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SYSTEM R-J Controller Series

Electrical Connection and


Maintenance Manual
MARMMTRBL02303E
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.
2000 South Adams Road
Auburn Hills, Michigan 483262800

The descriptions and specifications contained in this manual were in effect


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

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

FANUC Robotics conducts courses on its systems and products on a


regularly scheduled basis at the companys world headquarters in Auburn
Hills, Michigan. For additional information contact
FANUC Robotics North America, Inc.
Training and Documentation Department
2000 South Adams Road
Auburn Hills, Michigan 483262800
Tel: (810)3777234
FAX: (810)3777367 or (810)3777362

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


All Rights Reserved
The information illustrated or contained herein is not to be reproduced,
copied, translated into another language, or transmitted in whole or in part
in any way without the prior written consent of FANUC Robotics North
America, Inc.
AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL,
KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks,
PalletTool, SOCKETS, SOFT PARTS SpotTool,
TorchMate, and YagTool, are Registered Trademarks of FANUC
Robotics.
FANUC Robotics reserves all proprietary rights, including but not limited
to trademark and trade name rights, in the following names:
AccuFlow
ARC Mate
ARC Mate Sr.
IntelliTrak
LaserTool
MotionParts
PaintWorks II
PalletMate
SureWeld
TurboMove

FANUC Robotics Hotline


For a PRODUCTION robot that is DOWN
call 24 hours a day, 7 days a week
810-377-7159
For all other Troubleshooting and Technical Support
contact your local distributor or call the Hotline
Monday Friday, 8:00 A.M. 5:00 P.M. Eastern Time

BEFORE YOU CALL please have your Maintenance and Troubleshooting manual, and the
following information, ready.
INFORMATION

DETAILS

Customer Information

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

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

On the arm of the robot.

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

Ask your supervisor.

F Number

On the identification tag on the robot and controller, near


the cable connection.

Robot serial number


(if no F Number is available)

On the identification tag located near the cable connection.

Controller serial number


(if no F Number is available)

On the controller tag located on the doors.

Software edition and revision numbers

Shown on the CRT or teach pendant status screen during


the power-up sequence.

List of error messages

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

List of diagnostic LEDs

Note the PCB where the LED is located and the LED name
or designation.

History of problem

Description of events leading up to the problem.

Application software

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

MARMMTRBL02303E

Preface

vii

Purpose of this Manual

The SYSTEM R-J Controller Series Electrical Connection and


Maintenance Manual provides specific information regarding FANUC
Robotics electrical hardware. The information contained within the
manual has been arranged so that it can answer specific questions quickly
and accurately.

How to Use this


Manual

Use this table to locate specific information in the manual.


If you want to

Refer to

Find information about a specific topic

Table of Contents

Identify the components of the SYSTEM R-J


controller

Chapter 1, Overview

Use diagnostic and controller initialization


utilities

Chapter 2, Diagnostic
Screens

View status information on teach pendant


screens and using other indicators

Chapter 3, Lights and LEDs

Perform troubleshooting procedures and


identify specific errors

Chapter 4, Troubleshooting

Look at fuse information or replace a fuse

Chapter 5, Replacing a Fuse

Release the brakes

Chapter 6, Brake Release

Turn outputs on or off and simulate inputs

Chapter 7, Controlling I/O

Master the robot

Chapter 8, Mastering

Replace controller components

Chapter 9, Replacing
Components

Adjust switch settings and potentiometers


on printed circuit boards

Chapter 10, Board


Adjustments

Find controller connection schematics and


connector configurations

Chapter 11, Connections

Find connection information and


Input/Output specifications

Chapter 12, Complete Wiring


Diagrams

Find complete schematics of the controller


circuitry

Chapter 13, Prints

Use controller transportation and installation


information

Appendix A, Transportation
and Installation

viii

Conventions Used in
this Manual

PREFACE

MARMMTRBL02303E

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.

MARMMTRBL02303E

Table of Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ix

vii
xxv

Chapter 1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

1.1 BACKPLANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 MAIN CPU PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 AXIS CONTROL PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 POWER SUPPLY UNIT PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 EMERGENCY STOP CONTROL PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . .
1.6 SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 DCR AND DBR UNIT A05B-2302-C080 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 DISCHARGE UNIT A05B-2312-C100 FOR M-500 A05B-2313-C100 FOR S-900 . . . . . . .
1.9 MULTI-TAP TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10 INTERFACE DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10.1 Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10.2 Process I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10.3 ABRIO and Genius I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.11 FUSED FLANGE DISCONNECT AND CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . .
1.12 USER TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.13 OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.14 TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.15 HEAT EXCHANGE AND FANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17
18
111
112
113
114
121
122
123
126
127
131
133
134
137
137
139
141

Chapter 2
DIAGNOSTIC SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

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


2.2 POSITION STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 ROBOT AXES STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 ALARM LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 VERSION IDENTIFICATION STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 MEMORY STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22
24
27
28
210
213

Chapter 3
LIGHTS AND LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

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


3.2 OPERATOR PANEL DIAGNOSTIC LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 CIRCUIT BOARD DIAGNOSTIC LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Emergency Control Board (EMG) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32
33
34
36

TABLE OF CONTENTS

x
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.3.7
3.3.8
3.3.9

MARMMTRBL02303E

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


Axis Control Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servo Amplifier Diagnostic LED (7-Segment Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Optional) Process I/O Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R-H MAP INTERFACE LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R-H ABRIO LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37
38
312
313
314
315
316
317

Chapter 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

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


4.2 CLASS 2 FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 CLASS 3 FAULT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 SRVO-001 ER_SVAL1 Operator Panel EStop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 SRVO-002 ER_SVAL1 Teach Pendant Estop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.3 SRVO-003 ER_SVAL1 Deadman switch released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.4 SRVO-004 ER_SVAL1 Fence open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.5 SRVO-005 ER_SVAL1 Robot Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.6 SRVO-006 ER_SVAL1 Hand Broken . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.7 SRVO-007 ER_SVAL1 External emergency stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.8 SRVO-008 ER_SVAL Brake fuse blown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.9 SRVO-011 ER_SVAL1 TP Released While Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.10 SRVO-012 ER_SVAL1 Power Failure Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.11 SRVO-014 Fan Motor Abnormal (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.12 SRVO-015 ER_SVAL1 System Over Heat (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . .
4.3.13 SRVO-021 ER_SVAL1 SRDY off (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.14 SRVO-022 ER_SVAL1 SRDY on (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.15 SRVO-023 ER_SVAL1 Stop Error Excess (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . .
4.3.16 SRVO-024 ER_SVAL1 Move Error Excess (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . .
4.3.17 SRVO-026 ER_WARN Motor Speed Limit (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . .
4.3.18 SRVO-027 ER_WARN Robot Not Mastered (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . .
4.3.19 SRVO-033 ER_WARN Robot Not Calibrated (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . .
4.3.20 SRVO-035 ER_WARN Joint Speed Limit (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . .
4.3.21 SRVO-036 Imposition Time Over (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.22 SRVO-037 ER_SVAL1 IMSTP Input (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.23 SRVO-038 PULSE MISMATCH (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.24 SRVO-042 ER_SVAL2 MCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.25 SRVO-043 ER_SVAL2 DCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.26 SRVO-044 ER_SVAL2 HVAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.27 SRVO-045 ER_SVAL2 HCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .

42
416
418
419
422
424
426
428
430
432
436
440
440
440
442
444
444
445
445
445
445
445
446
446
446
447
447
448
449
450

MARMMTRBL02303E

4.3.28
4.3.29
4.3.30
4.3.31
4.3.32
4.3.33
4.3.34
4.3.35
4.3.36
4.3.37
4.3.38
4.3.39
4.3.40
4.3.41
4.3.42
4.3.43
4.3.44
4.3.45
4.3.46
4.3.47
4.3.48
4.3.49
4.3.50
4.3.51
4.3.52
4.3.53
4.3.54
4.3.55
4.3.56

TABLE OF CONTENTS

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


SRVO-047 ER_SVAL2 LVAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-049 ER_SVAL2 OHAL1 Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-050 ER_SVAL1 CLALM Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-051 ER_SVAL2 CUER Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-061 ER_SVAL2 CKAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-062 ER_SVAL2 BZAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-063 ER_SVAL2 RCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-064 ER_SVAL2 PHAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-065 ER_WARN BLAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-066 ER_SVAL2 CSAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-067 ER_SVAL2 OHAL2 Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-068 ER_SVAL2 DTERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-069 ER_SVAL2 CRCERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-070 ER_SVAL2 STBERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-071 ER_SVAL2 SPHAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-081 ER_WARN EROFL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-082 ER_WARN DAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-083 ER_WARN CKAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-084 ER_WARN BZAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-085 ER_WARN RCAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-086 ER_WARN PHAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-087 ER_WARN BLAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-088 ER_WARN CSAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-089 ER_WARN OHAL2 Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-090 ER_WARN DTERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-091 ER_WARN CRCERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-092 ER_WARN STBERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-093 ER_WARN SPHAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . .

xi
451
452
453
453
454
454
455
456
456
456
457
457
458
458
459
459
459
460
460
460
460
460
461
461
461
461
461
461
461

Chapter 5
REPLACING A FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

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


5.2 SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 EMERGENCY STOP CONTROL PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 PROCESS INPUT/OUTPUT PC BOARDS AA, AB, CA, CB, AND DA . . . . . . . . . . . . . . . .
5.6 PROCESS INPUT/OUTPUT PC BOARDS BA AND BB . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 MODULAR I/O UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8 AC OUTLET UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51
53
54
55
56
57
58
59

TABLE OF CONTENTS

xii

MARMMTRBL02303E

Chapter 6
BRAKE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

Chapter 7
CONTROLLING I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71

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


7.2 SIMULATING INPUTS AND OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 SOP I/O STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72
74
75

Chapter 8
MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81

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


8.2 ZERO DEGREE MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 SINGLE AXIS MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 QUICK MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82
85
88
811

Chapter 9
REPLACING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91

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


9.2 REPLACING A RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 REPLACING A PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.1 Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.2 Replacing a Component on the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . .
9.4 REPLACING A MODULE ON THE MAIN CPU OR AXIS CONTROL BOARD . . . . . . . . .
9.5 REPLACING THE PROCESS INPUT/OUTPUT PRINTED CIRCUIT BOARD
AA, AB, BA OR BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6 REPLACING COMPONENTS OF THE MODULAR INPUT/OUTPUT UNIT
REFER TO CHAPTER 1 FOR PART NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.1 Replacing the Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.2 Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7 REPLACING THE MULTI-TAP TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8 REPLACING A SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.9 REPLACING THE OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.10 REPLACING THE FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.11 REPLACING THE DISCHARGE RESISTOR (DCR) AND DYNAMIC BRAKE (DBR)
UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12 REPLACING THE REGENERATIVE DISCHARGE UNIT . . . . . . . . . . . . . . . . . . . . . . . . .
9.13 REPLACING THE OPTIONAL WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.14 REPLACING A SERIAL PULSE CODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92
94
95
96
97
98
911
912
912
914
916
917
918
919
921
923
924
925

MARMMTRBL02303E

TABLE OF CONTENTS

xiii

Chapter 10
BOARD ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101

10.1 AXIS CONTROL BOARD JUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


10.2 PROCESS I/O BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.1 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.2 Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.3 Output Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 BUILTIN CRT/KB UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 EMG BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101
102
105
106
107
108
1010

Chapter 11
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111

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


11.1.1 Robot Connection Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.2 Connecting the Input Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.3 Connecting the External Power Supply ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.4 External Emergency Stop Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES . . . . . .
11.2.1 Peripheral Device Interface Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.2 Process I/O Printed Circuit Board AA or AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.3 Process I/O Printed Circuit Board BA or BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.4 Process I/O Printed Circuit Board CA or CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.5 Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.6 Process I/O Printed Circuit Board with the Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . .
11.2.7 Two or More Process I/O Boards with the Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . .
11.2.8 Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.9 Mechanical Unit and End Effector Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.10 Control Unit and Welder Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.11 Peripheral Device Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.12 End Effector Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.13 Arc Welding Interface Process I/O AA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.14 Modular I/O Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.15 Modular I/O Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES
AND WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3.1 Peripheral Device Interface A Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3.2 Peripheral Device Interface B Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3.3 Arc Welding Interface Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS,
AND ARC WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4.1 Peripheral Device Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112
114
118
1110
1111
1113
1115
1116
1117
1118
1119
1120
1121
1122
1139
1142
1146
1148
1149
1151
1155
1165
1165
1165
1166
1167
1167

TABLE OF CONTENTS

xiv
11.4.2
11.4.3
11.4.4
11.4.5

MARMMTRBL02303E

Arc Welding Interface Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Effector Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1168
1169
1172
1174

Chapter 12
COMPLETE WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121

Chapter 13
PRINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

131

Appendix A
TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A1

A.1 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.1 Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.2 Assembly During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.3 Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.4 Adjustment and Checks at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.5 Resetting Overtravel and Emergency Stop at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

A1
A2
A2
A3
A4
A5
A6

List of Procedures
Procedure 21
Procedure 22
Procedure 23
Procedure 24
Procedure 25
Procedure 26
Procedure 61
Procedure 71
Procedure 72
Procedure 73
Procedure 81
Procedure 82
Procedure 83
Procedure 84
Procedure 85
Procedure 91
Procedure 92
Procedure 93
Procedure 94

Displaying Safety Signal Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Displaying Position Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying the Axis Status Pulse Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying the Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying the Version Identification Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Releasing the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forcing Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Simulating and Unsimulating Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying and Forcing SOP I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mastering to a Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mastering to Zero Degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mastering a Single Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recording the Quick Master Reference Position . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Mastering the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the SPC Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Component on the Backplane Printed Circuit Board . . . . . . . . . . . .

23
25
27
29
211
213
61
72
74
76
82
85
88
811
813
92
93
96
97

MARMMTRBL02303E

Procedure 95
Procedure 96
Procedure 97
Procedure 98
Procedure 99
Procedure 910
Procedure 911
Procedure 912
Procedure 913
Procedure 914
Procedure 915

TABLE OF CONTENTS

Replacing the Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Replacing the Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing an I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) unit
Replacing the Regenerative Discharge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Optional Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Serial Pulse Coder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xv
912
914
914
916
917
918
919
921
923
924
925

List of Figures
Figure 11. Cabinet Exterior, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12. Cabinet Exterior, B-Size Controller with Regenerative Discharge Unit . . . . . . . . . . .
Figure 13. Cabinet Exterior, B-Size Controller with Optional Side Cabinet . . . . . . . . . . . . . . . . .
Figure 14. Cabinet Exterior, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 15. Cabinet Interior, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16. Cabinet Interior, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17. Backplane with R-H Style Extended Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 18. Main CPU Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 19. Axis Control Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 110. Power Supply Unit Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 111. Emergency Stop Control Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 112. Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 113. Mounting Locations of Servo Amplifiers Robot with 6-amplifiers . . . . . . . . . . . .
Figure 114. Mounting Locations of Servo Amplifiers for the A-510 . . . . . . . . . . . . . . . . . . . . . .
Figure 115. Mounting Locations of Servo Amplifiers for the Arc Mate/ Arc Mate 100/S-6,
Arc Mate Sr./S-5/S-10 and L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 116. Mounting Locations of Servo Amplifiers for the S-500/S-700 and M-400 . . . . . . . .
Figure 117. Mounting Locations of Servo Amplifiers for the S-420 and S-800 . . . . . . . . . . . . . .
Figure 118. Mounting Locations of Servo Amplifiers for the S-420 and the DCR & DBR Unit .
Figure 119. Mounting Locations of Servo Amplifiers for the M-500 . . . . . . . . . . . . . . . . . . . . . .
Figure 120. Mounting Locations of Servo Amplifiers for the S-900 . . . . . . . . . . . . . . . . . . . . . . .
Figure 121. DCR and DBR Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 122. Discharge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 123. Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 124. Multi-Tap Transformer A80L00260013#A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 125. Modular I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 126. Process I/O Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 127. Fused Flange Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 128. Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 129. User Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12
12
13
14
15
16
17
19
111
112
113
114
115
116
116
117
117
118
118
119
121
122
124
125
127
131
135
135
137

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


Figure 131. Operator Panel, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 132. Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 133. Heat Exchange System, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 134. Heat Exchange System, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 21. Default PowerUp Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 22. Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 31. Teach Pendant LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 32. Operator Panel LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 33. Circuit Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 34. Emergency Control Board (EMG) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 35. Power Supply Unit (PSU) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 36. Axis Control Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 37. Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 38. Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 39. Process I/O Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 310. RH MAP LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 311. R-H ABRIO LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 41. 24 Volt (24E) Power Distribution Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 42. 24 Volt (24V) Power Distribution Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 43. Operator Panel E-Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 44. Teach Pendant E-Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 45. Deadman Switch Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 46. Fence Open Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 47. Robot Overtravel Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 48. Hand Broken Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 49. External Emergency Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 410. Brake Fuse Blown Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 411. Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 412. System Over Heat Circuitry Drawing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 413. System Over Heat Circuitry Drawing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 51. Replacing a Fuse of the Transformer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 52. Replacing the Fuse of a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 53. Replacing a Fuse of the Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 54. Replacing the Fuse on the Emergency Stop Control PC Board . . . . . . . . . . . . . . . . . .
Figure 55. Replacing the Fuse of the Process Input/Output PC Board AA, AB, CA, CB, or DA
Figure 56. Replacing the Fuse of the Process Input/Output PC Board BA or BB . . . . . . . . . . . .
Figure 57. Replacing the Fuse of the AC Outlet Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 91. Replacing the Battery (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 92. Replacing a Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 93. Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 94. Replacing Printed Circuit Boards on the Backplane Printed Circuit Board . . . . . . . . .

138
138
140
141
142
21
28
32
33
35
36
37
38
312
314
315
316
317
410
413
421
423
425
427
429
431
435
439
441
442
443
52
53
54
55
56
57
59
92
94
96
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xvii

Figure 95. Moving the Latches on the End of the Module Socket . . . . . . . . . . . . . . . . . . . . . . . .
98
Figure 96. Installing a New Module at an Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
98
Figure 97. Pushing in the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
Figure 98. Mounting Locations of the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
910
Figure 99. Replacing the Process Input/Output Printed Circuit Board AA, AB, BA, or BB . . . .
911
Figure 910. Replacing the Base Unit of the Modular Input/Output Unit . . . . . . . . . . . . . . . . . . .
913
Figure 911. Removing and Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
915
Figure 912. Removing and Replacing a Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
915
Figure 913. Replacing the Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
916
Figure 914. Replacing a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
917
Figure 915. Replacing the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
918
Figure 916. Replacing the Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
920
Figure 917. Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) Unit . . . . . . . . . . . .
922
Figure 918. Replacing the Regenerative Discharge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
923
Figure 919. Removing the Pulse Coder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
926
Figure 101. Axis Control Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101
Figure 102. Process I/O Board AA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102
Figure 103. Process I/O Board AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102
Figure 104. Process I/O Board BA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103
Figure 105. Process I/O Board BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103
Figure 106. Process I/O Board CA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
Figure 107. Process I/O Board CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
Figure 108. Process I/O Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105
Figure 109. Front View Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
Figure 1010. Jumper Setting CRT/KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
Figure 1011. EMG board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010
Figure 111. Block Diagram of Electrical Interface Connection . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
Figure 112. Mechanical Connection Diagram for S-420, S-500, S-700, S-800, and M-400 . . . . .
112
Figure 113. Mechanical Connection Diagram for ARC Mate, ARC Mate 100/S-6, ARC Mate Sr.,
A-510, and L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112
Figure 114. Mechanical Connection Diagram, Common Part . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113
Figure 115. Connection to Servo Amplifiers and Mechanical Unit for S-420 . . . . . . . . . . . . . . . .
114
Figure 116. Connection to Servo Amplifiers and Mechanical Unit for S-420, S-420D, ARC Mate,
S-5, ARC Mate 100/S-6, ARC Mate Sr., S-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114
Figure 117. Connection to Servo Amplifiers and Mechanical Unit for S-500 . . . . . . . . . . . . . . . .
115
Figure 118. Connection to Servo Amplifiers and Mechanical Unit for S-700 . . . . . . . . . . . . . . . .
115
Figure 119. Connection to Servo Amplifiers and Mechanical Unit for S-800 . . . . . . . . . . . . . . . .
116
Figure 1110. Connection to Servo Amplifiers and Mechanical Unit for A-510 . . . . . . . . . . . . . .
116
Figure 1111. Connection to Servo Amplifiers and Mechanical Unit for M-400 and M-500 . . . . .
117
Figure 1112. Connection to Servo Amplifiers and Mechanical Unit for L-1000 . . . . . . . . . . . . .
117
Figure 1113. Input Power Supply Connection, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . .
119
Figure 1114. Input Power Supply Connection, Fused Flange Disconnect . . . . . . . . . . . . . . . . . . .
119

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


Figure 1116. External Emergency Stop Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1117. External Emergency Stop Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1118. Locations of Peripheral Device Interfaces, B-Size Controller . . . . . . . . . . . . . . . . .
Figure 1119. Locations of Peripheral Devices, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1120. Peripheral Device Interface Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1121. Process I/O Printed Circuit Board AA or AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1122. Process I/O Printed Circuit Board BA or BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1123. Process I/O Printed Circuit Board CA or CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1124. Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1125. Process I/O Printed Circuit Board with Modular I/O . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1126. Two or More Process I/O Boards and the I/O Unit (Model A) . . . . . . . . . . . . . . . .
Figure 1127. Peripheral Device and Control Unit Connection -A1/A2 . . . . . . . . . . . . . . . . . . . . .
Figure 1128. Peripheral Device and Control Unit Connection -A3/A4 . . . . . . . . . . . . . . . . . . . . .
Figure 1129. Peripheral Device and Control Unit Connection - B1/B2 . . . . . . . . . . . . . . . . . . . .
Figure 1130. Peripheral Device and Control Unit Connection -C1 . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1131. Peripheral Device Interface Control for A1, A2, A3, and A4 . . . . . . . . . . . . . . . . .
Figure 1132. Peripheral Device Interface for A1, A2, A3, and A4 . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1133. Peripheral Device Control Interface B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1134. Peripheral Device Control Interface B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1135. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1136. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1137. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1138. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1139. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1140. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1141. Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1142. End Effector Pin Configuration Arc Mate/S-5, Arc Mate Sr/S-10, S-420, S-500,
S-700, S-800, S-900, M-400 and M-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1143. End Effector Pin Configuration Arc Mate 100/S-6 . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1144. End Effector Pin Configuration A-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1145. End Effector Pin Configuration L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1146. Control Unit and Welder Connection - CRW1/CRW2 . . . . . . . . . . . . . . . . . . . . . . .
Figure 1147. Control Unit and Welder Connection - CRW1 Analog Signal Assignment . . . . . . .
Figure 1148. Control Unit and Welder Connection - CRW1 Digital Signal Assignment . . . . . . .
Figure 1149. Control Unit and Welder Connection - CRW2 Analog Signal Assignment . . . . . . .
Figure 1150. Peripheral Device Interface A Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1151. Peripheral Device Interface B Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1152. Arc Welder Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1153. Peripheral Device Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1154. Arc Welder Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1155. Peripheral Device Cable Connector for A and B(Honda Tsushin Kogyo) . . . . . . . .

1110
1111
1112
1113
1114
1115
1116
1117
1118
1119
1120
1121
1125
1126
1127
1128
1129
1130
1131
1132
1133
1134
1135
1136
1137
1138
1139
1140
1140
1141
1141
1142
1143
1144
1145
1165
1165
1166
1167
1168
1169

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


Figure 1157. Peripheral Device Interface Cable C Connector (Phoenix Contact) . . . . . . . . . . . .
Figure 1158. Elbow Type Connector S-5, S-10, S-420, S-500, S-700, S-800, M-400, M-500,
ARC Mate, ARC Mate 100/S-6, ARC Mate Sr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1159. Connector L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 121. Internal Connection Diagram S-420, S-800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 122. Internal Connection Diagram S420 with three Servo Amplifiers, S420D) . . . . . . .
Figure 123. Internal Connection Diagram ARC Mate, ARC Mate Sr., ARC Mate 100/S-6, S-5,
and S-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 124. Internal Connection Diagram S-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 125. Internal Connection Diagram S-700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 126. Internal Connection Diagram S900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 127. Internal Connection Diagram A-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 128. Internal Connection Diagram M-400 (5-axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 129. Internal Connection Diagram M400 (4 axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1210. Internal Connection Diagram M500 (5 axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1211. Internal Connection Diagram M500 (4 axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1212. Internal Connection Diagram L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1213. Internal Connection Diagram Emergency Stop Control PCB . . . . . . . . . . . . . .
Figure 1214. Internal Connection Diagram Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1215. Internal Connection Diagram - Main CPU; Axis Control Board . . . . . . . . . . . . . . .
Figure 1216. Internal Connection Diagram Servo Amplifier Connection S-420, ARC Mate/S-5,
ARC Mate Sr./S-10, ARC Mate 100/S-6, S-500, S-700, and S-800 . . . . . . . . . . . . . .
Figure 1217. Internal Connection Diagram Servo Amplifier Connection A-510, L-1000,
and M-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1218. Internal Connection Diagram Servo Amplifier Connection S-900 and M-500 . . .
Figure 1219. Internal Connection Diagram Modular I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1220. Internal Connection Diagram Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1221. Internal Connection Diagram Main CPU Interface . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1222. Internal Connection Diagram Axis Control Board Interface . . . . . . . . . . . . . . . . .
Figure 1223. Internal Connection Diagram ARC Mate/S-5, ARC Mate Sr./S-10,
ARC Mate 100/S-6, S-420, S-500 and S-800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1224. Internal Connection Diagram S-700 and A-510 . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1225. Internal Connection Diagram M-400 and L-1000 . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1226. Internal Connection Diagram - M400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1227. External Connection Diagram M-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1228. External Connection Diagram S-900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1229. External Connection Diagram Process I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1230. External Connection Diagram Process I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1231. External Connection Diagram Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1232. Motor Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 131. R-J Control Signal and Power Distribution Overview . . . . . . . . . . . . . . . . . . . . . . . .
Figure 132. Main AC Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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


Figure 134. Power Supply Unit (PSU) With Power ON/OFF Circuit . . . . . . . . . . . . . . . . . . . . . .
Figure 135. EMG Stop & Brake Connection 100 VAC E-Stop Circuit 100 VDC Brake
Circuit (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 136. EMG Stop and Brake Connection 100 VDC Brake Circuit (2 of 2) . . . . . . . . . . . . .
Figure 137. EMG Stop and Brake Connection 24 VDC E-Stop Circuit (1 of 2) . . . . . . . . . . . . .
Figure 138. EMG Stop and Brake Connection 24VDC E-Stop Circuit (2 of 2) Modular
I/O Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 139. Overheat and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1310. Single Axis Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1311. Dual Axis Servo Amplifier (With Dynamic Brakes) . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1312. Dual Axis Servo Amplifier (Without Dynamic Brakes) . . . . . . . . . . . . . . . . . . . . . .
Figure 1313. Discharge Resistor and Dynamic Brake Unit (For Amp With No Dynamic Brake)
Figure 1314. LSI Module All Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1315. DV-M Module Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1316. ALM-M Module Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1317. Teach Pendant Power And Data Signal Interconnection . . . . . . . . . . . . . . . . . . . . .
Figure A1. Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure A2. Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure A3. Assembly During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure A4. Peripheral Device Interface Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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11. Main CPU Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


12. Axis Control Board Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13. Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14. Multi-Tap Transformer Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15. Selecting Transformer Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16. Selecting Transformer Taps for Transformer A80L00260013#A . . . . . . . . . . . . . .
17. Digital Input Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18. Digital Output Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19. I/O Module Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110. Process I/O Board Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111. Circuit Breaker, B-Size Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112. Circuit Breaker and Fused Flange Disconnect Switch, C-Size Cabinet . . . . . . . . . .
113. Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114. Teach Pendant Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21. Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22. Axis Status Pulse Screen Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23. Version Identification Status Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24. Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31. Teach Pendant Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Standard Operator Panel C-Size Controller Status Indicators . . . . . . . . . . . . . . . . . . .


Emergency Control Board (EMG) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Axis Control Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . .
Servo Amplifier LED Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Process I/O Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R-H MAP LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R-H ABRIO LED Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Procedure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Procedure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Procedure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Procedure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Procedure 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Procedure 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Class 2 Faults Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-001 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-002 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-003 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-004 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-005 Troubleshooting Procedure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-005 Troubleshooting Procedure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-006 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-007 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-008 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-014 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-015 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-021 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-022 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-023 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-036 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-038 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-042 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-043 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-044 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-045 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-046 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-047 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-049 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-050 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-051 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-061 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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434. SRVO-062 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


435. SRVO-063 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
436. SRVO-064 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
437. SRVO-065 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
438. SRVO-066 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
439. SRVO-067 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
440. SRVO-068 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
441. SRVO-071 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
442. SRVO-081 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
443. SRVO-082 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51. Multi-Tap Transformer Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52. Power supply unit for four-slot backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53. Power supply unit for six-slot backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54. Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71. Standard Operator Panel Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72. Standard Operator Panel Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81. Mastering Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91. Relay Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101. Axis Control Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102. Process I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103. Process I/O Board Potentiometer Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104. Output Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105. SBK Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111. Example of Leakage Current Circuit Breaker for Inverters . . . . . . . . . . . . . . . . . . .
112. External Emergency Stop Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113. External Emergency Stop Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114. Peripheral Device Interface Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115. Process I/O Printed Circuit Board AA or AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
116. Process I/O Printed Circuit Board BA or BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
117. Process I/O Printed Circuit Board CA or CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118. Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
119. Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1110. Two or More Process I/O Boards and the I/O Unit (Model A) . . . . . . . . . . . . . . . .
1111. Process I/O Printed Circuit Board Signals, DI Signals . . . . . . . . . . . . . . . . . . . . . .
1112. Process I/O Printed Circuit Board Signals, DO Signals . . . . . . . . . . . . . . . . . . . . .
1113. Applicable Process I/O Printed Circuit Board - A1/A2 . . . . . . . . . . . . . . . . . . . . .
1114. Applicable Process I/O Printed Circuit Board - A3/A4 . . . . . . . . . . . . . . . . . . . . .
1115. Applicable Process I/O Printed Circuit Board - B1/B2 . . . . . . . . . . . . . . . . . . . . . .
1116. Applicable Process I/O Printed Circuit Board - C1 . . . . . . . . . . . . . . . . . . . . . . . .
1117. Applicable Process I/O Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1118. Peripheral Device Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1119. End Effector Control Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS

1120. Arc Welding Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


1121. Input Modules AID32A and AID32B, Nonisolated . . . . . . . . . . . . . . . . . . . . . . .
1122. Input Modules AID16C and AID16D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1123. Input Modules AID32E and AID32F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1124. Input Module AIA16G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1125. Output Module AOD32A, Non-isolated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1126. Output Modules AOD08C and AOD08D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1127. Output Modules AOD16C and AOD16D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1128. Output Module AOD32C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1129. Output Module AOD32D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1130. Output Modules AOA05E and AOA08E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1131. Output Module AOA12F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1132. Output Modules AOR08G and AOR16G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1133. Output Module ADA02A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1134. Analog Input Module AAD04A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1135. Peripheral Device Cable Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . .
1136. Symbols Used in Figure 1155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1137. Peripheral Device Cable Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . .
1138. Symbols Used in Figure 1156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1139. Peripheral Device Interface Cable C Connector Specifications . . . . . . . . . . . . . . .
1140. Connection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1141. Recommended Cable for Peripheral Device Connection . . . . . . . . . . . . . . . . . . . .
1142. Recommended Cable for End Effector Connection . . . . . . . . . . . . . . . . . . . . . . . .
A1. Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A2. Adjustment and Checks at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xxiii
1149
1151
1152
1153
1154
1155
1156
1157
1158
1159
1160
1161
1162
1163
1164
1169
1169
1170
1170
1171
1171
1174
1174
A4
A5

SAFETY

Page2

MARMMTRBL02303E

Safety

xxv

FANUC Robotics is not and does not represent itself as an expert in safety
systems, safety equipment, or the specific safety aspects of your company
and/or its work force. It is the responsibility of the owner, employer, or
user to take all necessary steps to guarantee the safety of all personnel in
the workplace.
The appropriate level of safety for your application and installation can
best be determined by safety system professionals. FANUC Robotics
therefore, recommends that each customer consult with such professionals
in order to provide a workplace that allows for the safe application, use,
and operation of FANUC Robotic systems.
Additionally, as the owner, employer, or user of a robotic system, it is your
responsibility to arrange for the training of the operator of a robot system
to recognize and respond to known hazards associated with your robotic
system and to be aware of the recommended operating procedures for your
particular application and robot installation.
FANUC Robotics therefore, recommends that all personnel who intend to
operate, program, repair, or otherwise use the robotics system be trained in
an approved FANUC Robotics training course and become familiar with
the proper operation of the system. Persons responsible for programming
the systemincluding the design, implementation, and debugging of
application programsmust 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.

xxvi

CONSIDERING
SAFETY FOR YOUR
ROBOT
INSTALLATION

SAFETY

MARMMTRBL02303E

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







The safety of people and equipment


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

Keeping People and


Equipment Safe

The safety of people is always of primary importance in any


situation. However, equipment must be kept safe, too. When
prioritizing how to apply safety to your robotic system, consider
 People
 External devices
 Robot(s)
 Tooling
 Workpiece

Using Safety
Enhancing Devices

Always give appropriate attention to the work area that surrounds the
robot. The safety of the work area can be enhanced by the installation of
some or all of the following devices:
 Safety fences, barriers, or chains
 Light curtains
 Interlocks
 Pressure mats
 Floor markings
 Warning lights
 Mechanical stops
 EMERGENCY STOP buttons
 DEADMAN switches

Setting Up a Safe
Workcell

A safe workcell is essential to protect people and equipment. Observe the


following guidelines 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.

Install a lockout device that uses an access code to prevent


unauthorized persons from operating the robot.

Use antitiedown logic to prevent the operator from bypassing safety


measures.

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

MARMMTRBL02303E

SAFETY

xxvii

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.

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 joints 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.

Make sure all external devices are properly filtered, grounded,


shielded, and suppressed to prevent hazardous motion due to the
effects of electromagnetic interference (EMI), radio frequency
interference (RFI), and electrostatic 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.

xxviii

Staying Safe While


Teaching or Manually
Operating the Robot

SAFETY

MARMMTRBL02303E

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


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. However, if you must enter the work envelope, be
sure all safeguards are in place, and check the teach pendant
DEADMAN switch for proper operation. Take the teach pendant with
you, turn it on, and be prepared to release the DEADMAN switch.
Only the person with the teach pendant should be in the work
envelope.

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.

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.

MARMMTRBL02303E

Staying Safe During


Production Operation

Staying Safe During


Inspection

SAFETY

xxix

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


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 production operation.

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

Never enter or allow others to enter the work envelope during


production 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 panel, 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 panel.

If power is needed to check the robot motion or electrical circuits, be


prepared to press the EMERGENCY STOP button, in an emergency.

xxx

Staying Safe During


Maintenance

SAFETY

MARMMTRBL02303E

When performing maintenance on your robot system, observe the


following rules:


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


operation.

Before entering the work envelope, visually inspect the workcell to


make sure no potentially hazardous conditions exist.

Consider all or any overlapping work envelopes of adjoining 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 DEADMAN switch,
and turn the teach pendant on. Be prepared to release the DEADMAN
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 panel or enter the work envelope,
turn off and lock out the 3phase power source at the controller.

WARNING
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to
avoid electrical shock.
Turning the disconnect or circuit breaker to the OFF
position removes power from the output side of the device
only. High voltage is always present at the input side
whenever the controller is connected to a power source.


Release or block all stored energy. Before working on the pneumatic


system, shut off the system air supply and purge the air lines.

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.

MARMMTRBL02303E

SAFETY

xxxi

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


axis will fall if it is not supported or resting on a hard stop.

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. These measures are
outlined below.

Programming Safety
Precautions

Implement the following programming safety measures to prevent damage


to machine tools and other external devices.

Mechanical Safety
Precautions

Backcheck 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.

xxxii

KEEPING THE
ROBOT SAFE
Operating Safety
Precautions

SAFETY

Observe the following operating and programming guidelines to prevent


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





Programming Safety
Precautions

MARMMTRBL02303E

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.

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.

MARMMTRBL02303E

ADDITIONAL
SAFETY
CONSIDERATIONS
FOR PAINT ROBOT
INSTALLATIONS

SAFETY

xxxiii

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, todays 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 highvoltage electrostatic tools.
Paint robots are operated in three modes:




Teach or manual mode


Automatic mode, including production 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 Controller
Center (SCC), Manual Control Panel (MCP), if available, or Manual Paint
Station (MPS), if available, and can be monitored from outside the paint
booth. All personnel must remain outside of the booth or in a designated
safe area within the booth whenever automatic mode is initiated at the
SCC, MCP, or MPS.
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.

xxxiv

Paint System Safety


Features

SAFETY

MARMMTRBL02303E

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 Manual Control


Panel (MCP), or Manual Paint Station (MPS) panel, if supplied, inside
the booth, or on the System Controller Center (SCC) outside the
booth. Also, EMERGENCY STOP buttons are located near the
interior corners of each booth, and on the robot controller and teach
pendant. Become familiar with the locations of all ESTOP buttons.

An intrinsically safe teach pendant is used when teaching in hazardous


paint atmospheres.

A DEADMAN switch is located on each teach pendant. When this


switch is held in, power is applied to the robot servo system. If the
engaged DEADMAN 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 ESTOP other robots.
WARNING
An EMERGENCY STOP will occur if the DEADMAN switch
is released on a bypassed robot.

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.

MARMMTRBL02303E

SAFETY

xxxv

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 bypassed 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
OPTIONAL SAFETY DEVICE
Your robot may have a red flashing warning light. This is
an optional operator warning. It indicates:
D The robot is powered on
D The robot is armed (servo power on) and can move at
any time.
FANUC Robotics recommends that no one enter the work
envelope of a robot that is on. However, if you must enter
the work envelope, be sure all safeguards are in place, and
check the teach pendant DEADMAN switch for proper
operation. Take the tach pendant with you, turn it on, and
be prepared to release the DEADMAN switch. Only the
person with the teach pendant should be in the work
envelope.


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, mushroomshaped EMERGENCY STOP buttons


are located.

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

xxxvi

Staying Safe During


Maintenance

SAFETY

MARMMTRBL02303E

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 turning on
power to the robot servo system.

Never enter the work envelope or paint booth before turning on 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 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 panel within reach of the EMERGENCY STOP button. This
person must understand the robot and associated potential hazards.

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

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

MARMMTRBL02303E

SAFETY

xxxvii

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

During robot operations, be aware of the robots 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.

xxxviii

SAFETY

MARMMTRBL02303E

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 contact 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 contact with the skin or eyes, rinse with water for at
least 15 minutes.

MARMMTRBL02303E

OVERVIEW
11
The SYSTEM R-J Robot and controller consists of software, a robot, and
the SYSTEM R-J controller. The application software runs on the R-J
controller and is written to perform a specific task.
The SYSTEM RJ controller contains the computer that operates the
robot. It executes a user-defined program to perform the following
functions:


Supply drive power to the servomotors of an attached robot and, in


some cases, to motor-driven auxiliary devices to move the robot
through a series of program motions.

Supply drive power to the servomotors of an attached robot and, in


some cases, to motor-driven auxiliary devices comprising additional
axes, such as door openers, and/or hood/deck openers used in
conjunction with robot programs.

Send control signals to process devices and other peripheral


equipment.

Initiate and monitor the purge system of the robot and sometimes
associated opening devices.

The controller consists of modular circuit boards and components housed


in a cabinet. The controller is housed in either a B-size or C-size cabinet.
The controller consists of modular circuit boards and components housed
in a C-size cabinet.
Figure 11, Figure 12, and Figure 13 illustrate an external view of the
B-size cabinet and Figure 14 illustrates an external view of a C-size
cabinet. Figure 15 illustrates an internal view of a B-size cabinet and
Figure 16 illustrates an internal view of a C-size cabinet.
Figure 14 illustrates an external view of a C-size cabinet. Figure 17
illustrates an internal view of a C-size cabinet.

1. OVERVIEW
MARMMTRBL02303E

12
Figure 11. Cabinet Exterior, B-Size Controller

Teach
pendant

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

Regenerative
Discharge
Unit

Teach
pendant

1. OVERVIEW

13

MARMMTRBL02303E

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

Optional Side Cabinet

Teach
pendant

1. OVERVIEW
MARMMTRBL02303E

14
Figure 14. Cabinet Exterior, C-Size Controller

Teach
pendant

1. OVERVIEW

15

MARMMTRBL02303E

Figure 15. Cabinet Interior, B-Size Controller


Regenerative discharge unit
Servo amplifier 4

Fan 1

Servo amplifier 3

Additional cabinet

Operators panel
Main CPU printed
circuit board
Axis control printed
circuit board
Power supply unit
Printed circuit board for
emergency stop control
Process I/O printed
circuit board or
I/O unit model A
Circuit breaker
Fan 2

Servo amplifier 6
Servo amplifier 5

Transformer or
line filter unit

Servo amplifier 1

Fan 3

Servo amplifier 2
Teach pendant

Fan 4

Fan 5

Components for all models are placed in identical places except for the
servo amplifier. Refer to Section 1.6 for information on the servo
amplifiers locations for different robot models.

1. OVERVIEW
MARMMTRBL02303E

16

Figure 16. Cabinet Interior, C-Size Controller


Operator panel

Extended
Back plane

Modular I/O rack or


Process I/O rack

Power disconnect
Servo amplifier #1
Main CPU

Servo amplifier #2

Fuses FL13
Servo amplifier #3

Axis control board


Power supply unit

Servo amplifier #4 and #5

Emergency stop
control board

Servo amplifier #6

Option 1 and 2 slots

User transformer

Multitap transformer

1. OVERVIEW

17

MARMMTRBL02303E

Figure 17. Cabinet Interior, C-Size Controller

Operator panel

Servo Amplifiers

Contact Signal
Transducer
STAHL
Extended
ISBs
Back plane

STBI Term Strip


Purge 24V DC
Power Supply
Power disconnect

Main CPU
Fuses FL13
Transit Board

Axis control board


Power supply unit

Emergency stop
control board
Option 1 and 2 slots

BDX
ISB Unit

ALC
Relay

SPC Battery
Unit

Multitap transformer
User transformer

1. OVERVIEW
MARMMTRBL02303E

18

1.1

The control unit printed circuit boards are mounted on the backplane
printed circuit board. The backplane provides the bus structure for
communication between the various printed circuit boards in the controller.
A thermostat for sensing the temperature in the controller is mounted on
the backplane. If the internal temperature exceeds specifications (65C),
the controller will generate a system overheat alarm.

BACKPLANE
4-Slot A20B-1004-0420 or
A20B-2000-0800
6-Slot A20B-1004-0590 or
A20B-2000-0920

Two different backplane printed circuit boards are available both for the 4and 6-slot printed circuit board. Either of these printed circuit boards are
interchangeable.
The RH style extended backplane is available for using R-H style printed
circuit boards, such as MAP 3.0 and ABRIO. Figure 18 shows the
backplane with the R-H style extended backplane attached.

R-H Style Extended


Backplane
A20B-1004-0510

CNB15
CNA15

CNA14

CNBV2
CNAV2

JNAT

CNBV1
CNAV1

Figure 18. Backplane with R-H Style Extended Backplane

NOTE The A20B-2000-0800 and the A20B-2000-0920 printed circuit


boards have an additional connector that is not used in robot applications.

1. OVERVIEW

19

MARMMTRBL02303E

1.2
MAIN CPU PRINTED
CIRCUIT BOARD
A16B-2200-0840 to
A16B-2200-0843

The main CPU printed circuit board is mounted on the backplane in the
slot marked MAIN. It contains the CPU and the volatile and non-volatile
memory used by the controller.
The Main CPU printed circuit board also acts as the interface between the
controller and the operator and attached devices, through connections to:






The I/O unit(s)


The teach pendant
One or more generalpurpose serial communication ports
An optional built-in or remote computer terminal (CRT/KB)
The operator panel lights and pushbuttons

A super capacitor on the Main CPU printed circuit board maintains voltage
to the CMOS RAM for short periods of time (less than an hour) if
removed from the backplane. A connector, BAT-VBAT, is supplied to
connect the battery from the Power Supply Unit to the Main CPU printed
circuit board when the Power Supply Unit or Main CPU is removed from
the controller for an extended period of time. This will supply voltage to
the CMOS memory so the stored data is not lost.
The main CPU consists of a main motherboard with several daughter
modules installed perpendicular to it. The modules are small printed
circuit boards with components surface-mounted on both sides. The
modules are installed in sockets, allowing them to be changed quickly and
easily.


Flash ROM Module contains System and Application Software.

CMOS RAM Module stores user programs, system variables, I/O


configuration files, and mastering data.
SLC2 Module controls I/O communication.
M32i Module controls communication between the flash ROM,
CMOS, micro processor and boot ROM chip.
SCC Module controls communication with the operator panel.
Optional SCC Module communicates with any optional serial ports.






Figure 19 shows the board layout. Table 11 lists the part numbers for
the modules attached on the board.

1. OVERVIEW
MARMMTRBL02303E

110
Figure 19. Main CPU Board Layout

Flash ROM module

Optional SCC module

CMOS RAM module (option)

SLC2 module

CMOS RAM module (option)

M32i module

CMOS RAM module (standard)

SCC module

CMOS RAM module (standard)

NOTE Options are shown in phantom print.

1. OVERVIEW

111

MARMMTRBL02303E

Table 11.
Name

Main CPU Modules

Part Number

CMOS RAM module

A20B-2900-0500, 0501

Flash ROM module

A20B-2900-0480, 0482

M32I module

A20B-2900-0450

SCC module

A20B-2900-0430

SLC2 module

A20B-2900-0440, 0442

Optional SCC module

A20B-2900-0490, 0491, 0492

Remarks

MAIN CPU printed circuit board

NOTE CMOS RAM modules are replaced in pairs (two standard modules
or two optional modules).

1. OVERVIEW
MARMMTRBL02303E

112

1.3
AXIS CONTROL
PRINTED CIRCUIT
BOARD
A16B-2200-0852 to
A16B-2200-0855

The axis control printed circuit board is mounted on the backplane in the
slot marked AXIS. It performs the following functions:
 Receives command signals from the main CPU board, and receives
axis position and velocity signals from the serial pulse coders.
 Compares the command signal with the axis position signal and
generates pulse-width-modulated axis drive signals. These signals
switch the drive transistors on the servo amplifiers on and off applying
power to the servo motors.
 Monitors the status of the hand breakage and axis overtravel switches
in the mechanical unit.


Is the interface for the Robot Input (RI) and Robot Output (RO) I/O
signals.
Figure 110 shows the axis control board layout. Table 12 lists the part
numbers for the modules attached on the board.
Figure 110. Axis Control Board Layout

Servo control module (for axis 9 and 10)


Servo control module (for axis 7 and 8)
Servo control module (for axis 5 and 6)
Servo control module (for axis 3 and 4)
Servo control module (for axis 1 and 2)
Servo interface module (for axis 5 and 6)
Servo interface module (for axis 3 and 4)

Servo interface module (for axis 9 and 10)

Servo interface module (for axis 1 and 2)

Servo interface module (for axis 7 and 8)

NOTE Options are shown in phantom print.


Table 12.
Name
Servo interface module
Servo control module

Axis Control Board Modules

Part Number
A20B-2900-0380
A20B-2900-0160

Remarks
Axis control printed circuit board

1. OVERVIEW

113

MARMMTRBL02303E

1.4
POWER SUPPLY UNIT
PRINTED CIRCUIT
BOARD
4-Slot Backplane
A16B-12120471
6-Slot Backplane
A16B-1212-0531

The power supply unit printed circuit board is mounted on the backplane
in the slot marked PSU.
The power supply unit printed circuit board is supplied with 210 VAC
from the multi-tap transformer and produces the following DC voltages:


+24V used

For inputs, outputs receivers, drivers, and relays.


As the power source for the teach pendant power supply circuitry.


+15, 15, +5 used for logic circuitry within the controller.

The power supply unit printed circuit board also contains the ON/OFF
logic circuits used by the controller.

CAUTION
The CMOS RAM backup battery is mounted on the power
supply unit printed circuit board. If the board is removed from
the controller for longer than 30 minutes, all software in the
controller might be lost.

Figure 111. Power Supply Unit Printed Circuit Board


PSU

F5: 0.3A fuse for


auxiliary
power supply
Battery cover

PSU

F1 and F2:
Fuses for AC input
10-A for 6-slot backplane
7.5A for 4-slot backplane
PIL: green LED
for indicating the AC
power supply status

Battery

ALM: Red LED


for indicating
an alarm

F4:5Afuse for +24E


F3: Fuse for +24V
5-A slow blow for
6-slot backplane
3.2A slow blow for
4-slot backplane

(with battery cover removed)

1. OVERVIEW
MARMMTRBL02303E

114

1.5
EMERGENCY STOP
CONTROL PRINTED
CIRCUIT BOARD

The emergency stop control printed circuit board is mounted on the


backplane in the slot marked EMG. It contains the circuits that:


Supply 100VAC to the servo amplifiers magnetic control contactors


(MCCs) during normal operation.

A16B-1212-0540

Turn off 100VAC for the MCC during fault conditions such as:

A16B-1212-0730

Turn off 100VAC for the MCC during fault conditions such as:

Emergency stop
Axis overtravel
Safety fence open
Teach pendant DEADMAN switch
Hand breakage detection

Supply power to the motor brakes to release them during normal


operation. Brake power is turned off (applying motor brakes) during
major alarm conditions, or when regulated by the software.

Supply power to the motor brakes to release them during normal


operation. Brake power is turned off (applying motor brakes) during
major alarm conditions, or when regulated by the software. There is a
second brake circuit that is manually operated by a front panel key
switch. This key switch operated circuit provides a method to move
the robot manually should servo power fail, or when mastering is
required.

Monitor and control the purge system through a piggy-back style PCB,
purge control A16B16000520. This PCB is mounted internally
within the EMG PCB.

Supply 24VDC required for SPC encoder operation through the 24 to


5VDC converter unit located within the robot base and switched on
through the purge complete relay contacts of RL-1 for protection from
explosive gases.

Figure 112 shows the emergency stop control printed circuit board
layout.

1. OVERVIEW

115

MARMMTRBL02303E

Figure 112. Emergency Stop Control Printed Circuit Board

EMG
PCB

1. OVERVIEW
MARMMTRBL02303E

116
Figure 113. Emergency Stop Control PC Board

DS2

F1
DS1

F2
RL16

FUSE

RL1 RL2

RL4
CRR5
RL3

LED M1
LED M2

RL2
RL4 TIMER

RL1
RL3

RL6
RL5
RL8

CNPG

Purge Control PCB

RL7

RL9

CRT
CRX

1. OVERVIEW

117

MARMMTRBL02303E

1.6
SERVO AMPLIFIERS
Refer to Table 13 for
part numbers.

The servo amplifiers are mounted on the back wall of the controller. The
servo amplifier amplifies the drive signal from the axis control printed
circuit board and supplies it to the servomotor.
Servo amplifiers are supplied in single, double or triple-axis
configurations. Several different models of each configuration are used in
various FANUC robot controllers.
CAUTION
While two servo amplifiers might look identical, they might have
quite different output power capabilities. If you replace a servo
amplifier, make sure that the new unit has the same part
number as the old one. Otherwise, the servo amplifier or
servomotor might be damaged or destroyed.
See Figure 114 for a servo amplifier.
Figure 114. Servo Amplifier

Circuit breaker

LED
Terminal board T1

1. OVERVIEW
MARMMTRBL02303E

118
MCC Coil

Each servo amplifier has its own DC power supply, which is supplied
3-phase 210 VAC from the multi-tap transformer. The power lines
supplying the DC power supply are switched on and off by a magnetic
contactor (relay) called the Magnetic Control Contractor (MCC).
The MCC coil is energized by 100 VAC from the emergency stop control
printed circuit board. The MCC coil voltage is turned off during major
fault conditions or when regulated by the software.
When the MCC is turned off, its normally-closed contacts connect the
motor power leads together through low-resistance, high-power resistors,
stopping the motor immediately.

Circuit Breaker

The servo amplifier circuitry is protected by a circuit breaker. The reset


lever for the circuit breaker is visible on the front panel of the servo
amplifier. Refer to Section 1.9 for more information on the multi-tap
transformer.

Fault Detection

Each servo amplifier has fault detection circuits that detect such conditions
as excessive motor current and servo amplifier power supply failure.
A pair of terminals on the servo amplifier can be connected to a
temperature-sensing switch in the multi-tap transformer. If the switch
opens, the controller will signal a SRVO0043 DCAL alarm.

Servo Amplifier
Configuration

Table 13 lists the servo amplifiers for several FANUC robots.


Figure 115 shows the mounting locations of the servo amplifiers.

Servo Amplifier
Configuration

Table 13 lists the servo amplifiers for the P-155 robot and optional
auxiliary devices.. Figure 123 shows the mounting locations of the servo
amplifiers.
Figure 115. Mounting Locations of Servo Amplifiers Robot with 6-amplifiers

SLOT 4 SLOT 5 SLOT 6

SLOT 1 SLOT 2 SLOT 3

1. OVERVIEW

119

MARMMTRBL02303E

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

Figure 117. Mounting Locations of Servo Amplifiers for the Arc Mate/
Arc Mate 100/S-6, Arc Mate Sr./S-5/S-10 and L-1000

1. OVERVIEW

120

MARMMTRBL02303E

Figure 118. Mounting Locations of Servo Amplifiers for the S-500/S-700 and
M-400

Figure 119. Mounting Locations of Servo Amplifiers for the S-420 and S-800

1. OVERVIEW

121

MARMMTRBL02303E

Figure 120. Mounting Locations of Servo Amplifiers for the S-420 and the DCR &
DBR Unit

(S420) With 3 2-Axis Servo Amplifiers; S420D

Figure 121. Mounting Locations of Servo Amplifiers for the M-500

1. OVERVIEW
MARMMTRBL02303E

122

Figure 122. Mounting Locations of Servo Amplifiers for the S-900

Figure 123. Mounting Locations of Servo Amplifiers.


Amp 1

Amp 2 Amp 3

Axis 1
Axis 4

Axis 2
Axis 5

Amp 4 Amp 5
Axis 7

Axis 8
Axis 9

Axis 3
Axis 6

1. OVERVIEW

123

MARMMTRBL02303E

NOTE In Table 13, the part number of the specific amplifier is


A06B-6066-HXXX.

Table 13.
Machine Type

Servo Amplifiers

Servo
Amplifier 1

Servo
Amplifier 2

Servo
Amplifier 3

ARC Mate
S-5

H281
L;Axis 4/
M;Axis 1

H223
L;Axis 5/
M;Axis 2

H223
L;Axis 6/
M;Axis 3

ARC Mate
100/S-6

H234
L;Axis 4/
M;Axis 1

H224
L;Axis 5/
M;Axis 2

H223
L;Axis 6/
M;Axis 3

ARC Mate Sr.


S-10

H234
L;Axis 4/
M;Axis 1

H234
L;Axis 5/
M;Axis 2

H233
L;Axis 6/
M;Axis 3

H235
Axes 1 & 4

H235
Axes 2 & 5

H235
Axes 3 & 6

P-155

Servo
Amplifier 4

Servo
Amplifier 5

H005
Axis 7

Door Opener

H233
Axes 8 & 9

Hood & Deck

H244
Axes 8 & 9

S-420
(with five amplifiers)

H011
Axis 1

H006
Axis 2

H006
Axis 3

H244
L;Axis 5/
M;Axis 4

H291
L;Axis 4/
M;Axis 1

H291
L;Axis 5/
M;Axis 2

H291
L;Axis 6/
M;Axis 3

DCR & DBR


Unit

S-500

H011
Axis 1

H006
Axis 2

H234
L;Axis 4/
M;Axis 3

H233
L;Axis 6/
M;Axis 5

S700

H012
Axis 1

H006
Axis 2

H234
L;Axis 4/
M;Axis 3

H233
L;Axis 6/
M;Axis 5

S-800

H011
Axis 1

H006
Axis 6

H006
Axis 3

H260
L;Axis 5/
M;Axis 4

H006
Axis 6

S900

H008
Axis 1

H006
Axis 4

H008
Axis 2

H006
Axis 5

H008
Axis 3

M-400

H006
Axis 1

H011
Axis 2

H234
L;Axis 4/
M;Axis 3

H003
Axis 5

M-500

H008
Axis 1

H006
Axis 3

H244
L;Axis 4/
M;Axis 2

H004
Axis 5

A-510

H233
L;Axis 3/
M;Axis 1

H223
L;Axis 4/
M;Axis 2

L-1000

H234
L;Axis 4/
M;Axis 1

H234
L;Axis 5/
M;Axis 2

S-420 and S-420D


(with three 2-axis
amplifiers)

H003
Axis 3

Servo
Amplifier 6

H004
Axis 6

H006
Axis 6

1. OVERVIEW
MARMMTRBL02303E

124

1.7
DCR AND DBR UNIT
A05B-2302-C080

The Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) unit is
used in R-J controllers with three 2-axis amplifiers. It contains the
dynamic braking resistors and regenerative discharge resistors built into
the other model servo amplifiers. At the loss of either MCON (Motor
Control Connected) signal from the axis control module to the servo
amplifier, that amplifier turns off the 100C signal to the DBR (Dynamic
Braking) and DCR (Discharge Resistor) unit and its associated MCC.
This turns off the MCC contactor (one for each major and minor axis on
the DBR and DCR unit) for that amplifier, and engages the dynamic
brakes through the normally closed contacts of the corresponding MCC.
At the loss of the 100VAC from the emergency stop circuit, all of the
MCC contactors are turned off, engaging all of the dynamic brakes.
When the MCC deenergizes, it opens its normally open contact, relaying
no interlock (INTL).
The regenerative discharge resistor and its associated thermal switch, for
each amplifier, is mounted to the back of the DBR and DCR unit.
The thermal switches of transformer TF1, is also connected to the DBR
and DCR unit.
Figure 124. DCR and DBR Unit

1. OVERVIEW

125

MARMMTRBL02303E

1.8
DISCHARGE UNIT
A05B-2312-C100 for M-500
A05B-2313-C100 for S-900

A discharge unit, mounted on top of the controller, is used with the M-500
and S-900 robot models. This unit is connected to axis 1 on the M-500
and axes 1, 3, and 5 on the S-900.
The unit consists of low-resistance high-power resistors used to dissipate
the counter electromotive force generated by the servo motors when they
are shut off. Thermo overload switches connected to the overheat
terminals on the servo amplifiers are also in the discharge unit. Fans in the
discharge unit are used to cool the unit.
Figure 125. Discharge Unit

1. OVERVIEW
MARMMTRBL02303E

126

1.9
MULTI-TAP
TRANSFORMER
Refer to Table 14 for part
numbers.

The multitap transformer is located on the floor of the controller on the


right side.
The multi-tap transformer is supplied 3phase AC from the main
disconnect or circuit breaker. This supply voltage can be from 220 575
volts. To accommodate the various levels of supply, tap selections are
provided on the primary side of the transformer.
The transformer supplies the following output voltages:






3phase 210 VAC for the servo amplifiers


1phase 210 VAC for the backplanemounted components
1phase 210 VAC for the IBRC module
1phase 210 VAC for the 24VDC Purge Power Supply
1phase 100 VAC for the brakes and servo amplifiermounted MCCs

NOTE Transformer A80L00260013#A also supplies 115VAC for the


user receptacle.
Two seriesconnected thermostats are mounted on the transformer. They
are connected to fault detection circuitry in one servo amplifier. If the
transformer overheats, the controller will signal a SRVO0043 DCAL
alarm.
Figure 126 and Figure 127 show the transformers, and Table 14,
Table 15, and Table 16 lists the information necessary for selecting a
proper primary tap.
Figure 126 shows the transformers, and Table 14, and Table 15 lists
the information necessary for selecting a proper primary tap.
Table 14.

Multi-Tap Transformer Part Numbers

Transformer Type
7.5kVA
S-420, S-500, S-800,
M-500
ARC Mate Sr., S-700,
M-400, L-1000, S-10
ARC Mate, Arc Mate
100/S-6, A-510, S-5
S-420 with 3 2-axis
Servo Amplifiers; S-420D
S-900

Part Number
A80L00260010#A
A80L-0026-0010#A
A80L-0024-0010#A
A80L-0022-0007#A
A80L-0026-0013#A
A80L-0026-0010#A Main cabinet
A80L-0024-0011#A Side cabinet

1. OVERVIEW

127

MARMMTRBL02303E

Figure 126. Multi-Tap Transformer


1

575V
550V
500V
480V
460V
240/415V
220V/380V
F4
7.5

F1

F5
7.5

13

F2

2
3
4
5
6
7

F3

A1

A2

23

31

41

32

42

14

24

0V
575V
550V
500V
480V
460V
240/415V
220V/380V

9
10
11
12
13
14
15
16

0V
575V
550V
500V
480V
460V
240/415V
220V/380V

17
18
19
20
21
22
23

24

0V

Table 15.

Selecting Transformer Taps


Primary Tap

S pply Voltage
Supply

L1

L2

L3

Jumper

220

15

23

7-24, 15-8, 23-16

240

14

22

6-24, 14-8, 22-16

380

15

23

415

14

22

460

13

21

480

12

20

500

11

19

550

10

18

575

17

8-16-24

Connection Type


1. OVERVIEW
MARMMTRBL02303E

128
Figure 127. Multi-Tap Transformer A80L00260013#A

575V
480V
220V/380V

0V
F4
5A

F5
5A

F6

F7

F1

F2

1
2
3

F3
575V
480V
220V/380V

5
6
7

100V
41
100V
42
220
43
220
44
115
46
G
47
TOH1
51
TOH2
52

13

A1

A2

23

31

41

32

42

575V
480V
220V/380V

0V

14

9
10
11

12

24

Table 16. Selecting Transformer Taps for Transformer


A80L00260013#A
Primary Tap
S pply Voltage
Supply

Connection Type

L1

L2

L3

Jumper

220

11

4-7, 8-11, 12-3

380

11

480

10

4, 8, 12

575

1. OVERVIEW

129

MARMMTRBL02303E

1.10
INTERFACE DEVICES

The interface between the controller and peripheral devices is provided by


input and output signals from one or more of the following:


Modular I/O Unit

Process I/O printed circuit board

A printed circuit board specializing in communicating with a logic


controller, which includes

ABRIO for communication to an Allen-Bradley PLC


Genius I/O for communication to a GE Fanuc programmable
controller


Digital I/O to/from the robot through the axis control board.

1. OVERVIEW
MARMMTRBL02303E

130

1.10.1

The modular I/O unit provides communication between the controller and
various peripheral devices. See Figure 128.

Modular I/O Unit

Figure 128.

Interface Module

Modular I/O

I/O Module

Modular I/O Rack


(Backplane)

Slot 2
Slot 1
Slot I/F

I/O Module

Interface Module

The modular I/O unit uses the following communication modes:


 Discrete (On or Off) input and output signal lines at 24VDC or
120VAC. Outputs can be sink or source outputs.
 Analog signal lines, which can vary from 10VDC to +10VDC
The modular I/O unit consists of the following:
 The base unit
 The interface module
 Various discrete input and output (I/O) modules
The control can use as many as 64 modular I/O modules concatenated
(daisychained) together on multiple racks.
A single modular I/O unit is referred to as rack 1. The I/O modules are
located in slots 1 to 5 or 1 - 10, depending on the model used.
Base Unit
5 I/O Module Slot
A03B-0807-C002
10 I/O Module Slot
A03B-0807-C001

The base unit is the backplane for the modular I/O unit. The interface
module and the I/O modules plug into it.
The base unit has no LEDs, fuses, or electrical connections, except for the
module sockets.
The first slot to the left (I/F) always contains the interface module. The
other slots are used for the I/O modules.

1. OVERVIEW

131

MARMMTRBL02303E

Interface Module
With 1 Rack
A03B-0807-C011
For Additional Rack
A03B-0807-C012

The interface module transfers data between the main CPU and the I/O
modules.
The interface module is connected to the JD4 connector on the main CPU
printed circuit board through connector JD1B. The interface module is
always mounted in the I/F (first) slot.

Discrete Input Modules


Refer to Table 17 and
Table 19 for specifications
and part numbers.

Discrete input modules receive 24VDC or 120VAC signals on their


terminals and relay the data to the interface module.

Discrete Output Modules


Refer to Table 18 and
Table 19 for specifications
and part numbers.

Discrete output modules transmit 24VDC or 120VAC signals on their


terminals under command of the interface module.

1. OVERVIEW
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132
Table 17.
Input Type
Non-isolated
DC input

Optically
isolated
DC input
inp t

AC input

Rated
Voltage
24VDC

Rated
Current
7.5 mA

32

External
Connection
Connector

No-display

AID32B

24VDC

7.5 mA

Both

Maximum
2 ms

32

Connector

No-display

AID16C

24 VDC

7.5 mA

NEG

Maximum
20 ms

16

Terminal block Provided

AID16D

24VDC

7.5 mA

POS

Maximum
20 ms

16

Terminal block Provided

AID32E

24VDC

7.5 mA

Both

Maximum
20 ms

32

Connector

No-display

AID32F

24VDC

7.5 mA

Both

Maximum
2 ms

32

Connector

No-display

AIA16G

100~
120VAC

10.5 mA
(120VAC)

16

Terminal block Provided

* Polarity is defined as follows:

Not-Fused
DC output

AC output

Module
Name
AOD332A

Both

Response
Time
Maximum
20 ms

ON Max 35 ms
OFF Max 45 ms

Points

LED Display

2A

NEG
(Sink)

AOD08D

2A

POS
(Source)

Terminal block Provided

Fused

AOD16C

0.5 A

NEG
(Sink)

16

Terminal block Provided

Not fused

AOD16D

0.5 A

POS
(Source)

16

Terminal block Provided

Not fused

AOD32C

0.3 A

NEG
(Sink)

32

Connector

Not
provided

Not fused

AOD32D

0.3 A

POS
(Source)

32

Connector

Not
provided

Not fused

100 ~
240 VAC

2A

Terminal block Provided

Fused

1A

Terminal block Provided

Fused

AOA12F

100 ~
120 VAC

0.5 A

12

Terminal block Provided

Fused

AOR08G

Maximum
250 VAC
/30 VD

4A

Terminal block Provided

Not fused

2A

16

Terminal block Provided

Not fused

AOD08C

AOA05E

AOR16G

Rated
Voltage
5~
24 VDC
12 ~
24 VDC

Digital Output Module Specifications


LED
Display
Not
provided
Terminal block Provided

AOA08E

Relay
output

Polarity*

Negative: 0 V common (current source type); ON when input is at low level.


Positive: 24 V common (current sink type); ON when input is at high level.
Table 18.

Output
Type
Not fused
DC output
Fused
DC output

Digital Input Module Specifications

Module
Name
AID32A

* Polarity is defined as follows:

Maximum
Polarity* Points
Current
0.3A
NEG
32

Points/
Common
8

External
Connection
Connector

Fuses
Not fused
Fused

Negative:0 V common (current sink type); output is at low level when ON.
Positive: 24 V common (current source type); output is at high level when ON.

1. OVERVIEW

133

MARMMTRBL02303E

Table 19.

I/O Module Part Numbers


Part Number

Name
DC input
module

Non-isolated

32 points
20 ms

AID32A

A03B-0807-C101

32 points
2 ms

AID32B

A03B-0807-C102

16 points
NEG

AID16C

A03B-0807-C103

16 points
POS

AID16D

A03B-0807-C104

32 points
20 ms

AID32E

A03B-0807-C105

32 points
2 ms

AID32F

A03B-0807-C106

AIA16G

A03B-0807-C107

32 points
NEG

A0D32A

A03B-0807-C162

8 points
NEG

AOD08C

A03B-0807-C151

8 points
POS

AOD08D

A03B-0807-C152

16 points
NEG

AOD16C

A03B-0807-C153

16 points
POS

AOD16D

A03B-0807-C154

32 points
NEG

AOD32C

A03B-0807-C155

32 points
POS

AOD32D

AO3B-0807-C156

5 points, 2 A AOA05E

A03B-0807-C157

8 points
1A

AOA08E

A03B-0807-C158

12 points
0.5 A

AOA12F

A03B-0807-C159

8 points
4A

AOR08G

A03B-0807-C160

16 points
2A

AOR16G

A03B-0807-C161

Analog input module

AAD04A

A03B-0807-C051

Analog output module

ADA02A

A03B-0807-C052

Optically
isolated

AC input module
16 points
DC output
Not fused
module
Fused

Not fused

AC output module

Relay output module

1. OVERVIEW
MARMMTRBL02303E

134

1.10.2
Process I/O Board
Refer to Table 110 for
part numbers.

The process I/O printed circuit board provides communication between the
R-J controller on various peripheral devices.
The process I/O board uses:


Discrete input lines - Inputs are 24 volt sensing receivers. Common


voltage can be selected as +24VDC or ground.

Discrete output lines - Outputs are 24 volt sinking or sourcing


devices.

Analog input lines - Analog inputs are A D converters sensing an


analog signal 10VDC to 0V or 0V to +10VDC, providing a digital
signal to the processor.

Analog output lines - Analog outputs are D A converters that


output an analog signal 10VDC to 0V or 0V to +10VDC based on a
command from the processor.

Figure 129. Process I/O Printed Circuit Board

1. OVERVIEW

135

MARMMTRBL02303E

Figure 130. Process I/O Printed Circuit Board

Refer to Chapter 10, Board Adjustments, for the location of the output
drivers.

1. OVERVIEW
MARMMTRBL02303E

136
Table 110.
No.

Name

Process I/O Board Part Numbers


Number of I/O
Points

Part Number
DI

DO

D/A

Remarks

A/D

Process I/O printed circuit board AA

A16B-2200-0780

40

40

Standard (with welding interface)

Process I/O printed circuit board AB

A16B-2200-0782

40

40

Standard (without welding interface)

Process I/O printed circuit board BA

A16B-2201-0510
(weld interface)
A20B-2000-0540

32

32

Source type DO (with welding


interface)

Process I/O printed circuit board BB

A16B-2201-0510

32

32

Process I/O printed circuit board CA

A16B-2201-0470

40

40

Process I/O printed circuit board CB

A16B-2201-0472

40

40

Process I/O printed circuit board DA

A16B-2201-0480

96

96

Source type DO (without welding


interface)
Backplane installation type (with
welding interface)
Backplane installation type (without
welding interface)
Backplane installation type (without
welding interface)

1. OVERVIEW

137

MARMMTRBL02303E

1.10.3
ABRIO and Genius I/O
ABRIO
R-H style: A16B-2200-0430
(requires R-H adapter
backplane)
R-J style: A05B-2300-J120
and A05B-2300-J130
(requires R-J six-slot
backplane)
Genius I/O
A16B-2200-0310 (requires
R-H adapter backplane)

The ABRIO and Genius I/O printed circuit boards use serial
communication to interface to a programmable controller. These printed
circuit boards are used for communicating control information between the
SYSTEM R-J controller and the programmable controller.
Refer to the following manuals for information on these boards.



A Users Guide to the FANUC Robotics Remote I/O Interface for an


Allen-Bradley PLC
A Users Guide to the FANUC Robotics Genius Network Interface for
GEFanuc (R-H Style Board in R-J Controller)

1. OVERVIEW

138

1.11
FUSED FLANGE
DISCONNECT AND
CIRCUIT BREAKER

1.12

MARMMTRBL02303E

The SYSTEM R-J controller is supplied with either a fused flange


disconnect or a circuit breaker.

The SYSTEM R-J controller is supplied with a fused flange disconnect.

FUSED FLANGE
DISCONNECT
Fused Flange Disconnect
Refer to Table 112 for fuse
sizes, current rating, and part
numbers.

The fused flange disconnect provides overcurrent protection supply


through three fuses; one for each leg of the 3phase supply. See
Figure 131.

Circuit Breaker

The circuit breaker provides overcurrent protection to the controller and


the supply. The circuit breaker is available with or without ground fault
protection. See Figure 132.

Refer to Table 111 and


Table 112 for current rating
and part numbers.

The fused flange disconnect and the circuit breaker also provide a means
for shutting off power to the controller and locking the power out.

WARNING
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to
avoid electrical shock.
Turning the disconnect or circuit breaker to the OFF
position removes power from the output side of the device
only. High voltage is always present at the input side
whenever the controller is connected to a power source.

WARNING
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to
avoid electrical shock.
Turning the disconnect to the OFF position removes power
from the output side of the device only. High voltage is
always present at the input side whenever the controller is
connected to a power source.

1. OVERVIEW

139

MARMMTRBL02303E

Figure 131. Fused Flange Disconnect


MAIN
DISCONNECT

Fuse Block

FL1 FL2 FL3

Figure 132. Circuit Breaker

1. OVERVIEW
MARMMTRBL02303E

140
Table 111.

Circuit Breaker, B-Size Cabinet

Input
Voltage
g

Circuit Breaker
Current

Current

Part Number

50A

A60L-0001-0347
#B030S

30A

A60L-0001-0306 #BA

380
416
460
480
500
550

30A

A60L-0001-0347
#B015S

20A

A60L-0001-0306 #AA

15A

A60L-0001-0258
#SA538-15

Table 112.
Cabinet
Input
Voltage

Part Number

220
240

575

Circuit Breaker

Circuit Breaker with Ground


Fault

Not Available

Circuit Breaker and Fused Flange Disconnect Switch, C-Size

Circuit Breaker with Ground


Fault

Current

Part Number

Current

Part Number

220
240

50A

A60L0001-0308 #F050

50A

A60L0001-0306 #DA

380
416
460
480
500
550

30A

A60L0001-0347
#B030S

30A

A60L0001-0307
#B20B3

575

20A

A60L0001-0258
#SA53H-20

Fused Flange Disconnect Switch


Fuse
Size

Part Number

5A

A60L0001-0181 #175
Fuse A60L0001-0042
#JG2-50

30A

A60L0001-0181 #175
Fuse A60L0001-0042
#JG1-30

Not Available
Table 113.

Fused Flange Disconnect Switch, C-Size Cabinet


Fused Flange Disconnect Switch

Inputt
Inp
Voltage
220
240
380
416
460
480
500
550
575

Fuse
Size

Part Number

50A

A60L0001-0181 #175
Fuse A60L0001-0042 #JG2-50

30A

A60L0001-0181 #175
Fuse A60L0001-0042 #JG1-30

1. OVERVIEW

141

MARMMTRBL02303E

1.13
USER TRANSFORMER

C-size controllers might contain an optional user transformer. It supplies


120VAC single-phase power to a NEMA outlet receptacle. It is located on
the lower left side of the controller.

A80L-0001-0520
Figure 133. User Transformer

User Transformer
TF2

1.14
OPERATOR PANEL
Refer to Table 112 for part
numbers.

Pushbuttons and LEDs on the Operator Panel are used to control the robot
and to indicate robot status. It might be equipped with one or both of the
following:


Remote CRT/KB port for connecting a terminal to the controller.

DB25 connector for serial interface (external disk drive, for example)

Disconnectable teach pendant port with a switch so the robot can be


operated without the teach pendant connected.

1. OVERVIEW
MARMMTRBL02303E

142

An emergency stop button on the operator panel places the robot into the
emergency stop condition. The operator panel LED functions are
described in Chapter 3, Lights and LEDs.
Figure 134 shows the operator panel on a B-size controller. Figure 135
shows the operator panel on a C-size controller.
Figure 136 shows the operator panel on a C-size controller.
Figure 134. Operator Panel, B-Size Controller



BATTERY

TEACH PENDANT
ENABLED

HOUR METER

RS232C

CRT/KB

FAULT

FAULT RESET

HOLD

USER LED#1

USER PB#1

CYCLE START

USER LED#2

REMOTE

USER PB#2

REMOTE

ON

ALARM

OFF

EMERGENCY
STOP

LOCAL

Figure 135. Operator Panel, C-Size Controller

BATTERY

ALARM

CYCLE START

ON

TEACH PENDANT
ENABLED

HOLD

OFF

FAULT

FAULT RESET

REMOTE

USER LED#1

REMOTE

USER PB#1

LOCAL

USER LED#2

USER PB#2

HOUR METER

RS232C

CRT/KB

EMERGENCY STOP

1. OVERVIEW

143

MARMMTRBL02303E

Figure 136. Operator Panel, C-Size Controller

BATTERY
ALARM

CYCLE START

ON

TEACH PENDANT
ENABLED
HOLD

OFF

FAULT

FAULT RESET

PURGE
COMPLETE

REMOTE

PURGE ENABLE

REMOTE

LOCAL

PURGE
FAULT

BRAKE ENABLE
ON

HOUR METER

OFF

RS232C

CRT/KB

TEACH PENDANT
CONNECT/
DISCONNECT

Optional

EMERGENCY STOP

Table 114.

Part Numbers

Controller

Without Disconnectable
Teach Pendant
B-Size
A05B-2302-C020
C-size with Built-In A05B-2301-C001
CRT/KB
C-size with
A05B-2301-C002
Remote CRT/KB
Table 115.

With Disconnectable Teach


Pendant
A05B-2302-C021
A05B-2301-C003
A05B-2301-C004

Part Numbers

Controller

Without Disconnectable
Teach Pendant
C-size with Built-In A05B-2308H190
CRT/KB
C-size with
A05B-2308H191
Remote CRT/KB

With Disconnectable Teach


Pendant
A05B-2308H192
A05B-2308H193

1. OVERVIEW

144

1.15
TEACH PENDANT
Refer to Table 117 for
part numbers.

MARMMTRBL02303E

The teach pendant is a hand held device used for operating and
programming the robot. Keys on the teach pendant are used to enter data,
jog the robot, and to display menus.
The pendant has a liquid crystal display 16 lines long by 40 characters
wide. The teach pendant also has an emergency stop button that places the
robot into an emergency stop condition.
A deadman switch is mounted on the back of the teach pendant. It must be
held in while the teach pendant is turned on. If it is released while the
teach pendant is turned on, the robot will enter a fault condition similar to
emergency stop.

WARNING
The robot will become fully functional and capable of being
started at the operator panel if the teach pendant is turned
off and the fence circuit is not installed or closed. When
working in the robot envelope, ALWAYS CARRY THE
TEACH PENDANT and ALWAYS HAVE THE TEACH
PENDANT ENABLED.

Seven of the keys on the teach pendant provide different functions


depending on the software in the controller. Eleven LEDs display status of
the system. LEDs are different based on software operating in the
controller. When a nonintrinsic safe teach pendant is used, there are
eleven LEDs that display status of the system. LEDs are different based
on software operating in the controller.
Refer to Chapter 3, Lights and LEDs, for an explanation of the LEDs.
The teach pendant used with the P-155 robot is an Intrinsically Safe
device. It is powered by 8VDC, converted from 24VDC by the Intrinsic
Barrier unit, part number A20B-1005-0240, mounted on the rear of the
enclosure front door.

1. OVERVIEW

145

MARMMTRBL02303E

Figure 137. Teach Pendant

LCD Display
LEDs
Emergency Stop
Button

DEADMAN
Switches

Application-Dependant Keys

Table 116.

Teach Pendant Part Numbers

Application
Intrinsically Safe
NonIntrinsically Safe

Part Number
A05B-2308-H300
A05B-2301-H305

CAUTION
The intrinsically safe teach pendant and the non-intrinsically
safe teach pendant are not interchangeable and will damage
the controller, teach pendant cable, and teach pendant if the
incorrect model is attempted to be used.

Teach Pendant Intrinsically


Safe Barrier PCB
A05B2308C040

The teach pendant Intrinsically Safe Barrier PCB is mounted to the inside
of the cabinet door. The two main connectors, CRS1 and CRS2 join the
intrinsically safe teach pendant with the Main CPU. It is used to ensure
that there not be enough energy to induce a spark within the teach pendant.
This is accomplished by lowering the voltage and limiting current to the
teach pendant through the use of Intrinsically Safe Barriers (refer to
Section 1.19) and opto-isolation chips.
Table 117.

Teach Pendant Part Numbers

Application
Spot Welding
Material Handling
Arc Welding
Sealing
General Use

Part Number
A05B-2301-C300
A05B-2301-C301
A05B-2301-C302
A05B-2301-C303
A05B-2301-C305

Comment
Japanese

1. OVERVIEW
MARMMTRBL02303E

146
Table 117. (Contd) Teach Pendant Part Numbers
Application
Spot Welding
Material Handling
Arc Welding
Sealing
General Use

Part Number
A05B-2301-C310
A05B-2301-C311
A05B-2301-C312
A05B-2301-C313
A05B-2301-C315

Comment
English
g

1. OVERVIEW

147

MARMMTRBL02303E

1.16
HEAT EXCHANGE AND
FANS
Refer to Figure 139 for
part numbers

The temperature in the controller is kept within operating range through


the use of an air-to-air heat exchange system. The controller is sealed to
prohibit outside air from entering. Internal controller air is circulated by
fans around the inside of the controller and downward through the internal
side of the heat exchange unit. Outside air is circulated upward through
the external side of the heat exchange unit also by using a fan. This
process cools the inside air.
Fans are provided on the printed circuit board racks mounted on the
backplane to circulate air over the printed circuit boards.
Cooling fins connected to the servo amplifiers are within the heat
exchange unit to keep the heat generated by the servo power circuits out of
the controller.
Figure 138 shows the heat exchange system for a B-size controller.
Figure 139 shows the heat exchange system for a C-size controller.
Figure 139 shows the heat exchange system for a C-size controller.
Figure 138. Heat Exchange System, B-Size Controller

FANS

FAN 1
Fan Unit
A05B-2302-C901
Fan (Alone)
A90L-0001-0219 #A

AIR FLOW
INTERNAL AIR
OUTSIDE AIR

FAN 3
Fan Unit
A05B-2302-C902
Fan (Alone)
A90L-0001-0213 #A

OUTSIDE AIR IN

FAN 2
Fan Unit
A05B-2302-C900
Fan (Alone)
A90L-0001-0213 #A

1. OVERVIEW
MARMMTRBL02303E

148
Figure 139. Heat Exchange System, C-Size Controller
Fan (Alone)
A90L-0001-0378

FAN 1
Fan Unit
A05B-2301-C901
Fan (Alone)
A90L-0001-0219 #A

AIR FLOW
INTERNAL
AIR
OUTSIDE
AIR
FANS

FAN 2
Fan Unit
A05B-2302-C900
Fan (Alone)
A90L-0001-0213#A

FAN 3
Fan Unit
A02B0056-C904
Fan Alone
A90L-0001-0219 #A

1.17
PURGE SYSTEM
IBRC
A15200010020

OUTSIDE AIR IN

The IBRC is an intrinsically safe barrier unit that is used as part of the
purge system required in the P-155 robot. It has ten photo-isolated relays.
It provides an intrinsically safe barrier for the following signals:










PS-1 Pressure Switch #1 (used for the robot purge system)


FS1 Flow Switch #1 (used for the robot purge system)
FS2 Flow Switch #2 (used for opening device purge system)
ROT/FOT Robot Overtravel Switches (FOT is not applicable)
PS3 Pressure Switch #3 (used for opening device purge system)
EOAT 1 & 2 Not presently used
AUX HBLD Auxiliary Hand Broken (used with Color Trak System)
HBKD Hand Broken (used when a collision detect device is installed)
TPCO Teach Pendant Connect/Disconnect (used when a remote
pendant port is installed in the paint booth. Connected to a
connect/disconnect switch mounted on the pendant port)

1. OVERVIEW
MARMMTRBL02303E

149
The IBRC requires 210VAC from a secondary winding of TF1 to operate.
Internal circuitry provides 20VDC to the hazardous side terminals which
are isolated from the safe side terminals and their voltage of 24VDC.
There are ten red LEDs, one for each device used in the field. There are a
pair of terminals, labeled Px and Nx, for each hazardous signal, while the
corresponding safe side terminals have Ax, Bx, and Cx. Cx is the 24VDC
input, and Ax and Bx are the normally open and normally closed contact
outputs respectively. When voltage is being applied to the field switch
device contacts and they are closed, the IBRC LED will be illuminated for
that particular contact. Should a jumper be installed across the P and N
terminals, the LED for those terminals will be illuminated.
With plant air supplied to the robot, and power available to the IBRC
through the disconnect switch in the ON position, PS-1 LED should be
illuminated.

1.18
PURGE UNIT POWER
SUPPLY
A05B2308C040

The Purge Unit Power Supply is a 24VDC auxiliary power supply used
exclusively for the purge system. It is mounted alongside the IBRC unit.
It provides voltage necessary to energize the purge solenoid valve within
the robot and opening devices when applicable. It also provides 24VDC to
the relay coils mounted on the piggy-back Purge Control PCB in the EMG
module.
It requires 210VAC supplied by TF1 and is internally fused by two fuses
mounted on the power supply PCB itself, F-11 and F-12.

1.19
INTRINSICALLY SAFE
BARRIERS (STAHL)
ISBM890131280XX

The Intrinsically Safety Barriers (ISB) are mounted to the left of the IBRC
unit. They are used in the purge system similar to the IBRC unit, in that
they restrict power that may cause a spark. The solenoid of the purge
valve requires 24VDC, and is internally located within the robot cavity.
The internal atmosphere is to be considered hazardous prior to purging,
therefore an Intrinsically SafeBarrier device is used to prevent possible
sparking. Two of these devices will be used if opening devices are also
incorporated with the robot; one for the robot purge solenoid valve, and
the other for the opening device purge solenoid.
They are similar to a fuse. If one should be found defective, it must be
replaced by a known good Intrinsically Safe Barrier, discarding the
defective one.

1. OVERVIEW

150

MARMMTRBL02303E

WARNING
When replacing this Stahl Intrinsically Safe Barrier device, pay
careful attention to exact model or part number. Many models
appear physically identical, but have different power ratings.
Also, careful observance of which end of the device is
considered to be the SAFE side, or the HAZARDOUS side
is critical. Typically the end with the Blue colored cap should
be connected to the device located in the HAZARDOUS zone.

1.20
TRANSIT BOARD
A05B2308C030

The Transit Board is a PCB mounted on the internal side of the R-J
controller cabinet, equipped only with connectors and associated cabling
that route control signals and data to various locations within the P-155
R-J controller. It is a passive device used for interfacing purposes.

MARMMTRBL02303E

DIAGNOSTIC SCREENS
21
Various builtin diagnostic screens reveal important information regarding
the status of the SYSTEM R-J Controller. These screens with
explanations of the screen data are presented in this section.
Figure 21. Default PowerUp Screen

UTILITY Hints
JOINT 10 %
MENUS Provides a list of all menus.
FCTNS Provides helpful functions.
SELECT, EDIT, DATA, POSN, I/O, STAT
Displays menus with those names.
Function keys with [] show more
choices.
F1 [ TYPE ] function key lists related
screens with a menu.
[ TYPE ]

OFF

MENUS Key
Used to select the
teach pendant menus

SELECT Key
Used to SELECT and
create programs

HELP

ON

DATA Key
Examine and change
data register contents

EDIT Key
Used to edit a
particular program

The UTILITY Hints screen, shown in Figure 21, is the first screen to
appear in the menu structure; this is the starting level to the rest of the
diagnostic screens. Most operations begin by pressing MENUS. The F1,
[TYPE] function key will show submenus within any menu shown on the
screen.
This chapter contains information about the following diagnostic screens:
 Safety signals
 Position display
 Robot Axes motion
 Alarm log
 Version IDs
 Memory

2. DIAGNOSTIC SCREENS

22

MARMMTRBL02303E

2.1
SAFETY SIGNAL
STATUS

The STATUS Safety signal screen displays the status of safety-related


control signals coming into the controller.
The safety signal screen displays the current state (TRUE or FALSE) of
each safety signal. You cannot change the condition of the safety signal
using this screen. Table 21 lists and describes each safety signal. Use
Procedure 21 to display safety signal status.
Table 21.

SAFETY
SIGNAL

Safety Signals
DESCRIPTION

SOP E-Stop

Indicates whether the EMERGENCY STOP button on the operator panel has been pressed. The
status is TRUE if the operator panel EMERGENCY STOP button has been pressed.

TP E-Stop

Indicates whether the EMERGENCY STOP button on the teach pendant has been pressed. The
status is TRUE if the teach pendant EMERGENCY STOP button has been pressed.

Ext E-Stop

Indicates whether an external emergency exists. The status is TRUE if the external emergency stop
contacts are open on the emergency control PCB (EMG) and the following conditions exist:
 SOP E-STOP is FALSE
 TP E-Stop is FALSE
 Hand Broken is FALSE
 Overtravel is FALSE
If any one of these conditions is TRUE, Ext EStop is displayed as FALSE even though the external
emergency stop switch could be open.

Fence Open

Indicates whether the safety fence switch is open. The status is TRUE if the safety fence terminals
are open on the emergency control (EMG) PCB. This does not require the teach pendant to be
enabled.

TP Deadman

Indicates when either the left or right teach pendant DEADMAN switch is pressed. The status is
TRUE if either DEADMAN switch is pressed.

TP Enable

Indicates whether the teach pendant ON/OFF switch is ON. The status is TRUE when the teach
pendant ON/OFF switch is ON.

Overtravel

Indicates whether the robot has moved beyond its overtravel limits. The status is TRUE when the
robot has moved beyond its overtravel limits tripping the overtravel switch.

Low Air Alarm

Indicates whether the air pressure has decreased below the acceptable limit. Low Air Alarm is
usually connected to an air pressure sensing device. The status is TRUE when the air pressure is
below the acceptable limit. You must set the $PARAM_GROUP[1].$PPABN_ENBL system variable
to TRUE to use this signal.

2. DIAGNOSTIC SCREENS

23

MARMMTRBL02303E

Procedure 21
Step

Displaying Safety Signal Status


1 Press MENUS.
2 Select STATUS.
3 Press F1, [TYPE].
4 Select Safety Signal. You will see a screen similar to the following.
STATUS Safety
1
2
3
4
5
6
7
8
9
10

SIGNAL NAME
SOP EStop:
EStop:
SOP
TP EStop:
Ext EStop:
Fence Open:
TP Deadman:
TP Enable:
Hand Broken:
Overtravel:
Low Air Alarm
Belt Broken:

[ TYPE ]

JOINT
STATUS
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE

10 %
1/10

2. DIAGNOSTIC SCREENS

24

2.2
POSITION STATUS

MARMMTRBL02303E

The POSITION screen displays positional information in joint angles or


Cartesian coordinates. The positional information on this screen is
updated continuously when the robot moves. You cannot change the
displayed information using this screen.
NOTE E1, E2, and E3 indicate extended axis positional information if
extended axes are installed in your system.

Joint

The joint screen displays positional information in degrees for each robot
axis. Tool indicates the number of the active tool frame.

User

The user screen displays positional information in Cartesian coordinates


based on the user frame. Tool indicates the number of the active tool
frame. Frame indicates the number of the active user frame.

World

The world screen displays positional information in Cartesian coordinates


based on the world frame. Tool indicates the number of the active tool
frame.
Use Procedure 22 to display position status.

2. DIAGNOSTIC SCREENS

25

MARMMTRBL02303E

Procedure 22
Step

Displaying Position Status


1 Press MENUS.
2 Select POSITION.
3 Select the appropriate coordinate system.


For joint, press F2, JNT. You will see a screen similar to the
following.

POSITION
Joint
J1:
J4:
E1:

JOINT

.001 J2:
.000 J5:
.001 E2:

[ TYPE ]

JNT

10.028 J3:
34.998 J6:
.001 E3:

USER

10 %
Tool: 1

35.025
.001
.001

WORLD

NOTE E1: , E1:, and E3 are displayed only if you have extended axes.


For user, press F3, USER. You will see a screen similar to the
following.

POSITION
User

USER
Frame: 0

Configuration: F, 0, 0, 0
x: 1906.256 y:
.041
w: 178.752 p: 89.963
E1:
.001 E2:
.001

[ TYPE ]

JNT

USER

10 %
Tool: 1

z: 361.121
r:
1.249
E3:
.001

WORLD

2. DIAGNOSTIC SCREENS

26

MARMMTRBL02303E

For world, press F4, WORLD. You will see a screen similar to
the following.

POSITION
World

WORLD

Configuration: F, 0, 0, 0
x: 1906.256 y:
.041
w: 178.752 p: 89.963
E1:
.001 E2:
.001

[ TYPE ]

JNT

USER

10 %
Tool: 1

z: 361.121
r:
1.249
E3:
.001

WORLD

2. DIAGNOSTIC SCREENS

27

MARMMTRBL02303E

2.3
ROBOT AXES STATUS

The robot axes status screen displays information for each robot axis. This
information is continually updated. Use this information when you call
the FANUC Robotics Hotline if a problem occurs with your robot.
The Axis Status Pulse screen displays information about axis motion.
Table 22 lists and describes each kind of information displayed on this
screen.
Use Procedure 23 to display the axis status pulse screen.
Table 22.

Axis Status Pulse Screen Items

ITEM

DESCRIPTION

Motion
Command

Displays the desired value of the Absolute Pulse Coder (APC) when the robot gets to the position
commanded by the controller.

Machine Pulse

Shows the actual APC count as read by the controller.

Position Error

Displays the difference between the commanded APC count versus the actual APC count.

You cannot change any information on this screen except for the group
number. Group number only applies if you have multiple groups;
otherwise, it remains as 1.
Procedure 23
Step

Displaying the Axis Status Pulse Screen


1 Press MENUS.
2 Select STATUS.
3 Press F1, [TYPE].
4 Select Axis.
5 Display the status screen you want:


For Pulse, press F4, PULSE.

STATUS

J1:
J1:
J2:
J3:
J4:
J5:
J6:

JOINT

Position
Error
0
0
0
0
0
0

[ TYPE ]

STATUS1

Machine
Pulse
00000000
00000000
00000000
00000000
00000000
00000000

STATUS2

10 %

GRP [ 1]
Motion
Command
0
0
0
0
0
0

PULSE

GRP# >

2. DIAGNOSTIC SCREENS
MARMMTRBL02303E

28

2.4
ALARM LOG

The Alarm Log displays a list of the 100 most recent alarms. Figure 22
shows an example of the Alarm Log.
Figure 22. Alarm Log

1
2
3

SRVO049 OHAL 1 alarm (Group=1 Axis=6)


PROGRAM
LINE 4
Alarm
JOINT 10%
1/100
1 SRVO049 OHAL 1 alarm (Group:1 Axis:6)
2 SRVO042 MCAL 1 Alarm (Group:1 Axis:6)
3 R E S E T

[ TYPE ]

CLEAR

HELP

The areas of the Alarm Log are as follows:


1. This is the most recent alarm message. This message will be
displayed in this line regardless of the screen you choose.
2. Indicates the program name and line number of program last having
been acted upon.
3. Lists all of the alarm messages, up to 100, with the most recent alarm
on the top of the list. When the RESET key is pressed, a RESET is
logged on the alarm message screen.
4. Indicates the line number the cursor is on in proportion to how many
lines numbers available.
Use Procedure 24 to display the Alarm Log.

2. DIAGNOSTIC SCREENS

29

MARMMTRBL02303E

Procedure 24
Condition
Step

Displaying the Alarm Log




An error has occurred.

1 Press MENUS.
2 Select ALARM.
3 Press F1, [TYPE].
4 Select Alarm Log. The alarm log will be displayed. This lists all
errors. See the following screen for an example.
SRVO002 Teach pendant emergency stop
TEST1
LINE 15
ABORTED
Alarm
WORLD 100 %
1/100
1 SRVO002 Teach pendant emergency sto
2 SRVO001 Operator panel emergency st
3 R E S E T
4 SRVO029 Robot calibrated (Group:1)
5 SRVO001 Operator panel emergency st
6 SRVO012 Power fail recovery
7 INTP127 Power fail detected
8 SRVO047 LVAL alarm (Group:1 Axis:5)
9 SRVO047 LVAL alarm (Group:1 Axis:4)
10 SRVO002 Teach pendant emergency sto
[ TYPE ]

CLEAR

HELP

The most recent error is number 1.


5 To display the motion log, which lists only motion-related errors,
press F1, [TYPE], and select Motion Log.
6 To display the system log, which displays only system errors, press
F1, [TYPE], and select System Log.
7 To display the application log, which displays only
application-related errors, press F1, [TYPE], and select Appl Log.
8 To display more information about an error, move the cursor to the
error and press F5, HELP. The error help screen displays information
specific to the error you selected. When you are finished viewing the
information, press PREV.
9 To remove all of the error messages displayed on the screen, press
F4, CLEAR.

2. DIAGNOSTIC SCREENS

210

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2.5
VERSION
IDENTIFICATION
STATUS

The STATUS Version IDs screen displays information specific to your


controller. Use this information when you call the FANUC Robotics
Hotline if a problem occurs with your controller. You cannot change the
information displayed on this screen. Table 23 lists and describes the
version identification status information.
Table 23. Version Identification Status Items

VERSION ID ITEM

DESCRIPTION

Appl/Tool

The name of the application package.

Appl/Tool ID

The version number of the application package.

Robot Model

The robot model name, the torque on the wrist, and the type of wrist.

S/W Serial Number

The software order number for the disk set.

Core Name

The name of the core software.

Core ID

The version number of the core software.

Library Name

The name of the robot library.

Library ID

The version number of the robot library.

Servo Code ID

The version of servo parameters installed.

Mot Param ID

The software version for the software that controls motion

Update #110

The name and software version for which a post-release software update has been
installed.

Build ID

Internal software version information.

Use Procedure 25 to display version identification status.

2. DIAGNOSTIC SCREENS

211

MARMMTRBL02303E

Procedure 25
Step

Displaying the Version Identification Status


1 Press MENUS.
2 Select STATUS.
3 Press F1, [TYPE].
4 Select Version ID. You will see a screen similar to the following.
STATUS Version ID
ITEM:
1 Appl/Tool:
2 Appl/Tool ID:
3 Robot Name:
4 S/W Serial Number:
5 Core Name:
6 Core ID:
7 Library Name:
8 Library ID:
9 Servo Code ID:
10 Mot Param ID:
11 Update #1:

JOINT
10 %
SOFTWARE:
Std System Core
V3.06P
S500INLN
F00000
Std System Core
V3.06
Std Robot Library
V3.06P
J03.00
V1.00
Uninitialized

20 Update #10:
21 Build ID:

Uninitialized
V3.06
02/13/9X

[ TYPE ] SOFTWARE

MOT_ID

MOT_INF

SER_PAR

5 Press the key that corresponds to the version ID status screen you want
to display:


To display software version information, press F2,


SOFTWARE.

To display motor types for each axis, press F3, MOT_ID. You
will see a screen similar to the following.

STATUS Version IDs


1
1:
2:
3:
4:
5:
6:
7:
8:
9:
10:

GRP:
1
1
1
1
1
1
*
*
*
*

AXIS:
1
2
3
4
5
6
*
*
*
*

[ TYPE ] SOFTWARE

JOINT
MOTOR ID:
AC20
AC20F
AC20F
AC10
AC10
AC10
Uninitialized
Uninitialized
Uninitialized
Uninitialized
MOT_ID

MOT_INF

10 %
1/16

SER_PAR

2. DIAGNOSTIC SCREENS

212

MARMMTRBL02303E

To display the motor information for each axis, press F4,


MOT_INF. You will see a screen similar to the following.

STATUS Version IDs


GRP:
AXIS:
1
11: 1
2: 1
2
3: 1
3
4: 1
4
5: 1
5
6: 1
6
7: *
*
8: *
*
9: *
*
10: *
*
[ TYPE ] SOFTWARE

JOINT
10 %
MOTOR INFO:
1/16
H1 DSP1L
H2 DSP1M
H3 DSP2L
H4 DSP2M
H5 DSP3L
H6 DSP3M
Uninitialized
Uninitialized
Uninitialized
Uninitialized
MOT_ID

MOT_INF

SER_PAR

To display the servo parameters for each axis, press F5,


SER_PAR. You will see a screen similar to the following.

STATUS Version IDs


GRP:
AXIS:
1
1: 1
1
2: 1
2
3: 1
3
4: 1
4
5: 1
5
6: 1
6
7: *
*
8: *
*
9: *
*
10: *
*
[ TYPE ] SOFTWARE

JOINT
10 %
SERVO PARAM ID:
1/16
PO1.00
PO1.00
PO1.00
P01.00
PO1.00
P01.00
Uninitialized
Uninitialized
Uninitialized
Uninitialized
MOT_ID

MOT_INF

SER_PAR

2. DIAGNOSTIC SCREENS

213

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2.6

The STATUS Memory screen displays information about controller


memory. Table 24 lists and describes each memory status item. Use
Procedure 26 to display memory status.

MEMORY STATUS

Table 24. Memory Status


MEMORY STATUS

DESCRIPTION

User

Indicates the amount of memory for user programs: teach pendant programs and KAREL
programs.
 Total indicates the original size of the memory area.
 Free indicates how much memory is available.
 Largest Free indicates the largest contiguous segment of available memory.

System

Indicates the amount of memory for system information: FDICT (dictionary files that
define what is displayed on the screens), F-PROG (application, operating system, and
option files), and C-WORK (temporary memory used for system operations).
 Total indicates the original size of the memory area.
 Free indicates how much memory is available.
 Largest Free indicates the largest contiguous segment.

Hardware

Indicates the total amount of memory in FROM and CMOS RAM.

Procedure 26
Step

Displaying Memory Status


1 Press MENUS.
2 Select STATUS.
3 Press F1, [TYPE].
4 Select Memory. You will see a screen similar to the following.
STATUS Memory
USER
TOTAL
KAREL
2921.0KB
TPE
150.0KB
SYSTEM
F-DICT
320.0KB
FPROG
512.0KB
CWORK 1023.9KB
HARDWARE
FROM
2.0MB
CMOS
4.0MB
[ TYPE ]

JOINT

100 %

FREE
LRGST FREE
2062.0KB 1939.9KB
71.2KB
70.1KB
18.2KB
91.3KB
552.8KB

18.2KB
91.3KB
547.6KB

MARMMTRBL02303E

LIGHTS AND LEDS


31
This chapter describes the lights and LEDs you can use for diagnostics:




Teach pendant LEDs


Operator panel LEDs
Circuit board diagnostic LEDs

3. LIGHTS AND LEDS


MARMMTRBL02303E

32

3.1
TEACH PENDANT
DIAGNOSTIC LEDS

The non-intrinsically safe teach pendant has several LEDs to assist you in
determining the status of the controller. Figure 31 shows the teach
pendant LEDs. Table 31 lists and describes the teach pendant LEDs.
The LEDs whose labels are blank vary depending on the particular
application.
On the Intrinsically Safe Teach Pendant, these LEDs are simulated by
symbols on the teach pendant display.
Refer to the Setup and Operations Manual for your application for
information on application-specific LEDs.
Figure 31. Teach Pendant LEDs

ApplicationSpecific
LEDs

FAULT
HOLD
STEP
BUSY
RUNNING

JOINT
XYZ
TOOL

OFF

Table 31.

ON

Teach Pendant Status Indicators

INDICATOR

DESCRIPTION

FAULT

Indicates that a fault condition has occurred.

HOLD

Indicates that the robot is in a hold condition. HOLD is not on continuously during a hold condition.

STEP

Indicates that the robot is in step mode.

BUSY

Indicates that the controller is processing information.

RUNNING

Indicates that a program is being executed.

JOINT

Indicates that the current jog coordinate system is JOINT.

XYZ

Indicates that the current jog coordinate system is WORLDFRAME, JOGFRAME, or USERFRAME.

XYZ

Indicates that the current jog coordinate system is JOG frame or WORLD.

TOOL

Indicates that the current jog coordinate system is TOOL.

3. LIGHTS AND LEDS

33

MARMMTRBL02303E

3.2
OPERATOR PANEL
DIAGNOSTIC LEDS

The operator panel has several LEDs to assist you in determining the
status of the controller. Figure 32 shows the operator panel LEDs.
Table 32 lists and describes the operator panel LEDs.
Figure 32. Operator Panel LEDS

BATTERY
ALARM

CYCLE START

ON

TEACH PENDANT
ENABLED
HOLD

OFF

FAULT

FAULT RESET

USER LED#1

USER PB#1

USER LED#2

USER PB#2

RS232C

REMOTE

REMOTE

LOCAL

HOUR METER

CRT/KB

EMERGENCY STOP

3. LIGHTS AND LEDS


MARMMTRBL02303E

34
Figure 33. Operator Panel LEDS

BATTERY
ALARM

CYCLE START

ON

TEACH PENDANT
ENABLED
HOLD

OFF

FAULT


FAULT RESET

PURGE
COMPLETE

REMOTE

PURGE ENABLE

REMOTE

LOCAL

PURGE
FAULT

BRAKE ENABLE
ON

OFF

RS232C

CRT/KB

HOUR METER

TEACH PENDANT
CONNECT/
DISCONNECT

Optional

EMERGENCY STOP

Table 32.
INDICATOR
BATTERY ALARM
TEACH PENDANT ENABLED
FAULT
REMOTE

USER LED #1
USER LED #2
PURGE COMPLETE

Standard Operator Panel C-Size Controller Status Indicators

DESCRIPTION
Indicates that the backup battery voltage is low. Replace the battery, using
Procedure 9-1.
Indicates that the teach pendant is enabled and has motion control.
Indicates a fault condition has occurred.
Indicates that robot motion can only be started by a PLC or other remote device. The
operator panel cycle start pushbutton cannot cause robot motion. This is determined
by the position of the REMOTE/LOCAL keyswitch.
User-defined and accessible from a KAREL program or macros.
User-defined and accessible from a KAREL program or macros.
Identifies that the robot cavities have been purged and are presently at the prescribed
pressure as outlined in the P-155 Mechanical Service Manual.

This LED must be illuminated in order to turn power on to the R-J controller.
Indicates a fault exists with the purge system.
Indicates that the purge cycle has started. You can now release the pushbutton if you
are holding it.
POWER ON PUSHBUTTON LED
Indicates that the robot is powered on.
CYCLE START PUSHBUTTON LED Indicates that the robot is currently running a program
HOLD
Indicates that the robot is in a software hold condition.
PURGE FAULT
PURGE ENABLE PUSHBUTTON

3. LIGHTS AND LEDS

35

MARMMTRBL02303E

3.3
CIRCUIT BOARD
DIAGNOSTIC LEDS

The RJ Controller contains several diagnostic LEDs within the controller.


They are on the circuit boards that plug into the backplane, on the servo
amplifiers, and on the modular I/O unit. Figure 34 shows an overview of
the circuit board diagnostic LEDs. Refer to the sections that follow for
descriptions of the following circuit board diagnostic LEDs:











Emergency control board (EMG)


Power supply unit (PSU)
Axis control board
Main CPU board
Servo amplifier
Contact signal transducer (IBRC)
Modular I/O (optional)
Process I/O board (optional)
RH MAP Interface (optional)
ABRIO printed circuit board (optional)

3. LIGHTS AND LEDS


MARMMTRBL02303E

36
Figure 34. Circuit Board Diagnostic LEDs

OPTIONAL
INTERFACE
MODULE LEDS
Section 3.3.7

OPTIONAL
PROCESS I/O
BOARD LEDS
Section 3.3.8

OPTIONAL I/O
MODULE LEDS
Section 3.3.7

MAIN CPU
BOARD LEDS
Section 3.3.4

AXIS
CONTROL
BOARD LEDS
Section 3.3.3

PSU BOARD
LEDS
Section 3.3.2

EMG BOARD
LEDS
Section 3.3.1

SERVO
AMPLIFIER
DIAGNOSTIC
LED (7SEG)
Section 3.3.5

3. LIGHTS AND LEDS

37

MARMMTRBL02303E

Figure 35. Circuit Board Diagnostic LEDs

INTERFACE
MODULE LEDS
Section 3.3.7

IBRC LEDS

I/O
MODULE LEDS
Section 3.3.7

OPTIONAL
KRIO/GEF/MAP
MODULES
Sections 3.3.10
and 3.3.11

MAIN CPU
BOARD LEDS
Section 3.3.4

AXIS
CONTROL
BOARD LEDS
Section 3.3.3

PSU BOARD
LEDS
Section 3.3.2

EMG BOARD
LEDS
Section 3.3.1

SERVO
AMPLIFIER
DIAGNOSTIC
LED (7SEG)
Section 3.3.5

3. LIGHTS AND LEDS


MARMMTRBL02303E

38

3.3.1
Emergency Control
Board (EMG)
Diagnostic LEDs

Figure 37 shows the emergency control board (EMG) diagnostic LEDs.


Table 34 lists and describes each LED.
Figure 36. Emergency Control Board (EMG) Diagnostic LEDs

SON

BRKL

BRK1

BRK4

BRK2

BRK5

BRK3

BRK6

FALM

3. LIGHTS AND LEDS

39

MARMMTRBL02303E

Figure 37. Emergency Control Board (EMG) Diagnostic LEDs

BRK4

NOT USED

BRK5

BRK6

FALM

Table 33.

BRK1

SON

BRK2

BRK3

Emergency Control Board (EMG) Diagnostic LEDs

LED
SON
(Green)
BRK 1*
(Green)
BRK2*
(Green)
BRK3*
(Green)
FALM
(red)

Name
Servo on

BRK4*
(Green)
BRK5*
(Green)

Brake Circuit 4
Release
Brake Circuit 5
Release

Brake Circuit 1
Release
Brake Circuit 2
Release
Brake Circuit 3
Release
Fuse alarm of
the brake circuit

Description
When this LED lights, 100 VAC is supplied to the
servo amplifier MCC coils.
When this LED lights, axis 1 brake is energized.
When this LED lights, axis 2 and 3 brakes are
energized.
When this LED lights, axis 4, 5, and 6 brakes are
energized.
This LED lights if the brake-fuse is blown or a
voltage spike has occurred. Refer to Servo Alarm
SRVO-008.
When this LED lights, auxiliary axis are energized.
When this LED lights, auxiliary axis are energized.

3. LIGHTS AND LEDS


MARMMTRBL02303E

310

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


LED
BRK6*
(Green)
BRKL
Table 34.

Name
Brake Circuit 6
Release
Manual Brake
Release

Description
When this LED lights, auxiliary axis are energized.
Brakes are released by the front panel keyswitch

Emergency Control Board (EMG) Diagnostic LEDs

LED
SON
(Green)
BRK 1*
(Green)
BRK2*
(Green)
BRK3*
(Green)
FALM
(red)

Name
Servo on

BRK4*
(Green)
BRK5*
(Green)
BRK6*
(Green)

Brake Circuit 4
Release
Brake Circuit 5
Release
Brake Circuit 6
Release

Brake Circuit 1
Release
Brake Circuit 2
Release
Brake Circuit 3
Release
Fuse alarm of
the brake circuit

Description
When this LED lights, 100 VAC is supplied to the
servo amplifier MCC coils.
When this LED lights, brake circuit 1 is energized.
When this LED lights, brake circuit 2 is energized.
When this LED lights, brake circuit 3 is energized.
This LED lights if the 100 VAC brake-fuse is blown
or a voltage spike has occurred. Refer to Servo
Alarm SRVO-008.
When this LED lights, brake circuit 4 is energized.
When this LED lights, brake circuit 5 is energized.
When this LED lights, brake circuit 6 are energized.

* Refer to robot-specific electrical maintenance for brake connections.

3. LIGHTS AND LEDS

311

MARMMTRBL02303E

3.3.2

Figure 38 shows each power supply unit (PSU) diagnostic LED.

Power Supply Unit


(PSU) Diagnostic LEDs

Figure 38. Power Supply Unit (PSU) Diagnostic LEDs

PSU

Power Input LED (PIL) LED


This LED lights if 200 VAC is being supplied to the PSU
from Transformer TF1 (Main disconnect is on), if fuses
F1, F2, or F5 (on circuit board) are not blown, and the
power supply internal circuitry is okay.
ALM (Fuse Alarm) LED
This LED will light if fuse F3 is blown and/or there
are any DC power circuit malfunctions.

3. LIGHTS AND LEDS


MARMMTRBL02303E

312

3.3.3
Axis Control Board
Diagnostic LEDs

The four green status LEDs will also light on the axis control printed
circuit board at power on and then change during software initialization.
See Figure 39.
Figure 39. Axis Control Board Diagnostic LEDs

STATUS
ALARM

Table 35 contains supplementary troubleshooting information.

3. LIGHTS AND LEDS

313

MARMMTRBL02303E

Table 35.

Troubleshooting Axis Control Board Diagnostic LEDs

Remarks

LEDs

Procedure

Normally, all four green LEDs


1. Replace the axis control board.
come on when the robot is
2. Test FROM* and CMOS from the BMON screen and
turned on. They then turn off
replace as necessary.
and come back on as software
3. Reload software if a defective FROM or CMOS is found,
loads and circuits are tested.
otherwise replace the main CPU and then reload
This procedure should only be
software.
used when the four LEDs
come on and stay on without
turning off or FLASH.

Lights go out and initialization


of each printed circuit board
begins.

STATUS
ALARM

STATUS
ALARM

1. Check the power supply output voltages. Replace if


necessary.
2. Replace the axis control board.
3. Test FROM* and CMOS from the BMON screen and
replace as necessary.

Timer initialization

STATUS
ALARM

2. Reload software if a defective FROM or CMOS is found,


otherwise replace the main CPU and then reload
software.
1

Initialization of communication

STATUS
ALARM

1. Test FROM* and CMOS from the BMON screen and


replace as necessary.
2. Reload software if a defective FROM or CMOS is found,
otherwise replace the main CPU and then reload
software.

Initialization of software

STATUS
ALARM

1. Test FROM* and CMOS from the BMON screen and


replace as necessary.
2. Reload software if a defective FROM or CMOS is found,
otherwise replace the main CPU and then reload
software.

Initialization of software

STATUS
ALARM

1. Test FROM* and CMOS from the BMON screen and


replace as necessary.
2. Reload software if a defective FROM or CMOS is found,
otherwise replace the main CPU and then reload
software.

Initialization of software

STATUS
ALARM

1. Test FROM* and CMOS from the BMON screen and


replace as necessary.
2. Reload software if a defective FROM or CMOS is found,
otherwise replace the main CPU and then reload
software.

Initialization of software

STATUS
ALARM

1. Test FROM* and CMOS from the BMON screen and


replace as necessary.
2. Reload software if a defective FROM or CMOS is found,
otherwise replace the main CPU and then reload
software.

1
STATUS
ALARM

4. Reload software if a defective FROM or CMOS is found,


otherwise replace the main CPU and then reload
software.
1. Test FROM* and CMOS from the BMON screen and
replace as necessary.

Initialization of software

1. Replace the axis control printed circuit board.

3. LIGHTS AND LEDS


MARMMTRBL02303E

314

Table 35. (Contd) Troubleshooting Axis Control Board Diagnostic LEDs


LEDs
1

Remarks
3

Initialization of software

STATUS
ALARM

Procedure
1. Test FROM* and CMOS from the BMON screen and
replace as necessary.
2. Reload software if a defective FROM or CMOS is found,
otherwise replace the main CPU and then reload
software.

STATUS
ALARM

Communication to teach
pendant

1. Replace the teach pendant.


2. Replace the teach pendant cable.
3. Replace the main CPU.
4. Reload software.

STATUS
ALARM

Communication to process I/O


or modular I/O

Turn off controller power. Disconnect the cable from


connector JD4 of the main CPU and cold start the controller.
If the light pattern is normal, replace the device that the cable
connects to: process I/O module or modular I/O interface unit.
Otherwise:
1. Replace the I/O connection cable.
2. Replace the main CPU.
3. Reload software.

Initialization of software

STATUS
ALARM

1. Test FROM* and CMOS from the BMON screen and


replace as necessary.
2. Reload software if a defective FROM or CMOS is found,
otherwise replace the main CPU and then reload
software.

Initialization of software

STATUS
ALARM

1. Test FROM* and CMOS from the BMON screen and


replace as necessary.
2. Reload software if a defective FROM or CMOS is found,
otherwise replace the main CPU and then reload
software.

Teach pendant banner page


displayed

1. Replace the teach pendant.

Initialization of software

1. Replace the axis control board.

STATUS
ALARM

STATUS
ALARM

2. Test FROM* and CMOS from the BMON screen and


replace as necessary.
3. Reload software if a defective FROM or CMOS is found,
otherwise replace the main CPU and then reload
software.
1

STATUS
ALARM

Robot is working fine

3. LIGHTS AND LEDS

315

MARMMTRBL02303E

Table 35. (Contd) Troubleshooting Axis Control Board Diagnostic LEDs


LEDs

Remarks

Servo alarm on Axis Control


printed circuit board.

1. Replace the Axis Control printed circuit board.

(SYSFAIL)
Voltage level too low on *EN
signal

1. If the controller has an ABRIO board or a MAP board,


turn off controller power. Remove the two boards and
cold start the controller. If the light pattern is normal,
replace the ABRIO or MAP board device that the cable
connects to: process I/O module or modular I/O
interface unit.

STATUS
ALARM

STATUS
ALARM

Procedure

2. Check the power supply output voltages. Replace if


necessary.
3. Replace the axis control board.
4. Test FROM* and CMOS from the BMON screen and
replace as necessary.
5. Reload software if a defective FROM or CMOS is found,
otherwise replace the main CPU and then reload
software.
* The Flash ROM test checks for cleared FROM. If you test FROM you must first
clear the FROM.
NOTE 1: After replacing the main CPU printed circuit board, CMOS RAM modules,
or FROM module, you must perform a complete software load.
NOTE 2: If Axis Control alarm LEDs occur with LEDs on the Main CPU,
troubleshoot the Main CPU alarm LEDs first.

CAUTION
While working with the power supply unit, Main CPU, and axis
control modules, be advised of the following:
 There are static-sensitive devices on the Main CPU and
axis control modules. Wear a grounded wrist strap devices
and observe anti-static safety precautions when handling
this equipment.
 When removing the power supply unit or main CPU, the
battery backup is disconnected and must be reconnected
within 30 minutes or a loss of memory will occur.

3. LIGHTS AND LEDS


MARMMTRBL02303E

316

3.3.4

The Main CPU printed circuit board alarm LEDs are shown in
Figure 310. Table 36 provides supplementary troubleshooting
information.

Main CPU Board


Diagnostic LEDs

Figure 310. Main CPU Board Diagnostic LEDs

3 4

STATUS
ALARM

Table 36.
Remarks

LEDs
1

Troubleshooting Main CPU Board Diagnostic LEDs

STATUS
ALARM

Parity alarm on CMOS


RAM in the Main CPU.

Procedure
1. Test CMOS from the BMON screen and replace as necessary.
2. Reload software.
3. Replace the main CPU.

The battery voltage that


backs up the MAIN CPU
CMOS RAM memory is
low.

Replace the battery, using Procedure 91.

An error is encountered
in the serial link.

Turn off the controller. Disconnect the cable from connector JD4 of the
main CPU and cold start the controller. If the light pattern is normal,
replace the device that the cable connects to: process I/O module or
modular I/O interface unit.

STATUS
ALARM

STATUS
ALARM

Otherwise:
1. Test FROM and CMOS from the BMON screen and replace as
necessary.
2. Reload software.
3. Replace the main CPU.
1
STATUS
ALARM

Normal status

Controller should be operational.

3. LIGHTS AND LEDS

317

MARMMTRBL02303E

3.3.5

Table 37 shows and describes each servo amplifier diagnostic LED.

Servo Amplifier
Diagnostic LED
(7-Segment Display)
Table 37.
Name
Overvoltage(HV)

Indication

Servo Amplifier LED Functions


Description

An abnormally high DC voltage was detected in the power supply of the main circuit
of the servo amplifier.
Refer to Error code: SRVO-044 for troubleshooting information.

Insufficient voltage of the


control power supply
(LV5V)

An abnormally low voltage was detected in the control power supply of the servo
amplifier. (Rating: +5V)
Refer to Error code: SRVO-047 for troubleshooting information.

Insufficient DC link
voltage (LVDC)

An abnormally low DC voltage was detected in the power supply of the main circuit
of the servo amplifier.
Refer to Error code: SRVO-047 for troubleshooting information.

Faulty regenerative
control circuit (DCSW)

The regenerative energy discharge was too large for a short time. This alarm occurs
when the regenerative energy discharge circuit is defective.
Refer to Error code: SRVO-043 for troubleshooting information.

Excessive regenerative
discharge (DCOH)

The average regenerative energy discharge was too large. This alarm occurs when
the frequency of acceleration and deceleration exceeds a predetermined value.
Refer to Error code: SRVO-043 for troubleshooting information.

Servo amplifier overheat


(OH)

The thermostat in the servo amplifier operated. (Thermostat contact opened)


Refer to Error code: SRVO-049 for troubleshooting information.

Welded electromagnetic
contactor (MCC)

The contacts of the MCC contactor in the servo amplifier are stuck together.
Refer to Error code: SRVO-042 for troubleshooting information.

Overcurrent (HCL)

An overcurrent was detected in the oneaxis servo amplifier or the Laxis circuit of
the twoaxis servo amplifier.
Refer to Error code: SRVO-045 for troubleshooting information.

Overcurrent (HCM)

An overcurrent was detected in the Maxis circuit of the twoaxis servo amplifier.
Refer to Error code: SRVO-045 for troubleshooting information.

Overcurrent (HCLM)

An overcurrent was detected in both the Laxis and Maxis circuit of the twoaxis
servo amplifier.
Refer to Error code: SRVO-045 for troubleshooting information.

Servo amplifier not ready


Servo amplifier ready

The MCC contactor in the servo amplifier is turned off. The amplifier is unarmed and
cannot drive the motor. See teach pendant display for error code information.
The MCC contactor in the servo amplifier is turned on. The amplifier is armed and
can drive the motor.

NOTE Refer to Chapter 4, Troubleshooting, for more information.

3. LIGHTS AND LEDS


MARMMTRBL02303E

318

3.3.6
Contact Signal
Transducer (IBRC)

The LEDs associated with the IBRC are indicators that input terminals P
and N have been closed in the circuit loop for that LEDs channel.
Figure 311 shows the IBRC.
Figure 311. IBRC

3. LIGHTS AND LEDS

319

MARMMTRBL02303E

3.3.7
Modular I/O LEDs

The LEDs associated with module I/O are on the interface module printed
circuit board and on each I/O module. Figure 312 shows the modular I/O
LEDs. Table 38 describes each modular I/O LED.
Figure 312. Modular I/O LEDs

LEDS
PWR

LINK

A0 1 2 3 4 5 6 7

BAI

LEDS

BAO

B0 1 2 3 4 5 6 7

AIF0IA

JD1B

JD1A

CP32

JD2

INTERFACE MODULE

Table 38.

I/O MODULE

Modular I/O LEDs

LED
PWR
Link

Location
Interface
module
Interface
module

BA1

Interface
module

BA0

Interface
module

A01234567
B01234567

I/O Module

Description
ON: The interface module is supplied with
24 VDC power.
ON: The I/O Link is operating properly.
Normally, this LED lights several seconds
after the power is turned on.
These LEDs indicate that a fault has
occurred in the modular I/O system.

Indicates if the input or output is on.

3. LIGHTS AND LEDS


MARMMTRBL02303E

320

3.3.8
(Optional) Process I/O
Board Diagnostic LEDs
CB, DA Process I/O
Board (side view)

Figure 313 shows the process I/O board diagnostic LEDs. Table 71
shows and describes each process I/O board diagnostic LED.
Figure 313. Process I/O Board Diagnostic LEDs

AA, AB, BB, BA, CA Process I/O Board


(front view)

ALM0

FALM

STATUS
ALARM

Table 39.

ALM0

FALM

Process I/O Board Diagnostic LEDs

CB, DA

AA, AB, BB, BA, CA

Color

Process
I/O PCB

ALM0

Description

Red

A communication alarm occurred between the


main CPU and process I/O board. Check
cabling from Main CPU to I/O board. Replace I/O
board.

Red

A fuse (FUSE 1) in the process I/O board blew.


Replace fuse. If fuse blows again, replace board.

Green

Indicates the operations status of the process I/O


board.

STATUS
ALARM

ALM0
Process
I/O PCB

FALM

FALM

STATUS
ALARM

Process
I/O PCB

1
STATUS
ALARM

3. LIGHTS AND LEDS

321

MARMMTRBL02303E

3.3.9

Table 310 shows and describes each process I/O board diagnostic LED.

(Optional) Process I/O


Board Diagnostic LEDs

Table 310. Process I/O Board LEDs

RED

A communication alarm
occurred between the
main CPU and process
input/output. Check
cabling from Main CPU to
I/O board. Replace I/O
board.

RED

A fuse (FUSE 1) in the


process input/output blew.
Replace fuse. If fuse
blows again, replace
board.

GREEN

Indicates the operations


status of the Process I/O
Board.

Process
I/O PCB
1

STATUS
ALARM

STATUS
ALARM
Process
I/O PCB
1

STATUS
ALARM

Process
I/O PCB
1
STATUS
ALARM

3. LIGHTS AND LEDS


MARMMTRBL02303E

322

3.3.10
R-H MAP INTERFACE
LEDs

Figure 314 shows each RH MAP Interface LED. Table 311 describes
each LED.

Figure 314. RH MAP LEDs

Table 311.

R-H MAP LEDs

LED
Meaning
A
System fail
(RED)

B
C
D

Not used
Not used
Not used

Status
This LED is briefly turned on during power up/down by the
MAP interface board. This LED is turned on when a system
failure has occurred in the MAP interface board or other
subsystems in the controller. Therefore, the problem might
not exist with the MAP interface board.

3. LIGHTS AND LEDS

323

MARMMTRBL02303E

3.3.11

Figure 41 shows and Table 312 describes the R-H ABRIO LEDs.

R-H ABRIO LEDs

Figure 41. R-H ABRIO LEDs

POWER
ACTIVE
INTERBRD
FAULT
PC COMM
FAULT
PROC
FAULT

LED
POWER (green)

Table 312. R-H ABRIO LED Descriptions


On
Flashing
There is power to the ABRIO board.
Not applicable

Off
There is no power
to the ABRIO
board.

ACTIVE (green)

The ABRIO board is communicating with the


PLCs remote I/O scanner and the PLC is in
run mode. Input and output data in the ABRIO
board is being updated.

 The PLC is in PROGRAM or


TEST mode and the input and
output data to the interface is
being updated.
 A No Update condition is
indicated by the PLC remote I/O
scanner.
 Indicates an error in the rack
address setup. Error is possibly
an invalid value or an invalid
combination of starting module
group and rack size settings.

In conjunction
with one of the
other red LEDs
being on or
flashing indicates
an interface fault.
There is no
communication
with the PLCs
remote I/O
scanner.

INTERBOARD
COMMUNICATION
FAULT (red)

Communication between the ABRIO board and


the R-J controller has been broken. This might
be due to the inability of the ABRIO board to
gain access to the Common RAM or a
checksum error in the R-J output data.
Communication with the PLCs remote I/O
scanner is stopped.

 An error in communications
between the ABRIO board and
the R-J controller has occurred.
Communication with the PLCs
remote I/O scanner is stopped.
 The ABRIO board did not
detect the R-J controllers
operational code after power up
or reset.

Normal operation

PC
COMMUNICATIONS
FAULT (red)

ABRIO board is not communicating properly


with the PLC remote I/O scanner. The remote
I/O scanner might be faulted or a problem
might exist on the serial channel.

Not applicable

Normal operation

PROCESSOR
FAULT (red)

This LED is normally on for to 2 seconds


during initialization to indicate that the ABRIO
board is performing its power up diagnostics.
The LED is turned off after diagnostics have
been completed successfully and the R-J
controllers operation code has been set. If,
after initialization, this LED is on, this indicates
a fault in the ABRIO board hardware (RAM
integrity, EPROM checksum, or CPU watchdog
timeout). Communication with the PLCs
remote I/O scanner and with the R-J controller
has been stopped. When this LED is on, all
other LEDs except Power should be off.

This LED flashes along with the


ACTIVE LED to indicate that an
invalid rack address has been
set up via the DIP switches on
the ABRIO board.

No faults exist
with the remote
I/O CPU or
related circuitry.

MARMMTRBL02303E

TROUBLESHOOTING
41
This chapter describes the steps used to repair electrical faults in the robot.

WARNING
The procedures described in this section require you to
work with high voltage circuits. Carelessness or
inattention can kill you. Do not attempt any of these
procedures unless you are trained and experienced in
electrical repair.

Electrical faults are divided into three classes of symptoms:




A Class 1 Fault is a malfunction that prevents the controller from


operating. The main contactor might or might not be energized. No
text is displayed on the teach pendant.

A Class 2 Fault is a malfunction that prevents the bootROM from


turning the system over to the application software. Text will be
displayed on the the teach pendant, but the teach pendant display will
be frozen and will not respond to keypad entries.

A Class 3 Fault is a malfunction that prevents the robot from


operating normally, even though the application software is running.
A numbered alarm message will be displayed on the teach pendant.
You can access teach pendant menus and diagnostic screens during a
Class 3 fault.

If your robot has a class 1 fault, refer to Section 4.1.


If your robot has a class 2 fault, refer to Section 4.2.
If your robot has a class 3 fault, refer to Section 4.3.

4. TROUBLESHOOTING
MARMMTRBL02303E

42

4.1

To enable the user with a quick reference guide to powering on a P-155


controller, the following steps and events should be followed:

POWER ON
SEQUENCE
Procedure 41
Step

Purge Sequence
1 With the main disconnect ON, you should observe:





Purge complete LED out


Purge enable pushbutton (purging) lamp out
ON pushbutton lamp out
Purge fault LED on

2 Push and hold the purge enable pushbutton. You should observe




Purge solenoid engages when minimum pressure requirements are


met.
Purge fault LED goes out
Purging lamp (behind purge enable pushbutton) lights.

At this point you can release the purge enable pushbutton, no change
should occur.
3 At the end of the 5 minute purge, the purging lamp (behind the purge
enable pushbutton) will go out and the purge complete LED lights.
Also, the purge solenoid shuts off.
Procedure 42
Step

Enabling Power
1 With purge complete, you should observe:





Purge complete LED on


Purge enable pushbutton (purging) lamp out
ON pushbutton lamp out
Purge fault LED out

2 Push the ON pushbutton. You should observe:





ON pushbutton lamp lights


Main CPU and axis control PCBs go through internal diagnostics

At the end of diagnostics the MCC contactor on all servo amplifiers will
energize and click. The teach pendant should be energized and the
controller ready to operate manually.

4. TROUBLESHOOTING

43

MARMMTRBL02303E

4.2
CLASS 1 FAULT
TROUBLESHOOTING

How to use the


Troubleshooting Tables

This section contains troubleshooting information for Class 1 Faults.


A Class 1 fault prevents the controller from operating. The main ALC
contactor might or might not be energized. The Purge Complete light
might or might not be on. No text is displayed on the teach pendant or
CRT.
This section contains several tables. Each table provides procedures to
correct the fault. To troubleshoot a Class 1 fault, always start at
Table 44. Perform the procedures in order. You will either correct the
fault using Table 44 or it will refer you to another table in this section.
Use the other tables only when Table 44 refers you to them.

Class 1 Fault Condition

If the following conditions are true, follow the steps in Table 44.





The main disconnect is UP (on).


The ON button has been pushed.
The power on sequence (Section 4.1) has been attempted.
The controller does not operate.

4. TROUBLESHOOTING
MARMMTRBL02303E

44

Without turning off the main disconnect, open the controller door:
Release the disconnect latch by turning the screw to the lower right of the
disconnect handle.
Table 41.

Troubleshooting Procedure 1
Illustration

Troubleshooting Procedure
1. Find the Purge Complete light on the SOP.
 The light is on indicating that the purge cycle was successful.
If the light is on  go to Table 45.
If the light is off  continue.

Chapter 13
Print Reference
0806

H
OL
D

Purge
Complete
Light

2. Find the Purge Fault LED on the SOP.


If the LED is on  go to Step 4.
If the light is out  continue.

H
OL
D

Purge
Fault

0806

4. TROUBLESHOOTING

45

MARMMTRBL02303E

Table 41. (Contd) Troubleshooting Procedure 1


Troubleshooting Procedure

Illustration

3. Press and hold the Purge Enable pushbutton on the SOP until it
lights (1 5 seconds) and then release.
 After the purge cycle is completed, the Purge Complete light
should come on.
If the Purge Complete light comes on  test the controller for
proper operation.
If the Purge Enable (purging) or Purge Complete light does
not come on and/or the Purge Fault light comes on 
continue.

Chapter 13
Print Reference
0805
0806
0810

H
OL
D

Purge
Fault
Light

4. Turn off the power disconnect handle.


5. Connect jumper wires between terminals P1 and N1, and
between terminals P2 and N2 on the IBRC.
 These terminals are the inputs for the robot-mounted air
pressure and air flow switches.
 If opening devices are used, you will also need to jumper
between P3 and N3, and P5 and N5. These auxiliary
inputs are for the pressure switch and flow switch for an
opener.

0821
0822
0834
0835
0825
0826

6. Turn on the power disconnect handle.


7. Press and hold the Purge Enable pushbutton on the SOP until
it lights (1 5 seconds) and then release.
 If the purge circuit is cycling, the purge enable lamp (purging)
should stay lit until the 5 minute purge is complete. The
Purge Fault LED will be out.
 If the purge enable (purging) lamp does not stay lit, replace
the purge control PCB (piggy-back to EMG control PCB).
 If the purge enable (purging) lamp will not light, go to Table
42.
 If, during the purge cycle, the Purge Fault LED lights, go to
Table 42.
 If, after the 5 minute purge cycle, the Purge Complete light
comes on, locate and repair the break in the air pressure
and/or air flow switch circuits to the robot.
 If the purge is too long or too short, the timer on the purge
control PCB is incorrectly set or damaged. Repair or replace
it.

0805
0808

0811
0806

0943

4. TROUBLESHOOTING
MARMMTRBL02303E

46
Table 42.

Troubleshooting Procedure 2
Illustration

Troubleshooting Procedure

Chapter 13
Print Reference

1. Observe on the IBRC Unit that:


 Red lights on the IBRC panel indicate that 200 VAC is
supplied to it.
If all of the lights are off  continue.
If one or more of the lights are on  go to Table 43.

2. Measure the AC voltage coming into the IBRC unit.


 You should see 200 240 VAC.
If the voltage is OK  replace the IBRC Unit.

0710

TF1
43

If there is no voltage  troubleshoot the AC power distribution


circuit shown at the right.
G

44

1
2
FRA

CONTACT SIGNAL
TRANSDUCER IBRC
20VDC PSU
15ma MAX.
(+) ()

Table 43.

Troubleshooting Procedure 3

Troubleshooting Procedure
1. Observe the LEDs of channels 1 and 5 on the IBRC unit. If
either of these LEDs are out it implies that one or more cavities of
the robot is missing minimum air pressure. In the case of channel
5, if there are no auxiliary pressure switches, it could be that the
jumper across terminals P5 and N5 has come loose.
 Check that there is sufficient maintenance air at the robot.
 Check cables between robot and controller.
If LEDs 1 and 5 are lit  continue.

Illustration

Chapter 13
Print Reference
0819
0826

If either LED 1 and 5 are out  go to Step 8.


2. Turn off the power disconnect handle.
3. Reseat the following connectors:
 Contact signal transducer (IBRC) connector CRX
 Purge transit board connector CRX3
 Purge transit board connector CRX1
 Purge control PCB (mounted with EMG control PCB)
connector CRX.
4. Turn on the power disconnect handle.

0819 thru
0843
0925 thru
0950

4. TROUBLESHOOTING

47

MARMMTRBL02303E

Table 43. (Contd) Troubleshooting Procedure 3


Troubleshooting Procedure

Illustration

5. Observe on the SOP that:


 Purge fault LED is lit

Chapter 13
Print Reference
0810

H
OL
D

Purge
Fault

6. Re-initiate the purge sequence. See Section 4.1.


If the controller does not operate properly, continue.
7. Measure the DC voltage between the white and black wires in
the wiring harness at connector CRX5 (A1 and A2) of the Transit
Board.
 You should see 24 VDC.
If the voltage is OK  go to Step 10.

0815

If there is no voltage  replace the Purge Power Supply Board


(PSU2).
Note: The Purge Power Supply Board (PSU2) contains two
fuses that can be checked after the board is removed from the
controller.
If you wish, you can perform the following steps after the board
is removed:
1. Check the fuses.
2. If a fuse is bad, replace it and reinstall PSU2.
3. If a fuse blows again, replace PSU2.
8. If, on the IBRC unit, channel 5 LED is out, jumper terminals P5
to N5 and observe if the LED lights.
If the LED does not light 
replace the IBRC unit.
If the LED lights  repair the auxiliary flow switch or wiring for
proper operation or replace the jumper when auxiliary flow
switch is not used.

0825

4. TROUBLESHOOTING
MARMMTRBL02303E

48
Table 43. (Contd) Troubleshooting Procedure 3
Troubleshooting Procedure

Illustration

9. If channel 1 LED is out, jumper terminals P1 to N1 and observe


if the LED lights.
If the LED does not light 
replace the IBRC unit.

Chapter 13
Print Reference
0821

If the LED lights  repair the flow switch or wiring for proper
operation.
10. Repair or replace the following in the order shown:
 Purge enable switch
 IBRC unit
 Purge control PCB (mounted piggy-back on the EMG control
PCB)
 Cable 2003-T526 (1.6M) between SOP (CRX) and transit
board (CRX2)
 Cable 2003-T233 (2M) between purge control PCB and
IBRC unit.

Table 44.

Troubleshooting Procedure 1

Table 45.

Troubleshooting Procedure 4

Troubleshooting Procedure
1. Find the green PIL light in the center of the PSU module.
 The light is on indicating 200VAC to PSU through F5.
If the light is on  go to Table 43.

Illustration

PSU Module

Chapter 13
Print Reference
0218
0216
02-19

If the light is off  continue.

F1 and F2: 10-A fuses


for AC input
PIL: Green LED
for indicating the AC
power supply status

2. Check fuses F1 and F2 in the top center of the PSU module. If


no flag shows, turn off power. Pull fuses F1 and F2 from the PSU
and check the fuse with an ohmmeter.
 A white flag in the center of the fuse indicates it is bad. F1 &
2 monitor incoming 200VAC to PSU.
If fuse(s) are good, go to step 4, otherwise continue.

PSU Module

0208
0210
02-8

F1 and F2: 10-A


fuses for AC
input

02-10

4. TROUBLESHOOTING

49

MARMMTRBL02303E

Table 45. (Contd) Troubleshooting Procedure 4


Troubleshooting Procedure

Illustration

3. If one or both of the fuses are bad 


a. Turn off power at the main disconnect switch.
b. Unplug CP2 and CP3.
c. Replace any bad fuse(s).
d. Turn the main disconnect switch on, but do not press the
ON button.

Chapter 13
Print Reference
0218 thru
0223
0219
02-18 thru 02-22

If the fuse(s) blow again  Replace the PSU.


If the PIL light comes on  go to step 8.
4. Disconnect CP1 at the top of the PSU module. Measure the
voltage coming into the PSU on the two red wires in the harness
connector (S and R).
 You should see 200VAC.
If the voltage is ok  Continue.
If no voltage  go to Table 42.

5. Turn the main disconnect off, pull the PSU module out and
remove the fuse, F5, (located near the middle of the printed circuit
board).

0208 thru 0210

PSU Module

02-08
CP1
3 G
2 S
1 R

0215

PSU Module

02-16

F5: 0.3-A Fuse


for auxiliary
power supply

6. Using an ohmmeter, check fuse.


If the fuse is good  Replace the PSU.

0215
02-16

If the fuse is bad  Continue.


7. Replace fuse F5, insert the PSU module, and turn on the controller.
If the class1 fault is still present  replace the PSU

PSU Module

F5: 0.3-A Fuse


for auxiliary
power supply

4. TROUBLESHOOTING
MARMMTRBL02303E

410
Table 45. (Contd) Troubleshooting Procedure 4
Troubleshooting Procedure
8. If the PIL light is on,
Turn off the main disconnect switch and, using an ohmmeter,
test for a short in the wiring harness at CP2 and CP3.

Illustration

PSU Module

Chapter 13
Print Reference
02-19
0218 thru
0223
02-18 thru 02-22

F1 and F2: 10-A


fuses for AC
input

9. If no short is evident, reconnect CP2 and CP3 and turn the


main disconnect switch on. Press the Power ON pushbutton and
check for proper operation.
10. If the PIL light goes out, fuse(s) F1 and/or F2 have blown
again due to a short in one of the following:
 Wiring harness to ALC relay coil
 ALC relay coil
 Wiring harness to fans (check in particular where cable and
front door hinge point meet).
 Fan motor shorted.
Repair short, replace fuse(s) and go to Step 9.
If the PIL light stays on, check controller for proper operation.

0209
0126
0209
0203 thru
0208

02-08
01-26
02-08
02-22

4. TROUBLESHOOTING

411

MARMMTRBL02303E

Table 46.

Troubleshooting Procedure 2

Table 47.

Troubleshooting Procedure 5
Illustration

Troubleshooting Procedure
1. Measure the AC voltage between Multitap transformer terminals 43 and 44 of TF1.
 You should see 200 VAC.
If voltage is present  Replace or repair harness between
PSU and transformer.
If voltage is not present or incorrect  Continue.

Multi-Tap Transformer
43

Chapter 13
Print Reference
01-22

44

F4 F5
5A 5A

2. Check transformer tap settings.


 As shown in Section 1.9. (Should be Plant 3-phase voltage)
If the tap settings are incorrect  Correct.

01-14

If the tap settings are correct  Continue.

3. Check AC voltage between transformer primary terminals.


 Plant 3-phase voltage.
If voltage proper is present  Replace multi-tap transformer.

01-14

If incorrect or no voltage is present  Continue.


4. Check AC voltage between bottom terminals of FL1, FL2, &
FL3.
 Plant 3-phase voltage.
If voltage is present  Replace or repair wiring harness
between transformer and fuse unit.

Fuse Block
FL1 FL2 FL3

01-05,
01-07,
01-09

If voltage is not present  Continue.


5. Check AC voltage between top terminals of FL1, FL2, and FL3.
 Plant 3-phase voltage.
If voltage is present  F1, F2, F3 is/are blown. Replace bad
fuse. If it blows again, replace the multitap transformer.

01-05,
01-07,
01-09

If voltage is not present  Continue.


6. Check AC voltage between terminals at bottom of main disconnect switch.
 Plant 3-phase voltage.
If voltage is present  Replace or repair wiring harness
between fuse unit and main disconnect switch.

Main
Disconnect
Switch

01-05,
01-07,
01-09

If voltage is not present  Continue.


7. Check AC voltage between terminals at top of disconnect.
 Plant 3-phase voltage.
Replace main disconnect switch if voltage is present;
otherwise, contact plant maintenance.

FL1, FL2, FL3

01-05,
01-07,
01-09

4. TROUBLESHOOTING
MARMMTRBL02303E

412
Table 48.

Troubleshooting Procedure 3

Table 49.

Troubleshooting Procedure 6

Troubleshooting Procedure
1. Check the red alarm light in the center of the PSU module.
 The alarm light should be off.
If the light is ON  Go to Table 410.

Illustration

PSU Module

Chapter 13
Print Reference
02-14

If the light is ON  Go to Table 411.


If the light is OFF  Continue.

ALM: Red LED

F4: 5-Afuse for +24E


F3: 5-AS slowblow
fuse for +24V

2. Check the LED displays on the servo amplifier.


If any LED is on  Go to Table 413 .
If any LED is on  Go to Table 45.
If no LEDs are on  Continue.

08-24 thru 08-26


09-23 thru 09-25
08-09 thru 08-12
09-11 thru 09-13
10-11 thru 10-13

4. TROUBLESHOOTING

413

MARMMTRBL02303E

Table 49. (Contd) Troubleshooting Procedure 6


Troubleshooting Procedure
3. Listen and look for main cabinet cooling fans to be running.
 Fans should be running indicating 200VAC to ALC relay.
If fans are not running  Continue.
If fans are running  Go to step 5.

Illustration

Chapter 13
Print Reference
02-02 thru 08-08
02-02 thru 02-08
FAN 1
REAR

FRONT

FAN 2

FAN 3
CONTROLLER SIDE VIEW
4. Check for 200 VAC at CP2 or CP3.
 You should see 200 VAC 10VAC.
If there is 200VAC  Repair the wiring to the fans and the ALC
relay and check the controller for proper operation.

02-18 thru
02-21

PSU Module

02-18 thru 02-22

If there is not 200VAC  Go to step 8.

5. Check for 200VAC at ALC relay on A1 & A2.


 You should see 200VAC 10VAC.
If voltage is not correct or missing  Repair the wiring
harness coil between the PSU and the coil of the ALC relay.
Check the controller for proper operation.

01-25, 01-27
A1

A2

3
ALC

If voltage is present  Continue.

4. TROUBLESHOOTING
MARMMTRBL02303E

414
Table 49. (Contd) Troubleshooting Procedure 6
Troubleshooting Procedure

Illustration

Chapter 13
Print Reference

6. Check for 200VAC at the ALC relay between 2 & 4, 4& 6, and 2
& 6.
 You should see 200 VAC.
If voltage is not correct or missing  Check fuses F1, F2,
and F3. If the fuses are ok, replace the multitap transformer.

Multi-Tap Transformer

01-27

If voltage is present  Turn power off and repair wiring


between ALC contactor and servo amplifiers.

F1

13
31
32

F2

F3

A1

A2

3
ALC
2 4

If an external OFF button or door interlock is used  Test for


continuity of the external OFF, and DIL circuits, and repair it if
necessary.

23

41

42

14
7. Check the connector CRR4 on the EMG module for jumpers
between terminals 10 (EX-COM) and 12 (EX-OFF) and terminals
14 (DIL1) and 16 (DIL2).
 If you use an external OFF button or door interlock, there will
be a wire on each terminal.
If the terminals are connected with a jumper wire check for no
loose screws and good contact.

01-27
01-22

24
02-06
02-28 thru 02-33
CRR4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

100OUT3
EMGOU2
100OUT4
EMGOUTC
FENCE1
EMGOUT1
FENCE2
EX-ON
0V
EX-COM
0V
EX-OFF
5v
DIL1
15V
DIL2
-15V
EMGB1
+24V
EMGB2

4. TROUBLESHOOTING

415

MARMMTRBL02303E

Table 49. (Contd) Troubleshooting Procedure 6


Troubleshooting Procedure

Illustration

Chapter 13
Print Reference

7. Check the connector on the EMG module for jumpers between


terminals 32 (EX-COM) and 31 (EX-OFF) and terminals 30 (DIL1)
and 29 (DIL2).
 If you use an external OFF button or door interlock, there will
be a wire on each terminal.
If the terminals are connected with a jumper wire check for
loose screws and good contact.

02-28 thru 02-33

29 32

If an external OFF button or door interlock is used  Test for


continuity of the external OFF, and DIL circuits, and repair it if
necessary.

8. On the EMG board, connect 10 (Ex-COM) to ground with a


jumper wire; then momentarily connect 8 (ExON) to
10 (Ex-COM).
 Controller should turn on.
If the controller turns on  There is a break in the on/off
switch circuit. Repair or replace.

02-28 thru 02-33

If the controller does not turn on  Replace the PSU module.


PSU

9. On the Power Supply Unit, momentarily jumper the following


connections:
 CP4 connector terminal 1 (ON) to CP4 connector terminal 3
(COM)
 CP4 connector terminal 3 (COM) to ground
 The controller should turn on.
If the controller turns on  there is a break on the ON/OFF
switch circuit. Repair or replace.
If the controller does not turn on  continue.

02-16

4. TROUBLESHOOTING
MARMMTRBL02303E

416
Table 410.

Troubleshooting Procedure 4

Table 411.

Troubleshooting Procedure 7

Troubleshooting Procedure
1. Check fuse F3 at the bottom of the PSU.
 A white flag in the center of the fuse indicates it is bad and
that 24 power is missing.
If the fuse is blown  There might be a short circuit in one of
the following:
Backplane
24VDC Cooling Fans for module card cage
Process I/O 24 VDC supply
CRT/KB
Main CPU Module
Axis Module
Modular I/O 24 VDC supply
Option #1
Option #2
Extended Backplane

Illustration

Chapter 13
Print Reference
02-24

PSU Module

02-23

ALM: Red LED


for indicating an
alarm

F4: 5-Afuse for +24E


F3: 5-AS slow-blow
fuse for +24V

 Isolate the short and repair it.


If the fuse is good  Continue. See NO TAG.
2. Turn off the controller. Measure the resistance between the
following terminals of CRR4 on the EMG module:
Terminal 9 (0V) and Terminal 15 (+15)
Terminal 9 (0V) and Terminal 17 (15)
Terminal 9 (0V) and Terminal 13 (+5)
 Look for greater than 100 ohms at each measurement.
If all readings are ok  Replace the PSU.
If all readings are not ok  Continue.

NOTE A low reading means shorted power to ground


through or because of an EMG, Main CPU, PSU, Fence,
or Axis board. Remove them one at a time until you get
a normal reading. Replace the defective board.

06-24 thru 06-36

CRR4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

100OUT3
EMGOU2
100OUT4
EMGOUTC
FENCE1
EMGOUT1
FENCE2
EX-ON
0V
EX-COM
0V
EX-OFF
5v
DIL1
15V
DIL2
-15V
EMGB1
+24V
EMGB2

4. TROUBLESHOOTING

417

MARMMTRBL02303E

Table 411. (Contd) Troubleshooting Procedure 7


Troubleshooting Procedure
2. Turn off the controller. Measure the resistance between the
following terminals on the EMG module:
Ground and Terminal 39 (15)
Ground and Terminal 38 (+15)
Ground and Terminal 40 (+5)
 Look for greater than 100 ohms at each measurement.
If all readings are ok  Replace the PSU.

Illustration

Chapter 13
Print Reference

EMG

0934
0932
0931

If all readings are not ok  Continue.

NOTE A low reading means shorted power to ground


through or because of the Main CPU, PSU, Fence, or
Axis board EMG. Remove them one at a time until you
get a normal reading. Replace the defective board.

40
39
38

4. TROUBLESHOOTING
MARMMTRBL02303E

418
Figure 51. 24 Volt (24E) Power Distribution Chart

4. TROUBLESHOOTING

419

MARMMTRBL02303E

Table 412.

Troubleshooting Procedure 5

Table 413.

Troubleshooting Procedure 8

Troubleshooting Procedure
1. Turn the power disconnect switch on and press the power on
pushbutton. Check the lights on the operator panel.
 Any light on indicates 24E to the operator panel. This can
also be checked by measuring for 24VDC between terminals
5 and 9 of the EMG connector CRR4.
If any light is on  Go to Table 414.
If the lights are not on  Continue.

1. Turn the power disconnect switch on and press the power on


pushbutton. Check the lights on the operator panel.
 Any light on indicates 24E to operator panel. This can also
be checked by measuring for 24VDC between terminals 62
and Ground of the EMG control PCB.
If any light is on  Go to Table 415.
If the lights are not on  Continue.

2. Check fuse F4 at the bottom of the PSU module. If no flag


shows, check the fuse with an ohmmeter.
 White flag in the center of the fuse indicates it is bad.
If the fuse is good  Replace the PSU
If the fuse is bad  Continue.

Illustration

Chapter 13
Print Reference
06-25
06-29

H
O
L
D

H
O
L
D

PSU Module

02-23
02-31
02-23
06-25
06-29

ALM: Red LED for


indicating an alarm

F4: 5-Afuse for +24E


F3: 5-AS slow-blow
fuse for +24V

4. TROUBLESHOOTING
MARMMTRBL02303E

420
Table 413. (Contd) Troubleshooting Procedure 8
Troubleshooting Procedure
3. Turn off power, disconnect fence circuit or remove jumper, and
connect an ohmmeter between Fence1 terminal 36 and Ground
on the EMG module.
 If it does not show continuity (greater than 500 ohms),
replace fuse F4 and check the controller for proper
operation.
 If it does show continuity (less than 10 ohms), a
component is shorted, loading the 24E voltage supply.

Illustration

Chapter 13
Print Reference
09-50

EMG

0V 56
0V 55
36

3. Turn off power, disconnect fence circuit or remove jumper, and


connect an ohmmeter between Fence1 and 0V (CRR4 pin5 & 9 or
11) on EMG module.
 If it does not show continuity (greater than 500 ohms),
replace fuse F4 and check the controller for proper
operation.
 If it does show continuity (less than 500 ohms), a
component is shorted, loading the 24E voltage supply.

4. To find the shorted component, watch the ohmmeter while you


disconnect or remove the following parts in order:
 Main CPU
 Axis
 Option #1
 Option #2
 EMG
 Cards on the extended backplane one at a time
 If the ohmmeter shows greater than 500 ohms, the part is
OK. If the ohmmeter shows under 500 ohms, the part is
defective.
If it still does not work  Follow the short out to the failed
component and replace. See Figure 52.

06-25

CRR4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

100OUT3
EMGOU2
100OUT4
EMGOUTC
FENCE1
EMGOUT1
FENCE2
EX-ON
0V
EX-COM
0V
EX-OFF
5v
DIL1
15V
DIL2
-15V
EMGB1
+24V
EMGB2

4. TROUBLESHOOTING

421

MARMMTRBL02303E

Figure 52. 24 Volt (24V) Power Distribution Chart

4. TROUBLESHOOTING
MARMMTRBL02303E

422
Figure 53. Tracing a Short on 24E

4. TROUBLESHOOTING

423

MARMMTRBL02303E

Table 414.

Troubleshooting Procedure 6

Table 415.

Troubleshooting Procedure 9
Illustration

Troubleshooting Procedure
1. Press the OFF button. Press and hold USER PB1 and USER
PB2 and press the ON button.
If the BMON> prompt appears  Treat the problem as a
Class 2 Fault; otherwise, continue.

Operator Panel

H
O
L
D

USER
PB1

USER
PB2

1. Press the OFF button. Press and hold PURGE ENABLE


press the ON button.
If the BMON> prompt appears  Treat the problem as a
Class 2 Fault; otherwise, continue.

Chapter 13
Print Reference

ON

OFF

Operator Panel

H
OL
D

Purge
Enable
Button

ON

08-05
02-13

4. TROUBLESHOOTING
MARMMTRBL02303E

424
Table 415. (Contd) Troubleshooting Procedure 9
Troubleshooting Procedure

Illustration

2. If you have not done so already, measure the 24E voltage at


the EMG module connector CRR4 on terminals 5 (FENCE1) and
9 (0VDC) for 24VDC (10%). If the 24VE voltage is missing or out
of tolerance, go to Table 412.

Chapter 13
Print Reference
06-25
06-29
CRR4

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

2. If you have not done so already, measure the 24E voltage at


the EMG module on terminals 36 and Ground. for 24VDC (10%).
If the 24VE signal is missing or out of tolerance, go to Table 413.

100OUT3
EMGOU2
100OUT4
EMGOUTC
FENCE1
EMGOUT1
FENCE2
EX-ON
0V
EX-COM
0V
EX-OFF
5v
DIL1
15V
DIL2
-15V
EMGB1
+24V
EMGB2

0950

EMG

0V 56
0V 55
36

4. TROUBLESHOOTING

425

MARMMTRBL02303E

Table 415. (Contd) Troubleshooting Procedure 9


Troubleshooting Procedure
3. On the teach pendant, look for any lit LEDs or screen display.
If there is no display  the 24T power supplying the teach
pendant ISB unit is most likely missing. Visually check the
teach pendant cable K0402003T908 (10/20M) for damage.
If the 24T signal is missing or out of tolerance the following will
correct the problem. Replace the following, in order, one at a
time:

3
4
5
6
7

Replace the teach pendant cable.


Replace the ISB unit.
Replace the EMG module.
Replace the Main CPU printed circuit board.
Replace the backplane.

4. If there are LEDs or a screen display, there is a communication


fault between the Main CPU printed circuit board and the teach
pendant.
Replace the following in order, one at a time.
 Teach pendant cable
 Teach pendant
 Main CPU module

Illustration

Chapter 13
Print Reference
05-23

4. TROUBLESHOOTING
MARMMTRBL02303E

426

4.3
CLASS 2 FAULTS

A Class 2 Fault is indicated by frozen text (letters or numbers) displayed


on the teach pendant. This situation is an indication of a problem with the
Main CPU printed circuit board caused by either the memory, processor,
the board itself, or a bad teach pendant cable.
Table 416.

Class 2 Faults Troubleshooting Procedure

Troubleshooting Procedure
1. Is the Battery light on the main CPU module on?
If the Battery light is on  replace the battery. Refer to Procedure 91.
1

STATUS
ALARM

Battery Light

2. Perform a cold start of the controller.


3. Is a red light on the axis control board turned on?
If a red light is on  replace the axis control board.
4. Are all four green LEDs on the axis control board turned on?
If all four green LEDs are on  go to step 5.
If all four green LEDs are not on  troubleshoot the controller using Table 35 in Chapter 3, Lights and LEDs.
5. Turn the controller off. Hold down Purge Enable pushbutton and press the ON button.
 Check the teach pendant cable by swapping it with a known working cable or by doing a continuity test.
 Does the BMON> prompt appear on the teach pendant? If it does not appear, replace the main CPU printed circuit
board and reload software.
CAUTION

Continuing beyond this point will erase all software stored in the controller
including all taught positions in your application. It will also require a software
reload which will take at least two hours. Do not do this unless your controller
actually has a Class 2 fault.

4. TROUBLESHOOTING

427

MARMMTRBL02303E

Table 416. (Contd) Class 2 Faults Troubleshooting Procedure


Troubleshooting Procedure
6. Perform the following steps on the teach pendant:
a. Press the NEXT key twice.
b. Press F2, DIAG.
c. Press ENTER.
The prompt changes to DIAG> (diagnostic monitor).
d. Press the NEXT key.
e

Press F3, TEST.

f.

Press F1, CMOS.

g. Press ENTER.
The teach pendant will display a message that gives you an opportunity to exit without destroying the contents of CMOS
memory.
h. Press 1 if you want to continue with the test.
7. The CMOS memory test will take a few minutes to run. If an error is encountered, an address and good and bad data are
displayed on the teach pendant or CRT/KB. Record the address and refer to following to determine the board that failed.
Error Code
F1000000 F10FFFFF
F1100000 F11FFFFF
F1200000 F12FFFFF
F1300000 F13FFFFF

Replace Board
7MK1 (RAM MODULE) (STANDARD)
MJ1 (RAM MODULE) (STANDARD)
MH1 (RAM MODULE) (OPTION)
MG1 (RAM MODULE) (OPTION)

Replace defective memory boards as necessary and reload software. If the CMOs memory test passes, continue.
8. Perform the following steps on the teach pendant:
a. Press the NEXT key.
b. Press F1, EXIT.
c. Press ENTER.
d. Press the NEXT key.
e. Press F1, CLEAR.
f.

Press F2, FROM.

g. Press ENTER.
h. Press the NEXT key.
i.

Press F1, EXIT.

j.

Press the NEXT key twice.

k. Press F2, DIAG.


l.

Press ENTER.

m. Press F3, TEST.


n. Press F4, FROM.
o. Press ENTER.
The teach pendant will display a message that gives you an opportunity to exit without destroying the
contents of Flash ROM memory.
p. Press 1 if you want to continue with the test.
The Flash ROM memory test will take a few minutes to run. If an error is encountered, replace the Flash
ROM board and reload software. Otherwise, continue.
9. The hardware in your controller is OK. Reload your system application software.

4. TROUBLESHOOTING

428

4.4
CLASS 3 FAULT
TROUBLESHOOTING

MARMMTRBL02303E

This section contains troubleshooting information for Class 3 Faults. You


are here if the teach pendant displays a fault message on the teach pendant
screen.
1. Press the MENU key on the teach pendant.
2. Select ALARM from the menu.
3. Refer to the appropriate subsection in this section and follow the
troubleshooting procedure. The subsections that follow are arranged
in numerical error code order.

4. TROUBLESHOOTING

429

MARMMTRBL02303E

4.4.1

The operator panel emergency stop push button is pressed.

SRVO-001 ER_SVAL1
Operator Panel EStop

Remedy: Twist the operator panel emergency stop push button clockwise
to release. Press reset.
If the problem still exists, it is caused by an open circuit in the emergency
stop circuit or a bad Main CPU. Perform the troubleshooting procedure in
the following table.
Table 417.

SRVO-001 Troubleshooting Procedure


Illustration

Troubleshooting Procedure
1. Remove and reconnect:
 CN1 on the Operator Interface board
 CN5 on the Operator Interface board
 JRM5 on the Main CPU
Check for proper operation.
If the problem still exists  go to step 2.

Main CPU Printed Circuit Board

JRM5 connector

Operator Interface Printed Circuit Board

Operator panel,
rear face

CN1 connector

CN3 connector

Chapter 13
Print Reference
03-17
03-28

4. TROUBLESHOOTING
MARMMTRBL02303E

430
Table 417. (Contd) SRVO-001 Troubleshooting Procedure
Troubleshooting Procedure

Illustration

Chapter 13
Print Reference

2. Perform the following steps:

03-17

a. Turn off the controller.


b. At the operator panel emergency stop button,
remove the two blue wires and connect (strap) them
together.
c. Turn on the controller.
If the error message is cleared  replace the
emergency stop button.
If the error message reappears  go to step 3.

ESTOP REAR VIEW


3. Perform the following steps:

Main CPU Printed Circuit Board

03-25

a. Replace the cable between connector JRM5 at the


Main CPU module and the operator interface printed
circuit board.
b. Turn on the controller.
If the error message is cleared  check the
controller for proper operation.
If the error message reappears  replace the Main
CPU module.

JRM5 connector

PIN 1

PIN 26

PIN 25

PIN 50

4. TROUBLESHOOTING

431

MARMMTRBL02303E

Figure 54. Operator Panel E-Stop Circuitry

4. TROUBLESHOOTING
MARMMTRBL02303E

432

4.4.2

The teach pendant emergency stop push button is pressed.

SRVO-002 ER_SVAL1
Teach Pendant Estop

Remedy: Twist the teach pendant emergency stop push button clockwise
to release. Press reset.
If the problem still exists, it is caused by the loss of 24VDC to the teach
pendant relay RLY2 or the 5 VDC signal to the matrix decoding from the
normally closed contact of the teach pendant relay RLY2.
Any of the following can cause this problem:




A defective teach pendant emergency stop switch.


A defective component on the teach pendant printed circuit board.
Loss of 24VDC to the E-STOP switch (not part of the teach pendant
power).
This loss of power can be caused by a bad teach pendant emergency
stop switch, a broken wire in the teach pendant cable, or a bad EMG
module on relay RL-10. In most cases, you can fix it by replacing the
teach pendant.

If you want to troubleshoot the problem further, perform the following


troubleshooting procedure:
Table 418.

SRVO-002 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13
Print Reference

Perform the following steps:


a. Turn off power to the controller.
b. Remove the seven screws holding the teach pendant back in place.
c. Remove the teach pendant back cover.
d. Slide the E-stop wiring connector half way off connector CNEMG1.
e. Carefully energize the teach pendant and measure the DC voltage of CNEMG1 and
either of the GND test points on the teach pendant.
At pin 2, if there is 24VDC (5 VDC)  Measure pin 1. If 0VDC, go to step f.

15-33

At pin 1, if there is no 24VDC (5 VDC)  Replace the teach pendant emergency stop
switch.
If voltage is found  Replace the teach pendant.
f.

If no voltage is found, replace the teach pendant cable, and test for proper operation.

g. If the problem still exists, replace the EMG module.

Figure 55

4. TROUBLESHOOTING

433

MARMMTRBL02303E

Figure 55. Teach Pendant E-Stop Circuitry


JRS1 MAIN (RS422/TEACH PENDANT) HONDA High Density

9
7
5
3
1

TPDSC
EMGB1
TXTP
RXTP
4
*RXTP
10
9
+24T
+24T
16
15
EMGB2 EMGB1
20
0V

10
8
6
4
2

+24T
EMGB2
0V
*TXTP
*RXTP

3
RXTP
8
14
19
0V

2
*TXTP
7

1
TXTP
6

13
12
EMGEN EMGDM
18
17
TPDSC

Teach Pendant
External Connector CN1
Male HIROSE

20
18
16
14
12

19
17
15
13
11

5
11
EMGTP

+24T
EMGTP
EMGDM
EMGEN
0V

4. TROUBLESHOOTING
MARMMTRBL02303E

434

4.4.3

The teach pendant deadman switch is released while the teach pendant is
enabled.

SRVO-003 ER_SVAL1
Deadman switch
released

Remedy: Press and hold the teach pendant deadman switch. Press reset.
If the problem still exists, it is caused by:
 A defective teach pendant deadman switch
 A defective component on the teach pendant printed circuit board
 A possible break in the circuitry between the teach pendant and the
Main CPU.
In most cases, you can fix it by replacing the teach pendant.
If you want to troubleshoot the problem further, perform the following
troubleshooting procedure:
Table 419.

SRVO-003 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13
Print Reference

1. Perform the following steps:


a. Remove power from the controller.
b. Remove the seven screws holding the teach pendant back in place.

15-25
15-30

c. Remove the teach pendant back but leave all electrical connectors in place.
d. Press each deadman switch bar while watching the switch body inside the teach pendant.
e. Make sure that the copper strip presses the switch actuator all the way into the switch body.
You should be able to hear and feel it click into place.
If the actuator is frozen or will not click sharply  replace the switch.
2. Perform the following steps for each deadman switch:
a. Slide the wiring connector half way off the circuit board connector.
b. Measure the resistance between:
 Pins 1 and 2
 Pins 3 and 4
When the deadman switch is not pressed, there is continuity between pins 1 and 2 and no
continuity between pins 3 and 4
When the deadman switch is pressed, there is no continuity between pins 1 and 2 and
continuity between pins 3 and 4.
If one or more measurements are bad  replace the deadman switch assembly.
If the measurements are good  replace the teach pendant.

15-25
15-30

4. TROUBLESHOOTING

435

MARMMTRBL02303E

Figure 56. Deadman Switch Circuitry

4. TROUBLESHOOTING

436

4.4.4
SRVO-041
MOFAL Alarm
(Group:i Axis:j)

MARMMTRBL02303E

The motion command after the ramping algorithm in the servo software
exceeded one word. Contact the FANUC Robotics Hotline for more
information. DO NOT INCLUDE IN MANUAL!!!!!!

4. TROUBLESHOOTING

437

MARMMTRBL02303E

4.4.5

The safety fence gate is open.

SRVO-004 ER_SVAL1
Fence open

Remedy: Close the gate. Several gates in the workcell might be


involved.
If the problem still exists, perform the following troubleshooting
procedure:
Table 420.

SRVO-004 Troubleshooting Procedure

Troubleshooting Procedure
1. Perform the following steps to determine if a safety fence is
installed:
a. Look at terminals 5 and 7 on the EMG module connector
CRR4.
b. Check for a jumper connecting the terminals or a wire on
each terminal.
If a jumper is present  go to step 2.
If two wires are present  go to step 3.

2. Measure the resistance between the two terminals.


If there is continuity  replace the EMG module. If the
problem still exists, replace the axis control printed circuit
board.
If there is no continuity  repair or replace the jumper.

3. Measure the resistance between the two wires.


If there is continuity  replace the EMG module. If the
problem still exists, replace the axis control printed circuit
board.
If there is no continuity  locate and repair the break in the
safety fence switch circuit between the two terminals.

Illustration

Chapter 13
Print Reference
06-24 thru 06-26

CRR4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

100OUT3
EMGOU2
100OUT4
EMGOUTC
FENCE1
EMGOUT1
FENCE2
EX-ON
0V
EX COM
EX-COM
0V
EX-OFF
5v
DIL1
15V
DIL2
-15V
EMGB1
+24V
EMGB2

4. TROUBLESHOOTING
MARMMTRBL02303E

438
Figure 57. Fence Open Circuitry

4. TROUBLESHOOTING

439

MARMMTRBL02303E

4.4.6
SRVO-005 ER_SVAL1
Robot Overtravel

An overtravel error occurs when one or more of the robot axes move
beyond the software motion limits, tripping an overtravel limit switch.

Table 421.

SRVO-005 Troubleshooting Procedure 1

Troubleshooting Procedure
1. If you have not already done so, continuously press and hold
the DEADMAN switch and turn the teach pendant ON/OFF switch
to ON.
2. Hold down the SHIFT key and press RESET.
3. Press COORD until you select the JOINT coordinate system.
4. Jog the axis in overtravel off of the overtravel switch.
If you cannot jog the robot off of the overtravel switch  the
wrong motion inhibit flag has been set; therefore, continue to
the next step. Otherwise, the axis (or axes) are no longer in
overtravel and you can end the procedure now.
5. Cold start the controller and go to Step 1 in this procedure. If
the overtravel still cannot be cleared, continue to Step 6.
NOTE In some instances, the screen will indicate a FALSE for a
given axis when a TRUE should be set because of the way
overtravel is read in software. It is best to perform the following
procedure on all of the axes.
6. Press MENUS.
7. Select MANUAL FCTNS.
8. Press F1, [TYPE].
9. Select OT Release. See the following screen for an example.
10. Move the cursor to the OT PLUS or OT MINUS value of the
axis in overtravel. The status of OT PLUS or OT MINUS for that
axis is TRUE.
11. Press and hold SHIFT and press F2, RELEASE.
12. Press and hold SHIFT and press RESET.
13. Press COORD until you select the JOINT coordinate system.
14. Continuously press and hold the DEADMAN switch and turn
the teach pendant ON/OFF switch to ON.
15. Jog the axis off of the overtravel switch.
16. Turn the teach pendant ON/OFF switch OFF and release the
DEADMAN switch.

Illustration

Chapter 13
Print Reference
05-08 thru 05-20

4. TROUBLESHOOTING
MARMMTRBL02303E

440

If the problem still exists, it is caused by an open circuit in the overtravel


switch circuit or by a defective axis control board or EMG module.
Try the following steps in order, checking for proper operation after each.

Table 422.

SRVO-005 Troubleshooting Procedure 2

Troubleshooting Procedure
1. Remove all connectors from the axis control board and reseat them, starting with connector CRM1.
2. If spare boards are available, temporarily replace the EMG board and axis control board.
3. Using the schematic drawings and an ohmmeter, check the overtravel switches in the robot and their
wiring for continuity.
4. Replace the cable between axis control board connector CRM1 and the robot.

Figure 58. Robot Overtravel Circuitry

Reference

4. TROUBLESHOOTING

441

MARMMTRBL02303E

4.4.7
SRVO-006 ER_SVAL1
Hand Broken

A hand breakage error occurs when the hand (wrist) breakage detection
switch or aux hand breakage detection switch is tripped.
Remedy:
If you are not using the hand broken function, ensure that the HBK
jumper on the axis control printed circuit board is set to the A side.
If you are using the hand broken function, perform the following steps:
1. If you have not already done so, continuously press and hold the
DEADMAN switch and turn the teach pendant ON/OFF switch to ON.
2. Hold down the SHIFT key and press RESET. The robot can now be
moved.
3. Jog the robot to a safe position off of the limit switch.
4. Turn the teach pendant ON/OFF switch to OFF and release the
DEADMAN switch.

4. TROUBLESHOOTING
MARMMTRBL02303E

442

If the problem still exists, perform the following troubleshooting


procedure:
Table 423.

SRVO-006 Troubleshooting Procedure


Illustration

Troubleshooting Procedure

Reference

1. Remove power from the controller by


turning off the disconnect switch.

2. Test the end effector switch and its wires at


the robot for continuity.
If there is no continuity  replace or repair
the switch or its wires.
If there is continuity  continue.

3. Set the HBK jumper on the axis control


board to the A side and test the robot for
proper operation.
If the fault is fixed  replace the cable
between axis control board connector
CRM1 and the robot. Be sure to reset the
HBK jumper on the axis control board to the
B side.
If the fault is not fixed  replace the axis
control board.
NOTE: When replacing the axis control
module, ensure that the on-board jumpers
on the replacement board match those on
the original board.

COM
JUMPER

Figure 59. Hand Broken Circuitry

HBK
JUMPER

4. TROUBLESHOOTING

443

MARMMTRBL02303E

4.4.8
SRVO-007 ER_SVAL1
External emergency
stops

An external emergency stop button somewhere in the workcell has been


pressed. External emergency stop is signaled whenever the 100V to the
servo amplifiers is not present, and the operator panel emergency stop,
teach pendant emergency stop, overtravel, and hand broken signals are not
asserted.
Remedy: Locate and release the external emergency stop button. Press
reset on the operator panel or teach pendant.
If the problem still exists, perform the following troubleshooting
procedure:

4. TROUBLESHOOTING
MARMMTRBL02303E

444
Table 424.

SRVO-007 Troubleshooting Procedure


Illustration

Troubleshooting Procedure

CRR3

1. Perform the following steps:


a. Locate terminals 6, 8, and 10 on connector CRR3 of the
EMG module.
b. Check for jumpers between:
 6 and 8
 8 and 10
or else wires attached to the terminals. Wires indicate that
an external emergency stop is
connected to the controller.
If there is no jumper connecting the terminals or there are
no wires on each terminal  verify that no external emergency
stop should be installed and replace the missing jumper.
If a jumper is present or if wires are present  go to step 2.

Chapter 13
Print Reference

EMG

1 100IN1
2 OP1
3 100IN2
4 OP2
5 100IN3
6 EMGIN1
7 100IN4
8 EMGINC
9
10 EMGIN2
11 100OUT1
12 100OUT1
13 100OUT2
14 100OUT2
15 BKP4
16 BKM4
17 BKP5
18 BKM5
19 BKP6
20 BKM6

03-08, 03-09, 03-10

2. With controller power off, on the EMG module, measure the


resistance on CRR3 between:
 6 and 8
 8 and 10
If there is continuity  go to step 3.

03-08, 03-09
03-09, 03-10

If there is no continuity  repair or replace the jumper or locate


and repair the break in the external emergency stop circuit.
3. With controller power off, on the EMG module, measure the
resistance on CRR3 between terminals 2 and 4.
If there is continuity  go to step 4.
If there is no continuity  verify that the 100VAC contacts on
the operator panel emergency stop button are operating
properly.

03-06, 03-07

4. With controller power on, on the EMG module, measure the AC


voltage on CRR3 between terminals 1 and 3.
Is the voltage 100VAC  10%?
If the voltage is within tolerance  replace EMG
If the voltage is not within tolerance  go to step 5.

03-04

5. With controller power on, measure the AC voltage at transformer


TF1, terminals 41 and 42, for
100VAC  10%.
If the voltage is within tolerance  repair or replace the wiring
between TF1 terminals 41 and 42 and EMG module CRR3
terminals 1 and 3.
If voltage is out of tolerance  continue.

Multi-Tap Transformer
41 42

F4 F5
5A 5A

01-33, 01-34

4. TROUBLESHOOTING

445

MARMMTRBL02303E

Table 424. (Contd) SRVO-007 Troubleshooting Procedure


Troubleshooting Procedure
6. At the ALC relay, terminals 23 and 13, measure again for
100VAC  10%.
If the voltage is within tolerance  check for proper operation
of the ALC relay.

Illustration

01-26

Multi-Tap Transformer
13

A1

A2

23

31

41

32

42

14
7. Remove power from the controller, and with an ohmmeter test
fuses F4 and F5.
If F4 and F5 are good  transformer TF1 is not outputting
100VAC on its secondary legs and needs replacing.

Chapter 13
Print Reference

24

Multi-Tap Transformer
41 42

F4 F5
5A 5A

01-23

4. TROUBLESHOOTING
MARMMTRBL02303E

446
Figure 510. External Emergency Stop Circuitry

4. TROUBLESHOOTING

447

MARMMTRBL02303E

4.4.9

Indicates one of two symptoms:

SRVO-008 ER_SVAL
Brake fuse blown




The 5A brake fuse on the EMG module has blown.


A momentary surge of high current was detected in the brake circuit.
The FALM LED on the EMG module will be lit.

Remedy: By turning power off momentarily and then back on you will
reset the circuit and the LED will go out if the fault is caused by a current
surge.
If the fault does not reset or if it reoccurs frequently, perform the
following troubleshooting procedure:
Table 425.
Troubleshooting Procedure
1. Turn off the controller at the main disconnect and open
the cabinet door.
2. Remove all of the connectors on the front of the EMG
module and pull out the module.
3.Check the 5A fuse and replace it if necessary.

4. Place the EMG control printed circuit board back in its


slot and plug all connectors back into it.

SRVO-008 Troubleshooting Procedure


Illustration

Chapter 13
Print Reference

EMG
PCB

03-19

4. TROUBLESHOOTING
MARMMTRBL02303E

448
Table 425. (Contd) SRVO-008 Troubleshooting Procedure
Troubleshooting Procedure

Illustration

5. Using an ohmmeter, test the continuity between


CRR3, terminal 19 and the following points to test for a
shorted brake coil:
 CRR5 pins 1B, 2B, 3B, 1D, 2D, 3D
 CRR3 terminals 16, 18, and 20 (extended
axes only)
A short or resistance lower than 50 ohms could cause
the fuse to blow or the sensor to trip. Replace the
motor on the axis with the shorted brake coil.
If the resistance is OK  continue.

Chapter 13
Print Reference

CRR3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

100IN1
OP1
100IN2
OP2
100IN3
EMGIN1
100IN4
EMGINC

04-10 thru 04-38

EMGIN2
100OUT1
100OUT1
100OUT2
100OUT2
BKP4
BKM4
BKP5
BKM5
BKP6
BKM6

BRK4

NOT
USED

BRK5

BRK6
FALM

D CB A

BRK
CRR5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

VIOLET
BKM3
BKM3
BKM3

6. With the controller door open and all connectors and


plugs reattached, energize the controller.
If the FALM light comes on  replace the EMG
module.

BRK1

SON

BRK2

BRK3

100OUT3
EMGOU2
100OUT4
EMGOUTC
FENCE1
EMGOUT1
FENCE2
EX-ON
0V
EX-COM
0V
EX-OFF
5v
DIL1
15V
DIL2
-15V
EMGB1
+24V
EMGB2

CRR4

BLUE
BKP3
BKP3
BKP3

VIOLET
BKM2
BKM2
BKM1

BLUE
BKP2
BKP2
BKP1

03-32

4. TROUBLESHOOTING

449

MARMMTRBL02303E

Table 425. (Contd) SRVO-008 Troubleshooting Procedure


Troubleshooting Procedure

Illustration

Chapter 13
Print Reference

7. Power up the robot and jog the robot to verify robot


operation.
If the FALM light comes on  replace the EMG
module.
EMG CONTROL MODULE
SENSITIVITY
JUMPER
1
SET

9. If this problem occurs occasionally, change the SET


jumper from 2 to 1 on the EMG module.

0337

4. TROUBLESHOOTING
MARMMTRBL02303E

450
Figure 511. Brake Fuse Blown Circuitry

4. TROUBLESHOOTING

451

MARMMTRBL02303E

4.4.10

Teach pendant deadman switch released while enabled.

SRVO-011
ER_SVAL1
TP Released While
Enabled

Remedy: Press the deadman switch, then press RESET.

4.4.11

Normal power is on (hot start).

SRVO-012
ER_SVAL1
Power Failure
Recovery

Remedy: This message is normal and does not indicate a problem.

4.4.12

One or all of the 24VDC cooling fans in the backplane cage are not
running.

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

Each double-board board cage in the backplane has a cooling fan mounted
in its top. Each fan contains a centrifugal switch that opens when the fan
is not running.

Table 426.

SRVO-014 Troubleshooting Procedure

Troubleshooting Procedure
1. With power on, test whether each fan is turning by passing a strip of paper over the top of each
board cage.
All fans are turning  go to step 3.
One fan is motionless  continue.
2. Remove the circuit boards from the board cage with the motionless fan. Reconnect the four-wire
connector on the backplane behind the board cage. Reinstall the boards and power up the controller.
If the fault is not fixed  replace the fan.
3. One of the fans or the axis control board is probably defective. Determine which part is bad by
temporarily replacing it with a known-good part.
If the fault is not fixed  continue.
4.Replace the backplane.

Chapter 13
Print Reference

4. TROUBLESHOOTING
MARMMTRBL02303E

452
Figure 512. Backplane

AXIS

BACKPLANE
24V

CA39C
1

+24VDC

CA39C
2

+0VDC

5V

E71
RV

*FMM

JRA2
13

ALM

(SVRO 014
FAN MOTOR
ABNORMAL)

CA39C
3

ALMC

OPTION 1 & 2 PCB


COOLING FAN

CENTRIFUGAL

IC13
CA39B
1

+24VDC

CA39B
2

+0VDC

CA39B
3

IC11

CA39A
1
CA39A
2

0V

CA39A
3

IC12

0V

ALMB

AXIS & MAIN PCB


COOLING FAN

CENTRIFUGAL

+24VDC

+0VDC

ALMA

CENTRIFUGAL

EMG & PSU PCB


COOLING FAN

4. TROUBLESHOOTING

453

MARMMTRBL02303E

4.4.13
SRVO-015
ER_SVAL1
System Over Heat
(Group:i Axis:j)

The temperature in the controller is too high, or the overheat sensor


located on the backplane has opened.

Table 427.

SRVO-015 Troubleshooting Procedure

Troubleshooting Procedure

Line No. Reference


Chapter 13

1. Clean the controller air filter, allow the controller to cool down, and cold start the controller.
2. Check the heat exchanger fans for operation.
If the fans run ok replace the axis control board.
If one or more fans do not work  continue.
3. Check the AC voltage at the terminals of the non-working fan(s).
If the voltage is 180VAC 220VAC  replace the fan(s).
If the voltage is out of tolerance  replace or repair the fan motor wiring harness.
Figure 513. System Over Heat Circuitry Drawing 1

02-02
02-04
02-07

4. TROUBLESHOOTING
MARMMTRBL02303E

454
Figure 514. System Over Heat Circuitry Drawing 2

4. TROUBLESHOOTING

455

MARMMTRBL02303E

4.4.14
SRVO-021
ER_SVAL1
SRDY off
(Group:i Axis:j)

The axis control board sends a signal to the servo amplifiers in order to
energize the MCC contactors and turn on the servo amplifiers. When a
servo amplifier MCC coil is turned on, it sends a signal back to the axis
control board. If the axis control board sends its signal and does not
receive the reply within a few milliseconds, this alarm occurs.
Table 428.

SRVO-021 Troubleshooting Procedure

Troubleshooting Procedure
1. Does the alarm occur on three or more axes?
YES  repair or replace the wiring harness between the EMG board and terminals 5 and 6 of the
servo amplifier in the far left position.

Line No. Reference


Chapter 13
08-17
09-18
10-17
09-01 thru 09-09

NO  continue
2. Disconnect and reseat the signal cable between the axis control board and the affected servo
amplifier. If necessary, continue.
3. Exchange the axis control board-to-servo amplifier cable between the affected axis and a knowngood axis. Be sure to switch both ends of the cables.

10-01 thru 10-18

Does the fault message change to indicate a different axis?


YES  replace the bad cable.
NO  continue
4. Replace the axis control board. If the problem continues, replace the affected servo amplifier.

4.4.15
SRVO-022
ER_SVAL1
SRDY on
(Group:i Axis:j)

The axis control board sends a signal to the servo amplifiers in order to
energize the MCC contactors and turn on the servo amplifiers. When a
servo amplifier MCC coil is turned on, it sends a signal back to the axis
control board. If the axis control board receives the reply signal without
having sent its request signal, this alarm occurs.
Table 429.

SRVO-022 Troubleshooting Procedure

Troubleshooting Procedure
1. Exchange the axis control board-to-servo amplifier cable between the affected axis and a knowngood axis. Be sure to switch both ends of the cables.
Does the fault message change to indicate a different axis?
YES  replace the bad cable.
NO  continue
2.Replace the axis control board. If the problem continues, replace the affected servo amplifier.

Line No. Reference


Chapter 13
09-01 thru 09-09
08-01 thru 08-18
10-10 thru 10-18

4. TROUBLESHOOTING
MARMMTRBL02303E

456

4.4.16
SRVO-023
ER_SVAL1
Stop Error Excess
(Group:i Axis:j)

The axis position is too far from its commanded position when the robot is
stopping, or the robot is stopped and it will not move. The torque
necessary to decelerate an overloaded motor could cause this alarm to
occur.

Table 430.

SRVO-023 Troubleshooting Procedure

Troubleshooting Procedure

Line No. Reference


Chapter 13

1. Is the load over the specification?


If it is over  Reduce the load.
2. Check for a binding axis. Repair if required.
If the load is within the specification and the axes are not binding  Go to step 3.
3. Is the three phase input voltage lower than the FANUC specification (170V ~253V)?
If it is lower  The maximum torque of the motor decreases. Increase the input voltage within the
rated voltage. Check transformer TF1 for proper tap settings.

08-24, 25, 26
09-23, 24, 25
10-23, 24, 25

4. Replace the servo amplifier.


If the alarm occurs again  Go to step 4.
5. Replace the motor.

4.4.17
SRVO-024
ER_SVAL1
Move Error Excess
(Group:i Axis:j)

4.4.18
SRVO-026
ER_WARN
Motor Speed Limit
(Group:i Axis:j)

4.4.19
SRVO-027
ER_WARN
Robot Not Mastered
(Group:i Axis:j)

The servo error is too big when the robot is moving, or the robot moves
when it is supposed to be stopped.
Remedy: Same as SRVO-023, Stop Error Excess.

The motor cannot rotate as fast as the calculated speed required for the
current motion
Remedy: Even though this is just a warning, every attempt should be
made to eliminate this error by modifying the programmed speed or
motion.

The system variable $master_done is set to FALSE.


Remedy: Master the robot.

4. TROUBLESHOOTING

457

MARMMTRBL02303E

4.4.20
SRVO-033
ER_WARN
Robot Not Calibrated
(Group:i Axis:j)

4.4.21
SRVO-035
ER_WARN
Joint Speed Limit
(Group:i Axis:j)

4.4.22
SRVO-036
Imposition Time Over
(Group:i Axis:j)

The system variable $calibrate is set to FALSE.


Remedy: Calibrate the robot.

Joint cannot rotate as fast as the calculated speed required for the current
motion.
Remedy: Even though this is just a warning, every attempt should be
made to eliminate this error by modifying the programmed or motion
speed.

The robot is not in position for the specified period, or the servo error is in
excess of the commanded position when the robot is stopping, or the robot
is stopped and it will not move. The torque necessary to decelerate an
overloaded motor could cause this alarm to occur.

Table 431.

SRVO-036 Troubleshooting Procedure

Troubleshooting Procedure

Line No. Reference


Chapter 13

1. Is the load over the specification?


If it is over  Reduce the load.
2. Check for a binding axis. Repair if required.
If the load is within the specification and the axes are not binding  Go to step 3.
3. Is the three phase input voltage to the servo amplifier lower than the FANUC specification
(170V ~253V)?
If it is lower  Check transformer TF1 for the proper tap setting.
4. Replace the servo amplifier.
If the alarm occurs again  Go to step 4.

08-24, 25, 26
09-23, 24, 25
10-23, 24, 25

5. Replace the motor.

4.4.23
SRVO-037
ER_SVAL1
IMSTP Input
(Group:i Axis:j)

IMSTP (immediate stop) UOP input asserted.


Remedy: If using a UOP, determine the cause and repair. If not using
UOP, select the I/O menus and zero UOP mapping.

4. TROUBLESHOOTING
MARMMTRBL02303E

458

4.4.24

When the controller was powered up, one or more of its axes was at a
different position from when it was powered off. This might occur when a
motor is replaced or when a CPU from one controller is installed in
another.

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

Remedy: Perform the following procedure:

Table 432.

SRVO-038 Troubleshooting Procedure

Troubleshooting Procedure

Line No. Reference


Chapter 13

1. Press MENUS.
2. Select SYSTEM.
3. Press F1, [TYPE].
4. Select System Variables.
5. Move the cursor to $MCR.
6. Press ENTER.
7. Move the cursor to $SPC_RESET.
8. Press F4, TRUE. The display will reset to false. This is normal.
9. 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.

4.4.25
SRVO-042
ER_SVAL2
MCAL Alarm
(Group:i Axis:j)

The servo amplifier magnetic contactor (MCC) is welded closed. If the


contact of the magnetic contactor is already closed when the contactor is
turned on, this alarm circuit regards the contact as welded closed and the
MCC alarm occurs.

Table 433.

SRVO-042 Troubleshooting Procedure

Troubleshooting Procedure
1. Does this alarm occur with SRVO-049?
If SRVO-049 occurs  Check for the absence of input three-phase voltage to the servo amplifer.
Correct as necessary.
If SRVO-049 does not occur  Go to step 2
2. Does this alarm occur with the OH1 alarm?
If OH1 alarm occurs  Turn off the controller power for fifteen seconds and turn it on again. If still
present, remove and replace the connector CN1 or CN2 of the problem axis and check its
associated cable and connector at the axis module.
If OH1 alarm does not occur  Go to step 3.
3. Replace the servo amplifier.

Line No. Reference


Chapter 13
08-24, 25, 26
09-23, 24, 25
10-23, 24, 25

4. TROUBLESHOOTING
MARMMTRBL02303E

4.4.26
SRVO-041
MOFAL Alarm
(Group:i Axis:j)

459

The motion command after the ramping algorithm in the servo software
exceeded one word. Contact the FANUC Robotics Hotline for more
information. DO NOT INCLUDE IN MANUAL!!!!!!

4. TROUBLESHOOTING
MARMMTRBL02303E

460

4.4.27
SRVO-043
ER_SVAL2
DCAL Alarm
(Group:i Axis:j)

The regenerative energy produced by the motor exceeded the specification.


NOTE Energy feedback from motor to the amplifier is called regenerative
energy. This occurs when the axis is being slowed down. The amplifier
discharges this energy by converting it to heat energy through the
discharge resistor. If the charged energy exceeds the discharged energy,
this alarm occurs.
Remedy: Check the LED of the amplifier, then perform the following
troubleshooting procedure.
Table 434.

SRVO-043 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13
Print Reference

1. Is 4 or 5 indicated on the servo amplifier 7-segment display?


If indicated  Go to step 2 if 4 is indicated.
Go to step 3 if 5 is indicated.
If not indicated  Check for short to ground or an open circuit in the PWMC line of the specified
axis between the axis control printed circuit board and servo amplifier (connector JV-1 7). Swap
the axis control printed circuit board.
2. A 4 is indicated (DCSW alarm) when the regenerative transistor is on continuously for one
second or longer. Reduce the load of the robot.
If the error still exists  Replace the servo amplifier.
3. 5 is indicated (DCOH alarm). The DCOH alarm is caused when the regenerative resistor
overheats and is sensed by the thermostat or the thermostat in transformer TF1 opens.
If the average regenerative energy is excessive  This alarm occurs when the
acceleration/deceleration frequency is high or gravity energy at the axis is large. Relax the
operating conditions.
For robots with extended axes: When a separate regenerative discharge unit or power
transformer for the servo controller is used, check the wiring for the thermostat according to the
connection diagrams for proper wiring.
If the thermostat is incorrectly wired or is defective  When a separate regenerative discharge
unit or power transformer for the servo controller is used, check the wiring for the thermostat
according to the connection diagrams.

08-03, 09-03
11-03, 12-03
11-37, 12-37
08-37, 09-37
11-39, 12-39
08-39, 09-39

4. TROUBLESHOOTING

461

MARMMTRBL02303E

4.4.28
SRVO-044
ER_SVAL2
HVAL Alarm
(Group:i Axis:j)

The DC voltage on the main power circuit of the servo amplifier exceeded
specification.
Remedy: Check the three-phase voltage to the servo amplifier input. It
should not exceed 253 VAC phase-to-phase. Check the cabling between
the servo amplifier and the axis control printed circuit board if no alarm is
indicated on the servo amplifier 7-segment display.
If the problem still exists, perform the following troubleshooting
procedure:
Table 435.

SRVO-044 Troubleshooting Procedure

Troubleshooting Procedure
1. Is the voltage of the threephase input servo to the amplifier higher than 253 VAC?
If it is higher  Check transformer TF1 taps.

Chapter 13
Print Reference
08-24, 25, 26
09-23, 24, 25
01-38

2. Is the load of the robot within the specification? This alarm can be caused by the charge of the
regenerative energy when the load exceeds the specification.
If it exceeds the specification  Reduce the load of the robot.
3. Check the connection of the Separated Regenerative Discharge Unit. If one is being used, it should
be wired across terminals 17 and 19 of T1 and connected to terminals 1 and 2 of T3 on the discharge
unit. There should be no jumper connecting terminals 17 and 18.
If connected incorrectly  Connect correctly.
4. Check the resistance of the built-in regenerative resistor of the amplifier or that of the separate
regenerative resistor (14 ohms) across terminals 17 and 19 of T1.
If the value of the resistance is incorrect  Replace the regenerative discharge unit or servo
amplifier.
5. For robots with extended axes: The operating condition might not be appropriate for the
specification of the motor or the amplifier.
If this occurs  Relax the operating condition.
6. Replace the servo amplifier.

11-39

4. TROUBLESHOOTING
MARMMTRBL02303E

462

4.4.29

The current in the main power circuit of the servo amplifier exceeded
specification. The servo amplifier LED should display 8, 9, or 6.

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

Remedy: If no alarm is indicated on the servo amplifier 7-segment


display, check the cabling between the servo amplifier (CN1) and the axis
control printed circuit board (JV1-10).
If the problem still exists, perform the following troubleshooting
procedure:
Table 436.

SRVO-045 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13
Print Reference

1. Disconnect the motor power lines from the amplifier terminals and turn on the power. This alarm will
re-occur if
 The transistor module (TM) is defective.
 Resistor R3 has opened or raised resistance.
 The servo amplifier is defective.
If an HCAL alarm occurs  Replace these components as necessary or replace the servo
amplifier.

08-24, 25, 26
09-23, 24, 25
10-23, 24, 25

2. Remove the motor power lines from the amplifier terminals and check the continuity between GND
and each of the lines U, V, and W that go to the motor.
If any are short-circuited  Go to step 3.

08-24, 25, 26
09-23, 24, 25
10-23, 24, 25

If all are not shorted  Go to step 4.


3. Remove the power lines from the motor connectors (J1-6) and recheck the continuity between GND
and each of the lines U, V, and W to the robot motor.
If any are shorted  The motor is defective. Replace the motor.

08-24, 25, 26
09-23, 24, 25
10-23, 24, 25

If all are open  The power lines to the motor are defective. Replace the cable.
4. Remove the motor power lines from the amplifier terminals and measure the resistance
between U-V, V-W, and W-U on the servo amplifier using a measuring instrument sensitive
enough to detect small resistances.
If the three measured values are the same  Go to step 5.

08-24, 25, 26
09-23, 24, 25
10-23, 24, 25

If the three measured values are different  Go to step 6.


5. Remove the power lines from the motor connectors and remeasure the resistance between U-V,
V-W, and W-U using a measuring instrument sensitive enough to detect small resistances.
If the three measured values are the same  The power lines are defective. Replace the cable.

08-24, 25, 26
09-23, 24, 25
10-23, 24, 25

If the three measured values are different  The motor is defective. Replace the motor.
6. Replace the axis control printed circuit board.
If the alarm occurs again  Go to step 7.
7. Replace the servo amplifier.
8. Replace the serial pulse coder on the motor.
9. Check whether you are using the robot under conditions that exceed the specification. For
example, load, duty, and so forth. If there is no mechanical reason (binding and so forth) to cause this
alarm, this alarm might occur under conditions that exceed the specification. If you are using the robot
over the specification, relax the operating conditions.

08-12, 13

4. TROUBLESHOOTING

463

MARMMTRBL02303E

4.4.30
SRVO-046
ER_SVAL2
OVC Alarm
(Group:i Axis:j)

The average current calculated by the servo software exceeded


specification.
Remedy: Reduce the load on the robot.
If the problem still exists, perform the following troubleshooting
procedure:
Table 437.

SRVO-046 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13
Print Reference

1. Is the three-phase AC input power to the servo amplifier lower than 200 VAC?
If it is lower or missing  Check transformer TF1 taps and fuses.

08-24, 25, 26
09-23, 24, 25
10-23, 24, 25
01-15, 16

2. Replace the axis control printed circuit board.


If the alarm occurs again  The motor is defective.

08-11, 12, 13

4. TROUBLESHOOTING
MARMMTRBL02303E

464

4.4.31
SRVO-047
ER_SVAL2
LVAL Alarm
(Group:i Axis:j)

The DC voltage on the main power circuit of the servo amplifier is lower
than the specification even though the MCC is on.
Remedy: If no alarm is indicated on the servo amplifier LED, check the
cabling between the servo amplifier and the axis control printed circuit
board.
If the problem still exists, perform the following troubleshooting
procedure:
Table 438.

SRVO-047 Troubleshooting Procedure

Troubleshooting Procedure
1. Does the LED of the amplifier indicate 2?
a. Check for 200VAC input power to terminals 13 and 14 of the servo amplifier. If low or missing,
check transformer TF1 taps and fuses.

Chapter 13
Print Reference
08-23, 24, 25
09-23, 24, 25
10-23, 24, 25

b. If 200VAC is present, replace the servo amplifier.


2. Does the LED of the amplifier indicate 3? A 3 indicates the DC current in the main power circuit
is too low
a. Check the three-phase 200VAC input voltage to the servo amplifier.
If the voltage is lower than 200VAC Check the transformer TF1 taps and fuses.
b. Did the circuit breaker on the servo amplifier trip? (If a circuit breaker trips, this alarm will occur.)
If a circuit breaker trips  Turn on the breaker. If it trips again, replace the servo amplifier.
3. Does the LED of the amplifier indicate a 7? This alarm could occur when the contact of the
magnetic contactor is melted (welded together).
Refer to the SRVO-042 MCAL Alarm.

08-23, 24, 25
09-23, 24, 25
10-23, 24, 25

4. TROUBLESHOOTING

465

MARMMTRBL02303E

4.4.32
SRVO-049
ER_SVAL2
OHAL1 Alarm
(Group:i Axis:j)

The servo amplifier overheated. Servo amplifier LED indicates a 6.


This alarm indicates that the thermal switch mounted on the PC board of
the specified axis has opened.
Remedy: Check the fans and the heat exchange unit for proper operation.
If the problem still exists, perform the following troubleshooting
procedure:
Table 439.

SRVO-049 Troubleshooting Procedure

Troubleshooting Procedure
1. If the servo amplifier 7-segment display shows , check the cabling between the servo amplifier
(CN1) and axis control module (JV1-6).

Chapter 13
Print Reference
08-01 thru 08-08
09-01 thru 09-09
10-10 thru 10-18

2. Relax the operating condition.


If the alarm no longer occurs  The operating condition of the robot exceeded the specification.
3.Replace the servo amplifier.

4.4.33
SRVO-050
ER_SVAL1
CLALM Alarm
(Group:i Axis:j)

The servo software detected a disturbance torque that was too high or a
collision occurred and tripped a collision detection alarm.
Remedy: Reset the robot by using the teach pendant RESET button and
jog the robot away from obstructions.
If the problem still exists, perform the following troubleshooting
procedure:
Table 440.

SRVO-050 Troubleshooting Procedure

Troubleshooting Procedure
1. Does the load exceed the specifications? (When the robot moves over the specifications, the estimated disturbance torque might become larger and this alarm could occur.)
If the load exceeds the specifications Lower the load to within the specifications.
2. Is the three-phase AC input voltage to the servo amplifier lower than the rated voltage (200VAC)?
If it is lower  Check transformer TF1 taps and fuses.

3. Replace the servo amplifier.

Chapter 13
Print Reference

08-23, 24, 25
09-23, 24, 25
10-23, 24, 25
01-38

4. TROUBLESHOOTING
MARMMTRBL02303E

466

4.4.34

The feedback current is abnormal.

SRVO-051
ER_SVAL2
CUER Alarm
(Group:i Axis:j)
Table 441.

SRVO-051 Troubleshooting Procedure

Troubleshooting Procedure
1. Replace the axis control printed circuit board.
If the alarm still occurs  Go to step 2.

Chapter 13
Print Reference
08-11, 12, 13

2. Replace the servo amplifier. If the alarm continues, go to step 3.


3. Replace the pulse coder and master the robot.

4.4.35

The clock for the rotation counter in the pulse coder is abnormal.

SRVO-061
ER_SVAL2
CKAL Alarm
(Group:i Axis:j)
Table 442.

SRVO-061 Troubleshooting Procedure

Troubleshooting Procedure
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm?
YES  disregard SRVO_061 and refer to the remedy of any of the other three alarms.
If no alarms occur  Replace the pulse coder on the specified axis and master the robot.

Chapter 13
Print Reference

4. TROUBLESHOOTING

467

MARMMTRBL02303E

4.4.36

The battery voltage for the pulse coders is zero volts.

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

Table 443.

SRVO-062 Troubleshooting Procedure

Troubleshooting Procedure
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm?
YES  disregard the BZAL alarm and refer to the procedure for the other alarm (SRVO_68
SRVO_70).
NO  Continue
2. Did this alarm message list only one axis?
YES  Check the battery cable for the pulse coder of the axis listed in the alarm message.
Reconnect, repair, or replace as necessary. Go to Step 4.
NO  Continue
3. Press the teach pendant emergency stop button. Turn the controller on. Check the batteries behind
the black plastic hatch in the base of the controller.
Are the batteries ok?
YES  Repair or replace the battery compartment cable. Go to Step 4.
NO  Replace the batteries. Go to Step 4.
4. a. Press MENUS.
b. Select SYSTEM.
c. Press F1, [TYPE].
d. Select System Variables.
e. Move the cursor to $MCR.
f. Press ENTER.
g. Move the cursor to $SPC_RESET.
h. Press F4, TRUE. The display will reset to false. This is normal.
i. 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.

Chapter 13
Print Reference

4. TROUBLESHOOTING
MARMMTRBL02303E

468

4.4.37

The built-in rotation counter on the pulse coder is abnormal.

SRVO-063
ER_SVAL2
RCAL Alarm
(Group:i Axis:j)
Table 444.

SRVO-063 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13
Print Reference

1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm?
YES  disregard SRVO_063 and refer to the remedy of any of the other three alarms.
NO  Replace the pulse coder on the specified axis and master the robot.

4.4.38
SRVO-064
ER_SVAL2
PHAL Alarm
(Group:i Axis:j)

The relationship between the analog signals on the pulse coder are
abnormal.

Table 445.

SRVO-064 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13
Print Reference

1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm?
YES  disregard SRVO_064 and refer to the remedy of any of the other three alarms.
NO  Replace the pulse coder on the specified axis and master the robot.

4.4.39

The pulse coder batteries are low.

SRVO-065
ER_WARN
BLAL Alarm
(Group:i Axis:j)
Table 446.

SRVO-065 Troubleshooting Procedure

Troubleshooting Procedure
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm?
YES  disregard SRVO_065 and refer to the remedy of any of the other three alarms.
NO  Replace the APC backup batteries. Remaster the robot if necessary.
NOTE Replace the battery as soon as possible when this alarm occurs, otherwise, if the battery voltage goes to zero volts, the robot will require remastering.

Chapter 13
Print Reference

4. TROUBLESHOOTING

469

MARMMTRBL02303E

4.4.40

The pulse coder ROM checksum data are abnormal.

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

Table 447.

SRVO-066 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13
Print Reference

1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm?
YES  disregard SRVO_066 and refer to the remedy of any of the other three alarms.
If no alarms occur  Replace the pulse coder on the specified axis and master the robot.

4.4.41

The pulse coder overheated.

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

Table 448.

SRVO-067 Troubleshooting Procedure

Troubleshooting Procedure
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm?
YES  disregard SRVO-067 and refer to the remedy of any of the other three alarms.
2. Does the operating condition (load, duty) exceed the specifications?
If the operating condition exceeds the specifications  Relax the operating condition within the
specification. (Reduce the load, change the program, etc.)
3. Turn off the controller and when the temperature of the motor returns to normal, turn it back on.
If the alarm immediately occurs again  The built-in thermostat in the pulse coder is defective.
Replace the pulse coder.
If the alarm occurs again, but not immediately  the motor is generating too much heat. Replace
the motor.

Chapter 13
Print Reference
07-22

4. TROUBLESHOOTING
MARMMTRBL02303E

470

4.4.42
SRVO-068
ER_SVAL2
DTERR Alarm
(Group:i Axis:j)

The axis control printed circuit board sent the serial data request signal to
the pulse coder, but did not receive serial data from the pulse coder.

Table 449.

SRVO-068 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13
Print Reference

1. Check for connection and continuity of the feedback cable. Repair or replace if necessary.
If the alarm occurs again  Go to step 2.

08-16, 17, 18

2. Replace the axis control board.


If the alarm occurs again  Go to step 3.

08-01 thru 10

3. Replace the pulse coder and master the robot.

4.4.43
SRVO-069
ER_SVAL2
CRCERR Alarm
(Group:i Axis:j)

The serial data from the pulse coder changed during communication to the
axis control printed circuit board.
Refer to the SRVO_068 remedy.

4. TROUBLESHOOTING

471

MARMMTRBL02303E

4.4.44
SRVO-070
ER_SVAL2
STBERR Alarm
(Group:i Axis:j)

4.4.45
SRVO-071
ER_SVAL2
SPHAL Alarm
(Group:i Axis:j)

The communication stop and start bits are abnormal.


Refer to the SRVO-068 remedy.

The feedback velocity exceeds the specifications.


If the problem still exists, perform the following troubleshooting
procedure:

Table 450.

SRVO-071 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13
Print Reference

1. Does this alarm occur with any other alarm?


If another alarm occurs  This alarm is caused by another alarm of the serial pulse coder. Refer to
the other alarm for details.
2. Reduce the load within the specifications.

4.4.46

Line Tracking Overflow Error.

SRVO-081
ER_WARN
EROFL Alarm
(Track encoder:n)
Table 451.

SRVO-081 Troubleshooting Procedure

Troubleshooting Procedure
1. Check the connection between the controller and the line tracking device (absolute encoder or
pulse generator).
2. Check that the line speed is within the FANUC specification.
If the line speed is not within the specification  Relax the line speed.

Chapter 13
Print Reference

4. TROUBLESHOOTING
MARMMTRBL02303E

472

4.4.47
SRVO-082
ER_WARN
DAL Alarm
(Track encoder:n)

Line Tracking Pulse coder is disconnected.


Remedy: Check axis control printed circuit board for proper line tracking
cable connections.
If the problem still exists, perform the following troubleshooting
procedure:

Table 452.

SRVO-082 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13
Print Reference

1. Replace the axis control printed circuit board.


2. Replace the pulse coder.

4.4.48
SRVO-083
ER_WARN
CKAL Alarm
(Track encoder:n)

4.4.49
SRVO-084
ER_WARN
BZAL Alarm
(Track encoder:n)

4.4.50
SRVO-085
ER_WARN
RCAL Alarm
(Track encoder:n)

4.4.51
SRVO-086
ER_WARN
PHAL Alarm
(Track encoder:n)

The clock for the rotation counter in the line tracking pulse coder is
abnormal.
Remedy: Refer to SRVO-061 remedy.

The battery voltage for the line tracking pulse coder is zero volts.
Remedy: Refer to SRVO-062 remedy.

The built-in rotation counter on the line tracking pulse coder is abnormal.
Remedy: Refer to SRVO-063 remedy.

The relationship between the analog signals on the line tracking pulse
coder are abnormal.
Remedy: Refer to SRVO-064 remedy.

4. TROUBLESHOOTING

473

MARMMTRBL02303E

4.4.52
SRVO-087
ER_WARN
BLAL Alarm
(Track encoder:n)

4.4.53
SRVO-088
ER_WARN
CSAL Alarm
(Track encoder:n)

4.4.54
SRVO-089
ER_WARN
OHAL2 Alarm
(Track encoder:n)

4.4.55
SRVO-090
ER_WARN
DTERR Alarm
(Track encoder:n)

4.4.56
SRVO-091
ER_WARN
CRCERR Alarm
(Track encoder:n)

4.4.57
SRVO-092
ER_WARN
STBERR Alarm
(Track encoder:n)

4.4.58
SRVO-093
ER_WARN
SPHAL Alarm
(Track encoder:n)

The line tracking pulse coder batteries are low.


Remedy: Refer to SRVO-065 remedy.

The line tracking pulse coder ROM checksum data is abnormal.


Remedy: Refer to SRVO-066 remedy.

The line tracking pulse coder overheated.


Remedy: Refer to SRVO-067 remedy.

The axis control printed circuit board sent the request signal, but did not
receive serial data from the line tracking pulse coder.
Remedy: Refer to SRVO-068 remedy.

The serial data from the line tracking pulse coder changed during
communication to the axis control printed circuit board.
Remedy: Refer to SRVO-069 remedy.

The communication stop and start bits for line tracking axis are abnormal.
Remedy: Refer to SRVO-070 remedy.

The feedback velocity exceeds the specification for line tracking axis.
Remedy: Refer to SRVO-071 remedy.

MARMMTRBL02303E

REPLACING A FUSE
51
If a fuse blows in the control unit, eliminate the cause, then replace the
fuse.

5.1
MULTI-TAP
TRANSFORMER

F2, F2, and F3 : Fuses for three-phase 200 VAC servo power
F4 and F5
: Fuses for 100 VAC
Refer to Table 51.
Table 51.

Multi-Tap Transformer Fuses

Fuse Number

F1, F2, F3
F1, F2, F3

F4, F5
F4, F5

F6, F7

Machine
S-420, S-500,
S-800, S-900,
M-500
P-155
ARC Mate SR.,
S-700, M-400,
L-1000, S-10
ARC Mate, Arc
Mate 100, A-510,
S-5
P-155
S-420, S-500,
S-800, S-900,
M-500
ARC Mate Sr.,
ARC Mate, S-5,
Arc Mate 100,
S-10, L-1000,
S-700, M-400,
A-510
S-420, 3-servo
amplifier
configuration

Rated
Current
30A

A60L-0001-0042#JG130

30A
20A

A60L-0001-0042#JG130
A60L-0001-0042#JG120

10A

A60L0001-0042#JG1-10

7.5A
7.5A

A60L-0001-0101#P475H
A60L-0001-0101#P475H

5A

A60L-0001-0101#P450H

10A

A60L-0001-0042#JG1-10

Part Number

5. REPLACING A FUSE
MARMMTRBL02303E

52
Figure 61. Replacing a Fuse of the Transformer Unit

Fuse

Fuse

Fuse

Fuse

Fuse

Fuse

Fuse

WARNING
Before replacing a fuse, turn power off and lock out the
controller.

5. REPLACING A FUSE

53

MARMMTRBL02303E

5.2
SERVO AMPLIFIER

FUSE 1
: Fuse for control power supply
Part number: A60L-0001-0175#3.2A
FUSE 2 and 3 : Fuse for fan motors (only for one axis servo amplifier,
A06B-6066-H008)
Part number: A60L00010101#P405
Figure 62. Replacing the Fuse of a Servo Amplifier

F1

F2
F3

LED
Terminal board T1
Circuit breaker

5. REPLACING A FUSE
MARMMTRBL02303E

54

5.3
POWER SUPPLY UNIT

F1 and F2
F3
F4
F5

:
:
:
:

Fuses for AC input


Fuse for +24V
Fuse for +24E
Fuse for auxiliary power supply

Table 52.

Power supply unit for four-slot backplane

Fuse number
F1, F2
F3
F4
F5
Table 53.

Rated current
7.5A
3.2A
5A
0.3A

Part Number
A60L-0001-0245#GP75
A60L-0001-0075#3.2
A60L-0001-0046#5.0
A60L-0001-0290#LM03

Power supply unit for six-slot backplane

Fuse number
F1, F2
F3
F4
F5

Rated current
10A
5A
5A
0.3A

Part Number
A60L-0001-0245#G100
A60L-0001-0075#5.0
A60L-0001-0046#5.0
A60L-0001-0290#LM03

Figure 63. Replacing a Fuse of the Power Supply Unit


PSU

F5: 0.3A fuse for


auxiliary
power supply
Battery cover

PSU

F1 and F2:
Fuses for AC input
10-A for 6-slot backplane
7.5A for 4-slot backplane
PIL: green LED
for indicating the AC
power supply status

Battery

ALM: Red LED


for indicating
an alarm

F4:5Afuse for +24E


F3: Fuse for +24V
5-A slow blow for
6-slot backplane
3.2A slow blow for
4-slot backplane

(with battery cover removed)

5. REPLACING A FUSE

55

MARMMTRBL02303E

5.4
EMERGENCY STOP
CONTROL PC BOARD

FUSE
: 5.0 A brake circuit fuse
Part number: A60L-0001-0046#5.0
FUSE
: F1, F2, 3.2A Manual brake circuit fuse
Part number: A60L-0001-0175#3.2A
Figure 64. Replacing the Fuse on the Emergency Stop Control PC Board

F1
F2
FUSE

5. REPLACING A FUSE
MARMMTRBL02303E

56

Figure 65. Replacing the Fuse on the Emergency Stop Control PC Board
EMG
PCB

Fuse

5.5
PURGE POWER
SUPPLY
A05B2047C181

FUSE: F11, F12, 3.2A AC Input Line Fuses


Part Number: A60L00010175#3.2

5. REPLACING A FUSE

57

MARMMTRBL02303E

Figure 66. Purge Power Supply

Cover

F12
F11
Purge Power Supply

5. REPLACING A FUSE
MARMMTRBL02303E

58

5.6
PROCESS
INPUT/OUTPUT PC
BOARDS AA, AB, CA,
CB, AND DA

FUSE 1
: 2.0-A fuse for +24V
Part number: A60L-0001-0046#2.0
Figure 67. Replacing the Fuse of the Process Input/Output PC Board AA, AB,
CA, CB, or DA

Fuse

Fuse

Process input/output
PC boards AA and AB

Process input/output
PC boards CA, CB and DA

5. REPLACING A FUSE

59

MARMMTRBL02303E

5.7
PROCESS
INPUT/OUTPUT PC
BOARDS BA AND BB

FUSE 1 to 8 : 6.3 A fuses for +24V


Part number: A60L-0001-0046#6.3
Figure 68. Replacing the Fuse of the Process Input/Output PC Board BA or BB

Fuse

Process input/output PC boards BA and BB

5. REPLACING A FUSE
MARMMTRBL02303E

510

5.8
MODULAR I/O UNIT

The modules listed below have built-in fuses. If a fuse blows, remove the
cause, then replace the fuse with a spare.
Table 54.

Modular I/O Unit

Module
Interface module A1F01A
Interface module A1F01B
Output module with 8 DC
points AOD08C
Output module with 8 DC
points AOD08D
Output module with 5 AC
points AOA05E
Output module with 8 AC
points AOA08E
Output module with 12 AC
points AOA12F

Indication
PWR is off
PWR is off
F is on

Rating
3.2A
3.2A
5A

Fuse Specification
A60L-0001-0290=LN32
A60L-0001-0290=LM32
A60L-0001-0260=5R00

F is on

5A

A60L-0001-0260=5R00

F is on

3.15A

A60L-0001-0276=3.15

F is on

3.15A

A60L-0001-0276=3.15

F is on

3.15A

A60L-0001-0276=3.15

The fuses are on the PC boards in the modules.

5. REPLACING A FUSE

511

MARMMTRBL02303E

5.9
AC OUTLET UNIT

FUSE
: 2.0 A fuse for 100 VAC
Part number: A60L-0001-0101#P420H
Figure 69. Replacing the Fuse of the AC Outlet Unit

Fuse

MARMMTRBL02303E

BRAKE RELEASE
61
To perform some troubleshooting and error recovery procedures, you
might have to release the brakes. Use Procedure 61 to release the brakes.

Procedure 61

Releasing the Brakes

NOTE Clear all E-stops before proceeding.


Step

1 Press and release the EMERGENCY STOP button.


NOTE Do not press RESET. The servos must be off to release the
brakes.
2 Press MENUS.
3 Select NEXT PAGE.
4 Select SYSTEM.
5 Press F1, [TYPE].
6 Select Brake Ctrl. See the following screen for an example.
SYSTEM Brake Crtl
AXIS
SELECTED
1
NO
2
NO
3
NO
4
NO
5
NO
6
NO
7
NO
8
NO
9
NO

JOINT

10%

BRAKE STATE
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED

[TYPE] ENGSEL RELSEL

YES

NO

>

7 Highlight the number of the axis you want to release or engage.

WARNING
Releasing a brake could cause the robot to move. To
STOP the robot immediately, press the EMERGENCY STOP
button or press F2, ENGSEL to engage the brake.

6. BRAKE RELEASE
MARMMTRBL02303E

62
8 To release or engage a single brake:

a Select an axis to be released or engaged; press F4, YES.


NOTE To release axis 3 you must select both axis 2 and axis 3.
b Release the brake on the selected axis; hold down the shift key
and press F3, RELSEL.
c Engage the brake on the selected axis; press F2, ENGSEL.
9 To release ALL brakes:
a Press NEXT, > to display the next page of function keys.
SYSTEM Brake Crtl
AXIS
SELECTED
1
NO
2
NO
3
NO
4
NO
5
NO
6
NO
7
NO
8
NO
9
NO

JOINT

10%

BRAKE STATE
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED

[TYPE] ENGALL RELALL

GROUP

>

WARNING
The following step will release all brakes even though they
have not been selected by pressing F4, YES. This could
result in robot movement. Be prepared for all brakes to be
released, as personnel could be injured, or equipment
damaged.

b Hold down the SHIFT key and press F3, RELALL to release all
of the brakes.
10

To engage ALL brakes:


a Press the F2, ENGALL to engage all of the brakes.

11 When you are finished, press RESET.


NOTE If you are unable to jog the robot after releasing the brakes, press
and release the EMERGENCY STOP button, and then press RESET to
clear the fault.

MARMMTRBL02303E

CONTROLLING I/O
71
Controlling I/O allows you to test the I/O in your system for proper
function during testing operation. Controlling I/O includes




Forcing outputs
Simulating inputs and outputs
SOP I/O

7. CONTROLLING I/O
72

MARMMTRBL02303E

7.1
FORCING OUTPUTS

Forcing outputs is turning output signals on or off. Outputs can also be


forced within a program using I/O instructions. Use Procedure 71 to
force outputs outside of a program.
Refer to the application Specific Setup and Operations Manual for
information on using program I/O instructions.
NOTE RO[1] and RO[2] control HAND 1, and RO[3] and RO[4] control
HAND 2.

Procedure 71
Condition
Step

Forcing Outputs


The outputs you are forcing have been configured.

1 Press MENUS.
2 Select I/O.
3 Press F1, [TYPE].
4 Select the type of output you want to force: digital, analog, group,
robot, UOP, or SOP.

WARNING
Forcing digital outputs causes connected devices to
function. Make certain you know what the digital output is
connected to and how it will function before forcing it;
otherwise, injury to personnel or damage to equipment can
occur.

7. CONTROLLING I/O
73

MARMMTRBL02303E

For digital outputs for example, you will see a screen similar to the
following.
I/O Digital Out
#
SIM STATUS
DO[
1] U
OFF
DO[
2] U
ON
DO[
3] U
OFF
DO[
4] U
OFF
DO[
5] U
OFF
DO[
6] U
ON
DO[
7] U
OFF
DO[
8] U
OFF
DO[
9] U
OFF
DO[ 10] U
OFF
[ TYPE ]
DO[

4] U

OFF

CONFIG

WORLD
[
[
[
[
[
[
[
[
[
[

IN/OUT

10%
]
]
]
]
]
]
]
]
]
]

SIMULATE UNSIM

5 Move the cursor to the STATUS of the output you want to force.
6 Press the function key that corresponds to the value you want.
For digital, robot, UOP, and SOP outputs, press

AO[

4] U

12H

F4 for ON

F5 for OFF

For analog and group outputs, move the cursor to value, and use the
numeric keys to type the value. Value entry is always in decimal
format. To change the displayed value from decimal to hexadecimal,
press F4, FORMAT. Hexadecimal numbers are followed by an H
on the screen.

7. CONTROLLING I/O
74

MARMMTRBL02303E

7.2
SIMULATING INPUTS
AND OUTPUTS

Procedure 72
Condition
Step

Simulating inputs and outputs is forcing inputs and outputs without signals
entering or leaving the controller. Simulate I/O to test program logic and
motion when I/O devices and signals are not set up. You can simulate
digital, analog, and group I/O only; you cannot simulate robot, UOP, or
SOP I/O. When you are finished simulating a signal, you can reset, or
unsimulate, it. Use Procedure 72 to simulate and unsimulate I/O.
Simulating and Unsimulating Inputs and Outputs


The input or output has been configured.

1 Press MENUS.
2 Select I/O.
3 Press F1, [TYPE].
4 Select the type of input or output you want to simulate: digital,
analog, or group.
For digital inputs for example, you will see a screen similar to the
following.
I/O Digital Input
#
SIM STATUS
DI[
1] U
OFF
DI[
2] S
ON
DI[
3] U
OFF
DI[
4] U
OFF
DI[
5] U
OFF
DI[
6] U
ON
DI[
7] U
OFF
DI[
8] S
OFF
DI[
9] U
OFF
DI[ 10] U
OFF
[ TYPE ]

CONFIG

WORLD
[
[
[
[
[
[
[
[
[
[
IN/OUT

10%
]
]
]
]
]
]
]
]
]
]

SIMULATE UNSIM

5 If you simulate a signal, you can force the status by setting it to a


value. When the signal is unsimulated, its actual status is displayed.
DO[

4]

OFF

6 Move the cursor to the SIM column of the signal you want to simulate.


U means the signal is not simulated or unsimulated.

S means the signal is simulated.

7 Simulate or unsimulate the signal.




To simulate, press F4, SIMULATE.

To unsimulate, press F5, UNSIM.

8 To unsimulate all simulated signals, press FCTN and then select


UNSIM ALL I/O.

7. CONTROLLING I/O

75

MARMMTRBL02303E

7.3
SOP I/O STATUS

The I/O SOP screen indicates the status of the standard operator panel
signals. SOP input signals (SI) and SOP output signals (SO) correspond
to internal controller software Panel Digital Input signals (PDI) and Panel
Digital Output signals (PDO). Refer to Table 71 and Table 72.
Table 71.

SI

PDI

EMERGENCY
STOP

FAULT RESET

REMOTE

HOLD

CYCLE START

715

816

Standard Operator Panel Input Signals

Function

NOT USED

Description
Input signal is normally turned ON, indicating that the EMERGENCY STOP button is
not being pressed.
Input signal is normally turned OFF, indicating that the FAULT RESET button is not
being pressed.
Input signal is normally turned OFF, indicating that the controller is not set to remote.
Input signal is normally turned ON, indicating that the HOLD push button is not
being pressed.
Input signal is normally turned OFF, indicating that the CYCLE START push button
is not being pressed.
Open for additional PDI.

Table 72.

Standard Operator Panel Output Signals

SO

PDO

Function

Description

REMOTE LED

Output signal indicates the controller is set to remote.

CYCLE START

Output signal indicates the CYCLE START button has been pressed or a program is
running.

HOLD

FAULT LED

BATTERY ALARM

TEACH PENDANT
ENABLED

Output signal indicates the teach pendant is enabled.

815

916

NOT USED

Open for additional PDO.

Output signal indicates the HOLD button has been pressed or a hold condition exists.
Output signal indicates a fault has occurred.
Output signal indicates the voltage in the battery is low.

Use Procedure 73 to display and force SOP I/O.

7. CONTROLLING I/O

76

MARMMTRBL02303E

Procedure 73
Step

Displaying and Forcing SOP I/O


1 Press MENUS.
2 Select I/O.
3 Press F1, [TYPE].
4 Select SOP. You will see a screen similar to the following.

I/O SOP Out


#
SO[
SO[
SO[
SO[
SO[
SO[
SO[
SO[
SO[
SO[

STATUS
1] OFF
OFF
2] OFF
3] OFF
4] OFF
5] OFF
6] OFF
7] OFF
8] OFF
9] OFF
10] OFF

[ TYPE ]

JOINT
[
[
[
[
[
[
[
[
[
[

10 %

]
]
]
]
]
]
]
]
]
]
IN/OUT

ON

OFF

To change between the display of the input and output screens, press
F3, IN/OUT.
To move quickly through the information, press and hold the SHIFT
key and press the down or up arrow keys.
NOTE You can only view the status of input signals. Input signals cannot
be forced.
5 To force an output signal, move the cursor to the output you want to
change:


To turn on an output signal, press F4, ON.

To turn off an output signal, press F5, OFF.

MARMMTRBL02303E

MASTERING
81
When you master a robot you define the physical location of the robot by
synchronizing the mechanical information with the robots positional
information. A robot must be mastered to operate properly. Robots are
usually mastered before they leave FANUC Robotics. However, it is
possible that a robot might lose its mastering data and require to be
remastered.
You can master the robot using several different methods. Refer to
Table 81 to select the method that best meets your needs.
Table 81.

Mastering Methods

Mastering Method
Mastering to a fixture
(Fixture Position
Master)

Mastering to zero
degrees

Single axis mastering

Recording the quick


master reference
position
Quick mastering

Robot
Models
All

When to Use

 When mastery was lost due to


mechanical disassembly or repair.
 When a quick master reference position
was not previously set.
 Method of choice for P- and A-series
robots. Used for S- and M-series robots
when extreme precision is required.
M-series  When mastery was lost due to
mechanical disassembly or repair.
S-series
 When a quick master reference position
was not previously set.
 Method of choice for S- and M-series
robots when extreme precision is not
required.
M-series When mastery was lost due to mechanical
S-series disassembly or repair of a single axis (usually
due to motor replacement).
All
To record mastering data as a reference for
future quick mastering.
All

To retrieve mastering data that has been


stored as a quick master reference position
when mastery is lost due to an electrical or
software problem. Do not use if mastery was
lost due to mechanical disassembly or repair.

If you are using a FANUC Robotics A-series or P-series robot you must
use a mastering fixture to master your robot. Refer to the Mechanical
Service Manual specific to your robot model for procedures on how to set
up and use a mastering fixture.
If you are using a FANUC Robotics M-series or S-series robot you can
either master to a fixture or you can master to zero degrees. Refer to the
Mechanical Service Manual specific to your robot model for more
information on mastering using a fixture.
Quick mastering is a convenient way to master an M-series or S-series
robot after you have recorded a reference position. You cannot quick
master a robot unless the reference position was taught before mastering
was lost.

8. MASTERING
MARMMTRBL02303E

82

CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.

8.1
MASTERING TO A
FIXTURE (FIXTURE
POSITION MASTER)

When you master to a fixture, you use a mastering fixture to align the
robot axes and then record the position. You can master any robot to a
fixture. If you have a P-series or A-series robot, you must master it to a
fixture.
Use Procedure 81 to master to a fixture.

Procedure 81
Condition
Step

Mastering to a Fixture


You have the appropriate mastering fixture for your robot.

1 Press SYSTEM.
2 Press F1, [TYPE].
3 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 4.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key 1 and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
e Select Master/Cal. See the following screen for an example.

SYSTEM Master/Cal
1
2
3
4
5
6

JOINT 10%

FIXTURE POSITION MASTER


ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ENTER or number key to select.

[ TYPE ]

LOAD

8. MASTERING

83

MARMMTRBL02303E

SYSTEM Master/Cal
1
2
3
4
5
6

JOINT 10%

FIXTURE POSITION MASTER


ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ENTER or number key to select.

[ TYPE ]

LOAD

RES_PCA

4 If you are resetting a pulse coder alarm,


a Press F3, RES_PCA. See the following screen for an example.
SYSTEM Master/Cal
1
2
3
4
5
6

JOINT 10%

FIXTURE POSITION MASTER


ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ENTER or number key to select.

Reset pulse coder alarm? [NO]


[ TYPE ]
YES

NO

b Press F4, YES. See the following screen for an example.


SYSTEM Master/Cal
1
2
3
4
5
6

JOINT 10%

FIXTURE POSITION MASTER


ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Pulse coder alarm reset!

[ TYPE ]

LOAD

RES_PCA

5 Refer to the Mechanical Service Manual or Mechanical Connection


and Maintenance Manual specific to your robot model for the
procedures on how to set up and use a mastering fixture.

8. MASTERING
MARMMTRBL02303E

84
6 Select Fixture Position Master.

7 Press F4, YES. Mastering will be performed automatically.


8 Continue to Step 9.
9 Select Calibrate.

10

Press F4, YES.

11 Perform a cold start.


a Turn off the robot.
b Press and continue pressing the FAULT RESET button on the
operator panel.
c While still pressing FAULT RESET, press the ON button on the
operator panel.

8. MASTERING

85

MARMMTRBL02303E

8.2

When you master to zero degrees, you position all axes at their zero degree
witness marks and record the zero degree position. You can master any
M-series or S-series robot to zero degrees.

ZERO DEGREE
MASTERING

Use Procedure 82 to master to zero degrees.


Procedure 82
Step

Mastering to Zero Degrees


1 Press SYSTEM.
2 Press F1, [TYPE].
3 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 4.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key 1 and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
e Select Master/Cal. See the following screen for an example.

SYSTEM Master/Cal
1
2
3
4
5
6

JOINT 10%

FIXTURE POSITION MASTER


ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ENTER or number key to select.

[ TYPE ]

LOAD

8. MASTERING
MARMMTRBL02303E

86

SYSTEM Master/Cal
1
2
3
4
5
6

JOINT 10%

FIXTURE POSITION MASTER


ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ENTER or number key to select.

[ TYPE ]

LOAD

RES_PCA

4 If you are resetting a pulse coder alarm,


a Press F3, RES_PCA. See the following screen for an example.
SYSTEM Master/Cal
1
2
3
4
5
6

JOINT 10%

FIXTURE POSITION MASTER


ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ENTER or number key to select.

Reset pulse coder alarm? [NO]


[ TYPE ]
YES

NO

b Press F4, YES. See the following screen for an example.


SYSTEM Master/Cal
1
2
3
4
5
6

JOINT 10%

FIXTURE POSITION MASTER


ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Pulse coder alarm reset!

[ TYPE ]

LOAD

RES_PCA

5 Align the witness marks on the robot.


6 Select Zero Position Master.

8. MASTERING

87

MARMMTRBL02303E

7 Press F4, YES. Mastering will be performed automatically.


8 Select Calibrate.

9 Press F4, YES.


10

Perform a cold start.


a Turn off the robot.
b Press and continue pressing the FAULT RESET button on the
operator panel.
c While still pressing FAULT RESET, press the ON button on the
operator panel.

8. MASTERING
MARMMTRBL02303E

88

8.3

You can master a single axis of an M-series or S-series robot when mastery
was lost due to mechanical disassembly or repair of a single axis, usually
due to motor replacement.

SINGLE AXIS
MASTERING

Use Procedure 83 to master a single axis.


Procedure 83
Step

Mastering a Single Axis


1 Clear any servo faults that prevent you from jogging the robot.
a Press MENUS.
b Select SYSTEM.
c Press F1, [TYPE].
d Select Variables.
e Move the cursor to $MCR and press ENTER.
f Move the cursor to $SPC_RESET and press F4, TRUE.
The value will change to TRUE momentarily, and will then change to
FALSE.
g If the value does not change to TRUE momentarily, repeat
Step 1.
h Press RESET on the operator panel.
2 Using the JOINT coordinate system, jog the unmastered axis to the
zero degree position.
3 Press MENUS.
4 Select SYSTEM.
5 Press F1, [TYPE].
6 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 7.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key 1 and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
e Select Master/Cal. See the following screen for an example.

8. MASTERING

89

MARMMTRBL02303E

SYSTEM Master/Cal
1
2
3
4
5
6

JOINT 10%

FIXTURE POSITION MASTER


ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ENTER or number key to select.

[ TYPE ]

LOAD

RES_PCA

7 Select 4, Single Axis Master. See the following screen for an


example.

SINGLE AXIS MASTER


ACTUAL POS
J1
0.000
J2
3.514
J3
7.164
J4 357.366
J5
1.275
J6
4.571
E1
0.000
E2
0.000
E3
0.000
[ TYPE ]

(MSTR POS)
(
0.000)
( 35.000)
(100.000)
(
0.000)
( 80.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)

JOINT 10%
1/9
(SEL) [ST]
(0)
[2]
(0)
[0]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[0]
(0)
[0]
(0)
[0]

GROUP

EXEC

8 Move the cursor to the MSTR POS column for the unmastered axis
and press the 0 key.
9 Continuously press and hold the DEADMAN switch and turn the
teach pendant ON/OFF switch to ON.
10

Move the cursor to the SEL column for the unmastered axis and press
the numeric key 1.

11 Press ENTER.
12

Press F5, EXEC. Mastering will be performed automatically.

13

Press PREV.

14

Select Calibrate.

15

Press F4, YES.

8. MASTERING
MARMMTRBL02303E

810

16

Perform a cold start.


a Turn off the robot.
b Press and continue pressing the FAULT RESET button on the
operator panel.
c While still pressing FAULT RESET, press the ON button on the
operator panel.

8. MASTERING

811

MARMMTRBL02303E

8.4
QUICK MASTERING

Quick mastering allows you to minimize the time required to remaster the
robot using a reference position you established when the robot was
properly mastered. You cannot quick master the robot unless you have
previously recorded this quick master reference position.
Record the quick master reference position when the robot is properly
mastered. The best time to record the quick master reference position is
when the robot is still factory-mastered.
If you lose mastery due to an electrical or software problem, you can use
this reference position to master the robot in a minimum amount of time.
If you lose mastery due to mechanical disassembly or repair, you must
master to a fixture or perform zero degree mastering.
You can define a quick master reference position and perform quick
mastering on any robot model.
Use Procedure 84 to record the quick master reference position. Use
Procedure 85 to quick master the robot.
CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.

Procedure 84
Condition

Recording the Quick Master Reference Position




The robot is properly mastered.

1 Align the witness marks on the robot. This is the zero position, which
will be the quick master reference position.
If you have a P-series or A-series robot, jog all robot axes to zero
degrees and scribe witness marks on each axis.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
5 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 6.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key 1 and then press ENTER on the teach
pendant.

8. MASTERING
MARMMTRBL02303E

812
d Press F1, [TYPE].

e Select Master/Cal. See the following screen for an example.

SYSTEM Master/Cal
1
2
3
4
5
6

JOINT 10%

FIXTURE POSITION MASTER


ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ENTER or number key to select.

[ TYPE ]

LOAD

6 Move the cursor to SET QUICK MASTER REF and press ENTER.
Set quick master ref? [NO]

7 Press F4, YES.


8 Perform a cold start.
a Turn off the robot.
b Press and continue pressing the FAULT RESET button on the
operator panel.
c While still pressing FAULT RESET, press the ON button on the
operator panel.

8. MASTERING

813

MARMMTRBL02303E

Procedure 85
Condition

Quick Mastering the Robot




The robot has lost mastery due to an electrical or software problem.

NOTE If the robot has lost mastery due to mechanical disassembly or


repair, you cannot perform this procedure. In this case, master to a fixture
or master to zero degrees to restore robot mastery.


The quick master reference position was recorded before the robot lost
mastery.

1 Jog the robot to the quick master reference position (zero degree
position).
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
5 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 6.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key 1 and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
e Select Master/Cal. See the following screen for an example.

SYSTEM Master/Cal
1
2
3
4
5
6

JOINT 10%

FIXTURE POSITION MASTER


ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ENTER or number key to select.

[ TYPE ]

LOAD

6 Move the cursor to QUICK MASTER and press ENTER.


Quick master? [NO]

7 Press F4, YES.

8. MASTERING
MARMMTRBL02303E

814
8 Move the cursor to CALIBRATE and press ENTER
9 Press F4, YES.

10

Perform a cold start.


a Turn off the robot.
b Press and continue pressing the FAULT RESET button on the
operator panel.
c While still pressing FAULT RESET, press the ON button on the
operator panel.

MARMMTRBL02303E

REPLACING COMPONENTS
91
This chapter describes replacement of the following items:















Batteries
Relays
Printed Circuit Boards (PCB)
Modules
Process I/O Boards
Modular I/O Components
Transformers
Servo Amplifiers
Operator Panel
Fan Motors
Replacing the Discharge Resistor (DCR) and Dynamic Brake Resistor
(DRB) unit
Replacing the Regenerative Discharge unit
Replacing the Optional Warning Light
Replacing Serial Pulse coders

NOTE To replace output drivers on the process I/O boards, refer to


Chapter 10.

9. REPLACING COMPONENTS
MARMMTRBL02303E

92

9.1

FANUC Robotics recommends that all batteries be changed immediately


prior to production start up. Change the batteries annually to assure
reliable robot performance. Use Procedure 91 to replace the battery:
Use Procedure 92 to replace the SPC battery.

REPLACING THE
BATTERY

Procedure 91
Step

Replacing the Battery


1 Get the new battery. (number: A98L-0031-0007)
2 Power down and lock out the controller.
CAUTION
The battery must be replaced within 30 minutes. If the power is
turned off and the battery is removed for 30 minutes or more,
the contents of the memory on the main CPU printed circuit
board may be lost.

WARNING
Do not short circuit or incinerate a discarded battery.
Follow your companys procedures for disposing of lithium
batteries.

WARNING
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to
avoid electrical shock.
3 Remove the battery case from the front panel of the power supply unit.
The case can be removed easily by squeezing the top and bottom of it
and pulling.
Figure 101. Replacing the Battery (1)

BATTERY

Cable connector

Front panel of the


power supply unit
Battery
(ordering drawing
number:
A98L-0031-0007)

Battery case

Front panel of the


power supply unit

PC board
connector

4 Remove the connector from the battery.

Battery

9. REPLACING COMPONENTS

93

MARMMTRBL02303E

5 Replace the battery and reconnect the connector.


6 Install the battery case.
Procedure 92
Step

Replacing the SPC Batteries


1 Get four new alkaline Dcell batteries.
2 Turn on the controller.
3 Press the operator panel Emergency Stop button and the teach pendant
Emergency Stop button.
4 Turn on the teach pendant and take it with you into the workcell.
5 Remove the black plastic battery cover on the base of the robot.
6 Remove the old batteries.
7 Insert the new batteries. The new batteries must be arranged as
follows:
Upper left positive end out.
Upper right negative end out.
Lower left negative end out.
Lower right positive end out.
8 Replace the battery cover.
9 Cold start the controller. The teach pendant might display a
SRVO065 BLAL alarm. This is normal. It will reset when you cold
start the controller.

9. REPLACING COMPONENTS
MARMMTRBL02303E

94

9.2

A relay may fail after it is used for a long time. The relay or its circuit
board must be replaced. Relays RL1-RL6 on the EMG board are
replaceable.

REPLACING A RELAY

Figure 102. Replacing a Relay

DS2
F1
DS1

F2
RL16

FUSE

RL1 RL2
RL4
RL3

LED M1
LED M2

RL4 TIMER

6
8
CNPG

5
7

TM1
TM2
CRX

9. REPLACING COMPONENTS

95

MARMMTRBL02303E

Figure 103. Replacing a Relay

Relay

Table 91.

Relay Part Numbers

Name
RL1
RL2
RL3
RL4
RL5, RL6
Table 92.

Part Numbers
A58L00010192#1472R

A58L00010192#1192D

Relay Part Numbers

Name
RL1, RL2
RL3, RL16
RL4
RL5, RL8, RL10,
RL15
RL5, RL6

Part Numbers
A58L00010192#1472R
A58L00010192#1509A
A58L00010192#1192D
A58L00010260#234PH24
A58L00010192#1192D

9. REPLACING COMPONENTS
MARMMTRBL02303E

96

9.2.1

Part Number: A16B16000520

Purge Control PCB

Table 93.

PCB Relay Part Numbers

Name
RL4 Timer Relay
RL1, RL3, RL5, RL9

Part Numbers
A58L00010269#B24
A58L00010260#234PH24

9. REPLACING COMPONENTS
MARMMTRBL02303E

9.3
REPLACING A
PRINTED CIRCUIT
BOARD

97

When replacing a printed circuit board, take the following precautions:


1. Before starting replacement, power down and lock out the controller.
2. When removing the printed circuit board, do not touch semiconductor
components on it and do not let the components touch other
components.
3. Wear a grounded wrist strap. Do not remove the new board from its
conductive bag until you are ready to install it.
4. Check that any jumpers on the printed circuit board to be installed are
correctly set.
5. When replacing the main CPU printed circuit board, all software
stored in the controller will be lost. Before starting replacement, back
up your user programs, mastering data, and system variable data onto a
floppy disk.
6. Connect the cables removed for replacement to the original positions.
If the cable markings are missing or unclear, retag them before
disconnecting them.

9. REPLACING COMPONENTS
MARMMTRBL02303E

98

9.3.1

Use Procedure 93 to replace the backplane printed circuit board. The


backplane printed circuit board and the yellow board rack are removed and
replaced as one unit.

Replacing the
Backplane Printed
Circuit Board
Refer to Chapter 1 for part
numbers.
Procedure 93
Step

Replacing the Backplane Printed Circuit Board


1 Remove the battery from the power supply unit and plug it into the
battery connector on the front panel of the main CPU.
2 Remove all printed circuit boards from the backplane. Use
Procedure 94 .
3 Disconnect the ground wire from the backplane printed circuit board.
4 Remove the two or three mounting screws at the bottom of the rack.
5 Loosen the two or three mounting screws at the top of the rack and
remove the rack/backplane assembly.
6 Install the new rack/backplane assembly in reverse order. Be sure to
move the battery back to the power supply unit from the main CPU.
Figure 104. Replacing the Backplane Printed Circuit Board

Backplane
PC board

M5 mounting screw

9. REPLACING COMPONENTS

99

MARMMTRBL02303E

9.3.2

Use Procedure 94 to replace a component on the backplane printed


circuit board.

Replacing a
Component on the
Backplane Printed
Circuit Board
Refer to Chapter 1 for part
numbers.
Procedure 94

Step

Replacing a Component on the Backplane Printed Circuit


Board
NOTE When the main CPU is replaced, all software stored in the
controller will be lost. If possible, back up your user programs, mastering
data, and system variable data on a floppy disk before starting
replacement.
1 Turn off and lock out the controller.
2 Disconnect any cables and harnesses on the component to be replaced.
3 Squeeze the latch tabs at the top and bottom of the component and pull
the component straight out.
4 Set any jumpers on the new component to match the component being
replaced.
5 Insert the new component into the proper slot of the backplane rack.
Carefully press it into the slot until the latches engage at the top and
bottom.
6 Reconnect all cables and harnesses.
Figure 105. Replacing Printed Circuit Boards on the Backplane Printed Circuit
Board
Process input/output PC board CA, CB, or DA
Main CPU board (*1)
Axis control PC board
Power supply unit (*2)
Emergency stop control PC board

9. REPLACING COMPONENTS
MARMMTRBL02303E

910

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

Use the following procedure to replace a module:


1. Move the latches at both ends of the module socket toward the outside.
The spring of the contact tilts the module. See Figure 106.
Figure 106. Moving the Latches on the End of the Module Socket

Refer to Chapter 1 for part


numbers.

2. If the tilted module touches the next module, it might be difficult to


remove it. In this case, release the latches of the next module as
described in step 1 above.
3. Now the module is free in the socket. Pull out the module carefully in
a straight line. Do not pull it out in an arc. The contacts of the socket
or module might be damaged.
4. Install a new module in the socket at an angle. Push it into the socket
until the bottom of the module reaches the bottom of the socket
groove. Be sure you have the module facing in the proper direction.
align the groove in the module with the tab as shown in Figure 107.
Figure 107. Installing a New Module at an Angle

Short

Long
Fit the recess on
the module over
the tab in the
module socket.

9. REPLACING COMPONENTS

911

MARMMTRBL02303E

5. Push the module in the top edge so that the module stands upright.
See Figure 108.
Figure 108. Pushing in the Module

6. Check that the module is latched properly at both ends of the socket.
If it is insufficiently latched, the electrical contact might be improper
and a malfunction could occur.

9. REPLACING COMPONENTS
MARMMTRBL02303E

912

Figure 109 shows the mounting locations of the modules.


Figure 109. Mounting Locations of the Modules

FLASH

Flash ROM module

Optional SCC module

CMOS RAM module (option)

SLC2 module

CMOS RAM module (option)

M321 module

CMOS RAM module (standard)

SCC module

CMOS RAM module (standard)

Main CPU PC board

Servo control module (for axis 9 and 10)


Servo control module (for axis 7 and 8)
Servo control module (for axis 5 and 6)
Servo control module (for axis 3 and 4)
Servo control module (for axis 1 and 2)
Servo interface module (for axis 5 and 6)
Servo interface module (for axis 3 and 4)
Servo interface module (for axis 1 and 2)

Axis control PC board

9. REPLACING COMPONENTS

913

MARMMTRBL02303E

9.5
REPLACING THE
PROCESS
INPUT/OUTPUT
PRINTED CIRCUIT
BOARD AA, AB, BA OR
BB

Part numbers: A16B-2200-0780, A16B-2200-0782, and A16B-2201-0510


1. Remove the cable from the process input/output printed circuit board
to be replaced.
2. Remove the two screws from the left side of the process input/output
printed circuit board.
3. Remove the board by pulling outward to the left.
4. Replace the printed circuit board with a new one.

Refer to Chapter 1 for part


numbers.

5. Replace the two screws removed in step 2.


6. Replace the cables.
NOTE For replacing output drivers on the process I/O boards refer to
Chapter 10.
Figure 1010. Replacing the Process Input/Output Printed Circuit Board AA, AB,
BA, or BB

M4 screw

9. REPLACING COMPONENTS
MARMMTRBL02303E

914

9.6
REPLACING
COMPONENTS OF THE
MODULAR
INPUT/OUTPUT UNIT
Refer to Chapter 1 for part
numbers.

9.6.1

Use the information in this section to replace the following components of


the modular I/O unit:











Base Unit
Modules
Multi-Tap Transformer
Servo Amplifier
Operator Panel
Fan Motor
Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) Unit
Regenerative Discharge Unit
Optional Warning Light
Serial Pulse Coder

Use Procedure 95 to replace the base unit.

Replacing the Base


Unit
Ordering code:
A03B-0807-J002
Procedure 95
Step

Replacing the Base Unit


1 Remove the I/O modules from the base unit.
2 Loosen the upper two mounting screws.
3 Remove the lower two mounting screws and replace the base unit.

9. REPLACING COMPONENTS

915

MARMMTRBL02303E

Figure 1011. Replacing the Base Unit of the Modular Input/Output Unit

M4 screw

9. REPLACING COMPONENTS
MARMMTRBL02303E

916

9.6.2
Replacing a Module
Procedure 96
Removing the Interface
Module

Replacing the Interface Module


1 Power down and lock out the controller.
2 Disconnect the signal and power cables from the interface module.
3 Press the latch on the bottom of the module and rotate the module
toward you and up.

Installing the Interface


Module

1 Engage the hook at the top rear of the module with the bar above the
base unit socket.
2 Rotate the module downward until the latch engages.
3 Reconnect the signal and power cables to the interface module.

Procedure 97
Removing an I/O Module

Replacing an I/O Module


1 Power down and lock out the controller.
2 Remove the wiring harness block. (See Figure 1013.)
a Lift the latch at the lower left corner of the module window.
b Rotate the block toward you and down.
3 Press the latch on the bottom of the module and rotate the module
toward you and up. (See Figure 1012.)

Installing an I/O Module

1 Engage the hook at the top read of the module with the bar above the
base unit socket.
2 Rotate the module downward until the latch engages.

9. REPLACING COMPONENTS

917

MARMMTRBL02303E

Figure 1012. Removing and Replacing a Module

3 Install the wiring harness block.


a Engage the hook at the bottom rear of the block with the bar at the
bottom of the module.
b Rotate the block upward until the latch engages.
Figure 1013. Removing and Replacing a Terminal Block

9. REPLACING COMPONENTS
MARMMTRBL02303E

918

9.7

Use Procedure 98 to replace the multi-tap transformer.

REPLACING THE
MULTI-TAP
TRANSFORMER
Refer to Chapter 1 for part
numbers.
Procedure 98

Condition
Step

Replacing the Multi-Tap Transformer




The controller is turned off and locked out.

1 Remove the acrylic covers from the transformer and ALC relay.
2 Disconnect the wiring harnesses and ground wire from the transformer.
3 Disconnect the three wires from the bottom of the ALC relay.
4 After removing the eight screws fastening the transformer, remove the
transformer. Put a new transformer on the rail in the controller and
push it into the controller along the rail. Then reinstall the screws.
5 Reconnect the wires and harnesses.
6 Reinstall the acrylic covers.
Figure 1014. Replacing the Multi-Tap Transformer

M5 screws

9. REPLACING COMPONENTS

919

MARMMTRBL02303E

9.8

Use Procedure 99 to replace a servo amplifier.

REPLACING A SERVO
AMPLIFIER
Refer to Chapter 1 for part
numbers.
Procedure 99

Condition
Step

Replacing a Servo Amplifier




The controller is turned off and locked out.

1 Remove the five bus bars from the servo amplifier bank.
2 Disconnect the wires from the servo amplifier terminal strip. Remove
the two screws fastening the servo amplifier and remove the amplifier.
3 Set the terminal strip jumpers on the new servo amplifier to match
those of the one you removed.
4 Install the new servo amplifier by following these steps in reverse
order.
Figure 1015. Replacing a Servo Amplifier

M5 screw

9. REPLACING COMPONENTS
MARMMTRBL02303E

920

9.9

Use Procedure 910 to replace the operator panel.

REPLACING THE
OPERATOR PANEL
Refer to Chapter 1 for part
numbers.
Procedure 910
Condition
Step

Replacing the Operator Panel




The controller is turned off and locked out.

1 Remove the cable from the operator panel.


2 Remove the six nuts fastening the operator panel and replace the
operator panel.
3 When replacing only the operator panel printed circuit board, replace it
together with the metal plate.
4 After removing the cable from the operator panel printed circuit board,
remove the four nuts fastening the metal plate. Then replace the
operators panel printed circuit board.
Figure 1016. Replacing the Operator Panel

Operator panel
(rear face)
M4 nuts
(4 pieces)

9. REPLACING COMPONENTS

921

MARMMTRBL02303E

9.10

Use Procedure 911 to replace the fan motor.

REPLACING THE FAN


MOTOR
Refer to Chapter 1 for part
numbers.
Procedure 911
Condition
Step

Replacing the Fan Motor




The controller is turned off and locked out.

1 Remove the printed circuit board located below the fan motor to be
replaced, following Procedure 94 .
2 The cable connected to the fan motor is connected to the backplane
printed circuit board in the slot. Holding the connector, remove the
cable from the backplane printed circuit board.
3 Open the lid at the top of the backplane rack by placing the tip of a
flatblade screwdriver into the center hole at the front of the lid and
moving the screwdriver like a lever in the direction in Figure 1017 to
release the latch.
4 Remove the fan motor.
5 Install a new fan motor. Route the cable through the hole at the back
of the rack.
6 Close the lid until it is latched.
7 Connect the cable of the fan motor to the connector on the backplane
printed circuit board. Suspend the center of the cable on the hook in
the back of the rack.
8 Reinstall the removed printed circuit board using the procedure
described in Section 9.3.2.

9. REPLACING COMPONENTS
MARMMTRBL02303E

922
Figure 1017. Replacing the Fan Motor

(3)
(4)

Fan motor
Cable

Connector
Backplane PC board

9. REPLACING COMPONENTS

923

MARMMTRBL02303E

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

Procedure 912

Condition
Step

Use Procedure 912 to replace the discharge resistor (DCR) and dynamic
brake resistor (DBR) unit.

Replacing the Discharge Resistor (DCR) and Dynamic Brake


Resistor (DBR) unit


The controller is turned off and locked out.

1 Use FANUC part number A05B-2302-C080 to replace the DCR and


DBR unit.
2 Remove the cable from the DCR and DBR unit to be replaced.
3 Remove the two screws fastening the DCR and DBR unit and replace
it.
4 Reattach the cable to the new DCR and DCR unit.

9. REPLACING COMPONENTS
MARMMTRBL02303E

924

Figure 1018. Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) Unit

M5 SCREW (2 pieces)

9. REPLACING COMPONENTS

925

MARMMTRBL02303E

9.12

Use Procedure 913 to replace the regenerative discharge unit.

REPLACING THE
REGENERATIVE
DISCHARGE UNIT
Procedure 913
Condition
Step

Replacing the Regenerative Discharge Unit




The controller is turned off and locked out.

1 Use FANUC part number A05B-2312-C100 for the M-500, and part
number A05B-2313-C100 for the S-900, for replacement of the
regenerative discharge unit.
2 Disconnect the cable connected to the regenerative discharge unit.
3 Remove the four M5 screws fastening the discharge unit. Then
replace the unit.
Figure 1019. Replacing the Regenerative Discharge Unit
Four M5 fastening screws

9. REPLACING COMPONENTS
MARMMTRBL02303E

926

9.13

Use Procedure 914 to replace the optional warning light.

REPLACING THE
OPTIONAL WARNING
LIGHT
Procedure 914
Condition
Step

Replacing the Optional Warning Light




The controller is turned off and locked out.

1 Use FANUC part number LAMPXVAL74C024X to replace the


warning light.
2 Remove the existing light assembly from the robot and replace with
the new light assembly.
3 Reconnect the replacement light assembly.

9. REPLACING COMPONENTS

927

MARMMTRBL02303E

9.14

Use Procedure 915 to replace a serial pulse coder.

REPLACING A SERIAL
PULSE CODER

Procedure 915

Replacing a Serial Pulse Coder

NOTE The robot will have to be remastered after this procedure.


Condition
Step

The controller is turned off and locked out.

1 Remove the cables from the pulse coder. Refer to Figure 1020.
2 Remove the screws holding the pulse coder cable connector to the
pulse coder housing.
3 Retract the rubber boot on the inside of the pulse coder cable
connector.
4 Remove the snap ring on the inside of the pulse coder cable connector.
5 Detach the pulse coder cable from the pulse coder housing.

CAUTION
In the next step, be sure to remove the correct bolts, as shown
in Figure 1020. Removing the wrong bolts can destroy the
pulse coder.

6 Remove the four M4 bolts attaching the pulse coder to the motor.
7 Position the new pulse coder on the motor so that the Oldham
coupling engages. If there are witness marks on the pulse coder case
and the motor case, make sure that they line up.
8 Install the four M4 bolts.
9 Attach the pulse coder cable to the pulse coder housing.
10

Install the snap ring on the inside of the pulse coder cable connector.

11 Reposition the rubber boot on the inside of the pulse coder cable
connector.
12

Replace the screws holding the pulse coder cable connector to the
pulse coder housing.

13

Install the screws holding the pulse coder housing to the motor.

14

Attach the cables to the pulse coder housing.

9. REPLACING COMPONENTS
MARMMTRBL02303E

928
Figure 1020. Removing the Pulse Coder

Caution: Do not remove the screws from these four ribbed holes.
The serial pulse coder will seperate and be destroyed

M4 Mounting Bolt Holes

10

BOARD ADJUSTMENTS
101

MARMMTRBL02303E

This chapter contains information about components located on some


printed circuit boards that require adjustment. These components include
jumpers and potentiometers.

10.1
AXIS CONTROL
BOARD JUMPERS

You can set jumpers on the axis control board. Figure 111 shows an
illustration of the axis control board. Table 101 lists the standard
settings for the jumpers found on the axis control board.
Figure 111. Axis Control Board Jumpers

Table 101.
Name

COM
B
JUMPER

HBK
JUMPER

Axis Control Board Jumpers


Standard setting

Description

COM

Side A

Side A: The RI lines use 0V for the


common reference
Side B:The RI lines use +24 for the
common reference

HBK

Side B

Side A: The hand breakage detect feature


is not used.
Side B: The hand breakage detect feature
is used.

10. BOARD ADJUSTMENTS


MARMMTRBL02303E

102

10.2
PROCESS I/O BOARD

The process I/O board has jumpers, potentiometers you can adjust, and
output drivers you can replace. The process I/O boards are shown in
Figures 102 through Figure 108.
Figure 112. Process I/O Board AA

Figure 113. Process I/O Board AB

10. BOARD ADJUSTMENTS

103

MARMMTRBL02303E

Figure 114. Process I/O Board BA

Figure 115. Process I/O Board BB

10. BOARD ADJUSTMENTS


MARMMTRBL02303E

104
Figure 116. Process I/O Board CA

Figure 117. Process I/O Board CB

10. BOARD ADJUSTMENTS

105

MARMMTRBL02303E

Figure 118. Process I/O Board DA

10.2.1
Jumpers

Table 102 lists the standard settings for the jumpers located on the
process I/O board.
Table 102.

Process I/O Board Jumpers


Name

ICOM1

UDI1 to UDI20
(Connector CRM2A)

ICOM2

UDI21 to UDI40
(Connector CRM2B)

ICOM3

WI01 to WI08
(Connector CRW1)
See Note

SP1

Channel 1

SP2

Channel 2

Standard
setting

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

Side A
NOTE: Set ICOM3 to B side to use
WDI2 as weld detect input.

Open

The polarity of the output voltage is


switched to
Strapped: Negative ()
Open: Positive (+)

10. BOARD ADJUSTMENTS


MARMMTRBL02303E

106

10.2.2
Potentiometers

Table 103 lists the process I/O board potentiometers and the adjustments
you can make to them.
Table 103.

Process I/O Board Potentiometer Adjustments

Potentiometer

Description

Adjustment

Adjusts the gain of


channel 1

Execute a robot program and set AO[1] to


4095 on the teach pendant. Connect a
digital voltmeter to test pin AO1 and rotate
VR1 until the meter reads 12.0 V. Connect
the negative () lead of the digital voltmeter
to test pin 0VF.

Adjusts the gain of


channel 2

Execute a robot program and set AO[2] to


4095 on the teach pendant. Connect the
digital voltmeter to test pin AO2 and rotate
VR2 until the meter reads 12.0 V. Connect
the negative () lead of the digital voltmeter
to test pin 0VF. (The 0VF test pin is
different from the common 0V test pin.)

Adjusts the
reference supply
voltage of the
digital/analog
converter

Connect the digital voltmeter to test pin


P10V and rotate VR3 until the meter reads
10.00  0.1 V.

VR1

VR2

VR3

10. BOARD ADJUSTMENTS

107

MARMMTRBL02303E

10.2.3

Table 104 lists the output drivers for each process I/O board.

Output Drivers
Table 104.

Output Drivers
DO Signal

Driver

AA

AB

BA

BB

CA

CB

DA

DV1

CMDENBL, SYSRDY, PROGRUN, PAUSED

DV2

HELD, FAULT, ATPERCH, TPENBL

DV3

BATALM, BUSY, ACK1/SNO1, ACK2/SNO2

DV4

ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6

DV5

ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED

DV6

SO01, SO02, SO03, SO04

DV7

SO05, SO06, SO07, SO08

DV8

SO09, SO10, SO11, SO12

DV9

SO13, SO14, SO15, SO16

DV10

SO17, SO18, SO19, SO20

DV11

WO01, WO02,
WO03, WO04

WO01, WO02,
WO03, WO04

SO21, SO22,
SO23, SO24

DV12

WO05, WO06,
WO07, WO08

WO05, WO06,
WO07, WO08

SO25, SO26,
SO27, SO28

DV13

SO29, SO30,
SO31, SO32,

DV14

SO33, SO34,
SO35, SO36

DV15

SO37, SO38,
SO39, SO40

DV16

SO41, SO42,
SO43, SO44

DV17

SO45, SO46,
SO47, SO48

DV18

SO49, SO50,
SO51, SO52

DV19

SO53, SO54,
SO55, SO56

DV20

SO57, SO58,
SO59, SO60

DV21

SO61, SO62,
SO63, SO64

DV22

SO65, SO66,
SO67, SO68

DV23

SO69, SO70,
SO71, SO72

DV24

SO73, SO74,
SO75, SO76

RESERVED

To be used for
replacement

To be used for
replacement

To be used for
replacement

10. BOARD ADJUSTMENTS


MARMMTRBL02303E

108

10.3
BUILTIN CRT/KB UNIT

This section contains information about adjusting the built-in CRT/KB


unit.

CRT Display Unit

The following can be adjusted at the CRT Display Unit:

20 CRT/KB
A05B-2051-J101










40 CRT/KB
A05B-2301-J130

Brightness (BRIGHT)
Contrast (CONT)
Focus
Horizontal size (H-SIZE)
Vertical size (V-SIZE)
Horizontal Hold (H-HOLD)
Vertical Hold(V-HOLD)
Vertical linearity (V-LIN)
CAUTION
Keep fingers and tools away from the CRT display unit when
first turning the power on. Use caution at the display unit
anytime when power is on because 10-11 KV is present.

Brightness

Turn to the brightest level possible before roster (scanning lines) appear on
the screen.

Contrast

Adjust the CONT variable resistor until display characters achieve an


easy to read brightness level. Too much contrast can distort the characters.

Focus

Adjust FOCUS variable resistor to sharpen characters.

Horizontal Size (Width)

Adjust the HSIZE coil if picture width appears too small or distorted
on the sides.

Vertical Size (Height)

Adjust the VSIZE variable resistor if the picture height appears too
small or distorted at the top.

Horizontal Hold

Adjust the HHOLD variable resistor if the picture rolls or shifts


horizontally (or diagonally).

Vertical Hold (V-HOLD)

Adjust the VHOLD variable resistor if the picture rolls vertically.

Vertical Linearity (V-LIN)

Adjust the VLIN variable resistor to obtain equal character size


vertically in the upper and lower parts of the screen.

10. BOARD ADJUSTMENTS

109

MARMMTRBL02303E

The following can be adjusted at the CRT/KB Control Board:




+ 5VDC power supply

Refer to Figure 119 and adjust as follows:


+5VDC supply: Monitor the +5 VDC test point and adjust variable
resistor VR1 until + 5VDC  0.1V is obtained.


Jumper ST1

Refer to Figure 1110 for jumper setting.


Figure 119. Front View Control Board
VR1
Test point +5V
ST1

Figure 1110. Jumper Setting CRT/KB

Jumper

Standard
setting

ST1
A

SIDE A = KANA +
ALPHA NUMERIC

SIDE B = ALPHA
NUMERIC

10. BOARD ADJUSTMENTS


MARMMTRBL02303E

1010

10.4

The EMG board contains a jumper which controls the sensitivity of the
brake alarm circuit. Refer to SRVO_ALARM 008.

EMG BOARD

Figure 1111.

EMG board

EMG
PCB

Table 105.

SBK Jumper Settings

Standard Setting
NAME

S-5, S-10, Arc Mate, Arc


Mate 100/S-6, Arc Mate
Sr., A-510, L-1000,
S-900, M-500

SBK1

Open

S-500, S-700, S-800,


M-400

Side 2

SBK2
SBK3
SBK4
SBK5
SBK6
SET

S-420, S-420D

Description

The sensitivity of a brake is adjusted


(for a swiveling axis).

Open

Side 2

Side 1

The sensitivity for the fuse alarm of a


brake is adjusted to :
Side 1: Special setting
Side 2: Standard setting

MARMMTRBL02303E

11

CONNECTIONS
111
This chapter describes the electrical interface connections in the R-J
controller. Figure 121 is a block diagram of electrical interface
connections with the R-J controller.
Figure 121. Block Diagram of Electrical Interface Connection

Pneumatic pressure
Purge Source

ISB
Unit

Teach Pendant (ISTP)

ABKR I/O
GEF I/O
Modular I/O

Disk Drive

*1:
*2:

A remote display is connected.


Optional RS-232-C or RS-422/485 interface.

11. CONNECTIONS
MARMMTRBL02303E

112

11.1
MECHANICAL
CONNECTIONS

Figure 122 through Figure 1212 show connection diagrams to the


mechanical units.
Figure 122. Mechanical Connection Diagram for S-420, S-500, S-700, S-800, and
M-400

*1:
*2:

This cable is not included. It must be supplied by the customer.


Can be connected when the robot is S-500 or S-700.

Figure 123. Mechanical Connection Diagram for ARC Mate, ARC Mate 100/S-6,
ARC Mate Sr., A-510, and L-1000

*1:
*2:

This cable is not included. It must be supplied by the customer.


Can be connected when the robot is ARC Mate or ARC Mate Sr.

11. CONNECTIONS

113

MARMMTRBL02303E

Figure 124. Mechanical Connection Diagram for Six-Axis Pedestal Mount System
with Battery in Controller
RJ

ROBOT
M1
SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2

C1M1

SERVO AMP
TERMINAL/FRAME
AXIS 3

C1M3

SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6

C1M2

M3

M2

AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)

CRR5 EMG PCB


P & M BRAKE
SIGNALS

P1
C1P1

C1M5

D1
CONTACT SIGNAL
TRANSDUCER
(IBRC)

C1D1 (INTRINSIC)

+6V & 0V
BATT

C1B1 (INTRINSIC)

+24PG & 0V
PURGE CONTROL
PCB

C1P2

GROUND CABLE

DCDC
24V

5V

11. CONNECTIONS
MARMMTRBL02303E

114

Figure 125. Mechanical Connection Diagram for Six-Axis Pedestal Mount System
with Battery in Robot
RJ

ROBOT
M1

SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2

C1M1

SERVO AMP
TERMINAL/FRAME
AXIS 3

C1M3

SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6

C1M2

M3

AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)

CRR5 EMG PCB


P & M BRAKE
SIGNALS

CONTACT SIGNAL
TRANSDUCER
(IBRC)

+24PG & 0V
PURGE CONTROL
PCB

M2

P1
C1P1

C1M5

D1
C1D1 (INTRINSIC)

C1P2

GROUND CABLE

DCDC
24V

5V

11. CONNECTIONS

115

MARMMTRBL02303E

Figure 126. Mechanical Connection Diagram for Catrac Robot Clean-Wall Rail
System with Battery in Controller
RJ

JUNCTION BOX
M1

SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2

C1M1

SERVO AMP
TERMINAL/FRAME
AXIS 3 & 7

C1M3

SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6

C1M2

AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)

ROBOT
M1
C2M1

M3

M3
C2M3

M2

M2
C2M2

P1

P1

C1P1

C2P1

C1M5

C2M5

AXIS CONTROL
PCB JF7
(PULSE CODER
SIGNALAXIS7)

CRR5 EMG PCB


P & M BRAKE
SIGNALS

CONTACT SIGNAL
TRANSDUCER
(IBRC)
+6V & 0V
BATT
+24PG & 0V
PURGE CONTROL
PCB

D1

D1

C1D1 (INTRINSIC)

C2D1 (INTRINSIC)

C1B1 (INTRINSIC)

C2B1 (INTRINSIC)
P2

C1P2

GROUND CABLE

C2P2

GROUND CABLE

DCDC
24V

5V

11. CONNECTIONS
MARMMTRBL02303E

116

Figure 127. Mechanical Connection Diagram for Catrac Robot Clean-Wall Rail
System with Battery in Robot
RJ

JUNCTION BOX
M1

SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2

C1M1

SERVO AMP
TERMINAL/FRAME
AXIS 3 & 7

C1M3

SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6

C1M2

AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)

ROBOT
M1
C2M1

M3

M3
C2M3

M2

M2
C2M2

P1

P1

C1P1

C2P1

C1M5

C2M5

AXIS CONTROL
PCB JF7
(PULSE CODER
SIGNALAXIS7)

CRR5 EMG PCB


P & M BRAKE
SIGNALS

CONTACT SIGNAL
TRANSDUCER
(IBRC)

+24PG & 0V
PURGE CONTROL
PCB

D1
C1D1 (INTRINSIC)

D1
C2D1 (INTRINSIC)

P2
C1P2

GROUND CABLE

C2P2

GROUND CABLE

DCDC
24V

5V

11. CONNECTIONS

117

MARMMTRBL02303E

Figure 128. Mechanical Connection Diagram for SevenAxis Universal Rail


System with Battery in Controller
RJ

ROBOT
M1

SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2

C1M1

SERVO AMP
TERMINAL/FRAME
AXIS 3 & 7

C1M3

SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6

C1M2

AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)

M3

M2

P1
C1P1

AXIS CONTROL
PCB JF7
(PULSE CODER
SIGNALAXIS7)

CRR5 EMG PCB


P & M BRAKE
SIGNALS

CONTACT SIGNAL
TRANSDUCER
(IBRC)
+6V & 0V
BATT
+24PG & 0V
PURGE CONTROL
PCB

C1M5

D1
C1D1 (INTRINSIC)

C1B1 (INTRINSIC)

C1P2

GROUND CABLE

DCDC
24V

5V

11. CONNECTIONS
MARMMTRBL02303E

118

Figure 129. Mechanical Connection Diagram for Seven-Axis Universal Rail


System with Battery inRobot
RJ

ROBOT
M1

SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2

C1M1

SERVO AMP
TERMINAL/FRAME
AXIS 3 & 7

C1M3

SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6

C1M2

AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)

M3

M2

P1
C1P1

AXIS CONTROL
PCB JF7
(PULSE CODER
SIGNALAXIS7)

CRR5 EMG PCB


P & M BRAKE
SIGNALS

CONTACT SIGNAL
TRANSDUCER
(IBRC)

+24PG & 0V
PURGE CONTROL
PCB

C1M5

D1
C1D1 (INTRINSIC)

C1P2

GROUND CABLE

DCDC
24V

5V

11. CONNECTIONS

119

MARMMTRBL02303E

Figure 1210. Mechanical Connection Diagram for Seven-Axis Universal Rail


System with Battery in Controller and Junction Box
RJ

JUNCTION BOX

M1

M1

SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2

C1M1

SERVO AMP
TERMINAL/FRAME
AXIS 3 & 7

C1M3

SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6

C1M2

AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)

ROBOT

C2M1
M3

M3
C2M3

M2

M2
C2M2

P1

P1
C1P1

C2P1

C1M5

C2M5

AXIS CONTROL
PCB JF7
(PULSE CODER
SIGNALAXIS7)

CRR5 EMG PCB


P & M BRAKE
SIGNALS

D1

D1

CONTACT SIGNAL
TRANSDUCER
(IBRC)

C1D1 (INTRINSIC)

C2D1 (INTRINSIC)

+6V & 0V
BATT

C1B1 (INTRINSIC)

C2B1 (INTRINSIC)

+24PG & 0V
PURGE CONTROL
PCB

P2
C1P2

GROUND CABLE

C2P2

GROUND CABLE

DCDC
24V

5V

11. CONNECTIONS
MARMMTRBL02303E

1110

Figure 1211. Mechanical Connection Diagram for Seven-Axis Universal Rail


System with Battery in Robot and Junction Box

RJ

JUNCTION BOX
M1

SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2

C1M1

SERVO AMP
TERMINAL/FRAME
AXIS 3 & 7

C1M3

SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6

C1M2

AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)

ROBOT
M1
C2M1

M3

M3
C2M3

M2

M2
C2M2

P1

P1

C1P1

C2P1

C1M5

C2M5

AXIS CONTROL
PCB JF7
(PULSE CODER
SIGNALAXIS7)

CRR5 EMG PCB


P & M BRAKE
SIGNALS

D1

CONTACT SIGNAL
TRANSDUCER
(IBRC)

C1D1 (INTRINSIC)

+24PG & 0V
PURGE CONTROL
PCB

C1P2

D1
C2D1 (INTRINSIC)

P2

GROUND CABLE

C2P2

GROUND CABLE

DCDC
24V

5V

11. CONNECTIONS

1111

MARMMTRBL02303E

Figure 1212. Mechanical Connection Diagram, Common Part

(*2)

(*2)
or Floppy Disk Drive
(*3)

(*3)

(*3)

Auto breaker

(*3)

(*3)

*1:
*2:
*3:

K41 is optional. K40 is not required if K41 is specified.


This cable is provided with the FANUC Handy File or the floppy disk drive.
Not included. Must be supplied by the customer.

11. CONNECTIONS

1112

11.1.1
Robot Connection
Cables

MARMMTRBL02303E

For the S-420, cables K70, K71, and K72 are connected as shown in
Figure 1215.

11. CONNECTIONS

1113

MARMMTRBL02303E

11.1.2

For the P-155, cables C1M1, C1M2, C1M3, C1M5 and C1P1 are
connected as shown in Figure 1213 through Figure 1223.

Robot Connection
Cables
AMP 1

Figure 1213. Six-Axis Pedestal

AMP 2

AXIS

AMP 3

EMG

CONTROL

CONTROL

PCB
9
20
21
22

10
11
12

23

9
20
21
22

10
11
12

23

9
20
21
22

PCB

CRF1

10
CRR5

11
12

23

C1P1
<AXIS1

<AXIS2

<AXIS3
C1M5

C1M3

C1M1
<AXIS4

<AXIS5

<AXIS6

ROBOT
M1

C1M2

C1M1
M3
C1M3
M2
C1M2

P1
C1P1

C1M5

11. CONNECTIONS
MARMMTRBL02303E

1114
Figure 1214. Seven-Axis Catrac Robot Clean-Wall Rail
AMP 1

AMP 2

9
20
21
22

10
11
12

23

AMP 3

9
20
21
22

10
11
12

23

20
21
22

AMP 4

AMP 5

10

10

11

11

12

AXIS

EMG

CONTROL

CONTROL

PCB

PCB
CRF1

JF7

CRR5

12

23

C1M5

C1P1
<AXIS1

<AXIS2

<AXIS3

<AXIS7
(EXTENDED)

C1M3
C1M1
<AXIS4

<AXIS5

<AXIS6

C1M2

JUNCTION BOX

ROBOT

M1
C1M1

M1
C2M1

M3
C1M3

M3
C2M3

M2
C1M2

M2
C2M2

P1

P1

C1P1

C2P1

C1M5

C2M5

11. CONNECTIONS

1115

MARMMTRBL02303E

Figure 1215. Connection to Servo Amplifiers and Mechanical Unit for S-420
AXIS
CONTROL
PCB

CRM1

CRF1

K71
K72
K70

For the S-420 with three dual-axis servo amplifiers, ARC Mate, S-5, ARC
Mate Sr., and S-10, cables K70 and K71 are connected as shown in
Figure 1216.
Figure 1216. Connection to Servo Amplifiers and Mechanical Unit for S-420,
S-420D, ARC Mate, S-5, ARC Mate 100/S-6, ARC Mate Sr., S-10
AXIS
CONTROL
PCB

CRM1

CRF1

S-420,
S-420D
ARC Mate
ARCMate100/
S-6,
ARC Mate Sr.
S-10
S-5

K71

K70

11. CONNECTIONS
MARMMTRBL02303E

1116

For the S-500, cables K70, K71, and K72 are connected as shown in
Figure 1217.
Figure 1217. Connection to Servo Amplifiers and Mechanical Unit for S-500
AXIS
CONTROL
PCB

CRM1

CRF1

S-500

K71
K72
K70

For the S-700, cables K70, K71, and K72 are connected as shown in
Figure 1218.
Figure 1218. Connection to Servo Amplifiers and Mechanical Unit for S-700
AXIS
CONTROL
PCB

CRM1

CRF1

S-700

K71
K72
K70

11. CONNECTIONS

1117

MARMMTRBL02303E

For the S-800, cables K70, K71, and K72 are connected as shown in
Figure 1219
Figure 1219. Connection to Servo Amplifiers and Mechanical Unit for S-800
AXIS
CONTROL
PCB

CRM1

CRF1

S-800

K71
K72
K70

For the A-510, cables K70 and K71 are connected as shown in
Figure 1220
Figure 1220. Connection to Servo Amplifiers and Mechanical Unit for A-510
AXIS
CONTROL
PCB

CRM1

Not used

CRF1

A-510

K71

K70

11. CONNECTIONS
MARMMTRBL02303E

1118

For the M-400 and M-500, cables K70, K71, and K72 are connected as
shown in Figure 1221.
Figure 1221. Connection to Servo Amplifiers and Mechanical Unit for M-400 and
M-500
AXIS
CONTROL
PCB

CRM1

CRF1

M-400
M-500

K71
K72
K70

For the L-1000, cables K70 and K71 are connected as shown in
Figure 1222.
Figure 1222. Connection to Servo Amplifiers and Mechanical Unit for L-1000
AXIS
CONTROL
PCB

CRM1

CRF1

L-1000

K71

K70

11. CONNECTIONS

1119

MARMMTRBL02303E

Figure 1223. Seven-Axis Universal Rail


AMP 1

AMP 2

9
20
21
22

10
11
12

23

AMP 3

9
20
21
22

10
11
12

23

20
21
22

AMP 4

AMP 5

10

10

11

11

12

AXIS

EMG

CONTROL

CONTROL

PCB

PCB
CRF1

JF7

CRR5

12

23

C1M5

C1P1
<AXIS1

<AXIS2

<AXIS3

<AXIS7
(EXTENDED)

C1M3

C1M1
<AXIS4

<AXIS5

<AXIS6

C1M2

JUNCTION BOX

ROBOT

M1
C1M1

M1
C2M1

M3
C1M3

M3
C2M3

M2
C1M2

M2
C2M2

P1

P1

C1P1

C2P1

C1M5

C2M5

11. CONNECTIONS
MARMMTRBL02303E

1120

11.1.3

Use the following guidelines when connecting the input power supply:

Connecting the Input


Power Supply

Adjust the input transformer taps depending on the plant input voltage
before supplying power to the robot. Refer to Section 1.9 for the
correct tap setting information.

Consider the robot power capacity and the circuit breaker capacity.
Use the correct gauge wire to withstand the maximum current used.

Connect the power supply to the terminals located above the circuit
breaker or on the top of the disconnect.

Use a ground of class 3 or better.

Be sure to ground the work table or fixture used by an arc welding


robot so that it can handle the large current.

The motor is driven by the PWM inverter system using the power
transistor bridge. If the servo amplifier is used without a transformer, a
high-frequency leakage current flows through the stray capacitance
between the ground and the motor coils, power cable, and amplifier. This
might cause the leakage-current circuit breaker or leakage-protection relay
installed in the path of the power supply to cut out.
If connecting power directly to the servo amplifiers, use the leakage
current circuit breaker listed in Table 111 to prevent incorrect operation.
Table 111.

Example of Leakage Current Circuit Breaker for Inverters

Manufacture
Fuji Electric Co
Co., Ltd
Ltd.
Hitachi Ltd.
Hitachi,
Ltd
Matsushita Electric Works,
Works Ltd.
Ltd

Type
EG A series
SG A series
ES100C type
ES225C type
Leakage current circuit breaker, C type
Leakage current circuit breaker, KC type

Figure 1224 shows the cable connection for a circuit


breaker.Figure 1225 shows the cable connection for a fused flange
disconnect.
Figure 1225 shows the cable connection for a fused flange disconnect.

11. CONNECTIONS

1121

MARMMTRBL02303E

Figure 1224. Input Power Supply Connection, Circuit Breaker

Figure 1225. Input Power Supply Connection, Fused Flange Disconnect

K01

Main
Disconnect

FL1 FL2 FL3

Fuse Block

11. CONNECTIONS
MARMMTRBL02303E

1122

11.1.4
Connecting the
External Power Supply
ON/OFF Switch

The external power on/off signal turns on and off the power supply from
outside of the control unit, and is connected as shown in Figure 1227.

Figure 1226. External Power Supply ON/OFF Switch Connection


19

24

20

EXON

48

33 34

62

31 32

EXOFF

49

25
External power supply ON/OFF switch
Use a contact conforming to the following: Voltage rating: 50 VDC, current: 100 mA or more.

The power supply on/off timing chart is as follows:

11. CONNECTIONS

1123

MARMMTRBL02303E

Figure 1227. External Power Supply ON/OFF Switch Connection


EMG
PCB

Power on

Power off

External power supply ON/OFF switch


Use a contact conforming to the following: Voltage rating: 50 VDC, current: 100 mA or more.

The power supply on/off timing chart is as follows:

11. CONNECTIONS
MARMMTRBL02303E

1124

Figure 1228. External Emergency Stop Output Connection

19

EMG OUT1

24
EMG OUT C

External Emergency
Stop Connection

The external emergency stop connection is shown in Figure 1229 and


Figure 1231 and described in Table 112 and Table 113.

EMG OUT 2

27 28

11.1.5

EMG B1

20
1

62

48

49

25
Emergency Stop
Control PCB

EMGB2

11. CONNECTIONS

1125

MARMMTRBL02303E

Figure 1229. External Emergency Stop Output Connection

EMG
PCB

CRR3

CRR4

Emergency stop
control board

Table 112.
Signal

External Emergency Stop Output Signals


Description

Current,
Voltage

Emergency stop output signals


EMGOUT1

The contact is open if an emergency stop


occurs or the power is turned off.

EMGOUTC

The contact is closed during normal


operation.

EMGOUT2

Emergency stop output signals.

Rated contact:
250 VAC, 5
5-A
A
resistor load

The contact is open during normal operation.


EMGOUTC

EMGB1

The contact is closed if an emergency stop


occurs or the power is turned off.
Emergency stop output signals of the teach
pendant
The contact is open if the emergency stop
button on the teach pendant is pressed.

EMGB2

The contact is closed during normal


operation.

Rated contact:
24 VDC, 0.1-A
resistor load

11. CONNECTIONS
MARMMTRBL02303E

1126
Figure 1230. External Emergency Stop Input Connection

19

45 46

*E1N1

43 44

24

*E1NC

20
62

48

49

*E1NC

External EStops

*E1N2

35 36

*FENCE 1

25

*FENCE 2
* Jumper across switches when not in use.

11. CONNECTIONS

1127

MARMMTRBL02303E

Figure 1231. External Emergency Stop Input Connection

External Emergency stop switch


Connected at
shipment
(Note)
Connect to IMSTP
on the UOP
Printed circuit board
for emergency control

Door switch on safety fence


Connected at
shipment

Note: Connect to EMGIN1 or EMGIN2.

To connect to the external emergency stop input, connect a double-pole


emergency stop switch to both the Emergency Stop printed circuit board
and the peripheral device interface.
Use a contact rated at 250 V, 10 A or more on the Emergency Stop printed
circuit board.
Table 113.
Signal
EMGIN1
EMGINC
EMGIN
EMGIN2
EMGINC

External Emergency Stop Input Signals


Description
Connect one of the external emergency stop
switch circuits to the terminals.
100 VAC, 5 A,
If the external emergency stop switch is
open/close
pressed, the 100 VAC power for the motor is
cut directly. To affect EMGOUT1 or EMGOUT2,
connect to EMGIN1 and EMGINC. To not
affect EMGOUT1 or EMGOUT2, connect to
EMGIN2 and EMGINC.
If these signals are not used, short all external
emergency stop terminals together.
These signals are used to stop the robot when
the door on the safety fence is open.

FENCE1
FENCE2

Current,
Voltage

While the DEADMAN switch on the teach


pendant is pressed and the teach pendant
enable switch is ON, these signals are ignored
and an emergency stop does not occur.

24 VDC, 0.1 A,
open/close

If these signals are not used, short these


terminals.

M3 screws are provided on the terminal. Use crimp terminals 7 mm wide


or less.

11. CONNECTIONS
MARMMTRBL02303E

1128

11.2
PERIPHERAL DEVICE
AND END EFFECTOR
INTERFACES

11.3
PERIPHERAL DEVICE,
ARC WELDING, AND
END EFFECTOR
INTERFACES
No.

Name

The R-J I/O peripheral device interfaces include process I/O printed circuit
boards and/or a modular I/O unit selected according to the applications.
Table 114 lists the printed circuit boards and unit. Figure 1234 shows
the locations.

The R-J I/O peripheral device interfaces include process I/O printed circuit
boards and/or a modular I/O unit selected according to the applications.
Table 114 lists the printed circuit boards and unit. Figure 1232 and
Figure 1233 show their locations.
Table 114.

Peripheral Device Interface Types


Number of I/O
Points

Part Number

Remarks

DI

DO

D/A

A/D

Process I/O printed circuit board AA

A16B-2200-0780

40

40

Standard (with welding interface)

Process I/O printed circuit board AB

A16B-2200-0782

40

40

Standard (without welding interface)

Process I/O printed circuit board BA

A16B-2201-0510
(weld interface)
A20B-2000-0540

32

32

Source type DO (with welding


interface)

Process I/O printed circuit board BB

A16B-2201-0510

32

32

Process I/O printed circuit board CA

A16B-2201-0470

40

40

Process I/O printed circuit board CB

A16B-2201-0472

40

40

Process I/O printed circuit board DA

A16B-2201-0480

96

96

I/O unit model

A03B-0807-C002

Depending on a
selected I/O module

Source type DO (without welding


interface)
Backplane installation type (with
welding interface)
Backplane installation type (without
welding interface)
Backplane installation type (without
welding interface)
Up to 5 slots

A03B-0807-C001

Up to 10 slots

11. CONNECTIONS

1129

MARMMTRBL02303E

Figure 1232. Locations of Peripheral Device Interfaces, B-Size Controller

Main CPU printed circuit board


Printed circuit board for
emergency stop control

Process I/O printed circuit board


CA/CB/DA
Modular I/O unit or
Process I/O printed circuit board
AA/AB/BA/BB or I/O unit model A

11. CONNECTIONS
MARMMTRBL02303E

1130

Figure 1233. Locations of Peripheral Devices, C-Size Controller

Operator panel

Extended
Back plane

Modular I/O rack or


Process I/O rack

Power disconnect

Main CPU

Servo Amplifiers #1

Fuses FL13

Servo Amplifiers #2

Axis control board

Servo Amplifiers #3

Power supply unit

Emergency stop
control board

Servo Amplifiers #4 and #5


Servo Amplifiers #6

Option 1 and 2 slots

Multitap transformer
User transformer

11. CONNECTIONS

1131

MARMMTRBL02303E

Figure 1234. Locations of Peripheral Devices, C-Size Controller

Operator panel

Servo Amplifiers

STAHL
ISBs

Extended
Back plane

STBI Term Strip


Purge 24V DC
Power Supply
Power disconnect

Main CPU
Fuses FL13
Transit Board

Axis control board


Power supply unit

Emergency stop
control board
Option 1 and 2 slots

BDX
ISB Unit

ALC
relay

Multitap transformer
User transformer

11. CONNECTIONS
MARMMTRBL02303E

1132

11.3.1
Peripheral Device
Interface Combination

Process I/O printed circuit board AA, AB, BA, BB, CA, CB, and DA and
an I/O unit can be combined. Figure 1235 shows the combinations.

Figure 1235. Peripheral Device Interface Combination


1 Board

2-Board Combination

3-Board Combination

11. CONNECTIONS

1133

MARMMTRBL02303E

11.3.2
Process I/O Printed
Circuit Board AA or AB
Figure 1236. Process I/O Printed Circuit Board AA or AB

(Additional analog
signal input)

CRW1 and CRW2 are not provided for process I/O printed circuit board BB.
Table 115.
Cable
Number
K10

K50A
K50B

Name

Process I/O Printed Circuit Board AA or AB

Drawing Number

Process I/O connection cable

A05B2300J013
A05B2302J110

Peripheral device connection cable

A05B2302J11
A05B2302J112

K45

Welder connection cable

K46

Peripheral device connection cable

A05B2302J270
A05B2302J271
A05B2302J272

Remarks
R-J control unit internal cable
Connected length: 7 m
Honda Tsushin, 50 pins: one-to-one
Connected length: 14 m
Honda Tsushin, 50 pins: one-to-one
Connected length: 30 m
Honda Tsushin, 50 pins: one-to-one
Connected length: 3 m
Connected length: 6 m
Connected length: 13 m
Cannot be used for TIG welding
Not included. Must be supplied by customer.

11. CONNECTIONS
MARMMTRBL02303E

1134

11.3.3
Process I/O Printed
Circuit Board BA or BB
Figure 1237. Process I/O Printed Circuit Board BA or BB

(Additional analog
signal input)
CRW1 and CRW2 are not provided for process I/O printed circuit board BB.

Table 116.
Cable
Number
K10
K52
K53

Process I/O Printed Circuit Board BA or BB

Name

Drawing Number

Process I/O connection cable


Peripheral device connection cable
Peripheral device connection cable

A05B2300J013

A05B2302J270
A05B2302J271
A05B2302J272

K45

Welder connection cable

K46

Peripheral device connection cable

Remarks
R-J control unit internal cable
Not included. Must be supplied by the customer.
Not included. Must be supplied by the customer.
Connected length: 3 m
Connected length: 6 m
Connected length: 13 m
Cannot be used for TIG welding
Not included. Must be supplied by customer.

11. CONNECTIONS

1135

MARMMTRBL02303E

11.3.4
Process I/O Printed
Circuit Board CA or CB
Figure 1238. Process I/O Printed Circuit Board CA or CB

(Additional analog
signal input)

CRW1 and CRW2 are not provided for process I/O printed circuit board BB.

Table 117.
Cable
Number
K10
K11
K50A,
K50B
K50C
K50D

Process I/O Printed Circuit Board CA or CB

Name

Drawing Number

Process I/O connection cable


Peripheral device connection cable

A05B2300J013
A05B2300J014
A05B2302J113

Peripheral device connection cable

A05B2302J114
A05B2302J115

K45

Welder connection cable

K46

Peripheral device connection cable

A05B2302J273
A05B2302J274
A05B2302J275

Remarks
R-J control unit internal cable
R-J control unit internal cable (for connecting
additional printed circuit boards)
Connected length: 7 m
Honda Tsushin, 50 pins: one-to-one
Connected length: 14 m
Honda Tsushin, 50 pins: one-to-one
Connected length: 30 m
Honda Tsushin, 50 pins: one-to-one
Connected length: 3 m
Connected length: 6 m
Connected length: 13 m
Cannot be used for TIG welding
Not included. Must be supplied by customer.

11. CONNECTIONS
MARMMTRBL02303E

1136

11.3.5

Up to two boards can be installed in one cabinet.

Process I/O Printed


Circuit Board DA

Figure 1239. Process I/O Printed Circuit Board DA

Table 118.
Cable
Number
K10
K11

Process I/O Printed Circuit Board DA

Name

Drawing Number

Process I/O connection cable


Peripheral device connection cable

A05B2300J013
A05B2300J014
A05B2302J113

K50
A-H

Peripheral device connection cable

A05B2302J114
A05B2302J115
A05B2302J120

K51
A-D

Welder connection cable

A05B2302J121
A05B2302J122

Remarks
R-J control unit internal cable
R-J control unit internal cable (for connecting
additional printed circuit boards)
Connected length: 7 m
Honda Tsushin, 50 pins: one-to-one
Connected length: 14 m
Honda Tsushin, 50 pins: one-to-one
Connected length: 30 m
Honda Tsushin, 50 pins: one-to-one
Connected length: 7 m
Honda Tsushin, 20 pins: one-to-one
Connected length: 14 m
Honda Tsushin, 20 pins: one-to-one
Connected length: 30 m
Honda Tsushin, 20 pins: one-to-one

11. CONNECTIONS

1137

MARMMTRBL02303E

11.3.6
Process I/O Printed
Circuit Board with the
Modular I/O Unit
Figure 1240. Process I/O Printed Circuit Board with Modular I/O

Table 119.
Cable
Number
K15

Name

Process I/O Printed Circuit Board DA

Drawing Number

I/O unit connection cable

K16

I/O unit power connection cable

K54

Peripheral device connection cable

Remarks
R-J control unit internal cable. Attached to the I/O
unit mainframe.
R-J control unit internal cable. Attached to the I/O
unit mainframe.
Not included. Must be supplied by the customer.

11. CONNECTIONS
MARMMTRBL02303E

1138

11.3.7
Two or More Process
I/O Boards with the
Modular I/O Unit

Figure 1241 shows the connection when two or more process I/O printed
circuit boards and the modular I/O unit are used. Up to two process I/O
CA/CB/DAs and 1 process I/O AA/AB/BA/BB or I/O unit model A can
be installed in one cabinet.
Figure 1241. Two or More Process I/O Boards and the I/O Unit (Model A)

Table 1110.
Cable
Number
K10
K11

Two or More Process I/O Boards and the I/O Unit (Model A)

Name

Drawing Number

Process I/O connection cable


Peripheral device connection cable

A05B2300J013
A05B2300J014

K12

Process I/O connection cable

A05B-2300-J017

K15

I/O unit connection cable

K16

I/O unit power connection cable

Remarks
R-J control unit internal cable
R-J control unit internal cable (for connecting
additional printed circuit boards)
R-J control unit internal cable for connecting
additional printed circuit boards.
R-J control unit internal cable. Attached to the I/O
unit mainframe.
R-J control unit internal cable. Attached to the I/O
unit mainframe.

11. CONNECTIONS

1139

MARMMTRBL02303E

11.3.8
Peripheral Device and
Control Unit
Connection

There are 18 exclusive data inputs (DI) and 20 exclusive data outputs (DO)
for a process I/O printed circuit board. These signals are allocated to the
process IO printed circuit board connected first when two or more printed
boards are combined. General signals SI/SO are allocated to the second
and the following process I/O printed circuit boards.
The common voltage of the DI signals input to pins 1 to 4 of connector
CRM2A is clamped +24V (common) in each process I/O printed circuit
board. This is also true when multiple boards are combined.
Table 1111 shows signals of a process I/O printed circuit board
Table 1111.

Process I/O Printed Circuit Board Signals, DI Signals

Connector Number

Signal Name

CRM2A-1

*IMSTP

Immediate stop

Clamped at +24V common

CRM2A-2

*HOLD

Temporary stop

Clamped at +24V common

CRM2A-3

*SFSD

Safe speed

Clamped at +24V common

CRM2A-4

CSTOPI

Cycle stop

Clamped at +24V common

CRM2A-5

FAULT RESET

CMR2A-6

START

Start

CRM2A-7

HOME

Return to home position

CRM2A-8

ENBL

Operation enabled

CRM2A-9

RSR1

Robot service request

PNS1

Program number selection

CRM2A-10

RSR2

Robot service request

PNS2

Program number selection

CRM2A-11

RSR3

Robot service request

PNS3

Program number selection

CRM2A-12

RSR4

Robot service request

PNS4

Program number selection

RSR5

Robot service request

PNS5

Program number selection

RSR6

Robot service request

PNS6

Program number selection

CRM2A-15

RSR7

Robot service request

PNS7

Program number selection

CRM2A-16

RSR8

Robot service request

PNS8

Program number selection

CRM2A-29

PNSTROBE

CMR2A-30

PROD START

CRM2A-13
CRM2A-14

Description

Remarks

External reset

PNS strobe
Start of automatic operation

Option
Option
Option
Option
Option
Option
Option
Option

11. CONNECTIONS
MARMMTRBL02303E

1140

Table 1111. (Contd) Process I/O Printed Circuit Board Signals, DI Signals
Connector Number

Signal Name

CRM2A-31

SI01

CRM2A-32

SI02

CRM2B-1

SI03

CRM2B-2

SI04

CRM2B-3

SI05

CRM2B-4

SI06

CRM2B-5

SI07

CRM2B-6

SI08

CRM2B-7

SI09

CRM2B-8

SI10

CRM2B-9

SI11

CRM2B-10

SI12

CRM2B-11

SI13

CRM2B-12

SI14

CRM2B-13

SI15

CRM2B-14

SI16

CRM2B-15

SI17

CRM2B-16

SI18

CRM2B-29

SI19

CRM2B-30

SI20

CRM2B-31

SI21

CRM2B-32

SI22

Connector Number

Signal Name

CRM2A-33

CMDENBL

CRM2A-34

SYSRDY

CRM2A-35

PROGRUN

CRM2A-36

PAUSED

Description
Peripheral device status

Table 1112.

Description
Preparation completed
During regeneration
Program being interrupted

HELD

During temporary stop

FAULT

Alarm

CRM2A-40

ATPERCH

CRM2A-41

TPENBL

Teach pendant enabled

CRM2A-43

BATALM

Battery voltage drop

CRM2A-44

BUSY

During operation

CRM2A-19

Remarks

During automatic operation

CRM2A-39

CRM2A-46

General signal

Process I/O Printed Circuit Board Signals, DO Signals

CRM2A-38

CRM2A-45

Remarks

Home position

ACK1

Robot service request acceptance

SNO1

Selected program number

ACK2

Robot service request acceptance

SNO2

Selected program number

ACK3

Robot service request acceptance

SNO3

Selected program number

Option
Option
Option

11. CONNECTIONS

1141

MARMMTRBL02303E

Table 1112. (Contd) Process I/O Printed Circuit Board Signals, DO Signals
Connector Number

Signal Name

CRM2A-20

ACK4

Robot service request acceptance

SNO4

Selected program number

ACK5

Robot service request acceptance

SNO5

Selected program number

ACK6

Robot service request acceptance

SNO6

Selected program number

CRM2A-21
CRM2A-22
CRM2A-24
CRM2A-25

Description

Remarks
Option
Option
Option

ACK7

Robot service request acceptance

SNO7

Selected program number

ACK8

Robot service request acceptance

SNO8

Selected program number

Option

Peripheral device control signal

General signal

CRM2A-26

SNACK

CRM2A-27

RESERVED

CRM2B-33

SO01

CRM2B-34

SO02

CRM2B-35

SO03

CRM2B-36

SO04

CRM2B-38

SO05

CRM2B-39

SO06

CRM2B-40

SO07

CRM2B-41

SO08

CRM2B-43

SO09

CRM2B-44

SO10

CRM2B-45

SO11

CRM2B-46

SO12

CRM2B-19

SO13

CRM2B-20

SO14

CRM2B-21

SO15

CRM2B-22

SO16

CRM2B-24

SO17

CRM2B-25

SO18

CRM2B-26

SO19

CRM2B-27

SO20

Option

11. CONNECTIONS
MARMMTRBL02303E

1142

Figure 1242. Peripheral Device and Control Unit Connection -A1/A2

Note 1: The peripheral device connection cables


are optional.
Note 2: All of COM** are connected 0 V.

Table 1113.
Type
AA
AB
BA
BB
CA
CB
DA

Applicable Process I/O Printed Circuit Board - A1/A2


Specifications
A05B-2300-J001
A05B-2300-J002
A05B-2300-J020
A05B-2300-J021
A05B-2300-J030
A05B-2300-J031
A05B-2300-J035

 = applicable  = not applicable

CRM2A








CRM2B








11. CONNECTIONS

1143

MARMMTRBL02303E

Figure 1243. Peripheral Device and Control Unit Connection -A3/A4

Note 1: The peripheral device connection cables


are optional.
Note 2: All of COM** are connected 0 V.

Table 1114.

Applicable Process I/O Printed Circuit Board - A3/A4

Type
AA
AB
BA
BB
CA
CB
DA
 = applicable
 = not applicable

Specifications
A05B-2300-J001
A05B-2300-J002
A05B-2300-J020
A05B-2300-J021
A05B-2300-J030
A05B-2300-J031
A05B-2300-J035

CRM2C








CRM2D








11. CONNECTIONS
MARMMTRBL02303E

1144

Figure 1244. Peripheral Device and Control Unit Connection - B1/B2

Note 1: The peripheral device connection


cables are optional.
Note 2: All of COM** are connected 0 V.

Table 1115.

Applicable Process I/O Printed Circuit Board - B1/B2

Type
AA
AB
BA
BB
CA
CB
DA
 = applicable
 = not applicable

Specifications
A05B-2300-J001
A05B-2300-J002
A05B-2300-J020
A05B-2300-J021
A05B-2300-J030
A05B-2300-J031
A05B-2300-J035

CRM4A








CRM4B








11. CONNECTIONS

1145

MARMMTRBL02303E

Figure 1245. Peripheral Device and Control Unit Connection -C1

Note 1: The peripheral device connection cable is not


supplied by FANUC. It must be supplied by the
customer.

Table 1116.

Applicable Process I/O Printed Circuit Board - C1

Type
AA
AB
BA
BB
CA
CB
DA
 = applicable
 = not applicable

Specifications
A05B-2300-J001
A05B-2300-J002
A05B-2300-J020
A05B-2300-J021
A05B-2300-J030
A05B-2300-J031
A05B-2300-J035

TBI1








TB01








11. CONNECTIONS
MARMMTRBL02303E

1146

Figure 1246. Peripheral Device Interface Control for A1, A2, A3, and A4
Control Unit

A4

A1

Connector pin No.


+24E CRM2A(49,50)

A3

A2

SI43

SI23

SI03

*IMSTP

RV

SI44

SI24

SI04

*HOLD

RV

SI45

SI25

SI05

*SFSPD

RV

SI46

SI26

SI06

*CSTOPI

RV

SI47

SI27

SI07

FAULT RESET

RV

SI48

SI28

SI08

START

RV

SI49

SI29

SI09

HOME

RV

SI50

SI30

SI10

ENBL

RV

SI51

SI31

SI11

RSR1/PNS1

RV

SI52

SI32

SI12

RSR2/PNS2

RV

SI53

SI33

SI13

RSR3/PNS3

RV

SI54

SI34

SI14

RSR4/PNS4

RV

SI55

SI35

SI15

RSR5/PNS5

RV

SI56

SI36

SI16

RSR6/PNS6

RV

SI57

SI37

SI17

RSR7/PNS7

RV

SI58

SI38

SI18

RSR8/PNS8

RV

SI59

SI39

SI19

PNSTROBE

RV

SI60

SI40

SI20

PROD START

RV

SI61

SI41

SI21

SI01

RV

SI62

SI42

SI22

SI02

RV

Note: For A1, CRM2x = CRM2A and ICOMn = ICOM1


For A2, CRM2x = CRM2B and ICOMn = ICOM2
For A3, CRM2x = CRM2C and ICOMn = ICOM3
For A4, CRM2x = CRM2D and ICOMn = ICOM4

CRM2x (1)

CRM2x (2)

CRM2x (3)

CRM2x (4)

CRM2x (5)

CRM2x (6)

CRM2x (7)

CRM2x (8)

CRM2x (9)

CRM2x (10)

CRM2x (11)

CRM2x (12)

CRM2x (13)

CRM2x (14)

CRM2x (15)

CRM2x (16)

CRM2x (29)

CRM2x (30)

CRM2x (31)

CRM2x (32)

+24E
B

Common switching
set pin (ICOMn)

Peripheral device

11. CONNECTIONS

1147

MARMMTRBL02303E

Figure 1247. Peripheral Device Interface for A1, A2, A3, and A4

Control Unit

Connector Pin No.

A4

A3

A2

SO41

SO21

SO01

CMDENBL

SO42

SO22

SO02

SYSRDY

SO43
SO44
SO45
SO46
SO47

SO23
SO24
SO25
SO26
SO27

SO03
SO04
SO05
SO06
SO07

A1

PROGRUN
PAUSED
HELD
FAULT
ATPERCH

Peripheral Device

LOAD
DV

CRM2x(33)

RELAY

DV
DV
DV
DV
DV
DV

SO48

SO28

SO08

TPENBL

DV

SO49

SO29

SO09

BATALM

DV

SO50

SO30

SO10

BUSY

DV

SO51

SO31

SO11

ACK1/SNO1

DV

SO52

SO32

SO12

ACK2/SNO2

DV

SO53

SO33

SO13

ACK3/SNO3

DV

SO54

SO34

SO14

ACK4/SNO4

DV

SO55

SO35

SO15

ACK5/SNO5

DV

SO56

SO36

SO16

ACK6/SNO6

DV

SO57

SO37

SO17

ACK7/SNO7

DV

SO58

SO38

SO18

ACK8/SNO8

DV

SO59

SO39

SO19

SNACK

DV

SO60

SO40

SO20

RESERVED

DV

CRM2x(34)
CRM2x(35)
CRM2x(36)
CRM2x(38)
CRM2x(39)
CRM2x(40)
CRM2x(41)
CRM2x(43)
CRM2x(44)
CRM2x(45)
CRM2x(46)
CRM2x(19)
CRM2x(20)
CRM2x(21)
CRM2x(22)
CRM2x(24)
CRM2x(25)
CRM2x(26)
CRM2x(27)

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

CRM2x(23,28,37,42,47)

Note: For A1, CRM2x = CRM2A


For A2, CRM2x = CRM2B
For A3, CRM2x = CRM2C
For A4, CRM2x = CRM2D

0V
+24V
+24V regulated
power supply

11. CONNECTIONS
MARMMTRBL02303E

1148
Figure 1248. Peripheral Device Control Interface B1

Connector pin No.


+24E CRM4A(49,50)

SI63

RV

SI64

RV

SI65

RV

SI66

RV

SI67

RV

SI68

RV

SI69

RV

SI70

RV

Peripheral device

CRM4A(1)

CRM4A(2)

CRM4A(3)

CRM4A(4)

CRM4A(5)

CRM4A(6)

CRM4A(7)

CRM4A(13)

+24V B

Common Switching
Set Pin
(Icom5)

Connector Pin No.

LOAD
DV

CRM4A(14)

SO61

SO62
SO63
SO64
SO65
SO66
SO67
SO68

DV
DV
DV
DV
DV
DV
DV

CRM4A(15)
CRM4A(16)
CRM4A(17)
CRM4A(8)
CRM4A(9)
CRM4A(10)
CRM4A(11)

RELAY

LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD

CRM4A(20)
0V
+24V
+24V regulated
power supply

11. CONNECTIONS

1149

MARMMTRBL02303E

Figure 1249. Peripheral Device Control Interface B2

Connector pin No.


+24E CRM4B(49,50)

SI71

RV

SI72

RV

SI73

RV

SI74

RV

SI75

RV

SI76

RV

SI77

RV

SI78

RV

Peripheral device

CRM4B(1)

CRM4B(2)

CRM4B(3)

CRM4B(4)

CRM4B(5)

CRM4B(6)

CRM4B(7)

CRM4B(13)

+24V B

Common Switching
Set Pin
(Icom5)

Connector Pin No.

LOAD
DV

CRM4B(14)

SO69

SO70

DV

SO71

DV

SO72

DV

SO73

DV

SO74

DV

SO75

DV

SO76

DV

CRM4B(15)
CRM4B(16)
CRM4B(17)
CRM4B(8)
CRM4B(9)
CRM4B(10)
CRM4B(11)

RELAY

LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD

CRM4B(20)
0V
+24V
+24V regulated
power supply

11. CONNECTIONS
MARMMTRBL02303E

1150
Figure 1250. Peripheral Device Control Interface C1

Peripheral device
Receiver Circuit

*IMSTP

RV

*HOLD

RV

*SFSPD

RV

CSTOPI

RV

FAULT RESET

RV

START

RV

HOME
ENBL

TBI(1)

TBI(2)

TBI(3)

TBI(4)

TBI(5)

TBI(6)

TBI(7)

RV
TBI(8)

RV
COM1

TBI(9)

COM
(+24V or 0V)

0V TBI(10)
0V
+24V
+24V regulated
power supply

Receiver Circuit

RSR1/PNS1

RV

RSR2/PNS2

RV

RSR3/PNS3

RV

RSR4/PNS4

RV

RSR5/PNS5

RV

RSR6/PNS6

RV

RSR7/PNS7

RV

RSR8/PNS8

RV

TBI(11)

TBI(12)

TBI(13)

TBI(14)

TBI(15)

TBI(16)

TBI(17)

TBI(18)

COM2

TBI(19)

0V TBI(20)

COM
(+24V or 0V)

11. CONNECTIONS

1151

MARMMTRBL02303E

Figure 1251. Peripheral Device Control Interface C1

Peripheral device
Receiver Circuit

PNSTROBE

RV

PROD START

RV

SI01

RV

SI02

RV

SI03

RV

SI04

RV

SI05

RV

SI06

RV

TBI(21)

TBI(22)

TBI(23)

TBI(24)

TBI(25)

TBI(26)

TBI(27)

TBI(28)

COM1

TBI(29)

COM
(+24V or 0V)

0V TBI(30)

Receiver Circuit

SI07

RV

SI08

RV

SI09

RV

SI10

RV

SI11

RV

SI12

RV

SI13

RV

SI14

RV

TBI(31)

TBI(32)

TBI(33)

TBI(34)

TBI(35)

TBI(36)

TBI(37)

TBI(38)

COM1

TBI(39)

0V TBI(40)

COM
(+24V or 0V)

11. CONNECTIONS
MARMMTRBL02303E

1152
Figure 1252. Peripheral Device Control Interface C1

Control unit
(peripheral device control interface C1)

Peripheral device

+ 24 V regulated
power supply

Internal
circuit

+ 24 V regulated
power supply

Internal
circuit

11. CONNECTIONS

1153

MARMMTRBL02303E

Figure 1253. Peripheral Device Control Interface C1

Control unit
(peripheral device control interface C1)

Peripheral device
+ 24 V regulated
power supply

Internal
circuit

+ 24 V regulated
power supply

Internal
circuit

11. CONNECTIONS
MARMMTRBL02303E

1154
Figure 1254. Peripheral Device Control Interface C1

Control unit
(peripheral device control interface C1)

Peripheral device

+ 24 V regulated
power supply

Internal
circuit

+ 24 V regulated
power supply

Internal
circuit

11. CONNECTIONS

1155

MARMMTRBL02303E

Figure 1255. Peripheral Device Control Interface C1

Control unit
(peripheral device control interface C1)

Peripheral device

+ 24 V regulated
power supply

Internal
circuit

+ 24 V regulated
power supply

Internal
circuit

11. CONNECTIONS
MARMMTRBL02303E

1156

11.3.9
Mechanical Unit and
End Effector
Connection

Figure 1256. Mechanical Unit and End Effector

Mechanical unit

Refer to Figure 11-42 to 1145 for pin


configuration for your specific robot.

+24V B

End Effector

A
Common switching
set pin

11. CONNECTIONS

1157

MARMMTRBL02303E

Figure 1257. End Effector Pin Configuration Arc Mate/S-5, Arc Mate Sr/S-10,
S-420, S-500, S-700, S-800, S-900, M-400 and M-500

End Effector

Figure 1258. End Effector Pin Configuration Arc Mate 100/S-6

End Effector

OR

RDO1

*HBK

0V

RDI1

+24E

11. CONNECTIONS
MARMMTRBL02303E

1158
Figure 1259. End Effector Pin Configuration A-510

End Effector

Figure 1260. End Effector Pin Configuration L-1000

End Effector

11. CONNECTIONS

1159

MARMMTRBL02303E

11.3.10
Control Unit and
Welder Connection
Figure 1261. Control Unit and Welder Connection - CRW1/CRW2

Note: The welder and peripheral device


connection cable are optional.

Table 1117.

Applicable Process I/O Printed Circuit Board

Type
AA
AB
BA
BB
CA
CB
DA
 = applicable
 = not applicable

Specifications
A05B-2300-J001
A05B-2300-J002
A05B-2300-J020
A05B-2300-J021
A05B-2300-J030
A05B-2300-J031
A05B-2300-J035

CRW1








CRW2








11. CONNECTIONS

1160

MARMMTRBL02303E

Figure 1262. Control Unit and Welder Connection - CRW1 Analog Signal
Assignment

11. CONNECTIONS

1161

MARMMTRBL02303E

Figure 1263. Control Unit and Welder Connection - CRW1 Digital Signal
Assignment

11. CONNECTIONS

1162

MARMMTRBL02303E

Figure 1264. Control Unit and Welder Connection - CRW2 Analog Signal
Assignment

11. CONNECTIONS

1163

MARMMTRBL02303E

11.3.11

Table 1118 contains the specifications of the peripheral device interface.

Peripheral Device
Interface
Table 1118.
Example of Connection

Type
Output signals
in peripheral
device interface
A and B

Peripheral Device Interface Specifications


Signal Standards
Electrical Specifications
Rated voltage:
Maximum applied voltage:
Maximum load current:
Transistor type:
Saturation voltage at connection:

24 VDC
30 VDC
0.2 A
Open collector NPN
1.0 V (approx.)

Spark Killer Diode


Rated peak reverse voltage:
Rated effective forward current:

100 V or more
1 A or more

Note on Use
Do not use the +24V 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 is connected
causing a surge current when a lamp is turned on,
use a protective resistance.
Applicable Signals
Output signals of process I/O printed circuit board CRM2
and CRM4; CMDENBL, SYSRDY, PROGRUN, PAUSED,
HELD, FAULT, ATPERCH, TPENBL, BATALM, BUSY,
ACK1 to ACK8, SNO1 to SNO8, SNACK, SO1 to SO20

Input signals in
peripheral
device interface
A and B

Electrical Specifications of the Receiver


Type:
Grounded voltage receiver
Rated input voltage: Contact closed: +20V to +28V
Contact open: 0V to +4V
Maximum applied
input voltage:
+28 VDC
Input impedance:
3.3 k (approx.)
Response time:
5 ms to 20 ms

Peripheral
device
contact
signal

Robot
receiver
signal

TB: Chattering 5 ms or less


TC: 5 to 20 ms

Specifications of the Peripheral Decive Contact


Rated contact 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  or less
Opened circuit resistance: 100 k or more
Note on Use
Apply the +24V 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 printed circuit board CRM2
and CRM4; *IMSTP, *HOLD, *SFSD, CSTOPI, FAULT
RESET, START, HOME, ENBL, RSR1 to RSR8, PNS1 to
PNS8, PNSTROBE, PROD STASRT, SI1 to SI22

11. CONNECTIONS
MARMMTRBL02303E

1164

Table 1118. (Contd) Peripheral Device Interface Specifications


Type

Example of Connection

Output signals
in peripheral
device interface
C

Signal Standards
Electrical Specifications
Rated voltage:
24 VDC
Maximum applied voltage:
30 VDC
Maximum load current:
1.6 A (*1)
*1: This value is the maximum load current at one point.
When four points on the same common are turned on at
the same time, the maximum load current at one common
is 5.0 A.
Spark Killer Diode
Rated peak reverse voltage:
100 V or more
Rated effective forward current:
1 A or more
Note 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 is connected causing a surge current
when a lamp is turned on, use a protective resistance.
Applicable Signals
Output signals of process I/O printed circuit board BA/BB
TBO1; CMDENBL, SYSRDY, PROGRUN, PAUSED,
HELD, FAULT, ATPERCH, TPENBL, BATALM, BUSY,
ACK1 to ACK8, SNO1 to SNO8, SNACK, SO1 to SO12.

Input signals in
peripheral
device interface
C

Electrical Specifications of the Receiver


Type:
Grounded voltage receiver
Rated input voltage: Contact closed: +20V to +28V
Contact open:
0V to +4V
Maximum applied
input voltage:
+28 VDC
Input impedance:
3.3 k (approx.)
Response time:
5 ms to 20 ms
Specifications of the Peripheral Device Contact
Rated contact 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  or less
Opened circuit resistance: 100 k or more
Note on Use
Apply the +24V 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 printed circuit board BA/BB
TBI1; *IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET,
START, HOME, ENBL, RSR1 to RSR8, PNS1 to PNS8,
PNSTROBE, PROD STASRT, SI1 to SI24

Peripheral
device
contact
signal

Robot
receiver
signal

TB: Chattering 5 ms or less

TC: 5 to 20 ms

11. CONNECTIONS

1165

MARMMTRBL02303E

11.3.12
End Effector Control
Interface

Table 1119 contains the specifications of the end effector control


interface.
Table 1119.

End Effector Control Interface Signals

Example of Connection

Type
Output signals

Signal Standards
Electrical Specifications
Rated voltage:
Maximum applied voltage:
Maximum load current:
Transistor type:
Saturation voltage at connection:

24 VDC
30 VDC
0.2 A
Open collector NPN
1.0 V (approx.)

Spark Killer Diode


Rated peak reverse voltage:
Rated effective forward current:

100 V or more
1 A or more

Note on Use
The +24 V power supply at the robot can be used when
the total current of the welding interface and end effector
interface is 0.7 A or less. When loading a relay, solenoid,
and so on directly, connect them in parallel with diodes for
preventing 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 the end effector control interface
RO1 to RO8

Input signal

Electrical Specifications of the Receiver


Type:
Grounded voltage receiver
Rated input voltage: Contact closed: +20V to +28V
Contact open:
0V to +4V
Maximum applied
input voltage:
+28 VDC
Input impedance:
3.3 k (approx.)
Response time:
5 ms to 20 ms
Specifications of the Peripheral Device Contact
Rated contact 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  or less
Opened circuit resistance: 100 k or more
Peripheral
device
contact
signal

Note on Use
Apply the +24V power at the robot to the receiver.
However, the above signal specifications must be
satisfied at the robot receiver.

Robot
receiver
signal

Applicable Signals
Input signals of the end effector control interface
RI1 toRI 8, *HBK, *PPABN
TB: Chattering 5 ms or less

TC: 5 to 20 ms

11. CONNECTIONS
MARMMTRBL02303E

1166

11.3.13

Table 1120 contains the specifications of the arc welding interface.

Arc Welding Interface


Process I/O AA

Table 1120.

Arc Welding Interface Signals

Example of Connection

Type
Digital output
signals

Signal Standards
Electrical Specifications
Rated voltage:
Maximum applied voltage:
Maximum load current:
Transistor type:
Saturation voltage at connection:

24 VDC
30 VDC
0.2 A
Open collector NPN
1.0 V (approx.)

Spark Killer Diode


Rated peak reverse voltage:
Rated effective forward current:

100 V or more
1 A or more

Note on Use
The +24 V power supply at the robot can be used when
the total current of the welding interface and end effector
interface is 0.7 A or less. When loading a relay, solenoid,
and so on directly, connect them in parallel with diodes for
preventing 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 the end effector control interface
WO1 to WO8

Digital input
signals

Electrical Specifications of the Receiver


Type:
Grounded voltage receiver
Rated input voltage: Contact closed: +20V to +28V
Contact open:
0V to +4V
Maximum applied
input voltage:
+28 VDC
Input impedance:
3.3 k (approx.)
Response time:
5 ms to 20 ms
Specifications of the Peripheral Device Contact
Rated contact 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  or less
Opened circuit resistance: 100 k or more
Note on Use
Apply the +24V power at the robot to the receiver.
However, the above signal specifications must be
satisfied at the robot receiver.

Peripheral
device
contact
signal

Applicable Signals
Input signals of the arc welding interface
WI1 to WI8

Robot
receiver
signal

TB: Chattering 5 ms or less

TC: 5 to 20 ms

11. CONNECTIONS

1167

MARMMTRBL02303E

Table 1120. (Contd) Arc Welding Interface Signals


Type
Analog output
signals: welding
voltage
command, wire
feed speed
command

Analog input
signals: welding
voltage
detection,
welding current
detection

Analog input
signal: wire
stick detect
WDI+, WDI

Example of Connection
Arc Welding Interface

Arc Welding Interface

Arc Welding Interface

Signal Standards
Note on Use
Input impedance: 3.3 k or more
Install a high-frequency filter.

Note on Use
Output signals without ripples.

Note on Use
The resistance between the positive and negative
terminals on the welder must be 100  or more. The
maximum voltage of this circuit is 80 V. For TIG welding,
connected the wirestick detection signal line, insulating it
from a welding circuit (high frequency).

11. CONNECTIONS
MARMMTRBL02303E

1168

11.3.14

This section describes the connections and specifications for modular I/O
units.

Modular I/O Inputs

Table 1121.

Input Modules AID32A and AID32B, Nonisolated

AID32A

Item

AID32B

Points/module

32 points

32 points

Points/common

16 points/common

16 points/common

Sink/source current

Both directions

Both directions

Input voltage

24VDC +10% 20%

24 VDC +10% 20%

Input current

7.5mA (average)

7.5mA (average)

ON voltage current

Min. 18VDC min. 6 mA

Min. 18 VDC min. 6 mA

OFF voltage current

Max. 6VDC max. 1.5 mA

Max. 6VDC max. 1.5 mA

Respo
OFF  ON
nse
Time

Max. 20
ms

ON  OFF

Max. 20
ms

This is the value from input to output


in the module. The actual value is
determined by adding it to the
scanning time depending on each
system.

Max. 2 ms
Max. 2 ms

This is the value from input to output


in the module. The actual value is
determined by adding it to the
scanning time depending on each
system.

Input display

Not provided

Not provided

External connection

Connector (HONDA TSUSIN MR-50RMA)

Connector (HONDA TSUSIN MR-50RMA)

Terminal
connection and
circuitry

: input circuit CM
Internal
Circuit
CMA
A0
A1
A2
A3
A4
A5
A6
A7
B0
B1
B2
B3
B4
B5
B6
B7

29,45
49,50
16
32
48
15
31
47
30
46
12
28
44
11
27
43
10
42
13,17 +24V
14,18 GND

CMC
C0
C1
C2
C3
C4
C5
C6
D7
D0
D1
D2
D3
D4
D5
D6
D7

21,36
40,41
07
24
39
06
23
38
22
37
03
20
35
02
19
34
01
33
04,08 +24V
05,09 GND

+24V or GND can be selected for input common as above figure.


Note: Make sure to connect all common (CMA, CMC) pins.

11. CONNECTIONS

1169

MARMMTRBL02303E

Table 1122.

Input Modules AID16C and AID16D

AID16C

Item

AID16D

Points/module

16 points

16 points

Points/common

16 points/common

16 points/common

Sink/source current

Source current type

Sink current type

Input voltage

24VDC +10% 20%

24 VDC +10% 20%

Input current

7.5 mA (average)

7.5 mA (average)

ON voltage current

Min. 15VDC min. 4 mA

Min. 15 VDC min. 4 mA

OFF voltage current

Max. 5VDC max. 1.5 mA

Max. 5VDC max. 1.5 mA

Response
Time

OFF  ON

Max. 20ms

ON  OFF

Max. 20ms

This is the value from input to


output in the module. The
actual value is determined by
adding it to the scanning time
depending on each system.

Max. 20ms
Max. 20ms

This is the value from input to


output in the module. The
actual value is determined by
adding it to the scanning time
depending on each system.

Input display

LED display

LED display

External connection

Terminal block connector (20 terminals, M3.5


screw terminal)

Terminal block connector (20 terminals, M3.5


screw terminal)

Terminal connection and


circuitry

(C)

(D)

A0
A1
A2
A3
A4
A5
A6
A7
B0
B1
B2
B3
B4
B5
B6
B7

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

FOR AID16C
: input circuit
1

LED

FOR AID16D
: input circuit
LED
1

11. CONNECTIONS
MARMMTRBL02303E

1170

Table 1123.

Input Modules AID32E and AID32F

AID32E

Item

AID32F

Points/module

32 points

32 points

Points/common

8 points/common

8 points/common

Sink/source current

Both directions

Both directions

Input voltage

24VDC +10% 20%

24 VDC +10% 20%

Input current

7.5 mA (average)

7.5mA (average)

ON voltage current

Min. 15VDC min. 4.5 mA

Min. 15VDC min. 4.5 mA

OFF voltage current

Max. 6VDC max. 2 mA

Max. 6VDC max. 2 mA

Response
Time

OFF  ON

Max. 20
ms

ON  OFF

Max. 20
ms

This is the value from input to


output in the module. The
actual value is determined by
adding it to the scanning time
depending on each system.

Max. 2 ms
Max. 2 ms

This is the value from input to


output in the module. The
actual value is determined by
adding it to the scanning time
depending on each system.

Input display

Not provided

Not provided

External connection

Connector (HONDA TSUSIN MR-50RMA)

Connector (HONDA TSUSIN MR-50RMA)

Terminal connection and


circuitry
: input circuit CM

CMA
A0
A1
A2
A3
A4
A5
A6
A7

49,50
16
32
48
15
31
47
30
46

CMC
C0
C1
C2
C3
C4
C5
C6
C7

40,41
07
24
39
06
23
38
22
37

CMB
B0
B1
B2
B3
B4
B5
B6
B7

29,45
12
28
44
11
27
43
10
42

CMD
D0
D1
D2
D3
D4
D5
D6
D7

21,36
03
20
35
02
19
34
01
33

11. CONNECTIONS

1171

MARMMTRBL02303E

Table 1124.

Input Module AIA16G


AIA16G

Item
Points/module

16 points

Points/common

16 points/common

Rated load voltage

100 ~ 155VAC  15%

Max. input voltage

132Vrms 50/60Hz

Input current

10.5mArms (120VAC 50Hz)

ON voltage current

74Vrms min. 6mArms

OFF voltage current

20Vrms max. 2.2mArms

Response
Time

OFF  ON

Max. 35 ms

ON  OFF

Max. 35 ms

This is the value from input to


output in the module. The
actual value is determined by
adding it to the scanning time
depending on each system.

Input display

LED display

External connection

Terminal block connector (20 terminals, M3.5


screw terminal)

Common

16 points/common

Terminal connection and


circuitry
A0
A1
A2
A3
A4
A5
A6
A7
B0
B1
B2
B3
B4
B5
B6
B7

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

NC
NC

19
20

: input circuit
LED

19

11. CONNECTIONS
MARMMTRBL02303E

1172

11.3.15
Modular I/O Outputs

Table 1125.

Output Module AOD32A, Non-isolated

Item

AOD32A

Points/module

32 points

Points/common

8 points/common

Sink/source current

Sink current type

Rated load voltage

5 ~ 24VDC +20% 15%

Maximum load current

0.3A (however 2A/common)

Maximum voltage
drop when ON

0.24V (load current  0.8)

Maximum leak current


when OFF

0.1 mA

Response
Time

OFF  ON

Max. 1 ms

ON  OFF

Max. 1 ms

Output display

Not provided

External connection

Connector (HONDA TSUSIN MR-50RMA)

Terminal connection
and circuitry
O : output circuit +5~+24
Internal
Circuit

L : load

CM
L
L
L
L
L
L
L
L

+24A
A0
A1
A2
A3
A4
A5
A6
A7
CMA

17
16
32
48
15
31
47
30
46
49,50

O
O
O
O
O
O
O
O

L
L
L
L
L
L
L
L

+24B
B0
B1
B2
B3
B4
B5
B6
B7
CMB

13
12
28
44
11
27
43
10
42
29,45

O
O
O
O
O
O
O
O

L
L
L
L
L
L
L
L

+24C
C0
C1
C2
C3
C4
C5
D6
D7
CMC

08
07
24
39
06
23
38
22
37
40,41

O
O
O
O
O
O
O
O

L
L
L
L
L
L
L
L

+24D
D0
D1
D2
D3
D4
D5
D6
D7
CMD

04
03
20
35
02
19
34
01
33
21,36

O
O
O
O
O
O
O
O

11. CONNECTIONS

1173

MARMMTRBL02303E

Table 1126.

Output Modules AOD08C and AOD08D

AOD08C

Item

AOD08D

Points/module

8 points

8 points

Points/common

8 points/common

8 points/common

Sink/source current

Sink current type

Source current type

Rated load voltage

12 ~ 24VDC +20% 15%

12 ~ 24VDC +20% 15%

Maximum load current

2A (however 4A/fuse)

2A (however 4A/fuse)

Limit of load

Refer to load derating curve

Maximum voltage drop


when ON

0.8V (load current  0.4)

1.2V (load current  0.6)

Maximum leak current


when OFF

0.1mA

0.1mA

Response
Time

OFF  ON

Max. 2 ms

ON  OFF

Max. 2 ms

This is the value from input to


output in the module. The
actual value is determined by
adding it to the scanning time
depending on each system.

Max. 2 ms
Max. 2 ms

This is the value from input to


output in the module. The
actual value is determined by
adding it to the scanning time
depending on each system.

Output display

LED display

LED display

External connection

Terminal block connector (20 terminal, M3.5


screw terminal)

Terminal block connector (20 terminal, M3.5


screw terminal)

Fuse

5A, 1 piece for each output A0-A3 and A4-A7

5A, 1 piece for each output A0-A3 and A4-A7

Terminal connection
and circuitry

Fuses
1
load
L

load

3
A0

3
A0

5
L

A1

A1

A2

A2

A3

11
L

A4

12

A5

A4

14

A6

A5

16

A7

10

12

14

16

15
O

A6

17
L

13

15
L

11

13
L

9
10

A3

4
5

7
L

Fuses

1
2

17
18

19

A7

18

19
20

20

Fuses
O : output circuit

O : output circuit

2
Internal
Circuit

20

Internal
Circuit

LED

20

LED

11. CONNECTIONS
MARMMTRBL02303E

1174
Table 1127.

Output Modules AOD16C and AOD16D

AOD16C

Item

AOD16D

Points/module

16 points

16 points

Points/common

8 points/common

8 points/common

Sink/source current

Sink current type

Source current type

Rated load voltage

12 ~ 24VDC +20% 15%

12 ~ 24VDC +20% 15%

Maximum load current

0.5A (however 2A/common)

0.5A (however 2A/common)

Maximum voltage drop


when ON

0.7V (load current  1.4)

0.7V (load current  1.4)

Maximum leak current


when OFF

0.1mA

0.1mA

Response
Time

OFF  ON

Max. 2 ms

ON  OFF

Max. 2 ms

This is the value from input to


output in the module. The
actual value is determined by
adding it to the scanning time
depending on each system.

Max. 2 ms
Max. 2 ms

This is the value from input to


output in the module. The
actual value is determined by
adding it to the scanning time
depending on each system.

Output display

LED display

LED display

External connection

Terminal block connector (20 terminal, M3.5


screw terminal)

Terminal block connector (20 terminal, M3.5


screw terminal)

Terminal connection and


circuitry

: load

: load

A0

L
L

A1
A2
A3

A4

A5
A6

A7

1
2

3
4
5
6
8

O
O
O
O

O
O
O
O

A0

L
L
L

A1
A2
A3

L
L
L
L

A4
7

A7

L
+

12
14
15

L
L
L

B5
B6
B7

17

O
O
O
O

10

16
18
19

O
O
O

L
L
L
L
L
L
L
L

O
O
O

O
O

B0
B1
B2

12
13
14

B3
B4

15

B5
B6
B7

17

20

O
O
O

16

O
O
O

18

O
O

19
20

O : output circuit

O : output circuit

1
Internal
Circuit

10

O
O

11

13

B3
B4

B0
B1
B2

10

O
O

A5
A6

11
L

2
3

Internal
Circuit

LED

10

LED

11. CONNECTIONS

1175

MARMMTRBL02303E

Table 1128.

Output Module AOD32C


AOD32C

Item
Points/module

32 points

Points/common

8 points/common

Sink/source current

Sink current type

Rated load voltage

12 ~ 24VDC +20% 15%

Maximum load current

0.3A (however 2A/common)

Maximum voltage drop


when ON

0.24V (load current  0.8)

Maximum leak current


when OFF

0.1mA

Response
Time

OFF  ON

Max. 2 ms

ON  OFF

Max. 2 ms

This is the value from input to output in the module. The actual value is
determined by adding it to the scanning time depending on each system
system.

Output display

Not provided

External connection

Connector (HONDA TSUSIN MR-50RMA)

Terminal connection and


circuitry

O : output circuit

+24

Internal
Circuit

CM

: load
+24A

L
L
L
L
L
L
L
L

L
L
L
L
L
L
L
L

A0
A1
A2
A3
A4
A5
A6
A7
CMA

+24B
B0
B1
B2
B3
B4
B5
B6
B7
CMB

17
16
32
48
15
31
47
30
46
49,50

13
12
28
44
11
27
43
10
42
29,45

O
O
O
O
O
O
O
O

O
O
O
O
O
O
O
O

L
L
L
L
L
L
L
L

+24C
C0
C1
C2
C3
C4
C5
C6
C7
CMC

08
07
24
39
06
23
38
22

L
L
L
L
L
L
L
L

+24D
D0
D1
D2
D3
D4
D5
D6
D7
CMD

04
03
20
35
02
19
34
01

37
40,41

33
21,36

Note: For the common (CMA, CMB CMC, CMD) make sure to use both of them.

O
O
O
O
O
O
O
O

O
O
O
O
O
O
O
O

11. CONNECTIONS
MARMMTRBL02303E

1176
Table 1129.

Output Module AOD32D


AOD32D

Item
Points/module

32 points

Points/common

8 points/common

Sink/source current

Source current type

Rated load voltage

12 ~ 24VDC +20% 15%

Maximum load current

0.3A (however 2A/common)

Maximum voltage drop


when ON

0.24V (load current  0.8)

Maximum leak current


when OFF

0.1mA

Response
Time

OFF  ON

Max. 2 ms

ON  OFF

Max. 2 ms

This is the value from input to output in the module. The actual value is
determined by adding it to the scanning time depending on each system.

Output display

Not provided

External connection

Connector (HONDA TSUSIN MR-50RMA)

Terminal connection and


circuitry

O : output circuit

Internal
Circuit

: load
CMA

CM

L
L
L
L
L
L
L
L

L
L
L
L
L
L
L
L

A0
A1
A2
A3
A4
A5
A6
A7
0A

CMB
B0
B1
B2
B3
B4
B5
B6
B7
0B

49,50
16
32
48
15
31
47
30
46
1B

29,45
12
28
44
11
27
43
10
42
14

O
O
O
O
O
O
O
O

O
O
O
O
O
O
O
O

L
L
L
L
L
L
L
L

CMC
C0
C1
C2
C3
C4
C5
C6
C7
0C

40,41
07
24
39
06
23
38
22

L
L
L
L
L
L
L
L

CMD
D0
D1
D2
D3
D4
D5
D6
D7
0D

21,36
03
20
35
02
19
34
01

37
09

33
05

O
O
O
O
O
O
O
O

O
O
O
O
O
O
O
O

Note: For the common (CMA, CMB CMC, CMD) make sure to use both of them.

11. CONNECTIONS

1177

MARMMTRBL02303E

Table 1130.

Output Modules AOA05E and AOA08E

AOA05E

Item

AOA08E

Points/module

5 points

8 points

Points/common

1 point/common

4 points/common

Rated load voltage

100 ~ 230VAC  15%, 47 ~ 63Hz

100 ~ 230VAC  15%, 47 ~ 63Hz

Maximum load current

2A (however 5A/module)

1A (however 2A/common)

Maximum in rush current

25A (1 period)

10A (1 period)

Limit of load

Refer to load derating curve

Maximum voltage drop


when ON

1.5Vrms

1.5Vrms

Maximum leak current


when OFF

3.0mA (115VAC), 6.0mA (230VAC)

3.0mA (115VAC), 6.0mA (230VAC)

Response
Time

OFF  ON

Max. 1 ms

ON  OFF

Half of the
load
frequency
or less

This is the value from input to


output in the module
module. The
actual value is determined by
adding it to the scanning time
depending on each system.

This is the value from input to


output in the module
module. The
actual value is determined by
adding it to the scanning time
depending on each system.

Max. 1 ms
Half of the
load
frequency
or less

Output display

LED display

LED display

External connection

Terminal block connector (20 terminals, M3.5


screw terminal)

Terminal block connector (20 terminals, M3.5


screw terminal)

Fuse

3.2A, 1 piece for each output A0 ~ A4

3.2A, 1 piece for each output A0 ~ A3 and


A4~ A7

Terminal connection and


circuitry

1
L

2
O

3
L

A0

A0

A1

5
L

6
A1

A2

O
L

A3

A4

A5

16

18

A6

A7

16

20

18
19

Fuse
20

load

17

19

:
o
u
tp
u
t
c
i
rc
u
i
t

14
15

17

12
13

14

A4

O
Fuse

11

12

15

10
O

13

A3

10

11
A2

7
L

2
3

load
O

: output circuit

LED

LED
10 20

11. CONNECTIONS
MARMMTRBL02303E

1178
Table 1131.

Output Module AOA12F

Item

AOA12F

Points/module

12 points

Points/common

6 points/common

Rated load voltage

100 ~ 115VDC  15% 47 ~ 63Hz

Maximum load current

0.5A/point (however 2A/common)

Maximum in rush current

5A (1 period)

Limit of load

Refer to load derating curve

Maximum voltage drop


when ON

1.5Vrms

Maximum leak current


when OFF

1.5mA (115 VAC)

Response
Time

OFF  ON

Max. 1 ms

ON  OFF

Half of the load frequency or less

This is the value from input to


output in the module. The
actual value is determined by
adding it to the scanning time
depending on each system.

Output display

LED display

External connection

Terminal block connector (20 terminal, M3.5 screw terminal)

Fuse

3.2A, 1 piece for each output A0 ~ A5 and


B0 ~ B5

Terminal connection and


circuitry

: load
1

A0

L
L
L

A1
A2
A3

A4

A5

O
2

O
O
O

6
7
8
9

O
O
O
Fuse

10
L
L
L
L
L
L

B0
B1
B2
B3
B4

11
12

O
O

14

O
O

13
15

B5

16
17
18

O
O
O

19
20

Fuse

O : output circuit

LED
9 19

NOTE:
Each output signal group (A0A5 and
B0B5) contains six output signals.
However, each group must have an entire
group of eight signals assigned to it.
For example, A0A5 might be occupied
by digital outputs 1 through 6 and B0B5
might be occupied by digital outputs
9 through 14. Digital outputs 7 and 8 and
digital outputs 15 and 16 are unusuable.

11. CONNECTIONS

1179

MARMMTRBL02303E

Table 1132.
Item

Output Modules AOR08G and AOR16G


AOR08G

AOR16G

Points/module

8 points

8 points

Points/common

1 point/common

4 points/common

Maximum load

30VDC/250VAC, 4A (resistance load)

30VDC/250VAC, 2A (resistance load)

Minimum load

5VDC, 10mA

1A (however 2A/common)

Maximum current

4A/common

Limit of load

Refer to load derating curve

Refer to load derating curve

Response Time
OFF  ON

Max. 15ms

ON  OFF

Max. 15ms

This is the value


from input to output in the module.
The actual value is
determined by
adding it to the
scanning time
depending on
each system.

This is the value


from input to output in the module.
The actual value is
determined by
adding it to the
scanning time
depending on
each system.

Max. 15ms

Max. 15ms

Output display

LED display

LED display

External connection

Terminal block connector (20 terminals,


M3.5 screw terminal)

Terminal block connector (20 terminals,


M3.5 screw terminal)

Relay life

Mechanical

Min. 20,000,000 times

Min. 20,000,000 times

Electrical

Min. 100,000 times (resistance load)

Min. 100,000 times (resistance load)

Terminal connection and


circuitry

1
v
L

A0

A1

A2

A3

v
v

A0
A1
A2
A3

L
L
L
L
L
L
L

A4

A5
A6
A7

8
10

A4

13

A5

15

A6

17

14

A7

19
20

v : Direct current power or alternating


current power

BO

12

B1
B2
B3

13

B4

17

B5
B6
B7

19

14
15
16

L
L
L
L

18
L

10

16

11
L
L
L
L

12
L

4
5
6

11
v

1
L

18
20

: Direct current power or alternating


current power

11. CONNECTIONS
MARMMTRBL02303E

1180
Table 1133.

Output Module ADA02A


ADA02A

Item
Number of output
channels

2 channels/module

Digital input

12-bit binary (2s complement representation)

Analog output

10VDC ~ +10VDC (external load resistance: 10K or more) selectable


0mADC ~ + 20mADC (external load resistance: 400 or less) usable

Input/output
correspondence

Digital Input

Analog Output

+2000
+1000
0
1000
2000

+10V
+5V or +20mA
0V or 0mA
5V
10V

Resolution

5mV or 20 A

Comprehensive accuracy

Voltage output  0.5% (for the full scale)


Current output  1% (for the full scale)

Converting time

1ms or less. NOTE: The converting time is the one only inside the module. The actual
response time is added a scan time that is determined by the system.

Isolation

Photocopier isolation (between output signal and base). However, non-isolation between
output channels.

External connection

At removable terminal block (20 terminals, M3.5 screw terminals)

Number of occupied
output points

82

ADA02A

V0+
Channel 0
D/A
converter

Voltage output

Load

10K ohms or more

Voltage V0
4
amp.
Current
amp.

10+
8

10
10

V1+
Channel 1
D/A
converter

12

Voltage V1
14
amp.
Current 16
amp. 10+

Current output

18

10
20

(Note 1) Use a 2core twisted shielded cable as the connection cable.


(Note 2) Ground the cable shield on the load side

Load
400 ohms or less

11. CONNECTIONS

1181

MARMMTRBL02303E

Table 1134.

Analog Input Module AAD04A


AAD04A

Item
Number of input channels

4 channels/module

Analog input

10VDC to +10VDC (input resistance 4.7M)


20mADC to +20mADC (input resistance: 250 selectable

Digital output

12-bit binary (complementary representation of 2)

Input/output
correspondence

Analog Input

Digital Output

+10V
+5V or +20mA
0V or 0mA
5V or 20mA
10V

+2000
+1000
0
1000
2000

Resolution

5mV or 20 A

Total precision

Voltage input  0.5% (for the full scale)


Current input  1% (for the full scale)

Conversionary time

Maximum 2ms. NOTE: Actual response speed is determined by adding the scanning time
depending on each system to this conversion time.

Maximum input
voltage/current

15V 30mA

Insulation

Photocopier insulation (between output signal and base). However, non-insulation between
output channels.

External connection

At removable terminal block (20 terminals, M3.5 screw terminals)

Number of occupied
output points

82

10+

1
2

11+
Voltage input

V0+

3
V1+

Voltage
supply

V0
5

V1
6

COM0
COM1
8

7
FG0

MULTI
PROCESSOR

9
FG1 10
12+ 11
Current input

250
13+
12

V2+

13

Current
supply

V2
15

V3+
14

16

V3

COM2
17
COM3
18
FG2
19

FG3
20

(Note 1) Though the example above shows the connection of channels 0 and 2, it is just the
same with the channel 1 (I1+, V1+, V1, COM1 and FG1) and the channel 3 (I3+, V3+,
V3, COM3 and FG3).
(Note 2) Either voltage input or current input can be specified for each channel. When current input is specified,
make sure to shortcircuit in + and Vn+.
(Note 3) Use shielded cables of twisted pair for connecting.

11. CONNECTIONS
MARMMTRBL02303E

1182

11.4
SPECIFICATIONS OF
THE CABLES USED
FOR PERIPHERAL
DEVICES AND
WELDERS

11.4.1
Peripheral Device
Interface A Cable

If you manufacture cables, conform to the FANUC standard cables


described in this section. Refer to the description in Peripheral Device
Interface in this manual for the specifications of the FANUC standard
cables.

Figure 1265 shows the peripheral device interface A cable, CRM2:


Honda Tsushin, 50 pins.
Figure 1265. Peripheral Device Interface A Cable
HONDA TSUSHIN

HONDA TSUSHIN

HONDA TSUSHIN
HONDA TSUSHINS
SUPPLIED WITH AN ORDERED CABLE

11.4.2
Peripheral Device
Interface B Cable

Figure 1266 shows the peripheral device interface B cable, CRM4:


Honda Tsushin, 20 pins.
Figure 1266. Peripheral Device Interface B Cable
HONDA TSUSHIN

HONDA TSUSHIN

PERIPHERAL
DEVICE

HONDA TSUSHIN

HONDA TSUSHINS
SUPPLIED WITH AN ORDERED CABLE

11. CONNECTIONS

1183

MARMMTRBL02303E

11.4.3
Arc Welding Interface
Connection Cable

Figure 1267 shows the arc welder connection cable, CRW1: Honda
Tsushin, 34 pins.
Figure 1267. Arc Welder Connection Cable

PERIPHERAL
DEVICE

HONDA TSUSHIN

JAPAN AVIATION ELECTRONICS


INDUSTRY, LTD.
JAPAN AVIATION
ELECTRONICS
INDUSTRY, LTD.

STANDARD POSITION
OF GUIDE KEY

HONDA TSUSHIN

Use a welder connection cable conforming to the FANUC specifications.

11. CONNECTIONS
MARMMTRBL02303E

1184

11.5
CABLE CONNECTION
FOR THE PERIPHERAL
DEVICES, END
EFFECTORS, AND ARC
WELDERS

11.5.1
Peripheral Device
Connection Cable

Figure 1268. Peripheral Device Cable Connection

Process I/O printed


circuit board CA/
CB/DA
Process I/O printed
circuit board AA/
AB/BA/BB or I/O
unit model A

Partly cut off the peripheral device


connection cable to expose the
shield jacket, and fasten the jacket
to the shield plate with a clamp to
Shield jacket protect against noise.

Clamp fixture

Shield plate

11. CONNECTIONS

1185

MARMMTRBL02303E

11.5.2
Arc Welding Interface
Connection Cable

Figure 1269 shows the connection of the arc welder cable in the control
unit.
Figure 1269. Arc Welder Cable Connection

Process I/O printed


circuit board CA/
CB/DA
Process I/O printed
circuit board AA/
AB/BA/BB

Partly cut off the peripheral device


connection cable to expose the
shield jacket, and fasten the jacket
to the shield plate with a clamp to
protect against noise.
Clamp fixture
Shield jacket

Shield plate

11. CONNECTIONS
MARMMTRBL02303E

1186

11.5.3
Peripheral Device
Cable Connector

Figure 1270, Figure 1271, and Figure 1272 show the connector for
peripheral device cables A, B, and C.
Figure 1270. Peripheral Device Cable Connector for A and B(Honda Tsushin
Kogyo)

Table 1135.

Peripheral Device Cable Connector for A and B

CRM2

A
67.9

Dimensions
(B)
C
73.5 44.8

(D)
18

CRM4

39.3

44.9

17

Connector
Specifications

Applicable
Interface

MR50LMH
MR20LMH

Table 1136.
Symbol


39.8

Remark
Honda Tsushin
Kogyo, 50 pins
Honda Tsushin
Kogyo, 20 pins

Symbols Used in Figure 1270


Name
Connector cover

Cable clamp screw

Connector clamp spring

Connector clamp screw

Connector

50 pins (male)

MR50MH

20 pints (male)

MR20MH

11. CONNECTIONS

1187

MARMMTRBL02303E

Figure 1271. Peripheral Device Connector for A and B

Table 1137.

Peripheral Device Cable Connector for A and B

Connector
Specifications

Applicable
Interface

MR50RFH
MR20RFH

CRM2
CRM4

Table 1138.
Symbol


Dimensions
Remark
A
B
61.4 56.4 Honda Tsushin Kogyo, 50 pins
39.3 44.9 Honda Tsushin Kogyo, 20 pins

Symbols Used in Figure 1271


Name
Connector clamp screw

Screw 2.6 x 8

Connector

(MR50RFH)
(MR20RFH)

11. CONNECTIONS
MARMMTRBL02303E

1188

Figure 1272. Peripheral Device Interface Cable C Connector (Phoenix Contact)

Insert the plug vertically toward the


conductor. Insert the cable in the side
of the plug plate key groove.

Table 1139. Peripheral Device Interface Cable C Connector


Specifications
Number of
Terminals
6
10

Specifications
MVSTBR 2.5/6-ST-5.08
MVSTBR 2.5/10-ST-5.08
Table 1140.

Twisted wires
Solid wire

Wire Jacket

A mm
25.40
45.72

Connection Data
Applicable
Wire Size
AWG12

Rated
Current
12A

Rated
Voltage
AC250V

AWG12

12A

AC250V

Wire End Processing

11. CONNECTIONS
MARMMTRBL02303E

1189

11.5.4
End Effector Cable
Connector

Figure 1273. Elbow Type Connector S-5, S-10, S-420, S-500, S-700, S-800,
M-400, M-500, ARC Mate, ARC Mate 100/S-6, ARC Mate Sr.

11. CONNECTIONS
MARMMTRBL02303E

1190
Figure 1274. Connector L-1000

A:
B:
C:
D:

M22x1
48.82
30.5
3.0 to 9.0 (Inside diameter)

G:

Manufactured by Daiichi Denshi Kogyo JMCR1610

16.6

11. CONNECTIONS

1191

MARMMTRBL02303E

11.5.5
Recommended Cables
Peripheral Device
Connection Cable

Connect a peripheral device using a completely shielded, heavily protected


cable conforming to the specifications in Table 1141. Allow an extra
1.5m for routing the cable in the control unit. The maximum cable length
is 30 m.
Table 1141.

Number
of Wires

Wire
Specifications
(FANUC
Specifications)

Recommended Cable for Peripheral Device Connection

Conductor
Diameter
(mm)

Configuration

Sheath
Thickness
(mm)

Effective
O tside
Outside
Diameter
(mm)

Electrical Characteristics
Conductor
Resistance
(/km)

Allowable
Current (A)

50

A66L-0001-0042

1.05

7/0.18 AWG24

1.5

12.5

106

1.6

20

A66L-0001-0041

1.05

7/0.18 AWG24

1.5

10.5

106

1.6

End Effector Connection


Cable

Connect an end effector using a heavily protected cable with a movable


wire conforming to the specifications in Table 1142. The cable length is
determined so that the cable will not interfere with the end effector and the
wrist can move through its full stroke.
Table 1142.

Number
of Wires

Wire
Specifications
(FANUC
Specifications)

Recommended Cable for End Effector Connection

Conductor
Diameter
(mm)

Configuration

40/0.08
AWG24
40/0.08
AWG24

A66L-0001-0143

1.1

20

A66L-0001-0144

1.1

Sheath
Thickness
(mm)

Effective
O tside
Outside
Diameter
(mm)

1.0
1.0

Electrical Characteristics
Conductor
Resistance
(/km)

Allowable
Current (A)

5.3

91

3.7

8.6

91

2.3

12

COMPLETE WIRING DIAGRAMS


121

MARMMTRBL02303E

Complete wiring for the controller and the robot mechanical unit is shown
in Figure 131 through Figure 1332. The diagrams are valid for all
FANUC Robotics robot models (except where specific robot models are
indicated).
This chapter is useful for verifying the cable connections to all
components within the controller and robot.

12. COMPLETE WIRING DIAGRAMS


MARMMTRBL02303E

122

K022

K.23

CP2

K020

K021

&5

AMP6

K071

K072

Figure 131. Internal Connection Diagram S-420, S-800

12. COMPLETE WIRING DIAGRAMS


MARMMTRBL02303E

123
Figure 132. Internal Connection Diagram S420 with three Servo Amplifiers,
S420D)

12. COMPLETE WIRING DIAGRAMS


MARMMTRBL02303E

124

K022

K023

K021

K020

200VAC

AXIS6
AXIS3

AXIS5
AXIS2

AXIS4
AXIS1

Figure 133. Internal Connection Diagram ARC Mate, ARC Mate Sr., ARC Mate
100/S-6, S-5, and S-10

12. COMPLETE WIRING DIAGRAMS

125

MARMMTRBL02303E

19
26
33
40

18
25
32
39

17
24
31
38

K71

K72

15,16
22, 23
29, 30
36, 37

M1

Figure 134. Internal Connection Diagram S-500

12. COMPLETE WIRING DIAGRAMS


MARMMTRBL02303E

126
Figure 135. Internal Connection Diagram S-700

12. COMPLETE WIRING DIAGRAMS

127

MARMMTRBL02303E

Figure 136. Internal Connection Diagram S900

12. COMPLETE WIRING DIAGRAMS


MARMMTRBL02303E

128
Figure 137. Internal Connection Diagram A-510

12. COMPLETE WIRING DIAGRAMS

129

MARMMTRBL02303E

Figure 138. Internal Connection Diagram M-400 (5-axes)

12. COMPLETE WIRING DIAGRAMS


MARMMTRBL02303E

1210
Figure 139. Internal Connection Diagram M400 (4 axes)

12. COMPLETE WIRING DIAGRAMS

1211

MARMMTRBL02303E

Figure 1310. Internal Connection Diagram M500 (5 axes)

12. COMPLETE WIRING DIAGRAMS


MARMMTRBL02303E

1212
Figure 1311. Internal Connection Diagram M500 (4 axes)

12. COMPLETE WIRING DIAGRAMS

1213

MARMMTRBL02303E

Figure 1312. Internal Connection Diagram L-1000

12. COMPLETE WIRING DIAGRAMS


MARMMTRBL02303E

1214

K036

Figure 1313. Internal Connection Diagram Emergency Stop Control PCB

12. COMPLETE WIRING DIAGRAMS

1215

MARMMTRBL02303E

K022

Figure 1314. Internal Connection Diagram Power Supply Unit

12. COMPLETE WIRING DIAGRAMS


MARMMTRBL02303E

1216

K070

K040

Figure 1315. Internal Connection Diagram - Main CPU; Axis Control Board

12. COMPLETE WIRING DIAGRAMS

1217

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S-420 with three-servo amplifier configuration

Figure 1316. Internal Connection Diagram Servo Amplifier Connection S-420,


ARC Mate/S-5, ARC Mate Sr./S-10, ARC Mate 100/S-6, S-500, S-700, and S-800

12. COMPLETE WIRING DIAGRAMS

1218

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Figure 1317. Internal Connection Diagram Servo Amplifier Connection A-510,


L-1000, and M-400

12. COMPLETE WIRING DIAGRAMS


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1219
Figure 1318. Internal Connection Diagram Servo Amplifier Connection S-900
and M-500

12. COMPLETE WIRING DIAGRAMS


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1220

EMERGENCY STOP

K016

K015

Figure 1319. Internal Connection Diagram Modular I/O

12. COMPLETE WIRING DIAGRAMS

1221

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K042

K035

K040

K041

Figure 1320. Internal Connection Diagram Teach Pendant

12. COMPLETE WIRING DIAGRAMS

1222

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Figure 1321. Internal Connection Diagram Main CPU Interface

12. COMPLETE WIRING DIAGRAMS

1223

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Figure 1322. Internal Connection Diagram Axis Control Board Interface

12. COMPLETE WIRING DIAGRAMS

1224

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Figure 1323. Internal Connection Diagram ARC Mate/S-5, ARC Mate Sr./S-10,
ARC Mate 100/S-6, S-420, S-500 and S-800

12. COMPLETE WIRING DIAGRAMS

1225

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Figure 1324. Internal Connection Diagram S-700 and A-510

12. COMPLETE WIRING DIAGRAMS

1226

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Figure 1325. Internal Connection Diagram M-400 and L-1000

12. COMPLETE WIRING DIAGRAMS

1227

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Figure 1326. Internal Connection Diagram - M400

12. COMPLETE WIRING DIAGRAMS


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1228
Figure 1327. External Connection Diagram M-500

12. COMPLETE WIRING DIAGRAMS

1229

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Figure 1328. External Connection Diagram S-900

12. COMPLETE WIRING DIAGRAMS


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1230
Figure 1329. External Connection Diagram Process I/O

12. COMPLETE WIRING DIAGRAMS

1231

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Figure 1330. External Connection Diagram Process I/O

12. COMPLETE WIRING DIAGRAMS


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1232
Figure 1331. External Connection Diagram Teach Pendant

12. COMPLETE WIRING DIAGRAMS

1233

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Figure 1332. Motor Table

13

PRINTS
131

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This chapter includes all electrical prints.

13. PRINTS

132
NOTES

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MARMMTRBL02303E

Figure 141.

13. PRINTS

R-J Control Signal and Power Distribution Overview


Rev. 11/12/96 CD

133

134
NOTES

13. PRINTS
MARMMTRBL02303E

MARMMTRBL02303E

Figure 142.

13. PRINTS

Main AC Power Distribution


Rev. 11/12/96 CD

135

136
NOTES

13. PRINTS
MARMMTRBL02303E

MARMMTRBL02303E

Figure 143.

13. PRINTS

AC Power Distribution With Optional 115VAC Secondary

F6
7.5A

F7
7.5A

46

45

1A

AC POWER DISTRIBUTION WITH


OPTIONAL 115VAC SECONDARY

115 VAC @ 900VAC


TO USER CONNECTION

Rev. 11/12/96 CD

137

138
NOTES

13. PRINTS
MARMMTRBL02303E

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Figure 144.

13. PRINTS

Power Supply Unit (PSU) With Power ON/OFF Circuit


Rev. 11/12/96 CD

139

1310
NOTES

13. PRINTS
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Figure 145.

13. PRINTS

EMG Stop & Brake Connection 100 VAC E-Stop Circuit 100 VDC Brake Circuit (1 of 2)
Rev. 11/12/96 CD

1311

1312
NOTES

13. PRINTS
MARMMTRBL02303E

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Figure 146.

13. PRINTS

EMG Stop and Brake Connection 100 VDC Brake Circuit (2 of 2)

Rev. 11/12/96 CD

1313

1314
NOTES

13. PRINTS
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Figure 147.

13. PRINTS

EMG Stop and Brake Connection 24 VDC E-Stop Circuit (1 of 2)


Rev. 11/12/96 CD

1315

1316
NOTES

13. PRINTS
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Figure 148.

13. PRINTS

EMG Stop and Brake Connection 24VDC E-Stop Circuit (2 of 2) Modular I/O Power Distribution
Rev. 11/12/96 CD

1317

1318
NOTES

13. PRINTS
MARMMTRBL02303E

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Figure 149.

13. PRINTS

Overheat and Cooling


Rev. 11/12/96 CD

1319

1320
NOTES

13. PRINTS
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Figure 1410.

13. PRINTS

Single Axis Servo Amplifier


Rev. 11/12/96 CD

1321

1322
NOTES

13. PRINTS
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Figure 1411.

13. PRINTS

Dual Axis Servo Amplifier (With Dynamic Brakes)


Rev. 11/12/96 CD

1323

1324
NOTES

13. PRINTS
MARMMTRBL02303E

MARMMTRBL02303E

Figure 1412.

13. PRINTS

Dual Axis Servo Amplifier (Without Dynamic Brakes)


Rev. 11/12/96 CD

1325

1326
NOTES

13. PRINTS
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MARMMTRBL02303E

Figure 1413.

13. PRINTS

Discharge Resistor and Dynamic Brake Unit (For Amp With No Dynamic Brake)

Rev. 11/12/96 CD

1327

1328
NOTES

13. PRINTS
MARMMTRBL02303E

MARMMTRBL02303E

Figure 1414.

13. PRINTS

LSI Module All Servo Amplifiers


Rev. 11/12/96 CD

1329

1330
NOTES

13. PRINTS
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MARMMTRBL02303E

Figure 1415.

13. PRINTS

DV-M Module Servo Amplifier


Rev. 11/12/96 CD

1331

1332
NOTES

13. PRINTS
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MARMMTRBL02303E

Figure 1416.

13. PRINTS

ALM-M Module Servo Amplifier


Rev. 11/12/96 CD

1333

1334
NOTES

13. PRINTS
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MARMMTRBL02303E

Figure 1417.

13. PRINTS

Teach Pendant Power And Data Signal Interconnection

Rev. 11/12/96 CD

1335

1336
NOTES

13. PRINTS
MARMMTRBL02303E

MARMMTRBL02303E

TRANSPORTATION AND INSTALLATION


A1
This appendix includes information on transporting and installing an R-J
controller.

A.1
TRANSPORTATION

The control unit is transported by a crane. Attach a rope to eye bolts at the
top of the control unit, as shown in Figure A1.
Figure A1. Transportation

A. TRANSPORTATION AND INSTALLATION

A2

MARMMTRBL02303E

A.2
INSTALLATION

A.2.1
Installation Area

When installing the control unit, allow the space for maintenance shown in
Figure A2.
Figure A2. Installation Area

A. TRANSPORTATION AND INSTALLATION

A3

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A.2.2
Assembly During
Installation

Figure A3. Assembly During Installation

A. TRANSPORTATION AND INSTALLATION

A4

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Figure A4. Assembly During Installation

A. TRANSPORTATION AND INSTALLATION

A5

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A.2.3
Installation Conditions

Table A1.
Model

Item
Line filter

Installation Conditions
Specifications/Conditions

Common to all models

50 Hz; 200 VAC, +10%, 15%


60 Hz; 200 VAC to 220 VAC, +10%, 15%
50/60 Hz  1 Hz, 3-phase

Transformer

Common to all models

220, 240, 380, 415, 460, 480, 500, 550, 575 VAC,
+10%, 15%

Input power supply capacity

ARC Mate, S-5, A-510

2.5 kVA

ARC Mate Sr., S-10, L-1000

3 kVA

S-700

6.5 kVA

S-500, M-400

7 kVA

S-420, S-800

12 kVA

50/60 Hz  1 Hz, 3-phase

Average power consumption A-510

0.8 kW

ARC Mate, ARC Mate Sr., S-5, S-10 1.0 kW


L-1000

1.2 kW

S-500, S-700, M-400

1.7 kW

S-420

2.5 kW

Ambient temperature range

Common to all models

0 to 45 C

Ambient humidity range

Common to all models

75% RH max.
No condensation
95% RH maximum for up to 1 month

Atmosphere

Common to all models

No corrosive gases
Contact FANUC Robotics when operating the unit where
there is a lot of dust or cutting oil.

Vibration

Common to all models

0.5 G max.
Contact FANUC Robotics when operating the unit where
vibration frequently occurs.

Weight of control unit

Common to all models

Table A2.

Installation Conditions

Model

Item
Line filter

180 kg (approx.)

Common to all models

Specifications/Conditions
50 Hz; 200 VAC, +10%, 15%
60 Hz; 200 VAC to 220 VAC, +10%, 15%
50/60 Hz  1 Hz, 3-phase

Transformer

Common to all models

Input power supply capacity

P-155

220, 240, 380, 415, 460, 480, 500, 550, 575 VAC,
+10%, 15%
50/60 Hz  1 Hz, 3-phase

Average power consumption P-155


(idle condition)
Ambient temperature range
Common to all models

5 kVA
2.5 kW
0 to 45 C

A. TRANSPORTATION AND INSTALLATION

A6

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Table A2. (Contd) Installation Conditions


Item
Ambient humidity range

Model
Common to all models

Specifications/Conditions
75% RH max.
No condensation
95% RH maximum for up to 1 month

Atmosphere

Common to all models

No corrosive gases
Contact FANUC Robotics when operating the unit where
there is a lot of dust or cutting oil.

Vibration

Common to all models

0.5 G max.
Contact FANUC Robotics when operating the unit where
vibration frequently occurs.

Weight of control unit

Common to all models

180 kg (approx.)

A. TRANSPORTATION AND INSTALLATION

A7

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A.2.4

Adjust the robot according to the procedure in Table A3 at installation.

Adjustment and
Checks at Installation
Table A3.

Adjustment and Checks at Installation


Description

Step
1

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.

Check transformer tap setting.

Connect control unit and mechanical unit cables.

Turn the breaker or disconnect off and connect the input power cable.

Check the input power voltage.

Press the EMERGENCY STOP button on the operator panel and turn the power on. Check the output voltage.

Check the interface signals between the control unit and robot mechanical unit.

10

Check the parameters. If necessary, set them.

11

Release the EMERGENCY STOP button on the operator panel. Turn the power on.

12

Check the movement along each axis in the manual jog mode.

13

Check the end effector interface signals.

14

Check the peripheral device control interface signals.

A. TRANSPORTATION AND INSTALLATION

A8

A.2.5
Resetting Overtravel
and Emergency Stop at
Installation

MARMMTRBL02303E

An overtravel and emergency stop occur when the robot is operated for the
first time after it is installed and the mechanical and control units are
wired. This section describes how to reset the overtravel and emergency
stop.
Remove the red plate fastening the swiveling axis beforehand. The J2 and
J3 axes are pressed against the hard stops at shipment. Therefore, an
overtravel alarm occurs when the power is turned on after installation.
The robot enters the emergency stop state when the peripheral device
control interface is not connected.

Peripheral Device Interface


Processing

Take the following actions if signals *IMSTP, *HOLD, *SFSD, and


ENBL are not used.
Figure A5. Peripheral Device Interface Processing

Resetting Overtravel

Press the reset switch on the operator panel or the reset key on the teach
pendant. Manually move an axis that has overtraveled into the operating
range while pressing the shift key on the teach pendant.