Professional Documents
Culture Documents
C3*/C4*/C70/C80 CONTROLLER
Troubleshooting
Manual
90206-1023DED
Preface
Operator Training
If after reading the operation manual you have additional questions
about the use of this equipment, or if you need operator training, please
contact your authorized Kawasaki dealer, or Kawasaki Customer
Service. Kawasaki can provide or recommend available training
courses that address proper procedures for operation of the
equipment.
Warranties
The entire warranty for this product is set forth in the “Kawasaki
Express Limited Warranty,” which is provided as a separate document.
Nothing in this manual is intended, or should be interpreted, as creating
a waiver of said warranty provisions and limitations, or as establishing
an independent express or implied warranty concerning the product, its
use, and/or specifications.
! DANGER
This symbol identifies warnings or procedures
which, if not strictly observed, will result in serious
injury or death.
! WARNING
This symbol identifies special warnings or
procedures which, if not strictly observed, could
result in serious injury.
! CAUTION
This symbol identifies special instructions or
procedures which, if not correctly followed, may
result in injury or properly damage.
IMPORTANT
This symbol identifies special instructions or
procedures which, if not correctly followed, could
result in machine damage.
1. Safety
2. Overview
3. Description
4. Trouble shooting
OVERVIEW
DESCRIPTIONS
TROUBLESHOOTING
INDEX
1.1 INTRODUCTION
The following safety sections in this text are designed to support and
augment existing safety guidelines that may be in use in your plant, and/or
are provided by municipal, state, or federal governments, but are NOT
designed to supplant or supersede any existing rules, regulations, or
guidelines that may be in use.
Because safety is the primary responsibility of the user, owner, and/or
employer, Kawasaki recommends that specific safety guidelines and
recommendations be adopted from groups or individuals that are
professionals in safety design and implementation.
These recommended sources for national and federal safety laws and
regulations include:
• ISO 10218
• ANSI/IRA R15.06-1992
• OSHA
• EN 775
All safety related issues and descriptions, either presented in written or oral
form from any representative of Kawasaki are intended to provide general
safety precautions and procedures and, therefor, are not intended to
provide all safety measures necessary for the protection of all personnel in
the work environment.
Because Kawasaki does not engineer, design or configure robot work cells,
associated automation, and safety equipment, it is not responsible for
safety of personnel or equipment.
The work envelope of robot is the hatched area shown in the following
figure. Since this area is dangerous, never enter the work envelope during
automatic operations. Before entering this area for teach operation,
maintenance, etc., make sure of safety without fail.
safety fence
• Avoid wearing loose clothing, scarves, wrist watches, rings, and jewelry
when working on the controller and robot. It is also recommended that if
ties must be worn in your shop environment, that they be the clip-on
variety, rather than tied ties.
• Always wear safety glasses or goggles and approved safety shoes for
your shop conditions. Follow all applicable official and plant safety
specifications and procedures.
• Know the entire work cell ore area that the robot occupies. And be
aware of the entire work envelope of the robot and any peripheral
devices.
• Ensure that all personnel are clear of the work envelope before
initiating any motion commands for the robot.
• Be sure that the entire work area is free of debris, tools, fixturing,
lubricants, and cleaning equipment before operation of the robot is
attempted.
• Never defeat, render useless, jumper out, or bypass any safety related
device, whether mechanical or electrical in design.
• During operation of the robot, identify the maximum reach of the robot
in all directions, which is referred to as the work envelope.
• Always keep your work area clean and free of any debris which
includes, but is not limited to, oil, water, tool, fixture, electronic test
equipment, etc.
• During the teach operation of the robot always have a path of retreat
planned.
• Playback accuracy and speed can affect the geometry of the path
coordinates. Therefore, when changing accuracy or speed, always test
run the program at a slow speed, or point-to-point mode before
attempting the continuous path operation in the repeat mode.
• When removing an axis motor, be aware that the axis will fall if left
unsupported. The brake assembly is in the servo drive motor, therefore,
the axis of the robot will be unsupported if removed.
• When using the manual brake release switches in the controller, be aware
that the axis may fail if left unsupported.
! CAUTION
• When handling printed circuit boards, hold by their edges and avoid, as
much as possible, touching any circuit parts printed on the boards.
• Never put printed circuit boards on conductive materials like metal
plated !
• Printed circuit boards can be damaged by electro-static discharge. Touch
metal objects before handling printed circuit boards to discharge static
electricity. Use electrostatics.
• When storing printed circuit boards, always place them in static protection
bags.
• When replacing ROMs, check the version of software and/or board type
because different software and/or board types may require different
replacement procedures.
• When replacing ROMs, check the versions of software of other circuit
boards, since their software versions may not be compatible with the new
ones !
• When setting new jumpers and DIP switches, follow basically the old
settings. However, when options such as those related to the memory
size or IC model types are different, find proper jumper settings.
• Properly connect all cables and connectors to printed circuit boards.
When the connectors come with locking devices, make sure to lock them
as instructed ! When a printed circuit board has multiple connectors with
the same number of pins, make sure they are placed in the correct
connectors.
• When replacing RAM or ROM, check the number of pins of both the
memory and the socket since they may differ from each other.
• When the IC memory has a smaller number of pins than that socket, set
the IC memory as shown the following drawing. (This applies to both RAM
and ROM !)
• In case the IC memory was installed in the opposite direction,
• be sure to replace IC memory. This symbol identifies special instructions
or procedures which, if not correctly followed, may result in injury.
• Since some ROM and PALs may use PLCC types besides the usual DIP
types, make sure to use special IC removal tools when replacing them.
• Some circuit boards may carry the same name but may vary in their
contents. Be sure to check their specifications before replacing.
OVERVIEW
DESCRIPTIONS
TROUBLESHOOTING
INDEX
The Kawasaki U, Z, F, and J series Robot System, consists of the mechanical unit,
the Kawasaki robot controller and supporting peripheral equipment, and Kawasaki
robot controller software.
Due to the sophistication of this design, it has the capability to support
the following:
The Kawasaki U, and Z series mechanical unit, with proper tooling and
interface, is capable of performing many tasks in the industrial environment.
Some of these tasks include spot welding, sealant, and assembly/material
handling applications.
The two major components of the Kawasaki Robot System are the robot controller
and the mechanical unit (the robot itself). The C series robot controller is shown in
Figure 2-1, Figure 2-2 and Figure 2-3.
Multi Function Panel
(Teach Pendant)
Optional Interface
Panel
Main Disconnect
Operator Panel
Operator
Main Disconnect
Operator
Panel
Control
Power
Indicator
Disconnect Switch
Operator Panel
Disconnect
Switch
Optional Interface
Panel
Multi Function
Panel
The primary user interface components of the Kawasaki robot system include the
following:
The Kawasaki Operation Panel allow the user to perform many tasks such
as
• turning on Motor Power,
• selecting Teach or Repeat modes of operation,
• Hold or Run states,
• Cycle Start,
• resetting Error conditions, and
• selecting the Emergency Stop function.
Emergency Stop
Motor Power
Error Ind.
Emergency Stop
Error Ind.
Motor Power
Error Reset
Cycle Start
Teach/Repea
Hold or Run
Emergency Stop
Error Ind.
Error Reset
Motor Power
Cycle Start
Hold or Run
Teach / Repeat
Disconnect Switch
Emergency Stop
Error Ind.
Error Reset
Motor Power
Cycle Start
Hold or Run
Teach / Repeat
The Kawasaki Multi Function Panel (Teach Pendant) supplied with the robot
controller is equipped with a backlit LCD display, menu-driven touch sensor keys and
hard-keys. Through the use one of the MFP, the user can jog the mechanical unit in
the Joint, Base (XYZ), or Tool coordinates system.
The user can record geometric data for the mechanical unit by using the record
button on the MFP.
View
• XYZ position
• Joint angle position
• Joint angle command
• Input signals
• Output signals
The teach pendant is equipped with Deadman switches and a hardwired Emergency
Stop, along with a Teach Lock switch for user safety.
ON OFF
TEACH LOCK
LCD
Contrast
LCD Adjustment
Volume
PC Card
Insertation
Port
“Deadman” Switch
✎ MEMO
OVERVIEW
DESCRIPTIONS
TROUBLESHOOTING
INDEX
The Kawasaki C Controller Circuit Board Block Diagram displayed in Figure 3-1-1,
Figure 3-1-2 and Figure 3-1-3, depicts the major control printed circuit boards in the
Kawasaki robot controller.
MOTHER BOARD
TERMINAL
1HZ b'd
SERIAL I/F (PERSONAL COMPUTER)
MAIN CPU RS232C
USER MEMORY EXTERNAL EQUIPMENT
SYSTEM MEMORY
VME BUS
SERIAL I/F
RS485 IP I/F
EXTERNAL EQUIPMENT
A
1GA IP I/F
b'd B EXTERNAL EQUIPMENT
VME BUS
OPTIONAL BOARD
(VISION BOARD, I/O BOARD, etc.)
OPERATION PANEL
MOTOR POWER ON, CYCLE START, TEACH/REPEAT,
MOTOR POWER
RUN/HOLD, ERROR RESET, EMG-STOP
ON, EMG-STOP,
MC CONDITION
REMOTE,
ERROR
POWER FAILURE
DETECTION RELAY
+5V, +12V, -12V 1HY CIRCUIT
b'd
DC POWER
DC POWER +5V
+12V,-12V
+24V
CONTROL POWER POWER CIRCUIT
AVR CONTROL POWER(210Vac)
MOTOR POWER(300Vdc)
BRAKE POWER(26Vac)
BATTERY
(3.6V)
HOUR METER,
CONTROL POWER LAMP
EMG-STOP,TRIGGER
380-480Vac 50Hz 3φ(CE)
400-575Vac 60Hz 3φ(AMERICA)
SERIAL COMMUNICATION MFP, T/P
ROBOT ARM
SERVO MOTOR ASSY
Jt1-7
VALVE
ENCODER BRAKE MOTOR
LIMIT SW
SENSOR
DC POWER
(+12Vdc)
1FG b'd
BATTERY BACKUP
CONVEYOR ENCODER DC POWER for ENCODER
ENCODER SIGNAL,
SENSOR SIGNAL,
I/O 24Vdc, LIMIT SW,
BATTERY BACKUP
BATTERY ALARM
DC POWER for
ENCODER BRAKE LINE MOTOR LINE
POWER BLOCK
PWR SIGNAL,
CH 1 IPM ERROR Jt2 UNIT
CPU A
Jt1, 2, 3 SERVO CONTROL,
ERROR DETECTION,
HARDWARE ERROR MANAGEMENT
Jt3 UNIT
PWM SIGNAL,
CH 2
IPM ERROR
CPU B
Jt4, 5, 6 SERVO CONTROL, Jt4 UNIT
ERROR DETECTION
PWM SIGNAL,
IPM ERROR Jt5 UNIT
CPU C
CH 3 Jt7 SERVO CONTROL,
ERROR DETECTION,
CONVEYOR ENCODER MANAGEMENT
CH 0 Jt6 UNIT
CURRENT
FEEDBACK
BRAKE POWER
1GM b'd Jt7 UNIT
CURRENT FEEDBACK
CURRENT LIMIT
DC POWER
(1GC, 1GD b'd)
1GB
b'd
POWER UNIT
CONTROL CIRCUIT, THERMAL
POWER UNIT ERROR,
INRUSH CURRENT CONTROL SIGNAL P-N POWER ERROR DETECTION SW
CIRCUIT,
INRUSH CURRENT CONTROL REGENERATE CIRCUIT REGENERATE
RESISTOR
MOTOR POWER
300Vdc
MOTHER BOARD
TERMINAL(PERSONAL
1HJ b'd OPTION(FDD UNIT)
SERIAL I/F COMPUTER)
MAIN CPUUSER RS232C EXTERNAL
MEMORYSYSTEM EQUIPMENT
MEMORY
VME BUS
EXTERNAL
LAN I/F
TERMINAL
SERIAL I/F
RS485 IP I/F EXTERNAL 1HF
FDD UNIT
A EQUIPMENT b'd
1GA IP I/F EXTERNAL
b'd B EQUIPMENT
CONTROL POWER(+5Vdc)
VME BUS
OPTION BOARD
(VISON BOARD, I/O BOARD etc.)
BRAKE, CONTROLL
SERIAL POWER
COMMUNICATION
ROBOT ARM
SERVO MOTOR ASSY
JT1~7
VALVE
ENCODER BRAKE MOTOR
LIMIT SW
SENSOR
CONTROL POWER
(+12Vdc)
1HG b'd
BATTERY BACKUP BATTERY
CONVEYOR ENC DC POWER for ENCODER
POWER BLOCK
PWM SIGNAL,
CH1 IPM ERROR JT2 UNIT
CPU A
JT1, 2, 3 SERVO CONTROL,
ERROR DETECTION,
HARDWARE ERROR MANEGEMENT
JT3 UNIT
PWM SIGNAL,
CH2
IPM ERROR
CPU B
JT4, 5, 6 SERVO CONTROL, JT4 UNIT
ERROR DETECTION
PWM SIGNAL,
IPM ERROR JT5 UNIT
CPU C
CH3 JT7 SERVO CONTROL,
ERROR DETECTION,
CONVEYOR MANEGEMENT
CH0 JT6 UNIT
CURRENT
BRAKE POWER FEEDBACK
1GM b'd JT7 UNIT
CONTROL CURRENT FEEDBACK
POWER CURRENT LIMIT
(DC)
(1HN b'd)
1GB
b'd
MOTOR POWER
300Vdc
MOTHER BOARD
TERMINAL(PERSONAL
1HJ b'd OPTION(FDD UNIT)
SERIAL I/F COMPUTER)
MAIN CPUUSER RS232C EXTERNAL
MEMORYSYSTEM EQUIPMENT
MEMORY
VME BUS
EXTERNAL
LAN I/F
TERMINAL
SERIAL I/F
RS485 IP I/F EXTERNAL 1HF
FDD UNIT
A EQUIPMENT b'd
1HA IP I/F EXTERNAL
b'd B EQUIPMENT
CONTROL POWER(+5Vdc)
VME BUS
OPTION BOARD
(VISON BOARD, I/O BOARD etc.)
MOTOR POWER
EMG-STOP
MC ON RELAY CIRCUIT
POWER FAILURE BRAKE POWER
REMOTE,
DETECTION CONTROL
ERROR
+5,+12V, -12V POWER
BRAKE, CONTROLL
SERIAL POWER
COMMUNICATION
200-240Vac
MULTI FUNCTION PANEL 50/60Hz 1φ
ROBOT ARM
SERVO MOTOR ASSY
JT1~7
VALVE
ENCODER BRAKE MOTOR
LIMIT SW
SENSOR
CONTROL POWER
(+12Vdc)
1HG b'd
BATTERY BACKUP BATTERY
CONVEYOR ENC DC POWER for ENCODER
POWER BLOCK
PWM SIGNAL,
IPM ERROR JT2 UNIT
CH1 CPU A
JT1, 2, 3 SERVO CONTROL,
ERROR DETECTION,
HARDWARE ERROR MANEGEMENT
JT3 UNIT
PWM SIGNAL,
CH2 IPM ERROR
CPU B
JT4, 5, 6 SERVO CONTROL, JT4 UNIT
ERROR DETECTION
PWM SIGNAL,
IPM ERROR JT5 UNIT
CH3 CPU C
JT7 SERVO CONTROL,
ERROR DETECTION,
CONVEYOR MANEGEMENT
CH0 JT6 UNIT
CURRENT
FEEDBACK
BRAKE POWER
1GM b'd JT7 UNIT
CURRENT FEEDBACK
CURRENT LIMIT
CONTROL POWER(DC)
(1HN b'd)
1GB
b'd
MOTOR POWER
300Vdc
The 1GA/1HA PC board is the main CPU board of C-controller equipped with 32bit
RISC processor. The 1GA/1HA PC board chiefly does the operation plan of the robot,
the control system processing of the coordinates conversion etc. , and communication
processing with the outside with main CPU board.
The function of 1GA/1HA PC board is shown as follows.
• AS software and servo software are installed in the FLASH memory.
• Execution of AS software system
• Execution of servo position loop operation
• The storage of the user's program and the data (When the battery is connected, it is
possible to back up).
• 1MB(optional 4MB) of battery backup SRAM (The system memory contains).
• Communication function with servo board (5ch.)
1GA/1HA
IMPORTANT
Notes of SRAM backup
• The battery is installed in the motherboard. When Super Capacitor on 1GA/1HA PC board
charges full, the backup time of the memory is about 30 minutes when 1GA/1HA PC board is
detached from the motherboard.
• It takes about three hours or more to the super-capacitor on 1GA/1HA PC board to charge
full in the state of control power supply ON . The longevity of the battery shortens when a
new board (board which discharges the super-capacitor) is installed repeatedly because
consumption current of the battery increases.
• Take notes and save the content of memory to the SRAM card of the Multi-Function Panel
or the hard disk on your personal computer when you detach 1GA/1HA PC board from the
card rack because there is no method of confirming the charge with the super-capacitor.
• After off the control power supply, the longevity of the battery is about two years when the
option board by which the battery is consumed besides 1GA/1HA PC board is not installed.
TP1,2,3,4
CN1 CN2 CN3
SW2
SW1 LD1,2,3
CN4 CN5
CN6 CN7
IP-B IP-A
CN8 CN9
SW3
1GA/1HA
5 GND GND
The pin assignment of CN4, 5 is different depending on the kind 6 - -
of the IP PC board.
7 RTS RTS
8 CTS CTS
9 - -
●1HA Board
TP1,2,3,
CN1 CN2 CN3
SW2
LD6,4,5,7 LD1,2,3
CN4 CN5
CN6 CN7
IP-B IP-A
CN8 CN9
S3
1GA/1HA
CN1 and CN2 pin assign
No. CN1 CN2
CN1 : PC terminal port (RS232C B ch.) D-sub 9pin Female
1 - -
CN2 : Host communication port (RS232C A ch.) D-sub 9pin Male
2 RxD RxD
CN3 : LAN port (10BASE-T) (IEEE802.3 conform)
3 TxD TxD
CN4 : I/O connector for B side IP PC board
4 - -
CN5 : I/O connector for A side IP PC board
CN6,8 : System connector for B side IP PC board 5 GND GND
CN7,9 : System connector for A side IP PC board 6 - -
CN10 : VME bus connector (P2) (for 1GB, 1FT PC board communication) 7 RTS RTS
CN11 : VME bus connector (P1) (system bus) 8 CTS CTS
9 - -
1GA/1HA
LEDs
●1GA Board
No. color Lighting condition
1 red Light off at usually
Turning on when ACFAIL or CPU error
2 green Turning off when AS system starts
Blinks at 1 cycle of the second at usually.
3 green Turning on when CPU self-test ends normally.
Light usually
Turning off when CPU self-test ends abnormality
●1HA Board
No. color Lighting condition
1 red System error
Light up: Abnormal Put out: Normal
2 green System RUN
Blinking: Normal Light up/Put out: Abnormal
3 green CPU initialize status
Lighting up: Normal Put out: Abnormal
4 green LAN TRANSMIT (Be transmitting)
Light up: Be transmitting Put out: No transmit
Lighting up when LAN transmitting. No notification at the put out.
5 green LAN LINK (Link test status)
Light up: Link normal Put out: No link
Lighting up when LAN link.
6 green LAN COLLISION (Collision occuring)
Light up: Collision occurring. Put out: No collision
Lighting up when LAN collision
7 green LAN RECEIVE (Be receiving)
Light: Be receiving Put out: No receive
Light up when LAN receive.
Check pins
No. color Standard
1 black GND -
2 yellow VEE12 (-12V) voltage -12.0V±0.1V
3 yellow VCC12 (+12V) voltage +12.0V±0.1V
4 yellow VCC (+5V) voltage +5.00V±0.05V
1GA/1HA
Block diagram
●1GA Board
CPU
CN4
SRAM IP I/F
1M/4Mbyte 16bit×2
CN5
RS485 SV-CMD1
RTC SIO Half Duplex
RS485 SV-CMD2
Half Duplex
RS485 SV-CMD3
CIO SIO Half Duplex P2
RS485 SV-CMD4
Half Duplex
RS485 SV-DBG
ASIC SIO Half Duplex
RS485 T/P
Full Duplex
PC
RS232C CN1
ASIC SIO
µPD72001 HOST
RS232C CN2
1GA/1HA
●1HA Board
CPU
SDRAM
(16MB)
Bus Bridge
(FPGA)
P2
SIO
(8MB max)
I/O RS485 5ch
CN1 CN2
SRAM
(4MB max) (FPGA)
RS232C
RTC
32⇔16
Bus Buffer
CN3
IP bus I/F
P1
VME bus
I/F
The IP board is an option board installed on 1GA/1HA board. The IP board adds the function of the
analog input etc. to 1GA/1HA board.
It can install one IP board of 16bit single size and a double size on 1GA/1HA board respectively.
The I/O of the IP board is connected with CN4 and CN5 of 1GA/1HA board. However, since the use
state of the pin is different according to kind of the IP board; it connects the adapter harness with
CN4 and CN5 of 1GA/1HA board, and it is connected with Peripheral equipment.
Moreover, by way of the signal from Peripheral equipment according to the IP board and by way of
CN4 and CN5 of 1GA/1HA board. There is the one connected directly with the connector on the IP
board, too.
1GB
• Correspondence of axis No. and CPU channel. Three CPUs or less can be installed in
1GB PC board. The table below shows the correspondence of each axis and the
CPU.(CPU-C is not installed on 1GB PC board of six axes specification.) Three CPUs
are called A, B, and C unit respectively.
.
1GB
Connector and switch arrangement chart
TP1
TP2 SW1
CN7
CN
CPU-A CPU-B CPU-C 3
TP6,TP7
GATE GATE GATE TP8,TP9
ARRAY-A ARRAY-B ARRAY-C
Upper
1GM LED
CN8B
board゙ D26,D27,D28
D36,D37,D38
Lower
CN11
D39,D40,D41 CN8A
CN9 CN10
CN12 CN13
A dotted line part mounts
Screw for only seven axes
installation specification.
1GB
NOTE)
• Do not usually connect the connector with CN8B.
• Connect the cable of “GB-CN8" with CN8A (the lower) with the cable of servo unit.
Switch function
LED function
Check pin
No. Label
TP1 BR24G Motor brake power supply GND
TP2 BR24V Motor brake power supply +24V
TP3 RUN_A State of CPU-A operation
TP4 RUN_B State of CPU-B operation
TP5 RUN_C State of CPU-C operation
TP6 GND Control power supply GND
TP7 VCC Control power supply VCC
TP8 -12V Control power supply -12V
TP9 +12V Control power supply +12V
1GB
Block Diagram
CH1
command line
HIC Current feedback
CPU-A 1GMb'd CN
RS485 Overcurrent
(JT1,2,3) I/V Conversion 9
detection
Overcurrent
error
MSON
SVER.
Servo_control Jt2,3 PWM_signals CN
IPM_error 12
Jt1 PWM_signals
IPM_error
CN
PU_error
13
MSON(delay)
Brake
CN Motor thermal
6
Brake drive
circuit
To manual brake BOX
CN
5
CH2
Commnd_line
HIC Current feedback
CPU-B 1GMb'd CN
RS485 Overcurrent
(JT4,5,6) I/V Conversion 10
detection
Overcurrent
error
C Encoder
Gate array Encoder I/F CN
N
B RS485 2
1
SRAM
ERR-B
Jt4,5 PWM_signals CN
IPM_error 12
Jt6 PWM_signals CN
IPM_error 13
CH3
Commnd_line
HIC Current feedback
CPU-C 1GMb'd CN
RS485 Overcurrent
(JT7,conveyer) I/V Conversion 11
detection
Overcurrent
error
CN
conveyer 3
Jt7 PWM_signals CN
IPM_error 13
CH0
Debug_line
RS485
DC24V,LS,I/O CN
2
The 1GM PC board is a board which composes an output signal interface circuit of motor
current detection sensor provided to the Power Block.
The scale of current sensor output is varied depending upon the motor specifications.
This means that the scale conversion is conducted by every motor. There for, be careful
that the 1GM PC board specification is varied depending upon the Robot model (motor
specifications).
Since the 1GM PC board has separated ID codes for different specifications,
electronically denoted by the resistance jumper as shown in the diagram bellow.
NOTE
This ID code Is changed by the software as the control power
source is turned on.
Therefore, when the combination of the software for the 1GB PC
board and the 1GM PC board is incorrect, error messages will be
generated.
1GM PC Board
R R R R R R R R
1585 8
9 10 12
11 12 13 14 15
Item Number ID
ID CODE EXAMPLE
MSB LSB
0 1 0 0 0 0 0 1 Jumper with
Resistor
4 1
ID code = 41Hex.
(2) AMPLIFIER
1) The AMPLIFIER receives the PWM signal from the servo board (1GB board),
amplifies, and drives the AC SERVO MOTOR.
2) The power device of the AMPLIFIER adopts IPM. ( Intelligent Power module)
3) A current output type current sensor is adopted as a detector of the AMPLIFIER.
4) The AMPLIFIER has various protection functions. Refer to the another paragraph
for details.
When the POWER BLOCK which breaks down is exchanged, you does not exchange
POWER BLOCK for in the POWER BLOCK unit. You becomes an exchange with
SERVO UNIT.
PB
Block diagram
(1) Large POWER BLOCK (1GC board )
TO MS ON MS DRIVE VOLTAGE
MONITORING
SER MS OPERATION ACROSS P-N
MS OPERATION
CONFIRMATION REGENERATION
VO CONFIRNATION
SIGNAL
BOA ERROR SIGNAL
RD
U
+12V +15V CD
HIC IPM
V AC SERVO
PWM JT1 CD
W MOTOR
IPM ERR
CURRENT FEEDBACK
N P
U
+12V +15V CD
HIC IPM
V AC SERVO
PWM JT1 CD
W MOTOR
IPM ERR
CURRENT FEEDBACK
1GC PC BOARD
POWER BLOCK
PB
(2) Small POWER BLOCK (1GD board )
R P4 RUSH P
AC DIODE CURRENT
S
200V MODULE PROTECT & REGENERATING
T N DISCHARGE N RESISTOR TH FAN
CIRCUIT
P1 B
TO MS ON MS DRIVE VOLTAGE
MONITORING
SER MS OPERATION ACROSS P-N
MS OPERATION
CONFIRMATION REGENERATION
VO CONFIRNATION
SIGNAL
BOA ERROR SIGNAL
RD +24V
U
+12V +15V CD
HIC IPM
V AC SERVO
PWM JT1 CD
W MOTOR
IPM ERR
CURRENT FEEDBACK
N P
U
+12V +15V CD
HIC IPM
V AC SERVO
PWM JT1 CD
W MOTOR
IPM ERR
CURRENT FEEDBACK
1GD PC BOARD
POWER BLOCK
PB
About the error detection of the POWER BLOCK
P/B IPM ERROR Error which power module (IPM) on P/B detects. There are CONTROL
overcurrent protection, short-circuit current protection, A2 POWER OFF A,B,C P/B -1559
overheating protection, and a control voltage decrease.
REGENERATIVE When the regeneration continues for six seconds or more. POSSIBLE
POWER OVER The connection between 1GB boards CN13 <-> C A P/B -1567
TIME/B IPM 1GC/1GD- CN9 is abnormal.
ERROR
REGENERATIVE When thermal (140degC) connected with the regenerative After
RESISTOR resistor operates. At the increase regenerative resistor unit C recovering A P/B -1570
OVERHEAT or from the
set up. When thermal (90deg) heat sink , thermal (140deg) error, it is
DISCONNECT
resistor of the regenerative resistor operate. possible.
In wiring, the connection between 1GB board CN13 <->
1GC/1GD-CN9 and between 1GC/1GD-CN11 <-> thermal
are abnormal. At the increase regenerative resistor unit set
up. The connection between 1GC-CN21 <-> 1GJ - thermal
are abnormal.
PB
I
PM ERROR
ITEM DETECTION PART CONTENT
1GC PC board 1GD PC board NOTE
IPM RATINGS ERROR LEVEL IPM RATINGS ERROR LEVEL
OVER IPM OUTPUTJT1~3 150 210A o-p 30 39A o-p Min
CURRENT JT4~6 50 65A o-p 15 18A o-p
TRIP LEVEL JT7 30 39A o-p 30 39A o-p
BRAKE PART JT1 IPM BRAKE 65A o-p --- ---
SHORT IPM OUTPUTJT1~3 150 420A o-p 30 80A o-p Typ
CIRCUIT JT4~6 50 132A o-p 15 39A o-p
TRIP LEVEL JT7 30 80A o-p 30 80A o-p
BRAKE PART JT1 IPM BRAKE 132A o-p --- ---
OVER TEMP. IPM BASE-PLATE TEMPERATU --- 110℃ or more --- 110℃ or more
UNDER VOLT IPM POWER SUPPLY(DC+15V --- 12.5V or less --- 12.5V or less
! CAUTION
Attention on handling
• Please confirm the voltage is 0V between power units
P-N after the control power supply is turned off when
working and one minute or more passes because there
is a charge part in the power supply.
• Please mistake neither kind of 1GB board nor the model
of the correspondence of the number of axes etc. when
you exchange the SERVO UNIT.
• Please wire to agree to the terminal stand name and
connector No. the cable mark for the connector and the
cable.
PB
Externals chart
(1) Large POWER BLOCK (1GC board )
R S T CN12 CN21
CN11
D.B CN10
CN20 GB-CN11
+ -
P P1
N CN7
B
U
W
V CN6
V
CN1
W
U
C
N
W 9 U
1GCboard
U
W
N P
V CN4
CN3 C V
N
U 8 W
FG HEAT SINK
GB-CN9
THE GB-CN10
THE
FACE BACK
Only seven axes specification
is mounted.
LARGE POWER BLOCK
(1GC board) Screw hole for POWER BLOCK
PB
(2) Small POWER BLOCK (1GD board )
GB-CN11
D.B
R - G CN
CN CN CN
27 10 12
S + CN 7
T N CN11 26
CN
28 C CN FAN
CN
20 N 25
CN 9 CN
1 6
REGENERATING
RESISTOR
CN CN
21 24
CN CN
2 5
FAN
C
N
CN 8 CN
22 23
CN CN
3 4
THE THE
GB-CN9
FACE GB-CN10
BACK
Only seven axes specification
is mounted.
SMALL POWER BLOCK
(1GD board) Screw hole for POWER BLOCK
(2) AMPLIFIER
1) The AMPLIFIER receives the PWM signal from the servo board (1GB board),
amplifies, and drives the AC SERVO MOTOR.
2) The power device of the AMPLIFIER adopts IPM. ( Intelligent Power module)
3) A current output type current sensor is adopted as a detector of the AMPLIFIER.
4) The AMPLIFIER has various protection functions. Refer to the another paragraph
for details.
1HN
Block diagram
P
R RUSH
CURRENT
AC DIODE
PROTECT & REGENERATING
200V MODULE DISCHARGE N RESISTOR TH FAN
T CIRCUIT
P1 B
K3 ON K3 DRIVE
VOLTAGE
K3 OPERATION K3 OPERATION MONITORING
TO SERVO BOARD
+24V
U
CD
+12V +15V
V AC SERVO
PWM IPM
HIC MOTOR
JT1~7 W
IPM ERR
CURRENT FEEDBACK
1HN board
! CAUTION
The power supply part includes the charge part. Therefore, one minute or more must passed
since turned off the control power supply, and confirm the voltage is 0V while P-N the power
supply part. And, work.
Mistake neither kind of 1GB board nor the number etc. of axes when you exchange the servo
amplifier.
1HN
About the error detection of the POWER BLOCK
P/B IPM Error which power module (IPM) on P/B detects. There are CONTROL
A2 POWER A,B, P/B -1559
ERROR overcurrent protection, short-circuit current protection, overheating
OFF
protection, and a control voltage decrease.
C
REGENERATIV When the regeneration continues for 6 seconds or more. POSSIBL
E POWER C E A P/B -1567
The connection between 1GB boards CN13 <-> 1HN- CN13 is
OVER TIME/B abnormal.
IPM ERROR
REGENERATIV When thermal (140degC) connected with the regenerative resistor After
E RESISTOR C recoverin A P/B -1570
operates. At the increase regenerative resistor unit set up. When
OVERHEAT or g from the
thermal (70deg) heat sink , thermal (140deg) resistor of the error, it is
DISCONNECT
regenerative resistor operate. possible.
In wiring, the connection between 1GB board CN13 <-> 1HN-CN3
and between 1HN-CN14 <-> thermal are abnormal. At the increase
regenerative resistor unit set up. The connection between 1HN-CN8
<-> thermal are abnormal.
VOLTAGE of The voltage across P-N detect with DC60V or less. In wiring, the POSSIBL
P-N is LOW connection between 1GB board CN13 <-> 1HN board CN13 is C E A P/B -1568
abnormal. (However it is assumed to make an error only at servo ON
time.)
VOLTAGE of The voltage across P-N detect with DC410V or more. In wiring, the POSSIBL
P-N is HIGH connection between 1GB board CN13 <-> 1HN board CN13 is C E A P/B -1569
abnormal.
1HN
Externals chart
CN7
CN11 CN9
CN14
CNCS7
CNCS1
CN6
CN13 FAN
CN1
REGENERATE
CNCS6
CNCS2
RESISTOR
CN5
CN12
CN2
CNCS5 FAN
CNCS3
CN4
CN3
CNCS4
CN8
Model correspondence
J*005 J*006 J*030 UD100 UX070 UX200 UZ100 F*02 F*06N F*10N F*20N F*10L F*30
POWER BLOCK J*010 J*040 UD150 UX100 UZ120 03 F*06L F*10E F*20L 45
J*020 UX120 UZ150 F*10C
UX150
6 axes 7 axes
50607- 50607-
1GC X X X X X X X
1082 1083
50607- 50607-
1GD X X X X X
1084 1085
50607- 50607-
1HN X
1106 1107
X: Correspondence
! CAUTION
The approximate installing location and schematic figure of the 1FG PC board are
shown in Fig. 3-6-1.
How to replace the battery of the 1FG PC board with a new battery:
1. Switch OFF controller control power safely.
2. Remove the access cover from robot manipulator.
3. After disconnecting tie-band from the battery provided on the 1FG PC board. Then
dismount the battery from the PC board.
4. Set a new battery to the holder. Then fix it with the tie-band. After that, connect the
connector with the CN1.
5. Fix the once removed the access cover to Robot manipulator as it was before.
NOTE
The encoder is so designed as to maintain power even if the encoder is
disconnected from the battery.
But, in order to protect the internal data from breakage, be careful that
the battery replacement must be made at least within thirty (30) minuets
after removing the battery.
1FG
CN
13
CN
12
BATTERY
CN CN
8 11
CN
10
CN
CN
7
9
CN1 CN2 CN3 CN4 CN5 CN6
CN8 : From the controller (+12V, ENC Signal, LS1, LS2, Battery alarm etc.)
CN9 : For built-in I/0 board (current Not used) (SIG1~4, 24V for I/O etc. j
CN10 : Battery connect
CN11~13 :For Axis restriction Limit switch connect (Refer to below figure)
Short-circuit
CN11 CN12 CN13 connector
1 2 3 4 1 2 3 4 1 2 3 4
1FG
Block diagram
C
N JT5 Encoder Signal CN5
8
Limit Switch
CN11
CN12
CN13
The 1HG PC board is a printed circuit board housed in the Robot manipulator.
The 1HG PC board is provided with the following functions:
• When controller's power supply is ON, +12V voltage is converted into +5V voltage,
which is then applied to the applicable encoder.
• When controller's power supply is OFF, do the switch of the power supply supplied to the
encoder to the battery power supply to maintain the location data in the encoder.
• Detects the voltage decrease of the battery.
! CAUTION
The longevity of the battery is approx. one year-half (Control
Power OFF state, Continue). This value is different in the
condition of the ambient temperature etc.
How to replace the battery of the 1HG PC board with a new battery:
1. Be previous by which replaces the battery and record the encoder value.
2. Switch OFF controller control power safely. Remove the access cover from robot
manipulator.
3. After disconnecting tie-band from the battery provided on the 1HG PC board. Then
disconnect connector CN4, and dismount the battery.
4. Set a new battery to the holder. Then fix it with the tie-band. After that, connect the
connector with the CN4.
5. Fix the once removed the access cover to Robot manipulator as it was before.
Switch ON controller control power, and check whether to change the encoder value.
1HG
Block diagram
CN4
N
DC-DC Converter
3
CN1 CN2
JT7
JT7 Encoder Signal CN2
The 1GW/1HW PC board is the parallel I/O board, 32 channels input and 32 channels
outputs. As for 1GW and 1HW board, the polarity of the Common terminal is opposite.
I/O specification
Board Name General-purpose 32 General-purpose Note
Channels Input Output 32 Channels
1GW b’d + Common - Common (sink tyoe) North-American
1HW b’d - Common + Common (source type) Europe
Input specification
Number of input channels 32
Input system Photo coupler
Ratings input voltage DC24V
Range of input voltage DC24V +/- 10%
Ratings input current 10mA
Maximum input channels 100% (16channel/common)
Turning on simultaneously
Common system 16 channels/common
sensor line is 4 channels/common
Output specification
Number of output channels 32
Output system Photo coupler insulate transistor array
Ratings load voltage DC24V
The maximum load current 0.1A/channel (1.6A/common)
The maximum rushing into current 0.4A/channnel
Maximum output channels 100% (16channel/common)
Turning on simultaneously
Common system 16 channels/common
Valve line is 4 channels/common
• The 1GW/1HW PC boards can be used up to four. However, The number of piece for
which the 1GW/1HW PC board can be used might be limited by the use state of
other option boards. (the number of option slots of card rack is six slots)
• When I/O is connected, it is necessary to prepare the power supply of DC24V
• You can allocate 8 points in the output 32 points in the robot built-in valve. Moreover, you
can allocate 4 points in the input 32 points in the robot built-in sensor. However, supplies
DC24V from inside controllers and drives a built-in sensor/valve line. Therefore, External
need not supply DC24V. Moreover, supplies DC24V from inside controllers and drives the
sensor/the valve line. Therefore, External need not supply DC24V. Moreover, cannot do
the separation of the power supply for the sensor line and the valve line.
Refer to the solenoid value/sensor internal wiring diagram of “INSTALLATION AND
CONNECTION = CONTROLLER =” of the separate volume for wiring to the sensor/valve
line built-in of the robot.
1GW/1HW
Block diagram
Output Reset
Circuit OUT 1~8,17~32
Transistor
C
VME I/F Array for
P N
a:16/d:16 Output
1 2
32 Outputs
OUT9~16
JP
SOL 1~7
Valve Sig.
C
N
3
Sensor Sig.
SIG 1~4
IN13~16
JP
Photo
C
Coupler
N
for Input IN1~12,17~32 4
32 Inputs
1GW/1HW
● Wiring Diagram
1GW : Output
1GW : Input
1GW/1HW
1HW : Output
1HW : Input
1GW/1HW
● 1GW/1HW Board Pin Assignment
1 1 19 COM2
SOL1 OUT 1 (IN17∼32)
9 2 20 37
SOL5 OUT17 2 NC 18 COM1
SOL2 OUT 2
10 21 36 (IN1∼16)
3 3
SOL6 OUT18 NC 17
SOL3 OUT 3
11 22 35 NC
4 4
SOL7 OUT19 IN32 16
SOL4 OUT 4
12 23 34 IN16
5 5
SOL8 OUT20 IN31 15
DC24V(Input) OUT 5
13 24 33 IN15
6 6
24G (Input) OUT21 IN30 14
DC24V OUT 6
14 25 32 IN14
7 7
SIG3 OUT22 IN29 13
SIG1 OUT 7
15 26 31 IN13
8 8
SIG4 OUT23 IN28 12
SIG2 OUT 8
27 30 IN12
OUT24 9 IN27 11
28 OUT 9 29 IN11
OUT25 10 IN26 10
29 OUT10 28 IN10
OUT26 11 IN25 9
30 OUT11 27 IN 9
OUT27 12 IN24 8
31 OUT12 26 IN 8
OUT28 13 IN23 7
32 OUT13 25 IN 7
OUT29 14 IN22 6
33 OUT14 24 IN 6
OUT30 15 IN21 5
34 OUT15 23 IN 5
OUT31 16 IN20 4
35 OUT16 22 IN 4
OUT32 17 IN19 3
36 COM1 NC 21 IN 3
(OUT1∼16) 18 VIN1 IN18 2
37 COM2 (OUT1∼16) 20 IN 2
(OUT17∼32) 19 VIN2 IN17 1
(OUT17∼32) IN 1
Note 1)The above figure shows the pin assignment of connector on PC board.
The connector model for the harness is as follows.
Connector body : CN2 DC-37S-N (JAE) or equivalent
CN4 DC-37P-N (JAE) or equivalent
Connector cover : CN2,CN4 DC19678-3(JAE) or equivalent
Connection screw : CN2 DC20419-16J(JAE) or equivalent (M2.6)
CN4 DC20419-21J(JAE) or equivalent (M2.6)
Note 2)The channel numbers of second and consecutive 1GW/1HW boards, add 32 to the
number above.
! CAUTION
The harness connected with CN2 and CN4 must be use the harness of the AWG
22 ∼ 24 equivalent. And harness size is diameter 7.5φ or less.
1GW/1HW
● Connector Arrangement
Note) The output side transistor is mounted on the IC socket and is allocated as follows by each
every of the four outputs.
1GW board output transistor : TD62064BP-1 (Toshiba Corporation)
1HW board output transistor : TD62074AP (Toshiba Corporation)
1GW/1HW
● Jumper Setting
Jumper No. Function Setting Setting usually Note
OUT 1 ∼ 8 Output A-B: Option reset
All B-C short
J1 1 reset condition B-C: Standard
setting A B C
OUT 9 ∼ 16 Output A-B: Option reset
2 1 1-8
reset condition B-C: Standard
setting 2 9-16
OUT 17 ∼ 24 Output A-B: Option reset 3 18-24
3 reset condition B-C: Standard 4 25-32
setting ON OFF
OUT 25 ∼ 32 Output A-B: Option reset RESET
4 reset condition B-C: Standard
setting
Standard : When the power is turned on and SYSTEM reset, it had reset the output.
Option reset : When the power is turned on, SYSTEM reset, and there is no access from the
Bus line during the fixed time, it had reset the output.
Jumper
No. Function I/O Address Setting Setting usually Note
Jumper for I/O 1 ∼ 32 1: Short Do not mount the
J2 address (IN1 ∼ 32) (Additionally, open) I/O board board as which the
switch. (OUT1 ∼ 32) 1 1-32 (T board) I/O address is the
Switches of 1 shot same.
2 -64
setting in
proportion to 3 -96
the number of 4 -128
I/O channels, ADDR
and mount the ESS
I/O board.
33 ∼ 64 2: Short
(IN33 ∼ 64) Additionally, open)
(OUT33 ∼ 64)
1 1-32
2 -64
3 -96
4 -128
ADDR
ESS
65 ∼ 96 3: Short
(IN65 ∼ 96) Additionally, open)
(OUT65 ∼ 96)
1 1-32
2 -64
3 -96
4 -128
ADDR
ESS
97 ∼ 128 4: Short
(IN97 ∼ 128) Additionally, open)
(OUT97 ∼ 128)
1 1-32
2 -64
3 -96
4 -128
ADDR
ESS
1GW/1HW
Jumper
No. Function Setting Setting usually
SIGOUT
B-C is all short SIGOUT SIGOUT
SIGOUT
B-C is all short SIGOUT B-CSIGOUT
is all short
A-B is all short
Case input from Case input from Case input from
J5 Switch which of “CN4 connector” or CN4 robot built-in value CN4
“Robot built-in sensor line (CN3
line
Connector) “to input the input signal
of IN13∼16. IN13∼16 can switch only A B C A B C A B C
with the collectively. When you 1 24V 1 24V 1 24V
select the robot built-in sensor line, 2 WX13 2 WX13 2 WX13
the input signal of IN13∼16 are 3 WX14 3 WX14 3 WX14
switched respectively as follows. 4 WX15 4 WX15 4 WX15
IN13→SIG1, IN14→SIG2,
5 WX16 5 WX16 5 WX16
IN15→SIG3, and IN16→SIG4
CN4 CN3 CN3 CN2 CN3 CN2
! CAUTION
The power supply for the sensor line and the value line cannot be
separated.
Set each jumper J3, J4, and J5 as all respectively are the same.
When the I/F board for the Arc Welding is installed on the I/O board,
cannot select the robot built-in sensor/valve line.
1GW/1HW
1GW/1HW
Storing in EPLD (U29) and Version displaying
File name : GW_U29B.POF
Version displaying : GW_U29B
Check sum : C36DD
J1 J2 J3 J4 J5
A B C A B C
1 24V 1 24V A B C
A B C 2 OX9 2 OX13 1 24V
1 1-8 3 OX10 3 OX14 2 WX13
1 1-32 3 WX14
2 9-16 4 OX11 4 OX15
2 -64 4 WX15
3 17-24 5 OX12 5 OX16
3 -96 5 WX16
4 25-32 6 24G 6 24G
4 -128 CN4 CN3
ON OFF CN3 CN2 CN3 CN2
ADDR
RESET ESS SIGOUT SIGOUT SIGIN
J6 J7 SW1 SW2
A B C A B C ON ON
DA
NO.1 NO.2
ON OFF OPT DA OPTI/O
ADDRESS 1 2 3 4 1 2 3 4
RESET I/O
DA1 0-10 0-15 ±10 UNI DA2 0-10 0-15 ±10 UNI
The 1FS PC board is an option board installed in the card rack and the SLOGIC function
is achieved.
There are two kinds of the 1FS PC boards. The one that has the RI/O communication
function and the RS485 communication function and the another one that has the
communication function by Control-Net.
The 1FS PC board has neither PI/O nor an analog output (That differs from AD-controller
's 1AS PC board). These functions can be achieved by installing the 1HW PC board or
1GW PC board.
SW2
CN1
CN2
CN4
T T
C P P
N 0 0
5 4 1
CN3
T
T
1
P
0
P F
0
3
2
S
S1
1FS
HARDWARE SPECIFICATION
1FS
Block Diagram
FLASH EPROM
2MB 128kB
SIO Interrupt
WAG
Controlle
O
8pin
NA.Chip Timer
& PIO
BNC
C-Net P2
BNC
Controlle
FLASH
64kB
1FS
DIP Switches
S1
LEDs
CN3
BIT SIGNAL
1 R-I/O BLUE WIRE
2 R-I/O CLEAR WIRE
3 R-I/O SHIELD
4 CHASSIS GROUND (FG)
5 N.C.
6 RS485 SIGNAL GROUND
7 RS485 SD+
8 RS485 SD-
The 1HS board is board which functions as CC-Link remote device station of MITSUBISHI
MELSEC.
Feature
Bit data : 112/112 Ch(Max) Input-Output, Word data : 16/16 Ch(Max)Input-Output
Use as Software Dedicated Signal and General Purpose Signal of the robot.
(Bit data for CC-Link communication : Final 16/16 Ch(Max) is a system area among
128/128 Ch(Max).)
It can be use two pieces at the same time.
In this case, Bit data : 224/224 Ch (Max) Input-Output, Word data: I/O of 32/32 Ch
(Max) Input-Output
Input-Output with 1GW (I/O board)
D/A (Option)
! CAUTION
No motion normally if there is an empty slot between 1GA/1HA
board and 1HS board.
CN2 DA DB DG SLD FG
○ ○ ○ ○ ○ ←Each pins
1HS Installed side 1 2 3 4 5
1HS Solder side
S3
S2 S1 1HS Board
DIP SW DIP SW
EPROM
SOKET
CN1
EPLD COM
P2 P1
Channel number
SW 0 10 20 30 40 50 60 70 80 90
8 (SW80) OFF OFF OFF OFF OFF OFF OFF OFF ON ON
7 (SW40) OFF OFF OFF OFF ON ON ON ON OFF OFF
6 (SW20) OFF OFF ON ON OFF OFF ON ON OFF OFF
5 (SW10) OFF ON OFF ON OFF ON OFF ON OFF ON
Channel number
SW 0 1 2 3 4 5 6 7 8 9
4 (SW8) OFF OFF OFF OFF OFF OFF OFF OFF ON ON
3 (SW4) OFF OFF OFF OFF ON ON ON ON OFF OFF
2 (SW2) OFF OFF ON ON OFF OFF ON ON OFF OFF
1 (SW1) OFF ON OFF ON OFF ON OFF ON OFF ON
✱ For example, turn ON only 5th if you set it in 10Ch. (It is not the 2nd and 4th ON.)
(2) Baud rate setting : The 1st ∼ 4th of S1 (black dip switch)
Baud rate
SW 156 Kbps 625 Kbps 2.5 Mbps 5 Mbps 10 Mbps
4 OFF OFF OFF OFF OFF
3 OFF OFF OFF OFF ON
2 OFF OFF ON ON OFF
1 OFF ON OFF ON OFF
✱ Error excluding the above-mentioned
(3) Occupation channel number setting : The 5th and 6th of S1 (black dip switch)
1 Ch 2 Ch 3 Ch 4 Ch
Occupation Occupation Occupation Occupation
Bit data 16/16 48/48 80/80 112/112
Word data 4/4 8/8 12/12 16/16
CN1
C
N CN3
2
C C
N N
4 5 S68 S67 S6T S5 S4 S3 S2 S1 S15
C C
N N
6 7
CN8 CN9
1HZ-50
CN10
HZ-CN4 Signal(between 1GA/1HA PC board & 1GB PC board) harness to 1GB PC board
HZ-CN5,6,7
for External Axes
(optional)
built-in signal(Sig-1, Sig-2, Sig-3, Sig-4) harness to 1GW/1HW PC board(CN9 is
HZ-CN8,9
optional: Double Arms)
LS ORD SW
MPON
SVER +12V
ERR -12V
+24V
ERR
CN1(L
OWE
DSW1
R)
CN2(
UPPE
CN3(L
OWE
R)
CN4(
UPPE
JP1
TP
F
TP
F
1HP
Dip SW (DSW1) set up
1 2 3 4
1HP b’d(standard) ON ON ON OFF
1HP b’d(option) ON ON OFF OFF
Jumper(JP1)
setting
standard 1-2 & 4-5 short
Double Arm 2-3 & 5-6 short
Jumper(JP2)
Specifications setting
6 axes arm & no External axis (No.1 1HP) 1A-2A & 1B-2B short
1-6 External axes(No.2 1HP)
7 axes arm & no External axis(No.1 1HP) 2A-3A & 2B-3B short
6 axes arm & 1-3 External axes(No.1 1HP)
7-9 External axes(No.2 1HP)
6 axes arm & 4-6 External axes(No.1 1HP) 3A-4A & 3B-4B short
7 axes arm & 1-3 External axes(No.1 1HP)
Double 6 axes arms & no External axis(No.1 1HP)
10-12 External axes(No.2 1HP)
Test Pins
+24V(TP1) & +24G(TP1G)
Fuses
Location Capacity KHI P/N Type Maker Used location Caution when
No. exchanging
F1, F3 0.3A 60570-1 DM03 DAITO Connect location to Confirm the connect the
071 TSUSHIN +24V of Emergency Emergency Stop circuit.
Stop circuit. The (Especially, user
fuse melts and cuts connect part.)
off when the
Emergency Stop
circuit is a
line-to-ground-fault.
F2 1A 60570-1 DM10 DAITO Supply part in +24V Confirm the wiring for
051 TSUSHIN power for inside the inside machine
machine sensor/value.
sensor/value.
1HP
Connection Between 1HP & 1HY PC Board
FUSE
1 2 3 5 6 8 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 3 4
XHZ-CN10
XHP-CN3
XHY-CN1
XHY-CN4
2 3 4 5 6 7 8 9 10 11 12 B5 A6 B6
+24V
CR2
CR3
CR4
24G
1HY PC Board A5 B5 A6 B6 A1 B1 A2 B2 A3 B3 A4 B4
XHY-CN3
13 K1
13
14 K2
14
CN1 CN3
CN10
CN4
CN2
CN9
CN8
CN6
LD1
CN5
1HY-3x
LD2 LD3 LD4
1HY
Jumper(R5) setting
R5 open(standard): Hour Meter runs during MOTOR POWER ON.
R5 short: Hour Meter runs during CONTROL POWER ON
LEDs
LD1 is on while all EMERGENCY STOP Switches are released.
LD2∼4 are on as below during MOTOR POWER ON. While MOTOR POWER is off,
all LED is off.
LD2 - on on
LD3 on on on
LD4 on - -
The card file is rack which mounts the printed-circuit board which controls the robot, and it is
composed of the following parts.
Main body of rack which supports printed-circuit board
Motherboard (1HJ board) which connects supply of power supply to printed-circuit board and
signal while printed-circuit board
The card file of C70 and C80 controller installs the printed-circuit board and AVR as shown in the
figure below.
Battery
Card File
The battery for the backup of memory of 1GA/1HA board is installed on the card rack side.
1HJ
Connector, Jumper
S1 S2 S3 S4 S5
JP2
S7
S11 S6 S8 S9 S10
CN6
CN7 CN5
Jumper function
Jumper No. Function
JP1∼P21 For VME bus daisy chain
JP22 For FG-24G connect
1HK board is a printed-circuit board installed in the controller (card rack the under), and it has the
following functions.
• When the control power is turned on, it supplies the power supply to the fan among
controllers etc.
• Drives magnetic contactor at Motor Power ON, and supplies the PN power supply.
• Supplies the brake power supply.
The glass tube fuse is installed on 1HK board. (Refer to details the power supply circuit diagram)
CN8
HEAT
DIODE F1
SINK
TP4 BRIDGE
RS3 N RS4
DB1 HS1 CN3
TP3 K3 K2
PX
SURGE
RS2 RS1
TP5
KILLER CN4
P
LD1 K1 ON
LD2 K2 ON SK1
CN15A,B LD1 LD2 LD3 LD4 CN5
LD3 K3,4 ON
LD4 K5 ON
TP6 24G-HP
K1 TP2 T
P CN6
CN15 K4 CN16
TP1 R
CN10A,B
TP7 24V-HP CN7
CN12 P
K5 CN14
CN1 CN2
CN11 CN9
LED
LD No. Function Motion condition
LD1 For Motor Power ON Light at the time of K1 on
LD2 For Motor Power ON Light at the time of K2 on
LD3 For Motor Power ON Light at the time of K3, K4 on.
LD4 For EMERGENCY STOP Light at the time of releasing of EMERGENCY STOP
1HK
● Block diagram
T1 Line
for Outside Fuse
CN14
AC200-240V
CN1 CN2
CN8
AC200-240V
Fuse F1 CN3
(Only T1 side)
CN4
CN5
CN6
Rush in
Resistor
CN7
Electric
Discharge
Drive Signal Resistor
Contact Signal
Contact Signal
CN16
CN11 Energency Stop
DC24V
DC24V
Drive Signal
CN12 Thermal
CN14
● Fuse
Location Capacity KHI P/N Type Maker Used part Caution when
No. exchanging
F1 2A 60570-10 FGMT FUJI AC 200V system Confirm whether there
82 250V 2A TANSHI power supply for is defective wiring inside
inside controller fan controller and defective
and hour meter. fan.
CN3
SW1 (X206)
SW6
CN1
SW7
CN2
SW2 (X204)
SW3
SW4
SW5
CN4
DCP
● C70/C80 Controller
DCP
Error-AC INPUT
momentary power failure
When AC input fails, error signal is output. Detection level shall be 130 to 145VAC.
When this status is continued for 20 to 30 ms from zero phase, error signal is
output.
high level
Detection level shall be 253 to 263VAC or more. When this level of input is continued for
1 to 2s or more, error signal is output.
low level
Detection level shall be159 to 167VAC or less. When this level of input is continued for
1 to 2s or more, error signal is output.
• When AC input is turned off as a normal operation, error detection of momentary
power failure is activated and then error signal is output.
• The output voltage is turned on again after output voltage drops to 10% of the rated
voltage or lower. However, the load condition must be as shown below.
Error-DC OUTPUT
When overload or overvoltage protection function is activated, DC outputs drop.
3.18 Encoder
There are two kinds of encoders (the H20 type and the M21 type) for C controller by
the difference of the installation method to the motor. The basic specification is the
same as H20 and the M21 type.
Specifications
Electrical Specifications Optical Encoder Magnetic Encoder
Type Optical Disc Magnetic Incremental
Power 5±0.25V 3.6V or more
Current Consumption 180mA 25µA(*30µA)
13
Resolution 2 / rev = 8192 rev 1 count / rev
Response 6000 rpm
Countable Rotation Time 216 times = 65,536 times
• Operating Temperature -20 ∼ +80℃
• Storing Temperature -20 ∼ +80℃
• Humidity 95% RH or less without dew condition
• Vibration 10G,3000Hz or less
• Impact 100G,6msec or less
• Others Dust proof- water and oil resistant
Function
a) Motor rotation angle detection
The encoder data increases when the CCW direction rotates.
(seeing from the motor output axis side)
b) Communication
The position data is transmitted synchronizing with the data request signal from the
1GB PC board. (Half duplex serial communications and baud rate :1M bps)
c) Operation switch by power supply voltage
The operation is the following three kinds.
• State of non-operation : All functions stop when the power supply voltage is 3.0V or
less.
• State of backup : The rotation counter operates when the power supply voltage 3.3v
or more.
• State of usual operation : All functions operate when the power supply voltage is
5.0V.
d) Backup
Even in the state to remove connector with the battery board , the rotation counter
can operate for 30 minutes with the super-capacitor.
e) Motor CS signal detection
The magnetic pole position of the motor is detected by installing the encoder in the
position where the starting point in one rotation agrees with 0 crossing point of motor
generation voltage U.
Enc
f) Error detection
The error which occurs in the encoder is transmitted with the data as an alarm signal.
The detected alarm becomes an error shown in " " by three kinds of the following
through the processing of the controller side.
BUSY : "Encoder initialize error"
The scanning of absolute data is begun from the state of the non-operation
and the backup in the encoder immediately after the shift to the
usual-operation. In that case, BUSY=1 is output until the data is fixed.
ABSALM : "ABS-track error"
When the incremental counter data and absolute data are different ,
ABSALM=1 is output.(When the encoder usually works.)
INPALM : "INC-pulse error"
When the incremental pulse φA and B are abnormal,INPALM=1 is output.
(When the encoder usually works.)
Block Diagram
Main Board
ASIC-2
Absolute
data
Disc ƒÓA,B Amp
ABS
Communication
circuit
Error detect RS-485
Control signals
Communication
Sensor Board
MFP
• Software version of AS and Multi-Function Panel software is sets.
• Therefore, please confirm the combination of the version numbers when you install
software.
• You does not operate normally when the combination of versions is different.
(In present AS software, when the combination of the version is different, the error
display is done by the Multi-Function Panel) .
MFP
ON OFF
TEACH LOCK
LCD
PC card slot
SW2
MFP
Contrast
Adjustment
LCD
Volume
PC Card
Insertation
Port
“Deadman” Switch
MFP
Multi-Function Panel block diagram
Multi Function
Panel Contrast
Emergency
stop sw adjustment
Back light
CN2 power CN1
supply
LCD CN CN CN CN
22 20 5 1
1FU PC
board
1FT PC board
CN
21 CN
42 CN
2
CN JM8
41 use
CN3 debuggi
Touch Panel J1 ng
Earth
( fixes to
J2 the frame
Deadman Teach Deadman on the left
SW 1 lock SW2 of LCD)
(Left) SW (Right)
To controller T/P
OVERVIEW
DESCRIPTIONS
TROUBLESHOOTING
INDEX
● C3X/C4X Controller
Explanation:
There is a possibility that the AC power supply line is short-circuited among
controllers.
● C70/C80 Controller
Explanation:
As for the cause, the following item is thought.
It did trip as CB detected the over-current.
There is a possibility that the AC power supply line is short-circuited among
controllers.
Phenomenon 2: The control power supply lamp does not light up though
Disconnect Switch can be turned ON.
● C3X/C4X Controller
Explanation:
If (disconnect switch) is turned on, the control power supply lamp is lit up.
Therefore, the following are enumerated as a cause where this phenomenon is
generated.
(1) The primary power to the controller is not supplied, or the voltage is too low.
(2) The AC power supply is not supplied to the 1HY PC board.
(3) The power supply is not supplied to the control power supply lamp.
2. F3 turns off in the Power supply Is F3 of the Power supply circuit turned off ?
part.
● C70 Controller
Explanation:
If CB turns on, it lights up the control power supply lamp.
Therefore, the following are thought as a cause where this phenomenon occurs.
(1) The primary power to the controller is not supplied.
(2) The AC power supply is not supplied to 1HK board.
(3) The AC power supply is not supplied to the control power supply lamp.
T/P CN4
1HP Board
When key information on Multi Function Panel does not reach 1GA/1HA board or data does
not reach from 1GA/1HA board to the Multi Function Panel side oppositely, it becomes the
above-mentioned phenomenon.
The following is thought as a cause.
(1) Abnormality of disconnection of communication line Multi Function Panel and
while 1GA/1HA board etc.
(2) Defect of Multi Function Panel
(3) Defect of 1GA/1HA board
(4) Defect of 1HP board
(5) Defect of 1HZ/1HJ board
Factor Check item
1. Defect of communication line
1. Defect to Multi Function Panel of T/P harness 1. Confirm the T/P harness is correctly set in Multi Function
connect Panel.
2. Defect to Operation Unit of T/P harness 1. Confirm the T/P harness is correctly set in Operation Unit.
connect
3. The connect to 1HP board connector CN4 is 1. Confirm connector 1HP-CN4 is correctly connected.
defective.
4. The installation is defective of 1HP board. 1. Confirm 1HP board is correctly set.
5. The installation is defective of 1GA/1HA board. 1. Confirm 1GA/1HA board is correctly set.
6. Defect of T/P harness 1. Confirm whether the surface of the T/P harness includes the
wound etc.
2. Exchanged the T/P harness.
2. Defect of Multi Function Panel
1. The communication circuit is defective of the 1. Exchange Multi Function Panel.
printed-circuit board in Multi Function Panel.
3. Defect of 1GA/1HA board
1. The communication circuit is defective in 1. Exchange 1GA/1HA board.
1GA/1HA board.
4. Defect of 1HP board
1. Connector defective solder on communication 1. Exchange 1HP board.
line etc.
5. Defect of 1HZ/1HJ board
1. Connector defective solder on communication 1. Exchange 1HZ/1HJ board.
line etc.
This was to have become following when MOTOR POWER Switch (push-button switch
and lamp) of the operation panel was pressed.
Phenomenon 1: The Motor Power lamp does not light up.
Phenomenon 2: The switch of the operation panel is in the state of “Run/Repeat" and
magnet conductor K1 and K2 is not turned on.
Phenomenon 3: Even if the switch of the operation panel is in the state of “Run/Teach"
and Deadman Switch of Multi-Function Panel etc. is turned on, magnet
conductor K1 and K2 is not turned on.
Each phenomenon is explained as follows.
● C3X/C4X Controller
2. EMERGENCY STOP Switch is Confirm it is “STATUS” Screen of Multi-Function Panel and the
pressed. EMERGENCY STOP Switch is red. (Confirm red even if error
reset is pressed)
1. Confirm the EMERGENCY STOP Switch of the operation
panel.
2. Confirm the EMERGENCY STOP Switch of Multi-Function
Panel.
• Confirm the External EMERGENCY STOP Switch line.
Is not External EMERGENCY STOP Switch pressed?
• re it performed to wire between 5 and 6, 9 and 10 of
TB2 as shown in the figure below?
TB2 TB2
5 pin 5 pin
6 pin or 6 pin
9 pin 9 pin
10pin 10pin
(Short Circuit)
2 The line to K1 and K2 is abnormal. Check wiring from the operation panel.
• Is CN2 of 1HP board correctly set?
When abnormality occurs in the line until
EMERGENCY STOP Switch and 1. Are 1HP-CN3 and 1HY-CN4 correctly set at the case which
restricting of the axis LS, the error LD5 of 1HP board lights up? Moreover, confirm whether
appearing is done. Therefore, it does not there is damaging in the harness.
become appearing the error about the line 2. Confirm External EMERGENCY STOP.
such as the operation panels after that. 3. 1HP board is defective.
4. Is not there loosening in the TP harness connector in Multi
Function Panel?
5. Is not there loosening in the connect of the Operation Unit
connector of Multi Function Panel?
6. Is not there loosening in the connect to CN4 of 1HP board?
3 Software cannot turn on the Relay “STG”.
1. It does not accurately transmit 1. Confirm whether CN1 of 1HP board which is wiring from the
information from the operation panel operation panel to 1HP board is correctly set.
to 1GA/1HA board. 2. Defect of the 1HP board.
2. It does not accurately transmit Refer to phenomenon 6 that the control power supply does not
information from Multi Function Panel enter.
to 1GA/1HA board.
● C70/C80 Controller
Explanation:
We shows the route by which turns on magnet contactor K1 and K2 in the outline figure
below.
1. The error lamp of the operation panel lights up. Some errors occur. Confirm the content of the error with
“STATUS" Screen of Multi-Function Panel and correspond.
2. EMERGENCY STOP Switch is pressed. Confirm it is “STATUS" Screen of Multi-Function Panel and
the EMERGENCY STOP Switch is red. (Confirm red even if
error reset is pressed)
1. Confirm the EMERGENCY STOP Switch of the operation
panel.
2. Confirm the EMERGENCY STOP Switch of Multi-Function
Panel.
• Confirm the External EMERGENCY STOP Switch
line. Is not External EMERGENCY STOP Switch
pressed?
• Are it performed to wire for the CN2 connector 3 and
16 pin, 4 and 17pin on the 1HM PC board as shown in
the figure below?
1HM Board 1HM Board
X204 X204
3pin 3 pin
16 pin or 16 pin
4 pin 4 pin
17pin 17pin
(Short Circuit)
The error displaying is done at the case where Check of wiring from operation panel
• Is CN1 of 1HM board correctly set?
abnormality occurs in the line until EMERGENCY
• Is CN2 of 1HP board correctly set?
STOP and restricting the axis LS. Therefore, it
does not become an error displaying about the 1. Are 1HP-CN3 and 1HK-CN11 correctly set at the case which
line of the operation panel after that. LD5 of 1HP board lights up? Moreover, confirm whether
there is damaging in the harness.
2. Confirm External EMERGENCY STOP.
3. 1HP board is defective.
4. Is not there loosening in the TP harness connector in Multi
Function Panel?
5. Is not there loosening in the connect of the Operation Unit
connector of Multi Function Panel?
6. Is not there loosening in the connect to CN4 of 1HP board?
2. Setting the operation panel is wrong. Set the operation panel correctly.
3. The External Hold signal is input Release the External Hold signal.
(Repeat mode).
4. It becomes waiting for the condition of Release waiting for the condition.
the program in Cycle Start.
Content:
The editor ends. Data base (link list) information to control the teach data in user memory when
the teach data is accessed breaks.
Main cause:
• Memory is not normally backed up.
• Defect of the 1GA/1HA PC board.
• Memory error by noise etc.
Measures:
• Turn on the 1GA/1HA PC board SW2-8 promptly when this error is occurred. And, load the
teach data after initializing. (occur completely in system memory because a part of the
system data is maintained when Initializing does not initializing by “Auxiliary 100 system
initializations”, SYSINT command, .)
• Check the battery for the memory backup. And, exchange the board when the voltage
decreases.
• Exchange the 1GA/1HA PC board when the error relapses.
Content:
“Command value - current value” of each Joint was calculated at Repeat mode and the
following value was exceeded.
(The Joint max. speed is different depending on the model and Joint.)
Main cause:
• The singularity motion was caused at the robot motion.
• A defective connect etc. of the harness were causes and the robot malfunctioned.
Measure:
• Correct the teach data at the singularity motion.
• As for the malfunction, the connect mistake of the harness and abnormality etc. of the servo
system are thought.
• Check each harness and the boards.
Content:
The command value of Joint exceeded the user set work envelope at Check, Repeat mode.
Set the user set work envelope of each Joint by “Auxiliary 51 SOFTWARE LIMIT” or ULIMIT,
LLIMIT command.
(The work envelope when the robot is shipped is set in the maximum work envelope usually)
Main cause:
• Set mistake of user set work envelope.
• When the teaching posture(contain the robot moving posture) is the vicinity of the user set
work envelope.
Measure:
• Set the user set work envelope in an appropriate value.
• Change the teaching posture.
! CAUTION
The maximum work envelope > Mechanical stopper > Axis restriction limit switch > User set
work envelope
(The mechanical stopper and the axis restriction limit switch are the options. The installed axis
is different according to the model and the structure of the machine.)
There is a form which describes set of each value when each model and each title machine
are shipped with in the controller or each manual. Confirm this set table.
Keep this set table importantly so as not to lose.
Keep from a set content in this set table or another form when you change a set content.
Content:
The command value of Joint interferes mutually when 2, 3 axes of the UX, UT, UZ, series etc.
are robots of the link mechanism.
(In robots(JS series, etc.) of not link mechanisms 2, 3 axes, this error is detected)
Main cause:
• The teaching posture(including posture in move) is bad.
Measure:
• Change the teaching posture.
Content:
The check sum data of the system data (machine model, number of axes, and option setting,
etc.) of the AS software was rewritten for some reasons.
Main cause:
• When the AS software is exchanged, doing LOAD are normal the data file which the
system/the robot data enters when this error is occurred when setting the system/the robot
data (machine model and option) is changed.
• When this error is occurred in situations other than the above-mentioned
a) Defect of memory backup.
b) Defect etc. of the 1GA/1HA PC board.
c) Memory error by noise etc.
Measures:
• Set the error detection invalid function in the valid by “Auxiliary 78 CLEAR CHECK SUM
ERROR”, CHSUM command and do error reset.
• (CHSUM is set to turn ON the control power supply from turning OFF in “Invalid”.)
• When the error cannot do the change by executing the CHSUM command, the command
finding abnormality in the data is appeared. Again, release the error again by CHSUM
command after setting each command. (Refer to the AS LANGUAGE MANUAL and
OPERATION MANUAL.)
• Check the battery and exchange the 1GA/1HA PC board when the error cannot do the change
and the error is occurred again excluding the above-mentioned content.
Caution:
• There is a form which describes set of each value when each model and each title machine are
shipped with in the controller or each manual. Confirm this set table.
• Keep this set table importantly so as not to lose.
• Keep from a set content in this set table or another form when you change a set content.
Content:
The voltage of the battery for the memory backup supplied to the 1GA/1HA PC board detected
about 2.5V or less (ratings 3.6V) at control power supply ON and Motor Power ON.
(The hardware of the 1GA/1HA PC board is always observed)
Battery
Battery Mother Board Rating : 3.6V
Battery Voltage
Monitor Circuit
/ Voltage Change
Circuit
Battery Lower
Signal
to AS software
Main cause:
• The battery is longevity.
• The connect is defective of the battery line.
• Defect of the 1GA/1HA PC board and battery voltage monitor circuit.
• The battery is consumed in large quantities with each board on the motherboard and the
voltage descends.
(Excludes the power sequence board.)
Measures:
• Execute the all data saving promptly when the teaching data is maintained in memory.
• Execute the memory exchange promptly when the voltage of the battery decreases.
• Confirm each board, state of the connect of the connector, and exchange the 1GA/1HA PC
board when the voltage of the battery is normality.
• Detach each of one board (Excludes the power sequence board.) connected with the
motherboard which contains the 1GA/1HA PC board when the voltage decreases even if
you connect it with the motherboard with normal voltage of the battery unit. Exchange the
board because the board by which the voltage becomes normal is a cause.
! CAUTION
After error reset is done, this error can be automatic
operation if the teach data is normal (after LOAD is
executed again).
This error can make the error detection an invalid
by using the Auxiliary 101 BATTERY ERROR
CHECK, BATCHK command.
(As for setting BATCHK, the control power supply is
set again in the valid by turning off )
Content:
For abnormality the check sum of the AS system area in the flash memory on the 1GA/1HA PC
board when the control power supply is turned on
(The check sum data is made when the fchk command is executed and is recorded in the flash
memory at the down-load.)
Main cause:
• When the AS system was down-loaded, the fchk command was not executed.
• The addressing of the fchk command was wrong.
• The flash memory and the 1GA/1HA PC board Defective.
• The system in the flash memory damaged.
Measures:
• Confirms the content of the description the command file “as_load.cmd” file in the PC card
if immediately after down-loading the AS system. Execute down-loading again.
• Down-load the AS system again and confirm whether to occur this error.
• Exchange the 1GA/1HA PC board when this error relapses.
Content:
For abnormality the check sum of the servo system area in the flash memory on the 1GA1HA
PC board when the control power supply is turned on
(The check sum data is made when the fchk command is executed and is recorded in the flash
memory at the down-load.)
Main cause:
• When the servo system was down-loaded, the fchk command was not executed.
• The addressing of the fchk command was wrong.
• The flash memory and the 1GA/1HA PC board Defective.
• The system in the flash memory damaged.
Measures:
• Confirms the content of the description the command file “as_load.cmd” file in the PC card
if immediately after down-loading the servo system. Execute down-loading again.
• Down-load the servo system again and confirm whether to occur this error.
• Exchange the 1GA/1HA PC board when this error relapses.
Content:
The CPU of the 1GA/1HA PC board stopped. (Detect with the AS software)
Main cause:
• Defect of AS software and servo software.
• Defect of hardware.
• Malfunction by noise etc.
Measure:
• Confirm whether to occur error with which board referring to the message appeared in
the terminal software by the personal computer.(This error is not appeared in
Multi-Function Panel)
Example)
Error (-1100) CPU bus error No=1.
Task (Pc01) Stop SIG=00070004 [NMI(VME BUS ERROR)] PC=******
Occurring place.
IO BUS ERROR : Occurs error in the address on the I/O board such as 1GW/1HW.
PSB BUS ERROR : Occurs error with the power sequence board such as 1HP.
VME BUS ERROR : Occurs error with the board which uses the address on VME buses
other than the power sequence board and the I/O board.
(Which board for two or more boards such as I/O boards and the power sequence boards
which can be mounted cannot be distinguished)
• Turn ON the control power supply from turning OFF.
• At this time, LOAD again in “No” if the message of the initialization confirmation is
appeared.
• Do the teach data in LOAD again after initializing when the error does not return normally
even if this operation is done. (If Multi-Function Panel or the terminal software by the
personal computer is not State of RUN at initialization, initialization cannot be done.
(Initialization cannot be done in Small Teach Pendant alone))
• The defect of the AS system is thought if this error occurs in a certain specific part or a
certain specific operation was done when the teaching program is executed. Therefore,
report details (content of all messages, models, control models, title machines, AS
software/servo software versions, when the above-mentioned error is occurred,
situations such as program lists, and content of the option etc.) to KHI.
• Exchange the 1GA/1HA PC board etc. when reproducibility cannot be confirmed and
error cannot return normally and look at the appearance.
Content:
In the 1GA/1HA PC board, the bus error (In the VME bus line, data processing was not able to
be done normally) was occurred.(Detect with the AS software)
Main cause:
• Defect of the 1GA/1HA PC board.
• Defect of AS software.
• Malfunction by noise etc.
Measure:
• Confirm whether to occur error with which board referring to the message appeared in the
terminal software by the personal computer.(This error is not appeared in Multi-Function
Panel)
Example)
Error (-1101) main CPU bus error No=1.
Task (Pc01)Stop SIG=00070004 [NMI(VME BUS ERROR)] PC=******
Occurring place.
IO BUS ERROR : Occurs error in the address on the I/O board such as 1GW/1HW.
PSB BUS ERROR : Occurs error with the power sequence board such as 1HP.
VME BUS ERROR : Occurs error with the board which uses the address on VME buses
other than the power sequence board and the I/O board.
(Which board for two or more boards such as I/O boards and the power sequence boards
which can be mounted cannot be distinguished)
• Turn ON the control power supply from turning OFF.
• At this time, LOAD again in “No” if the message of the initialization confirmation is
appeared.
• Do the teach data in LOAD again after initializing when the error does not return normally
even if this operation is done. (If Multi-Function Panel or the terminal software by the
personal computer is not State of RUN at initialization, initialization cannot be done.
(Initialization cannot be done in Small Teach Pendant alone))
• The defect of the AS system is thought if this error occurs in a certain specific part or a
certain specific operation was done when the teaching program is executed. Therefore,
report details (content of all messages, models, control models, title machines, AS
software/servo software versions, when the above-mentioned error is occurred, situations
such as program lists, and content of the option etc.) to KHI.
• Exchange the 1GA/1HA PC board etc. when reproducibility cannot be confirmed and
error cannot return normally and look at the appearance.
Content:
In the 1GA/1HA PC board, the bus error (In the VME bus line, data processing was not able to
be done normally) was occurred.(Detect with the AS software)
Main cause:
• Defect of the 1GA/1HA PC board.
• Defect of AS software.
• Malfunction by noise etc.
Measure:
• Confirm whether to occur error with which board referring to the message appeared in the
terminal software by the personal computer.(This error is not appeared in Multi-Function
Panel)
Example)
Error (-1102) VME bus error No=1.
Task (Pc01)Stop SIG=00070004 [NMI(VME BUS ERROR)] PC=******
Occurring place.
IO BUS ERROR : Occurs error in the address on the I/O board such as 1GW/1HW.
PSB BUS ERROR : Occurs error with the power sequence board such as 1HP.
VME BUS ERROR : Occurs error with the board which uses the address on VME buses
other than the power sequence board and the I/O board.
(Which board for two or more boards such as I/O boards and the power sequence boards
which can be mounted cannot be distinguished)
• Turn ON the control power supply from turning OFF.
• At this time, LOAD again in “No” if the message of the initialization confirmation is
appeared.
• Do the teach data in LOAD again after initializing when the error does not return
normally even if this operation is done. (If Multi-Function Panel or the terminal software
by the personal computer is not State of RUN at initialization, initialization cannot be
done. (Initialization cannot be done in Small Teach Pendant alone))
• The defect of the AS system is thought if this error occurs in a certain specific part or a
certain specific operation was done when the teaching program is executed. Therefore,
report details (content of all messages, models, control models, title machines, AS
software/servo software versions, when the above-mentioned error is occurred,
situations such as program lists, and content of the option etc.) to KHI.
• Exchange the 1GA/1HA PC board etc. when reproducibility cannot be confirmed and
error cannot return normally and look at the appearance.
Content:
When the control power supply is turned on, the first address of the power sequence board
(1HP PC board etc.) of the first piece cannot be read. (Not mounted)
However, the control power supply does not enter when not mounted actually.
Main cause:
• The power sequence board (1HP PC Board etc.) is not mounted.
• Set mistake in address of power sequence board.
• Defect of power sequence board.
Measure:
• Mount on the position where setting the address of the power sequence board is set to
the first piece and the card rack is correct.
• (When the power sequence board of setting for the first piece is installed in the power
sequence board slave side of the motherboard, does not turn on the control power
supply.)
• Exchange the power sequence board (1HP PC Board etc.).
Content:
The first address of the power sequence board of the second piece (1HP PC Board etc.) cannot
read for the twin arm specification etc. to turn on the control power supply. (Not mounted)
Main cause:
• The power sequence board (1HP PC Board etc.) is not mounted.
• Set mistake in address of power sequence board.
• Defect of power sequence board.
Measure:
• Mount on the position where setting the address of the power sequence board is set to the
second piece and the card rack is correct.
• Exchange the power sequence board (1HP PC Board etc.).
Content:
Cannot read the first addresses of I/O board (1GW/1HW PC Board etc.) of the number of
signals of having set with DO (output point), DI (input point) of the ZSIGSPEC command when
the control power supply is turned on.(Not mounted)
(However, when the sequencer board is used, this error is not used)
ZSIGSPEC command DO, DI > The number of sheets of mounting I/O board*32 points.
( INT of the ZSIGSPEC command (internal signal point) is unrelated to the I/O board because of
a virtual signal in memory.)
Main cause:
• Set mistake I/O board (1GW/1HW PC Board etc.) in the ZSIGSPEC command is detached.
• Set mistake in board address of I/O board (1GW/1HW PC Board etc.).
• Defect of I/O board (1GW/1HW PC Board etc.).
Measure:
• Set a correct number of signals with the ZSIGSPEC command.
• Set the board address of the I/O board (1GW/1HW PC Board etc.) correctly and mount on
the card rack.
• (It is basic that the I/O board mounts the card rack from the right side toward., but The I/O
board operates normally on VME bus when mounting.)
! CAUTION
This error is in the state of the I/O board's not being
mounted after error reset is done and an automatic
operation can be executed.
However, the input not mounted is fixation while turned off.
And, the output is possible in the AS software ON/OFF as
usual.
However, the number of maximum signals in the software
which can be set with the ZSIGSPEC command is DO,
DI=256, INT=512 but DO and DI are restricted by
restricting hardware and other option.
(The I/O board (1HW/1GW PC Board etc.) is every 32
points usually.)
Content:
It is time when is not mounted IC(SIO) for serial communications for command line 3 and 4CH
for the communication with the servo CPU board on the main CPU board and it sets more than
seven axes at control power supply ON.
Main cause:
• Defect of the main CPU board.
Measure:
• Exchange the main CPU board.
Content:
The error is not classified though the error summary signal comes from the power sequence
board (1HP PC Board etc.).
Or, the error message which corresponds to the AS software when the error detection is newly
added on the power sequence board side does not exist.
EPLD
Register on VME Bus
Main cause:
• The error detection function of the power sequence board does not correspond to the error
processing function of the AS software.
• Defect of power sequence board.
• Defect of AS software.
Measure:
• Exchange the power sequence board.
• Improve the version of the AS software.
! CAUTION
• This error is shown to occur some errors excluding the
defect of the power sequence board.
• Investigate the situation such as the occurring
situation and reset of the error possible.
Content:
When the set data was changed by “Auxiliary 901 EXTERNAL AXIS SET”, tried to register the
wrong data.
Example:
When the servo channel (Are the servo CPU and communication processing done with which
channel of the 1GA/1HA PC board command line?) of the external axis is set, it is changing to
the channel number (channel used by another and channel, etc. which do not exist) which
cannot be changed.
Measure:
• Input a set value correctly.
! CAUTION
There is a form which describes set of each value when
each model and each title machine are shipped with in the
controller or each manual. Confirm this set table.
Keep this setting table importantly so as not to lose.
Keep from a set content in this set table or another form
when you change a set content.
Content:
The servo software and the servo parameter, etc. are usually written on the servo board (1GB
PC Board etc.) only at control power supply ON.
When the data of the servo parameter of the external axis, model setting and number etc. of
correspondence axes are changed with LOAD etc. of the robot/the system data, the new data
should write in the servo board at the 1GA/1HA PC board is exchanged and option axis since
seven axes is used. Therefore, try to turn on the control power supply.
Measure:
• Make the control power supply from turning off to turning on.
! CAUTION
When the model was changed, the robot motion stripes
had been normally corked if the servo software was not
exchanged for the corresponding model software.
Content:
When the servo software was written from the flash memory on the 1GA/1HA PC board to the
servo board (1GB PC Board etc.) in the command line, it did not end normally at control power
supply ON.(Check it with the AS software)
A 0 7
7: Down-loading mistake of servo program.
6: Down-loading mistake of servo parameter.
4: Trap mistake (Initialization defect of servo software).
CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB P Board A unit
or One axis Amplifier
D Second 1GB P Board B unit
or One axis Amplifier
Servo Board
JP (1GB Board etc.)
2nd Board/One axis Amp.
Unit A
Command line CH4
Unit B
Unit C
Main cause:
• Defect of servo board (one axis amplifier).
• Defect of the harness between power sequence board and servo board.
• Motherboard JP set mistake.
• The servo software is not in the flash memory on the 1GA/1HA PC board.
• Malfunction by noise etc.
• Version suitable combination of servo software and AS software.
• Version suitable combination of monitor ROM in servo software and servo board.
Measure:
• Exchange of 1GA/1HA, servo board, and each harness.
• Confirm the servo software and the servo board monitor ROM version and install the
corresponding servo software again.
• The confirmation of the version can be confirmed by “Auxiliary 90 SOFTWARE VERSION
DISPLAY”, ID command..
Content:
Among communications in the command line of each CPU of the servo board (1GB PC Board
etc.) and the 1GA/1HA PC board, the data reception from the servo board failed twice
continuously.
(The communication of the command line always communicates in each 4msec.)
When each CPU of the servo board stops, system might be detected by this error.
(Refer to ERR-1300)
The channel of the servo board CPU is appeared in “*” in the message.
CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier
Servo Board
JP (1GB Board etc.)
2nd Board/One axis Amp.
Unit A
Command line CH4
Unit B
Unit C
Main cause:
• Defect of the 1GA/1HA PC board.
• Defect of servo board.
• Defect of each communication harness.
• Defect of the encoder in case of Jt.3(A) or Jt.4(B)
• Malfunction by noise etc.
Measure:
Exchange of the 1GA/1HA, servo board, and each harness.
Content:
Error not basically occurred.
Though the error on hardware was detected from the servo board (1GB PC Board etc.), system
is processed by this error when there is no error processing corresponding to the AS software
side.
CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier
The internal error code number which the servo software detected is appeared in ****.
JP Servo Board
(1GB Board etc.)
2nd Board/One axis Amp.
Unit A
Command line CH4
Unit B
Unit C
Main cause:
• Defect of servo software.
• Malfunction by noise etc.
• Defect of harness during servo board and power sequence board (1HP PC Board etc.).
• Defect of servo board.
• Suitable combination of version of servo software and AS software.
• Something wrong with servo software and AS software.
Measures:
• The version up of the servo software and the AS software.
• Exchanges such as the 1GA/1HA PC board, servo boards, and each harness.
• When this error is occurred, report details (error code, code number appeared in ****,
models, control models, title machines, AS software/servo software versions, operation
when occurring making an error and situation such as program list, and content of the
option etc.) to KHI.
Content:
Error not basically occurred.
Though the error on hardware was detected from the servo board (1GB PC Board etc.), system
is processed by this error when there is no error processing corresponding to the AS software
side.
CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier
The internal error code number which the servo software detected is appeared in ****.
JP Servo Board
(1GB Board etc.)
2nd Board/One axis Amp.
Unit A
Command line CH4
Unit B
Unit C
Main cause:
• Defect of servo software.
• Malfunction by noise etc.
• Defect of harness during servo board and power sequence board (1HP PC Board etc.).
• Defect of servo board.
• Suitable combination of version of servo software and AS software.
• Something wrong with servo software and AS software.
Measures:
• The version up of the servo software and the AS software.
• Exchanges such as the 1GA/1HA PC board, servo boards, and each harness.
• When this error is occurred, report details (error code, code number appeared in ****, models,
control models, title machines, AS software/servo software versions, operation when
occurring making an error and situation such as program list, and content of the option etc.) to
KHI.
Content:
When setting was changed by “Auxiliary 976 SERVO PARAMETER”, a case different from the
content of the transmission was consecutive and occurred answer-back from the servo
software of each unit two times or more for the transmission of the data to the servo board (1GB
PC Board etc.) through the command line.
CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier
The internal error code number which the servo software detected is appeared in ****.
JP Servo Board
(1GB Board etc.)
2nd Board/One axis Amp.
Unit A
Command line CH4
Unit B
Unit C
Main cause:
• Defect of the 1GA/1HA PC board.
• Defect of servo board.
• Defect of each communication harness.
• The AS software or the servo software does not correspond.
• Malfunction by noise etc.
Measure:
• Exchange of the 1GA/1HA, servo board, and each harness.
• The version up of the AS software or the servo software.
• Resetting the error becomes possible when normally ending by setting again though error
reset is basically impossible.
• The control power supply should be OFFÆON when not normally ending.
Content:
Watch dog timer built into in each CPU of the 1GB PC board operated.
Detection block:
1GB PC Board
Watch dog
1GA PC Board Error Signal
CPU-A Gate Array
Watch dog
EPLD Error Signal
CPU-C Gate Array
Command Line
Main cause:
• Defect of the servo board.
• Something wrong with the servo software.
Measure:
• Exchange of the servo board.
Content:
The servo software receives a command of the uncorrespondence and a command not
adequate when each command is transmitted from the AS software to the servo software and
servo software has returned the error code (Each error code of the servo system is another) to
the AS software.
JP Servo Board
(1GB Board etc.)
2nd Board/One axis Amp.
Unit A
Command line CH4
Unit B
Unit C
Main cause:
• Defect of the 1GA/1HA PC board and servo board.
• Something wrong with AS software and servo software.
• Suitable combination of version of AS software and servo software. (uncorrespondence etc.
of option)
• Malfunction by noise etc.
• Defect of the harness between servo board and power sequence board.
Measures:
• Exchange of the 1GA/1HA PC board, servo board, and harness.
• Version up of AS software and servo software.
Content:
Though Motor Power (Magnet conductor (MC) for Motor Power) is turning ON in the AS
software, but MC is not turned ON (or, the signal of MCON is not fed back) because there is a
problem in hardware.
MC was turned OFF with the error code was not able to be recognized in the state of MC ON in
the AS software.
(Refer to the power supply circuit chart of Operation Unit for a detailed system chart)
Main cause:
• Defect of power sequence board (1HP PC Board etc.).
• Defect of relay board (1HY/1HK PC Board etc.).
• Something wrong with error detection circuit and error processing of each board.
• The Auxiliary contact of magnet contactor (MC) for Motor Power is coming in contact defective
and operation defective.
• Something wrong with servo software and AS software.
Measure:
• Exchange such as magnet contactor (MC) for power sequence board, relay board, and
Motor Power.
Content:
The monitor ROM version (Basic software printed out to CPU. It is not a main body of the servo
software.) of each unit on the 1GB PC board is different.
Main cause:
• Defect of the 1GB PC board.
Measure:
• Exchange the 1GB PC board.
Content:
Information of having done the demand of the brake open (It is not brake opening confirmation)
does not return within the fixed time (2 seconds) according to the command line communication
from the servo board even if servo control ON (SVCN) signal is sent from the AS software to the
servo board (1GB PC Board etc.) through the register of EPLD on the power sequence board
(1HP PC Board etc.).
1GA Board
Servo Board
(1GB PC Board )
Command
Line
CPU-A
Mother Board
Main cause:
• Defect of the power sequence board.
• Defect of the servo board.
• Defect of the harness between the power sequence board and servo board.
Measure:
• Exchange the power sequence board and the servo board, etc.
Content:
This error occurs when the safety gate is open in the repeat mode (When neither Emergency
stop nor the LS error occur).
Main cause:
• Safety plug open.
• Safety circuit fault.
Measure:
• Safety plug reinsert, etc.
Content:
The controller has two system MC line.
When no matching occurs in the motion of the two lines, it becomes this error.
Main cause:
• Emergency stop circuit line open.
• Axis restriction limit switch fault.
• User’s safety circuit fault.
• 1HP,1HY,1HZ PC Board fault or those connectors are not fastened.
Measure:
• Check safety circuit, etc.
Content:
Do the watch of MC ON command from controller and motion of actual MC. When no matching
occurs, it becomes this error.
The motion of electromagnetic contact device (K1, K2) in the power supply part is not correct.
(1) When it should turn ON Motor Power, the following cause is thought as for the case where
it does not turn ON electromagnetic contact device.
y Look at LD2, LD3, and LD4 of LED on 1HY board. (It is sure to light up LD1.)
i) 2 LED lights up among 3 LED.
y The coil wiring of K1 and K2 has come off.
y XHZ-CN10 (connector under the left of motherboard) has come off.
y XHY-CN2 has come off.
y Malfunction of K1 and K2.
y Malfunction of relay on 1HY board.
ii) 1 or 0 LED lights up among 3 LED
y XHY-CN4 has come off.
y Connector on 1HP board has come off.
y Additionally, abnormality of MC line.
y Malfunction of 1HP board.
y Malfunction of 1HY board.
(2) When motor power is turning OFF and when it has turned OFF the trigger by the teach
made, the following cause is thought as for the case which is turning ON electromagnetic
Contact device.
y Malfunction of K1 and K2 (contact stuck etc.)
y Malfunction of 1HY board.
y Malfunction of 1HP board.
Content:
At the savoring, the feedback current from a current sensor in the power block exceeded 144% of
the maximum current of the instantaneous of the motor.
A set value of Joint is set with the hardware of the 1GM PC board installed on the servo board
(1GB PC Board) and is detected by HIC.
1GB PC Board
Command
Line HIC 1GM PC
CPU Over Current Board
Detect I/V Conversion
Over Current Error Signal
Robot
Current
Sensor U,V,W,E
IPM Each Motor
Power Block
Main cause:
• Short in U, V, W from the power block to motor, and earthing wire line.
• Defect of the motor.
• Defect in the power block.
• Defect of the servo board (1GB PC Board etc.).
Measure:
• Check whether U, V, W to the motor, and the earthing wire line are disconnected from the
power block. And, exchange the separate robot harness/the inside machine harness.
• Exchange the motor.
• Exchange Servo Unit.
Content:
When the servo system error is occurred, this error is appeared.
Refer to the content of each error because each servo error is appeared at the same time.
Turning OFF becomes becoming of Motor Power when servo error signal (SVER) is output
from the servo board (1GB PC Board etc.) with the hardware of the power sequence board
(1HP PC Board etc.). Moreover, this signal is transmitted to the AS software via the
register of EPLD. Afterwards, after this error, the error code which corresponds to each
error is appeared because error information from the servo board is sent through the
command line.
1GB PC Board
Mother Board
Watch dog
Error Signal
Servo Error CPU-B
Signal Gate Array
Watch dog
EPLD Error Signal
CPU-C Gate Array
Motor Power ON
Circuit
Command Line
Main cause:
• The servo system error was occurred.
• Disconnection or connect defect of the harness between the power sequence board and
the servo board.
Measure:
• Furnace when error of servo system is occurred referring to each error code.
• Check and exchange the power sequence board for the disconnection of the harness
between the servo boards.
Content:
When the control power supply is turning ON, the ID code data that the ID code and the AS
software of the 1GM PC board installed on the 1GB PC board correspond is not
corresponding.
(The ID code is read by the communication of the command line)
1GM is fixation with 6 axes machine and KHI standard 7 axes machine for the traverse joint
against the model. However, because the model of the motor since the 7th axis is different,
you should specify the ID code on the AS software excluding KHI standard traverse and
more than 7 axes machine.
1GA PC Board
1GB PC Board
Mother Board
1GM PC
Board
ID Code (From Data Bus)
Command Line
CPU-A
Power Sequence Board
(1HP PC board)
Main cause:
• The 1GM PC board is not suitable for the AS software (robot model).
• The data of the ID code in the AS software is different from the 1GM PC board things
except more than 7 axes and a standard traverse joint.
• The AS software does not correspond to the 1GM PC board (model).
Measure:
• Install the 1GB PC board equipped with the correct 1GM PC board.
• LOAD again the robot/the system data when occurring this error immediately after
initializing.
• Because the read data is wrong when the error is occurred immediately after the robot/the
system data was LOAD. After initializing, try to read be the correct data.
Content:
An error occurs if the current feedback value is near 0 from the time the servo is turned ON to
when the brake is released, even though the commanded current value meets or exceeds a
certain current.
Main cause:
• Motor power line U, V, and/or W phase are disconnected.
(No software check is mach for disconnections.)
• Defective connection of the power harness line.
• Defect in the power block.
Measure:
• Check for a disconnection, mistake, or defect in the wiring, and replace the harness if
necessary.
• Exchange Servo Unit.
Content:
The current feedback from the power block was observed and the current which exceeded
the continuous ratings current of the motor flowed more than permissible time.
The servo software detects this error by the following data (OL curve).
Servo Error
Signal
Gate Current
Array A Feedback
To Power
Sequence
Board Robot
(1HP PC PWM
Board) Command
Continuous
Rating Motor Current Current
Current Sensor U,V,W,E
IPM Each
Motor
OL Curve
Power Block
Main cause:
• Mechanical factor.
• The robot arm comes in contact with the treatment device etc.
• The harness etc. are caught to the robot arm.
• The decelerator, the gear, and the bearing, etc. are damaged.
• In the gear deceleration part, the backlash is narrow.
• The weight of the load exceeds the ratings pay load of the robot.
• It is a robot motion (counter teach etc.) by which the robot motion pattern exceeds
ratings of the motor.
• The motor brake is not released.
• Electric factor.
• Motor power line U, V, and W phase are disconnected. (The disconnection is not
checked)
• The brake line is disconnected or the brake drive circuit (Build in the servo board
(1GB PC Board etc.)) is damaged.
(Neither the disconnection of the brake nor the short-circuit are checked)
• The power block is damaged.
• Defect of the servo board.
• Defect of the motor.
Measure:
• Check the decelerator etc. for a mechanical factor. And, exchange decelerator etc. if it is
necessary.
• Save the robot arm with Teach mode when the robot arm is interfering. Afterwards,
confirm the dislocation by driving part and the arm transformation such as decelerators.
• Check the harness and Servo Unit for an electric factor. And, exchange the harness and
Servo Unit if it is necessary.
! CAUTION
If this error is caused repeatedly, the motor will fail
to be burnt. Startup again after solving the cause
without fail.
Content:
The thermal contact connected with the machine harness worked. (motion by disconnection)
However, there is a model short-circuited without building a thermal contact into according to
the model in the connector box of the robot arm or model from which plural series are
connected with thermal.
The unit name of the servo board is appeared in *.
CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier
Main cause:
• Disconnection of thermal line.
• The connect is defective of the separate robot harness.
• Defect of the servo board.
• When thermal is built-in
• Immediately after occurring error such as overloads.
• The robot rated weight capacity is exceeded.
• The ambient temperature of the robot exceeds the temperature of the robot of use
environment.
Thermal Line
(TH)
Gate Array Thermal
B Rotor Trunk Switch
portion
1GB PC Board
• The robot motion which the load such as the counter teaches rested upon was
executed continuously.
• Hold of cooling fan which places to robot and defect of air purge for cooling.
• The servo ring was continued for a long time by posture hanging the gravity load on
the arm.
• Defect of thermal switch.
Measure:
When a thermal motor works, error reset cannot be done until cooling ends.
• Confirm the use condition of the robot and use the robot in ratings.
• Do the disconnection check of a thermal line and exchange the harness and the servo
board.
• Put from interlock etc. into the state of HOLD when robot continue the servo ring during
a long time (line holding etc.) by the posture hanging the gravity load on the arm . Or,
set “Automatic Servo Off” function with “Auxiliary 91 ENVIRONMENT DATA” and
ENV_DATA command.
Content:
Joint speed (motor speed) calculated with encoder value exceeded a regulated value.
(Detect with the servo software)
At the repeat :Joint ratings speed of robot*1.2
At teach/check. :At the equivalent radius position (The slide joint is actual command value
speed) 250mm/sec*1.5
Robot Arm
Command
Line Servo Board
CPU Encoder
(1GB PC Board) Encoder
Encoder
Servo Error Gate Array I/F
Signal
(only Output
Gate Array-A) Power
Battery
Supply
Encoder Power Encoder Backup Board
Supply (+12V) (1FG PC Board)
Controller
Main cause:
• Disconnect the motor power line U, V, and W phase, and fall of arm by power defective
block etc.
• Malfunction due to wiring mistake in motor power line and encoder line.
• Disconnection of the encoder signal line, short-circuit and defect of main body of encoder.
• The robot depends on the singularity motion.
• Defect in the servo board and power block.
• The moment of inertia exceeded the motor torque by installing the load more than ratings
at the highest velocity robot motion.
Measure:
• Check the disconnection and the short-circuit etc. of the wiring mistake and wiring and
exchange the harness and the encoder, etc.
• Exchange Servo Unit etc.
• Correct the teach data such as the reductions of the modification and setting of the speed
at the position (posture) in case of the singularity motion.
Content:
The difference between the current value from the encoder and the command value on the
AS software exceeded a regulated value.
(Detect by processing the servo position loop of the AS software. A regulated value is
different depending on the model and Joint, etc.)
Main cause:
• Mechanical factor:
• The robot arm comes in contact with the treatment device etc.
• The harness etc. are caught to the robot arm.
• The decelerator, the gear, and the bearing, etc. are damaged.
• In the gear deceleration part, the backlash is narrow.
• The weight of the load exceeds the ratings pay load of the robot.
• It is a robot motion (counter teach etc.) by which the robot motion pattern exceeds
ratings of the motor.
• The motor brake is not released.
• Electric factor.
• Motor power line U, V, and W phase are disconnected. (The disconnection is not
checked)
• The brake line is disconnected or the brake drive circuit (Build in the servo board (1GB
PC Board etc.)) is damaged.
(Neither the disconnection of the brake nor the short-circuit are checked)
• The power block is damaged.
• Defect of the servo board.
• Defect of the motor.
• When robot do the singularity motion
Measure:
• Check the decelerator etc. for a mechanical factor. And, exchange decelerator etc. if it is
necessary.
• Save the robot arm with Teach mode when the robot arm is interfering. Afterwards,
confirm the dislocation by driving part and the arm transformation such as decelerators.
• Check the harness and Servo Unit for an electric factor. And, exchange the harness and
Servo Unit if it is necessary.
• Correct the teach data in case of the singularity motion.
Content:
The voltage of the battery connected with the encoder battery board (1FG PC Board etc.)
which built-in the robot arm has decreased to 3.2V or less (ratings 3.6V).
Or, the encoder battery alarm signal (BAT_AL) signal from the encoder battery board was
disconnected.
However, this error is detected only at control power supply ON time and Motor Power ON
time.
Robot Arm
Command
Line Servo Board
Encoder
CPU (1GB PC Board) Encoder
Encoder
Servo Error Gate Array I/F
Signal
(only Output
Gate Array-A) Power
Battery
Supply
Encoder Power
Encoder Backup Board
Supply (+12V) (1FG PC Board)
Controller
Main cause:
• Longevity of the encoder battery.
• Defect of the encoder battery board.
• The defect of the encoder or, short of the harness from the battery board to the encoder
are a cause, the amount of the consumption of the battery increases, and the battery is
discharged.
• Battery alarm signal (BAT_AL) from the encoder battery board was disconnected.
• Defect of the servo board (1GB PC Board etc.).
Measure:
• There is a possibility that the internal data of the encoder is not maintained when this error
is occurred. Therefore, confirm whether the degree is 0 degrees after putting all axes
together on the position where the robot is marked (mechanical origin) with Teach mode
without fail.
• Execute zeroing when they are not 0 degrees.
• After error reset is done, this error can be automatic operation. However, note that there is
a possibility to cause the dislocation when the robot is operated without confirming zeroing
like the above-mentioned.
• Note that there is a possibility that the internal data of the encoder is not maintained when
the control power supply is turned off when this error is occurred.
• Exchange the battery promptly when the encoder battery decreases.(Exchange the
battery for the conveyer encoder, or for multi axis at the same time).
• Check each harness in disconnecting and the short-circuit and exchange the harness.
• Exchange the encoder, the servo board, and the encoder battery board, etc.
Content:
There is a difference with the data of the amount of the rotation sent from the data of the
amount of the rotation and the encoder obtained by the carry/borrow of the encoder data in
one rotation more than two rotations In the servo software.
Robot Arm
Command
Line Servo Board
Encoder
CPU (1GB PC Board) Encoder
Encoder
Servo Error Gate Array I/F
Signal
(only Output
Gate Array-A) Power
Supply Battery
Main cause:
• Defect of encoder.
• Malfunction by noise etc.
• Defect of encoder harness.
• Defect of the servo board (1GB PC Board etc.).
Measure:
• Check the disconnection of the encoder signal line and the short-circuit and exchange the
encoder signal line. (Separation signal harness or machine signal harness.)
• Exchange the encoder.
• Check and exchange the 1FG PC board.
• Process specific in the noise source and shield.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
• Exchange the servo board (1GB PC Board).
• Exchange the encoder.
! CAUTION
The error of Error -1553, -1554 and -155 etc. are
occasionally occurred because the gap is caused in the
current value in JT ENCODER and the servo software
immediately after the error is occurred.
Content:
When difference between current value when control power supply is turned off and
current value when control power supply is turned on is more than value set by “Auxiliary
43 ENCODER ERROR RANGE”, ENCCHK_DATA command.
(Detect with the AS software)
The ENCCHK_DATA command is usually set in 2.0 degrees with the rotation axis. This
error is not detected when setting as 0.0 degrees.
When a usual control power supply is turned on, this error is occasionally occurred when a
too small value is set.
Robot Arm
Main cause:
• The internal data of the encoder is not maintained with a disconnection of the decrease of
the encoder battery and the encoder harness and defective encoders, etc.
• The control power supply was turned OFF by an abnormal power supply etc. in the robot
motion (Make to turning OFF). The reason for the arm is that the gap might be caused in
the final current value which the AS software memorized and the current value which
stops actually (Turns ON the control power supply) because hold does not occur rapidly.
• Initializing was executed. (Occur with all axes)
• The motor (encoder) was exchanged.
• The arm (motor) operated by force when the control power supply was turned OFF.
Measure:
• When this error is occurred immediately after initializing is executed, it is not abnormal.
(When initializing, the current value at control power supply OFF of the last time is
initialized. Therefore, the error of all axes occurs.)
• Do zeroing promptly when you exchange the motor (encoder).
• There is a possibility that the internal data of the encoder is not maintained when this error
is occurred. Therefore, confirm whether the degree is 0 degrees after putting all axes
together on the position where the robot is marked (mechanical origin) with Teach mode
without fail.
• Execute zeroing when they are not 0 degrees.
• After error reset is done, this error can be automatic operation. However, note that there is
a possibility to cause the dislocation when the robot is operated without confirming zeroing
like the above-mentioned.
• Exchange the battery promptly when the encoder battery decreases.(Exchange the
battery for the conveyer encoder, or for multi axis at the same time).
• Check each harness in disconnecting and the short-circuit and exchange the harness.
• Exchange the encoder, the servo board, and the encoder battery board, etc.
Content:
When the encoder data was read immediately after the control power supply was turned
ON, the steady data was not able to be read.
(Detect with the servo software)
Robot Arm
Command
Line Servo Board
Encoder
CPU (1GB PC Board) Encoder
Encoder
Servo Error Gate Array I/F
Signal
(only Output
Gate Array-A) Power
Supply Battery
Main cause:
• Disconnection of encoder signal line and short-circuit and defect of main body of encoder.
• Defect of the servo board (1GB PC Board etc.).
Measure:
• Disconnection and short-circuit of encoder signal line and exchange the main body of the
encoder.
• Exchange the servo board (1GB PC Board).
Content:
The difference of the current value which counts the data in one rotation in the data of the
amount of the rotation and the servo software having obtained by the communication with
the encoder is large.
(Detect with the servo software)
Robot Arm
Command
Line Servo Board
Encoder
CPU (1GB PC Board) Encoder
Main cause:
• Defect of the encoder.
• Malfunction by external noise etc.
• Defect of the servo board (1GB PC Board etc.).
Measure:
• Exchange the encoder and/or the servo board.
• Exchange the 1FG PC board.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
• Check connections in the separation signal harness.
• Check connections in the machine harness.
• Process specific in the noise source and shield.
Reference:
• Either the magnetic portion or the optical portion of the encoder has a trouble.
• The encoder response error (-1553), the encoder communication error (-1554), and the
encoder data conversion error (-1555) have continued for long time during the robot
moves.
Content:
The encoder was not able to fix the absolute data at control power supply ON. (The
encoder might not be able to fix the absolute data when rotating by 300 rpm or more at
control power supply ON)
Robot Arm
Command
Line Servo Board
(1GB PC Board) Encoder
CPU Encoder
Reference:
The scanning of absolute data is begun from the state of the encoder non-operation
and the state of backup in the encoder immediately after the shift to the state of the
usual operation. In that case, BUSY=1 is output until the data is fixed.
Main cause:
• When the motor (encoder) is rotating by 300 rpm or more
(The conveyer encoder etc. correspond)
• Defect of the encoder and/or encoder connector.
• Defect of the servo board (1GB PC Board etc.).
• Defect of the 1FG PC board.
Measure:
• Adjust control power supply ON. as become 300 rpm or less at times the rotation of the
motor (encoder). (When the motor (encoder) works at control power supply ON, Excluding
the conveyer encoder, it becomes “Error -1517”.)
• Exchange the encoder and/or the servo board.
• Exchange the 1FG PC board.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
• Check connections in the separation signal harness.
• Check connections in the machine harness.
Content:
When the communication does not respond from the encoder or slowness
Robot Arm
Command
Line Servo Board Encoder
CPU Encoder
(1GB PC Board)
Main cause:
• Disconnection and short-circuit of encoder signal line.
• Defect of encoder.
• Malfunction by noise etc.
• Defect of the servo board (1GB PC Board).
Measure:
• Check the disconnection of the encoder signal line and the short-circuit and exchange
the encoder signal line. (Separation signal harness or machine signal harness.)
• Exchange the encoder.
• Check and exchange the 1FG PC board.
• Process specific in the noise source and shield.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
• Exchange the servo board (1GB PC Board).
• Exchange the encoder.
! CAUTION
Retry robot program execution or manual
operation carefully at slow speed, after reset
error.
Content:
Abnormality of CRC and flaming error was detected by the communication with the encoder.
CRC abnormal : CRC data information is added to the communication data and
abnormality is detected by the generation polynomial.
Flaming abnormal : The stop bit was not detected.
Robot Arm
Command
Encoder
Line Servo Board
(1GB PC Board) Encoder
CPU
Main cause:
• Disconnection and short-circuit of encoder signal line.
• Malfunction by noise etc.
• Defect of encoder.
• Defect of the servo board (1GB PC Board etc.).
Measure:
• Check the disconnection of the encoder signal line and the short-circuit and exchange
the encoder signal line. (Separation signal harness or machine signal harness.)
• Exchange the encoder.
• Check and exchange the 1FG PC board.
• Process specific in the noise source and shield.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
• Exchange the servo board (1GB PC Board) or the encoder.
! CAUTION
Retry robot program execution or manual
operation carefully at slow speed, after reset
error.
Content:
It was judged that the location data was absolutely mistaken and the encoder which
contained the redundancy bit was abnormal because of the detection type.
Robot Arm
Command
Line Servo Board
(1GB PC Board) Encoder
CPU
Encoder
Main cause:
• Defect of encoder.
• Disconnection and short-circuit of encoder signal line and defect of main body of encoder.
• Defect of the servo board (1GB PC Board etc.).
• Malfunction by noise etc.
Measure:
• Exchange the encoder and the servo board (1GB PC Board).
• Check the disconnection of the encoder signal line and the short-circuit and exchange the
encoder signal line. (Separate signal harness or Machine signal harness.)
• Exchange the 1FG PC board.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
• Process specific in the noise source and shield.
! CAUTION
Retry robot program execution or manual
operation carefully at slow speed, after reset
error.
Content:
The absolute data and the incremental data in the encoder are different.
Robot Arm
Command
Line Servo Board
(1GB PC Board) Encoder Encoder
CPU
Reference:
When the incremental counter data and the absolute data are different in the encoder,
the encoder outputs ABSALM=1.
The cause of ABSALM is that the incremental signal in the encoder is abnormal or that
M-code data has error pattern in the encoder or the absolute track in the encoder is
abnormal.
Main cause:
• Defect of encoder.
• Defect of the servo board (1GB PC Board etc.).
• Disconnection and short-circuit of encoder harness.
Measure:
• Exchange the encoder and the servo board (1GB PC Board).
• Exchange the encoder harness (Separate signal harness or Machine signal harness).
• Exchange the 1FG PC board.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
Content:
An abnormal pattern was detected in the output signal of the internal insertion circuit of the
incremental pulse in the encoder.
Robot
Command
Arm Motor
Line Each CPU
PWM Signal
Servo Error
Signal
(only Output IPM Error Signal
Gate Array-A)
Each Gate Array
DC/DC
HIC IPM
+12V dc +15V dc
Servo Board
(1GB PC Board) Power Block
Controller
Reference:
When the incremental pulse A and B phases are abnormal, the encoder outputs
INALM=1.
The cause of INALM is that the incremental counter circuit in the encoder has a trouble
or the incremental signal in the encoder is abnormal.
Main cause:
• Defect of the encoder.
• Defect of the servo board (1GB PC Board etc.).
• Disconnection and short-circuit of encoder harness.
Measure:
• Exchange the encoder and the servo board (1GB PC Board).
• Exchange the encoder harness (Separate signal harness or Machine signal harness).
• Exchange the 1FG PC board.
• Check connections, jumpers and switches on the servo board (1GB PC Board).
Content:
The error signal from the IPM module in the power block was detected.
Robot
Command
Arm Motor
Line Each CPU
PWM Signal
Servo Error
Signal
(only Output IPM Error Signal
Gate Array-A)
Each Gate Array
DC/DC
HIC IPM
+12V dc +15V dc
Servo Board
(1GB PC Board) Power Block
Controller
Main cause:
• Defect in the power block.
• Defect of the servo board (1GB PC Board etc.).
• Short-circuit of motor power line U, V, and W phase.
• Cooling by Hold etc. of the cooling fan in Servo Unit is defective.
• Defect the harness between the servo board and the power blocks and defect of connect.
Measure:
• Exchange Servo Unit.
• Check the short-circuit of the motor harness and exchange it.
Content:
The current sensor cable between the servo board (1GB PC Board etc.) and the power blocks
is not connected.
The unit name of the servo board is appeared in *.
CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit
C First 1GB PC Board C unit
or Second 1GB PC Board A unit
or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier
In case of the 1GB PC board and the power block (1GC, 1GD PC Board)
1GB PC Board unit A : 1GB-CN9 ÅÆ power block CN2 and (1,3).
1GB PC Board unit B : 1GB-CN10 ÅÆpower block CN5 and (4,6)
1GB PC Board unit C : 1GB-CN11 ÅÆ power block CN7.
Command
Line
Each CPU
Controller
Servo Error
Signal
(only Output
Gate Array-A)
Each Gate Array Current Sensor
Connection
Signal
GND
Power Block
1GB PC Board
Main cause:
• The 1GB PC board is not connected with the current sensor cable between the power
blocks.
• Defect of the 1GB PC board.
Measure:
• Connect a current sensor cable of the 1GB PC board and the power block.
Content:
When ±12V supplied to the 1GB PC board reaches the below value
+12V : +10.75V or less.
-12V : -10.4V or more.
The unit name of the servo board is appeared in *.
CH to Communication However, because it is unit A for 1GB PC board to do this error
detection to be alone, appearing "B, D" is not basically appeared.
A First 1GB PC Board A unit
Command
Line Main cause:
CPU A
• ±12V supplied to 1GB PC board decreases.
(However, there is a possibility turning off the control
power supply in a control abnormal power supply
Servo Error
Signal when the voltage of DC power supply decreases)
Gate Array-A
• Defect such as the harness between 1GB PC board
<-> motherboards <->DC power supply and the
connect is defective.
+12Vdc
-12Vdc Power Supply • Defect of 1GB PC board.
Monitor Circuit
1GB Board
Measure:
• Check the voltage and exchange the 1GB PC board and DC power supply, etc.
Content:
The regenerating time (time to throw the current to the regenerating resistor) was
consecutive from the power block and 6sec or more continued.
The motor enters the state of power generation by the inertia of the arm when the robot
decelerates. The voltage flows backward to Motor Power (Voltage between P-N) and the
voltage between P-N enters the state of the over-voltage. The regenerating processing is a
processing by which the current is thrown to the regenerating resistor when the voltage
rises more than a constant value and the elevation of the voltage is prevented.
In the condition to throw the current to the regenerating resistor, the voltage between P-N
is the below condition.(Usual, about DC300V:The voltage changes when the robot is
savoring.)
A First 1GB PC Board A unit However, because it is unit A for 1GB PC board to do this error
detection to be alone, appearing “B, D” is not basically appeared.
B First 1GB PC Board B unit
First 1GB PC Board C unit
C
or Second 1GB PC Board A
unit or One axis Amplifier
Second 1GB PC Board B unit
D
or One axis Amplifier
option
Command
Additional Regenerate Regenerate
Line
CPU-A Register Drive Circuit Register
Motor
Power
(P-N)
Regenerate Resistor Drive Signal
Servo Error
Signal
Gate Array
A Drive Circuit
Regenerate 1GC : IPM-1
Control 1GD : FET
Regenerative
Abnormal
Signal Circuit
Regenerate
Resistor
Servo Board
(1GB PC board) Power Block
controller
Main cause:
• The counter teach is high-speed in the robot.
• Fail the scorch of the regenerating resistor etc., and defect in power block.
• Defect of the servo board (1GB PC Board etc.).
• The connect is defective of the harness during the servo board (1GB-CN13) ÅÆ power
block (CN9).
• Defect of regenerating resistor unit for increase when regenerating resistor unit for built
more is connected.
Measure:
• Do not do the counter teach to the robot at the teaching modification. Or, reduce
execution speed.
• Install the built more regenerating resistor unit option.
• Exchange the servo board, the power block, and the regenerating resistor unit for the
built more, etc.
Content:
The voltage between P-N supplied to the power block is DC60V or less at the servoing.
! CAUTION
The arm falls between until detecting of the error because Motor
Power is not supplied at the servo ring when this error occurs. Other
errors of abnormal speed and abnormal deflection, etc. might be
detected.
A First 1GB PC Board A unit However, because it is unit A for 1GB PC board to do this error
detection to be alone, appearing "B, D" is not basically appeared.
B First 1GB PC Board B unit
First 1GB PC Board C unit
C
or Second 1GB PC Board A
unit or One axis Amplifier
Second 1GB PC Board B unit
D
or One axis Amplifier
Motor Power
Motor Power Circuit
(MS, Resistance etc.)
Command
Line
CPU A Motor Power
(P-N)
Servo Error
Signal
Gate Array-A Each IPM
Voltage Monitor
Circuit
Voltage Lower between P-N
Error
between
P-N Line
Servo Board
(1GB PC Board) Power Block
(Refer to each power supply circuit chart for details of Motor Power)
Main cause:
• Operation Unit side:
• Defect of MS.
• Defect of the relay board (1HY/1HK PC Board etc.).
• Defect of the power sequence board (1HP PC Board etc.).
• Servo Unit side:
• Defect of defective power unit .
• Defect of Motor Power circuit (diode bridge and MS, etc.).
• Defect of the servo board (1GB PC Board etc.).
• Defect of each harness between Operation Unit ÅÆ Servo Units and defect of connect.
Measure:
• Check and exchange the Motor Power circuit and each equipment.
• Exchange the power sequence board, the relay board, and Servo Unit.
Content:
The voltage between P-N supplied to the power block exceeded DC410V at the savoring.
The unit name of the servo board is appeared in *.
CH to Communication
A First 1GB PC Board A unit
B First 1GB PC Board B unit However, because it is unit A for 1GB PC board to do this error
C First 1GB PC Board C unit detection to be alone, appearing “B, D” is not basically appeared.
or Second 1GB PC Board A
unit or One axis Amplifier
D Second 1GB PC Board B unit
or One axis Amplifier
Motor Power
Motor Power Circuit
Command (MS, Resistance etc.)
Line
CPU A Motor Power
Built more
(P-N) Regenerative
Resistance
Unit
Servo Error Voltage Monitor
Signal Circuit
Gate Array-A between P-N Regenerative
Resistance
/Regenerative
Resistance
Voltage Lower Control Circuit
Error Voltage Monitor
between Circuit
P-N Line between P-N
Each IPM
Servo Board
(1GB PC Board) Power Block
Controller
(Refer to each power supply circuit chart for details of Motor Power)
Main cause:
• Defect of regenerating resistor control circuit, fail scorch of regenerating resistor, defect of
voltage watch circuit, and defect in power block.
• Defect of the servo board (1GB PC Board etc.).
• Defect of built more regenerating resistor unit.
• The counter teach etc. which hung excessively the regenerating function were executed.
Measure:
• Exchange Servo Unit and the built more regenerating resistor unit, etc.
• Add the regenerating resistor unit option when the regenerating function is excessive.
Content:
Thermal (140℃) for regenerating resistor in power block, thermal (140℃) for regenerating
resistor in built more regenerating resistor unit option, and a heat sink thermal (90℃) are
worked. (operation of disconnection)
(Because thermal of each is connected with the series, cannot distinguish on the AS
software)
Motor Power
Thermal
Motor Power Circuit (140 KC)
(MS, Resistance etc.)
Command Regenerative
Line Resistance
CPU A
Motor Power
(P-N)
Thermal
(140 KC)
Servo Board Heat Sink
Thermal
(1GB PC Board) Power Block (140 KC)
Main cause:
• Defect of cooling by hold of cooling fan in Servo Unit and regenerating resistor unit.
• The regenerating function ability is low at the counter teach etc.
• The temperature of the controller of use environment is high.
• Defect in power block.
• Defect of regenerating resistor unit.
• Defect of the servo board (1GB PC Board etc.).
• The connect is defective of the harness during the servo board (1GB-CN13) ÅÆ power
block (CN9).
• Defect of the harness between power block (1GC-CN21) ÅÆ built more regenerating
resistor units, and defect of connect. (Connect 1GC-CN21 with a short-circuit connector
when the built more regenerating resistor unit is a disconnect)
Measure:
• Exchange Servo Unit and the built more regenerating resistor unit, etc.
• Reduce the ambient temperature.
• Check each harness.
Content:
When abnormality occurs in the contact of the TEACH/REPEAT switch or in the contact of the
relay for the TEACH/REPEAT output signal.
Main cause:
• Defect of the 1HM board.
• There may be inconsistencies or problems in the software settings, if this error arises in
other controllers, except the C70 controller.
Measure:
• When error arises in C70 controller:
Exchange the 1HM board.
• When error arises in all other controllers:
Input the “Function number: 199” in the AUX Screen, and resister the following items by
the “199 Maintenance Function”.
Maintenance Function Accept
Pass Word 9894
And then, terminate the AUX Screen. Input the “Function number: 951” in the AUX Screen
again, and confirm the following item by the 2nd page of “AUX 951 Option 11”.
C70 Controller OFF
Resister the “OFF” again in case of “ON”.
Content:
Even if the fixed time has passed since the command value arrived at the robot motion
terminal, the current value does not become an axis coincidence (It is not in the range of
the precision setting).
(This error is detected with the AS software)
Main cause:
• Mechanical factor:
• The axis is heavy because of the damage of the decelerator and the bearing, etc.
• In the gear deceleration part, the backlash is narrow.
• The arm is interfering in the treatment device etc., or the harness etc. are caught etc.
• The motor brake is not released.
• Electric factor:
• Defect of the servo board (1GB PC Board etc.).
• Defect in power block etc.
• Disconnection of motor power line and brake line.
• Defect of the encoder and the encoder harness.
Measure:
• Adjust the exchange and the backlash such as decelerators for a mechanical factor.
• Exchange Servo Unit and the harness, etc. for an electric factor.
• Do the teach modification when the error occurs by a specific program step.
Content:
C3X/C4X Controller
The axis restriction limit switch operated with the current value exceeded the work
envelope of the user setting. (detection of disconnection)
The work envelope of each Joint of the user setting has been set with “Auxiliary 51
SOFTWARE LIMIT” /ULIMIT, LLIMIT command. (When the robot is shipped, it is set in the
maximum work envelope usually)
Set the work envelope of the user setting as becoming to the follow condition.
Maximum work envelope > Mechanical stopper > Axis restriction limit switch > User set
work envelope
(The mechanical stopper and the axis restriction limit switch are the options, and the axis
installed by the reason on the structure of the model and the machine etc. is different.)
So as not to operate, the AS software restricts robot more than the angle set by the user
set work envelope usually.
1GA PC Board
VME Bus
Mother Board
Axis Axis
Local VME Bus Restrict Restrict
1GB PC LS LS
Board
EPLD Register
on VME Bus
Motor Power
ON Circuit
1FG PC board
Power Sequence Board
(1HP PC Board)
The signal line in two systems is connected from CN4 of the 1HP PC board to the 1FG PC
board in the robot. However, this is connected in parallel in the 1HP PC board. If either is
short-circuits when the limit switch in two systems is connected with the 1FG PC board to
detect only 1CH, it can actually detect the error.
Moreover, CN11, 12, 13 of the 1FG PC board, and a part of model are connected and when
the limit switch is not connected with the LS connector of the inside machine harness, it
should connect the short-circuit connector.(Refer to the figure below)
LS1
CN11
LS2
1HZ
1GB PC CN12
PC
SW1 Board Board
CN13
1HP PC Board
P2 CN4 CN1 CN2 X3 X3A CN8
1FG PC Board
JS30/40 CN5
JS06/10 No.14
JS/JC/JW No.10
only (for JT1 LS)
Main cause:
• When the axis restriction limit switch is turning ON, the user set work envelope was set in
smaller value than the current value.
• The axis was moved by using the manual brake release etc. and the limit switch was
turned ON.
• The signal of the axis restriction limit was disconnected when the robot was outside the
user set work envelope.
• The axis restriction limit was turned ON by wrong of setting the zeroing and reckless
driving, etc.
• The limit was turned ON by the over shot by the inertia when the robot worked when the
user set work envelope is a value close to the robot motion angle of the axis restriction limit
switch..
• Disconnection of axis restriction limit signal and defect of harness.
Measure:
• When this error occurs, robot releases the axis restriction limit switch signal only while the
over ride switch of the power sequence board (1HP PC Board etc.) is being pressed. You
can turn ON Motor Power. And, move the arm with Teach mode in the work envelope.
• Or, You connects manual brake release BOX of the option with CN5 of the 1GB PC board.
Release the brake with the manual and move the arm in the work envelope.
• Turn OFF Motor Power ( MC OFF) and put into the state to release EMERGENCY STOP
Switch ( contains External EMERGENCY STOP Switch ) when you use the manual brake
release.
• Set the user set work envelope in an appropriate value.
• Change the installation angle of the axis restriction limit switch to an appropriate value.
• Check and exchange the harness and the limit switch.
• Exchange the power sequence board
C70/C80 Controller
In FS, Axis restriction limit switch processes the short-circuit in arm base with short-circuit
connector X102.
Therefore, execute the following measure if this error occurred.
・ Confirm whether the arm is in the work envelope.
Release the brake with the manual, and move the arm in the work envelope if outside
the work envelope.
Check that you remove the connector plate in the arm base part, and connector X102 in arm
Base is connected surely.
Content:
The axis restriction limit switch operated with the current value exceeded the work
envelope of the user setting.
(detection of disconnection)
The work envelope of each Joint of the user setting has been set with “Auxiliary 51
SOFTWARE LIMIT” /ULIMIT, LLIMIT command. (When the robot is shipped, it is set in the
maximum work envelope usually)
Set the work envelope of the user setting as becoming to the follow condition.
Maximum work envelope > Mechanical stopper > Axis restriction limit switch > User set
work envelope
(The mechanical stopper and the axis restriction limit switch are the options, and the axis
installed by the reason on the structure of the model and the machine etc. is different.)
So as not to operate, the AS software restricts robot more than the angle set by the user set
work envelope usually.
1GA PC Board
VME Bus
Mother Board
Axis Axis
Local VME Bus Restrict Restrict
1GB PC LS LS
Board
EPLD Register
on VME Bus
Motor Power
ON Circuit
The signal line in two systems is connected from CN4 of the 1HP PC board to the 1FG PC
board in the robot. However, this is connected in parallel in the 1HP PC board. If either is
short-circuits when the limit switch in two systems is connected with the 1FG PC board to
detect only 1CH, it can actually detect the error.
Moreover, CN11, 12, 13 of the 1FG PC board, and a part of model are connected and when
the limit switch is not connected with the LS connector of the inside machine harness, it
should connect the short-circuit connector.(Refer to the figure below)
LS1
CN11
LS2
1HZ
1GB PC CN12
PC
SW1 Board Board
CN13
1HP PC Board
P2 CN4 CN1 CN2 X3 X3A CN8
1FG PC Board
JS30/40 CN5
JS06/10 No.14
JS/JC/JW No.10
only (for JT1 LS)
Main cause:
• The signal of the axis restriction limit was disconnected (ON) while had set in the value
whose user set work envelope is larger than the limit switch.
• The axis restriction limit was turned ON by wrong of setting the zeroing and reckless
driving, etc.
• Disconnection of axis restriction limit signal, defect of harness.
• Defect of the limit switch.
• Defect of the power sequence board.
Measure:
• When this error occurs, robot releases the axis restriction limit switch signal only while the
over ride switch of the power sequence board (1HP PC Board etc.) is being pressed. You
can turn ON Motor Power. And, move the arm with Teach mode in the work envelope.
• Or, You connects manual brake release box of the option with CN5 of the 1GB PC board.
Release the brake with the manual and move the arm in the work envelope.
• Turn OFF Motor Power ( MC OFF) and put into the state to release EMERGENCY STOP
Switch ( contains External EMERGENCY STOP Switch ) when you use the manual brake
release.
• Set the user set work envelope in an appropriate value.
• Change the installation angle of the axis restriction limit switch to an appropriate value.
• Check and exchange the harness and the limit switch.
• Exchange the power sequence board.
Content:
LS for the torch interference detection built into the torch holder of the robot operated by the
arc welding specification. (disconnection detection)
Main cause:
The torch interfered with the object, and the limit switch in the torch bracket came off.
After resetting the error, you can move the robot by the teach motion.
In the repeat operation, it is not possible to operate as long as you does not return the torch
to previous state.
Measure:
The robot must by the teach motion after you resets it of the error, and return the torch
previous state.
Content:
The instantaneous decrease in the primary power was detected in the DC power supply.
(When 20-30msec continues with AC130-145V or less by 0 phases)
However, because the control power supply is turned OFF when this error occurs; Confirm
appearing the error remains when you turn ON the control power supply to next time.
C3X/C4X, C70/C80 Controller
Error Signal
+24Vdc
Voltage Monitor
Motor Power
Controller
Content:
DC+24V supplied to the power sequence board (1HP PC Board etc.) by the DC power
supply detected by about 21.6V or less.
However, because the control power supply is turned OFF when this error occurs; Confirm
appearing the error remains when you turn ON the control power supply to next time.
Error Signal
+24Vdc
Voltage Monitor
Motor Power
Controller
Measure:
• Check the power supply circuit, the machine valve, and the short-circuit of the sensor line
etc., and check the disconnection.
• Exchange the DC power supply, the power sequence board, and the relay board.
Content:
The voltage watch level height (when AC267-277V or more continues 1-2sec) of the DC
power supply was detected.
However, because the control power supply is turned OFF when this error occurs; Confirm
appearing the error remains when you turn ON the control power supply to next time.
Error Signal
+24Vdc
Voltage Monitor
Motor Power
Controller
Main cause:
• The primary power exceeds ratings. (defect of primary power) Defect of the DC power
supply.
• Defect of the power sequence board.
• Defect of the relay board and the power supply circuit.
Measure:
• Confirm whether the primary power is supplied according to ratings.
• Check the power supply circuit such as the DC power supply.
Content:
The voltage watch level low (when AC150-158V or less continues 1-2sec) of the DC power
supply was detected.
However, because the control power supply is turned OFF when this error occurs; Confirm
appearing the error remains when you turn ON the control power supply to next time.
Error Signal
+24Vdc
Voltage Monitor
Motor Power
Controller
Main cause:
• Defect etc. of primary power.
• AC200/220V supplied to the DC power supply became an instantaneous decrease.
• Defect of the DC power supply.
• Defect of CB (circuit breaker) for control power supply.
• Defect of the power sequence board (1HP PC Board etc.).
• Defect of the relay board (1HY/1HK PC Board etc.).
Measure:
• Confirm whether the primary power is supplied according to ratings.
• Check the power supply circuit such as the DC power supply and CB(circuit breaker).
Content:
DC+5V, DC±12V supplied to the 1GA PC board are not full of the ratings voltage.
DC+5V : Excluding +4.85-+5.45V
DC+12V : +10.75V or less.
DC-12V : -10.4V or more.
However, because the control power supply is turned OFF when this error occurs; Confirm
appearing the error remains when you turn ON the control power supply to next time.
Error Signal
+24Vdc
Voltage Monitor
Motor Power
Power Block
Controller
(Power supply circuit and refer to each block chart for details)
Main cause:
• Defect of the DC power supply.
• Defect of each board such as the 1GA PC boards.
• The contact of the motherboard is defective.
• Short and defect of MFP harness.
• Short in the servo board and the power block, etc.
• Defect of the encoder battery board (1FG PC Board) such as in robots.
• Short of harness from Servo Unit to the encoder battery board.
• Shorts of operation switch and lamps (error reset switch, cycle start switch, and lamp,
etc.).
• Short in option board and the connect equipment of built-in vision etc.
• The power capacity of the DC power supply is insufficient because of the use such as the
option boards.
Measure:
• Exchange the DC power supply and each board for the control power supply.
• Check short-circuits of each harness such as MFP, the operation panel equipment’s, and
the separation harness and exchange its.
Content:
After a power supply abnormality (ACFAIL) (the control power supply includes the time of
turning OFF) had been detected, memory was operated.
Measure:
If the control power supply is turned ON again, the error is released though it might usually
be gene rated when the control power supply is turned OFF.
MEMO
OVERVIEW
DESCRIPTIONS
TROUBLESHOOTING
INDEX
■ Wrist Axis Motor Harness Wiring ■ Major Axis Motor Harness Wiring
Diagram (C3*/C4*) Diagram (C3*/C4*)
X5 X4
Signal Name NO. Destination Signal Name NO. Destination
JT4-MOTOR U 5 X5A-5 JT1-MOTOR U 1 X4A-1
JT4-MOTOR V 6 X5A-6 JT1-MOTOR V 2 X4A-2
JT4-MOTOR W 7 X5A-7 JT1-MOTOR W 3 X4A-3
JT4-BRAKE P 3 X5A-3 JT2-MOTOR U 4 X4A-4
JT4-BRAKE N 4 X5A-4 JT2-MOTOR V 5 X4A-5
JT5-MOTOR U 15 X5A-15 THP a X4A-a
JT5-MOTOR V 16 X5A-16 JT2-MOTOR W 6 X4A-6
JT5-MOTOR W 17 X5A-17 JT3-MOTOR U 7 X4A-7
JT5-BRAKE P 13 X5A-13 JT3-MOTOR V 8 X4A-8
JT5-BRAKE N 14 X5A-14 JT3-MOTOR W 9 X4A-9
JT6-MOTOR U 25 X5A-25 EARTH X4A-
JT6-MOTOR V 26 X5A-26 THN b X4A-b
JT6-MOTOR W 27 X5A-27 10
JT6-BRAKE P 23 X5A-23 SHIELD X4A-
JT6-BRAKE N 24 X5A-24
JT7-MOTOR U 35 X5A-35
JT7-MOTOR V 36 X5A-36
JT7-MOTOR W 37 X5A-37
JT7-BRAKE P 33 X5A-33
JT7-BRAKE N 34 X5A-34
JT1-BRAKE P 1 X5A-1
JT1-BRAKE N 2 X5A-2
JT2-BRAKE P 11 X5A-11
JT2-BRAKE N 12 X5A-12
JT3-BRAKE P 21 X5A-21
JT3-BRAKE N 22 X5A-22
SIGO-1 8 X5A-8
SIGO-2 9 X5A-9
SIGO-3 18 X5A-18
SIGO-4 19 X5A-19
SIGO-5 28 X5A-28
SIGO-6 29 X5A-29
SIGO-7 38 X5A-38
SIGO-8 39 X5A-39
EARTH 40 X5A-40
UPPER X5A- UPPER
SHIELD LOWER X5A- LOWER
10
20
30
31
32
XGB-CN6
Signal Name NO. Destination
JT1-BRAKE P 1 X401-17
BRAKE N 9 X401-30
JT2-BRAKE P 2 X401-18
BRAKE N 10 X401-30
JT3-BRAKE P 3 X401-7
BRAKE N 11 X401-31
JT4-BRAKE P 4 X401-8
BRAKE N 12 X401-31
JT5-BRAKE P 5 X401-19
BRAKE N 13 X401-31
JT6-BRAKE P 6 X401-20
BRAKE N 14 X401-31
JT7-BRAKE P 7 X401-5
MTH P 8 X201-9
MTH N 15 X201-10
X201
Signal Name NO. Destination
JT1-BRAKE P 1 X401-41
BRAKE N 2 X401-42
JT2-BRAKE P 3 X401-43
BRAKE N 4 X401-44
JT7-BRAKE P 8 X401-29
MTH P 9 XGB-CN6-8
MTH N 10 XGB-CN6-10
X003
Signal Name NO. Destination
JT4 MOTOR-U 1 X401-71
JT4 MOTOR-V 2 X401-59
JT4 MOTOR-W 3 X401-47
JT5 MOTOR-U 4 X401-70
JT5 MOTOR-V 5 X401-58
JT5 MOTOR-W 6 X401-46
JT6 MOTOR-U 7 X401-69
JT6 MOTOR-V 8 X401-57
JT6 MOTOR-W 9 X401-45
JT7 MOTOR-U 10 X401-9
JT7 MOTOR-V 11 X401-10
JT7 MOTOR-W 12 X401-11
X001
Signal Name NO. Destination
JT1 MOTOR-E 1 X401-24
JT2 MOTOR-E 2 X401-24
JT3 MOTOR-E 3 X401-12
JT4 MOTOR-E 4 X401-12
JT5 MOTOR-E 5 X401-12
JT6 MOTOR-E 6 X401-12
JT7 MOTOR-E 7 X401-12
(N.C) 8
MTH P 9 X401-32
MTH N 10 X401-33
X4A
Signal Name NO. Destination Signal Name NO. Destination
JT1-MOTOR U 1 XMI-1 JT7M-E 39 X001-6
JT1-MOTOR V 2 XM1-2 BASE LS 1 40 BASE LS-1
JT1-MOTOR W 3 XM1-3 BASE LS 2 41 BASE LS-2
JT1-BRAKE P 4 XGB-CN6-1 42
JT1-BRAKE N 5 XGB-CN6-9 TH P 43 X001-10
JT4-MOTOR U 6 XM2-1 TH N 44 XGB-CN6-15
JT4-MOTOR V 7 XM2-2 JT7-MOTOR U 45 XM2-10
JT4-MOTOR W 8 XM2-3 JT7-MOTOR V 46 XM2-11
JT4-BRAKE P 9 XGB-CN6-4 JT7-MOTOR W 47 XM2-12
JT4-BRAKE N 10 XGB-CN6-12 JT7-BRAKE P 48 XGB-CN6-7
SIGO-1 11 X201-1 JT7-BRAKE N 49 XGB-CN6-14
SIGO-2 12 X201-2 SIGO-7 50 X201-7
BASE LS E 13 X001-7 SIGO-8 51 X201-8
JT2-MOTOR U 14 XM1-4 52
JT2-MOTOR V 15 XM1-5 SHIELD L SHIELD
JT2-MOTOR W 16 XM1-6
JT2-BRAKE P 17 XGB-CN6-2
JT2-BRAKE N 18 XGB-CN6-10
JT5-MOTOR U 19 XM2-4
JT5-MOTOR V 20 XM2-5
JT5-MOTOR W 21 XM2-6
JT5-BRAKE P 22 XGB-CN6-5
JT5-BRAKE N 23 XGB-CN6-13
SIGO-3 24 X201-3
SIGO-4 25 X201-4
JT1M/2M/3M-E 26 X001-1
JT4M/5M/6M-E X001-2
JT3-MOTOR U 27 XM1-7
JT3-MOTOR V 28 XM1-8
JT3-MOTOR W 29 XM1-9
JT3-BRAKE P 30 XGB-CN6-3
JT3-BRAKE N 31 XGB-CN6-11
JT6-MOTOR U 32 XM2-7
JT6-MOTOR V 33 XM2-8
JT6-MOTOR W 34 XM2-9
JT6-BRAKE P 35 XGB-CN6-3
JT6-BRAKE N 36 XGB-CN6-11
SIGO-5 37 X201-5
SIGO-6 38 X201-6
X105
Signal Name NO. Destination
JT1-BRAKE P 1 XJT1B-1
JT2-BRAKE P 2 XJT2B-1
JT3-BRAKE P 3 XJT3B-1
JT1-BRAKE N 4 XJT1B-2
JT2-BRAKE N 5 XJT2B-2
JT3-BRAKE N 6 XJT3B-2
EARTH BAR 1
Signal Name NO. Destination
EARCH 3 XJT1M-A1
EARCH 2 XJT2M-A1
EARCH 1 JT3M-A1
X5A X107
Signal Name NO. Destination Signal Name NO. Destination
JT6-MOTOR U 25 XJT6M-1 EPV P 1 X110-1
JT6-MOTOR V 26 XJT6M-2 EPV N 2 X110-2
JT6-MOTOR W 27 XJT6M-3
JT6-BRAKE N 24 XJT6M-5 X108
JT5-MOTOR U 15 XJT5M-1 Signal Name NO. Destination
JT5-MOTOR V 16 XJT5M-2 SIGO-3 1 X111-3
JT5-MOTOR W 17 XJT5M-3 2 X111-4
JT5-BRAKE N 14 XJT5M-5
JT4-MOTOR U 5 XJT4M-1 X109
JT4-MOTOR V 6 XJT4M-2 Signal Name NO. Destination
JT4-MOTOR W 7 XJT4M-3 SIGO-5 1 X111-5
JT7-BRAKE P 33 X106-A3 SIGO-6 2 X111-6
EARTH 40 EARTH NOTE SIGO-7 3 X111-7
31 SIGO-8 4 X111-8
32
JT4-BRAKE N 4 XJT4M-5 X113
JT7-MOTOR U 35 X106-B1 Signal Name NO. Destination
JT7-MOTOR V 36 X106-A2 SIGO-1 1 X5A-8
JT7-MOTOR W 37 X106-B2 SIGO-2 2 X111-1
JT4-BRAKE P 3 XJT4M-4
JT5-BRAKE P 13 XJT5M-4 X114
JT6-BRAKE P 23 XJT6M-4 Signal Name NO. Destination
JT7-BRAKE N 34 X106-B3 SIGO-1 1 X111-1
JT2-BRAKE P 11 X105-2 SIGO-2 2 X111-2
JT2-BRAKE N 12 X105-5
JT3-BRAKE N 22 X105-6 CN15
JT1-BRAKE N 1 X105-1 Signal Name NO. Destination
JT3-BRAKE P 21 X105-3 SIGO-3 1 X111-3
JT1-BRAKE P 2 X105-4 SIGO-4 2 X111-4
SIGO-1 8 X113-1
SIGO-2 9 X111-2
SIGO-3 18 X108-1 [ NOTE ]
SIGO-4 19 X108-2 CE5
SIGO-5 28 X109-1
SIGO-6 29 X109-2
XJT1M-A1
SIGO-7 38 X109-3 EARCH
XJT2M-A1
SIGO-8 39 X109-4 XJT3M-A1
20
■ U Series Inside Machine Harness (S2) ■ U Series Inside Machine Harness (S7)
XFG-CN1 XFG-CN6
Signal Name NO. Destination Signal Name NO. Destination
JT1-ENC P 1 XJT1E-1 JT6-ENC P 1 XJT6E-1
JT1-ENC N 2 XJT1E-2 JT6-ENC N 2 XJT6E-2
JT1+5B 3 XJT1E-3 JT6-+5B 3 XJT6E-3
JT1-GND 4 XJT1E-4 JT6-GND 4 XJT6E-4
■ U Series Inside Machine Harness (S3) ■ U Series Inside Machine Harness (LS)
XFG-CN2 XFG-CN11
Signal Name NO. Destination Signal Name NO. Destination
JT2-ENC P 1 XJT2E-1 LS1P 1 XLS1-N/C
JT2-ENC N 2 XJT2E-2 LS1N 2 XLS2-COM
JT2+5B 3 XJT2E-3 LS2P 3 XFG-CN-4
JT2-GND 4 XJT2E-4 LS2N 4 XFG-CN-3
5
■ U Series Inside Machine Harness (S4)
XFG-CN13
XFG-CN3
Signal Name NO. Destination
Signal Name NO. Destination
LS1P 1 CN19-1
JT3-ENC P 1 XJT3E-1
LS1N 2 CN20-2
JT3-ENC N 2 XJT3E-2
LS2P 3 CN19-3
JT3-+5B 3 XJT3E-3
LS2N 4 CN20-4
JT3-GND 4 XJT3E-4
5
■ U Series Inside Machine Harness (S5)
XFG-CN4 CN20
Signal Name NO. Destination Signal Name NO. Destination
JT4-ENC P 1 XJT4E-1 LS1P 1 CN19-2
JT4-ENC N 2 XJT4E-2 LS1N 2 XFG-CN13-2
JT4-+5B 3 XJT4E-3 LS2P 3 CN19-4
JT4-GND 4 XJT4E-4 LS2N 4 XFG-GN13-4
5
■ U Series Inside Machine Harness (S6)
XFG-CN5
Signal Name NO. Destination
JT5-ENC P 1 XJT5E-1
JT5-ENC N 2 XJT5E-2
JT5-+5B 3 XJT5E-3
JT5-GND 4 XJT5E-4
EARTH BAR
Signal Name NO. Destination
JT1-MOTOR E 1 XJT1M-A1
JT2-MOTOR E 2 XJT2M-A1
JT3-MOTOR E 3 XJT3M-A1
X105
Signal Name NO. Destination
JT1-BRAKE P 1 XJT1B-1
JT1-BRAKE N 2 XJT1B-2
JT2-BRAKE P 3 XJT2B-1
JT2-BRAKE N 4 XJT2B-2
JT3-BRAKE P 5 XJT3B-1
JT3-BRAKE N 6 XJT3B-2
X5A X107
Signal Name NO. Destination Signal Name NO. Destination
3 X105-1 EPV P 1 X110-1
4 X105-4 EPV N 2 X110-2
10 X105-2
11 X105-5 X108
17 X105-3 Signal Name NO. Destination
18 X105-6 SIGO-3 1 X111-3
JT4-MOTOR U 1 XJT4M-B1 X115-1
JT4-MOTOR V 8 XJT4M-A2 SIGO-4 2 X111-4
JT4-MOTOR W 15 XJT4M-B2 X115-2
JT4-BRAKE P 24 XJT4M-A3
JT4-BRAKE N 25 XJT4M-B3 X109
JT5-MOTOR U 22 X103-B1 Signal Name NO. Destination
JT5-MOTOR V 29 X103-A2 NOTE SIGO-5 1 X111-5
JT5-MOTOR W 36 X103-B2 SIGO-6 2 X111-6
JT5-BRAKE P 31 X103-A3 SIGO-7 3 X111-7
JT5-BRAKE N 32 X103-B3 SIGO-8 4 X111-8
JT7-MOTOR U 23 X106-B1
JT7-MOTOR V 30 X106-A2 X112
JT7-MOTOR W 37 X106-B2 Signal Name NO. Destination
JT7-BRAKE P 12 X106-A3 EPV P 1 X110-1
JT7-BRAKE N 13 X106-B3 EPV N 2 X110-2
JT7-MOTOR E 38 X106-A1
SHIELD U EB-8 X113
SERVO ON-P 7 X117-1 Signal Name NO. Destination
SERVO ON-N 14 X117-2 SIGO-1 1 X111-1
SIGO-3 26 X108-1 SIGO-2 2 X111-2
SIGO-4 27 X108-2
SIGO-5 33 X109-1 EARTH BAR
SIGO-6 34 X109-2 Signal Name NO. Destination
SIGO-7 40 X109-3 JT4-MOTOR E 4 XJT4M-A1
SIGO-8 41 X109-4 JT5-MOTOR E 5 XJT5M-A1
SIGO-1 19 X113-1
SIGO-2 20 X113-2
X111
Signal Name NO. Destination
SIGO-1 1 X119-1
SIGO-2 2 X119-2
SIGO-3 3 X119-3
SIGO-4 4 X119-4
SIGO-5 5 X119-5
SIGO-6 6 X119-6
SIGO-7 7 X119-7
SIGO-8 8 X119-8
X3A
Signal Name NO. Destination Signal Name NO. Destination
JT1-ENC P 1 XFG-CN8-1 EPV P 22 X107-1
JT1-ENC N 8 XFG-CN8-20 EPV N 23 X107-2
JT2-ENC P 2 XFG-CN8-5 U TAP
JT2-ENC N 9 XFG-CN8-24
JT3-ENC P 3 XFG-CN8-2
JT3-ENC N 10 XFG-CN8-21
JT4-ENC P 4 XFG-CN8-3
JT4-ENC N 11 XFG-CN8-22
JT5-ENC P 5 XFG-CN8-7
JT5-ENC N 12 XFG-CN8-26
JT6-ENC P 6 XFG-CN8-4
JT6-ENC N 13 XFG-CN8-23
JT7-ENC P 7 XFG-CN8-6
JT7-ENC N 14 XFG-CN8-25
LS1 P 27 XFG-CN8-9
LS1 N 34 XFG-CN8-28
LS2 P 38 XFG-CN8-10
LS2 N 35 XFG-CN8-29
SIG-1 15 XFG-CN8-14
SIG-2 16 XFG-CN8-33
+24V 33 XFG-CN8-13
GND(+24V) 26 XFG-CN8-32
+24V 39 XFG-CN8-12
GND(+24V) 40 XFG-CN8-31
SIG-3 17 XFG-CN8-18
SIG-4 18 XFG-CN8-37
BAT. AL. P 20 XFG-CN8-8
BAT. AL. N 21 XFG-CN8-27
+12V 31 XFG-CN8-15
GND 37 XFG-CN8-34
+12V 32 XFG-CN8-16
GND 30 XFG-CN8-35
+12V 36 XFG-CN8-17
X114-1
GND 38 XFG-CN8-36
GND 24 XFG-CN8-30
GND 25 XFG-CN8-11
GND 29 XFG-CN8-19
X114-2
■ ZD Series Inside Machine Harness (S2) ■ ZD Series Inside Machine Harness (S7)
XFG-CN1 XFG-CN6
Signal Name NO. Destination Signal Name NO. Destination
JT1-ENC P 1 XJT1E-1 JT6-ENC P 1 XJT6E-1
JT1-ENC N 2 XJT1E-2 JT6-ENC N 2 XJT6E-2
JT1+5B 3 XJT1E-3 JT6-+5B 3 XJT6E-3
JT1-GND 4 XJT1E-4 JT6-GND 4 XJT6E-4
■ ZD Series Inside Machine Harness (S3) ■ ZD Series Inside Machine Harness (S8)
XFG-CN2 XFG-CN9
Signal Name NO. Destination Signal Name NO. Destination
JT2-ENC P 1 XJT2E-1 JT7-ENC P 1 JT7E-1
JT2-ENC N 2 XJT2E-2 JT7-ENC N 2 JT7E-2
JT2+5B 3 XJT2E-3 JT7- +5B 3 JT7E-3
JT2-GND 4 XJT2E-4 JT7- GND 4 JT7E-4
■ ZD Series Inside Machine Harness (S4) ■ ZD Series Inside Machine Harness (S9)
XFG-CN3 XFG-CN1
Signal Name NO. Destination Signal Name NO. Destination
JT3-ENC P 1 XJT3E-1 SIG-1 6 X130-1
JT3-ENC N 2 XJT3E-2 SIG-2 5 X130-2
JT3-+5B 3 XJT3E-3 SIG-3 2 X130-3
JT3-GND 4 XJT3E-4 SIG-4 1 X130-4
+24V 4 X130-5
■ ZD Series Inside Machine Harness (S5) GND(+24V) 3 X130-6
XFG-CN4 COM 7 X130-7
Signal Name NO. Destination
JT4-ENC P 1 XJT4E-1
JT4-ENC N 2 XJT4E-2
JT4-+5B 3 XJT4E-3
JT4-GND 4 XJT4E-4
X4A
Signal Name NO. Destination
JT2-MOTOR E 4 XJT2M-B1
JT2-MOTOR U 5 XJT2M-A1
JT2-MOTOR V 6 XJT2M-B2
JT3-MOTOR W 7 XJT3M-B1
JT3-MOTOR E 8 XJT3M-A1
JT3-MOTOR U 9 XJT3M-B2
JT1-MOTOR V 1 XJT1M-B1
JT1-MOTOR W 2 XJT1M-A2
JT1-MOTOR E 3 XJT1M-B2
TH P a X4A-a
TH N b X4A-a
X105
Signal Name NO. Destination
JT1-BRAKE P 1 XJT1B-1
JT2-BRAKE P 2 XJT2B-1
JT3-BRAKE P 3 XJT3-B1
JT1-BRAKE N 4 XJT1-B2
JT2-BRAKE N 5 XJT2-B2
JT3-BRAKE N 6 XJT3-B2
EARTH BAR
Signal Name NO. Destination
JT1-MOTOR E 1 XJT1M-A1
JT2-MOTOR E 2 XJT2M-A1
JT3-MOTOR E 3 XJT3M-A1
X5A X107
Signal Name NO. Destination Signal Name NO. Destination
3 X105-1 EPV P 1 X110-1
4 X105-2 EPV N 2 X110-2
10 X105-3
11 X105-4 X108
17 X105-5 Signal Name NO. Destination
18 X105-6 SIGO-3 1 X111-3
JT4-MOTOR U 1 XJT4M-1 X115-1
JT4-MOTOR V 8 XJT4M-2 SIGO-4 2 X111-4
JT4-MOTOR W 15 XJT4M-3 X115-2
JT4-BRAKE P 24 XJT4M-4
JT4-BRAKE N 25 XJT4M-5 X109
JT5-MOTOR U 22 XJT5M-1 Signal Name NO. Destination
JT5-MOTOR V 29 XJT5M-2 SIGO-5 1 X111-5
JT5-MOTOR W 36 XJT5M-3 SIGO-6 2 X111-6
JT5-BRAKE P 31 XJT5M-4 SIGO-7 3 X111-7
JT5-BRAKE N 32 XJT5M-5 SIGO-8 4 X111-8
JT6-MOTOR U 2 XJT6M-1
JT6-MOTOR V 9 XJT6M-2 X113
JT6-MOTOR W 16 XJT6M-3 Signal Name NO. Destination
JT6-BRAKE P 5 XJT6M-4 SIGO-1 1 X111-1
JT6-BRAKE N 6 XJT6M-5 SIGO-2 2 X111-2
JT7-MOTOR U 23 X106-B1
JT7-MOTOR V 30 X106-A2 EARTH BAR
JT7-MOTOR W 37 X106-B2 Signal Name NO. Destination
JT7-BRAKE P 12 X106-A3 JT4-MOTOR E 4 XJT4M-
JT7-BRAKE N 13 X106-B3 JT5-MOTOR E 5 XJT5M-
JT7-MOTOR E 38 X106-A1 JT6-MOTOR E 6 XJT6M-
EARTH U EB-8
SERVO ON-P 7 X117-1
SERVO ON-N 14 X117-2
SIGO-3 26 X108-1
SIGO-4 27 X108-2
SIGO-5 33 X109-1
SIGO-6 34 X109-2
SIGO-7 40 X109-3
SIGO-8 41 X109-4
SIGO-1 19 X113-1
SIGO-2 20 X113-2
XFG-CN13
Signal Name NO. Destination
LS1P 1 X125-1
LS1N 2 X126-2
LS2P 3 X125-3
LS2N 4 X126-4
X126
Signal Name NO. Destination
LS1P 1 X125-2
LS1N 2 XFG-CN13-2
LS2P 3 X125-4
LS2N 4 XFG-CN13-4
5
X3A
Signal Name NO. Destination Signal Name NO. Destination
JT1-ENC P 1 XFG-CN8-1 EPV P 22 X107-1
JT1-ENC N 8 XFG-CN8-20 EPV N 23 X107-2
JT2-ENC P 2 XFG-CN8-5 U TAP
JT2-ENC N 9 XFG-CN8-24
JT3-ENC P 3 XFG-CN8-2
JT3-ENC N 10 XFG-CN8-21
JT4-ENC P 4 XFG-CN8-3
JT4-ENC N 11 XFG-CN8-22
JT5-ENC P 5 XFG-CN8-7
JT5-ENC N 12 XFG-CN8-26
JT6-ENC P 6 XFG-CN8-4
JT6-ENC N 13 XFG-CN8-23
JT7-ENC P 7 XFG-CN8-6
JT7-ENC N 14 XFG-CN8-25
LS1 P 27 XFG-CN8-9
LS1 N 34 XFG-CN8-28
LS2 P 28 XFG-CN8-10
LS2 N 35 XFG-CN8-29
SIG-1 15 XFG-CN8-14
SIG-2 16 XFG-CN8-33
+24V 33 XFG-CN8-13
GND(+24V) 26 XFG-CN8-32
+24V 39 XFG-CN8-12
GND(+24V) 40 XFG-CN8-31
SIG-3 17 XFG-CN8-18
SIG-4 18 XFG-CN8-37
BAT. AL. P 20 XFG-CN8-8
BAT. AL. N 21 XFG-CN8-27
+12V 31 XFG-CN8-15
GND 37 XFG-CN8-34
+12V 32 XFG-CN8-16
GND 30 XFG-CN8-35
+12V 36 XFG-CN8-17
GND 38 X114-1
GND 24 XFG-CN8-36
GND 25 XFG-CN8-30
GND 29 XFG-CN8-11
X114-2
■ ZX/ZT Series Inside Machine Harness (S2) ■ ZX/ZT Series Inside Machine Harness (S7)
XFG-CN1 XFG-CN6
Signal Name NO. Destination Signal Name NO. Destination
JT1-ENC P 1 XJT1E-1 JT6-ENC P 1 XJT6E-1
JT1-ENC N 2 XJT1E-2 JT6-ENC N 2 XJT6E-2
JT1+5B 3 XJT1E-3 JT6-+5B 3 XJT6E-3
JT1-GND 4 XJT1E-4 JT6-GND 4 XJT6E-4
■ ZX/ZT Series Inside Machine Harness (S3) ■ ZX/ZT Series Inside Machine Harness (S8)
XFG-CN2 XFG-CN11
Signal Name NO. Destination Signal Name NO. Destination
JT2-ENC P 1 XJT2E-1 JT7-ENC P 1 XJT7E-1
JT2-ENC N 2 XJT2E-2 JT7-ENC N 2 XJT7E-2
JT2+5B 3 XJT2E-3 JT7-+5B 3 XJT7E-3
JT2-GND 4 XJT2E-4 JT7- GND 4 XJT7E-4
■ JS30/40 Inside Machine Harness (M1) ■ JS30/40 Inside Machine Harness (M2)
X4A X5A
Signal Name NO. Destination Signal Name NO. Destination
JT2-MOTOR U 4 CN10-B1 JT4-MOTOR U 5 CN13-A1
JT4-MOTOR V 6 CN13-B1
JT2-MOTOR V 5 CN10-A2
JT4-MOTOR W 7 CN13-A2
JT2-MOTOR W 6 CN10-B2
JT5-MOTOR U 15 CN14-B2
JT3-MOTOR U 7 CN11-B1
JT5-MOTOR V 16 CN13-A3
JT3-MOTOR V 8 CN11-A2 JT5-MOTOR W 17 CN13-B3
JT3-MOTOR W 9 CN11-B2 JT6-MOTOR U 25 CN13-A4
JT1-MOTOR U 1 CN9-B1 JT6-MOTOR V 26 CN13-B4
JT1-MOTOR V 2 CN9-A2 JT6-MOTOR W 27 CN13-A5
JT1-MOTORW 3 CN9-B2 JT7-MOTOR E 40 SEE NOTE
MTH N b X4A-a JT7-MOTOR U 35 CN8-B1
MTH P a X4A-b JT7-MOTOR V 36 CN8-A2
EARTH U EARTH BAR-4 JT7-MOTOR W 37 CN8-B2
EARTH U CN13-B5
JT1-BRAKE P 1 CN12-1
EARTH BAR JT1-BRAKE N 2 CN12-2
Signal Name NO. Destination JT2-BRAKE P 11 CN14-1
EARTH 1 CN9-A1 JT2-BRAKE N 12 CN14-7
EARTH 2 CN10-A1 JT3-BRAKE P 21 CN14-2
JT3-BRAKE N 22 CN14-8
EARTH 3 CN11-A1
JT4-BRAKE P 3 CN14-3
EARTH 4 X4A- U
JT4-BRAKE N 4 CN14-9
JT5-BRAKE P 13 CN14-4
JT5-BRAKE N 14 CN14-10
JT6-BRAKE P 23 CN14-5
[ NOTE ] JT6-BRAKE N 24 CN14-11
JT7-BRAKE P 33 CN8-A3
JT7-BRAKE N 34 CN8-B3
SIGO-1 8 CN6-1
X5A-40 SIGO-2 9 CN6-2
CN8-A1 SIGO-3 18 CN15-3
CN6-3
SIGO-4 19 CN15-4
SIGO-5 28 CN15-5
SIGO-6 29 CN15-6
SIGO-7 38 CN15-7
SIGO-8 39 CN15-8
CN6
Signal Name NO. Destination
SOL-1 1 CN15-1
SOL-2 2 CN15-2
EARTH 3
■ JS30/40 Inside Machine Harness (M3) ■ JS30/40 Inside Machine Harness (M5)
CN9 CN13
Signal Name NO. Destination Signal Name NO. Destination
EARTH A1 JT1M-A1 JT4-MOTOR U A1 CN18-A1
JT1-MOTOR U B1 JT1M-B1 JT4-MOTOR V B1 CN18-B1
JT1-MOTOR V A2 JT1M-A2 JT4-MOTOR W A2 CN18-A2
JT1-MOTOR W B2 JT1M-B2 JT5-MOTOR U B2 CN18-B2
JT5-MOTOR V A3 CN18-A3
CN12 JT5-MOTOR W B3 CN18-B3
Signal Name NO. Destination JT6-MOTOR U A4 CN18-A4
JT1-BRAKE P 1 JT1B-1 JT6-MOTOR V B4 CN18-B4
JT1-BRAKE N 2 JT1B-2 JT6-MOTOR W A5 CN18-A5
EARTH B5 CN18-B5
■ JS30/40 Inside Machine Harness (M4) A6
CN10 B6
Signal Name NO. Destination
EARTH A1 JT2M-A1 CN14
JT2-MOTOR U B1 JT2M-B1 Signal Name NO. Destination
JT2-MOTOR V A2 JT2M-A2 JT2-BRAKE P 1 JT2B-1
JT2-MOTOR W B2 JT2M-B2 JT3-BRAKE P 2 CN17-1
JT4-BRAKE P 3 CN19-1
CN11 JT5-BRAKE P 4 CN19-2
Signal Name NO. Destination JT6-BRAKE P 5 CN19-3
EARTH A1 CN16-A1 6
JT3-MOTOR U B1 CN16-B1 JT2-BRAKE N 7 JT2B-2
JT3-MOTOR V A2 CN16-A2 JT3-BRAKE N 8 CN17-2
JT3-MOTOR W B2 CN16-B2 JT4-BRAKE N 9 CN19-9
JT5-BRAKE N 10 CN19-10
■ JS30/40 Inside Machine Harness (M6) JT6-BRAKE N 11 CN19-11
CN16 12
Signal Name NO. Destination
EARTH A1 JT3M- CN15
JT3-MOTOR U B1 JT3M-1 Signal Name NO. Destination
JT3-MOTOR V A2 JT3M-2 SIGO-1 1 CN19-4
JT3-MOTOR W B2 JT3M-2 SIGO-2 2 CN19-12
SIGO-3 3 CN19-5
CN17 SIGO-4 4 CN19-13
Signal Name NO. Destination SIGO-5 5 CN19-6
JT3-BRAKE P A1 JT3M-4 SIGO-6 6 CN19-14
JT3-BRAKE N B1 JT3M-5 SIGO-7 7 CN19-7
SIGO-8 8 CN19-15
JT6M-A1 [ NOTE ]
FG-CN5
Signal Name NO. Destination
JT5-ENC P 1 No.21-10
JT5-ENC N 2 No.21-11
JT5-+5B 3 No.21-12
JT5-GND 4 No.21-13
FG-CN6
Signal Name NO. Destination
JT6-ENC P 1 No.21-14
JT6-ENC N 2 No.21-15
JT6-+5B 3 No.21-16
JT6-GND 4 No.21-17
No.5
Signal Name NO. Destination
JT3-BRAKE P 1 JT3M-A3
JT4-BRAKE P 2 JT4M-A3
JT5-BRAKE P 3 No.8-3
JT6-BRAKE P 4 No.8-6
JT3-BRAKE N 5 JT3M-B3
JT4-BRAKE N 6 JT4M-B3
JT5-BRAKE N 7 No.8-9
JT6-BRAKE N 8 No.8-12
[ NOTE ]
No.6-9 No.9-9
No.6-10 No.9-10
SHIELD
CN28
Signal Name NO. Destination
SIGO-7 1 No.9-7
SIGO-8 2 CN27-4
3
4
■ JS10 Inside Machine Harness (S2) ■ JS10 Inside Machine Harness (S3)
FG-CN3 No.12
Signal Name NO. Destination Signal Name NO. Destination
JT3-ENC P 1 JT3E-1 JT5-ENC P 1 JT5E-1
JT3-ENC N 2 JT3E-2 JT5-ENC N 2 JT5E-2
JT3-+5B 3 JT3E-3 JT5-+5B 3 JT5E-3
JT3-GND 4 JT3E-4 JT5-GND 4 JT5E-4
JT6-ENC P 5 JT6E-1
FG-CN4
JT6-ENC N 6 JT6E-2
Signal Name NO. Destination
JT6-+5B 7 JT6E-3
JT4-ENC P 1 JT4E-1
JT6-GND 8 JT6E-4
JT4-ENC N 2 JT4E-2
JT4-+5B 3 JT4E-3
No.13
JT4-GND 4 JT4E-4
Signal Name NO. Destination
FG-CN5 SIG-1 1 SIG1
Signal Name NO. Destination SIG-2 2 SIG2
JT5-ENC P 1 No.12-1 SIG-3 3 SIG3
JT5-ENC N 2 No.12-2 SIG-4 4 SIG4
JT5-+5B 3 No.12-3 +24V 5 +24V
JT5-GND 4 No.12-4 24G 6 24G
FG-CN6
Signal Name NO. Destination ■ JS10 Inside Machine Harness (S4)
JT6-ENC P 1 No.12-5 FG-CN1
JT6-ENC N 2 No.12-6 Signal Name NO. Destination
JT6-+5B 3 No.12-7 JT1-ENC P 1 JT1E-1
JT6-GND 4 No.12-8 JT1-ENC N 2 JT1E-2
JT-+5B 3 JT1E-3
FG-CN9 JT1-GND 4 JT1E-4
Signal Name NO. Destination
SIG-1 1 No.13-1 ■ JS10 Inside Machine Harness (S5)
SIG-2 2 No.13-2 FG-CN2
3 Signal Name NO. Destination
4 JT2-ENC P 1 JT2E-1
+24V 5 No.13-5 JT2-ENC N 2 JT2E-2
24V 6 No.13-6 JT2-+5B 3 JT2E-3
SIG-3 7 No.13-3 JT2-GND 4 JT2E-4
SIG-4 8 No.13-4
FG-CN12
Signal Name NO. Destination
LS1P 1 No.16-1
LS1N 2 No.16-2
LS2P 3 No.16-3
LS2N 4 No.16-4
5
X401
Signal Name NO. Destination
SIG1 66 SIG1
SIG3 54 SIG2
SIG2 67 SIG3
SIG4 55 SIG4
+24V 68 +24V
+24G 56 +24G
LS1P 1 X402-1
LS1N 2 X402-2
LS2P 3 X402-3
LS2N 4 X402-4
SOLC 29 VAL1-1
SOL1 41 VAL1-2
SOLC 29 VAL1-3
SOL2 42 VAL1-4
SOLC 29 VAL2-1
SOL3 43 VAL2-2
SOLC 29 VAL2-3
SOL4 44 VAL2-4
JT1BRK-P 17 XJT1B-1
JT1BRK-N 30 XJT1B-2
JT2BRK-P 18 XJT2B-1
JT2BRK-N 30 XJT2B-2
JT3BRK-P 7 XJT3B-1
JT3BRK-N 31 XJT3B-2
JT4BRK-P 8 XJT4B-1
JT4BRK-N 31 XJT4B-2
JT5BRK-P 19 XJT5B-1
JT5BRK-N 31 XJT5B-2
JT6BRK-P 20 XJT6B-1
JT6BRK-N 31 XJT6B-2
(JT7BRK-P) 5 (XJT7B-1)
(JT7BRK-N) 6 (XJT7B-2)
XJT1E
Signal Name N‚n. Destination
JT1E-P 1 X401-13
JT1E-N 2 X401-14
+5V 3 XHG-CN4-1
GND 4 XHG-CN4-2
XJT2E
Signal Name NO. Destination
JT2E-P 1 X401-15
JT2E-N 2 X401-16
+5V 3 XHG-CN4-3
GND 4 XHG-CN4-4
XJT3E
Signal Name NO. Destination
JT3E-P 1 X401-25
JT3E-N 2 X401-26
+5V 3 X405
GND 4 X406
XJT4E
Signal Name NO. Destination
JT4E-P 1 X401-27
JT4E-N 2 X401-28
+5V 3 X405
GND 4 X406
XJT5E
Signal Name NO. Destination
JT5E-P 1 X401-37
JT5E-N 2 X401-38
+5V 3 X405
GND 4 X406
XJT6E
Signal Name NO. Destination
JT6E-P 1 X401-39
JT6E-N 2 X401-40
+5V 3 X405
GND 4 X406
XHG-CN1
Signal Name NO. Destination
JT7E-P 1 X401-61
JT7E-N 2 X401-62
BAT-AL+ 3 X401-63
BAT-AL- 4 X401-64
+12V 5 X401-65
GND 6 X401-49
+12V 7 X406
GND 8 X407
X403
Signal Name NO. Destination
JT2M-U 1 XJT2M-1
JT2M-V 2 XJT2M-2
JT2M-W 3 XJT2M-3
JT2M-E 4 XJT2M-4
X404
Signal Name NO. Destination
GND XJT3E-4
XJT4E-4
XJT5E-4
XJT6E-4
X405
Signal Name NO. Destination
+5V XJT3E-3
XJT4E-3
XJT5E-3
XJT6E-3
X406
Signal Name NO. Destination
+12V X401-50
X401-52
X407
Signal Name NO. Destination
GND X401-51
X401-53
X3A
Signal Name NO. Destination
EPV-P 36 X125-1
EPV-N 39 X125-2
LS1P 6 X126-1
LS2P 26 X126-3
LS1N 16 X121-2
LS2N 36 X121-4
JT3E-P 21 X121-5
JT3E-N 31 X121-6
JT1E-P 1 XJT1E-1
JT1E-N 11 XJT1E-2
JT2E-P 3 XJT2E-1
JT2E-N 13 XJT2E-2
JT4E-P 2 X122-1
JT4E-N 12 X122-2
JT5E-P 4 X123-1
JT5E-N 14 X123-2
JT6E-P 22 X123-5
JT6E-N 32 X123-6
+24V 7 X124-1
24G 17 X124-2
+24V 27 X124-3
24G 37 X124-4
24G 17 X124-5
SIG1 5 X124-6
24G 17 X124-7
SIG2 15 X124-8
24G 37 X124-9
SIG3 25 X124-10
24G 37 X124-11
SIG4 35 X124-12
JT7E-P 23 XHG-CN1-1
JT7E-N 33 XHG-CN1-2
BAT AL P 24 XHG-CN1-3
BAT AL N 34 XHG-CN1-4
+12V 10 XHG-CN1-5
GND(+12V) 20 XHG-CN1-6
+12V 8 XHG-CN1-7
GND(+12V) 18 XHG-CN1-8
GND(+12V) 28 XHG-CN1-6
GND(+12V) 30 XHG-CN1-6
+12V 9 XHG-CN1-7
GND(+12V) 19 XHG-CN1-8
GND(+12V) 29 XHG-CN1-8
X101
Signal Name NO. Destination
JT3MOTOR-U B1 XJT3M-B1
JT3MOTOR-V A2 XJT3M-A2
JT3MOTOR-W B2 XJT3M-B2
JT3MOTOR-FG A1 XJT3M-A1
JT3BRAKE-P A3 XJT3M-A3
JT3BRAKE-N B3 XJT3M-B3
X102
Signal Name NO. Destination
JT4MOTOR-U 1 XJT4M-1
JT4MOTOR-V 2 XJT4M-2
JT4MOTOR-W 3 XJT4M-3
JT4MOTOR-FG 6 XJT4M-4
JT4BRAKE-P 4 XJT4B-1
JT4BRAKE-N 5 XJT4B-2
SIGO-1 7 X106-1
SIGO-2 8 X106-3
SIGO-3 9 X107-1
SIGO-4 10 X107-2
SIGO-5 12 X108-1
SIGO-6 13 X108-2
SIGO-7 14 X109-1
SIGO-8 15 X106-2,4,
X107-2,4,
X108-2,4,
X109-2
X103
Signal Name NO. Destination
JT5MOTOR-U 1 XJT5M-1
JT5MOTOR-V 2 XJT5M-2
JT5MOTOR-W 3 XJT5M-3
JT5MOTOR-FG 4 XJT5M-4
JT5BRAKE-P 9 XJT5B-1
JT5BRAKE-N 10 XJT5B-2
JT6MOTOR-U 5 XJT6M-1
JT6MOTOR-V 6 XJT6M-2
JT6MOTOR-W 7 XJT6M-3
JT6MOTOR-FG 8 XJT6M-4
JT6BRAKE-P 11 XJT6B-1
JT6BRAKE-N 12 XJT6B-2
X121
Signal Name NO. Destination
LS1P 1 X127-1
LS2P 3 X127-3
LS1N 2 X127-2
LS2N 4 X127-4
JT3E-P 5 XJT3E-1
JT3E-N 6 XJT3E-2
JT3E-+5V 7 XJT3E-3
JT3E-GND 8 XJT3E-4
X122
Signal Name NO. Destination
JT4E-P 1 XJT4E-1
JT4E-N 2 XJT4E-2
JT4E-+5V 3 XJT4E-3
JT4E-GND 4 XJT4E-4
X123
Signal Name NO. Destination
JT5E-P 1 XJT5E-1
JT5E-N 2 XJT5E-2
JT5E-+5V 3 XJT5E-3
JT5E-GND 4 XJT5E-4
JT6E-P 5 XJT6E-1
JT6E-N 6 XJT6E-2
JT6E-+5V 7 XJT6E-3
JT6E-GND 8 XJT6E-4
X124
Signal Name NO. Destination
+24V 1 X24V
24G 2 X24G
+24V 3 X24V
24G 4 X24G
24G 5 X24G
SIG1 6 XSIG1
24G 7 X24G
SIG2 8 XSIG2
24G 9 X24G
SIG3 10 XSIG3
24G 11 X24G
SIG4 12 XSIG4
XHG-CN4
Signal Name NO. Destination
JT3E-GND 1 X121-8
JT3E-+5V 2 X121-7
JT1E-GND 3 XJT1E-4
JT1E-+5V 4 XJT1E-3
JT2E-GND 5 XJT2E-4
JT2E-+5V 6 XJT2E-3
JT4E-GND 7 X122-4
JT4E-+5V 8 X122-3
JT5E-GND 9 X123-4
JT5E-+5V 10 X123-3
JT6E-GND 11 X123-8
JT6E-+5V 12 X123-7
X3A
Signal Name NO. Destination
EPV-P 38 X125-1
EPV-N 39 X125-2
LS1P 6 X126-1
LS2P 26 X126-3
LS1N V X121-2
LS2N Sf X121-4
JT3E-P 21 X121-5
JT3E-N 31 X121-6
JT1E-P 1 XJT1E-1
JT1E-N 11 XJT1E-2
JT2E-P 3 XJT2E-1
JT2E-N 13 XJT2E-2
JT4E-P 2 X122-1
JT4E-N 12 X122-2
JT5E-P 4 X123-1
JT5E-N 14 X123-2
JT6E-P 22 X123-5
JT6E-N 32 X123-6
+24V 7 X124-1
24G 17 X124-2
+24V 27 X124-3
24G 37 X124-4
24G 17 X124-5
SIG1 5 X124-6
24G 17 X124-7
SIG2 15 X124-8
24G 37 X124-9
SIG3 25 X124-10
24G 37 X124-11
SIG4 35 X124-12
JT7E-P 23 XHG-CN1-1
JT7E-N 33 XHG-CN1-2
BAT AL P 24 XHG-CN1-3
BAT AL N 34 XHG-CN1-4
+12V 10 XHG-CN1-5
GND(+12V) 20 XHG-CN1-6
+12V 8 XHG-CN1-7
GND(+12V) 18 XHG-CN1-8
GND(+12V) 28 XHG-CN1-6
GND(+12V) 30 XHG-CN1-8
+12V 9 XHG-CN1-7
GND(+12V) 19 XHG-CN1-8
GND(+12V) 29 XHG-CN1-8
X109
Signal Name NO. Destination
JT3MOTOR-U B1 X112-B1
JT3MOTOR-V A2 X112-A2
JT3MOTOR-W B2 X112-B2
X110
Signal Name NO. Destination
JT1BRAKE-P 1 XJT1B-1
JT1BRAKE-N 2 XJT1B-2
JT2BRAKE-P 3 XJT2B-1
JT2BRAKE-N 4 XJT2B-2
X112
Signal Name NO. Destination
JT3MOTOR-U B1 XJT3M-1
JT3MOTOR-V A2 XJT3M-2
JT3MOTOR-W B2 XJT3M-3
JT3BRAKE-P A3 XJT3M-4
JT3BRAKE-N B3 XJT3M-5
JT3MOTOR-FG A1 XJT3M-
X113
Signal Name NO. Destination
JT4BRAKE-P A3 XJT4M-A3
JT4BRAKE-N B3 XJT4M-B3
JT4MOTOR-U B1 XJT4M-B1
JT4MOTOR-V A2 XJT4M-A2
JT4MOTOR-W B2 XJT4M-B2
JT4MOTOR-FG A1 XJT4M-A1
X114
Signal Name NO. Destination
SIGO-1 1 X106-1
SIGO-2 2 X106-3
SIGO-3 3 X107-1
SIGO-4 4 X107-2
SIGO-5 5 X108-1
SIGO-6 6 X108-2
SIGO-7 7 X109-1
SIGO-8 8 X106-2,4,
X107-2,4,
X108-2,4,
X109-2
X115
Signal Name NO. Destination
JT5BRAKE-P A3 XJT5B-1
JT5BRAKE-N B3 XJT5B-2
JT5MOTOR-U B1 XJT5M-1
JT5MOTOR-V A2 XJT5M-2
JT5MOTOR-W B2 XJT5M-3
JT5MOTOR-FG A1 XJT5M-4
X116
Signal Name NO. Destination
JT6BRAKE-P A3 XJT6B-1
JT6BRAKE-N B3 XJT6B-2
JT6MOTOR-U B1 XJT6M-1
JT6MOTOR-V A2 XJT6M-2
JT6MOTOR-W B2 XJT6M-3
JT6MOTOR-FG A1 XJT6M-4
EARTH BAR
Signal Name NO. Destination
EARTH CN1-P,CN2-P
XJT1M-A1,XJT2M-A1
X112-A1,X113-A1
X115-A1,X116-A1
X121
Signal Name NO. Destination
LS1P 1 X127-1
LS2P 3 X127-3
LS1N 2 X127-2
LS2N 4 X127-4
JT3E-P 5 XJT3E-1
JT3E-N 6 XJT3E-2
JT3E-+5V 7 XJT3E-3
JT3E-GND 8 XJT3E-4
X122
Signal Name NO. Destination
JT4E-P 1 XJT4E-1
JT4E-N 2 XJT4E-2
JT4E-+5V 3 XJT4E-3
JT4E-GND 4 XJT4E-4
X123
Signal Name NO. Destination
JT5E-P 1 XJT5E-1
JT5E-N 2 XJT5E-2
JT5E-+5V 3 XJT5E-3
JT5E-GND 4 XJT5E-4
JT6E-P 5 XJT6E-1
JT6E-N 6 XJT6E-2
JT6E-+5V 7 XJT6E-3
JT6E-GND 8 XJT6E-4
X124
Signal Name NO. Destination
+24V 1 X24V
24G 2 X24G
+24V 3 X24V
24G 4 X24G
24G 5 X24G
SIG1 6 XSIG1
24G 7 X24G
SIG2 8 XSIG2
24G 9 X24G
SIG3 10 XSIG3
24G 11 X24G
SIG4 12 XSIG4
XHG-CN4
Signal Name NO. Destination
JT3E-GND 1 X121-8
JT3E-+5V 2 X121-7
JT1E-GND 3 XJT1E-4
JT1E-+5V 4 XJT1E-3
JT2E-GND 5 XJT2E-4
JT2E-+5V 6 XJT2E-3
JT4E-GND 7 X122-4
JT4E-+5V 8 X122-3
JT5E-GND 9 X123-4
JT5E-+5V 10 X123-3
JT6E-GND 11 X123-8
JT6E-+5V 12 X123-7
X3A
Signal Name NO. Destination
EPV-P 38 X125-1
EPV-N 39 X125-2
LS1P 6 X126-1
LS2P 26 X126-3
LS1N V X121-2
LS2N Sf X121-4
JT3E-P 21 X121-5
JT3E-N 31 X121-6
JT1E-P 1 XJT1E-1
JT1E-N 11 XJT1E-2
JT2E-P 3 XJT2E-1
JT2E-N 13 XJT2E-2
JT4E-P 2 X122-1
JT4E-N 12 X122-2
JT5E-P 4 X123-1
JT5E-N 14 X123-2
JT6E-P 22 X123-5
JT6E-N 32 X123-6
+24V 7 X124-1
24G 17 X124-2
+24V 27 X124-3
24G 37 X124-4
24G 17 X124-5
SIG1 5 X124-6
24G 17 X124-7
SIG2 15 X124-8
24G 23 37
SIG3 25 X124-10
24G 37 X124-11
SIG4 35 X124-12
JT7E-P 23 XHG-CN1-1
JT7E-N 33 XHG-CN1-2
BAT AL P 24 XHG-CN1-3
BAT AL N 34 XHG-CN1-4
+12V 10 XHG-CN1-5
GND(+12V) 20 XHG-CN1-6
+12V 8 XHG-CN1-7
GND(+12V) 18 XHG-CN1-8
GND(+12V) 28 XHG-CN1-6
GND(+12V) 30 XHG-CN1-8
+12V 9 XHG-CN1-7
GND(+12V) 19 XHG-CN1-8
GND(+12V) 29 XHG-CN1-8
X109
Signal Name NO. Destination
JT3MOTOR-U B1 X112-B1
JT3MOTOR-V A2 X112-A2
JT3MOTOR-W B2 X112-B2
X110
Signal Name NO. Destination
JT1BRAKE-P 1 XJT1B-1
JT1BRAKE-N 2 XJT1B-2
JT2BRAKE-P 3 XJT2B-1
JT2BRAKE-N 4 XJT2B-2
X112
Signal Name NO. Destination
JT3MOTOR-U B1 XJT3M-1
JT3MOTOR-V A2 XJT3M-2
JT3MOTOR-W B2 XJT3M-3
JT3BRAKE-P A3 XJT3M-4
JT3BRAKE-N B3 XJT3M-5
JT3MOTOR-FG A1 XJT3M-
X113
Signal Name NO. Destination
JT4BRAKE-P A3 XJT4M-A3
JT4BRAKE-N B3 XJT4M-B3
JT4MOTOR-U B1 XJT4M-B1
JT4MOTOR-V A2 XJT4M-A2
JT4MOTOR-W B2 XJT4M-B2
JT4MOTOR-FG A1 XJT4M-A1
X114
Signal Name NO. Destination
SIGO-1 1 X106-1
SIGO-2 2 X106-3
SIGO-3 3 X107-1
SIGO-4 4 X107-2
SIGO-5 5 X108-1
SIGO-6 6 X108-2
SIGO-7 7 X109-1
SIGO-8 8 X106-2,4,
X107-2,4,
X108-2,4,
X109-2
X115
Signal Name NO. Destination
JT5BRAKE-P A3 XJT5M-A3
JT5BRAKE-N B3 XJT5M-B3
JT5MOTOR-U B1 XJT5M-B1
JT5MOTOR-V A2 XJT5M-A2
JT5MOTOR-W B2 XJT5M-B2
JT5MOTOR-FG A1 XJT5M-A1
X116
Signal Name NO. Destination
JT6BRAKE-P A3 XJT6M-A3
JT6BRAKE-N B3 XJT6M-B3
JT6MOTOR-U B1 XJT6M-B1
JT6MOTOR-V A2 XJT6M-A2
JT6MOTOR-W B2 XJT6M-B2
JT6MOTOR-FG A1 XJT6M-A1
EARTH BAR
Signal Name NO. Destination
EARTH CN1-P,CN2-P
XJT1M-A1,XJT2M-A1
X112-A1,X113-A1
X115-A1,X116-A1
X121
Signal Name NO. Destination
LS1P 1 X127-1
LS2P 3 X127-3
LS1N 2 X127-2
LS2N 4 X127-4
JT3E-P 5 XJT3E-1
JT3E-N 6 XJT3E-2
JT3E-+5V 7 XJT3E-3
JT3E-GND 8 XJT3E-4
X122
Signal Name NO. Destination
JT4E-P 1 XJT4E-1
JT4E-N 2 XJT4E-2
JT4E-+5V 3 XJT4E-3
JT4E-GND 4 XJT4E-4
X123
Signal Name NO. Destination
JT5E-P 1 XJT5E-1
JT5E-N 2 XJT5E-2
JT5E-+5V 3 XJT5E-3
JT5E-GND 4 XJT5E-4
JT6E-P 5 XJT6E-1
JT6E-N 6 XJT6E-2
JT6E-+5V 7 XJT6E-3
JT6E-GND 8 XJT6E-4
X124
Signal Name NO. Destination
+24V 1 X24V
24G 2 X24G
+24V 3 X24V
24G 4 X24G
24G 5 X24G
SIG1 6 XSIG1
24G 7 X24G
SIG2 8 XSIG2
24G 9 X24G
SIG3 10 XSIG3
24G 11 X24G
SIG4 12 XSIG4
XHG-CN4
Signal Name NO. Destination
JT3E-GND 1 X121-8
JT3E-+5V 2 X121-7
JT1E-GND 3 XJT1E-4
JT1E-+5V 4 XJT1E-3
JT2E-GND 5 XJT2E-4
JT2E-+5V 6 XJT2E-3
JT4E-GND 7 X122-4
JT4E-+5V 8 X122-3
JT5E-GND 9 X123-4
JT5E-+5V 10 X123-3
JT6E-GND 11 X123-8
JT6E-+5V 12 X123-7
OVERVIEW
DESCRIPTIONS
TROUBLESHOOTING
INDEX
OL curve 4-60,
one axis amplifier 4-39, 4-40, 4-41, 4-42, 4-44, 4-46,
one axis amplifier 4-48, 4-58, 4-62, 4-67, 4-81, 4-82
one axis amplifier 4-83, 4-85, 4-87, 4-88,
operation panel 2-7, 2-8 3-57, 4-8, 4-9, 4-11,
operation panel 4-12,
operation unit 4-7, 4-9, 4-11, 4-50, 4-86,
overcurrent 3-16, 3-25, 3-32, 4-56,
overheat 4-8, 4-62,
overload 3-69, 4-18, 4-60, 4-62,
PB 3-16, 3-18, 3-25, 3-26, 3-31
PC card 2-11, 3-72, 3-73, 3-75, 4-27, 4-28,
personal computer 3-8, 3-73, 4-29, 4-30, 4-31,
photo coupler 3-39,
PI/O 3-49, 3-51,
pinch point 1-6,
plant safety coordinator 1-5,
position envelope error 4-18, 4-65,
power block 3-22,
power sequence board 3-16,
power unit 3-20, 3-29,
protection seat 3-74,
PWM 3-16, 3-18, 3-22, 3-25, 3-29, 3-31
PWM 3-32,
regenerating resistor 3-18, 3-22, 3-29, 3-32,
regenerating resistor 3-23, 4-83, 4-84, 4-87, 4-88, 4-89,
regenerating resistor unit 4-84, 4-87, 4-88, 4-89,
relay board 3-60, 3-64, 4-86, 4-97, 4-98, 4-99,
relay board 4-100,
RI/O 3-49, 3-50, 3-52,
robot data 4-24,
robot harness 4-56, 4-62,
rotation counter 3-46,
rotation data 4-18, 4-69,
rotor magnet 3-70,
rotor trunk 4-62,
RS232C 3-8, 3-10 3-72
RS485 3-16 3-49 3-50 3-52 3-72
safety circuit 3-57,
safety gate 4-17, 4-53,
safety plug 1-7, 4-53
sensor line 3-39 3-46 4-98
servo board 3-8, 3-29, 3-35, 3-63
servo control 3-18 3-19, 4-17, 4-52,
servo control signal 3-18
servo CPU 4-17, 4-37, 4-48,
servo error 4-57,
servo parameter 4-17, 4-38, 4-46,
servo position loop operation 3-8
servo system 4-21, 4-28, 4-49, 4-57,
SRAM card 3-73
sum check 4-17, 4-27,
super-capacitor 3-70
teach lock switch 2-11, 2-12,
teach pendant 2-11,
teaching posture 4-22, 4-23,
touch panel 3-72 3-74
touch pen 2-12 3-74
transistor array 3-39
user set work envelope 4-22, 4-91, 4-92, 4-94, 4-95
✎ MEMO
Troubleshooting MANUAL
July 1998 : 1st Edition
June 2002 :4th Edition
90206-1023DED
Kawasaki Machine
Systems Korea
Kawasaki Robotics Taiwan Kawasaki Kawasaki Heavy
(USA), Inc. Robot Center Industries, LTD.
Tokyo Head Office
Kawasaki Robotics
San Jose Office
Kawasaki Robotics Units 6&7, Easter Court, Europa Boulevard TEL 44 -1925-71-3000
(UK) Limited Westbrook, Warrington, WA5 5ZB, England FAX 44 –1925-71-3001
* All descriptions in this booklet are subject to change for improvement without prior notice.