FANUC Robotics R-J3iBMate Controller (RIA R15.06 – 1999 Compliant) Maintenance Manual MARMIBRIA01021E REV.

B
B-81535EN/02

This publication contains proprietary information of FANUC Robotics North America, Inc. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics North America, Inc. FANUC Robotics North America, Inc. 3900 W. Hamlin Road Rochester Hills, Michigan 48309–3253

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

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

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

Copyright ¤2002 by FANUC Robotics North America, Inc. All Rights Reserved The information illustrated or contained herein is not to be reproduced, copied, translated into another language, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics North America, Inc. AccuStat£, ArcTool£, DispenseTool£, FANUC LASER DRILL£, KAREL£, INSIGHT£, INSIGHT II£, PaintTool£, PaintWorks£, PalletTool£, SOCKETS£, SOFT PARTS£ SpotTool£, TorchMate£, and YagTool£ are Registered Trademarks of FANUC Robotics. FANUC Robotics reserves all proprietary rights, including but not limited to trademark and trade name rights, in the following names: AccuAir™ AccuCal™ AccuChop™ AccuFlow™ AccuPath™ AccuSeal™ ARC Mate™ ARC Mate Sr. ™ ARC Mate System 1™ ARC Mate System 2™ ARC Mate System 3™ ARC Mate System 4™ ARC Mate System 5™ ARCWorks Pro™ AssistTool™ AutoNormal™ AutoTCP™ BellTool™ BODYWorks™ Cal Mate™ Cell Finder™ Center Finder™ Clean Wall™ CollisionGuard™ DispenseTool™ F-100™ F-200i™ FabTool™ FANUC LASER DRILL™ Flexibell™ FlexTool™ HandlingTool™ HandlingWorks™ INSIGHT™ INSIGHT II™ IntelliTrak™ Integrated Process Solution™ Intelligent Assist Device™ IPC -Integrated Pump Control™ IPD Integral Pneumatic Dispenser™ ISA Integral Servo Applicator™ ISD Integral Servo Dispenser™ Laser Mate System 3™ Laser Mate System 4™ LaserPro™ LaserTool™ LR Tool™ MIG Eye™ MotionParts™ NoBots™ Paint Stick™ PaintPro™ PaintTool 100™ PAINTWorks™ PAINTWorks II™ PAINTWorks III™ PalletMate™ PalletMate PC™ PalletTool PC™ PayloadID™ RecipTool™ RemovalTool™ Robo Chop™ Robo Spray™ S-420i™ S-430i™ ShapeGen™ SoftFloat™ SOF™ PARTS™ SpotTool+™ SR Mate™ SR ShotTool™ SureWeld™ SYSTEM R-J2 Controller™ SYSTEM RJ3 Controller™ SYSTEM R-J3iB Controller™ TCP Mate™ TurboMove™ TorchMate™ visLOC™ visPRO-3D™ visTRAC™ WebServer™ WebTP™ YagTool™

Conventions
This manual includes information essential to the safety of personnel, equipment, software, and data. This information is indicated by headings and boxes in the text. WARNING Information appearing under WARNING concerns the protection of personnel. It is boxed and in bold type to set it apart from other text.

CAUTION Information appearing under CAUTION concerns the protection of equipment, software, and data. It is boxed to set it apart from other text.

NOTE Information appearing next to NOTE concerns related information or useful hints.

Safety
Safety-1 FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner, employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace. The appropriate level of safety for your application and installation can best be determined by safety system professionals. FANUC Robotics therefore, recommends that each customer consult with such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC Robotic systems. According to the industry standard ANSI/RIA R15.06, the owner or user is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to recognize and respond to known hazards associated with your robotic system and to be aware of the recommended operating procedures for your particular application and robot installation. FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use the robotics system be trained in an approved FANUC Robotics training course and become familiar with the proper operation of the system. Persons responsible for programming the system–including the design, implementation, and debugging of application programs– must be familiar with the recommended programming procedures for your application and robot installation. The following guidelines are provided to emphasize the importance of safety in the workplace.

However. or chains Light curtains Interlocks Pressure mats Floor markings Warning lights Mechanical stops EMERGENCY STOP buttons DEADMAN switches Setting Up a Safe Workcell A safe workcell is essential to protect people and equipment. too. Never permit untrained personnel to operate the robots. equipment must be kept safe. Keep in mind the following factors with regard to safety: • • • • • • The safety of people and equipment Use of safety enhancing devices Techniques for safe teaching and manual operation of the robot(s) Techniques for safe automatic operation of the robot(s) Regular scheduled inspection of the robot and workcell Proper maintenance of the robot Keeping People and Equipment Safe The safety of people is always of primary importance in any situation. regulations. These suggestions are intended to supplement and not replace existing federal. consider the following: • • • • • People External devices Robot(s) Tooling Workpiece Using Safety Enhancing Devices Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the installation of some or all of the following devices: • • • • • • • • • Safety fences. and guidelines that pertain to safety. . When prioritizing how to apply safety to your robotic system. and local laws. state. • Sponsor your personnel for training in approved FANUC Robotics training course(s) related to your application. barriers.Safety-2 CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION Safety is essential whenever robots are used. Observe the following guidelines to ensure that the workcell is set up safely.

Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the operator and at critical points inside and around the outside of the workcell. Audible warning devices shall exceed the ambient noise level at the end–use application. whenever power is applied to the servo drive system. and special barriers.Safety-3 Install a lockout device that uses an access code to prevent unauthorized persons from operating the robot. Arrange the workcell so the operator faces the workcell and can see what is going on inside the cell. that is. Clearly identify the work envelope of each robot in the system with floor markings. If the tooling strikes an object. Install special guarding that prevents the operator from reaching into restricted areas of the work envelope. Use presence or proximity sensing devices such as light curtains. The work envelope is the area defined by the maximum motion range of the robot. and help to minimize damage to the tooling and robot. Wherever possible. Position all controllers outside the robot work envelope. these devices dislodge. signs. Use anti–tie–down logic to prevent the operator from bypassing safety measures. including any tooling attached to the wrist flange that extend this range. Periodically check the safety joints or safety clutches that can be optionally installed between the robot wrist flange and tooling. • • • • • • • • • • • • • . mats. Install flashing lights and/or audible warning devices that activate whenever the robot is operating. Use interlocks. Never rely on software as the primary safety element. install safety fences to protect against unauthorized entry by personnel into the work envelope. remove power from the system. and capacitance and vision systems to enhance safety.

warning. scarves. or debris. check the teach pendant DEADMAN switch for proper operation. be sure to provide appropriate interlocks. and beacons. turn it on. grounded. The area near the robot must be clean and free of oil. Pinch points are areas where personnel could get trapped between a moving robot and other equipment. provide electrical interlocks for lockout of material flow and pressure. water. or loose clothing that could get caught in moving machinery. except for robot teaching operations. Take the teach pendant with you. Before teaching. Make provisions for power lockout/tagout at the controller. neckties. Only the person with the teach pendant should be in the work envelope. shielded. • • • • • • Staying Safe While Teaching or Manually Operating the Robot Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules: • • • Never wear watches. FANUC Robotics recommends that no one enter the work envelope of a robot that is on.Safety-4 • Make sure all external devices are properly filtered. and be prepared to release the DEADMAN switch. be sure all safeguards are in place. Program the robot to load and unload material safely. if you must enter the work envelope. radio frequency interference (RFI). • • . visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. These include tooling attached to the wrist flange that extends this range. The work envelope is the area defined by the maximum motion range of the robot. and suppressed to prevent hazardous motion due to the effects of electro–magnetic interference (EMI). Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment. and place the robot in teach mode. and electro–static discharge (ESD). Immediately report unsafe working conditions to the supervisor or safety department. Provide enough room inside the workcell to permit personnel to teach the robot and perform maintenance safely. If high voltage electrostatics are present. rings. If materials are being applied at dangerously high pressure. However. Eliminate pinch points.

• • • Know the path that can be used to escape from a moving robot.Using a low motion speed. test run the program continuously for at least one full cycle.Safety-5 WARNING Never bypass. - • Staying Safe During Automatic Operation Advise all personnel who operate the robot during production to observe the following rules: • • Make sure all safety provisions are present and active. test run the program continuously for at least one full cycle. Know the entire workcell area. for any operational convenience. Make sure all personnel are outside the work envelope before running production. . Using a low motion speed. Failure to do so can result in injury. such as a limit switch. The workcell includes the robot and its work envelope. Understand the complete task the robot is programmed to perform before initiating automatic operation. . or otherwise deactivate a safety device. plus the area occupied by all external devices and other equipment with which the robot interacts. Test any program being run for the first time in the following manner: WARNING Stay outside the robot work envelope whenever a program is being run.Using the programmed speed. Make sure all personnel are outside the work envelope before operating the robot. Isolate the robot from all remote control signals that can cause motion while data is being taught. make sure the escape path is never blocked. single step the program for at least one full cycle. strap. Deactivating a safety device is known to have resulted in serious injury and death. • • .

or loose clothing that could get caught in moving machinery. scarves. The robot could be waiting for an input signal that will permit it to continue activity. If power is needed to check the robot motion or electrical circuits. Lock out and tag out the power source at the controller according to the policies of your plant. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel. rings. neckties. Be aware that when you remove a servomotor or brake. Never wear watches. do not assume it will continue to run in the same pattern. the associated robot arm will fall if it is not supported or resting on a hard stop. Be prepared to press these buttons in an emergency. with your body. Turn off the compressed air source and relieve the air pressure. press the EMERGENCY STOP button on the operator panel. be prepared to press the EMERGENCY STOP button. and control signals that could cause the robot to move. Know the location and status of all switches. • • • Staying Safe During Inspection When inspecting the robot. Support the arm on a solid support before you release the brake. be sure to • • • • • • Turn off power at the controller. Never assume that a program is complete if the robot is not moving. Know where the EMERGENCY STOP buttons are located on both the robot control and external control devices. in an emergency. observe the following rules: . If the robot is running in a pattern. or break its motion. sensors. Never try to stop the robot. teach pendant. If robot motion is not needed for inspecting the electrical circuits.Safety-6 • • • Never enter or allow others to enter the work envelope during automatic operation of the robot. or emergency stop stations around the workcell. • Staying Safe During Maintenance When performing maintenance on your robot system.

Whenever possible. If it is necessary for you to enter the robot work envelope while power is turned on. perform maintenance with the power turned off. you must be sure that you are in control of the robot. turn off and lock out the 3–phase power source at the controller. Be sure to take the teach pendant with you. Be extremely careful to avoid electrical shock. Before you open the controller front panel or enter the work envelope. . Test the teach pendant for proper operation before entering the work envelope. press the DEADMAN switch. rings. Never wear watches. visually inspect the workcell to make sure no potentially hazardous conditions exist. Support the arm on a solid support before you release the brake. Before entering the work envelope. Before working on the pneumatic system. neckties. and turn the teach pendant on. Turning the disconnect or circuit breaker to the OFF position removes power from the output side of the device only. Consider all or any overlapping work envelopes of adjoining robots when standing in a work envelope. WARNING Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. scarves. • • • Release or block all stored energy. shut off the system air supply and purge the air lines. Be aware that when you remove a servomotor or brake. the associated robot arm will fall if it is not supported or resting on a hard stop. Be prepared to release the DEADMAN switch to turn off servo power to the robot immediately. or loose clothing that could get caught in moving machinery. HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source.Safety-7 • • • • • • Never enter the work envelope while the robot or a program is in operation.

• • • KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE Programming Safety Precautions Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. and pins to prevent hazardous movement by the robot. mechanical stops. • • WARNING Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Support the arm on a solid support before you release the brake. Use blocks. • Be aware that when you remove a servomotor or brake.Safety-8 • Isolate the robot from all remote control signals. Before restarting a robot. Make sure that such devices do not create pinch points that could trap personnel. never use nonspecified fuses. Make sure the escape route is never blocked. Know the path that can be used to escape from a moving robot. When replacing or installing components. . Some of these measures are outlined below. The teach pendant must be held by this person. make sure the person inside the work envelope has sole control of the robot. Make sure you know all associated measures for safe use of such devices. To avoid fires and damage to parts in the controller. make sure dirt and debris do not enter the system. the associated robot arm will fall if it is not supported or resting on a hard stop. Doing so can result in serious personal injury and component destruction. be sure that the robot and all external devices are operating normally. Use only specified parts for replacement. If maintenance must be done when the power is on. Make sure personnel cannot get trapped between the moving robot and other equipment. Implement the following programming safety measures to prevent damage to machine tools and other external devices. make sure no one is inside the work envelope.

Visualize the movement the robot will make before you press the jog keys on the teach pendant. Use circuit breakers to guard against electrical overload. water. water.Safety-9 • • Back–check limit switches in the workcell to make sure they do not fail. Programming Safety Precautions The following safety measures are designed to prevent damage to the robot during programming: • Establish interference zones to prevent collisions when two or more robots share a work area. Make sure the work envelope is clean and free of oil. limit switches. . Program the robot to check the condition of all external devices during an operating cycle. • • Mechanical Safety Precautions Implement the following mechanical safety measures to prevent damage to machine tools and other external devices. Implement ‘‘failure routines” in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails. Use handshaking protocol to synchronize robot and external device operations. The following measures are designed to prevent damage to the robot during operation. KEEPING THE ROBOT SAFE Operating Safety Precautions Observe the following operating and programming guidelines to prevent damage to the robot. and debris. Use software limits. • • • • Use a low override speed to increase your control over the robot when jogging the robot. and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices. or debris. • • Make sure the workcell is clean and free of oil.

Therefore. • NOTE Any deviation from the methods and safety practices described in this manual must conform to the approved standards of your company. In dispensing applications. and high–voltage electrostatic tools. if available. Be aware of signals or other operations that could trigger operation of tooling resulting in personal injury or equipment damage. hood/deck and door opening devices. including automatic and exercise operation • Diagnostic mode During both teach and automatic modes. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s). for example. ventilation equipment must be used. ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS Process technicians are sometimes required to enter the paint booth. robot operation is initiated at the System Operator Console (SOC) or Manual Control Panel (MCP). In teach mode. be aware of all safety guidelines with respect to the dispensing materials. Although paint booth hazards have been minimized. potential dangers still exist. Whenever personnel are working inside the paint booth. If you have questions. All personnel must remain outside of the booth or in a designated safe . see your supervisor. and can be monitored from outside the paint booth. during daily or routine calibration or while teaching new paths to a robot. Maintenance personal also must work inside the paint booth periodically.Safety-10 • • Make sure that the program ends with the robot near or at the home position. In automatic mode. Paint robots are operated in three modes: • Teach or manual mode • Automatic mode. the robots in the paint booth will follow a predetermined pattern of movements. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor. today’s highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its capabilities. the process technician teaches (programs) paint paths using the teach pendant.

WARNING An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed robot. indicates that the electrostatic devices are enabled. To minimize the risk of injury when working near robots and related equipment. Learn what these are. and the robot comes to an EMERGENCY STOP. When this switch is held in. If the engaged DEADMAN switch is released during robot operation. but generally at production speeds. Become familiar with the locations of all E– STOP buttons. Your booth might have other kinds of indicators. personnel must comply strictly with the procedures in the manuals. they must stay in a designated safe area. Some paint booths have a blue beacon that. power is removed from the servo system. This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system. all axis brakes are applied. power is applied to the robot servo system. When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth. the robots will execute the path movements they were taught during teach mode. Learn what these are. EMERGENCY STOP buttons are located on the robot controller and teach pendant. Safety interlocks within the system might also E–STOP other robots. An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres. • • • • . and the teach pendant is on. Your booth might have other kinds of indicators. when illuminated. A DEADMAN switch is located on each teach pendant. The paint system includes the following safety features: • Most paint booths have red warning beacons that illuminate when the robots are armed and ready to paint. In automatic mode. Paint System Safety Features Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities.Safety-11 area within the booth whenever automatic mode is initiated at the SOC or MCP.

Know where all red. Be aware of overlapping work envelopes of adjacent robots. All of the major and minor axes are governed by software limits. located on the entrance/exit doors of each booth. Severe conditions result in automatic system shutdown. . For some systems. EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. WARNING Observe all safety rules and guidelines to avoid injury. strap. for any operational convenience. in addition to all rules for safe operation that apply to all robot systems. When present. WARNING Never bypass. such as a limit switch. photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit silhouette openings. observe the following rules. mushroom–shaped EMERGENCY STOP buttons are located. • • • • Know the work area of the entire paint station (workcell). Deactivating a safety device is known to have resulted in serious injury and death. Limit switches. Know the work envelope of the robot and hood/deck and door opening devices. • Staying Safe While Operating the Paint Robot When you work in or near the paint booth. • System status is monitored by computer. signals to these switches are inactive when the switch on the SCC is in teach mode. or otherwise deactivate a safety device. Limit switches and hardstops also limit travel by the major axes.Safety-12 • Overtravel by robot axes is prevented by software limits. will EMERGENCY STOP all equipment in the booth if a door is opened while the system is operating in automatic or manual mode.

conveyor. watches. Become familiar with the complete task the robot will perform BEFORE starting automatic mode.Safety-13 Know the location and status of all switches. and NFPA 70 National Electrical Code. and belts. or opening device and another object. WARNING When working with electrostatic paint equipment. Make sure that the work area near the robot is clean and free of water. Stay out of areas where you might get trapped between a moving robot. neckties. Never enter the work envelope during automatic operation unless a safe area has been designated. oil. Be aware of signals and/or operations that could result in the triggering of guns or bells. or loose clothing that could get caught in moving machinery. Report unsafe conditions to your supervisor. observe the following rules. such as rings. Be aware of all safety precautions when dispensing of paint is required. sensors. Also reference the following standards: NFPA 33 Standards for Spray Application Using Flammable or Combustible Materials. scarves. Follow the procedures described in this manual. follow all national and local codes as well as all safety guidelines within your organization. and opening devices to move. Never enter the work envelope or paint booth before you turn off power to the robot servo system. and debris. conveyor. Make sure all personnel are outside the paint booth before you turn on power to the robot servo system. • • • • • • • • • • • • Staying Safe While Operating Paint Application Equipment When you work with paint application equipment. rings. and/or control signals that might cause the robot. before entering a booth when the electrostatic devices are enabled. . in addition to all rules for safe operation that apply to all robot systems. Remove all metallic objects. Never wear watches.

• • • • • • • • Staying Safe During Maintenance When you perform maintenance on the painter system. When a maintenance technician is repairing or adjusting a robot. This person must understand the robot and associated potential hazards. trained service or maintenance personnel should perform repair work on a robot. robots. • . This includes the spray booth. Only qualified. workstations. Follow all manufacturer recommended cleaning procedures. Post all warning signs regarding the electrostatic equipment and operation of electrostatic equipment according to NFPA 33 Standard for Spray Application Using Flammable or Combustible Material. conveyors. Disable all air and paint pressure to bell.Safety-14 • Grounding: All electrically conductive objects in the spray area must be grounded. and all other maintenance safety rules that apply to all robot installations. All personnel not participating in the maintenance must stay out of the area. part carriers. Make sure all interlocks are operational. observe the following rules. No smoking. the work area is under the control of that technician. hooks. High Voltage: High voltage should only be on during actual spray operations. paint pressure pots. For some maintenance procedures. • • Paint robots operate in a potentially explosive environment. station a second person at the control panel within reach of the EMERGENCY STOP button. Grounding is defined as the object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms. Never leave high voltage on during a cap cleaning process. Voltage should be off when the painting process is completed. Use caution when working with electric tools. as well as solvent containers. Avoid any accumulation of combustible vapors or coating matter. Verify that the lines are not under pressure.

Overexposure could cause drowsiness.Safety-15 Be sure all covers and inspection plates are in good repair and in place. can alert you to potential problems. Whenever possible. rinse with water for at least 15 minutes. Always return the robot to the ‘‘home’’ position before you disarm it. If there is contact with the skin. Overexposure could cause drowsiness or skin and eye irritation. turn off the main electrical disconnect before you clean the robot. . When using paint remover observe the following: - Eye protection. Adequate ventilation is required. If there is contact with the skin or eyes. Excess vibration. During robot operations. boots. Never use machine power to aid in removing any component from the robot. unusual sounds. protective rubber gloves. and so forth. be aware of the robot’s movements. When using vinyl resin observe the following: • • • • • • • Wear eye protection and protective gloves during application and removal Adequate ventilation is required. and apron are required during booth cleaning. wash with water.

Update Section Single Phase Power Option .

.

.

.

.

.

.

.1 SAFETY OF THE END EFFECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .1 3. . . . Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT FUNCTIONS . . . . . . . .6 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 12 12 11 11 11 SAFETY IN MAINTENANCE . . . . . . . . . . . . . . Safety During Maintenance . . . . . . . . .9 VIBRATION OBSERVED DURING MOVEMENT . . . . . . . . 13 14 II MAINTENANCE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 SAFETY SIGNALS . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . Precautions for Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 11 10 10 1. . . . WARNING LABEL . . . . . . . . . . . . . . . . . . . . . .4 3. . . 32 MASTERING . . . . . . . .6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1. . . . . . . . . . . . . . . . . . . . . . OVERVIEW . . . . . . . . . . . . . . . . . . . . . POWER CANNOT BE TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . .B–81535EN/02 Table of Contents PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety of the Teach Pendant Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 3. . . . . . . Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2. . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 EXTERNAL VIEW OF THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 1. . . . . . . . . . . . . . . . . . . .4 1. . . . . . . . . . . . . .2 2. . . . . . .3 OPERATOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 TROUBLESHOOTING USING THE ERROR CODE . . . . . . . 19 20 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1. . . . . . . . . . . . . . . . . . . 92 TROUBLESHOOTING BASED ON LED INDICATIONS . . . . . . . . . . . . . .10 MANUAL OPERATION IMPOSSIBLE . . . . . . . . . .3. . . . . .1 1. . . . . 3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREVENTIVE MAINTENANCE . . . . . . . Precautions in Programming . . . CONFIGURATION .1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . Teach Pendant Cannot be Turned On . . . . . . . . . . . . . .5 1. . . . . . . .3 3. . . . . . . . . .3 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1. . . . . . . . . . . . . . . . . . . . . . . . . . Operator Safety . . . . . . . . . . . . . . 2. 35 TROUBLESHOOTING USING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Operation . . . . . . . 21 23 24 25 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 3. . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . Precautions for Mechanisms . . . . . . . . SAFETY OF THE ROBOT MECHANISM . . . . . 109 27 28 c–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 26 ALARM OCCURRENCE SCREEN . . .3. . . . .1. . . . . . . 97 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) . . . . . . . . . . . .2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY PRECAUTIONS . . . . . . . . . . . . . 108 3. . . . . . . . . . . 3. . . . . . . . p–1 I SAFETY PRECAUTIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . .1 1. . . . . . . . . . . . . . . . . . . .2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Screen Remains on the Teach Pendant . . 4 6 7 9 1. . .

.13. REPLACING THE POWER SUPPLY UNIT . . . . . REPLACING SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 7. . . . . . .4 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c–2 . . .3 7. . . . . . . –0011) . 127 REPLACING THE PRINTED–CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 7. . . . EMERGENCY STOP BOARD (A20B–1008–0010. . . . . . . . . . . . . . . .6 REPLACING THE EMERGENCY STOP UNIT . . . . . . . . . . . . . . . REPLACING THE CONTROL SECTION FAN MOTOR . . . . . . . . . . . . . . .2. . . . . . . .1 4. . . . . . . . . . . REPLACING A UNIT . . . . .1. . . . . . . . . . . . . . . . 126 CHECKING THE POWER SUPPLY UNIT . . . . . . . . . . . . .5 7. 112 116 117 118 5. . . . . . . . . . . . . . . . . . . .1 5. . . . . . . . . . . . .1 BLOCK DIAGRAMS OF THE POWER SUPPLY . . . . . . . . . . Replacing the Emergency Stop Board . . . . . . . . . . . . . . . . . . . . . . 121 122 6. . Replacing the Fuse on the Power Supply Module . . . 153 7. . . . . . . . . Replacing the Fuse on the Door . . . . . . . . . . . . . . . . . 133 REPLACING THE TRANSFORMER . . . . . . . . . . . .Table of Contents B–81535EN/02 4. . . . . . . . . . . . . . . REPLACING THE MAGNETIC CONTACTOR . . . . . . . . . . . . . . 154 7. . . . . . . . . . . . . . .13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVO AMPLIFIERS . . . . . . . . . .2 7. .2 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14. . . . .3 4. . . . . . . . . . . . . . .12 7. . . REPLACING A FUSE . . . . . . . . . . . . Replacing a Fuse on the Robot Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 REPLACING CARDS AND MODULES ON THE ROBOT CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 4. . . . . . . . . .3 7. . . . .1 7. . . . . . . . . . . .9 7. . . .2 6. . . . . . . . . . HF (A16B–2203–0765) . . . . . . . . . . . . . . . . . . .1 5. . . . . . . . . . . . . . . REPLACING THE OPERATOR PANEL . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . BACKPLANE BOARD (A20B–2003–0330) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 5. . . . SETTING THE POWER SUPPLY . . . . . . . . . . .2 ROBOT CONTROL BOARD (A16B–3200–0450) . . . . . . .7 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Replacing a Relay on the Emergency Stop Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 6. . . . . . . . . . . . . . . . . . . . . . . .6 7. . . . . . . . Replacing the Fuse on the Process I/O Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing a Fuse on the Emergency Stop Board . . . . . . . . . . . . . .13. . . . . .3 7. . . . . . . . . . . . . . . . . . . .10 7. . . . . . . 121 LED OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 OUTLINE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRINTED CIRCUIT BOARDS . REPLACING THE TEACH PENDANT . . . . . . .11 7. . . . . . . . . . . . . . . . . . . . . . . . . .4 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo Amplifier Module (A06B–6114–H205. . . . . . . . . 153 7. . . . . . . . .3 7. . . . . . . . . 120 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 124 Power Supply Module PSM (A06B–6115–H001) . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Servo Amplifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 6. . . . . . .8 7. . . . . . . . . A06B–6114–H302) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Replacing the Backplane Board (Unit) . . . . . . . . . 128 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE DOOR FAN UNIT AND HEAT EXCHANGER .1. . . . . . . . 130 131 132 7. . . . . . . . . . . . . . . . . . . . . . . . . .13. . .1. . . 137 138 139 140 141 142 143 144 145 146 147 147 148 149 150 151 152 137 7. . . . . . . . . . . . .13. . . . . . .2 7. . . . . . . . . . . . . . . . . . .1 5. . . . . . . . . . . . 127 CHECKING THE POWER SUPPLY MODULE . . . . .15. . . . . . . . . . LED of Servo Amplifier Module . Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit . . . . . . . . . . . PROCESS I/O BOARD HE (A16B–2203–0764). . . . . . . .1 Battery for Memory Backup (3 VDC) . . . . . . . . . . . . . . . . . . . . . . . 123 LED of Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FAN MOTOR OF THE SERVO AMPLIFIER CONTROL UNIT . . . . . . . . . . . . . . . . .13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 REPLACING A RELAY . . . . . . . . . . . . . . . . . . . . . .5 7. . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Brake Power Transformer . . . . . . . .2. . . . . .15 REPLACING BATTERY . . . . . .2 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . .4 CONNECTION OF POWER SUPPLY CABLE . .12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 4. . . . . . . . . . . . . .9 3. . . Connection Between the Control Unit and Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 4. . . . . . . . . . . . . . . . . Digital I/O Signal Specifications of End Effector Control Interface . .8 3. . . . External Emergency Stop Input . . . . . . . . . . . . . . . . . . . . . . . . . . .3 3. . . . . . . . . . . CONNECTION OF I/O LINK CABLE . . . . . . . . . . . . . . . . . . . .1 3. . . . . . . . . . . Peripheral Device Interfaces CRM79 and CRM81 . 197 3. . . . . . . . . . . . . . . . Circuit Diagram of Emergency Stop . . . . . . . . . . . . .12. . . . . . . . . . . . . . . . . . . . . . .6 3. . . When the Robot is Connected to the CNC by a Peripheral Device Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 3. . . . . . . . . . . . c–3 223 223 224 225 225 226 . . . .4 3. . . . . . .12. . INTERFACES . . . . . . .11 TREATMENT FOR THE SHIELDED CABLE .1 3. . .3. . . . . . . . .7 3. . . . . . . . . . . . . . . . . . GENERAL . . .8 3. . . . . . . . . . . Peripheral Device Interface Block Diagram and Specifications . . . . . . . . . . . . . .1 3. . . . . . . . . . . . . . . .10 Peripheral Device Interface Types . . . . . . . . . . . . . . . . External Emergency Stop Output . . . . . . . . . . . . . . . . . . . . . . . . . . 162 163 165 167 167 168 169 170 3. . Digital I/O Signal Specifications of Peripheral Device Interface A .10. . . . . . . .6 TRANSPORTATION . . . EMERGENCY STOP CIRCUIT . . External 24 V Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 pins) . Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 2. . . . . . . . . . . . . . . . . . . . . . . .2 3. . . . . . . . . . . . . . . . . .2 197 199 201 202 203 208 214 216 219 219 220 221 4. . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device and Control Unit Connection . . . . . . . CONNECTION OF TEACH PENDANT CABLE . . . . . . . . . . . . CONNECTING A CABLE TO A PERIPHERAL DEVICE . . . . . . . . . . . .9. . . . . . . . . . . . .3 3. . . . . . . . . . . ARC WELDING. . . . . . . . . . 201 3. . . . . . . . . . . . .9. . . . . . . . . . . . TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . INSTALLATION CONDITION .10. . . .1 4. . . . . . . . . . . . .1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O Signal Specifications for ARC–Welding Interface . . . . . . . .4. . . . . 161 3. . . . . . . . . . . . . . . Peripheral Device Cable Connector . . . . .12. . . . . BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . .12. . . .4 4. . . . . . . . . . . . . CONNECTION OF ROBOT . .12. . . . . . . . . . . . . .4 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT AND CHECKS AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOTE AT INSTALLATION . . .9. . . . . . . . . . . . . . . . . . . . . . . Digital I/O Signal Specifications .9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin. . . . . . .12 PERIPHERAL DEVICE. . . . . . . . . . . . . INSTALLATION . .7 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 3.9. . . . . . .2 3. . .5 3. . . .1 3. . . . . . . . . . . . . . . . . . . .2 3. .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 3.4 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 pins) . . . CONNECTION OF CABLE FOR RS–232–C/RS–422 . . . . . . . . .9 3. . . . . . . . . .5 COONECTION OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . .12. . . . . . . . . . . . . . . . . . . . . . 171 172 173 174 175 175 176 193 193 195 196 3. . . . . Peripheral Device Cable Connector . . .12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 3. . . . . . . . . . . . . . . . . . . . .1 Peripheral device interface CRM 79 and CRM 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Cables . . . . . . . . . . . . . . . . . . .12. . . . . . .4. . . . . . . . . . Connecting the Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . EXTERNAL CONTROLLER DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 END EFFECTOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARC Weld Connection Cable (CRW1: Honda Tsushin. . . . . . . .9. . . .12. . . . . . . . . . . . . . . . . . . . .B–81535EN/02 Table of Contents III CONNECTION 1. . .3 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FANUC I/O LINK . . . . . . . . . . . . . . CONNECTION DETAILS . 160 3. . . . . . . . . . . . . . . . . . . . . . . .5 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 229 B. . . . PERIPHERAL INTERFACE . . . . . . . . .2. . . . . . .2. . . . . . . . . . . . . .1 B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTICAL FIBER CABLE . . . . . .2 B. . . . . . . . . . . . . . . . . . . . . . .2 B. . . . .1 B. . . . . . . . . . . . . . 238 B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . TOTAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SIGNAL TYPES . 240 Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Signals . . . . . . . . . . . . . . . . 239 I/O SIGNALS . . . . . . . . . 242 242 243 C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 B. . . . . . . . .3 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT .3. . . . . . . .7 DISABLING HAND BREAK . . . . . . 242 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 c–4 . . . . . . . . . . . . . . . 226 APPENDIX A. . . . . . . . . . . . . .1 B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 241 B. . . . . . . . . . . . . . . . . . . Input/Output Hardware Usable in the R-J3iB Mate Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table of Contents B–81535EN/02 4. . . .

B–81535EN/02 PREFACE PREFACE This manual describes the following models. Model FANUC Robot LR Mate 100iB FANUC Robot LR Mate 200iB FANUC Robot ARC Mate 50iB Abbreviation LR Mate 100iB LR Mate 200iB ARC Mate 50iB p–1 .

I SAFETY PRECAUTIONS .

.

follow all safety precautions when operating a robot and its peripheral devices installed in a work cell.B–81535EN/02 SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS 1 SAFETY PRECAUTIONS For the safety of the operator and the system. 3 .

1. the robot is regarded as still in motion. (4) Provide the peripheral devices with appropriate grounding (Class 1. When the gate is opened and this signal received. Class 2. provide the system with an alarm to indicate visually or aurally that the robot is in motion. Contact our sales office for details. or Class 3). (6) Draw an outline on the floor. In this state. adequate safety precautions must be observed. To ensure operator safety. 4 . (1) Have the robot system operators attend the training courses held by FANUC. install a safety lock so that no one except the operator in charge can turn on the power of the robot. (3) Install a safety fence with a gate so that no operator can enter the work area without passing through the gate. it is possible that the robot is still ready to move state and is waiting for a signal.1. (8) If necessary. Careful consideration must be made to ensure operator safety. the controller stops the robot in an emergency. For connection. FANUC provides various training courses.1. clearly indicating the range of the robot motion. The controller is designed to receive this interlock signal. Equip the gate with an interlock that stops the robot when the gate is opened. (2) Even when the robot is stationary. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–81535EN/02 1. including the tools such as a hand. The following lists the general safety precautions. see Fig. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock. Because it is very dangerous to enter the operating space of the robot during automatic operation. (5) Try to install the peripheral devices outside the work area.1 OPERATOR SAFETY Operator safety is the primary safety consideration. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when an operator enters the work area.

be sure to turn off the power of the robot. Fig.1 Safety Fence and Safety Gate 5 .1. Safety gate which executes with opening the door.B–81535EN/02 SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS (9) When adjusting each peripheral device independently.

EMGIN12. (2) Operate the robot system at a location outside the work area. The robot controller is designed to be connected to an external EMERGENCY STOP button.1. the controller stops the robot operation when the external EMERGENCY STOP button is pressed. turn off the power of the robot controller or press the EMERGENCY STOP button. See the diagram below for connection. a worker who operates the teach pendant is also an operator. With this connection.1 Connection Diagram for External Emergency Stop Switch 6 . Fig. (4) Install an EMERGENCY STOP button within the operator’s reach. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–81535EN/02 1.1. However. (1) If it is not necessary for the robot to operate.1. (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the work area unexpectedly and also to prevent the worker from entering a dangerous area. and then proceed with necessary work. External EMERGENCY STOP button Emergency stop board EMGIN11 EMGIN12 EMGIN21 EMGIN22 Note) Connect between EMGIN1 and EMGIN2 and between EMGIN21 and EMGIN22. EMGIN21 and EMGIN22 are on the emergency stop board. this section does not apply to teach pendant operators.1 Operator Safety The operator is a person who operates the robot system.1. In this sense. EMGIN11.

B–81535EN/02 SAFETY PRECAUTIONS 1. When the mode switch is in the TI position and the enable/disable switch is in the disable position – The robot is brought to an emergency stop regardless of the operation of the deadman switch. EMERGENCY STOP button : Pressing this button always brings the robot to an emergency stop. it is necessary for the operator to enter the work area of the robot. When the mode switch is in the TI position and the enable/disable switch is in the enable position – Releasing the deadman switch brings the robot to an emergency stop. (2) Before teaching the robot. the teach pendant enable switch and the deadman switch also have the following function. The teach pendant operator should be well aware that the safety gate is not functional under this condition and bear full responsibility to ensure that no one enters the fence during teaching. Note)The deadman switch is provided to bring the robot to an emergency stop when the operator releases the teach pendant in an emergency. it is possible for an operator to enter the fence during teach operation without making the robot in the emergency stop condition. check that the robot and its peripheral devices are all in the normal operating condition. FANUC’s teach pendant has a switch for enabling or disabling the robot operation from the teach pendant and a deadman switch in addition to the EMERGENCY STOP button.1. (3) When entering the robot work area and teaching the robot. 7 . be sure to check the location and condition of the safety devices (such as the EMERGENCY STOP button and the deadman switch on the teach pendant). (1) Unless it is specifically necessary to enter the robot work area. In this case. The switches function as follows. the emergency stop factor (normally the safety gate) connected to FENCE11 and FENCE12 of the controller is invalidated. Deadman switch : The function of this switch depends on the state of the enable/disable switch and the mode switch of operator panel. (4) The teach pendant operator should pay careful attention so that no other workers enter the robot work area. the system understands that the combined operations of pressing the teach pendant enable switch and pressing the deadman switch indicates the start of teaching. By pressing the deadman switch while the enable switch is on.2 Safety of the Teach Pendant Operator While teaching the robot. In other words. NOTE In addition to the above. irrespective of the state of the enable/disable switch and the mode switch of operator panel. carry out all tasks outside the area. When the mode switch is in the AUTO position – The enable/disable switch and deadman switch are disabled. It is particularly necessary to ensure the safety of the teach pendant operator. SAFETY PRECAUTIONS 1.

(7) While operating the system in the automatic operation mode. (c) Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–81535EN/02 (5) When entering the robot work area. the teach pendant operator should leave the robot work area. and peripheral device interface send each robot start signal. (a) Run the program for at least one operation cycle in the single step mode at low speed. 8 . execute it in the automatic operation mode. However the validity of each signal changes as follows depending on the mode of the teach pendant enable switch and the mode switch the remote switch on the operator panel. operator panel. the teach pendant operator should enable the teach pendant whenever he or she enters the robot work area. (d) Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble. Operator panel mode switch T1 AUTO AUTO Teach pendant enable switch On Off Off Remote condition Independent Local Remote Teach pendant Allowed to start Not allowed Not allowed Operator panel Not allowed Allowed to start Not allowed Peripheral devices Not allowed Not allowed Allowed to start (6) When a program is completed. make certain that no start command is sent to the robot from any operator panel other than the teach pendant.1. (e) After checking the completeness of the program through the test run above. The teach pendant. while the teach pendant enable switch is off. (b) Run the program for at least one operation cycle in the continuous operation mode at low speed. In particular. be sure to carry out a test run according to the procedure below.

pay utmost attention to the following. such as belt conveyor. if necessary. check that the robot and its peripheral devices are all in the normal operating condition. take care to prevent foreign matter from entering the system. or when any moving device other than the robot is installed. make certain that their escape path is not obstructed. (11) When replacing parts. Lock the power switch. (1) Except when specifically necessary. turn off the power of the controller while carrying out maintenance. the worker should be ready to press the EMERGENCY STOP button at any time.1. turn off the power of the controller and also turn off the circuit breaker to protect against electric shock. have a worker who is familiar with the robot system stand beside the operator panel and observe the work being performed. so that no other person can turn it on. (5) Do not operate the robot in the automatic mode while anybody is in the robot work area. the worker should indicate that the machine is being serviced and make certain that no one starts the robot unexpectedly. be sure to use those specified by FANUC. (6) When it is necessary to maintain the robot alongside a wall or instrument. They may cause a fire or result in damage to the components in the controller. (9) When replacing or reinstalling components. In particular. (3) Before the start of teaching. (10)When handling each unit or printed circuit board in the controller during inspection. (7) When a tool is mounted on the robot. If any danger arises. (2) When disconnecting the pneumatic system.3 Safety During Maintenance For the safety of maintenance personnel.B–81535EN/02 SAFETY PRECAUTIONS 1. 9 . never use fuses or other parts of non-specified ratings. be sure to reduce the supply pressure. (4) If it is necessary to enter the robot work area for maintenance when the power is turned on. SAFETY PRECAUTIONS 1. pay careful attention to its motion. or when multiple workers are working nearby. (8) If necessary.

(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices. particular care must be taken in programming so that they do not interfere with each other. if necessary. and dust. 1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 1.1 Precautions in Programming (1) Use a limit switch or other sensor to detect a dangerous condition and. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–81535EN/02 1. (1) Keep the component cells of the robot system clean. (2) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot does not come into contact with its peripheral devices or tools. and operate the robot in an environment free of grease. even though the robot itself is normal. (4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states. design the program to stop the robot when the sensor signal is received. (3) For a system in which the robot and its peripheral devices are in synchronous motion.2.1.2 Precautions for Mechanism 10 . water.2.

3 Precautions for Mechanisms 11 . and dust.2 Precautions in Programming 1. and operate the robot in an environment free of grease.3. (1) Keep the work area of the robot clean. (1) When the work areas of robots overlap.3 SAFETY OF THE ROBOT MECHANISM 1.B–81535EN/02 SAFETY PRECAUTIONS 1. be sure you know in advance what motion the robot will perform in the jog mode. SAFETY PRECAUTIONS 1. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated. make certain that the motions of the robots do not interfere with each other. set it at an appropriate speed so that the operator can manage the robot in any eventuality.1 Precautions in Operation (1) When operating the robot in the jog mode. water. (2) Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin. (2) Before pressing the jog key.3. 1.3.

1. (2) Provide the end effector with a limit switch.4. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–81535EN/02 1.4 SAFETY OF THE END EFFECTOR 1. carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control.1 Precautions in Programming (1) To control the pneumatic. and control the robot system by monitoring the state of the end effector. 12 . hydraulic and electric actuators.

turn off the power of the controller and turn off the circuit breaker to protect against electric shock. In particular. be sure to reduce the pressure in the piping to zero by turning the pressure control on the air regulator. They may cause a fire or result in damage to the components in the controller. Turn off the power before entering the robot work area for inspection and maintenance. (6) Before restarting the robot. never use fuses or other parts of non-specified ratings. When replacing the parts in the pneumatic system. (5) When replacing parts. be sure to check that no one is in the robot work area and that the robot and its peripheral devices are all in the normal operating state. first press the EMERGENCY STOP button on the operator panel. (2) If it is necessary to enter the robot work area with the power turned on. (3) When replacing or reinstalling components.B–81535EN/02 SAFETY PRECAUTIONS 1. take care to prevent foreign matter from entering the system. SAFETY PRECAUTIONS 1. (4) When handling each unit or printed circuit board in the controller during inspection. be sure to use those specified by FANUC. 13 .5 SAFETY IN MAINTENANCE (1) Never enter the robot work area while the robot is operating.

as the section generates heat.1. then turn the circuit breaker off to avoid electric shock hazards. turn the power to the control unit off. Before starting maintenance.6 (b) High–Temperature Warning Label Description A high voltage is applied to the places where this label is attached. (1) Step–on prohibitive label Fig. (2) High–temperature warning label Fig. 14 . If you have to inevitably touch such a section when it is hot. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–81535EN/02 1. Be careful with servo amplifier and other units because high–voltage places in these units may remain in the high–voltage state for a fixed time.1.6 (a) Step–on Prohibitive Label Description Be cautious about a section where this label is affixed.6 WARNING LABEL Description Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing as well.1. use a protective provision such as heat–resistant gloves.

15 . SAFETY PRECAUTIONS (3) High–voltage warning label Fig. Before working on such a portion.1. In addition.B–81535EN/02 SAFETY PRECAUTIONS 1. turn off the power to the controller and set its circuit breaker to the off position to avoid shock hazards. be careful about servo amplifiers and other electric circuits because a high voltage may remain in them for a certain period of time after the power is turned off.6 (c) High–Voltage Warning Label Description There may be a high voltage in a place with this label.

.

II MAINTENANCE .

.

Maintenance Part : Troubleshooting.B–81535EN/02 MAINTENANCE 1. the terms “power supply module” and “servo amplifier module” refer to the individual modules. The term “servo amplifier” refers to the combination of the power supply module and servo amplifier module. Otherwise. OVERVIEW 1 OVERVIEW This manual describes the maintenance and connection of the R–J3iB Mate robot controller (called the R–J3iB Mate). The servo amplifier α i comprises a power supply module (PSM) and a servo amplifier module (SVM). and the setting. TERM The R–J3iB Mate robot controller uses the FANUC servo amplifier α i series (called the servo amplifier (i). 19 . adjustment. you could injure personnel or damage equipment. In this manual. be sure to turn off the power to the controller or press the EMERGENCY STOP button on the operator panel or teach pendant. and replacement of units Connection Part : Connection of the R–J3iB Mate controller to the robot mechanical unit and peripheral devices. and installation of the controller WARNING Before you enter the robot working area.

2. CONFIGURATION MAINTENANCE B–81535EN/02 2 CONFIGURATION 20 .

1 (a) shows the view of R–J3iB Mate. Fig. CONFIGURATION 2. Fig.2.2.1 EXTERNAL VIEW OF THE CONTROLLER The appearance and components might slightly differ depending on the controlled robot.1 (b) shows the R–J3iB Mate consists of the R–J3iB Mate controller. Teach pendant R–J3iB Mate controller Operator panel Teach pendant cable Fan unit Fig.1 (a) External View of the R–J3iB Mate Controller 21 . application. and options used.B–81535EN/02 MAINTENANCE 2.2.

CONFIGURATION MAINTENANCE B–81535EN/02 Teach pendant Power supply transformer Enable/disable switch Emergency stop for brake button Emergency stop unit Power supply unit Emergency stop board Circuit protector Emergency stop button Mode switch Heat exchange Back plane board Option slot (Process I/O board) Robot control board Servo amplifier module2 (AMP2) Servo amplifier module1 (AMP1) Power supply module (PSM) Fuse MCC Fig.2.1 (b) R–J3iB Mate interior (Front) Table 2.1 Servo amplifier specifications Robot LR Mate 100iB Power supply module A06B–6115–H001 (αPSMR–1i) Servo amplifier module1 A06B–6114–H205 (αSVM–20/20i) L M J1 J2 A06B–6114–H302 (αSVM–10/10/10i) L M N J1 J2 J3 Servo amplifier module2 A06B–6114–H302 (αSVM–10/10/10i) L M N J3 J4 J5 A06B–6114–H302 (αSVM–10/10/10i) L M N J4 J5 J6 LR Mate 200iB ARC Mate 50iB A06B–6115–H001 (αPSMR–1i) 22 .2.

– Backplane board Various control boards are mounted on the backplane board. – Emergency stop unit. CONFIGURATION 2. The input power is connected to the circuit protector in order to protect the equipment from a large current that could result from a problem in the electric system of the control unit or an abnormal input power.2 COMPONENT FUNCTIONS – Robot control printed circuit board This board is equipped with a microprocessor and its peripheral circuitry. The unit contains the power supply unit for converting the AC power to the DC power.B–81535EN/02 MAINTENANCE 2. heat exchanger These components are used to cool the inside of the control unit. data. The panel also has an EMERGENCY STOP button. – Operator panel The operator panel has a port for the serial interface to an external device. – MCC The MCC controls the main power of the servo amplifier. – Fan unit. – Circuit protector This component turns on or off the power. memory. – Teach pendant This unit is used to carry out all operations including robot programming. and brake. magnetic contactor (MCC) of the servo amplifier. and the like. emergency stop printed circuit board This unit controls the emergency stop system. 23 . – Servo amplifier The servo amplifier amplifies the power of the servo amplifier and controls the pulse coder. A servo control circuit is also included. and operator panel control circuit. The liquid crystal display (LCD) of this unit displays the status of the control unit.

clean the fan according to step (d) described below for inspection to be performed every 6 months. return the robot to the specified position. Clean each part. then turn off the controller. medium. (2) Maintenance tools The following maintenance tools are recommended: (a) Measuring instruments AC/DC voltmeter (A digital voltmeter is sometimes required. (c) Check after one month Check that the fan is rotating normally.3 PREVENTIVE MAINTENANCE Daily maintenance and periodic maintenance/inspection ensure reliable robot performance for extended periods of time. CONFIGURATION MAINTENANCE B–81535EN/02 2. and check for any damage or cracks. (d) Periodic inspection performed every six months Remove the top cover. If the fan has dirt and dust built up. Check the controller and peripheral devices for abnormalities. two channels (b) Tools Phillips screwdrivers : Large. and back panel (if possible). louver. Also check the following: (a) Before service operation Check the cable connected to the teach pendant for excessive twisting. (b) After service operation At the end of service operation. clean it. clean each part of the system and check the system parts for any damage or cracks. and small Nut driver set (Metric) Pliers Needle-nose pliers Diagonal cutting pliers 24 . medium. If the ventilation port of the controller is dusty. then remove any dirt and dust from the inside of the transformer compartment. Wipe off dirt and dust from the fan and transformer. and small Standard screwdrivers: Large.) Oscilloscope with a frequency range of 5 MHz or higher. (1) Daily maintenance Before operating the system each day.2.

25 . Refer to the operator ’s manual to release program alarms. TROUBLESHOOTING 3 TROUBLESHOOTING This chapter describes the checking method and corrective action for each error code indicated if a hardware alarm occurs.B–81535EN/02 MAINTENANCE 3.

LED of the power supply module Circuit protector Heat exchange for fan unit (door face) (Corrective action) Secondary side of the circuit protector Fuse 26 .3. replace the fuse. If the fuse on the back of the door has been blown. Circuit protector (on/off switch) Figure (Check 2) Check that the door fan unit and the fan motor of the heat exchanger are rotating and that the LED indication on the power supply module is “–”. TROUBLESHOOTING MAINTENANCE B–81535EN/02 3. Turn on the circuit protector. – Check the fuse on the back of the door. the fuse on the back of the door may have been blown.1 POWER CANNOT BE TURNED ON Check and Corrective action (Check 1) (Corrective action) Check that the circuit protector is on and has not tripped. If the fan motor is not rotating or if the LED of the power supply module is not glowing.

TROUBLESHOOTING 3. the FALM LED glows. the emergency stop unit may be faulty.1 Teach Pendant Cannot be Turned On Check and Corrective action (Check 1) (Corrective action) Check the LCD display and LED indication on the teach pendant.B–81535EN/02 MAINTENANCE 3. – If the fuse FUS4 on the emergency stop board is not blown.1. Replace the emergency stop unit. Figure Teach pendant Emergency stop board FALM LED Fuse FUS4 Emergency stop unit 27 . – Check whether the fuse FUS4 on the emergency stop board is blown. Check the LCD display and LED indication on the teach pendant to see whether the emergency stop unit is faulty. If the fuse is blown. Replace the blown fuse.

a) If the fuse FUS1 has been blown – See Corrective action (1). b) If the fuse FUS1 is not blown – See Corrective action (2). (For the LED indications. see Section 3. Replace the DC/DC converter module.3.” portion of the seven– segment LED glows on the robot control board. a) Problem in the DC/DC converter module Replace the DC/DC converter module. If the “. b) Problem in the DC/DC converter module If the DC/DC converter module gets faulty in the short–circuit mode. TROUBLESHOOTING MAINTENANCE B–81535EN/02 3. Alternatively. Before checking the fuse. the fuse FUS1 on the robot control board may be blown.7.”) Figure (Corrective action) +24V input connector CP5 (Corrective action(1)) DC/DC converter module dot part of seven segment LED (Corrective action(2)) FUS1 7.5A DC24V input fuse 28 .1. turn off the circuit protector. If the FUSE ALARM LED is glowing. Cause of the blowing of the fuse FUS1 and corrective action a) Check whether the device which is connected to the RS–232–C/ RS–422 port and requires the power supply of +24 V is sound. the fuse FUS1 may be blown.” portion is not glowing. The fuse FUS1 is provided on the robot control board.2 Initial Screen Remains on the Teach Pendant Check and Corrective action (Check 1) Check that the “. b) Problem in the robot control board Replace the robot control board. “TROUBLESHOOTING USING LEDS. the DC/DC converter module may be damaged. FUS1 is blown.

or a reset. the alarm occurrence screen displays the message “PAUSE or more serious alarm has not occurred. TROUBLESHOOTING 3. Press F3 [HIST].2 Alarm Occurrence Screen and Alarm History Screen Display Procedure 29 . the display begins with the most recent alarm.B–81535EN/02 MAINTENANCE 3. It is possible to disable PAUSE and some of more serious alarms from being displayed by setting the $ER_NOHIS system variable appropriately.3. NONE.2 ALARM OCCURRENCE SCREEN The alarm occurrence screen displays only the alarm conditions that are currently active. It will not display WARN. The alarm occurrence screen is intended to display PAUSE or more serious alarms.” The alarm occurrence screen displays only the alarm conditions (if any) that occur after the most recently entered alarm reset signal. To erase all alarm displays from the alarm occurrence screen. If an alarm has a cause code. If two or more alarms have occurred. it is displayed below the line indicating the alarm. Press the screen selection key to select [4 ALARM]. Alarm history screen display Fig. If an alarm reset signal is input to reset the alarm conditions. Up to 100 lines can be displayed. Press the CLEAR key (+ shift) on the alarm history screen. Press the alarm key. Automatic alarm display upon occurrence Alarm occurrence screen display Press F3 [ACTIVE].

To view messages that are currently not on the screen. press the F5.L 00000110 Alarm 1/25 1 INTP–224 (SAMPLE1. (3) To display the alarm detail screen. 30 . then press F4. press F5. press and hold down the SHIFT key. PREV (5) To delete all the alarm histories.3. CLEAR F4 HELP SHIFT NOTE When system variable $ER_NOHIS = 1. 7) Jump label is fail MEMO–027 Specified line does not exist Alarm JOINT 30 % 1/25 1 INTP–224 (SAMPLE1. NONE alarms or WARN alarms are not recorded. You will see a screen similar to the following 3 4 ALARM 5 I/O MENUS INTP–224 (SAMPLE1. WARN alarms. [HELP]. When $ER_NOHIS=2. HELP. When $ER_NOHIS=3. press the PREV key. resets. then press the right arrow key. 7) Jump label is 2 SRVO–002 Teach pendant E–stop [ TYPE ] CLEAR HELP (4) To return to the alarm history screen. (2) Select [ALARM]. and NONE alarms are not recorded. [CLEAR]. 7) Jump label is 2 SRVO–002 Teach pendant E–stop 3 R E S E T 4 SRVO–027 Robot not mastered(Group:1) 5 SYST–026 System normal power up [ TYPE ] CLEAR HELP NOTE The latest alarm is assigned number 1. resets are not recorded in the alarm history. 7) Jump label is fail INTP–224 (SAMPLE1. CLEAR HELP F5 INTP–224 (SAMPLE1. 7) Jump label is fail MEMO–027 Specified line does not exist 30–MAY–44 07:15 STOP. TROUBLESHOOTING MAINTENANCE B–81535EN/02 Displaying the alarm history/alarm detail information Step (1) Press the MENUS key to display the screen menu.

4 ALARM F1 [TYPE] Alarm : Active F1 [TYPE] F3 HIST Alarm : HIST F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP DETAIL Alarm F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP 31 . TROUBLESHOOTING The following map indicates teach pendant operations used to check an alarm.B–81535EN/02 MAINTENANCE 3.

the state is indicated as “TRUE”. If the EMERGENCY STOP board is pressed. This item indicates the state of the hand safety joint. This item indicates whether the DEADMAN switch on the teach pendant is grasped. If the EMERGENCY STOP signal is input. If the safety fence is open. an alarm occurs. This item indicates the state of the air pressure. the state is indicated as “TRUE”. and the safety joint is opened. If the hand interferes with a workpiece or anything like this. the screen indicates whether each safety signal is currently on. If the air pressure is not higher than the specified value. To be specific. This item indicates whether the teach pendant is operable. This item indicates whether the current position of the robot is out of the operation range. If the deadman switch is released when the teach pendant is operable. Press F1. If any robot articulation goes out of the operation range beyond the overtravel switch. the state is indicated as “TRUE”. Select Safety Signal. The abnormal air pressure signal is connected to the air pressure sensor. the state is indicated as “TRUE”. If the EMERGENCY STOP board is pressed. This item indicates the state of the external emergency stop signal. On this screen. TROUBLESHOOTING MAINTENANCE B–81535EN/02 3. JOINT 30% STATUS FALSE FALSE FALSE FALSE TRUE TRUE FALSE FALSE FALSE 1/11 SIGNAL NAME 1 2 3 4 5 6 7 8 9 SOP E–Stop: TP E–stop: Ext E–Stop: Fence Open: TP Deadman: TP Enable: Hand Broken: Over Travel: Low Air Alarm: SYSTEM Safety [TYPE] 32 . the state is indicated as “TRUE”. You will see a screen similar to the following. causing the servo power to be switched off. the state is indicated as “TRUE”. and the DEADMAN switch is grasped. Select STATUS on the next page. it is impossible to change the state of any safety signal. causing the servo power to be switched off. an alarm occurs. In this case.3 Safety Signals Description This item indicates the state of the emergency stop button on the operator panel. Table 3. If the teach pendant is operable. the state is indicated as “TRUE”. [TYPE] to display the screen switching menu.3. Teach pendant operable Hand broken Robot overtravel Abnormal air pressure Step (1) (2) (3) (4) Press the MENUS key to display the screen menu. This item indicates the state of the safety fence. the state is indicated as “TRUE”.3 SAFETY SIGNALS Safety signal Operator panel emergency stop Teach pendant emergency stop External emergency stop Fence open Deadman switch The safety signal screen indicates the state of signals related to safety. This item indicates the state of the emergency stop button on the teach pendant. In this case. an alarm occurs. the state is indicated as “TRUE”. If the teach pendant is operable. causing the servo power to be switched off.

jig position mastering should be performed later. System variable $MASTER_ENB must be set to 1 or 2. [TYPE] LOAD RES_PCA DONE F1 (5) Move the robot by jog feed to the mastering position. After zero–degree position mastering is used. Press F1. while item (2) requires zero–degree or jig position mastering. SYSTEM Variables 57 $MASTER_ENB JOINT 10% 57/136 1 Condition Step (1) (2) (3) (4) 9 USER 0 –– NEXT –– Press <MENUS>. Select SYSTEM.B–81535EN/02 MAINTENANCE 3. JOINT 30% 1 FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE SYSTEM Master/Cal MENUS 5 POSITION 6 SYSTEM 7 2 3 4 5 6 Master/Cal TYPE Press ’ENTER’ or number key to select. (Zero–degree position mastering is just for quick–fix purposes.) The mastering procedure is described below. Release the brake on the manual brake control screen if necessary. Item (1) requires simplified mastering. TYPE. refer to an applicable maintenance manual of mechanical unit or operator ’s manual of control unit. For details. 33 . TROUBLESHOOTING 3. or (2) The pulse coder is replaced. NOTE Mastering can not be performed until axis is rotated enough to establish a pulse. Select Master/Cal you will see a screen similar to the following.4 MASTERING Mastering is needed if: (1) The SRVO 062 BZAL or SRVO 038 pulse mismatch alarm occurs.

000> [ TYPE ] LOAD RES_PCA DONE YES NO F4 (8) Press F5 “DONE”. Mastering data is set. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER Master at master position? [NO] Master at master position? [NO] [ TYPE ] YES ENTER SYSTEM Master/Cal JOINT 30 % NO F4 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <122000309> <2000319> [ TYPE ] LOAD RES_PCA DONE (7) Select “6 CALIBRATE” and press the F4 key (yes).000> <–25. Calibration is performed.000> <–15. turn the power off. Alternatively. after mastering.3. DONE F5 34 . TROUBLESHOOTING MAINTENANCE B–81535EN/02 (6) Select “1 FIXTURE POSITION MASTER” and press the F4 key (yes). to perform positioning.000> <0.000> <40. Calibration is performed whenever the power is turned on. 5 SET QUICK MASTER REF 6 CALIBRATE ENTER Calibrate? [NO] Calibrate? [NO] [ TYPE ] SYSTEM Master/Cal JOINT 30 % 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <10.000> <5. then turn it on again.

(Action 3) Replace the emergency stop unit. (Action 1) Release the emergency stop button pressed on the operator panel. make a backup copy of all the programs and settings of the control unit.5 TROUBLESHOOTING USING THE ERROR CODE (1) SRVO–001 SVAL1 Operator panel E–stop (Explanation) The EMERGENCY STOP button on the operator panel is pressed.3. TROUBLESHOOTING 3. (Action 2) Release the EMERGENCY STOP button on the operator panel.5 (1) (a) SRVO–001 SVAL1 Operator panel E–stop 35 . (Action 4) Replace the robot control board.B–81535EN/02 MAINTENANCE 3. Before taking (Action 4). Emergency stop button Operator panel Robot control board Emergency stop unit Fig.

but the deadman switch is not pressed. (Action 2) Replace Teach Pendant.3. (Action 2) Replace the teach pendant. (Action 1) Press the deadman switch to run the robot.5 (3) SRVO–001 SVAL1 Deadman switch released 36 . TROUBLESHOOTING MAINTENANCE B–81535EN/02 (2) SRVO–002 SVAL1 Teach pendant E–stop (Explanation) The emergency stop button on the operator’s Teach Pendant was pressed.3.5 (2) SRVO–002 SVAL1 Teach pendant E–stop (3) SRVO–003 SVAL1 Deadman switch released (Explanation) The teach pendant is enabled. Emergency stop button Fig.3. Deadman switch Fig. (Action 1) Release the emergency stop button on the teach pendant.

Replace the robot control board. do not short–circuit this signal to disable it because the operation is dangerous. make safety provisions separately. Replace the operator panel. the mode switch may be faulty.B–81535EN/02 MAINTENANCE 3. FENCE21 and FENCE22. (Action 1) When the safety fence is connected. Short connection boards: two positions (terminal blocks located on the right when viewing from the front) Emergency stop unit Fig. When this signal must be temporarily short–circuited. the door of the safety fence is open. If the safety fence is connected between FENCE11 and FENCE12 and between FENCE21 and FENCE22. TROUBLESHOOTING (4) SRVO–004 SVAL1 Fence open (Explanation) In AUTO mode. (Action 4) (Action 5) (Action 6) When AUTO mode is not entered even though the mode switch is set to AUTO. short–circuit between FENCE11 and FENCE12 and between FENCE21 and FENCE22. there is no short circuit between FENCE11 and FENCE12 and between FENCE21 and FENCE22 on the terminal block TBEB5 of the emergency stop board. (Action 2) Check the cables and switches connected to FENCE11. (Action 3) When this signal is not used.3. close the door. make a backup copy of all the programs and settings of the control unit. Replace the emergency stop unit. Before taking (Action 6). FENCE12.5 (4) SRVO–004 SVAL1 Fence open 37 . NOTE In the system that uses the fence signal.

3. check that the connector CRM82 of the robot control board is securely connected. However. (Action 1) Check the robot interconnection cable (RMP) for the following. Before taking (Action 2). 2) The connector is securely connected. Next. 3) The cable is free from a break and ground fault. In addition. Robot control board Fig. 1) The male and female connection pins are not twisted or are not loose. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (5) SRVO–005 SVAL1 Robot overtravel (Explanation) This alarm should not occur because no overtravel input signal is provided.5 (5) SRVO–005 SVAL1 Robot overtravel 38 . check that the RMP cable is sound and free from a break or visible twist. (Action 2) Replace the robot control board. make a backup copy of all the programs and settings of the control unit. this alarm can be caused by an abnormal overtravel input signal across the robot interconnection cable and robot control board.3.

the HBK signal line of the robot interconnection cable has a break or ground fault. Before taking (Action 3). 2) The connector is securely connected. if any. 1) Replace the safety joint.B–81535EN/02 MAINTENANCE 3. is broken. check that the connector CRM82 of the robot control board is securely connected. check that the RMP cable is sound and free from a break or visible twist. 3) The cable is free from a break and ground fault.3. If no joint is broken. (Action 3) Replace the robot control board. make a backup copy of all the programs and settings of the control unit. (Action 1) Holding down the shift key. Next. Robot control board Fig. TROUBLESHOOTING (6) SRVO–006 SVAL1 Hand broken (Explanation) The safety joint. (Action 2) Check the robot interconnection cable (RMP) for the following. In addition. 2) Examine the cable. 1) The male and female connection pins are not twisted or are not loose. carry out jog feed to move the tool to the work area. This releases the alarm. Keeping on holding down the shift key.5 (6) SRVO–006 SVAL1 Hand broken 39 . press the alarm release button.

make a connection between EMGIN11 and EMGIN12 and a connection between EMGIN21 and EMGIN22. an additional safety provision must be provided.3. (Action 1) If an external emergency stop switch is connected. If an external emergency stop switch is connected across EMGIN11 and EMGIN12/EMGIN21 and EMGIN22. If it is necessary to run the robot by short–circuiting the signal even temporarily. the switch has been pressed. or disable.5 (7) SRVO–007 SVAL1 External E–stop 40 . releases the switch.3. (WARNING) (Action 4) Replace the emergency stop unit. WARNING Do NOT short–circuit. as it is very dangerous. (Action 2) Check the switch and cable connected to EMGIN11 and EMGIN12 and to EMGIN21 and EMGIN22. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (7) SRVO–007 SVAL1 External E–stop (Explanation) EMGIN11 and EMGIN12/EMGIN21 and EMGIN22 on the terminal block TBEB5 of the emergency stop board are not short–circuited. Short connection boards: two positions (terminal blocks located on the left when viewing from the front) Emergency stop unit Fig. this signal in a system in which the External emergency stop input signal is in use. (Action 3) When this signal is not used.

(Action 2) Replace the robot control board. Before taking (Action 2). The input signal is located on the end effector of the robot.5 (8) SRVO–009 SVAL1 Pneumatic pressure alarm 41 . If the peripheral device are normal. (Action 1) If an abnormal air pressure is detected. Robot control board Fig. check the robot connection cable. Refer to the manual of your robot.3.B–81535EN/02 MAINTENANCE 3. TROUBLESHOOTING (8) SRVO–009 SVAL1 Pneumatic pressure alarm (Explanation) An abnormal air pressure was detected. make a backup copy of all the programs and settings of the control unit. check the cause.

3. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (9) SRVO–014 WARN Fan motor abnormal (Explanation) A fan motor in the backplane unit is abnormal.3. Fan motor Fig. Replace them if necessary.5 (9) SRVO–014 WARN Fan motor abnormal 42 . (Action) Check the fan motor and its cables.

Fan motor (on the heat exchange) Fan motor (door face) Robot control board Fig.3. (Action 1) If the ambient temperature is higher than specified (45°C). check it and its cables. cool down ambient temperature. (Action 2) If the fan motor is not running.5 (10) SRVO–015 SVAL1 SYSTEM OVER HEAT 43 . TROUBLESHOOTING (10)SRVO–015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j) (Explanation) The temperature in the control unit exceeds the specified value. (Action 3) If the thermostat on the robot control board is defective. Replace them if necessary. replace the robot control board.B–81535EN/02 MAINTENANCE 3.

(Action 7) Replace the axis control card on the robot control board. 44 . the host will not issue this alarm (SRDY off).3. external emergency stop input.) If the servo amplifier magnetic contactor cannot be turned on when directed so. fence input) for a possibility of an instantaneous interruption. (HRDY is a signal with which the host detects the servo system whether to turn on or off the servo amplifier magnetic contactor. this alarm occurs. If a servo amplifier alarm has been detected. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (11) SRVO–021 SVAL1 SRDY off (Group : i Axis : j) (Explanation) The HRDY is on and the SRDY is off. Therefore. operator panel emergency stop. the servo amplifier module may be faulty. (Action 3) Check the EMERGENCY STOP line (teach pendant emergency stop. If the voltage is 170 VAC or lower. this alarm indicates that the magnetic contactor cannot be turned on for an unknown reason. (Action 5) If an alarm occurs on all axes. the power supply module may be faulty. teach pendant deadman switch. (Action 2) Check that CRR78 of the emergency stop board and CX3 and CX4 of the power supply module are securely connected. (Action 6) If an alarm occurs on a particular axis. Check the cables of the emergency stop board and power supply module for a break. adjust the input voltage. it is most likely that a servo amplifier alarm has occurred. Replace the power supply module. If the software cannot judge the cause of the alarm at an instantaneous interruption of the EMERGENCY STOP line. although there is no other cause of an alarm. (Action 1) Measure the voltage of the 200–VAC input to the power supply module. Replace the servo amplifier module controlling the axis. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on. teach pendant enable/disable switch. (Action 4) Replace the emergency stop unit.

5 (11) SRVO–021 SVAL1 SRDY off 45 . TROUBLESHOOTING Emergency stop unit Axis control card Robot control board Servo amplifier module Power supply module Fig.3.B–81535EN/02 MAINTENANCE 3.

(HRDY is a signal with which the host directs the servo system whether to turn on or off the servo amplifier magnetic contactor. the servo amplifier module may be faulty. the SRDY is already on.5 (12) SRVO–022 SVAL1 SRDY on 46 . Replace the power supply module. the power supply module may be faulty. (Action 1) Replace the axis control card on the robot control board. Replace the servo amplifier module controlling the axis. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on.3.3. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (12)SRVO–022 SVAL1 SRDY on (Group : i Axis : j) (Explanation) When the HRDY is about to go on. (Action 2) If an alarm occurs on all axes. Robot control board Servo amplifier module Power supply module Axis control card Fig. (Action 3) If an alarm occurs on a particular axis.

) (Action 5) If the line voltage is 170 VAC or higher. TROUBLESHOOTING (13)SRVO–023 SVAL1 Stop error excess (Group : i Axis : j) (Explanation) When the servo is at stop. (Action 1) Check whether the motor brake has been released. (If the voltage input to the servo amplifier becomes low. the motor becomes unable to follow the command. (Action 3) Check to see if the load is greater than the rating.) (Action 4) Check each phase voltage of the CZ1 connector of the three–phase power (200 VAC) input to the servo amplifier.B–81535EN/02 MAINTENANCE 3. As a result. (Action 6) Check disconnection of robot connection cable (RMP). (Action 2) Make sure that the servo amplifier CZ2L to N are connected tightly. If it is 170 VAC or lower. If greater. As a result the motor may become unable to follow the command. check the line voltage.5 (13) SRVO–023 SVAL1 Stop error excess 47 . Servo amplifier module Power supply module Fig. and an alarm is issued. hence possibly an alarm. (If the load is too greater. replace the power supply module or servo amplifier module. reduce it to within the rating. the torque output also becomes low. the position error is abnormally large. the torque required for acceleration / deceleration becomes higher than the capacity of the motor. (Action 7) Replace the motor.3.

48 .3. $INPOS _ TIME) elapsed. 2. Each actual axis speed is clamped to the maximum speed. its position error is greater than a specified value ($PARAM _ GROUP. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (14)SRVO–024 SVAL1 Move error excess (Group : i Axis : j) (Explanation) When the robot is running. (Action) Disable [Servo–off during pause] on the general setting menu (Select Setting general).$MOT_SPD_LIM) was specified.Supply power. (19)SRVO–031 SVAL1 User servo alarm (Group : i) (Explanation) An user servo alarm occurred. (20)SRVO–033 WARN Robot not calibrated (Group : i) (Explanation) An attempt was made to set up a reference point for simplified adjustment. (21)SRVO–034 WARN Ref pos not set (Group : i) (Explanation) An attempt was made to perform simplified adjustment. (Action) Master the robot. (Action) Set up a simplified adjustment reference point on the positioning menu. Disable the function if it is not necessary. The actual motor speed is clamped to the maximum speed. (Action) Turn on the *IMSTP signal. (15)SRVO–025 SVAL1 Motn dt overflow (Group : i Axis : j) (Explanation) The specified value is too great. (18)SRVO–030 SVAL1 Brake on hold (Group : i) (Explanation) This alarm occurs when the robot pauses. (23)SRVO–036 SVAL1 Inpos time over (Group : i Axis : j) (Explanation) The robot did not get to the effective area ($PARAM _ GROUP. $MOVER _ OFFST or $PARAM _ GROUP. (Action 2) Take the same actions as described for the above alarm. (Action 1) Check the robot for binding axis. (22)SRVO–035 WARN2 Joint speed limit (Group : i Axis : j) (Explanation) A value higher than the maximum axis speed ($PARAM_GROUP. (Action) Take the same actions as for SRVO–23 (large position error at a stop). (Action) Calibrate the robot. if the brake on hold function has been enabled ($SCR. but the robot had not been calibrated. $BRKHOLD _ ENB = 1). 1. It is likely that the robot cannot follow the speed specified by program. but the reference point had not been set up.Set up a simplified adjustment reference point using [Positioning] on the positioning menu. (16)SRVO–026 WARN2 Motor speed limit (Group : i Axis : j) (Explanation) A value higher than the maximum motor speed ($PARAM_GROUP.$ STOPTOL) even after the position check monitoring time ($PARAM _ GROUP. but the necessary adjustment had not been completed. (17)SRVO–027 WARN Robot not mastered (Group : i) (Explanation) An attempt was made to calibrate the robot. $TRKERRLIM).$JNTVELLIM) was specified. (24)SRVO–037 SVAL1 Imstp input (Group : i) (Explanation) The *IMSTP signal for a peripheral device interface was input.

7. It might be necessary to remaster the robot. 5. Press RESET. This alarm is asserted after exchange the pulsecoder or battery for back up of the pulsecoder data or loading back up data to the Robot control board. If the controller is still faulted with additional servo–related errors. TROUBLESHOOTING (25)SRVO–038 SVAL2 Pulse mismatch (Group : i Axis : j) (Explanation) The pulse count obtained when power is turned off does not match the pulse count obtained when power is applied. Press F3. 2. (Action) Cold start the controller. PES–PCA and YES. Select SYSTEM. 49 . 3. (26)SRVO–041 SVAL2 MOFAL alarm (Group : i Axis : j) (Explanation) The servo value was too high. cold start the controller. Press MENUS. 6.B–81535EN/02 MAINTENANCE 3. Execute mastering. The fault condition should reset. 4. (Action) Perform Absolute Pulse Coder reset and remaster robot (RES–PCA) 1. Select MASTER/CAL. Press F1 [TYPE].

check the line voltage. If it is higher than the rating.3. Power supply module Fig. (Action 3) Replace the power supply module. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (27)SRVO–044 SVAL1 HVAL alarm (Group : i Axis : j) (Explanation) The DC voltage (DC link voltage) of the main circuit power supply is abnormally high. (If the three–phase input voltage is higher than 253 VAC. (If the machine load is higher than the rating. the accumulation of regenerative energy might result in the HVAL alarm even when the three–phase input voltage is within the rating. reduce it to within the rating.3. (Action 1) Check the three–phase input voltage at the power supply module. high acceleration/deceleration can result in this alarm.) (Action 2) Check that the load weight is within the rating. The LED indication on the power supply module is “7” (HVAL).5 (27) SRVO–044 SVAL1 HVAL alarm 50 . If it is 253 VAC or higher.

Before taking (Action 4). Check each item in detail. and “d”. and W and U with a ohmmeter with a very low resistance range. the motor. robot interconnection cable. and check the insulation of each Robot connection cable (Motor power) (U. Robot control board Servo amplifier module Fig. If error occurs. make a backup copy of all the programs and settings of the control unit. or W) and the GND line. TROUBLESHOOTING (28)SRVO–045 SVAL1 HCAL alarm (Group : i Axis : j) (Explanation) Abnormally high current flowed in the main circuit of the servo amplifier module. robot interconnection cable.5 (28) SRVO–045 SVAL1 HCAL alarm 51 . If there is a short–circuit.B–81535EN/02 MAINTENANCE 3. or intra–robot cable is defective. or intra–robot cable is defective. The LED indications on the servo amplifier modules are “b”. replace the servo amplifier. (Action 1) Disconnect the Robot connection cable (Motor power) from the connector CZ2 of the servo amplifier module. (Action 4) Replace the robot control board. Check them and replace them if necessary. V and W. V.3. and measure the resistance between the U and V. (Action 2) Disconnect the Robot connection cable (Motor power) from the servo amplifier module connector (CZ2). If the resistances at these three places are different from each other. (Action 3) Disconnect the Robot connection cable (Motor power) from the servo amplifier module connector (CZ2). “C”. the motor.

If it is 170 VAC or lower. (Action 5) Replace the motor.3. Servo amplifier module Power supply module Fig. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (29)SRVO–046 SVAL2 OVC alarm (Group : i Axis : j) (Explanation) This alarm is issued to prevent the motor from thermal damage that might occur when the root meant square current calculated within the servo system is out of the allowable range.3.5 (29) SRVO–046 SVAL2 OVC alarm 52 . (Action 3) Replace the power supply module and servo amplifier module. (Action 2) Check each phase voltage of the three–phase input power (200 VAC for the power supply module. check the line voltage. (Action 1) Check the operating conditions for the robot and relax the service conditions. (Action 4) Check the robot connection cable (RMP).

OVL. and the separate regenerative resistor. 2) OVC and OVL alarms (overcurrent and overload alarms) The OVC and OVL alarms are intended to prevent overheat that may lead to the burnout of the motor winding. becomes higher than the time constant of the thermal relay. if the motor repeats to start and stop within a short time as shown in Fig. The OVL alarm occurs when each built–in thermal relay detects a temperature higher than the rated value. the temperature rise in the motor is steeper than that in the thermal relay. The OVC alarm is issued based on this estimated temperature. This method estimates the motor temperature with substantial accuracy. Temperature at which the winding starts to burn Time Fig. Thermal time constant of the thermal relay is low. and HC alarms and describes the purpose of each alarm. because these two components are different in material. if the motor frequently repeats to start and stop. and HC alarms Overview This section points out the differences among the OVC. Therefore. software is used to monitor the current in the motor constantly in order to estimate the temperature of the motor. Alarm detection section Abbreviation Designation Overcurrent alarm Overload alarm Detection section Servo software Thermal relay in the motor OHAL2 Thermal relay in the servo amplifier OHAL1 Thermal relay in the separate regenerative discharge unit DCAL Servo amplifier OVC OVL HC High current alarm Purpose of each alarm 1) HC alarm (high current alarm) If high current flow in a power transistor momentarily due to abnormality or noise in the control circuit. The HC alarm is intended to prevent such failures. Temperature Start Stop Start Stop Start Thermal time constant of the motor is high. For example. structure. this method is not necessarily perfect to prevent these failures.B–81535EN/02 MAINTENANCE 3. thus causing the motor to burn before the thermal relay detects an abnormally high temperature. or the magnet of the motor might be degaussed. and dimension.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles To prevent the above defects. the breakdown of the servo amplifier transistor. OVL. the power transistor and rectifier diodes might be damaged. However. which has a large mass. so it can prevent the failures described above. TROUBLESHOOTING Reference Relationships among the OVC. 1. 53 . the thermal time constant of the motor.

2 is taken into consideration for the OVC alarm. a double protection method is used. The relationship between the OVC and OVL alarms is shown in Fig 2. The motor might not be hot even if the OVC alarm has occurred. etc. The LED indication on the servo amplifier module is “2” (LVAL).3. do not change the parameters to relax protection.5 (30) SRVO–047 SVAL1 LVAL alarm 54 .2 Relationship between the OVC and OVL alarms NOTE The relationship shown in Fig. Servo amplifier module Fig. Current Protection area for the motor and servo amplifier Protection by the OVL Limit current Protection by the OVC Rated continuous current Time Fig. In this case. (30)SRVO–047 SVAL1 LVAL alarm (Group : i Axis : j) (Explanation) The control power voltage (+5 V. TROUBLESHOOTING MAINTENANCE B–81535EN/02 To sum up. and the OVL alarm is used for protection from long–term overload.3.) on the servo amplifier module is too low. the OVC alarm is used for protection from a short–time overcurrent. (Action 1) Replace the servo amplifier module.

Servo amplifier module Power supply module Fig.3.5 (31) SRVO–049 SVAL1 OHAL1 alarm 55 . This alarm indicates that any of the power supply module and servo amplifier modules is faulty. replace the power supply module. (Action 1) If this alarm occurs in relation to all axes.B–81535EN/02 MAINTENANCE 3. (Action 2) If this alarm occurs in relation to a specific axis. TROUBLESHOOTING (31)SRVO–049 SVAL1 OHAL1 alarm (Group : i Axis : j) (Explanation) This alarm does not occur when the power supply module and serve amplifier modules used with the R–J3iB Mate are under normal conditions. replace the servo amplifier module that controls the axis.

reduce it to within the rating.) (Action 4) Check the phase voltage of the three–phase input power (200 VAC) to the power supply module. If it is higher than the rating. check the line voltage. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (32)SRVO–050 SVAL1 CLALM alarm (Group : i Axis : j) (Explanation) The disturbance torque estimated by the servo software is abnormally high.5 (32) SRVO–050 SVAL1 CLALM alarm 56 . (Action 2) Make sure that the load setting is correct. If it has. possibly resulting in this alarm being detected. (Action 3) Check that the load weight is within the rating. (If the robot is used out of its usable range. reset the robot and jog–feed it to recover from the collision.) (Action 1) Check that the robot has collided with anything. Servo amplifier module Power supply module Fig.3. If it is 170 VAC or lower.3. (A collision has been detected. (Action 5) Replace the power supply module and the servo amplifier module. the estimated disturbance torque becomes abnormally high.

3.5 (33) SRVO–051 SVAL2 CUER alarm 57 . Servo amplifier module Fig. (Action) Replace the servo amplifier module. TROUBLESHOOTING (33)SRVO–051 SVAL2 CUER alarm (Group : i Axis : j) (Explanation) The offset of the current feedback value is abnormally high.B–81535EN/02 MAINTENANCE 3.

TROUBLESHOOTING MAINTENANCE B–81535EN/02 (34)SRVO–054 DSM Memory Error (Explanation) An access to the axis control card on the robot control board memory fails.3. (Action) Replace the axis control card. Robot control board Servo amplifier module Axis control card Fig.5 (34) SRVO–054 DSM Memory Error 58 .3.

Robot control board Servo amplifier module Axis control card Fig.3. Failure to perform this could result in damage to equipment or lost data. (Action 2) Replace the axis control card on the robot control board. perform a complete controller back–up to save all your programs and settings.5 (35) SRVO–055 SVAL2 FSSB com error 1 59 . Before continuing to the next step.B–81535EN/02 MAINTENANCE 3. (Action 1) Check the communication cable (optical fiber) between the robot control board and servo amplifier. TROUBLESHOOTING (35)SRVO–055 SVAL2 FSSB com error 1 (Group : i Axis : j) (Explanation) A communication error has occurred between the robot control board and servo amplifier. (Action 3) Replace the servo amplifier module. (Action 4) Replace the robot control board. Replace it if it is faulty.

3. (Action 3) Replace the servo amplifier module. Replace it if it is faulty. (Action 4) Replace the robot control board. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (36)SRVO–056 SVAL2 FSSB com error 2 (Group : i Axis : j) (Explanation) A communication error has occurred between the robot control board and servo amplifier. perform a complete controller back–up to save all your programs and settings. (Action 1) Check the communication cable (optical fiber) between the robot control board and servo amplifier. Failure to perform this could result in damage to equipment or lost data.5 (36) SRVO–056 SVAL2 FSSB com error 2 60 . (Action 2) Replace the axis control card on the robot control board.3. Robot control board Servo amplifier module Axis control card Fig. Before continuing to the next step.

Replace it if it is faulty. (Action 4) Replace the axis control card on the robot control board. (Action 3) Check the communication cable (optical fiber) between the robot control board and servo amplifier. (Action 1) Check whether fuse FU1 in the power supply module unit has blown.5 (37) SRVO–057 SVAL2 FSSB disconnect 61 . (+5V ground fault) Robot control board Servo amplifier module Power supply module Axis control card Fig.B–81535EN/02 MAINTENANCE 3. (Action 5) Replace the power supply module and the servo amplifier module. (Action 6) Replace the robot control board. Before continuing to the next step. (Action 2) Check whether fuse FU1 in the servo amplifier module has blown. Failure to perform this could result in damage to equipment or lost data. (Action 7) Check the RMP cable of robot connection cable. TROUBLESHOOTING (37)SRVO–057 SVAL2 FSSB disconnect (Group : i Axis : j) (Explanation) Communication was interrupted between the robot control board and servo amplifier.3. perform a complete controller back–up to save all your programs and settings.

(Action 6) If the seven–segment LED on the servo amplifier module is glowing.6. perform a complete controller back–up to save all your programs and settings. If they are on. If the seven–segment LED on the servo amplifier module is not glowing. (Action 5) Replace the axis control card on the robot control board. replace the servo amplifier module. Replace it if it is faulty. replace the power supply module. Robot controll board Servo amplifier module Power supply module Axis control card Fig.” (Action 2) Check whether seven segment LEDs on the servo amplifier module are on. perform “Action 3” and all actions that follow it. (Action 4) Check the communication cable (optical fiber) between the robot control board and servo amplifier module. perform “Action 4” and all actions that follow it. see Section 3. (Action 7) Replace the robot control board.5 (38) SRVO–058 SVAL2 FSSB init error 62 . Before continuing to the next step. Failure to perform this could result in damage to equipment or lost data. “Troubleshooting for Blown Fuse.3. (Action 1) Check whether fuse FU1 in the power supply module have blown. If they have blown.3. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (38)SRVO–058 SVAL2 FSSB init error (Group : i Axis : j) (Explanation) Communication was interrupted between the robot control board and servo amplifier module. If they are not on. (Action 3) Check whether connector CX1 on the power supply module is securely connected.

B–81535EN/02 MAINTENANCE 3. (42)SRVO–063 SVAL2 RCAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal counter). CRCERR. (Action) Remove the cause of the alarm. Servo amplifier module Power supply module Fig. (Action) Replace the pulse coder. Make sure they are installed correctly. set the system variable ($MCR. Mastering is required. (Action 2) Replace the power supply module and the servo amplifier module. perform actions associated with DTERR. (Action) Replace the pulse coder. 63 .5 (39) SRVO–059 SVAL2 Servo amp init error (40)SRVO–061 SVAL2 CKAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal count clock). perform actions associated with DTERR. NOTE In this case. or STBERR first. CRCERR. A probable cause is a broken battery cable or no batteries in the robot. (41)SRVO–062 SVAL2 BZAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if battery for pulse coder absolute-position backup is empty. (Action 1) Check all connectors on the PSM and SVM.3. NOTE In this case. or STBERR first. then turn the power off and on again. TROUBLESHOOTING (39)SRVO–059 SVAL2 Servo amp init error (Explanation) Servo amplifier initialzation is failed.$SPC RESET) to TRUE.

3. TROUBLESHOOTING

MAINTENANCE

B–81535EN/02

(43)SRVO–064 SVAL2 PHAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the phase of the pulses generated in the pulse coder is abnormal. (Action) Replace the pulse coder.
NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm.

(44)SRVO–065 WARN BLAL alarm (Group : i Axis : j) (Explanation) The battery voltage for the pulse coder is lower than the rating. (Action) Replace the battery. (If this alarm occurs, turn on the AC power and replace the battery as soon as possible. A delay in battery replacement may result in the BZAL alarm being detected. In this case, the position data will be lost. Once the position data is lost, mastering will become necessary. (45)SRVO–066 SVAL2 CSAL alarm (Group : i Axis : j) (Explanation) The ROM in the pulse coder is abnormal. (Action) Replace the pulse coder.
NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm.

(46)SRVO–067 SVAL2 OHAL2 alarm (Group : i Axis : j) (Explanation) The temperature inside the pulse coder or motor is abnormally high, and the built–in thermostat has operated. (Action 1) Check the operating conditions for the robot and relax the service conditions. (Action 2) When power is supplied to the motor after it has become sufficiently cool, if the alarm still occurs, replace the motor. (47)SRVO–068 SVAL2 DTERR alarm (Group : i Axis : j) (Explanation) The serial pulse coder does not return serial data in response to a request signal. – See actions on SRVO–070 (48)SRVO–069 SVAL2 CRCERR alarm (Group : i Axis : j) (Explanation) The serial data has disturbed during communication. – See actions on SRVO–070

64

B–81535EN/02

MAINTENANCE

3. TROUBLESHOOTING

(49)SRVO–070 SVAL2 STBERR alarm (Group : i Axis : j) (Explanation) The start and stop bits of the serial data are abnormal. (Action 1) Make sure that the JF1 to JF3 connector of servo amplifire module is connected tightly. (Action 2) Check that the shielding of the robot interconnection cable (for the pulse coder) and the peripheral equipment cable is connected securely to the grounding plate. (Action 3) Check that each unit is grounded securely. (Action 4) Replace the servo amplifier module. (Action 5) Replace the pulse coder. (Action 6) Replace the robot interconnection cable (RMP).

Servo amplifier module

Fig.3.5 (49) SRVO–070 SVAL2 STBERR alarm

(50)SRVO–071 SVAL2 SPHAL alarm (Group : i Axis : j) (Explanation) The feedback speed is abnormally high. (Action 1) If this alarm occurs together with the PHAL alarm (No. 064), this alarm does not correspond to the major cause of the failure. (Action 2) Replace the pulse coder. (51)SRVO–072 SVAL2 PMAL alarm (Group : i Axis : j) (Explanation) It is likely that the pulse coder is abnormal. (Action) Replace the pulse coder and remaster the robot. (52)SRVO–073 SVAL2 CMAL alarm (Group : i Axis : j) (Explanation) It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. (Action) Master the robot and enhance the shielding. (53)SRVO–074 SVAL2 LDAL alarm (Group : i Axis : j) (Explanation) The LED in the pulse coder is broken. (Action) Replace the pulse coder, and remaster the robot. (54)SRVO–075 WARN Pulse not established (Group : i Axis : j) (Explanation) The absolute position of the pulse coder cannot be established. (Action) Reset the alarm, and jog the axis on which the alarm has occurred until the same alarm will not occur again. (Jog one motor revolution)
65

3. TROUBLESHOOTING

MAINTENANCE

B–81535EN/02

(55)SRVO–076 SVAL1 Tip Stick Detection (Group : i Axis : j) (Explanation) An excessive disturbance was assumed in servo software at the start of operation. (An abnormal load was detected. The cause may be welding.) (Action 1) Check whether the robot comes into collision with foreign matter. If a collision occurs, reset the system, then switch it to the jog feed mode to avoid the collision. (Action 2) Check whether the load settings are valid. (Action 3) Check whether the load weight is within the rated range. If the weight exceeds the upper limit, decrease it to the limit. (Use of the robot with a load exceeding the limit applied may abnormally increase the assumed disturbance, resulting in this alarm.) (Action 4) Check each inter–phase voltage of the three–phase input (200 VAC) to the power supply module. If the voltage is 170 VAC or lower, check the input power supply voltage. (Action 5) Replace the power supply module and the servo amplifier module.

Servo amplifier module Power supply module

Fig.3.5 (60) SRVO–076 SVAL1 Tip Stick Detection

(56)SRVO–081 WARN EROFL alarm (Track enc : i) (Explanation) The pulse counter for line tracking has overflowed. (57)SRVO–082 WARN DAL alarm (Track ebc : i) (Explanation) The line tracking pulse coder has not been connected. (Action 1) Check the pulse coder connection cable, and replace it if necessary. (Action 2) Replace the pulse coder. (58)SRVO–083 WARN CKAL alarm (Track ebc : i) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal count clock). (Action) See the description about the SRVO–061 CKAL alarm.
66

B–81535EN/02

MAINTENANCE

3. TROUBLESHOOTING

(59)SRVO–084 WARN BZAL alarm (Track enc : i) (Explanation) This alarm occurs if the backup battery for the absolute position of the pulse coder has not been connected. See the description about the BZAL alarm (SRVO–062). (60)SRVO–085 WARN RCAL alarm (Track ebc : i) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal counter). (Action) See the description about the SRVO–063 RCAL alarm. (61)SRVO–086 WARN PHAL alarm (Track enc : i) (Explanation) This alarm occurs if the phase of pulses generated in the pulse coder is abnormal. See the description about the PHAL alarm (SRVO–064). (62)SRVO–087 WARN BLAL alarm (Track enc : i) (Explanation) This alarm occurs if the voltage of the backup battery for the absolute position of the pulse coder is low. See the description about the BLAL alarm (SRVO–065). (63)SRVO–088 WARN CSAL alarm (Track ebc : i) (Explanation) The ROM in the pulse coder is abnormal. (Action) See the description about the SRVO–066 CSAL alarm. (64)SRVO–089 WARN OHAL2 alarm (Track enc : i) (Explanation) The motor has overheated. See the description about the OHAL2 alarm (SRVO–067). (65)SRVO–090 WARN DTERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the DTERR alarm (SRVO–068). (66)SRVO–091 WARN CRCERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the CRCERR alarm (SRVO–069). (67)SRVO–092 WARN STBERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the STBERR alarm (SRVO–070). (68)SRVO–093 WARN SPMAL alarm (Track enc : i) (Explanation) This alarm occurs if the current position data from the pulse coder is higher than the previous position data. See the description about the SPHAL alarm (SRVO–071). (69)SRVO–094 WARN PMAL alarm (Track enc : i) (Explanation) It is likely that the pulse coder is abnormal. See the description about the PMAL alarm (SRVO–072). (70)SRVO–095 WARN CMAL alarm (Track enc : i) (Explanation) It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. See the description about the CMAL alarm (SRVO–073). (71)SRVO–096 WARN LDAL alarm (Track enc : i) (Explanation) The LED in the pulse coder is broken. See the description about the LDAL alarm (SRVO–074).
67

3. TROUBLESHOOTING

MAINTENANCE

B–81535EN/02

(72)SRVO–097 WARN Pulse not established (enc : i) (Explanation) The absolute position of the pulse coder cannot be established. See the description about (SRVO–075). Pulse not established. (73)SRVO–131 SVAL1 LVAL (PSM) alarm (Group : i Axis : j) (Explanation) The control power supply voltage (for example, +5 V) on the power supply module is abnormally low. The LED indication on the power supply module is “6” (LVAL). (Action 1) Replace the power supply module.

Power supply module

Fig.3.5 (73) SRVO–131 SVAL1 LVAL(PSM) alarm

68

The LED indication on the power supply module is “4. Magnetic contactor Servo amplifier module Power supply module Emergency stop unit Fig. check the input power supply voltage. (Action 2) Replace the power supply module. –If this alarm occurs before the magnetic contactor (MCC) is turned on: (Action 1) Check the emergency stop board and the wiring between the power supply module and magnetic contactor (MCC) for an abnormal condition. If it is 170 VAC or lower. (Action 3) Replace the emergency stop unit. TROUBLESHOOTING (74)SRVO–134 SVAL1 DCLVAL (PSM) alarm (Group : i Axis : j) (Explanation) The DC voltage (DC link voltage) of the main circuit power supply on the power supply module is abnormally low.” –If this alarm occurs during robot operation: (Action 1) Check the phase voltage of the three–phase input (200 VAC) to the power supply module. (Action 4) Replace the power supply module.5 (74) SRVO–134 SVAL1 DCLVAL (PSM) alarm 69 .3.B–81535EN/02 MAINTENANCE 3. (Action 2) Replace the magnetic contactor (MCC).

Fan Servo amplifier module Servo amplifier module Fig.5 (75) SRVO–135 SVAL FSAL alarm 70 . (Action 2) Replace the servo amplifier module.3.” (Action 1) Replace the fan motor of the servo amplifier module. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (75)SRVO–135 SVAL FSAL alarm (Group : i Axis : j) (Explanation) The internal cooling fan(s) of the servo amplifier module(s) is abnormal. The LED indication on the relevant servo amplifier module is “1.3.

B–81535EN/02

MAINTENANCE

3. TROUBLESHOOTING

(76)SRVO–136 SVAL1 DCLVAL alarm (Group : i Axis : j) (Explanation) The servo the DC current of servo amplifier module (DC link voltage) of the main power supply is abnormally low. The LED indication on the servo amplifier module becomes “5”. –This alarm occured in the robot operation. (Action 1) Check the phase voltage of the three–phase input power (200 VAC) to the power supply module. If it is 170 VAC or lower, check the line voltage. (Action 2) Replace the power supply module and the servo amplifier module. –If this alarm occurs before the magnetic contactor is turned on: (Action 1) Check the emergency stop board and the wiring between the power supply module and electromagnetic contactor (MCC) for an abnormal condition. (Action 2) Replace the magnetic contactor. (Action 3) Replace the E–stop unit. (Action 4) Replace the servo amplifier module.

Magnetic contactor

Robot control board Servo amplifier module Power supply module

Fig.3.5 (76) SRVO–136 SVAL1 DCLVAL alarm

71

3. TROUBLESHOOTING

MAINTENANCE

B–81535EN/02

(77)SRVO–156 SVAL1 IPMAL alarm (Group : i Axis : j) (Explanation) Abnormally high current flowed through the main circuit of the servo amplifier. The LED indications on the servo amplifier modules are “8.”, “9.”, and “A.”. (Action 1) Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, then turn on the power. If this operation causes the error to recur, replace the servo amplifier module. (Action 2) Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, then check the insulation between GND and each of the motor power lines U, V, and W individually. If a short–circuit is found, the motor, robot interconnection cable, or intra–robot cable may be faulty. Examine each of them for any problem. (Action 3) Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, then measure the resistance between the motor power lines U and V, V and W, and W and U, using an ohmmeter with a very low resistance range. If the three resistances are different, the motor, robot connection cable, or intra–robot cable may be faulty. Examine each of them for any problem. Before taking (Action 4), make a backup copy of all the programs and settings of the control unit. (Action 4) Replace the robot control board.

Robot control board Servo amplifier module

Fig.3.5 (77) SRVO–156 SVAL1 IPMAL alarm

72

B–81535EN/02

MAINTENANCE

3. TROUBLESHOOTING

(78)SRVO–157 SVAL1 CHGAL alarm (Group : i Axis : j) (Explanation) The capacitor for the DC link voltage of the servo amplifier module was not charged within the specified time. (Action 1) A short circuit may occur in the DC link voltage. Check the connection. (Action 2) Replace the servo amplifier module. (Action 3) Replace the power supply module.

Servo amplifier module Power supply module

Fig.3.5 (78) SRVO–157 SVAL1 CHGAL alarm

73

3. TROUBLESHOOTING

MAINTENANCE

B–81535EN/02

(79)SRVO–201 SVAL1 Panel E–stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator panel was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Check the EMERGENCY STOP button on the operator panel, and replace it if necessary. (Action 2) Replace the emergency stop unit. (Action 3) Replace the power supply module.
NOTE This alarm might occur if the EMERGENCY STOP button is pressed slowly.

emergency stop button

Power supply module Emergency stop unit

Fig.3.5 (79) SRVO–201 SVAL1 Panel E–stop or SVEMG abnormal

74

B–81535EN/02

MAINTENANCE

3. TROUBLESHOOTING

(80)SRVO–202 SVAL1 TP E–stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator panel was pressed, but the EMERGENCY STOP line was not disconnected. (Action 1) Check the teach pendant connection cable. (Action 2) Replace the teach pendant. (Action 3) Replace the emergency stop unit. (Action 4) Replace the power supply module.
NOTE This alarm might occur if the EMERGENCY STOP button is pressed slowly.

Teach pendant teach pendant cable

emergency stop button

Power supply module Emergency stop unit

Fig.3.5 (80) SRVO–202 SVAL1 TP E–stop or SVEMG abnormal

75

If the switch connected across EMGIN11 and EMGIN12 operates with a large delay. the EMERGENCY STOP line was not disconnected. this alarm may be issued. (Action 3) Replace the power supply module. (Action 1) Check whether there is a large difference in operation time between the switch connected across EMGIN11 and EMGIN12 and the switch connected across EMGIN21 and EMGIN22. Power supply module Emergency stop unit Fig. (Action 2) Replace the emergency stop unit.3.3.5 (81) SRVO–204 SVAL1 External (SVEMG abnormal) E–stop 76 . TROUBLESHOOTING MAINTENANCE B–81535EN/02 (81)SRVO–204 SVAL1 External (SVEMG abnormal) E–stop (Explanation) Although the switch connected across EMGIN11 and EMGIN12/EMGIN21 and EMGIN22 on the terminal block TBEB1 of the emergency stop board was pressed.

B–81535EN/02 MAINTENANCE 3. Power supply module Emergency stop unit Fig.5 (82) SRVO–205 SVAL1 Fence open (SVEMG abnormal) 77 .3. (Action 2) Replace the emergency stop unit. (Action 1) Check whether there is a large difference in operation time between the switch connected across EMGIN11 and EMGIN12 and the switch connected across EMGIN21 and EMGIN22. (Action 3) Replace the power supply module. this alarm may be issued. TROUBLESHOOTING (82)SRVO–205 SVAL1 Fence open (SVEMG abnormal) (Explanation) The EMERGENCY STOP line was not disconnected even though the switch connected between FENCE11 and FENCE12 and between FENCE21 and FENCE22 on the terminal block TBEB2 of the emergency stop board was open. If the switch connected across EMGIN11 and EMGIN12 operates with a large delay.

but the EMERGENCY STOP line was not disconnected. (Action 3) Replace the emergency stop unit.3. Power supply module Emergency stop unit Fig. (Action 2) Replace the teach pendant. (Action 1) The mode switch may be faulty. (Action 4) Replace the power supply module. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (83)SRVO–206 SVAL1 Deadman switch (SVEMG abnormal) (Explanation) The DEADMAN switch was released when the teach pendant was operable. Replace the operator panel.3.5 (83) SRVO–206 SVAL1 Deadman switch (SVEMG abnormal) 78 .

3. (Action 1) Check the teach pendant connection cable. TROUBLESHOOTING (84)SRVO–207 SVAL1 TP switch abnormal or door open (Explanation) The teach pendant is operable. but the EMERGENCY STOP line is kept disconnected. (Action 3) Replace the emergency stop unit. Teach pendant Teach pendant cable Emergency stop unit Fig.B–81535EN/02 MAINTENANCE 3. and the deadman switch has been grasped.5 (84) SRVO–207 SVAL1 TP switch abnormal or door open 79 . (Action 2) Replace the teach pendant.

(86)SRVO–216 SVAL1 OVC (total) (Robot : i) (Explanation) The current (total current for five axes or six axes) flowing through the motor is too large. (Action 2) Check each inter–phase voltage of the three–phase input (200 VAC) to the power supply module. If the robot is used with a condition exceeding the duty or load weight robot rating. (Action 1) Slow the motion of the robot where possible. Power supply module Fig.3. (Action 1) Check the cause and solve the problem.5 (86) SRVO–215 WARN Fuse blown (Aux axis) 80 . check the input power supply voltage. If the voltage is 170 VAC or lower. Check the robot operation conditions. then replace the fuse. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (85)SRVO–215 WARN Fuse blown (Aux axis) (Explanation) The fuse in the additional axis amplifier has blown. reduce the load condition value to the specification range.3.

B–81535EN/02 MAINTENANCE 3. If the number is invalid. (Example) When six axes are set. (Action 1) Check whether the set number of axes is valid. Section 7. Robot control board Servo amplifier module Power supply module Axis control card Fig. (Action 2) Replace the controlled axis card with a card corresponding to the set number of axes.5 (87) SRVO–221 SVAL1 Lack of DSP (Group : i Axis : j) 81 .2 in this manual. a controlled axis card for six or eight axes is available. see II MAINTENANCE.3. TROUBLESHOOTING (87)SRVO–221 SVAL1 Lack of DSP (Group : i Axis : j) (Explanation) A controlled axis card corresponding to the set number of axes is not mounted. set the correct number. For how to replace the controlled axis card.

(Action 3) Check whether power is properly supplied to the servo amplifier module.5 (88) SRVO–222 SVAL1 Lack of Amp (Amp : i) 82 .3.3. Servo amplifier module Fig. (Action 2) Replace the optical cable. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (88)SRVO–222 SVAL1 Lack of Amp (Amp : i) (Explanation) The FSSB has no SVM. (Action 1) Check that the optical cable is securely connected to the servo amplifier module.

3. (Action 2) Replace the emergency stop unit. Otherwise. T2/Door open 83 .B–81535EN/02 MAINTENANCE 3. Replace the operator panel. Teach pendant Mode switch FUS3 Emergency stop unit Emergency stop board Fig. set the enable switch of the teach pendant to Enable. (Action 3) Replace the teach pendant. (Action 1) During teaching operation. set the mode switch to AUTO mode. T2/Door open (Explanation) The teach pendant is disabled when the mode switch is in the T1 mode position.5 (89) SRVO–233 SVAL1 TP disabled in T1. (Action 4) The mode switch may be faulty. TROUBLESHOOTING (89)SRVO–233 SVAL1 TP disabled in T1.

TROUBLESHOOTING MAINTENANCE B–81535EN/02 (90)SRVO–264 SVAL1 “E.STOP circuit abnormal 2 84 . (Action 2) Replace the emergency stop unit.3.STOP circuit abnormal 1” (Explanation) An error occurred in the emergency stop circuit. (Action 3) Replace the power supply module. (Action 2) Replace the emergency stop unit.STOP circuit abnormal 1” (91)SRVO–265 SVAL1 E.3. (Action 3) Replace the power supply module.STOP circuit abnormal 2 (Explanation) When the servo amplifier is excited. (Action 1) Replace the magnetic contactor (MCC).5 (91) SRVO–265 SVAL1 E.3. Power supply module Emergency stop unit Fig. (Action 1) Check whether the CRR78 connectors on the E–STOP unit and the CX3 connector of the power supply module are connected securely. the monitor contact of the magnetic contactor (MCC) becomes faulty.5 (90) SRVO–264 SVAL1 “E. Power supply module Emergency stop unit Magnetic contactor (MCC) Fig.

replace the servo amplifier module. If a short circuit is detected. (Action 2) Detach the motor power lines from connector CZ2 of the servo amplifier module. and W of the motor power lines. (Action 1) Check whether the servo amplifier module fan stops. If the three resistances differ.” (Action 1) Detach the motor power lines from connector CZ2 of the servo amplifier module.B–81535EN/02 MAINTENANCE 3. Check them for an abnormal condition. “9. TROUBLESHOOTING (92)SRVO–290 SVAL1 DClink HC alarm (Group : i Axis : j) (Explanation) The DC link current in the servo amplifier module(s) is abnormal. Check them for an abnormal condition. The LED indications on the servo amplifier modules are “8. (Action 4) Replace the robot control board.”. robot connection cable. and “A.3. (Action 3) If this alarm is frequently issued. then turn the power on. (Action 3) Detach the motor power lines from connector CZ2 of the servo amplifier module. the motor. then check the insulation between GND and each of U.5 (92) SRVO–290 SVAL1 DClink HC alarm (93)SRVO–291 SVAL1 “IPM over heat (Group : i Axis : j)” (Explanation) The IPM in the servo amplifier overheats. V. back up all programs and settings for the control unit. or internal robot cable may be defective. Before proceeding with (Action 4). the motor. Robot control board Servo amplifier module Fig. and W–U resistances of the motor power lines. replace the amplifier module. The LED indication on the relevant servo amplifier module is “8. robot connection cable. 85 . (Action 2) Reduce the override because the use condition is too hard. If this alarm persists.”. V–W.”. then use a high–precision ohmmeter to measure U–V. or internal robot cable may be defective.

(Action 2) Check the servo amplifier modules and cables for connectors CX2A and CX2B of the power supply module. Before proceeding with (Action 5). Take measures against these alarms. (Action 3) Replace the axis control card on the robot control board. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (94)SRVO–295 SVAL1 SVM COM alarm (Group : i Axis : j) (Explanation) Communication between the servo amplifier modules is abnormal.” (Action 1) If “SRVO – 047 LVAL alarm” and “SRVO – 131 LVAL (PSM) alarm” also occur. (Action 4) Replace the servo amplifier modules. Robot control board Servo amplifier module Power supply module Axis control card Fig. the control power supply voltage is low. as well as their connection. The LED indications on the servo amplifier modules are “P. (Action 5) Replace the robot control board.3.3.5 (94) SRVO–295 SVAL1 SVM COM alarm 86 . back up all programs and settings for the control unit.

TROUBLESHOOTING (95)SRVO–296 SVAL1 DCAL alarm (Group : i Axis : j) (Explanation) The regenerative discharge energy is too high to be dissipated as heat.3. the robot moves along the vertical axis as the potential energy reduces. causing this alarm. (To move the robot. Power supply module Fig.B–81535EN/02 MAINTENANCE 3. The energy that the servo amplifier receives from the motor is called regenerative energy. The servo amplifier dissipates this energy as heat. If the amount of the regenerative energy dissipated as heat is smaller than was received.) The LED indication on the power supply module is “8” (DCAL: regenerative energy adder detection). This also occurs at deceleration even when no gravity is applied. (Action 1) This alarm may occur if the robot is subjected to frequent acceleration/deceleration or if the vertical axis generates a large amount of regenerative energy. the servo amplifier receives energy from the motor. the servo amplifier supplies energy to the robot. In this case. If a reduction in the potential energy is larger than the amount of acceleration energy. relax the service conditions.5 (95) SRVO–296 SVAL1 DCAL alarm 87 . the remainder is stored in the servo amplifier. When going down. (Action 2) Replace the power supply module.

If an open–phase condition is detected.5 (96) SRVO–297 SVAL1 DCLVAL alarm 88 . TROUBLESHOOTING MAINTENANCE B–81535EN/02 (96)SRVO–297 SVAL1 DCLVAL alarm (Group : i Axis : j) (Explanation) An open–phase condition has occurred in the input power supply to the main circuit on the power supply module. The LED indications on the power supply module is “E. Power supply module Fig.” (Action 1) Check the phase voltage of the three–phase input (200 VAC) to the power supply module. check the input power supply.3.3. (Action 2) Replace the power supply module.

(See II CONNECTION. (Action 2) Check whether the hand broken signal is connected to the robot.3. TROUBLESHOOTING (97)SRVO–300 SVAL1 Hand broken/HBK disabled SRVO–302 SVAL1 Set Hand broken to ENABLE (Explanation) Although HBK was disabled. When the hand broken signal circuit is connected. (Action 1) Press RESET on the teach pendant to release the alarm.) Robot control board Fig.B–81535EN/02 MAINTENANCE 3.5 (97) SRVO–300 SVAL1 Hand broken/HBK disabled SRVO–302 SVAL1 Set Hand broken to ENABLE 89 . enable hand broken.8 in this manual. the HBK signal was input. Section 3.

an emergency stop state was detected on the power supply module.STOP (Explanation) Although there is no cause for an emergency stop.3.5 (98) SRVO–320 SVAL1 E. Power supply module Emergency stop unit Fig. (Action 4) Replace the power supply module. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (98)SRVO–320 SVAL1 E. (Action 3) Replace the emergency stop unit.STOP 90 . (Action 2) Check the connections of the CRR78 connector on the emergency stop emergency stop board and the CX4 connector on the power supply module.3. (Action 1) Check external emergency stops and the safety fence.

Teach pendant teach pendant cable ENABLE/DISABLE switch Deadman switch (Back side) Robot control board Emergency stop unit Fig. (Action 4) Replace the robot control board.3.B–81535EN/02 MAINTENANCE 3.5 (98) SRVO–321 SVAL1 TP SW/Deadman abnormal 91 . make a backup copy of all the programs and settings of the control unit. (Action 3) Replace the emergency stop unit. (Action 1) Replace the teaching pendant cable. (Action 2) Replace the teaching pendant. TROUBLESHOOTING (99)SRVO–321 SVAL1 TP SW/Deadman abnormal (Explanation) The ENABLE/DISABLE switch or Deadman switch on the teaching pendant is abnormal. Before taking (Action 4).

6 TROUBLESHOOTING USING FUSES This section describes alarms that can occur when a fuse mounted on a board or unit is blown and corresponding corrective actions.3. TROUBLESHOOTING MAINTENANCE B–81535EN/02 3. FUS2 The teach pendant screen displays alarm information such as 1 Check that +24E used by the peripheral device is free from a Hand broken (SERVO – 006) or Robot overtravel (SERVO – ground fault. 3 Replace the robot control board. end effector. 2 Examine the peripheral device connection cable. The teach pendant displays the initial screen. 4 Examine the robot interconnection cable and intra–robot cable. 2 Replace the DC/DC converter module. and HBK Action 1 Check the units (fans) and cables connected to the CP2 and CP3 connectors of the power supply unit to see if there is any short circuit. (1) Fuses on the robot control board FUS1 : For generating power to the control circuit FUS2 : For protecting +24E output to peripheral device digital input/output. 005). Name FUS1 Problem caused by blown fuse The control power of the robot control board is shut off. FUS1 FUS2 92 . 3 Check that +24E used by the end effector is free from a ground fault. ROT.

Large error at rest (SERVO – 023). 2 Examine the teach pendant for any problem. Replace the emergency stop unit. and any other fault. The power supply to the teach pendant stops. or CLALM alarm (SERVO – 050) is displayed. 1 Check that the robot interconnection cable (RMP) and intra–mechanical–unit cable are free from faults such as a ground fault and short–circuit. 3 If a brake power transformer is used. TROUBLESHOOTING (2) Fuses on the emergency stop board FUS3 : For monitoring the emergency stop circuit FUS4 : For controlling the emergency stop circuit and teach pendant FUS5 : For the brake circuit Name FUS3 FUS4 Problem caused by blown fuse The teach pendant screen displays SVAL1 TP disabled in T1.B–81535EN/02 MAINTENANCE 3. short–circuit. and the system enters the emergency stop state. 2 If an additional axis is used. 1 Examine the teach pendant cable for any problem. Action Replace the emergency stop unit. FUS5 FUS4 FUS3 FUS5 Emergency stop board 93 . the screen display of the teach pendant disappears. note that a faulty brake power transformer can cause a too large current to flow. 4 Replace the emergency stop unit. check that the brake connection cable is free from a ground fault. and alarm information such as Large error in travel (SERVO – 024). Positioning time over (SERVO – 036). 3 Check that the external emergency stop input and servo off input are free from a ground fault and any other fault. Replace the brake power transformer. T2/Door open (SRVO–233) and so forth. The robot motor brake cannot be released.

and the power cannot be turned on.3. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (3) Blown fuse on the door Name FUS6 Problem caused by blown fuse The power supply unit on the emergency stop unit does not work. 2 Replace the power supply unit. Action 1 Check that the fan unit or cable is not short–circuited. FUS6 94 .

alarm or FSSB initialization alarm. FU1 Remove the face plate 95 . 1 Replace the fuse (5 A) on the control board of the power supThe teach pendant screen displays the FSSB disconnection ply module. TROUBLESHOOTING (4) Fuse on the power supply module FU1 : For protecting 200 VAC input to generate power to the control circuit Name FU1 Problem caused by blown fuse Action ALL LEDs of the servo amplifiers go out.B–81535EN/02 MAINTENANCE 3. 2 Replace the power supply module.

TROUBLESHOOTING MAINTENANCE B–81535EN/02 (5) Fuse on the servo amplifier module FU1 : For protecting +24 V input to generate power to the control circuit Name FU1 Problem caused by blown fuse Action ALL LEDs of the servo amplifier modules go out.2 A) on the control board of the servo amThe teach pendant screen displays the FSSB disconnection plifier module. 1 Replace the fuse (3. 2 Replace the servo amplifier module. alarm or FSSB initialization alarm.3. FU1 Remove the control board 96 .

Robot control board Servo amplifier module2 (AMP2) Servo amplifier module1 (AMP1) Power supply module (PSM) Emergency stop board 97 .7 TROUBLESHOOTING BASED ON LED INDICATIONS The printed circuit boards and servo amplifier are provided with alarm LEDs and status LEDs. TROUBLESHOOTING 3.B–81535EN/02 MAINTENANCE 3. The LED status and corresponding troubleshooting procedures are described below.

the contents of memory (parameters. * [Action2] Replace the FROM/SRAM module. the LEDs light as described in steps 1 to 18. [Action1] Replace the axis control card. the step in which the alarm occurred can be determined from which LEDs are lit.) will be lost. in the order described. After power–on. * [Action2] Replace the FROM/SRAM module. 10:DI/DO initialization * [Action1] Replace the FROM/SRAM module. * [Action3] Replace the FROM/SRAM module. 4: The initialization of SRAM and DPRAM is completed. 3: The initialization of dram on the CPU card is completed. * [Action2] Replace the robot control board. * [Action2] Replace the FROM/SRAM module. * If the robot control board or FROM/SRAM module is replaced. 8: Start–up of communication with the teach pendant.3. 7: Basic software start–up. [Action1] Replace the CPU card * [Action2] Replace the robot control board. etc. [Action3] Replace the servo amplifier. If an alarm is detected. [Action1] Replace the CPU card * [Action2] Replace the robot control board. therefore. all LEDs are lit. specified data. [Action1] Replace the CPU card * [Action2] Replace the robot control board. 2: Software operation start–up. 98 . * [Action1] Replace the robot control board. LED Action to be taken [Action1] Replace the CPU card * [Action2] Replace the robot control board. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (1) TROUBLESHOOTING USING THE LEDS ON THE robot control board To troubleshoot an alarm that arises before the teach pendant is ready to display. 9: The loading of optional software is completed. 6: The loading of the basic software is completed. make a backup copy of the data. * [Action1] Replace the robot control board. Step 1: After power–on. 11:The preparation of the SRAM module is completed. * [Action1] Replace the robot control board. * [Action2] Replace the robot control board. * [Action1] Replace the robot control board. check the status LEDs (green) on the robot control board at power–on. Before you replace the unit. 5: The initialization of the communication IC is completed. * [Action3] Replace the FROM/SRAM module. [Action1] Replace the CPU card * [Action2] Replace the robot control board.

17: Initialization is terminated. specified data. * If the robot control board or FROM/SRAM module is replaced. [Action3] Replace the servo amplifier. 13:Calibration is completed. 16:DI/DO output start–up. 18:Normal status Status LED 2 blink when the system is operating normally. therefore.B–81535EN/02 MAINTENANCE 3. Before you replace the unit.) will be lost. * [Action2] Replace the robot control board. make a backup copy of the data. 14:Start–up of power application for the servo system * [Action1] Replace the robot control board. the contents of memory (parameters. * [Action1] Replace the robot control board. etc. * [Action2] Replace the robot control board. [Action1] Replace the axis control card. 15:Program execution * [Action1] Replace the robot control board. TROUBLESHOOTING Step 12:Axis control card initialization LED Action to be taken [Action1] Replace the axis control card. Axis control card FROM/SRAM module (under the CPU card) CPU card 99 . [Action3] Replace the servo amplifier. Initialization has ended normally.

[Action1] Replace the axis control card.3. [Action2] Replace the CPU card. [Action2] Replace the robot control board. specified data. etc. [Action1] Replace the CPU card. “3”. * If the robot control board or FROM/SRAM module is replaced. [Description] A servo alarm condition has occurred on the robot control board. [Description] The SYSEMG alarm has occurred. [Action1] Replace the FROM/SRAM module. [Action2] Replace the robot control board. [Action3] Replace the robot control board. therefore. TROUBLESHOOTING MAINTENANCE B–81535EN/02 (2) TROUBLESHOOTING BY 7–SEGMENT LED INDICATOR 7–segment LED indicator Description [Description] A parity alarm condition has occurred in RAM on the CPU card installed on the robot control board. [Action1] Replace the axis control card. Before you replace the unit.) will be lost. 100 . make a backup copy of the data. [Description] The SYSFAIL alarm has occurred. “2”. [Action3] Replace the robot control board. [Description] A parity alarm condition has occurred in RAM on the FROM/SRAM module installed on the robot control board. and “4” are not displayed. the contents of memory (parameters. [Action1] Replace the axis control card. [Action2] Replace the robot control board. [Action2] Replace the CPU card.

Cause of the blowing of FUS1 and corrective actions [Action1] Check whether the device which is connected to the RS–232–C/RS–422 port and requires the power supply of +24 V is sound. [Action3] Short–circuited surge absorber PVS1 The system can be operated temporarily without PVS1. 101 . However. Cause of the blowing of FUS2 and corrective actions [Action1] Check that +24E used by the peripheral device is free from a ground fault. [Action3] Check that +24E used by the end effector is free from a ground fault. obtain and mount a new one at the earliest possible time. TROUBLESHOOTING (3) Troubleshooting using a fuse alarm LED LED indication Failure description and required measure [Description] A fuse (FUS1 or FUS2) is blown. [Action2] Faulty DC/DC converter module Replace the DC/DC converter module. [Action4] Faulty robot control board Replace the robot control board. [Action2] Examine the peripheral device connection cable.B–81535EN/02 MAINTENANCE 3. [Action4] Examine the robot interconnection cable and intra–robot cable.

and any other fault. [Action4] The emergency stop board is faulty. FALM LED Fuse FUS4 Fuse FUS3 Fuse FUS5 Emergency stop board Emergency stop unit 102 . Cause of the blowing of FUS4 and corrective actions [Action1] Check that the teach pendant cable is sound. Cause of the blowing of FUS3 and corrective action [Action] The emergency stop board is faulty. short–circuit. note that a faulty brake power transformer can cause a too large current to flow. short–circuit. [Action2] If an additional axis is used. Replace the emergency stop unit. [Action3] Check that the external emergency stop input and servo off input are free from a ground fault and any other fault. check that the brake connection cable is free from a ground fault. Replace the emergency stop unit. or FUS5) is blown.3. [Action4] The emergency stop board is faulty. TROUBLESHOOTING MAINTENANCE B–81535EN/02 Troubleshooting using an LED on the emergency stop board LED indication Problem and corrective action [Description] The fuse (FUS3. and any other fault. [Action2] Check that the teach pendant is sound. Replace the brake power transformer. [Action3] If a brake power transformer is used. Replace the emergency stop unit. Cause of the blowing of FUS5 and corrective actions [Action1] Check that the robot interconnection cable (RMP) and intra–mechanical–unit cable are free from a ground fault. FUS4.

[Action2] The regenerative resistor is faulty. [Action] Change the operating conditions. etc.). Replace the power supply module. external emergency stop input. For instance. [Action1] The input power was instantaneously interrupted. Check the power supply. Check the power requirements.B–81535EN/02 MAINTENANCE 3. TROUBLESHOOTING Troubleshooting using the LED of the power supply module The power supply module has a seven–segment LED. [Description] The control power voltage is low. Check the emergency stop circuit (emergency stop board. see the alarm displayed on the teach pendant screen. [Description] The input power is in the open–phase state. [Action] The input power is low. dot part of seven segment LED LED indication Problem and corrective action [Description] The voltage of the DC link of the main circuit is low. [Action2] The charge current controlling resistor is faulty. [Description] The main circuit could not be charged within a predetermined period. [Action3] The power to the main circuit was shut off in the emergency stop release state. Replace the power supply module. Change the operating conditions. lower the frequency of acceleration/deceleration. [Action2] The input supply voltage is low. [Description] The regeneration amount is too large. [Action1] The DC link is short–circuited. [Action1] The regenerative power is too large. [Description] The voltage of the DC link of the main circuit is too high. Check the connection. lower the frequency of acceleration/deceleration. magnetic contactor. Check the power supply. 103 . [Action] Check the power supply. [Description] The regenerative resistor was heated. [Action] Change the operating conditions. When taking a corrective action corresponding to the LED indication. For instance.

[Action1] Check that the fan is not blocked with a foreign substance. TROUBLESHOOTING MAINTENANCE B–81535EN/02 Troubleshooting using the LED of the servo amplifier module The servo amplifier module has a seven–segment LED. [Action1] Check that the DC link connection cable (bar) is securely screwed. take the action for alarm code 4 of the power supply module. (The voltage must be the rated input voltage multiplied by 0. [Description] The control supply voltage is low. [Action3] The fan is faulty.85 at least. [Action1] Check the CXA2A/B connector and the cable. Replace the fan. (Normal: 22. [Action3] Replace the servo amplifier module. [Action3] Replace the servo amplifier module. [Action2] If this alarm occurs in multiple servo amplifier modules. 104 . see the alarm displayed on the teach pendant screen. [Action2] Check that the fan connector is correctly connected.) [Action2] Measure the voltage of 24–V power supplied from the power supply module. dot part of seven segment LED LED indication Problem and corrective action [Description] The internal cooling fan stopped. [Action4] Replace the servo amplifier module. [Action2] Replace the control board of the servo amplifier module.3. When taking a corrective action corresponding to the LED indication. [Action1] Check the three–phase input voltage. [Description] The communication among servo amplifiers cannot be normally performed.8 V or higher) [Action3] Check the CXA2A/B connector and the cable. [Action4] Replace the servo amplifier module. [Description] The voltage of the DC link of the main circuit is low.

examine the robot interconnection cable or intra–robot cable. then check whether the motor or power line has deteriorated insulation. and “A. Detach the motor power lines from the connectors CZ2 of the servo amplifier modules. Separate the motor and power line. [Action2] [Action3] 105 .B–81535EN/02 MAINTENANCE 3. “8. “9. and check the insulation between PE and each of the motor power lines U. “8. and N–axis respectively. [Action2] Check that the motor is operated at its continuous rating or lower. a) If the insulation is deteriorated.”.”. [Action1] Check that the internal cooling fan does not stop. TROUBLESHOOTING LED indication Problem and corrective action [Description1] The IPM alarm was detected in the servo amplifier module. replace the servo amplifier module.”. [Action3] Check that the cooling capability of the cabinet is not lowered.) [Action4] Check that the ambient temperature is not high. b) If this alarm occurs. M– axis. and turn the power on. and N–axis respectively. M– axis. and “A.”. V. b) If the power line insulation is deteriorated. a) If the motor insulation is deteriorated. replace the servo amplifier module. b) If the insulation is normal. “9. go to Action 2.” represent that an alarm occurs on the L–axis. (Check the fan unit and heat exchanger. [Description2] The IPM alarm (overheat) was detected in the servo amplifier module. and W. a) If this alarm does not occur.” represent that an alarm occurs on the L–axis. [Action1] Detach the motor power lines from the connectors CZ2 of the servo amplifier modules. replace the motor. [Action5] Replace the servo amplifier module. go to Action 3.

b) If this alarm occurs. b) If the insulation is normal. “C”. [Action2] Detach the motor power lines from the connectors CZ2 of the servo amplifier modules. and W. replace the servo amplifier. Increase the acceleration/deceleration time constant and observe the operation. V. a) If this alarm does not occur. b) If the power line insulation is deteriorated. examine the robot interconnection cable and intra–robot cable. and “d” represent that an alarm occurs on the L–axis. a) If the insulation is deteriorated. [Action3] [Action4] 106 . go to Action 2. a) If the motor insulation is deteriorated. the motor operating conditions may be too harsh. M–axis. then check the insulation between PE and each of the power lines U. replace the servo amplifier module. then check whether the motor or power line has deteriorated insulation. “b”. If this alarm occurs only at a sudden acceleration or deceleration. [Action1] Check that the servo parameters are set to default values.3. replace the motor. Separate the motor and power line. Detach the motor power lines from the connectors CZ2 of the servo amplifier modules. go to Action 3. and N–axis respectively. then turn on the power. TROUBLESHOOTING MAINTENANCE B–81535EN/02 LED indication Problem and corrective action [Description] An abnormal current is flowing to the servo motor.

If the motor axis can be positioned normally. Press F1. then press the F4. Replace a faulty key of motor shaft or other faulty parts. press the screen selection key. and select STATUS from the menu. To display the position deviation. 107 .B–81535EN/02 MAINTENANCE 3. (Check 4) If checks 1 to 3 show normal results (Corrective action) (Corrective action) (Corrective action) (Corrective action) Replace the pulse coder and robot control board. TROUBLESHOOTING 3. select AXIS from the menu. (Check 2) Check whether the motor axis can be positioned normally. [TYPE]. (Check 3) Check the mechanical unit for backlash. check the position deviation in the stopped state. PULSE.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) (Check 1) On the status screen. Correct the parameters related to return to the reference position (positioning). check the mechanical unit.

Correct parameters.3. (Corrective action) (Corrective action) Replace a faulty key of motor shaft or other faulty parts.9 VIBRATION OBSERVED DURING MOVEMENT (Check 1) Check the settings of parameters such as the position loop gain parameter. (Check 2) Check the mechanical unit for backlash. TROUBLESHOOTING MAINTENANCE B–81535EN/02 3. 108 .

10 MANUAL OPERATION IMPOSSIBLE The following explains checking and corrective action required if the robot cannot be operated manually after the controller is turned on: (1) Check and corrective action to be made if manual operation is impossible (Check 1) Check whether the teach pendant is enabled. Put the peripheral-device control interface in the ENBL state. (Check 6) Check whether the controller is in the alarm status. To move an axis by manual operation. (Check whether the hold lamp on the teach pendant is on. TROUBLESHOOTING 3. (Check 3) Check whether the ENBL signal of the peripheral device control interface is set to 1. (Check 5) Check whether the previous manual operation has been completed.) (Corrective action) (Corrective action) If the HOLD signal is on. Place the peripheral device control interface in the ENBL status. (2) Check and corrective action to be taken if the program cannot be executed (Check 1) Check whether the ENBL signal for the peripheral-device control interface is on. (Check 4) Check whether the HOLD signal of the peripheral device control interface or the HOLD switch on the operator’s panel is on (hold status). If the robot cannot be placed in the effective area because of the offset of the speed command voltage preventing the previous operation from being completed. turn it off. and change the setting. press the axis selection key and case shift key at the same time. (Corrective action) (Corrective action) (Corrective action) (Corrective action) (Corrective action) (Corrective action) Release the alarm. Set the override for manual feed to a position other than the FINE and VFINE positions. (Check 2) Check whether the teach pendant is handled correctly. turn it off.B–81535EN/02 MAINTENANCE 3. (Check 2) Check whether the HOLD signal for the peripheral-device control interface is on.) Turn off the HOLD signal of the peripheral device control interface or the HOLD switch on the operator ’s panel. If the HOLD switch is on. Turn on the teach pendant “enable”. 109 . (Check whether the HOLD lamp on the teach pendant is on. check the position deviation on the status screen.

3. TROUBLESHOOTING

MAINTENANCE

B–81535EN/02

(Check 3) Check whether the previous manual operation has been
completed. If the robot cannot be placed in the effective area because of the offset of the speed command voltage, which prevents the previous operation from being completed, check the position deviation on the status screen, then change the setting. (Check 4) Check whether the controller is in the alarm status.

(Corrective action)

(Corrective action)
Release the alarm.

110

B–81535EN/02

MAINTENANCE

4. PRINTED CIRCUIT BOARDS

4

PRINTED CIRCUIT BOARDS

The printed circuit boards are factory-set for operation. Usually, you do not need to set or adjust them. This chapter describes the standard settings and adjustment required if a defective printed circuit board is replaced. It also describes the test pins and the LED indications. The standard printed circuit board includes the main unit printed circuit board and one or more cards or modules installed horizontally to the main–unit printed–circuit board. These boards have interface connectors, LED indicators, and a plastic panel at the front. At the rear, there is a backplane connector.

111

4. PRINTED CIRCUIT BOARDS

MAINTENANCE

B–81535EN/02

4.1
ROBOT CONTROL BOARD (A16B–3200–0450)

FROM/SRAM module under the CPU card

CPU card

DC/DC converter module

Total version

Axis control card

Fig.4.1 Robot control board Name
Robot control board DC/DC convert module CPU card

Board Specification
A16B–3200–0450 A20B–8100–0721 A20B–3300–0106 A20B–3300–0107

Note
I/O Link master/slave switcheable, SDI/SDO = 28/24

SDRAM 8M (Standard) SDRAM 16M 6–axis FROM 16M, SRAM 0.5M : Standard FROM 16M, SRAM 1MB FROM 16M, SRAM 2MB FROM 16M, SRAM 3MB

Axis control card FROM/SRAM module

A20B–3300–0241 A20B–3900–0181 A20B–3900–0160 A20B–3900–0161 A20B–3900–0162

112

B–81535EN/02

MAINTENANCE

4. PRINTED CIRCUIT BOARDS

(1) LEDs
Seven segment LED Description A parity alarm occurred in a RAM of the main CPU card on the Robot control board.

A parity alarm occurred in a RAM of the FROM/ SRAM module on the Robot control board.

“2”, “3”, and “4” are not displayed.

A servo alarm occurred on the Robot control board.

SYSEMG occurred.

SYSFAIL occurred.
This number appears temporarily after the power is switched on, but it is not abnormal.

113

4. PRINTED CIRCUIT BOARDS

MAINTENANCE

B–81535EN/02

Status LED

Description

STATUS LED

Indicates the system operating status.

Status LED

Description

FUSE ALARM LED

A fuse (FUS1 or FUS2) was blown.

114

SDO103. SDO83. RDO6. SDO107. SDO117. receiver Drawing number A76L–0151–0098 A76L–0151–0099 115 . SDO114. SDO108 SDO109. Reserved RDO1. RDO2. RDO3. SDO106. SDO116 SDO119. SDO104 SDO105. SDO112 SDO113. RDO4 RDO5. SDO84. SDO115. IC name G17 G16 Name and usage 75172. SDO110. SDO118 (3) Communication IC If the teach pendant displays nothing because of a damaged teach pendant connection cable or another reason. SDO111. Brake control (internal circuit) SDO82. driver 75173. the following communication driver or receiver may be damaged. SDO120.B–81535EN/02 MAINTENANCE 4. SDO102. SDO81. PRINTED CIRCUIT BOARDS (2) Correspondence between driver ICs and DO Driver IC specification: A76L–0151–0062 Driver IC name H9 G9 K9 J9 J13 H13 J6 J4 DO signal name SDO101.

2 Emergency stop board 116 .4.2 EMERGENCY STOP BOARD (A20B–1008–0010.4. PRINTED CIRCUIT BOARDS MAINTENANCE B–81535EN/02 4. –0011) Total version Fig.

3 BACKPLANE BOARD (A20B–2003–0330) Total version 117 .B–81535EN/02 MAINTENANCE 4. PRINTED CIRCUIT BOARDS 4.

HF (A16B–2203–0765) Total edition Test pins Fig.4. PRINTED CIRCUIT BOARDS MAINTENANCE B–81535EN/02 4.4 PROCESS I/O BOARD HE (A16B–2203–0764).4.4 Process I/O Board HA (1) Test pins Name P24V P5V GND1 GND2 GND3 P24VF P5VF GNDF AO1 AO2 +24V +5V GND GND GND +24V +5V GND Channel 1 Channel 2 Use For measuring the DC supply voltage Power for the digital/analog converter For measuring the voltage of the analog output signal (digital/analog) (2) Settings Name ICOM1 UDI1 to UDI20 (Connector CRM2A) Side A Standard setting Description UDI21 to UDI40 ICOM2 (Connector CRM2B) ICOM3 WDI01 to WDI08 (Connector CRW7) The common voltage is adjusted to: Side A : +24 V common Side B : 0 V common 118 .

) (4) LEDs Color Description Red A communication alarm occurred between the main CPU and process input/output. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 or VR2 until the meter reads 15. PROGRUN.0 V. SDO11. SDO19. Connect the digital voltmeter to test pin AOUT2 and rotate VR3 or VR4 until the meter reads 15.B–81535EN/02 MAINTENANCE 4. SDO06. SYSRDY. SDO10.0 V. Execute a robot program and set AOUT[2] to 3413 on the teach pendant. PRINTED CIRCUIT BOARDS (3) Adjustment VR1/VR2: Adjusts the gain and the offset of channel 1. (5) Correspondence between driver chips and DO signals Ordering code for the driver chips: A76L-0151-0062 Driver chip DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10 DO signal CMDENBL. Red A fuse (FUSE 1) in the process input/output below. SDO03. PAUSED HELD. SDO15. BUSY. (The 0VF test pin is different from the common GND test pin. SDO08 SDO09. SDO02. SDO12 SDO13. ACK8/SNO8. SDO16 SDO17. SNACK. FAULT. SDO20 119 . Connect the negative (–) lead of the digital voltmeter to test pin GNDF. ACK5/SNO5. RESERVED SDO01. SDO18. (GNDF test pin is different from the GND test pin. Execute a robot program and set AOUT[1] to 3413 on the teach pendant. TPENBL BATALM. ATPERCH. SDO14. SDO04 SDO05. ACK2/SNO2 ACK3/SNO3. ACK4/SNO4. SDO07. Connect the negative (–) lead of the digital voltmeter to test pin GNDF. ACK1/SNO1. ACK6/SNO6 ACK7/SNO7.) VR3/VR4: Adjusts the gain and the offset of channel 2.

This chapter describes the standard settings and adjustment required if a defective servo amplifier is replaced. It also describes the use of test pins and meanings of the LED indications. you do not need to set or adjust them. Usually. SERVO AMPLIFIERS MAINTENANCE B–81535EN/02 5 LR Mate 100iB SERVO AMPLIFIERS The servo amplifiers are factory-set for operation. Table 5 Servo amplifier specifications Robot Power supply module A06B–6115–H001 (αPSMR–1i) Servo amplifier module1 A06B–6114–H205 (αSVM–20/20i) L M J1 J2 A06B–6114–H302 (αSVM–10/10/10i) L M N J1 J2 J3 Servo amplifier module2 A06B–6114–H302 (αSVM–10/10/10i) L M N J3 J4 J5 A06B–6114–H302 (αSVM–10/10/10i) L M N J4 J5 J6 LR Mate 200iB ARC Mate 50iB A06B–6115–H001 (αPSMR–1i) 120 .5.

SERVO AMPLIFIERS 5.1.B–81535EN/02 MAINTENANCE 5.5.1 Power Supply Module PSM (A06B–6115–H001) 380 360 60 172 Fig.1.1 OUTLINE DRAWINGS 5.1 Outline drawing of power supply module PSM (A06B–6115–H001) 121 .

2 Servo Amplifier Module (A06B–6114–H205.5.2 Outline drawing of servo amplifier modules (A06B–6114–H205.1. A06B–6114–H302) A06B–6114–H205 A06B–6114–H302 380 360 60 172 Fig. SERVO AMPLIFIERS MAINTENANCE B–81535EN/02 5. A06B–6114–H302) 122 .1.5.

The input power is in the open–phase state. see the alarm displayed on the teach pendant screen.1 LED of Power Supply Module dot part of seven segment LED The power supply module has a seven–segment LED. LED indication The magnetic contactor controlled by the power supply module is in the on state and is ready for driving the motor. The main circuit cannot be charged within a predetermined period. The voltage of the DC link of the main circuit is too high. When taking a corrective action corresponding to the LED indication.B–81535EN/02 MAINTENANCE 5. The regenerative resistor was heated. Description The magnetic contactor controlled by the power supply module is in the off state and is not ready for driving the motor. The regeneration amount is too large. The voltage of the DC link of the main circuit is low.2 LED OF SERVO AMPLIFIER 5. SERVO AMPLIFIERS 5. 123 .2. The control power voltage is low.

“C”. M–axis. “9. The control power voltage is low.”. An abnormal current is flowing to the servo motor.2 LED of Servo Amplifier Module dot part of seven segment LED The servo amplifier module has a seven–segment LED.5. see the alarm displayed on the teach pendant screen. and N–axis respectively. M– axis. and N–axis respectively.”. b) The IPM alarm (overheat) was detected in the servo amplifier module. The communication among servo amplifier modules cannot be normally performed. Description The main circuit in the servo amplifier module is in the off state and is not ready for driving the motor. a) The IPM alarm was detected in the servo amplifier module.” represent that an alarm occurs on the L–axis. and “d” represent that an alarm occurs on the L–axis. “8.2. 124 . The voltage of the DC link of the main circuit is low. LED indication The main circuit in the servo amplifier module is in the on state and is ready for driving the motor. When taking a corrective action corresponding to the LED indication. “b”. SERVO AMPLIFIERS MAINTENANCE B–81535EN/02 5. The internal cooling fan stopped. and “A.

Usually. SETTING THE POWER SUPPLY 6 SETTING THE POWER SUPPLY The power supply is factory-set for operation. 125 . you do not need to set or adjust it.B–81535EN/02 MAINTENANCE 6.

3V +24E +24F Peripheral device (option) Fig.1 Block diagram of the power supply 126 . –15V CP8B +24V FUS1 CP5 +24E FUS2 +24E CRM82 +24E CRM79 +24E CRM81 +24V JD17 BATTERY Motor brake Motor powersupply Pulsecoder Robot Motor End Effector Teach pendant Peripheral device Peripheral device (option) Handy file etc.1 BLOCK DIAGRAMS OF THE POWER SUPPLY AC input 200 – 220 VAC 3φ Magnetic contactor (MCC) Circuit protector 200VAC 2φ 3φ FUS6 200VAC 2φ Servo amplifier Power supply module CZ1 Main circuit DC link FU1 regenerative resistor 200VAC CX1 FAN AC/DC +24V Power supply unit CN1 CXA2A L+. Process I/O board +24E FUSE1 CRM2 CRM4 +24V –15V +15V +5V +3.3V +15V.6. +3.6. L– Inverter circuit CZ2 L–N Emergency stop print board FUS3 FUS4 CP5A Monitor circuit CP5B EmergenFUS5 cy stop circuit Brake circuit CRS1 +24T TBEB3 Backplane Robot control board DC/DC converter module +5V. SETTING THE POWER SUPPLY MAINTENANCE B–81535EN/02 6. L– Emergency stop unit AC/DC +24V Servo amplifier module CRR77 CXA2B DC/DC +5V JF1–3 L+.

2 Rating of the Power supply unit Output +24V Rated voltage +24V Tolerance +23V to +25V 6. Table 6.3V +15V –15V Tolerance ±3% ±3% ±10% ±10% 127 .3 CHECKING THE POWER SUPPLY MODULE The power supply module need not be set or adjusted.2 CHECKING THE POWER SUPPLY UNIT The power supply unit need not be set or adjusted.1V +3.3 Rating of the Power supply module Output +5V +3.B–81535EN/02 MAINTENANCE 6.3V +15V –15V Rated voltage +5. SETTING THE POWER SUPPLY 6. Table 6.

Otherwise. turn off the control unit main power. 128 . WARNING Before you start to replace a unit. REPLACING A UNIT MAINTENANCE B–81535EN/02 7 REPLACING A UNIT This section explains how to replace each unit in the control section. Also keep all machines in the area of the control unit switched.7. you could injure personnel or damage equipment.

or Robot control board (including cards and modules) is replaced. observe the following cautions: 1 Keep the control unit power switched off. save a backup copy of the robot parameters and taught data to a memory card. do not touch the semiconductor devices on the board with your hand or make them touch other components.) 4 If the backplane board.1 REPLACING THE PRINTED–CIRCUIT BOARDS CAUTIONS When you replace printed–circuit boards. note its location.B–81535EN/02 MAINTENANCE 7. 3 Make sure that the replacement printed–circuit board has been set up appropriately. 2 When you remove a printed–circuit board. reconnect it exactly as before. 129 . power supply unit. (Setting plug etc. it is likely that robot parameters and taught data are lost. floppy disk. REPLACING A UNIT 7. If a cable is detached for replacement. Before you start to replace these components. 5 Before you disconnect a cable. or any other external memory device.

(6) To replace the backplane and rack.) (3) Detach the grounding cable from the backplane unit. reverse steps (1) – (6).7.1. USE STATIC PROTECTION.2. (2) Remove the robot control board and boards from the rack.1. do so together with the plastic rack.3VDC) and it is installed correctly.1 Replacing the Backplane Board (Unit) When replacing the backplane board. (1) Detach the cables from the robot control board and boards on the backplane board. CAUTION There is a possibility of data loss when a backplane board is replaced.1–3. REPLACING A UNIT MAINTENANCE B–81535EN/02 7. be sure that the battery is good (3. (5) Side rack up and out. Backplane board M5 nut (2 places) Fig. Remove the retaining screws from the lower section of the rack. (See Section 7. Be sure to back up all program and setup data on a floppy disk before proceeding.7. CAUTION When you remove the main robot control Board. (4) Loosen the retaining screws in the upper section of the rack.1.1 Replacing the Backplane Board 130 .

Robot control board. Slot 1 Option slot Slot 1 Slot 10 Barbed handles Rail (Left) Slot 9 Slot 2 Rail (Right) zoom Barbed handles Fig. align it to the right–side rail. then pull it toward you. for example. When inserting the robot control board. (2) Pinch the barbed handles on the upper and lower sections of the board to unlatch it. (4) There are two rails in the robot control board SLOT (slot 1). When the Robot control board is replaced.7. A full–size board occupies one slot. (3) Place the replacement board on the rail in the appropriate slot of the rack.1. and option boards.1.B–81535EN/02 MAINTENANCE 7.2 Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit The backplane unit incorporates the power unit. (1) Detach the cable from the printed–circuit board. There are two types of option boards: Full–size board and mini–size board. turn off the control unit main power. The robot control board is equipped with battery–backed memory devices for holding robot parameters and taught data. REPLACING A UNIT 7. CAUTION Before starting replacement.2 Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit 131 . A mini–size board uses part of a full–size board. then push it in gently by the handles until it is latched. the data in the memory devices is lost. whichever is to be replaced.

3 Emergency stop board replacement 132 .7. Pull out the upper terminal block sections.3 Replacing the Emergency Stop Board The board is at the emergency stop unit. The terminal blocks (TBEB1 and TBEB2) are of a connector type. 1 Remove the front nuts (2–M5) 2 Remove the back nuts (2–M5) 3 Remove the screws (6–M3) Fig. (2) Remove four retaining nuts from the emergency stop unit (1.1. and replace the emergency stop unit.7. REPLACING A UNIT MAINTENANCE B–81535EN/02 7. 2). (1) Detach all cables from the emergency stop unit consists of the emergency stop board and the power supply unit.1. (3) Remove six retaining screws from the emergency stop board (3). and replace the emergency stop board.

make a backup copy of robot parameters and taught data.B–81535EN/02 MAINTENANCE 7. then release each latch. Demounting a Card Card Card Card Card Spacer Connector Card Spacer Connector Fig. If the FROM/SRAM module is replaced. (2) Extract the card upward.2 (a) Demounting a card 133 .2 REPLACING CARDS AND MODULES ON THE ROBOT CONTROL BOARD CAUTION Before you start to replace a card or module.7. REPLACING A UNIT 7. memory contents are lost. (1) Pull outward the clip of each of the two spacers used to secure the card PCB.

7. (2) Push the clip of each spacer downward to secure the card PCB. then insert the card into the connector.2 (b) Mounting a card 134 .7. REPLACING A UNIT MAINTENANCE B–81535EN/02 (1) Check that the clip of each of the two spacers is latched outward. Mounting a Card Card Spacer Connector Card Card Card Card Spacer Connector Fig.

(a) (2) Extract the module by raising it at a 30 degree slant and pulling outward. (b) (2) Push the module inward and downward until it is locked. be careful not to touch the module contact. If you touch the contact inadvertently. (c) (a) (b) (c) Fig. (1) Move the clip of the socket outward. REPLACING A UNIT Demounting a module CAUTION When replacing the module. with side B facing upward.2 (c) Demounting/Mounting a module 135 . Mounting a module (1) Insert the module at a 30 degree slant into the module socket.B–81535EN/02 MAINTENANCE 7.7. wipe out dirt on the contact with a clean cloth.

FROM/SRAM module under the CPU card CPU card DC/DC converter module Total version Axis control card Fig. DC/DC converter module screws (3–M3) Fig. (2) Pull out the module. (2) Screw the screws (3–M3).7.7.7.2 (e) Locations of Cards and Modules 136 . REPLACING A UNIT MAINTENANCE B–81535EN/02 Removing the DC/DC converter module (1) Unscrew the screws (3–M3).2 (d) Mounting and removing the DC/DC converter module Figure 7.2 (e) shows the locations of the cards and modules. Mounting the module (1) Insert the module to the connector.

1 Replacing the brake power transformer 137 . (3) Re–connect the cable.3 REPLACING THE TRANSFORMER WARNING Before you start replacement procedure.7.3. Remore the nuts (2–M5) Fig.3. then replace the transformer.1 Replacing the Brake Power Transformer (1) Detach the cable from the transformer. 7.B–81535EN/02 MAINTENANCE 7. turn off the main power to the control unit. REPLACING A UNIT 7. (2) Remove the two nuts (M5) securing the transformer.

(3) Reconnect the cables. (1) Detach the cables from the emergency stop unit. Nut (4–M5) 2 Remove the back nuts (2–M5) screws 1 Remove the front nuts (2–M5) screws Fig. (2) Remove retaining screws (4–M5) from the emergency stop unit. and replace the emergency stop unit.7. REPLACING A UNIT MAINTENANCE B–81535EN/02 7.4 REPLACING THE EMERGENCY STOP UNIT WARNING Before you start replacement.7. turn off the control unit main power.4 Replacing the Emergency Stop Unit 138 .

(3) Mount a new magnetic contactor (MCC) on the DIN rail. (2) Holding down the magnetic contactor (MCC) a little.7. Magnetic contactor (MCC) Fig. turn off the control unit main power. REPLACING A UNIT 7.B–81535EN/02 MAINTENANCE 7.5 Replacing the magnetic contactor 139 . remove the MCC from the DIN rail. (4) Re–connect the cable. (1) Detach the cable from the magnetic contactor (MCC).5 REPLACING THE MAGNETIC CONTACTOR WARNING Before starting the replacement.

7.7.6 Replacing the servo Amplifier 140 . REPLACING A UNIT MAINTENANCE B–81535EN/02 7. turn off the control unit main power. Nut (2–M5) Power supply module servo amplifier module Fig. The following is the procedure for replacing the power supply module and servo amplifier module. (3) Mount a new servo amplifier. Remove the jumper connecting the DC link (L+ and L–). (1) Detach the cable from the servo amplifier. (4) Re–connect the cable and re–mount the jumper connecting the DC link (L+ and L–).6 REPLACING SERVO AMPLIFIERS WARNING Before you start replacement. reversing the removal step of (2). (2) Remove the two nuts from the top of the servo amplifier.

(2) Detach the cable from the teach pendant.7 Replacing the Teach Pendant 141 . check its specifications carefully. (1) Be sure that the power of a robot controller is off. REPLACING A UNIT 7.B–81535EN/02 MAINTENANCE 7.7 REPLACING THE TEACH PENDANT The specifications of the teach pendant vary with its use. When you replace the teach pendant. (3) Replace the teach pendant.7. Fig. Detach or attach the cable by rotating the connector retaining ring.

(4) Place a replacement fan on the upper section of the rack. (1) Be sure that the power of a robot controller is off. and pull the fan unit until it is unlatched.8 REPLACING THE CONTROL SECTION FAN MOTOR The control section fan motor can be replaced without using a tool.7. REPLACING A UNIT MAINTENANCE B–81535EN/02 7. Fan motor connector Fan motor Pull the fan motor unit toward you to unlatch it.7. Fig. The fan motor is mounted on the fan unit rack. (3) Lift the fan unit slightly. (2) Put your finger in the dent in the upper section of the fan unit. and slide it gently until it is latched. and dismount it from the rack.8 Replacing the Control Section Fan Motor 142 .

7.9 Replacing the fan motor of the servo amplifier control unit 143 . Lug White Black Red Note the orientation of the connector key. pull up the fan unit in the direction of the arrow (rightward in the figure).B–81535EN/02 MAINTENANCE 7. The fan unit is mounted at the top of the servo amplifier. Fan unit (for width of 60 mm) Fig. When mounting the fan motor. (1) Check that the robot controller is turned off. pull up the fan unit in the direction of the arrow. REPLACING A UNIT 7.9 REPLACING THE FAN MOTOR OF THE SERVO AMPLIFIER CONTROL UNIT The fan motor of the servo amplifier control unit can be replaced without using tools. and slightly press it in. note the orientation of the fan motor and connector. Holding the two lugs. (3) Place a new fan unit at the top of the servo amplifier. (2) Holding the two lugs.

Heat exchange Door fan unit Screws (4–M4) Nut (4–M5) Fig. (2) Detach the cable from the fan unit. Heat exchanger (1) Detach the cable from the heat exchanger.10 REPLACING THE DOOR FAN UNIT AND HEAT EXCHANGER WARNING Before starting the replacement. and pull the heat exchanger toward you.7.10 Replacing the door fan unit and heat exchanger 144 .7. (3) Detach the wiring from the door fan unit. reversing the removal procedure. (2) Remove the six fastening nuts (M4). REPLACING A UNIT MAINTENANCE B–81535EN/02 7. turn off the control unit main power. reversing the removal procedure. Never touch the fan motor while it is rotating. Door fan unit (1) Unscrew the four fastening screws (M4). (3) Mount a spare fan unit. (4) Mount a spare heat exchanger.

7. (4) Mount a new operator panel.11 REPLACING THE OPERATOR PANEL (1) Detach the cable from the circuit protector on the operator panel and the grounding line from the door. REPLACING A UNIT 7. Screw (4–M3) Fig.11 Replacing the operator panel NOTE The operator panel comprises the panel itself and the cables connected to the robot control board and emergency stop board. (2) Detach the cable (JD17) from the robot control board and the cable (CRT11) from the emergency stop board. reversing the removal steps of (1) to (3).B–81535EN/02 MAINTENANCE 7. (3) Unscrew the four screws (M3) fastening the operator panel. and remove the operator panel. 145 .

1 Remove the front nuts (2–M5) 2 Remove the back nuts (2–M5) 3 Remove the screws (4–M3) Fig.12 REPLACING THE POWER SUPPLY UNIT The power supply unit is mounted on the emergency stop unit. TBEB2) at the top.7.7. REPLACING A UNIT MAINTENANCE B–81535EN/02 7.12 Replacing the power supply unit 146 . (1) Detach all the cables from the emergency stop unit (emergency stop board and power supply unit). and replace the power supply unit. (2) Pull out the connector–type terminal block (TBEB1. (4) Unscrew the four screws fastening the power supply unit. (3) Remove the four nuts (1 and 2) fastening the emergency stop unit. and remove the emergency stop unit.

REPLACING A UNIT 7.13. find out the cause.5 If this fuse is blown. FUS1 FUS2 Fig. take an appropriate action. FUS1: For detecting a problem in the circuit on the robot control board: A60L–0001–0046#7. replace the DC/DC converter module.B–81535EN/02 MAINTENANCE 7. the DC/DC converter module or a device connected to the RS–232–C/RS–422 port may be faulty.5 If this fuse is blown.13 REPLACING A FUSE 7.1 Replacing a fuse on the robot control board 147 . If the device connected to the RS–232–C/RS–422 port is not faulty. FUS2: For protecting the 24V output to the peripheral device: A60L–0001–0046#7.1 Replacing a Fuse on the Robot Control Board If a fuse of the control unit is blown.7. then replace the fuse. The robot control board has the following fuses.13. the wiring to the peripheral device and a cable may be incorrect or damaged.

FUS4: For protecting the 24V output to the emergency stop circuit and teach pendant: A60L–0001–0046#1. robot.7.7. the brake circuit may be faulty.13. FUS5: For monitoring the emergency stop circuit: A60L–0001–0245 #GP20 If the fuse is blown. and robot interconnection cable. FUS4 FUS3 FUS5 Emergency stop board Fig.2 Replacing a Fuse on the Emergency Stop Board The emergency stop board has the following fuses.0 If this fuse is blown. the emergency stop board may be faulty. REPLACING A UNIT MAINTENANCE B–81535EN/02 7.0 If this fuse is blown. or the teach pendant or teach pendant cable may be faulty.13. FUS3: For monitoring the emergency stop circuit: A60L–0001–0046#1. the emergency stop circuit may be incorrectly routed. Replace the emergency stop board. Check the routing of the emergency stop circuit.2 Replacing a fuse on the emergency stop board 148 . Examine the brake. replace the emergency stop board. and replace the teach pendant and teach pendant cable. Alternatively.

7.3 Replacing a fuse on the emergency stop board 149 .B–81535EN/02 MAINTENANCE 7. REPLACING A UNIT 7. FUS6 Fig.3 Replacing the Fuse on the Door The door has the following fuse. the power supply unit on the emergency stop unit or the cooling fan unit may be faulty.13. FUS6: For protecting the 200VAC control output: A60L–0001–0101# P475H If this fuse is blown. Replace the power supply unit or cooling fan unit.13.

REPLACING A UNIT MAINTENANCE B–81535EN/02 7. Replace the power supply module. FU1 Remove the face plate Fig.13.4 Replacing the Fuse on the Power Supply Module The power supply module has the following fuse.13. FU1: For protecting the 200VAC input for generating power to the control circuit: A60L–0001–0359 If the fuse is blown.4 Replacing the fuse on the power supply module 150 .7.7. the power supply module may be faulty.

5 Replacing the Fuse on the Servo Amplifier Module The servo amplifier module has the following fuse.B–81535EN/02 MAINTENANCE 7.13. FU1: For protecting the +24 V input for generating power to the control unit: A60L–0001–0290#LM32C If this fuse is blown.7. Replace the servo amplifier module. FU1 Remove the control board Fig.5 Replacing the fuse on the servo amplifier module 151 . REPLACING A UNIT 7.13. the servo amplifier module may be faulty.

0 Process I/O board HE.7.13. HF FUSE1 Total edition 152 .6 Replacing the Fuse on the Process I/O Boards The following fuse is on each process I/O board. REPLACING A UNIT MAINTENANCE B–81535EN/02 7. A60L–0001–0046#2. FUSE1:Fuse for protecting the +24V output for peripheral equipment interfaces.

14.14. If such a failure occurs. The emergency stop board has the following relays. replace the relay.7. KA6: For external emergency stop output: A58L–0001–0192#1509A KA7: For brake control: A58L–0001–0192#1997R KA6 KA7 Emergency stop board Fig.B–81535EN/02 MAINTENANCE 7. REPLACING A UNIT 7.1 Replacing a relay on the emergency stop board 153 .14 REPLACING A RELAY 7.1 Replacing a Relay on the Emergency Stop Board Prolonged use of a relay might result in its contacts failing to make a secure connection or in them sticking to each other permanently.

15. Important data should be saved to the memory card or floppy disk beforehand in case of emergency. the battery alarm LED on the operator panel is lit. When replacing the memory backup battery. A new battery can maintain the contents of memory for about 4 years (Note). (4)Remove the old battery from the top of the Robot control board.1 Battery for Memory Backup (3 VDC) The programs. it becomes impossible to back up the content of the SRAM. and system variables are stored in the SRAM in the Robot control board. be needed within 4 years after the introduction of the robot. When the voltage of the battery becomes low. replace the battery as soon as possible. however. therefore. If the battery voltage gets lower. REPLACING A UNIT MAINTENANCE B–81535EN/02 7.7. and detach its connector. remove it from the battery holder. When this alarm is displayed. Clear the entire SRAM memory and reenter data after replacing the battery. the battery is factory–installed.15 REPLACING BATTERY 7. The above data is not lost even when the main battery goes dead. 154 . and the low–voltage battery alarm (system–035) is displayed on the teach pendant. the battery can be replaced within one or two weeks. In general. NOTE In a newly introduced robot. Replacing the lithium battery (1)Prepare a new lithium battery (ordering drawing number: A02B–0200–K102). do so while the robot controller is turned off in case of emergency. The power to the SRAM memory is backed up by a lithium battery mounted on the front panel of the Robot control board. (3)Turn the robot controller off. this depends on the system configuration. Battery replacement may. First unlatch the battery. (2)Turn the robot controller on for about 30 seconds. Turning on the power to the in this state causes system not to start and LED of seven segment on the Robot control board to be displayed “1” because the contents of memory are lost.

CAUTION Complete the steps (3) to (5) within 30 minutes.B–81535EN/02 MAINTENANCE 7. 155 . If the battery is left disconnected for a long time. To prevent possible data loss. insert a new one into the battery holder. Dispose of the replaced battery as an industrial waste. Confirm that the battery is latched firmly. according to the laws and other rules in the country where the controller is installed and those established by the municipality and other organizations that have jurisdiction over the area where the controller is installed. it is recommended that the robot data such as programs and system variables be backed up before battery replacement. REPLACING A UNIT Battery latch Battery connector Lithium battery (5)Remove the old battery. Replace the battery only with the specified battery (A02B–0200–K102). the contents of memory will be lost. and attach the connector. WARNING Using other than the recommended battery may result in the battery exploding.

.

III CONNECTION .

.

159 .B–81535EN/02 CONNECTIONS 1. GENERAL 1 GENERAL This chapter describes the connection and the installation of the electrical interface.

160 . R–J3iB Mate controller Peripheral device Robot control board Operation panel RS–232–C RS–422/485 Teach pendant (RDI/RDO) Emergency stop unit Power supply unit (Note2) Transformer Emergency stop board (Brake) Emergency stop Fan Robot Fuse Pulse coder Circuit protector MCC Servo amplifier Power NOTE Tranceformer is installed when the robot is for 6–axes brake specification. BLOCK DIAGRAM CONNECTIONS B–81535EN/02 2 BLOCK DIAGRAM Following are the block diagrams of the electrical interface connection for R–J3iB Mate.2.

21. 12. 21. 22 Battery CP5 JRS12 FENCE11.B–81535EN/02 CONNECTIONS 3. 22 CP5B CRS24 EMGOUT1. 12. 2 EXT24V. 0V CRS16 Teach pendant Emergency stop circuit PCMCIA PCMCIA COP10A CRM82 JD17 JD1A JD1B CRM79 CRM81 Servo amplifier Mechanical unit RS–232–C or RS–422/485 I/O Link (master) I/O Link (slave : option) Peripheral device Peripheral device (option) 161 . CONNECTION DETAILS 3 CONNECTION DETAILS Robot control board CP8B Emergency stop unit EMGIN11.

A grounding stud is provided beside the circuit protector. To primary power supply 3Φ200VAC By using cable straps. located beside the circuit protector. Circuit protector Terminal is M4. Connect the primary power ground wire to this stud. After connection. CONNECTION DETAILS CONNECTIONS B–81535EN/02 3. an optional power cable can be specified. Connect the primary power ground wire to the grounding stud. secure the primary power cable to the screws used to fasten the fan. insulate the protector terminal by fitting the provided terminal cover.3. Use the cable holders are provided at these locations.1 CONNECTION OF POWER SUPPLY CABLE When the stand–alone controller is used. Use an M4 crimp terminal. 162 . You can specify the power supply cables as the option. NOTE Connect the primary power cable to the circuit protector.

1 Name Robot control board Drawing number A16B–3200–0450 Master f(*) Slave f(*) Remarks Standard NOTE The I/O Link of the robot control board is in the master mode by default. The I/O Link can be used in the slave mode by changing the software parameter setting. Refer to the operator ’s manual for setting slave mode.2 FANUC I/O LINK Table 3. CONNECTION DETAILS 3. 163 .2 Types of FANUC I/O Links I/O Link No.B–81535EN/02 CONNECTIONS 3.

PLC When the R–J3iB Mate control unit is used as a slave of the I/O link (when a CNC or PLC is used as the master of the I/O link) JD1A CNC.3. JD1A1 JD1A2 ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏ ÏÏ ÏÏ Ï ÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏ Ï Ï Ï Ï Ï ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏ Ï Ï Ï Ï ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏ ÏÏÏ ÏÏÏÏÏÏ Ï ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏ ÏÏÏ ÏÏÏÏÏÏ Ï When the R–J3iB Mate control unit is used as the master of an I/O link (when R–J3iB Mate control the process I/O printed board) to other I/O link JD1B FANUC I/O Unit etc. PLC ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏ ÏÏÏ JD1B1 FANUC I/O Link connection unit JD1B2 164 ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏ Ï ÏÏ JD4* JD4* Process I/O printed boord etc. to other I/O link JD1B JD1A R–J3iB Mate *Note Robot control board is required. CONNECTION DETAILS CONNECTIONS B–81535EN/02 JD1A R–J3iB Mate *Note that the connector name differs from that of the standard FANUC I/O link. JD1B FANUC I/O Unit etc./Switch by the software . When the R–J3iB Mate control unit is used as the master and a slave of an I/O link JD1A R–J3iB Mate master JD1A CNC.

use +5V. b) If the power to the CNC or robot controller is turned off after the system has been started. Customer should be prepare this cable. Power off when it is connected. use +5V. turn off the power to all units. ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ When making a connection with a CNC via an I/O link. apply the following timing to turn the power to the CNC and robot controller on/off: a) Turn on the power to the slave units when or before turning on the master power. and 3 and 4. Note) When using an optical I/O link adaptor. and ground the shield on the CNC side. JD1A JD1B Robot control board For other I/O link Earth plate Peel off the sheath of the shielded cable. To reestablish normal connection via the I/O link. an I/O link error will occur. then turn on the power as explained in a) above. (1)Twisted–pair cables should be used for pin pairs 1 and 2. The customer is requested to ground the shield. CONNECTION DETAILS 3.3 CONNECTION OF I/O LINK CABLE Cable connections should be made according to the system. I/O Link cable connection 1. (2)Use unified shielding.B–81535EN/02 CONNECTIONS 3. 2. JD1A interface 11 0V JD4(JD1B) interface 11 0V 01 RXSLC1 03 TXSLC1 05 06 08 10 01 RXSLC2 03 TXSLC2 05 06 12 13 14 15 16 17 18 19 20 0V 0V 0V 0V 0V 02 *RXSLC1 04 *TXSLC1 12 13 14 15 16 17 18 19 20 0V 0V 0V 0V 0V 02 *RXSLC2 04 *TXSLC2 07 07 (+5V) (+5V) (+5V) (+5V) 08 10 09 (+5V) 09 (+5V) Note) When using an optical I/O link adaptor. then ground the shield here. 165 .

3. CONNECTION DETAILS CONNECTIONS B–81535EN/02 Cable connection Master Robot control board JD1A RXSLC1 (1) *RXSLC1 (2) TXSLC1 (3) *TXSLC1 (4) 0V (11) 0V (12) 0V (13) 0V (14) 0V (15) 0V (16) I/O unit. PLC etc JD1A [RX] SIN (1) [*RX] *SIN (2) [TX] SOUT (3) [*TX] *SOUT (4) 0V (11) 0V (12) 0V (13) 0V (14) 0V (15) 0V (16) Robot control board JD1B (1) RXSLC2 (2) *RXSLC2 (3) TXSLC2 (4) *TXSLC2 (11) 0V (12) 0V (13) 0V (14) 0V (15) 0V (16) 0V 166 . etc JD1B (1) SIN [RX] (2) *SIN [*RX] (3) SOUT [TX] (4) *SOUT [*TX] (11) 0V (12) 0V (13) 0V (14) 0V (15) 0V (16) 0V Slave CNC.

4. CONNECTION DETAILS 3.1 Circuit Diagram of Emergency Stop Teach pendant Emergency stop button +24T CRS16 Emergency stop board (From CP5A) 24VIN +24EXT FUS4 FUS3 +24V +24EXT +24V Operation panel mode switch CRT11 AUTO SR2–1 T1 +24T Enable/Disable switch KA1–3 KA2–2 KA3–2 +24EXT SR2–2 SR2–3 Emergency stop button 0V Dead man switch +24V KA1–1 +24EXT Robot control board MODE1 MODE2 JRS12 CRS24 0VEXT +24V INT24V EXT24V INT0V EXT0V TBEB1 24V external power supply External emergency stop OP–EMG 0V 0VEXT EMGIN11 EMGIN12 FENCE EX–EMG MCCMON 0VEXT KA2–1 + EMGIN21 EMGIN22 FENCE11 FENCE12 TBEB2 Safety fence Mode switch SR2–1 SR2–2 SR2–3 AUTO CLOSE OPEN CLOSE T1 OPEN CLOSE OPEN 0VEXT KA3–1 FENCE21 FENCE22 EMGOUT1 CRM83 +24V EMGOUT1 KA6–1 Servo amplifier (α PSMR–1i) CRR78 CX3 MCCOFF3 0V MCCOFF4 0V KA6–2 RL1 CX4 +24V ESP +24V ESP MCC (KM1) KM1–1 KM1–2 CZ1 3φ200VAC KM1–3 KM1–4 KM1–5 167 .B–81535EN/02 CONNECTIONS 3.4 EMERGENCY STOP CIRCUIT 3.

Confirm the operation of emergency stop switches on the teach pendant and on the front panel. but fence input is not reflected in the external emergency stop output. CONNECTION DETAILS CONNECTIONS B–81535EN/02 3. The contact between EMGIN21 and EMGIN22 or between FENCE21 and FENCE22 monitors the input state. To enable external emergency stop input and fence input. after you wired the external emergency stop input and the servo off input.4.2 External Emergency Stop Input Customer should prepare this cable TBEB1 EMGIN11 EMGIN12 EMGIN21 EMGIN22 TBEB2 FENCE11 FENCE12 FENCE21 FENCE22 EMGOUT1 EMGOUT2 Cable holder EXT24V INT24V INT0V EXT0V EMGIN11 EMGIN12 EMGIN21 EMGIN22 FENCE11 FENCE12 FENCE21 FENCE22 EMGIN1 EMGIN2 SVOFF1 SVOFF2 External emergency stop input Servo off input NOTE The contact between EMGIN11 and EMGIN12 or between FENCE11 and FENCE12 opens or closes the emergency stop circuit. prepare the contact for opening and closing the emergency stop circuit and the contact for monitoring. External emergency stop input is reflected in the external emergency stop output. first disconnect these jumper wires. 168 ÏÏ ÏÏ ÏÏ ÏÏ Emergency stop board When the robot is shipped.3. (Single–channel with monitoring safety circuit) When using external emergency stop input and fence input. ÏÏ ÏÏ ÏÏ ÏÏ . EMGIN11 and EMGIN12/ EMGIN21 and EMGIN22. FENCE11 and FENCE12/ FENCE21 and FENCE22 are short–connected. then make the necessary connections.

4.3 External Emergency Stop Output Customer should prepare this cable. CONNECTION DETAILS 3. Cable holder Emergency stop from the teach pendant and emergency stop from the operator panel are reflected to the external emergency stop outputs. TBEB1 EMGIN11 EMGIN12 EMGIN21 EMGIN22 TBEB2 FENCE11 FENCE12 FENCE21 FENCE22 EMGOUT1 EMGOUT2 EMGOUT1 EMGOUT2 TP Emergency stop OP Emergency stop EXT24V INT24V INT0V EXT0V Emergency stop board EMGOUT11 EMGOUT12 To peripheral control sequencer etc.B–81535EN/02 CONNECTIONS 3. 169 ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ . EMGOUT1 and EMGOUT2.

are always output regardless of the power state of the robot control unit. CONNECTION DETAILS CONNECTIONS B–81535EN/02 3. The circuit will not function properly if a plus ground power supply is connected. Before using external 24 V.4. 24 V power supply +24V EXT24V INT24V INT0V EXT0V EXT24V INT24V INT0V Emergency stop board 0V EXT0V NOTE Connect a minus ground power supply for externally connected +24V.3. remove this short connection board. EMGOUT1 and EMGOUT2. TBEB1 EMGIN11 EMGIN12 EMGIN21 EMGIN22 TBEB2 FENCE11 FENCE12 FENCE21 FENCE22 EMGOUT1 EMGOUT2 EXT24V EXT0V A short connection board is inserted at the factory. 170 ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ . the external emergency stop outputs. Cable holder When 24 V is applied externally.4 External 24 V Input Customer should prepare this cable.

B–81535EN/02

CONNECTIONS

3. CONNECTION DETAILS

3.5
COONECTION OF SERVO AMPLIFIER
LR Mate 100iB
PSM AMP1 AMP2

POWER SUPPLY MODULE (αPSMR–1i) A06B–6115–H001
TB1 from MCC CZ1 L+

SERVO AMPLIFIER MODULE (αSVM2–20/20i) A06B–6114–H205
TB1 L+

SERVO AMPLIFIER MODULE (αSVM3–10/10/10i) A06B–6114–H302
TB1 L+ L–

L– L– from circuit protector from emergency stop board COP10B CX1A CXA2A CXA2B CXA2A

COP10B CXA2B

COP10A CXA2A

CX3

JF1 (L) JF2 (M)

JF1 (L) JF2 (M) JF3 (N)

CX4

CZ2 L from robot control board CZ2 M

CZ2 L CZ2 M CZ2 N

to robot Pulse coder Motor power

LR Mate 200iB/ARC Mate 50iB
PSM AMP1 AMP2

POWER SUPPLY MODULE (αPSMR–1i) A06B–6115–H001
TB1 from MCC CZ1 L+

SERVO AMPLIFIER MODULE (αSVM3–10/10/10i) A06B–6114–H302
TB1 L+

SERVO AMPLIFIER MODULE (αSVM3–10/10/10i) A06B–6114–H302
TB1 L+ L–

L– L– from circuit protector from emergency stop board COP10B CX1A CXA2A CXA2B CXA2A

COP10B CXA2B

COP10A CXA2A

CX3

JF1 (L) JF2 (M)

JF1 (L) JF2 (M) JF3 (N)

CX4 JF3 (N) CZ2 L from robot control board CZ2 M CZ2 N

CZ2 L CZ2 M CZ2 N

to robot Pulse coder Motor power

171

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.6
CONNECTION OF ROBOT

CRM82 JF1–3

Power cable to RMP Signal cable Ground cable

TBEB3

CZ2 L, M, N

172

B–81535EN/02

CONNECTIONS

3. CONNECTION DETAILS

3.7
CONNECTION OF TEACH PENDANT CABLE

Emergency stop unit CRS16

To teach pendant

Earth plate

Fig.3.7 Teach pendant cable

173

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.8
CONNECTION OF CABLE FOR RS–232–C/RS–422

Selection of RS–232–C or RS–422 (option) interface need setting of software.

Communication port

ÏÏÏÏÏ ÏÏÏÏÏÏÏÏ Ï ÏÏÏÏÏÏÏÏ Ï ÏÏÏÏÏÏÏÏ Ï ÏÏÏÏ Ï ÏÏÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏÏÏ Ï ÏÏÏÏÏÏÏÏ Ï ÏÏÏÏÏÏÏÏ Ï ÏÏÏÏÏÏÏÏ Ï ÏÏÏÏÏÏÏÏ Ï ÏÏÏÏ Ï ÏÏÏÏÏÏÏÏ ÏÏÏÏÏ Ï
01 02 03 04 05 06 07 FG TXD RTS 14 15 (TX) RXD CTS 0V (*TX) (RX) 16 17 (*RX) DSR 18 19 20 21 22 23 24 25 08 09 10 11 12 13 DTR +24E

174

Ï Ï
Flopply, handy file etc.

Signals whose names are enclosed in parentheses are assigned to use the RS–422 (option) interface. The numbers of the interface differ from those of the standard RS–422 (option) interface. Take the caution when designing the interface.

B–81535EN/02

CONNECTIONS

3. CONNECTION DETAILS

3.9
CONNECTING A CABLE TO A PERIPHERAL DEVICE 3.9.1
Peripheral Device Interfaces CRM79 and CRM81
Table 3.9.1 Types of FANUC I/O Links Peripheral device interface No. 1 Name
Robot control board A

Drawing number A16B–3200–0450

CRM79 DI 20 DO 20

CRM81 DI 8 DO 4

Remarks Standard

NOTE The DI and DO signals of CRM79 and CRM81 include special signals.

Connecting a peripheral device (CRM79 or CRM81)

Robot control board CRM81 CRM79

to peripheral device Grounding plate Strip off the sheathing of the shield cable and connect the cable to the grounding plate.

Fig.3.9.1 Connecting the peripheral device cable

175

3. CONNECTION DETAILS CONNECTIONS B–81535EN/02 3. To use the +24V common. (Note) Maximum output current per one SDO signal is 70mA.LTD Connector MR–50LMH(Male) 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SDICOM1 SDICOM2 SDO120 SDI117 SDI118 SDI119 SDI120 SDO117 SDO118 SDO119 0V 0V +24E +24E SDICOM1 and SDICOM2 are the signals used for selecting a common for SDI signals. Turn off the controller when connecting the cable..2 When the Robot is Connected to the CNC by a Peripheral Device Cable NOTE See the operator’s MANUAL for the detail information.9.) SDI101 SDI102 SDI103 SDI104 SDI105 SDI106 SDI107 SDI108 SDI109 SDI110 SDI111 SDI112 SDI113 SDI114 SDI115 SDI116 0V 0V 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 SDO101 SDO102 SDO103 SDO104 SDO105 SDO106 SDO107 SDO108 SDO109 SDO110 SDO111 SDO112 SDO113 SDO114 SDO115 SDO116 +24E +24E Connector in cable side HONDA TSUSHIN CO. SDICOM1→Selects a common for SDI101 to SDI108. To use the 0V common. 176 ÏÏÏÏÏ Ï ÏÏÏÏÏÏ Ï ÏÏ ÏÏÏÏÏÏ Ï ÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ CNC ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï ÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï ÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ Ï ÏÏÏÏÏ Ï ÏÏÏÏÏ ÏÏÏÏÏ Ï ÏÏ ÏÏÏÏÏ Ï ÏÏÏÏÏ Ï . connect SDICOM1 and SDICOM2 to 0V. Robot control board CRM79 CRM81 CRM79 interface (Specified signals are not allocated and the Robot is connected to CNC and PLC by a FANUC I/O Link cable. SDICOM2→Selects a common for SDI109 to SDI120. connect SDICOM1 and SDICOM2 to +24V.

2 The common (selected with SDICOM2) for a dedicated signal should ideally be the +24V common.. 3 Allocation of the specified signals can be changed from the teach pendant. When 24 V common is used.LTD Connector MR–50LMH (Male) ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ SDO101 *HOLD START PNS1 10 12 13 14 PNS2 15 PNS3 0V 16 PNS4 0V 34 SDO102 19 SDICOM1 35 SDO103 20 SDICOM2 36 SDO104 21 SDO120 37 SDO105 22 SDI117 38 SDO106 23 SDI118 39 SDO107 24 SDI119 40 SDO108 25 SDI120 41 SDO109 26 SDO117 42 SDO110 27 SDO118 43 SDO111 28 SDO119 44 SDO112 29 0V 45 CMDENBL 30 0V 46 FAULT 31 +24E 47 BATALM 32 +24E 48 BUSY 49 +24E 50 +24E 17 18 SDICOM1 and SDICOM2 signal are common selection signal for SDI. SDICOM2”Selects a common for *HOLD. but the 0V common can also be used. and SDI117 to SDI120. START.B–81535EN/02 CONNECTIONS 3.) 01 02 03 04 05 06 07 08 09 11 SDI101 SDI102 SDI103 SDI104 SDI105 SDI106 SDI107 SDI108 RESET ENBL 33 Connector in cable side HONDA TSUUSHIN CO. ENBL. connect to +24V SDICOM1”Selects a common for SDI101 to SDI108. When 0V common is used. 177 . connect to 0V. RESET. NOTE 1 Maximum output current for one SDO signal is 70mA. PNS1 to PNS4. CONNECTION DETAILS CRM79 interface (standard allocation of specified signals and the Robot is connected to the CNC and PLC by a peripheral device cable.

RESET. 2 The common (selected with SDICOM1 and 2) for a dedicated signal should ideally be the +24V common. RSR4/PNS4. HOME. RSR2/PNS2. PNSTROBE. RSR8/PNS8. PROD_START. START. NOTE 1 Maximum output current for one SDO signal is 70mA. *HOLD. ENBL. When 0V common is used. connect to 0V. CONNECTION DETAILS CONNECTIONS B–81535EN/02 CRM79 interface (standard allocation of specified signals and the Robot is connected to the CNC and PLC by a peripheral device cable. 178 . but the 0V common can also be used. connect to +24V SDICOM1 → Selects a common for *IMSTP. RSR5/PNS5.. *SFSPD. RSR7/PNS7.LTD Connector MR–50LMH (Male) ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ Ï Ï ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ 33 CMDENBL SYSRDY PAUSED HELD FAULT *SFSPD CSTOPI RESET START HOME PROGRUN ATPERCH TPENBL BUSY BATALM ENBL 09 RSR1/PNS1 10 RSR2/PNS2 11 RSR3/PNS3 12 RSR4/PNS4 13 RSR5/PNS5 14 RSR6/PNS6 15 RSR7/PNS7 15 RSR8/PNS8 17 0V 18 0V ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 +24E +24E SDICOM1 and SDICOM2 signal are common selection signal for SDI. RSR6/PNS6. RSR3/PNS3. 3 Allocation of the specified signals can be changed from the teach pendant.) 01 02 03 04 05 06 07 08 *IMSTP *HOLD 34 19 SDICOM1 35 20 SDICOM2 36 reserve 21 37 22 PNSTROBE 38 23 PROD_START 39 24 SDI119 40 25 SDI120 41 26 ACK7/SNO7 42 27 ACK8/SNO8 43 SNACK 28 44 29 0V 45 30 0V 46 31 +24E 47 32 +24E 48 49 50 Connector in cable side HONDA TSUUSHIN CO. SDICOM2 → Selects a common for RSR1/PNS1. When 24 V common is used.3. CSTOPI.

30) 0V CRM79 (2) CRM79 (1) Peripheral device Fig.B–81535EN/02 CONNECTIONS 3. CONNECTION DETAILS In case +24V common at the peripheral device side.50) receiver circuit SDI101 SDI102 SDI103 SDI104 SDI105 SDI106 SDI107 SDI108 SDICOM1 SDI109 SDI110 SDI111 SDI112 SDI113 SDI114 SDI115 SDI116 SDI117 SDI118 SDI119 SDI120 SDICOM2 RV 3.3.2 (a) Peripheral device control interface : CRM79 (Input signal.9.29.3k RV CRM79 (3) RV CRM79 (4) RV CRM79 (5) RV CRM79 (6) RV CRM79 (7) RV CRM79 (8) RV CRM79 (19) RV CRM79 (9) RV CRM79 (10) RV CRM79 (11) RV CRM79 (12) RV CRM79 (13) RV CRM79 (14) RV CRM79 (15) RV CRM79 (16) RV CRM79 (22) RV CRM79 (23) RV CRM79 (24) RV CRM79 (25) RV CRM79 (20) RV CRM79 (17.32.18.49. (Specified signals are not allocated) Control unit (peripheral device interface : CRM79) +24E Connector pin No CRM79 (31. +24V common) 179 .

18.3.9.3k CRM79 (1) CRM79 (2) Peripheral device Fig. (Specified signals are not allocated) Control unit (peripheral device interface : CRM79) +24E Connector pin No CRM79 (31.50) receiver circuit SDI101 SDI102 SDI103 SDI104 SDI105 SDI106 SDI107 SDI108 SDICOM1 SDI109 SDI110 SDI111 SDI112 SDI113 SDI114 SDI115 SDI116 SDI117 SDI118 SDI119 SDI120 SDICOM2 RV RV CRM79 (3) RV CRM79 (4) RV CRM79 (5) RV CRM79 (6) RV CRM79 (7) RV CRM79 (8) RV CRM79 (19) RV CRM79 (9) RV CRM79 (10) RV CRM79 (11) RV CRM79 (12) RV CRM79 (13) RV CRM79 (14) RV CRM79 (15) RV CRM79 (16) RV CRM79 (22) RV CRM79 (23) RV CRM79 (24) RV CRM79 (25) RV CRM79 (20) RV CRM79 (17.2 (b) Peripheral device control interface : CRM79 (Input signal.32. CONNECTION DETAILS CONNECTIONS B–81535EN/02 In case 0V common at the peripheral device side.3.29.49.30) 0V 3. 0V common) 180 .

B–81535EN/02 CONNECTIONS 3.18. Fig.30) 0V LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD 0V +24V +24V regurated power supply Max.29.2 (c) Peripheral device control interface : CRM79 (Output signal) 181 .3. current per SDO is 70mA. CONNECTION DETAILS (Specified signals are not allocated) Control unit (peripheral device interface : CRM79) Connector pin No Driver circuit SDO101 DV CRM79 (33) Peripheral device LOAD RELAY SDO102 SDO103 SDO104 SDO105 SDO106 SDO107 SDO108 SDO109 SDO110 SDO111 SDO112 SDO113 SDO114 SDO115 SDO116 SDO117 SDO118 SDO119 SDO120 CRM79 (34) DV CRM79 (35) DV CRM79 (36) DV CRM79 (37) DV CRM79 (38) DV CRM79 (39) DV CRM79 (40) DV CRM79 (41) DV CRM79 (42) DV CRM79 (43) DV CRM79 (44) DV CRM79 (45) DV CRM79 (46) DV CRM79 (47) DV CRM79 (48) DV CRM79 (26) DV CRM79 (27) DV CRM79 (28) DV CRM79 (21) DV CRM79 (17.9.

30) 0V CRM79 (2) CRM79 (1) Peripheral device Fig.29.32.50) receiver circuit SDI101 SDI102 SDI103 SDI104 SDI105 SDI106 SDI107 SDI108 SDICOM1 SDI109 SDI110 SDI111 SDI112 SDI113 SDI114 SDI115 SDI116 SDI117 SDI118 SDI119 SDI120 SDICOM2 RV 3.3.2 (d) Peripheral device control interface : CRM79 (Input signal.3.49. CONNECTION DETAILS CONNECTIONS B–81535EN/02 In case +24V common at the peripheral device side.3k RV CRM79 (3) RV CRM79 (4) RV CRM79 (5) RV CRM79 (6) RV CRM79 (7) RV CRM79 (8) RV CRM79 (19) RV CRM79 (9) RV CRM79 (10) RV CRM79 (11) RV CRM79 (12) RV CRM79 (13) RV CRM79 (14) RV CRM79 (15) RV CRM79 (16) RV CRM79 (22) RV CRM79 (23) RV CRM79 (24) RV CRM79 (25) RV CRM79 (20) RV CRM79 (17.9. (Specified signals are allocated) Control unit (peripheral device interface : CRM79) +24E Connector pin No CRM79 (31.18. +24V common) 182 .

3k CRM79 (1) CRM79 (2) Peripheral device Fig.29.3.49. 0V common) 183 .B–81535EN/02 CONNECTIONS 3. CONNECTION DETAILS In case 0V common at the peripheral device side.9.18. (Specified signals are allocated) Control unit (peripheral device interface : CRM79) +24E Connector pin No CRM79 (31.50) receiver circuit SDI101 SDI102 SDI103 SDI104 SDI105 SDI106 SDI107 SDI108 SDICOM1 SDI109 SDI110 SDI111 SDI112 SDI113 SDI114 SDI115 SDI116 SDI117 SDI118 SDI119 SDI120 SDICOM2 RV RV CRM79 (3) RV CRM79 (4) RV CRM79 (5) RV CRM79 (6) RV CRM79 (7) RV CRM79 (8) RV CRM79 (19) RV CRM79 (9) RV CRM79 (10) RV CRM79 (11) RV CRM79 (12) RV CRM79 (13) RV CRM79 (14) RV CRM79 (15) RV CRM79 (16) RV CRM79 (22) RV CRM79 (23) RV CRM79 (24) RV CRM79 (25) RV CRM79 (20) RV CRM79 (17.2 (e) Peripheral device control interface : CRM79 (Input signal.30) 0V 3.32.

3.3.18. current per SDO is 70mA.9.2 (f) Peripheral device control interface : CRM79 (Output signal) 184 . CONNECTION DETAILS CONNECTIONS B–81535EN/02 (Specified signals are allocated) Control unit (peripheral device interface : CRM79) Connector pin No Driver circuit SDO101 DV CRM79 (33) Peripheral device LOAD RELAY SDO102 SDO103 SDO104 SDO105 SDO106 SDO107 SDO108 SDO109 SDO110 SDO111 SDO112 SDO113 SDO114 SDO115 SDO116 SDO117 SDO118 SDO119 SDO120 CRM79 (34) DV CRM79 (35) DV CRM79 (36) DV CRM79 (37) DV CRM79 (38) DV CRM79 (39) DV CRM79 (40) DV CRM79 (41) DV CRM79 (42) DV CRM79 (43) DV CRM79 (44) DV CRM79 (45) DV CRM79 (46) DV CRM79 (47) DV CRM79 (48) DV CRM79 (26) DV CRM79 (27) DV CRM79 (28) DV CRM79 (21) DV CRM79 (17.29.30) 0V LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD 0V +24V +24V regurated power supply Max. Fig.

32.3.18.30) 0V Fig.B–81535EN/02 CONNECTIONS 3.49. +24V common) 185 . CONNECTION DETAILS In case +24V common at the peripheral device side.3k CRM79 (4) RV CRM79 (5) RV CRM79 (6) RV CRM79 (7) RV CRM79 (8) RV CRM79 (19) RV CRM79 (9) RV CRM79 (10) RV CRM79 (11) RV CRM79 (12) RV CRM79 (13) RV CRM79 (14) RV CRM79 (15) RV CRM79 (16) RV CRM79 (22) RV CRM79 (23) RV CRM79 (24) SDI119 SDI120 SDICOM2 RV CRM79 (25) RV CRM79 (20) RV CRM79 (17. (Specified signals are allocated quickly) Control unit (peripheral device interface : CRM79) +24E Connector pin No CRM79 (31.29.2 (g) Peripheral device control interface : CRM79 (Input signal.9.50) receiver circuit *IMSTP *HOLD *SFSPD CSTOPI RESET SRART HOME ENBL SDICOM1 RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSTROBE PROD_START Peripheral device CRM79 (1) CRM79 (2) CRM79 (3) RV RV RV 3.

32.49. (Specified signals are allocated quickly) Control unit (peripheral device interface : CRM79) +24E Connector pin No CRM79 (31.9. 0V common) 186 .3.30) 0V 3.50) receiver circuit *IMSTP *HOLD *SFSPD CSTOPI RESET START HOME ENBL SDICOM1 RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSTROBE PROD_START Peripheral device RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV CRM79 (1) CRM79 (2) CRM79 (3) CRM79 (4) CRM79 (5) CRM79 (6) CRM79 (7) CRM79 (8) CRM79 (19) CRM79 (9) CRM79 (10) CRM79 (11) CRM79 (12) CRM79 (13) CRM79 (14) CRM79 (15) CRM79 (16) CRM79 (22) CRM79 (23) CRM79 (24) CRM79 (25) CRM79 (20) CRM79 (17. CONNECTION DETAILS CONNECTIONS B–81535EN/02 In case 0V common at the peripheral device side.3k SDI119 SDI120 SDICOM2 Fig.2 (h) Peripheral device control interface : CRM79 (Input signal.18.29.3.

18. Fig.2 (i) Peripheral device control interface : CRM79 (Output signal) 187 .30) 0V Max.29.3. CONNECTION DETAILS (Specified signals are allocated quickly) Control unit (peripheral device interface : CRM79) Driver circuit CMDENBL DV Connector pin No CRM79 (33) Peripheral device LOAD RELAY SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK reserve DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV CRM79 (34) CRM79 (35) CRM79 (36) CRM79 (37) CRM79 (38) CRM79 (39) CRM79 (40) CRM79 (41) CRM79 (42) CRM79 (43) CRM79 (44) CRM79 (45) CRM79 (46) CRM79 (47) CRM79 (48) CRM79 (26) CRM79 (27) CRM79 (28) CRM79 (21) LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD 0V +24V +24V regurated power supply CRM79 (17.9. current per SDO is 70mA.B–81535EN/02 CONNECTIONS 3.

188 .3. CAUTION The maximum output current of each SDO or special signal is 70 mA. CONNECTION DETAILS CONNECTIONS B–81535EN/02 CRM81 interface (When a special signal is not allocated. when CNC and PLC are connected by an I/O Link cable) A 01 02 03 04 05 06 07 08 09 10 +24V SDO81 SDO83 SDO82 SDO84 0V 0V SDI81 SDI83 SDI85 SDI87 SDICOM B SDI82 SDI84 SDI86 SDI88 Cable–side connector YAMAICHI ELECTRICITY Connector Housing – UFS–20B–04 Contact – Contact 66 type (UFS contact) CRM81 interface (When a special signal is allocated. when CNC and PLC are connected by a peripheral device cable) A 01 02 03 04 05 06 07 08 09 10 +24E CMDENBL B RESET ENBL PNS2 PNS4 Cable–side connector YAMAICHI ELECTRICITY Connector Housing – UFS–20B–04 Contact – Contact 66 type (UFS contact) *HOLD START PNS1 PNS3 SDICOM FAULT BUSY 0V 0V BATALM SDICOM1 is a common signal that can be used either as an SDI or special signal. +24 V common: Connected to 0 V 0 V common: Connected to +24 V SDICOM ³ Selects a common for SDI81 to SDI88.

CONNECTION DETAILS In case +24V common at the peripheral device side.9. (Specified signal is not allocated.3.B–81535EN/02 CONNECTIONS 3.B10) 0V 3.) Control unit (peripheral device interface : CRM81) +24E Connector pin No CRM81 (A10) receiver circuit SDI81 SDI82 SDI83 SDI84 SDI85 SDI86 SDI87 SDI88 SDICOM RV RV CRM81 (A2) RV CRM81 (B2) RV CRM81 (A3) RV CRM81 (B3) RV CRM81 (A4) RV CRM81 (B5) RV CRM81 (A5) RV CRM81 (B9. +24V common) 189 .2 (j) Peripheral device control interface : CRM81 (Input signal.3k CRM81 (A1) CRM81 (B1) Peripheral device Fig.

2 (k) Peripheral device control interface : CRM81 (Input signal. Fig. (Specified signal is not allocated.3k CRM81 (A1) CRM81 (B1) Peripheral device Fig.) Control unit (peripheral device interface : CRM81) Connector pin No Driver circuit SDO8 1 DV CRM81 (A7) RELAY Peripheral device LOAD SDO82 SDO83 SDO84 CRM81 (B7) DV CRM81 (A8) DV CRM81 (B8) DV CRM81 (B9.) Control unit (peripheral device interface : CRM81) +24E Connector pin No CRM81 (A10) receiver circuit SDI81 SDI82 SDI83 SDI84 SDI85 SDI86 SDI87 SDI88 SDICOM RV RV CRM81 (A2) RV CRM81 (B2) RV CRM81 (A3) RV CRM81 (B3) RV CRM81 (A4) RV CRM81 (B5) RV CRM81 (A5) RV CRM81 (B9.B10) 0V LOAD 0V +24V +24V regurated power supply LOAD LOAD Max.3. current per SDO is 70mA.3.9.B10) 0V 3. CONNECTION DETAILS CONNECTIONS B–81535EN/02 In case 0V common at the peripheral device side.3.2 (l) Peripheral device control interface : CRM81 (Output signal) 190 .9. 0V common) (Specified signal is not allocated.

+24V common) 191 .9.3. (Specified signal is allocated quickly) Control unit (peripheral device interface : CRM81) +24E Connector pin No CRM81 (A10) receiver circuit RV 3. CONNECTION DETAILS In case +24V common at the peripheral device side.B–81535EN/02 CONNECTIONS 3.3k RV RV RV RV RV RV RV RV CRM81 (A1) CRM81 (B1) CRM81 (A2) CRM81 (B2) CRM81 (A3) CRM81 (B3) CRM81 (A4) CRM81 (B5) CRM81 (A5) CRM81 (B9 .2 (m) Peripheral device control interface : CRM81 (Input signal.B10) 0V Peripheral device *HOLD RESET START ENBL PNS1 PNS2 PNS3 PNS4 SDICOM Fig.

3.3. (Specified signal is allocated quickly) Control unit (peripheral device interface : CRM81) +24E Connector pin No CRM81 (A10) receiver circuit *HOLD RESET START ENBL PNS1 PNS2 PNS3 PNS4 SDICOM RV RV RV RV RV RV RV RV RV 3. current per SDO is 70mA. CONNECTION DETAILS CONNECTIONS B–81535EN/02 In case 0V common at the peripheral device side.3.2 (o) Peripheral device control interface : CRM81 (Output signal) 192 .9.3k CRM81 (A1) CRM81 (B1) CRM81 (A2) CRM81 (B2) CRM81 (A3) CRM81 (B3) CRM81 (A4) CRM81 (B5) CRM81 (A5) CRM81 (B9 .9. Fig. 0V common) (Specified signal is allocated quickly) Control unit (peripheral device interface : CRM81) Connector pin No driver circuit CMDENBL DV CRM81 (A7) RELAY LOAD Peripheral device FAULT BATALM BUSY DV DV DV CRM81 (B7) CRM81 (A8) LOAD LOAD CRM81 (B8) LOAD CRM81 (B9 .B10) 0V Peripheral device Fig.2 (n) Peripheral device interface : CRM81 (Input signal.B10) 0V 0V +24V +24V regurated power supply Max.

3. use a protective resistance.0 V (approx.B–81535EN/02 CONNECTIONS 3.3 Digital I/O Signal Specifications This section describes the specifications of the digital I/O signals interfaced with the peripheral device and end effector. connect them in parallel with diodes for preventing back electromotive force. CONNECTION DETAILS 3.9.) D : 100 V or more : 1 A or more D D Notes on use Do not use the +24 V power supply of the robot. If a load causing a surge current such as turning on LED is connected.3.mA Open collector NPN 1. solenoid. When loading a relay. Applicable signal Output signal of peripheral device interface CRM79.1 Peripheral device interface CRM 79 and CRM 81 D Output signal regulation Example of connection Spark killer diode +24V 70 mA or less 0V 0V +24V 70 mA or less Lamp 0V Protective resistance 0V D Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at connection Spark killer diode Rated peak reverse voltage Rated effective forward current : : : : : 24 VDC 30 VDC 70. CRM81 : SDI101 to SDI120 (CRM79) SDI81 to SDI88 (CRM81) 193 . and so on directly.9.

3 kΩ SDICOM RV 0V Example of +24V common connection D Electrical specifications of the receiver Type : Grounded voltage receiver Rated input voltage : Contact close :+20 V to +28 V Contact open :0 V to +4 V Maximum applied input voltage: +28 VDC Input impedance : 3. However. CRM81 : SDO101 to SDO120 (CRM79) SDO81 to SDO84 (CRM81) 194 . 50 mA or more Input signal width : 200 ms or more (on/off) Chattering time : 5 ms or less Closed circuit resistance : 100Ω or less Opened circuit resistance : 100 kΩ or more (Signal) TB (Signal) TB D TB Peripheral device contact signal Robot receiver signal TC TC TB . CONNECTION DETAILS CONNECTIONS B–81535EN/02 D Input signal regulation Example of connection +24V RV SDI n 3. Chattering 5 ms or less 5 to 20 ms D D Note on use Apply the +24 V power of the robot to the receiver. Applicable signal Input signal of peripheral device interface CRM79. the above signal regulations must be satisfied at the robot receiver.3 kΩ (approx. TC .3.) Response time : 5 ms to 20 ms Specifications of the peripheral device contact Rated contact capacity : 30 VDC.

3.4 (a) Peripheral Device Cable Connector (CRM79 : Honda Tsushin Kogyo) 195 . Symbol 1 2 Connector specification MR50LWM Applicable interface CRM79 Connector cover Connector 50 pins (male) Dimensions A 67. CONNECTION DETAILS 3.4 Peripheral Device Cable Connector The figure below shows the connector for peripheral device cable.5 C 66.9 (B) 73.9.9.1 Name Remark (D) 20 Honda Tsushin Kogyo E φ 50 φ16 pins Fig.B–81535EN/02 CONNECTIONS 3.

6 1.12).12).54 6. (7/0.05 Configuration 7/0.9.3. heavily protected cable conforming to the specifications in Table 3.56 2. Allow an extra 1.86 Remark YAMAICHI ELECTRONICS (Housing) YAMAICHI ELECTRONICS (Contact) CRM81 Contact 66 type Applicable cable : AWG#28 (7/0. AWG#24 (19/0.5m for routing the cable in the control unit.54 A B 2.98 C 22.0 14.3 14.5.18 AWG24 7/0.9.18) Fig.4 (b) Peripheral Device Cable Connector (CRM81 : YAMAICHI ELECTRONICS) 3. CONNECTION DETAILS CONNECTIONS B–81535EN/02 3.18 AWG24 196 .5 1.5 Electrical characteristics Conductor resistance (Ω/km) 106 106 Allowable current (A) 1.5 Recommended Cables Connect a peripheral device using a completely shielded.9.6 Table 3.5 Connector specification UFS–20B–04 Applicable interface Dimensions A 29. AWG#26 (19/0. Conductor Sheath thickness (mm) 1.5 Effective outside diameter (mm) φ12.3.9.5 Recommended cable (For peripheral device connection) Number of wires 50 20 Wire specifications (FANUC specifications) A66L–0001–0042 A66L–0001–0041 Diameter (mm) φ1. The maximum cable length is 30m.1).5 φ10.05 φ1.

197 . For RDO signals. 1 Name Robot control board A Drawing number A16B–3200–0450 DI 6 DO 6 Remarks Standard NOTE Either RDI6 or *PPABN is selected by software. Mechanical unit EE 1 2 3 4 5 6 RDI1 RDI2 RDI3 RDI4 RDI5 RDI6 (*PPABN) 7 8 9 10 11 12 *HBK +24E +24E +24E 0V RDICOM End effecter NOTE RDO1 to RDO6 are used as the signals to turn on or off solenoid valves.1 Connecting the Mechanical Unit and End Effector Table 3.10. The end effector can use the RDI signals and *HBK signal. CONNECTION DETAILS 3.10.B–81535EN/02 CONNECTIONS 3. refer to the maintenance manual of the mechanical unit.1 Types of end effector interfaces End effector interface No.10 END EFFECTOR INTERFACE 3.

EE (8.1 (a) End effector interface (+24V common) Mechanical unit (end effector interface) +24E Connector pin No. EE (8.3k 0V Fig. CONNECTION DETAILS CONNECTIONS B–81535EN/02 Mechanical unit (end effector interface) +24E Connector pin No.8.10.3.8.10) EE (1) EE (2) EE (3) RDI3 RDI4 RDI5 RDI6 (*PPABN) RDICOM RV EE (4) RV EE (5) RV EE (6) RV EE (12) RV EE (11) End effecter Receiver circuit RDI1 RDI2 RV RV 3.3.3k 0V Fig.10) EE (1) EE (2) EE (3) RDI3 RDI4 RDI5 RDI6 (*PPABN) RDICOM RV EE (4) RV EE (5) RV EE (6) RV EE (12) RV EE (11) End effecter Receiver circuit RDI1 RDI2 RV RV 3.10.3.1 (b) End effector interface (0V common) 198 .

3 kΩ RDICOM RV 0V Example of +24V common connection Electrical specifications of the receiver Type : Grounded voltage receiver Rated input voltage : Contact close : +20 V to +28 V Contact open : 0 V to +4 V Maximum applied input voltage : +28 VDC Input impedance : 3. *HBK. TC .10.2 Digital I/O Signal Specifications of End Effector Control Interface Example of connection +24V RV RDI n 3.B–81535EN/02 CONNECTIONS 3. Chattering 5 ms or less 5 to 20 ms Note on use Apply the +24 V power at the robot to the receiver. Applicable signals Input signals of end effector control interface Additional I/O PCB CRW6 input signal WDI1 to WDI8 RDI 1 to 6. However. 50 mA or more Input signal width : 200 ms or more (on/off) Chattering time : 5 ms or less Closed circuit resistance : 100 Ω or less Opened circuit resistance : 100 kΩ or more TB (Signal) TB (Signal) TB Peripheral device contact signal Robot receiver signal TC TC TB . CONNECTION DETAILS 3.3 kΩ (approx. the above signal specifications must be satisfied at the robot receiver.) Response time : 5 ms to 20 ms Specifications of the peripheral device contact Rated contact capacity : 30 VDC. *PPABN (Switch RDI6 by software) 199 .

and fasten the jacket to the shield plate with a clamp to protect against noise.11 TREATMENT FOR THE SHIELDED CABLE In this manual the treatment for the shielded cable is shown on several pages.) Fig.3. CONNECTION DETAILS CONNECTIONS B–81535EN/02 3.2.12 Shielded cable treatment 200 . (In case of stand–alone type a shield plate is installed in the controller. Partly cut off the shielded cable to expose the shield jacket.

12.1 Peripheral Device Interface Types No.12 PERIPHERAL DEVICE. Drawing number A05B–2440–J002 A05B–2440–J003 Number of I/O points DI 40 40 DO 40 40 D/A 2 0 A/D 6 0 Remarks NOTE General purpose I/O (SDI/SDO) is a number which subtract an exclusive signal from the table value. 201 . 1 2 Name Process I/O board HE Process I/O board HF Connection to the peripheral device and the arc welding is available to use the process I/O board for R–J3iB Mate. ARC WELDING.B–81535EN/02 CONNECTIONS 3. INTERFACES 3. CONNECTION DETAILS 3.

12.2 Peripheral Device Interface Block Diagram and Specifications Process I/O board HE/HF Main board CRM2A JD1A (JD4) JD4A (JD1B) CRM2B JD4B (JD1A) CRW7 (NOTE 1) CRW2 (NOTE1) Peripheral device Fig.2 Block diagram of the process I/O board HE and HF NOTE 1 CRW2 and CRW7 are not provided for process I/O board HF.3. 202 .3. CONNECTION DETAILS CONNECTIONS B–81535EN/02 3.12.

CONNECTION DETAILS 3.B–81535EN/02 CONNECTIONS 3. refer to the OPERATOR’S MANUAL.3 Peripheral Device and Control Unit Connection Control unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 The connection is for the allocated specified signal.12. HF 203 . 2 All COM-** are connected to the 0V. *IMSTP Peripheral device control interface A1 CMDENBL 33 CRM2A 19 20 21 22 23 24 25 26 27 28 29 30 31 32 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 COM–A4 ACK7/SNO7 ACK8/SNO8 SNACK RESERVED COM–A5 PNSTROBE PROD START SDI01 SDI02 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 SYSRDY PROGRUN PAUSED COM–A1 HELD FAULT ATPERCH TPENBL COM–A2 BATALM BUSY ACK1/SNO1 ACK2/SNO2 COM–A3 +24E +24E *HOLD *SFSPD CSTOPI FAULT RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 0V 0V Peripheral device A1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 SDI03 Peripheral device control interface A2 SDO01 CRM2B 33 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SDO13 SDO14 SDO15 SDO16 COM–B4 SDO17 SDO18 SDO19 SDO20 COM–B5 SDI19 SDI20 SDI21 SDI22 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 SDO02 SDO03 SDO04 COM–B1 SDO05 SDO06 SDO07 SDO08 COM–B2 SDO09 SDO10 SDO11 SDO12 COM–B3 +24E +24E Peripheral device A2 SDI04 SDI05 SDI06 SDI07 SDI08 SDI09 SDI10 SDI11 SDI12 SDI13 SDI14 SDI15 SDI16 SDI17 SDI18 0V 0V NOTE 1 Peripheral device connection cable are optional. Applicable process I/O board type HE. For detail of the allocation.

CONNECTION DETAILS CONNECTIONS B–81535EN/02 Control unit (peripheral device control interface A1) +24E Connector pin No. CRM2A (49.18) 3.3.50) Receiver circuit *IMSTP *HOLD *SFSPD CSTOPI RV RV RV RV 0V FAULT RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSTROBE PROD START SDI01 SDI02 COM–1 RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV +24E B A 0V Common setting pin (ICOM1) 0V CRM2A (5) CRM2A (6) CRM2A (7) CRM2A (8) CRM2A (9) CRM2A (10) CRM2A (11) CRM2A (12) CRM2A (13) CRM2A (14) CRM2A (15) CRM2A (16) CRM2A (29) CRM2A (30) CRM2A (31) CRM2A (32) CRM2A (17. 204 .3k CRM2A (1) CRM2A (2) CRM2A (3) CRM2A (4) Peripheral device NOTE This is a connection diagram for +24V common.

37.28.B–81535EN/02 CONNECTIONS 3. current per UDO is 70mA 0V +24V +24V regurated power supply 205 . Driver circuit DV CMDENBL 0V DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV CRM2A (34) CRM2A (35) CRM2A (36) CRM2A (38) CRM2A (39) CRM2A (40) CRM2A (41) CRM2A (43) CRM2A (44) CRM2A (45) CRM2A (46) CRM2A (19) CRM2A (20) CRM2A (21) CRM2A (22) CRM2A (24) CRM2A (25) CRM2A (26) CRM2A (27) CRM2A (33) Peripheral device LOAD RELAY SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK RESERVED LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD CRM2A (23. CONNECTION DETAILS Control unit (peripheral device control interface A1) Connector pin No.42.47) 0V Max.

CRM2B (49. 206 .3k CRM2B (2) CRM2B (3) CRM2B (4) CRM2B (5) CRM2B (6) CRM2B (7) CRM2B (8) CRM2B (9) CRM2B (10) CRM2B (11) CRM2B (12) CRM2B (13) CRM2B (14) CRM2B (15) CRM2B (16) CRM2B (29) CRM2B (30) CRM2B (31) CRM2B (32) CRM2B (17. CONNECTION DETAILS CONNECTIONS B–81535EN/02 Control unit (peripheral device control interface A2) +24E Connector pin No.3.18) Peripheral device NOTE This is a connection diagram for +24V common.50) Receiver circuit SDI03 SDI04 SDI05 SDI06 SDI07 SDI08 SDI09 SDI10 SDI11 SDI12 SDI13 SDI14 SDI15 SDI16 SDI17 SDI18 SDI19 SDI20 SDI21 SDI22 COM–2 RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV RV +24E B A 0V Common setting pin (ICOM2) 0V CRM2B (1) 3.

37.47) 0V Max.28. current per DO is 70mA 0V +24V +24V regurated power supply 207 . CONNECTION DETAILS Control unit (peripheral device control interface A2) Connector pin No. Driver circuit DV SDO01 0V CRM2B (34) CRM2B (35) CRM2B (36) CRM2B (38) CRM2B (39) CRM2B (40) CRM2B (41) CRM2B (43) CRM2B (44) CRM2B (45) CRM2B (46) CRM2B (19) CRM2B (20) CRM2B (21) CRM2B (22) CRM2B (24) CRM2B (25) CRM2B (26) CRM2B (27) CRM2B (33) Peripheral device LOAD RELAY SDO02 SDO03 SDO04 SDO05 SDO06 SDO07 SDO08 SDO09 SDO10 SDO11 SDO12 SDO13 SDO14 SDO15 SDO16 SDO17 SDO18 SDO19 SDO20 DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD CRM2B (23.B–81535EN/02 CONNECTIONS 3.42.

4 Connection Between the Control Unit and Welder Control unit Analog input interface CRW2 Peripheral device NOTE Welder and peripheral device connection cable are optional. CONNECTION DETAILS CONNECTIONS B–81535EN/02 3.3. Applicable process I/O board type HE 208 .12.

ADCH4 COMAD4 CRW2 (16) CRW2 (17) ADCH5 COMAD5 CRW2 (18) CRW2 (19) ADCH6 COMAD6 0V CRW2 (8) CRW2 (9) 209 .B–81535EN/02 CONNECTIONS 3. CONNECTION DETAILS Analog connection of CRW2 connector (Analog input) Control unit (Analog input interface) Process I/O HE Peripheral device Connector pin number ADCH1 COMAD1 CRW2 (10) CRW2 (11) ADCH2 COMAD2 CRW2 (12) CRW2 (13) ADCH3 COMAD3 CRW2 (14) CRW2 (15) Output signals without ripples.

Applicable process I/O board type HE 210 . CONNECTION DETAILS CONNECTIONS B–81535EN/02 Control unit Welder interface CRW7 Welder NOTE Welder and peripheral device connection cable is option.3.

34) Welding voltage command signal Welding machine MS connector pin No.3k CRW7 (6) CRW7 (7) CRW7 (8) CRW7 (10) +24E B A CRW7 (33. 3. A B C D Wire speed command signal P T S R WDI02 WDI03 WDI04 WDI06 COM–3 RV RV RV RV RV +24E E Common setting pin 0V (ICOM3) WDO01 Welding start signal WCOM1 WDO04 Wire inching (+) WCOM4 WDO05 Wire inching (–) WCOM5 CRW7 (23) CRW7 (24) CRW7 (29) CRW7 (30) CRW7 (13) CRW7 (14) L K F G H J R=100 Ω or more M N Wire deposition detected signal WDI+ WDI– CRW1 (31) CRW1 (32) + – + Cabinet ground (shield clamp) – Welding power supply Welding machine frame ground 211 .B–81535EN/02 CONNECTIONS 3. and WDI/WDO connection: Connected to the +24 V common line) Control unit (welding interface) Process I/O HE DACH1 COMDA1 DACH2 COMDA2 Receiver circuit Arc detected signal Gas outage detected signal Broken–wire detected signal Arc turn–off detected signal (power supply failure) Connector pin No. CONNECTION DETAILS Attaching the CRW7 connector to the welding machine: FANUC interface (Analog output. welding wire deposition detected. CRW7 (1) CRW7 (2) CRW7 (3) CRW7 (4) Connector pin No.

212 .3. CONNECTION DETAILS CONNECTIONS B–81535EN/02 NOTE This is the connection for +24V.

welding wire deposition detected.34) CRW7 (19.20) Common setting pin 0V (ICOM3) 0V WDO01 Welding start signal WCOM1 WDO02 Gas signal WCOM2 WDO04 Wire inching (+) WCOM4 WDO05 Wire inching (–) WCOM5 CRW7 (21. CONNECTION DETAILS Attaching the CRW7 connector to the welding machine: FANUC interface (Analog output.B–81535EN/02 CONNECTIONS 3. A B E F Wire speed command signal c d e f g h j k CRW7 (23) CRW7 (24) CRW7 (23) CRW7 (24) CRW7 (29) CRW7 (30) CRW7 (13) CRW7 (14) R S a U V b R=100 Ω or more N P Wire deposition detected signal WDI+ WDI– CRW1 (31) CRW1 (32) + – s Cabinet ground (shield clamp) + – Welding power supply Welding machine frame ground 213 .3k CRW7 (5) CRW7 (6) CRW7 (7) CRW7 (8) CRW7 (9) CRW7 (10) CRW7 (11) CRW7 (12) CRW7 (2) CRW7 (3) CRW7 (4) Connector pin No.22) r m n Connector pin No. and WDI/WDO connection: Connected to the +24 V common line) Control unit (welding interface) Process I/O HE DACH1 COMDA1 DACH2 COMDA2 Receiver circuit WDI01 Arc detected signal Gas outage detected signal Broken–wire detected signal Cooling water outage signal Arc turn–off detected signal (power supply failure) WDI02 WDI03 WDI04 WDI05 WDI06 WDI07 WDI08 COM–3 +24E B A RV RV RV RV RV RV RV RV RV +24E CRW7 (33. 3. CRW7 (1) Welding voltage command signal Welding machine MS connector pin No.

) : 100 V or more : 1 A or more NOTE Do not use the +24 V power supply of the robot. SNACK.3. BATALM. use a protective resistance. ATPERCH. Applicable signals Output signals of process I/O board CRM2 CMDENBL. SYSRDY. FAULT. PROGRUN. When you load a relay.12. ACK1 to ACK8. TPENBL. CONNECTION DETAILS CONNECTIONS B–81535EN/02 3. BUSY. solenoid. If a load is connected causing a surge current when a lamp is turned on.0 V (approx. HELD.5 Digital I/O Signal Specifications of Peripheral Device Interface A (1) Output signals in peripheral device interface A Example of connection Spark killer diode +24V 70 mA or less 0V +24V Lamp 70 mA or less 0V Protective resistance Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at connection Spark killer diode Rated peak reverse voltage Rated effective forward current : : : : : 24 VDC 30 VDC 70 mA Open collector NPN 1. and so on directly. SDO1 to SDO76 214 . connect them in parallel with diodes to prevent back electromotive force. PAUSED.

FAULT RESET. However. 50 mA or more Input signal width : 200 ms or more (on/off) Chattering time : 5 ms or less Closed circuit resistance : 100 Ω or less Opened circuit resistance : 100 kΩ or more TB (Signal) TB (Signal) TB Peripheral device contact signal Robot receiver signal TC TC TB . SDI1 to SDI78 215 . Chattering 5 ms or less 5 to 20 ms NOTE Apply the +24 V power at the robot to the receiver. CONNECTION DETAILS (2) Input signals in peripheral device interface A Example of connection +24V RV 3. PROD START. HOME. *SFSD. RSR1 to RSR8. START. *HOLD.3 kΩ (approx.B–81535EN/02 CONNECTIONS 3. CSTOPI. the above signal specifications must be satisfied at the robot receiver. PNSTROBE.3 kW +24V B A ICOM Electrical specifications of the receiver Type : Grounded voltage receiver Rated input voltage : Contact close : +20 V to +28 V Contact open : 0 V to +4 V Maximum applied input voltage : +28 VDC Input impedance : 3. Applicable signals Input signals of process I/O board CRM2 *IMSTP.) Response time : 5 ms to 20 ms Specifications of the peripheral device contact Rated contact capacity : 30 VDC. TC . ENBL. PNS1 to PNS8.

6 I/O Signal Specifications for ARC–Welding Interface (1) Digital output signal specifications for an arc welding interface In case of process I/O HE Example connection Spark killer diode 0. To drive a relay or solenoid directly. CONNECTION DETAILS CONNECTIONS B–81535EN/02 3.3.12. can be used for interface signals of up to 0. connect a diode preventing back electromotive force to the load in parallel.3 A Relay connection output : 100 V or more : 1 A or more NOTE A power voltage of +24 V. This limit applies to the sum of the currents flowing through the arc–welding and end–effector control interfaces. provided for the robot. To connect a load which generates an inrush current when you turn on the control unit. connect a protective resistor.7 A. Applicable signals – Output signals on the arc–welding interface – WDO1 to WDO4 216 .3 A or less Electrical characteristics Rated voltage Maximum applied voltage Maximum load current Output type Spark killer diode Rated peak reverse voltage Rated effective forward current : : : : 24 VDC 30 VDC 0.

CONNECTION DETAILS (2) Digital input signal specifications for arc welding interface Example connection Electrical characteristics of receivers Type: Grounded voltage receiver Rated input voltage : +20 to +28 V with contacts closed 0 to +4 V when open Maximum input voltage : +28 VDC Input impedance : About 3. 50 mA or more Input signal width : 200 ms or more for on and off states Chattering period : 5 ms or less Closed–circuit resistance : 100 Ω or less Open–circuit resistance : 100 kΩ or more (Signal) Contact signal for peripheral (Signal) Receiver signal for robot TB: Chattering of 5 ms or less TC: 5 to 20 ms NOTE Supply the +24 V power. provided for the robot. to the receivers.3 k Response time : 5 to 20 ms Contact specifications for peripherals Rated contact capacity : 30 VDC. The receiver signal on the robot must satisfy the signal timing specified above.B–81535EN/02 CONNECTIONS 3. Applicable signals – Input signals for arc welding interface – WDI1 to WDI8 217 .

3 kΩ or more Connect a high–pass filter. HA : 0V to +15V 0V Welder NOTE Input impedance: 3. (Wire deposit detection: WDI+ and WDI–) Example connection Welder Welding electrode NOTE Connect a resistor of 100Ω or more between the positive and negative electrodes of the welder. CONNECTION DETAILS CONNECTIONS B–81535EN/02 (3) Analog output signal specifications for arc welding interface (Welding voltage command. which uses high–frequency components. The dielectric withstand voltage of this circuit is 80 V. (4) Analog input signal specifications for arc welding interface (Welding–voltage detection. 218 . EA : –10V to +10V Process I/O GA. welding–current detection) Example connection Welder –10V to +10V 0V NOTE The analog input signal should have no ripple for the circuit to operate properly.3. wire–feed rate command) Example connection Process I/O CA. Isolate the deposit detection signals for TIG welding from the welding circuit.

7 Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin. make sure they conform to the FANUC standard cables described in this section.12. (See the description in “Peripheral Device Interface” in this manual for the specifications of the FANUC standard cables.12. MS3108B28–21P MS3057–16 Japan Aviation Electronics Industry Ltd.) Honda Tsushin MR50LWF01 (MR50LF) Process I/O Honda Tsushin MR50LM01 (MR50LM) Peripheral device Honda Tsushin MR50RMA Honda Tsushin’s MR50RF Supplied with an ordered cable 3. 50 pins) If the customer manufactures cables. ARC welder Honda Tsushin Process I/O CRW1 or CRW7 Honda Tsushin MR34RFA Japan Aviation Electronics Industry Ltd.8 ARC Weld Connection Cable (CRW1: Honda Tsushin. 34 pins) Be sure to use the FANUC cable to connect the welder. MS3102A28–21S Standard position of guide key 219 .B–81535EN/02 CONNECTIONS 3. CONNECTION DETAILS 3.

12. 3.5 C 44.9 (B) 73.9 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo) 220 .9 Peripheral Device Cable Connector (1) Fig.8 (D) 18 Remark Honda Tsushin Kogyo.3. CONNECTION DETAILS CONNECTIONS B–81535EN/02 3.12.3. 50 pins Symbol      Connector cover Cable clamp screw Name Connector clamp spring Connector clamp screw Connector 50 pins (male) MR50M Fig.9 shows the connector for peripheral device cables A and B. (The connector is used for a peripheral device) Connector specifications MR50LM Applicable interface CRM2 Dimensions A 67.12.

05 Configuration 7/0. Conductor Effective outside diameter (mm) ø12.3. Allow an extra 50 cm for routing the cable in the control unit.12.10 Recommended Cables (1) Peripheral device connection cable Connect a peripheral device using a completely shielded.10 Recommended Cable (for Peripheral Device Connection) Number of wires 50 Wire specifications (FANUC specifications) A66L-0001-0042 Sheath thickness (mm) 1. heavily protected cable conforming to the specifications in Table 3.4 B 56. The maximum cable length is 30 m.5 Electrical characteristics Conductor resistance (Ω/km) 106 Allowable current (A) 1.12.6 Table 3.10 (a). 50 pins Symbol    Screw M2.12. CONNECTION DETAILS (2) Peripheral device connector Connector specifications MR50RF Applicable interface (CRM2) Dimensions A 61.5 Diameter (mm) ø1.4 Remark Honda Tsushin Kogyo.12.18 AWG24 221 .B–81535EN/02 CONNECTIONS 3.9 (b) Peripheral Device Connector (Honda Tsushin Kogyo) 3.6 8 Connector Name Connector clamp screw (MR50RF) Fig.

4. TRANSPORTATION AND INSTALLATION CONNECTION B–81535EN/02 4 TRANSPORTATION AND INSTALLATION 222 .

allow the space for maintenance shown in the following figure.2 INSTALLATION Installation area When the control unit is installed. Fig.1 TRANSPORTATION The control unit should be transported by a crane. Attach a sling to eye bolts at the top of the control unit. TRANSPORTATION AND INSTALLATION 4.4.B–81535EN/02 CONNECTION 4.2 Installation 223 .4.1 Transportation 4. Contrpl unit Contrpl unit Contrpl unit When the plural controller is installed. Fig.

TRANSPORTATION AND INSTALLATION CONNECTION B–81535EN/02 4. these weld nuts can be used to secure the control unit.4.3 EXTERNAL CONTROLLER DIMENSIONS Four M10 weld nuts The unit is shipped with the M10 bolts screwed to the weld nuts as 10–mm feet. Fig. After the M10 bolts are removed.4.3 External drawing of robot controller 224 .

+10%. Check if the screwed terminal is connected properly. and –20 to 60 C during shipment and storage with a temperature coefficient of 1. non–condensing. and/or X–rays). +10%.4 INSTALLATION CONDITION Item Input power supply Specifications/condition 50Hz. Check the movement along each axis in the manual jog mode. consult with your FANUC sales representative.4 kW (LR Mate 100iB) 0. 35kg Input power supply capacity Average power consumption Permissible ambient temperature Permissible ambient humidity Surrounding gas Vibration Altitude Ionized and nonionized radiations Weight of control unit 4. organic solvent. Press the EMERGENCY STOP button on the operator’s panel and turn the power on. 3–phase 1 kVA (LR Mate 100iB) 1.000 m above sea level A shielding provision is necessary if the machine is installed in an environment in which it is exposed to radiations (microwave. Check the parameters. 200VAC to 220 VAC. Approx. Not higher than 1. Check the end effector interface signals. set them.5 ADJUSTMENT AND CHECKS AT INSTALLATION Adjust and check according to following procedure at installation. dielectric fluid. Check that the connectors and printed circuit boards are inserted correctly. acid. and/or salt). Turn the breaker off and connect the input power cable. Check the peripheral device control interface signals. Check the interface signals between control unit and robot mechanical unit. ultraviolet rays. –15% 50/60 Hz"1Hz. Relative humidity: 30% to 95%.2 kVA (LR Mate 200iB/ARC Mate 50iB) 0.B–81535EN/02 CONNECTION 4. Release the EMERGENCY STOP button on the operator’s panel. 1 2 3 4 5 6 7 8 9 10 11 12 13 Description Visually check the inside and outside of the control unit. corrosive gas. –15% 60Hz. Turn the power on.5 G or less. 0.5 kW (LR Mate 200iB/ARC Mate 50iB) 0 to 45_C during operation. Check the input power voltagage. 200VAC. An additional protective provision is necessary if the machine is installed in an environment in which there are relatively large amounts of contaminants (dust. 225 .1_C/min. No. If necessary. laser beams. Check the output voltage. Connect control unit and mechanical unit cables. TRANSPORTATION AND INSTALLATION 4. When using the robot in a location subject to serious vibration.

Remove the red plate fastening the swiveling axis beforehand. the HBK detection is enabled. Hand break State 1 2 3 4 Hand break Enabled Enabled Disabled Disabled HBK (*1) CLOSE OPEN CLOSE OPEN HBK detection Detected Detected Detected (*2) Not detected Robot operation Possible Impossible Possible Possible Message Not provided SERVO 6 Not provided SERVO 300 at cold start NOTE 1 Robot end effector connector CLOSE 24V 24V OPEN *HBK *HBK 2 When the HBK circuit is closed. stopping the robot. the system enters state 4. Therefore. an overtravel alarm occurs when the power is turned on after installation. releasing the alarm.4. 3 If the power is turned off and on in the state described above. the SERVO 300 or SERVO 302 alarm occurs.7 DISABLING HAND BREAK (1) (2) (3) (4) (5) Press the [MENUS] key on the teach pendant. Select [SETUP]. The J2 and J3 axes are pressed against the hard stops at shipment.6 NOTE AT INSTALLATION An overtravel and emergency stop occur when the robot is operated for the first time after it is installed and the mechanical and control units are wired. TRANSPORTATION AND INSTALLATION CONNECTION B–81535EN/02 4. 4. If the HBK state changes from close to open. 226 . Select [Next]. This section describes how to reset the overtrvel and emergency stop. Select [Config] to disable or enable Hand Break. Press F1 [TYPE].

APPENDIX .

.

TOTAL CONNECTION DIAGRAM A TOTAL CONNECTION DIAGRAM 229 .B–81535EN/02 APPENDIX A.

A (a) Total connection diagram 230 .A. TOTAL CONNECTION DIAGRAM APPENDIX B–81535EN/02 Fig.

B–81535EN/02 APPENDIX A. TOTAL CONNECTION DIAGRAM 231 .

TOTAL CONNECTION DIAGRAM APPENDIX B–81535EN/02 Fig.A (b) Emergency stop circuit diagram 232 .A.

TOTAL CONNECTION DIAGRAM 233 .B–81535EN/02 APPENDIX A.

A (c) Emergency stop circuit diagram 234 . TOTAL CONNECTION DIAGRAM APPENDIX B–81535EN/02 Fig.A.

B–81535EN/02 APPENDIX A. TOTAL CONNECTION DIAGRAM 235 .

A. Emergency stop board connector interface 236 .A (d) Robot control board. TOTAL CONNECTION DIAGRAM APPENDIX B–81535EN/02 Fig.

A (e) Servo amplifier robot mechanical unit connector interface 237 .B–81535EN/02 APPENDIX A. TOTAL CONNECTION DIAGRAM Fig.

These signals are connected with a remote controller and the peripheral devices via the following interfaces and I/O links and they are used to control the robot from the outside.) (on master mode) D The JD1B interface (CNC and PLC are connected as a master of I/O link to R–J3iB Mate.B. D The JD1A interface (The process I/O board. 238 . PERIPHERAL INTERFACE APPENDIX B–81535EN/02 B PERIPHERAL INTERFACE Peripheral I/O (UI/UO) are a group of specialized signals whose usage is decided by the system.) (on slave mode) D CRM9 interface Refer to the operator ’s MANUAL for detail informations. the I/O Unit MODEL A and the MODEL B are connected as the slave of I/O link to R–J3iB Mate.

2.1.) Signal CMDENBL FAULT BATALM BUSY Input acceptable Alarm Battery alarm Busy Description 239 . Input signals (See Subsection B. PERIPHERAL INTERFACE B.2.1 SIGNAL TYPES The tables below list the special signals of the R–J3iB Mate robot controller.) Signal *HOLD RESET START ENBL PNS1 PNS2 PNS3 PNS4 Temporary stop Alarm release Cycle start Enable Program select (*1) Program select (*1) Program select (*1) Program select (*1) Description NOTE PNS (program select input) (optional) Output signals (See Subsection B.1.B–81535EN/02 APPENDIX B.

the following is executed: D The robot is decelerated until its stops.B. an alarm is generated. then the program execution is halted. only a program on hold can be started. D If ENABLED is specified at “Break on hold” on the general item setting screen. the robot is stopped. D When the START signal goes high. D If TRUE is specified at “START for CONTINUE only” on the system configuration screen. START. (Standard setting: DISABLED) The RESET signal cancels an alarm.2 I/O SIGNALS B. ENBL. *HOLD. UI [ 2 ] Start input signal. The alarm is canceled at the instant this signal falls in default setting. the RESET signal resets an alarm and aborts the currently selected program. (See the description of signals PNS1 to PNS4. The alarm output is not canceled until the servo power is turned on. Whether is program is selected or collated is specified by the setting of system variable $SHELL_CFG. It can select or collate a program and start the program. The remote controller uses the hold signal to halt the robot. (Standard setting: FALSE) The ENBL signal allows the robot to be moved and places the robot in the ready state. normally set the signal on. Fault reset input signal. and the servo power is turned off. UI [ 4 ] 240 .1 Input Signals Hold input signals. UI [ 3 ] (validated in the remote state) Enable input signal. the current program is started from the line at which the cursor is placed (current line). NOTE When the ENBL signal is not monitored. PERIPHERAL INTERFACE APPENDIX B–81535EN/02 B.$NUM_RSR [1]. PNS1 to PNS4 are read and the corresponding program is selected or collated. it is necessary to specify RISE at “Detect FAULT RESET signal” on the system configuration screen. D If TRUE is specified at “CSTOPI for ABORT” on the system configuration screen. When the ENBL signal is off. If the servo power is off. (Standard setting: FALL) The START signal has two functions. Because *HOLD input signal is a inverted signal. UI [ 1 ] Fellowing is each input signal. the system inhibits a jog feed of the robot and activation of a program including a motion (group). RESET.2. (Standard setting: FALSE) D To have alarms reset the instant the RESET signal rises. the RESET signal turns on the servo power.) D When the START signal goes low. When the signal goes off. A program which is being executed is halted when the ENBL signal is set off. strap the signal with the ground.

$NUM_RSR [1]. CMDENBL. If no programs are selected.$BATALM_OR system variable. 241 B. D The remote conditions are satisfied. The FAULT signal is output when an alarm occurs in the system. When the START signal goes on. UO [ 3 ] Busy output signal. If a warning (WARN alarm) occurs. D In the program end state. D A halted program can be resumed only when all PNS signals are set off. an error occurs. FAULT.2. UO [ 2 ] Battery alarm output signal. The current line of the selected or collated program is set to 1.Type 2 (when $SHELL_CFG. It is also possible to have the specified SDO output when the BZAL/BLAL alarm occurs.B–81535EN/02 APPENDIX B. If the programs do not agree with each other. Otherwise. PERIPHERAL INTERFACE Program number selection signals. The BATALM signal indicates that the voltage of the battery for supporting the memory has dropped.Type 1 (when $SHELL_CFG. Fellowing are peripheral device interface output signals. D The ready conditions are satisfied. it is necessary to set the $BLAL_OUT. BUSY. PNS1 to PNS4 are read and the corresponding program is selected or collated. The BUSY signal is output while a program is being executed. PNS1 to PNS4. the FAULT signal is not output. UO [ 1 ] Fault output signal. Whether the program is selected or collated is specified by the setting of system variable $SHELL_CFG. an error occurs. The BUSY signal is not output while a program is being halted.$NUM_RSR [1] is set to 1) The program specified by the PNS signals is collated with the current program. a program is selected or collated according to the state (0 or 1) of the PNS signals. The RESET signal cancels the alarm. To have the BATALM signal generated also when the BZAL/BLAL alarm occurs. the current program is executed from the current line.$NUM_RSR [1] is set to 0) The program specified by the PNS signals is selected. . The CMDENBL signal indicates that the remote controller can start a program including a motion (group). the PNS signals are ignored. Replace the battery while keeping the power of the controller on. an error occurs. The CMDENBL signal is output when the following conditions are satisfied. D If all PNS signals are low in the program end state. D While a program is being executed.2 Output Signals Command enable output signal. D The continuous operation mode is selected (the single step mode is disabled). . UO [ 4 ] . UI [ 5 to 8 ] (validated in the remote state) A program number selection signal has two functions. BATALM.

The R–J3iB Mate can use a total of up to 512 I/O points. PERIPHERAL INTERFACE APPENDIX B–81535EN/02 B. B.I/O unit model A The process I/O printed circuit board and the I/O unit model A can be used together.2 Input/Output Hardware Usable in the R-J3iB Mate Controller 242 . One analog input/output point uses the resources equivalent to those used by 16 digital I/O points. . The R–J3iB Mate controller can use up to 512 digital input and output points or an equivalent number of analog input and output points.3.1 Overview This section describes the external specifications of digital and analog input/output in the R–J3iB Mate controller.B.3 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT B.Process I/O printed circuit board . The R–J3iB Mate controller can use the following I/O hardware.3.

that is determined at hardware can be changed by software operation.3 Software Specifications (1) RDI/RDO These are signals sent to the connector at the wrist of the robot. The standard format is six inputs and six outputs. Any number of continuous signals of up to 16 bits can be set for its use. It can be set in the menu DETAILS on the group I/O screen.B–81535EN/02 APPENDIX B.3. It means that the value does not always represent the real I/O voltage. (2) SDI/SDO The signal No. 243 . The number of points that can be used for the connector at the wrist depends on the individual robot. (3) Analog I/O An analog I/O signal can access the analog I/O port (optional) on the process I/O printed circuit board or the I/O port on the analog I/O module (used together with the I/O unit model A). They cannot be assigned (redefined) and are fixed. PERIPHERAL INTERFACE B. It reads and writes the digital value converted from the analog value of the I/O voltage. (4) Group I/O Group I/O is a function which can input or output multiple DI/DO signals as binary codes.

their mating surfaces must be protected with the lid and caps with which they are supplied. the mating surfaces are likely to become dirty. Electrical/optical conversion module Lid Fiber optic cable Fiber optic cable caps Fig.C. (1) Protection during storage When the electrical/optical conversion module (mounted on the printed) circuit board and the fiber optic cable are not in use. possibly resulting in a poor cable connection. If left uncovered.C (a) Protection of electrical/optical conversion module and fiber optic cable (when not in use) 244 . Observe the following cautions when handling these fiber optic cables. OPTICAL FIBER CABLE APPENDIX B–81535EN/02 C OPTICAL FIBER CABLE The R–J3iB Mate uses fiber optic cables for communication between the robot control board and servo amplifier module and between the servo amplifier module and servo amplifier module.

Do not use any organic solvent other than ethyl alcohol. wipe them with tissue paper or absorbent cotton to remove dirt. always take note of the connector’s orientation before making the connection. making the cable unusable. Although optical connectors cannot be connected in other than the correct orientation. Do not clamp the uncovered portion of the cable with a nylon band. To remove the connector.7 19 max.B–81535EN/02 APPENDIX C. 35typ. Applying greater force to the cord is likely to cause the connector to come off. If they become dirty.) Fiber optic cord diameter : 2. Take care to keep both parts of the optical connector (cable side and PCB side) clean.2 mm 2 cords Tensile strength : Fiber optic cord :7 kg per cord Between fiber optic cord and connector : 2 kg Minimum bending radius of fiber optic cord :25 mm Flame resistance : Equivalent to UL VW–1 Operating temperature : –20 to 70°C 8. 245 . Do not pull on the fiber optic cord itself. 21 Code Bush Reinforced cover Fig.C (b) External dimensions of external optical cable Unit : mm D D D D Afler it is connected. The tissue paper or absorbent cotton may be moistened with ethyl alcohol. 60 max. (The maximum tensile strength between the fiber cord and connector is 2 kg. OPTICAL FIBER CABLE (2) Fiber optic cable D Grasp the optical connector firmly when connecting or disconnecting the cable.2 6. release the lock levers and pull the connector. the optical connector is automatically locked by the lock levers on its top.

224 External Emergency Stop Input.B–81535EN/02 Index [A] [E] Emergency Stop Board (A20B–1008–0010. 244 . 226 i–1 [N] Note at Installation. 123 LED of Servo Amplifier. 33 [D] Digital I/O Signal Specifications. 173 Coonection of Servo Amplifier. 127 Circuit Diagram of Emergency Stop. 193 Digital I/O Signal Specifications of End Effector Control Interface. 214 Disabling Hand Break. 242 Installation. 21 Adjustment and Checks at Installation. 116 Emergency Stop Circuit. 240 Initial Screen Remains on the Teach Pendant. 160 Block Diagrams of the Power Supply. 109 Mastering. 199 Digital I/O Signal Specifications of Peripheral Device Interface A. 127 Checking the Power Supply Unit. –0011). 223 Installation Condition. 208 Connection Details. 197 External Controller Dimensions. 175 Connecting the Mechanical Unit and End Effector. 6 Optical Fiber Cable. 240 Input/Output Hardware Usable in the R–J3iB Mate Controller. 172 Connection of Teach Pendant Cable. 154 Block Diagram. 197 Connection Between the Control Unit and Welder. 167 End Effector Interface. 163 [C] Checking the Power Supply Module. 117 Battery for Memory Backup (3 VDC). 225 [L] LED of Power Supply Module. 4. 174 Connection of I/O Link Cable. 162 Connection of Robot. 123 LED of Servo Amplifier Module. 34 pins). 20 Connecting a Cable to a Peripheral Device. 216 I/O Signals. 126 [F] FANUC I/O Link. 124 [M] Manual Operation Impossible. 167 Component Functions. 23 Configuration. 161 Connection of Cable for RS–232–C/RS–422. 29 ARC Weld Connection Cable (CRW1: Honda Tsushin. 219 [B] Backplane Board (A20B–2003–0330). 171 [I] I/O Signal Specifications for Arc–Welding Interface. 168 External Emergency Stop Output. 169 External View of the Controller. 225 Alarm Occurrence Screen. 165 Connection of Power Supply Cable. 226 [O] Operator Safety. 28 Input Signals.

ARC Welding. 121 Output Signals. 11 Precautions in Programming. 121 Precautions for Mechanism. 175 Peripheral Device. 143 Replacing the Fuse on the Door. 201 Peripheral interface. 26 Power Supply Module PSM (A06B–6115–H001). 137 Replacing the Control Section Fan Motor. 50 pins). 130 Replacing the Brake Power Transformer. 132 Replacing the Emergency Stop Unit. 229 Transportation. 125 Signal Types. 139 Replacing the Operator Panel. 152 Replacing the Fuse on the Servo Amplifier Module. 13 Safety of the End Effector. 147 Replacing a Relay. 9 Safety in Maintenance. A06B–6114–H302). 142 Replacing the Door Fan Unit and Heat Exchanger. 242 Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin. 131 Replacing the Teach Pendant. 107 Power Cannot be Turned On. 222 Treatment for the Shielded Cable. 11 Safety of the Teach Pendant Operator. 12 Preventive Maintenance. 221 Replacing a Fuse. 7 Safety of the Tools and Peripheral Devices. 202 Peripheral device interface CRM 79 and CRM 81. 140 Replacing the Backplane Board (Unit). 24 Printed Circuit Boards. 196. 241 [P] Peripheral Device and Control Unit Connection. 147 Replacing a Fuse on the Emergency Stop Board. 153 Replacing a Relay on the Emergency Stop Board. 193 Peripheral Device Interface Types. 201 Peripheral Device Interfaces CRM79 and CRM81. HF (A16B–2203–0765). 12 Safety of the Robot Mechanism. 11. 239 Software Specifications. 148 Replacing a Fuse on the Robot Control Board. 128 Replacing Battery. 220 Peripheral Device Interface Block Diagram and Specifications. 120 Setting the Power Supply. 27 Total Connection Diagram. 11 Precautions in Operation. 238 Position Deviation Found in Return to the Reference Position (Positioning). 144 i–2 [T] Teach Pendant Cannot be Turned On. 112 [S] Safety During Maintenance. Interfaces. 195. 32 Servo Amplifier Module (A06B–6114–H205. 3 Safety Signals. 141 Replacing the Transformer. 154 Replacing Cards and Modules on the Robot Control Board. 149 Replacing the Fuse on the Power Supply Module. 118 Replacing the Emergency Stop Board. 203 Peripheral Device Cable Connector. 243 Specifications of Digital Input/Output. 10. 145 Replacing the Power Supply Unit. 219 [R] Recommended Cables. 10 Precautions for Mechanisms. 122 Servo Amplifiers. 137 Robot Control Board (A16B–3200–0450). 10 Safety Precautions. 153 Replacing a Unit. 129 Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit. 223 Transportation and Installation. 133 Replacing Servo Amplifiers. 150 Replacing the Fuse on the Process I/O Boards. 111 Process I/O Board HE (A16B–2203–0764). 138 Replacing the Fan Motor of the Servo Amplifier Control Unit. 151 Replacing the Magnetic Contactor. 200 . 146 Replacing the Printed–Circuit Boards.Index B–81535EN/02 Outline Drawings.

176 [V] Vibration Observed During Movement. 108 i–3 . 92 Troubleshooting Using the Error Code.B–81535EN/02 Index Troubleshooting. 97 Troubleshooting Using Fuses. 35 Warning Label. 25 Troubleshooting Based on LED Indications. 14 [W] When the Robot is Connected to the CNC by a Peripheral Device Cable.

Revision Record FANUC Robot series R–J3iB Mate CONTROLLER for (RIA R15..06--1999 COMPLIANT) MAINTENANCE MANUAL (B–81535EN) 02 Oct. 2001 Edition Date Contents Edition Date Contents .. 2002 Addition of ARC Mate 50iB 01 Oct.

Sign up to vote on this title
UsefulNot useful