit
boards are removed from the controller,the data storage
battery is disconnected. All boards must be reinstalled properly
within half an hour to avoid data loss.
7.1.1 Ordering codes: A05B-2316-C105 (3-slot backplane printed circuit

board)
Replacing the
A05B-2316-C107 (2-slot backplane printed circuit board)
Backplane Printed A05B-2316-C111 (5-slot backplane printed circuit board)
Circuit Board
(a) When replacing the backplane printed circuit board, remove the
entire rack. Remove the power supply unit and printed circuit
board following the procedure described in Section 7.1.2.
(b) Remove the ground cable from the backplane printed circuit
board.
(c) Loosen the two screws fastening the rack at the top. Then remove
the two screws fastening the rack at the bottom and replace the
rack.
262
Backplane
printed circuit
board
Nuts or screws (depending on the cabinet)
i cabinet M5 nuts A30L–0010–0050#M5

B cabinet M5 screws A6–SW2NA–5X12S
Fig.7.1.1 (a) Replacing the Backplane Printed Circuit Board
263
Main CPU P.C board
Battery
(A98L–0031–0012)
Fig.7.1.1 (b) Connection of Battery
264
7.1.2
Replacing the Power (a) Turn the power off and remove the cable from the power supply
Supply Unit or a unit or printed circuit board to be replaced.
Printed Circuit Board (b) Hold the handles at the top and bottom of the front panel of the
on the Backplane power supply unit or printed circuit board. The latches of the con-
trol unit rack are released. Holding the handles in this state, pull
Printed Circuit Board out the unit or printed circuit board.
(c) Insert a new power supply unit or printed circuit board into the
slot of the control unit rack. Carefully push it into the slot until
the front panel is latched at the top and bottom.
Name Ordering code

Power supply unit A16B-1212-0871
Main CPU printed circuit board A16B-3200-0040
Process input/output printed circuit
board A16B-2201-0470, 0472, 0480
Additional axis control printed cir-

cuit board A16B-2202-0820
Main CPU printed circuit board (NOTE1)
Power supply unit (NOTE2)

Precess input/output printed circuit board CA,
CB or DA or additional axis control printed
circuit board (If five slots are provided on the
backplane, the process I/O printed circuit
board and additional axis control printed circuit
board can be mounted simultaneously.)
Fig.7.1.2 Replacing the Power Supply Unit and Printed Circuit Board on the Backplane Printed Circuit Board
265
7.1.3 Specification : A16B–3200–0230

Replacing the (a) Open the operation box door, then disconnect the cables from the
process I/O EA process I/O printed circuit board.
printed circuit board (b) Remove the two M5 huts which secure the process I/O printed
circuit board, then replace the board.
M5 nut (x 2)
A30L–0010–0050#M5
7.2
REPLACING A (1) Move the latches at both ends of the module socket toward the
outside. The spring of the contact tilts the module. (See Fig. 7.2 (a).)
MODULE
(2) If the tilted module touches the next module, it may be difficult to
remove it. In this case, release the latches of the next module as
described in step (1) above.
(3) Now the module is free in the socket. Pull out the module carefully
in a straight line. Do not pull it out in an arc. The contact of the socket
or module may be damaged.
(4) Install a new module in the socket at an angle. Push it into the socket
until the bottom of the module reaches the bottom of the socket
groove. (See Fig. 7.2 (b).)
(5) Push the module in the top edge so that the module stands upright.
(See Fig. 7.2 (c).)
266
(6) Check that the module is latched properly at both ends of the socket.
If it is insufficiently latched, the electrical contact may be improper
and a malfunction may occur.
Fig.7.2 (a)
Pin 1
Fig.7.2 (b)
Fig.7.2 (c)
267
Fig.7.2 (d)
Mounting locations of the modules
CMOS module
Flush ROM module DRAM module
Main CPU printed

circuit board
Fig.7.2 (e) Mounting locations of the modules
Name Specification
Axis module A20B–2902–0060 or
A20B–2902–0070
Flush ROM module A20B–2902–0370
A20B–2902–0371
A20B–2902–0372
A20B–2902–0373
DRAM module A20B–2902–0021
A20B–2902–0020 or A20B–2902–0531
A20B–2900–0650 or A20B–2902–0530
CMOS module A20B–2902–0211
A20B–2902–0210
A20B–2902–0380
268
7.3 To replace the distributed I/O (Model B) interface unit, perform the
following steps:
REPLACING THE I/O
UNIT MODEL B Unplug the cables from the upper left corner of the interface module.
INTERFACE UNIT Unplug the cables from the bracket of the interface module adapter
plate.
Remove the nuts holding the interface module adapter plate to the
controller wall and remove the plate from the controller.
Disconnect the wiring harness from the interface unit. If
necessary,mark the wires so that they can be connected to the new
unit in the proper places.

Remove the nuts holding the interface module to the adapter plate
and remove the module from the plate.
Install the new interface module by performing these steps in reverse
order.
Mounting location of I/O unit model B interface unit

(i cabinet)
Mounting hole
I/O unit model B interface unit

(with metal mounting plate)
Fig.7.3 (a) Replacing I/O unit MODEL B Interface unit
269
I/O unit model B

interface unit
I/O unit model B

basic unit
Mounting location of I/O unit model B (B–cabinet)
I/O unit model B

interface unit
I/O unit model B

basic unit
Mounting location of I/O unit model B (Cabinet for M–410i)
Fig.7.3 (b) Replacing I/O unit MODEL B Interface unit
270
7.4
REPLACING THE
INPUT/OUTPUT UNIT
OF MODEL A
7.4.1
Replacing the Base Remove the I/O modules from the base unit.
Unit of the Loosen the upper two mounting screws.
Input/Output Unit of
Remove the lower two mounting screws and replace the base unit.
Model A
Ordering code: A03B–0807–J002
Fig.7.4.1 Replacing the Base Unit of the Input/Output Unit of Model A
271
7.4.2 An interface module and input/output module can be easily installed in

Replacing a Module and removed from the base unit, as described below.
Removing the Interface
Module Turn off and lock out the controller.
Disconnect the signal and power cables from the interface module.
Press the latch on the bottom of the module and rotate the module
toward you and up.
Installing the Interface
Module Turn off and lock out the controller.
Engage the hook at the top rear of the module with the bar above the
base unit socket.
Rotate the module downward until the latch engages.
Reconnect the signal and power cables to the interface module.
Removing an I/O Module
Turn off and lock out the controller.
Remove the wiring harness block.(See Fig.7.4.2.)
(a) Lift the latch at the lower left corner of the module window.
(b) Rotate the block toward you and down.
press the latch on the bottom of the module and rotate the module
toward you and up.(See Fig.7.4.2.)
Installing an I/O Module
Engage the hook at the top read of the module with the bar above the
base unit socket.
Rotate the module downward until the latch engages.
Fig.7.4.2 Replacing the module

272
7.5 To remove a distributed I/O (Model B) unit mounted on a DIN

rail,perform the following steps:
MOUNTING I/O UNIT
MODEL B ON THE
DIN RAIL (USE A RAIL
THAT IS 3.5MM WIDE
AND 7.5MM HIGH.)
7.5.1
The DIN Rail is in the Disconnect the wiring harness from the unit. If necessary,mark the
Operator’s Box. wires so that they can be connected to the new unit in the proper
places.
Remove the screws holding the retainer plates to the unit and remove
the retainer plates.
Slide the unit upward and lift it out of the DIN rail.
Metal support for direct installation

DIN rail or installation on the DIN rail
(b) (b)
Basic unit
(a) (a)
Metal support for installation on the DIN rail
To install a distributed I/O(Model B)unit mounted on a DIN rail,perform

the following steps:
Hook the lower tabs of the I/O unit mounting brackets over the lower
lip of the DIN rail.
Lay the I/O unit in the DIN rail.
Slide the I/O unit downward. The upper tabs of the mounting
brackets will engage the upper lip of the DIN rail.
Position the retainer plates over the mounting brackets and install the
screws.

Reconnect the wiring harness.
273
7.6 (i cabinet)
Ordering code
REPLACING THE
Ordering code
TRANSFORMER Supply voltage Machine
for transformer
ARC Mate 100, ARC Mate 120,
ARC Mate 120i, S−6, S−12,
500 to 575 A80L−0026−0016
M−16i, S−420i, S−500, S−700,
A−520i, S−710i, M−400i
440 to 480 M−410i A80L−0026−0016#B
ARC Mate 100i, M−6i A80L−0024−0015
380 to 415 A80L−0026−0014
M−16i, S−420i, S−500, S−700,
A−520i, M−710i, M−400i
220 to 240 M−410i A80L−0026−0014#B
ARC Mate 100i, M−6i A80L−0024−0013
380 to 400 A80L−0026−0015
M−16i, S−420i, S−500, S−700,
A−520i, M−710i, M−400i
200 to 220 M−410i A80L−0026−0015#B
ARC Mate 100i, M−6i A80L−0024−0014
Supply voltage Machine Ordering code

for line filter
200 to 220 ARC Mate 100i, M−6i A81L−0001−0137
Lock out and tag out power to the robot.

Disconnect the cables connecting the controller to the robot.
Remove the controller cabinet from the robot using the quick change
procedure described in Section 4.10.
WARNING
Support the front module of the controller before disengaging
the latches. Otherwise,the module could fall and injure
personnel and damage equipment.
Remove the front module of the controller by disengaging the four

latches.

Disconnect the cable from the voltage setting tap.
Remove the voltage setting tap and its plate from the cabinet.
Remove the nuts securing the transformer.
Remove the transformer.
274
Transformer
Fig.7.6 (a) Mounting location of transformer (1/2)
Voltage setting tap M6 nut and ground washer
M6 nut
Fig.7.6 (a) Mounting location of transformer (2/2)
(B cabinet)
Table7.6 Specifications of Line Filter Unit and Transformer (B cabinet)
Unit Applicable robot model Specification No.

All models A81L–0001–0128
S–800, M–500 A81L–0001–0112
Line filter unit
S–450 A81L–0001–0130
M–410i (B–cabinet) A81L–0001–0129
A80L–0026–0010#D
S–420i, S–500 or
M–710i, M–400i A80L–0026–0013#B
(Note1)
ARC Mate 120, S–700,
S–12, A–520i,
A80L–0024–0010#F
Transformer ARC Mate 100i, ARC Mate
120i, M–6i, M–16i
ARC Mate 100, S–6 A80L–0022–0007#D
S–800, M–500 A80L–0026–0010#A
S–450 A80L–0026–0018
M–410i (B–cabinet) A80L–0026–0017
275
Unit Applicable robot model Specification No.

A81L–0001–0112 (Main cabinet)
Line filter unit S–900 (Note2) A81L–0001–0116
(Additional cabinet)
A81L–0026–0010#A
(Main cabinet)
Transformer S–900 (Note2)
A81L–0024–0011
(Additional cabinet)
NOTE
1 Input voltage: 220, 380, 400, 415, 460, 480, 500, or 575 V for
A80L–0026–0010#D
220, 380, 480, or 575 V for A80L–0026–0013#B
2 In case of S–900, Line filter unit or Transformer is installed in
both of Main locker and Additional locker.
Specifications: See Table 7.6.

Remove the acrylic covers from the transformer and ALC relay.
Disconnect the wiring harnesses and ground wire from the
transformer.
Disconnect the three wires from the bottom of the ALC relay.

After removing the eight screws fastening the transformer,remove
the transformer. Put a new transformer on the rail in the controller and
push it into the controller along the rail. Then reinstall the screws.
Reconnect the wires and harnesses.
Reinstall the acrylic covers.
Eight M5 mounting screws
Fig.7.6 (b) Replacing the Line Filter Unit or Transformer

276
7.7 For ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i,
S–6, S–12, M–6i, M–16i, S–420i, S–500, S–700, M–400i, M–710i,
REPLACING A A–520i
SERVO AMPLIFIER Ordering code : A06B–6076–H001 to H005 or A06B–6076–H101 to
H106
Disconnect all wires,cables,and harnesses from the servo amplifier.
If necessary,mark each wire,cable,and harness so that it can be
correctly connected to the new servo amplifier when it is installed.
Remove the four mounting nuts from the servo amplifier.
Lift the servo amplifier off of the studs and out of the cabinet.
277
For S–450 or M–410i

Remove the mounting screws from the servo amplifier.
Remove the servo amplifier from the cabinet.
Power supply module Servo module (1) Servo module (2)
Power supply module

Robot model Drawing No.
M–410i A06B–6087–H115
S–450 A06B–6077–H111
Servo module (1)

M–410i A06B–6079–H106
S–450 A06B–6079–H206
A06B–6079–H207
278
Servo module (2)

M–410i A06B–6079–H103
S–450 A06B–6079–H101 or
A06B–6079–H104
For S–800, S–900, M–500

Remove the mounting screws from the servo amplifier.
Remove the servo amplifier from the cabinet.
A06B–6066–H008 A06B–6066–H006
A06B–6089–H106 A06B–6089–H104
A06B–6089–H105
A06B–6089–H206
A06B–6089–H208
279
7.8 Ordering code : See follwing table

REPLACING THE (a) Open the door of the operator box and remove the clamp plate
from the cable inlet. (two M4 screws)
OPERATOR’S BOX
(b) Disconnect all cables from the operator box and replace the oper-
ator box.
(c) To replace only the operator box printed circuit board, replace it
together with its mounting plate.
(d) Disconnect the cable from the operator box printed circuit board,
remove the four nuts securing the metal plate, then replace the
operator box printed circuit board.
Table Operator’s Box
Specifications Indications in Remarks
A05B–2350–C029 English I/O Unit Model A and Model B can be mounted.
A05B–2350–C023 I/O Unit Model B can be mounted.
Japanese
A05B–2350–C026 I/O Unit Model A and Model B can be mounted.
A05B–2350–C037 English Only for ARC Mate 100i
A05B–2350–C038 Japanese Only for ARC Mate 100i
Operator’s box (option)
M5 nuts (4pieces)
A30L–0010–0050#M5
280
Replacing the operator’s panel

Specifications: A05B–2351–C020 (panel with Japanese legends)
A05B–2351–C021 (panel with English legends)
(a) Disconnect the cable connected to the operator panel
(b) Remove the six nuts securing the panel, then replace the panel.
(c) When only the operator–panel printed circuit board is to be re-
placed, replace it together with the attached metal sheet.
(d) Disconnect the cable connected to the operator–panel printed cir-
cuit board. Remove the four nuts securing the metal sheet, then
replace the board.
Operator’s panel (rear)
Four M4 nuts
A30L–0010–0050#M4
281
7.9 Ordering code: See Table 7.9.

REPLACING THE After removing the cable from the teach pendant, replace the teach
pendant.
TEACH PENDANT
Fig.7.9 Replacing the Teach Pendant
Table7.9 Ordering Codes for the Teach Pendants

Ordering code Use Remarks
A05B-2301-C300 Spot welding English
A05B-2301-C301 Material handling
A05B-2301-C302 Arc welding
A05B-2301-C303 Sealing
A05B-2301-C305 General use
A05B-2301-C310 Spot welding Japanese
A05B-2301-C311 Material handling
A05B-2301-C312 Arc welding
A05B-2301-C313 Sealing
A05B-2301-C315 General use
282
7.10 Ordering code: A90L-0001-0378 (for a two–slot rack, one for one unit)
A90L–0001–0385#A (for a one–slot rack, two for one unit)
REPLACING THE
(1) Replace the control unit printed circuit board placed below the fan
FAN MOTOR OF THE motor to be replaced, following the procedure described in Section
CONTROL UNIT 7.1.2.
(2) The cable suspended from the fan motor is connected to the backplane
printed circuit board which is mounted deep in the slot. Holding the
connector, remove the cable from the backplane printed circuit board.
(3) Open the lid at the top of the control unit rack. The lid can be opened
by placing the tip of a flat-blade screwdriver into the center hole at the
front of the lid and moving the screwdriver like a lever in the direction
of (3) in Fig. 7.9 to release the latch.
(4) Fully open the lid and take the fan motor out. As the fan motor is not
screwed to the rack, it can be removed easily.
(5) Install a new fan motor. Suspend the cable through the hole at the
back of the rack.
(6) Close the lid until it is latched.
(7) Connect the cable of the fan motor to the connector on the backplane
printed circuit board. Suspend the center of the cable on the hook in
the back of the rack.
(8) Install the removed control unit printed circuit board following the
procedure described in Section 7.1.2.
283
(3)
(4)
Fan motor
Cable
Connector
Back plane
Fig.7.10 Replacing the Fan Motor
284
7.11 When a fuse inside the control unit has blown, troubleshoot, take a proper
corrective action, and replace the fuse.
REPLACEMENT OF
FUSES
7.11.1 F1, F2, F3: Fuses for input voltage

Transformer, line filter F4, F5: Fuses for 100 VAC
unit Fuse No. Model Rating Specification
F1, F2, F3 ARC Mate 120, S–12, S–420i,
S–500, S–700, S–800, S–900,
M–710i, ARC Mate 100i, ARC Mate 30A A60L–0001–0358#JSIF–30
120i, M–6i, M–16i, S–450, M–410i,
M–500, M–400i
ARC Mate 100, ARC Mate 100i,
20A A60L–0001–0042#JSI–20
S–6
F4, F5 S–420i, S–500, S–800, ARC Mate
120, ARC Mate 120i, S–12, S–700,
S–900 ARC Mate 100i, M–6i, 5A A60L–0001–0101#P450H
M–16i, M–710i, M–500, M–400i,
S–450, M–410i
ARC Mate 100, S–6, A–520i 3.5A A60L–0001–0101#P435H
(B–cabinet: ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500, S–700, S–900,
S–800, M–500, M–710i, A–520i) Fuse Fuse Fuse
Fuses
Transformer
Line filter
(B–cabinet: S–450, M–410i)
Fuse Fuse Fuse Fuse
Transformer AC reactor
285
NOTE
Turn off the main breaker before replacing a fuse.
Fig.7.11 Replacing Fuses on Transformer/Line Filter Unit
If a fuse blows in the control unit, examine the cause and take action to
eliminate the cause. Then replace the fuse.
7.11.2 FUSE1 : For detecting a ground on the thermostat

F1, F2 : For protecting a servo amplifier internal circuit
Servo Amplifier
Fuse No. Rated current Ordering code
FUSE1 0.3A A60L–0001–0175#0.3A
F1, F2 2A A60L–0001–0245#GP20
Fuse1
Fuse F1 Fuse F2
Fig.7.11.2 Replacing a fuse
286
Power supply module

F1 : Fuse for AC input
F1 2A A60L–0001–0295
F2 2A A60L–0001–GP20
7.11.3
Replacing Fuses (1) Make sure that the recharge–under–way LED (red) is off.
The recharge–under–way LED (red) is at the center of terminal board
TB1. Open the cover at the top of the module, and check the LED.
For M–410i
TB1 Recharge–under–way LED
For S–450
Recharge–under–way LED
(2) Remove the face plate.
287
For M–410i Face plate
Remove the face

plate by inserting
the tip of a flat–
blade screwdriv-
er at the hooks
(six) on the face
plate.
For S–450 Face plate
Remove the
face plate by
inserting the
tip of a flat–
blade screw-
driver at the
hooks (four)
on the face
plate.
(3) Remove connector PCB.
For M–410i
Remove the self–tapping screws holding
down connector PCB, and shift it in the direc-
tion indicated with an arrow (left) to remove
the printed–circuit board.
Connector PCB
288
(4) Remove the case
For M–410i
Screws (eight) Flange surface
Remove the screws

(eight) fastening the
Fan cases, and remove
the case by pulling it
off the flange sur-
Heat face.
sink Case
For S–450

Case 1 Case 2
(chassis) (cover)

Remove the screws fastening

the case and the screws (5 x
M4) holding down the terminal
board.
(5) Replace the fuses according to the figure below.
F1
Fig. 7.12 Locations of the Fuses
289
Servo module
F2 3.2A A60L–0001–0290#LM32C
F2 : For control power supply
Fuse2
290
Servo amplifer
F1 Fuse for control power supply
Specification A60L–0001–0175#3.2A (A06B–6066–H006)–,
A60L–0001–0359 (A06B–6089–H104,
H105, H106, H206, H208)
F2, F3 Fuse for Fan motor (A06B–6066–H008 only)
Specification A60L–0001–0101# P405H
F2 Fuse for Fan motor (A06B–6089–H106 only)
Specification A60L–0001–0359
(A06B–6066–H008)
Fuse F1
Fuse F1
Fuse F2 F3
(A06B–6089–H106)
F1
F2
291
7.11.4 F1 : Fuse for AC input

Power Supply Unit F3 : Fuse for +24V
F4 : Fuse for +24E
F1 7.5A A60L−0001−0245#GP75
F3 5A A60L−0001−0075#5.0
F4 5A A60L−0001−0046#5.0
F1 : 7.5A
fuse for AC input
F3 : 5AS (slow–blow)
fuse for +24V
F4 : 5A
fuse for +24E
Fig.7.11.4 Power Supply Unit
292

F1 : Fuse for brake power supply
F2 : Fuse for +23E
F1 5A A60L−0001−0046#5.0
F2 0.32A A60L−0001−0046#0.32
Fuse2
Fuse1
293

FUSE : Fuse for brake power supply
FUSE 5A A60L−0001−0046#5.0
Fuse
294
7.11.5 FUSE1 : 2.0-A fuse for +24V

Process Input/Output Ordering code : A60L-0001-0046#2.0
Printed Circuit Boards
CA, CB, DA and EA
Fuse
printed circuit board CA, CB, and DA
Fuse
Process input/output printed circuit board EA
Fig.7.11.5 Replacing the Fuse of the Process Input/Output Printed Circuit

Board CA, CB, or DA
295
7.12 If used for a long time, a relay’s contacts may fail to provide a satisfactory
connection or may weld together. If this occurs, replace the relay as
REPLACING A described below:
RELAY printed circuit board for emergency stop control
RLY2 : To disconnect the MCC in the event of an emergency
stop
Ordering code : A58L–0001–0192#1509A
RLY6 : To disconnect the standby charging line in the event
of an emergency stop
Ordering code : A58L–0001–0422#3232K
Relay
Fig.7.12 Printed Circuit Board for emergency stop board
296
Emergency–stop control printed circuit board

RL1: Used for cutting off the reserved charging power (200 VAC)
upon an emergency stop
RL2: Used for cutting off MCC (200 VAC) upon an emergency stop
RL3: Used for cutting off the brake power (100 VAC) upon an
emergency stop
RL4, RL5, and RL6: Used for controlling the brake
Fuse No. Ordering code
RL1 A58L−0001−0422#3232K
RL2 A58L−0001−0192#1509A
RL3, RL4, RL5, RL6 A58L−0001−0192#1472R
Relay
297
Conversion printed circuit board (S–900) A16B–1212–0910
Relay
RL1 : For control brake

Ordering number A58L–0001–0192#1472R
298
7.13
REPLACING THE (1) Use a lithium battery (ordering drawing number: A98L-0031-0012).
(2) Turn on the R-J2. (The battery can be replaced when the power is
BATTERY
turned on and off. If the power is turned off, the battery must be
replaced within 30 minutes. If the power is turned off and the battery
is removed for 30 minutes or more, the contents of the memory on the
main CPU printed circuit board may be lost.)
(3) Remove the battery case from the front panel of the power supply
unit. The case can be removed easily by holding the top and bottom
of it and pulling.
Front panel of the

power supply unit
Battery case
ÏÏ
ÏÏÏÏ
Battery
(ordering drawing number : A98L–0031–0012)
Fig.7.13 (a) Replacing the Battery (1)
(4) Remove the connector from the battery.
BATTERY Cable connector
ÏÏÏÏ
ÏÏÏ
ÏÏÏÏÏ Battery
printed circuit panel of the

power supply unit
Fig.7.13 (b) Replacing the Battery (2)
(5) Replace the battery and reconnect the connector.

(6) Install the battery case.
(7) Turn off the R-J2.
299
III CONNECTIONS
Page2
III CONNECTIONS
B–80525E/04 CONNECTIONS 1. GENERAL
1 GENERAL
This section describes the electrical interface connections in the R-J2. It

also includes information about installation of the R-J2.
303
2. BLOCK DIAGRAM CONNECTIONS B–80525E/04
2 BLOCK DIAGRAM
Fig. 2 is a block diagram of electrical interface connections with the R-J2.
R-J2
Pneumatic pressure source
Mechanical unit End effector
Teach pendant (Note 4)

Operator’s box
or
operator’s panel (RS-232-C) (Note 2)
FANUC Handy File
Peripheral device A
Peripheral device B
Welder
(RS-232-C) (Note 3)
(RS-422/485) (Note 3)
AC power source
(Note 1) : Indicates electrical connection.

: Indicates mechanical connection.
(Note 2) A remote display is connected.
For more information, contact our service section.
(Note 3) Optional RS–232–C or RS–422/485 interface.
(Note 4) The teach pendant can be connected in either of two ways:
1. Through the operator’s box (I–cabinet)
2. Directly to the control unit (B–cabinet)
Fig.2 Block Diagram of Electrical Interface Connection
304
B–80525E/04 CONNECTIONS 3. ELECTRICAL CONNECTIONS
3 ELECTRICAL CONNECTIONS
3.1
CONNECTION Fig. 3.1 (a) and 3.1 (e) show mechanical connection diagrams.
DIAGRAM BETWEEN
MECHANICAL UNITS
R–J2 Robot
CRF3 Pulse coder

(Pulse coder signal) J1/J2/J3
CRF4 Pulse coder

(Pulse coder signal) J4/J5/J6
Motor power
J1
Motor power
J2/J3
Servo amplifier
terminal frame
Motor power
J4/J5/J6
CN6
Motor brake
(Brake control)
CRM11
Limit switch
(ROT)
CRM10
End effector
(RDI/RDO)
(Note) This cable is not included. It must be supplied by the customer.
Fig.3.1 (a) Mechanical Connection Diagram (i cabinet:ARC Mate100, ARC Mate120, ARC Mate 100i, ARC Mate 120i, S–6,
S–12, M–6i, M–16i, S–420i, S–500, S–700, M–400i, M–710i, A–520i)
305
3. ELECTRICAL CONNECTIONS CONNECTIONS B–80525E/04
Robot
Pulse coder
End effector
(Pulse coder signal)
Note 1
Servo amplifier Motor power M1

terminal
Motor brake
terminal
(Brake control)
Welder
Note 2
(Note 1) This cable is not included. It must be supplied by customer.

(Note 2) It is able to connect for S–500 and S–700.
Fig.3.1 (b) Mechanical Connection Diagram (B cabinet : S–420i/S–450/S–500/S–700/S–800/S–900/M–400i/M–710i)
Robot
Pulse coder
End effector
Note 1

terminal
Motor brake
(Brake control)
Welder
Note 2
(Note 1) This cable is not included. It must be supplied by customer.

(Note 2) It is able to connect for ARC Mate100, ARC Mate120 and ARC Mate 100i.
Fig.3.1 (c) Mechanical connection Diagram

(B cabinet : S–6/S–12/ARC Mate100/ARC Mate120, ARC Mate 100i/M–6i, ARC Mate 120i/M–16i, A–520i)
306
Robot
Pulse coder
End effector
Note 1
Limit switch
Motor power J1
Motor power J2
Servo amplifier
terminal frame
Motor power J3
Motor power J4
Motor brake
(Brake control)
(Note 1) This cable is not included. It must be supplied by the customer.
Fig.3.1 (d) Mechanical Connection Diagram (M–410i)
307
Robot
Pulse coder
End effector
Note 1

terminal frame
Motor brake
terminal frame
(Brake control)
(Note 1) This cable is not included. It must be supplied by the customer.
Fig.3.1 (e) Mechanical Connection Diagram (M–500)
308
R–J2
CRS1
(Main CPU) Teach pendant
TEACH PENDANT
(Operator’s box) (Note 1)
CRM2 (Note 2)
Peripheral device
(Process I/O)
Port 1 (Note 3) FANUC

(Operator’s box Handy File
or operator’s panel)
JD17 (Note 4, Note 5)

External device
(Main CPU)
U
Disconnect switch V
W Input power
or Braker G
PC board EX–ON (Note 4) External power

for operator’s box EX–COM
(TBOP2) EX–OFF ON/OFF swich
PC board EMGIN1 (Note 4) External emergency

for operator’s box EMGIN2 stop swich
(TBOP1)
(Note 1) The teach pendant can be connected in either of two ways:

1. Through the operator’s box or operator’s panel
2. Directly to the control unit
(Note 2) For more information about connection of peripheral devices,
see the description of the peripheral device interface in this manual.
(Note 3) This cable is provided with the FANUC Handy File.
(Note 4) Not included. Must be supplied by the customer.
(Note 5) For details of connecting on external device interface to enable expansion, refer to
the section explaining on external device interface.
Fig.3.1 (f) Mechanical Connection Diagram
309
3.2
EXTERNAL CABLE
WIRING DIAGRAM
3.2.1
Robot Connection (In case of combined type ARC Mate 100i, M–6i, S–420i, M–710i)
Cables
ARC Mate 100i, M–6i,
M–710i, S–420i
Pulse coder
RDI/O.HBK
Motor power/
brake
310
Details of cable connection to the servo amplifier
R–J2
Robot
PC board for
PC board for ARC Mate 100i,
AMP emergency
main CPU ARC Mate 120i,
stop control M–6i, M–16i,
S–420i, M–710i
5U 6U CRF3
5V 6V
5W 6W
CN6 CRM10 CRF4
3U 4U G
3V 4V G
3W 4W G
1U 2U G
1V 2V G
1W 2W G
Pulse coder
J1/J2/J3
J4/J5/J6
RDI/O.HBK
Motor brake
White Motor power
J1M
Black
J2M
Green
J3M
White J4M
Black J5M
Green J6M
Note) The motor power cables have connectors of different colors to

prevent incorrect connection.
Connector name Color

J1M White
J2M Black
J3M Green
J4M White
J5M Black
J6M Green
Fig.3.2.1 (a) Robot Connection Cables

(Combined type ARC Mate 100i, ARC Mate 120i, M–6i, M–16i, S–420i, M–710i)
311
(In case of separate type S–420i, M–710i)
Emergency
stop control
Robot S–420i, M–710i
Pulse coder
RP1
Motor power/brake
RM1
RM2
Main CPU PC board

CRM10
Servo amplifier
CN6
312
R–J2 Robot S–420i, M–710i

PC board for
AMP PC board for
emergency
main CPU stop control
Pulse coder
RP1
(Pulse coder, RDI/RDO
HBK, ROT)
Motor power/brake
RM1
RM2


J1M White
J2M Black
J3M Green
J4M White
J5M Black
J6M Green
Fig.3.2.1 (b) Robot Connection Cable (Separate type S–420i, M–710i)
313
(In case of separate type S–6, S–12, ARC Mate100, ARC Mate120, ARC
Mate 120i, ARC Mate 100i, M–6i, M–16i)
PC board for emergency

stop control
Robot
S–6
S–12
M–16i
ARC Mate 100
ARC Mate 120
ARC Mate 100i
ARC Mate 120i
Pulse coder
RP1
Motor power/brake
RM1
Main CPU PC board

CRM10
Servo amplifier
CN6
314
R–J2 Robot
PC board for S–6
AMP (6–axis amplifier) PC board for
emergency S–12
main CPU stop control ARC Mate 100
ARC Mate 120
ARC Mate 120i
ARC Mate 100i
M–6i
M–16i
Pulse coder
RP1
HBK, ROT)
Motor power/brake
RM1


J1M White
J2M Black
J3M Green
J4M White
J5M Black
J6M Green
Fig.3.2.1 (c) Robot Connection Cable

(Separate type S–6, S–12, ARC Mate100, ARC Mate120, ARC Mate 100i, ARC Mate 120i, M–6i, M–16i)
315
(In case of separate type S–500)
Emergency stop
control PC board
Robot S–500
Pulse coder
RP1
Motor power/brake
RM1
RM2
Main CPU PC board

CRM10
Servo amplifier
CN6
316
R–J2 Robot S–500

PC board for
emergency
Pulse coder
RP1
HBK, ROT)
Motor power/brake
RM1
RM2


J1M White
J2M Black
J3M Green
J4M White
J5M Black
J6M Green
Fig.3.2.1 (d) Robot Connection Cable (Separate type S–500)
317
(In case of separate type S–700)
Emergency stop
control PC board
Robot S–700
Pulse coder
RP1
Motor power/brake
RM1
RM2
Main CPU PC board

CRM10
Servo amplifier
CN6
318

PC board for
emergency
Pulse coder
P1
HBK, ROT)
Motor power/brake


J1M White
J2M Black
J3M Green
J4M White
J5M Black
J6M Green
Fig.3.2.1 (e) Robot Connection Cable (Separate type S–700)
319
(In case of B cabinet/S–420i, M–710i)
Amplifier
CN6
Emergency stop control PC board

CRF1
CRM11
Main CPU PC board

CRM10 Robot S–420i, M–710i
Motor
power/brake
RM1
RM2
Pulse coder
RP1
R–J2 Robot S–420i, M–710i
PC board for PC board for

AMP (6–axis amplifier) emergency
Pulse coder
RP1
HBK, ROT)
Motor power/brake
RM1
RM2
Fig.3.2.1 (f) Robot Connection Cable (B cabinet/S–420i/M–710i)
320
(In case of B cabinet S–6, S–12, ARC Mate100, ARC Mate120, ARC
Mate 100i, ARC Mate 120i, M–6i, M–16i)
Amplifier
CN6
CRF1
CRM11
Main CPU PC board Robot S–12, ARC Mate 100,

CRM10 ARC Mate 120, S–6, ARC Mate
100i, ARC Mate 120i, M–6i,
M–16i
Motor
power/brake
Pulse coder
R–J2 Robot
PC board for S–6
PC board for S–12
ARC Mate 100i,

ARC Mate 120i,
M–6i, M–16i
Pulse coder
RP1
HBK, ROT)
Motor power/brake
RM1
Fig.3.2.1 (g) Robot Connection Cable

(B cabinet/S–6, S–12, ARC Mate100, ARC Mate120, ARC Mate 100i, ARC Mate 120i, M–6i, M–16i)
321
(In case of B cabinet/S–500)
Amplifier
CN6

CRF1
CRM11
Main CPU PC board

CRM10
Robot S–500
Motor
power/brake
RM1
RM2
Pulse coder
RP1


Pulse coder
RP1
HBK, ROT)
Motor power/brake
RM1
RM2
Fig.3.2.1 (h) Robot Connection Cable (B cabinet/S–500)
322
Amplifier
CN6
Emergency stop
control PC board
CRF1
CRM11
Main CPU PC board

CRM10
Robot S–700
Motor
power/brake
RM1
RM2
Pulse coder
RP1

Pulse coder
RP1
HBK, ROT)
Motor power/brake
RM1
RM2
Fig.3.2.1 (i) Robot Connection Cable (B cabinet/S–700)
323
Emergency stop
Servo module5 control PC board
CRR5, CRM11
Servo module4
Servo module3
Main CPU PC board Robot S–800
Servo module2 CRM10
Servo module1
Motor power/brake
Pulse coder
Power supply module

Servo module PC board for PC board for
emergency
1 2 3 4 5 main CPU stop control
Pulse coder

HBK, ROT)
Motor power/brake
324
Fig.3.2.1 (j) Robot Connection Cable (S–800)
AMP6
AMP5
Main CPU PC board

CRM10
Conversion PC board
CRR5
Emergency stop
control PC board
CRF3, CRF4, CRM11
AMP4
AMP3
Robot
AMP2 S–900
AMP1
RM1
RM2
RM3
RBK
RP1
Robot
PC board PC board for S–900
Conversion
AMP1 AMP2 AMP3 AMP4 AMP5 AMP6 for main
PC board
emergency
CPU stop control
RP1
RBK
RM1
RM2
RM3
Fig.3.2.1 (k) Robot Connection Cable (B cabinet/S–900)
325
(In case of M–410i)

Servo module4
Servo module3
Servo module2
Servo module1
Robot M–410i
Motor power/brake
Pulse coder
Emergency stop
control PC board
CRR5
CRM11
CRF1
Main CPU PC board CRM10
R–J2 Robot M–410i

emergency
1 2 3 4 main CPU stop control
Pulse coder
326
Fig.3.2.1 (l) Robot Connection Cable (B cabinet/cabinet for M–410i)

(In case of B cabinet/M–500)
Emergency stop
Servo amplifier2 control PC board
CRR5, CRM11
Servo amplifier1
Main CPU PC board Robot M–500

Servo amplifier4 CRM10
Servo amplifier3
Motor power/brake
Pulse coder
Power supply module
R–J2 Robot M–500

emergency
1 2 3 4 main CPU stop control
Pulse coder

HBK, ROT)
Motor power/brake
Fig.3.2.1 (m) Robot Connection Cable (B cabinet/M–500)
327
(In case of A–520i)

CRF3
CRF4
CRM11 Robot A–520i
Pulse coder
Motor power/brake
Main CPU PC board

CRM10
Servo module CN6

R–J2 Robot A–520i
AMP emergency
Pulse coder
Motor power/brake
Note) Each connector used for a motor power cable has a different color for protection against wrong connection.
Connector Color Connector Color
White White
Black
Green
Fig.3.2.1 (n) Robot Connection Cable (B cabinet/A–520i)

328
(In case of Separate type A–520i)

CRF3
CRF4 Robot S–420i
CRM11
Pulse coder
Motor power/brake
Main CPU PC board

CRM10
Servo module CN6
AMP emergency
Pulse coder
HBK, ROT)
Motor power/brake
Each connector used for a motor power cable has a different color for protection against wrong connection.
White White
Black
Green
Fig.3.2.1 (o) Robot Connection Cable (Separate type A–520i)
329
(In case of A–520i)
Amplifier
CN6
Emergency stop
control PC board
CRF1
CRM11
Main CPU PC board

CRM10
Robot A–520i
Motor
power/brake
Pulse coder

Pulse coder
RP1
HBK, ROT)
Motor power/brake
Fig.3.2.1 (p) Robot Connection Cable (B cabinet/A–520i)

330
(In case of Separate type M–400i)

FAN4 terminal Emergency stop control printed board
unit A, B CRF3
CRF4 Robot M–400i
CRM11
Pulse coder
RDI/RDO
HBK
ROT
Motor
power/brake
Main CPU printed

board CRM10
Servo amplifier CN6
Detail of cable connection to the servo amplifier

Main CPU Emergency FAN4
AMP printed stop control Terminal
board printed board
Pulse coder
RP1
HBK, ROT)
Motor power/brake
RM1
(J3M, J4M, J5M, BK,
Fan)
RM2
(J1M, J2M)
Note) Each connector used for a motor power cable has a different color for protection against wrong connection.
White White
Black Black
Green
Fig.3.2.1 (q) Robot Connection Cable (Separated type M–400i)

331
(In case of B–cabinet/M–400i)
Amplifier Power supply unit

CN6 CP3
Emergency stop
control printed board
CRF1
CRM11

CRM10
Robot M–400i
Motor
power/brake
Pulse coder
RDI/RDO
HBK
ROT

Main CPU Emergency Power
Amplifier (6–axis amplifier) printed of stop control supply
board printed board unit
Pulse coder
RP1
HBK, ROT)
Motor power/brake
RM1
(J3M, J4M, J5M, BK,
Fan)
Fig.3.2.1 (r) Robot Connection Cable (B cabinet/M–400i)

332
(In case of S–450 (B–cabinet))

Servo module 1
Servo module 2
Servo module 4 CRR5
CRM11
CRF1

CRM10
Additional axis control Robot S–450

printed board
JF7
Motor power/
brake
Pulse coder

Servo module Main CPU Emergency stop Additional
printed control printed axis control
board board printed board
Pulse coder
RPI (J1–J6)
(Pulse coder, RDI/RDO,
HBK, ROT)
RP2 (J7)
Motor power/brake
RM1 (J4, J5, J6)
RM2 (J1, J2, J3)
RM3 (J7)
Fig.3.2.1 (s) Robot Connection Cable (B–Cabinet/S–450)
333
(In case of M–410i (B–cabinet))

Servo module 1
Servo module 3 CRR5
CRM11
CRF1

CRM10
Servo module 4 Robot M–410i
Motor
power/brake
Pulse coder

Servo module Main CPU Emergency stop Power
printed control printed supply
board board unit
Pulse coder
RPI
(Pulse coder,
RDI/RDO, HBK, ROT)
Motor brake
Motor power
Fig.3.2.1 (t) Robot Connection Cable (B–cabinet/M–410i)

334
3.2.2 (1) Teach pendant

Teach Pendant Cable The robot connection cable is connected the operator’s box as
follows. This figure applies to all device types.
Operator’s box Port Teach pendant

(option) “Teach pendant”
Teach pendant cable
Fig.3.2.2 (a) Teach Pendant Cable
335
Amplifier
Teach pendant
Main CPU PC board
CRM6
Teach pendant cable
Fig.3.2.2 (b) Teach Pendant Cable (In case of B cabinet)
3.2.3 Considering the robot power capacity and the circuit breaker capacity,
connect the power supply whose voltage conforms to the installation
Connecting the Input
conditions to the terminal located above the circuit breaker.
Power Supply
Use a ground of class 3 or better. The resistance to ground must not exceed
100 Ω.
Be sure to ground the work table or jig used by an arc welding robot or
the like so that it can handle a large current.
Use a thick wire to withstand the maximum current used.
Selection of an input transformer tap is necessary depending on the input
voltage.
The tap is set before shipment. However, check it referring to section 6.2
in ”Maintenance” when changing the input voltage and before supplying
power (before the breaker switch is turned on).
The motor is driven by the PWM inverter system using the 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
may cause the leakage-current circuit breaker or leakage-protection relay
installed in the path of the power supply to cut out.
336
Use the following leakage current circuit breaker for inverters to prevent
incorrect operation.
Example of Leakage Current Circuit Breaker for Inverters
Manufacture Type
Fuji Electric Co., Ltd. EG A series
SG A series
Hitachi, Ltd. ES100C type
ES225C type
Matsushita Electric Works, Leakage current circuit breaker, C type
Ltd. Leakage current circuit breaker, KC type
Fig. 3.2.3 shows the cable connection.
Use a bar lead.

(Recommended type:
H6.0/20 or H6.0/26,
manufactured by Nihon Weissmuller)
Operator’s box
Operator’s panel (option)
Disconnect switch
Fig.3.2.3 (a) Input Power Supply Connection (Operator’s box–disconnect switch)
337
Note) Always replace the cover

after completing the wiring.
Operator’s panel
Breaker
Fig.3.2.3 (b) Input Power Supply Connection (Operator’s box–breaker)
338

Fig.3.2.3 (c) Input Power Supply Connection (B cabinet)
339

Fig.3.2.3 (d) Input Power Supply Connection (M–410i)
340
3.2.4 The External Power On/Off signal turns on and off the power supply from
Connecting the the outside the control unit, and is connected as follows.
External Power Supply
ON/OFF Switch
Panel pc board
Operator’s panel
To external power
supply ON/OFF
Operator’s box
Panel pc board
Operator’s panel
To external power
supply ON/OFF
B–cabinet
341
Remove the jumper when the external

power supply ON/OFF switch is used.
Power ON Power OFF
External power supply ON/OFF switch
PC board for operator’s panel
Use a contact conforming to the following : Voltage rating : 50 VDC, current : 100mA or more
The power supply on/off timing chart is as follows
EX–ON–EX–COM
EX–OFF–EX–COM
Power on
TON y 0.5 sec, TOFF y 0.5 sec, TOFF–ON y 5 sec
Fig.3.2.4 External Power Supply ON/OFF Switch Connection
342
3.2.5
Connecting the
External Emergency
Stop
Panel pc board
Operator’s panel
To external emergency
stop ON/OFF
Operator’s box
Panel pc board
Operator’s panel
To external emergency
stop ON/OFF
B–cabinet
343
External emergency stop output
Panel pc board
Signal Description Current, voltage

EMGOUT1 Emergency stop output signals. The contact is open if an
emergency stop occurs or the power is turned off. The Rated contact:
contact is closed during normal operation. 250 VAC, 5-A resistor load
EMGOUTC
EMGOUT2 Emergency stop output signals. The contact is closed if an
emergency stop occurs or the power is turned off. The
contact is open during normal operation.
EMGOUTC
ESTOP1 Emergency stop output signals of the teach pendant and
operator’s panel. The contact is opened if which emergen- Rated contact:
cy stop switch is pressed. The contact is closed during 24 VDC, 0.1-A resistor load
ESTOP2 normal operation.
(Option)
M4 screws are provided on the terminal. Use crimp terminals 9 mm wide or less.
Fig.3.2.5 Connecting the External Emergency Stop
344
External emergency stop input
After connecting an external emergency stop switch and safety fence door switch, be sure to check the operations
of those switches, the emergency stop switch on the operator’s panel, and the emergency stop switch on the teach
pendant.
Connected at the factory.

Remove the jumperprior to use.
External emergency stop switch
Door switch on safety fense
Use a contact rated at 250 V, 10 A or more on the printed circuit board for emergency stop control.

Connect the contacts of the external emergency stop switch to
EMGIN1
these terminals. When using the contacts of a relay or contactor
Open and close of
instead of the switch, connect a spark killer to the coil of the relay or
24VDC 0.1A
EMGIN2 contactor, to suppress noise.
When these terminals are not used, jumper them.
These signals are used to stop the robot when the door on the safe-
ty fence is open.
FENCE1
While the deadman’s switch on the teach pendant is pressed and Open and close of
the teach pendant enable switch is validated, these signals are 24VDC 0.1A
FENCE2 ignored and an emergency stop does not occur.
If these signals are not used, short these terminals.
M3 screws are provided on the terminal. Use crimp terminals 9 mm wide or less.
345
Servo on input
After connecting a servo on input switch, be sure to check the operations of the switch, the emergency stop
switch on the operator’s panel, and the emergency stop switch on the teach pendant.
Connected at the factory.

Remove the jumperprior
to use.
Servo on input switch.

Connect the contacts of the servo–on input switch to these termi-
SVON1 nals. 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 24 VDC/0.1 A switch
suppress noise. When these terminals are not used, jumper them. on/off
SVON2
M4 screws are provided on the terminal. Use crimp terminals 9mm wide or less.
346
B–80525E/04 CONNECTIONS AND END EFFECTOR INTERFACES
PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR
4 INTERFACES
R-J2 I/O peripheral device interfaces include printed circuit boards and
a unit selected according to the applications. Table 4 lists the printed
circuit boards and unit. Fig. 4 shows their locations.
Table 4 Peripheral Device Interface Types
Number of I/O points

No. Name Drawing number Remarks
DI DO D/A A/D
Process I/O printed circuit A05B-2300-J030 40 40 2 6 Backplane installation
1 board CA type (with welding
interface)
Process I/O printed circuit A05B-2300-J031 40 40 – – Backplane installation
2 board CB type (without welding
interface)
Process I/O printed circuit A05B-2300-J035 Note Note – – Backplane installation
3 board DA 80 80 type (without welding
interface)
Process I/O printed circuit A05B–2300–J040 40 40 2 6 For ARC Mate 100i
board EA Operator’s box installation
4
type (without welding
interface)
I/O unit model A – Depending on a selected (Note 3)
5
I/O model.
I/O unit model B AO5B–2300–J001 Depending on a selected Interface unit
6
unit.
NOTE
1 Process I/O PC board DA of i cabinet has 96 input points
and 96 output points. Because of cable restrictions, only 80
input points and 80 output points can be used.
2 General purpose I/O (SDI/SDO) is a number which subtract
an exclusive signal from the table value.
Example : Process I/O printed circuit board CA
Table value Exclusive DI General purpose DI
DI; 40 – 18 = 22 points
Table value Exclusive DO General purpose DO
DO; 40 – 20 = 20 points
3 When you want to mount I/O unit model A in the operation
box, consult FANUC.
347
AND END EFFECTOR INTERFACES CONNECTIONS B–80525E/04
Operator’s box Note) Some operator’s boxes

(option) support the connection of
I/O unit model A. For details,
contact your FANUC
sales representative.
Basic unit of
I/O unit model B
Process I/O
CA/CB/DA
To peripheral device
Interface unit of I/O unit model B
Fig.4 (a) Locations of Peripheral Device Interfaces (i cabinet)
Operator’s box Process I/O EA
For peripheral device
348

Main CPU PC board
Process I/O PC board

CA/CB/DA
I/O unit MODEL A

or
I/O unit MODEL B
Fig.4 (b) Locations of Peripheral Device Interfaces (B cabinet)
I/O unit model B
I/O unit model A

or
I/O unit model B
Process I/O Printed Circuit board

Main CPU Printed Circuit board
Emergency stop control Printed Circuit board
Fig.4 (c) Locations of Peripheral Device Interfaces (Cabinet for M–410i)
349
4.1
PERIPHERAL
DEVICE INTERFACE
BLOCK DIAGRAM
4.1.1
When Process I/O
Printed Circuit Board
CA, CB or EA is used
In case of i cabinet
Main CPU printed Process I/O printed circuit
circuit board board (CA/CB)
K10 K50A
CRM2A Peripheral device
JD1A JD4A
K50B
CRM2B Peripheral device
JD4B CRW1 K45

Welding device
CRW2
CRW1 and CRW2 are not provided for process I/O printed circuit board.
Process I/O
CA/CB/DA
350
Cable Drawing
Name Remarks
number number
Process I/O A05B–2350–J R–J2 controller
K10 connection 100 internal cable
cable A
Peripheral de- A05B–2350–J Connected length :

vice 210 7m
connection Honda Tsushin,
Process I/O K50A cable 50,34pins : one to one
printed circuit K50B
board for CA K45 Peripheral de- A05B–2350–J Connected length :
vice 211 14m
cable 50,34pins : one to one
vice 200 7m
Process I/O K50A cable 50pins : one to one
printed circuit K50B
board for CB Peripheral de- A05B–2350–J Connected length :
vice 201 14m
cable 50pins : one to one
vice 240 7m
K50A cable 50pins : one to one
K50B Peripheral de- A05B–2350–J Connected length :
vice 241 14m
Process I/O cable 50pins : one to one
printed circuit
board for EA Welding de- A05B–2350–J Connected length :
vice connec- 250 7m
tion cable Honda Tsushin,
34pins
K45
Welding de- A05B–2350–J Connected length :
vice connec- 251 14m
tion cable Honda Tsushin,
34pins
351
In case of B cabinet, cabinet for M–410i
Main CPU Process I/O printed ci

printed rcuit board (CA/CB)
circuit board
Peripheral device
JD1A
Peripheral device
Welder
Analog signal input
Process I/O printed

circuit board (CA/CB)
Peripheral device
Peripheral device
(Note1) CRW1 and CRW2 are not provided for process I/O printed circuit board CB.
(Note2) In case of M–410i, process I/O is specified only one sheet.
352
Cable
Name Drawing number Remarks
number
K10 Process I/O connection cable A05B–2300–J013 Internal cable of R–J control unit
Internal cable of R–J control unit
K11 Process I/O connection cable A05B–2300–J014
For connecting additional PC board
Connected length : 7m
A05B–2302–J113
Honda Tsushin, 50pins : one to one
K50A
K50B Connected length : 14m
Peripheral device connecting cable A05B–2302–J114
K50C Honda Tsushin, 50pins : one to one
K50D
A05B–2302–J115
A05B–2302–J273 Connected length : 3m
A05B–2302–J274 Connected length : 6m
K45 Welder connecting cable
A05B–2302–J275
In case of Tig welding it is impossible to use
This cable is not included
K46 Peripheral device connecting cable ____
It must be supplied by customer
4.1.2
When Process I/O
Printed Cricuit Board
DA is used

circuit board board (DA)
K10 K50A
CRM2A Peripheral device
JD1A JD4A
K50B
CRM2B Peripheral device
K50C
JD4B CRM2C Peripheral device
K50D
CRM2D Peripheral device
353
(i cabinet)
To peripheral device
Cable Drawing
Name Group Remarks
number number
Process I/O A05B–2350– R–J2 controller
K10 connection PB1 J100 internal cable
cable A
Peripheral A05B–2350– Connected length :

Process device J220 7m
PC7
I/O K50A connection Honda Tsushin,
printed K50B cable 50pins : one to one
circuit K50C Peripheral A05B–2350– Connected length :
board for K50D device J221 14m
DA PC8
cable 50pins : one to one
354
In case of B cabinet, cabinet for M–410i
Main CPU Process I/O printed

printed circuit board (DA)
circuit board Peripheral device
JD1A Peripheral device
Peripheral device
Peripheral device
Peripheral device
Peripheral device
Process I/O printed

circuit board (DA)
Peripheral device
Peripheral device
Peripheral device
Peripheral device
Peripheral device
Peripheral device
(Note) In case of M–410i, process I/O is specified only one sheet.
Cable
number
K10 Process I/O connection cable A05B–2300–J013 Internal cable of R–J control unit
K11 Process I/O connection cable A05B–2300–J014
For connecting additional printed circuit board
A05B–2302–J113
K50 Connected length : 14m

Peripheral device connecting cable A05B–2302–J114
A–H Honda Tsushin, 50pins : one to one
A05B–2302–J115
A05B–2302–J120
K51 Connected length : 14m

Welder connection cable A05B–2302–J121
A–D Honda Tsushin, 20pins : one to one
A05B–2302–J122
355
4.1.3 In case of i cabinet

When I/O Unit Model A
is used
Main CPU Printed circuit

printed board
circuit board TBOP3
+24V
0V
JD1A JRM10
I/O unit model A power

JD1A connection cable
I/O unit model A

connection cable
JD1A JD1B CP32

I/O base unit
K54
Back plane
K54
K54 Peripheral
device welder
K54
K54
I/O unit model A is mounted in the operator’s box.

Refer to I/O model A manual for more details.
Cable
Name Group Drawing number Remarks
number
Operator’s box internal cable.
– I/O unit model A connection cable – ____
Attached to the I/O unit mainframe.
I/O unit model A power connection Operator’s box internal cable.
– – ____
cable Attached to the I/O unit mainframe.
Peripheral device connection Not included.
– – ____
cable Must be supplied by the customer.
356
In case of B cabinet/cabinet for M–410i
Power
supply unit
CP5
Main CPU
printed
circuit
board
JD1A
I/O base unit

Back plane
Peripheral device
Welder
Refer to model A I/O manual for more details.
Cable
number
K15 I/O unit model A connection cable ____
Attached to I/O unit mainframe
K16 I/O unit model A connection cable ____
Attached to I/O unit mainframe
This cable is not included
K54 Peripheral device connecting cable ____
It must be supplied by customer
357
4.1.4 In case of i cabinet

When I/O Unit Model B
is used
In control unit
Main CPU
printed
circuit I/O unit model B
board Interface unit
S1+ CRS7
JD1A JD1B Mechanical unit
S1– end effector
S2+ CRS8A
JD1A S2–
Power 24V S3+ CRS8B

supply unit 0V S3–
CP6
Printed circuit TBOP3

board for +24V
operator’s box 0V
I/O unit model B 24V
Basic unit 0V
CRS9
S+ DI/DO
S2+ S–
S2– FG
Peripheral
device
I/O unit model B 24V
Basic unit 0V
S+ DI/DO
S–
FG
In operator’s box
Refer to model B I/O manual for more details.
Cable
number
– I/O unit model B connection cable – ____ R-J2 controller unit internal cable
– I/O unit model B connection cable – ____ R-J2 controller unit internal cable
Peripheral device connection Not included.
– – ____
cable Must be supplied by the customer
358
Connection to I/O Unit Model B, installed in the operator’s box

(a) Connect terminals S2+ and S2– of terminal block TBOP3 on the
panel PCB to terminals S+ and S– of the Model B, as shown be-
low.
(b) Connect terminals +24V and 0V of terminal block TBOP3 on the
panel PCB to terminals +24V and 0V of the Model B, as shown
below.
(c) When the +24 V power of the panel PCB is used for LV, the maxi-
mum current is 2 A. If a current exceeding 2 A is required, use
other DC power units to supply power to LV.
Operator’s box (option)
M4 terminal
M3 terminal
Panel printed board
I/O unit model B M3 terminal
359
In case of B cabinet/cabinet for M–410i
Internal control unit

Main CPU
printed
circuit I/O unit model B
board
Interface unit
Mechanical
unit end
effector
I/O unit model B

Basic unit
Power
supply unit
Peripheral
device
I/O unit model B

Expanded unit
Peripheral
control I/O unit model B
Basic unit
Peripheral
device
I/O unit model B

Expanded unit
Cable
number
K** I/O unit model B connection cable – ____ Internal cable of R–J control unit
K** I/O unit model B connection cable – ____ Internal cable of R–J control unit
Peripheral device connection This cable is not included
K** – ____
cable It must be supplied by customer
360
4.1.5 (a) In case of cabinet i

When Two or more The following figure shows the connection when two or more process
Process I/O Printed I/O printed circuit boards and I/O unit (model A or model B) are used.
Circuit Boards and I/O 1 process I/O CA/CB/DAs and 1 I/O unit model A or I/O unit model
Unit (Model A or Model B can be installed in one cabinet, operator’s box.
B) are used
In controller
Main CPU
printed
circuit board Process I/O printed I/O unit model B
circuit board Interface unit
Power
supply unit
CP6
Printed circuit
board for
operator’s box
I/O unit model B
Basic unit
I/O unit model B

Basic unit
I/O base unit
I/O unit model A

Back plane
361
(b) B cabinet and M–410i cabinet

When several units of the process I/O PCB, I/O Unit Model A, or I/O
Unit Model B are used, connect them as shown below.
One cabinet can include two units of the process I/O PCB (CA, CB,
or DA) and one unit of I/O Unit Model A or B.

circuit board board (CA/CB/DA)
K10
JD1A JD4A
K11
JD4B
Process I/O printed circuit

board (CA/CB/DA)
Power supply unit JD4A
JD4B
K15
CP5
K16
I/O unit model B JD1A JD1B CP32

K12 Interface unit
JD1B
Interface module
JD1A
I/O
+24V
0V base
S+, S–, FG unit
S+, S–, I/O unit model B

FG basic unit
+24V
0V
Cable
number
K12 Process I/O connection cable ____
For connecting additional pc board
others See 4.1.1 to 4.1.3
362
4.2 The peripheral device interface can be used with combinations of process
I/O PC boards CA, CB, DA and EA as well as I/O unit models A and B.
PERIPHERAL
Fig. 4.2 shows the combinations.
DEVICE INTERFACE
COMBINATION (a) i cabinet
[1-board]
Combination A Combination B Combination C Combination D
CA/CB/EA (40 points) DA (80 points) I/O unit model A I/O unit model B
[2-board combination]
Combination AC Combination AD Combination BC Combination BD
CA/CB (40 points) CA/CB (40 points) DA (80 points) DA (80 points)
I/O unit model A I/O unit model B I/O unit model A I/O unit model B
Fig.4.2 Peripheral Device Interface Combination
(b) B cabinet, M410i cabinet
[1-board]
Combination C Combination D Combination E
CA/CB (40 points) DA (96 points) I/O unit model A

or model B
Combination CC Combination CE
CA/CB (40 points) CA/CB (40 points)
CA/CB (40 points) I/O unit model A

or model B
Combination DC Combination DD Combination DE
DA (96 points) DA (96 points) DA (96 points)
I/O unit model A

CA/CB (40 points) DA (96 points) or model B
Combination CCE Combination DCE Combination DDE
CA/CB (40 points) DA (96 points) DA (96 points)
CA/CB (40 points) CA/CB (40 points) DA (96 points)

I/O unit model A I/O unit model A I/O unit model A
or model B or model B or model B
363
4.3 There are 18 exclusive data inputs (DI) and 20 exclusive data outputs
(DO) for a process I/O printed circuit board.
PROCESS I/O
These signals are allocated to the process I/O printed circuit board
PRINTED CIRCUIT connected first when two or more printed boards are combined. (General
BOARD SIGNALS signals SDI/SDO are allocated to the second and the following process
I/O printed circuit boards.)
The common voltage of the DI signals input to pins 1 to 4 of connector
CRM2A is clamped +24 V (common) in each process I/O printed circuit
board.
Table 4.3 shows signals of a process I/O printed circuit board.
Table 4.3 Process I/O Printed Circuit Board Signals

(DI signals)
Connector
Signal name Description Remarks
number
CRM2A-1 *IMSTP Immediate stop Clamped at +24 V
common
CRM2A-2 *HOLD Temporary stop Clamped at +24 V
common
CRM2A-3 *SFSD Safe speed Clamped at +24 V
common
CRM2A-4 CSTOPI Cycle stop Clamped at +24 V
common
CRM2A-5 FAULT RESET External reset
CRM2A-6 START Start
CRM2A-7 HOME Return to home
position
CRM2A-8 ENBL Operation enabled
CRM2A-9 RSR1 Robot service request
PNS1 Program number Option
selection
selection
selection
selection
selection
selection
selection
364
Table4.3 Process I/O Printed Circuit Board Signals (Continued)

(DI signals)
Connector
number
selection
CRM2A-29 PNSTROBE PNS strobe
CRM2A-30 PROD START Start of automatic
operation
CRM2A-31 SDI01 Peripheral device General signal
status
CRM2A-32 SDI02
CRM2B-1 SDI03
CRM2B-2 SDI04
CRM2B-3 SDI05
CRM2B-4 SDI06
CRM2B-5 SDI07
CRM2B-6 SDI08
CRM2B-7 SDI09
CRM2B-8 SDI10
CRMSB-9 SDI11
CRM2B-10 SDI12
CRM2B-11 SDI13
CRM2B-12 SDI14
CRM2B-13 SDI15
CRM2B-14 SDI16
CRM2B-15 SDI17
CRM2B-16 SDI18
CRM2B-29 SDI19
CRM2B-30 SDI20
CRM2B-31 SDI21
CRM2B-32 SDI22
CRM2A-33 CMDENBL During automatic
operation
CRM2A-34 SYSRDY Preparation
completed
CRM2A-35 PROGRUN During regeneration
CRM2A-36 PAUSED Program being
interrupted
CRM2A-38 HELD During temporary stop
CRM2A-39 FAULT Alarm
CRM2A-40 ATPERCH Home position
CRM2A-41 TPENBL Teach pendant
enabled
CRM2A-43 BATALM Battery voltage drop
365

(DO signals)
Connector
number
CRM2A-44 BUSY During operation
CRM2A-45 ACK1 Robot service request
acceptance
SNO1 Selected program Option
number
acceptance
number
acceptance
number
acceptance
number
acceptance
number
acceptance
number
acceptance
number
acceptance
number
CRM2A-26 SNACK Response signal to
PNS
CRM2A-27 RESERVED
CRM2B-33 SDO01 Peripheral device General signal
control signal
CRM2B-34 SDO02
CRM2B-35 SDO03
CRM2B-36 SDO04
CRM2B-38 SDO05
CRM2B-39 SDO06
CRM2B-40 SDO07
CRM2B-41 SDO08
CRM2B-43 SDO09
366

(DI signals)
Connector
number
CRM2B-44 SDO10 Reripheral device General signal
control signal
CRMSB-45 SDO11
CRM2B-46 SDO12
CRM2B-19 SDO13
CRM2B-20 SDO14
CRM2B-21 SDO15
CRM2B-22 SDO16
CRM2B-24 SDO17
CRM2B-25 SDO18
CRM2B-26 SDO19
CRM2B-27 SDO20
367
4.4
INTERFACE FOR
PERIPHERAL
DEVICES, END
EFFECTORS, AND
WELDERS
4.4.1
Peripheral Device and
Control Unit
Connection
Control unit
Peripheral device control interface A1
CRM2A
1 *IMSTP 33 CMDENBL
2 *HOLD 34 SYSRDY
19 ACK3/SNO3
3 *SFSPD 35 PROGRUN
20 ACK4/SNO4
4 CSTOPI 36 PAUSED
21 ACK5/SNO5
5 FAULT RESET 37 COM–A1
22 ACK6/SNO6
6 START 38 HELD
23 COM–A4
7 HOME 39 FAULT
24 ACK7/SNO7
8 ENBL 40 ATPERCH
25 ACK8/SNO8 Peripheral
9 RSR1/PNS1 41 TPENBL device A1
26 SNACK
10 RSR2/PNS2 42 COM–A2
27 RESERVED
11 RSR3/PNS3 43 BATALM
28 COM–A5
12 RSR4/PNS4 44 BUSY
29 PNSTROBE
13 RSR5/PNS5 45 ACK1/SNO1
14 30 PROD START
RSR6/PNS6 46 ACK2/SNO2
31 SDI01
15 RSR7/PNS7 47 COM–A3
32 SDI02
16 RSR8/PNS8 48
17 0V 49 +24E
18 0V 50 +24E

CRM2B
1 SDI03 33 SDO01
2 SDI04 34 SDO02
19 SDI03
3 SDI05 35 SDO03
20 SDI14
4 SDI06 36 SDO04
21 SDI15
5 SDI07 37 COM–B1
22 SDI16
6 SDI08 38 SDO05
23 COM–B4
7 SDI09 39 SDO06
24 SDI17
8 SDI10 40 SDO07
25 SDI18 Peripheral
9 SDI11 41 SDO08 device A2
26 SDI19
10 SDI12 42 COM–B2
27 SD20
11 SDI13 43 SDO09
28 COM–B5
12 SDI14 44 SDO10
29 SDI19
13 SDI15 45 SDO11
30 SDI20
14 SDI16 46 SDO12
31 SDI21
15 SDI17 47 COM–B3
32 SDI22
16 SDI18 48
17 0V 49 +24E
18 0V 50 +24E
368
NOTE
1 The peripheral device connection cables are optional.
2 All of COM-** are connected to 0 V.
Applicable process I/O printed circuit board

Type Specifications CRM2A CRM2B
CA A05B-2300-J030
CB A05B-2300-J031
DA A05B-2300-J035
EA A05B-2300-J040
369
Control unit
CRM2C
1 SDI23 33 SDO21
2 SDI24 34 SDO22
19 SDO33
3 SDI25 35 SDO23
20 SDO34
4 SDI26 36 SDO24
21 SDO35
5 SDI27 37 COM–C1
22 SDO36
6 SDI28 38 SDO25
23 COM–C4
7 SDI29 39 SDO26
24 SDO37
8 SDI30 40 SDO27
25 SDO38 Pripheral
26 SDO39
10 SDI32 42 COM–C2
27 SDO40
11 SDI33 43 SDO29
28 COM–C5
12 SDI34 44 SDO30
29 SDI39
13 SDI35 45 SDO31
30 SDI40
14 SDI36 46 SDO32
31 SDI41
15 SDI37 47 COM–C3
32 SDI42
16 SDI38 48
17 0V 49 +24E
18 0V 50 +24E

CRM2D
1 SDI43 33 SDO41
2 SDI44 34 SDO42
19 SDO53
3 SDI45 35 SDO43
20 SDO54
4 SDI46 36 SDO44
21 SDO55
5 SDI47 37 COM–D1
22 SDO56
6 SDI48 38 SDO45
23 COM–D4
7 SDI49 39 SDO46
24 SDO57
8 SDI54 40 SDO47
25 SDO58 Pripheral
26 SDO59
10 SDI52 42 COM–D2
27 SDO60
11 SDI53 43 SDO49
28 COM–D5
12 SDI54 44 SDO50
29 SDI59
13 SDI55 45 SDO51
30 SDI60
14 SDI56 46 SDO52
31 SDI61
15 SDI57 47 COM–D3
32 SDI62
16 SDI58 48
17 0V 49 +24E
18 0V 50 +24E
NOTE
1. The peripheral device connection cables are optional.
2. All of COM-** are connected to 0 V.

Type Specifications CRM2C CRM2D
CA A05B-2300-J030
CB A05B-2300-J031
370
Type Specifications CRM2C CRM2D

DA A05B-2300-J035
EA A05B-2300-J040
Control unit Connector pin No. Peripheral device

(peripheral device control interface A1)
+24E
CRM2A (49,50)
Receiver circuit
CRM2A (1)
*IMSTP RV
CRM2A (2)
*HOLD RV
CRM2A (3)
*SFSPD RV
CRM2A (4)
CSTOPI RV
CRM2A (5)
FAULT RESET RV
CRM2A (6)
START RV
CRM2A (7)
HOME RV
CRM2A (8)
ENBL RV
CRM2A (9)
RSR1/PNS1 RV
CRM2A (10)
RSR2/PNS2 RV
CRM2A (11)
RSR3/PNS3 RV
CRM2A (12)
RSR4/PNS4 RV
CRM2A (13)
RSR5/PNS5 RV
CRM2A (14)
RSR6/PNS6 RV
CRM2A (15)
RSR7/PNS7 RV
CRM2A (16)
RSR8/PNS8 RV
CRM2A (29)
PNSROBE RV
CRM2A (30)
PROD START RV
CRM2A (31)
SDI01 RV
CRM2A (32)
SDI02 RV
+24E
B A
Common setting
pin (ICOM1)
371
NOTE
This is a connection diagram for +24v common.

Receiver circuit LOAD

DV CRM2A (33)
ÂÂ Â
RELAY
CMDENBL
CRM2A (34)
SYSRDY DV LOAD
CRM2A (35)
PROGRUN DV LOAD
CRM2A (36)
PAUSED DV LOAD
CRM2A (38)
HELD DV LOAD
CRM2A (39)
FAULT DV LOAD
CRM2A (40)
ATPERCH DV LOAD
CRM2A (41)
TPENBL DV LOAD
CRM2A (43)
BATALM DV LOAD
CRM2A (44)
BUSY DV LOAD
CRM2A (45)
ACK1/SNO1 DV LOAD
CRM2A (46)
ACK2/SNO2 DV LOAD
CRM2A (19)
ACK3/SNO3 DV LOAD
CRM2A (20)
ACK4/SNO4 DV LOAD
CRM2A (21)
ACK5/SNO5 DV LOAD
CRM2A (22)
ACK6/SNO6 DV LOAD
CRM2A (24)
ACK7/SNO7 DV LOAD
CRM2A (25)
ACK8/SNO8 DV LOAD
CRM2A (26)
SNACK DV LOAD
CRM2A (27)
RESERVED DV LOAD
CRM2A(23,28,37,
42,47)
0V +24V
+24 V regulated
power supply
372

+24E
CRM2B (49,50)
Receiver circuit
CRM2B (1)
SDI03 RV
CRM2B (2)
SDI04 RV
CRM2B (3)
SDI05 RV
CRM2B (4)
SDI06 RV
CRM2B (5)
SDI07 RV
CRM2B (6)
SDI08 RV
CRM2B (7)
SDI09 RV
CRM2B (8)
SDI10 RV
CRM2B (9)
SDI11 RV
CRM2B (10)
SDI12 RV
CRM2B (11)
SDI13 RV
CRM2B (12)
SDI14 RV
CRM2B (13)
SDI15 RV
CRM2B (14)
SDI16 RV
CRM2B (15)
SDI17 RV
CRM2B (16)
SDI18 RV
CRM2B (29)
SDI19 RV
CRM2B (30)
SDI20 RV
CRM2B (31)
SDI21 RV
CRM2B (32)
SDI22 RV
+24E
B A
Common setting
pin (ICOM2)
NOTE
This is a connection diagram for +24V common.
373
Control unit Peripheral device

Connector pin No. LOAD
Â
CRM2B (33)
SDO01 DV RELAY
CRM2B (34)
SDO02 DV LOAD
CRM2B (35)
SDO03 DV LOAD
CRM2B (36)
SDO04 DV LOAD
CRM2B (38)
SDO05 DV LOAD
CRM2B (39)
SDO06 DV LOAD
CRM2B (40)
SDO07 DV LOAD
CRM2B (41)
SDO08 DV LOAD
CRM2B (43)
SDO09 DV LOAD
CRM2B (44)
SDO10 DV LOAD
CRM2B (45)
SDO11 DV LOAD
CRM2B (46)
SDO12 DV LOAD
CRM2B (19)
SDO13 DV LOAD
CRM2B (20)
SDO14 DV LOAD
CRM2B (21)
SDO15 DV LOAD
CRM2B (22)
SDO16 DV LOAD
CRM2B (24)
SDO17 DV LOAD
CRM2B (25)
SDO18 DV LOAD
CRM2B (26)
SDO19 DV LOAD
CRM2B (27)
SDO20 DV LOAD
CRM2A(23,28,37,
42,47)
0V +24V
+24 V regulated
power supply
374

Connector pin No.
+24E
CRM2C (49,50)
Receiver circuit
CRM2C (1)
SDI23 RV
CRM2C (2)
SDI24 RV
CRM2C (3)
SDI25 RV
CRM2C (4)
SDI26 RV
CRM2C (5)
SDI27 RV
CRM2C (6)
SDI28 RV
CRM2C (7)
SDI29 RV
CRM2C (8)
SDI30 RV
CRM2C (9)
SDI31 RV
CRM2C (10)
SDI32 RV
CRM2C (11)
SDI33 RV
CRM2C (12)
SDI34 RV
CRM2C (13)
SDI35 RV
CRM2C (14)
SDI36 RV
CRM2C (15)
SDI37 RV
CRM2C (16)
SDI38 RV
CRM2C (29)
SDI39 RV
CRM2C (30)
SDI40 RV
CRM2C (31)
SDI41 RV
CRM2C (32)
SDI42 RV
+24E
B A
Common setting
pin (ICOM3)
NOTE
375

Â
CRM2C (33)
SDO21 DV
RELAY
ÂÂ
CRM2C (34)
SDO22 DV LOAD
CRM2C (35)
SDO23 DV LOAD
CRM2C (36)
SDO24 DV LOAD
CRM2C (38)
SDO25 DV LOAD
CRM2C (39)
SDO26 DV LOAD
CRM2C (40)
SDO27 DV LOAD
CRM2C (41)
SDO28 DV LOAD
CRM2C (43)
SDO29 DV LOAD
CRM2C (44)
SDO30 DV LOAD
CRM2C (45)
SDO31 DV LOAD
CRM2C (46)
SDO32 DV LOAD
CRM2C (19)
SDO33 DV LOAD
CRM2C (20)
SDO34 DV LOAD
CRM2C (21)
SDO35 DV LOAD
CRM2C (22)
SDO36 DV LOAD
CRM2C (24)
SDO37 DV LOAD
CRM2C (25)
SDO38 DV LOAD
CRM2C (26)
SDO39 DV LOAD
CRM2C (27)
SDO40 DV LOAD
CRM2C(23,28,37,
42,47)
0V +24V
+24 V regulated
power supply
376

Connector pin No.
+24E
CRM2D (49,50)
Receiver circuit
CRM2D (1)
SDI43 RV
CRM2D (2)
SDI44 RV
CRM2D (3)
SDI45 RV
CRM2D (4)
SDI46 RV
CRM2D (5)
SDI47 RV
CRM2D (6)
SDI48 RV
CRM2D (7)
SDI49 RV
CRM2D (8)
SDI40 RV
CRM2D (9)
SDI51 RV
CRM2D (10)
SDI52 RV
CRM2D (11)
SDI53 RV
CRM2D (12)
SDI54 RV
CRM2D (13)
SDI55 RV
CRM2D (14)
SDI56 RV
CRM2D (15)
SDI57 RV
CRM2D (16)
SDI58 RV
CRM2D (29)
SDI59 RV
CRM2D (30)
SDI60 RV
CRM2D (31)
SDI61 RV
CRM2D (32)
SDI62 RV
+24E
B A
Common setting
pin (ICOM4)
NOTE
377

Â
CRM2D (33)
SDO41 DV
RELAY
ÂÂ
CRM2D (34)
SDO42 DV LOAD
CRM2D (35)
SDO43 DV LOAD
CRM2D (36)
SDO44 DV LOAD
CRM2D (38)
SDO45 DV LOAD
CRM2D (39)
SDO46 DV LOAD
CRM2D (40)
SDO47 DV LOAD
CRM2D (41)
SDO48 DV LOAD
CRM2D (43)
SDO49 DV LOAD
CRM2D (44)
SDO50 DV LOAD
CRM2D (45)
SDO51 DV LOAD
CRM2D (46)
SDO52 DV LOAD
CRM2D (19)
SDO53 DV LOAD
CRM2D (20)
SDO54 DV LOAD
CRM2D (21)
SDO55 DV LOAD
CRM2D (22)
SDO56 DV LOAD
CRM2D (24)
SDO57 DV LOAD
CRM2D (25)
SDO58 DV LOAD
CRM2D (26)
SDO59 DV LOAD
CRM2D (27)
SDO60 DV LOAD
CRM2D(23,28,37,
42,47)
0V +24V
+24 V regulated
power supply
378
4.4.2
Connection Between
the Mechanical Unit
and End Effector
EE
379
NOTE
1. This is a connection diagram for +24V common.
2. The connector pin numbers of the end effector depend on
the robot.
380
4.4.3
Connection Between
the Control Unit and
Welder
Control unit
Welder interface
CRW1
Welder
Analog input interface

CRW2
Peripheral device
Type Drawing number CRW1 CRW2

CA A05B–2300–J030
CB A05B–2300–J031
DA A05B–2300–J035
EA A05B–2300–J040
Note1) Welder and peripheral device connection cable is option.
381
Control unit Welder

(Welding interface)
Connector pin number MS connector pin number
Welding voltage
command signal
The input impedance
shall be more than 3.3kΩ
high–pass filter shall be
provided.
Wire speed
command signal
Welding voltage
detection signal
Output signals
without ripples.
Welding current
detector signal
R=100Ω or more
Wire soldering
detector signal
Welding power supply
382
Control unit Welder

(Welding interface)
Welding start
signal
Gas signal
Wire inching
(positive) signal
Wire inching
(negative) signal
+24V regulated
power supply
Receiver circuit
Arc detection
signal
Gas shortage
detection signal
Wire cut
detection signal
Cooling water
shortage detection
signal
Welding power
supplu abnomality
signal
Common switching
set pin
Shield
FG (cabinet ground)
383

(Analog input interface)
Output signals without

ripples.
384
4.5 This section describes the specifications of the digital I/O signals
interfaced with the peripheral device, end effector, and arc welder.
DIGITAL I/O SIGNAL
SPECIFICATIONS
4.5.1
Peripheral Device (1) Output signals in peripheral device interface A
Interface Example of connection
Spark killer diode
+24V
0.2 A
or less
0V
+24V
Lamp
0.2 A
or less
0V
Protective resistance
Electrical specifications
Rated voltage : 24 VDC
Maximum applied voltage : 30 VDC
Maximum load current : 0.2 A
Transistor type : Open collector NPN
Saturation voltage at connection : 1.0 V (approx.)
Spark killer diode

Rated peak reverse voltage : 100 V or more
Rated effective forward current : 1 A or more
Note on use
Do not use the +24 V power supply of the robot.
When loading a relay, solenoid, and so on directly, connect them in
parallel with diodes for preventing back electromotive force.
If a load is connected causing a surge current when a lamp is turned
on, use a protective resistance.
Applicable signals
Output signals of process I/O printed circuit board CRM2
CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT,
ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNO1 to
SNO8, SNACK, SDO1 to SDO20
385
(2) Input signals in peripheral device interface A

Example of connection
+24V
RV
3.3 kW
+24V
B A
ICOM
Electrical specifications of the receiver

Type : Grounded voltage receiver
Rated input voltage : Contact close
: +20 V to +28 V
Contact open
: 0 V to +4 V
Maximum applied input voltage : +28 VDC
Input impedance : 3.3 kΩ (approx.)
Response time : 5 ms to 20 ms
Specifications of the peripheral device contact
Rated contact capacity : 30 VDC, 50 mA or more
Input signal width : 200 ms or more (on/off)
Chattering time : 5 ms or less
Closed circuit resistance : 100 Ω or less
Opened circuit resistance : 100 kΩ or more
TB (Signal) TB (Signal) TB
Peripheral device
contact signal
Robot receiver signal

TC TC TB ; Chattering 5 ms or less
TC ; 5 to 20 ms
Note on use
Apply the +24 V power at the robot to the receiver.
However, the above signal specifications must be satisfied at the
robot receiver.
Applicable signals
Input signals of process I/O printed circuit board CRM2
*IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET, START,
HOME, ENBL, RSR1 to RSR8, PNS1 to PNS8, PNSTROBE,
PROD START, SDI1 to SDI22
386
4.5.2
End Effector Control (1) Output signals
Interface Example of connection
Spark killer diode
+24V
0.2 A
or less
0V
+24V
Lamp
0.2 A
or less
0V
Protective resistance
Electrical specifications
Rated voltage : 24 VDC
Maximum applied voltage : 30 VDC
Maximum load current : 0.2 A
Transistor type : Open collector NPN
Saturation voltage at connection : 1.0 V (approx.)
Spark killer diode

Rated peak reverse voltage : 100 V or more
Rated effective forward current : 1 A or more
Note on use
The +24 V power supply at the robot can be used when the total
current of the welding interface and end effector interface is 0.7 A or
less.
When loading a relay, solenoid, and so on directly, connect them in
parallel with diodes for preventing back electromotive force.
If a load is connected causing a surge current when a lamp is turned
on, use a protective resistance.
Applicable signals
Output signals of the end effector control interface
RDO1 to RDO8
387
(2) Input signal

Example of connection
+24V
RV
3.3 kW
+24V
B A
ICOM
Electrical specifications of the receiver

Type : Grounded voltage receiver
Rated input voltage : Contact close : +20 V to +28 V
Contact open : 0 V to +4 V
Maximum applied input voltage : +28 VDC
Input impedance : 3.3 kΩ (approx.)
Response time : 5 ms to 20 ms
Specifications of peripheral device contact

Rated contact capacity : 30 VDC, 50 mA or more
Input signal width : 200 ms or more (on/off)
Chattering time : 5 ms or less
Closed circuit resistance : 100 Ω or less
Opened circuit resistance : 100 kΩ or more
TB (Signal) TB (Signal) TB
Peripheral device
contact signal
Robot receiver signal

TC TC
TB ; Chattering 5 ms or less
TC ; 5 to 20 ms
Note on use
Apply the +24 V power at the robot to the receiver.
However, the above signal specifications must be satisfied at the
robot receiver.
Applicable signals
Input signals of the end effector control interface
RDI1 to RDI8, *HBK, *PPABN
388
4.5.3
I/O Signal (1) Digital output signal specifications for arc–welding interface
Specifications for
ARC–Welding Interface Example connection
Spark killer diode
0.2 A or
less
Electrical characteristics
Rated voltage: 24 VDC
Maximum applied voltage: 30 VDC
Maximum load current: 0.2 A
Transistor type: Open–collector NPN
Saturation voltage at on: About 1.0 V
Spark killer diode
Rated peak reverse voltage: 100 V or more
Rated effective forward current: 1 A or more
NOTE on use
NOTE
A power voltage of +24 V, provided for the robot, can be
used for interface signals of up to 0.7 A. This limit applies
to the sum of the currents flowing through the arc–welding
and end–effector control interfaces. To directly drive a relay
or solenoid, connect a diode preventing back electromotive
force to the load in parallel. To connect a load which
generates an inrush current upon power–on connect a
protective resistor.
Applicable signals
– Output signals on the arc–welding interface
– WDO1 to WDO8
389
(2) Digital input signal specifications for arc–welding interface
Example connection
Electrical characteristics of receivers

Type: Grounded voltage receiver
Rated input voltage: +20 to +28 V with contacts closed
0 to +4 V when open
Maximum input voltage: +28 VDC
Input impedance: About 3.3 k
Response time: 5 to 20 ms
Contact specifications for peripherals
Rated contact capacity: 30 VDC, 50 mA or more
Input signal width: 200 ms or more for on and off states
Chattering period: 5 ms or less
Closed–circuit resistance: 100 or less
Open–circuit resistance: 100 k or more
(Signal) (Signal)
Contact signal
for peripheral
Receiver
signal for robot
TB: Chattering of 5 ms or less

TC: 5 to 20 ms
NOTE on use
NOTE
Supply the +24 V power, provided for the robot, to the
receivers. The receiver signal on the robot must satisfy the
signal timing specified above.
Applicable signals
– Input signals for arc–welding interface
– WDI1 to WDI8
390
(3) Analog output signal specifications for arc–welding interface

(Welding voltage command, wire–feedrate command)
Example connection
Welder
NOTE on use
NOTE
Input impedance: 3.3 k or more
Connect a high–pass filter.
(4) Analog input signal specifications for arc–welding interface

(Welding–voltage detection, welding–current detection)
Example connection
Welder
NOTE on use
NOTE
Output a signal with no ripple.
(Wire deposit detection: WDI+ and WDI–)
Example connection
Welder
Welding electrode
NOTE on use
NOTE
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 80 V.
391
4.6 If the customer manufactures cables, conform to the FANUC standard

cables described in this section.
SPECIFICATIONS OF
(See the description in ”Peripheral Device Interface” in this manual for
THE CABLES USED the specifications of the FANUC standard cables.)
FOR PERIPHERAL
DEVICES AND
WELDERS
4.6.1
Peripheral Device
Interface A Cable
(CRM2: Honda
Tsushin, 50 pins)
Honda Tsushin Honda Tsushin
Process I/O Peripheral

device
Honda Tsushin
Honda Tsushin’s MR50RFH
Supplied with an ordered cable
4.6.2
Peripheral Device
Interface B Cable
(CRM4: Honda
Tsushin, 20 pins)
Honda Tsushin Honda Tsushin
Process I/O Peripheral

device
CRM4*
Honda Tsushin
Honda Tsushin’s MR20RFH
Supplied with an ordered cable
392
4.6.3 Be sure to use our cable for connection of welder.

ARC Weld Connection
Cable (CRW1: Honda
Tsushin, 34 pins)
ARC welder
Honda Tsushin
Process I/O
Japan Aviation Electronics

Industry Ltd.
MS3102A28–21S
Honda Tsushin Japan Aviation Electronics Standard position of guide key
MR34RFA Industry Ltd.
MS3108B28–21P
MS3057–16
393
4.7
CABLE
CONNECTION FOR
THE PERIPHERAL
DEVICES, END
EFFECTORS, AND
ARC WELDERS
4.7.1 Fig. 4.7.1 shows the connection of the peripheral device cable in the
control unit.
Peripheral Device
Connection Cable
Operator’s box Process I/O EA
Note : Tight the clamp with hand.

Metallic clamp Do not use pliers.
External shield
Shield plate
Noise protection: Remove a part of the sheath of a peripheral cable to expose the outside shield.
Secure the cable to the shield plate with the metallic clamp at the exposed position.
Fig.4.7.1 (a) Peripheral Device Cable Connection (i cabinet)
394
Process I/O printed circuit board

CA/CB/DA
I/O unit model A

or
I/O unit model B
Note : Tight the clamp with hand.

Do not use pliers.
Metallic clamp
External shield
Shield plate
Noise protection: Remove a part of the sheath of a peripheral cable to expose the outside shield.
Secure the cable to the shield plate with the metallic clamp at the exposed position.
Fig.4.7.1 (b) Peripheral Device Cable Connection (B cabinet)
395
4.7.2
Peripheral Device (1) Fig. 4.7.2 shows the connector for peripheral device cables A and B.
Cable Connector
Connector Applicable Dimensions

Remark
specifications interface A (B) C (D)
MR50LMH CRM2 67.9 73.5 44.8 18 Honda Tsushin Kogyo,
50 pins
MR20LMH CRM4 39.3 44.9 39.8 17 Honda Tsushin Kogyo,
20 pins
Symbol Name
Connector cover
Cable clamp screw
Connector clamp spring
Connector clamp screw

Connector 50 pins (male) MR50MH
20 pins (male) MR20MH
Fig.4.7.2 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo)
396
(2) Peripheral device connector
Dimen-
Connector Applicable sions Remark
specifications interface
A B
MR50RFH (CRM2) 61.4 56.4 Honda Tsushin Kogyo,
50 pins
MR20RFH (CRM4) 39.3 44.9 Honda Tsushin Kogyo,
20 pins
Symbol Name
Connector clamp screw
Screw ø2.6_8
Connector (MR50RFH)
(MR20RFH)
Fig.4.7.2 (b) Peripheral Device Connector (Honda Tsushin Kogyo)
397
4.7.3
End Effector Cable (1) Connector
Connector
A : M301 E : ø33
B : 63.0 F : 11.2
C : 54.5 G : 24.7
D : 9.6 to 15.0 (Inside diameter)
Manufactured by Daiichi Denshi Kogyo JMLP2524M
Fig.4.7.3 (a) Connector (Elbow type)
A : M301 E : ø33
B : 54.1 F : 11.2
C : 37.5 G : 24.7
D : 9.6 to 15.0 (Inside diameter)
Manufactured by Daiichi Denshi Kogyo JMLP2524M
Fig.4.7.3 (b) Connector (Straight type)
398
4.7.4
Recommended Cables (1) Peripheral device connection cable
Connect a peripheral device using a completely shielded, heavily
protected cable conforming to the specifications in Table 4.7.5 (a).
Allow an extra 50 cm for routing the cable in the control unit.
The maximum cable length is 30 m.
Table 4.7.4 (a) Recommended Cable (for Peripheral Device Connection)
Electrical characteris-
Conductor Effective
Sheath tics
Number Wire specifications outside
thickness Conductor Allowable
of wires (FANUC specifications) Diameter Configura- diameter
(mm) resistance current
(mm) tion (mm)
(Ω/km) (A)
50 A66L-0001-0042 ø1.05 7/0.18 1.5 ø12.5 106 1.6
AWG24
20 A66L-0001-0041 ø1.05 7/0.18 1.5 ø10.5 106 1.6
AWG24
(2) End effector connection cable

Connect an end effector using a heavily protected cable with a
movable wire conforming to the specifications in Table 4.7.5 (b).
The cable length is determined so that the cable will not interfere with
the end effector and the wrist can move through its full stroke.
Table 4.7.4 (b) Recommended Cable (for End Effector Connection)
Electrical characteris-
Conductor Effective
Sheath tics
Number Wire specifications outside
thickness Conductor Allowable
of wires (FANUC specifications) Diameter Configura- diameter
(mm) resistance current
(mm) tion (mm)
(Ω/km) (A)
6 A66L-0001-0143 ø1.1 40/0.08 1.0 ø5.3 91 3.7
AWG24
20 A66L-0001-0144 ø1.1 40/0.08 1.0 ø8.6 91 2.3
AWG24
399
4.8
QUICK CHANGE
(i–cabinet)
4.8.1 With R–J2, the cabinet is so structured that it can be divided into a front
General cabinet unit and rear cabinet unit to allow immediate control unit
replacement if a failure occurs. The front cabinet unit houses units such
as a servo amplifier and control printed circuit board. The rear cabinet
unit houses units such as a transformer and emergency stop control unit.
If a failure in the control unit cannot be located easily and requires a long
troubleshooting time before recovery, operation can be resumed in about
15 minutes (excluding a time required to back up data such as programs)
by replacing the front cabinet unit. This replacement operation is referred
to as quick change. (Note that if an alarm associated with the emergency
stop system is issued, the operator’s box and emergency stop control unit
mounted in the rear cabinet unit must be checked first.)
Step 1: Start of work

Faulty unit
Disconnect the cables connecting
the front and rear units.
Front cabinet unit Rear cabinet unit
Step 2: Separating the front unit from the rear unit

Remove the brackets joining the front
unit and rear unit, then pull out the front
cabinet unit toward you.
400
Step 3: Replacement unit installation

Install a replacement unit.
Replacement unit
Step 4: Cable connection and start–up

Connect the cables by reversing the pro-
cedure used to disconnect the cables,
then load the backup data for start–up.
401
4.8.2
Flowchart
Occurrence of failure
Back up contents of memory

if not backed up yet(*1)(*3).
Start quick change.
Prepare replacement unit.
Remove faulty cabinet unit.

See Section 4.8.6.
Install replacement unit.
Read memory of faulty cabinet

unit via memory card, for
example, into replacement unit.
(Refer to the description of file I/O
in the operator’s manual.)(*3)
Start up control unit.
”Servo – 38 Pulse count YES

mismatch” occurred?
NO Perform operation indicated in *2.
NO
Control unit normal?
Cables wired correctly? YES

Printed circuit board specification Perform work such as laying
s same as those of faulty cabinet cables neatly and storing used
unit? tools.
Memory read normally?
Restart control unit. If control unit

cannot be started yet, contact
FANUC service center.
End of quick change
402
NOTE
1 In backup operation, save all of the TPE program, system
files, and applications. Also save the options of position
registers and pallet registers, if included. For backup
operation, see *3 below, and also refer to the description of
file I/O in the operator’s manual.
2 When the alarm ”Servo –38 Pulse count mismatch” is
issued, take action according to the following procedure:
1 Display the system variable screen.
2 Set $MCR.$SPC_RESET to TRUE.
($MCR.$SPC_RESET is reset to FALSE immediately
after being set to TRUE, but this poses no problem.)
3 Set $DMR_GRP.$MASTER_DONE to TRUE.
4 Turn off the power.
3 Two types of external memory units are available; memory
cards and Handy Files. A memory card allows data to be
saved and read at high speed. (When a system requires
about 15 minutes to save system data and programs with
a Handy File, for example, the same information can be
saved using a memory card in about 30 seconds.) The
method of using a memory card is described below.
(1) Installing a memory card

– Install the memory card interface printed circuit board (referred to
as the interface printed circuit board) in the slot next to the power
supply unit as shown below.
– Before installing or removing the interface printed circuit board,
turn off the power to the control unit. Otherwise, the interface
printed circuit board, memory card, and backplane and so forth can
be damaged. Moreover, install the interface printed circuit board
securely. If the interface printed circuit board is not installed
securely, a malfunction can occur.
403
Remove the blank

plate next to the
power supply unit.
Power supply unit
Memory card interface printed circuit board
Memory card
(2) Setting
Install the interface printed circuit board in the control unit, then
insert the memory card into the interface printed circuit board.
Turn on the power to the control unit.
Press the SCREEN SELECT key on the teach pendant, then select
7 (File).
Press the F5 key (Function) on the teach pendant, then select 1
(Switch Unit).

The upper part of the teach pendant screen displays selectable
units. Select 3 (Memory Card (MC:)). The left end of the fourth
line from the top of the teach pendant screen displays MC: *.*.
NOTE
If Memory Card (MC:) is not displayed, check the
connection of the interface printed circuit board.
This makes the memory card usable. Operations such as save,

read, and list processing can be performed using the same
procedures as used for the Handy File. (Refer to the description
of file I/O in the operator’s manual.)
NOTE
If the setting procedure above is used, the Handy File
cannot be used. To use the Handy File, select 1 (Serial
Floppy Disk) in step 5.
(3) Memory card initialization

As with a floppy disk, a memory card must be initialized before it can
be used. (Set the switch on the memory card to the middle position
to release write protection.)
Select Memory Card (MC:) in (2) above.
Press the SCREEN SELECT key on the teach pendant, then select
7 (File).
Press the F5 key (Function) on the teach pendant, then select
Format.
The teach pendant screen prompts the user for confirmation.
Press the F4 key (Yes).

The system asks you to enter a volume label. Press the INPUT
key.
404
4.8.3 A replacement front cabinet unit for quick change contains units such as
Replacement front a control printed circuit board, servo amplifier, and fan.
cabinet unit The configuration of the control printed circuit board, in particular, varies
from one system to another. So, prepare a replacement front cabinet unit
carefully. The configuration of major options is described below.
Model B unit (option)
Servo amplifier
Option printed circuit board
Power supply unit
1) The servo amplifier specification varies from one model of robot to

another.
2) The control printed circuit board consists of backplanes, a main CPU
printed circuit board, power supply unit, option printed circuit board,
and model B unit (option). The main CPU printed circuit board and
power supply unit are always necessary. For a system with no option
printed circuit board mounted, two slots of backplanes can be
specified. However, when an option printed circuit board is used,
three slots of backplanes are required.
3) On the main CPU printed circuit board, various modules are
mounted. These modules must have the same specifications as those
of the system before replacement.
405
4.8.4 The following items are required for quick change:

Hardware items
required for quick
change 1. Replacement cabinet unit (This unit must have the same specifi-
cations as the faulty unit. Pay attention to the option configura-
tion. No replacement is allowed between different models of ro-
bots.)
2. External memory unit such as a memory card to which the con-
tents of memory of the faulty unit are saved
3. Flat–blade screwdriver
4. Phillips screwdriver
4.8.5 Be sure to read this section before starting quick change.

Notes on quick change – Quick change must be performed by two persons.
– Required data must already be saved to an external memory unit
such as a memory card.
– Be sure to turn off the main power supply unit connected to the
control unit before starting quick change.
– A replacement unit for quick change must have an FROM module
with the same contents as those of the faulty unit, and must already
have its initial start work completed.
4.8.6 Replace a faulty unit with a replacement unit according to steps

through .
Faulty unit
replacement procedure Person A: Remove the two brackets securing the top cover, then
open the door of the control unit.
Person B: Check that the main power supply unit connected to the
control unit is turned off. Manually loosen the cap of
the cord grip securing the power cable, then pull the
rubber ring installed on the cable toward you. Next,
remove the four mounting screws securing the side
plate with a flat–blade screwdriver, then set the breaker
mounted in the control unit to off (when the control unit
has no breaker, set the breaker mounted in the
operator’s box, for example, to off.) Then, separate the
side plate as shown below. At this time, leave the
cables connected.
406
Cord grip
Rubber ring
Cap
Brackets (2 locations)
Side plate mounting screws

Each screw can be removed by rotating it by a one–fourth turn.
1/4 turn
Power cable
Operator’s box cable
407
Person A is to perform steps –1 to –4. Person B is to perform step

–5.
–1 Open the door of the front cabinet unit, then disconnect the
cables below.
– Cables connected to CP1 and CP2 of the power supply unit
– Cables connected to JF21, JRM10, JD1A, JD17, JRM3, and
CRM10 of the main CPU printed circuit board (When a process I/O
printed circuit board and model B unit are mounted, the cable
connected to JD1A need not be disconnected. See 2–2.)
– Cables connected to CN7B, CN8B, CN1, and CN6
408
Model B unit

or ME–NET printed circuit board
Power supply unit
Servo amplifier
Servo amplifier Main CPU printed circuit board Power supply unit
409
–2 When a process I/O printed circuit board, ME–NET printed

circuit board, and model B unit are mounted, disconnect the
cables and fixing plate below in addition to the cables listed in
–1.
– Cables connected to JD4B, CRM2, and CRW1 of the process I/O
printed circuit board, and cable fixing plate
– Cable connected to L1 (or L2) of the ME–NET printed circuit
board
– Cables connected to JD1A, CRS7, CRS8A, and CRS8B of the
model B unit
410
Peripheral equipment
connection cables
Fixing plate for peripheral

I/O model B unit equipment connection cables

or ME–NET printed circuit board
Process I/O printed circuit board ME–NET printed circuit board
I/O model B unit
Peripheral equipment connection interface
411
–3 Loosen the cable holders located on the near side of the cabinet,
then pull out the cables disconnected in steps –1 and –2.
Cable holder
–4 Disconnect the cables connected to the two Faston terminals

located in the inner left part of the cabinet.
412
Faston terminal
–5 Disconnect the cables below from the breaker room.

– Cables connected to JRF2, CRM9, and CRM15 of the emergency
stop control printed circuit board
– Cables (screwed at three locations) connected to the secondary side
(pins 2, 4, and 6) of the MCC
– Relay connectors for robot connection cables(*1)
NOTE
The robot connection cables consist of six cables, J1M to
J6M. The J1M to J6M cables are connected using relay
connectors. (These connectors have a strong mating
power.) These cables can be pulled out of the cabinet so
that the cables can be easily connected or disconnected.
When disconnecting the cables, pull the cables out of the
cabinet to make the work easier to perform.
413
Emergency stop control printed

circuit board
Pull the cables out of the cabinet.
Disconnect the cables while holding down the lock on the top of
the connector.
J1–J3 connector
Emergency stop control printed
circuit board Lock
Robot side cables
Control unit side cables
J4–J6 connector
414
Separate the front cabinet unit from the rear cabinet unit
The front cabinet unit weighs about 40 kg. This work must be
performed by two persons. While one person is holding the front
cabinet unit, the other person is to remove the lower brackets and the
upper brackets. Next, the two persons gradually pull the front cabinet
unit about 10 cm toward the near side. (When there is a step between
the front cabinet unit and the floor, be careful not to drop the front
cabinet unit.) In this state, the cables drop through openings for
cables on the front and rear cabinet units. Ensuring that the cables do
not tangle, separate the front cabinet unit.
(Front cabinet unit) (Rear cabinet unit)
Bracket
(two brackets each on
the right and left side)
Cables
Opening for cables
415
Install a replacement unit by reversing steps 1 through 3, observing

the notes below.
Notes on connection of the front and rear cabinet units:
– When running the cables through the openings for cables, run the
robot connection cables on the near side, and run the other cables
on the far side.
– Ensure that the cables are not caught between the front and rear
cabinet units. For easier work, connect the relay connectors for the
robot connection cables outside the cabinet, then push the
connectors into the front cabinet unit.
– Ensure that the cables connected to the Faston terminals located in
the inner left part of the front cabinet unit are not caught between
the front and rear cabinet units.
– When making connections to the connectors and terminals, be
careful not to make wrong connections by checking the wire marks
and stamps provided on the cables. (The connectors for the robot
connection cables have different colors. Match these colors when
making connections.)
416
Front cabinet unit Rear cabinet unit
Colors of robot connection

cable connectors
Connector No. Color
White
Black
Cables other than the robot
Green
Robot connection cables connection cables
(to be run on the near side) (to be run on the far side) White
Black
Green
Make a connection outside the Ensure that the cables are not caught between
cabinet, then push the connectors the front and rear cabinet units.
into the front cabinet unit.
417
5. TRANSPORTATION AND
INSTALLATION CONNECTIONS B–80525E/04
5 TRANSPORTATION AND INSTALLATION
5.1 The control unit is transported by a crane. Attach a rope to eye bolts at
the top of the control unit.
TRANSPORTATION
NOTE
A combination control unit is incorporated into the
mechanical unit of the robot.
(I–cabinet separate type) (B–cabinet)
Fig.5.1 Transportation
418
B–80525E/04 CONNECTIONS INSTALLATION
5.2
INSTALLATION
5.2.1 When installing the control unit, allow the space for maintenance shown
Installation Area in the following figure.
Fig.5.2.1 (a) Installation Area (Separate type i cabinet)
419
Control unit Control unit Control unit
Fig.5.2.1 (b) Installation Area (B cabinet : ARC Mate100, ARC Mate120, ARC Mate 100i, ARC Mate 120i, S–6, S–12,
M–6i, M–16i, S–420i, S–450, S–500, S–700, S–800, M–410i, M–500, M–400i, M–710i, A–520i)
Additional Control unit

Control unit locker locker Control unit
Fig.5.2.1 (c) Installation Area (S–900)
420
5.2.2
Connecting Cables at
Installation
(Combined Type of i
Cabinet)
Operator’s box
Input power cable
Teach pendant
Peripheral device connection cable
Fig.5.2.2(a) Connecting Cables at Installation
421
Separate type of i
cabinet
Operator’s box
Input power cable
Teach pendant
Robot mechanical unit connection cable
Peripheral device connection cable
Fig.5.2.2 (b) Connecting Cables at Installation (i cabinet)
422
(B cabinet)
Teach pendant connection
Robot mechanical unit

connection cable
Peripheral device
connection cable
Input power cable connection
Welding interface
connection cable
Fig.5.2.2 (c) Connecting Cables at Installation (B cabinet)
423
(Cabinet for M–410i)
Operator’s box
connection
Teach pendant
connection
Input power cable

Cabinet for M410i is installed
in Robot’s frame
Peripheral device
connection cable
Fig.5.2.2 (d) Connecting Cables at Installation (Cabinet for M–410i)
424
5.2.3 (ARC Mate100, ARC Mate120, ARC Mate 100i, ARC Mate 120i, S–6,
Separate–Type Control S–12, M–6i, M–16i, S–420i, S–500, S–700, M–710i, A–520i)
Unit of i Cabinet The control unit can be separated from the robot. To enable separate
installation of the control unit, an optional robot connection cable is
required.
Robot
Robot connection cable

(option)
Controller
Fig.5.2.3 Assembly of Controller
425
5.3
INSTALLATION
CONDITION
Item Model Specifications/condition
Line filter All models Three–phase 200 VAC +10% –15%, 50 q1 Hz;
three–phase 200 to 220 VAC +10% –15%, 60 q1 Hz
Transformer All models Three–phase 220, 240, 380, 415, 460, 480, 500, 550, or
575 V +10% –15%, 50/60 q1 Hz
Input power source capac- ARC Mate 100, S–6, ARC 2.5kVA
ity Mate 100i, M–6i, M–16i
ARC Mate 120, ARC Mate 3kVA
120i, S–12, A–520i
S–700, M–710i 6.5kVA
S–500, M–400i 7kVA
S–420i, S–800, M–410i, 12kVA
M–500, S–450
S–900 18kVA
Average power consump- ARC Mate 100, ARC Mate 120, 1.0KW
tion ARC Mate 120i, S–6, S–12,
ARC Mate100i, M–6i, M–16i
S–500, S–700, M–710i, 1.7KW
M–400i
M–500, A–520i 2.0KW
S–420i, S–800, M–410i, 2.5KW
S–450
S–900 3.5KW
Permissible ambient temper- All models 0xC to 45xC
ature
Permissible ambient humid- All models 75% RH or less, non–condensing, up to 95% RH for a lim-
ity ited period (within one month)
Surrounding gas All models No corrosive gas. When using the robot in an environment
with a high concentration of dust or coolant, consult with
your FANUC sales representative.
Vibration All models 0.5 G or less. When using the robot in a location subject
to serious vibration, consult with your FANUC sales repre-
sentative.
Weight of control unit B cabinet About 180 kg
i cabinet About 100 kg (front cabinet: About 40 kg, rear cabinet:
About 60 kg)
NOTE
As a continuous rating in the above capacity is enough
though, when the robot is rapidly accelerated, the capacity
of the power supply will momentarily need the capacity of
about two times the continuous rating value.
426
5.4 Adjust the robot according to the following procedure at installation.

ADJUSTMENT AND
CHECKS AT
INSTALLATION
No. Description
1 Visually check the inside and outside of the control unit.
2 Check if the screwed terminal is connected properly.
3 Check that the connectors and printed circuit boards are inserted correctly.
4 Check transformer tap setting. (See II MAINTENANCE 6.3)
5 Turn disconnector and the breaker off and connect the input power cable.
6 Check the input power voltage.
7 Press the EMERGENCY STOP button on the operator’s box and turn the power on. Check the output voltage. (See
II MAINTENANCE 6.3.)
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’s box. Turn the power on.
11 Check the movement along each axis in the manual jog mode.
12 Check the end effector interface signals.
13 Check the peripheral device control interface signals.
427
5.5 An overtravel and emergency stop occur when the robot is operated for
the first time after it is installed and the mechanical and control units are
RESETTING wired. This section describes how to reset the overtravel and emergency
OVERTRAVEL AND stop.
EMERGENCY STOP Remove the red plate fastening the swiveling axis beforehand.
AT INSTALLATION 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 enters the emergency stop state when the peripheral device
control interface is not connected.
5.5.1 Take the following actions if signals *IMSTP, *HOLD, *SFSD, and
ENBL are not used.
Peripheral Device
Interface Processing
CRM2A
+24F
49, 50
*IMSTP 1
RV
*HOLD 2
RV
*SFSD 3
RV
ENBL 8
RV Connect the signals to pins 49 and 50 of CRM2A.
5.5.2 Press the reset switch on the operator’s panel or the reset key on the teach
pendant.
Resetting Overtravel
Manually move an axis that has overtraveled into the operating range
while pressing the shift key on the teach pendant.
428
APPENDIX
Index
APPENDIX
B–80525E/04 APPENDIX A. TOTAL CONNECTION DIAGRAM
A TOTAL CONNECTION DIAGRAM
A.1
I–CABINET (ARC
Mate 100, ARC Mate
120, ARC Mate 100i,
ARC Mate 120i, S–6,
S–12, M–6i, M–16i,
S–420i, S–500, S–700,
M–400i, M–710i,
A–520i)
431
A. TOTAL CONNECTION DIAGRAM APPENDIX B–80525E/04
Fig.A.1 (a) Total Diagram (ARC Mate 100i, M–6i S–420i, M–710i, A–520i)
432
ROBOT
ARC Mate 100i
M–6i, S–420i,
M–400i, M–710ii A520i
CRR20
433
Fig.A.1 (b) Total Diagram (S–500, S–700, S–6, S–12, M–16i, ARC Mate 100, ARC Mate 120, ARC Mate 120i, M–400i)
434
THIS CONNECTION IS
DIFFERENT FOR EACH ROBOT
REFER TO THE PAGE ROBOT
”ROBOT CONNECTION” S–500
S–700
S–6
RM2 S–12
ARC Mate 100
ARC Mate 120
RM1
RP1
J1–J6 PULSE CODER
AND RDI/RDO
CRR20
435
TYPE 1 TRANSFORMER (7.5KVA; A80L–0026–0015, A80L–0024–0014)

Fig.A.1 (c) Transformer
M–400i, M–710i, A–520i)
436
Fig.A.1 (d) Power Supply Unit
M–400i, M–710i, A–520i)
437
*BRKALMZ
*BRKONZ
SVON–RV
SVON–EMG
Fig.A.1 (e) Main CPU
M–400i, M–710i, A–520i)
438
Fig.A.1 (f) Servo Amplifier 1 (Internal connection)
M–400i, M–710i, A–520i)
439
SERVO AMP
A06B–6076
A06B–6076
–C001
–C101
or
SERVO AMP
A06B–6076
A06B–6076
–C001
–C101
or
Fig.A.1 (g) Servo Amplifier 2 (S–420i, M–710i)
440
Fig.A.1 (h) Servo Amplifier 3
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M16i, M–710i)
441
Fig.A.1 (i) Servo Amplifier 4 (S–500, S–700)
442
Fig.A.1 (j) Servo Amplifier 5 (A–520i)
443
Fig.A.1 (k) Emergency Stop Unit
444
Fig.A.1 (l) Process I/O PCB
445
Fig.A.1 (m) External Connection Diagram (I/O Unit MODEL B)
M–400i, M–710i, A–520i)
446
447
EMGTP12
EMGB110
EMGB211
EMGDM03
EMGEN16
OPEMG A1 13A
OPEMG A2 13B
OPEMG C1 14A
OPEMG C2 14B
OPEMG B1 15A
ESTOP2 08
ESTOP1 07
Fig.A.1 (n) Emergency Stop Circuit
448
449
Fig.A.1 (o) Operator’s Box–1
450
451
SVON–EMG
SVON–RV
Fig.A.1 (p) External Connection Diagram (Operator’s Box–2)
452
A.2
B–CABINET (ARC
Mate 100, ARC Mate
120, ARC Mate 100i,
ARC Mate 120i, S–6,
S–12, M–6i, M–16i,
S–420i, S–500, S–700,
M–400i, M–710i,
A–520i)
453
Fig.A.2 (a) Total Diagram
454
455
Fig.A.2 (b) Transformer/Line filter
456
5-SLOT A20B–2001–0990
3-SLOT A20B–2001–0670
2-SLOT A20B–2001–0860
Fig.A.2 (c) DC Power Supply Unit
457
*BRKALMZ
*BRKONZ
SVON–RV
SVON–EMG
(RDI/RDO)
CRM10
5-SLOT A20B–2001–0990
3-SLOT A20B–2001–0670
2-SLOT A20B–2001–0860
Fig.A.2 (d) Main CPU
458
Fig.A.2 (e) Servo Amplifier
459
*BRKALMZ
*BRKONZ
Fig.A.2 (f) Emergency Stop Unit
460
461
Fig.A.2 (g) Operator’s Panel–1
462
463
SVON–EMG
SVON–RV
Fig.A.2 (h) Operator’s Panel–2
464
FG
OV Power 8
LV Power 7
I/O unit–MODEL B
OV Power
5
3 +24Y10GK 6
S+ 4
S–
1
2
Fig.A.2 (i) Mechanical Unit Interface
(S–420i, S–500, M–710i, ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i)
465
Fig.A.2 (j) Mechanical Unit Interface (A–520i/S–700)
466
Fig.A.2 (k) Process I/O
467
Fig.A.2 (l) I/O Unit MODEL A, B
468
469
Fig.A.2 (m) Emergency Stop Circuit
470
471
A.3
CABINET OF
S–800/M–500
472
473
Fig.A.3 (a) Total Diagram (S–800)
474
475
Fig.A.3 (b) Total Diagram (M–500)
476
477
Fig.A.3 (c) Transformer/Line filter (S–800, M–500)
478
479
5-SLOT A20B–2001–0990
3-SLOT A20B–2001–0670
2-SLOT A20B–2001–0860
Fig.A.3 (d) DC Power Supply Unit (S–800, M–500)
480
5-SLOT A20B–2001–0990
3-SLOT A20B–2001–0670
2-SLOT A20B–2001–0860
Fig.A.3 (e) Main CPU (S–800, M–500)
481
Fig.A.3 (f) Servo Amplifier (S–800, M–500)
482
Fig.A.3 (g) Emergency Stop PCB (S–800, M–500)
483
Fig.A.3 (h) Operator’s Panel–1 (Both Models)
484
485
Fig.A.3 (i) Operator’s Panel–2 (S–800, M–500)
486
Fig.A.3 (j) Mechanical Unit Interface (S–800)
487
Fig.A.3 (k) Mechanical Unit Interface (M–500)
488
Fig.A.3 (l) Process I/O (S–800, M–500)
489
Fig.A.3 (m) I/O Unit MODEL A, B (S–800, M–500)
490
491
Fig.A.3 (n) Emergency Stop Circuit (S–800, M–500)
492
493
A.4
CABINET OF M–410i
AND S–450
494
495
Fig.A.4 (a) Total Diagram (M–410i)
496
497
Fig.A.4 (b) Total Diagram (M–410i, B–cabinet)
498
499
Fig.A.4 (c) Total Diagram (S–450)
500
501
Fig.A.4 (d) Transformer/Line filter (M–410i)
502
503
Fig.A.4 (e) Tranformer/Line filter (M–410i, S–450/B–cabinet)
504
505
Fig.A.4 (f) DC Power Supply Unit (S–450, M–410i)
506
Fig.A.4 (g) Main CPU (S–450, M–410i)
507
Fig.A.4 (h) Addtional axis Control printed board (S–450)
508
Fig.A.4 (i) Servo Amplifier (S–450, M–410i)
509
Fig.A.4 (j) Emergency Stop Unit (S–450, M–410i)
510
511
Fig.A.4 (k) Operator’s Box–1 (M–410i)
512
513
Fig.A.4 (l) Operator’s Box–1 (M–410i/S–450/B–cabinet)
514
515
Fig.A.4 (m) Operator’s Box–2/Operator’s panel–2 (S–450, M–410i)
516
Fig.A.4 (n) Process I/O (S–450, M–410i)
517
Fig.A.4 (o) I/O Unit MODEL A, B (S–450, M–410i)
518
519
Fig.A.4 (p) Emergency Stop Circuit (S–450, M–410i)

520
521
A.5
B–CABINET OF
S–900
522
523
Fig.A.5 (a) Transformer/Line filter (Internal connection)
524
525
Fig.A.5 (b) Transformer/Line filter (B–cabinet) (S–900)
526
527
Fig.A.5 (c) Servo Amplifier (Internal connection)
528
529
5-SLOT A20B–2001–0990
3-SLOT A20B–2001–0670
2-SLOT A20B–2001–0860
Fig.A.5 (d) DC Power Supply Unit (Internal connection)
530
5-SLOT A20B–2001–0990
3-SLOT A20B–2001–0670
2-SLOT A20B–2001–0860
Fig.A.5 (e) Main CPU (Internal connection)
531
Fig.A.5 (f) Conversion PCB/Emergency Stop Unit (Internal connection)
532
Fig.A.5 (g) Conversion PCB/Emergency Stop Unit (Internal connection)
533
Fig.A.5 (h) Operator’s Panel–1 (Internal connection)
534
535
Fig.A.5 (i) Operator’s Panel–2
536
Fig.A.5 (j) Mechanical Unit Connection Interface
537
Fig.A.5 (k) Process I/O
538
Fig.A.5 (l) I/O Unit MODEL A, B (Internal Connection)
539
Fig.A.5 (m) Emergency Stop Circuit
540
541
B. SPECIFICATIONS OF
PERIPHERAL DEVICE INTERFACE APPENDIX B–80525E/04
B SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE
B.1 The following table lists the I/O signals used for the peripheral device
interface in the R-J2 controller.
SIGNALS
Input signals
Signal Description
*IMSTP Instantaneous stop signal
*HOLD Hold signal
*SFSPD Safety speed signal
CSTOPI Cycle stop signal
FAULT_RESET Alarm release signal
START Cycle start signal
HOME
ENBL Enabling signal
RSR1/PNS1 Robot service request/program number select signal (*1)
PNSTROBE PNS strobe signal
PROD_START Automatic operation start signal
SDI01 General-purpose input signal

*1: RSR : Robot Service Request (RSR5 to RSR8 are optional)
542
B–80525E/04 APPENDIX PERIPHERAL DEVICE INTERFACE
PNS : Program Number Select Input (optional)

Whether RSR is used or PNS is used can be preset.
Output signals
Signal Description
CMDENBL Command acceptance enabled signal
SYSRDY System ready signal
PROGRUN Program run signal
PAUSED Program paused signal
HELD Held signal
FAULT Alarm signal
ATPERCH Reference point signal
TPENBL Teach pendant enabled signal
BATALM Battery alarm signal
BUSY Operating signal
ACK1/SNO1 RSR acknowledge/Selected program number signal
SNACK PNS acknowledge signal
______ Not used (for future expansion)
SDO01 General-purpose output signal

543
B.2 The process I/O printed board has a setting pin to set the common voltage
of input signals to 0 V or 24 V. The system automatically adjusts the
SETTING COMMON polarity by software according to the status of this pin. Therefore, the user
VOLTAGE can operate the system without being concerned about the setting of the
common voltage.
To ensure safety, the reference voltage of the following four signals,
however, a common voltage is remained at +24V.
*IMSTP
*HOLD
*SFSPD
CSTOPI
B.3
I/O SIGNALS
B.3.1 This section describes the specifications of each input signal.

Input Signals (1) Instantaneous stop signal (input) *IMSTP
Effective : 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 con-
trolled 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
stop execution of the program.
(3) Hold signal (input) *HOLD
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 operator’s panel. It halts the current pro-
gram 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.
544
(4) Start signal (input) START

Effective : When the command acceptance enabled signal (out-
put) CMDENBL is turned on.
See the description of CMDENBL in Section 2.2.1 for
details.
Function : This input signal starts the selected program at the fal-
ling edge when the signal is turned off after being
turned on. Its function differs according to the setting
of parameter $SHELL_CFG.$CONT_ONLY.
- If parameter $SHELL_CFG.$CONT_ONLY is set
to DISABLED, the START signal starts the pro-
gram which has been selected from the teach pen-
dant. By default, the program starts from the cur-
rent 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
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
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.
545
(7) Safety speed signal (input) *SFSPD

Function : - Use the normally-closed switch because it is a re-
verse signal. Usually this switch should be con-
nected 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. $SFRU-
NOVLIM : For test execution.)
(8) Robot service request signal (input) RSR1/RSR2/RSR3/RSR4
details.
Function : - The user can choose between RSR and PNS (op-
tional), although they cannot be used simultaneous-
ly.
- Four input signals, RSR1 to RSR4, are used.
- If a signal is input to an RSR input, a specified. pro-
gram 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 pro-
gram 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).
546
- 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 regis-
tered in RSR2, the program to be started is the one
with the program name calculated from the expres-
sion
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 ex-
ample, $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 cor-
responding to the RSR, one of signals ACK1 to
ACK4, when the input of the RSR is accepted.
From the same menu, the width of the pulse can also
be specified.
It is possible to accept other RSRs while outputting
an acknowledge signal.
- Input of a CSTOPIT signal can clear the program
queue waiting for execution after acceptance of
RSRs.
547
(9) PNS/PNSTROBE (input)

Signal name : PNS : Program number select
PNSTROBE: Strobe input for PNS
details.
Function : - The PNS/PNSTROBE signal selects whether the
RSR function is used or the PNS function (option-
al) 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 en-
tered value plus the base number. For example, if the
PNS value is 23, the program to be started has the pro-
gram 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 execu-
tion of the selected program can only be started af-
ter input of automatic operation start signal
PROD_START.
548
- For safety, the selected program cannot be changed

from the teach pendant unless PNSTROBE is
turned off.
- If a program is selected by PNS, the program num-
ber 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 pro-
gram selected by PNS.
· Starting up a program by input of automatic op-
eration start signal PROD_START
· Restarting 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.
· Inputting 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
details.
Function : This input signal executes the selected program at the
falling edge when the signal is turned off after being
turned on.
549
B.3.2 This section describes the specifications of output signals for the
Output signals peripheral device interface.
(1) Command acceptance enabled signal (output) CMDENBL
Turned on : When the remote conditions are satisfied and the sys-
tem is not in the alarm status
Turned off : When the remote conditions are not satisfied or the sys-
tem is in the alarm status
The remote conditions are satisfied when all of the following are satis-
fied.
- The teach pendant is in the DISABLED status.
- The remote switch on the operator’s panel is set to
REMOTE side.
- Parameter $RMT_MASTER is set to 0 (external
interface).
- Signal *SFSPD is set to on, or in the normal status.
(2) System ready signal (output) SYSRDY

Turned on : When power is applied to the motor of the robot.
Turned off : When power is not applied to the motor of the robot.
(3) Program run signal (output) PROGRUN
Turned on : When the program is being executed.
Turned off : When the program is not being executed.
(4) Held signal (output) HELD
This signal is used to check the status of the hold input.
Turned on : When the hold button (or input) is being pressed down
(or turned on).
Turned off : When the hold button (or input) is not being pressed
down (or is turned off).
(5) Program paused signal (output) PAUSED
This signal is used together with output signal PROGRUN to deter-
mine 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.
550
(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.
Turned off : When the robot is not in the reference position speci-
fied in the parameter.
Up to three reference positions can be specified, but this signal is out-
put when the robot is in the first reference position. For the other two
reference positions, general-purpose signals can be assigned to output
as such. (They can be set from the setup screen.)
(8) Teach pendant enabled signal (output) TPENBL
Turned on : When the teach pendant is enabled.
Turned off : When the teach pendant is disabled.
(9) Battery alarm signal (output) BATALM
Turned on : When the voltage of the battery for the CMOS memory
backup drops below the reference.
Turned off : When the voltage of the battery for the CMOS memory
backup is at the normal level.
(10) Operating signal (output) BUSY
Turned on : When a program is being executed or is being pro-
cessed from operation panels such as the teach pen-
dant. (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 pro-
cessed from operation panels such as the teach pen-
dant.
(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 signals RSR1 to RSR4 is input and ac-
cepted. 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 out-
put.
551
CMDENBL (O)
(The remote conditions need to be satisfied.)
RSR1 (I)
The maximum delay is 32 msec.
ACK1 (O)
(The width of the pulse is set in the parameter.)
RSR2 (I)
ACK2 (O)
RSR3 (I)
ACK3 (O)
RSR4 (I)
ACK4 (O)
* Other RSR signals can be accepted even when the ACK signal is being output.
(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 num-
ber cannot be represented as an eight-bit number, it be-
comes 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.
552
CMDENBL (O)
(The remote conditions need to be satisfied.)
PNS1-8 (I)
(A value is input.)
PNSTROBE (I)
(A strobe is input for PNS.)
Detection and
processing of
PNSTROBE by (PNS is read within a maximum of 32 msec after PNSTROBE is turned
software. on.)
SNO1-8 (O)
SNACK (O)
PROD_START (I)
(Program execution
starts within 32 msec.)
PROGRUN (O)
553
B.4
SPECIFICATIONS OF
DIGITAL
INPUT/OUTPUT
B.4.1 This section describes the external specifications of digital and analog
Overview input/output in the R-J2 controller.
B.4.2 The R-J2 controller can use up to 512 digital input and output points or
Input/Output Hardware an equivalent number of analog input and output points. One analog
input/output point uses the resources equivalent to those used by 16
Usable in the R-J2 digital I/O points. The R-J2 can use a total of up to 512 I/O points.
Controller
The R-J2 controller can use the following I/O hardware.
- Process I/O printed circuit board
- I/O unit model A
- I/O unit model B
The process I/O printed circuit board and the I/O unit model A or B can
be used together.
B.4.3
Software (1) RDI/RDO
Specifications These are signals sent to the connector at the wrist of the robot.
They cannot be assigned (redefined) and are fixed.
The standard format is eight inputs and eight outputs. The number of
points that can be used for the connector at the wrist depends on the
individual robot.
(2) SDI/SDO
These signals can be assigned (redefined). Eight points form a pairs
and they are assigned in units of pairs.
(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.
554
B–80525E/04 APPENDIX C. DIAGRAM OF POWER SUPPLY PATH
C DIAGRAM OF POWER SUPPLY PATH
Fig.C.1 (a) 200VAC (i–cabinet)
555
C. DIAGRAM OF POWER SUPPLY PATH APPENDIX B–80525E/04
Fig.C.1 (b) 200VAC
(B–cabinet : ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i, S–500,
S–700,M–400i, M–710i)
556
Fig.C.1 (c) 200VAC (S–800, M–500)
557
Fig.C.1 (d) 200VAC (S–900)
558
Fig.C.1 (e) 200VAC (S–450, M–410i)
559
Fig.C.1 (f) 100VAC (S–450, S–800, S–900, M–410i, M–500)
560
Fig.C.1 (g) +5V/+15V/–15V (i–cabinet)
561
Fig.C.1 (h) +5V/+15V/–15V (B–cabinet : ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12,
M–6i, M–16i, S–420i, S–500, S–700, M–400i, M–710i, A–520i)
562
Fig.C.1 (i) +5V/+15V/–15V (S–450, S–800, M–410i, M–500)
563
Fig.C.1 (j) +5V/+15V/–15V (S–900)
564
Fig.C.1 (k) +5V Robot mechanicel unit
565
566
Fig.C.1 (l) +24V (i–cabinet/B–cabinet) (ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i,
M–16i, S–420i, S–500, S–700, M–400i, M–710i, A–520i)
Fig.C.1 (m) +24V (S–800, M–500)
567
568
Fig.C.1 (n) +24V (S–900)
Fig.C.1 (o) +24V (S–450, M–410i)
569
Fig.C.1 (p) +24V (Robot mechanical unit)
570
B–80525E/04 Index
[A]
Additional Axis Control Printed Board, 217
Adjustment and Checks at Installation, 427
ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins), 393
[B]
B–CABINET (ARC Mate 100, ARC Mate 120, ARC Mate 100i, S–6, S–12, M–6i, S–420i, S–500, S–700, M–400i,
M–710i, A–520i), 453
B–Cabinet of S–900, 522
Backplane PC Board, 204
Block Diagram, 304
Block Diagram of the Power Supply, 249
[C]
Cabinet of M–410i AND S–450, 494
Cabinet of S–800/M–500, 472
Cable Connection for the Peripheral Devices, end Effectors, and ARC Welders, 394
Checking the Line Filter Unit and Transformer, 255
Checking the Power Supply Unit, 257
Component Functions, 34
Configuration, 16
Connecting Cables at Installation (Combined Type of i Cabinet), 421
Connecting the External Emergency Stop, 343
Connecting the External Power Supply ON/OFF Switch, 341
Connecting the Input Power Supply, 336
Connection Between the Control Unit and Welder, 381
Connection Between the Mechanical Unit and End Effector, 379
Connection Diagram Between Mechanical Units, 305
[D]
Diagram of Power Supply Path, 555
Digital I/O Signal Specifications, 385
[E]
Electrical Connections, 305
Emergency Stop Control PC Board, 199
End Effector Cable Connector, 398
End Effector Control Interface, 387
External Cable Wiring Diagram, 310
External View of the Controller, 16
i–1
Index B–62574EN/02
[F]
Faulty unit replace ment procedure, 406
Flowchart, 402
[H]
Hardware items required for quick change, 406
[I]
I–CABINET (ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6i, M–16i, S–420i,
S–500, S–700, M–400i, M–710i, A–520i), 431
I/O Signal Specifications for Arc–Welding Interface, 389
I/O Signals, 544
Input Signals, 544
Input/Output Hardware Usable in the R-J2 Controller, 554
Installation, 419
Installation Area, 419
Installation Condition, 426
Interface for Peripheral Devices, End Effectors, and Welders, 368
[M]
Main CPU PC Boards (A16B–3200–0040), 197
Manual Operation Impossible, 194
Mounting I/O Unit Model B on the Din Rail (Use a Rail that is 3.5mm wide and 7.5mm high.), 273
[N]
Notes on quick change, 406
[O]
Operator Safety, 3, 5
Output signals, 550
[P]
Peripheral Device and Control Unit Connection, 368
Peripheral Device Cable Connector, 396
Peripheral Device Connection Cable, 394
Peripheral Device Interface, 385
i–2
B–80525E/04 Index
Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins), 392

Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins), 392
Peripheral Device Interface Block Diagram, 350
Peripheral Device Interface Combination, 363
Peripheral Device, ARC Welding, and End Effector Interfaces, 347
Position Deviation Found in Return to the Reference Position (Positioning), 194
Power Cannot be Turned On, 37
Power Supply Imodule (PSM) (A06B–6087–H115), 224
Power Supply Unit, 292
Precautions for Mechanism, 9
Precautions for Mechanisms, 10
Precautions in Operation, 10
Precautions in Programming, 9, 10, 11
Preventive Maintenance, 35
Printed Circuit Boards, 196
Process I/O Printed Board EA (A16B–3200–0230), 213
Process I/O Printed Circuit Board Signals, 364
Process Input/Output PC Board, 205
Process Input/Output PC Board CA (A16B–2201–0470), 205
Process Input/Output PC Board CB (A16B–2201–0472), 209
Process Input/Output PC Board DA (A16B–2201–0480), 211
Process Input/Output Printed Circuit Boards CA, CB, DA and EA, 295
[Q]
Quick Change (i–cabinet), 400
[R]
Recommended Cables, 399
Replacement front cabinetunit, 405
Replacement of Fuses, 285
Replacing a Module, 266, 272
Replacing a Printed Circuit Board, 262
Replacing a Relay, 296
Replacing a Servo Amplifier, 277
Replacing a Unit, 260
Replacing Fuses, 287
Replacing the Backplane Printed Circuit Board, 262
Replacing the Base Unit of the Input/Output Unit of Model A, 271
Replacing the Battery, 299
Replacing the Fan Motor of the Control Unit, 283
Replacing the I/O Unit Model B Interface Unit, 269
i–3
Index B–62574EN/02
Replacing the Input/Output Unit of Model A, 271

Replacing the Operator’s Box, 280
Replacing the Power Supply Unit or a Printed Circuit Board on the Backplane Printed Circuit Board, 265
Replacing the process I/O EA printed circuit board, 266
Replacing the Teach Pendant, 282
Replacing the Transformer, 274
Resetting Overtravel, 428
Resetting Overtravel and Emergency Stop at Installation, 428
Robot Connection Cables, 310
[S]
Safety During Maintenance, 7
Safety in Maintenance, 12
Safety of the End Effector, 11
Safety of the Robot Mechanism, 10
Safety of the Teach Pendant Operator, 6
Safety of the Tools and Peripheral Devices, 9
Safety Precautions, 3
Selecting Transformer Taps, 252
Separate–Type Control Unit of i Cabinet, 425
Servo Amplifier, 286
Servo Amplifier (A06B–6066–H006), 235
Servo Amplifier for (ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S–6, S–12, M–6, M–16i,
S–420i, S–500, S–700, M–400i, M–710i, A–520i), 220
Servo Amplifier Module (SVM) , 228
Servo Amplifier Unit (A06B–6089–H106), 240
Servo Amplifiers, 218
Setting and Adjusting the Power Supply, 248
Setting Common Voltage, 544
Signals, 542
Software Specifications, 554
Specifications of Digital Input/Output, 554
Specifications of Peripheral Device Interface, 542
Specifications of the Cables used for Peripheral Devices and Welders, 392
[T]
Teach Pendant Cable, 335
The DIN Rail is in the Operator’s Box., 273
Total Connection Diagram, 431
Transformer, line filter unit, 285
Transportation, 418
Transportation and Installation, 418
i–4
B–80525E/04 Index
Troubleshooting, 36
Troubleshooting Using the Error Code, 39
[V]
Vibration Observed During Movement, 194
[W]
When I/O Unit Model A is used, 356
When I/O Unit Model B is used, 358
When Process I/O Printed Circuit Board CA or CB is used, 350
When Process I/O Printed Cricuit Board DA is used, 353
When Two or more Process I/O Printed Circuit Boards and I/O Unit (Model A or Model B) are used, 361
i–5
Revision Record
FANUC Robot series R–J2 CONTROLLER MAINTENANCE MANUAL (B–80525E)
Addition of descriptions for ARC Mate 100i/M–6i, S–450,

04 Apr.,’97
A–520i, M–400i, M–710i and ARC Mate 120i/M–16i
03 Oct., ’95 Addition of descriptions for M–500, A–520i
02 Nov., ’94 Addition of cabinets
01 Aug., ’94
Edition Date Contents Edition Date Contents

R-J2 Controller Maintenance FANUC

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R-J2 Controller Maintenance FANUC

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MXXXXXXXXXXXXXE REV A 1

The descriptions and specifications contained in this manual were in effect

FANUC Robotics conducts courses on its systems and products on a

Copyright 2000 by FANUC Robotics North America, Inc.

The information illustrated or contained herein is not to be reproduced,

AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL,

NOTE Information appearing next to NOTE concerns related information

R–J2 B–Size Controller Cabinet Dimensions Updates–1

R–J2 B–Size Controller Cabinet Dimensions

Figure 1. B–Size Controller Cabinet Dimensions

Control unit Control unit Control unit

Note: Height of cabinet is

This manual covers the following models.

For a PRODUCTION robot that is DOWN

For all other Troubleshooting and Technical Support

4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

6. SETTING AND ADJUSTING THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . 248

7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

3. ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

4. PERIPHERAL DEVICE, ARC WELDING,

5. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418

B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE . . . . . . . . . . . . . . . . . 542

C. DIAGRAM OF POWER SUPPLY PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555

1.1 Operator safety is the primary safety consideration. Because it is very

(4) Provide the peripheral devices with appropriate grounding (Class 1,

The circuit breaker installed in the controller is designed to disable anyone

(9) When adjusting each peripheral device independently, be sure to turn

Limit switch which operates

Limit switch for

Note) Terminals FENCE1 and FENCE2 are

Fig.1.1 (a) Safety Fence and Safety Gate

The robot controller is designed to be connected to an external EMER-

External EMERGENCY STOP button

Note) Connect to EMGIN1 and EMGIN2.

Fig.1.1 (b) Connection Diagram for External Emergency Stop Switch

On Independent Allowed to Not allowed Not allowed

2.1 Fig. 2.1 (a) to (d) show the R-J2.

Integrated type ARC Mate 100i, M–6i, S420i, A520i, M–710i

Fig.2.1 (a) External View of the R-J2 Controller (i cabinet)

Fig.2.1 (b) External View of the R-J2 controller (B–Cabinet)

Fig.2.1 (c) External View of the R-J2 controller (B–Cabinet) (S–900)

R–J2 Control unit Teach pendant

Cabinet for M–410i is

Operator’s box Circuit breaker

FANUC Handy File Teach pendant

Main CPU printed

Regenerative discharge registance

Fig.2.1 (e) R-J2 Controller Interior (i Cabinet)

FANUC Handy File Teach pendant

Main CPU printed board

Optional printed board

I/O unit model A or model B

Line filter or transformer

FANUC Handy File

Servo amplifier 5 Fan 1

I/O unit model A or model B

Fig.2.1 (g) R-J2 Controller Interior (B–Cabinet) (S–800)

Regenerative discharge unit

Operator’s panel Conversion printed board

Printed board for emergecy

transformer or Line filter

(Additional cabinet interior)