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FANUC Robotics

R-J3iB and R-J3iB Mate Controllers


Auxiliary Axis and Local Stop Options
Connection and Maintenance Manual
MAREIBAUX11011E REV. E
A-82377 and A-83110

This publication contains proprietary information of FANUC Robotics


America, Inc. furnished for customer use only. No other uses are
authorized without the express written permission of FANUC
Robotics America, Inc.
FANUC Robotics America, Inc.
3900 W. Hamlin Road
Rochester Hills, Michigan 483093253

The descriptions and specifications contained in this manual were in


effect at the time this manual was approved for printing. FANUC
Robotics America, Inc, hereinafter referred to as FANUC Robotics,
reserves the right to discontinue models at any time or to change
specifications or design without notice and without incurring
obligations.
FANUC Robotics manuals present descriptions, specifications,
drawings, schematics, bills of material, parts, connections and/or
procedures for installing, disassembling, connecting, operating and
programming FANUC Robotics products and/or systems. Such
systems consist of robots, extended axes, robot controllers,
application software, the KAREL
programming language,
INSIGHT
vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been
trained in one or more approved FANUC Robotics Training
Course(s) be permitted to install, operate, use, perform procedures
on, repair, and/or maintain FANUC Robotics products and/or
systems and their respective components. Approved training
necessitates that the courses selected be relevant to the type of
system installed and application performed at the customer site.

WARNING
This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in accordance
with the instruction manual, may cause interference to radio
communications. As temporarily permitted by regulation, it
has not been tested for compliance with the limits for Class A
computing devices pursuant to subpart J of Part 15 of FCC
Rules, which are designed to provide reasonable protection
against such interference. Operation of the equipment in a
residential area is likely to cause interference, in which case
the user, at his own expense, will be required to take
whatever measure may be required to correct the
interference.

FANUC Robotics conducts courses on its systems and products on


a regularly scheduled basis at its headquarters in Rochester Hills,
Michigan. For additional information contact
FANUC Robotics America, Inc.
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com

Copyright 2004 by FANUC Robotics 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 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
FANUC LTD 2004

No part of this manual may be reproduced in any form.


All specifications and designs are subject to change without notice.

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.

MAREIBAUX11011E REV E

Contents - 1

Chapter 1
R-J3IB CONTROLLER - ALPHA I SERIES MOTOR / AMPLIFIER AUXILIARY AXIS OPTION

1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 B-Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 A-Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Auxiliary Axis Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Brake Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
2
2
3

3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Troubleshooting Using the Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Troubleshooting Based on LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6
6
12

4 REPLACING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Replacing the Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Replacing the Servo Amplifier Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Replacing the Brake Unit Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Replacing the Servo Amplifier Internal Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Replacing the Servo Amplifier External Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17
17
19
20
21
22
23

5 CABLE CONNETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 For B-Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 For A-Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25
25
28

6 TOTAL CONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

7 SETTING THE BRAKE NUMBER FOR THE AUXILIARY AXIS . . . . . . . . . . . . . . . . . . . . . .

38

Chapter 2
R-J3IB B-CABINET CONTROLLER - ALPHA SERIES MOTOR / AMPLIFIER AUXILIARY AXIS OPTION

1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

2 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 B-Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Brake Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41
41
42

3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Troubleshooting Using the Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Troubleshooting Based on LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44
44
54

4 REPLACING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Replacing the Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57
57

Contents - 2

MAREIBAUX11011E REV E

4.2 Replacing the Servo Amplifier Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


4.3 Replacing the Brake Unit Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58
59
60

5 CABLE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

6 TOTAL CONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62

Chapter 3
LOCAL STOP HARDWARE

3.1 LOCAL STOP OPTION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3.2 LOCAL STOP KIT ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5

3.3 CONNECTION AND HARDWARE MOUNTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . .

3-8

3.4 ARC WELDING APPLICATION CONNECTION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . .

3-14

3.5 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-21

Chapter 4
R-J3IB MATE CONTROLLER - AUXILIARY AXIS OPTION
1 CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 MOTOR CONNECTION CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 TOTAL CONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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:

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:

Using Safety
Enhancing Devices

People
External devices
Robot(s)
Tooling
Workpiece

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:

Setting Up a Safe
Workcell

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

Safety fences, barriers, or chains


Light curtains
Interlocks
Pressure mats
Floor markings
Warning lights
Mechanical stops
EMERGENCY STOP buttons
DEADMAN switches

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

Staying Safe While


Teaching or Manually
Operating the Robot

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.

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.

Staying Safe During


Automatic Operation

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.

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

Staying Safe During


Inspection

Staying Safe During


Maintenance

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.

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.

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

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.

Programming Safety
Precautions

Implement the following programming safety measures to prevent


damage to machine tools and other external devices.

Safety-9

Mechanical Safety
Precautions

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.

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

Observe the following operating and programming guidelines to


prevent damage to the robot.

Operating Safety
Precautions

The following measures are designed to prevent damage to the


robot during operation.

Programming Safety
Precautions

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.

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.

Staying Safe While


Operating the Paint
Robot

System status is monitored by computer. Severe conditions


result in automatic system shutdown.

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

Staying Safe While


Operating Paint
Application Equipment

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.

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

Staying Safe During


Maintenance

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.

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.

Chapter 1

R-J3iB Auxiliary Axis Option Maintenance Manual


(Alpha-i series motor/amplifier)
1. Scope
This manual is supplement for Auxiliary Axis Option (Alpha-i series motor/amplifier) of the
R-J3iB controller (Standard, RIA and CE). Refer to the R-J3iB maintenance manual for general
maintenance description.
2. Assembly
2.1 B-cabinet

Fig.2.1 B-cabinet

2.2 A-cabinet

EMERGENCY STOP UNIT


(E-STOP UNIT)

Fig.2.2 A-cabinet
2.3 Auxiliary axis cabinet

Fig.2.3 Auxiliary Axis Cabinet

2.4 Brake Unit

Fig.2.4.1 Brake Unit (with contactor)

Fig 2.4.2 Brake Unit

Fig 2.4.2 Brake Unit (with 2 contactors)

3. Troubleshooting
3.1 Troubleshooting using the error code
SRVO-021 SRDY off (Group:i Axis:j)
[Explanation]

When HDRY is on, SRDY is off even though no other alarm or emergency stop
condition is present. This alarm can also occur when HRDY is off and the servo
amplifier MCC is ON. HRDY is the signal sent from the host (Main board) to the
servo system to specify whether to turn the servo amplifier MCC (located on E-Stop
Unit) on or off. SRDY is the signal sent from the servo system to the host to indicate
whether the servo amplifier MCC is on or off.
If the servo amplifier MCC cannot be turned on when directed so, it is likely that a
servo amplifier alarm has occurred. The host does not issue this alarm (SRDY off) if
an alarm for the servo amplifier is detected. Therefore, this alarm indicates that the
MCC cannot be turned on for an unknown reason.
Check the alarm history and investigate the factor of this alarm as follows.
<Case 1>
If this alarm occurs on the 6-axis servo amplifier and the auxiliary axis servo
amplifiers at the same time,
[Action 1]
It is likely that the supply voltage stops instantaneously. Check the power supply.
[Action 2]
Replace the E-stop unit.
[Action 3]
Replace the 6-axis servo amplifier.
<Case 2>
If this alarm occurs with other alarms,
[Action 1]
In case other alarms occurs at the same time in the alarm history, check the
troubleshooting of other alarms.
[Action 2]
In case with SRVO-214 Fuse Blown (Amp), replace the fuse of the 6-axis servo
amplifier.
[Action 3]
In case with SRVO-222 Lack of Amp (Amp:i), see the troubleshooting of SRVO-222.
<Case 3>
If this alarm occurs on only the auxiliary axis servo amplifiers,
[Action 1]
Make sure that connector JX5 of the servo amplifier is connected tightly.
[Action 2]
Replace the auxiliary axis servo amplifier that is indicated by the alarm massage.
[Action 3]
Replace the 6-axis servo amplifier.
<NOTE>
A SRDY off may occur when the software setting is incorrect.
<1> If the parameter of the auxiliary axis is wrong, SRDY off occurs.
<2> If the machine lock is set to the 6-axis servo amplifier, SRDY off occurs on the auxiliary axis that is
subordinate to the 6-axis servo amplifier.
<3> If the machine lock is set to one axis of the 2-axis and 3-axis servo amplifier, SRDY off occurs on
the other auxiliary axis.

SRVO-022 SRDY on (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

After inputting the reset signal, the ready signal from the servo amplifier was on
before outputting the signal that let the amplifier to be ready.
Replace the servo card or the auxiliary axis board indicated by the alarm message.
Replace the servo amplifier that is indicated by the alarm massage.

SRVO-023 Stop error excess (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

[Action 3]
[Action 4]

[Action 5]

[Action 6]
[Action 7]
[Action 8]

The position error becomes abnormally large, when the servo is at stop,
Check whether the robot or the auxiliary axis has collided with anything.
Check whether the motor brake has been released.
<1> Check the continuity of the brake circuit (cable, coil) at the CRR65*.
<2> Make sure that the brake cable has no ground fault.
<3> In case the brake unit is mounted, check to see if the fuse FUSE1 of the brake
unit is blown.(If this fuse is blown, it may be caused by some defect of the brake
cable.)
Make sure that CZ2 connector at the servo amplifier and the power connector at the
motor are connected tightly and check the continuity of the servo power circuit at
CZ2.
Check to see if the load is greater than the rating. If greater, reduce it to within the
rating. (If the load is too great, the torque required for acceleration / deceleration
becomes higher than the capacity of the motor. As a result, the motor becomes unable
to follow the command, and an alarm is issued.
Check to see if the input voltage of the R-J3iB controller is within its rated voltage
and the voltage setting of the transformer is right. (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.)
Replace the servo amplifier indicated by the alarm message.
Replace the brake unit.
Replace the motor.

SRVO-024 Move error excess (Group:i Axis:j)


[Explanation]
[Action]

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.
Take the same actions as for SRVO-023.

SRVO-036 Inpos time over (Group:i Axis:j)


[Explanation]
[Action]

The robot did not get to the specified area ($PARAM_GROUP_$INPOS TIME) even
after the position check monitoring time ($PARAM_GROUP.$STOPTOL) elapsed.
Take the same actions as for SRVO-023.

SRVO-038 Pulse mismatch (Group:i Axis:j)


[Explanation]

The pulse count stored when power was turned off does not match the count obtained
when the power is turned on. This alarm will be asserted after changing the
pulsecoder, changing the back up battery for the pulse coder data or after loading
back up data into the main board.
Check the alarm history and investigate the factor of this alarm as follows.
[Action 1]
In case with SRVO-222 Lack of Amp (Amp:i), see the troubleshooting of SRVO-222.
[Action 2]
If the brake number is set to the non-brake motors, this alarm may occur. Check the
software setting of the brake number.
[Action 3]
In case the robot or the auxiliary axis motors have been moved using the brake
release unit while the power is off or when restoring the back-up data to the main
board, this alarm may occur. Remaster the robot and the auxiliary axis motors.
[Action 4]
If the robot or the auxiliary axis motors have been moved because the brake failed,
this alarm may occur. Remove the factors and remaster the robot and the auxiliary
axis motors.
[Action 5]
Replace the pulse coder and remaster the group axis that is indicated by the alarm
message.

SRVO-045 HCAL alarm (Group:i Axis:j)


[Explanation]
[Action 1]

[Action 2]
[Action 3]

Abnormally high current flowed in the main circuit of the servo amplifier.
Turn off the power, and disconnect the power cable for the auxiliary axis motor from
the servo amplifier indicated by the alarm message.(and disconnect the brake cable to
avoid the axis falling unexpectedly.) Supply power and see if the alarm occurs again.
If the alarm occurs again, replace the servo amplifier.
Turn off the power and disconnect the power cable for the auxiliary axis(CZ2*)
indicated by the alarm message, and check the insulation of their U, V, W and the
GND lines each other. If there is a short-circuit, replace the power cable.
Turn off the power and disconnect the power cable for the auxiliary axis (CZ2*)
indicated by the alarm message, and measure the resistance between their U and V,V
and W and W and U with an ohmmeter that has a very low resistance range. If the
resistances at the three places are different from each other, the motor, the power
cable for auxiliary axis is defective. Check each item in detail and replace it if
necessary.

SRVO-046 OVC alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

This alarm is issued to prevent the motor from thermal damage that might occur
when the root mean square current calculated within the servo system is out of the
allowable range.
Check the operating conditions for the robot and relax the service conditions if it is
possible.
Take the same actions as for SRVO-023.

SRVO-47 LVAL alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

The control power supply voltage(+24V) supplied to servo amplifier is abnormally low.
Replace the servo amplifier that is indicated by the alarm message.
Replace the power supply unit.

SRVO-50 Collision Detect alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

The disturbance torque estimated by the servo software is abnormally high. (A


collision has been detected.)
Check the software setting for this option.
Take the same actions as for SRVO-023.

SRVO-51 CUER alarm (Group:i Axis:j)


[Explanation]
[Action 1]

The offset of the current feedback value is abnormally high.


Replace the servo amplifier that is indicated by the alarm message.

SRVO-55 FSSB com error 1 (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]
[Action 3]
[Action 4]

A communication error has been detected by the servo amplifier.


Replace the communication cable (Optical fiber) on the COP10B side of the servo
amplifier indicated by the alarm message.
Replace the servo amplifier that is indicated by the alarm message.
Replace the servo amplifier between main board and the indicated servo amplifier.
Replace the servo card or the auxiliary axis board.

SRVO-56 FSSB com error 2 (Group:i Axis:j)


[Explanation]
[Action ]

A communication error has been detected by the servo software.


Take the same actions as described for the above alarm.

SRVO-57 FSSB disconnect (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]
[Action 3]
[Action 4]
[Action 5]
[Action 6]

Communication was broken between the main board and the servo amplifier.
Check whether fuse F3 in the power supply unit has blown.
Check whether fuse FS1 in the servo amplifier has blown.
Check the communication cable (Optical fiber) between the main board and the 6-axis
servo amplifier and between the 6-axis amplifier and the auxiliary axis servo
amplifier. Replace it if it is faulty.
Replace the servo card or the auxiliary axis.
Replace the 6-Axis amplifier and the auxiliary amplifier.
Check the robot connection cable RP1 and the pulse coder cable of the auxiliary axis
(+5V ground fault).

Caution

Before continuing to the next step, perform a complete controller back up to save all
your programs and settings. Failure to perform this could result in damage to
equipment or lost data.

[Action 7]

Replace the main board.

SRVO-061 CKAL alarm (Group:i Axis:j)


SRVO-062 BZAL alarm (Group:i Axis:j)
SRVO-063 RCAL alarm (Group:i Axis:j)
SRVO-064 PHAL alarm (Group:i Axis:j)
SRVO-065 BLAL alarm (Group:i Axis:j)
SRVO-066 CSAL alarm (Group:i Axis:j)
SRVO-067 OHAL2 alarm (Group:i Axis:j)
SRVO-068 DTERR alarm (Group:i Axis:j)
SRVO-069 CRCERR alarm (Group:i Axis:j)
SRVO-070 STBERR alarm (Group:i Axis:j)
SRVO-071 SPHAL alarm (Group:i Axis:j)
SRVO-072 PMAL alarm (Group:i Axis:j)
Refer to the R-J3iB control unit maintenance manual.
SRVO-073 CMAL alarm (Group:i Axis:j)
[Explanation]
[Action 1]
[Action 2]

It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due
to noise.
Reinforce the earth of the flange of the motor that is indicated by the alarm message.
Replace the pulse coder that is indicated by the alarm message.

SRVO-074 LDAL alarm (Group:i Axis:j)


Refer to the R-J3iB control unit maintenance manual.
SRVO-135 FSAL alarm (Group:i Axis:j)
[Explanation]
[Action 1]
[Action 2]

Faulty internal fan motor of the auxiliary axis servo amplifier.


Replace the internal fan motor of the auxiliary servo amplifier that is indicated by the
alarm message.
Replace the auxiliary servo amplifier that is indicated by the alarm message.

SRVO-136 DCLVAL alarm (Group:i Axis:j)


[Explanation]
The DC link voltage is abnormally low.
-In case this alarm occurred during robot operation:
[Action 1]
Check to see if the input voltage of the R-J3iB controller is within its rated voltage
and the voltage setting of the transformer is right.
[Action 2]
It is likely that the supply voltage stops instantaneously. Check the power supply.
[Action 3]
Replace the E-STOP unit.
[Action 4]
Replace the servo amplifier.
-In case this alarm occurs while the power up sequence or right after inputting reset signal:
[Action 1]
Check whether the circuit breaker in the emergency stop unit is off. If it is off, check
the servo amplifier and the wiring between the servo amplifier and the emergency
stop unit. If anything is abnormal, replace it.
[Action 2]
Check to see if the input voltage of the R-J3iB controller is within its rated voltage
and the voltage setting of the transformer is right.
[Action 3]
Replace the E-stop unit.
[Action 4]
Replace the servo amplifier that is indicated by the alarm message.
-In case this alarm occurs right after pushing emergency stop button.
[Action 1]
This alarm will occur in case the servo amplifier primary power is removed before an
emergency stop. Check whether the auxiliary axis unit is installed correctly.

10

SRVO-156 IPMAL alarm (Group:i Axis:j)


[Explanation]
[Action]

Abnormally high current flowed through the main circuit of the servo power.
Take the same actions as for SRVO-045.

SRVO-215 Fuse blown (Aux. Axis)


[Explanation]
[Action]

The fuse FUSE1 on the brake unit is blown.


Replace this fuse after replacing the brake cable because it may be defective. (If this
fuse is blown, it may be caused by some defect of the brake cable.)

SRVO-222 Lack of Amp (Amp:i)


[Explanation]
[Action 1]

[Action 2]
[Action 3]
[Action 4]
[Action 5]

The servo amplifiers were not found at the power up sequence.


Turn off the controller, disconnect the pulse coder cable JF1,JF2 from the servo
amplifier and turn on the controller again. If this alarm dose not occur, the pulse
coder cable may have +5V ground fault.(The LED of the servo amplifier may display
blinking - when the pulse coder cable has +5V ground fault.)
Replace the servo amplifier for auxiliary axis.
Replace the 6-Axis servo amplifier.
Replace the optical fiber cable.
Replace the servo card or the auxiliary axis servo card.

SRVO-290 DC link HC alarm (Group:i Axis:j)


[Explanation]
[Action]

The DC link current of the servo amplifier is abnormal


Take the same actions as for SRVO-045.

SRVO-291 IPM over heat (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]
[Action 3]

The IPM in the servo amplifier overheated


Check the operating conditions for the robot and relax the service conditions if it is
possible.
Check whether the amplifier fan has stopped.
If this alarm is frequency issued, replace the servo amplifier.

SRVO-292 EXT.FAN alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

The external fan of the auxiliary axis servo amplifier is faulty.


Replace the external fan of the auxiliary axis servo amplifier.
Replace the servo amplifier.

11

3.2 Troubleshooting based on LED indication.

LED indication

Description
[Explanation]

Internal cooling fan is stopped.

[Action 1

Check whether there is any foreign material in


the fan.

[Action 2]

Check that the fan connector is attached


correctly.

[Action 3]

Replace the fan.

[Action 4]

Replace the servo amplifier.

[Explanation]

Control power supply undervoltage

[Action 1

Replace the servo amplifier.

[Explanation]

DC link undervoltage

[Action 1

Check that the screws for the DC link


connection cable (bar) are tight.

[Action 2]

If DC link low voltage alarm occurs in only one


servo amplifier, replace that servo amplifier.

[Explanation]

Overheat

[Action 1

Check that the motor is being used at or below


its continuous rating.

[Action 2]

Check that cooling capacity of the cabinet is


sufficient (inspect the fans and filters).

[Action 3]

Check that the ambient temperature is not too


high.

[Action 4]

Replace the servo amplifier.

[Explanation]

Cooling fan stopped of the radiator

[Action 1

Check whether there is any foreign material in


the fan.

[Action 2]

Check that the fan connector is attached


correctly.

[Action 3]

Replace the fan.

[Action 4]

Replace the servo amplifier.

[Explanation]

There are no communications between the servo


amplifiers in the auxiliary axis option of R-J3iB.
If this alarm occurs, take the actions as follows

[Action 1

Check the short-connector JX5.

[Action 2]

Replace the servo amplifier.

12

LED indication

Description
[Explanation]

DC Link current alarm

[Action 1]

Disconnect the motor power leads from the


servo amplifier (, disconnect the brake cable to
prevent the axis from falling), and release the
servo amplifier from an emergency stop
condition.
<1> If no abnormal DC link current alarm
condition has occurred.
Go to [Action 2].
<2> If an abnormal DC link current alarm
condition has occurred.
Replace the servo amplifier.

[Action 2]

Disconnect the motor power leads from the servo


amplifier , and check the insulation between PE
and the motor power lead U,V, and W.
<1> If the insulation is deteriorated
Go to [Action 3]
<2> If the insulation is normal
Replace the servo amplifier.

[Action 3]

Disconnect the motor from its power leads, and


check whether insulation of the motor or power
leads is deteriorated.
<1> If the insulation
deteriorated.

of

the

motor

is

Replace the motor.


<2> If the insulation of any power lead is
deteriorated.
Replace the power lead.

13

LED indication

Description
[Explanation 1]

IPM Alarm.

[Action 1

Disconnect the motor power leads from the servo


amplifier (, disconnect the brake cable to
prevent the axis from falling), and release the
servo amplifier from an emergency stop
condition.
<1> If no IPM alarm condition has occurred
Go to [Action 2].
<2> If an IPM alarm condition has occurred
Replace the servo amplifier.

[Action 2]

Disconnect the motor power leads from the servo


amplifier, and check the insulation between PE
and the motor power lead U,V, and W
<1> If the insulation is deteriorated
Go to [Action 4].
<2> If the insulation is normal
Replace the servo amplifier

[Action 3]

Disconnect the motor from its power lead, and


check whether the insulation of motor or power
lead is deteriorated.
<1> If the insulation
deteriorated

of

the

motor

is

Replace the motor.


<2> If the insulation of any power lead is
deteriorated
Replace the power lead.
[Explanation 1]

IPM Alarm (OH).

[Action 1]

Check that the heat sink cooling fan is running.

[Action 2]

Check that the motor is being used at or below


its continuous rating.

[Action 3]

Check that the cooling capacity of the cabinet is


sufficient (inspect the fans and filters).

[Action 4]

Check that the ambient temperature is not too


high.

[Action 5]

Replace the servo amplifier.

LED 8. means that this alarm occurs in the L-Axis.


LED 9. means that this alarm occurs in the M-Axis.
LED A. means that this alarm occurs in the N-Axis.

14

LED indication

Description
[Explanation]

Abnormal motor current.

[Action 1

Check whether the servo parameter has default


values. Alternatively, if an abnormal motor
current alarm condition occurs only on rapid
acceleration/deceleration, it is likely that the
motor is being used under too harsh a condition.
Increase the acceleration/deceleration time
constant, and see what will occur.

[Action 2]

Disconnect the motor power leads from the servo


amplifier (, disconnect the brake cable to prevent
the axis from falling), and release the servo
amplifier from an emergency stop condition.
<1> If no abnormal motor current occurs
Go to [Action 3].
<2> If an abnormal motor current occurs
Replace the servo amplifier.

[Action 3]

Disconnect the motor power leads from the servo


amplifier, and check the insulation between PE
and the motor power lead U,V, and W
<1> If the insulation is deteriorated
Go to [Action 4].
<2> If the insulation is normal
Replace the servo amplifier

[Action 4]

Disconnect the motor from its power lead, and


check whether the insulation of motor or power
lead is deteriorated.
<1> If the insulation of the motor is deteriorated
Replace the motor.
<2>If the insulation of any power lead is
deteriorated
Replace the power lead.

LED b means that this alarm occurs in the L-Axis.


LED c means that this alarm occurs in the M-Axis.
LED d means that this alarm occurs in the N-Axis.

15

LED indication

Description
[Explanation]

Abnormal Control Power Supply

[Action 1

Disconnect the pulse coder cable(JF*) from the


servo amplifier, and then switch on the power.
<1> If blinking continues
Replace the servo amplifier.
<2> If blinking stops
Go to [Action 2]

Blinking

[Action 2

Disconnect the pulse coder cable(JF*) from the


pulse coder, and then switch on the power.(Keep
the cable on the servo amplifier side connected.)
<1> If blinking continues
Replace the cable.
<2> If blinking stops
Replace the motor.

[Explanation]

FSSB communication error.

[Action 1

Replace the optical cable(COP10B) that is the


nearest to the main board on which U is
displayed.(In Fig 3.1,the cable between UNIT2
and UNIT 3.)

[Action 2

Replace the servo amplifier that is the nearest to


the main board on which U is displayed.(In Fig
3.1, UNIT 3)

[Action 3

Replace the servo amplifier that is the farthest to


the main board on which L is displayed.(In Fig
3.1, UNIT 3)

[Action 4

Replace the servo card or the auxiliary axis servo


card that is indicated by the alarm.

Alarm U means FSSB communication error of COP10B side.


Alarm L means FSSB communication error of COP10A side.
Note: When the robot controller is turn on, U blinks momentarily,
and then - steadily lights. This is normal.

Fig. 3.1 LED indication U,L

16

4. Replacing Unit
4.1 Replacing the servo amplifier
(a) Detach the cable from the servo amplifier
(b) Remove retaining screws and replace the servo amplifier
(c) Reconnect the cables.

Fig. 4.1.1 Replacing the servo amplifier of B-cabinet

17

Fig.4.1.2 Replace the servo amplifier of Auxiliary axis cabinet

18

4.2 Replacing the fuse of the servo amplifier


There is one fuse on the servo amplifier printed-circuit board.
Fuse specification
FU1: A60L-0001-0290/LM32C

Fig. 4.2 Replacing the fuse of the servo amplifier

Caution:

In case this fuse is blown, replace the amplifier because it is likely that
this servo amplifier has some defect.

19

4.3 Replacing the fuse on the brake unit


There is one fuse to protect brake circuit on the brake unit.
Fuse specification
FUSE1: A60L-0001-0101/P420H

FUSE1

Fig. 4.3.1 Replacing the fuse on the brake unit

This fuse has a window to indicate whether the fuse is blown or not. When the fuse is
blown, a white metal piece appears on the window.

2 A

Alarm Window
Normal: semitransparent
Fuse blown: a white metal piece appears

250V

Fig. 4.3.2 Alarm window of the brake fuse.


Caution:

If this fuse is blown, brake circuit (brake cable for example) may have
some defect. So, replace the fuse after repairing the failure.

20

4.4 Replacing the internal fan motor of the servo amplifier


(a) Holding the two lugs on the fan unit, lift the fan unit in the direction of the
arrow (toward the right in the figure). When replacing the fan motor, pay
attention to its orientation and the orientation of the connector.

Fig.4.4. Replace the internal fan motor of the servo amplifier

21

4.5 Replacing the external fan of the servo amplifier


(a) Remove the fan motor mounting screws (two for one fan motor and four for two
fan motors.
(b) Remove the connector mounting screws (two)

Fig.4.5 Replacing the external fan of the servo amplifier

22

4.6 Replacing the battery


(a) Remove the top panel.
(b) Do not make a mistake on polarity when replace the battery.
(c) Close the battery unit panel
(Note 1) Before you replace the batteries, turn on the controller power and press an
emergency stop switch. If you replace the batteries with controller power off,
the current motor position will be lost.
(Note 2) Change batteries (Size D battery 4) every 18 months.
(Note 3) The auxiliary axis battery box location shown might be different depending
upon your application.

.
Figure 4.6.1 Replacing the battery of B-cabinet

23

Fig.4.6.2 Replacing the battery of Aux. Axis cabinet

24

5. Connection Cable.
5.1 For B-Cabinet

25

26

27

5.2 For A-Cabinet

28

29

(Note) Battery at the mechanical unit is used in case ARP/ARM cable is used.

6. Total connection diagram


6.1 Total connection diagram of B-cabinet (without Brake Unit)

30

(Note)

31

(Note) Battery at the mechanical unit is used in case ARP/ARM cable is used.

6.2 Total connection diagram of B-cabinet


(with Brake Unit (A05B-2485-J400/A05B-2452-C260))

(Note)

32

(Note) Battery at the mechanical unit is used in case ARP/ARM cable is used.

6.3 Total connection diagram of B-cabinet


(with Brake Unit (A05B-2485-J401/A05B-2452-C261))

(Note)

33

(Note) Battery at the mechanical unit is used in case ARP/ARM cable is used.

6.4 Total connection diagram of B-cabinet


(with Brake Unit (A05B-2485-J402/A05B-2452-C262))

(Note)

6.5 Total connection diagram of A-cabinet

34
(Note)

(Note) Battery at the mechanical unit is used in case ARP/ARM cable is used.

6.6 Total connection diagram of Brake UnitA05B-2485-J400/A05B-2452-C260

35

6.7 Total connection diagram of Brake UnitA05B-2485-J401/A05B-2452-C261

36

6.8 Total connection diagram of Brake UnitA05B-2485-J402/A05B-2452-C262

37

7.Setting the brake number of the auxiliary axis.


The auxiliary axis brake has a number that is set by the software as follows.
Brake Number
1
2
3
4

Connector
Note
CRR65A/CRR65B on the 6-axis servo
Same brake timing as the robot.
amplifier
Use this group for the axis with
CRR65C on the brake unit. (2 circuits)
gun-change function.
CRR65D on the brake unit. (2 circuits)
Reserve

Table 7. Setting the brake number of the auxiliary axis.

38

Chapter 2

R-J3iB/B-cabinet Auxiliary Axis Option


with alpha Motor/Amplifier
Maintenance Manual
1. Application
This manual is supplement for Auxiliary Axis Option of R-J3iB/B-cabinet. Refer
to the R-J3iB maintenance manual (B-81465 or B-81505) for general maintenance
description.
2. Assembly
2.1 B-cabinet

Fig.2.1 B-cabinet

41

2.2 Brake Unit

Fig.2.2 Brake Unit (for the gun change system)

42

BRAKE UNIT
FOR THE GUN CHANGE SYSTEM
(A05B-2452-C250)

Fig.2.3 Brake Unit

43

BRAKE UNIT
(A05B-2452-C251)

3. Troubleshooting
3.1 Troubleshooting using error code
SRVO-21 SVAL1 SRDY Off (Group:i Axis:j)
[Explanation]

[Action 1]
[Action 2]

[Action 3]
[Action 4]
[Action 5]
[Action 6]
[Action 7]
[Action 8]
[Action 9]

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 an 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 for an unknown reason.
Make sure the all cable connections to the all servo amplifier are connected tightly.
Especially check the optical fiber cables. And make sure that the CP2, CRM73,
CNMC2 and CNMC3 of the E-stop unit are connected tightly.
Check whether an outage has occurred on an emergency stop line (teach pendant
emergency stop, teach pendant enable/disable switch, external emergency stop input,
fence input, servo off input, or door switch). This alarm occurs if the alarm cause
cannot be detected by the software because of a short break and magnetic contactor
off.
Check the RP1 cable of robot connection cable and the pulse coder cable for the
auxiliary axis (+5V ground fault).
Replace the servo amplifier indicated in the alarm massage.
Replace the E-stop unit.
Replace the cable between the E-stop unit and the panel board.
Replace the cable between the E-stop unit and the servo amplifier.
Replace the axis control card on the main board or the auxiliary axis board in the
backplane indicated in the alarm message.
Replace the brake unit.

SRVO-22 SVAL1 SRDY On (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

When the HRDY is about go on, the SRDY is already on.


Replace the servo card indicated in the alarm message.
Replace the servo amplifier that indicated in the alarm massage.

44

SRVO-23 SVAL1 Stop error excess (Group:i Axis:j)


[Explanation]
[Action 1]

[Action 2]
[Action 3]

[Action 4]

[Action 5]
[Action 6]
[Action 7]
[Action 8]
[Action 9]

When the servo is stopped, the position error is abnormally large.


Check whether the motor brake has been released. If the motor brake of the auxiliary
axis is not released,
Check the continuity of the brake power cable and brake coil.

Check if there is no short circuit or grounding fault on the brake power cable.

Check if FUSE1 on the brake unit is not brown. ( If it was brown, brake cable

may be faulty)
Make sure that the servo amplifier CNJ1A to CNJ6 are connected tightly.
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.
Check each phase voltage of the CRR38A or CRR38B connector of the three-phase
power (200VAC) 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.)
If the line voltage is 170VAC or higher, replace the servo amplifier that indicated by
the alarm message.
Check the disconnection of motor power cable (RM1, RM2 or power cable of auxiliary
axis cable).
Replace the brake unit.
Replace the servo amplifier indicated in the alarm massage.
Replace the motor.

SRVO-24 SVAL1 Move error excess (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

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.
Check the robot for blind axis.
Take the same actions as SRVO-23 alarm.

SRVO-36 SVAL1 Inpos time over (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

The robot did not get to the effective area ($PARAM_GROUP_$INPOS TIME) even
after the position check monitoring time ($PARAM_GROUP.$STOPTOL) elapsed.
Check the robot for blind axis.
Take the same actions as for SRVO-23 (large position error at a stop) .

45

SRVO-38 SVAL2 Pulse count mismatch (Group:i Axis:j)


[Explanation]
[Action]

The pulse count obtained when power is turned off does not match the count obtained
when the power is applied. This alarm is asserted after exchange the pulsecoder or
battery for back up of the pulsecoder data or loading back up data to the Main Board.
Perform APC reset and remaster robot (RES-PCA)
1. Press MENUS
2. Select SYSTEM
3. Press F1 [TYPE]
4. Select MASTER/CAL
5. Press F3, PES-PCA
6. Press RESET
The fault condition should reset. If the controller is still faulted with additional servorelated errors , cold start the controller . It might be necessary to remaster the robot.

SRVO-42 SVAL1 MCAL alarm (Group:i Axis:j)


[Explanation]

[Action 1]

[Action 2]
[Action 3]

This alarm means that the contacts of the magnetic contactor have stuck each other.
The alarm condition occurs if the magnetic contactor turns out to be already on when
an attempt is made to turn it on. The alarm condition is detected between the time
contact sticking occurs and the time attempt is made to turn on the magnetic
contactor.
Check the magnetic contactor , and replace it if necessary . If the contacts of magnetic
contactor have stuck to each other, turn off the circuit breaker. If the power switched
off without turning off the circuit breaker, the servo amplifier may get damaged,
because the stuck contacts keep three-phase 200VAC applied to the servo amplifier.
Replace the E-stop unit.
Replace the servo amplifier indicated in the alarm message.

46

SRVO-43 SVAL1 DCAL alarm (Group:i Axis:j)


[Explanation]

[Action 1]

[Action 2]
[Action 3]
[Action 4]

[Action 5]

[Action 6]

The regenerative discharge energy was too high to be dissipated as heat.


(To run the robot, the servo amplifier supplies energy to the robot . When going down
the vertical axis, the robot operates from the potential energy. If a reduction in the
potential energy is higher than the energy needed for acceleration, the servo amplifier
receives energy from the motor. A similar phenomenon occurs even when no gravity is
applied, for example, at deceleration on a horizontal axis. The energy that the servo
amplifier receives from the motor is called the regenerative energy. The servo
amplifier dissipates this energy as heat. If the regenerative energy is higher than the
energy dissipated as heat, the difference is stored in the servo amplifier, causing an
alarm.) "8" is display on the servo segment LED of the servo amplifier.
Check the magnetic contactor , and replace it if necessary . If the contacts of magnetic
contactor have stuck to each other, turn off the circuit breaker. If the power switched
off without turning off the circuit breaker, the servo amplifier may get damaged,
because the stuck contacts keep three-phase 200V applied to the servo amplifier.
Check FS3 in the servo amplifier. If it has brown, remove the cause, and replace the
fuse. One of the probable causes of a blown fuse is a ground fault in the servo
amplifier for auxiliary axis.
Check the fan unit under the 6-ch servo amplifier, and replace it if necessary.
Make sure that the servo amplifier CRR63A, CRR63B and CRR63C are connected
tightly, then detach the cable from CRR63A, CRR63B and CRR63C connector on the
emergency stop board, and check for continuity between pins 1 and 2 of cable-end
connector. If there is no continuity between the pins, replace the regenerative resistor.
Make sure that the 6-ch servo amplifier CRR45A, CRR45B and CRR45C are
connected tightly then detach the cables from CRR45A, CRR45B and CRR45C on the
servo amplifier, and the check the resistance between pins 1 and 2 of each cable-end
connector. If the resistance is not 9-16, replace the regenerative resistor.
Replace the servo amplifier indicated in the alarm message.

47

SRVO-44 SVAL1 HVAL alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

[Action 3]

The DC voltage (DC link voltage) of main circuit power supply is abnormally high.
Check the three-phase input voltage at the servo amplifier. If it is 253 VAC or higher,
check the line voltage. (If the three-phase input voltage is higher than 253 VAC , high
acceleration/deceleration can result in this alarm.)
Check that the load weight is within the rating. If it is higher than the rating, reduce
it to within the rating. (If the machine load is higher than the rating, the
accumulation of regenerative energy might result in the HVAL alarm even when the
three-phase input voltage is within the rating.)
Replace the servo amplifier indicated by the alarm message.

SRVO-45 SVAL1 HCAL alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

[Action 3]

Abnormally high current flowed in the main circuit of the servo amplifier.
Disconnect the robot connection cable (RM1, RM2) and power cable of auxiliary axis
motor cable from servo amplifier. Supply power and see if the alarm occurs again. If
alarm occurs , replace the servo amplifier indicated by the alarm message.
Disconnect the robot connection cable (motor power) from the servo amplifier
connector (CNJ**) and power cable of auxiliary axis cable, and check insulation of
their U, V or W and the GND line. If there is a short-circuit, the motor, robot
connection cable, intra-robot cable or power cable of auxiliary axis cable is defective.
Check them and replace them if necessary.
Disconnect the robot connection cable (motor power) from the servo amplifier
connector (CNJ**) and power cable of auxiliary axis cable, and measure the resistance
between their U and V, V and W, and W and U with a ohmmeter with a very low
resistance range. If the resistances at the three places are different from each other,
the motor , robot connection cable, intra-robot cable or power cable of auxiliary axis
cable is defective. Check each item in detail and replace it if necessary.

SRVO-46 SVAL1 OVC alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]
[Action 3]

[Action 4]
[Action 5]
[Action 6]

This alarm is issued to prevent the motor from thermal damage that might occur
when the root mean square current calculated within the servo system is out of the
allowable range.
Check the operating conditions for the robot and relax the service conditions.
Check each phase voltage of the three-phase input power (200VAC for the servo
amplifier. If it is 170VAC or lower, check the line voltage.
Check whether the motor brake has been released. If the motor brake of the auxiliary
axis is not released,
Check the continuity of the brake power cable and brake coil.

Check if there is no short circuit or grounding fault on the brake power cable.

Check if FUSE1 on the brake unit is not brown. ( If it was brown, brake cable

may be faulty)
Replace the servo amplifier indicated in the alarm message.
Check the robot connection cable (RM1, RM2) and power cable of auxiliary axis cable.
If any problems are found in the cables, replace the cables.
Replace the motor.

48

SRVO-47 SVAL1 LVAL alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

The control power supply voltage (+5V, etc) supplied from the power supply circuit in
the servo amplifier is abnormally low.
Replace the servo amplifier indicated in the alarm message.
Replace the power supply unit.

SRVO-49 SVAL1 OHAL1 alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]
[Action 3]
[Action 4]
[Action 5]
[Action 6]
[Action 7]

The thermostat in the transformer worked. Alternatively, fuse F1 or F2 in the servo


amplifier has blown.
Make sure that the CRM73 connector of the E-stop unit is connected tightly.
Check the operating conditions for the robot and relax the service conditions.
If fuses F1 and F2 have blown, replace the servo amplifier.
If the fan motor in the cabinet is not running, check it and its cables. Replace it if
necessary.
Check the fan motor of the auxiliary axis servo amplifier. Replace it if necessary.
Replace the auxiliary axis servo amplifier.
Replace the transformer.

SRVO-50 SVAL1 CLALM alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]
[Action 3]

[Action 4]

[Action 5]
[Action 6]
[Action 7].

The disturbance torque estimated by the servo software is abnormally high. (A


collision has been detected.)
Check that the robot has collided with anything. If it has, reset the robot and jog-feed
it to recover from the collision
Make sure that the load setting is correct.
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.)
Check whether the motor brake has been released. If the motor brake of the auxiliary
axis is not released,
Check the continuity of the brake power cable and brake coil.

Check if there is no short circuit or grounding fault on the brake power cable.

Check if FUSE1 on the brake unit is not brown. ( If it was brown, brake cable

may be faulty)
Check the phase voltage of the three-phase input power (200VAC) to the servo
amplifier. If it is 170 VAC or lower, check the line voltage.
Replace the servo amplifier
Replace the motor.

SRVO-51 SVAL2 CUER alarm (Group:i Axis:j)


[Explanation]
[Action 1]

The offset of the current feedback value is abnormally high.


Replace the servo amplifier indicated in the alarm message.

49

SRVO-55 SVAL2 FSSB com error 1 (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]
[Action 3]

A communication error has occurred between the main board and servo amplifier
(from main board to servo amplifier).
Check the communication cable (optical fiber) between the main board and the servo
amplifier. Replace it if it is faulty.
Replace the axis control card on the main board or the auxiliary axis board in the
backplane indicated in the alarm message.
Replace the servo amplifier indicated in the alarm message.
Before continuing the next step, perform a complete controller back up to save all
your programs and settings. Failure to perform this could result in damage to
equipment or lost data.

[Action 4]

Replace the main board.

SRVO-56 SVAL2 FSSB com error 2 (Group:i Axis:j)


[Explanation]
[Action ]

A communication error has occurred between the main board and servo amplifier
(From servo amplifier to main board).
Take the same actions as SRVO-55 alarm.

SRVO-57 SVAL2 FSSB disconnect (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]
[Action 3]
[Action 4]
[Action 5]

Communication was interrupted between the main board and servo amplifier.
Check whether fuse F3 in the power supply unit has blown.
Check whether fuse FS1 in the servo amplifier has blown.
Check the communication cable (optical fiber) between the main board and the servo
amplifier. Replace it if it is faulty.
Replace the axis control card on the main board or the auxiliary axis board in the
backplane indicated in the alarm message.
Replace the servo amplifier indicated by the alarm message.
Before continuing the next step, perform a complete controller back up to save all
your programs and settings. Failure to perform this could result in damage to
equipment or lost data.

[Action 6]
[Action 7]

Replace the main board.


Check the RP1 cable of robot connection cable and the pulse coder cable for the
auxiliary axis (+5V ground fault).

50

SRVO-58 SVAL2 FSSB init error (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]
[Action 3]
[Action 4]
[Action 5]
[Action 6]

Communication was interrupted between the main board and servo amplifier.
Check whether fuse F3 in the power supply and fuse FS1 in the servo amplifier has
blown, see Section 3.6 ,Troubleshooting for Blown fuse of the R-J3iB control unit
maintenance manual.
Check whether LEDs (P5V and P3.3V) on the servo amplifier are on. If they are on,
perform Action 4 and all actions that follow it. If they are not on , perform Action 3
and all actions that follow it.
Check whether connectors CP6 and CRM67 on the emergency stop unit are securely
connected to connector CP6 on the power supply unit and connector CRM67 on the
servo amplifier, respectively.
Check the communication cable (optical fiber) between the main board and the servo
amplifier. Replace it if it is faulty.
Replace the axis control card on the main board or the auxiliary axis board in the
backplane indicated in the alarm message.
Replace the servo amplifier indicated by the alarm message.
Before continuing the next step, perform a complete controller back up to save all
your programs and settings. Failure to perform this could result in damage to
equipment or lost data.

[Action 7]

Replace the main board.

SRVO-061 SVAL2 OKAL alarm (Group:i Axis:j)


SRVO-062 SVAL2 BZAL alarm (Group:i Axis:j)
SRVO-063 SVAL2 RCAL alarm (Group:i Axis:j)
SRVO-064 SVAL2 PAHL alarm (Group:i Axis:j)
SRVO-065 WARN BLAL alarm (Group:i Axis:j)
SRVO-066 SVAL2 CSAL alarm (Group:i Axis:j)
SRVO-067 SVAL2 OHAL2 alarm (Group:i Axis:j)
SRVO-068 SVAL2 DTERR alarm (Group:i Axis:j)
SRVO-069 SVAL2 CRCERR alarm (Group:i Axis:j)
SRVO-070 SVAL2 STBERR alarm (Group:i Axis:j)
SRVO-071 SVAL2 SPHAL alarm (Group:i Axis:j)
SRVO-072 SVAL2 PMAL alarm (Group:i Axis:j)
SRVO-073 SVAL2 CMAL alarm (Group:i Axis:j)
SRVO-074 SVAL2 LDAL alarm (Group:i Axis:j)
Refer to the R-J3iB controller maintenance manual.

51

SRVO-135 SVAL2 FSAL alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

Faulty of the internal fan motor of the auxiliary axis servo amplifier.
Replace the internal fan motor of the auxiliary servo amplifier indicated by the alarm
message.
Replace the auxiliary servo amplifier indicated by the alarm message.

SRVO-136 SVAL1 DCLVAL alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]
[Action 1]
[Action 2]
[Action 3]
[Action 4]

The servo the DC current of amplifier (DC link voltage) of the main power supply is
abnormally low.
-This alarm occurred in the robot operation:
Check the phase voltage of the three-phase input power (200VAC) to the servo
amplifier. If it is 170 VAC or lower, check the line voltage.
Replace the servo amplifier.
-This alarm occurs before the magnetic contactor is turn on:
Check whether the circuit breaker in the emergency stop unit is OFF. If it is OFF,
check the servo amplifier and the wiring between the servo amplifier and the
emergency stop unit. If anything is abnormal, replace it.
Check each phase-to-phase voltage of the three-phase input (200 VAC) on the primary
side of the magnetic contactor. If the input is not higher than 170VAC, check the
input power supply voltage.
Replace the E-stop unit.
Replace the servo amplifier indicated by the alarm message.

SRVO-156 SVAL1 IPMAL alarm (Group:i Axis:j)


[Explanation]
[Action 1]

[Action 2]

[Action 3]

Abnormally high current flowed through the main circuit of the servo amplifier.
Disconnect the robot connection cable (RM1, RM2) and power cable of auxiliary axis
motor cable from servo amplifier. Switch on the power, and then check to see if the
alarm occurs again. If alarm occurs, replace the servo amplifier indicated in the alarm
message.
Disconnect the robot connection cable (motor power) from the servo amplifier
connector (CNJ**) and power cable of auxiliary axis cable, and check for insulation
between each motor power line (U, V, or W) and ground potential (GND). If there is a
short-circuit, the motor , robot connection cable, intra-robot cable or power cable of
auxiliary axis cable is defective. Check them and replace them if necessary.
Disconnect the robot connection cable (motor power) from the servo amplifier
connector (CNJ**) and power cable of auxiliary axis cable, and measure the resistance
between their U and V, V and W and W and V with an ohmmeter with a very low
resistance range. If these resistances are different from each other, the motor, robot
connection cable, intra-robot cable or power cable of auxiliary axis cable is defective.
Check each item in detail and replace it if necessary.

52

SRVO-290 DC LINK HC alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]

[Action 3]

DC link current of the servo amplifier is abnormal


Disconnect the robot connection cable (RM1, RM2) and power cable of auxiliary axis
motor cable from servo amplifier. Supply power and see if the alarm occurs again. If
alarm occurs , replace the servo amplifier indicated by the alarm message.
Disconnect the robot connection cable (motor power) from the servo amplifier
connector (CNJ**) and power cable of auxiliary axis cable, and check insulation of
their U, V or W and the GND line. If there is a short-circuit, the motor, robot
connection cable, intra-robot cable or power cable of auxiliary axis cable is defective.
Check them and replace them if necessary.
Disconnect the robot connection cable (motor power) from the servo amplifier
connector (CNJ**) and power cable of auxiliary axis cable, and measure the resistance
between their U and V, V and W and W and V with an ohmmeter with a very low
resistance range. If these resistances are different from each other, the motor, robot
connection cable, intra-robot cable or power cable of auxiliary axis cable is defective.
Check each item in detail and replace it if necessary.
Before continuing the next step, perform a complete controller back up to save all
your programs and settings. Failure to perform this could result in damage to
equipment or lost data.

[Action 4]

Replace the main board.

SRVO-291 SVAL1 IMP over heat alarm (Group:i Axis:j)


[Explanation]
[Action 1]
[Action 2]
[Action 3]

The IPM in the servo amplifier overheats


Check whether the amplifier fan stops.
Reduce the override because the use condition is too hard.
If this alarm is frequency issued, replace the servo amplifier.

SRVO-292 SVAL1 EXT fan alarm (Group:i Axis:j)


[Explanation]
[Action 1]

The external fan of the auxiliary axis servo amplifier is faulty.


Replace the external fan of the auxiliary axis servo amplifier.

53

3.2 Troubleshooting based on LED indication.

segment LED

LED indication

Description
[Explanation]

Internal cooling fan is stopped.

[Action 1

Check whether there is any foreign material in


the fan

[Action 2]

Check that the fan connector is attached


correctly.

[Action 3]

Replace the fan.

[Action 4]

Replace the servo amplifier.

[Explanation]

Control power supply undervoltage

[Action 1

Check the three-phase input voltage of the


amplifier (the voltage shall not be lower than
85% of the rated input voltage)

[Action 2]

Check the 24V power supply voltage output


from the 6-ch servo amplifier (The voltage shall
normally not lower than 22.8V).

[Action 3]

Check the connector and cable (CXA2A/B).

[Action 4]

Replace the servo amplifier.

[Explanation]

DC link undervoltage

[Action 1]

Check that the screws for the DC link


connection cable (bar) are tight.

[Action 2]

If DC link low voltage alarm occurs in both 6-ch


servo amplifier and the auxiliary axis servo
amplifier, replace the 6-ch servo amplifier.

[Action 3]

If DC link low voltage alarm occurs in only one


servo amplifier, replace that servo amplifier.

54

LED indication

Description

[Explanation]

Abnormal Current Alarms

[Action 1]

Remove the power line wires form terminals,


and release an emergency stop state.
<1> If an abnormal current alarm is issued, the
servo amplifier needs to be replaced.
<2> If not, go to [Action 2].

[Action 2]

Check for the insulation between PE and each of


the removed power wires U, V and W. If the
insulation is not perfect, disconnect the power
wires from the motor connector. Then check for
insulation between PE and each of the U, V and
W terminals on the motor.
<1> If there is a short-circuit between PE and
U, V and W of the motor, replace the motor.
<2> If the insulation of the motor is perfect,
replace the power wires.

55

LED indication

Description
[Explanation]

IPM Alarms
(Note that these codes
simultaneously with a period)

[Action 1]

are

displayed

Wait for about 10 minutes. Then release the


emergency stop state. If IPM alarm still occurs,
go to [Action 2]
If the cause is IPM overheat, the IPM alarm will
not recur. IPM overheat can occur if the ambient
temperature is high or the motor is overloaded.
Check the operating condition.

[Action 2]

Remove the power wires from the amplifier


terminals, and release an emergency stop state.
If the IPM alarm does not recur, go to [Action 3].
If the IPM alarm recurs, the probable cause is
the operation of the IPM protective function (for
overcurrent or power failure). Replace the
amplifier, and if the IPM alarm does not recur,
go to [Action 3].

[Action 3]

Check for the insulation between PE and each of


the removed power wires U, V and W. If the
insulation is not perfect, disconnect the power
wires from the motor connector. Then check for
insulation between PE and each of the U, V and
W terminals on the motor.
<1> If there is a short-circuit between PE and
U, V and W of the motor, replace the motor.
<2> If the insulation of the motor is perfect,
replace the power wires.

56

4. Replacing Unit
4.1 Replacing the servo amplifier
(d) Detach the cable from the servo amplifier
(e) Remove retaining screws and replace the servo amplifier
(f) Reconnect the cables.

Fig. 4.1. Replacing the servo amplifier

57

4.2 Replacing the fuse on the servo amplifier


There is one fuse for the 24V control power on the servo amplifier printed-circuit
board.
Fuse specification
FU1: A60L-0001-0290/LM32C

Fig. 4.2 Replacing the fuse on the servo amplifier

58

4.3 Replacing the fuse on the brake unit


There is one fuse to protect brake circuit on the brake unit.
Fuse specification
FUSE1: A60L-0001-0101/P420H
FUSE1

Fig. 4.3 Replacing the fuse on the brake unit


This fuse has a window to indicate whether the fuse is blown or not. When the fuse is
blown, a white metal piece appears on the window.

2 A

250V

Alarm Window
Normal: semitransparent
Fuse blown:
a white metal piece appears

Fig. 4.4 Alarm window of the brake fuse

59

4.4 Replacing the battery


1. Remove the top panel.
2. Do not make a mistake on the polarity when replace the battery.
3. Close the battery unit panel
(Note 1) When replacing the battery, turning on the control unit and the emergency
switch. If replacing the battery in turning off the power , the current
positions of the motors are lost.
(Note 2) Change to new battery annually.

Fig 4.5 Replace the battery.

60

5. Connection Cable

61

6. Total Circuit

62

In case of A05B-2487-J402

63

In case of A05B-2487-J400

64

In case of A05B-2487-J401

Chapter 3

Chapter 3
The Local Stop Option

Contents

Chapter 3
3.1
3.2
3.3
3.4
3.5

............................................................................
Local Stop Option Overview ......................................................................
Local Stop Kit Assemblies .........................................................................
Connection and Cabinet Mounting Diagrams ............................................
Arc Welding Application Connection Drawings .........................................
Parts List ...................................................................................................
The Local Stop Option

3 1
3 2
3 5
3 8
314
321

31

3. The Local Stop Option


This chapter provides hardware information on the optional FANUC Robotics Local Stop Printed
Circuit Board (PCB). Images of the Local Stop PCB and circuit diagrams are provided.
For information on how to set up your Local Stop hardware refer to the Setting Up Local Stop
Software Procedure in the FANUC Robotics SYSTEM R-J3iB Controller Software Installation Manual.

3.1 Local Stop Option Overview


The Local Stop Option allows you to stop an auxiliary axis without shutting down the controller. This
function can be performed while maintaining compliance to the ANSI/RIA R15.06 1999 standard.
See Figure 31.
Figure 31. Local Stop Printed Circuit Board

Figure 32. illustrates an Arc Welding System with one robot and two headstock positioners. Each
positioner uses a single auxiliary axis motor and is controlled by separate motion groups. In this

32

3. The Local Stop Option


application, an operator is loading or unloading a part on one headstock positioner while the robot
and other positioner continue to run. The Local Stop Unit protects the operator by disconnecting the
motor power from the desired headstock positioner and preventing accidental movement. By using
the Local Stop Unit to only deactivate the required motion group, the robot and the other auxiliary
axis can continue to run production. This facilitates the safe loading and unloading of parts in your
robotic system.
The Light Curtain on the load/unload side of the positioner is bypassed when the Local Stop Unit is
activated. This allows the operator to enter the work cell and manipulate the work piece. All other
safety signals are active and independent of the Local Stop Unit.
Each auxiliary axis motion group is required to have a Local Stop Unit if an operator will be
interacting with that motion group during production. A Local Stop Unit can only control one motion
group, but that motion group can control up to two axis. Up to three auxiliary axis motion groups can
be added to a robot system. If an auxiliary axis motor is in a system and has no interaction with an
operator during production, it might not require a Local Stop Unit.
Examples of this type of system include:

Robot rails or booms that use zone switches in conjunction with light curtains
Headstock positioners that are robotically loaded or unloaded and only require operator interaction
during maintenance when the entire system can be locked out

33

3. The Local Stop Option


Figure 32. Typical Arc Welding Robotic System

34

3. The Local Stop Option

3.2 Local Stop Kit Assemblies


There are four Local Stop Kits that can be combined for different applications. The type of kit
required is based upon how many auxiliary amplifiers your system is using, the number of axes
(channels) you plan to drive in each motion group, the number of motion groups in the robot system
and the type of connector (XX or XY) you require. The XX connector is for channel one on a single
or dual channel amplifier and the XY connector is for channel two of a dual channel amplifier.
Refer to Table 31 for more information and Figure 33 for an illustration. Figure 34 contains a
generic connection block diagram of the Local Stop PCB.
Table 31. Local Stop Kits
Part Number

For Configuration Type

EE-4707020

(1) Auxiliary Amplifier, (1) Channel and (1) XX Connection

EE-4707021

(2) Auxiliary Amplifier, (1) Channel each and (2) XX Connections

EE-4707022

(1) Auxiliary Amplifier, (2) Channels and (1) XX and (1) XY Connection

EE-4707023

(1) Auxiliary Amplifier, (2) Channels and (1) XY Connection

35

TB5

1730421

7117271

FRONT

LC1D2501
CONTACTOR
W/LA1DN04
AUX. CONTACT

FRONT

REV:

Made In USA
EE-3285-800-158

TB4

1-178136-2

CN4
AMP 3-POS
X-KEY

TB3

OMRON

1730421

EE-4707-006
XXXXXXXX XXXXX

R-J3iB LOCAL STOP UNIT #


1 AMP/2nd CHNL XY OPTION
ASSY NO:
SERIAL NO:

F
3900 W. Hamlin Rd. Rochester Hills, MI 48309

SIDE VIEW

G7SA-2A2B
G7SA-3A1B

1
1

OMRON

CN3

AMP

1-178313-2
X-KEY

TB2

-178136-2

X-KEY
CN5
AMP 3-POS

G7SA-2A2B
G7SA-3A1B

2-178136-2

CN2
AMP 3-POS
Y-KEY

1727094 - 10 POS.

OMRON

2-178136-2

CN1
AMP 3-POS
Y-KEY

TB1

1727117 - 12 POS.

MADE IN USA

R-J3iB LOCAL STOP UNIT


1 AMP-2nd CHNL XY OPTION
DIN RAIL SUB-ASSY
1
1727117 - 12 POS.

36

G7SA-2A2B
G7SA-3A1B

3. The Local Stop Option

Figure 33. Local Stop PCB Illustration

EE-4707-006

AMP

3. The Local Stop Option


Figure 34. Local Stop PCB Connection Block Diagram

Local Stop PCB Connection Block Diagram


(Refer to the Connection Diagrams portion of the manual for detailed drawings)

100VAC Transformer

R-J3iB Local Stop PCB


E-Stop PCB
TB8

CP2

CN1

CN4
Brake

200VAC
(200VAC for additional
Local Stop PCBs)

CP5A

(Brakes for
additional motors)

CN2

CN5

CN3
100VAC
(Aux. Contact Required)

TB3

MCC
(Daisy Chain
for additional
Local Stop PCBs)

Operator Panel PCB


TBOB4

TB1

TB1

(External E-Stop
Customer Inputs)
(Local Stop
Customer Inputs)

6 Channel Servo Amplifier


CRM39

TB2

TB7

(To additional
Local Stop PCBs)

CRF7

Contactor
KA4

SVMi Amplifier
DC Link

CXA2A

CXA2B

XX

XX

Power

JF1
Encoder
Motor

37

3. The Local Stop Option

3.3 Connection and Cabinet Mounting Diagrams


This section provides standard configuration illustrations of the Local Stop Option.

38

EE-4707-016-001

EE-4707-017-001

CP2

EE-4707-020

RJ3iB LOCAL STOP PBD

CN1

XX UNIT
PC BOARD ROADMAP
FOR SINGLE MOTOR DRIVE

KA1

200VAC IN

KA1

CN1
CP5A

EE-4707-012-001
CN2

TO MOTOR
BRAKE CONN

CN4

BRK+

TB8

XFMR

KA2
~ +

IN 100B

~ -

MCC

EES1

BEES1

EES11

BEES11

EES2

EES2

BEES2

EES21

EES21

BEES21

LS1

LS11

10

CRM39

EE-4707-013-001

EE-4707-009-001

SAFE TO ENTER

11
12

EES OUT TB

}
}

EXTERNAL E-STOP*
CUSTOMER INPUTS

*-JUMPER WHEN
NOT IN USE
LOCAL STOP*
CUSTOMER
INPUTS

24V

A3

B1

6
7
4

LS2
LS21

KA3

2
3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

A2

0V

TB2

A1

*BRKRLS3

TB1

6 CHANNEL AMP

*BRKRLS2

TB1

EES1
EES11

EE-4707-010-001

*BRKRLS1

24V

DAISY CHAIN TO TB3 PIN 2 OF


ALL SUBSEQUENT LOCAL STOP PCB UNITS
(PART OF EE-4707-012-001)

10

24V

0V

BRK-

DI

DI

D4

9
TBOP4

BRK+

TB3

PANEL BD

CN5

KA3

EE-4707-014-001

AUX. CONTACT REQUIRED

100VAC

DB3

IN 100A

CN3

5
6

200VAC

FU1
2A

CN3

A80L-0010-0071
1/CONTROLLER

BRK-

CN2
EE-4707-008-001

24V
KA1
24V

1
8
TB7
D6 R6

0V

0V

*BRKRLS1

D2

KA2

BRK REL

0V

KA1

LOCAL STOP PCB #2


LOCAL STOP PCB #3

CRF7

LOCAL STOP REQUEST

23

MOTOR(S) DISCONNECTED

40

MOTOR ON COMMAND

10

LOCAL STOP REQUEST

11

26
RDI8
25

D5 R5
D1

MOTOR(S) DISCONNECTED
EE-4707-011-001

LOCAL STOP PCB #2

12

KA1

MTR ON

MOTOR DISCONNECTED

KA2
DB1

SVMi AMPLIFIER
EE-4707-015-001

HV

CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

D3

KA3

0V

MOV1

R1

R8

R2

C1

TB3

TB3

1
2
3
4
5

RDI5

D7 R7

RDI6

CXA2A
24V A1,B1
0V A2,B2
*ESP
A4

LOCAL STOP PCB #3

RDO8

DC LINK

}
}

MOTOR ON COMMAND

24

RDO7

RDI7

6
7
8

39

1
3

MOTOR(S) DISCONNECTED

1
2
3
4
5

21
RDI3

LOCAL STOP REQUEST

3
4
5

RDI4

MOTOR ON COMMAND

10

22

38
RDO6

Figure 35. Single Motor and Amplifier XX Connector

ESTOP PC BD

TB4

TB3

TB5

XX

KA4

# - LOCAL STOP XX UNIT


STANDARD WIRING SET KIT
EE-4707-020

JF1

EE-4707-006-001

62

61

72

71

82

81

1
3
5
A1

2
4
6
A2

- CONTROLLER HOOKUP KIT


1/CONTROLLER
EE-4707-030
- USED WITH MULTIPLE LOCAL
STOPS IN 1 CONTROLLER

XX
MOTOR 1
MTR
ENC

BRK

39

3. The Local Stop Option

KEY
CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

EE-4707-017-001

RJ3iB LOCAL STOP PBD

KA1

- LOCAL STOP 2XX UNIT


STANDARD WIRING SET KIT
EE-4707-021

- CONTROLLER HOOKUP KIT


1/CONTROLLER
EE-4707-030

TB8

EE-4707-008-001

CN3

2
3
4

A80L-0010-0071
1/CONTROLLER

KA2
~ +
~ -

MCC

24V

DAISY CHAIN TO TB3 PIN 2 OF


ALL SUBSEQUENT LOCAL STOP PCB UNITS
(PART OF EE-4707-012-001)

10

TB1

TB1

EES1

EES1

BEES1

EES11

EES11

BEES11

EES2

EES2

BEES2

EES21

EES21

BEES21

EE-4707-009-001

EE-4707-010-001

6 CHANNEL AMP

CRM39

TB2

0V

EE-4707-013-001

9
10

LS2

11

LS21

12

KA3

2
3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

A2

*BRKRLS2
A3

EES OUT TB

}
}

EXTERNAL E-STOP*
CUSTOMER INPUTS

*-JUMPER WHEN
NOT IN USE
LOCAL STOP*
CUSTOMER
INPUTS

24V

4
5

*BRKRLS3
B1

24V

6
7
4

LS1
LS11

SAFE TO ENTER

A1

TO MOTOR
BRAKE CONN

BRK-

DI

0V

BRK+

D4

DI

*BRKRLS1

CN5

KA3

TB3

24V

DB3

IN 100B

TBOP4

FU1
2A

IN 100A

EE-4707-014-001

AUX. CONTACT REQUIRED

100VAC

BRK+

TO MOTOR
BRAKE CONN

BRK-

CN3

5
6

XFMR

CN4

- USED WITH MULTIPLE LOCAL


STOPS IN 1 CONTROLLER

CN2

PANEL BD

DRIVE USING 2 SINGLE AXIS AMPS

EE-4707-012-001
CN2

200VAC

R-J3iB LOCAL ESTOP 2XX UNIT


PC BOARD ROADMAP FOR DUAL MOTOR

KA1

CN1
CP5A

EE-4707-021

KEY

CN1

200VAC IN

KA1
24V

8
TB7
D6 R6

0V

0V

*BRKRLS1

D2

KA2

BRK REL

0V

KA1

LOCAL STOP PCB #2


LOCAL STOP PCB #3
CRF7
38

MOTOR ON COMMAND

22

LOCAL STOP REQUEST

21

MOTOR(S) DISCONNECTED

39

MOTOR ON COMMAND

24

LOCAL STOP REQUEST

23

MOTOR(S) DISCONNECTED

40

MOTOR ON COMMAND

10

LOCAL STOP REQUEST

11

25
RDI7

EE-4707-011-001

DC LINK

CXA2A
24V A1,B1
0V A2,B2
*ESP
A4

MOTOR(S) DISCONNECTED

D5 R5

12

D1

KA1

MTR ON

MOTOR DISCONNECTED

KA2
DB1

DB2

SVMi AMPLIFIER
EE-4707-015-001

D3

KA3

HV

CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

0V

MOV1

R1

R8

R2

R3

R4

C1

TB3

TB3

1
2
3
4
5

26
RDI8

LOCAL STOP PCB #2

6
7
8

RDI5

LOCAL STOP PCB #3

1
2
3
4
5

RDI6

RDO8

}
}

3
4
5

RDO7

9
10

RDI3

D7 R7

RDI4

RDO6

TB4

TB3

TB5

XX

KA4

KA5

JF1

SVMi AMPLIFIER

EE-4707-006-001

HV

62

61

62

72

71

72

82

81

82

81

1
3
5
A1

2
4
6
A2

1
3
5
A1

2
4
6
A2

61
71

XX
MOTOR 2
MTR

BRK

ENC

CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

XX

EE-4707-006-002

XX
MOTOR 1

CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

MTR
ENC

JF1

BRK

3. The Local Stop Option

EE-4707-016-001
CP2

Figure 36. Dual Motor and Amplifier XX Connector

310
ESTOP PC BD

EE-4707-016-001

EE-4707-017-001

CP2

EE-4707-022

RJ3iB LOCAL STOP PBD

CN1
KA1

200VAC IN

R-J3iB LOCAL ESTOP XX/XY UNIT


PC BOARD ROADMAP FOR DUAL MOTOR
DRIVE WITH DUAL AXIS AMP.

KA1

CN1
CP5A

EE-4707-012-001
CN2

TO MOTOR
BRAKE CONN

CN4

BRK+

TB8

KA2
~ +

IN 100B

~ -

CN5

KA3

BRK+

TO MOTOR
BRAKE CONN

D4

BRK-

EE-4707-014-001

AUX. CONTACT REQUIRED

100VAC

DB3

IN 100A

CN3

XFMR

FU1
2A

CN3

200VAC

BRK-

CN2

EE-4707-008-001

MCC

TB3
1

24V

2
9

PANEL BD

10

TBOP4
1

DI
2

24V

DI

0V

DAISY CHAIN TO TB3 PIN 2 OF


ALL SUBSEQUENT LOCAL STOP PCB UNITS
(PART OF EE-4707-012-001)

TB1

TB1

EES1

EES1

BEES1 5

EES11

EES11

BEES11 6

EES2

EES2

BEES2 7

EES21

EES21

BEES21 8
LS1 9

EE-4707-009-001

EE-4707-010-001

6 CHANNEL AMP

EE-4707-013-001

A1

A3

LS21 12

EXTERNAL E-STOP*
CUSTOMER INPUTS

*-JUMPER WHEN
NOT IN USE
LOCAL STOP*
CUSTOMER
INPUTS

24V

24V

B1

7
4

}
}

*BRKRLS3
0V

LS2 11

KA3

2
3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

A2

*BRKRLS2

SAFE TO ENTER

CRM39

*BRKRLS1

LS11 10

TB2

EES OUT TB

KEY

KA1
24V

1
8

- LOCAL STOP XX/XY


STANDARD WIRING SET KIT
EE-4707-023

- CONTROLLER HOOKUP KIT


1/CONTROLLER
EE-4707-030

TB7
D6 R6

0V

0V

*BRKRLS1

D2

KA2

BRK REL

0V

KA1

LOCAL STOP PCB #2

38

MOTOR ON COMMAND

22

LOCAL STOP REQUEST

21

MOTOR(S) DISCONNECTED

39

MOTOR ON COMMAND

LOCAL STOP REQUEST

MOTOR(S) DISCONNECTED

MOTOR ON COMMAND

10

LOCAL STOP REQUEST

11

12

MOTOR(S) DISCONNECTED

CXA2A
24V A1,B1
0V A2,B2
*ESP
A4

DB2

R1

R8

R2

R3

R4

TB3

TB3

TB4

TB3

C1

0V

MOV1

TB5

XX

KA4

KA5

JF1

62
72

EE-4707-006-001

61

62

61

71

72

71

82

81

82

81

1
3
5
A1

2
4
6
A2

1
3
5
A1

2
4
6
A2

XX

MOTOR 2
MTR

BRK

ENC

XY

EE-4707-007-001

XX

MOTOR 1
MTR
ENC

JF2

BRK

311

3. The Local Stop Option

CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

KA3

HV

CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

D3

EE-4707-015-001

DC LINK

KA2
DB1

SVMi AMPLIFIER

MTR ON

EE-4707-011-001

D1

MOTOR DISCONNECTED

25

D5 R5

KA1

26
RDI8

LOCAL STOP PCB #2

40

23
RDI5

LOCAL STOP PCB #3

RDI6

RDO8

}
}

10

24

RDI3

D7 R7

RDI4

RDO7

RDI7

- USED WITH MULTIPLE LOCAL


STOPS IN 1 CONTROLLER

LOCAL STOP PCB #3

CRF7

RDO6

Figure 37. Dual Motor and Single Amplifier XX and XY Connectors

ESTOP PC BD

EE-4707-017-001

EE-4707-023

RJ3iB LOCAL STOP PBD

CN1
KA1

200VAC IN

XY UNIT
PC BOARD ROADMAP
FOR SINGLE MOTOR DRIVE

KA1

CN1
CP5A

EE-4707-012-001
CN2

TO MOTOR
BRAKE CONN

CN4

BRK+

TB8

BRK-

CN2
EE-4707-008-001

FU1
2A

CN3

DB3

IN 100A

KA2
~ +

IN 100B

~ -

CN3

XFMR

BRK-

200VAC

BRK+

D4

A80L-0010-0071
1/CONTROLLER

CN5

KA3

100VAC

EE-4707-014-001

AUX. CONTACT REQUIRED

MCC

TB3
1

PANEL BD

DAISY CHAIN TO TB3 PIN 2 OF


ALL SUBSEQUENT LOCAL STOP PCB UNITS
(PART OF EE-4707-012-001)

10

TBOP4

24V

TB1

TB1

EES1

EES1

BEES1

EES11

EES11

BEES11

EES2

EES2

BEES2

EES21

EES21

BEES21

DI
24V
DI
0V

EE-4707-009-001

EE-4707-010-001

6 CHANNEL AMP

EE-4707-013-001

A1

A3

*BRKRLS3

9
10

LS2

11

LS21

12

EXTERNAL E-STOP*
CUSTOMER INPUTS

*-JUMPER WHEN
NOT IN USE
LOCAL STOP*
CUSTOMER
INPUTS

24V

24V

6
7
4

LS1
LS11

}
}

B1

0V

KA3

2
3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

A2

*BRKRLS2

SAFE TO ENTER

CRM39

*BRKRLS1

TB2

EES OUT TB

KA1
24V

8
TB7
D6 R6

0V

0V

*BRKRLS1

D2

KA2

BRK REL

0V

KA1

KEY

LOCAL STOP PCB #2


LOCAL STOP PCB #3

CRF7
38

MOTOR ON COMMAND

22

LOCAL STOP REQUEST

21

MOTOR(S) DISCONNECTED

39

MOTOR ON COMMAND

24

LOCAL STOP REQUEST

23

MOTOR(S) DISCONNECTED

40

MOTOR ON COMMAND

10

26

LOCAL STOP REQUEST

11

25

MOTOR(S) DISCONNECTED

12

CXA2A
24V A1,B1
0V A2,B2
*ESP
A4

CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

R1

R8

R2

TB3

TB3

TB4

1
TB3

C1

MOV1

0V

KA3

HV

D3

DC LINK

KA2
DB1

EE-4707-015-001

MOTOR DISCONNECTED

SVMi AMPLIFIER

EE-4707-011-001

MTR ON

RDI7

D1

TB5

XX

KA4
JF1

62
72

EE-4707-007-002

XY

61
71

82

81

1
3
5
A1

2
4
6
A2

XX
MOTOR 1
MTR
ENC

JF2

- LOCAL STOP XY UNIT


STANDARD WIRING SET KIT
EE-4707-023

- CONTROLLER HOOKUP KIT


1/CONTROLLER
EE-4707-030
- USED WITH MULTIPLE LOCAL
STOPS IN 1 CONTROLLER

D5 R5

KA1

RDI8

LOCAL STOP PCB #2

RDI5

LOCAL STOP PCB #3

RDI6

RDO8

}
}

10

RDI3

RDI4

RDO7

D7 R7

RDO6

BRK

3. The Local Stop Option

EE-4707-016-001
CP2

Figure 38. Single Motor and Amplifier XY Connector

312
ESTOP PC BD

313

3. The Local Stop Option

NOTE: THIS MAY OR MAY NOT


REFLECT YOUR CONFIGURATION

Figure 39. Controller Cabinet Hardware Mounting Diagram

EE-4707-040

3. The Local Stop Option

3.4 Arc Welding Application Connection Drawings


This section provides illustrations specific to the ARC Application.
Figure 310. Positioners

Ferris Wheel Positioner

Headstock Positioner

314

EE-4707-016-001

EE-4707-017-001

CP2

FE-4830-011

RJ3iB LOCAL STOP PBD

CN1

HEADSTOCK POSITIONER

KA1

200VAC IN

KA1

CN1
CP5A
CN2

TO MOTOR
BRAKE CONN

CN4

BRK+

BRK-

TB8

EE-4707-008-001

2
3
4

A80L-0010-0071
1/CONTROLLER

XFMR

KA2
~ +

IN 100B

~ -

MCC

EES1

BEES1

EES11

BEES11

EES2

EES2

BEES2

EES21

EES21

BEES21

LS1

LS11

10

CRM39

EE-4707-013-001

EE-4707-009-001

TB2

SAFE TO ENTER
SIGNAL OUT

A1

12

}
}

EXTERNAL E-STOP*
CUSTOMER INPUTS

*-JUMPER WHEN
NOT IN USE
LOCAL STOP*
CUSTOMER
INPUTS

(i.e. Light Curtain)


24V

24V

B1

7
4

11

EES OUT TB

A3

0V

LS2
LS21

KA3

2
3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

A2

*BRKRLS3

TB1

6 CHANNEL AMP

*BRKRLS2

TB1

EES1
EES11

EE-4707-010-001

*BRKRLS1

24V

DAISY CHAIN TO TB3 PIN 2 OF


ALL SUBSEQUENT LOCAL STOP PCB UNITS
(PART OF EE-4707-012-001)

10

24V

0V

BRK-

DI

DI

D4

9
TBOP4

BRK+

TB3

PANEL BD

CN5

KA3

EE-4707-014-001

AUX. CONTACT REQUIRED

100VAC

DB3

CN3

5
6

200VAC

FU1
2A

CN3

IN 100A

KA1

Figure 311. Single Headstock Positioner

ESTOP PC BD

24V

1
8
TB7
D6 R6

0V

0V

*BRKRLS1

D2

KA2

BRK REL

0V

KA1

LOCAL STOP PCB #2


LOCAL STOP PCB #3

CRF7

LOCAL STOP REQUEST

23

MOTOR(S) DISCONNECTED

40

MOTOR ON COMMAND

10

LOCAL STOP REQUEST

11

12

26
RDI8
25

MOTOR(S) DISCONNECTED
EE-4707-011-001

LOCAL STOP PCB #2

D5 R5
D1

KA1

MTR ON

MOTOR DISCONNECTED

KA2
DB1

SVMi AMPLIFIER
EE-4707-015-001

HV

CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

D3

KA3

0V

MOV1

R1

R8

R2

C1

TB3

TB3

1
2
3
4
5

RDI5

D7 R7

RDI6

CXA2A
24V A1,B1
0V A2,B2
*ESP
A4

LOCAL STOP PCB #3

RDO8

DC LINK

}
}

MOTOR ON COMMAND

24

RDO7

RDI7

6
7
8

39

1
3

MOTOR(S) DISCONNECTED

1
2
3
4
5

21
RDI3

LOCAL STOP REQUEST

3
4
5

RDI4

MOTOR ON COMMAND

10

22

38
RDO6

TB4

TB3

TB5

XX

KA4

# - LOCAL STOP XX UNIT


STANDARD WIRING SET KIT
EE-4707-020

JF1

EE-4707-006-001

62

61

72

71

82

81

1
3
5
A1

2
4
6
A2

- CONTROLLER HOOKUP KIT


1/CONTROLLER
EE-4707-030
- USED WITH MULTIPLE LOCAL
STOPS IN 1 CONTROLLER

XX
MOTOR 1
MTR
ENC

BRK

315

3. The Local Stop Option

KEY
CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

EE-4707-017-001

FE-4830-012

RJ3iB LOCAL STOP PBD

CN1
KA1

200VAC IN

TILT / ROTATE OR
DROP-CENTER POSITIONER

KA1

CN1
CP5A
CN2

TO MOTOR
BRAKE CONN

CN4

BRK+

BRK-

TB8

EE-4707-008-001

2
3
4

XFMR

KA2
~ +

IN 100B

~ -

CN5

KA3

BRK+

TO MOTOR
BRAKE CONN

D4

BRK-

EE-4707-014-001

AUX. CONTACT REQUIRED

100VAC

DB3

CN3

200VAC

FU1
2A

CN3

IN 100A

MCC

TB3
1

24V

2
9

PANEL BD

10

TBOP4
1

DI
2

24V

DI

0V

DAISY CHAIN TO TB3 PIN 2 OF


ALL SUBSEQUENT LOCAL STOP PCB UNITS
(PART OF EE-4707-012-001)

TB1

TB1

EES1

EES1

BEES1 5

EES11

EES11

BEES11 6

EES2

EES2

BEES2 7

EES21

EES21

BEES21 8
LS1 9

EE-4707-009-001

EE-4707-010-001

6 CHANNEL AMP

EE-4707-013-001

A1

A3

LS21 12

EXTERNAL E-STOP*
CUSTOMER INPUTS

*-JUMPER WHEN
NOT IN USE
LOCAL STOP*
CUSTOMER
INPUTS
(i.e. Light Curtain)

24V

24V

B1

7
4

}
}

*BRKRLS3
0V

LS2 11

KA3

2
3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

A2

*BRKRLS2

SAFE TO ENTER
SIGNAL OUT

CRM39

*BRKRLS1

LS11 10

TB2

EES OUT TB

KEY

KA1
24V

1
8

- LOCAL STOP XX/XY


STANDARD WIRING SET KIT
EE-4707-023

- CONTROLLER HOOKUP KIT


1/CONTROLLER
EE-4707-030

TB7
D6 R6

0V

0V

*BRKRLS1

D2

KA2

BRK REL

0V

KA1

LOCAL STOP PCB #2

38

MOTOR ON COMMAND

22

LOCAL STOP REQUEST

21

MOTOR(S) DISCONNECTED

39

MOTOR ON COMMAND

LOCAL STOP REQUEST

MOTOR(S) DISCONNECTED

MOTOR ON COMMAND

10

LOCAL STOP REQUEST

11

12

MOTOR(S) DISCONNECTED

CXA2A
24V A1,B1
0V A2,B2
*ESP
A4

DB2

CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

R1

R8

R2

R3

R4

TB3

TB3

TB4

TB3

C1

0V

MOV1

KA3

HV

CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

D3

EE-4707-015-001

DC LINK

KA2
DB1

SVMi AMPLIFIER

MTR ON

EE-4707-011-001

D1

MOTOR DISCONNECTED

25

D5 R5

KA1

26
RDI8

LOCAL STOP PCB #2

40

23
RDI5

LOCAL STOP PCB #3

RDI6

RDO8

}
}

10

24

RDI3

D7 R7

RDI4

RDO7

RDI7

- USED WITH MULTIPLE LOCAL


STOPS IN 1 CONTROLLER

LOCAL STOP PCB #3

CRF7

RDO6

TB5

XX

KA4

KA5

JF1

62
72

EE-4707-006-001

61

62

61

71

72

71

82

81

82

81

1
3
5
A1

2
4
6
A2

1
3
5
A1

2
4
6
A2

XX

MOTOR 2
MTR

BRK

ENC

XY

EE-4707-007-001

XX

MOTOR 1
MTR
ENC

JF2

BRK

3. The Local Stop Option

EE-4707-016-001
CP2

Figure 312. Tilt / Rotate or Drop-Center Positioner

316
ESTOP PC BD

Figure 313. Two Headstock Positioners

FE-4830-021
TWO HEADSTOCK POSITIONERS

KEY

- LOCAL STOP XX UNIT


STANDARD WIRING SET KIT
EE-4707-020
- CONTROLLER HOOKUP KIT
1/CONTROLLER
EE-4707-030
- USED WITH MULTIPLE LOCAL
STOPS IN 1 CONTROLLER

EE-4707-012-001

ESTOP PC BD

EE-4707-016-001

EE-4707-017-001

CP2

CN1

CN1

KA1

KA1

200VAC IN

EE-4707-012-001

CP5A

EE-4707-023 PACKAGE

RJ3iB LOCAL STOP PBD #2

EE-4707-020 PACKAGE

RJ3iB LOCAL STOP PBD #1

200VAC IN

KA1

CN1

KA1

CN1
CN2

TO MOTOR
BRAKE CONN

CN4

CN2

CN4

BRK+

BRK+

TO MOTOR
BRAKE CONN
TB8

CN2
EE-4707-008-001

100VAC

~ -

~ -

IN 100B
CN3

BRK-

MCC

TB3

TB3
1

AUX. CONTACT REQUIRED

24V

1
2

DAISY CHAIN TO TB3 PIN 2 OF


ALL SUBSEQUENT LOCAL STOP PCB UNITS
(PART OF EE-4707-012-001)

24V

TB1

TB1

TB1

TB1

EES OUT TB

EES1

EES1

BEES1

EES1

BEES1

EES11

EES11

BEES11

EES11

BEES11

EES2

EES2

BEES2

EES2

BEES2

EES21

BEES21

EES21

0V

BRK+

D4

EE-4707-014-001

24V

CN5

KA3

EE-4707-008-001

DI

KA2
~ +

IN 100A

CN3

10

TBOP4

DI

DB3

D4

PANEL BD

FU1
2A

CN3

CN5

KA3

5
6

XFMR

KA2
~ +

IN 100B

200VAC

DB3

IN 100A

A80L-0010-0071
1/CONTROLLER

FU1
2A

CN3

BRK-

BRK-

EE-4707-009-001

EE-4707-010-001

SAFE TO ENTER
SIGNAL OUT

A1

*BRKRLS3
0V

2
3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

A2

*BRKRLS2

BEES21

LS1

LS11

10

LS2

11

LS21

12

EE-4707-009-001
LOCAL STOP*
CUSTOMER
INPUTS

B1

6
7

TB2

24V

2
3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST

5
KA1

24V

TO CP5
ON E-STOP PCB

0V
9

D2

10

LS2

11

LS21

12

EXTERNAL E-STOP*
CUSTOMER INPUTS
*-JUMPER WHEN
NOT IN USE
LOCAL STOP*
CUSTOMER
INPUTS
(i.e. Light Curtain)

24V
KA1
24V

8
D6 R6

D6 R6

*BRKRLS1

24V

TB7

LS1
LS11

24V

0V

KA3

SAFE TO ENTER
SIGNAL OUT

(i.e. Light Curtain)

A3

KA3

EE-4707-013-001

CRM39

*BRKRLS1

6 CHANNEL AMP

EES21

TB2

}
}

BRK REL

0V

0V

KA1

KA2

*BRKRLS2

D2

KA2

BRK REL

0V

KA1

*BRKRLS2
LOCAL STOP PCB #3

CRF7

LOCAL STOP REQUEST

MOTOR(S) DISCONNECTED

2
1

24

LOCAL STOP REQUEST

23

MOTOR(S) DISCONNECTED

40

MOTOR ON COMMAND

10

26

LOCAL STOP REQUEST

11

25

MOTOR(S) DISCONNECTED

12

D5 R5

D5 R5

MOTOR DISCONNECTED

KA2

MOTOR ON COMMAND

10

LOCAL STOP REQUEST

11

MOTOR(S) DISCONNECTED

12

D1

KA1

MTR ON

MOTOR DISCONNECTED

KA2
DB1

DB1

EE-4707-015-001

HV

CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

D3

KA3

MOV1

R1

R8

R2

EE-4707-015-001

C1

D7 R7

SVMi AMPLIFIER
D3

KA3

MOV1

R1

R8

R2

C1

TB3

TB3

TB4

TB3

TB3

TB5

TB3

1
2
3
4
5

6
7
8

1
2
3
4
5

3
4
5

0V

9
10

#
0V

1
2
3
4
5

MTR ON

6
7
8

EE-4707-011-001

D1

KA1

1
2
3
4
5

RDI8

D7 R7

RDI5

CXA2A
24V A1,B1
0V A2,B2
*ESP
A4

LOCAL STOP PCB #3

MOTOR ON COMMAND

RDO8

DC LINK

39
RDI6

RDI7

MOTOR ON COMMAND

21
RDI3

3
4
5

22
RDI4

RDO7

9
10

38
RDO6

0V

TB4

TB3

TB5

XX

KA4

KA4
JF1

62

EE-4707-006-001

62

61

71

72

71

81

82

81

1
3
5
A1

2
4
6
A2

1
3
5
A1

2
4
6
A2

XY

XX

XX

MOTOR 2

MOTOR 1

JF2
MTR

MTR

BRK

ENC

ENC

EE-4707-007-002

0V
LOCAL STOP PCB #2
MOTOR ON COMMAND
LOCAL STOP REQUEST
MOTOR(S) DISCONNECTED

BRK

317

3. The Local Stop Option

61

72
82

- LOCAL STOP XX/XY


STANDARD WIRING SET KIT
EE-4707-023

- CONTROLLER HOOKUP KIT


1/CONTROLLER
EE-4707-030
- USED WITH MULTIPLE LOCAL
STOPS IN 1 CONTROLLER

ESTOP PC BD

EE-4707-017-001

EE-4707-016-001

RJ3iB LOCAL STOP PBD #1

CP2

EE-4707-022 PACKAGE

CN1
KA1

200VAC IN

KA1

CN1
CP5A
TO MOTOR
BRAKE CONN

CN4

CN2

BRK+

EE-4707-012-001
TB8
1

3
4

XFMR

100VAC

KA2
~ +

IN 100B

~ -

MCC

24V

0V

24V

DAISY CHAIN TO TB3 PIN 2 OF


ALL SUBSEQUENT LOCAL STOP PCB UNITS
(PART OF EE-4707-012-001)

TB1

TB1

EES1

EES1

BEES1

EES11

EES11

BEES11

EES2

EES2

BEES2

EES21

EES21

BEES21

EE-4707-009-001

EE-4707-010-001
EE-4707-013-001

SAFE TO ENTER
SIGNAL OUT

CRM39
A1

*BRKRLS1

A3

B1

10
11
12

EES OUT TB

LOCAL STOP*
CUSTOMER
INPUTS

(i.e. Light Curtain)

RJ3iB LOCAL STOP PBD #2

EE-4707-022 PACKAGE

CN1

24V

KA1

*-JUMPER WHEN
NOT IN USE

200VAC IN

KA1

24V

LS2
LS21

*BRKRLS3
0V

LS1
LS11
KA3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

A2

*BRKRLS2

TB2

6 CHANNEL AMP

TO MOTOR
BRAKE CONN

BRK-

DI

BRK+

D4

TB3

DI

CN5

KA3

EE-4707-014-001

AUX. CONTACT REQUIRED

10

TBOP4

DB3

IN 100A

CN3

200VAC

FU1
2A

CN3

PANEL BD

BRK-

CN2
EE-4707-008-001

CN1

KA1

CN2

24V

CN4

BRK+

1
8
TB7
D6 R6

0V

0V

*BRKRLS1

D2

KA2

BRKBRK REL
KA1

LOCAL STOP PCB #3


CRF7

FU1
2A

CN3

*BRKRLS2
0V

DB3

IN 100A

KA2
~ +

IN 100B

~ -

CN5

KA3

BRK+

D4

TO MOTOR
BRAKE CONN
BRK-

CN3
38

MOTOR ON COMMAND

22

LOCAL STOP REQUEST

LOCAL STOP REQUEST

23

MOTOR(S) DISCONNECTED

MOTOR ON COMMAND

10

LOCAL STOP REQUEST

11

MOTOR(S) DISCONNECTED

12

1
2
KA2
DB1

DB2

EE-4707-015-001

CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

BEES2 7

EES21

BEES21 8
LS1 9

D3

KA3

0V

MOV1

R1

R8

R2

R3

EE-4707-009-001

R4

C1

TB3

TB3

TB4

TB3

SAFE TO ENTER
SIGNAL OUT
TB5

LS21 12

7
CP5 ON
E-STOP PCB

EE-4707-006-001

62

61

62

61

72

71

72

71

82

81

82

81

1
3
5
A1

2
4
6
A2

1
3
5
A1

2
4
6
A2

}
}

EXTERNAL E-STOP*
CUSTOMER INPUTS
*-JUMPER WHEN
NOT IN USE
LOCAL STOP*
CUSTOMER
INPUTS
(i.e. Light Curtain)

KA5

JF1

EES OUT TB

24V

24V

6
KA4

LS2 11

KA3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

XX

LS11 10

TB2

5
CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

BEES1 5
BEES11 6

EES2

SVMi AMPLIFIER

HV

TB1
EES1
EES11

KA1
24V

8
D6 R6

0V
*BRKRLS2

D2

KA2

BRK REL

0V

KA1

XX
MOTOR 2
MTR

BRK

ENC

EE-4707-007-001

XY

XX
MOTOR 1
D5 R5
MTR

BRK

ENC

JF2

D1

MOTOR ON COMMAND

10

LOCAL STOP REQUEST

11

MOTOR(S) DISCONNECTED

12

KA1

MTR ON

MOTOR DISCONNECTED

KA2
DB1

DB2

SVMi AMPLIFIER

0V
CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

D3

KA3

0V

LOCAL STOP PCB #2

MOV1

R1

R8

R2

R3

R4

C1

TB3

TB3

TB4

1
2
3
4
5

6
7
8

EE-4707-015-001
HV

1
2
3
4
5

CXA2A
24V A1,B1
0V A2,B2
A4
*ESP

KA1

MOTOR DISCONNECTED

3
4
5

24V

TB1
MTR ON

9
10

EE-4707-011-001

D1

D7 R7

25

TB3

D5 R5

1
2
3
4
5

26
RDI8

EE-4707-014-001

6
7
8

40

D7 R7

RDI5

DC LINK

MOTOR ON COMMAND

24
RDI6

RDO8

RDI7

MOTOR(S) DISCONNECTED

39
RDO7

1
2
3
4
5

21
RDI3

LOCAL STOP PCB #3

3
4
5

RDI4

9
10

RDO6

TO MOTOR
BRAKE CONN

0V

TB3

TB5

XX

KA4

KA5

JF1
MOTOR ON COMMAND
LOCAL STOP REQUEST
MOTOR(S) DISCONNECTED

EE-4707-006-001

62

61

62

61

72

71

72

71

82

81

82

81

1
3
5
A1

2
4
6
A2

1
3
5
A1

2
4
6
A2

XX
MOTOR 4
MTR

BRK

ENC

XY

EE-4707-007-001

XX
MOTOR 3
MTR
ENC

JF2

BRK

3. The Local Stop Option

Figure 314. Two Tilt / Rotate Positioners

318

FE-4830-022
TWO TILT / ROTATE POSITIONERS
KEY

FERRIS WHEEL POSITIONER

100VAC

100VAC

EE-4707-008-001

#
EE-4707-017-001

EE-4707-016-001

ESTOP PC BD

CP2

EE-4707-020 PACKAGE

RJ3iB LOCAL STOP PBD #1


CN1

EE-4707-012-001

KA1

200VAC IN

KA1

TO MOTOR
BRAKE CONN

CN1
CP5A
CN2

CN4

BRK+

EE-4707-012-001
TB8

100VAC

KA2
~ +

IN 100B

~ -

MCC

24V

0V

EES2
EES21

EES2

EES21

CN2

CN4

BRK+

LS21 12
24V

LOCAL STOP*
CUSTOMER
INPUTS

BRK-

B1

6
7

FU1
2A

CN3

(i.e. Light Curtain)

DB3

KA2
~ +

IN 100A

CN5

KA3

BRK+

D4
~ -

IN 100B

A3

LS2 11

2
3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

A2

0V

LS11 10
KA3

SAFE TO ENTER
SIGNAL OUT

A1

*BRKRLS3

TO MOTOR
BRAKE CONN

BEES2 7
BEES21 8

TB2

EE-4707-013-001

CRM39

*BRKRLS2

- CONTROLLER HOOKUP KIT


1/CONTROLLER
EE-4707-030

KA1

LS1 9

EE-4707-009-001

*BRKRLS1

KA1

200VAC IN

BEES11 6

EES11

EE-4707-010-001

6 CHANNEL AMP

CN1

BEES1 5

EES1

- LOCAL STOP XX UNIT


STANDARD WIRING SET KIT
EE-4707-020

- USED WITH MULTIPLE LOCAL


STOPS IN 1 CONTROLLER

EE-4707-023 PACKAGE

RJ3iB LOCAL STOP PBD #2


TB1

TB1

EES11

24V

DAISY CHAIN TO TB3 PIN 2 OF


ALL SUBSEQUENT LOCAL STOP PCB UNITS
(PART OF EE-4707-012-001)

EES1

DI

TB3

#
BRK-

10

TBOP4

BRK+

D4

DI

KEY

CN5

KA3

EE-4707-014-001

AUX. CONTACT REQUIRED

PANEL BD

DB3

IN 100A

CN3

5
6

XFMR

200VAC

FU1
2A

CN3

A80L-0010-0071
1/CONTROLLER

BRK-

CN2
EE-4707-008-001

Figure 315. Ferris Wheel Positioner

FE-4830-031

EE-4707-008-001
BRK-

24V

KA1
24V

TB3

1
8

24V

TB7
2

D6 R6

0V

0V

*BRKRLS1

D2

BRK REL
KA1

KA2

EES1

BEES1 5

EES11

BEES11 6

LOCAL STOP PCB #3


2

0V
0V

LOCAL STOP REQUEST

21

MOTOR(S) DISCONNECTED

39

MOTOR ON COMMAND

LOCAL STOP REQUEST

26
RDI8
25
RDI7

MOTOR(S) DISCONNECTED

MOTOR ON COMMAND

10

11

12

LOCAL STOP REQUEST


MOTOR(S) DISCONNECTED

D1

KA1

MOTOR DISCONNECTED

KA2

KA3

0V

CXA2A
24V A1,B1
0V A2,B2
*ESP
A4

MOV1

R1

R8

R2

BRK+
TO MOTOR
BRAKE CONN
BRK-

IN 100A

KA2
~ +

IN 100B

~ -

TB3

*BRKRLS2

BRK-

TB3
1

D2

KA2

62

0V

KA1

CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

EE-4707-006-001

XX

71
81

1
3
5
A1

TB1

TB1

TB5

EES1

BEES1 5

EES11

BEES11 6

EES2

BEES2 7

EES21

BEES21 8
LS1 9

EE-4707-009-001

2
4
6
A2

D1

10

LOCAL STOP REQUEST

11

MOTOR(S) DISCONNECTED

12

KA1

SAFE TO ENTER
SIGNAL OUT

D5 R5

MOTOR ON COMMAND

0V
MTR

MOV1

R1

R8

TO CP5
ON E-STOP PCB

R2

(i.e. Light Curtain)

24V
KA1
24V

D6 R6

TB3

BRK

*-JUMPER WHEN
NOT IN USE

LOCAL STOP*
CUSTOMER
INPUTS

C1
0V

MOTOR 1

EXTERNAL E-STOP*
CUSTOMER INPUTS

24V

KA3

}
}

KA2

D3

XX

LS21 12

EES OUT TB

4
5

MOTOR(S) DISCONNECTED
DB1

EE-4707-015-001

JF1

LS2 11

KA3

2
3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

MTR ON

LS11 10

TB2

61

72
82

24V

2
BRK REL

KA4

HV

BRK+

KA1
24V

SVMi AMPLIFIER

CN5

KA3

24V

D6 R6

TB4

DB3

D4

0V

TB3

FU1
2A

CN3

C1

TB3

CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

CN4

LOCAL STOP*
CUSTOMER
INPUTS

(i.e. Light Curtain)

24V

TO CP5
ON E-STOP PCB

D3

1
2
3
4
5

3
4
5

D7 R7

EE-4707-015-001

9
10

KA1

CN2

EE-4707-012-001

DB1

EE-4707-011-001

DC LINK

LS21 12

2
3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

MTR ON

LS2 11

KA3

SAFE TO ENTER
SIGNAL OUT

TB3

TB4

*BRKRLS3

1
2
3
4
5

40

LS11 10

TB2

6
7
8

RDI5
RDO8

KA1

200VAC IN

LS1 9

EE-4707-009-001

D5 R5

1
2
3
4
5

23

BEES21 8

3
4
5

24

BEES2 7

EES21

9
10

22

EES2

D7 R7

RDI6

1
2
3
4
5

RDI3

MOTOR ON COMMAND

6
7
8

RDI4

RDO7

38

CN1

TB1

TB1

LOCAL STOP PCB #2

CRF7
RDO6

EE-4707-020 PACKAGE

RJ3iB LOCAL STOP PBD #3

0V

TB3

TB5

D2

KA2

BRK REL

0V

KA1

ENC

MOTOR ON COMMAND
LOCAL STOP REQUEST
MOTOR(S) DISCONNECTED

EE-4707-015-001

KA4

#
XY

0V
LOCAL STOP PCB #2

62
72

EE-4707-007-002

81

1
3
5
A1

2
4
6
A2

D5 R5

MOTOR ON COMMAND

D1

10

LOCAL STOP REQUEST

11

MOTOR DISCONNECTED

12

KA1

MTR ON

MOTOR DISCONNECTED

KA2
DB1

D7 R7

JF2

61
71

82

D3

KA3

MOV1

R1

R8

R2

C1

XX
BRK

TB3

TB3

1
2
3
4
5

6
7
8

1
2
3
4
5

3
4
5

10

0V
MTR

MOTOR 1
TB4

TB3

TB5

ENC

SVMi AMPLIFIER

0V
KA4

LOCAL STOP PCB #3


CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

MOTOR ON COMMAND

62

61

LOCAL STOP REQUEST


XX

72

MOTOR(S) DISCONNECTED

EE-4707-006-001
JF1

71

82

81

1
3
5
A1

2
4
6
A2

XX
MOTOR 1
MTR
ENC

BRK

319

3. The Local Stop Option

HV

EE-4707-016-001

EE-4707-017-001

CP2

RJ3iB LOCAL STOP PBD #1

KA1

KEY

KA1

CN2

TO MOTOR
BRAKE CONN

CN4

- LOCAL STOP XX/XY


STANDARD WIRING SET KIT
EE-4707-023

CN1

EE-4707-012-001

CP5A

EE-4707-020 PACKAGE

CN1

200VAC IN

BRK+

TB8

CN2

3
4

A80L-0010-0071
1/CONTROLLER

KA2
~ +

IN 100B

~ -

100VAC

MCC

24V

TB1

TB1

EES1

EES11

EES2

EES2

EES21

EES21

LS1

LS11

10

LS2

11

LS21

12

1
2

0V

- USED WITH MULTIPLE LOCAL


STOPS IN 1 CONTROLLER

TB3

DAISY CHAIN TO TB3 PIN 2 OF


ALL SUBSEQUENT LOCAL STOP PCB UNITS
(PART OF EE-4707-012-001)

10

TBOP4

24V

EE-4707-012-001
D4

EE-4707-014-001

PANEL BD

DI

EE-4707-009-001

EE-4707-010-001

SAFE TO ENTER
SIGNAL OUT

A1

B1

0V

6
7
8

KA3

CN1
KA1

KA1

CN1
LOCAL STOP*
CUSTOMER
INPUTS
(i.e. Light Curtain)

CN4

CN2

BRK+
TO MOTOR
BRAKE CONN

24V

BRK-

EE-4707-008-001

FU1
2A

CN3

24V
KA1

EE-4707-022 PACKAGE

RJ3iB LOCAL STOP PBD #2

200VAC IN

A3

*BRKRLS3

BEES2
BEES21

2
3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

A2

*BRKRLS2

BEES1
BEES11

EE-4707-013-001

CRM39

*BRKRLS1

EES1
EES11

TB2

#
6 CHANNEL AMP

- CONTROLLER HOOKUP KIT


1/CONTROLLER
EE-4707-030

CN5

KA3

CN3

AUX. CONTACT REQUIRED

7
8

DI

DB3

IN 100A

5
6

XFMR

200VAC

FU1
2A

CN3

BRK-

EE-4707-008-001

24V

DB3

IN 100A

KA2
~ +

IN 100B

~ -

CN5

KA3

BRK+

D4

TO MOTOR
BRAKE CONN
BRK-

CN3
8
TB7
D6 R6

0V

0V

*BRKRLS1

D2

KA2

BRK REL

0V

TB3

KA1

*BRKRLS2

24V

2
LOCAL STOP PCB #3

LOCAL STOP REQUEST

21

MOTOR(S) DISCONNECTED

39

MOTOR ON COMMAND

24

LOCAL STOP REQUEST

MOTOR ON COMMAND

10

26

LOCAL STOP REQUEST

11

25

MOTOR(S) DISCONNECTED

12

SAFE TO ENTER
SIGNAL OUT

MOTOR DISCONNECTED

KA2

HV

EES11

BEES11 6

EES2

BEES2 7

EES21

BEES21 8

R1

R8

TB3

TB3

CP5 ON
E-STOP PCB

TB4

KA1
24V

8
D6 R6

XX

*BRKRLS2

D2
KA2

BRK REL

JF1

D5 R5

KA1

MTR ON

MOTOR DISCONNECTED

KA2
DB1

XX

R1

R8

TB3

24V

DB2

R2

R3

R4

TB3

TB4

C1

0V

CXA2B

MOV1

D3
KA3

EE-4707-015-001
#

BRK

ENC

MOTOR 1
MTR

HV

TB3

12

11

MOTOR(S) DISCONNECTED

10

LOCAL STOP REQUEST

D1

MOTOR ON COMMAND

2
4
6
A2

81

1
3
5
A1

SVMi AMPLIFIER

61
71

82

EE-4707-006-001

A4

0V

KA1

KA4

62

A2,B2

(i.e. Light Curtain)

TB5

0V

72

A1,B1

*-JUMPER WHEN
NOT IN USE
LOCAL STOP*
CUSTOMER
INPUTS

24V

C1

TB3

EXTERNAL E-STOP*
CUSTOMER INPUTS

24V

10

CXA2A
A1,B1 24V
A2,B2 0V
A4
*ESP

0V

}
}

R2

CXA2B
A1,B1 24V
A2,B2 0V
A4
*ESP

LS21 12

5
MOV1

LS2 11

EES OUT TB

D3

KA3

LS11 10
KA3

CUSTOMER SUPPLIED
LOCAL STOP REQUEST
INPUT

DB1

SVMi AMPLIFIER
EE-4707-015-001

BEES1 5

D7 R7

CXA2A
24V A1,B1
0V A2,B2
*ESP
A4

EES1

TB2

MTR ON

D1

KA1

D7 R7

EE-4707-011-001

DC LINK

MOTOR(S) DISCONNECTED

40
RDI8

EE-4707-009-001
#

RDI5
RDO8

TB1

LS1 9

D5 R5

23

RDI6

LOCAL STOP PCB #3

RDO7

10

RDI3

RDI7

MOTOR ON COMMAND

22
RDI4

TB1

38
RDO6

0V

CRF7

TB5

0V
*ESP

XX

CXA2A
A1,B1
A2,B2
A4

24V
0V
*ESP

KA4

0V

JF1

KA5

LOCAL STOP PCB #2

62

61

62

61

MOTOR ON COMMAND

72

71

72

71

LOCAL STOP REQUEST

82

81

82

81

1
3
5
A1

2
4
6
A2

1
3
5
A1

2
4
6
A2

MOTOR(S) DISCONNECTED

EE-4707-006-001

XY

EE-4707-007-001

XX
MOTOR 4
MTR
ENC

BRK

XX
MOTOR 3
MTR
ENC

JF2

BRK

3. The Local Stop Option

ESTOP PC BD

Figure 316. Headstock and Tilt / Rotate Positioners

320

FE-4830-033
HEADSTOCK AND TILT / ROTATE POSTIONERS

3. The Local Stop Option

3.5 Parts List


Table 32. Local Stop Unit Parts List
Description

Part Number

Remarks

Local Stop Kits


Local Stop Kit
For use with: (1) Auxiliary
Amplifier, (1) Channel and
(1) XX Connection

EE-4707020

Kit Contents:
EE-4707001 (Din Rail Sub-Assembly)
EE-4707008001
EE-4707009001
EE-4707010001
EE-4707015001

Local Stop Kit


For use with: (2) Auxiliary
Amplifier, (1) Channel each
and (2) XX Connection

EE-4707021

Kit Contents:
EE-4707002 (Din Rail Sub-Assembly)
EE-4707008001
EE-4707009001
EE-4707010001
EE-4707015001

Local Stop Kit


For use with: (1) Auxiliary
Amplifier, (2) Channels
and (1) XX and (1) XY
Connection

EE-4707022

Kit Contents:
EE-4707003 (Din Rail Sub-Assembly)
EE-4707008001
EE-4707009001
EE-4707010001
EE-4707015001

Local Stop Kit


For use with: (1) Auxiliary
Amplifier, (2) Channels and
(1) XY Connection

EE-4707023

Kit Contents:
EE-4707006 (Din Rail Sub-Assembly)
EE-4707008001
EE-4707009001
EE-4707010001
EE-4707015001

Brake Transformer Harness

EE-4707008001

Part of Local Stop Kit Assembly

24V Panel Board Harness

EE-4707009001

24V E-Stop Board Harness

EE-4707010001

Data Signal Harness

EE-4707015001
Din Rail Sub-Assembly

Din Rail Sub-Assembly


For use with:
EE-4707020

EE-4707001

Sub-Assembly Contents:
EE-4707004
EE-4707006001

321

3. The Local Stop Option

Table 32. Local Stop Unit Parts List (Contd)


Description

Part Number

Remarks

Din Rail Sub-AssemblyFor


use with:
EE-4707021

EE-4707002

Sub-Assembly Contents:
EE-4707005
EE-4707006001
EE-4707006002

Din Rail Sub-AssemblyFor


use with:
EE-4707022

EE-4707003

Sub-Assembly Contents:
EE-4707005
EE-4707006001
EE-4707007001

Din Rail Sub-AssemblyFor


use with:
EE-4707023

EE-4707006

Sub-Assembly Contents:
EE-4707004
EE-4707007002

Local Stop PCB (Single


Channel)

EE-4707004

Board with all components

Local Stop PCB (Dual


Channel)

EE-4707005

Board with all components

Contactor Harness - Single


Channel Amplifier (XX Key
& K4 Tag)

EE-4707006001

Part of Din Rail Sub-Assembly

Contactor Harness - Single


Channel Amplifier (XX Key
& K5 Tag)

EE-4707006002

Contactor Harness - Single


or Dual Channel Amplifier
(XY Key & K5 Tag)

EE-4707007001

Contactor Harness - Single


or Dual Channel Amplifier
(XY Key & K4 Tag)

EE-4707007002

Controller Hookup Kit


Controller Hookup Kit

322

EE-4707030

Kit Contents:
EE-4707011001
EE-4707013001
EE-4707014001
EE-4707016001
EE-4707017001

3. The Local Stop Option

Table 32. Local Stop Unit Parts List (Contd)


Description

Part Number

6 Channel Amplifier Local


Stop Control Harness

EE-4707011001

Brake Signal Harness

EE-4707013001

Auxiliary Contact Harness

EE-4707014001

200V Transformer Power


Input Harness with Din Rail
TB-8

EE-4707016001

200V IN to Local Stop Unit


#1 Harness

EE-4707017001

Remarks
Part of Controller Hookup Kit Assembly

Miscellaneous Controller and Application Items


100V Brake Transformer

A80L-00100071

200V Jumper Harness

EE-4707012001

Required for Local Stop Units 2 and 3

AC 3 Pole Contactor

RLAYLC1D2501M6

TELEMEC.

323

Chapter 4

This manual is a supplement for the R-J3iB Mate Controller Auxiliary Axis Option.
Refer to the R-J3iB Mate maintenance manual for general maintenance descriptions.
Note: Local Stop functionality is not available for R-J3iB Mate Auxiliary Axis packages.

Auxiliary servo amplifie


(in case of B 20)

Power supply unit

Emergency stopunit
Fan

Operator panel

Noise filter(option)

Brake relay unit(option)

Main cabinet

MCC

Brake I/F

Auxiliary axis cabine

Battery unit

Connection cable for M0.4/4000,M0.5/4000,M1/4000


(A05B-2448-D200,201,202)

BRAKE

A1
A2
A3

BKP

BKM

2
BKP
3
BKM

POWER

B2
A2

W
G

B1
A1

U
V

1
U
4
G

2
V
3
W

PULSECODER

01
02
03
04
05
06
07
08
09
10

SD
XSD
REQ
XREQ

+5V-1

11
12
13
14
15
16
17
18
19
20

0V-1

1
2
3

0V-2

0V-2

+5V-2

+6V

XSD
SD
DRAIN

4
5
6
7

+6V
XREQ

REQ
0V-1

8
9
10

+5V-1
+5V-2

0V-2

Connection cable for 1/5000i,2/5000i,M2/5000i,M3/5000i


(A05B-2448-D220,221,222)

A1
A2
A3

BKP
6
BKM

BKM

5
BKP

4
G

3
W

2
V

POWER/BRAKE

B2
A2

W
G

B1
A1

U
V

PULSECODER

01
02
03
04
05
06
07
08
09
10

SD
XSD
REQ
XREQ

+5V-1

11
12
13
14
15
16
17
18
19
20

0V-1

1
2
3

0V-2

0V-2
+5V-2

+6V

XSD
SD
DRAIN

4
5
6
7

+6V
XREQ

REQ
0V-1

8
9
10

+5V-1
+5V-2

0V-2

1
U

Connection cable for 4/4000i,8/3000i,M8/4000i,M12/4000i


(A05B-2448-D240,241,242)

BRAKE

BKM

A1
A2
A3

BKP

BKP

BKM

POWER

B2
A2

W
G

B1
A1

A D
U G
B C
V W

U
V

PULSECODER

01
02
03
04
05
06
07
08
09
10

SD
XSD
REQ
XREQ

+5V-1

11
12
13
14
15
16
17
18
19
20

0V-1

1
2
3

0V-2

0V-2

+5V-2

+6V

XSD
SD
DRAIN

4
5
6
7

+6V
XREQ

REQ
0V-1

8
9
10

+5V-1
+5V-2

0V-2

Connection cable for12/3000i,22/3000i


(A05B-2448-D260,261,262)

BRAKE
A

BKM

A1
A2
A3

BKP

BKP

BKM

POWER

B2
A2

W
G

B1
A1

A D
U G
B C
V W

U
V

PULSECODER

01
02
03
04
05
06
07
08
09
10

SD
XSD
REQ
XREQ

+5V-1

11
12
13
14
15
16
17
18
19
20

0V-1

1
2
3

0V-2

0V-2 +6V

+5V-2

XSD
SD
DRAIN

4
5
6
7

+6V
XREQ

REQ
0V-1

8
9
10

+5V-1
+5V-2

0V-2

This section contains a list of spare parts used within an R-J3iB Mate Auxiliary Axis
system. Table 1, Table 2 and Table 3 provide part number information for the servo
motors and amplifiers available for use in an R-J3iB Mate Auxiliary Axis system.
Table 1. Alpha i Servo Motors
A06B-aaaa-B b c d
Model [aaaa]
Shaft/Brake [b]
0202: Alpha 1/5000i
0205: Alpha 2/5000i
0223: Alpha 4/4000i
0227: Alpha 8/3000i
0243: Alpha 12/3000i
0247: Alpha 22/3000i
0212: Alpha M2/5000i
0215: Alpha M3/5000i
0235: Alpha M8/4000i
0238: Alpha M12/4000i

Fan [c]

0: Taper Shaft
1: Straight shaft
2: Straight shaft with keyway
6: Taper shaft with Brake (DC90V)
7: Straight shaft with Brake (DC90V)
8: Straight shaft with Brake (DC90V)
and keyway

Table 2. Beta M Servo Motors


A06B-aaaa-B b cc # dddd
Model [aaaa]
Shaft/Brake [b]
0114: Beta M0.4/4000
0115: Beta M0.5/4000
0116: Beta M1/4000

0: Standard = without Fan


Pulsecoder [d]
5: Alpha A64i

Modification [dddd]

0: Straight shaft
2: Straight shaft with Brake (DC90V)
Pulsecoder [cc]

0000: Standard
0008: with keyway

75: Beta A64B


Table 3. Servo Amplifiers and Compatible Servo Motors
Servo Amplifier
Compatible Servo
Part Number
(Communication)
Motor
Beta M0.4/4000
Beta M0.5/4000
Beta M1/4000
Beta SVU-20
A06B-6093-H112
Alpha 1/5000i
(FSSB I/F)
Alpha 2/5000i
Alpha M2/5000i
Alpha M3/5000i
4/4000i
Beta SVU-40
A06B-6093-H113
8/3000i
(FSSB I/F)
Beta SVU-80
(FSSB I/F)

A06B-6093-H114

12/3000i
22/3000i
M8/4000i
M12/4000i

Note
Regeneration
resistance (30/20W)
is mounted separately
A06B-6093-H401
Amplifier includes
70W discharge
resistor
Amplifier includes
70W discharge
resistor

Table 4 provides the part number for the auxiliary axis connection cable. This cable
provides the DC signal, AC power and FSSB communication to the auxiliary axis
cabinet.
Table 4. Interconnection cable (Mate Controller to Auxiliary Axis Cabinet)
Description
Part Number
Note
Length = 3m
Connection cable
A05B-2448-J070
STD/RIA
Table 5 provides part numbers for a single and three phase noise filter. If your system is
using a SVU-40 or 80 Beta amplifier, you are required to use a noise filter.
Table 5. Noise Filter
Description

R-J3iB Mate
Power spec.

Part Number

Noise filter unit A

3 phase

A05B-2448-J090

Noise filter unit B

1 phase

A05B-2448-J091

Note
STD/RIA

Note: The use of Beta SVU-40 or 80 amplifiers requires the use of a noise filter.
Table 6 provides a list of motor connection cables. The cables come in 7, 14 and 20
meter lengths.
Table 6. Motor Connection Cables (Flex Type)
Servo Motor
Spec.
Beta M0.4/4000
STD
Beta M0.5/4000
RIA
Beta M1/4000
Alpha 1/5000i
Alpha 2/5000i
Alpha M2/5000i
Alpha M3/5000i
Alpha 4/4000i
Alpha 8/3000i
Alpha M8/4000i
Alpha M12/4000i
Alpha 12/3000i
Alpha 22/3000i

STD
RIA
STD
RIA
STD
RIA

Length
7m
14m
20m
7m
14m

Part Number
A05B-2448-D200
A05B-2448- D201
A05B-2448- D202
A05B-2448- D220
A05B-2448-D221

20m

A05B-2448-D222

7m
14m

A05B-2448-D240
A05B-2448-D241

20m

A05B-2448-D242

7m
14m
20m

A05B-2448-D260
A05B-2448-D261
A05B-2448-D262

Table 7. Servo Card


Description
Part Number
6 Axes Servo Card
A05B-2440-H020
8 Axes Servo Card

A05B-2440-H021

Note
For LR Mate100iB + 1 Auxiliary Axis
For LR Mate100iB + 2 Auxiliary Axes
For LR Mate200iB + 1 or 2 Auxiliary Axes

Table 8. MCC / Brake Interface and Power Supply Unit


Description
Part Number
MCC and Brake Interface
A05B-2448-C001

Note
STD/RIA

Table 9. Brake Relay Cable


Description
Part Number
Note
Brake relay cable
A05B-2448-J080
STD/RIA
Note: For LR Mate 100iB, the following cable is required for auxiliary axis brakes.
Table 10. Replacement Battery
Description
Part Number
Battery
A06B-6050-K061

Note
Alkaline dry battery