Fanuc R J3ib Controller 6b1e4v

FANUC Robotics R-J3iBMate Controller (RIA R15.06 – 1999 Compliant) Maintenance Manual MARMIBRIA01021E REV. B B-81535EN/02

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

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

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

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

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

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

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

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

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

Safety-2

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION

Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety: • • • • • •

Keeping People and Equipment Safe

The safety of people is always of primary importance in any situation. However, equipment must be kept safe, too. When prioritizing how to apply safety to your robotic system, consider the following: • • • • •

Using Safety Enhancing Devices

People External devices Robot(s) Tooling Workpiece

Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the installation of some or all of the following devices: • • • • • • • • •

Setting Up a Safe Workcell

The safety of people and equipment Use of safety enhancing devices Techniques for safe teaching and manual operation of the robot(s) Techniques for safe automatic operation of the robot(s) Regular scheduled inspection of the robot and workcell Proper maintenance of the robot

Safety fences, barriers, or chains Light curtains Interlocks Pressure mats Floor markings Warning lights Mechanical stops EMERGENCY STOP buttons DEAN switches

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

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

Safety-3 •

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

•

Use anti–tie–down logic to prevent the operator from bying safety measures.

•

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

•

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

•

Position all controllers outside the robot work envelope.

•

Never rely on software as the primary safety element.

•

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

•

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

•

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

•

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

•

Use interlocks.

•

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

•

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

Safety-4

Staying Safe While Teaching or Manually Operating the Robot

•

Make sure all external devices are properly filtered, grounded, shielded, and suppressed to prevent hazardous motion due to the effects of electro–magnetic interference (EMI), radio frequency interference (RFI), and electro–static discharge (ESD).

•

Make provisions for power lockout/tagout at the controller.

•

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

•

Provide enough room inside the workcell to permit personnel to teach the robot and perform maintenance safely.

•

Program the robot to load and unload material safely.

•

If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and beacons.

•

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

Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules: • • •

• •

Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery. Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment. Before teaching, visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These include tooling attached to the wrist flange that extends this range. The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe working conditions to the supervisor or safety department. FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except for robot teaching operations. However, if you must enter the work envelope, be sure all safeguards are in place, check the teach pendant DEAN switch for proper operation, and place the robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the DEAN switch. Only the person with the teach pendant should be in the work envelope.

Safety-5

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

• • •

Know the path that can be used to escape from a moving robot; make sure the escape path is never blocked. Isolate the robot from all remote control signals that can cause motion while data is being taught. Test any program being run for the first time in the following manner: WARNING Stay outside the robot work envelope whenever a program is being run. Failure to do so can result in injury.

-

•

Staying Safe During Automatic Operation

Using a low motion speed, single step the program for at least one full cycle. - Using a low motion speed, test run the program continuously for at least one full cycle. - Using the programmed speed, test run the program continuously for at least one full cycle. Make sure all personnel are outside the work envelope before running production.

Advise all personnel who operate the robot during production to observe the following rules: •

Make sure all safety provisions are present and active.

•

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

•

Understand the complete task the robot is programmed to perform before initiating automatic operation.

•

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

Safety-6

Staying Safe During Inspection

Staying Safe During Maintenance

•

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

•

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

•

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

•

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

•

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

•

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

When inspecting the robot, be sure to •

Turn off power at the controller.

•

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

•

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

•

If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY STOP button on the operator .

•

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

•

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

•

Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not ed or resting on a hard stop. the arm on a solid before you release the brake.

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

Safety-7 •

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

•

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

•

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

•

Consider all or any overlapping work envelopes of ading robots when standing in a work envelope.

•

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

•

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

•

Whenever possible, perform maintenance with the power turned off. Before you open the controller front or enter the work envelope, turn off and lock out the 3–phase power source at the controller.

•

Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not ed or resting on a hard stop. the arm on a solid before you release the brake. WARNING Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit breaker to the OFF position removes power from the output side of the device only.

•

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

Safety-8 •

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

•

Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked.

•

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

WARNING Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Doing so can result in serious personal injury and component destruction. •

Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not ed or resting on a hard stop. the arm on a solid before you release the brake.

•

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

•

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

•

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

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

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

Programming Safety Precautions

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

Safety-9

Mechanical Safety Precautions

•

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

•

Implement ‘‘failure routines” in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails.

•

Use handshaking protocol to synchronize robot and external device operations.

•

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

Implement the following mechanical safety measures to prevent damage to machine tools and other external devices. •

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

•

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

KEEPING THE ROBOT SAFE

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

Operating Safety Precautions

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

Programming Safety Precautions

•

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

•

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

•

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

•

Use circuit breakers to guard against electrical overload.

The following safety measures are designed to prevent damage to the robot during programming: •

Establish interference zones to prevent collisions when two or more robots share a work area.

Safety-10 •

Make sure that the program ends with the robot near or at the home position.

•

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

•

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

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

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS

Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personal also must work inside the paint booth periodically. Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor. Although paint booth hazards have been minimized, potential dangers still exist. Therefore, today’s highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its capabilities. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools. Paint robots are operated in three modes: • Teach or manual mode • Automatic mode, including automatic and exercise operation • Diagnostic mode During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant. In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control (M), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth or in a designated safe

Safety-11 area within the booth whenever automatic mode is initiated at the SOC or M. In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds. When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.

Paint System Safety Features

Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment, personnel must comply strictly with the procedures in the manuals. This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system. The paint system includes the following safety features: •

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

•

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

•

EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become familiar with the locations of all E– STOP buttons.

•

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

•

A DEAN switch is located on each teach pendant. When this switch is held in, and the teach pendant is on, power is applied to the robot servo system. If the engaged DEAN switch is released during robot operation, power is removed from the servo system, all axis brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within the system might also E–STOP other robots. WARNING An EMERGENCY STOP will occur if the DEAN switch is released on a byed robot.

Safety-12 •

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

•

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

•

Staying Safe While Operating the Paint Robot

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

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

WARNING Observe all safety rules and guidelines to avoid injury.

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

•

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

•

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

•

Be aware of overlapping work envelopes of adjacent robots.

•

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

Safety-13

Staying Safe While Operating Paint Application Equipment

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

Follow the procedures described in this manual.

When you work with paint application equipment, observe the following rules, in addition to all rules for safe operation that apply to all robot systems. WARNING When working with electrostatic paint equipment, follow all national and local codes as well as all safety guidelines within your organization. Also reference the following standards: NFPA 33 Standards for Spray Application Using Flammable or Combustible Materials, and NFPA 70 National Electrical Code.

Safety-14

Staying Safe During Maintenance

•

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

•

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

•

Avoid any accumulation of combustible vapors or coating matter.

•

Follow all manufacturer recommended cleaning procedures.

•

Make sure all interlocks are operational.

•

No smoking.

•

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

•

Disable all air and paint pressure to bell.

•

that the lines are not under pressure.

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

Paint robots operate in a potentially explosive environment. Use caution when working with electric tools.

•

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

•

For some maintenance procedures, station a second person at the control within reach of the EMERGENCY STOP button. This person must understand the robot and associated potential hazards.

Safety-15 •

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

•

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

•

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

•

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

•

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

•

When using vinyl resin observe the following:

•

-

Wear eye protection and protective gloves during application and removal

-

Adequate ventilation is required. Overexposure could cause drowsiness or skin and eye irritation.

-

If there is with the skin, wash with water.

When using paint remover observe the following:

-

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

-

Adequate ventilation is required. Overexposure could cause drowsiness.

-

If there is with the skin or eyes, rinse with water for at least 15 minutes.

Update Section Single Phase Power Option

Table of Contents

B–81535EN/02

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p–1

I SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

OPERATOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.1 1.1.2 1.1.3

1.2

SAFETY OF THE TOOLS AND PERIPHERAL DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1 1.2.2

1.3

Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY OF THE ROBOT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.1 1.3.2 1.3.3

1.4

Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety of the Teach Pendant Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions in Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY OF THE END EFFECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.1

Precautions in Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 6 7 9

10 10 10

11 11 11 11

12 12

1.5

SAFETY IN MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

1.6

WARNING LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

II MAINTENANCE 1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

2. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

2.1

EXTERNAL VIEW OF THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

2.2

COMPONENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

2.3

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

3.1

POWER CANNOT BE TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1 3.1.2

3.2

Teach Pendant Cannot be Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Screen Remains on the Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALARM OCCURRENCE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 27 28

29

3.3

SAFETY SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

3.4

MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

3.5

TROUBLESHOOTING USING THE ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

3.6

TROUBLESHOOTING USING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92

3.7

TROUBLESHOOTING BASED ON LED INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97

3.8

POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107

3.9

VIBRATION OBSERVED DURING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108

3.10

MANUAL OPERATION IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109

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4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 4.1

ROBOT CONTROL BOARD (A16B–3200–0450) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112

4.2

EMERGENCY STOP BOARD (A20B–1008–0010, –0011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116

4.3

BACKPLANE BOARD (A20B–2003–0330) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

117

4.4

PROCESS I/O BOARD HE (A16B–2203–0764), HF (A16B–2203–0765) . . . . . . . . . . . . . . . . . . .

118

5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 5.1

OUTLINE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 5.1.2

5.2

Power Supply Module PSM (A06B–6115–H001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo Amplifier Module (A06B–6114–H205, A06B–6114–H302) . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 5.2.2

LED of Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED of Servo Amplifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121 121 122

123 123 124

6. SETTING THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 6.1

BLOCK DIAGRAMS OF THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

126

6.2

CHECKING THE POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

127

6.3

CHECKING THE POWER SUPPLY MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

127

7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 7.1

REPLACING THE PRINTED–CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 7.1.2 7.1.3

Replacing the Backplane Board (Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit . . . . . . . . . . . Replacing the Emergency Stop Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

129 130 131 132

7.2

REPLACING CARDS AND MODULES ON THE ROBOT CONTROL BOARD . . . . . . . . . . . . .

133

7.3

REPLACING THE TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137

7.3.1

Replacing the Brake Power Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137

7.4

REPLACING THE EMERGENCY STOP UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

138

7.5

REPLACING THE MAGNETIC OR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

139

7.6

REPLACING SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140

7.7

REPLACING THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141

7.8

REPLACING THE CONTROL SECTION FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142

7.9

REPLACING THE FAN MOTOR OF THE SERVO AMPLIFIER CONTROL UNIT . . . . . . . . . .

143

7.10

REPLACING THE DOOR FAN UNIT AND HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . .

144

7.11

REPLACING THE OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145

7.12

REPLACING THE POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

146

7.13

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

147

7.13.1 7.13.2 7.13.3 7.13.4 7.13.5 7.13.6

7.14

REPLACING A RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14.1

7.15

Replacing a Fuse on the Robot Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing a Fuse on the Emergency Stop Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Servo Amplifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Fuse on the Process I/O Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing a Relay on the Emergency Stop Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15.1

Battery for Memory Backup (3 VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

c–2

147 148 149 150 151 152

153 153

154 154

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III CONNECTION 1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 3. CONNECTION DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 3.1

CONNECTION OF POWER SUPPLY CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

162

3.2

FANUC I/O LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

163

3.3

CONNECTION OF I/O LINK CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

165

3.4

EMERGENCY STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

167

3.4.1 3.4.2 3.4.3 3.4.4

Circuit Diagram of Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Emergency Stop Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Emergency Stop Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External 24 V Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

167 168 169 170

3.5

COONECTION OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

171

3.6

CONNECTION OF ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172

3.7

CONNECTION OF TEACH PENDANT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173

3.8

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

174

CONNECTING A CABLE TO A PERIPHERAL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

175

3.9

3.9.1 3.9.2 3.9.3 3.9.4 3.9.5

3.10

END EFFECTOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.1 3.10.2

3.11 3.12

Peripheral Device Interfaces CRM79 and CRM81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When the Robot is Connected to the CNC by a Peripheral Device Cable . . . . . . . . . . . . . . . . . . . . . . . Digital I/O Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.3.1 Peripheral device interface CRM 79 and CRM 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital I/O Signal Specifications of End Effector Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . .

175 176 193 193 195 196

197 197 199

TREATMENT FOR THE SHIELDED CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200

PERIPHERAL DEVICE, ARC WELDING, INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201

3.12.1 3.12.2 3.12.3 3.12.4 3.12.5 3.12.6 3.12.7 3.12.8 3.12.9 3.12.10

Peripheral Device Interface Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Interface Block Diagram and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection Between the Control Unit and Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital I/O Signal Specifications of Peripheral Device Interface A . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O Signal Specifications for ARC–Welding Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin, 50 pins) . . . . . . ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 202 203 208 214 216 219 219 220 221

4. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 4.1

TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

223

4.2

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

223

4.3

EXTERNAL CONTROLLER DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

224

4.4

INSTALLATION CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

225

4.5

ADJUSTMENT AND CHECKS AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

225

4.6

NOTE AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

226

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4.7

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DISABLING HAND BREAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

226

APPENDIX A. TOTAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 B. PERIPHERAL INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 B.1 B.2

SIGNAL TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

239

I/O SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240

B.2.1 B.2.2

B.3

Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS OF DIGITAL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.1 B.3.2 B.3.3

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input/Output Hardware Usable in the R-J3iB Mate Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240 241

242 242 242 243

C. OPTICAL FIBER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

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PREFACE

PREFACE

This manual describes the following models. Model

Abbreviation

FANUC Robot LR Mate 100iB

LR Mate 100iB

FANUC Robot LR Mate 200iB

LR Mate 200iB

FANUC Robot ARC Mate 50iB

ARC Mate 50iB

p–1

I SAFETY PRECAUTIONS

B–81535EN/02

1

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

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

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1. SAFETY PRECAUTIONS

1.1 OPERATOR SAFETY

SAFETY PRECAUTIONS

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Operator safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure operator safety. (1) Have the robot system operators attend the training courses held by FANUC. FANUC provides various training courses. our sales office for details.

(2) Even when the robot is stationary, it is possible that the robot is still ready to move state and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure operator safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. (3) Install a safety fence with a gate so that no operator can enter the work area without ing through the gate. Equip the gate with an interlock that stops the robot when the gate is opened. The controller is designed to receive this interlock signal. When the gate is opened and this signal received, the controller stops the robot in an emergency. For connection, see Fig.1.1.

(4) Provide the peripheral devices with appropriate grounding (Class 1, Class 2, or Class 3). (5) Try to install the peripheral devices outside the work area. (6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when an operator enters the work area. (8) If necessary, install a safety lock so that no one except the operator in charge can turn on the power of the robot. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.

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SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

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

Safety gate which executes with opening the door.

Fig.1.1 Safety Fence and Safety Gate

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1. SAFETY PRECAUTIONS

1.1.1 Operator Safety

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The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators. (1) If it is not necessary for the robot to operate, turn off the power of the robot controller or press the EMERGENCY STOP button, and then proceed with necessary work. (2) Operate the robot system at a location outside the work area. (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the work area unexpectedly and also to prevent the worker from entering a dangerous area. (4) Install an EMERGENCY STOP button within the operator’s reach. The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

External EMERGENCY STOP button

Emergency stop board EMGIN11 EMGIN12 EMGIN21 EMGIN22

Note)

Connect between EMGIN1 and EMGIN2 and between EMGIN21 and EMGIN22. EMGIN11, EMGIN12, EMGIN21 and EMGIN22 are on the emergency stop board.

Fig.1.1.1 Connection Diagram for External Emergency Stop Switch

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1.1.2 Safety of the Teach Pendant Operator

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

While teaching the robot, it is necessary for the operator to enter the work area of the robot. It is particularly necessary to ensure the safety of the teach pendant operator. (1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating condition. (3) When entering the robot work area and teaching the robot, be sure to check the location and condition of the safety devices (such as the EMERGENCY STOP button and the dean switch on the teach pendant). FANUC’s teach pendant has a switch for enabling or disabling the robot operation from the teach pendant and a dean switch in addition to the EMERGENCY STOP button. The switches function as follows. EMERGENCY STOP button : Pressing this button always brings the robot to an emergency stop, irrespective of the state of the enable/disable switch and the mode switch of operator . Dean switch

: The function of this switch depends on the state of the enable/disable switch and the mode switch of operator .

When the mode switch is in the AUTO position – The enable/disable switch and dean switch are disabled. When the mode switch is in the TI position and the enable/disable switch is in the enable position – Releasing the dean switch brings the robot to an emergency stop. When the mode switch is in the TI position and the enable/disable switch is in the disable position – The robot is brought to an emergency stop regardless of the operation of the dean switch. Note)The dean switch is provided to bring the robot to an emergency stop when the operator releases the teach pendant in an emergency.

(4) The teach pendant operator should pay careful attention so that no other workers enter the robot work area. NOTE In addition to the above, the teach pendant enable switch and the dean switch also have the following function. By pressing the dean switch while the enable switch is on, the emergency stop factor (normally the safety gate) connected to FENCE11 and FENCE12 of the controller is invalidated. In this case, it is possible for an operator to enter the fence during teach operation without making the robot in the emergency stop condition. In other words, the system understands that the combined operations of pressing the teach pendant enable switch and pressing the dean switch indicates the start of teaching. The teach pendant operator should be well aware that the safety gate is not functional under this condition and bear full responsibility to ensure that no one enters the fence during teaching.

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(5) When entering the robot work area, the teach pendant operator should enable the teach pendant whenever he or she enters the robot work area. In particular, while the teach pendant enable switch is off, make certain that no start command is sent to the robot from any operator other than the teach pendant. The teach pendant, operator , and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode of the teach pendant enable switch and the mode switch the remote switch on the operator .

Operator mode switch

Teach pendant enable switch

Remote condition

Teach pendant

Operator

Peripheral devices

T1

On

Independent

Allowed to start

Not allowed

Not allowed

AUTO

Off

Local

Not allowed

Allowed to start

Not allowed

AUTO

Off

Remote

Not allowed

Not allowed

Allowed to start

(6) When a program is completed, be sure to carry out a test run according to the procedure below. (a) Run the program for at least one operation cycle in the single step mode at low speed. (b) Run the program for at least one operation cycle in the continuous operation mode at low speed. (c) Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing. (d) Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble. (e) After checking the completeness of the program through the test run above, execute it in the automatic operation mode. (7) While operating the system in the automatic operation mode, the teach pendant operator should leave the robot work area.

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1.1.3 Safety During Maintenance

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

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

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1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 1.2.1 Precautions in Programming

(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received. (2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal. (3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other. (4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states.

1.2.2 Precautions for Mechanism

(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of grease, water, and dust. (2) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot does not come into with its peripheral devices or tools.

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1.3 SAFETY OF THE ROBOT MECHANISM 1.3.1 Precautions in Operation

1.3.2 Precautions in Programming

1.3.3 Precautions for Mechanisms

(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality. (2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the jog mode.

(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere with each other. (2) Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

(1) Keep the work area of the robot clean, and operate the robot in an environment free of grease, water, and dust.

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SAFETY PRECAUTIONS

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1.4 SAFETY OF THE END EFFECTOR 1.4.1 Precautions in Programming

(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control. (2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.

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1.5 SAFETY IN MAINTENANCE

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

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

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1.6 WARNING LABEL Description

Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing as well. (1) Step–on prohibitive label

Fig.1.6 (a) Step–on Prohibitive Label

Description

Be cautious about a section where this label is affixed, as the section generates heat. If you have to inevitably touch such a section when it is hot, use a protective provision such as heat–resistant gloves. (2) High–temperature warning label

Fig.1.6 (b) High–Temperature Warning Label

Description

A high voltage is applied to the places where this label is attached. Before starting maintenance, turn the power to the control unit off, then turn the circuit breaker off to avoid electric shock hazards. Be careful with servo amplifier and other units because high–voltage places in these units may remain in the high–voltage state for a fixed time. 14

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1. SAFETY PRECAUTIONS

(3) High–voltage warning label

Fig.1.6 (c) High–Voltage Warning Label

Description

There may be a high voltage in a place with this label. Before working on such a portion, turn off the power to the controller and set its circuit breaker to the off position to avoid shock hazards. In addition, be careful about servo amplifiers and other electric circuits because a high voltage may remain in them for a certain period of time after the power is turned off.

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II MAINTENANCE

MAINTENANCE

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1

1. OVERVIEW

OVERVIEW

This manual describes the maintenance and connection of the R–J3iB Mate robot controller (called the R–J3iB Mate). Maintenance Part : Troubleshooting, and the setting, adjustment, and replacement of units Connection Part : Connection of the R–J3iB Mate controller to the robot mechanical unit and peripheral devices, and installation of the controller WARNING Before you enter the robot working area, be sure to turn off the power to the controller or press the EMERGENCY STOP button on the operator or teach pendant. Otherwise, you could injure personnel or damage equipment.

TERM The R–J3iB Mate robot controller uses the FANUC servo amplifier α i series (called the servo amplifier (i). The servo amplifier α i comprises a power supply module (PSM) and a servo amplifier module (SVM). In this manual, the “power supply module” and “servo amplifier module” refer to the individual modules. The term “servo amplifier” refers to the combination of the power supply module and servo amplifier module.

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2. CONFIGURATION

2

MAINTENANCE

CONFIGURATION

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2.1 EXTERNAL VIEW OF THE CONTROLLER

2. CONFIGURATION

MAINTENANCE

The appearance and components might slightly differ depending on the controlled robot, application, and options used. Fig.2.1 (a) shows the view of R–J3iB Mate. Fig.2.1 (b) shows the R–J3iB Mate consists of the R–J3iB Mate controller. Teach pendant R–J3iB Mate controller

Operator

Teach pendant cable

Fan unit

Fig.2.1 (a) External View of the R–J3iB Mate Controller

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2. CONFIGURATION

MAINTENANCE

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Teach pendant Power supply transformer Enable/disable switch Emergency stop for brake button

Emergency stop unit Power supply unit Emergency stop board Circuit protector Emergency stop button

Heat exchange

Mode switch

Back plane board Option slot (Process I/O board) Robot control board Servo amplifier module2 (AMP2) Servo amplifier module1 (AMP1) Power supply module (PSM)

Fuse MCC

Fig.2.1 (b) R–J3iB Mate interior (Front) Table 2.1 Servo amplifier specifications Robot LR Mate 100iB

LR Mate 200iB ARC Mate 50iB

Power supply module A06B–6115–H001 (αPSMR–1i)

Servo amplifier module1 A06B–6114–H205 (αSVM–20/20i) L M J1 J2 A06B–6114–H302 (αSVM–10/10/10i) L M N J1 J2 J3

A06B–6115–H001 (αPSMR–1i)

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Servo amplifier module2 A06B–6114–H302 (αSVM–10/10/10i) L M N J3 J4 J5 A06B–6114–H302 (αSVM–10/10/10i) L M N J4 J5 J6

MAINTENANCE

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2.2 COMPONENT FUNCTIONS

2. CONFIGURATION

– Robot control printed circuit board This board is equipped with a microprocessor and its peripheral circuitry, memory, and operator control circuit. A servo control circuit is also included. – Emergency stop unit, emergency stop printed circuit board This unit controls the emergency stop system, magnetic or (MCC) of the servo amplifier, and brake. The unit contains the power supply unit for converting the AC power to the DC power. – Backplane board –

–

– –

– –

Various control boards are mounted on the backplane board. Teach pendant This unit is used to carry out all operations including robot programming. The liquid crystal display (LCD) of this unit displays the status of the control unit, data, and the like. Servo amplifier The servo amplifier amplifies the power of the servo amplifier and controls the pulse coder. MCC The MCC controls the main power of the servo amplifier. Operator The operator has a port for the serial interface to an external device. The also has an EMERGENCY STOP button. Fan unit, heat exchanger These components are used to cool the inside of the control unit. Circuit protector This component turns on or off the power. The input power is connected to the circuit protector in order to protect the equipment from a large current that could result from a problem in the electric system of the control unit or an abnormal input power.

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2.3 PREVENTIVE MAINTENANCE

MAINTENANCE

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

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3

3. TROUBLESHOOTING

TROUBLESHOOTING

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

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3.1 POWER CANNOT BE TURNED ON Check and Corrective action (Check 1)

Check that the circuit protector is on and has not tripped.

(Corrective action)

Turn on the circuit protector.

(Check 2)

Check that the door fan unit and the fan motor of the heat exchanger are rotating and that the LED indication on the power supply module is “–”.

(Corrective action)

If the fan motor is not rotating or if the LED of the power supply module is not glowing, the fuse on the back of the door may have been blown. – Check the fuse on the back of the door. If the fuse on the back of the door has been blown, replace the fuse.

Figure Circuit protector (on/off switch)

LED of the power supply module Circuit protector Heat exchange for fan unit (door face)

Secondary side of the circuit protector Fuse

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MAINTENANCE

3.1.1 Teach Pendant Cannot be Turned On Check and Corrective action (Check 1)

Check the LCD display and LED indication on the teach pendant.

(Corrective action)

Check the LCD display and LED indication on the teach pendant to see whether the emergency stop unit is faulty. – Check whether the fuse FUS4 on the emergency stop board is blown. If the fuse is blown, the FALM LED glows. Replace the blown fuse. – If the fuse FUS4 on the emergency stop board is not blown, the emergency stop unit may be faulty. Replace the emergency stop unit.

Figure Teach pendant

Emergency stop board FALM LED Fuse FUS4

Emergency stop unit

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3.1.2 Initial Screen Remains on the Teach Pendant Check and Corrective action (Check 1)

Check that the “.” portion of the seven– segment LED glows on the robot control board.

(Corrective action)

If the “.” portion is not glowing, the fuse FUS1 on the robot control board may be blown. Alternatively, the DC/DC converter module may be damaged. If the FUSE ALARM LED is glowing, the fuse FUS1 may be blown. The fuse FUS1 is provided on the robot control board. Before checking the fuse, turn off the circuit protector. a) If the fuse FUS1 has been blown – See Corrective action (1). b) If the fuse FUS1 is not blown – See Corrective action (2).

(Corrective action(1))

(Corrective action(2))

Figure

+24V input connector 5

Cause of the blowing of the fuse FUS1 and corrective action a) Check whether the device which is connected to the RS–232–C/ RS–422 port and requires the power supply of +24 V is sound. b) Problem in the DC/DC converter module If the DC/DC converter module gets faulty in the short–circuit mode, FUS1 is blown. Replace the DC/DC converter module.

DC/DC converter module dot part of seven segment LED

a) Problem in the DC/DC converter module Replace the DC/DC converter module. b) Problem in the robot control board Replace the robot control board. (For the LED indications, see Section 3.7, “TROUBLESHOOTING USING LEDS.”)

FUS1 7.5A DC24V input fuse

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3.2 ALARM OCCURRENCE SCREEN

3. TROUBLESHOOTING

MAINTENANCE

The alarm occurrence screen displays only the alarm conditions that are currently active. If an alarm reset signal is input to reset the alarm conditions, the alarm occurrence screen displays the message “PAUSE or more serious alarm has not occurred.” The alarm occurrence screen displays only the alarm conditions (if any) that occur after the most recently entered alarm reset signal. To erase all alarm displays from the alarm occurrence screen. Press the CLEAR key (+ shift) on the alarm history screen. The alarm occurrence screen is intended to display PAUSE or more serious alarms. It will not display WARN, NONE, or a reset. It is possible to disable PAUSE and some of more serious alarms from being displayed by setting the $ER_NOHIS system variable appropriately. If two or more alarms have occurred, the display begins with the most recent alarm. Up to 100 lines can be displayed. If an alarm has a cause code, it is displayed below the line indicating the alarm. Press the screen selection key to select [4 ALARM].

Press the alarm key.

Automatic alarm display upon occurrence

Alarm occurrence screen display

Press F3 [ACTIVE].

Press F3 [HIST].

Alarm history screen display

Fig.3.2 Alarm Occurrence Screen and Alarm History Screen Display Procedure

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Displaying the alarm history/alarm detail information

Step

(1) Press the MENUS key to display the screen menu. (2) Select [ALARM]. You will see a screen similar to the following 3 4 ALARM 5 I/O

INTP–224 (SAMPLE1, 7) Jump label is fail MEMO–027 Specified line does not exist Alarm T 30 % 1/25 1 INTP–224 (SAMPLE1, 7) Jump label is 2 SRVO–002 Teach pendant E–stop 3 R E S E T 4 SRVO–027 Robot not mastered(Group:1) 5 SYST–026 System normal power up

MENUS

[ TYPE ]

CLEAR

HELP

NOTE The latest alarm is assigned number 1. To view messages that are currently not on the screen, press the F5, HELP, then press the right arrow key. (3) To display the alarm detail screen, press F5, [HELP]. CLEAR

HELP F5

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

[ TYPE ]

CLEAR

HELP

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

(5) To delete all the alarm histories, press and hold down the SHIFT key, then press F4, [CLEAR]. CLEAR

SHIFT

F4

HELP

NOTE When system variable $ER_NOHIS = 1, NONE alarms or WARN alarms are not recorded. When $ER_NOHIS=2, resets are not recorded in the alarm history. When $ER_NOHIS=3, resets, WARN alarms, and NONE alarms are not recorded.

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MAINTENANCE

The following map indicates teach pendant operations used to check an alarm. 4 ALARM F1 [TYPE] Alarm : Active F1 [TYPE] F3 HIST Alarm : HIST F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP DETAIL Alarm F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP

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3.3 SAFETY SIGNALS

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

Safety signal

Description

Operator emergency stop

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

Teach pendant emergency stop

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

External emergency stop

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

Fence open

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

Dean switch

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

Teach pendant operable

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

Hand broken

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

Robot overtravel

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

Abnormal air pressure

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

Step

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

1 2 3 4 5 6 7 8 9

T 30%

SIGNAL NAME

STATUS

SOP E–Stop: TP E–stop: Ext E–Stop: Fence Open: TP Dean: TP Enable: Hand Broken: Over Travel: Low Air Alarm:

FALSE FALSE FALSE FALSE TRUE TRUE FALSE FALSE FALSE

[TYPE]

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3.4

Mastering is needed if:

MASTERING

(1) The SRVO 062 BZAL or SRVO 038 pulse mismatch alarm occurs, or (2) The pulse coder is replaced. Item (1) requires simplified mastering, while item (2) requires zero–degree or jig position mastering. (Zero–degree position mastering is just for quick–fix purposes. After zero–degree position mastering is used, jig position mastering should be performed later.) The mastering procedure is described below. For details, refer to an applicable maintenance manual of mechanical unit or operator’s manual of control unit.

Condition

System variable $MASTER_ENB must be set to 1 or 2. SYSTEM Variables 57 $MASTER_ENB

Step

T 10% 57/136 1

(1) Press <MENUS>. (2) Select SYSTEM. (3) Press F1, TYPE. (4) Select Master/Cal you will see a screen similar to the following. 9 0 –– NEXT ––

MENUS

5 POSITION 6 SYSTEM 7

Master/Cal TYPE

SYSTEM Master/Cal 1

FIXTURE POSITION MASTER

2 3 4 5 6

ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE

T 30%

Press ’ENTER’ or number key to select.

[TYPE]

LOAD RES_PCA

DONE

F1

(5) Move the robot by jog feed to the mastering position. Release the brake on the manual brake control screen if necessary. NOTE Mastering can not be performed until axis is rotated enough to establish a pulse.

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(6) Select “1 FIXTURE POSITION MASTER” and press the F4 key (yes). Mastering data is set. SYSTEM Master/Cal

SYSTEM Master/Cal ENTER

1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER Master at master position? [NO] Master at master position? [NO] [ TYPE ] YES

NO

F4

T

30 %

1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <122000309> <2000319>

[ TYPE ]

LOAD

RES_PCA

DONE

(7) Select “6 CALIBRATE” and press the F4 key (yes). Calibration is performed. Alternatively, to perform positioning, turn the power off, then turn it on again. Calibration is performed whenever the power is turned on. 5 SET QUICK MASTER REF 6 CALIBRATE ENTER Calibrate? [NO] Calibrate? [NO] [ TYPE ]

SYSTEM Master/Cal

YES

F4

NO

T

30 %

1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <10.000> <–25.000> <40.000> <5.000> <–15.000> <0.000> [ TYPE ] LOAD RES_PCA DONE

(8) Press F5 “DONE”, after mastering. DONE

F5

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3.5 TROUBLESHOOTING USING THE ERROR CODE

(1) SRVO–001 SVAL1 Operator E–stop (Explanation) The EMERGENCY STOP button on the operator is pressed. (Action 1) Release the emergency stop button pressed on the operator . (Action 2) Release the EMERGENCY STOP button on the operator . (Action 3) Replace the emergency stop unit. Before taking (Action 4), make a backup copy of all the programs and settings of the control unit. (Action 4) Replace the robot control board.

Emergency stop button

Operator

Robot control board Emergency stop unit

Fig.3.5 (1) (a) SRVO–001 SVAL1 Operator E–stop

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(2) SRVO–002 SVAL1 Teach pendant E–stop (Explanation) The emergency stop button on the operator’s Teach Pendant was pressed. (Action 1) Release the emergency stop button on the teach pendant. (Action 2) Replace Teach Pendant. Emergency stop button

Fig.3.5 (2) SRVO–002 SVAL1 Teach pendant E–stop

(3) SRVO–003 SVAL1 Dean switch released (Explanation) The teach pendant is enabled, but the dean switch is not pressed. (Action 1) Press the dean switch to run the robot. (Action 2) Replace the teach pendant.

Dean switch

Fig.3.5 (3) SRVO–001 SVAL1 Dean switch released

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(4) SRVO–004 SVAL1 Fence open (Explanation) In AUTO mode, there is no short circuit between FENCE11 and FENCE12 and between FENCE21 and FENCE22 on the terminal block TBEB5 of the emergency stop board. If the safety fence is connected between FENCE11 and FENCE12 and between FENCE21 and FENCE22, the door of the safety fence is open. (Action 1) When the safety fence is connected, close the door. (Action 2) Check the cables and switches connected to FENCE11, FENCE12, FENCE21 and FENCE22. (Action 3) When this signal is not used, short–circuit between FENCE11 and FENCE12 and between FENCE21 and FENCE22. NOTE In the system that uses the fence signal, do not short–circuit this signal to disable it because the operation is dangerous. When this signal must be temporarily short–circuited, make safety provisions separately. (Action 4)

When AUTO mode is not entered even though the mode switch is set to AUTO, the mode switch may be faulty. Replace the operator . Replace the emergency stop unit. Before taking (Action 6), make a backup copy of all the programs and settings of the control unit. Replace the robot control board.

(Action 5)

(Action 6)

Short connection boards: two positions (terminal blocks located on the right when viewing from the front)

Emergency stop unit

Fig.3.5 (4) SRVO–004 SVAL1 Fence open

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

Robot control board

Fig.3.5 (5) SRVO–005 SVAL1 Robot overtravel

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

Robot control board

Fig.3.5 (6) SRVO–006 SVAL1 Hand broken

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(7) SRVO–007 SVAL1 External E–stop (Explanation) EMGIN11 and EMGIN12/EMGIN21 and EMGIN22 on the terminal block TBEB5 of the emergency stop board are not short–circuited. If an external emergency stop switch is connected across EMGIN11 and EMGIN12/EMGIN21 and EMGIN22, the switch has been pressed. (Action 1) If an external emergency stop switch is connected, releases the switch. (Action 2) Check the switch and cable connected to EMGIN11 and EMGIN12 and to EMGIN21 and EMGIN22. (Action 3) When this signal is not used, make a connection between EMGIN11 and EMGIN12 and a connection between EMGIN21 and EMGIN22. (WARNING) (Action 4) Replace the emergency stop unit. WARNING Do NOT short–circuit, or disable, this signal in a system in which the External emergency stop input signal is in use, as it is very dangerous. If it is necessary to run the robot by short–circuiting the signal even temporarily, an additional safety provision must be provided.

Short connection boards: two positions (terminal blocks located on the left when viewing from the front)

Emergency stop unit

Fig.3.5 (7) SRVO–007 SVAL1 External E–stop

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

Robot control board

Fig.3.5 (8) SRVO–009 SVAL1 Pneumatic pressure alarm

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(9) SRVO–014 WARN Fan motor abnormal (Explanation) A fan motor in the backplane unit is abnormal. (Action) Check the fan motor and its cables. Replace them if necessary. Fan motor

Fig.3.5 (9) SRVO–014 WARN Fan motor abnormal

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(10) SRVO–015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j) (Explanation) The temperature in the control unit exceeds the specified value. (Action 1) If the ambient temperature is higher than specified (45°C), cool down ambient temperature. (Action 2) If the fan motor is not running, check it and its cables. Replace them if necessary. (Action 3) If the thermostat on the robot control board is defective, replace the robot control board.

Fan motor (on the heat exchange)

Fan motor (door face)

Robot control board

Fig.3.5 (10) SRVO–015 SVAL1 SYSTEM OVER HEAT

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

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Emergency stop unit

3. TROUBLESHOOTING

Robot control board Servo amplifier module Power supply module

Axis control card

Fig.3.5 (11) SRVO–021 SVAL1 SRDY off

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

Robot control board Servo amplifier module Power supply module Axis control card

Fig.3.5 (12) SRVO–022 SVAL1 SRDY on

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

Servo amplifier module Power supply module

Fig.3.5 (13) SRVO–023 SVAL1 Stop error excess

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

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

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

Power supply module

Fig.3.5 (27) SRVO–044 SVAL1 HVAL alarm

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

Robot control board Servo amplifier module

Fig.3.5 (28) SRVO–045 SVAL1 HCAL alarm

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

Servo amplifier module Power supply module

Fig.3.5 (29) SRVO–046 SVAL2 OVC alarm

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Reference

Relationships among the OVC, OVL, and HC alarms Overview This section points out the differences among the OVC, OVL, and HC alarms and describes the purpose of each alarm. Alarm detection section Abbreviation

Designation

Detection section

OVC

Overcurrent alarm

Servo software

OVL

Overload alarm

Thermal relay in the motor OHAL2 Thermal relay in the servo amplifier OHAL1 Thermal relay in the separate regenerative discharge unit DCAL

HC

High current alarm

Servo amplifier

Purpose of each alarm 1) HC alarm (high current alarm) If high current flow in a power transistor momentarily due to abnormality or noise in the control circuit, the power transistor and rectifier diodes might be damaged, or the magnet of the motor might be degaussed. The HC alarm is intended to prevent such failures. 2) OVC and OVL alarms (overcurrent and overload alarms) The OVC and OVL alarms are intended to prevent overheat that may lead to the burnout of the motor winding, the breakdown of the servo amplifier transistor, and the separate regenerative resistor. The OVL alarm occurs when each built–in thermal relay detects a temperature higher than the rated value. However, this method is not necessarily perfect to prevent these failures. For example, if the motor frequently repeats to start and stop, the thermal time constant of the motor, which has a large mass, becomes higher than the time constant of the thermal relay, because these two components are different in material, structure, and dimension. Therefore, if the motor repeats to start and stop within a short time as shown in Fig. 1, the temperature rise in the motor is steeper than that in the thermal relay, thus causing the motor to burn before the thermal relay detects an abnormally high temperature. Temperature Start

Stop

Start

Stop

Start Thermal time constant of the motor is high.

Temperature at which the winding starts to burn

Thermal time constant of the thermal relay is low.

Time

Fig.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles

To prevent the above defects, software is used to monitor the current in the motor constantly in order to estimate the temperature of the motor. The OVC alarm is issued based on this estimated temperature. This method estimates the motor temperature with substantial accuracy, so it can prevent the failures described above. 53

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To sum up, a double protection method is used; the OVC alarm is used for protection from a short–time overcurrent, and the OVL alarm is used for protection from long–term overload. The relationship between the OVC and OVL alarms is shown in Fig 2. Current Protection area for the motor and servo amplifier Protection by the OVL Limit current

Protection by the OVC

Rated continuous current Time

Fig.2 Relationship between the OVC and OVL alarms

NOTE The relationship shown in Fig. 2 is taken into consideration for the OVC alarm. The motor might not be hot even if the OVC alarm has occurred. In this case, do not change the parameters to relax protection. (30) SRVO–047 SVAL1 LVAL alarm (Group : i Axis : j) (Explanation) The control power voltage (+5 V, etc.) on the servo amplifier module is too low. The LED indication on the servo amplifier module is “2” (LVAL). (Action 1) Replace the servo amplifier module.

Servo amplifier module

Fig.3.5 (30) SRVO–047 SVAL1 LVAL alarm

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

Servo amplifier module Power supply module

Fig.3.5 (31) SRVO–049 SVAL1 OHAL1 alarm

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

Servo amplifier module Power supply module

Fig.3.5 (32) SRVO–050 SVAL1 CLALM alarm

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(33) SRVO–051 SVAL2 CUER alarm (Group : i Axis : j) (Explanation) The offset of the current value is abnormally high. (Action) Replace the servo amplifier module.

Servo amplifier module

Fig.3.5 (33) SRVO–051 SVAL2 CUER alarm

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(34) SRVO–054 DSM Memory Error (Explanation) An access to the axis control card on the robot control board memory fails. (Action) Replace the axis control card.

Robot control board Servo amplifier module Axis control card

Fig.3.5 (34) SRVO–054 DSM Memory Error

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

Robot control board Servo amplifier module Axis control card

Fig.3.5 (35) SRVO–055 SVAL2 FSSB com error 1

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

Robot control board Servo amplifier module Axis control card

Fig.3.5 (36) SRVO–056 SVAL2 FSSB com error 2

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

Robot control board Servo amplifier module Power supply module Axis control card

Fig.3.5 (37) SRVO–057 SVAL2 FSSB disconnect

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(38) SRVO–058 SVAL2 FSSB init error (Group : i Axis : j) (Explanation) Communication was interrupted between the robot control board and servo amplifier module. (Action 1) Check whether fuse FU1 in the power supply module have blown. If they have blown, see Section 3.6, “Troubleshooting for Blown Fuse.” (Action 2) Check whether seven segment LEDs on the servo amplifier module are on. If they are on, perform “Action 4” and all actions that follow it. If they are not on, perform “Action 3” and all actions that follow it. (Action 3) Check whether connector CX1 on the power supply module is securely connected. (Action 4) Check the communication cable (optical fiber) between the robot control board and servo amplifier module. Replace it if it is faulty. (Action 5) Replace the axis control card on the robot control board. (Action 6) If the seven–segment LED on the servo amplifier module is glowing, replace the servo amplifier module. If the seven–segment LED on the servo amplifier module is not glowing, replace the power supply module. Before continuing to the next step, perform a complete controller back–up to save all your programs and settings. Failure to perform this could result in damage to equipment or lost data. (Action 7) Replace the robot control board.

Robot controll board Servo amplifier module Power supply module Axis control card

Fig.3.5 (38) SRVO–058 SVAL2 FSSB init error

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(39) SRVO–059 SVAL2 Servo amp init error (Explanation) Servo amplifier initialzation is failed. (Action 1) Check all connectors on the PSM and SVM. Make sure they are installed correctly. (Action 2) Replace the power supply module and the servo amplifier module.

Servo amplifier module Power supply module

Fig.3.5 (39) SRVO–059 SVAL2 Servo amp init error

(40) SRVO–061 SVAL2 CKAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal count clock). (Action) Replace the pulse coder. NOTE In this case, perform actions associated with DTERR, CRCERR, or STBERR first. (41) SRVO–062 SVAL2 BZAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if battery for pulse coder absolute-position backup is empty. A probable cause is a broken battery cable or no batteries in the robot. (Action) Remove the cause of the alarm, set the system variable ($MCR.$SPC RESET) to TRUE, then turn the power off and on again. Mastering is required. (42) SRVO–063 SVAL2 RCAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal counter). (Action) Replace the pulse coder. NOTE In this case, perform actions associated with DTERR, CRCERR, or STBERR first.

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(43) SRVO–064 SVAL2 PHAL alarm (Group : i Axis : j) (Explanation) This alarm occurs if the phase of the pulses generated in the pulse coder is abnormal. (Action) Replace the pulse coder. NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm. (44) SRVO–065 WARN BLAL alarm (Group : i Axis : j) (Explanation) The battery voltage for the pulse coder is lower than the rating. (Action) Replace the battery. (If this alarm occurs, turn on the AC power and replace the battery as soon as possible. A delay in battery replacement may result in the BZAL alarm being detected. In this case, the position data will be lost. Once the position data is lost, mastering will become necessary. (45) SRVO–066 SVAL2 CSAL alarm (Group : i Axis : j) (Explanation) The ROM in the pulse coder is abnormal. (Action) Replace the pulse coder. NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm. (46) SRVO–067 SVAL2 OHAL2 alarm (Group : i Axis : j) (Explanation) The temperature inside the pulse coder or motor is abnormally high, and the built–in thermostat has operated. (Action 1) Check the operating conditions for the robot and relax the service conditions. (Action 2) When power is supplied to the motor after it has become sufficiently cool, if the alarm still occurs, replace the motor. (47) SRVO–068 SVAL2 DTERR alarm (Group : i Axis : j) (Explanation) The serial pulse coder does not return serial data in response to a request signal. –See actions on SRVO–070 (48) SRVO–069 SVAL2 CRCERR alarm (Group : i Axis : j) (Explanation) The serial data has disturbed during communication. –See actions on SRVO–070

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

Servo amplifier module

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

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

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

Servo amplifier module Power supply module

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

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

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

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

Power supply module

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

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

Magnetic or

Servo amplifier module Power supply module Emergency stop unit

Fig.3.5 (74) SRVO–134 SVAL1 DCLVAL (PSM) alarm

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(75) SRVO–135 SVAL FSAL alarm (Group : i Axis : j) (Explanation) The internal cooling fan(s) of the servo amplifier module(s) is abnormal. The LED indication on the relevant servo amplifier module is “1.” (Action 1) Replace the fan motor of the servo amplifier module. (Action 2) Replace the servo amplifier module.

Fan

Servo amplifier module

Servo amplifier module

Fig.3.5 (75) SRVO–135 SVAL FSAL alarm

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

Magnetic or

Robot control board Servo amplifier module Power supply module

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

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

Robot control board Servo amplifier module

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

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

Servo amplifier module Power supply module

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

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

emergency stop button

Power supply module Emergency stop unit

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

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

Teach pendant teach pendant cable

emergency stop button

Power supply module Emergency stop unit

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

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

Power supply module Emergency stop unit

Fig.3.5 (81) SRVO–204 SVAL1 External (SVEMG abnormal) E–stop

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

Power supply module Emergency stop unit

Fig.3.5 (82) SRVO–205 SVAL1 Fence open (SVEMG abnormal)

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(83) SRVO–206 SVAL1 Dean switch (SVEMG abnormal) (Explanation) The DEAN switch was released when the teach pendant was operable, but the EMERGENCY STOP line was not disconnected. (Action 1) The mode switch may be faulty. Replace the operator . (Action 2) Replace the teach pendant. (Action 3) Replace the emergency stop unit. (Action 4) Replace the power supply module.

Power supply module Emergency stop unit

Fig.3.5 (83) SRVO–206 SVAL1 Dean switch (SVEMG abnormal)

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(84) SRVO–207 SVAL1 TP switch abnormal or door open (Explanation) The teach pendant is operable, and the dean switch has been grasped, but the EMERGENCY STOP line is kept disconnected. (Action 1) Check the teach pendant connection cable. (Action 2) Replace the teach pendant. (Action 3) Replace the emergency stop unit. Teach pendant Teach pendant cable

Emergency stop unit

Fig.3.5 (84) SRVO–207 SVAL1 TP switch abnormal or door open

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

Power supply module

Fig.3.5 (86) SRVO–215 WARN Fuse blown (Aux axis)

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(87) SRVO–221 SVAL1 Lack of DSP (Group : i Axis : j) (Explanation) A controlled axis card corresponding to the set number of axes is not mounted. (Action 1) Check whether the set number of axes is valid. If the number is invalid, set the correct number. (Action 2) Replace the controlled axis card with a card corresponding to the set number of axes. (Example) When six axes are set, a controlled axis card for six or eight axes is available. For how to replace the controlled axis card, see II MAINTENANCE, Section 7.2 in this manual.

Robot control board Servo amplifier module Power supply module Axis control card

Fig.3.5 (87) SRVO–221 SVAL1 Lack of DSP (Group : i Axis : j)

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(88) SRVO–222 SVAL1 Lack of Amp (Amp : i) (Explanation) The FSSB has no SVM. (Action 1) Check that the optical cable is securely connected to the servo amplifier module. (Action 2) Replace the optical cable. (Action 3) Check whether power is properly supplied to the servo amplifier module.

Servo amplifier module

Fig.3.5 (88) SRVO–222 SVAL1 Lack of Amp (Amp : i)

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(89) SRVO–233 SVAL1 TP disabled in T1, T2/Door open (Explanation) The teach pendant is disabled when the mode switch is in the T1 mode position. (Action 1) During teaching operation, set the enable switch of the teach pendant to Enable. Otherwise, set the mode switch to AUTO mode. (Action 2) Replace the emergency stop unit. (Action 3) Replace the teach pendant. (Action 4) The mode switch may be faulty. Replace the operator . Teach pendant

Mode switch

FUS3 Emergency stop unit Emergency stop board

Fig.3.5 (89) SRVO–233 SVAL1 TP disabled in T1, T2/Door open

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(90) SRVO–264 SVAL1 “E.STOP circuit abnormal 1” (Explanation) An error occurred in the emergency stop circuit. (Action 1) Check whether the CRR78 connectors on the E–STOP unit and the CX3 connector of the power supply module are connected securely. (Action 2) Replace the emergency stop unit. (Action 3) Replace the power supply module.

Power supply module Emergency stop unit

Fig.3.5 (90) SRVO–264 SVAL1 “E.STOP circuit abnormal 1”

(91) SRVO–265 SVAL1 E.STOP circuit abnormal 2 (Explanation) When the servo amplifier is excited, the monitor of the magnetic or (MCC) becomes faulty. (Action 1) Replace the magnetic or (MCC). (Action 2) Replace the emergency stop unit. (Action 3) Replace the power supply module.

Power supply module Emergency stop unit Magnetic or (MCC)

Fig.3.5 (91) SRVO–265 SVAL1 E.STOP circuit abnormal 2

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(92) SRVO–290 SVAL1 DClink HC alarm (Group : i Axis : j) (Explanation) The DC link current in the servo amplifier module(s) is abnormal. The LED indication on the relevant servo amplifier module is “8.” (Action 1) Detach the motor power lines from connector CZ2 of the servo amplifier module, then turn the power on. If this alarm persists, replace the servo amplifier module. (Action 2) Detach the motor power lines from connector CZ2 of the servo amplifier module, then check the insulation between GND and each of U, V, and W of the motor power lines. If a short circuit is detected, the motor, robot connection cable, or internal robot cable may be defective. Check them for an abnormal condition. (Action 3) Detach the motor power lines from connector CZ2 of the servo amplifier module, then use a high–precision ohmmeter to measure U–V, V–W, and W–U resistances of the motor power lines. If the three resistances differ, the motor, robot connection cable, or internal robot cable may be defective. Check them for an abnormal condition. Before proceeding with (Action 4), back up all programs and settings for the control unit. (Action 4) Replace the robot control board.

Robot control board Servo amplifier module

Fig.3.5 (92) SRVO–290 SVAL1 DClink HC alarm

(93) SRVO–291 SVAL1 “IPM over heat (Group : i Axis : j)” (Explanation) The IPM in the servo amplifier overheats. The LED indications on the servo amplifier modules are “8.”, “9.”, and “A.”. (Action 1) Check whether the servo amplifier module fan stops. (Action 2) Reduce the override because the use condition is too hard. (Action 3) If this alarm is frequently issued, replace the amplifier module. 85

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

Robot control board Servo amplifier module Power supply module Axis control card

Fig.3.5 (94) SRVO–295 SVAL1 SVM COM alarm

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

Power supply module

Fig.3.5 (95) SRVO–296 SVAL1 DCAL alarm

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

Power supply module

Fig.3.5 (96) SRVO–297 SVAL1 DCLVAL alarm

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(97) SRVO–300 SVAL1 Hand broken/HBK disabled SRVO–302 SVAL1 Set Hand broken to ENABLE (Explanation) Although HBK was disabled, the HBK signal was input. (Action 1) Press RESET on the teach pendant to release the alarm. (Action 2) Check whether the hand broken signal is connected to the robot. When the hand broken signal circuit is connected, enable hand broken. (See II CONNECTION, Section 3.8 in this manual.)

Robot control board

Fig.3.5 (97)

SRVO–300 SVAL1 Hand broken/HBK disabled SRVO–302 SVAL1 Set Hand broken to ENABLE

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(98) SRVO–320 SVAL1 E.STOP (Explanation) Although there is no cause for an emergency stop, an emergency stop state was detected on the power supply module. (Action 1) Check external emergency stops and the safety fence. (Action 2) Check the connections of the CRR78 connector on the emergency stop emergency stop board and the CX4 connector on the power supply module. (Action 3) Replace the emergency stop unit. (Action 4) Replace the power supply module.

Power supply module Emergency stop unit

Fig.3.5 (98) SRVO–320 SVAL1 E.STOP

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(99) SRVO–321 SVAL1 TP SW/Dean abnormal (Explanation) The ENABLE/DISABLE switch or Dean switch on the teaching pendant is abnormal. (Action 1) Replace the teaching pendant cable. (Action 2) Replace the teaching pendant. (Action 3) Replace the emergency stop unit. Before taking (Action 4), make a backup copy of all the programs and settings of the control unit. (Action 4) Replace the robot control board. Teach pendant teach pendant cable

ENABLE/DISABLE switch Dean switch (Back side)

Robot control board Emergency stop unit

Fig.3.5 (98) SRVO–321 SVAL1 TP SW/Dean abnormal

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3.6

This section describes alarms that can occur when a fuse mounted on a board or unit is blown and corresponding corrective actions.

TROUBLESHOOTING USING FUSES

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(1) Fuses on the robot control board FUS1 : For generating power to the control circuit FUS2 : For protecting +24E output to peripheral device digital input/output, end effector, ROT, and HBK

Problem caused by blown fuse

Action

FUS1

The control power of the robot control board is shut off. The teach pendant displays the initial screen.

FUS2

The teach pendant screen displays alarm information such as 1 Check that +24E used by the peripheral device is free from a Hand broken (SERVO – 006) or Robot overtravel (SERVO – ground fault. 005). 2 Examine the peripheral device connection cable. 3 Check that +24E used by the end effector is free from a ground fault. 4 Examine the robot interconnection cable and intra–robot cable.

FUS1

1 Check the units (fans) and cables connected to the 2 and 3 connectors of the power supply unit to see if there is any short circuit. 2 Replace the DC/DC converter module. 3 Replace the robot control board.

FUS2

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(2) Fuses on the emergency stop board FUS3 : For monitoring the emergency stop circuit FUS4 : For controlling the emergency stop circuit and teach pendant FUS5 : For the brake circuit Name

Problem caused by blown fuse

Action

FUS3

The teach pendant screen displays SVAL1 TP disabled in T1, T2/Door open (SRVO–233) and so forth.

Replace the emergency stop unit.

FUS4

The power supply to the teach pendant stops, the screen display of the teach pendant disappears, and the system enters the emergency stop state.

1 Examine the teach pendant cable for any problem. 2 Examine the teach pendant for any problem. 3 Check that the external emergency stop input and servo off input are free from a ground fault and any other fault.

FUS5

Replace the emergency stop unit. The robot motor brake cannot be released, and alarm information such as Large error in travel (SERVO – 024), Large error at rest (SERVO – 023), Positioning time over (SERVO – 036), or CLALM alarm (SERVO – 050) is displayed.

1 Check that the robot interconnection cable (RMP) and intra–mechanical–unit cable are free from faults such as a ground fault and short–circuit. 2 If an additional axis is used, check that the brake connection cable is free from a ground fault, short–circuit, and any other fault. 3 If a brake power transformer is used, note that a faulty brake power transformer can cause a too large current to flow. Replace the brake power transformer. 4 Replace the emergency stop unit.

FUS4 FUS3

FUS5

Emergency stop board

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(3) Blown fuse on the door Name

Problem caused by blown fuse

FUS6

The power supply unit on the emergency stop unit does not work, and the power cannot be turned on.

Action 1 Check that the fan unit or cable is not short–circuited. 2 Replace the power supply unit.

FUS6

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(4) Fuse on the power supply module FU1 Name FU1

: For protecting 200 VAC input to generate power to the control circuit

Problem caused by blown fuse

Action

ALL LEDs of the servo amplifiers go out. 1 Replace the fuse (5 A) on the control board of the power supThe teach pendant screen displays the FSSB disconnection ply module. alarm or FSSB initialization alarm. 2 Replace the power supply module.

FU1

Remove the face plate

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(5) Fuse on the servo amplifier module FU1 Name FU1

: For protecting +24 V input to generate power to the control circuit

Problem caused by blown fuse

Action

ALL LEDs of the servo amplifier modules go out. 1 Replace the fuse (3.2 A) on the control board of the servo amThe teach pendant screen displays the FSSB disconnection plifier module. alarm or FSSB initialization alarm. 2 Replace the servo amplifier module.

FU1

Remove the control board

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3.7 TROUBLESHOOTING BASED ON LED INDICATIONS

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3. TROUBLESHOOTING

The printed circuit boards and servo amplifier are provided with alarm LEDs and status LEDs. The LED status and corresponding troubleshooting procedures are described below.

Robot control board

Emergency stop board

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(1) TROUBLESHOOTING USING THE LEDS ON THE robot control board To troubleshoot an alarm that arises before the teach pendant is ready to display, check the status LEDs (green) on the robot control board at power–on. After power–on, the LEDs light as described in steps 1 to 18, in the order described. If an alarm is detected, the step in which the alarm occurred can be determined from which LEDs are lit. Step

LED

Action to be taken

1: After power–on, all LEDs are lit.

[Action1] Replace the U card * [Action2] Replace the robot control board.

2: Software operation start–up.

[Action1] Replace the U card * [Action2] Replace the robot control board.

3: The initialization of dram on the U card is completed.

[Action1] Replace the U card * [Action2] Replace the robot control board.

4: The initialization of SRAM and DPRAM is completed.

[Action1] Replace the U card * [Action2] Replace the robot control board. * [Action3] Replace the FROM/SRAM module.

5: The initialization of the communication IC is completed.

[Action1] Replace the U card * [Action2] Replace the robot control board. * [Action3] Replace the FROM/SRAM module.

6: The loading of the basic software is completed.

* [Action1] Replace the robot control board. * [Action2] Replace the FROM/SRAM module.

7: Basic software start–up.

* [Action1] Replace the robot control board. * [Action2] Replace the FROM/SRAM module.

8: Start–up of communication with the teach pendant.

* [Action1] Replace the robot control board. * [Action2] Replace the FROM/SRAM module.

9: The loading of optional software is completed.

* [Action1] Replace the robot control board.

10:DI/DO initialization

* [Action1] Replace the FROM/SRAM module. * [Action2] Replace the robot control board.

11:The preparation of the SRAM module is completed.

[Action1] Replace the axis control card. * [Action2] Replace the robot control board. [Action3] Replace the servo amplifier.

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Step

LED

Action to be taken

12:Axis control card initialization

[Action1] Replace the axis control card. * [Action2] Replace the robot control board. [Action3] Replace the servo amplifier.

13:Calibration is completed.

[Action1] Replace the axis control card. * [Action2] Replace the robot control board. [Action3] Replace the servo amplifier.

14:Start–up of power application for the servo system

* [Action1] Replace the robot control board.

15:Program execution

* [Action1] Replace the robot control board.

16:DI/DO output start–up.

* [Action1] Replace the robot control board.

17: Initialization is terminated.

Initialization has ended normally.

18:Normal status

Status LED 2 blink when the system is operating normally.

* If the robot control board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.

Axis control card

FROM/SRAM module (under the U card)

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U card

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(2) TROUBLESHOOTING BY 7–SEGMENT LED INDICATOR 7–segment LED indicator

Description [Description] A parity alarm condition has occurred in RAM on the U card installed on the robot control board. [Action1] Replace the U card. [Action2] Replace the robot control board. [Description] A parity alarm condition has occurred in RAM on the FROM/SRAM module installed on the robot control board. [Action1] Replace the FROM/SRAM module. [Action2] Replace the robot control board. “2”, “3”, and “4” are not displayed.

[Description] A servo alarm condition has occurred on the robot control board. [Action1] Replace the axis control card. [Action2] Replace the robot control board.

[Description] The SYSEMG alarm has occurred. [Action1] Replace the axis control card. [Action2] Replace the U card. [Action3] Replace the robot control board. [Description] The SYSFAIL alarm has occurred. [Action1] Replace the axis control card. [Action2] Replace the U card. [Action3] Replace the robot control board.

* If the robot control board or FROM/SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.

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(3) Troubleshooting using a fuse alarm LED LED indication

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

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Troubleshooting using an LED on the emergency stop board LED indication

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

FALM LED

Fuse FUS4 Fuse FUS3 Fuse FUS5

Emergency stop board Emergency stop unit

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Troubleshooting using the LED of the power supply module The power supply module has a seven–segment LED. When taking a corrective action corresponding to the LED indication, see the alarm displayed on the teach pendant screen. dot part of seven segment LED

LED indication

Problem and corrective action [Description] The voltage of the DC link of the main circuit is low. [Action1] The input power was instantaneously interrupted. Check the power supply. [Action2] The input supply voltage is low. Check the power requirements. [Action3] The power to the main circuit was shut off in the emergency stop release state. Check the emergency stop circuit (emergency stop board, magnetic or, external emergency stop input, etc.). [Description] The main circuit could not be charged within a predetermined period. [Action1] The DC link is short–circuited. Check the connection. [Action2] The charge current controlling resistor is faulty. Replace the power supply module. [Description] The control power voltage is low. [Action] The input power is low. Check the power supply.

[Description] The voltage of the DC link of the main circuit is too high. [Action1] The regenerative power is too large. Change the operating conditions. [Action2] The regenerative resistor is faulty. Replace the power supply module. [Description] The regeneration amount is too large. [Action] Change the operating conditions. For instance, lower the frequency of acceleration/deceleration. [Description] The regenerative resistor was heated. [Action] Change the operating conditions. For instance, lower the frequency of acceleration/deceleration. [Description] The input power is in the open–phase state. [Action] Check the power supply.

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Troubleshooting using the LED of the servo amplifier module The servo amplifier module has a seven–segment LED. When taking a corrective action corresponding to the LED indication, see the alarm displayed on the teach pendant screen. dot part of seven segment LED

LED indication

Problem and corrective action [Description] The internal cooling fan stopped. [Action1] Check that the fan is not blocked with a foreign substance. [Action2] Check that the fan connector is correctly connected. [Action3] The fan is faulty. Replace the fan. [Action4] Replace the servo amplifier module. [Description] The control supply voltage is low. [Action1] Check the three–phase input voltage. (The voltage must be the rated input voltage multiplied by 0.85 at least.) [Action2] Measure the voltage of 24–V power supplied from the power supply module. (Normal: 22.8 V or higher) [Action3] Check the CXA2A/B connector and the cable. [Action4] Replace the servo amplifier module. [Description] The voltage of the DC link of the main circuit is low. [Action1] Check that the DC link connection cable (bar) is securely screwed. [Action2] If this alarm occurs in multiple servo amplifier modules, take the action for alarm code 4 of the power supply module. [Action3] Replace the servo amplifier module. [Description] The communication among servo amplifiers cannot be normally performed. [Action1] Check the CXA2A/B connector and the cable. [Action2] Replace the control board of the servo amplifier module. [Action3] Replace the servo amplifier module.

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LED indication

3. TROUBLESHOOTING

Problem and corrective action [Description1] The IPM alarm was detected in the servo amplifier module. [Action1] Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, and turn the power on. a) If this alarm does not occur, go to Action 2.

[Action2]

[Action3]

b) If this alarm occurs, replace the servo amplifier module. Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, and check the insulation between PE and each of the motor power lines U, V, and W. a) If the insulation is deteriorated, go to Action 3. b) If the insulation is normal, replace the servo amplifier module. Separate the motor and power line, then check whether the motor or power line has deteriorated insulation. a) If the motor insulation is deteriorated, replace the motor. b) If the power line insulation is deteriorated, examine the robot interconnection cable or intra–robot cable.

“8.”, “9.”, and “A.” represent that an alarm occurs on the L–axis, M– axis, and N–axis respectively. [Description2] The IPM alarm (overheat) was detected in the servo amplifier module. [Action1] Check that the internal cooling fan does not stop. [Action2] Check that the motor is operated at its continuous rating or lower. [Action3] Check that the cooling capability of the cabinet is not lowered. (Check the fan unit and heat exchanger.) [Action4] Check that the ambient temperature is not high. [Action5] Replace the servo amplifier module. “8.”, “9.”, and “A.” represent that an alarm occurs on the L–axis, M– axis, and N–axis respectively.

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LED indication

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Problem and corrective action [Description] An abnormal current is flowing to the servo motor. [Action1] Check that the servo parameters are set to default values. If this alarm occurs only at a sudden acceleration or deceleration, the motor operating conditions may be too harsh. Increase the acceleration/deceleration time constant and observe the operation. [Action2] Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, then turn on the power. a) If this alarm does not occur, go to Action 2.

[Action3]

[Action4]

b) If this alarm occurs, replace the servo amplifier module. Detach the motor power lines from the connectors CZ2 of the servo amplifier modules, then check the insulation between PE and each of the power lines U, V, and W. a) If the insulation is deteriorated, go to Action 3. b) If the insulation is normal, replace the servo amplifier. Separate the motor and power line, then check whether the motor or power line has deteriorated insulation. a) If the motor insulation is deteriorated, replace the motor. b) If the power line insulation is deteriorated, examine the robot interconnection cable and intra–robot cable.

“b”, “C”, and “d” represent that an alarm occurs on the L–axis, M–axis, and N–axis respectively.

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3.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING)

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3. TROUBLESHOOTING

(Check 1)

On the status screen, check the position deviation in the stopped state. To display the position deviation, press the screen selection key, and select STATUS from the menu. Press F1, [TYPE], select AXIS from the menu, then press the F4, PULSE. (Corrective action) Correct the parameters related to return to the reference position (positioning).

(Check 2)

Check whether the motor axis can be positioned normally. (Corrective action) If the motor axis can be positioned normally, check the mechanical unit.

(Check 3)

Check the mechanical unit for backlash. (Corrective action) Replace a faulty key of motor shaft or other faulty parts.

(Check 4)

If checks 1 to 3 show normal results (Corrective action) Replace the pulse coder and robot control board.

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3.9 VIBRATION OBSERVED DURING MOVEMENT

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(Check 1)

Check the settings of parameters such as the position loop gain parameter. (Corrective action) Correct parameters.

(Check 2)

Check the mechanical unit for backlash. (Corrective action) Replace a faulty key of motor shaft or other faulty parts.

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3. TROUBLESHOOTING

The following explains checking and corrective action required if the robot cannot be operated manually after the controller is turned on: (1) Check and corrective action to be made if manual operation is impossible (Check 1)

Check whether the teach pendant is enabled. (Corrective action) Turn on the teach pendant “enable”.

(Check 2)

Check whether the teach pendant is handled correctly. (Corrective action) To move an axis by manual operation, press the axis selection key and case shift key at the same time. Set the override for manual feed to a position other than the FINE and VFINE positions.

(Check 3)

Check whether the ENBL signal of the peripheral device control interface is set to 1. (Corrective action) Place the peripheral device control interface in the ENBL status.

(Check 4)

Check whether the HOLD signal of the peripheral device control interface or the HOLD switch on the operator’s is on (hold status). (Check whether the hold lamp on the teach pendant is on.) (Corrective action) Turn off the HOLD signal of the peripheral device control interface or the HOLD switch on the operator’s .

(Check 5)

Check whether the previous manual operation has been completed. (Corrective action) If the robot cannot be placed in the effective area because of the offset of the speed command voltage preventing the previous operation from being completed, check the position deviation on the status screen, and change the setting.

(Check 6)

Check whether the controller is in the alarm status. (Corrective action) Release the alarm.

(2) Check and corrective action to be taken if the program cannot be executed (Check 1)

Check whether the ENBL signal for the peripheral-device control interface is on. (Corrective action) Put the peripheral-device control interface in the ENBL state.

(Check 2)

Check whether the HOLD signal for the peripheral-device control interface is on. (Check whether the HOLD lamp on the teach pendant is on.) (Corrective action) If the HOLD signal is on, turn it off. If the HOLD switch is on, turn it off. 109

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(Check 3)

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

(Check 4)

Check whether the controller is in the alarm status. (Corrective action) Release the alarm.

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4

MAINTENANCE

4. PRINTED CIRCUIT BOARDS

PRINTED CIRCUIT BOARDS

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

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4.1 ROBOT CONTROL BOARD (A16B–3200–0450)

FROM/SRAM module under the U card

U card

DC/DC converter module

Total version

Axis control card

Fig.4.1 Robot control board Name Robot control board

Board Specification

Note

A16B–3200–0450

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

DC/DC convert module

A20B–8100–0721

U card

A20B–3300–0106

SDRAM 8M (Standard)

A20B–3300–0107

SDRAM 16M

A20B–3300–0241

6–axis

A20B–3900–0181

FROM 16M, SRAM 0.5M : Standard

A20B–3900–0160

FROM 16M, SRAM 1MB

A20B–3900–0161

FROM 16M, SRAM 2MB

A20B–3900–0162

FROM 16M, SRAM 3MB

Axis control card FROM/SRAM module

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(1) LEDs Seven segment LED

Description

A parity alarm occurred in a RAM of the main U card on the Robot control board.

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

“2”, “3”, and “4” are not displayed.

A servo alarm occurred on the Robot control board.

SYSEMG occurred.

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

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Status LED

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Description

STATUS LED

Indicates the system operating status.

Status LED

FUSE ALARM LED

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Description

A fuse (FUS1 or FUS2) was blown.

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(2) Correspondence between driver ICs and DO Driver IC specification: A76L–0151–0062 Driver IC name

DO signal name

H9

SDO101, SDO102, SDO103, SDO104

G9

SDO105, SDO106, SDO107, SDO108

K9

SDO109, SDO110, SDO111, SDO112

J9

SDO113, SDO114, SDO115, SDO116

J13

SDO119, SDO120, SDO81, Brake control (internal circuit)

H13

SDO82, SDO83, SDO84, Reserved

J6

RDO1, RDO2, RDO3, RDO4

J4

RDO5, RDO6, SDO117, SDO118

(3) Communication IC If the teach pendant displays nothing because of a damaged teach pendant connection cable or another reason, the following communication driver or receiver may be damaged. IC name

Name and usage

Drawing number

G17

75172, driver

A76L–0151–0098

G16

75173, receiver

A76L–0151–0099

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4.2 EMERGENCY STOP BOARD (A20B–1008–0010, –0011)

Total version

Fig.4.2 Emergency stop board

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4.3 BACKPLANE BOARD (A20B–2003–0330)

Total version

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4. PRINTED CIRCUIT BOARDS

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4.4 PROCESS I/O BOARD HE (A16B–2203–0764), HF (A16B–2203–0765)

Total edition Test pins

Fig.4.4 Process I/O Board HA

(1) Test pins Name

Use

P24V P5V GND1 GND2 GND3

+24V +5V GND GND GND

For measuring the DC supply voltage

P24VF P5VF GNDF

+24V +5V GND

Power for the digital/analog converter

AO1 AO2

Channel 1 Channel 2

For measuring the voltage of the analog output signal (digital/analog)

(2) Settings Name ICOM1

UDI1 to UDI20 (Connector CRM2A)

UDI21 to UDI40 ICOM2 (Connector CRM2B) ICOM3

Standard setting

WDI01 to WDI08 (Connector CRW7)

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Side A

Description

The common voltage is adjusted to: Side A : +24 V common Side B : 0 V common

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4. PRINTED CIRCUIT BOARDS

(3) Adjustment VR1/VR2: Adjusts the gain and the offset of channel 1. Execute a robot program and set AOUT[1] to 3413 on the teach pendant. Connect a digital voltmeter to test pin AOUT1 and rotate VR1 or VR2 until the meter reads 15.0 V. Connect the negative (–) lead of the digital voltmeter to test pin GNDF. (GNDF test pin is different from the GND test pin.) VR3/VR4: Adjusts the gain and the offset of channel 2. Execute a robot program and set AOUT[2] to 3413 on the teach pendant. Connect the digital voltmeter to test pin AOUT2 and rotate VR3 or VR4 until the meter reads 15.0 V. Connect the negative (–) lead of the digital voltmeter to test pin GNDF. (The 0VF test pin is different from the common GND test pin.) (4) LEDs Color

Description

Red

A communication alarm occurred between the main U and process input/output.

Red

A fuse (FUSE 1) in the process input/output below.

(5) Correspondence between driver chips and DO signals Ordering code for the driver chips: A76L-0151-0062 Driver chip DV1 DV2 DV3 DV4 DV5 DV6 DV7 DV8 DV9 DV10

DO signal CMDENBL, SYSRDY, PROGRUN, PAUSED HELD, FAULT, ATPERCH, TPENBL BATALM, BUSY, ACK1/SNO1, ACK2/SNO2 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED SDO01, SDO02, SDO03, SDO04 SDO05, SDO06, SDO07, SDO08 SDO09, SDO10, SDO11, SDO12 SDO13, SDO14, SDO15, SDO16 SDO17, SDO18, SDO19, SDO20

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SERVO AMPLIFIERS

The servo amplifiers are factory-set for operation. Usually, you do not need to set or adjust them. This chapter describes the standard settings and adjustment required if a defective servo amplifier is replaced. It also describes the use of test pins and meanings of the LED indications. Table 5 Servo amplifier specifications Robot LR Mate 100iB

LR Mate 200iB ARC Mate 50iB

Power supply module A06B–6115–H001 (αPSMR–1i)

A06B–6115–H001 (αPSMR–1i)

Servo amplifier module1 A06B–6114–H205 (αSVM–20/20i) L M J1 J2 A06B–6114–H302 (αSVM–10/10/10i) L M N J1 J2 J3

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Servo amplifier module2 A06B–6114–H302 (αSVM–10/10/10i) L M N J3 J4 J5 A06B–6114–H302 (αSVM–10/10/10i) L M N J4 J5 J6

5. SERVO AMPLIFIERS

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5.1 OUTLINE DRAWINGS 5.1.1 Power Supply Module PSM (A06B–6115–H001)

380

360

60

172

Fig.5.1.1 Outline drawing of power supply module PSM (A06B–6115–H001)

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5.1.2 Servo Amplifier Module (A06B–6114–H205, A06B–6114–H302)

A06B–6114–H205

A06B–6114–H302

380

360

60

172

Fig.5.1.2 Outline drawing of servo amplifier modules (A06B–6114–H205, A06B–6114–H302)

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5.2 LED OF SERVO AMPLIFIER 5.2.1 LED of Power Supply Module dot part of seven segment LED

The power supply module has a seven–segment LED. When taking a corrective action corresponding to the LED indication, see the alarm displayed on the teach pendant screen.

LED indication

Description The magnetic or controlled by the power supply module is in the off state and is not ready for driving the motor.

The magnetic or controlled by the power supply module is in the on state and is ready for driving the motor.

The voltage of the DC link of the main circuit is low.

The main circuit cannot be charged within a predetermined period.

The control power voltage is low.

The voltage of the DC link of the main circuit is too high.

The regeneration amount is too large.

The regenerative resistor was heated.

The input power is in the open–phase state.

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5.2.2 LED of Servo Amplifier Module dot part of seven segment LED

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The servo amplifier module has a seven–segment LED. When taking a corrective action corresponding to the LED indication, see the alarm displayed on the teach pendant screen.

LED indication

Description The main circuit in the servo amplifier module is in the off state and is not ready for driving the motor.

The main circuit in the servo amplifier module is in the on state and is ready for driving the motor.

The internal cooling fan stopped.

The control power voltage is low.

The voltage of the DC link of the main circuit is low.

The communication among servo amplifier modules cannot be normally performed.

a) The IPM alarm was detected in the servo amplifier module. b) The IPM alarm (overheat) was detected in the servo amplifier module. “8.”, “9.”, and “A.” represent that an alarm occurs on the L–axis, M– axis, and N–axis respectively.

An abnormal current is flowing to the servo motor. “b”, “C”, and “d” represent that an alarm occurs on the L–axis, M–axis, and N–axis respectively.

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6. SETTING THE POWER SUPPLY

SETTING THE POWER SUPPLY

The power supply is factory-set for operation. Usually, you do not need to set or adjust it.

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6.1 BLOCK DIAGRAMS OF THE POWER SUPPLY AC input

200 – 220 VAC 3φ

Servo amplifier

Power supply module Magnetic or (MCC) Circuit protector

200VAC 2φ

200VAC

3φ FUS6

200VAC

CZ1

2φ CX1

Main circuit DC link FU1 regenerative resistor

FAN

AC/DC +24V

Emergency stop unit

Power supply unit

CN1

AC/DC +24V

Emergency stop print board FUS3

Servo amplifier module

5A FUS4

Monitor circuit 5B

CRR77

CXA2A

L+, L–

CXA2B

L+, L– Inverter circuit

DC/DC +5V JF1–3

CZ2 L–N

EmergenFUS5 cy stop circuit Brake circuit CRS1

TBEB3

+24T

Backplane Robot control board DC/DC converter module +5V, +3.3V +15V, –15V 8B +24V FUS1 5

Motor brake Motor powersupply

BATTERY

Robot

Pulsecoder

Motor End Effector

+24E FUS2 +24E CRM82

Teach pendant

+24E CRM79

Peripheral device

+24E

Peripheral device (option)

CRM81 +24V JD17

Handy file etc.

Process I/O board +24E FUSE1

+24F

Peripheral device (option)

CRM2 CRM4 +24E

+24V –15V +15V +5V +3.3V

Fig.6.1 Block diagram of the power supply

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6.2 CHECKING THE POWER SUPPLY UNIT

6.3 CHECKING THE POWER SUPPLY MODULE

MAINTENANCE

6. SETTING THE POWER SUPPLY

The power supply unit need not be set or adjusted. Table 6.2 Rating of the Power supply unit Output

Rated voltage

Tolerance

+24V

+24V

+23V to +25V

The power supply module need not be set or adjusted. Table 6.3 Rating of the Power supply module Output

Rated voltage

Tolerance

+5V

+5.1V

±3%

+3.3V

+3.3V

±3%

+15V

+15V

±10%

–15V

–15V

±10%

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REPLACING A UNIT

This section explains how to replace each unit in the control section. WARNING Before you start to replace a unit, turn off the control unit main power. Also keep all machines in the area of the control unit switched. Otherwise, you could injure personnel or damage equipment.

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7. REPLACING A UNIT

7.1 REPLACING THE PRINTED–CIRCUIT BOARDS

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

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7.1.1

When replacing the backplane board, do so together with the plastic rack.

Replacing the Backplane Board (Unit)

(1) Detach the cables from the robot control board and boards on the backplane board. CAUTION When you remove the main robot control Board, be sure that the battery is good (3.1–3.3VDC) and it is installed correctly. USE STATIC PROTECTION. (2) Remove the robot control board and boards from the rack. (See Section 7.1.2.) (3) Detach the grounding cable from the backplane unit. (4) Loosen the retaining screws in the upper section of the rack. Remove the retaining screws from the lower section of the rack. (5) Side rack up and out. (6) To replace the backplane and rack, reverse steps (1) – (6). CAUTION There is a possibility of data loss when a backplane board is replaced. Be sure to back up all program and setup data on a floppy disk before proceeding.

Backplane board

M5 nut (2 places)

Fig.7.1.1 Replacing the Backplane Board

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7.1.2 Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit

7. REPLACING A UNIT

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The backplane unit incorporates the power unit, Robot control board, and option boards. There are two types of option boards: Full–size board and mini–size board. A full–size board occupies one slot. A mini–size board uses part of a full–size board. CAUTION Before starting replacement, turn off the control unit main power. The robot control board is equipped with battery–backed memory devices for holding robot parameters and taught data, for example. When the Robot control board is replaced, the data in the memory devices is lost. (1) Detach the cable from the printed–circuit board, whichever is to be replaced. (2) Pinch the barbed handles on the upper and lower sections of the board to unlatch it, then pull it toward you. (3) Place the replacement board on the rail in the appropriate slot of the rack, then push it in gently by the handles until it is latched. (4) There are two rails in the robot control board SLOT (slot 1). When inserting the robot control board, align it to the right–side rail. Slot 1 Option slot Slot 1

Slot 10 Barbed handles

Slot 2

Rail (Left)

Slot 9

Rail (Right) zoom

Barbed handles

Fig.7.1.2 Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit

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7.1.3

The board is at the emergency stop unit.

Replacing the Emergency Stop Board

(1) Detach all cables from the emergency stop unit consists of the emergency stop board and the power supply unit. The terminal blocks (TBEB1 and TBEB2) are of a connector type. Pull out the upper terminal block sections. (2) Remove four retaining nuts from the emergency stop unit (1, 2), and replace the emergency stop unit. (3) Remove six retaining screws from the emergency stop board (3), and replace the emergency stop board.

1 Remove the front nuts (2–M5)

2 Remove the back nuts (2–M5) 3 Remove the screws (6–M3)

Fig.7.1.3 Emergency stop board replacement

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MAINTENANCE

7.2 REPLACING CARDS AND MODULES ON THE ROBOT CONTROL BOARD

CAUTION Before you start to replace a card or module, make a backup copy of robot parameters and taught data. If the FROM/SRAM module is replaced, memory contents are lost. Demounting a Card (1) Pull outward the clip of each of the two spacers used to secure the card PCB, then release each latch. (2) Extract the card upward.

Card

Card

Card Card

Spacer Connector

Card

Spacer Connector Fig.7.2 (a) Demounting a card

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Mounting a Card (1) Check that the clip of each of the two spacers is latched outward, then insert the card into the connector. (2) Push the clip of each spacer downward to secure the card PCB.

Card

Spacer Connector

Card

Card

Card Card

Spacer Connector Fig.7.2 (b) Mounting a card

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7. REPLACING A UNIT

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

(b)

(c)

Fig.7.2 (c) Demounting/Mounting a module

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Removing the DC/DC converter module (1) Unscrew the screws (3–M3). (2) Pull out the module. Mounting the module (1) Insert the module to the connector. (2) Screw the screws (3–M3). DC/DC converter module

screws (3–M3)

Fig.7.2 (d) Mounting and removing the DC/DC converter module

Figure 7.2 (e) shows the locations of the cards and modules.

FROM/SRAM module under the U card

U card

DC/DC converter module

Total version

Axis control card

Fig.7.2 (e) Locations of Cards and Modules

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MAINTENANCE

7.3 REPLACING THE TRANSFORMER

WARNING Before you start replacement procedure, turn off the main power to the control unit.

7.3.1 Replacing the Brake Power Transformer

(1) Detach the cable from the transformer. (2) Remove the two nuts (M5) securing the transformer, then replace the transformer. (3) Re–connect the cable.

Remore the nuts (2–M5)

Fig.7.3.1 Replacing the brake power transformer

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7.4 REPLACING THE EMERGENCY STOP UNIT

WARNING Before you start replacement, turn off the control unit main power. (1) Detach the cables from the emergency stop unit. (2) Remove retaining screws (4–M5) from the emergency stop unit, and replace the emergency stop unit. (3) Reconnect the cables.

Nut (4–M5)

2 Remove the back nuts (2–M5) screws 1 Remove the front nuts (2–M5) screws

Fig.7.4 Replacing the Emergency Stop Unit

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7. REPLACING A UNIT

7.5 REPLACING THE MAGNETIC OR

WARNING Before starting the replacement, turn off the control unit main power. (1) Detach the cable from the magnetic or (MCC). (2) Holding down the magnetic or (MCC) a little, remove the MCC from the DIN rail. (3) Mount a new magnetic or (MCC) on the DIN rail. (4) Re–connect the cable.

Magnetic or (MCC)

Fig.7.5 Replacing the magnetic or

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7.6 REPLACING SERVO AMPLIFIERS

WARNING Before you start replacement, turn off the control unit main power. The following is the procedure for replacing the power supply module and servo amplifier module. (1) Detach the cable from the servo amplifier. Remove the jumper connecting the DC link (L+ and L–). (2) Remove the two nuts from the top of the servo amplifier. (3) Mount a new servo amplifier, reversing the removal step of (2). (4) Re–connect the cable and re–mount the jumper connecting the DC link (L+ and L–).

Nut (2–M5)

Power supply module

servo amplifier module

Fig.7.6 Replacing the servo Amplifier

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7.7 REPLACING THE TEACH PENDANT

7. REPLACING A UNIT

MAINTENANCE

The specifications of the teach pendant vary with its use. When you replace the teach pendant, check its specifications carefully. (1) Be sure that the power of a robot controller is off. (2) Detach the cable from the teach pendant. (3) Replace the teach pendant.

Detach or attach the cable by rotating the connector retaining ring.

Fig.7.7 Replacing the Teach Pendant

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7.8 REPLACING THE CONTROL SECTION FAN MOTOR

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The control section fan motor can be replaced without using a tool. The fan motor is mounted on the fan unit rack. (1) Be sure that the power of a robot controller is off. (2) Put your finger in the dent in the upper section of the fan unit, and pull the fan unit until it is unlatched. (3) Lift the fan unit slightly, and dismount it from the rack. (4) Place a replacement fan on the upper section of the rack, and slide it gently until it is latched.

Fan motor connector

Fan motor

Pull the fan motor unit toward you to unlatch it.

Fig.7.8 Replacing the Control Section Fan Motor

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7.9 REPLACING THE FAN MOTOR OF THE SERVO AMPLIFIER CONTROL UNIT

MAINTENANCE

7. REPLACING A UNIT

The fan motor of the servo amplifier control unit can be replaced without using tools. The fan unit is mounted at the top of the servo amplifier. (1) Check that the robot controller is turned off. (2) Holding the two lugs, pull up the fan unit in the direction of the arrow. (3) Place a new fan unit at the top of the servo amplifier, and slightly press it in. Holding the two lugs, pull up the fan unit in the direction of the arrow (rightward in the figure).

When mounting the fan motor, note the orientation of the fan motor and connector.

Lug

White Black Red Note the orientation of the connector key. Fan unit (for width of 60 mm)

Fig.7.9 Replacing the fan motor of the servo amplifier control unit

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7.10 REPLACING THE DOOR FAN UNIT AND HEAT EXCHANGER

WARNING Before starting the replacement, turn off the control unit main power. Never touch the fan motor while it is rotating. Door fan unit (1) Unscrew the four fastening screws (M4). (2) Detach the cable from the fan unit. (3) Mount a spare fan unit, reversing the removal procedure. Heat exchanger (1) Detach the cable from the heat exchanger. (2) Remove the six fastening nuts (M4), and pull the heat exchanger toward you. (3) Detach the wiring from the door fan unit. (4) Mount a spare heat exchanger, reversing the removal procedure.

Heat exchange Door fan unit Screws (4–M4)

Nut (4–M5)

Fig.7.10 Replacing the door fan unit and heat exchanger

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7. REPLACING A UNIT

7.11 REPLACING THE OPERATOR

(1) Detach the cable from the circuit protector on the operator and the grounding line from the door. (2) Detach the cable (JD17) from the robot control board and the cable (CRT11) from the emergency stop board. (3) Unscrew the four screws (M3) fastening the operator , and remove the operator . (4) Mount a new operator , reversing the removal steps of (1) to (3).

Screw (4–M3)

Fig.7.11 Replacing the operator

NOTE The operator comprises the itself and the cables connected to the robot control board and emergency stop board.

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7.12

The power supply unit is mounted on the emergency stop unit.

REPLACING THE POWER SUPPLY UNIT

(1) Detach all the cables from the emergency stop unit (emergency stop board and power supply unit). (2) Pull out the connector–type terminal block (TBEB1, TBEB2) at the top. (3) Remove the four nuts (1 and 2) fastening the emergency stop unit, and remove the emergency stop unit. (4) Unscrew the four screws fastening the power supply unit, and replace the power supply unit.

1 Remove the front nuts (2–M5)

2 Remove the back nuts (2–M5) 3 Remove the screws (4–M3)

Fig.7.12 Replacing the power supply unit

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7.13

7. REPLACING A UNIT

If a fuse of the control unit is blown, find out the cause, take an appropriate action, then replace the fuse.

REPLACING A FUSE 7.13.1

The robot control board has the following fuses.

Replacing a Fuse on the Robot Control Board

FUS1: For detecting a problem in the circuit on the robot control board: A60L–0001–0046#7.5 If this fuse is blown, the DC/DC converter module or a device connected to the RS–232–C/RS–422 port may be faulty. If the device connected to the RS–232–C/RS–422 port is not faulty, replace the DC/DC converter module. FUS2: For protecting the 24V output to the peripheral device: A60L–0001–0046#7.5 If this fuse is blown, the wiring to the peripheral device and a cable may be incorrect or damaged.

FUS1

FUS2

Fig.7.13.1 Replacing a fuse on the robot control board

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7.13.2

The emergency stop board has the following fuses.

Replacing a Fuse on the Emergency Stop Board

FUS3: For monitoring the emergency stop circuit: A60L–0001–0046#1.0 If this fuse is blown, the emergency stop board may be faulty. Replace the emergency stop board. FUS4: For protecting the 24V output to the emergency stop circuit and teach pendant: A60L–0001–0046#1.0 If this fuse is blown, the emergency stop circuit may be incorrectly routed, or the teach pendant or teach pendant cable may be faulty. Check the routing of the emergency stop circuit, and replace the teach pendant and teach pendant cable. FUS5: For monitoring the emergency stop circuit: A60L–0001–0245 #GP20 If the fuse is blown, the brake circuit may be faulty. Examine the brake, robot, and robot interconnection cable. Alternatively, replace the emergency stop board.

FUS4 FUS3

FUS5

Emergency stop board

Fig.7.13.2 Replacing a fuse on the emergency stop board

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7. REPLACING A UNIT

7.13.3

The door has the following fuse.

Replacing the Fuse on the Door

FUS6: For protecting the 200VAC control output: A60L–0001–0101# P475H If this fuse is blown, the power supply unit on the emergency stop unit or the cooling fan unit may be faulty. Replace the power supply unit or cooling fan unit.

FUS6

Fig.7.13.3 Replacing a fuse on the emergency stop board

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7.13.4

The power supply module has the following fuse.

Replacing the Fuse on the Power Supply Module

FU1: For protecting the 200VAC input for generating power to the control circuit: A60L–0001–0359 If the fuse is blown, the power supply module may be faulty. Replace the power supply module.

FU1

Remove the face plate

Fig.7.13.4 Replacing the fuse on the power supply module

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7.13.5

The servo amplifier module has the following fuse.

Replacing the Fuse on the Servo Amplifier Module

FU1: For protecting the +24 V input for generating power to the control unit: A60L–0001–0290#LM32C If this fuse is blown, the servo amplifier module may be faulty. Replace the servo amplifier module.

FU1

Remove the control board

Fig.7.13.5 Replacing the fuse on the servo amplifier module

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7.13.6

The following fuse is on each process I/O board.

Replacing the Fuse on the Process I/O Boards

FUSE1:Fuse for protecting the +24V output for peripheral equipment interfaces. A60L–0001–0046#2.0

Process I/O board HE, HF FUSE1

Total edition

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7.14 REPLACING A RELAY

7. REPLACING A UNIT

MAINTENANCE

Prolonged use of a relay might result in its s failing to make a secure connection or in them sticking to each other permanently. If such a failure occurs, replace the relay.

7.14.1

The emergency stop board has the following relays.

Replacing a Relay on the Emergency Stop Board

KA6: For external emergency stop output: A58L–0001–0192#1509A KA7: For brake control: A58L–0001–0192#1997R

KA6

KA7

Emergency stop board

Fig.7.14.1 Replacing a relay on the emergency stop board

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

The programs, and system variables are stored in the SRAM in the Robot control board. The power to the SRAM memory is backed up by a lithium battery mounted on the front of the Robot control board. The above data is not lost even when the main battery goes dead. A new battery can maintain the contents of memory for about 4 years (Note). When the voltage of the battery becomes low, the battery alarm LED on the operator is lit, and the low–voltage battery alarm (system–035) is displayed on the teach pendant. When this alarm is displayed, replace the battery as soon as possible. In general, the battery can be replaced within one or two weeks, however, this depends on the system configuration. If the battery voltage gets lower, it becomes impossible to back up the content of the SRAM. Turning on the power to the in this state causes system not to start and LED of seven segment on the Robot control board to be displayed “1” because the contents of memory are lost. Clear the entire SRAM memory and reenter data after replacing the battery. Important data should be saved to the memory card or floppy disk beforehand in case of emergency. When replacing the memory backup battery, do so while the robot controller is turned off in case of emergency. NOTE In a newly introduced robot, the battery is factory–installed. Battery replacement may, therefore, be needed within 4 years after the introduction of the robot.

Replacing the lithium battery

(1) Prepare a new lithium battery (ordering drawing number: A02B–0200–K102). (2) Turn the robot controller on for about 30 seconds. (3) Turn the robot controller off. (4) Remove the old battery from the top of the Robot control board. First unlatch the battery, remove it from the battery holder, and detach its connector.

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Battery latch

7. REPLACING A UNIT

Battery connector

Lithium battery

(5) Remove the old battery, insert a new one into the battery holder, and attach the connector. Confirm that the battery is latched firmly. WARNING Using other than the recommended battery may result in the battery exploding. Replace the battery only with the specified battery (A02B–0200–K102).

CAUTION Complete the steps (3) to (5) within 30 minutes. If the battery is left disconnected for a long time, the contents of memory will be lost. To prevent possible data loss, it is recommended that the robot data such as programs and system variables be backed up before battery replacement. Dispose of the replaced battery as an industrial waste, according to the laws and other rules in the country where the controller is installed and those established by the municipality and other organizations that have jurisdiction over the area where the controller is installed.

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III CONNECTION

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1

1. GENERAL

GENERAL

This chapter describes the connection and the installation of the electrical interface.

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2. BLOCK DIAGRAM

2

CONNECTIONS

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BLOCK DIAGRAM

Following are the block diagrams of the electrical interface connection for R–J3iB Mate.

R–J3iB Mate controller Peripheral device Robot control board

Operation

(RDI/RDO)

RS–232–C RS–422/485 Teach pendant

Emergency stop unit Power supply unit

Emergency stop board

(Note2)

Emergency stop (Brake)

Transformer

Robot

Fan

Fuse Pulse coder Circuit protector

MCC

Servo amplifier

Power

NOTE Tranceformer is installed when the robot is for 6–axes brake specification.

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CONNECTIONS

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CONNECTION DETAILS

Robot control board

Emergency stop unit 8B EMGIN11, 12, 21, 22 FENCE11, 12, 21, 22 5B

Battery 5

Emergency stop circuit

CRS24

JRS12

EMGOUT1, 2 EXT24V, 0V CRS16

PCMCIA

Teach pendant

PCMCIA

COP10A

Servo amplifier

CRM82

Mechanical unit

JD17

RS–232–C or RS–422/485

JD1A

I/O Link (master)

JD1B

I/O Link (slave : option)

CRM79

Peripheral device

CRM81

Peripheral device (option)

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3.1 CONNECTION OF POWER SUPPLY CABLE When the stand–alone controller is used, an optional power cable can be specified.

A grounding stud is provided beside the circuit protector. Connect the primary power ground wire to this stud. Use an M4 crimp terminal.

Use the cable holders are provided at these locations.

Circuit protector

To primary power supply 3Φ200VAC

Terminal is M4.

By using cable straps, secure the primary power cable to the screws used to fasten the fan.

NOTE Connect the primary power cable to the circuit protector. After connection, insulate the protector terminal by fitting the provided terminal cover. Connect the primary power ground wire to the grounding stud, located beside the circuit protector.

You can specify the power supply cables as the option.

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3.2 FANUC I/O LINK Table 3.2 Types of FANUC I/O Links I/O Link No. 1

Name Robot control board

Drawing number A16B–3200–0450

Master

Slave

f(*)

f(*)

Remarks Standard

NOTE The I/O Link of the robot control board is in the master mode by default. The I/O Link can be used in the slave mode by changing the software parameter setting. Refer to the operator’s manual for setting slave mode.

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ÏÏ ÏÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏÏ ÏÏ ÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏÏ ÏÏ ÏÏ ÏÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏ ÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏ When the R–J3iB Mate control unit is used as the master of an I/O link (when R–J3iB Mate control the process I/O printed board)

to other I/O link

JD4* JD4* Process I/O printed boord etc.

JD1A

R–J3iB Mate

*Note that the connector name differs from that of the standard FANUC I/O link.

When the R–J3iB Mate control unit is used as the master and a slave of an I/O link

JD1B

JD1A

FANUC I/O Unit etc.

R–J3iB Mate master

JD1B1

JD1A1

FANUC I/O Link connection unit

JD1A2

JD1B2

JD1A

JD1B

FANUC I/O Unit etc.

CNC, PLC

When the R–J3iB Mate control unit is used as a slave of the I/O link (when a CNC or PLC is used as the master of the I/O link)

ÏÏÏÏÏÏ ÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ

ÏÏÏÏÏÏÏ ÏÏ ÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ JD1B

JD1A

CNC, PLC

to other I/O link

JD1A

R–J3iB Mate

*Note Robot control board is required./Switch by the software

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3.3 CONNECTION OF I/O LINK CABLE Cable connections should be made according to the system. The customer is requested to ground the shield. JD1A JD1B Robot control board

For other I/O link Earth plate Peel off the sheath of the shielded cable, then ground the shield here. I/O Link cable connection 1. Customer should be prepare this cable. 2. Power off when it is connected.

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏ When making a connection with a CNC via an I/O link, apply the following timing to turn the power to the CNC and robot controller on/off: a) Turn on the power to the slave units when or before turning on the master power.

b) If the power to the CNC or robot controller is turned off after the system has been started, an I/O link error will occur. To reestablish normal connection via the I/O link, turn off the power to all units, then turn on the power as explained in a) above.

JD1A interface

JD4(JD1B) interface

11

0V

01 RXSLC1

11

0V

01 RXSLC2

12

0V

02 *RXSLC1

12

0V

02 *RXSLC2

0V

03 TXSLC2

13

0V

03 TXSLC1

13

14

0V

04 *TXSLC1

14

0V

04 *TXSLC2

0V

05

0V

15

0V

05

15

16

0V

06

16

07

17

08

18

09 (+5V)

19

10

20

17 18

(+5V)

19 20

(+5V)

Note) When using an optical I/O link adaptor, use +5V.

06

07

(+5V)

08

09 (+5V)

(+5V)

10

Note) When using an optical I/O link adaptor, use +5V.

(1) Twisted–pair cables should be used for pin pairs 1 and 2, and 3 and 4. (2) Use unified shielding, and ground the shield on the CNC side.

165

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

Cable connection

Master I/O unit, etc JD1B

Robot control board JD1A RXSLC1 (1) *RXSLC1 (2) TXSLC1 (3) *TXSLC1 (4) 0V (11) 0V (12) 0V (13) 0V (14) 0V (15) 0V (16)

(1) SIN [RX] (2) *SIN [*RX] (3) SOUT [TX] (4) *SOUT [*TX] (11) 0V (12) 0V (13) 0V (14) 0V (15) 0V (16) 0V

Slave CNC, PLC etc JD1A

Robot control board JD1B

[RX] SIN (1) [*RX] *SIN (2) [TX] SOUT (3) [*TX] *SOUT (4) 0V (11) 0V (12) 0V (13) 0V (14) 0V (15) 0V (16)

(1) RXSLC2 (2) *RXSLC2 (3) TXSLC2 (4) *TXSLC2 (11) 0V (12) 0V (13) 0V (14) 0V (15) 0V (16) 0V

166

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.4 EMERGENCY STOP CIRCUIT 3.4.1 Circuit Diagram of Emergency Stop Teach pendant Emergency stop button

Emergency stop board

+24T

(From 5A) 24VIN +24EXT

CRS16

FUS4

+24V FUS3

Operation mode switch

+24EXT +24V

CRT11

AUTO

T1

SR2–1 SR2–2

Enable/Disable switch +24T

SR2–3 +24EXT

KA1–3 KA2–2 KA3–2

0V

Emergency stop button

+24V

Dead man switch

KA1–1 +24EXT

Robot control board

JRS12

+24V

0VEXT

CRS24

TBEB1

INT24V MODE1

EXT24V

MODE2

INT0V

24V external power supply

EXT0V OP–EMG

External emergency stop

0V 0VEXT

EMGIN11 EMGIN12

FENCE 0VEXT

EMGIN21

KA2–1

EMGIN22

EX–EMG +

MCCMON

FENCE11

TBEB2

Safety fence

FENCE12

Mode switch SR2–1 SR2–2 SR2–3

AUTO CLOSE OPEN CLOSE

T1 OPEN CLOSE OPEN

KA3–1

0VEXT

FENCE21 FENCE22 EMGOUT1

CRM83 +24V

Servo amplifier (α PSMR–1i)

EMGOUT1 KA6–1

CRR78

CX3 MCCOFF3

0V MCCOFF4 0V

RL1

KA6–2 +24V

CX4 +24V ESP

MCC (KM1) KM1–1 KM1–2 KM1–3

3φ200VAC

KM1–4 KM1–5

167

CZ1

ESP

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.4.2 External Emergency Stop Input

Customer should prepare this cable TBEB1 EMGIN11 EMGIN12 EMGIN21 EMGIN22

Cable holder

ÏÏ ÏÏ EMGIN11 EMGIN12 EMGIN21 EMGIN22

FENCE11 FENCE12 FENCE21 FENCE22

EMGIN1 EMGIN2

SVOFF1

External emergency stop input

Servo off input

ÏÏ ÏÏ

When the robot is shipped, EMGIN11 and EMGIN12/ EMGIN21 and EMGIN22, FENCE11 and FENCE12/ FENCE21 and FENCE22 are short–connected. To enable external emergency stop input and fence input, first disconnect these jumper wires, then make the necessary connections. External emergency stop input is reflected in the external emergency stop output, but fence input is not reflected in the external emergency stop output. Confirm the operation of emergency stop switches on the teach pendant and on the front , after you wired the external emergency stop input and the servo off input.

ÏÏ ÏÏ

SVOFF2

Emergency stop board

EXT24V INT24V INT0V EXT0V

TBEB2 FENCE11 FENCE12 FENCE21 FENCE22 EMGOUT1 EMGOUT2

ÏÏ ÏÏ

NOTE The between EMGIN11 and EMGIN12 or between FENCE11 and FENCE12 opens or closes the emergency stop circuit. The between EMGIN21 and EMGIN22 or between FENCE21 and FENCE22 monitors the input state. (Single–channel with monitoring safety circuit) When using external emergency stop input and fence input, prepare the for opening and closing the emergency stop circuit and the for monitoring.

168

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.4.3 External Emergency Stop Output Customer should prepare this cable.

ÏÏ ÏÏ ÏÏ ÏÏ

Cable holder

EMGOUT1 EMGOUT2

TP Emergency stop

ÏÏ ÏÏ ÏÏ ÏÏ

Emergency stop from the teach pendant and emergency stop from the operator are reflected to the external emergency stop outputs, EMGOUT1 and EMGOUT2.

OP Emergency stop

TBEB1 EMGIN11 EMGIN12 EMGIN21 EMGIN22

TBEB2 FENCE11 FENCE12 FENCE21 FENCE22 EMGOUT1 EMGOUT2

EXT24V INT24V INT0V EXT0V

Emergency stop board EMGOUT11 EMGOUT12

169

To peripheral control sequencer etc.

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.4.4 External 24 V Input Customer should prepare this cable.

ÏÏ ÏÏ ÏÏ ÏÏ

Cable holder

EXT24V EXT0V

Emergency stop board

A short connection board is inserted at the factory. Before using external 24 V, remove this short connection board. 24 V power supply

+24V

ÏÏ ÏÏ ÏÏ ÏÏ

When 24 V is applied externally, the external emergency stop outputs, EMGOUT1 and EMGOUT2, are always output regardless of the power state of the robot control unit.

TBEB1 EMGIN11 EMGIN12 EMGIN21 EMGIN22

TBEB2 FENCE11 FENCE12 FENCE21 FENCE22 EMGOUT1 EMGOUT2

EXT24V INT24V INT0V EXT0V

EXT24V INT24V INT0V EXT0V

0V

NOTE Connect a minus ground power supply for externally connected +24V. The circuit will not function properly if a plus ground power supply is connected.

170

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.5 COONECTION OF SERVO AMPLIFIER LR Mate 100iB PSM

AMP1

AMP2

POWER SUPPLY MODULE (αPSMR–1i) A06B–6115–H001

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

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

TB1

TB1

TB1 from MCC

CZ1

L+

L+ L+

L–

L– L–

from circuit protector from emergency stop board

COP10B CX1A

CXA2A

COP10B

CXA2B

CXA2A

CX3

COP10A

CXA2B

CXA2A

JF1 (L)

JF1 (L)

JF2 (M)

JF2 (M)

CX4

JF3 (N)

from robot control board

CZ2 L

CZ2 L

CZ2 M

CZ2 M CZ2 N

to robot Pulse coder Motor power

LR Mate 200iB/ARC Mate 50iB PSM

AMP1

AMP2

POWER SUPPLY MODULE (αPSMR–1i) A06B–6115–H001

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

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

TB1

TB1

TB1 from MCC

CZ1

L+

L+ L+

L–

L– L–

from circuit protector from emergency stop board

COP10B CX1A

CXA2A

CXA2B

COP10B CXA2A

CX3

CXA2B

COP10A CXA2A

JF1 (L)

JF1 (L)

JF2 (M)

JF2 (M)

CX4

JF3 (N) JF3 (N)

from robot control board

CZ2 L

CZ2 L

CZ2 M

CZ2 M CZ2 N

CZ2 N to robot Pulse coder Motor power

171

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.6 CONNECTION OF ROBOT

CRM82 JF1–3

Power cable to RMP Signal cable Ground cable

TBEB3

172

CZ2 L, M, N

B–81535EN/02

CONNECTIONS

3. CONNECTION DETAILS

3.7 CONNECTION OF TEACH PENDANT CABLE

Emergency stop unit CRS16

To teach pendant

Earth plate

Fig.3.7 Teach pendant cable

173

3. CONNECTION DETAILS

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

CONNECTIONS

B–81535EN/02

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

Communication port

Ï Ï Ï ÏÏÏÏÏ ÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏ ÏÏÏÏÏ 01

FG

02

TXD

03

RXD

04

RTS

05

CTS

06

DSR

07

0V

08 09 10 11

12 13

14

(TX)

15

(*TX)

16

(RX)

17

(*RX)

18 19 20

DTR

21 22 23 24 25

174

+24E

Flopply, handy file etc.

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

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

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

Name Robot control board A

Drawing number A16B–3200–0450

CRM79

CRM81

DI

DO

DI

DO

20

20

8

4

Remarks Standard

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

Connecting a peripheral device (CRM79 or CRM81)

Robot control board CRM81 CRM79

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

Fig.3.9.1 Connecting the peripheral device cable

175

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.9.2 When the Robot is Connected to the CNC by a Peripheral Device Cable

NOTE See the operator’s MANUAL for the detail information. Turn off the controller when connecting the cable.

ÏÏÏÏ ÏÏ ÏÏÏÏ ÏÏ ÏÏÏÏ ÏÏ ÏÏÏÏ ÏÏ ÏÏÏÏ ÏÏ

ÏÏÏÏÏ ÏÏÏÏÏ ÏÏ ÏÏÏÏÏ ÏÏ ÏÏÏÏÏ ÏÏ ÏÏÏÏÏ ÏÏ

CRM79

Robot control board

CNC

CRM81

ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ

CRM79 interface (Specified signals are not allocated and the Robot is connected to CNC and PLC by a FANUC I/O Link cable.)

01

SDI101

33

SDO101

02

SDI102

34

SDO102

03

SDI103

35

SDO103

36

SDO104

37

SDO105

38

SDO106

39

SDO107

04

SDI104

05

SDI105

06

SDI106

07

SDI107

08

SDI108

09

SDI109

10

SDI110

11

12

SDI111

SDI112

13

SDI113

14

SDI114

19

SDICOM1

20

SDICOM2

21

SDO120

22

SDI117

23

SDI118

24

SDI119

40

25

SDI120

41

26

SDO117

42

27

SDO118

43

SDO108 SDO109 SDO110 SDO111

28

44

SDO112

29

SDO119 0V

30

0V

45

SDO113

31

+24E

46

SDO114

32

+24E

47

SDO115

48

SDO116

15

SDI115

16

SDI116

17

0V

49

+24E

18

0V

50

+24E

Connector in cable side HONDA TSUSHIN CO.,LTD Connector MR–50LMH(Male)

SDICOM1 and SDICOM2 are the signals used for selecting a common for SDI signals. To use the +24V common, connect SDICOM1 and SDICOM2 to 0V. To use the 0V common, connect SDICOM1 and SDICOM2 to +24V. SDICOM1→Selects a common for SDI101 to SDI108. SDICOM2→Selects a common for SDI109 to SDI120. (Note) Maximum output current per one SDO signal is 70mA.

176

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

CRM79 interface (standard allocation of specified signals and the Robot is connected to the CNC and PLC by a peripheral device cable.)

Connector in cable side HONDA TSUUSHIN CO.,LTD Connector MR–50LMH (Male)

ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ 01

SDI101

02

SDI102

03

SDI103

04

SDI104

05

SDI105

06

SDI106

07

SDI107

08

SDI108

09

*HOLD

10

RESET

11

START

12

ENBL

13

PNS1

14

PNS2

15

PNS3

16

PNS4

17

0V

49

+24E

18

0V

50

+24E

33

SDO101

34 SDO102 19 SDICOM1 35 SDO103 20 SDICOM2 36 SDO104 21 SDO120 37 SDO105 22 SDI117 38 SDO106 23 SDI118 39 SDO107 24 SDI119 40 SDO108 25 SDI120 41 SDO109 26 SDO117 42 SDO110 27 SDO118 43 SDO111 28 SDO119 44 SDO112 29 0V 45 CMDENBL 30 0V 46 FAULT 31 +24E 47 BATALM 32 +24E 48 BUSY

SDICOM1 and SDICOM2 signal are common selection signal for SDI. When 24 V common is used, connect to 0V. When 0V common is used, connect to +24V SDICOM1”Selects a common for SDI101 to SDI108. SDICOM2”Selects a common for *HOLD, RESET, START, ENBL, PNS1 to PNS4, and SDI117 to SDI120.

NOTE 1 Maximum output current for one SDO signal is 70mA. 2 The common (selected with SDICOM2) for a dedicated signal should ideally be the +24V common, but the 0V common can also be used. 3 Allocation of the specified signals can be changed from the teach pendant.

177

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

CRM79 interface (standard allocation of specified signals and the Robot is connected to the CNC and PLC by a peripheral device cable.)

Connector in cable side HONDA TSUUSHIN CO.,LTD Connector MR–50LMH (Male)

ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ 01

*IMSTP

02

*HOLD

03

*SFSPD

04

CSTOPI

05

RESET

06

START

07

HOME

08

ENBL 09 RSR1/PNS1

10 RSR2/PNS2 11 RSR3/PNS3 12 RSR4/PNS4 13 RSR5/PNS5 14 RSR6/PNS6 15 RSR7/PNS7 15 RSR8/PNS8

33 CMDENBL

34 19 SDICOM1 35 20 SDICOM2 36 reserve 21 37 22 PNSTROBE 38 23 PROD_START 39 24 SDI119 40 25 SDI120 41 26 ACK7/SNO7 42 27 ACK8/SNO8 43 28 SNACK 44 29 0V 45 30 0V 46 31 +24E 47 32 +24E 48

SYSRDY

PROGRUN PAUSED HELD

FAULT

ATPERCH TPENBL

BATALM BUSY

ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6

17

0V

49

+24E

18

0V

50

+24E

SDICOM1 and SDICOM2 signal are common selection signal for SDI. When 24 V common is used, connect to 0V. When 0V common is used, connect to +24V SDICOM1 → Selects a common for *IMSTP, *HOLD, *SFSPD, CSTOPI, RESET, START, HOME, ENBL. SDICOM2 → Selects a common for RSR1/PNS1, RSR2/PNS2, RSR3/PNS3, RSR4/PNS4, RSR5/PNS5, RSR6/PNS6, RSR7/PNS7, RSR8/PNS8, PNSTROBE, PROD_START.

NOTE 1 Maximum output current for one SDO signal is 70mA. 2 The common (selected with SDICOM1 and 2) for a dedicated signal should ideally be the +24V common, but the 0V common can also be used. 3 Allocation of the specified signals can be changed from the teach pendant.

178

CONNECTIONS

B–81535EN/02

3. CONNECTION DETAILS

In case +24V common at the peripheral device side. (Specified signals are not allocated)

Control unit (peripheral device interface : CRM79) +24E

Peripheral device

Connector pin No CRM79 (31,32,49,50)

receiver circuit SDI101

RV

SDI102

RV

SDI103

RV

SDI104

RV

SDI105

RV

SDI106

RV

SDI107

RV

SDI108

RV

SDICOM1

RV

SDI109

RV

SDI110

RV

SDI111

RV

SDI112

RV

SDI113

RV

SDI114

RV

SDI115

RV

SDI116

RV

SDI117

RV

SDI118

RV

SDI119

RV

SDI120

RV

SDICOM2

RV

CRM79 (1)

3.3k

CRM79 (2) CRM79 (3) CRM79 (4) CRM79 (5) CRM79 (6) CRM79 (7) CRM79 (8) CRM79 (19) CRM79 (9) CRM79 (10) CRM79 (11) CRM79 (12) CRM79 (13) CRM79 (14) CRM79 (15) CRM79 (16) CRM79 (22) CRM79 (23) CRM79 (24) CRM79 (25) CRM79 (20) CRM79 (17,18,29,30)

0V

Fig.3.9.2 (a) Peripheral device control interface : CRM79 (Input signal, +24V common)

179

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

In case 0V common at the peripheral device side. (Specified signals are not allocated)

Control unit (peripheral device interface : CRM79) +24E

Peripheral device

Connector pin No CRM79 (31,32,49,50)

receiver circuit SDI101

RV

SDI102

RV

SDI103

RV

SDI104

RV

SDI105

RV

SDI106

RV

SDI107

RV

SDI108

RV

SDICOM1

RV

SDI109

RV

SDI110

RV

SDI111

RV

SDI112

RV

SDI113

RV

SDI114

RV

SDI115

RV

SDI116

RV

SDI117

RV

SDI118

RV

SDI119

RV

SDI120

RV

SDICOM2

RV

CRM79 (1)

3.3k

CRM79 (2) CRM79 (3) CRM79 (4) CRM79 (5) CRM79 (6) CRM79 (7) CRM79 (8) CRM79 (19) CRM79 (9) CRM79 (10) CRM79 (11) CRM79 (12) CRM79 (13) CRM79 (14) CRM79 (15) CRM79 (16) CRM79 (22) CRM79 (23) CRM79 (24) CRM79 (25) CRM79 (20) CRM79 (17,18,29,30)

0V

Fig.3.9.2 (b) Peripheral device control interface : CRM79 (Input signal, 0V common)

180

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

(Specified signals are not allocated)

Control unit (peripheral device interface : CRM79) Connector pin No Driver circuit SDO101

SDO102 SDO103 SDO104 SDO105 SDO106 SDO107 SDO108 SDO109 SDO110 SDO111 SDO112 SDO113 SDO114 SDO115 SDO116 SDO117 SDO118 SDO119 SDO120

Peripheral device LOAD

CRM79 (33)

DV

RELAY

CRM79 (34) DV

LOAD CRM79 (35)

DV

LOAD CRM79 (36) LOAD

DV CRM79 (37) DV

LOAD CRM79 (38)

DV

LOAD CRM79 (39)

DV

LOAD CRM79 (40)

DV

LOAD CRM79 (41)

DV

LOAD CRM79 (42)

DV

LOAD CRM79 (43)

DV

LOAD CRM79 (44)

DV

LOAD CRM79 (45)

DV

LOAD CRM79 (46)

DV

LOAD CRM79 (47)

DV

LOAD CRM79 (48)

DV

LOAD CRM79 (26)

DV

LOAD CRM79 (27)

DV

LOAD CRM79 (28)

DV

LOAD CRM79 (21)

DV

LOAD CRM79 (17,18,29,30)

0V

0V +24V +24V regurated power supply

Max. current per SDO is 70mA.

Fig.3.9.2 (c) Peripheral device control interface : CRM79 (Output signal)

181

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

In case +24V common at the peripheral device side. (Specified signals are allocated)

Control unit (peripheral device interface : CRM79) +24E

Peripheral device

Connector pin No CRM79 (31,32,49,50)

receiver circuit SDI101

RV

SDI102

RV

SDI103

RV

SDI104

RV

SDI105

RV

SDI106

RV

SDI107

RV

SDI108

RV

SDICOM1

RV

SDI109

RV

SDI110

RV

SDI111

RV

SDI112

RV

SDI113

RV

SDI114

RV

SDI115

RV

SDI116

RV

SDI117

RV

SDI118

RV

SDI119

RV

SDI120

RV

SDICOM2

RV

CRM79 (1)

3.3k

CRM79 (2) CRM79 (3) CRM79 (4) CRM79 (5) CRM79 (6) CRM79 (7) CRM79 (8) CRM79 (19) CRM79 (9) CRM79 (10) CRM79 (11) CRM79 (12) CRM79 (13) CRM79 (14) CRM79 (15) CRM79 (16) CRM79 (22) CRM79 (23) CRM79 (24) CRM79 (25) CRM79 (20) CRM79 (17,18,29,30)

0V

Fig.3.9.2 (d) Peripheral device control interface : CRM79 (Input signal, +24V common)

182

CONNECTIONS

B–81535EN/02

3. CONNECTION DETAILS

In case 0V common at the peripheral device side. (Specified signals are allocated)

Control unit (peripheral device interface : CRM79) +24E

Peripheral device

Connector pin No CRM79 (31,32,49,50)

receiver circuit SDI101

RV

SDI102

RV

SDI103

RV

SDI104

RV

SDI105

RV

SDI106

RV

SDI107

RV

SDI108

RV

SDICOM1

RV

SDI109

RV

SDI110

RV

SDI111

RV

SDI112

RV

SDI113

RV

SDI114

RV

SDI115

RV

SDI116

RV

SDI117

RV

SDI118

RV

SDI119

RV

SDI120

RV

SDICOM2

RV

CRM79 (1)

3.3k

CRM79 (2) CRM79 (3) CRM79 (4) CRM79 (5) CRM79 (6) CRM79 (7) CRM79 (8) CRM79 (19) CRM79 (9) CRM79 (10) CRM79 (11) CRM79 (12) CRM79 (13) CRM79 (14) CRM79 (15) CRM79 (16) CRM79 (22) CRM79 (23) CRM79 (24) CRM79 (25) CRM79 (20) CRM79 (17,18,29,30)

0V

Fig.3.9.2 (e) Peripheral device control interface : CRM79 (Input signal, 0V common)

183

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

(Specified signals are allocated)

Control unit (peripheral device interface : CRM79) Connector pin No Driver circuit SDO101

SDO102 SDO103 SDO104 SDO105 SDO106 SDO107 SDO108 SDO109 SDO110 SDO111 SDO112 SDO113 SDO114 SDO115 SDO116 SDO117 SDO118 SDO119 SDO120

Peripheral device LOAD

CRM79 (33)

DV

RELAY

CRM79 (34) DV

LOAD CRM79 (35)

DV

LOAD CRM79 (36) LOAD

DV CRM79 (37) DV

LOAD CRM79 (38)

DV

LOAD CRM79 (39)

DV

LOAD CRM79 (40)

DV

LOAD CRM79 (41)

DV

LOAD CRM79 (42)

DV

LOAD CRM79 (43)

DV

LOAD CRM79 (44)

DV

LOAD CRM79 (45)

DV

LOAD CRM79 (46)

DV

LOAD CRM79 (47)

DV

LOAD CRM79 (48)

DV

LOAD CRM79 (26)

DV

LOAD CRM79 (27)

DV

LOAD CRM79 (28)

DV

LOAD CRM79 (21)

DV

LOAD CRM79 (17,18,29,30)

0V

0V +24V +24V regurated power supply

Max. current per SDO is 70mA.

Fig.3.9.2 (f) Peripheral device control interface : CRM79 (Output signal)

184

CONNECTIONS

B–81535EN/02

3. CONNECTION DETAILS

In case +24V common at the peripheral device side. (Specified signals are allocated quickly)

Control unit (peripheral device interface : CRM79) +24E

Peripheral device

Connector pin No CRM79 (31,32,49,50)

receiver circuit *IMSTP

RV

*HOLD

RV

*SFSPD

RV

CSTOPI

RV

RESET

RV

SRART

RV

HOME

RV

ENBL

RV

SDICOM1

RV

RSR1/PNS1

RV

RSR2/PNS2

RV

RSR3/PNS3

RV

RSR4/PNS4

RV

RSR5/PNS5

RV

RSR6/PNS6

RV

RSR7/PNS7

RV

RSR8/PNS8

RV

PNSTROBE

RV

PROD_START

RV

SDI119

RV

SDI120

RV

SDICOM2

RV

CRM79 (1)

3.3k

CRM79 (2) CRM79 (3) CRM79 (4) CRM79 (5) CRM79 (6) CRM79 (7) CRM79 (8) CRM79 (19) CRM79 (9) CRM79 (10) CRM79 (11) CRM79 (12) CRM79 (13) CRM79 (14) CRM79 (15) CRM79 (16) CRM79 (22) CRM79 (23) CRM79 (24) CRM79 (25) CRM79 (20) CRM79 (17,18,29,30)

0V

Fig.3.9.2 (g) Peripheral device control interface : CRM79 (Input signal, +24V common)

185

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

In case 0V common at the peripheral device side. (Specified signals are allocated quickly)

Control unit (peripheral device interface : CRM79)

Peripheral device

Connector pin No +24E CRM79 (31,32,49,50) receiver circuit *IMSTP

RV

*HOLD

RV

*SFSPD

RV

CSTOPI

RV

RESET

RV

START

RV

HOME

RV

ENBL

RV

SDICOM1

RV

RSR1/PNS1

RV

RSR2/PNS2

RV

RSR3/PNS3

RV

RSR4/PNS4

RV

RSR5/PNS5

RV

RSR6/PNS6

RV

RSR7/PNS7

RV

RSR8/PNS8

RV

PNSTROBE

RV

PROD_START

RV

SDI119

RV

SDI120

RV

SDICOM2

RV

CRM79 (1) 3.3k

CRM79 (2) CRM79 (3) CRM79 (4) CRM79 (5) CRM79 (6) CRM79 (7) CRM79 (8) CRM79 (19) CRM79 (9) CRM79 (10) CRM79 (11) CRM79 (12) CRM79 (13) CRM79 (14) CRM79 (15) CRM79 (16) CRM79 (22) CRM79 (23) CRM79 (24) CRM79 (25) CRM79 (20) CRM79 (17,18,29,30)

0V

Fig.3.9.2 (h) Peripheral device control interface : CRM79 (Input signal, 0V common)

186

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

(Specified signals are allocated quickly)

Control unit (peripheral device interface : CRM79) Driver circuit CMDENBL

SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK reserve

Connector pin No

Peripheral device LOAD

CRM79 (33)

DV

RELAY

CRM79 (34)

DV

LOAD CRM79 (35)

DV

LOAD

CRM79 (36)

DV

LOAD CRM79 (37)

DV

LOAD

CRM79 (38)

DV

LOAD CRM79 (39)

DV

LOAD

CRM79 (40)

DV

LOAD CRM79 (41)

DV

LOAD

CRM79 (42)

DV

LOAD CRM79 (43)

DV

LOAD

CRM79 (44)

DV

LOAD CRM79 (45)

DV

LOAD CRM79 (46)

DV

LOAD

CRM79 (47)

DV

LOAD CRM79 (48)

DV

LOAD

CRM79 (26)

DV

LOAD CRM79 (27)

DV

LOAD

CRM79 (28)

DV

LOAD CRM79 (21)

DV

CRM79 (17,18,29,30) 0V

LOAD 0V +24V +24V regurated power supply

Max. current per SDO is 70mA.

Fig.3.9.2 (i) Peripheral device control interface : CRM79 (Output signal)

187

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

CRM81 interface (When a special signal is not allocated; when CNC and PLC are connected by an I/O Link cable) A

B

01

SDI81

SDI82

02

SDI83

SDI84

03

SDI85

SDI86

04

SDI87

SDI88

05

SDICOM

06 07

SDO81

SDO82

08

SDO83

SDO84

09 10

Cable–side connector YAMAICHI ELECTRICITY Connector Housing – UFS–20B–04 – 66 type (UFS )

0V +24V

0V

CRM81 interface (When a special signal is allocated; when CNC and PLC are connected by a peripheral device cable) A

B

01

*HOLD

RESET

02

START

ENBL

03

PNS1

PNS2

04

PNS3

PNS4

05

SDICOM

06 07

CMDENBL

FAULT

08

BATALM

BUSY

09 10

Cable–side connector YAMAICHI ELECTRICITY Connector Housing – UFS–20B–04 – 66 type (UFS )

0V +24E

0V

SDICOM1 is a common signal that can be used either as an SDI or special signal. +24 V common: Connected to 0 V 0 V common: Connected to +24 V SDICOM ³ Selects a common for SDI81 to SDI88. CAUTION The maximum output current of each SDO or special signal is 70 mA.

188

CONNECTIONS

B–81535EN/02

3. CONNECTION DETAILS

In case +24V common at the peripheral device side. (Specified signal is not allocated.)

Control unit (peripheral device interface : CRM81) +24E

Peripheral device

Connector pin No CRM81 (A10)

receiver circuit SDI81

RV

SDI82

RV

SDI83

RV

SDI84

RV

SDI85

RV

SDI86

RV

SDI87

RV

SDI88

RV

SDICOM

RV

CRM81 (A1)

3.3k

CRM81 (B1) CRM81 (A2) CRM81 (B2) CRM81 (A3) CRM81 (B3) CRM81 (A4) CRM81 (B5) CRM81 (A5) CRM81 (B9,B10) 0V

Fig.3.9.2 (j) Peripheral device control interface : CRM81 (Input signal, +24V common)

189

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

In case 0V common at the peripheral device side. (Specified signal is not allocated.)

Control unit (peripheral device interface : CRM81) +24E

Peripheral device

Connector pin No CRM81 (A10)

receiver circuit SDI81

RV

SDI82

RV

SDI83

RV

SDI84

RV

SDI85

RV

SDI86

RV

SDI87

RV

SDI88

RV

SDICOM

RV

CRM81 (A1)

3.3k

CRM81 (B1) CRM81 (A2) CRM81 (B2) CRM81 (A3) CRM81 (B3) CRM81 (A4) CRM81 (B5) CRM81 (A5) CRM81 (B9,B10) 0V

Fig.3.9.2 (k) Peripheral device control interface : CRM81 (Input signal, 0V common)

(Specified signal is not allocated.)

Control unit (peripheral device interface : CRM81) Connector pin No Driver circuit SDO8 1

DV

SDO82

DV

SDO83 SDO84

Peripheral device LOAD

CRM81 (A7) RELAY

CRM81 (B7) LOAD CRM81 (A8) DV

LOAD CRM81 (B8)

DV

LOAD CRM81 (B9,B10)

0V

0V +24V +24V regurated power supply

Max. current per SDO is 70mA.

Fig.3.9.2 (l) Peripheral device control interface : CRM81 (Output signal)

190

CONNECTIONS

B–81535EN/02

3. CONNECTION DETAILS

In case +24V common at the peripheral device side. (Specified signal is allocated quickly)

Control unit (peripheral device interface : CRM81) +24E

Peripheral device

Connector pin No CRM81 (A10)

*HOLD RESET

receiver circuit RV 3.3k RV

START

RV

ENBL

RV

PNS1

RV

PNS2

RV

PNS3

RV

PNS4

RV

SDICOM

RV

CRM81 (A1) CRM81 (B1) CRM81 (A2) CRM81 (B2) CRM81 (A3) CRM81 (B3) CRM81 (A4) CRM81 (B5) CRM81 (A5) CRM81 (B9 ,B10)

0V

Fig.3.9.2 (m) Peripheral device control interface : CRM81 (Input signal, +24V common)

191

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

In case 0V common at the peripheral device side. (Specified signal is allocated quickly)

Control unit (peripheral device interface : CRM81) +24E

Peripheral device

Connector pin No CRM81 (A10)

receiver circuit *HOLD

RV

RESET

RV

START

RV

ENBL

RV

PNS1

RV

PNS2

RV

PNS3

RV

PNS4

RV

SDICOM

RV

CRM81 (A1) 3.3k

CRM81 (B1) CRM81 (A2) CRM81 (B2) CRM81 (A3) CRM81 (B3) CRM81 (A4) CRM81 (B5) CRM81 (A5) CRM81 (B9 ,B10)

0V

Fig.3.9.2 (n) Peripheral device interface : CRM81 (Input signal, 0V common)

(Specified signal is allocated quickly)

Control unit (peripheral device interface : CRM81)

Peripheral device

Connector pin No LOAD

driver circuit CMDENBL

DV

FAULT

DV

BATALM BUSY

CRM81 (A7) RELAY

CRM81 (B7) LOAD CRM81 (A8)

DV

LOAD CRM81 (B8)

DV

LOAD CRM81 (B9 ,B10) 0V

0V +24V +24V regurated power supply

Max. current per SDO is 70mA.

Fig.3.9.2 (o) Peripheral device control interface : CRM81 (Output signal)

192

B–81535EN/02

3.9.3 Digital I/O Signal Specifications

3. CONNECTION DETAILS

CONNECTIONS

This section describes the specifications of the digital I/O signals interfaced with the peripheral device and end effector.

3.9.3.1 Peripheral device interface CRM 79 and CRM 81 D Output signal regulation

Example of connection Spark killer diode +24V 70 mA or less

0V

0V

+24V Lamp 70 mA or less

0V

Protective resistance

D Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at connection

: : : : :

D Spark killer diode Rated peak reverse voltage Rated effective forward current

: 100 V or more : 1 A or more

0V

24 VDC 30 VDC 70.mA Open collector NPN 1.0 V (approx.)

D Notes on use Do not use the +24 V power supply of the robot. When loading a relay, solenoid, and so on directly, connect them in parallel with diodes for preventing back electromotive force. If a load causing a surge current such as turning on LED is connected, use a protective resistance. D Applicable signal Output signal of peripheral device interface CRM79, CRM81 : SDI101 to SDI120 (CRM79) SDI81 to SDI88 (CRM81)

193

3. CONNECTION DETAILS

D Input signal regulation

CONNECTIONS

B–81535EN/02

Example of connection +24V

SDI n

RV

3.3 kΩ SDICOM

RV

Example of +24V common connection

0V

D Electrical specifications of the receiver Type : Grounded voltage receiver Rated input voltage : close :+20 V to +28 V open :0 V to +4 V Maximum applied input voltage : +28 VDC Input impedance : 3.3 kΩ (approx.) Response time : 5 ms to 20 ms D Specifications of the peripheral device Rated capacity : 30 VDC, 50 mA or more Input signal width : 200 ms or more (on/off) Chattering time : 5 ms or less Closed circuit resistance : 100Ω or less Opened circuit resistance : 100 kΩ or more TB

(Signal)

TB

(Signal)

TB

Peripheral device signal

Robot receiver signal TC

TC

TB ; TC ;

Chattering 5 ms or less 5 to 20 ms

D Note on use Apply the +24 V power of the robot to the receiver. However, the above signal regulations must be satisfied at the robot receiver. D Applicable signal Input signal of peripheral device interface CRM79, CRM81 : SDO101 to SDO120 (CRM79) SDO81 to SDO84 (CRM81)

194

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.9.4

The figure below shows the connector for peripheral device cable.

Peripheral Device Cable Connector

Symbol

Name

1

Connector cover

2

Connector 50 pins (male) Dimensions

Remark

Connector specification

Applicable interface

A

(B)

C

(D)

MR50LWM

CRM79

67.9

73.5

66.1

20

Honda Tsushin Kogyo E φ16 φ 50 pins

Fig.3.9.4 (a) Peripheral Device Cable Connector (CRM79 : Honda Tsushin Kogyo)

195

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

A B

3.56 2.54

2.54 6.0

14.3 14.5

Connector specification

Dimensions

Applicable interface

UFS–20B–04

Remark

A

C

29.98

22.86

CRM81

YAMAICHI ELECTRONICS (Housing) YAMAICHI ELECTRONICS ()

66 type

Applicable cable : AWG#28 (7/0.12), AWG#26 (19/0.1), AWG#24 (19/0.12), (7/0.18)

Fig.3.9.4 (b) Peripheral Device Cable Connector (CRM81 : YAMAICHI ELECTRONICS)

3.9.5 Recommended Cables

Connect a peripheral device using a completely shielded, heavily protected cable conforming to the specifications in Table 3.9.5. Allow an extra 1.5m for routing the cable in the control unit. The maximum cable length is 30m.

Table 3.9.5 Recommended cable (For peripheral device connection) Conductor

Electrical characteristics

Sheath thickness (mm)

Effective outside diameter (mm)

Conductor resistance (Ω/km)

Allowable current (A)

7/0.18 AWG24

1.5

φ12.5

106

1.6

7/0.18 AWG24

1.5

φ10.5

106

1.6

Number of wires

Wire specifications (FANUC specifications)

Diameter (mm)

Configuration

50

A66L–0001–0042

φ1.05

20

A66L–0001–0041

φ1.05

196

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.10 END EFFECTOR INTERFACE 3.10.1 Connecting the Mechanical Unit and End Effector Table 3.10.1 Types of end effector interfaces End effector interface No. 1

Name

Drawing number A16B–3200–0450

Robot control board A

DI

DO

6

6

Remarks Standard

NOTE Either RDI6 or *PPABN is selected by software.

Mechanical unit EE 1 2 3 4 5

RDI1 RDI2 RDI3 RDI4 RDI5

7 8 9 10 11

*HBK +24E +24E +24E 0V

6

RDI6 (*PPABN)

12

RDICOM

End effecter

NOTE RDO1 to RDO6 are used as the signals to turn on or off solenoid valves. The end effector can use the RDI signals and *HBK signal. For RDO signals, refer to the maintenance manual of the mechanical unit.

197

3. CONNECTION DETAILS

CONNECTIONS

End effecter

Mechanical unit (end effector interface) +24E

Connector pin No. EE (8,8,10)

Receiver circuit RDI1

RV

RDI2

RV

RDI3

RV

RDI4

RV

RDI5

RV

RDI6 (*PPABN)

RV

RDICOM

RV

B–81535EN/02

EE (1)

3.3k

EE (2) EE (3) EE (4) EE (5) EE (6)

EE (12) EE (11)

0V

Fig.3.10.1 (a) End effector interface (+24V common)

End effecter

Mechanical unit (end effector interface) +24E

Connector pin No. EE (8,8,10)

Receiver circuit RDI1

RV

RDI2

RV

RDI3

RV

RDI4

RV

RDI5

RV

RDI6 (*PPABN)

RV

RDICOM

RV

EE (1)

3.3k

EE (2) EE (3) EE (4) EE (5) EE (6)

EE (12) EE (11)

0V

Fig.3.10.1 (b) End effector interface (0V common)

198

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.10.2 Digital I/O Signal Specifications of End Effector Control Interface

Example of connection

+24V

RDI n

RV

3.3 kΩ RDICOM

RV

Example of +24V common connection

0V

Electrical specifications of the receiver Type Rated input voltage

: Grounded voltage receiver : close : +20 V to +28 V open : 0 V to +4 V Maximum applied input voltage : +28 VDC Input impedance : 3.3 kΩ (approx.) Response time : 5 ms to 20 ms Specifications of the peripheral device Rated capacity Input signal width Chattering time Closed circuit resistance Opened circuit resistance TB

(Signal)

TB

(Signal)

: : : : :

30 VDC, 50 mA or more 200 ms or more (on/off) 5 ms or less 100 Ω or less 100 kΩ or more TB

Peripheral device signal

Robot receiver signal TC

TC

TB ; TC ;

Chattering 5 ms or less 5 to 20 ms

Note on use Apply the +24 V power at the robot to the receiver. However, the above signal specifications must be satisfied at the robot receiver. Applicable signals Input signals of end effector control interface Additional I/O PCB CRW6 input signal WDI1 to WDI8 RDI 1 to 6, *HBK, *PPABN (Switch RDI6 by software) 199

3. CONNECTION DETAILS

3.11 TREATMENT FOR THE SHIELDED CABLE

CONNECTIONS

B–81535EN/02

In this manual the treatment for the shielded cable is shown on several pages. Partly cut off the shielded cable to expose the shield jacket, and fasten the jacket to the shield plate with a clamp to protect against noise. (In case of stand–alone type a shield plate is installed in the controller.)

Fig.2.12 Shielded cable treatment

200

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.12

Connection to the peripheral device and the arc welding is available to use the process I/O board for R–J3iB Mate.

PERIPHERAL DEVICE, ARC WELDING, INTERFACES 3.12.1 Peripheral Device Interface Types No.

Name

1

Process I/O board HE

2

Process I/O board HF

Drawing number

Number of I/O points DI

DO

D/A

A/D

A05B–2440–J002

40

40

2

6

A05B–2440–J003

40

40

0

0

Remarks

NOTE General purpose I/O (SDI/SDO) is a number which subtract an exclusive signal from the table value.

201

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.12.2 Peripheral Device Interface Block Diagram and Specifications

Process I/O board HE/HF

Peripheral device

Main board CRM2A JD4A (JD1B)

JD1A (JD4)

CRM2B JD4B (JD1A) CRW7 (NOTE 1)

CRW2 (NOTE1)

Fig.3.12.2 Block diagram of the process I/O board HE and HF

NOTE 1 CRW2 and CRW7 are not provided for process I/O board HF.

202

CONNECTIONS

B–81535EN/02

3.12.3 Peripheral Device and Control Unit Connection Control unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

3. CONNECTION DETAILS

The connection is for the allocated specified signal. For detail of the allocation, refer to the OPERATOR’S MANUAL.

Peripheral device control interface A1 CMDENBL CRM2A 33

*IMSTP

*HOLD *SFSPD CSTOPI FAULT RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 0V 0V

19 20 21 22 23 24 25 26 27 28 29 30 31 32

ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 COM–A4 ACK7/SNO7 ACK8/SNO8 SNACK RESERVED COM–A5 PNSTROBE PROD START SDI01 SDI02

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

SYSRDY PROGRUN PAUSED COM–A1 HELD FAULT ATPERCH TPENBL COM–A2 BATALM BUSY ACK1/SNO1 ACK2/SNO2 COM–A3

Peripheral device A1

+24E +24E

Peripheral device control interface A2 SDO01 CRM2B 33

SDI03 SDI04 SDI05 SDI06 SDI07 SDI08 SDI09 SDI10 SDI11 SDI12 SDI13 SDI14 SDI15 SDI16 SDI17 SDI18 0V 0V

19 20 21 22 23 24 25 26 27 28 29 30 31 32

SDO13 SDO14 SDO15 SDO16 COM–B4 SDO17 SDO18 SDO19 SDO20 COM–B5 SDI19 SDI20 SDI21 SDI22

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

SDO02 SDO03 SDO04 COM–B1 SDO05 SDO06 SDO07 SDO08 COM–B2 SDO09 SDO10 SDO11 SDO12 COM–B3

Peripheral device A2

+24E +24E

NOTE 1 Peripheral device connection cable are optional. 2 All COM-** are connected to the 0V. Applicable process I/O board type HE, HF

203

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

Peripheral device

Control unit (peripheral device control interface A1) +24E Connector pin No. CRM2A (49,50) Receiver circuit *IMSTP

RV

*HOLD

RV

*SFSPD

RV

CSTOPI

RV

CRM2A (1) 3.3k CRM2A (2) CRM2A (3) CRM2A (4)

0V FAULT RESET

RV

START

RV

HOME

RV

ENBL

RV

RSR1/PNS1

RV

RSR2/PNS2

RV

RSR3/PNS3

RV

RSR4/PNS4

RV

RSR5/PNS5

RV

RSR6/PNS6

RV

RSR7/PNS7

RV

RSR8/PNS8

RV

PNSTROBE

RV

PROD START

RV

SDI01

RV

SDI02

RV

COM–1

CRM2A (5) CRM2A (6) CRM2A (7) CRM2A (8) CRM2A (9) CRM2A (10) CRM2A (11) CRM2A (12) CRM2A (13) CRM2A (14) CRM2A (15) CRM2A (16) CRM2A (29) CRM2A (30) CRM2A (31) CRM2A (32)

RV +24E

CRM2A (17,18) B

A 0V

Common setting pin (ICOM1)

0V

NOTE This is a connection diagram for +24V common.

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3. CONNECTION DETAILS

Peripheral device

Control unit (peripheral device control interface A1) Connector pin No. Driver circuit CRM2A (33)

DV

LOAD RELAY

CMDENBL 0V

SYSRDY

DV

PROGRUN

DV

PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8

CRM2A (34) CRM2A (35) CRM2A (36)

DV

CRM2A (38)

DV

CRM2A (39)

DV

CRM2A (40)

DV

CRM2A (41)

DV

CRM2A (43)

DV

CRM2A (44)

DV

CRM2A (45)

DV

CRM2A (46)

DV

CRM2A (19)

DV

CRM2A (20)

DV

CRM2A (21)

DV

CRM2A (22)

DV

CRM2A (24)

DV

CRM2A (25)

DV

SNACK

DV

RESERVED

DV

CRM2A (26) CRM2A (27)

LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD

CRM2A (23,28,37,42,47) 0V +24V +24V regurated power supply

0V Max. current per UDO is 70mA

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3. CONNECTION DETAILS

CONNECTIONS

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Peripheral device

Control unit (peripheral device control interface A2) +24E

Connector pin No. CRM2B (49,50)

Receiver circuit SDI03

RV

SDI04

RV

SDI05

RV

SDI06

RV

SDI07

RV

SDI08

RV

SDI09

RV

SDI10

RV

SDI11

RV

SDI12

RV

SDI13

RV

SDI14

RV

SDI15

RV

SDI16

RV

SDI17

RV

SDI18

RV

SDI19

RV

SDI20

RV

SDI21

RV

SDI22

RV

COM–2

RV

CRM2B (1) 3.3k CRM2B (2) CRM2B (3) CRM2B (4) CRM2B (5) CRM2B (6) CRM2B (7) CRM2B (8) CRM2B (9) CRM2B (10) CRM2B (11) CRM2B (12) CRM2B (13) CRM2B (14) CRM2B (15) CRM2B (16) CRM2B (29) CRM2B (30) CRM2B (31) CRM2B (32) CRM2B (17,18)

+24E

B

A 0V

Common setting pin (ICOM2)

0V

NOTE This is a connection diagram for +24V common.

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CONNECTIONS

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3. CONNECTION DETAILS

Peripheral device

Control unit (peripheral device control interface A2) Connector pin No. Driver circuit CRM2B (33)

DV

LOAD RELAY

SDO01 0V CRM2B (34)

SDO02

DV

SDO03

DV

SDO04

DV

SDO05

DV

SDO06

DV

SDO07

DV

SDO08

DV

SDO09

DV

CRM2B (35) CRM2B (36) CRM2B (38) CRM2B (39) CRM2B (40) CRM2B (41) CRM2B (43) CRM2B (44)

SDO10

DV CRM2B (45)

SDO11

DV CRM2B (46)

SDO12

DV CRM2B (19)

SDO13

DV CRM2B (20)

SDO14

DV CRM2B (21)

SDO15

DV CRM2B (22)

SDO16

DV CRM2B (24)

SDO17

DV CRM2B (25)

SDO18 SDO19 SDO20

DV CRM2B (26) DV CRM2B (27) DV CRM2B (23,28,37,42,47) 0V

Max. current per DO is 70mA

207

LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD LOAD

0V +24V +24V regurated power supply

3. CONNECTION DETAILS

CONNECTIONS

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3.12.4 Connection Between the Control Unit and Welder Control unit Anaput interface CRW2

Peripheral device

NOTE Welder and peripheral device connection cable are optional. Applicable process I/O board type HE

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CONNECTIONS

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3. CONNECTION DETAILS

Analog connection of CRW2 connector (Anaput) Control unit (Anaput interface) Process I/O HE

Peripheral device Connector pin number CRW2 (10) ADCH1 CRW2 (11) COMAD1

CRW2 (12) ADCH2 CRW2 (13) COMAD2

CRW2 (14) ADCH3 CRW2 (15) COMAD3 Output signals without ripples. CRW2 (16) ADCH4 CRW2 (17) COMAD4

CRW2 (18) ADCH5 CRW2 (19) COMAD5

CRW2 (8) ADCH6 CRW2 (9) COMAD6 0V

209

3. CONNECTION DETAILS

CONNECTIONS

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Control unit Welder interface CRW7

Welder

NOTE Welder and peripheral device connection cable is option. Applicable process I/O board type HE

210

CONNECTIONS

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3. CONNECTION DETAILS

Attaching the CRW7 connector to the welding machine: FANUC interface (Analog output, welding wire deposition detected, and WDI/WDO connection: Connected to the +24 V common line)

Control unit (welding interface) Process I/O HE

Welding voltage command signal

Wire speed command signal

CRW7 (1)

Welding machine MS connector pin No. A

CRW7 (2)

B

CRW7 (3)

C

CRW7 (4)

D

Connector pin No.

DACH1 COMDA1 DACH2 COMDA2

Connector pin No.

Receiver circuit Arc detected signal

WDI02

RV

Gas outage detected signal

WDI03

RV

Broken–wire detected signal Arc turn–off detected signal (power supply failure)

WDI04

RV

WDI06

RV

COM–3

RV +24E

3.3k

CRW7 (6)

P

CRW7 (7)

T

CRW7 (8)

S

CRW7 (10)

R

+24E B

A

CRW7 (33,34)

E

Common setting pin 0V (ICOM3)

WDO01

CRW7 (23)

L

WCOM1

CRW7 (24)

K

WDO04

CRW7 (29)

F

WCOM4

CRW7 (30)

G

WDO05

CRW7 (13)

H

WCOM5

CRW7 (14)

J

Welding start signal

Wire inching (+)

Wire inching (–)

R=100 Ω or more

Wire deposition detected signal

WDI+

CRW1 (31)

M

+

WDI–

CRW1 (32)

N

–

+ Cabinet ground (shield clamp)

211

–

Welding power supply Welding machine frame ground

3. CONNECTION DETAILS

CONNECTIONS

NOTE This is the connection for +24V.

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3. CONNECTION DETAILS

CONNECTIONS

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Attaching the CRW7 connector to the welding machine: FANUC interface (Analog output, welding wire deposition detected, and WDI/WDO connection: Connected to the +24 V common line) Control unit (welding interface) Process I/O HE

Connector pin No. CRW7 (1)

DACH1

Welding voltage command signal

CRW7 (2) COMDA1 CRW7 (3) DACH2

Wire speed command signal

CRW7 (4) COMDA2 Receiver circuit WDI01

RV

Arc detected signal

WDI02

RV

Gas outage detected signal Broken–wire detected signal Cooling water outage signal Arc turn–off detected signal (power supply failure)

WDI03

RV

WDI04

RV

WDI05

RV

WDI06

RV

WDI07

RV

WDI08

RV

COM–3

RV

+24E

B

Connector pin No. 3.3k CRW7 (5)

Welding machine MS connector pin No. A B E F

c

CRW7 (6)

d

CRW7 (7)

e

CRW7 (8)

f

CRW7 (9)

g

CRW7 (10)

h

CRW7 (11)

j

CRW7 (12)

k

CRW7 (33,34)

r

+24E

A

CRW7 (19,20) Common setting pin 0V (ICOM3)

CRW7 (21,22)

m n

0V WDO01 Welding start signal WCOM1 WDO02 Gas signal WCOM2 WDO04 Wire inching (+) WCOM4 WDO05

CRW7 (23)

R

CRW7 (24) CRW7 (23) CRW7 (24) CRW7 (29)

S a U

CRW7 (30) CRW7 (13)

V

Wire inching (–) WCOM5

Wire deposition detected signal

WDI+ WDI–

CRW7 (14)

b R=100 Ω or more

CRW1 (31)

N

+

CRW1 (32)

P

–

Cabinet ground (shield clamp)

213

s + – Welding power supply Welding machine frame ground

3. CONNECTION DETAILS

3.12.5 Digital I/O Signal Specifications of Peripheral Device Interface A

CONNECTIONS

B–81535EN/02

(1) Output signals in peripheral device interface A Example of connection Spark killer diode +24V

70 mA or less

0V +24V Lamp 70 mA or less

0V Protective resistance

Electrical specifications Rated voltage Maximum applied voltage Maximum load current Transistor type Saturation voltage at connection

: : : : :

Spark killer diode Rated peak reverse voltage Rated effective forward current

: 100 V or more : 1 A or more

24 VDC 30 VDC 70 mA Open collector NPN 1.0 V (approx.)

NOTE Do not use the +24 V power supply of the robot. When you load a relay, solenoid, and so on directly, connect them in parallel with diodes to prevent back electromotive force. If a load is connected causing a surge current when a lamp is turned on, use a protective resistance. Applicable signals Output signals of process I/O board CRM2 CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT, ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNACK, SDO1 to SDO76

214

3. CONNECTION DETAILS

CONNECTIONS

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(2) Input signals in peripheral device interface A Example of connection +24V

RV 3.3 kW +24V B

A

ICOM

Electrical specifications of the receiver Type : Grounded voltage receiver Rated input voltage : close : +20 V to +28 V open : 0 V to +4 V Maximum applied input voltage : +28 VDC Input impedance : 3.3 kΩ (approx.) Response time : 5 ms to 20 ms Specifications of the peripheral device Rated capacity : 30 VDC, 50 mA or more Input signal width : 200 ms or more (on/off) Chattering time : 5 ms or less Closed circuit resistance : 100 Ω or less Opened circuit resistance : 100 kΩ or more TB

(Signal)

TB

(Signal)

TB

Peripheral device signal

Robot receiver signal TC

TC

TB ; TC ;

Chattering 5 ms or less 5 to 20 ms

NOTE Apply the +24 V power at the robot to the receiver. However, the above signal specifications must be satisfied at the robot receiver. Applicable signals Input signals of process I/O board CRM2 *IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET, START, HOME, ENBL, RSR1 to RSR8, PNS1 to PNS8, PNSTROBE, PROD START, SDI1 to SDI78 215

3. CONNECTION DETAILS

CONNECTIONS

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3.12.6 I/O Signal Specifications for ARC–Welding Interface

(1) Digital output signal specifications for an arc welding interface In case of process I/O HE Example connection Spark killer diode

0.3 A or less

Electrical characteristics Rated voltage Maximum applied voltage Maximum load current Output type

: : : :

24 VDC 30 VDC 0.3 A Relay connection output

Spark killer diode Rated peak reverse voltage : 100 V or more Rated effective forward current : 1 A or more NOTE A power voltage of +24 V, provided for the robot, can be used for interface signals of up to 0.7 A. This limit applies to the sum of the currents flowing through the arc–welding and end–effector control interfaces. To drive a relay or solenoid directly, connect a diode preventing back electromotive force to the load in parallel. To connect a load which generates an inrush current when you turn on the control unit, connect a protective resistor. Applicable signals – Output signals on the arc–welding interface – WDO1 to WDO4

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3. CONNECTION DETAILS

CONNECTIONS

(2) Digital input signal specifications for arc welding interface Example connection

Electrical characteristics of receivers Type: Grounded voltage receiver Rated input voltage : +20 to +28 V with s closed 0 to +4 V when open Maximum input voltage : +28 VDC Input impedance : About 3.3 k Response time : 5 to 20 ms specifications for peripherals Rated capacity : 30 VDC, 50 mA or more Input signal width : 200 ms or more for on and off states Chattering period : 5 ms or less Closed–circuit resistance : 100 Ω or less Open–circuit resistance : 100 kΩ or more

(Signal)

(Signal)

signal for peripheral

Receiver signal for robot

TB: Chattering of 5 ms or less TC: 5 to 20 ms

NOTE Supply the +24 V power, provided for the robot, to the receivers. The receiver signal on the robot must satisfy the signal timing specified above. Applicable signals – Input signals for arc welding interface – WDI1 to WDI8 217

3. CONNECTION DETAILS

CONNECTIONS

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(3) Analog output signal specifications for arc welding interface (Welding voltage command, wire–feed rate command) Example connection

Welder

Process I/O CA, EA : –10V to +10V Process I/O GA, HA : 0V to +15V 0V

NOTE Input impedance: 3.3 kΩ or more Connect a high– filter. (4) Anaput signal specifications for arc welding interface (Welding–voltage detection, welding–current detection) Example connection Welder –10V to +10V 0V

NOTE The anaput signal should have no ripple for the circuit to operate properly. (Wire deposit detection: WDI+ and WDI–) Example connection Welder

Welding electrode

NOTE Connect a resistor of 100Ω or more between the positive and negative electrodes of the welder. Isolate the deposit detection signals for TIG welding from the welding circuit, which uses high–frequency components. The dielectric withstand voltage of this circuit is 80 V.

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3. CONNECTION DETAILS

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3.12.7

If the customer manufactures cables, make sure they conform to the FANUC standard cables described in this section. (See the description in “Peripheral Device Interface” in this manual for the specifications of the FANUC standard cables.)

Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin, 50 pins)

Honda Tsushin MR50LWF01 (MR50LF)

Honda Tsushin MR50LM01 (MR50LM) Peripheral device

Process I/O

Honda Tsushin MR50RMA

3.12.8

Honda Tsushin’s MR50RF Supplied with an ordered cable

Be sure to use the FANUC cable to connect the welder.

ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins)

ARC welder Honda Tsushin Process I/O CRW1 or CRW7 Honda Tsushin MR34RFA

Japan Aviation Electronics Industry Ltd. MS3108B28–21P MS3057–16

219

Japan Aviation Electronics Industry Ltd. MS3102A28–21S Standard position of guide key

3. CONNECTION DETAILS

CONNECTIONS

B–81535EN/02

3.12.9 Peripheral Device Cable Connector

(1) Fig. 3.12.9 shows the connector for peripheral device cables A and B. (The connector is used for a peripheral device)

Connector specifications

Applicable interface

MR50LM

CRM2

Dimensions A

(B)

C

67.9

73.5

44.8

Symbol

Remark

(D) 18

Honda Tsushin Kogyo, 50 pins

Name



Connector cover



Cable clamp screw



Connector clamp spring



Connector clamp screw



Connector

50 pins (male) MR50M

Fig.3.12.9 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo)

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3. CONNECTION DETAILS

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(2) Peripheral device connector

Connector specifications

Applicable interface

MR50RF

(CRM2)

Dimensions

Remark

A

B

61.4

56.4

Symbol

Honda Tsushin Kogyo, 50 pins

Name



Connector clamp screw



Screw M2.6 8



Connector

(MR50RF)

Fig.3.12.9 (b) Peripheral Device Connector (Honda Tsushin Kogyo)

3.12.10 Recommended Cables

(1) Peripheral device connection cable Connect a peripheral device using a completely shielded, heavily protected cable conforming to the specifications in Table 3.12.10 (a). Allow an extra 50 cm for routing the cable in the control unit. The maximum cable length is 30 m.

Table 3.12.10 Recommended Cable (for Peripheral Device Connection) Conductor Number of wires 50

Wire specifications (FANUC specifications) A66L-0001-0042

Diameter (mm) ø1.05

Configuration 7/0.18 AWG24

221

Sheath thickness (mm) 1.5

Effective outside diameter (mm) ø12.5

Electrical characteristics Conductor resistance (Ω/km) 106

Allowable current (A) 1.6

4. TRANSPORTATION AND INSTALLATION

4

CONNECTION

TRANSPORTATION AND INSTALLATION

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CONNECTION

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4.1 TRANSPORTATION

The control unit should be transported by a crane. Attach a sling to eye bolts at the top of the control unit.

Fig.4.1 Transportation

4.2 INSTALLATION

Contrpl unit

Installation area When the control unit is installed, allow the space for maintenance shown in the following figure.

Contrpl unit

Contrpl unit

When the plural controller is installed.

Fig.4.2 Installation

223

4. TRANSPORTATION AND INSTALLATION

CONNECTION

4.3 EXTERNAL CONTROLLER DIMENSIONS

Four M10 weld nuts The unit is shipped with the M10 bolts screwed to the weld nuts as 10–mm feet. After the M10 bolts are removed, these weld nuts can be used to secure the control unit.

Fig.4.3 External drawing of robot controller

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CONNECTION

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4. TRANSPORTATION AND INSTALLATION

4.4 INSTALLATION CONDITION

Item Input power supply

Input power supply capacity Average power consumption Permissible ambient temperature Permissible ambient humidity Surrounding gas

Vibration

Altitude Ionized and nonionized radiations

Weight of control unit

4.5 ADJUSTMENT AND CHECKS AT INSTALLATION

Specifications/condition 50Hz; 200VAC, +10%, –15% 60Hz; 200VAC to 220 VAC, +10%, –15% 50/60 Hz"1Hz, 3–phase 1 kVA (LR Mate 100iB) 1.2 kVA (LR Mate 200iB/ARC Mate 50iB) 0.4 kW (LR Mate 100iB) 0.5 kW (LR Mate 200iB/ARC Mate 50iB) 0 to 45_C during operation, and –20 to 60 C during shipment and storage with a temperature coefficient of 1.1_C/min. Relative humidity: 30% to 95%, non–condensing. An additional protective provision is necessary if the machine is installed in an environment in which there are relatively large amounts of contaminants (dust, dielectric fluid, organic solvent, acid, corrosive gas, and/or salt). 0.5 G or less. When using the robot in a location subject to serious vibration, consult with your FANUC sales representative. Not higher than 1,000 m above sea level A shielding provision is necessary if the machine is installed in an environment in which it is exposed to radiations (microwave, ultraviolet rays, laser beams, and/or X–rays). Approx. 35kg

Adjust and check according to following procedure at installation. No.

Description

1 2 3

Visually check the inside and outside of the control unit. Check if the screwed terminal is connected properly. Check that the connectors and printed circuit boards are inserted correctly. Connect control unit and mechanical unit cables.

4 5 6 7

11

Turn the breaker off and connect the input power cable. Check the input power voltagage. Press the EMERGENCY STOP button on the operator’s and turn the power on. Check the output voltage. Check the interface signals between control unit and robot mechanical unit. Check the parameters. If necessary, set them. Release the EMERGENCY STOP button on the operator’s . Turn the power on. Check the movement along each axis in the manual jog mode.

12 13

Check the end effector interface signals. Check the peripheral device control interface signals.

8 9 10

225

4. TRANSPORTATION AND INSTALLATION

CONNECTION

4.6

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An overtravel and emergency stop occur when the robot is operated for the first time after it is installed and the mechanical and control units are wired. This section describes how to reset the overtrvel and emergency stop. Remove the red plate fastening the swiveling axis beforehand. The J2 and J3 axes are pressed against the hard stops at shipment. Therefore, an overtravel alarm occurs when the power is turned on after installation.

NOTE AT INSTALLATION

4.7 DISABLING HAND BREAK

(1) Press the [MENUS] key on the teach pendant. (2) Select [Next]. (3) Select [SETUP]. (4) Press F1 [TYPE]. (5) Select [Config] to disable or enable Hand Break.

Hand break State

Hand break

HBK (*1)

HBK detection

Robot operation

Message

1 2

Enabled Enabled

CLOSE OPEN

Detected Detected

Possible Impossible

Not provided SERVO 6

3 4

Disabled Disabled

CLOSE OPEN

Detected (*2) Not detected

Possible Possible

Not provided SERVO 300 at cold start

NOTE 1 Robot end effector connector CLOSE

OPEN

24V

24V

*HBK

*HBK

2 When the HBK circuit is closed, the HBK detection is enabled. If the HBK state changes from close to open, the SERVO 300 or SERVO 302 alarm occurs, stopping the robot. 3 If the power is turned off and on in the state described above, the system enters state 4, releasing the alarm.

226

APPENDIX

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A

APPENDIX

TOTAL CONNECTION DIAGRAM

229

A. TOTAL CONNECTION DIAGRAM

A. TOTAL CONNECTION DIAGRAM

APPENDIX

Fig.A (a) Total connection diagram

230

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APPENDIX

231

A. TOTAL CONNECTION DIAGRAM

A. TOTAL CONNECTION DIAGRAM

APPENDIX

Fig.A (b) Emergency stop circuit diagram

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APPENDIX

233

A. TOTAL CONNECTION DIAGRAM

A. TOTAL CONNECTION DIAGRAM

APPENDIX

Fig.A (c) Emergency stop circuit diagram

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APPENDIX

235

A. TOTAL CONNECTION DIAGRAM

A. TOTAL CONNECTION DIAGRAM

APPENDIX

Fig.A (d) Robot control board, Emergency stop board connector interface

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APPENDIX

A. TOTAL CONNECTION DIAGRAM

Fig.A (e) Servo amplifier robot mechanical unit connector interface

237

B. PERIPHERAL INTERFACE

B

APPENDIX

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PERIPHERAL INTERFACE

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

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B.1 SIGNAL TYPES

B. PERIPHERAL INTERFACE

The tables below list the special signals of the R–J3iB Mate robot controller. Input signals (See Subsection B.2.1.) Signal *HOLD RESET START ENBL PNS1 PNS2 PNS3 PNS4

Description Temporary stop Alarm release Cycle start Enable Program select (*1) Program select (*1) Program select (*1) Program select (*1)

NOTE PNS (program select input) (optional)

Output signals (See Subsection B.2.1.) Signal

Description

CMDENBL FAULT BATALM BUSY

Input acceptable Alarm Battery alarm Busy

239

B. PERIPHERAL INTERFACE

APPENDIX

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B.2 I/O SIGNALS B.2.1

Fellowing is each input signal.

Input Signals Hold input signals, *HOLD, UI [ 1 ]

The remote controller uses the hold signal to halt the robot. Because *HOLD input signal is a inverted signal, normally set the signal on. When the signal goes off, the following is executed: D The robot is decelerated until its stops, then the program execution is halted. D If ENABLED is specified at “Break on hold” on the general item setting screen, the robot is stopped, an alarm is generated, and the servo power is turned off. (Standard setting: DISABLED)

Fault reset input signal, RESET, UI [ 2 ]

The RESET signal cancels an alarm. If the servo power is off, the RESET signal turns on the servo power. The alarm output is not canceled until the servo power is turned on. The alarm is canceled at the instant this signal falls in default setting. D If TRUE is specified at “CSTOPI for ABORT” on the system configuration screen, the RESET signal resets an alarm and aborts the currently selected program. (Standard setting: FALSE) D To have alarms reset the instant the RESET signal rises, it is necessary to specify RISE at “Detect FAULT RESET signal” on the system configuration screen. (Standard setting: FALL)

Start input signal, START, UI [ 3 ] (validated in the remote state)

The START signal has two functions. It can select or collate a program and start the program. D When the START signal goes high, PNS1 to PNS4 are read and the corresponding program is selected or collated. Whether is program is selected or collated is specified by the setting of system variable $SHELL_CFG.$NUM_RSR [1]. (See the description of signals PNS1 to PNS4.) D When the START signal goes low, the current program is started from the line at which the cursor is placed (current line). D If TRUE is specified at “START for CONTINUE only” on the system configuration screen, only a program on hold can be started. (Standard setting: FALSE)

Enable input signal, ENBL, UI [ 4 ]

The ENBL signal allows the robot to be moved and places the robot in the ready state. When the ENBL signal is off, the system inhibits a jog feed of the robot and activation of a program including a motion (group). A program which is being executed is halted when the ENBL signal is set off. NOTE When the ENBL signal is not monitored, strap the signal with the ground.

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B. PERIPHERAL INTERFACE

Program number selection signals, PNS1 to PNS4, UI [ 5 to 8 ] (validated in the remote state)

A program number selection signal has two functions. When the START signal goes on, PNS1 to PNS4 are read and the corresponding program is selected or collated. Whether the program is selected or collated is specified by the setting of system variable $SHELL_CFG.$NUM_RSR [1].

B.2.2

Fellowing are peripheral device interface output signals.

D In the program end state, a program is selected or collated according to the state (0 or 1) of the PNS signals. The current line of the selected or collated program is set to 1. - Type 1 (when $SHELL_CFG.$NUM_RSR [1] is set to 0) The program specified by the PNS signals is selected. - Type 2 (when $SHELL_CFG.$NUM_RSR [1] is set to 1) The program specified by the PNS signals is collated with the current program. If the programs do not agree with each other, an error occurs. D If all PNS signals are low in the program end state, the current program is executed from the current line. If no programs are selected, an error occurs. D A halted program can be resumed only when all PNS signals are set off. Otherwise, an error occurs. D While a program is being executed, the PNS signals are ignored.

Output Signals Command enable output signal, CMDENBL, UO [ 1 ]

The CMDENBL signal is output when the following conditions are satisfied. The CMDENBL signal indicates that the remote controller can start a program including a motion (group). D The remote conditions are satisfied. D The ready conditions are satisfied. D The continuous operation mode is selected (the single step mode is disabled).

Fault output signal, FAULT, UO [ 2 ]

The FAULT signal is output when an alarm occurs in the system. The RESET signal cancels the alarm. If a warning (WARN alarm) occurs, the FAULT signal is not output.

Battery alarm output signal, BATALM, UO [ 3 ]

The BATALM signal indicates that the voltage of the battery for ing the memory has dropped. Replace the battery while keeping the power of the controller on. To have the BATALM signal generated also when the BZAL/BLAL alarm occurs, it is necessary to set the $BLAL_OUT.$BATALM_OR system variable. It is also possible to have the specified SDO output when the BZAL/BLAL alarm occurs.

Busy output signal, BUSY, UO [ 4 ]

The BUSY signal is output while a program is being executed. The BUSY signal is not output while a program is being halted. 241

B. PERIPHERAL INTERFACE

APPENDIX

B–81535EN/02

B.3 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT B.3.1 Overview

B.3.2 Input/Output Hardware Usable in the R-J3iB Mate Controller

This section describes the external specifications of digital and anaput/output in the R–J3iB Mate controller.

The R–J3iB Mate controller can use up to 512 digital input and output points or an equivalent number of anaput and output points. One anaput/output point uses the resources equivalent to those used by 16 digital I/O points. The R–J3iB Mate can use a total of up to 512 I/O points. The R–J3iB Mate controller can use the following I/O hardware. - Process I/O printed circuit board - I/O unit model A The process I/O printed circuit board and the I/O unit model A can be used together.

242

B–81535EN/02

APPENDIX

B. PERIPHERAL INTERFACE

B.3.3 Software Specifications

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

243

C. OPTICAL FIBER CABLE

C

APPENDIX

B–81535EN/02

OPTICAL FIBER CABLE

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

Fiber optic cable

Lid

Fiber optic cable caps

Fig.C (a) Protection of electrical/optical conversion module and fiber optic cable (when not in use)

244

C. OPTICAL FIBER CABLE

APPENDIX

B–81535EN/02

(2) Fiber optic cable D Grasp the optical connector firmly when connecting or disconnecting the cable. Do not pull on the fiber optic cord itself. (The maximum tensile strength between the fiber cord and connector is 2 kg. Applying greater force to the cord is likely to cause the connector to come off, making the cable unusable.) Fiber optic cord diameter : 2.2 mm 2 cords Tensile strength : Fiber optic cord :7 kg per cord Between fiber optic cord and connector : 2 kg Minimum bending radius of fiber optic cord :25 mm Flame resistance : Equivalent to UL VW–1 Operating temperature : –20 to 70°C 8.2 6.7

19 max.

60 max.

35typ.

21 Bush

Code

Reinforced cover

Fig.C (b) External dimensions of external optical cable Unit : mm

D Afler it is connected, the optical connector is automatically locked by the lock levers on its top. To remove the connector, release the lock levers and pull the connector. D Although optical connectors cannot be connected in other than the correct orientation, always take note of the connector’s orientation before making the connection. D Take care to keep both parts of the optical connector (cable side and PCB side) clean. If they become dirty, wipe them with tissue paper or absorbent cotton to remove dirt. The tissue paper or absorbent cotton may be moistened with ethyl alcohol. Do not use any organic solvent other than ethyl alcohol. D Do not clamp the uncovered portion of the cable with a nylon band.

245

Index

B–81535EN/02

[A]

[E] Emergency Stop Board (A20B–1008–0010, –0011), 116

Adjustment and Checks at Installation, 225 Alarm Occurrence Screen, 29

Emergency Stop Circuit, 167

ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins), 219

End Effector Interface, 197 External Controller Dimensions, 224 External Emergency Stop Input, 168 External Emergency Stop Output, 169

[B]

External View of the Controller, 21

Backplane Board (A20B–2003–0330), 117 Battery for Memory Backup (3 VDC), 154

[F]

Block Diagram, 160 FANUC I/O Link, 163

Block Diagrams of the Power Supply, 126

[I]

[C] Checking the Power Supply Module, 127

I/O Signal Specifications for Arc–Welding Interface, 216

Checking the Power Supply Unit, 127

I/O Signals, 240

Circuit Diagram of Emergency Stop, 167

Initial Screen Remains on the Teach Pendant, 28

Component Functions, 23

Input Signals, 240

Configuration, 20

Input/Output Hardware Usable in the R–J3iB Mate Controller, 242

Connecting a Cable to a Peripheral Device, 175

Installation, 223

Connecting the Mechanical Unit and End Effector, 197

Installation Condition, 225

Connection Between the Control Unit and Welder, 208

[L]

Connection Details, 161

LED of Power Supply Module, 123

Connection of Cable for RS–232–C/RS–422, 174

LED of Servo Amplifier, 123

Connection of I/O Link Cable, 165

LED of Servo Amplifier Module, 124

Connection of Power Supply Cable, 162 Connection of Robot, 172

[M]

Connection of Teach Pendant Cable, 173

Manual Operation Impossible, 109

Coonection of Servo Amplifier, 171

Mastering, 33

[D]

[N]

Digital I/O Signal Specifications, 193

Note at Installation, 226

Digital I/O Signal Specifications of End Effector Control Interface, 199

[O]

Digital I/O Signal Specifications of Peripheral Device Interface A, 214 Operator Safety, 4, 6

Disabling Hand Break, 226

Optical Fiber Cable, 244 i–1

Index

B–81535EN/02

Outline Drawings, 121

Replacing the Emergency Stop Board, 132

Output Signals, 241

Replacing the Emergency Stop Unit, 138 Replacing the Fan Motor of the Servo Amplifier Control Unit, 143

[P]

Replacing the Fuse on the Door, 149 Replacing the Fuse on the Power Supply Module, 150

Peripheral Device and Control Unit Connection, 203

Replacing the Fuse on the Process I/O Boards, 152

Peripheral Device Cable Connector, 195, 220

Replacing the Fuse on the Servo Amplifier Module, 151

Peripheral Device Interface Block Diagram and Specifications, 202

Replacing the Magnetic or, 139

Peripheral device interface CRM 79 and CRM 81, 193

Replacing the Operator , 145

Peripheral Device Interface Types, 201

Replacing the Power Supply Unit, 146

Peripheral Device Interfaces CRM79 and CRM81, 175

Replacing the Printed–Circuit Boards, 129 Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit, 131

Peripheral Device, ARC Welding, Interfaces, 201 Peripheral interface, 238

Replacing the Teach Pendant, 141

Position Deviation Found in Return to the Reference Position (Positioning), 107

Replacing the Transformer, 137 Robot Control Board (A16B–3200–0450), 112

Power Cannot be Turned On, 26 Power Supply Module PSM (A06B–6115–H001), 121 Precautions for Mechanism, 10

[S]

Precautions for Mechanisms, 11 Precautions in Operation, 11

Safety During Maintenance, 9

Precautions in Programming, 10, 11, 12

Safety in Maintenance, 13

Preventive Maintenance, 24

Safety of the End Effector, 12

Printed Circuit Boards, 111

Safety of the Robot Mechanism, 11

Process I/O Board HE (A16B–2203–0764), HF (A16B–2203–0765), 118

Safety of the Teach Pendant Operator, 7 Safety of the Tools and Peripheral Devices, 10 Safety Precautions, 3 Safety Signals, 32

[R] Recommended Cables, 196, 221

Servo Amplifier Module (A06B–6114–H205, A06B–6114–H302), 122

Replacing a Fuse, 147

Servo Amplifiers, 120

Replacing a Fuse on the Emergency Stop Board, 148

Setting the Power Supply, 125

Replacing a Fuse on the Robot Control Board, 147

Signal Types, 239

Replacing a Relay, 153

Software Specifications, 243

Replacing a Relay on the Emergency Stop Board, 153

Specifications of Digital Input/Output, 242

Replacing a Unit, 128

Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin, 50 pins), 219

Replacing Battery, 154 Replacing Cards and Modules on the Robot Control Board, 133

[T]

Replacing Servo Amplifiers, 140

Teach Pendant Cannot be Turned On, 27

Replacing the Backplane Board (Unit), 130

Total Connection Diagram, 229

Replacing the Brake Power Transformer, 137

Transportation, 223

Replacing the Control Section Fan Motor, 142

Transportation and Installation, 222

Replacing the Door Fan Unit and Heat Exchanger, 144

Treatment for the Shielded Cable, 200 i–2

Index

B–81535EN/02

Troubleshooting, 25 Troubleshooting Based on LED Indications, 97 Troubleshooting Using Fuses, 92

[W]

Troubleshooting Using the Error Code, 35 Warning Label, 14

[V]

When the Robot is Connected to the CNC by a Peripheral Device Cable, 176

Vibration Observed During Movement, 108

i–3

Revision Record FANUC Robot series R–J3iB Mate CONTROLLER for (RIA R15.06--1999 COMPLIANT) MAINTENANCE MANUAL (B–81535EN)

02

Oct., 2002

01

Oct., 2001

Edition

Date

Addition of ARC Mate 50iB

Contents

Edition

Date

Contents