RJ Controller Maintenance Manual

7/26/2019 Fanuc R-J Controller Series Electrical Connection and Maintenance Manual
SYSTEM R-J Controller Series

Electrical Connection and
Maintenance Manual
MARMMTRBL02303E
This publication contains proprietary information of FANUC Robotics

North America, Inc. furnished for customer use only. No other uses are
authorized without the express written permission of FANUC Robotics
North America, Inc.
FANUC Robotics North America, Inc.
2000 South Adams Road
Auburn Hills, Michigan 48326–2800
http://slidepdf.com/reader/full/fanuc-r-j-controller-series-electrical-connection-and-maintenance-manual 1/435
The descriptions and specifications contained in this manual were in effect

at the time this manual was approved for printing. FANUC Robotics
North America, Inc, hereinafter referred to as FANUC Robotics, reserves
the right to discontinue models at any time or to change specifications or
design without notice and without incurring obligations.
FANUC Robotics manuals present descriptions, specifications, drawings,
schematics, bills of material, parts, connections and/or procedures for
installing, disassembling, connecting, operating and programming FANUC
Robotics’ products and/or systems. Such systems consist of robots,
extended axes, robot controllers, application software, the KAREL
programming language, INSIGHT vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been trained in
one or more approved FANUC Robotics Training Course(s) be permitted
to install, operate, use, perform procedures on, repair, and/or maintain
FANUC Robotics’ products and/or systems and their respective
components. Approved training necessitates that the courses selected be
relevant to the type of system installed and application performed at the
customer site.
WARNING
This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in
accordance with the instruction manual, may cause
interference to radio communications. As temporarily
permitted by regulation, it has not been tested for
compliance with the limits for Class A computing devices
pursuant to subpart J of Part 15 of FCC Rules, which are
designed to provide reasonable protection against such
interference. Operation of the equipment in a residential
area is likely to cause interference, in which case the user,
at his own expense, will be required to take whatever
measure may be required to correct the interference.
FANUC Robotics conducts courses on its systems and products on a

regularly scheduled basis at the company’s world headquarters in Auburn
Hills, Michigan. For additional information contact
FANUC Robotics North America, Inc.
Training and Documentation Department
2000 South Adams Road
Auburn Hills, Michigan 48326–2800
Tel: (810)377–7234
FAX: (810)377–7367 or (810)377–7362
Copyright 1995, 1996 by FANUC Robotics North America, Inc.

All Rights Reserved
The information
copied, translatedillustrated or contained
into another language,herein is not to in
or transmitted bewhole
reproduced,
or in part
in any way without the prior written consent of FANUC Robotics North
America, Inc.
AccuStat, ArcTool, DispenseTool , FANUC LASER DRILL,

KAREL, INSIGHT, INSIGHT II, PaintTool , PaintWorks,
PalletTool , SOCKETS, SOFT PARTS SpotTool ,
TorchMate, and YagTool , are Registered Trademarks of FANUC
Robotics.
FANUC Robotics reserves all proprietary rights, including but not limited
to trademark and trade name rights, in the following names:

AccuFlow
ARC Mate
ARC Mate Sr.
IntelliTrak 
LaserTool
MotionParts
PaintWorks II
PalletMate
SureWeld
TurboMove
FANUC Robotics Hotline
For a PRODUCTION robot that is DOWN

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

contact your local distributor or call the Hotline
Monday – Friday, 8:00 A.M. – 5:00 P.M. Eastern Time
BEFORE YOU CALL please have your Maintenance and Troubleshooting manual, and the
following information, ready.
INFORMATION DETAILS
Customer Information Include
 your company’s name
 caller’s name
 phone number where caller can be reached, including
area code and extension
Robot type On the arm of the robot.
(A, L, M, P, or S, & 3-digit number)
Controller style Ask your supervisor.
(RA, RB, RC, RF, RG, RG2, RH, RJ, RJ2)
F Number On the identification tag on the robot and controller, near
the cable connection.
Robot serial number On the identification tag located near the cable connection.
(if no F Number is available)
Controller serial number On the controller tag located on the doors.
(if no F Number is available)
Software edition and revision numbers Shown on the CRT or teach pendant status screen during
the power-up sequence.
List of error messages Include
 error message number
 message following error message number
 any numbers following error message
List of diagnostic LEDs Note the PCB where the LED is located and the LED name
or designation.
History of problem Description of events leading up to the problem.
Application software List
 any application software running the system
 the line number where the program halted
 a description of what is happening on that line
MARMMTRBL02303E Preface vii
The SYSTEM R-J Controller Series Electrical Connection and

Purpose of this Manual Maintenance Manual provides specific information regarding FANUC
Robotics electrical hardware. The information contained within the
manual has been arranged so that it can answer specific questions quickly
and accurately.
How to Use this Use this table to locate specific information in the manual.
Manual
If you want to Refer to
Find information about a specific topic Table of Contents
Identify the components of the SYSTEM R-J Chapter 1, Overview

controller
Use diagnostic and controller initialization Chapter 2, Diagnostic
utilities Screens
View status information on teach pendant Chapter 3, Lights and LEDs

screens and using other indicators
Perform troubleshooting procedures and Chapter 4, Troubleshooting

identify specific errors
Look at fuse information or replace a fuse Chapter 5, Replacing a Fuse
Release the brakes Chapter 6, Brake Release
Turn outputs on or off and simulate inputs Chapter 7, Controlling I/O
Master the robot Chapter 8, Mastering
Replace controller components Chapter 9, Replacing

Components
Adjust switch settings and potentiometers Chapter 10, Board

on printed circuit boards Adjustments
Find controller connection schematics and Chapter 11, Connections

connector configurations
Find connection information and Chapter 12, Complete Wiring

Input/Output specifications Diagrams
Find complete schematics of the controller Chapter 13, Prints
circuitry
Use controller transportation and installation Appendix A, Transportation
information and Installation
viii PREFACE MARMMTRBL02303E
Conventions Used in This manual includes information essential to the safety of personnel,
this Manual equipment, software, and data. This information is indicated by headings
and boxes in the text.
WARNING
Information appearing under WARNING concerns the
protection of personnel. It is boxed and in bold type to set
it apart from other text.
CAUTION
Information appearing under CAUTION concerns the protection
of equipment, software, and data. It is boxed to set it apart
from other text.
NOTE Information appearing next to NOTE concerns related information

or useful hints.
MARMMTRBL02303E Table of Contents ix
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxv
Chapter 1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.1 BACKPLANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
1.2 MAIN CPU PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
1.3 AXIS CONTROL PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
1.4 POWER SUPPLY UNIT PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
1.5 EMERGENCY STOP CONTROL PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . 1–13
1.6 SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
1.7 DCR AND DBR UNIT A05B-2302-C080 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21
1.8 DISCHARGE UNIT A05B-2312-C100 FOR M-500 A05B-2313-C100 FOR S-900 . . . . . . . 1–22
1.9 MULTI-TAP TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
1.10 INTERFACE DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26
1.10.1 Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27
1.10.2 Process I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–31
1.10.3 ABRIO and Genius I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–33
1.11 FUSED FLANGE DISCONNECT AND CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . 1–34
1.12 USER TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–37
1.13 OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–37
1.14 TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–39
1.15 HEAT EXCHANGE AND FANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–41
Chapter 2
DIAGNOSTIC SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.1 SAFETY SIGNAL STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
2.2 POSITION STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.3 ROBOT AXES STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.4 ALARM LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.5 VERSION IDENTIFICATION STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6 MEMORY STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
Chapter 3
LIGHTS AND LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1 TEACH PENDANT DIAGNOSTIC LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.2 OPERATOR PANEL DIAGNOSTIC LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3.3 CIRCUIT BOARD DIAGNOSTIC LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.3.1 Emergency Control Board (EMG) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
x TABLE OF CONTENTS MARMMTRBL02303E
3.3.2 Power Supply Unit (PSU) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7

3.3.3 Axis Control Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
3.3.4 Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
3.3.5 Servo Amplifier Diagnostic LED (7-Segment Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13
3.3.6 Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14
3.3.7 (Optional) Process I/O Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
3.3.8 R-H MAP INTERFACE LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
3.3.9 R-H ABRIO LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17
Chapter 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1 CLASS 1 FAULT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.2 CLASS 2 FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16
4.3 CLASS 3 FAULT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18
4.3.1 SRVO-001 ER_SVAL1 Operator Panel E–Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19
4.3.2 SRVO-002 ER_SVAL1 Teach Pendant E–stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22
4.3.3 SRVO-003 ER_SVAL1 Deadman switch released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24
4.3.4 SRVO-004 ER_SVAL1 Fence open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26
4.3.5 SRVO-005 ER_SVAL1 Robot Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28
4.3.6 SRVO-006 ER_SVAL1 Hand Broken . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–30
4.3.7 SRVO-007 ER_SVAL1 External emergency stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–32
4.3.8 SRVO-008 ER_SVAL Brake fuse blown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–36
4.3.9 SRVO-011 ER_SVAL1 TP Released While Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–40
4.3.10 SRVO-012 ER_SVAL1 Power Failure Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–40
4.3.11 SRVO-014 Fan Motor Abnormal (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–40
4.3.12 SRVO-015 ER_SVAL1 System Over Heat (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . 4–42
4.3.13 SRVO-021 ER_SVAL1 SRDY off (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–44
4.3.14 SRVO-022 ER_SVAL1 SRDY on (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–44
4.3.15 SRVO-023 ER_SVAL1 Stop Error Excess (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . 4–45
4.3.16 SRVO-024 ER_SVAL1 Move Error Excess (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . 4–45
4.3.17 SRVO-026 ER_WARN Motor Speed Limit (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . 4–45
4.3.18 SRVO-027 ER_WARN Robot Not Mastered (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . 4–45
4.3.19 SRVO-033 ER_WARN Robot Not Calibrated (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . 4–45
4.3.20 SRVO-035 ER_WARN Joint Speed Limit (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . 4–46
4.3.21 SRVO-036 Imposition Time Over (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–46
4.3.22 SRVO-037 ER_SVAL1 IMSTP Input (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–46
4.3.23 SRVO-038 PULSE MISMATCH (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–47
4.3.24 SRVO-042 ER_SVAL2 MCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–47
4.3.25 SRVO-043 ER_SVAL2 DCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–48
4.3.26 SRVO-044 ER_SVAL2 HVAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–49
4.3.27 SRVO-045 ER_SVAL2 HCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–50
MARMMTRBL02303E TABLE OF CONTENTS xi
4.3.28 SRVO-046 ER_SVAL2 OVC Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–51

4.3.29 SRVO-047 ER_SVAL2 LVAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–52
4.3.30 SRVO-049 ER_SVAL2 OHAL1 Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . 4–53
4.3.31 SRVO-050 ER_SVAL1 CLALM Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . 4–53
4.3.32 SRVO-051 ER_SVAL2 CUER Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–54
4.3.33 SRVO-061 ER_SVAL2 CKAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–54
4.3.34 SRVO-062 ER_SVAL2 BZAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–55
4.3.35 SRVO-063 ER_SVAL2 RCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–56
4.3.36 SRVO-064 ER_SVAL2 PHAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–56
4.3.37 SRVO-065 ER_WARN BLAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–56
4.3.38 SRVO-066 ER_SVAL2 CSAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–57
4.3.39 SRVO-067 ER_SVAL2 OHAL2 Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . 4–57
4.3.40 SRVO-068 ER_SVAL2 DTERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . 4–58
4.3.41 SRVO-069 ER_SVAL2 CRCERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . 4–58
4.3.42 SRVO-070 ER_SVAL2 STBERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . 4–59
4.3.43 SRVO-071 ER_SVAL2 SPHAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . 4–59
4.3.44 SRVO-081 ER_WARN EROFL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . 4–59
4.3.45 SRVO-082 ER_WARN DAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–60
4.3.46 SRVO-083 ER_WARN CKAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–60
4.3.47 SRVO-084 ER_WARN BZAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–60
4.3.48 SRVO-085 ER_WARN RCAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–60
4.3.49 SRVO-086 ER_WARN PHAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–60
4.3.50 SRVO-087 ER_WARN BLAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–61

4.3.51 SRVO-088 ER_WARN CSAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–61
4.3.52 SRVO-089 ER_WARN OHAL2 Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . 4–61
4.3.53 SRVO-090 ER_WARN DTERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . 4–61
4.3.54 SRVO-091 ER_WARN CRCERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . 4–61
4.3.55 SRVO-092 ER_WARN STBERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . 4–61
4.3.56 SRVO-093 ER_WARN SPHAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . 4–61
Chapter 5
REPLACING A FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1 MULTI-TAP TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.2 SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.3 POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4 EMERGENCY STOP CONTROL PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.5 PROCESS INPUT/OUTPUT PC BOARDS AA, AB, CA, CB, AND DA . . . . . . . . . . . . . . . . 5–6
5.6 PROCESS INPUT/OUTPUT PC BOARDS BA AND BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
5.7 MODULAR I/O UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.8 AC OUTLET UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
xii TABLE OF CONTENTS MARMMTRBL02303E
Chapter 6
BRAKE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
Chapter 7
CONTROLLING I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
7.1 FORCING OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
7.2 SIMULATING INPUTS AND OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.3 SOP I/O STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
Chapter 8
MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
8.1 MASTERING TO A FIXTURE (FIXTURE POSITION MASTER) . . . . . . . . . . . . . . . . . . . . . 8–2
8.2 ZERO DEGREE MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
8.3 SINGLE AXIS MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
8.4 QUICK MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
Chapter 9
REPLACING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
9.1 REPLACING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
9.2 REPLACING A RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
9.3 REPLACING A PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
9.3.1 Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
9.3.2 Replacing a Component on the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . 9–7
9.4 REPLACING A MODULE ON THE MAIN CPU OR AXIS CONTROL BOARD . . . . . . . . . 9–8
9.5 REPLACING THE PROCESS INPUT/OUTPUT PRINTED CIRCUIT BOARD
AA, AB, BA OR BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11
9.6 REPLACING COMPONENTS OF THE MODULAR INPUT/OUTPUT UNIT
REFER TO CHAPTER 1 FOR PART NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12
9.6.1 Replacing the Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12
9.6.2 Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14
9.7 REPLACING THE MULTI-TAP TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–16
9.8 REPLACING A SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
9.9 REPLACING THE OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–18
9.10 REPLACING THE FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–19
9.11 REPLACING THE DISCHARGE RESISTOR (DCR) AND DYNAMIC BRAKE (DBR)
UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–21
9.12 REPLACING THE REGENERATIVE DISCHARGE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . 9–23
9.13 REPLACING THE OPTIONAL WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–24
9.14 REPLACING A SERIAL PULSE CODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–25
MARMMTRBL02303E TABLE OF CONTENTS xiii
Chapter 10
BOARD ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
10.1 AXIS CONTROL BOARD JUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

10.2 PROCESS I/O BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2
10.2.1 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5
10.2.2 Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–6
10.2.3 Output Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–7
10.3 BUILT–IN CRT/KB UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–8
10.4 EMG BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–10
Chapter 11
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1
11.1 MECHANICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–2
11.1.1 Robot Connection Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4
11.1.2 Connecting the Input Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8
11.1.3 Connecting the External Power Supply ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10
11.1.4 External Emergency Stop Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–11
11.2 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES . . . . . . 11–13
11.2.1 Peripheral Device Interface Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–15
11.2.2 Process I/O Printed Circuit Board AA or AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–16
11.2.3 Process I/O Printed Circuit Board BA or BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–17
11.2.4 Process I/O Printed Circuit Board CA or CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–18
11.2.5 Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–19
11.2.6 Process I/O Printed Circuit Board with the Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . 11–20
11.2.7 Two or More Process I/O Boards with the Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . . 11–21
11.2.8 Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–22
11.2.9 Mechanical Unit and End Effector Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–39
11.2.10 Control Unit and Welder Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–42
11.2.11 Peripheral Device Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–46
11.2.12 End Effector Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–48
11.2.13 Arc Welding Interface Process I/O AA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–49
11.2.14 Modular I/O Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–51
11.2.15 Modular I/O Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–55
11.3 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES
AND WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–65
11.3.1 Peripheral Device Interface A Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–65
11.3.2 Peripheral Device Interface B Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–65
11.3.3 Arc Welding Interface Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–66
11.4 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS,
AND ARC WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–67
11.4.1 Peripheral Device Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–67
xiv TABLE OF CONTENTS MARMMTRBL02303E
11.4.2 Arc Welding Interface Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–68

11.4.3 Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–69
11.4.4 End Effector Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–72
11.4.5 Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–74
Chapter 12
COMPLETE WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1
Chapter 13
PRINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1
Appendix A
TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
A.1 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
A.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
A.2.1 Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
A.2.2 Assembly During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3
A.2.3 Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–4
A.2.4 Adjustment and Checks at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–5
A.2.5 Resetting Overtravel and Emergency Stop at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . A–6
List of Procedures
Procedure 2–1 Displaying Safety Signal Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Procedure 2–2 Displaying Position Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Procedure 2–3 Displaying the Axis Status Pulse Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
Procedure 2–4 Displaying the Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
Procedure 2–5 Displaying the Version Identification Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
Procedure 2–6 Displaying Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
Procedure 6–1 Releasing the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
Procedure 7–1 Forcing Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Procedure 7–2 Simulating and Unsimulating Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
Procedure 7–3 Displaying and Forcing SOP I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6

Procedure 8–1 Mastering to a Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
Procedure 8–2 Mastering to Zero Degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Procedure 8–3 Mastering a Single Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
Procedure 8–4 Recording the Quick Master Reference Position . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
Procedure 8–5 Quick Mastering the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–13
Procedure 9–1 Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
Procedure 9–2 Replacing the SPC Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Procedure 9–3 Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Procedure 9–4 Replacing a Component on the Backplane Printed Circuit Board . . . . . . . . . . . . 9–7
MARMMTRBL02303E TABLE OF CONTENTS xv
Procedure 9–5 Replacing the Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12

Procedure 9–6 Replacing the Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14
Procedure 9–7 Replacing an I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14
Procedure 9–8 Replacing the Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–16
Procedure 9–9 Replacing a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
Procedure 9–10 Replacing the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–18
Procedure 9–11 Replacing the Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–19
Procedure 9–12 Replacing the Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) unit 9–21
Procedure 9–13 Replacing the Regenerative Discharge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–23
Procedure 9–14 Replacing the Optional Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–24
Procedure 9–15 Replacing a Serial Pulse Coder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–25
List of Figures
Figure 1–1. Cabinet Exterior, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Figure 1–2. Cabinet Exterior, B-Size Controller with Regenerative Discharge Unit . . . . . . . . . . . 1–2
Figure 1–3. Cabinet Exterior, B-Size Controller with Optional Side Cabinet . . . . . . . . . . . . . . . . . 1–3
Figure 1–4. Cabinet Exterior, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Figure 1–5. Cabinet Interior, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Figure 1–6. Cabinet Interior, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
Figure 1–7. Backplane with R-H Style Extended Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Figure 1–8. Main CPU Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Figure 1–9. Axis Control Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Figure 1–10. Power Supply Unit Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
Figure 1–11. Emergency Stop Control Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Figure 1–12. Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
Figure 1–13. Mounting Locations of Servo Amplifiers – Robot with 6-amplifiers . . . . . . . . . . . . 1–15
Figure 1–14. Mounting Locations of Servo Amplifiers for the A-510 . . . . . . . . . . . . . . . . . . . . . . 1–16
Figure 1–15. Mounting Locations of Servo Amplifiers for the Arc Mate/ Arc Mate 100/S-6,
Arc Mate Sr./S-5/S-10 and L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
Figure 1–16. Mounting Locations of Servo Amplifiers for the S-500/S-700 and M-400 . . . . . . . . 1–17
Figure 1–17. Mounting Locations of Servo Amplifiers for the S-420 and S-800 . . . . . . . . . . . . . . 1–17
Figure 1–18. Mounting Locations of Servo Amplifiers for the S-420 and the DCR & DBR Unit . 1–18
Figure 1–19. Mounting Locations of Servo Amplifiers for the M-500 . . . . . . . . . . . . . . . . . . . . . . 1–18
Figure 1–20. Mounting Locations of Servo Amplifiers for the S-900 . . . . . . . . . . . . . . . . . . . . . . . 1–19
Figure 1–21. DCR and DBR Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21
Figure 1–22. Discharge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22
Figure 1–23. Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24
Figure 1–24. Multi-Tap Transformer A80L–0026–0013#A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–25
Figure 1–25. Modular I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27
Figure 1–26. Process I/O Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–31
Figure 1–27. Fused Flange Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–35
Figure 1–28. Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–35
Figure 1–29. User Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–37
xvi TABLE OF CONTENTS MARMMTRBL02303E
Figure 1–30. Operator Panel, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–38

Figure 1–31. Operator Panel, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–38
Figure 1–32. Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–40
Figure 1–33. Heat Exchange System, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–41
Figure 1–34. Heat Exchange System, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–42
Figure 2–1. Default Power–Up Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
Figure 2–2. Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
Figure 3–1. Teach Pendant LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
Figure 3–2. Operator Panel LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Figure 3–3. Circuit Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
Figure 3–4. Emergency Control Board (EMG) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Figure 3–5. Power Supply Unit (PSU) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
Figure 3–6. Axis Control Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
Figure 3–7. Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
Figure 3–8. Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14
Figure 3–9. Process I/O Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
Figure 3–10. R–H MAP LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
Figure 3–11. R-H ABRIO LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17
Figure 4–1. 24 Volt (24E) Power Distribution Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10
Figure 4–2. 24 Volt (24V) Power Distribution Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13
Figure 4–3. Operator Panel E-Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–21
Figure 4–4. Teach Pendant E-Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–23
Figure 4–5. Deadman Switch Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–25
Figure 4–6. Fence Open Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–27
Figure 4–7. Robot Overtravel Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–29
Figure 4–8. Hand Broken Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–31
Figure 4–9. External Emergency Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–35
Figure 4–10. Brake Fuse Blown Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–39
Figure 4–11. Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–41
Figure 4–12. System Over Heat Circuitry Drawing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–42
Figure 4–13. System Over Heat Circuitry Drawing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–43
Figure 5–1. Replacing a Fuse of the Transformer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
Figure 5–2. Replacing the Fuse of a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Figure 5–3. Replacing a Fuse of the Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
Figure 5–4. Replacing the Fuse on the Emergency Stop Control PC Board . . . . . . . . . . . . . . . . . . 5–5
Figure 5–5. Replacing the Fuse of the Process Input/Output PC Board AA, AB, CA, CB, or DA 5–6
Figure 5–6. Replacing the Fuse of the Process Input/Output PC Board BA or BB . . . . . . . . . . . . 5–7
Figure 5–7. Replacing the Fuse of the AC Outlet Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
Figure 9–1. Replacing the Battery (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
Figure 9–2. Replacing a Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Figure 9–3. Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Figure 9–4. Replacing Printed Circuit Boards on the Backplane Printed Circuit Board . . . . . . . . . 9–7
MARMMTRBL02303E TABLE OF CONTENTS xvii
Figure 9–5. Moving the Latches on the End of the Module Socket . . . . . . . . . . . . . . . . . . . . . . . . 9–8
Figure 9–6. Installing a New Module at an Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
Figure 9–7. Pushing in the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
Figure 9–8. Mounting Locations of the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
Figure 9–9. Replacing the Process Input/Output Printed Circuit Board AA, AB, BA, or BB . . . . 9–11
Figure 9–10. Replacing the Base Unit of the Modular Input/Output Unit . . . . . . . . . . . . . . . . . . . 9–13
Figure 9–11. Removing and Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–15
Figure 9–12. Removing and Replacing a Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–15
Figure 9–13. Replacing the Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–16
Figure 9–14. Replacing a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
Figure 9–15. Replacing the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–18
Figure 9–16. Replacing the Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–20
Figure 9–17. Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) Unit . . . . . . . . . . . . 9–22
Figure 9–18. Replacing the Regenerative Discharge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–23
Figure 9–19. Removing the Pulse Coder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–26
Figure 10–1. Axis Control Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
Figure 10–2. Process I/O Board AA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2
Figure 10–3. Process I/O Board AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2
Figure 10–4. Process I/O Board BA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3
Figure 10–5. Process I/O Board BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3
Figure 10–6. Process I/O Board CA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4
Figure 10–7. Process I/O Board CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4
Figure 10–8. Process I/O Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5
Figure 10–9. Front View Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–9
Figure 10–10. Jumper Setting CRT/KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–9
Figure 10–11. EMG board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–10
Figure 11–1. Block Diagram of Electrical Interface Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1
Figure 11–2. Mechanical Connection Diagram for S-420, S-500, S-700, S-800, and M-400 . . . . . 11–2
Figure 11–3. Mechanical Connection Diagram for ARC Mate, ARC Mate 100/S-6, ARC Mate Sr.,
A-510, and L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–2
Figure 11–4. Mechanical Connection Diagram, Common Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3
Figure 11–5. Connection to Servo Amplifiers and Mechanical Unit for S-420 . . . . . . . . . . . . . . . . 11–4
Figure 11–6. Connection to Servo Amplifiers and Mechanical Unit for S-420, S-420D, ARC Mate,
S-5, ARC Mate 100/S-6, ARC Mate Sr., S-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4
Figure 11–10. Connection to Servo Amplifiers and Mechanical Unit for A-510 . . . . . . . . . . . . . . 11–6
Figure 11–11. Connection to Servo Amplifiers and Mechanical Unit for M-400 and M-500 . . . . . 11–7
Figure 11–12. Connection to Servo Amplifiers and Mechanical Unit for L-1000 . . . . . . . . . . . . . 11–7
Figure 11–13. Input Power Supply Connection, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . 11–9
Figure 11–14. Input Power Supply Connection, Fused Flange Disconnect . . . . . . . . . . . . . . . . . . . 11–9
xviii TABLE OF CONTENTS MARMMTRBL02303E
Figure 11–15. External Power Supply ON/OFF Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . 11–10

Figure 11–16. External Emergency Stop Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–11
Figure 11–17. External Emergency Stop Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–12
Figure 11–18. Locations of Peripheral Device Interfaces, B-Size Controller . . . . . . . . . . . . . . . . . 11–13
Figure 11–19. Locations of Peripheral Devices, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . 11–14
Figure 11–20. Peripheral Device Interface Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–15
Figure 11–21. Process I/O Printed Circuit Board AA or AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–16
Figure 11–22. Process I/O Printed Circuit Board BA or BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–17
Figure 11–23. Process I/O Printed Circuit Board CA or CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–18
Figure 11–24. Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–19
Figure 11–25. Process I/O Printed Circuit Board with Modular I/O . . . . . . . . . . . . . . . . . . . . . . . . 11–20
Figure 11–26. Two or More Process I/O Boards and the I/O Unit (Model A) . . . . . . . . . . . . . . . . 11–21
Figure 11–27. Peripheral Device and Control Unit Connection -A1/A2 . . . . . . . . . . . . . . . . . . . . . 11–25
Figure 11–28. Peripheral Device and Control Unit Connection -A3/A4 . . . . . . . . . . . . . . . . . . . . . 11–26
Figure 11–29. Peripheral Device and Control Unit Connection - B1/B2 . . . . . . . . . . . . . . . . . . . . 11–27
Figure 11–30. Peripheral Device and Control Unit Connection -C1 . . . . . . . . . . . . . . . . . . . . . . . . 11–28
Figure 11–31. Peripheral Device Interface Control for A1, A2, A3, and A4 . . . . . . . . . . . . . . . . . 11–29
Figure 11–32. Peripheral Device Interface for A1, A2, A3, and A4 . . . . . . . . . . . . . . . . . . . . . . . . 11–30
Figure 11–33. Peripheral Device Control Interface B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–31
Figure 11–34. Peripheral Device Control Interface B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–32
Figure 11–35. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–33
Figure 11–41. Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–39
Figure 11–42. End Effector Pin Configuration – Arc Mate/S-5, Arc Mate Sr/S-10, S-420, S-500,
S-700, S-800, S-900, M-400 and M-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–40
Figure 11–43. End Effector Pin Configuration – Arc Mate 100/S-6 . . . . . . . . . . . . . . . . . . . . . . . . 11–40
Figure 11–44. End Effector Pin Configuration – A-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–41
Figure 11–45. End Effector Pin Configuration – L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–41
Figure 11–46. Control Unit and Welder Connection - CRW1/CRW2 . . . . . . . . . . . . . . . . . . . . . . . 11–42
Figure 11–47. Control Unit and Welder Connection - CRW1 Analog Signal Assignment . . . . . . . 11–43
Figure 11–48. Control Unit and Welder Connection - CRW1 Digital Signal Assignment . . . . . . . 11–44
Figure 11–49. Control Unit and Welder Connection - CRW2 Analog Signal Assignment . . . . . . . 11–45
Figure 11–50. Peripheral Device Interface A Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–65
Figure 11–51. Peripheral Device Interface B Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–65
Figure 11–52. Arc Welder Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–66
Figure 11–53. Peripheral Device Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–67
Figure 11–54. Arc Welder Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–68
Figure 11–55. Peripheral Device Cable Connector for A and B(Honda Tsushin Kogyo) . . . . . . . . 11–69
MARMMTRBL02303E TABLE OF CONTENTS xix
Figure 11–56. Peripheral Device Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–70

Figure 11–57. Peripheral Device Interface Cable C Connector (Phoenix Contact) . . . . . . . . . . . . 11–71
Figure 11–58. Elbow Type Connector S-5, S-10, S-420, S-500, S-700, S-800, M-400, M-500,
ARC Mate, ARC Mate 100/S-6, ARC Mate Sr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–72
Figure 11–59. Connector L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–73
Figure 12–1. Internal Connection Diagram – S-420, S-800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–2
Figure 12–2. Internal Connection Diagram – S420 with three Servo Amplifiers, S420D) . . . . . . . 12–3
Figure 12–3. Internal Connection Diagram – ARC Mate, ARC Mate Sr., ARC Mate 100/S-6, S-5,
and S-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–4
Figure 12–4. Internal Connection Diagram – S-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–5
Figure 12–5. Internal Connection Diagram – S-700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–6
Figure 12–6. Internal Connection Diagram – S900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7
Figure 12–7. Internal Connection Diagram – A-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–8
Figure 12–8. Internal Connection Diagram – M-400 (5-axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9

Figure 12–9. Internal Connection Diagram – M400 (4 axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10
Figure 12–10. Internal Connection Diagram – M500 (5 axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11
Figure 12–11. Internal Connection Diagram – M500 (4 axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12
Figure 12–12. Internal Connection Diagram – L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13
Figure 12–13. Internal Connection Diagram – Emergency Stop Control – PCB . . . . . . . . . . . . . . 12–14
Figure 12–14. Internal Connection Diagram – Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . 12–15
Figure 12–15. Internal Connection Diagram - Main CPU; Axis Control Board . . . . . . . . . . . . . . . 12–16
Figure 12–16. Internal Connection Diagram – Servo Amplifier Connection S-420, ARC Mate/S-5,
ARC Mate Sr./S-10, ARC Mate 100/S-6, S-500, S-700, and S-800 . . . . . . . . . . . . . . 12–17
Figure 12–17. Internal Connection Diagram – Servo Amplifier Connection A-510, L-1000,
and M-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–18
Figure 12–18. Internal Connection Diagram – Servo Amplifier Connection S-900 and M-500 . . . 12–19
Figure 12–19. Internal Connection Diagram – Modular I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–20
Figure 12–20. Internal Connection Diagram – Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–21
Figure 12–21. Internal Connection Diagram – Main CPU Interface . . . . . . . . . . . . . . . . . . . . . . . . 12–22
Figure 12–22. Internal Connection Diagram – Axis Control Board Interface . . . . . . . . . . . . . . . . . 12–23
Figure 12–23. Internal Connection Diagram – ARC Mate/S-5, ARC Mate Sr./S-10,
ARC Mate 100/S-6, S-420, S-500 and S-800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24
Figure 12–24. Internal Connection Diagram – S-700 and A-510 . . . . . . . . . . . . . . . . . . . . . . . . . . 12–25
Figure 12–25. Internal Connection Diagram – M-400 and L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . 12–26
Figure 12–26. Internal Connection Diagram - M–400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–27

Figure 12–27. External Connection Diagram – M-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–28
Figure 12–28. External Connection Diagram – S-900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–29
Figure 12–29. External Connection Diagram – Process I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–30
Figure 12–30. External Connection Diagram – Process I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–31
Figure 12–31. External Connection Diagram – Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–32
Figure 12–32. Motor Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–33
Figure 13–1. R-J Control Signal and Power Distribution Overview . . . . . . . . . . . . . . . . . . . . . . . . 13–3
Figure 13–2. Main AC Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–5
xx TABLE OF CONTENTS MARMMTRBL02303E
Figure 13–3. AC Power Distribution With Optional 115VAC Secondary . . . . . . . . . . . . . . . . . . . . 13–7

Figure 13–4. Power Supply Unit (PSU) With Power ON/OFF Circuit . . . . . . . . . . . . . . . . . . . . . . 13–9
Figure 13–5. EMG Stop & Brake Connection 100 VAC E-Stop Circuit 100 VDC Brake
Circuit (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–11
Figure 13–6. EMG Stop and Brake Connection 100 VDC Brake Circuit (2 of 2) . . . . . . . . . . . . . 13–13
Figure 13–7. EMG Stop and Brake Connection 24 VDC E-Stop Circuit (1 of 2) . . . . . . . . . . . . . 13–15
Figure 13–8. EMG Stop and Brake Connection 24VDC E-Stop Circuit (2 of 2) Modular
I/O Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–17
Figure 13–9. Overheat and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–19
Figure 13–10. Single Axis Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–21
Figure 13–11. Dual Axis Servo Amplifier (With Dynamic Brakes) . . . . . . . . . . . . . . . . . . . . . . . . 13–23
Figure 13–12. Dual Axis Servo Amplifier (Without Dynamic Brakes) . . . . . . . . . . . . . . . . . . . . . . 13–25
Figure 13–13. Discharge Resistor and Dynamic Brake Unit (For Amp With No Dynamic Brake) 13–27
Figure 13–14. LSI Module All Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–29

Figure 13–15. DV-M Module Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–31
Figure 13–16. ALM-M Module Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–33
Figure 13–17. Teach Pendant Power And Data Signal Interconnection . . . . . . . . . . . . . . . . . . . . . 13–35
Figure A–1. Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
Figure A–2. Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
Figure A–3. Assembly During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3
Figure A–4. Peripheral Device Interface Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–6
List of Tables
Table 1–1. Main CPU Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Table 1–2. Axis Control Board Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Table 1–3. Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20
Table 1–4. Multi-Tap Transformer Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
Table 1–5. Selecting Transformer Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24
Table 1–6. Selecting Transformer Taps for Transformer A80L–0026–0013#A . . . . . . . . . . . . . . 1–25
Table 1–7. Digital Input Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–29
Table 1–8. Digital Output Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–29
Table 1–9. I/O Module Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–30
Table 1–10. Process I/O Board Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–32
Table 1–11. Circuit Breaker, B-Size Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–36
Table 1–12. Circuit Breaker and Fused Flange Disconnect Switch, C-Size Cabinet . . . . . . . . . . 1–36
Table 1–13. Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–38
Table 1–14. Teach Pendant Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–40
Table 2–1. Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Table 2–2. Axis Status Pulse Screen Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
Table 2–3. Version Identification Status Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
Table 2–4. Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
Table 3–1. Teach Pendant Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
MARMMTRBL02303E TABLE OF CONTENTS xxi
Table 3–2. Standard Operator Panel C-Size Controller Status Indicators . . . . . . . . . . . . . . . . . . . 3–3
Table 3–3. Emergency Control Board (EMG) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Table 3–4. Troubleshooting Axis Control Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . 3–9
Table 3–5. Troubleshooting Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
Table 3–6. Servo Amplifier LED Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13
Table 3–7. Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14
Table 3–8. Process I/O Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
Table 3–9. R-H MAP LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
Table 3–10. R-H ABRIO LED Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17
Table 4–1. Troubleshooting Procedure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
Table 4–7. Class 2 Faults Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16
Table 4–8. SRVO-001 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19
Table 4–9. SRVO-002 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22
Table 4–10. SRVO-003 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24
Table 4–12. SRVO-005 Troubleshooting Procedure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28
Table 4–13. SRVO-005 Troubleshooting Procedure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–29
Table 4–15. SRVO-007 Troubleshooting Procedure ................................... 4–33
xxii TABLE OF CONTENTS MARMMTRBL02303E

Table 5–1. Multi-Tap Transformer Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
Table 5–2. Power supply unit for four-slot backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
Table 5–3. Power supply unit for six-slot backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
Table 5–4. Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
Table 7–1. Standard Operator Panel Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
Table 7–2. Standard Operator Panel Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
Table 8–1. Mastering Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
Table 9–1. Relay Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Table 10–1. Axis Control Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
Table 10–2. Process I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5
Table 10–3. Process I/O Board Potentiometer Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–6
Table 10–4. Output Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–7
Table 10–5. SBK Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–10
Table 11–1. Example of Leakage Current Circuit Breaker for Inverters . . . . . . . . . . . . . . . . . . . 11–8
Table 11–2. External Emergency Stop Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–11
Table 11–3. External Emergency Stop Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–12
Table 11–4. Peripheral Device Interface Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–13
Table 11–5. Process I/O Printed Circuit Board AA or AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–16
Table 11–6. Process I/O Printed Circuit Board BA or BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–17
Table 11–7. Process I/O Printed Circuit Board CA or CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–18
Table 11–8. Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–19
Table 11–9. Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–20
Table 11–10. Two or More Process I/O Boards and the I/O Unit (Model A) . . . . . . . . . . . . . . . . 11–21
Table 11–11. Process I/O Printed Circuit Board Signals, DI Signals . . . . . . . . . . . . . . . . . . . . . . 11–22
Table 11–12. Process I/O Printed Circuit Board Signals, DO Signals . . . . . . . . . . . . . . . . . . . . . 11–23
Table 11–13. Applicable Process I/O Printed Circuit Board - A1/A2 . . . . . . . . . . . . . . . . . . . . . 11–25
Table 11–14. Applicable Process I/O Printed Circuit Board - A3/A4 . . . . . . . . . . . . . . . . . . . . . 11–26
Table 11–15. Applicable Process I/O Printed Circuit Board - B1/B2 . . . . . . . . . . . . . . . . . . . . . . 11–27
Table 11–16. Applicable Process I/O Printed Circuit Board - C1 . . . . . . . . . . . . . . . . . . . . . . . . 11–28
Table 11–17. Applicable Process I/O Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–42
Table 11–18. Peripheral Device Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–46
Table 11–19. End Effector Control Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–48
MARMMTRBL02303E TABLE OF CONTENTS xxiii
Table 11–20. Arc Welding Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–49

Table 11–21. Input Modules AID32A and AID32B, Non–isolated . . . . . . . . . . . . . . . . . . . . . . . 11–51
Table 11–22. Input Modules AID16C and AID16D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–52
Table 11–23. Input Modules AID32E and AID32F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–53
Table 11–24. Input Module AIA16G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–54
Table 11–25. Output Module AOD32A, Non-isolated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–55
Table 11–26. Output Modules AOD08C and AOD08D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–56
Table 11–27. Output Modules AOD16C and AOD16D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–57
Table 11–28. Output Module AOD32C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–58
Table 11–29. Output Module AOD32D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–59
Table 11–30. Output Modules AOA05E and AOA08E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–60
Table 11–31. Output Module AOA12F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–61
Table 11–32. Output Modules AOR08G and AOR16G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–62
Table 11–33. Output Module ADA02A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–63
Table 11–34. Analog Input Module AAD04A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–64
Table 11–35. Peripheral Device Cable Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . . 11–69
Table 11–36. Symbols Used in Figure 11–55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–69
Table 11–37. Peripheral Device Cable Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . . 11–70
Table 11–38. Symbols Used in Figure 11–56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–70
Table 11–39. Peripheral Device Interface Cable C Connector Specifications . . . . . . . . . . . . . . . 11–71
Table 11–40. Connection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–71
Table 11–41. Recommended Cable for Peripheral Device Connection . . . . . . . . . . . . . . . . . . . . 11–74
Table 11–42. Recommended Cable for End Effector Connection . . . . . . . . . . . . . . . . . . . . . . . . 11–74
Table A–1. Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–4
Table A–2. Adjustment and Checks at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–5
Page2
MARMMTRBL02303E Safety xxv
FANUC Robotics is not and does not represent itself as an expert in safety
systems, safety equipment, or the specific safety aspects of your company
and/or its work force. It is the responsibility of the owner, employer, or
user to take all necessary steps to guarantee the safety of all personnel in
the workplace.
The appropriate level of safety for your application and installation can
best be determined by safety system professionals. FANUC Robotics
therefore, recommends that each customer consult with such professionals
in order to provide a workplace that allows for the safe application, use,
and operation of FANUC Robotic systems.
Additionally, as the owner, employer, or user of a robotic system, it is your
responsibility to arrange for the training of the operator of a robot system
to recognize and respond to known hazards associated with your robotic
system and to be aware of the recommended operating procedures for your
particular application and robot installation.
FANUC Robotics therefore, recommends that all personnel who intend to
operate, program, repair, or otherwise use the robotics system be trained in
an approved FANUC Robotics training course and become familiar with
the proper operation of the system. Persons responsible for programming
the system–including the design, implementation, and debugging of
application programs–must be familiar with the recommended
programming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance of
safety in the workplace.
xxvi SAFETY MARMMTRBL02303E
CONSIDERING Safety is essential whenever robots are used. Keep in mind the following
factors with regard to safety:
SAFETY FOR YOUR
 The safety of people and equipment
ROBOT  Use of safety enhancing devices
INSTALLATION  Techniques for safe teaching and manual operation of the robot(s)
 Techniques for safe automatic operation of the robot(s)
 Regular scheduled inspection of the robot and workcell
 Proper maintenance of the robot
Keeping People and The safety of people is always of primary importance in any
Equipment Safe situation. However, equipment must be kept safe, too. When
prioritizing how to apply safety to your robotic system, consider
 People
 External devices
 Robot(s)
 Tooling
 Workpiece
Using Safety Always give appropriate attention to the work area that surrounds the
Enhancing Devices robot. The safety of the work area can be enhanced by the installation of
some or all of the following devices:
 Safety fences, barriers, or chains
 Light curtains
 Interlocks
 Pressure mats

 Floor markings
Warning lights
 Mechanical stops
 EMERGENCY STOP buttons
 DEADMAN switches
Setting Up a Safe A safe workcell is essential to protect people and equipment. Observe the
Workcell following guidelines to ensure that the workcell is set up safely. These
suggestions are intended to supplement and not replace existing federal,
state, and local laws, regulations, and guidelines that pertain to safety.
 Sponsor your personnel for training in approved FANUC Robotics

training course(s) related to your application. Never permit untrained
personnel to operate the robots.
 Install a lockout device that uses an access code to prevent

unauthorized persons from operating the robot.
 Use anti–tie–down logic to prevent the operator from bypassing safety

measures.
 Arrange the workcell so the operator faces the workcell and can see
what is going on inside the cell.
MARMMTRBL02303E SAFETY xxvii
 Clearly identify the work envelope of each robot in the system with
floor markings, signs, and special barriers. The work envelope is the
area defined by the maximum motion range of the robot, including any
tooling attached to the wrist flange that extend this range.
 Position all controllers outside the robot work envelope.
 Never rely on software as the primary safety element.
 Mount an adequate number of EMERGENCY STOP buttons or

switches within easy reach of the operator and at critical points inside
and around the outside of the workcell.
 Install flashing lights and/or audible warning devices that activate

whenever the robot is operating, that is, whenever power is applied to
the servo drive system.
 Wherever possible, install safety fences to protect against unauthorized

entry by personnel into the work envelope.
 Install special guarding that prevents the operator from reaching into
restricted areas of the work envelope.
 Use interlocks.
 Use presence or proximity sensing devices such as light curtains, mats,

and capacitance and vision systems to enhance safety.
 Periodically check the safety joints or safety clutches that can be

optionally installed between the robot wrist flange and tooling. If the
tooling strikes an object, these devices dislodge, remove power from
the system, and help to minimize damage to the tooling and robot.
 Make sure all external devices are properly filtered, grounded,

shielded, and suppressed to prevent hazardous motion due to the
effects of electro–magnetic interference (EMI), radio frequency
interference (RFI), and electro–static discharge (ESD).
 Make provisions for power lockout/tagout at the controller.
 Eliminate pinch points. Pinch points are areas where personnel could

get trapped between a moving robot and other equipment.
 Provide enough room inside the workcell to permit personnel to teach

the robot and perform maintenance safely.
 Program the robot to load and unload material safely.
 If high voltage electrostatics are present, be sure to provide appropriate

interlocks, warning, and beacons.
 If materials are being applied at dangerously high pressure, provide

electrical interlocks for lockout of material flow and pressure.
xxviii SAFETY MARMMTRBL02303E
Staying Safe While Advise all personnel who must teach the robot or otherwise manually
Teaching or Manually operate the robot to observe the following rules:
Operating the Robot
 Know whether or not you are using an intrinsically safe teach pendant
if you are working in a hazardous environment.
 Before teaching, visually inspect the robot and work envelope to make
sure that no potentially hazardous conditions exist. The work
envelope is the area defined by the maximum motion range of the
robot. These include tooling attached to the wrist flange that extends
this range.
 The area near the robot must be clean and free of oil, water, or debris.
Immediately report unsafe working conditions to the supervisor or
safety department.
 FANUC Robotics recommends that no one enter the work envelope of
a robot that is on. However, if you must enter the work envelope, be
sure all safeguards are in place, and check the teach pendant
DEADMAN switch for proper operation. Take the teach pendant with
you, turn it on, and be prepared to release the DEADMAN switch.
Only the person with the teach pendant should be in the work
envelope.
 Know the path that can be used to escape from a moving robot; make
sure the escape path is never blocked.
 Isolate the robot from all remote control signals that can cause motion
while data is being taught.
 Test any program being run for the first time in the following manner:
WARNING
Stay outside the robot work envelope whenever a program
is being run. Failure to do so can result in injury.
– Using a low motion speed, single step the program for at least one
full cycle.
– Using a low motion speed, test run the program continuously for
at least one full cycle.
– Using the programmed speed, test run the program continuously

for at least one full cycle.
 Make sure all personnel are outside the work envelope before running
production.
MARMMTRBL02303E SAFETY xxix
Staying Safe During Advise all personnel who operate the robot during production to observe
Production Operation the following rules:
 Know the entire workcell area. The workcell includes the robot and its
work envelope, plus the area occupied by all external devices and
other equipment with which the robot interacts.
 Understand the complete task the robot is programmed to perform

before initiating production operation.
 Make sure all personnel are outside the work envelope before
operating the robot.
 Never enter or allow others to enter the work envelope during

production operation of the robot.
 Know the location and status of all switches, sensors, and control
signals that could cause the robot to move.
 Know where the EMERGENCY STOP buttons are located on both the
robot control and external control devices. Be prepared to press these
buttons in an emergency.
 Never assume that a program is complete if the robot is not moving.

The robot could be waiting for an input signal that will permit it to
continue activity.
 If
runthe
inrobot is running
the same pattern.in a pattern, do not assume it will continue to
 Never try to stop the robot, or break its motion, with your body. The
only way to stop robot motion immediately is to press an
EMERGENCY STOP button located on the controller panel, teach
pendant, or emergency stop stations around the workcell.
Staying Safe During When inspecting the robot, be sure to

Inspection
 Turn off power at the controller.
 Lock out and tag out the power source at the controller according to
the policies of your plant.
 Turn off the compressed air source and relieve the air pressure.
 If robot motion is not needed for inspecting the electrical circuits,

press the EMERGENCY STOP button on the operator panel.
 If power is needed to check the robot motion or electrical circuits, be

prepared to press the EMERGENCY STOP button, in an emergency.
xxx SAFETY MARMMTRBL02303E
Staying Safe During When performing maintenance on your robot system, observe the
Maintenance following rules:
 Never enter the work envelope while the robot or a program is in

operation.
 Before entering the work envelope, visually inspect the workcell to

make sure no potentially hazardous conditions exist.
 Consider all or any overlapping work envelopes of adjoining robots

when standing in a work envelope.
 Test the teach pendant for proper operation before entering the work
envelope.
 If it is necessary for you to enter the robot work envelope while power
is turned on, you must be sure that you are in control of the robot. Be
sure to take the teach pendant with you, press the DEADMAN switch,
and turn the teach pendant on. Be prepared to release the DEADMAN
switch to turn off servo power to the robot immediately.
 Whenever possible, perform maintenance with the power turned off.

Before you open the controller front panel or enter the work envelope,
turn off and lock out the 3–phase power source at the controller.
WARNING
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to shock.
avoid electrical a power source. Be extremely careful to
Turning the disconnect or circuit breaker to the OFF

position removes power from the output side of the device
only. High voltage is always present at the input side
whenever the controller is connected to a power source.
 Release or block all stored energy. Before working on the pneumatic

system, shut off the system air supply and purge the air lines.
 Isolate the robot from all remote control signals. If maintenance must
be done when the power is on, make sure the person inside the work
envelope has sole control of the robot. The teach pendant must be
held by this person.
 Make sure personnel cannot get trapped between the moving robot and
other equipment. Know the path that can be used to escape from a
moving robot. Make sure the escape route is never blocked.
 Use blocks, mechanical stops, and pins to prevent hazardous

movement by the robot. Make sure that such devices do not create
pinch points that could trap personnel.
MARMMTRBL02303E SAFETY xxxi
WARNING
Do not try to remove any mechanical component from the
robot before thoroughly reading and understanding the
procedures in the appropriate manual. Doing so can result
in serious personal injury and component destruction.
 Be aware that when you remove a servomotor or brake, the associated

axis will fall if it is not supported or resting on a hard stop.
 When replacing or installing components, make sure dirt and debris do

not enter the system.
 Use only specified parts for replacement. To avoid fires and damage
to parts in the controller, never use nonspecified fuses.

 Before restarting a robot, make sure no one is inside the work
envelope; be sure that the robot and all external devices are operating
normally.
KEEPING MACHINE Certain programming and mechanical measures are useful in keeping the
machine tools and other external devices safe. These measures are
TOOLS AND outlined below.
EXTERNAL
DEVICES SAFE
Programming Safety Implement the following programming safety measures to prevent damage
Precautions to machine tools and other external devices.
 Back–check limit switches in the workcell to make sure they do not

fail.
 Implement ‘‘failure routines” in programs that will provide appropriate

robot actions if an external device or another robot in the workcell
fails.
 Use handshaking protocol to synchronize robot and external device

operations.
 Program the robot

an operating cycle.to check the condition of all external devices during
Mechanical Safety Implement the following mechanical safety measures to prevent damage to
Precautions machine tools and other external devices.
 Make sure the workcell is clean and free of oil, water, and debris.
 Use software limits, limit switches, and mechanical hardstops to

prevent undesired movement of the robot into the work area of
machine tools and external devices.
xxxii SAFETY MARMMTRBL02303E
KEEPING THE Observe the following operating and programming guidelines to prevent
damage to the robot.
ROBOT SAFE
The following measures are designed to prevent damage to the robot
Operating Safety during operation.
Precautions  Use a low override speed to increase your control over the robot when
jogging the robot.
 Visualize the movement the robot will make before you press the jog
keys on the teach pendant.
 Make sure the work envelope is clean and free of oil, water, or debris.
 Use circuit breakers to guard against electrical overload.
Programming Safety The following safety measures are designed to prevent damage to the robot
Precautions during programming:
 Establish interference zones to prevent collisions when two or more

robots share a work area.
 Make sure that the program ends with the robot near or at the home
position.
 Be aware of signals or other operations that could trigger operation of
tooling resulting in personal injury or equipment damage.
 In dispensing applications, be aware of all safety guidelines with
respect to the dispensing materials.
NOTE Any deviation from the methods and safety practices described in
this
you manual must conform
have questions, to supervisor.
see your the approved standards of your company. If
MARMMTRBL02303E SAFETY xxxiii
ADDITIONAL Process technicians are sometimes required to enter the paint booth, for
example, during daily or routine calibration or while teaching new paths to
SAFETY a robot. Maintenance personal also must work inside the paint booth
CONSIDERATIONS periodically.
FOR PAINT ROBOT Whenever personnel are working inside the paint booth, ventilation
INSTALLATIONS equipment must be used. Instruction on the proper use of ventilating
equipment usually is provided by the paint shop supervisor.
Although paint booth hazards have been minimized, potential dangers still
exist. Therefore, today’s highly automated paint booth requires that
process and maintenance personnel have full awareness of the system and
its capabilities. They must understand the interaction that occurs between
the vehicle moving along the conveyor and the robot(s), hood/deck and
door opening devices, and high–voltage electrostatic tools.
Paint robots are operated in three modes:

 Teach or manual mode
 Automatic mode, including production and exercise operation
 Diagnostic mode
During both teach and automatic modes, the robots in the paint booth will
follow a predetermined pattern of movements. In teach mode, the process
technician teaches (programs) paint paths using the teach pendant.
In automatic mode, robot operation is initiated at the System Controller
Center (SCC), Manual Control Panel (MCP), if available, or Manual Paint
Station (MPS), if available, and can be monitored from outside the paint
booth. All personnel must remain outside of the booth or in a designated
safe area within the booth whenever automatic mode is initiated at the
SCC, MCP, or MPS.
In automatic mode, the robots will execute the path movements they were
taught during teach mode, but generally at production speeds.
When process and maintenance personnel run diagnostic routines that
require them to remain in the paint booth, they must stay in a designated
safe area.
xxxiv SAFETY MARMMTRBL02303E
Paint System Safety Process technicians and maintenance personnel must become totally
Features familiar with the equipment and its capabilities. To minimize the risk of
injury when working near robots and related equipment, personnel must
comply strictly with the procedures in the manuals.
This section provides information about the safety features that are
included in the paint system and also explains the way the robot interacts
with other equipment in the system.
The paint system includes the following safety features:
 Most paint booths have red warning beacons that illuminate when the
robots are armed and ready to paint. Your booth might have other
kinds of indicators. Learn what these are.
 Some paint booths have a blue beacon that, when illuminated,

indicates
have otherthat the of
kinds electrostatic
indicators.devices are enabled.
Learn what Your booth might
these are.
 EMERGENCY STOP buttons are located on the Manual Control

Panel (MCP), or Manual Paint Station (MPS) panel, if supplied, inside
the booth, or on the System Controller Center (SCC) outside the
booth. Also, EMERGENCY STOP buttons are located near the
interior corners of each booth, and on the robot controller and teach
pendant. Become familiar with the locations of all E–STOP buttons.
 An intrinsically safe teach pendant is used when teaching in hazardous

paint atmospheres.
 A DEADMAN switch is located on each teach pendant. When this

switch is held in, power is applied to the robot servo system. If the
engaged DEADMAN switch is released during robot operation, power
is removed from the servo system, all axis brakes are applied, and the
robot comes to an EMERGENCY STOP. Safety interlocks within the
system might also E–STOP other robots.
WARNING
An EMERGENCY STOP will occur if the DEADMAN switch
is released on a bypassed robot.
 Overtravel by robot axes is prevented by software limits. All of the

major and minor axes are governed by software limits. Limit switches
and hardstops also limit travel by the major axes.
MARMMTRBL02303E SAFETY xxxv
 EMERGENCY STOP limit switches and photoelectric eyes might be

part of your system. Limit switches, located on the entrance/exit doors
of each booth, will EMERGENCY STOP all equipment in the booth if
a door is opened while the system is operating in automatic or manual
mode. For some systems,signals to these switches are bypassed when
the switch on the SCC is in teach mode.
When present, photoelectric eyes are sometimes used to monitor

unauthorized intrusion through the entrance/exit silhouette openings.
 System status is monitored by computer. Severe conditions result in

automatic system shutdown.
Staying Safe While When you work in or near the paint booth, observe the following rules, in
addition to all rules for safe operation that apply to all robot systems.
Operating
Robot the Paint
WARNING
Observe all safety rules and guidelines to avoid injury.
WARNING
OPTIONAL SAFETY DEVICE
Your robot may have a red flashing warning light. This is
an optional operator warning. It indicates:
 The robot is powered on
 The robot is armed (servo power on) and can move at
FANUCany time. recommends that no one enter the work

Robotics
envelope of a robot that is on. However, if you must enter
the work envelope, be sure all safeguards are in place, and
check the teach pendant DEADMAN switch for proper
operation. Take the tach pendant with you, turn it on, and
be prepared to release the DEADMAN switch. Only the
person with the teach pendant should be in the work
envelope.
 Know the work area of the entire paint station (workcell).
 Know the work envelope of the robot and hood/deck and door opening
devices.
 Be aware of overlapping work envelopes of adjacent robots.
 Know where all red, mushroom–shaped EMERGENCY STOP buttons

are located.
 Know the location and status of all switches, sensors, and/or control
signals that might cause the robot, conveyor, and opening devices to
move.
xxxvi SAFETY MARMMTRBL02303E
 Make sure that the work area near the robot is clean and free of water,
oil, and debris. Report unsafe conditions to your supervisor.
 Become
BEFOREfamiliar
startingwith the complete
automatic mode. task the robot will perform
 Make sure all personnel are outside the paint booth before turning on
power to the robot servo system.
 Never enter the work envelope or paint booth before turning on power
to the robot servo system.
 Never enter the work envelope during automatic operation unless a

safe area has been designated.
 Never wear watches, rings, neckties, scarves, or loose clothing that

could get caught in moving machinery.
 Remove all metallic objects, such as rings, watches, and belts, before
entering a booth when the electrostatic devices are enabled.
 Stay out of areas where you might get trapped between a moving
robot, conveyor, or opening device and another object.
 Be aware of signals and/or operations that could result in the triggering

of guns or bells.
 Be aware of all safety precautions when dispensing of paint is
required.
 Follow the procedures described in this manual.
Staying Safe During When you perform maintenance on the painter system, observe the
Maintenance following rules, and all other maintenance safety rules that apply to all
robot installations. Only qualified, trained service or maintenance
personnel should perform repair work on a robot.
 Paint robots operate in a potentially explosive environment. Use

caution when working with electric tools.
 When a maintenance technician is repairing or adjusting a robot, the

work area is under the control of that technician. All personnel not
participating in the maintenance must stay out of the area.
 For some maintenance procedures, station a second person at the

control panel within reach of the EMERGENCY STOP button. This
person must understand the robot and associated potential hazards.
 Be sure all covers and inspection plates are in good repair and in place.
 Always return the robot to the ‘‘home’’ position before you disarm it.
MARMMTRBL02303E SAFETY xxxvii
 Never use machine power to aid in removing any component from the
robot.
 During robot
vibration, operations,
unusual sounds,beand
aware of thecan
so forth, robot’s
alert movements. Excess
you to potential
problems.
 Whenever possible, turn off the main electrical disconnect before you
clean the robot.
xxxviii SAFETY MARMMTRBL02303E
 When using vinyl resin observe the following:
– Wear eye protection and protective gloves during application and

removal
– Adequate ventilation is required. Overexposure could cause
drowsiness or skin and eye irritation.
– If there is contact with the skin, wash with water.
 When using paint remover observe the following:
– Eye protection, protective rubber gloves, boots, and apron are

required during booth cleaning.
– Adequate ventilation is required. Overexposure could cause

drowsiness.
– If there is contact with the skin or eyes, rinse with water for at
least 15 minutes.
1
OVERVIEW
MARMMTRBL02303E 1–1
The SYSTEM R-J Robot and controller consists of software, a robot, and
the SYSTEM R-J controller. The application software runs on the R-J
controller and is written to perform a specific task.
The SYSTEM R–J controller contains the computer that operates the
robot. It executes a user-defined program to perform the following
functions:
 Supply drive power to the servomotors of an attached robot and, in

some cases, to motor-driven auxiliary devices to move the robot
through a series of program motions.
 Supply drive power to the servomotors of an attached robot and, in

some cases, to motor-driven auxiliary devices comprising additional
axes, such as door openers, and/or hood/deck openers used in
conjunction with robot programs.
 Send control signals to process devices and other peripheral

equipment.
 Initiate and monitor the purge system of the robot and sometimes
associated opening devices.
The controller consists of modular circuit boards and components housed
in a cabinet. The controller is housed in either a B-size or C-size cabinet.
The controller consists of modular circuit boards and components housed
in a C-size cabinet.
Figure 1–1, Figure

B-size cabinet 1–2, and
and Figure 1–4Figure 1–3 illustrate
illustrates an view
an external external
of aview of the
C-size
cabinet. Figure 1–5 illustrates an internal view of a B-size cabinet and
Figure 1–6 illustrates an internal view of a C-size cabinet.
Figure 1–4 illustrates an external view of a C-size cabinet. Figure 1–7
illustrates an internal view of a C-size cabinet.
1. OVERVIEW
MARMMTRBL02303E
1–2
Figure 1–1. Cabinet Exterior, B-Size Controller
Î Î Î Î
Î
Î Î Î Î Î
Î Î
Î Î Î Î Î Î Î
Î
Î Î Î
Teach
pendant
Î Î Î Î
Î Î Î
Î Î Î Î Î
Î
Figure 1–2. Cabinet Exterior, B-Size Controller with Regenerative Discharge Unit
Regenerative
Discharge
Unit Î Î Î Î
Î
Î Î Î Î Î
Î
Î
Î Î Î Î Î Î Î
Teach
pendant
Î Î Î Î
Î Î Î Î Î Î
Î Î Î Î
Î Î Î Î Î
1. OVERVIEW
Figure 1–3. Cabinet Exterior, B-Size Controller with Optional Side Cabinet
Optional Side Cabinet

Î Î
Î Î
Î Î
Î Î Î Î
Î Î
Î Î Î Î Î
Î Î Î
Î Î Î Î
Teach
pendant
Î Î
Î Î
Î Î Î Î Î
Î Î Î
Î Î Î
1. OVERVIEW
MARMMTRBL02303E
1–4
Figure 1–4. Cabinet Exterior, C-Size Controller
Î Î
Î Î
Î Î
Î Î
Î
Î Î
Î Î
Teach
pendant
Î Î
Î Î
Î Î Î
Î Î
Î Î
Î
Î
Î
1. OVERVIEW
Figure 1–5. Cabinet Interior, B-Size Controller
Regenerative discharge unit

Servo amplifier 4
Servo amplifier 3 Fan 1
Additional cabinet
Operator’s panel
Main CPU printed
circuit board
Axis control printed
circuit board
Power supply unit
Printed circuit board for

emergency stop control
Process I/O printed

circuit board or
I/O unit model A
Circuit breaker
Fan 2
Transformer or
Fan 3 Servo amplifier 1 line filter unit
Servo amplifier 2
Servo amplifier 6
Servo amplifier 5 Teach pendant
Fan 4
Fan 5
Components for all models are placed in identical places except for the
servo amplifier. Refer to Section 1.6 for information on the servo
amplifiers locations for different robot models.
1. OVERVIEW
MARMMTRBL02303E
1–6
Figure 1–6. Cabinet Interior, C-Size Controller
Operator panel
Î
Î
Î Î
Î
Î
Î Ï
Î Î Î
Modular I/O rack or

Î Î
Extended Process I/O rack

Î
Î
Î
Î
Î Î
Î
Î
Back plane
Î Î Î
Î Î Î
Power disconnect
Servo amplifier #1
Servo amplifier #2 Main CPU

Fuses FL1–3
Servo amplifier #3
Axis control board
Power supply unit
Servo amplifier #4 and #5 Emergency stop

control board
Servo amplifier #6 Option 1 and 2 slots
User transformer
Multi–tap transformer
1. OVERVIEW
Figure 1–7. Cabinet Interior, C-Size Controller
Î Î
Operator panel
Î Î
Î Î Î Î
Î Î Î
Î Î Ï
Î Î
Î Î Î
Î Î Î
Î Î Î
Î Î Î Î
Î
Î
Î
Î
Contact Signal
Transducer
STAHL Extended
Servo Amplifiers ISB’s Back plane STBI Term Strip
Purge
Power 24V DC
Supply
Power disconnect
Main CPU
Fuses FL1–3
Transit Board Axis control board
Power supply unit
Emergency stop
control board
Option 1 and 2 slots
BDX
ISB Unit
ALC
Relay
SPC Battery
Unit
User transformer
1. OVERVIEW
1.2 The main CPU printed circuit board is mounted on the backplane in the
slot marked MAIN. It contains the CPU and the volatile and non-volatile
MAIN CPU PRINTED
CIRCUIT BOARD memory used by the controller.
The Main CPU printed circuit board also acts as the interface between the
A16B-2200-0840 to controller and the operator and attached devices, through connections to:
A16B-2200-0843  The I/O unit(s)
 The teach pendant
 One or more general–purpose serial communication ports
 An optional built-in or remote computer terminal (CRT/KB)
 The operator panel lights and pushbuttons
A super capacitor on the Main CPU printed circuit board maintains voltage
to the CMOS RAM for short periods of time (less than Â an hour) if
removed from the backplane. A connector, BAT-VBAT, is supplied to
connect the battery from the Power Supply Unit to the Main CPU printed
circuit board when the Power Supply Unit or Main CPU is removed from
the controller for an extended period of time. This will supply voltage to
the CMOS memory so the stored data is not lost.
The main CPU consists of a main motherboard with several daughter
modules installed perpendicular to it. The modules are small printed
circuit boards with components surface-mounted on both sides. The
modules are installed in sockets, allowing them to be changed quickly and
easily.
 Flash ROM Module contains System and Application Software.
 CMOS RAM Module stores user programs, system variables, I/O

configuration files, and mastering data.
 SLC2 Module controls I/O communication.
 M32i Module controls communication between the flash ROM,
CMOS, micro processor and boot ROM chip.
 SCC Module controls communication with the operator panel.
 Optional SCC Module communicates with any optional serial ports.
Figure 1–9 shows the board layout. Table 1–1 lists the part numbers for
the modules attached on the board.
1. OVERVIEW
MARMMTRBL02303E
1–10
Figure 1–9. Main CPU Board Layout
Flash ROM module Optional SCC module
CMOS RAM module (option) SLC2 module
CMOS RAM module (option) M32i module
CMOS RAM module (standard) SCC module

CMOS RAM module (standard)
NOTE Options are shown in phantom print.
1. OVERVIEW
Table 1–1. Main CPU Modules
Name Part Number Remarks
CMOS RAM module A20B-2900-0500, 0501

Flash ROM module A20B-2900-0480, 0482
M32I module A20B-2900-0450 MAIN CPU printed circuit board
SCC module A20B-2900-0430
SLC2 module A20B-2900-0440, 0442
Optional SCC module A20B-2900-0490, 0491, 0492
NOTE CMOS RAM modules are replaced in pairs (two standard modules
or two optional modules).
1. OVERVIEW
MARMMTRBL02303E
1–12
1.3 The axis control printed circuit board is mounted on the backplane in the
slot marked AXIS. It performs the following functions:
AXIS CONTROL
PRINTED CIRCUIT  Receives command signals from the main CPU board, and receives
axis position and velocity signals from the serial pulse coders.
BOARD  Compares the command signal with the axis position signal and
A16B-2200-0852 to generates pulse-width-modulated axis drive signals. These signals
A16B-2200-0855 switch the drive transistors on the servo amplifiers on and off applying
power to the servo motors.
 Monitors the status of the hand breakage and axis overtravel switches
in the mechanical unit.
 Is the interface for the Robot Input (RI) and Robot Output (RO) I/O
signals.
Figure 1–10 shows the axis control board layout. Table 1–2 lists the part
numbers for the modules attached on the board.
Figure 1–10. Axis Control Board Layout
Servo control module (for axis 9 and 10)

Servo interface module (for axis 5 and 6)
Servo interface module (for axis 3 and 4) Servo interface module (for axis 9 and 10)
Servo interface module (for axis 1 and 2) Servo interface module (for axis 7 and 8)
NOTE Options are shown in phantom print.

Table 1–2. Axis Control Board Modules
Name Part Number Remarks
Servo interface module A20B-2900-0380 Axis control printed circuit board
Servo control module A20B-2900-0160
1. OVERVIEW
1.4 The power supply unit printed circuit board is mounted on the backplane
in the slot marked PSU.
POWER SUPPLY UNIT
The power supply unit printed circuit board is supplied with 210 VAC
PRINTED CIRCUIT
BOARD from the multi-tap transformer and produces the following DC voltages:
4-Slot Backplane  +24V used
A16B-1212–0471 – For inputs, outputs receivers, drivers, and relays.
6-Slot Backplane
A16B-1212-0531 – As the power source for the teach pendant power supply circuitry.
 +15, –15, +5 used for logic circuitry within the controller.
The power supply unit printed circuit board also contains the ON/OFF
logic circuits used by the controller.
CAUTION
The CMOS RAM backup battery is mounted on the power
supply unit printed circuit board. If the board is removed from
the controller for longer than 30 minutes, all software in the
controller might be lost.
Figure 1–11. Power Supply Unit Printed Circuit Board
PSU PSU
F1 and F2:
Fuses for AC input
F5: 0.3A fuse for 10-A for 6-slot backplane
7.5A for 4-slot backplane
auxiliary
power supply
PIL: green LED
for indicating the AC
Battery cover power supply status
Battery
ALM: Red LED

for indicating
an alarm
F4:5–Afuse for +24E
F3: Fuse for +24V

5-A slow blow for
6-slot backplane
3.2A slow blow for
4-slot backplane (with battery cover removed)
1. OVERVIEW
MARMMTRBL02303E
1–14
1.5 The emergency stop control printed circuit board is mounted on the
backplane in the slot marked EMG. It contains the circuits that:
EMERGENCY STOP
CONTROL PRINTED  Supply 100VAC to the servo amplifiers magnetic control contactors
CIRCUIT BOARD (MCCs) during normal operation.
A16B-1212-0540  Turn off 100VAC for the MCC during fault conditions such as:
A16B-1212-0730  Turn off 100VAC for the MCC during fault conditions such as:
– Emergency stop
– Axis overtravel
– Safety fence open
– Teach pendant DEADMAN switch
– Hand breakage detection

 Supply power to the motor brakes to release them during normal
operation. Brake power is turned off (applying motor brakes) during
major alarm conditions, or when regulated by the software.
 Supply power to the motor brakes to release them during normal

operation. Brake power is turned off (applying motor brakes) during
major alarm conditions, or when regulated by the software. There is a
second brake circuit that is manually operated by a front panel key
switch. This key switch operated circuit provides a method to move
the robot manually should servo power fail, or when mastering is
required.
 Monitor and control the purge system through a piggy-back style PCB,
purge control A16B–1600–0520. This PCB is mounted internally
within the EMG PCB.
 Supply 24VDC required for SPC encoder operation through the 24 to

5VDC converter unit located within the robot base and switched on
through the purge complete relay contacts of RL-1 for protection from
explosive gases.
Figure 1–12 shows the emergency stop control printed circuit board
layout.
1. OVERVIEW
Figure 1–12. Emergency Stop Control Printed Circuit Board
EMG
PCB
1. OVERVIEW
MARMMTRBL02303E
1–16
Figure 1–13. Emergency Stop Control PC Board
DS2
F1
DS1
F2
RL16 RL1 RL2
FUSE RL4
CRR5
RL3 LED M1
LED M2
RL2 RL1
RL4 TIMER
RL3
RL6
RL5
RL8
RL7
RL9 CRT
CNPG CRX
Purge Control PCB
1. OVERVIEW
1.6 The servo amplifiers are mounted on the back wall of the controller. The
servo amplifier amplifies the drive signal from the axis control printed
SERVO AMPLIFIERS
circuit board and supplies it to the servomotor.
Refer to Table 1–3 for Servo amplifiers are supplied in single, double or triple-axis
part numbers. configurations. Several different models of each configuration are used in
various FANUC robot controllers.
CAUTION
While two servo amplifiers might look identical, they might have
quite different output power capabilities. If you replace a servo
amplifier, make sure that the new unit has the same part
number as the old one. Otherwise, the servo amplifier or
servomotor might be damaged or destroyed.
See Figure 1–14 for a servo amplifier.
Figure 1–14. Servo Amplifier
LED
Terminal board T1
Circuit breaker
1. OVERVIEW
MARMMTRBL02303E
1–18
MCC Coil Each servo amplifier has its own DC power supply, which is supplied
3-phase 210 VAC from the multi-tap transformer. The power lines
supplying the DC power supply are switched on and off by a magnetic
contactor (relay) called the Magnetic Control Contractor (MCC).
The MCC coil is energized by 100 VAC from the emergency stop control
printed circuit board. The MCC coil voltage is turned off during major
fault conditions or when regulated by the software.
When the MCC is turned off, its normally-closed contacts connect the
motor power leads together through low-resistance, high-power resistors,
stopping the motor immediately.
Circuit Breaker The servo amplifier circuitry is protected by a circuit breaker. The reset
lever for the circuit breaker is visible on the front panel of the servo
amplifier. Refer to Section 1.9 for more information on the multi-tap
transformer.
Fault Detection Each servo amplifier has fault detection circuits that detect such conditions
as excessive motor current and servo amplifier power supply failure.
A pair of terminals on the servo amplifier can be connected to a
temperature-sensing switch in the multi-tap transformer. If the switch
opens, the controller will signal a SRVO–0043 DCAL alarm.
Servo Amplifier Table 1–3 lists the servo amplifiers for several FANUC robots.
Configuration Figure 1–15 shows the mounting locations of the servo amplifiers.
Servo Amplifier Table 1–3 lists the servo amplifiers for the P-155 robot and optional
Configuration auxiliary devices.. Figure 1–23 shows the mounting locations of the servo
amplifiers.
Figure 1–15. Mounting Locations of Servo Amplifiers – Robot with 6-amplifiers
SLOT 4 SLOT 5 SLOT 6
SLOT 1 SLOT 2 SLOT 3
1. OVERVIEW
Figure 1–16. Mounting Locations of Servo Amplifiers for the A-510
Figure 1–17. Mounting Locations of Servo Amplifiers for the Arc Mate/
Arc Mate 100/S-6, Arc Mate Sr./S-5/S-10 and L-1000
1. OVERVIEW
MARMMTRBL02303E
1–20
Figure 1–18. Mounting Locations of Servo Amplifiers for the S-500/S-700 and
M-400
Figure 1–19. Mounting Locations of Servo Amplifiers for the S-420 and S-800
1. OVERVIEW
Figure 1–20. Mounting Locations of Servo Amplifiers for the S-420 and the DCR &
DBR Unit
(S–420) With 3 2-Axis Servo Amplifiers; S–420D
Figure 1–21. Mounting Locations of Servo Amplifiers for the M-500
1. OVERVIEW
MARMMTRBL02303E
1–22
Figure 1–22. Mounting Locations of Servo Amplifiers for the S-900
Figure 1–23. Mounting Locations of Servo Amplifiers.
Amp 1 Amp 2 Amp 3

Axis 1 Axis 2 Axis 3
Axis 4 Axis 5
Axis 6
Amp 4 Amp 5
Axis 7 Axis 8
Axis 9
1. OVERVIEW
NOTE In Table 1–3, the part number of the specific amplifier is

A06B-6066-HXXX.
Table 1–3. Servo Amplifiers

Machine Type Servo Servo Servo Servo Servo Servo
Amplifier 1 Amplifier 2 Amplifier 3 Amplifier 4 Amplifier 5 Amplifier 6
ARC Mate H281 H223 H223
S-5 L;Axis 4/ L;Axis 5/ L;Axis 6/
M;Axis 1 M;Axis 2 M;Axis 3
ARC Mate H234 H224 H223
100/S-6 L;Axis 4/ L;Axis 5/ L;Axis 6/
ARC Mate Sr. H234 H234 H233
S-10 L;Axis 4/ L;Axis 5/ L;Axis 6/
P-155 H235 H235 H235 H005
Axes 1 & 4 Axes 2 & 5 Axes 3 & 6 Axis 7
Door Opener H233
Axes 8 & 9
Hood & Deck H244
Axes 8 & 9
S-420 H011 H006 H006 H244 H004
(with five amplifiers) Axis 1 Axis 2 Axis 3 L;Axis 5/ Axis 6
M;Axis 4
S-420 and S-420D H291 H291 H291 DCR & DBR
(with three 2-axis L;Axis 4/ L;Axis 5/ L;Axis 6/ Unit
amplifiers) M;Axis 1 M;Axis 2 M;Axis 3
S-500 H011 H006 H234 H233
Axis 1 Axis 2 L;Axis 4/ L;Axis 6/
M;Axis 3 M;Axis 5
S–700 H012 H006 H234 H233
Axis 1 Axis 2 L;Axis 4/ L;Axis 6/
M;Axis 3 M;Axis 5
S-800 H011 H006 H006 H260 H006
Axis 1 Axis 6 Axis 3 L;Axis 5/ Axis 6
M;Axis 4
S–900 H008 H006 H008 H006 H008 H006
Axis 1 Axis 4 Axis 2 Axis 5 Axis 3 Axis 6
M-400 H006 H011 H234 H003
Axis 1 Axis 2 L;Axis
M;Axis4/
3 Axis 5
M-500 H008 H006 H244 H004

Axis 1 Axis 3 L;Axis 4/ Axis 5
M;Axis 2
A-510 H233 H223
L;Axis 3/ L;Axis 4/
M;Axis 1 M;Axis 2
L-1000 H234 H234 H003
L;Axis 4/ L;Axis 5/ Axis 3
M;Axis 1 M;Axis 2
1. OVERVIEW
MARMMTRBL02303E
1–24
1.7 The Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) unit is
used in R-J controllers with three 2-axis amplifiers. It contains the
DCR AND DBR UNIT
A05B-2302-C080 dynamic braking resistors and regenerative discharge resistors built into
the other model servo amplifiers. At the loss of either MCON (Motor
Control Connected) signal from the axis control module to the servo
amplifier, that amplifier turns off the 100C signal to the DBR (Dynamic
Braking) and DCR (Discharge Resistor) unit and its associated MCC.
This turns off the MCC contactor (one for each major and minor axis on
the DBR and DCR unit) for that amplifier, and engages the dynamic
brakes through the normally closed contacts of the corresponding MCC.
At the loss of the 100VAC from the emergency stop circuit, all of the
MCC contactors are turned off, engaging all of the dynamic brakes.
When the MCC deenergizes, it opens its normally open contact, relaying
“no interlock (INTL)”.
The regenerative discharge resistor and its associated thermal switch, for
each amplifier, is mounted to the back of the DBR and DCR unit.
The thermal switches of transformer TF1, is also connected to the DBR
and DCR unit.
Figure 1–24. DCR and DBR Unit
1. OVERVIEW
1.8 A discharge unit, mounted on top of the controller, is used with the M-500
and S-900 robot models. This unit is connected to axis 1 on the M-500
DISCHARGE UNIT
A05B-2312-C100 for M-500 and axes 1, 3, and 5 on the S-900.
A05B-2313-C100 for S-900 The unit consists of low-resistance high-power resistors used to dissipate
the counter electromotive force generated by the servo motors when they
are shut off. Thermo overload switches connected to the overheat
terminals on the servo amplifiers are also in the discharge unit. Fans in the
discharge unit are used to cool the unit.
Figure 1–25. Discharge Unit
1. OVERVIEW
MARMMTRBL02303E
1–26
1.9 The multi–tap transformer is located on the floor of the controller on the
right side.
MULTI-TAP
TRANSFORMER The multi-tap transformer is supplied 3–phase AC from the main
disconnect or circuit breaker. This supply voltage can be from 220 – 575
Refer to Table 1–4 for part volts. To accommodate the various levels of supply, tap selections are
numbers. provided on the primary side of the transformer.
The transformer supplies the following output voltages:
 3–phase 210 VAC for the servo amplifiers
 1–phase 210 VAC for the backplane–mounted components
 1–phase 210 VAC for the IBRC module
 1–phase 210 VAC for the 24VDC Purge Power Supply
 1–phase 100 VAC for the brakes and servo amplifier–mounted MCCs
NOTE Transformer A80L–0026–0013#A also supplies 115VAC for the

user receptacle.
Two series–connected thermostats are mounted on the transformer. They

are connected to fault detection circuitry in one servo amplifier. If the
transformer overheats, the controller will signal a SRVO–0043 DCAL
alarm.
Figure 1–26 and Figure 1–27 show the transformers, and Table 1–4,
Table 1–5, and Table 1–6 lists the information necessary for selecting a
proper primary tap.
Figure 1–26 shows the transformers, and Table 1–4, and Table 1–5 lists
the information necessary for selecting a proper primary tap.
Table 1–4. Multi-Tap Transformer Part Numbers

Transformer Type Part Number
7.5kVA A80L–0026–0010#A
S-420, S-500, S-800, A80L-0026-0010#A
M-500
ARC Mate Sr., S-700, A80L-0024-0010#A
M-400, L-1000, S-10
ARC Mate, Arc Mate A80L-0022-0007#A
100/S-6, A-510, S-5
S-420 with 3 2-axis A80L-0026-0013#A
Servo Amplifiers; S-420D
S-900 A80L-0026-0010#A – Main cabinet
A80L-0024-0011#A – Side cabinet
1. OVERVIEW
Figure 1–26. Multi-Tap Transformer

1
575V
2
550V 3
500V
480V 4
5
460V
6
240/415V
7
220V/380V
F4 F5 F1 F2 F3
7.5 7.5
8
0V
9
575V 10
550V 11
500V
12
480V
13
460V
14
A1 A2 240/415V
15
13 23 220V/380V
16
0V
31 1 3 5 41 17
575V 18
550V 19
32 2 4 6 42 500V
20
480V
21
460V
22
14 24 240/415V
23
220V/380V
24
0V
Table 1–5. Selecting Transformer Taps
Primary Tap
Supply Voltage Connection Type
L1 L2 L3 Jumper
220 7 15 23 7-24, 15-8, 23-16

240 6 14 22 6-24, 14-8, 22-16
380 7 15 23
415 6 14 22
460 5 13 21
480 4 12 20 8-16-24 Y
500 3 11 19
550 2 10 18
575 1 9 17
1. OVERVIEW
MARMMTRBL02303E
1–28
Figure 1–27. Multi-Tap Transformer A80L–0026–0013#A

1
575V
2
480V 3
220V/380V
4
0V
F4 F5 F6 F7 F1 F2 F3
5A 5A
5
575V
6
480V
7
220V/380V
8
1 2
V V 0 0 5 H
0 0 2 2 3 2 4 1 6 7 H O 1 O 2
0 1 0 A1 A2
1 4 1 4 2 4 2 4 1 4 G 4 T 5 T 5 9
13 23 575V 10
480V
220V/380V 11
31 1 3 5 41
32 2 4 6 42
12
0V
14 24
Table 1–6. Selecting Transformer Taps for Transformer

A80L–0026–0013#A
Primary Tap
Supply Voltage Connection Type
L1 L2 L3 Jumper
220 3 7 11 4-7, 8-11, 12-3 
380 3 7 11
480 2 6 10 4, 8, 12 Y
575 1 5 9
1. OVERVIEW
1.10 The interface between the controller and peripheral devices is provided by
input and output signals from one or more of the following:
INTERFACE DEVICES
 Modular I/O Unit
 Process I/O printed circuit board
 A printed circuit board specializing in communicating with a logic

controller, which includes
– ABRIO for communication to an Allen-Bradley PLC
– Genius I/O for communication to a GE Fanuc programmable
controller
 Digital I/O to/from the robot through the axis control board.
1. OVERVIEW
MARMMTRBL02303E
1–30
1.10.1 The modular I/O unit provides communication between the controller and
various peripheral devices. See Figure 1–28.
Modular I/O Unit
Figure 1–28. Modular I/O
Interface Module I/O Module
Modular I/O Rack

(Backplane)
Slot 2
Slot 1 I/O Module
Slot I/F
Interface Module
The modular I/O unit uses the following communication modes:

 Discrete (On or Off) input and output signal lines at 24VDC or
120VAC. Outputs can be sink or source outputs.
 Analog signal lines, which can vary from –10VDC to +10VDC
The modular I/O unit consists of the following:
 The base unit
 The interface module
 Various discrete input and output (I/O) modules
The control can use as many as 64 modular I/O modules concatenated
(daisy–chained) together on multiple racks.
A single modular I/O unit is referred to as rack 1. The I/O modules are
located in slots 1 to 5 or 1 - 10, depending on the model used.
Base Unit The base unit is the backplane for the modular I/O unit. The interface
5 I/O Module Slot module and the I/O modules plug into it.
A03B-0807-C002 The base unit has no LEDs, fuses, or electrical connections, except for the
module sockets.
10 I/O Module Slot
A03B-0807-C001 The first slot to the left (I/F) always contains the interface module. The
other slots are used for the I/O modules.
1. OVERVIEW
Interface Module The interface module transfers data between the main CPU and the I/O
With 1 Rack modules.
A03B-0807-C011
The interface module is connected to the JD4 connector on the main CPU
For Additional Rack printed circuit board through connector JD1B. The interface module is
A03B-0807-C012 always mounted in the I/F (first) slot.
Discrete Input Modules Discrete input modules receive 24VDC or 120VAC signals on their
Refer to Table 1–7 and terminals and relay the data to the interface module.
Table 1–9 for specifications
and part numbers.
Discrete Output Modules Discrete output modules transmit 24VDC or 120VAC signals on their
Refer to Table 1–8 and terminals under command of the interface module.
Table 1–9 for specifications
and part numbers.
1. OVERVIEW
MARMMTRBL02303E
1–32
Table 1–7. Digital Input Module Specifications

Module Rated Rated Response External
Input Type Polarity* Points LED Display
Name Voltage Current Time Connection
Non-isolated
DC input AID32A 24VDC 7.5 mA Both Maximum 32 Connector No-display
20 ms
AID32B 24VDC 7.5 mA Both Maximum 32 Connector No-display
2 ms
Optically AID16C 24 VDC 7.5 mA NEG Maximum 16 Terminal block Provided
isolated 20 ms
DC input AID16D 24VDC 7.5 mA POS Maximum 16 Terminal block Provided
20 ms
AID32E 24VDC 7.5 mA Both Maximum 32 Connector No-display
20 ms
AID32F 24VDC 7.5 mA Both Maximum 32 Connector No-display
2 ms
AC input AIA16G 100~ 10.5 mA ON Max 35 ms 16 Terminal block Provided
120VAC (120VAC) OFF Max 45 ms
* Polarity is defined as follows: Negative: 0 V common (current source type); ON when input is at low level.
Positive: 24 V common (current sink type); ON when input is at high level.
Table 1–8. Digital Output Module Specifications

Output Module Rated Maximum Points/ External LED
Polarity* Points Fuses
Type Name Voltage Current Common Connection Display
Not fused AOD332A 5~ 0.3A NEG 32 8 Connector Not Not fused
DC output 24 VDC provided
Fused AOD08C 12 ~ 2A NEG 8 8 Terminal block Provided Fused
DC output 24 VDC (Sink)
AOD08D 2A POS 8 8 Terminal block Provided Fused
(Source)
Not-Fused AOD16C 0.5 A NEG 16 8 Terminal block Provided Not fused
DC output (Sink)
AOD16D 0.5 A POS 16 8 Terminal block Provided Not fused
(Source)
AOD32C 0.3 A NEG 32 8 Connector Not Not fused
(Sink) provided
AOD32D 0.3 A POS 32 8 Connector Not Not fused

(Source) provided
AC output AOA05E 100 ~ 2A — 5 1 Terminal block Provided Fused
AOA08E 240 VAC 1A — 8 4 Terminal block Provided Fused
AOA12F 100 ~ 0.5 A — 12 6 Terminal block Provided Fused
120 VAC
Relay AOR08G Maximum 4A — 8 1 Terminal block Provided Not fused
ou pu
p
AOR16G /30 VD 2A — 16 4 Terminal block Provided Not fused
* Polarity is defined as follows: Negative: 0 V common (current sink type); output is at low level when ON.
Positive: 24 V common (current source type); output is at high level when ON.
1. OVERVIEW
Table 1–9. I/O Module Part Numbers

Name Part Number
DC input Non-isolated 32 points AID32A A03B-0807-C101
module 20 ms
32 points AID32B A03B-0807-C102
2 ms
Optically 16 points AID16C A03B-0807-C103
isolated NEG
16 points AID16D A03B-0807-C104
POS
32 points AID32E A03B-0807-C105
20 ms
32 points AID32F A03B-0807-C106
2 ms
AC input module AIA16G A03B-0807-C107
16 points
DC output Not fused 32 points A0D32A A03B-0807-C162
module NEG
Fused 8 points AOD08C A03B-0807-C151
NEG
8 points AOD08D A03B-0807-C152
POS
Not fused 16 points AOD16C A03B-0807-C153
NEG
16 points AOD16D A03B-0807-C154
POS
32 points AOD32C A03B-0807-C155
NEG
32 points AOD32D AO3B-0807-C156
POS
AC output module 5 points, 2 A AOA05E A03B-0807-C157
8 points AOA08E A03B-0807-C158
1A
12 points AOA12F A03B-0807-C159
0.5 A
Relay output module 8 points AOR08G A03B-0807-C160
4A
16 points AOR16G A03B-0807-C161
2A
Analog input module AAD04A A03B-0807-C051
Analog output module ADA02A A03B-0807-C052
1. OVERVIEW
MARMMTRBL02303E
1–34
1.10.2 The process I/O printed circuit board provides communication between the
R-J controller on various peripheral devices.
Process I/O Board
Refer to Table 1–10 for The process I/O board uses:
part numbers.
 Discrete input lines - Inputs are 24 volt sensing receivers. Common
voltage can be selected as +24VDC or ground.
 Discrete output lines - Outputs are 24 volt sinking or sourcing

devices.
 Analog input lines - Analog inputs are A – D converters sensing an

analog signal –10VDC to 0V or 0V to +10VDC, providing a digital
signal to the processor.
 Analog output lines - Analog outputs are D – A converters that

output an analog signal –10VDC to 0V or 0V to +10VDC based on a
command from the processor.
Figure 1–29. Process I/O Printed Circuit Board
1. OVERVIEW
Figure 1–30. Process I/O Printed Circuit Board
Refer to Chapter 10, “Board Adjustments,” for the location of the output
drivers.
1. OVERVIEW
MARMMTRBL02303E
1–36
Table 1–10. Process I/O Board Part Numbers

Number of I/O
No. Name Part Number Points Remarks
DI DO D/A A/D
1 Process I/O printed circuit board AA A16B-2200-0780 40 40 2 4 Standard (with welding interface)
2 Process I/O printed circuit board AB A16B-2200-0782 40 40 — — Standard (without welding interface)
3 Process I/O printed circuit board BA A16B-2201-0510 32 32 2 4 Source type DO (with welding
(weld interface) interface)
A20B-2000-0540
4 Process I/O printed circuit board BB A16B-2201-0510 32 32 — — Source type DO (without welding
interface)
5 Process I/O printed circuit board CA A16B-2201-0470 40 40 2 4 Backplane installation type (with
welding interface)
6 Process I/O printed circuit board CB A16B-2201-0472 40 40 — — Backplane installation type (without
welding interface)
7 Process I/O printed circuit board DA A16B-2201-0480 96 96 — — Backplane installation type (without
welding interface)
1. OVERVIEW
MARMMTRBL02303E
1–38
1.11 The SYSTEM R-J controller is supplied with either a fused flange
disconnect or a circuit breaker.
FUSED FLANGE
DISCONNECT AND
CIRCUIT BREAKER
1.12 The SYSTEM R-J controller is supplied with a fused flange disconnect.
FUSED FLANGE
DISCONNECT
Fused Flange Disconnect The fused flange disconnect provides overcurrent protection supply
through three fuses; one for each leg of the 3–phase supply. See
Refer to Table 1–12 for fuse Figure 1–31.
sizes, current rating, and part
numbers.
Circuit Breaker The circuit breaker provides overcurrent protection to the controller and
the supply. The circuit breaker is available with or without ground fault
protection. See Figure 1–32.
Refer to Table 1–11 and The fused flange disconnect and the circuit breaker also provide a means
Table 1–12 for current rating for shutting off power to the controller and locking the power out.
and part numbers.
WARNING
CONNECTED to a power source. Be extremely careful to
avoid electrical shock.
Turning the disconnect or circuit breaker to the OFF

position removes power from the output side of the device
only. High voltage is always present at the input side
whenever the controller is connected to a power source.
WARNING
Turning the disconnect to the OFF position removes power

from the output side of the device only. High voltage is
always present at the input side whenever the controller is
connected to a power source.
1. OVERVIEW
Figure 1–31. Fused Flange Disconnect
MAIN
DISCONNECT Fuse Block
FL1 FL2 FL3
Figure 1–32. Circuit Breaker
1. OVERVIEW
MARMMTRBL02303E
1–40
Table 1–11. Circuit Breaker, B-Size Cabinet
Input Circuit Breaker Circuit Breaker with Ground

Voltage Fault
Current Part Number Current Part Number
220 A60L-0001-0347
50A 30A A60L-0001-0306 #BA
240 #B030S
380
416
460 A60L-0001-0347
30A 20A A60L-0001-0306 #AA
480 #B015S
500
550
575 A60L-0001-0258
15A Not Available
#SA538-15
Table 1–12. Circuit Breaker and Fused Flange Disconnect Switch, C-Size
Cabinet
Circuit Breaker Circuit Breaker with Ground Fused Flange Disconnect Switch
Input Fault
Voltage Fuse
Current Part Number Current Part Number Part Number
Size
A60L–0001-0181 #175
220
50A A60L–0001-0308 #F050 50A A60L–0001-0306 #DA 5A Fuse A60L–0001-0042
240
#JG2-50
380
416
460 A60L–0001-0347 A60L–0001-0307
30A 30A A60L–0001-0181 #175
480 #B030S #B20B3
500 30A Fuse A60L–0001-0042
550 #JG1-30
A60L–0001-0258
575 20A Not Available
#SA53H-20
Table 1–13. Fused Flange Disconnect Switch, C-Size Cabinet

Fused Flange Disconnect Switch
Input
Voltage Fuse
Part Number
Size
220 A60L–0001-0181 #175
50A
240 Fuse A60L–0001-0042 #JG2-50
380
416
460
480 A60L–0001-0181 #175
30A
500 Fuse A60L–0001-0042 #JG1-30
550
575
1. OVERVIEW
1.13 C-size controllers might contain an optional user transformer. It supplies

120VAC single-phase power to a NEMA outlet receptacle. It is located on
USER TRANSFORMER
the lower left side of the controller.
A80L-0001-0520
Figure 1–33. User Transformer
User Transformer
TF2
Pushbuttons and LEDs on the Operator Panel are used to control the robot
1.14
OPERATOR PANEL
and to indicate robot status. It might be equipped with one or both of the
following:
Refer to Table 1–12 for part
numbers.
 Remote CRT/KB port for connecting a terminal to the controller.
 DB–25 connector for serial interface (external disk drive, for example)
 Disconnectable teach pendant port with a switch so the robot can be

operated without the teach pendant connected.
1. OVERVIEW
MARMMTRBL02303E
1–42
An emergency stop button on the operator panel places the robot into the
emergency stop condition. The operator panel LED functions are
described in Chapter 3, “Lights and LEDs”.
Figure 1–34 shows the operator panel on a B-size controller. Figure 1–35
shows the operator panel on a C-size controller.
Figure 1–36 shows the operator panel on a C-size controller.
Figure 1–34. Operator Panel, B-Size Controller

TEACH PENDANT BATTERY
ENABLED FAULT ALARM ON
Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ
HOUR METER
RS–232–C CRT/KB FAULT RESET HOLD CYCLE START

OFF
USER LED#1 USER LED#2 REMOTE

Ñ Ñ
Ñ Ñ Ñ Ñ
EMERGENCY
Ñ
Ñ
Ñ
Ñ Ñ Ñ Ñ Ñ
STOP
USER PB#1 USER PB#2 REMOTE
Ñ Ñ Ñ Ñ Ì Ñ Ñ Ñ
LOCAL
Ñ Ñ Ñ Ñ Ì Ñ Ñ Ñ
Figure 1–35. Operator Panel, C-Size Controller

BATTERY
ALARM
CYCLE START ON
Ñ Ñ
TEACH PENDANT
ENABLED
Ñ Ñ
HOLD OFF
Ñ
FAULT
Ñ
FAULT RESET
Ñ Ñ
USER LED#1 REMOTE
Ñ Ñ
REMOTE
USER PB#1
Ñ Ñ Ì
LOCAL
Ñ Ñ
USER LED#2 Ì
USER PB#2
Ñ
Ñ Ñ
HOUR METER
RS–232–C CRT/KB
EMERGENCY STOP
Ñ Ñ Ñ
Ñ Ñ Ñ
1. OVERVIEW
Figure 1–36. Operator Panel, C-Size Controller
BATTERY
ALARM CYCLE START ON
Ñ Ñ
TEACH PENDANT
ENABLED
Ñ Ñ
HOLD OFF
FAULT
Ñ
Ñ Ñ
PURGE
FAULT RESET COMPLETE REMOTE
Ñ Ñ Ñ
PURGE ENABLE REMOTE

Ñ Ñ Ñ
LOCAL
Ñ Ñ Ì Ì
PURGE
FAULT
Ì Ì
BRAKE ENABLE
ON
Ñ Ñ
HOUR METER
Ñ Ñ Ì Ì
OFF
RS–232–C CRT/KB TEACH PENDANT

CONNECT/
Ì Ì
DISCONNECT Optional
EMERGENCY STOP
Ñ Ñ
Ñ Ñ
Ñ Ñ
Table 1–14. Part Numbers

Controller Without Disconnectable With Disconnectable Teach
Teach Pendant Pendant
B-Size A05B-2302-C020 A05B-2302-C021
C-size with Built-In A05B-2301-C001 A05B-2301-C003
CRT/KB
C-size with A05B-2301-C002 A05B-2301-C004
Remote CRT/KB
Table 1–15. Part Numbers

Controller Without Disconnectable With Disconnectable Teach
Teach Pendant Pendant
C-size with Built-In A05B-2308–H190 A05B-2308–H192

CRT/KB
C-size with A05B-2308–H191 A05B-2308–H193
Remote CRT/KB
1. OVERVIEW
MARMMTRBL02303E
1–44
1.15 The teach pendant is a hand held device used for operating and
programming the robot. Keys on the teach pendant are used to enter data,
TEACH PENDANT
jog the robot, and to display menus.
Refer to Table 1–17 for The pendant has a liquid crystal display 16 lines long by 40 characters
part numbers. wide. The teach pendant also has an emergency stop button that places the
robot into an emergency stop condition.
A deadman switch is mounted on the back of the teach pendant. It must be
held in while the teach pendant is turned on. If it is released while the
teach pendant is turned on, the robot will enter a fault condition similar to
emergency stop.
WARNING
The robot will become fully functional and capable of being
started at the operator panel if the teach pendant is turned
off and the fence circuit is not installed or closed. When
working in the robot envelope, ALWAYS CARRY THE
TEACH PENDANT and ALWAYS HAVE THE TEACH
PENDANT ENABLED.
Seven of the keys on the teach pendant provide different functions

depending on the software in the controller. Eleven LEDs display status of
the system. LEDs are different based on software operating in the
controller. When a non–intrinsic safe teach pendant is used, there are
eleven LEDs that display status of the system. LEDs are different based
on software operating in the controller.
Refer to Chapter 3, “Lights and LEDs,” for an explanation of the LEDs.
The teach pendant used with the P-155 robot is an Intrinsically Safe
device. It is powered by 8VDC, converted from 24VDC by the Intrinsic
Barrier unit, part number A20B-1005-0240, mounted on the rear of the
enclosure front door.
1. OVERVIEW
Figure 1–37. Teach Pendant
LCD Display
LEDs
Emergency Stop
Button
DEADMAN
Switches
Application-Dependant Keys
Table 1–16. Teach Pendant Part Numbers

Application Part Number
Intrinsically Safe A05B-2308-H300
Non–Intrinsically Safe A05B-2301-H305
CAUTION
The
safe intrinsically
teach pendantsafeare
teach
not pendant and the non-intrinsically
interchangeable and will damage
the controller, teach pendant cable, and teach pendant if the
incorrect model is attempted to be used.
Teach Pendant Intrinsically The teach pendant Intrinsically Safe Barrier PCB is mounted to the inside
Safe Barrier PCB of the cabinet door. The two main connectors, CRS1 and CRS2 join the
A05B–2308–C040 intrinsically safe teach pendant with the Main CPU. It is used to ensure
that there not be enough energy to induce a spark within the teach pendant.
This is accomplished by lowering the voltage and limiting current to the
teach pendant through the use of Intrinsically Safe Barrier’s (refer to
Section 1.19) and opto-isolation chips.
Table 1–17. Teach Pendant Part Numbers

Application Part Number Comment
Spot Welding A05B-2301-C300 Japanese
Material Handling A05B-2301-C301
Arc Welding A05B-2301-C302
Sealing A05B-2301-C303
General Use A05B-2301-C305
1. OVERVIEW
MARMMTRBL02303E
1–46
Table 1–17. (Cont’d) Teach Pendant Part Numbers

Application Part Number Comment
Spot Welding A05B-2301-C310 English
Material Handling A05B-2301-C311
Arc Welding A05B-2301-C312
Sealing A05B-2301-C313
General Use A05B-2301-C315
1. OVERVIEW
1.16 The temperature in the controller is kept within operating range through
the use of an air-to-air heat exchange system. The controller is sealed to
HEAT EXCHANGE AND
FANS prohibit outside air from entering. Internal controller air is circulated by
fans around the inside of the controller and downward through the internal
side of the heat exchange unit. Outside air is circulated upward through
Refer to Figure 1–39 for the external side of the heat exchange unit also by using a fan. This
part numbers process cools the inside air.
Fans are provided on the printed circuit board racks mounted on the
backplane to circulate air over the printed circuit boards.
Cooling fins connected to the servo amplifiers are within the heat
exchange unit to keep the heat generated by the servo power circuits out of
the controller.
Figure 1–38 shows the heat exchange system for a B-size controller.
Figure 1–39 shows the heat exchange system for a C-size controller.
Figure 1–39 shows the heat exchange system for a C-size controller.
Figure 1–38. Heat Exchange System, B-Size Controller
FAN 1
Fan Unit
A05B-2302-C901
FANS Fan (Alone)
A90L-0001-0219 #A
AIR FLOW
INTERNAL AIR
OUTSIDE AIR
FAN 3 FAN 2
Fan Unit Fan Unit
A05B-2302-C902 A05B-2302-C900
Fan (Alone) Fan (Alone)
A90L-0001-0213 #A OUTSIDE AIR IN A90L-0001-0213 #A
1. OVERVIEW
MARMMTRBL02303E
1–48
Figure 1–39. Heat Exchange System, C-Size Controller
Fan (Alone) FAN 1

A90L-0001-0378 Fan Unit
A05B-2301-C901
Fan (Alone)
A90L-0001-0219 #A
AIR FLOW
INTERNAL
AIR
OUTSIDE
FANS AIR
FAN 2
Fan Unit
A05B-2302-C900
Fan (Alone)
A90L-0001-0213#A
FAN 3 OUTSIDE AIR IN
Fan Unit
A02B–0056-C904
Fan Alone
A90L-0001-0219 #A
1.17 The IBRC is an intrinsically safe barrier unit that is used as part of the
purge system required in the P-155 robot. It has ten photo-isolated relays.
PURGE SYSTEM
It provides an intrinsically safe barrier for the following signals:
IBRC
 PS-1 Pressure Switch #1 (used for the robot purge system)
A152–0001–0020  FS–1 Flow Switch #1 (used for the robot purge system)
 FS–2 Flow Switch #2 (used for opening device purge system)
 ROT/FOT Robot Overtravel Switches (FOT is not applicable)
 PS–3 Pressure Switch #3 (used for opening device purge system)
 EOAT 1 & 2 Not presently used
 AUX HBLD Auxiliary Hand Broken (used with Color Trak System)
 HBKD Hand Broken (used when a collision detect device is installed)
 TPCO Teach Pendant Connect/Disconnect (used when a remote
pendant port is installed in the paint booth. Connected to a
connect/disconnect switch mounted on the pendant port)
1. OVERVIEW
The IBRC requires 210VAC from a secondary winding of TF1 to operate.

Internal circuitry provides 20VDC to the hazardous side terminals which
are isolated from the safe side terminals and their voltage of 24VDC.
There are ten red LEDs, one for each device used in the field. There are a
pair of terminals, labeled Px and Nx, for each hazardous signal, while the
corresponding safe side terminals have Ax, Bx, and Cx. Cx is the 24VDC
input, and Ax and Bx are the normally open and normally closed contact
outputs respectively. When voltage is being applied to the field switch
device contacts and they are closed, the IBRC LED will be illuminated for
that particular contact. Should a jumper be installed across the P and N
terminals, the LED for those terminals will be illuminated.
With plant air supplied to the robot, and power available to the IBRC
through the disconnect switch in the ON position, PS-1 LED should be
illuminated.
1.18 The Purge Unit Power Supply is a 24VDC auxiliary power supply used
exclusively for the purge system. It is mounted alongside the IBRC unit.
PURGE UNIT POWER
It provides voltage necessary to energize the purge solenoid valve within
SUPPLY the robot and opening devices when applicable. It also provides 24VDC to
A05B–2308–C040 the relay coils mounted on the piggy-back Purge Control PCB in the EMG
module.
It requires 210VAC supplied by TF1 and is internally fused by two fuses
mounted on the power supply PCB itself, F-11 and F-12.
1.19 The Intrinsically Safety Barriers (ISB) are mounted to the left of the IBRC
unit. They are used in the purge system similar to the IBRC unit, in that
INTRINSICALLY SAFE
they restrict power that may cause a spark. The solenoid of the purge
BARRIERS (STAHL) valve requires 24VDC, and is internally located within the robot cavity.
The internal atmosphere is to be considered hazardous prior to purging,
ISBM890131280XX therefore an Intrinsically SafeBarrier device is used to prevent possible
sparking. Two of these devices will be used if opening devices are also
incorporated with the robot; one for the robot purge solenoid valve, and
the other for the opening device purge solenoid.
They are similar to a fuse. If one should be found defective, it must be

replaced by a known good Intrinsically Safe Barrier, discarding the
defective one.
1. OVERVIEW
MARMMTRBL02303E
1–50
WARNING
When replacing this Stahl Intrinsically Safe Barrier device, pay
careful attention to exact model or part number. Many models
appear physically identical, but have different power ratings.
Also, careful observance of which end of the device is

considered to be the “SAFE” side, or the “HAZARDOUS” side
is critical. Typically the end with the “Blue” colored cap should
be connected to the device located in the HAZARDOUS zone.
1.20 The Transit Board is a PCB mounted on the internal side of the R-J
TRANSIT BOARD controller cabinet, equipped only with connectors and associated cabling
that route control signals and data to various locations within the P-155
A05B–2308–C030 R-J controller. It is a passive device used for interfacing purposes.
2
DIAGNOSTIC SCREENS
Various built–in diagnostic screens reveal important information regarding

the status of the SYSTEM R-J Controller. These screens with
explanations of the screen data are presented in this section.
Figure 2–1. Default Power–Up Screen
UTILITY Hints JOINT 10 %

MENUS – Provides a list of all menus.
FCTNS – Provides helpful functions.
SELECT, EDIT, DATA, POSN, I/O, STAT –
Displays menus with those names.
Function keys with [] show more
choices.
F1 [ TYPE ] function key lists related
screens with a menu.
[ TYPE ] HELP
OFF ON
DATA Key
Examine and change
MENUS Key data register contents
Used to select the
teach pendant menus
EDIT Key
Used to edit a
particular program
SELECT Key
Used to SELECT and
create programs
The UTILITY Hints screen, shown in Figure 2–1, is the first screen to
appear in the menu structure; this is the starting level to the rest of the
diagnostic screens.
[TYPE] function keyMost
will operations beginwithin
show submenus by pressing MENUS.
any menu shownThe F1,
on the
screen.
This chapter contains information about the following diagnostic screens:
 Safety signals
 Position display
 Robot Axes – motion
 Alarm log
 Version IDs
 Memory
2. DIAGNOSTIC SCREENS
2–2 MARMMTRBL02303E
2.1 The STATUS Safety signal screen displays the status of safety-related
control signals coming into the controller.
SAFETY SIGNAL
STATUS The safety signal screen displays the current state (TRUE or FALSE) of
each safety signal. You cannot change the condition of the safety signal
using this screen. Table 2–1 lists and describes each safety signal. Use
Procedure 2–1 to display safety signal status.
Table 2–1. Safety Signals
SAFETY
DESCRIPTION
SIGNAL
SOP E-Stop Indicates whether the EMERGENCY STOP button on the operator panel has been pressed. The
status is TRUE if the operator panel EMERGENCY STOP button has been pressed.
TP E-Stop Indicates whether the EMERGENCY STOP button on the teach pendant has been pressed. The
status is TRUE if the teach pendant EMERGENCY STOP button has been pressed.
Ext E-Stop Indicates whether an external emergency exists. The status is TRUE if the external emergency stop
contacts are open on the emergency control PCB (EMG) and the following conditions exist:
 SOP E-STOP is FALSE
 TP E-Stop is FALSE
 Hand Broken is FALSE
 Overtravel is FALSE
If any one of these conditions is TRUE, Ext E–Stop is displayed as FALSE even though the external
emergency stop switch could be open.
Fence Open Indicates whether the safety fence switch is open. The status is TRUE if the safety fence terminals
are open on the emergency control (EMG) PCB. This does not require the teach pendant to be
enabled.
TP Deadman Indicates whenDEADMAN

TRUE if either either the left or right
switch teach pendant DEADMAN switch is pressed. The status is
is pressed.
TP Enable Indicates whether the teach pendant ON/OFF switch is ON. The status is TRUE when the teach
pendant ON/OFF switch is ON.
Overtravel Indicates whether the robot has moved beyond its overtravel limits. The status is TRUE when the
robot has moved beyond its overtravel limits tripping the overtravel switch.
Low Air Alarm Indicates whether the air pressure has decreased below the acceptable limit. Low Air Alarm is
usually connected to an air pressure sensing device. The status is TRUE when the air pressure is
below the acceptable limit. You must set the $PARAM_GROUP[1].$PPABN_ENBL system variable
to TRUE to use this signal.
Procedure 2–1 Displaying Safety Signal Status
Step 1 Press MENUS.

2 Select STATUS.
3 Press F1, [TYPE].
4 Select Safety Signal. You will see a screen similar to the following.
STATUS Safety JOINT 10 %

SIGNAL NAME STATUS 1/10
1 SOP E–Stop:
SOP E–Stop: TRUE
2 TP E–Stop: FALSE
3 Ext E–Stop: FALSE
4 Fence Open: FALSE
5 TP Deadman: FALSE
6 TP Enable: FALSE
7 Hand Broken: FALSE
8 Overtravel: FALSE
9 Low Air Alarm FALSE
10 Belt Broken: FALSE
[ TYPE ]
2.2 The POSITION screen displays positional information in joint angles or

Cartesian coordinates. The positional information on this screen is
POSITION STATUS
updated continuously when the robot moves. You cannot change the
displayed information using this screen.
NOTE E1, E2, and E3 indicate extended axis positional information if
extended axes are installed in your system.
Joint The joint screen displays positional information in degrees for each robot
axis. Tool indicates the number of the active tool frame.
User The user screen displays positional information in Cartesian coordinates

based on the user frame. Tool indicates the number of the active tool
frame. Frame indicates the number of the active user frame.
World The world screen displays positional information in Cartesian coordinates

based on the world frame. Tool indicates the number of the active tool
frame.
Use Procedure 2–2 to display position status.
Procedure 2–2 Displaying Position Status
Step 1 Press MENUS.

2 Select POSITION.
3 Select the appropriate coordinate system.
 For joint, press F2, JNT. You will see a screen similar to the
following.
POSITION JOINT 10 %
Joint Tool: 1
J1: .001 J2: 10.028 J3: –35.025

J4: –.000 J5: 34.998 J6: .001
E1: .001 E2: .001 E3: .001
[ TYPE ] JNT USER WORLD
NOTE E1: , E1:, and E3 are displayed only if you have extended axes.
 For user, press F3, USER. You will see a screen similar to the
following.
POSITION USER 10 %
User Frame: 0 Tool: 1
Configuration: F, 0, 0, 0
x: 1906.256 y: .041 z: 361.121
w: 178.752 p: –89.963 r: 1.249
E1: .001 E2: .001 E3: .001
 For world, press F4, WORLD. You will see a screen similar to
the following.
POSITION WORLD 10 %
World Tool: 1
Configuration: F, 0, 0, 0
x: 1906.256 y: .041 z: 361.121
w: 178.752 p: –89.963 r: 1.249
E1: .001 E2: .001 E3: .001
2.3 The robot axes status screen displays information for each robot axis. This
information is continually updated. Use this information when you call
ROBOT AXES STATUS
the FANUC Robotics Hotline if a problem occurs with your robot.
The Axis Status Pulse screen displays information about axis motion.
Table 2–2 lists and describes each kind of information displayed on this
screen.
Use Procedure 2–3 to display the axis status pulse screen.
Table 2–2. Axis Status Pulse Screen Items
ITEM DESCRIPTION
Motion Displays the desired value of the Absolute Pulse Coder (APC) when the robot gets to the position
Command commanded by the controller.
Machine Pulse Shows the actual APC count as read by the controller.
Position Error Displays the difference between the commanded APC count versus the actual APC count.
You cannot change any information on this screen except for the group
number. Group number only applies if you have multiple groups;
otherwise, it remains as 1.
Procedure 2–3 Displaying the Axis Status Pulse Screen
Step 1 Press MENUS.
2 Select STATUS.
3 Press F1, [TYPE].
4 Select Axis.
5 Display the status screen you want:
 For Pulse, press F4, PULSE.
STATUS JOINT 10 %
GRP [ 1]
Position Machine Motion
J1:
Error Pulse Command
J1: 0 00000000 0
J2: 0 00000000 0
J3: 0 00000000 0
J4: 0 00000000 0
J5: 0 00000000 0
J6: 0 00000000 0
[ TYPE ] STATUS1 STATUS2 PULSE GRP# >
MARMMTRBL02303E
2–8
2.4 The Alarm Log displays a list of the 100 most recent alarms. Figure 2–2
shows an example of the Alarm Log.
ALARM LOG
Figure 2–2. Alarm Log
1 SRVO–049 OHAL 1 alarm (Group=1 Axis=6)
PROGRAM LINE 4
2 Alarm JOINT 10%
1/100 4
1 SRVO–049 OHAL 1 alarm (Group:1 Axis:6)
1
3 2 SRVO–042 MCAL 1 Alarm (Group:1 Axis:6)
3 R E S E T
[ TYPE ] CLEAR HELP
The areas of the Alarm Log are as follows:
1. This is the most recent alarm message. This message will be

displayed in this line regardless of the screen you choose.
2. Indicates the program name and line number of program last having
been acted upon.
3. Lists all of the alarm messages, up to 100, with the most recent alarm
on the top of the list. When the RESET key is pressed, a RESET is
logged on the alarm message screen.
4. Indicates the line number the cursor is on in proportion to how many

lines numbers available.
Use Procedure 2–4 to display the Alarm Log.
Procedure 2–4 Displaying the Alarm Log
Condition  An error has occurred.

Step 1 Press MENUS.
2 Select ALARM.
3 Press F1, [TYPE].
4 Select Alarm Log. The alarm log will be displayed. This lists all
errors. See the following screen for an example.
SRVO–002 Teach pendant emergency stop

TEST1 LINE 15 ABORTED
Alarm WORLD 100 %
1/100
1
1 SRVO–002 Teach pendant emergency sto
2 SRVO–001 Operator panel emergency st
3 R E S E T
4 SRVO–029 Robot calibrated (Group:1)
5 SRVO–001 Operator panel emergency st
6 SRVO–012 Power fail recovery
7 INTP–127 Power fail detected
8 SRVO–047 LVAL alarm (Group:1 Axis:5)
9 SRVO–047 LVAL alarm (Group:1 Axis:4)
10 SRVO–002 Teach pendant emergency sto
[ TYPE ] CLEAR HELP

The most recent error is number 1.
5 To display the motion log, which lists only motion-related errors,
press F1, [TYPE], and select Motion Log.
6 To display the system log, which displays only system errors, press
F1, [TYPE], and select System Log.
7 To display the application log, which displays only
application-related errors, press F1, [TYPE], and select Appl Log.
8 To display more information about an error, move the cursor to the

error and press F5, HELP. The error help screen displays information
specific to the error you selected. When you are finished viewing the
information, press PREV.
9 To remove all of the error messages displayed on the screen, press
F4, CLEAR.
2.5 The STATUS Version IDs screen displays information specific to your
controller. Use this information when you call the FANUC Robotics
VERSION
IDENTIFICATION Hotline if a problem occurs with your controller. You cannot change the
information displayed on this screen. Table 2–3 lists and describes the
STATUS version identification status information.
Table 2–3. Version Identification Status Items
VERSION ID ITEM DESCRIPTION
Appl/Tool The name of the application package.

Appl/Tool ID The version number of the application package.
Robot Model The robot model name, the torque on the wrist, and the type of wrist.
S/W Serial Number The software order number for the disk set.
Core Name The name of the core software.

Core ID The version number of the core software.
Library Name The name of the robot library.
Library ID The version number of the robot library.
Servo Code ID The version of servo parameters installed.
Mot Param ID The software version for the software that controls motion
Update #1–10 The name and software version for which a post-release software update has been
installed.
Build ID Internal software version information.
Use Procedure 2–5 to display version identification status.
Procedure 2–5 Displaying the Version Identification Status
Step 1 Press MENUS.

2 Select STATUS.
3 Press F1, [TYPE].
4 Select Version ID. You will see a screen similar to the following.
STATUS Version ID JOINT 10 %

ITEM: SOFTWARE:
1 Appl/Tool: Std System Core
2 Appl/Tool ID: V3.06P
3 Robot Name: S500–INLN
4 S/W Serial Number: F00000
5 Core Name: Std System Core
6 Core ID: V3.06
7 Library Name: Std Robot Library
8 Library ID: V3.06P
9 Servo Code ID: J03.00
10 Mot Param ID: V1.00
11 Update #1: Uninitialized
20 Update #10: Uninitialized

21 Build ID: V3.06 02/13/9X
[ TYPE ] SOFTWARE MOT_ID MOT_INF SER_PAR
5 Press the key that corresponds to the version ID status screen you want
to display:
 To display software version information, press F2,
SOFTWARE.
 To display motor types for each axis, press F3, MOT_ID. You
will see a screen similar to the following.
STATUS Version IDs JOINT 10 %

GRP: AXIS: MOTOR ID: 1/16
1
1: 1 1 AC20
2: 1 2 AC20F
3: 1 3 AC20F
4: 1 4 AC10
5: 1 5 AC10
6: 1 6 AC10
7: * * Uninitialized
 To display the motor information for each axis, press F4,

MOT_INF. You will see a screen similar to the following.

GRP: AXIS: MOTOR INFO: 1/16
11: 1 1 H1 DSP1–L
2: 1 2 H2 DSP1–M
3: 1 3 H3 DSP2–L
4: 1 4 H4 DSP2–M
5: 1 5 H5 DSP3–L
6: 1 6 H6 DSP3–M
 To display the servo parameters for each axis, press F5,

SER_PAR. You will see a screen similar to the following.

GRP: AXIS: SERVO PARAM ID: 1/16
1
1: 1 1 PO1.00
2: 1 2 PO1.00
3: 1 3 PO1.00
4: 1 4 P01.00
5: 1 5 PO1.00
6: 1 6 P01.00
2.6 The STATUS Memory screen displays information about controller

memory. Table 2–4 lists and describes each memory status item. Use
MEMORY STATUS
Procedure 2–6 to display memory status.
Table 2–4. Memory Status
MEMORY STATUS DESCRIPTION
User Indicates the amount of memory for user programs: teach pendant programs and KAREL
programs.
 Total indicates the original size of the memory area.
 Free indicates how much memory is available.
 Largest Free indicates the largest contiguous segment of available memory.
System Indicates the amount of memory for system information: F–DICT (dictionary files that
define what is displayed on the screens), F-PROG (application, operating system, and
option files), and C-WORK (temporary memory used for system operations).
 Total indicates the original size of the memory area.
 Free indicates how much memory is available.
 Largest Free indicates the largest contiguous segment.
Hardware Indicates the total amount of memory in FROM and CMOS RAM.
Procedure 2–6 Displaying Memory Status
Step 1 Press MENUS.

Select STATUS.
2
3 Press F1, [TYPE].
4 Select Memory. You will see a screen similar to the following.
STATUS Memory JOINT 100 %

USER TOTAL FREE LRGST FREE
KAREL 2921.0KB 2062.0KB 1939.9KB
TPE 150.0KB 71.2KB 70.1KB
SYSTEM
F-DICT 320.0KB 18.2KB 18.2KB
F–PROG 512.0KB 91.3KB 91.3KB
C–WORK 1023.9KB 552.8KB 547.6KB
HARDWARE
FROM 2.0MB
CMOS 4.0MB
[ TYPE ]
3
LIGHTS AND LEDS
This chapter describes the lights and LEDs you can use for diagnostics:
 Teach pendant LEDs
 Operator panel LEDs
 Circuit board diagnostic LEDs
3. LIGHTS AND LEDS

MARMMTRBL02303E
3–2
3.1 The non-intrinsically safe teach pendant has several LEDs to assist you in
determining the status of the controller. Figure 3–1 shows the teach
TEACH PENDANT
DIAGNOSTIC LEDS pendant LEDs. Table 3–1 lists and describes the teach pendant LEDs.
The LEDs whose labels are blank vary depending on the particular
application.
On the Intrinsically Safe Teach Pendant, these LEDs are simulated by
symbols on the teach pendant display.
Refer to the Setup and Operations Manual for your application for
information on application-specific LEDs.
Figure 3–1. Teach Pendant LEDs
Ñ Ñ
FAULT
Ñ
Ñ
Ñ
Ñ
Ñ
Ñ
HOLD
STEP
Ñ Ñ
BUSY
RUNNING
Application-
Ñ Ñ
Ñ Ñ
Specific Ñ
Ñ
Ñ
Ñ
LEDs
Ñ Ñ
JOINT
Ñ
Ñ
Ñ
Ñ
XYZ
Ñ
Ñ
Ñ
Ñ
TOOL
OFF ON
Table 3–1. Teach Pendant Status Indicators
INDICATOR DESCRIPTION
FAULT Indicates that a fault condition has occurred.

HOLD Indicates that the robot is in a hold condition. HOLD is not on continuously during a hold condition.
STEP Indicates that the robot is in step mode.
BUSY Indicates that the controller is processing information.
RUNNING Indicates that a program is being executed.
JOINT Indicates that the current jog coordinate system is JOINT.
XYZ Indicates that the current jog coordinate system is WORLDFRAME, JOGFRAME, or USERFRAME.
XYZ Indicates that the current jog coordinate system is JOG frame or WORLD.
TOOL Indicates that the current jog coordinate system is TOOL.
3. LIGHTS AND LEDS
3.2 The operator panel has several LEDs to assist you in determining the
status of the controller. Figure 3–2 shows the operator panel LEDs.
OPERATOR PANEL
DIAGNOSTIC LEDS Table 3–2 lists and describes the operator panel LEDs.
Figure 3–2. Operator Panel LEDS
BATTERY
ALARM
CYCLE START ON
Ñ
TEACH PENDANT
ENABLED
Ñ
HOLD OFF
Ñ
FAULT
Ñ
FAULT RESET USER LED#1 REMOTE

Ñ Ñ Ñ
USER PB#1 REMOTE

Ñ Ñ Ñ
Ñ Ñ Ì Ì LOCAL
USER LED#2
Ì Ì
Ñ
USER PB#2
Ñ
HOUR METER
Ñ Ñ
RS–232–C CRT/KB
EMERGENCY STOP
Ñ Ñ Ñ
Ñ Ñ Ñ
Ñ Ñ Ñ
3. LIGHTS AND LEDS

MARMMTRBL02303E
3–4
Figure 3–3. Operator Panel LEDS

BATTERY
ALARM CYCLE START
Ñ Ñ
ON
TEACH PENDANT
Ñ Ñ
Ñ
ENABLED
HOLD OFF
Ñ Ñ Ñ
FAULT
Ñ Ñ Ñ
PURGE
Ñ
FAULT RESET
Ñ
COMPLETE REMOTE
Ñ Ñ Ñ Ñ
PURGE ENABLE REMOTE

Ì Ì
LOCAL
Ì Ì
PURGE
Ñ Ñ
FAULT
Ñ Ñ
BRAKE ENABLE
Ñ
ON
Ñ
HOUR METER
Ñ Ñ Ì Ì
OFF
TEACH PENDANT
RS–232–C CRT/KB CONNECT/
DISCONNECT Optional
EMERGENCY STOP
Ñ Ñ Ñ
Ñ Ñ Ñ
Ñ Ñ Ñ
Table 3–2. Standard Operator Panel C-Size Controller Status Indicators

INDICATOR DESCRIPTION
BATTERY ALARM Indicates that the backup battery voltage is low. Replace the battery, using
Procedure 9-1.
TEACH PENDANT ENABLED Indicates that the teach pendant is enabled and has motion control.
FAULT Indicates a fault condition has occurred.
REMOTE Indicates that robot motion can only be started by a PLC or other remote device. The
operator panel cycle start pushbutton cannot cause robot motion. This is determined
by the position of the REMOTE/LOCAL keyswitch.
USER LED #1 User-defined and accessible from a KAREL program or macros.
USER LED #2 User-defined and accessible from a KAREL program or macros.
PURGE COMPLETE Identifies that the robot cavities have been purged and are presently at the prescribed
pressure as outlined in the P-155 Mechanical Service Manual.
This LED must be illuminated in order to turn power on to the R-J controller.
PURGE FAULT Indicates a fault exists with the purge system.
PURGE ENABLE PUSHBUTTON Indicates that the purge cycle has started. You can now release the pushbutton if you
are holding it.
POWER ON PUSHBUTTON LED Indicates that the robot is powered on.
CYCLE START PUSHBUTTON LED Indicates that the robot is currently running a program
HOLD Indicates that the robot is in a software hold condition.
3. LIGHTS AND LEDS
3.3 The R–J Controller contains several diagnostic LEDs within the controller.
They are on the circuit boards that plug into the backplane, on the servo
CIRCUIT BOARD
DIAGNOSTIC LEDS amplifiers, and on the modular I/O unit. Figure 3–4 shows an overview of
the circuit board diagnostic LEDs. Refer to the sections that follow for
descriptions of the following circuit board diagnostic LEDs:
 Emergency control board (EMG)
 Power supply unit (PSU)
 Axis control board
 Main CPU board
 Servo amplifier
 Contact signal transducer (IBRC)
 Modular I/O (optional)
 Process I/O board (optional)
 R–H MAP Interface (optional)
 ABRIO printed circuit board (optional)
3. LIGHTS AND LEDS

MARMMTRBL02303E
3–6
Figure 3–4. Circuit Board Diagnostic LEDs
OPTIONAL OPTIONAL I/O

INTERFACE MODULE LEDS
MODULE LEDS Section 3.3.7
Section 3.3.7
OPTIONAL AXIS
PROCESS I/O MAIN CPU PSU BOARD EMG BOARD
CONTROL
BOARD LEDS BOARD LEDS LEDS LEDS
BOARD LEDS
Section 3.3.8 Section 3.3.4 Section 3.3.2 Section 3.3.1
Section 3.3.3
SERVO
AMPLIFIER
DIAGNOSTIC
LED (7–SEG)
Section 3.3.5
3. LIGHTS AND LEDS
Figure 3–5. Circuit Board Diagnostic LEDs
INTERFACE
MODULE LEDS
Section 3.3.7 IBRC LEDS
I/O
MODULE LEDS
Section 3.3.7
OPTIONAL AXIS
KRIO/GEF/MAP MAIN CPU PSU BOARD EMG BOARD
CONTROL
MODULES BOARD LEDS LEDS LEDS
BOARD LEDS
Sections 3.3.10 Section 3.3.4 Section 3.3.2 Section 3.3.1
Section 3.3.3
and 3.3.11
SERVO
AMPLIFIER
DIAGNOSTIC
LED (7–SEG)
Section 3.3.5
3. LIGHTS AND LEDS

MARMMTRBL02303E
3–8
3.3.1 Figure 3–7 shows the emergency control board (EMG) diagnostic LEDs.
Table 3–4 lists and describes each LED.
Emergency Control
Board (EMG) Figure 3–6. Emergency Control Board (EMG) Diagnostic LEDs
Diagnostic LEDs
SON BRKL
BRK1 BRK4
BRK2 BRK5
BRK3 BRK6
FALM
3. LIGHTS AND LEDS
Figure 3–7. Emergency Control Board (EMG) Diagnostic LEDs
BRK4 NOT USED
BRK5 BRK6
FALM
BRK1 SON
BRK2 BRK3
Table 3–3. Emergency Control Board (EMG) Diagnostic LEDs
LED Name Description

SON Servo on When this LED lights, 100 VAC is supplied to the
(Green) servo amplifier MCC coils.
BRK 1* Brake Circuit 1 When this LED lights, axis 1 brake is energized.
(Green) Release
BRK2* Brake Circuit 2 When this LED lights, axis 2 and 3 brakes are
(Green) Release energized.
BRK3* Brake Circuit 3 When this LED lights, axis 4, 5, and 6 brakes are
(Green) Release energized.
FALM Fuse alarm of This LED lights if the brake-fuse is blown or a
(red) the brake circuit voltage spike has occurred. Refer to Servo Alarm
SRVO-008.
BRK4* Brake Circuit 4 When this LED lights, auxiliary axis are energized.
(Green) Release
(Green) Release
3. LIGHTS AND LEDS

MARMMTRBL02303E
3–10
Table 3–3. (Cont’d) Emergency Control Board (EMG) Diagnostic LEDs

(Green) Release
BRKL Manual Brake Brakes are released by the front panel keyswitch
Release
Table 3–4. Emergency Control Board (EMG) Diagnostic LEDs
SON Servo on When this LED lights, 100 VAC is supplied to the
(Green) servo amplifier MCC coils.
BRK 1* Brake Circuit 1 When this LED lights, brake circuit 1 is energized.
(Green) Release
BRK2* Brake Circuit 2 When this LED lights, brake circuit 2 is energized.
(Green) Release
(Green) Release
FALM Fuse alarm of This LED lights if the 100 VAC brake-fuse is blown
(red) the brake circuit or a voltage spike has occurred. Refer to Servo
Alarm SRVO-008.
(Green) Release
(Green) Release
BRK6* Brake Circuit 6 When this LED lights, brake circuit 6 are energized.
(Green) Release
* Refer to robot-specific electrical maintenance for brake connections.
3. LIGHTS AND LEDS
3.3.2 Figure 3–8 shows each power supply unit (PSU) diagnostic LED.
Power Supply Unit
(PSU) Diagnostic LEDs Figure 3–8. Power Supply Unit (PSU) Diagnostic LEDs
PSU
Power Input LED (PIL) LED

This LED lights if 200 VAC is being supplied to the PSU
from Transformer TF1 (Main disconnect is on), if fuses
F1, F2, or F5 (on circuit board) are not blown, and the
power supply internal circuitry is okay.
ALM (Fuse Alarm) LED

This LED will light if fuse F3 is blown and/or there
are any DC power circuit malfunctions.
3. LIGHTS AND LEDS

MARMMTRBL02303E
3–12
3.3.3 The four green status LEDs will also light on the axis control printed
circuit board at power on and then change during software initialization.
Axis Control Board
Diagnostic LEDs See Figure 3–9.
Figure 3–9. Axis Control Board Diagnostic LEDs
1 2 3 4
STATUS
ALARM
Table 3–5 contains supplementary troubleshooting information.
3. LIGHTS AND LEDS
Table 3–5. Troubleshooting Axis Control Board Diagnostic LEDs

LEDs Remarks Procedure
1 2 3 4 Normally, all four green LEDs 1. Replace the axis control board.
STATUS
ALARM come on when the robot is 2. Test FROM* and CMOS from the BMON screen and
turned on. They then turn off
replace as necessary.
and come back on as software
loads and circuits are tested. 3. Reload software if a defective FROM or CMOS is found,
This procedure should only be otherwise replace the main CPU and then reload
used when the four LEDs software.
come on and stay on without
turning off or FLASH.
1 2 3 4 Lights go out and initialization 1. Check the power supply output voltages. Replace if
STATUS of each printed circuit board necessary.
ALARM begins.
2. Replace the axis control board.
3. Test FROM* and CMOS from the BMON screen and
4. Reload software if a defective FROM or CMOS is found,

otherwise replace the main CPU and then reload
software.
1 2 3 4 Timer initialization 1. Test FROM* and CMOS from the BMON screen and
STATUS replace as necessary.
ALARM
software.
1 2 3 4 Initialization of communication 1. Test FROM* and CMOS from the BMON screen and
ALARM
software.
1 2 3 4 Initialization of software 1. Test FROM* and CMOS from the BMON screen and
ALARM
software.
ALARM
software.
ALARM
software.
ALARM
software.
1 2 3 4 Initialization of software 1. Replace the axis control printed circuit board.
STATUS
ALARM
3. LIGHTS AND LEDS

MARMMTRBL02303E
3–14
Table 3–5. (Cont’d) Troubleshooting Axis Control Board Diagnostic LEDs

STATUS
ALARM
software.
1 2 3 4 Communication to teach 1. Replace the teach pendant.
STATUS pendant
ALARM 2. Replace the teach pendant cable.
3. Replace the main CPU.
4. Reload software.
1 2 3 4 Communication to process I/O Turn off controller power. Disconnect the cable from
STATUS or modular I/O connector JD4 of the main CPU and cold start the controller.
ALARM If the light pattern is normal, replace the device that the cable
connects to: process I/O module or modular I/O interface unit.
Otherwise:
1. Replace the I/O connection cable.
3. Reload software.
ALARM
software.
ALARM
software.
1 2 3 4 Teach pendant banner page 1. Replace the teach pendant.
STATUS displayed
ALARM
1 2 3 4 Initialization of software 1. Replace the axis control board.
STATUS
ALARM 2. Test FROM* and CMOS from the BMON screen and
software.
1 2 3 4 Robot is working fine
STATUS
ALARM
3. LIGHTS AND LEDS
Table 3–5. (Cont’d) Troubleshooting Axis Control Board Diagnostic LEDs

1 2 3 4 Servo alarm on Axis Control 1. Replace the Axis Control printed circuit board.
STATUS
ALARM
printed circuit board.
1 2 3 4 (SYSFAIL) 1. If the controller has an ABRIO board or a MAP board,
STATUS Voltage level too low on *EN turn off controller power. Remove the two boards and
ALARM signal cold start the controller. If the light pattern is normal,
replace the ABRIO or MAP board device that the cable
connects to: process I/O module or modular I/O
interface unit.
2. Check the power supply output voltages. Replace if
necessary.
3. Replace the axis control board.
4. Test FROM* and CMOS from the BMON screen and
software.
* The Flash ROM test checks for cleared FROM. If you test FROM you must first
clear the FROM.
NOTE 1: After replacing the main CPU printed circuit board, CMOS RAM modules,
or FROM module, you must perform a complete software load.
NOTE 2: If Axis Control alarm LEDs occur with LEDs on the Main CPU,
troubleshoot the Main CPU alarm LEDs first.
CAUTION
While working with the power supply unit, Main CPU, and axis
control modules, be advised of the following:
 There are static-sensitive devices on the Main CPU and
axis control modules. Wear a grounded wrist strap devices
and observe anti-static safety precautions when handling
this equipment.
 When removing the power supply unit or main CPU, the
battery backup is disconnected and must be reconnected
within 30 minutes or a loss of memory will occur.
3. LIGHTS AND LEDS

MARMMTRBL02303E
3–16
3.3.4 The Main CPU printed circuit board alarm LEDs are shown in
Figure 3–10. Table 3–6 provides supplementary troubleshooting
Main CPU Board
Diagnostic LEDs information.
Figure 3–10. Main CPU Board Diagnostic LEDs
1 2 3 4
STATUS
ALARM
Table 3–6. Troubleshooting Main CPU Board Diagnostic LEDs

1 2 3 4 Parity alarm on CMOS 1. Test CMOS from the BMON screen and replace as necessary.
STATUS
ALARM RAM in the Main CPU. 2. Reload software.
1 2 3 4 The battery voltage that Replace the battery, using Procedure 9–1.
STATUS backs up the MAIN CPU
ALARM CMOS RAM memory is
low.
1 2 3 4 An error is encountered Turn off the controller. Disconnect the cable from connector JD4 of the
STATUS in the serial link. main CPU and cold start the controller. If the light pattern is normal,
ALARM replace the device that the cable connects to: process I/O module or
modular I/O interface unit.
Otherwise:
1. Test FROM and CMOS from the BMON screen and replace as
necessary.
2. Reload software.
1 2 3 4 Normal status Controller should be operational.
STATUS
ALARM
3. LIGHTS AND LEDS
3.3.5 Table 3–7 shows and describes each servo amplifier diagnostic LED.
Servo Amplifier
Diagnostic LED
(7-Segment Display)
Table 3–7. Servo Amplifier LED Functions
Name Indication Description
Overvoltage(HV) An abnormally high DC voltage was detected in the power supply of the main circuit
of the servo amplifier.
Refer to Error code: SRVO-044 for troubleshooting information.

Insufficient voltage of the An abnormally low voltage was detected in the control power supply of the servo
control power supply amplifier. (Rating: +5V)
(LV5V)
Insufficient DC link
voltage (LVDC) An abnormally
of the low DC voltage was detected in the power supply of the main circuit
servo amplifier.

Faulty regenerative The regenerative energy discharge was too large for a short time. This alarm occurs
control circuit (DCSW) when the regenerative energy discharge circuit is defective.

Excessive regenerative The average regenerative energy discharge was too large. This alarm occurs when
discharge (DCOH) the frequency of acceleration and deceleration exceeds a predetermined value.

Servo amplifier overheat The thermostat in the servo amplifier operated. (Thermostat contact opened)
(OH)
Welded electromagnetic The contacts of the MCC contactor in the servo amplifier are stuck together.
contactor (MCC)
Overcurrent (HCL) An overcurrent was detected in the one–axis servo amplifier or the L–axis circuit of
the two–axis servo amplifier.

Overcurrent (HCM) An overcurrent was detected in the M–axis circuit of the two–axis servo amplifier.

Overcurrent (HCLM) An overcurrent was detected in both the L–axis and M–axis circuit of the two–axis
servo amplifier.

Servo amplifier not ready The MCC contactor in the servo amplifier is turned off. The amplifier is unarmed and
cannot drive the motor. See teach pendant display for error code information.
Servo amplifier ready The MCC contactor in the servo amplifier is turned on. The amplifier is armed and
can drive the motor.
NOTE Refer to Chapter 4, Troubleshooting, for more information.
3. LIGHTS AND LEDS

MARMMTRBL02303E
3–18
3.3.6 The LEDs associated with the IBRC are indicators that input terminals P
and N have been closed in the circuit loop for that LED’s channel.
Contact Signal
Transducer (IBRC) Figure 3–11 shows the IBRC.
Figure 3–11. IBRC
3. LIGHTS AND LEDS
3.3.7 The LEDs associated with module I/O are on the interface module printed
circuit board and on each I/O module. Figure 3–12 shows the modular I/O
Modular I/O LEDs
LEDs. Table 3–8 describes each modular I/O LED.
Figure 3–12. Modular I/O LEDs
LEDS
PWR LINK A0 1 2 3 4 5 6 7
BAI LEDS
B0 1 2 3 4 5 6 7
BAO
AIF0IA
JD1B JD1A
CP32 JD2
INTERFACE MODULE I/O MODULE
Table 3–8. Modular I/O LEDs

LED Location Description
PWR Interface ON: The interface module is supplied with
module 24 VDC power.
Link Interface ON: The I/O Link is operating properly.
module Normally, this LED lights several seconds
after the power is turned on.
BA1 Interface
module These LEDs
occurred indicate
in the thatI/O
modular a fault has
system.
BA0 Interface
module
A01234 567 I/O Module Indicates if the input or output is on.

B01234567
3. LIGHTS AND LEDS

MARMMTRBL02303E
3–20
3.3.8 Figure 3–13 shows the process I/O board diagnostic LEDs. Table 7–1
shows and describes each process I/O board diagnostic LED.
(Optional) Process I/O
Board Diagnostic LEDs
Figure 3–13. Process I/O Board Diagnostic LEDs
CB, DA Process I/O AA, AB, BB, BA, CA Process I/O Board
Board (side view) (front view)
ALM0
FALM
1 2 3 4
STATUS
ALARM
Table 3–9. Process I/O Board Diagnostic LEDs

AA, AB, BB, BA, CA CB, DA Color Description
ALM0
Red A communication alarm occurred between the
Process
I/O PCB main CPU and process I/O board. Check
cabling from Main CPU to I/O board. Replace I/O
ALM0 board.
FALM 1 2 3 4
STATUS
ALARM
ALM0
Red A fuse (FUSE 1) in the process I/O board blew.
Process Replace fuse. If fuse blows again, replace board.
I/O PCB
FALM FALM 1 2 3 4
STATUS
ALARM
Green Indicates the operations status of the process I/O

Process board.
I/O PCB
1 2 3 4
STATUS
ALARM
3. LIGHTS AND LEDS
3.3.9 Table 3–10 shows and describes each process I/O board diagnostic LED.
(Optional) Process I/O
Board Diagnostic LEDs Table 3–10. Process I/O Board LEDs
Process A communication alarm

I/O PCB occurred between the
main CPU and process
RED input/output. Check
1 2 3 4
cabling from Main CPU to
1 2 3 4 STATUS
I/O board. Replace I/O
ALARM
STATUS board.
ALARM
Process
I/O PCB A fuse (FUSE 1) in the
process input/output blew.
RED Replace fuse. If fuse
1 2 3 4
blows again, replace
STATUS
ALARM board.
Process
I/O PCB
Indicates the operations
GREEN status of the Process I/O
1 2 3 4
Board.
STATUS
ALARM
3. LIGHTS AND LEDS

MARMMTRBL02303E
3–22
3.3.10 Figure 3–14 shows each R–H MAP Interface LED. Table 3–11 describes
each LED.
R-H MAP INTERFACE
LEDs
Figure 3–14. R–H MAP LEDs
A D
B C
Table 3–11. R-H MAP LEDs

LED Meaning Status
A System fail This LED is briefly turned on during power up/down by the
(RED) MAP interface board. This LED is turned on when a system
failure has occurred in the MAP interface board or other
subsystems in the controller. Therefore, the problem might
not exist with the MAP interface board.
B Not used
C Not used
D Not used
3. LIGHTS AND LEDS
3.3.11 Figure 4–1 shows and Table 3–12 describes the R-H ABRIO LEDs.
R-H ABRIO LEDs Figure 4–1. R-H ABRIO LEDs
POWER
ACTIVE
INTERBRD
FAULT
PC COMM
FAULT
PROC
FAULT
Table 3–12. R-H ABRIO LED Descriptions

LED On Flashing Off
POWER (green) There is power to the ABRIO board. Not applicable There is no power
to the ABRIO
board.
ACTIVE (green) The ABRIO board is communicating with the  The PLC is in PROGRAM or In conjunction
PLC’s remote I/O scanner and the PLC is in TEST mode and the input and with one of the
run mode. Input and output data in the ABRIO output data to the interface is other red LEDs
board is being updated. being updated. being on or
 A No Update condition is flashing indicates
indicated by the PLC remote I/O an interface fault.
scanner. There is no
 Indicates an error in the rack communication
address setup. Error is possibly with the PLC’s
an invalid value or an invalid remote I/O
combination of starting module scanner.
group and rack size settings.

INTERBOARD Communication between the ABRIO board and  An error in communications Normal operation
COMMUNICATION the R-J controller has been broken. This might between the ABRIO board and
FAULT (red) be due to the inability of the ABRIO board to the R-J controller has occurred.
gain access to the Common RAM or a Communication with the PLC’s
checksum error in the R-J output data. remote I/O scanner is stopped.
Communication with the PLC’s remote I/O  The ABRIO board did not
scanner is stopped. detect the R-J controller’s
operational code after power up
or reset.
PC ABRIO board is not communicating properly Not applicable Normal operation
COMMUNICATIONS with the PLC remote I/O scanner. The remote
FAULT (red) I/O scanner might be faulted or a problem
might exist on the serial channel.
PROCESSOR This LED is normally on for Â to 2 seconds This LED flashes along with the No faults exist
FAULT (red) during initialization to indicate that the ABRIO ACTIVE LED to indicate that an with the remote
board is performing its power up diagnostics. invalid rack address has been I/O CPU or
The LED is turned off after diagnostics have set up via the DIP switches on related circuitry.
been completed successfully and the R-J the ABRIO board.
controller’s operation code has been set. If,
after initialization, this LED is on, this indicates
a fault in the ABRIO board hardware (RAM
integrity, EPROM checksum, or CPU watchdog
timeout). Communication with the PLC’s
remote I/O scanner and with the R-J controller
has been stopped. When this LED is on, all
other LEDs except Power should be off.
4
TROUBLESHOOTING
This chapter describes the steps used to repair electrical faults in the robot.
WARNING
The procedures described in this section require you to
work with high voltage circuits. Carelessness or
inattention can kill you. Do not attempt any of these
procedures unless you are trained and experienced in
electrical repair.
Electrical faults are divided into three classes of symptoms:
 A Class 1 Fault is a malfunction that prevents the controller from

operating. The main contactor might or might not be energized. No
text is displayed on the teach pendant.

 A Class 2 Fault is a malfunction that prevents the bootROM from
turning the system over to the application software. Text will be
displayed on the the teach pendant, but the teach pendant display will
be frozen and will not respond to keypad entries.
 A Class 3 Fault is a malfunction that prevents the robot from

operating normally, even though the application software is running.
A numbered alarm message will be displayed on the teach pendant.
You can access teach pendant menus and diagnostic screens during a
Class 3 fault.
If your robot has a class 1 fault, refer to Section 4.1.

4. TROUBLESHOOTING
MARMMTRBL02303E
4–2
4.1 To enable the user with a quick reference guide to powering on a P-155
controller, the following steps and events should be followed:
POWER ON
SEQUENCE
Procedure 4–1 Purge Sequence
Step 1 With the main disconnect ON, you should observe:

 Purge complete LED out
 Purge enable pushbutton (purging) lamp out
 ON pushbutton lamp out
 Purge fault LED on
2 Push and hold the purge enable pushbutton. You should observe
 Purge solenoid engages when minimum pressure requirements are
met.
 Purge fault LED goes out
 Purging lamp (behind purge enable pushbutton) lights.
At this point you can release the purge enable pushbutton, no change
should occur.
3 At the end of the 5 minute purge, the purging lamp (behind the purge
enable pushbutton) will go out and the purge complete LED lights.
Also, the purge solenoid shuts off.
Procedure 4–2 Enabling Power
Step 1 With purge complete, you should observe:

 Purge complete LED on
 Purge enable pushbutton (purging) lamp out
 ON pushbutton lamp out
 Purge fault LED out
2 Push the ON pushbutton. You should observe:
 ON pushbutton lamp lights
 Main CPU and axis control PCBs go through internal diagnostics
At the end of diagnostics the MCC contactor on all servo amplifiers will
energize and “click”. The teach pendant should be energized and the
controller ready to operate manually.
4. TROUBLESHOOTING
4.2 This section contains troubleshooting information for Class 1 Faults.

A Class 1 fault prevents the controller from operating. The main ALC
CLASS 1 FAULT
TROUBLESHOOTING contactor might or might not be energized. The Purge Complete light
might or might not be on. No text is displayed on the teach pendant or
CRT.
How to use the This section contains several tables. Each table provides procedures to
Troubleshooting Tables correct the fault. To troubleshoot a Class 1 fault, always start at
Table 4–4. Perform the procedures in order. You will either correct the
fault using Table 4–4 or it will refer you to another table in this section.
Use the other tables only when Table 4–4 refers you to them.
Class 1 Fault Condition If the following conditions are true, follow the steps in Table 4–4.
 The main disconnect is UP (on).
 The ON button has been pushed.
 The power on sequence (Section 4.1) has been attempted.
 The controller does not operate.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–4
Without turning off the main disconnect, open the controller door:
Release the disconnect latch by turning the screw to the lower right of the
disconnect handle.
Table 4–1. Troubleshooting Procedure 1

Troubleshooting Procedure Illustration Chapter 13
Print Reference
1. Find the Purge Complete light on the SOP. 08–06
 The light is on indicating that the purge cycle was successful. Ï Ï
If the light is on  go to Table 4–5. H

Ï Ï
OL
D
If the light is off  continue.
Purge Ï Ï
Complete
Light Ï Ï
Ï Ï Î
Ï
Ï Ï Î
Ï Ï
Ï Ï
Ï Ï
2. Find the Purge Fault LED on the SOP. 08–06

If the LED is on  go to Step 4. Ï
If the light is out  continue. Ï

H
OL
D
Ï
Purge
Ï Ï
Fault Ï Ï Î
Ï
Ï Ï Î
Ï Ï Ï
Ï Ï Ï
4. TROUBLESHOOTING
Table 4–1. (Cont’d) Troubleshooting Procedure 1

Print Reference
3. Press and hold the Purge Enable pushbutton on the SOP until it 08–05
lights (1 – 5 seconds) and then release. 08–06
 After the purge cycle is completed, the Purge Complete light
Ï
08–10
H
should come on. Ï OL
D
If the Purge Complete light comes on  test the controller for Ï
proper operation.
Ï Ï
If the Purge Enable (purging) or Purge Complete light does

not come on and/or the Purge Fault light comes on 
Ï Ï Î
Purge
continue. Fault Ï
Light
Ï Ï Î
Ï Ï
Ï Ï
Ï Ï
4. Turn off the power disconnect handle.

5. Connect jumper wires between terminals P1 and N1, and 08–21
between terminals P2 and N2 on the IBRC. 08–22
 These terminals are the inputs for the robot-mounted air 08–34
pressure and air flow switches. 08–35
 If opening devices are used, you will also need to jumper 08–25
between P3 and N3, and P5 and N5. These auxiliary 08–26
inputs are for the pressure switch and flow switch for an
opener.
6. Turn on the power disconnect handle.
7. Press and hold the Purge Enable pushbutton on the SOP until 08–05
it lights (1 – 5 seconds) and then release.
 If the purge circuit is cycling, the purge enable lamp (purging) 08–08
should stay lit until the 5 minute purge is complete. The
Purge Fault LED will be out.
 If the purge enable (purging) lamp does not stay lit, replace
the purge control PCB (piggy-back to EMG control PCB).
 If the purge enable (purging) lamp will not light, go to Table
4–2. 08–11
 If, during the purge cycle, the Purge Fault LED lights, go to
Table 4–2. 08–06
 If, after the 5 minute purge cycle, the Purge Complete light
comes on, locate and repair the break in the air pressure
and/or air flow switch circuits to the robot.
 If the purge is too long or too short, the timer on the purge 09–43
control PCB is incorrectly set or damaged. Repair or replace
it.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–6

Print Reference
1. Observe on the IBRC Unit that:

 Red lights on the IBRC panel indicate that 200 VAC is
supplied to it.
If all of the lights are off  continue.
If one or more of the lights are on  go to Table 4–3.
2. Measure the AC voltage coming into the IBRC unit. 07–10

 You should see 200 – 240 VAC. TF1
If the voltage is OK  replace the IBRC Unit. 43 44
If there is no voltage  troubleshoot the AC power distribution R S 1

FRA
2
circuit shown at the right.
G R S
CONTACT SIGNAL
TRANSDUCER IBRC
20VDC PSU
15ma MAX.
(+) (−)

Print Reference
1. Observe the LEDs of channels 1 and 5 on the IBRC unit. If 08–19
either of these LED’s are out it implies that one or more cavities of
the robot is missing minimum air pressure. In the case of channel 08–26
5, if there are no auxiliary pressure switches, it could be that the
jumper across terminals P5 and N5 has come loose.
 Check that there is sufficient maintenance air at the robot.
 Check cables between robot and controller.
If LED’s 1 and 5 are lit  continue.
If either LED 1 and 5 are out  go to Step 8.
2. Turn off the power disconnect handle.

3. Reseat the following connectors: 08–19 thru
 Contact signal transducer (IBRC) connector CRX 08–43
 Purge transit board connector CRX3
 Purge transit board connector CRX1 09–25 thru
 Purge control PCB (mounted with EMG control PCB) 09–50
connector CRX.
4. Turn on the power disconnect handle.
4. TROUBLESHOOTING

Print Reference
5. Observe on the SOP that: 08–10

 Purge fault LED is lit Ï
H
Ï OL
D
Ï
Ï Ï
Ï Ï Î Î
Purge
Fault Ï
Ï Ï Î
Ï Ï Ï
Ï Ï Ï
Ï Ï Ï
6. Re-initiate the purge sequence. See Section 4.1.
If the controller does not operate properly, continue.

7. Measure the DC voltage between the white and black wires in 08–15
the wiring harness at connector CRX5 (A1 and A2) of the Transit
Board.
 You should see 24 VDC.
If the voltage is OK  go to Step 10.
If there is no voltage  replace the Purge Power Supply Board
(PSU2).
Note: The Purge Power Supply Board (PSU2) contains two
fuses that can be checked after the board is removed from the
controller.
If you wish, you can perform the following steps after the board
is removed:
1. Check the fuses.
2. If a fuse is bad, replace it and reinstall PSU2.
3. If a fuse blows again, replace PSU2.
8. If, on the IBRC unit, channel 5 LED is out, jumper terminals P5 08–25
to N5 and observe if the LED lights.
If the LED does not light  replace the IBRC unit.
If the LED lights  repair the auxiliary flow switch or wiring for
proper operation or replace the jumper when auxiliary flow
switch is not used.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–8

Print Reference
9. If channel 1 LED is out, jumper terminals P1 to N1 and observe 08–21

if the LED lights.
If the LED does not light  replace the IBRC unit.
If the LED lights  repair the flow switch or wiring for proper
operation.
10. Repair or replace the following in the order shown:
 Purge enable switch
 IBRC unit
 Purge control PCB (mounted piggy-back on the EMG control
PCB)
 Cable 2003-T526 (1.6M) between SOP (CRX) and transit
board (CRX2)

Cable 2003-T233 (2M) between purge control PCB and
IBRC unit.

Print Reference
1. Find the green PIL light in the center of the PSU module. PSU Module 02–18
 The light is on indicating 200VAC to PSU through F5.
02–16
If the light is on  go to Table 4–3.
If the light is off  continue. 02-19
F1 and F2: 10-A fuse
for AC input
PIL: Green LED

power supply status
2. Check fuses F1 and F2 in the top center of the PSU module. If PSU Module 02–08
no flag shows, turn off power. Pull fuses F1 and F2 from the PSU
and check the fuse with an ohmmeter. 02–10
 A white flag in the center of the fuse indicates it is bad. F1 & 02-8
2 monitor incoming 200VAC to PSU.
If fuse(s) are good, go to step 4, otherwise continue. 02-10
F1 and F2: 10-A
fuses for AC
input
4. TROUBLESHOOTING

Print Reference
3. If one or both of the fuses are bad  02–18 thru

a. Turn off power at the main disconnect switch. 02–23
b. Unplug CP2 and CP3.
c. Replace any bad fuse(s). 02–19
d. Turn the main disconnect switch on, but do not press the 02-18 thru 02-22
ON button.
If the fuse(s) blow again  Replace the PSU.
If the PIL light comes on  go to step 8.
4. Disconnect CP1 at the top of the PSU module. Measure the PSU Module 02–08 thru 02–10
voltage coming into the PSU on the two red wires in the harness 02-08
connector (S and R).
CP1
 You should see 200VAC. 3 G
If the voltage is ok  Continue. 2 S
1 R
If no voltage  go to Table 4–2.
5. Turn the main disconnect off, pull the PSU module out and PSU Module 02–15
remove the fuse, F5, (located near the middle of the printed circuit 02-16
board).
F5: 0.3-A Fuse

for auxiliary
power supply
6. Using an ohmmeter, check fuse. 02–15

If the fuse is good  Replace the PSU. 02-16
If the fuse is bad  Continue.
7. Replace fuse F5, insert the PSU module, and turn on the con- PSU Module
troller.
If the class1 fault is still present  replace the PSU
F5: 0.3-A Fuse

for auxiliary
power supply
4. TROUBLESHOOTING
MARMMTRBL02303E
4–10

Print Reference
8. If the PIL light is on, PSU Module 02-19

Turn off the main disconnect switch and, using an ohmmeter, 02–18 thru
test for a short in the wiring harness at CP2 and CP3. 02–23
02-18 thru 02-22
F1 and F2: 10-A

fuses for AC
input
9. If no short is evident, reconnect CP2 and CP3 and turn the

main disconnect switch on. Press the Power ON pushbutton and
check for proper operation.
10. If the PIL light goes out, fuse(s) F1 and/or F2 have blown 02–09
again due to a short in one of the following: 01–26
 Wiring harness to ALC relay coil 02–09
02–03 thru
 ALC relay coil 02–08
 Wiring harness to fans (check in particular where cable and
front door hinge point meet).
 Fan motor shorted. 02-08
Repair short, replace fuse(s) and go to Step 9. 01-26
If the PIL light stays on, check controller for proper operation.
02-08
02-22
4. TROUBLESHOOTING

Print Reference
1. Measure the AC voltage between Multi–tap transformer termi- Multi-Tap Transformer 01-22
nals 43 and 44 of TF1.
43 44
 You should see 200 VAC.
If voltage is present  Replace or repair harness between
PSU and transformer.
F4 F5
If voltage is not present or incorrect  Continue. 5A 5A
2. Check transformer tap settings. 01-14

 As shown in Section 1.9. (Should be Plant 3-phase voltage)
If the tap settings are incorrect  Correct.
If the tap settings are correct  Continue.
3. Check AC voltage between transformer primary terminals. 01-14

 Plant 3-phase voltage.
If voltage proper is present  Replace multi-tap transformer.
If incorrect or no voltage is present  Continue.
4. Check AC voltage between bottom terminals of FL1, FL2, & Fuse Block 01-05,
FL3. FL1 FL2 FL3 01-07,
 Plant 3-phase voltage. 01-09
If voltage is present  Replace or repair wiring harness
between transformer and fuse unit.
If voltage is not present  Continue.
5. Check AC voltage between top terminals of FL1, FL2, and FL3. 01-05,
 Plant 3-phase voltage. 01-07,
01-09
If voltage is present  F1, F2, F3 is/are blown. Replace bad
fuse. If it blows again, replace the multi–tap transformer.
6. Check AC voltage between terminals at bottom of main discon- 01-05,
nect switch. Main 01-07,
 Plant 3-phase voltage. Disconnect 01-09
If voltage is present  Replace or repair wiring harness Switch
between fuse unit and main disconnect switch.
7. Check AC voltage between terminals at top of disconnect. FL1, FL2, FL3 01-05,
 Plant 3-phase voltage. 01-07,
01-09
Replace main disconnect switch if voltage is present;
otherwise, contact plant maintenance.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–12

Print Reference
1. Check the red alarm light in the center of the PSU module. PSU Module 02-14
 The alarm light should be off.
If the light is ON  Go to Table 4–10.
If the light is ON  Go to Table 4–11.
If the light is OFF  Continue. ALM: Red LED
F4: 5-Afuse for +24E
F3: 5-AS slow–blow

fuse for +24V
2. Check the LED displays on the servo amplifier. 08-24 thru 08-26
If any LED is on  Go to Table 4–13 . 09-23 thru 09-25
08-09 thru 08-12
If any LED is on  Go to Table 4–5.
09-11 thru 09-13
If no LEDs are on  Continue.
10-11 thru 10-13
4. TROUBLESHOOTING

Print Reference
3. Listen and look for main cabinet cooling fans to be running. 02-02 thru 08-08
 Fans should be running indicating 200VAC to ALC relay. 02-02 thru 02-08
If fans are not running  Continue. FAN 1
FRONT REAR
If fans are running  Go to step 5.
FAN 2
FAN 3
CONTROLLER SIDE VIEW
4. Check for 200 VAC at CP2 or CP3. PSU Module 02-18 thru
 You should see 200 VAC ±10VAC. 02-21
If there is 200VAC  Repair the wiring to the fans and the ALC 02-18 thru 02-22
relay and check the controller for proper operation.
If there is not 200VAC  Go to step 8.
5. Check for 200VAC at ALC relay on A1 & A2. 01-25, 01-27

 You should see 200VAC ±10VAC. A1 A2
If voltage is not correct or missing  Repair the wiring
harness coil between the PSU and the coil of the ALC relay.
Check the controller for proper operation. 1 3 5
If voltage is present  Continue. ALC
2 4 6
4. TROUBLESHOOTING
MARMMTRBL02303E
4–14

Print Reference
6. Check for 200VAC at the ALC relay between 2 & 4, 4& 6, and 2 Multi-Tap Transformer 01-27
& 6. 01-22
 You should see 200 VAC. 01-27
If voltage is not correct or missing  Check fuses F1, F2,
and F3. If the fuses are ok, replace the multi–tap transformer.
If voltage is present  Turn power off and repair wiring F1 F2 F3
between ALC contactor and servo amplifiers.
A1 A2
13 23
31 1 3 5 41
ALC
32 2 4 6 42
14 24
7. Check the connector CRR4 on the EMG module for jumpers 02-06
between terminals 10 (EX-COM) and 12 (EX-OFF) and terminals 02-28 thru 02-33
14 (DIL1) and 16 (DIL2).
 If you use an external OFF button or door interlock, there will CRR4
be a wire on each terminal. 1 100OUT3
2 EMGOU2
If the terminals
loose aregood
screws and connected with a jumper wire check for no
contact. 3 100OUT4
4 EMGOUTC
5 FENCE1
If an external OFF button or door interlock is used  Test for 6 EMGOUT1
continuity of the external OFF, and DIL circuits, and repair it if 7 FENCE2
8 EX-ON
necessary. 9 0V
10 EX-COM
11 0V
12 EX-OFF
13 —5v
14 DIL1
15 —15V
16 DIL2
17 -15V
18 EMGB1
19 +24V
20 EMGB2
4. TROUBLESHOOTING

Print Reference
7. Check the connector on the EMG module for jumpers between 02-28 thru 02-33
terminals 32 (EX-COM) and 31 (EX-OFF) and terminals 30 (DIL1)
and 29 (DIL2).
 If you use an external OFF button or door interlock, there will
be a wire on each terminal.
If the terminals are connected with a jumper wire check for
loose screws and good contact.
If an external OFF button or door interlock is used  Test for
continuity of the external OFF, and DIL circuits, and repair it if
necessary.
2
3
9
2
8. On the EMG board, connect 10 (Ex-COM) to ground with a 02-28 thru 02-33
jumper wire; then momentarily connect 8 (Ex–ON) to
10 (Ex-COM).
 Controller should turn on.
If the controller turns on  There is a break in the on/off
switch circuit. Repair or replace.
If the controller does not turn on  Replace the PSU module.
PSU 02-16
9. On the Power Supply Unit, momentarily jumper the following
connections:
 CP4 connector terminal 1 (ON) to CP4 connector terminal 3
(COM)
 CP4 connector terminal 3 (COM) to ground
 The controller should turn on.
If the controller turns on  there is a break on the ON/OFF
switch circuit. Repair or replace.
If the controller does not turn on  continue.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–16

Print Reference
1. Check fuse F3 at the bottom of the PSU. PSU Module 02-24
 A white flag in the center of the fuse indicates it is bad and 02-23
that 24 power is missing.
If the fuse is blown  There might be a short circuit in one of
the following:
ALM: Red LED
Backplane for indicating an
24VDC Cooling Fans for module card cage alarm
Process I/O 24 VDC supply
CRT/KB
Main CPU Module F4: 5-Afuse for +24E
Axis Module
Modular I/O 24 VDC supply
Option #1 F3:
fuse5-AS slow-blow
for +24V
Option #2
Extended Backplane
 Isolate the short and repair it.
If the fuse is good  Continue. See NO TAG.
2. Turn off the controller. Measure the resistance between the 06-24 thru 06-36
following terminals of CRR4 on the EMG module:
Terminal 9 (0V) and Terminal 15 (+15)
Terminal 9 (0V) and Terminal 17 (–15)
Terminal 9 (0V) and Terminal 13 (+5) CRR4
1 100OUT3
 Look for greater than 100 ohms at each measurement. 2 EMGOU2
If all readings are ok  Replace the PSU. 3 100OUT4
4 EMGOUTC
If all readings are not ok  Continue. 5 FENCE1
6 EMGOUT1
7 FENCE2
NOTE A low reading means shorted power to ground 8 EX-ON
9 0V
through or because of an EMG, Main CPU, PSU, Fence, 10 EX-COM
or Axis board. Remove them one at a time until you get 11 0V
12 EX-OFF
a normal reading. Replace the defective board. 13 —5v
14 DIL1
15 —15V
16 DIL2
17 -15V
18 EMGB1
19 +24V
20 EMGB2
4. TROUBLESHOOTING

Print Reference
2. Turn off the controller. Measure the resistance between the EMG
following terminals on the EMG module: 09–34
Ground and Terminal 39 (–15) 09–32
Ground and Terminal 38 (+15) 09–31
Ground and Terminal 40 (+5)
 Look for greater than 100 ohms at each measurement.
If all readings are ok  Replace the PSU.
If all readings are not ok  Continue.
NOTE A low reading means shorted power to ground 40

39
through or because of the Main CPU, PSU, Fence, or 38
Axis board EMG. Remove them one at a time until you

get a normal reading. Replace the defective board.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–18
Figure 5–1. 24 Volt (24E) Power Distribution Chart
4. TROUBLESHOOTING

Print Reference
1. Turn the power disconnect switch on and press the power on 06-25
pushbutton. Check the lights on the operator panel. 06-29
 Any light on indicates 24E to the operator panel. This can
Ï
Ï
H
also be checked by measuring for 24VDC between terminals Ï
O
L
5 and 9 of the EMG connector CRR4. D
If any light is on  Go to Table 4–14.

Ï
Ï Ï
If the lights are not on  Continue.

Ï Ï Ï Î Î
Ï
Ï Ï Ï
Ï Ï
Ï Ï
1. Turn the power disconnect switch on and press the power on

pushbutton. Check the lights on the operator panel. Ï
 Any light on indicates 24E to operator panel. This can also H

be checked by measuring for 24VDC between terminals 62
Ï
O
L
and Ground of the EMG control PCB. Ï
Ï
D Ï
If any light is on  Go to Table 4–15. Ï Ï Ï Ï Î Î Ï
If the lights are not on  Continue. Ï Ï Ï

Ï
Î Î
Ï
Ï Ï Ï
Ï Ï
Ï Ï
2. Check fuse F4 at the bottom of the PSU module. If no flag PSU Module 02-23
shows, check the fuse with an ohmmeter. 02-31
 White flag in the center of the fuse indicates it is bad. 02-23
If the fuse is good  Replace the PSU 06-25
06-29
If the fuse is bad  Continue.
ALM: Red LED for
indicating an alarm
F4: 5-Afuse for +24E
F3: 5-AS slow-blow

fuse for +24V
4. TROUBLESHOOTING
MARMMTRBL02303E
4–20

Print Reference
3. Turn off power, disconnect fence circuit or remove jumper, and EMG 09-50
connect an ohmmeter between Fence1 terminal 36 and Ground
on the EMG module.
 If it does not show continuity (greater than 500 ohms),
replace fuse F4 and check the controller for proper
operation.
 If it does show continuity (less than “10 ohms”), a
component is shorted, loading the 24E voltage supply.
0V 56
0V 55
36
3. Turn off power, disconnect fence circuit or remove jumper, and 06-25
connect an ohmmeter between Fence1 and 0V (CRR4 pin5 & 9 or
11) on EMG module.
 If it does not show continuity (greater than 500 ohms), CRR4
replace fuse F4 and check the controller for proper 1 100OUT3
operation. 2 EMGOU2
3 100OUT4
 If it does show continuity (less than 500 ohms), a 4 EMGOUTC
component is shorted, loading the 24E voltage supply. 5 FENCE1
6 EMGOUT1
7 FENCE2
8 EX-ON
9 0V
10 EX-COM
11 0V
12 EX-OFF
13 —5v
14 DIL1
15 —15V
16 DIL2
17 -15V
18 EMGB1
19 +24V
20 EMGB2
4. To find the shorted component, watch the ohmmeter while you
disconnect or remove the following parts in order:
 Main CPU
 Axis
 Option #1
 Option #2
 EMG
 Cards on the extended backplane one at a time
 If
OK.the Ifohmmeter showsshows
the ohmmeter greater than500
under 500ohms,
ohms,the
thepart
partisis
defective.
If it still does not work  Follow the short out to the failed
component and replace. See Figure 5–2.
4. TROUBLESHOOTING
Figure 5–2. 24 Volt (24V) Power Distribution Chart
4. TROUBLESHOOTING
MARMMTRBL02303E
4–22
Figure 5–3. Tracing a Short on 24E
4. TROUBLESHOOTING

Print Reference
1. Press the ‘‘OFF” button. Press and hold USER PB1 and USER Operator Panel
PB2 and press the ‘‘ON” button.
If the ‘‘BMON>’’ prompt appears  Treat the problem as a
Class 2 Fault; otherwise, continue. Ï Ï
ON
H
O
Ï
Ï
Ï
Ï
L OFF
D
USER Ï Ï
Ï Ï
PB1 Ï Ï Î
Ï
USER
PB2 Ï Ï
Ï Ï
Ï Ï
1. Press the ‘‘OFF” button. Press and hold PURGE ENABLE Operator Panel 08-05
press the ‘‘ON” button. ON 02-13
If the ‘‘BMON>’’ prompt appears  Treat the problem as a
Class 2 Fault; otherwise, continue.
Ï
H
Ï
OL
D
Ï
Purge Ï Ï
Enable
Button Ï Ï Î
Ï
Ï Ï Î
Ï Ï
Ï Ï
Ï Ï
4. TROUBLESHOOTING
MARMMTRBL02303E
4–24

Print Reference
2. If you have not done so already, measure the 24E voltage at

the EMG module connector CRR4 on terminals 5 (FENCE1) and 06-25
9 (0VDC) for 24VDC (±10%). If the 24VE voltage is missing or out 06-29
of tolerance, go to Table 4–12.
CRR4
1 100OUT3
2 EMGOU2
3 100OUT4
4 EMGOUTC
5 FENCE1
6 EMGOUT1
7 FENCE2
8 EX-ON
9 0V
10 EX-COM
11 0V
12 EX-OFF
13 —5v
14 DIL1
15 —15V
16 DIL2
17 -15V
18 EMGB1
19 +24V
20 EMGB2
2. If you have not done so already, measure the 24E voltage at 09–50
the EMG module on terminals 36 and Ground. for 24VDC (±10%). EMG
If the 24VE signal is missing or out of tolerance, go to Table 4–13.
0V 56
0V 55
36
4. TROUBLESHOOTING

Print Reference
3. On the teach pendant, look for any lit LEDs or screen display.
If there is no display  the 24T power supplying the teach 05-23
pendant ISB unit is most likely missing. Visually check the
teach pendant cable K0402003–T908 (10/20M) for damage.
If the 24T signal is missing or out of tolerance the following will
correct the problem. Replace the following, in order, one at a
time:
3 Replace the teach pendant cable.
4 Replace the ISB unit.
5 Replace the EMG module.
6 Replace the Main CPU printed circuit board.
7 Replace the backplane.
4. If there are LEDs or a screen display, there is a communication
fault between the Main CPU printed circuit board and the teach
pendant.
Replace the following in order, one at a time.
 Teach pendant cable
 Teach pendant
 Main CPU module
4. TROUBLESHOOTING
MARMMTRBL02303E
4–26
4.3 A Class 2 Fault is indicated by frozen text (letters or numbers) displayed

on the teach pendant. This situation is an indication of a problem with the
CLASS 2 FAULTS
Main CPU printed circuit board caused by either the memory, processor,
the board itself, or a bad teach pendant cable.
Table 4–16. Class 2 Faults Troubleshooting Procedure

Troubleshooting Procedure
1. Is the Battery light on the main CPU module on?
If the Battery light is on  replace the battery. Refer to Procedure 9–1.
1 2 3 4
STATUS
ALARM
Battery Light
2. Perform a cold start of the controller.

3. Is a red light on the axis control board turned on?
If a red light is on  replace the axis control board.

4. Are all four green LEDs on the axis control board turned on?
If all four green LEDs are on  go to step 5.
If all four green LEDs are not on  troubleshoot the controller using Table 3–5 in Chapter 3, “Lights and LEDs.”
5. Turn the controller off. Hold down Purge Enable pushbutton and press the ON button.
 Check the teach pendant cable by swapping it with a known working cable or by doing a continuity test.
 Does the “BMON>” prompt appear on the teach pendant? If it does not appear, replace the main CPU printed circuit
board and reload software.
CAUTION
Continuing beyond this point will erase all software stored in the controller
including all taught positions in your application. It will also require a software
reload which will take at least two hours. Do not do this unless your controller
actually has a Class 2 fault.
4. TROUBLESHOOTING
Table 4–16. (Cont’d) Class 2 Faults Troubleshooting Procedure

Troubleshooting Procedure
6. Perform the following steps on the teach pendant:
a. Press the NEXT key twice.
b. Press F2, DIAG.
c. Press ENTER.
The prompt changes to DIAG> (diagnostic monitor).
d. Press the NEXT key.
e Press F3, TEST.
f. Press F1, CMOS.
g. Press ENTER.
The teach pendant will display a message that gives you an opportunity to exit without destroying the contents of CMOS
memory.
h. Press 1 if you want to continue with the test.
7. The CMOS memory test will take a few minutes to run. If an error is encountered, an address and good and bad data are
displayed on the teach pendant or CRT/KB. Record the address and refer to following to determine the board that failed.
Error Code Replace Board

F1000000 – F10FFFFF 7MK1 (RAM MODULE) (STANDARD)
F1100000 – F11FFFFF MJ1 (RAM MODULE) (STANDARD)
F1200000 – F12FFFFF MH1 (RAM MODULE) (OPTION)
F1300000 – F13FFFFF MG1 (RAM MODULE) (OPTION)
Replace defective memory boards as necessary and reload software. If the CMOs memory test passes, continue.
8. Perform the following steps on the teach pendant:
a. Press the NEXT key.
b. Press F1, EXIT.

c. Press ENTER.
d. Press the NEXT key.
e. Press F1, CLEAR.
f. Press F2, FROM.
g. Press ENTER.
h. Press the NEXT key.
i. Press F1, EXIT.
j. Press the NEXT key twice.
k. Press F2, DIAG.
l. Press ENTER.
m. Press F3, TEST.

n. Press F4, FROM.
o. Press ENTER.
The teach pendant will display a message that gives you an opportunity to exit without destroying the
contents of Flash ROM memory.
p. Press 1 if you want to continue with the test.
The Flash ROM memory test will take a few minutes to run. If an error is encountered, replace the Flash
ROM board and reload software. Otherwise, continue.
9. The hardware in your controller is OK. Reload your system application software.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–28
4.4 This section contains troubleshooting information for Class 3 Faults. You
are here if the teach pendant displays a fault message on the teach pendant
CLASS 3 FAULT
TROUBLESHOOTING screen.
1. Press the MENU key on the teach pendant.
2. Select ALARM from the menu.
3. Refer to the appropriate subsection in this section and follow the
troubleshooting procedure. The subsections that follow are arranged
in numerical error code order.
4. TROUBLESHOOTING
4.4.1 The operator panel emergency stop push button is pressed.

SRVO-001 ER_SVAL1
Operator Panel E–Stop Remedy: Twist the operator panel emergency stop push button clockwise
to release. Press reset.
If the problem still exists, it is caused by an open circuit in the emergency

stop circuit or a bad Main CPU. Perform the troubleshooting procedure in
the following table.
Table 4–17. SRVO-001 Troubleshooting Procedure
Print Reference
1. Remove and reconnect: Main CPU Printed Circuit Board 03-17
 CN1 on the Operator Interface board 03-28
 CN5 on the Operator Interface board

 JRM5 on the Main CPU
Check for proper operation.
If the problem still exists  go to step 2.
JRM5 connector
Operator Interface Printed Circuit Board
Operator panel,
rear face
CN1 connector
CN3 connector
4. TROUBLESHOOTING
MARMMTRBL02303E
4–30
Table 4–17. (Cont’d) SRVO-001 Troubleshooting Procedure

Print Reference
2. Perform the following steps: 03-17
a. Turn off the controller.
b. At the operator panel emergency stop button,
remove the two blue wires and connect (strap) them
together.
c. Turn on the controller.
If the error message is cleared  replace the
emergency stop button.
If the error message reappears  go to step 3.
E–STOP REAR VIEW

3. Perform the following steps: Main CPU Printed Circuit Board 03-25
a. Replace the cable between connector JRM5 at the
Main CPU module and the operator interface printed
circuit board.
b. Turn on the controller.
If the error message is cleared  check the
controller for proper operation.
If the error message reappears  replace the Main
CPU module.
JRM5 connector
PIN 1
PIN 26
PIN 25
PIN 50
4. TROUBLESHOOTING
Figure 5–4. Operator Panel E-Stop Circuitry
4. TROUBLESHOOTING
MARMMTRBL02303E
4–32
4.4.2 The teach pendant emergency stop push button is pressed.

SRVO-002 ER_SVAL1
Teach Pendant E–stop Remedy: Twist the teach pendant emergency stop push button clockwise
to release. Press reset.
If the problem still exists, it is caused by the loss of 24VDC to the teach
pendant relay RLY2 or the 5 VDC signal to the matrix decoding from the
normally closed contact of the teach pendant relay RLY2.
Any of the following can cause this problem:
 A defective teach pendant emergency stop switch.
 A defective component on the teach pendant printed circuit board.
 Loss of 24VDC to the E-STOP switch (not part of the teach pendant
power).
This loss of power can be caused by a bad teach pendant emergency

stop switch, a broken wire in the teach pendant cable, or a bad EMG
module on relay RL-10. In most cases, you can fix it by replacing the
teach pendant.
If you want to troubleshoot the problem further, perform the following
troubleshooting procedure:

Troubleshooting Procedure Chapter 13
Print Reference
Perform the following steps:
a. Turn off power to the controller.
b. Remove the seven screws holding the teach pendant back in place.
c. Remove the teach pendant back cover.
d. Slide the E-stop wiring connector half way off connector CNEMG1.
e. Carefully energize the teach pendant and measure the DC voltage of CNEMG1 and 15-33
either of the GND test points on the teach pendant.
At pin 2, if there is 24VDC (±5 VDC)  Measure pin 1. If 0VDC, go to step f.
At pin 1, if there is no 24VDC (±5 VDC)  Replace the teach pendant emergency stop
switch.
If voltage is found  Replace the teach pendant.
f. If no voltage is found, replace the teach pendant cable, and test for proper operation. Figure 5–5
g. If the problem still exists, replace the EMG module.
4. TROUBLESHOOTING
Figure 5–5. Teach Pendant E-Stop Circuitry
JRS1 MAIN (RS422/TEACH PENDANT) HONDA High Density

10 +24T
9 TPDSC 8 EMGB2 19 20
18 +24T
EMGTP
7 EMGB1 17
6 0V 16 EMGDM
5 15
4 *TXTP 14 EMGEN
3 TXTP 13
2 *RXTP 12 0V
1 RXTP 11
4 3 2 1
*RXTP RXTP *TXTP TXTP
10 9 8 7 6 5
+24T +24T
16 15 14 13 12 11
EMGB2 EMGB1 EMGEN EMGDM EMGTP
20 19 18 17
0V 0V TPDSC
Teach Pendant
External Connector CN1
Male HIROSE
4. TROUBLESHOOTING
MARMMTRBL02303E
4–34
4.4.3 The teach pendant deadman switch is released while the teach pendant is
enabled.
SRVO-003 ER_SVAL1
Deadman switch Remedy: Press and hold the teach pendant deadman switch. Press reset.
released
If the problem still exists, it is caused by:
 A defective teach pendant deadman switch
 A defective component on the teach pendant printed circuit board
 A possible break in the circuitry between the teach pendant and the
Main CPU.
In most cases, you can fix it by replacing the teach pendant.
If you want to troubleshoot the problem further, perform the following
troubleshooting procedure:

Print Reference
1. Perform the following steps:
a. Remove power from the controller.
15-25
b. Remove the seven screws holding the teach pendant back in place. 15-30
c. Remove the teach pendant back but leave all electrical connectors in place.
d. Press each deadman switch bar while watching the switch body inside the teach pendant.
e. Make sure that the copper strip presses the switch actuator all the way into the switch body.
You should be able to hear and feel it click into place.
If the actuator is frozen or will not click sharply  replace the switch.
2. Perform the following steps for each deadman switch:
a. Slide the wiring connector half way off the circuit board connector. 15-25
15-30
b. Measure the resistance between:
 Pins 1 and 2
 Pins 3 and 4
When the deadman switch is not pressed, there is continuity between pins 1 and 2 and no
continuity between pins 3 and 4
When the deadman switch is pressed, there is no continuity between pins 1 and 2 and
continuity between pins 3 and 4.
If one or more measurements are bad  replace the deadman switch assembly.
If the measurements are good  replace the teach pendant.
4. TROUBLESHOOTING
Figure 5–6. Deadman Switch Circuitry
4. TROUBLESHOOTING
MARMMTRBL02303E
4–36
4.4.4 The motion command after the ramping algorithm in the servo software
exceeded one word. Contact the FANUC Robotics Hotline for more
SRVO-041
MOFAL Alarm information. DO NOT INCLUDE IN MANUAL!!!!!!
(Group:i Axis:j)
4. TROUBLESHOOTING
4.4.5 The safety fence gate is open.

SRVO-004 ER_SVAL1 Remedy: Close the gate. Several gates in the workcell might be
Fence open involved.
If the problem still exists, perform the following troubleshooting
procedure:
Print Reference
1. Perform the following steps to determine if a safety fence is 06-24 thru 06-26
installed:
a. Look at terminals 5 and 7 on the EMG module connector
CRR4. CRR4
b. Check for a jumper connecting the terminals or a wire on 1 100OUT3
2 EMGOU2
each terminal.
3
4 100OUT4
If a jumper is present  go to step 2. EMGOUTC
5 FENCE1
If two wires are present  go to step 3. 6 EMGOUT1
7 FENCE2
8 EX-ON
9 0V
10 EX-COM
2. Measure the resistance between the two terminals. 11 0V
If there is continuity  replace the EMG module. If the 12 EX-OFF
13 —5v
problem still exists, replace the axis control printed circuit 14 DIL1
board. 15 —15V
16 DIL2
If there is no continuity  repair or replace the jumper. 17 -15V
18 EMGB1
19 +24V
20 EMGB2
3. Measure the resistance between the two wires.
If there is continuity  replace the EMG module. If the
problem still exists, replace the axis control printed circuit
board.
If there is no continuity  locate and repair the break in the
safety fence switch circuit between the two terminals.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–38
Figure 5–7. Fence Open Circuitry
4. TROUBLESHOOTING
4.4.6 An overtravel error occurs when one or more of the robot axes move
beyond the software motion limits, tripping an overtravel limit switch.
SRVO-005 ER_SVAL1
Robot Overtravel
Table 4–21. SRVO-005 Troubleshooting Procedure 1
Print Reference
1. If you have not already done so, continuously press and hold 05-08 thru 05-20
the DEADMAN switch and turn the teach pendant ON/OFF switch
to ON.
2. Hold down the SHIFT key and press RESET.
3. Press COORD until you select the JOINT coordinate system.
4. Jog the axis in overtravel off of the overtravel switch.
If you cannot jog the robot off of the overtravel switch  the
wrong motion
the next step. inhibit flag has
Otherwise, thebeen
axis set; therefore,
(or axes) are nocontinue to
longer in
overtravel and you can end the procedure now.
5. Cold start the controller and go to Step 1 in this procedure. If
the overtravel still cannot be cleared, continue to Step 6.
NOTE In some instances, the screen will indicate a FALSE for a
given axis when a TRUE should be set because of the way
overtravel is read in software. It is best to perform the following
procedure on all of the axes.
6. Press MENUS.
7. Select MANUAL FCTNS.
8. Press F1, [TYPE].
9. Select OT Release. See the following screen for an example.
10. Move the cursor to the OT PLUS or OT MINUS value of the
axis in overtravel. The status of OT PLUS or OT MINUS for that
axis is TRUE.
11. Press and hold SHIFT and press F2, RELEASE.
12. Press and hold SHIFT and press RESET.
13. Press COORD until you select the JOINT coordinate system.
14. Continuously press and hold the DEADMAN switch and turn
the teach pendant ON/OFF switch to ON.
15. Jog the axis off of the overtravel switch.
16. Turn the teach pendant ON/OFF switch OFF and release the
DEADMAN switch.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–40
If the problem still exists, it is caused by an open circuit in the overtravel

switch circuit or by a defective axis control board or EMG module.
Try the following steps in order, checking for proper operation after each.
Table 4–22. SRVO-005 Troubleshooting Procedure 2
Troubleshooting Procedure Reference

1. Remove all connectors from the axis control board and reseat them, starting with connector CRM1.
2. If spare boards are available, temporarily replace the EMG board and axis control board.
3. Using the schematic drawings and an ohmmeter, check the overtravel switches in the robot and their
wiring for continuity.
4. Replace the cable between axis control board connector CRM1 and the robot.
Figure 5–8. Robot Overtravel Circuitry
4. TROUBLESHOOTING
4.4.7 A hand breakage error occurs when the hand (wrist) breakage detection
switch or aux hand breakage detection switch is tripped.
SRVO-006 ER_SVAL1
Hand Broken Remedy:
If you are not using the hand broken function, ensure that the HBK
jumper on the axis control printed circuit board is set to the A side.
If you are using the hand broken function, perform the following steps:
1. If you have not already done so, continuously press and hold the
DEADMAN switch and turn the teach pendant ON/OFF switch to ON.
2. Hold down the SHIFT key and press RESET. The robot can now be
moved.
3. Jog the robot to a safe position off of the limit switch.
4. Turn the teach pendant ON/OFF switch to OFF and release the
DEADMAN switch.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–42

procedure:

Troubleshooting Procedure Illustration Reference
1. Remove power from the controller by
turning off the disconnect switch.
2. Test the end effector switch and its wires at

the robot for continuity.
If there is no continuity  replace or repair
the switch or its wires.
If there is continuity  continue.
3. Set the HBK jumper on the axis control

board to the A side and test the robot for
proper operation.
If the fault is fixed  replace the cable
between axis control board connector
CRM1 and the robot. Be sure to reset the
HBK jumper on the axis control board to the
B side.
If the fault is not fixed  replace the axis
control board.
NOTE: When replacing the axis control
module, ensure that the on-board jumpers
on the
the replacement
original board. board match those on
A COM B B HBK A
JUMPER JUMPER
Figure 5–9. Hand Broken Circuitry
4. TROUBLESHOOTING
4.4.8 An external emergency stop button somewhere in the workcell has been
pressed. External emergency stop is signaled whenever the 100V to the
SRVO-007 ER_SVAL1
External emergency servo amplifiers is not present, and the operator panel emergency stop,
teach pendant emergency stop, overtravel, and hand broken signals are not
stops asserted.
Remedy: Locate and release the external emergency stop button. Press
reset on the operator panel or teach pendant.

procedure:
4. TROUBLESHOOTING
MARMMTRBL02303E
4–44

Print Reference
1. Perform the following steps: CRR3

a. Locate terminals 6, 8, and 10 on connector CRR3 of the 1 100IN1
2 OP1
EMG module. 3 100IN2
4 OP2
b. Check for jumpers between: 5 100IN3 03-08, 03-09, 03-10
6 EMGIN1
 6 and 8 7 100IN4
8 EMGINC
 8 and 10 9
10 EMGIN2
or else wires attached to the terminals. Wires indicate that 11 100OUT1
an external emergency stop is EMG 12 100OUT1
13 100OUT2
connected to the controller. 14 100OUT2
15 BKP4
If there is no jumper connecting the terminals or there are 16 BKM4
no wires on each terminal  verify that no external emergency 17 BKP5
18 BKM5
stop should be installed and replace the missing jumper. 19 BKP6
20 BKM6
If a jumper is present or if wires are present  go to step 2.
2. With controller power off, on the EMG module, measure the
resistance on CRR3 between: 03-08, 03-09
 6 and 8
03-09, 03-10
 8 and 10
If there is continuity  go to step 3.
If there is no continuity  repair or replace the jumper or locate
and repair the break in the external emergency stop circuit.
3. With controller power off, on the EMG module, measure the 03-06, 03-07
resistance on CRR3 between terminals 2 and 4.
If there is continuity  go to step 4.
If there is no continuity  verify that the 100VAC contacts on
the operator panel emergency stop button are operating
properly.
4. With controller power on, on the EMG module, measure the AC 03-04
voltage on CRR3 between terminals 1 and 3.
Is the voltage 100VAC  10%?
If the voltage is within tolerance  replace EMG
If the voltage is not within tolerance  go to step 5.
5. With controller power on, measure the AC voltage at transformer Multi-Tap Transformer 01-33, 01-34
TF1, terminals 41 and 42, for
100VAC  10%. 41 42
If the voltage is within tolerance  repair or replace the wiring
between TF1 terminals 41 and 42 and EMG module CRR3
terminals 1 and 3. F4 F5
5A 5A
If voltage is out of tolerance  continue.
4. TROUBLESHOOTING

Print Reference
6. At the ALC relay, terminals 23 and 13, measure again for Multi-Tap Transformer 01-26
100VAC  10%.
If the voltage is within tolerance  check for proper operation A1 A2
of the ALC relay. 13 23
31 1 3 5 41
32 2 4 6 42
14 24
7. Remove power from the controller, and with an ohmmeter test Multi-Tap Transformer 01-23
fuses F4 and F5.
If F4 and F5 are good  transformer TF1 is not outputting 41 42
100VAC on its secondary legs and needs replacing.
F4 F5
5A 5A
4. TROUBLESHOOTING
MARMMTRBL02303E
4–46
Figure 5–10. External Emergency Stop Circuitry
4. TROUBLESHOOTING
4.4.9 Indicates one of two symptoms:

SRVO-008 ER_SVAL  The 5A brake fuse on the EMG module has blown.
Brake fuse blown  A momentary surge of high current was detected in the brake circuit.
The FALM LED on the EMG module will be lit.
Remedy: By turning power off momentarily and then back on you will
reset the circuit and the LED will go out if the fault is caused by a current
surge.
If the fault does not reset or if it reoccurs frequently, perform the

following troubleshooting procedure:

Print Reference
1. Turn off the controller at the main disconnect and open
the cabinet door.
2. Remove all of the connectors on the front of the EMG
module and pull out the module.
3.Check the 5A fuse and replace it if necessary. EMG 03-19
PCB
4. Place the EMG control printed circuit board back in its

slot and plug all connectors back into it.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–48

Print Reference
5. Using an ohmmeter, test the continuity between CRR3
CRR3, terminal 19 and the following points to test for a
shorted brake coil: 1 100IN1
2 OP1
 CRR5 pins 1B, 2B, 3B, 1D, 2D, 3D 3 100IN2
4 OP2 04-10 thru 04-38
 CRR3 terminals – 16, 18, and 20 (extended 5 100IN3
axes only) 6 EMGIN1
7 100IN4
A short or resistance lower than 50 ohms could cause 8 EMGINC
9
the fuse to blow or the sensor to trip. Replace the 10 EMGIN2
motor on the axis with the shorted brake coil. 11 100OUT1
12 100OUT1
If the resistance is OK  continue. 13 100OUT2
14 100OUT2
15 BKP4
16 BKM4
17 BKP5
18 BKM5
19 BKP6
20 BKM6
BRK4 NOT
USED
BRK5 BRK6
FALM
D CB A
BRK1 SON
BRK BRK2 BRK3

CRR5
1 100OUT3
2 EMGOU2
3 100OUT4
4 EMGOUTC
5 FENCE1
6 EMGOUT1
7 FENCE2
8 EX-ON
9 0V
10 EX-COM
11 0V
12 EX-OFF
13 5v
14 DIL1
15 15V
16 DIL2
17 -15V
18 EMGB1
19 +24V
20 EMGB2
CRR4
VIOLET BLUE VIOLET BLUE
BKM3 BKP3 BKM2 BKP2
BKM3
BKM3 BKP3
BKP3 BKM2
BKM1 BKP2
BKP1
6. With the controller door open and all connectors and 03-32
plugs reattached, energize the controller.
If the FALM light comes on  replace the EMG
module.
4. TROUBLESHOOTING

Print Reference
7. Power up the robot and jog the robot to verify robot
operation.
If the FALM light comes on  replace the EMG
module.
9. If this problem occurs occasionally, change the ‘SET’ EMG CONTROL MODULE
jumper from 2 to 1 on the EMG module. 03–37
SENSITIVITY
JUMPER
1
T
E
S
4. TROUBLESHOOTING
MARMMTRBL02303E
4–50
Figure 5–11. Brake Fuse Blown Circuitry
4. TROUBLESHOOTING
4.4.10 Teach pendant deadman switch released while enabled.

SRVO-011
ER_SVAL1 Remedy: Press the deadman switch, then press RESET.
TP Released While
Enabled
4.4.11 Normal power is on (hot start).

SRVO-012
Remedy: This message is normal and does not indicate a problem.
ER_SVAL1
Power Failure
Recovery
4.4.12 One or all of the 24VDC cooling fans in the backplane cage are not
running.
SRVO-014
Fan Motor Abnormal Each double-board board cage in the backplane has a cooling fan mounted
(Group:i Axis:j) in its top. Each fan contains a centrifugal switch that opens when the fan
is not running.

Print Reference
1. With power on, test whether each fan is turning by passing a strip of paper over the top of each
board cage.
All fans are turning  go to step 3.
One fan is motionless  continue.
2. Remove the circuit boards from the board cage with the motionless fan. Reconnect the four-wire
connector on the backplane behind the board cage. Reinstall the boards and power up the controller.
If the fault is not fixed  replace the fan.
3. One of the fans or the axis control board is probably defective. Determine which part is bad by
temporarily replacing it with a known-good part.
If the fault is not fixed  continue.
4.Replace the backplane.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–52
Figure 5–12. Backplane
AXIS BACKPLANE
24V
CA39C
1 +24VDC
5V OPTION 1 & 2 PCB

CA39C COOLING FAN
2 +0VDC
CA39C CENTRIFUGAL
JRA2 3 ALMC
E7−1 6 *FMM 13 ALM
RV IC1−3
(SVRO014
FAN MOTOR CA39B
1 +24VDC
ABNORMAL)
AXIS & MAIN PCB
CA39B COOLING FAN
2 +0VDC
CA39B CENTRIFUGAL
IC1−1 3 ALMB
CA39A
1 +24VDC
EMG & PSU PCB

0V CA39A
2 +0VDC COOLING FAN
CA39A CENTRIFUGAL
IC1−2 3 ALMA
0V
4. TROUBLESHOOTING
4.4.13 The temperature in the controller is too high, or the overheat sensor
located on the backplane has opened.
SRVO-015
ER_SVAL1
System Over Heat
(Group:i Axis:j)

Troubleshooting Procedure Line No. Reference
Chapter 13
1. Clean the controller air filter, allow the controller to cool down, and cold start the controller.
2. Check the heat exchanger fans for operation.
If the fans run ok  replace the axis control board. 02-02
02-04
If one or more fans do not work  continue. 02-07
3. Check the AC voltage at the terminals of the non-working fan(s).
If the voltage is 180VAC – 220VAC  replace the fan(s).
If the voltage is out of tolerance  replace or repair the fan motor wiring harness.
Figure 5–13. System Over Heat Circuitry Drawing 1
4. TROUBLESHOOTING
MARMMTRBL02303E
4–54
Figure 5–14. System Over Heat Circuitry Drawing 2
4. TROUBLESHOOTING
4.4.14 The axis control board sends a signal to the servo amplifiers in order to
energize the MCC contactors and turn on the servo amplifiers. When a
SRVO-021
ER_SVAL1 servo amplifier MCC coil is turned on, it sends a signal back to the axis
control board. If the axis control board sends its signal and does not
SRDY off receive the reply within a few milliseconds, this alarm occurs.
(Group:i Axis:j)
Chapter 13
1. Does the alarm occur on three or more axes? 08-17
YES  repair or replace the wiring harness between the EMG board and terminals 5 and 6 of the 09-18
servo amplifier in the far left position. 10-17
09-01 thru 09-09
NO  continue
2. Disconnect and reseat the signal cable between the axis control board and the affected servo 10-01 thru 10-18
amplifier. If necessary, continue.
3. Exchange the axis control board-to-servo amplifier cable between the affected axis and a known-
good axis. Be sure to switch both ends of the cables.
Does the fault message change to indicate a different axis?

YES  replace the bad cable.
NO  continue
4. Replace the axis control board. If the problem continues, replace the affected servo amplifier.
4.4.15 The axis control board sends a signal to the servo amplifiers in order to
SRVO-022 energize the MCC contactors and turn on the servo amplifiers. When a
servo amplifier MCC coil is turned on, it sends a signal back to the axis
ER_SVAL1 control board. If the axis control board receives the reply signal without
SRDY on having sent its request signal, this alarm occurs.
(Group:i Axis:j)
Chapter 13
1. Exchange the axis control board-to-servo amplifier cable between the affected axis and a known- 09-01 thru 09-09
good axis. Be sure to switch both ends of the cables. 08-01 thru 08-18
10-10 thru 10-18
Does the fault message change to indicate a different axis?
YES  replace the bad cable.
NO  continue
2.Replace the axis control board. If the problem continues, replace the affected servo amplifier.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–56
4.4.16 The axis position is too far from its commanded position when the robot is
stopping, or the robot is stopped and it will not move. The torque
SRVO-023
ER_SVAL1 necessary to decelerate an overloaded motor could cause this alarm to
occur.
Stop Error Excess
(Group:i Axis:j)

Chapter 13
1. Is the load over the specification?
If it is over  Reduce the load.
2. Check for a binding axis. Repair if required.
If the load is within the specification and the axes are not binding  Go to step 3.
3. Is the three phase input voltage lower than the FANUC specification (170V ~253V)? 08-24, 25, 26
If it is lower  The maximum torque of the motor decreases. Increase the input voltage within the 09-23, 24, 25
rated voltage. Check transformer TF1 for proper tap settings. 10-23, 24, 25
4. Replace the servo amplifier.
If the alarm occurs again  Go to step 4.
5. Replace the motor.
4.4.17 The servo error is too big when the robot is moving, or the robot moves
when it is supposed to be stopped.
SRVO-024
ER_SVAL1 Remedy: Same as SRVO-023, Stop Error Excess.
Move Error Excess
(Group:i Axis:j)
4.4.18 The motor cannot rotate as fast as the calculated speed required for the
current motion
SRVO-026
ER_WARN Remedy: Even though this is just a warning, every attempt should be
Motor Speed Limit made to eliminate this error by modifying the programmed speed or
(Group:i Axis:j) motion.
4.4.19 The system variable $master_done is set to FALSE.

SRVO-027
Remedy: Master the robot.
ER_WARN
Robot Not Mastered
(Group:i Axis:j)
4. TROUBLESHOOTING
4.4.20 The system variable $calibrate is set to FALSE.

SRVO-033
ER_WARN Remedy: Calibrate the robot.
Robot Not Calibrated
(Group:i Axis:j)
4.4.21 Joint cannot rotate as fast as the calculated speed required for the current
motion.
SRVO-035
ER_WARN Remedy: Even though this is just a warning, every attempt should be
Joint Speed Limit made to eliminate this error by modifying the programmed or motion
(Group:i Axis:j)
speed.
4.4.22 The robot is not in position for the specified period, or the servo error is in
excess of the commanded position when the robot is stopping, or the robot
SRVO-036
is stopped and it will not move. The torque necessary to decelerate an
Imposition Time Over overloaded motor could cause this alarm to occur.
(Group:i Axis:j)

Chapter 13
1. Is the load over the specification?
If it is over  Reduce the load.
2. Check for a binding axis. Repair if required.
If the load is within the specification and the axes are not binding  Go to step 3.
3. Is the three phase input voltage to the servo amplifier lower than the FANUC specification 08-24, 25, 26
(170V ~253V)? 09-23, 24, 25
If it is lower  Check transformer TF1 for the proper tap setting. 10-23, 24, 25
5. Replace the motor.
4.4.23 IMSTP (immediate stop) UOP input asserted.

SRVO-037
Remedy: If using a UOP, determine the cause and repair. If not using
ER_SVAL1 UOP, select the I/O menus and zero UOP mapping.
IMSTP Input
(Group:i Axis:j)
4. TROUBLESHOOTING
MARMMTRBL02303E
4–58
4.4.24 When the controller was powered up, one or more of its axes was at a
different position from when it was powered off. This might occur when a
SRVO-038
PULSE MISMATCH motor is replaced or when a CPU from one controller is installed in
another.
(Group:i Axis:j)
Remedy: Perform the following procedure:

Chapter 13
1. Press MENUS.
2. Select SYSTEM.
3. Press F1, [TYPE].
4. Select System Variables.
5. Move the cursor to $MCR.
6. Press ENTER.
7. Move the cursor to $SPC_RESET.
8. Press F4, TRUE. The display will reset to false. This is normal.
9. Press RESET.
The fault condition should reset. If the controller is still faulted with additional servo-related
errors, cold start the controller.
It might be necessary to remaster the robot.
4.4.25 The servo amplifier magnetic contactor (MCC) is welded closed. If the
contact of the magnetic contactor is already closed when the contactor is
SRVO-042
turned on, this alarm circuit regards the contact as welded closed and the
ER_SVAL2 MCC alarm occurs.
MCAL Alarm
(Group:i Axis:j)
Chapter 13
1. Does this alarm occur with SRVO-049? 08-24, 25, 26
If SRVO-049 occurs  Check for the absence of input three-phase voltage to the servo amplifer. 09-23, 24, 25
Correct as necessary. 10-23, 24, 25
If SRVO-049 does not occur  Go to step 2

2. Does this alarm occur with the OH1 alarm?
If OH1 alarm occurs  Turn off the controller power for fifteen seconds and turn it on again. If still
present, remove and replace the connector CN1 or CN2 of the problem axis and check its
associated cable and connector at the axis module.
If OH1 alarm does not occur  Go to step 3.
4. TROUBLESHOOTING
4.4.26 The motion command after the ramping algorithm in the servo software
exceeded one word. Contact the FANUC Robotics Hotline for more
SRVO-041
MOFAL Alarm information. DO NOT INCLUDE IN MANUAL!!!!!!
(Group:i Axis:j)
4. TROUBLESHOOTING
MARMMTRBL02303E
4–60
4.4.27 The regenerative energy produced by the motor exceeded the specification.
SRVO-043
ER_SVAL2 NOTE Energy feedback from motor to the amplifier is called regenerative
energy. This occurs when the axis is being slowed down. The amplifier
DCAL Alarm discharges this energy by converting it to heat energy through the
(Group:i Axis:j) discharge resistor. If the charged energy exceeds the discharged energy,
this alarm occurs.
Remedy: Check the LED of the amplifier, then perform the following
troubleshooting procedure.

Print Reference
1. Is “4” or “5” indicated on the servo amplifier 7-segment display?
If indicated  Go to step 2 if “4” is indicated.
Go to step 3 if “5” is indicated.
If not indicated  Check for short to ground or an open circuit in the PWMC line of the specified 08-03, 09-03
axis between the axis control printed circuit board and servo amplifier (connector JV-1 – 7). Swap
11-03, 12-03
the axis control printed circuit board.
2. A “4” is indicated (DCSW alarm) when the regenerative transistor is on continuously for one 11-37, 12-37
second or longer. Reduce the load of the robot. 08-37, 09-37
If the error still exists  Replace the servo amplifier.
3. ‘‘5’’ is indicated (DCOH alarm). The DCOH alarm is caused when the regenerative resistor 11-39, 12-39
overheats and is sensed by the thermostat or the thermostat in transformer TF1 opens. 08-39, 09-39
If the average regenerative energy is excessive  This alarm occurs when the
acceleration/deceleration frequency is high or gravity energy at the axis is large. Relax the
operating conditions.
For robots with extended axes: When a separate regenerative discharge unit or power
transformer for the servo controller is used, check the wiring for the thermostat according to the
connection diagrams for proper wiring.
If the thermostat is incorrectly wired or is defective  When a separate regenerative discharge
unit or power transformer for the servo controller is used, check the wiring for the thermostat
according to the connection diagrams.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–62
4.4.29 The current in the main power circuit of the servo amplifier exceeded
specification. The servo amplifier LED should display “8”, “9”, or “6.”
SRVO-045
ER_SVAL2 Remedy: If no alarm is indicated on the servo amplifier 7-segment
HCAL Alarm display, check the cabling between the servo amplifier (CN1) and the axis
(Group:i Axis:j) control printed circuit board (JV1-10).
procedure:
Print Reference
1. Disconnect the motor power lines from the amplifier terminals and turn on the power. This alarm will 08-24, 25, 26
re-occur if 09-23, 24, 25
 The transistor module (TM) is defective. 10-23, 24, 25
 Resistor R3 has opened or raised resistance.
 The servo amplifier is defective.
If an HCAL alarm occurs  Replace these components as necessary or replace the servo
amplifier.
2. Remove the motor power lines from the amplifier terminals and check the continuity between GND 08-24, 25, 26
and each of the lines U, V, and W that go to the motor. 09-23, 24, 25
If any are short-circuited  Go to step 3. 10-23, 24, 25
If all are not shorted  Go to step 4.

3. Remove the power lines from the motor connectors (J1-6) and recheck the continuity between GND 08-24, 25, 26
and each of the lines U, V, and W to the robot motor. 09-23, 24, 25
If any are shorted  The motor is defective. Replace the motor. 10-23, 24, 25
If all are open  The power lines to the motor are defective. Replace the cable.
4. Remove the motor power lines from the amplifier terminals and measure the resistance 08-24, 25, 26
between U-V, V-W, and W-U on the servo amplifier using a measuring instrument sensitive 09-23, 24, 25
enough to detect small resistances. 10-23, 24, 25
If the three measured values are the same  Go to step 5.
If the three measured values are different  Go to step 6.
5. Remove the power lines from the motor connectors and remeasure the resistance between U-V, 08-24, 25, 26
V-W, and W-U using a measuring instrument sensitive enough to detect small resistances. 09-23, 24, 25
If the three measured values are the same  The power lines are defective. Replace the cable. 10-23, 24, 25
If the three measured values are different  The motor is defective. Replace the motor.
6. Replace the axis control printed circuit board. 08-12, 13
8. Replace the serial pulse coder on the motor.
9. Check whether you are using the robot under conditions that exceed the specification. For
example, load, duty, and so forth. If there is no mechanical reason (binding and so forth) to cause this
alarm, this alarm might occur under conditions that exceed the specification. If you are using the robot
over the specification, relax the operating conditions.
4. TROUBLESHOOTING
4.4.30 The average current calculated by the servo software exceeded

specification.
SRVO-046
ER_SVAL2 Remedy: Reduce the load on the robot.
OVC Alarm
(Group:i Axis:j) If the problem still exists, perform the following troubleshooting
procedure:

Print Reference
1. Is the three-phase AC input power to the servo amplifier lower than 200 VAC? 08-24, 25, 26
If it is lower or missing  Check transformer TF1 taps and fuses. 09-23, 24, 25
10-23, 24, 25
01-15, 16
2. Replace the axis control printed circuit board. 08-11, 12, 13

If the alarm occurs again  The motor is defective.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–64
4.4.31 The DC voltage on the main power circuit of the servo amplifier is lower
than the specification even though the MCC is on.
SRVO-047
ER_SVAL2 Remedy: If no alarm is indicated on the servo amplifier LED, check the
LVAL Alarm cabling between the servo amplifier and the axis control printed circuit
(Group:i Axis:j) board.

procedure:

Print Reference
1. Does the LED of the amplifier indicate ‘‘2’’? 08-23, 24, 25
a. Check for 200VAC input power to terminals 13 and 14 of the servo amplifier. If low or missing, 09-23, 24, 25
check transformer TF1 taps and fuses. 10-23, 24, 25
b. If 200VAC is present, replace the servo amplifier.

2. Does the LED of the amplifier indicate ‘‘3’’? A “3” indicates the DC current in the main power circuit 08-23, 24, 25
is too low 09-23, 24, 25
a. Check the three-phase 200VAC input voltage to the servo amplifier. 10-23, 24, 25
If the voltage is lower than 200VAC Check the transformer TF1 taps and fuses.
b. Did the circuit breaker on the servo amplifier trip? (If a circuit breaker trips, this alarm will occur.)
If a circuit breaker trips  Turn on the breaker. If it trips again, replace the servo amplifier.
3. Does the LED of the amplifier indicate a ‘‘7’’? This alarm could occur when the contact of the
magnetic contactor is melted (welded together).
Refer to the SRVO-042 MCAL Alarm.
4. TROUBLESHOOTING
4.4.32 The servo amplifier overheated. Servo amplifier LED indicates a “6.”
This alarm indicates that the thermal switch mounted on the PC board of
SRVO-049
ER_SVAL2 the specified axis has opened.
OHAL1 Alarm Remedy: Check the fans and the heat exchange unit for proper operation.
(Group:i Axis:j)
procedure:

Print Reference
1. If the servo amplifier 7-segment display shows “–’’, check the cabling between the servo amplifier 08-01 thru 08-08
(CN1) and axis control module (JV1-6). 09-01 thru 09-09
10-10 thru 10-18
2. Relax the operating condition.
If the alarm no longer occurs  The operating condition of the robot exceeded the specification.
3.Replace the servo amplifier.
4.4.33 The servo software detected a disturbance torque that was too high or a
collision occurred and tripped a collision detection alarm.
SRVO-050
ER_SVAL1 Remedy: Reset the robot by using the teach pendant RESET button and
CLALM Alarm jog the robot away from obstructions.
(Group:i Axis:j)
procedure:

Print Reference
1. Does the load exceed the specifications? (When the robot moves over the specifications, the esti-
mated disturbance torque might become larger and this alarm could occur.)
If the load exceeds the specifications Lower the load to within the specifications.
2. Is the three-phase AC input voltage to the servo amplifier lower than the rated voltage (200VAC)? 08-23, 24, 25
If it is lower  Check transformer TF1 taps and fuses. 09-23, 24, 25
10-23, 24, 25
01-38
4. TROUBLESHOOTING
MARMMTRBL02303E
4–66
4.4.34 The feedback current is abnormal.

SRVO-051
ER_SVAL2
CUER Alarm
(Group:i Axis:j)

Print Reference
1. Replace the axis control printed circuit board. 08-11, 12, 13
If the alarm still occurs  Go to step 2.
2. Replace the servo amplifier. If the alarm continues, go to step 3.
3. Replace the pulse coder and master the robot.
4.4.35 The clock for the rotation counter in the pulse coder is abnormal.
SRVO-061
ER_SVAL2
CKAL Alarm
(Group:i Axis:j)

Print Reference
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm?
YES  disregard SRVO_061 and refer to the remedy of any of the other three alarms.
If no alarms occur  Replace the pulse coder on the specified axis and master the robot.
4. TROUBLESHOOTING
4.4.36 The battery voltage for the pulse coders is zero volts.
SRVO-062
ER_SVAL2
BZAL Alarm
(Group:i Axis:j)

Print Reference
YES  disregard the BZAL alarm and refer to the procedure for the other alarm (SRVO_68 –
SRVO_70).
NO  Continue
2. Did this alarm message list only one axis?
YES  Check the battery cable for the pulse coder of the axis listed in the alarm message.
Reconnect, repair, or replace as necessary. Go to Step 4.
NO  Continue
3. Press the teach pendant emergency stop button. Turn the controller on. Check the batteries behind
the black plastic hatch in the base of the controller.
Are the batteries ok?

YES  Repair or replace the battery compartment cable. Go to Step 4.
NO  Replace the batteries. Go to Step 4.
4. a. Press MENUS.
b. Select SYSTEM.
c. Press F1, [TYPE].
d. Select System Variables.
e. Move the cursor to $MCR.
f. Press ENTER.
g. Move the cursor to $SPC_RESET.
h. Press F4, TRUE. The display will reset to false. This is normal.
i. Press RESET. The fault condition should reset. If the controller is still faulted with additional
servo-related errors, cold start the controller.
It might be necessary to remaster the robot.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–68
4.4.37 The built-in rotation counter on the pulse coder is abnormal.

SRVO-063
ER_SVAL2
RCAL Alarm
(Group:i Axis:j)

Print Reference
NO  Replace the pulse coder on the specified axis and master the robot.
4.4.38 The relationship between the analog signals on the pulse coder are
abnormal.
SRVO-064
ER_SVAL2
PHAL Alarm
(Group:i Axis:j)
Print Reference
NO  Replace the pulse coder on the specified axis and master the robot.
4.4.39 The pulse coder batteries are low.

SRVO-065
ER_WARN
BLAL Alarm
(Group:i Axis:j)
Print Reference
NO  Replace the APC backup batteries. Remaster the robot if necessary.
NOTE Replace the battery as soon as possible when this alarm occurs, otherwise, if the battery volt-
age goes to zero volts, the robot will require remastering.
4. TROUBLESHOOTING
4.4.40 The pulse coder ROM checksum data are abnormal.

SRVO-066
ER_SVAL2
CSAL Alarm
(Group:i Axis:j) Table 4–47. SRVO-066 Troubleshooting Procedure
Print Reference
If no alarms occur  Replace the pulse coder on the specified axis and master the robot.
4.4.41 The pulse coder overheated.

SRVO-067
ER_SVAL2
OHAL2 Alarm
Print Reference
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm? 07-22
YES  disregard SRVO-067 and refer to the remedy of any of the other three alarms.
2. Does the operating condition (load, duty) exceed the specifications?
If the operating condition exceeds the specifications  Relax the operating condition within the
specification. (Reduce the load, change the program, etc.)
3. Turn off the controller and when the temperature of the motor returns to normal, turn it back on.
If the alarm immediately occurs again  The built-in thermostat in the pulse coder is defective.
Replace the pulse coder.
If the alarm occurs again, but not immediately  the motor is generating too much heat. Replace
the motor.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–70
4.4.42 The axis control printed circuit board sent the serial data request signal to
the pulse coder, but did not receive serial data from the pulse coder.
SRVO-068
ER_SVAL2
DTERR Alarm
Print Reference
1. Check for connection and continuity of the feedback cable. Repair or replace if necessary. 08-16, 17, 18
2. Replace the axis control board. 08-01 thru 10
3. Replace the pulse coder and master the robot.
4.4.43 The serial data from the pulse coder changed during communication to the
axis control printed circuit board.
SRVO-069
ER_SVAL2 Refer to the SRVO_068 remedy.
CRCERR Alarm
(Group:i Axis:j)
4. TROUBLESHOOTING
4.4.44 The communication stop and start bits are abnormal.

SRVO-070
ER_SVAL2 Refer to the SRVO-068 remedy.
STBERR Alarm
(Group:i Axis:j)
4.4.45 The feedback velocity exceeds the specifications.

SRVO-071
ER_SVAL2 procedure:
SPHAL Alarm
(Group:i Axis:j)

Print Reference
1. Does this alarm occur with any other alarm?
If another alarm occurs  This alarm is caused by another alarm of the serial pulse coder. Refer to
the other alarm for details.
2. Reduce the load within the specifications.
4.4.46 Line Tracking Overflow Error.

SRVO-081
ER_WARN
EROFL Alarm
(Track encoder:n)
Print Reference
1. Check the connection between the controller and the line tracking device (absolute encoder or
pulse generator).
2. Check that the line speed is within the FANUC specification.
If the line speed is not within the specification  Relax the line speed.
4. TROUBLESHOOTING
MARMMTRBL02303E
4–72
4.4.47 Line Tracking Pulse coder is disconnected.

SRVO-082
ER_WARN Remedy: Check axis control printed circuit board for proper line tracking
cable connections.
DAL Alarm
(Track encoder:n) If the problem still exists, perform the following troubleshooting
procedure:

Print Reference
1. Replace the axis control printed circuit board.
2. Replace the pulse coder.
4.4.48 The clock for the rotation counter in the line tracking pulse coder is
abnormal.
SRVO-083
ER_WARN Remedy: Refer to SRVO-061 remedy.
CKAL Alarm
(Track encoder:n)
4.4.49 The battery voltage for the line tracking pulse coder is zero volts.
SRVO-084
Remedy: Refer to SRVO-062 remedy.
ER_WARN
BZAL Alarm
(Track encoder:n)
4.4.50 The built-in rotation counter on the line tracking pulse coder is abnormal.
SRVO-085 Remedy: Refer to SRVO-063 remedy.

ER_WARN
RCAL Alarm
(Track encoder:n)
4.4.51 The relationship between the analog signals on the line tracking pulse
coder are abnormal.
SRVO-086
PHAL Alarm
(Track encoder:n)
4. TROUBLESHOOTING
4.4.52 The line tracking pulse coder batteries are low.

SRVO-087
BLAL Alarm
(Track encoder:n)
4.4.53 The line tracking pulse coder ROM checksum data is abnormal.
SRVO-088
ER_WARN
CSAL Alarm
(Track encoder:n)
4.4.54 The line tracking pulse coder overheated.

SRVO-089
ER_WARN
OHAL2 Alarm
(Track encoder:n)
4.4.55 The axis control printed circuit board sent the request signal, but did not
receive serial data from the line tracking pulse coder.
SRVO-090
DTERR Alarm
(Track encoder:n)
4.4.56 The serial data from the line tracking pulse coder changed during
communication to the axis control printed circuit board.
SRVO-091
CRCERR Alarm
(Track encoder:n)
4.4.57 The communication stop and start bits for line tracking axis are abnormal.
SRVO-092
ER_WARN
STBERR Alarm
(Track encoder:n)
4.4.58 The feedback velocity exceeds the specification for line tracking axis.
SRVO-093
ER_WARN
SPHAL Alarm
(Track encoder:n)
5
REPLACING A FUSE
If a fuse blows in the control unit, eliminate the cause, then replace the
fuse.
5.1 F2, F2, and F3 : Fuses for three-phase 200 VAC servo power
F4 and F5 : Fuses for 100 VAC
MULTI-TAP
Refer to Table 5–1.
TRANSFORMER
Table 5–1. Multi-Tap Transformer Fuses
Rated
Fuse Number Machine Part Number
Current
S-420, S-500, 30A A60L-0001-0042#JG1–30
S-800, S-900,
M-500
F1, F2, F3 P-155 30A A60L-0001-0042#JG1–30
F1, F2, F3 ARC Mate SR., 20A A60L-0001-0042#JG1–20
S-700, M-400,
L-1000, S-10
ARC Mate, Arc 10A A60L–0001-0042#JG1-10
Mate 100, A-510,
S-5
F4, F5 P-155 7.5A A60L-0001-0101#P475H
F4, F5 S-420, S-500, 7.5A A60L-0001-0101#P475H
S-800, S-900,
M-500
ARC Mate Sr., 5A A60L-0001-0101#P450H
ARC Mate, S-5,
Arc Mate 100,
S-10, L-1000,
S-700, M-400,
A-510
F6, F7 S-420, 3-servo 10A A60L-0001-0042#JG1-10
amplifier
configuration
5. REPLACING A FUSE
MARMMTRBL02303E
5–2
Figure 6–1. Replacing a Fuse of the Transformer Unit
Fuse Fuse Fuse
Fuse
Fuse Fuse Fuse
WARNING
Before replacing a fuse, turn power off and lock out the
controller.
5. REPLACING A FUSE
5.2 FUSE 1 : Fuse for control power supply

Part number: A60L-0001-0175#3.2A
SERVO AMPLIFIER
FUSE 2 and 3 : Fuse for fan motors (only for one axis servo amplifier,
A06B-6066-H008)
Part number: A60L–0001–0101#P405
Figure 6–2. Replacing the Fuse of a Servo Amplifier
F1
F2
F3
LED
Terminal board T1
Circuit breaker
5. REPLACING A FUSE
MARMMTRBL02303E
5–4
5.3 F1 and F2 : Fuses for AC input

F3 : Fuse for +24V
POWER SUPPLY UNIT
F4 : Fuse for +24E
F5 : F use for auxiliary power supply
Table 5–2. Power supply unit for four-slot backplane

Fuse number Rated current Part Number
F1, F2 7.5A A60L-0001-0245#GP75
F3 3.2A A60L-0001-0075#3.2
F4 5A A60L-0001-0046#5.0
F5 0.3A A60L-0001-0290#LM03
Table 5–3. Power supply unit for six-slot backplane

Fuse number Rated current Part Number
F1, F2 10A A60L-0001-0245#G100
F3 5A A60L-0001-0075#5.0
F4 5A A60L-0001-0046#5.0
F5 0.3A A60L-0001-0290#LM03
Figure 6–3. Replacing a Fuse of the Power Supply Unit
PSU PSU
F1 and F2:
Fuses for AC input
F5: 0.3A fuse for 10-A for 4-slot
7.5A for 6-slot backplane
backplane
auxiliary
power supply
PIL: green LED
Battery cover power supply status
Battery
ALM: Red LED

for indicating
an alarm
F4:5–Afuse for +24E
F3: Fuse for +24V

5-A slow blow for
6-slot backplane
3.2A slow blow for
4-slot backplane (with battery cover removed)
5. REPLACING A FUSE
5.4 FUSE : 5.0 A brake circuit fuse

Part number: A60L-0001-0046#5.0
EMERGENCY STOP
CONTROL PC BOARD
FUSE : F1, F2, 3.2A Manual brake circuit fuse
Part number: A60L-0001-0175#3.2A
Figure 6–4. Replacing the Fuse on the Emergency Stop Control PC Board
F1
F2
FUSE
5. REPLACING A FUSE
MARMMTRBL02303E
5–6
Figure 6–5. Replacing the Fuse on the Emergency Stop Control PC Board
EMG
PCB
Fuse
5.5 FUSE: F11, F12, 3.2A AC Input Line Fuses

Part Number: A60L–0001–0175#3.2
PURGE POWER
SUPPLY
A05B–2047–C181
5. REPLACING A FUSE
Figure 6–6. Purge Power Supply
Cover
F12
F11
Purge Power Supply
5. REPLACING A FUSE
MARMMTRBL02303E
5–8
5.6 FUSE 1 : 2.0-A fuse for +24V

Part number: A60L-0001-0046#2.0
PROCESS
INPUT/OUTPUT PC Figure 6–7. Replacing the Fuse of the Process Input/Output PC Board AA, AB,
BOARDS AA, AB, CA, CA, CB, or DA
CB, AND DA Fuse
Fuse
Process input/output Process input/output

PC boards AA and AB PC boards CA, CB and DA
5. REPLACING A FUSE
5.7 FUSE 1 to 8 : 6.3 A fuses for +24V

Part number: A60L-0001-0046#6.3
PROCESS
INPUT/OUTPUT PC Figure 6–8. Replacing the Fuse of the Process Input/Output PC Board BA or BB
BOARDS BA AND BB
Fuse
Process input/output PC boards BA and BB
5. REPLACING A FUSE
MARMMTRBL02303E
5–10
5.8 The modules listed below have built-in fuses. If a fuse blows, remove the
cause, then replace the fuse with a spare.
MODULAR I/O UNIT
Table 5–4. Modular I/O Unit
Module Indication Rating Fuse Specification
Interface module A1F01A PWR is off 3.2A A60L-0001-0290=LN32
Interface module A1F01B PWR is off 3.2A A60L-0001-0290=LM32
Output module with 8 DC F is on 5A A60L-0001-0260=5R00
points AOD08C
Output module with 8 DC F is on 5A A60L-0001-0260=5R00
points AOD08D
Output module with 5 AC F is on 3.15A A60L-0001-0276=3.15
points AOA05E
points AOA08E
points AOA12F
The fuses are on the PC boards in the modules.
5. REPLACING A FUSE
5.9 FUSE : 2.0 A fuse for 100 VAC

Part number: A60L-0001-0101#P420H
AC OUTLET UNIT
Figure 6–9. Replacing the Fuse of the AC Outlet Unit
Fuse
6
BRAKE RELEASE
To perform some troubleshooting and error recovery procedures, you

might have to release the brakes. Use Procedure 6–1 to release the brakes.
Procedure 6–1 Releasing the Brakes
NOTE Clear all E-stops before proceeding.
Step 1 Press and release the EMERGENCY STOP button.
NOTE Do not press RESET. The servos must be off to release the
brakes.
2 Press MENUS.
3 Select NEXT PAGE.
4 Select SYSTEM.
5 Press F1, [TYPE].
6 Select Brake Ctrl. See the following screen for an example.
SYSTEM Brake Crtl JOINT 10%

AXIS SELECTED BRAKE STATE
1 NO ENGAGED
2 NO ENGAGED
3 NO ENGAGED
4 NO ENGAGED
5 NO ENGAGED
6 NO ENGAGED
7 NO ENGAGED
8 NO ENGAGED
9 NO ENGAGED
[TYPE] ENG–SEL REL–SEL YES NO >
7 Highlight the number of the axis you want to release or engage.
WARNING
Releasing a brake could cause the robot to move. To
STOP the robot immediately, press the EMERGENCY STOP
button or press F2, ENG–SEL to engage the brake.
6. BRAKE RELEASE
MARMMTRBL02303E
6–2
8 To release or engage a single brake:
a Select an axis to be released or engaged; press F4, YES.
NOTE To release axis 3 you must select both axis 2 and axis 3.
b Release the brake on the selected axis ; hold down the shift key
and press F3, REL–SEL.
c Engage the brake on the selected axis; press F2, ENG–SEL.
9 To release ALL brakes:
a Press NEXT, > to display the next page of function keys.
SYSTEM Brake Crtl JOINT 10%

AXIS SELECTED BRAKE STATE
1 NO ENGAGED
2 NO ENGAGED
3 NO ENGAGED
4 NO ENGAGED
5 NO ENGAGED
6 NO ENGAGED
7 NO ENGAGED
8 NO ENGAGED
9 NO ENGAGED
[TYPE] ENG–ALL REL–ALL GROUP >
WARNING
The following step will release all brakes even though they
have not been selected by pressing F4, YES. This could
result in robot movement. Be prepared for all brakes to be
released, as personnel could be injured, or equipment
damaged.
b Hold down the SHIFT key and press F3, REL–ALL to release all
of the brakes.
10 To engage ALL brakes:
a Press the F2, ENG–ALL to engage all of the brakes.
11 When you are finished, press RESET.
NOTE If you are unable to jog the robot after releasing the brakes, press
and release the EMERGENCY STOP button, and then press RESET to
clear the fault.
7
CONTROLLING I/O
Controlling I/O allows you to test the I/O in your system for proper
function during testing operation. Controlling I/O includes
 Forcing outputs
 Simulating inputs and outputs
 SOP I/O
7. CONTROLLING I/O
7.1 Forcing outputs is turning output signals on or off. Outputs can also be
forced within a program using I/O instructions. Use Procedure 7–1 to
FORCING OUTPUTS
force outputs outside of a program.
Refer to the application Specific Setup and Operations Manual for
information on using program I/O instructions.
NOTE RO[1] and RO[2] control HAND 1, and RO[3] and RO[4] control
HAND 2.
Procedure 7–1 Forcing Outputs
Condition  The outputs you are forcing have been configured.

Step 1 Press MENUS.
2 Select I/O.
3 Press F1, [TYPE].
4 Select the type of output you want to force: digital, analog, group,
robot, UOP, or SOP.
WARNING
Forcing digital outputs causes connected devices to
function. Make certain you know what the digital output is
connected to and how it will function before forcing it;
otherwise, injury to personnel or damage to equipment can
occur.
7. CONTROLLING I/O
For digital outputs for example, you will see a screen similar to the
following.
I/O Digital Out WORLD 10%

# SIM STATUS
DO[ 1] U OFF [ ]
DO[ 2] U ON [ ]
DO[ 3] U OFF [ ]
DO[ 4] U OFF [ ]
DO[ 5] U OFF [ ]
DO[ 6] U ON [ ]
DO[ 7] U OFF [ ]
DO[ 8] U OFF [ ]
DO[ 9] U OFF [ ]
DO[ 10] U OFF [ ]
[ TYPE ] CONFIG IN/OUT SIMULATE UNSIM
DO[ 4] U OFF 5 Move the cursor to the STATUS of the output you want to force.
6 Press the function key that corresponds to the value you want.
For digital, robot, UOP, and SOP outputs, press
 F4 for ON
 F5 for OFF
AO[ 4] U 12H For analog and group outputs, move the cursor to value, and use the
numeric keys to type the value. Value entry is always in decimal
format. To change the displayed value from decimal to hexadecimal,
press F4, FORMAT. Hexadecimal numbers are followed by an ‘‘H’’
on the screen.
7. CONTROLLING I/O
7.2 Simulating inputs and outputs is forcing inputs and outputs without signals
entering or leaving the controller. Simulate I/O to test program logic and
SIMULATING INPUTS
AND OUTPUTS motion when I/O devices and signals are not set up. You can simulate
digital, analog, and group I/O only; you cannot simulate robot, UOP, or
SOP I/O. When you are finished simulating a signal, you can reset, or
unsimulate, it. Use Procedure 7–2 to simulate and unsimulate I/O.
Procedure 7–2 Simulating and Unsimulating Inputs and Outputs
Condition  The input or output has been configured.

Step 1 Press MENUS.
2 Select I/O.
3 Press F1, [TYPE].
4 Select the type of input or output you want to simulate: digital,
analog, or group.
For digital inputs for example, you will see a screen similar to the
following.
I/O Digital Input WORLD 10%

# SIM STATUS
DI[ 1] U OFF [ ]
DI[ 2] S ON [ ]
DI[ 3] U OFF [ ]
DI[ 4] U OFF [ ]
DI[ 5] U OFF [ ]
DI[ 6] U ON [ ]
DI[ 7] U OFF [ ]
DI[ 8] S OFF [ ]
DI[ 9] U OFF [ ]
DI[ 10] U OFF [ ]
[ TYPE ] CONFIG IN/OUT SIMULATE UNSIM
5 If you simulate a signal, you can force the status by setting it to a

value. When the signal is unsimulated, its actual status is displayed.
DO[ 4] OFF 6 Move the cursor to the SIM column of the signal you want to simulate.
 U means the signal is not simulated or unsimulated.
 S means the signal is simulated.
7 Simulate or unsimulate the signal.
 To simulate, press F4, SIMULATE.
 To unsimulate, press F5, UNSIM.
8 To unsimulate all simulated signals, press FCTN and then select
UNSIM ALL I/O.
7. CONTROLLING I/O
7.3 The I/O SOP screen indicates the status of the standard operator panel
signals. SOP input signals (SI) and SOP output signals (SO) correspond
SOP I/O STATUS
to internal controller software Panel Digital Input signals (PDI) and Panel
Digital Output signals (PDO). Refer to Table 7–1 and Table 7–2.
Table 7–1. Standard Operator Panel Input Signals

SI PDI Function Description
EMERGENCY Input signal is normally turned ON, indicating that the EMERGENCY STOP button is
0 1
STOP not being pressed.
Input signal is normally turned OFF, indicating that the FAULT RESET button is not
1 2 FAULT RESET
being pressed.
2 3 REMOTE Input signal is normally turned OFF, indicating that the controller is not set to remote.
Input signal is normally turned ON, indicating that the HOLD push button is not
3 4 HOLD
being pressed.
Input signal is normally turned OFF, indicating that the CYCLE START push button
6 7 CYCLE START is not being pressed.
7–15 8–16 NOT USED Open for additional PDI.
Table 7–2. Standard Operator Panel Output Signals

SO PDO Function Description
0 1 REMOTE LED Output signal indicates the controller is set to remote.

Output signal indicates the CYCLE START button has been pressed or a program is
1 2 CYCLE START
running.
Output signal indicates the HOLD button has been pressed or a hold condition exists.
2 3 HOLD
3 4 FAULT LED Output signal indicates a fault has occurred.

Output signal indicates the voltage in the battery is low.
4 5 BATTERY ALARM
TEACH PENDANT Output signal indicates the teach pendant is enabled.
7 8
ENABLED
8–15 9–16 NOT USED Open for additional PDO.
Use Procedure 7–3 to display and force SOP I/O.
7. CONTROLLING I/O
Procedure 7–3 Displaying and Forcing SOP I/O
Step 1 Press MENUS.

2 Select I/O.
3 Press F1, [TYPE].
4 Select SOP. You will see a screen similar to the following.
I/O SOP Out JOINT 10 %

# STATUS
SO[ 1] OFF
OFF [ ]
SO[ 2] OFF [ ]
SO[ 3] OFF [ ]
SO[ 4] OFF [ ]
SO[ 5] OFF [ ]
SO[ 6] OFF [ ]
SO[ 7] OFF [ ]
SO[ 8] OFF [ ]
SO[ 9] OFF [ ]
SO[ 10] OFF [ ]
[ TYPE ] IN/OUT ON OFF
To change between the display of the input and output screens , press
F3, IN/OUT.
To move quickly through the information, press and hold the SHIFT
key and press the down or up arrow keys.
NOTE You can only view the status of input signals. Input signals cannot
be forced.
5 To force an output signal, move the cursor to the output you want to
change:
 To turn on an output signal , press F4, ON.
 To turn off an output signal, press F5, OFF.
8
MASTERING
When you master a robot you define the physical location of the robot by
synchronizing the mechanical information with the robot’s positional
information. A robot must be mastered to operate properly. Robots are
usually mastered before they leave FANUC Robotics. However, it is
possible that a robot might lose its mastering data and require to be
remastered.
You can master the robot using several different methods. Refer to
Table 8–1 to select the method that best meets your needs.
Table 8–1. Mastering Methods

Robot
Mastering Method When to Use
Models
Mastering to a fixture All  When mastery was lost due to
(Fixture Position mechanical disassembly or repair.
Master)  When a quick master reference position
was not previously set.
 Method of choice for P- and A-series
robots. Used for S- and M-series robots
when extreme precision is required.
Mastering to zero M-series  When mastery was lost due to
degrees S-series mechanical disassembly or repair.
 When a quick master reference position
was not previously set.
 Method of choice for S- and M-series
robots when extreme precision is not
required.
Single axis mastering M-series When mastery was lost due to mechanical
disassembly or repair of a single axis (usually
S-series due to motor replacement).
Recording the quick All To record mastering data as a reference for
master reference future quick mastering.
position
Quick mastering All To retrieve mastering data that has been
stored as a quick master reference position
when mastery is lost due to an electrical or
software problem. Do not use if mastery was
lost due to mechanical disassembly or repair.
If you are using a FANUC Robotics A-series or P-series robot you must
use a mastering fixture to master your robot. Refer to the Mechanical
Service Manual specific to your robot model for procedures on how to set
up and use a mastering fixture.
If you are using a FANUC Robotics M-series or S-series robot you can
either master to a fixture or you can master to zero degrees. Refer to the
Mechanical Service Manual specific to your robot model for more
information on mastering using a fixture.
Quick mastering is a convenient way to master an M-series or S-series

robot after you have recorded a reference position. You cannot quick
master a robot unless the reference position was taught before mastering
was lost.
8. MASTERING
MARMMTRBL02303E
8–2
CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.
8.1 When you master to a fixture, you use a mastering fixture to align the
robot axes and then record the position. You can master any robot to a
MASTERING TO A
fixture. If you have a P-series or A-series robot, you must master it to a
FIXTURE (FIXTURE fixture.
POSITION MASTER)
Use Procedure 8–1 to master to a fixture.
Procedure 8–1 Mastering to a Fixture
Condition  You have the appropriate mastering fixture for your robot.
Step 1 Press SYSTEM.
2 Press F1, [TYPE].
3 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 4.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key “1” and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
e Select Master/Cal. See the following screen for an example.
SYSTEM Master/Cal JOINT 10%
1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press ’ENTER’ or number key to select.
[ TYPE ] LOAD
8. MASTERING

3 QUICK MASTER
6 CALIBRATE
[ TYPE ] LOAD RES_PCA
If you are resetting a pulse coder alarm

4 ,
a Press F3, RES_PCA. See the following screen for an example.

3 QUICK MASTER
6 CALIBRATE
Reset pulse coder alarm? [NO]

[ TYPE ] YES NO
b Press F4, YES. See the following screen for an example.

3 QUICK MASTER
4
5 SINGLE AXIS
SET QUICK MASTER
MASTER REF
6 CALIBRATE
Pulse coder alarm reset!
5 Refer to the Mechanical Service Manual or Mechanical Connection

and Maintenance Manual specific to your robot model for the
procedures on how to set up and use a mastering fixture.
8. MASTERING
MARMMTRBL02303E
8–4
6 Select Fixture Position Master.

7 Press F4, YES. Mastering will be performed automatically.
8 Continue to Step 9.
9 Select Calibrate.
10 Press F4, YES.
Ï
11 Perform a cold start.
Ï
Ï
a Turn off the robot.

Ï
b Press and continue pressing the FAULT RESET button on the

Ï Ï Ï Ï
Ï Ï Ï
operator panel.
Ï Ï Ï
Ï Ï Î Î Ï Î Î Ï
Î Î Î Î
Ï Ï
c While still pressing FAULT RESET, press the ON button on the

Ï Ï
operator panel.
Ï
8. MASTERING
8.2 When you master to zero degrees, you position all axes at their zero degree
witness marks and record the zero degree position. You can master any
ZERO DEGREE
MASTERING M-series or S-series robot to zero degrees.
Use Procedure 8–2 to master to zero degrees.
Procedure 8–2 Mastering to Zero Degrees
Step 1 Press SYSTEM.

2 Press F1, [TYPE].

pendant.
d Press F1, [TYPE].

3 QUICK MASTER
6 CALIBRATE
[ TYPE ] LOAD
8. MASTERING
MARMMTRBL02303E
8–6

3 QUICK MASTER
6 CALIBRATE
4 If you are resetting a pulse coder alarm,

a Press F3, RES_PCA. See the following screen for an example.

3 QUICK MASTER
6 CALIBRATE
Reset pulse coder alarm? [NO]

[ TYPE ] YES NO
b Press F4, YES. See the following screen for an example.

3 QUICK MASTER
6 CALIBRATE
Pulse coder alarm reset!
5 Align the witness marks on the robot.

6 Select Zero Position Master.
8. MASTERING
7 Press F4, YES. Mastering will be performed automatically.

8 Select Calibrate.
9 Press F4, YES.

Ï

Ï
Ï
Ï Ï Ï
Ï ÏÎ
Ï
Î Ï
Ï
Î Î
operator panel.
Ï
Ï
Ï
Ï
Ï

operator panel.
Ï
Ï
8. MASTERING
MARMMTRBL02303E
8–8
8.3 You can master a single axis of an M-series or S-series robot when mastery
was lost due to mechanical disassembly or repair of a single axis, usually
SINGLE AXIS
MASTERING due to motor replacement.
Use Procedure 8–3 to master a single axis.
Procedure 8–3 Mastering a Single Axis
Step 1 Clear any servo faults that prevent you from jogging the robot.
a Press MENUS.
b Select SYSTEM.
c Press F1, [TYPE].
d Select Variables.
e Move the cursor to $MCR and press ENTER.
f Move the cursor to $SPC_RESET and press F4, TRUE.
The value will change to TRUE momentarily, and will then change to
FALSE.
g If the value does not change to TRUE momentarily, repeat

Step 1.
h Press RESET on the operator panel.

2 Using the JOINT coordinate system, jog the unmastered axis to the
zero degree position.
3 Press MENUS.
4 Select SYSTEM.
5 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
8. MASTERING

3 QUICK MASTER
6 CALIBRATE
7 Select 4, Single Axis Master. See the following screen for an

example.
SINGLE AXIS MASTER JOINT 10%

1/9
ACTUAL POS (MSTR POS) (SEL) [ST]
J1 0.000 ( 0.000) (0) [2]
J2 3.514 ( 35.000) (0) [0]
J3 –7.164 (–100.000) (0) [2]
J4 –357.366 ( 0.000) (0) [2]
J5 –1.275 ( –80.000) (0) [2]
J6
E1 4.571
0.000 (
( 0.000)
0.000) (0)
(0) [2]
[0]
E2 0.000 ( 0.000) (0) [0]
E3 0.000 ( 0.000) (0) [0]
[ TYPE ] GROUP EXEC
8 Move the cursor to the MSTR POS column for the unmastered axis
and press the “0” key.
9 Continuously press and hold the DEADMAN switch and turn the
teach pendant ON/OFF switch to ON.
10 Move the cursor to the SEL column for the unmastered axis and press
the numeric key “1.”
11 Press ENTER.
12 Press F5, EXEC. Mastering will be performed automatically.
13 Press PREV.
14 Select Calibrate.
15 Press F4, YES.
8. MASTERING
MARMMTRBL02303E
8–10

Ï
Ï

Ï
Ï Ï Ï
Ï Ï Î Î Î Î
operator panel.
Ï Ï Ï

operator panel.
Ï
Ï
8. MASTERING
8.4 Quick mastering allows you to minimize the time required to remaster the
robot using a reference position you established when the robot was
QUICK MASTERING
properly mastered. You cannot quick master the robot unless you have
previously recorded this quick master reference position.
Record the quick master reference position when the robot is properly
mastered. The best time to record the quick master reference position is
when the robot is still factory-mastered.
If you lose mastery due to an electrical or software problem, you can use
this reference position to master the robot in a minimum amount of time.
If you lose mastery due to mechanical disassembly or repair, you must
master to a fixture or perform zero degree mastering.
You can define a quick master reference position and perform quick
mastering on any robot model.
Use Procedure 8–4 to record the quick master reference position. Use
Procedure 8–5 to quick master the robot.
CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.
Procedure 8–4 Recording the Quick Master Reference Position
Condition  The robot is properly mastered.

1 Align the witness marks on the robot. This is the zero position, which
will be the quick master reference position.
If you have a P-series or A-series robot, jog all robot axes to zero
degrees and scribe witness marks on each axis.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].

pendant.
8. MASTERING
MARMMTRBL02303E
8–12
d Press F1, [TYPE].


3 QUICK MASTER
6 CALIBRATE
[ TYPE ] LOAD
6 Move the cursor to SET QUICK MASTER REF and press ENTER.
Set quick master ref? [NO] 7 Press F4, YES.
Ï
Ï
Ï
operator panel.
Ï Ï Î Î Î Î
Ï Ï
Ï
Ï
Ï
Ï
operator panel.
Ï
Ï
8. MASTERING
Procedure 8–5 Quick Mastering the Robot
Condition  The robot has lost mastery due to an electrical or software problem.
NOTE If the robot has lost mastery due to mechanical disassembly or
repair, you cannot perform this procedure. In this case, master to a fixture
or master to zero degrees to restore robot mastery.
 The quick master reference position was recorded before the robot lost
mastery.
1 Jog the robot to the quick master reference position (zero degree
position).
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].

pendant.
d Press F1, [TYPE].

3 QUICK MASTER
6 CALIBRATE
[ TYPE ] LOAD
6 Move the cursor to QUICK MASTER and press ENTER.

Quick master? [NO] 7 Press F4, YES.
8. MASTERING
MARMMTRBL02303E
8–14
8 Move the cursor to CALIBRATE and press ENTER

9 Press F4, YES.

Ï
Ï
Ï

operator panel.
Î Î Î Î
Ï Ï
Ï Ï
operator panel.
Ï
Ï
9. REPLACING COMPONENTS
MARMMTRBL02303E
9–2
9.1 FANUC Robotics recommends that all batteries be changed immediately

prior to production start up. Change the batteries annually to assure
REPLACING THE
BATTERY reliable robot performance. Use Procedure 9–1 to replace the battery:
Use Procedure 9–2 to replace the SPC battery.
Procedure 9–1 Replacing the Battery
Step 1 Get the new battery. (number: A98L-0031-0007)

2 Power down and lock out the controller.
CAUTION
The battery must be replaced within 30 minutes. If the power is
turned off and the battery is removed for 30 minutes or more,
the contents of the memory on the main CPU printed circuit
board may be lost.
WARNING
Do not short circuit or incinerate a discarded battery.
Follow your company’s procedures for disposing of lithium
batteries.
WARNING
3 Remove the battery case from the front panel of the power supply unit.
The case can be removed easily by squeezing the top and bottom of it
and pulling.
Figure 10–1. Replacing the Battery (1)
Front panel of the
power supply unit
BATTERY
Front panel of the Cable connector
power supply unit
Battery Battery case PC board

(ordering drawing
connector Battery
number:
A98L-0031-0007)
4 Remove the connector from the battery.
5 Replace the battery and reconnect the connector.

6 Install the battery case.
Procedure 9–2 Replacing the SPC Batteries
Step 1 Get four new alkaline D–cell batteries.

2 Turn on the controller.
3 Press the operator panel Emergency Stop button and the teach pendant
Emergency Stop button.
4 Turn on the teach pendant and take it with you into the workcell.
5 Remove the black plastic battery cover on the base of the robot.
6 Remove the old batteries.
7 Insert the new batteries. The new batteries must be arranged as
follows:
Upper left – positive end out.
Upper right – negative end out.
Lower left – negative end out.
Lower right – positive end out.
8 Replace the battery cover.
9 Cold start the controller. The teach pendant might display a

SRVO–065 BLAL alarm. This is normal. It will reset when you cold
start the controller.
MARMMTRBL02303E
9–4
9.2 A relay may fail after it is used for a long time. The relay or its circuit
board must be replaced. Relays RL1-RL6 on the EMG board are
REPLACING A RELAY
replaceable.
Figure 10–2. Replacing a Relay
DS2
F1
DS1
F2
RL16 RL1 RL2
FUSE
RL4
RL3 LED M1
LED M2
2 1
RL4 TIMER 3
6
5 TM1
8 TM2
7
CNPG 9 CRX
Figure 10–3. Replacing a Relay
Relay
Table 9–1. Relay Part Numbers
Name Part Numbers

RL1
RL2 A58L–0001–0192#1472R
RL3
RL4
RL5, RL6 A58L–0001–0192#1192D
Table 9–2. Relay Part Numbers

Name Part Numbers
RL1, RL2 A58L–0001–0192#1472R
RL3, RL16 A58L–0001–0192#1509A
RL4 A58L–0001–0192#1192D
RL5, RL8, RL10,
RL15 A58L–0001–0260#234PH–24
RL5, RL6 A58L–0001–0192#1192D
MARMMTRBL02303E
9–6
9.2.1 Part Number: A16B–1600–0520

Purge Control PCB Table 9–3. PCB Relay Part Numbers
Name Part Numbers
RL4 Timer Relay A58L–0001–0269#B24
RL1, RL3, RL5, RL9 A58L–0001–0260#234PH–24
9.3 When replacing a printed circuit board, take the following precautions:
REPLACING A
PRINTED CIRCUIT 1. Before starting replacement, power down and lock out the controller.
BOARD 2. When removing the printed circuit board, do not touch semiconductor
components on it and do not let the components touch other
components.
3. Wear a grounded wrist strap. Do not remove the new board from its
conductive bag until you are ready to install it.
4. Check that any jumpers on the printed circuit board to be installed are
correctly set.
5. When replacing the main CPU printed circuit board, all software
stored in the controller will be lost. Before starting replacement, back
up your user programs, mastering data, and system variable data onto a
floppy disk.
6. Connect the cables removed for replacement to the original positions.

If the cable markings are missing or unclear, retag them before
disconnecting them.
MARMMTRBL02303E
9–8
9.3.1 Use Procedure 9–3 to replace the backplane printed circuit board. The
backplane printed circuit board and the yellow board rack are removed and
Replacing the
Backplane Printed replaced as one unit.
Circuit Board
Refer to Chapter 1 for part
numbers.
Procedure 9–3 Replacing the Backplane Printed Circuit Board
Step 1 Remove the battery from the power supply unit and plug it into the
battery connector on the front panel of the main CPU.
2 Remove all9–4
Procedure printed
. circuit boards from the backplane. Use
3 Disconnect the ground wire from the backplane printed circuit board.
4 Remove the two or three mounting screws at the bottom of the rack.
5 Loosen the two or three mounting screws at the top of the rack and
remove the rack/backplane assembly.
6 Install the new rack/backplane assembly in reverse order. Be sure to
move the battery back to the power supply unit from the main CPU.
Figure 10–4. Replacing the Backplane Printed Circuit Board
Backplane
PC board
M5 mounting screw
9.3.2 Use Procedure 9–4 to replace a component on the backplane printed

circuit board.
Replacing a
ComponentPrinted
Backplane on the
Circuit Board
numbers.
Procedure 9–4 Replacing a Component on the Backplane Printed Circuit
Board
NOTE When the main CPU is replaced, all software stored in the
controller will be lost. If possible, back up your user programs, mastering
data, and system variable data on a floppy disk before starting
replacement.
Step 1 Turn off and lock out the controller.
2 Disconnect any cables and harnesses on the component to be replaced.
3 Squeeze the latch tabs at the top and bottom of the component and pull
the component straight out.
4 Set any jumpers on the new component to match the component being
replaced.
5 Insert the new component into the proper slot of the backplane rack.
Carefully press it into the slot until the latches engage at the top and
bottom.
6 Reconnect all cables and harnesses.
Figure 10–5. Replacing Printed Circuit Boards on the Backplane Printed Circuit
Board
Process input/output PC board CA, CB, or DA

Main CPU board (*1)
Axis control PC board
Power supply unit (*2)
Emergency stop con-
trol PC board
MARMMTRBL02303E
9–10
9.4 Use the following procedure to replace a module:

REPLACING A
MODULE ON THE 1. Move the latches at both ends of the module socket toward the outside.
The spring of the contact tilts the module. See Figure 10–6.
MAIN CPU OR AXIS
CONTROL BOARD Figure 10–6. Moving the Latches on the End of the Module Socket

numbers.
2. If the tilted module touches the next module, it might be difficult to

remove it. In this case, release the latches of the next module as
described in step 1 above.
3. Now the module is free in the socket. Pull out the module carefully in
a straight line. Do not pull it out in an arc. The contacts of the socket
or module might be damaged.
4. Install a new module in the socket at an angle. Push it into the socket
until the bottom of the module reaches the bottom of the socket
groove. Be sure you have the module facing in the proper direction.
align the groove in the module with the tab as shown in Figure 10–7.
Figure 10–7. Installing a New Module at an Angle
Short Long
Fit the recess on

the module over
the tab in the
module socket.
5. Push the module in the top edge so that the module stands upright.
See Figure 10–8.
Figure 10–8. Pushing in the Module
6. Check that the module is latched properly at both ends of the socket.
If it is insufficiently latched, the electrical contact might be improper
and a malfunction could occur.
MARMMTRBL02303E
9–12
Figure 10–9 shows the mounting locations of the modules.
Figure 10–9. Mounting Locations of the Modules
FLASH
Flash ROM module Optional SCC module
CMOS RAM module (option) SLC2 module
CMOS RAM module (option) M321 module

CMOS RAM module (standard) SCC module
CMOS RAM module (standard)
Main CPU PC board

Axis control PC board
9.5 Part numbers: A16B-2200-0780, A16B-2200-0782, and A16B-2201-0510

REPLACING THE
1. Remove the cable from the process input/output printed circuit board
PROCESS
INPUT/OUTPUT to be replaced.
PRINTED CIRCUIT 2. Remove the two screws from the left side of the process input/output
BOARD AA, AB, BA OR printed circuit board.
BB 3. Remove the board by pulling outward to the left.
4. Replace the printed circuit board with a new one.
Refer to Chapter 1 for part 5. Replace the two screws removed in step 2.
numbers.
6. Replace the cables.
NOTE For replacing output drivers on the process I/O boards refer to
Chapter 10.
Figure 10–10. Replacing the Process Input/Output Printed Circuit Board AA, AB,
BA, or BB
M4 screw
MARMMTRBL02303E
9–14
9.6 Use the information in this section to replace the following components of
the modular I/O unit:
REPLACING
COMPONENTS OF THE
 Base Unit
MODULAR
 Modules
INPUT/OUTPUT UNIT
 Multi-Tap Transformer
 Servo Amplifier
numbers.  Operator Panel
 Fan Motor
 Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) Unit
 Regenerative Discharge Unit
 Optional Warning Light
 Serial Pulse Coder
9.6.1 Use Procedure 9–5 to replace the base unit.

Replacing the Base
Unit
Ordering code:
A03B-0807-J002
Procedure 9–5 Replacing the Base Unit
Step 1 Remove the I/O modules from the base unit.

2 Loosen the upper two mounting screws.
3 Remove the lower two mounting screws and replace the base unit.
Figure 10–11. Replacing the Base Unit of the Modular Input/Output Unit
M4 screw
MARMMTRBL02303E
9–16
9.6.2
Replacing a Module
Procedure 9–6 Replacing the Interface Module
Removing the Interface 1 Power down and lock out the controller.
Module
2 Disconnect the signal and power cables from the interface module.
3 Press the latch on the bottom of the module and rotate the module
toward you and up.
Installing the Interface 1 Engage the hook at the top rear of the module with the bar above the
Module base unit socket.
2 Rotate the module downward until the latch engages.
3 Reconnect the signal and power cables to the interface module.
Procedure 9–7 Replacing an I/O Module
Removing an I/O Module 1 Power down and lock out the controller.
2 Remove the wiring harness block. (See Figure 10–13.)
a Lift the latch at the lower left corner of the module window.
b Rotate the block toward you and down.
3 Press the latch on the bottom of the module and rotate the module
toward you and up. (See Figure 10–12.)
Installing an I/O Module 1 Engage the hook at the top read of the module with the bar above the
base unit socket.
2 Rotate the module downward until the latch engages.
Figure 10–12. Removing and Replacing a Module
3 Install the wiring harness block.

a Engage the hook at the bottom rear of the block with the bar at the
bottom of the module.
b Rotate the block upward until the latch engages.
Figure 10–13. Removing and Replacing a Terminal Block
MARMMTRBL02303E
9–18
9.7 Use Procedure 9–8 to replace the multi-tap transformer.

REPLACING THE
MULTI-TAP
TRANSFORMER
numbers.
Procedure 9–8 Replacing the Multi-Tap Transformer
Condition  The controller is turned off and locked out.
Step 1 Remove the acrylic covers from the transformer and ALC relay.
2 Disconnect the wiring harnesses and ground wire from the transformer.
3 Disconnect the three wires from the bottom of the ALC relay.
4 After removing the eight screws fastening the transformer, remove the
transformer. Put a new transformer on the rail in the controller and
push it into the controller along the rail. Then reinstall the screws.
5 Reconnect the wires and harnesses.
6 Reinstall the acrylic covers.
Figure 10–14. Replacing the Multi-Tap Transformer
M5 screws
9.8 Use Procedure 9–9 to replace a servo amplifier.

REPLACING A SERVO
AMPLIFIER
numbers.
Procedure 9–9 Replacing a Servo Amplifier
Step 1 Remove the five bus bars from the servo amplifier bank.
2 Disconnect the wires from the servo amplifier terminal strip. Remove
the two screws fastening the servo amplifier and remove the amplifier.
3 Set the terminal strip jumpers on the new servo amplifier to match
those of the one you removed.
4 Install the new servo amplifier by following these steps in reverse

order.
Figure 10–15. Replacing a Servo Amplifier
M5 screw
MARMMTRBL02303E
9–20
9.9 Use Procedure 9–10 to replace the operator panel.

REPLACING THE
OPERATOR PANEL
numbers.
Procedure 9–10 Replacing the Operator Panel

Step 1 Remove the cable from the operator panel.
2 Remove the six nuts fastening the operator panel and replace the
operator panel.
3 When replacing only the operator panel printed circuit board, replace it
together with the metal plate.
4 After removing the cable from the operator panel printed circuit board,
remove the four nuts fastening the metal plate. Then replace the
operator’s panel printed circuit board.
Figure 10–16. Replacing the Operator Panel
Operator
(rear face)panel
M4 nuts
(4 pieces)
9.10 Use Procedure 9–11 to replace the fan motor.

REPLACING THE FAN
MOTOR
numbers.
Procedure 9–11 Replacing the Fan Motor

Step 1 Remove the printed circuit board located below the fan motor to be
replaced, following Procedure 9–4 .
2 The cable connected to the fan motor is connected to the backplane
printed circuit board in the slot. Holding the connector, remove the
cable from the backplane printed circuit board.
3 Open the lid at the top of the backplane rack by placing the tip of a
flat–blade screwdriver into the center hole at the front of the lid and
moving the screwdriver like a lever in the direction in Figure 10–17 to
release the latch.
4 Remove the fan motor.
5 Install a new fan motor. Route the cable through the hole at the back
of the rack.
6 Close the lid until it is latched.
7 Connect the cable of the fan motor to the connector on the backplane
printed circuit board. Suspend the center of the cable on the hook in
the back of the rack.
8 Reinstall the removed printed circuit board using the procedure
described in Section 9.3.2.
MARMMTRBL02303E
9–22
Figure 10–17. Replacing the Fan Motor
(3)
(4)
Fan motor
Cable
Connector
Backplane PC board
9.11 Use Procedure 9–12 to replace the discharge resistor (DCR) and dynamic
brake resistor (DBR) unit.
REPLACING THE
DISCHARGE
RESISTOR (DCR) AND
DYNAMIC BRAKE
(DBR) UNIT
Procedure 9–12 Replacing the Discharge Resistor (DCR) and Dynamic Brake
Resistor (DBR) unit

Step 1 Use FANUC part number A05B-2302-C080 to replace the DCR and
DBR unit.
2 Remove the cable from the DCR and DBR unit to be replaced.
3 Remove the two screws fastening the DCR and DBR unit and replace
it.
4 Reattach the cable to the new DCR and DCR unit.
9.12 Use Procedure 9–13 to replace the regenerative discharge unit.

REPLACING THE
REGENERATIVE
DISCHARGE UNIT
Procedure 9–13 Replacing the Regenerative Discharge Unit

Step 1 Use FANUC part number A05B-2312-C100 for the M-500, and part
number A05B-2313-C100 for the S-900, for replacement of the
regenerative discharge unit.
2 Disconnect the cable connected to the regenerative discharge unit.

3 Remove the four M5 screws fastening the discharge unit. Then
replace the unit.
Figure 10–19. Replacing the Regenerative Discharge Unit
Four M5 fastening screws
MARMMTRBL02303E
9–26
9.13 Use Procedure 9–14 to replace the optional warning light.

REPLACING THE
OPTIONAL WARNING
LIGHT
Procedure 9–14 Replacing the Optional Warning Light

Step 1 Use FANUC part number LAMPXVAL74C024X to replace the
warning light.
2 Remove the existing light assembly from the robot and replace with
the new light assembly.
3 Reconnect the replacement light assembly.
9.14 Use Procedure 9–15 to replace a serial pulse coder.

REPLACING A SERIAL
PULSE CODER
Procedure 9–15 Replacing a Serial Pulse Coder
NOTE The robot will have to be remastered after this procedure.
Step 1 Remove the cables from the pulse coder. Refer to Figure 10–20.
2 Remove the screws holding the pulse coder cable connector to the
pulse coder housing.
3 Retract the rubber boot on the inside of the pulse coder cable
connector.
4 Remove the snap ring on the inside of the pulse coder cable connector.
5 Detach the pulse coder cable from the pulse coder housing.
CAUTION
In the next step, be sure to remove the correct bolts, as shown
in Figure 10–20. Removing the wrong bolts can destroy the
pulse coder.
6 Remove the four M4 bolts attaching the pulse coder to the motor.
7 Position the new pulse coder on the motor so that the Oldham
coupling engages. If there are witness marks on the pulse coder case
and the motor case, make sure that they line up.
8 Install the four M4 bolts.
9 Attach the pulse coder cable to the pulse coder housing.
10 Install the snap ring on the inside of the pulse coder cable connector.
11 Reposition the rubber boot on the inside of the pulse coder cable
connector.
12 Replace the screws holding the pulse coder cable connector to the
pulse coder housing.
13 Install the screws holding the pulse coder housing to the motor.
14 Attach the cables to the pulse coder housing.
MARMMTRBL02303E
9–28
Figure 10–20. Removing the Pulse Coder

Caution: Do not remove the screws from these four ribbed holes.
The serial pulse coder will seperate and be destroyed
M4 Mounting Bolt Holes
10
BOARD ADJUSTMENTS
This chapter contains information about components located on some

printed circuit boards that require adjustment. These components include
jumpers and potentiometers.
10.1 You can set jumpers on the axis control board. Figure 11–1 shows an
illustration of the axis control board. Table 10–1 lists the standard
AXIS CONTROL
settings for the jumpers found on the axis control board.
BOARD JUMPERS
Figure 11–1. Axis Control Board Jumpers
A COM B B HBK A
JUMPER JUMPER
Table 10–1. Axis Control Board Jumpers
Name Standard setting Description

COM Side A Side A: The RI lines use 0V for the
common reference
Side B:The RI lines use +24 for the
common reference
HBK Side B Side A: The hand breakage detect feature
is not used.
Side B: The hand breakage detect feature
is used.
10. BOARD ADJUSTMENTS

MARMMTRBL02303E
10–2
10.2 The process I/O board has jumpers, potentiometers you can adjust, and
output drivers you can replace. The process I/O boards are shown in
PROCESS I/O BOARD
Figures 10–2 through Figure 10–8.
Figure 11–2. Process I/O Board AA
Figure 11–3. Process I/O Board AB
Figure 11–4. Process I/O Board BA
Figure 11–5. Process I/O Board BB

MARMMTRBL02303E
10–4
Figure 11–6. Process I/O Board CA
Figure 11–7. Process I/O Board CB
Figure 11–8. Process I/O Board DA
10.2.1 Table 10–2 lists the standard settings for the jumpers located on the
process I/O board.
Jumpers
Table 10–2. Process I/O Board Jumpers
Name Standard Description

setting
UDI1 to UDI20
ICOM1 The common voltage is adjusted to
(Connector CRM2A)
Side A: 0 V common
UDI21 to UDI40 Side B: +24 V common
ICOM2
(Connector CRM2B) Side A
WI01 to WI08
ICOM3 (Connector CRW1) NOTE: Set ICOM3 to B side to use
See Note WDI2 as weld detect input.
SP1 Channel 1 The polarity of the output voltage is

switched to
Open
p
Channel 2 Strapped: Negative (–)
SP2 Open: Positive (+)

MARMMTRBL02303E
10–6
10.2.2 Table 10–3 lists the process I/O board potentiometers and the adjustments
you can make to them.
Potentiometers
Table 10–3. Process I/O Board Potentiometer Adjustments
Potentiometer Description Adjustment

Adjusts the gain of Execute a robot program and set AO[1] to
channel 1 4095 on the teach pendant. Connect a
digital voltmeter to test pin AO1 and rotate
VR1
VR1 until the meter reads 12.0 V. Connect
the negative (–) lead of the digital voltmeter
to test pin 0VF.
Adjusts the gain of Execute a robot program and set AO[2] to
channel 2 4095 on the teach pendant. Connect the
digital voltmeter to test pin AO2 and rotate
VR2 VR2 until the meter reads 12.0 V. Connect
the negative
to test (–) lead
pin 0VF. (The of
0VFthetest
digital
pin voltmeter
is
different from the common 0V test pin.)
Adjusts the Connect the digital voltmeter to test pin
reference supply P10V and rotate VR3 until the meter reads
VR3 voltage of the 10.00  0.1 V.
digital/analog
converter
10.2.3 Table 10–4 lists the output drivers for each process I/O board.
Output Drivers
Table 10–4. Output Drivers
DO Signal
Driver
AA AB BA BB CA CB DA
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FAULT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 SO01, SO02, SO03, SO04
DV7 SO05, SO06, SO07, SO08
DV8 SO09, SO10, SO11, SO12
DV9 SO13, SO14, SO15, SO16
DV10 SO17, SO18, SO19, SO20
DV11 WO01, WO02, — — — WO01, WO02, — SO21, SO22,
WO03, WO04 WO03, WO04 SO23, SO24
DV12 WO05, WO06, — — — WO05, WO06, — SO25, SO26,
WO07, WO08 WO07, WO08 SO27, SO28
DV13 — — — — — — SO29, SO30,
SO31, SO32,
DV14 — — — — — — SO33, SO34,
SO35, SO36
DV15 — — — — — — SO37, SO38,
SO39, SO40
DV16 — — — — — — SO41, SO42,
SO43, SO44
DV17 — — — — — — SO45, SO46,
SO47, SO48
DV18 — — — — — — SO49, SO50,
SO51, SO52
DV19 — — — — — — SO53, SO54,
SO55, SO56
DV20 — — — — — — SO57, SO58,
SO59, SO60
DV21 — — — — — — SO61, SO62,
SO63, SO64
DV22 — — — — — — SO65, SO66,
SO67, SO68
DV23 — — — — — — SO69, SO70,
SO71, SO72
DV24 — — — — — — SO73, SO74,
SO75, SO76
RESERVED — — — — To be used for To be used for To be used for
replacement replacement replacement

MARMMTRBL02303E
10–8
10.3 This section contains information about adjusting the built-in CRT/KB
unit.
BUILT–IN CRT/KB UNIT
CRT Display Unit The following can be adjusted at the CRT Display Unit:
20³ CRT/KB  Brightness (BRIGHT)
A05B-2051-J101  Contrast (CONT)
 Focus
40³ CRT/KB  Horizontal size (H-SIZE)
A05B-2301-J130  Vertical size (V-SIZE)
 Horizontal Hold (H-HOLD)
 Vertical Hold(V-HOLD)
 Vertical linearity (V-LIN)
CAUTION
Keep fingers and tools away from the CRT display unit when
first turning the power on. Use caution at the display unit
anytime when power is on because 10-11 KV is present.
Brightness Turn to the brightest level possible before roster (scanning lines) appear on
the screen.
Contrast Adjust the “CONT” variable resistor until display characters achieve an
easy to read brightness level. Too much contrast can distort the characters.
Focus Adjust “FOCUS” variable resistor to ”sharpen” characters.
Horizontal Size (Width) Adjust the “H–SIZE” coil if picture width appears too small or distorted
on the sides.
Vertical Size (Height) Adjust the “V–SIZE” variable resistor if the picture height appears too
small or distorted at the top.
Horizontal Hold Adjust the “H–HOLD” variable resistor if the picture rolls or shifts
horizontally (or diagonally).
Vertical Hold (V-HOLD) Adjust the “V–HOLD” variable resistor if the picture rolls vertically.
Vertical Linearity (V-LIN) Adjust the “V–LIN” variable resistor to obtain equal character size
vertically in the upper and lower parts of the screen.
The following can be adjusted at the CRT/KB Control Board:
 + 5VDC power supply

Refer to Figure 11–9 and adjust as follows:
+5VDC supply: Monitor the ”+5 VDC” test point and adjust variable
resistor VR1 until + 5VDC  0.1V is obtained.
 Jumper ST1
Refer to Figure 11–10 for jumper setting.
Figure 11–9. Front View Control Board
VR1
Test point ”+5V”
ST1
Figure 11–10. Jumper Setting CRT/KB
Jumper Standard SIDE A = KANA +

setting ALPHA NUMERIC
ST1 SIDE B = ALPHA

NUMERIC
A É É É É
B

É É É É

MARMMTRBL02303E
10–10
10.4 The EMG board contains a jumper which controls the sensitivity of the
brake alarm circuit. Refer to SRVO_ALARM 008.
EMG BOARD
Figure 11–11. EMG board
EMG
PCB
Table 10–5. SBK Jumper Settings

Standard Setting
NAME S-5, S-10, Arc Mate, Arc S-500, S-700, S-800, S-420, S-420D Description
Mate 100/S-6, Arc Mate M-400
Sr., A-510, L-1000,
S-900, M-500
SBK1 Open Side 2 The sensitivity of a brake is adjusted
(for a swiveling axis).
SBK2 Open
SBK3
SBK4
SBK5
SBK6
SET Side 2 Side 1 The sensitivity for the fuse alarm of a
brake is adjusted to :
Side 1: Special setting
Side 2: Standard setting
11
CONNECTIONS
This chapter describes the electrical interface connections in the R-J

controller. Figure 12–1 is a block diagram of electrical interface
connections with the R-J controller.
Figure 12–1. Block Diagram of Electrical Interface Connection
Pneumatic pressure
Purge Source
ISB
Unit Teach Pendant (ISTP)
––ABKR I/O
––GEF I/O
Modular I/O
Disk Drive
*1: A remote display is connected.

*2: Optional RS-232-C or RS-422/485 interface.
11. CONNECTIONS
MARMMTRBL02303E
11–2
11.1 Figure 12–2 through Figure 12–12 show connection diagrams to the
mechanical units.
MECHANICAL
CONNECTIONS Figure 12–2. Mechanical Connection Diagram for S-420, S-500, S-700, S-800, and
M-400
*1: This cable is not included. It must be supplied by the customer.

*2: Can be connected when the robot is S-500 or S-700.
Figure 12–3. Mechanical Connection Diagram for ARC Mate, ARC Mate 100/S-6,
ARC Mate Sr., A-510, and L-1000
*1: This cable is not included. It must be supplied by the customer.

*2: Can be connected when the robot is ARC Mate or ARC Mate Sr.
11. CONNECTIONS
Figure 12–4. Mechanical Connection Diagram for Six-Axis Pedestal Mount System
with Battery in Controller
R−J ROBOT
M1
SERVO AMP C1M1
TERMINAL/FRAME
AXIS 1 & 2
M3
SERVO AMP C1M3
TERMINAL/FRAME
AXIS 3
M2
SERVO AMP C1M2
TERMINAL/FRAME
AXIS 4,5, & 6
AXIS CONTROL P1
PCB − CRF1 C1P1
(PULSE CODER
SIGNAL)
CRR5 − EMG PCB C1M5

P & M BRAKE
SIGNALS
D1
CONTACT SIGNAL C1D1 (INTRINSIC)
TRANSDUCER
(IBRC)
+6V & 0V C1B1 (INTRINSIC)

BATT
+24PG & 0V DC−DC

C1P2
PURGE CONTROL 24V
PCB 5V

GROUND CABLE
11. CONNECTIONS
MARMMTRBL02303E
11–4
Figure 12–5. Mechanical Connection Diagram for Six-Axis Pedestal Mount System
with Battery in Robot
R−J ROBOT
M1
SERVO AMP C1M1
TERMINAL/FRAME
AXIS 1 & 2
M3
SERVO AMP C1M3
TERMINAL/FRAME
AXIS 3
M2
SERVO AMP C1M2
TERMINAL/FRAME
AXIS 4,5, & 6
AXIS CONTROL P1
PCB − CRF1 C1P1
(PULSE CODER
SIGNAL)

P & MBRAKE
SIGNALS
D1
TRANSDUCER
(IBRC)
+24PG & 0V DC−DC

C1P2
PURGE CONTROL 24V
PCB 5V

GROUND CABLE
11. CONNECTIONS
Figure 12–6. Mechanical Connection Diagram for Catrac Robot Clean-Wall Rail
System with Battery in Controller
R−J JUNCTION BOX ROBOT
M1 M1
SERVO AMP C1M1 C2M1
TERMINAL/FRAME
AXIS 1 & 2
M3 M3
SERVO AMP C1M3 C2M3
TERMINAL/FRAME
AXIS 3 & 7
M2 M2
SERVO AMP C1M2 C2M2
TERMINAL/FRAME
AXIS 4,5, & 6
AXIS CONTROL P1 P1
PCB − CRF1 C1P1 C2P1
(PULSE CODER
SIGNAL)
AXIS CONTROL
PCBCODER
(PULSE − JF7
SIGNAL−AXIS7)
CRR5 − EMG PCB C1M5 C2M5

P & MBRAKE
SIGNALS
D1 D1
CONTACT SIGNAL C1D1 (INTRINSIC) C2D1 (INTRINSIC)
TRANSDUCER
(IBRC)
+6V& 0V C1B1 (INTRINSIC) C2B1 (INTRINSIC)

BATT
P2
+24PG & 0V DC−DC
PURGE CONTROL C1P2 C2P2 24V
PCB 5V

GROUND CABLE GROUND CABLE
11. CONNECTIONS
MARMMTRBL02303E
11–6
Figure 12–7. Mechanical Connection Diagram for Catrac Robot Clean-Wall Rail
System with Battery in Robot
M1 M1
SERVO AMP C1M1 C2M1
TERMINAL/FRAME
AXIS 1 & 2
M3 M3
SERVO AMP C1M3 C2M3
TERMINAL/FRAME
AXIS 3 & 7
M2 M2
SERVO AMP C1M2 C2M2
TERMINAL/FRAME
AXIS 4,5, & 6
AXIS CONTROL P1 P1
(PULSE CODER
SIGNAL)
AXIS CONTROL
PCB − JF7
(PULSE CODER
SIGNAL−AXIS7)

P & M BRAKE
SIGNALS
D1 D1
TRANSDUCER
(IBRC)
P2
+24PG & 0V DC−DC
C1P2 C2P2
PURGE CONTROL 24V
PCB 5V

11. CONNECTIONS
Figure 12–8. Mechanical Connection Diagram for Seven–Axis Universal Rail

System with Battery in Controller
R−J ROBOT
M1
SERVO AMP C1M1
TERMINAL/FRAME
AXIS 1 & 2
M3
SERVO AMP C1M3
TERMINAL/FRAME
AXIS 3 & 7
M2
SERVO AMP C1M2
TERMINAL/FRAME
AXIS 4,5, & 6
AXIS CONTROL P1
PCB − CRF1 C1P1
(PULSE CODER
SIGNAL)
AXIS CONTROL
PCBCODER
(PULSE − JF7
SIGNAL−AXIS7)

P & M BRAKE
SIGNALS
D1
TRANSDUCER
(IBRC)
+6V & 0V C1B1 (INTRINSIC)

BATT
DC−DC
+24PG
PURGE & 0V
CONTROL C1P2 24V
PCB 5V

GROUND CABLE
11. CONNECTIONS
MARMMTRBL02303E
11–8
Figure 12–9. Mechanical Connection Diagram for Seven-Axis Universal Rail

System with Battery inRobot
R−J ROBOT
M1
SERVO AMP C1M1
TERMINAL/FRAME
AXIS 1 & 2
M3
SERVO AMP C1M3
TERMINAL/FRAME
AXIS 3 & 7
M2
SERVO AMP C1M2
TERMINAL/FRAME
AXIS 4,5, & 6
AXIS CONTROL P1
PCB − CRF1 C1P1
(PULSE CODER
SIGNAL)
AXIS CONTROL
PCB − JF7
(PULSE CODER
SIGNAL−AXIS7)

P & M BRAKE
SIGNALS
D1
TRANSDUCER
(IBRC)
+24PG & 0V DC−DC

C1P2
PURGE CONTROL 24V
PCB 5V

GROUND CABLE
11. CONNECTIONS

System with Battery in Controller and Junction Box
M1 M1
SERVO AMP C1M1 C2M1
TERMINAL/FRAME
AXIS 1 & 2
M3 M3
SERVO AMP C1M3 C2M3
TERMINAL/FRAME
AXIS 3 & 7
M2 M2
SERVO AMP C1M2 C2M2
TERMINAL/FRAME
AXIS 4,5, & 6
AXIS CONTROL P1 P1
(PULSE CODER
SIGNAL)
AXIS CONTROL
PCB − JF7
(PULSE CODER
SIGNAL−AXIS7)

P & M BRAKE
SIGNALS
D1 D1
TRANSDUCER
(IBRC)
+6V& 0V C1B1 (INTRINSIC) C2B1 (INTRINSIC)

BATT
P2
+24PG & 0V DC−DC
C1P2 C2P2
PURGE CONTROL 24V
PCB 5V

11. CONNECTIONS
MARMMTRBL02303E
11–10

System with Battery in Robot and Junction Box
M1 M1
SERVO AMP C1M1 C2M1
TERMINAL/FRAME
AXIS 1 & 2
M3 M3
SERVO AMP C1M3 C2M3
TERMINAL/FRAME
AXIS 3 & 7
M2 M2
SERVO AMP C1M2 C2M2
TERMINAL/FRAME
AXIS 4,5, & 6
AXIS CONTROL P1 P1
(PULSE CODER
SIGNAL)
AXIS CONTROL
PCB − JF7
(PULSE CODER
SIGNAL−AXIS7)

P & MBRAKE
SIGNALS
D1 D1
TRANSDUCER
(IBRC)
P2 DC−DC
+24PG & 0V C1P2 C2P2
PURGE CONTROL 24V
PCB 5V

11. CONNECTIONS
Figure 12–12. Mechanical Connection Diagram, Common Part
(*2)
(*2)
or Floppy Disk Drive
(*3)
(*3)
(*3)
Auto breaker
(*3)
(*3)
*1: K41 is optional. K40 is not required if K41 is specified.

*2: This cable is provided with the FANUC Handy File or the floppy disk drive.
*3: Not included. Must be supplied by the customer.
11. CONNECTIONS
MARMMTRBL02303E
11–12
11.1.1 For the S-420, cables K70, K71, and K72 are connected as shown in
Figure 12–15.
Robot Connection
Cables
11. CONNECTIONS
11.1.2 For the P-155, cables C1M1, C1M2, C1M3, C1M5 and C1P1 are
connected as shown in Figure 12–13 through Figure 12–23.
Robot Connection
Cables Figure 12–13. Six-Axis Pedestal
AXIS EMG
AMP 1 AMP 2 AMP 3 CONTROL CONTROL
PCB PCB
CRF1
9 9 9
20 20 20
10 10 10
21 21 21 CRR5
11 11 11
22 22 22
12 12 12
23 23 23
C1P1
<−AXIS1 <−AXIS2 <−AXIS3
C1M5
C1M3
C1M1
ROBOT
<−AXIS4 <−AXIS5 <−AXIS6 M1

C1M2 C1M1
M3
C1M3
M2
C1M2
P1
C1P1
C1M5
11. CONNECTIONS
MARMMTRBL02303E
11–14
Figure 12–14. Seven-Axis Catrac Robot Clean-Wall Rail

AXIS EMG
AMP 1 AMP 2 AMP 3 AMP 4 AMP 5 CONTROL CONTROL
PCB PCB
CRF1
9 9 9 9
20 20 20
10 10 10 10
21 21 21 JF7 CRR5
11 11 11 11
22 22 22
12 12 12 12
23 23 23
C1M5
C1P1
<−AXIS1 <−AXIS2 <−AXIS3 <−AXIS7

(EXTENDED)
C1M3
C1M1

C1M2
JUNCTION BOX ROBOT
M1 M1
C1M1 C2M1
M3 M3
C1M3 C2M3
M2 M2
C1M2 C2M2
P1 P1
C1P1 C2P1
C1M5 C2M5
11. CONNECTIONS
Figure 12–15. Connection to Servo Amplifiers and Mechanical Unit for S-420
AXIS
CONTROL
PCB
CRM1
CRF1
K71
K72
K70
For the S-420 with three dual-axis servo amplifiers, ARC Mate, S-5, ARC
Mate Sr., and S-10, cables K70 and K71 are connected as shown in
Figure 12–16.
Figure 12–16. Connection to Servo Amplifiers and Mechanical Unit for S-420,
S-420D, ARC Mate, S-5, ARC Mate 100/S-6, ARC Mate Sr., S-10
AXIS
CONTROL
PCB
CRM1
CRF1
S-420,
S-420D
ARC Mate
ARCMate100/
S-6,
ARC Mate Sr.
S-10
S-5
K71
K70
11. CONNECTIONS
MARMMTRBL02303E
11–16
For the S-500, cables K70, K71, and K72 are connected as shown in
Figure 12–17.
AXIS
CONTROL
PCB
CRM1
CRF1
S-500
K71
K72
K70
Figure 12–18.
AXIS
CONTROL
PCB
CRM1
CRF1
S-700
K71
K72
K70
11. CONNECTIONS
Figure 12–19
AXIS
CONTROL
PCB
CRM1
CRF1
S-800
K71
K72
K70
For the A-510, cables K70 and K71 are connected as shown in
Figure 12–20
Figure 12–20. Connection to Servo Amplifiers and Mechanical Unit for A-510
AXIS
CONTROL
PCB
CRM1
Not used CRF1

A-510
K71
K70
11. CONNECTIONS
MARMMTRBL02303E
11–18
For the M-400 and M-500, cables K70, K71, and K72 are connected as
shown in Figure 12–21.
Figure 12–21. Connection to Servo Amplifiers and Mechanical Unit for M-400 and
M-500
AXIS
CONTROL
PCB
CRM1
CRF1
M-400
M-500
K71
K72
K70
For the L-1000, cables K70 and K71 are connected as shown in
Figure 12–22.
Figure 12–22. Connection to Servo Amplifiers and Mechanical Unit for L-1000
AXIS
CONTROL
PCB
CRM1
CRF1
L-1000
K71
K70
11. CONNECTIONS
Figure 12–23. Seven-Axis Universal Rail

AXIS EMG
AMP 1 AMP 2 AMP 3 AMP 4 AMP 5 CONTROL CONTROL
PCB PCB
CRF1
9 9 9 9
20 20 20
10 10 10 10
21 21 21 JF7 CRR5
11 11 11 11
22 22 22
12 12 12 12
23 23 23
C1M5
C1P1
<−AXIS1 <−AXIS2 <−AXIS3 <−AXIS7

(EXTENDED)
C1M3
C1M1

C1M2
JUNCTION BOX ROBOT
M1 M1
C1M1 C2M1
M3 M3
C1M3 C2M3
M2 M2
C1M2 C2M2
P1 P1
C1P1 C2P1
C1M5 C2M5
11. CONNECTIONS
MARMMTRBL02303E
11–20
11.1.3 Use the following guidelines when connecting the input power supply:
Connecting the Input
Power Supply  Adjust the input transformer
before supplying power to thetaps depending
robot. onSection
Refer to the plant
1.9input voltage
for the
correct tap setting information.
 Consider the robot power capacity and the circuit breaker capacity.
Use the correct gauge wire to withstand the maximum current used.
 Connect the power supply to the terminals located above the circuit
breaker or on the top of the disconnect.
 Use a ground of class 3 or better.
 Be sure to ground the work table or fixture used by an arc welding

robot so that it can handle the large current.
The motor is driven by the PWM inverter system using the power
transistor bridge. If the servo amplifier is used without a transformer, a
high-frequency leakage current flows through the stray capacitance
between the ground and the motor coils, power cable, and amplifier. This
might cause the leakage-current circuit breaker or leakage-protection relay
installed in the path of the power supply to cut out.
If connecting power directly to the servo amplifiers, use the leakage
current circuit breaker listed in Table 11–1 to prevent incorrect operation.
Table 11–1. Example of Leakage Current Circuit Breaker for Inverters

Manufacture Type
EG A series
u ec r c o., .
SG A series
ES100C type
ac , .
ES225C type
Leakage current circuit breaker, C type
a sus a ec r c or s, .
Leakage current circuit breaker, KC type
Figure 12–24 shows the cable connection for a circuit

breaker.Figure 12–25 shows the cable connection for a fused flange
disconnect.
Figure 12–25 shows the cable connection for a fused flange disconnect.
11. CONNECTIONS
Figure 12–24. Input Power Supply Connection, Circuit Breaker
Figure 12–25. Input Power Supply Connection, Fused Flange Disconnect
K–01
Main
Disconnect
FL1 FL2 FL3
Fuse Block
11. CONNECTIONS
MARMMTRBL02303E
11–22
11.1.4 The external power on/off signal turns on and off the power supply from
outside of the control unit, and is connected as shown in Figure 12–27.
Connecting the
External Power Supply
ON/OFF Switch
Figure 12–26. External Power Supply ON/OFF Switch Connection
19
24
20 EX–ON
1
62
4
3
48 3
3
EX–OFF
2
3
1
3
49
25
External power supply ON/OFF switch

Use a contact conforming to the following: Voltage rating: 50 VDC, current: 100 mA or more.
The power supply on/off timing chart is as follows:
11. CONNECTIONS
Figure 12–27. External Power Supply ON/OFF Switch Connection
EMG
PCB
Power on Power off
External power supply ON/OFF switch
Use a contact conforming to the following: Voltage rating: 50 VDC, current: 100 mA or more.
The power supply on/off timing chart is as follows:
11. CONNECTIONS
MARMMTRBL02303E
11–24
11.1.5 The external emergency stop connection is shown in Figure 12–29 and
Figure 12–31 and described in Table 11–2 and Table 11–3.
External Emergency
Stop Connection Figure 12–28. External Emergency Stop Output Connection
19
24
3 EMG OUT1
2 EMG OUT C
1 EMG OUT 2
20
1
62
48
8 EMG B1
2
49 7 EMGB2
2
25
Emergency Stop
Control PCB
11. CONNECTIONS
Figure 12–29. External Emergency Stop Output Connection
EMG
PCB
CRR3
CRR4
Emergency stop
control board
Table 11–2. External Emergency Stop Output Signals

Description Current,
Signal
Voltage
Emergency stop output signals
EMGOUT1 The contact is open if an emergency stop
occurs or the power is turned off.
EMGOUTC The contact is closed during normal Rated contact:
operation. 250 VAC, 5-A
Emergency stop output signals. resistor load
EMGOUT2
The contact is open during normal operation.
The contact is closed if an emergency stop
EMGOUTC
occurs or the power is turned off.
Emergency stop output signals of the teach
pendant
EMGB1 Rated contact:
The contact is open if the emergency stop
button on the teach pendant is pressed. 24 VDC,load
resistor 0.1-A
EMGB2
The contact is closed during normal
operation.
11. CONNECTIONS
MARMMTRBL02303E
11–26
Figure 12–30. External Emergency Stop Input Connection
19
24
6 *E1N1
4
5
4
20 *E1NC
External E–Stops
1
62 4 *E1NC
4
3
48 4
*E1N2
49
*FENCE 1
6
3
5
3
25 *FENCE 2
* Jumper across switches when not in use.
11. CONNECTIONS
Figure 12–31. External Emergency Stop Input Connection
External Emergency stop switch

Connected at
shipment
(Note)
Connect to IMSTP
on the UOP
Printed circuit board

for emergency control
Door switch on safety fence

Connected at
shipment
Note: Connect to EMGIN1 or EMGIN2.
To connect to the external emergency stop input, connect a double-pole

emergency stop switch to both the Emergency Stop printed circuit board
and the peripheral device interface.
Use a contact rated at 250 V, 10 A or more on the Emergency Stop printed
circuit board.
Table 11–3. External Emergency Stop Input Signals
Description Current,
Signal
Voltage
Connect one of the external emergency stop
EMGIN1 switch circuits to the terminals.
If the external emergency stop switch is 100 VAC, 5 A,
EMGINC pressed, the 100 VAC power for the motor is open/close
cut directly. To affect EMGOUT1 or EMGOUT2,
connect to EMGIN1 and EMGINC.. To not
EMGIN2 affect EMGOUT1 or EMGOUT2, connect to
EMGIN2 and EMGINC.
EMGINC If these signals are not used, short all external
emergency stop terminals together.
These signals are used to stop the robot when
the door on the safety fence is open. 24 VDC, 0.1 A,
FENCE1 While the DEADMAN switch on the teach open/close
pendant is pressed and the teach pendant
enable switch is ON, these signals are ignored
FENCE2 and an emergency stop does not occur.
If these signals are not used, short these
terminals.
M3 screws are provided on the terminal. Use crimp terminals 7 mm wide

or less.
11. CONNECTIONS
MARMMTRBL02303E
11–28
11.2 The R-J I/O peripheral device interfaces include process I/O printed circuit
boards and/or a modular I/O unit selected according to the applications.
PERIPHERAL DEVICE
AND END EFFECTOR Table 11–4 lists the printed circuit boards and unit. Figure 12–34 shows
the locations.
INTERFACES
11.3 The R-J I/O peripheral device interfaces include process I/O printed circuit
boards and/or a modular I/O unit selected according to the applications.
PERIPHERAL DEVICE,
Table 11–4 lists the printed circuit boards and unit. Figure 12–32 and
ARC WELDING, AND Figure 12–33 show their locations.
END EFFECTOR
INTERFACES
Table 11–4. Peripheral Device Interface Types
Number of I/O
No. Name Part Number Points Remarks
DI DO D/A A/D
1 Process I/O printed circuit board AA A16B-2200-0780 40 40 2 6 Standard (with welding interface)
2 Process I/O printed circuit board AB A16B-2200-0782 40 40 — — Standard (without welding interface)
3 Process I/O printed circuit board BA A16B-2201-0510 32 32 2 4 Source type DO (with welding
(weld interface) interface)
A20B-2000-0540
4 Process I/O printed circuit board BB A16B-2201-0510 32 32 — — Source type DO (without welding
interface)
5 Process I/O printed circuit board CA A16B-2201-0470 40 40 2 4 Backplane installation type (with
welding interface)
6 Process I/O printed circuit board CB A16B-2201-0472 40 40 — — Backplane installation type (without
welding interface)
7 Process I/O printed circuit board DA A16B-2201-0480 96 96 — — Backplane installation type (without
welding interface)
8 I/O unit model A03B-0807-C002 Depending on a Up to 5 slots
A03B-0807-C001 selected I/O module Up to 10 slots
11. CONNECTIONS
Figure 12–32. Locations of Peripheral Device Interfaces, B-Size Controller
Main CPU printed circuit board
Printed circuit board for

emergency stop control
Process I/O printed circuit board

CA/CB/DA
Modular I/O unit or

Process I/O printed circuit board
AA/AB/BA/BB or I/O unit model A
11. CONNECTIONS
MARMMTRBL02303E
11–30
Figure 12–33. Locations of Peripheral Devices, C-Size Controller
Operator panel
Î Î
Î Î
Extended
Î
Î
Î
Î
Î Î
Back plane Modular I/O rack or

Î Î Ï
Process I/O rack

Î Î Î Î
Î Î
Î Î
Power disconnect
Î Î Î Î
Î Î
Î
Î Î
Servo Amplifiers #1 Main CPU

Fuses FL1–3
Servo Amplifiers #2
Axis control board
Servo Amplifiers #3
Power supply unit
Servo Amplifiers #4 and #5 Emergency stop

control board
Servo Amplifiers #6 Option 1 and 2 slots
User transformer
11. CONNECTIONS
Figure 12–34. Locations of Peripheral Devices, C-Size Controller
Î Î Î
Operator panel
Î Î Î Î Ï
Ï Î
Î Î Î
Î Î Î
Î Î
Î Î Î Î
Î Î
Î Î Î
Î
Î Î
Î Î
STAHL Extended
Servo Amplifiers ISB’s Back plane STBI Term Strip
Purge 24V DC
Power Supply
Power disconnect
Main CPU
Fuses FL1–3
Transit Board Axis control board
Power supply unit
Emergency stop
control board
Option 1 and 2 slots
BDX
ISB Unit
ALC
relay
User transformer
11. CONNECTIONS
MARMMTRBL02303E
11–32
11.3.1 Process I/O printed circuit board AA, AB, BA, BB, CA, CB, and DA and
an I/O unit can be combined. Figure 12–35 shows the combinations.
Peripheral Device
Interface Combination
Figure 12–35. Peripheral Device Interface Combination
1 Board
2-Board Combination
3-Board Combination
11. CONNECTIONS
11.3.2
Process I/O Printed
Circuit Board AA or AB
Figure 12–36. Process I/O Printed Circuit Board AA or AB
(Additional analog
signal input)
CRW1 and CRW2 are not provided for process I/O printed circuit board BB.
Table 11–5. Process I/O Printed Circuit Board AA or AB

Cable
Name Drawing Number Remarks
Number
K10 Process I/O connection cable A05B–2300–J013 R-J control unit internal cable
A05B–2302–J110 Connected length: 7 m
Honda Tsushin, 50 pins: one-to-one
K50A Peripheral device connection cable A05B–2302–J11 Connected length: 14 m
K50B Honda Tsushin, 50 pins: one-to-one
K45 Welder connection cable A05B–2302–J271 Connected length: 6 m
Cannot be used for TIG welding
K46 Peripheral device connection cable –– Not included. Must be supplied by customer.
11. CONNECTIONS
MARMMTRBL02303E
11–34
11.3.3
Process I/O Printed
Circuit Board BA or BB
Figure 12–37. Process I/O Printed Circuit Board BA or BB
(Additional analog
signal input)
Table 11–6. Process I/O Printed Circuit Board BA or BB

Cable
Number
K52 Peripheral device connection cable –– Not included. Must be supplied by the customer.
K53 Peripheral device connection cable –– Not included. Must be supplied by the customer.
11. CONNECTIONS
11.3.4
Process I/O Printed
Circuit Board CA or CB
Figure 12–38. Process I/O Printed Circuit Board CA or CB
(Additional analog
signal input)
Table 11–7. Process I/O Printed Circuit Board CA or CB

Cable
Number
K11 Peripheral device connection cable A05B–2300–J014 R-J control unit internal cable (for connecting
additional printed circuit boards)
K50A, A05B–2302–J113 Connected length: 7 m
K50B Honda Tsushin, 50 pins: one-to-one
K50C Peripheral device connection cable A05B–2302–J114 Connected length: 14 m
K50D Honda Tsushin, 50 pins: one-to-one
11. CONNECTIONS
MARMMTRBL02303E
11–36
11.3.5 Up to two boards can be installed in one cabinet.

Process I/O Printed
Circuit Board DA Figure 12–39. Process I/O Printed Circuit Board DA
Table 11–8. Process I/O Printed Circuit Board DA

Cable
Number
K50 Peripheral device connection cable A05B–2302–J114 Connected length: 14 m
A-H Honda Tsushin, 50 pins: one-to-one
A-D Honda Tsushin, 20 pins: one-to-one
11. CONNECTIONS
11.3.6
Process I/O Printed
Circuit Board with the
Modular I/O Unit
Figure 12–40. Process I/O Printed Circuit Board with Modular I/O
Table 11–9. Process I/O Printed Circuit Board DA

Cable
Number
K15 I/O unit connection cable — R-J control unit internal cable. Attached to the I/O
unit mainframe.
K16 I/O unit power connection cable — R-J control unit internal cable. Attached to the I/O
unit mainframe.
K54 Peripheral device connection cable — Not included. Must be supplied by the customer.
11. CONNECTIONS
MARMMTRBL02303E
11–38
11.3.7 Figure 12–41 shows the connection when two or more process I/O printed
circuit boards and the modular I/O unit are used. Up to two process I/O
Two or More Process
I/O Boards with the CA/CB/DAs and 1 process I/O AA/AB/BA/BB or I/O unit model A can
be installed in one cabinet.
Modular I/O Unit
Figure 12–41. Two or More Process I/O Boards and the I/O Unit (Model A)
Table 11–10. Two or More Process I/O Boards and the I/O Unit (Model A)
Cable
Number
K12 Process I/O connection cable A05B-2300-J017 R-J control unit internal cable for connecting
additional printed circuit boards.
K15 I/O unit connection cable — R-J control unit internal cable. Attached to the I/O
unit mainframe.
K16 I/O unit power connection cable — R-J control unit internal cable. Attached to the I/O
unit mainframe.
11. CONNECTIONS
11.3.8 There are 18 exclusive data inputs (DI) and 20 exclusive data outputs (DO)
for a process I/O printed circuit board. These signals are allocated to the
Peripheral Device and
Control Unit process IO printed circuit board connected first when two or more printed
boards are combined. General signals SI/SO are allocated to the second
Connection and the following process I/O printed circuit boards.
The common voltage of the DI signals input to pins 1 to 4 of connector

CRM2A is clamped +24V (common) in each process I/O printed circuit
board. This is also true when multiple boards are combined.
Table 11–11 shows signals of a process I/O printed circuit board
Table 11–11. Process I/O Printed Circuit Board Signals, DI Signals

Connector Number Signal Name Description Remarks
CRM2A-1 *IMSTP Immediate stop Clamped at +24V common
CRM2A-2 *HOLD Temporary stop Clamped at +24V common
CRM2A-3 *SFSD Safe speed Clamped at +24V common
CRM2A-4 CSTOPI Cycle stop Clamped at +24V common
CRM2A-5 FAULT RESET External reset
CMR2A-6 START Start
CRM2A-7 HOME Return to home position
CRM2A-8 ENBL Operation enabled
CRM2A-9 RSR1 Robot service request
PNS1 Program number selection Option
CRM2A-29 PNSTROBE PNS strobe
CMR2A-30 PROD START Start of automatic operation
11. CONNECTIONS
MARMMTRBL02303E
11–40
Table 11–11. (Cont’d) Process I/O Printed Circuit Board Signals, DI Signals

CRM2A-31 SI01 Peripheral device status General signal
CRM2A-32 SI02
CRM2B-1 SI03
CRM2B-2 SI04
CRM2B-3 SI05
CRM2B-4 SI06
CRM2B-5 SI07
CRM2B-6 SI08
CRM2B-7 SI09
CRM2B-8 SI10
CRM2B-9 SI11
CRM2B-10 SI12
CRM2B-11 SI13
CRM2B-12 SI14
CRM2B-13 SI15
CRM2B-14 SI16
CRM2B-15 SI17
CRM2B-16 SI18
CRM2B-29 SI19
CRM2B-30 SI20
CRM2B-31 SI21
CRM2B-32 SI22
Table 11–12. Process I/O Printed Circuit Board Signals, DO Signals

CRM2A-33 CMDENBL During automatic operation
CRM2A-34 SYSRDY Preparation completed
CRM2A-35 PROGRUN During regeneration
CRM2A-36 PAUSED Program being interrupted
CRM2A-38 HELD During temporary stop
CRM2A-39 FAULT Alarm
CRM2A-40 ATPERCH Home position
CRM2A-41 TPENBL Teach pendant enabled
CRM2A-43 BATALM Battery voltage drop
CRM2A-44 BUSY During operation
CRM2A-45 ACK1 Robot service request acceptance
SNO1 Selected program number Option
11. CONNECTIONS
Table 11–12. (Cont’d) Process I/O Printed Circuit Board Signals, DO Signals

CRM2A-26 SNACK
CRM2A-27 RESERVED
CRM2B-33 SO01 Peripheral device control signal General signal
CRM2B-34 SO02
CRM2B-35 SO03
CRM2B-36 SO04
CRM2B-38 SO05
CRM2B-39 SO06
CRM2B-40 SO07
CRM2B-41 SO08
CRM2B-43 SO09
CRM2B-44 SO10
CRM2B-45 SO11
CRM2B-46 SO12
CRM2B-19 SO13
CRM2B-20 SO14
CRM2B-21 SO15
CRM2B-22 SO16
CRM2B-24 SO17
CRM2B-25 SO18
CRM2B-26 SO19
CRM2B-27 SO20
11. CONNECTIONS
MARMMTRBL02303E
11–42
Figure 12–42. Peripheral Device and Control Unit Connection -A1/A2
Note 1: The peripheral device connection cables

are optional.
Note 2: All of COM–** are connected 0 V.
Table 11–13. Applicable Process I/O Printed Circuit Board - A1/A2

Type Specifications CRM2A CRM2B
AA A05B-2300-J001  
AB A05B-2300-J002  
BA
BB A05B-2300-J020
A05B-2300-J021 
 

CA A05B-2300-J030  
CB A05B-2300-J031  
DA A05B-2300-J035  
 = applicable  = not applicable
11. CONNECTIONS
Figure 12–43. Peripheral Device and Control Unit Connection -A3/A4
Note 1: The peripheral device connection cables

are optional.
Table 11–14. Applicable Process I/O Printed Circuit Board - A3/A4
Type Specifications CRM2C CRM2D

AA A05B-2300-J001  
AB A05B-2300-J002  
BA A05B-2300-J020  
BB A05B-2300-J021  
CA A05B-2300-J030  
CB A05B-2300-J031  
DA A05B-2300-J035  
 = applicable
 = not applicable
11. CONNECTIONS
MARMMTRBL02303E
11–44
Figure 12–44. Peripheral Device and Control Unit Connection - B1/B2
Note 1: The peripheral device connection

cables are optional.
Table 11–15. Applicable Process I/O Printed Circuit Board - B1/B2

Type Specifications CRM4A CRM4B
AA A05B-2300-J001  
AB A05B-2300-J002  
BA A05B-2300-J020  
BB A05B-2300-J021  
CA A05B-2300-J030  
CB A05B-2300-J031  
DA A05B-2300-J035  
 = applicable
11. CONNECTIONS
Figure 12–45. Peripheral Device and Control Unit Connection -C1
Note 1: The peripheral device connection cable is not

supplied by FANUC. It must be supplied by the
customer.
Table 11–16. Applicable Process I/O Printed Circuit Board - C1
Type Specifications TBI1 TB01

AA A05B-2300-J001  
AB A05B-2300-J002  
BA A05B-2300-J020  
BB A05B-2300-J021  
CA A05B-2300-J030  
CB A05B-2300-J031  
DA A05B-2300-J035  
 = applicable
11. CONNECTIONS
MARMMTRBL02303E
11–46
Figure 12–46. Peripheral Device Interface Control for A1, A2, A3, and A4
Control Unit Connector pin No. Peripheral device

+24E CRM2A(49,50)
A4 A3 A2 A1
CRM2x (1)
SI43 SI23 SI03 *IMSTP RV
CRM2x (2)
SI44 SI24 SI04 *HOLD RV
CRM2x (3)
SI45 SI25 SI05 *SFSPD RV
CRM2x (4)
SI46 SI26 SI06 *CSTOPI RV
CRM2x (5)
SI47 SI27 SI07 FAULT RESET RV
CRM2x (6)
SI48 SI28 SI08 START RV
CRM2x (7)
SI49 SI29 SI09 HOME RV
CRM2x (8)
SI50 SI30 SI10 ENBL RV
CRM2x (9)
SI31 SI11 RSR1/PNS1 RV
SI51
CRM2x (10)
SI52 SI32 SI12 RSR2/PNS2 RV
CRM2x (11)
CRM2x (12)
CRM2x (13)
CRM2x (14)
CRM2x (15)
CRM2x (16)
CRM2x (29)
SI59 SI39 SI19 PNSTROBE RV
CRM2x (30)
SI60 SI40 SI20 PROD START RV
CRM2x (31)
SI61 SI41 SI21 SI01 RV
CRM2x (32)
SI62 SI42 SI22 SI02 RV
Note: For A1, CRM2x = CRM2A and ICOMn = ICOM1 +24E
For A2, CRM2x = CRM2B and ICOMn = ICOM2 B A
For A3, CRM2x = CRM2C and ICOM n = ICOM3 Common switching
For A4, CRM2x = CRM2D and ICOM n = ICOM4 set pin (ICOMn)
11. CONNECTIONS
Figure 12–47. Peripheral Device Interface for A1, A2, A3, and A4
Control Unit Connector Pin No. Peripheral Device
A4 A3 A2 A1 LOAD
DV CRM2x(33)
SO41 SO21 SO01 CMDENBL RELAY
CRM2x(34)
SO42 SO22 SO02 SYSRDY DV LOAD
CRM2x(35)
SO43 SO23 SO03 PROGRUN DV LOAD
CRM2x(36)
SO44 SO24 SO04 PAUSED DV LOAD
CRM2x(38)
SO45 SO25 SO05 HELD DV LOAD
CRM2x(39)
SO46 SO26 SO06 FAULT DV LOAD
SO47 SO27 SO07 ATPERCH DV CRM2x(40) LOAD

CRM2x(41)
SO48 SO28 SO08 TPENBL DV LOAD
CRM2x(43)
SO49 SO29 SO09 BATALM DV LOAD
CRM2x(44)
SO50 SO30 SO10 BUSY DV LOAD
CRM2x(45)
SO51 SO31 SO11 ACK1/SNO1 DV LOAD
CRM2x(46)
CRM2x(19)
CRM2x(20)
CRM2x(21)
CRM2x(22)
CRM2x(24)
CRM2x(25)
CRM2x(26)
SO59 SO39 SO19 SNACK DV LOAD
CRM2x(27)
SO60 SO40 SO20 RESERVED DV LOAD
CRM2x(23,28,37,42,47)
Note: For A1, CRM2x = CRM2A 0V +24V
+24V regulated
power supply
For A2, CRM2x = CRM2B
For A3, CRM2x = CRM2C
For A4, CRM2x = CRM2D
11. CONNECTIONS
MARMMTRBL02303E
11–48
Figure 12–48. Peripheral Device Control Interface B1
Connector pin No. Peripheral device

+24E CRM4A(49,50)
CRM4A(1)
SI63 RV
CRM4A(2)
SI64 RV
CRM4A(3)
SI65 RV
CRM4A(4)
SI66 RV
CRM4A(5)
SI67 RV
CRM4A(6)
SI68 RV
CRM4A(7)
SI69 RV
CRM4A(13)
SI70 RV
+24V B A
Common Switching
Set Pin
(Icom5)
Connector Pin No.

LOAD
DV CRM4A(14)
SO61 RELAY
CRM4A(15)
SO62 DV LOAD
CRM4A(16)
SO63 DV LOAD
CRM4A(17)
SO64 DV LOAD
CRM4A(8)
SO65 DV LOAD
CRM4A(9)
SO66 DV LOAD
CRM4A(10)
SO67 DV LOAD
CRM4A(11)
SO68 DV LOAD
CRM4A(20)
0V +24V
+24V regulated
power supply
11. CONNECTIONS
Figure 12–49. Peripheral Device Control Interface B2
Connector pin No. Peripheral device

+24E CRM4B(49,50)
CRM4B(1)
SI71 RV
CRM4B(2)
SI72 RV
CRM4B(3)
SI73 RV
CRM4B(4)
SI74 RV
CRM4B(5)
SI75 RV
CRM4B(6)
SI76 RV
CRM4B(7)
SI77 RV
CRM4B(13)
SI78 RV
+24V B A
Common Switching
Set Pin
(Icom5)
Connector Pin No.
LOAD
DV CRM4B(14)
SO69 RELAY
CRM4B(15)
SO70 DV LOAD
CRM4B(16)
SO71 DV LOAD
CRM4B(17)
SO72 DV LOAD
CRM4B(8)
SO73 DV LOAD
SO74 DV CRM4B(9) LOAD

CRM4B(10)
SO75 DV LOAD
CRM4B(11)
SO76 DV LOAD
CRM4B(20)
0V +24V
+24V regulated
power supply
11. CONNECTIONS
MARMMTRBL02303E
11–50
Figure 12–50. Peripheral Device Control Interface C1
Peripheral device
Receiver Circuit
TBI(1)
*IMSTP RV
TBI(2)
*HOLD RV
TBI(3)
*SFSPD RV
TBI(4)
CSTOPI RV
TBI(5)
FAULT RESET RV
START RV TBI(6)
TBI(7)
HOME
RV
TBI(8)
ENBL
RV
COM1 TBI(9) COM

(+24V or 0V)
0V TBI(10)
0V +24V
+24V regulated
power supply
Receiver Circuit
RSR1/PNS1 RV TBI(11)
TBI(12)
RSR2/PNS2 RV
TBI(13)
RSR3/PNS3 RV
TBI(14)
RSR4/PNS4 RV
TBI(15)
RSR5/PNS5 RV
TBI(16)
RSR6/PNS6 RV
TBI(17)
RSR7/PNS7 RV
TBI(18)
RSR8/PNS8 RV
COM2 TBI(19) COM

(+24V or 0V)
0V TBI(20)
11. CONNECTIONS
Peripheral device
Receiver Circuit
TBI(21)
PNSTROBE RV
TBI(22)
PROD START RV
TBI(23)
SI01 RV
TBI(24)
SI02 RV
TBI(25)
SI03 RV
SI04 RV TBI(26)
TBI(27)
SI05 RV
TBI(28)
SI06 RV
COM1 TBI(29) COM

(+24V or 0V)
0V TBI(30)
Receiver Circuit
SI07 RV TBI(31)
TBI(32)
SI08 RV
TBI(33)
SI09 RV
TBI(34)
SI10 RV
TBI(35)
SI11 RV
TBI(36)
SI12 RV
TBI(37)
SI13 RV
TBI(38)
SI14 RV
COM1 TBI(39) COM

(+24V or 0V)
0V TBI(40)
11. CONNECTIONS
MARMMTRBL02303E
11–52
Control unit Peripheral device

(peripheral device control interface C1)
+ 24 V regulated
power supply
Internal
circuit
+ 24 V regulated
power supply
Internal
circuit
11. CONNECTIONS

+ 24 V regulated
power supply
Internal
circuit
+ 24 V regulated
power supply
Internal
circuit
11. CONNECTIONS
MARMMTRBL02303E
11–54

+ 24 V regulated
power supply
Internal
circuit
+ 24 V regulated
power supply
Internal
circuit
11. CONNECTIONS

+ 24 V regulated
power supply
Internal
circuit
+ 24 V regulated
power supply
Internal
circuit
11. CONNECTIONS
MARMMTRBL02303E
11–56
11.3.9
Mechanical Unit and
End Effector
Connection Figure 12–56. Mechanical Unit and End Effector
Mechanical unit
Refer to Figure 11-42 to 11–45 for pin

configuration for your specific robot. End Effector
+24V B A
Common switching
set pin
11. CONNECTIONS
Figure 12–57. End Effector Pin Configuration – Arc Mate/S-5, Arc Mate Sr/S-10,
S-420, S-500, S-700, S-800, S-900, M-400 and M-500
End Effector
Figure 12–58. End Effector Pin Configuration – Arc Mate 100/S-6
End Effector
–OR–
1 2 3
RDO1 *HBK 0V
4 5
RDI1 +24E
11. CONNECTIONS
MARMMTRBL02303E
11–58
Figure 12–59. End Effector Pin Configuration – A-510
End Effector
Figure 12–60. End Effector Pin Configuration – L-1000
End Effector
11. CONNECTIONS
11.3.10
Control Unit and
Welder Connection
Figure 12–61. Control Unit and Welder Connection - CRW1/CRW2
Note: The welder and peripheral device

connection cable are optional.
Table 11–17. Applicable Process I/O Printed Circuit Board
Type Specifications CRW1 CRW2

AA A05B-2300-J001  
AB A05B-2300-J002  
BA A05B-2300-J020  
BB A05B-2300-J021  
CA A05B-2300-J030  
CB A05B-2300-J031  
DA A05B-2300-J035  
 = applicable
11. CONNECTIONS
MARMMTRBL02303E
11–60
Figure 12–62. Control Unit and Welder Connection - CRW1 Analog Signal
Assignment
11. CONNECTIONS
Figure 12–63. Control Unit and Welder Connection - CRW1 Digital Signal
Assignment
11. CONNECTIONS
MARMMTRBL02303E
11–62
Figure 12–64. Control Unit and Welder Connection - CRW2 Analog Signal
Assignment
11. CONNECTIONS
11.3.11 Table 11–18 contains the specifications of the peripheral device interface.
Peripheral Device
Interface
Table 11–18. Peripheral Device Interface Specifications
Type Example of Connection Signal Standards
Output signals Electrical Specifications
in peripheral Rated voltage: 24 VDC
device interface Maximum applied voltage: 30 VDC
A and B Maximum load current: 0.2 A
Transistor type: Open collector NPN
Saturation voltage at connection: 1.0 V (approx.)
Spark Killer Diode
Rated peak reverse voltage: 100 V or more
Rated effective forward current: 1 A or more
Note on Use
Do not use the +24V power supply of the robot.
When loading a relay, solenoid, and so on directly,
connect them in parallel with diodes for preventing
back electromotive force. If a load is connected
causing a surge current when a lamp is turned on,
use a protective resistance.
Applicable Signals
Output signals of process I/O printed circuit board CRM2
and CRM4; CMDENBL, SYSRDY, PROGRUN, PAUSED,
HELD, FAULT, ATPERCH, TPENBL, BATALM, BUSY,
ACK1 to ACK8, SNO1 to SNO8, SNACK, SO1 to SO20
Input signals in
peripheral
device interface Electrical Specifications of the Receiver
A and B Type: Grounded voltage receiver
Rated input voltage: Contact closed: +20V to +28V
Contact open: 0V to +4V
Maximum applied
input voltage: +28 VDC
Input impedance: 3.3 k (approx.)
Response time: 5 ms to 20 ms
Specifications of the Peripheral Decive Contact
Rated contact capacity: 30 VDC, 50 mA or more
Input signal width: 200 ms or more (on/off)
Chattering time: 5 ms or less
Closed circuit resistance: 100  or less
Peripheral
Opened circuit resistance: 100 k or more
device
contact Note on Use
signal Apply the +24V power at the robot to the receiver.
However, the above signal specifications must be
satisfied at the robot receiver.
Robot
receiver Applicable Signals
signal
Input signals of process I/O printed circuit board CRM2
and CRM4; *IMSTP, *HOLD, *SFSD, CSTOPI, FAULT
RESET, START, HOME, ENBL, RSR1 to RSR8, PNS1 to
TB: Chattering 5 ms orless PNS8, PNSTROBE, PROD STASRT, SI1 to SI22
TC: 5 t o 20 ms
11. CONNECTIONS
MARMMTRBL02303E
11–64
Table 11–18. (Cont’d) Peripheral Device Interface Specifications

in peripheral Rated voltage: 24 VDC
device interface Maximum applied voltage: 30 VDC
C Maximum load current: 1.6 A (*1)
*1: This value is the maximum load current at one point.
When four points on the same common are turned on at
the same time, the maximum load current at one common
is 5.0 A.
Spark Killer Diode
Note on Use
Do not use the +24 V power supply of the robot. When
loading a relay, solenoid, and so on directly, connect them
in parallel with diodes for preventing back electromotive
force. If a load is connected causing a surge current
when a lamp is turned on, use a protective resistance.
Applicable Signals
Output signals of process I/O printed circuit board BA/BB
TBO1; CMDENBL, SYSRDY, PROGRUN, PAUSED,
HELD, FAULT, ATPERCH, TPENBL, BATALM, BUSY,
ACK1 to ACK8, SNO1 to SNO8, SNACK, SO1 to SO12.
Input signals in
peripheral Electrical Specifications of the Receiver
Type: Grounded voltage receiver
device interface
C Contact open: 0V to +4V
Maximum applied
Specifications of the Peripheral Device Contact
Note on Use
Apply the +24V power at the robot to the receiver.
Applicable Signals
Input signals of process I/O printed circuit board BA/BB
TBI1; *IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET,
START, HOME, ENBL, RSR1 to RSR8, PNS1 to PNS8,
PNSTROBE, PROD STASRT, SI1 to SI24
Peripheral
device
contact
signal
Robot
receiver
signal
TB: Chattering 5 ms orless TC: 5 t o 20 m s
11. CONNECTIONS
11.3.12 Table 11–19 contains the specifications of the end effector control
interface.
End Effector Control
Interface
Table 11–19. End Effector Control Interface Signals
Rated voltage: 24 VDC
Maximum applied voltage: 30 VDC
Maximum load current: 0.2 A
Spark Killer Diode
Note on Use
The +24 V power supply at the robot can be used when
the total current of the welding interface and end effector
interface is 0.7 A or less. When loading a relay, solenoid,
and so on directly, connect them in parallel with diodes for
preventing back electromotive force. If a load is
connected causing a surge current when a lamp is turned
on, use a protective resistance.
Applicable Signals
Output signals of the end effector control interface
RO1 to RO8
Input signal
Electrical Specifications of the Receiver
Maximum applied
Peripheral
device Note on Use
contact
signal Apply the +24V power at the robot to the receiver.
Robot Applicable Signals
receiver
signal Input signals of the end effector control interface
RI1 toRI 8, *HBK, *PPABN
TB: Chattering5 ms orless TC: 5 t o 20 m s
11. CONNECTIONS
MARMMTRBL02303E
11–66
11.3.13 Table 11–20 contains the specifications of the arc welding interface.
Arc Welding Interface
Process I/O AA
Table 11–20. Arc Welding Interface Signals
Digital output Electrical Specifications
signals Rated voltage: 24 VDC
Maximum applied voltage: 30 VDC
Maximum load current: 0.2 A
Spark Killer Diode
Note on Use
The +24 V power supply at the robot can be used when
the total current of the welding interface and end effector
interface is 0.7 A or less. When loading a relay, solenoid,
and so on directly, connect them in parallel with diodes for
preventing back electromotive force. If a load is
connected causing a surge current when a lamp is turned
on, use a protective resistance.
Applicable Signals
Output signals of the end effector control interface
WO1 to WO8
Digital input
Electrical Specifications of the Receiver
signals
Maximum applied
Input impedance:
Response time: 3.3
5 msk
to (approx.)
20 ms
Note on Use
Apply the +24V power at the robot to the receiver.
Peripheral However, the above signal specifications must be
device satisfied at the robot receiver.
contact
signal
Applicable Signals
Input signals of the arc welding interface
WI1 to WI8
Robot
receiver
signal
TB: Chattering 5 ms orless TC: 5 t o 20 m s
11. CONNECTIONS
Table 11–20. (Cont’d) Arc Welding Interface Signals

Analog output Arc Welding Interface Note on Use
signals: welding Input impedance: 3.3 k or more
voltage Install a high-frequency filter.
command, wire
feed speed
command
Analog input Note on Use

signals: welding Output signals without ripples.
voltage
detection,
welding current
detection
Analog input
Arc Welding Interface Note on Use
signal: wire The resistance between the positive and negative
stick detect terminals on the welder must be 100  or more. The
WDI+, WDI– maximum voltage of this circuit is 80 V. For TIG welding,
connected the wirestick detection signal line, insulating it
from a welding circuit (high frequency).
11. CONNECTIONS
MARMMTRBL02303E
11–68
11.3.14 This section describes the connections and specifications for modular I/O
units.
Modular I/O Inputs
Table 11–21. Input Modules AID32A and AID32B, Non–isolated
Item AID32A AID32B
Points/module 32 points 32 points
Points/common 16 points/common 16 points/common
Sink/source cur- Both directions Both directions
rent
Input voltage 24VDC +10% –20% 24 VDC +10% –20%
Input current 7.5mA (average) 7.5mA (average)
ON voltage cur- Min. 18VDC min. 6 mA Min. 18 VDC min. 6 mA
rent
OFF voltage cur- Max. 6VDC max. 1.5 mA Max. 6VDC max. 1.5 mA
rent
Respo Max. 20 This is the value from input to output This is the value from input to output
nse OFF  ON in the module. The actual value is Max. 2 ms in the module. The actual value is
ms
me e erm ne y a ng o e e erm ne y a ng o e
Max. 20 scanning time depending on each scanning time depending on each
ON  OFF Max. 2 ms
ms system. system.
Input display Not provided Not provided
External connec- Connector (HONDA TSUSIN MR-50RMA) Connector (HONDA TSUSIN MR-50RMA)
tion
Terminal : input circuit CM
connection and Internal
circuitry Circuit
29,45 21,36
CMA 49,50 CMC 40,41
A0 16 C0 07
A1 32 C1 24
A2 48 C2 39
A3 15 C3 06
A4 31 C4 23
A5 47 C5 38
A6 30 C6 22
A7 46 D7 37
B0 12 D0 03
B1 28 D1 20
B2 44 D2 35
B3 11 D3 02
B4 27 D4 19
B5 43 D5 34
B6 10 D6 01
B7 42 D7 33
13,17 ––+24V 04,08 ––+24V
14,18 ––GND 05,09 ––GND
+24V or GND can be selected for input common as above figure.

Note: Make sure to connect all common (CMA, CMC) pins.
11. CONNECTIONS
Table 11–22. Input Modules AID16C and AID16D
Item AID16C AID16D

Sink/source current Source current type Sink current type
Input current 7.5 mA (average) 7.5 mA (average)
ON voltage current Min. 15VDC min. 4 mA Min. 15 VDC min. 4 mA
OFF voltage current Max. 5VDC max. 1.5 mA Max. 5VDC max. 1.5 mA
Response This is the value from input to This is the value from input to
Time OFF  ON Max. 20ms output in the module. The Max. 20ms output in the module. The
ac ua va ue s e erm ne y ac ua va ue s e erm ne y
ON  OFF Max. 20ms adding it to the scanning time Max. 20ms adding it to the scanning time
depending on each system. depending on each system.
Input display LED display LED display
External connection Terminal block connector (20 terminals, M3.5 Terminal block connector (20 terminals, M3.5
screw terminal) screw terminal)
Terminal connection and
circuitry (C) (D)
1
A0 2
A1 3
A2 4
A3 5
A4 6
A5 7
+ –
A6 9
8
– + A7
B0 10
B1 11
B2 12
B3 13
B4 14
B5 15
B6 16
B7 17
18
19
20
FOR AID16C FOR AID16D

: input circuit : input circuit
LED LED
1 1
11. CONNECTIONS
MARMMTRBL02303E
11–70
Table 11–23. Input Modules AID32E and AID32F
Item AID32E AID32F

Sink/source current Both directions Both directions
Input current 7.5 mA (average) 7.5mA (average)
ON voltage current Min. 15VDC min. 4.5 mA Min. 15VDC min. 4.5 mA
OFF voltage current Max. 6VDC max. 2 mA Max. 6VDC max. 2 mA
Response Max. 20 This is the value from input to This is the value from input to
Time OFF  ON output in the module. The Max. 2 ms output in the module. The
ms
ON  OFF Max. 20 adding it to the scanning time Max. 2 ms adding it to the scanning time
ms depending on each system. depending on each system.
Input display Not provided Not provided
External connection Connector (HONDA TSUSIN MR-50RMA) Connector (HONDA TSUSIN MR-50RMA)
circuitry
: input circuit CM
CMA 49,50 CMC 40,41

A0 16 C0 07
A1 32 C1 24
A2 48 C2 39
A3 15 C3 06
A4 31 C4 23
A5 47 C5 38
A6 30 C6 22
A7 46 C7 37
CMB 29,45 CMD 21,36

B0 12 D0 03
B1 28 D1 20
B2 44 D2 35
B3 11 D3 02
B4
B5 27
43 D4
D5 19
34
B6 10 D6 01
B7 42 D7 33
11. CONNECTIONS
Table 11–24. Input Module AIA16G
Item AIA16G
Points/module 16 points
Points/common 16 points/common
Rated load voltage 100 ~ 155VAC  15%
Max. input voltage 132Vrms 50/60Hz
Input current 10.5mArms (120VAC 50Hz)
ON voltage current 74Vrms min. 6mArms
OFF voltage current 20Vrms max. 2.2mArms
Response This is the value from input to
Time OFF  ON Max. 35 ms output in the module. The
ac ua va ue s e erm ne y
ON  OFF Max. 35 ms adding it to the scanning time
depending on each system.
Input display LED display
External connection Terminal block connector (20 terminals, M3.5
screw terminal)
Common 16 points/common
circuitry
A0 1
A1 2
A2 3
A3 4
5
A4
A5 6
A6 7
A7 8
B0 9
B1 10
B2 11
B3 12
B4 13
B5 14
B6 15
B7 16
17 NC
18 NC
19
20
: input circuit
LED
19
11. CONNECTIONS
MARMMTRBL02303E
11–72
11.3.15
Modular I/O Outputs
Table 11–25. Output Module AOD32A, Non-isolated
Item AOD32A
Sink/source current Sink current type
Rated load voltage 5 ~ 24VDC +20% –15%
Maximum load current 0.3A (however 2A/common)
Maximum voltage 0.24V (load current  0.8)
drop when ON
Maximum leak current 0.1 mA
when OFF
Response OFF  ON Max. 1 ms
Time
Output display Not provided
External connection Connector (HONDA TSUSIN MR-50RMA)
Terminal connection
and circuitry
O : output circuit +5~+24
Internal
Circuit
L : load CM
+24A 17 +24C 08
L A0 16 O L C0 07 O
L A1 32 O L C1 24 O
L A2 48 O L C2 39 O
+
L A3 15 O
+ L C3 06 O
L A4 31 O L C4 23 O
– L A5 47 O – L C5 38 O
L A6 30 O L D6 22 O
L A7 46 O L D7 37 O
CMA 49,50 CMC 40,41
+24B 13 +24D 04
L B0 12 O L D0 03 O
L B1 28 O L D1 20 O
L B2 44 O L D2 35 O
+ L
L B3
B4 11
27 O
O + L
L D3
D4 02
19 O
O
– L B5 43 O – L D5 34 O
L B6 10 O L D6 01 O
L B7 42 O L D7 33 O
CMB 29,45 CMD 21,36
11. CONNECTIONS
Table 11–26. Output Modules AOD08C and AOD08D

Item AOD08C AOD08D
Sink/source current Sink current type Source current type
Rated load voltage 12 ~ 24VDC +20% –15% 12 ~ 24VDC +20% –15%
Maximum load current 2A (however 4A/fuse) 2A (however 4A/fuse)
Limit of load — Refer to load derating curve
Maximum voltage drop 0.8V (load current  0.4) 1.2V (load current  0.6)
when ON
Maximum leak current 0.1mA 0.1mA
when OFF
OFF  ON Max. 2 ms Max. 2 ms
Time output in the
ac ua va ue smodule.
e erm The
ne y output in the
ac ua va ue smodule.
e erm The
ne y
ON  OFF Max. 2 ms adding it to the scanning time Max. 2 ms adding it to the scanning time
Output display LED display LED display
External connection Terminal block connector (20 terminal, M3.5 Terminal block connector (20 terminal, M3.5
Fuse 5A, 1 piece for each output A0-A3 and A4-A7 5A, 1 piece for each output A0-A3 and A4-A7
Terminal connection Fuses Fuses
and circuitry 1 1
2 2
load 3 load 3
L A0 4 O L A0 4 O
L A1 5 O L A1 5
6 6 O
7 7
L A2 8 O L A2 8 O
9 9
L A3 10 O + L A3 10 O
+ 11 11
– L A4 12 O – L A4 12 O
13 13
L A5 14 O L A5 14 O
15 15
L A6 16 O L A6 16 O
17 17
L A7 O L A7 O
18 18
19 19
20 20
Fuses
O : output circuit O : output circuit

2 2
Internal Internal
LED Circuit
LED
Circuit
20 20
11. CONNECTIONS
MARMMTRBL02303E
11–74
Table 11–27. Output Modules AOD16C and AOD16D

Item AOD16C AOD16D
Sink/source current Sink current type Source current type
Rated load voltage 12 ~ 24VDC +20% –15% 12 ~ 24VDC +20% –15%
Maximum load current 0.5A (however 2A/common) 0.5A (however 2A/common)
Maximum voltage drop 0.7V (load current  1.4) 0.7V (load current  1.4)
when ON
Maximum leak current 0.1mA 0.1mA
when OFF
Time OFF  ON Max. 2 ms output in the module. The Max. 2 ms output in the module. The
ON  OFF Max. 2 ms adding it to the scanning time Max. 2 ms adding it to the scanning time
Output display LED display LED display
External connection Terminal block connector (20 terminal, M3.5 Terminal block connector (20 terminal, M3.5
Terminal connection and L : load L : load
circuitry 1 1
L A0 2 O L A0 2 O
L A1 3 O L A1 3 O
L A2 4 O L A2 4 O
+ +
L A3 5 O L A3 5 O
– L A4 6 O – L A4 6 O
L A5 7 O L A5 7 O
L A6 9 8 O L A6 9 8 O
L A7 O L A7 O
10 10
11 11
L B0 12 O L B0 12 O
L B1 13 O L B1 13 O
L B2 14 O L B2 14 O
+ L B3 15 O + L B3 15 O
L B4 O L B4 O
– 16 – 16
L B5 17 O L B5 17 O
L B6 18
O L B6 18
O
L B7 19 O L B7 19 O
20 20
O : output circuit O : output circuit
1 1
Internal Internal
Circuit LED LED
Circuit
10 10
11. CONNECTIONS
Table 11–28. Output Module AOD32C

Item AOD32C
Sink/source current Sink current type
Maximum voltage drop 0.24V (load current  0.8)
when ON
Maximum leak current 0.1mA
when OFF
Response OFF  ON Max. 2 ms This is the value from input to output in the module. The actual value is
Time determined by adding it to the scanning time depending
p on each system.
Terminal connection and +24
circuitry O : output circuit
Internal
Circuit
CM
L : load
+24A 17 +24C 08
L A0 16 O L C0 07 O
L A1 32 O L C1 24 O
L A2 48 O L C2 39 O
+ L
L A3
A4 15
31 O
O + L C3
C4 06
23 O
O
L
– L A5 47 O – L C5 38 O
L A6 30 O L C6 22 O
L A7 46 O L C7 37 O
CMA 49,50 CMC 40,41
+24B 13 +24D 04
L B0 12 O L D0 03 O
L B1 28 O L D1 20 O
L B2 44 O L D2 35 O
+ L B3 11 O L D3 02 O
L B4 27 O L D4 19 O
– L B5 43 O L D5 34 O
L B6 10 O L D6 01 O
L B7 42 O L D7 33 O
CMB 29,45 CMD 21,36
Note: For the common (CMA, CMB CMC, CMD) make sure to use both of them.
11. CONNECTIONS
MARMMTRBL02303E
11–76
Table 11–29. Output Module AOD32D

Item AOD32D
Sink/source current Source current type
Maximum voltage drop 0.24V (load current  0.8)
when ON
Maximum leak current 0.1mA
when OFF
Response Max. 2 ms This is the value from input to output in the module. The actual value is
OFF  ON
Time determined by adding it to the scanning time depending on each system.
CM
circuitry O : output circuit Internal
Circuit
0
L : load
CMA 49,50 CMC 40,41

L A0 16 O L C0 07 O
L A1 32 O L C1 24 O
L A2 48
15 O L C2 39
06 O
L A3 O L C3 O
+ +
L A4 31 O L C4 23 O
– L A5 47 O – L C5 38 O
L A6 30 O L C6 22 O
L A7 46 O L C7 37 O
0A 1B 0C 09
CMB 29,45 CMD 21,36

L B0 12 O L D0 03 O
L B1 28 O L D1 20 O
L B2 44 O L D2 35 O
+ L B3 11 O + L D3 02 O
L B4 27 O L D4 19 O
– L B5 43 O – L D5 34 O
L B6 10 O L D6 01 O
L B7 42 O L D7 33 O
0B 14 0D 05
Note: For the common (CMA, CMB CMC, CMD) make sure to use both of them.
11. CONNECTIONS
MARMMTRBL02303E
11–78
Table 11–31. Output Module AOA12F
Item AOA12F
Rated load voltage 100 ~ 115VDC  15% 47 ~ 63Hz
Maximum load current 0.5A/point (however 2A/common)
Maximum in rush current 5A (1 period)
Limit of load Refer to load derating curve
Maximum voltage drop 1.5Vrms
when ON
Maximum leak current 1.5mA (115 VAC)
when OFF
Response This is the value from input to
Time OFF  ON Max. 1 ms output in the module. The
ac ua va ue s e erm ne y
ON  OFF Half of the load frequency or less adding it to the scanning time
depending on each system.
Output display LED display
External connection Terminal block connector (20 terminal, M3.5 screw terminal)
Fuse 3.2A, 1 piece for each output A0 ~ A5 and
B0 ~ B5
Terminal connection and L : load
circuitry
L A0 1 O
L A1 2 O
L A2 3 O
L A3 4 O
L A4 5 O
L A5 6 O
7 O
8 O
9
Fuse
10
L B0 11 O
L B1 12 O
L B2 13 O
L B3 14 O
L B4 15 O
L B5 O
16
17 O
O
18
19
Fuse
NOTE:
Each output signal group (A0–A5 and
20 B0–B5) contains six output signals.
O : output circuit However, each group must have an entire
group of eight signals assigned to it.
For example, A0–A5 might be occupied
by digital outputs 1 through 6 and B0–B5
might be occupied by digital outputs
LED 9 through 14. Digital outputs 7 and 8 and
9 19 digital outputs 15 and 16 are unusuable.
11. CONNECTIONS
MARMMTRBL02303E
11–80
Table 11–33. Output Module ADA02A
Item ADA02A
Number of output 2 channels/module
channels
Digital input 12-bit binary (2’s complement representation)
Analog output –10VDC ~ +10VDC (external load resistance: 10K or more) selectable
0mADC ~ + 20mADC (external load resistance: 400 or less) usable
Input/output D igital Input Analog Output
correspondence
+2000 +10V
+1000 +5V or +20mA
0 0V or 0mA
–1000 –5V
–2000 –10V
Resolution 5mV or 20 A
Comprehensive accuracy Voltage output  0.5% (for the full scale)
Current output  1% (for the full scale)
Converting time 1ms or less. NOTE: The converting time is the one only inside the module. The actual
response time is added a scan time that is determined by the system.
Isolation Photocopier isolation (between output signal and base). However, non-isolation between
output channels.
External connection At removable terminal block (20 terminals, M3.5 screw terminals)
Number of occupied 82
output points
ADA02A
Load
V0+ Voltage output
2
Channel 0 10K ohms or more
Voltage V0–
amp. 4
D/A
converter
Current 6
amp.
10+
8
10–
10
V1+
12
Channel 1
Voltage V1–
amp. 14
D/A
converter
Current 16 Load
amp. 10+ Current output
18
10– 400 ohms or less
20
(Note 1) Use a 2–core twisted shielded cable as the connection cable.

(Note 2) Ground the cable shield on the load side
11. CONNECTIONS
Table 11–34. Analog Input Module AAD04A
Item AAD04A
Number of input channels 4 channels/module
Analog input –10VDC to +10VDC (input resistance 4.7M)
–20mADC to +20mADC (input resistance: 250 selectable
Digital output 12-bit binary (complementary representation of “2”)
Input/output Analog Input Digital Output
correspondence
+10V +2000
+5V or +20mA +1000
0V or 0mA 0
–5V or –20mA –1000
–10V –2000
Resolution 5mV or 20 A
Total precision Voltage input  0.5% (for the full scale)
Current input  1% (for the full scale)
Conversionary time Maximum 2ms. NOTE: Actual response speed is determined by adding the scanning time
depending on each system to this conversion time.
Maximum input 15V 30mA
voltage/current
Insulation Photocopier insulation (between output signal and base). However, non-insulation between
output channels.
External connection At removable terminal block (20 terminals, M3.5 screw terminals)
Number of occupied 82
output points
10+ 1
11+ 2
Voltage input V0+ 3
V1+
Voltage 4
V0–
supply
5
V1–
6
COM0
7 COM1 MULTI
8 PROCESSOR
FG0
9
FG1 10
12+ 11
13+ 250
12
Current input V2+
13
V3+
Current 14
V2–
supply 15
V3–
16
COM2
17
COM3
18
FG2
19
FG3
20
(Note 1) Though the example above shows the connection of channels 0 and 2, it is just the
same with the channel 1 (I1+, V1+, V1–, COM1 and FG1) and the channel 3 (I3+, V3+,
V3–, COM3 and FG3).
(Note 2) Either voltage input or current input can be specified for each channel. When current input is specified,
make sure to short–circuit in + and Vn+.
(Note 3) Use shielded cables of twisted pair for connecting.
11. CONNECTIONS
MARMMTRBL02303E
11–82
11.4 If you manufacture cables, conform to the FANUC standard cables

described in this section. Refer to the description in “Peripheral Device
SPECIFICATIONS OF
THE CABLES USED Interface” in this manual for the specifications of the FANUC standard
cables.
FOR PERIPHERAL
DEVICES AND
WELDERS
11.4.1 Figure 12–65 shows the peripheral device interface A cable, CRM2:
Honda Tsushin, 50 pins.
Peripheral Device
Interface A Cable Figure 12–65. Peripheral Device Interface A Cable
HONDA TSUSHIN HONDA TSUSHIN
HONDA TSUSHIN
HONDA TSUSHIN’S
SUPPLIED WITH AN ORDERED CABLE
11.4.2 Figure 12–66 shows the peripheral device interface B cable, CRM4:
Honda Tsushin, 20 pins.
Peripheral Device
Interface B Cable Figure 12–66. Peripheral Device Interface B Cable
HONDA TSUSHIN HONDA TSUSHIN
PERIPHERAL
DEVICE
HONDA TSUSHIN’S
HONDA TSUSHIN SUPPLIED WITH AN ORDERED CABLE
11. CONNECTIONS
11.4.3 Figure 12–67 shows the arc welder connection cable, CRW1: Honda
Tsushin, 34 pins.
Connection Cable Figure 12–67. Arc Welder Connection Cable
PERIPHERAL
HONDA TSUSHIN DEVICE
JAPAN AVIATION ELECTRONICS

INDUSTRY, LTD.
JAPAN AVIATION
ELECTRONICS STANDARD POSITION
INDUSTRY, LTD. OF GUIDE KEY
HONDA TSUSHIN
Use a welder connection cable conforming to the FANUC specifications.
11. CONNECTIONS
MARMMTRBL02303E
11–84
11.5
CABLE CONNECTION
FOR THE PERIPHERAL
DEVICES, END
EFFECTORS, AND ARC
WELDERS
11.5.1
Peripheral Device
Connection Cable Figure 12–68. Peripheral Device Cable Connection
Process I/O printed

circuit board CA/
CB/DA
Process I/O printed

circuit board AA/
AB/BA/BB or I/O
unit model A
Partly cut off the peripheral device

Clamp fixture connection cable to expose the
shield jacket, and fasten the jacket
to the shield plate with a clamp to
Shield jacket protect against noise.
Shield plate
11. CONNECTIONS
11.5.2 Figure 12–69 shows the connection of the arc welder cable in the control
unit.
Connection Cable Figure 12–69. Arc Welder Cable Connection
Process I/O printed

circuit board CA/
CB/DA
Process I/O printed

circuit board AA/
AB/BA/BB
Partly cut off the peripheral device

connection cable to expose the
shield jacket, and fasten the jacket
to the shield plate with a clamp to
protect against noise.
Clamp fixture
Shield jacket
Shield plate
11. CONNECTIONS
MARMMTRBL02303E
11–86
11.5.3 Figure 12–70, Figure 12–71, and Figure 12–72 show the connector for
peripheral device cables A, B, and C.
Peripheral Device
Cable Connector Figure 12–70. Peripheral Device Cable Connector for A and B(Honda Tsushin
Kogyo)
Table 11–35. Peripheral Device Cable Connector for A and B
Connector Applicable Dimensions

emar
Specifications Interface A (B) C (D)
MR50LMH CRM2 67.9 73.5 44.8 18 Honda Tsushin
Kogyo, 50 pins
MR20LMH CRM4 39.3 44.9 39.8 17 Honda Tsushin
Kogyo, 20 pins
Table 11–36. Symbols Used in Figure 12–70

Symbol Name
 Connector cover
 Cable clamp screw
 Connector clamp spring
 Connector clamp screw
 Connector 50 pins (male) MR50MH
20 pints (male) MR20MH
11. CONNECTIONS
Figure 12–71. Peripheral Device Connector for A and B
Table 11–37. Peripheral Device Cable Connector for A and B
Connector Applicable Dimensions

emar
Specifications Interface A B
MR50RFH CRM2 61.4 56.4 Honda Tsushin Kogyo, 50 pins
MR20RFH CRM4 39.3 44.9 Honda Tsushin Kogyo, 20 pins
Table 11–38. Symbols Used in Figure 12–71

Symbol Name
 Connector clamp screw
 Screw 2.6 x 8
 Connector (MR50RFH)
(MR20RFH)
11. CONNECTIONS
MARMMTRBL02303E
11–88
Figure 12–72. Peripheral Device Interface Cable C Connector (Phoenix Contact)
Insert the plug vertically toward the

conductor. Insert the cable in the side
of the plug plate key groove.
Table 11–39. Peripheral Device Interface Cable C Connector

Specifications
Number of
Specifications A mm
Terminals
MVSTBR 2.5/6-ST-5.08 6 25.40
MVSTBR 2.5/10-ST-5.08 10 45.72
Table 11–40. Connection Data

Applicable Rated Rated Wire End Processing
Wire Size Current Voltage
Twisted wires AWG12 12A AC250V
Solid wire AWG12 12A AC250V
Wire Jacket
11. CONNECTIONS
11.5.4
End Effector Cable
Connector Figure 12–73. Elbow Type Connector S-5, S-10, S-420, S-500, S-700, S-800,
M-400, M-500, ARC Mate, ARC Mate 100/S-6, ARC Mate Sr.
11. CONNECTIONS
MARMMTRBL02303E
11–90
Figure 12–74. Connector L-1000
A: M22x1
B: 48.82 G: 16.6
C: 30.5
D: 3.0 to 9.0 (Inside diameter)
Manufactured by Daiichi Denshi Kogyo JMCR1610
11. CONNECTIONS
11.5.5
Recommended Cables
Peripheral Device Connect a peripheral device using a completely shielded, heavily protected
Connection Cable cable conforming to the specifications in Table 11–41. Allow an extra
1.5m for routing the cable in the control unit. The maximum cable length
is 30 m.
Table 11–41. Recommended Cable for Peripheral Device Connection

Number Wire Conductor Sheath Effective Electrical Characteristics
of Wires Specifications Thickness Outside
Diameter Configuration Conductor Allowable
(FANUC (mm) Diameter
(mm) Resistance Current (A)
Specifications) (mm)
(/km)
50 A66L-0001-0042 1.05 7/0.18 AWG24 1.5 12.5 106 1.6
20 A66L-0001-0041 1.05 7/0.18 AWG24 1.5 10.5 106 1.6
End Effector Connection Connect an end effector using a heavily protected cable with a movable
Cable wire conforming to the specifications in Table 11–42. The cable length is
determined so that the cable will not interfere with the end effector and the
wrist can move through its full stroke.
Table 11–42. Recommended Cable for End Effector Connection

Number Wire Conductor Sheath Effective Electrical Characteristics
of Wires Specifications Thickness Outside
Diameter Configuration Conductor Allowable
(FANUC (mm) Diameter
(mm) Resistance Current (A)
Specifications) (mm)
(/km)
6 A66L-0001-0143 1.1 40/0.08 1.0 5.3 91 3.7
AWG24
20 A66L-0001-0144 1.1 40/0.08 1.0 8.6 91 2.3
AWG24
12
COMPLETE WIRING DIAGRAMS
Complete wiring for the controller and the robot mechanical unit is shown
in Figure 13–1 through Figure 13–32. The diagrams are valid for all
FANUC Robotics robot models (except where specific robot models are
indicated).
This chapter is useful for verifying the cable connections to all
components within the controller and robot.
12. COMPLETE WIRING DIAGRAMS

MARMMTRBL02303E
12–2
Figure 13–1. Internal Connection Diagram – S-420, S-800
2 1
7 7
0 0
K K
6
P
M
A
5
&
1
2
0
K
0
2 K.23
0
K
2
2
0
K
2
P
C
Figure 13–2. Internal Connection Diagram – S420 with three Servo Amplifiers,
S420D)

MARMMTRBL02303E
12–4
Figure 13–3. Internal Connection Diagram – ARC Mate, ARC Mate Sr., ARC Mate
100/S-6, S-5, and S-10
K
4 1 5 2 6 3

S
I S
I S
I S
I S
I S
I
X X X X X X
A A A A A A
C
A
V
0
0
2
0
2
0
K
1
2
0
K
3 2
2 2
0 0
K K
Figure 13–4. Internal Connection Diagram – S-500
1
M
6 3 0
7 7 4 1 8 8 5 2 9 9 6 3 0
1
, 2 3
3 1 2 3 3 1 2 3 3 1 2 3 4
, , ,
5 2
1 2 9
6
2
3
2
7
K 1
7
K

MARMMTRBL02303E
12–6
Figure 13–5. Internal Connection Diagram – S-700
Figure 13–6. Internal Connection Diagram – S900

MARMMTRBL02303E
12–8
Figure 13–7. Internal Connection Diagram – A-510
Figure 13–8. Internal Connection Diagram – M-400 (5-axes)

MARMMTRBL02303E
12–10
Figure 13–9. Internal Connection Diagram – M400 (4 axes)

MARMMTRBL02303E
12–12
Figure 13–12. Internal Connection Diagram – L-1000

MARMMTRBL02303E
12–14
Figure 13–13. Internal Connection Diagram – Emergency Stop Control – PCB
6
3
0
K
Figure 13–14. Internal Connection Diagram – Power Supply Unit
2
2
0
K

MARMMTRBL02303E
12–16
Figure 13–15. Internal Connection Diagram - Main CPU; Axis Control Board
0
4
0
K
0
7
0
K
Figure 13–16. Internal Connection Diagram – Servo Amplifier Connection S-420,

ARC Mate/S-5, ARC Mate Sr./S-10, ARC Mate 100/S-6, S-500, S-700, and S-800
n
o
i
t
a
r
u
g
i
f
n
o
c
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e
i
f
i
l
p
m
a
o
v
r
e
s
-
e
e
r
h
t
h
t
i
w
0
2
4
-
S

MARMMTRBL02303E
12–18
Figure 13–17. Internal Connection Diagram – Servo Amplifier Connection A-510,

L-1000, and M-400
Figure 13–18. Internal Connection Diagram – Servo Amplifier Connection S-900

and M-500

MARMMTRBL02303E
12–20
Figure 13–19. Internal Connection Diagram – Modular I/O
5 6
1 1
0 0
K K
P
O
T
S
Y
C
N
E
G
R
E
M
E
Figure 13–20. Internal Connection Diagram – Teach Pendant
1
4
0
K
0 5
4 3 2
0 0 4
K K 0
K K K

MARMMTRBL02303E
12–22
Figure 13–21. Internal Connection Diagram – Main CPU Interface
Figure 13–22. Internal Connection Diagram – Axis Control Board Interface

MARMMTRBL02303E
12–24
Figure 13–23. Internal Connection Diagram – ARC Mate/S-5, ARC Mate Sr./S-10,
ARC Mate 100/S-6, S-420, S-500 and S-800
Figure 13–24. Internal Connection Diagram – S-700 and A-510

MARMMTRBL02303E
12–26
Figure 13–25. Internal Connection Diagram – M-400 and L-1000
Figure 13–26. Internal Connection Diagram - M–400

MARMMTRBL02303E
12–28
Figure 13–27. External Connection Diagram – M-500
Figure 13–28. External Connection Diagram – S-900

MARMMTRBL02303E
12–30
Figure 13–29. External Connection Diagram – Process I/O
Figure 13–30. External Connection Diagram – Process I/O

MARMMTRBL02303E
12–32
Figure 13–31. External Connection Diagram – Teach Pendant
Figure 13–32. Motor Table
13
PRINTS
This chapter includes all electrical prints.
13. PRINTS
MARMMTRBL02303E
13–2
NOTES
3
–
3
1
D
C
6
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A
TRANSPORTATION AND INSTALLATION
MARMMTRBL02303E A–1
This appendix includes information on transporting and installing an R-J

controller.
A.1 The control unit is transported by a crane. Attach a rope to eye bolts at the
top of the control unit, as shown in Figure A–1.
TRANSPORTATION
Figure A–1. Transportation
A. TRANSPORTATION AND INSTALLATION
A–2 MARMMTRBL02303E
A.2
INSTALLATION
A.2.1 When installing the control unit, allow the space for maintenance shown in
Figure A–2.
Installation Area
Figure A–2. Installation Area
A.2.2
Assembly During
Installation Figure A–3. Assembly During Installation
Figure A–4. Assembly During Installation
A.2.3
Installation Conditions
Table A–1. Installation Conditions
Item Model Specifications/Conditions
Line filter Common to all models 50 Hz; 200 VAC, +10%, –15%
60 Hz; 200 VAC to 220 VAC, +10%, –15%
50/60 Hz  1 Hz, 3-phase
Transformer Common to all models 220, 240, 380, 415, 460, 480, 500, 550, 575 VAC,
+10%, –15%
50/60 Hz  1 Hz, 3-phase
Input power supply capacity ARC Mate, S-5, A-510 2.5 kVA
ARC Mate Sr., S-10, L-1000 3 kVA
S-700 6.5 kVA
S-500, M-400 7 kVA

S-420, S-800 12 kVA
Average power consumption A-510 0.8 kW
ARC Mate, ARC Mate Sr., S-5, S-10 1.0 kW
L-1000 1.2 kW
S-500, S-700, M-400 1.7 kW
S-420 2.5 kW
Ambient temperature range Common to all models 0 to 45C
Ambient humidity range Common to all models 75% RH max.
No condensation
95% RH maximum for up to 1 month
Atmosphere Common to all models No corrosive gases
Contact FANUC Robotics when operating the unit where
there is a lot of dust or cutting oil.
Vibration Common to all models 0.5 G max.
vibration frequently occurs.
Weight of control unit Common to all models 180 kg (approx.)
Table A–2. Installation Conditions

Line filter Common to all models 50 Hz; 200 VAC, +10%, –15%
60 Hz; 200 VAC to 220 VAC, +10%, –15%
50/60 Hz  1 Hz, 3-phase
Transformer Common to all models 220, 240, 380, 415, 460, 480, 500, 550, 575 VAC,
+10%, –15%
50/60 Hz  1 Hz, 3-phase
Input power supply capacity P-155 5 kVA
Average power consumption P-155 2.5 kW
(idle condition)
Ambient temperature range Common to all models 0 to 45C
Table A–2. (Cont’d) Installation Conditions

Ambient humidity range Common to all models 75% RH max.
No condensation
95% RH maximum for up to 1 month
Atmosphere Common to all models No corrosive gases
there is a lot of dust or cutting oil.
Vibration Common to all models 0.5 G max.
vibration frequently occurs.
Weight of control unit Common to all models 180 kg (approx.)
A.2.4 Adjust the robot according to the procedure in Table A–3 at installation.
Adjustment and
Checks at Installation
Table A–3. Adjustment and Checks at Installation
Step Description
1 Visually check the inside and outside of the control unit.
2 Check if the screwed terminal is connected properly.
3 Check that the connectors and printed circuit boards are inserted correctly.
4 Check transformer tap setting.
5 Connect control unit and mechanical unit cables.
6 Turn the breaker or disconnect off and connect the input power cable.
7 Check the input power voltage.
8 Press the EMERGENCY STOP button on the operator panel and turn the power on. Check the output voltage.
9 Check the interface signals between the control unit and robot mechanical unit.
10 Check the parameters. If necessary, set them.
11 Release the EMERGENCY STOP button on the operator panel. Turn the power on.
12 Check the movement along each axis in the manual jog mode.
13 Check the end effector interface signals.
14 Check the peripheral device control interface signals.

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7/26/2019 Fanuc R-J Controller Series Electrical Connection and Maintenance Manual

SYSTEM R-J Controller Series

This publication contains proprietary information of FANUC Robotics

The descriptions and specifications contained in this manual were in effect

FANUC Robotics conducts courses on its systems and products on a

Copyright 1995, 1996 by FANUC Robotics North America, Inc.

AccuStat, ArcTool, DispenseTool , FANUC LASER DRILL,

to trademark and trade name rights, in the following names:

FANUC Robotics Hotline

For a PRODUCTION robot that is DOWN

For all other Troubleshooting and Technical Support

MARMMTRBL02303E Preface vii

The SYSTEM R-J Controller Series Electrical Connection and

Find information about a specific topic Table of Contents

Identify the components of the SYSTEM R-J Chapter 1, Overview

View status information on teach pendant Chapter 3, Lights and LEDs

Perform troubleshooting procedures and Chapter 4, Troubleshooting

Look at fuse information or replace a fuse Chapter 5, Replacing a Fuse

Release the brakes Chapter 6, Brake Release

Turn outputs on or off and simulate inputs Chapter 7, Controlling I/O

Master the robot Chapter 8, Mastering

Replace controller components Chapter 9, Replacing

Adjust switch settings and potentiometers Chapter 10, Board

Find controller connection schematics and Chapter 11, Connections

Find connection information and Chapter 12, Complete Wiring

Find complete schematics of the controller Chapter 13, Prints

viii PREFACE MARMMTRBL02303E

NOTE Information appearing next to NOTE concerns related information

MARMMTRBL02303E Table of Contents ix

x TABLE OF CONTENTS MARMMTRBL02303E

3.3.2 Power Supply Unit (PSU) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7

MARMMTRBL02303E TABLE OF CONTENTS xi

4.3.28 SRVO-046 ER_SVAL2 OVC Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–51

4.3.50 SRVO-087 ER_WARN BLAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–61

xii TABLE OF CONTENTS MARMMTRBL02303E

MARMMTRBL02303E TABLE OF CONTENTS xiii

10.1 AXIS CONTROL BOARD JUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

xiv TABLE OF CONTENTS MARMMTRBL02303E

11.4.2 Arc Welding Interface Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–68

Procedure 7–3 Displaying and Forcing SOP I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6

MARMMTRBL02303E TABLE OF CONTENTS xv

Procedure 9–5 Replacing the Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12

xvi TABLE OF CONTENTS MARMMTRBL02303E

Figure 1–30. Operator Panel, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–38

MARMMTRBL02303E TABLE OF CONTENTS xvii

xviii TABLE OF CONTENTS MARMMTRBL02303E

Figure 11–15. External Power Supply ON/OFF Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . 11–10

MARMMTRBL02303E TABLE OF CONTENTS xix

Figure 11–56. Peripheral Device Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–70

Figure 12–8. Internal Connection Diagram – M-400 (5-axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9

Figure 12–26. Internal Connection Diagram - M–400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–27

xx TABLE OF CONTENTS MARMMTRBL02303E

Figure 13–3. AC Power Distribution With Optional 115VAC Secondary . . . . . . . . . . . . . . . . . . . . 13–7

Figure 13–14. LSI Module All Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–29

MARMMTRBL02303E TABLE OF CONTENTS xxi

xxii TABLE OF CONTENTS MARMMTRBL02303E

Table 4–34. SRVO-062 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–55

MARMMTRBL02303E TABLE OF CONTENTS xxiii

Table 11–20. Arc Welding Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–49

MARMMTRBL02303E Safety xxv

xxvi SAFETY MARMMTRBL02303E

 Sponsor your personnel for training in approved FANUC Robotics

 Install a lockout device that uses an access code to prevent

 Use anti–tie–down logic to prevent the operator from bypassing safety