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FANUC Robotics

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

This publication contains proprietary information of FANUC Robotics


North America, Inc. furnished for customer use only. No other uses
are authorized without the express written permission of FANUC
Robotics North America, Inc.
FANUC Robotics North America, Inc.
3900 W. Hamlin Road
Rochester Hills, Michigan 483093253

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 its headquarters in Rochester Hills,
Michigan. For additional information contact
FANUC Robotics North America, Inc.
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com

Copyright 2002 by FANUC Robotics North America, Inc.


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

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

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

NOTE Information appearing next to NOTE concerns related information


or useful hints.

Safety
Safety-1
FANUC Robotics is not and does not represent itself as an expert in
safety systems, safety equipment, or the specific safety aspects of
your company and/or its work force. It is the responsibility of the
owner, employer, or 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.
According to the industry standard ANSI/RIA R15.06, the owner or
user is advised to consult the standards to ensure compliance with
its requests for Robotics System design, usability, operation,
maintenance, and service. Additionally, as the owner, employer, or
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 programs
must be familiar with the recommended programming procedures
for your application and robot installation.
The following guidelines are provided to emphasize the importance
of safety in the workplace.

Safety-2

CONSIDERING
SAFETY FOR YOUR
ROBOT
INSTALLATION

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


following factors with regard to safety:

Keeping People and


Equipment Safe

The safety of people is always of primary importance in any


situation. However, equipment must be kept safe, too. When
prioritizing how to apply safety to your robotic system, consider the
following:

Using Safety
Enhancing Devices

People
External devices
Robot(s)
Tooling
Workpiece

Always give appropriate attention to the work area that surrounds


the robot. The safety of the work area can be enhanced by the
installation of some or all of the following devices:

Setting Up a Safe
Workcell

The safety of people and equipment


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

Safety fences, barriers, or chains


Light curtains
Interlocks
Pressure mats
Floor markings
Warning lights
Mechanical stops
EMERGENCY STOP buttons
DEADMAN switches

A safe workcell is essential to protect people and equipment.


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

Sponsor your personnel for training in approved FANUC


Robotics training course(s) related to your application. Never
permit untrained personnel to operate the robots.

Safety-3

Install a lockout device that uses an access code to prevent


unauthorized persons from operating the robot.

Use 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.

Clearly identify the work envelope of each robot in the system


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

Position all controllers outside the robot work envelope.

Never rely on software as the primary safety element.

Mount an adequate number of EMERGENCY STOP buttons or


switches within easy reach of the operator and at critical points
inside and around the outside of the workcell.

Install flashing lights and/or audible warning devices that


activate whenever the robot is operating, that is, whenever
power is applied to the servo drive system. Audible warning
devices shall exceed the ambient noise level at the enduse
application.

Wherever possible, install safety fences to protect against


unauthorized entry by personnel into the work envelope.

Install special guarding that prevents the operator from reaching


into restricted areas of the work envelope.

Use interlocks.

Use presence or proximity sensing devices such as light


curtains, mats, and capacitance and vision systems to enhance
safety.

Periodically check the safety 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.

Safety-4

Staying Safe While


Teaching or Manually
Operating the Robot

Make sure all external devices are properly filtered, grounded,


shielded, and suppressed to prevent hazardous motion due to
the effects of 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.

Advise all personnel who must teach the robot or otherwise


manually operate the robot to observe the following rules:

Never wear watches, rings, neckties, scarves, or loose clothing


that could get caught in moving machinery.
Know whether or not you are using an intrinsically safe teach
pendant if you are working in a hazardous environment.
Before teaching, visually inspect the robot and work envelope to
make sure that no potentially hazardous conditions exist. The
work envelope is the area defined by the maximum motion
range of the robot. These include tooling attached to the wrist
flange that extends this range.
The area near the robot must be clean and free of oil, water, or
debris. Immediately report unsafe working conditions to the
supervisor or safety department.
FANUC Robotics recommends that no one enter the work
envelope of a robot that is on, except for robot teaching
operations. However, if you must enter the work envelope, be
sure all safeguards are in place, check the teach pendant
DEADMAN switch for proper operation, and place the robot in
teach mode. Take the teach pendant with you, turn it on, and be
prepared to release the DEADMAN switch. Only the person
with the teach pendant should be in the work envelope.

Safety-5

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

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

Staying Safe During


Automatic Operation

Using a low motion speed, single step the program for at


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

Advise all personnel who operate the robot during production to


observe the following rules:

Make sure all safety provisions are present and active.

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

Understand the complete task the robot is programmed to


perform before initiating automatic operation.

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

Safety-6

Staying Safe During


Inspection

Staying Safe During


Maintenance

Never enter or allow others to enter the work envelope during


automatic operation of the robot.

Know the location and status of all switches, sensors, and


control signals that could cause the robot to move.

Know where the EMERGENCY STOP buttons are located on


both the robot control and external control devices. Be prepared
to press these buttons in an emergency.

Never assume that a program is complete if the robot is not


moving. The robot could be waiting for an input signal that will
permit it to continue activity.

If the robot is running in a pattern, do not assume it will continue


to run in the same pattern.

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

Never wear watches, rings, neckties, scarves, or loose clothing


that could get caught in moving machinery.

If power is needed to check the robot motion or electrical


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

Be aware that when you remove a servomotor or brake, the


associated robot arm will fall if it is not supported or resting on a
hard stop. Support the arm on a solid support before you
release the brake.

When performing maintenance on your robot system, observe the


following rules:

Safety-7

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


operation.

Before entering the work envelope, visually inspect the workcell


to make sure no potentially hazardous conditions exist.

Never wear watches, rings, neckties, scarves, or loose clothing


that could get caught in moving machinery.

Consider all or any overlapping work envelopes of 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.

Be aware that when you remove a servomotor or brake, the


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

Release or block all stored energy. Before working on the


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

Safety-8

Isolate the robot from all remote control signals. If maintenance


must be done when the power is on, make sure the person
inside the work envelope has sole control of the robot. The
teach pendant must be held by this person.

Make sure personnel cannot get trapped between the moving


robot and other equipment. Know the path that can be used to
escape from a moving robot. Make sure the escape route is
never blocked.

Use blocks, mechanical stops, and pins to prevent hazardous


movement by the robot. Make sure that such devices do not
create pinch points that could trap personnel.

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

Be aware that when you remove a servomotor or brake, the


associated robot arm will fall if it is not supported or resting on a
hard stop. Support the arm on a solid support before you
release the brake.

When replacing or installing components, make sure dirt and


debris do not enter the system.

Use only specified parts for replacement. To avoid fires and


damage to parts in the controller, never use nonspecified fuses.

Before restarting a robot, make sure no one is inside the work


envelope; be sure that the robot and all external devices are
operating normally.

KEEPING MACHINE
TOOLS AND
EXTERNAL
DEVICES SAFE

Certain programming and mechanical measures are useful in


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

Programming Safety
Precautions

Implement the following programming safety measures to prevent


damage to machine tools and other external devices.

Safety-9

Mechanical Safety
Precautions

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.

KEEPING THE
ROBOT SAFE

Observe the following operating and programming guidelines to


prevent damage to the robot.

Operating Safety
Precautions

The following measures are designed to prevent damage to the


robot during operation.

Programming Safety
Precautions

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

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

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

Use circuit breakers to guard against electrical overload.

The following safety measures are designed to prevent damage to


the robot during programming:

Establish interference zones to prevent collisions when two or


more robots share a work area.

Safety-10

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

Be aware of signals or other operations that could trigger


operation of tooling resulting in personal injury or equipment
damage.

In dispensing applications, be aware of all safety guidelines with


respect to the dispensing materials.

NOTE Any deviation from the methods and safety practices


described in this manual must conform to the approved standards of
your company. If you have questions, see your supervisor.

ADDITIONAL
SAFETY
CONSIDERATIONS
FOR PAINT ROBOT
INSTALLATIONS

Process technicians are sometimes required to enter the paint


booth, for example, during daily or routine calibration or while
teaching new paths to a robot. Maintenance personal also must
work inside the paint booth periodically.
Whenever personnel are working inside the paint booth, ventilation
equipment must be used. Instruction on the proper use of
ventilating equipment usually is provided by the paint shop
supervisor.
Although paint booth hazards have been minimized, potential
dangers still exist. Therefore, 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 automatic and exercise operation
Diagnostic mode
During both teach and automatic modes, the robots in the paint
booth will follow a predetermined pattern of movements. In teach
mode, the process technician teaches (programs) paint paths using
the teach pendant.
In automatic mode, robot operation is initiated at the System
Operator Console (SOC) or Manual Control Panel (MCP), if
available, and can be monitored from outside the paint booth. All
personnel must remain outside of the booth or in a designated safe

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

Paint System Safety


Features

Process technicians and maintenance personnel must become


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

Most paint booths have red warning beacons that illuminate


when the robots are armed and ready to paint. Your booth
might have other kinds of indicators. Learn what these are.

Some paint booths have a blue beacon that, when illuminated,


indicates that the electrostatic devices are enabled. Your booth
might have other kinds of indicators. Learn what these are.

EMERGENCY STOP buttons are located on the robot controller


and teach pendant. Become familiar with the locations of all E
STOP buttons.

An intrinsically safe teach pendant is used when teaching in


hazardous paint atmospheres.

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


switch is held in, and the teach pendant is on, power is applied to the
robot servo system. If the engaged 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.

Safety-12

Overtravel by robot axes is prevented by software limits. All of


the major and minor axes are governed by software limits. Limit
switches and hardstops also limit travel by the major axes.

EMERGENCY STOP limit switches and photoelectric eyes


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

Staying Safe While


Operating the Paint
Robot

System status is monitored by computer. Severe conditions


result in automatic system shutdown.

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

WARNING
Observe all safety rules and guidelines to avoid injury.

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

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

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

Be aware of overlapping work envelopes of adjacent robots.

Know where all red, mushroomshaped EMERGENCY STOP


buttons are located.

Safety-13

Staying Safe While


Operating Paint
Application Equipment

Know the location and status of all switches, sensors, and/or


control signals that might cause the robot, conveyor, and
opening devices to move.

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

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

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

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

Never enter the work envelope during automatic operation


unless a safe area has been designated.

Never wear watches, rings, neckties, scarves, or loose clothing


that could get caught in moving machinery.

Remove all metallic objects, such as rings, watches, and belts,


before entering a booth when the electrostatic devices are
enabled.

Stay out of areas where you might get trapped between a


moving robot, conveyor, or opening device and another object.

Be aware of signals and/or operations that could result in the


triggering of guns or bells.

Be aware of all safety precautions when dispensing of paint is


required.

Follow the procedures described in this manual.

When you work with paint application equipment, observe the


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

Safety-14

Staying Safe During


Maintenance

Grounding: All electrically conductive objects in the spray area


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

High Voltage: High voltage should only be on during actual


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

Avoid any accumulation of combustible vapors or coating


matter.

Follow all manufacturer recommended cleaning procedures.

Make sure all interlocks are operational.

No smoking.

Post all warning signs regarding the electrostatic equipment and


operation of electrostatic equipment according to NFPA 33
Standard for Spray Application Using Flammable or
Combustible Material.

Disable all air and paint pressure to bell.

Verify that the lines are not under pressure.

When you perform maintenance on the painter system, observe the


following rules, and all other maintenance safety rules that apply to
all robot installations. Only qualified, trained service or maintenance
personnel should perform repair work on a robot.

Paint robots operate in a potentially explosive environment. Use


caution when working with electric tools.

When a maintenance technician is repairing or adjusting a robot,


the work area is under the control of that technician. All
personnel not participating in the maintenance must stay out of
the area.

For some maintenance procedures, station a second person at


the control panel within reach of the EMERGENCY STOP
button. This person must understand the robot and associated
potential hazards.

Safety-15

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

Always return the robot to the home position before you


disarm it.

Never use machine power to aid in removing any component


from the robot.

During robot operations, be aware of the 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.

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.

Update Section
Single Phase Power Option

Table of Contents

B81535EN/02

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p1

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

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

1.2

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


1.2.1
1.2.2

1.3

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

SAFETY OF THE ROBOT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


1.3.1
1.3.2
1.3.3

1.4

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

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

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


1.4.1

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

3
4
6
7
9

10
10
10

11
11
11
11

12
12

1.5

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

13

1.6

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

14

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

19

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

20

2.1

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

21

2.2

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

23

2.3

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

24

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

25

3.1

POWER CANNOT BE TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


3.1.1
3.1.2

3.2

Teach Pendant Cannot be Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Initial Screen Remains on the Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

26
27
28

29

3.3

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

32

3.4

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

33

3.5

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

35

3.6

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

92

3.7

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

97

3.8

POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION


(POSITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107

3.9

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

108

3.10

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

109

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B81535EN/02

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


4.1

ROBOT CONTROL BOARD (A16B32000450) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112

4.2

EMERGENCY STOP BOARD (A20B10080010, 0011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116

4.3

BACKPLANE BOARD (A20B20030330) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

117

4.4

PROCESS I/O BOARD HE (A16B22030764), HF (A16B22030765) . . . . . . . . . . . . . . . . . . .

118

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


5.1

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

5.2

Power Supply Module PSM (A06B6115H001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Servo Amplifier Module (A06B6114H205, A06B6114H302) . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.2.1
5.2.2

LED of Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


LED of Servo Amplifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121
121
122

123
123
124

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


6.1

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

126

6.2

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

127

6.3

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

127

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


7.1

REPLACING THE PRINTEDCIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


7.1.1
7.1.2
7.1.3

Replacing the Backplane Board (Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Replacing the Robot Control Board and PrintedCircuit Boards on the Backplane Unit . . . . . . . . . . .
Replacing the Emergency Stop Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

129
130
131
132

7.2

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

133

7.3

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

137

7.3.1

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

137

7.4

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

138

7.5

REPLACING THE MAGNETIC CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

139

7.6

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

140

7.7

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

141

7.8

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

142

7.9

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

143

7.10

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

144

7.11

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

145

7.12

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

146

7.13

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

147

7.13.1
7.13.2
7.13.3
7.13.4
7.13.5
7.13.6

7.14

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

7.15

Replacing a Fuse on the Robot Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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

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

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

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147
148
149
150
151
152

153
153

154
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B81535EN/02

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

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

162

3.2

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

163

3.3

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

165

3.4

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

167

3.4.1
3.4.2
3.4.3
3.4.4

Circuit Diagram of Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


External Emergency Stop Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Emergency Stop Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External 24 V Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

167
168
169
170

3.5

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

171

3.6

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

172

3.7

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

173

3.8

CONNECTION OF CABLE FOR RS232C/RS422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

174

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

175

3.9

3.9.1
3.9.2
3.9.3
3.9.4
3.9.5

3.10

END EFFECTOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


3.10.1
3.10.2

3.11
3.12

Peripheral Device Interfaces CRM79 and CRM81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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

175
176
193
193
195
196

197
197
199

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

200

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

201

3.12.1
3.12.2
3.12.3
3.12.4
3.12.5
3.12.6
3.12.7
3.12.8
3.12.9
3.12.10

Peripheral Device Interface Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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

201
202
203
208
214
216
219
219
220
221

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


4.1

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

223

4.2

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

223

4.3

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

224

4.4

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

225

4.5

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

225

4.6

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

226

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4.7

B81535EN/02

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

226

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

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

239

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

240

B.2.1
B.2.2

B.3

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

SPECIFICATIONS OF DIGITAL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


B.3.1
B.3.2
B.3.3

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

240
241

242
242
242
243

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

c4

B81535EN/02

PREFACE

PREFACE

This manual describes the following models.


Model

Abbreviation

FANUC Robot LR Mate 100iB

LR Mate 100iB

FANUC Robot LR Mate 200iB

LR Mate 200iB

FANUC Robot ARC Mate 50iB

ARC Mate 50iB

p1

I SAFETY PRECAUTIONS

B81535EN/02

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

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

1. SAFETY PRECAUTIONS

1.1
OPERATOR SAFETY

SAFETY PRECAUTIONS

B81535EN/02

Operator safety is the primary safety consideration. Because it is very


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

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

(4) Provide the peripheral devices with appropriate grounding (Class 1,


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

B81535EN/02

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

(9) When adjusting each peripheral device independently, be sure to turn


off the power of the robot.

Safety gate which executes with opening the door.

Fig.1.1 Safety Fence and Safety Gate

1. SAFETY PRECAUTIONS

1.1.1
Operator Safety

SAFETY PRECAUTIONS

B81535EN/02

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

External EMERGENCY STOP button

Emergency stop board


EMGIN11
EMGIN12
EMGIN21
EMGIN22

Note)

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

Fig.1.1.1 Connection Diagram for External Emergency Stop Switch

B81535EN/02

1.1.2
Safety of the Teach
Pendant Operator

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

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

: The function of this switch depends on the


state of the enable/disable switch and the
mode switch of operator panel.

When the mode switch is in the AUTO position


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

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

1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

B81535EN/02

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

Operator panel
mode switch

Teach pendant
enable switch

Remote
condition

Teach
pendant

Operator panel

Peripheral
devices

T1

On

Independent

Allowed to start

Not allowed

Not allowed

AUTO

Off

Local

Not allowed

Allowed to start

Not allowed

AUTO

Off

Remote

Not allowed

Not allowed

Allowed to start

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

B81535EN/02

1.1.3
Safety During
Maintenance

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

For the safety of maintenance personnel, pay utmost attention to the


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

1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

B81535EN/02

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

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

1.2.2
Precautions for
Mechanism

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

10

B81535EN/02

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

1.3
SAFETY OF THE
ROBOT MECHANISM
1.3.1
Precautions in
Operation

1.3.2
Precautions in
Programming

1.3.3
Precautions for
Mechanisms

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

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

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

11

1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

B81535EN/02

1.4
SAFETY OF THE END
EFFECTOR
1.4.1
Precautions in
Programming

(1) To control the pneumatic, hydraulic and electric actuators, carefully


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

12

B81535EN/02

1.5
SAFETY IN
MAINTENANCE

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

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

13

1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

B81535EN/02

1.6
WARNING LABEL
Description

Do not step on or climb the robot or controller as it may adversely affect


the robot or controller and you may get hurt if you lose your footing as
well.
(1) Stepon prohibitive label

Fig.1.6 (a) Stepon Prohibitive Label

Description

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


generates heat. If you have to inevitably touch such a section when it is
hot, use a protective provision such as heatresistant gloves.
(2) Hightemperature warning label

Fig.1.6 (b) HighTemperature Warning Label

Description

A high voltage is applied to the places where this label is attached.


Before starting maintenance, turn the power to the control unit off, then
turn the circuit breaker off to avoid electric shock hazards. Be careful with
servo amplifier and other units because highvoltage places in these units
may remain in the highvoltage state for a fixed time.
14

B81535EN/02

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

(3) Highvoltage warning label

Fig.1.6 (c) HighVoltage Warning Label

Description

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

15

II MAINTENANCE

MAINTENANCE

B81535EN/02

1. OVERVIEW

OVERVIEW

This manual describes the maintenance and connection of the RJ3iB


Mate robot controller (called the RJ3iB Mate).
Maintenance Part : Troubleshooting, and the setting, adjustment,
and replacement of units
Connection Part : Connection of the RJ3iB Mate controller to the
robot mechanical unit and peripheral devices,
and installation of the controller
WARNING
Before you enter the robot working area, be sure to turn off
the power to the controller or press the EMERGENCY
STOP button on the operator panel or teach pendant.
Otherwise, you could injure personnel or damage
equipment.

TERM
The RJ3iB Mate robot controller uses the FANUC servo
amplifier i series (called the servo amplifier (i).
The servo amplifier i comprises a power supply module
(PSM) and a servo amplifier module (SVM).
In this manual, the terms power supply module and servo
amplifier module refer to the individual modules. The term
servo amplifier refers to the combination of the power
supply module and servo amplifier module.

19

2. CONFIGURATION

MAINTENANCE

CONFIGURATION

20

B81535EN/02

B81535EN/02

2.1
EXTERNAL VIEW OF
THE CONTROLLER

2. CONFIGURATION

MAINTENANCE

The appearance and components might slightly differ depending on the


controlled robot, application, and options used.
Fig.2.1 (a) shows the view of RJ3iB Mate.
Fig.2.1 (b) shows the RJ3iB Mate consists of the RJ3iB Mate controller.
Teach pendant
RJ3iB Mate controller

Operator
panel

Teach pendant cable

Fan unit

Fig.2.1 (a) External View of the RJ3iB Mate Controller

21

2. CONFIGURATION

MAINTENANCE

B81535EN/02

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

Emergency stop unit


Power supply unit
Emergency stop board
Circuit protector
Emergency stop
button

Heat exchange

Mode
switch

Back plane board


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

Fuse
MCC

Fig.2.1 (b) RJ3iB Mate interior (Front)


Table 2.1 Servo amplifier specifications
Robot
LR Mate 100iB

LR Mate 200iB
ARC Mate 50iB

Power supply module


A06B6115H001
(PSMR1i)

Servo amplifier module1


A06B6114H205
(SVM20/20i)
L
M
J1
J2
A06B6114H302
(SVM10/10/10i)
L
M
N
J1
J2
J3

A06B6115H001
(PSMR1i)

22

Servo amplifier module2


A06B6114H302
(SVM10/10/10i)
L
M
N
J3
J4
J5
A06B6114H302
(SVM10/10/10i)
L
M
N
J4
J5
J6

MAINTENANCE

B81535EN/02

2.2
COMPONENT
FUNCTIONS

2. CONFIGURATION

Robot control printed circuit board


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

Various control boards are mounted on the backplane board.


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

23

2. CONFIGURATION

2.3
PREVENTIVE
MAINTENANCE

MAINTENANCE

B81535EN/02

Daily maintenance and periodic maintenance/inspection ensure reliable


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

24

MAINTENANCE

B81535EN/02

3. TROUBLESHOOTING

TROUBLESHOOTING

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

25

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

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

Check that the circuit protector is on and


has not tripped.

(Corrective
action)

Turn on the circuit protector.

(Check 2)

Check that the door fan unit and the fan


motor of the heat exchanger are rotating
and that the LED indication on the power
supply module is .

(Corrective
action)

If the fan motor is not rotating or if the


LED of the power supply module is not
glowing, the fuse on the back of the door
may have been blown.
Check the fuse on the back of the
door.
If the fuse on the back of the door has
been blown, replace the fuse.

Figure
Circuit protector
(on/off switch)

LED of the power supply module


Circuit protector
Heat exchange for
fan unit (door face)

Secondary side of the circuit protector


Fuse

26

B81535EN/02

3. TROUBLESHOOTING

MAINTENANCE

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

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

(Corrective
action)

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

Figure
Teach pendant

Emergency stop board


FALM LED
Fuse FUS4

Emergency stop unit

27

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

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

Check that the . portion of the seven


segment LED glows on the robot control
board.

(Corrective
action)

If the . portion is not glowing, the fuse


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

(Corrective
action(1))

(Corrective
action(2))

Figure

+24V input
connector
CP5

Cause of the blowing of the fuse FUS1


and corrective action
a) Check whether the device which is
connected to the RS232C/
RS422 port and requires the power
supply of +24 V is sound.
b) Problem in the DC/DC converter
module
If the DC/DC converter module gets
faulty in the shortcircuit mode,
FUS1 is blown.
Replace the DC/DC converter module.

DC/DC converter
module
dot part of seven
segment LED

a) Problem in the DC/DC converter


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

FUS1 7.5A
DC24V input fuse

28

B81535EN/02

3.2
ALARM
OCCURRENCE
SCREEN

3. TROUBLESHOOTING

MAINTENANCE

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

Press the alarm key.

Automatic alarm display


upon occurrence

Alarm occurrence screen display

Press F3 [ACTIVE].

Press F3 [HIST].

Alarm history screen display

Fig.3.2 Alarm Occurrence Screen and Alarm History Screen Display


Procedure

29

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

Displaying the alarm history/alarm detail information

Step

(1) Press the MENUS key to display the screen menu.


(2) Select [ALARM].
You will see a screen similar to the following
3
4 ALARM
5 I/O

INTP224 (SAMPLE1, 7) Jump label is fail


MEMO027 Specified line does not exist
Alarm
JOINT 30 %
1/25
1 INTP224 (SAMPLE1, 7) Jump label is
2 SRVO002 Teach pendant Estop
3 R E S E T
4 SRVO027 Robot not mastered(Group:1)
5 SYST026 System normal power up

MENUS

[ TYPE ]

CLEAR

HELP

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

HELP
F5

INTP224 (SAMPLE1, 7) Jump label is fail


INTP224 (SAMPLE1, 7) Jump label is fail
MEMO027 Specified line does not exist
30MAY44 07:15
STOP.L
00000110
Alarm
1/25
1 INTP224 (SAMPLE1, 7) Jump label is
2 SRVO002 Teach pendant Estop

[ TYPE ]

CLEAR

HELP

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

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

SHIFT

F4

HELP

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

30

B81535EN/02

3. TROUBLESHOOTING

MAINTENANCE

The following map indicates teach pendant operations used to check an


alarm.
4 ALARM
F1 [TYPE]
Alarm : Active
F1 [TYPE]
F3 HIST
Alarm : HIST
F1 [TYPE]
F3 [ACTIVE]
F4 CLEAR
F5 HELP
DETAIL Alarm
F1 [TYPE]
F3 [ACTIVE]
F4 CLEAR
F5 HELP

31

3. TROUBLESHOOTING

3.3
SAFETY SIGNALS

MAINTENANCE

B81535EN/02

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

Safety signal

Description

Operator panel emergency stop

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

Teach pendant emergency stop

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

External emergency stop

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

Fence open

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

Deadman switch

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

Teach pendant operable

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

Hand broken

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

Robot overtravel

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

Abnormal air pressure

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

Step

(1) Press the MENUS key to display the screen menu.


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

1
2
3
4
5
6
7
8
9

JOINT 30%

SIGNAL NAME

STATUS

SOP EStop:
TP Estop:
Ext EStop:
Fence Open:
TP Deadman:
TP Enable:
Hand Broken:
Over Travel:
Low Air Alarm:

FALSE
FALSE
FALSE
FALSE
TRUE
TRUE
FALSE
FALSE
FALSE

[TYPE]

32

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3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

3.4

Mastering is needed if:

MASTERING

(1) The SRVO 062 BZAL or SRVO 038 pulse mismatch alarm occurs,
or
(2) The pulse coder is replaced.
Item (1) requires simplified mastering, while item (2) requires
zerodegree or jig position mastering. (Zerodegree position mastering
is just for quickfix purposes. After zerodegree position mastering is
used, jig position mastering should be performed later.)
The mastering procedure is described below. For details, refer to an
applicable maintenance manual of mechanical unit or operators manual
of control unit.

Condition

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


SYSTEM Variables
57 $MASTER_ENB

Step

JOINT 10%
57/136
1

(1) Press <MENUS>.


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

MENUS

5 POSITION
6 SYSTEM
7

Master/Cal
TYPE

SYSTEM Master/Cal
1

FIXTURE POSITION MASTER

2
3
4
5
6

ZERO POSITION MASTER


QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE

JOINT 30%

Press ENTER or number key to select.

[TYPE]

LOAD RES_PCA

DONE

F1

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

33

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(6) Select 1 FIXTURE POSITION MASTER and press the F4 key


(yes). Mastering data is set.
SYSTEM Master/Cal

SYSTEM Master/Cal
ENTER

1 FIXTURE POSITION MASTER


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

NO

F4

JOINT

30 %

1 FIXTURE POSITION MASTER


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

[ TYPE ]

LOAD

RES_PCA

DONE

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


performed.
Alternatively, to perform positioning, turn the power off, then turn it
on again. Calibration is performed whenever the power is turned on.
5 SET QUICK MASTER REF
6 CALIBRATE
ENTER
Calibrate? [NO]
Calibrate? [NO]
[ TYPE ]

SYSTEM Master/Cal

YES

F4

NO

JOINT

30 %

1 FIXTURE POSITION MASTER


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

(8) Press F5 DONE, after mastering.


DONE

F5

34

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

3.5
TROUBLESHOOTING
USING THE ERROR
CODE

(1) SRVO001 SVAL1 Operator panel Estop


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

Emergency stop button

Operator
panel

Robot control board


Emergency stop unit

Fig.3.5 (1) (a) SRVO001 SVAL1 Operator panel Estop

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3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(2) SRVO002 SVAL1 Teach pendant Estop


(Explanation) The emergency stop button on the operators Teach
Pendant was pressed.
(Action 1)
Release the emergency stop button on the teach
pendant.
(Action 2)
Replace Teach Pendant.
Emergency stop button

Fig.3.5 (2) SRVO002 SVAL1 Teach pendant Estop

(3) SRVO003 SVAL1 Deadman switch released


(Explanation) The teach pendant is enabled, but the deadman switch
is not pressed.
(Action 1)
Press the deadman switch to run the robot.
(Action 2)
Replace the teach pendant.

Deadman switch

Fig.3.5 (3) SRVO001 SVAL1 Deadman switch released

36

MAINTENANCE

B81535EN/02

3. TROUBLESHOOTING

(4) SRVO004 SVAL1 Fence open


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

When AUTO mode is not entered even though the


mode switch is set to AUTO, the mode switch may be
faulty. Replace the operator panel.
Replace the emergency stop unit.
Before taking (Action 6), make a backup copy of all
the programs and settings of the control unit.
Replace the robot control board.

(Action 5)

(Action 6)

Short connection boards:


two positions (terminal blocks
located on the right when
viewing from the front)

Emergency stop unit

Fig.3.5 (4) SRVO004 SVAL1 Fence open

37

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(5) SRVO005 SVAL1 Robot overtravel


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

Robot control board

Fig.3.5 (5) SRVO005 SVAL1 Robot overtravel

38

B81535EN/02

MAINTENANCE

3. TROUBLESHOOTING

(6) SRVO006 SVAL1 Hand broken


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

Robot control board

Fig.3.5 (6) SRVO006 SVAL1 Hand broken

39

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(7) SRVO007 SVAL1 External Estop


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

Short connection boards:


two positions (terminal blocks
located on the left when
viewing from the front)

Emergency stop unit

Fig.3.5 (7) SRVO007 SVAL1 External Estop

40

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MAINTENANCE

3. TROUBLESHOOTING

(8) SRVO009 SVAL1 Pneumatic pressure alarm


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

Robot control board

Fig.3.5 (8) SRVO009 SVAL1 Pneumatic pressure alarm

41

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(9) SRVO014 WARN Fan motor abnormal


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

Fig.3.5 (9) SRVO014 WARN Fan motor abnormal

42

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MAINTENANCE

3. TROUBLESHOOTING

(10) SRVO015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j)


(Explanation) The temperature in the control unit exceeds the
specified value.
(Action 1)
If the ambient temperature is higher than specified
(45C), cool down ambient temperature.
(Action 2)
If the fan motor is not running, check it and its cables.
Replace them if necessary.
(Action 3)
If the thermostat on the robot control board is
defective, replace the robot control board.

Fan motor
(on the heat exchange)

Fan motor (door face)

Robot control board

Fig.3.5 (10) SRVO015 SVAL1 SYSTEM OVER HEAT

43

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(11) SRVO021 SVAL1 SRDY off (Group : i Axis : j)


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

44

B81535EN/02

MAINTENANCE

Emergency stop unit

3. TROUBLESHOOTING

Robot control board


Servo amplifier module
Power supply module

Axis control card

Fig.3.5 (11) SRVO021 SVAL1 SRDY off

45

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(12) SRVO022 SVAL1 SRDY on (Group : i Axis : j)


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

Robot control board


Servo amplifier module
Power supply module
Axis control card

Fig.3.5 (12) SRVO022 SVAL1 SRDY on

46

B81535EN/02

MAINTENANCE

3. TROUBLESHOOTING

(13) SRVO023 SVAL1 Stop error excess (Group : i Axis : j)


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

Servo amplifier module


Power supply module

Fig.3.5 (13) SRVO023 SVAL1 Stop error excess

47

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(14) SRVO024 SVAL1 Move error excess (Group : i Axis : j)


(Explanation) When the robot is running, its position error is greater
than a specified value ($PARAM _ GROUP.
$MOVER _ OFFST or $PARAM _ GROUP.
$TRKERRLIM). It is likely that the robot cannot
follow the speed specified by program.
(Action 1)
Check the robot for binding axis.
(Action 2)
Take the same actions as described for the above
alarm.
(15) SRVO025 SVAL1 Motn dt overflow (Group : i Axis : j)
(Explanation) The specified value is too great.
(16) SRVO026 WARN2 Motor speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum motor speed
($PARAM_GROUP.$MOT_SPD_LIM)
was
specified. The actual motor speed is clamped to the
maximum speed.
(17) SRVO027 WARN Robot not mastered (Group : i)
(Explanation) An attempt was made to calibrate the robot, but the
necessary adjustment had not been completed.
(Action)
Master the robot.
(18) SRVO030 SVAL1 Brake on hold (Group : i)
(Explanation) This alarm occurs when the robot pauses, if the brake
on hold function has been enabled ($SCR.
$BRKHOLD _ ENB = 1). Disable the function if it is
not necessary.
(Action)
Disable [Servooff during pause] on the general
setting menu (Select Setting general).
(19) SRVO031 SVAL1 User servo alarm (Group : i)
(Explanation) An user servo alarm occurred.
(20) SRVO033 WARN Robot not calibrated (Group : i)
(Explanation) An attempt was made to set up a reference point for
simplified adjustment, but the robot had not been
calibrated.
(Action)
Calibrate the robot.
1.Supply power.
2.Set up a simplified adjustment reference point
using [Positioning] on the positioning menu.
(21) SRVO034 WARN Ref pos not set (Group : i)
(Explanation) An attempt was made to perform simplified adjustment,
but the reference point had not been set up.
(Action)
Set up a simplified adjustment reference point on the
positioning menu.
(22) SRVO035 WARN2 Joint speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum axis speed
($PARAM_GROUP.$JNTVELLIM) was specified.
Each actual axis speed is clamped to the maximum
speed.
(23) SRVO036 SVAL1 Inpos time over (Group : i Axis : j)
(Explanation) The robot did not get to the effective area ($PARAM _
GROUP.$ STOPTOL) even after the position check
monitoring time ($PARAM _ GROUP. $INPOS _
TIME) elapsed.
(Action)
Take the same actions as for SRVO23 (large position
error at a stop).
(24) SRVO037 SVAL1 Imstp input (Group : i)
(Explanation) The *IMSTP signal for a peripheral device interface
was input.
(Action)
Turn on the *IMSTP signal.
48

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3. TROUBLESHOOTING

(25) SRVO038 SVAL2 Pulse mismatch (Group : i Axis : j)


(Explanation) The pulse count obtained when power is turned off
does not match the pulse count obtained when power
is applied. This alarm is asserted after exchange the
pulsecoder or battery for back up of the pulsecoder
data or loading back up data to the Robot control
board.
(Action)
Perform Absolute Pulse Coder reset and remaster
robot (RESPCA)
1. Press MENUS.
2. Select SYSTEM.
3. Press F1 [TYPE].
4. Select MASTER/CAL.
5. Press F3, PESPCA and YES.
6. Execute mastering.
7. Press RESET.
The fault condition should reset. If the controller
is still faulted with additional servorelated errors,
cold start the controller.
It might be necessary to remaster the robot.
(26) SRVO041 SVAL2 MOFAL alarm (Group : i Axis : j)
(Explanation) The servo value was too high.
(Action)
Cold start the controller.

49

3. TROUBLESHOOTING

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(27) SRVO044 SVAL1 HVAL alarm (Group : i Axis : j)


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

Power supply module

Fig.3.5 (27) SRVO044 SVAL1 HVAL alarm

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MAINTENANCE

3. TROUBLESHOOTING

(28) SRVO045 SVAL1 HCAL alarm (Group : i Axis : j)


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

Robot control board


Servo amplifier module

Fig.3.5 (28) SRVO045 SVAL1 HCAL alarm

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(29) SRVO046 SVAL2 OVC alarm (Group : i Axis : j)


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

Servo amplifier module


Power supply module

Fig.3.5 (29) SRVO046 SVAL2 OVC alarm

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Reference

Relationships among the OVC, OVL, and HC alarms


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

Designation

Detection section

OVC

Overcurrent alarm

Servo software

OVL

Overload alarm

Thermal relay in the motor OHAL2


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

HC

High current alarm

Servo amplifier

Purpose of each alarm


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

Stop

Start

Stop

Start
Thermal time constant
of the motor is high.

Temperature at
which the winding
starts to burn

Thermal time constant


of the thermal relay is
low.

Time

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

To prevent the above defects, software is used to monitor the current


in the motor constantly in order to estimate the temperature of the
motor. The OVC alarm is issued based on this estimated temperature.
This method estimates the motor temperature with substantial
accuracy, so it can prevent the failures described above.
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To sum up, a double protection method is used; the OVC alarm is used
for protection from a shorttime overcurrent, and the OVL alarm is
used for protection from longterm overload. The relationship
between the OVC and OVL alarms is shown in Fig 2.
Current
Protection area for
the motor and
servo amplifier
Protection by the OVL
Limit current

Protection by
the OVC

Rated continuous current


Time

Fig.2 Relationship between the OVC and OVL alarms

NOTE
The relationship shown in Fig. 2 is taken into consideration
for the OVC alarm. The motor might not be hot even if the
OVC alarm has occurred. In this case, do not change the
parameters to relax protection.
(30) SRVO047 SVAL1 LVAL alarm (Group : i Axis : j)
(Explanation) The control power voltage (+5 V, etc.) on the servo
amplifier module is too low. The LED indication on
the servo amplifier module is 2 (LVAL).
(Action 1)
Replace the servo amplifier module.

Servo amplifier module

Fig.3.5 (30) SRVO047 SVAL1 LVAL alarm

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(31) SRVO049 SVAL1 OHAL1 alarm (Group : i Axis : j)


(Explanation) This alarm does not occur when the power supply
module and serve amplifier modules used with the
RJ3iB Mate are under normal conditions.
This alarm indicates that any of the power supply
module and servo amplifier modules is faulty.
(Action 1)
If this alarm occurs in relation to all axes, replace the
power supply module.
(Action 2)
If this alarm occurs in relation to a specific axis,
replace the servo amplifier module that controls the
axis.

Servo amplifier module


Power supply module

Fig.3.5 (31) SRVO049 SVAL1 OHAL1 alarm

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(32) SRVO050 SVAL1 CLALM alarm (Group : i Axis : j)


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

Servo amplifier module


Power supply module

Fig.3.5 (32) SRVO050 SVAL1 CLALM alarm

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(33) SRVO051 SVAL2 CUER alarm (Group : i Axis : j)


(Explanation) The offset of the current feedback value is abnormally
high.
(Action)
Replace the servo amplifier module.

Servo amplifier module

Fig.3.5 (33) SRVO051 SVAL2 CUER alarm

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(34) SRVO054 DSM Memory Error


(Explanation) An access to the axis control card on the robot control
board memory fails.
(Action)
Replace the axis control card.

Robot control board


Servo amplifier module
Axis control card

Fig.3.5 (34) SRVO054 DSM Memory Error

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(35) SRVO055 SVAL2 FSSB com error 1 (Group : i Axis : j)


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

Robot control board


Servo amplifier module
Axis control card

Fig.3.5 (35) SRVO055 SVAL2 FSSB com error 1

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(36) SRVO056 SVAL2 FSSB com error 2 (Group : i Axis : j)


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

Robot control board


Servo amplifier module
Axis control card

Fig.3.5 (36) SRVO056 SVAL2 FSSB com error 2

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(37) SRVO057 SVAL2 FSSB disconnect (Group : i Axis : j)


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

Robot control board


Servo amplifier module
Power supply module
Axis control card

Fig.3.5 (37) SRVO057 SVAL2 FSSB disconnect

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(38) SRVO058 SVAL2 FSSB init error (Group : i Axis : j)


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

Robot controll board


Servo amplifier module
Power supply module
Axis control card

Fig.3.5 (38) SRVO058 SVAL2 FSSB init error

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(39) SRVO059 SVAL2 Servo amp init error


(Explanation) Servo amplifier initialzation is failed.
(Action 1)
Check all connectors on the PSM and SVM. Make
sure they are installed correctly.
(Action 2)
Replace the power supply module and the servo
amplifier module.

Servo amplifier module


Power supply module

Fig.3.5 (39) SRVO059 SVAL2 Servo amp init error

(40) SRVO061 SVAL2 CKAL alarm (Group : i Axis : j)


(Explanation) This alarm occurs if the rotation speed count in the
pulse coder is abnormal (abnormal count clock).
(Action)
Replace the pulse coder.
NOTE
In this case, perform actions associated with DTERR,
CRCERR, or STBERR first.
(41) SRVO062 SVAL2 BZAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if battery for pulse coder
absolute-position backup is empty.
A probable cause is a broken battery cable or no
batteries in the robot.
(Action)
Remove the cause of the alarm, set the system
variable ($MCR.$SPC RESET) to TRUE, then turn
the power off and on again. Mastering is required.
(42) SRVO063 SVAL2 RCAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if the rotation speed count in the
pulse coder is abnormal (abnormal counter).
(Action)
Replace the pulse coder.
NOTE
In this case, perform actions associated with DTERR,
CRCERR, or STBERR first.

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(43) SRVO064 SVAL2 PHAL alarm (Group : i Axis : j)


(Explanation) This alarm occurs if the phase of the pulses generated
in the pulse coder is abnormal.
(Action)
Replace the pulse coder.
NOTE
This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.
(44) SRVO065 WARN BLAL alarm (Group : i Axis : j)
(Explanation) The battery voltage for the pulse coder is lower than
the rating.
(Action)
Replace the battery.
(If this alarm occurs, turn on the AC power and
replace the battery as soon as possible. A delay in
battery replacement may result in the BZAL alarm
being detected. In this case, the position data will be
lost. Once the position data is lost, mastering will
become necessary.
(45) SRVO066 SVAL2 CSAL alarm (Group : i Axis : j)
(Explanation) The ROM in the pulse coder is abnormal.
(Action)
Replace the pulse coder.
NOTE
This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.
(46) SRVO067 SVAL2 OHAL2 alarm (Group : i Axis : j)
(Explanation) The temperature inside the pulse coder or motor is
abnormally high, and the builtin thermostat has
operated.
(Action 1)
Check the operating conditions for the robot and relax
the service conditions.
(Action 2)
When power is supplied to the motor after it has
become sufficiently cool, if the alarm still occurs,
replace the motor.
(47) SRVO068 SVAL2 DTERR alarm (Group : i Axis : j)
(Explanation) The serial pulse coder does not return serial data in
response to a request signal.
See actions on SRVO070
(48) SRVO069 SVAL2 CRCERR alarm (Group : i Axis : j)
(Explanation) The serial data has disturbed during communication.
See actions on SRVO070

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(49) SRVO070 SVAL2 STBERR alarm (Group : i Axis : j)


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

Servo amplifier module

Fig.3.5 (49) SRVO070 SVAL2 STBERR alarm

(50) SRVO071 SVAL2 SPHAL alarm (Group : i Axis : j)


(Explanation) The feedback speed is abnormally high.
(Action 1)
If this alarm occurs together with the PHAL alarm
(No. 064), this alarm does not correspond to the major
cause of the failure.
(Action 2)
Replace the pulse coder.
(51) SRVO072 SVAL2 PMAL alarm (Group : i Axis : j)
(Explanation) It is likely that the pulse coder is abnormal.
(Action)
Replace the pulse coder and remaster the robot.
(52) SRVO073 SVAL2 CMAL alarm (Group : i Axis : j)
(Explanation) It is likely that the pulse coder is abnormal or the pulse
coder has malfunctioned due to noise.
(Action)
Master the robot and enhance the shielding.
(53) SRVO074 SVAL2 LDAL alarm (Group : i Axis : j)
(Explanation) The LED in the pulse coder is broken.
(Action)
Replace the pulse coder, and remaster the robot.
(54) SRVO075 WARN Pulse not established (Group : i Axis : j)
(Explanation) The absolute position of the pulse coder cannot be
established.
(Action)
Reset the alarm, and jog the axis on which the alarm
has occurred until the same alarm will not occur
again. (Jog one motor revolution)
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(55) SRVO076 SVAL1 Tip Stick Detection (Group : i Axis : j)


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

Servo amplifier module


Power supply module

Fig.3.5 (60) SRVO076 SVAL1 Tip Stick Detection

(56) SRVO081 WARN EROFL alarm (Track enc : i)


(Explanation) The pulse counter for line tracking has overflowed.
(57) SRVO082 WARN DAL alarm (Track ebc : i)
(Explanation) The line tracking pulse coder has not been connected.
(Action 1)
Check the pulse coder connection cable, and replace
it if necessary.
(Action 2)
Replace the pulse coder.
(58) SRVO083 WARN CKAL alarm (Track ebc : i)
(Explanation) This alarm occurs if the rotation speed count in the
pulse coder is abnormal (abnormal count clock).
(Action)
See the description about the SRVO061 CKAL
alarm.
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(59) SRVO084 WARN BZAL alarm (Track enc : i)


(Explanation) This alarm occurs if the backup battery for the absolute
position of the pulse coder has not been connected. See
the description about the BZAL alarm (SRVO062).
(60) SRVO085 WARN RCAL alarm (Track ebc : i)
(Explanation) This alarm occurs if the rotation speed count in the
pulse coder is abnormal (abnormal counter).
(Action)
See the description about the SRVO063 RCAL
alarm.
(61) SRVO086 WARN PHAL alarm (Track enc : i)
(Explanation) This alarm occurs if the phase of pulses generated in
the pulse coder is abnormal. See the description
about the PHAL alarm (SRVO064).
(62) SRVO087 WARN BLAL alarm (Track enc : i)
(Explanation) This alarm occurs if the voltage of the backup battery
for the absolute position of the pulse coder is low. See
the description about the BLAL alarm (SRVO065).
(63) SRVO088 WARN CSAL alarm (Track ebc : i)
(Explanation) The ROM in the pulse coder is abnormal.
(Action)
See the description about the SRVO066 CSAL
alarm.
(64) SRVO089 WARN OHAL2 alarm (Track enc : i)
(Explanation) The motor has overheated. See the description about
the OHAL2 alarm (SRVO067).
(65) SRVO090 WARN DTERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
description about the DTERR alarm (SRVO068).
(66) SRVO091 WARN CRCERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
description about the CRCERR alarm (SRVO069).
(67) SRVO092 WARN STBERR alarm (Track enc : i)
(Explanation) Communication between the pulse coder and line
tracking interface board is abnormal. See the
description about the STBERR alarm (SRVO070).
(68) SRVO093 WARN SPMAL alarm (Track enc : i)
(Explanation) This alarm occurs if the current position data from the
pulse coder is higher than the previous position data.
See the description about the SPHAL alarm
(SRVO071).
(69) SRVO094 WARN PMAL alarm (Track enc : i)
(Explanation) It is likely that the pulse coder is abnormal. See the
description about the PMAL alarm (SRVO072).
(70) SRVO095 WARN CMAL alarm (Track enc : i)
(Explanation) It is likely that the pulse coder is abnormal or the pulse
coder has malfunctioned due to noise. See the
description about the CMAL alarm (SRVO073).
(71) SRVO096 WARN LDAL alarm (Track enc : i)
(Explanation) The LED in the pulse coder is broken. See the
description about the LDAL alarm (SRVO074).
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(72) SRVO097 WARN Pulse not established (enc : i)


(Explanation) The absolute position of the pulse coder cannot be
established. See the description about (SRVO075).
Pulse not established.
(73) SRVO131 SVAL1 LVAL (PSM) alarm (Group : i Axis : j)
(Explanation) The control power supply voltage (for example, +5
V) on the power supply module is abnormally low.
The LED indication on the power supply module is
6 (LVAL).
(Action 1)
Replace the power supply module.

Power supply module

Fig.3.5 (73) SRVO131 SVAL1 LVAL(PSM) alarm

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(74) SRVO134 SVAL1 DCLVAL (PSM) alarm (Group : i Axis : j)


(Explanation) The DC voltage (DC link voltage) of the main circuit
power supply on the power supply module is
abnormally low. The LED indication on the power
supply module is 4.
If this alarm occurs during robot operation:
(Action 1)
Check the phase voltage of the threephase input (200
VAC) to the power supply module. If it is 170 VAC
or lower, check the input power supply voltage.
(Action 2)
Replace the power supply module.
If this alarm occurs before the magnetic contactor (MCC) is turned
on:
(Action 1)
Check the emergency stop board and the wiring
between the power supply module and magnetic
contactor (MCC) for an abnormal condition.
(Action 2)
Replace the magnetic contactor (MCC).
(Action 3)
Replace the emergency stop unit.
(Action 4)
Replace the power supply module.

Magnetic contactor

Servo amplifier module


Power supply module
Emergency stop unit

Fig.3.5 (74) SRVO134 SVAL1 DCLVAL (PSM) alarm

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(75) SRVO135 SVAL FSAL alarm (Group : i Axis : j)


(Explanation) The internal cooling fan(s) of the servo amplifier
module(s) is abnormal. The LED indication on the
relevant servo amplifier module is 1.
(Action 1)
Replace the fan motor of the servo amplifier module.
(Action 2)
Replace the servo amplifier module.

Fan

Servo amplifier module

Servo amplifier module

Fig.3.5 (75) SRVO135 SVAL FSAL alarm

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(76) SRVO136 SVAL1 DCLVAL alarm (Group : i Axis : j)


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

Magnetic contactor

Robot control board


Servo amplifier module
Power supply module

Fig.3.5 (76) SRVO136 SVAL1 DCLVAL alarm

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(77) SRVO156 SVAL1 IPMAL alarm (Group : i Axis : j)


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

Robot control board


Servo amplifier module

Fig.3.5 (77) SRVO156 SVAL1 IPMAL alarm

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(78) SRVO157 SVAL1 CHGAL alarm (Group : i Axis : j)


(Explanation) The capacitor for the DC link voltage of the servo
amplifier module was not charged within the
specified time.
(Action 1)
A short circuit may occur in the DC link voltage.
Check the connection.
(Action 2)
Replace the servo amplifier module.
(Action 3)
Replace the power supply module.

Servo amplifier module


Power supply module

Fig.3.5 (78) SRVO157 SVAL1 CHGAL alarm

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(79) SRVO201 SVAL1 Panel Estop or SVEMG abnormal


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

emergency stop button

Power supply module


Emergency stop unit

Fig.3.5 (79) SRVO201 SVAL1 Panel Estop or SVEMG abnormal

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(80) SRVO202 SVAL1 TP Estop or SVEMG abnormal


(Explanation) The EMERGENCY STOP button on the operator
panel was pressed, but the EMERGENCY STOP line
was not disconnected.
(Action 1)
Check the teach pendant connection cable.
(Action 2)
Replace the teach pendant.
(Action 3)
Replace the emergency stop unit.
(Action 4)
Replace the power supply module.
NOTE
This alarm might occur if the EMERGENCY STOP button
is pressed slowly.

Teach pendant
teach pendant cable

emergency stop button

Power supply module


Emergency stop unit

Fig.3.5 (80) SRVO202 SVAL1 TP Estop or SVEMG abnormal

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(81) SRVO204 SVAL1 External (SVEMG abnormal) Estop


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

Power supply module


Emergency stop unit

Fig.3.5 (81) SRVO204 SVAL1 External (SVEMG abnormal) Estop

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(82) SRVO205 SVAL1 Fence open (SVEMG abnormal)


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

Power supply module


Emergency stop unit

Fig.3.5 (82) SRVO205 SVAL1 Fence open (SVEMG abnormal)

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B81535EN/02

(83) SRVO206 SVAL1 Deadman switch (SVEMG abnormal)


(Explanation) The DEADMAN switch was released when the teach
pendant was operable, but the EMERGENCY STOP
line was not disconnected.
(Action 1)
The mode switch may be faulty. Replace the operator
panel.
(Action 2)
Replace the teach pendant.
(Action 3)
Replace the emergency stop unit.
(Action 4)
Replace the power supply module.

Power supply module


Emergency stop unit

Fig.3.5 (83) SRVO206 SVAL1 Deadman switch (SVEMG abnormal)

78

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(84) SRVO207 SVAL1 TP switch abnormal or door open


(Explanation) The teach pendant is operable, and the deadman
switch has been grasped, but the EMERGENCY
STOP line is kept disconnected.
(Action 1)
Check the teach pendant connection cable.
(Action 2)
Replace the teach pendant.
(Action 3)
Replace the emergency stop unit.
Teach pendant
Teach pendant cable

Emergency stop unit

Fig.3.5 (84) SRVO207 SVAL1 TP switch abnormal or door open

79

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(85) SRVO215 WARN Fuse blown (Aux axis)


(Explanation) The fuse in the additional axis amplifier has blown.
(Action 1)
Check the cause and solve the problem, then replace
the fuse.
(86) SRVO216 SVAL1 OVC (total) (Robot : i)
(Explanation) The current (total current for five axes or six axes)
flowing through the motor is too large.
(Action 1)
Slow the motion of the robot where possible. Check
the robot operation conditions. If the robot is used
with a condition exceeding the duty or load weight
robot rating, reduce the load condition value to the
specification range.
(Action 2)
Check each interphase voltage of the threephase
input (200 VAC) to the power supply module. If the
voltage is 170 VAC or lower, check the input power
supply voltage.

Power supply module

Fig.3.5 (86) SRVO215 WARN Fuse blown (Aux axis)

80

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MAINTENANCE

3. TROUBLESHOOTING

(87) SRVO221 SVAL1 Lack of DSP (Group : i Axis : j)


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

Robot control board


Servo amplifier module
Power supply module
Axis control card

Fig.3.5 (87) SRVO221 SVAL1 Lack of DSP (Group : i Axis : j)

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3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(88) SRVO222 SVAL1 Lack of Amp (Amp : i)


(Explanation) The FSSB has no SVM.
(Action 1)
Check that the optical cable is securely connected to
the servo amplifier module.
(Action 2)
Replace the optical cable.
(Action 3)
Check whether power is properly supplied to the
servo amplifier module.

Servo amplifier module

Fig.3.5 (88) SRVO222 SVAL1 Lack of Amp (Amp : i)

82

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(89) SRVO233 SVAL1 TP disabled in T1, T2/Door open


(Explanation) The teach pendant is disabled when the mode switch
is in the T1 mode position.
(Action 1)
During teaching operation, set the enable switch of
the teach pendant to Enable. Otherwise, set the mode
switch to AUTO mode.
(Action 2)
Replace the emergency stop unit.
(Action 3)
Replace the teach pendant.
(Action 4)
The mode switch may be faulty. Replace the operator
panel.
Teach pendant

Mode switch

FUS3
Emergency stop unit
Emergency stop board

Fig.3.5 (89) SRVO233 SVAL1 TP disabled in T1, T2/Door open

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3. TROUBLESHOOTING

MAINTENANCE

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(90) SRVO264 SVAL1 E.STOP circuit abnormal 1


(Explanation) An error occurred in the emergency stop circuit.
(Action 1)
Check whether the CRR78 connectors on the
ESTOP unit and the CX3 connector of the power
supply module are connected securely.
(Action 2)
Replace the emergency stop unit.
(Action 3)
Replace the power supply module.

Power supply module


Emergency stop unit

Fig.3.5 (90) SRVO264 SVAL1 E.STOP circuit abnormal 1

(91) SRVO265 SVAL1 E.STOP circuit abnormal 2


(Explanation) When the servo amplifier is excited, the monitor
contact of the magnetic contactor (MCC) becomes
faulty.
(Action 1)
Replace the magnetic contactor (MCC).
(Action 2)
Replace the emergency stop unit.
(Action 3)
Replace the power supply module.

Power supply module


Emergency stop unit
Magnetic contactor (MCC)

Fig.3.5 (91) SRVO265 SVAL1 E.STOP circuit abnormal 2

84

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3. TROUBLESHOOTING

(92) SRVO290 SVAL1 DClink HC alarm (Group : i Axis : j)


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

Robot control board


Servo amplifier module

Fig.3.5 (92) SRVO290 SVAL1 DClink HC alarm

(93) SRVO291 SVAL1 IPM over heat (Group : i Axis : j)


(Explanation) The IPM in the servo amplifier overheats.
The LED indications on the servo amplifier modules
are 8., 9., and A..
(Action 1)
Check whether the servo amplifier module fan stops.
(Action 2)
Reduce the override because the use condition is too
hard.
(Action 3)
If this alarm is frequently issued, replace the amplifier
module.
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3. TROUBLESHOOTING

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(94) SRVO295 SVAL1 SVM COM alarm (Group : i Axis : j)


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

Robot control board


Servo amplifier module
Power supply module
Axis control card

Fig.3.5 (94) SRVO295 SVAL1 SVM COM alarm

86

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3. TROUBLESHOOTING

(95) SRVO296 SVAL1 DCAL alarm (Group : i Axis : j)


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

Power supply module

Fig.3.5 (95) SRVO296 SVAL1 DCAL alarm

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3. TROUBLESHOOTING

MAINTENANCE

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(96) SRVO297 SVAL1 DCLVAL alarm (Group : i Axis : j)


(Explanation) An openphase condition has occurred in the input
power supply to the main circuit on the power supply
module. The LED indications on the power supply
module is E.
(Action 1)
Check the phase voltage of the threephase input (200
VAC) to the power supply module. If an openphase
condition is detected, check the input power supply.
(Action 2)
Replace the power supply module.

Power supply module

Fig.3.5 (96) SRVO297 SVAL1 DCLVAL alarm

88

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3. TROUBLESHOOTING

(97) SRVO300 SVAL1 Hand broken/HBK disabled


SRVO302 SVAL1 Set Hand broken to ENABLE
(Explanation) Although HBK was disabled, the HBK signal was
input.
(Action 1)
Press RESET on the teach pendant to release the
alarm.
(Action 2)
Check whether the hand broken signal is connected to
the robot. When the hand broken signal circuit is
connected, enable hand broken.
(See II
CONNECTION, Section 3.8 in this manual.)

Robot control board

Fig.3.5 (97)

SRVO300 SVAL1 Hand broken/HBK disabled


SRVO302 SVAL1 Set Hand broken to ENABLE

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3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(98) SRVO320 SVAL1 E.STOP


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

Power supply module


Emergency stop unit

Fig.3.5 (98) SRVO320 SVAL1 E.STOP

90

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3. TROUBLESHOOTING

MAINTENANCE

(99) SRVO321 SVAL1 TP SW/Deadman abnormal


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

ENABLE/DISABLE
switch
Deadman switch
(Back side)

Robot control board


Emergency stop unit

Fig.3.5 (98) SRVO321 SVAL1 TP SW/Deadman abnormal

91

3. TROUBLESHOOTING

MAINTENANCE

3.6

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

TROUBLESHOOTING
USING FUSES

Name

B81535EN/02

(1) Fuses on the robot control board


FUS1 : For generating power to the control circuit
FUS2 : For protecting +24E output to peripheral device digital
input/output, end effector, ROT, and HBK

Problem caused by blown fuse

Action

FUS1

The control power of the robot control board is shut off.


The teach pendant displays the initial screen.

FUS2

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

FUS1

1 Check the units (fans) and cables connected to the CP2 and
CP3 connectors of the power supply unit to see if there is any
short circuit.
2 Replace the DC/DC converter module.
3 Replace the robot control board.

FUS2

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(2) Fuses on the emergency stop board


FUS3 : For monitoring the emergency stop circuit
FUS4 : For controlling the emergency stop circuit and teach pendant
FUS5 : For the brake circuit
Name

Problem caused by blown fuse

Action

FUS3

The teach pendant screen displays SVAL1 TP disabled in T1, T2/Door open (SRVO233) and so forth.

Replace the emergency stop unit.

FUS4

The power supply to the teach pendant stops, the


screen display of the teach pendant disappears, and
the system enters the emergency stop state.

1 Examine the teach pendant cable for any problem.


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

FUS5

Replace the emergency stop unit.


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

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

FUS4
FUS3

FUS5

Emergency stop board

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(3) Blown fuse on the door


Name

Problem caused by blown fuse

FUS6

The power supply unit on the emergency stop unit does


not work, and the power cannot be turned on.

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

FUS6

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3. TROUBLESHOOTING

(4) Fuse on the power supply module


FU1
Name
FU1

: For protecting 200 VAC input to generate power to the


control circuit

Problem caused by blown fuse

Action

ALL LEDs of the servo amplifiers go out.


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

FU1

Remove the face plate

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(5) Fuse on the servo amplifier module


FU1
Name
FU1

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


circuit

Problem caused by blown fuse

Action

ALL LEDs of the servo amplifier modules go out.


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

FU1

Remove the control board

96

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3.7
TROUBLESHOOTING
BASED ON LED
INDICATIONS

MAINTENANCE

3. TROUBLESHOOTING

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

Robot control board

Emergency stop board

97

Servo amplifier module2 (AMP2)


Servo amplifier module1 (AMP1)
Power supply module (PSM)

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(1) TROUBLESHOOTING USING THE LEDS ON THE robot control


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

LED

Action to be taken

1: After poweron, all LEDs are


lit.

[Action1] Replace the CPU card


* [Action2] Replace the robot control board.

2: Software operation startup.

[Action1] Replace the CPU card


* [Action2] Replace the robot control board.

3: The initialization of dram on


the CPU card is completed.

[Action1] Replace the CPU card


* [Action2] Replace the robot control board.

4: The initialization of SRAM


and DPRAM is completed.

[Action1] Replace the CPU card


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

5: The initialization of the communication IC is completed.

[Action1] Replace the CPU card


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

6: The loading of the basic software is completed.

* [Action1] Replace the robot control board.


* [Action2] Replace the FROM/SRAM module.

7: Basic software startup.

* [Action1] Replace the robot control board.


* [Action2] Replace the FROM/SRAM module.

8: Startup of communication
with the teach pendant.

* [Action1] Replace the robot control board.


* [Action2] Replace the FROM/SRAM module.

9: The loading of optional software is completed.

* [Action1] Replace the robot control board.

10:DI/DO initialization

* [Action1] Replace the FROM/SRAM module.


* [Action2] Replace the robot control board.

11:The preparation of the SRAM


module is completed.

[Action1] Replace the axis control card.


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

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

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Step

LED

Action to be taken

12:Axis control card initialization

[Action1] Replace the axis control card.


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

13:Calibration is completed.

[Action1] Replace the axis control card.


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

14:Startup of power application


for the servo system

* [Action1] Replace the robot control board.

15:Program execution

* [Action1] Replace the robot control board.

16:DI/DO output startup.

* [Action1] Replace the robot control board.

17: Initialization is terminated.

Initialization has ended normally.

18:Normal status

Status LED 2 blink when the system is operating normally.

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

Axis control card

FROM/SRAM module
(under the CPU card)

99

CPU card

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(2) TROUBLESHOOTING BY 7SEGMENT LED INDICATOR


7segment LED
indicator

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

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

[Description] The SYSEMG alarm has occurred.


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

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

100

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MAINTENANCE

3. TROUBLESHOOTING

(3) Troubleshooting using a fuse alarm LED


LED indication

Failure description and required measure


[Description] A fuse (FUS1 or FUS2) is blown.
Cause of the blowing of FUS1 and corrective actions
[Action1]
Check whether the device which is connected to the RS232C/RS422 port
and requires the power supply of +24 V is sound.
[Action2]
Faulty DC/DC converter module
Replace the DC/DC converter module.
[Action3]
Shortcircuited surge absorber PVS1
The system can be operated temporarily without PVS1. However, obtain and
mount a new one at the earliest possible time.
[Action4]
Faulty robot control board
Replace the robot control board.
Cause of the blowing of FUS2 and corrective actions
[Action1]
Check that +24E used by the peripheral device is free from a ground fault.
[Action2]
Examine the peripheral device connection cable.
[Action3]
Check that +24E used by the end effector is free from a ground fault.
[Action4]
Examine the robot interconnection cable and intrarobot cable.

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Troubleshooting using an LED on the emergency stop board


LED indication

Problem and corrective action


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

FALM LED

Fuse FUS4
Fuse FUS3
Fuse FUS5

Emergency stop board


Emergency stop unit

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Troubleshooting using the LED of the power supply module


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

LED indication

Problem and corrective action


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

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

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Troubleshooting using the LED of the servo amplifier module


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

LED indication

Problem and corrective action


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

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LED indication

3. TROUBLESHOOTING

Problem and corrective action


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

[Action2]

[Action3]

b) If this alarm occurs, replace the servo amplifier


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

8., 9., and A. represent that an alarm occurs on the Laxis, M


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

105

3. TROUBLESHOOTING

MAINTENANCE

LED indication

B81535EN/02

Problem and corrective action


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

[Action3]

[Action4]

b) If this alarm occurs, replace the servo amplifier


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

b, C, and d represent that an alarm occurs on the Laxis, Maxis,


and Naxis respectively.

106

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

MAINTENANCE

3. TROUBLESHOOTING

(Check 1)

On the status screen, check the position deviation in the


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

(Check 2)

Check whether the motor axis can be positioned normally.


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

(Check 3)

Check the mechanical unit for backlash.


(Corrective action)
Replace a faulty key of motor shaft or other faulty parts.

(Check 4)

If checks 1 to 3 show normal results


(Corrective action)
Replace the pulse coder and robot control board.

107

3. TROUBLESHOOTING

3.9
VIBRATION
OBSERVED DURING
MOVEMENT

MAINTENANCE

B81535EN/02

(Check 1)

Check the settings of parameters such as the position loop


gain parameter.
(Corrective action)
Correct parameters.

(Check 2)

Check the mechanical unit for backlash.


(Corrective action)
Replace a faulty key of motor shaft or other faulty parts.

108

B81535EN/02

3.10
MANUAL
OPERATION
IMPOSSIBLE

MAINTENANCE

3. TROUBLESHOOTING

The following explains checking and corrective action required if the


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

Check whether the teach pendant is enabled.


(Corrective action)
Turn on the teach pendant enable.

(Check 2)

Check whether the teach pendant is handled correctly.


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

(Check 3)

Check whether the ENBL signal of the peripheral device


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

(Check 4)

Check whether the HOLD signal of the peripheral device


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

(Check 5)

Check whether the previous manual operation has been


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

(Check 6)

Check whether the controller is in the alarm status.


(Corrective action)
Release the alarm.

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


executed
(Check 1)

Check whether the ENBL signal for the peripheral-device


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

(Check 2)

Check whether the HOLD signal for the peripheral-device


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

3. TROUBLESHOOTING

MAINTENANCE

B81535EN/02

(Check 3)

Check whether the previous manual operation has been


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

(Check 4)

Check whether the controller is in the alarm status.


(Corrective action)
Release the alarm.

110

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MAINTENANCE

4. PRINTED CIRCUIT BOARDS

PRINTED CIRCUIT BOARDS

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

111

4. PRINTED CIRCUIT BOARDS

MAINTENANCE

B81535EN/02

4.1
ROBOT CONTROL
BOARD
(A16B32000450)

FROM/SRAM module
under the CPU card

CPU card

DC/DC converter module

Total version

Axis control card

Fig.4.1 Robot control board


Name
Robot control board

Board Specification

Note

A16B32000450

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

DC/DC convert module

A20B81000721

CPU card

A20B33000106

SDRAM 8M (Standard)

A20B33000107

SDRAM 16M

A20B33000241

6axis

A20B39000181

FROM 16M, SRAM 0.5M :


Standard

A20B39000160

FROM 16M, SRAM 1MB

A20B39000161

FROM 16M, SRAM 2MB

A20B39000162

FROM 16M, SRAM 3MB

Axis control card


FROM/SRAM module

112

B81535EN/02

MAINTENANCE

4. PRINTED CIRCUIT BOARDS

(1) LEDs
Seven segment LED

Description

A parity alarm occurred in a RAM of the main CPU


card on the Robot control board.

A parity alarm occurred in a RAM of the FROM/


SRAM module on the Robot control board.

2, 3, and 4 are not displayed.

A servo alarm occurred on the Robot control board.

SYSEMG occurred.

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

113

4. PRINTED CIRCUIT BOARDS

MAINTENANCE

Status LED

B81535EN/02

Description

STATUS
LED

Indicates the system operating status.

Status LED

FUSE
ALARM
LED

114

Description

A fuse (FUS1 or FUS2) was blown.

B81535EN/02

4. PRINTED CIRCUIT BOARDS

MAINTENANCE

(2) Correspondence between driver ICs and DO


Driver IC specification: A76L01510062
Driver IC name

DO signal name

H9

SDO101, SDO102, SDO103, SDO104

G9

SDO105, SDO106, SDO107, SDO108

K9

SDO109, SDO110, SDO111, SDO112

J9

SDO113, SDO114, SDO115, SDO116

J13

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

H13

SDO82, SDO83, SDO84, Reserved

J6

RDO1, RDO2, RDO3, RDO4

J4

RDO5, RDO6, SDO117, SDO118

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

Name and usage

Drawing number

G17

75172, driver

A76L01510098

G16

75173, receiver

A76L01510099

115

4. PRINTED CIRCUIT BOARDS

MAINTENANCE

B81535EN/02

4.2
EMERGENCY STOP
BOARD
(A20B10080010,
0011)

Total version

Fig.4.2 Emergency stop board

116

B81535EN/02

MAINTENANCE

4.3
BACKPLANE BOARD
(A20B20030330)

Total version

117

4. PRINTED CIRCUIT BOARDS

4. PRINTED CIRCUIT BOARDS

MAINTENANCE

B81535EN/02

4.4
PROCESS I/O
BOARD HE
(A16B22030764),
HF (A16B22030765)

Total edition
Test pins

Fig.4.4 Process I/O Board HA

(1) Test pins


Name

Use

P24V
P5V
GND1
GND2
GND3

+24V
+5V
GND
GND
GND

For measuring the DC supply voltage

P24VF
P5VF
GNDF

+24V
+5V
GND

Power for the digital/analog converter

AO1
AO2

Channel 1
Channel 2

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

(2) Settings
Name
ICOM1

UDI1 to UDI20
(Connector CRM2A)

UDI21 to UDI40
ICOM2
(Connector CRM2B)
ICOM3

Standard
setting

WDI01 to WDI08
(Connector CRW7)

118

Side A

Description

The common voltage is


adjusted to:
Side A : +24 V common
Side B : 0 V common

B81535EN/02

MAINTENANCE

4. PRINTED CIRCUIT BOARDS

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

Description

Red

A communication alarm occurred between


the main CPU and process input/output.

Red

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


below.

(5) Correspondence between driver chips and DO signals


Ordering code for the driver chips: A76L-0151-0062
Driver chip
DV1
DV2
DV3
DV4
DV5
DV6
DV7
DV8
DV9
DV10

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

119

5. SERVO AMPLIFIERS

MAINTENANCE

B81535EN/02

SERVO AMPLIFIERS

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

LR Mate 200iB
ARC Mate 50iB

Power supply module


A06B6115H001
(PSMR1i)

A06B6115H001
(PSMR1i)

Servo amplifier module1


A06B6114H205
(SVM20/20i)
L
M
J1
J2
A06B6114H302
(SVM10/10/10i)
L
M
N
J1
J2
J3

120

Servo amplifier module2


A06B6114H302
(SVM10/10/10i)
L
M
N
J3
J4
J5
A06B6114H302
(SVM10/10/10i)
L
M
N
J4
J5
J6

5. SERVO AMPLIFIERS

MAINTENANCE

B81535EN/02

5.1
OUTLINE DRAWINGS
5.1.1
Power Supply Module
PSM (A06B6115H001)

380

360

60

172

Fig.5.1.1 Outline drawing of power supply module PSM (A06B6115H001)

121

5. SERVO AMPLIFIERS

MAINTENANCE

B81535EN/02

5.1.2
Servo Amplifier Module
(A06B6114H205,
A06B6114H302)

A06B6114H205

A06B6114H302

380

360

60

172

Fig.5.1.2 Outline drawing of servo amplifier modules (A06B6114H205, A06B6114H302)

122

5. SERVO AMPLIFIERS

MAINTENANCE

B81535EN/02

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

The power supply module has a sevensegment LED. When taking a


corrective action corresponding to the LED indication, see the alarm
displayed on the teach pendant screen.

LED indication

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

The magnetic contactor controlled by the power supply module is in


the on state and is ready for driving the motor.

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

The main circuit cannot be charged within a predetermined period.

The control power voltage is low.

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

The regeneration amount is too large.

The regenerative resistor was heated.

The input power is in the openphase state.

123

5. SERVO AMPLIFIERS

MAINTENANCE

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

B81535EN/02

The servo amplifier module has a sevensegment LED. When taking a


corrective action corresponding to the LED indication, see the alarm
displayed on the teach pendant screen.

LED indication

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

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

The internal cooling fan stopped.

The control power voltage is low.

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

The communication among servo amplifier modules cannot be normally performed.

a) The IPM alarm was detected in the servo amplifier module.


b) The IPM alarm (overheat) was detected in the servo amplifier module.
8., 9., and A. represent that an alarm occurs on the Laxis, M
axis, and Naxis respectively.

An abnormal current is flowing to the servo motor.


b, C, and d represent that an alarm occurs on the Laxis, Maxis,
and Naxis respectively.

124

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MAINTENANCE

6. SETTING THE POWER SUPPLY

SETTING THE POWER SUPPLY

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

125

6. SETTING THE POWER SUPPLY

MAINTENANCE

B81535EN/02

6.1
BLOCK DIAGRAMS
OF THE POWER
SUPPLY
AC input

200 220 VAC


3

Servo amplifier

Power supply module


Magnetic
contactor
(MCC)
Circuit
protector

200VAC
2

200VAC

3
FUS6

200VAC

CZ1

2
CX1

Main circuit
DC link
FU1
regenerative
resistor

FAN

AC/DC
+24V

Emergency stop
unit

Power
supply
unit

CN1

AC/DC
+24V

Emergency stop
print board
FUS3

Servo
amplifier
module

CP5A
FUS4

Monitor circuit
CP5B

CRR77

CXA2A

L+, L

CXA2B

L+, L
Inverter
circuit

DC/DC
+5V
JF13

CZ2 LN

EmergenFUS5
cy stop
circuit
Brake
circuit
CRS1

TBEB3

+24T

Backplane
Robot control
board
DC/DC
converter
module
+5V, +3.3V
+15V, 15V CP8B
+24V
FUS1 CP5

Motor brake
Motor powersupply

BATTERY

Robot

Pulsecoder

Motor
End Effector

+24E
FUS2
+24E
CRM82

Teach pendant

+24E
CRM79

Peripheral device

+24E

Peripheral device
(option)

CRM81
+24V
JD17

Handy file etc.

Process I/O board


+24E FUSE1

+24F

Peripheral device
(option)

CRM2
CRM4
+24E

+24V
15V
+15V
+5V
+3.3V

Fig.6.1 Block diagram of the power supply

126

B81535EN/02

6.2
CHECKING THE
POWER SUPPLY
UNIT

6.3
CHECKING THE
POWER SUPPLY
MODULE

MAINTENANCE

6. SETTING THE POWER SUPPLY

The power supply unit need not be set or adjusted.


Table 6.2 Rating of the Power supply unit
Output

Rated voltage

Tolerance

+24V

+24V

+23V to +25V

The power supply module need not be set or adjusted.


Table 6.3 Rating of the Power supply module
Output

Rated voltage

Tolerance

+5V

+5.1V

3%

+3.3V

+3.3V

3%

+15V

+15V

10%

15V

15V

10%

127

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

REPLACING A UNIT

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

128

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MAINTENANCE

7. REPLACING A UNIT

7.1
REPLACING THE
PRINTEDCIRCUIT
BOARDS

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

129

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

7.1.1

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

Replacing the
Backplane Board (Unit)

(1) Detach the cables from the robot control board and boards on the
backplane board.
CAUTION
When you remove the main robot control Board, be sure
that the battery is good (3.13.3VDC) and it is installed
correctly. USE STATIC PROTECTION.
(2) Remove the robot control board and boards from the rack. (See
Section 7.1.2.)
(3) Detach the grounding cable from the backplane unit.
(4) Loosen the retaining screws in the upper section of the rack. Remove
the retaining screws from the lower section of the rack.
(5) Side rack up and out.
(6) To replace the backplane and rack, reverse steps (1) (6).
CAUTION
There is a possibility of data loss when a backplane board
is replaced. Be sure to back up all program and setup data
on a floppy disk before proceeding.

Backplane board

M5 nut (2 places)

Fig.7.1.1 Replacing the Backplane Board

130

7.1.2
Replacing the Robot
Control Board and
PrintedCircuit Boards
on the Backplane Unit

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

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

Slot 10
Barbed
handles

Slot 2

Rail
(Left)

Slot 9

Rail
(Right)
zoom

Barbed
handles

Fig.7.1.2 Replacing the Robot Control Board and PrintedCircuit Boards


on the Backplane Unit

131

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

7.1.3

The board is at the emergency stop unit.

Replacing the
Emergency Stop Board

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

1 Remove the front nuts


(2M5)

2 Remove the back nuts (2M5)


3 Remove the
screws (6M3)

Fig.7.1.3 Emergency stop board replacement

132

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7. REPLACING A UNIT

MAINTENANCE

7.2
REPLACING CARDS
AND MODULES ON
THE ROBOT
CONTROL BOARD

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

Card

Card

Card
Card

Spacer
Connector

Card

Spacer
Connector
Fig.7.2 (a) Demounting a card

133

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

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

Card

Spacer
Connector

Card

Card

Card
Card

Spacer
Connector
Fig.7.2 (b) Mounting a card

134

MAINTENANCE

B81535EN/02

7. REPLACING A UNIT

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

(b)

(c)

Fig.7.2 (c) Demounting/Mounting a module

135

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

Removing the DC/DC converter module


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

screws
(3M3)

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

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

FROM/SRAM module
under the CPU card

CPU card

DC/DC converter module

Total version

Axis control card

Fig.7.2 (e) Locations of Cards and Modules

136

B81535EN/02

7. REPLACING A UNIT

MAINTENANCE

7.3
REPLACING THE
TRANSFORMER

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

7.3.1
Replacing the Brake
Power Transformer

(1) Detach the cable from the transformer.


(2) Remove the two nuts (M5) securing the transformer, then replace the
transformer.
(3) Reconnect the cable.

Remore the nuts (2M5)

Fig.7.3.1 Replacing the brake power transformer

137

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

7.4
REPLACING THE
EMERGENCY STOP
UNIT

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

Nut (4M5)

2 Remove the back nuts


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

Fig.7.4 Replacing the Emergency Stop Unit

138

B81535EN/02

MAINTENANCE

7. REPLACING A UNIT

7.5
REPLACING THE
MAGNETIC
CONTACTOR

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

Magnetic contactor (MCC)

Fig.7.5 Replacing the magnetic contactor

139

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

7.6
REPLACING SERVO
AMPLIFIERS

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

Nut
(2M5)

Power supply
module

servo amplifier
module

Fig.7.6 Replacing the servo Amplifier

140

B81535EN/02

7.7
REPLACING THE
TEACH PENDANT

7. REPLACING A UNIT

MAINTENANCE

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

Detach or attach the cable by rotating


the connector retaining ring.

Fig.7.7 Replacing the Teach Pendant

141

7. REPLACING A UNIT

7.8
REPLACING THE
CONTROL SECTION
FAN MOTOR

MAINTENANCE

B81535EN/02

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

Fan motor connector

Fan motor

Pull the fan motor unit


toward you to unlatch it.

Fig.7.8 Replacing the Control Section Fan Motor

142

B81535EN/02

7.9
REPLACING THE
FAN MOTOR OF THE
SERVO AMPLIFIER
CONTROL UNIT

MAINTENANCE

7. REPLACING A UNIT

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

When mounting the fan motor, note


the orientation of the fan motor and
connector.

Lug

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

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

143

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

7.10
REPLACING THE
DOOR FAN UNIT AND
HEAT EXCHANGER

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

Heat exchange
Door fan unit
Screws (4M4)

Nut (4M5)

Fig.7.10 Replacing the door fan unit and heat exchanger

144

B81535EN/02

MAINTENANCE

7. REPLACING A UNIT

7.11
REPLACING THE
OPERATOR PANEL

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

Screw (4M3)

Fig.7.11 Replacing the operator panel

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

145

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

7.12

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

REPLACING THE
POWER SUPPLY
UNIT

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

1 Remove the front nuts


(2M5)

2 Remove the back nuts (2M5)


3 Remove the screws (4M3)

Fig.7.12 Replacing the power supply unit

146

MAINTENANCE

B81535EN/02

7.13

7. REPLACING A UNIT

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

REPLACING A FUSE
7.13.1

The robot control board has the following fuses.

Replacing a Fuse on
the Robot Control
Board

FUS1: For detecting a problem in the circuit on the robot control board:
A60L00010046#7.5
If this fuse is blown, the DC/DC converter module or a device
connected to the RS232C/RS422 port may be faulty. If the
device connected to the RS232C/RS422 port is not faulty,
replace the DC/DC converter module.
FUS2: For protecting the 24V output to the peripheral device:
A60L00010046#7.5
If this fuse is blown, the wiring to the peripheral device and a cable
may be incorrect or damaged.

FUS1

FUS2

Fig.7.13.1 Replacing a fuse on the robot control board

147

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

7.13.2

The emergency stop board has the following fuses.

Replacing a Fuse on
the Emergency Stop
Board

FUS3: For monitoring the emergency stop circuit: A60L00010046#1.0


If this fuse is blown, the emergency stop board may be faulty.
Replace the emergency stop board.
FUS4: For protecting the 24V output to the emergency stop circuit and
teach pendant: A60L00010046#1.0
If this fuse is blown, the emergency stop circuit may be incorrectly
routed, or the teach pendant or teach pendant cable may be faulty.
Check the routing of the emergency stop circuit, and replace the
teach pendant and teach pendant cable.
FUS5: For monitoring the emergency stop circuit: A60L00010245
#GP20
If the fuse is blown, the brake circuit may be faulty. Examine the
brake, robot, and robot interconnection cable. Alternatively,
replace the emergency stop board.

FUS4
FUS3

FUS5

Emergency stop board

Fig.7.13.2 Replacing a fuse on the emergency stop board

148

B81535EN/02

MAINTENANCE

7. REPLACING A UNIT

7.13.3

The door has the following fuse.

Replacing the Fuse on


the Door

FUS6: For protecting the 200VAC control output: A60L00010101#


P475H
If this fuse is blown, the power supply unit on the emergency stop
unit or the cooling fan unit may be faulty. Replace the power
supply unit or cooling fan unit.

FUS6

Fig.7.13.3 Replacing a fuse on the emergency stop board

149

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

7.13.4

The power supply module has the following fuse.

Replacing the Fuse on


the Power Supply
Module

FU1: For protecting the 200VAC input for generating power to the
control circuit: A60L00010359
If the fuse is blown, the power supply module may be faulty.
Replace the power supply module.

FU1

Remove the face plate

Fig.7.13.4 Replacing the fuse on the power supply module

150

B81535EN/02

7. REPLACING A UNIT

MAINTENANCE

7.13.5

The servo amplifier module has the following fuse.

Replacing the Fuse on


the Servo Amplifier
Module

FU1: For protecting the +24 V input for generating power to the control
unit: A60L00010290#LM32C
If this fuse is blown, the servo amplifier module may be faulty.
Replace the servo amplifier module.

FU1

Remove the control board

Fig.7.13.5 Replacing the fuse on the servo amplifier module

151

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

7.13.6

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

Replacing the Fuse on


the Process I/O Boards

FUSE1:Fuse for protecting the +24V output for peripheral equipment


interfaces.
A60L00010046#2.0

Process I/O board HE, HF


FUSE1

Total
edition

152

B81535EN/02

7.14
REPLACING A
RELAY

7. REPLACING A UNIT

MAINTENANCE

Prolonged use of a relay might result in its contacts failing to make a


secure connection or in them sticking to each other permanently. If such
a failure occurs, replace the relay.

7.14.1

The emergency stop board has the following relays.

Replacing a Relay on
the Emergency Stop
Board

KA6: For external emergency stop output: A58L00010192#1509A


KA7: For brake control: A58L00010192#1997R

KA6

KA7

Emergency stop board

Fig.7.14.1 Replacing a relay on the emergency stop board

153

7. REPLACING A UNIT

MAINTENANCE

B81535EN/02

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

The programs, and system variables are stored in the SRAM in the Robot
control board. The power to the SRAM memory is backed up by a lithium
battery mounted on the front panel of the Robot control board. The above
data is not lost even when the main battery goes dead. A new battery can
maintain the contents of memory for about 4 years (Note).
When the voltage of the battery becomes low, the battery alarm LED on
the operator panel is lit, and the lowvoltage battery alarm (system035)
is displayed on the teach pendant. When this alarm is displayed, replace
the battery as soon as possible. In general, the battery can be replaced
within one or two weeks, however, this depends on the system
configuration.
If the battery voltage gets lower, it becomes impossible to back up the
content of the SRAM. Turning on the power to the in this state causes
system not to start and LED of seven segment on the Robot control board
to be displayed 1 because the contents of memory are lost. Clear the
entire SRAM memory and reenter data after replacing the battery.
Important data should be saved to the memory card or floppy disk
beforehand in case of emergency.
When replacing the memory backup battery, do so while the robot
controller is turned off in case of emergency.
NOTE
In a newly introduced robot, the battery is factoryinstalled.
Battery replacement may, therefore, be needed within 4
years after the introduction of the robot.

Replacing the lithium


battery

(1) Prepare a new lithium battery (ordering drawing number:


A02B0200K102).
(2) Turn the robot controller on for about 30 seconds.
(3) Turn the robot controller off.
(4) Remove the old battery from the top of the Robot control board.
First unlatch the battery, remove it from the battery holder, and detach
its connector.

154

B81535EN/02

MAINTENANCE

Battery latch

7. REPLACING A UNIT

Battery
connector

Lithium battery

(5) Remove the old battery, insert a new one into the battery holder, and
attach the connector. Confirm that the battery is latched firmly.
WARNING
Using other than the recommended battery may result in the
battery exploding.
Replace the battery only with the specified battery
(A02B0200K102).

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

155

III CONNECTION

CONNECTIONS

B81535EN/02

1. GENERAL

GENERAL

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

159

2. BLOCK DIAGRAM

CONNECTIONS

B81535EN/02

BLOCK DIAGRAM

Following are the block diagrams of the electrical interface connection for
RJ3iB Mate.

RJ3iB Mate controller


Peripheral device
Robot
control
board

Operation
panel

(RDI/RDO)

RS232C
RS422/485
Teach pendant

Emergency
stop unit
Power
supply
unit

Emergency stop
board

(Note2)

Emergency stop
(Brake)

Transformer

Robot

Fan

Fuse
Pulse coder
Circuit
protector

MCC

Servo
amplifier

Power

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

160

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

CONNECTION DETAILS

Robot control
board

Emergency
stop unit
CP8B
EMGIN11, 12, 21, 22
FENCE11, 12, 21, 22
CP5B

Battery
CP5

Emergency
stop circuit

CRS24

JRS12

EMGOUT1, 2
EXT24V, 0V
CRS16

PCMCIA

Teach pendant

PCMCIA

COP10A

Servo amplifier

CRM82

Mechanical unit

JD17

RS232C or RS422/485

JD1A

I/O Link (master)

JD1B

I/O Link (slave : option)

CRM79

Peripheral device

CRM81

Peripheral device (option)

161

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

A grounding stud is provided


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

Use the cable holders are


provided at these locations.

Circuit protector

To primary power supply


3200VAC

Terminal is M4.

By using cable straps, secure


the primary power cable to the
screws used to fasten the fan.

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

You can specify the power supply cables as the option.

162

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

Name
Robot control board

Drawing number
A16B32000450

Master

Slave

f(*)

f(*)

Remarks
Standard

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

163

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

When the RJ3iB Mate control unit is used as the master of an I/O link
(when RJ3iB Mate control the process I/O printed board)

to other I/O link

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

JD1A

RJ3iB Mate

*Note that the connector name differs from


that of the standard FANUC I/O link.

When the RJ3iB Mate control unit is used as the master and a slave of an I/O link

JD1B

JD1A

FANUC I/O
Unit etc.

RJ3iB Mate
master

JD1B1

JD1A1

FANUC I/O Link


connection unit

JD1A2

JD1B2

JD1A

JD1B

FANUC I/O
Unit etc.

CNC, PLC

When the RJ3iB Mate control unit is used as a slave of the I/O link
(when a CNC or PLC is used as the master of the I/O link)

JD1B

JD1A

CNC, PLC

to other I/O link

JD1A

RJ3iB Mate

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

164

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

For other I/O link


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

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

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

JD1A interface

JD4(JD1B) interface

11

0V

01 RXSLC1

11

0V

01 RXSLC2

12

0V

02 *RXSLC1

12

0V

02 *RXSLC2

0V

03 TXSLC2

13

0V

03 TXSLC1

13

14

0V

04 *TXSLC1

14

0V

04 *TXSLC2

0V

05

0V

15

0V

05

15

16

0V

06

16

07

17

08

18

09 (+5V)

19

10

20

17
18

(+5V)

19
20

(+5V)

Note) When using an optical


I/O link adaptor, use +5V.

06

07

(+5V)

08

09 (+5V)

(+5V)

10

Note) When using an optical I/O link


adaptor, use +5V.

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

165

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

Cable connection

Master
I/O unit, etc
JD1B

Robot control board


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

(1) SIN [RX]


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

Slave
CNC, PLC etc
JD1A

Robot control board


JD1B

[RX] SIN (1)


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

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

166

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

Emergency stop board

+24T

(From CP5A)
24VIN +24EXT

CRS16

FUS4

+24V
FUS3

Operation panel
mode switch

+24EXT +24V

CRT11

AUTO

T1

SR21
SR22

Enable/Disable switch
+24T

SR23
+24EXT

KA13 KA22 KA32

0V

Emergency stop button

+24V

Dead man switch

KA11
+24EXT

Robot control
board

JRS12

+24V

0VEXT

CRS24

TBEB1

INT24V
MODE1

EXT24V

MODE2

INT0V

24V external
power supply

EXT0V
OPEMG

External
emergency stop

0V
0VEXT

EMGIN11
EMGIN12

FENCE
0VEXT

EMGIN21

KA21

EMGIN22

EXEMG
+

MCCMON

FENCE11

TBEB2

Safety fence

FENCE12

Mode switch
SR21
SR22
SR23

AUTO
CLOSE
OPEN
CLOSE

T1
OPEN
CLOSE
OPEN

KA31

0VEXT

FENCE21
FENCE22
EMGOUT1

CRM83 +24V

Servo amplifier
( PSMR1i)

EMGOUT1
KA61

CRR78

CX3
MCCOFF3

0V
MCCOFF4
0V

RL1

KA62
+24V

CX4
+24V
ESP

MCC
(KM1)
KM11
KM12
KM13

3200VAC

KM14
KM15

167

CZ1

ESP

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

3.4.2
External Emergency
Stop Input

Customer should prepare this cable


TBEB1
EMGIN11
EMGIN12
EMGIN21
EMGIN22

Cable holder

EMGIN11
EMGIN12
EMGIN21
EMGIN22

FENCE11
FENCE12
FENCE21
FENCE22

EMGIN1
EMGIN2

SVOFF1

External emergency
stop input

Servo off input

When the robot is shipped, EMGIN11 and EMGIN12/


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

SVOFF2

Emergency stop board

EXT24V
INT24V
INT0V
EXT0V

TBEB2
FENCE11
FENCE12
FENCE21
FENCE22
EMGOUT1
EMGOUT2

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

168

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

3.4.3
External Emergency
Stop Output
Customer should prepare this cable.

Cable holder

EMGOUT1
EMGOUT2

TP
Emergency
stop

Emergency stop from the teach pendant and


emergency stop from the operator panel are
reflected to the external emergency stop outputs, EMGOUT1 and EMGOUT2.

OP
Emergency
stop

TBEB1
EMGIN11
EMGIN12
EMGIN21
EMGIN22

TBEB2
FENCE11
FENCE12
FENCE21
FENCE22
EMGOUT1
EMGOUT2

EXT24V
INT24V
INT0V
EXT0V

Emergency stop board


EMGOUT11
EMGOUT12

169

To peripheral control sequencer etc.

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

3.4.4
External 24 V Input
Customer should prepare this cable.

Cable holder

EXT24V
EXT0V

Emergency stop board

A short connection board is


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

+24V

When 24 V is applied externally, the external


emergency stop outputs, EMGOUT1 and
EMGOUT2, are always output regardless of
the power state of the robot control unit.

TBEB1
EMGIN11
EMGIN12
EMGIN21
EMGIN22

TBEB2
FENCE11
FENCE12
FENCE21
FENCE22
EMGOUT1
EMGOUT2

EXT24V
INT24V
INT0V
EXT0V

EXT24V
INT24V
INT0V
EXT0V

0V

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

170

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

3.5
COONECTION OF
SERVO AMPLIFIER
LR Mate 100iB
PSM

AMP1

AMP2

POWER SUPPLY
MODULE
(PSMR1i)
A06B6115H001

SERVO AMPLIFIER
MODULE
(SVM220/20i)
A06B6114H205

SERVO AMPLIFIER
MODULE
(SVM310/10/10i)
A06B6114H302

TB1

TB1

TB1
from MCC

CZ1

L+

L+
L+

L
L

from circuit
protector
from emergency
stop board

COP10B
CX1A

CXA2A

COP10B

CXA2B

CXA2A

CX3

COP10A

CXA2B

CXA2A

JF1 (L)

JF1 (L)

JF2 (M)

JF2 (M)

CX4

JF3 (N)

from robot control


board

CZ2 L

CZ2 L

CZ2 M

CZ2 M
CZ2 N

to robot
Pulse coder
Motor power

LR Mate 200iB/ARC Mate 50iB


PSM

AMP1

AMP2

POWER SUPPLY
MODULE
(PSMR1i)
A06B6115H001

SERVO AMPLIFIER
MODULE
(SVM310/10/10i)
A06B6114H302

SERVO AMPLIFIER
MODULE
(SVM310/10/10i)
A06B6114H302

TB1

TB1

TB1
from MCC

CZ1

L+

L+
L+

L
L

from circuit
protector
from emergency
stop board

COP10B
CX1A

CXA2A

CXA2B

COP10B
CXA2A

CX3

CXA2B

COP10A
CXA2A

JF1 (L)

JF1 (L)

JF2 (M)

JF2 (M)

CX4

JF3 (N)
JF3 (N)

from robot control


board

CZ2 L

CZ2 L

CZ2 M

CZ2 M
CZ2 N

CZ2 N
to robot
Pulse coder
Motor power

171

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

3.6
CONNECTION OF
ROBOT

CRM82
JF13

Power cable to RMP


Signal cable
Ground cable

TBEB3

172

CZ2 L, M, N

B81535EN/02

CONNECTIONS

3. CONNECTION DETAILS

3.7
CONNECTION OF
TEACH PENDANT
CABLE

Emergency stop unit


CRS16

To teach pendant

Earth plate

Fig.3.7 Teach pendant cable

173

3. CONNECTION DETAILS

3.8
CONNECTION OF
CABLE FOR
RS232C/RS422

CONNECTIONS

B81535EN/02

Selection of RS232C or RS422 (option) interface need setting of


software.

Communication port

01

FG

02

TXD

03

RXD

04

RTS

05

CTS

06

DSR

07

0V

08
09
10
11

12
13

14

(TX)

15

(*TX)

16

(RX)

17

(*RX)

18
19
20

DTR

21
22
23
24
25

174

+24E

Flopply, handy file etc.

Signals whose names are enclosed in


parentheses are assigned to use the
RS422 (option) interface. The numbers of the interface differ from those
of the standard RS422 (option) interface. Take the caution when designing the interface.

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

Name
Robot control board A

Drawing number
A16B32000450

CRM79

CRM81

DI

DO

DI

DO

20

20

Remarks
Standard

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

Connecting a peripheral device (CRM79 or CRM81)

Robot control board


CRM81
CRM79

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

Fig.3.9.1 Connecting the peripheral device cable

175

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

NOTE
See the operators MANUAL for the detail information.
Turn off the controller when connecting the cable.

CRM79

Robot
control
board

CNC

CRM81

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

01

SDI101

33

SDO101

02

SDI102

34

SDO102

03

SDI103

35

SDO103

36

SDO104

37

SDO105

38

SDO106

39

SDO107

04

SDI104

05

SDI105

06

SDI106

07

SDI107

08

SDI108

09

SDI109

10

SDI110

11

12

SDI111

SDI112

13

SDI113

14

SDI114

19

SDICOM1

20

SDICOM2

21

SDO120

22

SDI117

23

SDI118

24

SDI119

40

25

SDI120

41

26

SDO117

42

27

SDO118

43

SDO108
SDO109
SDO110
SDO111

28

44

SDO112

29

SDO119
0V

30

0V

45

SDO113

31

+24E

46

SDO114

32

+24E

47

SDO115

48

SDO116

15

SDI115

16

SDI116

17

0V

49

+24E

18

0V

50

+24E

Connector in cable side


HONDA TSUSHIN CO.,LTD
Connector MR50LMH(Male)

SDICOM1 and SDICOM2 are the signals used for selecting a common for SDI signals.
To use the +24V common, connect SDICOM1 and SDICOM2 to 0V.
To use the 0V common, connect SDICOM1 and SDICOM2 to +24V.
SDICOM1Selects a common for SDI101 to SDI108.
SDICOM2Selects a common for SDI109 to SDI120.
(Note) Maximum output current per one SDO signal is 70mA.

176

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

Connector in cable side


HONDA TSUUSHIN CO.,LTD
Connector MR50LMH (Male)

01

SDI101

02

SDI102

03

SDI103

04

SDI104

05

SDI105

06

SDI106

07

SDI107

08

SDI108

09

*HOLD

10

RESET

11

START

12

ENBL

13

PNS1

14

PNS2

15

PNS3

16

PNS4

17

0V

49

+24E

18

0V

50

+24E

33

SDO101

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

SDICOM1 and SDICOM2 signal are common selection signal for SDI.
When 24 V common is used, connect to 0V.
When 0V common is used, connect to +24V
SDICOM1Selects a common for SDI101 to SDI108.
SDICOM2Selects a common for *HOLD, RESET,
START, ENBL, PNS1 to PNS4, and SDI117 to SDI120.

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

177

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

Connector in cable side


HONDA TSUUSHIN CO.,LTD
Connector MR50LMH (Male)

01

*IMSTP

02

*HOLD

03

*SFSPD

04

CSTOPI

05

RESET

06

START

07

HOME

08

ENBL
09 RSR1/PNS1

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

33 CMDENBL

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

SYSRDY

PROGRUN
PAUSED
HELD

FAULT

ATPERCH
TPENBL

BATALM
BUSY

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

17

0V

49

+24E

18

0V

50

+24E

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

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

178

CONNECTIONS

B81535EN/02

3. CONNECTION DETAILS

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

Control unit (peripheral device interface : CRM79)


+24E

Peripheral device

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

receiver circuit
SDI101

RV

SDI102

RV

SDI103

RV

SDI104

RV

SDI105

RV

SDI106

RV

SDI107

RV

SDI108

RV

SDICOM1

RV

SDI109

RV

SDI110

RV

SDI111

RV

SDI112

RV

SDI113

RV

SDI114

RV

SDI115

RV

SDI116

RV

SDI117

RV

SDI118

RV

SDI119

RV

SDI120

RV

SDICOM2

RV

CRM79 (1)

3.3k

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

0V

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

179

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

Control unit (peripheral device interface : CRM79)


+24E

Peripheral device

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

receiver circuit
SDI101

RV

SDI102

RV

SDI103

RV

SDI104

RV

SDI105

RV

SDI106

RV

SDI107

RV

SDI108

RV

SDICOM1

RV

SDI109

RV

SDI110

RV

SDI111

RV

SDI112

RV

SDI113

RV

SDI114

RV

SDI115

RV

SDI116

RV

SDI117

RV

SDI118

RV

SDI119

RV

SDI120

RV

SDICOM2

RV

CRM79 (1)

3.3k

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

0V

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

180

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

(Specified signals are not allocated)

Control unit (peripheral device interface : CRM79)


Connector pin No
Driver circuit
SDO101

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

Peripheral device
LOAD

CRM79 (33)

DV

RELAY

CRM79 (34)
DV

LOAD
CRM79 (35)

DV

LOAD
CRM79 (36)
LOAD

DV
CRM79 (37)
DV

LOAD
CRM79 (38)

DV

LOAD
CRM79 (39)

DV

LOAD
CRM79 (40)

DV

LOAD
CRM79 (41)

DV

LOAD
CRM79 (42)

DV

LOAD
CRM79 (43)

DV

LOAD
CRM79 (44)

DV

LOAD
CRM79 (45)

DV

LOAD
CRM79 (46)

DV

LOAD
CRM79 (47)

DV

LOAD
CRM79 (48)

DV

LOAD
CRM79 (26)

DV

LOAD
CRM79 (27)

DV

LOAD
CRM79 (28)

DV

LOAD
CRM79 (21)

DV

LOAD
CRM79 (17,18,29,30)

0V

0V
+24V
+24V regurated
power supply

Max. current per SDO is 70mA.

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

181

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

Control unit (peripheral device interface : CRM79)


+24E

Peripheral device

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

receiver circuit
SDI101

RV

SDI102

RV

SDI103

RV

SDI104

RV

SDI105

RV

SDI106

RV

SDI107

RV

SDI108

RV

SDICOM1

RV

SDI109

RV

SDI110

RV

SDI111

RV

SDI112

RV

SDI113

RV

SDI114

RV

SDI115

RV

SDI116

RV

SDI117

RV

SDI118

RV

SDI119

RV

SDI120

RV

SDICOM2

RV

CRM79 (1)

3.3k

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

0V

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

182

CONNECTIONS

B81535EN/02

3. CONNECTION DETAILS

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

Control unit (peripheral device interface : CRM79)


+24E

Peripheral device

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

receiver circuit
SDI101

RV

SDI102

RV

SDI103

RV

SDI104

RV

SDI105

RV

SDI106

RV

SDI107

RV

SDI108

RV

SDICOM1

RV

SDI109

RV

SDI110

RV

SDI111

RV

SDI112

RV

SDI113

RV

SDI114

RV

SDI115

RV

SDI116

RV

SDI117

RV

SDI118

RV

SDI119

RV

SDI120

RV

SDICOM2

RV

CRM79 (1)

3.3k

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

0V

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

183

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

(Specified signals are allocated)

Control unit (peripheral device interface : CRM79)


Connector pin No
Driver circuit
SDO101

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

Peripheral device
LOAD

CRM79 (33)

DV

RELAY

CRM79 (34)
DV

LOAD
CRM79 (35)

DV

LOAD
CRM79 (36)
LOAD

DV
CRM79 (37)
DV

LOAD
CRM79 (38)

DV

LOAD
CRM79 (39)

DV

LOAD
CRM79 (40)

DV

LOAD
CRM79 (41)

DV

LOAD
CRM79 (42)

DV

LOAD
CRM79 (43)

DV

LOAD
CRM79 (44)

DV

LOAD
CRM79 (45)

DV

LOAD
CRM79 (46)

DV

LOAD
CRM79 (47)

DV

LOAD
CRM79 (48)

DV

LOAD
CRM79 (26)

DV

LOAD
CRM79 (27)

DV

LOAD
CRM79 (28)

DV

LOAD
CRM79 (21)

DV

LOAD
CRM79 (17,18,29,30)

0V

0V
+24V
+24V regurated
power supply

Max. current per SDO is 70mA.

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

184

CONNECTIONS

B81535EN/02

3. CONNECTION DETAILS

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

Control unit (peripheral device interface : CRM79)


+24E

Peripheral device

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

receiver circuit
*IMSTP

RV

*HOLD

RV

*SFSPD

RV

CSTOPI

RV

RESET

RV

SRART

RV

HOME

RV

ENBL

RV

SDICOM1

RV

RSR1/PNS1

RV

RSR2/PNS2

RV

RSR3/PNS3

RV

RSR4/PNS4

RV

RSR5/PNS5

RV

RSR6/PNS6

RV

RSR7/PNS7

RV

RSR8/PNS8

RV

PNSTROBE

RV

PROD_START

RV

SDI119

RV

SDI120

RV

SDICOM2

RV

CRM79 (1)

3.3k

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

0V

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

185

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

Control unit (peripheral device interface : CRM79)

Peripheral device

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

RV

*HOLD

RV

*SFSPD

RV

CSTOPI

RV

RESET

RV

START

RV

HOME

RV

ENBL

RV

SDICOM1

RV

RSR1/PNS1

RV

RSR2/PNS2

RV

RSR3/PNS3

RV

RSR4/PNS4

RV

RSR5/PNS5

RV

RSR6/PNS6

RV

RSR7/PNS7

RV

RSR8/PNS8

RV

PNSTROBE

RV

PROD_START

RV

SDI119

RV

SDI120

RV

SDICOM2

RV

CRM79 (1)
3.3k

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

0V

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

186

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

(Specified signals are allocated quickly)

Control unit (peripheral device interface : CRM79)


Driver circuit
CMDENBL

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

Connector pin No

Peripheral device
LOAD

CRM79 (33)

DV

RELAY

CRM79 (34)

DV

LOAD
CRM79 (35)

DV

LOAD

CRM79 (36)

DV

LOAD
CRM79 (37)

DV

LOAD

CRM79 (38)

DV

LOAD
CRM79 (39)

DV

LOAD

CRM79 (40)

DV

LOAD
CRM79 (41)

DV

LOAD

CRM79 (42)

DV

LOAD
CRM79 (43)

DV

LOAD

CRM79 (44)

DV

LOAD
CRM79 (45)

DV

LOAD
CRM79 (46)

DV

LOAD

CRM79 (47)

DV

LOAD
CRM79 (48)

DV

LOAD

CRM79 (26)

DV

LOAD
CRM79 (27)

DV

LOAD

CRM79 (28)

DV

LOAD
CRM79 (21)

DV

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

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

Max. current per SDO is 70mA.

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

187

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

01

SDI81

SDI82

02

SDI83

SDI84

03

SDI85

SDI86

04

SDI87

SDI88

05

SDICOM

06
07

SDO81

SDO82

08

SDO83

SDO84

09
10

Cableside connector
YAMAICHI ELECTRICITY
Connector
Housing UFS20B04
Contact Contact 66 type
(UFS contact)

0V
+24V

0V

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

01

*HOLD

RESET

02

START

ENBL

03

PNS1

PNS2

04

PNS3

PNS4

05

SDICOM

06
07

CMDENBL

FAULT

08

BATALM

BUSY

09
10

Cableside connector
YAMAICHI ELECTRICITY
Connector
Housing UFS20B04
Contact Contact 66 type
(UFS contact)

0V
+24E

0V

SDICOM1 is a common signal that can be used either as an SDI or special


signal.
+24 V common: Connected to 0 V
0 V common: Connected to +24 V
SDICOM Selects a common for SDI81 to SDI88.
CAUTION
The maximum output current of each SDO or special signal
is 70 mA.

188

CONNECTIONS

B81535EN/02

3. CONNECTION DETAILS

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

Control unit (peripheral device interface : CRM81)


+24E

Peripheral device

Connector pin No
CRM81 (A10)

receiver circuit
SDI81

RV

SDI82

RV

SDI83

RV

SDI84

RV

SDI85

RV

SDI86

RV

SDI87

RV

SDI88

RV

SDICOM

RV

CRM81 (A1)

3.3k

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

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

189

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

Control unit (peripheral device interface : CRM81)


+24E

Peripheral device

Connector pin No
CRM81 (A10)

receiver circuit
SDI81

RV

SDI82

RV

SDI83

RV

SDI84

RV

SDI85

RV

SDI86

RV

SDI87

RV

SDI88

RV

SDICOM

RV

CRM81 (A1)

3.3k

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

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

(Specified signal is not allocated.)

Control unit (peripheral device interface : CRM81)


Connector pin No
Driver circuit
SDO8
1

DV

SDO82

DV

SDO83
SDO84

Peripheral device
LOAD

CRM81 (A7)
RELAY

CRM81 (B7)
LOAD
CRM81 (A8)
DV

LOAD
CRM81 (B8)

DV

LOAD
CRM81 (B9,B10)

0V

0V
+24V
+24V regurated
power supply

Max. current per SDO is 70mA.

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

190

CONNECTIONS

B81535EN/02

3. CONNECTION DETAILS

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

Control unit (peripheral device interface : CRM81)


+24E

Peripheral device

Connector pin No
CRM81 (A10)

*HOLD
RESET

receiver circuit
RV
3.3k
RV

START

RV

ENBL

RV

PNS1

RV

PNS2

RV

PNS3

RV

PNS4

RV

SDICOM

RV

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

0V

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

191

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

Control unit (peripheral device interface : CRM81)


+24E

Peripheral device

Connector pin No
CRM81 (A10)

receiver circuit
*HOLD

RV

RESET

RV

START

RV

ENBL

RV

PNS1

RV

PNS2

RV

PNS3

RV

PNS4

RV

SDICOM

RV

CRM81 (A1)
3.3k

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

0V

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

(Specified signal is allocated quickly)

Control unit (peripheral device interface : CRM81)

Peripheral device

Connector pin No
LOAD

driver circuit
CMDENBL

DV

FAULT

DV

BATALM
BUSY

CRM81 (A7)
RELAY

CRM81 (B7)
LOAD
CRM81 (A8)

DV

LOAD
CRM81 (B8)

DV

LOAD
CRM81 (B9 ,B10)
0V

0V
+24V
+24V regurated
power supply

Max. current per SDO is 70mA.

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

192

B81535EN/02

3.9.3
Digital I/O Signal
Specifications

3. CONNECTION DETAILS

CONNECTIONS

This section describes the specifications of the digital I/O signals


interfaced with the peripheral device and end effector.

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

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

0V

0V

+24V
Lamp
70 mA
or less

0V

Protective resistance

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

:
:
:
:
:

D Spark killer diode


Rated peak reverse voltage
Rated effective forward current

: 100 V or more
: 1 A or more

0V

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

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

193

3. CONNECTION DETAILS

D Input signal regulation

CONNECTIONS

B81535EN/02

Example of connection
+24V

SDI n

RV

3.3 k
SDICOM

RV

Example of
+24V common connection

0V

D Electrical specifications of the receiver


Type
: Grounded voltage receiver
Rated input voltage
: Contact close :+20 V to +28 V
Contact open :0 V to +4 V
Maximum applied input voltage : +28 VDC
Input impedance
: 3.3 k (approx.)
Response time
: 5 ms to 20 ms
D 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
TB

(Signal)

TB

(Signal)

TB

Peripheral device
contact signal

Robot receiver signal


TC

TC

TB ;
TC ;

Chattering 5 ms or less
5 to 20 ms

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

194

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

3.9.4

The figure below shows the connector for peripheral device cable.

Peripheral Device
Cable Connector

Symbol

Name

Connector cover

Connector 50 pins (male)


Dimensions

Remark

Connector
specification

Applicable
interface

(B)

(D)

MR50LWM

CRM79

67.9

73.5

66.1

20

Honda Tsushin
Kogyo E 16
50
pins

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

195

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

A
B

3.56
2.54

2.54
6.0

14.3
14.5

Connector
specification

Dimensions

Applicable
interface

UFS20B04

Remark

29.98

22.86

CRM81

YAMAICHI ELECTRONICS
(Housing)
YAMAICHI ELECTRONICS
(Contact)

Contact 66 type

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

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

3.9.5
Recommended Cables

Connect a peripheral device using a completely shielded, heavily


protected cable conforming to the specifications in Table 3.9.5.
Allow an extra 1.5m for routing the cable in the control unit.
The maximum cable length is 30m.

Table 3.9.5 Recommended cable (For peripheral device connection)


Conductor

Electrical characteristics

Sheath
thickness
(mm)

Effective
outside
diameter
(mm)

Conductor
resistance
(/km)

Allowable
current (A)

7/0.18
AWG24

1.5

12.5

106

1.6

7/0.18
AWG24

1.5

10.5

106

1.6

Number of
wires

Wire specifications
(FANUC
specifications)

Diameter
(mm)

Configuration

50

A66L00010042

1.05

20

A66L00010041

1.05

196

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

Name

Drawing number
A16B32000450

Robot control board A

DI

DO

Remarks
Standard

NOTE
Either RDI6 or *PPABN is selected by software.

Mechanical unit
EE
1
2
3
4
5

RDI1
RDI2
RDI3
RDI4
RDI5

7
8
9
10
11

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

RDI6
(*PPABN)

12

RDICOM

End effecter

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

197

3. CONNECTION DETAILS

CONNECTIONS

End effecter

Mechanical unit (end effector interface)


+24E

Connector pin No.


EE (8,8,10)

Receiver circuit
RDI1

RV

RDI2

RV

RDI3

RV

RDI4

RV

RDI5

RV

RDI6
(*PPABN)

RV

RDICOM

RV

B81535EN/02

EE (1)

3.3k

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

EE (12)
EE (11)

0V

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

End effecter

Mechanical unit (end effector interface)


+24E

Connector pin No.


EE (8,8,10)

Receiver circuit
RDI1

RV

RDI2

RV

RDI3

RV

RDI4

RV

RDI5

RV

RDI6
(*PPABN)

RV

RDICOM

RV

EE (1)

3.3k

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

EE (12)
EE (11)

0V

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

198

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

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

Example of connection

+24V

RDI n

RV

3.3 k
RDICOM

RV

Example of
+24V common connection

0V

Electrical specifications of the receiver


Type
Rated input voltage

: Grounded voltage receiver


: Contact close
: +20 V to +28 V
Contact open
: 0 V to +4 V
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
Input signal width
Chattering time
Closed circuit resistance
Opened circuit resistance
TB

(Signal)

TB

(Signal)

:
:
:
:
:

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

Peripheral device
contact signal

Robot receiver signal


TC

TC

TB ;
TC ;

Chattering 5 ms or less
5 to 20 ms

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

3. CONNECTION DETAILS

3.11
TREATMENT FOR
THE SHIELDED
CABLE

CONNECTIONS

B81535EN/02

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

Fig.2.12 Shielded cable treatment

200

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

3.12

Connection to the peripheral device and the arc welding is available to use
the process I/O board for RJ3iB Mate.

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

Name

Process I/O board HE

Process I/O board HF

Drawing number

Number of I/O points


DI

DO

D/A

A/D

A05B2440J002

40

40

A05B2440J003

40

40

Remarks

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

201

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

3.12.2
Peripheral Device
Interface Block
Diagram and
Specifications

Process I/O
board
HE/HF

Peripheral
device

Main
board
CRM2A
JD4A
(JD1B)

JD1A
(JD4)

CRM2B
JD4B
(JD1A)
CRW7
(NOTE 1)

CRW2
(NOTE1)

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

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

202

CONNECTIONS

B81535EN/02

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

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

3. CONNECTION DETAILS

The connection is for the allocated specified signal.


For detail of the allocation, refer to the OPERATORS MANUAL.

Peripheral device control interface A1


CMDENBL
CRM2A
33

*IMSTP

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

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

ACK3/SNO3
ACK4/SNO4
ACK5/SNO5
ACK6/SNO6
COMA4
ACK7/SNO7
ACK8/SNO8
SNACK
RESERVED
COMA5
PNSTROBE
PROD START
SDI01
SDI02

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

SYSRDY
PROGRUN
PAUSED
COMA1
HELD
FAULT
ATPERCH
TPENBL
COMA2
BATALM
BUSY
ACK1/SNO1
ACK2/SNO2
COMA3

Peripheral
device A1

+24E
+24E

Peripheral device control interface A2


SDO01
CRM2B
33

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

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

SDO13
SDO14
SDO15
SDO16
COMB4
SDO17
SDO18
SDO19
SDO20
COMB5
SDI19
SDI20
SDI21
SDI22

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

SDO02
SDO03
SDO04
COMB1
SDO05
SDO06
SDO07
SDO08
COMB2
SDO09
SDO10
SDO11
SDO12
COMB3

Peripheral
device A2

+24E
+24E

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

203

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

Peripheral device

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

RV

*HOLD

RV

*SFSPD

RV

CSTOPI

RV

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

0V
FAULT RESET

RV

START

RV

HOME

RV

ENBL

RV

RSR1/PNS1

RV

RSR2/PNS2

RV

RSR3/PNS3

RV

RSR4/PNS4

RV

RSR5/PNS5

RV

RSR6/PNS6

RV

RSR7/PNS7

RV

RSR8/PNS8

RV

PNSTROBE

RV

PROD START

RV

SDI01

RV

SDI02

RV

COM1

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

RV
+24E

CRM2A (17,18)
B

A
0V

Common setting
pin (ICOM1)

0V

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

204

CONNECTIONS

B81535EN/02

3. CONNECTION DETAILS

Peripheral device

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

DV

LOAD
RELAY

CMDENBL
0V

SYSRDY

DV

PROGRUN

DV

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

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

DV

CRM2A (38)

DV

CRM2A (39)

DV

CRM2A (40)

DV

CRM2A (41)

DV

CRM2A (43)

DV

CRM2A (44)

DV

CRM2A (45)

DV

CRM2A (46)

DV

CRM2A (19)

DV

CRM2A (20)

DV

CRM2A (21)

DV

CRM2A (22)

DV

CRM2A (24)

DV

CRM2A (25)

DV

SNACK

DV

RESERVED

DV

CRM2A (26)
CRM2A (27)

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

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

0V
Max. current per UDO is 70mA

205

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

Peripheral device

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

Connector pin No.


CRM2B (49,50)

Receiver circuit
SDI03

RV

SDI04

RV

SDI05

RV

SDI06

RV

SDI07

RV

SDI08

RV

SDI09

RV

SDI10

RV

SDI11

RV

SDI12

RV

SDI13

RV

SDI14

RV

SDI15

RV

SDI16

RV

SDI17

RV

SDI18

RV

SDI19

RV

SDI20

RV

SDI21

RV

SDI22

RV

COM2

RV

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

+24E

A
0V

Common setting
pin (ICOM2)

0V

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

206

CONNECTIONS

B81535EN/02

3. CONNECTION DETAILS

Peripheral device

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

DV

LOAD
RELAY

SDO01
0V
CRM2B (34)

SDO02

DV

SDO03

DV

SDO04

DV

SDO05

DV

SDO06

DV

SDO07

DV

SDO08

DV

SDO09

DV

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

SDO10

DV
CRM2B (45)

SDO11

DV
CRM2B (46)

SDO12

DV
CRM2B (19)

SDO13

DV
CRM2B (20)

SDO14

DV
CRM2B (21)

SDO15

DV
CRM2B (22)

SDO16

DV
CRM2B (24)

SDO17

DV
CRM2B (25)

SDO18
SDO19
SDO20

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

Max. current per DO is 70mA

207

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

0V
+24V
+24V regurated
power supply

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

3.12.4
Connection Between
the Control Unit and
Welder
Control unit
Analog input interface
CRW2

Peripheral device

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

208

CONNECTIONS

B81535EN/02

3. CONNECTION DETAILS

Analog connection of CRW2 connector (Analog input)


Control unit
(Analog input interface)
Process I/O HE

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

CRW2 (12)
ADCH2
CRW2 (13)
COMAD2

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

CRW2 (18)
ADCH5
CRW2 (19)
COMAD5

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

209

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

Control unit
Welder interface
CRW7

Welder

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

210

CONNECTIONS

B81535EN/02

3. CONNECTION DETAILS

Attaching the CRW7 connector to the welding machine: FANUC interface


(Analog output, welding wire deposition detected, and WDI/WDO connection: Connected to the +24 V common
line)

Control unit (welding interface)


Process I/O HE

Welding voltage
command signal

Wire speed command


signal

CRW7 (1)

Welding machine
MS connector
pin No.
A

CRW7 (2)

CRW7 (3)

CRW7 (4)

Connector pin No.

DACH1
COMDA1
DACH2
COMDA2

Connector pin No.

Receiver circuit
Arc detected signal

WDI02

RV

Gas outage detected


signal

WDI03

RV

Brokenwire detected
signal
Arc turnoff detected
signal (power supply
failure)

WDI04

RV

WDI06

RV

COM3

RV
+24E

3.3k

CRW7 (6)

CRW7 (7)

CRW7 (8)

CRW7 (10)

+24E
B

CRW7 (33,34)

Common setting pin


0V
(ICOM3)

WDO01

CRW7 (23)

WCOM1

CRW7 (24)

WDO04

CRW7 (29)

WCOM4

CRW7 (30)

WDO05

CRW7 (13)

WCOM5

CRW7 (14)

Welding start signal

Wire inching (+)

Wire inching ()

R=100 or more

Wire deposition
detected signal

WDI+

CRW1 (31)

WDI

CRW1 (32)

+
Cabinet ground
(shield clamp)

211

Welding power supply


Welding machine frame ground

3. CONNECTION DETAILS

CONNECTIONS

NOTE
This is the connection for +24V.

212

B81535EN/02

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

Attaching the CRW7 connector to the welding machine: FANUC interface


(Analog output, welding wire deposition detected, and WDI/WDO connection: Connected to the +24 V common
line)
Control unit (welding interface)
Process I/O HE

Connector pin No.


CRW7 (1)

DACH1

Welding voltage
command signal

CRW7 (2)
COMDA1
CRW7 (3)
DACH2

Wire speed command


signal

CRW7 (4)
COMDA2
Receiver circuit
WDI01

RV

Arc detected signal

WDI02

RV

Gas outage detected


signal
Brokenwire detected
signal
Cooling water outage
signal
Arc turnoff detected
signal (power supply
failure)

WDI03

RV

WDI04

RV

WDI05

RV

WDI06

RV

WDI07

RV

WDI08

RV

COM3

RV

+24E

Connector pin No.


3.3k
CRW7 (5)

Welding machine
MS connector
pin No.
A
B
E
F

CRW7 (6)

CRW7 (7)

CRW7 (8)

CRW7 (9)

CRW7 (10)

CRW7 (11)

CRW7 (12)

CRW7 (33,34)

+24E

CRW7 (19,20)
Common setting pin
0V
(ICOM3)

CRW7 (21,22)

m
n

0V
WDO01
Welding start signal
WCOM1
WDO02
Gas signal
WCOM2
WDO04
Wire inching (+)
WCOM4
WDO05

CRW7 (23)

CRW7 (24)
CRW7 (23)
CRW7 (24)
CRW7 (29)

S
a
U

CRW7 (30)
CRW7 (13)

Wire inching ()
WCOM5

Wire deposition
detected signal

WDI+
WDI

CRW7 (14)

b R=100 or more

CRW1 (31)

CRW1 (32)

Cabinet ground
(shield clamp)

213

s
+

Welding power supply


Welding machine frame ground

3. CONNECTION DETAILS

3.12.5
Digital I/O Signal
Specifications of
Peripheral Device
Interface A

CONNECTIONS

B81535EN/02

(1) Output signals in peripheral device interface A


Example of connection
Spark killer diode
+24V

70 mA
or less

0V
+24V
Lamp
70 mA
or less

0V
Protective resistance

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

:
:
:
:
:

Spark killer diode


Rated peak reverse voltage
Rated effective forward current

: 100 V or more
: 1 A or more

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

NOTE
Do not use the +24 V power supply of the robot.
When you load a relay, solenoid, and so on directly, connect
them in parallel with diodes to prevent back electromotive
force.
If a load is connected causing a surge current when a lamp
is turned on, use a protective resistance.
Applicable signals
Output signals of process I/O board CRM2
CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT,
ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNACK,
SDO1 to SDO76

214

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

(2) Input signals in peripheral device interface A


Example of connection
+24V

RV
3.3 kW
+24V
B

ICOM

Electrical specifications of the receiver


Type
: Grounded voltage receiver
Rated input voltage
: Contact close
: +20 V to +28 V
Contact open
: 0 V to +4 V
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
TB

(Signal)

TB

(Signal)

TB

Peripheral device
contact signal

Robot receiver signal


TC

TC

TB ;
TC ;

Chattering 5 ms or less
5 to 20 ms

NOTE
Apply the +24 V power at the robot to the receiver.
However, the above signal specifications must be satisfied
at the robot receiver.
Applicable signals
Input signals of process I/O board CRM2
*IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET, START,
HOME, ENBL, RSR1 to RSR8, PNS1 to PNS8, PNSTROBE,
PROD START, SDI1 to SDI78
215

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

3.12.6
I/O Signal
Specifications for
ARCWelding Interface

(1) Digital output signal specifications for an arc welding interface


In case of process I/O HE
Example connection
Spark killer diode

0.3 A or
less

Electrical characteristics
Rated voltage
Maximum applied voltage
Maximum load current
Output type

:
:
:
:

24 VDC
30 VDC
0.3 A
Relay connection output

Spark killer diode


Rated peak reverse voltage
: 100 V or more
Rated effective forward current : 1 A or more
NOTE
A power voltage of +24 V, provided for the robot, can be
used for interface signals of up to 0.7 A. This limit applies
to the sum of the currents flowing through the arcwelding
and endeffector control interfaces. To drive a relay or
solenoid directly, connect a diode preventing back
electromotive force to the load in parallel. To connect a load
which generates an inrush current when you turn on the
control unit, connect a protective resistor.
Applicable signals
Output signals on the arcwelding interface
WDO1 to WDO4

216

B81535EN/02

3. CONNECTION DETAILS

CONNECTIONS

(2) Digital input signal specifications for arc welding interface


Example connection

Electrical characteristics of receivers


Type: Grounded voltage receiver
Rated input voltage
: +20 to +28 V with contacts closed
0 to +4 V when open
Maximum input voltage : +28 VDC
Input impedance
: About 3.3 k
Response time
: 5 to 20 ms
Contact specifications for peripherals
Rated contact capacity
: 30 VDC, 50 mA or more
Input signal width
: 200 ms or more for on and off states
Chattering period
: 5 ms or less
Closedcircuit resistance : 100 or less
Opencircuit resistance : 100 k or more

(Signal)

(Signal)

Contact signal
for peripheral

Receiver
signal for robot

TB: Chattering of 5 ms or less


TC: 5 to 20 ms

NOTE
Supply the +24 V power, provided for the robot, to the
receivers. The receiver signal on the robot must satisfy the
signal timing specified above.
Applicable signals
Input signals for arc welding interface
WDI1 to WDI8
217

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

(3) Analog output signal specifications for arc welding interface


(Welding voltage command, wirefeed rate command)
Example connection

Welder

Process I/O CA, EA : 10V to +10V


Process I/O GA, HA : 0V to +15V
0V

NOTE
Input impedance: 3.3 k or more
Connect a highpass filter.
(4) Analog input signal specifications for arc welding interface
(Weldingvoltage detection, weldingcurrent detection)
Example connection
Welder
10V to +10V
0V

NOTE
The analog input signal should have no ripple for the circuit
to operate properly.
(Wire deposit detection: WDI+ and WDI)
Example connection
Welder

Welding electrode

NOTE
Connect a resistor of 100 or more between the positive
and negative electrodes of the welder. Isolate the deposit
detection signals for TIG welding from the welding circuit,
which uses highfrequency components. The dielectric
withstand voltage of this circuit is 80 V.

218

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

3.12.7

If the customer manufactures cables, make sure they conform to the


FANUC standard cables described in this section. (See the description in
Peripheral Device Interface in this manual for the specifications of the
FANUC standard cables.)

Specifications of the
Cables used for
Peripheral Devices A
(CRM2: Honda
Tsushin, 50 pins)

Honda Tsushin
MR50LWF01
(MR50LF)

Honda Tsushin
MR50LM01
(MR50LM)
Peripheral
device

Process I/O

Honda Tsushin
MR50RMA

3.12.8

Honda Tsushins MR50RF


Supplied with an ordered cable

Be sure to use the FANUC cable to connect the welder.

ARC Weld Connection


Cable (CRW1: Honda
Tsushin, 34 pins)

ARC welder
Honda Tsushin
Process I/O
CRW1
or
CRW7
Honda Tsushin
MR34RFA

Japan Aviation Electronics


Industry Ltd.
MS3108B2821P
MS305716

219

Japan Aviation Electronics


Industry Ltd.
MS3102A2821S
Standard position of guide key

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

3.12.9
Peripheral Device
Cable Connector

(1) Fig. 3.12.9 shows the connector for peripheral device cables A and
B. (The connector is used for a peripheral device)

Connector
specifications

Applicable
interface

MR50LM

CRM2

Dimensions
A

(B)

67.9

73.5

44.8

Symbol

Remark

(D)
18

Honda Tsushin Kogyo,


50 pins

Name

Connector cover

Cable clamp screw

Connector clamp spring

Connector clamp screw

Connector

50 pins (male) MR50M

Fig.3.12.9 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo)

220

3. CONNECTION DETAILS

CONNECTIONS

B81535EN/02

(2) Peripheral device connector

Connector
specifications

Applicable
interface

MR50RF

(CRM2)

Dimensions

Remark

61.4

56.4

Symbol

Honda Tsushin Kogyo,


50 pins

Name

Connector clamp screw

Screw M2.6 8

Connector

(MR50RF)

Fig.3.12.9 (b) Peripheral Device Connector (Honda Tsushin Kogyo)

3.12.10
Recommended Cables

(1) Peripheral device connection cable


Connect a peripheral device using a completely shielded, heavily
protected cable conforming to the specifications in Table 3.12.10 (a).
Allow an extra 50 cm for routing the cable in the control unit.
The maximum cable length is 30 m.

Table 3.12.10 Recommended Cable (for Peripheral Device Connection)


Conductor
Number
of wires
50

Wire specifications
(FANUC specifications)
A66L-0001-0042

Diameter
(mm)
1.05

Configuration
7/0.18
AWG24

221

Sheath
thickness
(mm)
1.5

Effective
outside
diameter
(mm)
12.5

Electrical characteristics
Conductor
resistance
(/km)
106

Allowable
current
(A)
1.6

4. TRANSPORTATION AND
INSTALLATION

CONNECTION

TRANSPORTATION AND INSTALLATION

222

B81535EN/02

4. TRANSPORTATION AND
INSTALLATION

CONNECTION

B81535EN/02

4.1
TRANSPORTATION

The control unit should be transported by a crane. Attach a sling to eye


bolts at the top of the control unit.

Fig.4.1 Transportation

4.2
INSTALLATION

Contrpl unit

Installation area
When the control unit is installed, allow the space for maintenance shown
in the following figure.

Contrpl unit

Contrpl unit

When the plural


controller is
installed.

Fig.4.2 Installation

223

4. TRANSPORTATION AND
INSTALLATION

CONNECTION

4.3
EXTERNAL
CONTROLLER
DIMENSIONS

Four M10 weld nuts


The unit is shipped with the M10 bolts
screwed to the weld nuts as 10mm feet.
After the M10 bolts are removed, these
weld nuts can be used to secure the
control unit.

Fig.4.3 External drawing of robot controller

224

B81535EN/02

CONNECTION

B81535EN/02

4. TRANSPORTATION AND
INSTALLATION

4.4
INSTALLATION
CONDITION

Item
Input power supply

Input power supply capacity


Average power consumption
Permissible ambient temperature
Permissible ambient humidity
Surrounding gas

Vibration

Altitude
Ionized and nonionized radiations

Weight of control unit

4.5
ADJUSTMENT AND
CHECKS AT
INSTALLATION

Specifications/condition
50Hz; 200VAC, +10%, 15%
60Hz; 200VAC to 220 VAC, +10%, 15%
50/60 Hz"1Hz, 3phase
1 kVA (LR Mate 100iB)
1.2 kVA (LR Mate 200iB/ARC Mate 50iB)
0.4 kW (LR Mate 100iB)
0.5 kW (LR Mate 200iB/ARC Mate 50iB)
0 to 45_C during operation, and 20 to 60 C
during shipment and storage with a temperature coefficient of 1.1_C/min.
Relative humidity: 30% to 95%, noncondensing.
An additional protective provision is necessary if the machine is installed in an environment in which there are relatively large
amounts of contaminants (dust, dielectric
fluid, organic solvent, acid, corrosive gas,
and/or salt).
0.5 G or less. When using the robot in a location subject to serious vibration, consult with
your FANUC sales representative.
Not higher than 1,000 m above sea level
A shielding provision is necessary if the
machine is installed in an environment in
which it is exposed to radiations (microwave,
ultraviolet rays, laser beams, and/or Xrays).
Approx. 35kg

Adjust and check according to following procedure at installation.


No.

Description

1
2
3

Visually check the inside and outside of the control unit.


Check if the screwed terminal is connected properly.
Check that the connectors and printed circuit boards are inserted correctly.
Connect control unit and mechanical unit cables.

4
5
6
7

11

Turn the breaker off and connect the input power cable.
Check the input power voltagage.
Press the EMERGENCY STOP button on the operators panel and
turn the power on. Check the output voltage.
Check the interface signals between control unit and robot mechanical
unit.
Check the parameters. If necessary, set them.
Release the EMERGENCY STOP button on the operators panel.
Turn the power on.
Check the movement along each axis in the manual jog mode.

12
13

Check the end effector interface signals.


Check the peripheral device control interface signals.

8
9
10

225

4. TRANSPORTATION AND
INSTALLATION

CONNECTION

4.6

B81535EN/02

An overtravel and emergency stop occur when the robot is operated for
the first time after it is installed and the mechanical and control units are
wired. This section describes how to reset the overtrvel and emergency
stop.
Remove the red plate fastening the swiveling axis beforehand.
The J2 and J3 axes are pressed against the hard stops at shipment.
Therefore, an overtravel alarm occurs when the power is turned on after
installation.

NOTE AT
INSTALLATION

4.7
DISABLING HAND
BREAK

(1) Press the [MENUS] key on the teach pendant.


(2) Select [Next].
(3) Select [SETUP].
(4) Press F1 [TYPE].
(5) Select [Config] to disable or enable Hand Break.

Hand break
State

Hand break

HBK (*1)

HBK detection

Robot operation

Message

1
2

Enabled
Enabled

CLOSE
OPEN

Detected
Detected

Possible
Impossible

Not provided
SERVO 6

3
4

Disabled
Disabled

CLOSE
OPEN

Detected (*2)
Not detected

Possible
Possible

Not provided
SERVO 300 at cold start

NOTE
1 Robot end effector connector
CLOSE

OPEN

24V

24V

*HBK

*HBK

2 When the HBK circuit is closed, the HBK detection is


enabled.
If the HBK state changes from close to open, the SERVO
300 or SERVO 302 alarm occurs, stopping the robot.
3 If the power is turned off and on in the state described
above, the system enters state 4, releasing the alarm.

226

APPENDIX

B81535EN/02

APPENDIX

TOTAL CONNECTION DIAGRAM

229

A. TOTAL CONNECTION DIAGRAM

A. TOTAL CONNECTION DIAGRAM

APPENDIX

Fig.A (a) Total connection diagram

230

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B81535EN/02

APPENDIX

231

A. TOTAL CONNECTION DIAGRAM

A. TOTAL CONNECTION DIAGRAM

APPENDIX

Fig.A (b) Emergency stop circuit diagram

232

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B81535EN/02

APPENDIX

233

A. TOTAL CONNECTION DIAGRAM

A. TOTAL CONNECTION DIAGRAM

APPENDIX

Fig.A (c) Emergency stop circuit diagram

234

B81535EN/02

B81535EN/02

APPENDIX

235

A. TOTAL CONNECTION DIAGRAM

A. TOTAL CONNECTION DIAGRAM

APPENDIX

Fig.A (d) Robot control board, Emergency stop board connector interface

236

B81535EN/02

B81535EN/02

APPENDIX

A. TOTAL CONNECTION DIAGRAM

Fig.A (e) Servo amplifier robot mechanical unit connector interface

237

B. PERIPHERAL INTERFACE

APPENDIX

B81535EN/02

PERIPHERAL INTERFACE

Peripheral I/O (UI/UO) are a group of specialized signals whose usage is


decided by the system. These signals are connected with a remote
controller and the peripheral devices via the following interfaces and I/O
links and they are used to control the robot from the outside.
D The JD1A interface (The process I/O board, the I/O Unit MODEL A
and the MODEL B are connected as the slave of I/O link to RJ3iB
Mate.) (on master mode)
D The JD1B interface (CNC and PLC are connected as a master of I/O
link to RJ3iB Mate.) (on slave mode)
D CRM9 interface
Refer to the operators MANUAL for detail informations.

238

APPENDIX

B81535EN/02

B.1
SIGNAL TYPES

B. PERIPHERAL INTERFACE

The tables below list the special signals of the RJ3iB Mate robot
controller.
Input signals (See Subsection B.2.1.)
Signal
*HOLD
RESET
START
ENBL
PNS1
PNS2
PNS3
PNS4

Description
Temporary stop
Alarm release
Cycle start
Enable
Program select (*1)
Program select (*1)
Program select (*1)
Program select (*1)

NOTE
PNS (program select input) (optional)

Output signals (See Subsection B.2.1.)


Signal

Description

CMDENBL
FAULT
BATALM
BUSY

Input acceptable
Alarm
Battery alarm
Busy

239

B. PERIPHERAL INTERFACE

APPENDIX

B81535EN/02

B.2
I/O SIGNALS
B.2.1

Fellowing is each input signal.

Input Signals
Hold input signals,
*HOLD, UI [ 1 ]

The remote controller uses the hold signal to halt the robot. Because
*HOLD input signal is a inverted signal, normally set the signal on. When
the signal goes off, the following is executed:
D The robot is decelerated until its stops, then the program execution is
halted.
D If ENABLED is specified at Break on hold on the general item
setting screen, the robot is stopped, an alarm is generated, and the
servo power is turned off. (Standard setting: DISABLED)

Fault reset input signal,


RESET, UI [ 2 ]

The RESET signal cancels an alarm. If the servo power is off, the RESET
signal turns on the servo power. The alarm output is not canceled until the
servo power is turned on. The alarm is canceled at the instant this signal
falls in default setting.
D If TRUE is specified at CSTOPI for ABORT on the system
configuration screen, the RESET signal resets an alarm and aborts the
currently selected program. (Standard setting: FALSE)
D To have alarms reset the instant the RESET signal rises, it is necessary
to specify RISE at Detect FAULT RESET signal on the system
configuration screen. (Standard setting: FALL)

Start input signal,


START, UI [ 3 ] (validated
in the remote state)

The START signal has two functions. It can select or collate a program
and start the program.
D When the START signal goes high, PNS1 to PNS4 are read and the
corresponding program is selected or collated. Whether is program is
selected or collated is specified by the setting of system variable
$SHELL_CFG.$NUM_RSR [1]. (See the description of signals
PNS1 to PNS4.)
D When the START signal goes low, the current program is started from
the line at which the cursor is placed (current line).
D If TRUE is specified at START for CONTINUE only on the system
configuration screen, only a program on hold can be started. (Standard
setting: FALSE)

Enable input signal,


ENBL, UI [ 4 ]

The ENBL signal allows the robot to be moved and places the robot in the
ready state. When the ENBL signal is off, the system inhibits a jog feed
of the robot and activation of a program including a motion (group). A
program which is being executed is halted when the ENBL signal is set
off.
NOTE
When the ENBL signal is not monitored, strap the signal
with the ground.

240

B81535EN/02

APPENDIX

B. PERIPHERAL INTERFACE

Program number
selection signals, PNS1
to PNS4, UI [ 5 to 8 ]
(validated in the remote
state)

A program number selection signal has two functions.


When the START signal goes on, PNS1 to PNS4 are read and the
corresponding program is selected or collated. Whether the program is
selected or collated is specified by the setting of system variable
$SHELL_CFG.$NUM_RSR [1].

B.2.2

Fellowing are peripheral device interface output signals.

D In the program end state, a program is selected or collated according


to the state (0 or 1) of the PNS signals. The current line of the selected
or collated program is set to 1.
- Type 1 (when $SHELL_CFG.$NUM_RSR [1] is set to 0)
The program specified by the PNS signals is selected.
- Type 2 (when $SHELL_CFG.$NUM_RSR [1] is set to 1)
The program specified by the PNS signals is collated with the
current program. If the programs do not agree with each other, an
error occurs.
D If all PNS signals are low in the program end state, the current program
is executed from the current line. If no programs are selected, an error
occurs.
D A halted program can be resumed only when all PNS signals are set
off. Otherwise, an error occurs.
D While a program is being executed, the PNS signals are ignored.

Output Signals
Command enable output
signal, CMDENBL,
UO [ 1 ]

The CMDENBL signal is output when the following conditions are


satisfied. The CMDENBL signal indicates that the remote controller can
start a program including a motion (group).
D The remote conditions are satisfied.
D The ready conditions are satisfied.
D The continuous operation mode is selected (the single step mode is
disabled).

Fault output signal,


FAULT, UO [ 2 ]

The FAULT signal is output when an alarm occurs in the system. The
RESET signal cancels the alarm. If a warning (WARN alarm) occurs, the
FAULT signal is not output.

Battery alarm output


signal, BATALM, UO [ 3 ]

The BATALM signal indicates that the voltage of the battery for
supporting the memory has dropped. Replace the battery while keeping
the power of the controller on.
To have the BATALM signal generated also when the BZAL/BLAL alarm
occurs, it is necessary to set the $BLAL_OUT.$BATALM_OR system
variable. It is also possible to have the specified SDO output when the
BZAL/BLAL alarm occurs.

Busy output signal,


BUSY, UO [ 4 ]

The BUSY signal is output while a program is being executed. The BUSY
signal is not output while a program is being halted.
241

B. PERIPHERAL INTERFACE

APPENDIX

B81535EN/02

B.3
SPECIFICATIONS OF
DIGITAL
INPUT/OUTPUT
B.3.1
Overview

B.3.2
Input/Output Hardware
Usable in the R-J3iB
Mate Controller

This section describes the external specifications of digital and analog


input/output in the RJ3iB Mate controller.

The RJ3iB Mate controller can use up to 512 digital input and output
points or an equivalent number of analog input and output points. One
analog input/output point uses the resources equivalent to those used by
16 digital I/O points. The RJ3iB Mate can use a total of up to 512 I/O
points.
The RJ3iB Mate controller can use the following I/O hardware.
- Process I/O printed circuit board
- I/O unit model A
The process I/O printed circuit board and the I/O unit model A can be used
together.

242

B81535EN/02

APPENDIX

B. PERIPHERAL INTERFACE

B.3.3
Software
Specifications

(1) RDI/RDO
These are signals sent to the connector at the wrist of the robot.
They cannot be assigned (redefined) and are fixed.
The standard format is six inputs and six outputs. The number of
points that can be used for the connector at the wrist depends on the
individual robot.
(2) SDI/SDO
The signal No. that is determined at hardware can be changed by
software operation.
(3) Analog I/O
An analog I/O signal can access the analog I/O port (optional) on the
process I/O printed circuit board or the I/O port on the analog I/O
module (used together with the I/O unit model A).
It reads and writes the digital value converted from the analog value
of the I/O voltage. It means that the value does not always represent
the real I/O voltage.
(4) Group I/O
Group I/O is a function which can input or output multiple DI/DO
signals as binary codes.
Any number of continuous signals of up to 16 bits can be set for its
use.
It can be set in the menu DETAILS on the group I/O screen.

243

C. OPTICAL FIBER CABLE

APPENDIX

B81535EN/02

OPTICAL FIBER CABLE

The RJ3iB Mate uses fiber optic cables for communication between the
robot control board and servo amplifier module and between the servo
amplifier module and servo amplifier module. Observe the following
cautions when handling these fiber optic cables.
(1) Protection during storage
When the electrical/optical conversion module (mounted on the
printed) circuit board and the fiber optic cable are not in use, their
mating surfaces must be protected with the lid and caps with which
they are supplied. If left uncovered, the mating surfaces are likely to
become dirty, possibly resulting in a poor cable connection.
Electrical/optical conversion module

Fiber optic cable

Lid

Fiber optic
cable caps

Fig.C (a) Protection of electrical/optical conversion module and fiber


optic cable (when not in use)

244

C. OPTICAL FIBER CABLE

APPENDIX

B81535EN/02

(2) Fiber optic cable


D Grasp the optical connector firmly when connecting or
disconnecting the cable. Do not pull on the fiber optic cord itself.
(The maximum tensile strength between the fiber cord and
connector is 2 kg. Applying greater force to the cord is likely to
cause the connector to come off, making the cable unusable.)
Fiber optic cord diameter : 2.2 mm
2 cords
Tensile strength : Fiber optic cord
:7 kg per cord
Between fiber optic cord and connector : 2 kg
Minimum bending radius of fiber optic cord
:25 mm
Flame resistance
: Equivalent to UL VW1
Operating temperature
: 20 to 70C
8.2
6.7

19 max.

60 max.

35typ.

21
Bush

Code

Reinforced cover

Fig.C (b) External dimensions of external optical cable Unit : mm

D Afler it is connected, the optical connector is automatically locked


by the lock levers on its top. To remove the connector, release the
lock levers and pull the connector.
D Although optical connectors cannot be connected in other than the
correct orientation, always take note of the connectors orientation
before making the connection.
D Take care to keep both parts of the optical connector (cable side and
PCB side) clean. If they become dirty, wipe them with tissue paper
or absorbent cotton to remove dirt. The tissue paper or absorbent
cotton may be moistened with ethyl alcohol. Do not use any
organic solvent other than ethyl alcohol.
D Do not clamp the uncovered portion of the cable with a nylon band.

245

Index

B81535EN/02

[A]

[E]
Emergency Stop Board (A20B10080010, 0011),
116

Adjustment and Checks at Installation, 225


Alarm Occurrence Screen, 29

Emergency Stop Circuit, 167

ARC Weld Connection Cable (CRW1: Honda Tsushin,


34 pins), 219

End Effector Interface, 197


External Controller Dimensions, 224
External Emergency Stop Input, 168
External Emergency Stop Output, 169

[B]

External View of the Controller, 21

Backplane Board (A20B20030330), 117


Battery for Memory Backup (3 VDC), 154

[F]

Block Diagram, 160


FANUC I/O Link, 163

Block Diagrams of the Power Supply, 126

[I]

[C]
Checking the Power Supply Module, 127

I/O Signal Specifications for ArcWelding Interface,


216

Checking the Power Supply Unit, 127

I/O Signals, 240

Circuit Diagram of Emergency Stop, 167

Initial Screen Remains on the Teach Pendant, 28

Component Functions, 23

Input Signals, 240

Configuration, 20

Input/Output Hardware Usable in the RJ3iB Mate


Controller, 242

Connecting a Cable to a Peripheral Device, 175

Installation, 223

Connecting the Mechanical Unit and End Effector,


197

Installation Condition, 225

Connection Between the Control Unit and Welder,


208

[L]

Connection Details, 161

LED of Power Supply Module, 123

Connection of Cable for RS232C/RS422, 174

LED of Servo Amplifier, 123

Connection of I/O Link Cable, 165

LED of Servo Amplifier Module, 124

Connection of Power Supply Cable, 162


Connection of Robot, 172

[M]

Connection of Teach Pendant Cable, 173

Manual Operation Impossible, 109

Coonection of Servo Amplifier, 171

Mastering, 33

[D]

[N]

Digital I/O Signal Specifications, 193

Note at Installation, 226

Digital I/O Signal Specifications of End Effector Control Interface, 199

[O]

Digital I/O Signal Specifications of Peripheral Device


Interface A, 214
Operator Safety, 4, 6

Disabling Hand Break, 226

Optical Fiber Cable, 244


i1

Index

B81535EN/02

Outline Drawings, 121

Replacing the Emergency Stop Board, 132

Output Signals, 241

Replacing the Emergency Stop Unit, 138


Replacing the Fan Motor of the Servo Amplifier Control Unit, 143

[P]

Replacing the Fuse on the Door, 149


Replacing the Fuse on the Power Supply Module, 150

Peripheral Device and Control Unit Connection, 203

Replacing the Fuse on the Process I/O Boards, 152

Peripheral Device Cable Connector, 195, 220

Replacing the Fuse on the Servo Amplifier Module,


151

Peripheral Device Interface Block Diagram and Specifications, 202

Replacing the Magnetic Contactor, 139

Peripheral device interface CRM 79 and CRM 81, 193

Replacing the Operator Panel, 145

Peripheral Device Interface Types, 201

Replacing the Power Supply Unit, 146

Peripheral Device Interfaces CRM79 and CRM81,


175

Replacing the PrintedCircuit Boards, 129


Replacing the Robot Control Board and PrintedCircuit Boards on the Backplane Unit, 131

Peripheral Device, ARC Welding, Interfaces, 201


Peripheral interface, 238

Replacing the Teach Pendant, 141

Position Deviation Found in Return to the Reference


Position (Positioning), 107

Replacing the Transformer, 137


Robot Control Board (A16B32000450), 112

Power Cannot be Turned On, 26


Power Supply Module PSM (A06B6115H001), 121
Precautions for Mechanism, 10

[S]

Precautions for Mechanisms, 11


Precautions in Operation, 11

Safety During Maintenance, 9

Precautions in Programming, 10, 11, 12

Safety in Maintenance, 13

Preventive Maintenance, 24

Safety of the End Effector, 12

Printed Circuit Boards, 111

Safety of the Robot Mechanism, 11

Process I/O Board HE (A16B22030764), HF


(A16B22030765), 118

Safety of the Teach Pendant Operator, 7


Safety of the Tools and Peripheral Devices, 10
Safety Precautions, 3
Safety Signals, 32

[R]
Recommended Cables, 196, 221

Servo Amplifier Module (A06B6114H205,


A06B6114H302), 122

Replacing a Fuse, 147

Servo Amplifiers, 120

Replacing a Fuse on the Emergency Stop Board, 148

Setting the Power Supply, 125

Replacing a Fuse on the Robot Control Board, 147

Signal Types, 239

Replacing a Relay, 153

Software Specifications, 243

Replacing a Relay on the Emergency Stop Board, 153

Specifications of Digital Input/Output, 242

Replacing a Unit, 128

Specifications of the Cables used for Peripheral Devices A (CRM2: Honda Tsushin, 50 pins), 219

Replacing Battery, 154


Replacing Cards and Modules on the Robot Control
Board, 133

[T]

Replacing Servo Amplifiers, 140

Teach Pendant Cannot be Turned On, 27

Replacing the Backplane Board (Unit), 130

Total Connection Diagram, 229

Replacing the Brake Power Transformer, 137

Transportation, 223

Replacing the Control Section Fan Motor, 142

Transportation and Installation, 222

Replacing the Door Fan Unit and Heat Exchanger,


144

Treatment for the Shielded Cable, 200


i2

Index

B81535EN/02

Troubleshooting, 25
Troubleshooting Based on LED Indications, 97
Troubleshooting Using Fuses, 92

[W]

Troubleshooting Using the Error Code, 35


Warning Label, 14

[V]

When the Robot is Connected to the CNC by a Peripheral Device Cable, 176

Vibration Observed During Movement, 108

i3

Revision Record
FANUC Robot series RJ3iB Mate CONTROLLER for (RIA R15.06--1999 COMPLIANT) MAINTENANCE MANUAL (B81535EN)

02

Oct., 2002

01

Oct., 2001

Edition

Date

Addition of ARC Mate 50iB

Contents

Edition

Date

Contents