SK6 Dual MRC Manipulator Manual

Minc MRC Controller
SK6 Dual MRC

Manipulator Manual
Part Number 140067-1
February 28, 1998
MOTOMAN
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200 FAX: (937) 847-6277
24-HOUR SERVICE HOTLINE: (937) 847-3200
The information contained within this document is the proprietary property of Motoman, Inc., and
may not be copied, reproduced or transmitted to other parties without the expressed written
authorization of Motoman, Inc.
©1998 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications
without notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
SK6 DUAL MRC MANIPULATOR MANUAL
TABLE OF CONTENTS
Chapter/Section Page
CHAPTER 1 INTRODUCTION
CHAPTER 2 SAFETY
1 INTRODUCTION........................................................................................1-1
2 STANDARD CONVENTIONS......................................................................2-1
3 GENERAL SAFEGUARDING TIPS..............................................................3-1
4 MECHANICAL SAFETY DEVICES...............................................................4-1
5 INSTALLATION SAFETY ...........................................................................5-1
6 PROGRAMMING SAFETY .........................................................................6-1
7 OPERATION SAFETY ................................................................................7-1
8 MAINTENANCE SAFETY ...........................................................................8-1
CHAPTER 3 SK6 MANIPULATOR INSTRUCTIONS
1 RECEIVING ...............................................................................................1-1
2 INSTALLATION .........................................................................................2-1
3 WIRING ....................................................................................................3-1
4 SPECIFICATIONS......................................................................................4-1
5 PRECAUTIONS FOR ALLOWABLE WRIST LOAD ......................................5-1
6 ALLOWABLE LOAD ON U-AXIS ................................................................6-1
7 ROBOT CONSTRUCTION ..........................................................................7-1
8 MAINTENANCE .........................................................................................8-1
9 RECOMMENDED SPARE PARTS ..............................................................9-1
10 PARTS LIST............................................................................................10-1
CHAPTER 4 SK6 DUAL MRC INSTRUCTIONS
1 INTRODUCTION........................................................................................1-1
2 EQUIPMENT DESCRIPTION......................................................................2-1
3 BASIC OPERATION...................................................................................3-1
4 CONTROLLER MAINTENANCE..................................................................4-1
5 TROUBLESHOOTING ................................................................................5-1
6 DIAGRAMS...............................................................................................6-1
CHAPTER 5 SK6 ELEMENTARY DIAGRAMS
SK6 Dual MRC Manipulator Manual i MOTOMAN

CHAPTER 1
INTRODUCTION
February 28, 1998
MOTOMAN
805 Liberty Lane
TEL: (937) 847-6200 FAX: (937) 847-6277
INTRODUCTION
About this Document
This manual provides information, including basic installation and maintenance
information for the SK6 and operation and maintenance instructions for the SK6
Dual MRC Controller. It is your responsibility to familiarize yourself thoroughly
with the information presented in this manual. Before you proceed, be sure you
have read and understand CHAPTER 2, SAFETY.
This manual is divided into the following chapters:
CHAPTER 1 - INTRODUCTION
Chapter 1 provides general information regarding this manual, a list of reference
documents, and customer service information.
CHAPTER 2 - SAFETY
Chapter 2 provides specific safety information designed to supplement training
received in an approved Motoman training course.
CHAPTER 3 - SK6 MANIPULATOR INSTRUCTIONS

Chapter 3 provides basic handling, installation, and wiring information for
the SK6. In addition, preventive checks, maintenance, and specifications are also
provided.
CHAPTER 4 - SK6 DUAL MRC INSTRUCTIONS

The Dual MRC processes input and output signals, controls manipulator
movement, operates welding power supply, and provides the signals to operate
the welding system. It maintains variable data and performs the numeric
processing to convert to and from different coordinate systems. The controller
also provides main logic functions, servo control, program and constant data
memory, and power distribution. In addition to the above, Chapter 4 also
provides basic information for troubleshooting the SK6 Dual MRC Controller.
CHAPTER 5 - ELEMENTARY DIAGRAMS

Chapter 5 provides reference information and block wiring diagrams of the
various components of the Dual MRC controller and SK6 manipulator.
Reference to Other Documentation

For additional information refer to the following:
• Motoman User Function Manual (Part Number 132331-1)
• Vendor manuals for system components not manufactured by Motoman
SK6 Manipulator Introduction 1-1 MOTOMAN

INTRODUCTION
Customer Service Information

If you are in need of technical assistance, contact the Motoman service staff at
(937) 847-3200. Please have the following information ready before you call:
• Robot Type (SK6)
• Application Type (Welding, Handling, etc.)
• Robot Serial Number (located on the back side of the robot arm)
• Robot Sales Order Number (located on back side of MRC controller)
SK6 Manipulator Introduction 1-2 MOTOMAN

CHAPTER 2
SAFETY
February 28, 1998
MOTOMAN
805 Liberty Lane
TEL: (937) 847-6200 FAX: (937) 847-6277
TABLE OF CONTENTS
Section Page
1 INTRODUCTION.......................................................................................................1-1
2 STANDARD CONVENTIONS ....................................................................................2-1
3 GENERAL SAFEGUARDING TIPS.............................................................................3-1
4 MECHANICAL SAFETY DEVICES..............................................................................4-1
5 INSTALLATION SAFETY ..........................................................................................5-1
6 PROGRAMMING SAFETY ........................................................................................6-1
7 OPERATION SAFETY ...............................................................................................7-1
8 MAINTENANCE SAFETY ..........................................................................................8-1
SK6 Manipulator Safety i MOTOMAN

SECTION 1
INTRODUCTION
It is the purchaser's responsibility to ensure that all local, county,
state, and national codes, regulations, rules, or laws relating to
safety and safe operating conditions for each installation are met
and followed.
We suggest that you obtain and review a copy of the ANSI/RIA National Safety
Standard for Industrial Robots and Robot Systems. This information can be
obtained from the Robotic Industries Association by requesting ANSI/RIA
R15.06. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: 313/994-6088
FAX: 313/994-3338
Ultimately, the best safeguard is trained personnel. The user is responsible for
providing personnel who are adequately trained to operate, program, and maintain
the robot cell. The robot must not be operated by personnel who have not
been trained!
We recommend that all personnel who intend to operate, program, repair, or use
the robot system be trained in an approved Motoman training course and become
familiar with the proper operation of the system.
This chapter addresses the following:
• Introduction (Section 1)
• Standard Conventions (Section 2)
• General Safeguarding Tips (Section 3)
• Mechanical Safety Devices (Section 4)
• Installation Safety (Section 5)
• Programming Safety (Section 6)
• Operation Safety (Section 7)
• Maintenance Safety (Section 8)
SK6 Manipulator Safety 1-1 MOTOMAN

SECTION 2
STANDARD CONVENTIONS
This manual includes information essential to the safety of personnel and
equipment. As you read through this manual, be alert to the four signal words:
• DANGER
• WARNING
• CAUTION
• NOTE
Pay particular attention to the information provided under these headings which
are defined below (in descending order of severity).
DANGER!
Information appearing under the DANGER caption concerns the
protection of personnel from the immediate and imminent hazards
that, if not avoided, will result in immediate, serious personal injury
or loss of life in addition to equipment damage.
WARNING!
Information appearing under the WARNING caption concerns the
protection of personnel and equipment from potential hazards that
can result in personal injury or loss of life in addition to equipment
damage.
CAUTION!
Information appearing under the CAUTION caption concerns the
protection of personnel and equipment, software, and data from
hazards that can result in minor personal injury or equipment
damage.
NOTE: Information appearing in a NOTE caption provides additional information which is helpful in
understanding the item being explained.

SECTION 3
GENERAL SAFEGUARDING TIPS
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General safeguarding
tips are as follows:
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
should be permitted to operate this robot system.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the robot cell.
• Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs and
Outputs).
• The robot must be placed in Emergency Stop (E-Stop) mode whenever it is
not in use.
• In accordance with ANSI/RIA R15.06, Section 6.13.4 and 6.13.5, use
lockout/tagout procedures during equipment maintenance. Refer also to
Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health
Standards for General Industry (OSHA).

SECTION 4
MECHANICAL SAFETY DEVICES
The safe operation of the robot, positioner, auxiliary equipment, and system is
ultimately the user's responsibility. The conditions under which the equipment
will be operated safely should be reviewed by the user. The user must be aware
of the various national codes, ANSI/RIA R15.06 safety standards, and other local
codes that may pertain to the installation and use of industrial equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following
safety measures are available:
• Safety fences and barriers
• Light curtains
• Door interlocks
• Safety mats
• Floor markings
• Warning lights
Check all safety equipment frequently for proper operation. Repair or replace any
non-functioning safety equipment immediately.

SECTION 5
INSTALLATION SAFETY
Safe installation is essential for protection of people and equipment. The
following suggestions are intended to supplement, but not replace, existing
federal, local, and state laws and regulations. Additional safety measures for
personnel and equipment may be required depending on system installation,
operation, and/or location. Installation tips are as follows:
• Be sure that only qualified personnel familiar with national codes, local
codes, and ANSI/RIA R15.06 safety standards are permitted to install the
equipment.
• Identify the work envelope of each robot with floor markings, signs, and
barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against unauthorized
entry into the work envelope.
• Eliminate areas where personnel might get trapped between a moving robot
and other equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching and
maintenance procedures.

SECTION 6
PROGRAMMING SAFETY
equipment must understand potential dangers of operation. Programming tips are
as follows:
• Any modifications to PART 1 of the controller PLC can cause severe
personal injury or death, as well as damage to the robot! Do not make any
modifications to PART 1. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!
• Some operations require standard passwords and some require special
passwords. Special passwords are for Motoman use only. Y O U R
WARRANTY WILL BE VOID if you use these special passwords.
• Back up all programs and jobs onto a floppy disk whenever program
changes are made. To avoid loss of information, programs, or jobs, a
backup must always be made before any service procedures are done and
before any changes are made to options, accessories, or equipment.
• The concurrent I/O (Input and Output) function allows the customer to
modify the internal ladder inputs and outputs for maximum robot
performance. Great care must be taken when making these modifications.
Double-check all modifications under every mode of robot operation to
ensure that you have not created hazards or dangerous situations that may
damage the robot or other parts of the system.
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
• Inspect the robot and work envelope to be sure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place.
• Check the E-STOP button on the teach pendant for proper operation before
programming.
• Carry the teach pendant with you when you enter the workcell.
• Be sure that only the person holding the teach pendant enters the workcell.
• Test any new or modified program at low speed for at least one full cycle.

SECTION 7
OPERATION SAFETY
equipment must understand potential dangers of operation. Operation tips are as
follows:
• Be sure that only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
are permitted to operate this robot system.
• Check all safety equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Inspect the robot and work envelope to ensure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Ensure that all safeguards are in place.
must have the teach pendant when they enter the cell.
not in use.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage
the robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.

SECTION 8
MAINTENANCE SAFETY
equipment must understand potential dangers of operation. Maintenance tips are
as follows:
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Check all safety equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Back up all your programs and jobs onto a floppy disk whenever program
changes are made. A backup must always be made before any servicing or
changes are made to options, accessories, or equipment to avoid loss of
information, programs, or jobs.
must have the teach pendant when they enter the cell.
not in use.
• Be sure all safeguards are in place.
• Use proper replacement parts.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage
the robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.
• Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs and
Outputs).

CHAPTER 3
SK6 MANIPULATOR
INSTRUCTIONS
February 28, 1998
MOTOMAN
805 Liberty Lane
TEL: (937) 847-6200 FAX: (937) 847-6277
GENERAL PRECAUTIONS
This instruction manual is intended to give operating instructions and maintenance
procedures for the Motoman SK6. Some drawings in this manual are shown with
the protective cover or shields removed, in order to describe their detail with more
clarity. Make sure all covers and shields are replaced before operating this robot.
Motoman is not responsible for any modification of the product made by the user
since that will void our guarantee.
The information contained within this document is the proprietary property of
Motoman, Inc., and may not be copied, reproduced or transmitted to other parties
without the express written authorization of Motoman, Inc.
Because we are constantly improving our products, we reserve the right to change
specifications without notice. MOTOMAN is a registered trademark of
YASKAWA Electric Manufacturing.
© 1998 by MOTOMAN
All Rights Reserved
TABLE OF CONTENTS
Section Page
LIST OF FIGURES ............................................................................................................. i i
LIST OF TABLES .............................................................................................................. i ii
1 RECEIVING.............................................................................................................. 1-1
2 INSTALLATION ....................................................................................................... 2-1
2.1 Selecting a Location ..................................................................................... 2-1
2.2 Positioning the SK6 ..................................................................................... 2-1
2.3 Mounting the SK6 on the Floor....................................................................2-3
2.4 Mounting SK6 on the Wall or Ceiling............................................................2-4
2.5 Safety Guards .............................................................................................2-5
3 WIRING................................................................................................................... 3-1
3.1 Connecting the Earth Grounds ....................................................................3-1
3.2 Cable Connection ........................................................................................3-2
3.3 Conducting a Safety/Operation Check...........................................................3-4
4 SPECIFICATIONS ................................................................................................... 4-1
4.1 Basic Specification....................................................................................... 4-1
4.2 Nomenclature and Working Axes .................................................................4-2
4.3 Dimensions and Working Ranges ..................................................................4-2
4.4 Working Range of B-axis .............................................................................4-3
4.5 Alterable Working Range .............................................................................4-3
5 PRECAUTIONS FOR ALLOWABLE WRIST LOAD ....................................................5-1
5.1 Allowable Wrist Load ................................................................................... 5-1
5.2 Wrist Flange................................................................................................5-2
6 ALLOWABLE LOAD ON U-AXIS ............................................................................. 6-1
6.1 Mounting Equipment ....................................................................................6-1
6.2 Incorporate Wire and Airduct.......................................................................6-2
7 ROBOT CONSTRUCTION ....................................................................................... 7-1
7.1 Position of Limit Switches ............................................................................7-1
7.2 Internal Connections................................................................................... 7-1
8 MAINTENANCE ...................................................................................................... 8-1
8.1 Preventive Maintenance .............................................................................. 8-1
8.2 Maintenance Procedures .............................................................................8-4
8.2.1 Replacing the Battery ......................................................................8-4
8.2.2 S-axis Speed Reducer Lubrication Procedure .....................................8-4
8.2.3 L- and U-axis Speed Reducers Lubrication Procedures.......................8-5
8.2.4 R-axis Speed Reducer Lubrication Procedure.....................................8-6
8.2.5 B- and T-axes Speed Reducers Lubrication Procedure .......................8-7
8.2.6 T-axis Gear Lubrication Procedure ...................................................8-8
SK6 Manipulator Instructions i MOTOMAN
Section Page
8.2.7 R-axis Cross Roller Bearing Lubrication Procedure ..........................8-8
8.2.8 L-axis Cross Roller Bearing Lubrication Procedure ...........................8-9
8.2.9 L- and U-axes Link/Link Roller Bearing Lubrication Procedures .........8-9
9 RECOMMENDED SPARE PARTS ............................................................................9-1
10 PARTS LIST ........................................................................................................... 10-1
INDEX
LIST OF FIGURES
Figures Page
Figure 2-1 Lifting the SK6...........................................................................................2-2
Figure 2-2 Mounting SK6 Directly To The Floor..........................................................2-3
Figure 2-3 Manipulator Baseplate Mounting ...............................................................2-4
Figure 2-4 Wall- and Ceiling-Mounted Variations .........................................................2-4
Figure 3-1 Grounding the SK6 ....................................................................................3-2
Figure 3-2 SK6 Power Cables .....................................................................................3-3
Figure 3-3 Cable Connection Details ...........................................................................3-3
Figure 4-1 SK6 Nomenclature and Working Axes ........................................................4-2
Figure 4-2 SK6 Dimensions and Working Ranges.........................................................4-2
Figure 4-3 SK6 Working Range of B-axis ....................................................................4-3
Figure 5-1 SK6 Moment Arm Rating........................................................................... 5-1
Figure 5-2 SK6 Wrist Flange.......................................................................................5-2
Figure 6-1 Allowable Load on U-axis ........................................................................... 6-1
Figure 6-2 Internal Wires, Connectors, and Air Inlet Locations ...................................6-2
Figure 6-3 Connector Pin Detail .................................................................................6-2
Figure 7-1 Limit Switch Locations ................................................................................7-1
Figure 7-2 Connector Numbers and Locations ............................................................. 7-1
Figure 7-3 Internal Connection Diagram - 1 of 4.........................................................7-2
Figure 7-3 Internal Connection Diagram - 2 of 4 ........................................................7-3
Figure 8-1 Inspection Points.......................................................................................8-3
SK6 Manipulator Instructions ii MOTOMAN

LIST OF TABLES
Figures Page
Table 4-1 Basic Specifications for SK6 ...................................................................... 4-1
Table 4-2 S-axis Working Range ................................................................................4-3
Table 5-1 Moment and Total Inertia .......................................................................... 5-1
Table 7-1 Connector Types .......................................................................................7-6
Table 8-1 Preventive Maintenance Checks and Services ............................................8-2
Table 9-1 Spare Parts for SK6 Robot ........................................................................9-1
SK6 Manipulator Instructions iii MOTOMAN

SECTION 1
RECEIVING
1. After unpacking, check the following:
• Manipulator
• MOTOMAN MRC Controller
• Programming Pendant
• Feeder Cable between MRC and SK6
CAUTION!
Confirm that the manipulator and the MOTOMAN MRC controller
have the same order number. Special care must be taken when
more than one manipulator is to be installed.
2. Check that the order numbers of the manipulator and controller agree. If the
numbers do not match, manipulators may not perform as expected and cause
injury or damage.
THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE SAME ORDER NUMBER.
THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE SAME ORDER NUMBER.
ORDER.NO.
ORDER.NO.
ORDER.NO.
Figure 1-1 Manipulator/Robot Order Number
SK6 Manipulator Instructions 1-1 MOTOMAN

SECTION 2
INSTALLATION
2.1 Selecting a Location
CAUTION!
Install the manipulator in a location where a fully extended arm
with tool will not reach a side wall or MRC cabinet.
Installation location can have a profound effect on the positioning accuracy and life
of the robot. Locate the robot in an area that meets the following criteria:
• Ambient temperature is between 0˚C to 45˚C (32˚F to 113˚F)
• No corrosive gases or liquids
• No explosive gases
• No large electrical noise (plasma)
• No excessive vibration
• Enough room to safely operate manipulator
• Level, undamaged floor surface (no cracks or other defects)
2.2 Positioning the SK6

The SK6 can be placed in its final position by either being lifted with a hoist and
cable or sling or with a forklift. To lift the SK6 with a cable or sling, proceed as
follows:
1. Ensure all shipping brackets are securely in place, as shown in Figure 2-1.
WARNING!
• The MOTOMAN SK6 weighs approximately 150 kg (331 lbs),
including the shipping bolts and brackets. Use a cable or
sling, that can withstand this weight.
• Eyebolts are designed to support the robot weight. Use the
bolts for lifting the robot ONLY.
2. Ensure that eyebolts are attached securely to the robot.
3. Attach a suitable lifting device securely to the eyebolts.

INSTALLATION
CAUTION!
• Crane operations or sling applications must be performed b y
authorized personnel only, or injury or damage may result.
• Be sure to use a spreader bar to keep dual chains from pulling
against the robot assembly and damaging it.
4. Carefully lift the robot, taking care to avoid excessive vibration/shock or
exerting force on the arm or motor unit, and place in the desired location.
SPREADER ATTACHED
TO LIFTING DEVICE
EYEBOLT (M10) EYEBOLT (M10)
3 BOLTS (M6)
SHIPPING
4 BOLTS (M16) BRACKETS
PALLET
Figure 2-1 Lifting the SK6

To lift the SK6 with a forklift, proceed as follows:
1. Ensure all shipping brackets are securely in place, as shown in Figure 2-1.
WARNING!
The MOTOMAN SK6 weighs approximately 150 kg (331 lbs),
including the shipping bolts and brackets. Use a suitable pallet
and forklift that can withstand this weight.
2. Attach SK6 to a suitable pallet with shipping bolts (see Figure 2-1).
CAUTION!
Forklift operation must be performed by authorized personnel
only, or injury or damage may result.
3. Carefully lift the robot, taking care to avoid excessive vibration or shock or
exerting force on the arm or motor unit, and place in the desired location.
INSTALLATION
2.3 Mounting the SK6 on the Floor

The SK6 can be mounted to a common base, that is secured to the floor, or directly
to the floor without a common base.
To mount the robot directly to the floor (see Figure 2-2):
WARNING!
The MOTOMAN SK6 weighs approximately 150 kg (331 lbs).
Inspect the floor for unevenness, cracks, and other defects.
Correct all defects before mounting the robot.
1. Secure the robot to the floor with four M16 (50 mm) anchor bolts, spring
washers, and washers. Tighten anchor bolts securely.
ANCHOR BOLTS (M16) ANCHOR BOLTS (M16)

OR MORE
150 mm
CONCRETE
Figure 2-2 Mounting SK6 Directly To The Floor

To mount the SK6 to a common base, proceed as follows (see Figure 2-3):
1. Ensure the common base will be strong enough to support the robot and
withstand repulsion forces during acceleration and deceleration. The common
base must be at least 40mm thick and rugged enough to prevent the SK6
from shifting.
2. Attach the SK6 to the common base with four M16 anchor bolts, springs
washers, and washers. Tighten anchor bolts securely.
3. Attach the common base to the floor with M16 (50 mm) anchor bolts.
Tighten anchor bolts securely.

INSTALLATION
4 BOLTS (M16)
SPRING
WASHER MANIPULATOR BASE
WASHER
20mm
40mm
40mm
orormore
more
COMMON BASE
MANIPULATOR BASE
ANCHOR BOLT (M16
COMMON BASE
Figure 2-3 Manipulator Baseplate Mounting
2.4 Mounting SK6 on the Wall or Ceiling

The standard method of mounting the SK6 is on the floor. However wall-
and ceiling-mounted types are also available with the following differences (see
Figure 2-4):
NOTE: When using wall-mounted or ceiling-mounted types, contact your MOTOMAN
representative.
DANGER!
The MOTOMAN SK6 weighs approximately 150 kg (331 lbs). The
ceiling or wall must be strong enough to support at least this
much weight. Also, for safe operation, always use safety counter
measures to prevent the manipulator from falling.
NOTE: When the SK6 is mounted on the wall, the S-axis working range is restricted to + 30˚C.
1. Ensure the mounting (wall or ceiling) can support the weight of the
manipulator.
SUPPORT SUPPORT
MANIPULATOR BASE 4 HEX. SOCKET HEAD

CAP BOLTS (M16)
Figure 2-4 Wall- and Ceiling-Mounted Variations

INSTALLATION
2. Using adequate supports, attach the SK6 to the wall or ceiling with four M16
hexagon socket head cap bolts that have a tensile strength of 1200 N/mm2 or
more. Tighten bolts to 21 kgf.m (152 ft lb).
2.5 Safety Guards

DANGER!
Failure to install safety guards may result in injury or damage.
To ensure maximum safety for your personnel, always install safety guards around
the SK6. The following is quoted from American National Standard ANSI/RIA
R15.06-1986:
"The user of a robot or robot system shall ensure that safeguards are provided
and used in accordance with Sections 6, 7, and 8 of this standard. The means and
degree of safeguarding, including any redundancies, shall correspond directly to
the type and level of hazard presented by the robot system consistent with the
robot application. Safeguarding may include, but not limited to, safeguarding
devices, barriers, interlock barriers, perimeter guarding, awareness barriers, and
awareness signals."

SECTION 3
WIRING
DANGER!
Bone Wiring should be performed only by a qualified electrician.
Electrical and grounding connections must comply with
applicable portions of the national electrical code and/or local
electrical codes.
WARNING!
Bone Before beginning any wiring procedures, ensure the primary
AC Power Disconnect Switch is in the OFF position and has been
locked out and tagged out as specified in ANSI/RIA R15.06 and
OSHA, Section 1910.147.
3.1 Connecting the Earth Grounds

The robot and the MRC must each be connected to an earth ground. An earth
ground is a ground in which the equipment is connected to a ground stake driven
into the earth. The ground stake must be driven a minimum of eight feet into the
earth, and the earth must be treated with chemicals in order to reduce resistance to
the ground stake. Deeper ground stakes may be required depending on area soil
conditions. A maximum of 100 ohms ground resistance is recommended.
WARNING!
• If proper earth grounds cannot be provided, do not use the
equipment! Serious injury or death can occur.
• You must use class 3 ground (ground resistance 100 Ω or less).
Failure to observe this warning may result in fire or electric
shock.
NOTE: If the robot and the MRC are within 15 feet of each other, a common earth ground may be
used. Otherwise, separate earth grounds must be used.
To ground the robot and the MRC:
1. Use a class 3 ground (ground resistance 100Ω or less) with 5.5mm2 or larger
ground line.
NOTE: • Do not use this line in common with other ground lines or grounding electrode for other
electric power, motive power, welding device, etc.
• Where the metal duct, metallic conduit, or distributing rack is used for cable laying, ground
in accordance with Electric Equipment Technical Standards.

WIRING
2. Connect one end of the first earth ground cable to the lug marked EARTH
GROUND on the bottom back of the robot (see Figure 3-1).
3. Connect the other end of the first earth ground cable to the earth ground stake.
4. Connect one end of the second earth ground cable to the common ground bus
bar inside the MRC.
GROUNDING
BOLT
5.5mm 2 OR LARGER
GROUND LINE
Figure 3-1 Grounding the SK6

5. Connect the other end of the second earth ground cable to the earth
ground stake.
3.2 Cable Connection

There are two power supply cables that run from the MRC to the SK6; one is a
signal cable for detection (IBC) and the other is a power cable (2BC) (see Figure 3-
2). Refer to Figure 3-3 for cable connection details. To connect the cables to the
SK6, proceed as follows (see Figure 3-2):
1. Carefully connect two power supply cables (labeled 1BC and 2BC), running
from the MRC, to the 1BC and 2BC connections on the back of the SK6.

WIRING
1BC CABLE 2BC CABLE
Figure 3-2 SK6 Power Cables
MRC ROBOT
CONNECTIONS CONNECTIONS
BAT -1
BAT - 1
E CONNECTOR
1SV-12CN
1SV-12CN TERMINAL
1SV-22CN
1SV-22CN CONNECTOR
MAIN KEY POSITION
1SV-32CN
1SV-32CN
2SV-32CN
2SV-12CN
1BC
2SV-22CN
2SV-22CN
SIGNAL CABLE FOR DETECTION (1BC)

2SV32CN
2SV-32CN CONNECTOR
KEYWAY
CN6-18
CN6-20
MTU-6
MTU-6 CONNECTOR
MAIN KEY POSITION
MAIN KEY POSITION
2BC
POWER CABLE (2BC)

CONNECTOR CONNECTOR
Figure 3-3 Cable Connection Details

WIRING
3.3 Conducting a Safety/Operation Check

Before installing the tooling and fixtures for your application, take a few minutes to
perform a safety/operation check. To conduct a safety/operation check, proceed as
follows:
1. Ensure that the robot and components have been firmly and properly
anchored.
2. Ensure that all three yellow shipping brackets have been removed from
the robot.
3. Ensure that all safety guards, fencing, and mats are in place.
4. Ensure that all cable connections are tight.
5. Verify that incoming line power matches the input power as specified on the
front of the MRC.
CAUTION!
The SK6 should only be operated by personnel who have received
operator training from Motoman, Inc. and are familiar with the
operation of the SK6.
Your SK6 is now be ready for power up. Turn the main power ON, and continue
the safety/operation check.
6. Check all E-STOPS (pendant, op-station, shock sensor, playback box).
7. Check system Hold buttons.

SECTION 4
SPECIFICATIONS
4.1 Basic Specification
Table 4-1 Basic Specifications for SK6
Operation Mode Vertically Articulated
Degree of Freedom 6
Payload 6 kg (13.2 lbs)
Repetitive Positioning Accuracy +0.1 mm (0.0039 in.)
Motion Range
S-axis (Turning) +170°
L-axis (Lower Arm) +150° , -90°
U-axis (Upper Arm) +90° , -110°
R-axis (Rotation) +180°
B-axis (Bend) +135°
T-axis (Turning) +320°
Maximum Speed
S-axis 2.09 rad/s, 120°/s
L-axis 2.09 rad/s, 120°/s
U-axis 2.09 rad/s, 120°/s
R-axis 5.24 rad/s, 300°/s
B-axis 5.24 rad/s, 300°/s
T-axis 7.85 rad/s, 450°/s
Allowable Moment
R-axis 11.8 N•m (1.2 kgf•m)
B-axis 9.8 N•m (1.0 kgf•m)
T-axis 5.9 N•m (0.6 kgf•m)
Allowable Inertia
R-axis 0.24 kg•m 2
B-axis 0.17 kg•m 2
T-axis
0.06 kg•m 2
Weight 150 kg (331 lbs)
Temperature 0 to 45°C
Noise Level Below 80 dB
Power Capacity 3.5 kVA
Ambient Conditions
Humidity 20 to 80% RH (non-condensing)
Vibration Less than 0.5 G
Others • Free from corrosive or
explosive gases and liquids
• Clean and dry
• Free from excessive
electrical noise (plasma)

SPECIFICATIONS
4.2 Nomenclature and Working Axes

UPPER (U) ARM WRIST
U+ R+ B+ T+
WRIST FLANGE
U- R- B- T-
L- L+
LOWER (L)
ARM
ROTARY (S)
HEAD
S+
S-
BASE
Figure 4-1 SK6 Nomenclature and Working Axes
4.3 Dimensions and Working Ranges

BASEPLATE
170˚ 4 -18 DIAMETER
300
260
153 + 0.1
5
R33 270 53 + 0.1
196
60
260
300
60
100 + 0.1 12 + 00.018 DIAMETER
(29) 130 + 0.1
R13
25
R5
29
1 7 0˚
1325
415
265
380
529
0
1700
DIMENSIONS IN MM
150 735 95
60
64
136
˚
1265
115
75˚
POINT P
831
450
552
1159
150
o
90
˚
530
168
231
590
604
Figure 4-2 SK6 Dimensions and Working Ranges

SPECIFICATIONS
4.4 Working Range of B-axis

The working range of B-axis maintaining a constant angle to the center of U-axis is
shown in Figure 4-3.
U-AXIS ROTATION
CENTER
135˚
135˚
B-AXIS ROTATION
CENTER
L-AXIS ROTATION
CENTER
S-AXIS ROTATION
CENTER
Figure 4-3 SK6 Working Range of B-axis
4.5 Alterable Working Range

The working range of S-axis can be altered according to the operating conditions, as
shown in Table 4-2. If alteration is necessary, contact your MOTOMAN
representative in advance.
Table 4-2 S-axis Working Range
Item Specifications
S-axis +170˚ (Standard)
Working +150˚
Range +120˚
+90˚
+60˚
+30˚

SECTION 5
PRECAUTIONS FOR
ALLOWABLE WRIST LOAD
5.1 Allowable Wrist Load
1. The allowable wrist load for the SK6 is 6 kg (13.2 lbs). The following
conditions should be observed.
2. If force is applied to the wrist instead of the load, force on R-, B-, and T-axes
should be within the value shown in Table 5-1. Contact your MOTOMAN
representative for further information or assistance.
Table 5-1 Moment and Total Inertia
Axis Moment N-m Total Inertia

(GD2/4)kg•m2
R-axis 11.8 0.24
B-axis 9.8 0.17
T-axis 5.9 0.06
3. Where the volume of load is small, refer to moment arm rating (see
Figure 5-1).
LOAD GRAVITY
LB POSITION
95mm
T-AXIS & R-AXIS
LT
ROTATION
CENTER LINE
B-AXIS ROTATION
CENTER LINE
200
W=3kg
L T (mm) 100
W=6kg
0 100 200 300
L B (mm)
Figure 5-1 SK6 Moment Arm Rating

PRECAUTIONS FOR ALLOWABLE WRIST LOAD
5.2 Wrist Flange

Wrist flange dimensions are shown in Figure 5-2. In order to see the tram marks,
it is recommended that the attachment be mounted inside the fitting. Fitting depth
of inside and outside fittings must be 5mm (0.2 in.) or less.
TRAM MARK
6mm
45˚
DIAMETER
4 TAPPED HOLES (M6),
9mm DEEP
6mm P.C.
D40
50 – 0.016
0
6 + 00.012 DIAMETER,
25 + 00.013 DIAMETER
6mm DEEP
Figure 5-2 SK6 Wrist Flange
NOTE: Wash out anti-corrosive paint on wrist flange surface with thinner or light oil before mounting
the tools.

SECTION 6
ALLOWABLE LOAD
ON U-AXIS
6.1 Mounting Equipment
When peripheral equipment is attached to the U-axis, the following conditions
should be observed. Never modify the robot for other mountings.
CAUTION!
The maximum allowable load on the U-axis, including the wrist
load, is 15 kg (30.4 lbs).
W2
A
24
25 o
177
W1
U-AXIS ROTATION
CENTER
4-M6P1.0,
10mm DEEP
80
50
VIEW A
DIMENSIONS ARE IN MILLIMETERS (mm)
(kg)
W1 =0
15
W1 =3 W1 = LOAD GRAVITY (kg)
10 W1 =6*
WEIGHT
(W2 ) * WHEN LOAD CAPACITY (W1)
EQUALS 6kg UNBALANCED
5 MOMENT IS NOT PERMITTED
0
200 100 0 100 200 300 400 (mm)
DISTANCE BETWEEN U-AXIS ROTATION

CENTER AND LOAD GRAVITY
Figure 6-1 Allowable Load on U-axis

ALLOWABLE LOAD ON U-AXIS
6.2 Incorporated Wire and Airduct

Wires and an air line are incorporated into the robot for user application. Following
are ratings for sixteen wires and air ducts:
• Allowable current for wires: 6.6 A or below/wire. Total current value for
pins 1 to 16 must be 40 A or below.
• Maximum pressure for air duct: 490 kPa (5 kgf/cm2) or below.
A Air inlet: PT 3/8 tap, with bull plug
B S-axis Cable Connector: Type JL05-2A20-29PC (with cap) Mating plug:
Type JL05-6A20-29S
C Air inlet: PT 3/8 tap, with bull plug
D U-axis Cable Connector: Type JL05-2A20-29SC (with cap) Mating plug:
Type JL05-6A20-29P
A B
C
C D
Figure 6-2 Internal Wires, Connectors, and Air Inlet Locations

1
2
3
4 1
5 2 3
6
4 5 6
7
8 7 8
PINS USED 9 10
10 9
11 11 12
12 13 14
13 (1.25 mm 2) 15 16
14 (1.25 mm 2)
15 (1.25 mm 2)
16 (1.25 mm 2)
INTERNAL WIRES: 0.3 mm2 , 12 WIRES

1.25 mm2, 4 WIRES
Figure 6-3 Connector Pin Detail

SECTION 7
ROBOT CONSTRUCTION
7.1 Position of Limit Switches
The limit switches are located as shown in Figure 7-1. The inspection and
adjustment of the limit switches should be made after removing the cover.
LU-AXIS INTEREFERENCE
LIMIT SWITCH
(OPTIONAL)
S-AXIS OVERRUN
LIMIT SWITCH
L-AXIS OVERRUN
LIMIT SWITCH
(OPTIONAL)
Figure 7-1 Limit Switch Locations
7.2 Internal Connections

High reliability connectors, which can be easily removed, are used with each
connector part. For the numbers and locations of connectors, refer to Figure 7-2.
Nos. 18 TO 25
Nos. 7 TO 17
INTERNAL WIRE CONNECTOR
Nos. 1, 3, 4, 6
Nos. 2, 5
No. 26
1BC 2BC 3BC (FOR INTERNAL WIRE)
Figure 7-2 Connector Numbers and Locations

ROBOT CONSTRUCTION
YASNAC-MRC
POWER CABLE BATTERY
1-178288-3 OBT BAT
BAT-1-2
-1 1BC (36-74)
P
1BC-1 PA1
1 SV- 12CN -16 P -2 *PA1
-17
-18 -5 PB1
P -6 *PB1
MR-20L -19
-14 -12 PC1
P -13 *PC1
-15 -3 PC1
P -4 OBT P
-4 -10 +5 -1
-5 P -19 +5 -1 P
P -11 OV-1 P
-1 -20 OV-1
-2 -7 FG-1
-20
P
-8 PA-2
1 SV- 22CN -16 P -9 *PA-2
-17 -16 PB-2
-18 P -17 PB-2
MR-20L -19 -17 PB-2
-14 P -18 PC-2
-15
-4 -18 +5 -2
-5 P -34 +5 -2 P
-1 P -27 OV -2 P
-2 -35 OV -2
-20 -33 FG 2
P
-21 PA 3
1 SV- 32CN -16 P -28 *PA 3
-17 -29 PB 3
-18 P
MR-20L -19
-30 *PB 3
-38 PC 3
-14 P -39 *PC 2
-15
-36 +5 - 3
-4 P -45 +5 - 3 P
-5 P -37 OV - 3 P
-1 -46 OV - 3
-2 -47 FG 3
-20
-14 PA 4
2 SV- 12CN -16 P -15 *PA 4
-17 -22 PB 4
MR-20L -18 P -23 *PB 4
-19 -31 PC 4
-14 P -32 *PC 4
-15
-4 -40 +5 - 4
P -48 +5 - 3 P
-5 P -41 P
OV - 4
-1 -49
-2 OV - 4
-20 -24 FG 4
2 SV- 22CN -16 -42 PA 5

P -51 *PA 5
-17
-18 -59 PB 5
MR-20L -19
P -60 *PB 5
-61 PC 5
-14 P -67 *PC 5
-15
-43 +5 - 5
-4 P -52 +5 - 5 P
-5 P -44 OV - 5 P
-1 -53 OV - 5
-2 -50 FG 5
-20
-54 PA 6
2 SV- 32CN -16 P -55 *PA 6
-17 -62 PB 6
MR-20L -18 P -63 *PB 6
-19 -64 PC 6
-14 P -70 *PC 6
-15
-68 +5 - 6
P -72 +5 - 6 P
-4 P P
-5 -69 OV - 6
-1 -73 OV - 6
-2 -71 FG 6
-20
Figure 7-3 Internal Connection Diagram - 1 of 4

ROBOT CONSTRUCTION
NO 1
1CN-1 PA1
P -2 *PA1
-3 PB1
P -4 *PB1
-5 PC1
P -6 PC1
-7 BAT PG S- AXIS
P -8 OBT
-9 +5V
P -10 OV
SHIELD -11 FG-1

-12 RST
NO 1
2CN-1 PA2
P -2 *PA2
-3 PB2
P -4 *PB2
-5 PC2
P -6 PC2
-7 BAT PG L- AXIS
P -8 OBT
-9 +5V
P -10 OV
SHIELD -11 FG-2

-12 RST
NO 1
3CN-1 PA3
P -2 *PA3
-3 PB3
P -4 *PB3
-5 PC3
P -6 PC3
-7 BAT PG U- AXIS
P -8 OBT
-9 +5V
P -10 OV
SHIELD -11 FG-3

-12 RST
NO 1
7CN-1 PA4
P -2 *PA4
-3 PB4
P -4 *PB4
-5 PC4
P -6 PC4
NO 1
PG R- AXIS
P 8CN-1 BAT
-2 OBT
P -3 +5V
SHIELD -4 OV
-5 FG-4
-6 RST
P
NO 9 NO 18
9CN-1 PA5 18CN-1 PA5

-2 *PA5 P -2 *PA5
P -3 PB5 -3 PB5 B- AXIS
-4 *PB5 P -4 *PB5
P -5 PC5 -5 PC5
-6 *PC5 P -6 *PC5
NO 10 NO 19 PG
10CN-1 BAT 19CN-1 BAT
-2 OBT P -2 OBT
P -3 +5V -3 +5V
SHIELD -4 OV P -4 OV
-5 FG-5 SHIELD -5 FG-5
-6 RST
NO11 NO 20
11CN-1 PA6 20CN-1 PA5

P -2 *PA6 P -2 *PA5
-3 PB6 -3 PB5 T- AXIS
P -4 *PB6 P -4 *PB5
-5 PC6 -5 PC5
P -6 *PC6 P -6 *PC5
NO 21 PG
NO 12 19CN-1 BAT
12CN-1 +5V -2 OBT
P -2 OV P -3 +5V
SHIELD -3 FG-6 SHIELD -4 OV
-5 FG-5
-6 RST
1 1
2 2

ROBOT CONSTRUCTION
No. 26
26 CN-1 B1 B1
MTU-6-15 -2 SS1 SS1

-8 -3 BC1 U
-20 -4 LA1
-56 +24 V
-2 P -57 LB1 -5 LB1
-11 -58 BC2 -6 BC2
-9 -65 SS2 SS2
MR-20LW -18 P -66 OV B2
-14
E E
CN21 (28-21) BASE
2BC (28-21)
E
E
E
2BC-33 AC1
CN21-33
-36 -36 AC2
-1 MU1
-1 -2 MV1
-2 -5 MW1
-5 -6 MF1
-6 -10 BA1
-10 -11 BB1
-11
-3 -3 MU2
-4 -4 MV2
-7 -7 MW2
-8 -8 MF2
-12 BA2
-12
-3 -9 MU3
-4 -14 MV3
-7 -15 MW3
-19 MF3
-8
-20 BA3
-12
-16 -16 MU4

-17 -17 MV4
-18 -18 MW4
-23 -23 MF4
-24 BA4
-24
-25 -25 BB4
-22 -22 MU5

-26 -26 MV5
-27 -27 MW5
-28 -28 MF5
-32 -32 BA5
-29 -29 MV 6
-30 -30 MV6
-31 -31 MW6
-34 -34
-35 -35 BA6
-13 -13
-21 -21
3BC (20-29)
E
-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 -8
-8 -9
-9 -10
-10 -11
-11 -12
-12 -13
-13
-14
-14
-15
-15 -16
-16

ROBOT CONSTRUCTION
V P
For LAMP (OPTION)

LB1 LB3
LB2 P LA3
LB2 LB2 A
LB1 P LA1
LA1
LB1 S-AXIS OVERRUN L.S.
AL1
P P AL2
AC1 For FAN (OPTION)
AC2
No.4
4CN-1 MU1
-2 MV1
-3 MW1 SM S-AXIS
-4 ME1
-5 BA1
-6 BB1 YB
No.5
5 CN-1 MU2
-2 MV2
-3 MW2 SM L-AXIS
-4 ME2
-5 BA2
-6 BB2 YB
No.5
6CN-1 MU3
-2 MV3
-3 MW3 SM U-AXIS
-4 ME3
-5 BA3
-6 BB3 YB
No.13
13CN-1 MU4
-2 MV4
-3 MW4 SM R-AXIS
-4 ME4
No.14
14CN-1 BA4
-2 BB4 YB
No.15 No.22
15CN-1 MU5 22CN-1 MU5
-2 MV5 -2 MV5
-3 MW5 -3 MW5 SM B-AXIS
-4 ME5 -4 ME5
No.16 No.23
16CN-1 BA5 23CN-1 BA5

-2 BB5 -2 BB5 YB
No.17 No.24
17CN-1 MU6 24CN-1 MU6

-2 MV6 -2 MV6 SM T-AXIS
-3 MW6 -3 MW6
-4 BA6 -4 ME6
No.25
25CN-1 BA6
CASING -2 BB6 YB
3BC (20-29)
E E
-1 -1 1 2BC-1
P -2 -2 2
-3 -3 3 -2
P
-4 -4 4 -3
5 -4
P 6 -5
-6 FOR SPARE
7
P 8 -7
9 -8
P 10 -9
11 -10
12 -11
13 -12
14 -13
15 -14
16 -15
-16
LB3
LA3
LU-AXIS INTERFERENCE L.S.
LB2 LB2
LA2 L-AXIS OVERRUN L.S.
LB1 A
LB1
LA1 S-AXIS OVERRUN L.S.
LU-AXIS L.S. SPECIFICATIONS

ROBOT CONSTRUCTION
Table 7-1 Connector Types
Name No. Receptacle Type Plug Type
Base 1BC JL05-2A36-74PC JL05-6A36-74SC
Connector 2BC JL05-2A28-21PC JL05-6A28-21SC
For Internal 3BC JL05-2A20-29PC JL05-6A20-29S
Wires (Optional)
9, 11 172168-1 172160-1
10 1-172168-2 1-172160-2
Intermediate 12, 15 172167-1 172159-1
Connector 16 172165-1 172233-1
17 172167-2 172159-2
Motor 4, 5, 6 172168-1 172160-1
Connectors 13, 22, 24 172167-1 172159-1
14, 23, 25 172165-1 172233-1
Feedback 1,2,3 172170-1 172162-1
Unit 7, 18, 20 172168-1 172160-1
Connector 8, 19, 21 1-178168-2 1-172160-2
Connector JL05-2A20-29SC JL05-6A20-29P
for Internal (Opitonal)
Wires

SECTION 8
MAINTENANCE
8.1 Preventive Maintenance
Proper preventive maintenance is essential to ensure the equipment will provide
many years of trouble-free performance. Table 8-1, Preventive Maintenance
Checks and Service lists when, what, and how to inspect/service specific
components of the SK6. All Item No.'s correspond to numbered components in
Figure 8-1 except for item 18, Overhaul, which refers to the overall robot.
When performing the procedures in Table 8-1, it is important to keep the following
guidelines in mind:
WARNING!
Only personnel who have been trained in the operation and
maintenance of the SK6 should perform preventive maintenance,
checks, and services or personal injury or damage to equipment
could result.
1. Only personnel who have been trained in the operation and maintenance of
the SK6 should perform the procedures listed in this section.
2. Inspection intervals are based on servo power supply ON time.
3. These inspections/services have been established for arc welding applications.
It will be necessary to re-examine them for different, or special applications.
4. For axes that are used very frequently (in handling applications, for example)
it is recommended that inspection intervals be cut-in-half from what is
listed in Table 8-1.
5. When using a multimeter to check conductivity on wire harness leads (items
14 and 15), remove detector side connectors for each axis from the motor.
CAUTION!
For overhaul, disassembly, or repair contact MOTOMAN Service
Department at (937) 847-3200.
6. Wire harnesses (items 14 and 15) are to be replaced at Overhaul (24000H).

MAINTENANCE
Table 8-1 Preventive Maintenance Checks and Services
Item Interval Item to be
Procedure
No. (Daily/Hours) Inspected
1 Daily Tram Mark Check for Tram Mark.
2 Daily External Leads Check leads for damage or deterioration.
3 Daily Robot and Work • Check robot for cracks or damage.
Area • Clean work area of dust and/or spatter.
4 Daily L- and U-axes Check for grease leakage.
Mounting Baseplate
5 • 1000H Baseplate Mounting Tighten loose bolts. Replace bolts if necessary.
• 6000H Bolts
• 12000H
6 • 1000H Cover Mounting Tighten loose bolts. Replace bolts if necessary.
• 6000H Screws
• 12000H
7 • 1000H Base Connectors Check for loose connectors. Tighten connectors, if necessary.
• 6000H
• 12000H
8 • 6000H S-axis Speed • Check for malfunction. Replace if necessary.
• 12000H Reducer • Grease at 6000H with Molywhite RE No. 00 (see Sec. 8.2.2).
• Replace grease at 12000H with Molywhite RE No. 00 (see
Sec. 8.2.2).
9 • 6000H L- and U-axes Speed • Check for malfunction. Replace if necessary.
• 12000H Reducer • Grease at 6000H with Molywhite RE No. 00 (see Section 8.2.3).
• Replace grease at 12000H with Molywhite RE No. 00 (see
Sec. 8.2.3).
10 • 6000H R-, B-, and T-axes • Check for malfunction. Replace if necessary.
• 12000H Speed Reducers • Grease at 6000H with Harmonic Grease SK (see Sections 8.2.4
and 8.2.5).
11 • 6000H T-axis Gear • Check for malfunction. Replace if necessary.
• 12000H • Grease at 6000H with Harmonic Grease SK-1 (see Sec. 8.2.6).
12 • 6000H L- and R-axes Cross • Check for malfunction. Replace if necessary.
• 12000H Roller Bearings • Grease at 6000H with Alvania EP (see Sections 8.2.7 and 8.2.8).
13 • 12000H R-, B-, and T-axes Check for adequate tension and excessive belt wear.
Timing Belt
14 • 12000H Wire Harness Leads • Check S-, L-, U-, R-, B-, and T-axes leads for conductivity
for S-, L-, U-, R-, B-, between base main connector and intermediate connector.
and T-axes • Check for excessive wear on protective spring and insulation.
15 • 12000H Wire Harness Leads • Check B-, and T-axes leads for conductivity between terminals.
for B- and T-axes • Check for excessive wear on protective spring and insulation.
16 • 12000H L- and U-axes Link • Check for bearing wear (looseness) by moving L- and
U-axes forward, backward, up, and down.
• Grease with Alvania EP Grease 2 (see Sec. 8.2.9).
17 • 12000H Battery • Check voltage. If less than 2.8V, replace battery (see Sec. 8.2.1).
18 • 6000H Overhaul Contact the Motoman Service Department at (937) 847-3200.
• 24000H

MAINTENANCE
13 T-AXIS 11
13
13 B-AXIS
5
1
10
12 1 T-AXIS
1 B-AXIS
10
14
1 U-AXIS
4 4
16 16
14
16
1 L-AXIS
14
U-AXIS 9 9
2 2
7 8 14
14 S-AXIS 1
12 17
Figure 8-1 Inspection Points

MAINTENANCE
8.2 Maintenance Procedures

DANGER!
In accordance with ANSI/RIA R15.06, Section 6.13.4 and 6.13.5,
use lockout/tagout procedures during equipment maintenance.
Refer also to Section 1910.147 (29CFR, Part 1910), Occupational
Safety and Health Standards for General Industry (OSHA).
8.2.1 Replacing the Battery

To replace the battery, proceed as follows:
1. Remove the battery unit mounting screws and cover.
2. Remove the pins 1 and 2 on both sides of the battery.
1 2
BATTERY DIODE
3. Remove old battery.

4. Install new battery and connect the pins in correct direction.
5. Install cover and mounting screws. Tighten securely.
SCREW (M4)
BASE CONNECTOR
BATTERY BASE
Figure 8-2 Battery Location
8.2.2 S-axis Speed Reducer Lubrication Procedure

To lubricate the S-axis speed reducer, proceed as follows:
CAUTION!
Be sure to remove So exhaust plug before adding grease to the
S-axis speed reducer or damage to the motor may result.
NOTE: For ceiling-mounted robot, the exhaust port and the grease fitting locations are reversed.
1. Remove So exhaust plug.
2. Inject 30cc (60cc for the initial lubrication) of Molywhite RE No. 00 into the
S1 grease fitting (see Figure 8-3).

MAINTENANCE
SO : EXHAUST PLUG
(G NIPPLE A-PT 1/8)
S-AXIS SPEED REDUCER S I : GREASE FITTING

(G NIPPLE A-PT 1/8)
Figure 8-3 S-axis Speed Reducer Lubrication
NOTE: To replace the old grease with new grease, inject 400cc of Molywhite RE No. 00 into the S1
grease fitting, or until new grease starts to exit the So exhaust port.
3. Operate the S-axis for 30 minutes to discharge any extra grease.
4. Install the So exhaust plug.
5. Wipe the So exhaust port with a clean cloth, if necessary.
8.2.3 L- and U-axis Speed Reducers Lubrication Procedures

To lubricate the L- and U-axes speed reducers, proceed as follows:
1. Position U-axis within the angles shown in Figure 8-4.
ALLOWABLE SUPPLY
ANGLE FOR U-AXIS
15
˚
45˚
45˚
˚
10
ALLOWABLE SUPPLY
ANGLE FOR U-AXIS
Figure 8-4 U-axis Lubrication Position

MAINTENANCE
CAUTION!
Be sure to remove Lo and Uo exhaust plugs before adding grease
to the L- and U-axes speed reducers or damage to the motors may
result.
2. Remove Lo and Uo exhaust plugs.
3. Inject 30cc (60cc for the initial lubrication) of Molywhite RE No. 00 into the
L1 and the U1 grease fittings (see Figure 8-5).
LO: EXHAUST PLUG L-AXIS U-AXIS UO: EXHAUST PLUG
(G NIPPLE A-MT6x1) SPEED REDUCER SPEED REDUCER (G NIPPLE A-MT6x1)
L I :GREASE FITTING UI :GREASE FITTING

(G NIPPLE A-MT6x1) (G NIPPLE A-MT6x1)
Figure 8-5 L- and U-axes Speed Reducers Lubrication
NOTE: To replace the old grease with new grease, inject 300cc of Molywhite RE No. 00 into each L1
and U1 grease fittings, or until new grease starts to exit the L1 and U1 exhaust ports.
4. Operate L- and U-axes for 30 minutes to discharge the extra grease.
5. Install the Lo and Uo exhaust plugs.
6. Wipe Lo and Uo exhaust ports with a clean cloth, if necessary.
8.2.4 R-axis Speed Reducer Lubrication Procedure

To lubricate the R-axis speed reducer, proceed as follows (see Figure 8-6):
1. Remove Ro plug.
2. Inject 8cc (16cc for the initial lubrication) of Harmonic Grease SK-1 into the
R1 grease fitting.
3. Install Ro plug and wipe exhaust port with a clean cloth, if necessary.

MAINTENANCE
RO: PLUG FOR AIR FLOW
(HEXAGON SOCKET HEAD M6)
R-AXIS SPEED REDUCER
RI :GREASE FITTING
(G NIPPLE A-MT6 x 1 )
Figure 8-6 R-axis Speed Reducer Lubrication
8.2.5 B- and T-axes Speed Reducers Lubrication Procedure

1. Remove U-arm cover (B-axis side) (see Figure 8-7).
2. Remove Bo and To plugs.
3. Inject 10cc (20cc for the initial lubrication) of Harmonic Grease SK-1into the
B1 grease fitting.
4. Inject 5cc (10cc for the initial lubrication) of Harmonic Grease SK-1 into the
T1 grease fitting.
5. Reinstall the Bo and To plugs and wipe exhaust ports with a clean cloth, if
necessary.
6. Install the U-arm cover (B-axis side).
B-AXIS SPEED T-AXIS SPEED
REDUCER REDUCER
TI : GREASE FITTING
(G NIPPLE A-MT6 x1)
TO : PLUG FOR AIR FLOW

(MAGIC SCREW M6)
BO: PLUG FOR AIR FLOW

(MAGIC SCREW M6)
B I : GREASE FITTING
(G NIPPLE A-MT6 x1)
Figure 8-7 B- and T-axes Speed Reducer Lubrication

MAINTENANCE
8.2.6 T-axis Gear Lubrication Procedure

1. Remove To plug (see Figure 8-8).
2. Inject 5cc (10cc for the initial lubrication) of Harmonic Grease SK into the
GEAR1 grease fitting.
3. Install the To plug and wipe exhaust port with a clean cloth, if necessary.
BO: PLUG FOR AIR FLOW

(HEXAGON SOCKET HEAD M6)
GEARI : GREASE FITTING

(G NIPPLE A-MT6x1)
Figure 8-8 T-axis Gear Lubrication
8.2.7 R-axis Cross Roller Bearing Lubrication Procedure

To lubricate the R-axis cross roller bearing, proceed as follows (see Figure 8-9):
1. Inject 5cc of Alvania EP Grease 2 into the Rc grease fitting.
2. Wipe fitting with a clean cloth, if necessary.
R-AXIS CROSS
ROLLER BEARING
Rc:GREASE FITTING
(G NIPPLE A-MT6x1 )
Figure 8-9 R-axis Cross Roller Bearing Lubrication

MAINTENANCE
8.2.8 L-axis Cross Roller Bearing Lubrication Procedure

To lubricate the L-axis cross roller bearing, proceed as follows (see Figure 8-10):
1. Inject 5cc of Alvania EP Grease 2 into the Lc grease fitting.
2. Wipe grease fitting with a clean cloth, if necessary.
L-AXIS CROSS
ROLLER BEARING
L C : GREASE FITTING
(G NIPPLE A-MT6x1)
Figure 8-10 L-axis Cross Roller Bearing

8.2.9 L- and U-axes Link/Link Roller Bearing Lubrication Procedures
To lubricate the L- and U-axes link/link roller bearing, proceed as follows:
1. Remove plugs 1 through 3 (see Figure 8-11).
2. Inject 3cc (6cc for the initial lubrication) of Alvania EP Grease 2 into links 1
through 3 grease fittings.
3. Install plugs1 through 3.
4. Wipe link grease fittings with a clean cloth, if necessary.

MAINTENANCE
LINK 1 : TAPER 2 : PLUG FOR LINK 1 : TAPER
ROLLER BEARING AIR FLOW ROLLER BEARING
LINK 2 : TAPER
ROLLER BEARING x 1
LINK 2 : GREASE FITTING 1 : PLUG FOR

(G NIPPLE A-MT6x1) AIR FLOW
LINK 1 : GREASE FITTING

LINK 3 : TAPER
(G NIPPLE A-MT6x1)
ROLLER BEARING
LINK 3 : GREASE FITTING 3 : PLUG FOR

(G NIPPLE A-MT6x1) AIR FLOW
Figure 8-11 L and U-axes Link, and Link Taper Roller Bearing Lubrication

SECTION 9
RECOMMENDED SPARE PARTS
Table 9-1 lists parts that are recommended stock as spare parts for the SK6 robot
and are ranked as follows:
Rank A: Expendable and frequently replaced parts
Rank B: Parts for which replacement may be necessary as a result of
frequent operation.
Rank C: Drive unit
NOTE: For replacing parts rank B and C, contact your MOTOMAN representative.
Table 9-1 Spare Parts for SK6 Robot

Qty.
No. Rank Part Name Type Manufacturer Qty. per Remarks
Unit
1 A Limit Switch set HW9470694-A Yaskawa Electric Corp. 1 1 S-axis, lead terminal
treatment completion
2 A Grease Molywhite RE Yaskawa Electric Corp. 16 kg
No.00
3 A Grease Harmonic Grease Harmonic Drive System 2.5 kg
SK-1 Co., Ltd.
4 A Grease Alvania EP Showa Oil Co., Ltd. 16 kg
Grease 2
5 A Silicon Rubber Modifier Silicon Konishi Co., Ltd. – –
Compound Caulk
6 A Battery unit HW8471030-A Yaskawa Electric Corp. 1 1
7 B R-axis timing belt 60S4.5 M338 Mitsuboshi Belting Ltd. 1 1
8 B S-axis speed HW9280631-A Yaskawa Electric Corp. 1 1
reducer
9 B L- and U-axes HW9280632-A Yaskawa Electric Corp. 1 2
speed reducer
10 B R-axis drive unit HW9370833-A Yaskawa Electric Corp. 1 1
11 C AC servomotor for HW9380948-A Yaskawa Electric Corp. 1 2 Without brake, with
S-axis key, lead terminal
12 C AC servo motor HW9380949-A Yaskawa Electric Corp. 1 1 With brake, with key,
for L- and U-axes lead terminal treatment
completion
13 C AC servo motor HW9380936-A Yaskawa Electric Corp. 1 1 Without brake, with
for R-axis key, lead terminal
14 C Wrist unit HW9171174-A Yaskawa Electric Corp. 1 1
15 C Internal wiring HW9170963-A Yaskawa Electric Corp. 1 1
16 C B- and T-axes HW9370827-A Yaskawa Electric Corp. 1 1 In U-arm
internal wiring

SECTION 10
PARTS LIST
This section provides illustrations and parts lists for SK6 replacement parts and is
broken down in the following manner:
• S-axis Driving Unit
• L-, U-axes Driving Unit
• R-axis Driving Unit
• Wrist Unit

PARTS LIST

PARTS LIST

PARTS LIST

PARTS LIST

PARTS LIST

PARTS LIST

INDEX
A N
Allowable Load on U-axis, 6-1 Nomenclature and Working Axes, 4-2
Allowable Wrist Load, 5-1
Alterable Working Range, 4-3 P
Parts List, 10-1
B Position of Limit Switches, 7-1
B- and T-axes Speed Reducers Positioning the SK6, 2-1
Lubrication Procedure, 8-7 Precautions for Allowable Wrist Load, 5-1
Basic Specification, 4-1 Preventive Maintenance, 8-1
C R
Cable Connection, 3-2 R-axis Cross Roller Bearing Lubrication
Conducting a Safety/Operation Check, 3-3 Procedure, 8-8
Connecting the Earth Grounds, 3-1 R-axis Driving Unit, 10-8
R-axis Speed Reducer Lubrication Procedure, 8-6
D Receiving, 1-1
Dimensions and Working Ranges, 4-2
Recommended Spare Parts, 9-1
Replacing the Battery, 8-4
I
Incorporate Wire and Airduct, 6-2 Robot Construction, 7-1
Installation, 2-1
S
Internal Connections, 7-1
S-axis Driving Unit, 10-2
S-axis Speed Reducer Lubrication Procedure, 8-4
L
L- and U-axes Link/Link Roller Bearing Safety Guards, 2-5
Lubrication Procedures, 8-9 Selecting a Location, 2-1
L- and U-axis Speed Reducers Lubrication Specifications, 4-1
Procedures, 8-5
L-, U-axes Driving Unit, 10-5 T
L-axis Cross Roller Bearing Lubrication T-axis Gear Lubrication Procedure, 8-8
Procedure, 8-9
List of Figures, ii W
List of Tables, iii Wiring, 3-1
Working Range of B-axis, 4-3
M Wrist Flange, 5-2
Maintenance Procedures, 8-4 Wrist Unit, 10-11
Maintenance, 8-1
Mounting Equipment, 6-1
Mounting SK6 on the Wall or Ceiling, 2-4
Mounting the SK6 on the Floor, 2-3
SK6 Manipulator Instructions MOTOMAN

CHAPTER 4
SK6 DUAL MRC

INSTRUCTIONS
February 28, 1998
MOTOMAN
805 Liberty Lane
TEL: (937) 847-6200 FAX: (937) 847-6277
TABLE OF CONTENTS
Section Page
LIST OF FIGURES............................................................................................................. iii
LIST OF TABLES ............................................................................................................... v
1 INTRODUCTION.......................................................................................................1-1
1.1 About the SK6 Dual MRC Controller...........................................................1-1
1.2 About this Document..................................................................................1-1
1.3 Reference to Other Documentation ............................................................1-2
1.4 Customer Service Information....................................................................1-2
2 EQUIPMENT DESCRIPTION ....................................................................................2-1
2.1 External Components .................................................................................2-1
2.1.1 Playback Box ..................................................................................2-2
2.1.2 Programming Pendant....................................................................2-5
2.1.3 Brake Release ...............................................................................2-14
2.2 Internal Components ................................................................................2-15
2.2.1 Incoming Voltage..........................................................................2-15
2.2.2 Cooling System............................................................................. 2-15
2.2.3 Servopacks ...................................................................................2-16
2.2.4 Contactor Unit ..............................................................................2-17
2.2.5 I/O Rack Configuration..................................................................2-18
2.2.6 CPU Rack Configuration ...............................................................2-19
2.3 Diagnostic Displays ..................................................................................2-20
2.3.1 Input Status Displays....................................................................2-21
2.3.2 Output Status Displays ................................................................. 2-22
2.3.3 RIN Input Display..........................................................................2-22
2.3.4 System Monitoring Time Displays ................................................2-23
2.3.5 Alarm List Displays .......................................................................2-24
2.3.6 Servo Display................................................................................2-26
2.4 Alarms and Errors ....................................................................................2-28
2.4.1 Error Messages............................................................................. 2-28
2.4.2 Minor Alarms................................................................................2-28
2.4.3 Major Alarms ................................................................................2-28
2.5 Specifications ...........................................................................................2-29
3 BASIC OPERATION..................................................................................................3-1
3.1 Using the ENABLE Switch ..........................................................................3-1
3.2 Servo Power...............................................................................................3-2
3.2.1 Servo Power in Teach Mode ...........................................................3-2
3.2.2 Servo Power in Play Mode..............................................................3-2
SK6 Dual MRC Instructions i MOTOMAN

Section Page
3.3 Teach Lock .................................................................................................3-3
3.4 Brake Release Control ................................................................................3-4
3.5 Coordinates and Axes.................................................................................3-5
3.5.1 Setting Axis Keys for World or Cylindrical Coordinates ..................... 3-7
3.6 Specified Point ...........................................................................................3-9
4 CONTROLLER MAINTENANCE ................................................................................4-1
4.1 Opening/Closing the Door ..........................................................................4-1
4.2 Incoming Voltage .......................................................................................4-2
4.3 Connecting the Equipment..........................................................................4-4
4.4 Connecting External Power Supply ............................................................4-5
4.5 Short-Pinning for Shock Sensor Use..........................................................4-6
4.6 Battery Replacement ..................................................................................4-7
4.7 I/O Board Replacement...............................................................................4-8
4.8 CPU Board Replacement ............................................................................4-9
4.9 Fuse Replacement ....................................................................................4-10
4.10 Servo-On Indicator Light Replacement..................................................... 4-11
5 TROUBLESHOOTING...............................................................................................5-1
5.1 Alarm Codes...............................................................................................5-1
5.1.1 Standard Alarm Codes ....................................................................5-1
5.1.2 CPU Rack 7-segment LED Display..................................................5-1
5.1.3 Displaying Major and Minor Alarms ...............................................5-3
5.1.4 Clearing Overrun Alarms.................................................................5-4
6 DIAGRAMS..............................................................................................................6-1
6.1 Power Flow.................................................................................................6-1
6.2 Signal Flow .................................................................................................6-2
6.3 External Power Connection for I/O..............................................................6-3
6.4 MIO04-1/2 Board .......................................................................................6-4
6.5 MIO04-2/2 Board .......................................................................................6-5
6.6 Welding Board ............................................................................................6-6
6.7 Exclusive-use Input/Output ........................................................................6-7
INDEX
SK6 Dual MRC Instructions ii MOTOMAN

LIST OF FIGURES
Figures Page
Figure 2-1 SK6 Dual MRC Controller - External ......................................................... 2-1
Figure 2-2 Playback Box ............................................................................................2-2
Figure 2-3 Front Panel ...............................................................................................2-3
Figure 2-4 Subpanel...................................................................................................2-4
Figure 2-5 Programming Pendant..............................................................................2-5
Figure 2-6 ENABLE Switch ........................................................................................2-6
Figure 2-7 Display......................................................................................................2-7
Figure 2-8 Display Areas............................................................................................2-7
Figure 2-9 Job Content Display..................................................................................2-7
Figure 2-10 Status Display...........................................................................................2-8
Figure 2-11 Alternate Status Display............................................................................2-9
Figure 2-12 Human Interface Display Area ..................................................................2-9
Figure 2-13 Function Keys ......................................................................................... 2-10
Figure 2-14 Soft Keys ................................................................................................2-11
Figure 2-15 SERVO POWER ON Indicator ................................................................. 2-11
Figure 2-16 ENABLE Key, E-STOP Button, and HOLD/RELEASE Key ......................... 2-12
Figure 2-17 Editing Keys............................................................................................2-13
Figure 2-18 Robot Axes and Brake Release Control...................................................2-14
Figure 2-19 SK6 Dual MRC Controller - Internal ........................................................2-15
Figure 2-20 Servopack LED Indicators ......................................................................2-16
Figure 2-21 Contactor Unit ........................................................................................2-17
Figure 2-22 I/O Rack Configuration............................................................................2-18
Figure 2-23 CPU Rack Configuration ......................................................................... 2-19
Figure 2-24 Universal Input Status ............................................................................2-21
Figure 2-25 Specified Input Status............................................................................. 2-21
Figure 2-26 Universal Output Status ..........................................................................2-22
Figure 2-27 Specified Output Status ..........................................................................2-22
Figure 2-28 RIN Input Display....................................................................................2-22
Figure 2-29 System Monitoring Time ........................................................................2-23
Figure 2-30 Servo Power Input Time Display............................................................. 2-23
Figure 2-31 Playback Time Display............................................................................2-23
Figure 2-32 Moving Time Display ..............................................................................2-24
Figure 2-33 Operating Time Display ..........................................................................2-24
Figure 2-34 Minor Alarm List Display ........................................................................2-24
Figure 2-35 Major Alarm List..................................................................................... 2-25
Figure 2-36 I/O Alarm (System Section) List ............................................................. 2-25
Figure 2-37 I/O Alarm (User Section) List..................................................................2-25
Figure 2-38 Off-line Alarm List ..................................................................................2-26
Figure 2-39 Alarm Details ..........................................................................................2-26
SK6 Dual MRC Instructions iii MOTOMAN

Figures Page
Figure 2-40 Digital Value Monitor (Position Feedback)............................................. 2-26
Figure 2-41 Speed Status (Reference, Feedback) ..................................................... 2-27
Figure 2-42 Speed Status (Speed Error) ....................................................................2-27
Figure 2-43 Torque Status ......................................................................................... 2-27
Figure 3-1 Operating the ENABLE Switch ..................................................................3-1
Figure 3-2 Playback Box ............................................................................................3-2
Figure 3-3 Robot Axes and Brake Release Control ....................................................3-4
Figure 3-4 Programming Pendant Axes .....................................................................3-5
Figure 3-5 Axis Keys ..................................................................................................3-5
Figure 3-6 Path of X-Axis Movement in World...........................................................3-6
Figure 3-7 Path of Y-Axis Movement in World...........................................................3-6
Figure 3-8 Path of Z-Axis Movement in World...........................................................3-6
Figure 3-9 Path of X-Axis Movement in Cylindrical....................................................3-6
Figure 3-10 Path of Y-Axis Movement in Cylindrical....................................................3-7
Figure 3-11 Path of Z-Axis Movement in Cylindrical ....................................................3-7
Figure 3-12 Axis Keys to Change Tool's Angle of Orientation ......................................3-8
Figure 3-13 Programming Pendant Coordinates..........................................................3-8
Figure 3-14 Specified Point Position Display ............................................................. 3-10
Figure 3-15 SK6 Home Position................................................................................. 3-10
Figure 4-1 Opening/Closing Cabinet Door..................................................................4-1
Figure 4-2 Factory-Set Voltage ..................................................................................4-2
Figure 4-3 Input Line Terminal Strip ..........................................................................4-3
Figure 4-4 Incoming Power Connections...................................................................4-4
Figure 4-5 External Power Supply Connection for I/O................................................4-5
Figure 4-6 Short-Pinning I/O Boards for Shock Sensor Use ......................................4-6
Figure 4-7 Battery Replacement ................................................................................4-7
Figure 4-8 Replacing an I/O Board in the I/O Rack ....................................................4-8
Figure 4-9 Replacing a System Control Board on the CPU Rack ...............................4-9
Figure 4-10 Location of Fuses in MRC Cabinet ..........................................................4-10
Figure 4-11 Servo-On Indicator Light ........................................................................4-11
Figure 5-1 CPU Rack 7-segment LED Display............................................................5-2
Figure 6-1 Power Flow...............................................................................................6-1
Figure 6-2 Signal Flow ...............................................................................................6-2
Figure 6-3 External Power Connection for I/O............................................................6-3
Figure 6-4 MIO04-1/2 Board......................................................................................6-4
Figure 6-5 MIO04-2/2 Board......................................................................................6-5
Figure 6-6 Welding Board ..........................................................................................6-6
Figure 6-7 Connection of Exclusive-use Input ...........................................................6-7
Figure 6-8 Connection of Exclusive-use Output ......................................................... 6-7
SK6 Dual MRC Instructions iv MOTOMAN

LIST OF TABLES
Tables Page
Table 2-1 Controller Specifications......................................................................... 2-29
Table 4-1 Jumper Connections for Input Line Voltages (Decal) ...............................4-3
Table 4-2 Incoming Power Specifications (Decal) ....................................................4-4
Table 4-3 Fuse Replacement Data ..........................................................................4-11
Table 5-1 Alarm Code Type Classification ................................................................5-1
Table 5-2 1-digit Number Fixed Display ...................................................................5-1
Table 5-3 4-digit Number Repeated Display ............................................................. 5-2
Table 5-4 List of Alarm Messages at Initial Diagnosis ..............................................5-4
Table 5-5 List of Alarm Messages ............................................................................5-6
SK6 Dual MRC Instructions v MOTOMAN

SECTION 1
INTRODUCTION
1.1 About the SK6 Dual MRC Controller
This controller has been certified as meeting, and often exceeding, rigid
Underwriters Laboratory (UL) specifications for safety, as set forth by the
Robotics Industry Association (refer to Chapter 2, SAFETY).
1.2 About this Document

This manual provides information, including basic operation and maintenance
instructions, for the SK6 Dual MRC Controller. It is your responsibility to
familiarize yourself thoroughly with the information presented in this manual,
especially Chapter 2, SAFETY. This manual is divided into the following
sections:
SECTION 1 - INTRODUCTION
This section provides general information regarding this manual, a list of
reference documents, and customer service information.
SECTION 2 - EQUIPMENT DESCRIPTION

This section is a detailed description of the major components of the SK6 Dual
MRC.
SECTION 3 - BASIC OPERATION

This section covers the basic operation of the SK6 Dual MRC.
SECTION 4 - CONTROLLER MAINTENANCE

This section provides instructions for basic maintenance of the SK6 Dual MRC.
SECTION 5 - TROUBLESHOOTING
This section provides basic information for troubleshooting the SK6 Dual MRC.
SECTION 6 - DIAGRAMS
This section provides diagrams and schematics of SK6 Dual MRC.
APPENDICES
The Appendices provide reference information and block wiring diagrams of the
various components of the SK6 Dual MRC.
SK6 Dual MRC Instructions 1-1 MOTOMAN

INTRODUCTION
1.3 Reference to Other Documentation

For additional information refer to the following:
• Motoman manuals that came with your system
• Vendor manuals for system components not manufactured by Motoman
1.4 Customer Service Information

If you are in need of technical assistance, contact the Motoman service staff at
(937) 847-3200. Please have the following information ready before you call:
• Robot Type (SK6)
• Application Type (welding)
• Robot Serial Number (located on the back side of the robot arm)
• Robot Sales Order Number (located on back side of MRC controller)

EQUIPMENT DESCRIPTION
SECTION 2
The SK6 Dual MRC, as shown in Figure 2-1, controls manipulator movement and
welding power supply, processes input and output signals, and provides the
signals to operate the welding system. It maintains variable data and performs
numeric processing to convert to and from different coordinate systems. In
addition, the controller provides the following: main logic functions, servo
control, program and constant data memory, and power distribution.
Systems using the Dual MRC are configured such that one controller can direct
the action of both robots, designated as R1 and R2. The Dual MRC coordinates
the operation of the entire cell and delegates tasks to both robots. Both welders
(weld 1 and weld 2) and the servo-controlled positioner (S1) are also controlled
by the Dual MRC.
2.1 External Components

The SK6 Dual MRC Controller consists of the following external components:
• Playback Box
• Programming Pendant with ENABLE Switch
• Brake Release Control
• AC Power Disconnect
PROGRAMMING PENDANT AC POWER DISCONNECT
PLAYBACK BOX
SERVO POWER MODE CYCLE E.STOP
PLAY TEACH REMOTE AUTO 1 CYCLE STEP
RESET
ET
RES
ES
ALARM/ R T
ERROR
HOLD START
YASNAC MRC
480 VOLTS
BRAKE RELEASE CONTROL

BRAKE RELEASE CONTROL
U-Axis U-Axis
R-Axis R-Axis
B-Axis B-Axis
MOTOM MOTOM
AN AN
T-Axis T-Axis
L-Axis L-Axis
S-Axis S-Axis
WARNING WARNING
DUAL
ROBOT SIDE CONTROLLER SIDE
Figure 2-1 SK6 Dual MRC Controller - External

2.1.1 Playback Box

The playback box is divided into two distinct areas: the Front Panel and the
Subpanel, as shown in Figure 2-2.
FRONT PANEL

RESET
ET
RES
ES
ET
ALARM/ R
ERROR
ON ON OVERRUN RECOVERY
HOLD START
POWER EDIT LOCK
OFF OFF
AC100V 0.5A RS-232C
SUBPANEL
Figure 2-2 Playback Box
Front Panel
E-STOP
E-STOP (Emergency Stop) (see Figure 2-3) drops servo motor power and applies
brakes to the robot. The SERVO POWER light is turned off and the pendant
LCD displays an Emergency Stop message. Twist the button 1/4 turn clockwise
to release the E-Stop. E-Stop functions the same in Teach, Play, or Remote mode.
START
START (see Figure 2-3) begins automatic operation of the robot. The START
button light remains lit the entire time the robot is running the program. This
function is only valid in Play mode.
HOLD
In the Play mode, HOLD (see Figure 2-3) temporarily stops program execution.
Servo power remains live and the brakes are not applied. The HOLD light is lit
only as long as the button is pressed. However, the robot will not continue
executing the program until the START button is pressed again.
SERVO POWER
The SERVO POWER push button turns servo power ON. An indicator lamp in
the switch lights when servo power is on. In TEACH mode, the SERVO ON
push button operates only when the ENABLE switch on the programming
pendant is held in.
MODE Buttons
Three MODE buttons (see Figure 2-3) determine control of the manipulator.
These buttons are PLAY, TEACH, and REMOTE. Each button has an indicator
light which is lit when the mode is selected.

SERVO MODE CYCLE
POWER BUTTONS BUTTONS E-STOP

RESET
ET
RES
ES
ET
ALARM/
R
ERROR START
BUTTON
HOLD START
ALARM/ERROR HOLD
INDICATOR BUTTON
Figure 2-3 Front Panel

Play Mode
When the PLAY mode button is pressed, the MRC is in control of the
manipulator motors. The robot must be in the Play mode for a job to be run
automatically.
Teach Mode
When the TEACH mode button is pressed, the operator has control of the
manipulator. Usually, when the robot is taught, edited, or moved manually, it is
in the Teach mode.
Remote Mode
Pressing the REMOTE mode button allows the MRC and manipulator to be
controlled by an external device such as a remote operator station or a host
computer. This function is optional and may not respond in all systems.
CYCLE Buttons
Three CYCLE buttons (see Figure 2-3) determine how the START button
functions in the Play mode. They also affect the TEST START function of the
programming pendant (see Figure 2-16). These buttons are STEP, 1-CYCLE, and
AUTO. The selected cycle is indicated by a light.
Step
When the STEP button is pressed, the robot will execute one line of the selected
job each time the START button is pressed.
1-Cycle
When the 1-CYCLE button and the START button are pressed, the robot executes
the selected job one time, starting at the cursor location. The robot runs the
selected job until it encounters the program END instruction.
Auto
When the AUTO button and the START button are pressed, the robot will execute
the selected job repetitively.

ALARM/ERROR Indicator Light
If an error or alarm occurs, the ALARM/ERROR indicator light illuminates (see
Figure 2-3) and remains on until the condition is cleared. In addition, the status of
the playback box buttons can not be changed and the programming pendant keys
are disabled.
Subpanel
ON/OFF EDIT LOCK
KEY SWITCH KEY SWITCH

RESET
ET
RES
ES
ET
ALARM/ R
ERROR
ON ON OVERRUN RECOVERY
HOLD START
POWER EDIT LOCK
OFF OFF
AC100V 0.5A RS-232C
AC POWER OUTLET RS-232C PORT OVERRUN RECOVERY

SWITCH
Figure 2-4 Subpanel

ON/OFF Key Switch (Optional)
Turn the ON/OFF Key Switch (see Figure 2-4) ON to supply power to the robot
controller. Even if the main power switch is ON at the controller, robot controller
power is not ON if this key switch is OFF. This ON/OFF switch is usually found
on a system with a remote playback box.
EDIT LOCK Key switch
The EDIT LOCK Key Switch (see Figure 2-4) prevents any data from being
changed in the controller, including files, jobs, parameters, etc., while in the ON
position. The key cannot be removed while in the OFF position, but should be
removed when EDIT LOCK is ON.
AC Power Outlet
This 100VAC, 0.5A outlet (see Figure 2-4) can be used to power a floppy disk
drive unit (FC1 or FC2) or a host computer.
RS-232C Port
This RS-232C Port (see Figure 2-4) is used for data communication between the
MRC and a floppy disk controller (FC1 or FC2), or the MRC and a host
computer.
OVERRUN RECOVERY Switch
The OVERRUN RECOVERY switch (see Figure 2-4) is used as a momentary
release of axis overtravel and may be used to recover from shock sensor actuated
E-Stops. Continuously pressing this button allows you to power up the servo
motors and jog the robot away from the overtravel or shock sensor condition.

2.1.2 Programming Pendant

The programming pendant, as shown in Figure 2-5, consists of the following
features: ENABLE Switch, Servo Power On push button, Display area, Soft
Keys, E-stop, Function Keys, and Editing Keys, as well as other specific keys and
indicators. These features are described on the following pages.
DISPLAY
YASNAC MRC
J: S: TEACH AUTO STOP
COORD MAN SPD
JOINT FST
COORDINATE WLD
MED MANUAL
CYL
SYSTEM TOOL SLW
SPEED
INDICATORS =>
INCHING
INDICATORS
USER !
SERVO SOFT KEYS

POWER ON
F1 F2 F3 F4 F5 MORE
RESET
,
SERVO E.STOP
POWER ON
ET
DISP EDIT SELECT FUNC CUSTOMER
RES
E-STOP
ES
R ET
MAN SPD
GROUP HIGH
SPD COORD
ENABLE AXIS SLW FST
1 X- X+ x x 4
S- S+ R- R+
2 Y- Y+ y y 5
FUNCTION KEYS
L- L+ B- B+
ENABLE SWITCH
3 Z- Z+ z z 6
U- U+ T- T+
HOLD
TEST
RELEASE BWD FWD
START
GROUP ENTER
AXIS
MODIFY DELETE INSERT MODIFY
7 8 9 EDITING KEYS
WEAV ON ARC ON FEED
4 5 6
WEAV OFF ARC OFF RETRACT
CANCEL 1 2 3
TIMER VOLT CUR
0 . -
MOTION PLAY POS
TYPE REF PNT VOLT CUR
SPD LVL
Figure 2-5 Programming Pendant

TEACH LOCK
DANGER!
When using the programming pendant in the workcell, always
engage the Teach Lock function first to prevent serious personal
injury or death, or equipment damage.
Whenever the programming pendant is being used in the workcell, engage Teach
Lock. When Teach Lock has been engaged, the word "LOCK" will flash in the
top center of the programming pendant display. This signifies that control of the
manipulator rests solely with the programming pendant and operation is not
possible from the playback box. The Teach Lock function is an important and
necessary safety feature. To use the Teach Lock feature, refer to Section 4.3.
ENABLE SWITCH
The ENABLE switch is a 3-position switch located on the left rear of the
programming pendant, as shown in Figure 2-6. The ENABLE switch is a safety
feature which controls servo power while in TEACH mode. While depressed, it
allows servo power to be ON; however, should the operator release the switch, or
grasp it too tightly, servo power is immediately disabled.
When the switch is in the first position (resting) servo power is OFF. When the
switch is in the second position (center), servo power is ON. When the switch is
in the third position (holding too tightly), servo power is OFF. To correctly
operate the robot arm with the ENABLE switch, refer to Section 4.1.
BACK OF
PROGRAMMING
PENDANT
ENABLE SWITCH
Figure 2-6 ENABLE Switch

DISPLAY
The display is a 4 inch, 12 line, 40 character LCD, as shown in Figure 2-7. It
allows the operator to monitor and edit programs, display files, etc.
YASNAC MRC
COORD MAN SPD
JOINT FST
WLD DISPLAY AREA MED
CYL
TOOL SLW
=>
USER ! INCHING
Figure 2-7 Display

Display Areas
The screen can display 40 columns by 12 lines and is divided into three areas, as
shown in Figure 2-8.
J: S: TEACH AUTO STOP STATUS DISPLAY AREA
GENERAL-PURPOSE AREA
=>
! HUMAN INTERFACE DISPLAY AREA
Figure 2-8 Display Areas

Each screen has a title that is displayed in the upper left corner in the status
display area. Figure 2-9 is displaying Job Content. This is the body of the job
and contains all the normal job structure, including all lines and steps and all
related instructions.
SCREEN TITLE
J:WORK-C S:006 LOCK CYCLE STOP DISP

JOB CONTENT
L: S: INST TOOL: 00
0004 004 MOVL V=276
0005 005 MOVJ VJ=50.00
0006 006 MOVJ VJ=50.00
0007 END
=>
!
JOB POSN FILE VAR DIAG
Figure 2-9 Job Content Display

STATUS DISPLAY AREA
The status display area shows the data related to the controller's condition. The
items shown in Figure 2-10 are always displayed.
N
TIO
RA
PE
O
ING
DE C LE O
M
O
CY NG DE
N O O
E N F
M . IO IO O M
NA NO AT T S EN
R RA TU E
B EP PE PE A CR
JO ST O O ST S
J:WORK-C S:006 LOCK CYCLE STOP DISP
Figure 2-10 Status Display

Job Name/Step No.
In Play mode, the active job is displayed. In Teach mode, the job to be edited
is displayed.
Operation Mode
PLAY • TEACH • REMOTE • LOCK
Displays current mode and if the safety feature (TEACH LOCK) is engaged.
Operation Cycle
AUTO • CYCLE • STEP
Displays current cycle. (Display of Operation Cycle alternates in 1 second
intervals with Operable Group Axes. Refer to Figure 2-11.)
Status of Ongoing Operation
STOP • START • HOLD • E. STOP • ALARM
Displays current status. (Display of Status of Ongoing Operation alternates in 1
second intervals with Motion Type. Refer to Figure 2-11.)
Screen Mode
DISP • EDIT • SEL • FCTN • CUST
Displays current mode of the programming pendant (see Figure 2-13). (Display
of Screen Mode alternates in 1 second intervals with Battery Strength. Refer to
Figure 2-11.)

ES
AX TH
UP G
RO EN
G PE R
TY ST
LE
AB O
N RY
R TI TE
PE O T
O M BA
S2 LINEAR
Figure 2-11 Alternate Status Display

Operable Group Axes
R1-R2: ROBOT AXES/S1-S6: STATION AXES
When the system has station axes (external positioner, etc.) or more than one
robot, Operable Group Axes numbers are displayed. If the system has one robot
and no external axes, R1 is displayed. (Display of Operable Group Axes
alternates in 1 second intervals with Operation Cycle. Refer to Figure 2-10.)
Motion Type
JOINT • LINEAR • CIRCULAR • SPLINE
Displays motion type set at teaching. (Display of Motion Type alternates in
1-second intervals with Status of Ongoing Operation . Refer to Figure 2-10.)
Battery Strength
The battery symbol appears when controller or manipulator batteries become
weak. (Display of Battery Strength alternates in 1 second intervals with Screen
Mode. Refer to Figure 2-10.)
HUMAN INTERFACE DISPLAY AREA
This area, as shown in Figure 2-12, displays the data for User Interface and
usually consists of four lines.
=>TIMER INPUT BUFFER LINE

>T= INPUT LINE
! Enter time value MESSAGE LINE
SOFT KEY LABEL LINE(S)
Figure 2-12 Human Interface Display Area

Input Buffer Line
This line is used for temporary display of instructions and/or data from the Input
Line prior to insertion into the job being edited.
Input Line
This line is for data input and appears only when data entry is required.

Message Line
Error messages and dialog messages are displayed on this line. If an error occurs
while entering data, the error message is displayed, taking precedence over dialog
messages. If a message is too long to display on a single line in the screen, the
screen automatically moves to the left to display the unseen part of the message.
Soft Key Label Line
This line indicates what functions are assigned to the soft keys. Five function
names (as soft key labels) are displayed on a single line, corresponding to F1 to
F5 (see Figure 2-14). If six or more soft key labels are on the same level, “->“ is
displayed on the right of this line. Press MORE to display these labels. If two or
more soft key labels lines are shown, press the ARROW UP key once to access
the second line and twice to access the third line, etc.
FUNCTION KEYS
Function keys, shown in Figure 2-13, are used in conjunction with the soft keys
(F1 - F5, Figure 2-14). They initiate the appropriate menu hierarchy, based on
which soft key is pressed.
FUNCTION KEYS
=>
USER INCHING
!
F1 F2 F3 F4 F5 MORE
RESET
,
SERVO E.STOP
POWER ON
ET
RES
ES
R ET
MAN SPD
GROUP HIGH
SPD COORD
ENABLE AXIS SLW FST
Figure 2-13 Function Keys

DISP
The DISP key allows the operator to display a variety of information on the
screen, such as jobs, welding files, variables, I/O status, and alarm lists.
EDIT
The EDIT key functions only in Teach mode and displays menu selections to
program jobs or makes changes in jobs, files, etc. The EDIT key must be pressed
before any changes can be made .
SELECT
In the TEACH mode, the SELECT key allows access to the soft keys to program
new jobs or select an existing job. In the PLAY mode, the SELECT key accesses
special playback selections.
FUNC
The FUNC key allows access to selected floppy drive functions and most
purchased software options.

CUSTOMER
The CUSTOMER key displays functions of the controller such as Tool Center or
Control Point (TCP) and User Coordinates. In addition, it allows access to a
password protected area of the software, allowing some customization of system
operation.
SOFT KEYS
Soft keys, shown in Figure 2-14, allow selection of additional menu options,
based on which function is selected.
=>
SOFT KEYS USER ! INCHING
F1 F2 F3 F4 F5 MORE
RESET
,
SERVO E.STOP
POWER ON
ET
RES
ES
R ET
MAN SPD
GROUP HIGH
SPD COORD
ENABLE AXIS SLW FST
Figure 2-14 Soft Keys

F1-F5
Change menus based on function key selection.
More
Displays the remaining soft keys of the same level.
Arrow Up
Allows you to select from the menu lines above.
SERVO POWER ON
Robot operation is not possible unless servo power is applied. There is a green
SERVO POWER ON push button on the programming pendant, as shown in
Figure 2-15, which is used to apply servo power to the system. In TEACH mode,
the SERVO ON pushbutton operates only when the ENABLE switch on the
programming pendant is held in.
=>
USER INCHING
!
SERVO
POWER ON
F1 F2 F3 F4 F5 MORE
RESET
,
SERVO E.STOP
POWER ON
ET

RES
ES
R ET
MAN SPD
GROUP HIGH
SPD COORD
ENABLE AXIS SLW FST
Figure 2-15 SERVO POWER ON Indicator

ENABLE, E-STOP, and HOLD/RELEASE
=>
USER INCHING
!
F1 F2 F3 F4 F5 MORE
E-STOP BUTTON
RESET
,
SERVO E.STOP
POWER ON
ET
ENABLE KEY DISP EDIT SELECT FUNC CUSTOMER
RES
ES
R ET
MAN SPD
GROUP HIGH
SPD COORD
ENABLE AXIS SLW FST
HOLD/RELEASE 1 X- X+ x x 4
BUTTON S- S+ R- R+
2 Y- Y+ y
B- B+
y 5
L- L+
3 Z- Z+ z z 6
U- U+ T- T+
HOLD
TEST
RELEASE BWD FWD
START
Figure 2-16 ENABLE Key, E-STOP Button, and HOLD/RELEASE Key

ENABLE Key
In the Teach mode, with servo power ON, pressing the ENABLE key (see Figure
2-16) activates the six pairs of axis keys on the programming pendant, which
allows jogging of the manipulator. The TEST START, BWD, and FWD keys,
which are used for path confirmation, are also activated. The ENABLE key LED
indicator will light when ENABLE has been activated. To select Play mode, the
programming pendant ENABLE key must be turned OFF.
E-STOP Button
Pressing the E-STOP button (see Figure 2-16) immediately cuts servo power and
applies brakes to the robot. The SERVO POWER lamp turns OFF and the LCD
displays an Emergency Stop message. Twist the E-STOP button 1/4 turn to the
right (clockwise) to release the E-STOP condition.
HOLD/RELEASE
In Play mode, pressing the HOLD/RELEASE key temporarily stops program
execution, while Servo power remains ON and the brakes are not applied.
HOLD/RELEASE is a latching circuit. To release the hold, press the
HOLD/RELEASE key again. It is now possible to continue the program by
pressing the START button on the playback box.
NOTE: Changing modes from Play to Teach will also cause the program to cease execution.

EDITING KEYS
Enter
The ENTER key (see Figure 2-17) stores selected data into the controller.
Keypad
The keypad is used for entering numeric and device operating values into the
controller. Negative values and decimal values are accepted.
HOLD
TEST
BWD FWD
ASTERISK KEY RELEASE START
GROUP ENTER
AXIS
MODIFY DELETE INSERT MODIFY ENTER KEY
CURSOR KEYS
7 8 9
WEAV ON ARC ON FEED
4 5 6
CANCEL KEY WEAV OFF ARC OFF RETRACT KEYPAD
CANCEL 1 2 3
TIMER VOLT CUR
0 . -
MOTION PLAY POS
TYPE REF PNT VOLT CUR
SPD LVL
Figure 2-17 Editing Keys

CANCEL
The CANCEL key (see Figure 2-17) clears the input line, allowing new data to be
entered. It is also used to clear error messages or to cancel an Edit function.
Cursor Keys
The cursor keys, up, down, left, and right, move the cursor through a job or
certain files. Using cursor keys with the asterisk (*) key expands functionality.
DOWN — moves the cursor to the next line of the job.

DOWN + * — page down
UP — moves the cursor to the previous line of the job.

UP + * — page up
UP & DOWN — when pressed together, moves cursor to top of the job.
LEFT — moves cursor to the left.

LEFT + * — scrolls the instruction side of a job left (4 characters with each
press of keys).
RIGHT — moves cursor to the right.

RIGHT + * — scrolls the instruction side of a job right (4 characters with
each press of keys).
LEFT & RIGHT — when pressed together, all messages on the message line
can be viewed in sequence.
NOTE: The address side of a job always remains in full view.
2.1.3 Brake Release
WARNING!
Releasing brakes could cause personal injury or machine damage.
The brake release control, as shown in Figure 2-18, is a safety feature which
allows you to release the automatic brakes on the robot in the event of an
emergency situation or a robot failure.
The robot has six individual axes: Sweep (S), Lower arm (L), Upper arm (U),
Rotate (R), Bend (B), and Twist (T). The S-, L-, and U-axes are controlled by
individual brake release buttons. Enabling one of these buttons releases the
indicated axis. However, the release mechanisms for the R-, B-, and T-axes are
combined into a single button. Enabling this button releases the brakes on the R-,
B-, and T-axes simultaneously. For instructions on using the brake release
control, refer to Section 3.4.
NOTE: You must press both the selected axis button and the ENABLE button simultaneously for the
axis to remain released. Releasing either button will automatically lock the brakes again.
ENABLE S-AXIS L-AXIS U-AXIS R-,B-,T-AXIS
U-Axis
R-Axis
! WARNING:
RELEASING BRAKES B-Axis
MOT
OMA
COULD CAUSE N
T-Axis
PERSONAL INJURY
OR MACHINE DAMAGE. L-Axis
TO RELEASE BRAKES,
DEPRESS THE ENABLE S-Axis
AND DESIRED AXIS
BUTTONS SIMULTANEOUSLY.

RESET
ET
RES
ES
ALARM/ R T
ERROR
HOLD START
YASNAC MRC
480 VOLTS
U-Axis U-Axis
R-Axis R-Axis
MOTOMAN
MOT B-Axis MOTOMAN
MOT B-Axis
T-Axis T-Axis
L-Axis L-Axis
S-Axis S-Axis
WARNING WARNING
Figure 2-18 Robot Axes and Brake Release Control

2.2 Internal Components

The SK6 Dual MRC Controller, as shown in Figure 2-19, consists of the
following major internal components:
• Servopacks • I/O Rack
• Contactor Unit • CPU Rack
CONTACTOR UNITS
SERVOPACKS
NO3
NO2
NO4 NO3
2CN
11 2CN 11
NO1
CN CN
13CN 13CN NO2
FU1 NO4
12 12 NO1
SERVOPACKS
CN2
CN4
CN8
CN CN
2CN
11
CN
13CN
3CN 3CN FU1
CN1
CN2
CN4
CN8
21 21
CN CN 12
CHARGE CHARGE CN
23CN 23CN
CN5
1TB 1TB
R R
3CN
CN6
CN1
S S
CN3
22 22
CN CN
T T 21
CN5
CN
CHARGE
23CN
1TB
CN6
R
CN7 CN9
CN3
31 31
S
CN CN 22
33CN 33CN
CN
T
32 32 CN7 CN9
CN CN
31
CN
33CN
32
CN
I/O RACK
2CN
11
CN
13CN
MRYO1 MIO04 MIO04 MEW02
12
CN
3CN
21
CN
CHARGE
23CN
1TB
S
22
CN
T
31
CN
33CN
32
CN
CPU RACK
ROBOT SIDE DUAL CONTROLLER SIDE
Figure 2-19 SK6 Dual MRC Controller - Internal
2.2.1 Incoming Voltage

The MRC incoming voltage is preset to 480 VAC, but is reconfigurable to 240
VAC or 575 VAC. Refer to the voltage label next to the disconnect switch (see
Figure 2-1) to determine the incoming voltage set for your equipment. If the
existing voltage setting is not appropriate for your factory voltage, refer to Section
4.2 to reconfigure your equipment's incoming voltage for the appropriate setting.
2.2.2 Cooling System

Air drawn in to the rear of the cabinet circulates to regulate internal controller
temperature. Three internal fan assemblies provide air to cool the servos,
regenerative resistors, and system power transformer. A twin fan assembly inside
the controller circulates air in the front to reduce hot spots and maintain a
consistent operating temperature.

2.2.3 Servopacks
The SK6 Dual MRC uses four servopacks; 1SV and 2SV to control the six robot
axes on the robot side, and 3SV and 4SV to control the six robot axes on the Dual
Controller Side (see Figure 2-19). The 1SV and 3SV servopacks (IR010101FD)
control the S-, L-, and U-axes for both robots. The 2SV and 4SV (IR050505FD)
control the R-, B-, and T-axes for both robots. LED’s for all servopacks are
described below (see Figure 2-20).
TYPICAL RED LED
CHARGE
1TB
2CN 2CN
11 11
CN CN
13CN 13CN
12 12
CN CN
3CN 3CN
TYPICAL GREEN LED
21 21
CN CN
CHARGE CHARGE
23CN 23CN
1TB 1TB
R R
S S
22 22
CN CN
T T
31 31
CN CN
33CN 33CN
32 32
CN CN
Figure 2-20 Servopack LED Indicators

Servopack LED Indicators
Each servopack has both red and green LED's which indicate the servopack's
condition with servo power ON. The programming pendant will display the type
of error as an alarm. Refer to Section 5.1 for alarm codes.
Green LED's
If all green LED's are illuminated, then the servopacks are operating normally
with no error or alarm. If one or more of the green LED's are not illuminated
while power is ON, then there is an error with its axis. Green LED's are located at
the following servopack plug/connections: All 1CN and 2CN's, 3CN, 11CN,
12CN, 21CN, 22CN, 31CN, and 32CN.
Red LED's
If the red LED's are all illuminated, then the servopacks are operating normally
with no error or alarm. If a red LED is not illuminated while power is ON, then

there is an error with the servopack or the servo power contactor. Red LED's are
located on each servopack.
2.2.4 Contactor Unit

There are two contactor units on the Dual MRC (see Figure 2-19). Each contactor
unit (see Figure 2-21) consists of control transfer, fusing, and a servo power
contactor (SVM). Contactor units control the power ON/OFF by indirectly
operating the AC contactor.
NO3
NO2
NO4
NO1 1A FUSE
FU1
CN2
CN4
CN8
CONTACTOR BOARD
4A FUSES
CN1
FU5 4A
FU4 4A
2A and 5A FUSES
CN5
5A
FU1
CN6
2A
FU3
CN3
5A
FU2
CN7 CN9
AC CONTACTOR
Figure 2-21 Contactor Unit

FUSES
A 2-amp fuse, and two 4- and 5-amp fuses protect the controller circuitry.

2.2.5 I/O Rack Configuration

TERMINAL BOARD (MBB02)
CN6 TB1
CN2
CN11 CN10 CN8
CN4
CN3 CN1
CN8 FU1 CN5
TM6 TM4 TM1
TM7 TM5 TM2

3A FUSES
TM8 TM3
CN7 FU2
MRY 01 02 03 04 05
MRY01 MIO04 MEW02
CN2
CN1
MEW02 BOARD
FOR ADDITIONAL I/O BOARDS
MIO04 BOARD
MRY01B BOARD
Figure 2-22 I/O Rack Configuration

MEW02 BOARD (WELDING BOARD)
This board provides the welder with the ARC-ON signal and the current and
voltage command for the welding condition. This board also functions as an
interface board to detect abnormal status in the welder.
MIO04 BOARD (I/O BOARD)
The MIO04 I/O board(s) provides 24 input and output addresses. This is the
standard I/O board that comes with the system. Additional I/O boards are
available depending upon your controller's application.
MRY01B BOARD (POWER SUPPLY RELAY BOARD)
This board provides terminal connections for various components.
FUSES
Two 3-amp fuses protect the I/O rack and boards.

2.2.6 CPU Rack Configuration

7-SEGMENT LED
MCP01 MIF01 MCP02 MSV01

SYSTEM
YASNAC
BATTERY
ALARM LED's CN03
BAT
ALM
SOURCE
POWER ON
+5 V
+24 V
MONITOR/ALARM DISPLAY
OUT
ALM
CN02
BAT
ALM
CN01
ON1
FOR ADDITIONAL BOARD

SERVO CONTROL BOARD
MOTION CONTROL BOARD
CONCURRENT I/O BOARD
SYSTEM CONTROL BOARD
Figure 2-23 CPU Rack Configuration

7-SEGMENT LED Display
As shown in Figure 2-23, the 7-segment LED, on MCP01, illuminates when
certain types of faults occur. For more information, refer to Section 5.1.2.
BATTERY ALARM LED's
Battery LED's illuminate when memory batteries need to be replaced. To replace
batteries, refer to Section 4.6.
SERVO CONTROL BOARD
This board controls the robot's 6-axis servo motors. Speed (pps) and position are
controlled using the maximum rotation speed and position loop gain (kp).
Overspeed is detected by this board. Additional system control boards can be
added to the CPU rack to control additional axes.
MOTION CONTROL BOARD
This board controls motion, calculates for interpolation, and provides an interface
with the servo control board. Includes an MMM04 board mounted for extended
memory.
CONCURRENT I/O BOARD
The concurrent I/O board consists of the I/O control CPU, CMOS memory, and
the I/O transmission LSI. The board keeps teaching data and parameters in
memory, and controls I/O to and from the I/O unit on the I/O rack and the
playback box. An MMM01 board can be mounted for extended CMOS memory.
SYSTEM CONTROL BOARD
This board controls the user interface for editing, diagnosis, job management, and
output displays on the programming pendant. Includes an MMM02 board
mounted for extended memory.
2.3 Diagnostic Displays

The following diagnostics are available to check output and input signals,
operations of the command system and the servo systems, and various kinds of
periodic information.
DISP JOB
POSN
FILE FILE
VAR FILE
DIAG SP IN
SP OUT
RIN INPUT DIS CHG
I/O MON UNIV IN

TIME UNIV OUT
APL 1 EXT IN
EXT OUT
SP IN
EACH
ALM LIST MAJ ALM
ON/OFF MIN ALM SP OUT

ROBOT 1
DROP ROBOT 2 I/O SYSTEM TIMER
I/O USER AUX RLY

STATION 1
STATION 2 OFF LINE DETAILS CON
DL
QUIT
STATION 3
BLOCK STATION 4
STATION 5
STATION 6
ROBOT 3 DIS CNG
DIS CNG
SERVO MON SIG FILE
FB FILE
SPEED
ANALOG SP ERROR
TORQUE
Tmax CLEAR

2.3.1 Input Status Displays

Input Status displays show each of the closed (ON) or opened (OFF) external
input signals.
Universal Input Status
To display the Universal Input, proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key. UNIVERSAL INPUT STATUS
GROUP IG#01 123:DEC D1:HEX
3. Press UNIV IN (F1) Key. INDV INPUT NO. STATUS NAME
IN #001 WORK
IN #002
IN #003
IN #004
IN #005
IN #006
Figure 2-24 Universal Input Status

Specified Input Status
To display the Specified Input, proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key. SPECIFIED INPUT STATUS
GROUP 123:DEC D1:HEX
3. Press SP IN (F3) Key. INDV INPUT NO. STATUS NAME
SIN #001
SIN #002
SIN #003
SIN #004
SIN #005
SIN #006
Figure 2-25 Specified Input Status

2.3.2 Output Status Displays

Output Status displays are useful for confirming output signals set up by an output
instruction.
Universal Output Status
To display the Universal Output, proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key. UNIVERSAL OUTPUT STATUS
GROUP OG#01 123:DEC D1:HEX
3. Press UNIV OT (F2) Key. INDV OUTPUT NO. STATUS NAME
OUT #001 WORK
OUT #002
OUT #003
OUT #004
OUT #005
OUT #006
Figure 2-26 Universal Output Status

Specified Output Status
To display the Specified Output, proceed as follows:
1. Press DISP Key.
2. Press DIAG (F5) key. SPECIFIED OUTPUT STATUS
GROUP 123:DEC D1:HEX
3. Press SP OUT (F4) key. INDV OUTPUT NO. STATUS NAME
SOUT #001
SOUT #002
SOUT #003
SOUT #004
SOUT #005
SOUT #006
Figure 2-27 Specified Output Status
2.3.3 RIN Input Display

To display the RIN Input, proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key. RIN INPUT STATUS
INPUT NO. STATUS
3. Press RPD IN (F5) key. RIN #001
RIN #002
RIN #003
RIN #004
Figure 2-28 RIN Input Display

2.3.4 System Monitoring Time Displays

To display the System Monitoring Time, proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key. SYSTEM MONITORING TIME
CONTROL POWER (1996/11/08 10 : 00 ~ )
3. Press MORE key. 12345 : 12' 12
SERVO POWER (1996/11/08 10 : 00 ~ )
4. Press TIME (F2) key. 12345 : 12' 12
PLAYBACK TIME (1996/11/08 10 : 00 ~ )
12345 : 12' 12
MOVING TIME (1996/11/08 10 : 00 ~ )
12345 : 12' 12
Figure 2-29 System Monitoring Time

Servo Power Input Time
To display the Servo Power Input Time, scroll to it using the ARROW
UP/DOWN keys, then press EACH (F5) key.
SERVO POWER INPUT

ROBOT 1 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
ROBOT 2 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
ROBOT 3 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
STATION 1 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
Figure 2-30 Servo Power Input Time Display

Playback Time
To display the Playback Time, scroll to it using the ARROW UP/DOWN keys,
then press EACH (F5) key.
PLAYBACK TIME
ROBOT 1 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
ROBOT 2 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
ROBOT 3 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
STATION (1996/11/08 10 : 00 ~ )
12345 : 12' 12
Figure 2-31 Playback Time Display

Moving Time
To display the Moving Time Display, scroll to it using the ARROW UP/DOWN
keys, then press EACH (F5) key.
MOVING TIME
ROBOT 1 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
ROBOT 2 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
ROBOT 3 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
STATION 1 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
Figure 2-32 Moving Time Display

Operating Time
To display the Moving Time, scroll to it using the ARROW UP/DOWN keys,
then press EACH (F5) key.
OPERATING TIME
APL 1 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
APL 2 (1996/11/08 10 : 00 ~ )
12345 : 12' 12
Figure 2-33 Operating Time Display

2.3.5 Alarm List Displays
In this display, you can view the 20 most recent minor, major, I/O (system
section), I/O (user section), and off-line alarms.
Minor Alarm List
To display the Minor Alarm List, proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key. MINOR ALARM
CODE DATE CLOCK
3. Press MORE key two times. 1 4010 1996/11/08 12 : 47
2 4020 1996/11/07 10 : 09
4. Press ALM LST (FI) key. 3
4
5. Press MIN ALM (F2) key. 5
6
To initialize this alarm: 7
1. Press EDIT key.

2. Press INITIAL (F5) key.
Figure 2-34 Minor Alarm List Display
Major Alarm List

To display the Major Alarm List, proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key. MAJOR ALARM
CODE DATE CLOCK
3. Press MORE two times. 1 1010 1996/11/08 12 : 34
2 1020 1996/11/07 10 : 11
4. Press ALM LST (F1) key. 3
4
5. Press MAJ ALM (F1) key. 5
6
7
Figure 2-35 Major Alarm List

I/O Alarm (System Section) Display
To display the I/O Alarm (System Section), proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key. I/O ALARM (SYSTEM SECTION)
CODE DATE CLOCK
2 9020 1996/11/07 10 : 14
4
5. Press I/O SYS (F3) key. 5
6
1. Press EDIT key.

Figure 2-36 I/O Alarm (System Section) List
I/O Alarm (User Section) Display
To display the I/O Alarm (User Section), proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key. I/O ALARM (USER SECTION)
CODE DATE CLOCK
2 1070 1996/11/07 10 : 45
4
5. Press I/O USR (F4) key. 5
6
1. Press EDIT key.

Figure 2-37 I/O Alarm (User Section) List

Off-line Alarm List
To display the Offline Alarm, proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key.
OFF-LINE ALARM
3. Press MORE key two times. CODE DATE CLOCK
1 0010 1996/11/08 12 : 10
4. Press ALM LST (F1) key. 2 0020 1996/11/07 10 : 31
3
5. Press OFFLINE (F5) key. 4
5
6
7
Figure 2-38 Off-line Alarm List

Alarm Details
To display details of any of the above alarms, move cursor to the desired alarm
and press DETAILS (F5) key.
ALARM DETAILS
ALARM CODE
MESSAGE: SERVO POWER ERROR
STATION [S,L,U,R,B,T]
JOB : SAMPLE-3
LINE NO. : 0020
STEP NO. : 010
DATE : 1996/11/08
CLOCK : 12 : 17
Figure 2-39 Alarm Details

2.3.6 Servo Display
In these displays, each value can be displayed as a digital value.
Position Feedback
To display the Position Feedback, proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key. POSITION FEEDBACK
FEEDBACK (PULSE) DEVIATION (PULSE)
3. Press MORE key two times. R1 : S -12345678 -12345
:L
4. Press SERVO (F1) key. :U
:R
5. Press FB (F2) key. :B
:T
B1 : 1 -12345678 -12345
Figure 2-40 Digital Value Monitor

(Position Feedback)
Speed Status (Reference, Feedback)

To display the Speed Status (Reference, Feedback), proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key. SPEED STATUS
REFERENCE (PPS) FEEDBACK (PPS)
:L
:R
5. Press SPEED (F3) key. :B
:T
B1 : 1 -1234567890 -1234567890
Figure 2-41 Speed Status

(Reference, Feedback)
Speed Status (Speed Error)
To display the Speed Status (Speed Error), proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key.
SPEED STATUS
3. Press MORE key two times. SPEED ERROR (PPS)
R1 : S -1234567890
4. Press SERVO (F1) key. :L
:U
5. Press SP ERR (F4) key. :R
:B
:T
B1 : 1 -1234567890
Figure 2-42 Speed Status (Speed Error)

Torque Status
To display the Torque Status, proceed as follows:
1. Press DISP key.
2. Press DIAG (F5) key. TORQUE STATUS
REFERENCE (%) MAX TORQUE (%)
:L
:R
5. Press TORQUE (F5) key. :B
:T
B1 : 1 -123 -123
Figure 2-43 Torque Status

2.4 Alarms and Errors

Alarm or error codes cause the program to stop execution. There are three levels
of alarms and errors: Error Messages, Minor Alarms, and Major Alarms. For a
complete listing of alarms, refer to Table 6-5.
2.4.1 Error Messages

Error Messages occur when simple mistakes have been made, such as pressing the
START button while robot is not in Play mode. A four-digit error code and a
message appear at the bottom of the display. These errors are cleared by pressing
the CANCEL key on the programming pendant. Error Messages turn OFF the
ENABLE key.
NOTE: Error codes can begin with the same numbers as Minor or Major Alarm codes because they are
not part of the alarm list register in the pendant diagnostics displays.
2.4.2 Minor Alarms

Minor Alarms usually indicate simple programming errors, such as a circle that
has been programmed with fewer than three circular points, etc. The four-digit
alarm codes for Minor Alarms normally begin with 4, 5, 6, 7, or 8. The alarm
code and message will appear at the top of the display. Servo power remains ON.
These alarms are cleared by pressing the RESET (F5) soft key on the
programming pendant. Minor Alarms turn OFF the ENABLE key.
2.4.3 Major Alarms

Major Alarms are hardware failures. These alarms may occur because of a servo
tracking error or an abnormal speed. Major Alarms are often associated with
crashes. The four-digit alarm codes for major alarms normally begin with 0, 1, 2,
or 3. The alarm code and a message will appear at the top of the display. Servo
power will turn OFF. Major Alarms are cleared by turning off power to the
controller and turning it back ON again.
Important: Write down alarm number and message, for future reference, before
powering down.
NOTE: During a Major Alarm, the RESET soft key (F5) is displayed. Pressing this key will not clear
the alarm.

2.5 Specifications
Specifications for the SK6 Dual MRC Controller are listed in Table 2-1.
Table 2-1 Controller Specifications
DIMENSIONS
Height 1303.5 mm (51.32 in.)
Width 602 mm (23.7 in.)
Length 1298 mm (51.1 in.)
Weight 345 kg (760 lbs)
SERVICE REQUIREMENTS
Air Pressure 90 psi (620 kPa), 5 CFM
Welding Gas As required
COOLING FANS
Front One Twin Assembly
Rear Three Single Assemblies
PLAYBACK BOX JZNC - MPB02
PROGRAMMING PENDANT JZNC-MPP21E
AXIS MOTORS
S-Axis SGMP-08AWYR41
L- & U-Axes SGMP-08AWYR32
R-, B-, & T-Axes SGMP-01AWYR22
SERVOPACK
S-, L-, & U-Axes CACR-IR050505FB
R-, B-, & T-Axes CACR-IR010101FB
CONTROL POWER SUPPLY (CPS 18F)
Rated AC Input Voltage 200/220V AC
Voltage Variation +10% to -15%
Frequency 50/60Hz + 2Hz
Output Voltage Specification +5V 15A
Output Voltage Specification +24V 4.5A
CONTACTOR UNIT JZNC-MTU02-1
I/O RACK JZNC-MRK09
Welding Board JANCD-MEW02
I/O Board(s) JANCD-MIO04
Power Supply Relay Board JANCD-MRY01B-1
I/O Rack Back Board JANCD-MBB02
CPU RACK
System Control Board JANCD-MCP01
Concurrent Input/Output Board JANCD-MIF01
Motion Control Board JANCD-MCP02
Servo Control Board JANCD-MSV01

SECTION 3
BASIC OPERATION
3.1 Using the ENABLE Switch
The ENABLE switch is a 3-position switch located on the left rear of the
programming pendant, as shown in Figure 3-1. When the switch is in the first
position (resting) servo power is OFF. When the switch is in the second position
(center), servo power is ON. When the switch is in the third position (holding too
tightly), servo power is OFF.
The ENABLE switch is a safety feature which controls servo power while in
TEACH mode. The ENABLE switch allows the operator to turn servo power ON
using the SERVO ON push buttons, but should the operator lose control of the
programming pendant and release the switch or grasp it too tightly, servo power is
immediately disabled, preventing further robot movement.
To correctly operate the robot arm with the ENABLE switch, hold the
programming pendant with your left hand and lightly grasp the switch, holding it
in the second position.
BACK OF
PROGRAMMING
PENDANT
ENABLE SWITCH
Figure 3-1 Operating the ENABLE Switch

BASIC OPERATION
3.2 Servo Power

3.2.1 Servo Power in Teach Mode
To turn servo power ON in Teach mode, proceed as follows (see Figure 3-2):
1. Make sure the E-STOP buttons on the playback box and on the
programming pendant are released.
2. Press Teach mode button.
3. Lightly grasp the ENABLE switch on the programming pendant, holding it
in the second position.
4. Press the SERVO ON push button. Servo power will turn ON, as indicated
by the SERVO POWER lights illuminating on the playback box and
programming pendant.
To turn servo power OFF while in Teach mode, release the ENABLE switch on
the programming pendant.
NOTE: Servo power will turn OFF, and remain OFF, if you grasp the ENABLE switch too tightly. Once
the switch has been placed in the third position, it must be completely released to the first
position, before the ENABLE switch will allow servo power to be reactivated.
SERVO MODE
POWER BUTTONS E-STOP

RESET
ET
RES
ES
ET
ALARM/
R
ERROR
HOLD START
Figure 3-2 Playback Box
3.2.2 Servo Power in Play Mode

To turn servo power ON in Play mode, proceed as follows (see Figure 3-2):
WARNING!
The ENABLE switch is not active in Play mode. Never enter the
robot operating envelope during automatic operation.
1. Make sure the E-STOP buttons on the playback box and on the
programming pendant are released.
2. Press the PLAY button on the playback box

BASIC OPERATION
3. Press the SERVO ON push button. Servo power will turn ON, as indicated
by the indicator light on the robot upper arm and the SERVO POWER lights
on the playback box and the programming pendant illuminating.
To turn servo power OFF while in Play mode, press either E-STOP button.
3.3 Teach Lock

DANGER!
When using the programming pendant in the workcell, always
engage the Teach Lock function first to prevent serious personal
injury or death, or equipment damage.
Whenever the programming pendant is being used in the workcell, engage Teach
Lock. The word "LOCK" flashes in the top center of the programming pendant
display. This signifies that control of the manipulator rests solely with the
programming pendant and operation is not possible from the playback box. The
Teach Lock function is an important and necessary safety feature.
To manually turn the Teach Lock ON:
1. Press SELECT.
2. Press T-LOCK (F1).
NOTE: The message “!TEACH-LOCK set” appears.
Once operation from the programming pendant is complete, and control is to be
returned to the playback box, press the ENABLE key to turn the LED off
(disable), and release Teach Lock to allow Play mode.
To manually turn the Teach Lock OFF:
1. Press SELECT.
2. Press MORE.
3. Press the ARROW UP soft key.
4. Press UNLOCK (F1).
NOTE: The message “!Caution! TEACH-LOCK mode released” appears.

BASIC OPERATION
3.4 Brake Release Control

The brake release control is a safety feature which allows you to release
the automatic brakes on the robot in the event of an emergency situation or robot
failure (see Figure 3-3). To release the brakes:
1. Press the E-Stop button on the programming pendant or on the playback box
to ensure servo power is OFF.
WARNING!
Releasing brakes without proper support for the axis to be released
could cause personal injury or machine damage.
2. Provide adequate support for the axis to be released. Support must be
able to withstand the payload of the robot and approximate weight of the
axis. Any support for the SK6 must be able to withstand AT LEAST 91 kg
(200 lbs).
3. Release the specific axis brake by pressing and holding the specific axis
button and the Enable button at the same time (see Figure 3-3).
NOTE: You must press both the selected axis button and the Enable button simultaneously for the
axis to remain released. Releasing either button will automatically lock the brakes again.
ENABLE S-AXIS L-AXIS U-AXIS R-,B-,T-AXIS
U-Axis
R-Axis
! WARNING:
RELEASING BRAKES B-Axis
MOT
OMA
COULD CAUSE N
T-Axis
PERSONAL INJURY
OR MACHINE DAMAGE. L-Axis
TO RELEASE BRAKES,
DEPRESS THE ENABLE S-Axis
AND DESIRED AXIS
BUTTONS SIMULTANEOUSLY.

RESET
ET
RES
ES
ALARM/ R T
ERROR
HOLD START
YASNAC MRC
480 VOLTS
U-Axis U-Axis
R-Axis R-Axis
MOTOMAN
MOT B-Axis MOTOMAN
MOT B-Axis
T-Axis T-Axis
L-Axis L-Axis
S-Axis S-Axis
WARNING WARNING
Figure 3-3 Robot Axes and Brake Release Control

BASIC OPERATION
3.5 Coordinates and Axes
YASNAC MRC
COORD MAN SPD
JOINT FST
COORDINATE WLD
MED
MANUAL
CYL
SYSTEM TOOL SLW
SPEED
INDICATORS USER
=>
INCHING
INDICATORS
!
F1 F2 F3 F4 F5 MORE
RESET
SERVO E.STOP
POWER ON
ET
RES
ES
R ET
MAN SPD
GROUP HIGH
SPD COORD
ENABLE AXIS SLW FST
AXIS KEYS
1 X- X+ x x 4
S- S+ R- R+
2 Y- Y+ y
B- B+
y 5
L- L+
3 Z- Z+ z z 6
U- U+ T- T+
HOLD
TEST
RELEASE BWD FWD
START
Figure 3-4 Programming Pendant Axes

Axis Keys/Coordinate Systems
The programming pendant has six pairs of axis keys with “+” and “-” for each
axis, making a total of twelve keys (see Figure 3-4). Each key is multi-function
and is labeled, as shown in Figure 3-5.
X- X+
S- S+
Figure 3-5 Axis Keys

The applicable label is determined by which one of the following coordinate
systems is selected and is indicated by the LED:
Joint Coordinate
When in Joint coordinate, the S, L, U, R, B, and T designations apply, as shown
in Figure 3-4. This coordinate allows the operator to move the robot one axis
(one motor) at a time in a positive or negative direction. Each axis is
independent. This is the default coordinate system upon power up or job
selection.
World, Cylindrical, Tool, or User
When in World, Cylindrical, Tool, or User coordinates, the XYZ designations
apply, as shown in Figure 3-4. They will, however, act differently in each
coordinate system. World, Tool, and User coordinates are based on the X-Y-Z
rectangular (Cartesian) coordinate system. In World, the TCP (Tool Control or
Center Point) moves in a straight line path, as shown in Figures 3-6, 3-7, and 3-8.
Figures 3-9, 3-10, and 3-11 show TCP movement in Cylindrical. Tool
coordinates are based on the X-Y-Z coordinates as related to tool orientation.
User coordinates are based on a user-defined plane in space.
BASIC OPERATION
X- X+
S- S+
Figure 3-6 Path of X-Axis Movement in World
Y- Y+
L- L+
Figure 3-7 Path of Y-Axis Movement in World
Z+
U+
Z-
U-
Figure 3-8 Path of Z-Axis Movement in World
X- X+
S- S+
Figure 3-9 Path of X-Axis Movement in Cylindrical

BASIC OPERATION
Y- Y+
L- L+
Figure 3-10 Path of Y-Axis Movement in Cylindrical
Z+
U+
Z-
U-
Figure 3-11 Path of Z-Axis Movement in Cylindrical
3.5.1 Setting Axis Keys for World or Cylindrical Coordinates

To set the AXIS KEYS to operate in the World (Rectangular) or the Cylindrical
coordinate system, proceed as follows:
1. Press SELECT on the programming pendant.
2. Press MORE.
3. Press COND 1 (F4).
4. Move the cursor to Item #1, the RECT/CYL line.
5. Press ON (F3) to select World, or press OFF (F4) to select Cylindrical.
6. Press QUIT (F5).
Pressing one of the six axis keys grouped on the right side, as shown in
Figure 3-12, will change the tool's angle of orientation. The TCP will maintain
the position accurately when the tool is rotated with a 45° angle about the X or Y
axis or pivoted about the Z axis.

BASIC OPERATION
1 X- X+ x x 4
S- S+ R- R+
2 Y- Y+ y
B- B+
y 5
L- L+
3 Z- Z+ z z 6
U- U+ T- T+
Figure 3-12 Axis Keys to Change Tool's Angle of Orientation

Group Axis 1-6
The numbers 1-6, next to the axis keys (see Figure 3-12), are valid only when the
controller is operating external servo motors (such as a track or headstock), and
when the GROUP AXES key has also been selected. The “1” key will allow
jogging of the first external axis, “2” the second, etc.
GROUP AXIS Key
Pressing this key (see Figure 3-13) configures the axis keys to move the external
servo motors. Pressing the key again re-configures the axis keys to move the
manipulator. If the system includes the COORDINATED MOTION option, the
indicator LED will light whenever GROUP AXIS has been selected; otherwise,
the status line display (see Figure 3-11, Operable Group Axes) is the only way to
see the currently selected axis group. The GROUP AXIS key will not function
unless external axes have been selected for the current job.
COORD Key
The programming pendant defaults to Joint coordinates after a power-up sequence
or after the selection of another job. If a different coordinate system is desired,
the COORD (coordinate) key (see Figure 3-13) must be pressed. The coordinate
system LED indicates which system has been selected.
YASNAC MRC
COORD MAN SPD
JOINT FST
COORDINATE WLD
MED
MANUAL
CYL
SYSTEM TOOL SLW
SPEED
INDICATORS USER
=>
INCHING
INDICATORS
!
GROUP AXIS F1 F2 F3 F4 F5 MORE

RESET
KEY SERVO E.STOP
POWER ON
ET

RES
ES
R ET
MAN SPD
GROUP HIGH
SPD COORD
ENABLE AXIS SLW FST
1 X- X+ x x 4
S- S+ R- R+
HIGH SPEED COORDINATE
KEY 2 Y- Y+ y
B- B+
y 5
KEY
L- L+
3 Z- Z+ z z 6
U- U+ T- T+
HOLD
TEST
RELEASE BWD FWD
START
Figure 3-13 Programming Pendant Coordinates

BASIC OPERATION
MAN SPD Keys
MAN SPD (manual speed) (see Figure 3-13) determines the velocity at which the
manipulator will move, while in TEACH Mode (does not affect playback speeds).
There are five speeds available. The speeds listed below are the first four:
1. Fast (FST)
2. Medium (MED)
3. Slow (SLW)
4. Inching (INCHING)
These four speeds are selected by pressing the SLW key or the FST key on the
programming pendant. An LED indicates which speed has been selected.
Pressing both keys simultaneously causes the programming pendant to default to
SLW from any setting. The programming pendant also defaults to SLW after a
power-up sequence.
When INCHING has been selected, each press of an axis key will move the
manipulator one pulse count in Joint coordinates or 0.3 mm in all other coordinate
systems.
HIGH SPD Key
The fifth manual speed key is the HIGH SPD key (see Figure 3-13). Pressing and
holding the HIGH SPD key overrides slow, medium, or fast speed and moves the
manipulator at a set high speed. This key is a momentary override. Releasing the
key takes the manipulator back to the selected manual speed. HIGH SPD will not
override inching speed. This key is operational only in TEACH Mode and does
not affect playback speeds.
3.6 Specified Point

If the robot manipulator has been moved while the controller was turned off, the
MRC will generate the “ALARM: 5040 OUT OF RANGE (ABSO DATA)”
alarm message upon power up. After resetting the alarm and turning the servo
power ON, you will be prompted in the message line to “Check Position.”
Checking position involves driving the robot manipulator back to a known
position (that is, a specified point) and then ensuring the robot actually stops at
the proper position. This position is usually where all the alignment marks on
each robot axis are in line.
To check the Specified Point, perform the following steps:
1. Press RESET (F5) on the programming pendant to reset the “Out of Range”
alarm if needed.
2. Press TEACH on the playback box.
3. Press the CUSTOMER key on the programming pendant.
4. Press SPEC PT (F3) on the programming pendant. The display shows a
data screen with columns, as shown in Figure 3-14.
5. Turn servo power ON by holding the ENABLE Switch on the programming
pendant (refer to Section 3.1).
6. Press PSN CHG (F1). The display flashes “HOME POSN CHANGE.”

BASIC OPERATION
J:WORK-A S:032 TEACH CYCLE STOP CUST

SPECIFIED POINT HOME POSN CHANGE
SPECIFIED CURRENT DIFFERENCE
R1:S 0 5000 5000
L 0 0 0
U 0 0 0
R 0 0 0
B 0 0 0
T 0 0 0
BASE1 0 0 0
!Check position
PSN CHG CHECK QUIT
Figure 3-14 Specified Point Position Display

7. Press the ENABLE key on the programming pendant.
8. Ensure the pendant is in JOINT coordinates.
9. Increase speed to MED or FST.
CAUTION!
An error in the pulse generator (PG) system can cause an alarm.
The operation below may cause a crash when the FWD key is
pressed. Use extreme care during this procedure. If PG failure is
suspected, then do not FWD; jog each axis separately in JOINT
coordinates.
10. Press and hold the FWD key to drive the manipulator to the Specified
Point. “HOME POSN CHANGE” stops flashing when the point is reached,
and the data display changes to all zeros in the DIFFERENCE column.
Look at the alignment marks (see Figure 3-15) to check if the robot is actually in
the specified point position.
U-AXIS 0° B-AXIS -90°
L-AXIS 0°
Figure 3-15 SK6 Home Position

11. Press CHECK (F4). The soft key selection CHECK (F4) and “HOME PSN
CHANGE” display disappear, and the message line displays “! Home
position checked.”
12. Press QUIT (F5). This action returns the soft keys to the original
CUSTOMER soft key menu.
SECTION 4
CONTROLLER MAINTENANCE
Before attempting to service the MRC Controller, you must be thoroughly
familiar with proper safety procedures as described in Chapter 2, SAFETY.
4.1 Opening/Closing the Door

The following procedure applies to either door on the MRC cabinet. To open the
either door, proceed as follows:
WARNING!
Before attempting any service procedures on the MRC Controller,
ensure the AC Power Disconnect Switch is in the OFF position and
has been locked out and tagged out as specified in ANSI/RIA R15.06
and OSHA, Section 1910.147.
1. Move the AC POWER DISCONNECT switch (see Figure 4-1) to the "OFF"
position. Follow lockout/tagout procedures as specified in ANSI/RIA
R15.06 and OSHA, Section 1910.146.
2. To open the door, insert a standard screwdriver into the DOOR LATCH on
the front of the controller and turn 90 degrees CW (to the right).
WARNING
DOOR LATCH
AC POWER DISCONNECT

RESET
ET
RES
ES
ALARM/ R T
ERROR
HOLD START
YASNAC MRC
480 VOLTS
U-Axis U-Axis
R-Axis R-Axis
MOTOMAN
MOT B-Axis MOTOMAN
MOT B-Axis
T-Axis T-Axis
L-Axis L-Axis
S-Axis S-Axis
WARNING WARNING
Figure 4-1 Opening/Closing Cabinet Door

3. To close the door, carefully close the controller door and turn the
screwdriver 90 degrees CCW (to the left). Remove the screwdriver.
4. Unlock and remove tags, then move the AC POWER DISCONNECT switch
to "ON."
4.2 Incoming Voltage

CAUTION!
During installation, be sure to provide sufficient clearance around
MRC Controller. See label on rear panel of cabinet for clearance
specifications.
The MRC incoming voltage is preset to 480 VAC, but is reconfigurable to 240
VAC or 575 VAC. Refer to the voltage label next to the disconnect switch (see
Figure 4-2) to determine the pre-set incoming voltage for your equipment. If the
existing voltage setting is not appropriate for your factory voltage, use the
following procedure to reconfigure your equipment's incoming voltage.
480 VOLTS
ON
FACTORY-SET VOLTAGE

RESET
ET
RES
ES
ALARM/ R T
ERROR
HOLD START
YASNAC MRC
480 VOLTS
U-Axis U-Axis
R-Axis R-Axis
MOTOMAN
MOT B-Axis MOTOMAN
MOT B-Axis
T-Axis T-Axis
L-Axis L-Axis
S-Axis S-Axis
WARNING WARNING
Figure 4-2 Factory-Set Voltage

WARNING!
Prior to removing rear wall of the MRC cabinet, make sure the MRC
Main Disconnect Switch is OFF, locked out and tagged out. Refer to
ANSI/RIA R15.06 and OSHA, Section 1910.146.
To reconfigure your MRC for a different incoming voltage:
1. Remove six Phillips-head screws and the rear panel from the MRC cabinet.
2. Locate the terminal strip on rear wall of the MRC cabinet (see Figure 4-3).
3. Reconfigure the jumper connections for the appropriate input line voltage.
Refer to Table 4-1 for the correct jumper connections for the desired input
line voltage (240, 480, or 575).
4. Install the rear panel on the MRC cabinet and secure with six Phillips-head
screws. Torque screws to 3.4 N•m (30.0 in. lbs).
BACK OF MRC, ROBOT SIDE

WITH REAR WALL REMOVED.
X3 X2 X1 X0 H15 H14 H12 H13 H11 H10 H9 H7 H8 H6 H5 H4 H2 H3 H1
RU
12" 6" (5 NEEDED)

X3 X2 X1 X0 T S R
X3 X2 X1 X0 H15 H14 H12 H13 H11 H10 H9 H7 H8 H6 H5 H4 H2 H3 H1
480V CONFIGURATION SHOWN
Figure 4-3 Input Line Terminal Strip

Table 4-1 Jumper Connections for Input Line Voltages (Decal)
INPUT VOLTAGE CONNECTIONS 3Ø INPUT
240 H1 to H3; H2 to H4 to H6; H6 to H8; H7 to H9 to H1
H11; H11 to H13; H12 to H14 to H1
480 H2 to H3; H4 to H6; H7 to H8; H9 to H11; H12 H6
to H13; H14 to H1
575 H2 to H3; H5 to H6; H7 to H8; H10 to H11; H12 H11
to H13; H15 to H1
4.3 Connecting the Equipment

WARNING!
Electrical and grounding connections must comply with applicable
portions of the national electrical code and/or local electrical
codes.
To connect incoming power:
1. Install 3-phase power wiring at the disconnect switch located on the inside
center wall of the MRC cabinet (see Figure 4-4). Table 4-2 shows the size
and type of wire needed.
2. Tighten screws to the proper torque (see Table 4-2).
3. Install an M5 lug on the incoming ground wire.
4. Terminate ground wire on frame ground M5 threaded stud (see Figure 4-4)
with M5 hardware provided.
INSIDE CABINET, CENTER WALL
CONNECT INCOMING,
3-PHASE POWER HERE
ON
OFF
M5 THREADED STUD
(Ground Termination)
ON
OFF
POWER DISCONNECT
Figure 4-4 Incoming Power Connections
Table 4-2 Incoming Power Specifications (Decal)

Lug Data 60/75˚ C wire
Catalog No TCAL14
Wire Size #14-8 Copper
#12-8 Aluminum
Torque #14-8, 4.0 N•m (35 lb-in.)

4.4 Connecting External Power Supply

Power supplies of about 1A, 24V are used to drive I/O of the MRC Controller. If
higher current is needed or if the inside and outside of the MRC cabinet are to be
insulated, use an external 24V power supply. For a diagram of the External
Power Connection, refer to Section 6.3.
1. To connect external power, connect power supply TB1-2 and TB1-3 on the
I/O Rack Terminal Board (MBB02 board) (see Figure 4-5).
2. For external power supplies only, move the plug from CN7 to CN8 (one or
the other must be short-circuited).
NOTE: The external power input terminal incorporates a 3A fuse. Mount the external power supply
outside the panel to prevent noise inside the panel.
EXTERNAL I/O POWER
POWER (24 VDC) SUPPLY (24VDC)
1 2 3 4 5 6 7
24V 0 24 V 24V 0 24 V
FG NOT NOT
USED USED
IN IN OUT OUT
CN6 TB1
CN8 CN11 CN10

CN4
CN2
CN8
CN3 CN1
CN8 FU1 CN5
TM6 TM4 TM1
TM7 TM5 TM2
TM8 TM3
CN7 FU2
MRY 01 02 03 04 05
MRY01 MIO04 MEW02
CN7
CN2
CN1
Figure 4-5 External Power Supply Connection for I/O

4.5 Short-Pinning for Shock Sensor Use

When the shock sensor is used, you must short-pin the MBB02 and MRY01B
boards as follows (see Figure 4-6):
1. Short-pin connection TM4, on the I/O Rack Terminal Board (MBB02
board), between pins 2 and 3.
2. Remove the MRY01B board from the I/O rack (refer to Section 4.7). Short-
pin SW1 in one of the following ways: To obtain SERVO OFF status, short
between pins 2 and 3; to obtain HOLD status, short between pins 1 and 2.
1 2 3
TM4

CN6 TB1
CN2
CN11 CN10 CN8
CN4
CN3 CN1
CN8 FU1 CN5
TM6 TM4 TM1
TM7 TM5 TM2
TM8 TM3
CN7 FU2
SERVO OFF HOLD MRY 01 02 03 04 05
Status Status
MRY01 MIO04 MEW02
SW1 SW1
1 2 3 1 2 3
CN2
MRY01B BOARD
CN1
Figure 4-6 Short-Pinning I/O Boards for Shock Sensor Use

4.6 Battery Replacement

The battery must be replaced within 48 hours after the battery change alarm
occurs. When the battery needs to be replaced, a message will appear on the
programming pendant (see Figure 2-11) and the Battery Alarm Display LED(s),
on the CPU rack, will illuminate. To replace the battery(s), proceed as follows
(see Figure 4-7):
1. Open the cabinet door.
2. Pull the upper and lower pins, on the cover plate, toward you.
3. Remove the connector and the battery from the battery board.
4. Install new battery and attach connector to the battery board.
5. Install cover plate over batteries, pushing upper and lower pins into place.
6. Close the cabinet door.
NOTE: Although ICRAM and the absolute encoder are backed up by the super capacitor, install a new
battery as soon as possible if the battery alarm occurs. Leaving the board without a battery
over 48 hours will result in the loss of the job data.
BATTERY
CONNECTOR
CPU RACK
COVER PLATE MCP01 MIF01 MCP02 MSV01

YASNAC
SYSTEM
CN03
SOURCE
BAT POWER ON
ALM
+5 V
+24 V
OUT
ALM
CN02
BAT
ALM
CN01
ON1
Figure 4-7 Battery Replacement

4.7 I/O Board Replacement

CAUTION!
Always turn the power OFF before replacing an I/O board.
NOTE: Be sure to use proper anti-static procedures when handling PC or I/O boards.
To replace an I/O board, proceed as follows (see Figure 4-8):
2. Remove any connector(s) from the board to be replaced.
3. Loosen attaching screw and remove board from I/O rack.
4. Install new I/O board and attach any connector(s).
5. Tighten attaching screw.
6. Close and lock the cabinet door.
CN6 TB1
CN2
CN11 CN10 CN8
CN4
CN3 CN1
CN8 FU1 CN5
TM6 TM4 TM1
ATTACHING SCREW TM5 TM2
TM7
TM8 TM3
CN7 FU2
MRY 01 02 03 04 05
I/O BOARD MRY01 MIO04 MEW02

CN2
CN1
Figure 4-8 Replacing an I/O Board in the I/O Rack

4.8 CPU Board Replacement

CAUTION!
Always turn the power OFF before replacing a system control board.
NOTE: Be sure to use proper anti-static procedures when handling system control boards.
To replace a system control board (an MCP01 board is used as an example),
proceed as follows (see Figure 4-9):
2. Remove any connector(s) from the board to be replaced.
3. Loosen two screws and remove the cover plate.
4. Flip the upper latch up and the lower latch down, then remove the board.
5. Insert the new board in the appropriate slot in the CPU rack.
6. Flip the lower latch down and the upper latch up.
7. Install cover plate and tighten screws securely.
8. Connect any connector(s) that were previously removed.
9. Close and lock the cabinet door.
UPPER LATCH COVER PLATE
SYSTEM
CONTROL
BOARD MCP01 MIF01 MCP02 MSV01
SYSTEM
YASNAC
CN03
BAT
ALM
SOURCE
POWER ON
+5 V
+24 V
OUT
ALM
CN02
BAT
ALM
CN01
ON1
LOWER LATCH
Figure 4-9 Replacing a System Control Board on the CPU Rack

4.9 Fuse Replacement

Figure 4-10 illustrates the location of fuses within the MRC cabinet. Refer to
Table 4-3 for replacement fuse ratings and part numbers.
CONTACTOR UNITS
FU4
FU5
BRAKE RELEASE BOARD BRAKE RELEASE BOARD
F2 FU2 F2
FU3
FU1
F1 F1
NO3
CN8
NO2
NO4 NO3
2CN
11 2CN 11
NO1
CN CN
13CN 13CN NO2
I/O RACK
FU1 NO4
12 12 NO1
CN2
CN4
CN8
CN CN
2CN
11
CN
13CN
3CN 3CN FU1
CN1
CN2
CN4
CN8
21 21
CN CN 12
CHARGE CHARGE CN
23CN 23CN
CN5
1TB 1TB
R R
CN6
3CN
CN1
S S
CN3
22 22
CN CN
T T 21
CN5
CN
CHARGE
23CN
1TB
CN6
R
CN7 CN9
CN3
31 31
S
CN CN 22
33CN 33CN
CN
T
32 32 CN7 CN9
FU1
CN CN
31
CN
33CN
32
CN
FU2
2CN
11
CN
13CN
MRYO1 MIO04 MIO04 MEW02
12
CN
3CN
21
CN
CHARGE
23CN
1TB
S
22
CN
T
31
CN
33CN
32
CN
CABINET FLOOR CABINET FLOOR

FU6
FU7
FU6
FU7
POWER ASSEMBLY POWER ASSEMBLY
FUSE BOARDS
FU502
FU503
FU501
FU302
FU303
FU301
F3
MOTOMAN
F2
F1
ON
OFF
POWER ASSEMBLY
FU305
FU304
LEFT WALL CENTER WALL, CENTER WALL,

LEFT SIDE RIGHT SIDE
Figure 4-10 Location of Fuses in MRC Cabinet

Table 4-3 Fuse Replacement Data
FUSE LOCATION AMPERAGE VOLTAGE PART NUMBER
FU301 - FU303 POWER ASSEMBLY 20A 250V AC 133653-2
FU1 - FU2 I/O RACK 3A 250V AC 130293-7
FU1 - FU2 CONTACTOR UNIT 5A 250V AC 130293-9
FU3 CONTACTOR UNIT 2A 250V AC 130293-5
FU4 - FU5 CONTACTOR UNIT 4A 250V AC 479652-2
FU6 - FU7 CABINET FLOOR 0.5A 250V AC 130293-2
F1 - F3 FUSE BOARD 0.5A 250V AC 137723-1
F1 BRAKE RELEASE 3.15A 250V AC 137725-1
F2 BRAKE RELEASE 0.5A 250V AC 137724-1
F1 - F3 MEW02 I/O Board 0.5A 250V AC 137724-1
4.10 Servo-On Indicator Light Replacement

The servo-on light indicates when drive power is applied to the robot. The robot
may not be moving, but the servo-ON light indicates the robot has the potential to
move. The SK6 has two indicator lights (see Figure 4-11) which are located on
either side of the lower arm. To replace lamps, proceed as follows:
1. Remove amber cover by turning to the left (CCW).
2. Turn burned-out lamp 1/4 turn to the left (CCW) and remove from socket.
3. Insert new lamp and turn 1/4 turn to the right (CW).
4. Install amber cover and turn to the right (CW) to secure.
SERVO-ON INDICATOR LIGHT
Figure 4-11 Servo-On Indicator Light

SECTION 5
TROUBLESHOOTING
5.1 Alarm Codes
5.1.1 Standard Alarm Codes
Standard alarm codes are classified, as shown in Table 5-1. Refer to Tables 5-4
and 5-5 for a comprehensive listing of all controller alarm codes.
Table 5-1 Alarm Code Type Classification
ALARM ALARM TO RESET ALARM
CODE LEVEL
0* Level 0
(Major Failure)
1 to 2 Level 1 to 2 Resetting is not possible with either ALARM RESET or
(Major Failure) specific input signal for ALARM RESET. Turn OFF the
main power and remove the cause of the failure, then turn ON
the main power.
3 Level 3 Resetting is possible only with ALARM RESET key but not
(Major Failure) with specific input signal for ALARM RESET. After
resetting, remove the cause of the failure and turn ON the
servo power.
4 to 8 Level 4 to 8 Resetting is possible with both ALARM RESET and specific
(Minor Failure) input signal for ALARM RESET.
9 Level 9
(User Alarm)
* Alarm during pre-online
5.1.2 CPU Rack 7-segment LED Display

Under normal conditions, the 7-segment LED lamps of the MCP01 (SYSCON)
board will not illuminate (see Figure 5-1). However, the LED's will illuminate
under certain types of fault conditions. There are two types of displays that may
occur: 1-digit number fixed display and 4-digit number repeated display. Tables
5-2 and 5-3 list the various types of displays and their meanings.
Table 5-2 1-digit Number Fixed Display
INDICATORS FAULT
All Segment LED's Light System Control Board (MCP01/MMM02) is defective.
. (period) Error during initializing process with power ON.
Either MCP01, MCP02, MIF01, or MSV01 board(s) have been
improperly inserted or may be defective.
0 Concurrent Input/Output Board (MIF01) improperly inserted or
may be defective.
1 to F Communication error between System Control Board (MCP01)
and programming pendant.
The 4-digit Repeated Display numbers illuminate when a No Maskable
Interruption (NMI) occurs. An NMI will automatically occur at system error.
TROUBLESHOOTING
7-SEGMENT LED
MCP01 MIF01 MCP02 MSV01

SYSTEM
YASNAC
CN03
BAT
ALM
SOURCE
POWER ON
+5 V
+24 V
OUT
ALM
CN02
BAT
ALM
CN01
ON1
Figure 5-1 CPU Rack 7-segment LED Display
Table 5-3 4-digit Number Repeated Display

NMI DISPLAY MEANING
0000 NMI Factor Identification Disabled
0900's (Watchdog Timer Error)
0900 (MCP02 Watchdog Timer Error)
0901 (Reserved Watchdog Timer Error)
0902 (MSL#1 [ID=2] Watchdog Timer Error)
0903 (MSL#2 [ID=3] Watchdog Timer Error)
0906 (MCP01 Watchdog Timer Error)
0907 (MIF01 Watchdog Timer Error)
0910 (MSV#1 Watchdog Timer Error)

TROUBLESHOOTING
Table 5-3 4-digit Number Repeated Display - continued
NMI DISPLAY MEANING
0920 (MIF02 Watchdog Timer Error)
0930's (MSV#2 Watchdog Timer Error)
0930 (MCP02 Access Error)
0931 (Reserved Access Error)
0932 (MSL#1 A-bus Error)
0933 (MSL#2 Access Error)
0936 (MCP01 Access Error)
0937 (MIF01 Access Error)
0940's (A-bus Error)
0940 (MCP02 A-bus Error)
0941 (Reserved A-bus Error)
0946 (MCP01 A-bus Error)
0947 (MIF01 A-bus Error)
5.1.3 Displaying Major and Minor Alarms

The programming pendant keeps a log of the last 20 Major Alarms and the last 20
Minor Alarms. To display lists of these alarms, proceed as follows:
1. Press TEACH on the playback box.
2. Press DISP on the programming pendant.
3. Press DIAG (F5).
4. Press MORE twice.
5. Press ALM LST (F1).
6. Press MAJ ALM (F1) or MIN ALM (F2).
NOTE: Steps 7 and 8 are optional and will provide more details about the alarm.
7. Move the cursor to choose a specific alarm.
8. Press DETAILS (F5).

TROUBLESHOOTING
5.1.4 Clearing Overrun Alarms

Overrun alarms, 4670 or 4671, occur when one of the axes overruns its limits.
When this occurs, the servo power is automatically shut OFF. To clear the
overrun alarm, proceed as follows:
1. While depressing the OVERRUN RECOVERY switch (see Figure 2-4),
press RESET (F5) (See Figure 2-14).
2. In the Teach mode with servo power ON, press the ENABLE key (see
Figure 2-16) to activate the axis keys on the programming pendant.
3. Using the axis keys, jog the manipulator away from the limit switch.
Table 5-4 List of Alarm Messages at Initial Diagnosis
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
0010 CPU BOARD Check error of CPU board Check the insertion of the board.
INSERTION ERROR "provided/not."
0020 CPU CPU communication test error. • Check the insertion of the board.
COMMUNICATION • Replace the board.
ERROR
0030 ROM ERROR ROM total check error. Replace ROM.
0040 RAM ERROR Local RAM read/write check error. • Check the insertion of the board.
(LOCAL) • Replace the board.
0050 RTC ERROR RTC interrupt error. • Check the insertion of the board.
• Replace the board.
0060 RAM ERROR A bus common RAM read/write • Check the insertion of the board.
(A-BUS COMMON ) check error. • Replace the board.
0070 RAM ERROR D bus 2 port RAM read/write check • Check the insertion of the board.
(D-BUS 2-PORT) error. • Replace the board.
0080 RAM ERROR S bus 2 port RAM read/write check • Check the insertion of the board.
(S-BUS 2-PORT) error. • Replace the board.
0090 I/O MODULE Communication error between • Check the insertion of the board.
COMMUNICATION MIF01 board and I/O module. • Replace the board.
ERROR
0100 IAMP Communication error between MSV • Check connection of the cable.
COMMUNICATION board and SERVOPACK. • Replace the SERVOPACK.
ERROR
0110 IAMP PARAM Write-in parameter read-back • Check connection of the cable.
MODIFICATION (verification) check error. • Replace the SERVOPACK.
ERROR
0120 ENCODER Communication error between MSV • Check the connection of the cable.
COMMUNICATION board and encoder. • Replace the encoder.
ERROR
0130 ENCODER Encoder fault. Replace the encoder.
OVERSPEED
0131 ENCODER DATA Encoder fault. Replace the encoder.
ERROR
0132 ENCODER BACK-UP Encoder internal data destroyed. • Replace battery.
ERROR • Perform zero-point positioning.

TROUBLESHOOTING
Table 5-4 List of Alarm Messages at Initial Diagnosis - continued
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
0133 ENCODER Encoder internal data destroyed. • Replace battery.
CHECKSUM ERROR • Perform zero-point positioning.
0134 ENCODER BATTERY Voltage for battery dropped. Replace battery.
ERROR
0135 ENCODER Parameter file total check error. Cool the encoder.
OVERHEAT
0200 FAULT Local RAM read/write check error. Initialize the parameter again.
(PARAMETER)
0210 FAULT (SYSTEM Total check error of the system Execute system configuration again.
CONFIG-DATA) configuration data.
0220 FAULT (JOB Job management data total check Initialize the job again.
MANAGEMENT error.
DATA)
0230 FAULT (CIO CIO ladder data total check error. Initialize the CIO ladder again.
LADDER)
0240 FAULT (Application Turbo application program error. Initialize turbo application program.
Program)
0250 FAULT (ME-NET ME-NET data error. Initialize ME-NET data (Customer
DATA) maintenance mode).
0300 VERIFY ERROR Parameter does not match system Initialize the parameter again.
(SYSTEM CONFIG- configuration.
DATA)
0310 VERIFY ERROR Parameter setting is larger than Change the parameter.
(CMOS MEMORY the mounted CMOS MEMORY
SIZE) capacity.
0320 VERIFY ERROR Parameter setting does not Change the parameter.
(I/O MODULE) match the mounted I/O module.
0330 ILLEGAL Parameter setting range exceeded. Change the parameter.

PARAMETER
0340 VERIFY ERROR Parameter setting does not match Change the parameter.
(SERVOPACK TYPE) the mounted SERVOPACK type.
0350 VERIFY ERROR Parameter setting does not match Change the parameter.
(ENCODER TYPE) the mounted encoder type.
0360 VERIFY ERROR Incorrect parameter setting. Change the parameter.

(APPLICATION)
0370 VERIFY ERROR Incorrect parameter setting. Change the parameter.

(SENSOR FUNCTION)

TROUBLESHOOTING
Table 5-4 List of Alarm Messages at Initial Diagnosis - continued
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
0400 PARAMETER A fault occurred at the internal • Turn OFF power and then turn it ON again.
TRANSMISSION control check. • For maintenance alarm code, contact
MOTOMAN Customer Service at
ERROR (937) 847-3200.
0410 MODE CHANGE A fault occurred at the internal • Turn OFF power and then turn it ON again.
ERROR control check. • For maintenance alarm code, contact
(937) 847-3200.
0420 APPL. PROG. A fault occurred upon turbo • Turn OFF power and then turn it ON again.
TRANSMISSION program application transmission. • For maintenance alarm code, contact
ERROR (937) 847-3200.
Table 5-5 List of Alarm Messages

ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
0900 WATCH DOG TIMER Fault at MCP02. • Turn OFF power and then turn it ON again.
ERROR • For maintenance alarm code, contact
(937) 847-3200.
0901 WATCH DOG TIMER Reserved • Turn OFF power and then turn it ON again.
(937) 847-3200.
0902 WATCH DOG TIMER Fault at MSL#1. • Turn OFF power and then turn it ON again.
(937) 847-3200.
0903 WATCH DOG TIMER Fault at MSL#2. • Turn OFF power and then turn it ON again.
(937) 847-3200.
(937) 847-3200.
(937) 847-3200.
0906 WATCH DOG TIMER Fault at MCP01. • Turn OFF power and then turn it ON again.
(937) 847-3200.
0907 WATCH DOG TIMER Fault at MIF01. • Turn OFF power and then turn it ON again.
(937) 847-3200.
0910 WATCH DOG TIMER Fault at MSV#1. • Turn OFF power and then turn it ON again.
(937) 847-3200.

TROUBLESHOOTING
Table 5-5 List of Alarm Messages - continued
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
(937) 847-3200.
(937) 847-3200.
(937) 847-3200.
(937) 847-3200.
(937) 847-3200.
0916 WATCH DOG TIMER Fault at MSV# 7. • Turn OFF power and then turn it ON again.
(937) 847-3200.
(937) 847-3200.
0920 WATCH DOG TIMER Fault at MIF02. • Turn OFF power and then turn it ON again.
(937) 847-3200.
0930 ACCESS ERROR Fault at MIF02. • Turn OFF power and then turn it ON again.
• For maintenance alarm code, contact
(937) 847-3200.
0931 ACCESS ERROR Reserved • Turn OFF power and then turn it ON again.
(937) 847-3200.
0932 ACCESS ERROR Fault at MSL#1. • Turn OFF power and then turn it ON again.
(937) 847-3200.
0933 ACCESS ERROR Fault at MSL#2. • Turn OFF power and then turn it ON again.
(937) 847-3200.
(937) 847-3200.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
(937) 847-3200.
0936 ACCESS ERROR Fault at MCP01. • Turn OFF power and then turn it ON again.
(937) 847-3200.
0937 ACCESS ERROR Fault at MIF01. • Turn OFF power and then turn it ON again.
(937) 847-3200.
0940 A-BUS ERROR Fault at MCP02. • Turn OFF power and then turn it ON again.
(937) 847-3200.
0941 A-BUS ERROR Reserved • Turn OFF power and then turn it ON again.
(937) 847-3200.
0942 A-BUS ERROR Fault at MSL#1. • Turn OFF power and then turn it ON again.
(937) 847-3200.
0943 A-BUS ERROR Fault at MSL#2. • Turn OFF power and then turn it ON again.
(937) 847-3200.
(937) 847-3200.
(937) 847-3200.
0946 A-BUS ERROR Fault at MCP01. • Turn OFF power and then turn it ON again.
(937) 847-3200.
0947 A-BUS ERROR Fault at MIF01. • Turn OFF power and then turn it ON again.
(937) 847-3200.
0999 NMI ERROR NMI error occurred. • Turn OFF power and then turn it ON again.
(937) 847-3200.
1000 Non-Defined Alarm Non-defined alarm occurred. For maintenance alarm code, contact
(937) 847-3200.
1010 ROM ERROR System control section CPU ROM Replace ROM board (MMM02) for system
(SYSCON) check error. control.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
1020 ROM ERROR Motion section CPU ROM Replace ROM board (MM04) for motion.
(MOTION) check error.
1021 [Decimal Data]
1022
1030 ROM ERROR Concurrent I/O section CPU ROM Replace ROM board (MIF01) for
(CIO) check error. concurrent I/O.
1040 ROM ERROR The system is malfunctioning. • Turn OFF power and then turn it ON again.
(SYSCON) • For maintenance alarm code, contact
[Decimal Data] MOTOMAN Customer Service at
(937) 847-3200.
1050 ROM ERROR Sensor CPU ROM check error. Turn OFF power and then turn it ON again.
(SENSOR)
1051 [Decimal Data]
1060 SYSTEM ERROR A system error occurred. • Turn OFF power and then turn it ON again.
(CIO) • For maintenance alarm code, contact
(Binary Data) MOTOMAN Customer Service at
(937) 847-3200.
1070 FAULT • Parameter total check error over • Turn OFF power and then turn it ON again.
(PARAMETER) CMOS. • For maintenance alarm code, contact
[Decimal Data] Data = Parameter types MOTOMAN Customer Service at
(937) 847-3200.
1080 FAULT (LASER FILE) Laser file fault. • Turn OFF power and then turn it ON again.
[File Categories] • For maintenance alarm code, contact
(937) 847-3200.
1090 FILE FAILURE Various file total check error. • Turn OFF power and then turn it ON again.
(MOTION) • For maintenance alarm code, contact
1091 [Decimal Data] MOTOMAN Customer Service at
1092 (937) 847-3200.
1100 FILE TOTAL Various internal data total check • Turn OFF power and then turn it ON again.
CHECKSUM ERROR error. • For maintenance alarm code, contact
1101 (MOTION) MOTOMAN Customer Service at
1102 [Decimal Data] (937) 847-3200.
1110 SET-UP PROCESS • A fault occurred in the set up • Turn OFF power and then turn it ON again.
ERROR (SYSCON) process. • Replace MCP02 board.
[Decimal Data] • Data 1 : Motion section set up • For maintenance alarm code, contact
incomplete. MOTOMAN Customer Service at
(937) 847-3200.
1120 WRONG SEGMENT Segment clock data set in Load same system file.
CLOCK VALUE the system and in phase
1121 [Decimal Data] compensation file are different.
1130 MMM ERROR A fault occurred at the internal • Turn OFF power and then turn it ON again.
[Decimal Data] control check. • For maintenance alarm code, contact
(937) 847-3200.
1140 MMM ERROR A fault occurred at the internal • Turn OFF power and then turn it ON again.
Decimal Data] control check. • For maintenance alarm code, contact
(937) 847-3200.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
1150 FAULT A fault occurred at the internal • Turn OFF power and then turn it ON again.
1151 MOTOMAN Customer Service at
1152 (937) 847-3200.
1160 HIGH _________ For maintenance alarm code, contact

TEMPERATURE MOTOMAN Customer Service at
(IN CTRL BOX (937) 847-3200.
1170 OVERRUN LIMIT Limit switch recovery switch Check for the limit switch recovery switch.
SWITCH RELEASED operated during playback.
1180 SERVO MONITOR Monitor CPU for servo (MSV) is • Turn OFF power and then turn it ON again.
SYSTEM ERROR abnormal. • Replace MSV01 (MSV02) board.
thru [Decimal Data] • Replace MCP01 or MCP02 board.
1186
1190 SERVO SYSTEM DSP for servo (MSV) is abnormal. • Turn OFF power and then turn it On again.
ERROR • Replace MCP01 (MCP02) board.
thru [Decimal Data] • Replace MCP01 (MCP02) board.
1196 • Check the command cable.
1201 OVERCURRENT • Control board fault. • Turn OFF power and then turn it ON again.
(Axis Data) • Power supply feedback circuit • Replace the SERVOPACK.
thru fault. • Replace the motor.
1206 • Main circuit transistor module • Check the grounding.
fault or overheat. • Check the wiring.
• Motor grounding.
1210 MCCB TRIPPED • Control board fault. • Replace the SERVOPACK.
Faulty Machine • Main circuit thyristor/diode • Check for disconnection of wiring lead in
thru [Axis Data] mixed module fault. the SERVOPACK (when MCCB is turned
1216 ON).
• Check the motor grounding if alarm occurs
when the servo is turned ON.
1220 GROUND FAULT • SERVOPACK fault. • Replace the SERVOPACK.
Faulty Machine • Motor power line grounding fault • Check the grounding.
thru [Axis Data] (some certain section). • Check the grounding where the alarm occurs.
1226
1230 DEFECTIVE • SERVOPACK fault. • Replace the SERVOPACK.
CURRENT OFFSET • Parameter of SERVOPACK fault.
thru [Axis Data]
1236
1240 ENCODER • Transmission error between • Turn OFF power and then turn it ON again.
TRANSMISSION encoder and MSV board. • Replace the encoder.
thru ERROR • Replace MSV01 (MSV02) board.
1246 [Axis Data] • Remove noise and check wiring.
1250 DEFECTIVE • Encoder internal data fault. Replace the encoder.

ENCODER • Damaged r/main data or internal
thru INTERNAL DATA status data.
1256 [Axis Data]
1260 DEFECTIVE Encoder pulse detecting section Replace the encoder.

ENCODER fault.
thru ABSOLUTE DATA
1266 [Axis Data]

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
1270 ENCODER Encoder section overheat. • Cool the encoder.
OVERHEAT • Review the load.
thru [Axis Data]
1276
1280 SERVO MONITOR • Transmission error between the • Turn OFF power and then turn it ON again.
TRANSMISSION monitor CPU for servo (MSV) • Replace MSV01 (MSV02) board.
thru ERROR and the SERVOPACK. • Replace the SERVOPACK.
1286 [Axis Data] • MSV board fault. • Recheck the wiring and connectors.
1290 SERVO CPU • Servo (MSV) CPU is abnormal. • Turn OFF power and then turn it ON again.
SYNCHRONIZING • Internal control clock is • Replace MSV01 (MSV02)board.
thru ERROR abnormal. • Replace MCP01 or MCP02 board.
1296 • Perform the countermeasure against noise.
1300 DSP PROGRAM • Check error of DSP program • Turn OFF power and then turn it ON again.
CHECKSUM ERROR PROM for servo (SV). • Replace MSV01 (MSV02) board.
thru • MSV board fault. • Recheck the wiring and connectors.
1306
1310 MON PRGM TOTAL • Check error of monitor CPU • Turn OFF power and turn it ON again.
CHECKSUM ERROR program PROM for servo (SV). • Replace MSV01 (MSV02) board.
thru • Perform the countermeasure against noise.
1316
1320 SERVOPACK • The SERVOPACK has • Turn OFF power and then turn it ON again.
FAILURE malfunctioned. • Replace the SERVOPACK.
thru [Axis Data] • No fault occurs with the • Check the command cable.
1326 SERVOPACK failure signal ON. • Replace MSV01 (MSV02) board.
1330 POSITION ERROR • Control board fault. • Replace the SERVOPACK.

[Axis Data] • Wrong connection of absolute • Turn OFF power and then turn it ON again.
thru encoder. • Check the countermeasure against noise.
1336 • Malfunction of internal • Replace MSV01 (MSV02) board.
PG pulse counter. • Replace the encoder.
1340 OVERLOAD 1 • Control board fault. • Replace the SERVOPACK.
[Axis Data] • Load exceeded to 105 to 130% of • Review load.
thru rated load. • Correct the wiring.
1346 • Motor circuit wrongly connected, • Check the motor circuit.
wrong U-V, V-W ,W-U • Replace MSV01 (MSV02) board.
connections or one-phase open.
1350 OVERLOAD2 • Control board fault. • Replace the SERVOPACK.
[Axis Data] • Load exceeded to 105 to 130% of • Review load.
thru rated load. • Correct the wiring.
1356 • Motor circuit wrongly connected, • Check the motor circuit.
wrong U-V, V-W ,W-U • Replace MSV01 (MSV02) board.
connections or one-phase open.
1360 BROKEN PG LINE • Cable disconnection or imperfect • Check that PG cable mounted on the motor
[Axis Data] connector contact between the side and cable between MSV01s are
thru axis encoder and the MSV01 connected properly.
1366 board. • Replace MSV01 (MSV02) board.
• PG disconnection in • Replace the SERVOPACK.
SERVOPACK.
1370 OVER SPEED • Abnormal speed. ( The number of • Replace MSV01 (MSV02) board.
[Axis Data] PG pulses for a certain time • Review the job where the alarm occurs.
thru increase abnormally.)
1376

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
1380 SERVO TRACKING • Excessive load is applied to the • Check for excessive load in the mechanical
ERROR faulty mechanism axis. system of the faulty axis.
thru [Axis Data] • A fault occurs on the servo • Replace MSV01 ( MSV02) board.
1386 system. (Deviation pulse • Check the motor power line connection.
becomes abnormal.) • Replace the SERVOPACK.
• Review the job where the alarm occurs.
1390 SPEED ERROR • Abnormal speed occurs in the • Replace MSV01 ( MSV02) board.
(MONITOR) faulty mechanism ( the number • Review the job where the alarm occurs.
thru [Axis Data] of PG pulses for a certain time
1396 increases abnormally).
1420 FAULT (LASER FILE) • Laser file fault. • Turn OFF power and then turn it ON again.
[File Categories] • For maintenance alarm code, contact
(937) 847-3200.
1430 SYNCHRONIZING Connection error at MSL02 or a • Turn OFF power and then turn it ON again.
ERROR (MSL02 CPU) fault occurred at the internal control • Turn OFF power and check control board.
1431 (Decimal Data) check. • For maintenance alarm code, contact
(937) 847-3200.
1440 SYSTEM ERROR Connection error at MSL02 or a • Turn OFF power and then turn it ON again.
(MSL02 CPU) fault occurred at the internal control • Turn OFF power and check control board.
1441 (Decimal Data) check. • For maintenance alarm code, contact
(937) 847-3200.
1450 SYSTEM ERROR For maintenance alarm code, contact
(TRUBO) MOTOMAN Customer Service at
(937) 847-3200.
1460 INTERRUPT ERROR For maintenance alarm code, contact
(TURBO) MOTOMAN Customer Service at
(937) 847-3200.
1470 COMMAND ERROR For maintenance alarm code, contact
(TURBO) MOTOMAN Customer Service at
(937) 847-3200.
1480 ME-NET ME-NET Communication CPU • Turn OFF power and the turn it ON again.
COMUNICATION error. • Replace the communication control board.
CPU
ERROR
(Decimal Data)
1490 ME-NET SYSTEM Significant error at MSC02 board • Turn OFF power and the turn it ON again.
ERROR 1 during communication process. • Replace MSC02 board.
(Decimal Data)
1500 COMMAND For maintenance alarm code, contact
RESPONSE ERR0R MOTOMAN Customer Service at
(Decimal Data) (937) 847-3200.
1510 MINI PP For maintenance alarm code, contact
COMMUNICATION MOTOMAN Customer Service at
1511 ERROR (937) 847-3200.
1520 BROKEN For maintenance alarm code, contact
(MRCII) PROGRAMMING MOTOMAN Customer Service at
PENDANT LINE (937) 847-3200.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
3000 NOT READY FOR • SERVOPACK fault. • Turn OFF power and the turn it ON again.
SERVO SYSTEM • Disconnection of command • Check the wiring between the MSV01
thru [Axis Data] cable. board and the faulty SERVOPACK.
3006 • Check that the main circuit power supply is
turned ON.
• Check the primary side power supply
voltage. Maximum: 220V + 10%.
• Check the SERVOPACK LED's. Refer to
Section 3.2.3.
3010 SERVO ON • Motor is operating at the wrong • Review the servo ON timing.
DEFECTIVE SPEED speed at servo ON. (For example, • Investigate the cause of moving.
thru [Axis Data] servo ON during DB stop.) • Replace MSV01 (MSV02) board.
3016 • Fault of monitor CPU for servo • Check the brake.
(MSV).
3020 SERVO ON • DB OFF of SERVOPACK at • Turn OFF power and then turn it ON again.
DEFECTIVE DB servo ON does not work well. • Replace the SERVOPACK.
thru [Axis Data] • Fault of monitor CPU for servo
3026 (MSV).
3030 REGENERATIVE Detects a regenerative circuit fault • Replace the SERVOPACK.

TROUBLE such as a regenerative transistor • Check the regenerative resistor and replace
thru [Axis Data] short-circuit, or regenerative resistor the SERVOPACK.
3036 disconnection, etc. • Review the operating condition.
• Control board fault.
• Regenerative transistor fault.
• Regenerative resistor
disconnection.
3040 OVERVOLTAGE Detects when the main circuit power • Check machine side inertia in motor axis
(Axis Data) supply exceeds the allowable conversion.
thru because of insufficient regenerative • Check the primary side power supply
3d046 process or excessive regeneration. voltage. Maximum: 220V + 10%.
Detection voltage: 400 to 420V • Replace the SERVOPACK.
• Load inertia is too large.
• Regenerative processing circuit
fault.
• Power supply voltage too large.
3050 VOLTAGE DROP Detects when the main circuit power • Check the primary side power supply
supply becomes 150V or less in voltage. Minimum : 220V - 15%.
thru [Axis Data] order to prevent the motor from • Replace the SERVOPACK.
3056 abnormal rotation caused by
reduction of the main circuit power
supply during motor driving.
• Main circuit power supply
reduction, open phase.
• Main circuit thyristor/diode
mixed module fault.
3060 HEAT SINK Main circuit transistor circuit Replace the SERVOPACK.
OVERHEAT in the SERVOPACK overheat.
thru [Axis Data}
3066

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
3070 SERVO BLOWN Detects that power 1C is short- • Correct the motor main circuit wiring
FUSE circuited (when power 1C is short- manually.
thru [Axis Data] circuited, the main circuit power • Replace the SERVOPACK.
3076 supply breaks down and the fuse is
blown).
• Motor wiring short-circuit,
grounding fault.
• Control board fault.
3080 BROKEN CURRENT • Disconnection of cable between • Cable check, connection check.
REF CABLE MSV01 board and • Replace the SERVOPACK.
thru [Axis Data] SERVOPACK.
3086
3090 OPEN PHASE Disconnection of main circuit R, Cable check, connection check.
[Axis Data] S, and T.
thru
3096
4000 NOT READY A fault occurred at the internal • After alarm reset, execute operation again.
(ARITH) control check. • For maintenance alarm code, contact
4002 (937) 847-3200.
4010 CUR POSITION SET A fault occurred at the internal • After alarm reset, execute operation again.
PROG ERROR control check. • For maintenance alarm code, contact
(937) 847-3200.
4020 SERVO POWER ON A fault occurred at the internal • After alarm reset, execute operation again.
SEQUENCE ERROR control check. • For maintenance alarm code, contact
4022 (937) 847-3200.
4030 SERVO POWER OFF A fault occurred at the internal • After alarm reset, execute operation again.
SEQUENCE ERROR control check. • For maintenance alarm code, contact
4032 (937) 847-3200.
4040 HOME When positioning at home • After alarm reset, execute the home
CALIBRATION position, there is an axis where positioning again.
4041 ERROR the home position is not registered. • Replace MCP02 board or MSV board.
4042 [Decimal Data]
4050 ABSO DATA There is an axis where the home • After alarm reset, execute the home
CHANGE ERROR position change operation (absolute positioning again.
4051 (Decimal Data) data change) is not completed. • Replace MCP02 board or MSV board.
4052
4060 SEGMENT DATA A fault occurred at the internal • After alarm reset, execute operation again.
OUTPUT ERROR control check. • For maintenance alarm code, contact
4062 (937) 847-3200.
4070 AXIS PARAMETER Improper S1D, S2D parameter Check S1D, S2D parameter.
ERROR setting.
4071 [Decimal Data]
4072
4080 TABLE PRMTR Improper S1D, S2D parameter Check S1D, S2D parameter.
ERROR setting.
4081 FOR ACTL AXIS
4082 [Decimal Data]

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
4090 SEQUENCE TASK A fault occurred at the internal • After alarm reset, execute operation again.
CONTR ERROR control check. • For maintenance alarm code, contact
4092 (937) 847-3200.
4100 DATA REFRESH A fault occurred at the internal • After alarm reset, execute operation again.
4102 (937) 847-3200.
4110 UNDEFINED A fault occurred at the internal • After alarm reset, execute operation again.
COMMAND control check. • For maintenance alarm code, contact
4111 (ARITH) MOTOMAN Customer Service at
4112 (937) 847-3200.
4120 SYSTEM ERROR A fault occurred at the internal • After alarm reset, execute operation again.
(ARITH) control check. • For maintenance alarm code, contact
4122 (937) 847-3200.
4130 ARITHMETIC ERROR A fault occurred at the internal • After alarm reset, execute operation again.
4131
4132 (937) 847-3200.
4140 SELECT ERROR A fault occurred at the internal • After alarm reset, execute operation again.
(PARAMETER) control check. • For maintenance alarm code, contact
4142 (937) 847-3200.
4150 GROUP AXIS A fault occurred at the internal • After alarm reset, execute operation again.
CONTROL ERROR control check. • For maintenance alarm code, contact
4152 (937) 847-3200.
4160 TWO STEPS SAME Two or more of the three instructed After alarm reset, program in three different
POSITION points are the same. points.
4161 [CIRC]
4162
POSITION [SPLINE] points are the same. points.
4171
4172
POSITION [3-STEPS] points are the same. points.
4181 (Data such as calibration between
4182 user coordinate and robot).
4190 TWO STEPS SAME Weaving reference point and wall After alarm reset, program in three different
POSITION [WEAV] point are same. points.
4191
4192
4200 TEACH ERROR Distance between instructed Provide instructions so that the distance
[SPLINE] points is not correct. between the instruction points will be
4201 correct.
4202
4210 IMPOSSIBLE Operation disabled if the forms of Set the forms of axes L and U and provide
LINEAR MOTION axes L and U differ at the starting a new instruction.
4211 [L/U] and ending points in
4212 interpolation (except MOVJ).

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
4220 IMPOSSIBLE LINEAR Operation disabled if the forms of Set the forms of axes S and L and provide
axes S and L differ at the staring a new instruction.
4221 MOTION and ending points in interpolation
4222 (S/L) (except MOVJ).
4230 EXCESSIVE The specified speed exceeds the After alarm reset, decrease the speed of the
SEGMENT motor rated r/min. step ( move command) where the alarm
4231 (LOW SPEED) occurred or change the robot position.
4232 [Axis Data]
4240 EXCESSIVE The specified speed exceeds the After alarm reset, decrease the speed of the
SEGMENT motor rated r/min. step ( move command) where the alarm
4241 (HIGH SPEED) occurred or change the robot position.
4242 [Axis Data]
4250 PULSE LIMIT (MIN.) The minimum pulse soft limit was Release the alarm and give another instruction.
[Axis Data) exceeded.
4251
4252
4260 PULSE LIMIT (MAX.) The maximum pulse soft limit was Release the alarm and give another instruction.
[Axis Data) exceeded.
4261
4262
4270 CUBE LIMIT (MIN) The minimum cube soft limit was Release the alarm and give another instruction.
(XYZ) exceeded.
4271
4272
4280 CUBE LIMIT (MAX) The maximum cube soft limit was Release the alarm and give another instruction.
(XYZ) exceeded.
4281
4282
4290 SPECIAL SOFT The minimum special soft limit was Release the alarm and give another instruction.
LIMIT (MIN) exceeded.
4291 (XYZ)
4292
4300 SPECIAL SOFT LIMIT The maximum special soft limit was Release the alarm and give another instruction.
(MAX.) exceeded.
4301 [Axis Data)
4302
4310 MECHANICAL The axes of the machine (displayed After alarm reset, provide another instruction.
INTERFERENCE reversely) interfere with each other.
4311 (MIN.)
4312 [Axis Data)
4320 MECHANICAL The axes of the machine (displayed After alarm reset, provide another instruction.
INTERFERENCE reversely) interfere with each other.
4321 (MAX.)
4322 [Axis Data)
4330 SPECIAL The axes of the machine (displayed After alarm reset, provide another instruction.
MECHANICAL reversely) interfere with each other.
4331 INTRF (MIN)
4332 [Axis Data]

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
4340 SPECIAL The axes of the machine (displayed After alarm reset, provide another instruction.
MECHANICAL reversely) interfere with each other.
4341 INTRF (MAX)
4342 (Axis Data]
4350 PULSE The machine exceeds pulse soft After alarm reset, provide another instruction.
MECHANICAL limit.
4351 LIMIT (MIN)
4352 [Axis Data)
4360 PULSE The machine exceeds pulse soft After alarm reset, provide another instruction.
MECHANICAL limit.
4361 LIMIT (MAX)
4362 [Axis Data)
4370 STATION AXIS An error occurred at the internal • After alarm reset, execute operation again.
DATA INPUT ERROR control deck. • For maintenance alarm code, contact
4372 (937) 847-3200.
4380 SEGMENT CONTROL An error occurred at the internal • After alarm reset, execute operation again.
ERROR control deck. • For maintenance alarm code, contact
4381 [Decimal Data} MOTOMAN Customer Service at
4382 (937) 847-3200.
4390 SUB SEGMENT An error occurred at the internal • After alarm reset, execute operation again.
CONTROL ERROR control deck. • For maintenance alarm code, contact
4392 (937) 847-3200.
4400 WRONG SPECIFIED An error occurred at the internal • After alarm reset, execute operation again.
CONTROL GROUP control deck. • For maintenance alarm code, contact
4402 (937) 847-3200.
4410 CPU An error occurred at the internal • After alarm reset, execute operation again.
COMMUNICATION control deck. • For maintenance alarm code, contact
4411 ERROR MOTOMAN Customer Service at
4412 [Decimal Data] (937) 847-3200.
4420 FAILED TO SELECT An attempt to change the overspeed After alarm reset, provide another instruction.
OVER SP LEVEL level at an axis, the level was not
4421 [Decimal Data] changed as indicated.
4422 Data: 1 Change permission status
fault.
Data: 2 During Axis processing.
Data: 3 Axis process not
completed.
4430 AVERAGING An attempt was made to change • After alarm reset, execute operation again.
NUMBER the number of averaging times to • Turn OFF the power supply and turn it ON
4431 CHANGING ERROR an axis, the number was not changed again.
4432 [Decimal Data] as indicated. • Replace the MSV01 (MSV02) board.
Data: 1 Change permission status
fault.
Data: 2 During axis processing.
Data: 3 Axis Process not
completed.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
4440 TORQUE LIMIT An attempt to change the torque • After alarm reset, execute operation again.
CHANGE ERROR limit value was made to an axis, the • Turn OFF power supply and turn it ON
4441 [Decimal Data] value was not changed as indicated. again.
4442 Data: 1 Change permission • Replace the MSV01 (MSV02) board.
status fault.
Data: 2 During axis processing.
Data: 3 Axis process not
completed.
4450 JMS ERROR An error occurred at the internal • After alarm reset, execute operation again.
[Decimal Data] control deck. • For maintenance alarm code, contact
4451
4452 (937) 847-3200.
4453
4460 JHM ERROR An error occurred at the internal • Turn OFF power and then turn it ON again.
[Decimal Data) control deck. • For maintenance alarm code, contact
4461
4462 (937) 847-3200.
4470 INSTRUCTION An error occurred at the internal • Turn OFF power and then turn it ON again.
INTERPRETER control deck. • For maintenance alarm code, contact
4472 [ Decimal Data) (937) 847-3200.
4480 UNDEFINED The global variable range is not After setting the parameter again, Turn OFF
GLOBAL defined ( SID parameter). power supply and turn it ON again.
4481 VARIABLE
4482 [Decimal Data]
4490 VAR-SCOREBOARD An error occurred at the internal • After alarm reset, execute operation again.
CONTROL ERROR control check. • For maintenance alarm code, contact
4492 (937) 847-3200.
4500 UNDEFINED Local variable is not defined. Set the local-variable to the job header.
LOCAL-VARIABLE
4501 [Decimal Data]
4502
4510 LESS THAN 3 STEPS A circle step does not contain a After alarm reset, teach at lease 3 consecutive
(CIRCULAR) minimum of three consecutive points for the circle step.
4511 [Decimal Data] points.
4512
4520 LESS THAN 3-STEPS Less than three spline steps are Reteach three or more steps continuously for
[SPLINE] provided continuously. spline interpolation.
4521
4522
4530 UNDEFINED JOB Job is not registered. After alarm reset, provide another instruction.
[Decimal Data]
4531
4532
4540 UNDEFINED JOB There is no label in the job under After the alarm reset, provide an instruction
[Decimal Data] execution. so that more than three steps can be provided
4541 continuously.
4542

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
4550 UNDEFINED There is no return in job call/stack. After alarm reset, register the label. Or delete
RETURN JOB the JUMP or CALL instruction where the
4551 [Decimal Data] alarm occurs.
4552
4560 LACK OF LOCAL- Local variable in the job has been Decrease the use of the local variable.
VARIABLE AREA used excessively.
4561 [Decimal Data]
4562
4570 ALOCAL-VARIABLE An error occurred at the internal • After alarm reset, execute operation again.
CONTROL ERROR control deck. • For maintenance alarm code, contact
4572 (937) 847-3200.
4580 JOB CALL STACK An error occurred at the internal • Turn OFF power and then turn it ON again.
4581 [Decimal Data) MOTOMAN Customer Service at
4582 (937) 847-3200.
4590 FEEDBACK PULSE An error occurred at the internal • Turn OFF power and then turn it ON again.
MAKING ERROR control deck. • For maintenance alarm code, contact
4591 [ Decimal Data) MOTOMAN Customer Service at
4592 (937) 847-3200.
4600 UNSUCCESSFUL Interface fault with axis board. • After alarm reset, execute operation again.
FINE • Turn OFF power and turn it ON again.
4601 POSITIONING • Replace MSV01 (MSV02) board.
4602 [Decimal Data] • For maintenance alarm code, contact
(937) 847-3200.
4610 PENDING An error at the internal control deck. • After alarm reset, execute operation again.
BLOCK-END ERROR • For maintenance alarm code, contact
4612 (937) 847-3200.
4620 DATA PRESET An error occurred at the internal • After alarm reset, execute operation again.
4622 (937) 847-3200.
4630 VARIABLE DATA An error occurred at the internal • After alarm reset, execute operation again.
TYPE ERROR control deck. • For maintenance alarm code, contact
4632 (937) 847-3200.
4640 OVER VARIABLE Exceeds the numerical value range Select the variable so as not to exceed the
LIMIT of the variables in the place where numerical value range.
4641 [Decimal Data] the data is stored.
4642
4650 DEFECTIVE A line connecting three circular After alarm reset, provide another instruction.
TAUGHT POINT points is linear.
4651 [SPLINE]
4652
4660 WEAVING CONTROL An error occurred at the internal • After alarm reset, execute operation again.
4662 (937) 847-3200.
4670 OVERRUN IN Either robot overrun limit switch Refer to the releasing method at overrun.
ROBOT AXIS operates.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
4671 OVERRUN IN Either station overrun limit switch Refer to the releasing method at overrun.
EXTERNAL AXIS operates.
[Decimal Data]
4680 FAULT (TOOL FILE) Total check error of tool file on • After alarm reset, execute operation again.
[File No.) CMOS. • For maintenance alarm code, contact
Data= File No. MOTOMAN Customer Service at
(937) 847-3200.
4690 FAULT (USER Total check error of tool file on • After alarm reset, execute operation again.
FRAME FILE) CMOS. Data= File No. • For maintenance alarm code, contact
[File No.) MOTOMAN Customer Service at
(937) 847-3200.
4700 FAULT (SERVO MON Total check error of signal file for • After alarm reset, execute operation again.
SIGNAL FILE) servo monitor on CMOS. • For maintenance alarm code, contact
(937) 847-3200.
4710 FAULT (WEAVING Total check error of weaving file on • After alarm reset, execute operation again.
FILE) CMOS. • For maintenance alarm code, contact
[File No.) Data= File No. MOTOMAN Customer Service at
(937) 847-3200.
4720 FAULT (HOME POSN Total check error of home position • After alarm reset, execute operation again.
ABS-DATA FILE) absolute data file on CMOS. • For maintenance alarm code, contact
(937) 847-3200.
4730 FAULT (SPECIFIED- Total check error of second home • After alarm reset, execute operation again.
POINT DATA) position file on CMOS. • For maintenance alarm code, contact
(937) 847-3200.
4740 POSN FILE DATA A fault occurred at the internal • After alarm reset, execute operation again.
READ-OUT ERROR control check. • For maintenance alarm code, contact
4742 (937) 847-3200.
4750 UNMATCHED POSN The typo of the data in data storage Use the same data type (pulse/orthogonal).
VAR DATA TYPE (pulse/orthogonal) is different from
4751 [Binary Data] the type of the type of data to be
4752 stored.
4760 FILE NO. ERROR An error occurred at the internal • After alarm reset, execute operation again.
[Decimal Data] control deck. • For maintenance alarm code, contact
4761
4762 (937) 847-3200.
4770 UNDEFINED Reference point is not registered. Register the reference point.
REFERENCE Or insufficient reference points are
4771 POINT registered.
4772 [Binary Data]
4780 STACK MORE Stack for job call exceeded. After alarm reset, change the job to reduce job
THAN 8 ( JOB CALL) call nesting.
4781
4782
4790 ARITHMETIC An error occurred at the internal • After alarm reset, execute operation again.
SECTION control check. • For maintenance alarm code, contact
4791 REQUEST ERROR MOTOMAN Customer Service at
4792 [Decimal Data) (937) 847-3200.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
4800 REQUEST-TO-SEND An error occurred at the internal • After alarm reset, execute operation again.
4801 [ Decimal Data) MOTOMAN Customer Service at
4802 (937) 847-3200.
4810 OVER VARIABLE Interface fault with axis board. • After alarm reset, execute operation again.
NO. • For maintenance alarm code, contact
4811
4812 (937) 847-3200.
4820 POSITION DATA An error occurred at the internal • After alarm reset, execute operation again.
MANAGEMENT control check. • For maintenance alarm code, contact
4822 [Decimal Data} (937) 847-3200.
4830 UNDEFINED Welding machine characteristic file Complete the setting of welding machine
WELDER is not set. characteristic file.
4831 CONDITION FILE
4832 [Decimal Data}
4840 UNDEFINED ARC Welding machine characteristic file Complete the setting of welding start condition
START COND FILE is not set. file.
4841 [Decimal Data]
4842
4850 UNDEFINED ARC Welding machine characteristic file Complete the setting of welding end condition
END CONDITION is not set. file.
4851 FILE
4852 [Decimal Data]
4860 WRONG WELDER Welding voltage reference unit and Match the welding voltage reference unit.
SELECTION welding machine power supply type
4861 do not match.
4862
4870 FAULT (WELDER Total check error of welding • After alarm reset, execute operation again.
CONDITION FILE) machine characteristic file on • For maintenance alarm code, contact
[Decimal Data] CMOS. MOTOMAN Customer Service at
Data= File No. (937) 847-3200.
4880 FAULT (ARC START Total check error of arc start • After alarm reset, execute operation again.
CONDITION FILE) condition file in CMOS memory. • For maintenance alarm code, contact
[Decimal Data] Data= File No. MOTOMAN Customer Service at
(937) 847-3200.
4890 FAULT (ARC START Total check error of welding start • After alarm reset, execute operation again.
CONDITION FILE) condition file on CMOS. • For maintenance alarm code, contact
{Decimal Data) Data = File No MOTOMAN Customer Service at
(937) 847-3200.
4900 FAULT (ARC Total check error of welding start • After alarm reset, execute operation again.
CONDITION SUPP. condition auxiliary file on CMOS. • For maintenance alarm code, contact
FILE) Data = File No MOTOMAN Customer Service at
[Decimal Data) (937) 847-3200.
4910 AX-CPU COMMAND AXIS-CPU command area is • After alarm reset, execute operation again.
AREA ERROR abnormal. • For maintenance alarm code, contact
4912 (937) 847-3200.
4920 FAULT (COM-ARC3 Total check error of COM-ARC3 • After alarm reset, execute operation again.
CONDITION FILE) condition file on CMOS. • For maintenance alarm code, contact
[Decimal Data] Data = File No. MOTOMAN Customer Service at
(937) 847-3200.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
4930 FAULT (COM-ARC3 Total check error of COM-ARC3 • After alarm reset, execute operation again.
DATA FILE) data file on CMOS. • For maintenance alarm code, contact
[Decimal Data] Data = File No. MOTOMAN Customer Service at
(937) 847-3200.
4940 FAULT Total check error of tracking • After alarm reset, execute operation again.
(CORRECTION correction condition file on CMOS. • For maintenance alarm code, contact
CONDITION FILE) Data = File No. MOTOMAN Customer Service at
[Decimal Data] (937) 847-3200.
4950 FAULT (PHASE Total check error of phase offset • After alarm reset, execute operation again.
OFFSET value data file on CMOS. • For maintenance alarm code, contact
DATA FILE) Data = File No. MOTOMAN Customer Service at
[Decimal Data] (937) 847-3200.
4960 SYSTEM CHANGE Data (parameter) affecting the Turn OFF power supply and turn it ON again.
[Decimal Data] system has changed and the power
supply ON.
Data= Changing parameter
4970 EQUATION A fault occurred at the internal • After alarm reset, execute operation again.
(937) 847-3200.
4980 EXCESSIVE The equation is excessively long. Make it shorter by dividing it, etc.
INSTRUCTION
4981 EQUATION
4982 [Decimal Data]
4990 ENCODER BATTERY Battery voltage drop. Make it shorter by dividing it.
ERROR
[Decimal Data]
5000 ENCODER Encoder overheat. Cool the encoder.
OVERHEAT
5010 ILLEGAL Improper parameter setting. • After changing the parameter, turn OFF the
PARAMETER power supply and turn it ON again.
(937) 847-3200.
5020 ZERO DEVICED Division is performed with 0. Do not perform division with 0.
OCCURRENCE
5021 [Decimal Data)
5022
5030 GLOBAL -VARIABLE The total of the global variable range Set the parameter again so that the global
AREA PARAM exceeds the allowable range (SID variable range will be within the allowable
5031 ERROR parameter value fault). range in total.
5032 [Decimal Data]
5040 OPUT OF RANGE The difference between the position • Perform axis operation of the faulty
(ABSO DATA) at power OFF and ON of either machine and move it to the position of
[Axis Data] machine exceeds the allowable current position "0" : check the home
range. position mark (arrow). If they don not
match, the faulty displayed axis PG system
is defective.
5060 UNDEFINED Arc auxiliary file welding release Set the number again and execute the operation
AUTO-WELD condition time is 0. again.
5061 RELEASE COND
5062 [Decimal Data]

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
5070 UNDEFINED Arc retry is set and there is no move Set a move instruction after ARCON.
POSITION FOR instruction after ARCON.
5071 ARC RETRY
5072 [Decimal Data]
5080 OVERSPEED LIMIT Overspeed limit. • For maintenance alarm code, contact
(937) 847-3200.
5090 DC 24V POWER External 24V power supply does not Check the external 24V power supply system.
SUPPLY FAILURE output.
5100 SHOCK SENSOR Shock sensor operates. Check the shock sensor operation factor.
ACTION
5110 BRAKE FUSE Break fuse is blown. Replace the fuse. Refer to Section 4.9.
BLOWN
5120 PARITY ERROR Universal I/O group has parity Examine some actions to prevent a parity error.
error.
5120
5122
5130 OVER BCD RANGE The variable value attempted to be • Set the data again so as not to exceed the
output exceeds the maximum value range.
5130 in BCD range [99 • Review the data specification
5132 (Decimal ) for no parity, 79 (binary/BCD) and parity check
(Decimal) for parity]. specification.
Or attempted to read unrepresentable
data in BCD range (exceeded nine at
four bits at hypostasis or epistasis).
5140 OVER BINARY The parity check is commanded and • Set the data gain so as not to exceed the
RANGE the variable value exceeded 127 range.
5141 (PARITY CHECK) (Decimal): it was attempted to be • Release parity check setting.
5142 output as an universal output.
5150 OFFLINE An error occurred at the internal • After alarm reset, execute operation again.
UNDEFINED control check. • For maintenance alarm code, contact
5151 COMMAND MOTOMAN Customer Service at
5152 (ARITH) (937) 847-3200.
5160 OFFLINE SYSTEM An error occurred at the internal • After alarm reset, execute operation again.
ERROR (ARITH) control check. • For maintenance alarm code, contact
5161
5162 (937) 847-3200.
5170 ROBOT An error occurred at the internal • After alarm reset, execute operation again.
CALIBRATION control check. • For maintenance alarm code, contact
5171 DATA ERROR MOTOMAN Customer Service at
5172 (937) 847-3200.
5180 ROBOT An error occurred at the internal • After alarm reset, execute operation again.
CALIBRATION control check. • For maintenance alarm code, contact
5181 FRAME ERROR MOTOMAN Customer Service at
5182 (937) 847-3200.
5190 ARITHMETIC An error occurred at the internal • After alarm reset, execute operation again.
SECTION control check. • For maintenance alarm code, contact
5191 INIT ERROR MOTOMAN Customer Service at
5192 [Decimal Data] (937) 847-3200.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
5200 SET-UP PROCESS An error occurred at the internal • After alarm reset, execute operation again.
ERROR (MOTION) control check. • For maintenance alarm code, contact
5202 (937) 847-3200.
5210 SYSTEM ERROR An error occurred at the internal • After alarm reset, execute operation again.
(MOTION) control check. • For maintenance alarm code, contact
5211
5212 (937) 847-3200.
5220 SERVO READY An error occurred at the internal • After alarm reset, execute operation again.
MONITORING control check. • For maintenance alarm code, contact
5222 [Decimal Data) (937) 847-3200.
5230 CALIBRATION An error occurred at the internal • After alarm reset, execute operation again.
DATA control check. • For maintenance alarm code, contact
5232 [Decimal Data) (937) 847-3200.
5240 TOOL CALIBRATION An error occurred at the internal • After alarm reset, execute operation again.
DATA ERROR control check. • For maintenance alarm code, contact
5242 (937) 847-3200.
5250 FAULT (ROBOT File total check error of calibration • After alarm reset, execute operation again.
CALIBRATION FILE) between robots on CMOS. • For maintenance alarm code, contact
[Decimal Data) Data = File No. MOTOMAN Customer Service at
(937) 847-3200.
5260 FAULT (TOOL File total check error of calibration • After alarm reset, execute operation again.
CALIBRATION FILE) of tool on CMOS. • For maintenance alarm code, contact
(937) 847-3200.
5270 FAULT (ARC START File total check error of welding start • After alarm reset, execute operation again.
COND GUIDE FILE) condition guide on CMOS. • For maintenance alarm code, contact
(937) 847-3200.
5280 FAULT (ARC END File total check error of welding start • After alarm reset, execute operation again.
COND GUIDE FILE) condition guide on CMOS. • For maintenance alarm code, contact
(937) 847-3200.
5290 FAULT (WELDER File total check error of welder • After alarm reset, execute operation again.
USER-DEFINED FILE characteristic initial guide on • For maintenance alarm code, contact
[Decimal Data) CMOS. MOTOMAN Customer Service at
Data = File No. (937) 847-3200.
5300 FAULT (LADDER File total check error of ladder • After alarm reset, execute operation again.
PROGRAM FILE) program on CMOS. • For maintenance alarm code, contact
(937) 847-3200.
5310 ARITHMATIC An error occurred at the internal • After alarm reset, execute operation again.
ALARM control check. • For maintenance alarm code, contact
5311 RESET ERROR MOTOMAN Customer Service at
5312 [Decimal Data) (937) 847-3200.
5320 WRONG CONTROL A jump call was made to a job which Call job to the control group which is same or
GROUP AXIS is different from the control group. includes the control group to be called.
5321 [Decimal Data)
5322

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
5330 CANNOT EXECUTE Robot is not included in the Add a robot to the job control group.
JOB(NO ROBOT) regulated control group of the job at
5331 [Decimal Data) execution of an instruction such as
5332 ARLON, WVON, etc.
5340 SENSING DATA An fault occurred at the internal • After alarm reset, execute operation again.
REQUEST ERROE control check. • For maintenance alarm code, contact
5342 (937) 847-3200.
5350 MAIN CONTACTOR At servo ON, the information that • After the alarm reset, execute the operation
ON REPLY ERROR the servo was ON did not arrive in again.
5351 [Decimal Data) the main factor. • Replace RY board.
5352
5360 MAIN CONTACTOR At servo OFF, the information that • After the alarm reset, execute the operation
OFF REPLY ERROR the servo was OFF did not arrive in again.
5361 [Decimal Data) the main factor. • Replace RY board.
5362
5370 BRAKING LOCK Brake is not turned ON. • After the alarm reset, execute the operation
REPLY ERROR again.
5371 [Decimal Data) • Replace RY board.
5372
5380 BRAKING RELEASE Brake is not turned OFF. • After the alarm reset, execute the operation
REPLY ERROR again.
5381 [Decimal Data) • Replace RY board.
5382
5390 SERVO-READY ON At servo ON, input signal servo • Check the connection cable between each
ERROR READY from the servo is not turned SERVOPACK and controller.
5391 Decimal Data) ON. • Replace the SERVOPACK.
5392 • Check that the power line to the motor is not
grounded.
5400 SERVO-READY OFF At the external servo OFF, input • Check the connection cable between each
ERROR signal servo READY from the servo SERVOPACK and controller.
5401 Decimal Data) is not turned ON after the servotacter • Replace the SERVOPACK.
5402 has been turned OFF. • Check that the power line to the motor is not
grounded.
5410 BASE-BLOCK ON Base block is not turned ON at servo • After alarm reset, execute operation again.
ERROR OFF. • Replace MSV01 (MSV02) board.
5411 [Binary Data)
5412
5420 BASE-BLOCK OFF Base block is not turned OFF at • After alarm reset, execute operation again.
ERROR servo OFF. • Replace MSV01 (MSV02) board.
5421 [Binary Data)
5422
5430 DYNAMIC BRAKE Dynamic brake is not turned ON. • After alarm reset, execute operation again.
ON ERROR • Replace MSV01 (MSV02) board.
5431 [Binary Data)
5432
5440 DYNAMIC BRAKE Dynamic brake is not turned OFF. • After alarm reset, execute operation again.
OFF ERROR • Replace MSV01 (MSV02) board.
5441 [Binary Data)
5442

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
5450 UNUSED(ON) An error occurred at the internal • After alarm reset, execute operation again.
[Decimal Data) control check. • For maintenance alarm code, contact
5451
5452 (937) 847-3200.
5460 UNUSED(OFF) An error occurred at the internal • After alarm reset, execute operation again.
5461
5462 (937) 847-3200.
5470 CANNOT EDIT An attempt to override an editing Replace edit lock setting.
(EDIT LOCK JOB) lock job was made.
5471 [Decimal Data)
5472
5480 SELECT ERROR System setting does not match. For maintenance alarm code, contact
(APPLICATION 1) MOTOMAN Customer Service at
5481 [Decimal Data) (937) 847-3200.
5482
(APPLICATION 2) MOTOMAN Customer Service at
5491 [Decimal Data) (937) 847-3200.
5492
(SENSOR 1) MOTOMAN Customer Service at
5501 [Decimal Data) (937) 847-3200.
5502
(SENSOR 2) MOTOMAN Customer Service at
5511 [Decimal Data) (937) 847-3200.
5512
5520 WRONG PORT NO. System setting does not match. For maintenance alarm code, contact
(ANALOG OUTPUT) MOTOMAN Customer Service at
5521 [Decimal Data) (937) 847-3200.
5522
5530 PASS OVER The path exceeded the set path-over • Release the factor of path-over.
[Decimal Data) monitoring area. • Set the path-over radius again so that it
5531 will be within the allowable range.
5532
5540 WRONG SELECT ION System setting does not match. For maintenance alarm code, contact
(SENSOR ) MOTOMAN Customer Service at
5541 [Decimal Data) (937) 847-3200.
5542
5550 WRONG MECH An error occurred at the internal • After alarm reset, execute operation again.
PARAMETER FILE control deck. • For maintenance alarm code, contact
5552 (937) 847-3200.
5560 INCOMPLETE PT An error occurred at the internal • After alarm reset, execute operation again.
FRAME control deck. • For maintenance alarm code, contact
5562 (937) 847-3200.
5570 DEFECTIVE An error occurred at the internal • After alarm reset, execute operation again.
TAUGHT control check. • For maintenance alarm code, contact
5571 POINT (CUTTING) MOTOMAN Customer Service at
5572 [Decimal Data) (937) 847-3200.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
5580 DEFECTIVE An error occurred at the internal • After alarm reset, execute operation again.
TAUGHT control check. • For maintenance alarm code, contact
5581 POINT (ENDLESS) MOTOMAN Customer Service at
5582 [Decimal Data) (937) 847-3200.
5590 CORRECTIONAL An error occurred at the internal • After alarm reset, execute operation again.
DIRECTION ERROR control check. • For maintenance alarm code, contact
5592 (937) 847-3200.
5600 POSITION An error occurred at the internal • After alarm reset, execute operation again.
CORRECTION control check. • For maintenance alarm code, contact
5602 [Decimal Data) (937) 847-3200.
5610 OVER TOOL FILE An error occurred at the internal • After alarm reset, execute operation again.
NO. control check. • For maintenance alarm code, contact
5612 (937) 847-3200.
5620 DEFECTIVE Weaving reference point teaching Teach the reference point again.
TAUGHT error.
5621 POINT (WEAV)
5622 [Decimal Data)
5630 UNDEFINED ROBOT Calibration between robots was not Perform calibration between robots.
CALIBRATION performed a execution of
5631 coordination instruction.
5632
5640 PARAMETER ERROR Zero-division is performed for Set the parameter again.
internal data according to the
5641 parameter.
5642
5650 DEFECTIVE Teaching point failure. Perform teaching again.
TAUGHT
5651 POINT (CALIB)
5652
5660 DM-BANK An error occurred at the internal • After alarm reset, execute operation again.
5662 (937) 847-3200.
5670 CANNOT EXECUTE An attempt to execute a disabled Register the instruction by a job with group
JOB (NO GRP AXIS) instruction was made by a job axis.
5671 without a group axis.
5672
5680 UNIV. DATA PRESET An error occurred at the internal • After alarm reset, execute operation again.
REQUEST ERROR control check. • For maintenance alarm code, contact
5681
5682 (937) 847-3200.
5690 BRAKING An error occurred at the internal • After alarm reset, execute operation again.
SEQUENCE control check. • For maintenance alarm code, contact
5692 (937) 847-3200.
5700 PROCESS ERROR An error occurred at the internal • After alarm reset, execute operation again.
(SYSCON->AXIS) control check. • For maintenance alarm code, contact
5701
5702 (937) 847-3200.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
5710 ILLEGAL SV Servo constant parameter setting Set the servo constant parameter again.
PARAMETER fault.
5711 (ONLINE)
5712
5720 KP CHANGE Improper response from axis section. • After alarm reset, execute operation again.
PROCESS • Replace MSV01 (MSV02) board.
5721 ERROR
5722
5730 SV PARAM CHANGE Improper response from axis section. • After alarm reset, execute operation again.
ERROR (ONLINE) • Replace MSV01 (MSV02) board.
5731
5732
5740 ILLEGAL MAX Max speed parameter setting error. Set the parameter again.
SPEED
5741 PARAMETER
5742
5750 UNDEFINED Position type variable which was not Set the position type variable.
POSITION set was used.
5751 VARIABLE
5752
5760 UNDEFINED USER User coordinate was used that was Set the user coordinate.
FRAME not set.
5761
5762
5770 OUT OF RANGE An error occurred at the internal • After alarm reset, execute operation again.
PARALLEL control check. • For maintenance alarm code, contact
5771 PROCESS) MOTOMAN Customer Service at
5772 [Decimal Data] (937) 847-3200.
5780 SL BOARD ON-LINE An error occurred at the internal • After alarm reset, execute operation again.
5781
5782 (937) 847-3200.
5790 INTERRUPT ERROR An error occurred at the internal • After alarm reset, execute operation again.
(SENSOR) control check. • For maintenance alarm code, contact
5791
5792 (937) 847-3200.
5800 OUT OF CURRENT An error occurred at the internal • After alarm reset, execute operation again.
DETECTOR RANGE control check. • For maintenance alarm code, contact
5801
5802 (937) 847-3200.
5810 COMMAND ERROR An error occurred at the internal • After alarm reset, execute operation again.
(937) 847-3200.
5820 PROCESS ERROR An error occurred at the internal • After alarm reset, execute operation again.
(937) 847-3200.
5830 PARALLEL START Parallel start instruction could not • After alarm reset, execute operation again.
INSTRUCTION be executed. • After alarm reset, review IOSTART,
ERROR PSTART instructions.
[Decimal Data)

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
5840 CANNOT EXECUTE Activation of the job (group axis) • After alarm reset, execute operation again.
JOB (GRP AXIS) was attempted by IOSTART • After alarm reset, review IOSTART,
5841 instruction. PSTART instructions.
5842
5850 MEASURE INST An error occurred at the internal • After alarm reset, execute operation again.
EXECUTE ERROR control check. • For maintenance alarm code, contact
5851
5852 (937) 847-3200.
5860 COORDINATE An error occurred at the internal • After alarm reset, execute operation again.
TRANSPORTATION control check. • For maintenance alarm code, contact
5862 (937) 847-3200.
5870 FAULT (CUTTING A fault occurred in cutting data file. • Initialize cutting data file (Customer
DATA FILE) Maintenance Mode).
• Load cutting data file saved on a floppy
disk and recover it.
5880 UNDEFINED ARC retry cannot be performed Register a step before ARCON instruction.
POSITION because of no step before ARCON
5881 FOR ARC ON instruction.
5882 [Decimal Data}
5890 UNDEFINED Restart cannot be performed because After alarm reset, extend the distance between
POSITION of no restart return step in the current search starting and target points.
5891 FOR RESTART job.
5892 RETURN Example: Retry is commanded
during performing the called job.
5900 REEP POS ERROR Search direction cannot be specified After alarm reset, extend the distance between
(SEARCH MOTION) because of a lack of distance search starting and target points.
5901 between search starting and target
5902 points.
5910 SPECIFIED ERROR Confirming position cannot be After alarm reset, change the coordinate.
(COORDINATE) performed because of TF and MTF
5911 [Decimal Data] specified at the coordinate with
5912 position-variable (P).
Data: 0 TF
Data: 1 MTF
5920 WRONG EXECUTION An error occurred during executing After alarm reset, clear the error by using
OF SAVEINST instruction with DCI function. alarm data.
[Decimal Data] Data: See the transmission
function manual.
OF LOAD INST instruction with DCI function. alarm data.
function manual.
OF DELETE INST instruction with DCI function. alarm data.
function manual.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
5950 FILE TYPE ERROR An error occurred at the internal • After alarm reset, execute operation again.
(BASE AXIS) control check. • For maintenance alarm code, contact
5952 (937) 847-3200.
5960 MFRAME ERROR Data: 8 Position file is not registered • Register the position file.
[Decimal Data) • For maintenance alarm code, contact
5961
5962 (937) 847-3200.
5970 CANNOT EXECUTE The second argument is negative. Check the job.
INSTRUCTION
5971 (SQRT)
5972 [Decimal Data)
5980 OUT OF RANGE Pulse difference of motor between After alarm reset, turn ON the servo.
(DROP VALUE servos ON and OFF is larger than
5981 Control Group) that specified by parameter.
5982
5990 TWO STEPS SAME The position of three points at the Program three different points.
LINE user coordinate, or more than three
5991 (3 STEPS) instructed points at the calibration
5992 between robots are on the same line.
6000 EMS ERROR An error occurred at the internal • After alarm reset, execute operation again.
[Decimal Data} control check. • For maintenance alarm code, contact
(937) 847-3200.
6010 DMS ERROR An error occurred at the internal • After alarm reset, execute operation again.
[Decimal Data} control check. • For maintenance alarm code, contact
(937) 847-3200.
6020 MAJOR An error occurred at the internal • After alarm reset, execute operation again.
ERROR MOTOMAN Customer Service at
[Decimal Data} (937) 847-3200.
6030 EXCESSIVE The specified speed exceeds the safe After alarm reset, decrease the speed of the
SEGMENT speed. step (Move instruction) where the alarm
6031 (SAFETY 1) : LOW occurred or change the robot attitude.
6032 [Axis Data}
6040 EXCESSIVE The specified speed exceeds the safe After the alarm reset, decrease the speed of the
6041 (SAFETY 1) : HIGH occurred or change the robot attitude.
6042 [Axis Data}
6051 (SAFETY 2) : LOW occurred or change the robot attitude.
6052 [Axis Data}
6061 (SAFETY 2) : HIGH occurred or change the robot attitude.
6062 [Axis Data}

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
6070 OBSERVER DATA • Instruct execution error. For maintenance alarm code, contact
OUTPUT ERROR • Ultra pierce data error. MOTOMAN Customer Service at
6071 (Decimal Data) • Shutter open/close error. (937) 847-3200.
6072 • VCO start incomplete.
• VCO manual start.
6080 WRONG EXECUTION 1: Instruct execution error. • Check the system condition.
OF LASER PROCESS 2: Ultra pierce data error. • Check job/data file.
(Decimal Data) 3: Shutter open/close error. • For maintenance alarm code, contact
4: VCO start incomplete. MOTOMAN Customer Service at
5: VCO manual start. (937) 847-3200.
6090 POOR LASER 1: Data file number beyond range. Set the correct value.
CONDITION 2: Gap amount data beyond
SETTING category.
(Decimal Data)
6100 OPERATION ERROR Operation error during sampling or After alarm reset, execute operation again.
(LASER PROCESS) upon VCO stop.
(Decimal Data)
6110 SEARCH MONITOR An error occurred at the internal • After alarm reset, execute operation again.
SET ERROR control check. • For maintenance alarm code, contact
6111 ( AXIS ) MOTOMAN Customer Service at
6112 [Decimal Data) (937) 847-3200.
6120 SEARCH MONITOR An error occurred at the internal • After alarm reset, execute operation again.
RELEASE ERROR control check. • For maintenance alarm code, contact
6121 ( AXIS ) MOTOMAN Customer Service at
6122 [Decimal Data) (937) 847-3200.
6130 CONV ERROR An error occurred at the internal • After alarm reset, execute operation again.
( F/B PULSE->CUR control check. • For maintenance alarm code, contact
6131 POS) MOTOMAN Customer Service at
6132 [Decimal Data) (937) 847-3200.
6160 SV PARAM CHG An error occurred at the internal • After alarm reset, execute operation again.
PROC ERROR control check. • For maintenance alarm code, contact
6161 (ONLINE) MOTOMAN Customer Service at
6162 [Decimal Data) (937) 847-3200.
6180 SPHERE INTRF ERR Data: 1 Calibration not performed. • Perform calibration between robots.
(ROBOT ) • For maintenance alarm code, contact
6182 (937) 847-3200.
6190 AXIS BLOCKING Data: Control group to be operated. Release the block for axis operation.
[Control Group}
6191
6192
6200 WRONG JOB TYPE Occurred by performing different Check the job.
[Binary Data} job types.
6201 Example: Robot job<----
6202 >Concurrent job Robot job<---->
Vision job Vision job<----
>Concurrent job
6210 TAG DATA CHANGE An error occurred at the changing Check the job or file.
PROCESS ERROR the welding condition.
6211
6212

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
6220 ONLY The starting job at the third series Check the job.
CONCURRENT is not the concurrent job.
6221 JOB POSSIBLE
6222
6230 CANNOT EXECUTE There is an instruction which cannot Check the job.
INST be executed in the concurrent job.
6231 (CONCUR JOB)
6232
6240 CANNOT EXECUTE Execute the robot job with IO Check the job.
SPECIFIED JOB START instruction.
6241
6242
6250 SYNTAX ERROR IN An error occurred at the internal • After alarm reset, execute operation again.
EQUATION INST control check. • For maintenance alarm code, contact
6252 (937) 847-3200.
6260 UNDEFINED PORT An error occurred at the internal • After alarm reset, execute operation again.
NO. (AOUT) control check. • For maintenance alarm code, contact
6262 (937) 847-3200.
6270 SYNTAX ERROR An error occurred at the internal • After alarm reset, execute operation again.
6272 (937) 847-3200.
6280 VISION SYSTEM An error occurred at vision system. • After alarm reset, execute operation again.
ERROR 1 • Turn OFF power then turn it ON again.
6281 (Decimal Data)
6291 (Decimal Data)
6301 (Decimal Data)
6311 (Decimal Data)
6321 (Decimal Data)
6331 (Decimal Data)
6341 (Decimal Data)
6351 (Decimal Data)
6360 VISION SYSTEM Vision system fault data. • Initialize either file or template and then
ERROR 9 • File fault. load file or template saved on a floppy
6361 (Decimal Data) • Ten plate fault. disk and recover it.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
6371 (Decimal Data)
6381 (Decimal Data)
6390 VISION JOB Alarm Data: Clear errors according to alarm data.
EXECUTION 1:Instruction interpretation error.
6391 ERROR 1 2:Additional items interpretation
error.
3: Label to be jumped is not
specified.
4: Job to be jumped is not
specified.
5: Job to be called is not
specified.
6: Calling place is not specified.
7:Job other than vision job was
executed by VSTART command.
10: Job call stack over.
20: Local variable number error.
21: Vision user variable number
error.
30: Selected vision job doesn't
exist.
40: Instruction structure error.
50: VPI is not executed.
6400 VISION JOB For maintenance alarm code, contact
EXECUTION MOTOMAN Customer Service at
6401 ERROR 2 (937) 847-3200.
(Decimal Data)
6410 VISION ARITH. Alarm Data: Clear errors according to alarm data.
ERROR 1: Divided by 0.
6411 (Decimal Data) 2: Byte variable overflow.
3: Integral number variable
overflow.
4: Real variable overflow.
5: Integral number variable
underflow.
6: Real variable underflow.
7: Byte variable underflow.
13: SQRT arith. error.
30:Vision user variable
unmatched.
6420 VISION SITUATION Alarm Data: • Clear errors according to alarm data.
FILE ERROR 1: Situation is not specified. • 1-13: Check if correct variable is used.
6421 (Decimal Data) 2: Situation data fault. • 30: Match variables.
3: Situation is not selected.
4: Situation data is full.
6440 VISION USER FILE Alarm Data: Clear errors according to alarm data.
ERROR 1: Vision user axis is not 1: Check vision user axis number.
6441 (Decimal Data) specified. 2: Specify vision user axis again.
2: Vision user axis fault.
6450 VISION EXECUTION For maintenance alarm code, contact
CONTROL ERROR MOTOMAN Customer Service at
6451 (Decimal Data) (937) 847-3200.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
6460 VISION INST For maintenance alarm code, contact
ERROR 1 MOTOMAN Customer Service at
6461 (Decimal Data) (937) 847-3200.
6470 VISION INST For maintenance alarm code, contact
ERROR 2 MOTOMAN Customer Service at
6471 (Decimal Data) (937) 847-3200.
6480 VISION TEMPLATE Alarm Data: Clear errors according to alarm data.
MATCHING ERROR 1: VTMPOS command is executed
6481 before VTMATCH command
is executed.
2: Template is not specified.
3: Mask number is beyond correct
category.
4: Specified matching point
doesn't exist.
6490 LASER VCO REPLY Alarm Data: • Start over laser.
ERROR 1: VCO start/finish reply error. • For maintenance alarm code, contact
6491 2: VCO operation preparation MOTOMAN Customer Service at
complete reply error. (937) 847-3200.
3: Super pulse effect reply error.
4: Specified matching point
doesn't exist.
6500 LASER CONTROL Alarm Data: • Turn OFF power and then turn it ON again.
PANEL 1: Flaming error. • For maintenance alarm code, contact
TRANSMISSION 2: Parity error. MOTOMAN Customer Service at
ERROR 3: Overrun error. (937) 847-3200.
(Decimal Data) • After alarm reset, execute operation again.
6510 TWIN SYNCHRONIS Alarm Data: Set R❑+S❑ job for jobs starting with
ERROR 1: No effective control group. synchronization.
6511 (Decimal Data) 2: No master control group.
6512 3: No slave control group.
4: No other step end during
synchronization.
5: No other segment data during
synchronization.
6520 CONVEYOR Encoder cable line cut or encoder Check encoder cable/encoder.
ENCODER ERROR fault.
6521 (123) Data is alarm occurrence conveyor
number.
6530 PORT NUMBER Port number set in conveyor or /and Check conveyor/press file setting.
ERROR press file doesn't exist on board.
6531 (123) This error happens when CH2/3
ports are specified in case of
MSL01-0, CH3 port is specified in
case of MSL01-2.
Data is alarm occurrence conveyor
number or press file number.
6540 MSL02CPU Parameter arithmetic error when data Check if data from conveyor or press file is set
PARAMETER ERROR is taken from conveyor press file. correctly.
6541 (Decimal Data)
6550 CONVEYOR Conveyor position counter pulse • Check conveyor position.
POSITION LIMIT overflow occurred. • Since conveyor position is not reset after
6551 OVER Data is alarm occurrence conveyor this error happens, execute the operation at
(123) file number. the position where the alarm occurred.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
6560 CONVEYOR Conveyor position counter pulse • Check conveyor position counter pulse
COUNTER overflow occurred. (conveyor resolution).
6561 LIMIT OVER Data is alarm occurrence conveyor • Since conveyor position is not reset after
(123) file number. this error happens, execute the operation at
the position where the alarm occurred.
6570 CONVEYOR FILE CMOS memory conveyor file fault • Initialize conveyor file (Customer
FAULT occurred. maintenance).
(File Number) Data corresponds to file number. • Load conveyor file from floppy disk and
recover it.
6580 CONVEYOR SYNC. Alarm Data: Clear errors according to alarm data after the
ERROR 1: Driving axis direction error. alarm reset.
6581 (Decimal Data) When conveyor file base axis
6582 is specified other than 1,2,
and 3.
2: Robot group doesn't exist
during robot axis tracking.
3: Base group doesn't exist during
robot axis tracking.
4: CV select <-> CVF #
unmatched.
5: No data for conveyor starting
point during reading ahead.
6: Conveyor position latch error
during reading ahead.
7: Sync. start signal doesn't come
on.
8: Conveyor position reset is not
allowed.
9: Conveyor correction amount
reading error.
6590 UNDEFINED Conveyor file is not defined. Define the conveyor file ➔1: USE.
CONVEYOR FILE
6591 (Decimal Data)
6592
6600 CONVEYOR SPEED An error occurred at the internal • Turn OFF power and then turn it ON again.
DECREASE control check. • Turn OFF power and check the control board.
6601 (Decimal Data) Data corresponds to alarm number. • For maintenance alarm code, contact
(937) 847-3200.
6610 CONVEYOR SYNC. An error occurred at the internal • Turn OFF power and then turn it ON again.
ARITHMETIC ERROR control check. • Turn OFF power and check the control board.
6611 (Decimal Data) Alarm Data: • For maintenance alarm code, contact
6612 1: Conveyor sync. control group MOTOMAN Customer Service at
error. (937) 847-3200.
2: Conveyor sync. user axis
specifying error.
3: Conveyor sync. coordinated
slave error.
6620 TORQUE At operating in specified speed, load After alarm reset, decrease the speed of the step
INTERFERENCE torque of the robot axis and the (Move instruction) where the alarm occurred or
6621 motor exceeds allowance. change the robot attitude.
6622

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
6630 SERVO POWER OFF The servo power supply is OFF for Turn OFF the servo power and then turn the
FOR JOB the group axis of the operated job. servo power supply ON again for the group
6631 [Control Group] axis to operate.
6632
6640 PSEND ERROR Data 1 : Performed the PSEND Change the job.
[Decimal Data] instruction to own task.
6641
6642
6650 PRECV ERROR Data 1 : Performed the PRECV Change the job.
[Decimal Data] instruction to own task.
6651
6652
6660 OFFLINE MAILBOX An error occurred at the internal • After alarm reset, execute operation again.
PROCESSING ERR control check. • For maintenance alarm code, contact
6662 (937) 847-3200.
6680 CANNOT USE Performed robot follow-up by Change the instruction, or for the system with
SMOVJ SMOVJ instruction. base axis, specify base axis follow-up.
6681 DURING TRACKING
6682 [Decimal Data)
6690 DATA SENDING An error occurred while using the After alarm reset, clear the error by using alarm
ERROR data transmission function. data.
[Decimal Data) Data: 1 Retry for NAK
instruction exceeded.
Data: 2 Retry for timer A timeup
exceeded.
Data: 3 Retry for mutual
response error exceeded.
6700 DATA RECEIVING An error occurred while using the After alarm reset, clear the error by using
ERROR data transmission function. alarm data.
[Decimal Data) Data: 1 Receiving timeup
(Timer A).
Data: 2 Receiving timeup
(Timer B).
Data: 3 The heading length is
short.
Data: 4 The heading length is
long.
Data: 5 Header number fault.
Data: 6 Text length exceeds 256
characters.
6710 TRANSMISSION An error occurred while using the After alarm reset, clear the error by using alarm
HARDWARE ERROR data transmission function. data.
[Decimal Data) Data: 1 Excess error.
Data: 2 Parity error.
Data: 3 Flaming error.
Data: 4 Sending timeup (Timer
A).
Data: 5 Sending timeup (Timer
B).
6730 TRANSMISSION An error occurred at using the data • After alarm reset, execute operation again.
SYSTEM ERROR transmission function. • For maintenance alarm code, contact
(Decimal Data) MOTOMAN Customer Service at
(937) 847-3200.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
6720 TRANSMISSION An error occurred at using the data • After alarm reset, execute operation again.
SYSTEM ERROR transmission function. • For maintenance alarm code, contact
(937) 847-3200.
6740 FAULT (PAINT Painting characteristic file total • Load the storage painting characteristic file
CHARACTERISTICS check error on CMOS. from FC 1/2.
6750 FILE) Data: File Number • Initialize the painting characteristic file by
[File No.) maintenance mode.
(937) 847-3200.
6760 FAULT (WRIST Wrist weaving amplitude • Load the storage wrist weaving amplitude
WEAV characteristics file total check error characteristic file from FC 1/2.
AMPLITUDE FILE) on CMOS. • Initialize the wrist weaving amplitude
characteristic file by maintenance mode.
(937) 847-3200.
6770 CORNER R • Corner R is not allowed to use • Do not use Corner R during coordinated
CONTROL ERROR during coordinated operation. operation.
6771 (Decimal Data) • No reference point. • Give another instruction.
6772 • Excessive angle • Adjust the set value for Corner R operation.
• Impossible to track internally
touched arch with specified
radius.
1: Corner R coordinated control
slave specifying error.
2: Corner R pass reference point
error.
3: Corner R pass angle error.
4: Corner R operation radius data
error.
5: Corner R operation group
specifying error.
6: Corner R master command
error.
6780 JOB QUE EMPTY Performed CALL QUE and JUMP Check the job.
ERROR QUE with no JOB QUE.
6781
6782
6790 UNDEFINED PAINT The painting characteristic file is not Set completely the painting characteristic.
CHARACTERISTICS set.
6791 FILE
6792
6800 MRESET ERROR An error occurred at using the data • After alarm reset, execute operation again.
[Decimal Data] transmission function. • For maintenance alarm code, contact
6802 (937) 847-3200.
6810 SERVOAVERAGING An error occurred at using the data • After alarm reset, execute operation again.
BUFFER ERROR transmission function. • For maintenance alarm code, contact
6812 (937) 847-3200.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
6820 FAULT (INT JOB Interruption job table file total check • Initialize the job table file by maintenance
TABLE FILE) error on CMOS. mode.
(937) 847-3200.
6830 OUT OF RANGE Data shows channel number bit: • Check the cable between the outside
(INPUT VOLTAGE) 0000-0001:CH1 position correction device and MSL board.
6831 (Binary Data) 0000-0010:CH2 • Check parameter set value.
0000-0100:CH3
0000-1000:CH4
0001-0000:CH5
0010-0000:CH6
6840 OUT OF RANGE Data shows channel number bit: • Set the outside position correction device
(INITIAL VOLTAGE) 0000-0001:CH1 and MSL board.
6841 (Binary Data) 0000-0010:CH2 • In case of re-occurrence, check the input
0000-0100:CH3 voltage of channel which causes error and
0000-1000:CH4 then adjust set value of "off-set voltage"
0001-0000:CH5 and "initial voltage."
0010-0000:CH6
6850 PARAMETER ERROR Wrong setting for parameter (sensor) Set the parameter correctly.
(SENSOR) (S1E/S2E parameter).
6851
6880 STACK LESS THAN 0 An error occurred at using the data • After alarm reset, execute operation again.
( JOB CALL) transmission function. • For maintenance alarm code, contact
6882 (937) 847-3200.
6890 JOB ATTRIBUTE Job attribute is not correct such as: • Check job attribute specified with
NOT SAME (MULT) 1: Sampling reverse job is not MLTSPML command.
6891 (Decimal Data) reverse attribute when it is • Check if sampling reverse job was made.
6892 specified with MLTSMPL • Match job attributes specified with
command. MLTSCAL.
2: Either initial job or sampling
forward job specified with
MLTSMPL command is
reversed attribute.
3: Unmatched attribute between
sampling job specified with
MLTSCAL and N pass job.
6900 JOB CONTROL Control group is unmatched between Select jobs that match control group.
GROUP NOT SAME specified jobs (MLTSMPL,
6901 (MULT) MLTSCAL).
6902 (Decimal Data)
6910 NUMBER OF STEPS Total number of steps are not the Match number of steps between jobs.
NOT SAME (MULT) same between specified jobs
6911 (Decimal Data) (MLTSMPL, MLTSCAL).
6912
6920 NUMBER OF Number of reference points is not Match number of reference points between
REFERENCE POINTS same between specified jobs jobs.
6921 NOT SAME (MULT) (MLTSMPL, MLTSCAL).
6922 (Decimal Data)
6930 COORDINATE NOT Coordinates of positioning data are Match coordinates between jobs.
SAME (MULT) not same between specified jobs
6931 (Decimal Data) (MLTSMPL, MLTSCAL).
6932

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
6940 TEACHING TOOL Teaching files are not same between Match tool files between jobs.
NOT SAME (MULT) specified jobs (MLTSMPL,
6941 (Decimal Data) MLTSCAL).
6942
6950 UNDEFINED WELD Welding section (SENSON Define left-mentioned welding sections for
SECT. (MULT) COMARC- SENSOF COMARC, each job.
6951 (Decimal Data) SENSON SCOMARC - SENSOF
6952 SCOMARC, ARCON - ARCOF) is
not defined in specified jobs
(MLTSMPL, MLTSCAL).
6960 STEPS NOT SAME Number of steps are not the same Match number of steps between specified jobs.
WELD SECT (MULT) between specified job (MLTSMPL,
6961 (Decimal Data) MLTSCAL).
6962
6970 ERROR OF MULT Alarm Data: For maintenance alarm code, contact
LAYER FUNCTION 1: MULT sampling cue underflow MOTOMAN Customer Service at
6971 (Decimal Data) (MLTSMPL). (937) 847-3200.
6972 2: MULT sampling cue overflow
(MLTSMPL).
3: MULT sampling cue FATAL
error (MLTSMPL).
4: MULT sampling cue job name
is not defined.
5:MULT scaling arithmetic error
(approach point).
6: MULT scaling arithmetic error
(sensing starting point).
(sensing starting reference
point).
(sensing middle point).
(sensing end point).
10: MLTWESET file pointer is not
correct.
11. Excessive number of answer
points for scaling shift
arithmetic.
6980 DUPLICATE Duplicate execution of MLTSMPL. Check job and then correct duplicate command.
EXECUTION OF
6981 MLTSMPL
6982 (Decimal Data)
6990 UNDEFINED MULT MULT layer file is not defined Define MULT layer file.
LAYER FILE (MLTSSET, MLTWSET).
6991 (Decimal Data)
6992
7000 UNDEFINED MULT Unused MULT layer condition file is Check the specified MULT layer condition
LAYER COND. FILE specified (MLTSSET, MLTWSET). file.
7001 (Decimal Data)
7002
7010 WELD SECT. NOT Number of welding sections Match number of weld sections between jobs.
SAME (SENSON COMARC- SENSOF
7011 (MULT) COMARC, SENSON SCOMARC -
7012 (Decimal Data) SENSOF SCOMARC, ARCON -
ARCOF) are not same in specified
jobs (MLTSMPL, MLTSCAL).

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
7020 DUPLICATED WELD SENSON, ARCON command exists Match number of weld sect. between jobs.
SECT. within weld sect. in specified jobs
7021 (MULT) (MLTSMPL, MLTSCAL).
7022 (Decimal Data)
7030 OVER 10 WELD Number of weld sect. is more than Set number of weld sect. in jobs 1-10.
SECT. 10 (MLTSMPL, MLTSCAL).
7031 (MULT)
7032 (Decimal Data)
7040 MOVE Move instruction types are not the Match move instruction types between
INSTRUCTION NOT same between specified jobs specified jobs.
7041 SAME (MULT) (MLTSCAL).
7042 (Decimal Data)
7050 SAME POINT ERROR 3 same points are set within scaling Set 2 points the same at most.
(MOVL 3 POINTS) shift sect. (MLTSCAL).
7051
7052
7060 SAME POINT ERROR REFP command is given at the same Instruct REFP same point again.
(REFP) point within scaling shift sect.
7061 (MLTSCAL).
7062
7070 SAME POINT ERROR Start point and end point are set at Instruct start point and end point at different
(START, END) the same point within scaling shift positions.
7071 sect. (MLTSCAL).
7072
7080 ERROR OF SCALING Alarm Data: For maintenance alarm code, contact
CALCULATION 1: Internal transaction error 1. MOTOMAN Customer Service at
7081 (Decimal Data) 2: Internal transaction error 2. (937) 847-3200.
7082 3: Arithmetic error (MLTSCAL).
7090 LINE MATCHING Alarm Data: Clear errors according to alarm data.
ERROR (VISION) 1: VLMPOS command was 1: Execute VLMATCH command first.
7091 (Decimal Data) executed before VLMATCH 2: Check line file number.
7092 command is executed. 3: Set correct line number.
2: Line file is not defined. 4: Set correct sort number.
3: Specified line number doesn't 5: Execute VLMPOS command.
exist. 6: Register line file again.
4: Sort number is wrong.
5: VLMPOS command is not
executed.
6: Line file fault.
7110 TRANSMISSION Alarm Data: Clear errors according to alarm data.
ERROR (SENSOR) 1: Parity error or overrun error or 1: Check whether or not transmission method
7111 (Decimal Data) flaming error occurred. between controller and sensor is matched.
2: Answer was not given within 3 2: Check line connection.
seconds from sensor during 3: Check data from sensor.
transmission.
3: Data from sensor has error
(BCC check result error).
7120 FAULT (SENSOR CMOS memory cutting cond. file • Initialize cutting condition file (customer
MONITOR fault. maintenance).
CONDITION FILE) Data indicates file number. • Load the file saved on a floppy disk and
(Decimal Data) recover it.
7130 APPLICATION Another application started during Check job after resetting the alarm.
PROGRAM application program execution.
STARTING ERROR
(Decimal Data)

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
7140 UNDEFINED Undefined application started with Either change name of APSTART command or
APPLICATION APSTART command. load application program.
PROGRAM
(Decimal Data)
7150 8086 EMULATOR For maintenance alarm code, contact
STARTING ERROR MOTOMAN Customer Service at
(Decimal Data) (937) 847-3200.
7160 ZERO DIVIDED Application program executed zero Correct application program.
OCCURRENCE divided (emulation mode).
(TURBO)
(Decimal Data)
7170 REQUEST ERROR Request cannot go through from • Turn OFF power and then turn it ON again.
(SL) motion area to sensor area. • Turn OFF power and check the insertion of
7171 (Decimal Data) the MLS board.
7172 • For maintenance alarm code, contact
(937) 847-3200.
7180 SOFTWARE Alarm Data: For maintenance alarm code, contact
UNMATCH 1: MULT layer weld function. MOTOMAN Customer Service at
7181 (Decimal Data) 2: Observer function. (937) 847-3200.
7182 3: Turbo function.
4: COMARC function.
5: Conveyor/press sync. function.
6: Shared movement function.
7: Weight movement function.
8: General purpose sensor
function.
9: Servofloat function.
10: Laser cutting function.
11: Servo gun function (for spot
weld).
7190 FAULT (NAME CMOS memory name position file For maintenance alarm code, contact
POSITION FILE) fault. MOTOMAN Customer Service at
(File Number) Data indicates file number. (937) 847-3200.
Position name development is under
discontinuation.
7200 NAME POSITION Position name development is under For maintenance alarm code, contact
FILE SYSTEM discontinuation. MOTOMAN Customer Service at
7201 ERROR (937) 847-3200.
7202 (Decimal Data)
7210 UNDEFINED NAME Position name development is under For maintenance alarm code, contact
POSITION FILE discontinuation. MOTOMAN Customer Service at
7211 (937) 847-3200.
7212
7220 USER FRAME Position name development is under For maintenance alarm code, contact
MAKING ERROR discontinuation. MOTOMAN Customer Service at
7221 (Decimal Data) 1: User frame making position (937) 847-3200.
7222 teaching error.
2: User frame rotating position
teaching error.
3: Robot doesn't exist in rotating
position occupation group.
4: Name position data user frame
number error.
5: Name position data position
tag error.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
7230 CANNOT MONITOR MOVJ, MOVS were going to be Either change command names to MOVL,
DISTANCE executed under arc-retry, restart MOVC or do not execute arc-retry, restart
operation. operation.
7240 ME-NET SYSTEM MSC02 board error during Check other station's data.
ERROR 2 communication.
(Decimal Data) Value of type 1 receiving frame NI
(relay link sending size) and NY
(register link sending size) doesn't
match that of data link parameter.
7250 ME-NET COMM Communication monitor flag is zero Restart communication at error station and
MONITOR FLAG at alarm set station. then reset alarm.
ERROR 1-63: error stations (mother station is
(Decimal Data) not included).
This error occurs only at alarm set
station.
7260 ME-NET STAT Communication monitor flag 1 is zero Restart programming at error station and then
MONITOR FLAG at alarm set station. reset alarm.
ERROR1 1-64: error stations (64 indicates
(Decimal Data) mother station).
station.
7270 ME-NET STAT Communication monitor flag 2 is zero Clear errors at error station and then reset
MONITOR FLAG at alarm set station. alarm.
ERROR2 1-64: error stations (64 indicates
(Decimal Data) mother station).
station.
7280 DATA LINK Alarm Data: Correct data link allocation of self-station or
PARAMETER ERROR 10: Number of stations error (not mother station data link parameter.
(Decimal Data) 2 number of stations, 64).
11: Total amount of relay and
register sending size per
station on data link parameter
exceeds 1024.
12: Total amount of all stations
relay sending size on data link
parameter exceeds 256.
13: Total amount of all stations
register sending size on data
link parameter exceeds 2048.
14: Relay off-set exceeds mother
stations relay area size on data
link parameter.
15: Register off-set exceeds
mother stations relay area size
on data link parameter.
20: Block specified with data link
allocation exceeds self-station
relay area size specified with
data link parameter.
(Block whose total amount of
off-set and byte length is
bigger than self-station relay
area size on data link
parameter exists.)

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
7280 DATA LINK Alarm Data, continued: Correct data link allocation of self-station or
Continued PARAMETER ERROR 22: Block specified with data link mother station data link parameter.
(Decimal Data) allocation exceeds other
Continued station relay area size
specified with data
link parameter.
bigger than other station
relay area size on data link
parameter exists.)
23: Block specified with data link
allocation exceeds other
station register area size
specified with data link
parameter.
bigger than other station
register area size on data link
parameter exists.)
24: Station number specified with
data link allocation is not
included in number of stations
on data link parameter.
7290 WAITING DATA Waiting for data link parameter from Restart communication with mother station
LINK PARAMETER mother station. and then reset alarm.
7300 FAULT (OPERATION CMOS memory operation origin data Since this is a system data file problem,
ORIGIN DATA) fault. contact MOTOMAN Customer Service at
(937) 847-3200.
7310 FAULT CMOS memory servofloat condition • Initialize spot gun cond. file (customer
(SERVOFLOAT file fault. maintenance).
COND. FILE) Data indicates file number. • Load the file saved on a floppy disk and
(File Number) recover it.
7320 FAULT (PRESS CMOS memory press cond. data file Initialize press cond. data file (customer
COND. DATA FILE) fault. Data indicates file number. maintenance).
7330 UNDEFINED PRESS Specified press cond. data file in job is Select "use" for specified cond. data file.
COND. DATA FILE not defined.
7331 (Decimal Data)
7332
7340 UNDEFINED PRESS Specified press resolution data file is Define data the select "complete."
RESOLUTION DATA not defined.
7341 (Decimal Data)
7342
7350 SL-CPU DATA Request (to initialize) cannot go • Turn OFF power and then turn it ON
INITIALIZATION through from motion area to sensor again.
7351 ERROR area. • Turn OFF power and check the insertion
7352 of the MLS board.
(937) 847-3200.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
7360 SV FLOAT MODE For maintenance alarm code, contact
SET ERROR (AXIS) MOTOMAN Customer Service at
7361 (937) 847-3200.
7362
7370 SV FLOAT MODE For maintenance alarm code, contact
RELEASE ERROR MOTOMAN Customer Service at
7371 (Axis) (937) 847-3200.
7380 PRESS ENCODER Encoder cable is cut or encoder itself Check encoder cable/encoder.
ERROR is broken.
7381 (123) Data indicates error press number.
7390 PRESS POSITION Press position exceeds limit (21m). Check press stroke.
LIMIT Data indicates error press cond. data
7391 (123) file number.
7400 PRESS COUNTER Press position counter pulse Check press position counter pulse (press
LIMIT overflow. resolution).
7401 (123)
7410 CPU RACK SERVO CPU rack/board error. Wrong board • Check board insertion.
ERROR was inserted. • Check MSV board connector/short pin.
(937) 847-3200.
7420 PRESS ENCODER Encoder cable is cut or encoder itself Check encoder cable/encoder.
POSITION ERROR is broken.
7421 (123) Data indicates error press number.
7430 INTERNAL CLOCK For maintenance alarm code, contact
CHANGE ERROR MOTOMAN Customer Service at
7431 (123) (937) 847-3200.
7440 SERVOPACK 1: Main power is "ON." For maintenance alarm code, contact
POWER OFF ERROR 2: SRDY is "OFF." MOTOMAN Customer Service at
7441 (Decimal Data) (937) 847-3200.
7442
7450 SERVOPACK 1: Main power is "OFF." For maintenance alarm code, contact
POWER ON ERROR 2: SRDY is "ON." MOTOMAN Customer Service at
7451 (Decimal Data) (937) 847-3200.
7452
7460 FAULT (SPOT GUN CMOS memory spot gun cond. file • Initialize spot gun cond. file (customer
COND. FILE) fault. Data indicates file number. maintenance).
(File Number) • Load the file saved on a floppy disk and
recover it.
7470 FAULT (SPOT CMOS memory spot welder cond. • Initialize spot gun cond. file (customer
WELDER COND. file fault. Data indicates file number. maintenance).
FILE) • Load the file saved on a floppy disk and
7480 FAULT (SERVO GUN CMOS memory servo gun pressure • Initialize spot gun cond. file (customer
PRESSURE FILE) cond. file fault. Data indicates file maintenance).
(File Number) number. • Load the file saved on a floppy disk and
recover it.

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
7490 FAN ERROR Fan (regenerative resistor) revolution • After resetting alarm, move manipulator
(REGENERATIVE decreased. to safe location.
RESISTOR) • Fan needs to be replaced. Contact
(937) 847-3200.
7500 UNDEFINED SERVO For maintenance alarm code, contact
GUN CONTROL MOTOMAN Customer Service at
7501 GROUP (937) 847-3200.
7502
7510 UNDEFINED SIGNAL For maintenance alarm code, contact
FOR SPOT WELD MOTOMAN Customer Service at
7511 COMPLETE (937) 847-3200.
7512
7520 SPOT WELD For maintenance alarm code, contact
COMPETE TIME MOTOMAN Customer Service at
7521 LIMT (937) 847-3200.
7522
7530 ERROR IN WELD For maintenance alarm code, contact
START TIMING MOTOMAN Customer Service at
7531 (937) 847-3200.
7532
7540 SERVO GUN CONT. For maintenance alarm code, contact
MODE SET ERROR MOTOMAN Customer Service at
7541 (AXIS) (937) 847-3200.
7542
7550 SERVO GUN CONT. For maintenance alarm code, contact
MODE RELEASE MOTOMAN Customer Service at
7551 ERROR (AXIS) (937) 847-3200.
7552
7560 KD CHANGE For maintenance alarm code, contact
PROCESS ERROR MOTOMAN Customer Service at
7561 (Decimal Data) (937) 847-3200.
7562
7570 SPOT WELD ERROR For maintenance alarm code, contact
7571 (937) 847-3200.
7572
7580 FAULT CMOS memory anticipation OT file • Initialize anticipation OT file (customer
(ANTICIPATION OT fault. Data indicates file number. maintenance).
FILE). • Load the file saved on a floppy disk and
7590 FAULT CMOS memory anticipation OG file • Initialize anticipation OG file (customer
(ANTICIPATION OG fault. Data indicates file number. maintenance).
FILE). • Load the file saved on a floppy disk and
7600 ANTICIPATION Many operation commands are set PAINTON PAINTON
CONTROL ERROR continuously. ê
7601 (Decimal Data) PAINTOF è MOVL
7602 PAINTOF
MOVL

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
7610 ANTICIPATION No return step upon re-paint function After alarm reset, execute operation again.
DISTANCE NOT after emergent stop.
7611 ENOUGH
7612
7620 DEFECTIVE OT file is set"-." After alarm reset, set correct number.
ANTICIPATION OT 1: OT output ;number error.
7621 FILE 2: OG output number error.
7622 (File Number)
7630 IMPOSSIBLE TO The axis that makes servo disconnect After alarm reset, do the correct operation.
DISCONNECT is specified.
SERVO
7640 CONVEYOR QUEUE Conveyor origin SL went on without • Check pieces and keep number of them at
OVERFLOW using all 6 conveyor queues. 6 or less.
• In addition to piece under sync., • Check LS (chattering).
pieces passed conveyor origin LS
add up to more than 6.
• Conveyor origin LS worked
improperly.
7650 NO CONVEYOR • CVQUE command was executed Change the timing for CVQUE command
QUEUE DATA without using all conveyor and/or conveyor queue clear signal.
7651 queues.
• Conveyor queue clear signal was
sent.
7660 MPCT FUNCTION MPCT function is used without Set "conveyor queue use permission" ("1")
NOT SPECIFIED setting "conveyor queue use and then use MPCT function.
7661 permission" in conveyor cond. data
7662 file.
7670 CONVSFT ERROR Arithmetic error occurred upon For maintenance alarm code, contact
(Decimal Data) CONVSFT command execution. MOTOMAN Customer Service at
7671 (937) 847-3200.
7672
7680 CANNOT EXECUTE For maintenance alarm code, contact
GUN TYPE MOTOMAN Customer Service at
7681 (937) 847-3200.
7682
7690 STARWAIT TIME For maintenance alarm code, contact
LIMIT MOTOMAN Customer Service at
7691 (937) 847-3200.
7692
7700 SENSOR INITIAL For maintenance alarm code, contact
DATA BEYOND MOTOMAN Customer Service at
7701 RANGE (937) 847-3200.
(Binary Data)
7720 CANNOT EXECUTE For maintenance alarm code, contact
CALIBRATION MOTOMAN Customer Service at
7721 (937) 847-3200.
7730 PG ON ERROR For maintenance alarm code, contact
(AXIS) MOTOMAN Customer Service at
7731 (937) 847-3200.
7732

TROUBLESHOOTING
ALARM REMEDIAL
MESSAGE CAUSE
CODE ACTION
7740 PG OFF ERROR For maintenance alarm code, contact
(AXIS) MOTOMAN Customer Service at
7741 (937) 847-3200.
7742
7750 SERVO GUN For maintenance alarm code, contact
CHANGE ERROR MOTOMAN Customer Service at
7751 (937) 847-3200.
7752
7760 SERVO GUN For maintenance alarm code, contact
INSTALLATION MOTOMAN Customer Service at
7761 ERROR (937) 847-3200.
7762
7770 FAULT (SERVO GUN For maintenance alarm code, contact
STROKE FIKE) MOTOMAN Customer Service at
(Decimal Data) (937) 847-3200.

SECTION 6
DIAGRAMS
6.1 Power Flow
SVM
CN2 CKT SYSTEM MAIN CKT

MTUOX-X PROTECTION TRANSFORMER BREAKER CUSTOMER
SUPPLY
SVMX FU1 3 1
1LF R
NCM FU2 S 50/60 HZ.
0 220 4 10A 2 T
G 3 PHASE
AC
FU2 CONTACTOR
CN3
+24VI AC
FU5 BRX CONTACTOR
OPTION
FU4
M M
FUSE
BOARD
2CN
GP32 3.2AX2 DUAL
CONTROL.
CN4 ROBOT
SIDE
SIDE
CN2
SVM M M
1SV 1SV
SVMX (S,L,U) (S,L,U)
CEILING
FAN M M
FAN
MEW
02 FAN
FAN
REAR SIDE
MBB02 DUCT FAN
FAN
FAN
CN6
M M
2CN
DUAL
1PS ROBOT CONTROL.
SIDE SIDE
5VDC, 24VDC M M
CN2 CN3 2SV 2SV
(R,B,T) (R,B,T)
CPS-18F
24VDC M M
(CAN BE SEPARATED BY OPTION)
CN1
FOR CN1
FDD PLAYBACK
ll BOX
CN3
(90 VDC)
RECEPTACLE BRAKE
100VAC
0.5A MAX.
CN1
MBB01
( S, L, U
R, B, T (
MFC03-1
PROGRAMMING MFC03-2
PENDANT
BATTERY
Figure 6-1 Power Flow

DIAGRAMS
6.2 Signal Flow
MTU02-
NFB R2
THREE-PHASE
1LF 200/220VAC MTU02
50/60 HZ
CN5 CN6
MRU02
ROBOT1 ROBOT2
LAMP LAMP
(CAN BE SEPARATED BY OPTION)
CPS-18F POWER ON OTI S OTI S
POWER OFF
SHOCK SHOCK
EDIT LOCK
(OPTION)
RS232
MCP01
E-STOP
MMM02 LCD
CN5 CN6
PLAYBACK CN5 CN4
CN01
M1F01 CN1 MBB02 CN2 CN2 BOX PROGRAMMING
PENDANT
CN5 CN4 CN3
Expansion**
MMM01 MRY01B-2*
MBB01
MEW02*
MODE SW KB
MIO04*
E-STOP
MCP02
START
MMM04 HOLD
OT RECOVERY
1SV PG
PG
MSV01B
PG
PG
2SV
PG
PG
MSV02
1SV PG
PG
MSV01B
PG
PG
2SV
PG
PG
MSV02
MFC03-1
MFC03-2
* Provided as standard boards.

**Expansion slots provide for additional I/O.
Figure 6-2 Signal Flow

TROUBLESHOOTING
6.3 External Power Connection for I/O

JANCO-MBB02
CN6 +5V
-1 (VCC)
+5V +24 V
EXTERNAL -4 (GND)
POWER PLUGCN8 AVR INTERNAL
0V
-1 -3 (+24V) GND
POWER +24
-2 -5 (024 V CPS)
024V
-3 CN8
-4 -1 (+24VE)
CN7 CPS 024 V
-1 -2 (+24VU)
-2 -3 (024 VE)
-3 -4 (024 VU) +24
-4
CN7 VU
-1 (+24V)
-2 (+24VU)
INTERNAL -3 (024 V)
POWER -4 (024 VU)
INTERNAL AVR
CN8
POWER
-1
-2
-3 024 VU
-4
PLUG CN7 CPS
-1
-2
-3
EXTERNAL POWER SM1101 3A
-4 X2
TB1
+24 VEXT -2 (+24 VE) FU1
+24
024 VEXT P -3 (024 VE) FU2
024
+24 VU
(NOTE)
-6 (+24 VE)
Switching jig is AVR EV24 -7 (024 VU)
made by
providing a -1 (FG)
jumper for con- (024 VU)
nector, as
SWITCHING shown here.
JIG
Figure 6-3 External Power Connection for I/O

DIAGRAMS
6.4 MIO04-1/2 Board

The MIO04 boards have 24 input and output points.
CN2 CONNECTOR (TWO CONNECTORS = ONE SET) CONNECTOR-TERMINAL
MODEL: FCN-361J040-AU (connector) CONVERTER (OPTION)
FCN-360J040-B (hood) Model: XW2B-40F5-P
+24VU
Connector Terminal
No. Signal No.
2-B1 IN 2
2-A1 IN 1
2-B2 IN 4
2-A2 IN 3
Each Point:
24VDC 2-B3 IN 6
MAX 5mA
2-A3 IN 5
2-B4 IN 8
2-A4 IN 7
2-B5 IN 10
2-A5 IN 9
2-B6 IN 12
2-A6 IN 11
2-B7 024VU 14
2-A7 024VU 13
2-B8 16
2-A8 15
Output 2-B9 OUT 18 RLY
Common:
24VDC 2-A9 OUT 17 RLY
MAX 0.5A 20
(per point) RLY
2-B10 OUT
19 RLY
2-A10 OUT
22
2-B11
21
2-A11
24 RLY
2-B12 OUT
23 RLY
2-B13 OUT
Each 26 RLY
Contact: 2-A13 OUT
24VDC 25 RLY
MAX 0.5A 2-B14
28
2-A14 27
2-B15 OUT
30 RLY
2-A15 OUT 29 RLY
2-B16 OUT 32 RLY
JANCD-MBB02 2-A16 OUT 31 RLY
2-B17 024VU 34
INTERNAL
POWER CN7/8 2-A17 024VU 33
+24 V 2-B18 024VU 36
024 V
2-A18 024VU 35
2-B19 024VU 38
2-A19 024VU 37
EXTERNAL
POWER 2-B20 FG 40
+24 VU
+24 VE CN7/8 2-A20 +24VU 39
024 VE
024 VE
NOTES:
indicates internal relay contact.
RLY in the above figure indicates
Figure 6-4 MIO04-1/2 Board

TROUBLESHOOTING
6.5 MIO04-2/2 Board

The MIO04 boards have 24 input and output points.
CN2 CONNECTOR (TWO CONNECTORS = ONE SET) CONNECTOR-TERMINAL
MODEL: FCN-361J040-AU (connector) CONVERTER
FCN-360J040-B (hood) Model: XW2B-40F5-P
+24VU
Connector Terminal
No. Signal No.
1-B1 IN 2
1-A1 IN 1
1-B2 IN 4
1-A2 IN 3
Each Point: 1-B3 IN 6
24VDC
MAX 5mA 1-A3 IN 5
1-B4 IN 8
1-A4 IN 7
1-B5 IN 10
1-A5 IN 9
1-B6 IN 12
1-A6 IN 11
1-B7 024VU 14
1-A7 024VU 13
1-B8 16
1-A8 15
Output 1-B9 OUT 18 RLY
Common:
24VDC 17 RLY
MAX 0.5A
1-A9 OUT
(per point)
20 RLY
1-B10 OUT
19 RLY
1-A10 OUT
22
1-B11
21
1-A11
24 RLY
1-B12 OUT
23 RLY
1-A12 OUT
Each 26 RLY
Contact: 1-A13 OUT
24VDC 25 RLY
MAX 0.5A 1-B14
28
1-A14 27
1-B15 OUT
30 RLY
1-A15 OUT 29 RLY
1-B16 OUT 32 RLY
JANCD-MBB02 1-A16 OUT 31 RLY
1-B17 024VU 34
INTERNAL
POWER CN7/8 1-A17 024VU 33
+24 V 1-B18 024VU 36
024 V
1-A18 024VU 35
1-B19 024VU 38
1-A19 024VU 37
EXTERNAL
POWER 1-B20 FG 40
+24 VU
+24 VE CN7/8 1-A20 +24VU 39
024 VE
024 VE
NOTES:
indicates internal relay contact.
RLY in the above figure indicates
Figure 6-5 MIO04-2/2 Board

DIAGRAMS
6.6 Welding Board

This board provides the welder with the arc-on signal and the current and voltage
command for the welding condition. This board also functions as an interface
board to detect an abnormal status in the welder.
MRC WELDER
CN 1
-2
GASOF
-3
GASOF } GAS
SHORTAGE
-4
-5
WIRCUT
WIRCUT } WIRE
SHORTAGE
-6
ARCACT
-7 }
ARCACT START
ARC
-13
ARCOFF -26
-14
ARCOFF
}
ARCOFF DETECT
ARC OFF
STICK
DETECTOR (RY1) -27
STICK1
STICK2 } WELDING
DETECT
+5V
ARCON ARCON -15
ARCON
RY2 (RY2)
WIRINCH
-16
ARCON } ARC ON
WIRINCH -17
WIRINCH WIRE
RY3 (RY3)
-18
WIRINCH
}
INCHING
WIRRTR WIRRTR -19
RY4 (RY4)
+24V -29
-10 }
WIRRTR WIRE
RETRACT
WIRRTR INCHING
+24V
-30
024V
024V(C3) -31 CHO_A
D/A *P (ANALOG OUT)
-32
CHO_G
-33 CH1_A
D/A (ANALOG OUT)
-34 *P
CH1_G
+5V RY5
-21
RY5
-22
OUT 1
OUT 1
} FOR
FUTURE
EXTENSION
Figure 6-6 Welding Board

TROUBLESHOOTING
6.7 Exclusive-use Input/Output

INPUT
JANCD-MRY01
TM1 EXT
+24VU -14,-15,-16
-17,-24,-25 +24VU
EXESP
-23 EXESP
RY11 EXTERNAL EMERGENCY STOP
-22 EXHOLD
EXTERNAL HOLD
EXOT
-19 EXOT
RY12 EXTERNAL AXIS OVERRUN
EXSVON -21 EXSVON
RY2 SERVO ON
EXOT
EXOT-R -20 RECOVERY
RY1 OVERRUN RECOVERY
024V
TM1
-1
PON CONTROL POWER ON
-2
PCOM
-3
EOF CONTROL POWER OFF
NOTE: For details, refer to (2) "Power

ON/OFF setting".
-4
-5
+24V
024VU TM1
4.7K -6 DIN0E
DIN0 -7 DIN0COM
4.7K -8 DIN1E
DIN1 -9 DIN1COM
FOR FUTURE
4.7K -10 DIN2E EXPANSION
DIN2 -11 DIN2COM
4.7K -12 DIN3E

DIN3
-13 DIN3COM
Figure 6-7 Connection of Exclusive-use Input

OUTPUT
4TB EXT.
1
PPSEP1
2 PROGRAMMING PENDANT
PPSEP2 EMERGENCY STOP
3
PBOXESP1
4 PLAYBACK BOX
PBOXESP2 EMERGENCY STOP
Figure 6-8 Connection of Exclusive-use Output

INDEX
A D
About the SK6 Dual MRC Controller, 1-1 Diagnostic Displays, 2-20
About this Document, 1-1 Diagrams, 6-1
AC Power Outlet, 2-4 Disp, 2-10
Alarm Codes, , 5-1 Display Areas, 2-7
Alarm Details, 2-26 Display, 2-7
Alarm List Displays, 2-24 Displaying Major and Minor Alarms, 5-3
Alarm/Error Indicator Light, 2-4
Alarms and Errors, 2-28 E
E-stop 2-2, 2-12
Arrow Up, 2-11
Edit Lock Key switch, 2-4
Auto, 2-3
Edit, 2-10
Axis Keys/Coordinate Systems, 3-5
Editing Keys, 2-13
B Enable Key, 2-12
Basic Operation, 3-1 Enable Switch, 2-6
Battery Alarm LED's, 2-19 Enable, E-stop, and Hold/Release, 2-12
Battery Replacement, 4-7 Enter, 2-13
Battery Strength, 2-9 Equipment Description, 2-1
Brake Release 2-14, 3-4 Error Messages, 2-28
Exclusive-use Input/Output, 6-7
C External Components, 2-1
Cancel, 2-13
External Power Connection for I/O, 6-3
Clearing Overrun Alarms, 5-4
Concurrent I/O Board, 2-19 F
Connecting External Power Supply, 4-5 F1-F5, 2-11
Connecting the Equipment, 4-4 Front Panel, 2-2
Contactor Unit, 2-17 Func, 2-10
Controller Maintenance, 4-1 Function Keys, 2-10
Cooling System, 2-15 Fuse Replacement, 4-10
Coord Key, 3-8 Fuses, 2-17, 2-18
Coordinates and Axes, 3-5
CPU Board Replacement, 4-9 G
Green LED's, 2-16
CPU Rack 7-segment LED Display, 5-1
Group Axis Keys, 3-8
CPU Rack Configuration, 2-19
Cursor Keys, 2-13
H
Customer Service Information, 1-2 High Spd Key, 3-9
Customer, 2-11 Hold, 2-2
Cycle Buttons, 2-3 Hold/Release, 2-12
Human Interface Display Area, 2-9
SK6 Dual MRC Instructions MOTOMAN

INDEX
I
I/O Alarm (System Section) Display, 2-25 Opening/Closing the Door, 4-1
I/O Alarm (User Section) Display, 2-25 Operable Group Axes, 2-9
I/O Board Replacement, 4-8 Operating Time, 2-24
I/O Rack Configuration, 2-18 Operation Cycle, 2-8
Incoming Voltage, 2-15, 4-2 Operation Mode, 2-8
Input Buffer Line, 2-9 Output Status Displays, 2-22
Input Line, 2-9 Output, 6-7
Input Status Displays, 2-21 Overrun Recovery Switch, 2-4
Input, 6-7
Internal Components, 2-15 P
Play Mode, 2-3
Introduction, 1-1
Playback Box, 2-2
J Playback Time, 2-23
Job Name/Step No. , 2-8 Position Feedback, 2-26
Joint Coordinate, 3-5 Power Flow, 6-1
Programming Pendant, 2-5
K
Keypad, 2-13 R
Red LED's, 2-16
M Reference to Other Documentation, 1-2
Major Alarm List, 2-25
Remote Mode, 2-3
Major Alarms, 2-28
RIN Input Display, 2-22
Man Spd Keys, 3-9
RS-232C Port, 2-4
Message Line, 2-10
MEW02 Board , 2-18 S
Minor Alarm List, 2-24 Screen Mode, 2-8
Minor Alarms, 2-28 Select, 2-10
MIO04 Board , 2-18 7-segment LED Display, 2-19
MIO04-1/2 Board, 6-4 Servo Control Board, 2-19
MIO04-2/2 Board, 6-5 Servo Display, 2-26
Mode Buttons, 2-2 Servo Power in Play Mode, 3-2
More, 2-11 Servo Power in Teach Mode, 3-2
Motion Control Board, 2-19 Servo Power Input Time, 2-23
Motion Type, 2-9 Servo Power On, 2-11
Moving Time, 2-24 Servo Power, 2-2, 3-2
MRY01B Board, 2-18 Servo-On Indicator Light Replacement, 4-11
Servopack LED Indicators, 2-16
O Servopacks, 2-16
Off-line Alarm List, 2-26
Short-Pinning for Shock Sensor Use, 4-6
1-Cycle, 2-3
Signal Flow, 6-2
On/Off Key Switch (Optional) , 2-4
Soft Key Label Line, 2-10
INDEX
S - continued T
Soft Keys, 2-11 Teach Lock, 2-6, 3-3
Specifications, 2-29 Teach Mode, 2-3
Specified Input Status, 2-21 Torque Status, 2-27
Specified Output Status, 2-22 Troubleshooting, 5-1
Specified Point, 3-9
Speed Status (Reference, Feedback) , 2-27 U
Universal Input Status, 2-21
Speed Status (Speed Error) , 2-27
Universal Output Status, 2-22
Standard Alarm Codes, 5-1
Using the Enable Switch, 3-1
Start, 2-2
Status Display Area, 2-8
W
Status of Ongoing Operation, 2-8 Welding Board, 6-6
Step, 2-3 World, Cylindrical, Tool, or User, 3-5
Subpanel, 2-4
System Control Board, 2-19
System Monitoring Time Displays, 2-23

CHAPTER 5
SK6 ELEMENTARY DIAGRAMS
February 28, 1998
MOTOMAN
805 Liberty Lane
TEL: (937) 847-6200 FAX: (937) 847-6277

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Minc MRC Controller

SK6 Dual MRC

February 28, 1998