controler maintenance r30ia.pdf

FANUC Robot series(RIA R15.06-1999 COMPLIANT)

R-30iA CONTROLLER

MAINTENANCE MANUAL

MARMCRIA304071E REV. BThis publication contains proprietary information of FANUC Robotics America, Inc. furnished for

customer use only. No other uses are authorized without the express written permission of

FANUC Robotics America, Inc.

FANUC Robotics America, Inc.3900 W. Hamlin Road

Rochester Hills, Michigan 48309–3253

B-82595EN-2/02

The descriptions and specifications contained in this manual were ineffect at the time this manual was approved for printing. FANUCRobotics America, Inc, hereinafter referred to as FANUC Robotics,reserves the right to discontinue models at any time or to changespecifications or design without notice and without incurringobligations.FANUC Robotics manuals present descriptions, specifications,drawings, schematics, bills of material, parts, connections and/orprocedures for installing, disassembling, connecting, operating andprogramming FANUC Robotics’ products and/or systems. Suchsystems 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 beentrained in one or more approved FANUC Robotics TrainingCourse(s) be permitted to install, operate, use, perform procedureson, repair, and/or maintain FANUC Robotics’ products and/orsystems and their respective components. Approved trainingnecessitates that the courses selected be relevant to the type ofsystem installed and application performed at the customer site.

WARNINGThis equipment generates, uses, and can radiate radiofrequency energy and if not installed and used in accordancewith the instruction manual, may cause interference to radiocommunications. As temporarily permitted by regulation, ithas not been tested for compliance with the limits for Class Acomputing devices pursuant to subpart J of Part 15 of FCCRules, which are designed to provide reasonable protectionagainst such interference. Operation of the equipment in aresidential area is likely to cause interference, in which casethe user, at his own expense, will be required to takewhatever measure may be required to correct theinterference.

FANUC Robotics conducts courses on its systems and products ona regularly scheduled basis at its headquarters in Rochester Hills,Michigan. For additional information contact

FANUC Robotics America, Inc.Training Department3900 W. Hamlin RoadRochester Hills, Michigan 48309-3253www.fanucrobotics.com

Send your comments and suggestions about this manual to:[email protected]

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www.fanucrobotics.com

mailto:

Copyright 2007 by FANUC Robotics America, Inc.All Rights ReservedThe information illustrated or contained herein is not to bereproduced, copied, downloaded, translated into another language,published in any physical or electronic format, including internet, ortransmitted in whole or in part in any way without the prior writtenconsent of FANUC Robotics 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 FANUCRobotics.FANUC Robotics reserves all proprietary rights, including but notlimited to trademark and trade name rights, in the following names:AccuAir AccuCal AccuChop AccuFlow AccuPathAccuSeal ARC Mate ARC Mate Sr. ARC Mate System 1ARC Mate System 2 ARC Mate System 3 ARC Mate System4 ARC Mate System 5 ARCWorks Pro AssistToolAutoNormal AutoTCP BellTool BODYWorks Cal Mate CellFinder Center Finder Clean Wall CollisionGuardDispenseTool F-100 F-200i FabTool FANUC LASERDRILL Flexibell FlexTool HandlingTool HandlingWorksINSIGHT INSIGHT II IntelliTrak Integrated Process SolutionIntelligent Assist Device IPC -Integrated Pump Control IPDIntegral Pneumatic Dispenser ISA Integral Servo Applicator ISDIntegral Servo Dispenser Laser Mate System 3 Laser MateSystem 4 LaserPro LaserTool LR Tool MIG EyeMotionParts NoBots Paint Stick PaintPro PaintTool 100PAINTWorks PAINTWorks II PAINTWorks III PalletMatePalletMate PC PalletTool PC PayloadID RecipToolRemovalTool Robo Chop Robo Spray S-420i S-430iShapeGen SoftFloat SOF PARTS SpotTool+ SR MateSR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM R-J3 Controller SYSTEM R-J3iB Controller TCP MateTurboMove TorchMate visLOC visPRO-3D visTRACWebServer WebTP YagTool

FANUC LTD 2007

• No part of this manual may be reproduced in any form.• All specifications and designs are subject to change without notice.

This manual includes information essential to the safety ofpersonnel, equipment, software, and data. This information isindicated by headings and boxes in the text.

WARNINGInformation appearing under WARNING concerns theprotection of personnel. It is boxed and in bold type to set itapart from other text.

CAUTIONInformation appearing under CAUTION concerns the protection ofequipment, software, and data. It is boxed to set it apart fromother text.

NOTE Information appearing next to NOTE concerns relatedinformation or useful hints.

Conventions

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Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand the content. This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.

• No part of this manual may be reproduced in any form. • All specifications and designs are subject to change without notice. The products in this manual are controlled based on Japan’s “Foreign Exchange and Foreign Trade Law”. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. In this manual we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as ”impossible”.

B-82595EN-2/02 PREFACE

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PREFACE This manual describes the following models (R-30iA controller).

Model Abbreviation FANUC Robot R-2000iB/210F R-2000iB/210F FANUC Robot R-2000iB/200R R-2000iB/200R FANUC Robot R-2000iB/200EW R-2000iB/200EW FANUC Robot R-2000iB/165R R-2000iB/165R FANUC Robot R-2000iB/165F R-2000iB/165F FANUC Robot R-2000iB/165EW R-2000iB/165EW FANUC Robot R-2000iB/165CF R-2000iB/165CF FANUC Robot R-2000iB/125L R-2000iB/125L FANUC Robot R-2000iB/100P R-2000iB/100P FANUC Robot R-2000iB/200T R-2000iB/200T

R-2000iB

FANUC Robot M-6iB M-6iB FANUC Robot M-6iB/6T M-6iB/6T FANUC Robot M-6iB/6S M-6iB/6S FANUC Robot M-6iB/2HS M-6iB/2HS FANUC Robot M-6iB/6C M-6iB/6C

M-6iB

FANUC Robot M-10iA M-10iA FANUC Robot M-16iB/20 M-16iB/20 FANUC Robot M-16iB/10L M-16iB/10L FANUC Robot M-16iB/20T M-16iB/20T FANUC Robot M-16iB/10LT M-16iB/10LT

M-16iB

FANUC Robot ARC Mate 100iB ARC Mate 100iB FANUC Robot ARC Mate 100iBe ARC Mate 100iBe FANUC Robot ARC Mate 100iB/6S ARC Mate 100iB/6S

ARC Mate 100iB

FANUC Robot ARC Mate 100iC ARC Mate 100iC FANUC Robot ARC Mate 120iB ARC Mate 120iB FANUC Robot ARC Mate 120iBe ARC Mate 120iBe FANUC Robot ARC Mate 120iB/10L ARC Mate 120iB/10L FANUC Robot ARC Mate 120iB/20T ARC Mate 120iB/20T FANUC Robot ARC Mate 120iB/10LT ARC Mate 120iB/10LT

ARC Mate 120iB

FANUC Robot M-710iC/70 M-710iC/70 FANUC Robot M-710iC/70T M-710iC/70T FANUC Robot M-710iC/50 M-710iC/50 FANUC Robot M-710iC/50S M-710iC/50S FANUC Robot M-710iC/50T M-710iC/50T FANUC Robot M-710iC/20L M-710iC/20L

M-710iC

FANUC Robot M-410iB/160 M-410iB/160 FANUC Robot M-410iB/300 M-410iB/300 FANUC Robot M-410iB/450 M-410iB/450

M-410iB

FANUC Robot M-420iA M-420iA FANUC Robot M-421iA M-421iA FANUC Robot M-430iA/2F M-430iA/2F FANUC Robot M-430iA/2P M-430iA/2P

M-430iA

FANUC Robot M-900iA/260L M-900iA/260L FANUC Robot M-900iA/350 M-900iA/350 FANUC Robot M-900iA/600 M-900iA/600

M-900iA

FANUC Robot F-200iB F-200iB

B-82595EN-2/02 TABLE OF CONTENTS

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TABLE OF CONTENTS

PREFACE.......................................................................................................1

I. SAFETY PRECAUTIONS

1 SAFETY PRECAUTIONS........................................................................3 1.1 WORKING PERSON..................................................................................... 3 1.2 WORKING PERSON SAFETY ...................................................................... 5

1.2.1 General Person Safety ..............................................................................................7 1.2.2 Safety of the Teaching Operator ..............................................................................8 1.2.3 Safety During Maintenance....................................................................................10

1.3 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES........................... 11 1.3.1 Precautions in Programming ..................................................................................11 1.3.2 Precautions for Mechanism ....................................................................................11

1.4 SAFETY OF THE ROBOT MECHANISM .................................................... 12 1.4.1 Precautions in Operation ........................................................................................12 1.4.2 Precautions in Programming ..................................................................................12 1.4.3 Precautions for Mechanisms...................................................................................12

1.5 SAFETY OF THE END EFFECTOR............................................................ 12 1.5.1 Precautions in Programming ..................................................................................12

1.6 WARNING LABEL ....................................................................................... 13

II. MAINTENANCE

1 OVERVIEW ...........................................................................................17 2 CONFIGURATION ................................................................................18

2.1 EXTERNAL VIEW OF THE CONTROLLER ................................................ 19 2.2 COMPONENT FUNCTIONS........................................................................ 32 2.3 PREVENTIVE MAINTENANCE................................................................... 33

3 TROUBLESHOOTING ..........................................................................34 3.1 POWER CANNOT BE TURNED ON ........................................................... 35 3.2 ALARM OCCURRENCE SCREEN.............................................................. 39 3.3 SAFETY SIGNALS ...................................................................................... 42 3.4 MASTERING ............................................................................................... 43 3.5 TROUBLESHOOTING USING THE ERROR CODE ................................... 45

TABLE OF CONTENTS B-82595EN-2/02

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3.6 FUSE-BASED TROUBLESHOOTING....................................................... 146 3.7 TROUBLESHOOTING BASED ON LED INDICATIONS ........................... 154 3.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE

POSITION (POSITIONING)....................................................................... 166 3.9 MANUAL OPERATION IMPOSSIBLE ....................................................... 167

4 PRINTED CIRCUIT BOARDS.............................................................169 4.1 MAIN BOARD (A16B-3200-0600, -0601) .................................................. 170 4.2 EMERGENCY STOP CONTROL BOARD (A20B-1008-0740) .................. 173 4.3 BACKPLANE BOARD ............................................................................... 174 4.4 PANEL BOARD (A20B-2101-0370)........................................................... 176 4.5 PROCESS I/O BOARD CA (A16B-2201-0470) ......................................... 177 4.6 PROCESS I/O BOARD EA (A16B-3200-0230).......................................... 180 4.7 PROCESS I/O BOARD EB (A16B-3200-0231).......................................... 183 4.8 PROCESS I/O BOARD FA (A16B-3200-0420).......................................... 185 4.9 PROCESS I/O BOARD GA (A16B-2203-0520) ......................................... 187 4.10 PROCESS I/O BOARD HA (A16B-2203-0760) ......................................... 189 4.11 PROCESS I/O BOARD JA (A16B-2204-0010) .......................................... 192 4.12 PROCESS I/O BOARD JB (A16B-2204-0011) .......................................... 194 4.13 PROCESS I/O BOARD KA (A16B-2204-0050).......................................... 196 4.14 PROCESS I/O BOARD KB（A16B-2204-0051）...................................... 199 4.15 PROCESS I/O BOARD KC（A16B-2204-0052）...................................... 202

5 SERVO AMPLIFIERS .........................................................................204 5.1 LED OF SERVO AMPLIFIER .................................................................... 206 5.2 SETTING OF SERVO AMPLIFIER............................................................ 207

6 SETTING THE POWER SUPPLY .......................................................208 6.1 BLOCK DIAGRAM OF THE POWER SUPPLY ......................................... 209 6.2 TRANSFORMER....................................................................................... 210 6.3 CHECKING THE POWER SUPPLY UNIT (A16B-2203-0910) .................. 214

7 REPLACING A UNIT...........................................................................215 7.1 A-CABINET................................................................................................ 216

7.1.1 Replacing the A-cabinet Top Panel......................................................................216 7.1.2 Replacing the A-cabinet Rear Panel.....................................................................217 7.1.3 Replacing the A-cabinet Louver...........................................................................218 7.1.4 Replacing the A-cabinet Door ..............................................................................219

7.2 REPLACING THE PRINTED-CIRCUIT BOARDS ..................................... 220 7.2.1 Replacing the Backplane Board (Unit).................................................................221


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7.2.2 Replacing the Power Unit and Printed-Circuit Boards on the Backplane Unit ....222 7.2.3 Replacing the Panel Board ...................................................................................224 7.2.4 Replacing the Process I/O Board EA,EB,FA,GA,KA,KB,KC (A-cabinet) .........226

7.3 REPLACING CARDS AND MODULES ON THE MAIN BOARD ............... 227 7.4 REPLACING THE TRANSFORMER ......................................................... 231 7.5 REPLACING THE REGENERATIVE RESISTOR UNIT ............................ 238 7.6 REPLACING THE E-STOP UNIT .............................................................. 241 7.7 REPLACING SERVO AMPLIFIERS .......................................................... 243 7.8 REPLACING I/O Unit-MODEL A................................................................ 250

7.8.1 Replacing the Base Unit of I/O Unit-MODEL A.................................................250 7.8.2 Replacing a Module..............................................................................................251

7.9 REPLACING THE TEACH PENDANT and i PENDANT............................ 252 7.10 REPLACING THE CONTROL SECTION FAN MOTOR ............................ 253 7.11 REPLACING THE AC FAN MOTOR ......................................................... 254

7.11.1 Replacing the Heat Exchanger and Door Fan Unit (A-cabinet) ...........................254 7.11.2 Replacing External Air Fan Unit (A-cabinet) ......................................................255 7.11.3 Replacing External Air Fan Unit and Door Fan (B-cabinet)................................256

7.12 REPLACE THE MODE SWITCH............................................................... 258 7.13 REPLACING FUSES ................................................................................. 260

7.13.1 Replacing Fuses in the Servo Amplifier...............................................................260 7.13.2 Replacing Fuses in the Power Unit ......................................................................261 7.13.3 Replacing Fuses in the Main board ......................................................................262 7.13.4 Replacing the Fuse on the Process I/O Boards.....................................................263 7.13.5 Replacing the Fuse on the Panel Board................................................................267

7.14 REPLACING RELAYS............................................................................... 268 7.14.1 Replacing Relays on the Panel Board ..................................................................268

7.15 REPLACING BATTERY ............................................................................ 269 7.15.1 Battery for Memory Backup (3 VDC)..................................................................269

8 HOW TO USE THE PLATE TO FIX THE COMPACT FLASH MEMORY CARD ..................................................................................................272

III. CONNECTIONS

1 GENERAL ...........................................................................................277 2 BLOCK DIAGRAM..............................................................................278


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3 ELECTRICAL CONNECTIONS...........................................................280 3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS .................. 281 3.2 EXTERNAL CABLE WIRING DIAGRAM ................................................... 283

3.2.1 Robot Connection Cables.....................................................................................283 3.2.2 Teach Pendant Cable ............................................................................................297 3.2.3 Connecting the Input Power .................................................................................298 3.2.4 Connecting the External Power Supply ON/OFF Switch ....................................301 3.2.5 Connecting the External Emergency Stop............................................................303 3.2.6 Connecting the Non-Teaching Enabling (NTED) Signal (CRM65) ....................314 3.2.7 Connecting the Auxiliary Axis Brake（CRR65 A/B）.......................................316

3.2.8 Connecting the Auxiliary Axis Over Travel (CRM68)........................................317 3.2.9 Connecting the Operation Box .............................................................................318

4 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES......................................................................................319 4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM.......................... 322

4.1.1 When Process I/O Board EA/EB/GA is Used (A-cabinet)...................................322 4.1.2 When Process I/O Board FA is Used (A-cabinet) ................................................324 4.1.3 When Process I/O Board CA/HA is Used (B-cabinet).........................................325 4.1.4 When Process I/O Board JA is Used (B-cabinet).................................................327 4.1.5 When Process I/O Board KA is Used (A-Cabinet) ..............................................328 4.1.6 When I/O Unit-MODEL A is Used......................................................................329

4.1.6.1 In case of B-cabinet ......................................................................................... 329

4.1.7 When Two or more Process I/O Printed Circuit Boards and I/O Unit-MODEL A are Used 330 4.1.7.1 In case of B-cabinet ......................................................................................... 330

4.2 PERIPHERAL DEVICE INTERFACE COMBINATION .............................. 331 4.2.1 In Case of A-cabinet.............................................................................................331 4.2.2 In Case of B-cabinet .............................................................................................332

4.3 PROCESS I/O BOARD SIGNALS ............................................................. 333 4.4 INTERFACE FOR PERIPHERAL DEVICES.............................................. 336

4.4.1 Peripheral Device and Control Unit Connection (Source Type DO) .............336 4.4.2 Peripheral Device and Control Unit Connection (Sink Type DO)..............351

4.5 INTERFACE FOR WELDER...................................................................... 364 4.5.1 Connection Between the Control Unit and Welder ..............................................364

4.6 INTERFACE FOR END EFFECTOR ......................................................... 374 4.6.1 Connection Between the Mechanical Unit and End Effector...............................374

4.7 DIGITAL I/O SIGNAL SPECIFICATIONS .................................................. 376


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4.7.1 Peripheral Device Interface A ..............................................................................376 4.7.2 End Effector Control Interface .............................................................................380 4.7.3 I/O Signal Specifications for ARC-Welding Interface.........................................382

4.8 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS ........................................................................................ 386 4.8.1 Peripheral Device Interface A Cable (CRM2, CRMA5: Honda Tsushin, 50 pins)

386 4.8.2 Peripheral Device Interface B Cable (CRM4, CRMA6: Honda Tsushin, 20 pins)

386 4.8.3 ARC Weld Connection Cable (CRW1, CRW7:Honda Tsushin,34pins)..............387 4.8.4 ARC Weld Connection Cable（CRW10 : Honda Tsushin, 50 pins） ................387

4.9 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS, AND ARC WELDERS ........................................................ 388 4.9.1 Peripheral Device Connection Cable....................................................................388 4.9.2 Peripheral Device Cable Connector .....................................................................389 4.9.3 End Effector Cable Connector .............................................................................391 4.9.4 Recommended Cables ..........................................................................................392

4.10 CONNECTION OF HDI ............................................................................. 393 4.10.1 Connecting HDI ...................................................................................................393 4.10.2 Input Signal Rules for the High-speed Skip (HDI) ..............................................395

4.11 CONNECTING THE COMMUNICATION UNIT ......................................... 396 4.11.1 RS-232-C Interface...............................................................................................396

4.11.1.1 Interface ........................................................................................................... 396 4.11.1.2 RS-232-C interface signals .............................................................................. 397 4.11.1.3 Connection between RS-232-C interface and I/O device ................................ 398

4.11.2 Ethernet Interface .................................................................................................400 4.11.2.1 Connection to Ethernet .................................................................................... 401 4.11.2.2 10/100 BASE-T connector (CD38) pin assignments....................................... 402 4.11.2.3 Cable connection ............................................................................................. 402 4.11.2.4 Lead materials.................................................................................................. 404 4.11.2.5 Connector specification ................................................................................... 406 4.11.2.6 Cable clamp and shielding............................................................................... 406 4.11.2.7 Grounding the network.................................................................................... 407

5 TRANSPORTATION AND INSTALLATION .......................................410 5.1 TRANSPORTATION.................................................................................. 411 5.2 INSTALLATION ......................................................................................... 412

5.2.1 Installation Method...............................................................................................412 5.2.2 Assemble at Installation .......................................................................................418


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5.3 INSTALLATION CONDITION .................................................................... 420 5.4 ADJUSTMENT AND CHECKS AT INSTALLATION .................................. 421 5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION

................................................................................................................... 422 5.5.1 Peripheral Device Interface Processing................................................................422 5.5.2 Resetting Overtravel.............................................................................................422 5.5.3 How to Disable/Enable HBK ...............................................................................423 5.5.4 How to Disable/Enable Pneumatic Pressure Alarm (PPABN).............................423

APPENDIX

A TOTAL CONNECTION DIAGRAM......................................................427 B SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE ...............466

B.1 SIGNAL ..................................................................................................... 467 B.2 SETTING COMMON VOLTAGE................................................................ 469 B.3 I/O Signals ................................................................................................. 470

B.3.1 Input Signals.........................................................................................................470 B.3.2 Output Signals ......................................................................................................474

B.4 Specifications of Digital Input/Output ......................................................... 478 B.4.1 Overview ..............................................................................................................478 B.4.2 Input/Output Hardware Usable in the R-30iA Controller ....................................478 B.4.3 Software Specifications ........................................................................................478

C OPTICAL FIBER CABLE....................................................................479

I. SAFETY PRECAUTIONS

SafetyFANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, orthe 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 safetysystem professionals. FANUC Robotics therefore, recommends that each customer consult with suchprofessionals in order to provide a workplace that allows for the safe application, use, and operation ofFANUC Robotic systems.

According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult thestandards 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 yourresponsibility to arrange for the training of the operator of a robot system to recognize and respond toknown hazards associated with your robotic system and to be aware of the recommended operatingprocedures 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 andbecome familiar with the proper operation of the system. Persons responsible for programming thesystem-including the design, implementation, and debugging of application programs-must be familiarwith the recommended programming procedures for your application and robot installation.

The following guidelines are provided to emphasize the importance of safety in the workplace.

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION

Safety is essential whenever robots are used. 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. However, equipment must bekept safe, too. When prioritizing how to apply safety to your robotic system, consider the following:

i

Safety

• 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 workarea can be enhanced by the installation of some or all of the following devices:

• Safety fences, barriers, or chains

• Light curtains

• Interlocks

• Pressure mats

• Floor markings

• Warning lights

• Mechanical stops

• EMERGENCY STOP buttons

• DEADMAN switches

Setting Up a Safe Workcell

A safe workcell is essential to protect people and equipment. Observe the following guidelines toensure that the workcell is set up safely. These suggestions are intended to supplement and not replaceexisting federal, state, and local laws, regulations, and guidelines that pertain to safety.

• Sponsor your personnel for training in approved FANUC Robotics training course(s) related toyour application. Never permit untrained personnel to operate the robots.

• Install a lockout device that uses an access code to prevent unauthorized persons from operatingthe robot.

• Use anti-tie-down logic to prevent the operator from bypassing safety measures.

• Arrange the workcell so the operator faces the workcell and can see what is going on inside thecell.

ii

Safety

• Clearly identify the work envelope of each robot in the system with floor markings, signs, andspecial barriers. The work envelope is the area defined by the maximum motion range of therobot, including any tooling attached to the wrist flange that extend this range.

• Position all controllers outside the robot work envelope.

• Never rely on software or firmware based controllers as the primary safety element unless theycomply with applicable current robot safety standards.

• Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of theoperator and at critical points inside and around the outside of the workcell.

• Install flashing lights and/or audible warning devices that activate whenever the robot isoperating, that is, whenever power is applied to the servo drive system. Audible warning devicesshall exceed the ambient noise level at the end-use application.

• Wherever possible, install safety fences to protect against unauthorized entry by personnel intothe work envelope.

• Install special guarding that prevents the operator from reaching into restricted areas of thework envelope.

• Use interlocks.

• Use presence or proximity sensing devices such as light curtains, mats, and capacitance andvision systems to enhance safety.

• Periodically check the safety joints or safety clutches that can be optionally installed between therobot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, removepower from the system, and help to minimize damage to the tooling and robot.

• Make sure all external devices are properly filtered, grounded, shielded, and suppressed toprevent hazardous motion due to the effects of electro-magnetic interference (EMI), radiofrequency interference (RFI), and electro-static discharge (ESD).

• Make provisions for power lockout/tagout at the controller.

• Eliminate pinch points . Pinch points are areas where personnel could get trapped between amoving robot and other equipment.

• Provide enough room inside the workcell to permit personnel to teach the robot and performmaintenance safely.

• Program the robot to load and unload material safely.

• If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, andbeacons.

• If materials are being applied at dangerously high pressure, provide electrical interlocks forlockout of material flow and pressure.

iii

Safety

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 thefollowing rules:

• Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in movingmachinery.

• Know whether or not you are using an intrinsically safe teach pendant if you are working ina hazardous environment.

• Before teaching, visually inspect the robot and work envelope to make sure that no potentiallyhazardous conditions exist. The work envelope is the area defined by the maximum motion rangeof the robot. These include tooling attached to the wrist flange that extends this range.

• The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafeworking conditions to the supervisor or safety department.

• FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except forrobot teaching operations. However, if you must enter the work envelope, be sure all safeguardsare in place, check the teach pendant DEADMAN switch for proper operation, and place therobot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release theDEADMAN switch. Only the person with the teach pendant should be in the work envelope.

Warning

Never bypass, strap, or otherwise deactivate a safety device, such as alimit switch, for any operational convenience. Deactivating a safetydevice is known to have resulted in serious injury and death.

• Know the path that can be used to escape from a moving robot; make sure the escape path isnever blocked.

• Isolate the robot from all remote control signals that can cause motion while data is being taught.

• Test any program being run for the first time in the following manner:

Warning

Stay outside the robot work envelope whenever a program is beingrun. Failure to do so can result in injury.

— Using a low motion speed, single step the program for at least one full cycle.

— Using a low motion speed, test run the program continuously for at least one full cycle.

— Using the programmed speed, test run the program continuously for at least one full cycle.

• Make sure all personnel are outside the work envelope before running production.

iv

Safety

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.

• Know the entire workcell area. The workcell includes the robot and its work envelope, plus thearea occupied by all external devices and other equipment with which the robot interacts.

• Understand the complete task the robot is programmed to perform before initiating automaticoperation.

• Make sure all personnel are outside the work envelope before operating the robot.

• Never enter or allow others to enter the work envelope during automatic operation of the robot.

• Know the location and status of all switches, sensors, and control signals that could cause therobot to move.

• Know where the EMERGENCY STOP buttons are located on both the robot control and externalcontrol devices. Be prepared to press these buttons in an emergency.

• Never assume that a program is complete if the robot is not moving. The robot could be waitingfor an input signal that will permit it to continue activity.

• If the robot is running in a pattern, do not assume it will continue to run in the same pattern.

• Never try to stop the robot, or break its motion, with your body. The only way to stop robotmotion immediately is to press an EMERGENCY STOP button located on the controller panel,teach pendant, or emergency stop stations around the workcell.

Staying Safe During Inspection

When inspecting the robot, be sure to

• Turn off power at the controller.

• Lock out and tag out the power source at the controller according to the policies of your plant.

• Turn off the compressed air source and relieve the air pressure.

• If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCYSTOP button on the operator panel.


• If power is needed to check the robot motion or electrical circuits, be prepared to press theEMERGENCY STOP button, in an emergency.

• Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it isnot supported or resting on a hard stop. Support the arm on a solid support before you releasethe brake.

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Safety

Staying Safe During Maintenance

When performing maintenance on your robot system, observe the following rules:

• Never enter the work envelope while the robot or a program is in operation.

• Before entering the work envelope, visually inspect the workcell to make sure no potentiallyhazardous conditions exist.


• Consider all or any overlapping work envelopes of adjoining robots when standing in a workenvelope.

• Test the teach pendant for proper operation before entering the work envelope.

• If it is necessary for you to enter the robot work envelope while power is turned on, you must besure that you are in control of the robot. Be sure to take the teach pendant with you, press theDEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switchto turn off servo power to the robot immediately.

• Whenever possible, perform maintenance with the power turned off. Before you open thecontroller front panel or enter the work envelope, turn off and lock out the 3-phase power sourceat the controller.

• Be aware that an applicator bell cup can continue to spin at a very high speed even if the robot isidle. Use protective gloves or disable bearing air and turbine air before servicing these items.


Warning

Lethal voltage is present in the controller WHENEVER IT ISCONNECTED to a power source. Be extremely careful to avoidelectrical shock.HIGH VOLTAGE IS PRESENT at the input sidewhenever the controller is connected to a power source. Turning thedisconnect or circuit breaker to the OFF position removes power fromthe output side of the device only.

• Release or block all stored energy. Before working on the pneumatic system, shut off the systemair supply and purge the air lines.

• Isolate the robot from all remote control signals. If maintenance must be done when the poweris on, make sure the person inside the work envelope has sole control of the robot. The teachpendant must be held by this person.

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Safety

• Make sure personnel cannot get trapped between the moving robot and other equipment. Knowthe path that can be used to escape from a moving robot. Make sure the escape route is neverblocked.

• Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make surethat such devices do not create pinch points that could trap personnel.

Warning

Do not try to remove any mechanical component from the robotbefore thoroughly reading and understanding the procedures in theappropriate manual. Doing so can result in serious personal injury andcomponent destruction.


• When replacing or installing components, make sure dirt and debris do not enter the system.

• Use only specified parts for replacement. To avoid fires and damage to parts in the controller,never use nonspecified fuses.

• Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot andall external devices are operating normally.

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

Certain programming and mechanical measures are useful in keeping the machine tools and otherexternal devices safe. Some of these measures are outlined below. Make sure you know all associatedmeasures for safe use of such devices.

Programming Safety Precautions

Implement the following programming safety measures to prevent damage to machine tools andother external devices.

• Back-check limit switches in the workcell to make sure they do not fail.

• Implement “failure routines” in programs that will provide appropriate robot actions if an externaldevice or another robot in the workcell fails.

• Use handshaking protocol to synchronize robot and external device operations.

• Program the robot to check the condition of all external devices during an operating cycle.

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Safety

Mechanical Safety Precautions

Implement the following mechanical safety measures to prevent damage to machine tools and otherexternal devices.

• Make sure the workcell is clean and free of oil, water, and debris.

• Use software limits, limit switches, and mechanical hardstops to prevent undesired movement ofthe robot into the work area of machine tools and external devices.

KEEPING THE ROBOT SAFE

Observe the following operating and programming guidelines to prevent damage to the robot.

Operating Safety Precautions

The following measures are designed to prevent damage to the robot during operation.

• Use a low override speed to increase your control over the robot when jogging the robot.

• Visualize the movement the robot will make before you press the jog keys on the teach pendant.

• Make sure the work envelope is clean and free of oil, water, or debris.

• Use circuit breakers to guard against electrical overload.

Programming Safety 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 that the program ends with the robot near or at the home position.

• Be aware of signals or other operations that could trigger operation of tooling resulting inpersonal injury or equipment damage.

• In dispensing applications, be aware of all safety guidelines with respect to the dispensingmaterials.

Note Any deviation from the methods and safety practices described in this manual must conformto the approved standards of your company. If you have questions, see your supervisor.

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Safety

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOTINSTALLATIONS

Process technicians are sometimes required to enter the paint booth, for example, during daily orroutine calibration or while teaching new paths to a robot. Maintenance personal also must workinside the paint booth periodically.

Whenever personnel are working inside the paint booth, ventilation equipment must be used.Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor.

Although paint booth hazards have been minimized, potential dangers still exist. Therefore, today’shighly automated paint booth requires that process and maintenance personnel have full awareness ofthe system and its capabilities. They must understand the interaction that occurs between the vehiclemoving along the conveyor and the robot(s), hood/deck and door opening devices, and high-voltageelectrostatic tools.

Paint robots are operated in three modes:

• Teach or manual mode

• Automatic mode, including automatic and exercise operation

• Diagnostic mode

During both teach and automatic modes, the robots in the paint booth will follow a predeterminedpattern of movements. In teach mode, the process technician teaches (programs) paint paths usingthe teach pendant.

In automatic mode, robot operation is initiated at the System Operator Console (SOC) or ManualControl Panel (MCP), if available, and can be monitored from outside the paint booth. All personnelmust remain outside of the booth or in a designated safe area within the booth whenever automaticmode is initiated at the SOC or MCP.

In automatic mode, the robots will execute the path movements they were taught during teach mode,but generally at production speeds.

When process and maintenance personnel run diagnostic routines that require them to remain in thepaint booth, they must stay in a designated safe area.

Paint System Safety Features

Process technicians and maintenance personnel must become totally familiar with the equipment andits capabilities. To minimize the risk of injury when working near robots and related equipment,personnel must comply strictly with the procedures in the manuals.

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Safety

This section provides information about the safety features that are included in the paint system andalso explains the way the robot interacts with other equipment in the system.

The paint system includes the following safety features:

• Most paint booths have red warning beacons that illuminate when the robots are armed and readyto paint. Your booth might have other kinds of indicators. Learn what these are.

• Some paint booths have a blue beacon that, when illuminated, indicates that the electrostaticdevices are enabled. Your booth might have other kinds of indicators. Learn what these are.

• EMERGENCY STOP buttons are located on the robot controller and teach pendant. Becomefamiliar with the locations of all E-STOP buttons.

• An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres.

• A DEADMAN switch is located on each teach pendant. When this switch is held in, and theteach pendant is on, power is applied to the robot servo system. If the engaged DEADMANswitch is released during robot operation, power is removed from the servo system, all axisbrakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks withinthe system might also E-STOP other robots.

Warning

An EMERGENCY STOP will occur if the DEADMAN switch is releasedon a bypassed robot.

• Overtravel by robot axes is prevented by software limits. All of the major and minor axes aregoverned by software limits. Limit switches and hardstops also limit travel by the major axes.

• EMERGENCY STOP limit switches and photoelectric eyes might be part of your system.Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP allequipment in the booth if a door is opened while the system is operating in automatic or manualmode. For some systems, signals to these switches are inactive when the switch on the SCC isin teach mode.When present, photoelectric eyes are sometimes used to monitor unauthorizedintrusion through the entrance/exit silhouette openings.

• System status is monitored by computer. Severe conditions result in automatic system shutdown.

Staying Safe While Operating the Paint Robot

When you work in or near the paint booth, observe the following rules, in addition to all rules forsafe operation that apply to all robot systems.

Warning

Observe all safety rules and guidelines to avoid injury.

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Safety

Warning

Never bypass, strap, or otherwise deactivate a safety device, such as alimit switch, for any operational convenience. Deactivating a safety deviceis known to have resulted in serious injury and death.

Warning

Enclosures shall not be opened unless the area is know to benonhazardous or all power has been removed from devices within theenclosure. Power shall not be restored after the enclosure has beenopened until all combustible dusts have been removed from the interiorof the enclosure and the enclosure purged. Refer to the Purge chapterfor the required purge time.

• Know the work area of the entire paint station (workcell).

• Know the work envelope of the robot and hood/deck and door opening devices.

• Be aware of overlapping work envelopes of adjacent robots.

• Know where all red, mushroom-shaped EMERGENCY STOP buttons are located.

• Know the location and status of all switches, sensors, and/or control signals that might cause therobot, conveyor, and opening devices to move.

• Make sure that the work area near the robot is clean and free of water, oil, and debris. Reportunsafe conditions to your supervisor.

• Become familiar with the complete task the robot will perform BEFORE starting automatic mode.

• Make sure all personnel are outside the paint booth before you turn on power to the robotservo system.

• Never enter the work envelope or paint booth before you turn off power to the robot servo system.

• Never enter the work envelope during automatic operation unless a safe area has been designated.


• Remove all metallic objects, such as rings, watches, and belts, before entering a booth when theelectrostatic devices are enabled.

• Stay out of areas where you might get trapped between a moving robot, conveyor, or openingdevice and another object.

• Be aware of signals and/or operations that could result in the triggering of guns or bells.

• Be aware of all safety precautions when dispensing of paint is required.

• Follow the procedures described in this manual.

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Safety

Special Precautions for Combustible Dusts (powder paint)

When the robot is used in a location where combustible dusts are found, such as the application ofpowder paint, the following special precautions are required to insure that there are no combustibledusts inside the robot.

• Purge maintenance air should be maintained at all times, even when the robot power is off. Thiswill insure that dust can not enter the robot.

• A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed to dustwhen maintenance air is not present, it will be necessary to remove the covers and clean out anyaccumulated dust. Do not energize the robot until you have performed the following steps.

1. Before covers are removed, the exterior of the robot should be cleaned to remove accumulateddust.

2. When cleaning and removing accumulated dust, either on the outside or inside of the robot, besure to use methods appropriate for the type of dust that exists. Usually lint free rags dampenedwith water are acceptable. Do not use a vacuum cleaner to remove dust as it can generate staticelectricity and cause an explosion unless special precautions are taken.

3. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust.

4. When the dust has been removed, the covers must be replaced immediately.

5. Immediately after the covers are replaced, run a complete purge cycle. The robot can nowbe energized.

Staying Safe While Operating Paint Application Equipment

When you work with paint application equipment, observe the following rules, in addition to all rulesfor safe operation that apply to all robot systems.

Warning

When working with electrostatic paint equipment, follow all national andlocal codes as well as all safety guidelines within your organization.Also reference the following standards: NFPA 33 Standards for SprayApplication Using Flammable or Combustible Materials , and NFPA 70National Electrical Code .

• Grounding : All electrically conductive objects in the spray area must be grounded. Thisincludes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots,as well as solvent containers. Grounding is defined as the object or objects shall be electricallyconnected to ground with a resistance of not more than 1 megohms.

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Safety

• High Voltage : High voltage should only be on during actual spray operations. Voltage should beoff when the painting process is completed. Never leave high voltage on during a cap cleaningprocess.

• Avoid any accumulation of combustible vapors or coating matter.

• Follow all manufacturer recommended cleaning procedures.

• Make sure all interlocks are operational.

• No smoking.

• Post all warning signs regarding the electrostatic equipment and operation of electrostaticequipment according to NFPA 33 Standard for Spray Application Using Flammable orCombustible Material.

• Disable all air and paint pressure to bell.

• Verify that the lines are not under pressure.

Staying Safe During Maintenance

When you perform maintenance on the painter system, observe the following rules, and all othermaintenance safety rules that apply to all robot installations. Only qualified, trained service ormaintenance personnel should perform repair work on a robot.

• Paint robots operate in a potentially explosive environment. Use caution when working withelectric tools.

• When a maintenance technician is repairing or adjusting a robot, the work area is under the controlof that technician. All personnel not participating in the maintenance must stay out of the area.

• For some maintenance procedures, station a second person at the control panel within reachof the EMERGENCY STOP button. This person must understand the robot and associatedpotential hazards.

• Be sure all covers and inspection plates are in good repair and in place.

• Always return the robot to the ‘‘home’’ position before you disarm it.

• Never use machine power to aid in removing any component from the robot.

• During robot operations, be aware of the robot’s movements. Excess vibration, unusual sounds,and so forth, can alert you to potential problems.

• Whenever possible, turn off the main electrical disconnect before you clean the robot.

• When using vinyl resin observe the following:

— Wear eye protection and protective gloves during application and removal

— Adequate ventilation is required. Overexposure could cause drowsiness or skin and eyeirritation.

— If there is contact with the skin, wash with water.

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Safety

— Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.

• When using paint remover observe the following:

— Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning.

— Adequate ventilation is required. Overexposure could cause drowsiness.

— If there is contact with the skin or eyes, rinse with water for at least 15 minutes. Then,seek medical attention as soon as possible.

— Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.

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B-82595EN-2/02 1.SAFETY PRECAUTIONS

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1 SAFETY PRECAUTIONS For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell.

1.1 WORKING PERSON The personnel can be classified as follows. Operator : • Power ON/OFF for robot controller • Start of robot program with operator’s panel Programmer or teaching operator : • Operate for Robot • Teaching inside safety fence Maintenance engineer : • Operate for Robot • Teaching inside safety fence • Maintenance (adjustment, replacement)

- An operator cannot work inside the safety fence. - A programmer, Teaching operator and maintenance engineer can

work inside the safety fence. The workings inside safety fence are lifting, setting, teaching, adjusting, maintenance, etc..

- To work inside the fence, the person must be trained for the robot.

Table 1 lists the workings of outside the fence. In this table, the symbol “ ” means the working allowed to be carried out by the personnel.

1.SAFETY PRECAUTIONS B-82595EN-2/02

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Table 1 List of workings outside the fence

Operator Programmer or Teaching

operator

Maintenance engineer

Power ON/OFF for Robot controller Select operating mode (AUTO, T1, T2) Select Remote/Local mode Select robot program with teach pendant Select robot program with external device Start robot program with operator’s panel Start robot program with teach pendant Reset alarm with operator’s panel Reset alarm with teach pendant Set data on the teach pendant Teaching with teach pendant Emergency stop with operator’s panel Emergency stop with teach pendant Emergency stop with safety fence open Maintain for operator’s panel Maintain for teach pendant

In operating, programming and maintenance, the programmer, teaching operator and maintenance engineer take care of their safety using the following safety protectors, for example. • Use adequate clothes, uniform, overall for operation • Put on the safety shoes • Use helmet


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1.2 WORKING PERSON SAFETY Working person safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure working person safety. (1) Have the robot system working person attend the training courses

held by FANUC. FANUC provides various training courses. Contact our sales office for details.

(2) Even when the robot is stationary, it is possible that the robot is

still in a ready to move state, and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working person safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion.

(3) Install a safety fence with a gate so that no working person can

enter the work area without passing through the gate. Install an interlock switch, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened.

The controller is designed to receive this interlock signal of the door switch. When the gate is opened and this signal received, the controller stops the robot in an emergency. For connection, see Fig.1.1.

(4) Provide the peripheral devices with appropriate grounding (Class

A, Class B, Class C, and Class D). (5) Try to install the peripheral devices outside the work area. (6) Draw an outline on the floor, clearly indicating the range of the

robot motion, including the tools such as a hand. (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 working person enters the work area.

(8) If necessary, install a safety lock so that no one except the

working person in charge can turn on the power of the robot. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.


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(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.

Interlock switch and safety plug when the door is opening.

RI/RO, HBK, ROT

Fig.1.2 Safety fence and safety gate

NOTE Terminals EAS1, EAS11, EAS2, and EAS21 are on

the PC board in the operator box or operator panel.


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1.2.1 General Person Safety The general person is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also a general person. However, this section does not apply to teaching operators. (1) If it is not necessary for the robot to operate, turn off the power

of the robot controller or press the EMERGENCY STOP button, and then proceed with necessary work.

(2) Operate the robot system at a location outside of the safety fence (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.

(4) Install an EMERGENCY STOP button within the general person’s reach.

The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

NOTE Connect to EES1 and EES11, EES2 and EES21.

Fig.1.2.1 Connection diagram for external emergency stop button


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1.2.2 Safety of the Teaching Operator While teaching the robot, it is necessary for the operator to enter the work area of the robot. It is particularly necessary to ensure the safety of the teaching operator. (1) Unless it is specifically necessary to enter the robot work area,

carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral

devices are all in the normal operating condition. (3) When entering the robot work area and teaching the robot, 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).

(4) The teaching operator should pay careful attention so that no other workers enter the robot work area.

Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the automatic operation mode set, the robot enters the emergency stop state. After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety fence.

Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and switch function as follows: (1) Emergency stop button: Causes an emergency stop when pressed. (2) DEADMAN switch: Functions differently depending on the mode

switch setting status. (a) Automatic operation mode: The DEADMAN switch is disabled. (b) Teach mode: Causes an emergency stop when the operator

releases the DEADMAN switch or when the operator presses the switch strongly. Note) The DEADMAN switch is provided to place the robot in the

emergency stop state when the operator releases the teach pendant or presses the pendant strongly in case of emergency. The R-30iA employs a 3-position DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly, the robot enters the emergency stop state.

The operator's intention of starting teaching is determined by the control unit through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should make sure that the robot can operate in such conditions and be responsible in carrying out tasks safely.


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The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode switch of the operator panel DEADMAN switch, the teach pendant enable switch and the remote condition on the software.

Mode Teach pendant enable switch

Software remote

conditionTeach pendant Operator panel Peripheral

device

Local Not allowed Not allowed Not allowed On Remote Not allowed Not allowed Not allowed

Local Not allowed Allowed to start Not allowed AUTO mode

Off Remote Not allowed Not allowed Allowed to start

Local Allowed to start Not allowed Not allowed On Remote Allowed to start Not allowed Not allowed

Local Not allowed Not allowed Not allowed T1, T2 mode

Off Remote Not allowed Not allowed Not allowed

(5) To start the system using the operator's panel, make certain that

nobody is in the robot work area and that there are no abnormal conditions in the robot work area.

(6) When a program is completed, be sure to carry out a test run according to the procedure below. (a) Run the program for at least one operation cycle in the

single step mode at low speed. (b) Run the program for at least one operation cycle in the

continuous operation mode at low speed. (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.

(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.

(e) After checking the completeness of the program through the test run above, execute it in the automatic operation mode.

(7) While operating the system in the automatic operation mode, the teaching operator should leave the robot work area.


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1.2.3 Safety During Maintenance For the safety of maintenance personnel, pay utmost attention to the following. (1) During operation, never enter the robot work area. (2) Except when specifically necessary, turn off the power of the

controller while carrying out maintenance. Lock the power switch, if necessary, so that no other person can turn it on.

(3) If it becomes necessary to enter the robot operation range while the power is on, press the emergency stop button on the operator panel, or the teach pendant before entering the range. The maintenance personnel must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly.

(4) When disconnecting the pneumatic system, be sure to reduce the supply pressure.

(5) Before the start of teaching, check that the robot and its peripheral devices are all in the normal operating condition.

(6) Do not operate the robot in the automatic mode while anybody is in the robot work area.

(7) When it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers are working nearby, make certain that their escape path is not obstructed.

(8) When a tool is mounted on the robot, or when any moving device other than the robot is installed, such as belt conveyor, pay careful attention to its motion.

(9) If necessary, have a worker who is familiar with the robot system stand beside the operator panel and observe the work being performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time.

(10) When replacing or reinstalling components, take care to prevent foreign matter from entering the system.

(11) When handling each unit or printed circuit board in the controller during inspection, turn off the circuit breaker to protect against electric shock.

(12) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of non-specified

ratings. They may cause a fire or result in damage to the components in the controller.

(13) When restarting the robot system after completing maintenance work, make sure in advance that there is no person in the work area and that the robot and the peripheral devices are not abnormal.


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1.3 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

1.3.1 Precautions in Programming (1) Use a limit switch or other sensor to detect a dangerous condition

and, if necessary, design the program to stop the robot when the sensor signal is received.

(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal.

(3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other.

(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.

1.3.2 Precautions for Mechanism

(1) Keep the component cells of the robot system clean, and operate

the robot in an environment free of grease, water, and dust. (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.


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1.4 SAFETY OF THE ROBOT MECHANISM

1.4.1 Precautions in Operation (1) When operating the robot in the jog mode, set it at an appropriate

speed so that the operator can manage the robot in any eventuality.

(2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the jog mode.

1.4.2 Precautions in Programming

(1) When the work areas of robots overlap, make certain that the

motions of the robots do not interfere with each other. (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.

Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

1.4.3 Precautions for Mechanisms

(1) Keep the work area of the robot clean, and operate the robot in an

environment free of grease, water, and dust.

1.5 SAFETY OF THE END EFFECTOR

1.5.1 Precautions in Programming (1) To control the pneumatic, hydraulic and electric actuators,

carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control.

(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.


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1.6 WARNING LABEL (1) Step-on prohibitive label

Fig.1.6 (a) Step-on prohibitive 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.

(2) High-temperature warning label

Fig.1.6 (b) High-temperature warning label

Description Be cautious about a section where this label is affixed, as

the section generates heat. If you have to inevitably touch such a section when it is hot, use a protective provision such as heat-resistant gloves.


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(3) High-voltage warning label

Fig.1.6 (c) High-voltage warning label

Description A high voltage is applied to the places where this label is

attached. Before starting maintenance, turn the power to the control

unit off, then turn the circuit breaker off to avoid electric shock hazards. 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.

II. MAINTENANCE

B-82595EN-2/02 MAINTENANCE 1.OVERVIEW

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1 OVERVIEW This manual describes the maintenance and connection of the R-30iA robot controller (called the R-30iA). Maintenance Part : Troubleshooting, and the setting, adjustment, and replacement of

units Connection Part : Connection of the R-30iA controller to the robot mechanical unit

and peripheral devices, and installation of the controller

WARNING Before you enter the robot working area, be sure to

turn off the power to the controller or press the EMERGENCY STOP button on the operator's panel or teach pendant.

Otherwise, you could injure personnel or damage equipment.

- The RIA R15.06 - - 1999 compliant controller has safety circuit

performance compliant with 4.5.4 control reliable. - For information on third party approvals, contact your FANUC

representative. - The controller is designed to meet R15.06 - - 1999 American

standard for industrial robots and robot systems - - safety requirements.

2.CONFIGURATION MAINTENANCE B-82595EN-2/02

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2 CONFIGURATION

B-82595EN-2/02 MAINTENANCE 2.CONFIGURATION

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2.1 EXTERNAL VIEW OF THE CONTROLLER The appearance and components might slightly differ depending on the controlled robot, application, and options used. Fig.2.1 (a) to (c) shows the view of R-30iA. Fig.2.1 (d) to (i) show the construction of the R-30iA controller. Fig.2.1 (j) to (l) show the external view of the operator’s panel. Fig.2.1 (m) and (n) show the block diagram of R-30iA.

Fig.2.1 (a) External view of the R-30iA controller (A-cabinet)

Fig.2.1 (b) External view of the R-30iA controller (Integrated operation box)

Teach pendant

Operation box

R-30iA controller

Teach pendant

Integrated operation box

R-30iA controller


- 20 -

Operator’s panel

Teach pendant

Fig.2.1 (c) External view of the R-30iA controller (B-cabinet)


- 21 -

Fig.2.1 (d) R-30iA A-cabinet interior

Regenerative

resistor unit

Teach pendant

Emergency stop

button

Enable switch

Emergency stop unit

Main board

Power supply unit

Fan unit

Servo amplifier

Transformer

Side fan type Rear fan type

FANUNIT


- 22 -

Fig.2.1 (e) R-30iA A-cabinet interior (M-430iA)

Emergency stop unit

Servo amplifier

Main board

Power supply unit

Fan unit

Heat exchanger

Teach pendant

Emergency stop button

Enable switch

2-axis servo amplifier(AMP2)-M-430iA/2F

3-axis servo amplifier(AMP2)-M-430iA/2P


- 23 -

Fig.2.1 (f) R-30iA B-cabinet interior (Front)

3 mode switch

DC fan unit Servo amplifier


Panel board


Enable switch

Teach pendant Door fan Optional slot

Main board Power supply unit

Emergency stop unit

RCC I/F unit (only M-900iA/260L, M-900iA/350)

Back plane

Circuit breaker

External air fan unit

Battery


- 24 -

Fig.2.1 (g) R-30iA B-cabinet interior (Front) (M-900 iA/600)

3 mode switch DC fan unit


Panel board

Enable switch

Teach pendant Door fan Optional slot


Emergency stop unit

RCC I/F unit

Back plane

Circuit breaker


Battery

6-servo amplifier (AMP1) 2-axis servo amplifier (AMP2)1-axis Servo amplifier (AMP3)



- 25 -

Fig. 2.1 (h) R-30iA B-cabinet interior（Front）(M-430iA)

Transformer

Regenerative resistor unit

Fig.2.1 (i) R-30iA B-cabinet interior (Back)

Mode switch DC fan unit


Panel board


Enable switch

Teach pendant Door fan Option slot


Emergency stop unit

RCC I/F unit

Back plane

Circuit breaker


Battery

6-axis servo amplifier（AMP1） 2-axis servo amplifier(AMP2)-M-430iA/2F 3-axis servo amplifier(AMP2)-M-430iA/2P


- 26 -

EMERGENCY STOPFAULT RESET

CYCLE START

FAULT POWER

Fig.2.1 (j) R-30iA panel overview

2 mode switch 3 mode switch

Fig.2.1 (k) Mode switch operation


- 27 -

Fig.2.1 (l) USB/RS-232-C interface overview


- 28 -

Table 2.1 (a) Servo amplifier specification

REGENERATIVE REGISTOR ROBOT SERVO AMPLIFIER A-CABINET B-CABINET

M-900iA/600 A06B-6107-H001 (AMP1) A06B-6117-H209 (AMP2) A06B-6117-H105 (AMP3)

A05B-2502-C100

R-2000iB/200T M-900iA/260L M-900iA/350

M-410iB

A06B-6107-H001

A05B-2501-C102

A05B-2502-C100

R-2000iB （except /200T）

M-710iC A05B-2501-C103 M-16iB ARC Mate 120iB (Except ARC Mate 120iBe.)

A05B-2501-C100

M-420iA, M-421iA

A06B-6107-H002

A05B-2501-C102

A05B-2502-C100

M-6iB ARC Mate 100iB ARC Mate 120iBe

A05B-2501-C101

F-200iB

A06B-6107-H003

A05B-2501-C105

A05B-2502-C101

ARC Mate 100iC M-10iA A06B-6107-H004 A05B-2501-C101 A05B-2502-C101

M-430iA/2F A06B-6107-H007 (AMP 1) A06B-6117-H201 (AMP 2)

M-430iA/2P A06B-6107-H007 (AMP 1) A06B-6117-H301 (AMP 2)

A05B-2501-C105 A05B-2502-C101


- 29 -

Table 2.1(b) fan type list for A-cabinet

FAN TYPE ROBOT REAR FAN SIDE FAN

M-410iB ― M-710iC ― M-16iB ― ARC Mate 120iB ― M-420iA, M-421iA ― M-6iB ― ARC Mate 100iB ― F-200iB ― ARC Mate 100iC ― M-430iA ― M-10iA ―


- 30 -

Fig.2.1 (m) Block diagram of the R-30iA (A-cabinet)


- 31 -

Bac

kpla

ne P

rinte

d-ci

rcui

t boa

rd

Pow

er s

uppl

y un

it M

ain

boar

d P

roce

ss I/

O

I/O

Uni

t-MO

DE

L A

Fan

Tran

sfor

mer

Circuit breaker

AC

inpu

t

3Φ

20

0 –

230

VAC

38

0 –

400

VAC

38

0 –

415

VAC

44

0 –

500

VAC

50

0 –

575

VAC

E–s

top

unit

Ope

rato

r's p

anel

Pan

el b

oard

Mem

ory

card

Battery

US

B m

emor

y

Sw

itch Ser

vo a

mpl

ifier

(6

–axi

s am

plifi

er)

Reg

ener

ativ

e re

sist

or

200 V, single-phase output

200 V, single-phase input

Servo signal (FSSB)

24VDC

Signals for I/O Link and Teach pendant

24VDC EMG signal

200

V, 3

-pha

se

Tran

sfor

mer

ov

erhe

at s

igna

l

200

V, 3

-pha

se

EM

G s

igna

l

Pul

se c

oder

sig

nals

, Rob

ot D

I/DO

sig

nals

Mot

or p

ower

sup

ply,

Bra

ke p

ower

sup

ply

Per

iphe

ral

devi

ce (S

eria

l)

Per

iphe

ral

devi

ce

(Ser

ial)

Per

iphe

ral

devi

ce

(Eth

erne

t)

Teac

h pe

ndan

t

Ext

erna

l E–s

top

Ext

erna

l on/

off

Rob

ot

Fig.2.1 (n) Block diagram of the R-30iA (B-cabinet)


- 32 -

2.2 COMPONENT FUNCTIONS • Main board The main board contains a microprocessor, its peripheral circuits,

memory, and operator's panel control circuit. The main CPU controls servo mechanism positioning.

• I/O printed circuit board, FANUC I/O Unit MODEL-A Various types of printed circuit boards are provided for

applications including process I/O. The FANUC I/O unit MODEL-A can also be installed. When it is used, various I/O types can be selected. These are connected with FANUC I/O Link.

• E-stop unit and MCC unit This unit controls the emergency stop system for both of the

magnetic contactor and the precharge of the servo amplifier. • Power supply unit The power supply unit converts the AC power to various levels

of DC power. • Backplane printed circuit board The various control printed circuit boards are mounted on the

backplane printed circuit board. • Teach pendant All operations including robot programming are performed with

this unit. The controller status and data are indicated on the liquid-crystal display (LCD) on the pendant.

• Servo amplifier The servo amplifier controls servomotor, pulse coder signal,

brake control, overtravel and hand broken. • Operator's panel Buttons and LEDs on the operator's panel are used to start the

robot and to indicate the robot status. The panel has a port and an USB interface for the serial interface to an external device and an interface to connect the memory card for data backup. It also controls the emergency stop control circuit.

• Transformer The supply voltage is converted to an AC voltage required for

the controller by the transformer. • Fan unit, heat exchanger These components cool the inside of the controller. • Circuit breaker If the electric system in the controller malfunctions, or if

abnormal input power causes high current in the system, the input power is connected to the circuit breaker to protect the equipment.

• Regenerative resistor To discharge the counter electromotive force from the

servomotor, connect a regenerative resistor to the servo amplifier.


- 33 -

2.3 PREVENTIVE MAINTENANCE Daily maintenance and periodic maintenance/inspection ensure reliable robot performance for extended periods of time. (1) Daily maintenance Before operating the system each day, clean each part of the

system and check the system parts for any damage or cracks. Also check the following: (a) Before service operation Check the cable connected to the teach pendant for

excessive twisting. Check the controller and peripheral devices for abnormalities.

(b) After service operation At the end of service operation, return the robot to the

specified position, then turn off the controller. Clean each part, and check for any damage or cracks. If the ventilation port of the controller is dusty, clean it.

(2) Check after one month Check that the fan is rotating normally. If the fan has dirt and

dust built up, clean the fan according to step (d) described below for inspection to be performed every 6 months.

(3) Periodic inspection performed every six months Remove the top cover, louver, and back panel (if possible), then

remove any dirt and dust from the inside of the transformer compartment. Wipe off dirt and dust from the fan and transformer.

(4) Battery daily check Replace the battery on the front panel of the main board every 4

years. Please refer to the section 7.14. (5) Maintenance tools The following maintenance tools are recommended:

(a) Measuring instruments AC/DC voltmeter (A digital voltmeter is sometimes

required.) Oscilloscope with a frequency range of 5 MHz or higher,

two channels (b) Tools Phillips screwdrivers : Large, medium, and small Standard screwdrivers : Large, medium, and small Nut driver set (Metric) Pliers Needle-nose pliers Diagonal cutting pliers

3.TROUBLESHOOTING MAINTENANCE B-82595EN-2/02

- 34 -

3 TROUBLESHOOTING This chapter describes the checking method and corrective action for each error code indicated if a hardware alarm occurs. Refer to the operator's manual to release program alarms.

B-82595EN-2/02 MAINTENANCE 3.TROUBLESHOOTING

- 35 -

3.1 POWER CANNOT BE TURNED ON

Check and Corrective action Figure (Check 1) Check that the circuit breaker is

on and has not tripped. (Corrective action)

Turn on the circuit breaker.

Circuit breaker

(Check 2) Check whether the LED (PIL:

green) on the power supply unit is on.

(Corrective action)

If the LED is not on, 200 VAC is not supplied to the power supply unit. It is likely that fuse F1 in the power supply unit has blown. - If 200 VAC is not supplied: Find the cause by referencing

the general schematic diagram presented in the appendix.

- If 200 VAC is supplied: Find the cause of the blown

fuse. Fuse F1 is in the power supply unit. Before you start troubleshooting, turn off the circuit breaker. a) If fuse F1 has blown: - See Corrective action

(1). b) If fuse F1 has not blown: - Replace the power

supply unit.

DB1: Diode stack

F1(8.0A): Fuse for AC input

CP1: Connector for AC inputCP1A: Connector for AC output CP2, CP3: Connector for AC outputF3(7.5A): Fuse for +24E F4(7.5A): Fuse for +24V PIL: LED (green) CP5: Connector for +24E CP6: Connector for +24V

ALM: LED (red) CP4: Connector for control

VS1: Surge absorber

H1: Auxiliary power module

Circuit breaker


- 36 -

Check and Corrective action Figure (Corrective action(1))

Causes of blown fuses F1 and corrective action a) Check whether the unit and

printed-circuit board connected to the connectors CP2 and CP3 in the power supply unit are abnormal, by referencing the general schematic diagram presented in the appendix.

b) Short-circuit in the surge absorber VS1

VS1 is inserted to absorb surge voltage between input lines.

If the surge voltage is excessive or sustained, excessively high voltage is applied to VS1 and a failure occurs in the short-circuit mode, causing F1 to blow. If a short-circuit occurs in VS1, and there is not a spare part, the system is permitted to operate without VS1. In this case, however, obtain and install a new VS1 as soon as possible.

VS1 ordering number: A70L-0001-0015#20DK431

c) Short-circuit of diode stack DB1

d) The secondary power supply module is faulty :

If one of the causes (b) to (c) above is detected, replace the power supply unit with a spare unit.

The ordering number. for F1 is : A60L-0001-0450#8RO


- 37 -

Check and Corrective action Figure (Check 3) Check whether the EXON1 and

EXON2 signals, and the EXOFF1 and EXOFF2 signals are connected on the terminal block on the panel board.

(Corrective action)

If the external ON/OFF function is not used, connect terminal EXON1 to EXON2 and terminal EXOFF1 to EXOFF2. If the external ON and OFF lines are already used, check the mating contacts and the cable.

Short–circuit plate : Between EXON1 and -EXON2 Short–circuit plate : Between EXOFF1 and EXOFF2

(Check 4) Check whether the connector (JRS15) on the main board or the connector (JRS15) on the panel board is connected properly. Another probable cause is that the cable connected to either of these connectors is faulty. Confirm that the 200VAC power is supplied to connector CP1 by reverifying Checks 1 - 3, and verifying that the ON/OFF switch is functioning properly. If the red ALM (Alarm) LED on the power supply unit is on, verify that the +24V external connection cable is connected to 0V or ground. If the problem still exists, check the power supply unit using the following procedure : a) Check Fuse F4.

- If the fuse is blown, see Corrective action 2.

b) Fuse F4 is not blown. - A printed circuit board or

unit that uses a DC supply (+2.5V, +3.3V, +5V, +24V, or +15V) is faulty.

- Verify that 200VAC is being supplied to connector CP1. If the power is supplied, replace the power supply unit.

(Corrective action)

If the power supply unit is not faulty, replace the panel board or operator panel.

DB1: Diode stack


CP1: Connector for AC inputCP1A: Connector for AC output

CP2, CP3:Connector for AC output

F3(7.5A): Fuse for +24E F4(7.5A): Fuse for +24V PIL: LED (green) CP5: Connector for +24E CP6: Connector for +24V

ALM: LED (red) CP4: Connector for control

VS1: Surge absorber

H1: Auxiliary power module


- 38 -

Check and Corrective action Figure (Corrective action(2))

Causes of blown fuse F4 and corrective action The device connected to connector CP5 of the power supply unit may be faulty. If no device is connected to CP5 or the connected device is normal, the +24 V power used in a printed circuit board connected to the backplane is faulty. The ordering number of F4 is A60L-0001-0046#7.5 :


- 39 -

3.2 ALARM OCCURRENCE SCREEN The alarm occurrence screen displays only the alarm conditions that are currently active. If an alarm reset signal is input to reset the alarm conditions, the alarm occurrence screen displays the message "PAUSE or more serious alarm has not occurred." 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. Press the CLEAR key (+ shift) on the alarm history screen. The alarm occurrence screen is intended to display PAUSE or more serious alarms. It will not display WARN, NONE, or a reset. It is possible to disable PAUSE and some of more serious alarms from being displayed by setting the $ER_NOHIS system variable appropriately. If two or more alarms have occurred, the display begins with the most recent alarm. Up to 100 lines can be displayed. If an alarm has a cause code, it is displayed below the line indicating the alarm.

Alarm history screen display

Press F3 [HIST]. Press F3 [ACTIVE].

Alarm occurrence screen display

Press the alarm key. Automatic alarm display upon occurrence

Press the screen selection key to select [4 ALARM].

Fig.3.2 Alarm occurrence screen and alarm history screen display

procedure


- 40 -

Displaying the alarm history/alarm detail information

Step (1) Press the MENUS key to display the screen menu. (2) Select [ALARM]. You will see a screen similar to the following

MENUS

3 4 ALARM 5 I/O

INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Specified line does not exist Alarm JOINT 30 % 1/25 1 INTP-224 (SAMPLE1, 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. To view

messages that are currently not on the screen, press the F5, HELP, then press the right arrow key.

(3) To display the alarm detail screen, press F5, [HELP].

INTP-224 (SAMPLE1, 7) Jump label is fail INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Specified line does not exist 30-MAY-44 07:15 STOP.L 00000110 Alarm 1/25 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop [ TYPE ] CLEAR HELP

CLEAR HELP

F5

(4) To return to the alarm history screen, press the PREV key.

PREV

(5) To delete all the alarm histories, press and hold down the SHIFT

key, then press F4, [CLEAR].

NOTE When system variable $ER_NOHIS = 1, NONE

alarms or WARN alarms are not recorded. When $ER_NOHIS=2, resets are not recorded in the alarm history. When $ER_NOHIS=3, resets, WARN alarms, and NONE alarms are not recorded.

CLEAR HELP

F4 SHIFT


- 41 -

The following map indicates teach pendant operations used to check an alarm. 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


- 42 -

3.3 SAFETY SIGNALS The safety signal screen indicates the state of signals related to safety. To be specific, the screen indicates whether each safety signal is currently on. On this screen, it is impossible to change the state of any safety signal.

Table 3.3 Safety signals Safety signal Description

Operator’s panel emergency stop

This item indicates the state of the emergency stop button on the operator’s panel. If the EMERGENCY STOP button is pressed, the state is indicated as “TRUE”.

Teach pendant emergency stop

This item indicates the state of the emergency stop button on the teach pendant. If the EMERGENCY STOP button is pressed, the state is indicated as “TRUE”.

External emergency stop This item indicates the state of the external emergency stop signal. If the EMERGENCY STOP signal is asserted, the state is indicated as “TRUE”.

Fence open This item indicates the state of the safety fence. If the safety fence is open, the state is indicated as “TRUE”.

DEADMAN switch This item indicates whether the DEADMAN switch on the teach pendant is grasped. If the teach pendant is operable, and the DEADMAN switch is grasped correctly, the state is indicated as “TRUE”. If the DEADMAN switch is released or is grasped tightly when the teach pendant is operable, an alarm occurs, causing the servo power to be switched off.

Teach pendant operable This item indicates whether the teach pendant is operable. If the teach pendant is operable, the state is indicated as “TRUE”.

Hand broken This item indicates the state of the hand safety joint. If the hand interferes with a workpiece or anything like this, and the safety joint is opened, the state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be switched off.

Robot overtravel This item indicates whether the current position of the robot is out of the operation range. If any robot articulation goes out of the operation range beyond the overtravel switch, the state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be switched off.

Abnormal air pressure This item indicates the state of the air pressure. The abnormal air pressure signal is connected to the air pressure sensor. If the air pressure is not higher than the specified value, the state is indicated as “TRUE”.

Step

(1) Press the MENUS key to display the screen menu. (2) Select STATUS on the next page. (3) Press F1, [TYPE] to display the screen switching menu. (4) Select Safety Signal. You will see a screen similar to the

following.

SYSTEM Safety JOINT 30% SIGNAL NAME STATUS 1/11 1 SOP E-Stop: FALSE 2 TP E-stop: FALSE 3 Ext E-Stop: FALSE 4 Fence Open: FALSE 5 TP Deadman: TRUE 6 TP Enable: TRUE 7 Hand Broken: FALSE 8 Over Travel: FALSE 9 Low Air Alarm: FALSE [TYPE]


- 43 -

3.4 MASTERING Mastering is needed if: (1) The SRVO-062 BZAL or SRVO-038 pulse mismatch alarm

occurs, or (2) The pulse coder is replaced. Item (1) requires simplified mastering, while item (2) requires zero-degree or fixture position mastering. (Zero-degree position mastering is just for quick-fix purposes. After zero-degree position mastering is used, fixture position mastering should be performed later.) The mastering procedure is described below. For details, refer to an applicable maintenance manual of mechanical unit or operator's manual of control unit.

Condition System variable $MASTER_ENB must be set to 1 or 2.

SYSTEM Variables JOINT 10% 57/136 57 $MASTER_ENB 1

Step (1) Press <MENUS>. (2) Select SYSTEM. (3) Press F1, TYPE. (4) Select Master/Cal you will see a screen similar to the following.

F1

Master/ 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 Press 'ENTER' or number key to select. [TYPE] LOAD RES_PCA DONE

5 POSITION6 SYSTEM 7

MENUS

9 0 -- NEXT --

(5) Move the robot by jog feed to the mastering position. Release the

brake on the manual brake control screen if necessary.

NOTE Mastering can not be performed until axis is rotated

enough to establish a pulse.


- 44 -

(6) Select "1 FIXTURE POSITION MASTER" and press the F4 key (yes). Mastering data is set.

F4

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 Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <122000309> <2000319> [ TYPE ] LOAD RES_PCA DONE

SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER Master at master position?[NO]

ENTER

Master at master position?[ ][ TYPE ] YES NO

(7) Select "6 CALIBRATE" and press the F4 key (yes). Calibration

is performed. Alternatively, to perform positioning, turn the power off, then

turn it on again. Calibration is performed whenever the power is turned on.

F4

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> <-25.000> <40.000> <5.000> <-15.000> <0.000> [ TYPE ] LOAD RES_PCA DONE

5 SET QUICK MASTER REF 6 CALIBRATE Calibrate? [NO] ENTER

Calibrate? [NO] [ TYPE ] YES

(8) Press F5 "DONE", after mastering.

F5

DONE


- 45 -

3.5 TROUBLESHOOTING USING THE ERROR CODE (1) SRVO-001 Operator panel E-stop

(Explanation) The emergency stop button on the operator's panel is pressed.

(Action 1) Release the emergency stop button pressed on the operator's panel.

(Action 2) Check the wires connecting between the emergency stop button and the panel board (CRT16) for continuity. If an open wire is found, replace the entire harness.

(Action 3) Check the wires connecting between the teach pendant and the panel board (CRS20) for continuity. If an open wire is found, replace the entire harness.

(Action 4) With the emergency stop in the released position, check for continuity across the terminals of the switch. If continuity is not found, the emergency stop button is broken. Replace the switch unit or the operator's panel.

(Action 5) Replace the teach pendant. (Action 6) Replace the panel board.

Before executing the (Action 7), perform a complete controller back-up to save all your programs and settings. (Action 7) Replace the main board.

NOTE If SRVO-001 is issued together with SRVO-213, a

fuse may have blown. Take the same actions as for SRVO-213.


- 46 -


(A-cabinet) (B-cabinet)

Fig.3.5 (1) (a) SRVO-001 Operator panel E-stop

(Panel board) Fig.3.5 (1) (b) SRVO-001 Operator panel E-stop

(Main board)

Fig.3.5 (1) (c) SRVO-001 Operator panel E-stop

CRS20CRT16

Emergency stop

button


- 47 -

(2) SRVO-002 Teach pendant E-stop (Explanation) The emergency stop button on the teach pendant

was pressed. (Action 1) Release the emergency stop button on the teach

pendant. (Action 2) Replace the teach pendant.


Fig.3.5 (2) SRVO-002 Teach pendant E-stop


- 48 -

(3) SRVO-003 DEADMAN switch released (Explanation) The teach pendant is enabled, but the DEADMAN

switch is not pressed. Alternatively, the DEADMAN switch is pressed strongly.

(Action 1) Check the intermediate position of the DEADMAN switch on the teach pendant.

(Action 2) Check that the mode switch on the operator's panel and the enable switch on the teach pendant are at the correct positions.

(Action 3) Replace the teach pendant. (Action 4) Check the mode switch connection and operation.

If trouble is found, replace the mode switch. (Action 5) Replace the panel board.

Enable switch DEADMAN switch

Fig.3.5 (3) (a) SRVO-003 DEADMAN switch released


(Mode switch)


- 49 -

(Panel board) Fig. 3.5 (3) (b) SRV0-003 Mode switch and panel board


- 50 -

(4) SRVO-004 Fence open (Explanation) In the automatic operation mode, the safety fence

contact connected to EAS1-EAS11 or EAS2-EAS21 of TBOP4 is open.

(Action 1) When a safety fence is connected, close the safety fence.

(Action 2) Check the cables and switches connected between EAS1 and EAS11 and between EAS2 and EAS21 of the terminal block TBOP4 on the panel board.

(Action 3) If the safety fence signal is not used, make a connection between EAS1 and EAS11 and between EAS2 and EAS21 of the terminal block TBOP4 on the panel board.

(Action 4) Check the mode switch. If trouble is found, replace the mode switch.

(Action 5) Replace the panel board.



EAS1 EAS11 EAS2 EAS22

(Panel board)


- 51 -


(Mode switch)

Fig. 3.5 (4) Panel board and mode switch

WARNING In a system using the safety fence signal, it is very

dangerous to disable the signal when a connection is made between EAS1 and EAS11 and between EAS2 and EAS21 of TBOP4. Never make such an attempt. If a temporary connection is needed for operation, separate safety measures must be taken.


- 52 -

(5) SRVO-005 Robot overtravel (Explanation) The robot has moved beyond a hardware limit

switch on the axes. (Action 1)

1) Select [System OT release] on the overtravel release screen to release each robot axis from the overtravel state.

2) Hold down the shift key, and press the alarm release button to reset the alarm condition.

3) Still hold down the shift key, and jog to bring all axes into the movable range.

(Action 2) Replace the limit switch. (Action 3) Check the FS2 fuse on the servo amplifier. If the

SRVO-214 Fuse blown alarm is also generated, the FS2 fuse has blown.

(Action 4) Check the end effector connector. (Action 5) Replace the servo amplifier. (Action 6) Verify the following for connector RP1 at the base

of the robot : 1) There are no bent or dislocated pins in the male

or female connectors. 2) The connector is securely connected.

Then verify that connectors CRF8 and CRM68 on the servo amplifier are securely connected. Also verify that the RP1 cable is in good condition, and there are no cuts or kinks visible. If no limit switch is in use, jumper connector must be attached in the mechanical unit. Check for the jumper connector.

NOTE It is factory-placed in the overtravel state for

packing purposes. If the Overtravel signal is not in use, it may have

been disabled by short-circuiting in the mechanical unit.


- 53 -

Servo amplifier

Servo amplifier


Connector (CRF8)

Connector (CRM68)

FS2

(Servo amplifier)

Fig. 3.5 (5) SRVO-005 Robot overtravel


- 54 -

(6) SRVO-006 Hand broken (Explanation) The safety joint (if in use) might have been broken.

Alternatively, the HBK signal on the robot connection cable might be a ground fault or a cable disconnection.

(Action 1) Hold down the shift key, and press the alarm release button to reset the alarm condition. Still hold down the shift key, and jog the tool to the work area. 1) Replace the safety joint. 2) Check the safety joint cable.

(Action 2) Replace the servo amplifier. (Action 3) Verify the following for connector RP1 at the base

of the robot : 1) There are no bent or dislocated pins in the male

or female connectors. 2) The connector is securely connected.

Then verify that connector CRF8 on the servo amplifier is securely connected.

Also verify that the RP1 cable is in good condition, and there are no cuts or kinks visible. Check the robot connection cable (RP1) for a ground fault or a cable disconnection.

NOTE If the Hand broken signal is not in use, it can be

disabled by software setting. Refer to Subsection 5.5.3 How to Disable/Enable

HBK in Part III, "CONNECTIONS" of "Maintenance Manual" to disable the Hand broken signal.

Servo amplifier

Servo amplifier



- 55 -

Connector (CRF8)

Connector (CRM68)

FS2

(Servo amplifier)

Fig. 3.5 (6) SRVO-006 Hand broken


- 56 -

(7) SRVO-007 External E-stop (Explanation) On the terminal block TBOP4 of the panel board,

no connection of external emergency stop is made between EES1 and EES11, EES2 and EES21.

(Action 1) If an external emergency stop switch is connected, release the switch.

(Action 2) Check the switch and cable connected to EES1-EES11 and EES2-EES21 on TBOP4.

(Action 3) When this signal is not used, make a connection between EES1 and EES11, EES2 and EES21.




(Panel board)

Fig.3.5 (7) SRVO-007 Panel board

WARNING In a system using the external emergency stop

signal, it is very dangerous to disable the signal when a connection is made between EES1 and EES11 and between EES2 and EES21 of TBOP4. Never make such an attempt. If a temporary connection is needed for operation, separate safety measures must be taken.

EES1 EES11 EES2 EES22


- 57 -

(8) SRVO-009 Pneumatic pressure abnormal (Explanation) An abnormal air pressure was detected. The input

signal is located on the end effector of the robot. Refer to the manual of your robot.

(Action 1) If an abnormal air pressure is detected, check the cause.

(Action 2) Check the end effector connector. (Action 3) Check the robot connection cable (RP1) for a

ground fault or a cable disconnection. If a fault or a disconnection is detected, replace the cable.

(Action 4) Replace the servo amplifier. (Action 5) Replace the internal cables of the robot.

NOTE Pneumatic pressure alarm input is on the end

effector. Please refer to the manual of your robot.

Servo amplifier

Servo amplifier


Fig.3.5 (8) SRVO-009 Pneumatic pressure alarm


- 58 -

(9) SRVO-014 Fan motor abnormal (Explanation) When a fan motor stops on backplane unit, TP shows the following message.In one minutes from occurring of alarm, robot stops and can not be operated from TP. The robot can be recovered by replacing a fan motor.Number in the bracket indicateds which fan is abnormal. (1): fan above the slot1 (2): fan above slot2 (3) : both fans (Action 1) Check the fan motor and its cables. Replace them

if necessary. (Action 2) Replace the backplane unit. Before executing the (Action 3), perform a

complete controller back-up to save all your programs and settings.

(Action 3) Replace the main board.

Fan motor

Main board

Fig. 3.5 (9) SRVO-014 Fan motor abnormal


- 59 -

(10) SRVO-015 SYSTEM OVER HEAT (Group : i Axis : j) (Explanation) The temperature in the control unit exceeds the

specified value. (Action 1) If the ambient temperature is higher than specified

(45), cool down the ambient temperature. (Action 2) If the fan motor is not running, check it and its

cables. Replace them if necessary. Before executing the (Action 3), perform a

complete controller back-up to save all your programs and settings.

(Action 3) Replace the main board. (The thermostat on the main board may be faulty.)

Main board Heat exchanger

Fan unit

A-cabinet (Front)

Fan unit

Fan unit

A-cabinet (Side fan type) A-cabinet (Rear fan type)


- 60 -

Servo amplifier

Main board

Door fan unit B-cabinet (Front)

Amplifier fan

B-cabinet (Back)

Fig.3.5 (10) SRVO-015 SYSTEM OVER HEAT


- 61 -

(11) SRVO-018 Brake abnormal (Explanation) An excessive brake current is detected. The ALM

LED on the servo amplifier is lit. (Action 1) Check the robot connection cable (RM1) and

cables internal to the mechanical section for a short-circuit and connection to the ground. If a fault or a disconnection is detected, replace the cable.

(Action 2) This alarm may occur if the brake connector is not attached.

Make sure that connector CRM88 is securely attached to the servo amplifier.

(Action 3) Replace the servo amplifier.

Servo amplifier

Servo amplifier


Fig.3.5 (11) SRVO-018 Brake abnormal

CAUTION This error can be caused by the optional brake

release unit if the on/off switch is left in on position while the operator attempts to jog the robot. To recover, turn the brake release unit off and cycle the controller power.


- 62 -

(12) SRVO-021 SRDY off (Group : i Axis : j) (Explanation) The HRDY is on and the SRDY is off, although

there is no other cause of an alarm. (HRDY is a signal with which the host detects the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on.)

If the servo amplifier magnetic contactor cannot be turned on when directed so, it is most likely that a servo amplifier alarm has occurred. If a servo amplifier alarm has been detected, the host will not issue this alarm (SRDY off). Therefore, this alarm indicates that the magnetic contactor cannot be turned on for an unknown reason.

(Action 1) Make sure that the emergency stop board connectors CP2, CRM96, CNMC3, and servo amplifier SRM96 are securely attached to the servo amplifier.

(Action 2) It is possible that an instant disconnection of power source causes this alarm. Check whether an instant disconnection occurred.

(Action 3) Replace the E-stop unit. (Action 4) Replace the servo amplifier.

Servo amplifier Main board

E-stop unit

Servo amplifier

Main board E-stop unit

(A-cabinet) (B-cabinet) Fig.3.5 (12) SRVO-021 SRDY off


- 63 -

(13) SRVO-022 SRDY on (Group : i Axis : j) (Explanation) When the HRDY is about to go on, the SRDY is

already on. (HRDY is a signal with which the host directs the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on.)

(Action 1) Replace the servo amplifier as the alarm message.


E-stop unit

Servo amplifier

Main board E-stop unit

(A-cabinet) (B-cabinet) Fig.3.5 (13) SRVO-022 SRDY on


- 64 -

(14) SRVO-023 Stop error excess (Group : i Axis : j) (Explanation) When the servo is at stop, the position error is

abnormally large. Check whether the brake is released through the

clack sound of the brake or vibration. In case that the brake is not released.

(Action 1) If the brake is not released, check the continuity of the brake line in the robot connection cable and the robot internal cable.

(Action 2) If the disconnection is not found, replace the servo amplifier or the servo motor.

In case that the brake is released. (Action 1) Check whether the obstacle disturbs the robot

motion. (Action 2) Make sure that connectors CNJ1A-CNJ6 are

securely attached to the servo amplifier. (Action 3) Check the continuity of the robot connection cable

and the internal robot power cable. (Action 4) Check to see if the load is greater than the rating. If

greater, reduce it to within the rating. (If the load is too great, the torque required for acceleration / deceleration becomes higher than the capacity of the motor.

As a result, the motor becomes unable to follow the command, and an alarm is issued.)

(Action 5) Check the input voltage to the controller is within the rated voltage and no phase is lack. And check the setting of the transformer is correct.

Check each phase voltage of the CRR38A or CRR38B connector of the three-phase power (200 VAC) input to the servo amplifier. If it is 210 VAC or lower, check the line voltage. (If the voltage input to the servo amplifier becomes low, the torque output also becomes low. As a result, the motor may become unable to follow the command, hence possibly causing an alarm.).

(Action 6) Replace the servo amplifier. (Action 7) Replace the motor of the alarm axis.

NOTE Incorrect setting of the brake number causes this

alarm.


- 65 -

Servo amplifier

Servo amplifier


Fig.3.5 (14) SRVO-023 Stop error excess


- 66 -

(15) SRVO-024 Move error excess (Group : i Axis : j) (Explanation) When the robot is running, its position error is greater than a specified value ($PARAM _ GROUP. $MOVER _ OFFST or $PARAM _ GROUP. $TRKERRLIM). It is likely that the robot cannot follow the speed specified by program. (Action 1) Take the same actions as SRVO-023.

(16) SRVO-027 Robot not mastered (Group : i) (Explanation) An attempt was made to calibrate the robot, but the necessary adjustment had not been completed. (Action) Check whether the mastering is valid. If the mastering is invalid, master the robot. WARNING

If the position data is incorrect, the robot or additional axis can operate abnormally, set the position data correctly. Otherwise, you could injure personnel or damage equipment.

(17) SRVO-030 Brake on hold (Group:i)

(Explanation) If the temporary halt alarm function is enabled ($SCR.$BRKHOLD ENB=1), SRVO-030 is issued when a temporary halt occurs. When this function is not used, disable the setting.

(Action) Disable [Servo-off in temporary halt] on the general item setting screen [6 General Setting Items].

(18) SRVO-033 Robot not calibrated (Group : i)

(Explanation) An attempt was made to set up a reference point for simplified adjustment, but the robot had not been calibrated.

(Action) Calibrate the robot. 1. Supply power. 2. Set up a simplified adjustment reference point using [Positioning] on the positioning menu.

(19) SRVO-034 Ref pos not set (Group : i)

(Explanation) An attempt was made to perform simplified adjustment, but the reference point had not been set up.

(Action) Set up a simplified adjustment reference point on the positioning menu.


- 67 -

(20) SRVO-036 Inpos time over (Group : i Axis : j) (Explanation) The robot did not get to the effective area

($PARAM _ GROUP.$ STOPTOL) even after the position check monitoring time ($PARAM _ GROUP. $INPOS _ TIME) elapsed.

(Action) Take the same actions as for SRVO-023 (large position error at a stop).

(21) SRVO-037 IMSTP input (Group : i)

(Explanation) The *IMSTP signal for a peripheral device interface was input.

(Action) Turn on the *IMSTP signal. (22) SRVO-038 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. This alarm is asserted after exchange the pulsecoder or battery for back up of the pulsecoder data or loading back up data to the Main Board.

Check the alarm history. (Action 1) If the brake number is set to the non-brake motors,

this alarm may occur. Check the software setting of the brake number.

(Action 2) In case the robot has been moved by using the brake release unit while the power is off or when restoring the back-up data to the main board, this alarm may occur. Remaster the robot.

(Action 3) If the robot has been moved because the brake failed, this alarm may occur. Check the cause of the brake trouble. Then remaster the robot.

(Action 4) Replace the pulsecoder and master the robot.

Main board (A-cabinet)


- 68 -

Main board

Axis control card

(B-cabinet) (Main board)

Fig.3.5 (22) SRVO-038 Pulse mismatch (23) SRVO-042 MCAL alarm (Group : i Axis : j)

(Explanation) This alarm means that the contacts of the magnetic contactor have stuck to each other. The alarm condition occurs if the magnetic contactor turns out to be already on when an attempt is made to turn it on. The alarm condition is detected between the time contact sticking occurs and the time an attempt is made to turn on the magnetic contactor.


Servo amplifier

E-stop unit

Magnetic contactor

(A-cabinet)


- 69 -

Servo amplifier

E-stop unit

Magnetic contactor

(B-cabinet)

Fig.3.5 (23) SRVO-042 MCAL alarm (24) SRVO-043 DCAL alarm (Group : i Axis : j)

(Explanation) The regenerative discharge energy was too high to be dissipated as heat. (To run the robot, the servo amplifier supplies energy to the robot. When going down the vertical axis, the robot operates from the potential energy. If a reduction in the potential energy is higher than the energy needed for acceleration, the servo amplifier receives energy from the motor. A similar phenomenon occurs even when no gravity is applied, for example, at deceleration on a horizontal axis. The energy that the servo amplifier receives from the motor is called the regenerative energy. The servo amplifier dissipates this energy as heat. If the regenerative energy is higher than the energy dissipated as heat, the difference is stored in the servo amplifier, causing an alarm.)

(Action 1) This alarm may occur if the axis is subjected to frequent acceleration/deceleration or if the axis is vertical and generates a large amount of regenerative energy.

If this alarm has occurred, relax the service conditions.

(Action 2) Check fuse FS3 in the servo amplifier. If it has blown, remove the cause, and replace the fuse. One of the probable causes of a blown fuse is a ground fault in the servo amplifier for the auxiliary axis.


- 70 -

(Action 3) The ambient temperature is excessively high. Or the regenerative resistor can't be cooled effectively. Check the fan unit, and replace it if it stops. Clean up the fun unit, the regenerative resistor and the louver if they are dirty.

(Action 4) Measure each inter-phase voltage of the input power supply, and make sure that all measurements satisfy the input voltage stipulation. If voltage is wrong, check the power supply facility. If voltage is correct, replace the E-stop unit.

(Action 5) Make sure that the servo amplifier CRR63A and CRR63B connectors are connected tightly. Then detach the cable from CRR63A and CRR63B connectors on the Servo amplifier, and check for continuity between pins 1 and 2 of the cable-end connector. If there is no continuity between the pins, replace the regenerative resistor.

(Action 6) Make sure that the servo amplifier CRR45A and CRR45B are connected tightly, then detach the cables from CRR45A and CRR45B on the servo amplifier and check the resistance between pins 1 and 2 of each cable end connector. If the resistance is not 9-16Ω, replace the regenerative resistor. CRR45B may not be used depending on the robot model.


Servo amplifier

E-stop unit

A-cabinet (Front)


- 71 -


Transformer


Transformer

Side fan type Rear fan type A-cabinet (Back)

Servo amplifier

regenerative resistor unit

Fan unit

B-cabinet (Front) B-cabinet (Back)

Fig.3.5 (24) SRVO-043 DCAL alarm (25) SRVO-044 HVAL alarm (Group : i Axis : j)

(Explanation) The DC voltage (DC link voltage) of the main circuit power supply is abnormally high.

(Action 1) Check the three-phase input voltage at the servo amplifier. If it is 240 VAC or higher, check the line voltage. (If the three-phase input voltage is higher than 240 VAC, high acceleration/deceleration can cause in this alarm.)

(Action 2) Check that the load weight is within the rating. If it is higher than the rating, reduce it to within the rating. (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.)

(Action 3) Check that the CRR63A and CRR63B connectors of the servo amplifier are attached firmly. Next,


- 72 -

detach the cables then check the continuity between pins 1 and 2 of the cable-side connectors. If a disconnection is found, replace the regenerative resistor.


Servo amplifier

Servo amplifier


Fig.3.5 (25) SRVO-044 HVAL alarm (26) SRVO-045 HCAL alarm (Group : i Axis : j)

(Explanation) Abnormally high current flowed in the main circuit of the servo amplifier.

(Action 1) Turn off the power, and disconnect the power cable from the servo amplifier indicated by the alarm message. (And disconnect the brake cable (CRR88 on the servo amplifier) to avoid the axis falling unexpectedly.) Supply power and see if the alarm occurs again. If the alarm occurs again, replace the servo amplifier.

(Action 2) Turn off the power and disconnect the power cable from the servo amplifier indicated by the alarm message, and check the insulation of their U, V, W and the GND lines each other. If there is a short-circuit, replace the power cable.

(Action 3) Turn off the power and disconnect the power cable from the servo amplifier by the alarm message, and measure the resistance between their U and V, V and W and W and U with an ohmmeter that has a very low resistance range. If the resistances at the three places are different from each other, the motor, the power cable is defective. Check each item in detail and replace it if necessary.


- 73 -

Servo amplifier

Servo amplifier

(A-cabinet) (B-cabinet) Fig.3.5 (26) SRVO-045 HCAL alarm

(27) SRVO-046 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.

(Action 1) Check the operating condition for the robot and relax the service condition if possible. If the load or operating condition has exceeded the rating, reduce the load or relax the operating condition to meet the rating.

(Action 2) Check whether the voltage input to the controller is within the rated voltage and also check whether the voltage set for the transformer of the controller is correct.

(Action 3) Check whether the brake of the corresponding axis is released.

(Action 4) Check whether there is a factor that has increased the mechanical load on the corresponding axis.

(Action 5) Replace the servo amplifier. (Action 6) Replace the motor of the corresponding axis. (Action 7) Replace the E-stop unit (Action 8) Replace the motor power line (robot connection

cable) of the corresponding axis. (Action 9) Replace the motor power line and brake line

(inside the mechanical section) of the corresponding axis.


- 74 -

Servo amplifier

Servo amplifier


Fig.3.5 (27) SRVO-046 OVC alarm

Reference Relationships among the OVC, OHAL, and HC alarms

- Overview This section points out the differences among the OVC, OHAL, and HC alarms and describes the purpose of each alarm.

- Alarm detection section Abbreviation Designation Detection section

OVC Overcurrent alarm Servo software OHAL Overheat alarm Thermal relay in the motor

Thermal relay in the servo amplifier Thermal relay in the separate regenerative discharge unit

HC High current alarm Servo amplifier

- 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 power transistor and rectifier diodes might be damaged, or the magnet of the motor might be degaussed. The HC alarm is intended to prevent such failures.

2) OVC and OHAL alarms (overcurrent and overload alarms) The OVC and OHAL alarms are intended to prevent overheat

that may lead to the burnout of the motor winding, the breakdown of the servo amplifier transistor, and the separate regenerative resistor.

The OHAL alarm occurs when each built-in thermal relay detects a temperature higher than the rated value. However, this


- 75 -

method is not necessarily perfect to prevent these failures. For example, if the motor frequently repeats to start and stop, the thermal time constant of the motor, which has a large mass, becomes higher than the time constant of the thermal relay, because these two components are different in material, structure, and dimension. Therefore, if the motor continues to start and stop within a short time as shown in Fig. 3.5 (a), the temperature rise in the motor is steeper than that in the thermal relay, thus causing the motor to burn before the thermal relay detects an abnormally high temperature.

Temperature

Start StartStartStop Stop

Temperature at which the winding starts to burn

Thermal time constant of the motor is high.

Thermal time constant of the thermal relay is low.

Time Fig.3.5 (a) Relationship between the temperatures of the motor and thermal relay on start/stop cycles

To prevent the above defects, software is used to monitor the current in the motor constantly in order to estimate the temperature of the motor. The OVC alarm is issued based on this estimated temperature. This method estimates the motor temperature with substantial accuracy, so it can prevent the failures described above. To sum up, a double protection method is used; the OVC alarm is used for protection from a short-time overcurrent, and the OHAL alarm is used for protection from long-term overload. The relationship between the OVC and OHAL alarms is shown in Fig.3.5 (b).

Current Protection area for the motor and servo amplifier

Protection by the OHAL Limit current

Protection by the OVC

Rated continuous current

Time Fig.3.5 (b) Relationship between the OVC and OHAL alarms


- 76 -

NOTE The relationship shown in Fig.3.5 (b) is taken into

consideration for the OVC alarm. The motor might not be hot even if the OVC alarm has occurred. In this case, do not change the parameters to relax protection.

(28) SRVO-047 LVAL alarm (Group : i Axis : j)

(Explanation) The control power supply voltage (+5 V, etc.) supplied from the power supply circuit in the servo amplifier is abnormally low.

(Action 1) Replace the servo amplifier. (Action 2) Replace the power supply unit.

Servo amplifier Power supply unit

Servo amplifier

Power supply unit (A-cabinet) (B-cabinet)

Fig.3.5 (28) SRVO-047 LVAL alarm


- 77 -

(29) SRVO-049 OHAL1 alarm (Group : i Axis : j) (Explanation) The thermostat in the transformer worked.

Alternatively, fuse F1 or F2 in the servo amplifier has blown.

(Action 1) Check whether the fan is stopped and also check whether the vent hole is clogged. If necessary, clean or replace them.

(Action 2) If SRVO-049 is issued when the robot operating condition is severe, check the robot operating condition then relax the condition when possible.

(Action 3) Check that a connection is made between the transformer connector CPOH and the emergency stop unit CRM73.

(Action 4) Replace the servo. (Action 5) Replace the transformer.

Servo amplifier

E-stop unit

A-cabinet (Front)


Transformer


Transformer



- 78 -

Servo amplifier

E-stop unit

regenerative resistor unit

Fan unitTransformer


Fig.3.5 (29) SRVO-049 OHAL1 alarm


- 79 -

(30) SRVO-050 CLALM alarm (Group : i Axis : j) (Explanation) The disturbance torque estimated by the servo

software is abnormally high. (A collision has been detected.)

(Action 1) Check whether the robot has collided and also check whether there is a factor that has increased the mechanical load on the corresponding axis.

(Action 2) Check whether the load settings are valid. (Action 3) Check whether the brake of the corresponding axis

is released. (Action 4) If the load weight exceeds the rated range, decrease

it to within the limit. (Action 5) Check whether the voltage input to the controller is

within the rated voltage and also check whether the voltage set for the transformer of the controller is correct.

(Action 6) Replace the servo amplifier. (Action 7) Replace the motor of the corresponding axis. (Action 8) Replace the E-stop unit. (Action 9) Replace the motor power line (robot connection

cable) of the corresponding axis. (Action 10) Replace the motor power line and brake line

(inside the mechanical section) of the corresponding axis.

Servo amplifier

Servo amplifier


Fig.3.5 (30) SRVO-050 CLALM alarm


- 80 -

(31) SRVO-051 CUER alarm (Group : i Axis : j) (Explanation) The offset of the current feedback value is

abnormally high. (Action) Replace the servo amplifier.

Servo amplifier

Servo amplifier


Fig.3.5 (31) SRVO-051 CUER alarm


- 81 -

(32) SRVO-055 FSSB com error 1 (Group : i Axis : j) (Explanation) A communication error has occurred between the

main board and servo amplifier. (Action 1) Check the communication cable (optical fiber)

between the main board and servo amplifier. Replace it if it is faulty.

(Action 2) Replace the axis control card on the main board. (Action 3) Replace the servo amplifier.


(A-cabinet)

Servo amplifier

Main board

Axis control card


Fig.3.5 (32) SRVO-055 FSSB com error 1


- 82 -

(33) SRVO-056 FSSB com error 2 (Group : i Axis : j) (Explanation) A communication error has occurred between the

main board and servo amplifier. (Action 1) Check the communication cable (optical fiber)

between the main board and servo amplifier. Replace it if it is faulty.

(Action 2) Replace the axis control card on the main board. (Action 3) Replace the servo amplifier.


(A-cabinet)

Servo amplifier

Main board

Axis control card


Fig.3.5 (33) SRVO-056 FSSB com error 2


- 83 -

(34) SRVO-057 FSSB disconnect (Group : i Axis : j) (Explanation) Communication was interrupted between the

main board and servo amplifier. (Action 1) Check whether fuse F4 in the power supply unit

has blown. If the fuse has blown, replace the servo amplifier including the fuse.

(Action 2) Replace the optical cable between the axis control card and servo amplifier.

(Action 3) Replace the axis control card on the main board. (Action 4) Replace the servo amplifier. (Action 5) Check for a point where the robot connection

cable RP1 or an internal cable running to each pulse coder through the robot mechanical section is grounded.

Before continuing to the next step, perform a complete controller back-up to save all your programs and settings. (Action 6) Replace the main board.


- 84 -


(A-cabinet)

Servo amplifier

Main board

Axis control card


Fig.3.5 (34) SRVO-057 FSSB disconnect


- 85 -

(35) SRVO-058 FSSB init error (Group : i Axis : j) (Explanation) Communication was interrupted between the main

board and servo amplifier. (Action 1) Check whether fuse F4 in the power supply unit

has blown. If the fuse has blown, check and correct the cause then replace the fuse.

(Action 2) Check whether fuse FS1 on the servo amplifier has blown. If the fuse has blown, replace the servo amplifier including the fuse.

(Action 3) Turn off the power and disconnect the CRF8 connector on the servo amplifier. Then check whether this alarm occurs again. (Ignore the alarm SRVO-068 because of disconnecting the CRF8 connector.)

If this alarm does not occur, the RP1 cable of the robot connection cable or the internal cable of the robot may be short-circuited to the ground. Check the cables and replace it if necessary.

(Action 4) Check whether the LED (P5V and P3.3V) on the servo amplifier is lit. If they are not lit, the DC power is not supplied to the servo amplifier.

Make sure the connector CRP24 and CRM96 on the E-stop unit and the connector CRM96 on the servo amplifier are connected tightly. If they are connected tightly, replace the servo amplifier.

(Action 5) Check the communication cable (optical fiber) between the axis control board and servo amplifier. Replace it if it is faulty.

(Action 6) Replace the servo card on the main board. (Action 7) Replace the servo amplifier. (Action 8) If the other units (the servo amplifier for the

auxiliary axis and the line tracking interface) are connected in the FSSB optical communication, disconnect these units and connect only servo amplifier for the robot. Then turn on the power. If this alarm does not occur, search the failed unit and replace it.

Before executing the (Action9), perform a complete controller back-up to save all your programs and settings. (Action 9) Replace the main board.


- 86 -


(A-cabinet)

Servo amplifier

Main board

Axis control card


Fig.3.5 (35) SRVO-058 FSSB init error


- 87 -

(36) SRVO-059 Servo amp init error (Explanation) Servo amplifier initialization is failed. (Action 1) Check the wiring of the servo amplifier. (Action 2) Replace the servo amplifier.

Servo amplifier

Servo amplifier


Fig.3.5 (36) SRVO-059 Servo amp init error (37) SRVO-062 BZAL alarm (Group : i Axis : j)

(Explanation) This alarm occurs if battery for pulse coder absolute-position backup is empty.

A probable cause is a broken battery cable or no batteries in the robot.

(Action 1) Replace the battery in the battery box of the robot base.

(Action 2) Replace the pulse coder with which an alarm has been issued.

(Action 3) Check whether the robot internal cable for feeding power from the battery to the pulse coder is not disconnected and grounded. If an abnormality is found, replace the cable.

CAUTION

After correcting the cause of this alarm, set the system variable (＄MCR.$SPC_RESET) to TRUE then turn on the power again. Mastering is needed.


- 88 -

(38) SRVO-064 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.

(39) SRVO-065 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 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.

(40) SRVO-067 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 robot operating conditions. If a condition such as the duty cycle and load weight has exceeded the rating, relax the robot load condition to meet the allowable range.

(Action 2) When power is supplied to the motor after it has become sufficiently cool, if the alarm still occurs, replace the motor.

(41) SRVO-068 DTERR alarm (Group : i Axis : j)

(Explanation) The serial pulse coder does not return serial data in response to a request signal.

(Action 1) Make sure that the RP1 connector of servo amplifier (motor side) is connected tightly.

(Action 2) Check that the shielding of the RP1 cable is grounded securely in the cabinet.

(Action 3) Replace the pulse coder. (Action 4) Replace the servo amplifier. (Action 5) Replace the RP1 cable. (Action 6) Replace the robot interconnection cable (for the

pulse coder). (42) SRVO-069 CRCERR alarm (Group : i Axis : j)

(Explanation) The serial data has disturbed during communication. - See actions on SRVO-070


- 89 -

(43) SRVO-070 STBERR alarm (Group : i Axis : j) (Explanation) The start and stop bits of the serial data are

abnormal. (Action) Replace the RPI cable.

Servo amplifier

Servo amplifier


Fig.3.5 (43) SRVO-070 STBERR alarm (44) SRVO-071 SPHAL alarm (Group : i Axis : j)

(Explanation) The feedback speed is abnormally high. (Action) Action as same as the SRVO-068.

NOTE If this alarm occurs together with the PHAL alarm

(SRVO-064), this alarm does not correspond to the major cause of the failure.

(45) SRVO-072 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.

(46) SRVO-073 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 1) Reinforce the earth of the motor flange. (Action 2) Replace the pulse coder.

(47) SRVO-074 LDAL alarm (Group : i Axis : j)

(Explanation) The LED in the pulse coder is broken. (Action) Replace the pulse coder, and remaster the robot.


- 90 -

(48) SRVO-075 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.

(49) SRVO-076 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 has collided. Or check whether the machinery load of the corresponding axis is increased.

(Action 2) Check whether the load settings are valid. (Action 3) Check whether the brake of the corresponding axis

is released. (Action 4) Check whether the load weight is within the rated

range. If the weight exceeds the upper limit, decrease it to the limit.

(Action 5) Check whether the voltage input to the controller is within the rated voltage and also check whether the voltage set for the transformer of the controller is correct.

(Action 6) Replace the servo amplifier. (Action 7) Replace the corresponding servo motor. (Action 8) Replace the E-stop unit. (Action 9) Replace the power cable of the robot connection

cable in which the corresponding axis is connected. (Action 10) Replace the power cable of the robot

interconnection cable in which the corresponding axis is connected.

Servo amplifier

E-stop unit

Servo amplifier

E-stop unit (A-cabinet) (B-cabinet)

Fig.3.5 (49) SRVO-076 Tip Stick Detection


- 91 -

(50) SRVO-081 EROFL alarm (Track enc : i) (Explanation) The pulse counter for line tracking has overflowed. (Action 1) Check whether the condition of the line tracking

exceeds the limitation. (Action 2) Replace the pulse coder. (Action 3) Replace the line tracking interface board.

(51) SRVO-082 DAL alarm (Track ebc : i)

(Explanation) The line tracking pulse coder has not been connected.

(Action 1) Check the connection cable at each end (the line tracking interface board and the motor side)

(Action 2) Check whether the shielding of the connection cable is connected securely to the grounding plate.

(Action 3) Replace the line tracking cable. (Action 4) Replace the pulse coder. (Action 5) Replace the line tracking interface board.

(52) SRVO-084 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).

(53) SRVO-087 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).

(54) SRVO-089 OHAL2 alarm (Track enc : i)

(Explanation) The motor has overheated. When power is supplied to the pulse coder after it has become sufficiently cool, if the alarm still occurs. See the description about the OHAL2 alarm (SRVO-067).

(55) SRVO-090 DTERR alarm (Track ebc : i)

(Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the SRVO-068 DTERR alarm.

(Action 1) Check the connection cable at each end (the line tracking interface board and the pulse coder)

(Action 2) Check whether the shielding of the connection cable is connected securely to the grounding plate.

(Action 3) Replace the pulse coder. (Action 4) Replace the line tracking cable. (Action 5) Replace the line tracking interface board.


- 92 -

(56) SRVO-091 CRCERR alarm (Track enc : i) (Explanation) Communication between the pulse coder and line

tracking interface board is abnormal. (Action) Action as same as the SRVO-090.

(57) SRVO-092 STBERR alarm (Track enc : i)

(Explanation) Communication between the pulse coder and line tracking interface board is abnormal.

(Action) Action as same as the SRVO-090. (58) SRVO-093 SPHAL alarm (Track enc : i)

(Explanation) This alarm occurs if the current position data from the pulse coder is higher than the previous position data.

(Action) Action as same as the SRVO-090. (59) SRVO-094 PMAL alarm (Track enc : i)

(Explanation) It is likely that the pulse coder is abnormal. See the description about the PMAL alarm (SRVO-072).

(60) SRVO-095 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).

(Action 1) Reinforce the earth of the flange of the pulse coder. (Action 2) Replace the pulse coder.

(61) SRVO-096 LDAL alarm (Track enc : i)

(Explanation) The LED in the pulse coder is broken. See the description about the LDAL alarm (SRVO-074).

(62) SRVO-097 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.

(Action 1) Reset the alarm, and jog the axis on which the alarm has occurred until the same alarm does not occur again. (Jog one motor revolution)


- 93 -

(63) SRVO-105 Door open or E-stop (Explanation) The cabinet door is open. - When the door switch is mounted. (Action 1) When the door is open, close it. (Action 2) Check the door switch and door switch connection

cable. If the switch or cable is faulty, replace it. - When the door switch is not mounted. (Action 3) Check that the CRM72, CRM95, and CRM96

connectors on the E-STOP unit are connected securely.

(Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier. (Action 6) Replace the panel board. (Action 7) Replace the connection cable between the panel

board and the E-stop unit.

(A-cabinet)

Fig.3.5 (63) SRVO-105 Door open or E-stop

Door switch


E-stop unit


- 94 -

(64) SRVO-136 DCLVAL alarm (Group : i Axis : j) (Explanation) The servo the DC current of amplifier (DC link

voltage) of the main power supply is abnormally low.

- This alarm occurred during robot operation. (Action 1) Check the input voltage to the controller is within

the rated voltage and no phase is lack. And check the setting of the transformer is correct.

(Action 2) It is possible that an instant disconnection of power source causes this alarm. Check whether an instant disconnection occurred.

(Action 3) Modify the program in order that robot and the auxiliary axis do not accelerate simultaneously in the system with the auxiliary axis.

(Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier. - If this alarm occurred before the magnetic contactor is

turned on: (Action 1) Check whether the circuit breaker in the

emergency stop unit is OFF. If it is OFF, check the servo amplifier and the wiring between the servo amplifier and the emergency stop unit. If anything is abnormal, replace it. Else turn on the breaker.




- 95 -

Servo amplifier

E-stop unit

Magnetic contactor

(A-cabinet)

Servo amplifier

E-stop unit

Magnetic contactor

(B-cabinet)

Fig.3.5 (64) SRVO-136 DCLVAL alarm


- 96 -

(65) SRVO-156 IPMAL alarm (Group : i Axis : j) (Explanation) Abnormally high current flowed through the main

circuit of the servo amplifier. (Action 1) Turn off the power, and disconnect the power

cable from the servo amplifier indicated by the alarm message. (And disconnect the brake cable (CRR88 on the servo amplifier) to avoid the axis falling unexpectedly.) Supply power and see if the alarm occurs again. If the alarm occurs again, replace the servo amplifier.

(Action 2) Turn off the power and disconnect the power cable from the servo amplifier indicated by the alarm message, and check the insulation of their U, V, W and the GND lines each other. If there is a short-circuit, replace the power cable.

(Action 3) Turn off the power and disconnect the power cable from the servo amplifier by the alarm message, and measure the resistance between their U and V, V and W and W and U with an ohmmeter that has a very low resistance range. If the resistances at the three places are different from each other, the motor, the power cable is defective. Check each item in detail and replace it if necessary.

Servo amplifier

Servo amplifier


Fig.3.5 (65) SRVO-156 IPMAL alarm


- 97 -

(66) SRVO-157 CHGAL alarm (Group : i Axis : j) (Explanation) The capacitor for the condenser voltage of the

servo amplifier was not charged within the specified time when the servo power is on.

(Action 1) Replace the E-stop unit. (Action 2) Replace the servo amplifier. (Action 3) Replace the auxiliary amplifier for system of the

auxiliary axis.

Servo amplifier

E-stop unit

Servo amplifier

E-stop unit (A-cabinet) (B-cabinet)

(B-cabinet)

Fig.3.5 (66) SRVO-157 CHGAL alarm


- 98 -

(67) SRVO-194 Servo disconnect (Explanation) The external contact connected to SD4-SD41 or

SD5-SD51 of the terminal block TBOP3 on the panel board is open.

(Action 1) If external circuitry is connected to SD4-SD41 or SD5-SD51 of the terminal block TBOP3 on the panel board, check the external circuitry.

(Action 2) If this signal is not used, make a connection between SD4 and SD41 and between SD5 and SD51 of the terminal block TBOP3 on the panel board.



- 99 -

(A-cabinet)

Panel board

(B-cabinet)

Fig.3.5 (67) SRVO-194 Servo disconnect

WARNING In a system using the servo disconnect signal, it is

very dangerous to disable the signal when a connection is made between SD4 and SD41 and between SD5 and SD51 of the terminal block TBOP3 on the panel board. Never make such an attempt. If a temporary connection is needed for operation, separate safety measures must be taken.

Panel board


- 100 -

(68) SRVO-201 Panel E-stop or SVEMG abnormal (Explanation) The EMERGENCY STOP button on the operator’s

panel was pressed, but the EMERGENCY STOP line was not disconnected.

(Action 1) Replace the panel board. (Action 2) Replace the E-stop unit. (Action 3) Replace the servo amplifier.

Servo amplifier

E-stop unit

(A-cabinet)

Servo amplifier

E-stop unit

Panel board

EMERGENCY STOP button

(B-cabinet)

Fig.3.5 (68) SRVO-201 Panel E-stop or SVEMG abnormal

Panel board Emergency stop button


- 101 -

(69) SRVO-202 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) Replace the teach pendant. (Action 2) Check the teach pendant cable. If this inferior,

replace the cable. (Action 3) Replace the operator's panel. (Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier.

NOTE This alarm might occur if the EMERGENCY STOP

button is pressed slowly.


- 102 -

Servo amplifier

E-stop unit

(A-cabinet)

Servo amplifier

E-stop unit

Panel board

Teach pendant

(B-cabinet)

Fig.3.5 (69) SRVO-202 TP E-stop or SVEMG abnormal

Panel board


- 103 -

(70) SRVO-204 External (SVEMG abnormal) E-stop (Explanation) The switch connected across EES1 – EES11 and

EES2 – EES21 on the TBOP4 terminal board on the panel board was pressed, but the EMERGENCY STOP line was not disconnected.

In case that RDY LED (green) is lit. (Action 1) Check the switch and cable connected to EES1 –

EES11 and EES2 – EES21 on TBOP4 terminal board. If the cable are abnormal replace it.



- 104 -

Servo amplifier

E-stop unit

(A-cabinet)

Servo amplifier

E-stop unit

Panel board

(B-cabinet)

Panel board


- 105 -

(Panel board)

Fig.3.5 (70) SRVO-204 External (SVEMG abnormal) E-stop



- 106 -

(71) SRVO-205 Fence open (SVEMG abnormal) (Explanation) The switch connected across EES1 – EES11 and

EES2 – EES21 on the TBOP4 terminal board on the panel board was pressed, but the EMERGENCY STOP line was not disconnected.

In case that RDY LED (green) is lit. (Action 1) Check the switch and cable connected to EES1 –

EES11 and EES2 – EES21. If the cable are abnormal, replace it.


Servo amplifier (A-cabinet)

Servo amplifierPanel board

(B-cabinet)

Panel board


- 107 -

(Panel board)

Fig.3.5 (71) SRVO-205 Fence open (SVEMG abnormal) (72) SRVO-206 DEADMAN switch (SVEMG abnormal)

(Explanation) When the teach pendant was enabled, the DEADMAN switch was released or pressed strongly, but the emergency stop line was not disconnected.

(Action 1) Replace the teach pendant. (Action 2) Check the teach pendant cable. If it is inferior,

replace the cable. (Action 3) Replace the panel board. (Action 4) When the NTED signal is used, check whether the

cabling of the signal connected to CRM65 on the panel board is correct.




- 108 -

Servo amplifier

E-stop unit

(A-cabinet)

Servo amplifier

E-stop unit

Panel board

Teach pendant

(B-cabinet)

Fig.3.5 (72) SRVO-206 DEADMAN switch (SVEMG abnormal)

Panel board


- 109 -

(73) SRVO-213 WARN Fuse blown (Panel PCB) (Explanation) A fuse (FUSE1 or FUSE2) on the panel board has

blown, or no voltage is supplied to EXT24V. (Action 1) Check whether the fuse (FUSE1) on the panel

board has blown. If the fuse has blown, +24EXT may be short-circuited to 0EXT. Take Action 2. If FUSE1 has not blown, take Action 3 and up.

(Action 2) Disconnect the connection destinations of +24EXT that can cause grounding then check that FUSE1 does not blow. Disconnect the following on the panel board then turn on the power: - CRS20 - CRT16 - TBOP4: EES1, EES11, EAS1, EAS11, EGS1,

EGS11 - TBOP3: SD4, SD41

If FUSE1 does not blow in this state, +24EXT and 0EXT may be short-circuited at any of the connection destinations above. Isolate the faulty location then take action. If FUSE1 blows even when the connection destinations above are detached, replace the panel board.

(Action 3) Check whether 24 V is applied to between EXT24V and EXT0V of TBOP6. If not, check the external power supply circuit. If no external power supply is used, check whether the terminals above are connected to the INT24V and INT0V terminals, respectively.

(Action 4) Replace the panel board. (Action 5) Replace the teach pendant cable. (Action 6) Replace the teach pendant.

(panel board)

JRS15

LED (green)


- 110 -

(A-cabinet)

Main board

Panel board

(B-cabinet)

Connector JRS15

(Main board)

Fig.3.5 (73) SRVO-213 WARN Fuse blown (Panel PCB)

Panel board


- 111 -

(74) SRVO-214 Fuse blown (Servo amplifier) (Explanation) A fuse in the servo amplifier has blown.

In case that FS1 is blown (Action 1) Replace the servo amplifier.

In case that FS2 or FS3 is blown (Action 1) A fuse is blown, eliminate the cause, then replace

the fuse. (See Section 3.6 in the Part II, “MAINTENANCE”.)



Servo amplifier

(B-cabinet)

Fig.3.5 (74) SRVO-214 Fuse blown (Panel PCB)


- 112 -

(75) SRVO-216 OVC (total) (Robot : i) (Explanation) The current (total current for six axes) flowing

through the motor is too large. (Action 1) Slow the motion of the robot where possible.

Check the robot operation conditions. If the robot is used with a condition exceeding the duty or load weight robot rating, reduce the load condition value to the specification range.



Servo amplifier Servo amplifier

(B-cabinet)

Fig.3.5 (75) SRVO-216 OVC (total) (Robot : i)


- 113 -

(76) SRVO-221 Lack of DSP (Group : i Axis : j) (Explanation) A controlled axis card corresponding to the set

number of axes is not mounted. (Action 1) Check whether the set number of axes is valid. If

the number is invalid, set the correct number. (Action 2) Replace the axis control card with a card

corresponding to the set number of axes.


(A-cabinet)

Main board

Axis control card


Fig.3.5 (76) SRVO-221 Lack of DSP (Group : i Axis : j)


- 114 -

(77) SRVO-223 DSP dry run(a b) (Explanation) Servo system initialization was stopped because of

a hardware failure or improver software setting. The controller has been started in the DSP dry run mode.

(Action 1) When the value is 1, 5, or 6: An incorrect setting is made. Check whether the dry run mode is set and also check whether the setting of the hard start axis is correct.

(Action 2) When the value is 2, 3, 4, or 7: Replace the servo card.

(Action 3) When the value is 8 or 10: Take action for an FSSB initialization error that has occurred at the same time.

(Action 4) When the value is 9: Take the following action: Check whether the servo amplifier is connected. Replace the optical cable used for servo amplifier

connection. Replace the servo amplifier

Servo amplifier

Servo amplifier

Fig.3.5 (77) SRVO-223 DSP dry run(a b)


- 115 -

(78) SRVO-230 Chain 1 (+24V) abnormal SRVO-231 Chain 2 (0V) abnormal

(Explanation) A mismatch occurred between duplicate safety signals. SRVO-230 is issued if such a mismatch that a contact connected on the chain 1 side (between EES1 and EES11, between EAS1 and EAS11, between EGS1 and EGS11, between SD4 and SD41, and so forth) is closed, and a contact on the chain 2 side (between EES2 and EES21, between EAS2 and EAS21, between EGS2 and EGS21, between SD5 and SD51, and so forth) is open occurs. SRVO-231 is issued if such a mismatch that a contact on the chain 1 side is open, and a contact on the chain 2 side is closed occurs. If a chain error is detected, correct the cause of the alarm then reset the alarm according to the method described later.

(Action) Check the alarms issued at the same time in order to identify with which signal the mismatch occurred. SRVO-266 through SRVO-275 and SRVO-370 through SRVO-385 are issued at the same time. Take the action(s) described for each item.

(Caution 1) After correcting the cause of the hardware chain error according to the work described above, set "YES" for chain error resetting on the system setting screen. Finally, press the reset key on the teach pendant. For details, see "Chain error reset procedure" described later.

(Caution 2) If this alarm is issued, do not reset the chain error alarm until the failure is identified and repaired. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.

Servo amplifier

E-stop unit

(A-cabinet)

Panel board


- 116 -

Servo amplifier

E-stop unit

Panel board

(B-cabinet)

Fig.3.5 (78) SRVO-230 Chain 1 (+24V) abnormal / SRVO-231 Chain 2 (0V) abnormal

CAUTION 1 The state of this alarm is preserved by software.

After correcting the cause of the alarm, reset the chain error alarm according to the chain error reset procedure described later.

2 Until a chain error is reset, no ordinary reset operation must be performed. If an ordinary reset operation is performed before chain error resetting, the message "SRVO-237 Chain error cannot be reset" is displayed on the teach pendant.

Alarm history display method

1. Press the screen selection key on the teach pendant. 2. Select [4 ALARM] on the teach pendant. 3. Press F3 [HIST] on the teach pendant.

Chain error reset procedure CAUTION

Do not perform this operation until the cause of the alarm is corrected.


- 117 -

<Method 1> 1. Press the emergency stop button. 2. Press the screen selection key on the teach pendant. 3. Select [0 NEXT PAGE] on the teach pendant. 4. Press [6 SYSTEM] on the teach pendant. 5. Press [7 SYSTEM SETTING] on the teach pendant. 6. Find "28" Chain Error Reset Execution. 7. Press F3 on the teach pendant to reset "Chain Error". <Method 2> 1. Press the screen selection key on the teach pendant. 2. Select [4 ALARM] on the teach pendant. 3. Press F4 [CHAIN RESET] on the teach pendant. (79) SRVO-232 NTED input

(Explanation) In the teach mode, the NTED signal connected to CRM65 on the panel board was placed in the open state.

(Action 1) Check the operation of the device connected to NTED.

(Action 2) Replace the teach pendant. (Action 3) Replace the teach pendant cable. (Action 4) Replace the panel board (Action 5) Check the mode switch and its cable. Replace them

if a defect is found.


Panel board


- 118 -

Servo amplifier Panel board

Teach pendant

(B-cabinet)

Fig.3.5 (79) SRVO-232 NTED input


- 119 -

(80) SRVO-233 TP disabled in T1, T2/Door open (Explanation) Teach pendant is disabled when the mode switch is

T1 or T2. Or controller door is opened. (Action 1) Enable the teach pendant in teaching operation. In

other case the mode switch should be AUTO mode.

(Action 2) Close the controller door, if open. (Action 3) Replace the teach pendant. (Action 4) Replace the teach pendant cable. (Action 5) Replace the mode switch. (Action 6) Replace the panel board. (Action 7) Replace the E-stop unit. (Action 8) Replace the servo amplifier.

(A-cabinet)

Door switch

Mode switchPanel board

Servo amplifier

E-stop unit


- 120 -

Servo amplifier

E-stop unit

Panel board

Teach pendant

Mode switch

Enable switch

(B-cabinet)

Fig.3.5 (80) SRVO-233 TP disabled in T1, T2/Door open


- 121 -

(81) SRVO-235 Short term Chain abnormal (Explanation) Short term single chain failure condition is

detected. • Cause of this alarm is ; - Half release of DEADMAN switch - Half operation of emergency stop switch.

(Action 1) Cause the same error to occur again, then perform resetting.


Servo amplifier

E-stop unit

(A-cabinet)

Servo amplifier

E-stop unit

Panel board

(B-cabinet)

Panel board


- 122 -

Enable switch Deadman switch

(Teach pendant)

Fig.3.5 (81) SRVO-235 Short term Chain abnormal


- 123 -

(82) SRVO-251 DB relay abnormal (Explanation) An abnormality was detected in the internal relay

(DB relay) of the servo amplifier. (Action) Replace the servo amplifier.

(83) SRVO-252 Current detect abnl

(Explanation) An abnormality was detected in the current detection circuit inside the servo amplifier.

(Action) Replace the servo amplifier. (84) SRVO-253 Amp internal over heat

(Explanation) An overheat was detected inside the servo amplifier.

(Action) Replace the servo amplifier.


Servo amplifier

(B-cabinet)

Fig.3.5 (82) SRVO-251 DB relay abnormal / SRVO-252 Current detect abnl / SRVO-253 Amp internal over heat


- 124 -

(85) SRVO-266 FENCE1 status abnormal a,b SRVO-267 FENCE2 status abnormal a,b

(Explanation) A chain alarm was detected with the EAS (FENCE) signal.

(Action 1) Check whether the circuitry connected to the dual input signal (EAS) is faulty.

(Action 2) Check whether the timing of the dual input signal (EAS) satisfies the timing specification

(See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS).


CAUTION 1 For the procedure of recovery from this alarm, see

the descriptions of SRVO-230 and SRVO-231. 2 If this alarm is issued, do not reset the chain error

alarm until the failure is checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.


Fig.3.5 (85) SRVO-266 FENCE1 status abnormal a,b / SRVO-267 FENCE2 status abnormal a,b


- 125 -

(86) SRVO-268 SVOFF1 status abnormal a,b SRVO-269 SVOFF2 status abnormal a,b

(Explanation) A chain alarm was detected with the EGS (SVOFF) signal.

(Action 1) Check whether the circuitry connected to the dual input signal (EGS) is faulty.

(Action 2) Check whether the timing of the dual input signal (EGS) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS).





Fig.3.5 (86) SRVO-268 SVOFF1 status abnormal a,b / SRVO-269 SVOFF2 status abnormal a,b

EGS1 EGS11 EGS2 EGS22


- 126 -

(87) SRVO-270 EXEMG1 status abnormal a,b SRVO-271 EXEMG2 status abnormal a,b

(Explanation) A chain alarm was detected with the EES (EXEMG) signal.

(Action 1) Check whether the circuitry connected to the dual input signal (EES) is faulty.

(Action 2) Check whether the timing of the dual input signal (EES) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS).





Fig.3.5 (87) SRVO-270 EXEMG1 status abnormal a,b / SRVO-271 EXEMG2 status abnormal a,b



- 127 -

(88) SRVO-272 SVDISC1 status abnormal a,b SRVO-273 SVDISC2 status abnormal a,b

(Explanation) A chain alarm was detected with the SD4 or SD5 (SVDISC) signal.

(Action 1) Check whether the circuitry connected to the dual input signal (SD) is faulty.

(Action 2) Check whether the timing of the dual input signal (SD) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS).





Fig.3.5 (88) SRVO-272 SVDISC1 status abnormal a,b / SRVO-273 SVDISC2 status abnormal a,b

SD4 SD41 SD5 SD51


- 128 -

(89) SRVO-274 NTED1 status abnormal a,b SRVO-275 NTED2 status abnormal a,b

(Explanation) A chain alarm was detected with the NTED signal. (Action 1) This alarm may be issued when the DEADMAN

switch is pressed to a proper position or is operated very slowly. In such a case, release the DEADMAN switch once completely then press the DEADMAN switch again.

(Action 2) Check whether the circuitry connected to the dual input signal (NTED) is faulty.

(Action 3) Check whether the timing of the dual input signal (NTED) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTIONS).

(Action 4) Replace the panel board. (Action 5) Replace the teach pendant cable. (Action 6) Replace the teach pendant. (Action 7) Replace the mode switch on the operator's panel.

CAUTION

1 For the procedure of recovery from this alarm, see the descriptions of SRVO-230 and SRVO-231.

2 If this alarm is issued, do not reset the chain error alarm until the failure is checked and corrected. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.

Panel board


Panel board


- 129 -

Enable switch Deadman switch

Fig.3.5 (89) SRVO-274 NTED1 status abnormal a,b / SRVO-275 NTED2 status abnormal a,b

CRM65


- 130 -

(90) SRVO-277 Panel E-stop(SVEMG abnormal) (Explanation) The emergency stop line was not disconnected

although the emergency stop button on the operator's panel was pressed.

(Action 1) Replace the panel board. (Action 2) Replace the E-stop unit (Action 3) Replace the servo amplifier.

Servo amplifier

E-stop unit

(A-cabinet)

Servo amplifier

E-stop unit

Panel board

(B-cabinet)

Fig.3.5 (90) SRVO-277 Panel E-stop(SVEMG abnormal)

Panel board


- 131 -

(91) SRVO-278 TP E-stop(SVEMG abnormal) (Explanation) The emergency stop line was not disconnected

although the emergency stop button on the operator's panel was pressed.

(Action 1) Replace the teach pendant. (Action 2) Replace the teach pendant cable. (Action 3) Replace the panel board. (Action 4) Replace the E-stop unit (Action 5) Replace the servo amplifier.

NOTE This alarm may be issued if the emergency stop

button is pressed very slowly.


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Servo amplifier

E-stop unit

(A-cabinet)

Servo amplifier

E-stop unit

Panel board


Teach pendant

Fig.3.5 (91) SRVO-278 TP E-stop(SVEMG abnormal)

Panel board


- 133 -

(92) SRVO-280 SVOFF input (Explanation) The external contact connected to EGS1-EGS11 or

EGS2-EGS21 of the terminal block TBOP4 on the panel board is open.

(Action 1) If external circuitry is connected to EGS1-EGS11 or EGS2-EGS21 of the terminal block TBOP4 on the panel board, check the external circuitry.

(Action 2) If this signal is not used, make a connection between EGS1 and EGS11 and between EGS2 and EGS21 of the terminal block TBOP4 on the panel board.


Panel board


Panel board


- 134 -

Fig.3.5 (92) SRVO-280 SVOFF input

WARNING

In a system using the SVOFF signal, it is very dangerous to disable the signal when a connection is made between EGS1 and EGS11 and between EGS2 and EGS21 of TBOP4. Never make such an attempt. If a temporary connection is needed for operation, separate safety measures must be taken.



- 135 -

(93) SRVO-281 SVOFF input (SVEMG abnormal) (Explanation) The emergency stop line was not disconnected

although the contact connected between EGS1 and EGS11 or between EGS2 and EGS21 of the terminal block TBOP4 on the panel board was open. The emergency stop circuit is faulty.

(Action 1) Check the switch and cable connected to EGS1-EGS11and EGS2-EGS21 on TBOP4. If the cable are abnormal replace it.

(Action 2) Replace the panel board. (Action 3) Replace the E-stop unit. (Action 4) Replace the servo amplifier. (Action 5) Replace the connection cable between the panel

board and the E-stop unit.

Servo amplifier

E-stop unit

(A-cabinet)

Servo amplifier

E-stop unit

Panel board

(B-cabinet)

Panel board


- 136 -

Fig.3.5 (93) SRVO-281 SVOFF input (SVEMG abnormal)

(94) SRVO-291 IPM over heat (G:i A:j) (Explanation) IPM on the servo amplifier is overheated. (Action 1) Check whether the fan for cabinet ventilation is

stopped and also check whether the vent hole is clogged. If necessary, clean or replace them.

(Action 2) If SRVO-291 is issued when the robot operating condition is severe, check the robot operating condition then relax the condition when possible.

(Action 3) If SRVO-291 is issued frequently, replace the servo amplifier.



- 137 -

Servo amplifier

A-cabinet (Front)

External air fan

External air fan

Side fan type Rear fan type

A-cabinet (Back)

Servo amplifier

External air fan


Fig.3.5 (94) SRVO-291 IPM over heat (G:i A:j)


- 138 -

(95) SRVO-300 Hand broken/HBK disabled SRVO-302 Set Hand broken to ENABLE

(Explanation) Although HBK was disabled, the HBK signal was input.

(Action 1) Press RESET on the teach pendant to release the alarm.

(Action 2) Check whether the hand broken signal is connected to the robot. When the hand broken signal circuit is connected, enable hand broken.

(See Subsection 5.5.3 in Part III, “CONNECTIONS”.)

(96) SRVO-335 DCS OFFCHK alarm a,b (Explanation) A failure was detected in the safety signal input

circuit. (Action) Replace the panel board.

Panel board


Fig.3.5 (96) SRVO-335 DCS OFFCHK alarm a,b

(97) SRVO-348 DCS MCC OFF alarm a,b

(Explanation) A command was issued to turn off the magnetic contactor, but the magnetic contactor was not turned off.

(Action 1) Replace the E-stop unit. (Action 2) Replace the panel board. (Action 3) If a signal is connected to the emergency stop unit

CRM72, check whether there is a problem in the connection destination.

Panel board


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(98) SRVO-349 DCS MCC ON alarm a,b (Explanation) A command was issued to turn on the magnetic

contactor, but the magnetic contactor was not turned on.

(Action 1) Replace the E-stop unit. (Action 2) Replace the panel board. (Action 3) Replace the servo amplifier.

Servo amplifier

E-stop unit

(A-cabinet)

Servo amplifier

E-stop unit

Panel board

Fig.3.5 (98) 348 DCS MCC OFF alarm a,b / 349 DCS MCC ON alarm a,b

Panel board


- 140 -

(99) SRVO-370 SVON1 status abnormal a,b SRVO-371 SVON2 status abnormal a,b

(Explanation) A chain alarm was detected with the panel board internal signal (SVON).

(Action) Replace the panel board.




Panel board


Fig.3.5 (99) SRVO-370 SVON1 status abnormal a,b / SRVO-371 SVON2 status abnormal a,b

Panel board


- 141 -

(100)SRVO-372 OPEMG1 status abnormal a,b (Explanation) A chain alarm was detected with the emergency

stop switch on the operator's panel. (Action 1) Replace the panel board. (Action 2) Replace the teach pendant cable. (Action 3) Replace the teach pendant. (Action 4) Replace the emergency stop button on the

operator's panel.





- 142 -

(A-cabinet)

Panel board


Teach pendant

(B-cabinet)

Fig.3.5 (100) SRVO-372 OPEMG1 status abnormal a,b / SRVO-373 OPEMG2 status abnormal a,b

Panel board Emergency stop button


- 143 -

(101)SRVO-374 MODE11 status abnormal a,b SRVO-375 MODE12 status abnormal a,b SRVO-376 MODE21 status abnormal a,b SRVO-377 MODE22 status abnormal a,b

(Explanation) A chain alarm was detected with the mode switch signal.

(Action 1) Check the mode switch and its cable. Replace them if a defect is found.






- 144 -

(A-cabinet)

Panel board Mode switch

(B-cabinet)

Fig.3.5 (101) SRVO-374 MODE11 status abnormal a,b / SRVO-375 MODE12 status abnormal a,b /

SRVO-376 MODE21 status abnormal a,b / SRVO-377 MODE22 status abnormal a,b

Panel board Mode switch


- 145 -

(102)SRVO-378 OPSFTY11 status abnormal a,b SRVO-379 OPSFTY12 status abnormal a,b SRVO-380 OPSFTY21 status abnormal a,b SRVO-381 OPSFTY22 status abnormal a,b SRVO-382 OPSFTY31 status abnormal a,b SRVO-383 OPSFTY32 status abnormal a,b SRVO-384 OPSFTY41 status abnormal a,b SRVO-385 OPSFTY42 status abnormal a,b

(Explanation) A chain alarm was detected with the OPSFTY signal.

(Action 1) Check whether the circuitry connected to the dual input signal (OPSFTY) is faulty.

(Action 2) Check whether the timing of the dual input signal (OPSFTY) satisfies the timing specification (See Section 3.2.5, Table 3.2.5 of Part III CONNECTION).





Fig.3.5 (102) SRVO-378 OPSFTY11 status abnormal a,b / SRVO-379 OPSFTY12 status abnormal a,b / SRVO-380 OPSFTY21 status abnormal a,b / SRVO-381 OPSFTY22 status abnormal a,b / SRVO-382 OPSFTY31 status abnormal a,b / SRVO-383 OPSFTY32 status abnormal a,b / SRVO-384 OPSFTY41 status abnormal a,b / SRVO-385 OPSFTY42 status abnormal a,b

CRMA8


- 146 -

3.6 FUSE-BASED TROUBLESHOOTING This section describes the alarms and symptoms generated and actions required when the fuses installed on the printed circuit boards and units have blown. (1) When the fuses of the power supply unit have blown

F1: Fuse for AC input F3: Fuse for +24 E F4: Fuse for +24 V

Name Symptom observed when fuse has blown Action

F1 The LED (PIL: Green) of the power supply unit does not light, and the power cannot be turned on.

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.

2 Replace the power supply unit. F3 If the fuse blows when the power supply is turned

on, an alarm such as for overtravel, hand breakage, FSSB disconnect, LVAL is output on the teach pendant. If the fuse turns out to have already blown when the power supply is turned on, the FSSB initialization alarm is displayed on the teach pendant.

1 Check the printed circuit boards, units, servo amplifier, and cables using +24 E according to the power supply system diagram. Replace a faulty printed circuit board, unit, servo amplifier or cable if any.

2 Replace the power supply unit.

F4 The power, when turned on, is immediately turned off. At this time, the LED (ALM: Red) lights.

1 Check the printed circuit boards, units, and cables using +24 V according to the power supply system diagram. Replace a faulty printed circuit board, unit, or cable if any. The LED of ALM is turned off by pressing the OFF button once.

2 Replace the power supply unit.


- 147 -

(A-cabinet)

Servo amplifier

Power supply unit

F3(7.5A): Fuse for +24E F4（7.5A）: Fuse for +24V PIL: LED (green)


ALM: LED (red)

(B-cabinet) (Power supply unit)

Servo amplifier Power supply unit


- 148 -

(2) Main board fuse FU1: For protection of the +12V output for the vision sensor (This fuse is mounted on the mainboard of the total edition “06B” after.)

Name Symptom observed when fuse has blown Action FU1 +12V is not output. 1 Check +12V used by the vision sensor for a ground fault.

2 Check the vision sensor and the connection cable. 3 Replace the main board.

75173 (Receiver)

75172 (Driver)

CPU card

FROM/SRAM module

(Behind the axis control card)

Axis control card

FU1 Fuse(0.5A)

(Total edition “06B” after)


- 149 -

(3) Servo amplifier fuse FS1: For generation of the power to the amplifier control circuit FS2: For protection of the 24V output to the end effector, ROT,

and HBK FS3: For protection of the 24V output to the regenerative

resistance and the additional axis amplifier

Name Symptom observed when fuse has blown Action FS1 All LEDs on the servo amplifier go out.

The FSSB disconnection or initialization alarm is displayed on the teach pendant.

Replace the servo amplifier.

FS2 The Fuse Blown (Amp) alarm (SRVO-214), Hand broken (SRVO-006), and ROBOT OVER TRAVEL are displayed on the teach pendant.

1 Check +24VF used by the end effector for a ground fault. 2 Check the robot connection cable and the robot’s internal

cable. 3 Replace the servo amplifier.

FS3 The Fuse Blown (Amp) alarm (SRVO-214) and DCAL are displayed on the teach pendant.

1 Check the regenerative resistance, and replace it if required.

2 Check the additional axis amplifier and its wiring, and replace them if required.

3 Replace the servo amplifier.

5A

3.2A 3.2A

CRR88


- 150 -

(4) Panel board fuses FUSE1: For +24EXT line (emergency stop line) protection FUSE2: For protection of the teach pendant emergency stop line

Name Symptom observed when fuse has blown Action FUSE1 The teach pendant displays external

emergency stop, fence open, or SVOFF input fuse blown (panel PCB).

1 If an alarm is issued when the fuse has not blown, check the voltages of EXT24V and EXT0V (TBOP6). If external 24V or 0V is not used, check the jumper pin between EXT24V and INT24V or between EXT0V and INT0V.

2 Check the +24EXT line (emergency stop line) for a short circuit or connection to ground.

3 Replace the panel board. FUSE2 The display on the teach pendant disappears. 1 Check the teach pendant cable for a fault, and replace it

if required. 2 Check the teach pendant for a fault, and replace it if

required. 3 Replace the panel board.


- 151 -

(5) Fuse on the process I/O printed circuit board FUSE1: Fuse for +24E

Name Symptom observed when fuse has blown Action FUSE1 The LED (ALM-2 or FALM) on the process I/O

printed circuit board lights, and an alarm such as IMSTP input is output on the teach pendant. (The display data depends on state of peripheral equipment connection.)

1 Check if the cables and peripheral equipment connected to the process I/O printed circuit board are normal.

2 Replace the process I/O printed circuit board.

Process I/O board CA

Process I/O board EA, EB Fuse location is common to EA and EB.The following is figure of EA.


- 152 -

Process I/O board FA

Process I/O board GA

Process I/O board HA


- 153 -

Process I/O board JA, JB Fuse location is common to JA and JB.The following is figure of JA.

Process I/O JA

Process I/O board KA, KB, KC

Fuse location is common to KA, KB and KC. The following is figure of KA.

FUSE1 LED

Process I/O KA


- 154 -

3.7 TROUBLESHOOTING BASED ON LED INDICATIONS The printed circuit boards and servo amplifier are provided with alarm LEDs and status LEDs. The LED status and corresponding troubleshooting procedures are described below.

Servo amplifier


(A-cabinet)

Servo amplifier Panel board

Optional slot Main board Power supply unit

(B-cabinet)

Panel board Process I/O


- 155 -

TROUBLESHOOTING USING THE LEDS ON THE MAIN BOARD (1) Troubleshooting using the status display LED To troubleshoot an alarm that arises before the teach pendant is

ready to display, check the status LEDs (green) on the main board at power-on. After power-on, the LEDs light as described in steps 1 to end, in the order described. If an alarm is detected, the step in which the alarm occurred can be determined from which LEDs are lit.

Step LED Action to be taken

1: After power-on, all LEDs are lit.

[Action1] Replace the CPU card. * [Action2] Replace the main board.

2: Software operation start-up.


3: The initialization of dram on the CPU card is completed.


4: The initialization of DPRAM on the communication IC is completed.

[Action1] Replace the CPU card. * [Action2] Replace the main board. * [Action3] Replace the FROM/SRAM module.

5: The initialization of the communication IC is completed.

[Action1] Replace the CPU card. * [Action2] Replace the main board. * [Action3] Replace the FROM/SRAM module.

6: The loading of the basic software is completed.

* [Action1] Replace the main board. * [Action2] Replace the FROM/SRAM module.

7: Basic software start-up.


8: Start-up of communication with the teach pendant.



- 156 -

Step LED Action to be taken 9: The loading of

optional software is completed.

* [Action1] Replace the main board. [Action2] Replace the process I/O board.

10: DI/DO initialization

* [Action1] Replace the FROM/SRAM module. * [Action2] Replace the main board.

11: The preparation of the SRAM module is completed.

[Action1] Replace the axis control card. * [Action2] Replace the main board. [Action3] Replace the servo amplifier.

12: Axis control card initialization


13: Calibration is completed.


14: Start-up of power application for the servo system

* [Action1] Replace the main board.

15: Program execution

* [Action1] Replace the main board. [Action2] Replace the process I/O board.

16: DI/DO output start-up.

* [Action1] Replace the main board.

17: Initialization is terminated.

Initialization has ended normally.

18: Normal status

Status LEDs 1 and 2 blink when the system is operating normally.


- 157 -

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.

If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.

CPU card

FROM/SRAM module

Axis control card


- 158 -

(2) TROUBLESHOOTING BY 7-SEGMENT LED INDICATOR

7-segment LED indicator Description

[Description] A parity alarm condition has occurred in DRAM on the CPU card installed on the main board.


[Description] A parity alarm condition has occurred in SRAM on the FROM/SRAM module installed on the main board.

[Action1] Replace the FROM/SRAM module. * [Action2] Replace the main board.

[Description] A bus error has occurred in the communication controller. * [Action] Replace the main board.

[Description] A parity alarm condition has occurred in DRAM controlled by the communication controller.

* [Action] Replace the main board.

[Description] A servo alarm condition has occurred on the main board. [Action1] Replace the axis control card. * [Action2] Replace the main board.

[Description] The SYSEMG alarm has occurred. [Action1] Replace the axis control card. [Action2] Replace the CPU card. * [Action3] Replace the main board.

[Description] The SYSFAIL alarm has occurred. [Action1] Replace the axis control card. [Action2] Replace the CPU card. * [Action3] Replace the main board.

[Description] 5V is supplied to Main board. Above alarms do not occur.

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified

data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data. If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.


- 159 -

Troubleshooting by LEDs on power supply unit

LED indication Failure description and required measure

[Description] When ALM LED (red) turned on, power supply alarm has occurred. [Action1] Check fuse F4 (+24V) on the power supply unit, and replace it if it has

blown. [Action2] Check the printed-circuit boards powered by the DC power supplies (+5V,

15V, and +24V), the relevant units, and cables, and replace them if defective.

[Action3] Replace the power supply unit.

[Description] If the PIL LED (Green) does not light, the power supply unit has not been supplied with 200 VAC.

[Action1] Check fuse F1 on the power supply unit, and replace it if it has blown. For detailed causes of fuse blown out, please refer to section 3.6.

[Action2] Replace the power supply unit.


- 160 -

F1 (8.0A) : Fuse for AC input

F3 (7.5A) : Fuse for +24E

F4 (7.5A) : Fuse for +24V

PIL : LED (green)

ALM :LED (red)

(Power supply unit)


- 161 -

Troubleshooting by LED on the panel board - A20B-2101-0370

LED indication Failure description and required measure

ALM1 ALM2

[Description] When the ALM1 and ALM2 (red) tourned on, communication with the main board does not execute.

[Action1] Check the communication cable between the main and panel boards, and replace it if necessary.

[Action2] Replace the main board. [Action3] Replace the panel board.

5V [Description] When the LED does not light. The power supply inside the panel board does not generate +5 V normally.

[Action1] Check the CRM96 connector and check that 24 V is supplied. [Action2] Replace the panel board.

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified

data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data. If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.

(Panel board)


- 162 -

Troubleshooting by alarm LEDs on the process I/O printed circuit board

LED Description and action to be taken Process I/O CA/HA/JA/JB

Process I/O EA/EB/FA/GA/KA/KB/KC

ALM0

FALM

[Description] A communication alarm occurred between the main CPU PC board and process I/O PC board.

[Action1] Replace the process I/O PC board. * [Action2] Replace the main CPU PC board. [Action3] Replace the I/O link connection cable.

Process I/O CA/HA/JA/JB


ALM0

FALM

[Description] A fuse on the process I/O PC board is blown. [Action1] Replace the blown fuse on the process I/O PC board. [Action2] Examine the cables and peripheral devices connected

to the process I/O PC board. Replace any failed components.

[Action3] Replace the process I/O PC board.

Fuse

Process I/O CA/HA

Fuse


Fuse specification: A60L-0001-0046#2.0


- 163 -

Process I/O JA/JB

Fuse specification: A60L-0001-0046#2.0


- 164 -

Troubleshooting by LEDs on servo amplifier The servo amplifier has alarm LEDs. Troubleshoot the alarm indicated by the LEDs, referring also to the alarm indication on the teach pendant.

Check that the voltage is not higher than 50V.

CAUTION Before touching the servo amplifier, check the DC

link voltage with the screws located above the LED "D7". By using a DC voltage tester, check that the voltage is 50 V or less.

LED Color Description P5V Green Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V

normally. If the LED does not light: [Measure 1] Check the robot connection cable (RP1) to see if there is a ground fault in the

+5V wire. [Measure 2] Replace the servo amplifier.

P3.3V Green Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V normally. If the LED does not light: [Measure] Replace the servo amplifier.


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LED Color Description SVEMG Red Lights when an emergency stop signal is input to the servo amplifier.

If the LED lights when the machine is not at an emergency stop: [Measure] Replace the servo amplifier. If the LED does light when the machine is at an emergency stop: [Measure] Replace the servo amplifier.

ALM Red Lights when the servo amplifier detects an alarm. If the LED lights when there is no alarm condition in the machine: [Measure] Replace the servo amplifier. If the LED does not light when there is an alarm condition in the machine: [Measure] Replace the servo amplifier.

DRDY Green Lights when the servo amplifier is ready to drive the servo motor. If the LED does not light when the motor is activated: [Measure] Replace the servo amplifier.

OPEN Green Lights when the communication between the servo amplifier and the main board is normal. If the LED does not light: [Measure 1] Check for the connection of the FSSB optical cable. [Measure 2] Replace the servo card. [Measure 3] Replace the servo amplifier.

D7 Red Lights when the DCLINK circuit inside the servo amplifier is charged to reach the specified voltage. If the LED does not light after pre-charge is finished: [Measure 1] It is likely that the DC Link may be short-circuited. Check for connection. [Measure 2] It is likely that the charge current control resistor may be defective. Replace the

emergency stop unit. [Measure 3] Replace the servo amplifier.


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3.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING)

(Check 1) On the status screen, check the position deviation in the

stopped state. To display the position deviation, press the screen selection key, and select STATUS from the menu. Press F1, [TYPE], select AXIS from the menu, then press the F4, PULSE.

(Corrective action) Correct the parameters related to return to the reference

position (positioning). (Check 2) Check whether the motor axis can be positioned normally. (Corrective action) If the motor axis can be positioned normally, check the

mechanical unit. (Check 3) Check the mechanical unit for backlash. (Corrective action) Replace a faulty key of motor shaft or other faulty parts. (Check 4) If checks 1 to 3 show normal results (Corrective action) Replace the pulse coder and main board. * If the main board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.


- 167 -

3.9 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. (Corrective action) Turn on the teach pendant "enable". (Check 2) Check whether the teach pendant is handled correctly. (Corrective action) To move an axis by manual operation, press the axis

selection key and shift key at the same time. Set the override for manual feed to a position other

than the FINE and VFINE positions. (Check 3) Check whether the ENBL signal of the peripheral

device control interface is set to 1. (Corrective action) Place the peripheral device control interface in the

ENBL status. (Check 4) Check whether the HOLD signal of the peripheral

device control interface (hold status). (Check whether the hold lamp on the teach pendant is on.)

(Corrective action) Turn off the HOLD signal of the peripheral device

control interface. (Check 5) Check whether the previous manual operation has

been completed. (Corrective action) 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, check the position deviation on the status screen, and change the setting.

(Check 6) Check whether the controller is in the alarm status. (Corrective action) Release the alarm.

(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. (Corrective action) Put the peripheral-device control interface in the

ENBL state.


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(Check 2) Check whether the HOLD signal for the peripheral-device control interface is on. Also check whether the HOLD lamp on the teach pendant is on.

(Corrective action) If the HOLD signal of the peripheral device control

interface is on, turn it off. (Check 3) Check whether the previous manual operation has

been completed. (Corrective action) 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) Release the alarm.

B-82595EN-2/02 MAINTENANCE 4.PRINTED CIRCUIT BOARDS

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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 control unit 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 PC boards have interface connectors, LED indicators, and a plastic panel at the front. At the rear, there is a backplane connector.

4.PRINTED CIRCUIT BOARDS MAINTENANCE B-82595EN-2/02

- 170 -

4.1 MAIN BOARD (A16B-3200-0600, -0601)

75173 (Receiver)

75172 (Driver)

CPU card

FROM/SRAM module


Axis control card

FU1 Fuse(0.5A)


Fig.4.1 Main board

Name Ordering Specification Board Specification Note

A05B-2500-H001 A16B-3200-0600 Main board A05B-2500-H002 A16B-3200-0601 With force sensor I/F

CPU card A05B-2500-H020 A20B-3400-0020 SDRAM 32M A05B-2500-H040 A20B-3300-0448 8-axis A05B-2500-H041 A20B-3300-0447 12-axis

Axis control card

A05B-2500-H042 A20B-3300-0442 16-axis A05B-2500-H060 A20B-3900-0163

A20B-3900-0223 FROM 32M/ SRAM 1M

A05B-2500-H061 A20B-3900-0164 A20B-3900-0224

FROM 32M/ SRAM 2M

A05B-2500-H062 A20B-3900-0165 A20B-3900-0225

FROM 32M/ SRAM 3M

A05B-2500-H063 A20B-3900-0166 A20B-3900-0226

FROM 64M/ SRAM 1M

FROM/SRAM module

A05B-2500-H064 A20B-3900-0167 A20B-3900-0227

FROM 64M/ SRAM 2M


- 171 -

(1) Test pins

Name Use GND1 GND2 GND3

CACHOFF LOAD

For testing the printed circuit board

(2) LEDs Seven segment

LED Description

A parity alarm occurred in a DRAM of the CPU card on the main board.

A parity alarm occurred in a SRAM of the FROM/SRAM module on the main board.

Bus error occurred on the communication controller.

A parity alarm occurred in DRAM controlled by communication controller.

A servo alarm occurred on the main board.

SYSEMG occurred.

SYSFAIL occurred.

5V is supplied to Mainboard. Above 0-7 alarms do not occur.


- 172 -

Status LED Description Operating status of the system.

ETHERNET LED Color Description

TX Green Flashes during data transmission. L/RX

GreenLights when a link is established, and blinks when data is received.

(3) Communication IC If the teach pendant cannot display anything because of, for

example, a broken wire in the teach pendant connection cable, it is likely that the communication driver or receiver may be defective.

Name Drawing number

75172 (Driver) A76L-0151-0098 75173 (Receiver) A76L-0151-0099

Please refer to Fig.4.1.


- 173 -

4.2 EMERGENCY STOP CONTROL BOARD (A20B-1008-0740)

Fig.4.2 Emergency stop control board


- 174 -

4.3 BACKPLANE BOARD

(A20B-2003-0890)

Fig.4.3 (a) Backplane Board (A20B-2003-0890)

(1) Test pins

Name Use HIGH TEST LOW



- 175 -

(A20B-2004-0040)

Fig.4.3 (b) Backplane board (A20B-2004-0040)

(1) Test pins

Name Use HIGH TEST LOW



- 176 -

4.4 PANEL BOARD (A20B-2101-0370)

Fig.4.4 Panel Board

(1) Meanings of LEDs

Name Color Use 5V Green Lights when +5 V is output normally from the internal

power supply of the panel board. ALM1 ALM2

Red Lights when communication with the main board is interrupted.


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4.5 PROCESS I/O BOARD CA (A16B-2201-0470)

Fig. 4.6 Process I/O Board CA

(1) Test pins

Name Use P24V P5V

P15VC M15VC GND1 GND2

+24V +5V +15V -15V GND GND

For measuring the DC supply voltage

P10V +10V For measuring the reference voltage of the digital/analog converter

P15VF M15VF GNDF

+15V -15V GND

Power for the digital/analog converter

AI1 AI2 AI3 AI4 AI5 AI6

Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6

For measuring the ovltage of the analog input signal (analog/digital)

AOUT1 AOUT2

Channel 1 Channel 2

For measuring the voltage of the analog output signal (digital/analog)


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(2) Setting

Name Standardsetting

Description

ICOM1 UDI1 to UDI20 (Connector CRM2A)

ICOM2 UDI21 to UDI40 (Connector CRM2B)

ICOM3 WI01 to WI08 (Connector CRW1)

Side A Set this jumper according to the common voltage of input devices. Side A : +24V common SideB : 0V common

SP1 Channel 1 SP2 Channel 2

Open The polarity of the output voltage is switched to: Strapped: Negative (-) Open : Positive (+)

(3) Adjustment VR1: Adjust the gain of channel 1. Execute a robot program and set AOUT[1] to 4095 on the teach

pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 until the meter reads 12.0V.

Connect the negative (-) lead of the digital voltmeter to test pin GNDF. (The GNDF test pin is different from the common GND test pin.)

VR2: Adjust the gain of channel 2. Execute a robot program and set AOUT[2] to 4095 on the teach

pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR2 until the meter reads 12.0V.


VR3: Adjust the reference supply voltage of the digital/analog converter.

Connect the digital voltmeter to test pin P10V and rotate VR3 until the meter reads 10.0±0.1V.

(4) LEDs

Color Description

Red A communication alarm occurred between the main CPU and process input/output.

Red A fuse (FUSE 1) in the process input/output blew.


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(5) Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062

Driver IC DO signal DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED DV2 HELD, FALT, ATPERCH, TPENBL DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED DV6 DO01, DO02, DO03, DO04 DV7 DO05, DO06, DO07, DO08 DV8 DO09, DO10, DO11, DO12 DV9 DO13, DO14, DO15, DO16

DV10 DO17, DO18, DO19, DO20 DV11 WO01, WO02, WO03, WO04 DV12 WO05, WO06, WO07, WO08

RESERVED For replacement


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4.6 PROCESS I/O BOARD EA (A16B-3200-0230)

Fig. 4.6 Process I/O Board EA

(1) Test pins

Name Use P24V P5V

P15VC M15VC GND1 GND2

+24V +5V +15V -15V GND GND


P10V +10V For measuring the reference voltage of the digital/analog converter

P15VF M15VF GNDF

+15V -15V GND

For measuring power for the digital/analog converter

AI1 AI2 AI3 AI4 AI5 AI6

Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6

For measuring the ovltage of the analog input signal (analog/digital)

AOUT1 AOUT2

Channel 1 Channel 2



- 181 -

(2) Setting


Description





SP1 Channel 1 SP2 Channel 2

Open Output voltage is adjusted to: Short : Output voltage minus (-)Open : Output voltage plus(+)

(3) Adjustment VR1: Adjust the gain of channel 1. Execute a robot program and set AOUT[1] to 4095 on the teach

pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 until the meter reads 12.0V.


VR2: Adjust the gain of channel 2. Execute a robot program and set AOUT[2] to 4095 on the teach

pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR2 until the meter reads 12.0V.


VR3: Adjust the standard voltage for the digital/analog converter. Connect the digital voltmeter to test pin P10V and rotate VR3 until the meter reads 10.0±0.1V

VR4, VR5: Adjust the internal power supply This volume is adjusting the internal power supplu. Adjusting when shipping from the factory, so you need not to

adjust.


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(4) LEDs

Color Description

Red A communication alarm occurred between the main CPU and process I/O board.

Red A fuse (FUSE 1) in the process I/O board blew.

(5) Correspondence between driver IC and DO signals

Ordering code for the driver IC: A76L-0151-0062


DV10 DO17, DO18, DO19, DO20 DV11 WO01, WO02, WO03, WO04 DV12 WO05, WO06, WO07, WO08


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4.7 PROCESS I/O BOARD EB (A16B-3200-0231)

Fig. 4.7 PROCESS I/O BOARD EB (A16B-3200-0231)

(1) Test pins

Name Use P24V P5V

GND1 GND2

+24V +5V GND GND


(2) Setting


Description





- 184 -

(3) LEDs

Color Description






DV10 DO17, DO18, DO19, DO20


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4.8 PROCESS I/O BOARD FA (A16B-3200-0420)

Fig. 4.8 Process I/O Board FA

(1) Test pins

Name Use P24V P5V

GND1 GND2

+24V +5V GND GND


(2) Setting


Description



ICOM3 UDI41 to UDI60 (Connector CRM2C)

ICOM4 UDI61 to UDI80 (Connector CRM2D)



Side A

Set this jumper according to the common voltage of input devices. Side A : +24V common SideB : 0V common


- 186 -

(3) LEDs

Color Description






DV10 DO17, DO18, DO19, DO20 DV11 DO21, DO22, DO23, DO24 DV12 DO25, DO26, DO27, DO28 DV13 DO29, DO30, DO31, DO32 DV14 DO33, DO34, DO35, DO36 DV15 DO37, DO38, DO39, DO40 DV16 DO41, DO42, DO43, DO44 DV17 DO45, DO46, DO47, DO48 DV18 DO49, DO50, DO51, DO52 DV19 DO53, DO54, DO55, DO56 DV20 DO57, DO58, DO59, DO60 DV21 DO61, DO62, DO63, DO64 DV22 DO65, DO66, DO67, DO68 DV23 DO69, DO70, DO71, DO72 DV24 DO73, DO74, DO75, DO76


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4.9 PROCESS I/O BOARD GA (A16B-2203-0520)

(1) Test pins

Name Use P24V P5V

GND1 GND2 GND3

+24V +5V GND GND GND


P24VF P5VF GNDF

+24V +5V GND


AOUT1 AOUT2

Channel 1 Channel 2


(2) Setting


Description






- 188 -

(3) Adjustment VR1/VR2: Adjust the gain and the offset of channel 1. Execute a robot program and set AOUT[1] to 3413 on the teach

pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 or VR2 until the meter reads 15.0V.


VR3/VR4: Adjust the gain and the offset of channel 2. Execute a robot program and set AOUT[2] to 3413 on the teach

pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR3 or VR4 until the meter reads 15.0V.


(4) LEDs

Color Description






DV10 DO17, DO18, DO19, DO20


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4.10 PROCESS I/O BOARD HA (A16B-2203-0760)

Fig. 4.10 Process I/O Board HA

(1) Test pins

Name Use P24V P5V

GND1 GND2 GND3

+24V +5V GND GND GND


P24VF P5VF GNDF

+24V +5V GND


AO1 AO2

Channel 1 Channel 2



- 190 -

(2) Setting


Description





(3) Adjustment VR1/VR2: Adjust the gain and the offset of channel 1. Execute a robot program and set AOUT[1] to 3413 on the teach

pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 or VR2 until the meter reads 15.0V.


VR3/VR4: Adjust the gain and the offset of channel 2. Execute a robot program and set AOUT[2] to 3413 on the teach

pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR3 or VR4 until the meter reads 15.0V.


(4) LEDs

Color Description




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(5) Correspondence between driver IC and DO signals Ordering code for the driver IC: A76L-0151-0062


DV10 DO17, DO18, DO19, DO20


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4.11 PROCESS I/O BOARD JA (A16B-2204-0010)

ICOM1 ICOM5 GND1

ICOM2

ICOM6

ICOM3

ICOM4

FUSE (2A)

LED CRMA6A CRMA6B TBSRC3 TBSRC1 CRMA5A CRMA5B

CRMA5C CRMA5D TBSRC2 I/O-LK JD1B I/O-LK JD1A

P24V

P5V

GND2

Fig.4.11 Process I/O Board JA

(1) Test pins

Name Use P24V P5V

GND1 GND2

+24V +5V GND GND



- 193 -

(2) Settings

Name Standard setting

Description

ICOM1 UDI1 to 20 (Connector CRMA5A)

ICOM2 UDI21 to 40 (Connector CRMA5B)

ICOM3 UDI41 to 60 (Connector CRMA5C)

ICOM4 UDI61 to 80 (Connector CRMA5D)



Side A Set the common voltageSide A : +24 V commonSide B : 0 V common

(3) LEDs

Color Description

Red A communication alarm occurred between the main CPU and process I/O.

Red A fuse (FUSE 1) in the process I/O blew.


- 194 -

4.12 PROCESS I/O BOARD JB (A16B-2204-0011)

ICOM1 ICOM2

LED

TBSRC1 CRMA5A CRMA5B

I/O-LK JD1B I/O-LK JD1A

FUSE (2A)

Fig.4.12 Process I/O Board JB

(1) Test pins

Name Use P24V P5V

GND1 GND2

+24V +5V GND GND


P5V P24V GND1

GND2


- 195 -

(2) Settings


Description



Side A Set the common voltageSide A : +24 V commonSide B : 0 V common

(3) LEDs

Color Description

Red A communication alarm occurred between the main CPU and process I/O.

Red A fuse (FUSE 1) in the process I/O blew.


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4.13 PROCESS I/O BOARD KA (A16B-2204-0050)

P24V P5V

P15V

N15V

GND1

GND2 GND3

GND4

P5VF

P24VF

GNDF

AI1 AI2

VR5 VR6 VR4 VR3 VR2

VR1

AOUT1

AOUT2

AOUT3

ICOM1

ICOM2

ICOM3

LED DV1

DRV1 DRV2

(1) Meanings of check pins

Name Use

P24V

P5V

P15V

N15V

GND1

GND2

GND3

GND4

＋24V

＋5V

＋15V

－15V

GND

GND

GND

GND

For DC power measurement

P5VF

P24VF

GNDF

＋5V

+24V

GND

D/A converter power supply

AI1

AI2

Channel 1

Channel 2

For analog input signal (A/D) voltage

measurement

AOUT1

AOUT2

AOUT3

Channel 1 Channel 2 Channel 3

For analog output signal (D/A) voltage

measurement

Total edition


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(2) Setting Name Standard

setting Use

ICOM1 UDI1～20

（connector CRMA5A）

ICOM2 UDI21～40

（connector CRMA5B）

ICOM3 WI01～08

（connector CRW10）

Side A For common voltage setting Side A: +24 V common Side B: 0 V common

(3) Adjustment

VR1/VR2 Channel 1 gain and offset adjustment Connect the "+" and "-" terminals of a digital voltmeter,

respectively, to the AOUT1 check pin and the GNDF check pin (not a general ground point). From the teach pendant, execute AOUT[1]=3413, using a robot program. While observing the voltage at the AOUT1 check pin with the digital voltmeter, adjust potentiometers VR1 and VR2 for 15.0 V.






- 198 -

(4) Meaning of LEDs Color Meaning

Red A communication alarm occurred between the main CPU and the process I/O board.

Red The fuse (FUSE1) on the process I/O board has blown.

(5) Correspondence between driver ICs and DO signals

Driver IC specification:DRV1, DRV2：A76L-1151-0167 DV1：A76L-1151-0070

Driver IC name DO signal name DRV1 CMDENBL，SYSRDY，PROGRUN，PAUSED

HELD，FAULT，ATPERCH，TPENBL

BATALM，BUSY，ACK1/SNO1，ACK2/SNO2

ACK3/SNO3，ACK4/SNO4，ACK5/SNO5，ACK6/SNO6

DRV2 ACK7/SNO7，ACK8/SNO8，SNACK，RESERVED

DO01， DO02， DO03， DO04

DO05， DO06， DO07， DO08

DO09， DO10， DO11， DO12

DV1 DO13， DO14， DO15， DO16

DO17， DO18， DO19， DO20


- 199 -

4.14 PROCESS I/O BOARD KB（A16B-2204-0051）

P24V P5V

GND1

GND2 GND3

GND4

P5VF

P24VF

GNDFVR4

VR2

VR1

AOUT1

AOUT2

ICOM1

ICOM2

ICOM3

LED DV1

DRV1 DRV2

VR3


Name Use

P24V

P5V

GND1

GND2

GND3

GND4

＋24V

＋5V

GND

GND

GND

GND


P5VF

P24VF

GNDF

＋5V

+24V

GND

D/A converter power supply

AOUT1

AOUT2

Channel 1

Channel 2

For analog output signal (D/A) voltage

measurement

Total edition


- 200 -

(2) Setting Name Standard

setting Use

ICOM1 UDI1～20

(connector CRMA5A)

ICOM2 UDI21～40

(connector CRMA5B)

ICOM3 WI01～08

(connector CRW10)


(3) Adjustment






- 201 -











DO01， DO02， DO03， DO04

DO05， DO06， DO07， DO08

DO09， DO10， DO11， DO12

DV1 DO13， DO14， DO15， DO16

DO17， DO18， DO19， DO20


- 202 -

4.15 PROCESS I/O BOARD KC（A16B-2204-0052）

P24V P5V

GND1

GND2 GND3

GND4

ICOM1

ICOM2

LED DV1

DRV1 DRV2


Name Use

P24V

P5V

GND1

GND2

GND3

GND4

＋24V

＋5V

GND

GND

GND

GND


(2) Setting


Use

ICOM1 UDI1～20

(connector CRMA5A)

ICOM2 UDI21～40

(connector CRMA5B)


Total edition


- 203 -











DO01， DO02， DO03， DO04

DO05， DO06， DO07， DO08

DO09， DO10， DO11， DO12

DV1 DO13， DO14， DO15， DO16

DO17， DO18， DO19， DO20

5.SERVO AMPLIFIERS MAINTENANCE B-82595EN-2/02

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5 SERVO AMPLIFIERS The servo amplifiers 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 servo amplifier is replaced. It also describes the use of test pins and meanings of the LED indications.

Table 5 Servo amplifier specification REGENERATIVE REGISTOR ROBOT SERVO AMPLIFIER

A-CABINET B-CABINET

M-900iA/600 A06B-6107-H001 (AMP1) A06B-6117-H209 (AMP2) A06B-6117-H105 (AMP3)

A05B-2502-C100

R-2000iB/200T M-900iA/260L M-900iA/350

M-410iB

A06B-6107-H001

A05B-2501-C102

A05B-2502-C100

R-2000iB （except /200T）

M-710iC A05B-2501-C103 M-16iB ARC Mate 120iB (Except ARC Mate 120iBe.)

A05B-2501-C100

M-420iA, M-421iA

A06B-6107-H002

A05B-2501-C102

A05B-2502-C100

M-6iB ARC Mate 100iB ARC Mate 120iBe

A05B-2501-C101

F-200iB

A06B-6107-H003

A05B-2501-C105

A05B-2502-C101

ARC Mate 100iC M-10iA A06B-6107-H004 A05B-2501-C101 A05B-2502-C101

M-430iA/2F A06B-6107-H007 (AMP 1) A06B-6117-H201 (AMP 2)

M-430iA/2P A06B-6107-H007 (AMP 1) A06B-6117-H301 (AMP 2)

A05B-2501-C105 A05B-2502-C101

B-82595EN-2/02 MAINTENANCE 5.SERVO AMPLIFIERS

- 205 -


NOTE Before touching the servo amplifier, for example,

for maintenance purposes, check the voltage at the screw above the LED “D7” with a DC voltage tester to see if the remaining voltage is not higher than 50V.

5.SERVO AMPLIFIERS MAINTENANCE B-82595EN-2/02

- 206 -

5.1 LED OF SERVO AMPLIFIER

LED Color Description P5V Green Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V

normally. P3.3V Green Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V

normally. SVEMG Red Lights when an emergency stop signal is input to the servo amplifier. SVALM Red Lights when the servo amplifier detects an alarm. DRDY Green Lights when the servo amplifier is ready to drive the servo motor. OPEN Green Lights when the communication between the servo amplifier and the main board is normal.

D7 Red Lights when the DCLINK circuit inside the servo amplifier is charged to reach a specific voltage.

B-82595EN-2/02 MAINTENANCE 5.SERVO AMPLIFIERS

- 207 -

5.2 SETTING OF SERVO AMPLIFIER Settings


Description

COM1 Side A Robot Digital Input (RDI) device common voltage. Side A: +24V common Side B: 0V common

A side

B side

RI

RI

Circuit based on jumper pin location

6.SETTING THE POWER SUPPLY MAINTENANCE B-82595EN-2/02

- 208 -

6 SETTING THE POWER SUPPLY Setting and adjustment of the power supply is factory-set for operation. Usually, you do not need to set or adjust it.

B-82595EN-2/02 MAINTENANCE 6.SETTING THE POWER SUPPLY

- 209 -

6.1 BLOCK DIAGRAM OF THE POWER SUPPLY

Robot

AC power supply unit AC 200 ～ 230 V AC 380 ～ 400 V AC 380 ～ 415 V AC 440 ～ 500 V AC 500 ～ 575 V

Transformer

Breaker

E-stop unit

210VAC3φ

210VAC

Servo amplifier (6-axis amplifier)

Backplane Power supply unit CP1A

CP2

CP3

CP6

CP5

DC/DC +5V, +3.3V +2.5V, +15V, -15V +24V, +24E

Fan

+24E

+24V

CRP24

CN

J

CR

F8

CR

R64

CRR38

CRM96CRM96

CP2

+24V

Main board

JRS16

Battery

Process I/O board

CRM2 CRM4 CRMA5 CRMA6

Power

Brake

Pulse corder+5V

+24VF

End effector

Motor

Panel board

+24EC

RM

95

CR

M95

DC/DC+5V

CRS20Teach pendant +24T

Peripheral device +24F

+3.3V+5V +15V -15V +24E +24V

F1

F3

F4

FUSE2

+24E

DC/DC +5V, +3.3V +15V, -15V

FS1

FS3 Regenerative res. aux. axis

FS2

Breaker

+24E

CP5A

FUSE1

CP8B

JD1A

JD17

E-stop circuit

Power supplyI/O unit

CRS26

CA69A

RS-232-C

I/O LINK

RS-232-C/RS-485

FORCE SENSOR

SERVO CHECK I/F

200VAC １φ

CP1

+2.5V

200VAC １φ

(FU1)

JRL6VIDEO INPUT

24V→ 12V

Fig. 6.1 Block diagram of the power supply

CR

R88


- 210 -

6.2 TRANSFORMER Select a transformer and tap according to the supply voltage. Select a transformer tap among the rated voltage.

A-cabinet

Transformer specification Rated

voltage 13.0KVA 10.5KVA 7.5KVA 3KVA

500 to 575

440 to 500 TYPE E

380 to 415

A80L-0028-0024#A A80L-0026-0040#A A80L-0024-0028

200 to 230 TYPE D

380 to 400 A80L-0028-0027#A A80L-0026-0041#A A80L-0024-0029

B-cabinet

Transformer specification Rated

voltage 13.0KVA 10.5KVA 7.5KVA 3KVA

500 to 575

440 to 500 TYPE E

380 to 415

A80L-0028-0025 A80L-0028-0024 A80L-0026-0040 A80L-0024-0028

200 to 230 TYPE D

380 to 400 A80L-0028-0028 A80L-0028-0027 A80L-0026-0041 A80L-0024-0029


Transformer


- 211 -

Transformer

B-Cabinet (Back)

Fig.6.2 (a) Transformer mounting locations and structure


- 212 -

Cabinet side connector 1. TYPE E (500V-575V) 4. TYPE D (380V-400V)

2. TYPE E (440V-500V)

3. TYPE E (380V-415V)

5. TYPE D (200V-230V)

Circuit breaker

Dummy plug Dummy plug

Y connection cable

Dummy plug Dummy plug

Dummy plug

Dummy plug

Circuit breaker

Circuit breaker

Circuit breaker

Circuit breaker∆ connection

cable

(B-cabinet)

Y - ∆ connection unit

Circuit breakerY connection

cable

(A-cabinet)

Fig. 6.2(b) Setting the input voltage


- 213 -

1 Type E: 500V-575V Insert the connector connected to the circuit

breaker into connector LA and the dummy plug into connectors LB and LC.

2 Type E: 440-500V Insert the connector connected to the circuit breaker into connector LB and the dummy plug into connectors LA and LC.

3 Type E: 380-415V Insert the connector connected to the circuit breaker into connector LC and the dummy plug into connectors LA and LB.

4 Type D: 380-400V Insert the Y connection cable connected to the circuit breaker into connectors LA and LB.

5 Type D: 200-230V Insert the Δ connection cable connected to the circuit breaker into connectors LA and LB.

CAUTION The secondary voltage of the transformer depneds

on the cable connection between a breaker and a transformer. Be careful for the cable connection in the mainternance.


- 214 -

6.3 CHECKING THE POWER SUPPLY UNIT (A16B-2203-0910) The power supply unit need not be set or adjusted.

Table 6.3 Rating of the Power supply unit Output Rated voltage Tolerance

+5V +5.1V ±3% +3.3V +3.3V ±3% +2.5V +2.5V ±3% +24V +24V ±5% +24E +24V ±5% +15V +15V ±10% -15V -15V ±10%

DB1 : Diode stack

F1 (8.0A) : Fuse for AC input

VS1 : Surge absorber

H1 : Auxiliary power module

CP1 : Connector for AC input CP1A : Connector for AC output CP2, CP3 : Connector for AC output

F3 (7.5A) : Fuse for +24E F4 (7.5A) : Fuse for +24V PIL : LED (green)

CP5 : Connector for +24V CP6 : Connector for +24E ALM : LED (red) CP4 : Connector for control

Fig.6.3 (a) Interface of the power supply unit

B-82595EN-2/02 MAINTENANCE 7.REPLACING A UNIT

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7 REPLACING A UNIT This section explains how to replace each unit in the control section.

WARNING 1 Before you start to replace a unit, turn off the

control unit main power. Also keep all machines in the area of the control unit switched. Otherwise, you could injure personnel or damage equipment.

2 Before replacing components, read the maintenance manual to understand the replacement procedure. Performing an incorrect replacement procedure can lead to an unpredictable accident, resulting in breakage in the robot or personal injury.

3 When a heavy component or unit is to be handled, support the workers with a crane or the like not to apply excessive loads to the workers. Note that incorrect handling can cause serious injury to the workers.

CAUTION

Components in the control unit heat up, so care should be taken. When you have to touch a heated component, prepare a protector such as heat-resistant gloves.

7.REPLACING A UNIT MAINTENANCE B-82595EN-2/02

- 216 -

7.1 A-CABINET The following components of the A-cabinet can be removed.

7.1.1 Replacing the A-cabinet Top Panel Remove three M4 screws from the upper edge of the rear surface. Pull the top panel slightly backward, then lift it off.

Fig.7.1.1 Replacing the Top Panel

NOTE In case of the Rear fan type, replace the Top panel

after remove the Rear louver.

M4 screws (3 places)


- 217 -

7.1.2 Replacing the A-cabinet Rear Panel Remove the retaining M4 screws and four M10 bolts from the rear panel.

Fig.7.1.2 Replacing the Top Panel NOTE In case of the Rear fan type, replace the Rear

Panel after remove the Rear louver.


M10 bolts (4 places)


- 218 -

7.1.3 Replacing the A-cabinet Louver (a) Side fan type Loosen four retaining M4 screws from the louver, then remove the louver.

Fig.7.1.3 (a) Replacing the Louver (Side fan type)

(b) Rear fan type

Loosen four retaining M4 screws from the louver (the louver is fastened together with the rear panel), then remove the louver.

Fig.7.1.3 (b) Replacing the Louver (Rear fan type)


- 219 -

7.1.4 Replacing the A-cabinet Door Detach the cables from each unit (such as the fan unit) installed on the door. Lift the door off its hinges to dismount it.

Fig.7.1.4 Replacing the Door

Lift up the door

to mount it.


- 220 -

7.2 REPLACING THE PRINTED-CIRCUIT BOARDS

CAUTION When you replace printed-circuit boards, observe

the following cautions: 1 Keep the controller power switched off. 2 When you remove a printed-circuit board, do not

touch the semiconductor devices on the board with your hand or make them touch other components.

3 Make sure that the replacement printed-circuit board has been set up appropriately. (Setting plug etc.)

4 After replacing a printed-circuit board, make adjustments correctly if the board needs to be adjusted.

5 If the backplane board, power supply unit, or main board (including cards and modules) is replaced, it is likely that robot parameters and taught data are lost. Before you start to replace these components, save a backup copy of the robot parameters and taught data to an external memory device.

6 Before you disconnect a cable, note its location. If a cable is detached for replacement, reconnect it exactly as before.


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7.2.1 Replacing the Backplane Board (Unit) When replacing the backplane board, do so together with the plastic rack. (1) Detach the cables from the power unit and boards on the

backplane board.

CAUTION When you remove the main PC Board, be sure that

the battery is good (3.1-3.3VDC) and it is installed correctly. USE STATIC PROTECTION.

(2) Remove the power unit and boards from the rack. (See Section

7.2.2.) (3) Detach the grounding cable from the backplane unit. (4) Loosen the retaining screws in the upper section of the rack.

Remove the retaining screws from the lower section of the rack. (5) Side rack up and out. (6) To replace the backplane and rack, reverse steps (1) - (6).

CAUTION There is a possibility of data loss when a

backplane- mounted printed circuit board is replaced. Be sure to back up all program and setup data on an external device such as a memory card before proceeding.


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7.2.2 Replacing the Power Unit and Printed-Circuit Boards on the Backplane Unit

The backplane unit incorporates the power unit, main board, and option boards. There are two types of option boards: Full-size board and mini-size board. A full-size board occupies one slot. A mini-size board uses part of a full-size board.

CAUTION Before starting replacement, turn off the control unit

main power. The main board is equipped with battery-backed memory devices for holding robot parameters and taught data, for example. When the main board is replaced, the data in the memory devices is lost.

(1) Detach the cable from the power supply unit or the

printed-circuit board, whichever is to be replaced. (2) Pinch the barbed handles on the upper and lower sections of the

board to unlatch it, then pull it toward you. (3) Place the replacement board on the rail in the appropriate slot of

the rack, then push it in gently by the handles until it is latched. (4) There are two rails in the main board SLOT (slot 1). When

inserting the main board, align it to the right-side rail. (5) There are two rails in slots 3 (slots for a full-size option board).

When you insert a full-size option board, align it to the left-side rail.

Backplane board

Left rail Right rail

Fig.7.2.2(a) Replacing the backplane board


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SLOT 3 SLOT 2

SLOT 1

Handles

PSU (Power supply SLOT)

Handles

SLOT 1

Fig.7.2.2(b) Replacing the power unit and printed-circuit boards on the backplane unit


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7.2.3 Replacing the Panel Board The panel board is at the back of the operator panel. (1) Detach all cables from the panel board. The terminal blocks

(TBOP3, TBOP4, and TBOP6) are of a connector type. Pull out the upper terminal block sections.

(2) Remove four retaining screws from the panel board, and replace the panel board.

(3) Remove two M3 screws from the fixing sheet metal of the panel board, and remove the sheet metal.

(4) Attach the fixing sheet metal to a new panel board, and attach the new panel board to the operator panel.

A-cabinet


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Details of section A B-cabinet

Fig. 7.2.3 Panel board replacement


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7.2.4 Replacing the Process I/O Board EA,EB,FA,GA,KA,KB,KC (A-cabinet)

Fig. 7.2.4 Replacing the Process I/O Board



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7.3 REPLACING CARDS AND MODULES ON THE MAIN BOARD

CAUTION

Before you start to replace a card or module, make a backup copy of robot parameters and taught data. If the FROM/SRAM module is replaced, SRAM memory contents are lost.

Demounting a Card

(1) Pull outward the clip of each of the two spacers used to secure the card PCB, then release each latch.

(2) Extract the card upward.

Be sure to hold this part to pull out the card.

(2)

Card

Spacer

Connector

Fig. 7.3 (a) Demounting the card on the main board


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Mounting a Card (1) Check that the clip of each of the two spacers is latched outward,

then insert the card into the connector. (2) Push the clip of each spacer downward to secure the card PCB.

(1)

Be sure to hold this part to push the card.

Spacer

Connector

Connector

Be sure to hold this part to push the card.

Fig. 7.3 (b) Mounting the card on the main board


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Demounting a module CAUTION

When replacing the module, be careful not to touch the module contact. If you touch the contact inadvertently, wipe out dirt on the contact with a clean cloth.

(1) Move the clip of the socket outward. (a) (2) Extract the module by raising it at a 30 degree slant and pulling

outward.

Mounting a module (1) Insert the module at a 30 degree slant into the module socket,

with side B facing upward. (b) (2) Push the module inward and downward until it is locked. (c)

(a)

A

Details of section A

(b)

ADetails of section A

(c)

Fig.7.3 (c) Demounting/mounting a module


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Figure 7.3 (d) shows the locations of the cards and modules.

CPU card

FROM/SRAM module(Behind the axis control card)

Axis control card

Fig.7.3 (d) Locations of cards and modules


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7.4 REPLACING THE TRANSFORMER

WARNING The transformer is heavy. When replacing the

transformer, be careful not to cause injury. (The transformer weighs 45 to 60 kg.)

In case of A-cabinet Following (1) to (3) are not need for the remote type A-cabinet. For the remote type A-cabinet, start from (4). If the A-cabinet is connected to the robot, it will need to be separated. Cabinet separation (1) Disconnect the cable connectors and ground clamps coming from

the robot. These cables are generally at the following connectors on the Servo amplifier: CRF8, CNJ1 to 6, and CNJGA to CNJGC, and the ground cables.

Motor power cable

Pulse coder cableGrounding cable


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(2) Remove the four M10 robot retaining bolts that hold the cabinet to a robot.

(3) Being careful not to strain or break any cables, gently separate the

cabinet from the robot and it’s cables. (4) Disconnect the power cable from the transformer input connector

panel. (The power cable comes from the opration box. )

(5) Remove three M4 screws from the upper edge of the rear surface.

(Refer to a Fig.7.1.1) Remove the retaining M4 screws and four M10 bolts the rear panel. (Refer to a Fig.7.1.2)

Robot retaining boltsM10 (4 places)

Transformer input connector’s panel


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Following (6) to (7) are not need for the Rear fan type.

(6) Unscrew and Remove the regenerative resistor from the plate on the top of the transformer. (Refer to a Fig.7.5)

(7) Unscrew and Remove the plate on the top of the transformer.

(8) Remove four screws from a metal plate of connector’s panel, and

remove the metal plate.

A metal plate of connector’s panel

Screw Washer

Screw (M5) 3 places


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(9) Remove the two M6 screws holding the transformer in place and remove the transformer.

Screws (2-M6)

(10) Install a replacement transformer by reversing steps 1 through 9.


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In case of B-cabinet (1) Remove the screws and detach the back panel.


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(2) Detach the connectors of LA, LB, LC, OUT, and CPOH. If a cable is fastened with nylon ties, cut them with a diagonal

cutter to release the cable. Be careful not to damage the cable.

In case of TYPE E

In case of TYPE D

(3) Remove the retaining screws from the transformer terminal board

and remove the metal plate.

A



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(4) Remove the two retaining M6 screws from the transformer, then

remove the transformer.

(5) Install a replacement transformer by reversing procedure (1) to

(4).


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7.5 REPLACING THE REGENERATIVE RESISTOR UNIT

WARNING Before you start, turn off the controller main power.

Be careful not to get burned, because the regenerative resistor unit is very hot immediately after operation.

In case of A-cabinet (a) Remove the top panel from the A-cabinet. Remove the Louver

plate and the lower plate on the right side of the cabinet. (In case of the Rear fan type, remove the rear panel or fan unit.)

(b) Unplug connector CRR45 and CRR63 at the Servo amplifier. (c) Unscrew the cord grip nut inside the transformer compartment and

pull the cables through, being careful not to damage the connectors or cables.

(d) Unscrew the retaining screws on the regenerative resistor unit and

remove it. (e) Install the replacement unit by reversing this procedure (a) to (d).

CRR45 CRR63


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(Side fan type)

(Rear fan type)

Screw Washer

The type of the regenerative resistor varies with the model of the robot.

Transformer The cable is retained using a cord grip. Remove thecord grip, and pull out the cable. The cord grip isretained with nuts on the rear side. Remove the lowerright plate beforehand.

Screw (M4) 2 places

The type of the regenerative resistor varies with the model of the robot.

Transformer The cable is retained using a cord grip. Remove thecord grip, and pull out the cable. The cord grip isretained with nuts on the rear side. Remove the lowerright plate beforehand.


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In case of B-cabinet (a) Remove the servo amplifier. (See Section 7.6) (b) Remove the metal plate securing the cable of the regenerative

resistor unit. If a cable is fastened with nylon ties, cut them with a diagonal

cutter to release the cable. Be careful not to damage the cable.

A


Fig. 7.5 (a) Cable part of the regenerative resister (c) Of the two nuts fastening the regenerative resistor unit, remove

the upper nut, loosen the lower nut, then remove the regenerative resistor unit.

A


Fig. 7.5 (b) Regenerative resistor unit (d) Install a replacement regenerative resistor unit and a servo

amplifier by reversing the procedure (a) to (c).


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7.6 REPLACING THE E-STOP UNIT In case of A-cabinet NOTE

The magnetic contactor mounted in the emergency stop unit is turned on when the conditions are satisfied. While the controller is turned on, do not press the button on the magnetic contactor in any case. Otherwise, the contactor may be damaged.

E-stop unit (A-cabinet)

(a) Detach the cables from the emergency stop unit. (b) Remove retaining screws (M4 4 places) from the emergency stop

unit, and replace the emergency stop unit. (c) Reconnect the cables.

E-stop unit

4-M4 screws

Note) Do not press this switch in any case.


- 242 -

In case of B-cabinet NOTE

The magnetic contactor mounted in the emergency stop unit is turned on when the conditions are satisfied. While the controller is turned on, do not press the button on the magnetic contactor in any case. Otherwise, the contactor may be damaged.

E-stop unit (B-cabinet)

(a) Detach the cables from the emergency stop unit. (b) Of the four screws fastening the emergency stop unit, remove the

upper two screws, loosen the lower two screws, then replace the emergency stop unit.

(c) Reconnect the cables.

A Details of section A

Fig.7.6 Replacing the emergency stop unit

Note) Do not press this switch in any case.


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7.7 REPLACING SERVO AMPLIFIERS

WARNING Because the servo amplifier is heated immediately

after operation, leave the servo amplifier until it cools down thoroughly, before replacing it.

In case of A-cabinet A servo amplifier can be dismounted by pulling it out from the side, using its rail. Only a flat-head screwdriver is required, provided that servo amplifier SHIPPING screws have been removed. These screws are intended to prevent damage to the servo amplifier during shipment. (a) Make sure that servo amplifier shipping screws (2 phillips head)

have been removed. Retain screws for shipping purposes. (b) Check the voltage at the screw above the LED "D7" with a DC

voltage tester to see if the remaining voltage is not higher than 50V.


(c) Detach the cables from the servo amplifier. Pull out the detected

cables away from the amplifier toward you so that they will not be caught when it slides along the rail.


- 244 -

(d) Unlock the servo amplifier by rotating the quarter-turn screws on the outside surface of the plate using a coin or the like.

(e) Hold the upper and lower handles, and pull out the servo amplifier

slowly. Be sure that all cables are unplugged from the servo amplifier before you try to remove the servo amplifier. After pulling the servo amplifier a little, check again that it is all right to continue to pull the servo amplifier. Be careful not to let the servo amplifier slide off the rail.

(f) Place a replacement servo amplifier on the rail, slide it in gently

untill it is hooked on the guide pins. (g) Rotate the quarter-turn screws on the outside surface of the plate

to lock the servo amplifier. (h) Reconnect the cables.

Unlock Lock

Servo amplifier shipping screws (M5, 2 places)

Quarter-turn screws (4 places)


- 245 -

Rail

Handles

Guide pin

Guide pin


- 246 -

In case of B-cabinet (a) Detach the amplifier cover, and pull out the cable.



- 247 -

(b) Check the voltage at the screw above the LED "D7" with a DC voltage tester to see if the remaining voltage is not higher than 50 V.



- 248 -

(c) Turn the retaining pin at the top of the amplifier 90 degrees counterclockwise. (At the middle of the top of the amplifier, there is an M5 screw that fastens the amplifier during transport of the cabinet. After the installation of the cabinet, remove the screw.

This improves maintainability.)

Fixation screw for transport


- 249 -

(d) Holding the handles located at the top and bottom of the amplifier, pull out the amplifier toward you.

(e) Pull the amplifier up while keeping it slanted.


- 250 -

7.8 REPLACING I/O Unit-MODEL A

7.8.1 Replacing the Base Unit of I/O Unit-MODEL A First dismount the modules from the base unit of I/O Unit-MODEL A. The base unit is retained with 4 screws. Of these screws, loosen the upper 2 screws and remove the lower 2 screws, then replace the base unit.


Fig.7.8.1 Replacing the base unit of I/O unit model A


- 251 -

7.8.2 Replacing a Module An interface module and input/output module can be easily installed in and removed from the base unit, as described below.

Installing a module (a) Put the upper hook of the module into the upper hole of the base

unit. (b) Fit the connectors of the module and the base unit to each other. (c) Push the module until the lower stopper of the module is caught

in the lower hole of the base unit.

Removing a module (a) Press the lever at the bottom of the module to release the stopper. (b) Lift the module up.

Fig.7.8.2 Replacing the module


- 252 -

7.9 REPLACING THE TEACH PENDANT and i PENDANT The specifications of the teach pendant vary with its use. When you replace the teach pendant, check its specifications carefully. (1) Be sure that the power of a robot controller is off. (2) Detach the cable from the teach pendant. (3) Replace the teach pendant.

Detach or attach the cable by rotating theconnector retaining ring.

Fig.7.9 Replacing the teach pendant


- 253 -

7.10 REPLACING THE CONTROL SECTION FAN MOTOR The control section fan motor can be replaced without using a tool. The fan motor is mounted on the fan unit rack. (1) Be sure that the power of a robot controller is off. (2) Put your finger in the dent in the upper section of the fan unit,

and pull the fan unit until it is unlatched. (3) Lift the fan unit slightly, and dismount it from the rack. (4) Place a replacement fan on the upper section of the rack, and

slide it gently until it is latched.

Fan motor

Pull the fan motorunit toward you tounlatch it.

Fan motor connector

Dent

Fig.7.10 Replacing the control section fan motor


- 254 -

7.11 REPLACING THE AC FAN MOTOR

WARNING Do not touch the fan motor when it is rotating, or

you could be injured.

7.11.1 Replacing the Heat Exchanger and Door Fan Unit (A-cabinet) The heat exchanger of the A-cabinet is inside its door. To replace the heat exchanger, it is necessary to remove the door fan unit in advance. Door fan unit (1) Remove retaining screws (M4, 4 places). (2) Detach the cable from the heat exchanger. (3) Mount the replacement fan unit by reversing the removal

procedure. Be careful not to let the cable get caught in the fan. Heat exchanger (1) Dismount the fan unit from the door. (See the above procedure.) (2) Open the A-cabinet door, and detach cables. (3) Remove retaining nuts (M5, 4 places), and dismount the unit. (4) Mount the replacement heat exchanger by reversing the

dismounting procedure.

Door fan unit Screws (4-M4)


- 255 -

7.11.2 Replacing External Air Fan Unit (A-cabinet) The external air fan unit has two fans mutually connected with a cable. When the fan unit is replaced, the cable is replaced together with the fan unit. (1) Loosen the retaining screws of the louver, then remove it (see

Section 7.1.3) (2) In case of the Side fan type, detach the fan unit. (The fan is

fastened together with the louver.) In case of the Rear fan type, loosen four retaining M4 screws from the Rear fan unit, and then detach the fan unit.

(3) Detach the fan unit lead-out cable and grounding wire. (The cable is terminated with a connector. The grounding wire is fastened with a screw.)

(4) Replace the fan unit with a new one.

(Side fan type)

Nuts (4-M5)

Heat Exchanger

The fan cable is attached using an in-line connector.

Screws (4-M4) used to fasten both the fan unit and louver.


- 256 -

(Rear fan type)

7.11.3 Replacing External Air Fan Unit and Door Fan (B-cabinet)

Door fan

(1) Detach the cable from the fan unit. (2) Remove the retaining screws from the fan unit, then dismount it. (3) Install a new fan unit by reversing the dismounting procedure.

(Replacing the Door Fan Unit)

Screws M4 (4 places)


- 257 -

External Air fan unit (1) Detach the cable connecting the fan unit. (2) Remove the screws and pull out the fan unit toward you. (3) Install a new fan unit by reversing the dismounting procedure.

(Replacing the Air Fan Unit)


- 258 -

7.12 REPLACE THE MODE SWITCH (a) Remove the cable from the mode switch. (b) Remove the screws fastening the mode switch, and replace the

mode switch.

NOTE 1 When mounting the mode switch, do not

overtighten the screws. (Tightening torque: 0.3 N⋅m)

2 Tighten the screws evenly so that the mode switch flat surface becomes parallel- to the sheet metal.

Fig. 7.12 (a) Replacing the mode switch (1/3)

Fig. 7.12 (b) Replacing the mode switch (2/3)

Mode switch


- 259 -

A

Tightening torque:0.3N⋅m


(Back plane of operator’s panel)

Fig. 7.12 (c) Replacing the mode switch (3/3)


- 260 -

7.13 REPLACING FUSES If a fuse in the control unit has blown, find the cause and take an appropriate measure before replacing the fuse.

7.13.1 Replacing Fuses in the Servo Amplifier The following fuses are in the servo amplifier. FS1: For generation of the power to the amplifier control circuit

(A60L-0001-0290#LM32C) FS2: For protection of the 24 V output to the end effector, ROT,

and HBK (A60L-0001-0290#LM32C) FS3: For protection of the 24 V output to the regenerative

resistance and the additional axis amplifier (A60L-0001-0290#LM50C)

5A

3.2A 3.2A

CRR88

Fig.7.13.1 Replacing fuses in the servo amplifier


- 261 -

7.13.2 Replacing Fuses in the Power Unit The following fuses are in the power unit. F1: Fuse for the AC input, A60L-0001-0450#8RO F3: Fuse for protecting the +24E output, A60L-0001-0046#7.5 F4: Fuse for protecting the +24V output, A60L-0001-0046#7.5

F1 8.0A

Fuse for AC input

F3 7.5A

Fuse for +24E

F4 7.5A

Fuse for +24V


Details of section B

Fig.7.13.2 Replacing fuses in the power unit


- 262 -

7.13.3 Replacing Fuses in the Main board The following fuses are in the power unit. FU1: For protection of the +12V output for the vision sensor, A60L-0001-0175#0.5A

75173 (Receiver)

75172 (Driver)

CPU card

FROM/SRAM module


Axis control card

FU1 Fuse(0.5A)


Fig.7.13.3 Replacing fuses in the main board


- 263 -

7.13.4 Replacing the Fuse on the Process I/O Boards The following fuse is on each process I/O board. FUSE1: Fuse for protecting the +24V output for peripheral equipment interfaces. A60L-0001-0046#2.0

Process I/O board CA

Fig. 7.13.4 (a) Process I/O board CA

Process I/O board EA, EB Fuse location is common to EA and EB.The following is figure of EA.

Fig. 7.13.4 (b) Process I/O board EA, EB


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Process I/O board FA

Fig. 7.13.4 (c) Process I/O board FA

Process I/O board GA

Fig. 7.13.4 (d) Process I/O board GA


- 265 -

Process I/O board HA

Fig. 7.13.4 (e) Process I/O board HA

Process I/O board JA, JB

Fuse location is common to JA and JB.The following is figure of JA.

FUSE (2A)

Fig. 7.13.4 (f) Replacing the fuse on the process I/O boards


- 266 -

Process I/O board KA, KB, KC Fuse location is common to KA, KB and KC. The following is figure of KA.

FUSE1 LED

Fig. 7.13.4 (g) Process I/O Board KA


- 267 -

7.13.5 Replacing the Fuse on the Panel Board The following fuse is on the panel board. FUSE1 : For protection of the +24EXT line (emergency stop line) FUSE2 : For protection of the teach pendant emergency stop line A60L-0001-0046#1.0

(Panel board)

Fig.7.13.5 Replacing the fuse on the panel board

FUSE2 (1A) FUSE1 (1A)


- 268 -

7.14 REPLACING RELAYS Prolonged use of a relay might result in its contacts failing to make a secure connection or sticking to each other permanently. If such a failure occurs, replace the relay.

7.14.1 Replacing Relays on the Panel Board KA21, KA22 : Relay for emergency stop circuit A58L-0001-0192#1997R

Fig.7.14.1 Replacing relays on the panel board

KA22 KA21


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7.15 REPLACING BATTERY

7.15.1 Battery for Memory Backup (3 VDC) The programs, and system variables are stored in the SRAM in the main board. The power to the SRAM memory is backed up by a lithium battery mounted on the front panel of the main board. The above data is not lost even when the main power of controller is turned off. A new battery can maintain the contents of memory for about 4 years (Note). When the voltage of the battery becomes low, the low-voltage battery alarm (system-035) is displayed on the teach pendant. When this alarm is displayed, replace the battery as soon as possible. In general, the battery can be replaced within one or two weeks, however, this depends on the system configuration. If the battery voltage gets lower, it becomes impossible to back up the content of the SRAM. Cycling power to the controller in this state causes system not to start, and LED located on the main board displays "1" because the contents of memory have been lost. Clear the entire SRAM memory and reenter data after replacing the battery. Important data should be saved to the memory card or other external device beforehand in case of emergency.

NOTE In a newly introduced robot, the battery is

factory-installed. Battery replacement may, therefore, be needed within 4 years after the introduction of the robot.


- 270 -

Replacing the lithium battery (1) Prepare a new lithium battery (ordering drawing number:

A02B-0200-K102). (2) Turn the robot controller on for about 30 seconds.

CAUTION Complete the steps (3) to (5) within 30 minutes. If the battery is left disconnected for a long time,

the contents of memory will be lost. To prevent possible data loss, it is recommended

that the robot data such as programs and system variables be backed up before battery replacement.

(3) Turn the robot controller off. (4) Remove the old battery from the top of the main board. First unlatch the battery, remove it from the battery holder, and

detach its connector.

Battery connector

Lithium battery

Battery latch

(5) Remove the old battery, insert a new one into the battery holder,

and attach the connector. Confirm that the battery is latched firmly.


- 271 -

WARNING Using other than the recommended battery may

result in the battery explosion. Replace the battery only with the specified battery

(A02B-0200-K102). Dispose of the replaced battery as an industrial waste, 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.

8. HOW TO USE THE PLATE TO FIX THECOMPACT FLASH MEMORY CARD

MAINTENANCE B-82595EN-2/02

- 272 -

8 HOW TO USE THE PLATE TO FIX THE COMPACT FLASH MEMORY CARD

Optional plate to fix the compact flash memory card (CF card) can make it possible to perform a back-up on fixing the CF card on the mainboard. Parts ・ Fixing plate ・ Adapter for CF card (made by fanuc)

2. Fixing plate

Main board

Compact flash memory card (The card is not included. It must be supplied by the customer.)

1. Adapter for CF card (made by fanuc)

8. HOW TO USE THE PLATE TO FIX THECOMPACT FLASH MEMORY CARD

B-82595EN-2/02 MAINTENANCE

- 273 -

Installation of the CF card

Removal of the CF card

1. Insert the CF card into the

Adapter.

2. Lock the latch, and drive the

screw.

1. Loosen the screw, and unlock the latch.

2. Pull the CF card out of the

Adapter.

III. CONNECTIONS

B-82595EN-2/02 CONNECTIONS 1.GENERAL

- 277 -

1 GENERAL This section describes the electrical interface connections in the R-30iA. It also includes information about installation of the R-30iA.

2.BLOCK DIAGRAM CONNECTIONS B-82595EN-2/02

- 278 -

2 BLOCK DIAGRAM Fig.2 is a block diagram of electrical interface connections with the R-30iA.

R-30iA (A-cabinet)

Mechanical unit

Pneumatic pressure source

End effector

Operation box

USB memory (Note2)

Teach pendant

RS-232-C (Note3)

Ethernet

Peripheral device

Welding machine

AC power supply

Memory card (PCMCIA)

Fig.2 (a) Block Diagram of Electrical Interface Connection (A-cabinet)

NOTE 1 : Indicates electrical connection. -------- : Indicates mechanical connection. 2 In case the length of the connection cable between

A-cabinet and Operation box is 10m or longer, there is the USB interface panel and RS-232-C interface on the A-cabinet.

3 For more information, contact our service section.

B-82595EN-2/02 CONNECTIONS 2.BLOCK DIAGRAM

- 279 -

R-30iA B-cabinet Pneumatic

pressure source

Mechanical unit End effector

USB memory

Memory card(PCMCIA)

RS-232-C

Teach pendant

Peripheral device

Ethernet

Welding machine

AC power supply

Fig.2 (b) Block Diagram of Electrical Interface Connection (B-cabinet)

NOTE 1 : Indicates electrical connection. -------- : Indicates mechanical connection. 2 For more information, contact our service section.

3.ELECTRICAL CONNECTIONS CONNECTIONS B-82595EN-2/02

- 280 -

3 ELECTRICAL CONNECTIONS

B-82595EN-2/02 CONNECTIONS 3.ELECTRICAL CONNECTIONS

- 281 -

3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS

Fig.3.1 (a) Mechanical connection diagram

NOTE 1 This cable is not included. It must be supplied by

the customer.

R-30iA

Robot RP1 (Pulse coder, RI/RO , HBK, ROT) RM1 (Motor power/brake)

RM2 (Motor power)

Servo amplifier

CRF8(Pulse coder, RI/RO,

HBK, ROT)

CNJx (Motor power)

CNGx (Ground)

CRR88 (Brake control)

(Note1)

RCC I/F UNIT (M-900iA ONLY)

EEEnd effector


- 282 -

Note 2

Note 2

Note 2

Note 2

Note 2

Note 2

R-30iA

(Panel board)

USB memory

(Process I/O)

Teach pendant

Peripheral device

Ethernet

(Main board)

Panel board (TBOP3) External power

ON/OFF switch

External device

Input power

External emergency stop switch

Fence

Servo off switch

Port A (Operator's panel)

(Main board)

Circuit breaker

Panel board (TBOP4)

Panel board (TBOP4)

Panel board (TBOP4)

Fig.3.1 (b) Mechanical connection unit

NOTE 1 For detail of the peripheral device connection,

see the section of Peripheral device interface. 2 This cable is not included. It must be supplied by

the customer.


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3.2 EXTERNAL CABLE WIRING DIAGRAM

3.2.1 Robot Connection Cables

CAUTION Before operating the robot, uncoil the

interconnection cables from their shipping position to prevent excessive heat, which may damage the cables. (Coiled part should be shorter than 10 meter.)

There are two types of the robot connection cable; Non-flex type: usage is restricted to fixed laying Flex type: possible to use in the cable track

Specification of cable Non-flex type Flex type

Robot Diameter (mm)

Weight (kg/m)

Minimum bending radius (mm)

Diameter (mm)

Weight (kg/m)

Minimum bending radius (mm)

RP1 All models 15.7 0.45 200 20.5 0.71 200 Group 1 26.1 1.22 200 25.4 1.2 200 Group 2 20.0 0.7 200 18.4 0.7 200 Group 3 26.1 1.22 200 25.4 1.2 200 Group 4 26.1 1.22 200 25.4 1.2 200 Group 5 26.1 1.22 200 25.4 1.2 200

RM1

Group 6 20.0 0.7 200 - - - Group 3 26.1 1.22 200 25.4 1.2 200 Group 4 26.1 1.22 200 25.4 1.2 200 RM2 Group 5 26.1 1.22 200 25.4 1.2 200

RP1 15.7 0.45 200 - - - RM1

Group 7 20.0 0.7 200 - - -

RP1 14.2 0.31 200 20.5 0.71 200 RMP1

RM1 Group 8

20.0 0.7 200 18.4 0.7 200 EARTH All models 4.7 0.065 200 4.7 0.065 200

Group1 R-2000iB (except /200T), M-420iA, M-421iA M-710iC Group2 ARC Mate 100iB, ARC Mate 120iB, M-6iB, M-16iB, F-200iB Group3 R-2000iB/200T, M-410iB Group4 M-900iA/260L,M-900iA/350 Group5 M-900iA/600 Group6 M-430iA/2F Group7 M-430iA/2P Group8 ARC Mate 100iC,M-10iA


- 284 -

Using condition of flex type cable (1) When routing cables in movable places, use a cable bearer. (2) The bending radius (R) of the cable track is more than 200mm. (3) The cable should be fixed to the cable track by using the clamp.

(e.g. rubber packing) (4) The size of the hole to support a cable in the cable track should

be more than 110% of the cable size and should have the gap more than 3mm.

(5) When cables are laid in the cable track, pay attention for the cable not to be twisted.

Robot Model Group1:R-2000iB (expect /200T), M-420iA, M-421iA M-710iC Group2:ARC Mate 100iB, ARC Mate 120iB, M-6iB, M-16iB, F-200iB

In case of A-cabinet

RI,RO,HBK,ROT

(Connection A-cabinet and Robot)


- 285 -

In case of B-cabinet

RI,RO,HBK,ROT

(Connection B-cabinet and Robot)

- Detail of cable connection to servo amplifier.

Fig. 3.2.1 (a) Robot connection cable (Group1, Group2)

R-30iA(Servo amplifier)

Robot RP1 (Pulse coder, RI/RO, HBK, ROT)

RM1 Motor power/brake (J1M, J2M, J3M, J4M, J5M, J6M, BK)

CNJ2A CNJ4 CNJ5CNJ1A

CRR88 CNGA CNJ3A

CNGC

CRF8

CNJ6


- 286 -

Robot Model Group3:R-2000iB/200T, M-410iB In case of A-cabinet

RI,RO,HBK,ROT



- 287 -


RI,RO,HBK,ROT (Connection B-cabinet and Robot)


Fig. 3.2.1 (b) Robot connection cable (Group3)




RM2 Motor power (J1M, J2M, J3M)

CNJ2B CNJ1B

CNJ3B

CNJ1A

CRR88 CNGA CNJ3A

CNGC

CRF8

CNJ6

CNJ2A CNJ4 CNJ5

CNGB


- 288 -

Robot Model Group4:M-900iA/260L, M-900iA/350 In case of B-cabinet



Fig. 3.2.1 (c) Robot connection cable (Group4)




RM2 Motor power (J1M, J2M, J3M)

CNJ1B CNJ2B

CNJ3B

CNJ1A

CRR88 CNGA CNJ3A

CNGC

CRF8

CNJ6

CNJ2A CNJ4 CNJ5

RM

1A

RM

1B

RM

2A

RCC I/F UNIT

CNGB


- 289 -

Robot Model Group5:M-900iA/600 In case of B-cabinet



- 290 -


Fig. 3.2.1 (d) Robot connection cable (Group5)

R-30iA 6-Axis Servo amplifier (AMP1) 2-Axis Servo amplifier (AMP2) 1-Axis Servo amplifier (AMP3)



RM2 Motor power (J1M, J2M, J3M, J4M, J5M, J6M)

CNJ3A

CNJ1A

CNJ1B

CRR88 CNGA

CNJ2A

CNJ2B

CNJ3B

RM

1A

RM

1B

RM

2A

RCC I/F UNIT

CRF8

CZ2 JF

CZ2L

CZ2M JF2

JF1

CNGB


- 291 -

Robot Model Group6:M-430iA/2F In case of A-cabinet

RI,RO,HBK,ROT



- 292 -


RI,RO,HBK,ROT


Detail of cable connection to servo amplifier.

Fig. 3.2.1(e) Robot Connection Cable（Group6）



RM1 Motor power/brake (J1MA, J1MB, J2MA, J2MB, J3MA, J3MB, J4M,, J5M, J6M, BK) CNJ2A CNJ4 CNJ5CNJ1A

CRR88 CNGA CNJ3A

CNGC

CRF8

CNJ6

Servo amplifier

CZ2M

JF1

JF2

CZ2L


- 293 -

Robot Model Group7:M-430iA/2P In case of A-cabinet

RI,RO,HBK,ROT



- 294 -


RI,RO,HBK,ROT



Fig. 3.2.1(f) Robot Connection Cable（Group7）


Robot RMP1 (Pulse coder, RI/RO, HBK, ROT)

Motor power/brake

CNJ5CNJ1A

CRR88 CNGA CNJ3A

CRF8

Servo amplifier

CZ2M

JF2

JF3

CZ2L

CZ2N

JF1


- 295 -

Robot Model Group8: ARC Mate 100iC,M-10iA In case of A-cabinet

RI,RO,HBK,ROT



- 296 -


RI,RO,HBK,ROT



Fig. 3.2.1(g) Robot Connection Cable（Group8）


Robot RMP1 (Pulse coder, RI/RO, HBK, ROT)

Motor power/brake

CNJ2A CNJ4 CNJ5CNJ1A

CRR88 CNGA CNJ3A

CRF8

CNJ6


- 297 -

3.2.2 Teach Pendant Cable

(A-cabinet)

Panel board

Teach pendant

Teach pendant cable

(B-cabinet)

Fig.3.2.2 Teach pendant cable

Teach pendant

Panel board

Teach pendant cable


- 298 -

3.2.3 Connecting the Input Power Considering the robot power capacity and the circuit breaker capacity, connect the power supply whose voltage conforms to the installation conditions to the terminal located above the circuit breaker. Provide a class-D or better ground.

CAUTION Disconnection of protective earth ground may

impair the protection provided by the system. There shall be no switches or disconnects in the grounding conductor. The resistance to the ground must not exceed 100Ω. Use a thick wire to withstand the maximum current used. Selection of an input transformer tap is necessary depending on the input voltage. The tap is set to the specified voltage before shipment. However, check it referring to section 6.2 in "Maintenance" before supplying power (before the breaker switch is turned on). The motor is driven by the PWM inverter system using a power transistor bridge. If the servo amplifier is used without a transformer, a high-frequency leakage current flows through the stray capacitance between the ground and the motor coils, power cable, and amplifier. This might cause the leakage-current circuit breaker or leakage-protection relay installed in the path of the power supply to cut out. Use the following leakage current circuit breaker for inverters to prevent incorrect operation.

Example of leakage current circuit breaker for inverters Manufacture Type

Fuji Electric Co., Ltd. EG A series or later SG A series or later

Hitachi, Ltd. ES100C type ES225C type

Matsushita Electric Works, Ltd.

Leakage current circuit breaker, C type Leakage current circuit breaker, KC type

Fig.3.2.3 shows the cable connection.


- 299 -

(A-cabinet)

(Note) Always replace the cover after completing Input Power supply

(B-cabinet)

Fig.3.2.3 Input power supply connection (B-cabinet)

Input power supply cable

(Note) Always replace thecover after completing


- 300 -

NOTE On/off timing by the breaker If the power supply is turned on, turned off, and then turned on again repeatedly in a short time, the controller may not be started up. If the power is turned off before the controller is completely started up (it takes about 30 seconds), wait for at least 10 seconds before turning on the power again.

OFF

ON

TOFF-ON ≥ 10 secTON-OFF ≦ 30 sec

The power is turned off within 30 seconds after it has been turned on.


- 301 -

3.2.4 Connecting the External Power Supply ON/OFF Switch

(A-cabinet)

Panel board

(B-cabinet)

Fig.3.2.4 (a) Connection of the external power supply ON/OFF switch

Panel board

TBOP3


- 302 -

Contact specifications Withstand voltage: 50VDC (across contacts) Current: 100mA min. (min. load 2mA)

When using the external ON/OFF switch, remove the short-circuit plate between EXOFF1 and EXOFF2, and attach the cable to these terminals.

Short–circuit plate : between EXON1 and EXON2

EXON1EXON2

EXOFF1EXOFF2

CloseEXOFF1-2

POWER OFF

ON

Open

TOFF-ON ≥ 5 sec

NOTE 1 When the external power supply ON/OFF switch is

set to ON (closed), the controller can be turned on and off by using the circuit breaker.

2 When the external power supply ON/OFF switch is set to OFF (open), the controller cannot be turned on and off by using the circuit breaker.

Fig.3.2.4 (b) Connection of the external power supply switch ON and OFF


- 303 -

3.2.5 Connecting the External Emergency Stop

(A-cabinet)

Panel board

(B-cabinet)

Fig.3.2.5 (a) Connection of the external emergency stop

Panel board

TBOP3

TBOP4

TBOP6


- 304 -

External emergency stop output

Panel board

For the circuit, see Figure A (e) in Appendix A, "TOTAL CONNECTION DIAGRAM". The SVOFF input signal does not affect EMGOUT

Signal Description Current, voltage Min. load ESPB1 ESPB11 ESPB2 ESPB21 ESPB3 ESPB31 ESPB4 ESPB41

Emergency stop output signals. The contact is open if an emergency stop occurs or the power is turned off. The contact is closed during normal operation.

Rated contact: 250 VAC, 5-A resistor load 300 VDC, 5-A resistor load

(Reference value)DC5V 10mA

ESPB1

ESPB11

ESPB2

ESPB21

ESPB3

ESPB31

ESPB4

ESPB41


- 305 -

ESPB1 ESPB11ESPB2 ESPB21


Internal circuit

+24EXT

0EXT

0EXT +24EXT

TP emergency stop button

KA21

KA22

Control

circuit


Example of the connection with the safety relayRobot controller Safety relay unit

Contact output signal ensured safety

WARNING In case of using the contact of theemergency stop output signal, besure to pair ESPB1 with ESPB2,and ESPB3 with ESPB4. Robot controller does not detectthe breakdown of the contact ofthe emergency stop output signal.Take countermeasures such asinspecting the duplicatedcontacts, or using a safety relaycircuit that can detect thebreakdown.

Operator panel emergency stop button


- 306 -

External emergency stop input External emergency stop switch

Fence

Servo ON/OFF input switch

Servo disconnectswitch signal

These terminals are factory-jumpered. When using external emergency stop inputs, remove the short-circuit plate.

EG

S21

EG

S2

EG

S11

EG

S1

EA

S21

EA

S2

EA

S11

EA

S1

EE

S21

EE

S2

EE

S11

EE

S1

SD4SD41SD5SD51

Signal Description Current, voltage EES1 EES11 EES2 EES21

Connect the contacts of the external emergency stop switch to these terminals. When a contact is open, the servo power supply is turned off, and the robot is immediately placed in the emergency stop state. When using the contacts of a relay or contactor instead of the switch, connect a spark killer to the coil of the relay or contactor, to suppress noise. When these terminals are not used, jumper them.

Open and close of 24VDC 0.1A (Note 1)


These signals are used to stop the robot safely when the safety fence gate is opened during operation in the AUTO mode. When a contact is open, the robot decelerates then stops, and the servo power supply is turned off. In the T1 or T2 mode, the robot can be operated even when the safety fence gate is open. When using the contacts of a relay or contactor instead of the switch, connect a spark killer to the coil of the relay or contactor, to suppress noise. When these terminals are not used, jumper them.



Connect the contacts of the servo-off input switch to these terminals. When a contact is open, the robot decelerates then stops, and the servo power supply is turned off. When using the contacts of a relay or contactor instead of the switch, connect a spark killer to the coil of the relay or contactor, to suppress noise. When these terminals are not used, jumper them.



- 307 -

Signal Description Current, voltage SD4 SD41 SD5 SD51

Connect the contacts of the servo disconnect switch to these terminals. When a contact is open, the servo power supply is turned off, and the robot stops immediately. When using the contacts of a relay or contactor instead of the switch, connect a spark killer to the coil of the relay or contactor, to suppress noise. When these terminals are not used, jumper them.


NOTE 1 Use a contact which minimum load is 5 mA less.

EES1

EES11

EES2

EES21

Examples of connection of duplicate safety signals


EES1

EES11

EES2

EES21


Correct connection

Discrepancy in duplicate inputs results in an alarm.

Wrong connection

Input timing of duplicate safety signals

Duplicate inputs are used for signals such as the external emergency stop signal, safety fence signal, and servo off signal so that a response is made even when a single failure occurs. The statuses of these duplicate input signals must always be changed at the same timing according to the timing specifications provided in this section. The robot control unit always checks that the statuses of the duplicate inputs are the same, and if the control unit finds a discrepancy, it issues an alarm. If the timing specifications are not satisfied, an alarm may be issued because of a signal discrepancy.


- 308 -

Open

Close EES1 EAS1 EGS1 SD4

EES2 EAS2 EGS2 SD5

TDIF

TOPEN

TOPEN

TDIF

TDIF (input time difference)< 200msec

Open

Close

TOPEN (input hold period) > 2sec

Fig. 3.2.5(b) Input timing of duplicate safety signals


- 309 -

External power connection

The relays for emergency stop input and output can be separated from controller’s power.Please connect external +24V instead of internal +24V,if emeregency stop output must not be effected controller’s power.

EXT24V INT24V INT0V EXT0V

Example of the connection

In case of not using the external power source

In case of using the external power source

EXT24VINT24V INT0V EXT0V

24V

0V

External power source

+24V(±10%) more than 300mA

EXT0V EXT24V

External power source +24V(±10%)

more than 300mA

EXT

0V 24V INT


- 310 -

Connecting external on/off and external emergency stop signal input/output wires

FANUC's specification Manufacturer's specification (WAGO)

Remark

8-pole terminal block (TBOP3)

A63L-0001-0783#308 231-311/026-000 External emergency stop

12-pole terminal block (TBOP4,6)

A63L-0001-0783#312 231-304/026-000 External ON/OFF

Jumper pin A63L-0001-0783#902 231-902 Operation lever A63L-0001-0783#131-M 231-131 2 pieces of 231-131 and operation

manual are included in FANUC's specification

1. Detach the plug connector block from the panel board. 2. Insert the tip of a flat-blade screwdriver into the manipulation

slot and push down its handle. 3. Insert the end of the signal wire into the wire slot. 4. Pull out the screwdriver. 5. Attach the plug connector block to the panel board. Do not insert a wire into the wire hole of a plug connector or pull

it out with the plug connector block mounted on the panel board; otherwise, the panel board may be damaged.

FANUC recommonds the lever (A05B-2400-K030) for connecting the signal wire to the plug connector block instead of Flat-blade screwdriver.

Manipulation slotFlat-blade screwdriver

Signal wire



- 311 -

(1) Pull down the lever.

(2) Push in the conductor while

holding the lever.

(3) Set the lever free. * And pull the conductor softly to

check the clamping.

* Don't pull strongly.

Wiring


- 312 -

(1) Pull off the lever. Be careful not

to lose the lever.

(2) Hook the lever to the rectangle

hole.。

(3) Push down the lever untill click in.

(1) Push in the connector to header.

* Be careful to fit theshape of each other.

(2) Please check if the latch is hooked to header.

(1) Attach levers to connector.

(2) Hold down levers at the same time,

then put the jumper into connector.

* Please check the direction of the

jumper.

Replace the lever

Fit to header

Installation of "Jumper"


- 313 -

- Without jumpers

* Max wire size 0 2.0mm2 (AWG14)

(with "Ferrule")

- With jumper

- Additional wire is available under the

jumper. * Max wire size 0 0.5mm2 (AWG20)

(with "Ferrule")

- With two jumpers

- Additional wire is not available

under the jumper.

(1) Put the wire through thehole of ferrules.

(2) Introduce wire with ferruleinto cramping station.

(3) Squeeze handles untilratchet mechanism isreleased.

(4) Please check ifthe wire crimpedcorrectly.

Crimping Toole (Specification : WAGO Item-No.206-204)

WAGO

Item-No. Wire size

mm2 Color Stripped Length (mm)

L L1 D (mm)

D1 D2 Pack.-unit pcs

216-301 216-302 216-201 216-202 216-203 216-204 216-205

0.25 0.34 0.5 0.75 1.0 1.5 2.0

light yellow light green white gray red black yellow

9.5 9.5 9.5

10.0 10.0 10.0 10.0

12.512.514.014.014.014.014.0

8.08.08.08.08.08.08.0

2.5 2.5 3.1 3.3 3.5 4.0 4.2

2.0 2.0 2.6 2.8 3.0 3.5 3.7

0.8 0.8 1.0 1.2 1.4 1.7 2.0

100 100 100 100 100 100 100

CAUTION Please make sure to use WAGO 206-204 to crimp the ferrules.

Availability of wires

Installation of "Ferrules"

Specifications of Ferrules


- 314 -

3.2.6 Connecting the Non-Teaching Enabling (NTED) Signal (CRM65)

Fig. 3.2.6 Connecting the NTED Signal

NTED signal is the signal to be able to connect with the switch that is same function as deadman switch on the teach pendant.In the auto mode, robot moves without reference to the state of the switch connected with NTED signal. Refer to “APPENDIX A,Total connection Diagram Fig.A(e)” about NTED circuit. Input timing of NTED signal must comply with rules in the section “Input timing of duplicate safety signals”. NOTE

After connnecting NTED switch, be sure to check the operation of those switches, the emergency stop button on the operator’s panel/operation box, and the emergency stop button on the teach pendant.

CRM65 (NTED)


- 315 -

CRM65 connector A1 NTED1 B1 NTED2 A2 NTED11 B2 NTED21 A3 B3

NTED signal connector manufactured by Tyco Electronics AMP k.k. ( Specification Rece-housing 1-1318119-3

Rece-contact 131807-1）

NTED1 NTED11NTED2 NTED21

Enabling Device


- 316 -

3.2.7 Connecting the Auxiliary Axis Brake（CRR65 A/B）

Fig.3.2.7 6-axis servo amplifier

CRR65 A/B A1 BKA1 B1 BKA2 A2 B2 A3 COMMON B3 COMMON

CRR65 A/B connector manufacutured by Tyco Electronics AMP k.k. ( Specification Rece-housing 1-178129-6


CRR65


- 317 -

3.2.8 Connecting the Auxiliary Axis Over Travel (CRM68)

Fig.3.2.8 6-axis servo amplifier

CRM68 A1 AUXOT1 A2 AUXOT2 A3

CRM68 connector manufacutured by Tyco Electronics AMP k.k. ( Specification Rece-housing 1-1318120-3


CRM68


- 318 -

3.2.9 Connecting the Operation Box The operation box is not connected to the controller in shipment in some robot models. In this case connect the operation box connection cable to the operation box as following drawings. Also connect the input power cable and the teach pendant cable as described in section 3.2.2 and 3.2.3

JD1B

Signal Line

Power Line

Port (M4 NUT 3 Places)

JRS15

CRM95

Cable clamp

B-82595EN-2/02 CONNECTIONS

- 319 -

4. PERIPHERAL DEVICE, ARC WELDING, AND END

EFFECTOR INTERFACES

4 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES

R-30iA I/O peripheral device interfaces include printed circuit boards and a unit selected according to the applications. Table 4 lists details of the printed-circuit boards and units. Figure 4 shows the locations of these boards and units.

Table 4 Peripheral Device Interface Types Number of I/O points No. Name Drawing

number DI DO D/A A/DRemarks

1 Process I/O board CA A05B-2500-J003 40 40 (sink type) 2 6 Installed in back plane 2 Process I/O board EA A05B-2500-J012 40 40 (sink type) 2 3 Installed in operation box 3 Process I/O board EB A05B-2500-J013 40 40 (sink type) 0 0 Installed in operation box 4 Process I/O board FA A05B-2500-J014 96 96 (sink type) 0 0 Installed in operation box 5 Process I/O board GA A05B-2500-J015 40 40 (sink type) 2 0 Installed in operation box 6 Process I/O board HA A05B-2500-J006 40 40 (sink type) 2 0 Installed in back plane 7 Process I/O board JA A05B-2500-J001 96 96

(source type) 0 0 Installed in back plane

8 Process I/O board JB A05B-2500-J002 40 40 (source type)

0 0 Installed in back plane

9 Process I/O board KA A05B-2500-J010 40 40 (source type)

3 2 Installed in operation box

10 Process I/O board KB A05B-2500-J011 40 40 (source type)


11 Process I/O board KC A05B-2500-J016 40 40 (source type)


12 I/O Unit-MODEL A A05B-2502-J090(Base and interface unit)

Depending on selected I/O module. Common to both A and B-cabinet (five slots)

CONNECTIONS B-82595EN-2/02

- 320 -

4. PERIPHERAL DEVICE, ARCWELDING, AND END

EFFECTOR INTERFACES

NOTE 1 General purpose I/O (DI/DO) is a number which subtract an exclusive signal from

the table value. Example : Process I/O board JB Table value Exclusive DI General purpose DI DI; 40 - 18 = 22 points Table value Exclusive DO General purpose DO DO; 40 - 20 = 20 points 2 When there are slave units on the I/O Link and the power for control to these slave

units is supplied from other than the robot control unit, the power to the controller and the power to the slave units must be turned on and off at the following timings: a) The power to the slave units must be turned on before or when the power to the

controller, which is the master of the I/O Link, is turned on. b) If the power to a slave unit is turned off after the system has started up, an I/O

Link error occurs. To establish the I/O Link again, turn off the power to all units including the control unit, then turn on the power to the units in the order described in a).


- 321 -


EFFECTOR INTERFACES

(A-cabinet)

Optional slot I/O Unit-MODEL A

(B-cabinet) Fig.4 Locations of Peripheral Device Interfaces

Process I/O board


- 322 -


EFFECTOR INTERFACES

4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM Following are a block diagram of the peripheral device interface and the specifications.

4.1.1 When Process I/O Board EA/EB/GA is Used (A-cabinet)

A-cabinet Operation box

Main

board

JD1A JD1B

CP5

Process I/Oboard EA/EB/GA

CRM2A

CRM2B

CRW1or CRW7(NOTE 2)

CRW2

Panel board

Peripheral device

(1)

(2)(5)

(4) (3)

CP5A

Fig.4.1.1 Block diagram of the process I/O board EA, EB and GA

NOTE 1 CRW1 and CRW2 are not provided for process I/O board EB 2 In case of process I/O board EA: CRW1

In case of process I/O board GA: CRW7


- 323 -


EFFECTOR INTERFACES

Number Name Drawing number Remarks

A05B-2501-H460 Connected length : 5m A05B-2501-H461 Connected length : 10m

(1) Operation box connection cable

A05B-2501-H462 Connected length : 2m (2) Process I/O power supply cable A05B-2501-J150

A05B-2501-J203 Connected length : 10m (one) A05B-2501-J204 Connected length : 20m (one)

(3) (4) Peripheral device connection cable (Process I/O EA, EB, FA, GA)

A05B-2501-J205 Connected length : 30m (one) A05B-2501-J279 Connected length : 10m (one) CRW1 A05B-2501-J280 Connected length : 20m (one) CRW1

Welding device connection cable (Process I/O EA) (Fanuc interface / elbow) A05B-2501-J281 Connected length : 30m (one) CRW1

A05B-2501-J229 Connected length : 10m (one) CRW1 A05B-2501-J230 Connected length : 20m (one) CRW1

Welding device connection cable (Process I/O EA) (Fanuc interface / straight) A05B-2501-J231 Connected length : 30m (one) CRW1


Welding device connection cable (Process I/O GA) (General-purpose interface / elbow) A05B-2501-J284 Connected length : 30m (one) CRW7


Welding device connection cable (Process I/O GA) (General-purpose interface / straight) A05B-2501-J234 Connected length : 30m (one) CRW7


Welding device connection cable (Process I/O GA) (Fanuc interface / elbow) A05B-2501-J287 Connected length : 30m (one) CRW7


(5)

Welding device connection cable (Process I/O GA) (Fanuc interface / straight) A05B-2501-J237 Connected length : 30m (one) CRW7


- 324 -


EFFECTOR INTERFACES

4.1.2 When Process I/O Board FA is Used (A-cabinet)


Main

board

JD1A JD1B

CP5

Process I/Oboard FA

Panel board

Peripheral device

(1)

(2)

CRM2A

CRM2B (4) (3)

CP5A CRM2C

CRM2D (6) (5)

CRM4A

CRM4B (8) (7)

Fig.4.1.2 Block diagram of the process I/O board FA


A05B-2501-H460 Connected length : 5m A05B-2501-H461 Connected length : 10m

(1) Operation box connection cable

A05B-2501-H462 Connected length : 2m (2) Process I/O power supply cable A05B-2501-J150


(3) (4) (5) (6)

Peripheral device connection cable

A05B-2501-J205 Connected length : 30m (one) A05B-2501-J253 Connected length : 10m (one) A05B-2501-J254 Connected length : 20m (one)

(7) (8)


A05B-2501-J255 Connected length : 30m (one)


- 325 -


EFFECTOR INTERFACES

4.1.3 When Process I/O Board CA/HA is Used (B-cabinet)

Main board

JD1A JD1B

(JD4A)

Process I/O board CA/HA

Process I/O board CA/HA

Peripheral device

(1)

(2)

(5)

(4)

(3)CRM2A

CRM2B

CRW1 or CRW7

(NOTE)

CRW2

CRM2A

CRM2B

CRW1 or CRW7

(NOTE)

CRW2

JD1A

(JD4B)

JD1B

(JD4A)

JD1A

(JD4B)

Fig.4.1.3 Block diagram of the process I/O board CA/HA

NOTE Process I/O board CA: CRW1 Process I/O board HA: CRW7


- 326 -


EFFECTOR INTERFACES


(1) I/O Link cable A05B-2502-J130 Between main board and process I/O (2) I/O Link cable A05B-2502-J131 Between process I/O and process I/O


(3) (4) Peripheral device connection cable (Process I/O CA, HA)

A05B-2502-J172 Connected length : 30m (one) A05B-2502-J200 Connected length : 10m (one) CRW1 A05B-2502-J201 Connected length : 20m (one) CRW1

Welding device connection cable (Process I/O CA) (Fanuc interface / elbow) A05B-2502-J202 Connected length : 30m (one) CRW1


Welding device connection cable (Process I/O CA) (Fanuc interface / straight) A05B-2502-J205 Connected length : 30m (one) CRW1


Welding device connection cable (Process I/O HA) (General-purpose interface / elbow) A05B-2502-J208 Connected length : 30m (one) CRW7


Welding device connection cable (Process I/O HA) (General-purpose interface / straight) A05B-2502-J212 Connected length : 30m (one) CRW7


Welding device connection cable (Process I/O HA) (Fanuc interface / elbow) A05B-2502-J215 Connected length : 30m (one) CRW7


(5)

Welding device connection cable (Process I/O HA) (Fanuc interface / straight) A05B-2502-J218 Connected length : 30m (one) CRW7


- 327 -


EFFECTOR INTERFACES

4.1.4 When Process I/O Board JA/JB is Used (B-cabinet)

Main board

JD1A JD1B

JD1A

JD1B

JD1A

Process I/O board JA/JB

CRMA5A

CRMA5B

CRMA5C

CRMA6B

CRMA5DCRMA6A

CRMA6B

CRMA5A

CRMA5B

CRMA5C

CRMA5D

CRMA6A

Process I/O board JA/JB

Peripheral device

(1)

(2)

(5)

(6)

(4)

(3)

(7)

(8)

Fig.4.1.4 Block diagram of the process I/O board JA/JB

NOTE The process I/O board JB has none of CRMA5C, CRMA5D, CRMA6A, and CRMA6B.


(1) I/O Link cable A05B-2502-J130 Between main board and process I/O (2) I/O Link cable A05B-2502-J131 Between process I/O and process I/O


(3) (4) (5) (6)

Peripheral device connection cable (Process I/O JA, JB)

A05B-2502-J162 Connected length : 30m (one) A05B-2502-J180 Connected length : 10m (one) A05B-2502-J181 Connected length : 20m (one)

(7) (8)

Peripheral device connection cable (Process I/O JA)

A05B-2502-J182 Connected length : 30m (one)


- 328 -


EFFECTOR INTERFACES

4.1.5 When Process I/O Board KA/KB/KC is Used (A-Cabinet)


Main board

JD1A JD1B

CP5

Process I/Oboard KA/KB/KC

CRMA5A

CRMA5B

CRW10

Panel board

Peripheral

device

(1)

(2)(5)

(4)

(3)

CP5A

Fig. 4.1.5 Block diagram of the process I/O board KA/KB/KC NOTE CRW10 is not provided for process I/O board KC.


A05B-2501-H450 Connection length of 4 m A05B-2501-H451 Connection length of 10 m

(1) Operator panel box connection cable

A05B-2501-H452 Connection length of 2 m (2) Process I/O board power supply

cable A05B-2501-J150

A05B-2501-J050 Connection length of 10 m (one) A05B-2501-J051 Connection length of 20 m (one)

(3) (4)


A05B-2501-J052 Connection length of 30 m (one) A05B-2501-J053 Connection length of 3 m (one),

CRW10 A05B-2501-J054 Connection length of 7 m (one),

CRW10

Welding machine connection cable (for process I/O board KB) (general interface/elbow type)

A05B-2501-J055 Connection length of 14 m (one), CRW10



(5)

Welding machine connection cable (for process I/O board KA, KB) (FANUC interface/elbow type)



- 329 -


EFFECTOR INTERFACES

4.1.6 When I/O Unit-MODEL A is Used

4.1.6.1 In case of B-cabinet

B-cabinet

Peripheral device

Main board

JD1A

Interface module

Back plane (five-slot)

― JD1A

JD1B

CP

32

K25

K54

K54

K54

K54

K54

E-Stop unit CP5A

CP5A

K26

Fig.4.1.6.1 Block diagram of I/O Unit-A (In case of B-cabinet)

Cable

number Name Drawing number Remarks

K25 I/O Link cable - Included in A05B-2502-J090 K26 I/O Link cable - Included in A05B-2502-J090 K54 Peripheral device

connection cable-

Must be supplied by the customer.

K54 Peripheral device connection cable

- Must be supplied by the customer.


- 330 -


EFFECTOR INTERFACES

4.1.7 When Two or more Process I/O Printed Circuit Boards and I/O Unit-MODEL A are Used

4.1.7.1 In case of B-cabinet

When several units of the process I/O PCB, I/O Unit-A are used, connect them as shown below.

B-cabinet

Back plane (five-slot)

I/O Unit-A Interface module

JD1B

JD1A

CP32

Main board

JD1A

Process I/O board

JD1B

JD1A

Process I/O board

JD1B

JD1A

A05B-2502-J130

A05B-2502-J131

Included in model A baseunit A05B-2502-J090

DC power is supplied from the back plane.

E-stop unit

CP5A

Fig.4.1.7.1 Block diagram of two or more process I/O printed circuit boards and I/O unit-MODEL A (In case of B-cabinet)


- 331 -


EFFECTOR INTERFACES

4.2 PERIPHERAL DEVICE INTERFACE COMBINATION Peripheral device interfaces can be used by using process I/O boards and the I/O Unit-MODEL A.

4.2.1 In Case of A-cabinet Only one of the following peripheral device interfaces can be used in A-cabinet. Process I/O board EA Process I/O board EB Process I/O board FA Process I/O board GA Process I/O board KA Process I/O board KB Process I/O board KC I/O unit Model A (5 slots)

If you want to use more than one interface unit in combination in case of A-cabinet, you need another box contact a FANUC sales representative for details.


- 332 -


EFFECTOR INTERFACES

4.2.2 In Case of B-cabinet One board or one unit is used Combination C Process I/O board CA/HA/JB (40 points/40 points) Combination D Process I/O board JA (96 points/96 points) Combination E I/O Unit-MODEL A Two boards/units are used in combination

Combination CE Process I/O board CA/HA/JB (40 points/40 points) + I/O Unit-MODEL A

Combination DC Process I/O board JA (96 points/96 points) + Process I/O board CA/HA/JB (40 points/40 points)

Combination DD Process I/O board JA (96 points/96 points) + Process I/O board JA (96 points/96 points)

Combination DE Process I/O board JA (96 points/96 points) + I/O Unit-MODEL A

Three boards/units are used in combination

Combination DCE

Process I/O board JA (96 points/96 points) + Process I/O board CA/HA/JB (40 points/40 points) + I/O Unit-MODEL A

Combination DDE

Process I/O board JA (96 points/96 points) + Process I/O board JA (96 points/96 points) + I/O Unit-MODEL A


- 333 -


EFFECTOR INTERFACES

4.3 PROCESS I/O BOARD SIGNALS There are 18 exclusive data inputs (DI) and 20 exclusive data outputs (DO) for a process I/O board. These signals are allocated to the process I/O board connected first when two or more printed boards are combined. (General signals DI/DO are allocated to the second and the following process I/O boards.) The common voltage of the DI signals input to pins 1 to 4 of connector CRMA5A or CRM2A is clamped +24 V (common) in each process I/O board. Table 4.3 shows signals of a process I/O board.

Table 4.3 Process I/O Board Signals Connector

number Signal name Description Remarks

(DI signals) CRMA5A- 1 (CRM2A is similar to CRMA5A)

*IMSTP Immediate stop Clamped at +24 V common

CRMA5A- 2 *HOLD Temporary stop Clamped at +24 V common

CRMA5A- 3 *SFSD Safe speed Clamped at +24 V common

CRMA5A- 4 CSTOPI Cycle stop Clamped at +24 V common

CRMA5A- 5 FAULT RESET External reset CRMA5A- 6 START Start CRMA5A- 7 HOME Return to home position CRMA5A- 8 ENBL Operation enabled CRMA5A- 9 RSR1 Robot service request PNS1 Program number selection Option CRMA5A-10 RSR2 Robot service request PNS2 Program number selection Option CRMA5A-11 RSR3 Robot service request PNS3 Program number selection Option CRMA5A-12 RSR4 Robot service request PNS4 Program number selection Option CRMA5A-13 RSR5 Robot service request PNS5 Program number selection Option CRMA5A-14 RSR6 Robot service request PNS6 Program number selection Option CRMA5A-15 RSR7 Robot service request PNS7 Program number selection Option CRMA5A-16 RSR8 Robot service request PNS8 Program number selection Option CRMA5A-29 PNSTROBE PNS strobe CRMA5A-30 PROD START Start of automatic operation CRMA5A-31 DI01 Peripheral device status General signal CRMA5A-32 DI02 Peripheral device status General signal CRMA5B- 1 DI03 Peripheral device status General signal


- 334 -


EFFECTOR INTERFACES

Connector number Signal name Description Remarks

CRMA5B- 2 DI04 Peripheral device status General signal CRMA5B- 3 DI05 Peripheral device status General signal CRMA5B- 4 DI06 Peripheral device status General signal CRMA5B- 5 DI07 Peripheral device status General signal CRMA5B- 6 DI08 Peripheral device status General signal CRMA5B- 7 DI09 Peripheral device status General signal CRMA5B- 8 DI10 Peripheral device status General signal CRMA5B- 9 DI11 Peripheral device status General signal CRMA5B-10 DI12 Peripheral device status General signal CRMA5B-11 DI13 Peripheral device status General signal CRMA5B-12 DI14 Peripheral device status General signal CRMA5B-13 DI15 Peripheral device status General signal CRMA5B-14 DI16 Peripheral device status General signal CRMA5B-15 DI17 Peripheral device status General signal CRMA5B-16 DI18 Peripheral device status General signal CRMA5B-29 DI19 Peripheral device status General signal CRMA5B-30 DI20 Peripheral device status General signal CRMA5B-31 DI21 Peripheral device status General signal CRMA5B-32 DI22 Peripheral device status General signal (DO signals) CRMA5A-33 CMDENBL During automatic operation CRMA5A-34 SYSRDY Preparation completed CRMA5A-35 PROGRUN Program running CRMA5A-36 PAUSED Program being interrupted CRMA5A-38 HELD During temporary stop CRMA5A-39 FAULT Alarm CRMA5A-40 ATPERCH Home position CRMA5A-41 TPENBL Teach pendant enabled CRMA5A-43 BATALM Battery voltage drop CRMA5A-44 BUSY During operation CRMA5A-45 ACK1 Robot service request acceptance SNO1 Selected program number Option CRMA5A-46 ACK2 Robot service request acceptance SNO2 Selected program number Option CRMA5A-19 ACK3 Robot service request acceptance SNO3 Selected program number Option CRMA5A-20 ACK4 Robot service request acceptance SNO4 Selected program number Option CRMA5A-21 ACK5 Robot service request acceptance SNO5 Selected program number Option CRMA5A-22 ACK6 Robot service request acceptance SNO6 Selected program number Option CRMA5A-24 ACK7 Robot service request acceptance SNO7 Selected program number Option CRMA5A-25 ACK8 Robot service request acceptance SNO8 Selected program number Option CRMA5A-26 SNACK Response signal to PNS CRMA5A-27 RESERVED CRMA5B-33 DO01 Peripheral device control signal General signal CRMA5B-34 DO02 Peripheral device control signal General signal CRMA5B-35 DO03 Peripheral device control signal General signal


- 335 -


EFFECTOR INTERFACES

Connector number Signal name Description Remarks

CRMA5B-36 DO04 Peripheral device control signal General signal CRMA5B-38 DO05 Peripheral device control signal General signal CRMA5B-39 DO06 Peripheral device control signal General signal CRMA5B-40 DO07 Peripheral device control signal General signal CRMA5B-41 DO08 Peripheral device control signal General signal CRMA5B-43 DO09 Peripheral device control signal General signal CRMA5B-44 DO10 Peripheral device control signal General signal CRMA5B-45 DO11 Peripheral device control signal General signal CRMA5B-46 DO12 Peripheral device control signal General signal CRMA5B-19 DO13 Peripheral device control signal General signal CRMA5B-20 DO14 Peripheral device control signal General signal CRMA5B-21 DO15 Peripheral device control signal General signal CRMA5B-22 DO16 Peripheral device control signal General signal CRMA5B-24 DO17 Peripheral device control signal General signal CRMA5B-25 DO18 Peripheral device control signal General signal CRMA5B-26 DO19 Peripheral device control signal General signal CRMA5B-27 DO20 Peripheral device control signal General signal


- 336 -


EFFECTOR INTERFACES

4.4 INTERFACE FOR PERIPHERAL DEVICES

4.4.1 Peripheral Device and Control Unit Connection (Source Type DO)

Peripheral device control interface A1 (Source type DO)

CRMA5A 01 *IMSTP 33 CMDENBL 02 *HOLD 19 ACK3/SNO3 34 SYSRDY 03 *SFSPD 20 ACK4/SNO4 35 PROGRUN 04 CSTOPI 21 ACK5/SNO5 36 PAUSED 05 FAULT RESET 22 ACK6/SNO6 37 DOSRC1 06 START 23 DOSRC1 38 HELD 07 HOME 24 ACK7/SNO7 39 FAULT 08 ENBL 25 ACK8/SNO8 40 ATPERCH 09 RSR1/PNS1 26 SNACK 41 TPENBL 10 RSR2/PNS2 27 RESERVED 42 DOSRC1 11 RSR3/PNS3 28 DOSRC1 43 BATALM 12 RSR4/PNS4 29 PNSTROBE 44 BUSY 13 RSR5/PNS5 30 PROD START 45 ACK1/SNO1 14 RSR6/PNS6 31 DI01 46 ACK2/SNO2 15 RSR7/PNS7 32 DI02 47 DOSRC1 16 RSR8/PNS8 48 17 0V 49 +24E 18 0V

50 +24E


CRMA5B 01 DI03 33 DO01 02 DI04 19 DO13 34 DO02 03 DI05 20 DO14 35 DO03 04 DI06 21 DO15 36 DO04 05 DI07 22 DO16 37 DOSRC1 06 DI08 23 DOSRC1 38 DO05 07 DI09 24 DO17 39 DO06 08 DI10 25 DO18 40 DO07 09 DI11 26 DO19 41 DO08 10 DI12 27 DO20 42 DOSRC1 11 DI13 28 DOSRC1 43 DO09 12 DI14 29 DI19 44 DO10 13 DI15 30 DI20 45 DO11 14 DI16 31 DI21 46 DO12 15 DI17 32 DI22 47 DOSRC1 16 DI18 48 17 0V 49 +24E 18 0V

50 +24E

Terminal block

TBSRC1 1 DOSRC1 2 0V

Peripheral device A1


Control unit


- 337 -


EFFECTOR INTERFACES

NOTE 1 The peripheral device connection cables are

optional. 2 The DOSRC1 pins of the CRMA5A and CRMA5B

are pins for supplying power to drivers. (None of these pins can be left open.)

3 When the level of the voltage applied to the load is insufficient for a cause such as a too long peripheral device connection cable, supply power from the TBSRC1 terminal block.

Applicable process I/O board type JA, JB, KA, KB, KC


- 338 -


EFFECTOR INTERFACES


CRMA5C 01 DI23 33 DO21 02 DI24 19 DO33 34 DO22 03 DI25 20 DO34 35 DO23 04 DI26 21 DO35 36 DO24 05 DI27 22 DO36 37 DOSRC2 06 DI28 23 DOSRC2 38 DO25 07 DI29 24 DO37 39 DO26 08 DI30 25 DO38 40 DO27 09 DI31 26 DO39 41 DO28 10 DI32 27 DO40 42 DOSRC2 11 DI33 28 DOSRC2 43 DO29 12 DI34 29 DI39 44 DO30 13 DI35 30 DI40 45 DO31 14 DI36 31 DI41 46 DO32 15 DI37 32 DI42 47 DOSRC2 16 DI38 48 17 0V 49 +24E 18 0V

50 +24E


CRMA5D 01 DI43 33 DO41 02 DI44 19 DO53 34 DO42 03 DI45 20 DO54 35 DO43 04 DI46 21 DO55 36 DO44 05 DI47 22 DO56 37 DOSRC2 06 DI48 23 DOSRC2 38 DO45 07 DI49 24 DO57 39 DO46 08 DI50 25 DO58 40 DO47 09 DI51 26 DO59 41 DO48 10 DI52 27 DO60 42 DOSRC2 11 DI53 28 DOSRC2 43 DO49 12 DI54 29 DI59 44 DO50 13 DI55 30 DI60 45 DO51 14 DI56 31 DI61 46 DO52 15 DI57 32 DI62 47 DOSRC2 16 DI58 48 17 0V 49 +24E 18 0V

50 +24E

Terminal block




Control unit


- 339 -


EFFECTOR INTERFACES


optional. 2 The DOSRC2 pins of the CRMA5C and CRMA5D



Applicable process I/O board type JA


- 340 -


EFFECTOR INTERFACES

Control unit

Peripheral device control interface B1 (Source type DO)

CRMA6A 01 DI63 08 DO65 14 DO61 02 DI64 09 DO66 15 DO62 03 DI65 10 DO67 16 DO63 04 DI66 11 DO68 17 DO64 05 DI67 12 DOSRC3 18 DOSRC3 06 DI68 13 DI70 19 +24E 07 DI69 20 0V

Peripheral device control interface B2 (Source type DO)

CRMA6B 01 DI71 08 DO73 14 DO69 02 DI72 09 DO74 15 DO70 03 DI73 10 DO75 16 DO71 04 DI74 11 DO76 17 DO72 05 DI75 12 DOSRC3 18 DOSRC3 06 DI76 13 DI78 19 +24E 07 DI77 20 0V

Terminal block



optional. 2 The DOSRC3 pins of the CRMA6A and CRMA6B



Applicable process I/O board type JA

Peripheral device B1



- 341 -


EFFECTOR INTERFACES

Set this jumper according to the common voltage of input devices. (ICOM1)

Control unit (peripheral device control interface A1) Peripheral device

*IMSTP CRMA5A (1)

CRMA5A (49,50)Connector pin No.+24E

Receiver circuit

ENBL CRMA5A (8)

DI02 CRMA5A (32)

COM-1 CRMA5A (17,18)

0V

*HOLD CRMA5A (2)

*SFSPD CRMA5A (3)

CSTOPI CRMA5A (4)

FAULT RESET CRMA5A (5)

START CRMA5A (6)

HOME CRMA5A (7)

RSR1/PNS1CRMA5A (9)

CRMA5A (10)

CRMA5A (11)

CRMA5A (12)

CRMA5A (13)

CRMA5A (14)

CRMA5A (15)

CRMA5A (16)

PNSTROBECRMA5A (29)

PROD STARTCRMA5A (30)

DI01 CRMA5A (31)

3.3k

+24E

0V

B A


0V

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RSR2/PNS2

RSR3/PNS3

RSR4/PNS4

RSR5/PNS5

RSR6/PNS6

RSR7/PNS7

RSR8/PNS8

NOTE In this diagram, common voltage of input devices is

+24V.


- 342 -


EFFECTOR INTERFACES


CMDENBL

CRMA5A (34)

CRMA5A (33)

Connector pin No.

Driver circuit

TPENBLCRMA5A (43)

RESERVED

SYSRDYCRMA5A (35)PROGRUNCRMA5A (36)PAUSEDCRMA5A (38)HELDCRMA5A (39)FAULTCRMA5A (40)ATPERCHCRMA5A (41)

BATALMCRMA5A (44)

BUSYCRMA5A (45)

ACK1/SNO1CRMA5A (46)

CRMA5A (19)

CRMA5A (20)

CRMA5A (21)

CRMA5A (22)

CRMA5A (24)

CRMA5A (25)

CRMA5A (26)SNACKCRMA5A (27)

DVLOAD

RELAY

A maximum output current per DO point is 0.2 A.

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

CRMA5A (23,28,37,42,47)

DOSRC1

+24V 0V +24V regulated power supply

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

CRMA5A (17,18)

0V

DOSRC1(1)

TBSRC1(2)

ACK2/SNO2

ACK3/SNO3

ACK4/SNO4

ACK5/SNO5

ACK6/SNO6

ACK7/SNO7

ACK8/SNO8


- 343 -


EFFECTOR INTERFACES


DI03 CRMA5B (1)

CRMA5B (49,50)Connector pin No.+24E

Receiver circuit

DI10 CRMA5B (8)

DI22 CRMA5B (32)

COM-2 CRMA5B (17,18)

0V

DI04 CRMA5B (2)

DI05 CRMA5B (3)

DI06 CRMA5B (4)

DI07CRMA5B (6)DI08

CRMA5B (5)

DI09 CRMA5B (7)

DI11CRMA5B (9)

CRMA5B (10)

CRMA5B (11)

CRMA5B (12)

CRMA5B (13)

CRMA5B (14)

CRMA5B (15)

CRMA5B (16)

DI19CRMA5B (29)

DI20CRMA5B (30)

DI21 CRMA5B (31)

3.3k

+24E

0V

B A

Set this jumper according to thecommon voltage of input devices.(ICOM2)

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

DI12

DI13

DI14

DI15

DI16

DI17

DI18


+24V.


- 344 -


EFFECTOR INTERFACES


DO01

CRMA5B (34)

CRMA5B (33)

Connector pin No.

Driver circuit

DO08CRMA5B (43)

DO20

DO02CRMA5B (35)DO03CRMA5B (36)DO04CRMA5B (38)DO05CRMA5B (39)DO06CRMA5B (40)DO07CRMA5B (41)

DO09CRMA5B (44)

DO10CRMA5B (45)

DO11CRMA5B (46)

CRMA5B (19)

CRMA5B (20)

CRMA5B (21)

CRMA5B (22)

CRMA5B (24)

CRMA5B (25)

CRMA5B (26)DO19CRMA5B (27)

DVLOAD

RELAY


LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

CRMA5B (23,28,37,42,47)

DOSRC1 +24V 0V +24V regulated power supply

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

CRMA5B (17,18)

0V

DOSRC1(1)

TBSRC1(2)

DO12

DO13

DO14

DO15

DO16

DO17

DO18


- 345 -


EFFECTOR INTERFACES


DI23 CRMA5C (1)

CRMA5C (49,50)Connector pin No.+24E

Receiver circuit

DI30 CRMA5C (8)

DI42 CRMA5C (32)

COM-3 CRMA5C (17,18)

0V

DI24 CRMA5C (2)

DI25 CRMA5C (3)

DI26 CRMA5C (4)

DI27CRMA5C (6)DI28

CRMA5C (5)

DI29 CRMA5C (7)

DI31CRMA5C (9)

CRMA5C (10)

CRMA5C (11)

CRMA5C (12)

CRMA5C (13)

CRMA5C (14)

CRMA5C (15)

CRMA5C (16)

DI39CRMA5C (29)

DI40CRMA5C (30)

DI41 CRMA5C (31)

3.3k

+24E

0V

B A

Set this jumper according tothe common voltage of inputdevices.(ICOM3)

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

DI32

DI33

DI34

DI35

DI36

DI37

DI38


+24V.


- 346 -


EFFECTOR INTERFACES


DO21

CRMA5C (34)

CRMA5C (33)

Connector pin No.

Driver circuit

DO28CRMA5C (43)

DO40

DO22CRMA5C (35)DO23CRMA5C (36)DO24CRMA5C (38)DO25CRMA5C (39)DO26CRMA5C (40)DO27CRMA5C (41)

DO29CRMA5C (44)

DO30CRMA5C (45)

DO31CRMA5C (46)

CRMA5C (19)

CRMA5C (20)

CRMA5C (21)

CRMA5C (22)

CRMA5C (24)

CRMA5C (25)

CRMA5C (26)DO39CRMA5C (27)

DVLOAD

RELAY


LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

CRMA5C (23,28,37,42,47)

DOSRC2 +24V 0V +24V regulated power supply

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

CRMA5C (17,18)

0V

TBSRC2(1)

TBSRC2(2)

DO32

DO33

DO34

DO35

DO36

DO37

DO38


- 347 -


EFFECTOR INTERFACES


DI43 CRMA5D (1)

CRMA5D (49,50)+24E

DI50 CRMA5D (8)

DI62 CRMA5D (32)

COM-4 CRMA5D (17,18)

0V

DI44 CRMA5D (2)

DI45 CRMA5D (3)

DI46 CRMA5D (4)

DI47CRMA5D (6)DI48

CRMA5D (5)

DI49 CRMA5D (7)

DI51CRMA5D (9)

CRMA5D (10)

CRMA5D (11)

CRMA5D (12)

CRMA5D (13)

CRMA5D (14)

CRMA5D (15)

CRMA5D (16)

DI59CRMA5D (29)

DI60CRMA5D (30)

DI61 CRMA5D (31)

3.3k

+24E

0V

B A

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

DI52

DI53

DI54

DI55

DI56

DI57

DI58

Connector pin No.

Receiver circuit



+24V.


- 348 -


EFFECTOR INTERFACES


DO41

CRMA5D (34)

CRMA5D (33)

Connector pin No.

Driver circuit

DO48CRMA5D (43)

DO60

DO42CRMA5D (35)DO43CRMA5D (36)DO44CRMA5D (38)DO45CRMA5D (39)DO46CRMA5D (40)DO47CRMA5D (41)

DO49CRMA5D (44)

DO50CRMA5D (45)

DO51CRMA5D (46)

CRMA5D (19)

CRMA5D (20)

CRMA5D (21)

CRMA5D (22)

CRMA5D (24)

CRMA5D (25)

CRMA5D (26)DO59CRMA5D (27)

DV LOAD

RELAY

A maximum output current per DO point is 0.2 A

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

CRMA5D (23,28,37,42,47)

DOSRC2 +24V 0V

+24V regulated power supply

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

CRMA5D (17,18)

0V

DOSRC2(1)

TBSRC2(2)

DO52

DO53

DO54

DO55

DO56

DO57

DO58


- 349 -


EFFECTOR INTERFACES

Control unit (peripheral device control interface B1) Peripheral device

DI63 CRMA6A (1)

CRMA6A (19)+24E

DI70 CRMA6A (13)

COM-5

DI64 CRMA6A (2)

DI65 CRMA6A (3)

DI66 CRMA6A (4)

DI67CRMA6A (6)DI68

CRMA6A (5)

DI69 CRMA6A (7)

3.3k

+24E

0V

B A

RV

RV

RV

RV

RV

RV

RV

RV

RV

DO61

CRMA6A (15)

CRMA6A (14)

DO68

DO62CRMA6A (16)DO63CRMA6A (17)DO64CRMA6A (8)DO65CRMA6A (9)DO66

CRMA6A (10)DO67CRMA6A (11)

DV LOAD

RELAY

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

CRMA6A (12,18)

DOSRC3 +24V 0V


DOSRC3(1)

CRMA6A (20)

0V

TBSRC3(2)

DV

DV

DV

DV

DV

DV

DV

Connector pin No.

Driver circuit


Receiver circuit

Connector pin No.



+24V.


- 350 -


EFFECTOR INTERFACES

Control unit (peripheral device control interface B2) Peripheral device

DI71 CRMA6B (1)

CRMA6B (19)+24E

DI78 CRMA6B (13)

COM-6

DI72 CRMA6B (2)

DI73 CRMA6B (3)

DI74 CRMA6B (4)

DI75CRMA6B(6)DI76

CRMA6B (5)

DI77 CRMA6B (7)

3.3k

+24E

0V

B A

RV

RV

RV

RV

RV

RV

RV

RV

RV

DO69

CRMA6B (15)

CRMA6B (14)

DO76

DO70CRMA6B (16)DO71CRMA6B (17)DO72CRMA6B (8)DO73CRMA6B (9)DO74

CRMA6B (10)DO75CRMA6B (11)

DV LOAD

RELAY

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

CRMA6B (12,18)

DOSRC3 +24V 0V


DOSRC3(1)

CRMA6B (20)

0V

TBSRC3(2)

DV

DV

DV

DV

DV

DV

DV

Connector pin No.

Driver circuit


Receiver circuit

Connector pin No.



+24V.


- 351 -


EFFECTOR INTERFACES

4.4.2 Peripheral Device and Control Unit Connection (Sink Type DO)



Peripheral device control interface A2 Sink type DO

0V

Control unit Peripheral device control interface A1 Sink type DO

NOTE 1 The peripheral device connection cables are optional. 2 All of COM-∗∗ are connected to 0V.

Applicable process I/O board type

CA, EA, EB, FA, GA, HA


- 352 -


EFFECTOR INTERFACES

Control unit Peripheral device control interface A3 Sink type DO

Peripheral device control interface A4 Sink type DO





FA


- 353 -


EFFECTOR INTERFACES

Control unit Peripheral device control interface B1 Sink type DO

Control unit Peripheral device control interface B2 Sink type DO





FA


- 354 -


EFFECTOR INTERFACES

Control unit (peripheral device interface A1) Peripheral device

*IMSTPCRM2A (1)

CRM2A (49,50)

Connector pin No.+24E

Receiver circuit

ENBLCRM2A (8)

DI02CRM2A (32)

COM-1 CRM2A (17,18)

0V

*HOLDCRM2A (2)

*SFSPDCRM2A (3)

CSTOPICRM2A (4)

FAULT RESETCRM2A (5)

STARTCRM2A (6)

HOMECRM2A (7)

RSR1/PNS1CRM2A (9)

RSR2/PNS2CRM2A (10)

RSR3/PNS3CRM2A (11)

RSR4/PNS4CRM2A (12)

RSR5/PNS5CRM2A (13)

RSR6/PNS6CRM2A (14)

RSR7/PNS7CRM2A (15)

RSR8/PNS8CRM2A (16)

PNSTROBECRM2A (29)

PROD STARTCRM2A (30)

DI01CRM2A (31)

3.3k

+24E

0V

B A

Set this jumper according to the common voltage of input devices.

(ICOM1)

0V

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

NOTE In this diagram, common voltage of input devices is +24V.


- 355 -


EFFECTOR INTERFACES


- 356 -


EFFECTOR INTERFACES


DI03CRM2B (1)

CRM2B (49,50)Connector pin No.+24E

Receiver circuit

DI10CRM2B (8)

DI22CRM2B (32)

COM-2 CRM2B (17,18)

0V

DI04CRM2B (2)

DI05CRM2B (3)

DI06CRM2B (4)

DI07CRM2B (5)

DI08CRM2B (6)

DI09CRM2B (7)

DI11CRM2B (9)

DI12CRM2B (10)

DI13CRM2B (11)

DI14CRM2B (12)

DI15CRM2B (13)

DI16CRM2B (14)

DI17CRM2B (15)

DI18CRM2B (16)

DI19CRM2B (29)

DI20CRM2B (30)

DI21CRM2B (31)

3.3k

+24E

0V

B A


（ICOM2）

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV



- 357 -


EFFECTOR INTERFACES


DO01

CRM2B (34)

CRM2B (33)

Connector pin No.Driver circuit

DO08CRM2B (43)

DO20

CRM2B (23,28,37,42,47)

0V

DO02CRM2B (35)

DO03CRM2B (36)

DO04CRM2B (38)

DO05CRM2B (39)

DO06CRM2B (40)

DO07CRM2B (41)

DO09CRM2B (44)

DO10CRM2B (45)

DO11CRM2B (46)

DO12CRM2B (19)

DO13CRM2B (20)

DO14CRM2B (21)

DO15CRM2B (22)

DO16CRM2B (24)

DO17CRM2B (25)

DO18CRM2B (26)

DO19CRM2B (27)

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

LOAD

RELAY

0V +24V


LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

0V

+24 V regulated power supply


- 358 -


EFFECTOR INTERFACES


DI23CRM2C (1)

CRM2C (49,50)Connector pin No.+24E

Receiver circuit

DI30CRM2C (8)

DI42CRM2C (32)

COM-3 CRM2C (17,18)

0V

DI24CRM2C (2)

DI25CRM2C (3)

DI26CRM2C (4)

DI27CRM2C (5)

DI28CRM2C (6)

DI29CRM2C (7)

DI31CRM2C (9)

DI32CRM2C (10)

DI33CRM2C (11)

DI34CRM2C (12)

DI35CRM2C (13)

DI36CRM2C (14)

DI37CRM2C (15)

DI38CRM2C (16)

DI39CRM2C (29)

DI40CRM2C (30)

DI41CRM2C (31)

3.3k

+24E

0V

B A


（ICOM3）

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV



- 359 -


EFFECTOR INTERFACES


DO21

CRM2C (34)

CRM2C (33)


DO28CRM2C (43)

DO40

CRM2C (23,28,37,42,47)

0V

DO22CRM2C (35)

DO23CRM2C (36)

DO24CRM2C (38)

DO25CRM2C (39)

DO26CRM2C (40)

DO27CRM2C (41)

DO29CRM2C (44)

DO30CRM2C (45)

DO31CRM2C (46)

DO32CRM2C (19)

DO33CRM2C (20)

DO34CRM2C (21)

DO35CRM2C (22)

DO36CRM2C (24)

DO37CRM2C (25)

DO38CRM2C (26)

DO39CRM2C (27)

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

LOAD

RELAY

0V +24V


LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

0V



- 360 -


EFFECTOR INTERFACES


DI43CRM2D (1)

CRM2D (49,50)


Receiver circuit

DI50CRM2D (8)

DI62CRM2D (32)

COM-4 CRM2D (17,18)

0V

DI44CRM2D (2)

DI45CRM2D (3)

DI46CRM2D (4)

DI47CRM2D (5)

DI48CRM2D (6)

DI49CRM2D (7)

DI51CRM2D (9)

DI52CRM2D (10)

DI53CRM2D (11)

DI54CRM2D (12)

DI55CRM2D (13)

DI56CRM2D (14)

DI57CRM2D (15)

DI58CRM2D (16)

DI59CRM2D (29)

DI60CRM2D (30)

DI61CRM2D (31)

3.3k

+24E

0V

B A


（ICOM4）

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV



- 361 -


EFFECTOR INTERFACES


DO41

CRM2D (34)

CRM2D (33)Connector pin No.Driver circuit

DO48CRM2D (43)

DO60

CRM2D (23,28,37,42,47)

0V

DO42CRM2D (35)

DO43CRM2D (36)

DO44CRM2D (38)

DO45CRM2D (39)

DO46CRM2D (40)

DO47CRM2D (41)

DO49CRM2D (44)

DO50CRM2D (45)

DO51CRM2D (46)

DO52CRM2D (19)

DO53CRM2D (20)

DO54CRM2D (21)

DO55CRM2D (22)

DO56CRM2D (24)

DO57CRM2D (25)

DO58CRM2D (26)

DO59CRM2D (27)

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

LOAD

RELAY

0V +24V


LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

0V



- 362 -


EFFECTOR INTERFACES

Control unit (peripheral device interface B1) Peripheral device

DI63CRM4A (1)

CRM4A (19)Connector pin No.+24E

Receiver circuit

DI70CRM4A (13)

COM-5 CRM4A (20)

0V

DI64CRM4A (2)

DI65CRM4A (3)

DI66CRM4A (4)

DI67CRM4A (5)

DI68CRM4A (6)

DI69CRM4A (7)

3.3k

+24E

0V

B A


（ICOM5）

RV

RV

RV

RV

RV

RV

RV

RV

RV

DO68

CRM4A (12, 18)

0V

CRM4A (15)DO62

CRM4A (16)DO63

CRM4A (17)DO64

CRM4A (8)DO65

CRM4A (9)DO66

CRM4A (10)DO67

CRM4A (11)DV

DV

DV

DV

DV

DV

DV

0V +24V


LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

DO61

CRM4A (14)


DV LOAD

RELAY

0V




- 363 -


EFFECTOR INTERFACES

Control unit (peripheral device interface B2) Peripheral device

DI71CRM4B (1)

CRM4B (19)


Receiver circuit

DI78CRM4B (13)

COM-6 CRM4B (20)

0V

DI72CRM4B (2)

DI73CRM4B (3)

DI74CRM4B (4)

DI75CRM4B (5)

DI76CRM4B (6)

DI77CRM4B (7)

3.3k

+24E

0V

B A


（ICOM6）

RV

RV

RV

RV

RV

RV

RV

RV

RV

DO76

CRM4B (12, 18)

0V

CRM4B (15)DO70

CRM4B (16)DO71

CRM4B (17)DO72

CRM4B (8)DO73

CRM4B (9)DO74

CRM4B (10)DO75

CRM4B (11)DV

DV

DV

DV

DV

DV

DV

0V +24V


LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

DO69

CRM4B (14)

Connector pin No. Driver circuit

DV LOAD

RELAY

0V




- 364 -


EFFECTOR INTERFACES

4.5 INTERFACE FOR WELDER

4.5.1 Connection Between the Control Unit and Welder

Control unit Welding machine interface

Welding machine

Peripheral device

Analog input interface

WI1 WI2 WI3 WI4 WI5 WI6 WI7 WI8

WO1WO2WO3WO4WO5WO6WO7WO8

NOTE Welder and peripheral device connection cable are

optional. Applicable process I/O board type

CA, EA


- 365 -


EFFECTOR INTERFACES


- 366 -


EFFECTOR INTERFACES

Control unit (welding machine interface) Process I/O boards CA and EA

Welding machine

WI01CRW1 (5)

CRW1 (33,34)

Connector pin No.

+24V

Receiver circuit

WI08CRW1 (12)

COM-3

CRW1 (21,22)

WI02CRW1 (6)

WI03CRW1 (7)

WI04CRW1 (8)

WI05CRW1 (9)

WI06CRW1 (10)

WI07CRW1 (11)

3.3k

+24E

0V

B A


（ICOM3）

RV

RV

RV

RV

RV

RV

RV

RV

RV

WO08

CRW1 (19,20)

0V

CRW1 (24)WO02

CRW1 (25)WO03

CRW1 (26)WO04

CRW1 (27)WO05

CRW1 (28)WO06

CRW1 (29)WO07

CRW1 (30)DV

DV

DV

DV

DV

DV

DV

0V +24V

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

WO01

CRW1 (23)Connector pin No.

Driver circuit DV

LOAD

RELAY

0V

r

c

d

e

f

g

h

j

k

R

S

T

U

V

W

X

Z

a,m

b,n

Arc regeneration detection signal

+24 V regulated power

Out-of-gas detection signal Broken-wire detection signal Out-of-cooling-water detection signal Abnormal-welding power signal

Welding start signal

Gas signal

Wire inching (+) signal Wire inching (-) signal

s

Welding machine frame ground Cabinet ground (shield clamped)）



- 367 -


EFFECTOR INTERFACES

CRW2 connector analog connection (analog input)

(Relationships between process I/O points and analog inputs)

Analog inputs

Process I/O points

ADCH1 COMAD1

ADCH2 COMAD2

ADCH3 COMAD3

ADCH4 COMAD4

ADCH5 COMAD5

ADCH6 COMAD6

Process I/O CA points In CRW1 In CRW1 Process I/O EA points In CRW1 In CRW1 × × × Process I/O GB points Process I/O HB points


- 368 -


EFFECTOR INTERFACES

Control unit Welding machine interface

Welding machine

WI1 WI2

WI3

WI4

WI5

WI6 WI7

WI8

WO5

WO1

WO2

WO3

WO4

NOTE Welder and peripheral device connection cable are

optional. Applicable process I/O board type

GA, HA


- 369 -


EFFECTOR INTERFACES

General-purpose interface

Control unit (welding machine interface) Process I/O boards GA, HA, and HB

Welding machine

DACH1CRW7 (1)

Connector pin No.

R = 100 Ω or higher

COMDA1CRW7 (2)

DACH2CRW7 (3)

COMDA2CRW7 (4)

＋

Welding voltage specification signal

Wire speed specification signal

A

B

C

D

MS connector pin No.

WDI+CRW1 (31)

WDI-CRW1 (32)Wire deposition

detection signal

M

N

－ Welding power

WI02CRW7 (6)

CRW7 (33,34)

Connector pin No.Receiver circuit

COM-3

WI03CRW7 (7)

WI04CRW7 (8)

WI06CRW7 (10)

3.3k

+24E

0V

B A


（ICOM3）

RV

RV

RV

RV

RV

E

P

T

S

R

Arc detection signal Out-of-gas

detection signal Broken-wire

detection signal

Arc-off detection signal (power

supply abnormal)

CRW7 (23)L

Welding start signal WO01

Wire inching (+)

WCOM1CRW7 (24)

K

CRW7 (29)F WO04

WCOM4CRW7 (30)

G

CRW7 (13)H WO05

WCOM5CRW7 (14)

J Wire inching (-)

＋

－

Welding machine frame ground

Cabinet ground (shield clamped)

+24E



- 370 -


EFFECTOR INTERFACES

FANUC interface

Control unit (welding machine interface) Process I/O boards GA, HA, and HB

Welding machine

DACH1CRW7 (1)

Connector pin No.


COMDA1CRW7 (2)

DACH2CRW7 (3)

COMDA2CRW7 (4)

＋



A

B

E

F


WDI+CRW1 (31)

WDI-CRW1 (32)

Wire deposition detection signal

N

P

－

Welding power

WI01CRW7 (5)

CRW7 (33,34)


COM-3

WI02CRW7 (6)

WI03CRW7 (7)

WI04CRW7 (8)

3.3k

+24E

0V

B A


（ICOM3）

RV

RV

RV

RV

RV

r

c

d

e

f

Arc detection signalOut-of-gas


detection signal


supply abnormal)

CRW7 (23)R

Welding start signalWO01

Wire inching (+)

WCOM1CRW7 (24)

CRW7 (29)U WO04

WCOM4CRW7 (30)

CRW7 (13)V WO05

WCOM5CRW7 (14)

b Wire inching (-)

＋

－

WI05CRW7 (9)

WI06CRW7 (10)

WI07CRW7 (11)

WI08CRW7 (12)

RV

RV

RV

RV

h

j

k

g

+24E

Out-of-cooling-water detection

CRW7 (19,20)m

CRW7 (21,22)n

0V

CRW7 (25)S

Gas signal WO02

WCOM2CRW7 (26)

a

s





- 371 -


EFFECTOR INTERFACES

Welding machine interface

CRW10 01 DACH1 33 WO1 02 COMDA1 19 ADCH1 34 WCOM1 03 DACH2 20 COMAD1 35 WO2 04 COMDA2 21 ADCH2 36 WCOM12 05 DACH3 22 COMAD2 37 WO3 06 COMDA3 23 38 WCOM3 07 WI1 24 39 WO4 08 WI2 25 WDI+ 40 WCOM4 09 WI3 26 WDI- 41 WO5 10 WI4 27 42 WCOM5 11 WI5 28 43 WO6 12 WI6 29 44 WCOM6 13 WI7 30 45 WO7 14 WI8 31 46 WCOM7 15 0V 32 47 WO8 16 0V 48 WCOM8 17 0V 49 +24E 18 0V

50 +24E

NOTE The welding machine connection cables are options.

Applicable process I/O board types

KA

Control unit

Welding machine


- 372 -


EFFECTOR INTERFACES

Pin-to-pin connection between CRW10 connector and welding machine connector (general interface) (analog output, welding wire deposition detection, WI/WO connection, for connections with +24 V common)

Control unit（Welding machine interface） Process I/O board KB

Welding machine

DACH1CRW10 (1)

Connector pin No.

R=100Ωor higher

COMDA1CRW10 (2)

DACH2CRW10 (3)

COMDA2CRW10 (4)

＋



A

B

C

D


WDI+CRW10 (25)

WDI-CRW10 (26)


M

N

－ Welding power

WI02CRW10 (8)

CRW10 (49,50)


COM-3

WI03CRW10 (9)

WI04CRW10 (10)

WI06CRW10 (12)

3.3k

+24E

0V

B A


（ICOM3）

RV

RV

RV

RV

RV

E

P

S

T

R



detection signal Arc-off detection

signal (power supply abnormal)

CRW10 (33)L

Welding start signal WO01

Wire inching (+)

WCOM1CRW10 (34)

K

CRW10 (39)FWO04

WCOM4CRW10 (40)

G

CRW10 (41)HWO05

WCOM5CRW10 (42)

JWire inching (-)

＋

－



+24E

NOTE

In this diagram, common voltage of input devices is +24V.


- 373 -


EFFECTOR INTERFACES

Pin-to-pin connection between CRW10 connector and welding machine connector: FANUC interface (analog input/output, welding wire deposition detection, WI/WO connection, for connections with +24 V common)

Control unit (welding machine interface) Process I/O boards KA, KB

Welding machine

DACH1CRW10 (1)

Connector pin No.

COMDA1CRW10 (2)

DACH2CRW10 (3)

COMDA2CRW10 (4)



A

B

E

F


r

c

d

e

f

WI08

WI01

COM-3

WI02

WI03

WI04

WI05

WI06

WI07

CRW10 (7)Connector pin No.

CRW10 (8)

CRW10 (9)

CRW10 (10)

CRW10 (11)

CRW10 (12)

CRW10 (13)

CRW10 (14)

Receiver circuit RV

RV

RV

RV

RV

RV

RV

RV

RV

h

j

k

g



detection signal


supply abnormal)

Out-of-cooling-water detection

A

0V

m

n

CRW10 (49,50)+24E

CRW10 (15,16)

CRW10 (17,18)

0V


+24E B


（ICOM3）

3.3k

ADCH1CRW10 (19)

COMAD1CRW10 (20)

ADCH2CRW10 (21)

COMAD2CRW10 (22)

0V

sCabinet ground (shield clamped)

J

K

L

M

Ripples must have been removed from the output signals.

Welding start signal

－

Wire inching (+)

Gas signal

WO01

WCOM1

WO03

WCOM3

WO04

WCOM4

WO02

WCOM2

CRW10 (33)

CRW10 (34)

CRW10 (37)

CRW10 (38)

CRW10 (39)

CRW10 (40)

CRW10 (35)

CRW10 (36)

Wire inching (-)

－

－

－

WO05

WCOM5

WO07

WCOM7

WO08

WCOM8

WO06

WCOM6

CRW10 (41)

CRW10 (42)

CRW10 (45)

CRW10 (46)

CRW10 (47)

CRW10 (48)

CRW10 (43)

CRW10 (44)

WDI+CRW10 (25)

WDI-CRW10 (26)



＋

N

P

－Welding power

R

U

V

＋

－

S

T

a

b

W

Z

X

Welding voltage detection signal

Welding current detection signal


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EFFECTOR INTERFACES

4.6 INTERFACE FOR END EFFECTOR

4.6.1 Connection Between the Mechanical Unit and End Effector

Mechanical unit

EE 1 2 3 4 RO1 RO2 RO3 RO4 5 6 7 8 9 RO5 RO6 *HBK 0V RI1 10 11 12 13 14 15 RI2 RI3 RI4 RI8 *PPABN RI5

16 17 18 19 20 RI6 +24VF +24VF +24VF +24VF 21 22 23 24 RO7 RO8 0V RI7

Fig.4.6.1 In case of the R-2000iB, M-710iC (For other robots, refer to the each operators manual.)

End effector


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EFFECTOR INTERFACES

Mechanical unit (end-effector interface) Peripheral device

Wrist breakage *HBKdetection signal

EE (7)

EE(17,18,19,20)Connector pin No.+24VF

Receiver circuit

RI7EE (24)

RI9

RI1EE (9)

RI2EE (10)

RI3EE (11)

RI4EE (15)

RI5

EE (12)

RI6EE (16)

3.3k

+24E

0V

B A

Set this jumper according to the common voltage of

input devices. (COM1)

RV

RV

RV

RV

RV

RV

RV

RV

RV

RO1

EE (2)

EE (1)

Driver circuit

RO8

RO2EE (3)

RO3EE (4)

RO4EE (5)

RO5EE (6)

RO6EE (21)

RO7EE (22)

DV LOAD

RELAY

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

+24VF

A maximum output current per RO point is 0.2 A.

EE (8,23)

0V

DV

DV

DV

DV

DV

DV

DV

RI8EE (13)

RV

‘(Pneumatic pressure *PPABN)abnormal signal)

0V

EE (13)

NOTE 1 In this diagram, common voltage of input devices is +24V. 2 The common-level change-over setting pin (COM1) is in the 6-axis servo amplifier.


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EFFECTOR INTERFACES

4.7 DIGITAL I/O SIGNAL SPECIFICATIONS This section describes the specifications of the digital I/O signals interfaced with the peripheral device, end effector, and arc welder.

4.7.1 Peripheral Device Interface A (1) Output signals in peripheral device interface A (Source type DO)

(a) Example of connection

Spark killer diode

0.2A or less

(b) Electrical specifications Maximum load current when driver is on: 200 mA

(including momentary level) Saturation voltage when driver is on: 1.0 V max. Dielectric strength: 24 V ±20% (including momentary

level) Leakage current when driver is off: 100 µA

(c) The external power supply to output signals must satisfy the

following: Power supply voltage: +24 V ±10% Power supply current: For each printed circuit board of this type (Total sum of maximum load currents including

momentary levels + 100 mA or more) Power-on timing: At the same time when the control unit is turned on or

earlier Power-off timing: At the same time when the control unit is turned off or

later

(d) Spark killer diode Rated peak reverse voltage : 100 V or more Rated effective forward current : 1 A or more

(e) Driver for output signals In the driver device, the current of each output signal is

monitored, and when an overcurrent is detected, the relevant output is turned off. After an output has been turned off by overcurrent, the overcurrent state is released because the output is off, so the output on state is restored. Therefore,


- 377 -


EFFECTOR INTERFACES

in the ground fault or overcurrent state, the output is turned on and off repeatedly. Such a condition is found also when a load with a high surge current is connected.

The driver device also includes an overheat detection circuit, which turns off all outputs of the device when the internal temperature of the device has increased as a result of a continued overcurrent state due to a ground fault of an output and so on. The outputs are held off, but their normal states can be restored by turning the power to the controller on and off after the internal temperature of the device has lowered.

(f) Note on use When adding a relay, solenoid, or the like directly to the

circuit, connect a diode for counter electromotive voltage protection in parallel to the load.

(g) Applicable signals Output signals of process I/O board CRMA5 and CRMA6 CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD,

FAULT, ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNO1 to SNO8, SNACK, DO1 to DO76

(2) Output signals in peripheral device interface A (Sink type DO)


0V

+24V

0.2A

or less

Spark killer diode

(b) Electrical specifications Rated voltage :24VDC Maximum applied voltage :30VDC Maximum load current :0.2A Transistor type :Open collector NPN Saturation voltage at connection :1.0V (approx.) (c) Spark killer diode

Rated peak reverse voltage :100V or more Rated effective forward current :1A or more

(d) Note on use


- 378 -


EFFECTOR INTERFACES

Do not use the +24V power supply of the robot. When adding a relay, solenoid, or the like directly to the


(e) Applicable signals Output signals of process I/O board CRM2 and CRM4 CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD,

FAULT, ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNO1 to SNO8, SNACK, DO1 to DO76

(2) Input signals in peripheral device interface A


+24V

3.3kΩ

ＢＡ

ＩＣＯＭ

+24V

ＲＶ

(b) Electrical specifications of the receiver Type : Grounded voltage receiver Rated input voltage : Contact close +20V to +28V : Contact open 0V to +4V Maximum applied input voltage : +28VDC

Input impedance : 3.3kΩ(approx.) Response time : 5ms to 20ms (d) specifications of the peripheral device contact

Rated contact capacity : 30VDC, 50mA or more Input signal width : 200ms or more (on/off)

Chattering time : 5ms or less Closed circuit resistance : 100Ω or less Opened circuit resistance : 100kΩ or more


- 379 -


EFFECTOR INTERFACES

(Signal)(Signal)

TCTC

TBTBTB

Peripheral device contact signal

Robot receiver signal TB ; Chattering 5 ms or less TC ; 5 to 20 ms

(e) Note on use Apply the +24 V power at the robot to the receiver. However, the above signal specifications must be satisfied

at the robot receiver.

(f) Applicable signals Input signals of process I/O board CRM2, CRM4, CRMA5

and CRMA6 *IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET,

START, HOME, ENBL, RSR1 to RSR8, PNSTROBE, PROD START, DI1 to DI78


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EFFECTOR INTERFACES

4.7.2 End Effector Control Interface (1) Output signals in end effector interface


0V

+24V

0.2A or less

Spark killer diode

(b) Electrical specifications Maximum load current when driver is on: 200 mA

(including momentary level) Saturation voltage when driver is on: 1.0 V max. Dielectric strength: 24 V ±20% (including momentary

level) Leakage current when driver is off: 100 µA

(c) Power supply to output signals The +24 V power supply on the robot side can be used if the

total current level, including the current of the welding interface, is 0.7 A or less.

(d) Driver for output signals In the driver device, the current of each output signal is

monitored, and when an overcurrent is detected, the relevant output is turned off. After an output has been turned off by overcurrent, the overcurrent state is released because the output is off, so the output on state is restored. Therefore, in the ground fault or overcurrent state, the output is turned on and off repeatedly. Such a condition is found also when a load with a high surge current is connected.

The driver device also includes an overheat detection circuit, which turns off all outputs of the device when the internal temperature of the device has increased as a result of a continued overcurrent state due to a ground fault of an output and so on. The outputs are held off, but their normal states can be restored by turning the power to the control unit on and off after the internal temperature of the device has lowered.

(e) Note on use When adding a relay, solenoid, or the like directly to the



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EFFECTOR INTERFACES

(f) Applicable signals RO1 to RO8

(2) Input signal in peripheral device interface The input signals are the same as those of other I/O boards.

(Refer to Subsection 4.5.1 in CONNECTIONS.)

(a) Applicable signals RI1 to RI8, *HBN, *PPABN


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EFFECTOR INTERFACES

4.7.3 I/O Signal Specifications for ARC-Welding Interface (1) Digital Output signals specifications for an arc welding interface In case of process I/O CA,EA


0V

+24V

0.2A

or less

Spark killer diode

(b) Electrical specifications Rated voltage :24VDC Maximum applied voltage :30VDC Maximum load current :0.2A Transistor type :Open collector NPN Saturation voltage at connection :1.0V (approx.) (c) Spark killer diode


(d) Note on use Do not use the +24V power supply of the robot. When adding a relay, solenoid, or the like directly to the


(e) Applicable signals Output signals of process I/O board CRW1 WO1 to WO8


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EFFECTOR INTERFACES

In case of process I/O GA,HA (a) Example of connection

0V

+24V

0.3A

or less

Spark killer diode

(b) Electrical specifications Rated voltage :24VDC Maximum applied voltage :30VDC Maximum load current :0.3A Transistor type :Relay connect output (c) Spark killer diode


(d) Note on use Do not use the +24V power supply of the robot. When adding a relay, solenoid, or the like directly to the


(e) Applicable signals Output signals of process I/O board CRW7 WO1 to WO8

(2) Digital input signals specifications for an arc welding interface The input signals are the same as those of other I/O boards.

(Refer to Subsection 4.5.1 in CONNECTIONS.)

(a) Applicable signals Input signals of process I/O board CRW1, CRW7 WI1 to WI8


- 384 -


EFFECTOR INTERFACES

(3) Analog output signal specifications for an arc welding interface (Welding voltage command, wire-feed rate command)


0V

Welder

Process I/O CA, EA: -10V to +10V Process I/O GA, HA: 0V to +15V

(b) Note on use Input impedance: 3.3kΩ or more Connect a high-pass filter

(2) Analog input signal specifications for an arc welding interface

(Welding-voltage detection , welding-current detection) (a) Example of connection

0V

Welder

－10V～＋10V

(b) Note on use Input impedance: 2kΩ The analog input signal should have no ripple for the circuit

to operate properly.


- 385 -


EFFECTOR INTERFACES

(Wire deposit detection: WDI+ and WDI-)


Welder

max. +15V 85mA

Welding electrode

+

‐

(b) Note on use Connect a resistor of 100Ω or more between the positive

and negative electrodes of the welder. Isolate the deposit detection signals for TIG welding from the welding circuit, which uses high-frequency components. The dielectric withstand voltage of this circuit is 80V.


- 386 -


EFFECTOR INTERFACES

4.8 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS

If the customer manufactures cables, make sure they conform to the FANUC standard cables described in this section. (See the description in "Peripheral Device Interface" in this manual for the specifications of the FANUC standard cables.)

4.8.1 Peripheral Device Interface A Cable (CRM2, CRMA5: Honda Tsushin, 50 pins)

Process I/O

Honda Tsushin MR50RMA

Peripheral device

Honda Tsushin MR50LWF01 (MR50LF)

Honda Tsushin MR50LM01 (MR50LM)

Honda Tsushin's MR50RF Supplied with an ordered cable

CRMA5*

4.8.2 Peripheral Device Interface B Cable (CRM4, CRMA6: Honda Tsushin, 20 pins)

Process I/O Peripheraldevice

Process I/O

Honda Tsushin MR20RMA

Peripheral device

Honda Tsushin MR20LWF01 (MR20LF)

Honda Tsushin MR20LM01 (MR20LM)

Honda Tsushin's MR20RF Supplied with an ordered cable

CRMA6*


- 387 -


EFFECTOR INTERFACES

4.8.3 ARC Weld Connection Cable (CRW1, CRW7:Honda Tsushin,34pins)

Be sure to use our cable to connect the welder.

4.8.4 ARC Weld Connection Cable（CRW10 : Honda Tsushin, 50 pins）

Be sure to use our cable to connect the Welder.

CRW10

MRH-50RFD

MR-50LWMH Process I/O

Honda Tsushin

Honda Tsushin Japan Aviation Electronics Industry Ltd.

ARC Welder

Japan Aviation Electronics Industry Ltd.

Standard position of guide key


- 388 -


EFFECTOR INTERFACES

4.9 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS, AND ARC WELDERS

4.9.1 Peripheral Device Connection Cable

Fig.4.9.1 shows the connection of the peripheral device cable in the cabinet.

(A-cabinet)

Shield plate

Metallic clamp Optional board CRMA5A CRMA5B

(B-cabinet) For noise protection, cut part of the jacket of the peripheral device cable to expose the shield sheath, and fasten this part to the shield plate with the clamp.

Fig.4.9.1 Peripheral Device Cable Connection

Process I/O board

CRM2A or CRMA5A CRM2B or CRMA5B

CRW1 or CRW7 or CRW10


- 389 -


EFFECTOR INTERFACES

4.9.2 Peripheral Device Cable Connector (1) Fig.4.9.2 shows the connector for peripheral device cables A and

B.

Dimensions Connector specifications

Applicable interface A (B) C (D)

Remark

MR50LM CRMA5 67.9 73.5 44.8 18 Honda Tsushin Kogyo, 50 pinsMR20LM CRMA6 39.3 44.9 39.8 17 Honda Tsushin Kogyo, 20 pins

Symbol Name

1 Connector cover 2 Cable clamp screw 3 Connector clamp spring 4 Connector clamp screw

5 Connector 50 pins (male) MR50M

20 pins (male) MR20M

Fig.4.9.2 (a) Peripheral device cable connector (Honda Tsushin Kogyo)


- 390 -


EFFECTOR INTERFACES

(2) Peripheral device connector

，

Dimensions Connector specifications

Applicable interface A B

Remark

MR50RF (CRM2) (CRMA5)

61.4 56.4 Honda Tsushin Kogyo, 50 pins

MR20RF (CRM4) (CRMA6)

39.3 44.9 Honda Tsushin Kogyo, 20 pins

Symbol Name

1 Connector clamp screw 2 Screw M2.6 8

3 Connector (MR50RF)

(MR20RF)

Fig.4.9.2 (b) Peripheral device connector (Honda Tsushin Kogyo)


- 391 -


EFFECTOR INTERFACES

4.9.3 End Effector Cable Connector (1) Connector external view (For R-2000iB and M-710iC. Refer to

the each operators manual for other robots.)

A : M30#1 B : 63.0 C : 54.5 D : 9.6 to 15.0 (Inside diameter) E : #33 F : 11.2 G : 24.7 Manufactured by Fujikura JMLP2524M

Fig.4.9.3 (a) Connector (Elbow Type)

A : M30#1 B : 54.1 C : 37.5 D : 9.6 to 15.0 (Inside diameter) E : #33 F : 11.2 G : 24.7 Manufactured by Fujikura JMLP2524M

Fig.4.9.3 (b) Connector (Straight Type)


- 392 -


EFFECTOR INTERFACES

4.9.4 Recommended Cables (1) Peripheral device connection cable Connect a peripheral device using a completely shielded, heavily

protected cable conforming to the specifications in Table 4.9.4 (a).

Allow an extra 50 cm for routing the cable in the control unit. The maximum cable length is 30 m.

Table 4.9.4 (a) Recommended Cable (for Peripheral Device Connection) Conductor Electrical characteristics

Number of wires Wire specifications

(FANUC specifications)

Diameter (mm) Configuration

Sheath thickness

(mm)

Effective outside

diameter (mm)

Conductor resistance

(Ω/km)

Allowable current (A)

50 A66L-0001-0042 φ1.05 7/0.18 AWG24 1.5 φ12.5 106 1.6A 20 A66L-0001-0041 φ1.05 7/0.18 AWG24 1.5 φ10.5 106 1.6A

(2) End effector connection cable Connect an end effector using a heavily protected cable with a

movable wire conforming to the specifications in Table 4.9.4 (b). The cable length is determined so that the cable will not interfere

with the end effector and the wrist can move through its full stroke.

Table 4.9.4 (b) Recommended Cable (for End Effector Connection)

Conductor Electrical characteristics

Number of wires Wire specifications

(FANUC specifications)

Diameter (mm) Configuration

Sheath thickness

(mm)

Effective outside

diameter (mm)

Conductor resistance

(Ω/km)

Allowable current (A)

6 A66L-0001-0143 φ1.1 40/0.08 AWG24 1.0 φ5.3 91 3.7 20 A66L-0001-0144 φ1.1 40/0.08 AWG24 1.0 φ8.6 91 2.3 24 A66L-0001-0459 φ0.58 40/0.08 AWG24 1.0 φ8.3 93 2.3


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EFFECTOR INTERFACES

4.10 CONNECTION OF HDI

4.10.1 Connecting HDI The HDI signals are used in combination with special application software. The HDI signals cannot be used as general-purpose DIs.

R-30iA

Main board JRL5

1 HDI0 11 HDI1 2 0V 12 0V 3 HDI2 13 HI3 4 0V 14 0V 5 0V 15 HDI5 6 HDI4 16 0V 7 17 HDI6 8 18 0V 9 19 HDI7 10 20 0V


- 394 -


EFFECTOR INTERFACES

Cable connections

Recommended cable connector: PCR-E20FA (Honda Tsushin Kogyo) FI30-20S (Hirose Electric) FCN-247J020-G/E (Fujitsu) 52622-2011 (Molex Japan)

HDI0

0V

HDI1

0V

HDI2

0V

HDI3

0V

HDI4

0V

HDI5

0V

HDI6

0V

HDI7

0V

1

2

11

12

3

4

13

14

6

5 or 10

15

16

17

18

19

20

7

8

9

10

JRL5

Shield

Ground plate


- 395 -


EFFECTOR INTERFACES

4.10.2 Input Signal Rules for the High-speed Skip (HDI)

Circuit configuration

R-30iA

VH/VL

DRIVER

SHIELD

FILTER liL/liH RECEIVER

Absolute maximum rating Input voltage range Vin: -3.6 to +10 V Input characteristics

Unit Symbol Specification Unit Remark High level input voltage VH 3.6 to 7 V Low level input voltage VL 0 to 1.0 V

2 max mA Vin=5 V High level input current liH 11 max mA Vin = 10 V

Low level input current liL -8.0 max mA Vin = 0 V Input signal pulse duration

20 min m s

Input signal delay or variations

0.02(max) ms

NOTE 1 The plus (+) sign of IiH/IiL represents the direction

of flow into the receiver. The minus (-) sign of IiH/IiL represents the direction of flow out of the receiver.

2 The high-speed skip signal is assumed to be 1 when the input voltage is at the low level and 0 when it is at the high level.


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EFFECTOR INTERFACES

4.11 CONNECTING THE COMMUNICATION UNIT

4.11.1 RS-232-C Interface

4.11.1.1 Interface This interface can be connected to a communication unit from FANUC.

(A-cabinet)

RS-232-C port

(B-cabinet)

RS-232-C port

RS-232-C port

In case of the length of operation box connection cable that is 10m or longer.


- 397 -


EFFECTOR INTERFACES

ER

+24V

14

16 15

17

19 18

20

22 21

23

25 24

SD FG

RD

CS RS

DR SG

1

3 2

4

6 5

7

9 8

10

12 11

13

R-30iA

> <

Main board Operator's panel Connector (DBM-25S)

>

NOTE 1 +24 V can be used as the power supply for FANUC

RS-232-C equipment. 2 Do not connect anything to those pins for which

signal names are not indicated.

4.11.1.2 RS-232-C interface signals Generally signals as follows are used in RS-232-C interface.

R-30iA

SD (Send data)

RD (Receive data)

RS (Request to Send)

CS (Enable to send)

ER (Ready)

DR (Data set ready)

SG (Signal ground)

FG (Frame ground)

When CS is not used shortCS and RS.

When DR is not used short DR and ER.

Output

Input

Fig.4.11.1.2 RS-232-C interface


- 398 -


EFFECTOR INTERFACES

4.11.1.3 Connection between RS-232-C interface and I/O device The figure below shows a connection with the handshaking of the ER/DR, RS/CS signals.

R-30iA I/O device side SD

RD

RS

CS

ER

DR

CD

SG

FG

SD

RD

RS

CS

ER

DR

CD

SG

FG FG (Frame ground)


- 399 -


EFFECTOR INTERFACES

• The figure below shows a connection without the handshaking of the RS/CS, ER/DR signals.

External device side SD

RD

RS

CS

ER

DR

SG

FG

SD

RD

RS

CS

ER

DR

CD

SG

FG

R-30iA

FG (Frame ground)

Cable connection

DR

R-30iA

Cable : twist 10 pairs 0.18mm2, with shield

SDRD

RSCS

SG

ER

Pair each signal with SG.


- 400 -


EFFECTOR INTERFACES

4.11.2 Ethernet Interface

CAUTION Before connecting or disconnecting cables to and

from the Ethernet board, cut the power supply of R-30iA, and make sure that the power is off.

NOTE Please ask each manufacturer about the network

construction of network or the condition of using the equipment except the Ethernet board (hub, transceiver, cable etc.). When configuring your network, you must take other sources of electrical noise into consideration to prevent your network from being influenced by electrical noise. Make sure that network wiring is sufficiently separated from power lines and other sources of electrical noise such as motors, and ground each of the devices as necessary. Also, a high and insufficient ground impedance may cause interference during communications. After installing the machine, conduct a communications test before you actually start operating the machine.

We cannot ensure operation that is influenced by network trouble caused by a device other than the main board.


- 401 -


EFFECTOR INTERFACES

4.11.2.1 Connection to Ethernet The main board is provided with a 10/100 BASE-T interface. Prepare a hub for connecting the Ethernet board to the Ethernet trunk. The following shows an example of a general connection.

R-30iA

Some devices (hub, transceiver, etc.) that are needed for building a network do not come in a dust-proof construction. Using such devices in an atmosphere where they are subjected to dust or oil mist will interfere with communications or damage the Ethernet board. Be sure to install such devices in a dust-proof cabinet.


- 402 -


EFFECTOR INTERFACES

4.11.2.2 10/100 BASE-T connector (CD38) pin assignments CD38

Pin No. Signal Name Description 1 TX+ Send + 2 TX- Send - 3 RX+ Receive + 4 Not used 5 Not used 6 RX- Receive - 7 Not used 8 Not used

4.11.2.3 Cable connection

The figure below shows the cable connection between the 10/100 BASE-T connector (CD38) of the main board and hub.

Ethernet board

RJ-45 modular connector

MAX.100m

Shielded cable

• For details on shielding, see Subsection 4.7.1, "Peripheral Device

Connection Cable" in the Part III, “CONNECTIONS”. • Keep the total cable length to within 100 m. (FANUC

recommends the cable length to within 50 m for movable parts.) Do not extend the cable longer than necessary.


- 403 -


EFFECTOR INTERFACES

(For the A-cabinet)

Use any connector not in use

Clamp : A02B-0083-K301 The cable should be fixed on the shield plate.


- 404 -


EFFECTOR INTERFACES

4.11.2.4 Lead materials Unshielded cable (UTP cable) is commercially available as 10/100 BASE-T twisted-pair cable. However, be sure to use shielded Category 5 twisted-pair cable (STP) to improve the resistance to electrical noise in an FA environment. (For details on shielding, see Subsection 4.7.1, "Peripheral Device Connection Cable" in the Part III, “CONNECTIONS”. Recommended Cable (For fixed parts)

Manufacturer Specification Furukawa Electric Co., Ltd. DTS5087-4P Nissei Electric Co., Ltd. F-4PFWMF

Inquiries

Manufacturer Contact Address Furukawa Electric Co., Ltd., Sales Headquarters

Maru-no-uchi 2-6-1, Chiyoda-ku. Tokyo 100-8322 TEL: 03-3286-3126

Remarks Nissei Electric Co., Ltd., Machida Branch

4F MS center Bldg., Minami-narise 1-2-2, Machida City, Tokyo 194-0045 TEL: 0427-29-2531 FAX: 0427-29-3375

Overseas Sales Office IWATANI International Corporation - Tokyo Head Office21-8 NISHI-SHINBASHI 3-CHOME, MINATO-KU, TOKYO, 105-8458, JAPAN TEL:03-5405-5810 Telex : 2524256 IWATYO J

Remarks Cables with connectors at both ends can be supplied.

NOTE The recommended cables cannot be connected to

movable portions. Recommended Cable (For movable parts)

Manufacturer Specification Remarks Oki Electric Cable Co., Ltd.

AWG26 4P TPMC-C5-F(SB) FANUC-specific cable

Cable specifications (FANUC-specific cable No connector) Drawing number: A66L-0001-0453 Manufacturer: Oki Electric Cable Co., Ltd. Nagano Sales Office TEL: 0266-27-1597


- 405 -


EFFECTOR INTERFACES

Specifications • Electric characteristics: Conform to EIA/TIA 568A categories

3 and 5. For reasons related to attenuation performance, the distance to

the hub must be 50 m or shorter. • Structure: Common shield cable (braided shield). Drain wire

provided. The conductor is AWG26 annealed copper stranded wire. The

sheath thickness is 0.8 mm. The outside diameter is 6.7±0.3 mm.

• Flame resistance: UL1581 VW-1 • Oil resistance: Based on the FANUC standard. (equivalent to the conventional oil-resistant electric cables) • Flexing resistance: 1 million times or more with 50 mm of a

bend radius (U-shape flexing test) • UL style No.: AWM 20276 (80n/30 V/VW-1)

NOTE Always use connector TM21CP-88P(03)

manufactured by Hirose Electric for this cable. Cable assembly

Oki Electric Cable Co., Ltd. also supplies cable assemblies using connector TM21CP-88P(03) manufactured by Hirose Electric. Make arrangements directly with the manufacturer for the specifications (length, outgoing inspection, packing, and others) and purchase cable assemblies.

Contact point: Oki Electric Cable Co., Ltd. Sales contact point) Nagano Sales Office TEL: 0266-27-1597


- 406 -


EFFECTOR INTERFACES

4.11.2.5 Connector specification As a connector used with a twisted pair cable for Ethernet, an 8-bit modular connector called RJ-45 is used. Use the following connector or equivalent:

Specification Manufacturer Remarks For solid wire 5-569530-3 Tyco Electronics AMP For solid wire MS8-RSZT-EMC SK KOHKI Co., Ltd. Special tool

required For twisted wire 5-569552-3 Tyco Electronics AMP For twisted wire TM11AP-88P Hirose Electric Co., Ltd. Special tool

required

For movable parts Specification Manufacturer RemarksFor cable AWG26 4P TPMC-C5-F(SB)

TM21CP-88P(03) Hirose Electric Co., Ltd. (Note)

NOTE TM21CP-88P(03) Connector (manufacturer standard part) Drawing number: A63L-0001-0823#P Manufacturer: Hirose Electric Co., Ltd. Manufacturer catalog number: TM21CP-88P(03) Conforms to EIA/TIA 568A categories 3 and 5. For how to assemble the connector and cable,

contact Hirose Electric. (Hirose Electric technical document

"TM21CP-88P(03) Connection Procedure Specifications" (technical specification No. ATAD-E2367) is available.)

4.11.2.6 Cable clamp and shielding

Shield the cables as like as other cables are shielded. (See Subsection 4.7.1, "Peripheral Device Connection Cable" in the Part III, “CONNECTIONS”.)


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EFFECTOR INTERFACES

4.11.2.7 Grounding the network Even if the grounding conditions on the machine are satisfied, electrical noise from the machine sometimes enters the communications line and causes communications interference depending on the installation conditions and the peripheral environment of the machine. To prevent the entry of such electrical noise, separating and insulating the machine from the Ethernet trunk cable and the personal computer effectively reduces the influence of electrical noise. The following figure shows an example of such a connection.


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EFFECTOR INTERFACES

Large-scale Network

Small-scale Network

Electrically separated by 10/100 BASE-T cable connection

Electrically separated by 10/100 BASE-T cable connection


- 409 -


EFFECTOR INTERFACES

NOTE 1 The ground between the PC/Trunk line side and

machine system side must be separated. If it is impossible to separate the ground because there is only one grounding point, connect the ground cable for each system to the grounding point independently. (Refer Fig.4.9.2.7)

The resistance for grounding must be less than 100-ohm (Class 3).

The thickness of the ground cable is the same as the thickness of AC power cable or more. At least thickness of 5.5mm2 is necessary.

2 Please use the HUB that has unshielded interface connector. FANUC recommends the HCN-7500 (Hitachi-Densen LTD) or equivalent.

3 There is the possibility that noise makes the obstacle of communication even if the ground is separated using the 10/100 BASE-T. In the case of using the Ethernet board under the worst environment, please separate between the PC/Trunk line side and machine system side completely using the 10/100 BASE-FL (Optical fiber media).

Fig.4.11.2.7 Wiring on a single ground point

5.TRANSPORTATION AND INSTALLATION CONNECTIONS B-82595EN-2/02

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5 TRANSPORTATION AND INSTALLATION This chapter describes the transportation and installation for the controller.

B-82595EN-2/02 CONNECTIONS 5.TRANSPORTATION AND INSTALLATION

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5.1 TRANSPORTATION The controller is transported by a crane. Attach a strap to eye bolts at the top of the control unit.


Fig. 5.1 Transportation

Eye bolt (M12)

Crane capacity : Minimum 300kg Sling capacity : Minimum 300kg

Eye bolt (M12)


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5.2 INSTALLATION

5.2.1 Installation Method Following is the installation method for cabinet. When installing the controller, allow the space for maintenance shown in the following figure.

Munsell Color

5GY3.5/0.5 Gray

Fig. 5.2.1 (a) External dimension (A-cabinet Rear fan type)


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Munsell Color

5GY3.5/0.5 Gray

Fig. 5.2.1 (b) External dimension (A-cabinet Side fan type)


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Munsell Color

Body 5GY3.5/0.5 Gray Door 3.0GY8.2/0.9 White

Op.panel N1.5 Black

Fig. 5.2.1 (c) External dimension (B-cabinet)


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Fig. 5.2.1 (d) Installtion dimension (A-cabinet)


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Controller Controller Controller

100100

NOTE Keep this area for maintenance and the radiation of

heat.

Fig. 5.2.1 (e) Installtion dimension (B-cabinet)


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Munsell Color

Body 5GY3.5/0.5 Gray

Door 3.0GY8.2/0.9 White

Fig. 5.2.1 (f) External dimension (A-cabinet operation box)

Munsell Color

Body 5GY3.5/0.5 Gray Door 3.0GY8.2/0.9 White

Fig. 5.2.1 (g) External dimension (Integrated operation box)


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5.2.2 Assemble at Installation

Fig.5.2.2 (a) Assemble at installation (A-cabinet)

Fig.5.2.2 (b) Assemble at installation (Integrated operation box)


Operation box

Teach pendant

Robot connection cable

R-30iA controller

Teach pendant

Integrated operation box

Peripheral device connection

cable



- 419 -

Teach pendant

R-30iA controller



Fig.5.2.2 (c) Assemble at installation (B-cabinet)


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5.3 INSTALLATION CONDITION Item Model Specification/condition

Rated Voltage All models Trans. Type E 380-415, 440-500, 500-575VAC Trans. Type D 380-400, 200-230VAC 50/60Hz 3phases

Tolerant fluctuation All models Tolerant voltage fluctuation: +10% -15% Tolerant frequency fluctuation: ±1Hz

M-900iA/600 18KVA R-2000iB/200T,M-410iB, M-900iA/260L,M-900iA/350

15KVA

R-2000iB(except /200T) M-420iA /M-421iA,M-710iC

12KVA

F-200iB 5KVA M-16iB,ARC Mate 120iB 3KVA M-6iB,ARC Mate 100iB 2.5KVA M-430iA/2F 3.5KVA M-430iA/2P 3.5KVA

Input power source capacity

ARC Mate 100iC, M-10iA 2.0KVA M-900iA/600 5KW R-2000iB/200T,M-410iB, M-900iA/260L,M-900iA/350

3KW

R-2000iB(except /200T) M-420iA /M-421iA,M-710iC

2.5KW

M-6iB, M-16iB ARC Mate100iB ARC Mate120iB, F-200iB

1.0KW

M-430iA/2F 1.0KW M-430iA/2P 1.0KW

Average power consumption

ARC Mate 100iC, M-10iA 1.0KW Permissible ambient temperature

All models 0 to 45ºC during operation, and -20 to 60ºC during shipment and storage with a temperature coefficient of 1.1ºC/min

Permissible ambient humidity

All models Relative humidity: 30% to 95%, non-condensing

Surrounding gas All models An additional protective provision is necessary if the machine is installed in an environment in which there are relatively large amounts of contaminants (dust, dielectric fluid, organic solvent, acid, corrosive gas, and/of salt).

Installation category All models Installation category III, Pollution degree 3, IEC60664-1 and IEC61010-1

Vibration All models 0.5G or less. When using the robot in a location subject to serious vibration, consult with your FANUC sales representative.

Altitude Common to all models Not higher than 1,000m above sea level Ionized and non-ionized radiation Common to all models A shielding provision is necessary if the machine is

installed in an environment in which it is exposed to radiation (microwave, ultraviolet rays, laser beams, and/or X-rays).

All models (except below models)

Approx. 120kg A-cabinet

M-410iB Approx. 140kg All models (except below models)

Approx. 180kg

Mass of control unit

B-cabinet

M-900iA, M-410iB, R-2000iB/200T

Approx. 200kg


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NOTE The power rating indicated above is sufficient as the continuous rating. However, when

the robot is rapidly accelerating, the instantaneous requirement may increase to several times the continuous rating.

5.4 ADJUSTMENT AND CHECKS AT INSTALLATION Adjust the robot according to the following procedure at installation.

No. Description 1 Visually check the inside and outside of the control unit. 2 Check the screw terminals for proper connection. 3 Check that the connectors and printed circuit boards are firmly

connected. 4 Check transformer tap setting. (See II MAINTENANCE section 6.2)5 The breaker off and connect the input power cable. 6 Check the input power voltage and transformer outputs. 7 Press the EMERGENCY STOP button on the operator panel and

turn on the control unit. 8 Check the interface signals between control unit and robot

mechanical unit. 9 Check the parameters. If necessary, set them.

10 Release the EMERGENCY STOP button on the operator panel. Turn on the controller.

11 Check the movement along each axis in manual jog mode. 12 Check the end effector interface signals. 13 Check the peripheral device control interface signals.


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5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP 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. This section describes how to reset the overtravel and emergency stop. Remove the red plate fastening the swiveling axis beforehand. The J2 and J3 axes are pressed against the hard stops at shipment. Therefore, an overtravel alarm occurs when the power is turned on after installation. The robot can also be in an emergency stop state if the peripheral device control interface is not connected.

5.5.1 Peripheral Device Interface Processing Take the following actions if signals *IMSTP, *HOLD, *SFSD, and ENBL are not used.

49, 50 +24F

1*IMSTPRV

2*HOLDRV

3*SFSDRV

4ENBLRV

CRM2A

5.5.2 Resetting Overtravel 1) Select [OT release] on the overtravel release screen to release

each robot axis from the overtravel state. 2) Hold down the shift key, and press the alarm release button to

reset the alarm condition. 3) Still hold down the shift key, and jog to bring all axes into the

movable range.


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5.5.3 How to Disable/Enable HBK 1) Press [MENUS] on the teach pendant. 2) Select [NEXT]. 3) Select [SYSTEM]. 4) Press "F1" (TYPE) on the teach pendant. 5) Select "Config" to disable/enable HBK.

Status Hand Broken enable/disable setting HBK (*1) HBK detection Robot operation Message

1 Enable CLOSE Yes Possible None 2 Enable OPEN Yes Impossible SRVO-006 3 Disable CLOSE Yes(*2) Possible None 4 Disable OPEN No Possible At cold start, SRVO-300

NOTE 1 Robot end effector connector

24V

*HBK

24V

*HBK

CLOSE OPEN

2 The moment the HBK circuit is closed, HBK detection becomes enabled. When the HBK circuit is opened again, alarm "Servo 300" or "Servo 302" occurs,

causing the robot to stop. 3 If the power is turned off and on again under the condition stated in *2, status 4 is

entered, so the alarm condition is removed.

5.5.4 How to Disable/Enable Pneumatic Pressure Alarm (PPABN) 1) Press [MENUS] on the teach pendant. 2) Select [NEXT]. 3) Select [SYSTEM]. 4) Press "F1" (TYPE) on the teach pendant. 5) Select "Config" to disable/enable PPABN.

APPENDIX

B-82595E

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AP

PE

ND

IX

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 427 -

A

TOTA

L CO

NN

ECTIO

N D

IAG

RA

M

CRMA8

VISION

RI/RO

Fig. A

(a) System block diagram

(A-cabinet)

System Block Diagram A-Cabinet

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

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B-82595E

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- 428 -

CRMA8

CRMA7

VISION

RI/RO

Fig. A(b) System

block diagram (B

-cabinet)

B-82595E

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A.TO

TAL C

ON

NE

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N D

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- 429 -

A1

A2 A3

: B1

: B2

: A1

: A2

: B1

: B2

A1

A2 A3

: B1

: B2: B3

Fig. A(c) A

C pow

er line connection diagram (in case of TYPE E transform

er / A-cabinet)

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

IX

B-82595E

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- 430 -

: A1

: A2 : A3

: B1

: B2

: A1

: A2

: B1

: B2

A1

A2 A3

: B1

: B2: B3

Fig. A(d) A

C pow

er line connection diagram (in case of TYPE E transform

er / B-cabinet)

B-82595E

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PE

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A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 431 -

CPOH

Fig. A

(e) AC

power line connection diagram

(in case of TYPE D linefilter transform

er)

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

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B-82595E

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: B2 : B1

: A2 : A1

Fig. A(f) D

C pow

er line connection diagram (A

-cabinet)

B-82595E

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PE

ND

IX

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 433 -

RS-232-C

: B2 : B1

: A2 : A1

Fig. A(g) D

C pow

er line connection diagram (B

-cabinet)

A.TOTAL CONNECTION DIAGRAM APPENDIX B-82595EN-2/02

- 434 -

CRMA8

Fig. A (h) E-STOP circuit connection diagram

B-82595EN-2/02 APPENDIX A.TOTAL CONNECTION DIAGRAM

- 435 -

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

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B-82595E

N-2/02

- 436 -

Fig. A

(i) Emergency stop board connector table

B-82595E

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AP

PE

ND

IX

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 437 -

CAMDI0

CAMDI1

12V

Fig. A(j) M

ain board connector table

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

IX

B-82595E

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Fig. A

(k) Panel board connection diagram

B-82595E

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AP

PE

ND

IX

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 439 -

Fig. A

(l) Panel board connector table

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

IX

B-82595E

N-2/02

- 440 -

Fig. A(m

) Servo amplifier connector table

B-82595E

N-2/02

AP

PE

ND

IX

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 441 -

Fig. A

(n) Motor pow

er connection (Group1)

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

IX

B-82595E

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Fig. A

(o) Motor pow


B-82595E

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PE

ND

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A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 443 -

Fig. A

(p) Motor pow


A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

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B-82595E

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- 444 -

Fig. A

(q) Motor pow


B-82595E

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PE

ND

IX

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 445 -

Fig. A(r) M

otor power connection (G

roup5)

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

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B-82595E

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- 446 -

Fig. A

(s) Motor Pow

er Connection(G

roup 6)

B-82595E

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AP

PE

ND

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A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 447 -

Fig. A

(t) Motor Pow

er Connection(G

roup 7)

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

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B-82595E

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- 448 -

Fig. A

(u) Motor Pow

er Connection(G

roup 8)


- 449 -

Fig. A (v) RI/RO connection diagram


- 450 -

Fig. A (w) RI/RO Connection Diagram(Group6,Group7)


- 451 -

Fig. A (x) RI/RO Connection Diagram(Group8)

There are many type EE connector of mechanical unit.

The detail is shown on the mechanical unit manual.


- 452 -

Fig. A (y) Pulse coder signal connection diagram


- 453 -

Fig.A (z) Pulse coder Signal Connection Diagram(Group5)


- 454 -

Fig.A (aa) Pulse coder Signal Connection Diagram(Group6)


- 455 -

Fig.A (ab) Pulse coder Signal Connection Diagram(Group7)


- 456 -

Fig.A (ac) Pulse coder Signal Connection Diagram(Group8)

B-82595E

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A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 457 -

Fig. A(ad) M

echanical unit interface(Group1, G

roup2)

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

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B-82595E

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- 458 -

Fig. A(ae) M

echanical unit interface(Group3, G

roup4)

B-82595E

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A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 459 -

Fig. A

(af) Mechanical U

nit Interface (Group5,G

roup6)

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

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B-82595E

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- 460 -

Fig. A

(ag) Mechanical U

nit Interface (Group7,G

roup8)

B-82595E

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A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 461 -

DI/DO

WI / WO

Fig. A(ah) I/O

device connection diagram (A

-cabinet)

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

IX

B-82595E

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- 462 -

DI/DO

Fig. A

(ai) I/O device connection diagram

(B-cabinet)

B-82595E

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PE

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IX

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 463 -

Fig. A

(aj) Process I/O connector table (Process I/O

JA, JB

)

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

AP

PE

ND

IX

B-82595E

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- 464 -

Fig. A(ak) Process I/O

connector table (Process I/O C

A,EA

,EB,FA

)

B-82595E

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AP

PE

ND

IX

A.TO

TAL C

ON

NE

CTIO

N D

IAG

RA

M

- 465 -

Fig. A

(al) Process I/O connector table (Process I/O

KA

, KB

, KC

)

B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE APPENDIX B-82595EN-2/02

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B SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE

B-82595EN-2/02 APPENDIX B.SPECIFICATIONS OF PERIPHERAL DEVICE INTERACE

- 467 -

B.1 SIGNAL The following table lists the I/O signals used for the peripheral device interface in the R-30iA controller. Input signals (Refer to B.3.1)

Signal Description *IMSTP *HOLD *SFSPD CSTOPI FAULT_RESETSTART HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSTROBE PROD_START DI01 DI02 DI03 DI04 DI05 DI06 DI07 DI08 DI09 DI10 DI11 DI12 DI13 DI14 DI15 DI16 DI17 DI18 DI19 DI20 DI21 DI22

Instantaneous stop signal Hold signal Safety speed signal Cycle stop signal Alarm release signal Cycle start signal Robot service request/program number select signal (*1) Enabling signal Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) Robot service request/program number select signal (*1) PNS strobe signal Automatic operation start signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal General-purpose input signal

*1: RSR :Robot Service Request (RSR5 to RSR8 are optional) PNS :Program Number Select Input (optional) Whether RSR is used or PNS is used can be preset.


- 468 -

Output signals (Refer to B.3.2)

Signal Description CMDENBL 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 ______ DO01 DO02 DO03 DO04 DO05 DO06 DO07 DO08 DO09 DO10 DO11 DO12 DO13 DO14 DO15 DO16 DO17 DO18 DO19 DO20

Command acceptance enabled signal System ready signal Program run signal Program paused signal Held signal Alarm signal Reference point signal Teach pendant enabled signal Battery alarm signal Operating signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal RSR acknowledge/Selected program number signal PNS acknowledge signal Not used (for future expansion) General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal General-purpose output signal


- 469 -

B.2 SETTING COMMON VOLTAGE All process I/O printed boards have a jumper to set the common voltage of input signals to 0 V or 24 V. The system automatically adjusts the polarity by software according to the status of this pin. Therefore, you can operate the system without being concerned about the setting of the common voltage. To ensure safety, the common reference voltage of the following four signals, is remains at +24V. *IMSTP *HOLD *SFSPD CSTOPI


- 470 -

B.3 I/O Signals

B.3.1 Input Signals This section describes the specifications of each input signal. (1) Instantaneous stop signal (input) *IMSTP

Effective : At any time Function : Use the normally-closed switch because it is a reverse signal. The system turns off power to the servo unit when the *IMSTP is open (turned off). This signal has the same effect as that of the emergency stop signal, but it is controlled by software. For this reason, use the emergency stop external interface on the emergency stop control board for wiring of the emergency stop signal. Do not use *IMSTP.

(2) Alarm release signal (input) FAULT RESET

Effective : In the alarm status Function : The FAULT RESET signal releases the alarm status. If the servo unit has been turned off, it also turns on the unit. At the same time, the alarm display on the teach pendant (the top line) is cleared. Description: This signal releases only the alarm status. It does not re-start execution of the program. The robot will keep running if the signal is triggered "ON" during operation.

(3) Hold signal (input) *HOLD

Effective:At any time Function : Use the normally-closed switch because it is a reverse signal. The *HOLD signal has the same function as the hold button on the teach pendant. It halts the current program and stops the operation of the robot. While this signal is being input, the held signal (output) HELD is turned on and the robot cannot be operated.

(4) Start signal (input) START

Effective : When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details. Function : This input signal starts the selected program at the falling edge when the signal is turned off after being turned on. Its function differs according to the setting of parameter $SHELL_CFG.$CONT_ONLY.


- 471 -

- If parameter $SHELL_CFG.$CONT_ONLY is set to DISABLED, the START signal starts the program which has been selected from the teach pendant. By default, the program starts from the current cursor position.

- If parameter $SHELL_CFG.$CONT_ONLY is set to ENABLED, the START signal only resumes the execution of the temporarily held program. To execute an inactivated program from the start, input the PROD_START signal.

(5) Cycle stop signal (input) CSTOPI

Effective : At any time Function : - If parameter $SHELL_CFG.$USE_ABORT is set to

DISABLED, the CSTOPI signal releases the program from the wait status caused by an RSR. It does not stop the execution of the current program and allows it to continue processing (by default).

- If parameter $SHELL_CFG.$USE_ABORT is set to ENABLED, the CSTOPI signal immediately cancels the execution of the current program. The program returns to the status in which it was before execution, and the information for the subprogram to return to the main program is lost. At the same time, this signal also releases the program from the wait status caused by RSR.

(6) Enabling signal (input) ENBL

Effective : At any time Function : If the ENBL signal is turned off, the operation of the robot or the activation of a program is inhibited, and the execution of the current program is suspended.

(7) Safety speed signal (input) *SFSPD

Effective : At any time Function : - Use the normally-closed switch because it is a reverse signal.

Usually this switch should be connected to safety fence. It must be set normally on.

- Since the *SFSPD signal is counted as a remote condition, such input signals as RSR and START to the peripheral device interface cannot take effect unless this signal is turned on.

- If this signal is turned from on to off during robot operation, the execution of the current program is suspended. At the same time, the overriding value is switched to a preset value (parameter $SCR. $FENCEOVER.)

- As long as this signal is off, the overriding value cannot be increased beyond the preset value ($SCR.$SFJOGOVLIM: For jog, $SCR. $SFRUNOVLIM : For test execution.)

(8) Robot service request signal (input) RSR1/RSR2/RSR3/RSR4


- 472 -

Effective : When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details. Function : - The user can choose between RSR and PNS (optional),

although they cannot be used simultaneously. - Four input signals, RSR1 to RSR4, are used. - If a signal is input to an RSR input, a specified. program is

started. The program number can be set by a menu. - If another program has already started processing, the newly

activated program enters the wait status. As soon as the current program terminates, the waiting program starts processing.

- By using an RSR instruction, each RSR in a program can be enabled or disabled.

- A menu is provided to register the program number of a specified program when each RSR is input. (Refer to the application manual for details of the menu).

- When an RSR is input, the program whose program name consists of the specified program number plus a base value is started. For exam ple, if a signal is input to RSR2 when program number 23 is registered in RSR2, the program to be started is the one with the program name calculated from the expression

RSR + (RSR2 program number + base number), i.e., RSR0123. The base number is stored in parameter

$SHELL_CFG.$JOB_BASE, and can be changed in a program with a parameter instruction. (For example, $SHELL_ CFG. $JOB_BASE =100). In this way, the combination of programs which can be started by RSRs can be changed.

- Whether the system should output an acknowledge signal to an RSR can be selected from the menu. If so specified, a pulse is output from the signal corresponding to the RSR, one of signals ACK1 to ACK4, when the input of the


- 473 -

RSR is accepted. From the same menu, the width of the pulse can also be specified.

It is possible to accept other RSRs while outputting an acknowledge signal.

- Input of a CSTOPIT signal can clear the program queue waiting for execution after acceptance of RSRs.

(9) PNS/PNSTROBE (input)

Signal name : PNS: Program number select PNSTROBE : Strobe input for PNS Effective : When the command acceptance enabled signal

(output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for

details. Function : - The PNS/PNSTROBE signal selects whether the RSR

function is used or the PNS function (optional) is used. If the PNS function is enabled, the RSR function cannot be used.

- The eight signals PNS1 to PNS8 are used to specify a program at the instant the strobe signal PNSTROBE rises.

- A menu is provided to specify the information about PNS.

If a number other than zero is entered to PNS input, a

program is selected whose program number is the entered value plus the base number. For example, if the PNS value is 23, the program to be started has the program name calculated from the expression

PNS + (entered PNS value + base number), i.e., PNS0123. If zero is entered to PNS input, it is cleared as if no

selection has been made. - A PNS signal, which can only select a program, cannot

execute the selected program. The execution of the selected program can only be started after input of automatic operation start signal PROD_START.

- For safety, the selected program cannot be changed from the

teach pendant unless PNSTROBE is turned off.


- 474 -

- If a program is selected by PNS, the program number is output to selected program number signal (output) SNO, and a pulse is output to program selection acknowledge signal SNACK. Using these signals, peripheral devices can confirm the correct program has been selected. For the timing of these signals, see the sections describing SNO and SNACK.

- The following operations are effective for the program selected by PNS. You can:

- Start up a program by input of automatic operation start signal PROD_START

- Restart the program that has been suspended. Inputting the START signal restarts the program selected by

PNS when $SHELL_CFG.$CONT_ ONLY is set to ENABLED.

- Input of CSTOPI cancels execution of the pro-grams selected by PNS when $SHELL_CFG.$USE_ ABORT is set to ENABLED.

(10) Automatic operation start signal (input) PROD_START

Effective : When the command acceptance enabled signal (output) CMDENBL is turned on. See the description of CMDENBL in Section B.3.2 (1) for details. Function : This input signal executes the selected program at the falling edge when the signal is turned off after being turned on.

B.3.2 Output Signals This section describes the specifications of output signals for the peripheral device interface. (1) Command acceptance enabled signal (output) CMDENBL

Turned on :When the remote conditions are satisfied and the system is not in the alarm status Turned off:When the remote conditions are not satisfied or the system is in the alarm status The remote conditions are satisfied when all of the following are satisfied. - The teach pendant is in the DISABLED status. - The remote/local setting is set to REMOTE. - Parameter $RMT_MASTER is set to 0 (external interface). - Signal *SFSPD is set to on, or in the normal status.

(2) System ready signal (output) SYSRDY Turned on : When power is applied to the motor of the robot. Turned off: When power is not applied to the motor of the robot.

(3) Program run signal (output) PROGRUN Turned on: When the program is being executed. Turned off: When the program is not being executed.


- 475 -

(4) Held signal (output) HELD

This signal is used to check the status of the hold input. Turned on : When the hold button on the teach pendant (or input) is being pressed down (or turned on). Turned off : When the hold button on the teach pendant (or input) is not being pressed down (or is turned off).

(5) Program paused signal (output) PAUSED This signal is used together with output signal PROGRUN to

determine whether a program can be restarted while it is being held. Turned on: When a program is held and has not been restarted yet. While this signal is on, the program can be restarted and retains information such as that to return from a subprogram to the main program. Turned off: When a program is being executed or is ready to start. If signal PROGRUN is on, the program is being executed. If signal PROGRUN is off, the program has not been executed and can be started from this status.

(6) Alarm status signal (output) FAULT

Turned on: When the system is in the alarm status (or an alarm which can stop a program execution is detected.) The indicator lamp does not go on in warning. Turned off :When the alarm status is released by an alarm release operation.

(7) Reference point signal (output) ATPERCH

Turned on: When the robot is in the reference position specified in the parameter. (the reference point No.1 in reference point setup screen.) Turned off: When the robot is not in the reference position specified in the parameter. (the reference point No.1 in reference point setup screen.) Up to three reference positions can be specified, but this signal is output when the robot is in the first reference position. For the other two reference positions, general-purpose signals can be assigned to output as such. (They can be set from the setup screen.)

(8) Teach pendant enabled signal (output) TPENBL

Turned on: When the teach pendant is enabled. Turned off: When the teach pendant is disabled.

(9) Battery alarm signal (output) BATALM Turned on: When the voltage of the battery for the CMOS


- 476 -

memory backup drops below the reference. Turned off: When the voltage of the battery for the CMOS memory backup is at the normal level.

(10) Operating signal (output) BUSY Turned on: When a program is being executed or is being processed from operation panels such as the teach pendant. (This has the same function as that of the BUSY lamp on the teach pendant.) Turned off: When a program is not being executed nor is being processed from operation panels such as the teach pendant.

(11) RSR acknowledge signals (output) ACK1/ACK2/ACK3/ACK4 These signals are used together with the RSR function. They

can be specified to be enabled or disabled from the RSR setup menu. Turned on: When one of the signals from RSR1 to RSR4 is input and accepted. A pulse whose width is specified from the menu is output to acknowledge the signal. Turned off: Normally. Since these signals are always output as pulses, they are normally in the off status.

The following chart shows the timing of the RSR input and ACK output.


- 477 -

* Other RSR signals can be accepted even when the ACK signal is being output. (12) PNS acknowledge signal (output) SNO/SNACK These signals are used together with the PNS function.

Turned on: Whenever the PNS function is enabled. The selected program number is displayed in binary code (SN01 to SN08) on the teach pendant. If the number cannot be represented as an eight-bit number, it becomes zero. After selecting a program by PNS, a pulse is output from signal SNACK as a part of the PNS operation. The width of the pulse can be specified from the menu. See the timing chart below.


- 478 -

B.4 Specifications of Digital Input/Output

B.4.1 Overview This section describes the external specifications of digital and analog input/output in the R-30iA controller.

B.4.2 Input/Output Hardware Usable in the R-30iA Controller The R-30iA controller can use up to 512 digital input and output points or an equivalent number of analog input and output points. One analog input/output point uses the resources equivalent to those used by 16 digital I/O points. The R-30iA can use a total of up to 512 I/O points. The R-30iA controller can use the following I/O hardware. - Process I/O printed circuit board - I/O unit model A The process I/O printed circuit board and the I/O unit model A can be used together.

B.4.3 Software Specifications (1) RI/RO These are signals sent to the connector at the wrist of the robot. They cannot be assigned (redefined) and are fixed. The standard format is eight inputs and eight outputs. The

number of points that can be used for the connector at the wrist depends on the individual robot.

(2) DI/DO The signal No. that is determined at hardware can be changed by

software operation. (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).

It reads and writes the digital value converted from the analog value of the I/O voltage. It means that the value does not always represent the real 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. 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-82595EN-2/02 APPENDIX C.OPTICAL FIBER CABLE

- 479 -

C OPTICAL FIBER CABLE The R-30iA uses fiber optic cables for communication between the main board and servo amplifiers. Observe the following cautions when handling these fiber optic cables. Handle fiber optic cables with utmost care, especially when installing the unit. (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, their mating surfaces must be protected with the lid and caps with which they are supplied. If left uncovered, the mating surfaces are likely to become dirty, possibly resulting in a poor cable connection.

Fig.C (a) Protection of electrical/optical conversion module and fiber optic cable (when not in use)

(2) Fiber optic cable - Although the reinforcing cover of the external optical cable has

sufficient mechanical strength, be careful not to drop heavy objects on the cable.

C.OPTICAL FIBER CABLE APPENDIX B-82595EN-2/02

- 480 -

- Grasp the optical connector firmly when connecting or disconnecting the cable. Do not pull on the fiber optic cord itself. (The maximum tensile strength between the fiber cord and connector is 2 kg. Applying greater force to the cord is likely to cause the connector to come off, making the cable unusable.)

Fiber optic cord diameter:2.2 mm×2 cords Diameter of cable with reinforced cover : 7.6 mm Tensile strength: Cable with reinforced cover :75 kg Fiber optic cord :7 kg per cord Between fiber optic cord and connector : 2 kg Minimum bending radius of fiber optic cord :25 mm Minimum bending radius of cable with reinforced cover :50 mm Bending resistance (cable with reinforced cover) : 10 million bending cycles at room temperature(when the bending radius is 100 mm) Flame resistance: Equivalent to UL VW-1 Operating temperature: -20 to 705C

Fig.C (b) External dimensions of external optical cable Unit : mm

- After it is connected, the optical connector is automatically

locked by the lock levers on its top. To remove the connector, release the lock levers and pull the connector.

- Although optical connectors cannot be connected in other than

the correct orientation, always take note of the connector's orientation before making the connection.

- Take care to keep both parts of the optical connector (cable side

and PCB side) clean. If they become dirty, wipe them with tissue paper or absorbent cotton to remove dirt. The tissue paper or absorbent cotton may be moistened with ethyl alcohol. Do not use any organic solvent other than ethyl alcohol.

- Fix the reinforcing cover by using a cable clamp, as shown in Fig.

C(c), to prevent the weight of the fiber optic cable from being applied directly to the connecting part of the optical connector.

B-82595EN-2/02 APPENDIX C.OPTICAL FIBER CABLE

- 481 -

Fig.C (c) Fixing the cable with a clamp - Any superfluous portion of the cable might be wound into a

loops. Should this prove necessary, make sure the diameter of each loop is at least 150 mm (for an external cable). Winding the cable into smaller loops can produce sharp curves that exceed the specified bend radius limit. Such bending can result in transmission loss, ultimately leading to a communication failure.

- When using a nylon band (cable tie) as a cable clamp, follow the

instructions given below. Also, take care not to apply a bending force to one particular part of the cable when fixing it with a clamp. Failing to clamp the cable correctly might cut or damage it.

External cable : Do not clamp the uncovered portion of the cable with a nylon band. When clamping the cable by the reinforcing cover, the clamping force is not an important factor to consider. However, ensure that the clamping force is as small as possible to ensure that the reinforcing cover is not deformed by the clamping. If possible, the clamping force should be 5kg (111bs) or less.

B-82595EN-2/02 INDEX

i-1

INDEX<Number>

10/100 BASE-T connector (CD38) pin assignments.....402

<A> A-CABINET .................................................................216

ADJUSTMENT AND CHECKS AT

INSTALLATION.........................................................421

ALARM OCCURRENCE SCREEN...............................39

ARC Weld Connection Cable (CRW1, CRW7:Honda

Tsushin,34pins) .............................................................387 ARC Weld Connection Cable（CRW10 : Honda

Tsushin, 50 pins） ........................................................387

Assemble at Installation ................................................418

<B> BACKPLANE BOARD................................................174

Battery for Memory Backup (3 VDC) ..........................269

BLOCK DIAGRAM .....................................................278

BLOCK DIAGRAM OF THE POWER SUPPLY ........209

<C> Cable clamp and shielding ............................................406

Cable connection...........................................................402

CABLE CONNECTION FOR THE PERIPHERAL

DEVICES, END EFFECTORS, AND ARC WELDERS

......................................................................................388

CHECKING THE POWER SUPPLY UNIT

(A16B-2203-0910) ........................................................ 214

COMPONENT FUNCTIONS.........................................32

CONFIGURATION........................................................18

Connecting HDI ............................................................393 Connecting the Auxiliary Axis Brake（CRR65 A/B） 316

Connecting the Auxiliary Axis Over Travel (CRM68) .317

CONNECTING THE COMMUNICATION UNIT ......396

Connecting the External Emergency Stop.....................303

Connecting the External Power Supply ON/OFF

Switch ...........................................................................301

Connecting the Input Power..........................................298

Connecting the Non-Teaching Enabling (NTED)

Signal (CRM65) ............................................................314

Connecting the Operation Box......................................318

Connection between RS-232-C interface and I/O

device ............................................................................398

Connection Between the Control Unit and Welder....... 364

Connection Between the Mechanical Unit and End

Effector ........................................................................ 374

CONNECTION DIAGRAM BETWEEN

MECHANICAL UNITS ............................................... 281

CONNECTION OF HDI .............................................. 393

Connection to Ethernet ................................................. 401

Connector specification ................................................ 406

<D> DIGITAL I/O SIGNAL SPECIFICATIONS ................ 376

<E> ELECTRICAL CONNECTIONS ................................. 280

EMERGENCY STOP CONTROL BOARD

(A20B-1008-0740)........................................................ 173

End Effector Cable Connector ...................................... 391

End Effector Control Interface...................................... 380

Ethernet Interface.......................................................... 400

EXTERNAL CABLE WIRING DIAGRAM................ 283

EXTERNAL VIEW OF THE CONTROLLER .............. 19

<F> FUSE-BASED TROUBLESHOOTING....................... 146

<G> GENERAL.................................................................... 277

General Person Safety....................................................... 7

Grounding the network ................................................. 407

<H> How to Disable/Enable HBK........................................ 423

How to Disable/Enable Pneumatic Pressure Alarm

(PPABN)....................................................................... 423

HOW TO USE THE PLATE TO FIX THE COMPACT

FLASH MEMORY CARD........................................... 272

<I> I/O Signal Specifications for ARC-Welding Interface.. 382

I/O Signals .................................................................... 470

In Case of A-cabinet ..................................................... 331

In case of B-cabinet ............................................... 329,330

In Case of B-cabinet ..................................................... 332

Input Signal Rules for the High-speed Skip (HDI) ....... 395

Input Signals ................................................................. 470

INDEX B-82595EN-2/02

i-2

Input/Output Hardware Usable in the R-30iA

Controller ......................................................................478

INSTALLATION..........................................................412

INSTALLATION CONDITION................................... 420

Installation Method .......................................................412

Interface ........................................................................396

INTERFACE FOR END EFFECTOR .......................... 374

INTERFACE FOR PERIPHERAL DEVICES .............336

INTERFACE FOR WELDER.......................................364

<L> Lead materials ...............................................................404

LED OF SERVO AMPLIFIER.....................................206

<M> MAIN BOARD (A16B-3200-0600, -0601) ..................170

MANUAL OPERATION IMPOSSIBLE......................167

MASTERING .................................................................43

<O> OPTICAL FIBER CABLE............................................479

Output Signals...............................................................474

Overview.......................................................................478

OVERVIEW ...................................................................17

<P> PANEL BOARD (A20B-2101-0370) ........................... 176

Peripheral Device and Control Unit Connection

(Sink Type DO)............................................................351

Peripheral Device and Control Unit Connection

(Source Type DO)........................................................336

Peripheral Device Cable Connector ..............................389

Peripheral Device Connection Cable ............................388

Peripheral Device Interface A .......................................376

Peripheral Device Interface A Cable (CRM2, CRMA5:

Honda Tsushin, 50 pins)................................................386

Peripheral Device Interface B Cable (CRM4, CRMA6:

Honda Tsushin, 20 pins)................................................386

PERIPHERAL DEVICE INTERFACE BLOCK

DIAGRAM....................................................................322

PERIPHERAL DEVICE INTERFACE

COMBINATION ..........................................................331

Peripheral Device Interface Processing.........................422

PERIPHERAL DEVICE, ARC WELDING, AND END

EFFECTOR INTERFACES..........................................319

POSITION DEVIATION FOUND IN RETURN TO

THE REFERENCE POSITION (POSITIONING) ....... 166

POWER CANNOT BE TURNED ON ........................... 35

Precautions for Mechanism............................................. 11

Precautions for Mechanisms ........................................... 12

Precautions in Operation................................................. 12

Precautions in Programming...................................... 11,12

PREVENTIVE MAINTENANCE.................................. 33

PRINTED CIRCUIT BOARDS.................................... 169

PROCESS I/O BOARD CA (A16B-2201-0470) .......... 177

PROCESS I/O BOARD EA (A16B-3200-0230) .......... 180

PROCESS I/O BOARD EB (A16B-3200-0231) .......... 183

PROCESS I/O BOARD FA (A16B-3200-0420) .......... 185

PROCESS I/O BOARD GA (A16B-2203-0520).......... 187

PROCESS I/O BOARD HA (A16B-2203-0760).......... 189

PROCESS I/O BOARD JA (A16B-2204-0010) ........... 192

PROCESS I/O BOARD JB (A16B-2204-0011) ........... 194

PROCESS I/O BOARD KA (A16B-2204-0050).......... 196 PROCESS I/O BOARD KB（A16B-2204-0051）...... 199

PROCESS I/O BOARD KC（A16B-2204-0052）...... 202

PROCESS I/O BOARD SIGNALS .............................. 333

<R> Recommended Cables................................................... 392

REPLACE THE MODE SWITCH ............................... 258

Replacing a Module ...................................................... 251

REPLACING A UNIT.................................................. 215

REPLACING BATTERY............................................. 269

REPLACING CARDS AND MODULES ON THE MAIN

BOARD ........................................................................ 227

Replacing External Air Fan Unit (A-cabinet) ............... 255

Replacing External Air Fan Unit and Door Fan (B-cabinet)

...................................................................................... 256

REPLACING FUSES ................................................... 260

Replacing Fuses in the Main board............................... 262

Replacing Fuses in the Power Unit ............................... 261

Replacing Fuses in the Servo Amplifier ....................... 260

REPLACING I/O Unit-MODEL A............................... 250

REPLACING RELAYS................................................ 268

Replacing Relays on the Panel Board ........................... 268

REPLACING SERVO AMPLIFIERS .......................... 243

REPLACING THE AC FAN MOTOR......................... 254

Replacing the A-cabinet Door....................................... 219

Replacing the A-cabinet Louver ................................... 218

Replacing the A-cabinet Rear Panel ............................. 217

Replacing the A-cabinet Top Panel .............................. 216

B-82595EN-2/02 INDEX

i-3

Replacing the Backplane Board (Unit) .........................221

Replacing the Base Unit of I/O Unit-MODEL A ..........250

REPLACING THE CONTROL SECTION FAN

MOTOR ........................................................................253

REPLACING THE E-STOP UNIT...............................241

Replacing the Fuse on the Panel Board.........................267

Replacing the Fuse on the Process I/O Boards..............263

Replacing the Heat Exchanger and Door Fan Unit

(A-cabinet) ....................................................................254

Replacing the Panel Board ............................................224

Replacing the Power Unit and Printed-Circuit Boards

on the Backplane Unit ..................................................222

REPLACING THE PRINTED-CIRCUIT BOARDS....220

Replacing the Process I/O Board

EA,EB,FA,GA,KA,KB,KC (A-cabinet)........................226

REPLACING THE REGENERATIVE RESISTOR

UNIT .............................................................................238

REPLACING THE TEACH PENDANT and i

PENDANT ....................................................................252

REPLACING THE TRANSFORMER .........................231

Resetting Overtravel......................................................422

RESETTING OVERTRAVEL AND EMERGENCY

STOP AT INSTALLATION......................................... 422

Robot Connection Cables..............................................283

RS-232-C Interface .......................................................396

RS-232-C interface signals............................................397

<S> Safety During Maintenance.............................................10

SAFETY OF THE END EFFECTOR.............................12

SAFETY OF THE ROBOT MECHANISM ...................12

Safety of the Teaching Operator .......................................8

SAFETY OF THE TOOLS AND PERIPHERAL

DEVICES........................................................................11

SAFETY PRECAUTIONS ...............................................3

SAFETY SIGNALS........................................................42

SERVO AMPLIFIERS .................................................204

SETTING COMMON VOLTAGE ...............................469

SETTING OF SERVO AMPLIFIER ............................207

SETTING THE POWER SUPPLY...............................208

SIGNAL........................................................................467

Software Specifications.................................................478

Specifications of Digital Input/Output ..........................478

SPECIFICATIONS OF PERIPHERAL DEVICE

INTERACE...................................................................466

SPECIFICATIONS OF THE CABLES USED FOR

PERIPHERAL DEVICES AND WELDERS ............... 386

<T> Teach Pendant Cable .................................................... 297

TOTAL CONNECTION DIAGRAM........................... 427

TRANSFORMER......................................................... 210

TRANSPORTATION................................................... 411

TRANSPORTATION AND INSTALLATION............ 410

TROUBLESHOOTING.................................................. 34

TROUBLESHOOTING BASED ON LED

INDICATIONS............................................................. 154

TROUBLESHOOTING USING THE ERROR CODE .. 45

<W> WARNING LABEL ....................................................... 13

When I/O Unit-MODEL A is Used .............................. 329

When Process I/O Board CA/HA is Used (B-cabinet).. 325

When Process I/O Board EA/EB/GA is Used

(A-cabinet) .................................................................... 322

When Process I/O Board FA is Used (A-cabinet)......... 324

When Process I/O Board JA is Used (B-cabinet).......... 327

When Process I/O Board KA is Used (A-Cabinet) ....... 328

When Two or more Process I/O Printed Circuit

Boards and I/O Unit-MODEL A are Used.................... 330

WORKING PERSON....................................................... 3

WORKING PERSON SAFETY ....................................... 5

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