FANUC Robotics R-J3iBMate Controller (RIA R15.06 1999 Compliant) Maintenance Manual MARMIBRIA01021E REV.

B
B-81535EN/02

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 483093253

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 www.fanucrobotics.com Send your comments and suggestions about this manual to: product.documentation@fanucrobotics.com

Copyright 2002 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: AccuAir AccuCal AccuChop AccuFlow AccuPath AccuSeal ARC Mate ARC Mate Sr. ARC Mate System 1 ARC Mate System 2 ARC Mate System 3 ARC Mate System 4 ARC Mate System 5 ARCWorks Pro AssistTool AutoNormal AutoTCP BellTool BODYWorks Cal Mate Cell Finder Center Finder Clean Wall CollisionGuard DispenseTool F-100 F-200i FabTool FANUC LASER DRILL Flexibell FlexTool HandlingTool HandlingWorks INSIGHT INSIGHT II IntelliTrak Integrated Process Solution Intelligent Assist Device IPC -Integrated Pump Control IPD Integral Pneumatic Dispenser ISA Integral Servo Applicator ISD Integral Servo Dispenser Laser Mate System 3 Laser Mate System 4 LaserPro LaserTool LR Tool MIG Eye MotionParts NoBots Paint Stick PaintPro PaintTool 100 PAINTWorks PAINTWorks II PAINTWorks III PalletMate PalletMate PC PalletTool PC PayloadID RecipTool RemovalTool Robo Chop Robo Spray S-420i S-430i ShapeGen SoftFloat SOF PARTS SpotTool+ SR Mate SR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM RJ3 Controller SYSTEM R-J3iB Controller TCP Mate TurboMove TorchMate visLOC visPRO-3D visTRAC WebServer WebTP YagTool

Conventions
This manual includes information essential to the safety of personnel, equipment, software, and data. This information is indicated by headings and boxes in the text. WARNING Information appearing under WARNING concerns the protection of personnel. It is boxed and in bold type to set it apart from other text.

CAUTION Information appearing under CAUTION concerns the protection of equipment, software, and data. It is boxed to set it apart from other text.

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

Safety
Safety-1 FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner, employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace. The appropriate level of safety for your application and installation can best be determined by safety system professionals. FANUC Robotics therefore, recommends that each customer consult with such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC Robotic systems. According to the industry standard ANSI/RIA R15.06, the owner or user is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to recognize and respond to known hazards associated with your robotic system and to be aware of the recommended operating procedures for your particular application and robot installation. FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use the robotics system be trained in an approved FANUC Robotics training course and become familiar with the proper operation of the system. Persons responsible for programming the systemincluding the design, implementation, and debugging of application programs must be familiar with the recommended programming procedures for your application and robot installation. The following guidelines are provided to emphasize the importance of safety in the workplace.

Safety-2

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION

Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety: The safety of people and equipment Use of safety enhancing devices Techniques for safe teaching and manual operation of the robot(s) Techniques for safe automatic operation of the robot(s) Regular scheduled inspection of the robot and workcell Proper maintenance of the robot

Keeping People and Equipment Safe

The safety of people is always of primary importance in any situation. However, equipment must be kept safe, too. When prioritizing how to apply safety to your robotic system, consider the following: People External devices Robot(s) Tooling Workpiece

Using Safety Enhancing Devices

Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the installation of some or all of the following devices: Safety fences, barriers, or chains Light curtains Interlocks Pressure mats Floor markings Warning lights Mechanical stops EMERGENCY STOP buttons DEADMAN switches

Setting Up a Safe Workcell

A safe workcell is essential to protect people and equipment. Observe the following guidelines to ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace existing federal, state, and local laws, regulations, and guidelines that pertain to safety. Sponsor your personnel for training in approved FANUC Robotics training course(s) related to your application. Never permit untrained personnel to operate the robots.

Safety-3 Install a lockout device that uses an access code to prevent unauthorized persons from operating the robot. Use antitiedown logic to prevent the operator from bypassing safety measures. Arrange the workcell so the operator faces the workcell and can see what is going on inside the cell. Clearly identify the work envelope of each robot in the system with floor markings, signs, and special barriers. The work envelope is the area defined by the maximum motion range of the robot, including any tooling attached to the wrist flange that extend this range. Position all controllers outside the robot work envelope. Never rely on software as the primary safety element. Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the operator and at critical points inside and around the outside of the workcell. Install flashing lights and/or audible warning devices that activate whenever the robot is operating, that is, whenever power is applied to the servo drive system. Audible warning devices shall exceed the ambient noise level at the enduse application. Wherever possible, install safety fences to protect against unauthorized entry by personnel into the work envelope. Install special guarding that prevents the operator from reaching into restricted areas of the work envelope. Use interlocks. Use presence or proximity sensing devices such as light curtains, mats, and capacitance and vision systems to enhance safety. Periodically check the safety joints or safety clutches that can be optionally installed between the robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove power from the system, and help to minimize damage to the tooling and robot.

Safety-4 Make sure all external devices are properly filtered, grounded, shielded, and suppressed to prevent hazardous motion due to the effects of electromagnetic interference (EMI), radio frequency interference (RFI), and electrostatic discharge (ESD). Make provisions for power lockout/tagout at the controller. Eliminate pinch points. Pinch points are areas where personnel could get trapped between a moving robot and other equipment. Provide enough room inside the workcell to permit personnel to teach the robot and perform maintenance safely. Program the robot to load and unload material safely. If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and beacons. If materials are being applied at dangerously high pressure, provide electrical interlocks for lockout of material flow and pressure.

Staying Safe While Teaching or Manually Operating the Robot

Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules: Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment. Before teaching, visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These include tooling attached to the wrist flange that extends this range. The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe working conditions to the supervisor or safety department. FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except for robot teaching operations. However, if you must enter the work envelope, be sure all safeguards are in place, check the teach pendant DEADMAN switch for proper operation, and place the robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the DEADMAN switch. Only the person with the teach pendant should be in the work envelope.

Safety-5

WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.

Know the path that can be used to escape from a moving robot; make sure the escape path is never blocked. Isolate the robot from all remote control signals that can cause motion while data is being taught. Test any program being run for the first time in the following manner: WARNING Stay outside the robot work envelope whenever a program is being run. Failure to do so can result in injury. Using a low motion speed, single step the program for at least one full cycle. - Using a low motion speed, test run the program continuously for at least one full cycle. - Using the programmed speed, test run the program continuously for at least one full cycle. Make sure all personnel are outside the work envelope before running production.

Staying Safe During Automatic Operation

Advise all personnel who operate the robot during production to observe the following rules: Make sure all safety provisions are present and active. Know the entire workcell area. The workcell includes the robot and its work envelope, plus the area occupied by all external devices and other equipment with which the robot interacts. Understand the complete task the robot is programmed to perform before initiating automatic operation. Make sure all personnel are outside the work envelope before operating the robot.

Safety-6 Never enter or allow others to enter the work envelope during automatic operation of the robot. Know the location and status of all switches, sensors, and control signals that could cause the robot to move. Know where the EMERGENCY STOP buttons are located on both the robot control and external control devices. Be prepared to press these buttons in an emergency. Never assume that a program is complete if the robot is not moving. The robot could be waiting for an input signal that will permit it to continue activity. If the robot is running in a pattern, do not assume it will continue to run in the same pattern. Never try to stop the robot, or break its motion, with your body. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel, teach pendant, or emergency stop stations around the workcell.

Staying Safe During Inspection

When inspecting the robot, be sure to Turn off power at the controller. Lock out and tag out the power source at the controller according to the policies of your plant. Turn off the compressed air source and relieve the air pressure. If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY STOP button on the operator panel. Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. If power is needed to check the robot motion or electrical circuits, be prepared to press the EMERGENCY STOP button, in an emergency. Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.

Staying Safe During Maintenance

When performing maintenance on your robot system, observe the following rules:

Safety-7 Never enter the work envelope while the robot or a program is in operation. Before entering the work envelope, visually inspect the workcell to make sure no potentially hazardous conditions exist. Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Consider all or any overlapping work envelopes of adjoining robots when standing in a work envelope. Test the teach pendant for proper operation before entering the work envelope. If it is necessary for you to enter the robot work envelope while power is turned on, you must be sure that you are in control of the robot. Be sure to take the teach pendant with you, press the DEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switch to turn off servo power to the robot immediately. Whenever possible, perform maintenance with the power turned off. Before you open the controller front panel or enter the work envelope, turn off and lock out the 3phase power source at the controller. Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake. WARNING Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit breaker to the OFF position removes power from the output side of the device only.

Release or block all stored energy. Before working on the pneumatic system, shut off the system air supply and purge the air lines.

Safety-8 Isolate the robot from all remote control signals. If maintenance must be done when the power is on, make sure the person inside the work envelope has sole control of the robot. The teach pendant must be held by this person. Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked. Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure that such devices do not create pinch points that could trap personnel.

WARNING Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Doing so can result in serious personal injury and component destruction. Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake. When replacing or installing components, make sure dirt and debris do not enter the system. Use only specified parts for replacement. To avoid fires and damage to parts in the controller, never use nonspecified fuses. Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot and all external devices are operating normally.

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

Programming Safety Precautions

Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. Some of these measures are outlined below. Make sure you know all associated measures for safe use of such devices.

Implement the following programming safety measures to prevent damage to machine tools and other external devices.

Safety-9 Backcheck limit switches in the workcell to make sure they do not fail. Implement failure routines in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails. Use handshaking protocol to synchronize robot and external device operations. Program the robot to check the condition of all external devices during an operating cycle.

Mechanical Safety Precautions

Implement the following mechanical safety measures to prevent damage to machine tools and other external devices. Make sure the workcell is clean and free of oil, water, and debris. Use software limits, limit switches, and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices.

KEEPING THE ROBOT SAFE

Operating Safety Precautions

Observe the following operating and programming guidelines to prevent damage to the robot. The following measures are designed to prevent damage to the robot during operation. Use a low override speed to increase your control over the robot when jogging the robot. Visualize the movement the robot will make before you press the jog keys on the teach pendant. Make sure the work envelope is clean and free of oil, water, or debris. Use circuit breakers to guard against electrical overload.

Programming Safety Precautions

The following safety measures are designed to prevent damage to the robot during programming: Establish interference zones to prevent collisions when two or more robots share a work area.

Safety-10 Make sure that the program ends with the robot near or at the home position. Be aware of signals or other operations that could trigger operation of tooling resulting in personal injury or equipment damage. In dispensing applications, be aware of all safety guidelines with respect to the dispensing materials.

NOTE Any deviation from the methods and safety practices described in this manual must conform to the approved standards of your company. If you have questions, see your supervisor.

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS

Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personal also must work inside the paint booth periodically. Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor. Although paint booth hazards have been minimized, potential dangers still exist. Therefore, todays highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its capabilities. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and highvoltage electrostatic tools. Paint robots are operated in three modes: Teach or manual mode Automatic mode, including automatic and exercise operation Diagnostic mode During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant. In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth or in a designated safe

Safety-11 area within the booth whenever automatic mode is initiated at the SOC or MCP. In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds. When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.

Paint System Safety Features

Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment, personnel must comply strictly with the procedures in the manuals. This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system. The paint system includes the following safety features: Most paint booths have red warning beacons that illuminate when the robots are armed and ready to paint. Your booth might have other kinds of indicators. Learn what these are. Some paint booths have a blue beacon that, when illuminated, indicates that the electrostatic devices are enabled. Your booth might have other kinds of indicators. Learn what these are. EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become familiar with the locations of all E STOP buttons. An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres. A DEADMAN switch is located on each teach pendant. When this switch is held in, and the teach pendant is on, power is applied to the robot servo system. If the engaged DEADMAN switch is released during robot operation, power is removed from the servo system, all axis brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within the system might also ESTOP other robots. WARNING An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed robot.

Safety-12 Overtravel by robot axes is prevented by software limits. All of the major and minor axes are governed by software limits. Limit switches and hardstops also limit travel by the major axes. EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all equipment in the booth if a door is opened while the system is operating in automatic or manual mode. For some systems, signals to these switches are inactive when the switch on the SCC is in teach mode. When present, photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit silhouette openings. System status is monitored by computer. Severe conditions result in automatic system shutdown.

Staying Safe While Operating the Paint Robot

When you work in or near the paint booth, observe the following rules, in addition to all rules for safe operation that apply to all robot systems.

WARNING Observe all safety rules and guidelines to avoid injury.

WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.

Know the work area of the entire paint station (workcell). Know the work envelope of the robot and hood/deck and door opening devices. Be aware of overlapping work envelopes of adjacent robots. Know where all red, mushroomshaped EMERGENCY STOP buttons are located.

Safety-13 Know the location and status of all switches, sensors, and/or control signals that might cause the robot, conveyor, and opening devices to move. Make sure that the work area near the robot is clean and free of water, oil, and debris. Report unsafe conditions to your supervisor. Become familiar with the complete task the robot will perform BEFORE starting automatic mode. Make sure all personnel are outside the paint booth before you turn on power to the robot servo system. Never enter the work envelope or paint booth before you turn off power to the robot servo system. Never enter the work envelope during automatic operation unless a safe area has been designated. Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Remove all metallic objects, such as rings, watches, and belts, before entering a booth when the electrostatic devices are enabled. Stay out of areas where you might get trapped between a moving robot, conveyor, or opening device and another object. Be aware of signals and/or operations that could result in the triggering of guns or bells. Be aware of all safety precautions when dispensing of paint is required. Follow the procedures described in this manual.

Staying Safe While Operating Paint Application Equipment

When you work with paint application equipment, observe the following rules, in addition to all rules for safe operation that apply to all robot systems. WARNING When working with electrostatic paint equipment, follow all national and local codes as well as all safety guidelines within your organization. Also reference the following standards: NFPA 33 Standards for Spray Application Using Flammable or Combustible Materials, and NFPA 70 National Electrical Code.

Safety-14

Grounding: All electrically conductive objects in the spray area must be grounded. This includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots, as well as solvent containers. Grounding is defined as the object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms. High Voltage: High voltage should only be on during actual spray operations. Voltage should be off when the painting process is completed. Never leave high voltage on during a cap cleaning process. Avoid any accumulation of combustible vapors or coating matter. Follow all manufacturer recommended cleaning procedures. Make sure all interlocks are operational. No smoking. Post all warning signs regarding the electrostatic equipment and operation of electrostatic equipment according to NFPA 33 Standard for Spray Application Using Flammable or Combustible Material. Disable all air and paint pressure to bell. Verify that the lines are not under pressure.

Staying Safe During Maintenance

When you perform maintenance on the painter system, observe the following rules, and all other maintenance safety rules that apply to all robot installations. Only qualified, trained service or maintenance personnel should perform repair work on a robot. Paint robots operate in a potentially explosive environment. Use caution when working with electric tools. When a maintenance technician is repairing or adjusting a robot, the work area is under the control of that technician. All personnel not participating in the maintenance must stay out of the area. For some maintenance procedures, station a second person at the control panel within reach of the EMERGENCY STOP button. This person must understand the robot and associated potential hazards.

Safety-15 Be sure all covers and inspection plates are in good repair and in place. Always return the robot to the home position before you disarm it. Never use machine power to aid in removing any component from the robot. During robot operations, be aware of the robots movements. Excess vibration, unusual sounds, and so forth, can alert you to potential problems. Whenever possible, turn off the main electrical disconnect before you clean the robot. When using vinyl resin observe the following:

Wear eye protection and protective gloves during application and removal Adequate ventilation is required. Overexposure could cause drowsiness or skin and eye irritation. If there is contact with the skin, wash with water.

When using paint remover observe the following:

Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning. Adequate ventilation is required. Overexposure could cause drowsiness. If there is contact with the skin or eyes, rinse with water for at least 15 minutes.

Update Section
Single Phase Power Option

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Table of Contents

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p1

I SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1

1.2 1.3

1.1.1 1.1.2 1.1.3

OPERATOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety of the Teach Pendant Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4
6 7 9

1.2.1 1.2.2 1.3.1 1.3.2 1.3.3

SAFETY OF THE TOOLS AND PERIPHERAL DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY OF THE ROBOT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions in Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

11

10 10

1.4 1.5 1.6

1.4.1

SAFETY OF THE END EFFECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12
12

11 11 11

SAFETY IN MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 14

II MAINTENANCE
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 20

2.1 2.2 2.3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8

EXTERNAL VIEW OF THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER CANNOT BE TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Teach Pendant Cannot be Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Screen Remains on the Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 23 24
25

3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 3.1.2

26

ALARM OCCURRENCE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 SAFETY SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 TROUBLESHOOTING USING THE ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 TROUBLESHOOTING USING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 TROUBLESHOOTING BASED ON LED INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 3.9 VIBRATION OBSERVED DURING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 3.10 MANUAL OPERATION IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

27 28

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4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

4.1 4.2 4.3 4.4 5.1 5.2

ROBOT CONTROL BOARD (A16B32000450) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMERGENCY STOP BOARD (A20B10080010, 0011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BACKPLANE BOARD (A20B20030330) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCESS I/O BOARD HE (A16B22030764), HF (A16B22030765) . . . . . . . . . . . . . . . . . . .

112 116 117 118

5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

5.1.1 5.1.2 5.2.1 5.2.2

OUTLINE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 LED OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

LED of Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED of Servo Amplifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 124 Power Supply Module PSM (A06B6115H001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo Amplifier Module (A06B6114H205, A06B6114H302) . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 122

6. SETTING THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

6.1 6.2 6.3 7.1

BLOCK DIAGRAMS OF THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 CHECKING THE POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 CHECKING THE POWER SUPPLY MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 REPLACING THE PRINTEDCIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Replacing the Backplane Board (Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Robot Control Board and PrintedCircuit Boards on the Backplane Unit . . . . . . . . . . . Replacing the Emergency Stop Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Brake Power Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 131 132

7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

7.1.1 7.1.2 7.1.3

7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13

7.3.1

REPLACING CARDS AND MODULES ON THE ROBOT CONTROL BOARD . . . . . . . . . . . . . 133 REPLACING THE TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 138 139 140 141 142 143 144 145 146 147
147 148 149 150 151 152 137

7.14 REPLACING A RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 7.15 REPLACING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

7.15.1 Battery for Memory Backup (3 VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 7.14.1 Replacing a Relay on the Emergency Stop Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

7.13.1 7.13.2 7.13.3 7.13.4 7.13.5 7.13.6

REPLACING THE EMERGENCY STOP UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE MAGNETIC CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE CONTROL SECTION FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FAN MOTOR OF THE SERVO AMPLIFIER CONTROL UNIT . . . . . . . . . . REPLACING THE DOOR FAN UNIT AND HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING A FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Fuse on the Robot Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing a Fuse on the Emergency Stop Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Servo Amplifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Process I/O Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Table of Contents

III CONNECTION
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 3. CONNECTION DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

3.1 3.2 3.3 3.4

3.5 3.6 3.7 3.8 3.9

3.4.1 3.4.2 3.4.3 3.4.4

CONNECTION OF POWER SUPPLY CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FANUC I/O LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTION OF I/O LINK CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMERGENCY STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram of Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Emergency Stop Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Emergency Stop Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External 24 V Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

162 163 165 167

167 168 169 170

3.9.1 3.9.2 3.9.3 3.9.4 3.9.5

COONECTION OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTION OF ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTION OF TEACH PENDANT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTION OF CABLE FOR RS232C/RS422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTING A CABLE TO A PERIPHERAL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Peripheral Device Interfaces CRM79 and CRM81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When the Robot is Connected to the CNC by a Peripheral Device Cable . . . . . . . . . . . . . . . . . . . . . . . Digital I/O Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.3.1 Peripheral device interface CRM 79 and CRM 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital I/O Signal Specifications of End Effector Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . .

171 172 173 174 175

175 176 193 193 195 196

3.10 END EFFECTOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 3.11 TREATMENT FOR THE SHIELDED CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 3.12 PERIPHERAL DEVICE, ARC WELDING, INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.12.1 3.12.2 3.12.3 3.12.4 3.12.5 3.12.6 3.12.7 3.12.8 3.12.9 3.12.10 Peripheral Device Interface Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Interface Block Diagram and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection Between the Control Unit and Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital I/O Signal Specifications of Peripheral Device Interface A . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O Signal Specifications for ARCWelding Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin, 50 pins) . . . . . . ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.1 3.10.2 197 199

201 202 203 208 214 216 219 219 220 221

4. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

4.1 4.2 4.3 4.4 4.5 4.6

TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXTERNAL CONTROLLER DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT AND CHECKS AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOTE AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.7

DISABLING HAND BREAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

APPENDIX
A. TOTAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 B. PERIPHERAL INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

B.1 B.2 B.3

B.2.1 B.2.2

SIGNAL TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 I/O SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 241

B.3.1 B.3.2 B.3.3

SPECIFICATIONS OF DIGITAL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input/Output Hardware Usable in the R-J3iB Mate Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 242 243

C. OPTICAL FIBER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

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PREFACE

PREFACE

This manual describes the following models.

Model FANUC Robot LR Mate 100iB FANUC Robot LR Mate 200iB FANUC Robot ARC Mate 50iB Abbreviation LR Mate 100iB LR Mate 200iB ARC Mate 50iB

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SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell.

1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

B81535EN/02

1.1
OPERATOR SAFETY

Operator safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure operator safety. (1) Have the robot system operators attend the training courses held by FANUC.
FANUC provides various training courses. Contact our sales office for details.

(2) Even when the robot is stationary, it is possible that the robot is still ready to move state and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure operator safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. (3) Install a safety fence with a gate so that no operator can enter the work area without passing through the gate. Equip the gate with an interlock that stops the robot when the gate is opened.
The controller is designed to receive this interlock signal. When the gate is opened and this signal received, the controller stops the robot in an emergency. For connection, see Fig.1.1.

(4) Provide the peripheral devices with appropriate grounding (Class 1, Class 2, or Class 3). (5) Try to install the peripheral devices outside the work area. (6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when an operator enters the work area. (8) If necessary, install a safety lock so that no one except the operator in charge can turn on the power of the robot.
The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.

B81535EN/02

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.

Safety gate which executes with opening the door.

Fig.1.1 Safety Fence and Safety Gate

1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

B81535EN/02

1.1.1
Operator Safety

The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators. (1) If it is not necessary for the robot to operate, turn off the 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 operators reach.
The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

External EMERGENCY STOP button

Emergency stop board EMGIN11 EMGIN12 EMGIN21 EMGIN22

Note)

Connect between EMGIN1 and EMGIN2 and between EMGIN21 and EMGIN22. EMGIN11, EMGIN12, EMGIN21 and EMGIN22 are on the emergency stop board.

Fig.1.1.1 Connection Diagram for External Emergency Stop Switch

B81535EN/02

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

1.1.2
Safety of the Teach Pendant Operator

While teaching the robot, it is necessary for the operator to enter the work area of the robot. It is particularly necessary to ensure the safety of the teach pendant operator. (1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating condition. (3) When entering the robot work area and teaching the robot, be sure to check the location and condition of the safety devices (such as the EMERGENCY STOP button and the deadman switch on the teach pendant).
FANUCs teach pendant has a switch for enabling or disabling the robot operation from the teach pendant and a deadman switch in addition to the EMERGENCY STOP button. The switches function as follows. EMERGENCY STOP button : Pressing this button always brings the robot to an emergency stop, irrespective of the state of the enable/disable switch and the mode switch of operator panel. Deadman switch : The function of this switch depends on the state of the enable/disable switch and the mode switch of operator panel.

When the mode switch is in the AUTO position The enable/disable switch and deadman switch are disabled. When the mode switch is in the TI position and the enable/disable switch is in the enable position Releasing the deadman switch brings the robot to an emergency stop. When the mode switch is in the TI position and the enable/disable switch is in the disable position The robot is brought to an emergency stop regardless of the operation of the deadman switch. Note)The deadman switch is provided to bring the robot to an emergency stop when the operator releases the teach pendant in an emergency.

(4) The teach pendant operator should pay careful attention so that no other workers enter the robot work area.
NOTE
In addition to the above, the teach pendant enable switch and the deadman switch also have the following function. By pressing the deadman switch while the enable switch is on, the emergency stop factor (normally the safety gate) connected to FENCE11 and FENCE12 of the controller is invalidated. In this case, it is possible for an operator to enter the fence during teach operation without making the robot in the emergency stop condition. In other words, the system understands that the combined operations of pressing the teach pendant enable switch and pressing the deadman switch indicates the start of teaching. The teach pendant operator should be well aware that the safety gate is not functional under this condition and bear full responsibility to ensure that no one enters the fence during teaching.

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(5) When entering the robot work area, the teach pendant operator should enable the teach pendant whenever he or she enters the robot work area. In particular, while the teach pendant enable switch is off, make certain that no start command is sent to the robot from any operator panel other than the teach pendant.
The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode of the teach pendant enable switch and the mode switch the remote switch on the operator panel.

Operator panel mode switch T1 AUTO AUTO

Teach pendant enable switch On Off Off

Remote condition Independent Local Remote

Teach pendant Allowed to start Not allowed Not allowed

Operator panel Not allowed Allowed to start Not allowed

Peripheral devices Not allowed Not allowed Allowed to start

(6) When a program is completed, be sure to carry out a test run according to the procedure below. (a) Run the program for at least one operation cycle in the single step mode at low speed. (b) Run the program for at least one operation cycle in the continuous operation mode at low speed. (c) Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing. (d) Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble. (e) After checking the completeness of the program through the test run above, execute it in the automatic operation mode. (7) While operating the system in the automatic operation mode, the teach pendant operator should leave the robot work area.

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1. SAFETY PRECAUTIONS

1.1.3
Safety During Maintenance

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

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1.2
SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 1.2.1
Precautions in Programming

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

1.2.2
Precautions for Mechanism

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1. SAFETY PRECAUTIONS

1.3
SAFETY OF THE ROBOT MECHANISM 1.3.1
Precautions in Operation

(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality. (2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the jog mode. (1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere with each other. (2) Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated. (1) Keep the work area of the robot clean, and operate the robot in an environment free of grease, water, and dust.

1.3.2
Precautions in Programming

1.3.3
Precautions for Mechanisms

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1.4
SAFETY OF THE END EFFECTOR 1.4.1 Precautions in Programming

(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control. (2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.

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1. SAFETY PRECAUTIONS

1.5
SAFETY IN MAINTENANCE

(1) Never enter the robot work area while the robot is operating. Turn off the power before entering the robot work area for inspection and maintenance. (2) If it is necessary to enter the robot work area with the power turned on, first press the EMERGENCY STOP button on the operator panel. (3) When replacing or reinstalling components, take care to prevent foreign matter from entering the system. When replacing the parts in the pneumatic system, be sure to reduce the pressure in the piping to zero by turning the pressure control on the air regulator. (4) When handling each unit or printed circuit board in the controller during inspection, turn off the power of the controller and turn off the circuit breaker to protect against electric shock. (5) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of non-specified ratings. They may cause a fire or result in damage to the components in the controller. (6) Before restarting the robot, be sure to check that no one is in the robot work area and that the robot and its peripheral devices are all in the normal operating state.

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1.6
WARNING LABEL
Description

Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing as well. (1) Stepon prohibitive label

Fig.1.6 (a) Stepon Prohibitive Label

Description

Be cautious about a section where this label is affixed, as the section generates heat. If you have to inevitably touch such a section when it is hot, use a protective provision such as heatresistant gloves. (2) Hightemperature warning label

Fig.1.6 (b) HighTemperature Warning Label

Description

A high voltage is applied to the places where this label is attached. Before starting maintenance, turn the power to the control unit off, then turn the circuit breaker off to avoid electric shock hazards. Be careful with servo amplifier and other units because highvoltage places in these units may remain in the highvoltage state for a fixed time.
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1. SAFETY PRECAUTIONS

(3) Highvoltage warning label

Fig.1.6 (c) HighVoltage Warning Label

Description

There may be a high voltage in a place with this label. Before working on such a portion, turn off the power to the controller and set its circuit breaker to the off position to avoid shock hazards. In addition, be careful about servo amplifiers and other electric circuits because a high voltage may remain in them for a certain period of time after the power is turned off.

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MAINTENANCE

1. OVERVIEW

OVERVIEW

This manual describes the maintenance and connection of the RJ3iB Mate robot controller (called the RJ3iB Mate). Maintenance Part : Troubleshooting, and the setting, adjustment, and replacement of units Connection Part : Connection of the RJ3iB Mate controller to the robot mechanical unit and peripheral devices, and installation of the controller
WARNING Before you enter the robot working area, be sure to turn off the power to the controller or press the EMERGENCY STOP button on the operator panel or teach pendant. Otherwise, you could injure personnel or damage equipment.

TERM The RJ3iB Mate robot controller uses the FANUC servo amplifier i series (called the servo amplifier (i). The servo amplifier i comprises a power supply module (PSM) and a servo amplifier module (SVM). In this manual, the terms power supply module and servo amplifier module refer to the individual modules. The term servo amplifier refers to the combination of the power supply module and servo amplifier module.

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CONFIGURATION

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2. CONFIGURATION

2.1
EXTERNAL VIEW OF THE CONTROLLER

The appearance and components might slightly differ depending on the controlled robot, application, and options used. Fig.2.1 (a) shows the view of RJ3iB Mate. Fig.2.1 (b) shows the RJ3iB Mate consists of the RJ3iB Mate controller.
Teach pendant RJ3iB Mate controller

Operator panel

Teach pendant cable

Fan unit

Fig.2.1 (a) External View of the RJ3iB Mate Controller

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Teach pendant Power supply transformer Enable/disable switch Emergency stop for brake button

Emergency stop unit Power supply unit Emergency stop board Circuit protector Emergency stop button Mode switch Heat exchange

Back plane board Option slot (Process I/O board) Robot control board Servo amplifier module2 (AMP2) Servo amplifier module1 (AMP1) Power supply module (PSM)

Fuse MCC

Fig.2.1 (b) RJ3iB Mate interior (Front) Table 2.1 Servo amplifier specifications Robot LR Mate 100iB Power supply module A06B6115H001 (PSMR1i) Servo amplifier module1 A06B6114H205 (SVM20/20i) L M J1 J2 A06B6114H302 (SVM10/10/10i) L M N J1 J2 J3 Servo amplifier module2 A06B6114H302 (SVM10/10/10i) L M N J3 J4 J5 A06B6114H302 (SVM10/10/10i) L M N J4 J5 J6

LR Mate 200iB ARC Mate 50iB

A06B6115H001 (PSMR1i)

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2. CONFIGURATION

2.2
COMPONENT FUNCTIONS

Robot control printed circuit board This board is equipped with a microprocessor and its peripheral circuitry, memory, and operator panel control circuit. A servo control circuit is also included. Emergency stop unit, emergency stop printed circuit board This unit controls the emergency stop system, magnetic contactor (MCC) of the servo amplifier, and brake. The unit contains the power supply unit for converting the AC power to the DC power. Backplane board Various control boards are mounted on the backplane board. Teach pendant This unit is used to carry out all operations including robot programming. The liquid crystal display (LCD) of this unit displays the status of the control unit, data, and the like. Servo amplifier The servo amplifier amplifies the power of the servo amplifier and controls the pulse coder. MCC The MCC controls the main power of the servo amplifier. Operator panel The operator panel has a port for the serial interface to an external device. The panel also has an EMERGENCY STOP button. Fan unit, heat exchanger These components are used to cool the inside of the control unit. Circuit protector This component turns on or off the power. The input power is connected to the circuit protector in order to protect the equipment from a large current that could result from a problem in the electric system of the control unit or an abnormal input power.

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2.3
PREVENTIVE MAINTENANCE

Daily maintenance and periodic maintenance/inspection ensure reliable robot performance for extended periods of time. (1) Daily maintenance Before operating the system each day, clean each part of the system and check the system parts for any damage or cracks. Also check the following: (a) Before service operation Check the cable connected to the teach pendant for excessive twisting. Check the controller and peripheral devices for abnormalities. (b) After service operation At the end of service operation, return the robot to the specified position, then turn off the controller. Clean each part, and check for any damage or cracks. If the ventilation port of the controller is dusty, clean it. (c) Check after one month Check that the fan is rotating normally. If the fan has dirt and dust built up, clean the fan according to step (d) described below for inspection to be performed every 6 months. (d) Periodic inspection performed every six months Remove the top cover, louver, and back panel (if possible), then remove any dirt and dust from the inside of the transformer compartment. Wipe off dirt and dust from the fan and transformer. (2) Maintenance tools The following maintenance tools are recommended: (a) Measuring instruments AC/DC voltmeter (A digital voltmeter is sometimes required.) Oscilloscope with a frequency range of 5 MHz or higher, two channels (b) Tools Phillips screwdrivers : Large, medium, and small Standard screwdrivers: Large, medium, and small Nut driver set (Metric) Pliers Needle-nose pliers Diagonal cutting pliers

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3. TROUBLESHOOTING

TROUBLESHOOTING

This chapter describes the checking method and corrective action for each error code indicated if a hardware alarm occurs. Refer to the operator s manual to release program alarms.

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3.1
POWER CANNOT BE TURNED ON
Check and Corrective action
(Check 1) (Corrective action) Check that the circuit protector is on and has not tripped. Turn on the circuit protector. Circuit protector (on/off switch)

Figure

(Check 2)

Check that the door fan unit and the fan motor of the heat exchanger are rotating and that the LED indication on the power supply module is . If the fan motor is not rotating or if the LED of the power supply module is not glowing, the fuse on the back of the door may have been blown. Check the fuse on the back of the door. If the fuse on the back of the door has been blown, replace the fuse.

LED of the power supply module Circuit protector Heat exchange for fan unit (door face)

(Corrective action)

Secondary side of the circuit protector Fuse

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3. TROUBLESHOOTING

3.1.1
Teach Pendant Cannot be Turned On
Check and Corrective action
(Check 1) (Corrective action) Check the LCD display and LED indication on the teach pendant. Check the LCD display and LED indication on the teach pendant to see whether the emergency stop unit is faulty. Check whether the fuse FUS4 on the emergency stop board is blown. If the fuse is blown, the FALM LED glows. Replace the blown fuse. If the fuse FUS4 on the emergency stop board is not blown, the emergency stop unit may be faulty. Replace the emergency stop unit.

Figure
Teach pendant

Emergency stop board FALM LED Fuse FUS4

Emergency stop unit

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3.1.2
Initial Screen Remains on the Teach Pendant
Check and Corrective action
(Check 1) Check that the . portion of the seven segment LED glows on the robot control board. If the . portion is not glowing, the fuse FUS1 on the robot control board may be blown. Alternatively, the DC/DC converter module may be damaged. If the FUSE ALARM LED is glowing, the fuse FUS1 may be blown. The fuse FUS1 is provided on the robot control board. Before checking the fuse, turn off the circuit protector. a) If the fuse FUS1 has been blown See Corrective action (1). b) If the fuse FUS1 is not blown See Corrective action (2). Cause of the blowing of the fuse FUS1 and corrective action a) Check whether the device which is connected to the RS232C/ RS422 port and requires the power supply of +24 V is sound. b) Problem in the DC/DC converter module If the DC/DC converter module gets faulty in the shortcircuit mode, FUS1 is blown. Replace the DC/DC converter module. a) Problem in the DC/DC converter module Replace the DC/DC converter module. b) Problem in the robot control board Replace the robot control board. (For the LED indications, see Section 3.7, TROUBLESHOOTING USING LEDS.)

Figure

(Corrective action)

+24V input connector CP5

(Corrective action(1))

DC/DC converter module dot part of seven segment LED

(Corrective action(2))

FUS1 7.5A DC24V input fuse

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3. TROUBLESHOOTING

3.2
ALARM OCCURRENCE SCREEN

The alarm occurrence screen displays only the alarm conditions that are currently active. If an alarm reset signal is input to reset the alarm conditions, the alarm occurrence screen displays the message PAUSE or more serious alarm has not occurred. The alarm occurrence screen displays only the alarm conditions (if any) that occur after the most recently entered alarm reset signal. To erase all alarm displays from the alarm occurrence screen. Press the CLEAR key (+ shift) on the alarm history screen. The alarm occurrence screen is intended to display PAUSE or more serious alarms. It will not display WARN, NONE, or a reset. It is possible to disable PAUSE and some of more serious alarms from being displayed by setting the $ER_NOHIS system variable appropriately. If two or more alarms have occurred, the display begins with the most recent alarm. Up to 100 lines can be displayed. If an alarm has a cause code, it is displayed below the line indicating the alarm.
Press the screen selection key to select [4 ALARM]. Press the alarm key. Automatic alarm display upon occurrence

Alarm occurrence screen display

Press F3 [ACTIVE].

Press F3 [HIST].

Alarm history screen display

Fig.3.2 Alarm Occurrence Screen and Alarm History Screen Display Procedure

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Displaying the alarm history/alarm detail information

Step

(1) Press the MENUS key to display the screen menu. (2) Select [ALARM]. You will see a screen similar to the following
3 4 ALARM 5 I/O
MENUS

INTP224 (SAMPLE1, 7) Jump label is fail MEMO027 Specified line does not exist Alarm JOINT 30 % 1/25 1 INTP224 (SAMPLE1, 7) Jump label is 2 SRVO002 Teach pendant Estop 3 R E S E T 4 SRVO027 Robot not mastered(Group:1) 5 SYST026 System normal power up

[ TYPE ]

CLEAR

HELP

NOTE The latest alarm is assigned number 1. To view messages that are currently not on the screen, press the F5, HELP, then press the right arrow key.

(3) To display the alarm detail screen, press F5, [HELP].

CLEAR HELP F5 INTP224 (SAMPLE1, 7) Jump label is fail INTP224 (SAMPLE1, 7) Jump label is fail MEMO027 Specified line does not exist 30MAY44 07:15 STOP.L 00000110 Alarm 1/25 1 INTP224 (SAMPLE1, 7) Jump label is 2 SRVO002 Teach pendant Estop [ TYPE ] CLEAR HELP

(4) To return to the alarm history screen, press the PREV key.
PREV

(5) To delete all the alarm histories, press and hold down the SHIFT key, then press F4, [CLEAR].
CLEAR F4 HELP

SHIFT

NOTE When system variable $ER_NOHIS = 1, NONE alarms or WARN alarms are not recorded. When $ER_NOHIS=2, resets are not recorded in the alarm history. When $ER_NOHIS=3, resets, WARN alarms, and NONE alarms are not recorded.

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3. TROUBLESHOOTING

The following map indicates teach pendant operations used to check an alarm. 4 ALARM F1 [TYPE] Alarm : Active F1 [TYPE] F3 HIST Alarm : HIST F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP DETAIL Alarm F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP

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3.3
SAFETY SIGNALS
Safety signal Operator panel emergency stop Teach pendant emergency stop External emergency stop Fence open Deadman switch

The safety signal screen indicates the state of signals related to safety. To be specific, the screen indicates whether each safety signal is currently on. On this screen, it is impossible to change the state of any safety signal.
Table 3.3 Safety Signals Description This item indicates the state of the emergency stop button on the operator panel. If the EMERGENCY STOP board is pressed, the state is indicated as TRUE. This item indicates the state of the emergency stop button on the teach pendant. If the EMERGENCY STOP board is pressed, the state is indicated as TRUE. This item indicates the state of the external emergency stop signal. If the EMERGENCY STOP signal is input, the state is indicated as TRUE. This item indicates the state of the safety fence. If the safety fence is open, the state is indicated as TRUE. This item indicates whether the DEADMAN switch on the teach pendant is grasped. If the teach pendant is operable, and the DEADMAN switch is grasped, the state is indicated as TRUE. If the deadman switch is released when the teach pendant is operable, an alarm occurs, causing the servo power to be switched off. This item indicates whether the teach pendant is operable. If the teach pendant is operable, the state is indicated as TRUE. This item indicates the state of the hand safety joint. If the hand interferes with a workpiece or anything like this, and the safety joint is opened, the state is indicated as TRUE. In this case, an alarm occurs, causing the servo power to be switched off. This item indicates whether the current position of the robot is out of the operation range. If any robot articulation goes out of the operation range beyond the overtravel switch, the state is indicated as TRUE. In this case, an alarm occurs, causing the servo power to be switched off. This item indicates the state of the air pressure. The abnormal air pressure signal is connected to the air pressure sensor. If the air pressure is not higher than the specified value, the state is indicated as TRUE.

Teach pendant operable Hand broken

Robot overtravel

Abnormal air pressure

Step

(1) (2) (3) (4)

Press the MENUS key to display the screen menu. Select STATUS on the next page. Press F1, [TYPE] to display the screen switching menu. Select Safety Signal. You will see a screen similar to the following.
JOINT 30% STATUS FALSE FALSE FALSE FALSE TRUE TRUE FALSE FALSE FALSE 1/11 SIGNAL NAME 1 2 3 4 5 6 7 8 9 SOP EStop: TP Estop: Ext EStop: Fence Open: TP Deadman: TP Enable: Hand Broken: Over Travel: Low Air Alarm:

SYSTEM Safety

[TYPE]

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3.4
MASTERING

Mastering is needed if: (1) The SRVO 062 BZAL or SRVO 038 pulse mismatch alarm occurs, or (2) The pulse coder is replaced. Item (1) requires simplified mastering, while item (2) requires zerodegree or jig position mastering. (Zerodegree position mastering is just for quickfix purposes. After zerodegree position mastering is used, jig position mastering should be performed later.) The mastering procedure is described below. For details, refer to an applicable maintenance manual of mechanical unit or operator s manual of control unit. System variable $MASTER_ENB must be set to 1 or 2.
SYSTEM Variables 57 $MASTER_ENB JOINT 10% 57/136 1

Condition

Step

(1) (2) (3) (4)

9 USER 0 NEXT

Press <MENUS>. Select SYSTEM. Press F1, TYPE. Select Master/Cal you will see a screen similar to the following.
JOINT 30% 1 FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE

SYSTEM Master/Cal

MENUS

5 POSITION 6 SYSTEM 7

2 3 4 5 6

Master/Cal TYPE

Press ENTER or number key to select. [TYPE] LOAD RES_PCA DONE

F1

(5) Move the robot by jog feed to the mastering position. Release the brake on the manual brake control screen if necessary.
NOTE Mastering can not be performed until axis is rotated enough to establish a pulse.

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(6) Select 1 FIXTURE POSITION MASTER and press the F4 key (yes). Mastering data is set.
SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER Master at master position? [NO] Master at master position? [NO] [ TYPE ] YES
ENTER

SYSTEM Master/Cal

JOINT

30 %

NO

F4

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

(7) Select 6 CALIBRATE and press the F4 key (yes). Calibration is performed. Alternatively, to perform positioning, turn the power off, then turn it on again. Calibration is performed whenever the power is turned on.
5 SET QUICK MASTER REF 6 CALIBRATE ENTER Calibrate? [NO] Calibrate? [NO] [ TYPE ] SYSTEM Master/Cal JOINT 30 % 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <10.000> <25.000> <40.000> <5.000> <15.000> <0.000> [ TYPE ] LOAD RES_PCA DONE

YES

NO

F4

(8) Press F5 DONE, after mastering.

DONE

F5

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3.5
TROUBLESHOOTING USING THE ERROR CODE

(1) SRVO001 SVAL1 Operator panel Estop (Explanation) The EMERGENCY STOP button on the operator panel is pressed. (Action 1) Release the emergency stop button pressed on the operator panel. (Action 2) Release the EMERGENCY STOP button on the operator panel. (Action 3) Replace the emergency stop unit. Before taking (Action 4), make a backup copy of all the programs and settings of the control unit. (Action 4) Replace the robot control board.

Emergency stop button

Operator panel

Robot control board Emergency stop unit

Fig.3.5 (1) (a) SRVO001 SVAL1 Operator panel Estop

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(2) SRVO002 SVAL1 Teach pendant Estop (Explanation) The emergency stop button on the operators Teach Pendant was pressed. (Action 1) Release the emergency stop button on the teach pendant. (Action 2) Replace Teach Pendant.
Emergency stop button

Fig.3.5 (2) SRVO002 SVAL1 Teach pendant Estop

(3) SRVO003 SVAL1 Deadman switch released (Explanation) The teach pendant is enabled, but the deadman switch is not pressed. (Action 1) Press the deadman switch to run the robot. (Action 2) Replace the teach pendant.

Deadman switch

Fig.3.5 (3) SRVO001 SVAL1 Deadman switch released

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(4) SRVO004 SVAL1 Fence open (Explanation) In AUTO mode, there is no short circuit between FENCE11 and FENCE12 and between FENCE21 and FENCE22 on the terminal block TBEB5 of the emergency stop board. If the safety fence is connected between FENCE11 and FENCE12 and between FENCE21 and FENCE22, the door of the safety fence is open. (Action 1) When the safety fence is connected, close the door. (Action 2) Check the cables and switches connected to FENCE11, FENCE12, FENCE21 and FENCE22. (Action 3) When this signal is not used, shortcircuit between FENCE11 and FENCE12 and between FENCE21 and FENCE22.
NOTE In the system that uses the fence signal, do not shortcircuit this signal to disable it because the operation is dangerous. When this signal must be temporarily shortcircuited, make safety provisions separately.

(Action 4) (Action 5) (Action 6)

When AUTO mode is not entered even though the mode switch is set to AUTO, the mode switch may be faulty. Replace the operator panel. Replace the emergency stop unit. Before taking (Action 6), make a backup copy of all the programs and settings of the control unit. Replace the robot control board.

Short connection boards: two positions (terminal blocks located on the right when viewing from the front)

Emergency stop unit

Fig.3.5 (4) SRVO004 SVAL1 Fence open

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(5) SRVO005 SVAL1 Robot overtravel (Explanation) This alarm should not occur because no overtravel input signal is provided. However, this alarm can be caused by an abnormal overtravel input signal across the robot interconnection cable and robot control board. (Action 1) Check the robot interconnection cable (RMP) for the following. 1) The male and female connection pins are not twisted or are not loose. 2) The connector is securely connected. 3) The cable is free from a break and ground fault. Next, check that the connector CRM82 of the robot control board is securely connected. In addition, check that the RMP cable is sound and free from a break or visible twist. Before taking (Action 2), make a backup copy of all the programs and settings of the control unit. (Action 2) Replace the robot control board.

Robot control board

Fig.3.5 (5) SRVO005 SVAL1 Robot overtravel

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(6) SRVO006 SVAL1 Hand broken (Explanation) The safety joint, if any, is broken. If no joint is broken, the HBK signal line of the robot interconnection cable has a break or ground fault. (Action 1) Holding down the shift key, press the alarm release button. This releases the alarm. Keeping on holding down the shift key, carry out jog feed to move the tool to the work area. 1) Replace the safety joint. 2) Examine the cable. (Action 2) Check the robot interconnection cable (RMP) for the following. 1) The male and female connection pins are not twisted or are not loose. 2) The connector is securely connected. 3) The cable is free from a break and ground fault. Next, check that the connector CRM82 of the robot control board is securely connected. In addition, check that the RMP cable is sound and free from a break or visible twist. Before taking (Action 3), make a backup copy of all the programs and settings of the control unit. (Action 3) Replace the robot control board.

Robot control board

Fig.3.5 (6) SRVO006 SVAL1 Hand broken

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(7) SRVO007 SVAL1 External Estop (Explanation) EMGIN11 and EMGIN12/EMGIN21 and EMGIN22 on the terminal block TBEB5 of the emergency stop board are not shortcircuited. If an external emergency stop switch is connected across EMGIN11 and EMGIN12/EMGIN21 and EMGIN22, the switch has been pressed. (Action 1) If an external emergency stop switch is connected, releases the switch. (Action 2) Check the switch and cable connected to EMGIN11 and EMGIN12 and to EMGIN21 and EMGIN22. (Action 3) When this signal is not used, make a connection between EMGIN11 and EMGIN12 and a connection between EMGIN21 and EMGIN22. (WARNING) (Action 4) Replace the emergency stop unit.
WARNING Do NOT shortcircuit, or disable, this signal in a system in which the External emergency stop input signal is in use, as it is very dangerous. If it is necessary to run the robot by shortcircuiting the signal even temporarily, an additional safety provision must be provided.

Short connection boards: two positions (terminal blocks located on the left when viewing from the front)

Emergency stop unit

Fig.3.5 (7) SRVO007 SVAL1 External Estop

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(8) SRVO009 SVAL1 Pneumatic pressure alarm (Explanation) An abnormal air pressure was detected. The input signal is located on the end effector of the robot. Refer to the manual of your robot. (Action 1) If an abnormal air pressure is detected, check the cause. If the peripheral device are normal, check the robot connection cable. Before taking (Action 2), make a backup copy of all the programs and settings of the control unit. (Action 2) Replace the robot control board.

Robot control board

Fig.3.5 (8) SRVO009 SVAL1 Pneumatic pressure alarm

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(9) SRVO014 WARN Fan motor abnormal (Explanation) A fan motor in the backplane unit is abnormal. (Action) Check the fan motor and its cables. Replace them if necessary.
Fan motor

Fig.3.5 (9) SRVO014 WARN Fan motor abnormal

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(10)SRVO015 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 (45C), cool down ambient temperature. (Action 2) If the fan motor is not running, check it and its cables. Replace them if necessary. (Action 3) If the thermostat on the robot control board is defective, replace the robot control board.

Fan motor (on the heat exchange)

Fan motor (door face)

Robot control board

Fig.3.5 (10) SRVO015 SVAL1 SYSTEM OVER HEAT

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(11) SRVO021 SVAL1 SRDY off (Group : i Axis : j) (Explanation) The HRDY is on and the SRDY is off, although there is no other cause of an alarm. (HRDY is a signal with which the host detects the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on.) If the servo amplifier magnetic contactor cannot be turned on when directed so, it is most likely that a servo amplifier alarm has occurred. If a servo amplifier alarm has been detected, the host will not issue this alarm (SRDY off). Therefore, this alarm indicates that the magnetic contactor cannot be turned on for an unknown reason. (Action 1) Measure the voltage of the 200VAC input to the power supply module. If the voltage is 170 VAC or lower, adjust the input voltage. (Action 2) Check that CRR78 of the emergency stop board and CX3 and CX4 of the power supply module are securely connected. Check the cables of the emergency stop board and power supply module for a break. (Action 3) Check the EMERGENCY STOP line (teach pendant emergency stop, teach pendant enable/disable switch, teach pendant deadman switch, operator panel emergency stop, external emergency stop input, fence input) for a possibility of an instantaneous interruption. If the software cannot judge the cause of the alarm at an instantaneous interruption of the EMERGENCY STOP line, this alarm occurs. (Action 4) Replace the emergency stop unit. (Action 5) If an alarm occurs on all axes, the power supply module may be faulty. Replace the power supply module. (Action 6) If an alarm occurs on a particular axis, the servo amplifier module may be faulty. Replace the servo amplifier module controlling the axis. (Action 7) Replace the axis control card on the robot control board.

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Emergency stop unit Axis control card

Robot control board Servo amplifier module Power supply module

Fig.3.5 (11) SRVO021 SVAL1 SRDY off

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(12)SRVO022 SVAL1 SRDY on (Group : i Axis : j) (Explanation) When the HRDY is about to go on, the SRDY is already on. (HRDY is a signal with which the host directs the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on. (Action 1) Replace the axis control card on the robot control board. (Action 2) If an alarm occurs on all axes, the power supply module may be faulty. Replace the power supply module. (Action 3) If an alarm occurs on a particular axis, the servo amplifier module may be faulty. Replace the servo amplifier module controlling the axis.

Robot control board Servo amplifier module Power supply module Axis control card

Fig.3.5 (12) SRVO022 SVAL1 SRDY on

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(13)SRVO023 SVAL1 Stop error excess (Group : i Axis : j) (Explanation) When the servo is at stop, the position error is abnormally large. (Action 1) Check whether the motor brake has been released. (Action 2) Make sure that the servo amplifier CZ2L to N are connected tightly. (Action 3) Check to see if the load is greater than the rating. If greater, reduce it to within the rating. (If the load is too greater, the torque required for acceleration / deceleration becomes higher than the capacity of the motor. As a result, the motor becomes unable to follow the command, and an alarm is issued.) (Action 4) Check each phase voltage of the CZ1 connector of the threephase power (200 VAC) input to the servo amplifier. If it is 170 VAC or lower, check the line voltage. (If the voltage input to the servo amplifier becomes low, the torque output also becomes low. As a result the motor may become unable to follow the command, hence possibly an alarm.) (Action 5) If the line voltage is 170 VAC or higher, replace the power supply module or servo amplifier module. (Action 6) Check disconnection of robot connection cable (RMP). (Action 7) Replace the motor.

Servo amplifier module Power supply module

Fig.3.5 (13) SRVO023 SVAL1 Stop error excess

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(14)SRVO024 SVAL1 Move error excess (Group : i Axis : j) (Explanation) When the robot is running, its position error is greater than a specified value ($PARAM _ GROUP. $MOVER _ OFFST or $PARAM _ GROUP. $TRKERRLIM). It is likely that the robot cannot follow the speed specified by program. (Action 1) Check the robot for binding axis. (Action 2) Take the same actions as described for the above alarm. (15)SRVO025 SVAL1 Motn dt overflow (Group : i Axis : j) (Explanation) The specified value is too great. (16)SRVO026 WARN2 Motor speed limit (Group : i Axis : j) (Explanation) A value higher than the maximum motor speed ($PARAM_GROUP.$MOT_SPD_LIM) was specified. The actual motor speed is clamped to the maximum speed. (17)SRVO027 WARN Robot not mastered (Group : i) (Explanation) An attempt was made to calibrate the robot, but the necessary adjustment had not been completed. (Action) Master the robot. (18)SRVO030 SVAL1 Brake on hold (Group : i) (Explanation) This alarm occurs when the robot pauses, if the brake on hold function has been enabled ($SCR. $BRKHOLD _ ENB = 1). Disable the function if it is not necessary. (Action) Disable [Servooff during pause] on the general setting menu (Select Setting general). (19)SRVO031 SVAL1 User servo alarm (Group : i) (Explanation) An user servo alarm occurred. (20)SRVO033 WARN Robot not calibrated (Group : i) (Explanation) An attempt was made to set up a reference point for simplified adjustment, but the robot had not been calibrated. (Action) Calibrate the robot. 1.Supply power. 2.Set up a simplified adjustment reference point using [Positioning] on the positioning menu. (21)SRVO034 WARN Ref pos not set (Group : i) (Explanation) An attempt was made to perform simplified adjustment, but the reference point had not been set up. (Action) Set up a simplified adjustment reference point on the positioning menu. (22)SRVO035 WARN2 Joint speed limit (Group : i Axis : j) (Explanation) A value higher than the maximum axis speed ($PARAM_GROUP.$JNTVELLIM) was specified. Each actual axis speed is clamped to the maximum speed. (23)SRVO036 SVAL1 Inpos time over (Group : i Axis : j) (Explanation) The robot did not get to the effective area ($PARAM _ GROUP.$ STOPTOL) even after the position check monitoring time ($PARAM _ GROUP. $INPOS _ TIME) elapsed. (Action) Take the same actions as for SRVO23 (large position error at a stop). (24)SRVO037 SVAL1 Imstp input (Group : i) (Explanation) The *IMSTP signal for a peripheral device interface was input. (Action) Turn on the *IMSTP signal.
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(25)SRVO038 SVAL2 Pulse mismatch (Group : i Axis : j) (Explanation) The pulse count obtained when power is turned off does not match the pulse count obtained when power is applied. This alarm is asserted after exchange the pulsecoder or battery for back up of the pulsecoder data or loading back up data to the Robot control board. (Action) Perform Absolute Pulse Coder reset and remaster robot (RESPCA) 1. Press MENUS. 2. Select SYSTEM. 3. Press F1 [TYPE]. 4. Select MASTER/CAL. 5. Press F3, PESPCA and YES. 6. Execute mastering. 7. Press RESET. The fault condition should reset. If the controller is still faulted with additional servorelated errors, cold start the controller. It might be necessary to remaster the robot. (26)SRVO041 SVAL2 MOFAL alarm (Group : i Axis : j) (Explanation) The servo value was too high. (Action) Cold start the controller.

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(27)SRVO044 SVAL1 HVAL alarm (Group : i Axis : j) (Explanation) The DC voltage (DC link voltage) of the main circuit power supply is abnormally high. The LED indication on the power supply module is 7 (HVAL). (Action 1) Check the threephase input voltage at the power supply module. If it is 253 VAC or higher, check the line voltage. (If the threephase input voltage is higher than 253 VAC, high acceleration/deceleration can result in this alarm.) (Action 2) Check that the load weight is within the rating. If it is higher than the rating, reduce it to within the rating. (If the machine load is higher than the rating, the accumulation of regenerative energy might result in the HVAL alarm even when the threephase input voltage is within the rating. (Action 3) Replace the power supply module.

Power supply module

Fig.3.5 (27) SRVO044 SVAL1 HVAL alarm

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(28)SRVO045 SVAL1 HCAL alarm (Group : i Axis : j) (Explanation) Abnormally high current flowed in the main circuit of the servo amplifier module. The LED indications on the servo amplifier modules are b, C, and d. (Action 1) Disconnect the Robot connection cable (Motor power) from the connector CZ2 of the servo amplifier module. If error occurs, replace the servo amplifier. (Action 2) Disconnect the Robot connection cable (Motor power) from the servo amplifier module connector (CZ2), and check the insulation of each Robot connection cable (Motor power) (U, V, or W) and the GND line. If there is a shortcircuit, the motor, robot interconnection cable, or intrarobot cable is defective. Check them and replace them if necessary. (Action 3) Disconnect the Robot connection cable (Motor power) from the servo amplifier module connector (CZ2), and measure the resistance between the U and V, V and W, and W and U with a ohmmeter with a very low resistance range. If the resistances at these three places are different from each other, the motor, robot interconnection cable, or intrarobot cable is defective. Check each item in detail. Before taking (Action 4), make a backup copy of all the programs and settings of the control unit. (Action 4) Replace the robot control board.

Robot control board Servo amplifier module

Fig.3.5 (28) SRVO045 SVAL1 HCAL alarm

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(29)SRVO046 SVAL2 OVC alarm (Group : i Axis : j) (Explanation) This alarm is issued to prevent the motor from thermal damage that might occur when the root meant square current calculated within the servo system is out of the allowable range. (Action 1) Check the operating conditions for the robot and relax the service conditions. (Action 2) Check each phase voltage of the threephase input power (200 VAC for the power supply module. If it is 170 VAC or lower, check the line voltage. (Action 3) Replace the power supply module and servo amplifier module. (Action 4) Check the robot connection cable (RMP). (Action 5) Replace the motor.

Servo amplifier module Power supply module

Fig.3.5 (29) SRVO046 SVAL2 OVC alarm

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Reference

Relationships among the OVC, OVL, and HC alarms

Overview

This section points out the differences among the OVC, OVL, and HC alarms and describes the purpose of each alarm.
Alarm detection section
Abbreviation Designation Overcurrent alarm Overload alarm Detection section Servo software Thermal relay in the motor OHAL2 Thermal relay in the servo amplifier OHAL1 Thermal relay in the separate regenerative discharge unit DCAL Servo amplifier

OVC OVL

HC

High current alarm

Purpose of each alarm

1) HC alarm (high current alarm) If high current flow in a power transistor momentarily due to abnormality or noise in the control circuit, the power transistor and rectifier diodes might be damaged, or the magnet of the motor might be degaussed. The HC alarm is intended to prevent such failures. 2) OVC and OVL alarms (overcurrent and overload alarms) The OVC and OVL alarms are intended to prevent overheat that may lead to the burnout of the motor winding, the breakdown of the servo amplifier transistor, and the separate regenerative resistor. The OVL alarm occurs when each builtin thermal relay detects a temperature higher than the rated value. However, this method is not necessarily perfect to prevent these failures. For example, if the motor frequently repeats to start and stop, the thermal time constant of the motor, which has a large mass, becomes higher than the time constant of the thermal relay, because these two components are different in material, structure, and dimension. Therefore, if the motor repeats to start and stop within a short time as shown in Fig. 1, the temperature rise in the motor is steeper than that in the thermal relay, thus causing the motor to burn before the thermal relay detects an abnormally high temperature.

Temperature Start Stop Start Stop Start Thermal time constant of the motor is high. Thermal time constant of the thermal relay is low.

Temperature at which the winding starts to burn

Time

Fig.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles

To prevent the above defects, software is used to monitor the current in the motor constantly in order to estimate the temperature of the motor. The OVC alarm is issued based on this estimated temperature. This method estimates the motor temperature with substantial accuracy, so it can prevent the failures described above.
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To sum up, a double protection method is used; the OVC alarm is used for protection from a shorttime overcurrent, and the OVL alarm is used for protection from longterm overload. The relationship between the OVC and OVL alarms is shown in Fig 2.
Current Protection area for the motor and servo amplifier Protection by the OVL Limit current

Protection by the OVC

Rated continuous current Time

Fig.2 Relationship between the OVC and OVL alarms

NOTE The relationship shown in Fig. 2 is taken into consideration for the OVC alarm. The motor might not be hot even if the OVC alarm has occurred. In this case, do not change the parameters to relax protection.

(30)SRVO047 SVAL1 LVAL alarm (Group : i Axis : j) (Explanation) The control power voltage (+5 V, etc.) on the servo amplifier module is too low. The LED indication on the servo amplifier module is 2 (LVAL). (Action 1) Replace the servo amplifier module.

Servo amplifier module

Fig.3.5 (30) SRVO047 SVAL1 LVAL alarm

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(31)SRVO049 SVAL1 OHAL1 alarm (Group : i Axis : j) (Explanation) This alarm does not occur when the power supply module and serve amplifier modules used with the RJ3iB Mate are under normal conditions. This alarm indicates that any of the power supply module and servo amplifier modules is faulty. (Action 1) If this alarm occurs in relation to all axes, replace the power supply module. (Action 2) If this alarm occurs in relation to a specific axis, replace the servo amplifier module that controls the axis.

Servo amplifier module Power supply module

Fig.3.5 (31) SRVO049 SVAL1 OHAL1 alarm

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(32)SRVO050 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 jogfeed it to recover from the collision. (Action 2) Make sure that the load setting is correct. (Action 3) Check that the load weight is within the rating. If it is higher than the rating, reduce it to within the rating. (If the robot is used out of its usable range, the estimated disturbance torque becomes abnormally high, possibly resulting in this alarm being detected.) (Action 4) Check the phase voltage of the threephase input power (200 VAC) to the power supply module. If it is 170 VAC or lower, check the line voltage. (Action 5) Replace the power supply module and the servo amplifier module.

Servo amplifier module Power supply module

Fig.3.5 (32) SRVO050 SVAL1 CLALM alarm

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(33)SRVO051 SVAL2 CUER alarm (Group : i Axis : j) (Explanation) The offset of the current feedback value is abnormally high. (Action) Replace the servo amplifier module.

Servo amplifier module

Fig.3.5 (33) SRVO051 SVAL2 CUER alarm

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(34)SRVO054 DSM Memory Error (Explanation) An access to the axis control card on the robot control board memory fails. (Action) Replace the axis control card.

Robot control board Servo amplifier module Axis control card

Fig.3.5 (34) SRVO054 DSM Memory Error

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(35)SRVO055 SVAL2 FSSB com error 1 (Group : i Axis : j) (Explanation) A communication error has occurred between the robot control board and servo amplifier. (Action 1) Check the communication cable (optical fiber) between the robot control board and servo amplifier. Replace it if it is faulty. (Action 2) Replace the axis control card on the robot control board. (Action 3) Replace the servo amplifier module. Before continuing to the next step, perform a complete controller backup to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data. (Action 4) Replace the robot control board.

Robot control board Servo amplifier module Axis control card

Fig.3.5 (35) SRVO055 SVAL2 FSSB com error 1

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(36)SRVO056 SVAL2 FSSB com error 2 (Group : i Axis : j) (Explanation) A communication error has occurred between the robot control board and servo amplifier. (Action 1) Check the communication cable (optical fiber) between the robot control board and servo amplifier. Replace it if it is faulty. (Action 2) Replace the axis control card on the robot control board. (Action 3) Replace the servo amplifier module. Before continuing to the next step, perform a complete controller backup to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data. (Action 4) Replace the robot control board.

Robot control board Servo amplifier module Axis control card

Fig.3.5 (36) SRVO056 SVAL2 FSSB com error 2

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(37)SRVO057 SVAL2 FSSB disconnect (Group : i Axis : j) (Explanation) Communication was interrupted between the robot control board and servo amplifier. (Action 1) Check whether fuse FU1 in the power supply module unit has blown. (Action 2) Check whether fuse FU1 in the servo amplifier module has blown. (Action 3) Check the communication cable (optical fiber) between the robot control board and servo amplifier. Replace it if it is faulty. (Action 4) Replace the axis control card on the robot control board. (Action 5) Replace the power supply module and the servo amplifier module. Before continuing to the next step, perform a complete controller backup to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data. (Action 6) Replace the robot control board. (Action 7) Check the RMP cable of robot connection cable. (+5V ground fault)

Robot control board Servo amplifier module Power supply module Axis control card

Fig.3.5 (37) SRVO057 SVAL2 FSSB disconnect

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(38)SRVO058 SVAL2 FSSB init error (Group : i Axis : j) (Explanation) Communication was interrupted between the robot control board and servo amplifier module. (Action 1) Check whether fuse FU1 in the power supply module have blown. If they have blown, see Section 3.6, Troubleshooting for Blown Fuse. (Action 2) Check whether seven segment LEDs on the servo amplifier module are on. If they are on, perform Action 4 and all actions that follow it. If they are not on, perform Action 3 and all actions that follow it. (Action 3) Check whether connector CX1 on the power supply module is securely connected. (Action 4) Check the communication cable (optical fiber) between the robot control board and servo amplifier module. Replace it if it is faulty. (Action 5) Replace the axis control card on the robot control board. (Action 6) If the sevensegment LED on the servo amplifier module is glowing, replace the servo amplifier module. If the sevensegment LED on the servo amplifier module is not glowing, replace the power supply module. Before continuing to the next step, perform a complete controller backup to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data. (Action 7) Replace the robot control board.

Robot controll board Servo amplifier module Power supply module Axis control card

Fig.3.5 (38) SRVO058 SVAL2 FSSB init error

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(39)SRVO059 SVAL2 Servo amp init error (Explanation) Servo amplifier initialzation is failed. (Action 1) Check all connectors on the PSM and SVM. Make sure they are installed correctly. (Action 2) Replace the power supply module and the servo amplifier module.

Servo amplifier module Power supply module

Fig.3.5 (39) SRVO059 SVAL2 Servo amp init error

(40)SRVO061 SVAL2 CKAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal count clock). (Action) Replace the pulse coder.
NOTE In this case, perform actions associated with DTERR, CRCERR, or STBERR first.

(41)SRVO062 SVAL2 BZAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if battery for pulse coder absolute-position backup is empty. A probable cause is a broken battery cable or no batteries in the robot. (Action) Remove the cause of the alarm, set the system variable ($MCR.$SPC RESET) to TRUE, then turn the power off and on again. Mastering is required. (42)SRVO063 SVAL2 RCAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal counter). (Action) Replace the pulse coder.
NOTE In this case, perform actions associated with DTERR, CRCERR, or STBERR first.

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(43)SRVO064 SVAL2 PHAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the phase of the pulses generated in the pulse coder is abnormal. (Action) Replace the pulse coder.
NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm.

(44)SRVO065 WARN BLAL alarm (Group : i Axis : j) (Explanation) The battery voltage for the pulse coder is lower than the rating. (Action) Replace the battery. (If this alarm occurs, turn on the AC power and replace the battery as soon as possible. A delay in battery replacement may result in the BZAL alarm being detected. In this case, the position data will be lost. Once the position data is lost, mastering will become necessary. (45)SRVO066 SVAL2 CSAL alarm (Group : i Axis : j) (Explanation) The ROM in the pulse coder is abnormal. (Action) Replace the pulse coder.
NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm.

(46)SRVO067 SVAL2 OHAL2 alarm (Group : i Axis : j) (Explanation) The temperature inside the pulse coder or motor is abnormally high, and the builtin thermostat has operated. (Action 1) Check the operating conditions for the robot and relax the service conditions. (Action 2) When power is supplied to the motor after it has become sufficiently cool, if the alarm still occurs, replace the motor. (47)SRVO068 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 SRVO070 (48)SRVO069 SVAL2 CRCERR alarm (Group : i Axis : j) (Explanation) The serial data has disturbed during communication. See actions on SRVO070

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(49)SRVO070 SVAL2 STBERR alarm (Group : i Axis : j) (Explanation) The start and stop bits of the serial data are abnormal. (Action 1) Make sure that the JF1 to JF3 connector of servo amplifire module is connected tightly. (Action 2) Check that the shielding of the robot interconnection cable (for the pulse coder) and the peripheral equipment cable is connected securely to the grounding plate. (Action 3) Check that each unit is grounded securely. (Action 4) Replace the servo amplifier module. (Action 5) Replace the pulse coder. (Action 6) Replace the robot interconnection cable (RMP).

Servo amplifier module

Fig.3.5 (49) SRVO070 SVAL2 STBERR alarm

(50)SRVO071 SVAL2 SPHAL alarm (Group : i Axis : j) (Explanation) The feedback speed is abnormally high. (Action 1) If this alarm occurs together with the PHAL alarm (No. 064), this alarm does not correspond to the major cause of the failure. (Action 2) Replace the pulse coder. (51)SRVO072 SVAL2 PMAL alarm (Group : i Axis : j) (Explanation) It is likely that the pulse coder is abnormal. (Action) Replace the pulse coder and remaster the robot. (52)SRVO073 SVAL2 CMAL alarm (Group : i Axis : j) (Explanation) It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. (Action) Master the robot and enhance the shielding. (53)SRVO074 SVAL2 LDAL alarm (Group : i Axis : j) (Explanation) The LED in the pulse coder is broken. (Action) Replace the pulse coder, and remaster the robot. (54)SRVO075 WARN Pulse not established (Group : i Axis : j) (Explanation) The absolute position of the pulse coder cannot be established. (Action) Reset the alarm, and jog the axis on which the alarm has occurred until the same alarm will not occur again. (Jog one motor revolution)
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(55)SRVO076 SVAL1 Tip Stick Detection (Group : i Axis : j) (Explanation) An excessive disturbance was assumed in servo software at the start of operation. (An abnormal load was detected. The cause may be welding.) (Action 1) Check whether the robot comes into collision with foreign matter. If a collision occurs, reset the system, then switch it to the jog feed mode to avoid the collision. (Action 2) Check whether the load settings are valid. (Action 3) Check whether the load weight is within the rated range. If the weight exceeds the upper limit, decrease it to the limit. (Use of the robot with a load exceeding the limit applied may abnormally increase the assumed disturbance, resulting in this alarm.) (Action 4) Check each interphase voltage of the threephase input (200 VAC) to the power supply module. If the voltage is 170 VAC or lower, check the input power supply voltage. (Action 5) Replace the power supply module and the servo amplifier module.

Servo amplifier module Power supply module

Fig.3.5 (60) SRVO076 SVAL1 Tip Stick Detection

(56)SRVO081 WARN EROFL alarm (Track enc : i) (Explanation) The pulse counter for line tracking has overflowed. (57)SRVO082 WARN DAL alarm (Track ebc : i) (Explanation) The line tracking pulse coder has not been connected. (Action 1) Check the pulse coder connection cable, and replace it if necessary. (Action 2) Replace the pulse coder. (58)SRVO083 WARN CKAL alarm (Track ebc : i) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal count clock). (Action) See the description about the SRVO061 CKAL alarm.
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(59)SRVO084 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 (SRVO062). (60)SRVO085 WARN RCAL alarm (Track ebc : i) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal counter). (Action) See the description about the SRVO063 RCAL alarm. (61)SRVO086 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 (SRVO064). (62)SRVO087 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 (SRVO065). (63)SRVO088 WARN CSAL alarm (Track ebc : i) (Explanation) The ROM in the pulse coder is abnormal. (Action) See the description about the SRVO066 CSAL alarm. (64)SRVO089 WARN OHAL2 alarm (Track enc : i) (Explanation) The motor has overheated. See the description about the OHAL2 alarm (SRVO067). (65)SRVO090 WARN DTERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the DTERR alarm (SRVO068). (66)SRVO091 WARN CRCERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the CRCERR alarm (SRVO069). (67)SRVO092 WARN STBERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the STBERR alarm (SRVO070). (68)SRVO093 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 (SRVO071). (69)SRVO094 WARN PMAL alarm (Track enc : i) (Explanation) It is likely that the pulse coder is abnormal. See the description about the PMAL alarm (SRVO072). (70)SRVO095 WARN CMAL alarm (Track enc : i) (Explanation) It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. See the description about the CMAL alarm (SRVO073). (71)SRVO096 WARN LDAL alarm (Track enc : i) (Explanation) The LED in the pulse coder is broken. See the description about the LDAL alarm (SRVO074).
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(72)SRVO097 WARN Pulse not established (enc : i) (Explanation) The absolute position of the pulse coder cannot be established. See the description about (SRVO075). Pulse not established. (73)SRVO131 SVAL1 LVAL (PSM) alarm (Group : i Axis : j) (Explanation) The control power supply voltage (for example, +5 V) on the power supply module is abnormally low. The LED indication on the power supply module is 6 (LVAL). (Action 1) Replace the power supply module.

Power supply module

Fig.3.5 (73) SRVO131 SVAL1 LVAL(PSM) alarm

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(74)SRVO134 SVAL1 DCLVAL (PSM) alarm (Group : i Axis : j) (Explanation) The DC voltage (DC link voltage) of the main circuit power supply on the power supply module is abnormally low. The LED indication on the power supply module is 4. If this alarm occurs during robot operation: (Action 1) Check the phase voltage of the threephase input (200 VAC) to the power supply module. If it is 170 VAC or lower, check the input power supply voltage. (Action 2) Replace the power supply module. If this alarm occurs before the magnetic contactor (MCC) is turned on: (Action 1) Check the emergency stop board and the wiring between the power supply module and magnetic contactor (MCC) for an abnormal condition. (Action 2) Replace the magnetic contactor (MCC). (Action 3) Replace the emergency stop unit. (Action 4) Replace the power supply module.

Magnetic contactor

Servo amplifier module Power supply module Emergency stop unit

Fig.3.5 (74) SRVO134 SVAL1 DCLVAL (PSM) alarm

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(75)SRVO135 SVAL FSAL alarm (Group : i Axis : j) (Explanation) The internal cooling fan(s) of the servo amplifier module(s) is abnormal. The LED indication on the relevant servo amplifier module is 1. (Action 1) Replace the fan motor of the servo amplifier module. (Action 2) Replace the servo amplifier module.

Fan

Servo amplifier module

Servo amplifier module

Fig.3.5 (75) SRVO135 SVAL FSAL alarm

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(76)SRVO136 SVAL1 DCLVAL alarm (Group : i Axis : j) (Explanation) The servo the DC current of servo amplifier module (DC link voltage) of the main power supply is abnormally low. The LED indication on the servo amplifier module becomes 5. This alarm occured in the robot operation. (Action 1) Check the phase voltage of the threephase input power (200 VAC) to the power supply module. If it is 170 VAC or lower, check the line voltage. (Action 2) Replace the power supply module and the servo amplifier module. If this alarm occurs before the magnetic contactor is turned on: (Action 1) Check the emergency stop board and the wiring between the power supply module and electromagnetic contactor (MCC) for an abnormal condition. (Action 2) Replace the magnetic contactor. (Action 3) Replace the Estop unit. (Action 4) Replace the servo amplifier module.

Magnetic contactor

Robot control board Servo amplifier module Power supply module

Fig.3.5 (76) SRVO136 SVAL1 DCLVAL alarm

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(77)SRVO156 SVAL1 IPMAL alarm (Group : i Axis : j) (Explanation) Abnormally high current flowed through the main circuit of the servo amplifier. The LED indications on the servo amplifier modules are 8., 9., and A.. (Action 1) Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, then turn on the power. If this operation causes the error to recur, replace the servo amplifier module. (Action 2) Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, then check the insulation between GND and each of the motor power lines U, V, and W individually. If a shortcircuit is found, the motor, robot interconnection cable, or intrarobot cable may be faulty. Examine each of them for any problem. (Action 3) Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, then measure the resistance between the motor power lines U and V, V and W, and W and U, using an ohmmeter with a very low resistance range. If the three resistances are different, the motor, robot connection cable, or intrarobot cable may be faulty. Examine each of them for any problem. Before taking (Action 4), make a backup copy of all the programs and settings of the control unit. (Action 4) Replace the robot control board.

Robot control board Servo amplifier module

Fig.3.5 (77) SRVO156 SVAL1 IPMAL alarm

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(78)SRVO157 SVAL1 CHGAL alarm (Group : i Axis : j) (Explanation) The capacitor for the DC link voltage of the servo amplifier module was not charged within the specified time. (Action 1) A short circuit may occur in the DC link voltage. Check the connection. (Action 2) Replace the servo amplifier module. (Action 3) Replace the power supply module.

Servo amplifier module Power supply module

Fig.3.5 (78) SRVO157 SVAL1 CHGAL alarm

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(79)SRVO201 SVAL1 Panel Estop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator panel was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Check the EMERGENCY STOP button on the operator panel, and replace it if necessary. (Action 2) Replace the emergency stop unit. (Action 3) Replace the power supply module.
NOTE This alarm might occur if the EMERGENCY STOP button is pressed slowly.

emergency stop button

Power supply module Emergency stop unit

Fig.3.5 (79) SRVO201 SVAL1 Panel Estop or SVEMG abnormal

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(80)SRVO202 SVAL1 TP Estop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator panel was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Check the teach pendant connection cable. (Action 2) Replace the teach pendant. (Action 3) Replace the emergency stop unit. (Action 4) Replace the power supply module.
NOTE This alarm might occur if the EMERGENCY STOP button is pressed slowly.

Teach pendant teach pendant cable

emergency stop button

Power supply module Emergency stop unit

Fig.3.5 (80) SRVO202 SVAL1 TP Estop or SVEMG abnormal

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(81)SRVO204 SVAL1 External (SVEMG abnormal) Estop (Explanation) Although the switch connected across EMGIN11 and EMGIN12/EMGIN21 and EMGIN22 on the terminal block TBEB1 of the emergency stop board was pressed, the EMERGENCY STOP line was not disconnected. (Action 1) Check whether there is a large difference in operation time between the switch connected across EMGIN11 and EMGIN12 and the switch connected across EMGIN21 and EMGIN22. If the switch connected across EMGIN11 and EMGIN12 operates with a large delay, this alarm may be issued. (Action 2) Replace the emergency stop unit. (Action 3) Replace the power supply module.

Power supply module Emergency stop unit

Fig.3.5 (81) SRVO204 SVAL1 External (SVEMG abnormal) Estop

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(82)SRVO205 SVAL1 Fence open (SVEMG abnormal) (Explanation) The EMERGENCY STOP line was not disconnected even though the switch connected between FENCE11 and FENCE12 and between FENCE21 and FENCE22 on the terminal block TBEB2 of the emergency stop board was open. (Action 1) Check whether there is a large difference in operation time between the switch connected across EMGIN11 and EMGIN12 and the switch connected across EMGIN21 and EMGIN22. If the switch connected across EMGIN11 and EMGIN12 operates with a large delay, this alarm may be issued. (Action 2) Replace the emergency stop unit. (Action 3) Replace the power supply module.

Power supply module Emergency stop unit

Fig.3.5 (82) SRVO205 SVAL1 Fence open (SVEMG abnormal)

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(83)SRVO206 SVAL1 Deadman switch (SVEMG abnormal) (Explanation) The DEADMAN switch was released when the teach pendant was operable, but the EMERGENCY STOP line was not disconnected. (Action 1) The mode switch may be faulty. Replace the operator panel. (Action 2) Replace the teach pendant. (Action 3) Replace the emergency stop unit. (Action 4) Replace the power supply module.

Power supply module Emergency stop unit

Fig.3.5 (83) SRVO206 SVAL1 Deadman switch (SVEMG abnormal)

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(84)SRVO207 SVAL1 TP switch abnormal or door open (Explanation) The teach pendant is operable, and the deadman switch has been grasped, but the EMERGENCY STOP line is kept disconnected. (Action 1) Check the teach pendant connection cable. (Action 2) Replace the teach pendant. (Action 3) Replace the emergency stop unit.
Teach pendant Teach pendant cable

Emergency stop unit

Fig.3.5 (84) SRVO207 SVAL1 TP switch abnormal or door open

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(85)SRVO215 WARN Fuse blown (Aux axis) (Explanation) The fuse in the additional axis amplifier has blown. (Action 1) Check the cause and solve the problem, then replace the fuse. (86)SRVO216 SVAL1 OVC (total) (Robot : i) (Explanation) The current (total current for five axes or six axes) flowing through the motor is too large. (Action 1) Slow the motion of the robot where possible. Check the robot operation conditions. If the robot is used with a condition exceeding the duty or load weight robot rating, reduce the load condition value to the specification range. (Action 2) Check each interphase voltage of the threephase input (200 VAC) to the power supply module. If the voltage is 170 VAC or lower, check the input power supply voltage.

Power supply module

Fig.3.5 (86) SRVO215 WARN Fuse blown (Aux axis)

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(87)SRVO221 SVAL1 Lack of DSP (Group : i Axis : j) (Explanation) A controlled axis card corresponding to the set number of axes is not mounted. (Action 1) Check whether the set number of axes is valid. If the number is invalid, set the correct number. (Action 2) Replace the controlled axis card with a card corresponding to the set number of axes. (Example) When six axes are set, a controlled axis card for six or eight axes is available. For how to replace the controlled axis card, see II MAINTENANCE, Section 7.2 in this manual.

Robot control board Servo amplifier module Power supply module Axis control card

Fig.3.5 (87) SRVO221 SVAL1 Lack of DSP (Group : i Axis : j)

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(88)SRVO222 SVAL1 Lack of Amp (Amp : i) (Explanation) The FSSB has no SVM. (Action 1) Check that the optical cable is securely connected to the servo amplifier module. (Action 2) Replace the optical cable. (Action 3) Check whether power is properly supplied to the servo amplifier module.

Servo amplifier module

Fig.3.5 (88) SRVO222 SVAL1 Lack of Amp (Amp : i)

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(89)SRVO233 SVAL1 TP disabled in T1, T2/Door open (Explanation) The teach pendant is disabled when the mode switch is in the T1 mode position. (Action 1) During teaching operation, set the enable switch of the teach pendant to Enable. Otherwise, set the mode switch to AUTO mode. (Action 2) Replace the emergency stop unit. (Action 3) Replace the teach pendant. (Action 4) The mode switch may be faulty. Replace the operator panel.
Teach pendant

Mode switch

FUS3 Emergency stop unit Emergency stop board

Fig.3.5 (89) SRVO233 SVAL1 TP disabled in T1, T2/Door open

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(90)SRVO264 SVAL1 E.STOP circuit abnormal 1 (Explanation) An error occurred in the emergency stop circuit. (Action 1) Check whether the CRR78 connectors on the ESTOP unit and the CX3 connector of the power supply module are connected securely. (Action 2) Replace the emergency stop unit. (Action 3) Replace the power supply module.

Power supply module Emergency stop unit

Fig.3.5 (90) SRVO264 SVAL1 E.STOP circuit abnormal 1

(91)SRVO265 SVAL1 E.STOP circuit abnormal 2 (Explanation) When the servo amplifier is excited, the monitor contact of the magnetic contactor (MCC) becomes faulty. (Action 1) Replace the magnetic contactor (MCC). (Action 2) Replace the emergency stop unit. (Action 3) Replace the power supply module.

Power supply module Emergency stop unit Magnetic contactor (MCC)

Fig.3.5 (91) SRVO265 SVAL1 E.STOP circuit abnormal 2

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(92)SRVO290 SVAL1 DClink HC alarm (Group : i Axis : j) (Explanation) The DC link current in the servo amplifier module(s) is abnormal. The LED indication on the relevant servo amplifier module is 8. (Action 1) Detach the motor power lines from connector CZ2 of the servo amplifier module, then turn the power on. If this alarm persists, replace the servo amplifier module. (Action 2) Detach the motor power lines from connector CZ2 of the servo amplifier module, then check the insulation between GND and each of U, V, and W of the motor power lines. If a short circuit is detected, the motor, robot connection cable, or internal robot cable may be defective. Check them for an abnormal condition. (Action 3) Detach the motor power lines from connector CZ2 of the servo amplifier module, then use a highprecision ohmmeter to measure UV, VW, and WU resistances of the motor power lines. If the three resistances differ, the motor, robot connection cable, or internal robot cable may be defective. Check them for an abnormal condition. Before proceeding with (Action 4), back up all programs and settings for the control unit. (Action 4) Replace the robot control board.

Robot control board Servo amplifier module

Fig.3.5 (92) SRVO290 SVAL1 DClink HC alarm

(93)SRVO291 SVAL1 IPM over heat (Group : i Axis : j) (Explanation) The IPM in the servo amplifier overheats. The LED indications on the servo amplifier modules are 8., 9., and A.. (Action 1) Check whether the servo amplifier module fan stops. (Action 2) Reduce the override because the use condition is too hard. (Action 3) If this alarm is frequently issued, replace the amplifier module.
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(94)SRVO295 SVAL1 SVM COM alarm (Group : i Axis : j) (Explanation) Communication between the servo amplifier modules is abnormal. The LED indications on the servo amplifier modules are P. (Action 1) If SRVO 047 LVAL alarm and SRVO 131 LVAL (PSM) alarm also occur, the control power supply voltage is low. Take measures against these alarms. (Action 2) Check the servo amplifier modules and cables for connectors CX2A and CX2B of the power supply module, as well as their connection. (Action 3) Replace the axis control card on the robot control board. (Action 4) Replace the servo amplifier modules. Before proceeding with (Action 5), back up all programs and settings for the control unit. (Action 5) Replace the robot control board.

Robot control board Servo amplifier module Power supply module Axis control card

Fig.3.5 (94) SRVO295 SVAL1 SVM COM alarm

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(95)SRVO296 SVAL1 DCAL alarm (Group : i Axis : j) (Explanation) The regenerative discharge energy is too high to be dissipated as heat. (To move the robot, the servo amplifier supplies energy to the robot. When going down, the robot moves along the vertical axis as the potential energy reduces. If a reduction in the potential energy is larger than the amount of acceleration energy, the servo amplifier receives energy from the motor. This also occurs at deceleration even when no gravity is applied. The energy that the servo amplifier receives from the motor is called regenerative energy. The servo amplifier dissipates this energy as heat. If the amount of the regenerative energy dissipated as heat is smaller than was received, the remainder is stored in the servo amplifier, causing this alarm.) The LED indication on the power supply module is 8 (DCAL: regenerative energy adder detection). (Action 1) This alarm may occur if the robot is subjected to frequent acceleration/deceleration or if the vertical axis generates a large amount of regenerative energy. In this case, relax the service conditions. (Action 2) Replace the power supply module.

Power supply module

Fig.3.5 (95) SRVO296 SVAL1 DCAL alarm

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(96)SRVO297 SVAL1 DCLVAL alarm (Group : i Axis : j) (Explanation) An openphase condition has occurred in the input power supply to the main circuit on the power supply module. The LED indications on the power supply module is E. (Action 1) Check the phase voltage of the threephase input (200 VAC) to the power supply module. If an openphase condition is detected, check the input power supply. (Action 2) Replace the power supply module.

Power supply module

Fig.3.5 (96) SRVO297 SVAL1 DCLVAL alarm

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(97)SRVO300 SVAL1 Hand broken/HBK disabled SRVO302 SVAL1 Set Hand broken to ENABLE (Explanation) Although HBK was disabled, the HBK signal was input. (Action 1) Press RESET on the teach pendant to release the alarm. (Action 2) Check whether the hand broken signal is connected to the robot. When the hand broken signal circuit is connected, enable hand broken. (See II CONNECTION, Section 3.8 in this manual.)

Robot control board

Fig.3.5 (97)

SRVO300 SVAL1 Hand broken/HBK disabled SRVO302 SVAL1 Set Hand broken to ENABLE

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(98)SRVO320 SVAL1 E.STOP (Explanation) Although there is no cause for an emergency stop, an emergency stop state was detected on the power supply module. (Action 1) Check external emergency stops and the safety fence. (Action 2) Check the connections of the CRR78 connector on the emergency stop emergency stop board and the CX4 connector on the power supply module. (Action 3) Replace the emergency stop unit. (Action 4) Replace the power supply module.

Power supply module Emergency stop unit

Fig.3.5 (98) SRVO320 SVAL1 E.STOP

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(99)SRVO321 SVAL1 TP SW/Deadman abnormal (Explanation) The ENABLE/DISABLE switch or Deadman switch on the teaching pendant is abnormal. (Action 1) Replace the teaching pendant cable. (Action 2) Replace the teaching pendant. (Action 3) Replace the emergency stop unit. Before taking (Action 4), make a backup copy of all the programs and settings of the control unit. (Action 4) Replace the robot control board.
Teach pendant teach pendant cable

ENABLE/DISABLE switch Deadman switch (Back side)

Robot control board Emergency stop unit

Fig.3.5 (98) SRVO321 SVAL1 TP SW/Deadman abnormal

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3.6
TROUBLESHOOTING USING FUSES

This section describes alarms that can occur when a fuse mounted on a board or unit is blown and corresponding corrective actions. (1) Fuses on the robot control board FUS1 : For generating power to the control circuit FUS2 : For protecting +24E output to peripheral device digital input/output, end effector, ROT, and HBK
Action 1 Check the units (fans) and cables connected to the CP2 and CP3 connectors of the power supply unit to see if there is any short circuit. 2 Replace the DC/DC converter module. 3 Replace the robot control board.

Name FUS1

Problem caused by blown fuse The control power of the robot control board is shut off. The teach pendant displays the initial screen.

FUS2

The teach pendant screen displays alarm information such as 1 Check that +24E used by the peripheral device is free from a Hand broken (SERVO 006) or Robot overtravel (SERVO ground fault. 005). 2 Examine the peripheral device connection cable. 3 Check that +24E used by the end effector is free from a ground fault. 4 Examine the robot interconnection cable and intrarobot cable.

FUS1

FUS2

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(2) Fuses on the emergency stop board FUS3 : For monitoring the emergency stop circuit FUS4 : For controlling the emergency stop circuit and teach pendant FUS5 : For the brake circuit
Name
FUS3 FUS4

Problem caused by blown fuse

The teach pendant screen displays SVAL1 TP disabled in T1, T2/Door open (SRVO233) and so forth. The power supply to the teach pendant stops, the screen display of the teach pendant disappears, and the system enters the emergency stop state. Replace the emergency stop unit. The robot motor brake cannot be released, and alarm information such as Large error in travel (SERVO 024), Large error at rest (SERVO 023), Positioning time over (SERVO 036), or CLALM alarm (SERVO 050) is displayed.

Action
Replace the emergency stop unit. 1 Examine the teach pendant cable for any problem. 2 Examine the teach pendant for any problem. 3 Check that the external emergency stop input and servo off input are free from a ground fault and any other fault. 1 Check that the robot interconnection cable (RMP) and intramechanicalunit cable are free from faults such as a ground fault and shortcircuit. 2 If an additional axis is used, check that the brake connection cable is free from a ground fault, shortcircuit, and any other fault. 3 If a brake power transformer is used, note that a faulty brake power transformer can cause a too large current to flow. Replace the brake power transformer. 4 Replace the emergency stop unit.

FUS5

FUS4 FUS3

FUS5

Emergency stop board

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(3) Blown fuse on the door

Name
FUS6

Problem caused by blown fuse

The power supply unit on the emergency stop unit does not work, and the power cannot be turned on.

Action
1 Check that the fan unit or cable is not shortcircuited. 2 Replace the power supply unit.

FUS6

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(4) Fuse on the power supply module FU1 : For protecting 200 VAC input to generate power to the control circuit
Name
FU1

Problem caused by blown fuse

Action

ALL LEDs of the servo amplifiers go out. 1 Replace the fuse (5 A) on the control board of the power supThe teach pendant screen displays the FSSB disconnection ply module. alarm or FSSB initialization alarm. 2 Replace the power supply module.

FU1

Remove the face plate

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(5) Fuse on the servo amplifier module FU1 : For protecting +24 V input to generate power to the control circuit
Name
FU1

Problem caused by blown fuse

Action

ALL LEDs of the servo amplifier modules go out. 1 Replace the fuse (3.2 A) on the control board of the servo amThe teach pendant screen displays the FSSB disconnection plifier module. alarm or FSSB initialization alarm. 2 Replace the servo amplifier module.

FU1

Remove the control board

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3.7
TROUBLESHOOTING BASED ON LED INDICATIONS

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

Robot control board Servo amplifier module2 (AMP2) Servo amplifier module1 (AMP1) Power supply module (PSM)

Emergency stop board

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(1) TROUBLESHOOTING USING THE LEDS ON THE robot control board To troubleshoot an alarm that arises before the teach pendant is ready to display, check the status LEDs (green) on the robot control board at poweron. After poweron, the LEDs light as described in steps 1 to 18, in the order described. If an alarm is detected, the step in which the alarm occurred can be determined from which LEDs are lit.
Step
1: After poweron, all LEDs are lit.

LED

Action to be taken
[Action1] Replace the CPU card * [Action2] Replace the robot control board.

2: Software operation startup.

[Action1] Replace the CPU card * [Action2] Replace the robot control board.

3: The initialization of dram on the CPU card is completed.

[Action1] Replace the CPU card * [Action2] Replace the robot control board.

4: The initialization of SRAM and DPRAM is completed.

[Action1] Replace the CPU card * [Action2] Replace the robot control board. * [Action3] Replace the FROM/SRAM module.

5: The initialization of the communication IC is completed.

[Action1] Replace the CPU card * [Action2] Replace the robot control board. * [Action3] Replace the FROM/SRAM module.

6: The loading of the basic software is completed.

* [Action1] Replace the robot control board. * [Action2] Replace the FROM/SRAM module.

7: Basic software startup.

* [Action1] Replace the robot control board. * [Action2] Replace the FROM/SRAM module.

8: Startup of communication with the teach pendant.

* [Action1] Replace the robot control board. * [Action2] Replace the FROM/SRAM module.

9: The loading of optional software is completed.

* [Action1] Replace the robot control board.

10:DI/DO initialization

* [Action1] Replace the FROM/SRAM module. * [Action2] Replace the robot control board.

11:The preparation of the SRAM module is completed.

[Action1] Replace the axis control card. * [Action2] Replace the robot control board. [Action3] Replace the servo amplifier.

* If the robot control board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.
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Step
12:Axis control card initialization

LED

Action to be taken
[Action1] Replace the axis control card. * [Action2] Replace the robot control board. [Action3] Replace the servo amplifier.

13:Calibration is completed.

[Action1] Replace the axis control card. * [Action2] Replace the robot control board. [Action3] Replace the servo amplifier.

14:Startup of power application for the servo system

* [Action1] Replace the robot control board.

15:Program execution

* [Action1] Replace the robot control board.

16:DI/DO output startup.

* [Action1] Replace the robot control board.

17: Initialization is terminated.

Initialization has ended normally.

18:Normal status

Status LED 2 blink when the system is operating normally.

* If the robot control board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.

Axis control card

FROM/SRAM module (under the CPU card)

CPU card

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(2) TROUBLESHOOTING BY 7SEGMENT LED INDICATOR

7segment LED indicator Description [Description] A parity alarm condition has occurred in RAM on the CPU card installed on the robot control board. [Action1] Replace the CPU card. [Action2] Replace the robot control board. [Description] A parity alarm condition has occurred in RAM on the FROM/SRAM module installed on the robot control board. [Action1] Replace the FROM/SRAM module. [Action2] Replace the robot control board.
2, 3, and 4 are not displayed.

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

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

* If the robot control board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.

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(3) Troubleshooting using a fuse alarm LED

LED indication Failure description and required measure [Description] A fuse (FUS1 or FUS2) is blown. Cause of the blowing of FUS1 and corrective actions [Action1] Check whether the device which is connected to the RS232C/RS422 port and requires the power supply of +24 V is sound. [Action2] Faulty DC/DC converter module Replace the DC/DC converter module. [Action3] Shortcircuited surge absorber PVS1 The system can be operated temporarily without PVS1. However, obtain and mount a new one at the earliest possible time. [Action4] Faulty robot control board Replace the robot control board. Cause of the blowing of FUS2 and corrective actions [Action1] Check that +24E used by the peripheral device is free from a ground fault. [Action2] Examine the peripheral device connection cable. [Action3] Check that +24E used by the end effector is free from a ground fault. [Action4] Examine the robot interconnection cable and intrarobot cable.

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Troubleshooting using an LED on the emergency stop board

LED indication Problem and corrective action [Description] The fuse (FUS3, FUS4, or FUS5) is blown. Cause of the blowing of FUS3 and corrective action [Action] The emergency stop board is faulty. Replace the emergency stop unit. Cause of the blowing of FUS4 and corrective actions [Action1] Check that the teach pendant cable is sound. [Action2] Check that the teach pendant is sound. [Action3] Check that the external emergency stop input and servo off input are free from a ground fault and any other fault. [Action4] The emergency stop board is faulty. Replace the emergency stop unit. Cause of the blowing of FUS5 and corrective actions [Action1] Check that the robot interconnection cable (RMP) and intramechanicalunit cable are free from a ground fault, shortcircuit, and any other fault. [Action2] If an additional axis is used, check that the brake connection cable is free from a ground fault, shortcircuit, and any other fault. [Action3] If a brake power transformer is used, note that a faulty brake power transformer can cause a too large current to flow. Replace the brake power transformer. [Action4] The emergency stop board is faulty. Replace the emergency stop unit.

FALM LED

Fuse FUS4 Fuse FUS3 Fuse FUS5

Emergency stop board Emergency stop unit

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Troubleshooting using the LED of the power supply module

The power supply module has a sevensegment LED. When taking a corrective action corresponding to the LED indication, see the alarm displayed on the teach pendant screen.
dot part of seven segment LED

LED indication

Problem and corrective action [Description] The voltage of the DC link of the main circuit is low. [Action1] The input power was instantaneously interrupted. Check the power supply. [Action2] The input supply voltage is low. Check the power requirements. [Action3] The power to the main circuit was shut off in the emergency stop release state. Check the emergency stop circuit (emergency stop board, magnetic contactor, external emergency stop input, etc.). [Description] The main circuit could not be charged within a predetermined period. [Action1] The DC link is shortcircuited. Check the connection. [Action2] The charge current controlling resistor is faulty. Replace the power supply module. [Description] The control power voltage is low. [Action] The input power is low. Check the power supply.

[Description] The voltage of the DC link of the main circuit is too high. [Action1] The regenerative power is too large. Change the operating conditions. [Action2] The regenerative resistor is faulty. Replace the power supply module. [Description] The regeneration amount is too large. [Action] Change the operating conditions. For instance, lower the frequency of acceleration/deceleration. [Description] The regenerative resistor was heated. [Action] Change the operating conditions. For instance, lower the frequency of acceleration/deceleration. [Description] The input power is in the openphase state. [Action] Check the power supply.

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Troubleshooting using the LED of the servo amplifier module

The servo amplifier module has a sevensegment LED. When taking a corrective action corresponding to the LED indication, see the alarm displayed on the teach pendant screen.
dot part of seven segment LED

LED indication

Problem and corrective action [Description] The internal cooling fan stopped. [Action1] Check that the fan is not blocked with a foreign substance. [Action2] Check that the fan connector is correctly connected. [Action3] The fan is faulty. Replace the fan. [Action4] Replace the servo amplifier module. [Description] The control supply voltage is low. [Action1] Check the threephase input voltage. (The voltage must be the rated input voltage multiplied by 0.85 at least.) [Action2] Measure the voltage of 24V power supplied from the power supply module. (Normal: 22.8 V or higher) [Action3] Check the CXA2A/B connector and the cable. [Action4] Replace the servo amplifier module. [Description] The voltage of the DC link of the main circuit is low. [Action1] Check that the DC link connection cable (bar) is securely screwed. [Action2] If this alarm occurs in multiple servo amplifier modules, take the action for alarm code 4 of the power supply module. [Action3] Replace the servo amplifier module. [Description] The communication among servo amplifiers cannot be normally performed. [Action1] Check the CXA2A/B connector and the cable. [Action2] Replace the control board of the servo amplifier module. [Action3] Replace the servo amplifier module.

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LED indication

Problem and corrective action [Description1] The IPM alarm was detected in the servo amplifier module. [Action1] Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, and turn the power on. a) If this alarm does not occur, go to Action 2. b) If this alarm occurs, replace the servo amplifier module. Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, and check the insulation between PE and each of the motor power lines U, V, and W. a) If the insulation is deteriorated, go to Action 3. b) If the insulation is normal, replace the servo amplifier module. Separate the motor and power line, then check whether the motor or power line has deteriorated insulation. a) If the motor insulation is deteriorated, replace the motor. b) If the power line insulation is deteriorated, examine the robot interconnection cable or intrarobot cable. 8., 9., and A. represent that an alarm occurs on the Laxis, M axis, and Naxis respectively. [Description2] The IPM alarm (overheat) was detected in the servo amplifier module. [Action1] Check that the internal cooling fan does not stop. [Action2] Check that the motor is operated at its continuous rating or lower. [Action3] Check that the cooling capability of the cabinet is not lowered. (Check the fan unit and heat exchanger.) [Action4] Check that the ambient temperature is not high. [Action5] Replace the servo amplifier module. 8., 9., and A. represent that an alarm occurs on the Laxis, M axis, and Naxis respectively.

[Action2]

[Action3]

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LED indication

Problem and corrective action [Description] An abnormal current is flowing to the servo motor. [Action1] Check that the servo parameters are set to default values. If this alarm occurs only at a sudden acceleration or deceleration, the motor operating conditions may be too harsh. Increase the acceleration/deceleration time constant and observe the operation. [Action2] Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, then turn on the power. a) If this alarm does not occur, go to Action 2. b) If this alarm occurs, replace the servo amplifier module. Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, then check the insulation between PE and each of the power lines U, V, and W. a) If the insulation is deteriorated, go to Action 3. b) If the insulation is normal, replace the servo amplifier. Separate the motor and power line, then check whether the motor or power line has deteriorated insulation. a) If the motor insulation is deteriorated, replace the motor. b) If the power line insulation is deteriorated, examine the robot interconnection cable and intrarobot cable. b, C, and d represent that an alarm occurs on the Laxis, Maxis, and Naxis respectively.

[Action3]

[Action4]

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

(Check 1) On the status screen, check the position deviation in the

stopped state. To display the position deviation, press the screen selection key, and select STATUS from the menu. Press F1, [TYPE], select AXIS from the menu, then press the F4, PULSE.

Correct the parameters related to return to the reference position (positioning). (Check 2) Check whether the motor axis can be positioned normally. If the motor axis can be positioned normally, check the mechanical unit. (Check 3) Check the mechanical unit for backlash. Replace a faulty key of motor shaft or other faulty parts. (Check 4) If checks 1 to 3 show normal results

(Corrective action)

(Corrective action) (Corrective action) (Corrective action)

Replace the pulse coder and robot control board.

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3.9
VIBRATION OBSERVED DURING MOVEMENT

(Check 1) Check the settings of parameters such as the position loop

gain parameter. Correct parameters. (Check 2) Check the mechanical unit for backlash.

(Corrective action) (Corrective action)

Replace a faulty key of motor shaft or other faulty parts.

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3.10
MANUAL OPERATION IMPOSSIBLE

The following explains checking and corrective action required if the robot cannot be operated manually after the controller is turned on: (1) Check and corrective action to be made if manual operation is impossible (Check 1) Check whether the teach pendant is enabled. Turn on the teach pendant enable. (Check 2) Check whether the teach pendant is handled correctly. 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. Place the peripheral device control interface in the ENBL status. (Check 4) Check whether the HOLD signal of the peripheral device control interface or the HOLD switch on the operators panel is on (hold status). (Check whether the hold lamp on the teach pendant is on.) 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. 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)

(Corrective action)

(Corrective action)

(Corrective action)

(Corrective action)

(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. Put the peripheral-device control interface in the ENBL state. (Check 2) Check whether the HOLD signal for the peripheral-device control interface is on. (Check whether the HOLD lamp on the teach pendant is on.)

(Corrective action)

(Corrective action)

If the HOLD signal is on, turn it off. If the HOLD switch is on, turn it off.
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(Check 3) Check whether the previous manual operation has been

completed. 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)

(Corrective action)
Release the alarm.

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PRINTED CIRCUIT BOARDS

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

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4.1
ROBOT CONTROL BOARD (A16B32000450)

FROM/SRAM module under the CPU card

CPU card

DC/DC converter module

Total version

Axis control card

Fig.4.1 Robot control board Name

Robot control board DC/DC convert module CPU card

Board Specification
A16B32000450 A20B81000721 A20B33000106 A20B33000107

Note
I/O Link master/slave switcheable, SDI/SDO = 28/24

SDRAM 8M (Standard) SDRAM 16M 6axis FROM 16M, SRAM 0.5M : Standard FROM 16M, SRAM 1MB FROM 16M, SRAM 2MB FROM 16M, SRAM 3MB

Axis control card FROM/SRAM module

A20B33000241 A20B39000181 A20B39000160 A20B39000161 A20B39000162

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(1) LEDs
Seven segment LED Description A parity alarm occurred in a RAM of the main CPU card on the Robot control board.

A parity alarm occurred in a RAM of the FROM/ SRAM module on the Robot control board.

2, 3, and 4 are not displayed.

A servo alarm occurred on the Robot control board.

SYSEMG occurred.

SYSFAIL occurred.
This number appears temporarily after the power is switched on, but it is not abnormal.

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Status LED

Description

STATUS LED

Indicates the system operating status.

Status LED

Description

FUSE ALARM LED

A fuse (FUS1 or FUS2) was blown.

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(2) Correspondence between driver ICs and DO Driver IC specification: A76L01510062

Driver IC name H9 G9 K9 J9 J13 H13 J6 J4 DO signal name SDO101, SDO102, SDO103, SDO104 SDO105, SDO106, SDO107, SDO108 SDO109, SDO110, SDO111, SDO112 SDO113, SDO114, SDO115, SDO116 SDO119, SDO120, SDO81, Brake control (internal circuit) SDO82, SDO83, SDO84, Reserved RDO1, RDO2, RDO3, RDO4 RDO5, RDO6, SDO117, SDO118

(3) Communication IC If the teach pendant displays nothing because of a damaged teach pendant connection cable or another reason, the following communication driver or receiver may be damaged.
IC name G17 G16 Name and usage 75172, driver 75173, receiver Drawing number A76L01510098 A76L01510099

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4.2
EMERGENCY STOP BOARD (A20B10080010, 0011)

Total version

Fig.4.2 Emergency stop board

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4.3
BACKPLANE BOARD (A20B20030330)

Total version

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4.4
PROCESS I/O BOARD HE (A16B22030764), HF (A16B22030765)

Total edition Test pins

Fig.4.4 Process I/O Board HA

(1) Test pins

Name P24V P5V GND1 GND2 GND3 P24VF P5VF GNDF AO1 AO2 +24V +5V GND GND GND +24V +5V GND Channel 1 Channel 2 Use

For measuring the DC supply voltage

Power for the digital/analog converter For measuring the voltage of the analog output signal (digital/analog)

(2) Settings
Name ICOM1 UDI1 to UDI20 (Connector CRM2A) Side A Standard setting Description

UDI21 to UDI40 ICOM2 (Connector CRM2B) ICOM3 WDI01 to WDI08 (Connector CRW7)

The common voltage is adjusted to: Side A : +24 V common Side B : 0 V common

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(3) Adjustment VR1/VR2: Adjusts the gain and the offset of channel 1. Execute a robot program and set AOUT[1] to 3413 on the teach pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 or VR2 until the meter reads 15.0 V. Connect the negative () lead of the digital voltmeter to test pin GNDF. (GNDF test pin is different from the GND test pin.) VR3/VR4: Adjusts the gain and the offset of channel 2. Execute a robot program and set AOUT[2] to 3413 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR3 or VR4 until the meter reads 15.0 V. Connect the negative () lead of the digital voltmeter to test pin GNDF. (The 0VF test pin is different from the common GND test pin.) (4) LEDs
Color Description

Red

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

Red

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

(5) Correspondence between driver chips and DO signals Ordering code for the driver chips: A76L-0151-0062
Driver chip DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 DO signal CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FAULT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED SDO01, SDO02, SDO03, SDO04 SDO05, SDO06, SDO07, SDO08 SDO09, SDO10, SDO11, SDO12 SDO13, SDO14, SDO15, SDO16 SDO17, SDO18, SDO19, SDO20

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5
LR Mate 100iB

SERVO AMPLIFIERS

The servo amplifiers are factory-set for operation. Usually, you do not need to set or adjust them. This chapter describes the standard settings and adjustment required if a defective servo amplifier is replaced. It also describes the use of test pins and meanings of the LED indications.
Table 5 Servo amplifier specifications Robot Power supply module A06B6115H001 (PSMR1i) Servo amplifier module1 A06B6114H205 (SVM20/20i) L M J1 J2 A06B6114H302 (SVM10/10/10i) L M N J1 J2 J3 Servo amplifier module2 A06B6114H302 (SVM10/10/10i) L M N J3 J4 J5 A06B6114H302 (SVM10/10/10i) L M N J4 J5 J6

LR Mate 200iB ARC Mate 50iB

A06B6115H001 (PSMR1i)

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5.1
OUTLINE DRAWINGS 5.1.1
Power Supply Module PSM (A06B6115H001)

380

360

60

172

Fig.5.1.1 Outline drawing of power supply module PSM (A06B6115H001)

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5.1.2
Servo Amplifier Module (A06B6114H205, A06B6114H302)

A06B6114H205

A06B6114H302

380

360

60

172

Fig.5.1.2 Outline drawing of servo amplifier modules (A06B6114H205, A06B6114H302)

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5.2
LED OF SERVO AMPLIFIER 5.2.1
LED of Power Supply Module
dot part of seven segment LED

The power supply module has a sevensegment LED. When taking a corrective action corresponding to the LED indication, see the alarm displayed on the teach pendant screen.
Description The magnetic contactor controlled by the power supply module is in the off state and is not ready for driving the motor.

LED indication

The magnetic contactor controlled by the power supply module is in the on state and is ready for driving the motor.

The voltage of the DC link of the main circuit is low.

The main circuit cannot be charged within a predetermined period.

The control power voltage is low.

The voltage of the DC link of the main circuit is too high.

The regeneration amount is too large.

The regenerative resistor was heated.

The input power is in the openphase state.

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5.2.2
LED of Servo Amplifier Module
dot part of seven segment LED

The servo amplifier module has a sevensegment LED. When taking a corrective action corresponding to the LED indication, see the alarm displayed on the teach pendant screen.
Description The main circuit in the servo amplifier module is in the off state and is not ready for driving the motor.

LED indication

The main circuit in the servo amplifier module is in the on state and is ready for driving the motor.

The internal cooling fan stopped.

The control power voltage is low.

The voltage of the DC link of the main circuit is low.

The communication among servo amplifier modules cannot be normally performed.

a) The IPM alarm was detected in the servo amplifier module. b) The IPM alarm (overheat) was detected in the servo amplifier module. 8., 9., and A. represent that an alarm occurs on the Laxis, M axis, and Naxis respectively.

An abnormal current is flowing to the servo motor. b, C, and d represent that an alarm occurs on the Laxis, Maxis, and Naxis respectively.

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6. SETTING THE POWER SUPPLY

SETTING THE POWER SUPPLY

The power supply is factory-set for operation. Usually, you do not need to set or adjust it.

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6.1
BLOCK DIAGRAMS OF THE POWER SUPPLY
AC input

200 220 VAC 3

Magnetic contactor (MCC) Circuit protector 200VAC 2 3 FUS6 200VAC 2

Servo amplifier

Power supply module

CZ1

Main circuit DC link FU1 regenerative resistor

200VAC

CX1

FAN

AC/DC +24V Power supply unit CN1 CXA2A L+, L

Emergency stop unit

AC/DC +24V

Servo amplifier module

CRR77

CXA2B DC/DC +5V JF13

L+, L Inverter circuit CZ2 LN

Emergency stop print board

FUS3 FUS4

CP5A

Monitor circuit CP5B

EmergenFUS5 cy stop circuit Brake circuit CRS1 +24T TBEB3

Backplane Robot control board

DC/DC converter module +5V, +3.3V +15V, 15V CP8B +24V FUS1 CP5 +24E FUS2 +24E CRM82 +24E CRM79 +24E CRM81 +24V JD17 BATTERY

Motor brake Motor powersupply Pulsecoder

Robot

Motor End Effector

Teach pendant Peripheral device Peripheral device (option) Handy file etc.

Process I/O board

+24E FUSE1 CRM2 CRM4 +24V 15V +15V +5V +3.3V +24E +24F

Peripheral device (option)

Fig.6.1 Block diagram of the power supply

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6.2
CHECKING THE POWER SUPPLY UNIT

The power supply unit need not be set or adjusted.

Table 6.2 Rating of the Power supply unit Output +24V Rated voltage +24V Tolerance +23V to +25V

6.3
CHECKING THE POWER SUPPLY MODULE

The power supply module need not be set or adjusted.

Table 6.3 Rating of the Power supply module Output +5V +3.3V +15V 15V Rated voltage +5.1V +3.3V +15V 15V Tolerance 3% 3% 10% 10%

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REPLACING A UNIT

This section explains how to replace each unit in the control section.
WARNING Before you start to replace a unit, turn off the control unit main power. Also keep all machines in the area of the control unit switched. Otherwise, you could injure personnel or damage equipment.

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7.1
REPLACING THE PRINTEDCIRCUIT BOARDS
CAUTIONS When you replace printedcircuit boards, observe the following cautions: 1 Keep the control unit power switched off. 2 When you remove a printedcircuit board, do not touch the semiconductor devices on the board with your hand or make them touch other components. 3 Make sure that the replacement printedcircuit board has been set up appropriately. (Setting plug etc.) 4 If the backplane board, power supply unit, or Robot control board (including cards and modules) is replaced, it is likely that robot parameters and taught data are lost. Before you start to replace these components, save a backup copy of the robot parameters and taught data to a memory card, floppy disk, or any other external memory device. 5 Before you disconnect a cable, note its location. If a cable is detached for replacement, reconnect it exactly as before.

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7.1.1
Replacing the Backplane Board (Unit)

When replacing the backplane board, do so together with the plastic rack. (1) Detach the cables from the robot control board and boards on the backplane board.
CAUTION When you remove the main robot control Board, be sure that the battery is good (3.13.3VDC) and it is installed correctly. USE STATIC PROTECTION.

(2) Remove the robot control board and boards from the rack. (See Section 7.1.2.) (3) Detach the grounding cable from the backplane unit. (4) Loosen the retaining screws in the upper section of the rack. Remove the retaining screws from the lower section of the rack. (5) Side rack up and out. (6) To replace the backplane and rack, reverse steps (1) (6).
CAUTION There is a possibility of data loss when a backplane board is replaced. Be sure to back up all program and setup data on a floppy disk before proceeding.

Backplane board

M5 nut (2 places)

Fig.7.1.1 Replacing the Backplane Board

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7. REPLACING A UNIT

7.1.2
Replacing the Robot Control Board and PrintedCircuit Boards on the Backplane Unit

The backplane unit incorporates the power unit, Robot control board, and option boards. There are two types of option boards: Fullsize board and minisize board. A fullsize board occupies one slot. A minisize board uses part of a fullsize board.
CAUTION Before starting replacement, turn off the control unit main power. The robot control board is equipped with batterybacked memory devices for holding robot parameters and taught data, for example. When the Robot control board is replaced, the data in the memory devices is lost.

(1) Detach the cable from the printedcircuit board, whichever is to be replaced. (2) Pinch the barbed handles on the upper and lower sections of the board to unlatch it, then pull it toward you. (3) Place the replacement board on the rail in the appropriate slot of the rack, then push it in gently by the handles until it is latched. (4) There are two rails in the robot control board SLOT (slot 1). When inserting the robot control board, align it to the rightside rail.
Slot 1 Option slot Slot 1

Slot 10 Barbed handles

Rail (Left)

Slot 9

Slot 2

Rail (Right) zoom

Barbed handles

Fig.7.1.2 Replacing the Robot Control Board and PrintedCircuit Boards on the Backplane Unit

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7.1.3
Replacing the Emergency Stop Board

The board is at the emergency stop unit. (1) Detach all cables from the emergency stop unit consists of the emergency stop board and the power supply unit. The terminal blocks (TBEB1 and TBEB2) are of a connector type. Pull out the upper terminal block sections. (2) Remove four retaining nuts from the emergency stop unit (1, 2), and replace the emergency stop unit. (3) Remove six retaining screws from the emergency stop board (3), and replace the emergency stop board.

1 Remove the front nuts (2M5)

2 Remove the back nuts (2M5) 3 Remove the screws (6M3)

Fig.7.1.3 Emergency stop board replacement

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7. REPLACING A UNIT

7.2
REPLACING CARDS AND MODULES ON THE ROBOT CONTROL BOARD
CAUTION Before you start to replace a card or module, make a backup copy of robot parameters and taught data. If the FROM/SRAM module is replaced, memory contents are lost.

(1) Pull outward the clip of each of the two spacers used to secure the card PCB, then release each latch. (2) Extract the card upward.

Demounting a Card

Card

Card

Card Card

Spacer Connector

Card

Spacer Connector Fig.7.2 (a) Demounting a card

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(1) Check that the clip of each of the two spacers is latched outward, then insert the card into the connector. (2) Push the clip of each spacer downward to secure the card PCB.

Mounting a Card

Card

Spacer Connector

Card

Card

Card Card

Spacer Connector Fig.7.2 (b) Mounting a card

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7. REPLACING A UNIT

Demounting a module
CAUTION When replacing the module, be careful not to touch the module contact. If you touch the contact inadvertently, wipe out dirt on the contact with a clean cloth.

(1) Move the clip of the socket outward. (a) (2) Extract the module by raising it at a 30 degree slant and pulling outward.

Mounting a module

(1) Insert the module at a 30 degree slant into the module socket, with side B facing upward. (b) (2) Push the module inward and downward until it is locked. (c)
(a)

(b)

(c)

Fig.7.2 (c) Demounting/Mounting a module

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Removing the DC/DC converter module

(1) Unscrew the screws (3M3). (2) Pull out the module.

Mounting the module

(1) Insert the module to the connector. (2) Screw the screws (3M3).
DC/DC converter module

screws (3M3)

Fig.7.2 (d) Mounting and removing the DC/DC converter module

Figure 7.2 (e) shows the locations of the cards and modules.

FROM/SRAM module under the CPU card

CPU card

DC/DC converter module

Total version

Axis control card

Fig.7.2 (e) Locations of Cards and Modules

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7. REPLACING A UNIT

7.3
REPLACING THE TRANSFORMER
WARNING Before you start replacement procedure, turn off the main power to the control unit.

7.3.1
Replacing the Brake Power Transformer

(1) Detach the cable from the transformer. (2) Remove the two nuts (M5) securing the transformer, then replace the transformer. (3) Reconnect the cable.

Remore the nuts (2M5)

Fig.7.3.1 Replacing the brake power transformer

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7.4
REPLACING THE EMERGENCY STOP UNIT
WARNING Before you start replacement, turn off the control unit main power.

(1) Detach the cables from the emergency stop unit. (2) Remove retaining screws (4M5) from the emergency stop unit, and replace the emergency stop unit. (3) Reconnect the cables.

Nut (4M5)

2 Remove the back nuts (2M5) screws 1 Remove the front nuts (2M5) screws

Fig.7.4 Replacing the Emergency Stop Unit

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7. REPLACING A UNIT

7.5
REPLACING THE MAGNETIC CONTACTOR
WARNING Before starting the replacement, turn off the control unit main power.

(1) Detach the cable from the magnetic contactor (MCC). (2) Holding down the magnetic contactor (MCC) a little, remove the MCC from the DIN rail. (3) Mount a new magnetic contactor (MCC) on the DIN rail. (4) Reconnect the cable.

Magnetic contactor (MCC)

Fig.7.5 Replacing the magnetic contactor

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7.6
REPLACING SERVO AMPLIFIERS
WARNING Before you start replacement, turn off the control unit main power.

The following is the procedure for replacing the power supply module and servo amplifier module. (1) Detach the cable from the servo amplifier. Remove the jumper connecting the DC link (L+ and L). (2) Remove the two nuts from the top of the servo amplifier. (3) Mount a new servo amplifier, reversing the removal step of (2). (4) Reconnect the cable and remount the jumper connecting the DC link (L+ and L).

Nut (2M5)

Power supply module

servo amplifier module

Fig.7.6 Replacing the servo Amplifier

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7. REPLACING A UNIT

7.7
REPLACING THE TEACH PENDANT

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

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

Fig.7.7 Replacing the Teach Pendant

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7.8
REPLACING THE CONTROL SECTION FAN MOTOR

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

Fan motor connector

Fan motor

Pull the fan motor unit toward you to unlatch it.

Fig.7.8 Replacing the Control Section Fan Motor

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7. REPLACING A UNIT

7.9
REPLACING THE FAN MOTOR OF THE SERVO AMPLIFIER CONTROL UNIT

The fan motor of the servo amplifier control unit can be replaced without using tools. The fan unit is mounted at the top of the servo amplifier. (1) Check that the robot controller is turned off. (2) Holding the two lugs, pull up the fan unit in the direction of the arrow. (3) Place a new fan unit at the top of the servo amplifier, and slightly press it in.
Holding the two lugs, pull up the fan unit in the direction of the arrow (rightward in the figure). When mounting the fan motor, note the orientation of the fan motor and connector.

Lug

White Black Red Note the orientation of the connector key. Fan unit (for width of 60 mm)

Fig.7.9 Replacing the fan motor of the servo amplifier control unit

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7.10
REPLACING THE DOOR FAN UNIT AND HEAT EXCHANGER
WARNING Before starting the replacement, turn off the control unit main power. Never touch the fan motor while it is rotating.

Door fan unit

(1) Unscrew the four fastening screws (M4). (2) Detach the cable from the fan unit. (3) Mount a spare fan unit, reversing the removal procedure.

Heat exchanger

(1) Detach the cable from the heat exchanger. (2) Remove the six fastening nuts (M4), and pull the heat exchanger toward you. (3) Detach the wiring from the door fan unit. (4) Mount a spare heat exchanger, reversing the removal procedure.

Heat exchange Door fan unit Screws (4M4)

Nut (4M5)

Fig.7.10 Replacing the door fan unit and heat exchanger

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7. REPLACING A UNIT

7.11
REPLACING THE OPERATOR PANEL

(1) Detach the cable from the circuit protector on the operator panel and the grounding line from the door. (2) Detach the cable (JD17) from the robot control board and the cable (CRT11) from the emergency stop board. (3) Unscrew the four screws (M3) fastening the operator panel, and remove the operator panel. (4) Mount a new operator panel, reversing the removal steps of (1) to (3).

Screw (4M3)

Fig.7.11 Replacing the operator panel

NOTE The operator panel comprises the panel itself and the cables connected to the robot control board and emergency stop board.

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7.12
REPLACING THE POWER SUPPLY UNIT

The power supply unit is mounted on the emergency stop unit. (1) Detach all the cables from the emergency stop unit (emergency stop board and power supply unit). (2) Pull out the connectortype terminal block (TBEB1, TBEB2) at the top. (3) Remove the four nuts (1 and 2) fastening the emergency stop unit, and remove the emergency stop unit. (4) Unscrew the four screws fastening the power supply unit, and replace the power supply unit.

1 Remove the front nuts (2M5)

2 Remove the back nuts (2M5) 3 Remove the screws (4M3)

Fig.7.12 Replacing the power supply unit

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7. REPLACING A UNIT

7.13
REPLACING A FUSE 7.13.1
Replacing a Fuse on the Robot Control Board

If a fuse of the control unit is blown, find out the cause, take an appropriate action, then replace the fuse. The robot control board has the following fuses. FUS1: For detecting a problem in the circuit on the robot control board: A60L00010046#7.5 If this fuse is blown, the DC/DC converter module or a device connected to the RS232C/RS422 port may be faulty. If the device connected to the RS232C/RS422 port is not faulty, replace the DC/DC converter module. FUS2: For protecting the 24V output to the peripheral device: A60L00010046#7.5 If this fuse is blown, the wiring to the peripheral device and a cable may be incorrect or damaged.

FUS1

FUS2

Fig.7.13.1 Replacing a fuse on the robot control board

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7.13.2
Replacing a Fuse on the Emergency Stop Board

The emergency stop board has the following fuses. FUS3: For monitoring the emergency stop circuit: A60L00010046#1.0 If this fuse is blown, the emergency stop board may be faulty. Replace the emergency stop board. FUS4: For protecting the 24V output to the emergency stop circuit and teach pendant: A60L00010046#1.0 If this fuse is blown, the emergency stop circuit may be incorrectly routed, or the teach pendant or teach pendant cable may be faulty. Check the routing of the emergency stop circuit, and replace the teach pendant and teach pendant cable. FUS5: For monitoring the emergency stop circuit: A60L00010245 #GP20 If the fuse is blown, the brake circuit may be faulty. Examine the brake, robot, and robot interconnection cable. Alternatively, replace the emergency stop board.

FUS4 FUS3

FUS5

Emergency stop board

Fig.7.13.2 Replacing a fuse on the emergency stop board

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7. REPLACING A UNIT

7.13.3
Replacing the Fuse on the Door

The door has the following fuse. FUS6: For protecting the 200VAC control output: A60L00010101# P475H If this fuse is blown, the power supply unit on the emergency stop unit or the cooling fan unit may be faulty. Replace the power supply unit or cooling fan unit.

FUS6

Fig.7.13.3 Replacing a fuse on the emergency stop board

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7.13.4
Replacing the Fuse on the Power Supply Module

The power supply module has the following fuse. FU1: For protecting the 200VAC input for generating power to the control circuit: A60L00010359 If the fuse is blown, the power supply module may be faulty. Replace the power supply module.

FU1

Remove the face plate

Fig.7.13.4 Replacing the fuse on the power supply module

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7. REPLACING A UNIT

7.13.5
Replacing the Fuse on the Servo Amplifier Module

The servo amplifier module has the following fuse. FU1: For protecting the +24 V input for generating power to the control unit: A60L00010290#LM32C If this fuse is blown, the servo amplifier module may be faulty. Replace the servo amplifier module.

FU1

Remove the control board

Fig.7.13.5 Replacing the fuse on the servo amplifier module

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7.13.6
Replacing the Fuse on the Process I/O Boards

The following fuse is on each process I/O board. FUSE1:Fuse for protecting the +24V output for peripheral equipment interfaces. A60L00010046#2.0

Process I/O board HE, HF FUSE1

Total edition

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7. REPLACING A UNIT

7.14
REPLACING A RELAY 7.14.1
Replacing a Relay on the Emergency Stop Board

Prolonged use of a relay might result in its contacts failing to make a secure connection or in them sticking to each other permanently. If such a failure occurs, replace the relay. The emergency stop board has the following relays. KA6: For external emergency stop output: A58L00010192#1509A KA7: For brake control: A58L00010192#1997R

KA6

KA7

Emergency stop board

Fig.7.14.1 Replacing a relay on the emergency stop board

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7.15
REPLACING BATTERY 7.15.1
Battery for Memory Backup (3 VDC)

The programs, and system variables are stored in the SRAM in the Robot control board. The power to the SRAM memory is backed up by a lithium battery mounted on the front panel of the Robot control board. The above data is not lost even when the main battery goes dead. A new battery can maintain the contents of memory for about 4 years (Note). When the voltage of the battery becomes low, the battery alarm LED on the operator panel is lit, and the lowvoltage battery alarm (system035) is displayed on the teach pendant. When this alarm is displayed, replace the battery as soon as possible. In general, the battery can be replaced within one or two weeks, however, this depends on the system configuration. If the battery voltage gets lower, it becomes impossible to back up the content of the SRAM. Turning on the power to the in this state causes system not to start and LED of seven segment on the Robot control board to be displayed 1 because the contents of memory are lost. Clear the entire SRAM memory and reenter data after replacing the battery. Important data should be saved to the memory card or floppy disk beforehand in case of emergency. When replacing the memory backup battery, do so while the robot controller is turned off in case of emergency.
NOTE In a newly introduced robot, the battery is factoryinstalled. Battery replacement may, therefore, be needed within 4 years after the introduction of the robot.

Replacing the lithium battery

(1)Prepare a new lithium battery (ordering drawing number: A02B0200K102). (2)Turn the robot controller on for about 30 seconds. (3)Turn the robot controller off. (4)Remove the old battery from the top of the Robot control board. First unlatch the battery, remove it from the battery holder, and detach its connector.

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7. REPLACING A UNIT

Battery latch

Battery connector

Lithium battery

(5)Remove the old battery, insert a new one into the battery holder, and attach the connector. Confirm that the battery is latched firmly.
WARNING Using other than the recommended battery may result in the battery exploding. Replace the battery only with the specified battery (A02B0200K102).

CAUTION Complete the steps (3) to (5) within 30 minutes. If the battery is left disconnected for a long time, the contents of memory will be lost. To prevent possible data loss, it is recommended that the robot data such as programs and system variables be backed up before battery replacement.

Dispose of the replaced battery as an industrial waste, according to the laws and other rules in the country where the controller is installed and those established by the municipality and other organizations that have jurisdiction over the area where the controller is installed.

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1. GENERAL

GENERAL

This chapter describes the connection and the installation of the electrical interface.

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BLOCK DIAGRAM

Following are the block diagrams of the electrical interface connection for RJ3iB Mate.

RJ3iB Mate controller Peripheral device Robot control board Operation panel RS232C RS422/485 Teach pendant

(RDI/RDO)

Emergency stop unit Power supply unit (Note2)

Transformer

Emergency stop board (Brake)

Emergency stop

Fan

Robot

Fuse Pulse coder Circuit protector MCC Servo amplifier

Power

NOTE Tranceformer is installed when the robot is for 6axes brake specification.

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3. CONNECTION DETAILS

CONNECTION DETAILS

Robot control board CP8B

Emergency stop unit EMGIN11, 12, 21, 22

Battery CP5 JRS12

FENCE11, 12, 21, 22 CP5B CRS24 EMGOUT1, 2 EXT24V, 0V CRS16 Teach pendant Emergency stop circuit

PCMCIA

PCMCIA

COP10A CRM82 JD17 JD1A JD1B CRM79 CRM81

Servo amplifier Mechanical unit RS232C or RS422/485 I/O Link (master) I/O Link (slave : option) Peripheral device Peripheral device (option)

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3.1
CONNECTION OF POWER SUPPLY CABLE
When the standalone controller is used, an optional power cable can be specified.

A grounding stud is provided beside the circuit protector. Connect the primary power ground wire to this stud. Use an M4 crimp terminal.

Use the cable holders are provided at these locations.

Circuit protector

Terminal is M4.

To primary power supply 3200VAC

By using cable straps, secure the primary power cable to the screws used to fasten the fan.

NOTE Connect the primary power cable to the circuit protector. After connection, insulate the protector terminal by fitting the provided terminal cover. Connect the primary power ground wire to the grounding stud, located beside the circuit protector.

You can specify the power supply cables as the option.

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3. CONNECTION DETAILS

3.2
FANUC I/O LINK
Table 3.2 Types of FANUC I/O Links I/O Link No. 1 Name
Robot control board

Drawing number A16B32000450

Master f(*)

Slave f(*)

Remarks Standard

NOTE The I/O Link of the robot control board is in the master mode by default. The I/O Link can be used in the slave mode by changing the software parameter setting.

Refer to the operator s manual for setting slave mode.

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JD1A

RJ3iB Mate

*Note that the connector name differs from that of the standard FANUC I/O link.

When the RJ3iB Mate control unit is used as the master and a slave of an I/O link

JD1A

RJ3iB Mate master

JD1A

CNC, PLC

When the RJ3iB Mate control unit is used as a slave of the I/O link (when a CNC or PLC is used as the master of the I/O link)

JD1A

CNC, PLC

JD1B1

FANUC I/O Link connection unit

JD1B2

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JD4* JD4* Process I/O printed boord etc. JD1A1 JD1A2

When the RJ3iB Mate control unit is used as the master of an I/O link (when RJ3iB Mate control the process I/O printed board) to other I/O link

JD1B

FANUC I/O Unit etc.

JD1B

FANUC I/O Unit etc.

to other I/O link JD1B JD1A

RJ3iB Mate

*Note Robot control board is required./Switch by the software

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3. CONNECTION DETAILS

3.3
CONNECTION OF I/O LINK CABLE
Cable connections should be made according to the system. The customer is requested to ground the shield. JD1A JD1B Robot control board

For other I/O link Earth plate Peel off the sheath of the shielded cable, then ground the shield here. I/O Link cable connection 1. Customer should be prepare this cable. 2. Power off when it is connected.

When making a connection with a CNC via an I/O link, apply the following timing to turn the power to the CNC and robot controller on/off: a) Turn on the power to the slave units when or before turning on the master power. b) If the power to the CNC or robot controller is turned off after the system has been started, an I/O link error will occur. To reestablish normal connection via the I/O link, turn off the power to all units, then turn on the power as explained in a) above. JD1A interface 11 0V JD4(JD1B) interface 11 0V 01 RXSLC1 03 TXSLC1 05 06 08 10 01 RXSLC2 03 TXSLC2 05 06 12 13 14 15 16 17 18 19 20 0V 0V 0V 0V 0V 02 *RXSLC1 04 *TXSLC1 12 13 14 15 16 17 18 19 20 0V 0V 0V 0V 0V 02 *RXSLC2 04 *TXSLC2 07 07 (+5V) (+5V) (+5V) (+5V) 08 10 09 (+5V) 09 (+5V) Note) When using an optical I/O link adaptor, use +5V. Note) When using an optical I/O link adaptor, use +5V.

(1)Twistedpair cables should be used for pin pairs 1 and 2, and 3 and 4. (2)Use unified shielding, and ground the shield on the CNC side.

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Cable connection

Master Robot control board JD1A

RXSLC1 (1) *RXSLC1 (2) TXSLC1 (3) *TXSLC1 (4) 0V (11) 0V (12) 0V (13) 0V (14) 0V (15) 0V (16)

I/O unit, etc JD1B

(1) SIN [RX] (2) *SIN [*RX] (3) SOUT [TX] (4) *SOUT [*TX] (11) 0V (12) 0V (13) 0V (14) 0V (15) 0V (16) 0V

Slave CNC, PLC etc JD1A

[RX] SIN (1) [*RX] *SIN (2) [TX] SOUT (3) [*TX] *SOUT (4) 0V (11) 0V (12) 0V (13) 0V (14) 0V (15) 0V (16)

Robot control board JD1B

(1) RXSLC2 (2) *RXSLC2 (3) TXSLC2 (4) *TXSLC2 (11) 0V (12) 0V (13) 0V (14) 0V (15) 0V (16) 0V

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3. CONNECTION DETAILS

3.4
EMERGENCY STOP CIRCUIT 3.4.1
Circuit Diagram of Emergency Stop
Teach pendant Emergency stop button
+24T CRS16

Emergency stop board

(From CP5A) 24VIN +24EXT FUS4 FUS3 +24V +24EXT +24V

Operation panel mode switch

CRT11
AUTO SR21 T1

+24T

Enable/Disable switch
KA13 KA22 KA32 +24EXT

SR22 SR23 Emergency stop button

0V

Dead man switch

+24V KA11 +24EXT

Robot control board

MODE1 MODE2

JRS12

CRS24

0VEXT

+24V INT24V EXT24V INT0V EXT0V

TBEB1

24V external power supply

External emergency stop

OPEMG

0V 0VEXT EMGIN11 EMGIN12

FENCE EXEMG MCCMON

0VEXT

KA21 +

EMGIN21 EMGIN22 FENCE11 FENCE12

TBEB2

Safety fence

Mode switch
SR21 SR22 SR23 AUTO CLOSE OPEN CLOSE T1 OPEN CLOSE OPEN

0VEXT

KA31

FENCE21 FENCE22 EMGOUT1

CRM83 +24V

EMGOUT1 KA61

Servo amplifier ( PSMR1i)

CRR78 CX3
MCCOFF3

0V MCCOFF4 0V KA62 RL1

CX4
+24V ESP

+24V

ESP

MCC
(KM1) KM11 KM12

CZ1

3200VAC

KM13 KM14 KM15

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3.4.2
External Emergency Stop Input

Customer should prepare this cable

TBEB1 EMGIN11 EMGIN12 EMGIN21 EMGIN22 TBEB2 FENCE11 FENCE12 FENCE21 FENCE22 EMGOUT1 EMGOUT2

Cable holder

EXT24V INT24V INT0V EXT0V

EMGIN11 EMGIN12 EMGIN21 EMGIN22

FENCE11 FENCE12 FENCE21 FENCE22

EMGIN1 EMGIN2

SVOFF1 SVOFF2

External emergency stop input

Servo off input

NOTE The contact between EMGIN11 and EMGIN12 or between FENCE11 and FENCE12 opens or closes the emergency stop circuit. The contact between EMGIN21 and EMGIN22 or between FENCE21 and FENCE22 monitors the input state. (Singlechannel with monitoring safety circuit) When using external emergency stop input and fence input, prepare the contact for opening and closing the emergency stop circuit and the contact for monitoring.

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Emergency stop board

When the robot is shipped, EMGIN11 and EMGIN12/ EMGIN21 and EMGIN22, FENCE11 and FENCE12/ FENCE21 and FENCE22 are shortconnected. To enable external emergency stop input and fence input, first disconnect these jumper wires, then make the necessary connections. External emergency stop input is reflected in the external emergency stop output, but fence input is not reflected in the external emergency stop output. Confirm the operation of emergency stop switches on the teach pendant and on the front panel, after you wired the external emergency stop input and the servo off input.

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3. CONNECTION DETAILS

3.4.3
External Emergency Stop Output
Customer should prepare this cable.
Cable holder

Emergency stop from the teach pendant and emergency stop from the operator panel are reflected to the external emergency stop outputs, EMGOUT1 and EMGOUT2.

TBEB1 EMGIN11 EMGIN12 EMGIN21 EMGIN22

TBEB2 FENCE11 FENCE12 FENCE21 FENCE22 EMGOUT1 EMGOUT2

EMGOUT1 EMGOUT2

TP Emergency stop

OP Emergency stop

EXT24V INT24V INT0V EXT0V

Emergency stop board EMGOUT11 EMGOUT12 To peripheral control sequencer etc.

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3.4.4
External 24 V Input
Customer should prepare this cable.
Cable holder

When 24 V is applied externally, the external emergency stop outputs, EMGOUT1 and EMGOUT2, are always output regardless of the power state of the robot control unit.

TBEB1 EMGIN11 EMGIN12 EMGIN21 EMGIN22

TBEB2 FENCE11 FENCE12 FENCE21 FENCE22 EMGOUT1 EMGOUT2

EXT24V EXT0V

A short connection board is inserted at the factory. Before using external 24 V, remove this short connection board. 24 V power supply
+24V

EXT24V INT24V INT0V EXT0V

EXT24V INT24V INT0V

Emergency stop board

0V

EXT0V

NOTE Connect a minus ground power supply for externally connected +24V. The circuit will not function properly if a plus ground power supply is connected.

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3. CONNECTION DETAILS

3.5
COONECTION OF SERVO AMPLIFIER
LR Mate 100iB
PSM AMP1 AMP2

POWER SUPPLY MODULE (PSMR1i) A06B6115H001

TB1 from MCC CZ1 L+

SERVO AMPLIFIER MODULE (SVM220/20i) A06B6114H205

TB1 L+

SERVO AMPLIFIER MODULE (SVM310/10/10i) A06B6114H302

TB1 L+ L

L L from circuit protector from emergency stop board COP10B CX1A CXA2A CXA2B CXA2A

COP10B CXA2B

COP10A CXA2A

CX3

JF1 (L) JF2 (M)

JF1 (L) JF2 (M) JF3 (N)

CX4

CZ2 L from robot control board CZ2 M

CZ2 L CZ2 M CZ2 N

to robot Pulse coder Motor power

LR Mate 200iB/ARC Mate 50iB

PSM AMP1 AMP2

POWER SUPPLY MODULE (PSMR1i) A06B6115H001

TB1 from MCC CZ1 L+

SERVO AMPLIFIER MODULE (SVM310/10/10i) A06B6114H302

TB1 L+

SERVO AMPLIFIER MODULE (SVM310/10/10i) A06B6114H302

TB1 L+ L

L L from circuit protector from emergency stop board COP10B CX1A CXA2A CXA2B CXA2A

COP10B CXA2B

COP10A CXA2A

CX3

JF1 (L) JF2 (M)

JF1 (L) JF2 (M) JF3 (N)

CX4 JF3 (N) CZ2 L from robot control board CZ2 M CZ2 N

CZ2 L CZ2 M CZ2 N

to robot Pulse coder Motor power

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3.6
CONNECTION OF ROBOT

CRM82 JF13

Power cable to RMP Signal cable Ground cable

TBEB3

CZ2 L, M, N

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3.7
CONNECTION OF TEACH PENDANT CABLE

Emergency stop unit CRS16

To teach pendant

Earth plate

Fig.3.7 Teach pendant cable

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3.8
CONNECTION OF CABLE FOR RS232C/RS422

Selection of RS232C or RS422 (option) interface need setting of software.

Communication port

01 02 03 04 05 06 07 FG TXD RTS 14 15 (TX) RXD CTS 0V (*TX) (RX) 16 17 (*RX) DSR 18 19 20 21 22 23 24 25 08 09 10 11 12 13 DTR +24E

174

Flopply, handy file etc.

Signals whose names are enclosed in parentheses are assigned to use the RS422 (option) interface. The numbers of the interface differ from those of the standard RS422 (option) interface. Take the caution when designing the interface.

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3.9
CONNECTING A CABLE TO A PERIPHERAL DEVICE 3.9.1
Peripheral Device Interfaces CRM79 and CRM81
Table 3.9.1 Types of FANUC I/O Links Peripheral device interface No. 1 Name
Robot control board A

Drawing number A16B32000450

CRM79 DI 20 DO 20

CRM81 DI 8 DO 4

Remarks Standard

NOTE The DI and DO signals of CRM79 and CRM81 include special signals.

Connecting a peripheral device (CRM79 or CRM81)

Robot control board CRM81 CRM79

to peripheral device Grounding plate Strip off the sheathing of the shield cable and connect the cable to the grounding plate.

Fig.3.9.1 Connecting the peripheral device cable

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3.9.2
When the Robot is Connected to the CNC by a Peripheral Device Cable
NOTE See the operators MANUAL for the detail information.

Turn off the controller when connecting the cable.

Robot control board CRM79

CRM81

CRM79 interface (Specified signals are not allocated and the Robot is connected to CNC and PLC by a FANUC I/O Link cable.) SDI101 SDI102 SDI103 SDI104 SDI105 SDI106 SDI107 SDI108 SDI109 SDI110 SDI111 SDI112 SDI113 SDI114 SDI115 SDI116 0V 0V 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 SDO101 SDO102 SDO103 SDO104 SDO105 SDO106 SDO107 SDO108 SDO109 SDO110 SDO111 SDO112 SDO113 SDO114 SDO115 SDO116 +24E +24E Connector in cable side HONDA TSUSHIN CO.,LTD Connector MR50LMH(Male)

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18

19 20 21 22 23 24 25 26 27 28 29 30 31 32

SDICOM1 SDICOM2 SDO120 SDI117 SDI118 SDI119

SDI120

SDO117 SDO118 SDO119 0V 0V +24E +24E

SDICOM1 and SDICOM2 are the signals used for selecting a common for SDI signals. To use the +24V common, connect SDICOM1 and SDICOM2 to 0V. To use the 0V common, connect SDICOM1 and SDICOM2 to +24V.
SDICOM1Selects a common for SDI101 to SDI108. SDICOM2Selects a common for SDI109 to SDI120.

(Note) Maximum output current per one SDO signal is 70mA.

176

CNC

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CRM79 interface (standard allocation of specified signals and the Robot is connected to the CNC and PLC by a peripheral device cable.) 01 02 03 04 05 06 07 08 09 11 SDI101 SDI102 SDI103 SDI104 SDI105 SDI106 SDI107 SDI108 RESET ENBL 33

Connector in cable side HONDA TSUUSHIN CO.,LTD Connector MR50LMH (Male)

SDO101 *HOLD START PNS1 10 12 13 14 PNS2 15 PNS3 0V 16 PNS4 0V 34 SDO102 19 SDICOM1 35 SDO103 20 SDICOM2 36 SDO104 21 SDO120 37 SDO105 22 SDI117 38 SDO106 23 SDI118 39 SDO107 24 SDI119 40 SDO108 25 SDI120 41 SDO109 26 SDO117 42 SDO110 27 SDO118 43 SDO111 28 SDO119 44 SDO112 29 0V 45 CMDENBL 30 0V 46 FAULT 31 +24E 47 BATALM 32 +24E 48 BUSY 49 +24E 50 +24E 17 18

SDICOM1 and SDICOM2 signal are common selection signal for SDI. When 24 V common is used, connect to 0V. When 0V common is used, connect to +24V SDICOM1Selects a common for SDI101 to SDI108. SDICOM2Selects a common for *HOLD, RESET, START, ENBL, PNS1 to PNS4, and SDI117 to SDI120.

NOTE 1 Maximum output current for one SDO signal is 70mA. 2 The common (selected with SDICOM2) for a dedicated signal should ideally be the +24V common, but the 0V common can also be used. 3 Allocation of the specified signals can be changed from the teach pendant.

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CRM79 interface (standard allocation of specified signals and the Robot is connected to the CNC and PLC by a peripheral device cable.) 01 02 03 04 05 06 07 08 *IMSTP *HOLD 34 19 SDICOM1 35 20 SDICOM2 36 reserve 21 37 22 PNSTROBE 38 23 PROD_START 39 24 SDI119 40 25 SDI120 41 26 ACK7/SNO7 42 27 ACK8/SNO8 43 SNACK 28 44 29 0V 45 30 0V 46 31 +24E 47 32 +24E 48 49 50

Connector in cable side HONDA TSUUSHIN CO.,LTD Connector MR50LMH (Male)

33 CMDENBL SYSRDY PAUSED HELD FAULT *SFSPD CSTOPI RESET START HOME PROGRUN ATPERCH TPENBL BUSY BATALM ENBL 09 RSR1/PNS1 10 RSR2/PNS2 11 RSR3/PNS3 12 RSR4/PNS4 13 RSR5/PNS5 14 RSR6/PNS6 15 RSR7/PNS7 15 RSR8/PNS8 17 0V 18 0V ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 +24E +24E

SDICOM1 and SDICOM2 signal are common selection signal for SDI. When 24 V common is used, connect to 0V. When 0V common is used, connect to +24V SDICOM1 Selects a common for *IMSTP, *HOLD, *SFSPD, CSTOPI, RESET, START, HOME, ENBL. SDICOM2 Selects a common for RSR1/PNS1, RSR2/PNS2, RSR3/PNS3, RSR4/PNS4, RSR5/PNS5, RSR6/PNS6, RSR7/PNS7, RSR8/PNS8, PNSTROBE, PROD_START.

NOTE 1 Maximum output current for one SDO signal is 70mA. 2 The common (selected with SDICOM1 and 2) for a dedicated signal should ideally be the +24V common, but the 0V common can also be used. 3 Allocation of the specified signals can be changed from the teach pendant.

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In case +24V common at the peripheral device side. (Specified signals are not allocated)

Control unit (peripheral device interface : CRM79) +24E Connector pin No CRM79 (31,32,49,50) receiver circuit SDI101 SDI102 SDI103 SDI104 SDI105 SDI106 SDI107 SDI108 SDICOM1 SDI109 SDI110 SDI111 SDI112 SDI113 SDI114 SDI115 SDI116 SDI117 SDI118 SDI119 SDI120 SDICOM2 RV 3.3k RV CRM79 (3) RV CRM79 (4) RV CRM79 (5) RV CRM79 (6) RV CRM79 (7) RV CRM79 (8) RV CRM79 (19) RV CRM79 (9) RV CRM79 (10) RV CRM79 (11) RV CRM79 (12) RV CRM79 (13) RV CRM79 (14) RV CRM79 (15) RV CRM79 (16) RV CRM79 (22) RV CRM79 (23) RV CRM79 (24) RV CRM79 (25) RV CRM79 (20) RV CRM79 (17,18,29,30) 0V CRM79 (2) CRM79 (1)

Peripheral device

Fig.3.9.2 (a) Peripheral device control interface : CRM79 (Input signal, +24V common)

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In case 0V common at the peripheral device side. (Specified signals are not allocated)

Control unit (peripheral device interface : CRM79) +24E Connector pin No CRM79 (31,32,49,50) receiver circuit SDI101 SDI102 SDI103 SDI104 SDI105 SDI106 SDI107 SDI108 SDICOM1 SDI109 SDI110 SDI111 SDI112 SDI113 SDI114 SDI115 SDI116 SDI117 SDI118 SDI119 SDI120 SDICOM2 RV RV CRM79 (3) RV CRM79 (4) RV CRM79 (5) RV CRM79 (6) RV CRM79 (7) RV CRM79 (8) RV CRM79 (19) RV CRM79 (9) RV CRM79 (10) RV CRM79 (11) RV CRM79 (12) RV CRM79 (13) RV CRM79 (14) RV CRM79 (15) RV CRM79 (16) RV CRM79 (22) RV CRM79 (23) RV CRM79 (24) RV CRM79 (25) RV CRM79 (20) RV CRM79 (17,18,29,30) 0V 3.3k CRM79 (1) CRM79 (2)

Peripheral device

Fig.3.9.2 (b) Peripheral device control interface : CRM79 (Input signal, 0V common)

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(Specified signals are not allocated)

Control unit (peripheral device interface : CRM79) Connector pin No Driver circuit SDO101 DV CRM79 (33)

Peripheral device LOAD RELAY

SDO102 SDO103 SDO104 SDO105 SDO106 SDO107 SDO108 SDO109 SDO110 SDO111 SDO112 SDO113 SDO114 SDO115 SDO116 SDO117 SDO118 SDO119 SDO120

CRM79 (34) DV CRM79 (35) DV CRM79 (36) DV CRM79 (37) DV CRM79 (38) DV CRM79 (39) DV CRM79 (40) DV CRM79 (41) DV CRM79 (42) DV CRM79 (43) DV CRM79 (44) DV CRM79 (45) DV CRM79 (46) DV CRM79 (47) DV CRM79 (48) DV CRM79 (26) DV CRM79 (27) DV CRM79 (28) DV CRM79 (21) DV CRM79 (17,18,29,30) 0V LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD

0V +24V +24V regurated power supply

Max. current per SDO is 70mA.

Fig.3.9.2 (c) Peripheral device control interface : CRM79 (Output signal)

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In case +24V common at the peripheral device side. (Specified signals are allocated)

Control unit (peripheral device interface : CRM79) +24E Connector pin No CRM79 (31,32,49,50) receiver circuit SDI101 SDI102 SDI103 SDI104 SDI105 SDI106 SDI107 SDI108 SDICOM1 SDI109 SDI110 SDI111 SDI112 SDI113 SDI114 SDI115 SDI116 SDI117 SDI118 SDI119 SDI120 SDICOM2 RV 3.3k RV CRM79 (3) RV CRM79 (4) RV CRM79 (5) RV CRM79 (6) RV CRM79 (7) RV CRM79 (8) RV CRM79 (19) RV CRM79 (9) RV CRM79 (10) RV CRM79 (11) RV CRM79 (12) RV CRM79 (13) RV CRM79 (14) RV CRM79 (15) RV CRM79 (16) RV CRM79 (22) RV CRM79 (23) RV CRM79 (24) RV CRM79 (25) RV CRM79 (20) RV CRM79 (17,18,29,30) 0V CRM79 (2) CRM79 (1)

Peripheral device

Fig.3.9.2 (d) Peripheral device control interface : CRM79 (Input signal, +24V common)

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In case 0V common at the peripheral device side. (Specified signals are allocated)

Control unit (peripheral device interface : CRM79) +24E Connector pin No CRM79 (31,32,49,50) receiver circuit SDI101 SDI102 SDI103 SDI104 SDI105 SDI106 SDI107 SDI108 SDICOM1 SDI109 SDI110 SDI111 SDI112 SDI113 SDI114 SDI115 SDI116 SDI117 SDI118 SDI119 SDI120 SDICOM2 RV RV CRM79 (3) RV CRM79 (4) RV CRM79 (5) RV CRM79 (6) RV CRM79 (7) RV CRM79 (8) RV CRM79 (19) RV CRM79 (9) RV CRM79 (10) RV CRM79 (11) RV CRM79 (12) RV CRM79 (13) RV CRM79 (14) RV CRM79 (15) RV CRM79 (16) RV CRM79 (22) RV CRM79 (23) RV CRM79 (24) RV CRM79 (25) RV CRM79 (20) RV CRM79 (17,18,29,30) 0V 3.3k CRM79 (1) CRM79 (2)

Peripheral device

Fig.3.9.2 (e) Peripheral device control interface : CRM79 (Input signal, 0V common)

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(Specified signals are allocated)

Control unit (peripheral device interface : CRM79) Connector pin No Driver circuit SDO101 DV CRM79 (33)

Peripheral device LOAD RELAY

SDO102 SDO103 SDO104 SDO105 SDO106 SDO107 SDO108 SDO109 SDO110 SDO111 SDO112 SDO113 SDO114 SDO115 SDO116 SDO117 SDO118 SDO119 SDO120

CRM79 (34) DV CRM79 (35) DV CRM79 (36) DV CRM79 (37) DV CRM79 (38) DV CRM79 (39) DV CRM79 (40) DV CRM79 (41) DV CRM79 (42) DV CRM79 (43) DV CRM79 (44) DV CRM79 (45) DV CRM79 (46) DV CRM79 (47) DV CRM79 (48) DV CRM79 (26) DV CRM79 (27) DV CRM79 (28) DV CRM79 (21) DV CRM79 (17,18,29,30) 0V LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD

0V +24V +24V regurated power supply

Max. current per SDO is 70mA.

Fig.3.9.2 (f) Peripheral device control interface : CRM79 (Output signal)

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In case +24V common at the peripheral device side. (Specified signals are allocated quickly)
Control unit (peripheral device interface : CRM79) +24E Connector pin No CRM79 (31,32,49,50) receiver circuit *IMSTP *HOLD *SFSPD CSTOPI RESET SRART HOME ENBL SDICOM1 RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSTROBE
PROD_START

Peripheral device

CRM79 (1) CRM79 (2) CRM79 (3)

RV RV RV

3.3k

CRM79 (4) RV CRM79 (5) RV CRM79 (6) RV CRM79 (7) RV CRM79 (8) RV CRM79 (19) RV CRM79 (9) RV CRM79 (10) RV CRM79 (11) RV CRM79 (12) RV CRM79 (13) RV CRM79 (14) RV CRM79 (15) RV CRM79 (16) RV CRM79 (22) RV CRM79 (23) RV CRM79 (24) SDI119 SDI120 SDICOM2 RV CRM79 (25) RV CRM79 (20) RV CRM79 (17,18,29,30) 0V

Fig.3.9.2 (g) Peripheral device control interface : CRM79 (Input signal, +24V common)

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In case 0V common at the peripheral device side. (Specified signals are allocated quickly)

Control unit (peripheral device interface : CRM79) +24E Connector pin No CRM79 (31,32,49,50) receiver circuit *IMSTP *HOLD *SFSPD CSTOPI RESET START HOME ENBL SDICOM1 RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSTROBE
PROD_START

Peripheral device

RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV

CRM79 (1) CRM79 (2) CRM79 (3) CRM79 (4) CRM79 (5) CRM79 (6) CRM79 (7) CRM79 (8) CRM79 (19) CRM79 (9) CRM79 (10) CRM79 (11) CRM79 (12) CRM79 (13) CRM79 (14) CRM79 (15) CRM79 (16) CRM79 (22) CRM79 (23) CRM79 (24) CRM79 (25) CRM79 (20) CRM79 (17,18,29,30) 0V

3.3k

SDI119 SDI120 SDICOM2

Fig.3.9.2 (h) Peripheral device control interface : CRM79 (Input signal, 0V common)

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(Specified signals are allocated quickly)

Control unit (peripheral device interface : CRM79) Driver circuit CMDENBL DV Connector pin No CRM79 (33)

Peripheral device LOAD RELAY

SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK reserve

DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV

CRM79 (34) CRM79 (35) CRM79 (36) CRM79 (37) CRM79 (38) CRM79 (39) CRM79 (40) CRM79 (41) CRM79 (42) CRM79 (43) CRM79 (44) CRM79 (45) CRM79 (46) CRM79 (47) CRM79 (48) CRM79 (26) CRM79 (27) CRM79 (28) CRM79 (21)

LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD 0V +24V +24V regurated power supply

CRM79 (17,18,29,30) 0V Max. current per SDO is 70mA.

Fig.3.9.2 (i) Peripheral device control interface : CRM79 (Output signal)

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CRM81 interface (When a special signal is not allocated; when CNC and PLC are connected by an I/O Link cable)
A 01 02 03 04 05 06 07 08 09 10 +24V SDO81 SDO83 SDO82 SDO84 0V 0V SDI81 SDI83 SDI85 SDI87 SDICOM B SDI82 SDI84 SDI86 SDI88
Cableside connector YAMAICHI ELECTRICITY Connector Housing UFS20B04 Contact Contact 66 type (UFS contact)

CRM81 interface (When a special signal is allocated; when CNC and PLC are connected by a peripheral device cable)
A 01 02 03 04 05 06 07 08 09 10 +24E
CMDENBL

B RESET ENBL PNS2 PNS4

Cableside connector YAMAICHI ELECTRICITY Connector Housing UFS20B04 Contact Contact 66 type (UFS contact)

*HOLD START PNS1 PNS3 SDICOM

FAULT BUSY 0V 0V

BATALM

SDICOM1 is a common signal that can be used either as an SDI or special signal. +24 V common: Connected to 0 V 0 V common: Connected to +24 V SDICOM Selects a common for SDI81 to SDI88.
CAUTION The maximum output current of each SDO or special signal is 70 mA.

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In case +24V common at the peripheral device side. (Specified signal is not allocated.)
Control unit (peripheral device interface : CRM81) +24E Connector pin No CRM81 (A10) receiver circuit SDI81 SDI82 SDI83 SDI84 SDI85 SDI86 SDI87 SDI88 SDICOM RV RV CRM81 (A2) RV CRM81 (B2) RV CRM81 (A3) RV CRM81 (B3) RV CRM81 (A4) RV CRM81 (B5) RV CRM81 (A5) RV CRM81 (B9,B10) 0V 3.3k CRM81 (A1) CRM81 (B1) Peripheral device

Fig.3.9.2 (j) Peripheral device control interface : CRM81 (Input signal, +24V common)

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In case 0V common at the peripheral device side. (Specified signal is not allocated.)
Control unit (peripheral device interface : CRM81) +24E Connector pin No CRM81 (A10) receiver circuit SDI81 SDI82 SDI83 SDI84 SDI85 SDI86 SDI87 SDI88 SDICOM RV RV CRM81 (A2) RV CRM81 (B2) RV CRM81 (A3) RV CRM81 (B3) RV CRM81 (A4) RV CRM81 (B5) RV CRM81 (A5) RV CRM81 (B9,B10) 0V 3.3k CRM81 (A1) CRM81 (B1) Peripheral device

Fig.3.9.2 (k) Peripheral device control interface : CRM81 (Input signal, 0V common)

(Specified signal is not allocated.)

Control unit (peripheral device interface : CRM81) Connector pin No Driver circuit SDO8 1 DV CRM81 (A7) RELAY

Peripheral device LOAD

SDO82 SDO83 SDO84

CRM81 (B7) DV CRM81 (A8) DV CRM81 (B8) DV CRM81 (B9,B10) 0V LOAD 0V +24V +24V regurated power supply LOAD LOAD

Max. current per SDO is 70mA.

Fig.3.9.2 (l) Peripheral device control interface : CRM81 (Output signal)

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In case +24V common at the peripheral device side. (Specified signal is allocated quickly)
Control unit (peripheral device interface : CRM81) +24E Connector pin No CRM81 (A10) receiver circuit RV 3.3k RV RV RV RV RV RV RV RV CRM81 (A1) CRM81 (B1) CRM81 (A2) CRM81 (B2) CRM81 (A3) CRM81 (B3) CRM81 (A4) CRM81 (B5) CRM81 (A5) CRM81 (B9 ,B10) 0V Peripheral device

*HOLD RESET START ENBL PNS1 PNS2 PNS3 PNS4 SDICOM

Fig.3.9.2 (m) Peripheral device control interface : CRM81 (Input signal, +24V common)

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In case 0V common at the peripheral device side. (Specified signal is allocated quickly)
Control unit (peripheral device interface : CRM81) +24E Connector pin No CRM81 (A10) receiver circuit *HOLD RESET START ENBL PNS1 PNS2 PNS3 PNS4 SDICOM RV RV RV RV RV RV RV RV RV 3.3k CRM81 (A1) CRM81 (B1) CRM81 (A2) CRM81 (B2) CRM81 (A3) CRM81 (B3) CRM81 (A4) CRM81 (B5) CRM81 (A5) CRM81 (B9 ,B10) 0V Peripheral device

Fig.3.9.2 (n) Peripheral device interface : CRM81 (Input signal, 0V common)

(Specified signal is allocated quickly)

Control unit (peripheral device interface : CRM81) Connector pin No driver circuit CMDENBL DV CRM81 (A7) RELAY LOAD

Peripheral device

FAULT BATALM BUSY

DV DV DV

CRM81 (B7) CRM81 (A8)

LOAD LOAD

CRM81 (B8) LOAD CRM81 (B9 ,B10) 0V 0V +24V +24V regurated power supply

Max. current per SDO is 70mA.

Fig.3.9.2 (o) Peripheral device control interface : CRM81 (Output signal)

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3.9.3
Digital I/O Signal Specifications

This section describes the specifications of the digital I/O signals interfaced with the peripheral device and end effector.

3.9.3.1
Peripheral device interface CRM 79 and CRM 81
D Output signal regulation

Example of connection
Spark killer diode +24V 70 mA or less

0V

0V +24V 70 mA or less Lamp

0V

Protective resistance

0V

Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at connection Spark killer diode Rated peak reverse voltage Rated effective forward current

: : : : :

24 VDC 30 VDC 70.mA Open collector NPN 1.0 V (approx.)

: 100 V or more : 1 A or more

Notes on use Do not use the +24 V power supply of the robot. When loading a relay, solenoid, and so on directly, connect them in parallel with diodes for preventing back electromotive force. If a load causing a surge current such as turning on LED is connected, use a protective resistance. Applicable signal Output signal of peripheral device interface CRM79, CRM81 : SDI101 to SDI120 (CRM79) SDI81 to SDI88 (CRM81)

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D Input signal regulation

Example of connection
+24V

RV

SDI n 3.3 k SDICOM

RV

0V

Example of +24V common connection

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 k (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 or less Opened circuit resistance : 100 k or more
(Signal) TB (Signal) TB

TB Peripheral device contact signal

Robot receiver signal TC TC TB ; TC ; Chattering 5 ms or less 5 to 20 ms

Note on use Apply the +24 V power of the robot to the receiver. However, the above signal regulations must be satisfied at the robot receiver. Applicable signal Input signal of peripheral device interface CRM79, CRM81 : SDO101 to SDO120 (CRM79) SDO81 to SDO84 (CRM81)

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3.9.4
Peripheral Device Cable Connector

The figure below shows the connector for peripheral device cable.

Symbol 1 2 Connector specification MR50LWM Applicable interface CRM79 Connector cover Connector 50 pins (male) Dimensions A 67.9 (B) 73.5 C 66.1

Name

Remark (D) 20 Honda Tsushin Kogyo E 50 16 pins

Fig.3.9.4 (a) Peripheral Device Cable Connector (CRM79 : Honda Tsushin Kogyo)

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3.56 2.54

A B 2.54 6.0

14.3 14.5

Connector specification UFS20B04

Applicable interface

Dimensions A 29.98 C 22.86 Remark YAMAICHI ELECTRONICS (Housing) YAMAICHI ELECTRONICS (Contact)

CRM81 Contact 66 type

Applicable cable : AWG#28 (7/0.12), AWG#26 (19/0.1), AWG#24 (19/0.12), (7/0.18)

Fig.3.9.4 (b) Peripheral Device Cable Connector (CRM81 : YAMAICHI ELECTRONICS)

3.9.5
Recommended Cables

Connect a peripheral device using a completely shielded, heavily protected cable conforming to the specifications in Table 3.9.5. Allow an extra 1.5m for routing the cable in the control unit. The maximum cable length is 30m.
Conductor Sheath thickness (mm) 1.5 1.5 Effective outside diameter (mm) 12.5 10.5 Electrical characteristics Conductor resistance (/km) 106 106 Allowable current (A) 1.6 1.6

Table 3.9.5 Recommended cable (For peripheral device connection)

Number of wires 50 20 Wire specifications (FANUC specifications) A66L00010042 A66L00010041

Diameter (mm) 1.05 1.05

Configuration 7/0.18 AWG24 7/0.18 AWG24

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3.10
END EFFECTOR INTERFACE 3.10.1
Connecting the Mechanical Unit and End Effector
Table 3.10.1 Types of end effector interfaces End effector interface No. 1 Name
Robot control board A

Drawing number A16B32000450

DI 6

DO 6

Remarks Standard

NOTE Either RDI6 or *PPABN is selected by software.

Mechanical unit EE 1 2 3 4 5 6 RDI1 RDI2 RDI3 RDI4 RDI5

RDI6 (*PPABN)

7 8 9 10 11 12

*HBK +24E +24E +24E 0V RDICOM

End effecter

NOTE RDO1 to RDO6 are used as the signals to turn on or off solenoid valves. The end effector can use the RDI signals and *HBK signal. For RDO signals, refer to the maintenance manual of the mechanical unit.

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Mechanical unit (end effector interface) +24E Connector pin No. EE (8,8,10) EE (1) EE (2) EE (3) RDI3 RDI4 RDI5 RDI6 (*PPABN) RDICOM RV EE (4) RV EE (5) RV EE (6) RV EE (12) RV EE (11)

End effecter

Receiver circuit RDI1 RDI2 RV RV 3.3k

0V

Fig.3.10.1 (a) End effector interface (+24V common)

Mechanical unit (end effector interface) +24E Connector pin No. EE (8,8,10) EE (1) EE (2) EE (3) RDI3 RDI4 RDI5 RDI6 (*PPABN) RDICOM RV EE (4) RV EE (5) RV EE (6) RV EE (12) RV EE (11)

End effecter

Receiver circuit RDI1 RDI2 RV RV 3.3k

0V

Fig.3.10.1 (b) End effector interface (0V common)

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3. CONNECTION DETAILS

3.10.2
Digital I/O Signal Specifications of End Effector Control Interface

Example of connection
+24V

RV

RDI n 3.3 k RDICOM

RV

0V

Example of +24V common connection

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 k (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 or less Opened circuit resistance : 100 k or more
TB (Signal) TB (Signal) TB

Peripheral device contact signal

Robot receiver signal TC TC TB ; TC ; Chattering 5 ms or less 5 to 20 ms

Note on use Apply the +24 V power at the robot to the receiver. However, the above signal specifications must be satisfied at the robot receiver. Applicable signals Input signals of end effector control interface Additional I/O PCB CRW6 input signal WDI1 to WDI8 RDI 1 to 6, *HBK, *PPABN (Switch RDI6 by software)
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3.11
TREATMENT FOR THE SHIELDED CABLE

In this manual the treatment for the shielded cable is shown on several pages. Partly cut off the shielded cable to expose the shield jacket, and fasten the jacket to the shield plate with a clamp to protect against noise. (In case of standalone type a shield plate is installed in the controller.)

Fig.2.12 Shielded cable treatment

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3.12
PERIPHERAL DEVICE, ARC WELDING, INTERFACES 3.12.1
Peripheral Device Interface Types
No. 1 2 Name Process I/O board HE Process I/O board HF

Connection to the peripheral device and the arc welding is available to use the process I/O board for RJ3iB Mate.

Drawing number A05B2440J002 A05B2440J003

Number of I/O points DI 40 40 DO 40 40 D/A 2 0 A/D 6 0

Remarks

NOTE General purpose I/O (SDI/SDO) is a number which subtract an exclusive signal from the table value.

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3.12.2
Peripheral Device Interface Block Diagram and Specifications

Process I/O board HE/HF Main board CRM2A JD1A (JD4) JD4A (JD1B) CRM2B JD4B (JD1A) CRW7 (NOTE 1) CRW2 (NOTE1)

Peripheral device

Fig.3.12.2 Block diagram of the process I/O board HE and HF

NOTE 1 CRW2 and CRW7 are not provided for process I/O board HF.

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3.12.3
Peripheral Device and Control Unit Connection
Control unit
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

The connection is for the allocated specified signal. For detail of the allocation, refer to the OPERATORS MANUAL.

*IMSTP

Peripheral device control interface A1 CMDENBL 33 CRM2A

19 20 21 22 23 24 25 26 27 28 29 30 31 32 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 COMA4 ACK7/SNO7 ACK8/SNO8 SNACK RESERVED COMA5 PNSTROBE PROD START SDI01 SDI02 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 SYSRDY PROGRUN PAUSED COMA1 HELD FAULT ATPERCH TPENBL COMA2 BATALM BUSY ACK1/SNO1 ACK2/SNO2 COMA3 +24E +24E

*HOLD *SFSPD CSTOPI FAULT RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 0V 0V

Peripheral device A1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

SDI03

Peripheral device control interface A2 SDO01 CRM2B 33

19 20 21 22 23 24 25 26 27 28 29 30 31 32 SDO13 SDO14 SDO15 SDO16 COMB4 SDO17 SDO18 SDO19 SDO20 COMB5 SDI19 SDI20 SDI21 SDI22 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 SDO02 SDO03 SDO04 COMB1 SDO05 SDO06 SDO07 SDO08 COMB2 SDO09 SDO10 SDO11 SDO12 COMB3 +24E +24E Peripheral device A2

SDI04 SDI05 SDI06 SDI07 SDI08 SDI09 SDI10 SDI11 SDI12 SDI13 SDI14 SDI15 SDI16 SDI17 SDI18 0V 0V

NOTE 1 Peripheral device connection cable are optional. 2 All COM-** are connected to the 0V.

Applicable process I/O board type

HE, HF

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Control unit (peripheral device control interface A1) +24E Connector pin No. CRM2A (49,50) Receiver circuit *IMSTP *HOLD *SFSPD CSTOPI RV RV RV RV 0V FAULT RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSTROBE PROD START SDI01 SDI02 COM1 RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV +24E B A 0V Common setting pin (ICOM1) 0V CRM2A (5) CRM2A (6) CRM2A (7) CRM2A (8) CRM2A (9) CRM2A (10) CRM2A (11) CRM2A (12) CRM2A (13) CRM2A (14) CRM2A (15) CRM2A (16) CRM2A (29) CRM2A (30) CRM2A (31) CRM2A (32) CRM2A (17,18) 3.3k CRM2A (1) CRM2A (2) CRM2A (3) CRM2A (4)

Peripheral device

NOTE This is a connection diagram for +24V common.

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Control unit (peripheral device control interface A1) Connector pin No. Driver circuit DV CMDENBL 0V DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV CRM2A (34) CRM2A (35) CRM2A (36) CRM2A (38) CRM2A (39) CRM2A (40) CRM2A (41) CRM2A (43) CRM2A (44) CRM2A (45) CRM2A (46) CRM2A (19) CRM2A (20) CRM2A (21) CRM2A (22) CRM2A (24) CRM2A (25) CRM2A (26) CRM2A (27) CRM2A (33)

Peripheral device

LOAD RELAY

SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK RESERVED

LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD

CRM2A (23,28,37,42,47)

0V Max. current per UDO is 70mA

0V +24V +24V regurated power supply

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Control unit (peripheral device control interface A2) +24E Connector pin No. CRM2B (49,50) Receiver circuit SDI03 SDI04 SDI05 SDI06 SDI07 SDI08 SDI09 SDI10 SDI11 SDI12 SDI13 SDI14 SDI15 SDI16 SDI17 SDI18 SDI19 SDI20 SDI21 SDI22 COM2 RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV +24E B A 0V Common setting pin (ICOM2) 0V CRM2B (1) 3.3k CRM2B (2) CRM2B (3) CRM2B (4) CRM2B (5) CRM2B (6) CRM2B (7) CRM2B (8) CRM2B (9) CRM2B (10) CRM2B (11) CRM2B (12) CRM2B (13) CRM2B (14) CRM2B (15) CRM2B (16) CRM2B (29) CRM2B (30) CRM2B (31) CRM2B (32) CRM2B (17,18)

Peripheral device

NOTE This is a connection diagram for +24V common.

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Control unit (peripheral device control interface A2) Connector pin No. Driver circuit DV SDO01 0V CRM2B (34) CRM2B (35) CRM2B (36) CRM2B (38) CRM2B (39) CRM2B (40) CRM2B (41) CRM2B (43) CRM2B (44) CRM2B (45) CRM2B (46) CRM2B (19) CRM2B (20) CRM2B (21) CRM2B (22) CRM2B (24) CRM2B (25) CRM2B (26) CRM2B (27) CRM2B (33)

Peripheral device

LOAD RELAY

SDO02 SDO03 SDO04 SDO05 SDO06 SDO07 SDO08 SDO09 SDO10 SDO11 SDO12 SDO13 SDO14 SDO15 SDO16 SDO17 SDO18 SDO19 SDO20

DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV

LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD

CRM2B (23,28,37,42,47) 0V Max. current per DO is 70mA

0V +24V +24V regurated power supply

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3.12.4
Connection Between the Control Unit and Welder
Control unit Analog input interface CRW2

Peripheral device

NOTE Welder and peripheral device connection cable are optional.

Applicable process I/O board type

HE

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Analog connection of CRW2 connector (Analog input)

Control unit (Analog input interface) Process I/O HE Peripheral device Connector pin number ADCH1 COMAD1 CRW2 (10) CRW2 (11)

ADCH2 COMAD2

CRW2 (12) CRW2 (13)

ADCH3 COMAD3

CRW2 (14) CRW2 (15) Output signals without ripples.

ADCH4 COMAD4

CRW2 (16) CRW2 (17)

ADCH5 COMAD5

CRW2 (18) CRW2 (19)

ADCH6 COMAD6 0V

CRW2 (8) CRW2 (9)

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Control unit Welder interface CRW7

Welder

NOTE Welder and peripheral device connection cable is option.

Applicable process I/O board type

HE

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Attaching the CRW7 connector to the welding machine: FANUC interface (Analog output, welding wire deposition detected, and WDI/WDO connection: Connected to the +24 V common line)
Control unit (welding interface) Process I/O HE DACH1 COMDA1 DACH2 COMDA2 Receiver circuit Arc detected signal
Gas outage detected signal Brokenwire detected signal Arc turnoff detected signal (power supply failure)

Connector pin No. CRW7 (1) CRW7 (2) CRW7 (3) CRW7 (4) Connector pin No. 3.3k CRW7 (6) CRW7 (7) CRW7 (8) CRW7 (10) +24E B A CRW7 (33,34)

Welding voltage command signal

Welding machine MS connector pin No. A B C D

Wire speed command signal

P T S R

WDI02 WDI03 WDI04 WDI06 COM3

RV RV RV RV RV +24E

Common setting pin 0V (ICOM3)

WDO01 Welding start signal WCOM1 WDO04 Wire inching (+) WCOM4 WDO05 Wire inching () WCOM5

CRW7 (23) CRW7 (24) CRW7 (29) CRW7 (30) CRW7 (13) CRW7 (14)

L K F G H J R=100 or more M N

Wire deposition detected signal

WDI+ WDI

CRW1 (31) CRW1 (32)

+
Cabinet ground (shield clamp)

Welding power supply Welding machine frame ground

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NOTE This is the connection for +24V.

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Attaching the CRW7 connector to the welding machine: FANUC interface (Analog output, welding wire deposition detected, and WDI/WDO connection: Connected to the +24 V common line)
Control unit (welding interface) Process I/O HE DACH1 COMDA1 DACH2 COMDA2 Receiver circuit WDI01 Arc detected signal Gas outage detected signal Brokenwire detected signal Cooling water outage signal Arc turnoff detected signal (power supply failure) WDI02 WDI03 WDI04 WDI05 WDI06 WDI07 WDI08 COM3 +24E B A RV RV RV RV RV RV RV RV RV +24E CRW7 (33,34) CRW7 (19,20) Common setting pin 0V (ICOM3) 0V WDO01 Welding start signal WCOM1 WDO02 Gas signal WCOM2 WDO04 Wire inching (+) WCOM4 WDO05 Wire inching () WCOM5 CRW7 (21,22) r m n Connector pin No. 3.3k CRW7 (5) CRW7 (6) CRW7 (7) CRW7 (8) CRW7 (9) CRW7 (10) CRW7 (11) CRW7 (12) CRW7 (2) CRW7 (3) CRW7 (4) Connector pin No. CRW7 (1) Welding voltage command signal Welding machine MS connector pin No. A B E F

Wire speed command signal

c d e f g h j k

CRW7 (23) CRW7 (24) CRW7 (23) CRW7 (24) CRW7 (29) CRW7 (30) CRW7 (13) CRW7 (14)

S a U

V b R=100 or more N P

Wire deposition detected signal

WDI+ WDI

CRW1 (31) CRW1 (32)

s Cabinet ground (shield clamp)

Welding power supply Welding machine frame ground

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3.12.5
Digital I/O Signal Specifications of Peripheral Device Interface A

(1) Output signals in peripheral device interface A Example of connection

Spark killer diode +24V

70 mA or less 0V +24V Lamp 70 mA or less 0V

Protective resistance

Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at connection Spark killer diode Rated peak reverse voltage Rated effective forward current

: : : : :

24 VDC 30 VDC 70 mA Open collector NPN 1.0 V (approx.)

: 100 V or more : 1 A or more

NOTE Do not use the +24 V power supply of the robot. When you load a relay, solenoid, and so on directly, connect them in parallel with diodes to prevent back electromotive force. If a load is connected causing a surge current when a lamp is turned on, use a protective resistance.

Applicable signals Output signals of process I/O board CRM2 CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT, ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNACK, SDO1 to SDO76

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(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 k (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 or less Opened circuit resistance : 100 k or more
TB (Signal) TB (Signal) TB

Peripheral device contact signal

Robot receiver signal TC TC TB ; TC ; Chattering 5 ms or less 5 to 20 ms

NOTE Apply the +24 V power at the robot to the receiver. However, the above signal specifications must be satisfied at the robot receiver.

Applicable signals Input signals of process I/O board CRM2 *IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET, START, HOME, ENBL, RSR1 to RSR8, PNS1 to PNS8, PNSTROBE, PROD START, SDI1 to SDI78
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3.12.6
I/O Signal Specifications for ARCWelding Interface

(1) Digital output signal specifications for an arc welding interface In case of process I/O HE
Example connection
Spark killer diode

0.3 A or less

Electrical characteristics Rated voltage Maximum applied voltage Maximum load current Output type Spark killer diode Rated peak reverse voltage Rated effective forward current

: : : :

24 VDC 30 VDC 0.3 A Relay connection output

: 100 V or more : 1 A or more

NOTE A power voltage of +24 V, provided for the robot, can be used for interface signals of up to 0.7 A. This limit applies to the sum of the currents flowing through the arcwelding and endeffector control interfaces. To drive a relay or solenoid directly, connect a diode preventing back electromotive force to the load in parallel. To connect a load which generates an inrush current when you turn on the control unit, connect a protective resistor.

Applicable signals Output signals on the arcwelding interface WDO1 to WDO4

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(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 Closedcircuit resistance : 100 or less Opencircuit resistance : 100 k or more
(Signal) Contact signal for peripheral (Signal)

Receiver signal for robot

TB: Chattering of 5 ms or less TC: 5 to 20 ms

NOTE Supply the +24 V power, provided for the robot, to the receivers. The receiver signal on the robot must satisfy the signal timing specified above.

Applicable signals Input signals for arc welding interface WDI1 to WDI8
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(3) Analog output signal specifications for arc welding interface (Welding voltage command, wirefeed rate command)
Example connection
Process I/O CA, EA : 10V to +10V Process I/O GA, HA : 0V to +15V 0V Welder

NOTE Input impedance: 3.3 k or more Connect a highpass filter.

(4) Analog input signal specifications for arc welding interface (Weldingvoltage detection, weldingcurrent detection)
Example connection
Welder 10V to +10V 0V

NOTE The analog input signal should have no ripple for the circuit to operate properly.

(Wire deposit detection: WDI+ and WDI)

Example connection
Welder

Welding electrode

NOTE Connect a resistor of 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 highfrequency components. The dielectric withstand voltage of this circuit is 80 V.

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3.12.7
Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin, 50 pins)

If the customer manufactures cables, make sure they conform to the FANUC standard cables described in this section. (See the description in Peripheral Device Interface in this manual for the specifications of the FANUC standard cables.)

Honda Tsushin MR50LWF01 (MR50LF) Process I/O

Honda Tsushin MR50LM01 (MR50LM) Peripheral device

Honda Tsushin MR50RMA

Honda Tsushins MR50RF Supplied with an ordered cable

3.12.8
ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins)

Be sure to use the FANUC cable to connect the welder.

ARC welder Honda Tsushin Process I/O CRW1 or CRW7 Honda Tsushin MR34RFA Japan Aviation Electronics Industry Ltd. MS3108B2821P MS305716

Japan Aviation Electronics Industry Ltd. MS3102A2821S Standard position of guide key

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3.12.9
Peripheral Device Cable Connector

(1) Fig. 3.12.9 shows the connector for peripheral device cables A and B. (The connector is used for a peripheral device)

Connector specifications MR50LM

Applicable interface CRM2

Dimensions A 67.9 (B) 73.5 C 44.8 (D) 18 Remark Honda Tsushin Kogyo, 50 pins

Symbol
    Connector cover Cable clamp screw

Name

Connector clamp spring Connector clamp screw Connector 50 pins (male) MR50M

Fig.3.12.9 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo)

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(2) Peripheral device connector

Connector specifications MR50RF

Applicable interface (CRM2)

Dimensions A 61.4 B 56.4

Remark Honda Tsushin Kogyo, 50 pins

Symbol
  Screw M2.6 8 Connector

Name Connector clamp screw (MR50RF)

Fig.3.12.9 (b) Peripheral Device Connector (Honda Tsushin Kogyo)

3.12.10
Recommended Cables

(1) Peripheral device connection cable Connect a peripheral device using a completely shielded, heavily protected cable conforming to the specifications in Table 3.12.10 (a). Allow an extra 50 cm for routing the cable in the control unit. The maximum cable length is 30 m.
Conductor Effective outside diameter (mm) 12.5 Electrical characteristics Conductor resistance (/km) 106 Allowable current (A) 1.6

Table 3.12.10 Recommended Cable (for Peripheral Device Connection)

Number of wires 50 Wire specifications (FANUC specifications) A66L-0001-0042 Sheath thickness (mm) 1.5

Diameter (mm) 1.05

Configuration 7/0.18 AWG24

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4. TRANSPORTATION AND INSTALLATION

4.1
TRANSPORTATION

The control unit should be transported by a crane. Attach a sling to eye bolts at the top of the control unit.

Fig.4.1 Transportation

4.2
INSTALLATION

Installation area When the control unit is installed, allow the space for maintenance shown in the following figure.

Contrpl unit

Contrpl unit

Contrpl unit

When the plural controller is installed.

Fig.4.2 Installation

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4.3
EXTERNAL CONTROLLER DIMENSIONS

Four M10 weld nuts The unit is shipped with the M10 bolts screwed to the weld nuts as 10mm feet. After the M10 bolts are removed, these weld nuts can be used to secure the control unit.

Fig.4.3 External drawing of robot controller

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4.4
INSTALLATION CONDITION
Item Input power supply Specifications/condition 50Hz; 200VAC, +10%, 15% 60Hz; 200VAC to 220 VAC, +10%, 15% 50/60 Hz"1Hz, 3phase 1 kVA (LR Mate 100iB) 1.2 kVA (LR Mate 200iB/ARC Mate 50iB) 0.4 kW (LR Mate 100iB) 0.5 kW (LR Mate 200iB/ARC Mate 50iB) 0 to 45_C during operation, and 20 to 60 C during shipment and storage with a temperature coefficient of 1.1_C/min. Relative humidity: 30% to 95%, noncondensing. An additional protective provision is necessary if the machine is installed in an environment in which there are relatively large amounts of contaminants (dust, dielectric fluid, organic solvent, acid, corrosive gas, and/or salt). 0.5 G or less. When using the robot in a location subject to serious vibration, consult with your FANUC sales representative. Not higher than 1,000 m above sea level A shielding provision is necessary if the machine is installed in an environment in which it is exposed to radiations (microwave, ultraviolet rays, laser beams, and/or Xrays). Approx. 35kg

Input power supply capacity Average power consumption Permissible ambient temperature Permissible ambient humidity Surrounding gas

Vibration

Altitude Ionized and nonionized radiations

Weight of control unit

4.5
ADJUSTMENT AND CHECKS AT INSTALLATION

Adjust and check according to following procedure at installation.

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Description Visually check the inside and outside of the control unit. Check if the screwed terminal is connected properly. Check that the connectors and printed circuit boards are inserted correctly. Connect control unit and mechanical unit cables. Turn the breaker off and connect the input power cable. Check the input power voltagage. Press the EMERGENCY STOP button on the operators panel and turn the power on. Check the output voltage. Check the interface signals between control unit and robot mechanical unit. Check the parameters. If necessary, set them. Release the EMERGENCY STOP button on the operators panel. Turn the power on. Check the movement along each axis in the manual jog mode. Check the end effector interface signals. Check the peripheral device control interface signals.

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4.6
NOTE AT INSTALLATION

An overtravel and emergency stop occur when the robot is operated for the first time after it is installed and the mechanical and control units are wired. This section describes how to reset the overtrvel and emergency stop. Remove the red plate fastening the swiveling axis beforehand. The J2 and J3 axes are pressed against the hard stops at shipment. Therefore, an overtravel alarm occurs when the power is turned on after installation.

4.7
DISABLING HAND BREAK

(1) (2) (3) (4) (5)

Press the [MENUS] key on the teach pendant. Select [Next]. Select [SETUP]. Press F1 [TYPE]. Select [Config] to disable or enable Hand Break.

Hand break
State 1 2 3 4 Hand break Enabled Enabled Disabled Disabled HBK (*1) CLOSE OPEN CLOSE OPEN HBK detection Detected Detected Detected (*2) Not detected Robot operation Possible Impossible Possible Possible Message Not provided SERVO 6 Not provided SERVO 300 at cold start

NOTE 1 Robot end effector connector

CLOSE 24V 24V OPEN

*HBK

*HBK

2 When the HBK circuit is closed, the HBK detection is enabled. If the HBK state changes from close to open, the SERVO 300 or SERVO 302 alarm occurs, stopping the robot. 3 If the power is turned off and on in the state described above, the system enters state 4, releasing the alarm.

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APPENDIX

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APPENDIX

A. TOTAL CONNECTION DIAGRAM

TOTAL CONNECTION DIAGRAM

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Fig.A (a) Total connection diagram

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Fig.A (b) Emergency stop circuit diagram

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A. TOTAL CONNECTION DIAGRAM

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Fig.A (c) Emergency stop circuit diagram

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A. TOTAL CONNECTION DIAGRAM

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Fig.A (d) Robot control board, Emergency stop board connector interface

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A. TOTAL CONNECTION DIAGRAM

Fig.A (e) Servo amplifier robot mechanical unit connector interface

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B. PERIPHERAL INTERFACE

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PERIPHERAL INTERFACE

Peripheral I/O (UI/UO) are a group of specialized signals whose usage is decided by the system. These signals are connected with a remote controller and the peripheral devices via the following interfaces and I/O links and they are used to control the robot from the outside. D The JD1A interface (The process I/O board, the I/O Unit MODEL A and the MODEL B are connected as the slave of I/O link to RJ3iB Mate.) (on master mode) D The JD1B interface (CNC and PLC are connected as a master of I/O link to RJ3iB Mate.) (on slave mode) D CRM9 interface Refer to the operator s MANUAL for detail informations.

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APPENDIX

B. PERIPHERAL INTERFACE

B.1
SIGNAL TYPES

The tables below list the special signals of the RJ3iB Mate robot controller.
Input signals (See Subsection B.2.1.) Signal *HOLD RESET START ENBL PNS1 PNS2 PNS3 PNS4 Temporary stop Alarm release Cycle start Enable Program select (*1) Program select (*1) Program select (*1) Program select (*1) Description

NOTE PNS (program select input) (optional)

Output signals (See Subsection B.2.1.) Signal CMDENBL FAULT BATALM BUSY Input acceptable Alarm Battery alarm Busy Description

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B81535EN/02

B.2
I/O SIGNALS B.2.1
Input Signals
Hold input signals, *HOLD, UI [ 1 ]

Fellowing is each input signal. The remote controller uses the hold signal to halt the robot. Because *HOLD input signal is a inverted signal, normally set the signal on. When the signal goes off, the following is executed: D The robot is decelerated until its stops, then the program execution is halted. D If ENABLED is specified at Break on hold on the general item setting screen, the robot is stopped, an alarm is generated, and the servo power is turned off. (Standard setting: DISABLED) The RESET signal cancels an alarm. If the servo power is off, the RESET signal turns on the servo power. The alarm output is not canceled until the servo power is turned on. The alarm is canceled at the instant this signal falls in default setting. D If TRUE is specified at CSTOPI for ABORT on the system configuration screen, the RESET signal resets an alarm and aborts the currently selected program. (Standard setting: FALSE) D To have alarms reset the instant the RESET signal rises, it is necessary to specify RISE at Detect FAULT RESET signal on the system configuration screen. (Standard setting: FALL) The START signal has two functions. It can select or collate a program and start the program. D When the START signal goes high, PNS1 to PNS4 are read and the corresponding program is selected or collated. Whether is program is selected or collated is specified by the setting of system variable $SHELL_CFG.$NUM_RSR [1]. (See the description of signals PNS1 to PNS4.) D When the START signal goes low, the current program is started from the line at which the cursor is placed (current line). D If TRUE is specified at START for CONTINUE only on the system configuration screen, only a program on hold can be started. (Standard setting: FALSE) The ENBL signal allows the robot to be moved and places the robot in the ready state. When the ENBL signal is off, the system inhibits a jog feed of the robot and activation of a program including a motion (group). A program which is being executed is halted when the ENBL signal is set off.
NOTE When the ENBL signal is not monitored, strap the signal with the ground.

Fault reset input signal, RESET, UI [ 2 ]

Start input signal, START, UI [ 3 ] (validated in the remote state)

Enable input signal, ENBL, UI [ 4 ]

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B. PERIPHERAL INTERFACE

Program number selection signals, PNS1 to PNS4, UI [ 5 to 8 ] (validated in the remote state)

A program number selection signal has two functions. When the START signal goes on, PNS1 to PNS4 are read and the corresponding program is selected or collated. Whether the program is selected or collated is specified by the setting of system variable $SHELL_CFG.$NUM_RSR [1]. D In the program end state, a program is selected or collated according to the state (0 or 1) of the PNS signals. The current line of the selected or collated program is set to 1. - Type 1 (when $SHELL_CFG.$NUM_RSR [1] is set to 0) The program specified by the PNS signals is selected. - Type 2 (when $SHELL_CFG.$NUM_RSR [1] is set to 1) The program specified by the PNS signals is collated with the current program. If the programs do not agree with each other, an error occurs. D If all PNS signals are low in the program end state, the current program is executed from the current line. If no programs are selected, an error occurs. D A halted program can be resumed only when all PNS signals are set off. Otherwise, an error occurs. D While a program is being executed, the PNS signals are ignored. Fellowing are peripheral device interface output signals. The CMDENBL signal is output when the following conditions are satisfied. The CMDENBL signal indicates that the remote controller can start a program including a motion (group). D The remote conditions are satisfied. D The ready conditions are satisfied. D The continuous operation mode is selected (the single step mode is disabled). The FAULT signal is output when an alarm occurs in the system. The RESET signal cancels the alarm. If a warning (WARN alarm) occurs, the FAULT signal is not output. The BATALM signal indicates that the voltage of the battery for supporting the memory has dropped. Replace the battery while keeping the power of the controller on. To have the BATALM signal generated also when the BZAL/BLAL alarm occurs, it is necessary to set the $BLAL_OUT.$BATALM_OR system variable. It is also possible to have the specified SDO output when the BZAL/BLAL alarm occurs. The BUSY signal is output while a program is being executed. The BUSY signal is not output while a program is being halted.
241

B.2.2
Output Signals
Command enable output signal, CMDENBL, UO [ 1 ]

Fault output signal, FAULT, UO [ 2 ]

Battery alarm output signal, BATALM, UO [ 3 ]

Busy output signal, BUSY, UO [ 4 ]

B. PERIPHERAL INTERFACE

APPENDIX

B81535EN/02

B.3
SPECIFICATIONS OF DIGITAL INPUT/OUTPUT B.3.1
Overview

This section describes the external specifications of digital and analog input/output in the RJ3iB Mate controller. The RJ3iB Mate controller can use up to 512 digital input and output points or an equivalent number of analog input and output points. One analog input/output point uses the resources equivalent to those used by 16 digital I/O points. The RJ3iB Mate can use a total of up to 512 I/O points. The RJ3iB Mate controller can use the following I/O hardware. - Process I/O printed circuit board - I/O unit model A The process I/O printed circuit board and the I/O unit model A can be used together.

B.3.2
Input/Output Hardware Usable in the R-J3iB Mate Controller

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B. PERIPHERAL INTERFACE

B.3.3
Software Specifications

(1) RDI/RDO These are signals sent to the connector at the wrist of the robot. They cannot be assigned (redefined) and are fixed. The standard format is six inputs and six outputs. The number of points that can be used for the connector at the wrist depends on the individual robot. (2) SDI/SDO The signal No. that is determined at hardware can be changed by software operation. (3) Analog I/O An analog I/O signal can access the analog I/O port (optional) on the process I/O printed circuit board or the I/O port on the analog I/O module (used together with the I/O unit model A). It reads and writes the digital value converted from the analog value of the I/O voltage. It means that the value does not always represent the real I/O voltage. (4) Group I/O Group I/O is a function which can input or output multiple DI/DO signals as binary codes. Any number of continuous signals of up to 16 bits can be set for its use. It can be set in the menu DETAILS on the group I/O screen.

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C. OPTICAL FIBER CABLE

APPENDIX

B81535EN/02

OPTICAL FIBER CABLE

The RJ3iB Mate uses fiber optic cables for communication between the robot control board and servo amplifier module and between the servo amplifier module and servo amplifier module. Observe the following cautions when handling these fiber optic cables. (1) Protection during storage When the electrical/optical conversion module (mounted on the printed) circuit board and the fiber optic cable are not in use, their mating surfaces must be protected with the lid and caps with which they are supplied. If left uncovered, the mating surfaces are likely to become dirty, possibly resulting in a poor cable connection.
Electrical/optical conversion module Lid

Fiber optic cable

Fiber optic cable caps

Fig.C (a) Protection of electrical/optical conversion module and fiber optic cable (when not in use)

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C. OPTICAL FIBER CABLE

(2) Fiber optic cable D Grasp the optical connector firmly when connecting or disconnecting the cable. Do not pull on the fiber optic cord itself. (The maximum tensile strength between the fiber cord and connector is 2 kg. Applying greater force to the cord is likely to cause the connector to come off, making the cable unusable.) Fiber optic cord diameter : 2.2 mm 2 cords Tensile strength : Fiber optic cord :7 kg per cord Between fiber optic cord and connector : 2 kg Minimum bending radius of fiber optic cord :25 mm Flame resistance : Equivalent to UL VW1 Operating temperature : 20 to 70C
8.2 6.7 19 max. 60 max. 35typ.

21 Code Bush Reinforced cover

Fig.C (b) External dimensions of external optical cable Unit : mm

Afler it is connected, the optical connector is automatically locked by the lock levers on its top. To remove the connector, release the lock levers and pull the connector. Although optical connectors cannot be connected in other than the correct orientation, always take note of the connectors orientation before making the connection. Take care to keep both parts of the optical connector (cable side and PCB side) clean. If they become dirty, wipe them with tissue paper or absorbent cotton to remove dirt. The tissue paper or absorbent cotton may be moistened with ethyl alcohol. Do not use any organic solvent other than ethyl alcohol. Do not clamp the uncovered portion of the cable with a nylon band.

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Index
[A] [E]
Emergency Stop Board (A20B10080010, 0011), 116 Emergency Stop Circuit, 167 End Effector Interface, 197 External Controller Dimensions, 224 External Emergency Stop Input, 168 External Emergency Stop Output, 169 External View of the Controller, 21

Adjustment and Checks at Installation, 225 Alarm Occurrence Screen, 29 ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins), 219

[B]
Backplane Board (A20B20030330), 117 Battery for Memory Backup (3 VDC), 154 Block Diagram, 160 Block Diagrams of the Power Supply, 126

[F]
FANUC I/O Link, 163

[C]
Checking the Power Supply Module, 127 Checking the Power Supply Unit, 127 Circuit Diagram of Emergency Stop, 167 Component Functions, 23 Configuration, 20 Connecting a Cable to a Peripheral Device, 175 Connecting the Mechanical Unit and End Effector, 197 Connection Between the Control Unit and Welder, 208 Connection Details, 161 Connection of Cable for RS232C/RS422, 174 Connection of I/O Link Cable, 165 Connection of Power Supply Cable, 162 Connection of Robot, 172 Connection of Teach Pendant Cable, 173 Coonection of Servo Amplifier, 171

[I]
I/O Signal Specifications for ArcWelding Interface, 216 I/O Signals, 240 Initial Screen Remains on the Teach Pendant, 28 Input Signals, 240 Input/Output Hardware Usable in the RJ3iB Mate Controller, 242 Installation, 223 Installation Condition, 225

[L]
LED of Power Supply Module, 123 LED of Servo Amplifier, 123 LED of Servo Amplifier Module, 124

[M]
Manual Operation Impossible, 109 Mastering, 33

[D]
Digital I/O Signal Specifications, 193 Digital I/O Signal Specifications of End Effector Control Interface, 199 Digital I/O Signal Specifications of Peripheral Device Interface A, 214 Disabling Hand Break, 226
i1

[N]
Note at Installation, 226

[O]
Operator Safety, 4, 6 Optical Fiber Cable, 244

Index

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Outline Drawings, 121 Output Signals, 241

[P]
Peripheral Device and Control Unit Connection, 203 Peripheral Device Cable Connector, 195, 220 Peripheral Device Interface Block Diagram and Specifications, 202 Peripheral device interface CRM 79 and CRM 81, 193 Peripheral Device Interface Types, 201 Peripheral Device Interfaces CRM79 and CRM81, 175 Peripheral Device, ARC Welding, Interfaces, 201 Peripheral interface, 238 Position Deviation Found in Return to the Reference Position (Positioning), 107 Power Cannot be Turned On, 26 Power Supply Module PSM (A06B6115H001), 121 Precautions for Mechanism, 10 Precautions for Mechanisms, 11 Precautions in Operation, 11 Precautions in Programming, 10, 11, 12 Preventive Maintenance, 24 Printed Circuit Boards, 111 Process I/O Board HE (A16B22030764), HF (A16B22030765), 118

Replacing the Emergency Stop Board, 132 Replacing the Emergency Stop Unit, 138 Replacing the Fan Motor of the Servo Amplifier Control Unit, 143 Replacing the Fuse on the Door, 149 Replacing the Fuse on the Power Supply Module, 150 Replacing the Fuse on the Process I/O Boards, 152 Replacing the Fuse on the Servo Amplifier Module, 151 Replacing the Magnetic Contactor, 139 Replacing the Operator Panel, 145 Replacing the Power Supply Unit, 146 Replacing the PrintedCircuit Boards, 129 Replacing the Robot Control Board and PrintedCircuit Boards on the Backplane Unit, 131 Replacing the Teach Pendant, 141 Replacing the Transformer, 137 Robot Control Board (A16B32000450), 112

[S]
Safety During Maintenance, 9 Safety in Maintenance, 13 Safety of the End Effector, 12 Safety of the Robot Mechanism, 11 Safety of the Teach Pendant Operator, 7 Safety of the Tools and Peripheral Devices, 10 Safety Precautions, 3 Safety Signals, 32 Servo Amplifier Module (A06B6114H205, A06B6114H302), 122 Servo Amplifiers, 120 Setting the Power Supply, 125 Signal Types, 239 Software Specifications, 243 Specifications of Digital Input/Output, 242 Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin, 50 pins), 219

[R]
Recommended Cables, 196, 221 Replacing a Fuse, 147 Replacing a Fuse on the Emergency Stop Board, 148 Replacing a Fuse on the Robot Control Board, 147 Replacing a Relay, 153 Replacing a Relay on the Emergency Stop Board, 153 Replacing a Unit, 128 Replacing Battery, 154 Replacing Cards and Modules on the Robot Control Board, 133 Replacing Servo Amplifiers, 140 Replacing the Backplane Board (Unit), 130 Replacing the Brake Power Transformer, 137 Replacing the Control Section Fan Motor, 142 Replacing the Door Fan Unit and Heat Exchanger, 144
i2

[T]
Teach Pendant Cannot be Turned On, 27 Total Connection Diagram, 229 Transportation, 223 Transportation and Installation, 222 Treatment for the Shielded Cable, 200

B81535EN/02

Index

Troubleshooting, 25 Troubleshooting Based on LED Indications, 97 Troubleshooting Using Fuses, 92 Troubleshooting Using the Error Code, 35 Warning Label, 14

[W]
When the Robot is Connected to the CNC by a Peripheral Device Cable, 176

[V]
Vibration Observed During Movement, 108

i3

Revision Record

FANUC Robot series RJ3iB Mate CONTROLLER for (RIA R15.06--1999 COMPLIANT) MAINTENANCE MANUAL (B81535EN)

02

Oct., 2002

Addition of ARC Mate 50iB

01

Oct., 2001

Edition

Date

Contents

Edition

Date

Contents