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AR52 controller

(Software) system version


Applicable to V01.001 and after

Second edition

NACHI-FUJIKOSHI Corp.
NACHI-FUJIKOSHI CORP.
JAPAN MAIN OFFICE Phone:(03)5403-0491 Fax:(03)5403-0488 World Trade Center 2-4-1 Hamamatsu-cho, Minato-ku, TOKYO, 105-6125 JAPAN

NACHI ROBOTIC SYSTEMS INC.


NACHI ROBOTIC SYSTEMS INC. Phone:(248)305-6545 Fax:(248)305-6542 22285 Roethel Drive, Novi, Michigan 48375 U.S.A.
Support Group Phone:(248)305-6551 Fax:(248)305-6554 47840 Anna Court, Wixom, Michigan 48393 U.S.A.
Toronto Branch Office Phone:(905)856-9542 Fax:(905)856-5228 215 Rowntree Dairy Road, Woodbridge, Ontario L4L 8B8 Canada
Indiana Branch Office Phone:(317)870-0390 Fax:(317)870-0395 5032 West 79th St. Indianapolis, Indiana 46268 U.S.A.
Mexico Branch Office Phone:(525)576-7582 Fax:(525)576-5228 Oficina de Representacion, Ingenieros Militares 85, C 1-2
Col.Argentina 11230, Mexico, D.F.
St.Louis Service Center Phone:(314)391-0345 Fax:(314)391-0904 234 Old Merramec Station Road, Suite B, Manchester, Missouri 63021
U.S.A.

Copy by NACHI-FUJIKOSHI CORP.


Robot division
1-1-1, FUJIKOSHIHONMACHI, TOYAMA CITY,
JAPAN 930-8511
Tel (0764)23-5137
Fax (0764)93-5252

There is author's rights of this book on NACHI-FUJIKOSHI CORP.


No part of this manual may be photocopied or reproduced in any from without prior written consent
from NACHI-FUJIKOSHI CORP.
Contents of this book are sometimes modified without a previous notice.
A missing page, an erratic pagination book are replaced.
9906,EARE-041-002
CONTENTS

For safety use ........................................................................................................................................... 1


1 Setting of AR52 Controller
1.1 Specifications .........................................................................................................................................1-1
1.2 Transfer .................................................................................................................................................1-1
1.3 Installation .............................................................................................................................................1-3
1.4 Connection .............................................................................................................................................1-4

2 Composition of AR52 Controller


2.1 Parts layout of AR52 controller ...........................................................................................................2-2
2.2 Controllers block diagram ..................................................................................................................2-3
2.3 Functions of each unit...........................................................................................................................2-6
2.3.1 Main CPU board (UM870) .......................................................................................................2-6
2.3.2 Flash ROM board (UM871)......................................................................................................2-8
2.3.3 I/O board (UM803/UM080)......................................................................................................2-9
2.3.4 Sequence board (UM880) .......................................................................................................2-10
2.3.5 Analog I/O board (UM820).....................................................................................................2-11
2.3.6 RIO I/F board (UM858) ..........................................................................................................2-14
2.3.7 I/O maser board (UM873).......................................................................................................2-16
2.3.8 AC I/O board (UM887/UM104) .............................................................................................2-19
2.3.9 Servo amp board (UM860) .....................................................................................................2-26
2.3.10 Motion controller board (UM883/UM884).............................................................................2-28
2.3.11 Board rack ...............................................................................................................................2-30
2.3.12 Composite power unit (SR1)...................................................................................................2-30
2.3.13 Drive unit ................................................................................................................................2-31
2.3.14 Operation panel and teach pendant .........................................................................................2-33
2.3.15 FDD.........................................................................................................................................2-34

3 Troubleshooting
3.1 Examples of troubleshooting................................................................................................................3-3
3.1.1 Ex. 1 Some axes unmovable (Manually unmovable) ...............................................................3-3
3.1.2 Ex. 2 Display of teach pendant improper or its keys not effective
(In case of replacing the board UM862 in the teach pendant, for example) .........................3-4
3.1.3 Ex. 3 Displacement between recording point and playback point............................................3-5
3.1.4 Ex. 4 Displacement occurred.
(Despite proper functioning up to a certain time,
a playback position displaces as time passes.) ......................................................................3-6
3.1.5 Ex. 5 Not displayed even primary power breaker is turned ON...............................................3-7
3.1.6 E02 Program check-sum fault .................................................................................................3-8
3.1.7 E10 Servo units are not ready. Turn off and turn on again.......................................................3-9
3.1.8 E12 Accuracy not matched.....................................................................................................3-10
3.1.9 E13 Servo error: No speed command .....................................................................................3-11
3.1.10 E20 Servo error: Abnormal change in command data............................................................3-12
3.1.11 E21 Servo error: Servo following error ..................................................................................3-13
3.1.12 E22 Servo error: Deviation error ............................................................................................3-14
3.1.13 E23 Servo error: EC disconnection
E25 Servo error: Bit jump
E27 Excessive change of encoder data...................................................................................3-15

CONTENTS - 1
CONTENTS
3.1.14 E24 Servo error: CPU error ....................................................................................................3-16
3.1.15 E26 Servo error: Interference .................................................................................................3-17
3.1.16 E28 Servo error: Drive unit voltage down..............................................................................3-18
3.1.17 E29 Servo error: Check sum error in encoder ........................................................................3-19
3.1.18 E30 Servo error: Sensor check error.......................................................................................3-20
3.1.19 E31 Servo error: Motors rotation too fast when power on....................................................3-21
3.1.20 E32 Servo error: Over-current ................................................................................................3-22
3.1.21 E34 The amplifier unit returns no answer ..............................................................................3-23
3.1.22 E35 I/O CPU error ..................................................................................................................3-24
3.1.23 E36 Fuse blown ......................................................................................................................3-25
3.1.24 E38 Servo error: Over-load ....................................................................................................3-26
3.1.25 E39 Servo error: Over-rotation...............................................................................................3-27
3.1.26 E40 The teach pendants CPU error.......................................................................................3-28
3.1.27 E42 Motor temperature fault ..................................................................................................3-29
3.1.28 E44 Overvoltage .....................................................................................................................3-30
3.1.29 E46 Temperature error of regenerative discharge resistance..................................................3-31
3.1.30 E50 Servo error: CTR-OVFE52
E51 Servo error: Data transmission error ..............................................................................3-32
3.1.31 E52 Servo error: Battery discharged......................................................................................3-33
3.1.32 E54 Servo error: Position deviation.......................................................................................3-34
3.1.33 E55 Servo error: Encoder data abnormal...............................................................................3-35
3.1.34 E56 Servo error: Pre-load error .............................................................................................3-36
3.1.35 E57 Servo error: Count status error .......................................................................................3-37
3.1.36 E60 Panel temperature error ...................................................................................................3-38
3.1.37 E61 Tripping of thermal or circuit protector ..........................................................................3-39
3.1.38 E62 MOTORS ON sequence error .........................................................................................3-40
3.1.39 E66 Arm interference LS activated ........................................................................................3-41
3.1.40 E67 The I/O master returns no answer ...................................................................................3-42
3.1.41 E256 Step data reading fault...................................................................................................3-43
3.1.42 E896 Hardware version of amp. Card is not correct...............................................................3-44
3.1.43 E8001 Motors-off sequence fault.
E8002 Input sequence fault.
E8007 System error(memory full). .........................................................................................3-45
3.1.44 E8004 Brake sequence fault....................................................................................................3-46

4 Parsts replacement & Adjustment


4.1 Parts replacement .................................................................................................................................4-3
4.1.1 Replacement of CPU unit.............................................................................................................4-3
4.1.2 Replacement of drive unit ............................................................................................................4-4
4.1.3 Replacement of PCB ....................................................................................................................4-5
4.1.4 Battery replacement......................................................................................................................4-7
4.1.5 Replacement of position detection power supply (SR2) ..............................................................4-7
4.1.6 Replacement of composite power unit on the board rack ............................................................4-8
4.2 Adjustment ............................................................................................................................................4-9
4.2.1 Adjustment of power system........................................................................................................4-9
4.2.2 Transformers tap change...........................................................................................................4-10
4.2.3 Brightness adjustment of Teach Pendant ROP500.....................................................................4-11

CONTENTS - 2
CONTENTS

5 Periodic Inspection
5.1 Inspection schedule ...............................................................................................................................5-1
5.2 General cautions for periodic inspection ............................................................................................5-2
5.3 Daily inspection .....................................................................................................................................5-3
5.4 Initial inspection (750H inspection).....................................................................................................5-3
5.5 3-, 6-month & 1-year inspection ..........................................................................................................5-4
5.6 Inspection of long vacation...................................................................................................................5-5
5.7 Cleaning and inspection of fan motor and heat sink..........................................................................5-6
5.8 Maintenance parts list ..........................................................................................................................5-7

6 Parts layout and electric circuit diagrams..6-1


Fig. 1 External view of controller6-2
Fig. 2 Parts layout viewing from controllers front 6-3
Fig. 3 Parts layout viewing from controllers rear...6-4
Fig. 4 Terminal block layout (TB1).....6-5
Fig. 5 Parts layout in board rack..6-6
Fig. 6 Exterior view of drive unit.....6-7
Fig. 7 Signal system diagram (stamping).....6-8
Fig. 8 Signal system diagram (assembly)....6-9
Fig. 9 Power system diagram......6-10
Fig. 10 Power supply unit circuit diagram 16-11
Fig. 11 Power supply unit circuit diagram 26-12
Fig. 12 Operation panel & teach pendant connection diagram 1.6-13
Fig. 13 Operation panel & teach pendant connection diagram 2.6-14
Fig. 14 Drive unit connection diagram 1(SA & SG series) 6-15
Fig. 15 Drive unit connection diagram 1(SC35/50)6-16
Fig. 16 Drive unit connection diagram 1(SC15).6-17
Fig. 17 Drive unit connection diagram 2..6-18
Fig. 18 Brake circuit diagram(SA & SG series)..6-19
Fig. 19 Brake circuit diagram(SC35/50)..6-20
Fig. 20 Brake circuit diagram(SC15)..6-21
Fig. 21 Encoder cable connection diagram..6-22
Fig. 22 Sequence circuit diagram 1...6-23
Fig. 23 Sequence circuit diagram 2...6-24

7 Robot oparating principle ..............................................7-1


7.1 Teaching and playback system ............................................................................................................7-2
7.2 Robot construction ................................................................................................................................7-3
7.2.1 Power supply section....................................................................................................................7-4
7.2.2 Microcomputer section.................................................................................................................7-4
7.2.3 Servo mechamism ........................................................................................................................7-5
7.2.4 Encoder .......................................................................................................................................7-6

CONTENTS - 3
For safety use

For safety use


Be sure to carefully read and understand this manual and other related manuals prior to operation and then conduct
maintenance, inspection and repair.
In this manual, the following symbol marks are used depending on safety level.

... shows a high risk of danger surely causing a fatal condition either dead or serious wound if
DANGER the machine is mishandled or operated wrong, thus requires to pay the maximum attention to
operation and handling.

... shows a medium risk of danger probably causing a fatal condition either dead or serious
WARNING wound if the machine is mishandled or operated wrong, thus requires the maximum attention
to operation and handling.

... shows a low risk of danger probably causing a medium level of damage if the machine is
CAUTION mishandled or operated wrong, thus requires a thorough attention to operation and handling.

... shows a mandatory matter to conduct.


MUST

... shows things which should be in no way to be conducted.


INHIBIT

... shows important points to notice.


IMPORTANT

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It is required to carefully read, understand and conduct the following IMPORTANT PRECAUTIONS prior to actual
operation.

1. Transfer and installation

DANGER

Observe the following matters by all means because there exists a danger to people by
overturning or falling of the controller:
Transfer the controller only by operators who are licensed for sling work, crane or
fork lift operation.
Hoist the controller in accordance with the description in this manual.

Observe the following matters by all means to avoid electric shock:


Do not cause damage to or put a heavy thing onto cables or press them tightly.
Conduct earthing work precisely according to the description in this manual.

2. Inspection and replacement

DANGER

Electric shock may occur.


Conduct inspection and replacement 5 minutes after turning off primary power.
Do not conduct inspection and replacement with wet hand.

INHIBIT

Conduct maintenance and inspection only by those who completed the ROBOT
SCHOOL (maintenance course) held by Nachi-Fujikoshi Corp.

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For safety use

Warning labels attached to the controller are described below:

Primary power inlet

DANGER

Under the cover of this label there exists the primary power voltage (AC200 to
AC480V) which may result in electric shock. In case of operating with the cover
removed, turn off power not only of the controllers breaker but of the distributor.

Controllers front

DANGER

You may touch inside the controller 5 minutes after turning


off primary power.
And you may be electrically shocked if touched with wet
hand.

MUST

Conduct parts replacement according to the description of this manual.


Wrong methods, if employed, may invite malfunction, failure or accident.

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1 Setting of AR52 Controller

1 Setting of AR52 Controller


1 Setting of AR52 Controller ........................................................................................................................................1-1
1.1 Specifications ......................................................................................................................................................1-1
1.2 Transfer ...............................................................................................................................................................1-1
1.3 Installation...........................................................................................................................................................1-3
1.4 Connection ..........................................................................................................................................................1-4

1.1 Specifications

Item Specifications
Construction Hermetic box-type
Cooling system Indirect cooling system
Ambient humidity 20 to 85% (Dewing not accepted)
Ambient temperature 0 to 52
Input power source AC400V to 480V10% 50/60Hz
Power consumption Approx. 8.5 kVA (Differs from robot type.)
External size Controller W720H1195D690 (mm)
Weight Approx. 280 Kgf

1.2 Transfer

Observe the following for transport work:

Only those who are licensed with sling, crane or fork lift operation are permissible for
DANGER transfer operation.
Check the weight of a controller and handle it so as to suit for its weight.

Avoid a big shock to the controller during transfer.


IMPORTANT

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1-1
Transfer of AR52 Controller

Transfer AR52 controller using a crane or a forklift by observing the following.


Transfer the controller with rope put through eye bolts on the controller in case of using a crane.

DANGER

The controller weighs about 280 Kgf and check eye bolts located on top of the controller if they are tightly
secured.
Remove items not secured on the top of controller, if any.
Secure the controller firmly so that it may not overturn or slide when using a forklift.

IMPORTANT

Check if the front door is closed firmly.


Avoid a big shock to the controller which is a sophisticated machine.
When hoisting the controller, care should be taken not to make controllers surface parts damaged by wire.

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1-2
1 Setting of AR52 Controller

1.3 Installation

Installation of AR52 Controller

Check the following items prior to installing the controller:

1. Install the controller outside the operating range of a manipulator.


2. Keep the space for controller maintenance.
3. The controller is of such design that environment for its use is taken into consideration but try to satisfy the
following environmental conditions of an installing place:

(1) Ambient temperature: 0 to 52


Ambient humidity: 20 to 85% and dewing not acceptable
(2) The place has little dust, oily smoke or water.
(3) There exists no inflammable and corrosive liquid and gas.
(4) The place is not subjected to a big shock or vibration.
(5) There does not exist a big electric noise source near the place concerned.

Install the controller on a flat place where the following maintenance space can be secured.

Controller

660
105

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1-3
1.4 Connection

Connection of AR52 Controller

The robot and AR52 controller consist of:

Manipulator,
Controller and
Teach pendant.

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1 Setting of AR52 Controller

Connection of Teach Pendant

Connect the cable connector of teach pendant to a receptacle in the rear of the controller.

TEACH
PENDANT

Teach pendant cable

Connection between manipulator and AR52

Connect between the manipulator and the controller with wire-harness cables.
Check the name of a receptacle and key groove and then connect the cable to the cable connector.
Connectors position and number may vary with a robot type and thus this needs to be borne in mind.

Manipulator

CNR1 CNR4

CNR1 CNR4

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1-5
Connection between AR52 and primary power source

An electric shock may occur and thus turn off primary power source and break the circuit
DANGER breaker of the controller.

Connection method

Pull the primary power cable into the controller through the cable inlet.
Open the front door.
Connect the primary power cable to the breaker.
Attach a crimp-type solderless terminal to each cable end.
Close the front door.

Primary power breaker (Inside) Primary


power inlet

Breaker handle

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1-6
1 Setting of AR52 Controller

Connection of earth

Make earthing firmly to the controller to avoid electric shock and noise by using an exclusive earthing wire,
more than 5.5mm2 , wiring as short as possible from an installing position (Class 3 earthing).
Make earthing for peripheral jigs, etc. also to make electric potential the same as that of the controller as
illustrated below. Wiring should be as short as possible because a long wire makes the effect of electric
potential useless. Make earthing in the same manner to peripheral operation panels and conduit tubes.
It is important to keep a certain space where earthing is made in the same electric potential as mush as possible
to avoid electric shock and noise. If a specific device is earth-connected to a far place, an electric potential
differs from other peripherals, resulting in earthing ineffective. This needs to be borne in mind.

Manipulator

Hand Controller

Work
Switch board

Class 3 earthing

or

Manipulator

Hand Controller

Work

Class 3 earthing

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Other precautions

Precaution for installing an earth leakage breaker (Servo transless specification)


The robot controller is provided with an electric leakage breaker having a sensitivity of 100mA. Use an
electric leakage breaker having more than 100mA sensitivity when it is installed to primary power source.

Precaution for power line wiring


Make wiring while keeping at least 200mm apart between a power line in which a big current is running e.g.
welding and the robot cable. When they are put inside the same duct, they should be separated clearly using a
separator, for example, if possible.

Precaution when primary power is turned ON


Check again power source specifications and service power specifications for AR52 prior to turning on
primary power.

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2 Composition of AR52 Controller

2 Composition of AR52 Controller


The controller consists roughly of the controller proper and a teach pendant. Persons in charge of maintenance are
required to do their job after thorough understanding of each unit, parts arrangement and their functions inside the
controller.
Composition of the controller is described below.

2 Composition of AR52 Controller ...................................................................................................................... 2-1


2.1 Parts layout of AR52 controller.................................................................................................................. 2-2
2.2 Controllers block diagram......................................................................................................................... 2-2
2.3 Functions of each unit ................................................................................................................................ 2-2
2.3.1 Main CPU board (UM870).................................................................................................................... 2-2
2.3.2 Flash ROM board (UM871) .................................................................................................................. 2-2
2.3.3 I/O board (UM803/UM080) .................................................................................................................. 2-2
2.3.4 Sequence board (UM880) ..................................................................................................................... 2-2
2.3.5 Analog I/O board(UM820).................................................................................................................... 2-2
2.3.6 RIO I/F board(UM858) ......................................................................................................................... 2-2
2.3.7 I/O master board (UM873).................................................................................................................... 2-2
2.3.8 AC I/O board(UM887/UM104) ............................................................................................................ 2-2
2.3.9 Servo amp board (UM860).................................................................................................................... 2-2
2.3.10 Motion controller board (UM883/UM884) ......................................................................................... 2-2
2.3.11 Board rack ........................................................................................................................................... 2-2
2.3.12 Composite power unit (SR1) ............................................................................................................... 2-2
2.3.13 Drive unit............................................................................................................................................. 2-2
2.3.14 Operation panel and teach pendant...................................................................................................... 2-2
2.3.15 FDD..................................................................................................................................................... 2-2

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- 2-1 -
2.1 Parts layout of AR52 controller

Parts for AR52 are arranged as illustrated in Fig. 2.1 below.

CPU unit

Sequence board
(UM880)

6-axis drive unit

Position detector power unit


(SR2)

Power circuit unit Servo transformer

Fig. 2.1 Parts layout of AR52 controller

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2 Composition of AR52 Controller

2.2 Controllers block diagram

For AR52, the block diagram is shown in Fig. 2.2.1 & Fig. 2.2.2 and the function of each part is listed in Table
2.2.1.

Fig. 2.2.1 AR52 controller block diagram (UM883/UM884 specification)

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Fig. 2.2.2 AR52 controller block diagram (UM860 specification)

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2 Composition of AR52 Controller

Table 2.2.1 Functions of each part

No. Unit name Functions


1 Main CPU board (UM870) Microprocessor and its peripheral circuits
Teach pendant I/F
RS 232C I/F 1 port
CMOS-RAM : For user program save
: For robot constants save
FDC I/F
Digital cassette I/F
2 Flash ROM board (UM871) ROM for system program
IC card I/F
3 I/O board (UM803/UM080) I/O circuit for panel
I/O circuit for external interlock
4 Servo amp board (UM860) CPU for servo control
Robot type: SC series
Encoder I/F
Motion controller board CPU for servo control
(UM883/UM884) Encoder I/F
Robot type: SA,SG series
DSP for interpolation
calculation
5 Sequence board (UM880) Sequence circuit inside the panel
6 Board rack (UM895) System bus
Power supply
(Mother board is built in the board rack. 9 slots are in the board
rack and 1 slot among which is for power supply.)
7 Analog I/O board (UM820) Analog input-and-output circuit
8 RIO I/F board (UM858) Communicative circuit
9 I/O master (UM873) Input-and-output control of regulator
Serial communication (RS232C, RS422)
Built-in PC
10 AC I/O board (UM887/UM104) Input-and-output circuit of AC and DC
11 Power supply unit (FJK2005A) DC+5V (15A)
DC+15V (2.5A)
DC-15V (2.5A)
DC+12V (2.1A)
DC+24V (2A)
12 Drive unit (UM843) Power amp. Circuit for servo motor
Detection circuit for voltage drop & error
13 Drive unit (UM881) Power circuit for motor drive
14 Drive unit (UM886) Brake circuit
15 Operation panel Various operation switches
Status display lamps
16 Teach pendant (ROP501) Key SW matrix circuit
LCD
Data communication circuit
17 Power supply (SR01) DC+15V for ANALOG I/F Board
DC+5V for ANALOG I/F Board
DC-15Vfor ANALOG I/F Board
18 Power supply for position detector DC+5V power for position detector
19 Heat exchanger Cooling of panels inside the controller

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2.3 Functions of each unit

Functions of each unit are described below.

2.3.1 Main CPU board (UM870)


UM870 processes various data to control the movement of a manipulator and is provided with RS232C I/F, teach
pendant I/F, digital cassette I/F, ROM I/F and floppy disk I/F.

Connector
CNCRT
Connector for LCD display of the teach pendant
CNRS
Connector for general-purpose serial communication and the teach pendant
CNDCA
Connector for digital cassette I/F
CNFD
Connector for floppy disk I/F
CNP12
12V power connector for digital cassette I/F
CNBAT
Battery connector for CMOS memory backup
CNR
Connector with the flash ROM board UM871

LED
CPE
Lighting up when CPU stops (Red)
POW
Lighting on normally (Green)
LOWBAT
Lighting up when the battery voltage of CNBAT lowers. (Red)

Standard setting of jumper and DSW


J1: OPEN
J2: SHORT
J3: OPEN
J4: OPEN
J5: OPEN
J6: SHORT
J7: OPEN
J8: SHORT
J9: OPEN

DSW: No. 2 is ON and the rest of all are OFF.

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2 Composition of AR52 Controller

CNCRT
CNR

J1
CNRS J2
J3 CNBH
J4
J5
J8

DIPSW
POW
CPE J7
J9
LOWBAT
CNP12 J6

CNDCA
CNBL

CNFD
CNJ

CNBAT

Battery

Fig. 2.3.1 Main CPU board

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2.3.2 Flash ROM board (UM871)
UM871 is a flash ROM board for the system program, having I/F for IC card.

Connector
CNCARD
This is an I/F connector for IC card.
* Be careful about a slot in the IC card when inserted.
CNR
This is a connector with main CPU board UM870.

Standard setting of jumper


JP1: SHORT
JP2: OPEN
JP3: OPEN
JP4: OPEN

JJJJ
1P
P 2P
4P 3

C CNR
N
IC card C
A
R
D

Fig. 2.3.2 Flash ROM board

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2 Composition of AR52 Controller

2.3.3 I/O board (UM803/UM080)


UM803 is an I/O board to interlock between I/O used in the panel and external I/O.
UM080 is a board specific to output signal connectors and mounted on UM803.

Connector
CNIN1
Connector for input signal used in the panel
CNIN2, CNIN3
Connector for interlock input signal with external I/O
CNOT1
Connector for output signal used in the panel
CNOT2, CNOT3
Connector for interlock output signal with external I/O

(*) Refer to AR Controller Operation Manual for positions and connection of connector pins.

UM803
UM080
CNOT1
CNIN1
CNOT2
CNIN2
CNIN3
CNOT3

Fig. 2.3.4 I/O board

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2.3.4 Sequence board (UM880)
UM880 is provided with operation panel I/O, panel sequential circuit and so forth.

Connector
CNOP
Connector with the operation panel
CNEX
Connector for sequence in the panel
CNS
Connector with drive unit
CNSQ
Connector with I/O board UM803/UM080
CNTB
Connector for external emergency stop, safety plug and external motors ON
CNP
Connector to supply +24, +12 and +5V
CNA
Connector to input AC100V for sequence

LED
LED1
LED lights up when encoder power is turned ON. (Red)

Standard setting of jumper


JP1: SHORT
JP2: SHORT
JP3: OPEN
JP4: OPEN
JP5: SHORT
JP6: SHORT
JP7: Relay side
JP8: SHORT
CNA CNP

CNFV
JP8 CNTB
JP6
JP1
JP2

JP7
CNS
LED1
CNSQ
JP5
JP4
CNEX JP3

CNOP

Fig. 2.3.5 Sequence board

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2 Composition of AR52 Controller

2.3.5 Analog I/O board(UM820)


UM820 is an ANALOG I/O board.
Refer to the list below.

Specifications
No. of port 2 for input and 3 for output
Input -10V to +10V (4096 steps)
Output -12V to +12V (1024 steps)

Connector
CNEX Connector for analog output signal.
(MR16LF by HONDA TSUSHIN KOGYO CO. LTD. (attached at the time of delivery) is used.)

Pin No. Signal name Use


1 CH1 output Port 1
2 Common Port 1
3 CH2 output Port 2
4 Common Port 2
5 CH3 output Port 3
6 Common Port 3
7 Not used
8 Not used
CNIN Connector for analog input signal.
(MR16LF by HONDA TSUSHIN KOGYO CO. LTD. (attached at the time of delivery) is used.)
Pin No. Signal name Use
1 CH1 + input Port 1
2 CH1 input Port 1
3 Not used
4 Not used
5 CH2 + input Port 2
6 CH2 input Port 2
7 Not used
8 Not used
CNP Connector to input DC power for analog I/F.
Pin No. Signal name Use
1 PX15 +15V
2 PX5 +5V
3 MX0 0V
4 NX15 -15V
Solder the wiring to connectors using wires of A.W.G.24 or A.W.G.22.

9906,EARE-041-002
- 2-11 -
Board circuit

Power PX15 Board UM820


source
SR01 PX5 CNIN It refers to ta
AC100V ble of forwar
NX15 d page
CNEX
MX0

Power supply SR01 : COSEL RMC50-2


Fig. 2.3.6 Wiring of UM820 and SR01

Fig. 2.3.7 UM820

9906,EARE-041-002
- 2-12 -
2 Composition of AR52 Controller

Schematic I/O circuit of UM820

+15V

CH1 output

Common

-15V

Fig. 2.3.8 Output circuit

+5V +15V -15V


+15V


IH6208 CH1 + input

-15V
+15V

CH1 - input

-15V

Fig. 2.3.9 Input circuit

9906,EARE-041-002
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2.3.6 RIO I/F board(UM858)
This function is able to communicate discrete inputs and outputs directly via bus-line with "NA-Chi
p" which is manufactured by ALLEN BRADLEY.

Connector
TB-NA
Connector communicator with external equipment.

Connection of communication
To connect with RIO-Scanner or another robot controller, please use
twisted-pair shield wires 1770-CD (ALLEN BRADLEY) and connec
t it into terminal-block TB-NA on UM858.

There is no terminate register mounted on UM858, so please conne


ct ALLEN BRADLEY 1770-XT Terminator on the communication
wiring edge.
Communication Cable

Fig. 2.3.10 UM858

9906,EARE-041-002
- 2-14 -
2 Composition of AR52 Controller

DIP-SWITCHES SETTING on UM858

To set the Rack Address of this NA-Chip.(Octal)


DSW1
8 Rack Address 102 Each Rack Address is divided into 4 quarters. Here is setting
of the beginning quarter-rack boundary.
7 102
Bit 1 Bit 0 Starting Quarter
6 102
0 0 First (valid for all four rack sizes)
5 12
0 1 Second (only valid 1/4,1/2,3/4 racks)
4 12 1 0 Third (only valid 1/4,1/2 racks)
3 12 1 1 Fourth (only valid 1/4 rack size)
2 Starting Quarter 21
1 20 Set OFF when inputs from scanner should be cleared after reset
command is accepted in case that scanner is in PROG mode.
When set ON, they are held in their last states.
DSW2
8 Always set OFF After communication is faulted, when set ON communication i
7 Hold Last State s never re-started. But set OFF, communication is re-started.
6 Processor Rest Lockout
5 Data Rate 21 To set the RIO link communication rate.
4 20 Bit 1 Bit 0 Data Rate
3 Last Rack 0 0 57.6 kbits/second
0 1 115.2 kbits/second
2 Rack Size 21
1 X 230.4 kbits/second
1 20
Set ON when this includes the highest module group
To set the Rack Size of this NA-Chip.
Bit 1 Bit 0 Starting Quarter
0 0 1/4 Rack Size ( 32 I/O signals)
0 1 1/2 Rack Size ( 64 I/O signals)
1 0 3/4 Rack Size ( 96 I/O signals)
1 1 FULL Rack Size (128 I/O signals)

9906,EARE-041-002
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2.3.7 I/O master board (UM873)

UM873 is a I/0 control board of AR controller.


Besides, a serial communication (RS232C, RS422), special communication facility can be incor
porated.

Connector
(1) CNRS: Connector for general-purpose serial communication(RS232C)
(2) CNPT: Connector for general-purpose serial communication(RS422)
(3) CNIO: Not used
(4) CNBAT: Battery connector for CMOS memory backup
(5) CNCARD: An I/F connector for IC card
* Be careful about a slot in the IC card when inserted.

Dip switch setting


DSW1
Setting contents
ONInternal PC use OFFInternal PC no use
Always OFF
Always ON
Always OFF
Always OFF

Internal PC program is initialized by dip switch 1 Off at the time of power source on.
Please turn Internal PC use into ON.

9906,EARE-041-002
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2 Composition of AR52 Controller

Jumper setting
J1J25: RS422 setting
UM873-10 UM873-20
RS422 setting Without Half duplex
RS422 asynchronous
J2J7
J11J17
J1
J8
J9
J10
J18
J19
J20
J21
J22
J23
J24
J25
: short circuit : open
UM873-10 does not have RS422. By UM873-10, J1J25 is the open.

J101: serial interface CPU abnormality detection


Setting conditions Valid (standard) No valid
J101

J106: serial interface RS232C hardware handshaking selections (RTS/CTS)


Specification No valid PRG. saving (standard) Valid
J106

9906,EARE-041-002
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J107J109: serial interface
Setting Valid (standard) No valid
J107, J108, J109

LED
Contents
LED1 CPU error of UM873
LED2 Battery error of UM873
LED11 Serial interface error of UM873

fig.2.3.11 UM873

9906,EARE-041-002
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2 Composition of AR52 Controller

2.3.8 AC I/O board(UM887/UM104)


AC100AC120VInput-and-output boardis input-and-output board of type which it incl
udes in board rack of robot regulator. It has provided input and output of AC and DC. UM887, fi
lial board are UM104 in terms of baseboard of 2 sheets piling board. It usually calls it by nomen
clature of baseboard.
Connector
Refer to table 2.3.2 table 2.3.5.

Specification
No. Item Specification contents
Stand- Output mark AC100VAC120V32 points
ard set (1,2 DC24V 16 points(For system control of
UM board total) robot regulator usage)
887
1 AC100VAC120V32 points
2 Input mark DC24V 12 points
(1,2 +4 points (Fixed area for user
board total) outside stopping)
+24 points (For system control of
robot regulator usage)

Output specification AC100VAC120V


Electric current permission
2A/ Point of contact
8A/ Block type
(1 block type 8 points unit )
Oversight electric current
10mA Below
(At the time of AC200V)
Electrical potential difference
letdown at the time of ON
1.6Vrms Below
Acting time
1/2-stroke cycle of load power source
+ 1msec Below
Usage element SSR(There is solid state
relay zero cross function and)
DC24V Electric current permission
0.1A(Our company UM803,
UM837 and equality)

9906,EARE-041-002
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Setup
Setup of connector is like draft plan. rack and there is not question.

UM104 UM104

Fig.2.3.12 UM887-1,UM887-2

Set of jumper and set of terminal block key


UM887-1 is interchangeable by renewal of jumper between UM887-2.

Jumper setting table


J1 J2 J3
UM887-1
UM887-2

9906,EARE-041-002
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2 Composition of AR52 Controller

Table 2.3.1 Terminal block keyCord clip, Cord markSetting table


UM887-1
TBO1-1 TBO2-1 TBI1-1 TBI2-1
Plug Socket Plug Socket Plug Socket Plug Socket
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
8 8 8 8
CM CM CM CM

UM887-2
TBO1-2 TBO2-2 TBI1-2 TBI2-2
Plug Socket Plug Socket Plug Socket Plug Socket
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
8 8 8 8
CM CM CM CM

There is cord mark and


There is cord rebound and alignment clip and
It makes it nothing and Socket Cord clip
Cord mark

Plug

Fig.2.3.13 Terminal block key

9906,EARE-041-002
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Table 2.3.2
Built-in PC-1 Input-and-output terminal sequencing table-1 (UM887-1)

CNIN-1 (DC24V) TBI1-1 (AC120V)


Pin No. I/O name Pin No. I/O name
1 1 0000
2 2 0001
3 3 0002
4 4 0003
5 5 0004
6 6 0005
7 7 0006
8 8 0007
9 9 CIAC1-1 (com)
10
11
12
13 In system TBI2-1 (AC120V)
14 control of Pin No. I/O name
15 robot 1 0008
16 regulator 2 0009
17 usage 3 0010
18 4 0011
19 5 0012
20 6 0013
21 7 0014
22 8 0015
23 9 CIAC2-1 (com)
24
25
26
27
28
29
30
31
32
33
34

9906,EARE-041-002
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2 Composition of AR52 Controller

Table 2.3.3
Built-in PC-1 Input-and-output terminal sequencing table-2 (UM887-1)

CNOT1-1 (DC24V) TBO1-1 (AC120V)


Pin No. I/O name Pin No. I/O name
1 1 2208
2 2 2209
3 3 2210
4 4 2211
5 5 2212
6 6 2213
7 7 2214
8 In system c 8 2215
ontrol of
9 9 COAC1-1 (com)
robot
10
regulator
11
usage
12
13 TBO2-1 (AC120V)
14 Pin No. I/O name
15 1 1600
16 2 1601
17 3 1602
18 4 1603
19 5 1604
20 6 1605
21 7 1606
22 8 1607
23 9 COAC2-1 (com)
24
25

9906,EARE-041-002
- 2-23 -
Table 2.3.4
Built-in PC-2 Input-and-output terminal sequencing table-3 (UM887-2)

CNIN-1 (DC24V) TBI1-1 (AC120V)


Pin No. I/O name Pin No. I/O name
1 0600 1 0100
2 0601 2 0101
3 0602 3 0102
4 0603 4 0103
5 0604 5 0104
6 0605 6 0105
7 0606 7 0610
8 0607 8 0611
9 0700 9 CIAC1-2 (com)
10 0701
11 0702
12 Outside starting
13 Outside stopping
Outside running provi TBI2-1 (AC120V)
14
sion limit Pin No. I/O name
15 Safety plug 1 0608
16 0703 2 0609
17 Free 3 0106
18 Free 4 0107
19 Free 5 0612
20 Free 6 0613
21 Free 7 0614
22 Free 8 0615
23 Free 9 CIAC2-2 (com)
24 Free
25 Free
26 Free
27 P24 (com)
28 P24 (com)
29 CIDC1-2 Reserved
30 CIDC1-2 Reserved
31 CIDC1-2 Reserved
32 Free
33 Free
34 P24 (com)

9906,EARE-041-002
- 2-24 -
2 Composition of AR52 Controller

Table 2.3.5
Built-in PC-2 Input-and-output terminal sequencing table-4 (UM887-2)

CNOT1-1 (DC24V) TBO1-1 (AC120V)


Pin No. I/O name Pin No. I/O name
1 2108 1 1608
2 2109 2 1609
3 2110 3 1610
4 2111 4 1611
5 2112 5 1612
6 2113 6 1613
7 2114 7 1614
8 2115 8 1615
9 CODC1-2 (com) 9 COAC1-2 (com)
10 CODC1-2 (com)
11 2200
12 2201
13 2202 TBO2-1 (AC120V)
14 2203 Pin No. I/O name
15 2204 1 1700
16 2205 2 1701
17 2206 3 1702
18 2207 4 1703
19 CODC2-2 (com) 5 1704
20 CODC2-2 (com) 6 1705
21 Free 7 1706
22 Free 8 1707
23 Free 9 COAC2-2 (com)
24 Free
25 Free

9906,EARE-041-002
- 2-25 -
2.3.9 Servo amp board (UM860)
UM860 is a servo amp CPU board for 7 motor axes, and the servo amp block diagram is shown in Fig. 2.3.15.

Connector
CNEC
Connector to connect with encoder
CNBS
Connector to connect with drive unit

LED
LED1 Lighting when the master CPU1 is at CPU stop.
LED2 Lighting when the master CPU2 is at CPU stop.
LED3 Lighting when No.1 axis CPU is at CPU stop.
LED4 Lighting when No.2 axis CPU is at CPU stop.
LED5 Lighting when No.3 axis CPU is at CPU stop.
LED6 Lighting when No.4 axis CPU is at CPU stop.
LED7 Lighting when No.5 axis CPU is at CPU stop.
LED8 Lighting when No.6 axis CPU is at CPU stop.
LED9 Lighting when No.7 axis CPU is at CPU stop.

Setting standard of jumper

J1: OPEN
J2: SHORT

#1 #2
J9: SHORT OPEN
J10: SHORT OPEN
J11: OPEN SHORT
No.6 No.7
J12: OPEN SHORT To drive unit axis axis

No. of control axis


No.5 No.3
axis axis
J3:
J4:
J7: No.4 No.2
To manipulator axis axis
J8:
(: SHORT : OPEN)
Master No.1
J5: OPEN 2 axis
J6: SHORT
To manipulator
Master
1

Fig. 2.3.14 Servo amp board

9906,EARE-041-002
- 2-26 -
2 Composition of AR52 Controller

UM860 Drive unit

Position
command Servo Current amp. Gate
Motor
PWM control drive

Current feedback

Encoder
A-phase, B-phase
Encoder signal

I/F Serial signal

Fig. 2.3.15 Servo amp block diagram

9906,EARE-041-002
- 2-27 -
2.3.10 Motion controller board (UM883/UM884)
UM883 is a servo amp CPU board for 6 motor axes.
UM884 is a DSP board for interpolation operation and mounted on UM883.
UM883 and UM884 together are referred to as a motion controller board.
The motion controller block diagram is illustrated in Fig. 2.3.17.

Connector (UM883)
CNEC
Connector to connect with the encoder.
CNBS
Connector to connect with the drive unit.
CNDSP1
Connector to connect with the DSP board UM884 for interpolation operation.
CNDSP2
Connector to connect with the board UM885 for added axes (No. 7 and 8 axes).

Connector (UM884)
CNDSP1
Connector to connect with the servo amp CPU board UM883.

LED (UM883)
LED1 Lighting up when No.1 axis CPU is at CPU stop.
LED2 Lighting up when No.2 axis CPU is at CPU stop.
LED3 Lighting up when No.3 axis CPU is at CPU stop.
LED4 Lighting up when No.4 axis CPU is at CPU stop.
LED5 Lighting up when No.5 axis CPU is at CPU stop.
LED6 Lighting up when No.6 axis CPU is at CPU stop.

Standard setting of jumper (UM883)


J6 UM883
J6: SHORT
To drive unit
#1 #2
J7: SHORT OPEN CNDSP2
J8: OPEN SHORT

CT4
CT3
Standard setting of jumper (UM884) CT2 J8
To manipulator J7
No. of control axis CNEC1 UM884

J1: LED6 J1
CT1 J2
J2: M0
LED1
J3
J3: To manipulator
(: SHORT : OPEN) CNEC2
CNDSP1

Fig. 2.3.16 Motion controller board

9906,EARE-041-002
- 2-28 -
2 Composition of AR52 Controller

Motion controller Drive unit

Target
data Creating locus Servo Current amp. Gate
Motor
Accel. control loop PWM control drive

UM884 Current feedback


Position
command Encoder
A-phase, B-phase
signal
Encoder
I/F Serial signal

UM883

Fig. 2.3.17 Motion controller block diagram

9906,EARE-041-002
- 2-29 -
2.3.11 Board rack
There are 12 slots in the board rack, one slot among which is exclusively used for composite power SR1, and
other 11 slots are all the same in signal pin layout and thus boards can be operated whichever slot the board is put
in.
However, do not change the slot in which the board is inserted from the status of delivery because there may
invite poor wiring connection.

2.3.12 Composite power unit (SR1)


A composite power unit (SR1) is a composite power used exclusively for AR board rack.
Power can be fed from 2 96-pin DIN connectors located at the back (connector name: CNBL, CNBH) and a
terminal board located at the front.

Terminal name Signal name


G1 M0
+12V P12
G1 M0
-15V N15
+15V P15
+5V P5
+24V P1
+24V P1
G2 M2
G2 M2
AC100 B4
AC100 C4
FG G

Fig. 2.3.18 Board rack and composite power unit

9906,EARE-041-002
- 2-30 -
2 Composition of AR52 Controller

2.3.13 Drive unit


Drive unit consists of motor drive power circuit for 6 axes, gate drive circuit, IGBT, current detector and brake
circuit. Three boards are provided; board UM881 as motor drive power circuit and IGBT and board UM843 as
gate drive circuit and board UM886 as brake circuit.
And UM 843 includes voltage drop detection circuit, over-voltage detection circuit and regenerative discharge
circuit.

Connector
CNBS1, CNBS2
Connector with servo amp board UM860 or motion controller board UM883/UM884
CNV
Connector with sequence board UM880
CNP1 (No. 1 axis) to CNP6 (No. 6 axis)
Connector to feed power to motors
CNRST
Connector to feed power to drive unit
CNPRB
Connector for drive unit power control
CNR
Connector for regenerative discharge resistor
CNPB
Connector for brake power feeding
CNSR
Connector with sequence board UM880
CNBK1
Connector for brake

LED
Refer to Fig. 2.3.20.

Brake release switch (UM886)


SW1 (for No.1 axis) ~ SW8 (for No.8 axis)
(No.7 and No.8 axes can be operated in case of the servo axis added specification.)
These are switches to manually release motor built-in brakes, and the brake can be released for each axis.
Operate the switches with controller power ON.

Use care that the arms may fall when the brake release switch is operated.
DANGER
Regenerative
discharge resistor

UM881
Drive unit varies with a robot Current
and hence make sure of the type detector
3-phase, 200V Motor
indicated on the right side of a
drive unit when replacing.
Brake

Error signal Ov ervo ltag e Reg en er ativ e


to UM880 detectio n d is ch ar g e Gate drive
cir cuit cir cu it

Error signal to Vo ltag e dro p


UM860 or UM883 detectio n
PWM signal from cir cuit
UM843
UM860 or UM883
To UM860 or UM883
Brake signal
Brake circuit
from UM880
UM886

Fig. 2.3.19 Drive unit block diagram


9906,EARE-041-002
- 2-31 -
LED
SB Lighting up when PWM is ON (Yellow)
VE Going out when voltage drops. (Green)
POW Lighting up with power ON (Yellow)
DR Lighting up during regenerative discharge (Red)
AL Lighting up when alarm occurs. (Red)

Over-voltage error occurs.


Thermos-sensor of the heat sink activates. To and after RAX**B
Regenerative discharge GTR output is shorted and
regenerative resistor is left discharged for a certain
period or more (about 30 ms).

Fig. 2.3.20 Front view of drive unit

History of drive unit versions (All are compatible with each other.)
RAX**
RAX**A Three-phases of pre-charge circuit Compatibility with controller
1997.3~ drive units for overseas
RAX**B Overheat detection function added Function shown the left added.
1997.5~ to drive unit
RAX**C Inner power wiring route changed Function remains unchanged.
1997.6~

9906,EARE-041-002
- 2-32 -
2 Composition of AR52 Controller

2.3.14 Operation panel and teach pendant


Operation panel consists of mode keys, various button switches, emergency stop button.
Teach pendant is a device to operate the manipulator and input data. Inside the teach pendant are a
communication board with the control panel (UM862), an LCD and a SW panel.

Jumper setting of the board UM862 is shown below:

Standard setting of jumper

J1: OPEN
J2: OPEN
J3: OPEN
J4: OPEN (For effective to save LCD energy)
J5: SHORT
J6: SHORT
J7: SHORT
J8: OPEN
J9: SHORT
J10: SHORT
J11: OPEN
J12: SHORT

AR52 controller Operation panel Teach pendant

LCD

Mode select SW UM862


UM870

UM880 Press button SW SW

Emergency stop SW Emergency stop SW

Transformer T11 Breaker Main power

RS232C connector

Fig. 2.3.21 Operation panel, teach pendant connection diagram

9906,EARE-041-002
- 2-33 -
2.3.15 FDD
FDD of AR52 controller has functions following that recording and saving of programs and constant files.

FDD standard setting


1.44MB.

FDD jumper setting

Terminal name Jumper Note


IF Open
Selection for
T1 Open
disk format
T2 Open
H2 Open Selection for signal of
H4 Open High density
DC Open Selection for
DC2 Open signal of Ready,
RY Short disk change
DS0 Short Selection for
DS1 Open Drive No.

Diagram of jumper location


T1
YD-702D-6539D

YD-702D-6639D

T2 DS0

DS1
RY

DC IF

DC2

H4
H2

Short Open

9906,EARE-041-002
- 2-34 -
2 Composition of AR52 Controller

FDD

Fig. 2.3.22 Location of FDD

9906,EARE-041-002
- 2-35 -
3 Troubleshooting

3 Troubleshooting
The AR52 controller was designed placing greatest emphasis on high precision and reliability, and that troubleshooting
and recovery can be easily made when error occurs. Please read and understand this manual thoroughly so that it can be
used to perform efficient troubleshooting.

3 Troubleshooting .........................................................................................................................................................3-1
3.1 Examples of troubleshooting...............................................................................................................................3-3
3.1.1 Ex. 1 Some axes immovable. (Manually immovable)..........................................................................3-3
3.1.2 Ex. 2 Display of teach pendant improper or its keys not effective.
(In case of replacing the board UM862 in the teach pendant, for example) ..................................3-4
3.1.3 Ex. 3 Displacement between recording point and playback point........................................................3-5
3.1.4 Ex. 4 Displacement occurred.
(Despite proper functioning up to a certain time, a playback position
displaces as time passes.) ......................................................................................................................3-6
3.1.5 Ex. 5 Not displayed even primary power breaker is turned ON...........................................................3-7
3.1.6 E02 Program check-sum fault. .............................................................................................................3-8
3.1.7 E10 Servo units are not ready. Turn off and turn on again...................................................................3-9
3.1.8 E12 Accuracy not matched.................................................................................................................3-10
3.1.9 E13 Servo error: No speed command.................................................................................................3-11
3.1.10 E20 Servo error: Abnormal change in command data........................................................................3-12
3.1.11 E21 Servo error: Servo following error..............................................................................................3-13
3.1.12 E22 Servo error: Deviation error........................................................................................................3-14
3.1.13 E23 Servo error: Encoder cable broken.
E25 Servo error: Bit jump.
E27 Servo error: Encoder data changed too mach. ............................................................................3-15
3.1.14 E24 Servo error: CPU error................................................................................................................3-16
3.1.15 E26 Servo error: Interference .............................................................................................................3-17
3.1.16 E28 Servo error: Drive unit voltage down..........................................................................................3-18
3.1.17 E29 Servo error: Check sum error in encoder. ...................................................................................3-19
3.1.18 E30 Servo error: Sensor check error. .................................................................................................3-20
3.1.19 E31 Servo error: Motors rotation too fast when power on................................................................3-21
3.1.20 E32 Servo error: Over-current............................................................................................................3-22
3.1.21 E34 The amplifier unit returns no answer. .........................................................................................3-23
3.1.22 E35 I/O CPU error..............................................................................................................................3-24
3.1.23 E36 Servo error: Fuse blown..............................................................................................................3-25
3.1.24 E38 Servo error: Over-load ................................................................................................................3-26
3.1.25 E39 Servo error: Over-rotation...........................................................................................................3-27
3.1.26 E40 The teach pendants CPU error...................................................................................................3-28
3.1.27 E42 Motor temperature fault. .............................................................................................................3-29
3.1.28 E44 Over-voltage found in drive unit, or heat sink exceeded temp. limit. .........................................3-30
3.1.29 E46 The discharge resistance exceeded temperature limit. ................................................................3-31
3.1.30 E50 Servo error: CTR-OVF.
E51 Servo error: Data transmission error. .........................................................................................3-32
3.1.31 E52 Servo error: Battery discharged. ................................................................................................3-33
3.1.32 E54 Servo error: Position deviation. .................................................................................................3-34
3.1.33 E55 Servo error: Encoder data abnormal. .........................................................................................3-35
3.1.34 E56 Servo error: Pre-load error. ........................................................................................................3-36
3.1.35 E57 Servo error: Count status error...................................................................................................3-37
3.1.36 E60 Controller temperature fault........................................................................................................3-38
3.1.37 E61 Thermal relay or circuit protector tripped. ..................................................................................3-39
3.1.38 E62 MOTORS-ON sequence fault. ....................................................................................................3-40
3.1.39 E66 Arm interference limit switch was activated...............................................................................3-41
3.1.40 E67 The I/O master returns no answer. ..............................................................................................3-42

3-1 9906,EARE-041-002
3.1.41 E256 Step data reading fault. ............................................................................................................. 3-43
3.1.42 E896 Hardware version of amp. card is not correct. .......................................................................... 3-44
3.1.43 E8001 Motors-off sequence fault.
E8002 Input sequence fault.
E8007 System error(memory full). .................................................................................................... 3-45
3.1.44 E8004 Brake sequence fault............................................................................................................... 3-46

3-2 9906,EARE-0041-002
3 Troubleshooting

3.1 Examples of troubleshooting

3.1.1 Ex. 1 Some axes immovable. (Manually immovable)

Does MOTORS ON turn OFF and


Yes Refer to troubleshooting of
error occur shortly after pressing an
error code displayed.
axis operation SW on teach pendant?

No
Service(PF1)MonitorEach axis data 1
Monitor axis data using
monitor function. Refer to AR Controller Operation Manual for
details.

Does the command position Motion control board UM883/ UM884


Yes (or Servo amp board UM860) may be
change when pressing an axis
operation SW on teach pendant? defective. Replace it.

No

Teach pendant may be defective.


Replace it.

UM883/UM884 or UM860

Controller front view

3-3 9906,EARE-041-002
3.1.2 Ex. 2 Display of teach pendant improper or its keys not effective.
(After replacing board UM862 in the teach pendant, for example)

Are jumper settings of Correct jumper settings by


No
PCB UM862 inside the referring to 2.3.14.
teach pendant correct?

Yes

Are connectors CNCRT, CNRS Yes Tighten the connections.


on CPU PCB UM870 loose?

No

Teach pendant may be defective.


Replace it.

UM870

Controller front view

3-4 9906,EARE-0041-002
3 Troubleshooting

3.1.3 Ex. 3 Discrepancy between recorded point and actual playback point.

Does displacement disappear when Yes Accuracy setting is probably excessive.


timer is put into recording point? Review accuracy settings.

No

Does displacement occur when Play may exist in mechanism or


Yes
play-backed in reverse of encoder. Check it/them.
recorded direction?

No

Contact NACHI service department.

3-5 9906,EARE-041-002
3.1.4 Ex. 4 Position displacement. (Despite initial error free playback,
actual playback position displaces as time passes.)

Check positions of fixture/work, installed


conditions of robot base & play in robot
mechanism. Work deformation from a Yes Correct the play.
previous process is likely to appear as a
position displacement.
Any play the in mechanisms?

No

Check if deformation, displacement or


Yes Correct abnormality, if any.
play exists due to interference of hand,
gun or bracket. Anything abnormal?

No

Correct encoder reference using the


Is the reference position of No correction function in Constant setting
encoders correct? mode as in AR Operation Manual.

Yes Refer to Operation Manual.

Correct program and wait. Contact


NACHI service department.

3-6 9906,EARE-0041-002
3 Troubleshooting

3.1.5 Ex. 5 Nothing displayed when primary power breaker is turned ON.

Primary power line of control transformer


Yes T11 or secondary power line of T11
Is the circuit protector CP7 tripped?
shorted. Replace the power circuit unit.

No

Controller power lines B4-C4 or B5-C5


Are fuses F1 or F2 in power Yes shorted or equipment using this power (e.g.
supply unit blown? fan, heat exchanger, drive unit, switching
regulator, UM880) defective.

No

Contact NACHI service department. Correct short and/or replace defective


equipment.

CP7

F1 & F2

Power supply unit


Controller front view Power supply unit front view

3-7 9906,EARE-041-002
3.1.6 E02 Program check-sum fault.

Is battery of CPU PCB UM870 No


E02 occurred connected properly?

Yes
Properly connect the battery, then format
the memory.

Format the memory, then turn


Yes
controller ON again.
Did this cancel the error?

No

Replace UM870, then format the


memory. Yes
Did this cancel the error?

No

The battery for memory may be dead.


Replace it, then format the memory.

Load the back-up programs &


constant files.
UM870 UM870

Battery connector Battery connector


CNBAT CNBAT

3-8 9906,EARE-0041-002
3 Troubleshooting

3.1.7 E10 Servo units were not ready. Turn controller off then on again.

This error occurs when the servo amp. board is not properly prepared when po
E10 occurred wer is turned ON.

Turn controller power ON again. No


Does an error occur?

Yes

Rectify the error according to message


or by troubleshooting, then turn power
OFF then ON again.

Turn motors ON. No End


Does an error occur?

Yes

Motion control PCB UM883/UM884


(or servo amp PCB UM860) may be
defective. Replace it.
UM883/UM884 or UM860

Controller front view

3-9 9906,EARE-041-002
3.1.8 E12 Accuracy not matched.

Does the robot interfere Yes Remove the obstruction.


E12 occurred with a fixture? Or alter robot (program) locus.

No

Did this error occur after Yes Check the controller was formatted with
formatting?
the correct robot type.

No

Is supply voltage of switching regulator Adjust the switching regulator SR2 volume pot on the
SR2 for encoder power correct? No power supply unit to the correct value.
(Refer to Robot Manipulator If it cant be adjusted then replace SR2.
Maintenance manual)

Yes

Is encoder wiring OK? No Correct faulty wiring.

Yes

Contact NACHI service department..

SR2

Power supply unit


Controller front view Power supply unit front view

3-10 9906,EARE-0041-002
3 Troubleshooting

3.1.9 E13 Servo error: No speed command.

Is supply voltage of encoder


(SR2) OK? Adjust the switching regulator SR2
No
E13 occurred (Refer to Robot Manipulator volume pot on the power supply unit to
Maintenance manual.) the correct value.
If it cant be adjusted then replace SR2.
Yes

Is encoder wiring OK? Yes Correct faulty wiring.

No

Contact NACHI service department.

SR2

Power supply unit


Controller front view Power supply unit front view

3-11 9906,EARE-041-002
3.1.10 E20 Servo error: Abnormal change in command data.

Replace the CPU PCB UM870. Yes


E20 occurred Does this rectify the error? End

No

Replace motion control PCB UM883/ 884 (or


servo amp PCB UM860). Yes
End
Does this rectify the error?

No

Contact NACHI service department.

UM870

Controller front view

3-12 9906,EARE-0041-002
3 Troubleshooting

3.1.11 E21 Servo error: Servo following error.

Has the robot collided


No with Yes Remove the obstruction.
E21 occurred anything? Or alter robot (program) locus.

No

Move the robot manually


No
(teach mode). Yes Restart the controller.
Does the robot move?

No

Does robot move when using the brake


Yes The motor power system is abnormal.
release switch? USE CAUTION
Correct it! (motor, drive unit, sequence
ROBOT ARM DROPS!
PCB UM880)

No

The brake system is abnormal.


Correct it!
(drive unit, power supply unit(PB,MB
voltage), sequence PCB UM880, motor,
manipulator)

UM880

Drive unit

Power supply unit


Controller front view

3-13 9906,EARE-041-002
3.1.12 E22 Servo error: Deviation error

Does robot interfere Remove the obstruction.


E22 occurred Yes
with anything (fixture, Or alter robot (program) locus.
work-piece)?

No

Does the tool load exceed rating? Yes Reduce load to within rating.

No

Contact NACHI service department.

3-14 9906,EARE-0041-002
3 Troubleshooting

3.1.13 E23 Servo error: Encoder cable broken.


E25 Servo error: Bit jump.
E27 Servo error: Encoder data changed too mach.

Is wiring of connector CNEC on


E23, 25, 27 motion control PCB UM883/ No Correct faulty wiring.
occurred 884 (or servo amp PCB UM860)
OK?

Yes

Is wiring to wire-harness & No Correct faulty wiring.


encoder OK?

Yes

Is encoder power voltage Adjust the switching regulator SR2


No volume pot on the panel to the correct
between P5E and M5E within
DC5.10.1V? reference value. (See Note)

Yes
Refer to Robot Manipulator
UM883/UM884 (or UM860) or encoder Maintenance service manual.
may be defective. Replace it/them.

Note) Adjust the switching regulator SR2


from the front of power supply unit.

UM883/UM884 or UM860

SR2

Power supply unit


Controller front view Power supply unit front view

3-15 9906,EARE-041-002
3.1.14 E24 Servo error: CPU error

Replace the motion control PCB


E24 occurred UM883/UM884 (or servo amp PCB Yes End
UM860). Problem rectified?

No

Contact NACHI service department.

UM883/UM884 or UM860

Controller front view

3-16 9906,EARE-0041-002
3 Troubleshooting

3.1.15 E26 Servo error: Interference

Has the robot collided with Yes Remove the obstruction.


E26 occurred anything? Or alter robot (program)locus.

No

Is the load (hand, gun, etc.) within


No Reduce load to within rating.
rating specified in the Robot
Manipulator Maintenance manual?

Yes

The weight of the tool, tool center of gravity


position and interference detection levels
arent compatible.
Re-set the interference detection level.

Does the error still occur? No


End

Yes

The robot is assumed to have a problem.

3-17 9906,EARE-041-002
3.1.16 E28 Servo error: Drive unit voltage down.

Is the primary voltage within No


E28 occurred 10% of rating?
Increase/decrease supply power to within rating.

Yes

Is the switching regulator SR1 No 100V AC line may be defective.


primary voltage within 10% of Repair it or change the power supply unit.
100V AC?

Yes

Is the voltage at power supply


unit connector CNAC4 No Replace the power supply unit.
(1)-(2),(3)-(4) within 10% of 18V

Yes

Is connector CNBS of motion control PCB


UM883/UM884 (or servo amp PCB Yes Ensure good connection.
UM860) or connector CNBS of drive unit UM883/UM884
loose? or UM860

No
SR1

Is wiring between connector CNBS of


UM883/UM884 (or UM860) and connector No Correct faulty wiring..
CNBS on drive unit OK.

Yes
Drive unit
UM883/UM884 (or UM860) may be
defective.
Yes

Power supply unit


Replace UM883/UM884 (or PCB UM860). Yes End
Is the problem rectified?

No Controller front view


The drive unit may be defective. CNAC4
Replace it. SR2

Power supply unit front view

3-18 9906,EARE-0041-002
3 Troubleshooting

3.1.17 E29 Servo error: Check sum error in encoder.

Is the switching regulator SR2 voltage No Adjust the SR2 voltage on power supply unit.
E29 occurred within rating? If it cant be adjusted, replace it.

Yes

Is the encoder wiring OK? No Correct faulty wiring.

No

It is possible that encoder reset is not complete.


Reset the encoder.

Did this rectify the error? Yes End

No

The encoder may be defective.


Replace the encoder.

Did this rectify the error? Yes


End

No

Contact NACHI service department.

SR2
Power supply unit

Power supply unit front view Controller front view

3-19 9906,EARE-041-002
3.1.18 E30 Servo error: Sensor check error.

Is the switching regulator SR2 voltage No Adjust the SR2 voltage on power supply unit.
E30 occurred If it cant be adjusted, replace it.
within rating?

Yes

Is encoder wiring OK? No Correct faulty wiring.

No

The encoder may be defective.


Replace the encoder.

Did this rectify the error? Yes


End

No

Contact NACHI service department.

SR2

Power supply unit


Controller front view Power supply unit front view

3-20 9906,EARE-0041-002
3 Troubleshooting

3.1.19 E31 Servo error: Motor rotation too fast when power on.

Is the switching regulator SR2 voltage No Adjust the SR2 voltage on power supply unit.
E31 occurred If it cant be adjusted, replace power supply unit.
within rating?

Yes

Is encoder wiring OK? No Correct faulty wiring.

No

The encoder may be defective.


Replace the encoder.

Did this rectify the error? Yes End

No

Contact NACHI service department.

SR2

Power supply unit


Controller front view Power supply unit front view

3-21 9906,EARE-041-002
3.1.20 E32 Servo error: Over-current

Turn Primary power OFF.


E32 occurred Remove connector CNP1-6 & CNR
of the drive unit.
Check 3 wire strand U,V & W

Is connector short-circuited
between U-V, V-W or W-U? Remove motor Canon plug. No
Yes
Or is CNR pin P, DR & U, V, W Are any pins on motor
short-circuited? connector short-circuited?

No Yes

Replace the motor. Replace the cable.

Is cable between the drive unit and motion


control PCB UM883/ UM884 (or servo amp
PCB UM860) OK? Connector CNBS No Replace the cable.
Between 5A pins (Detect. signal common)
Between 6A pins (No. 1 axis detect. signal)
Between 6B pins (No. 2 axis detect. signal)
Between 7A pins (No. 3 axis detect. signal)

If the cable or motor is defective, the drive unit


Yes might be damaged. Replace the drive unit if E36
occurs again when in MOTORS ON status.
Replace the drive unit and PCB
UM883/UM884 (or UM860).

UM883/UM884 or UM860

Drive unit

Controller front view

3-22 9906,EARE-0041-002
3 Troubleshooting

3.1.21 E34 The amplifier unit returns no answer.

Is the motion control PCB UM883/UM884 No


E34 occurred (or servo amp PCB UM860) connected
Rectify faulty connection.
correctly?

Yes

Are PCB jumpers on PCB No


correct? Set jumpers correctly.
(If just installed)

Yes

UM883/UM884 (or UM860) may be


defective. Replace it.

UM883/UM884 or UM860

Controller front view

3-23 9906,EARE-041-002
3.1.22 E35 I/O CPU error.

Is the CPU chip on I/O master PCB UM873 No Push CPU chip into the socket of
E35 occurred inserted correctly into the socket? the I/O master PCB UM873.

Yes

I/O master board UM873 may be Yes


defective. Change it. End
Did this rectify problem?

No

Contact NACHI service department.

UM873

Controller front view

3-24 9906,EARE-0041-002
3 Troubleshooting

3.1.23 E36 Servo error: Fuse blown.

Turn primary power OFF.


E36 occurred Remove connectors CNP1-6 & CNR
from the drive unit.
Check 3 wire strand U,V & W

Is connector short-circuited
between U-V, V-W or W-U? Yes Remove motor Canon plug. No
Or is CNR pin P, DR & U, V, W Are any pins on motor
short-circuited? connector short-circuited?

No Yes

Replace the motor. Replace the cable.

Is cable between the drive unit and motion


control PCB UM883/ UM884 (or servo amp
PCB UM860) OK? Connector CNBS Yes Replace the cable.
Between 5A pins (Detect. signal common)
Between 6A pins (No. 1 axis detect. signal)
Between 6B pins (No. 2 axis detect. signal)
Between 7A pins (No. 3 axis detect. signal)

If the cable or motor are defective, the drive unit


No might be damaged. Replace the drive unit if E36
occurs again when in MOTORS ON status.
Replace the drive unit and UM883/UM884 (or
UM860).

UM883/UM884 or UM860

Drive unit

Controller front view

3-25 9906,EARE-041-002
3.1.24 E38 Servo error: Over-load

E38 occurred Press MOTORS ON button.

Drive unit or motion control PCB


Does MOTORS ON function ? No UM883/UM884 (or servo amp PCB
UM860) might be defective. Replace it.
Yes

Is the load (hand, gun, etc.) within rating


specified in Robot Manipulator No Reduce load to be within rating.
Maintenance manual within Rating?

Yes

Check if bearings or reduction gear, etc.


Can noise be heard when Yes are seized.
manually operating robot? Replace any damaged parts.

No

In MOTORS OFF state, can the Drive unit or motion control PCB
Yes UM883/UM884 (or servo amp PCB
brake be released using the brake
release SW on the drive unit? UM860) might be defective. Replace it.

No Note) CAUTION!! robot arm may


fall when brake is released.
Measure voltage between PB & MB
of CNPB1 on power supply unit.

No Check wiring of rectification


More than 24V? stack REC1.

Yes

Remove canon plug on motor in error. No Check wiring to


24V or more with brake release SW ON? the motor.

Yes

Motor is defective.
Replace it.

3-26 9906,EARE-0041-002
3 Troubleshooting

3.1.25 E39 Servo error: Over-rotation.

E39 occurred Press MOTORS ON button.

Drive unit or motion control PCB


No UM883/UM884 (or servo amp PCB
Does MOTORS ON function?
UM860) might be defective. Replace it.
Yes

Does error occur even when No Decrease playback


playback speed is decreased? speed.

Yes

Is load within rating? No Reduce load to


within rating.

Yes

Contact NACHI service department.

UM883/UM884 or UM860

Drive unit

Controller front view

3-27 9906,EARE-041-002
3.1.26 E40 Teach pendant CPU error.

Teach pendant may be defective.


E40 occurred Replace it Yes End
Did this rectify problem?

No

Contact NACHI service department.

3-28 9906,EARE-0041-002
3 Troubleshooting

3.1.27 E42 Motor temperature fault.

No
E42 occurred Is wiring to thermostat of motor OK? Replace wiring.

Yes

Does error occur even Decrease the robot


No
when playback speed is speed.
decreased?

Yes

Is load (hand, gun, etc.) within rating Decrease load to


No
specified by Robot Manipulator within rating.
Maintenance manual?

Yes

Yes Check if bearings or reduction gear, etc.


Can noise be heard when
are seized.
manually operating robot?
Replace any damaged parts.

No

In MOTORS OFF state, can the Drive unit or motion control PCB
Yes
brake be released using the UM883/UM884 (or servo amp PCB
brake release SW on the drive UM860) might be defective. Replace it.

No Note) CAUTION!! robot arm may


fall when brake is released.
Measure voltage between PB & MB
of CNPB1 on power supply unit.

No

No Check wiring of rectification


More than 24V? stack REC1.

Yes

Remove canon plug on motor in error. 24V No Check wiring to


or more with brake release SW ON? the motor.

Yes

Motor is defective.
Replace it.

If replacing the motor does not rectify problem.

Contact NACHI service department.

3-29 9906,EARE-041-002
3.1.28 E44 Over-voltage found in drive unit, or heat sink exceeded temp. limit.

Is primary power voltage No


E44 occurred Increase/decrease power to be within rating.
within 10% of rating?

Yes

Does over-voltage occur when the Yes


robot comes to a sudden stop?

No Drive unit may be


Is resistance between pins (1) and (2)
Yes defective. Replace
on PCB wiring side of drive unit
connector CNR 7.5? it.

No

Are there any defects in wiring from the drive


Yes Repair faulty wiring.
unit connector CNR to regenerative
discharge resistor DSR10?

No

The regenerative discharge resistor DSR10 and


/or drive unit may be defective. Replace it/them.

Is wiring from drive unit to No Repair faulty wiring.


UM880 OK?

Yes

Can noise be heard when Yes Locate and rectify noise problem.
manually operating robot?

No
Regenerative
Drive unit might be defective. discharge resistor
Replace it.
DSR10

UM880

Controller front view Controller rear view

3-30 9906,EARE-0041-002
3 Troubleshooting

3.1.29 E46 The discharge resistance exceeded temperature limit.

Does error disappear when Check wiring to thermostat attached


Yes
E46 occurred drive unit connector CNR to regenerative discharge resistor.
3-1 pins are shorted?

No

Are fans in the rear panel No Fan motor is defective.


rotating? Replace it.

Yes

Does a gap of 20cm or more exist No Increase gap to over 20mm.


at rear of controller?

Yes

Is primary power voltage less No Increase the power voltage to within


than 10% of specified voltage? 10% of specified voltage.

Yes

Does error occur even when No


playback speed is decreased? Decrease the playback speed.

Yes

Contact NACHI service department..

Regenerative
discharge resistor Power supply unit
DSR10

Controller rear view Power supply unit front view

3-31 9906,EARE-041-002
3.1.30 E50 Servo error: CTR-OVF.
E51 Servo error: Data transmission error.

Refer to Robot Manipulator


Maintenance service manual.

E50 occurred Yes


Is encoder power SR2 voltage 0V?
E51 occurred
It is possible wiring is faulty.
No Investigate and repair encoder
Remove wiring from SR2 output. Yes power supply line (P5E,M5E).
Does SR2 output have voltage?

No
No Is encoder power SR2
voltage correct?

Adjust the SR2 voltage.


Yes
No Check and correct B6-C6
Is the primary voltage of SR2 100V? (100V) line.

Is the connector CNEC1, CNEC2 of motion Yes


No control PCB UM883/UM884 (or servo
amp. PCB UM860) well connected?

Rectify poor connection . Replace SR2.


Yes

Is the wire-harness and robot No Replace faulty wire-harness or robot wiring.


wiring OK?

Yes

Swap encoder cannon plug of the axis in


error with another axis and turn on
controller power.

Does the axis in error change? Yes The encoder may be defective.
Replace the motor.

UM883/UM884 or UM860
No

UM883/UM884 (or UM860) might be


defective. Replace it.

SR2

Power supply unit

Controller front view Power supply unit front view

3-32 9906,EARE-0041-002
3 Troubleshooting

3.1.31 E52 Servo error: Battery discharged.

With controller power ON, replace encoder battery.


Zero encoders. Refer to Robot Manipulator
Maintenance service manual.
E52 occurred

Perform encoder correction. Refer to AR controller


operation manual.

Turn controller power OFF then ON again. Yes End


Did this rectify problem?

No

Reconfirm battery voltage. No Replace battery again and perform encoder reset
Is voltage 3.2 - 3.6V? once more.

Yes

Is wiring between the battery No Repair faulty robot wiring.


and the motor OK?

Yes

Exchange the motion control UM883/UM884 or UM860


PCB UM883/UM884 (or servo Yes End
amp PCB UM860).
Did this rectify problem?

No

Encoder may be defective.


Exchange motor.

Controller front view

3-33 9906,EARE-041-002
3.1.32 E54 Servo error: Position deviation.

No
E54 occurred Is there voltage at SR2output P5E-M5E?

Yes It is possible wiring is faulty.


Is there voltage at SR2 output after Yes Repair faulty wiring.
removing wiring from SR2output?

No
No Is the output voltage 5.2 - 5.4 V?

Adjust the SR2volume pot.


Yes
Are 100 V AC supplied to No Check a 100 V system.
SR2?

Are jumper settings on motion control PCB Yes


No UM883/UM884 (or servo amp PCB
UM860) correct?
(When exchanging PCB.)
Set correct jumper settings. Exchange SR2.
Yes

Is the wire harness and No Replace wire harness or robot wiring.


robot wiring OK?

Yes

Swap encoder cannon plug of the axis


in error with another axis and turn on
controller power.
Yes

Yes The encoder may be defective.


Does the axis in error change?
Replace the motor.

No

UM883/UM884 (or UM860) might be defective.


Replace it.

If replacing the PCB does not rectify problem.

Contact NACHI service department.

3-34 9906,EARE-0041-002
3 Troubleshooting

3.1.33 E55 Servo error: Encoder data abnormal.

It is possible the motor was moving at high


speed during power failure. Reset the Yes
E55 occurred encoder.
End
Did this rectify the problem?

No

It is possible the encoder malfunctioned.


Exchange encoder. Yes
End
Did this rectify the problem?

No

Contact NACHI service department.

3-35 9906,EARE-041-002
3.1.34 E56 Servo error: Pre-load error.

Yes Remove the obstruction.


E056 Has the robot collided with anything?
Or alter robot (program)locus

No

Monitor axis data using Service(PF1)MonitorEach axis data 1


monitor function. Refer to AR Controller Operation Manual for
details.

In MOTORS OFF state, is it No


possible to release brake with
the brake release switch?

Yes
Is connector CNBK on UM886 No Make good connection.
on drive unit connected well?

Yes
When brake is released does No
present position on the monitor
change?

Replace the wire harness


Is wire harness and robot No or faulty robot wiring.
Yes internal wiring OK?

Replace the drive unit.


Yes

Encoder may be defective.


Replace the motor.

Note: Preloading
Preloading is an automatic controller function that enables the encoder mode to
change from 32 pulse/rev to 2048 pulse/rev. In order for the mode to change the
motor must slightly turn so the encoder is at one of the 32 pulse intervals.
Preloading is performed the first time MOTORS ON is pushed after the controller
power has been turned on.
Error occurs when the motor can not turn in order to align with one of the 32 pulse
intervals.

3-36 9906,EARE-0041-002
3 Troubleshooting

3.1.35 E57 Servo error: Count status error.

Replace the encoder. Yes


E57 occurred Did this rectify the problem? End

No

Contact NACHI Service Department.

3-37 9906,EARE-041-002
3.1.36 E60 Controller temperature fault.

Is ambient temperature within No


E60 occurred Move Controller to correct environment or change
0 - 52 deg. C? environment to within specification.

Yes

Is the heat exchanger No


fan rotating?

Is the heat exchanger No Repair faulty wiring.


wiring OK?

Yes

Replace the heat exchanger.

Does a gap of 20mm or more exist No Increase gap to over 20mm.


at rear of controller?

Yes

Excessive heat might be being generated in some part of


the panel. Contact NACHI Service department.

Heat exchanger

Controller rear view

3-38 9906,EARE-0041-002
3 Troubleshooting

3.1.37 E61 Thermal relay or circuit protector tripped.

E61 occurred Has the circuit protector Yes Reset circuit breaker.
been tripped? (See note)

No

Check wiring between the alarm contact of Refer to Appendix 1, Power


circuit breaker and sequence PCB UM880. unit circuit diagram 2.

Are there any faulty connectors or Yes Repair faulty connections/wiring.


wiring?

No
Note) CP1, 4, 6, 7, OL1
Contact NACHI Service Department.

Power supply unit


Controller front view Power supply unit front view

3-39 9906,EARE-041-002
3.1.38 E62 MOTORS-ON sequence fault.

Does CRD10 on sequence PCB No


E62 occurred UM880 turn ON (LED ON) when
MOTORS ON button is pressed?

Yes
Are relays CRD4, CRD10 No Seat relay firmly.
disconnected?

Yes

Replace UM880.

Does magnet SW, MSB, on drive


No
unit turn ON when MOTORS ON
button is pressed?

Yes
Is wiring between UM880 CNA pin No. 6 No Repair faulty wiring.
and CNPRB pin A2 OK?

Does magnet SW MSHP Yes


No
turn ON when MOTORS
ON button is pressed?

Is wiring between pin B2 on CNPRB No Repair faulty wiring.


in drive unit and MSHP OK?

Yes

Is wiring between UM880 and input No Repair faulty wiring.


PCB UM803 (or UM887) OK?

Yes
Top view of power supply unit
UM803 (or UM887) may be
defective. Replace it.

Electromagnetic SW
(MSHP)

3-40 9906,EARE-0041-002
3 Troubleshooting

3.1.39 E66 Arm interference limit switch was activated.

Does LS activate beyond Yes Return it within the stroke in the


E66 occurred constant setting mode.
the arm interference angle?

No

Remove CNR04 canon. Check


conductivity between (f) and (r) Check internal wiring of the manipulator.
No
of BJ1 box, CNP04. Refer to Robot Manipulator Maintenance manual.
Conductive Yes
Nonconductive No

Yes

Check conductivity between pins 5 Wire-harness is defective.


& 6 of CNPE in power supply unit. No Replace it.
Conductive Yes
Nonconductive No

Yes

Is wiring between sequence PCB No Repair faulty wiring.


UM880 and connector CNEX OK?

Yes

Is relay CRD7 of UM880 No Replace UM880.


turned ON?

Yes

Is wiring between UM880 and input PCB No


UM803 (or UM887) OK? Repair faulty wiring.

Yes

UM803 (or UM887) may be


defective. Replace it.

3-41 9906,EARE-041-002
3.1.40 E67 The I/O master returns no answer.

Is I/O master PCB UM873 No Connect I/O master PCB UM873


E67 occurred connected correctly? with PCB rack correctly.

Yes

Is the 1C chip microcomputer on the No Correctly insert the 1 chip


I/O master PCB inserted correctly? microcomputer in the socket.

Yes

UM873 may be defective.


Replace it.

UM873

Controller front view

3-42 9906,EARE-0041-002
3 Troubleshooting

3.1.41 E256 Step data reading fault.

CPU PCB UM870 may be defective.


E256 occurred Replace it.

UM870

Controller front view

3-43 9906,EARE-041-002
3.1.42 E896 Hardware version of amp. Card is not correct.

Was servo amp PCB UM860 Yes The UM860 version is incompatible.
E896 occurred exchanged? Replace with compatible version.

No

UM860 may be defective.


Replace it.

UM860
SC-F series uses servo amp PCB UM860-30.
This error occurs when attempting to install UM860-10.

3-44 9906,EARE-0041-002
3 Troubleshooting

3.1.43 E8001 Motors-off sequence fault.


E8002 Input sequence fault.
E8007 System error(memory full).

E8001 occurred These are system software errors.


These errors seldom occur.
E8002 occurred Contact NACHI service department if any of these errors occur.
E8007 occurred

3-45 9906,EARE-041-002
3.1.44 E8004 Brake sequence fault.

Was the emergency stop button pushed Yes Not a controller error.
E8004 occurred or an external stop signal given? Reset the error.

No

Are any of the following cables broken or


have poor connections: Motor thermostat, Yes Replace faulty cable or correct
Arm interference LS, Robot end LS, or poor connection.
Emergency stop cable?

No

Exchange sequence PCB UM880 or Yes


input PCB UM803 (or UM887). Replace the PCB.
Is problem rectified?

No

Replace UM883/UM884 (or UM860). Yes End


Is problem rectified?

No UM883/UM884 or UM860

Magnet switch MSHP may be defective. UM803 or UM887


Replace it.

UM880
Top view of power supply unit

Electromagnetic SW
(MSHP)

POWER SUPPLY UNIT

Controller front view

3-46 9906,EARE-0041-002
4 Parts replacement & Adjustment

4 Parts replacement & Adjustment

4 Parts replacement & Adjustment......................................................................................................................... 4-1


4.1 Parts replacement ......................................................................................................................................... 4-3
4.1.1 Replacement of CPU unit............................................................................................................... 4-3
4.1.2 Replacement of drive unit .............................................................................................................. 4-4
4.1.3 Replacement of PCB ...................................................................................................................... 4-5
4.1.4 Battery replacement........................................................................................................................ 4-7
4.1.5 Replacement of position detection power supply (SR2) ................................................................ 4-7
4.1.6 Replacement of composite power unit on the board rack............................................................... 4-8
4.2 Adjustment ................................................................................................................................................... 4-9
4.2.1 Adjustment of power system .......................................................................................................... 4-9
4.2.2 Transformers tap change ............................................................................................................. 4-10
4.2.3 Brightness adjustment of Teach Pendant ROP501....................................................................... 4-11

4-1 9906,EARE-041-002
DANGER

Pay attention to electric shock.


Make replacement 5 minutes after turning off primary power.
Avoid wet hand in replacement work.

INHIBIT

Replacement can only be made by those who completed the Robot School
(maintenance course) held by Nachi-Fujikoshi.

MUST

Short between operators body (hand) and G terminal of Controller


electrically so that both can be in the same electric potential.

INHIBIT

There are lots of connectors in each PCB and hence extreme care should
be taken not to make connection mistaken or missing.

IMPORTANT

Do not damage wiring during replacement.


Be sure not to touch electronic parts, patterns in PCB and contacts in
connectors in replacement. Hold the edge of a PCB in your hand.

How to replace units and PCBs is described hereinafter.

4-2 9906,EARE-041-002
4 Parts replacement & Adjustment

4.1 Parts replacement


It is possible for AR52 controller to replace each unit in a short time, thus resulting in shortening its recovery ti
me. Unit can be divided into CPU unit and drive unit. Bear safety first in mind while observing the following pr
ecautions
.
4.1.1 Replacement of CPU unit

Precautions for CPU unit replacement


When replacing CPU unit, save necessary programs and constant file into the IC card etc., in
advance. Make a copy of the saved file to the controller after replacement.

Removing

Remove the connector fixed to PCB, the connectors CNBC and CNP.
Connectors CNBC and CNP are located between CPU unit and the bottom plate.
Remove 2 machine screws fixing CPU unit.
Pull out CPU unit.
CPU unit (Machine screws)

Fitting

Insert CPU unit.


Tighten machine screws to fix CPU unit.
Fit all connectors which were connected to the PCB and power feeding connectors CNBC and CNP.

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4.1.2 Replacement of drive unit

Removing

Remove all connectors attached to the drive unit from outside.


Remove 4 machine screws which fix the drive unit.
Pull the drive unit forward carefully.
(Use care not to make the unit hit to the rear heat sink.)
Remove the fitting frame attached to the drive unit.

Drive unit (Machine screws)

Fitting

Attach the fitting frame to the drive unit.


Insert the drive unit from the front of controller.
Tighten the machine screws to fix the drive unit.
Attach all connectors to the drive unit.

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4 Parts replacement & Adjustment

4.1.3 Replacement of PCB

Precautions for UM870 replacement


When replacing UM870 , save necessary programs and constant file into the IC card etc., in
advance.
Programs and constant data with teaching applied are saved in IC memory of UM870 but it
will be deleted once battery is discharged. Even if controllers power is turned off , power is
fed to IC memory from the battery. But when the battery is removed the power can not be
fed to IC memory, thus resulting in complete deletion of the saved memory. When replacing
UM870, save necessary programs and constant data, etc., to IC card etc., in advance
accordingly.

Replace PCB step by step according to the above precautions.

Removal of connectors attached to PCB is described first.

Removal of black connector


A socket can be removed if the lock levers of a header are opened to Socket
both sides as is illustrated in the figure. When attaching, insert the
socket first and then close the lock levers firmly until clicking.
Lock lever
Header

Removal of connector having a case (made by Honda


Comm.)
Loosen fixing machine screws on both sides of the
connector and then press the lock strongly.

Press Press

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(1) Replacement of PCB in board rack

Removing

Loosen machine screws which are fixing Slide the supporter itself to the left so as to pull it
supporters up and down of the board rack. out.

Remove the connector attached to the PCB. Pull out the inside of card puller attached to the
PCB with fingers outward of the rack.

Fitting

Insert the PCB along the board guide rail of a rack.


Insert both edges of card puller into the board rack groove and push the card puller with fingers.

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4 Parts replacement & Adjustment

4.1.4 Battery replacement

Lithium battery is used for CMOS memory in the controller. Replace it once every two years with primary power
ON.

4.1.5 Replacement of position detection power supply (SR2)

Removing

Remove the board for position detection power supply in front left upper of power circuit unit.
Remove the position detection power supply from the board.
Remove wiring from the terminal board of position detection power supply.

Fitting

Do in the reverse order of removing.

Precautions after replacement


Be sure to adjust power voltage after replacement.
Refer to 3.3.1 Adjustment of power system.

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4.1.6 Replacement of composite power unit on the board rack

Removing

Remove the terminal block cover of Remove all terminal block wirings of
composite power unit. composite power unit.

Remove 4 machine screws fixing the power Pull it back to remove from the rack.
unit to the board rack.

Fitting

Insert the composite power unit into the rightmost guide rail in the board rack.
Do in the opposite order of removing.

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4 Parts replacement & Adjustment

4.2 Adjustment

It is normally unnecessary to adjust AR52 controller with the exception of partial adjustment when parts are replaced.
Adjustment positions and adjustment practices are described below. Do not touch adjustment positions unless
otherwise necessary and do not make adjustment until the cause is clarified.

4.2.1 Adjustment of power system

Measure a voltage of each power when a trouble occurred in the power system or the power unit is replaced, and
make adjustment of those which are out of reference values.
(Use a digital voltmeter for measurement.)

Power Measuring point Reference value Adjusting positions


Primary Breaker CB1 Spec. voltage Primary tap change of transformer
power 10% T11 & T12 (Note 3)
B4 - C4 B4~C4 of composite power AC100V10% Secondary tap change of transformer
unit SR1 T11 & T12 (Note 3)
P1 - M1 P1~M1 of composite power DC24V2.0V (Note 1)
unit SR1
P5 - M0 +5V~G1 of terminal block on DC5V+0.1V-0V Volume of SR1
composite power unit SR1
P15 - M0 +15V~G1 of terminal block on DC15V0.5V (Note 1)
composite power unit SR1
N15 - M0 -15V~G1 of terminal block on DC-15V0.5V (Note 1)
composite power unit SR1
P12 - M0 P12~M0 of composite power DC12V0.1V Volume of SR1
unit SR1
P5E - M5E Terminal block for robot DC5.1V0.1V Volume of SR2 (Note 2)
external wiring and connector
pins P5E~M5E

Note 1) The composite power unit should be replaced if a voltage measured is not within the reference value.
Note 2) Measure the terminal block & between connector pins nearest to the robot encoder.
Refer to Manipulator Maintenance Manual.
Note 3) Refer to the following pages for transformers tap change.

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4.2.2 Transformers tap change

How to change

Remove the wiring connected to primary terminal of the transformer.


Connect the removed wiring to a desired voltage terminal.

Note) Change the transformer tap only on the primary terminal side,
but not on the secondary terminal side.

(A) AR controllers transformer T11

(B) Servo transformer T12

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4 Parts replacement & Adjustment

4.2.3 Brightness adjustment of Teach Pendant ROP501

Fixing screws of rear cover

Front view Rear view

1. Remove the rear cover of a teach pendant.


The rear cover is fixed with 8 M3 tapping screws.
Remove all these screws.
(Refer to the above figure.)

2. Adjust the contrast adjust volume VR1 (for contrast of


characters).
A volume of VR1 is located on the board UM862
inside the teach pendant (for contrast adjustment) and
hence adjust the contrast of characters by turning the
volume.
The screen becomes bright with VR1 turned CW and
dark with VR1 CCW.
Refer to the left figure for the locations of the board and
volume.

3. Adjust the brightness adjust volume VR2 (for brightness of


the screen).
Adjust brightness of the screen by turning the volume VR2
on UM862 (for brightness adjustment) if characters are
not clear.
30 wires
flat cable
4. Fix the rear cover after adjustment while taking care so that
wiring may not be crushed with the rear cover edge.
For tapping screws to fix the rear cover, some teach
pendant is provided with short screws only for upper
portion (shown with * in the above figure) and hence pay
attention to this.

4-11 9906,EARE-041-002
5 Periodic Inspection

5 Periodic Inspection
Periodic inspection of NACHI Robot is necessary to minimize trouble occurrence and maintain it performance long.
Cautions and work content when making the periodic inspection are described below.

5 Periodic Inspection.............................................................................................................................................. 5-1


5.1 Inspection schedule ...................................................................................................................................... 5-2
5.2 General cautions for periodic inspection...................................................................................................... 5-2
5.3 Daily inspection............................................................................................................................................ 5-3
5.4 Initial inspection (750H inspection) ............................................................................................................. 5-3
5.5 3-, 6-month & 1-year inspection .................................................................................................................. 5-4
5.6 Inspection of long vacation .......................................................................................................................... 5-5
5.7 Cleaning and inspection of fan motor and heat sink .................................................................................... 5-6
5.8 Maintenance parts list................................................................................................................................... 5-7

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5-1
5.1 Inspection schedule

Inspection should basically be made as shown in Fig. 4.1.


Periodic inspection is essential not only to prevent troubles in advance but to keep its mechanism long, secure
safety and maintain its accuracy, and hence be sure to inspect the controller as is specified regularly even though
it is operating normally.

0H 750H 1500H 3000H 5000H

Daily inspection Repetition from 3-month inspection

3-month 3-month 3-month 3-month


inspection inspection inspection inspection

6-month 6-month 6-month


inspection inspection inspection

1-year 1-year
inspection inspection

Fig. 4.1 Inspection schedule

5.2 General cautions for periodic inspection

Inspection should be made only by those who completed the Robot School (maintenance course) held by
Nachi-Fujikoshi.
Check parts, tools and drawings necessary for work prior to inspection.
Be sure to use specific parts designated by Nachi-Fujikoshi for replacement.
Be sure to turn off power first when making inspection of the manipulator.
Be sure to turn off primary power first prior to opening the controllers window, and use extreme care not to
make dust come inside from surrounding.
Do not touch parts of the control panel with oily hand. Remove oil and so forth thoroughly from hand in
advance. Those who make inspection are cautioned that, when touching PCBs and connectors in particular, IC
parts may not be damaged by electrostatic discharge, for example.
Never enter the operating range of a manipulator in inspection while operating it.
Measure a voltage at a designated place and pay much attention to electric shock and short-circuited wiring.
Do not inspect the manipulator and the control panel at the same time.
Before starting normal running, be sure to confirm the manipulators operation in idling after inspection.

9906,EARE-0041-002
5-2
5 Periodic Inspection

5.3 Daily inspection

No. Inspection point Check item Method


Manipulator Is there any abnormal noise when Listening
1
operating?
Control panel Are display lamps functioning Visual
2
well?
3 Manipulator Dust, spatters, etc. not existing? Visual & cleaning
Electric wiring & wire-harness of Scratch, fouling, crush not Visual
4
manipulator existing?
Machine screws fixing various Machine screws not loosened? Re-tightening
5
attachments on the wrist tip
6 Controllers window Is the window closed tightly?

5.4 Initial inspection (750H inspection)

No. Inspection point Check item Method


External & major bolts & machine Bolts & machine screws not Re-tightening
1
screws loosened?
Wiring connectors & wire-harness Connectors not loosened? Re-tightening
2
of manipulator
Fixing screws of dogs & limit Machine screws not loosened? Re-tightening
3
switches

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5-3
5.5 3-, 6-month & 1-year inspection
Period
No. 3 6 1 Check item Method Remarks
M M Y
Doors packing & Deformation of clearance &
1 locking key packing
Function of key
Rear panel Cleaning & rotation of heat
exchangers cooling fan
2
Fouling & cleaning of regenerative
resistor
Wireharness Check clearance & connectors
3 looseness. Retighten them, if
necessary.
Drive unit Check if terminal block of drive
unit and its connectors are loosened
4
or damaged. Retighten if
necessary.
Terminal block Visually check if machine screws
5 are missing or loosened. Retighten
if necessary.
6 Board connectors Check if it is loosened with hand.
Operating part Visually check if push-buttons
display well and also they are
7
cleaned.
Cleaning of operating seat
Entire panel Visually check if there is much dust
8 & fouling.
Cleaning of fouling
Voltage Primary supply voltage Spec. voltage10%
measurement R4-S4-T4 AC200V10%
B4-C4 (Control power in panel) AC100V10%
P5-M0 DC5V+0.1V-0V
9 P15-M0 DC15V0.1V
N15-M0 DC-15V0.1V
P12-M0 DC12V0.1V
P5E-M5E Note 1) DC5.1V0.1V
P1-M1 DC24V0.2V
Transformer room Check if there exist heat generated,
10
noise or smell visually & feeling.
Earth Check if there exists looseness and
11
defect.
12 Relay Visually check fouling & defect.
Battery Check voltage of lithium battery
13
and make periodic inspection.
Teach pendant Visually check fouling & damage.
Retighten, if necessary.
14
Cleaning of operating seat and
confirmation of display
Note1) Voltage of P5E~M5E is DC5.1V0.1V on the manipulator side, and that inside the controller is about
5.4V depending on the specifications.
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5-4
5 Periodic Inspection

5.6 Inspection of long vacation

In case of a long vacation, check the following matters prior to turning power off.

(1) Confirmation of battery LED


When battery voltage is low, the content of memory is deleted if power is turned off.
Refer to 2.3.1 Main CPU board (UM870).
(2) The door of controller should be closed.

9906,EARE-0041-002
5-5
5.7 Cleaning and inspection of fan motor and heat sink

Execute cleaning of a fan motor and a heat sink to improve a cooling effect of the controller on the basis of every
3 months depending on environment and conditions.
However, when the controller stops with Error 44 (Over-voltage of drive unit or over-temperature of heat sink),
execute cleaning immediately.
(This applies to and after the system software version ARV21.087.)

Cleaning method

[Cleaning and inspection of the rear fan]


Turn off the controllers power.
Remove the rear panel.
Wipe dirt off the fan.
Turn the fan slightly with fingers and make sure that the fan can rotate smoothly.
Wipe dirt off the fan and the blades of heat exchanger.
Turn the fan of an heat exchanger slightly with fingers and make sure that the fan can rotate smoothly.
Wipe dirt off the heat sink fins of an amp unit. Remove dirt if the fins are clogged.
Attach the rear panel.

Remove dirt off


the blades.

Remove dirt off


the heat sink fins.

FM3 FM4

Remove dirt off


the fan.

(Rear view)

Fig. 1 Cleaning of the rear fan and heat sink.

Periodic replacement parts

Replace the following fan motors every year.


Fan motors are connected by tab terminals.

Part name Type Maker Qty Remarks


Fan motor 5915PC-10T-B30-B00 Minebea 2 FM3,FM4

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5-6
5 Periodic Inspection

5.8 Maintenance parts list

Recommendable parts are divided into 2 types, A & B in view of their service life and operation frequency.

Maintenance parts A
Major maintenance parts recommendable to prepare for daily maintenance and inspection:
A-1 Standard attachment spare parts
A-2 Important backup parts
A-3 Periodic replacement parts

Maintenance parts B
Maintenance parts recommendable to prepare when purchasing plural number of robot:
B-1 Maintenance parts recommendable to purchase from Nachi-Fujikoshi
B-2 Parts which can be purchased directly from makers

A-2 and A-3 are minimum & essentially required parts to maintain normal operation and thus it is
recommendable to purchase one set.
In addition, PCBs are provided with high performance parts and thus pay attention to the following in
maintenance:

Storage temperature: -10~+50


It is recommendable for a long time preservation to keep a temperature at 2510 for securing reliability.
Preservation humidity: 20%~85%
It is recommendable for a long time preservation to keep a humidity at 45~65%for securing reliability.
Avoid the preservation under dewing condition. And use care not to make mold grown.
Prevention of electrostatic charge
Static electricity is likely to be charged if parts are preserved under extremely dry condition and thus
semiconductors might be damaged by a shock at a time of discharge.
Preserve parts in a charge preventive bag.
Other ambient conditions
Preserve parts where poisonous gas does not generate and dust is less, and avoid loading onto preserved
parts.

9906,EARE-0041-002
5-7
Maintenance parts A-1 (Standard attachment spare parts)
No Part name Type Maker Recomd No. Remarks
1 Connector MR-25LM Honda Comm. 1 CNIN2(UM803)
2 Connector MR-34LM Honda Comm. 1 CNIN3(UM803)
3 Connector MR-34LF Honda Comm. 2 CNOT2,3(UM080)
4 Fuse element GP150 Daito Comm. 2
Maintenance parts A-2 (Important backup parts)
No Part name Type Maker Recomd No. Remarks
RAX11-10(for
Drive unit varies with the robot type.
1 Drive unit SA,SG) Fujikoshi 1
Check a type on the right side of the drive unit.
RAX13-10(for SC)
Type 10M represents the 10 meter long cable.
2 Teach pendant ROP501-10M Fujikoshi 1
Two specifications; Japanese and English, are available.
Controllers type (Indicated on
the upper right of front door) Print board configuration
varies with the controllers
AR52-02 AR52-07 type.

5-8
AR52-03
3 PCB (CPU) UM870-20 Fujikoshi 1
4 PCB (ROM) UM871-20 Fujikoshi 1
UM873-10 Fujikoshi 1
5 PCB (I/O Master)
UM873-20 Fujikoshi 1 Option board
UM860-30 Fujikoshi 1
6 PCB (Servo Control) UM883-10 Fujikoshi 1
UM884-10 Fujikoshi 1
UM803-30 Fujikoshi 1
UM080-10 Fujikoshi 1
7 PCB (I/O Interface)
UM887-10,-20 Fujikoshi 2 Option board
UM104-10,-20 Fujikoshi 2 Option board
8 PCB (Sequence) UM880-10 Fujikoshi 1
9 PCB (Analog I/O) UM820-10 Fujikoshi 1 Option board

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10 PCB (RIO Interface) UM858-10 Fujikoshi 1 Option board
Maintenance parts A-3 (Periodic replacement parts)
No. Part name Type Maker Recomd No. Remarks
1 Battery BAT02 Fujikoshi 2 Replace every 2 years regardless of operating hours
2 Fan motor 5915PC-10T-B30-B00 Minebea 2 FM3,FM4 Heat Exchanger

Maintenance parts B-1 (Parts recommendable to purchase from Fujikoshi)


No. Part name Type Maker Recomd No. Remarks
1 Wire-harness Fujikoshi 1 set Control panel ~ manipulator
2 Composite power supply FJK2005A Fujikoshi 1 SR1

5-9
Maintenance parts B-2 (Parts which can be purchased directly from makers)
No. Part name Type Maker Recomd No. Remarks
1 Small-size relay MY4N(DC24V) Omron 3 On UM880 (CDR3,4,10)
2 Circuit breaker BU-ESB3030L Fuji Elec. 1
3 Switching regulator R25U-5 or R25U-6 Cosel 1 SR2 (Depending on the length of harness)
4 Switching regulator RMC50-2 Cosel 1 SR01(For Analog I/O board UM820)

9906,EARE-0041-002
5 Periodic Inspection
6 Parts layout and electric circuit diagram

6 Parts layout and electric circuit diagrams


Page
Fig. 1 Exterior view of controller 6-
Fig. 2 Parts layout viewing from controllers front 6-
Fig. 3 Parts layout viewing from controllers rear 6-
Fig. 4 Terminal block layout (TB1) 6-
Fig. 5 Parts layout in board rack 6-
Fig. 6 Exterior view of drive unit 6-
Fig. 7 Signal system diagram (stamping) 6-
Fig. 8 Signal system diagram (assembly) 6-
Fig. 9 Power system diagram 6-
Fig. 10 Power supply unit circuit diagram 1 6-
Fig. 11 Power supply unit circuit diagram 2 6-
Fig. 12 Operation panel & teach pendant connection diagram 1 6-
Fig. 13 Operation panel & teach pendant connection diagram 2 6-
Fig. 14 Drive unit connection diagram 1(SA & SG series) 6-
Fig. 15 Drive unit connection diagram 1(SC35/50) 6-
Fig. 16 Drive unit connection diagram 1(SC15) 6-
Fig. 17 Drive unit connection diagram 2 6-
Fig. 18 Brake circuit diagram(SA & SG series) 6-
Fig. 19 Brake circuit diagram(SC35/50) 6-
Fig. 20 Brake circuit diagram(SC15) 6-
Fig. 21 Encoder cable connection diagram 6-
Fig. 22 Sequence circuit diagram 1 6-
Fig. 23 Sequence circuit diagram 2 6-

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Fig. 1 Exterior view of controller
6 Parts layout and electric circuit diagram

Fig. 2 Parts layout viewing from controllers front

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Fig. 3 Parts layout viewing from controllers rear
6 Parts layout and electric circuit diagram

Fig. 4 Terminal block layout (TB1)

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Fig. 5 Parts layout in board rack
6 Parts layout and electric circuit diagram

Fig. 6 Exterior view of drive unit

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Fig. 7 Signal system diagram (stamping)
6 Parts layout and electric circuit diagram

Fig. 8 Signal system diagram (assembly)

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Fig. 9 Power system diagram
6 Parts layout and electric circuit diagram

Fig. 10 Power supply unit circuit diagram 1

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Fig. 11 Power supply unit circuit diagram 2
6 Parts layout and electric circuit diagram

Fig. 12 Operation panel & teach pendant connection diagram 1

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Fig. 13 Operation panel & teach pendant connection diagram 2
6 Parts layout and electric circuit diagram

Fig. 14 Drive unit connection diagram 1(SA & SG series)

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Fig. 15 Drive unit connection diagram 1(SC35/50)
6 Parts layout and electric circuit diagram

Fig. 16 Drive unit connection diagram 1(SC15)

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Fig. 17 Drive unit connection diagram 2
6 Parts layout and electric circuit diagram

Fig. 18 Brake circuit diagram(SA & SG series)

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Fig. 19 Brake circuit diagram(SC35/50)
6 Parts layout and electric circuit diagram

Fig. 20 Brake circuit diagram(SC15)

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Fig. 21 Encoder cable connection diagram
6 Parts layout and electric circuit diagram

Fig. 22 Sequence circuit diagram 1

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Fig. 23 Sequence circuit diagram 2
6 Parts layout and electric circuit diagram

6- 9906,EARE-041-001
7 Principle of function

7 Robot operating principle


As for electric playback robot which is adopted with the NACHI robot, the mechanism of the operation is explained.

7 Robot operating principle ..................................................................................7-1


7.1 Teaching and playback system .........................................................................7-2
7.2 Robot construction .............................................................................................7-3
7.2.1 Power supply section.........................................................................................7-4
7.2.2 Microcomputer section ......................................................................................7-4
7.2.3 Servo mechanism ..............................................................................................7-5
7.2.4 Encoder ..............................................................................................................7-6

9906,EARE-041-002
7-1
7.1 Teaching and playback system
Playback robot means manipulator of the following contents usually. [The manipulator which can do the work
repeatedly by to make memorize the order of the work, a position and the other information by human being's
instructing in the work beforehand, moving a manipulator and making replay it]
It is generally known as teaching playback.

The teaching system is classified into the method by the teach pendant and direct programming. NACHI robot use
the teaching playback system by the teach pendant.
There are axis operation switches according to the number of axes and teaching switches on the teach pendant.
The repeating the above, one job can be taught to the robot. The taught job is done during playback as a series of
movement. The above are repeated as many times as desired.
The control system moving from point to point is called PTP Control (Point to Point Control).

Fig.7-1 PTP Control


(This path is not a problem.)

PTP control cares about only positioning at recorded points and path between them is not controlled. The above is
not sufficient for a welding or handling robot, and NACHI robot obtains oath between recorded points by
computation (by connecting two points by a straight line or circular arc) and performs control to subdivide the
path between two points.

Circular arc
Straight line

Taught point

Fig.7-2 Interpolation path control and PTP teaching

Robot positioning is explained above. Besides, in the teaching, speed and an output signal, an input signal, a
various direction and so on are recorded simultaneously with the position information of each step.

9906,EARE-041-002
7-2
7 Principle of function

7.2 Robot construction


It is possible to say that the teaching and the playback are all of the operation of the robot but the construction to
realize the function is explained.

Motion controller Drive unit


CPU

Teaching data CPU Target data Creating locus Servo Current amp. Gate
Motor
(Memory) Accel. control loop PWM control drive

UM870 UM884 Current feedback


Position
command Encoder
Input/output A-phase, B-phase
Encoder signal

Microcomputer section I/F Serial signal

UM883

Power supply section Servo mechanism

Robot controller

Fig. 7-3 Robot construction

When dividing the composition of the robot very roughly, it separates into the microcomputer section, the servo
mechanism and the power supply section as shown in Fig.7-3.

9906,EARE-041-002
7-3
7.2.1 Power supply section
Power supply section supplies power to the microcomputer section and the servo mechanism.
Note that power to be supplied to the servo mechanism is supplied to the motor through the servo amplifier.

7.2.2 Microcomputer section

Memory
System
Data memory
program

Input interface Output interface

Fig.7-4 block diagram of microcomputer section

It is possible to think that the microcomputer section in the robot control equipment, too, consists of the
same general computer style, the input unit (the input interface), the output unit (the output interface),
arithmetic control unit (CPU), the memory unit (the memory).
However, the type of the input/output unit is quite different from that of a general computer. The input unit
of the robot includes teach pendant and operation panel. The output unit includes the display panel and
output relay signals.

As another important input and output, there are output of the command value to the servo mechanism
(operation command to the manipulator) and input of the present value from the encoder (feedback of
manipulator position). It can be said that the microcomputer section works as a robot controller by the above
element.

The memory unit has the same hardware as a general computer. Data (software) stored in memory unit are
peculiar to the robot and consists of the system program (the control program written by the manufacturer
before shipment) and data (position, speed, auxiliary function, etc.) made by programming.

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7 Principle of function

7.2.3 Servo mechanism


The servo mechanism, another important element of the robot is explained below. The robot has servo
mechanisms for the number of axes (6 axes for SA sires robot).
Servo mechanism is defined as an automatic control system designed to follow optional change of target
value (input) with object position, direction, points, etc. as controlled quantity.

In case of the robot, by optional targets to stay in this position or to maintain this speed, each axis
motor moves to follow the position and speed. By composing movements of all axes, the robot can draw a
desired path on the space.

Motion controller Drive unit

Target
data Creating locus Servo Current amp. Gate
Motor
Accel. control loop PWM control drive

UM884 Current feedback


Position
command Encoder
A-phase, B-phase
Encoder signal

I/F Serial signal

UM883
Fig. 7-5 Servo mechanism

Fig. 7-5 shows the Servo mechanism of AR52 controller.

The servo mechanism used in the AR52 controller is explained above. Fig. 7-5 shows its block diagram. At
the AR52 controller, it confirms the position of the robot in encoder, it compares command value data and
encoder data in motion controller UM883 and it is moving a motor to the command value data through the
drive unit.

Hereinafter, it does a supplement explanation.


It takes in serial communication data ( the information of the position ) and the data of the A aspect and the
B aspect ( the pulse signal and the direction of the operation and the speed information ) from encoder and
feed-backing to servo loop of motion controller UM883.
It is using serial communication data in the feedback signal in the position of the robot and it is using the A
aspect and B aspect signal as the speed confirmation signal of the motor axis.
Motion controller compares position data from encoder and order position data from UM884 and amplifies
the difference in the servo loop part.
In the servo loop part, it has the speed loop and the electric current feedback loop of the motor to make the
operation of the robot smooth in addition to the position data loop.
The command data which passed these loop parts is output to the drive unit. In the drive unit, it applies an
electric current to the motor for the command value data and it moves a robot. Also, it fixes a way of
passing an electric current using the signal of the A aspect and the B aspect which is output from encoder.

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7.2.4 Encoder
Encoder is optical formula encoder of compact absolute type and is a motor incorporation type.
Basically, the position is absolute position encoder to understand simultaneously with power supply
investing.
The output data of this encoder is rough absolute position data immediately after power supply investing
but has the characteristic which switches over to the detailed data when moving a little. Generally, it is the
one which is called a pre-loading operation type. The AR52 controller works a motor axis angle by 2
degrees forcing when supplying a motor with the electric power first after power supply investing and is
making pre-load.

There are serial communication data and a pulse signal which is called A aspect and B aspect in the output
data from encoder.

The encoder present position data and the status data which shows the condition of encoder are contained
in the serial communication data. Position data is used by the feedback loop of the position of the
servomechanism, and the checking of the malfunction of encoder uses status data.

The signal of the A aspect and the B aspect is the pulse signal with which a phase was shifted and the
number of the pulses which occurs by 1 turn is set. The operation speed can be confirmed from the
direction of the operation, the number of the cycles by these two signals.
It is using as the speed feedback signal.

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