osacom 8700 controller (same as inst & maint (1l4000b-9)
DESCRIPTION
Manual of controlador Daihen OTC OSACOM 8700.TRANSCRIPT
June 1997
No.1 L4000B -9
C O N T R O L L E R
~stributor I' you do not understand
HEN Corporation
We really appreciate you to purchase our products. There are some mistakes on this manual, and the following list describes the corrections of the mistakes. We apologize for any inconvenience this clerical error has caused and will do our best to see that such errors do not occur.
TABLE 0.0.0.1 List of Errata (113)
Page
1-16
1-17
1-17
1-18
1-21
1-24
1-25
2-8
2-10
2-25
Mistakes
5. The location of breaker in the control unit is shown in Fig.=
____ Braker Handle
2. The Control units contains many ... of them while is ON may ... needs to be opened with the ... ... of a failure, never any of ...
5. Ensure that the ground of each of is ...
3. Connect connectors are all the same
type connectors but have ...
1. Connect connector CN16 of Teaching box to CN16
2. Connect optical fiber connector to IC124 of !$jg&
m. (1) Operation Status (LED ...
4. ... OC LED of also ... 5. Overvoltage of main power supply
The main power supply is ... . ... deceleration is w.
ELED502's Status] ON indicates Voltage Drop (below
[2nd bit's Function When ON] ... SW1 on m, causing ...
Section
1.2.1
Fig.1.2.2.1
Inthe WARNING
1.2.3
1.3.1
1.3.2
1.3.3
2.3.2
Table 2.4.2.1
LED GREEN RED
@ @
Table 2.8.2.1
Table 2.8.3.1
Corrections
5. The location of breaker in the control unit is shown in Fig.=
Handle
2. The Control units contains many ... of them while is ON may ... needs to be opened with the ... ... of a failure, never @&& any of ...
5. Ensure that the ground of each of is ...
3. Connect connectors
are all the same type connectors but have ...
1. Connect connector CN16 of Teaching box to CNl6 pJ -.
2. Connect optical fiber connector to lC124 of A Board
(1) Operation Status (LED ...
4. ... OC LED of also ... 5. Overvoltage of main power supply
The main power supply is ... . ... deceleration is w.
[LED5023 Status] ON indicates Voltage Drop (below 3.J$Jv>
[2nd bit's Function When ON] ... SW1 on M, causing ...
TABLE 0.0.0.1 List of Errata (213)
ry contact (Relay CR22) MRON m, DC24V
... and the
5-15
-
5-20
5-42
2nd Item of
-1
5th Item of
-1
Line 3 of (2)
Check connection and connect it properly.
LED 100 on Motion control board OFF(0N in the condition.)
... be also displayed for & failures.)
Check connection and connect it properly.
LED 100 on Motion Control board OFF(0N in the condition.)
... be also displayed for failures.)
TABLE 0.0.0.1 List of Errata (313)
Correction
Switch box
Motion control board or Servo Control board
Reduce the voltage
Reduce the load
[Part] Memory lithium
[I te mf
[Item]
[Item]
[Remarks]
..... voltage range by the
Page
5-49
5-54
5-55
6-2
7-4 7-6 7-1 0
7-18
7-34 7-36 7-38 7-40
Al-1
A1-3
Section
. 2nd, 3rd, 5th and 6th items of paK Cause1
5th and 10th items of /Action/
6th and 8th items of
/Possible Cause1
4th item of
/Action] 9th item of
-1
Ref No.9 in 6.4 List of In- spection Items
Ref No. a -2
Ref No. @
Ref. No.
Ref No. @ in TABLE 1.1.1.1
Line 3
Mistakes
Switch Box
Motion control board or Servo Control board fi?ilur
Reduce the voltage
Reduce the a load
[Part] Memory lithium
[Item]
[Item]
[Item]
[Remarks]
..... voltage range by the
This instruction manual describes instruction of installation and maintenance for Manipulator, ROBOT CONTROL UNIT and its peripheral equipments such as the Teach Pendant, Operation Box and so on. Read and understand the entire contents of this manual, with special emphasis on the safety devices throughout the manual, before installing, operating or maintaining the Manipulator, Robot Control Unit, and its peripheral equipments. These equipments such as the Manipulator, Robot Control Unit, its peripheral equipments and these instructions are for use only by persons trained and experienced in the safe operation of the above mentioned equipments. Do not allow untrained persons t o install, operate, or maintain these equipments. Contact your distributor i f you do not fully understand these instructions. Following Instruction manuals are provided for these equipments. These instruction manuals shall be referred where necessary in accordance with installation, operation and maintenance.
Model GOlS Model VOlS Model VlOS Model V20S Model V40S Model WOl S OSACOM SUPER 8700 OSACOM SUPER 8700 OSACOM SUPER 8700 OSACOM SUPER 8700 INDUSTRIAL ROBOT
MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR CONTROLLER TEACH l NG INTERFACE WITH JIG OPTION SAFETY WARNING
TRAINING COURSES
The equipments such as the Manipulator, Robot Control Unit, its peripheral equipments and these instructions are for use only by persons trained and experienced in the safe operation of the above mentioned equipments. Therefore, DAIHEN Corporation provides various training courses such as the SAFETY, OPERATION, MAINTENANCE and so on.For the details, contact your distributor or DAIHEN Corporation.
1 LIMITED WARRANTY / DAIHEN Corporation warrants this equipment against defects in parts and workmanship, which have occurred under the appropriate service and maintenance conditions including the periodic inspection described in the manual, for shorter period of either 14 months after B/L date of shipment f rom Japan, or 2000 hours actual working time from the date of delivery of equipment to the original user. This warranty shall be invalidated by any abuse, misuse, misapplication or improper installation of the original user. DAIHEN, at its option, will repair or replace any equipments during the warranty period, which DAIHEN, upon inspection, shall determine to be defective in material and/or workmanship. The foregoing shall constitute the sole remedy any breach of DAIHEN's warranty.
DAIHEN MAKES NO WARRANTIES, EITHER EXPRESS OR IMPLIED, EXCEPT AS PROVIDED HEREIN, INCLUDING WITHOUT LIMITATION THEREOF, WARRANTIES AS TO MARKETABILITY, MERCHANTABILITY, FOR A PARTICULAR PURPOSE OF USE, OR AGAINST INFRINGEMENT OF ANY PATENT.IN NO EVENT SHALL DAIHEN BE LIABLE FOR ANY DIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE, OR LOSSES OR EXPENSES RESULTING FROM ANY DEFECTIVE PRODUCT OR THE USE OF ANY PRODUCT.
I SAFETY WARNING / THE FOLLOWING ROBOTIC SAFETY SHALL BE KEPT STRICTLY.IF NOT, SERIOUS PERSONAL INJURY OR LOSS OF LIFE IS CAUSED.
A. GENERAL INFORMATION AND SAFETY
19.11 General
Information presented in this section and on various labels, tags, and plates on the unit pertains t o equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment.
A.2 Safety
The installation, operation, maintenance, and troubleshooting of arc welding robots require practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is to be installed, operated, and maintained only by qualified persons in accordance with the safety standard which is applied for your country such as ANSI/RIA document, "American National Standard For Industrial Robots Systems - Safety Requirements" and all other safety material found in this Section and throughout the entire manual. In addition, follow all other codes as applicable to the application. See Arc Welding Safety Precautions Sections in the welding power supply Owner's Manual for safety precautions regarding the operation of arc welding power supplies and welding equipment.
B. SAFETY ALERT SYMBC)L AND SIGNAL WORDS
The following safety alert symbol and signal words are used throughout this manual to call attention t o and identify different levels of hazard and special instructions.
This safety alert symbol is used with the signal words WARNING and CAUTION t o call attention t o the safety statements.
WARNING statements identify procedures o r practices which must be followed t o avoid serious personal injury o r loss of life.
CAUTION statements identify procedures o r practices which must be followed to avoid minor personal injury o r damage to this equipment.
IMPORTANT statements identify special instructions necessary for the most efficient operation of this equipment.
C. G E N E R A L S A F E T Y REQUIREMENTS
Read, understand and comply with the following safety rules a t robot maintenance.
1 KEEP OUT of robot working envelope when main power is on.
2 STAY ALERT when near robot.
3 KEEP INFORMED about status of robot and general working conditions.
4 HAVE AN EMERGENCY STOP BUTTON IN HAND whenever you are near the robot.
5 UNDERSTAND AND BE FAMILIAR WITH ROBOTIC MOVEMENTS. Robots are unique industrial devices and can present unexpected hazards t o personnel because of their movements.Unpredictable robot motion can occur in even the best designed areas of operation.
6 NEVER STAND with your back toward the robot.
7 NEVER PLACE yourself between robot work stations i f more than one work station is used.
8 THOROUGHLY TRAIN A L L PERSONNEL in robot operation and safety
9 READ robot safety regulation of the country installed robot and PUT INTO EFFECT it.
10 DO NOT REMOVE, DESTROY, OR COVER the WARNING and CAUTION labels on Robot Control Unit and Manipulator.
D. SAFETY REQU l REMENTS FOR l NSTALLATlON (Figure D-I)
The robot cell requires initial safety conditions that are vital for both personnel and equipment. Make safety provisions part of the basic cell design.lmplement the following during installation:
1 Brightly mark floor with distinctive areas identifying Zones 1 and 2 on Figure D-1.
2 Route all cables and hoses so that they will not be damaged and will not clutter the cell f loor space.
3 Protect welding system components f rom spatter, slag, heat, and the general welding environment by locating equipment to minimize exposure.
4 I f any welding components must be located in a high-exposure area, provide proper ' guards o r shields to minimize d i r t and spatter.
5 Consider all necessary jig requirements to include turntables, sliding trays, etc., that will become a part of the application so that the operator does not have t o enter the work envelope(Zone 1).
6 Install pressure-sensitive f loor mats, proximity devices, l imit switches, light curtains, etc., to suit the application and number of work stations so that Emergency Stop will occur i f there is any instruction or violation of the robot work envelope.
7 lnstall chain fences and light batteries around other cell portions that are not t o be violated.
8 Locate Teach Pendant and Operation Box outside robot work envelope.
9 Provide proper Electrostatic Discharge(ESD) protection fo r electronic components in Robot Control Unit and Teach Pendant.
10 MAINTAIN SAFE INTEGRITY OF CELL AT A L L TIMES.
Zone 3
Zone 1 - Robot Work Envelope(Area) Zone 2 - Operator Work Area Zone 3 - Outer Area of Robotic Cell
IMPORTANT : See Instruction manual "MANIPULATOR" fo r vertical space requirements of robot.
Figure D-1 Layout Considerations for a Typical Robotic Cell
E, OPERATOR SAFETY REQUIREMENT Provide proper ventilation for welding areas.Supply fresh air i f required o r use approved breathing device.
Wear approved head and body protection (this includes, but is not limited to, protective headgear, gloves, and safety shoes).
Install approved filter lens into welding helmet to protect eyes f rom arc rays.
Press an EMERGENCY STOP button before entering robot area.
Stay alert for unexpected robot motion o r movement.
Provide arc guard curtains o r shields around the welding area so that arc rays do not injure operator o r other personnel.
Keep robotic cell clean, neat, and orderly.
Close and secure all access doors and panels on components.
Unless i t is specifically necessary to enter the working area of robot system, t o avoid accident, no worker including the operator should enter the working area of robot system. When entering the working area of the robot system for teaching the robot, be sure to check the location and condition of the safety devices such as the EMERGENCY STOP button and DEADMAN SWITCH on the Teach Pendant. And place the EMERGENCY STOP button within the operator's reach for the robot should malfunction.
The robot is keeping the safety speed sufficiently during the teaching mode, however, there is a possibility that the operator is caught in the robot by slow speed.To avoid injury, pay attention to the following:
a) Space requirement for the robotic system cell must allow sufficient area t o include installing robot system components, movement around the work envelope by one o r more operators into and out of the cell.
b) The operator should always have some predetermined escape place. c) Never block the escape place of the operator by the other person o r something. d) I f the operator o r the other worker realize the operator's danger, press the
EMERGENCY STOP button immediately. e) A t the worst, it means that i f the operator was caught in the robot, take the
following procedure.
1) Press the Emergency Stop button immediately. 2) Turn of f the primary power switch of the Robot Control Unit. 3) To avoid fall the robot arm, l i f t the 2nd and 3rd axis of robot by wire ropes. 4) Turn on the primary power switch of the Robot Control Unit again.
(DO NOT TURN ON THE SERVO POWER.) 5) To release the brake, connect pin No. 1 and pin No.2 of terminal block on the
Interlock Board by jumping wire. For search the location of pins, see following Figure E-1.
6 ) To escape the person who was caught in the robot, move the robot arm (the Axis 2).
7) Disconnect the jumping wire, after person escaped.
While operating the system in the automatic operation mode, operator should leave the working area of the robot system.
Figure E-1 Location of Brake release pins
F. SAFETY PROCEDURES DURING TEACHING (PROGRAMMING) Teaching (programming) often requires the operator to enter the robot work envelope. As a result, always do the following during teaching procedures:
1 Move robot slowly (see instruction manual "TEACHING" - Teaching for speed entry information).
2 Always assign and position a watchperson, with an Emergency Stop button in hand, to present and ready during teaching operations.
3 I f jig motion was programmed to operate from external output control, the jig could energize during teaching.Be careful and alert for jig motion.
G. SAFETY CHECKS AFTER ENTERING A PROGRAM
1 Have all unauthorized persons leave robotic cell.
2 Check the operation of all warning devices, such as lamps o r horns.
3 Check and be sure that the robot moves normally through its program sequences using the block operation mode(either step or continuous).
4 Check movement of all jigs, and be sure their operation is normal.
5 Check fo r proper operation of EMERGENCY STOP buttons.
. SAFETY PROCEDURES BEFORE AUTOMAT96 OPERATION
Before starting automatic robot operation, do the following:
1 Verify the correct program number allocation is assigned to the appropriate Starting Box(es).
2 Have all unauthorized persons leave the robotic cell area.
3 Close and secure all gates and guard doors, and energizedight fences, barriers, and curtains as applicable for the entire specific cell.
4 Place all jigs in their normal, start-work positions.
5 Place the robot in the axes origin o r work origin position as required for the operation.
6 Remove all tools f rom the robot work envelope.
7 Place welding workpiece(s) into proper position(s).
8 Place all equipment switches in the proper positions.
I. SAFETY PROCEDURES DURING AUTOMATIC OPERATION
During automatic operation, do the following:
1 Turn of f main power o r press an EMERGENCY STOP button BEFORE entering the robot work envelope.Entry may be required for nozzle, tip, wire, o r gas adjustments o r replacements.
DO NOT ENTER WORK ENVELOPE UNLESS AN EMERGENCY STOP BUTTON IS PRESSED !
2 Be alert for jig movement initiated by an external control signal during operation.
3 Do not allow unauthorized persons to operate controls.
4 I f two o r more Starting Boxes are used, be sure that the operators ful ly understand all procedures and cooperate with each other.
5 Press an EMERGENCY STOP button i f any problem occurs.
6 Since this an arc welding operation, protect operator(s) f rom arc rays, fumes, and hot parts.
7 Be sure that the Automatic mode can only be selected a t a safe location outside the work envelope.
J. SAFETY PROCEDURES AT END OF WORK
1 Place robot welding torch into an area from which movement to axes origin o r work origin positions is possible without striking any objects.This may require manual operation with Teach Pendant.
2 Press an EMERGENCY STOP button to turn of f robot Servo power.
3 Turn off welding power source and all associated equipment. This includes jig power supplies as applicable.
4 Place line disconnect switches for Robot Control Unit and welding power supply in the OFF positions.
5 Allow robot and all equipment to cool.
6 Clean robot, jigs, and entire cell area.
7 Install protective covers over all equipment AFTER proper cooling has occurred to reduce dust and d i r t entry.
I(. SAFETY PROCEDURES DURING INSPECTION, MA1NTEMANCEf ADJUSTMENT, AND SERVICING PROCEDURES
Since these procedures can involve entering the robot work envelope and may require that the main power and servo power are turned on, be sure to always do the following during any maintenance, adjustment, o r repair procedures:
1 Train all service personnel in the functions, operations, and jig movements of the specific robotic cell.
2 Allow only trained and qualified persons to service the robot.
3 Always assign and position a watchperson, with an EMERGENCY STOP button in hand, to be present and ready during any servicing or adjustment procedures.
4 Determine in advance i f the procedure(s) requires an energized robot.When power is not required, turn it off.
5 Determine in advance i f the procedure can be done outside the work envelope.Always work outside the robot work envelope whenever possible.
6 Turn of f o r disable all jig(s) and external equipment not required for the specific procedure.
7 Provide proper Electrostatic Discharge (ESD) protection fo r circuit boards in Robot Control Unit and Teach Pendant.
8 When the procedure is finished, always correctly, securely, and carefully reconnect any wires and reinstall necessary hardware, plugs, covers, and panels.
L. ARC WELDING SAFETY PROCEDURES
Read and understand, and comply with all safety rules at beginning of welding power supply manual in addition t o the following before beginning arc welding operations.
1 Prevent electric shock as follows:
1) INSTALL AND GROUND all equipment according to national, regional, and local codes.
2) DO NOT TOUCH live electrical parts.
3) WEAR DRY INSULATING GLOVES AND CLOTHING; be sure gloves have no holes.
4) DISCONNECT INPUT POWER before installing, inspecting, maintaining, servicing any equipment.
2 Provide proper protection f rom fumes and gases as follows:
1) KEEP YOUR HEAD out of the fumes.
2) USE FORCED EXHAUST VENTILATION at the arc.
3) VENTILATE CELL t o prevent build-up of fumes and gases.
4) I f ventilation is inadequate, USE APPROVED BREATHING DEVICE.
5) READ AND FOLLOW WARNING LABELS on all containers of welding materials.
6) Before use, READ AND UNDERSTAND the manufacture's instructions, Material Safety Data Sheets (MSDSs), and your employer's safety practices.
3 Protect eyes and skin from arc rays ; protect ears from noise as follows:
1) WEAR PROPERLY FITTING WELDING HELMET with proper shade of fi lter lens (See ANSI 249.1).
2) INSTALL ARC PROTECTIVE CURTAINS between operator and the arc.
3) WEAR PROPER SAFETY GLASSES in work area at all times.
4) WEAR PROPER EAR PROTECTION,
5) WEAR PROPER BODY PROTECTION to include woolen clothing, flame-proof apron and gloves, leather leggings, high boots and leather arm and shoulder gauntlets.
4 Prevent f ire and burns cause by hot metal, spatter, slag, and arc sparks as follows:
1 ) KEEP FLAMMABLE MATERIALS out of the robotic cell.
2) Have operator(s) keep their sleeves, pockets, and collars down and buttoned as applicable. Wear pants without cuffs.
3) WATCH for fire.
4) Have a f ire extinguisher nearby, and know how to use it.
5) Allow equipment and work t o cool before handling.
5 Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs as follows:
1) FASTEN CYLINDERS SECURELY so they cannot fall (use insulated chain or equivalent).
2) INSULATE CYLINDERS from mounts so that they are never grounded or par t of an electrical circuit.
3) KEEP CYLINDERS AWAY from the welding arc and other heat sources.
4) LOCATE CYLINDERS AWAY from personnel and vehicle traff ic patterns.
6 Provide impact protection to all persons in the cell as follows:
1) ALWAYS WEAR PROPER PROTECTIVE HEADGEAR, such as safety helmet, when in the robotic cell.
2) WEAR SHATTER-RESISTANT SAFETY GLASSES a t all times when in the robotic cel I.
7 Since magnetic fields from high currents can affect pacemaker operation, have wearers consult their doctor before going near arc welding operations.
8 TURN OFF robot and welding power source input power before entering work envelope or working on welding power source.
9 Prevent EMC (Electro-Magnetic Compatibility) noise caused by welding arc as follows:
1) KEEP PRECISION DEVICES AWAY from the welding arc.
2 ) Supply primary power to precision devices and welding power supply separately.
M. WARNING LABELS DO NOT REMOVE, DESTROY, or COVER the following labels on the Robot Control Unit and Manipulator. I f following labels become dir ty or peeled off, order spare ones immediately. The locations of these labels are shown in the instruction manual "MANIPULATOR" and "CONTROLLER".
KEEP OUT OF ROBOT AREA WHEN MAIN POWER IS ON.
A WARNING I
Keep out of robot area when main power is on. Read Instruction Manual.
ct ion Manual carefully.
@ Always wear dry insulating gloves. o Insulate yourself f rom the work and the ground. O Do not touch live electrical parts.
Keep your head out of the fumes. @ Ventilate area, or use a breathing device.
@ Do not weld near flammable material. @ Watch for fire; keep extinguisher nearby. 9 Do not locate unit over combustible surfaces.
NOISE c a n damage hear ing.
Wear welding helmet wi th correct filter.
a Read and follow thts label and the lnsrrucrlon Manua l carefully
r Insulate yourself from the work and the ground. r D o not touch live electrical pans
lble surfaces.
* Keep a w a y f rom rnovlng parts.
@ Keep hands, loose clothing, and tools away during operation.
* Keep away from pinch points during operatton. @ Know and understand equrprnent operation before
0 Always wear dry insulating gloves s Insulate yourself from the work and the ground. 8 Do not touch live electrical parts.
Disconnect ~npu t power before servicing
NK3717
@Do not touch live electrical
@Disconnect all power before installing or servicing.
@Multiple sources of voltage may exist inside this
@Keep out of robot area when main power is on.
@Do not locate this device in robot work area.
I I @Read Instruct ion Manual . I
a WARNING ELECTRIC S H O C K can kill.
(D Do not touch l ive electrical parts.
Read this label and Instruction Manual carefully.
O Disconnect all power before installing or servicing.
@ Only qualified persons are to install. operate. or service this equipment according to all codes and employer's safety practices.
.Wear dry insulating gloves and body protection.
@ D o not locate over combustible surfaces.
@ Keep al l panels, covers, and guards securely in place.
eB For protection against fire hazard. Replace only w i th the same type and rating of fuse.
- NC8052
1
A WARNING s Read manual for connection procedures.
@ Connect grounding conductor and input
conductors to proper terminals inside
unit-grounding conductor first.
ee Be sure grounding conductor goes to
a proper earth ground and has less
than 100 ohms of resistance.
Doublecheck grounding conductor,
input voltage, and frequency before
applying power.
NC8055
Contents
Chapter1 Installation 1 1 Configuration ............................................................................................................................................................... 1 . 2
1.1.1 CO~/MAG welding ~ ~ b ~ t standard configuration 1- 2 1.1 . 2 optional ~ ~ ~ i ~ ~ ~ ~ t ................... 1-14
1.2 Connecting primary power Supply .......................................................................................................... 1 - 16 1 . 2 . 1 Connecting primary power Cable 1-16
1 2.2 opening control uni t D~~~ ................................................................................................................... 1 - 17
1 2 3 Grounding ............................................................................................................................................................. 1 - 18 . . 1 3 External Connection .............................................................................................................................................. 1 - 20
1.3.1 Connecting Control Cable 1,2, 3 (BIRBX-1005/BIRBX-8005) 1 - 21 1 . 3.2 connecting hi^^ B~~ ........................................................................................................................ 1-24 1.3.3 Connecting Control Cable 5 (BWCB-5105) o r Welding Interface
(BBWF-0105) 1 -25
1.3.4 connecting operation panel ................................................................................................................. 1 - 27 1 .3. 5 Connecting Starting Box ......................................................................................................................... 1-28 1 . 3.6 Connecting Miscellaneous Option 1-29
1 4 placing printed ~~~~d~ ...................................................................................................................................... 1 - 30 1 . 4. 1 connecting ~~i~ processor ~~~~d 1-30 1 4 2 placing Servo Control Boards 1-31 1 4 3 placing Motion Control Board 1-31 . . 1.4.4 Placing I/() Management Board ....................................................................................................... 1-31
Chapter2 Internal Configuration of Control Unit 2 1 ~~i~ P~~~~~~~~ ~~~~d ~ 3 7 0 0 ~ 2- 5
2.1.1 Functions ............................................................................................................................................................... 2 - 5 2 . 1 . 2 Operation Status Indicator 2- 5 2.1.3 ~ ~ ~ l ~ ~ i ~ ~ ~~i~ P~~~~~~~~ ~~~~d .................................................................................................... 2- 6
2 2 ti^^ control ~~~~d ~ 3 7 0 0 ~ .................................................................................................................... 2- 7 2 2.1 Functions 2 - 7 2.2.2 Operation Status Indicator .................................................................................................................... 2- 7
2.3 1/0 Management Board L3700M (Standard) o r L4024M (Extension) ........................ 2- 8 2.3.1 Functions ............................................................................................................................................................... 2 - 8 2.3.2 operation status ~ ~ d i ~ ~ t ~ ~ .................................................................................................................... 2- 8
2.4 Servo Control Board (SCON) L4268R (or L4000R) and position control ~~~~d (PCON) ~ 4 1 9 0 ~ .............................................................................................. 2- 9
2 4 1 Functions of Servo Control Board 2- 9 . . 2.4.2 operation status ~ ~ d i ~ ~ t ~ ~ ~ of servo control ~~~~d ....................................................... 2- 9
2 4 3 Switch Settings of Servo Control Board ...................................................................................... 2-11 . . 2.4 4 jumper pin settings of servo control ~~~~d 2- 14
2.4.5 punctions of position control ~~~~d ............................................................................................. 2 - 16
2.4.6 Operation Status Indicators of Position Control Board 2- 16
2.4.7 switch settings of position control ~~~~d .............................................................................. 2-16 2.5 Servo Driver Unit ~ 4 0 0 0 ~ (G01) ~ 4 0 0 1 Q (V01) ............................................................................ 2-18 ,
2.5.1 ti^ ti^^^ 2 - 19
2 5 2 operation status ~ ~ d i ~ ~ t ~ ~ ~ .................................................................................................................. 2-19 . . 2 6 Servo power Unit E5499A or E5787A 2-21
2 6 1 Functions ............................................................................................................................................................... 2-21 . . 2.6.2 Operation Status Indicators ................................................................................................................ 2-21
2 7 ~ ~ ~ k ~ l ~ ~ ~ ~~~~d ~ 3 7 0 2 ~ (or ~ 3 7 0 0 ~ ) 2 - 22 2 7 1 Functions 2 - 22 . . 2 7 2 Connectors 2 - 22 . . 2 7 3 switch settings ................................................................................................................................................. 2-23 . .
2.8 Interlock Board L3899Y ..................................................................................................................................... 2-24 2.8.1 ~~~~~i~~~ 2 - 24 2.8.2 Operation Status Indicators ................................................................................................................. 2-24 2 8 3 Switch Settings 2 - 25 . . 2.8.4 Fuses and Connectors ................................................................................................................................. 2-27
2.8 5 Connecting Jig Terminals on Interlock Board ....................................................................... 2-28
2 9 constant voltage power supply ~ - ~ 0 0 2 0 3 ........................................................................................... 2-30 2.9.1 ti^^^ 2 - 30 2 . 9.2 operation status indicators 2-30
............... 2.10 Terminal Block Unit E5741A (Option) and Relay Unit E5685A (Option) 2-32 2 10.1 Functions of Terminal Block Unit 2 - 32
2.10.2 Connecting External Equipment (Jig, etc.) via Terminal Block Units ............. 2-32 2.10.3 ti^^^ of R ~ ] ~ ~ unit ........................................................................................................................ 2-35
2 . 10.4 connectors and J~~~~~ pins on ~~l~~ unit 2-36
...... 2.11 Charging Battery Unit W-LO0471 (Not mounted on IRBCX-532) 2-36 2 11 1 Functions ............................................................................................................................................................. 2-36 . . 2.11.2 ~~~~ifi~~t.~~~ 2-36 2 . 11 . 3 Replacing Charging Battery Unit ................................................................................................. 2-36
2 12 M~~~~~ ~ ~ t t ~ ~ ~ ~ 3 3 9 1 ~ ................................................................................................................................. 2-37 2-12 1 ti^^^ ............................................................................................................................................................ 2-37 2 . 12 . 2 Specifications 2 - 37 2. 12 3 Replacing Memory Battery 2 - 37
2 13 Switch Box E5760 or E5809 ........................................................................................................................... 2-38 2.13 1 Functions ............................................................................................................................................................ 2-38 213.2 Fuse 2-38
2.14 ~ ~ ~ i l i ~ ~ ~ ~~~~~f~~~~~ W - L O O ~ ~ O 2 -40 2 14.1 ~~~~~i~~~ ............................................................................................................................................................. 2-40
2.15 Step-down Transformer (Option) 2 -40 2 . 15 . 1 T~~~~ of step-down ~~~~~f~~~~~~ 2-40 2. 15.2 connecting step-down ~~~~~f~~~~~ 2-41
2.15 3 voltage switching T~~~ of step-down ~~~~~f~~~~~ ....................................................... 2-42 2 16 power Unit E6029A 2 -45
2 16 1 Functions of power Unit 2-45 . . 2 16 2 Specifications of power Unit .............................................................................................................. 2-45 . .
Chapter3 Peripheral Equipment of Robot Control Unit 3 1 hi^^ B~~ ............................................................................................................................................................... 3 - 2
3 1 1 ~~~~~i~~~ ............................................................................................................................................................... 3 - 2 . . 3.1.2 outside view of hi^^ B~~ ........................................................................................................... 3 - 2 3.1.3 Notes on Usage ............................................................................................................................................... 3 - 3 3.1.4 Internal Configuration 3 - 3
3 2 Operation Panel . 3- 4 3.2.1 switches and ti^^^ ............................................................................................................................ 3 - 4 3 2 2 Outside View and Internal Circuit ................................................................................................... 3 - 5 . .
3.3 Operation Box (Option) ................................................................................................................................... 3 - 6 3.3.1 switches and $'Unctions ........................................................................................................................... 3 - 6 3 3 2 Outside View and Internal Circuit ................................................................................................... 3 - 6 . .
3 4 Starting Box (Option) ................................................................................................. 3 - 8 3.4.1 Switches and Functions ............................................................................................................................ 3 - 8 3 . 4 . 2 Connecting Starting Box 3- 9 3.4.3 Outside View and Internal Circuit .................................................................................................. 3-10
3 5 ~ ~ b ~ t ~ ~ d i ~ ~ t ~ d welding power supply (option) ...................................................................... 3-11
3.5.1 Notes on Using Robot Dedicated Welding Power Supply ................... . 3-11 3.5.2 Outside View and Internal Configuration of Robot Dedicated
welding power supply 3-11 3 6 Welding Interface (Option) 3 - 12
3 6 1 Functions 3- 12 . . 3.6.2 Description of parts 3-13 3 6 3 Printed Board E5624G 3- 13 . . 3 6 4 External Connection .................................................................................................................................... 3-15 . . 3.6.5 Operation Sequence 3-16
3 6 6 Internal Circuit ................................................................................................................................................. 3-18 . . 3 7 External Storage (Option) .............................................................................................................................. 3-19
3 7 1 Specifications 3 - 1 g . . 3 7 2 Configuration of External Storage 3-20 . . 3 7 3 Connecting External Storage 3 - 21 . . 3.7.4 Notes on Handling External Storage ............................................................................................. 3-22 3.7.5 Notes on ~ ~ ~ d l i ~ ~ ~l~~~~ ~ i ~ k ~ 3-22
3 8 printer Interface Unit (option) 3-23 3 8 1 Functions 3 - 23 . . 3 8 2 Configuration ..................................................................................................................................................... 3-23 . . 3 8 3 Connecting printer Interface Unit .................................................................................................... 3-25 . .
3 8 3 1 When External Storage is not used 3-25 . . . 3.8.3.2 When External Storage is used ................................................................................................ 3-26
3 8 4 Connecting printer ' .................................. 3-26 . . 3.8.5 Notes on Usage 3-27
Chapter4 Connecting Robot Peripheral Jig (External Axis) 4.1 T~~~~ of Robot peripheral ~i~~ 4 - 2
4.2 connecting peripheral ~i~ to ~ ~ b ~ t control unit ....................................................................... 4 - 3 4.2.1 system configuration ................................................................................................................................ 4 - 3 4.2.2 control cables for peripheral ~i~ 4 - 4
............ 4.3 Internal Switch Settings and Connection Drawings of Robot Control Unit 4- 5 4.3. 1 GOIS+ 1 Axis System 4 - 7
4 3 2 G01S+2 Axis System .................................................................................................................................... 4 - 9 . . 4 3 3 ~ 0 1 ~ + 3 ~~i~ system ............................................................................................. 4-11 . . 4 3.4 VOlS+ 1 Axis System 4- 13
4 3 5 V01S+2 Axis System .................................................................................................................................... 4-15 . . 4 3 6 VOlSS.3 Axis System .................................................................................................................................... 4-17 . .
Chapter5 Troubleshooting 5 1 Symptoms 5 - 15
5 1 1 Nothing Appears on the Teaching Box ......................................................................................... 5-15 . . 5.1 2 The ~ i ~ ~ l ~ ~ on the Teaching Box Is Unsteady ...................................................................... 5-16
5.1 . 3 initial Diagnosis Is ~~t completed ................................................................................................ 5-17
5 1 4 ?'he servo power supply cannot B~ ~~~~~d ON ................................................................. 5-20 . . .............. 5.1.5 The Servo Power Supply Is Shut OFF Immediately When Turned ON 5-21
5.1.6 Manual Manipulation Does Not Function ................................................................................ 5-22
5.2 A Failure Code and A Failure Message Are Displayed ............................................................. 5-23
5.2.1 ~h~ ~ i ~ ~ l ~ ~ of A ~ ~ i l ~ ~ ~ ......................................................................................................................... 5-23 5 2 2 Logical Outputs for Failures 5-26 . . 5.2.3 shock sensor 5-27 5 2 4 Servo power shutoff 5 - 28 . . 5 2 5 software ~ i ~ i ~ ,I ~ i ~ k software ~ i ~ i t .......................................................................................... 5-29 . . 5 2 6 Overrun ................................................................................................................................................................. 5 - 31 . . 5.2 7 ~ ~ ~ ~ ~ ~ i ~ ~ ~ i ~ ~ ~ ~ i l ~ ~ ~ ~ 5 - 32 5 2 8 Data Installation Failures 5 - 34 . . 5.2.9 r \ / ~ ~ ~ ~ ~ ~ ~ ~ i l ~ ~ ~ ~ 5-36
5.2.10 setting E~~~~~ .................................................................................................................................................. 5-37
5 2 11 ABSO Data Failure 5 - 39 . . 5 3 When Servo Failure Occurred ...................................................................................................................... 5-40
5 3 1 How To See the Servo Failure Display 5-40 . . 5.3.2 ~ ~ ~ ~ b l ~ ~ h ~ ~ t i ~ ~ for servo ~ ~ i l ~ ~ ~ ~ ............................................................................................... 5-46
Chapter6 Periodic Inspection 6 1 Warranty period 6-1 6 2 periodic Inspection Schedule 6 - 1 6 3 Notes for Performing Periodic Inspection .......................................................................................... 6-2 6.4 List of Inspection Items 6-2
Chapter7 Parts L is t 7 1 IRBCX-422 Robot Control Unit .................................................................................................................. 7 - 2 7 2 IRBCX-462 Robot Control Unit .................................................................................................................. 7 - 4 7 3 IRBCX-512 Robot Control Unit .................................................................................................................. 7 . 6 7.4 IRBCX-532 Robot Control Unit .................................................................................................................. 7 - 8 7 5 IRBCX-541 Robot Control Unit .................................................................................................................. 7-10 7 6 IRBCX-551 Robot Control Unit .................................................................................................................. 7-12 7.7 BBOpX-3000 Operation panel .................................................................................................................... 7-14 7.8 BBOP-3005 Operation Pane] 7-16 7.9 BBTBX-6008 Teaching Box ............................................................................................................................ 7-18 7.10 BBST-4005 Starting Box .................................................................................................................................. 7-20 7 . 11 BBWF-0105 welding Interface .................................................................................................................... 7-22 7 12 BIRBX-1005 Control Cables 7 - 24
7 12 1 control cable 1 2 3 ~ 0 1 ~ 0 1 ~ 0 1 ) ................................................................................... 7-24 . . , > 9
7 12 2 cables / H~~~ 7 - 24 . . 7.12.3 Control Cable5 (For Almega Auto 11% Robot Control Unit) ............................... 7-25
7 13 BIRBX-8005 Control Cables 7-26
7 13 1 Control Cable 1 2 3 (For V10 ~ 2 0 ) 7-26 . . , , 7.13 2 ~~~l control cable ( F ~ ~ ~ 1 0 ~ 2 0 ) 7-27
9
7 14 BIRBX-6005 Control Cables 7-28
7 14 1 Control Cable 1 2 3 (For V40) ........................................................................................................... 7-28 . . 9 ,
7 14 2 ~~~l control cable ( F ~ ~ ~ 4 0 ) .......................................................................................................... 7-29 . . 7 15 Robot Control Unit for External Axes ............................................................................................... 7-30
7 15 1 IRBCX-422-1 Robot Control Unit 7 - 30 . . 7 15 2 IRBCX-422-2 Robot Control Unit 7-32 . . 7 15 3 IRBCX-422-3 Robot Control Unit 7-34 . . 7 15 4 IRBCX-512-1 Robot Control Unit 7-36 . . 7 15 5 IRBCX-512-2 Robot Control Unit .................................................................................................. 7-38 . . 7 15 6 IRBCX-512-3 Robot Control Unit .................................................................................................. 7-40 . .
Chapter8 Electrical Connection Diagram
8 1 Electrical Diagram of Robot Control Unit IRBCX-422 462 ................................................. 8 - 1 1
8 2 Electrical Diagram of Robot Control Unit IRBCX-512 .............................................................. 8 - 7
8 3 Electrical Diagram of Robot Control Unit IRBCX-541 .............................................................. 8-13
8.4 Electrical Diagram of Robot Control Unit IRBCX-551 .............................................................. 8-19
8.5 Internal Sequence Diagram of Robot Control Unit .................................................................... 8-25 8.6 Outside Dimensional Drawing of Robot Control Unit ............................................................. 8-33
8.6.1 IRBCX-422 462 512 541 551 ................................................................................................................ 8-33 , t ' I
8 6 2 IRBCX-532 ............................................................................................................................................................. 8-34 . . 8 7 Electrical Diagram of Control Cable 8 - 35
APPENDIX I-WELDING EQUIPMENTS 1.1 connecting ~ ~ b ~ t ~ ~ d i ~ ~ t ~ d Welding power Supply Al - 1
1 . 1.1 ~ ~ t ~ ~ ~ ~ l connecting cable Al - 1 1 1.2 Connecting Cables A1 - 2
1.2 Connecting Welding Interface and Welding Power Supply A l - 3 1 . 2. 1 External Connecting Cable ................................................................................................................ A l - 3 1.2.2 Connecting Method of Cables A l - 4
1 3 TIG Interface E5743 ........................................................................................................................................... A l - 6 1 . 3. 1 A~~~~~~~~~ of TIG interface A l - 6
1 . 3.2 setting J~~~~~ wires of TIG ~ ~ t ~ ~ f ~ ~ ~ Al - 7 1 . 3.3 Connecting TIG Interface Al - 7
1 4 Filler Wire Feed Control Unit EST56 Al - 8
1.4.1 Appearance of Filler Wire Feed Control Unit .................................................................... Al- 8
1 4 2 Connecting Filler Wire Feed Control Unit ............................................................................. A1 - 8 . . 1 5 CUT Interface E5782 ......................................................................................................................................... Al- 9
1 . 5. 1 Appearance of CUT Interface .......................................................................................................... Al- 9 1 .5.2 setting J~~~~~ wires of CUT interface ................................................................................. A1 - 10 1 . 5.3 connecting CUT ~ ~ t ~ ~ f ~ ~ ~ A1 - 10
1 6 Weld Stick Detection Unit E5391 A1 -11
1 .6 . 1 Specifications of Weld Stick Detection Unit ......................................................................... Al-11
1.6 2 Functions of Weld Stick Detection Unit .................................................................................... A1 - 12
1 .6. 3 Connecting Weld Stick Detection Unit ....................................................................................... A1 - 13 1.7 Connection Examples of Various Welding Power Supplies ............................................ A1-15
1 . 7. 1 C02/MAG/MIG Welding Power Supply ................................................................................. A1 - 16
1.7.2 TIG Welding Power Supply ................................................................................................................ A1-22
1 7 3 ~i~ plasma cutt ing power supply ............................................................................................... ~1 -24 . .
Contents
1 . 3 External Connection 1-20
... . 1.3.1 Connecting Control Cable 1,2, 3 (BIRBX-1005/BIRBX-8005) 1 - 21 1 . 3 . 2 connecting hi^^ B~~ 1-24
1.3.3 Connecting Control Cable 5 (BWCB-5105) o r Welding Interface (BBWF-0105) ....................................................................................................................................................... 1-25
1 3 4 Connecting Operation Panel .................................................................................................................... . . 1-27 1 3 5 Connecting Starting Box ............................................................................................................................. . . 1-28 1 3.6 Connecting Miscellaneous Options 1-29
1. Ins ta l la t ion WAKNlNt i
1. Before the installation and connecting cables to the robot ELECTRIC SHOCK control unit, ensure that the switch of the switchboard and the @Do not touch live electrical
breaker in the control unit are installing or servicing.
turned OFF so that no voltage is ources of voltage
being impressed.
2. Install the robot control unit and its peripheral equipment such a s the welding power supply, the starting box,and so on out of the a8 Read instruction manual.
action range of the robot.
3. To install the robot control unit, the welding power supply and the likes on a high place such a s on a frame (over Zm),arrange a working floor just a s shown in Fig.l.1 .for easy adjustment and maintenance.
Fig.1 . l . Installation of robot control unit on high place
T O AVOID DAMAGE T O THE ROBOT CONTROL UNIT, KEEP THE AIR INLET A N D EXHAUST
A CAUTION FAILURE TO CONNECT CN47 T O BATTERIES will cause loss of absolute offset data. 0 Di~connscf input wwar before installing or servicing.
C o n n e c t CN47 to bsttarics bafors using robot CN47 is located on the Icfl rids of the main transformer.
0 Perfom absoluts ofbot adjustment according to Inrtructioo Monval nftsr CN47 is connectad.
0 Whon raplacing banariss, bs sure tho1 the control pawar is on.
.--...
A LAU l IUN 5
1. Install the robot control unit over 20cm away from wall.
2. After completing the installation work, carry out the "Absolute Offset Setting"
Installation 1 - 1
described in the Instruction Manual "TEACHING", so that the attitude of the manipulator and the position coordinate data of the robot control unit should coincide with each other.
"..",, 3. Keep the space for the cable connection
on the side of Robot Control Unit over 30cm away from wall.
\ /
2 . 1 Configuration
1 .I .1 COp/MAG Welding Robot Standard Configuration
1. ALMEGA GOlS Basic Configuration
@ ~ ~ ~ i ~ ~ l ~ t ~ ~ ..................................................................... I R B - Q ~ ( G O ~ S ) ~ Standard accessories
Wrench
Clamping bolts
@ Control Unit IRBCX-422 1
(OSACOM SUPER 8700)
@) Teaching Box .................................................................... BBTBX-6008 1 (Cable 8m)
@ Operation Panel .......................................................... BBOPX-3000 1 (Optional)
@ Control Cable 1 ,2,3 ................................................... BIRBX-1005 lset (3 cables:5m length)
(For Manipulator-Control Unit)
COu'MAG Welding Components
@ Robot Dedicated Welding Power Supply -.-- CPVAS-350 1
a control cable 5 BWCB-5105 1 (Cable length 5m)
(For Control Unit-Robot Dedicated Welding Power Supply)
@ Wire Reel Stand L318H 1
0 ~ ~ b l ~ ~ / ~ ~ ~ ~ ~ BIRB-3005 lset
1 Workpiece Side Welding Cable --.----.-..- L3442B (1) (Cable length 5m)
(For Welding Power Supply-Workpiece)
~ - 2 ~~~~h side welding cable ........................ L2527D (1) (Cable length 5m)
(For Welding Power Supply-Manipulator)
0 3 G~~ H~~~ .................................................................. L2527B (I) (Cable length 5m)
@-4 control cable 4 ~ 3 3 9 2 ~ (1) (Cable length 5m)
(For Welding Power Supply-Manipulator)
@ G~~ ~ ~ ~ ~ l ~ t ~ ~ ............................................................... 5092-320 1 (FCR-8033)
1 - 2 Installation
Installation 1 - 3
2. ALMEGA WOlS Basic Configuration
a ~ ~ ~ i ~ ~ l ~ t ~ ~ 1 ~ ~ - 4 6 1 1 Standard accessories
(WOlS) * Wrench
Clamping bolts
@ Control Unit ..................................................................... IRBCX-462 1
(OSACOM SUPER 8700)
@ hi^^ B~~ BBTBX-6008 1 (Cable 8m)
Operation panel BBopX-3000 1 (Optional)
@ Control Cable 1 2 3 ...................................................... BIRBX-1005 , , lset (3 cables:5m length)
(For Manipulator-Control Unit)
COdMAG Welding Components
@ Robot Dedicated Welding Power Supply .-- CPVAS-350 1
a Control Cable 5 ............................................................. BWCB-5105 1 (Cable length 5m)
(For Control Unit-Robot Dedicated Welding Power Supply)
@ Wire Reel Stand L318H 1
@ Wire Feed Unit L6065A 1
@ Cape Hanger .................................................................... L6058D 1
Coaxial power Cable K2863A 1 (2.5m)
@ COz Welding Torch ...................................................... MTX-3502 1
@ Torch Attached Bracket ....................................... L318G 1
@ Torch Gauge Assembly .......................................... L3382G 1
0 ~ ~ b l ~ ~ / ~ ~ ~ ~ ~ BIRB-3005 lset
0 - 1 Workpiece Side Welding Cable -.--..--.--..----- L3442B (I) (Cable length 5m)
(For Welding Power Supply-Workpiece)
0 - 2 Torch Side Welding Cable -..--..-.-------.--------- L2527D (1) (Cable length 5m)
(For Welding Power Supply-Manipulator)
Q-3 G~~ H~~~ ................................................................... ~ 2 5 2 7 ~ (1) (Hose length 5m)
0 - 4 control cable 4 ---.- ........... ~ 3 3 9 2 ~ (1) (Cable length 5 5 m)
(For Welding Power Supply-Manipulator)
@ Gas Regulator ................................................................. 5092-320 1 (FCR-8033)
Q Conduit ................................................................................. Z318D41 1 (3x1)
1 - 4 Installation
3. ALMEGA VOlS Basic Configuration
a Manipulator ...................................................................... IRB-511 1 Standard accessories
(VOlS) Clamping bolts
@ Control Unit .................................................................... IRBCX-512 1
(OSACOM SUPER 8700)
@ Teaching Box .................................................................. BBTBX-6008 1 (Cable 8m)
@ operation panel ........................................................... BBOPX-3000 1 (Optional)
@ Control Cable 1 2 3 ..................................................... BIRBX-1005
, , Iset (3 cables:5 m length)
(For Manipulator-Control Unit)
C02/MAG Welding Components
@ Robot Dedicated Welding Power Supply .-- CPVAS-350 1
a Control Cable 5 ............................................................. BWCB-5105 1 (Cable length 5m)
(For Control Unit-Robot Dedicated Welding Power Supply)
@ Wire Reel Stand L318H 1
@ Wire 'Feed Unit L3603A 1
@ Coaxial Power Cable ................................................ K2364A 1 (1.2m)
C02 Welding Torch MTXC-3501 1 (With shock sensor)
@) Torch Attached Bracket ........................................ L6300B 1
@ Torch Gauge Assembly L6300C 1
@ G~~ ~ ~ ~ ~ l ~ t ~ ~ ................................................................ 5092-320 1 (FCR-8033)
@) Conduit .................................................................................. Z318D41 1 (3m)
@ Cables/Hoses ................................................................... BIRB-3005 lset
1 Workpiece Side Welding Cable ...-..-..-------- L3442B (1) (Cable length 5m)
(For Welding Power Supply-Workpiece)
@-2 Torch Side Welding Cable .-------------.-------..... L2527D (I) (Cable length 5m)
(For Welding Power Supply-Manipulator)
@-3 G~~ H~~~ L2527B (1) (Hose length 5m)
@-4 Control Cable 4 ................................................... L3392G (1) (Cable length 5m)
(For Welding Power Supply-Manipulator)
1 - 6 Installation
Installation 1 - 7
4. ALMEGA VlOS Basic Configuration
@ ~ ~ ~ i ~ ~ l ~ ~ ~ ~ IRB-541 ( ~ 1 0 s ) 1 Standard accessories
Clamping bolts
@ Control Unit IRBCX-541 1
(OSACOM SUPER 8700)
@ hi^^ B~~ BBTBX-6008 1 (Cable 8m)
operation panel ............................................................ BBOPX-3000 1 (Optional)
@ Control Cable 1 2 3 ...................................................... BIRBX-8005 , , lset (3 cables:5 m length)
(For Manipulator-Control Unit)
COdMAG Welding Components
@ Robot Dedicated Welding Power Supply -. CPVAS-350 1
a control cable 5 ............................................................. BWCB-5105 1 (Cable length 5m)
(For Control Unit-Robot Dedicated Welding Power Supply)
@ Wire Reel Stand ............................................................. L318H 1
@ Wire Feed Unit L3603A 1
0 coaxial power cable ................................................ ~ 2 3 6 4 ~ 1 (1.2m)
0 COz Welding Torch MTXC-3501 1 (With shock sensor)
@ Torch Attached Bracket ....................................... L3585p 1
@) Torch Gauge Assembly L3585M 1
G~~ ~ ~ ~ ~ l ~ t ~ ~ 5092-320 1 (FCR-8031)
@ Conduit ................................................................................. Z318D41 1 (3m)
@ ~ ~ b l ~ ~ / ~ ~ ~ ~ ~ .................................................................... BIRB-3005 lset
- 1 Workpiece Side Welding Cable .--.---.--.---.-- L3442B (1) (Cable length 5m)
(For Welding Power Supply-Workpiece)
- 2 Torch Side Welding Cable L2527D (1) (Cable length 5m)
(For Welding Power Supply-Manipulator)
@-3 G~~ H~~~ ................................................................... ~ 2 5 2 7 ~ (1) (Cable length 5m)
0 4 Control Cable 4 .................................................. L3392G (1) (Cable length 5m)
(For Welding Power Supply-Manipulator)
1 - 8 Installation
Installation 1 - 9
5. ALMEGA V20S Basic Configuration
Manipulator ...................................................... IRB-551 0720s) 1 Standard accessories
Clamping bolts
@ Control Unit IRBCX-551 1
(OSACOM SUPER 8700)
@ hi^^ B~~ BBTBX-6008 1 (Cable 8m)
@ operation panel BBOPX-3000 1 (Optional)
@ Control Cable 1 2 3 BIRBX-8005 I , lset (3 cables:5m length)
(For Manipulator-Control Unit)
1 - 1 0 Installation
Installation 1 - 1 1
6. ALMEGA V40S Basic Configuration
a ~ ~ ~ i ~ ~ l ~ ~ ~ ~ IRB - 531 ( ~ 4 0 ~ ) 1 Standard accessories
Clamping bolts
@ Control Unit ...................................................... IRBCX-532 1
(OSACOM SUPER 8700)
@ hi^^ B~~ . BBTBX - 6008 1 (Cable 8m)
a operation panel ......................................... BBOPX-~OOO 1 (Optional)
@ Control Cable 1 2 3 4 .................................. BIRBX-f'j005 , , , lset (4 cables:5 m length)
(For Manipulator-Control Unit)
I - 1 2 Installation
Installation 1 - 1 3
1.1.2 Optional Equipments
The following Equipments are provided as options.
@ Teaching Box
@ Control Cable 1,2,3 (For Manipulator-Control Unit)
Model
BBTBX-6015
a ) For VOlS,GOlS,WOlS
Specifications
Cable Length: 15m
b) For VlOS,V20S
Model I Specifications
BIRBX-8003 I Cable Length: 3m
BIRBX-8010 Cable Length: lOm
BIRBX-8015 I Cable Length:15m
c) For V40S (Control Cable 1,2,3,4)
@ Control Cable 5 (For Control Unit-Almega Auto II )
Model I Specifications
BWCB-5110 I Cable Length: lOrn(Optica1 fiber)
@ Cables/Hose (For Control Unit-Almega Auto II )
BWCB-5115
I Constructions
Cable Length: 15 m (Optical fiber)
Model
1 - 1 4 Installation
--- -
BIRB-3010
BIRB-3015
Specifications
L3375T
L3375V
Control Cable 4
Workpiece Side Welding Cable Gas Hose
L3375E
L3375G
Torch Side Welding Cable
L3375L
L3375N
L3443B
L3444B
Cable Length: lOm
Cable Length: 15m
@ Tool Control Cable
a ) For VlOS,V2OS
b) For V40S
Model
BIRBX-9105
BIRBX-9110
BIRBX-9115
Specifications
Cable Length: 5m
Cable Length: lOm
Cable Length: 15m
0 Operation Box
Model
BIRBX-6105
BIRBX-6110
BIRBX-6115
Model
Specifications
Cable Length: 5m
Cable Length: lOm
Cable Length: 15 m
I Specifications
BBOPX-3005 I Operation Box with 5m cable
BBOPX-3008 I Operation Box with 8m cable
BBOPX-3015
~ ~ t ~ ~ ~ ~ l storage E5777A
External Connecting Cable ..................................................................................................................... E5657L
Cable Assy(l) E5777K
Cable Assy(2) E5777 J
Interface printed Board E5657C
Accessories E5777N
@ Welding Interface E5624A
(For COz o r MAG Welding Power Unit expect CPVAS) @ personal Computer Interface Cable E5623B
(For Personal Computer-Backplane board) 0 Terminal Block Unit E574 1 A
Q Relay uni t E5685A
@ ~ ~ t ~ ~ d ~ d Terminal Block Unit ............................................................................................................ E5766A
@ ~ ~ t ~ ~ d ~ d Relay Unit E5772A
Operation Box with 15m cable
Starting Box
Installation 1 - 1 5
Model
BBST-4005
BBST-4008
BBST-4015
Specifications
Cable Length: 5m
Cable Length: 8m
Cable Length: 15m
1.2 Connecting Primary Power Supply
1.2.1 Connecting Pr imary Power Cable
1. Primary Power Supply
3 phase AC200V (+lo%,- 15%), 50/60Hz
3KVA (GOl,WOl,VOl), 4kVA (VlO),
5kVA (V20), 7kVA (V40)
2. To primary power cable of 3 .5d min. x 3
wires,attach a M4 round crimpstyle
terminal a t the control unit side.
CAUTION Be sure that grounding is carried out a s a prevention against electric shock. For the grounding method, see1.2.3.
Fig. 1.2.1.1 Connecting Primary Power Cable
3. Install a nonfuse breaker (3 phase, 200V) on a leakage breaker between primary
power supply and control unit.
GO1 + 1-3 Axes
4. For wiring both control unit and welding power supply,in order to reduce noise
effects,install separately wiring to primary power supply and grounding terminal.
5. The location of breaker in the control unit is shown in Fig.l.2.1.1.
6. Supply primary power to each of control unit and welding power supply from its
independent power supply
@ NOTE 1. This robot control unit is equipped with inverter circuit to control AC
servo motors. Therefore, if implying a leakage breaker,be sure to specify a leakage breaker for inverter in order to prevent its leakage current generated from the inverter circuit.
2. In the use of high sensitivity type of a leakage breakerjnstall one per control unit.In the case of the collective use among multiple control unit, install one middle sensitivity type leakage breaker for several control units.
1 - 1 6 Installation
1.2.2 Opening Control Unit Door
Door Key - t---7 1. Unlock the upper and lower
/ door keys. Use a minus screwdriver.
Braker .+ I - 2. Turn the breaker handle to "Open Reset" in the direction of the arrow in Fig.1.2.2.1 to
i open the door. At this moment,the primary
i power of the control unit is shut off.
//
Door Key I /-----
Fig.1.2.2.1 Door of control unit
ELECTRIC SHOCK can kill. *Do not touch live electrical
parts. @Disconnect all power
before installing or servicing. .Multiple sources of voltage
may exist inside this enclosure.
If the door needs to be opened with the power ON,for example to check the control unit a t any occurrence of a failure, follow the procedures described below:
Fig. 1.2.2.2 Breaker handle
Unlock the upper and lower door keys. Use a minus screwdriver.
Turn "Release" button to the arrow shown in Fig.1.2.2.2 with a screwdriver,and you may open the door with the power ON.
WARNING 1. Voltage is impressed on the primary side of the breaker even after the
breaker of the control unit is turned OFF. Therefore, in case of opening the door for maintenance, be sure to turn OFF the power source switch.
2. The control units contains many high-voltage components and touching any of them while powere is ON may cause electric shock. Therefore, if the door needs to be opened with the power ON, for example to check the control unit a t any occurrence of a failure, never fouch any of components inside of the unit.
Installation 1 - 1 7
1.2.3 Grounding
For a safety operation, install the grounding arrangement a s shown in Fig.1.2.3.1.
1. For the manipulator, use a MI2 tap located a t the bottom of the body to provide an
independent ground with a grounding cable over 3.5d.
2. For the robot control unit,provide an independent ground with a grounding cable
over 3.5mnT.
The grounding terminal of the control unit is located on the top and the bottom of
the breaker.
3. For the welding power supply,provide an independent ground with a grounding
cable over 14d .
4. Be sure to apply ground resistance below 100 9 .
5. Ensure that the ground of each of 1,2,3,and 4 is separated from one another,as
shown in Fig.l.2.3.1,and never use them together with the grounding cable o r
grounding pole from other electric power.
6. For the use of metallic conduit,duct and cable rack for wiring of grounding cables,
follow the Electrical Installation Technical Standards in your country.
l r ~ s u l a t l n s P l a t e ,
M a n l F u l a t o r Sloe W s ! d i n g C a b l e ( A ) - R o b o t C o n t r o l U n i t
\
W e l r r i n g T o r c h -
e x c e e d i n g 100Q)
n o t l e s s t h a n 3 5mm2 ( w i t h i n :Onj
Fig.1.2.3.1 Grounding
A CAUTION \
Be sure of the danger of imperfect connection of, particularly, the workpiece side cable B, a s shown in Fig.1.2.3.2, which may cause a welding current to flow into the control unit through the motor frame, resulting in damage in the control unit. Similarly, pay attention when using another welding power supply
I for temporary welding of workpiece. I
1 - 1 8 Installation
[ r Read manual for connection procedures. I
A : Torch Side Welding Cable
B : Work Side Welding Cable
Fig. 1.2.3.2 Welding current flowing
into control unit
e Connect grounding conductor and input
conductors to proper terminals inside
unit-grounding conductor first.
e Be sure grounding conductor goes to
a proper earth ground and has less
than 100 ohms of resistance.
e Doublecheck grounding conductor.
input voltage, and frequency before
applying power.
Installation 1 - 1 9
1.3 External Connection Notes on Connection
1. Before connecting cables to the robot control unit,make sure that the switch of the
switch board of the distribution panel and the breaker within the control unit a r e
turned "OFF" s o that no voltage is being impressed.
2 . Make sure that the connections (connectors and terminals) of cables and hoses a r e
tightened.
3. Do not put any load on the cables.
4. Do not cross various cables.
5. Do not install cables under the welding power supply.
6. Separately place the welding cables and other control cables without binding them up.
7. Cables may be installed inside the unit from both the right and left sides.Connect
them in accordance with the description shown in the following pages.
8. As for connecting to the jig,refer to "Interface with Jig" in the instruction manual.
G.B. and servo driver as indicated
@Connect 6N67, CN68, CN69, CN70, CN71 andCN72 of control cable. to Interlock Board as following drawing.
@Connect 6N31, 6N32 and CN33 of starting Box to Interlock Board as in the -Following
as positioner and slider. In case of a single mechanism (one manipulator) system, 613169 and 6N72 are not connected.
@As for details of each cable connection, Read Instruction Manuals.
NC8068
1 - 2 0 Installation
1.3.1 Connecting Control Cable 1,2,3 (BIRBX-1005/BIRBX-8005)
The manipulator and the robot control unit are connected with 3 cables.
CNl ,connectors CN67, 68
and CN51-56.
(1) Connecting Control Cable 1
1. Connect cannon plug CN1 Connecting cannon plug
of Manipulator.
2. Connect connectors CN67
and CN68 to CN67 and CN
*
Duct 68 of Interlock board /
. Servo Driver
L C N I C o n t r o l
C a b l e I
respectively.
Connect connectors CN51-
56 to CN51-56 a re all the
same type connectors but
have different colors to
identify each axis.
After connection,be sure
to check that they are all
correctly connected.
Place the cables connected
to servo Drivers in the
ducts located a t the right
side and the upper part .
Connect a grounding cable
to a grounding plate
mounted on the bottom of
Control Unit.
Fig.l.3.1.1 Connecting Control Cable 1
CAUTION 'I 1. Because this cable is a motor power cable,do not bind it with other signal
cables. 2. Connector CN56 is for V01.
Therefore, if manipulator is GO1,this connector should not be connected. L J
Installation 1 - 2 1
1 CN2,connectors CN7 and 1
(2) Connecting Control Cable 2
CN2 Con t
Connecting cannon plug
Fig.1.3.1.2 Connecting Control Cable 2
+
C a b l
1. Connect cannon plug CN2
to CN2 of Manipulator.
2. Wire along the left side
and connect connector
CN70 to CN70 of Interlock
Board.
3. Connect connector CN7 to
CN7 of Servo Control
Board 1.
A CAUTION 1. Since this cable is the signal cable for encoder, do not bind it with other
motor cables and AC input cables. 2. Connectors of the same type as the connector CN70 a re employed in CN5 in
SCON Board 1 and 2. To avoid damage for printed circuit board, do not mis-connect.
1 - 2 2 Instal lat ion
(3) Connecting Control Cable 3
Inter Fa l o c k
Connecting cannon plug
CN3,connectors CN7 and
CN71
f
G r o u n d i n g P1atcX3
+ 1. Connect cannon plug CN3
to CN3 of Manipulator.
2. Wire along the left side
and connect connector
CN71 to CN71 of Interlock
Board.
3. Connect connector CN7 to
CN7 of Servo Control
Board 2.
Fig.1.3.1.3 Connecting Control Cable 3
1 CAUTION ? 1. Since this cable is the signal cable for encoder, do not bind it with other
motor cables and AC input cables. 2. Connectors of the same type as the connector CN71 a re employed in CN5 in
SCON Board 1 and 2. To avoid damage for printed circuit board, do not mis-connect.
Installation 1 - 2 3
"1.3.2 Connecting Teaching Box
Fig.1.3.2.1 Connecting Teaching Box
Connecting connector CN16 1. Connect connector CN16
of Teaching box to CN16
on the side of Control
Unit.
+
1 - 2 4 Installation
1.3.3 Connecting Control Cable 5 (BWCB-5105) o r Welding Interface (BBWF-0105)
1. Connect connector CN37
to CN37 of Interlock Board.
2. Connect optical fiber
connector to IC124 of Back
plane.
Connecting connector
CN37 and optical fiber
connector
to R o b o t Welding P o w e r SuPP l Y or
*
W e l d i n g Interface
Fig. 1.3.3.1 Connecting Robot Dedicated Welding Power Supply
@ NOTE
I Connect welding interface like control cable (BWCB-5105).
Instal lat ion 1 - 2 5
cover (Fig.a) and fiber cap (Fig.b). (The unclean connection of optical fiber cable causes malfunction of the robot.)
Q a c k P l a n e
C o n n e c t o r C o v e r
(Fig. a) (Fig. b)
Fig.1.3.3.2 Optical Fiber Connector
1 - 2 6 Installation
1.3.4 Connecting Operation Panel
1 Connecting connectors I *
Fig.1.3.4.1 Coilnecting Operation Panel
1. Connect connectors CN28
and CN31 to CN28 and
CN31 of Interlock Board
respectively.
Installation 1 - 2 7
1.3.5 Connecting Starting Box
(Note) Station Nos. and their corresponding
Connector Nos. are a s follows:
Connecting connector
CN3 1
(Le f t S i d e ) I
+ 1. Connect connector CN31 of Starting Box to
CN32-CN36 of Interlock Board and Relay Unit
PCB5 (The Inside o f Door)
I + t o S t a r t i n g B o x
Fig.1.3.5.1 Connecting Starting Box
1 - 2 8 Installation
I .3.6 Connecting Miscellaneous Options
1. Connect Line Master and
Personal Computer to the
following connectors of
Backplane board:
CN19 for Line Master
CN18 for Personal Computer
Fig. 1.3.6.1 Connecting Miscellaneous Options
CAUTION Do not bind all these cables with motor cable.
Installation 1 - 2 9
1.4 Placing Printed Boards Cautions on Placing Printed Boards
1. The printed boards connected to Backplane Board a r e inserted in the slots.After
insertion,in order to prevent imperfect contact of the connector connection which
may cause malfunction due to vibration and shock,ensure that the printed boards a r e
fixed with printed board metal fixing plates (2).
Maln Processor Board /
Motion Control Board /I/O Management Board
Fig.l.4.0.1 Fixing Printed Board
2. After placing the printed boards,be sure to check that the boards a r e all in the
correct slots.Misplacing may damage a board.
1.4.1 Connecting Ma in Processor Board
Connect connectors J l , J 2 of Main Processor Board to connectors 51-4 and 52-4 of
Backplane Board.(See Fig.l.4.O.l)
1 - 3 0 Installation
1.4.2 Placing Servo Control Boards
1. Connect connector CN1 of Servo Control Board 1 to connector 52-2 of Backplane
Board.(See Fig.l.4.O.l)
2. Connect connector CN1 of Servo Control Board 2 to connector 52-1 of Backplane
Board.(See Fig.l.4.0.1)
1.4.3 Placing Motion Control Board
Connect connectors J1,52 of Motion Control Board of connectors 51-3,52-3 of
Backplane Board.
1.4.4 Placing 1/0 Management Board
Connect connectors J1,J2 of I/O Management Board to connectors 51-5,5255 of
Backplane Board.
Installation 1 - 3 1
Chapter 2 Internal Conf igurat ion o f Cont ro l U n i t
Contents
2.2 1 Functions ........................................................................................................................................................
2 2 2 Operation Status Indicator ............................................................................................................. . . 2.3 1/0 Management Board L3700M (Standard) or L4024M (Extension) .................
2 3.1 Functions ........................................................................................................................................................
2 3 2 Operation Status Indicator ............................................................................................................. . . 2.4 Servo Control Board (SCON) L4268R (or L4000R) and
position Control Board (pCON) U1CjOS .........................................................................................
2 4 1 Functions of Servo Control Board . . 2.4.2 Operation Status Indicators of Servo Control Board ..............................................
2.4.3 switch settings of servo control ~~~~d .............................................................................
2 . 4 . 4 Jumper pin Settings of Servo Control Board 2 4 5 Functions of position Control Board ..................................................................................... . . 2.4.6 Operation Status Indicators of Position Control Board ........................................
2 4 7 Switch Settings of position Control Board ....................................................................... . . 2.5 servo ~~i~~~ unit ~ 4 0 0 0 ~ (01) ~ 4 0 0 1 ~ ( ~ 0 1 ) I
2 . In te rna l Con f i gu ra t i on o f Con t ro l U n i t This chapter explains the functions. operation status indicators. and switch settings of
the following components contained in the robot control unit: For IRBCX.422. 462. 512. 541 (1) ~~i~ processor ~~~~d ~ 3 7 0 0 ~ (2) ti^^ control ~~~~d ~ 3 7 0 0 ~
(3) 1/0 Management Board (Standard) ................... L3700M I/() Management Board (Extension) ...................................... L4024M
(4) Servo Control Board ........................................................................... L4268R
(5) Servo Driver Unit (6) Servo power Unit E5787A (7) ~ ~ ~ k ~ l ~ ~ ~ ~~~~d L3702F (8) Interlock Board ........................................................................................ L3899Y (9) Terminal Block Unit (Option) E5741A
Relay Unit (Option) E5685A
00) charging ~ ~ t t ~ ~ ~ unit ...................................................................... W - LO0471 (11) Memory Battery ..................................................................................... L3391V (12) ~ ~ ~ i l i ~ ~ ~ ~~~~~f~~~~~ W - LO0470 03) power Unit E6029A
.O. 0.1 and
Fig.Z.O.O.1 Parts Arrangement Drawing of Robot Control Unit
(IRBCX-422, 462, 512. 541)
Internal Configuration of Control Unit 2 . 1
For IRBCX-551
(I) Main Processor Board ...................................................................... ~ 3 7 0 0 ~ (2) Motion control ~~~~d ...................................................................... ~ 3 7 0 0 ~
(3) 1/0 Management Board (Standard) .... L3700M 1/O Management Board ( ~ ~ t ~ ~ ~ i ~ ~ ) L4024M
(4) Servo Control Board L4268R or position control ~~~~d ~ 4 1 9 0 ~
(5) Servo Driver Unit
(6) Servo power Unit ................................................................................... E5787A (7) Backplane Board ~ 3 7 0 2 ~ (8) Interlock Board ~ 3 8 g g y
(9) constant voltage power supply ................................................ ~ - ~ 0 0 2 0 3 (10) Terminal Block Unit (Option) E5741A
Relay Unit (Option) ............................................................................ E5685A
(11) Charging Battery Unit ...................................................................... w - ~00471
(12) Memory Battery L3391V (13) Switch Box E5760A @4) Auxiliary Transformer w - ~00470
The component arrangement drawing and block diagram are presented in Fig.2.0.0.2 and Fig.2.0.0.4, respectively .
Fig.2.0.0.2 Par t s Arrangement Drawing of Robot Control Unit (IRBCX-551)
2 . 2 Internal Configurat ion of Control Un i t
Arc Sensor Teaching Box Robot Dedicated Welding
Power Supply f Personal f 4 $- computer 1 r
Operation (Operation
Panel Box)
1 t I C N ~ S iCiZ4 CNiQ CNie CN16 I A A A A,
Charging
PCB 1
Backplane Board
Jl-5 J2-5 Jl-4 JZ-4 J1-3 J2-3 JZ-2 J2- I
~ C R I tnjll PCB IS PCB14 PCB13
I/O
(Memory Backup)
Interlock Board
/[PC851 l l I P C ~ O I I 8
Battery Unit
1 Manipulator
F Fo
Operation (Operation
Panel Box)
I Manipulator
2.1 Main Processor Board L3700C 2.1.1 Functions
The Main Processor board controls the overall robot control unit and has the
following functions:
(1) Controls the overall robot system.
(2) Stores data such a s teaching data, system parameters, and calender data.
(3) Controls the external storage.
(4) Communicates with the teaching box.
2.1.2 Operation Status Indicator
(1) Operation Status Indicator (LED100 Red)
This LED illuminates when the processor on the Main Processor board properly
operates. It goes out when the processor does not properly operate due to a drop in
supply voltage or a failure of the Main Processor board. In this event, the Main
Processor board transmits a system down signal to other boards to shut off the
servo power. To replace this printed board due to a failure, follow the steps in 2.1.3.
Fig.2.1.2.1 Outside View of Main Processor Board
Internal Configuration of Control Uni t 2 - 5
2.1.3 Replacing Main Processor Board
The memory on the Main Processor board stores important data such a s teaching
data and system parameters. These data are backed up by a memory battery mounted
outside the Main Processor board.
Therefore, to replace this printed board, follow the steps below:
(1) Store the teaching data and system parameters to the external storage.
(2) Remove the board from the slot. Do not put the removed board on a conductive
material such a s a metal because the data are backed up for several hours by the
condenser mounted on the board.
(3) Place a new Main Processor board in the slot.
(4) Initialize the printed board. (For initialization, see the Teaching instruction
manual.)
(5) Transfer the stored teaching data and system parameters from the external
storage.
2 - 6 Internal Configurat ion of Control Uni t
2.2 Motion Control Board L3700D 2.2.1 Functions
The Motion Control board controls movements of the manipulator and has the
following functions:
(1) Computes the movement and path of each arm of the manipulator.
(2) Processes various arithmetic operations a t high speed necessary for the above
computations.
2.2.2 Operation Status Indicator
(1) Operation Status Indicator (LED100 Red)
This LED illuminates when the processor on the Motion Control board properly
operates. It goes out when the processor does not properly operate due to a failure,
etc. In this event, the Motion Control board outputs a system down signal to shut
off the servo power.
Fig.2.2.2.1 Outside View of Motion Control Board
Internal Configurat ion of Control U n i t 2 - 7
2.3 1/O Management Board L3700M (Standard) or L4024M (Extension) 2.3.1 Functions
The I/O Management board controls input/output signals transmitted within the
robot control unit and from/to peripheral equipment and has the following functions:
(1) Receives various 1/0 signals transmitted within the robot control unit and
from/to the peripheral jig.
(2) Performs logical arithmetic operations responding to each of input/output signals.
(3) Communicates with the peripheral equipment such as the Line Master and a
personal computer.
2.3.2 Operation Status Indicator
(I) Operation Status Indication (LED100 Red)
This LED illuminates when the processor on the I/O Management board properly
operates. I t goes out when the processor does not properly operate due to a failure,
etc. In this event, the I/O Management board outputs a system down signal to shut
off the servo power.
Fig.2.3.2.1 Outside View of 11'0 Management Board
2 - 8 Internal Configuration of Control Unit
2.4 Servo Control Board (SCON) L4268R (or L4000R) and
Position Control Board (PCON) L4190S Servo Control board (SCON) is used for IRBCX-422 (GOl), IRBCX-462 (WOl),
IRBCX-512 (VOl), IRBCX-541 (VlO), and IRBCX-551 (V20), while Position Control
board (PCON) is used for IRBCX-532 (V40).
2.4.1 Functions of Servo Control Board
One Servo Control board is capable of controlling the servo system for a maximum
of 3 axes. The functions are a s follows:
(1) Processes arithmetic operations a t high speed necessary to control the servo
system.
(2) Controls the position, speed and current loops in the servo system, and generates
switching signals to drive the servo motors.
(3) Receives encoder signals.
(4) Receives position data from the absolute encoders.
(5) Detects various failures relating to the servo system.
(6) Outputs encoder signals to the Line Master.
2.4.2 Operation Status l nd icators of Servo Control Board
The Servo Control board is equipped with two kinds of LEDs; one is green and the
other is red. In the normal condition, the green LED is ON and the red LED is OFF.
A ON/OFF combination of these LEDs helps you to identify the cause of a failure.
For details, see Table 2.4.2.1.
Internal Configuration of Control Un i t 2 - 9
Table 2.4.2.1 LED Indications of Servo Control Board
1 1 The encoder cable is disconnected or unconnected. Power is not supplied to the encoders. Encoder failure.
2. Overheat of power transistor The motor load is too large.
3. Unconnected cable between Servo driver and Servo Control board. 4. Overcurrent (The OC LED of Servodriver also illuminates.)
The motor load is too large. Any setting of motor selector rotary dip switches, 3/4/5 is wrong. The motor cable is short-circuited. The ramps of motor acceleration/deceleration are too large.
The main power supply is abnormal. The ramp of motor deceleration is toolarge. (Error detected in the hardware)
1. Normal 2. Motor overheat
The motor load is too large.
I
1 1 3. Undervoltage of main power supply
1 5. Overvoltage of main power supply
I I The main power supply is abnormal. The primary supply voltage has dropped.
1 I The connectors of the main power supply and control power supply
I I are disconnected or unconnected. 4. Halt signal input 5. Over limit of momentary current
The motor load is too large. Any setting of motor selector rotary dip switches, 3/4/5 is wrong The motor cable is short-circuited. The ramps of motor acceleration/deceleration are too large.
6. Over limit of speed detection 7. Over limit of position deviation 8. Overcurrent
The motor load is large. Any setting of motor selector rotary dip switches, 3/4/5 is wrong. The ramps of motor acceleration/deceleration are too large. (Error detected in the software)
1. Voltage drop of Servo Control board 2. No input of synchronizing signal
Synchronizing signal between Servo Control board and Motion Control board is abnormal.
3. Imperfect cable connection between Servo driver and Servo Control board 1 / 4. Supolv voltage drop or power shut-off within Servo driver
A * " - 0 0 / Supply voltage drop of Servo Control board
@: ON 0: OFF
2 - 1 0 Internal Configuration of Control Unit
2.4.3 Switch Settings of Servo Control Board
(1) Reset Switch SW1
This switch causes the Servo Control board to be reset.
Normally, it does not need to be pressed.
SW 1 but
is a P u s h ton switch
/- 0 Green LED
0 R e d LED -r
Location o f each switch
SW2-SW8 are rotary s w i t c h e s
Fig 2.4.3.1 Location of Each Switch on Servo Control Board
(2) Board Identify Switch SW2
The robot control unit is equipped with multiple Servo Control boards. This switch
is used to set a identification number to define the servo system (axes) controlled by
the Servo Control board. For a standard ALMEGA G01, W01, V01, V10, o r V20, the
switch is preset a s shown in the Table 2.4.3.1:
Table 2.4.3.1 SW2 Settings
Printed Board No. / Slot NO. I SW2 Setting I Servo System Controlled
PCB12 (SCON3) 51 - 12 / 5 2 - 1 2 1 External Axis ( o ~ t i o n )
PCB14 (SCON1)
PCB13 (SCON2)
External Axis
51 -2 52-2 51-1 52-1
PCBll(SCON4) (option)
-
* 1: A standard control unit does not have a slot. Internal Configuration of Control Uni t 2 - 1 1
1
2
51-11*1 52-11
GO1/WO1/V01/V10/V20: Axes 1-3 GOl/WOl: Axes 4/5 VOl/VlO/V20: Axes 4-6
4 External Axis
(3) Axis Setting Switches SW3, SW4, and SW5
Theses switches a r e used to set moving axes of the manipulator controlled by the
Servo Control Board. One board capable of controlling up to 3 axes has 3 switches,
SW3, SW4, and SW5. The settings and corresponding moving axes a r e shown in
Table 2.4.3.2:
Table 2.4.3.2 SW3, SW4, and SW5 Settings
SW3/4/5 Settings 1 Corrsponding Axes of Manipulator
1 GOl/WOI: Axes 4/5, and unused axes
/ G01: Axes 1/2
1
2
1 VOl : Axes 21'3
V01: Axes 4/5/6
GO1 : Axis 3
1 V01: Axis 1
1 V10: Axes 4/5/6
/ V20: Axes 4/5/6 WO1 :Axis3
1 V10: Axes 2/3
V10/W01: Axis 1 V20: Axes 1/2/3
The settings, 3, 5, 6, 9 and F, do not correspond to moving axes of the manipulator.
E
(4) Switch to set the number of controlled axes SW6
WOl: Axis 2
This switch is used to set the number of axes in the servo system controlled by the
Servo Control board. The settings and number of controlled axes a r e shown in Table
VOl/VlO/V20 : SCONl (PCB14)/ SCON2 (PCB13)
GO1 : SCONl (PCB14)
Table 2.4.3.3 SW6 Settings
2 1 1 / External axis, etc.
SW6 Setting
2 - 1 2 Internal Configuration of Control Un i t
NO. of Controlled Axes Example of Application
(5) Spare Switches SW7 and SW8 (not provided on L4268R) Normally, set them to 0.
(6) Standard settings of Switches
For a standard robot control unit, the switches described above a r e preset as
shown in Tables 2.4.3.4 through 2.4.3.8: (These settings may vary, for example, if an
external axis is added. Therefore, be sure to check the settings before replacing the
Servo Control board.)
Table 2.4.3.4 Settings for IRBCX -422 (ALMEGA G01)
Table 2.4.3.5 Settings for IRBCX-462 (ALMEGA W01)
Table 2.4.3.6 Settings for IRBCX - 512 (ALMEGA V01)
P r i n t e d B o a r d Axis 1 1 1 1 1 1 1 Manipulator SW2 SW3 SW4 SW5 SW6 SW7 SW8 1 60. Controlled
SW4
4
0
Manipulator
GO 1
SW2
1
2
Table 2.4.3.7 Settings for IRBCX-541 (ALMEGA VlO)
SW5
2
0
Printed Board
NO.
PCB14 (SCON1)
PCB13(SCON2)
SW3
4
0
vo 1
Axis
Controlled
Axes 1-3
Axes4-5
Table 2.4.3.8 Settings for IRBCX - 541 (ALMEGA V20)
SW6
0
1
PCB14 (SCON1)
PCB13 (SCON2)
Internal Configuration of Control Un i t 2 - 1 3
SW7
0
0
Axes 1-3
Axes 4-6
SW4
C
A
Manipulator
v10
SW8
0
0
SW2
1
2
1
2
SW5
C
A
SW3
D
A
Printed Board
No.
PCB14(SCONl)
PCB13(SCON2)
SW3
D
B
Manipulator
v20
SW6
0
0
Axis
Controlled
Axes l -3
Axes4-6
Axis
Controlled
Axes l -3
Axes 4-6
Printed Board
NO.
PCB14(SCONl)
PCB13 (SCON2)
8
1
SW4
D
B
SW2
1
2
7
1
SW5
D
B
SW6
0
0
7
1
0
0
0
0
0
0
2.4.4 Jumper Pin Settings of Servo Control Board
The Servo Control board is equipped with the following jumper pins used for various
settings:
(1) JT1: Setting for detection on/off of voltage drop of the servo motor driving power.
Normally, close 1-2 (to detect on).
(2) JT2: Setting for detection on/off of encoder disconnection of each axis connected
to the Servo Control board.
Normally, set the jumper pins which correspond to the axes connected to the servo
system a s ON, and the jumper pins which correspond to the axes unconnected a s
OFF. If the jumper pin which corresponds to an axis unconnected to the servo
system is set a s ON, an error message is displayed.
The axes numbers used for Servo Control board and ON/OFF settings a re shown
in Table 2.4.3.9:
Table 2.4.3.9 Axes Nos. and Settings for Detection ON/OFF of Disconnectioii
Corresponding Axis No* I Detection ON I Detection OFF --
1
2
Servo Control board but not of the manipulator.
3
(3) JT3: Normally, close 2-3
Close 8 - 9
Close 5 - 6
(4) Standard settings of Jumper pins
For a standard robot control unit, the jumper pins described above are preset a s
shown in Tables 2.4.3.10. and 2.4.3.11 (These settings may vary, for example, if an
external axis is added.
Therefore, be sure to check the settings before replacing the Servo Control board.)
Table 2.4.3.10 Settings for IRBCX-422/462 (ALMEGA GOl/WOl)
Close 7 - 8
Close 4 - 5
* The corresponding axis number is a axis number used for
Close 2 - 3
Printed Board Axis Manipulator 1 Controlled 1 1
Close 1 - 2
2 - 1 4 Internal Configuration of Control Unit
GOl/WOl PCB14 (SCON1)
PCB13 (SCON2)
Axes 1-3
Axes 4-5
Close 1-2
Close 1-2
Close 8-9, 5-6, 2-3
Close 8-9, 5-6, 1-2
Close 2-3
Close 2-3
Table 2.4.3.11 Settings for IRBCX-512/-541-1'551 (ALMEGA VOi/VlO/V20)
Fig. 2.4.4.1 Outside View of Servo Control Board
Internal Configuration of Control Un i t 2 - 1 5
JT3
Close 2-3
Close 2-3
JT1
Close 1-2
Close 1-2
Axis
Controlled
Axes 1-3
Axes 4-6
Manipulator
v01/v10/v20
JT2
Close 8-9, 5-6, 2-3
Close 8-9, 5-6, 1-2
Printed Board
NO.
PCB14 (SCON1)
PCB13 (SCON2)
2.4.5 Functions of Position Control Board
One Position Control board capable of controlling the servo system of a maximum of
3 axes has the following functions:
(1) Receives position data from the absolute encoders.
(2) Converts a specified position received from the Main board to a specified speed.
(3) Detects Servo failures.
NOTE
Position Control boards used for OSACOM 8700 are not compatible with those for 6800 (IRBC-421/-511/-531) due to differences in the specifications.
2.4.6 Operation Status Indicators of Position Control Board
The Position Control board is equipped with the following indicators:
(1) LED 1 (Red) ON when an encoder is abnormal.
This LED illuminates when failure is detected in any encoder of three axes.
(2) LED 2 (Red) ON when monitored speed is abnormal.
This LED illuminates when the speed of any of three axes exceeds the monitoring
limit during teaching or manual manipulation.
The speed monitoring value is set with SW 1-3.
(3) LED 3 (Green) ON when the CPU properly operates.
This LED illuminates when the CPU on the Position Control board operates
properly, and goes out when the CPU does not properly operate due to failure, etc.
2.4.7 Switch Settings of Position Control Board
For a standard robot control unit for ALMEGA V40, the switches a re preset a s
shown in Tables 2.4.7.1 and 2.4.7.2:
Table 2.4.7.1 DSl/DS2/DS3 Settings for IRBCX-532 (ALMEGA V40)
2 - 1 6 Internal Configuration of Control Uni t
PCB14 (PCON1)
PCB13 (PCON2)
Axes 1 - 3
Axes 4 - 6
ON
OFF
ON
O F F 0
0
0
0000
0000
0
0
0000
000
00
00
0
0
0
0
0
0
0
0
00
00
Fig. 2.4.7.1 Outside View of Position Control Board
Table 2.4.7.2 RSWl/RSWZ/RSW3 Settings for IRBCX-532 (ALMEGA V40)
Internal Configurat ion of Control U n i t 2 - 1 7
RSW3
F
F
RSW2
F
F
RSWl
F
F
Printed Board No.
PCB14 (PCON1)
PCB13 (PCON2)
Axis Controlled
Axes 1 - 3
Axes 4 - 6
2.5 Servo Driver Unit L4000Q (GOI), L4001Q (V01) This unit consists of a set of servo drivers, and these types depend on the motor
capacity and quantity required for each manipulator type, as shown in Tables 2.5.0.1
through 2.5.0.6: (Some of the configurations may vary, for example, if a n external axis
is added.)
Table 2.5.0.1 Configuration of Servo Driver Unit IRBCX-422 (ALMEGA G01)
Manipulator / Servo Driver NO. 1 Par t NO. / Spec. 1 Capacity
Table 2.5.0.2 Confinuration of Servo Drive Unit IRBCX-462 (ALMEGA W01)
Axis Driven
GO 1
Table 2.5.0.3 Configuration of Servo Drive Unit IRBCX-512 (ALMEGA V01)
Table 2.5.0.4 Configuration of Servo Driver Unit IRBCX-541 (ALMEGA V10)
SD 1
SD2
Table 2.5.0.5 Configuration of Servo Driver Unit IRBCX-551 (ALMEGA V20)
5096-138
5096-139
Table 2.5.0.6 Configuration of Servo Driver Unit IRBCX-532 (ALMEGA V40)
Manipulator
v20
W-LO0455
W-LOO456
2 - 1 8 Internal Configurat ion of Control Unit
Servo Driver No.
SDl
SD2
Manipulator
30A X2+ 15A X 1
15AX2
Axes 1-3
Axes 4 - 5
Par t No.
5096-159
5096-155
Servo Driver NO. SDI
Spec.
W-LOO568
W-LOO553
Par t No. 5096-1 15
Capacity
50A X 3
15AX3
Spec. W-LOO395
Axis Driven
Axes 1-3
Axes 4 - 6
Capacity 2.5kw
Axis Driven Axis 1
2.5.1 Functions
The Servo Driver supplies power to the servo motors in response to a control signal
transmitted from the Servo Control board, and has the following functions:
(1) Converts a control signal transmitted from the Servo Control board to power for
driving the servo motors and supplies the power to the servo motors.
(2) Indicates failures detected in the servo motor driving system on the servo driver
panel and transmits the data to the Servo Control board.
(3) Detects the current of each servo motor and transmits the data to the Servo
Control board.
2.5.2 Operation Status Indicators
The servo driver panel is equipped with 4 kinds of LEDs; RDY (Green), OH (Red),
OC (Red) and OV (Red). When a servo failure occurs, the indications of these LEDs
allow you to identify the possible cause. The LED indications and possible causes a re
shown in Table 2.5.2.1.
Table 2.5.2.1 LED Indications and Possible Causes
(@:ON, 0 : O F F ) ( * :Possible Cause)
Internal Configuration of Control Un i t 2 - 1 9
0
*
*
0
*
*
*
*
L E
Cause
@
*
*
RDY(green)
OH (red)
OC (red)
OV (red)
0 0
*
*
*
@
0 0 0 0 @ @ @ @ 0 0 0 0 @ @ @ @ 0 0 @ @ 0 0 @ @ 0 0 @ @ 0 0 @ ~ @
0 @ 0 @ 0 @ 0 @ 0 @ 0 @ 0 @ 0 1 @
Motor main voltage over
385V
Motor main voltage below
170V.
Power transistor heating
error in any axis.
Overcurrent in any axis
Blown fuse of any axis
Overvoltage in any axis
Servo Control board in the
reset state
0
*
@
*
*
0
* * * * * * * *
I
@
*
*
*
*
@
*
*
@
* * * * * * * *
*
0
*
@
*
*
*
0
* * * *
*
*
@
*
*
*
*
*
Power I/F Board
CN3, CN5, CN7
connected to
Manipulator
(motor)
Servo Control Board
CN4, CN6, CN8, connected to Servo Power Supply Unit connected connector
fo r Servo Control Board
Glass Tube Fuse 5A-15.4 specified Driver (200W rnax.)
10A-30.4 specified Driver (500W min.)
10A-50A specified Driver (1200W)
Fig. 2.5.2.1 Outside View of Servo Driver
2 - 2 0 Internal Configuration of Control Unit
2.6 Servo Power Unit E5499A or E5787A
2.6.1 Functions
This unit supplies power for driving the servo motors, and has the following
functions:
(1) Supplies DC (Direct Current) voltage of the power source for driving the servo
motors to the servo drivers.
(2) Absorbs the regenerative voltage produced by the servo motors.
Fig. 2.6.2.1 Panel of Servo Power Unit
2.6.2 Operation Status Indicators
(1) POWER LED (Green)
Internal Configuration of Control Un i t 2 - 2 1
0 0
O
0
T B l O
o C N 6 5 0
This LED illuminates when the 3-phase
ACZOOV is supplied to the Servo Power unit by
turning on the servo power. If it is not ON,
check whether the 3-phase ACZOOV is supplied
a t each of terminals, R, S, and T of TB10, a s
the primary power phases could be lost.
(2) RE.GEN LED (Yellow)
This LED illuminates when the Servo Power
unit is absorbing the regenerative voltage
produced by the motors. It repeats ON and
OFF during a normal automatic operation.
If it stays ON, check the voltage a t terminals
P-N, a s the output voltage of the Servo Power
unit may have increased. (The proper output
voltage; DC280V)
2.7 Backplane Board L3702F (or L3700F) 2.7.1 Functions
This printed board relays signals transmitted from each printed board in the robot
control unit, and has the following functions:
(1) Relays bus signals within printed boards such a s Main Processor board, Motion
Control board, 1/0 Management board, and Servo Control boards.
(2) Relays signals transmitted from the peripheral equipment connected to the robot
control unit to each printed board.
2.7.2 Connectors The Backplane board is equipped with the connectors shown in Table 2.7.2.1 to
connect peripheral equipment.
Table 2.7.2.1 Connectors on Backplane Board
Connector Equipment to be connected Spare Teaching box
CN18 Personal com~u te r , etc. CN19 / Line h4aster
O SCON3 SCON2 SCDN! IKON0 CSP VAIN OPTION IX) O
v
IC124 (Optical Fiber)
Fig. 2.7.2.1 Outside View of Backplane Board (L3702F)
(L3700F does not has a slot for SCON3.)
Welding interface o r Robot dedicated welding power unit
2 - 2 2 Internal Configuration of Control Unit
2.7.3 Switch Settings
(1) Jumper Pin (JP10) (Not provided for L3700F)
This jumper pin is set to select whether a 3rd Servo Control board (SCON3) is used
or not. Open it if the control unit is equipped with a 3rd Servo Control board to
connect an external axis (axes), or close it if only 2 Servo Control boards for a
single robot system. (See Table 2.7.3.1.)
Table 2.7.3.1 JPlO Settings
3 boards (for system using an external axis) I Open
-
The number of Servo Control boards mounted
2 boards (for single system)
(2) Dip Switch: DSW 100
The Backplane board is equipped with a dip switch to confirm that the connected
mechanism (Manipulator) matches the mechanism configuration defined in the
system program. Set the switch according to the manipulator type to be connected,
as shown in Table 2.7.3.2:
Table 2.7.3.2 DSWlOO Settings
JPlO Setting
Close
1 DSWlOO Settincrs Manipulator Type
IRB-5ll(VOl) 1 y: 1 1 [O 1 !: IRB-541(V10)
IRB - 551(V20) ON OFF
- -
IRB-421(G01)
IRB-461(W01)
.d
The settings in Table 2.7.3.2 are for a standard control unit, and may vary if an
external axis is added.
ON
OFF
-
IRB-531(V40)
Internal Configuration of Control Unit 2 - 2 3
4 1
ON
ON
OFF
2 3
ON
OFF
OFF
ON
ON
ON ON
2.8 l nterlock Board L3899Y 2.8.1 Functions
This printed board controls various internal and external 1/0 signals of the control
unit, and has the following functions:
(1) Controls the sequence circuits of the high voltage system and 24V system.
(2) Receives general and specialized input signals of Operation panel, Starting box, etc.
(3) Controls general and specialized output signals of Operation panel, Starting box,
etc.
(4) Controls the manipulator brakes.
(5) Charges the absolute encoder charging batteries when the primary power is ON,
and supplies the backup power to the absolute encoders from the charging batteries
when the power is shut off.
(6) Detects overdischarge and abnormal voltage by monitoring the voltages of the
charging batteries, and cuts off the charging batteries from the load when
overdischarge is detected.
(7) Outputs signals to reset the absolute encoders.
2.8.2 Operation Status Indicators
The interlock board is equipped with LEDs shown in Table 2.8.2.1 to indicate the
operation s ta tus of the sequence circuits in the control unit.
Table 2.8.2.1 Operation Status Indicators of Interlock Board -
LEDNa
LED101 1 (Green)
LED203 1 (Green) 1 Teach Mode 1 ON indicates Teach Mode
LED201
LED202
LED204 1 (Green) I Running 1 ON indicates Running
Function
Servo Power ON
LED205 1 (Green) / Halted 1 ON indicates Halted
Status
ON indicates Servo Power ON
(Green)
(Green)
LED303 I (Green) 1 Servo ON Permit / ON indicates Servo ON Permit
Teaching Box Servo ON
Auto Mode
LED301
~ ~ ~ 3 0 2
ON indicates Teaching Box Servo ON
ON indicates Auto Mode
Shock Sensor
(Green)
(Green)
LED304 OFF indicates that the shock sensor is
operating. (Green)
Shock Sensor ON
Servo Shut Off
Emergency Stop
ON indicates Servo Shut Off when the
shock sensor operates
OFF indicates Servo Shut Off
OFF indicates Emergency Stop
2 - 2 4 Internal Configuration of Control Uni t
LEDNa
Voltage Drop of LED502 1 (Red) 1
Charging Battery
Function
Auto Mode Input
Teach Mode Input
Start Nal Input
Start Na2 Input
Start No.3 Input
Halt Input
Charging Current ON
LED401
LED402
LED403
LED404
LED405
LED406
LED501
ON indicates Voltage Drop
(below 380V)
Overvoltage of 0 1 (Red) 1
Charging Battery
Status
ON indicates Auto Mode Input
ON indicates Teach Mode Input
ON indicates Start Nal Input ON
ON indicates Start No.2 Input ON
ON indicates Start Na3 Input ON
ON indicates Halt Input
ON indicates Charging
(Green)
(Green)
(Green)
(Green)
(Green)
(Green)
(Green)
ON indicates Overvoltage
LED601
LED602
2.8.3 Switch Settings
(1) Reset Switch SWl
This push button switch causes the absolute encoder data of all the axes to be
cleared to 0. In order to set the absolute offset values, for example, when the robot
is installed, it is necessary to reset the absolute encoders by pressing this switch.
Do not press it for any purpose other than this. If you do, the origin of the robot
LED603
will change.
(2) Reset Mask Switch DSWl
This dip switch is used to prohibit the absolute encoder data from being carelessly
reset. The function and setting corresponding to each bit of this switch for a
standard control unit are shown in Table 2.8.3.1:
Table 2.8.3.1 DSWl Settings
(Green)
(Green)
(Green)
I ON 1 causing resetting the absolute encoders with the teaching box to be
Overrun Detection Input (1)
Overrun Detection Input (2)
invalid.
OFF disables a reset switch SW1 on Interlockboard, causing
OFF indicates Overrun of any of axes 1-3.
OFF indicates Overrun of any of axes 1-6.
Overrun Detection Input (3)
Function
OFF disables any reset signal input from Motion Control board,
DSWl
OFF indicates Overrun of any of axes 1-9.
Setting
Internal Configuration of Control Unit 2 - 2 5
2 ON resetting the absolute encoders to be invalid.
(3) Jumper Pin Settings
The interlock board is equipped with jumper pins shown in Table 2.8.3.2. Set these
jumper pins according to your robot system configuration.
Jumper Pi1
JP301
2 - 2 6 Internal Configuration of Control Un i t
Table 2.8.3.2 Jumper Pin Settings of Interlock Board
Function Sets Emergency Stop inputs of Terminal Block
it and Relay unit ON/OFF. If the control unit equipped with Terminal block unit o r Relay unit,
be sure to open this jumper pin. I Sets Emergency Stop input of Operation panel (or Operation box) ON/OFF. To connect the Operation panel (or Operation box), be sure to open this jumper pin. Sets Emergency Stop input of Starting box 2 ON/ OFF. To connect the Starting box 2, be sure to open this jumper pin. Sets Emergency Stop input of Starting box 3 ON/ OFF. To connect the Starting box 3, be sure to open this jumper pin. Selects connection (CN40 o r TB1) of Shock Sensor Input signal. To connect Shock Sensor Input signal to CN40 via External Axis board, open this jumper pin, o r to connect to TB1, close it. (A standard control unit is not equipped with External Axis board.) Sets detection ON/OFF of charging circuit failure of External Axis board. If the control unit is equipped with External Axis board, open this jumper pin. Sets Overrun Detect signal connected to CN71 ON/ OFF. If the manipulator connected to CN71 via Control cable 3 is equipped with a overrun detect switch, open this jumper pin (ON). Sets Overrun Detect signal connected to CN72 ON/ OFF. To use any external axis (such as a slider and positioner) and connect a Overrun detect switch for external axis to CN72, open this jumper pin (ON). Sets Encoder Cable Connection Check signal for external axis ON/OFF. To use any external axis, open this jumper pin (ON) according to the number of external axes.
Standard Setting Close (if equipped with neither Terminal unit nor Relay unit) Open (if equipped with Operation panel (or Operation box))
Close (not to connect Starting box 2) Close (not to connect Starting box 3) Close (terminals 4-5 of TB1 not to connect a shock sensor)
Close (if not equipped with External Axis board)
Close (not to use any external axis)
Close (not to use any external axis)
Close (not to use any external axis)
2.8.4 Fuses and Connectors
The interlock board is equipped with fuses shown in Table 2.8.4.1.
To replace a blown fuse, remove the cause, and use a fuse which has the same rating.
Table 2.8.4.1 Fuses on Interlock Board
Fuse Na
250V, 3A 1 tube fuse
I , Rating
Power supply for releasing the manipulator brakes
F2
Application
F3
The Interlock board is equipped with the connectors shown in Table 2.8.5.lto connect
peripheral equipment:
250V, 1A
glass tube fuse
F4
Table 2.8.4.2. Connectors on Interlock Board
AClOOV power supply for the welding interface
250V, 3A
glass tube fuse 24V system in the control unit
250V, 2A
glass tube fuse
1 Operation box (Start I)
AC8.5V for charging
Connector Peripheral Equipment to be connected
CN33 1 Starting box 3
I
I
CN32 Starting box 2
CN67
CN68
Manipulator (power supply for brakes)
Manipulator (power supply for brakes)
CN69
CN70
When Operation box and Starting boxes are connected, set also the jumper pins a s
External axis (power supply for brake)
Manipulator (overrun, batteries, et'c.)
CN71
CN72
shown in Table 2.8.3.2.
Manipulator (overrun, batteries, etc.)
External axis (power supply for brake)
Internal Configuration of Control Un i t 2 - 2 7
2.8.5 Connecting J i g Terminals on Interlock Board
(1) Connecting TB1
1 Emergency Stop Input Terminals (1 - 3)
Used to connect a n external emergency stop switch. For the use of multiple switches, connect in series. If this switch is not used, close terminals 1-3 with a jumper wire.
Servo OFF Input Terminals (2-3) Used to connect a n external Servo OFF switch. If this switch is not used, close terminals 2-3 with a jumper wire.
Shock Sensor Input Terminals (4-5) Used to connect-a shock sensor but not via a Control cable. If a shock sensor is not used, close JP305 and terminals 4-5 with a jumper wire.
Input Common (6 and 7) These a r e common terminals of
l-----l terminals 8- 14.
I @ IIServo ON Indicator Lamp Output Terminal (8) I-, To mount a n external Servo ON
I indicator lamp, connect to terminal 8-INCOM (terminals 61'7). (Connectable indicator lamp must be; DC24V and current consum~t ion not I @ Il \greater than 0.1A.)
o ode Switching Input Terminals (9/10) 171 To input Auto/Teach modes through - I I \ an external switch, connect to these I @ lJ \ terminals - INCOM.
'start Input Terminals (11/12/13) To input Starts(l/2/3) through an external switch, connect to these terminals - INCOM.
Halt Input Terminal (14)
0 To input Halt through a n external switch, connect to this terminal - INCOM.
\ Servo ON Input Terminals (15-16) To turn on the servo power through a n external switch, connect to terminals 15-16.
2 - 2 8 Internal Configuration of Control Unit
(2) Connecting TB2
Emergency Stop Output Terminals(1-2) Open between terminals 1-2 during emergency stop.
,Mode State Output Terminals (3/4) Closed between terminal 3-OCOM in Auto mode, and between terminal 4 - OCOM in Teach mode.
Start/Halt Output Terminals (5/6) Closed between terminal 5-OCOM in a starting statet, and between terminal 6-OCOM in a halted state.
Output Common Terminal (7) Common terminal of terminals 3-6.
I @ 1' / Output (Indicator Lamp) Common Terminal (8) Common terminal to connect indicator lamps to terminals 9- 14.
Indicator lamp Output Terminals (9 - 14) The indicator lamp connected to each terminal illuminate in the following state: (Connectable indicator lamps must be; DC24V and current consumption not greater than 0.1A.l
LAMP1 (Terminal 9) : Auto Mode LAMP2 (Terminal 10): Teach Mode LAMP3 (Terminal 11): Star t 1 LAMP4 (Terminal 12): Star t 2 LAMP5 (Terminal 13): Star t 3 LAMP6 (Terminal 14): Halt
Servo ON Terminals (15-16) Closed between terminals 15- 16 in a servo ON state.
Internal Configuration of Control Unit 2 - 2 9
Fig. 2.8.5.1 Outside View of Interlock Board
2.9 Constant Voltage Power Supply W-LO0203
2.9.1 Functions
This unit supplies power to the printed boards, etc. in the control unit, and has the
following functions:
(I) Supplies DC5V, DC+ 15V, DC- 15V, and DC24V to each of the units, printed boards,
etc.
(2) Indicates the output state of each voltage with LED.
2.9.2 Operation Status Indicators
This unit is equipped with a LED per voltage supplied by the constant voltage power
to indicate the operation status.
As the LED may illuminate even if the output voltage is not a proper value, check
2 - 3 0 Internal Configuration of Control Un i t
each voltage with a tester, etc. The normal range of each output voltage is shown in
Table 2.9.2.1:
Table 2.9.2.1 Output Voltages of Constant Voltage Power Supply Unit
Current Consumption
6A
Output Voltage
5V
Normal Voltage Range
5.OOV-5.2OV
CAUTION 1. The GNDs for 5V and t 15V power supplies are shared in the constant
voltage power supply unit. 2. The OV side terminal of 24V power supply is isolated from the GND
terminals for 5V, 2 15V power supplies. 3. The output voltages of the constant voltage power unit are pre-adjusted in
the normal range. However, if any voltage is not in the normal range due to, for example, replacement of the unit, it can be changed by adjusting the potentiometer. (Because overvoltage may damage the printed board, etc., care care should be taken to adjust it.)
+5V power supply f 24V power supply +/-I5 power supply I I I
/ Potentiometer for adjusting 24V output voltage
/potentiometer for adjusting 5V output voltage
Fig.2.9.2.1 Bottom View of Constant Voltage Power Unit
(3 u '
5Y t15Y -15V 24V
0 0 0 0
5v
5v
DM3
O M
+15V
GM) CN42
-1sv
2%'
ov
FG
*$I CN4 1
T B 5
\ f l L/
Fig.2.9.2.2 Front View of Constant Voltage Power Unit
Internal Configuration of Control Unit 2 - 3 1
2.m Terminal Block Unit E5741A (Option) and Relay Unit E5685A (Option)
2.IO.1 Functions of Terminal Block Unit
This printed board connects 1/0 signals of external equipment such as a jig, and has
the following functions:
(1) Receives 20 general physical inputs.
(2) Outputs 20 general physical outputs with open collector.
The specifications of a relay, etc. connectable to terminals must be; DC30V and
current not greater than 100mA. (For detailed explanations of general physical
inputs/outputs, refer to the instruction manual for "Interfacing with Jig" .)
WARNING To use a Terminal Block unit o r Rely unit, open jumper pin JP301 on Interlock board, as shown in Table 2.8.3.2.
2.10.2 Connecting External Equipment (Jig, etc.) via Terminal Block Units
To connect external equipment (such a s a jig) to the Terminal Block unit, refer to
the following circuit configurations:
(1) Input Circuit Configuration (TB13/14)
The inputs transmitted from external equipment a re connected to the robot control
unit through the Terminal Block unit of the circuit configuration shown in Fig.2.10.2.1.
The maximum DC30V/10mA flows through switches connected to the input terminals
of the Terminal Block unit.
4 " ~ o b o t Control Unit Ci
I Ti313
I
Fig. 2.10.2.1 Input Circuit Configuration
2 - 3 2 Internal Configuration of Control Un i t
(2) Output Circuit Configuration (TB111'12)
The outputs transmitted from the robot control unit a r e connected t o external
equipment through the Terminal Block unit of the circuit configuration shown in Fig.
2.10.2.2. The specifications of a relay, etc. connectable to the output terminals of the
Terminal Block unit must be; DC24V and current not greater than 100mA.
For load of a relay, etc. to be
connected, at tach a diode for
absorbing surge o r a surge
absorber.
Tai 1 n
TIT Fig. 2.10.2.2 Output Circuit Configuration
(3) Connecting External Power Supply for Outputs
The external power supply for outputs of the Terminal Block unit can be connected
as shown in Fig. 2.10.2.3:
Fig. 2.10.2.3 External Power Supply to Terminal Block Unit
Internal Configuration of Control Unit 2 - 3 3
T B 1 3 T B 1 4 in ' 0 A ] 1-1;Fl FC23 T B l I T B 1 2 C N 2 2 t-
O O @ O O O @ O O @ O O O O O O O O O O O O O O O O 0- 0
Fig. 2.10.2.4 Outside View of Terminal Block Unit
(4) Fuse
The Terminal Block unit is equipped with a fuse as shown in Table 2.10.2.1. If the
fuse is blown, replace with a fuse that has the same rating after removing the cause.
Table 2.10.2.1 Fuse on Terminal Block Unit
Fuse No. 1 Rating 1 Application
2 - 3 4 Internal Configuration of Control Uni t
250V, 2A 1 Glass tube fuse 24V system for external outputs
2.10.3 Functions of Relay Unit
Like a terminal block unit, this printed board connects 1/0 signals of external
equipment such as a jig, and has the following functions:
(1) Receives 20 general physical inputs.
(2) Outputs 20 general physical outputs with relay contact.
(3) Connects up to 3 Starting boxes.
Fig. 2.10.3.1 Outside View of Relay Unit
Internal Configuration of Control Unit 2 - 3 5
2.10.4 Connectors and Jumper Pins on Relay Unit
The Relay Unit is equipped with connectors to connect Starting boxes, as shown in
Table 2.10.4.1. When Starting boxes a r e connected, set also jumper pins.
Table 2.10.4.1 Connectors on Relay Unit
CN35 / Starting Box 5 1 To connect Starting Box 5, be sure to OPEN JP2.
Connector
CN34
2.1 1 Charging Battery Unit W-LO0471 (Not mounted on I RBCX-532)
2.1 1 .I Functions
The control unit is equipped with a charging battery unit to backup the da ta of the
absolute encoders used for the manipulator. This battery unit is charged while the
control power supply is turned on and supplies backup power to the encoders while the
control power supply is shut off. Therefore, if the robot is not used for a long time, the
residual battery capacity may not be enough to supply power t o the encoders. In this
case, before performing automatic operation, be sure to carry out the manipulator
origin alignment.
Starting Box
Starting Box 4
CN36
2.1 1.2 Specifications
Nominal voltage
Capacity
Discharge voltage
Note
To connect Starting Box 4, be sure to OPEN JP1.
2.OV X 2(2 charging batteries in series)
25AH
3.8V-4.2V (when load is connected)
Starting Box 6
2.1 1.3 Replacing Charging Battery Unit
The charging batteries degrade in the course of repetitive charges and discharges.
Therefore, the unit must be replaced with a new one each time the 3 year periodic
inspection is performed.
To replace it, follow the steps below:
(1) Run the origin check program (P999) by block operation, and confirm that the
alignment marks match a t the origin. If not matched, mark that position with a
layout line.
To connect Starting Box 6, be sure to OPEN JP3.
2 - 3 6 Internal Configuration of Control Unit
(2) Remove the unit together with the connecting cable from CN47 of Interlock board
while the control power supply is turned on.
(3) Attach the cable to a new battery unit and connect to CN47 of Interlock Board.
(4) Run the origin check program (P999) by block operation, and check that the
alignment marks match a s (1).
A WARNING 1. If the charging battery unit is removed when the control power supply is
turned off, the data of the absolute encoders will be lost. 2. The output of the charging battery unit is supplied to the absolute encoder of
each axis through CN70/CN71 of Interlock board and CN2/CN3 of Manipulator. Therefore, regardless of the ON/OFF status of the control power supply, if these connectors are disconnected, the data of the absolute encoders will be lost. When these connectors were removed to perform maintenance, inspection, etc., be sure to carry out the origin alignment.
3. The battery backup duration may be shortened depending on the operating condition of the robot, the ambient temperature, etc.
2.12 Memory Battery L3391V
2.12.1 Functions
The Memory Battery has a function to backup the data, such a s teaching data and
system parameters, stored in the memory on Main Processor board, and supplies
backup power to Main processor board via Backplane board.
2.12.2 Specifications
Type
Nominal voltage
Primary lithium battery
3.0V
2.12.3 Replacing Memory Battery
Though the life of the memory battery varies according to the operating condition
and environment, etc., replace it with a new one when Alarm indicating a battery
voltage drop is displayed or each time the 3 year periodic inspection is performed.
To replace the memory battery, follow the steps below:
(1) Store the teaching data and the system parameters to the external storage.
Internal Configurat ion of Control U n i t 2 - 3 7
(2) Remove the memory battery from CN4 of Backplane board while the control power
supply is turned on.
(3) Connect a new memory battery to CN4.
(4) Transfer the teaching data and the system parameters from the external storage.
CAUTION (1) Replace the memory battery that has been used for more than 3 years, even
if the voltage is normal.
(2) Because the memory battery is not a charging battery, never charge it. Otherwise, it will be damaged.
(3) The battery backup duration may be shortened depending on the operating condition, the ambient temperature, etc.
2.13 Switch Box E5760 or E5809
2.13.1 Functions
The Switch Box has the following functions:
(1) Supplies AC200V and lOOV to each unit in the control unit after eliminating a noise
from the primary power.
(2) Supplies DC5V to the servo drivers and absolute encoders.
(3) Turns the servo power supply ON/OFF.
(4) Supplies AClOOV to the external storage. (Rating: 1A)
2.13.2 Fuse
The switch box is equipped with a fuse shown in Table 2.13.2.1
When the fuse is blown, remove the cause, and replace with a new one that has the
rating below:
Table 2.13.2.1 Fuse on Switch Box
Fuse N a m e Rating 1 Application - = 1 2 5 v / l ~ 1 100V power supply for external storage
Glass tube fuse
2 - 3 8 Internal Configuration of Control Unit
cm74 - A a W V
-OUTPUT I Z O A I
_I
AC 1 OOV INPUT
T
S
R
-
- A C Z W V I NPUT
-
E
Fig. 2.13.1.1 Outside View of Switch Box
Internal Configuration of Control Uni t 2 - 3 9
2.14 Auxiliary Transformer W-LO0470 2.14.1 Func t ions
The auxiliary transformer TF1 has the following functions:
(1) Outputs AC8.5V used for power supply to charge the charging battery unit.
(2) Outputs AClOOV used for releasing the brakes, for the welding interface, for
driving the magnetic switches, and for the external storage.
2.15 Step-down Transformer (Option) The primary input voltage of the control unit is; 3-phase AC200V+10% and - 15%
(50/60Hz). To apply the input voltage other than the above rating, the step-down
transformer is available, which can step down the voltage of the power supplied t o the
control unit to 200V.
2.E.1 T y p e s of Step-down T r a n s f o r m e r s
Table 2.15.1.1 shows the types and capacities of Step-down transformers. I t is
necessary to select a n appropriate transformer according to the system configuration
(capacity of the load).
Table 2.15.1.1 Types of Step-down Transformers
T ip - 1 Capacity Examples of Applicable
System Configuration (Note)
/ Single G01, W01 o r V01, GO1 + 2 W-LO0246 3kVA built-in
1 / external axes, and V01 + 1 external axis
W-LO0557
Built-in type: Built in the control unit
Separate type: Installed outside the control unit
W-LO0558
A CAUTION \
These examples a r e given for your reference. To select a step-down transformer, contact DAIHEN.
7kVA separate
2 - 4 0 Internal Configuration of Control Uni t
Single V10, V20, o r V40, GO1 + 3-7
external axes, and V01 + 2-6 ext.
l2kVA separate Systems using the number of axes
more than the above
2.15.2 Connecting Step-down Transformer
The way of connecting a step-down transformer depends on the type, Built-in o r
Separate, as shown in Fig.2.15.2.1 o r Fig.2.15.2.2, respectively:
- - -- I - - ~ r e a k e r sGC- down power un i t PsKF
Primary
Power
Supply
~ r a n s f o k e r (Built-in) Switch Box SBI
Primary
Power
Supply
1 Robot Control Unit - - - - - - -- i
Fig.2.15.2.1 Connecting Step-down Transformer (Built-in Type)
-.."------ - - - - -- - - - - Step-d0wn 1 r Breaker Power Unit PSI
Breaker Transformer . , NFRl Switch BOX S B ~
Fig.2.15.2.2 Connecting Step-down Transformer (Separate Type)
Internal Configuration of Control Unit 2 - 4 1
2.15.3 Voltage Switching Taps of Step-down Transformer
The step-down transformer is applicable to the primary-side input voltages; ACISO,
200, 208, 220, 230, 240, 380, 400, 415, 440, 460, 480, and 515V. As shown in Fig. 2.15.3.1,
the step-down transformer is equipped with voltage switchiilg taps to select a voltage
from among these voltages. According to the voltage of the power supply used, switch
the taps by connecting jumper wires a s shown in Table 2.15.3.1.:
Fig. 2.15.3.1 Voltage Switching Taps of Step-down Transformer
Fig. 2.15.3.2 Internal Circuit of Step-down Transformer
2 - 4 2 Internal Configuration of Control Unit
b WARNING T o safeguard against electric shock, before attempting to switch the voltage taps , make su re tha t no voltage is impressed to the step-down transformer. In addition, some safety measures should be taken, for example, by providing a
notice plate indicating "Working" a t the switch of the power source s o tha t the control unit cannot be carelessly energized during the work.
Supply
Voltage
Table 2.15.3.1 Connecting Jumpers According t o Pr imary Supply Voltage
P r i m a r y T a p
P r imary
Second-
a r y T a p
J u m p e r C o n n e c t i o n
Internal Configuration of Control Un i t 2 - 4 3
220V
230V
240V
380V
400V
415V
U-U8, U4-U12, U4-V, V-V8, V4-V12, V4-W, W-W8, W4-W12, W4-U
U-U8, U5-U13, U5-V, V-V8, V5-V13, V5-W, W-W8, W5-W13, W5-U
U-U8, U6-U14, U6-V, V-V8, V6-V14, V6-W, W-W8, W6-W14, W6-U
U1-U8, US-V, V1-V8, V9-W, W1-W8, W9-U
U2-U8, U10-V, V2-V8, V10-W, W2-W8, W10-U
U3-U8, U11-V, V3-V8, V11-W, W3-W8, W11-U
R-TI ,
R1-S,
and
S1-T
Fig. 2.15.3.3 Connection Example of Input Voltage 240V
i 6 0 Fig. 2.15.3.4 Connection Example of Input Voltage 415V
unit. Before turning on the power supply, be sure to check that the jumper wire connections a r e correct and appropriate to the actually supplied voltage.
2 - 4 4 Internal Configuration of Control Uni t
2.1 6 Power Unit E6029A 2.16.1 Functions of Power Unit
The Power Unit is the one to supply to the printed boards and the like used within
the control unit, and has the following function:
(1) Function to remove noise from the primary power source and to supply AC2OOV
and AClOOV to the units within the control unit.
(2) Function to supply DC5V,+ 15V, -15V, 24V power, and s o on to the units and
printed boards.
(3) Function to supply DC5.5V power to the Servo Control board and the absolute
encoder.
(4) Function to supply AClOOV power to External Memory Unit.
(5) Function to turn ON/OFF the servo power.
2.16.2 Specifications of Power Unit (1) Rated Output Voltage/Current DC5.5V 3A
DC5.2V 10A
DC+15V 0.5A
DC-15V 0.5A
DC24.2V 1.5A
(2) Dimensions 300(H) X 125(W) ~250(D)mm
(Inside Layout of Unit) (Front View of Panal)
Fig.2.16.2.1 Outside View of Power Unit and Inside Layout of Unit
Internal Configuration of Control Unit 2 - 4 5
2.16.3 Output Voltage of Power Unit The normal range of each output voltage of the Power Unit is as shown in TABLE
2.16.3.1.
Each output voltage of the Power Unit is set within the normal range a t shipment,
however when to exchange units due to failure o r so, confirm the voltage of the output
terminal in the table below
DC 5.5V 1 5.40-5.50V (no load) CN136 0-0 ( 0 : +) 1
TABLE 2.16.3.1 Output Voltage of Power Unit
I 5.10-5.2OV (with load) CN42 0-0 ( 0 : +) I PSU2-VR2
Adjustment Portion
Input Voltage
PSUl -VR1
15.0-15.4V (no load)
Terminal for Checking
TB16 @-@-a CNl50 0-0 CN135 0-0 ( 0 : +)
Rated Voltage
3 q5 AC2OOV
1 q5 AClOOV
5.05-5.25V (with load)
None
Normal Voltage RANGE
180-220V (no load)
90-110V (no load)
CN2A 0-0 ( 0 : +)
CN2B 0-0 ( 0 : -I-)
None
24.1-24.3V (no load) I CN41 @-@ (@ : +) I
-15.0%- 15.4V (no load)
CAUTION
1. Values marked with "no load" in the normal voltage range in TABLE 2.16.3.1 a r e ones measured with connector unconnected. While those marked with "with load" a re values measured with connector connected.
2. The GND of DC5V power source, that of +15V, and that of - 15V a r e in common within the Power Unit.
3. The terminal of DC24V power source a t 0 V side is insulated from the GND terminal of 5V, + 15V, and - 15V.
i
CN2A @--@ (0 : -1
CN2B @-@ (0: -1
Internal Configuration of Control Unit 2 - 4 7
T e r m i n a l B l o c k
,/' N -I OJ - + L_JOLED i
VFI 1
Fig.2.16.3.1 Pa r t s Layout of Constant Voltage Unit (PSU1)
F o r
CN6 CN5 CN4
Fig.2.16.3.2 P a r t s Layout of Constant Voltage Unit (PSU2)
4 8 Internal Configuration of Control Uni t
F o r
2.16.4 Fuse of Power Unit
The Power Unit contains the fuse shown in TABLE 2.16.4.1.
When to exchange fuses due to melting, first remove the cause and exchange the
defective fuse with a new one of the same rating.
TABLE 2.16.4.1 Fuse of Power Unit
2.16.5 Connectors of Power Unit
The Power Unit is equipped with connectors shown in TABLE 2.16.5.1 to supply
Fuse NO.
F1
power source to units inside.
Application
AClOOV Power Source for
Floppy Disk Storage Unit
Rating
250V,lA
Glass Tube Fuse
( $6.4~3Omm)
TABLE 2.16.5.1 Connectors of Power Unit
P a r t No.
4610-008
CN42 1 (Internal) j Backplane Board (CN10) 5V, t15V
CN2 / (Internal) i Servo Driver 1 (CN2) 5V, i- 15V
CN2B / (Internal) i Servo Driver 2 (CN2) 5V, ?c 15V
CN2C / (Internal Spare) Servo Driver 3 (CN2) 5V, t 15V
CN137 I (Internal Spare) Servo Control Board 3 (CN6) 5.5V
CN135
CN136
CN138 / (Internal) Interlock Board (CN38)
(Internal) j Servo Control Board 1 (CN6) 5.5V
(Internal) j Servo Control Board 2 (CN6) 5.5V
CN150 / (Internal) j AC Outlet AClOOV
A CAUTION > To avoid damage for the components of Robot Coutrol Unit, never use the
internal spare and internal connectors in TABLE 2.16.5.1 for other purpose.
Internal Configuration of Control Un i t 2 - 4 9
Chapter 3 Peripheral Equipment o f Robot Control Un i t
Contents
3.1 Teaching Box ......................................................................................................................................................
3.1.1 Functions
3.1 . 2 Outside View of Teaching Box
3 1 3 Notes on Usage ........................................................................................................................................ . .
3.1 . 4 Internal Configuration .......................................................................................................................
3.2 operation panel ...................................................
3.2.1 switches and ti^^^
3.2 2 outside view and ~ ~ t ~ ~ ~ ~ l circuit ............................................................................................
3 3 Operation Box (Option)
3 3 1 Switches and Functions ..................................................................................................................... . .
3.3 2 Outside View and Internal Circuit
3 4 Starting Box (Option) ................................................................................................................................
3 4 1 Switches and Functions . . 3.4.2 connecting starting B~~ ..................................................................................................................
3 4 3 Outside View and Internal Circuit ........................................................................................... . . 3.5 Robot Dedicated Welding power Supply (option) .............................................................
3.5.1 Notes on Using Robot Dedicated Welding Power Supply
3.5.2 Outside View and Internal Configuration of Robot Dedicated
Welding Power Supply .........................................................................................................................
3.6 Welding Interface (Option)
3 6 1 Functions . .
3 . 6 . 2 Description of parts
3 6 3 printed Board E5624G ........................................................................................................................ . .
3 6 4 External Connection ............................................................................................................................. . . 3.6 5 Operation Sequence ...............................................................................................................................
3. Per iphera l Equipment o f Robot C o n t r o l U n i t This chapter describes the peripheral equipment connected to the robot control unit,
including:
(1) Teaching Box
(2) Operation Panel
(3) Operation Box (Option)
(4) Starting Box (Option)
(5) Robot Dedicated Welding Power Unit (Option)
(6) Welding Interface (Option)
(7) External Storage (Option)
(8) Printer Interface (Option)
BQ$ WARN l NG
I Be sure to install these peripheral equipment outside the robot working area.
Peripheral Equipment of Robot Control Un i t 3 - 1
3.1 Teaching Box
3.1.1 Functions
The teaching box is used to teach robot task programs, and has the following
functions:
(1) Transmits various key operations necessary for teaching works to the robot
control unit.
(2) Displays the contents of a task program and the robot operation status on the
liquid crystal display unit.
(3) Turns on the servo power supplied to the robot by the push button switch being
operated.
(4) Stops the robot in emergency by the push button switch being operated.
3.1.2 Outside View of Teaching Box
The outside view of each type of Teaching Box is shown in Fig.3.1.2.1:
Fig.3.1.2.1 outside View of Teaching Box
3 - 2 Peripheral Equipment of Robot Control Uni t
3.1.3 Notes on Usage
(1) The teaching box is equipped with precision parts . Because a shock may damage
these parts , be careful not to drop or hit it when you handle it.
(2) The ambient temperature in the environment may cause the dark background of
the LCD unit o r slowdown of changing characters displayed on the screen, but these
incidents do not indicate a failure.
(3) The LCD unit and a EL lamp used for back light which a r e in long service cause
the blurred characters on the screen and deteriorate illumination. In these events, it
is recommended that the LCD unit and EL lamp be replaced.
3.1.4 Internal Configurat ion
The internal circuit of the teaching box is shown in Fig.3.1.4.1:
TEACHING BOX -- - - - - - - - - - - - - - - - -. - - - -. - - . - - - - - - - ROBOT CONTROL
Fig.3.1.4.1 Internal Circuit of Teaching Box
Peripheral Equipment of Robot Control Unit 3 - 3
3.2 Operation Panel The Operation Panel mounted on the door of the control unit is equipped with switches
to switch robot operation modes, to turn on the servo power, and to start/halt the robot.
The control unit must be installed in a place which allows the operator to operate the
operation panel outside the dangerous area. Note that the operation panel is not
available if the operation box is installed outside the control unit, o r if the jig control
panel is substituted for its functions.
3.2.1 Switches and Functions
(1) Servo ON (SERVO ON) Switch @ This switch is used to turn on the servo power when the initial diagnosis is
completed following the control power ON, and illuminates when the servo power is
turned on.
(2) Teach (TEACH) Switch @
This button is used to change a robot operation mode to Teach mode, and
illuminates when the robot is in teach mode.
It has the same effect a s that of the Teach Mode key on the teaching box.
(3) Auto (AUTO) Switch
This button is used to change a robot operation mode to Auto mode, and
illuminates when the robot is in auto mode.
(4) START switch @
This button is used to activate automatic operation of a program assigned to the
switch when the robot is in auto mode, and illuminates during automatic operation
of the program.
Before operating automatic operation of the robot, be sure that all personnel a re
clear of the dangerous area.
(5) STOP switch @
This button is used to halt the robot during automatic operation, and illuminates
during a halt of the robot. It has the same effect a s that of the Stop key on the
teaching box.
(6) EMERGENCY Stop switch @
This button is used to stop the robot in emergency. Pressing it causes the servo
power to be shut off so that the brakes will be engaged. To cancel the Emergency
Stop, turn this button to the arrow.
For detailed procedures for switching a robot operation mode, for automatic
operation, and for recovery from the state of emergency stop, refer to the "Teaching"
instruction manual.
3 - 4 Peripheral Equipment of Robot Control Uni t
3.2.2 Outside View and Internal Circui t
L - - - J
Ik L---J
m T I C CWI4TICN
OSACOM
Fig.3.2.2.1 Outside View of Operation Panel
------- I(0Doratlon Box) 1
E merrsncr s t o p I I I I I
I I 24E I Start dlsDla1 1 I H a l t dlsDlaY I
I I
S e r v o ON I I
T e a c h node selectlonl ~ u t o mode selection I Servo @i dlsDlaY I I
I I I
T e a c h n o d s dlsPlaJ I Auto mode dlSDlaY I
c - '-&!A - - - - - - - - - - - -I
Fig.3.2.2.2 Internal Circuit of Operation Panel
WARN l NG
1. To connect the operation panel, open JP302 of Interlock board. 2. Though it is possible to connect a s tar t signal connector CN31 of the
operation panel to any of starting box connectors CN31-CN33 of Interlock board, normally connect to CN31 (Start 1).
Peripheral Equipment of Robot Control Uni t 3 - 5
3.3 Operation Box (Option) When the control unit is located too far for the operator to operate the operation
panel, the operation box can be provided outside the control unit to substitute for the
functions of the operation panel. If the operation box is employed, the operation panel
is not available.
WARNING
Be sure to fix the operation box outside the dangerous area.
3.3.1 Switches and Functions The functions of the switches are all the same a s those of the operation panel.
3.3.2 Outside View and Internal Circuit The outside view and internal circuit of the operation box a re shown in Fig.3.3.2.1
and Fig.3.3.2.2, respectively:
S E? - @ ! + i t I S7,RT STOP
Fig.3.3.2.1 Outside View of Operation Box
3 - 6 Peripheral Equipment of Robot Control Uni t
SERVO ON
TEACH I NG
ALJTO
STOP
START
-
0 0 @
TEACH I NG
AUTO
STOP
START
0- PBZ I 902 EMERGENCY STOP
46 j SERVO ON
Fig.3.3.2.2 Internal Circuit of Operation Box
WARNING 1. To connect the operation box,
open JP302 of Interlock board. 2. To connect the operation box,
Relay cable (E5785F) is required.
3. Though it is possible to connect CN31 of Relay cable to any of Starting box connectors CN31-CN33 of Interlock board, normally connect to CN31 (Start 1).
CN31 CN30 ( i n t e r l o c k ( O o e r a t i o n
B o a r d b o x )
CN28 ( I n t e r l o c ~
B o a r d
-LI
Fig.3.3.2.3 Relay Cable for Operation Box
Peripheral Equipment of Robot Control Uni t 3 - 7
3.4 Starting Box (Option) If the robot is used in the Multi-station system, install a Starting box a t each station.
The standard robot control unit is capable of controlling up to 3 stations (with the
operation panel and 2 starting boxes), and adding an optional relay unit enables it to
control up to 6 stations.
A WARNING
I Be sure to fix any Starting box outside the dangerous area.
3.4.1 Switches and Functions
(1) START
This switch is used in auto mode of the robot to initiate automatic operation of a
program assigned to that station, and illuminates during automatic operation of the
program.
Before performing automatic operation, ensure that all personnel a re clear of the
dangerous area.
(2) STOP
This button is used to halt the robot, and illuminates during a halt of the robot.
It has the same effect a s that of the Stop key on the teaching box.
(3) Emergency Stop
This switch is used to stop the robot in emergency. Pressing it causes the servo
power to be shut off so that the brakes will be engaged. To cancel the Emergency
Stop, turn this button to the arrow.
For detailed procedures for automatic operation and for recovery from the state
of emergency stop, refer to the "Teaching" instruction manual.
3 - 8 Peripheral Equipment of Robot Control Un i t
3.4.2 Connecting Starting Box
To use a Starting box, connect it to the connector corresponding to the relevant
station number, and open the jumper pin o r pins corresponding to that connector.
For station numbers and their corresponding connectors/jumper pins, see Table 3.4.2.1.
Without the corresponding jumper pin or pins being opened, the Emergency Stop
switch on that Starting box does not function.
For detailed procedures for assigning a task program to each station, refer to the
"Teaching" instruction manual.
Table 3.4.2.1 Station Nos. and Corresponding Connectors
Remarks
Jumper
Pin to
Open
Location of
Connector/
Jumper Pin
1
Preset
Jumper Pin
Setting
2
3
Peripheral Equipment of Robot Control Un i t 3 - 9
CN31
--
4
5
6
CN32
CN33
JP302
CN34
CN35
CN36
JP303
JP304
Interlock
board
Close
JP301/
J P 1
JP301/
JP2
JP301/
JP3
Open
JP301: Inter-
lock board
JPl/JPZ/JP3/
CN34/CN35/
CN36: Relay
board (option)
Normally, to connect
Operation panel.
Close
Close
Close
If Relay board is
not included, close
JP301.
3.4.3 Outside View and Internal Circuit
The outside view and internal circuit of the Starting box are shown in Fig.3.4.3.1 and
Fig.3.4.3.2, respectively:
Fig.3.4.3.1 Outside View of Starting Box w
STOP
START
STOP
* T ~ EMERGENCY STOP
Fig.3.4.3.2 Internal Circuit of Starting Box
3 - 1 0 Peripheral Equipment of Robot Control Uni t
3.5 Robot Dedicated Welding Power Supply (Option) The Robot Dedicated Welding Power Supply is equipped with the built-in interface
communicating with the robot.
Rated Input I 18kVA I 29kVA 1 17kVA
The following 3 types of robot dedicated welding power supplies a re available a s shown
in TABLE 3.5.0.1
TABLE 3.5.0.1 Specifications of Robot Dedicated Welding Power Supply
Input Voltage
Allowable R a n ~ e
Name
Type
Almega Auto II 350
CPVAS-350
Almega Auto 11 500
CPVAS-500
Rated Frequency
Welding Method
Output Current Range I 40-350A I 40-500A I 40-350A
Almega Fuzzy Auto
CPDA-350
50/60Hz
COJMAG Welding
Rated Output Current
Rated Load Voltage
Dimensions (W x D x H) 1 360 X 550 X 650 1 440 X 610 X 880 1 350 X 510 X 795
350A
36V
Output Voltage Range
Rated Service Rate
3.5.1 Notes on Using Robot Dedicated Welding Power Supply (I) The interface circuit of the robot dedicated power supply is internally energized.
Therefore, turn on the robot dedicated welding power supply prior to the power
supply of the robot control unit.
If the robot control unit is energized first, which will cause the robot dedicated
power supply to be unconnected.
(2) Optical fiber is used for connection between the robot control unit and the robot
dedicated welding power supply.
Handle it with care, because bending optical fiber or the unclean connector
connection may cause communication failure.
(3) When the connector part becomes dirty, wipe the dirt off with a dry soft cloth.
Insert the optical fiber connector firm enough to be locked.
500A
45V
15-36V
50%
Weight (kg)
3.5.2 Outside View and Internal Configuration of Robot Dedicated Welding Power Supply
The outside view and the internal configuration of Robot Dedicated Welding Power
Supply are shown in each Instruction manual.
350A
36V
Peripheral Equipment of Robot Control Unit 3 - 1 1
15-45V
100%
52
14-36V
60%
100 61
3.6 Welding Interface (Option) When a general semiautolnatic welding power supply which has no built-in function of
interface with the robot is employed, the Welding Interface is required for the use with the robot.
3.6."1unctions The welding Interface has the following functions to control the welding power
supply according to the data transmitted from the robot control unit:
(1) Transmits a startup command to the welding machine according to the robot task program.
(2) Outputs the instructed voltage to the welding power supply by conditions taught in the task program according to the welding characteristic data stored in the system parameter file.
(3) Controls the wire feed unit and the gas electromagnetic valve. (4) Checks the arc s tar t failure, no arc generation, and wire stick a t the welding end.
3 - 1 2 Peripheral
- Fig.3.6.1.1 Outside View of Welding Interface
Equipment of Robot Control Unit
3.6.2 Description of Parts (1) Power Indication Lamp
AClOOV is supplied to the Welding Interface from the robot control unit. When power is normally supplied to the Welding Interface, an indicator mounted on the front face panel of the Welding Interface illuminates. If the indicator does not illuminate, in spite of power ON a t the robot control unit, check fuse F1 in the Welding Interface or the fuse F2 on the Interlock Board within the robot control unit for melting.
(2) Gas Check Switch Gas check switch is arranged a t the front face of the Welding Interface a s shown
in Fig.3.6.1.1. Turning this switch upward causes the gas electromagnetic valve to be opened, and
the supply of shield gas may be supplied and checked. (Normally turn this switch downward.)
3.6.3 Printed Board E5624G
V o l t a g e I R a n g e
REF1 S w i t c h i n g
REF2 S w i t c h i n g
F22l I A I
la GAS Va I v e
LED25 LED22
L E ~ GAS V a l v e
SOL
TP9 TPlO TPIZ T P l l
V o l t a s a C o n n a n d S l s n a l C u r r e n t Conmand S l s n a l
Fig.3.6.3.1 Parts Arrangement of Printed Board E5624G
Peripheral Equipment of Robot Control Unit 3 - 1 3
(I) Operation Status Indicators of Printed Board E5624G TABLE 3.6.3.1 shows the functions of LEDs on the printed board E5624G to
indicate the operation status of the Welding Interface.
TABLE 3.6.3.1 Operation Status Indicators of Printed Board E5624G
Operation Status ON while welding
LED No.
LED 21
LED 24 (Red)
LED 25 (Red)
(2) Setting Switches of Printed Board E5624G The following switches are arranged on the printed board E5624G within the
Function Welding Startup Indicator
LED 27 (Red)
Welding Interface to set the command voltage and polarity to meet welding
(Red) *This is lit when a welding startup command
LED 22 .This is lit when wire inching/retract operation is operation
(Red) carried out from the Teaching Box.
the welding power supply. Wire Feed Normal/Reverse Rotation Indicator *This illuminates when wire feed motor rotation is reversed.
Wire Stick Check Indicator *This illuminates when the Welding Interface is checking wire stick.
power supply.
LED 23 (Red)
ON during wire retracting
ON a t welding end.However, it will not illuminate if wire stick "Not Check" is selected in the system parameter.
Gas Valve Operation Indicator .This illumintes when open command of the gas electromagnetic valve is being output.
ON during a gas check and welding
(REF1 1 Current Switching ( of a current command signal to be transmitted to
Wire Feed Indicator .This illuminates when a wire feed command signal is being output to the wire feed unit and
TABLE 3.6.3.2 Switches of Printed Board E5624G
Switching)
ON while welding and wire inching/retracting
the welding power supply. In the case of TIG welding power supply, it switches
Remarks This switch switches the voltage range and polarity
Switch SWll
Functions Instructed Welding
instructed voltage range and polarity proper to the welding power supply used.
SW12 (REF2 Switching)
For the voltage range and polarity of a command signal proper to each of welding power supplies, refer to TABLE 3.6.3.3
3 - 1 4 Peripheral Equipment of Robot Control Unit
Voltage can be selected in the range of 0 - 5V, 0 - 10V, 0 - 15V, 0 - 22V, and polarity of either positive (+)/negative (-), connect jumper pins according to the
Instructed Welding Voltage Switching
the setting of base current command signal. This switch switches the voltage range and polarity of a voltage command signal to be transmitted to the welding power supply. In the case of TIG welding power supply, it switches the setting of filler wire feed command signal.
TABLE 3.6.3.3 Instructed Voltage Range based on Type of Welding Machine
3.6.4 External Connection
Connection of the Welding Interface and the welding power supply requires
exchanging signals, a s shown in Fig.3.6.4.1
As for the kinds of cables for various welding power supplies and connecting method
of the Welding Interface and various welding power supplies, refer to the APPENDIX 1.
Peripheral Equipment of Robot Control Un i t 3 - 1 5
Welding Power
supply
C02/MAG Welding Machine
CPMS-350/500
CPXS-350/500
TRM( W)-350/500
TRA-350/500
CPV-350/500
CPVB-350
CPVP-350
CPVPA-350
CPVWP-350
CPVMB-180
TIG Welding Machine
VRTP-300
AEP(AES)-300
MRHS-300
AVP-300
Air Plasma Cutting Machine
TRC-120
Instructed Welding Voltage
Switching Switch SW12
Instructed Welding Current
Switching Switch SWll
(REF2
Voltage Range
15V
15V
15V
-
15V
-
(REF1
Voltage Range
15V
15V
15V
15V
1 OV
1OV
Switching)
Polarity
Negative
Positive
Positive
-
Negative
-
Switching)
Polarity
Negative
Positive
Positive
Negative
Positive
Positive
C u r r e n t C k e
WCR [ C u r r e n t Checx r e l a y ) i
I
V e l d i n s Powsr F e l l u r e 1 I I
I & w e l d i n s Power F e l l u r e 21
Fig.3.6.4.1 External Connection of Welding Interface
3.6.5 Operation Sequence The Welding Interface outputs signals shown in the timing chart. Fig.3.6.5.1, to the
welding power supply according to the instructions of welding start/end and wire inching transmitted from the robot control unit and the setting of the system parameters.
CAUTION 3
Fig.3.6.5.1 shows an example of operation sequence of the Welding Interface, and the actual action may vary with the kinds of welding power supply and the contents of system parameter setting.
'. /
3 - 1 6 Peripheral Equipment of Robot Control Unit
Signal Name
I l l
Welding
Startup
(Totch
Switch)
Signal Rating
Dry contact (Relay CR21)
OMRON LY2, DC24V
MAX: 5A, AC1 lOV, DC24V
MIN:O.lA, DC5V
Timing Chart
Wire
Inching
ON/OFF
Instructed
Dry contact (Relay CR22)
OMRON LY2, DC24V
MAX:2.5A, ACllOV, DC24V
MIN:O.lA, DC5V
0-15V DC
MAX: 50mA Current
(REF 1)
I l l
ON I ! : , , , 6 I I , $ I
~fl, I t , , / I , # ,
I I 1 1 1 I , ,
(Polarity depends on the
welding power supply.)
Instructed 0-15V DC
MAX: 50mA Voltage
(REF 2) (Polarity depends on the
welding power supply.)
Wire Feed
Motor
ON/OFF
I I I l l 1 1 1
d i f Slowdown
r - - - - - - - - - -
Dry contact (Relay CR23)
OMRON LY2, DC24V
MAX:5A, ACllOV, DC24V
MIN:O.lA, DC5V
Gas Valve
ON/OFF
I I . , . , . . ,
I I I I I I
; ;!lot S t a r t Voltage i / i j j ! ,
DC 24V output
MAX 200mA
! Hot S t a r t Time : S t i c k Cancel l a r a t i o n
8 . ? I 8 , , a , ! I , , ,
GAS Pref low I : I , I
I GAS A f t e r f
I / , I
AS : : : : AE , , , ,
Wire Stick DC 24V output
Check 100mA constant current
YJCR-ON WCR-OFF
Fig.3.6.5.1 Example of Operation Sequence of the Welding Interface
Fig.3.6.5.1 shows one example of the operation sequence of the Welding Interface. Therefore, the actual operation may differ according to the type of welding power supply used and parameter setting.
Peripheral Equipment of Robot Control U n i t 3 - 1 7
3.6.6 Internal Circuit Internal circuit of the Welding Interface is shown in Fig. 3.6.6.1 Fig.3.6.6.1 shows a simplified circuit to explain the internal configuration of the
Welding Interface.
3 - 1 8 Peripheral Equipment of Robot Control Uni t
3.7 External Storage (Option) The external storage can be connected to transfer data from the robot control unit to
a floppy disk. For detailed operating procedures, refer to the "Teaching" instruction
manual.
3.7.1 Specifications
Operating temperature 1 5-35°C
Item Name
Type Memorv medium
Specifications Floppy disk storage E5777 3.5in. 2HD floppy disk
Allowable nono~eratinrr vibration I 2G max.
Nonoperating temperature Ambient humidity Floating dust Allowable o~eratinrr vibration
Allowable operating shock I 5G max.(lOms max.)
-20-60°C 20-80%(Noncondensing) Not serious 0.5G max.
Allowable nonoperating shock I 15G max.(lOms max.) Dimensions I 130 X 50 X 25Omm
(Le f t )
P o r e r S*l tch C o n n e c t o r
I 1
F u s s (0. 5 A )
Power C a b l e
/ O D e r a t I n 6 Lamu
\ E l e c t B u t t o n
F l o u p r D l s t i n l e t
(Front I
Fig.3.7.1.1 Outside View of External Storage
Peripheral Equipment of Robot Control U n i t 3 - 1 9
3.7.2 Configuration of External Storage
The external storage consists of the components shown in Table 3.7.2.1 and Fig.
Table 3.7.2.1 Configuration of Floppy Disk Storage
( )indicates an optional attachment.
A CAUTION
As a floppy disk is not included, the user needs to prepare a 3.5in. 2HD floppy disk.
OSACOM Sup\er 8700
T h e components I n the broten
r--- I Ins are oPtlonal attachments
F I O P P Y D ~ s x Memorr
L L-- ------------I
------- Fig.3.7.2.1 Configuration of External Storage
lcNg51
Fig.3.7.2.2 Outside View of Connecting Cable
3 - 2 0 Peripheral Equipment of Robot Control Uni t
3.7.3 Connecting External Storage To connect the external storage, be sure to turn off the robot control unit and the
external storage, and then follow the steps below:
(1) Attach FDD interface printed board (E5657C) on the door inside face of the
control unit.
(2) Remove the connector cover on the control unit front door, attach connector
CN95 of connecting cable @ (E5777K), and then connect the other connector FC2 to
connector FC2 of FDD interface printed board. (Insert an attachment dustproof
packing between the door and the connector.)
(3) Connect connector FC3A of connecting cable @ (E5777J) to connector FC1 of FDD
interface printed board, and also the other connector FC3 to connector FC3 of Main
Processor board in the robot control unit.
(4) Connect connector CN95 of external connecting cable O(E5657L)
to the connector of the cable attached in above (2), and also the other connector CN90
to the connector on the back of the external storage.
(5) Connect the power cable plug of the external storage to the plug socket on the side
face of the control unit.
A CAUTION > I Do not use this plug socket for any purposes other than to connect to the exter I I nal storage. I
F r l n t e d O a e r l
Ma ~n Processor
Prln!ed E o 3 r d flxlns b o a r d (Ac.9 SS. :.j j Y ESTn:Il
0 C 3 5 1 ? E5777J
Fig.3.7.3.1 Illustration for Connecting External Storage
Peripheral Equipment of Robot Control Un i t 3 - 2 1
3.7.4 Notes on Handling External Storage
(1) Before connecting the external storage, be sure to turn off the control unit and
the external storage.
(2) For power supply of the external storage, use the plug socket on the side face of
the robot control unit.
(3) To use the external storage, turn on the external storage prior to robot control
unit.
(4) When a floppy disk exists in the external storage, turning on/off the external
storage o r the robot control unit may destroy the data on the floppy disk. Before
turning on/off, remember to remove the disk from the external strage.
(5) When not using the external storage, store it in a dust free condition.
(6) Take care to prevent the external storage from shock such a s falling and hitting
shocks.
3.7.5 Notes on Handling Floppy Disks
(1) Store your floppy disks in a specialized case.
(2) Keep materials which produce magnetic fields, such a s a magnetic stone, away
from the floppy disks. Magnetic fields may destroy the data on the disk. Due to the
same reason, do not leave the disk in the robot control unit.
(3) Excessive force o r a heavy load, or dropping may damage the floppy disk. Take
care to protect the disks from harm.
(4) When the environment has rapidly changed, leave the floppy disk in the new
environment for several hours before you use it.
3 - 2 2 Peripheral Equipment of Robot Control Unit
3.8 Printer Interface Unit (Option) The printer interface can be connected to print the contents o r a list of Task
programs and various Condition files with a printer (equivalent to NEC PC-PRZO1)
For detailed procedures for operating the printer output feature, refer to the
"Teaching" instruction manual.
3.8.1 Functions
(1) The contents of Task programs, various Condition files, and user parameters can
be printed.
(2) A list of Task programs or various Condition files can be printed.
3.8.2 Configuration
The printer interface consists of the components shown in Table 3.8.2.1 and Fig.
3.8.2.1:
Table 3.8.2.1 Configuration of Printer Interface
L CAUTION \
A printer and printer cable (Printer <- -+ Control unit front face) are not included. The user needs to prepare a PC-PRZO1 (NEC) type printer and a printer cable (such a s a commercial printer cable connectable between your printer and a NEC PC 9801 personal computer, except note types).
Peripheral Equipment of Robot Control Unit 3 - 2 3
Ref .No.
0 0
0
@
0
Drawing Na
E5802C
E580ZB
E5802D
E5802E
E5802F
Item
Printed board
Mounting board
Cable (1)
Cable (2)
Attachments
Q'ty
1
(1)
(1)
(1)
(1)
Remarks
Printer interface
Mounting board and screws
Control unit front face +--+ Printed board
Main Processor board c-, Printed board
Rubber packing and Display board
Main
Robot control unit
1 -4,
Printer cable P Printer d
Fig.3.8.2.1 Configuration of Printer Interface
Cable (1) E5802D Cable (2) E5802E
Fig.3.8.2.2 Outside View of Connecting Cable
3 - 2 4 Peripheral Equipment of Robot Control U n i t
3.8.3 Connecting Printer Interface Unit To connect the printer interface, be sure to turn off the robot control unit, and then
follow the steps below. Note that these steps depend on whether the external storage
is used o r not.
3.8.3.1 When External Storage is not used
(1) Fix the printed board mounting board on the inside face of the control unit door
with screws.
(2) Attach a supporter to the mounting board, and then fix the printer interface
with screws.
(3) Remove the connector cover on the door, and then glue a dustproof rubber
packing from the inside.
(4) Insert cable (1) (E5802D) from the outside of the case, fix connector CN96 with
round vis and nut, and then connect the other connector FC30 to the printer
interface printed board.
(5) Connect connector FC3 of cable (2) (E5802E) to connector FC3 of Printer
interface printed board, and then connect the other connector FC3 to FC3 of Main
Processor board in the control unit. (FC1 is not connected.)
A CAUTION \
The plug socket on the side face of the control unit is used only for the external storage. Be sure to provide another power supply for printer.
/'
0 Printed baord board E5802B
& Cable (1) Printer cable E5802D
Printer interface printed board E5802C
A Main Processor board
@ Cable (2) E5802E
Fig.3.8.3.1 Connecting Printer Interface When External Storage is not used
Peripheral Equipment of Robot Control U n i t 3 - 2 5
3.8.3.2 When External Storage is used
(I) Unscrew the FDD interface printed board mounted on the inside face of the
control unit door, and then fix it with a supporter included in the printer interface
unit.
(2) Fix the printer interface over the FDD interface unit with screws.
(3) Remove the connector cover on the door, and glue a dustproof rubber packing
from the inside.
(4) Insert cable (1) (E5802D) from the outside of the case, fix connector CN96 with
screw and nut, and then connect the other connector FC30 to the printer interface
printed board.
(5) Remove the cable connecting FC1 of the FDD interface to FC3 of Main
Processor board. Connect connectors FC1 and FC3 of cable (2) (E5802E) to
connector FC1 of FDD interface printed board and connector FC3 of Printer
interface printed board, respectively, and then connect the other connector FC3 to
FC3 of Main Processor board.
3.8.4 Connecting Pr in te r
(I) Place the printer on a stable place such a s the control unit.
(2) Connect connector of the printer parallel interface (Centronics type) to CN96 on
the front face of the control unit with a printer cable. External connecting cable E5757C
Printed board mounting board E5802B
\ @ Cable (2) E5802E
Cable E5777J
Fig.3.8.4.1 Connecting Printer Interface When External Storage is in use
3 - 2 6 Peripheral Equipment of Robot Control Uni t
3.8.5 Notes on Usage
(1) Before connecting the printer interface unit, be sure to turn off the robot control
unit.
(2) The plug socket mounted on the side face of the control unit is used only for the
external storage. Provide another power supply for printer.
(3) For details of printer operations, refer to the instrucion manual for your printer
type.
Peripheral Equipment of Robot Control Un i t 3 - 2 7
Chapter 4 Connecting Robot Peripheral J ig (External Axis)
Contents
4 . 1 Types of Robot Peripheral Jigs ..........................................................................................................
4.2 connecting peripheral j ig to ~ ~ b ~ t control un i t ...............................................................
4 2 1 System Configuration ........................................................................................................................... . .
4 2 2 Control Cables for peripheral Jig ............................................................................................ . .
4.3 Internal Switch Settings and Connection Drawings of Robot Control Unit ....
4 . 3 . 1 GOIS + 1 Axis System
4.3.2 GO1S+2 Axis System ...........................................................................................................................
4 3 3 ~ 0 1 ~ + 3 ~~i~ system ..................................... : ..................................................................................... . . 4.3.4 VOlS+ 1 Axis System
4.3.5 V01S+2 Axis System ...........................................................................................................................
4 3 6 VOlS+ 3 Axis System ........................................................................................................................... . .
4. Connect ing Robot Per iphera l J ig This chapter provides information of the connections of Jig Control cables and of the
settings of various switches in the robot control unit which are necessary to connect a
robot peripheral jig, such as a positioner or sliders, or a combination of them to the robot
control unit.
In order to combine a robot peripheral jig with the robot, it is necessary to install data
including system parameters into the robot control unit according to the system
configuration. For details of the procedures, refer to the "Teaching" instruction manual.
4 - 1 Connecting Robot Peripheral J ig
4.1 Types of Robot Peripheral Jigs
As peripheral jigs that can be combined with the robot, DAIHEN provides the products
listed in Table 4.1.0.1:
Table 4.1.0.1 Robot Peripheral Jigs
Moving Axis No.
Axis 1 Axis 2 t Item Specification
Maximum payload 200kg 1 4 1 - Positioner
RPH-500
RPH- 1000
RPlS-1000
Maximum payload 500kg
Maximum payload 1000kg
Maximum payload 1000kg
head stock
1-axis side positioner
Maximum payload 300kg 1 7 / 7
1-axis double
support positioner
Z-axis double
support positioner Maximum payload 150kg 1 C I C
RPlD-200
RPlD-500
RPlD-1000
Maximum payload 300kg 1 C I C
2-axis tilt
Maximum payload 200kg
Maximum payload 500kg
Maximum payload 1000kg
Maximum payload 500kg 1 8 1 8
positioner
4
8
8
Maximumpayload lOOOkg 1 8 1 8
-
-
-
Traverse stroke 4.9m
Turntable
Portable slider
Standard slider
Traverse stroke 5.9m / 7 / -
RP1T-500
RPlT-1000
RSB-1000
RSB-2000
RSR-2900
RSR-3900
I RSR-6900 / Traverse stroke 6.9m / 7 / -
/ RSR-1900P / Traverse stroke 1.9m 1 7 1 -
Maximum payload 500kg
Maximum payload 1000kg
Traverse stroke 1.0m
Traverse stroke 2.0m
Traverse stroke 2.9m
Traverse stroke 3.9m
8
8
4
4
7
7
Slider with
a connecting wagon
Connecting Robot Peripheral J i g 4 - 2
-
-
-
-
-
-
RSR-5900P
RSR-2900P
RSR-3900P
RSR-4900P
* Moving axis numbers are used to set the Servo Control boards described later in
this chapter.
Traverse stroke 5.9m
Traverse stroke 2.9m
Traverse stroke 3.9m
Traverse stroke 4.9m
7
7
7
7 -
-
-
-
4.2 Connecting Peripheral Jig to Robot Control Unit 4.2.1 System Configuration
Aside from the manipulator, it is possible to connect up to a total of 3 axes of
peripheral jigs to the standard robot control unit.
Some typical examples of this system configuration are presented in Table 4.2.1.1:
Table 4.2.1.1 Examples of System Configuration
Peripheral Jig Q'ty of Control
Cables for
of axes Peripheral Jig
1 axis
GO1
1 -axis positioner
1 -axis slider
3 axes
1 set
2 axes
1 axis
-
-
I I I I
1-axis slider
2 sets
1 set
Z-axis positioner
1-axis slider
1-axis positioner
1 -axis slider
VO 1
Z-axis positioner
-
4 - 3 Connecting Robot Peripheral J i g
-
1-axis positioner
3 sets
2 axes
3 axes
2 sets
Z-axis positioner
1 -axis slider
1-axis slider
-
1-axis positioner
Z-axis positioner 3 sets
4.2.2 Control Cables f o r Per ipheral J i g
A peripheral jig is connected to the robot control unit with Control cables listed in
Table 4.2.2.1. To connect a 1-axis peripheral jig, a set of 2 Control cables-one motor
cable (Control Cable 1) and one encoder cable (Control Cable 2)-is required:
Table 4.2.2.1 Control Cables for Peripheral Jig
Type
BIRBX-7003
BIRBX-7005
BIRBX-7010
BIRBX-7015
BIRBX-7103
BIRBX-7105
external axis
to robot V01,
Component
Item 1 p a r t NO. ~ ' t y
- -
BIRBX-7110
Control Cable 1
Control Cable 2
Control Cable 1
Control Cable 2
Control Cable 1
Control Cable 2
Control Cable 1
Control Cable 2
Control Cable 1
Control Cable 2
Control Cable 1
Control Cable 2
o r any external
axis t o G01.
Cable length
-
Control Cable 1
Control Cable 2
BIRBX-7115
Connecting Robot Peripheral J i g 4 - 4
Remarks
L4029B00
L4029C00
L4030B00
L4030C00
L4031B00
L4031C00
L4032B00
L4032C00
L4034B00
L4034C00
L4035B00
L4035C00
L4036B00
L4036C00
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Control Cable 1
Control Cable 2
L4037B00
L4037C00
3m
5m
10m
15m
3m
5m
These cables
a re used to
connect one
external axis
to robot V01.
These cables
a re used to
connect more
than one
4.3 Internal Switch Settings and Connection Drawings of Robot Control Unit
In order to connect a robot peripheral jig such a s a positioner o r slider to the robot
control unit, it is necessary to change the settings of the switches and jumper pins on
each printed board in the control unit. These settings a re presented in Tables 4.3.0.1 and
4.3.0.2:
Table 4.3.0.1 List of Switches and Jumper Pins on Servo Control Boards
I JT1 I Jumper pin to detect voltage drop of the servo motor d r i v i n ~ power
Servo Control
Board 1
1 SW3 I Moving axis setting switch (Axis 4)
SW5 SW6
SW7/8
JT2
JT3 SW2
/ SW4 I Moving axis setting switch (Axis 5)
Moving axis setting switch (Axis 3) Switch to set the number of control axes Spare switches
Jumper pin to switch detecting encoder disconnection ON/OFF Spare jumper pin Board identifvina switch
Board 2
(SCON2)
Servo Control SW5 SW6
SW7/8
I SW4 I Movinn axis setting switch (Axis 8)
Moving axis setting switch (Axis 6) Switch to set the number of control axes Spare switches Jumper pin to detect voltage drop of the servo motor driving power
JT2
JT3 SW2 SW3
Jumper pin to switch detecting encoder disconnection ON/OFF Spare jumper pin Board identifying switch Moving axis set tin^ switch (Axis 7)
Board 3
(SCON3)
Servo Control
I Tm, 1 Jumper pin to switch detecting encoder
SW5 SW6
SW7/8
JT1
Moving axis setting switch (Axis 9) Switch to set the number of control axes Spare switches Jumper pin to detect voltage drop of the servo motor driving power
4 - 5 Connecting Robot Peripheral J i g
cl lL
JT3 disconnection ON/OFF Spare jumper pin
Table 4.3.0.2 List of Switches and Jumper Pins for Backplane Board and Interlock Board
Printed Board I Switch and Jumper Pin Ref.No. I Item I Ref.Na I Item
PCB 2
PCB 1
Interlock
board
DSWlOO Dip switch to check the mechanism
Backplane configuration
board Jumper pin to set detecting SCON 3 hardware failure ON/OFF Jumper pin to set detecting charging
JP601 Jumper pin to set Axis 6 overrun detect s i ~ n a l ON/OFF
/ JP602 / Jumper pin to set Axes 7 - 9 overrun detect signal ON/OFF
JP603 Jumper pin to set External Axis board
JP701
Connecting Robot Peripheral Jig 4 - 6
4.3.1 GO1 S + 1 -Axis System
(1) Example of System Configuration
Table 4.3.1.1 GOlSf l-Axis System Configuration
1 Axis Configuration
System Configuration
Manipulator GO1
(2) Switch Settings of Servo Control Boards
Table 4.3.1.2 Switch Settings of Servo Control Boards
* For SW5 of SCON2, refer to Table 4.1.0.1 and set the value of the moving axis
number applicable to the peripheral jig.
PCB13 (SCON2)
(3) Jumper Pin Settings of Servo Control Boards
Axes 4 - 6
PCB14 ( S C O N ~ ) Axes 1 - 3 1 Close 1-2 / Close 8-9. 5-6, 2-3 / Close 2-3
Table 4.3.1.3 Jumper Pin Settings of Servo Control Boards
2 0 0 * 0 0
(4) Switch/Jumper Pin Settings of Backplane Board
Table 4.3.1.4 Switch/Jumper Pin Settings of Backplane Board
0
JT3 Printed Board 1 Axes Controlled 1 JT1
- -
PCB13 (SCON2)
JT2
Axes 4 - 6
Printed Board
(5) Jumper Pin Settings of Interlock Board
Table 4.3.1.5 Jumper Pin Settings of Interlock Board
PCB 1
Close 1-2
JPlO 1
ON
JP501 JP601 JP602 JP603 Board I I I I
4 - 7 Connecting Robot Peripheral Jig
Close 8-9, 5-6, 2-3
JP701
1 - 8 1 2 - 7 3 - 6 1 4 - 5
Close 2-3
2
ON
I I I
Close
3
ON
PCB2
4
Close Open Close
OFF
Close
Close
Close Close Close
Fig. 4.3.1.1 Connection Drawing of External Cables for GO1+1-Axis (Digital)
Connecting Robot Peripheral Jig 4 - 8
4.3.2 GO1 S + 2-Axis System (1) Example of System Configuration
Table 4.3.2.1 GOlS+2-Axis System Configuration
System Configuration
Manipulator GO1
1-axis positioner (1P)
(2) Switch Settings of Servo Control Boards
Table 4.3.2.2 Switch Settings of Servo Control Boards
Printed Board 1 Axes Controlled 1 SW2 / SW3 I SW4 / SW5 1 SW6 / SW7 / SW8 -
PCB14 (SCON1)
PCB13 (SCON2)
* F o r SW3/SW4 of SCON3, refer to Table 4.1.0.1 and set the values of the moving
axis numbers applicable to the peripheral jig(s).
PCB12 (SCON~)/ Axes 71'8
(3) Jumper Pin Settings of Servo Control Boards
Table 4.3.2.3 Jumper Pin Settings of Servo Control Boards
Axes 1 - 3
Axes 4/5
3
PCB14 (SCONI)/ Axes 1 - 3 1 Close 1-2 1 Close 8-9, 5-6, 2-3 / Close 2-3
1 4 4 2
2 0 0 0
Printed Board Axes Controlled 1 JT1
PCB13 (SCON~)/ Axes 41'5 1 Close 1-2 / Close 8-9, 5-6, 1-2 1 Close 2-3
* 1
JT2
(4) Switch/Jumper Pin Settings of Backplane Board
*
JT3
-
PCB12 ( S C O N ~ ) ~ Axes 7/8
Table 4.3.2.4 Switch/Jumper Pins Settings of Backplane Board
0 0 0
0 0
0
Close 1-2
I I I I I
P C B ~ I ON I ON I ON I OFF I open
Printed Board
(5) Jumper Pin Settings of Interlock Board
1
Close 8-9, 5-6, 1-2 Close 2-3
DSWlOO
1 1 2 1 3 1 4
0
JPlO
Table 4.3.2.5 Jumper Pins Settings of Interlock Board
PCB2 / Close I Close I Open / Close I Open / Close I Close I Close
0
Printed I Board
4 - 9 Connecting Robot Peripheral J ig
JP701 JP501 JP601 JP602 JP603
1 - 8 2 - 7 3 - 6 4 - 5
'ewer Supply
Fig. 4.3.2.1 Connection Drawing of External Cables for GO1 +2-Axis (Digital)
Connecting Robot Peripheral J ig 4 - 1 0
4.3.3 GO1 S i-3-Axis System (1) Example of System Configuration
Table 4.3.3.1 GOlS + 3-Axis System Configuration
Axis Configuration
System Configuration
GOlS + 1-axis slider (1s) +
(2) Switch Settings of Servo Control Boards
Table 4.3.3.2 Switch Settings of Servo Control Boards
Printed Board 1 Axes Controlled 1 SW2 ] SW3 1 SW4 I SW5 1 SW6 1 SW7 1 SW8
PCB14 (SCONI)~ Axes 1 - 3 1 1 1 4 1 4 1 2 1 0 1 0 1 0
*For SW3 - SW5 of SCON3, refer to Table 4.1.0.1 and set the values of the moving
axis numbers applicable to the peripheral jigs.
(3) Jumper Pin Settings of Servo Control Boards
Table 4.3.3.3 Jumper Pin Settings of Servo Control Boards
PCB12 (SCON~)/ Axes 7 - 9 1 Close 1-2 / Close 8-9, 5-6, 2-3 / Close 2-3
PCB13 ( S C O N ~ ) ~ Axes 41'5
(4) Switch/Jumper Pin Settings of Backplane Board
Table 4.3.3.4 Switcli/Jumper Pins Settings of Backplane Board
Close 1-2
PCBI 1 ON 1 ON I ON / OFF / Open
Printed Board
(5) Jumper Pin Settings of Interlock Board
Table 4.3.3.5 Jumper Pins Settings of Interlock Board
Close 8-9, 5-6, 1-2 Close 2-3
DSWlOO
1 1 2 1 3 1 4
4 - 1 1 Connecting Robot Peripheral J i g
JPlO
Printed
Board
PCB2
JP501
Close
JP601
Close
JP602
Open
JP603
Close
JP701
1 - 8
Open
2 - 7
Close
3 - 6
Close
4 - 5
Close
Fig. 4.3.3.1 Connection Drawing of External Cables for GO1 + 3-Axis (Digital)
Connecting Robot Peripheral J i g 4 - 1 2
(1) Example of System Configuration
Table 4.3.4.1 VOlS+ l-Axis System Configuration
Axis Configuration
System Configuration
(2) Switch Settings of Servo Control Boards
Table 4.3.4.2 Switch Settings for Servo Control Boards
* F o r SW3 of SCON3, refer to Table 4.1.0.1 and set the value of the moving axis
number applicable to the peripheral jig.
(3) Jumper Pin Settings of Servo Control Boards
Table 4.3.4.3 Jumper Pin Settings of Servo Control Boards
(4) Switch/Jumper Pin Settings for Backplane Board
Table 4.3.4.4 Switch/Jumper Pins Settings of Backplane Board
PCBI I OFF I ON I ON I OFF I Open
Printed Board
(5) Jumper Pin Settings of Interlock Board
Table 4.3.4.5 Jumper Pin Settings of Interlock Board
4 - I 3 Connecting Robot Peripheral J i g
DSWlOO
1 1 2 1 3 1 4 JPlO
Fig. 4.3.4.1 Connection Drawing of External Cables for VO1+1-Axis (Digital)
Connecting Robot Peripheral J ig 4 - 1 4
4.3.5 VOl S 4-2-Axis System (1) Example of System Configuration
Table 4.3.5.1 VOlS+2-Axis System Configuration
Axis Configuration
System Configuration
Manipulator V01
(2) Switch Settings of Servo Control Boards
Table 4.3.5.2 Switch Settings of Servo Control Boards
* F o r SW3/SW4 of SCON3, refer to Table 4.1.0.1, and set the values of the moving
axis numbers according to your peripheral jig(s).
(3) Jumper Pin Settings of Servo Control Boards
Table 4.3.5.3 Jumper Pin Settings of Servo Control Boards
(4) Switch/Jumper Pin Settings for Backplane Board
Table 4.3.5.4 Switch/Jumper Pin Settings of Backplane Board
Printed Board 1 JPlO
(5) Jumper Pin Settings of Interlock Board
Table 4.3.5.5 Jumper Pin Settings of Interlock Board
JP501 JP601 JP602 JP603 printed Board 1 I 1 I
4 - 1 5 Connecting Robot Peripheral J i g
JP701
1 - 8 / 2 - 7 3 - 6 4 - 5 I I I I I
Close Close Close Open PCB2 Open Close Close Close
Fig. 4.3.5.1 Connection Drawing of External Cables for V01 + 2-Axis (Digital)
Connecting Robot Peripheral J i g 4 - 1 6
4.3.6 VO1 S +3-Axis System (1) Example of System Configuration
Table 4.3.6.1 VOlS+3-Axis System Configuration
Axis Configuration
2-Axis positioner (2P)
System Configuration
VOlS + 1-axis slider (1s) +
(2) Switch Settings of Servo Control Boards
Table 4.3.6.2 Switch Settings of Servo Control Boards
* F o r SW3 - SW5 of SCON3, refer to Table 4.1.0.1 and set the values of the moving
axis numbers applicable to the peripheral jigs.
SCON 1
(3) Jumper Pin Settings of Servo Control Boards
Table 4.3.6.3 Jumper Pin Settings of Servo Control Boards
Manipulator V01
SCON 2
Ax-3 Ax-1
SCON 3
Ax-2
PCB13 (SCONX)/ Axes 4 - 6 1 Close 1-2 1 Close 8-9, 5-6, 2-3 1 Close 2-3
Ax-6
1 s
Ax-4
--
Printed Board
PCB14 (SCON1)
Ax-9
2P
Ax-7 Ax-5
(4) Switch/Jumper Pin Settings of Backplane Board
Ax-8
Axes Controlled
Axes 1 - 3
-
PCB12 ( S C O N ~ ) ~ Axis 7 - 9
Table 4.3.6.4 Switch/Jumper Pin Settings of Backplane Board
JT1
Close 1-2
Close 1-2
(5 ) Jumper Pin Settings of Interlock Board
Printed Board
Table 4.3.6.5 Jumper Pin Settings of Interlock Board
JT2
Close 8-9, 5-6, 2-3
Close 8-9, 5-6, 2-3
JT3
Close 2-3
Close 2-3
DSWlOO
1 1 2 1 3 1 4
- .- I I I I I I I I
PCB2 I Close / Close I Open I Close I O ~ e n / Close I Close / Close
JPlO
JP501 JP601 JP602 JP603 Printed Board 1 I I 1
4 - 1 7 Connecting Robot Peripheral Jig
JP701
rn 4 - 5
1
CN,O,C TO external asis AS-9
CNlOlB To external arls AS-8
CNlolA To externel axis AX-7
cai To iManipiilator
gig To external axis AX-9
TO external axis AX-8
gig; To external axis AX-7
MZ TO Menipulator
m3 To Manipulator
Fig. 4.3.6.1 Connection Drawing of External Cables for V01+3-Axis (Digital)
Connecting Robot Peripheral Jig 4 - 1 8
CAUTION 1. Before connecting the peripheral jig(s), it is necessary to set a system
parameter to define what number of axis in the entire system each moving axis of the peripheral jig(s) should be assigned to. Any peripheral jig must be connected in accordance with this definition. Incorrect connection may not only cause malfunction or unexpected motion but also damage the jig(s).
2. In principle, the moving axis numbers of peripheral jigs a re defined in accordance with priority below:
Lower
Axis Nos.
Higher
Slider
2-axis positioner
tilt axis
I 2-axis positioner
table axis + I-axis positioner r
4 - I 9 Connecting Robot Peripheral J ig
5. Troubleshoot ing This chapter describes solutions for failures that may occur during operations of the robot.
Failures a r e mainly divided into 3 groups according to the symptoms :
* Where the servo power supply cannot be turned on, nothing appears on the teaching
box, etc. (see Table 5.1.)
* Where a failure code and a failure message a re highlighted (See Table 5.2.)
* Where a failure message except the above is displayed (See Table 5.3)
These failures a r e listed in Table 5.1 through Table 5.3. When a failure occurred, refer to
them to find a solution. If you need replace par ts such as boards, contact DAIHEN.
Table 5.1. Symptoms
box. 1
Symptoms
Nothing appears on the teaching
--
The display on the teaching box For details, see section 5.1.2.
Solution
For details, see section 5.1.1.
is unsteady. 1 Initial diagnosis is not completed.
The servo power supply cannot
For details, see section 5.1.3
For details, see section 5.1.4
be turned on.
The servo power supply is shut
function. I
Fo r details, see section 5.1.5.
off immediately when turned on.
Manual manipulation does not
Troubleshooting 5 - 1
For details, see section 5.1.6.
EMERGENCSTOP --.RELEASE
Table 5.2. Failure Codes and Messages
SHOCK-S ERR -+RESET EA0040 1 -XXXX SERVO DOWN +RESET
Solution
Pull the Emergency Stop button (or Code / Message
EA00101-XXXX o r emergency stop signal was entered. During automatic operation
Cause The Emergency Stop button
the torch interfered
1) The servo power was shut off due to a n unidentified cause.
2) The hand was released
cancel the emergency stop signal) and press SERVO ON button. For details, see section 5.2.3.
1 from the deadman switch.
For details, see section 5.2.4
1 EA10201-XXXX WIF TIMEOUT --. RESET
Communication trouble between Welding Interface and I/O management board during welding. The specified Arc Star t
After pressing the RESET key, turn on the SERVO POWER and restart . If not recovered, turn the CONTROL POWER off and on again. Create a n Arc Star t Condition file.
NO ASC FILE 1 Condition file does not exist. I --. RESET EA50101-XXXX NO AEC FILE
NO WFP FILE / Patterned Weaving 1 Condition file.
-> RESET EA50102-XXXX
-+ RESET
The specified Arc End Condition file does not exist.
EA50102-XXXX NO WAX FILE
Create a n Arc End Condition file.
The specified Fixed
Condition file does not exist. The specified Axis Weaving Condition file does exist.
Create a Fixed Patterned Weaving
Create a n Axis Weaving Condition file.
+ RESET
-+ RESET EA50103-XXXX NO ASM FILE
EA50103-XXXX NO AEM FILE + RESET EA50104-XXXX NO OFS FILE
The specified Multi-pass Welding Star t file does not
exist. The specified Multi-pass Welding End file does not
Create a Multi-pass Welding Star t file.
exist. The specified Offset Condition file does not exist
Create a Multi-pass Welding End file.
Create a n Offset Condition file.
NO CL PRG. 1 to call. I RESET
EA50105-XXXX
NO J F PRG. / to jump to. I
There is no Task program
-+ RESET EA50106-XXXX
--. RESET
Create a Task program to call.
5 - 2 Troubleshooting
There is no Task program Create a Task program to jump to.
Code / Message EA50107-XXXX NO PM -+ RESET
Cause Solution --
Add a Point Mark instruction. There is no point mark to jump to.
EA50110-XXXX C1 TEACH ERR -. RESET EA50111-XXXX
There is no reference point for the former half of a :ircular arc. There is no reference point For the latter half of a nircular arc.
A circular arc is formed by 3 points. Add a reference point.
-
A circular arc is formed by 3 points. Add a reference point. C2 TEACH ERR
-+ RESET EA50112-XXXX COORD.ERROR -+ RESET
Teaching of the target/ reference points for an circular arc in the different coordinate systems.
Teach all 3 points in the same coordinate system to form a circular arc.
EA50113-XXXX SAME POINT C + RESET
The target and reference points for a circular arc are the same. The number of time counts exceeded 9.
Teach again to form a circular arc.
The max. number of timers that can count time a t one time during automatic operation is 9. Check the setting time of each instruction of S, R, N, and F.
EA50114-XXXX 11'0 TIMER -+ RESET
EA50120-XXXX CALL NESTING OVER -+RESET EA50201 -XXXX S.LIMIT * * * * -+ RESET
The nest has overflown due to program calls.
Calling in the call destination program is possible but limited to the maximum 4 layers. Check the the DroEram.
The robot has reached the software limit.
For details, see section 5.2.5.
EA50202-XXXX LNKS.LIMITM * -+ RESET
The robot has reached the link software limit.
Check the s tar t allocation and assign the correct Task program number.
EA50301 -XXXX NO PROGRAM + RESET EA50302-XXXX NO PROGRAM -. RESET
The Task program assigned to the station does not exist.
The Task program with the number entered does not exist. Task program No. has not been entered into the port s~ecified.
Enter the correct Task program number.
Enter a Task program number EA50303-XXXX NO PROGRAM I -+ RESET EA50401 -XXXX ON TIME OUT -+ RESET
No ON input within the specified monitoring time.
Check the input status of the external control signals and the teaching data.
EA50402-XXXX OFF TIME OUT -+ RESET
No OFF input within the specified monitoring time.
Troubleshooting 5 - 3
Code / Message EA50701 -XXXX OPTION ERROR + RESET EA50702-XXXX OPTION ERROR + RESET EA50704-XXXX OPTION ERROR -> RESET EA50705-XXXX OPTION ERROR + RESET EA50706-XXXX OPTION ERROR -. RESET EA50708-XXXX OPTION ERROR + RESET EA50709-XXXX OPTION ERROR + RESET EB00301-XXXX OVER RUN -> RESET EB 10404-XXXX CALC. IMPOS. + RESET
EB10710-00XX DATA ERROR + RESET EC10206-XXXX COMUCTN ERR +POWER OFF
Cause
The software for Synchromotion has not been installed. The software for Multipass Welding has not been installed. The software for External Axis Shift has not been installed. The software for welding monitor has not been installed. The software for PM8700 has not been installed.
--
The software for Endress Rotation has not been installed. The software for Super Arc Sensor has not been installed. The manipulator overran.
1) A positioning instruction P is taught base on Work o r Tool coordinate system in the synchromotion system.
2) The panipulator is unable to move a t a position on the path taught with a
Linear o r Circular interpolation instruction.
The Task program contains a damaged instruction.
Communication between boards cannot be made correctly.
Solution If you want to use the optional function, purchase its optional software. Press the RESET key to continue the operation.
For details, see section 5.2.6.
1) Modify the relevant instruction P to a
synchromotion instruction HP, o r t ry teaching based on the Base o r World coordinate system again.
2) Correct the taught positions(start/end points). If the manipulator is unable to move, correct the position d a t a of the relevant instruction in search mode o r by using the PC editing system.
Delete the damaged instruction and add a n instruction. If the failure recurs, delete the Task program. For details, see section 5.2.7.
5 - 4 Troubleshooting
Code / Message EC10208-XXXX COM. ERR +POWER OFF
teaching box failure. I
Cause I/O management board or
EC10209-XXXX DPRAM ERROR -. POWER OFF
Solution For details, see section 5.2.7.
Main board o r I/O management board failure.
EC10210-XXXX COM LSI ERR + POWER OFF
Motion control board failure.
/ Replace the Motion control board.
EC10403-XXXX CALC.ERR -. POWER OFF
Motion control board failure.
Replace the Motion control board.
EC10504-XXXX DC24V ERROR + POWER OFF
DC24V power supply failure. Replace the DC24V power supply.
ECl0505-XXXX DC15V ERROR +POWER OFF
1) DC15V power supply 1) Replace the DC15V power supply. failure.
2) Connector (CN24) is 2) Check the CN42 connection. disconnected.
Data installation can not be EC10601-XXXX NO FILE +POWER OFF
For details, see section 5.2.8. performed correctly.
EC10603-XXXX PCB MISMATCH
SCON/PCON Board is not in place.Or, imperfect
NO SYS FILE -. POWER OFF EC10801 -XXXX ROM ERROR -, POWER OFF EC10802-XXXX RAM ERROR -. POWER OFF
Check the SCON/PCON board connection.
+ POWER OFF EC10605-XXXX
control data is not found o r is insufficient.
If not recoverd, contact DAIHEN
contact. Multi-synchromotion
Misplacement of EPROM, o r imperfect contact.
Install the system parameters again.
For details, see section 5.2.9.
The identified board o r RAM on that board is broken.
EC1 1301-XXXX I/O PORT ERR
I/O management board failure.
TB LCD ERROR + POWER OFF
Replace the mother board.
-+ POWER OFF EC11401-XXXX
Troubleshooting 5 - 5
Teaching box LCD failure. Replace the teaching box.
Code / Message EC20101 -XXXX MOTOR ERROR + POWER OFF
EC20102-XXXX AXIS SET ERR --. POWER OFF
A 00201-XXXX SHOCKS ALARM --. RESET A 00301-XXXX OVER RUN -+ RESET
A 10301-XXXX TEMP. ERROR -> RESET A 10404-XXXX CALC. IMPOS. + RESET
A 10502-XXXX CMOS BATTERY -> RESET A 10503-XXXX ABS BATTERY -+ RESET
A 10601 -XXXX NO FILE + RESET
Cause The system parameter setting for motor is wrong, o r any setting of the SCON board rotary switches 3-5 is wrong. The system parameter setting for motor is wrong, o r the setting of the SCON board rotary switch 6 is wrong. The torch interfered in Auto mode but not during automatic operation. Overrun was detected during initial-diagnosis.
The temperature in the controller exceeded 60°C
1) A positioning instruction P is taught base on Work o r Tool coordinate system in the synchromotion system.
2) The panipulator is unable to move a t a position on the path taught with a Linear o r Circular interpolat ion instruction.
The voltage of the memory battery dropped below 2.5V.
1) The voltage of the charging battery dropped.
2) Imperfect connection of Connector(CN47). Data installation cannot be performed correctly.
Solution For details, see section 5.2.10
For details, see section 5.2.3.
After initial diagnosis is completed, perform manual manipulation while holding down the SERVO ON button to escape from overrun. Turn off the control power supply and leave the robot a s it is until the temperature decrease below 60°C 1) Modify the relevant instruction P to a
synchromotion instruction HP, o r t ry teaching based on the Base o r World coordinate system again.
2) Correct the taught positions(start/ end points). If the manipulator is unable to move, correct the position da ta of the relevant instruction in search mode o r by using the PC editing system.
Save all the da ta by using the external storage.
1) Charge the battery, o r replace the charging battery. Be sure to perform the absolute offset adjustment.
2) Check the CN47 connection. For details, see section 5.2.8.
5 - 6 Troubleshooting
Code / Message A 10710-XXXX DATA ERROR - RESET A 11102-XXXX ABS MISMATCH -+ RESET A 11103-XXXX ABS DATA OUT -+ RESET
A 30201-XXXX OVER TRCKNG.
RESTART
A 30203-XXXX ARC UNSTABLE -+ RESTART
A 30205-XXXX PARA.CALC. +RESTART A 30208-XXXX OVER DETECT. +RESTART
A 30209-XXXX OVER DIST. -+ RESTART
A 30210-XXXX OVER SRCHNG -. RESTART
A 30211-XXXX OVER DIST. +RESTART
A 30213-XXXX OVER SRCHNG. -> RESTART
Cause The Task program contains a damaged instruction.
Position deviation has occurred.
The absolute offset data have been destroyed o r absolute encoders have not been reset. During seam tracking by the a r c sensor, the resultant vector length in horizontal and vertical directions exceeded the specified value. During seam tracking by the a r c sensor, the frequency ra te that the average current exceeds the allowance exceeded defined rate. During automatic editing of parameters, arithmetic problem occurred. During wire extension detection (SFO), the deviation exceeded the specified allowable limit. During wire extension detection (SFO), the searching distance exceeded the specified maximum. During unidirectional search (SFl) , the deviation exceeded the specified allowable limit. During unidirectional search (SFl) , the searching distance exceeded the specified maximum. During patterned search (SFZ), the deviation exceeded the s~eci f ied limit.
Solution Delete the damaged instruction and add a n instruction. If the failure recurs, delete the Task program. For details, section 5.2.1 1.
Reset the encoders and perform the absolute offset adjustment.
See the Arc Sensor instruction manual.
Troubleshooting 5 - 7
Code / Message A 30214-XXXX OVER DIST. -.. RESTART
A 30215-XXXX SF2 CMD. ERR -.. RESTART A 30216-XXXX SF2 PRM.OVER -. RESTART A 30217-XXXX SF2 PRM.OVER -. RESTART A 30218-XXXX SF2 OVERLAP + RESTART A 30220-XXXX TS RANGE ERR -.. RESTART A 30221-XXXX A.S.TRNS.ERR + RESTART A 40101-XXXX A.S. FAILURE -+ RESTART
A 40102-XXXX WIRE STICK + RESTART A 40103-XXXX OUT OF ARC --.. RESTART A 40201-XXXX WPS NOT RDY --.. RESTART
A 40201-XXXX WPS NOT RDY -. RESET
Cause
During patterned search search (SF2), the searching distance exceeded the specified maximum. The SF2 file (Search Pattern file) contains a n invalid command other than SF2. A SF2 parameter setting is outside the setting range.
A SF2 parameter condition is wrong.
The SF2 s t a r t position and vector specified position a re the same. Teaching of AS o r AE in the touch section.
Communication with the a rc sensor cannot be made.
The a r c was not generated within the set time after a welding s t a r t signal being input. Wire was sticked.
The a r c is out.
The robot dedicated welding power unit o r welding interface has not been connected.
Communication trouble between the robot and welding interface or the robot dedicated welding power unit.
-
Solution See the Arc Sensor instruction manual
Press the START button to res tar t
Cut the deposited wire. After that , press the START button to res tar t welding
Press the START button.
1) Check the connection between the controller and the robot dedicated power unit o r welding interface.
2) Turn the robot dedicated power unit ON.
Turn the CONTROL POWER off and on again.
5 - 8 Troubleshooting
OUT O F WIRE / the wire was broken. 1 START button.
Code / Message A 40202-XXXX WPS ABNORMAL -+ RESTART A 40301-XXXX
-t RESTART 1 I A 40302-XXXX LACK O F GAS + RESTART
Cause Problem of ALMEGA AUTO I1 o r ALMEGA FUZZY AUTO. During automatic operation
The gas pressure is too low. Displayed only if a detector is provided. There is no cooling water.
Solution Remove the cause of the problem of ALMEGA AUTO II o r ALMEGA FUZZY AUTO. Remove the cause. After that , press the
Remove the cause. After that , press the START button.
A 40303-XXXX LACK OF WATK -+ RESTART
Remove the cause. After that , press the START button.
A 50101-XXXX NO ASC FILE + RESET
The specified Arc Star t Condition file does not exist.
Create a n Arc Star t Condition file.
A 50101-XXXX NO AEC FILE -. RESET
The specified Arc End Condition file does not exist.
Create a n Arc End Condition file.
Create a Fixed Patterned Weaving Condition file.
A 50102-XXXX NO WFP FILE -+ RESET A 50102-XXXX NO WAX FILE + RESET
Create a n Axis Weaving Condition file.
The specified Fixed Patterned Weaving Condition file does not exist. The specified Axis Weaving Condition file does exist.
A 50103-XXXX NO ASM FILE -> RESET
The specified Multi-pass Welding Star t file does not
Create a Multi-pass Welding Star t file.
exist. The specified Multi-pass Create a Multi-pass Welding End file. A 50103-XXXX
NO AEM FILE + RESET
Welding End file does not exist.
A 50104-XXXX NO OFS FILE -+ RESET
The specified Offset Condition file does not exist.
Create a n Offset Condition file.
A 50105-XXXX NO CL PRG. -. RESET
There is no Task program to call.
Create a Task program to call.
A 50106-XXXX NO J F PRG. -. RESET
There is no Task program to to jump to.
Create a Task program to jump to.
A 50107-XXXX NO P M -+ RESET
There is no point mark to jump to.
Add a Point Mark instruction.
Troubleshooting 5 - 9
Code / Messag' A 50110-XXXX C1 TEACH ERR + RESET A 50111-XXXX C2 TEACH ERR -. RESET A 50112-XXXX COORD. ERROR + RESET
A 50113-XXXX SAME POINT C -, RESET A 50114-XXXX I/O TIMER -> RESET
A 50120-XXXX CALL NESTING OVER -.RESET
A 50201-XXXX S.LIMIT * * * * -+ RESET A 50202-XXXX LNKS.LIMITM * + RESET A 50401-XXXX ON TIME OUT -+ RESET A 50402-XXXX OFF TIME OUT -, RESET A 50501-XXXX SERVO OFF +SERVO ON
A 50502-XXXX OUT O F START ENABLE AREA
Cause There is no reference point for the former half of a
circular arc. There is no reference point fo r the latter half of a circular arc. Teaching of the target and reference points for circular a r c in the different coordinate systems. The target and reference points for a circular a r c a r e the same. The number of timer counts exceeded 9.
The nest has overflown due to program calls.
The robot has reached the software limit.
The robot has reached the link software limit.
No ON input within the specified monitoring time.
No OFF input within the specified monitoring time
Servo ON when the mode was changed to AUTO. Or, the servo power supply was turned on before automatic operation o r after com~let ion of the iob. Outside the Star t Enable Area
Solution A circular a rc is formed by 3 points. Add a reference point.
A circular a r c is formed by 3 points. Add a reference point.
Teach all 3 points in the same coordinate system to form a circular arc.
Teach again to form a circular a r c can be made.
The max. number of timers that can count time a t one time during automatic operation is 9. Check the setting time of each instruction of S, R, N, and F. Calling in the call destination program is possible, but limited to the maximum 4 layers. Check the program. For details, see section 5.2.5.
Check the input s ta tus of the external control signals and the teaching data .
Turn the servo power supply ON.
Perform manual operation to move the manipulator to within the Star t Enable Area.
5 - 1 0 Troubleshooting
OPTION ERROR -+ RESET A 50702-XXXX OPTION ERROR + RESET A 50704-XXXX
Solution After completion of initial diagnosis, perform the absolute offset adjustment.
If you want to use the optional function,
Code / Message A 50601-XXXX ABSO ERROR -+ RESET A 50701-XXXX
purchase its optional software. installed. Press the RESET key to continue the
Welding has not been
Cause After initialization of the memory, ABSO setting has not been performed. The software for
installed. The software for External
OPTION ERROR -+ RESET
Axis Shift has not been installed.
A 50705-XXXX OPTION ERROR
The software for welding monitor has not been
4 RESET A 50706-XXXX
A 50708-XXXX OPTION ERROR
installed. The PM8700 software has
OPTION ERROR RESET
The software for Endress Rotation has not been
not been installed
OPTION ERROR / Arc Sensor has not been 1 + RESET A 50709-XXXX
-+ RESET
installed. The software for Super
I 00201-XXXX SHOCK SENSOR +RELEASE
I 10208-XXXX COM. ERROR -+ RESET
installed. This occurs during escape from Shock Sensor Error or Shock Sensor Alarm, or when the torch interfered in Teach mode. The user parameter setting of CRT ON/OFF was ON wlien the CRT power supply was turned off. During automatic operation,
COM. ERROR 1 trouble occurred in the CRT 1 -+ RESTART 1 communication circuit due 1 I 11202-XXXX LIMIT SPD. -+ RESET
For details, see section 5.2.3.
Press the reset key on CRT to switch the display to the teaching box.
Automatic operation will continue.
/ the meclianism.
to some cause. In synchronous Cartesian manual manipulation, the sub mechanism is unable to synchronize with the main
Troubleshooting 5 - 1 1
Increase the speed of manual manipulation.
Code / Message I 11401-XXXX CRT ABNMAL * RESTART I 30100-XXXX L. S. TRNS. ERR -> RESET I 30203-XXXX ARC UNSTABLE
RESEST
I 30204-XXXX WELD SHRTG. -> RESET I 30205-XXXX PARA.CALC. + RESET I 30208-XXXX OVER DETECT -+ RESET
I 30209-XXXX OVER DIST. -+ RESET
I 30210-XXXX OVER SRCHNG -+ RESET
I 30211-XXXX OVER DIST. -. RESET
I 30213-XXXX OVER SRCHNG. -. RESET I 30214-XXXX OVER DIST. + RESET
I 30221-XXXX A. S. TRNS. ERR -+ RESET
Cause Trouble occured in the CRT printed board.
Communictation with laser sensor cannot be made.
During seam tracking by the a r c sensor, the frequency that the average current exceeds the allowance exceeded the defined data. The welding time was not enough during automatic editing of parameters. During automatic editing of parameters, arithmetic problem occured. During wire extension detection (SFO), the deviation exceeded the specified allowable limit. During wire extension detection (SFO), the searching distance exceeded the specified maximum. During unidirectional search (SFl) , the deviation exceeded the specified allowable limit. During unidirectional search (SFl) , the searching distance exceeded the specified maximum. During patterned search (SF2), the deviation exceeded the specified limit. During patterned search search (SF21 , the searching distance exceeded the specified maximum. Communication with the arc sensor cannot be made.
Solution Trun off and on the CONTROL POWER.
Connect the laser sensor
For details, see the Arc Sensor instruction manual.
5 - 1 2 Troubleshooting
CRT DISCNNCT can not be made. + RESET
Solution To use CRT, turn on CRT first, and then the controller.
I 30302-XXXX CRT INVALID -+ RESET I 40201-XXXX WPS NOT RDY -+ RESET
The user parameter setting of CRT ON/OFF will be changed to OFF. 1) The robot dedicated
welding power unit o r welding interface is not connected.
2) The robot dedicated power unit is OFF.
Push RESET key
1) Check the connection between the controller and the welding interface.
2) Turn the robot dedicated power unit ON.
I 40301-XXXX OUT O F WIRE -+ RESET
The residual wire is not enough. Displayed if a detector is provided.
Supply the wire.
Troubleshooting 5 - 1 3
Failure Message
COM DATA ERR XX-YY
XX: 03 o r 85 YY: 01 - 05 SVC error
board). 1
Table 5.3 Failure Messages
Servo Control board 1
Cause Failure was detected a t Servo Control board (SCON
malfunctioned.
Solution For details, see section 5.3.2.
The servo power supply was I shut off due to a n 1 unexrsected cause. I The temperature in the 1 con troller has I extraordinarily increased. Trouble occurred in the Servo driver unit. 1 Trouble occurred in the I Servo Control board. The servo driver unit is unable to be set in the servo 1 ON state. I The position deviation I exceeded the set value. I The commanded speed I exceeded the set value. Servo Control board malfunctioned. 1 Trouble occurred when the I servo power supply was 1
1 and then on again.
turned on. Control program failure.
1 If this failure recurs, note down
Turn off the control power supply
I the information displayed on the
displayed on the teaching box and contact DAIHEN.
Control program failure.
5 - 1 4 Troubleshooting
teaching box and contact DAIHEN. Note down the information
5. 1 Symptoms
5.1.1 NothingAppearsontheTeaching Box
1 Symptom 1
Nothing
appears on the
teaching box
and all LEDs
on the
keyboard a re
OFF.
Primary power
supply indicator
lamp OFF.
(ON in the
normal state)
U Cooling fan not U I rotating
1 LEDs of
I constant voltage
power unit(5V,
1- 15V) is
/ flickering palely. I
_I No primary power L
Loss of V phase
(wire 5) of
primary power
1 1 power unit(5V, I 1 primary power 1 -
All LEDs on
Interlock board
a re OFF. (In
normal state,
LEDs 301, 302,
304, 601, 602 and
603 are ON.)
LEDs of
constant voltage -
f 15V 24V) a re 1 1 OFF.
Loss of W phase
(wire 6) of
I supply
I primary power supply / -
I and connect correctly. I
Check the voltage of
each phase of the
of Interlock board H connection and connect / Imperfect contact
CN41 - constant 1 / it properly. 1
Check the flat cable
voltage power unit 1 I
Troubleshooting 5 - 1 5
Interlock board
failure.
Replace the Interlock
board.
I Possible Cause I I Action I
Imperfect contact
of backplane
board FCll -
Interlock board
FCll
Check the flat cable
connection and connect
it properly.
24V is not supply Check 24V of Interlock
1 to teaching box.
Replace the cable.
/ board.
The display of
the teaching
box is
unsteady and
flickers.
5. "1 2 The Display on the Teaching Box Is Unsteady
- 1 Red LED on
Servo Control
board ON
LEDs(red) on
servo driver
flickering
I Action I Check the voltage on 1 1 primary power 1 / the primary power
5 - 1 6 Troubleshooting
supply (below AC / supply.
5. 1.3 Initial Diagnosis Is Not Completed
1 Symptom 1
The display
"START
DIAGNOSIS"
stays on the
teaching box.
I Check Item I
"COMUCTN
ERR"
( Communication
error) is
displayed a t the
right top of the
teaching box
screen.
i Nothing is
displayed a t the
right top of the
teaching box
I screen. I
I Possible Cause I
4 Refer to 5.2.7 in this part.
1 1/0 management U Check that I/O
1 board failure 1 management board is 1 I connected correctly. I
Replace the I/O
management board.
1 stops a t step1 / I 1 of initial
The teaching
box display
I diagnosis. I
P
"NO FILE" is
displayed a t the
-
right top of the I
Refer to 5.2.8 in this part.
teaching box I I screen. I
Nothing is
displayed a t the
right top of the
teaching box
screen.
I Action I
i 1/0 management
board failure
Check that 1/0
management board is
connected correctly.
I 1 Replace the I/O
I management board. I
Troubleshooting 5 - 1 7
1 Symptom 1 The teaching
box display
stops a t step2
of initial
The teaching
box display
stops a t step3
of initial
I "NO FILE" is
displayed a t the
right top of the
teaching box
screen.
Nothing is
displayed a t the
right top of the
teaching box
screen.
"NO FILE" is
displayed a t the
right top of the
teaching box
screen.
--A Refer to 5.2.8 in this part. I
Motion control Check that Motion control board is
I Action I
/ Replace the Motion 1
Refer to 5.2.8 in this part .
"WPS NOT
RDY" is
displayed a t the
right top of the
teaching box
screen.
1 control board.
Welding interface
o r robot dedicated
1 welding power unit 1 1 not connected.
Check that the welding
interface o r robot
dedicated welding
power unit is connected
correctly.
1 Nothing is 1/0 management U Check that 1/0
Turn on the robot
dedicated welding -
I unit OFF
] displayed a t the / / board failure I management board I
I power unit.
1 right top of the /
Robot dedicated
welding power
I is connected correctly.
-
1 teaching box I - I screen. I / Replace the I/O 1
5 - 1 8 Troubleshooting
I 1
management board.
The teaching
box display
stops a t step4
of initial
I Check Item 1 I Possible Cause I
"NO FILE" is
displayed a t the
right top of tlie
teaching box
screen.
Refer to 5.2.8 in this part.
"A.S.TRNS.ERRfl
is displayed a t
the right top of
the teaching box
screen.
Arc sensor unit Check that the Arc
I not connected. sensor is connected
Nothing is Arc sensor unit Check that Arc sensor
Arc sensor unit
OFF
1 displayed a t the
Turn on the Arc
sensor unit.
right top of the
teaching box
1 failure 1 is connected correctly. I
Replace the Arc sensor 7
Troubleshooting 5 - 2 9
screen. I unit.
5.1.4 The Servo Power Supply Cannot Be Turned ON
The servo
power cannot
be turned on.
I Action I
Interlock board
LEDs 203/301/
303 OFF (ON in
the normal
condition)
I
Red LED on
Electromagnetic
contactor MS1
not ON
each Servo
1- failure p -
contactor MS1.
- Electromagnetic
contactor MS1
Control board
Replace the
electromagnetic
ON (only green
ON in the
normal
condition)
I I
OH/OC/OV
LEDs on each
Servo driver ON
(only RDY ON
in the normal
condition)
Motion control
board OFF (ON
1 in the norm-a1 I I condition) I
LED 303 on
Interlock board
ON (OFF in the
normal
condition)
Check the voltage on
primary power the primary power
supply(3-phase 200
V) (Below AC150V)
Replace the Motion
5 - 2 0 Troubleshooting
I board failure 1 control board. 1
5 .1 .5 The Servo Power Is Shut OFF Immediately When Turned ON
I Symptom I I Check Item I I Possible Cause I
The servo
power is shut
off while
"SERVO ON"
stays 011 the
teaching box
screen.
LEDs 101/301/
303(green) on
Interlock board
OFF (ON in the
normal
condition)
Motion control
Servo Control
board failure
4 Main board failure 1 I LEDs 101/301/ H I/O management
303/ 203 ( green )
on Interlock
I board OFF (ON I I in the normal) I
I board failure 1
Check that each board I is in place. , 1 Replace faulty board. 1
Troubleshooting 5 - 2 1
5. 1 .6 Manual Manipulat ion Does Not Function
1 can moves by 1
Only one axis
of axes 1 - 6
/ manual I I / manipulation. 1
Only axes 4/5/ -
6 move by
Check the connections
of servo driver
Bad connection of
motor line
/ manual
-
/ manipulation. I
Able to move
axes 1/2/3 by
manual
None of axes
1-6 moves by 1 I manual I 1 manipulation. 1
manipulation
1 connectors CN51-56. 1
H Disconnection of Replace the cable.
/ motor line
Motor failure Replace the motor.
1 No power supply
to axes 4/5/6 servo
drivers
{ Check the connections I I of servo driver
connectors CN4, CN6,
and CN8.
CR3A/CR3B
contacts on
Interlock board
OFF (ON in the
normal
condition)
Bad connection of
motor line I-
] Redace the cable. 1
Check the connection
of control cable 1.
(Manipulator-side CN1)
Disconnection of
motor line
function set ON 1 1 function OFF.
Machine lock
5 - 2 2 Troubleshooting
-side CN1)
-
Set the machine lock
Replace the control
cable 1. (Manipulator
5. 2 Failure Codes and Failure Messages
5.2. 1 The Display of A Failure
If a failure occurred, a failure code and a failure message are displayed on the
teaching box.
(Example) Emergency Stop
+ Failure code
EMERGENCSTOP * Failure message
+RELEASE
A failure code is displayed in the following format:
a : Indicates the severity of a failure (Error, Alarm, or Information)
- Error (EA/EB/EC)
The Error class includes failures, such a s failures of parts and internal data,
which cause the operation to be disabled unless the causes are removed, o r
which can cause harm to the system and operators if the operation is
continued.
- Alarm (A)
The Alarm class includes failures which can develop to Errors unless measures
are taken soon, or which require a simple operation, check, or action before
the operation is carried on though they may not cause harm to the system and
operators.
- Information (I)
The Information class includes failures which should be told to the operator
and peripheral equipment though they do not cause trouble to continue the
operation, or which can develop to Alarms later.
Troubleshooting 5 - 2 3
b: Indicates the cause of failure.
- Urgent Failure (0)
This includes failures which cause the system to be stopped a s a last resort
when a failure handling action such a s a detection or stop cannot be taken
due to the occurrence of another failure.
- Control Failure (1)
This includes internal control system failures being detected a t the main board ,
motion control board, I/O management board and the teaching box.
- Servo Failure (2)
This includes servo system failures being detected a t servo control boards and
servo drivers.
- Peripheral Equipment Failure (3)
This includes failures relating to peripheral equipment (optional equipment)
such a s sensors.
- Welding Failure (4)
This includes welding failures being detected a t the welding power supply and
the welding interface.
- Operational Failure (5)
This includes failures relating to operations such a s misoperations.
c: Shows the more detailed cause of b.
d: Indicates the unit where the failure occurred (called a unit code) o r detailed
information of the failure.
For unit codes, see Table 5.4.
e: Indicates the mode (called a mode code) or detailed information of the failure.
For mode codes, see Table 5.5.
5 - 2 4 Troubleshooting
Table 5.4. Unit Codes
Note) PCON: Position control board SCON: Servo control board
Table 5.5. Mode Codes
Code
0 0 0 1 0 2 0 3 0 4
0 5 0 6 0 7 0 8 0 9 1 1 1 2 1 3 1 4 1 5 1 6 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8
Code 1 Mode I Function
Diagnosis Teach
Teaching
Unit
Main board Motion control board 1/0 management board Teaching box Welding interface o r ALMEGA AUTO II or ALMEGA FUZZY AUTO Interlock board Backplane board
Analog board External axis board PCON/SCON board 1 PCON/SCON board 2 PCON/SCON board 3 PCON/SCON board 4 PCON/SCON board 5 PCON/SCON board 6 PCON/SCON board 1 Axis 1 PCON/SCON board 1 Axis 2 PCON/SCON board 1 Axis 3 PCON/SCON board 2 Axis 4 PCON/SCON board 2 Axis 5 PCON/SCON board 2 Axis 6 PCON/SCON board 3 Axis 7 PCON/SCON board 3 Axis 8 PCON/SCON board 3 Axis 9 PCON/SCON board 4 Axis 10 PCON/SCON board 4 Axis 11 PCON/SCON board 4 Axis 12 PCON/SCON board 5 Axis 13 PCON/SCON board 5 Axis 14 PCON/SCON board 5 Axis 15 PCON/SCON board 6 Axis 16 PCON/SCON board 6 Axis 17 PCON/SCON board 6 Axis 18
Troubleshooting 5 - 2 5
Code
6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 7 0 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 8 0 8 1 8 2 8 3 8 4 8 5 8 6 9 0 9 1 9 2 9 3
1 0
2 0
Unit
Axis 1 servo driver Axis 2 servo driver Axis 3 servo driver Axis 4 servo driver Axis 5 servo driver Axis 6 servo driver Axis 7 servo driver Axis 8 servo driver Axis 9 servo driver Axis 10 servo driver Axis 11 servo driver Axis 12 servo driver Axis 13 servo driver Axis 14 servo driver Axis 15 servo driver Axis 16 servo driver Axis 17 servo driver Axis 18 servo driver Personal computer Arc sensor
Laser sensor Main board of CRT unit CRTC board of CRT unit External storage
Printer I/F
Auto
Remote control
5.2.2 Logical Outputs fo r Fai lures
Failure output ports a r e provided to inform external devices of the cause, severity,
and solution of a failure:
Table 5.5 Logical Outputs for Failures
Name I Logical Output Por t No
Urgent Failure I 0 2 0 1
Control Failure 1 0 2 0 2
Servo Failure 1 0 2 0 3
Peripheral Equipment Failure
Welding Failure
Alarm 1 0 2 1 2
0 2 0 4
0 2 0 5
Operational Failure
Error
0 2 0 6
0 2 1 1
--
Information
ABSO Adjust Request
0 2 1 3
0 2 0 8
Reset Request
Star t Request
For details of these output ports, see the instruction manual "Interface With Jig".
0 2 0 9
0 2 7 0
Failure Code
5 - 2 6 Troubleshooting
0 3 7 0 - 0 3 7 4
5.2.3 Shock Sensor
Shock Sensor is a failure which occurs when the torch hits a peripheral jig.
Shock Sensor Er ro r (during automatic operation)
EA00210-XXXX
SHOCK-S ERR
-+ RESET
* Shock Sensor Alarm (in Auto mode but not during automatic operation)
-1 1 SHOCKS ALARM 1 / -> RESET I
Shock Sensor Information (in Teach mode o r during a n escape from Shock Sensor
Error or Alarm)
SHOCK SENSOR
+RELEASE
Solution
0 If the torch is equipped with a shook sensor
Perform manual manipulation in the direction which allows Shock Sensor to be
cancelled.
(B) If the torch is not equipped with a shock sensor
Short-circuit pins 4 - 5 of terminal block TB1 on the Interlock board.
Troubleshooting 5 - 2 7
5.2 .4 Servo Power Shutoff
This failure occurs when:
A failure occurred and was momentarily removed.
* You release the hand from the deadman switch, provided that the teaching box is
equipped with a deadman switch.
The output form of failure varies with the setting of the user parameter
"ABNOMALTY ENCODE" available for setting the teaching box key s ta tus
Table 5.7 Differences of Output Form according to Special Failure Output ON/OFF
/ SERVO DOWN erased after being 1 (Automatically reset after
Setting
ON
1 1 output for 2 seconds. / being output for 2 sec.)
Display of Failure
EA00401-01XX
Solution
(A) When the setting is OFF
OFF
(Default)
After being displayed on the teaching box for 2 seconds, the failure is
Cancellation
Automatically
automatically erased. Then, turn on the servo power supply.
Output Signal
Failure Code(0374-370)
EA00401-01XX
SERVO DOWN
+ RESET
IB) When the setting is ON
After pressing the RESET key, turn on the servo power supply.
In case of this failure, because it is automatically cancelled, you can carry on the
operation you a r e doing, or can restart the automatic operation.
By the RESET key o r
Reset input.
If this failure recurs during automatic operation, the shock sensor may be working.
In this case, correct the path o r attitude to avoid interference with the jig.
Urgent failure (0201)
Error (0221)
Reset Request (0209)
Failure Code (0374 - 370)
5 - 2 8 Troubleshooting
The "ABNOMLTY ENCODE" ON setting affects the signals being output when the
following failures occur:
Emergency Stop
1 EMERGENCSTOP 1
Servo OFF
/ SERVO OFF I
If the setting is ON, Urgent Failure (0201)
and Error (0211) a re not output.
If the setting is ON, Operational Failure (0205)
and Alarm (0212) a r e not output.
5.2.5 Software Limit /L ink Software L im i t
(1) Software Limit Failure
This failure is detected when the mechanism attempts to move out of the working
area .
* Teach mode
p G i z x q 1 S.LIMIT XYZZ I 1 +MANUAL OPE. 1
* Auto mode
EA50201-0110
S.LIMIT XYZZ
X: Mechanism number
Y: Axis number (Displays the lowest axis number if multiple axes a r e involved)
Z: Axis information (Displays the Soft Limit of each axis a s bit information)
Tens' place 1 Unit's place
Axis Axis Axis Axis Axis Axis
Troubleshooting 5 - 2 9
(Example] When Software Limit occurs a t Axes 4 and 5
Tens' place 1 Unit's place
Axis Axis Axis Axis Axis Axis
In this case, "28" is displayed a t the ZZ.
Solution
(A) Teach mode
Perform manual manipulation in the direction which allows the Software Limit
to be cancelled.
03) Auto mode
After pressing the RESET key, turn on the servo power supply. Then,
perform manual manipulation in the direction which allows the Software Limit to
be cancelled.
(2) Link Software Limit
This failure occurs when the mechanisms could interfere with each other.
Teach mode
-1 +MANUAL OPE.
Auto mode
YY: Axis numbers (For example, if "23" is displayed, this indicates that Link
Software Limit has occurred a t axes 2 and 3.)
Solution
(A) Teach mode
Perform manual manipulation in the direction which allows the Link Software
Limit to be cancelled.
03) Auto mode
After pressing the RESET key, turn on the servo power supply. Then, perform
manual manipulation in the direction which allows the Link Software Limit t o
be cancelled.
5 - 3 0 Troubleshooting
5.2.6 Overrun
This failure occurs when the robot overruns.
EB00301 -XXXX
OVER RUN
-+ RESET
Solution
After pressing the RESET key, perform manual manipulation in the direction
which allows Overrun to be cancelled, while holding the SERVO CN button down
If this failure occurs though the robot has not overrun, the cause may be the
following:
(A) Any one of JP 501, 502, and 503 on the Interlock board is not short-circuited.
-,Short-circuit it.
(B) 24V is not supplied to Interlock board.
+Check the connection between CN 41 of the Int' .-lock board and CN41 of
the constant voltage power supply.
(C) The fuse on the Interlock board is blown.
+Replace the fuse.
(D) Interlock board failure.
+Replace the Interlock board.
Troubleshooting 5 - 3 1
5.2.7 Communication Fai lures
(1) Board To Board Communication Failure
This failure occurs when communication cannot be performed correctly between
boards.
EC10206-YYXX
COMUCTN ERR
-+ POWER OFF
Y Y : 0 1 ... Main Board - Motion Control Board Communication Failure
0 2 Main Board - 1/0 Management Board
Comniunication Failure
0 3 ... Main Board - Teaching Box Communication Failure
Solution
02) YY:O1
Make sure that the Motion control board or EPROM on the Motion control
board is placed correctly.
(B) YY:02
Make sure that the I/O management board o r EPROM on the 1/0 management
board is placed correctly.
(C) YY:03
Make sure that the Main board o r EPROM on the Main board is placed
correctly.
(2) Echo Back Communication Failure
This is 1/0 management board or Teaching box failure.
EC10208-YYXX
COM. ERR
-+ POWER OFF
Y Y : 0 2 Main Board - 1/0 Management Board.
0 3 .-. Main Board - Teaching Box
5 - 3 2 Troubleshooting
Solution
(A) Y Y : O 2
Replace the I/O management board.
(13) Y Y : 0 3
Replace the teaching box.
(3) DPRAM Failure
This is Main board o r 1 /0 management board failure.
EC10209-YYXX
DPRAM ERROR
-+ POWER OFF
Y Y : 0 0 Main board - Motion control board.
0 2 ..- Motion control board - 1/0 management board.
Solution
(A) Y Y : O O
Replace the Main Board.
03) Y Y : 0 2
Replace the 1 /0 management board.
Troubleshooting 5 - 3 3
5.2.8 Data Installation Failures
This failure is detected when data (files) necessary to operate the robot do not exist.
If this failure is detected, it is necessary to create a required file with the System
Initialize function.
(1) Data Installation Error
p i K i E F 1 NO FILE 1 1 +-POWER OFF 1 Y Y Y Y : 0 1 0 0 -.. Can't find System Parameter file.
0 1 0 1 ... Can't find Manual Operating Speed Table file.
0 1 0 2 .-. Can't find Block Operating Speed Table file.
0 2 0 0 Can't find Sequencer file.
Solution
0 YYYY: 0100
If your system consists of a single robot unit, select the "SYSTEM" function
key with the System Initialize function and create a System Parameter file. Then,
set the offset adjusting values and the tool parameters.
If your system consists of multiple mechanisms, select the "SPECIAL" function
key with the System Initialize function and load the system parameters from the
external storage.
u3) YYYY: 0101
Select the "MANUAL" function key with the System Initialize function and
create a Manual Operating Speed Table file.
(C) YYYY: 0102
Select the "BLOCK" function key with the System Initialize function and create
a Block Operating Speed Table file.
(Dl YYYY: 0200
Select the "SQ" function key with the System Initialize function and create a
Sequencer file.
5 - 3 4 Troubleshooting
(2) Data Installation Alarm
A 10601-YYYY
NO FILE
+POWER OFF
Y Y Y Y : 0 2 0 1 .-. Can't find Welding Characteristic Data file.
0 2 0 2 Can't find Welding Control file.
0 2 0 3 ..- Can't find Current Conversion Table.
8 1 0 0 ... Can't find Arc Sensor file.
8 4 0 0 Can't find Laser Sensor file.
Solution
(A) YYYY : 0201, 0202, o r 0203
Select the "WELD" function key with the System Initialize function and
create a file.
(E3) YYYY: 8100
Select the "ARC-S" function key with the System Initialize function and
create a Arc Sensor file.
(C) YYYY: 8400
Select the "LASER-S" function key with the System Initialize function and
create a Laser Sensor file.
Troubleshooting 5 - 3 5
5.2.9 Memory Fai lures
(1) ROM Failure
This failure is detected when the EPROM o r board is broken o r the wrong EPROM
is inserted.
EC10801 -YY00
ROM ERROR
+POWER OFF
Y Y : 0 0 ... Main board
0 1 Motion control board
0 2 -.. I/O management board
0 3 ... Teaching box
Solution
Replace the EPROM on the identified board o r that board itself.
(2) RAM Failure
The identified board is failure.
EC10802-YY00
RAM ERROR
+ POWER OFF
Y Y : 0 0 Main board
0 1 ..- Motion control board
0 2 4 . . 1/0 management board
0 3 ... Teaching box
Solution
Replace the identified board.
5 - 3 6 Troubleshooting
5. 2.10 Setting Errors (1) Motor Setting Failure
This failure occurs when the system parameter setting for rnotor type differs from
the SCON board setting for motor type.
EC20101-XXXX
MOTOR ERROR
-+ POWER OFF
Solution
Turn off the control power supply, set the rotary switches SW 3 - SW 5 on the SCON
boards to the correct values.
The following table shows the SCON board rotary switch setting for each mechanism:
Table 5.8 Rotary Switch Settings for Axis Motors of Manipulator
1 SCON for Base Axes I SCON for Wrist Axes
V40 I SCON not in use for V40
Manipulator
PSB series 1
Axis 1
S W 3
Table 5.9 Rotary Switch Settings for Slider Motor
RSR series I 7
Slider
Troubleshooting 5 - 3 7
Axis 2
S W 4
Relevant switch setting of SCON SW3 to SW5
Axis 3
S W 5
Axis 4
S W 3
Axis 5
S W 4
Axis 6
S W 5
1 Relevant switch / Relevant switch
Table 5.10 Rotary Switch Settings for Positioner
/ setting of SW3 -SW5 / setting of SW3 -SW5
Axis 1
(2) Axis Setting Failure
This failure occurs when the SCON board rotary switch setting for the number of
controlled axes is wrong.
Axis 2
EC20102-XXXX
AXIS SET ERR
-+ POWER OFF
Solution
Turn off the control power supply and set the SCON board rotary switch SW 5 to the
correct value.
The following table shows the SCON board SW5 setting for the number of controlled
axes:
Table 5.11 SCON Board SW5 Settings for the Number of Controlled Axes
SW6 Setting I Controlled Axes
5 - 3 8 Troubleshooting
5.2.1 1 ABSO Data Failure
This failure is detected when the difference is larger than the allowance in
comparison with the encoder value given when the servo power is shut off and that
when turned on. The allowance and check ON/OFF a r e set in "FUNC OF ABSO DATA
CHECK" of the user parameters for setting the system status.
A 11102-YYXX
ABS MISMATCH
-+RESET
YY: 11 - 15 ... SCON/PCON board No.1 - No. 5 (See the unit code table.)
Solution
Run Task program P999 used for checking the origin by block operation and check
the marks. If these marks do not align, reset the absolute encoders and perform the
absolute offset adjustment. If the marks align, the absolute offset values a r e correct.
Troubleshooting 5 - 3 9
5. 3 When Servo Failure Occurred 5.3. 1 How to see the Servo Failure Display
This section describes how to see the Servo Failure Code. When Servo Failure
occurred, the Teach Pendant displays the abnormal axis and information of the
failure as shown in Fig.5.1.
Servo Failure can be identified in detail according to:
* Failure category No.
Message (not displayed in some cases)
Failure information codes
t t t
Column : a b e d
Fig.5.1 Example of Servo Failure Display
+Failure category No.
+-Message
I Failure information
codes
5 - 4 0 Troubleshooting
(1) Failure Category No.
When Servo Failure occurred, the Teach Pendant displays the following:
"SERVO ABN * * "
A number is displayed a t " * * ", by which the detailed failure can be identified
a s shown in Table 5.12:
Table 5.12 Failure Category Nos.
Troubleshooting 5 - 4 1
Meaning
Failure was detected a t Servo Control
Board.
Servo Control Board malfunctioned.
Servo power was shut off due to
unknown cause.
The temperature extremely increased in
the control unit.
Failure occurred in the Servo Driver
Unit
(For details, see Table 5.14 and 5.15)
Failure occurred in the Servo Driver
Unit.
(For details, see Table 5.14 and 5.15)
The Servo Driver cannot be energized.
The position deviation exceeded the set
value.
The commanded speed exceeded the set
value.
The commanded voltage exceeded the
set value.
Failure occurred when the servo power
was turned on.
* *
3
4
6
7
8
9
1 0
1 2
1 3
1 4
9 9
Name of Failure
Servo Control Board error
CPU failure of SCON Board
Servo power shutoff
Overheat in the Control Unit
Servo Driver failure
Position output failure
Abnormal position/speed
loop ON state
Beyond the position deviation
limit
Beyond the speed command
limit
Beyond the current command
limit
Failure a t the servo startup
(2) Message (not displayed in some cases)
For Servo Failure 8 "Servo Driver Unit failure", a message and failure
information codes a r e displayed to give more detailed information.(These
information may be also displayed for othe failures.)
The content of a message corresponds to the failure information codes, and is
displayed a s shown below. If multiple failure a r e detected, only the earliest failure is
displayed.
Mechanism [No. 11Axis [No. 21 [Failure information]
[No. 11 indicates the number of the mechanism where failure was detected.
This number corresponds to any of mechanism numbers 1 - 4 of LEDs which a r e
illuminated by selecting the Axis Changeover key "MECHANISM".
[N0.21 indicates the axis number of the mechanism displayed a t [No. 11.
Note that this number is not an axis number used in the entire control unit.
[Failure information] shows the information of a detected failure, for example:
- MECHA * * AXS MOTOR 0-HEAT(Motor Overheat a t Mechanism * Axis * ) - MECHA * * AXS ENCODER ABN.(Encoder Failure a t Mechanism * Axis * ) - MECHA * * AXS POWTR.0-HEAT
(Power Transistor Overheat a t Mechanism * Axis * ) - MECHA * * AXS OVER CURRENT(0ver Current a t Mechanism * Axis * ) - MECHA * * AXS CURRENT ABN.
(Instantaneous Current Limit Over a t Mechanism * Axis * ) - MECHA * * AXS OVER LOAD (Over Load a t Mechanism * Axis * ) - MECHA * * AXS OVER SPEED
(Speed exceeding detectable limit a t Mechanism * Axis * ) - MECHA * * AXS OVER DEVIAT.
(Position Deviation Limit Over a t Mechanism * Axis * ) - UNIT * OVER VOLTAGE(0ver Voltage a t Unit * ) - UNIT * LACK VOLTAGE(Low Voltage a t Unit * ) - UNIT * STOP INVRTR(1nverter Disconnect a t Unit * ) - UNIT * A/D ABNORMAL(Fai1ure of A/D signal line a t Unit * ) - UNIT * STOP SIGNAL (Stop signal input a t Unit * )
5 - 4 2 Troubleshooting
(3) Failure information codes
The abnormal par t can be identified from Fig.5.1, as shown in Table 5.13:
Table 5.13 Interpretations of Codes
0000 indicates that that part is normal, while any number (displayed in the
hexadecimal notation) except 0000 indicates that that par t is not normal.
Furthermore, the detailed failure can be identified by the number.
Troubleshooting 5 - 4 3
d
Failure of
Axis 3
Failure of
Axis 6
Failure of
Axis 9
Failure of
Axis 12
Failure of
Axis 15
Column -+
UNIT 1
(Axes 1-31
UNIT 2
(Axes 4-6)
UNIT 3
(Axes 7-9)
UNIT 4
(Axes 10-12)
UNIT 5
(Axes 13-15)
b
Failure of
Axis 1
Failure of
Axis 4
Failure of
Axis 7
Failure of
Axis 10
Failure of
Axis 13
a
Failure of P a r t common
to each axis
Failure of Par t common
to each axis
Failure of P a r t common
to each axis
Failure of Par t common
to each axis
Failure of Par t common
to each axis
c
Failure of
Axis 2
Failure of
Axis 5
Failure of
Axis 8
Failure of
Axis 11
Failure of
Axis 14
a ) Failures Common to Each Axis
When a number, except 0000, is displayed a t column a in Fig.5.1, a failure can be
identified from Table 5.14
Table 5.14 Common Failure Codes
Code I Meaning
Overvoltage of Main power
+This bit sometimes
(Main power off) indicates that the
0004
0008
Disconnection of Inverter signal line servo power is shut
Failure of A/D signal line off, and in that case
0010
0020
Codes in Table 5.14 a r e displayed in the hexadecimal notation on the Teach
Pendant.
If multiple failures occur, a sum of these codes is displayed.
not failure.
0100
(Example1 Meaning of Failure a t column "a" of UNIT 1
Input of Stop signal
0004 : Disconnection of the inverter signal line of the first Servo Control board
+) 0008 : Failure of the A/D signal line of the first Servo Control board
OOOC : Disconnection of the inverter signal line (0004H) and failure of the A/D
signal line (0008H) of the first Servo Control board (0004H + 0008H)
5 - 4 4 Troubleshooting
b ) Failure Codes of Each Axis
When a number, except 0000, is displayed a t column b, c, o r d in Fig.5.1, a failure
can be identified from Table 5.15:
Table 5.15 Failure Codes of Each Axis
I Overheat of power transistor
Code
0 0 0 1
0 0 0 2
I Overcurrent
Meaning
Motor overheat
Encoder failure
I Over limit of momentary current
I Overload
I Over limit of detectable speed
Codes in Table 5.13 a re displayed in the hexadecimal notation on the Teach
Pendant.
If multiple failures occur a t one time, a sum of these codes is displayed.
0 2 0 0
(Example] Meaning of Failure a t column "c" of UNIT 2
Over limit of position deviation
0001 : Overheat of Axis 5 motor
+) 0004 : Overheat of Axis 5 power transistor
0005 : Motor Overheat(0001H) and Power Transistor Overheat(0004H) of Axis 5
(0001H + 0004H)
Troubleshooting 5 - 4 5
5.3.2 Troubleshooting for Servo Failures
1 Symptom 1 I Check Item 1 I Possible Cause 1
Servo Failure
1 4 1 CPU failure of
Refer to (3) of section 5.
3.1 to remove the cause.
SCON board
Failure detail
codes not "0000"
Servo Failure
3
1 Servo gFailur-e t
-
SCON board
Servo power
-
shutoff
Red LED ON
and green LED
OFF on Servo
error -
li Imperfect contact H Check that the Servo I I / of Servo Control
Take some measures to
protect from noise.
All failure codes
showing "0000"
Noise affecting the
servo system
I Control board is in 1
- -
I Control board
I I board. 1 place.
Servo con- Replace the Servo
Problem of system Install the system
board failure 1 Control board.
Noise affecting the Take some measures to
parameters 1 parameters again.
Red LED on
Motion control 1 board ON 1 servo system
Incorrect
placement of
Motion control
1 protect from noise.
Motion control
board or Servo
Control board
failure
Make sure that the
Motion control board
is placed correctly.
Replace the Motion
control o r Servo
Control board.
5 - 4 6 Troubleshooting
Control board
and Servo driver
flickering. + Slow rotation of
the fan I lOOV outlet
I below 75V I
I Action I Low voltage on Verify the voltage on
primary power the primary power
supply (below AC
I5OV)
the controller Ambient temp. Use within the I
Replace the cooling
unit.
1 over the allowance 1 1 allowable temperature. I
P
Servo Failure
7
Replace the Backplane
Overheat in
Temperature in
the controller
-
over 60°C.
Troubleshooting 5 - 4 7
-
the controller
under 60°C.
Cooling unit
failure
I element failure
-
1 board. I
Servo Failure
Servo driver
failure
Display of
Servo Failure
I on teaching box 1 /SERVO ABN 8 / 1
I Power supply
indicator lamp
U N I T ~ :-
showing "0002"
Loss of U phase
(wire 4) of
primary power
supply (3-phase
"UNIT1 LACK
VOLTAGE " a t
Q,"OOO2" a t
UNITla, and
INVRTR" a t
@ a , and "0002"
a t UNIT2 @ shown
Imperfect contact
of cable connecting
servo driver CN1
for axis shown by
"000C" o r "0002"
and Servo Ctrl.
board CN2, or
cable connecting
servo driver CN2
and power unit
1 Replace the breaker. I
-
1 Make sure that the
cable connection is
correct.
Verify the voltage on
each of the primary
side phases before
connecting.
Replace the cable. m
I Replace the cable.
"UNIT1 LACK
VOLTAGE" a t
Q , and "0002"
a t UNIT1 @ and
5 - 4 8 Troubleshooting
I ,
LED 301 (OUT1)
on relay unit ON
Motion control
board failure
- ---- Replace the Motion
control board.
"UNIT2 LACK
VOLTAGE a t @, " 0002 " a t UNIT1
@, and UNIT2
@, "0002" a t
UNIT^@@@ and
UNIT2 @ shown
--
Possible Cause I Action I
Imperfect contact
of control cable 2
(manipulator CN2
and CN7 on Servo
Control board 1)
Imperfect contact
of cable connecting
CN6 on Servo
Control board 1
and switch box
CN135
Make sure that the
control cable
connection is correct.
/ Replace the cable.
I Make sure that the
cable connection is
correct.
/ Replace the cable.
Switch box failure Replace the Switch box
1 of control cable 3 1 ~ m ~ e r f e c ~ ~
(manipulator CN3
and CN7 on Servo
Control board 2)
Make sure that the
control cable
-
I connection is correct. 1
Replace the cable. + Imperfect contact
of cable connecting
CN6 on Servo
Control board 2
and switch box CN
136
1 Make sure that the
cable connection is
correct
-
Replace the cable. + Switch box failure Replace the Switch box
Troubleshooting 5 - 4 9
"MECHAl 0 AXS OVER
LOAD" a t @, "0020" a t any of
UNITl m, and UNIT2 @@ @ shown
Possible Cause I I Action I
Imperfect contact Make sure that the
control cable
connection is correct.
1 Disconnection of Replace the cable.
I motor line
"MECHAl 0 AXS CURRENT
ABN" a t @ "0010"at any of
UNITl m and UNIT2
shown
" M E C H A 1 0
AXS OVER
CURRENT"
current a t @, and "0008" a t
any of UNITl @ @@ ,and UNIT2
m shown
Wrong dip switch Check the dip switch
1 setting on Servo 1 1 setting and set I
----- Fuse blown by Check the fuse.
/ Control board
I over current flow / I
1 correctly.
5 - 5 0 Troubleshooting
/ to servo driver I Replace the fuse
1 Symptom 1 I Check Item I
"MECHA1 O A X
S OVER DEVIA
T." a t @and
"0200" a t any of
~ ~ 1 ~ 1 m , a n d
UNIT2
shown
"UNIT1 STOP
INVRTR" a t @ and "0004" a t
UNITl@ shown
[ Possible Cause I
The origins of Perform absolute
mechanical stopper
and software limit
I offset adjustment. I
Imperfect contact Check the encoder
/ that axis. 1 / of encoder cable
Disconnection of Replace the encoder
1 cable connection of
Motor failure Replace the motor.
/ encoder cable
Disconnection of Replace the cable.
/ cable.
I motor line
--r/ Imperfect contact
I / of flat cable
connecting Servo
Control board and
"UNIT2 STOP
INVRTR" a t @ 1 -4 and "0004" a t /--
I UNIT2 @ shown /
I servo driver
-
Make sure that the
Check the flat cable
connection.
-
I is placed correctly.
Disconnection of
flat cable
board failure
Replace the servo
-4 Replace the flat cable. 1
I Servo Control board I
Troubleshooting 5 - 5 1
failure driver.
I Symptom I
"MECHA10
OVERCURRENT'
a t @. and "0008"
a t any of UNITl
shown
I "MECHA10
AXS CURRENT
ABN." a t @, and
"0010" a t any of
UNITl
I Action 1
"MECHA10
AXS CURRENT
ABN." a t @, and
"0010" a t any of
UNIT2
shown
- - Blown fuse on Check the fuse.
servo driver o r
-
robot overrun
I
/ Cancel the overrun.
1 Wrong flat cable
1 connection between 1 I Servo Control / 1 board and servo 1 1 driver (Base axes) 1
Wrong encoder
cable connection
(CN7) between
Servo Control
board (Base axes)
and (Wrist axes).
1 Check the cable I 1 connection and connect 1 correctly.
Note)
Check the fuse on the
I servo driver indicated I 1 because it may be 1 / blown.
1 Check the encoder
cable connections and
connect correctly.
5 - 5 2 Troubleshooting
Replace the servo
driver.
- -
Servo driver
failure
- -
All detail codes
showing "0000"
-
Both red and
green LEDs on
Servo Control
board ON
Servo system I failure
I Only green LED
on Servo Control
I board ON
"MOTOR
0-HEAT" at@,
and "0001" a t
any of 1 shown 1
--( Refer to (3) of section 5. 1 3.1 to remove the cause.
r/ Overload on the H Reduce the load.
I manipulator I
1 driving mechanism I Defective
adjustment to the
I of the machine I
Check the machine.
--( "ENCODER
ABNMat 8 , and
"0001" a t any of
m shown
Replace the motor.
Check the encoder
of encoder cable 1 cable connections
and connect
I correctly. I Disconnection of Replace the encoder
Replace the servo
I encoder cable.
/ AT" a t 8, and I I failure. / driver.
1 cable. I
1 "0004" a any of 1 I m shown !
Troubleshooting 5 - 5 3
Servo Failure I 9 t Position
output failure
Servo Failure l-2L.J Abnormal
position/speed
loop ON state
I Possible Cause I Action I
" A/D Imperfect contact Check the cable
Replace the encoder.
Replace the servo
-
/ shown
ABNORMAL1' a t I / of cable in servo 1 1 connection and connect I
"OVER SPEED"
a t @ and "0100"
a t any of @@@ 1 failure
"OVER VOLT- Reduce the
[ driver.
@ and "0008" a t driver. 1 correctly.
( shown 1
AGE" a t @ and
"0008" a t @
) board 1 board 1 is placed correctly.
voltage on ACBOOV primaryside voltage.
Replace the Motion
Incorrect placement
of Motion control
--- -
board or Servo control board or Servo
board or Servo control board or Servo
Make sure that the
Motion control board Red LED 3 on
Motion control
Detail f a r 1 I Refer to (3) of section 5. 1
Check the printed
board is placed
correctly.
-
codes not "0000" 1 3.1 to remove the cause. /
5 - 5 4 Troubleshooting
Green LED on
Servo Control
board OFF
Incorrect
placement of Servo
Control board
---- -
I Symptom 1
Servo Failure
Beyond the
position
deviation limit
1 Check Item I I Possible Cause I I Action 1
Re-install the system
Replace the fuse.
showing "0000" 1
/ I Interlock board I
Noise affecting the Take some measures to
parameters parameters.
None of Axesl- 6
operable by
manual
system
I manipulation /
I protect from noise.
Imperfect contact
of motor line
i Check the connections I I of Servo driver
I connectors CN51- CN56. I
I operation I
Failure a t Problem of system Re-install the system
Reduce the mechanical
load.
highspeed 1 I parameters parameters. I
Too large load -
Beyond the
Failure a t
highspeed
/ operation
1 1 6 operable by I 1 of motor line / of the motor power I
speed
command limit
I / manual I I line.
--( None of Axes 1 - Check the connection
/ manipulation
Noise affecting Take some measures to
1 the system
Beyond the
current
1 protect from noise.
command limit
Reduce the mechani
cal load.
1 operation Take some measures
Servo Failure
14
- -
Failure when
starting
Troubleshooting 5 - 5 5
4 Too heavy
1 the system 1 to protect from noise. /
I Symptom I I Check Item I Possible Cause I
servo s tar tup
- Servo Failure
99
Failure a t the 1 according t o the
Perform the same
checks as those of
Servo Failure 8
1 servo failure display on
/ the teaching box.
5 - 5 6 Troubleshooting
Chapter 6 Periodic Inspection
Contents
6. Per iodic Inspect ion 6.1 Warranty Period
(1) DAIHEN provides free repair for any defect in the product which arises out of
defective workmanship during the warranty period- a shorter period of either one year
after the date of the takeover o r 2000 hours of the cumulative operating time-, provided
that the product is properly used, maintained, and inspected in accordance with the
instructions described in the manuals.
(2) The warranty does not include free repair for:
01$ Any defects arising out of mis-operation o r improper operation
(B) Any defects arising out of repair o r reconstruction done by the user o r a third
party
(C) Any damages and failures caused by natural disasters such as earthquakes, fires
and floods
(Dl Any defects arising out of improper transfer o r storage of the product after the
takeover
(E) Any other defects that a r e not covered in (1)
(3) This warranty is only applicable to the robot equipment installed in Japan.
6.2 Periodic lnspection Schedule The periodic inspection is a n indispensable activity for safety and efficient operation of
the robot, and should be conducted in accordance with the following schedules:
Routine inspection / Daily inspection before and after operation
3 month inspection / Inspection a t each 500 hour interval
6 month inspection / Inspection a t each 1000 hour interval
1 year inspection 1 Inspection a t each 2000 hour interval
3 year inspection 1 Inspection a t each 6000 hour interval
6 year inspection I Inspection a t each 12000 hour interval
These inspection intervals a r e based on the standard operating hours (8 hours/day).
Periodic lnspection 6 - 1
6.3 Notes for Performing Periodic lnspection (1) The periodic inspection should be carried out by o r in the presence of personnel who
attended a national o r DAIHEN special training course and a DAIHEN maintenance
training course.
(Refer to the Regulations on Industrial Robots, Art.19 and Art.36, Para.32.)
(2) Before performing maintenance/inspection works, be sure to turn the external
switchboard OFF. If not, the primary voltage is impressed to the breaker in the
control unit even if the breaker is turned off. Take some measures to prevent the
power source from being carelessly turned on during inspection, for example, by
providing a notice plate indicating "Inspection".
CAUTION 3
For routine inspection items, refer to the "Safety Management" instruction manual.
\ 2
6.4 L is t of lnspection Items
6 - 2 Periodic Inspection
7
8 9 --
0
0
Interface
Cooling unit
Charging batteries 0 Memory lithium batter Replace.
Grease, fume, and dust
pp
found.
Clean up.
Replace.
C h a p t e r 7 P a r t s L i s t
Contents
7.12 BIRBX-1005 control cables 7-24
7.12 1 control cable 1 2 3 ( F ~ ~ ~ 0 1 ~ 0 1 ~ 0 1 ) 7-24 , f 8 t
7 12 2 cables / H~~~ .................................................................................................................................................... 7-24 . . 7.12.3 Control Cable5 (For Almega Auto II- Robot Control Unit) 7-25
This chapter presents par ts lists of the standard robot control units including their
peripheral equipments. Because these par ts numbers could be different from those available for
special products, when placing a n order for replacement, you a r e requested product number
marked on the brand plate of the robot control unit along with the par ts numbers.
For delivery and price of maintenance parts , contact a robot distributor o r a DAIHEN sales
representative.
Par tsL is t 7 - 1
7.1 IRBCX-422 Robot Control Unit (Fig. 7.1.0.1)
* :Use the par ts marked " * " for Robot Control Unit shipped as TIG Welding o r Plasma
Cutting Specifications.
7 - 2 Parts List
P a r t s No. 4810-912
E6029A00
4519-009
4610-008
4814-017
4814-018
4805-027
4600-317
4600-341
5096-138
5096-156 * 5096-139
5096-157 * E5787A00
L4000R00
L4268R00 * L3700D00
L3700COO
L3700M00
L4024M00
L3702F00
L3899YOO
E5741A00
E5685A00
5096-095
5096-140
L4000E00
4614-046
4739-272
4739-273
4732-017
3364-005
3364-123
Q'ty 1
1
(1)
(1)
(1)
(1) 4
1
1
1
1
1
2
Drawing No. /Type
W-LOO470
E6029A00
NDHOO3
lA, AC125V
RWS15A-5
LWQ130-5FF4
4715PS-20T-B30
AH164-ZSWM1
NPA10-2H-WS
W-LO0455 o r
W-LOO554
W-LO0456 o r
W-LOO555
E5787A00
L4000R00 o r
L4268R00
Ref Na
0 0
0 - 1
0 - 2
0 - 3
0 - 4
0 @ 0
@
0
Item
Auxiliary Transformer
Power Unit
Noise Filter
Glass Fiber Fuse
Constant Voltage Power Supply
Constant Voltage Power Supply
Cooling Fan
Lamp
Neon Lamp
Servo Driver Unit
Servo Driver Unit
Servo Power Unit
P.C.B.(Servo Control)
0 8
8
@ 8
@
0 @ 8 @ 0 8 @ @ 8
P.C.B.(Motion Control) pp
P.C.B.(Main Processor)
P.C.B.(I/O Management, Standard type)
P.C.B.(I/O Management, Extended Type)
~ . C . ~ . ( ~ a c k ~ l a n e )
P.C.B.(Interlock) P.C.B.(Terminal Block) o r
P.C.B.(Relay) Memory Battery
Charging Battery
Cooling Unit
Auto Breaker
Breaker Handle
Door Key Handle
AC Socket
Eye Bolt
Hanger
L3700COO
L3700M00
L4024M00
L3702F00
L3899YOO
E5741 A00
E5685A00
W-LOO233
W-LOO471
L4000E00
SA33B-30A
BZ-N2OB
A-120-1
AC-T04FB04
M12-ZMC
A-1042B-7
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
Fig.7.1 .O. 1 IRBCX-422 Robot Control Unit
Parts List 7 - 3
7.2 I RBCX-462 Robot Control Unit (Fig. 7.2.0.1)
Servo Driver Unit
* :Use the parts marked " * " for Robot Control Unit shipped a s TIG Welding o r Plasma
Cutting Specifications.
7 - 4 Parts List
Fig.7.2.0.1 IRBCX-462 Robot Control Unit
Parts List 7 - 5
7.3 I RBCX-512 Robot Control Unit (Fig. 7.3.0.1)
* :Use the par ts marked " * " for Robot Control Unit shipped as TIG Welding o r Plasma
Cutting Specifications.
7 - 6 Parts List
Ref No.
0 0
0 - 1
0 - 2
0 - 3
0 - 4
@
Item
Auxiliary Transformer
Power Unit
Noise Filter
Magnetic Contact
Constant Voltage Power Supply
Constant Voltage Power Supply
Cooling Fan
Drawing No./Type
W-LOO470
E6029A00
NDH003
lA, AC125V
RWS15A-5
LWQ130-5FF4
4715PS-20T-B30
Q'ty 1
1
(1)
(1)
(1)
(1)
4
@ 0
8
0
P a r t s NO.
4810-912
E6029A00
4519-009
4610-008
4814-017
4814-018
4805-027
1
1
1
1
4600-317
4600-341
5096-136
5096-154 * 5096-137
5096-155 * --
Lamp
Neon Lamp
Servo Driver Unit
Servo Driver Unit
E5787A00
L4000R00
L4268R00 * L3700D00
L3700COO
L3700M00
L4024M00
L3702F00
L3899YOO
E5741A00
E5685A00
5096-095
5096-140
L4000E00
4614-046
4739-272
4739-273
4732-017
3364-005
3364-123
8
0
0 8
8
@ @
8
0 @ 8 @ 8 @ @ @ 8
AH164-ZSWM1
NPA10-2H-WS
W-LO0393 o r
W-LOO552
W-LO0394 o r
W-LOO553
Servo Power Unit
P.C.B.(Servo Control)
P.C.B.(Motion Control)
P.C.B.(Main Processor)
P.C.B.(I/O Management, Standard type)
P.C.B.(I/O Management, Extended Type)
P.C.B.(Backplane)
P.C.B.(Interlock)
P.C.B.(Terminal Block) o r
P.C.B.(Relay)
Memory Battery
Charging Battery
Cooling Unit
Auto Breaker
Breaker Handle
Door Key Handle
AC Socket
Eye Bolt
Hanger
E5787A00
L4000R00 o r
L4268R00
L3700D00
L3700COO
L3700M00
L4024M00
L3702F00
L3899YOO
E5741A00
E5685A00
W-LOO233
W-LOO471
L4000E00
SA33B-30A
BZ-N20B
A-120-1
AC-T04FB04
M12-ZMC
A-1042B-7
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
Par tsL is t 7 - 7
7.4 IRBCX-532 Robot Control Unit (Fig. 7.4.0.1 >
Mark 33 shows the different parts from IRBCX-512.
% @ % 0
- 1
% @ % 8 33 @
@ 8 @
7 - 8 Parts L is t
P.C.B.(Break Unit)
Cooling Unit
Cooling Fan
Auto Breaker
Breaker Handle
Door Key Handle
AC Socket
Eye Bolt
Hanger
E5735A00
L3887E00
1099302
SA53B-50A
BZ-N20B
A-120-1
AC-T04FB04
M12-ZMC
A-1042B-7
1
1
(4) 1
1
3
1
2
1
E5735C00
L3887E00
4805-031
4614-039
4739-272
4739-273
4732-017
3364-005
3364-123
Fig.7.4.0.1 IRBCX-532 Robot Control Unit Parts L i s t 7 - 9
7.5 I RBCX-541 Robot Control Unit (Fig. 7.5.0.11
* :Use the par ts marked " * " for Robot Control Unit shipped a s TIG Welding o r Plasma
Cutting Specifications.
Mark 33 shows the different parts from IRBCX-512.
0 8 @ @ @ 0
7 - 1 0 Par ts L i s t
Auto Breaker
Breaker Handle
Door Key Handle
AC Socket
Eye Bolt
Hanger
SA33B-30A
BZ-N2OB
A-120-1
AC-T04FB04
M12-ZMC
A-1042B-7
1
1
2
1
2
1
4614-046
4739-272
4739-273
4732-017
3364-005
3364-123
Parts L is t 7 - 1 1
7.6 IRBCX-551 Robot Control Unit (Fig. 7.6.0.1)
Servo Driver Unit
* :Use the par ts marked " * " for Robot Control Unit shipped as TIG Welding o r Plasma
Cutting Specifications.
Mark % shows the different parts from IRBCX-512.
Parts List 7 - 1 3
7.7 BBOPX-3000 Operation Panel (Fig. 7.7.0.1 > Ref No. I Item 1 Drawing No. /Type I Q'ty 1 P a r t s NO.
I I I I
0 I Push Button Switch 1 AVN3OlN-R 1 1
0
4250-023
0
@
7 - 1 4 Parts List
Illuminated Push Button Switch
0
@
Illuminated Push Button Switch
Illuminated Push Button Switch
AH164-TLR11E3
Panel
Protection Cover Assy
AH164-TLY 1 lE3
AH164-TLGl lE3
2
E5761B01
4250-069
2
1
4250-070
4250-071
1
1
E5761B01
Fig.7.7.0.1 BBOPX-3000 Operation Panel
Parts List 7 - I 5
7.8 BBOP-3008 Operation Box (Fig. 7.8.0.1)
LED Lamp
0 Dust Proof Cover
@ Protection Cover
0 Panel
7 - 1 6 Parts List
Fig7.8.0.1 BBOP-3008 Operation Box
PartsList 7 - 1 7
7.9 BBTBX-6008 Teaching Box (Fig. 7.9.0.1 ) Ref NO. I Item / Drawing No./Type I Q'ty 1 Par t s No.
% I Printed Board I I I
Cable Assy
Sheet Keyboard
Sheet-key Cover
Liquid Crystal Unit
Window Sheet
Ultraviolet Cut-off Filter
Push Button Switch (Emergency Stop)
Push Button Switch (Servo ON)
Push Button Switch (Light)
Lamp Bracket
Pilot Lamp
Panel
Case
I Protective Sheet
Handle
7 - 1 8 Parts List
Insulating Sheet 2 E5680B04
W-LOO588
E5680B07
E5680H00
NB10146
E5680B08
W-36233
MB-2011-8K
MB-2065
B-113 El0
2.2V, 0.25A
E5680B02
E5680B01
E5680B03
W-LOO230
E5680B04
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5096-184
E5680B07
E5680H00
NB10146
E5680B08
4250-021
4250-028
4250-029
4600-327
4600-304
E5680B02
E5680B01
E5680B03
3364-006
Parts L is t 7 - 1 9
7."1 BBST-4005 Starting Box (Fig. 7.10.0.1 ) Ref Na I Item 1 DrawingNa/Type / Q'ty / P a r t s NO.
@ I Illuminated Push Button Switch (G) / AH164-TLGllE3 / 1 1 4250-071
I I I 6
I LED Lamp
@I I Illuminated Push Button Switch (R) / AH164-TLRllE3 / 1 / 4250-069
0 Protection Cover
1 AB6M-VIR 0
--
8 Panel
4250-082 Push Button Switch
0 Case / E6039B01 / 1 / E6039B01
8 Connector
7 - 2 0 Parts List
fig.7.10.0.1 BBST-4005 Start ing Box
Parts List 7 - 2 1
7.1 1 BBWF-0105 Welding Interface (Fig. 7.11.0.1)
Ref NO.
0
0 0 @
0 @ 0
@
@
@
0
@ 8
0 8
@
63
0 @
8
@ @ @,
8
Drawing No. /Type
W-35692
199-RK
250V 2A
250V 0.5A
250V 2A
250V 1A
NSA-015-50P
109S091 or
MU925S-11
GGlOV 1R
S-332R
E5136E00
E5136F00
E5624G00
E5620C00
HS25RE-4
HS25RE-6
SRCN2A-21-10s
25-5BD
SG-22A
LY2-DH2 DC24V
G4D-212P-200
DC24V
LY2-DH2 DC24V
LY2-DH2 DC24V
G-2VN-234P
L3497YOO
Item
Auxiliary Transformer
Indicator
Glass Tube Fuse
Glass Tube Fuse
Glass Tube Fuse
Glass Tube Fuse
Power Supply
Small Fan
Coil Resistor
Toggle Switch
Printed Board
Printed Board
Printed Board
Printed Board
Metal Plug Socket (4 Poles)
Metal Plug Socket (6 Poles)
Metal Plug Socket (10 poles)
Metal Plug Socket (6 Poles)
Grommet
Relay
Relay
Relay
Relay
Relay
Cable Assy
Q'ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
(5 m >
Parts NO.
4810-910
4600-307
4610-009
4610-011
4610-009
4610-008
4814-007
4805-025
4504-109
4251-026
E5136E00
E5136F00
E5624G00
E5620C00
4730-006
4730-010
4730-602
4730-008
3364-117
4341-101
4340-608
4341-101
4341-101
4341-126
L3497Y 00
Fig.7.11.0.1 BBWF-0105 Welding Interface
Parts L is t 7 - 2 3
7.1 2 BI RBX-1005 Control Cables (Fig. 7.12.0.1)
7.12.1 Control Cable 1,2,3 or GOl,WOl,VOl) (1) BIRBX-1003 L3996A (3rd
0 0
0 Control Cable2 (5m) CN2 L3997COO 1 L3997COO
0 Control Cable3 (5m) CN3 L3997D00 1 L3997D00
(2) BIRBX-1005 L3997A (5m)
(3) BIRBX-1010 L3998A (10m)
Ref NO. Item Drawing N o . / ~ y ~ e Q'ty Par ts NO.
0 Control Cable1 (lorn) CN1 L3998B00 1 L3998B00
Q'ty 1
Drawing No./Type
L3996B00
Ref Na
0 Control Cable2 (3m) CN2
Control Cable3 (3m) CN3
@ I Control Cable2 (10m) CN2 / L3998C00 I 1 / L3998COO
Parts Na
L3996B00
Item
Control Cable1 (3m) CN1
Parts NO.
L3997B00
0 I Control Cable3 (10m) CN3 1 L3998D00 / 1 1 L3998D00
L3996COO
L3996D00
Ref NO.
0 Drawing No./Type
L3997B00
Item
Control Cable1 (5m) CNl
1
1
Q'ty 1
Ref No.
0
7.12.2 Cables/ Hose
L3996COO
L3996D00
0 I Control Cable3 (15m) CN3
Item
Control Cable1 (l5m) CN1
L3999D00 I 1 1 L3999D00
@ I Workpiece Side Welding Cable(5m) I L3442B00 / 1 I L3442B00
Ref NO.
@ 0
0 I Control Cable4(5m) CN4 I L3392G00 / 1 1 L3392G00
Drawing Na/Type
L3999B00
(2) BIRB-3010 L3443A (10m)
Ref Na I Item l ~ r a w i n ~ NO. / ~ y ~ e l Q'ty 1 Parts No.
Item
Gas Hose (5m)
Torch Side Welding Cable (5m)
@ I Gas Hose (10m)
Q'ty 1
0 I Torch Side Welding Cable (lorn11 L3375E00 I 1 I L3375E00
Par ts No. L3999B00
Drawing Na/Type
L2527B00
L2527D00
@ I Workpiece Side Welding Cable(l0rn) I L3375L00 / 1 I L3375LOO
0 I Control Cable4(lOm) CN4 / L3443B00 / 1 1 L3443B00
7 - 2 4 Parts List
Q'ty 1
1
Par ts Na
L2527B00
L2527D00
@ ( Workpiece Side Welding Cable(l5m) 1 L3375N00 ( 1 ( L3375N00
Ref No. @ 0
I Control Cable4 (15rn) CN4 I L3444B00 I 1 I L3444B00
7.12.3 Control Ca ble5 (For Al mega Auto I1 -- Robot Control Unit)
Item
Gas Hose (15m)
Torch Side Welding Cable (15m)
(2) BWCB-5110 L3512A (10m)
Ref No. I Item l ~ r a w i n ~ ~ o . / T ~ ~ e l Q'ty I P a r t s NO.
Drawing No./Type
L3375VOO
L3375G00
Ref Na
@
@ I Control Cable5 (lorn) Optical Fibed L3512B00 r 1 rL3512Bo0-
Q'ty 1
1
Item
Control Cable5 (5m) Optical Fiber
/ Workpiece
Par t s Na L3375VOO
L3375G00
Ref No. @
U Manipulator
Drawing No./Type
L3392Y00
l.----J Fig.7.12.0.1 Control Cables
Item
Control Cable5 (15m) Optical Fiber
Parts L is t 7 - 2 5
Q'ty 1
P a r t s No. L3392YOO
Drawing Na /Type
L3513B00 Q'ty
1
Par t s No.
L3513B00
7.13 BI RBX-8005 Control Cables (Fig. 7.13.0.1)
7.13.1 Control Cable 1,2,3 (For V10,V20)
(1) BIRBX-8003 L4309A (3m)
7 - 2 6 Parts List
7.13.2 Tool Control Cable (For VIO,V20)
(1) BIRBX-9105 L4357A (5m)
Ref NO.
@
Robot Coiitrol Unit IRBCX-541,551
Item
Tool Control Cable (5m) CN4
Ref NO.
0
Ref No.
@
Fig.7.13.0.1 Control Cables
Q'ty
1
Parts L i s t 7 - 2 7
Drawing Na/Type
L4357F00
Item
Tool Control Cable (10m) CN4
Parts NO.
L4358F00
Item
Tool Control Cable (15m) CN4
Drawing Na/Type
L4358F00
Q'ty
1
Drawing No./Type
L4359F00
Parts NO.
L4357F00
Q'ty
1
Par ts No.
L4359F00
7.14 B I RBX-6005 Control Cables (Fig. 7.14.0.1)
7.14.1 Control Cable 1 2 3 (For V40)
(1) BIRBX-6005 L4177A (5m)
Ref No.
0
0
0
@
7 - 2 8 Parts List
Item
Control Cable1 (lorn) CNI
Control Cable2 (lorn) CN2
Control Cable3 (10m) CN3
Control Cable4 (lorn) CIS4
P a r t s No.
L3909B00
L3909COO
L4179D00
L4179E00
Ref No.
0
0
0
@
Drawing Na/Type
L3908B00
L3908COO
L4178D00
L4178E00
Item
Control Cable1 (l5m) CN1
Control Cable2 (15m) CN2
Control Cable3 (15rn) CN3
Control Cable4 (15m) CN4
Q'ty
1
1
1
1
Drawing No./Type
L3909B00
L3909COO
L4179D00
L4179E00
Par t s No.
L3908B00
L3908COO
L4178D00
L4178E00
Q'ty
1
1
1
1
7.14.2 Tool Control Cable(ForV40)
(1) BIRBX-6105 L4209A (5m)
P a r t s NO.
L4177F00
Ref NO.
0
Robot Control Unit IRBCX-532
P a r t s No.
L4178F00
Ref Na
0
Fig.7.14.0.1 Control Cables
Item
Tool Control Cable (5m) CN5
Ref Na
0
PartsList 7 - 2 9
Drawing No. /Type
L4178F00
Item
Tool Control Cable (10m) CN5
Item
Tool Control Cable (15m) CN5
Drawing No. /Type
L4177F00
Q'ty
1
Q'ty
1
Drawing No./Type
L4179F00
Q'ty
1
P a r t s NO.
L4179F00
7.1 5 Robot Control Unit for External Axes 7.15.1 IRBCX-422-1 Robot Control Unit (Fig. 7.15.1.1)
* :Use the par ts marked " * " for Robot Control Unit shipped a s TIC Welding o r Plasma
Cutting Specifications.
Mark % shows the different parts from IRBCX-422.
Servo Driver Unit
P.C.B.(Servo Control)
@ @ 0 8 @ @ 8
Cooling Unit
Auto Breaker
Breaker Handle
Door Key Handle
AC Socket
Eye Bolt
Hanger
L4000E00
SA33B-30A
BZ-N2OB
A-120-1
AC-T04FB04
M12-ZMC
A-1042B-7
1
1
1
2
1
2
1
L4000E00
4614-046
4739-272
4739-273
4732-017
3364-005
3364-123
Fig.7.15.1.1 IRBCX-422-1 Robot Control Unit
Parts List 7 - 3 1
0 - 1 I Noise Filter
7.15.2 IRBCX-422-2 Robot Control Uni t (Fig. 7.15.2.1)
Glass Fiber Fuse lA, AC125V (1) 4610-008
Constant Voltage Power Supply RWS15A-5 (1) 4814-017 - Constant Voltage Power Supply LWQ130-5FF4 il) 4814-018
Coolinn Fan 4715PS-20T-B30 5 4805-027
Lamp / AH164-ZSWM1 I 1 1 4600-317
0 I Neon Lamp 1 NPAlO-2H-WS 1 1 / 4600-341
Q'ty 1
1
Drawing Na /Type
W-LOO470
E6029A00
Ref Na
0 % 0
@ Servo Driver Unit
P a r t s No. 4810-912
E6029A00
Item
Auxiliary Transformer
Power Unit
0 Servo Driver Unit I I I
8 Servo Power Unit E5787A00 1 E5787A00
P.C.B.(Servo Control)
P.C.B.(Motion Control) L3700D00 1 L3700D00
P.C.B.(Main Processor) L3700COO 1 L3700COO
P.C.B.(I/O Management, Standard type) L3700M00 1 L3700M00
P.C.B.(I/O Management, Extended Type) L4024M00 1 L4024M00
P.C.B.(Backplane) L3702F00 1 L3702F00
P.C.B.(Interlock) L3899YOO 1 L3899YOO
P.C.B.(Terminal Block) o r E574 1 A00 E574 1 A00 1
P.C.B.(Relay) E5685A00 E5685A00
Memory Battery W-LOO233 1 5096-095
Charging Battery W-LOO471 1 5096-140
Cooling Unit L4000E00 1 L4000E00
Auto Breaker SA33B-30A 1 4614-046
Breaker Handle BZ-N2OB 1 4739-272
Door Key Handle A-120-1 2 4739-273
AC Socket AC-T04FB04 1 4732-017
Eye Bolt M12-ZMC 2 3364-005
Hanger A-1042B-7 1 3364-123
Servo Driver Unit W-LOO606 1 5096-174
* :Use the par ts marked " * " for Robot Control Unit shipped as TIG Welding o r P l a s m a
Cutting Specifications.
Mark % shows the different par ts from IRBCX-422.
7 - 3 2 Parts List
Parts List 7 - 3 3
7.15.3 IRBCX-422-3 Robot Control Unit (Fig. 7.15.3.1)
* :Use the pa r t s marked " * " for Robot Control Unit shipped as TIG Welding o r Plasm a
Cutting Specifications.
Mark % shows the different par ts from IRBCX-422.
Ref No.
0 0
0 - 1
0 - 2
0 - 3
0 - 4
0 @ 0
7 - 3 4 Parts List
Item
Auxiliary Transformer
Power Unit
Noise Filter
Glass Fiber Fuse
Constant Voltage Power Supply
Constant Voltage Power Supply
Cooling Fan
L a m p
Neon L a m p
Servo Driver Unit
Drawing Na /Type
W-LOO470
E6029A00
NDHOO3
lA, AC125V
RWS15A-5
LWQ130-5FF4
4715PS-20T-B30
AH164-ZSWM1
NPA10-2H-WS
W-LO0455 o r
Q'ty 1
1
(1)
(1)
(1)
(1) 7
1
1
P a r t s Na 4810-912
E6029A00
4519-009
4610-008
4814-017
4814-018
4805-027
4600-317
4600-341
5096-138
Fig.7.15.3.1 IRBCX-422-3 Robot Control Unit
7.15.4 IRBCX-512-1 Robot Control Unit (Fig. 7.15.4.1)
Servo Driver Unit
P.C.B.(Servo Control)
% @ Servo Driver Unit W-LOO605 1 5096-173
* :Use the par ts marked " * " for Robot Control Unit shipped as TIG Welding o r Plasma
Cutting Specifications.
Mark 3% shows the different parts from IRBCX-512.
7 - 3 6 Parts List
Fig.7.15.4.1 IRBCX-512-1 Robot Control Unit
7.15.5 IRBCX-512-2 Robot Control Unit (Fig. 7.15.5.1)
* :Use the par ts marked " * " for Robot Control Unit shipped a s TIG Welding o r Plasma
Cutting Specifications.
Marli % shows the different parts from IRBCX-512.
Ref No.
0 0
0 - 1
0 - 2
0 - 3
0 - 4
0 @ 0
@
0
8
93 @
0 a 0
0 8
7 - 3 8 Parts List
Item
Auxiliary Transformer
Power Unit
Noise Filter
Glass Fiber Fuse
Constant Voltage Power Supply
Constant Voltage Power Supply
Cooling Fan
Lamp
Neon Lamp
Servo Driver Unit
Servo Driver Unit
Servo Driver Unit
P.C.B.(Servo Control)
P.C.B.(Motion Control)
P.C.B.(Main Processor)
P.C.B.(I/O Management, Standard type)
p.C.B.(I/O Management, Extended Type)
P.C.B.(Backplane)
P.C.B.(Interlock)
P.C.B.(Terminal Block) o r
Drawing No./Type
W-LOO470
E6029A00
NDH003
1A, ACl25V
RWS15A-5
LWQ130-5FF4
4715PS-20T-B30
AH164-ZSWM1
NPA10-2H-WS
W-LO0393 o r -
W-LOO552
W-LO0394 o r -
W-LOO553
E5787A00
L4000R00 o r
L4268R00
L3700D00
L3700COO
L3700M00
L4024M00
L3702F00
L3899YOO
E5741A00
E5685A00
5096-095
5096-140
L4000E00
@ 1 P.C.B.(Relay)
@ @ @
Q'ty 1
1
(1)
(1)
(1)
(1)
5
1
1
1
1
1
3
1
1
1
1
1
1
Par t s Na
4810-912
E6029A00
4519-009
4610-008
4814-017
4814-018
4805-027
4600-317
4600-341
5096-136
5096-154 * 5096-137
5096-155 * E5787A00
L4000R00
L4268R00 * L3700D00
L3700COO
L3700M00
L4024M00
L3702F00
L3899YOO
E574 1 A00
M e n ory Battery
Charging Battery
Coolimg Unit
W-J_iOO233
W-LOO471
L4000E00
1
1
1
Fig. 7.15.5.1 IRBCX-512-2 Robot Control Unit
Parts L is t 7 - 3 9
7.15.6 IRBCX-512-3 Robot Control Unit (Fig. 7.15.6.1)
* :Use the par ts marked " * " for Robot Control Unit shipped as TIG Welding o r Plasma
Cutting Specifications.
Mark 5% shows the different par ts from IRBCX-512.
Ref Na
0 0
0 - 1
0 - 2
0 - 3
0 - 4
0 @ 0
8
0
8
5% @
('Dl
Item
Auxiliary Transformer
Power Unit
Noise Filter
Glass Fiber Fuse
Constant Voltage Power Supply
Constant Voltage Power Supply
Cooling Fan
Lamp
Neon Lamp
Servo Driver Unit
Servo Driver Unit
Servo Driver Unit
P.C.B.(Servo Control)
P.C.B.(Motion Control)
Drawing No./Type
W-LOO470
E6029A00
NDHOO3
lA, AC125V
RWS15A-5
LWQ130-5FF4
4715PS-201'-B30
AH164-ZSWMI
NPA10-2H-WS
W-LO0393 o r
W-LOO552
W-LO0392 o r
W-LOO553
E5787A00
L4000R00 o r -
L4268R00
L3700D00
L3700M00
L4024M00
L3702F00
L3899YOO
E574 1 A00
E5685A00
5096-095
5096-140
L4000E00
4614-046
4739-272
4739-273
4732-017
3364-005
3364-123
5096-154
8
@ 8
@
0 @ 8 0 @ @
Q'ty 1
1
(1)
(1)
(1)
(1)
5
1
1
1
1
1
3
1
1
P.C.B.(I/O Management, Standard type)
P.C.B.(I/O Management, Extended Type)
P.C.B.(Backplane)
P.C.B.(Interlock)
P.C.B.(Terminal Block) o r
P.C.B.(Relay)
Memory Battery
Charging Battery
Cooling Unit
Auto Breaker
Breaker Handle
Door Key Handle
P a r t s NO.
4810-912
E6029A00
4519-009
4610-008
4814-017
4814-018
4805-027
4600-317
4600-341
5096-136
5096-154 * 5096-137
5096-155 * E5787A00
L4000R00
L4268R00 * L3700D00 -- L3700COO
8 AC Socket 1
L3700M00
L4024M00
L3702F00
L3899YOO
E5741A00
E5685A00
W-LOO233
W-LOO471
L4000E00
SA33B-30A
BZ-N2OB
A-120-1
- @ 8
5% @
1
1
1
1
1
1
1
1
1
1
2
Eye Bolt
Hanger
Servo Driver Unit
M12-ZMC
A-1042B-7
W-LOO552
2
1
1
Fig.7.15.6.1 IRBCX-512-3 Robot Control Unit
Par ts L i s t 7 - 4 1
Electr ical Connection Diagram
Contents
8.1 Electrical Diagram of Robot Control Uni t IRBCX-422, 462
Electr ical Connection D i a g r a m 8 - 1
bEO
EEO
ZEO
I € 0
Note)Accordlns to the use of PC% or PCB3 and also PCB5 or PCD4. BACWLANE BOARD tho nuns and vlrs No. of each tarnlnsl should be followad:
PC8 l PC88 PCB4 RESERVE 2 4 E l W T l 9 0 0 RESERVE 24EIQIJTI 900 COML 8 8 0 2 4 E l W T 1 8 0 0 COME 8 9 5 24E lOUT l Q00 COMZ 9 9 1 24E lOUT l 8 0 0 CUM7 8 9 6 24E lOUT l 900 COM3 8 9 2 24E lOUT l 9 0 0 COMB 9 9 7 2 4 E I W T l 900 COM4 8 8 3 Z4EIOUTI 8 0 0 COM9 9 9 8 24E lOUT l 800 CQMS 8 8 4 2 4 E I W T I 8 0 0 COMlO 8 9 9 Z I E I W T I 800
8121T871 ITBQlT
TUX(INAL BLOCK VI4IT EXT. 1ERMIML BLOCK U N I T I
CHRG ALMZ
3 BK COM
BK A
BKB
%& ::;+
VBAT-
BAT 5) OVERLS9r @ OISCON3. @J OVERCOM3 @
OE1"1 LAMP @
+cz~vOfi
BRAKE* @)
VBAT+
VBAT-
B R E A K
B R E A K
GN) GN)
GN)
BGT MA BAT BAT OVERRUN L S I OVERRUN L S 2 OVERRUN L S 3 OVERRUN
GNI GN)
GN)
BAT BAT B4T OVERRUN L S 4 OVERRUN 1 5 5 OVERRUN L S 6 2 4 W SHOCK SENSOR
N I PUL
I LAMP
I _ _ - - - \ .--_
Electrical Diagram of Robot Control Unit IRBCX-422, 462 (4/6)
CN 2
A+ 1 PA
A- 1 PA.
B+ 1 PB
B- 1 PEW
s + 1 PC
S- 1 PC.
ABS + i ABS
ABS - 1 ABSU
R-OND 1 R-OND 5E 1 + 5 . 5 v
GNDE I GNDE 1
A+2 PA
A - 2 PA.
B+2 PB
8 - 2 PB.
S+ 2 PC
5 - 2 PC.
ABS + 2 ABS
ABS - 2 ABSl
R-GND 2 R-GNO 5 E Z +5.5V
G N M 2 GNDE2
A+3 PA
A-3 P A 1
B + 3 P B
8 - 3 PBm
S + 3 PC
S-3 PC.
ABS+3 ABS
ABS-3 ABSm
R-OND3 R-OND
5 E 3 +5. 5 V
GNDE3 GNDE3
F G 9-JLF
MAN l PULATOR
AX- 1 ENCODER
AX- 1 ENCODER
PS* ( I
AX-2 MOTOR I
AX-3 ENCODER
I AX-3 1 MOTOR 1
PSZ ( P S I (
Electrical Diagram of Robot Control Unit IRBCX-422, 462 (51'6)
u L-J 4
ul N
a m
I I
I I
I E K I W W L ----------------,
I n 0
I 9 0 LOO I 0 I 0
I
I X z X Z I I
Q W Q W I I -- 0 I \ 0 > - O > N n z m w d I
4 : m b o : $ $ $ : $ , : m l o : E $ y d $ ' m a a a a a a 4 4 n + o a a a a a a 4 < n + o I \ L
0 0 0 m m m
0 0 0 0 0 0 t t P
r - r r - r - rr V T P
0 0 0 0 0 0 0 0 0 r r r
%-J 0 - N - 0 0 0
0 - N
f T P 0 0 0
IC N N N a o a N N N
> u Z . - - - W Z N N N W t j m m m w v < m v u < m v < m u
U
8 - 6 Electrical Connection Diagram
0 - h m ~ u ~ o r r n - - - - - - - - g f l " - - I
c o o o c a 4 t l ! ? r -01 - ? T P V t t T - ? t m m U I C u l L C u I u I U m m Q b &
h N N r . ( \ N m m - r m - -
I
~ ~ w W o =
I 1
0658 0756
GROUNDING NL1 NEON LAMP
AC SOCKET 1-b;: oov
Ft 3'63 UNI PS I
T
1 oov
~ ' - Y - J -
] 32 0 1 5 % tow tow tow a B a J 3 C H 4
SV - GND 27
24, 3 26 OV gJ 25
C
t o SERVO 07 1 A 27 2 GND
28 3 +15v
c@ 071A 27 4 GND
29 5 -15V
2 GND GND 2 27 031D t o BACKPLAE WARD 3 +15V +15V 3 PCB1
4 GND CNlO
5 -15V - 15V 5 29 0310
Electrical Diagram of Robot Control Unit IRBCX-512 (1/6)
r----------1 / ROBOT DEDICATED WELDING I BACKPLANE BOARD / POWER SUPPLY
I I EMRGEWY I STOP I I I ! I
PSl CH42
Electrical Diagram of Robot Control Unit IRBCX-512 ( 2 / 6 )
B A C K P L A N E BOARD PCB1
N o t e ) A c c o r d i n a t o t h e u s e o f PCB5 o r PCB3 a n a a l s o PCB6 o r PCB4. t h e name a n d w i r e No. o f e a c h t e r m i n a l s h o u l d b e f a l l o w e d :
PC85 PC83 PC86 PC84 RESERVE Z4EIOUTI 900 RESERVE Z4EIOUTl 900 COMl 990 Z4EIOUTI 900 COM6 995 24EIOUTl 900 COMZ $01 24ElOUTl 900 COM7 995 24EIOUTI 900
CRZA ESTOP
CRB TEACH
C R I I START
C R 1 3 STOP
L A M P l l A U T O l
L A M P Z I T E A C H )
L A M P 3 l S T A R T I I
LAMP415TARTZ1
L A M P 5 I S T A R T 3 1
L A M P 6 I S T O P I
C R 1 2 SERVO ON
3 BK COM
BKA
BOARD BREAK
BREAK
MANIPULATOR
+czYvOm
BRAKE* @)
OCQOV 181 Q VBAT- @
I LAMP
I ---- L- - - .
Electrical Diagram of Robot Control Unit IRBCX-5 12 (4/6)
$ :, - - - - . - - - - -; G N N N N N N N N N N N m m m m m m m m m m m 0 :;&A:,&;:,g"g :.k&&&:,;,:$?g# :;&A:,A:,11,9g#' m m o a 4 4 I
m m o z 4 4 & " m m o z
4 4 1 a
0 0 0 m m m w w w 0 0 0
0 - N 0 - 0 0 N N N
Electrical Connection Diagram 8 - 1 1
6 - - - - - - - - -;t; N N N N N N N N N N N m m m m m m m m m m m m z & & , A & & $ A g l o g : : & , A & A $ A g i # : & & & & & & & 9 $ B L
m m o 4 4 1
m m o z 4 4 & 0
m m o z 4 4 1 C1
8 - 1 2 Electrical Connection Diagram
8.3 Electrical Diagram of Robot Control Uni t IRBCX-541
- .- - - - - - - -. - - I O P W A T I O N PAML ( O P E R A T I O N BOX);
1 QLT 1 EMERGENCY STOP 1 I
STP,RT 1 1 HALT 1 COM I 2 4 E I 5TAHT INDICATOH I 1 H A L T INDICATOR 1 I
I I
SERVO ON
I TEACH M E S E E C i I M l l
r - - - - - - - - - -1 AUTO Lag SELECTIONI
1 ROBOT DEDICATED WELDING 1 SEAYO ON INDICATOR I I POWER SUPPLY I
I I EIERGENCY TUCH M E IXDIQTOR~
STOP AUTO ----- NDE INDICAIOAJ i
-&N 1 0
s N 1 9 - I 5 V 0902513
(SENSOR)
--------.A
(SPT I CAL F I BER
B A C K P L A N E BOARD
PCB 1
033
I SERVO ON BT 1
034 1
Electrical Diagram of Robot Control Unit IRBCX-541 (2/6)
Nots)Aooordlna to t h e u s s a f PC85 o r PC83 and slsa PCB6 or PCE4. t h ~ nsas and r l r e No. o f e a o h terminal s h o u l d b a f o l l o w e d :
BACKPLANE BOARD ?C86 PCB4
PCB 1 RESERVE Z4EIOUTI 900 RESERVE 24EIOUTI 900
mMI 9QO 24EtOUT1 900 COM6 995 24ElOUTl 900 COMZ QQI Z4EIOUTI 900 COM7 996 24EtOUTI 900
COM3 QQZ Z4EtOUT1 900 COM8 997 24ElOUT1 900
COM4 993 24ElOUTl 900 COM9 998 24E(OUil 900
COffi 984 24ElOUT1 900 COMlO 999 24ElOUTI 900
TERMINAL BLOCK UNIT I
EXT OVER1
Electrical Diagram of Robot Control Unit IRBCX-541 (3/6)
ESTOP I N T E R L O C K PCB2
3 BK COM
BK A
B K 8
C N 6 1 BOARD +
C N 6 +
C N 6
I I
BREAK
BREAK
TPUT I
CR2A ESTOP
CR6 AUTO
CRB TEACH
CR 1 l START
CR I3 STOP
OUT CQM
2 4 E
LAMP1 I A U T O I
LAMPZITEACH1
L A M P 3 l S T A R T I I
L A M P 4 f S T A R T Z l
LAMPSISTART31
LAMPGISTOPI
C R i Z SERVO ON
OE 181 LAMP @
C N 4 7
\'BAT +
VBAT -
V B A l , VBAT - VBAT+
VBAT-
GN) GN) GN) BAT BAT BAT OVERRUN L S 1 OVERRUN LS2 OVERRUN L S 3 OVERRUN CIECK(GN))
GI@ G N I GtQ BAT BAT BAT OVERRUN LS4 OVERRilN L S 5 OVERRUN L S 6 2 4 W SHOCK SENSOR LAMP
- - - -
MAN I Pi
- -
JLAl
Electrical Diagram of Robot Control Unit IRBCX-541 (4/6)
GND
- I5V
CN 2
A+ 1 PA
A- 1 PAR
B+ 1
8- 1
s + 1
s- 1
ABS t 1 ABS
ABS - 1 ABSN
A-OND 1 R-OND 5E l i 5 . 5 V
GNOE l GNDE 1
A + 2 PA
A-2 PAW
B + Z
8- 2
S + 2
S - 2
ABS + 2 ABS
ABS -2 ABSU
R-GND 2 R-GND 5E2 + 5 . 5 V
GNDEZ GNDEZ
A+3 PA
A-3 PAR
B + 3
8 - 3
S + 3
5 - 3
ABS+3 ABS
ABS-3 ABS*
R-GND3 R-GND
5E3 +5. 5 V
GNDE3 GNDE3
FG SH 1 EL0
I I I I I I I I I I I I I I I I I I I I I i I I
AX-1 I
MOTOR
I I 1 E;:R I 1 %:R I
- - - - - - A
MAN I PULATOR
P S I
AX- 1 ENCODER
AX-2 ENCODER
PSZ
AX-3 ENCODER
Electrical Diagram of Robot Control Unit IRBCX-541 (5/6)
CT a K I T O LOO W O 1 I t i t i t X O x o x o I I QI 4 2 1
8 - 1 8 Electrical Connection D i a g r a m
A
ACZOOV 3 @ 50/60HZ
NEON LAMP
GRCXJNDING PLATE
SWITCH BOX AClOOV S B 1
v To BACKPLANE
Electrical Diagram of Robot Control Unit IRBCX-551 (1/6)
- .- - - - - - - -. - - , GWATION PAKL (OPERATION BOX);
47 EMEEMERCY STOP I
IKiWLCCK 83PRD
r----------1 1 ROBOT DEDICATED WELDING / I POWER SUPPLY
I EWEGENCY STOP
I
(SENSOR)
BACKPLANE BOARD
PCB 1
1 I ! I
I SERVO ON
BT 1
Electrical Diagram of Robot Control Unit IRBCX-551 (2/6)
BACKPLANE BOARD PCB1
Nots)Aocordlna to t h e u s e $ I ( PCB5 or X % 3 a n o a l s o PCB6 o r ?C84 t n s n r n s a n d r lrs No. o : e a c h !ersii\ai snould b s ! U I I O W H ~ :
PC85 PC83 . - 'cB~ PC84 iiESERVE 24E I OUT I 300 iilr5tRVE 245 IOU I ! 3 i l U
COMI 960 24EIOUTl 900 .;:)'A6 995 24E IOUT 1 900 COM2 901 24EIOUTI 900 COht-I 396 24E IOUTi YO0
ESTOP I N T E R L O C K
CRZA ESTOP
CR8 TEACH
CR I I START
CR I3 STOP
L A M P I I A U T O I
L A M P Z I T E A C H I
L A M P 3 1 S T A R T I l
L A M P 4 I S T A R T Z 1
L A M P S ( S T A R T 3 1
LAMPGISTOPI
C R l Z SERVO ON
3 BK COM
BKA
B K B
BKC
OVERRUN 1 *
VBAT -
VBAT i
VBAT-
VBAT+
VBAT -
------
B R E A K
BREAK
GN) GN) GN) BAT BAT BAT OVERRUN LS1 OVERRUN LS2 OVERRUN LS3 OVERRUN CtECK(CM))
GND G M GN)
B4T BAT BAT OVERRUN LS4 OVERRUN LS5 OVERRUN LS6 2 4 W SHOCK SENSOR LAMP
M A N I P U L A T O R I I
Electrical Diagram of Robot Control Unit IRBCX-551 (4/6)
PS* { P5, {
MAN I PULATOR
/ 1 _---- I I I I I I I I I I I I I I I I I I I I I I I I I
AX-1 I
MOTOR
I I
AX-2 1 1 MOTOR
I
I - - - - - - A
Electrical Diagram of Robot Control Unit IRBCX-551 (51'6)
2 - - - - - - - - - z z y y y y y y y y N ~ ~ m m m m m m m m m m m o Z i & A & l , A h g m s 4 4 m m u l m m m ~ : X : : & r b & 1 , & 1 , 4 i 1 ( H L
m m o 4 4 1 s s z 5 m m o z
4 4 1 o
8 - 2 4 Electrical Connection Diagram
Electrical Connection Diagram 8 - 2 5
8 - 2 6 Electrical Connection Diagram
BKCONT . ILOTIOH CCNlROC DWLO)
I KCIIANISM 1 I - - - - - - -_ I
KCIIANISM 2- r-----
I
I I
IC107 ------ &k l$&- - - - - - - J
(BACKPLANE MND)
Internal Relay Sequence Diagram of Control Unit (3/8)
I m N 0 -
I f f f f 1 0 0 0 0
I I I I I I I I I
I I I I I I I I-
8 - 2 8 Electrical Connection D iagram
IX) MANAGCKNT R)MD
I
I
I I
N I w L ----------- - ---- J
l/O WMG0,GnANr WMD - - - - - - - - - - - - - - - - - - TELUINAL OLKK UilT - - - - - - - - - - - - - - I
I I ICI61
r-------
IWTFZ
I w T F ~ ~
I L - - - - - - - lCI84
I r-------
L - - - - - - - IC165 I
r -------
I I I L ---------------- J
Internal Relay Sequence Diagram of Control Unit (5/8)
RELAY UNIT I/O M N A C M N T WARD r-------------- I/O MI\NAGDAENT WMD RELAY UN l T
r _ - _ - - - _ - _ - _ - _ _-- - - - - - - - - -__-_--
~ ~ U T E S ~ L- - - - - -
I I C 1 6 2 r - - - - 7 -
I W T E ~ ~ L------
I 1C163r - - - - - -
Internal Relay Sequence Diagram of Control Unit (6 ,
€XI IUMIf4AL OLKK UNIT I/O M N A C M K I D3MD
I I I
L ---------------- J
I/O M E M C M N T NMD r - - - - - - - - - - -
EXT. TEWINAL mKK UNIT 7 r - - - - - - - - - - - - 7
IOUTCG =--j
IOCITC~ I L - - - - - -. - Z4VIGiJTt
I I I
Internal Relay Sequence Diagram of Control Unit (7/8)
r------------------------------------------------------- 0 - m *
I , , o = L f r f ~ a . 2 g r z o a N 2 ~ ~ - - L o - T u, a r. z ~ z z g g 2 g I I - u - f - - " 5 f Z v - - I -
0 I r3-A-k-i7;J-J-i-i,;3-A-A-17;A-A-A-il;2--!--L-il I
%I I I I I I I I I I I I 8 I I I I I 2 I I I i 1 : -,J I -,J 1 1
d i I
2 I I
/ -ct, i I 3 / I q j l 3 / I +-, I
L-*-*-LJ L - + - + - L A L - . c - I - C J L - + - + - + A L -4 -4-4 ----- 2 - ~ m r m a r - o m o - N m r m o + m o o
m m m m m m m r g E Z g ~ f z ~ g z z_ 5 >
8 - 3 2 Electrical Connection Diagram
8.6 Outside Dimensional Drawing of Robot Control Uni t
Electrical Connection Diagram 8 - 3 3
O I L
8 - 3 4 Electrical Connection Diagram
8.7 Electrical Diagram of Control Cable
8 rii
Electrical Connection Diagram 8 - 3 5
8 - 3 6 Electrical Connection D iagram
Electr ical Connect ion Diagram 8 - 3 7
APPENDIX 1-WELDING EQUIPMENTS
Contents
1 3 TIG Interface E5743 ................................................................................................................................................. A1 . 6 1.3.1 A~~~~~~~~~ of TIG interface ................................................................................................................. Al- 6 1 . 3.2 setting J~~~~~ wires of TIG l'terface Al - 7 1 3 3 Connecting TIG Interface ........................................................................................................................... A1 - 7 . .
1 5 CUT Interface E5782 ................................................................................................................................................. A1 - 9 1 . 5. 1 Appearance of CUT Interface ............................................................................................................... A l - 9 1 . 5.2 setting J~~~~~ wires of CUT ~ ~ t ~ ~ f ~ ~ ~ ....................................................................................... A1-10 1 . 5 . 3 Connecting CUT Interface A1 - 10
APPENDIX 1-WELDING EQUIPMENTS This chapter describes the connecting method of the peripheral equipment necessary for
the aforementioned Robot Dedicated Welding Power Supply, the Welding Interface, and various welding methods.
This chapter explains the particulars necessary for the combination of the Welding Interface and like with various welding power supplies.
In order to carry out welding by use of those welding power supplies, necessary are the preparation of welding equipment including welding torch and wire feed unit and the likes and the input operation of welding characteristic data.
1 . I Connecting Robot Dedicated Welding Power Supply In this section,the connecting method of the Robot Dedicated Welding Power Supply is
explained with Almega Auto I1 (CPVAS-350) a s an example.
1.1.1 External Connecting Cable The connection of the robot dedicated welding power supply requires the external
connecting cables shown in TABLE 1.1.1.1. TABLE 1.1.1.1 External Connecting Cable
Control Cable 4 (L3392G)
Ref .No.
@
@
@
@
To Manipulator
Control Cable 5
Robot Control
To Manipulator Weldinn Cable
F i g . 1 . 1 Connecting Robot Dedicated Welding Power Supply
APPENDIX 1-WELDING EQUIPMENTS A 1 - 1
Name
Control Cable 5
Control Cable 4 Torch Side Welding Cable Workpiece Side Welding Cable Gas Hose
Connecting Portion
CN31 IC104 ICN4
Part No.
L3392Y
L3392G
L2527D
L3442B
L2527B
Q'ty
1
1
1
1
1
Remarks
BCWB-5105
BIRB-3005 Configuration
1 .I .2 Connecting Cables
A WARNING Turn OFF the switch of the distribution panel and confirm that power supply is shut off prior to the connection of cables.
(1) Connecting Control Cable 5 (BWCB-5105)
Remove the upper cover of the welding power supply.
Lead the connector CN31 side of the control cable through the back side of the
welding power supply to the inside of the welding power supply,and connect the
optical fiber connector to the optical fiber module IC104 of the printed board
P9745W.
Then connect the connector CN31 to CN31 of the printed board P9745W, and place
back the upper cover.
(2) Connecting Control Cable (L3392G)
Connect the control cable to the connector ICN4 of the welding power supply and
the connector CN4 of the manipulator.
(3) Connecting Workpiece Side Welding Cable (L3442B)
Connect the workpiece side welding cable to the - (minus) terminal of the welding
power supply.
(4) Connecting Torch Side Welding Cable (L2527D)
Connect the torch side welding cable to the + (plus) terminal of the welding
power supply.
A 1 - 2 APPENDIX 1-WELDING EQUIPMENTS
1.2 Connecting Welding Interface and Welding Power Supply This section describes the method to connect the aforementioned Welding Interface. When to connect the Welding Interface to welding power supply,as mentioned in the
foregoing chapter,necessary are the setting of the instructed voltage range by the swich of the printed board E5624G within the Welding Interface and the external connection described below.
1.2.1 External Connecting Cable The connection of the Welding Interface and various welding power supplies requires the . ..
external connecting cables as shown in TABLE 1.2.1.1. (TABLE 1.2.1.1. shows an example of CPV-350.)
TABLE 1.2.1.1 External Connecting Cable (for CPV-350)
Terminal Block Grommet
To Workpiece Terminal Block
Ref .No.
O @ @ @
@ @ a @
To Manipulator @ @ @ @ @ To Manipulator
Figl.Z.l.l Connecting Welding Interface and Welding Power Supply
APPENDIX 1-WELDING EQUIPMENTS
Remarks
Cable attached to welding interface Varies with various welding power supplies. Refer to TABLE1.2.1.2 to prepare connecting cables corresponding to welding power supplies used.
BIRB-3005 Configuration
Name
Cable Assembly
Control Cable Control Cable
Detection Cable 1
Detection Cable 2
Control Cable 4 Torch Side Welding Cable Workpiece Side Welding Cable Gas Hose
part N ~ .
L3497Y
E5186E K1754P
K1754F
K1754G
L3392G
LZ527D
L3442B
L2527B
Portion
ICN2 ICN3
For WCR
For detection of weld stick ICN4
Q . ~ ~
1 1
1
1
1
1
TABLE1.2.1.2 Connecting Cables with Various Welding Power Supplies
Welding Power
1.2.2 Connecting Method of Cables A WARNING
Turn OFF the switch of the distribution panel and confirm that power supply is shut off prior to the connection of cables.
Connecting Detection Cable 1 (for WCR) and Detection Cable 2 (for Wire stick)
*Remove the upper cover of the welding power supply.
*Make a hole on the grommet a t the rear portion of the welding power supply.
*Remove the cover of the Welding Interface.
*Make a hole on the grommet with membrane a t the bottom of the Welding
Interface.
*Connect the detection cables 1 and 2 as shown in Fig.1.2.2.1.
*Connect cables to the terminal block a s shown in Fig.1.2.2.1.
*Attach the cover of the Welding Interface.
WELDING INTERFACE ,,Short Circuit Plate
WELDING POWER SUPPLY
& TO WELDING POWER
- M U BE L C D 1 I q-?- - SUPPLY WCR
!J v ?J k!J I I (TERMINAL BLOC
I I L - - - - - - _ - - - - - - - - .- - - - - - - --
TO WELDING POWER SUPPLYOUTPUT
@ TERMINAL
I DETECTING CABLE(2) I
Fig1.2.2.1 Connecting Detection Cables
A 1 - 4 APPENDIX 1-WELDING EQUIPMENTS
(2) Fixing Welding Interface After the connection of the detection cables,fix the Welding Interface onto the welding power supply according to the procedures described below: -Remove the hook of the welding interface. *Fix the welding interface to the hanger with the bolts that fix the hook. *Fix the hanger to the welding interface with the eyebolts and bolts for mounting the upper cover of the welding power supply removed in (1) section.
.Fix the upper cover with remaining eyebolts and bolts.
I INTERFACE
I - WELDING POWER SUPPLY
Fig1.2.2.2 Fixation of Welding Interface
(3) Connecting Control Cable (E5186E) Connect one connector of the control cable E5186E to the connector ICN2 of the Welding Interface,and connect another connector to the 4 - pin connector for "Wire Feed UnitVof the welding power supply.
(4) Connecting Control Cable (K1754P) Connect one connector of the control cable K1754P to the connector ICN3 of the Welding Interface,and connect another connector to the 4 - pin connector for "RemoteVof the welding power supply.
(5) Connecting Control Cable 4 (L3392G) Connect the connector of the control cable 4 to the connector ICN4 of the Welding Interface and the connector CN4 of the manipulator.
(6) Connecting Torch Side Welding Cable (L2527D) Connect the torch side welding cable to the + (plus) terminal of the welding power supply - At this moment,connect the terminal of the wire No.2 of the detection cable 2 also to the plus (+) terminal of the welding power supply.
(7) Connecting Workpiece Side Welding Cable (L3442B) Connect the workpiece side welding cable to the minus (-) terminal of the welding power supply. At this moment,connect the terminal of the wire Nal of the detection cable 2 also to the minus (-) terminal of the welding power supply.
APPENDIX 1-WELDING EQUIPMENTS A 1 - 5
1.3 7- I G Interface E5743 This unit is the interface in the case to combine the robot control unit and TIG welding
power supply.
This comprises the filter circuit to reduce high-frequency noise,etc. generated a t TIG
welding.
1.3.1 Appearance of TIG lnterface
7<57<?fflRBr?BiBI 7i5'74VIBPjiR@4f(?3l%(lB) Slslgia fiLlER YlRt RIDER COXTRCL UY lT F l l i t R 1lR6 FEEDER COYTRCL lill1lELOlKC iOER SW??lTi EiDlX PCYUl SWLY
IiCNJI I T \ -1
Fig.l.3.1.1 Appearance of TIG Interface
A 1 - 6 APPENDIX 1-WELDING EQUIPMENTS
1.3.2 Setting Jumper Wires of TIG Interface
This unit is equipped with the terminal blocks TB1 and TB2 to connect jumper wires
to correspond to various TIG welding supplies.Connect the jumper wires as shown
TABLE 1.3.2.1 according to the welding power supplies to be employed.
TABLE 1.3.2.1 Connecting Jumper Wires of Terminal Blocks
Supply / TBl(5-pole) / TB2 (10-pole)
TB1 (5-pole) and TB2 (10-pole)
AEP 1 123-122 /
Welding Power
VRTP (S-1) 123-121
@-@, @-63, @-@, a-@
Jumper Wire
AVP 1 VRTP (S-4)
1.3.3 Connecting TIG Interface
In this unit, connecting cables vary with the welding methods and corresponding
types as shown in TABLE 1.3.3.1.Therefore,prepare connecting cables according to
your requirements.
TIG Welding
(without Filler)
TABLE 1.3.3.1 List of TIG interface Connecting Cables
TIG Filler Welding
Connecting Cable Welding Method
Connecting Cable(1) E5239E
Correponding Type
E5749 Connecting Cable(1) E5243E
Connecting Cable(2) E5243F
/ 1 Connecting Cable(5) E5223G
E5750
/ Connecting Cable(6) E5208H
Connecting Cable(2) E5239F
Connecting Cable(3) E5208E
Connecting Cable($) E5208F
APPENDIX 1-WELDING EOUIPMENTS A 1 - 7
I .4 Filler Wire Feed Control Unit E5756 This is the unit to control the TIG filler wire feed speed in the case to combine the
robot control unit and the TIG welding power supply.
1.4.1 Appearance of F i l l e r Wire Feed Control Uni t
Fig.l.4.1.1 Outside View of Filler Wire Feed Control Unit
1.4.2 Connecting F i l l e r Wi re Feed Control Uni t As for the method to connect this unit,refer to the Section 1.7
A 1 - 8 APPENDIX 1-WELDING EQUIPMENTS
I .5 CUT lnterface E5782 This unit is the interface in the case to combine the robot control unit and Air
Plasma cutting power supply. This comprises the filter circuit to reduce high-frequency
noise generated a t plasma cutting.
1.5.1 Appearance o f CUT lnterface
Fig. 1.5.1.1 Outside View of CUT Interface
APPENDIX 1-WELDING EQUIPMENTS A 1 - 9
"15.2 Setting Jumper Wires o f CUT Interface
This unit is equipped with the terminal blocks TB1 and TB2 to connect jumper wires
to correspond to various TIG weIding,and plasma cutting power supplies.When to use
Air plasma cutting power supply,there is no need to set these jumper wires,so you may
use the interface with its jumper wires a s set a t shipment from factory. The setting a t
shipment from factory a r e shown in TABLE 1.5.2.1.
TABLE 1.5.2.1 Connecting Jumper Wires of Terminal Blocks
TB1 (5-pole) and TB2 (10-pole)
1.5.3 Connecting Cut Interface
In this unit,connecting cables vary with corresponding types as shown in TABLE
1.5.3.1.
Therefore,prepare connecting cables according to your requirements.
(Setting a t shipment from factory)
TABLE 1.5.3.1 List of CUT Interface Connecting Cables
Cutting Power Jumper Wire
A l - 1 0 APPENDIX 1-WELDING EQUIPMENTS
Corresponding Type
TRC-120
Connecting Cable
E5769B
1.6 Weld Stick Detection Unit E5391 This unit is the device to monitor the welding voltage during TIG welding and output a
detection signal to the external when the value goes down below a specified one.
Name
1.6.1 Specifications of Weld Stick Detection Uni t
/ Weld Stick Detection Unit
Item
Input Power
Specifications
Frequency 50/60Hz
Detection Voltage
(Input Voltage)
I
Up to 40V (AC and DC) 3-phase AC200/220V ( t 10%) 2A
I
Dimensions
Detection Time
Weld Stick Detection
Voltage Level
I I PCB l I
0.0-1.0 second
6.0-7.0 Volt
r - i r - i r - 1 I I I I I I I I I I I I I CR3
L - - - - - I TL /CHI! ~ W C R ; r - - - - -
Q I 1 1 1 1 I I CRZ I I 1 I I I L - - - - - L - J L - J L . - J
Fig.1.6.1.1 Outside View of Weld Stick Detection Unit
APPENDIX 1-WELDING EQUIPMENTS A 1 - 1 1
1.6.2 Functions of Weld Stick Detection Un i t
This unit output an error when the time period in which the welding voltage goes
down below the weld stick detection level during welding (while WCR relay is ON)
exceeds the setting time of the timer (TI).
This timing chart is shown in Fig.1.6.2.1
CR 1 :Welding Voltage Detection Auxiliary Relay
WCR :Welding Current Detection Relay
CR2 ,CR3 :Welding Voltage Detection Star t Relay
T 1 :Weld Stick Detection Output, Detection Delay Timer
Weld Stick
- - - - - - -
I I I I l l I l l I I I I I l l I I I I I I I I l l I l l I I l l I l l I l l I
I I I I l l I I I
I l l I I
I 1 1 1 1 I I l l I l l I
I l l I I l l I l l
I I Abnormal
t:Timer Setting Output
CR1 EFF I 1 ~ 1 ~ I I ~ I I I I I I l l 1 I I l l I I I I I I l l 1 < t I l l l < t I I I I mii""-- 7-i- I l l I
I I I I I
I I I
Fig.1.6.2.1 Timing Chart of Weld Stick Detection
I I l l I I l l
I l l I l l
A 1 - 1 2 APPENDIX 1-WELDING EQUIPMENTS
I
WCR gFF 1 1 1 I I I I l l I
I I I I l l I l l I I
I I I I l l I I I I I I I l l I I I I I I I l l I l l I
I l l I l l I I
I l l ON I l l I l l I l l I
I l l
OFF I 0 1 1 , I l l
I I I I l l I l l I
1.6.3 Connecting Weld Stick Detection Uni t Referring to Fig.l.6.3.1,follow the procedures of connection described below:
A WARNING Turn OFF the switch of the distribution panel and confirm that power supply is shut off prior to the connection of cables.
WELD STICK Welding Power Supply (1) Installing Unit DETECTION UNIT (VRTP-300 S-5 etc.)
Install this unit away from welding
power supply.
(2) Connecting Welding Voltage Detection
Cable
Welding voltage detection cable should
be connected to different printed
boards according to welding power Jcik~elding Power Cable supplies.Refer to TABLE 1.6.3.1 to Torch.WorkPiece
connect the cable.
Install this connecting cable away
from the welding cables.
TABLE 1.6.3.1 Printed Boards to connect Workpiece Welding Torch
Welding Voltage Detection Cable
P6768T P9943T Printed Board % Electric Protection
CN8 Connector
%When to use AEP-300,disconnect the
connector (CN2) of the welding WELD STICK DETECTION UNIT
voltage detection cable,and connect it : to the pins No.5 and No.6 of the
electric protection connector (9-pin
connector) within the welding power
supply.
(3) Connecting WCR Input,Output Cables
Terminal numbers of WCR input cable
vary with welding power supplies.
Refer to TABLE 1.6.3.2 to connect the
cable.
Install this connecting cable away
from the welding cables.
WCR INPUT
WCR OUTPUT
Weld Stick Detection (Abnormal Output)
APPENDIX 1-WELDING EOUIPMENTS A I - 1 3
Install this connecting cable away from other connecting cables.
TABLE 1.6.3.2 Terminal Number to conliect WCR Input Cable
Fig.1.6.3.1 External connection of Weld Stick Detection Unit
Welding Power
Supply Type
Connected place
A 1 - 1 4 APPENDIX ?-WELDING EQUIPMENTS
(4) Connecting Weld Stick Detection Cable
VRTP -300
P.C.B P6773Q
TB CN12 No.7 and 8
(WCR)
AVP -300
P.C.B P6783Q
TB CN12 No.7 and 8
(WCR)
AVP -500
WCR wire No. 162,163
AEP -300
WCR wire No.
59,60
1.7 Connection Examples of Various Welding Power Supplies This section describes the connection of the aforementioned welding interface and the
welding power supplies with the following welding power supplies as examples:
C02/MAG/MIG Welding Power Supply
(1) Almega Auto II 350/500(CPVAS-350/500)
(2) Almega Fuzzy Auto 350(CPDA-350)
(3) Inverter Auto 350TB(CPVB-350)
(4) Inverter Auto TURBO PULSE 350(CPVP-350),Inverter MIG PULSE AUTO 350
(CPVPA-350)
(5) Inverter MIG WAVE PULSE 350/500(CPVWP-350/500)
(6) Transistor PULSE AUTO 350/500(TRA-350/500)
TIG Welding Power Su~rsly
(1) Inverter ACCUTIG 300P/500~(~VP-300/500)
(2) Inverter ACCUTIG 300P/500P(AVP-300/50O)with filler wire feed
(3) Inverter ARGO 300P(VRTP-300),Pulse COMPA 300P(AEP-300)
(4) Inverter ARGO 300P(VRTP-300),Pulse COMPA 300P(AEP-300)with filler wire feed
Air Plasma Cutting Power Supply
(1) Super Plasma D-12000(TRC-120)
(2) Super Plasma D-8000(TRC-81)
WARNING Turn OFF the switch of the distribution panel and confirm that power supply is shut off prior to the connection of cables.
ELECTRIC SHOCK
@Do not touch live electrical
@Disconnect all power before installing or servicing.
@Multiple sources of voltage may exist inside this
APPENDIX 1-WELDING EQUIPMENTS A 1 - 1 5
1.7.1 CO~/MAG/MIG Welding Power Supply (1) Almega Auto 11 350/500 (CPVAS-350/500)
;g Pswer SaPeiv R o b o t C o n t r o
1 1 I C N 3 C N 2 CNI I Man i n u
B - )
3
Fig. 1.7.1.1 Connection of COJMAG Welding Power Supply,
Almega Auto I[ 350/500 (CPVAS-350/500) A 1 - 1 6 APPENDIX 1-WELDING EQUIPMENTS
(2) Almega Fuzzy Auto 350 (CPDA-350)
Fig. 1.7.1.2 Connection of COJMAG Welding Power Supply,
Almega Fuzzy Auto 350 (CPDA-350)
APPENDIX 1-WELDING EQUIPMENTS A 1 - 1 7
(3) Inverter Auto 350TB (CPVB-350)
W? 1 d i n g Fower SGPP I Y W e l d i n g Interface CFVB-350
r-----l
--- .- --i
R o b o t C o n t r o l Un
Fig.1.7.1.3 Connection of COu'MAG Welding Power Supply,
Inverter Auto 350TB (CPVB-350)
A 1 - 1 8 APPENDIX $-WELDING EQUIPMENTS
(4) Inverter Auto TURBO PULSE 350(CPVP-350),Inverter MIG PULSE AUTO 350
We i d i ns Power SuPP i V W e l d i n g Interface i 1
CPVP-350/CPVPA-350 E 5 6 2 4 R c b c t C o r , t r o i Ur
Fig. 1.7.1.4 Connection of COz/MAG/MIG Welding Power Supply, Inverter Auto TURBO PULSE 350(CPVP-350)and Inverter MIG PULSE AUTO 350(CPVPA-350)
APPENDIX 1-WELDING EQUIPMENTS A I - 1 9
Fig.1.7.1.5 Connection of MIG Welding Power Supply, Inverter MIG WAVE PULSE 350/500 (CPVWP-350/500)
A 1 - 2 0 APPENDIX 1-WELDING EQUIPMENTS
(6) Transistor PULSE AUTO 350/500(TRA-350/500)
r - - - - - - - - - - - - - -
,#Setting o f P. C. 0. ~ 5 6 2 4 ~ ; REF1 : 15V, iE(P0SITIVE) REF2: 15V. iE(P0SITIVE) i
We id i ns Power S u P P i Y W e l d i n g i n t e r f a c e J
T R A - 3 5 0 / 5 0 0 E5624 R o b o t C o n t r o l U n i t
Fig.1.7.1.6 Connection of MIG Welding Power Supply,
Transistor PULSE AUTO 350/500 (TRA-350/500)
APPENDIX 1-WELDING EQUIPMENTS A 1 - 2 1
1.7.2 TIG Welding Power Supply (1) Inverter ACCUTIG 300P (AVP-300), Inverter ARGO 300P (VRTP-3001,
I R e m o t e Box Connect the Pemcte Box o f k'eIdi?l Pore? SuPoiY. rn rhsn uss Pulss chirrent. psg
L 'Setis6 b l R C Snt ted bl Rtaote
- -. . -. .. -. - - . -. . .- . - 5243EG3 3-1
Welding Power Supply AvP/VRTP/AEP
Fig. 1.7.2.1 Connection of TIG Welding Power Supply, Inverter ACCUTIG 300P (AVP-300) Inverter ARGO 300P (VRTP-300) and Pulse COMPA 300p(AEP-300)
A 1 - 2 2 APPENDIX I-WELDING EOUIPMENTS
(2) Inverter ACCUTIG 300P (AVP-3001, Inverter ARGO 300P (VRTP-SOO), Pulse COMPA 300P (AEP-300) with filler wire feed
R o c o t C c n t r s i Unit
. --
C1 - . i . C L f r
Welding Power Supply AVP/VRTP/AEP Fig.1.7.2.2 Connection of TIG Welding Power Supply,
Inverter ACCUTIG 300P (AVP-300), Inverter ARGO 300P (VRTP-300) and Pulse COMPA 300P (AEP-300) with filler wire feed
APPENDIX 1-WELDING EQUIPMENTS A 1 - 2 3
1.7.3 Air Plasma Cutting Power Supply (I) Super Plasma D-12000 (TRC-120)
C b t t i r i p P L v , f r S:';F: Y T F ; - ; ? i
Fig.1.7.3.1 Connection of Air Plasma Power Supply, Super Plasma D-12000 (TRC-120)
- 2 4 APPENDIX 1-WELDING EQUIPMENTS
(2) Super Plasma D-8000(TRC-81)
C r : r z F o r ~ r S T C 1 % VCP E
Fig. 1.7.3.2 Connection of Air Plasma Power Supply ,Super Plasma D-8000 (TRC-81)
APPENDIX 1-WELDING EQUIPMENTS A 1 - 2 5
Various kinds of welding machines are available from DAlHEN. DAlHEN produces and sells every kinds of welding machines.
ITEMS OF MAIN PRODUCTS
ARC WELDING MACHINES
AC ARC WELDING MACHINES
DC ARC WELDING MACHINES
CO, GAS-SHIELDED ARC WELDING MACHINES
M A G ARC WELDING MACHINES
MIG ARC WELDING MACHINES
TIG ARC WELDING MACHINES
SUBMERGED ARC WELDING MACHINES
NO-GAS-SHIELDED ARC WELDING MACHINES
STUD WELDING MACHINES
AIR PLASMA CUTTING MACHINES
ARC WELDING ROBOT
CO, LASER EQUIPMENTS
Printed in Japan
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