fanuc r-j controller series electrical connection and maintenance manual

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

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SYSTEM R-J Controller SeriesElectrical Connection andMaintenance Manual

MARMMTRBL02303E

This publication contains proprietary information of FANUC RoboticsNorth America, Inc. furnished for customer use only. No other uses areauthorized without the express written permission of FANUC RoboticsNorth America, Inc.

FANUC Robotics North America, Inc.

2000 South Adams Road

Auburn Hills, Michigan 483262800


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The descriptions and specifications contained in this manual were in effectat the time this manual was approved for printing. FANUC RoboticsNorth America, Inc, hereinafter referred to as FANUC Robotics, reserves

the right to discontinue models at any time or to change specifications ordesign without notice and without incurring obligations.

FANUC Robotics manuals present descriptions, specifications, drawings,schematics, bills of material, parts, connections and/or procedures forinstalling, disassembling, connecting, operating and programming FANUCRobotics products and/or systems. Such systems consist of robots,extended axes, robot controllers, application software, the KARELprogramming language, INSIGHTvision equipment, and special tools.

FANUC Robotics recommends that only persons who have been trained inone or more approved FANUC Robotics Training Course(s) be permittedto install, operate, use, perform procedures on, repair, and/or maintain

FANUC Robotics products and/or systems and their respectivecomponents. Approved training necessitates that the courses selected berelevant to the type of system installed and application performed at thecustomer site.

WARNINGThis equipment generates, uses, and can radiate radiofrequency energy and if not installed and used inaccordance with the instruction manual, may causeinterference to radio communications. As temporarilypermitted by regulation, it has not been tested for

compliance with the limits for Class A computing devicespursuant to subpart J of Part 15 of FCC Rules, which aredesigned to provide reasonable protection against suchinterference. Operation of the equipment in a residentialarea is likely to cause interference, in which case the user,at his own expense, will be required to take whatevermeasure may be required to correct the interference.

FANUC Robotics conducts courses on its systems and products on aregularly scheduled basis at the companys world headquarters in AuburnHills, Michigan. For additional information contact

FANUC Robotics North America, Inc.Training and Documentation Department2000 South Adams RoadAuburn Hills, Michigan 483262800Tel: (810)3777234FAX: (810)3777367 or (810)3777362


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

All Rights Reserved

The information illustrated or contained herein is not to be reproduced,copied, translated into another language, or transmitted in whole or in partin any way without the prior written consent of FANUC Robotics NorthAmerica, 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 not limited

to trademark and trade name rights, in the following names:AccuFlowARC MateARC Mate Sr.IntelliTrakLaserToolMotionPartsPaintWorks IIPalletMateSureWeldTurboMove


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FANUC Robotics Hotline

For a PRODUCTION robot that isDOWNcall 24 hours a day, 7 days a week

810-377-7159

For all other Troubleshooting and Technical Supportcontact your local distributor or call the Hotline

Monday Friday, 8:00 A.M. 5:00 P.M. Eastern Time

BEFORE YOU CALL please have your Maintenance and Troubleshooting manual, and thefollowing information, ready.

INFORMATION DETAILS

Customer Information Include

your companys name callers name phone number where caller can be reached, including area code and extension

Robot type

(A, L, M, P, or S, & 3-digit number)

On the arm of the robot.

Controller style

(RA, RB, RC, RF, RG, RG2, RH, RJ, RJ2)

Ask your supervisor.

F Number On the identification tag on the robot and controller, nearthe cable connection.

Robot serial number

(if no F Number is available)

On the identification tag located near the cable connection.

Controller serial number

(if no F Number is available)

On the controller tag located on the doors.

Software edition and revision numbers Shown on the CRT or teach pendant status screen duringthe power-up sequence.

List of error messages Include

error message number message following error message number any numbers following error message

List of diagnostic LEDs Note the PCB where the LED is located and the LED nameor designation.

History of problem Description of events leading up to the problem.

Application software List

any application software running the system the line number where the program halted a description of what is happening on that line


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PrefaceMARMMTRBL02303E vii

The SYSTEM R-J Controller Series Electrical Connection andMaintenance Manualprovides specific information regarding FANUCRobotics electrical hardware. The information contained within themanual has been arranged so that it can answer specific questions quicklyand accurately.

Use this table to locate specific information in the manual.

If you want to Refer to

Findinformation about a specific topic Table of Contents

Identify the components of the SYSTEM R-J

controller

Chapter 1, Overview

Use diagnostic and controller initializationutilities

Chapter 2, DiagnosticScreens

View statusinformation on teach pendantscreens and using other indicators

Chapter 3, Lights and LEDs

Perform troubleshooting procedures andidentify specific errors

Chapter 4, Troubleshooting

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

Release the brakes Chapter 6, Brake Release

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

Master the robot Chapter 8, Mastering

Replace controller components Chapter 9, ReplacingComponents

Adjust switch settings and potentiometerson printed circuit boards

Chapter 10, BoardAdjustments

Find controller connectionschematics andconnector configurations

Chapter 11, Connections

Find connection information andInput/Output specifications

Chapter 12, Complete WiringDiagrams

Find complete schematicsof the controller

circuitry

Chapter 13, Prints

Usecontroller transportation and installationinformation

Appendix A,Transportationand Installation

Purpose of this Manual

How to Use thisManual


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PREFACE MARMMTRBL02303Eviii

This manual includes information essential to the safety of personnel,equipment, software, and data. This information is indicated by headingsand boxes in the text.

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

CAUTIONInformation appearing under CAUTIONconcerns the protectionof equipment, software, and data. It is boxed to set it apart

from other text.

NOTE Information appearing next to NOTEconcerns related informationor useful hints.

Conventions Used inthis Manual


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Table of ContentsMARMMTRBL02303E ix

Preface vii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety xxv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 1

OVERVIEW 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 BACKPLANE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 MAIN CPU PRINTED CIRCUIT BOARD 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 AXIS CONTROL PRINTED CIRCUIT BOARD 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 POWER SUPPLY UNIT PRINTED CIRCUIT BOARD 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 EMERGENCY STOP CONTROL PRINTED CIRCUIT BOARD 113. . . . . . . . . . . . . . . . . . . . . .

1.6 SERVO AMPLIFIERS 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7 DCR AND DBR UNIT A05B-2302-C080 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8 DISCHARGE UNIT A05B-2312-C100 FOR M-500 A05B-2313-C100 FOR S-900 122. . . . . . .

1.9 MULTI-TAP TRANSFORMER 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.10 INTERFACE DEVICES 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.10.1 Modular I/O Unit 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.10.2 Process I/O Board 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.10.3 ABRIO and Genius I/O 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.11 FUSED FLANGE DISCONNECT AND CIRCUIT BREAKER 134. . . . . . . . . . . . . . . . . . . . . . .

1.12 USER TRANSFORMER 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.13 OPERATOR PANEL 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.14 TEACH PENDANT 139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15 HEAT EXCHANGE AND FANS 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 2

DIAGNOSTIC SCREENS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 SAFETY SIGNAL STATUS 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 POSITION STATUS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 ROBOT AXES STATUS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 ALARM LOG 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 VERSION IDENTIFICATION STATUS 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 MEMORY STATUS 213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 3

LIGHTS AND LEDS 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 TEACH PENDANT DIAGNOSTIC LEDS 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 OPERATOR PANEL DIAGNOSTIC LEDS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 CIRCUIT BOARD DIAGNOSTIC LEDS 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Emergency Control Board (EMG) Diagnostic LEDs 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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TABLE OF CONTENTS MARMMTRBL02303Ex

3.3.2 Power Supply Unit (PSU) Diagnostic LEDs 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3 Axis Control Board Diagnostic LEDs 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.4 Main CPU Board Diagnostic LEDs 312. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.5 Servo Amplifier Diagnostic LED (7-Segment Display) 313. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.6 Modular I/O LEDs 314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.7 (Optional) Process I/O Board Diagnostic LEDs 315. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.8 R-H MAP INTERFACE LEDs 316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.9 R-H ABRIO LEDs 317. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4

TROUBLESHOOTING 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 CLASS 1 FAULT TROUBLESHOOTING 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 CLASS 2 FAULTS 416. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 CLASS 3 FAULT TROUBLESHOOTING 418. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 SRVO-001 ER_SVAL1 Operator Panel EStop 419. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2 SRVO-002 ER_SVAL1 Teach Pendant Estop 422. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.3 SRVO-003 ER_SVAL1 Deadman switch released 424. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.4 SRVO-004 ER_SVAL1 Fence open 426. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.5 SRVO-005 ER_SVAL1 Robot Overtravel 428. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.6 SRVO-006 ER_SVAL1 Hand Broken 430. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.7 SRVO-007 ER_SVAL1 External emergency stops 432. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.8 SRVO-008 ER_SVAL Brake fuse blown 436. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.9 SRVO-011 ER_SVAL1 TP Released While Enabled 440. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.10 SRVO-012 ER_SVAL1 Power Failure Recovery 440. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.11 SRVO-014 Fan Motor Abnormal (Group:i Axis:j) 440. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.12 SRVO-015 ER_SVAL1 System Over Heat (Group:i Axis:j) 442. . . . . . . . . . . . . . . . . . . . . . . .

4.3.13 SRVO-021 ER_SVAL1 SRDY off (Group:i Axis:j) 444. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.14 SRVO-022 ER_SVAL1 SRDY on (Group:i Axis:j) 444. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.15 SRVO-023 ER_SVAL1 Stop Error Excess (Group:i Axis:j) 445. . . . . . . . . . . . . . . . . . . . . . . .

4.3.16 SRVO-024 ER_SVAL1 Move Error Excess (Group:i Axis:j) 445. . . . . . . . . . . . . . . . . . . . . . .

4.3.17 SRVO-026 ER_WARN Motor Speed Limit (Group:i Axis:j) 445. . . . . . . . . . . . . . . . . . . . . . .

4.3.18 SRVO-027 ER_WARN Robot Not Mastered (Group:i Axis:j) 445. . . . . . . . . . . . . . . . . . . . . .

4.3.19 SRVO-033 ER_WARN Robot Not Calibrated (Group:i Axis:j) 445. . . . . . . . . . . . . . . . . . . . .4.3.20 SRVO-035 ER_WARN Joint Speed Limit (Group:i Axis:j) 446. . . . . . . . . . . . . . . . . . . . . . . .

4.3.21 SRVO-036 Imposition Time Over (Group:i Axis:j) 446. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.22 SRVO-037 ER_SVAL1 IMSTP Input (Group:i Axis:j) 446. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.23 SRVO-038 PULSE MISMATCH (Group:i Axis:j) 447. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.24 SRVO-042 ER_SVAL2 MCAL Alarm (Group:i Axis:j) 447. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.25 SRVO-043 ER_SVAL2 DCAL Alarm (Group:i Axis:j) 448. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.26 SRVO-044 ER_SVAL2 HVAL Alarm (Group:i Axis:j) 449. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.27 SRVO-045 ER_SVAL2 HCAL Alarm (Group:i Axis:j) 450. . . . . . . . . . . . . . . . . . . . . . . . . . .


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TABLE OF CONTENTSMARMMTRBL02303E xi

4.3.28 SRVO-046 ER_SVAL2 OVC Alarm (Group:i Axis:j) 451. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.29 SRVO-047 ER_SVAL2 LVAL Alarm (Group:i Axis:j) 452. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.30 SRVO-049 ER_SVAL2 OHAL1 Alarm (Group:i Axis:j) 453. . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.31 SRVO-050 ER_SVAL1 CLALM Alarm (Group:i Axis:j) 453. . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.32 SRVO-051 ER_SVAL2 CUER Alarm (Group:i Axis:j) 454. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.33 SRVO-061 ER_SVAL2 CKAL Alarm (Group:i Axis:j) 454. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.34 SRVO-062 ER_SVAL2 BZAL Alarm (Group:i Axis:j) 455. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.35 SRVO-063 ER_SVAL2 RCAL Alarm (Group:i Axis:j) 456. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.36 SRVO-064 ER_SVAL2 PHAL Alarm (Group:i Axis:j) 456. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.37 SRVO-065 ER_WARN BLAL Alarm (Group:i Axis:j) 456. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.38 SRVO-066 ER_SVAL2 CSAL Alarm (Group:i Axis:j) 457. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.39 SRVO-067 ER_SVAL2 OHAL2 Alarm (Group:i Axis:j) 457. . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.40 SRVO-068 ER_SVAL2 DTERR Alarm (Group:i Axis:j) 458. . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.41 SRVO-069 ER_SVAL2 CRCERR Alarm (Group:i Axis:j) 458. . . . . . . . . . . . . . . . . . . . . . . . .

4.3.42 SRVO-070 ER_SVAL2 STBERR Alarm (Group:i Axis:j) 459. . . . . . . . . . . . . . . . . . . . . . . . .

4.3.43 SRVO-071 ER_SVAL2 SPHAL Alarm (Group:i Axis:j) 459. . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.44 SRVO-081 ER_WARN EROFL Alarm (Track encoder:n) 459. . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.45 SRVO-082 ER_WARN DAL Alarm (Track encoder:n) 460. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.46 SRVO-083 ER_WARN CKAL Alarm (Track encoder:n) 460. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.47 SRVO-084 ER_WARN BZAL Alarm (Track encoder:n) 460. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.48 SRVO-085 ER_WARN RCAL Alarm (Track encoder:n) 460. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.49 SRVO-086 ER_WARN PHAL Alarm (Track encoder:n) 460. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.50 SRVO-087 ER_WARN BLAL Alarm (Track encoder:n) 461. . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.51 SRVO-088 ER_WARN CSAL Alarm (Track encoder:n) 461. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.52 SRVO-089 ER_WARN OHAL2 Alarm (Track encoder:n) 461. . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.53 SRVO-090 ER_WARN DTERR Alarm (Track encoder:n) 461. . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.54 SRVO-091 ER_WARN CRCERR Alarm (Track encoder:n) 461. . . . . . . . . . . . . . . . . . . . . . . .

4.3.55 SRVO-092 ER_WARN STBERR Alarm (Track encoder:n) 461. . . . . . . . . . . . . . . . . . . . . . . .

4.3.56 SRVO-093 ER_WARN SPHAL Alarm (Track encoder:n) 461. . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 5

REPLACING A FUSE 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 MULTI-TAP TRANSFORMER 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 SERVO AMPLIFIER 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 POWER SUPPLY UNIT 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 EMERGENCY STOP CONTROL PC BOARD 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 PROCESS INPUT/OUTPUT PC BOARDS AA, AB, CA, CB, AND DA 56. . . . . . . . . . . . . . . .

5.6 PROCESS INPUT/OUTPUT PC BOARDS BA AND BB 57. . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 MODULAR I/O UNIT 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 AC OUTLET UNIT 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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Chapter 6

BRAKE RELEASE 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7

CONTROLLING I/O 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 FORCING OUTPUTS 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 SIMULATING INPUTS AND OUTPUTS 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 SOP I/O STATUS 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 8

MASTERING 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 MASTERING TO A FIXTURE (FIXTURE POSITION MASTER) 82. . . . . . . . . . . . . . . . . . . . .

8.2 ZERO DEGREE MASTERING 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 SINGLE AXIS MASTERING 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4 QUICK MASTERING 811. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 9

REPLACING COMPONENTS 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 REPLACING THE BATTERY 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 REPLACING A RELAY 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 REPLACING A PRINTED CIRCUIT BOARD 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3.1 Replacing the Backplane Printed Circuit Board 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3.2 Replacing a Component on the Backplane Printed Circuit Board 97. . . . . . . . . . . . . . . . . . . . .

9.4 REPLACING A MODULE ON THE MAIN CPU OR AXIS CONTROL BOARD 98. . . . . . . . .

9.5 REPLACING THE PROCESS INPUT/OUTPUT PRINTED CIRCUIT BOARDAA, AB, BA OR BB 911. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6 REPLACING COMPONENTS OF THE MODULAR INPUT/OUTPUT UNITREFER TO CHAPTER 1 FOR PART NUMBERS. 912. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6.1 Replacing the Base Unit 912. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6.2 Replacing a Module 914. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.7 REPLACING THE MULTI-TAP TRANSFORMER 916. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.8 REPLACING A SERVO AMPLIFIER 917. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.9 REPLACING THE OPERATOR PANEL 918. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.10 REPLACING THE FAN MOTOR 919. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.11 REPLACING THE DISCHARGE RESISTOR (DCR) AND DYNAMIC BRAKE (DBR)UNIT 921. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.12 REPLACING THE REGENERATIVE DISCHARGE UNIT 923. . . . . . . . . . . . . . . . . . . . . . . . .

9.13 REPLACING THE OPTIONAL WARNING LIGHT 924. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.14 REPLACING A SERIAL PULSE CODER 925. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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Chapter 10

BOARD ADJUSTMENTS 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 AXIS CONTROL BOARD JUMPERS 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2 PROCESS I/O BOARD 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.1 Jumpers 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.2 Potentiometers 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2.3 Output Drivers 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3 BUILTIN CRT/KB UNIT 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.4 EMG BOARD 1010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 11

CONNECTIONS 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1 MECHANICAL CONNECTIONS 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.1 Robot Connection Cables 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.2 Connecting the Input Power Supply 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.3 Connecting the External Power Supply ON/OFF Switch 1110. . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.4 External Emergency Stop Connection 1111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES 1113. . . . . .

11.2.1 Peripheral Device Interface Combination 1115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.2 Process I/O Printed Circuit Board AA or AB 1116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.3 Process I/O Printed Circuit Board BA or BB 1117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.4 Process I/O Printed Circuit Board CA or CB 1118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.5 Process I/O Printed Circuit Board DA 1119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.6 Process I/O Printed Circuit Board with the Modular I/O Unit 1120. . . . . . . . . . . . . . . . . . . . . . .

11.2.7 Two or More Process I/O Boards with the Modular I/O Unit 1121. . . . . . . . . . . . . . . . . . . . . . . .

11.2.8 Peripheral Device and Control Unit Connection 1122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.9 Mechanical Unit and End Effector Connection 1139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.10 Control Unit and Welder Connection 1142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.11 Peripheral Device Interface 1146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.12 End Effector Control Interface 1148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.13 Arc Welding Interface Process I/O AA 1149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.14 Modular I/O Inputs 1151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.15 Modular I/O Outputs 1155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.3 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICESAND WELDERS 1165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.3.1 Peripheral Device Interface A Cable 1165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.3.2 Peripheral Device Interface B Cable 1165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.3.3 Arc Welding Interface Connection Cable 1166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.4 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS,AND ARC WELDERS 1167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.4.1 Peripheral Device Connection Cable 1167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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11.4.2 Arc Welding Interface Connection Cable 1168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.4.3 Peripheral Device Cable Connector 1169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.4.4 End Effector Cable Connector 1172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.4.5 Recommended Cables 1174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 12

COMPLETE WIRING DIAGRAMS 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 13

PRINTS 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix ATRANSPORTATION AND INSTALLATION A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 TRANSPORTATION A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2 INSTALLATION A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2.1 Installation Area A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2.2 Assembly During Installation A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2.3 Installation Conditions A4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2.4 Adjustment and Checks at Installation A5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2.5 Resetting Overtravel and Emergency Stop at Installation A6. . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Procedures

Procedure 21 Displaying Safety Signal Status 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 22 Displaying Position Status 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 23 Displaying the Axis Status Pulse Screen 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 24 Displaying the Alarm Log 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 25 Displaying the Version Identification Status 211. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 26 Displaying Memory Status 213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 61 Releasing the Brakes 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 71 Forcing Outputs 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 72 Simulating and Unsimulating Inputs and Outputs 74. . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 73 Displaying and Forcing SOP I/O 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure 81 Mastering to a Fixture 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 82 Mastering to Zero Degrees 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 83 Mastering a Single Axis 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 84 Recording the Quick Master Reference Position 811. . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 85 Quick Mastering the Robot 813. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 91 Replacing the Battery 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 92 Replacing the SPC Batteries 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 93 Replacing the Backplane Printed Circuit Board 96. . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 94 Replacing a Component on the Backplane Printed Circuit Board 97. . . . . . . . . . . .


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Procedure 95 Replacing the Base Unit 912. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 96 Replacing the Interface Module 914. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 97 Replacing an I/O Module 914. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 98 Replacing the Multi-Tap Transformer 916. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure 99 Replacing a Servo Amplifier 917. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 910 Replacing the Operator Panel 918. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 911 Replacing the Fan Motor 919. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 912 Replacing the Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) unit 921

Procedure 913 Replacing the Regenerative Discharge Unit 923. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 914 Replacing the Optional Warning Light 924. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure 915 Replacing a Serial Pulse Coder 925. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Figures

Figure 11. Cabinet Exterior, B-Size Controller 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 12. Cabinet Exterior, B-Size Controller with Regenerative Discharge Unit 12. . . . . . . . . . .

Figure 13. Cabinet Exterior, B-Size Controller with Optional Side Cabinet 13. . . . . . . . . . . . . . . . .

Figure 14. Cabinet Exterior, C-Size Controller 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 15. Cabinet Interior, B-Size Controller 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 16. Cabinet Interior, C-Size Controller 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 17. Backplane with R-H Style Extended Backplane 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 18. Main CPU Board Layout 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 19. Axis Control Board Layout 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 110. Power Supply Unit Printed Circuit Board 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 111. Emergency Stop Control Printed Circuit Board 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 112. Servo Amplifier 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 113. Mounting Locations of Servo Amplifiers Robot with 6-amplifiers 115. . . . . . . . . . . .

Figure 114. Mounting Locations of Servo Amplifiers for the A-510 116. . . . . . . . . . . . . . . . . . . . . .

Figure 115. Mounting Locations of Servo Amplifiers for the Arc Mate/ Arc Mate 100/S-6,Arc Mate Sr./S-5/S-10 and L-1000 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 116. Mounting Locations of Servo Amplifiers for the S-500/S-700 and M-400 117. . . . . . . .

Figure 117. Mounting Locations of Servo Amplifiers for the S-420 and S-800 117. . . . . . . . . . . . . .

Figure 118. Mounting Locations of Servo Amplifiers for the S-420 and the DCR & DBR Unit 118.

Figure 119. Mounting Locations of Servo Amplifiers for the M-500 118. . . . . . . . . . . . . . . . . . . . . .

Figure 120. Mounting Locations of Servo Amplifiers for the S-900 119. . . . . . . . . . . . . . . . . . . . . . .

Figure 121. DCR and DBR Unit 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 122. Discharge Unit 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 123. Multi-Tap Transformer 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 124. Multi-Tap Transformer A80L00260013#A 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 125. Modular I/O 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 126. Process I/O Printed Circuit Board 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 127. Fused Flange Disconnect 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 128. Circuit Breaker 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 129. User Transformer 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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Figure 130. Operator Panel, B-Size Controller 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 131. Operator Panel, C-Size Controller 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 132. Teach Pendant 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 133. Heat Exchange System, B-Size Controller 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 134. Heat Exchange System, C-Size Controller 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 21. Default PowerUp Screen 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 22. Alarm Log 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 31. Teach Pendant LEDs 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 32. Operator Panel LEDS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 33. Circuit Board Diagnostic LEDs 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 34. Emergency Control Board (EMG) Diagnostic LEDs 36. . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 35. Power Supply Unit (PSU) Diagnostic LEDs 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 36. Axis Control Board Diagnostic LEDs 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 37. Main CPU Board Diagnostic LEDs 312. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 38. Modular I/O LEDs 314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 39. Process I/O Board Diagnostic LEDs 315. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 310. RH MAP LEDs 316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 311. R-H ABRIO LEDs 317. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 41. 24 Volt (24E) Power Distribution Chart 410. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 42. 24 Volt (24V) Power Distribution Chart 413. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 43. Operator Panel E-Stop Circuitry 421. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 44. Teach Pendant E-Stop Circuitry 423. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 45. Deadman Switch Circuitry 425. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 46. Fence Open Circuitry 427. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 47. Robot Overtravel Circuitry 429. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 48. Hand Broken Circuitry 431. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 49. External Emergency Stop Circuitry 435. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 410. Brake Fuse Blown Circuitry 439. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 411. Backplane 441. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 412. System Over Heat Circuitry Drawing 1 442. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 413. System Over Heat Circuitry Drawing 2 443. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 51. Replacing a Fuse of the Transformer Unit 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 52. Replacing the Fuse of a Servo Amplifier 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 53. Replacing a Fuse of the Power Supply Unit 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 54. Replacing the Fuse on the Emergency Stop Control PC Board 55. . . . . . . . . . . . . . . . . .

Figure 55. Replacing the Fuse of the Process Input/Output PC Board AA, AB, CA, CB, or DA 56

Figure 56. Replacing the Fuse of the Process Input/Output PC Board BA or BB 57. . . . . . . . . . . .

Figure 57. Replacing the Fuse of the AC Outlet Unit 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 91. Replacing the Battery (1) 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 92. Replacing a Relay 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 93. Replacing the Backplane Printed Circuit Board 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 94. Replacing Printed Circuit Boards on the Backplane Printed Circuit Board 97. . . . . . . . .


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Figure 95. Moving the Latches on the End of the Module Socket 98. . . . . . . . . . . . . . . . . . . . . . . .

Figure 96. Installing a New Module at an Angle 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 97. Pushing in the Module 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 98. Mounting Locations of the Modules 910. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 99. Replacing the Process Input/Output Printed Circuit Board AA, AB, BA, or BB 911. . . .

Figure 910. Replacing the Base Unit of the Modular Input/Output Unit 913. . . . . . . . . . . . . . . . . . .

Figure 911. Removing and Replacing a Module 915. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 912. Removing and Replacing a Terminal Block 915. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 913. Replacing the Multi-Tap Transformer 916. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 914. Replacing a Servo Amplifier 917. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 915. Replacing the Operator Panel 918. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 916. Replacing the Fan Motor 920. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 917. Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) Unit 922. . . . . . . . . . . .

Figure 918. Replacing the Regenerative Discharge Unit 923. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 919. Removing the Pulse Coder 926. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 101. Axis Control Board Jumpers 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 102. Process I/O Board AA 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 103. Process I/O Board AB 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 104. Process I/O Board BA 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 105. Process I/O Board BB 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 106. Process I/O Board CA 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 107. Process I/O Board CB 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 108. Process I/O Board DA 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 109. Front View Control Board 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1010. Jumper Setting CRT/KB 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1011. EMG board 1010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 111. Block Diagram of Electrical Interface Connection 111. . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 112. Mechanical Connection Diagram for S-420, S-500, S-700, S-800, and M-400 112. . . . .

Figure 113. Mechanical Connection Diagram for ARC Mate, ARC Mate 100/S-6, ARC Mate Sr.,A-510, and L-1000 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 114. Mechanical Connection Diagram, Common Part 113. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 115. Connection to Servo Amplifiers and Mechanical Unit for S-420 114. . . . . . . . . . . . . . . .

Figure 116. Connection to Servo Amplifiers and Mechanical Unit for S-420, S-420D, ARC Mate,

S-5, ARC Mate 100/S-6, ARC Mate Sr., S-10 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 117. Connection to Servo Amplifiers and Mechanical Unit for S-500 115. . . . . . . . . . . . . . . .



Figure 1110. Connection to Servo Amplifiers and Mechanical Unit for A-510 116. . . . . . . . . . . . . .

Figure 1111. Connection to Servo Amplifiers and Mechanical Unit for M-400 and M-500 117. . . . .

Figure 1112. Connection to Servo Amplifiers and Mechanical Unit for L-1000 117. . . . . . . . . . . . .

Figure 1113. Input Power Supply Connection, Circuit Breaker 119. . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1114. Input Power Supply Connection, Fused Flange Disconnect 119. . . . . . . . . . . . . . . . . . .


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Figure 1115. External Power Supply ON/OFF Switch Connection 1110. . . . . . . . . . . . . . . . . . . . . . . .

Figure 1116. External Emergency Stop Output Connection 1111. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1117. External Emergency Stop Input Connection 1112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1118. Locations of Peripheral Device Interfaces, B-Size Controller 1113. . . . . . . . . . . . . . . . .

Figure 1119. Locations of Peripheral Devices, C-Size Controller 1114. . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1120. Peripheral Device Interface Combination 1115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1121. Process I/O Printed Circuit Board AA or AB 1116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1122. Process I/O Printed Circuit Board BA or BB 1117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1123. Process I/O Printed Circuit Board CA or CB 1118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1124. Process I/O Printed Circuit Board DA 1119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1125. Process I/O Printed Circuit Board with Modular I/O 1120. . . . . . . . . . . . . . . . . . . . . . . .

Figure 1126. Two or More Process I/O Boards and the I/O Unit (Model A) 1121. . . . . . . . . . . . . . . .

Figure 1127. Peripheral Device and Control Unit Connection -A1/A2 1125. . . . . . . . . . . . . . . . . . . . .

Figure 1128. Peripheral Device and Control Unit Connection -A3/A4 1126. . . . . . . . . . . . . . . . . . . . .

Figure 1129. Peripheral Device and Control Unit Connection - B1/B2 1127. . . . . . . . . . . . . . . . . . . .

Figure 1130. Peripheral Device and Control Unit Connection -C1 1128. . . . . . . . . . . . . . . . . . . . . . . .

Figure 1131. Peripheral Device Interface Control for A1, A2, A3, and A4 1129. . . . . . . . . . . . . . . . .

Figure 1132. Peripheral Device Interface for A1, A2, A3, and A4 1130. . . . . . . . . . . . . . . . . . . . . . . .

Figure 1133. Peripheral Device Control Interface B1 1131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1134. Peripheral Device Control Interface B2 1132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1135. Peripheral Device Control Interface C1 1133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






Figure 1141. Mechanical Unit and End Effector 1139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1142. End Effector Pin Configuration Arc Mate/S-5, Arc Mate Sr/S-10, S-420, S-500,S-700, S-800, S-900, M-400 and M-500 1140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1143. End Effector Pin Configuration Arc Mate 100/S-6 1140. . . . . . . . . . . . . . . . . . . . . . . .

Figure 1144. End Effector Pin Configuration A-510 1141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1145. End Effector Pin Configuration L-1000 1141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1146. Control Unit and Welder Connection - CRW1/CRW2 1142. . . . . . . . . . . . . . . . . . . . . . .

Figure 1147. Control Unit and Welder Connection - CRW1 Analog Signal Assignment 1143. . . . . . .Figure 1148. Control Unit and Welder Connection - CRW1 Digital Signal Assignment 1144. . . . . . .

Figure 1149. Control Unit and Welder Connection - CRW2 Analog Signal Assignment 1145. . . . . . .

Figure 1150. Peripheral Device Interface A Cable 1165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1151. Peripheral Device Interface B Cable 1165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1152. Arc Welder Connection Cable 1166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1153. Peripheral Device Cable Connection 1167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1154. Arc Welder Cable Connection 1168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1155. Peripheral Device Cable Connector for A and B(Honda Tsushin Kogyo) 1169. . . . . . . .


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Figure 1156. Peripheral Device Connector for A and B 1170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1157. Peripheral Device Interface Cable C Connector (Phoenix Contact) 1171. . . . . . . . . . . .

Figure 1158. Elbow Type Connector S-5, S-10, S-420, S-500, S-700, S-800, M-400, M-500,

ARC Mate, ARC Mate 100/S-6, ARC Mate Sr. 1172. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 1159. Connector L-1000 1173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 121. Internal Connection Diagram S-420, S-800 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 122. Internal Connection Diagram S420 with three Servo Amplifiers, S420D) 123. . . . . . .

Figure 123. Internal Connection Diagram ARC Mate, ARC Mate Sr., ARC Mate 100/S-6, S-5,and S-10 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 124. Internal Connection Diagram S-500 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 125. Internal Connection Diagram S-700 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 126. Internal Connection Diagram S900 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 127. Internal Connection Diagram A-510 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 128. Internal Connection Diagram M-400 (5-axes) 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 129. Internal Connection Diagram M400 (4 axes) 1210. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1210. Internal Connection Diagram M500 (5 axes) 1211. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1211. Internal Connection Diagram M500 (4 axes) 1212. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1212. Internal Connection Diagram L-1000 1213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1213. Internal Connection Diagram Emergency Stop Control PCB 1214. . . . . . . . . . . . . .

Figure 1214. Internal Connection Diagram Power Supply Unit 1215. . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1215. Internal Connection Diagram - Main CPU; Axis Control Board 1216. . . . . . . . . . . . . . .

Figure 1216. Internal Connection Diagram Servo Amplifier Connection S-420, ARC Mate/S-5,ARC Mate Sr./S-10, ARC Mate 100/S-6, S-500, S-700, and S-800 1217. . . . . . . . . . . . . .

Figure 1217. Internal Connection Diagram Servo Amplifier Connection A-510, L-1000,and M-400 1218. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1218. Internal Connection Diagram Servo Amplifier Connection S-900 and M-500 1219. . .

Figure 1219. Internal Connection Diagram Modular I/O 1220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1220. Internal Connection Diagram Teach Pendant 1221. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1221. Internal Connection Diagram Main CPU Interface 1222. . . . . . . . . . . . . . . . . . . . . . . .

Figure 1222. Internal Connection Diagram Axis Control Board Interface 1223. . . . . . . . . . . . . . . . .

Figure 1223. Internal Connection Diagram ARC Mate/S-5, ARC Mate Sr./S-10,ARC Mate 100/S-6, S-420, S-500 and S-800 1224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1224. Internal Connection Diagram S-700 and A-510 1225. . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1225. Internal Connection Diagram M-400 and L-1000 1226. . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1226. Internal Connection Diagram - M400 1227. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 1227. External Connection Diagram M-500 1228. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1228. External Connection Diagram S-900 1229. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1229. External Connection Diagram Process I/O 1230. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1230. External Connection Diagram Process I/O 1231. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1231. External Connection Diagram Teach Pendant 1232. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1232. Motor Table 1233. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 131. R-J Control Signal and Power Distribution Overview 133. . . . . . . . . . . . . . . . . . . . . . . .

Figure 132. Main AC Power Distribution 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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Figure 133. AC Power Distribution With Optional 115VAC Secondary 137. . . . . . . . . . . . . . . . . . . .

Figure 134. Power Supply Unit (PSU) With Power ON/OFF Circuit 139. . . . . . . . . . . . . . . . . . . . . .

Figure 135. EMG Stop & Brake Connection 100 VAC E-Stop Circuit 100 VDC Brake

Circuit (1 of 2) 1311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 136. EMG Stop and Brake Connection 100 VDC Brake Circuit (2 of 2) 1313. . . . . . . . . . . . .

Figure 137. EMG Stop and Brake Connection 24 VDC E-Stop Circuit (1 of 2) 1315. . . . . . . . . . . . .

Figure 138. EMG Stop and Brake Connection 24VDC E-Stop Circuit (2 of 2) ModularI/O Power Distribution 1317. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 139. Overheat and Cooling 1319. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1310. Single Axis Servo Amplifier 1321. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1311. Dual Axis Servo Amplifier (With Dynamic Brakes) 1323. . . . . . . . . . . . . . . . . . . . . . . .

Figure 1312. Dual Axis Servo Amplifier (Without Dynamic Brakes) 1325. . . . . . . . . . . . . . . . . . . . . .

Figure 1313. Discharge Resistor and Dynamic Brake Unit (For Amp With No Dynamic Brake) 1327

Figure 1314. LSI Module All Servo Amplifiers 1329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 1315. DV-M Module Servo Amplifier 1331. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1316. ALM-M Module Servo Amplifier 1333. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1317. Teach Pendant Power And Data Signal Interconnection 1335. . . . . . . . . . . . . . . . . . . . .

Figure A1. Transportation A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure A2. Installation Area A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure A3. Assembly During Installation A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure A4. Peripheral Device Interface Processing A6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Tables

Table 11. Main CPU Modules 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 12. Axis Control Board Modules 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 13. Servo Amplifiers 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 14. Multi-Tap Transformer Part Numbers 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 15. Selecting Transformer Taps 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 16. Selecting Transformer Taps for Transformer A80L00260013#A 125. . . . . . . . . . . . . .

Table 17. Digital Input Module Specifications 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 18. Digital Output Module Specifications 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 19. I/O Module Part Numbers 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 110. Process I/O Board Part Numbers 132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 111. Circuit Breaker, B-Size Cabinet 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 112. Circuit Breaker and Fused Flange Disconnect Switch, C-Size Cabinet 136. . . . . . . . . .

Table 113. Part Numbers 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 114. Teach Pendant Part Numbers 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 21. Safety Signals 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 22. Axis Status Pulse Screen Items 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 23. Version Identification Status Items 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 24. Memory Status 213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 31. Teach Pendant Status Indicators 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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TABLE OF CONTENTSMARMMTRBL02303E xxi

Table 32. Standard Operator Panel C-Size Controller Status Indicators 33. . . . . . . . . . . . . . . . . . .

Table 33. Emergency Control Board (EMG) Diagnostic LEDs 36. . . . . . . . . . . . . . . . . . . . . . . . .

Table 34. Troubleshooting Axis Control Board Diagnostic LEDs 39. . . . . . . . . . . . . . . . . . . . . . .

Table 35. Troubleshooting Main CPU Board Diagnostic LEDs 312. . . . . . . . . . . . . . . . . . . . . . . . .

Table 36. Servo Amplifier LED Functions 313. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 37. Modular I/O LEDs 314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 38. Process I/O Board Diagnostic LEDs 315. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 39. R-H MAP LEDs 316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 310. R-H ABRIO LED Descriptions 317. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 41. Troubleshooting Procedure 1 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






Table 47. Class 2 Faults Troubleshooting Procedure 416. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 48. SRVO-001 Troubleshooting Procedure 419. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 49. SRVO-002 Troubleshooting Procedure 422. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 410. SRVO-003 Troubleshooting Procedure 424. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Table 412. SRVO-005 Troubleshooting Procedure 1 428. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 413. SRVO-005 Troubleshooting Procedure 2 429. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Table 415. SRVO-007 Troubleshooting Procedure 433. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 416. SRVO-008 Troubleshooting Procedure 436. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .









Table 425. SRVO-043 Troubleshooting Procedure 448. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 426. SRVO-044 Troubleshooting Procedure 449. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .









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Table 51. Multi-Tap Transformer Fuses 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 52. Power supply unit for four-slot backplane 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 53. Power supply unit for six-slot backplane 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 54. Modular I/O Unit 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 71. Standard Operator Panel Input Signals 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 72. Standard Operator Panel Output Signals 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 81. Mastering Methods 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 91. Relay Part Numbers 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 101. Axis Control Board Jumpers 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 102. Process I/O Board Jumpers 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 103. Process I/O Board Potentiometer Adjustments 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 104. Output Drivers 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 105. SBK Jumper Settings 1010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 111. Example of Leakage Current Circuit Breaker for Inverters 118. . . . . . . . . . . . . . . . . . .Table 112. External Emergency Stop Output Signals 1111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 113. External Emergency Stop Input Signals 1112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 114. Peripheral Device Interface Types 1113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 115. Process I/O Printed Circuit Board AA or AB 1116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 116. Process I/O Printed Circuit Board BA or BB 1117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 117. Process I/O Printed Circuit Board CA or CB 1118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 118. Process I/O Printed Circuit Board DA 1119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 119. Process I/O Printed Circuit Board DA 1120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1110. Two or More Process I/O Boards and the I/O Unit (Model A) 1121. . . . . . . . . . . . . . . .

Table 1111. Process I/O Printed Circuit Board Signals, DI Signals 1122. . . . . . . . . . . . . . . . . . . . . .Table 1112. Process I/O Printed Circuit Board Signals, DO Signals 1123. . . . . . . . . . . . . . . . . . . . .

Table 1113. Applicable Process I/O Printed Circuit Board - A1/A2 1125. . . . . . . . . . . . . . . . . . . . .

Table 1114. Applicable Process I/O Printed Circuit Board - A3/A4 1126. . . . . . . . . . . . . . . . . . . . .

Table 1115. Applicable Process I/O Printed Circuit Board - B1/B2 1127. . . . . . . . . . . . . . . . . . . . . .

Table 1116. Applicable Process I/O Printed Circuit Board - C1 1128. . . . . . . . . . . . . . . . . . . . . . . .

Table 1117. Applicable Process I/O Printed Circuit Board 1142. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1118. Peripheral Device Interface Specifications 1146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1119. End Effector Control Interface Signals 1148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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Table 1120. Arc Welding Interface Signals 1149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1121. Input Modules AID32A and AID32B, Nonisolated 1151. . . . . . . . . . . . . . . . . . . . . . .

Table 1122. Input Modules AID16C and AID16D 1152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1123. Input Modules AID32E and AID32F 1153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1124. Input Module AIA16G 1154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1125. Output Module AOD32A, Non-isolated 1155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1126. Output Modules AOD08C and AOD08D 1156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1127. Output Modules AOD16C and AOD16D 1157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1128. Output Module AOD32C 1158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1129. Output Module AOD32D 1159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1130. Output Modules AOA05E and AOA08E 1160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1131. Output Module AOA12F 1161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1132. Output Modules AOR08G and AOR16G 1162. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1133. Output Module ADA02A 1163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1134. Analog Input Module AAD04A 1164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1135. Peripheral Device Cable Connector for A and B 1169. . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1136. Symbols Used in Figure 1155 1169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1137. Peripheral Device Cable Connector for A and B 1170. . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1138. Symbols Used in Figure 1156 1170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1139. Peripheral Device Interface Cable C Connector Specifications 1171. . . . . . . . . . . . . . .

Table 1140. Connection Data 1171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1141. Recommended Cable for Peripheral Device Connection 1174. . . . . . . . . . . . . . . . . . . .

Table 1142. Recommended Cable for End Effector Connection 1174. . . . . . . . . . . . . . . . . . . . . . . .

Table A1. Installation Conditions A4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table A2. Adjustment and Checks at Installation A5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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SafetyMARMMTRBL02303E xxvFANUC Robotics is not and does not represent itself as an expert in safetysystems, safety equipment, or the specific safety aspects of your companyand/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 inthe workplace.

The appropriate level of safety for your application and installation canbest be determined by safety system professionals. FANUC Roboticstherefore, recommends that each customer consult with such professionalsin order to provide a workplace that allows for the safe application, use,and operation of FANUC Robotic systems.

Additionally, as the owner, employer, or user of a robotic system, it is yourresponsibility to arrange for the training of the operator of a robot systemto recognize and respond to known hazards associated with your roboticsystem and to be aware of the recommended operating procedures for your

particular application and robot installation.

FANUC Robotics therefore, recommends that all personnel who intend tooperate, program, repair, or otherwise use the robotics system be trained inan approved FANUC Robotics training course and become familiar withthe proper operation of the system. Persons responsible for programmingthe systemincluding the design, implementation, and debugging ofapplication programsmust be familiar with the recommendedprogramming procedures for your application and robot installation.

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


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SAFETY MARMMTRBL02303Exxvi

Safety is essential whenever robots are used. Keep in mind the followingfactors 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

The safety of people is always of primary importance in anysituation. However, equipment must be kept safe, too. Whenprioritizing how to apply safety to your robotic system, consider

People External devices

Robot(s) Tooling Workpiece

Always give appropriate attention to the work area that surrounds therobot. The safety of the work area can be enhanced by the installation ofsome 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

A safe workcell is essential to protect people and equipment. Observe thefollowing guidelines to ensure that the workcell is set up safely. Thesesuggestions are intended to supplement and notreplace existing federal,state, and local laws, regulations, and guidelines that pertain to safety.

Sponsor your personnel for training in approved FANUC Robotics

training course(s) related to your application. Never permit untrainedpersonnel to operate the robots.

Install a lockout device that uses an access code to preventunauthorized persons from operating the robot.

Use antitiedown logic to prevent the operator from bypassing safetymeasures.

Arrange the workcell so the operator faces the workcell and can seewhat is going on inside the cell.

CONSIDERINGSAFETY FOR YOUR

ROBOTINSTALLATION

Keeping People andEquipment Safe

Using SafetyEnhancing Devices

Setting Up a SafeWorkcell


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SAFETYMARMMTRBL02303E xxvii

Clearly identify th

fanuc r-j controller series electrical connection and maintenance manual

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