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SYSTEM R-J Controller Series Electrical Connection and Maintenance Manual MARMMTRBL02303E This publication contains proprietary information of FANUC Robotics North America, Inc. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics North America, Inc. FANUC Robotics North America, Inc. 2000 South Adams Road Auburn Hills, Michigan 48326–2800

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

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

FANUC Robotics conducts courses on its systems and products on a regularly scheduled basis at the company’s world headquarters in Auburn Hills, Michigan. For additional information contact FANUC Robotics North America, Inc. Training and Documentation Department 2000 South Adams Road Auburn Hills, Michigan 48326–2800 Tel: (810)377–7234 FAX: (810)377–7367 or (810)377–7362

Copyright 1995, 1996 by FANUC Robotics North America, Inc. All Rights Reserved The information illustrated or contained herein is not to be reproduced, copied, translated into another language, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics North America, Inc. AccuStat
, ArcTool
, DispenseTool
, FANUC LASER DRILL
, KAREL
, INSIGHT
, INSIGHT II
, PaintTool
, PaintWorks
, PalletTool
, SOCKETS
, SOFT PARTS
SpotTool
, TorchMate
, and YagTool
, are Registered Trademarks of FANUC Robotics. FANUC Robotics reserves all proprietary rights, including but not limited to trademark and trade name rights, in the following names: AccuFlow ARC Mate ARC Mate Sr. IntelliTrak LaserTool MotionParts PaintWorks II PalletMate SureWeld TurboMove

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

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

DETAILS

Customer Information

Include  your company’s name  caller’s name  phone number where caller can be reached, including area code and extension

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

On the arm of the robot.

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

Ask your supervisor.

F Number

On the identification tag on the robot and controller, near the cable connection.

Robot serial number (if no F Number is available)

On the identification tag located near the cable connection.

Controller serial number (if no F Number is available)

On the controller tag located on the doors.

Software edition and revision numbers

Shown on the CRT or teach pendant status screen during the power-up sequence.

List of error messages

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

List of diagnostic LEDs

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

History of problem

Description of events leading up to the problem.

Application software

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

MARMMTRBL02303E

Preface

vii

Purpose of this Manual

The SYSTEM R-J Controller Series Electrical Connection and Maintenance Manual provides specific information regarding FANUC Robotics electrical hardware. The information contained within the manual has been arranged so that it can answer specific questions quickly and accurately.

How to Use this Manual

Use this table to locate specific information in the manual. If you want to

Refer to

Find information about a specific topic

Table of Contents

Identify the components of the SYSTEM R-J controller

Chapter 1, Overview

Use diagnostic and controller initialization utilities

Chapter 2, Diagnostic Screens

View status information on teach pendant screens and using other indicators

Chapter 3, Lights and LEDs

Perform troubleshooting procedures and identify specific errors

Chapter 4, Troubleshooting

Look at fuse information or replace a fuse

Chapter 5, Replacing a Fuse

Release the brakes

Chapter 6, Brake Release

Turn outputs on or off and simulate inputs

Chapter 7, Controlling I/O

Master the robot

Chapter 8, Mastering

Replace controller components

Chapter 9, Replacing Components

Adjust switch settings and potentiometers on printed circuit boards

Chapter 10, Board Adjustments

Find controller connection schematics and connector configurations

Chapter 11, Connections

Find connection information and Input/Output specifications

Chapter 12, Complete Wiring Diagrams

Find complete schematics of the controller circuitry

Chapter 13, Prints

Use controller transportation and installation information

Appendix A, Transportation and Installation

viii

Conventions Used in this Manual

PREFACE

MARMMTRBL02303E

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

WARNING Information appearing under WARNING concerns the protection of personnel. It is boxed and in bold type to set it apart from other text.

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

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

MARMMTRBL02303E

Table of Contents

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

ix

vii xxv

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

1–1

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

1–7 1–8 1–11 1–12 1–13 1–14 1–21 1–22 1–23 1–26 1–27 1–31 1–33 1–34 1–37 1–37 1–39 1–41

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

2–1

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

2–2 2–4 2–7 2–8 2–10 2–13

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

3–1

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

3–2 3–3 3–4 3–6

TABLE OF CONTENTS

x 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 3.3.8 3.3.9

MARMMTRBL02303E

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

3–7 3–8 3–12 3–13 3–14 3–15 3–16 3–17

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

4–1

4.1 CLASS 1 FAULT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 CLASS 2 FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 CLASS 3 FAULT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 SRVO-001 ER_SVAL1 Operator Panel E–Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 SRVO-002 ER_SVAL1 Teach Pendant E–stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3 SRVO-003 ER_SVAL1 Deadman switch released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.4 SRVO-004 ER_SVAL1 Fence open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.5 SRVO-005 ER_SVAL1 Robot Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.6 SRVO-006 ER_SVAL1 Hand Broken . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.7 SRVO-007 ER_SVAL1 External emergency stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.8 SRVO-008 ER_SVAL Brake fuse blown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.9 SRVO-011 ER_SVAL1 TP Released While Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.10 SRVO-012 ER_SVAL1 Power Failure Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.11 SRVO-014 Fan Motor Abnormal (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.12 SRVO-015 ER_SVAL1 System Over Heat (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . 4.3.13 SRVO-021 ER_SVAL1 SRDY off (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.14 SRVO-022 ER_SVAL1 SRDY on (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.15 SRVO-023 ER_SVAL1 Stop Error Excess (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . 4.3.16 SRVO-024 ER_SVAL1 Move Error Excess (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . 4.3.17 SRVO-026 ER_WARN Motor Speed Limit (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . 4.3.18 SRVO-027 ER_WARN Robot Not Mastered (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . 4.3.19 SRVO-033 ER_WARN Robot Not Calibrated (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . 4.3.20 SRVO-035 ER_WARN Joint Speed Limit (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . 4.3.21 SRVO-036 Imposition Time Over (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.22 SRVO-037 ER_SVAL1 IMSTP Input (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.23 SRVO-038 PULSE MISMATCH (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.24 SRVO-042 ER_SVAL2 MCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.25 SRVO-043 ER_SVAL2 DCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.26 SRVO-044 ER_SVAL2 HVAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.27 SRVO-045 ER_SVAL2 HCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–2 4–16 4–18 4–19 4–22 4–24 4–26 4–28 4–30 4–32 4–36 4–40 4–40 4–40 4–42 4–44 4–44 4–45 4–45 4–45 4–45 4–45 4–46 4–46 4–46 4–47 4–47 4–48 4–49 4–50

MARMMTRBL02303E

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

TABLE OF CONTENTS

SRVO-046 ER_SVAL2 OVC Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-047 ER_SVAL2 LVAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-049 ER_SVAL2 OHAL1 Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-050 ER_SVAL1 CLALM Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-051 ER_SVAL2 CUER Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-061 ER_SVAL2 CKAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-062 ER_SVAL2 BZAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-063 ER_SVAL2 RCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-064 ER_SVAL2 PHAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-065 ER_WARN BLAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-066 ER_SVAL2 CSAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-067 ER_SVAL2 OHAL2 Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-068 ER_SVAL2 DTERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-069 ER_SVAL2 CRCERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-070 ER_SVAL2 STBERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-071 ER_SVAL2 SPHAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-081 ER_WARN EROFL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-082 ER_WARN DAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-083 ER_WARN CKAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-084 ER_WARN BZAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-085 ER_WARN RCAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-086 ER_WARN PHAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-087 ER_WARN BLAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-088 ER_WARN CSAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-089 ER_WARN OHAL2 Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-090 ER_WARN DTERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . SRVO-091 ER_WARN CRCERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . SRVO-092 ER_WARN STBERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . SRVO-093 ER_WARN SPHAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . .

xi 4–51 4–52 4–53 4–53 4–54 4–54 4–55 4–56 4–56 4–56 4–57 4–57 4–58 4–58 4–59 4–59 4–59 4–60 4–60 4–60 4–60 4–60 4–61 4–61 4–61 4–61 4–61 4–61 4–61

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

5–1

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

5–1 5–3 5–4 5–5 5–6 5–7 5–8 5–9

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

6–1

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

7–1

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

7–2 7–4 7–5

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

8–1

8.1 MASTERING TO A FIXTURE (FIXTURE POSITION MASTER) . . . . . . . . . . . . . . . . . . . . . 8.2 ZERO DEGREE MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 SINGLE AXIS MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 QUICK MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8–2 8–5 8–8 8–11

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

9–1

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

9–2 9–4 9–5 9–6 9–7 9–8 9–11 9–12 9–12 9–14 9–16 9–17 9–18 9–19 9–21 9–23 9–24 9–25

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

10–1

10.1 AXIS CONTROL BOARD JUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 PROCESS I/O BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.1 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.2 Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.3 Output Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 BUILT–IN CRT/KB UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 EMG BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10–1 10–2 10–5 10–6 10–7 10–8 10–10

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

11–1

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

11–2 11–4 11–8 11–10 11–11 11–13 11–15 11–16 11–17 11–18 11–19 11–20 11–21 11–22 11–39 11–42 11–46 11–48 11–49 11–51 11–55 11–65 11–65 11–65 11–66 11–67 11–67

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Arc Welding Interface Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End Effector Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11–68 11–69 11–72 11–74

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

12–1

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

13–1

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

A–1

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

A–1 A–2 A–2 A–3 A–4 A–5 A–6

List of Procedures Procedure 2–1 Procedure 2–2 Procedure 2–3 Procedure 2–4 Procedure 2–5 Procedure 2–6 Procedure 6–1 Procedure 7–1 Procedure 7–2 Procedure 7–3 Procedure 8–1 Procedure 8–2 Procedure 8–3 Procedure 8–4 Procedure 8–5 Procedure 9–1 Procedure 9–2 Procedure 9–3 Procedure 9–4

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

2–3 2–5 2–7 2–9 2–11 2–13 6–1 7–2 7–4 7–6 8–2 8–5 8–8 8–11 8–13 9–2 9–3 9–6 9–7

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Procedure 9–5 Procedure 9–6 Procedure 9–7 Procedure 9–8 Procedure 9–9 Procedure 9–10 Procedure 9–11 Procedure 9–12 Procedure 9–13 Procedure 9–14 Procedure 9–15

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

xv 9–12 9–14 9–14 9–16 9–17 9–18 9–19 9–21 9–23 9–24 9–25

List of Figures Figure 1–1. Cabinet Exterior, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–2. Cabinet Exterior, B-Size Controller with Regenerative Discharge Unit . . . . . . . . . . . Figure 1–3. Cabinet Exterior, B-Size Controller with Optional Side Cabinet . . . . . . . . . . . . . . . . . Figure 1–4. Cabinet Exterior, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–5. Cabinet Interior, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–6. Cabinet Interior, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–7. Backplane with R-H Style Extended Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–8. Main CPU Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–9. Axis Control Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–10. Power Supply Unit Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–11. Emergency Stop Control Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–12. Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–13. Mounting Locations of Servo Amplifiers – Robot with 6-amplifiers . . . . . . . . . . . . Figure 1–14. Mounting Locations of Servo Amplifiers for the A-510 . . . . . . . . . . . . . . . . . . . . . . Figure 1–15. Mounting Locations of Servo Amplifiers for the Arc Mate/ Arc Mate 100/S-6, Arc Mate Sr./S-5/S-10 and L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–16. Mounting Locations of Servo Amplifiers for the S-500/S-700 and M-400 . . . . . . . . Figure 1–17. Mounting Locations of Servo Amplifiers for the S-420 and S-800 . . . . . . . . . . . . . . Figure 1–18. Mounting Locations of Servo Amplifiers for the S-420 and the DCR & DBR Unit . Figure 1–19. Mounting Locations of Servo Amplifiers for the M-500 . . . . . . . . . . . . . . . . . . . . . . Figure 1–20. Mounting Locations of Servo Amplifiers for the S-900 . . . . . . . . . . . . . . . . . . . . . . . Figure 1–21. DCR and DBR Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–22. Discharge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–23. Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–24. Multi-Tap Transformer A80L–0026–0013#A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–25. Modular I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–26. Process I/O Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–27. Fused Flange Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–28. Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–29. User Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–2 1–2 1–3 1–4 1–5 1–6 1–7 1–9 1–11 1–12 1–13 1–14 1–15 1–16 1–16 1–17 1–17 1–18 1–18 1–19 1–21 1–22 1–24 1–25 1–27 1–31 1–35 1–35 1–37

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Figure 1–30. Operator Panel, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–31. Operator Panel, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–32. Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–33. Heat Exchange System, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1–34. Heat Exchange System, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2–1. Default Power–Up Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2–2. Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–1. Teach Pendant LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–2. Operator Panel LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–3. Circuit Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–4. Emergency Control Board (EMG) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–5. Power Supply Unit (PSU) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–6. Axis Control Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–7. Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–8. Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–9. Process I/O Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–10. R–H MAP LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3–11. R-H ABRIO LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–1. 24 Volt (24E) Power Distribution Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–2. 24 Volt (24V) Power Distribution Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–3. Operator Panel E-Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–4. Teach Pendant E-Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–5. Deadman Switch Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–6. Fence Open Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–7. Robot Overtravel Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–8. Hand Broken Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–9. External Emergency Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–10. Brake Fuse Blown Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–11. Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–12. System Over Heat Circuitry Drawing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4–13. System Over Heat Circuitry Drawing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–1. Replacing a Fuse of the Transformer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–2. Replacing the Fuse of a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–3. Replacing a Fuse of the Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5–4. Replacing the Fuse on the Emergency Stop Control PC Board . . . . . . . . . . . . . . . . . . Figure 5–5. Replacing the Fuse of the Process Input/Output PC Board AA, AB, CA, CB, or DA Figure 5–6. Replacing the Fuse of the Process Input/Output PC Board BA or BB . . . . . . . . . . . . Figure 5–7. Replacing the Fuse of the AC Outlet Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–1. Replacing the Battery (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–2. Replacing a Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–3. Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9–4. Replacing Printed Circuit Boards on the Backplane Printed Circuit Board . . . . . . . . .

1–38 1–38 1–40 1–41 1–42 2–1 2–8 3–2 3–3 3–5 3–6 3–7 3–8 3–12 3–14 3–15 3–16 3–17 4–10 4–13 4–21 4–23 4–25 4–27 4–29 4–31 4–35 4–39 4–41 4–42 4–43 5–2 5–3 5–4 5–5 5–6 5–7 5–9 9–2 9–4 9–6 9–7

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Figure 9–5. Moving the Latches on the End of the Module Socket . . . . . . . . . . . . . . . . . . . . . . . . 9–8 Figure 9–6. Installing a New Module at an Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8 Figure 9–7. Pushing in the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9 Figure 9–8. Mounting Locations of the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10 Figure 9–9. Replacing the Process Input/Output Printed Circuit Board AA, AB, BA, or BB . . . . 9–11 Figure 9–10. Replacing the Base Unit of the Modular Input/Output Unit . . . . . . . . . . . . . . . . . . . 9–13 Figure 9–11. Removing and Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–15 Figure 9–12. Removing and Replacing a Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–15 Figure 9–13. Replacing the Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–16 Figure 9–14. Replacing a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17 Figure 9–15. Replacing the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–18 Figure 9–16. Replacing the Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–20 Figure 9–17. Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) Unit . . . . . . . . . . . . 9–22 Figure 9–18. Replacing the Regenerative Discharge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–23 Figure 9–19. Removing the Pulse Coder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–26 Figure 10–1. Axis Control Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 Figure 10–2. Process I/O Board AA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2 Figure 10–3. Process I/O Board AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2 Figure 10–4. Process I/O Board BA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3 Figure 10–5. Process I/O Board BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3 Figure 10–6. Process I/O Board CA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4 Figure 10–7. Process I/O Board CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4 Figure 10–8. Process I/O Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5 Figure 10–9. Front View Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–9 Figure 10–10. Jumper Setting CRT/KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–9 Figure 10–11. EMG board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–10 Figure 11–1. Block Diagram of Electrical Interface Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1 Figure 11–2. Mechanical Connection Diagram for S-420, S-500, S-700, S-800, and M-400 . . . . . 11–2 Figure 11–3. Mechanical Connection Diagram for ARC Mate, ARC Mate 100/S-6, ARC Mate Sr., A-510, and L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–2 Figure 11–4. Mechanical Connection Diagram, Common Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3 Figure 11–5. Connection to Servo Amplifiers and Mechanical Unit for S-420 . . . . . . . . . . . . . . . . 11–4 Figure 11–6. Connection to Servo Amplifiers and Mechanical Unit for S-420, S-420D, ARC Mate, S-5, ARC Mate 100/S-6, ARC Mate Sr., S-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4 Figure 11–7. Connection to Servo Amplifiers and Mechanical Unit for S-500 . . . . . . . . . . . . . . . . 11–5 Figure 11–8. Connection to Servo Amplifiers and Mechanical Unit for S-700 . . . . . . . . . . . . . . . . 11–5 Figure 11–9. Connection to Servo Amplifiers and Mechanical Unit for S-800 . . . . . . . . . . . . . . . . 11–6 Figure 11–10. Connection to Servo Amplifiers and Mechanical Unit for A-510 . . . . . . . . . . . . . . 11–6 Figure 11–11. Connection to Servo Amplifiers and Mechanical Unit for M-400 and M-500 . . . . . 11–7 Figure 11–12. Connection to Servo Amplifiers and Mechanical Unit for L-1000 . . . . . . . . . . . . . 11–7 Figure 11–13. Input Power Supply Connection, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . 11–9 Figure 11–14. Input Power Supply Connection, Fused Flange Disconnect . . . . . . . . . . . . . . . . . . . 11–9

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Figure 11–15. External Power Supply ON/OFF Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–16. External Emergency Stop Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–17. External Emergency Stop Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–18. Locations of Peripheral Device Interfaces, B-Size Controller . . . . . . . . . . . . . . . . . Figure 11–19. Locations of Peripheral Devices, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–20. Peripheral Device Interface Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–21. Process I/O Printed Circuit Board AA or AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–22. Process I/O Printed Circuit Board BA or BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–23. Process I/O Printed Circuit Board CA or CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–24. Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–25. Process I/O Printed Circuit Board with Modular I/O . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–26. Two or More Process I/O Boards and the I/O Unit (Model A) . . . . . . . . . . . . . . . . Figure 11–27. Peripheral Device and Control Unit Connection -A1/A2 . . . . . . . . . . . . . . . . . . . . . Figure 11–28. Peripheral Device and Control Unit Connection -A3/A4 . . . . . . . . . . . . . . . . . . . . . Figure 11–29. Peripheral Device and Control Unit Connection - B1/B2 . . . . . . . . . . . . . . . . . . . . Figure 11–30. Peripheral Device and Control Unit Connection -C1 . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–31. Peripheral Device Interface Control for A1, A2, A3, and A4 . . . . . . . . . . . . . . . . . Figure 11–32. Peripheral Device Interface for A1, A2, A3, and A4 . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–33. Peripheral Device Control Interface B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–34. Peripheral Device Control Interface B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–35. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–36. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–37. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–38. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–39. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–40. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–41. Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–42. End Effector Pin Configuration – Arc Mate/S-5, Arc Mate Sr/S-10, S-420, S-500, S-700, S-800, S-900, M-400 and M-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–43. End Effector Pin Configuration – Arc Mate 100/S-6 . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–44. End Effector Pin Configuration – A-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–45. End Effector Pin Configuration – L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–46. Control Unit and Welder Connection - CRW1/CRW2 . . . . . . . . . . . . . . . . . . . . . . . Figure 11–47. Control Unit and Welder Connection - CRW1 Analog Signal Assignment . . . . . . . Figure 11–48. Control Unit and Welder Connection - CRW1 Digital Signal Assignment . . . . . . . Figure 11–49. Control Unit and Welder Connection - CRW2 Analog Signal Assignment . . . . . . . Figure 11–50. Peripheral Device Interface A Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–51. Peripheral Device Interface B Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–52. Arc Welder Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–53. Peripheral Device Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–54. Arc Welder Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–55. Peripheral Device Cable Connector for A and B(Honda Tsushin Kogyo) . . . . . . . .

11–10 11–11 11–12 11–13 11–14 11–15 11–16 11–17 11–18 11–19 11–20 11–21 11–25 11–26 11–27 11–28 11–29 11–30 11–31 11–32 11–33 11–34 11–35 11–36 11–37 11–38 11–39 11–40 11–40 11–41 11–41 11–42 11–43 11–44 11–45 11–65 11–65 11–66 11–67 11–68 11–69

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Figure 11–56. Peripheral Device Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–57. Peripheral Device Interface Cable C Connector (Phoenix Contact) . . . . . . . . . . . . Figure 11–58. Elbow Type Connector S-5, S-10, S-420, S-500, S-700, S-800, M-400, M-500, ARC Mate, ARC Mate 100/S-6, ARC Mate Sr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11–59. Connector L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–1. Internal Connection Diagram – S-420, S-800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–2. Internal Connection Diagram – S420 with three Servo Amplifiers, S420D) . . . . . . . Figure 12–3. Internal Connection Diagram – ARC Mate, ARC Mate Sr., ARC Mate 100/S-6, S-5, and S-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–4. Internal Connection Diagram – S-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–5. Internal Connection Diagram – S-700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–6. Internal Connection Diagram – S900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–7. Internal Connection Diagram – A-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–8. Internal Connection Diagram – M-400 (5-axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–9. Internal Connection Diagram – M400 (4 axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–10. Internal Connection Diagram – M500 (5 axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–11. Internal Connection Diagram – M500 (4 axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–12. Internal Connection Diagram – L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–13. Internal Connection Diagram – Emergency Stop Control – PCB . . . . . . . . . . . . . . Figure 12–14. Internal Connection Diagram – Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–15. Internal Connection Diagram - Main CPU; Axis Control Board . . . . . . . . . . . . . . . Figure 12–16. Internal Connection Diagram – Servo Amplifier Connection S-420, ARC Mate/S-5, ARC Mate Sr./S-10, ARC Mate 100/S-6, S-500, S-700, and S-800 . . . . . . . . . . . . . . Figure 12–17. Internal Connection Diagram – Servo Amplifier Connection A-510, L-1000, and M-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–18. Internal Connection Diagram – Servo Amplifier Connection S-900 and M-500 . . . Figure 12–19. Internal Connection Diagram – Modular I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–20. Internal Connection Diagram – Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–21. Internal Connection Diagram – Main CPU Interface . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–22. Internal Connection Diagram – Axis Control Board Interface . . . . . . . . . . . . . . . . . Figure 12–23. Internal Connection Diagram – ARC Mate/S-5, ARC Mate Sr./S-10, ARC Mate 100/S-6, S-420, S-500 and S-800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–24. Internal Connection Diagram – S-700 and A-510 . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–25. Internal Connection Diagram – M-400 and L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–26. Internal Connection Diagram - M–400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–27. External Connection Diagram – M-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–28. External Connection Diagram – S-900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–29. External Connection Diagram – Process I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–30. External Connection Diagram – Process I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–31. External Connection Diagram – Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 12–32. Motor Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–1. R-J Control Signal and Power Distribution Overview . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–2. Main AC Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xix 11–70 11–71 11–72 11–73 12–2 12–3 12–4 12–5 12–6 12–7 12–8 12–9 12–10 12–11 12–12 12–13 12–14 12–15 12–16 12–17 12–18 12–19 12–20 12–21 12–22 12–23 12–24 12–25 12–26 12–27 12–28 12–29 12–30 12–31 12–32 12–33 13–3 13–5

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Figure 13–3. AC Power Distribution With Optional 115VAC Secondary . . . . . . . . . . . . . . . . . . . . Figure 13–4. Power Supply Unit (PSU) With Power ON/OFF Circuit . . . . . . . . . . . . . . . . . . . . . . Figure 13–5. EMG Stop & Brake Connection 100 VAC E-Stop Circuit 100 VDC Brake Circuit (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–6. EMG Stop and Brake Connection 100 VDC Brake Circuit (2 of 2) . . . . . . . . . . . . . Figure 13–7. EMG Stop and Brake Connection 24 VDC E-Stop Circuit (1 of 2) . . . . . . . . . . . . . Figure 13–8. EMG Stop and Brake Connection 24VDC E-Stop Circuit (2 of 2) Modular I/O Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–9. Overheat and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–10. Single Axis Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–11. Dual Axis Servo Amplifier (With Dynamic Brakes) . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–12. Dual Axis Servo Amplifier (Without Dynamic Brakes) . . . . . . . . . . . . . . . . . . . . . . Figure 13–13. Discharge Resistor and Dynamic Brake Unit (For Amp With No Dynamic Brake) Figure 13–14. LSI Module All Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–15. DV-M Module Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–16. ALM-M Module Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13–17. Teach Pendant Power And Data Signal Interconnection . . . . . . . . . . . . . . . . . . . . . Figure A–1. Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A–2. Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A–3. Assembly During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A–4. Peripheral Device Interface Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–7 13–9 13–11 13–13 13–15 13–17 13–19 13–21 13–23 13–25 13–27 13–29 13–31 13–33 13–35 A–1 A–2 A–3 A–6

List of Tables Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table

1–1. Main CPU Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2. Axis Control Board Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3. Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4. Multi-Tap Transformer Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5. Selecting Transformer Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6. Selecting Transformer Taps for Transformer A80L–0026–0013#A . . . . . . . . . . . . . . 1–7. Digital Input Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8. Digital Output Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9. I/O Module Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10. Process I/O Board Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11. Circuit Breaker, B-Size Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12. Circuit Breaker and Fused Flange Disconnect Switch, C-Size Cabinet . . . . . . . . . . 1–13. Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14. Teach Pendant Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1. Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2. Axis Status Pulse Screen Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3. Version Identification Status Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4. Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1. Teach Pendant Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–10 1–11 1–20 1–23 1–24 1–25 1–29 1–29 1–30 1–32 1–36 1–36 1–38 1–40 2–2 2–7 2–10 2–13 3–2

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Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table

3–2. 3–3. 3–4. 3–5. 3–6. 3–7. 3–8. 3–9. 3–10. 4–1. 4–2. 4–3. 4–4. 4–5. 4–6. 4–7. 4–8. 4–9. 4–10. 4–11. 4–12. 4–13. 4–14. 4–15. 4–16. 4–17. 4–18. 4–19. 4–20. 4–21. 4–22. 4–23. 4–24. 4–25. 4–26. 4–27. 4–28. 4–29. 4–30. 4–31. 4–32. 4–33.

TABLE OF CONTENTS

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

xxi 3–3 3–6 3–9 3–12 3–13 3–14 3–15 3–16 3–17 4–3 4–5 4–6 4–9 4–11 4–14 4–16 4–19 4–22 4–24 4–26 4–28 4–29 4–31 4–33 4–36 4–40 4–42 4–44 4–44 4–45 4–46 4–47 4–47 4–48 4–49 4–50 4–51 4–52 4–53 4–53 4–54 4–54

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4–34. SRVO-062 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–35. SRVO-063 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–36. SRVO-064 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–37. SRVO-065 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–38. SRVO-066 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–39. SRVO-067 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–40. SRVO-068 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–41. SRVO-071 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–42. SRVO-081 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–43. SRVO-082 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1. Multi-Tap Transformer Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2. Power supply unit for four-slot backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3. Power supply unit for six-slot backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4. Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1. Standard Operator Panel Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2. Standard Operator Panel Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1. Mastering Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1. Relay Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1. Axis Control Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2. Process I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3. Process I/O Board Potentiometer Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4. Output Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5. SBK Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1. Example of Leakage Current Circuit Breaker for Inverters . . . . . . . . . . . . . . . . . . . 11–2. External Emergency Stop Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3. External Emergency Stop Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4. Peripheral Device Interface Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–5. Process I/O Printed Circuit Board AA or AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–6. Process I/O Printed Circuit Board BA or BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7. Process I/O Printed Circuit Board CA or CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8. Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–9. Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10. Two or More Process I/O Boards and the I/O Unit (Model A) . . . . . . . . . . . . . . . . 11–11. Process I/O Printed Circuit Board Signals, DI Signals . . . . . . . . . . . . . . . . . . . . . . 11–12. Process I/O Printed Circuit Board Signals, DO Signals . . . . . . . . . . . . . . . . . . . . . 11–13. Applicable Process I/O Printed Circuit Board - A1/A2 . . . . . . . . . . . . . . . . . . . . . 11–14. Applicable Process I/O Printed Circuit Board - A3/A4 . . . . . . . . . . . . . . . . . . . . . 11–15. Applicable Process I/O Printed Circuit Board - B1/B2 . . . . . . . . . . . . . . . . . . . . . . 11–16. Applicable Process I/O Printed Circuit Board - C1 . . . . . . . . . . . . . . . . . . . . . . . . 11–17. Applicable Process I/O Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–18. Peripheral Device Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–19. End Effector Control Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–55 4–56 4–56 4–56 4–57 4–57 4–58 4–59 4–59 4–60 5–1 5–4 5–4 5–8 7–5 7–5 8–1 9–4 10–1 10–5 10–6 10–7 10–10 11–8 11–11 11–12 11–13 11–16 11–17 11–18 11–19 11–20 11–21 11–22 11–23 11–25 11–26 11–27 11–28 11–42 11–46 11–48

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11–20. Arc Welding Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–21. Input Modules AID32A and AID32B, Non–isolated . . . . . . . . . . . . . . . . . . . . . . . 11–22. Input Modules AID16C and AID16D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–23. Input Modules AID32E and AID32F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–24. Input Module AIA16G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–25. Output Module AOD32A, Non-isolated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–26. Output Modules AOD08C and AOD08D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–27. Output Modules AOD16C and AOD16D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–28. Output Module AOD32C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–29. Output Module AOD32D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–30. Output Modules AOA05E and AOA08E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–31. Output Module AOA12F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–32. Output Modules AOR08G and AOR16G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–33. Output Module ADA02A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–34. Analog Input Module AAD04A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–35. Peripheral Device Cable Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . . 11–36. Symbols Used in Figure 11–55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–37. Peripheral Device Cable Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . . 11–38. Symbols Used in Figure 11–56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–39. Peripheral Device Interface Cable C Connector Specifications . . . . . . . . . . . . . . . 11–40. Connection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–41. Recommended Cable for Peripheral Device Connection . . . . . . . . . . . . . . . . . . . . 11–42. Recommended Cable for End Effector Connection . . . . . . . . . . . . . . . . . . . . . . . . A–1. Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2. Adjustment and Checks at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xxiii 11–49 11–51 11–52 11–53 11–54 11–55 11–56 11–57 11–58 11–59 11–60 11–61 11–62 11–63 11–64 11–69 11–69 11–70 11–70 11–71 11–71 11–74 11–74 A–4 A–5

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Safety

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

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CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION

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

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

Keeping People and Equipment Safe

The safety of people is always of primary importance in any situation. However, equipment must be kept safe, too. When prioritizing how to apply safety to your robotic system, consider  People  External devices  Robot(s)  Tooling  Workpiece

Using Safety Enhancing Devices

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

Setting Up a Safe Workcell

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

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



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



Use anti–tie–down 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.

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



Position all controllers outside the robot work envelope.



Never rely on software as the primary safety element.



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



Install flashing lights and/or audible warning devices that activate whenever the robot is operating, that is, whenever power is applied to the servo drive system.



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



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



Use interlocks.



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



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



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



Make provisions for power lockout/tagout at the controller.



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



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



Program the robot to load and unload material safely.



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



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

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Staying Safe While Teaching or Manually Operating the Robot

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

Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment.



Before teaching, visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These include tooling attached to the wrist flange that extends this range.



The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe working conditions to the supervisor or safety department.



FANUC Robotics recommends that no one enter the work envelope of a robot that is on. However, if you must enter the work envelope, be sure all safeguards are in place, and check the teach pendant DEADMAN switch for proper operation. Take the teach pendant with you, turn it on, and be prepared to release the DEADMAN switch. Only the person with the teach pendant should be in the work envelope.



Know the path that can be used to escape from a moving robot; make sure the escape path is never blocked.



Isolate the robot from all remote control signals that can cause motion while data is being taught.



Test any program being run for the first time in the following manner:

WARNING Stay outside the robot work envelope whenever a program is being run. Failure to do so can result in injury.

– Using a low motion speed, single step the program for at least one full cycle.

– Using a low motion speed, test run the program continuously for at least one full cycle.

– Using the programmed speed, test run the program continuously for at least one full cycle. 

Make sure all personnel are outside the work envelope before running production.

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Staying Safe During Production Operation

Staying Safe During Inspection

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

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



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



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



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



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



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



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



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



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

When inspecting the robot, be sure to 

Turn off power at the controller.



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



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



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



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

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Staying Safe During Maintenance

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

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



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



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



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



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



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

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

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



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



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



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

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

Be aware that when you remove a servomotor or brake, the associated axis will fall if it is not supported or resting on a hard stop.



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



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



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

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. These measures are outlined below.

Programming Safety Precautions

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

Mechanical Safety Precautions



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



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



Use handshaking protocol to synchronize robot and external device operations.



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

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

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



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

xxxii

KEEPING THE ROBOT SAFE Operating Safety Precautions

SAFETY

Observe the following operating and programming guidelines to prevent damage to the robot. The following measures are designed to prevent damage to the robot during operation.    

Programming Safety Precautions

MARMMTRBL02303E

Use a low override speed to increase your control over the robot when jogging the robot. Visualize the movement the robot will make before you press the jog keys on the teach pendant. Make sure the work envelope is clean and free of oil, water, or debris. Use circuit breakers to guard against electrical overload.

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

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



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



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



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

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

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ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS

SAFETY

xxxiii

Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personal also must work inside the paint booth periodically. Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor. Although paint booth hazards have been minimized, potential dangers still exist. Therefore, today’s highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its capabilities. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools. Paint robots are operated in three modes:   

Teach or manual mode Automatic mode, including production and exercise operation Diagnostic mode

During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant. In automatic mode, robot operation is initiated at the System Controller Center (SCC), Manual Control Panel (MCP), if available, or Manual Paint Station (MPS), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth or in a designated safe area within the booth whenever automatic mode is initiated at the SCC, MCP, or MPS. In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds. When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.

xxxiv

Paint System Safety Features

SAFETY

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

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



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



EMERGENCY STOP buttons are located on the Manual Control Panel (MCP), or Manual Paint Station (MPS) panel, if supplied, inside the booth, or on the System Controller Center (SCC) outside the booth. Also, EMERGENCY STOP buttons are located near the interior corners of each booth, and on the robot controller and teach pendant. Become familiar with the locations of all 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, 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 E–STOP other robots. WARNING An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed robot.



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

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SAFETY



xxxv

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



Staying Safe While Operating the Paint Robot

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

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

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



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



Be aware of overlapping work envelopes of adjacent robots.



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



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

xxxvi

Staying Safe During Maintenance

SAFETY

MARMMTRBL02303E



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



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



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



Never enter the work envelope or paint booth before turning on power to the robot servo system.



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



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



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



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



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



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



Follow the procedures described in this manual.

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

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



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



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



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



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

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SAFETY

xxxvii



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



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



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

xxxviii

SAFETY



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When using vinyl resin observe the following:

– Wear eye protection and protective gloves during application and removal

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

– If there is contact with the skin, wash with water. 

When using paint remover observe the following:

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

– Adequate ventilation is required. Overexposure could cause drowsiness.

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

MARMMTRBL02303E

1

OVERVIEW 1–1 The SYSTEM R-J Robot and controller consists of software, a robot, and the SYSTEM R-J controller. The application software runs on the R-J controller and is written to perform a specific task. The SYSTEM R–J controller contains the computer that operates the robot. It executes a user-defined program to perform the following functions: 

Supply drive power to the servomotors of an attached robot and, in some cases, to motor-driven auxiliary devices to move the robot through a series of program motions.



Supply drive power to the servomotors of an attached robot and, in some cases, to motor-driven auxiliary devices comprising additional axes, such as door openers, and/or hood/deck openers used in conjunction with robot programs.



Send control signals to process devices and other peripheral equipment.



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

The controller consists of modular circuit boards and components housed in a cabinet. The controller is housed in either a B-size or C-size cabinet. The controller consists of modular circuit boards and components housed in a C-size cabinet. Figure 1–1, Figure 1–2, and Figure 1–3 illustrate an external view of the B-size cabinet and Figure 1–4 illustrates an external view of a C-size cabinet. Figure 1–5 illustrates an internal view of a B-size cabinet and Figure 1–6 illustrates an internal view of a C-size cabinet. Figure 1–4 illustrates an external view of a C-size cabinet. Figure 1–7 illustrates an internal view of a C-size cabinet.

1. OVERVIEW MARMMTRBL02303E

1–2 Figure 1–1. Cabinet Exterior, B-Size Controller

ÎÎÎ ÎÎ Î ÎÎÎÎ ÎÎÎ Î ÎÎ Î Î ÎÎÎ ÎÎ Î Î

ÎÎÎ Î ÎÎ Î ÎÎÎ Î ÎÎÎ Î ÎÎÎÎ

Teach pendant

Figure 1–2. Cabinet Exterior, B-Size Controller with Regenerative Discharge Unit

Regenerative Discharge Unit

ÎÎÎ ÎÎ Î ÎÎÎ ÎÎÎÎ Î ÎÎ Î ÎÎÎ Î ÎÎ Î

ÎÎÎ Î ÎÎ Î ÎÎÎ Î ÎÎÎ ÎÎ ÎÎ

Teach pendant

1. OVERVIEW

1–3

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Figure 1–3. Cabinet Exterior, B-Size Controller with Optional Side Cabinet

Optional Side Cabinet

ÎÎ Î Î Î ÎÎ ÎÎ ÎÎÎ ÎÎ Î Î ÎÎ Î ÎÎ ÎÎÎÎ Î Î ÎÎ Î

Teach pendant

1. OVERVIEW MARMMTRBL02303E

1–4 Figure 1–4. Cabinet Exterior, C-Size Controller

Î ÎÎ ÎÎ Î Î ÎÎ Î Î ÎÎ Î

ÎÎ ÎÎ ÎÎÎ Î Î

Teach pendant

1. OVERVIEW

1–5

MARMMTRBL02303E

Figure 1–5. Cabinet Interior, B-Size Controller Regenerative discharge unit Servo amplifier 4

Fan 1

Servo amplifier 3

Additional cabinet

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

Servo amplifier 6 Servo amplifier 5

Transformer or line filter unit

Servo amplifier 1

Fan 3

Servo amplifier 2 Teach pendant

Fan 4

Fan 5

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

1. OVERVIEW MARMMTRBL02303E

1–6

Î ÎÎ Î Ï ÎÎÎ Î Î ÎÎ ÎÎ ÎÎÎÎÎÎÎ

Figure 1–6. Cabinet Interior, C-Size Controller Operator panel

Extended Back plane

Modular I/O rack or Process I/O rack

Power disconnect Servo amplifier #1 Main CPU

Servo amplifier #2

Fuses FL1–3 Servo amplifier #3

Axis control board Power supply unit

Servo amplifier #4 and #5

Emergency stop control board

Servo amplifier #6

Option 1 and 2 slots

User transformer

Multi–tap transformer

1. OVERVIEW

1–7

MARMMTRBL02303E

Figure 1–7. Cabinet Interior, C-Size Controller

ÎÎ ÎÎÎ ÎÎÎÎ Ï ÎÎÎÎÎ Î ÎÎÎ ÎÎÎÎ Î ÎÎÎÎ

Operator panel

Servo Amplifiers

Contact Signal Transducer STAHL Extended ISB’s Back plane

STBI Term Strip Purge 24V DC Power Supply Power disconnect

Main CPU Fuses FL1–3 Transit Board

Axis control board Power supply unit

Emergency stop control board Option 1 and 2 slots

BDX ISB Unit

ALC Relay

SPC Battery Unit

Multi–tap transformer User transformer

1. OVERVIEW MARMMTRBL02303E

1–8

1.1

The control unit printed circuit boards are mounted on the backplane printed circuit board. The backplane provides the bus structure for communication between the various printed circuit boards in the controller. A thermostat for sensing the temperature in the controller is mounted on the backplane. If the internal temperature exceeds specifications (65³C), the controller will generate a system overheat alarm.

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

Two different backplane printed circuit boards are available both for the 4and 6-slot printed circuit board. Either of these printed circuit boards are interchangeable. The R–H style extended backplane is available for using R-H style printed circuit boards, such as MAP 3.0 and ABRIO. Figure 1–8 shows the backplane with the R-H style extended backplane attached.

R-H Style Extended Backplane A20B-1004-0510

CNB15 CNA15

CNA14

CNBV2 CNAV2

JNAT

CNBV1 CNAV1

Figure 1–8. Backplane with R-H Style Extended Backplane

NOTE The A20B-2000-0800 and the A20B-2000-0920 printed circuit boards have an additional connector that is not used in robot applications.

1. OVERVIEW

1–9

MARMMTRBL02303E

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

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

The I/O unit(s) The teach pendant One or more general–purpose serial communication ports An optional built-in or remote computer terminal (CRT/KB) The operator panel lights and pushbuttons

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

Flash ROM Module contains System and Application Software.



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

   

Figure 1–9 shows the board layout. Table 1–1 lists the part numbers for the modules attached on the board.

1. OVERVIEW MARMMTRBL02303E

1–10 Figure 1–9. Main CPU Board Layout

Flash ROM module

Optional SCC module

CMOS RAM module (option)

SLC2 module

CMOS RAM module (option)

M32i module

CMOS RAM module (standard)

SCC module

CMOS RAM module (standard)

NOTE Options are shown in phantom print.

1. OVERVIEW

1–11

MARMMTRBL02303E

Table 1–1. Name

Main CPU Modules

Part Number

CMOS RAM module

A20B-2900-0500, 0501

Flash ROM module

A20B-2900-0480, 0482

M32I module

A20B-2900-0450

SCC module

A20B-2900-0430

SLC2 module

A20B-2900-0440, 0442

Optional SCC module

A20B-2900-0490, 0491, 0492

Remarks

MAIN CPU printed circuit board

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

1. OVERVIEW MARMMTRBL02303E

1–12

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

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

Is the interface for the Robot Input (RI) and Robot Output (RO) I/O signals. Figure 1–10 shows the axis control board layout. Table 1–2 lists the part numbers for the modules attached on the board. Figure 1–10. Axis Control Board Layout

Servo control module (for axis 9 and 10) Servo control module (for axis 7 and 8) Servo control module (for axis 5 and 6) Servo control module (for axis 3 and 4) Servo control module (for axis 1 and 2) Servo interface module (for axis 5 and 6) Servo interface module (for axis 3 and 4)

Servo interface module (for axis 9 and 10)

Servo interface module (for axis 1 and 2)

Servo interface module (for axis 7 and 8)

NOTE Options are shown in phantom print. Table 1–2. Name Servo interface module Servo control module

Axis Control Board Modules

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

Remarks Axis control printed circuit board

1. OVERVIEW

1–13

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1.4 POWER SUPPLY UNIT PRINTED CIRCUIT BOARD 4-Slot Backplane A16B-1212–0471 6-Slot Backplane A16B-1212-0531

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

+24V used

– For inputs, outputs receivers, drivers, and relays. – As the power source for the teach pendant power supply circuitry. 

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

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

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

Figure 1–11. Power Supply Unit Printed Circuit Board PSU

F5: 0.3A fuse for auxiliary power supply Battery cover

PSU

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

Battery

ALM: Red LED for indicating an alarm

F4:5–Afuse for +24E F3: Fuse for +24V 5-A slow blow for 6-slot backplane 3.2A slow blow for 4-slot backplane

(with battery cover removed)

1. OVERVIEW MARMMTRBL02303E

1–14

1.5 EMERGENCY STOP CONTROL PRINTED CIRCUIT BOARD

The emergency stop control printed circuit board is mounted on the backplane in the slot marked EMG. It contains the circuits that: 

Supply 100VAC to the servo amplifiers magnetic control contactors (MCCs) during normal operation.

A16B-1212-0540



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

A16B-1212-0730



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

– – – – –

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



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



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



Monitor and control the purge system through a piggy-back style PCB, purge control A16B–1600–0520. This PCB is mounted internally within the EMG PCB.



Supply 24VDC required for SPC encoder operation through the 24 to 5VDC converter unit located within the robot base and switched on through the purge complete relay contacts of RL-1 for protection from explosive gases.

Figure 1–12 shows the emergency stop control printed circuit board layout.

1. OVERVIEW

1–15

MARMMTRBL02303E

Figure 1–12. Emergency Stop Control Printed Circuit Board

EMG PCB

1. OVERVIEW MARMMTRBL02303E

1–16 Figure 1–13. Emergency Stop Control PC Board

DS2

F1 DS1

F2 RL16

FUSE

RL1 RL2

RL4 CRR5 RL3

LED M1 LED M2

RL2 RL4 TIMER

RL1 RL3

RL6 RL5 RL8

CNPG

Purge Control PCB

RL7

RL9

CRT CRX

1. OVERVIEW

1–17

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1.6 SERVO AMPLIFIERS Refer to Table 1–3 for part numbers.

The servo amplifiers are mounted on the back wall of the controller. The servo amplifier amplifies the drive signal from the axis control printed circuit board and supplies it to the servomotor. Servo amplifiers are supplied in single, double or triple-axis configurations. Several different models of each configuration are used in various FANUC robot controllers. CAUTION While two servo amplifiers might look identical, they might have quite different output power capabilities. If you replace a servo amplifier, make sure that the new unit has the same part number as the old one. Otherwise, the servo amplifier or servomotor might be damaged or destroyed. See Figure 1–14 for a servo amplifier. Figure 1–14. Servo Amplifier

Circuit breaker

LED Terminal board T1

1. OVERVIEW MARMMTRBL02303E

1–18 MCC Coil

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

Circuit Breaker

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

Fault Detection

Each servo amplifier has fault detection circuits that detect such conditions as excessive motor current and servo amplifier power supply failure. A pair of terminals on the servo amplifier can be connected to a temperature-sensing switch in the multi-tap transformer. If the switch opens, the controller will signal a SRVO–0043 DCAL alarm.

Servo Amplifier Configuration

Table 1–3 lists the servo amplifiers for several FANUC robots. Figure 1–15 shows the mounting locations of the servo amplifiers.

Servo Amplifier Configuration

Table 1–3 lists the servo amplifiers for the P-155 robot and optional auxiliary devices.. Figure 1–23 shows the mounting locations of the servo amplifiers. Figure 1–15. Mounting Locations of Servo Amplifiers – Robot with 6-amplifiers

SLOT 4 SLOT 5 SLOT 6

SLOT 1 SLOT 2 SLOT 3

1. OVERVIEW

1–19

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Figure 1–16. Mounting Locations of Servo Amplifiers for the A-510

Figure 1–17. Mounting Locations of Servo Amplifiers for the Arc Mate/ Arc Mate 100/S-6, Arc Mate Sr./S-5/S-10 and L-1000

1. OVERVIEW

1–20

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Figure 1–18. Mounting Locations of Servo Amplifiers for the S-500/S-700 and M-400

Figure 1–19. Mounting Locations of Servo Amplifiers for the S-420 and S-800

1. OVERVIEW

1–21

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Figure 1–20. Mounting Locations of Servo Amplifiers for the S-420 and the DCR & DBR Unit

(S–420) With 3 2-Axis Servo Amplifiers; S–420D

Figure 1–21. Mounting Locations of Servo Amplifiers for the M-500

1. OVERVIEW MARMMTRBL02303E

1–22

Figure 1–22. Mounting Locations of Servo Amplifiers for the S-900

Figure 1–23. Mounting Locations of Servo Amplifiers. Amp 1

Amp 2 Amp 3

Axis 1 Axis 4

Axis 2 Axis 5

Amp 4 Amp 5 Axis 7

Axis 8 Axis 9

Axis 3 Axis 6

1. OVERVIEW

1–23

MARMMTRBL02303E

NOTE In Table 1–3, the part number of the specific amplifier is A06B-6066-HXXX.

Table 1–3. Machine Type

Servo Amplifiers

Servo Amplifier 1

Servo Amplifier 2

Servo Amplifier 3

ARC Mate S-5

H281 L;Axis 4/ M;Axis 1

H223 L;Axis 5/ M;Axis 2

H223 L;Axis 6/ M;Axis 3

ARC Mate 100/S-6

H234 L;Axis 4/ M;Axis 1

H224 L;Axis 5/ M;Axis 2

H223 L;Axis 6/ M;Axis 3

ARC Mate Sr. S-10

H234 L;Axis 4/ M;Axis 1

H234 L;Axis 5/ M;Axis 2

H233 L;Axis 6/ M;Axis 3

H235 Axes 1 & 4

H235 Axes 2 & 5

H235 Axes 3 & 6

P-155

Servo Amplifier 4

Servo Amplifier 5

H005 Axis 7

Door Opener

H233 Axes 8 & 9

Hood & Deck

H244 Axes 8 & 9

S-420 (with five amplifiers)

H011 Axis 1

H006 Axis 2

H006 Axis 3

H244 L;Axis 5/ M;Axis 4

H291 L;Axis 4/ M;Axis 1

H291 L;Axis 5/ M;Axis 2

H291 L;Axis 6/ M;Axis 3

DCR & DBR Unit

S-500

H011 Axis 1

H006 Axis 2

H234 L;Axis 4/ M;Axis 3

H233 L;Axis 6/ M;Axis 5

S–700

H012 Axis 1

H006 Axis 2

H234 L;Axis 4/ M;Axis 3

H233 L;Axis 6/ M;Axis 5

S-800

H011 Axis 1

H006 Axis 6

H006 Axis 3

H260 L;Axis 5/ M;Axis 4

H006 Axis 6

S–900

H008 Axis 1

H006 Axis 4

H008 Axis 2

H006 Axis 5

H008 Axis 3

M-400

H006 Axis 1

H011 Axis 2

H234 L;Axis 4/ M;Axis 3

H003 Axis 5

M-500

H008 Axis 1

H006 Axis 3

H244 L;Axis 4/ M;Axis 2

H004 Axis 5

A-510

H233 L;Axis 3/ M;Axis 1

H223 L;Axis 4/ M;Axis 2

L-1000

H234 L;Axis 4/ M;Axis 1

H234 L;Axis 5/ M;Axis 2

S-420 and S-420D (with three 2-axis amplifiers)

H003 Axis 3

Servo Amplifier 6

H004 Axis 6

H006 Axis 6

1. OVERVIEW MARMMTRBL02303E

1–24

1.7 DCR AND DBR UNIT A05B-2302-C080

The Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) unit is used in R-J controllers with three 2-axis amplifiers. It contains the dynamic braking resistors and regenerative discharge resistors built into the other model servo amplifiers. At the loss of either MCON (Motor Control Connected) signal from the axis control module to the servo amplifier, that amplifier turns off the 100C signal to the DBR (Dynamic Braking) and DCR (Discharge Resistor) unit and its associated MCC. This turns off the MCC contactor (one for each major and minor axis on the DBR and DCR unit) for that amplifier, and engages the dynamic brakes through the normally closed contacts of the corresponding MCC. At the loss of the 100VAC from the emergency stop circuit, all of the MCC contactors are turned off, engaging all of the dynamic brakes. When the MCC deenergizes, it opens its normally open contact, relaying “no interlock (INTL)”. The regenerative discharge resistor and its associated thermal switch, for each amplifier, is mounted to the back of the DBR and DCR unit. The thermal switches of transformer TF1, is also connected to the DBR and DCR unit. Figure 1–24. DCR and DBR Unit

1. OVERVIEW

1–25

MARMMTRBL02303E

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

A discharge unit, mounted on top of the controller, is used with the M-500 and S-900 robot models. This unit is connected to axis 1 on the M-500 and axes 1, 3, and 5 on the S-900. The unit consists of low-resistance high-power resistors used to dissipate the counter electromotive force generated by the servo motors when they are shut off. Thermo overload switches connected to the overheat terminals on the servo amplifiers are also in the discharge unit. Fans in the discharge unit are used to cool the unit. Figure 1–25. Discharge Unit

1. OVERVIEW MARMMTRBL02303E

1–26

1.9 MULTI-TAP TRANSFORMER Refer to Table 1–4 for part numbers.

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

3–phase 210 VAC for the servo amplifiers 1–phase 210 VAC for the backplane–mounted components 1–phase 210 VAC for the IBRC module 1–phase 210 VAC for the 24VDC Purge Power Supply 1–phase 100 VAC for the brakes and servo amplifier–mounted MCCs

NOTE Transformer A80L–0026–0013#A also supplies 115VAC for the user receptacle. Two series–connected thermostats are mounted on the transformer. They are connected to fault detection circuitry in one servo amplifier. If the transformer overheats, the controller will signal a SRVO–0043 DCAL alarm. Figure 1–26 and Figure 1–27 show the transformers, and Table 1–4, Table 1–5, and Table 1–6 lists the information necessary for selecting a proper primary tap. Figure 1–26 shows the transformers, and Table 1–4, and Table 1–5 lists the information necessary for selecting a proper primary tap. Table 1–4.

Multi-Tap Transformer Part Numbers

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

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

1. OVERVIEW

1–27

MARMMTRBL02303E

Figure 1–26. Multi-Tap Transformer 1

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

F1

F5 7.5

13

F2

2 3 4 5 6 7

F3

A1

A2

23

31

1

3

5

41

32

2

4

6

42

14

24

8

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

9 10 11 12 13 14 15 16

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

17 18 19 20 21 22 23

24

0V

Table 1–5.

Selecting Transformer Taps Primary Tap

S pply Voltage Supply

L1

L2

L3

Jumper

220

7

15

23

7-24, 15-8, 23-16

240

6

14

22

6-24, 14-8, 22-16

380

7

15

23

415

6

14

22

460

5

13

21

480

4

12

20

500

3

11

19

550

2

10

18

575

1

9

17

8-16-24

Connection Type


Y

1. OVERVIEW MARMMTRBL02303E

1–28 Figure 1–27. Multi-Tap Transformer A80L–0026–0013#A

575V 480V 220V/380V

0V F4 5A

F5 5A

F6

F7

F1

F2

1 2 3

4

F3 575V 480V 220V/380V

5 6 7

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

8

13

A1

A2

23

31

1

3

5

41

32

2

4

6

42

575V 480V 220V/380V

0V

14

9 10 11

12

24

Table 1–6. Selecting Transformer Taps for Transformer A80L–0026–0013#A Primary Tap S pply Voltage Supply

Connection Type

L1

L2

L3

Jumper

220

3

7

11

4-7, 8-11, 12-3




380

3

7

11

480

2

6

10

4, 8, 12

Y

575

1

5

9

1. OVERVIEW

1–29

MARMMTRBL02303E

1.10 INTERFACE DEVICES

The interface between the controller and peripheral devices is provided by input and output signals from one or more of the following: 

Modular I/O Unit



Process I/O printed circuit board



A printed circuit board specializing in communicating with a logic controller, which includes

– ABRIO for communication to an Allen-Bradley PLC – Genius I/O for communication to a GE Fanuc programmable controller 

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

1. OVERVIEW MARMMTRBL02303E

1–30

1.10.1

The modular I/O unit provides communication between the controller and various peripheral devices. See Figure 1–28.

Modular I/O Unit

Figure 1–28.

Interface Module

Modular I/O

I/O Module

Modular I/O Rack (Backplane)

Slot 2 Slot 1 Slot I/F

I/O Module

Interface Module

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

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

1. OVERVIEW

1–31

MARMMTRBL02303E

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

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

Discrete Input Modules Refer to Table 1–7 and Table 1–9 for specifications and part numbers.

Discrete input modules receive 24VDC or 120VAC signals on their terminals and relay the data to the interface module.

Discrete Output Modules Refer to Table 1–8 and Table 1–9 for specifications and part numbers.

Discrete output modules transmit 24VDC or 120VAC signals on their terminals under command of the interface module.

1. OVERVIEW MARMMTRBL02303E

1–32 Table 1–7. Input Type Non-isolated DC input

Optically isolated DC input inp t

AC input

Rated Voltage 24VDC

Rated Current 7.5 mA

32

External Connection Connector

No-display

AID32B

24VDC

7.5 mA

Both

Maximum 2 ms

32

Connector

No-display

AID16C

24 VDC

7.5 mA

NEG

Maximum 20 ms

16

Terminal block Provided

AID16D

24VDC

7.5 mA

POS

Maximum 20 ms

16

Terminal block Provided

AID32E

24VDC

7.5 mA

Both

Maximum 20 ms

32

Connector

No-display

AID32F

24VDC

7.5 mA

Both

Maximum 2 ms

32

Connector

No-display

AIA16G

100~ 120VAC

10.5 mA (120VAC)

16

Terminal block Provided

* Polarity is defined as follows:

Not-Fused DC output

AC output

Module Name AOD332A

Both

Response Time Maximum 20 ms

ON Max 35 ms OFF Max 45 ms

Points

LED Display

2A

NEG (Sink)

8

8

AOD08D

2A

POS (Source)

8

8

Terminal block Provided

Fused

AOD16C

0.5 A

NEG (Sink)

16

8

Terminal block Provided

Not fused

AOD16D

0.5 A

POS (Source)

16

8

Terminal block Provided

Not fused

AOD32C

0.3 A

NEG (Sink)

32

8

Connector

Not provided

Not fused

AOD32D

0.3 A

POS (Source)

32

8

Connector

Not provided

Not fused

100 ~ 240 VAC

2A

—

5

1

Terminal block Provided

Fused

1A

—

8

4

Terminal block Provided

Fused

AOA12F

100 ~ 120 VAC

0.5 A

—

12

6

Terminal block Provided

Fused

AOR08G

Maximum 250 VAC /30 VD

4A

—

8

1

Terminal block Provided

Not fused

2A

—

16

4

Terminal block Provided

Not fused

AOD08C

AOA05E

AOR16G

Rated Voltage 5~ 24 VDC 12 ~ 24 VDC

Digital Output Module Specifications LED Display Not provided Terminal block Provided

AOA08E

Relay output

Polarity*

Negative: 0 V common (current source type); ON when input is at low level. Positive: 24 V common (current sink type); ON when input is at high level. Table 1–8.

Output Type Not fused DC output Fused DC output

Digital Input Module Specifications

Module Name AID32A

* Polarity is defined as follows:

Maximum Polarity* Points Current 0.3A NEG 32

Points/ Common 8

External Connection Connector

Fuses Not fused Fused

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

1. OVERVIEW

1–33

MARMMTRBL02303E

Table 1–9.

I/O Module Part Numbers Part Number

Name DC input module

Non-isolated

32 points 20 ms

AID32A

A03B-0807-C101

32 points 2 ms

AID32B

A03B-0807-C102

16 points NEG

AID16C

A03B-0807-C103

16 points POS

AID16D

A03B-0807-C104

32 points 20 ms

AID32E

A03B-0807-C105

32 points 2 ms

AID32F

A03B-0807-C106

AIA16G

A03B-0807-C107

32 points NEG

A0D32A

A03B-0807-C162

8 points NEG

AOD08C

A03B-0807-C151

8 points POS

AOD08D

A03B-0807-C152

16 points NEG

AOD16C

A03B-0807-C153

16 points POS

AOD16D

A03B-0807-C154

32 points NEG

AOD32C

A03B-0807-C155

32 points POS

AOD32D

AO3B-0807-C156

5 points, 2 A AOA05E

A03B-0807-C157

8 points 1A

AOA08E

A03B-0807-C158

12 points 0.5 A

AOA12F

A03B-0807-C159

8 points 4A

AOR08G

A03B-0807-C160

16 points 2A

AOR16G

A03B-0807-C161

Analog input module

AAD04A

A03B-0807-C051

Analog output module

ADA02A

A03B-0807-C052

Optically isolated

AC input module 16 points DC output Not fused module Fused

Not fused

AC output module

Relay output module

1. OVERVIEW MARMMTRBL02303E

1–34

1.10.2 Process I/O Board Refer to Table 1–10 for part numbers.

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

Discrete input lines - Inputs are 24 volt sensing receivers. Common voltage can be selected as +24VDC or ground.



Discrete output lines - Outputs are 24 volt sinking or sourcing devices.



Analog input lines - Analog inputs are A – D converters sensing an analog signal –10VDC to 0V or 0V to +10VDC, providing a digital signal to the processor.



Analog output lines - Analog outputs are D – A converters that output an analog signal –10VDC to 0V or 0V to +10VDC based on a command from the processor.

Figure 1–29. Process I/O Printed Circuit Board

1. OVERVIEW

1–35

MARMMTRBL02303E

Figure 1–30. Process I/O Printed Circuit Board

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

1. OVERVIEW MARMMTRBL02303E

1–36 Table 1–10. No.

Name

Process I/O Board Part Numbers Number of I/O Points

Part Number DI

DO

D/A

Remarks

A/D

1

Process I/O printed circuit board AA

A16B-2200-0780

40

40

2

4

Standard (with welding interface)

2

Process I/O printed circuit board AB

A16B-2200-0782

40

40

—

—

Standard (without welding interface)

3

Process I/O printed circuit board BA

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

32

32

2

4

Source type DO (with welding interface)

4

Process I/O printed circuit board BB

A16B-2201-0510

32

32

—

—

5

Process I/O printed circuit board CA

A16B-2201-0470

40

40

2

4

6

Process I/O printed circuit board CB

A16B-2201-0472

40

40

—

—

7

Process I/O printed circuit board DA

A16B-2201-0480

96

96

—

—

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

1. OVERVIEW

1–37

MARMMTRBL02303E

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

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

A User’s Guide to the FANUC Robotics Remote I/O Interface for an Allen-Bradley PLC A User’s Guide to the FANUC Robotics Genius Network Interface for GEFanuc (R-H Style Board in R-J Controller)

1. OVERVIEW

1–38

1.11 FUSED FLANGE DISCONNECT AND CIRCUIT BREAKER

1.12

MARMMTRBL02303E

The SYSTEM R-J controller is supplied with either a fused flange disconnect or a circuit breaker.

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

FUSED FLANGE DISCONNECT Fused Flange Disconnect Refer to Table 1–12 for fuse sizes, current rating, and part numbers.

The fused flange disconnect provides overcurrent protection supply through three fuses; one for each leg of the 3–phase supply. See Figure 1–31.

Circuit Breaker

The circuit breaker provides overcurrent protection to the controller and the supply. The circuit breaker is available with or without ground fault protection. See Figure 1–32.

Refer to Table 1–11 and Table 1–12 for current rating and part numbers.

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

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

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

1. OVERVIEW

1–39

MARMMTRBL02303E

Figure 1–31. Fused Flange Disconnect MAIN DISCONNECT

Fuse Block

FL1 FL2 FL3

Figure 1–32. Circuit Breaker

1. OVERVIEW MARMMTRBL02303E

1–40 Table 1–11.

Circuit Breaker, B-Size Cabinet

Input Voltage g

Circuit Breaker Current

Current

Part Number

50A

A60L-0001-0347 #B030S

30A

A60L-0001-0306 #BA

380 416 460 480 500 550

30A

A60L-0001-0347 #B015S

20A

A60L-0001-0306 #AA

15A

A60L-0001-0258 #SA538-15

Table 1–12. Cabinet Input Voltage

Part Number

220 240

575

Circuit Breaker

Circuit Breaker with Ground Fault

Not Available

Circuit Breaker and Fused Flange Disconnect Switch, C-Size

Circuit Breaker with Ground Fault

Current

Part Number

Current

Part Number

220 240

50A

A60L–0001-0308 #F050

50A

A60L–0001-0306 #DA

380 416 460 480 500 550

30A

A60L–0001-0347 #B030S

30A

A60L–0001-0307 #B20B3

575

20A

A60L–0001-0258 #SA53H-20

Fused Flange Disconnect Switch Fuse Size

Part Number

5A

A60L–0001-0181 #175 Fuse A60L–0001-0042 #JG2-50

30A

A60L–0001-0181 #175 Fuse A60L–0001-0042 #JG1-30

Not Available Table 1–13.

Fused Flange Disconnect Switch, C-Size Cabinet Fused Flange Disconnect Switch

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

Fuse Size

Part Number

50A

A60L–0001-0181 #175 Fuse A60L–0001-0042 #JG2-50

30A

A60L–0001-0181 #175 Fuse A60L–0001-0042 #JG1-30

1. OVERVIEW

1–41

MARMMTRBL02303E

1.13 USER TRANSFORMER

C-size controllers might contain an optional user transformer. It supplies 120VAC single-phase power to a NEMA outlet receptacle. It is located on the lower left side of the controller.

A80L-0001-0520 Figure 1–33. User Transformer

User Transformer TF2

1.14 OPERATOR PANEL Refer to Table 1–12 for part numbers.

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

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



DB–25 connector for serial interface (external disk drive, for example)



Disconnectable teach pendant port with a switch so the robot can be operated without the teach pendant connected.

1. OVERVIEW MARMMTRBL02303E

1–42

An emergency stop button on the operator panel places the robot into the emergency stop condition. The operator panel LED functions are described in Chapter 3, “Lights and LEDs”. Figure 1–34 shows the operator panel on a B-size controller. Figure 1–35 shows the operator panel on a C-size controller. Figure 1–36 shows the operator panel on a C-size controller. Figure 1–34. Operator Panel, B-Size Controller

ÑÑ ÑÑ ÑÑ ÑÑ ÑÑ ÑÑ ÑÑ ÑÑ

Ñ ÑÑ Ñ Ñ ÑÑÑ ÑÑ ÑÑÑÑ ÑÑ ÑÑ ÑÑÑÑ ÑÑÑ ÑÑ Ì ÑÑ Ì BATTERY

TEACH PENDANT ENABLED

HOUR METER

RS–232–C

CRT/KB

FAULT

FAULT RESET

HOLD

USER LED#1

USER PB#1

CYCLE START

USER LED#2

REMOTE

USER PB#2

REMOTE

ÑÑ ÑÑ ÑÑ ÑÑ ON

ALARM

OFF

ÑÑÑ ÑÑÑ EMERGENCY STOP

LOCAL

Figure 1–35. Operator Panel, C-Size Controller

Ñ ÑÑ ÑÑ Ñ ÑÑ Ñ ÑÑ Ñ Ñ ÑÑ Ì ÑÑ Ì Ñ ÑÑ BATTERY

ALARM

CYCLE START

ON

TEACH PENDANT ENABLED

HOLD

OFF

FAULT

FAULT RESET

REMOTE

USER LED#1

REMOTE

USER PB#1

LOCAL

USER LED#2

USER PB#2

HOUR METER

RS–232–C

CRT/KB

ÑÑÑ ÑÑÑ EMERGENCY STOP

1. OVERVIEW

1–43

MARMMTRBL02303E

Figure 1–36. Operator Panel, C-Size Controller

ÑÑ ÑÑ ÑÑ ÑÑ BATTERY ALARM

CYCLE START

ON

TEACH PENDANT ENABLED HOLD

OFF

FAULT

ÑÑ Ñ ÑÑ Ñ ÑÑ ÌÌ ÌÌ ÑÑ ÑÑ ÌÌ ÌÌ FAULT RESET

PURGE COMPLETE

REMOTE

PURGE ENABLE

REMOTE

LOCAL

PURGE FAULT

BRAKE ENABLE ON

HOUR METER

OFF

RS–232–C

CRT/KB

TEACH PENDANT CONNECT/ DISCONNECT

Optional

ÑÑ ÑÑ ÑÑ

EMERGENCY STOP

Table 1–14.

Part Numbers

Controller

Without Disconnectable Teach Pendant B-Size A05B-2302-C020 C-size with Built-In A05B-2301-C001 CRT/KB C-size with A05B-2301-C002 Remote CRT/KB Table 1–15.

With Disconnectable Teach Pendant A05B-2302-C021 A05B-2301-C003 A05B-2301-C004

Part Numbers

Controller

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

With Disconnectable Teach Pendant A05B-2308–H192 A05B-2308–H193

1. OVERVIEW

1–44

1.15 TEACH PENDANT Refer to Table 1–17 for part numbers.

MARMMTRBL02303E

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

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

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

1. OVERVIEW

1–45

MARMMTRBL02303E

Figure 1–37. Teach Pendant

LCD Display LEDs Emergency Stop Button

DEADMAN Switches

Application-Dependant Keys

Table 1–16.

Teach Pendant Part Numbers

Application Intrinsically Safe Non–Intrinsically Safe

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

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

Teach Pendant Intrinsically Safe Barrier PCB A05B–2308–C040

The teach pendant Intrinsically Safe Barrier PCB is mounted to the inside of the cabinet door. The two main connectors, CRS1 and CRS2 join the intrinsically safe teach pendant with the Main CPU. It is used to ensure that there not be enough energy to induce a spark within the teach pendant. This is accomplished by lowering the voltage and limiting current to the teach pendant through the use of Intrinsically Safe Barrier’s (refer to Section 1.19) and opto-isolation chips. Table 1–17.

Teach Pendant Part Numbers

Application Spot Welding Material Handling Arc Welding Sealing General Use

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

Comment Japanese

1. OVERVIEW MARMMTRBL02303E

1–46 Table 1–17. (Cont’d) Teach Pendant Part Numbers Application Spot Welding Material Handling Arc Welding Sealing General Use

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

Comment English g

1. OVERVIEW

1–47

MARMMTRBL02303E

1.16 HEAT EXCHANGE AND FANS Refer to Figure 1–39 for part numbers

The temperature in the controller is kept within operating range through the use of an air-to-air heat exchange system. The controller is sealed to prohibit outside air from entering. Internal controller air is circulated by fans around the inside of the controller and downward through the internal side of the heat exchange unit. Outside air is circulated upward through the external side of the heat exchange unit also by using a fan. This process cools the inside air. Fans are provided on the printed circuit board racks mounted on the backplane to circulate air over the printed circuit boards. Cooling fins connected to the servo amplifiers are within the heat exchange unit to keep the heat generated by the servo power circuits out of the controller. Figure 1–38 shows the heat exchange system for a B-size controller. Figure 1–39 shows the heat exchange system for a C-size controller. Figure 1–39 shows the heat exchange system for a C-size controller. Figure 1–38. Heat Exchange System, B-Size Controller

FANS

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

AIR FLOW INTERNAL AIR OUTSIDE AIR

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

OUTSIDE AIR IN

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

1. OVERVIEW MARMMTRBL02303E

1–48 Figure 1–39. Heat Exchange System, C-Size Controller Fan (Alone) A90L-0001-0378

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

AIR FLOW INTERNAL AIR OUTSIDE AIR FANS

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

FAN 3 Fan Unit A02B–0056-C904 Fan Alone A90L-0001-0219 #A

1.17 PURGE SYSTEM IBRC A152–0001–0020

OUTSIDE AIR IN

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

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

1. OVERVIEW MARMMTRBL02303E

1–49 The IBRC requires 210VAC from a secondary winding of TF1 to operate. Internal circuitry provides 20VDC to the hazardous side terminals which are isolated from the safe side terminals and their voltage of 24VDC. There are ten red LEDs, one for each device used in the field. There are a pair of terminals, labeled Px and Nx, for each hazardous signal, while the corresponding safe side terminals have Ax, Bx, and Cx. Cx is the 24VDC input, and Ax and Bx are the normally open and normally closed contact outputs respectively. When voltage is being applied to the field switch device contacts and they are closed, the IBRC LED will be illuminated for that particular contact. Should a jumper be installed across the P and N terminals, the LED for those terminals will be illuminated. With plant air supplied to the robot, and power available to the IBRC through the disconnect switch in the ON position, PS-1 LED should be illuminated.

1.18 PURGE UNIT POWER SUPPLY A05B–2308–C040

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

1.19 INTRINSICALLY SAFE BARRIERS (STAHL) ISBM890131280XX

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

1. OVERVIEW

1–50

MARMMTRBL02303E

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

1.20 TRANSIT BOARD A05B–2308–C030

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

MARMMTRBL02303E

2

DIAGNOSTIC SCREENS 2–1 Various built–in diagnostic screens reveal important information regarding the status of the SYSTEM R-J Controller. These screens with explanations of the screen data are presented in this section. Figure 2–1. Default Power–Up Screen

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

OFF

MENUS Key Used to select the teach pendant menus

SELECT Key Used to SELECT and create programs

HELP

ON

DATA Key Examine and change data register contents

EDIT Key Used to edit a particular program

The UTILITY Hints screen, shown in Figure 2–1, is the first screen to appear in the menu structure; this is the starting level to the rest of the diagnostic screens. Most operations begin by pressing MENUS. The F1, [TYPE] function key will show submenus within any menu shown on the screen. This chapter contains information about the following diagnostic screens:  Safety signals  Position display  Robot Axes – motion  Alarm log  Version IDs  Memory

2. DIAGNOSTIC SCREENS

2–2

MARMMTRBL02303E

2.1 SAFETY SIGNAL STATUS

The STATUS Safety signal screen displays the status of safety-related control signals coming into the controller. The safety signal screen displays the current state (TRUE or FALSE) of each safety signal. You cannot change the condition of the safety signal using this screen. Table 2–1 lists and describes each safety signal. Use Procedure 2–1 to display safety signal status. Table 2–1.

SAFETY SIGNAL

Safety Signals DESCRIPTION

SOP E-Stop

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

TP E-Stop

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

Ext E-Stop

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

Fence Open

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

TP Deadman

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

TP Enable

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

Overtravel

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

Low Air Alarm

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

2. DIAGNOSTIC SCREENS

2–3

MARMMTRBL02303E

Procedure 2–1 Step

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

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

[ TYPE ]

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

10 % 1/10

2. DIAGNOSTIC SCREENS

2–4

2.2 POSITION STATUS

MARMMTRBL02303E

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

Joint

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

User

The user screen displays positional information in Cartesian coordinates based on the user frame. Tool indicates the number of the active tool frame. Frame indicates the number of the active user frame.

World

The world screen displays positional information in Cartesian coordinates based on the world frame. Tool indicates the number of the active tool frame. Use Procedure 2–2 to display position status.

2. DIAGNOSTIC SCREENS

2–5

MARMMTRBL02303E

Procedure 2–2 Step

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

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

POSITION Joint J1: J4: E1:

JOINT

.001 J2: –.000 J5: .001 E2:

[ TYPE ]

JNT

10.028 J3: 34.998 J6: .001 E3:

USER

10 % Tool: 1

–35.025 .001 .001

WORLD

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

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

POSITION User

USER Frame: 0

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

[ TYPE ]

JNT

USER

10 % Tool: 1

z: 361.121 r: 1.249 E3: .001

WORLD

2. DIAGNOSTIC SCREENS

2–6

MARMMTRBL02303E



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

POSITION World

WORLD

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

[ TYPE ]

JNT

USER

10 % Tool: 1

z: 361.121 r: 1.249 E3: .001

WORLD

2. DIAGNOSTIC SCREENS

2–7

MARMMTRBL02303E

2.3 ROBOT AXES STATUS

The robot axes status screen displays information for each robot axis. This information is continually updated. Use this information when you call the FANUC Robotics Hotline if a problem occurs with your robot. The Axis Status Pulse screen displays information about axis motion. Table 2–2 lists and describes each kind of information displayed on this screen. Use Procedure 2–3 to display the axis status pulse screen. Table 2–2.

Axis Status Pulse Screen Items

ITEM

DESCRIPTION

Motion Command

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

Machine Pulse

Shows the actual APC count as read by the controller.

Position Error

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

You cannot change any information on this screen except for the group number. Group number only applies if you have multiple groups; otherwise, it remains as 1. Procedure 2–3 Step

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

For Pulse, press F4, PULSE.

STATUS

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

JOINT

Position Error 0 0 0 0 0 0

[ TYPE ]

STATUS1

Machine Pulse 00000000 00000000 00000000 00000000 00000000 00000000

STATUS2

10 %

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

PULSE

GRP# >

2. DIAGNOSTIC SCREENS MARMMTRBL02303E

2–8

2.4 ALARM LOG

The Alarm Log displays a list of the 100 most recent alarms. Figure 2–2 shows an example of the Alarm Log. Figure 2–2. Alarm Log

1 2 3

SRVO–049 OHAL 1 alarm (Group=1 Axis=6) PROGRAM LINE 4 Alarm JOINT 10% 1/100 1 SRVO–049 OHAL 1 alarm (Group:1 Axis:6) 2 SRVO–042 MCAL 1 Alarm (Group:1 Axis:6) 3 R E S E T

[ TYPE ]

CLEAR

4

HELP

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

2. DIAGNOSTIC SCREENS

2–9

MARMMTRBL02303E

Procedure 2–4 Condition Step

Displaying the Alarm Log 

An error has occurred.

1 Press MENUS. 2 Select ALARM. 3 Press F1, [TYPE]. 4 Select Alarm Log. The alarm log will be displayed. This lists all errors. See the following screen for an example. SRVO–002 Teach pendant emergency stop TEST1 LINE 15 ABORTED Alarm WORLD 100 % 1/100 1 SRVO–002 Teach pendant emergency sto 2 SRVO–001 Operator panel emergency st 3 R E S E T 4 SRVO–029 Robot calibrated (Group:1) 5 SRVO–001 Operator panel emergency st 6 SRVO–012 Power fail recovery 7 INTP–127 Power fail detected 8 SRVO–047 LVAL alarm (Group:1 Axis:5) 9 SRVO–047 LVAL alarm (Group:1 Axis:4) 10 SRVO–002 Teach pendant emergency sto [ TYPE ]

CLEAR

HELP

The most recent error is number 1. 5 To display the motion log, which lists only motion-related errors, press F1, [TYPE], and select Motion Log. 6 To display the system log, which displays only system errors, press F1, [TYPE], and select System Log. 7 To display the application log, which displays only application-related errors, press F1, [TYPE], and select Appl Log. 8 To display more information about an error, move the cursor to the error and press F5, HELP. The error help screen displays information specific to the error you selected. When you are finished viewing the information, press PREV. 9 To remove all of the error messages displayed on the screen, press F4, CLEAR.

2. DIAGNOSTIC SCREENS

2–10

MARMMTRBL02303E

2.5 VERSION IDENTIFICATION STATUS

The STATUS Version IDs screen displays information specific to your controller. Use this information when you call the FANUC Robotics Hotline if a problem occurs with your controller. You cannot change the information displayed on this screen. Table 2–3 lists and describes the version identification status information. Table 2–3. Version Identification Status Items

VERSION ID ITEM

DESCRIPTION

Appl/Tool

The name of the application package.

Appl/Tool ID

The version number of the application package.

Robot Model

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

S/W Serial Number

The software order number for the disk set.

Core Name

The name of the core software.

Core ID

The version number of the core software.

Library Name

The name of the robot library.

Library ID

The version number of the robot library.

Servo Code ID

The version of servo parameters installed.

Mot Param ID

The software version for the software that controls motion

Update #1–10

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

Build ID

Internal software version information.

Use Procedure 2–5 to display version identification status.

2. DIAGNOSTIC SCREENS

2–11

MARMMTRBL02303E

Procedure 2–5 Step

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

JOINT 10 % SOFTWARE: Std System Core V3.06P S500–INLN F00000 Std System Core V3.06 Std Robot Library V3.06P J03.00 V1.00 Uninitialized

20 Update #10: 21 Build ID:

Uninitialized V3.06 02/13/9X

[ TYPE ] SOFTWARE

MOT_ID

MOT_INF

SER_PAR

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

To display software version information, press F2, SOFTWARE.



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

STATUS Version IDs 1 1: 2: 3: 4: 5: 6: 7: 8: 9: 10:

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

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

[ TYPE ] SOFTWARE

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

MOT_INF

10 % 1/16

SER_PAR

2. DIAGNOSTIC SCREENS

2–12

MARMMTRBL02303E



To display the motor information for each axis, press F4, MOT_INF. You will see a screen similar to the following.

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



JOINT 10 % MOTOR INFO: 1/16 H1 DSP1–L H2 DSP1–M H3 DSP2–L H4 DSP2–M H5 DSP3–L H6 DSP3–M Uninitialized Uninitialized Uninitialized Uninitialized MOT_ID

MOT_INF

SER_PAR

To display the servo parameters for each axis, press F5, SER_PAR. You will see a screen similar to the following.

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

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

MOT_INF

SER_PAR

2. DIAGNOSTIC SCREENS

2–13

MARMMTRBL02303E

2.6

The STATUS Memory screen displays information about controller memory. Table 2–4 lists and describes each memory status item. Use Procedure 2–6 to display memory status.

MEMORY STATUS

Table 2–4. Memory Status MEMORY STATUS

DESCRIPTION

User

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

System

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

Hardware

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

Procedure 2–6 Step

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

JOINT

100 %

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

18.2KB 91.3KB 547.6KB

MARMMTRBL02303E

3

LIGHTS AND LEDS 3–1 This chapter describes the lights and LEDs you can use for diagnostics:   

Teach pendant LEDs Operator panel LEDs Circuit board diagnostic LEDs

3. LIGHTS AND LEDS MARMMTRBL02303E

3–2

3.1 TEACH PENDANT DIAGNOSTIC LEDS

The non-intrinsically safe teach pendant has several LEDs to assist you in determining the status of the controller. Figure 3–1 shows the teach pendant LEDs. Table 3–1 lists and describes the teach pendant LEDs. The LEDs whose labels are blank vary depending on the particular application. On the Intrinsically Safe Teach Pendant, these LEDs are simulated by symbols on the teach pendant display. Refer to the Setup and Operations Manual for your application for information on application-specific LEDs. Figure 3–1. Teach Pendant LEDs

ApplicationSpecific LEDs

ÑÑ ÑÑ ÑÑ ÑÑ ÑÑ ÑÑ ÑÑ ÑÑ

FAULT HOLD STEP BUSY RUNNING

JOINT XYZ TOOL

OFF

Table 3–1.

ON

Teach Pendant Status Indicators

INDICATOR

DESCRIPTION

FAULT

Indicates that a fault condition has occurred.

HOLD

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

STEP

Indicates that the robot is in step mode.

BUSY

Indicates that the controller is processing information.

RUNNING

Indicates that a program is being executed.

JOINT

Indicates that the current jog coordinate system is JOINT.

XYZ

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

XYZ

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

TOOL

Indicates that the current jog coordinate system is TOOL.

3. LIGHTS AND LEDS

3–3

MARMMTRBL02303E

3.2 OPERATOR PANEL DIAGNOSTIC LEDS

The operator panel has several LEDs to assist you in determining the status of the controller. Figure 3–2 shows the operator panel LEDs. Table 3–2 lists and describes the operator panel LEDs. Figure 3–2. Operator Panel LEDS

Ñ Ñ Ñ Ñ

BATTERY ALARM

CYCLE START

ON

TEACH PENDANT ENABLED HOLD

OFF

FAULT

Ñ Ñ ÑÑ Ñ Ñ ÑÑ

FAULT RESET

USER LED#1

USER PB#1

USER LED#2

USER PB#2

RS–232–C

ÑÑ ÑÑ ÌÌ ÌÌ REMOTE

REMOTE

LOCAL

HOUR METER

CRT/KB

ÑÑÑ ÑÑÑ ÑÑÑ

EMERGENCY STOP

3. LIGHTS AND LEDS MARMMTRBL02303E

3–4 Figure 3–3. Operator Panel LEDS

ÑÑ ÑÑÑ ÑÑ Ñ ÑÑÑ ÑÑÑ

BATTERY ALARM

CYCLE START

ON

TEACH PENDANT ENABLED HOLD

OFF

FAULT

ÑÑ Ñ ÑÑ ÌÌ ÌÌ ÑÑ ÑÑ ÑÑ ÑÑ ÌÌ FAULT RESET

PURGE COMPLETE

REMOTE

PURGE ENABLE

REMOTE

LOCAL

PURGE FAULT

BRAKE ENABLE ON

OFF

RS–232–C

CRT/KB

HOUR METER

TEACH PENDANT CONNECT/ DISCONNECT

Optional

ÑÑÑ ÑÑÑ ÑÑÑ

EMERGENCY STOP

Table 3–2. INDICATOR BATTERY ALARM TEACH PENDANT ENABLED FAULT REMOTE

USER LED #1 USER LED #2 PURGE COMPLETE

Standard Operator Panel C-Size Controller Status Indicators

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

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

3. LIGHTS AND LEDS

3–5

MARMMTRBL02303E

3.3 CIRCUIT BOARD DIAGNOSTIC LEDS

The R–J Controller contains several diagnostic LEDs within the controller. They are on the circuit boards that plug into the backplane, on the servo amplifiers, and on the modular I/O unit. Figure 3–4 shows an overview of the circuit board diagnostic LEDs. Refer to the sections that follow for descriptions of the following circuit board diagnostic LEDs:          

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

3. LIGHTS AND LEDS MARMMTRBL02303E

3–6 Figure 3–4. Circuit Board Diagnostic LEDs

OPTIONAL INTERFACE MODULE LEDS Section 3.3.7

OPTIONAL PROCESS I/O BOARD LEDS Section 3.3.8

OPTIONAL I/O MODULE LEDS Section 3.3.7

MAIN CPU BOARD LEDS Section 3.3.4

AXIS CONTROL BOARD LEDS Section 3.3.3

PSU BOARD LEDS Section 3.3.2

EMG BOARD LEDS Section 3.3.1

SERVO AMPLIFIER DIAGNOSTIC LED (7–SEG) Section 3.3.5

3. LIGHTS AND LEDS

3–7

MARMMTRBL02303E

Figure 3–5. Circuit Board Diagnostic LEDs

INTERFACE MODULE LEDS Section 3.3.7

IBRC LEDS

I/O MODULE LEDS Section 3.3.7

OPTIONAL KRIO/GEF/MAP MODULES Sections 3.3.10 and 3.3.11

MAIN CPU BOARD LEDS Section 3.3.4

AXIS CONTROL BOARD LEDS Section 3.3.3

PSU BOARD LEDS Section 3.3.2

EMG BOARD LEDS Section 3.3.1

SERVO AMPLIFIER DIAGNOSTIC LED (7–SEG) Section 3.3.5

3. LIGHTS AND LEDS MARMMTRBL02303E

3–8

3.3.1 Emergency Control Board (EMG) Diagnostic LEDs

Figure 3–7 shows the emergency control board (EMG) diagnostic LEDs. Table 3–4 lists and describes each LED. Figure 3–6. Emergency Control Board (EMG) Diagnostic LEDs

SON

BRKL

BRK1

BRK4

BRK2

BRK5

BRK3

BRK6

FALM

3. LIGHTS AND LEDS

3–9

MARMMTRBL02303E

Figure 3–7. Emergency Control Board (EMG) Diagnostic LEDs

BRK4

NOT USED

BRK5

BRK6

FALM

Table 3–3.

BRK1

SON

BRK2

BRK3

Emergency Control Board (EMG) Diagnostic LEDs

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

Name Servo on

BRK4* (Green) BRK5* (Green)

Brake Circuit 4 Release Brake Circuit 5 Release

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

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

3. LIGHTS AND LEDS MARMMTRBL02303E

3–10

Table 3–3. (Cont’d) Emergency Control Board (EMG) Diagnostic LEDs LED BRK6* (Green) BRKL Table 3–4.

Name Brake Circuit 6 Release Manual Brake Release

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

Emergency Control Board (EMG) Diagnostic LEDs

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

Name Servo on

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

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

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

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

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

3. LIGHTS AND LEDS

3–11

MARMMTRBL02303E

3.3.2

Figure 3–8 shows each power supply unit (PSU) diagnostic LED.

Power Supply Unit (PSU) Diagnostic LEDs

Figure 3–8. Power Supply Unit (PSU) Diagnostic LEDs

PSU

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

3. LIGHTS AND LEDS MARMMTRBL02303E

3–12

3.3.3 Axis Control Board Diagnostic LEDs

The four green status LEDs will also light on the axis control printed circuit board at power on and then change during software initialization. See Figure 3–9. Figure 3–9. Axis Control Board Diagnostic LEDs

1

2

3

4

STATUS ALARM

Table 3–5 contains supplementary troubleshooting information.

3. LIGHTS AND LEDS

3–13

MARMMTRBL02303E

Table 3–5.

Troubleshooting Axis Control Board Diagnostic LEDs

Remarks

LEDs

Procedure

1

2

3

4

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

1

2

3

4

Lights go out and initialization of each printed circuit board begins.

STATUS ALARM

STATUS ALARM

1. Check the power supply output voltages. Replace if necessary. 2. Replace the axis control board. 3. Test FROM* and CMOS from the BMON screen and replace as necessary.

1

2

3

4

Timer initialization

STATUS ALARM

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

2

3

4

Initialization of communication

STATUS ALARM

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

1

2

3

4

Initialization of software

STATUS ALARM

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

1

2

3

4

Initialization of software

STATUS ALARM

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

1

2

3

4

Initialization of software

STATUS ALARM

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

1

2

3

4

Initialization of software

STATUS ALARM

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

1 STATUS ALARM

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

2

3

4

Initialization of software

1. Replace the axis control printed circuit board.

3. LIGHTS AND LEDS MARMMTRBL02303E

3–14

Table 3–5. (Cont’d) Troubleshooting Axis Control Board Diagnostic LEDs LEDs 1

2

Remarks 3

4

Initialization of software

STATUS ALARM

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

1

2

3

4

STATUS ALARM

Communication to teach pendant

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

1

2

3

4

STATUS ALARM

Communication to process I/O or modular I/O

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

1

2

3

4

Initialization of software

STATUS ALARM

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

1

2

3

4

Initialization of software

STATUS ALARM

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

1

2

3

4

Teach pendant banner page displayed

1. Replace the teach pendant.

1

2

3

4

Initialization of software

1. Replace the axis control board.

STATUS ALARM

STATUS ALARM

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

STATUS ALARM

2

3

4

Robot is working fine

3. LIGHTS AND LEDS

3–15

MARMMTRBL02303E

Table 3–5. (Cont’d) Troubleshooting Axis Control Board Diagnostic LEDs LEDs

Remarks

2

3

4

Servo alarm on Axis Control printed circuit board.

1. Replace the Axis Control printed circuit board.

1

2

3

4

(SYSFAIL) Voltage level too low on *EN signal

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

STATUS ALARM

STATUS ALARM

Procedure

1

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

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

3. LIGHTS AND LEDS MARMMTRBL02303E

3–16

3.3.4

The Main CPU printed circuit board alarm LEDs are shown in Figure 3–10. Table 3–6 provides supplementary troubleshooting information.

Main CPU Board Diagnostic LEDs

Figure 3–10. Main CPU Board Diagnostic LEDs

1

2

3 4

STATUS ALARM

Table 3–6. Remarks

LEDs 1

2

Troubleshooting Main CPU Board Diagnostic LEDs

3

4

STATUS ALARM

Parity alarm on CMOS RAM in the Main CPU.

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

1

2

3

4

The battery voltage that backs up the MAIN CPU CMOS RAM memory is low.

Replace the battery, using Procedure 9–1.

1

2

3

4

An error is encountered in the serial link.

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

STATUS ALARM

STATUS ALARM

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

2

3

4

Normal status

Controller should be operational.

3. LIGHTS AND LEDS

3–17

MARMMTRBL02303E

3.3.5

Table 3–7 shows and describes each servo amplifier diagnostic LED.

Servo Amplifier Diagnostic LED (7-Segment Display) Table 3–7. Name Overvoltage(HV)

Indication

Servo Amplifier LED Functions Description

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

Insufficient voltage of the control power supply (LV5V)

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

Insufficient DC link voltage (LVDC)

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

Faulty regenerative control circuit (DCSW)

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

Excessive regenerative discharge (DCOH)

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

Servo amplifier overheat (OH)

The thermostat in the servo amplifier operated. (Thermostat contact opened) Refer to Error code: SRVO-049 for troubleshooting information.

Welded electromagnetic contactor (MCC)

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

Overcurrent (HCL)

An overcurrent was detected in the one–axis servo amplifier or the L–axis circuit of the two–axis servo amplifier. Refer to Error code: SRVO-045 for troubleshooting information.

Overcurrent (HCM)

An overcurrent was detected in the M–axis circuit of the two–axis servo amplifier. Refer to Error code: SRVO-045 for troubleshooting information.

Overcurrent (HCLM)

An overcurrent was detected in both the L–axis and M–axis circuit of the two–axis servo amplifier. Refer to Error code: SRVO-045 for troubleshooting information.

Servo amplifier not ready Servo amplifier ready

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

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

3. LIGHTS AND LEDS MARMMTRBL02303E

3–18

3.3.6 Contact Signal Transducer (IBRC)

The LEDs associated with the IBRC are indicators that input terminals P and N have been closed in the circuit loop for that LED’s channel. Figure 3–11 shows the IBRC. Figure 3–11. IBRC

3. LIGHTS AND LEDS

3–19

MARMMTRBL02303E

3.3.7 Modular I/O LEDs

The LEDs associated with module I/O are on the interface module printed circuit board and on each I/O module. Figure 3–12 shows the modular I/O LEDs. Table 3–8 describes each modular I/O LED. Figure 3–12. Modular I/O LEDs

LEDS PWR

LINK

A0 1 2 3 4 5 6 7

BAI

LEDS

BAO

B0 1 2 3 4 5 6 7

AIF0IA

JD1B

JD1A

CP32

JD2

INTERFACE MODULE

Table 3–8.

I/O MODULE

Modular I/O LEDs

LED PWR Link

Location Interface module Interface module

BA1

Interface module

BA0

Interface module

A01234567 B01234567

I/O Module

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

Indicates if the input or output is on.

3. LIGHTS AND LEDS MARMMTRBL02303E

3–20

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

1

2

3

Figure 3–13 shows the process I/O board diagnostic LEDs. Table 7–1 shows and describes each process I/O board diagnostic LED. Figure 3–13. Process I/O Board Diagnostic LEDs

AA, AB, BB, BA, CA Process I/O Board (front view)

ALM0

FALM

4

STATUS ALARM

Table 3–9.

ALM0

FALM

Process I/O Board Diagnostic LEDs

CB, DA

AA, AB, BB, BA, CA

Color

Process I/O PCB

ALM0

1

2

3

Description

Red

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

Red

A fuse (FUSE 1) in the process I/O board blew. Replace fuse. If fuse blows again, replace board.

Green

Indicates the operations status of the process I/O board.

4

STATUS ALARM

ALM0 Process I/O PCB

FALM

FALM

1

2

3

4

STATUS ALARM

Process I/O PCB

1 STATUS ALARM

2

3

4

3. LIGHTS AND LEDS

3–21

MARMMTRBL02303E

3.3.9

Table 3–10 shows and describes each process I/O board diagnostic LED.

(Optional) Process I/O Board Diagnostic LEDs

Table 3–10. Process I/O Board LEDs

RED

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

RED

A fuse (FUSE 1) in the process input/output blew. Replace fuse. If fuse blows again, replace board.

GREEN

Indicates the operations status of the Process I/O Board.

Process I/O PCB 1

1

2

3

4

2

3

4

STATUS ALARM

STATUS ALARM Process I/O PCB 1

2

3

4

STATUS ALARM

Process I/O PCB 1 STATUS ALARM

2

3

4

3. LIGHTS AND LEDS MARMMTRBL02303E

3–22

3.3.10 R-H MAP INTERFACE LEDs

Figure 3–14 shows each R–H MAP Interface LED. Table 3–11 describes each LED.

Figure 3–14. R–H MAP LEDs

Table 3–11.

D

B

C

R-H MAP LEDs

LED Meaning A System fail (RED)

B C D

A

Not used Not used Not used

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

3. LIGHTS AND LEDS

3–23

MARMMTRBL02303E

3.3.11

Figure 4–1 shows and Table 3–12 describes the R-H ABRIO LEDs.

R-H ABRIO LEDs

Figure 4–1. R-H ABRIO LEDs

POWER ACTIVE INTERBRD FAULT PC COMM FAULT PROC FAULT

LED POWER (green)

Table 3–12. R-H ABRIO LED Descriptions On Flashing There is power to the ABRIO board. Not applicable

Off There is no power to the ABRIO board.

ACTIVE (green)

The ABRIO board is communicating with the PLC’s remote I/O scanner and the PLC is in run mode. Input and output data in the ABRIO board is being updated.

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

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

INTERBOARD COMMUNICATION FAULT (red)

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

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

Normal operation

PC COMMUNICATIONS FAULT (red)

ABRIO board is not communicating properly with the PLC remote I/O scanner. The remote I/O scanner might be faulted or a problem might exist on the serial channel.

Not applicable

Normal operation

PROCESSOR FAULT (red)

This LED is normally on for  to 2 seconds during initialization to indicate that the ABRIO board is performing its power up diagnostics. The LED is turned off after diagnostics have been completed successfully and the R-J controller’s operation code has been set. If, after initialization, this LED is on, this indicates a fault in the ABRIO board hardware (RAM integrity, EPROM checksum, or CPU watchdog timeout). Communication with the PLC’s remote I/O scanner and with the R-J controller has been stopped. When this LED is on, all other LEDs except Power should be off.

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

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

MARMMTRBL02303E

4

TROUBLESHOOTING 4–1 This chapter describes the steps used to repair electrical faults in the robot.

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

Electrical faults are divided into three classes of symptoms: 

A Class 1 Fault is a malfunction that prevents the controller from operating. The main contactor might or might not be energized. No text is displayed on the teach pendant.



A Class 2 Fault is a malfunction that prevents the bootROM from turning the system over to the application software. Text will be displayed on the the teach pendant, but the teach pendant display will be frozen and will not respond to keypad entries.



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

If your robot has a class 1 fault, refer to Section 4.1. If your robot has a class 2 fault, refer to Section 4.2. If your robot has a class 3 fault, refer to Section 4.3.

4. TROUBLESHOOTING MARMMTRBL02303E

4–2

4.1

To enable the user with a quick reference guide to powering on a P-155 controller, the following steps and events should be followed:

POWER ON SEQUENCE Procedure 4–1 Step

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

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

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

Purge solenoid engages when minimum pressure requirements are met. Purge fault LED goes out Purging lamp (behind purge enable pushbutton) lights.

At this point you can release the purge enable pushbutton, no change should occur. 3 At the end of the 5 minute purge, the purging lamp (behind the purge enable pushbutton) will go out and the purge complete LED lights. Also, the purge solenoid shuts off. Procedure 4–2 Step

Enabling Power 1 With purge complete, you should observe:    

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

2 Push the ON pushbutton. You should observe:  

ON pushbutton lamp lights Main CPU and axis control PCBs go through internal diagnostics

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

4. TROUBLESHOOTING

4–3

MARMMTRBL02303E

4.2 CLASS 1 FAULT TROUBLESHOOTING

How to use the Troubleshooting Tables

This section contains troubleshooting information for Class 1 Faults. A Class 1 fault prevents the controller from operating. The main ALC contactor might or might not be energized. The Purge Complete light might or might not be on. No text is displayed on the teach pendant or CRT. This section contains several tables. Each table provides procedures to correct the fault. To troubleshoot a Class 1 fault, always start at Table 4–4. Perform the procedures in order. You will either correct the fault using Table 4–4 or it will refer you to another table in this section. Use the other tables only when Table 4–4 refers you to them.

Class 1 Fault Condition

If the following conditions are true, follow the steps in Table 4–4.    

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

4. TROUBLESHOOTING MARMMTRBL02303E

4–4

Without turning off the main disconnect, open the controller door: Release the disconnect latch by turning the screw to the lower right of the disconnect handle. Table 4–1.

Troubleshooting Procedure 1 Illustration

Troubleshooting Procedure 1. Find the Purge Complete light on the SOP.  The light is on indicating that the purge cycle was successful. If the light is on  go to Table 4–5. If the light is off  continue.

ÏÏ Ï Ï ÏÏ Ï ÏÏ Ï Ï ÏÏ Î Ï ÏÏÎ ÏÏ ÏÏ ÏÏ Ï Ï Ï Ï Ï ÏÏ Î Ï ÏÏÎ

Chapter 13 Print Reference 08–06

H OL D

Purge Complete Light

2. Find the Purge Fault LED on the SOP. If the LED is on  go to Step 4. If the light is out  continue.

H OL D

Purge Fault

ÏÏÏ ÏÏÏ

08–06

4. TROUBLESHOOTING

4–5

MARMMTRBL02303E

Table 4–1. (Cont’d) Troubleshooting Procedure 1 Troubleshooting Procedure

Illustration

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

Ï Ï Ï Ï Ï ÏÏ Î Ï ÏÏÎ ÏÏ ÏÏ ÏÏ

Chapter 13 Print Reference 08–05 08–06 08–10

H OL D

Purge Fault Light

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

08–21 08–22 08–34 08–35 08–25 08–26

6. Turn on the power disconnect handle. 7. Press and hold the Purge Enable pushbutton on the SOP until it lights (1 – 5 seconds) and then release.  If the purge circuit is cycling, the purge enable lamp (purging) should stay lit until the 5 minute purge is complete. The Purge Fault LED will be out.  If the purge enable (purging) lamp does not stay lit, replace the purge control PCB (piggy-back to EMG control PCB).  If the purge enable (purging) lamp will not light, go to Table 4–2.  If, during the purge cycle, the Purge Fault LED lights, go to Table 4–2.  If, after the 5 minute purge cycle, the Purge Complete light comes on, locate and repair the break in the air pressure and/or air flow switch circuits to the robot.  If the purge is too long or too short, the timer on the purge control PCB is incorrectly set or damaged. Repair or replace it.

08–05 08–08

08–11 08–06

09–43

4. TROUBLESHOOTING MARMMTRBL02303E

4–6 Table 4–2.

Troubleshooting Procedure 2 Illustration

Troubleshooting Procedure

Chapter 13 Print Reference

1. Observe on the IBRC Unit that:  Red lights on the IBRC panel indicate that 200 VAC is supplied to it. If all of the lights are off  continue. If one or more of the lights are on  go to Table 4–3.

2. Measure the AC voltage coming into the IBRC unit.  You should see 200 – 240 VAC. If the voltage is OK  replace the IBRC Unit.

07–10

TF1 43

If there is no voltage  troubleshoot the AC power distribution circuit shown at the right. G

44

R

S

R

S

1 2 FRA

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

Table 4–3.

Troubleshooting Procedure 3

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

Illustration

Chapter 13 Print Reference 08–19 08–26

If either LED 1 and 5 are out  go to Step 8. 2. Turn off the power disconnect handle. 3. Reseat the following connectors:  Contact signal transducer (IBRC) connector CRX  Purge transit board connector CRX3  Purge transit board connector CRX1  Purge control PCB (mounted with EMG control PCB) connector CRX. 4. Turn on the power disconnect handle.

08–19 thru 08–43 09–25 thru 09–50

4. TROUBLESHOOTING

4–7

MARMMTRBL02303E

Table 4–3. (Cont’d) Troubleshooting Procedure 3 Troubleshooting Procedure

Illustration

5. Observe on the SOP that:  Purge fault LED is lit

Ï Ï Ï Ï Ï ÏÏ ÎÎ Ï ÏÏÎ ÏÏÏ ÏÏÏ ÏÏÏ

Chapter 13 Print Reference 08–10

H OL D

Purge Fault

6. Re-initiate the purge sequence. See Section 4.1. If the controller does not operate properly, continue. 7. Measure the DC voltage between the white and black wires in the wiring harness at connector CRX5 (A1 and A2) of the Transit Board.  You should see 24 VDC. If the voltage is OK  go to Step 10.

08–15

If there is no voltage  replace the Purge Power Supply Board (PSU2). Note: The Purge Power Supply Board (PSU2) contains two fuses that can be checked after the board is removed from the controller. If you wish, you can perform the following steps after the board is removed: 1. Check the fuses. 2. If a fuse is bad, replace it and reinstall PSU2. 3. If a fuse blows again, replace PSU2. 8. If, on the IBRC unit, channel 5 LED is out, jumper terminals P5 to N5 and observe if the LED lights. If the LED does not light  replace the IBRC unit. If the LED lights  repair the auxiliary flow switch or wiring for proper operation or replace the jumper when auxiliary flow switch is not used.

08–25

4. TROUBLESHOOTING MARMMTRBL02303E

4–8 Table 4–3. (Cont’d) Troubleshooting Procedure 3 Troubleshooting Procedure

Illustration

9. If channel 1 LED is out, jumper terminals P1 to N1 and observe if the LED lights. If the LED does not light  replace the IBRC unit.

Chapter 13 Print Reference 08–21

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

Table 4–4.

Troubleshooting Procedure 1

Table 4–5.

Troubleshooting Procedure 4

Troubleshooting Procedure 1. Find the green PIL light in the center of the PSU module.  The light is on indicating 200VAC to PSU through F5. If the light is on  go to Table 4–3.

Illustration

PSU Module

Chapter 13 Print Reference 02–18 02–16 02-19

If the light is off  continue.

F1 and F2: 10-A fuses for AC input PIL: Green LED for indicating the AC power supply status

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

PSU Module

02–08 02–10 02-8

F1 and F2: 10-A fuses for AC input

02-10

4. TROUBLESHOOTING

4–9

MARMMTRBL02303E

Table 4–5. (Cont’d) Troubleshooting Procedure 4 Troubleshooting Procedure

Illustration

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

Chapter 13 Print Reference 02–18 thru 02–23 02–19 02-18 thru 02-22

If the fuse(s) blow again  Replace the PSU. If the PIL light comes on  go to step 8. 4. Disconnect CP1 at the top of the PSU module. Measure the voltage coming into the PSU on the two red wires in the harness connector (S and R).  You should see 200VAC. If the voltage is ok  Continue. If no voltage  go to Table 4–2.

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

02–08 thru 02–10

PSU Module

02-08 CP1 3 G 2 S 1 R

02–15

PSU Module

02-16

F5: 0.3-A Fuse for auxiliary power supply

6. Using an ohmmeter, check fuse. If the fuse is good  Replace the PSU.

02–15 02-16

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

PSU Module

F5: 0.3-A Fuse for auxiliary power supply

4. TROUBLESHOOTING MARMMTRBL02303E

4–10 Table 4–5. (Cont’d) Troubleshooting Procedure 4 Troubleshooting Procedure 8. If the PIL light is on, Turn off the main disconnect switch and, using an ohmmeter, test for a short in the wiring harness at CP2 and CP3.

Illustration

PSU Module

Chapter 13 Print Reference 02-19 02–18 thru 02–23 02-18 thru 02-22

F1 and F2: 10-A fuses for AC input

9. If no short is evident, reconnect CP2 and CP3 and turn the main disconnect switch on. Press the Power ON pushbutton and check for proper operation. 10. If the PIL light goes out, fuse(s) F1 and/or F2 have blown again due to a short in one of the following:  Wiring harness to ALC relay coil  ALC relay coil  Wiring harness to fans (check in particular where cable and front door hinge point meet).  Fan motor shorted. Repair short, replace fuse(s) and go to Step 9. If the PIL light stays on, check controller for proper operation.

02–09 01–26 02–09 02–03 thru 02–08

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

4. TROUBLESHOOTING

4–11

MARMMTRBL02303E

Table 4–6.

Troubleshooting Procedure 2

Table 4–7.

Troubleshooting Procedure 5 Illustration

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

Multi-Tap Transformer 43

Chapter 13 Print Reference 01-22

44

F4 F5 5A 5A

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

01-14

If the tap settings are correct  Continue.

3. Check AC voltage between transformer primary terminals.  Plant 3-phase voltage. If voltage proper is present  Replace multi-tap transformer.

01-14

If incorrect or no voltage is present  Continue. 4. Check AC voltage between bottom terminals of FL1, FL2, & FL3.  Plant 3-phase voltage. If voltage is present  Replace or repair wiring harness between transformer and fuse unit.

Fuse Block FL1 FL2 FL3

01-05, 01-07, 01-09

If voltage is not present  Continue. 5. Check AC voltage between top terminals of FL1, FL2, and FL3.  Plant 3-phase voltage. If voltage is present  F1, F2, F3 is/are blown. Replace bad fuse. If it blows again, replace the multi–tap transformer.

01-05, 01-07, 01-09

If voltage is not present  Continue. 6. Check AC voltage between terminals at bottom of main disconnect switch.  Plant 3-phase voltage. If voltage is present  Replace or repair wiring harness between fuse unit and main disconnect switch.

Main Disconnect Switch

01-05, 01-07, 01-09

If voltage is not present  Continue. 7. Check AC voltage between terminals at top of disconnect.  Plant 3-phase voltage. Replace main disconnect switch if voltage is present; otherwise, contact plant maintenance.

FL1, FL2, FL3

01-05, 01-07, 01-09

4. TROUBLESHOOTING MARMMTRBL02303E

4–12 Table 4–8.

Troubleshooting Procedure 3

Table 4–9.

Troubleshooting Procedure 6

Troubleshooting Procedure 1. Check the red alarm light in the center of the PSU module.  The alarm light should be off. If the light is ON  Go to Table 4–10.

Illustration

PSU Module

Chapter 13 Print Reference 02-14

If the light is ON  Go to Table 4–11. If the light is OFF  Continue.

ALM: Red LED

F4: 5-Afuse for +24E F3: 5-AS slow–blow fuse for +24V

2. Check the LED displays on the servo amplifier. If any LED is on  Go to Table 4–13 . If any LED is on  Go to Table 4–5. If no LEDs are on  Continue.

08-24 thru 08-26 09-23 thru 09-25 08-09 thru 08-12 09-11 thru 09-13 10-11 thru 10-13

4. TROUBLESHOOTING

4–13

MARMMTRBL02303E

Table 4–9. (Cont’d) Troubleshooting Procedure 6 Troubleshooting Procedure 3. Listen and look for main cabinet cooling fans to be running.  Fans should be running indicating 200VAC to ALC relay. If fans are not running  Continue. If fans are running  Go to step 5.

Illustration

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

FRONT

FAN 2

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

02-18 thru 02-21

PSU Module

02-18 thru 02-22

If there is not 200VAC  Go to step 8.

5. Check for 200VAC at ALC relay on A1 & A2.  You should see 200VAC ±10VAC. If voltage is not correct or missing  Repair the wiring harness coil between the PSU and the coil of the ALC relay. Check the controller for proper operation.

01-25, 01-27 A1

A2

1

3 ALC

5

2

4

6

If voltage is present  Continue.

4. TROUBLESHOOTING MARMMTRBL02303E

4–14 Table 4–9. (Cont’d) Troubleshooting Procedure 6 Troubleshooting Procedure

Illustration

Chapter 13 Print Reference

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

Multi-Tap Transformer

01-27

If voltage is present  Turn power off and repair wiring between ALC contactor and servo amplifiers.

F1

13 31 32

F2

F3

A1

A2

1

3 ALC 2 4

If an external OFF button or door interlock is used  Test for continuity of the external OFF, and DIL circuits, and repair it if necessary.

23

5

41

6

42

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

01-27 01-22

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

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

4. TROUBLESHOOTING

4–15

MARMMTRBL02303E

Table 4–9. (Cont’d) Troubleshooting Procedure 6 Troubleshooting Procedure

Illustration

Chapter 13 Print Reference

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

02-28 thru 02-33

29 32

If an external OFF button or door interlock is used  Test for continuity of the external OFF, and DIL circuits, and repair it if necessary.

8. On the EMG board, connect 10 (Ex-COM) to ground with a jumper wire; then momentarily connect 8 (Ex–ON) to 10 (Ex-COM).  Controller should turn on. If the controller turns on  There is a break in the on/off switch circuit. Repair or replace.

02-28 thru 02-33

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

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

02-16

4. TROUBLESHOOTING MARMMTRBL02303E

4–16 Table 4–10.

Troubleshooting Procedure 4

Table 4–11.

Troubleshooting Procedure 7

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

Illustration

Chapter 13 Print Reference 02-24

PSU Module

02-23

ALM: Red LED for indicating an alarm

F4: 5-Afuse for +24E F3: 5-AS slow-blow fuse for +24V

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

NOTE A low reading means shorted power to ground through or because of an EMG, Main CPU, PSU, Fence, or Axis board. Remove them one at a time until you get a normal reading. Replace the defective board.

06-24 thru 06-36

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

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

4. TROUBLESHOOTING

4–17

MARMMTRBL02303E

Table 4–11. (Cont’d) Troubleshooting Procedure 7 Troubleshooting Procedure 2. Turn off the controller. Measure the resistance between the following terminals on the EMG module: Ground and Terminal 39 (–15) Ground and Terminal 38 (+15) Ground and Terminal 40 (+5)  Look for greater than 100 ohms at each measurement. If all readings are ok  Replace the PSU.

Illustration

Chapter 13 Print Reference

EMG

09–34 09–32 09–31

If all readings are not ok  Continue.

NOTE A low reading means shorted power to ground through or because of the Main CPU, PSU, Fence, or Axis board EMG. Remove them one at a time until you get a normal reading. Replace the defective board.

40 39 38

4. TROUBLESHOOTING MARMMTRBL02303E

4–18 Figure 5–1. 24 Volt (24E) Power Distribution Chart

4. TROUBLESHOOTING

4–19

MARMMTRBL02303E

Table 4–12.

Troubleshooting Procedure 5

Table 4–13.

Troubleshooting Procedure 8

Troubleshooting Procedure 1. Turn the power disconnect switch on and press the power on pushbutton. Check the lights on the operator panel.  Any light on indicates 24E to the operator panel. This can also be checked by measuring for 24VDC between terminals 5 and 9 of the EMG connector CRR4. If any light is on  Go to Table 4–14. If the lights are not on  Continue.

1. Turn the power disconnect switch on and press the power on pushbutton. Check the lights on the operator panel.  Any light on indicates 24E to operator panel. This can also be checked by measuring for 24VDC between terminals 62 and Ground of the EMG control PCB. If any light is on  Go to Table 4–15. If the lights are not on  Continue.

2. Check fuse F4 at the bottom of the PSU module. If no flag shows, check the fuse with an ohmmeter.  White flag in the center of the fuse indicates it is bad. If the fuse is good  Replace the PSU If the fuse is bad  Continue.

Illustration

Ï Ï ÏÏ Ï ÏÏÏ ÎÎ Ï ÏÏÏ ÏÏ ÏÏ

Chapter 13 Print Reference 06-25 06-29

H O L D

Ï Ï ÏÏ Ï ÏÏ Ï ÎÎ Ï Ï ÏÏÏÏÎÎ ÏÏÏÏ ÏÏ ÏÏ H O L D

PSU Module

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

ALM: Red LED for indicating an alarm

F4: 5-Afuse for +24E F3: 5-AS slow-blow fuse for +24V

4. TROUBLESHOOTING MARMMTRBL02303E

4–20 Table 4–13. (Cont’d) Troubleshooting Procedure 8 Troubleshooting Procedure 3. Turn off power, disconnect fence circuit or remove jumper, and connect an ohmmeter between Fence1 terminal 36 and Ground on the EMG module.  If it does not show continuity (greater than 500 ohms), replace fuse F4 and check the controller for proper operation.  If it does show continuity (less than “10 ohms”), a component is shorted, loading the 24E voltage supply.

Illustration

Chapter 13 Print Reference 09-50

EMG

0V 56 0V 55 36

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

4. To find the shorted component, watch the ohmmeter while you disconnect or remove the following parts in order:  Main CPU  Axis  Option #1  Option #2  EMG  Cards on the extended backplane one at a time  If the ohmmeter shows greater than 500 ohms, the part is OK. If the ohmmeter shows under 500 ohms, the part is defective. If it still does not work  Follow the short out to the failed component and replace. See Figure 5–2.

06-25

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

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

4. TROUBLESHOOTING

4–21

MARMMTRBL02303E

Figure 5–2. 24 Volt (24V) Power Distribution Chart

4. TROUBLESHOOTING MARMMTRBL02303E

4–22 Figure 5–3. Tracing a Short on 24E

4. TROUBLESHOOTING

4–23

MARMMTRBL02303E

Table 4–14.

Troubleshooting Procedure 6

Table 4–15.

Troubleshooting Procedure 9 Illustration

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

Operator Panel

ÏÏ Ï ÏÏ Ï ÏÏÏÏ Ï ÏÏ Î Ï ÏÏ ÏÏ ÏÏ H O L D

USER PB1

USER PB2

1. Press the ‘‘OFF” button. Press and hold PURGE ENABLE press the ‘‘ON” button. If the ‘‘BMON>’’ prompt appears  Treat the problem as a Class 2 Fault; otherwise, continue.

Chapter 13 Print Reference

ON

OFF

Operator Panel

Ï Ï Ï Ï Ï ÏÏ Î Ï ÏÏÎ ÏÏ ÏÏ ÏÏ H OL D

Purge Enable Button

ON

08-05 02-13

4. TROUBLESHOOTING MARMMTRBL02303E

4–24 Table 4–15. (Cont’d) Troubleshooting Procedure 9 Troubleshooting Procedure

Illustration

2. If you have not done so already, measure the 24E voltage at the EMG module connector CRR4 on terminals 5 (FENCE1) and 9 (0VDC) for 24VDC (±10%). If the 24VE voltage is missing or out of tolerance, go to Table 4–12.

Chapter 13 Print Reference 06-25 06-29 CRR4

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

2. If you have not done so already, measure the 24E voltage at the EMG module on terminals 36 and Ground. for 24VDC (±10%). If the 24VE signal is missing or out of tolerance, go to Table 4–13.

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

09–50

EMG

0V 56 0V 55 36

4. TROUBLESHOOTING

4–25

MARMMTRBL02303E

Table 4–15. (Cont’d) Troubleshooting Procedure 9 Troubleshooting Procedure 3. On the teach pendant, look for any lit LEDs or screen display. If there is no display  the 24T power supplying the teach pendant ISB unit is most likely missing. Visually check the teach pendant cable K0402003–T908 (10/20M) for damage. If the 24T signal is missing or out of tolerance the following will correct the problem. Replace the following, in order, one at a time:

3 4 5 6 7

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

4. If there are LEDs or a screen display, there is a communication fault between the Main CPU printed circuit board and the teach pendant. Replace the following in order, one at a time.  Teach pendant cable  Teach pendant  Main CPU module

Illustration

Chapter 13 Print Reference 05-23

4. TROUBLESHOOTING MARMMTRBL02303E

4–26

4.3 CLASS 2 FAULTS

A Class 2 Fault is indicated by frozen text (letters or numbers) displayed on the teach pendant. This situation is an indication of a problem with the Main CPU printed circuit board caused by either the memory, processor, the board itself, or a bad teach pendant cable. Table 4–16.

Class 2 Faults Troubleshooting Procedure

Troubleshooting Procedure 1. Is the Battery light on the main CPU module on? If the Battery light is on  replace the battery. Refer to Procedure 9–1. 1

2

3

4

STATUS ALARM

Battery Light

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

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

4. TROUBLESHOOTING

4–27

MARMMTRBL02303E

Table 4–16. (Cont’d) Class 2 Faults Troubleshooting Procedure Troubleshooting Procedure 6. Perform the following steps on the teach pendant: a. Press the NEXT key twice. b. Press F2, DIAG. c. Press ENTER. The prompt changes to DIAG> (diagnostic monitor). d. Press the NEXT key. e

Press F3, TEST.

f.

Press F1, CMOS.

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

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

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

Press F2, FROM.

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

Press F1, EXIT.

j.

Press the NEXT key twice.

k. Press F2, DIAG. l.

Press ENTER.

m. Press F3, TEST. n. Press F4, FROM. o. Press ENTER. The teach pendant will display a message that gives you an opportunity to exit without destroying the contents of Flash ROM memory. p. Press 1 if you want to continue with the test. The Flash ROM memory test will take a few minutes to run. If an error is encountered, replace the Flash ROM board and reload software. Otherwise, continue. 9. The hardware in your controller is OK. Reload your system application software.

4. TROUBLESHOOTING

4–28

4.4 CLASS 3 FAULT TROUBLESHOOTING

MARMMTRBL02303E

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

4. TROUBLESHOOTING

4–29

MARMMTRBL02303E

4.4.1

The operator panel emergency stop push button is pressed.

SRVO-001 ER_SVAL1 Operator Panel E–Stop

Remedy: Twist the operator panel emergency stop push button clockwise to release. Press reset. If the problem still exists, it is caused by an open circuit in the emergency stop circuit or a bad Main CPU. Perform the troubleshooting procedure in the following table. Table 4–17.

SRVO-001 Troubleshooting Procedure Illustration

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

Main CPU Printed Circuit Board

JRM5 connector

Operator Interface Printed Circuit Board

Operator panel, rear face

CN1 connector

CN3 connector

Chapter 13 Print Reference 03-17 03-28

4. TROUBLESHOOTING MARMMTRBL02303E

4–30 Table 4–17. (Cont’d) SRVO-001 Troubleshooting Procedure Troubleshooting Procedure

Illustration

Chapter 13 Print Reference

2. Perform the following steps:

03-17

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

E–STOP REAR VIEW 3. Perform the following steps:

Main CPU Printed Circuit Board

03-25

a. Replace the cable between connector JRM5 at the Main CPU module and the operator interface printed circuit board. b. Turn on the controller. If the error message is cleared  check the controller for proper operation. If the error message reappears  replace the Main CPU module.

JRM5 connector

PIN 1

PIN 26

PIN 25

PIN 50

4. TROUBLESHOOTING

4–31

MARMMTRBL02303E

Figure 5–4. Operator Panel E-Stop Circuitry

4. TROUBLESHOOTING MARMMTRBL02303E

4–32

4.4.2

The teach pendant emergency stop push button is pressed.

SRVO-002 ER_SVAL1 Teach Pendant E–stop

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

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

If you want to troubleshoot the problem further, perform the following troubleshooting procedure: Table 4–18.

SRVO-002 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13 Print Reference

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

15-33

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

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

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

Figure 5–5

4. TROUBLESHOOTING

4–33

MARMMTRBL02303E

Figure 5–5. Teach Pendant E-Stop Circuitry JRS1 MAIN (RS422/TEACH PENDANT) HONDA High Density

9 7 5 3 1

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

10 8 6 4 2

+24T EMGB2 0V *TXTP *RXTP

3 RXTP 8 14 19 0V

2 *TXTP 7

1 TXTP 6

13 12 EMGEN EMGDM 18 17 TPDSC

Teach Pendant External Connector CN1 Male HIROSE

20 18 16 14 12

19 17 15 13 11

5 11 EMGTP

+24T EMGTP EMGDM EMGEN 0V

4. TROUBLESHOOTING MARMMTRBL02303E

4–34

4.4.3

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

SRVO-003 ER_SVAL1 Deadman switch released

Remedy: Press and hold the teach pendant deadman switch. Press reset. If the problem still exists, it is caused by:  A defective teach pendant deadman switch  A defective component on the teach pendant printed circuit board  A possible break in the circuitry between the teach pendant and the Main CPU. In most cases, you can fix it by replacing the teach pendant. If you want to troubleshoot the problem further, perform the following troubleshooting procedure: Table 4–19.

SRVO-003 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13 Print Reference

1. Perform the following steps: a. Remove power from the controller. b. Remove the seven screws holding the teach pendant back in place.

15-25 15-30

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

15-25 15-30

4. TROUBLESHOOTING

4–35

MARMMTRBL02303E

Figure 5–6. Deadman Switch Circuitry

4. TROUBLESHOOTING

4–36

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

MARMMTRBL02303E

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

4. TROUBLESHOOTING

4–37

MARMMTRBL02303E

4.4.5

The safety fence gate is open.

SRVO-004 ER_SVAL1 Fence open

Remedy: Close the gate. Several gates in the workcell might be involved. If the problem still exists, perform the following troubleshooting procedure: Table 4–20.

SRVO-004 Troubleshooting Procedure

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

2. Measure the resistance between the two terminals. If there is continuity  replace the EMG module. If the problem still exists, replace the axis control printed circuit board. If there is no continuity  repair or replace the jumper.

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

Illustration

Chapter 13 Print Reference 06-24 thru 06-26

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

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

4. TROUBLESHOOTING MARMMTRBL02303E

4–38 Figure 5–7. Fence Open Circuitry

4. TROUBLESHOOTING

4–39

MARMMTRBL02303E

4.4.6 SRVO-005 ER_SVAL1 Robot Overtravel

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

Table 4–21.

SRVO-005 Troubleshooting Procedure 1

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

Illustration

Chapter 13 Print Reference 05-08 thru 05-20

4. TROUBLESHOOTING MARMMTRBL02303E

4–40

If the problem still exists, it is caused by an open circuit in the overtravel switch circuit or by a defective axis control board or EMG module. Try the following steps in order, checking for proper operation after each.

Table 4–22.

SRVO-005 Troubleshooting Procedure 2

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

Figure 5–8. Robot Overtravel Circuitry

Reference

4. TROUBLESHOOTING

4–41

MARMMTRBL02303E

4.4.7 SRVO-006 ER_SVAL1 Hand Broken

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

4. TROUBLESHOOTING MARMMTRBL02303E

4–42

If the problem still exists, perform the following troubleshooting procedure: Table 4–23.

SRVO-006 Troubleshooting Procedure Illustration

Troubleshooting Procedure

Reference

1. Remove power from the controller by turning off the disconnect switch.

2. Test the end effector switch and its wires at the robot for continuity. If there is no continuity  replace or repair the switch or its wires. If there is continuity  continue.

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

A

COM JUMPER

B

Figure 5–9. Hand Broken Circuitry

B

HBK JUMPER

A

4. TROUBLESHOOTING

4–43

MARMMTRBL02303E

4.4.8 SRVO-007 ER_SVAL1 External emergency stops

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

4. TROUBLESHOOTING MARMMTRBL02303E

4–44 Table 4–24.

SRVO-007 Troubleshooting Procedure Illustration

Troubleshooting Procedure

CRR3

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

Chapter 13 Print Reference

EMG

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

03-08, 03-09, 03-10

2. With controller power off, on the EMG module, measure the resistance on CRR3 between:  6 and 8  8 and 10 If there is continuity  go to step 3.

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

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

03-06, 03-07

4. With controller power on, on the EMG module, measure the AC voltage on CRR3 between terminals 1 and 3. Is the voltage 100VAC
10%? If the voltage is within tolerance  replace EMG If the voltage is not within tolerance  go to step 5.

03-04

5. With controller power on, measure the AC voltage at transformer TF1, terminals 41 and 42, for 100VAC
10%. If the voltage is within tolerance  repair or replace the wiring between TF1 terminals 41 and 42 and EMG module CRR3 terminals 1 and 3. If voltage is out of tolerance  continue.

Multi-Tap Transformer 41 42

F4 F5 5A 5A

01-33, 01-34

4. TROUBLESHOOTING

4–45

MARMMTRBL02303E

Table 4–24. (Cont’d) SRVO-007 Troubleshooting Procedure Troubleshooting Procedure 6. At the ALC relay, terminals 23 and 13, measure again for 100VAC
10%. If the voltage is within tolerance  check for proper operation of the ALC relay.

Illustration

01-26

Multi-Tap Transformer 13

A1

A2

23

31

1

3

5

41

32

2

4

6

42

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

Chapter 13 Print Reference

24

Multi-Tap Transformer 41 42

F4 F5 5A 5A

01-23

4. TROUBLESHOOTING MARMMTRBL02303E

4–46 Figure 5–10. External Emergency Stop Circuitry

4. TROUBLESHOOTING

4–47

MARMMTRBL02303E

4.4.9

Indicates one of two symptoms:

SRVO-008 ER_SVAL Brake fuse blown

 

The 5A brake fuse on the EMG module has blown. A momentary surge of high current was detected in the brake circuit. The FALM LED on the EMG module will be lit.

Remedy: By turning power off momentarily and then back on you will reset the circuit and the LED will go out if the fault is caused by a current surge. If the fault does not reset or if it reoccurs frequently, perform the following troubleshooting procedure: Table 4–25. Troubleshooting Procedure 1. Turn off the controller at the main disconnect and open the cabinet door. 2. Remove all of the connectors on the front of the EMG module and pull out the module. 3.Check the 5A fuse and replace it if necessary.

4. Place the EMG control printed circuit board back in its slot and plug all connectors back into it.

SRVO-008 Troubleshooting Procedure Illustration

Chapter 13 Print Reference

EMG PCB

03-19

4. TROUBLESHOOTING MARMMTRBL02303E

4–48 Table 4–25. (Cont’d) SRVO-008 Troubleshooting Procedure Troubleshooting Procedure

Illustration

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

Chapter 13 Print Reference

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

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

04-10 thru 04-38

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

BRK4

NOT USED

BRK5

BRK6 FALM

D CB A

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

VIOLET BKM3 BKM3 BKM3

6. With the controller door open and all connectors and plugs reattached, energize the controller. If the FALM light comes on  replace the EMG module.

BRK1

SON

BRK2

BRK3

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

CRR4

BLUE BKP3 BKP3 BKP3

VIOLET BKM2 BKM2 BKM1

BLUE BKP2 BKP2 BKP1

03-32

4. TROUBLESHOOTING

4–49

MARMMTRBL02303E

Table 4–25. (Cont’d) SRVO-008 Troubleshooting Procedure Troubleshooting Procedure

Illustration

Chapter 13 Print Reference

7. Power up the robot and jog the robot to verify robot operation. If the FALM light comes on  replace the EMG module. EMG CONTROL MODULE SENSITIVITY JUMPER 1 SET

9. If this problem occurs occasionally, change the ‘SET’ jumper from 2 to 1 on the EMG module.

2

03–37

4. TROUBLESHOOTING MARMMTRBL02303E

4–50 Figure 5–11. Brake Fuse Blown Circuitry

4. TROUBLESHOOTING

4–51

MARMMTRBL02303E

4.4.10

Teach pendant deadman switch released while enabled.

SRVO-011 ER_SVAL1 TP Released While Enabled

Remedy: Press the deadman switch, then press RESET.

4.4.11

Normal power is on (hot start).

SRVO-012 ER_SVAL1 Power Failure Recovery

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

4.4.12

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

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

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

Table 4–26.

SRVO-014 Troubleshooting Procedure

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

Chapter 13 Print Reference

4. TROUBLESHOOTING MARMMTRBL02303E

4–52 Figure 5–12. Backplane

AXIS

BACKPLANE 24V

CA39C 1

+24VDC

CA39C 2

+0VDC

5V

E7−1 RV

6

*FMM

JRA2 13

ALM

(SVRO 014 FAN MOTOR ABNORMAL)

CA39C 3

ALMC

OPTION 1 & 2 PCB COOLING FAN

CENTRIFUGAL

IC1−3 CA39B 1

+24VDC

CA39B 2

+0VDC

CA39B 3

IC1−1

CA39A 1 CA39A 2

0V

CA39A 3

IC1−2

0V

ALMB

AXIS & MAIN PCB COOLING FAN

CENTRIFUGAL

+24VDC

+0VDC

ALMA

CENTRIFUGAL

EMG & PSU PCB COOLING FAN

4. TROUBLESHOOTING

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MARMMTRBL02303E

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

The temperature in the controller is too high, or the overheat sensor located on the backplane has opened.

Table 4–27.

SRVO-015 Troubleshooting Procedure

Troubleshooting Procedure

Line No. Reference Chapter 13

1. Clean the controller air filter, allow the controller to cool down, and cold start the controller. 2. Check the heat exchanger fans for operation. If the fans run ok replace the axis control board. If one or more fans do not work  continue. 3. Check the AC voltage at the terminals of the non-working fan(s). If the voltage is 180VAC – 220VAC  replace the fan(s). If the voltage is out of tolerance  replace or repair the fan motor wiring harness. Figure 5–13. System Over Heat Circuitry Drawing 1

02-02 02-04 02-07

4. TROUBLESHOOTING MARMMTRBL02303E

4–54 Figure 5–14. System Over Heat Circuitry Drawing 2

4. TROUBLESHOOTING

4–55

MARMMTRBL02303E

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

The axis control board sends a signal to the servo amplifiers in order to energize the MCC contactors and turn on the servo amplifiers. When a servo amplifier MCC coil is turned on, it sends a signal back to the axis control board. If the axis control board sends its signal and does not receive the reply within a few milliseconds, this alarm occurs. Table 4–28.

SRVO-021 Troubleshooting Procedure

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

Line No. Reference Chapter 13 08-17 09-18 10-17 09-01 thru 09-09

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

10-01 thru 10-18

Does the fault message change to indicate a different axis? YES  replace the bad cable. NO  continue 4. Replace the axis control board. If the problem continues, replace the affected servo amplifier.

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

The axis control board sends a signal to the servo amplifiers in order to energize the MCC contactors and turn on the servo amplifiers. When a servo amplifier MCC coil is turned on, it sends a signal back to the axis control board. If the axis control board receives the reply signal without having sent its request signal, this alarm occurs. Table 4–29.

SRVO-022 Troubleshooting Procedure

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

Line No. Reference Chapter 13 09-01 thru 09-09 08-01 thru 08-18 10-10 thru 10-18

4. TROUBLESHOOTING MARMMTRBL02303E

4–56

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

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

Table 4–30.

SRVO-023 Troubleshooting Procedure

Troubleshooting Procedure

Line No. Reference Chapter 13

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

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

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

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

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

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

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

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

The system variable $master_done is set to FALSE. Remedy: Master the robot.

4. TROUBLESHOOTING

4–57

MARMMTRBL02303E

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

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

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

The system variable $calibrate is set to FALSE. Remedy: Calibrate the robot.

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

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

Table 4–31.

SRVO-036 Troubleshooting Procedure

Troubleshooting Procedure

Line No. Reference Chapter 13

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

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

5. Replace the motor.

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

IMSTP (immediate stop) UOP input asserted. Remedy: If using a UOP, determine the cause and repair. If not using UOP, select the I/O menus and zero UOP mapping.

4. TROUBLESHOOTING MARMMTRBL02303E

4–58

4.4.24

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

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

Remedy: Perform the following procedure:

Table 4–32.

SRVO-038 Troubleshooting Procedure

Troubleshooting Procedure

Line No. Reference Chapter 13

1. Press MENUS. 2. Select SYSTEM. 3. Press F1, [TYPE]. 4. Select System Variables. 5. Move the cursor to $MCR. 6. Press ENTER. 7. Move the cursor to $SPC_RESET. 8. Press F4, TRUE. The display will reset to false. This is normal. 9. Press RESET. The fault condition should reset. If the controller is still faulted with additional servo-related errors, cold start the controller. It might be necessary to remaster the robot.

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

The servo amplifier magnetic contactor (MCC) is welded closed. If the contact of the magnetic contactor is already closed when the contactor is turned on, this alarm circuit regards the contact as welded closed and the MCC alarm occurs.

Table 4–33.

SRVO-042 Troubleshooting Procedure

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

Line No. Reference Chapter 13 08-24, 25, 26 09-23, 24, 25 10-23, 24, 25

4. TROUBLESHOOTING MARMMTRBL02303E

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

4–59

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

4. TROUBLESHOOTING MARMMTRBL02303E

4–60

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

The regenerative energy produced by the motor exceeded the specification. NOTE Energy feedback from motor to the amplifier is called regenerative energy. This occurs when the axis is being slowed down. The amplifier discharges this energy by converting it to heat energy through the discharge resistor. If the charged energy exceeds the discharged energy, this alarm occurs. Remedy: Check the LED of the amplifier, then perform the following troubleshooting procedure. Table 4–34.

SRVO-043 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13 Print Reference

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

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

4. TROUBLESHOOTING

4–61

MARMMTRBL02303E

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

The DC voltage on the main power circuit of the servo amplifier exceeded specification. Remedy: Check the three-phase voltage to the servo amplifier input. It should not exceed 253 VAC phase-to-phase. Check the cabling between the servo amplifier and the axis control printed circuit board if no alarm is indicated on the servo amplifier 7-segment display. If the problem still exists, perform the following troubleshooting procedure: Table 4–35.

SRVO-044 Troubleshooting Procedure

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

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

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

11-39

4. TROUBLESHOOTING MARMMTRBL02303E

4–62

4.4.29

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

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

Remedy: If no alarm is indicated on the servo amplifier 7-segment display, check the cabling between the servo amplifier (CN1) and the axis control printed circuit board (JV1-10). If the problem still exists, perform the following troubleshooting procedure: Table 4–36.

SRVO-045 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13 Print Reference

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

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

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

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

If all are not shorted  Go to step 4. 3. Remove the power lines from the motor connectors (J1-6) and recheck the continuity between GND and each of the lines U, V, and W to the robot motor. If any are shorted  The motor is defective. Replace the motor.

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

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

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

If the three measured values are different  Go to step 6. 5. Remove the power lines from the motor connectors and remeasure the resistance between U-V, V-W, and W-U using a measuring instrument sensitive enough to detect small resistances. If the three measured values are the same  The power lines are defective. Replace the cable.

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

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

08-12, 13

4. TROUBLESHOOTING

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MARMMTRBL02303E

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

The average current calculated by the servo software exceeded specification. Remedy: Reduce the load on the robot. If the problem still exists, perform the following troubleshooting procedure: Table 4–37.

SRVO-046 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13 Print Reference

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

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

2. Replace the axis control printed circuit board. If the alarm occurs again  The motor is defective.

08-11, 12, 13

4. TROUBLESHOOTING MARMMTRBL02303E

4–64

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

The DC voltage on the main power circuit of the servo amplifier is lower than the specification even though the MCC is on. Remedy: If no alarm is indicated on the servo amplifier LED, check the cabling between the servo amplifier and the axis control printed circuit board. If the problem still exists, perform the following troubleshooting procedure: Table 4–38.

SRVO-047 Troubleshooting Procedure

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

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

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

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

4. TROUBLESHOOTING

4–65

MARMMTRBL02303E

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

The servo amplifier overheated. Servo amplifier LED indicates a “6.” This alarm indicates that the thermal switch mounted on the PC board of the specified axis has opened. Remedy: Check the fans and the heat exchange unit for proper operation. If the problem still exists, perform the following troubleshooting procedure: Table 4–39.

SRVO-049 Troubleshooting Procedure

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

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

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

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

The servo software detected a disturbance torque that was too high or a collision occurred and tripped a collision detection alarm. Remedy: Reset the robot by using the teach pendant RESET button and jog the robot away from obstructions. If the problem still exists, perform the following troubleshooting procedure: Table 4–40.

SRVO-050 Troubleshooting Procedure

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

3. Replace the servo amplifier.

Chapter 13 Print Reference

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

4. TROUBLESHOOTING MARMMTRBL02303E

4–66

4.4.34

The feedback current is abnormal.

SRVO-051 ER_SVAL2 CUER Alarm (Group:i Axis:j) Table 4–41.

SRVO-051 Troubleshooting Procedure

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

Chapter 13 Print Reference 08-11, 12, 13

2. Replace the servo amplifier. If the alarm continues, go to step 3. 3. Replace the pulse coder and master the robot.

4.4.35

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

SRVO-061 ER_SVAL2 CKAL Alarm (Group:i Axis:j) Table 4–42.

SRVO-061 Troubleshooting Procedure

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

Chapter 13 Print Reference

4. TROUBLESHOOTING

4–67

MARMMTRBL02303E

4.4.36

The battery voltage for the pulse coders is zero volts.

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

Table 4–43.

SRVO-062 Troubleshooting Procedure

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

Chapter 13 Print Reference

4. TROUBLESHOOTING MARMMTRBL02303E

4–68

4.4.37

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

SRVO-063 ER_SVAL2 RCAL Alarm (Group:i Axis:j) Table 4–44.

SRVO-063 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13 Print Reference

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

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

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

Table 4–45.

SRVO-064 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13 Print Reference

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

4.4.39

The pulse coder batteries are low.

SRVO-065 ER_WARN BLAL Alarm (Group:i Axis:j) Table 4–46.

SRVO-065 Troubleshooting Procedure

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

Chapter 13 Print Reference

4. TROUBLESHOOTING

4–69

MARMMTRBL02303E

4.4.40

The pulse coder ROM checksum data are abnormal.

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

Table 4–47.

SRVO-066 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13 Print Reference

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

4.4.41

The pulse coder overheated.

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

Table 4–48.

SRVO-067 Troubleshooting Procedure

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

Chapter 13 Print Reference 07-22

4. TROUBLESHOOTING MARMMTRBL02303E

4–70

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

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

Table 4–49.

SRVO-068 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13 Print Reference

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

08-16, 17, 18

2. Replace the axis control board. If the alarm occurs again  Go to step 3.

08-01 thru 10

3. Replace the pulse coder and master the robot.

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

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

4. TROUBLESHOOTING

4–71

MARMMTRBL02303E

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

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

The communication stop and start bits are abnormal. Refer to the SRVO-068 remedy.

The feedback velocity exceeds the specifications. If the problem still exists, perform the following troubleshooting procedure:

Table 4–50.

SRVO-071 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13 Print Reference

1. Does this alarm occur with any other alarm? If another alarm occurs  This alarm is caused by another alarm of the serial pulse coder. Refer to the other alarm for details. 2. Reduce the load within the specifications.

4.4.46

Line Tracking Overflow Error.

SRVO-081 ER_WARN EROFL Alarm (Track encoder:n) Table 4–51.

SRVO-081 Troubleshooting Procedure

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

Chapter 13 Print Reference

4. TROUBLESHOOTING MARMMTRBL02303E

4–72

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

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

Table 4–52.

SRVO-082 Troubleshooting Procedure

Troubleshooting Procedure

Chapter 13 Print Reference

1. Replace the axis control printed circuit board. 2. Replace the pulse coder.

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

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

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

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

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

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

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

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

4. TROUBLESHOOTING

4–73

MARMMTRBL02303E

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

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

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

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

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

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

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

The line tracking pulse coder batteries are low. Remedy: Refer to SRVO-065 remedy.

The line tracking pulse coder ROM checksum data is abnormal. Remedy: Refer to SRVO-066 remedy.

The line tracking pulse coder overheated. Remedy: Refer to SRVO-067 remedy.

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

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

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

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

MARMMTRBL02303E

5

REPLACING A FUSE 5–1 If a fuse blows in the control unit, eliminate the cause, then replace the fuse.

5.1 MULTI-TAP TRANSFORMER

F2, F2, and F3 : Fuses for three-phase 200 VAC servo power F4 and F5 : Fuses for 100 VAC Refer to Table 5–1. Table 5–1.

Multi-Tap Transformer Fuses

Fuse Number

F1, F2, F3 F1, F2, F3

F4, F5 F4, F5

F6, F7

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

Rated Current 30A

A60L-0001-0042#JG1–30

30A 20A

A60L-0001-0042#JG1–30 A60L-0001-0042#JG1–20

10A

A60L–0001-0042#JG1-10

7.5A 7.5A

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

5A

A60L-0001-0101#P450H

10A

A60L-0001-0042#JG1-10

Part Number

5. REPLACING A FUSE MARMMTRBL02303E

5–2 Figure 6–1. Replacing a Fuse of the Transformer Unit

Fuse

Fuse

Fuse

Fuse

Fuse

Fuse

Fuse

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

5. REPLACING A FUSE

5–3

MARMMTRBL02303E

5.2 SERVO AMPLIFIER

FUSE 1 : Fuse for control power supply Part number: A60L-0001-0175#3.2A FUSE 2 and 3 : Fuse for fan motors (only for one axis servo amplifier, A06B-6066-H008) Part number: A60L–0001–0101#P405 Figure 6–2. Replacing the Fuse of a Servo Amplifier

F1

F2 F3

LED Terminal board T1 Circuit breaker

5. REPLACING A FUSE MARMMTRBL02303E

5–4

5.3 POWER SUPPLY UNIT

F1 and F2 F3 F4 F5

: : : :

Fuses for AC input Fuse for +24V Fuse for +24E Fuse for auxiliary power supply

Table 5–2.

Power supply unit for four-slot backplane

Fuse number F1, F2 F3 F4 F5 Table 5–3.

Rated current 7.5A 3.2A 5A 0.3A

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

Power supply unit for six-slot backplane

Fuse number F1, F2 F3 F4 F5

Rated current 10A 5A 5A 0.3A

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

Figure 6–3. Replacing a Fuse of the Power Supply Unit PSU

F5: 0.3A fuse for auxiliary power supply Battery cover

PSU

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

Battery

ALM: Red LED for indicating an alarm

F4:5–Afuse for +24E F3: Fuse for +24V 5-A slow blow for 6-slot backplane 3.2A slow blow for 4-slot backplane

(with battery cover removed)

5. REPLACING A FUSE

5–5

MARMMTRBL02303E

5.4 EMERGENCY STOP CONTROL PC BOARD

FUSE : 5.0 A brake circuit fuse Part number: A60L-0001-0046#5.0 FUSE : F1, F2, 3.2A Manual brake circuit fuse Part number: A60L-0001-0175#3.2A Figure 6–4. Replacing the Fuse on the Emergency Stop Control PC Board

F1 F2 FUSE

5. REPLACING A FUSE MARMMTRBL02303E

5–6

Figure 6–5. Replacing the Fuse on the Emergency Stop Control PC Board EMG PCB

Fuse

5.5 PURGE POWER SUPPLY A05B–2047–C181

FUSE: F11, F12, 3.2A AC Input Line Fuses Part Number: A60L–0001–0175#3.2

5. REPLACING A FUSE

5–7

MARMMTRBL02303E

Figure 6–6. Purge Power Supply

Cover

F12 F11 Purge Power Supply

5. REPLACING A FUSE MARMMTRBL02303E

5–8

5.6 PROCESS INPUT/OUTPUT PC BOARDS AA, AB, CA, CB, AND DA

FUSE 1 : 2.0-A fuse for +24V Part number: A60L-0001-0046#2.0 Figure 6–7. Replacing the Fuse of the Process Input/Output PC Board AA, AB, CA, CB, or DA

Fuse

Fuse

Process input/output PC boards AA and AB

Process input/output PC boards CA, CB and DA

5. REPLACING A FUSE

5–9

MARMMTRBL02303E

5.7 PROCESS INPUT/OUTPUT PC BOARDS BA AND BB

FUSE 1 to 8 : 6.3 A fuses for +24V Part number: A60L-0001-0046#6.3 Figure 6–8. Replacing the Fuse of the Process Input/Output PC Board BA or BB

Fuse

Process input/output PC boards BA and BB

5. REPLACING A FUSE MARMMTRBL02303E

5–10

5.8 MODULAR I/O UNIT

The modules listed below have built-in fuses. If a fuse blows, remove the cause, then replace the fuse with a spare. Table 5–4.

Modular I/O Unit

Module Interface module A1F01A Interface module A1F01B Output module with 8 DC points AOD08C Output module with 8 DC points AOD08D Output module with 5 AC points AOA05E Output module with 8 AC points AOA08E Output module with 12 AC points AOA12F

Indication PWR is off PWR is off F is on

Rating 3.2A 3.2A 5A

Fuse Specification A60L-0001-0290=LN32 A60L-0001-0290=LM32 A60L-0001-0260=5R00

F is on

5A

A60L-0001-0260=5R00

F is on

3.15A

A60L-0001-0276=3.15

F is on

3.15A

A60L-0001-0276=3.15

F is on

3.15A

A60L-0001-0276=3.15

The fuses are on the PC boards in the modules.

5. REPLACING A FUSE

5–11

MARMMTRBL02303E

5.9 AC OUTLET UNIT

FUSE : 2.0 A fuse for 100 VAC Part number: A60L-0001-0101#P420H Figure 6–9. Replacing the Fuse of the AC Outlet Unit

Fuse

MARMMTRBL02303E

6

BRAKE RELEASE 6–1 To perform some troubleshooting and error recovery procedures, you might have to release the brakes. Use Procedure 6–1 to release the brakes.

Procedure 6–1

Releasing the Brakes

NOTE Clear all E-stops before proceeding. Step

1 Press and release the EMERGENCY STOP button. NOTE Do not press RESET. The servos must be off to release the brakes. 2 Press MENUS. 3 Select NEXT PAGE. 4 Select SYSTEM. 5 Press F1, [TYPE]. 6 Select Brake Ctrl. See the following screen for an example. SYSTEM Brake Crtl AXIS SELECTED 1 NO 2 NO 3 NO 4 NO 5 NO 6 NO 7 NO 8 NO 9 NO

JOINT

10%

BRAKE STATE ENGAGED ENGAGED ENGAGED ENGAGED ENGAGED ENGAGED ENGAGED ENGAGED ENGAGED

[TYPE] ENG–SEL REL–SEL

YES

NO

>

7 Highlight the number of the axis you want to release or engage.

WARNING Releasing a brake could cause the robot to move. To STOP the robot immediately, press the EMERGENCY STOP button or press F2, ENG–SEL to engage the brake.

6. BRAKE RELEASE MARMMTRBL02303E

6–2 8 To release or engage a single brake:

a Select an axis to be released or engaged; press F4, YES. NOTE To release axis 3 you must select both axis 2 and axis 3. b Release the brake on the selected axis; hold down the shift key and press F3, REL–SEL. c Engage the brake on the selected axis; press F2, ENG–SEL. 9 To release ALL brakes: a Press NEXT, > to display the next page of function keys. SYSTEM Brake Crtl AXIS SELECTED 1 NO 2 NO 3 NO 4 NO 5 NO 6 NO 7 NO 8 NO 9 NO

JOINT

10%

BRAKE STATE ENGAGED ENGAGED ENGAGED ENGAGED ENGAGED ENGAGED ENGAGED ENGAGED ENGAGED

[TYPE] ENG–ALL REL–ALL

GROUP

>

WARNING The following step will release all brakes even though they have not been selected by pressing F4, YES. This could result in robot movement. Be prepared for all brakes to be released, as personnel could be injured, or equipment damaged.

b Hold down the SHIFT key and press F3, REL–ALL to release all of the brakes. 10

To engage ALL brakes: a Press the F2, ENG–ALL to engage all of the brakes.

11 When you are finished, press RESET. NOTE If you are unable to jog the robot after releasing the brakes, press and release the EMERGENCY STOP button, and then press RESET to clear the fault.

MARMMTRBL02303E

7

CONTROLLING I/O 7–1 Controlling I/O allows you to test the I/O in your system for proper function during testing operation. Controlling I/O includes   

Forcing outputs Simulating inputs and outputs SOP I/O

7. CONTROLLING I/O 7–2

MARMMTRBL02303E

7.1 FORCING OUTPUTS

Forcing outputs is turning output signals on or off. Outputs can also be forced within a program using I/O instructions. Use Procedure 7–1 to force outputs outside of a program. Refer to the application Specific Setup and Operations Manual for information on using program I/O instructions. NOTE RO[1] and RO[2] control HAND 1, and RO[3] and RO[4] control HAND 2.

Procedure 7–1 Condition Step

Forcing Outputs 

The outputs you are forcing have been configured.

1 Press MENUS. 2 Select I/O. 3 Press F1, [TYPE]. 4 Select the type of output you want to force: digital, analog, group, robot, UOP, or SOP.

WARNING Forcing digital outputs causes connected devices to function. Make certain you know what the digital output is connected to and how it will function before forcing it; otherwise, injury to personnel or damage to equipment can occur.

7. CONTROLLING I/O 7–3

MARMMTRBL02303E

For digital outputs for example, you will see a screen similar to the following. I/O Digital Out # SIM STATUS DO[ 1] U OFF DO[ 2] U ON DO[ 3] U OFF DO[ 4] U OFF DO[ 5] U OFF DO[ 6] U ON DO[ 7] U OFF DO[ 8] U OFF DO[ 9] U OFF DO[ 10] U OFF [ TYPE ] DO[

4] U

OFF

CONFIG

WORLD [ [ [ [ [ [ [ [ [ [

IN/OUT

10% ] ] ] ] ] ] ] ] ] ]

SIMULATE UNSIM

5 Move the cursor to the STATUS of the output you want to force. 6 Press the function key that corresponds to the value you want. For digital, robot, UOP, and SOP outputs, press

AO[

4] U

12H



F4 for ON



F5 for OFF

For analog and group outputs, move the cursor to value, and use the numeric keys to type the value. Value entry is always in decimal format. To change the displayed value from decimal to hexadecimal, press F4, FORMAT. Hexadecimal numbers are followed by an ‘‘H’’ on the screen.

7. CONTROLLING I/O 7–4

MARMMTRBL02303E

7.2 SIMULATING INPUTS AND OUTPUTS

Procedure 7–2 Condition Step

Simulating inputs and outputs is forcing inputs and outputs without signals entering or leaving the controller. Simulate I/O to test program logic and motion when I/O devices and signals are not set up. You can simulate digital, analog, and group I/O only; you cannot simulate robot, UOP, or SOP I/O. When you are finished simulating a signal, you can reset, or unsimulate, it. Use Procedure 7–2 to simulate and unsimulate I/O. Simulating and Unsimulating Inputs and Outputs 

The input or output has been configured.

1 Press MENUS. 2 Select I/O. 3 Press F1, [TYPE]. 4 Select the type of input or output you want to simulate: digital, analog, or group. For digital inputs for example, you will see a screen similar to the following. I/O Digital Input # SIM STATUS DI[ 1] U OFF DI[ 2] S ON DI[ 3] U OFF DI[ 4] U OFF DI[ 5] U OFF DI[ 6] U ON DI[ 7] U OFF DI[ 8] S OFF DI[ 9] U OFF DI[ 10] U OFF [ TYPE ]

CONFIG

WORLD [ [ [ [ [ [ [ [ [ [ IN/OUT

10% ] ] ] ] ] ] ] ] ] ]

SIMULATE UNSIM

5 If you simulate a signal, you can force the status by setting it to a value. When the signal is unsimulated, its actual status is displayed. DO[

4]

OFF

6 Move the cursor to the SIM column of the signal you want to simulate. 

U means the signal is not simulated or unsimulated.



S means the signal is simulated.

7 Simulate or unsimulate the signal. 

To simulate, press F4, SIMULATE.



To unsimulate, press F5, UNSIM.

8 To unsimulate all simulated signals, press FCTN and then select UNSIM ALL I/O.

7. CONTROLLING I/O

7–5

MARMMTRBL02303E

7.3 SOP I/O STATUS

The I/O SOP screen indicates the status of the standard operator panel signals. SOP input signals (SI) and SOP output signals (SO) correspond to internal controller software Panel Digital Input signals (PDI) and Panel Digital Output signals (PDO). Refer to Table 7–1 and Table 7–2. Table 7–1.

SI

PDI

0

1

EMERGENCY STOP

1

2

FAULT RESET

2

3

REMOTE

3

4

HOLD

6

7

CYCLE START

7–15

8–16

Standard Operator Panel Input Signals

Function

NOT USED

Description Input signal is normally turned ON, indicating that the EMERGENCY STOP button is not being pressed. Input signal is normally turned OFF, indicating that the FAULT RESET button is not being pressed. Input signal is normally turned OFF, indicating that the controller is not set to remote. Input signal is normally turned ON, indicating that the HOLD push button is not being pressed. Input signal is normally turned OFF, indicating that the CYCLE START push button is not being pressed. Open for additional PDI.

Table 7–2.

Standard Operator Panel Output Signals

SO

PDO

Function

Description

0

1

REMOTE LED

Output signal indicates the controller is set to remote.

1

2

CYCLE START

Output signal indicates the CYCLE START button has been pressed or a program is running.

2

3

HOLD

3

4

FAULT LED

4

5

BATTERY ALARM

7

8

TEACH PENDANT ENABLED

Output signal indicates the teach pendant is enabled.

8–15

9–16

NOT USED

Open for additional PDO.

Output signal indicates the HOLD button has been pressed or a hold condition exists. Output signal indicates a fault has occurred. Output signal indicates the voltage in the battery is low.

Use Procedure 7–3 to display and force SOP I/O.

7. CONTROLLING I/O

7–6

MARMMTRBL02303E

Procedure 7–3 Step

Displaying and Forcing SOP I/O 1 Press MENUS. 2 Select I/O. 3 Press F1, [TYPE]. 4 Select SOP. You will see a screen similar to the following.

I/O SOP Out # SO[ SO[ SO[ SO[ SO[ SO[ SO[ SO[ SO[ SO[

STATUS 1] OFF OFF 2] OFF 3] OFF 4] OFF 5] OFF 6] OFF 7] OFF 8] OFF 9] OFF 10] OFF

[ TYPE ]

JOINT [ [ [ [ [ [ [ [ [ [

10 %

] ] ] ] ] ] ] ] ] ] IN/OUT

ON

OFF

To change between the display of the input and output screens, press F3, IN/OUT. To move quickly through the information, press and hold the SHIFT key and press the down or up arrow keys. NOTE You can only view the status of input signals. Input signals cannot be forced. 5 To force an output signal, move the cursor to the output you want to change: 

To turn on an output signal, press F4, ON.



To turn off an output signal, press F5, OFF.

MARMMTRBL02303E

8

MASTERING 8–1 When you master a robot you define the physical location of the robot by synchronizing the mechanical information with the robot’s positional information. A robot must be mastered to operate properly. Robots are usually mastered before they leave FANUC Robotics. However, it is possible that a robot might lose its mastering data and require to be remastered. You can master the robot using several different methods. Refer to Table 8–1 to select the method that best meets your needs. Table 8–1.

Mastering Methods

Mastering Method Mastering to a fixture (Fixture Position Master)

Mastering to zero degrees

Single axis mastering

Recording the quick master reference position Quick mastering

Robot Models All

When to Use

 When mastery was lost due to mechanical disassembly or repair.  When a quick master reference position was not previously set.  Method of choice for P- and A-series robots. Used for S- and M-series robots when extreme precision is required. M-series  When mastery was lost due to mechanical disassembly or repair. S-series  When a quick master reference position was not previously set.  Method of choice for S- and M-series robots when extreme precision is not required. M-series When mastery was lost due to mechanical S-series disassembly or repair of a single axis (usually due to motor replacement). All To record mastering data as a reference for future quick mastering. All

To retrieve mastering data that has been stored as a quick master reference position when mastery is lost due to an electrical or software problem. Do not use if mastery was lost due to mechanical disassembly or repair.

If you are using a FANUC Robotics A-series or P-series robot you must use a mastering fixture to master your robot. Refer to the Mechanical Service Manual specific to your robot model for procedures on how to set up and use a mastering fixture. If you are using a FANUC Robotics M-series or S-series robot you can either master to a fixture or you can master to zero degrees. Refer to the Mechanical Service Manual specific to your robot model for more information on mastering using a fixture. Quick mastering is a convenient way to master an M-series or S-series robot after you have recorded a reference position. You cannot quick master a robot unless the reference position was taught before mastering was lost.

8. MASTERING MARMMTRBL02303E

8–2

CAUTION Record the quick master reference position after the robot is installed to preserve the factory mastering settings for future remastering.

8.1 MASTERING TO A FIXTURE (FIXTURE POSITION MASTER)

When you master to a fixture, you use a mastering fixture to align the robot axes and then record the position. You can master any robot to a fixture. If you have a P-series or A-series robot, you must master it to a fixture. Use Procedure 8–1 to master to a fixture.

Procedure 8–1 Condition Step

Mastering to a Fixture 

You have the appropriate mastering fixture for your robot.

1 Press SYSTEM. 2 Press F1, [TYPE]. 3 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 4. a Select VARIABLE from the [TYPE] menu. b Move the cursor to $MASTER_ENB. c Press the numeric key “1” and then press ENTER on the teach pendant. d Press F1, [TYPE]. e Select Master/Cal. See the following screen for an example.

SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ’ENTER’ or number key to select.

[ TYPE ]

LOAD

8. MASTERING

8–3

MARMMTRBL02303E

SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ’ENTER’ or number key to select.

[ TYPE ]

LOAD

RES_PCA

4 If you are resetting a pulse coder alarm, a Press F3, RES_PCA. See the following screen for an example. SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ’ENTER’ or number key to select.

Reset pulse coder alarm? [NO] [ TYPE ] YES

NO

b Press F4, YES. See the following screen for an example. SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Pulse coder alarm reset!

[ TYPE ]

LOAD

RES_PCA

5 Refer to the Mechanical Service Manual or Mechanical Connection and Maintenance Manual specific to your robot model for the procedures on how to set up and use a mastering fixture.

8. MASTERING MARMMTRBL02303E

8–4 6 Select Fixture Position Master.

7 Press F4, YES. Mastering will be performed automatically. 8 Continue to Step 9. 9 Select Calibrate.

Ï Ï ÏÏÏÏ ÏÎÎ ÏÏÏ ÎÎ Ï ÎÎ ÏÏÎÎ ÏÏ Ï

10

Press F4, YES.

11 Perform a cold start. a Turn off the robot. b Press and continue pressing the FAULT RESET button on the operator panel. c While still pressing FAULT RESET, press the ON button on the operator panel.

8. MASTERING

8–5

MARMMTRBL02303E

8.2

When you master to zero degrees, you position all axes at their zero degree witness marks and record the zero degree position. You can master any M-series or S-series robot to zero degrees.

ZERO DEGREE MASTERING

Use Procedure 8–2 to master to zero degrees. Procedure 8–2 Step

Mastering to Zero Degrees 1 Press SYSTEM. 2 Press F1, [TYPE]. 3 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 4. a Select VARIABLE from the [TYPE] menu. b Move the cursor to $MASTER_ENB. c Press the numeric key “1” and then press ENTER on the teach pendant. d Press F1, [TYPE]. e Select Master/Cal. See the following screen for an example.

SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ’ENTER’ or number key to select.

[ TYPE ]

LOAD

8. MASTERING MARMMTRBL02303E

8–6

SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ’ENTER’ or number key to select.

[ TYPE ]

LOAD

RES_PCA

4 If you are resetting a pulse coder alarm, a Press F3, RES_PCA. See the following screen for an example. SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ’ENTER’ or number key to select.

Reset pulse coder alarm? [NO] [ TYPE ] YES

NO

b Press F4, YES. See the following screen for an example. SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Pulse coder alarm reset!

[ TYPE ]

LOAD

RES_PCA

5 Align the witness marks on the robot. 6 Select Zero Position Master.

8. MASTERING

8–7

MARMMTRBL02303E

7 Press F4, YES. Mastering will be performed automatically. 8 Select Calibrate.

Ï Ï ÏÏÏ ÏÏÏÏ ÏÎÎ ÏÏÏÎÎ ÏÏÏÏ ÏÏ

9 Press F4, YES. 10

Perform a cold start. a Turn off the robot. b Press and continue pressing the FAULT RESET button on the operator panel. c While still pressing FAULT RESET, press the ON button on the operator panel.

8. MASTERING MARMMTRBL02303E

8–8

8.3

You can master a single axis of an M-series or S-series robot when mastery was lost due to mechanical disassembly or repair of a single axis, usually due to motor replacement.

SINGLE AXIS MASTERING

Use Procedure 8–3 to master a single axis. Procedure 8–3 Step

Mastering a Single Axis 1 Clear any servo faults that prevent you from jogging the robot. a Press MENUS. b Select SYSTEM. c Press F1, [TYPE]. d Select Variables. e Move the cursor to $MCR and press ENTER. f Move the cursor to $SPC_RESET and press F4, TRUE. The value will change to TRUE momentarily, and will then change to FALSE. g If the value does not change to TRUE momentarily, repeat Step 1. h Press RESET on the operator panel. 2 Using the JOINT coordinate system, jog the unmastered axis to the zero degree position. 3 Press MENUS. 4 Select SYSTEM. 5 Press F1, [TYPE]. 6 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 7. a Select VARIABLE from the [TYPE] menu. b Move the cursor to $MASTER_ENB. c Press the numeric key “1” and then press ENTER on the teach pendant. d Press F1, [TYPE]. e Select Master/Cal. See the following screen for an example.

8. MASTERING

8–9

MARMMTRBL02303E

SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ’ENTER’ or number key to select.

[ TYPE ]

LOAD

RES_PCA

7 Select 4, Single Axis Master. See the following screen for an example.

SINGLE AXIS MASTER ACTUAL POS J1 0.000 J2 3.514 J3 –7.164 J4 –357.366 J5 –1.275 J6 4.571 E1 0.000 E2 0.000 E3 0.000 [ TYPE ]

(MSTR POS) ( 0.000) ( 35.000) (–100.000) ( 0.000) ( –80.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000)

JOINT 10% 1/9 (SEL) [ST] (0) [2] (0) [0] (0) [2] (0) [2] (0) [2] (0) [2] (0) [0] (0) [0] (0) [0]

GROUP

EXEC

8 Move the cursor to the MSTR POS column for the unmastered axis and press the “0” key. 9 Continuously press and hold the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. 10

Move the cursor to the SEL column for the unmastered axis and press the numeric key “1.”

11 Press ENTER. 12

Press F5, EXEC. Mastering will be performed automatically.

13

Press PREV.

14

Select Calibrate.

15

Press F4, YES.

8. MASTERING MARMMTRBL02303E

8–10

Ï Ï ÏÏÏ ÏÏÏÏ ÏÎÎ ÏÎÎ ÏÏÏÏ ÏÏ

16

Perform a cold start. a Turn off the robot. b Press and continue pressing the FAULT RESET button on the operator panel. c While still pressing FAULT RESET, press the ON button on the operator panel.

8. MASTERING

8–11

MARMMTRBL02303E

8.4 QUICK MASTERING

Quick mastering allows you to minimize the time required to remaster the robot using a reference position you established when the robot was properly mastered. You cannot quick master the robot unless you have previously recorded this quick master reference position. Record the quick master reference position when the robot is properly mastered. The best time to record the quick master reference position is when the robot is still factory-mastered. If you lose mastery due to an electrical or software problem, you can use this reference position to master the robot in a minimum amount of time. If you lose mastery due to mechanical disassembly or repair, you must master to a fixture or perform zero degree mastering. You can define a quick master reference position and perform quick mastering on any robot model. Use Procedure 8–4 to record the quick master reference position. Use Procedure 8–5 to quick master the robot. CAUTION Record the quick master reference position after the robot is installed to preserve the factory mastering settings for future remastering.

Procedure 8–4 Condition

Recording the Quick Master Reference Position 

The robot is properly mastered.

1 Align the witness marks on the robot. This is the zero position, which will be the quick master reference position. If you have a P-series or A-series robot, jog all robot axes to zero degrees and scribe witness marks on each axis. 2 Press MENUS. 3 Select SYSTEM. 4 Press F1, [TYPE]. 5 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6. a Select VARIABLE from the [TYPE] menu. b Move the cursor to $MASTER_ENB. c Press the numeric key “1” and then press ENTER on the teach pendant.

8. MASTERING MARMMTRBL02303E

8–12 d Press F1, [TYPE].

e Select Master/Cal. See the following screen for an example.

SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ’ENTER’ or number key to select.

[ TYPE ]

LOAD

6 Move the cursor to SET QUICK MASTER REF and press ENTER. Set quick master ref? [NO]

Ï Ï ÏÎÎ ÏÏÏ ÏÏÏ ÎÎÏ ÏÎÎ ÏÏÏÎÎ ÏÏÏÏ Ï Ï

7 Press F4, YES. 8 Perform a cold start. a Turn off the robot. b Press and continue pressing the FAULT RESET button on the operator panel. c While still pressing FAULT RESET, press the ON button on the operator panel.

8. MASTERING

8–13

MARMMTRBL02303E

Procedure 8–5 Condition

Quick Mastering the Robot 

The robot has lost mastery due to an electrical or software problem.

NOTE If the robot has lost mastery due to mechanical disassembly or repair, you cannot perform this procedure. In this case, master to a fixture or master to zero degrees to restore robot mastery. 

The quick master reference position was recorded before the robot lost mastery.

1 Jog the robot to the quick master reference position (zero degree position). 2 Press MENUS. 3 Select SYSTEM. 4 Press F1, [TYPE]. 5 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6. a Select VARIABLE from the [TYPE] menu. b Move the cursor to $MASTER_ENB. c Press the numeric key “1” and then press ENTER on the teach pendant. d Press F1, [TYPE]. e Select Master/Cal. See the following screen for an example.

SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ’ENTER’ or number key to select.

[ TYPE ]

LOAD

6 Move the cursor to QUICK MASTER and press ENTER. Quick master? [NO]

7 Press F4, YES.

8. MASTERING MARMMTRBL02303E

8–14 8 Move the cursor to CALIBRATE and press ENTER 9 Press F4, YES.

Ï Ï ÏÎÎ ÏÏÏ ÏÏÏ ÎÎÏ ÎÎ ÏÏÎÎ ÏÏ ÏÏ

10

Perform a cold start. a Turn off the robot. b Press and continue pressing the FAULT RESET button on the operator panel. c While still pressing FAULT RESET, press the ON button on the operator panel.

MARMMTRBL02303E

9

REPLACING COMPONENTS 9–1 This chapter describes replacement of the following items:              

Batteries Relays Printed Circuit Boards (PCB) Modules Process I/O Boards Modular I/O Components Transformers Servo Amplifiers Operator Panel Fan Motors Replacing the Discharge Resistor (DCR) and Dynamic Brake Resistor (DRB) unit Replacing the Regenerative Discharge unit Replacing the Optional Warning Light Replacing Serial Pulse coders

NOTE To replace output drivers on the process I/O boards, refer to Chapter 10.

9. REPLACING COMPONENTS MARMMTRBL02303E

9–2

9.1

FANUC Robotics recommends that all batteries be changed immediately prior to production start up. Change the batteries annually to assure reliable robot performance. Use Procedure 9–1 to replace the battery: Use Procedure 9–2 to replace the SPC battery.

REPLACING THE BATTERY

Procedure 9–1 Step

Replacing the Battery 1 Get the new battery. (number: A98L-0031-0007) 2 Power down and lock out the controller. CAUTION The battery must be replaced within 30 minutes. If the power is turned off and the battery is removed for 30 minutes or more, the contents of the memory on the main CPU printed circuit board may be lost.

WARNING Do not short circuit or incinerate a discarded battery. Follow your company’s procedures for disposing of lithium batteries.

WARNING Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock. 3 Remove the battery case from the front panel of the power supply unit. The case can be removed easily by squeezing the top and bottom of it and pulling. Figure 10–1. Replacing the Battery (1)

BATTERY

Cable connector

Front panel of the power supply unit Battery (ordering drawing number: A98L-0031-0007)

Battery case

Front panel of the power supply unit

PC board connector

4 Remove the connector from the battery.

Battery

9. REPLACING COMPONENTS

9–3

MARMMTRBL02303E

5 Replace the battery and reconnect the connector. 6 Install the battery case. Procedure 9–2 Step

Replacing the SPC Batteries 1 Get four new alkaline D–cell batteries. 2 Turn on the controller. 3 Press the operator panel Emergency Stop button and the teach pendant Emergency Stop button. 4 Turn on the teach pendant and take it with you into the workcell. 5 Remove the black plastic battery cover on the base of the robot. 6 Remove the old batteries. 7 Insert the new batteries. The new batteries must be arranged as follows: Upper left – positive end out. Upper right – negative end out. Lower left – negative end out. Lower right – positive end out. 8 Replace the battery cover. 9 Cold start the controller. The teach pendant might display a SRVO–065 BLAL alarm. This is normal. It will reset when you cold start the controller.

9. REPLACING COMPONENTS MARMMTRBL02303E

9–4

9.2

A relay may fail after it is used for a long time. The relay or its circuit board must be replaced. Relays RL1-RL6 on the EMG board are replaceable.

REPLACING A RELAY

Figure 10–2. Replacing a Relay

DS2 F1 DS1

F2 RL16

FUSE

RL1 RL2 RL4 RL3

LED M1 LED M2

2

1

RL4 TIMER

3

6 8 CNPG

9

5 7

TM1 TM2 CRX

9. REPLACING COMPONENTS

9–5

MARMMTRBL02303E

Figure 10–3. Replacing a Relay

Relay

Table 9–1.

Relay Part Numbers

Name RL1 RL2 RL3 RL4 RL5, RL6 Table 9–2.

Part Numbers A58L–0001–0192#1472R

A58L–0001–0192#1192D

Relay Part Numbers

Name RL1, RL2 RL3, RL16 RL4 RL5, RL8, RL10, RL15 RL5, RL6

Part Numbers A58L–0001–0192#1472R A58L–0001–0192#1509A A58L–0001–0192#1192D A58L–0001–0260#234PH–24 A58L–0001–0192#1192D

9. REPLACING COMPONENTS MARMMTRBL02303E

9–6

9.2.1

Part Number: A16B–1600–0520

Purge Control PCB

Table 9–3.

PCB Relay Part Numbers

Name RL4 Timer Relay RL1, RL3, RL5, RL9

Part Numbers A58L–0001–0269#B24 A58L–0001–0260#234PH–24

9. REPLACING COMPONENTS MARMMTRBL02303E

9.3 REPLACING A PRINTED CIRCUIT BOARD

9–7

When replacing a printed circuit board, take the following precautions: 1. Before starting replacement, power down and lock out the controller. 2. When removing the printed circuit board, do not touch semiconductor components on it and do not let the components touch other components. 3. Wear a grounded wrist strap. Do not remove the new board from its conductive bag until you are ready to install it. 4. Check that any jumpers on the printed circuit board to be installed are correctly set. 5. When replacing the main CPU printed circuit board, all software stored in the controller will be lost. Before starting replacement, back up your user programs, mastering data, and system variable data onto a floppy disk. 6. Connect the cables removed for replacement to the original positions. If the cable markings are missing or unclear, retag them before disconnecting them.

9. REPLACING COMPONENTS MARMMTRBL02303E

9–8

9.3.1

Use Procedure 9–3 to replace the backplane printed circuit board. The backplane printed circuit board and the yellow board rack are removed and replaced as one unit.

Replacing the Backplane Printed Circuit Board Refer to Chapter 1 for part numbers. Procedure 9–3 Step

Replacing the Backplane Printed Circuit Board 1 Remove the battery from the power supply unit and plug it into the battery connector on the front panel of the main CPU. 2 Remove all printed circuit boards from the backplane. Use Procedure 9–4 . 3 Disconnect the ground wire from the backplane printed circuit board. 4 Remove the two or three mounting screws at the bottom of the rack. 5 Loosen the two or three mounting screws at the top of the rack and remove the rack/backplane assembly. 6 Install the new rack/backplane assembly in reverse order. Be sure to move the battery back to the power supply unit from the main CPU. Figure 10–4. Replacing the Backplane Printed Circuit Board

Backplane PC board

M5 mounting screw

9. REPLACING COMPONENTS

9–9

MARMMTRBL02303E

9.3.2

Use Procedure 9–4 to replace a component on the backplane printed circuit board.

Replacing a Component on the Backplane Printed Circuit Board Refer to Chapter 1 for part numbers. Procedure 9–4

Step

Replacing a Component on the Backplane Printed Circuit Board NOTE When the main CPU is replaced, all software stored in the controller will be lost. If possible, back up your user programs, mastering data, and system variable data on a floppy disk before starting replacement. 1 Turn off and lock out the controller. 2 Disconnect any cables and harnesses on the component to be replaced. 3 Squeeze the latch tabs at the top and bottom of the component and pull the component straight out. 4 Set any jumpers on the new component to match the component being replaced. 5 Insert the new component into the proper slot of the backplane rack. Carefully press it into the slot until the latches engage at the top and bottom. 6 Reconnect all cables and harnesses. Figure 10–5. Replacing Printed Circuit Boards on the Backplane Printed Circuit Board Process input/output PC board CA, CB, or DA Main CPU board (*1) Axis control PC board Power supply unit (*2) Emergency stop control PC board

9. REPLACING COMPONENTS MARMMTRBL02303E

9–10

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

Use the following procedure to replace a module: 1. Move the latches at both ends of the module socket toward the outside. The spring of the contact tilts the module. See Figure 10–6. Figure 10–6. Moving the Latches on the End of the Module Socket

Refer to Chapter 1 for part numbers.

2. If the tilted module touches the next module, it might be difficult to remove it. In this case, release the latches of the next module as described in step 1 above. 3. Now the module is free in the socket. Pull out the module carefully in a straight line. Do not pull it out in an arc. The contacts of the socket or module might be damaged. 4. Install a new module in the socket at an angle. Push it into the socket until the bottom of the module reaches the bottom of the socket groove. Be sure you have the module facing in the proper direction. align the groove in the module with the tab as shown in Figure 10–7. Figure 10–7. Installing a New Module at an Angle

Short

Long Fit the recess on the module over the tab in the module socket.

9. REPLACING COMPONENTS

9–11

MARMMTRBL02303E

5. Push the module in the top edge so that the module stands upright. See Figure 10–8. Figure 10–8. Pushing in the Module

6. Check that the module is latched properly at both ends of the socket. If it is insufficiently latched, the electrical contact might be improper and a malfunction could occur.

9. REPLACING COMPONENTS MARMMTRBL02303E

9–12

Figure 10–9 shows the mounting locations of the modules. Figure 10–9. Mounting Locations of the Modules

FLASH

Flash ROM module

Optional SCC module

CMOS RAM module (option)

SLC2 module

CMOS RAM module (option)

M321 module

CMOS RAM module (standard)

SCC module

CMOS RAM module (standard)

Main CPU PC board

Servo control module (for axis 9 and 10) Servo control module (for axis 7 and 8) Servo control module (for axis 5 and 6) Servo control module (for axis 3 and 4) Servo control module (for axis 1 and 2) Servo interface module (for axis 5 and 6) Servo interface module (for axis 3 and 4) Servo interface module (for axis 1 and 2)

Axis control PC board

9. REPLACING COMPONENTS

9–13

MARMMTRBL02303E

9.5 REPLACING THE PROCESS INPUT/OUTPUT PRINTED CIRCUIT BOARD AA, AB, BA OR BB

Part numbers: A16B-2200-0780, A16B-2200-0782, and A16B-2201-0510 1. Remove the cable from the process input/output printed circuit board to be replaced. 2. Remove the two screws from the left side of the process input/output printed circuit board. 3. Remove the board by pulling outward to the left. 4. Replace the printed circuit board with a new one.

Refer to Chapter 1 for part numbers.

5. Replace the two screws removed in step 2. 6. Replace the cables. NOTE For replacing output drivers on the process I/O boards refer to Chapter 10. Figure 10–10. Replacing the Process Input/Output Printed Circuit Board AA, AB, BA, or BB

M4 screw

9. REPLACING COMPONENTS MARMMTRBL02303E

9–14

9.6 REPLACING COMPONENTS OF THE MODULAR INPUT/OUTPUT UNIT Refer to Chapter 1 for part numbers.

9.6.1

Use the information in this section to replace the following components of the modular I/O unit:          

Base Unit Modules Multi-Tap Transformer Servo Amplifier Operator Panel Fan Motor Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) Unit Regenerative Discharge Unit Optional Warning Light Serial Pulse Coder

Use Procedure 9–5 to replace the base unit.

Replacing the Base Unit Ordering code: A03B-0807-J002 Procedure 9–5 Step

Replacing the Base Unit 1 Remove the I/O modules from the base unit. 2 Loosen the upper two mounting screws. 3 Remove the lower two mounting screws and replace the base unit.

9. REPLACING COMPONENTS

9–15

MARMMTRBL02303E

Figure 10–11. Replacing the Base Unit of the Modular Input/Output Unit

M4 screw

9. REPLACING COMPONENTS MARMMTRBL02303E

9–16

9.6.2 Replacing a Module Procedure 9–6 Removing the Interface Module

Replacing the Interface Module 1 Power down and lock out the controller. 2 Disconnect the signal and power cables from the interface module. 3 Press the latch on the bottom of the module and rotate the module toward you and up.

Installing the Interface Module

1 Engage the hook at the top rear of the module with the bar above the base unit socket. 2 Rotate the module downward until the latch engages. 3 Reconnect the signal and power cables to the interface module.

Procedure 9–7 Removing an I/O Module

Replacing an I/O Module 1 Power down and lock out the controller. 2 Remove the wiring harness block. (See Figure 10–13.) a Lift the latch at the lower left corner of the module window. b Rotate the block toward you and down. 3 Press the latch on the bottom of the module and rotate the module toward you and up. (See Figure 10–12.)

Installing an I/O Module

1 Engage the hook at the top read of the module with the bar above the base unit socket. 2 Rotate the module downward until the latch engages.

9. REPLACING COMPONENTS

9–17

MARMMTRBL02303E

Figure 10–12. Removing and Replacing a Module

3 Install the wiring harness block. a Engage the hook at the bottom rear of the block with the bar at the bottom of the module. b Rotate the block upward until the latch engages. Figure 10–13. Removing and Replacing a Terminal Block

9. REPLACING COMPONENTS MARMMTRBL02303E

9–18

9.7

Use Procedure 9–8 to replace the multi-tap transformer.

REPLACING THE MULTI-TAP TRANSFORMER Refer to Chapter 1 for part numbers. Procedure 9–8

Condition Step

Replacing the Multi-Tap Transformer 

The controller is turned off and locked out.

1 Remove the acrylic covers from the transformer and ALC relay. 2 Disconnect the wiring harnesses and ground wire from the transformer. 3 Disconnect the three wires from the bottom of the ALC relay. 4 After removing the eight screws fastening the transformer, remove the transformer. Put a new transformer on the rail in the controller and push it into the controller along the rail. Then reinstall the screws. 5 Reconnect the wires and harnesses. 6 Reinstall the acrylic covers. Figure 10–14. Replacing the Multi-Tap Transformer

M5 screws

9. REPLACING COMPONENTS

9–19

MARMMTRBL02303E

9.8

Use Procedure 9–9 to replace a servo amplifier.

REPLACING A SERVO AMPLIFIER Refer to Chapter 1 for part numbers. Procedure 9–9

Condition Step

Replacing a Servo Amplifier 

The controller is turned off and locked out.

1 Remove the five bus bars from the servo amplifier bank. 2 Disconnect the wires from the servo amplifier terminal strip. Remove the two screws fastening the servo amplifier and remove the amplifier. 3 Set the terminal strip jumpers on the new servo amplifier to match those of the one you removed. 4 Install the new servo amplifier by following these steps in reverse order. Figure 10–15. Replacing a Servo Amplifier

M5 screw

9. REPLACING COMPONENTS MARMMTRBL02303E

9–20

9.9

Use Procedure 9–10 to replace the operator panel.

REPLACING THE OPERATOR PANEL Refer to Chapter 1 for part numbers. Procedure 9–10 Condition Step

Replacing the Operator Panel 

The controller is turned off and locked out.

1 Remove the cable from the operator panel. 2 Remove the six nuts fastening the operator panel and replace the operator panel. 3 When replacing only the operator panel printed circuit board, replace it together with the metal plate. 4 After removing the cable from the operator panel printed circuit board, remove the four nuts fastening the metal plate. Then replace the operator’s panel printed circuit board. Figure 10–16. Replacing the Operator Panel

Operator panel (rear face) M4 nuts (4 pieces)

9. REPLACING COMPONENTS

9–21

MARMMTRBL02303E

9.10

Use Procedure 9–11 to replace the fan motor.

REPLACING THE FAN MOTOR Refer to Chapter 1 for part numbers. Procedure 9–11 Condition Step

Replacing the Fan Motor 

The controller is turned off and locked out.

1 Remove the printed circuit board located below the fan motor to be replaced, following Procedure 9–4 . 2 The cable connected to the fan motor is connected to the backplane printed circuit board in the slot. Holding the connector, remove the cable from the backplane printed circuit board. 3 Open the lid at the top of the backplane rack by placing the tip of a flat–blade screwdriver into the center hole at the front of the lid and moving the screwdriver like a lever in the direction in Figure 10–17 to release the latch. 4 Remove the fan motor. 5 Install a new fan motor. Route the cable through the hole at the back of the rack. 6 Close the lid until it is latched. 7 Connect the cable of the fan motor to the connector on the backplane printed circuit board. Suspend the center of the cable on the hook in the back of the rack. 8 Reinstall the removed printed circuit board using the procedure described in Section 9.3.2.

9. REPLACING COMPONENTS MARMMTRBL02303E

9–22 Figure 10–17. Replacing the Fan Motor

(3) (4)

Fan motor Cable

Connector Backplane PC board

9. REPLACING COMPONENTS

9–23

MARMMTRBL02303E

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

Procedure 9–12

Condition Step

Use Procedure 9–12 to replace the discharge resistor (DCR) and dynamic brake resistor (DBR) unit.

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

The controller is turned off and locked out.

1 Use FANUC part number A05B-2302-C080 to replace the DCR and DBR unit. 2 Remove the cable from the DCR and DBR unit to be replaced. 3 Remove the two screws fastening the DCR and DBR unit and replace it. 4 Reattach the cable to the new DCR and DCR unit.

9. REPLACING COMPONENTS MARMMTRBL02303E

9–24

Figure 10–18. Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) Unit

M5 SCREW (2 pieces)

9. REPLACING COMPONENTS

9–25

MARMMTRBL02303E

9.12

Use Procedure 9–13 to replace the regenerative discharge unit.

REPLACING THE REGENERATIVE DISCHARGE UNIT Procedure 9–13 Condition Step

Replacing the Regenerative Discharge Unit 

The controller is turned off and locked out.

1 Use FANUC part number A05B-2312-C100 for the M-500, and part number A05B-2313-C100 for the S-900, for replacement of the regenerative discharge unit. 2 Disconnect the cable connected to the regenerative discharge unit. 3 Remove the four M5 screws fastening the discharge unit. Then replace the unit. Figure 10–19. Replacing the Regenerative Discharge Unit Four M5 fastening screws

9. REPLACING COMPONENTS MARMMTRBL02303E

9–26

9.13

Use Procedure 9–14 to replace the optional warning light.

REPLACING THE OPTIONAL WARNING LIGHT Procedure 9–14 Condition Step

Replacing the Optional Warning Light 

The controller is turned off and locked out.

1 Use FANUC part number LAMPXVAL74C024X to replace the warning light. 2 Remove the existing light assembly from the robot and replace with the new light assembly. 3 Reconnect the replacement light assembly.

9. REPLACING COMPONENTS

9–27

MARMMTRBL02303E

9.14

Use Procedure 9–15 to replace a serial pulse coder.

REPLACING A SERIAL PULSE CODER

Procedure 9–15

Replacing a Serial Pulse Coder

NOTE The robot will have to be remastered after this procedure. Condition Step



The controller is turned off and locked out.

1 Remove the cables from the pulse coder. Refer to Figure 10–20. 2 Remove the screws holding the pulse coder cable connector to the pulse coder housing. 3 Retract the rubber boot on the inside of the pulse coder cable connector. 4 Remove the snap ring on the inside of the pulse coder cable connector. 5 Detach the pulse coder cable from the pulse coder housing.

CAUTION In the next step, be sure to remove the correct bolts, as shown in Figure 10–20. Removing the wrong bolts can destroy the pulse coder.

6 Remove the four M4 bolts attaching the pulse coder to the motor. 7 Position the new pulse coder on the motor so that the Oldham coupling engages. If there are witness marks on the pulse coder case and the motor case, make sure that they line up. 8 Install the four M4 bolts. 9 Attach the pulse coder cable to the pulse coder housing. 10

Install the snap ring on the inside of the pulse coder cable connector.

11 Reposition the rubber boot on the inside of the pulse coder cable connector. 12

Replace the screws holding the pulse coder cable connector to the pulse coder housing.

13

Install the screws holding the pulse coder housing to the motor.

14

Attach the cables to the pulse coder housing.

9. REPLACING COMPONENTS MARMMTRBL02303E

9–28 Figure 10–20. Removing the Pulse Coder

Caution: Do not remove the screws from these four ribbed holes. The serial pulse coder will seperate and be destroyed

M4 Mounting Bolt Holes

10

BOARD ADJUSTMENTS 10–1

MARMMTRBL02303E

This chapter contains information about components located on some printed circuit boards that require adjustment. These components include jumpers and potentiometers.

10.1 AXIS CONTROL BOARD JUMPERS

You can set jumpers on the axis control board. Figure 11–1 shows an illustration of the axis control board. Table 10–1 lists the standard settings for the jumpers found on the axis control board. Figure 11–1. Axis Control Board Jumpers

A

Table 10–1. Name

COM B JUMPER

B

HBK JUMPER

A

Axis Control Board Jumpers Standard setting

Description

COM

Side A

Side A: The RI lines use 0V for the common reference Side B:The RI lines use +24 for the common reference

HBK

Side B

Side A: The hand breakage detect feature is not used. Side B: The hand breakage detect feature is used.

10. BOARD ADJUSTMENTS MARMMTRBL02303E

10–2

10.2 PROCESS I/O BOARD

The process I/O board has jumpers, potentiometers you can adjust, and output drivers you can replace. The process I/O boards are shown in Figures 10–2 through Figure 10–8. Figure 11–2. Process I/O Board AA

Figure 11–3. Process I/O Board AB

10. BOARD ADJUSTMENTS

10–3

MARMMTRBL02303E

Figure 11–4. Process I/O Board BA

Figure 11–5. Process I/O Board BB

10. BOARD ADJUSTMENTS MARMMTRBL02303E

10–4 Figure 11–6. Process I/O Board CA

Figure 11–7. Process I/O Board CB

10. BOARD ADJUSTMENTS

10–5

MARMMTRBL02303E

Figure 11–8. Process I/O Board DA

10.2.1 Jumpers

Table 10–2 lists the standard settings for the jumpers located on the process I/O board. Table 10–2.

Process I/O Board Jumpers Name

ICOM1

UDI1 to UDI20 (Connector CRM2A)

ICOM2

UDI21 to UDI40 (Connector CRM2B)

ICOM3

WI01 to WI08 (Connector CRW1) See Note

SP1

Channel 1

SP2

Channel 2

Standard setting

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

Side A NOTE: Set ICOM3 to B side to use WDI2 as weld detect input.

Open

The polarity of the output voltage is switched to Strapped: Negative (–) Open: Positive (+)

10. BOARD ADJUSTMENTS MARMMTRBL02303E

10–6

10.2.2 Potentiometers

Table 10–3 lists the process I/O board potentiometers and the adjustments you can make to them. Table 10–3.

Process I/O Board Potentiometer Adjustments

Potentiometer

Description

Adjustment

Adjusts the gain of channel 1

Execute a robot program and set AO[1] to 4095 on the teach pendant. Connect a digital voltmeter to test pin AO1 and rotate VR1 until the meter reads 12.0 V. Connect the negative (–) lead of the digital voltmeter to test pin 0VF.

Adjusts the gain of channel 2

Execute a robot program and set AO[2] to 4095 on the teach pendant. Connect the digital voltmeter to test pin AO2 and rotate VR2 until the meter reads 12.0 V. Connect the negative (–) lead of the digital voltmeter to test pin 0VF. (The 0VF test pin is different from the common 0V test pin.)

Adjusts the reference supply voltage of the digital/analog converter

Connect the digital voltmeter to test pin P10V and rotate VR3 until the meter reads 10.00
0.1 V.

VR1

VR2

VR3

10. BOARD ADJUSTMENTS

10–7

MARMMTRBL02303E

10.2.3

Table 10–4 lists the output drivers for each process I/O board.

Output Drivers Table 10–4.

Output Drivers DO Signal

Driver

AA

AB

BA

BB

CA

CB

DA

DV1

CMDENBL, SYSRDY, PROGRUN, PAUSED

DV2

HELD, FAULT, ATPERCH, TPENBL

DV3

BATALM, BUSY, ACK1/SNO1, ACK2/SNO2

DV4

ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6

DV5

ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED

DV6

SO01, SO02, SO03, SO04

DV7

SO05, SO06, SO07, SO08

DV8

SO09, SO10, SO11, SO12

DV9

SO13, SO14, SO15, SO16

DV10

SO17, SO18, SO19, SO20

DV11

WO01, WO02, WO03, WO04

—

—

—

WO01, WO02, WO03, WO04

—

SO21, SO22, SO23, SO24

DV12

WO05, WO06, WO07, WO08

—

—

—

WO05, WO06, WO07, WO08

—

SO25, SO26, SO27, SO28

DV13

—

—

—

—

—

—

SO29, SO30, SO31, SO32,

DV14

—

—

—

—

—

—

SO33, SO34, SO35, SO36

DV15

—

—

—

—

—

—

SO37, SO38, SO39, SO40

DV16

—

—

—

—

—

—

SO41, SO42, SO43, SO44

DV17

—

—

—

—

—

—

SO45, SO46, SO47, SO48

DV18

—

—

—

—

—

—

SO49, SO50, SO51, SO52

DV19

—

—

—

—

—

—

SO53, SO54, SO55, SO56

DV20

—

—

—

—

—

—

SO57, SO58, SO59, SO60

DV21

—

—

—

—

—

—

SO61, SO62, SO63, SO64

DV22

—

—

—

—

—

—

SO65, SO66, SO67, SO68

DV23

—

—

—

—

—

—

SO69, SO70, SO71, SO72

DV24

—

—

—

—

—

—

SO73, SO74, SO75, SO76

RESERVED

—

—

—

—

To be used for replacement

To be used for replacement

To be used for replacement

10. BOARD ADJUSTMENTS MARMMTRBL02303E

10–8

10.3 BUILT–IN CRT/KB UNIT

This section contains information about adjusting the built-in CRT/KB unit.

CRT Display Unit

The following can be adjusted at the CRT Display Unit:

20³ CRT/KB A05B-2051-J101

       

40³ CRT/KB A05B-2301-J130

Brightness (BRIGHT) Contrast (CONT) Focus Horizontal size (H-SIZE) Vertical size (V-SIZE) Horizontal Hold (H-HOLD) Vertical Hold(V-HOLD) Vertical linearity (V-LIN) CAUTION Keep fingers and tools away from the CRT display unit when first turning the power on. Use caution at the display unit anytime when power is on because 10-11 KV is present.

Brightness

Turn to the brightest level possible before roster (scanning lines) appear on the screen.

Contrast

Adjust the “CONT” variable resistor until display characters achieve an easy to read brightness level. Too much contrast can distort the characters.

Focus

Adjust “FOCUS” variable resistor to ”sharpen” characters.

Horizontal Size (Width)

Adjust the “H–SIZE” coil if picture width appears too small or distorted on the sides.

Vertical Size (Height)

Adjust the “V–SIZE” variable resistor if the picture height appears too small or distorted at the top.

Horizontal Hold

Adjust the “H–HOLD” variable resistor if the picture rolls or shifts horizontally (or diagonally).

Vertical Hold (V-HOLD)

Adjust the “V–HOLD” variable resistor if the picture rolls vertically.

Vertical Linearity (V-LIN)

Adjust the “V–LIN” variable resistor to obtain equal character size vertically in the upper and lower parts of the screen.

10. BOARD ADJUSTMENTS

10–9

MARMMTRBL02303E

The following can be adjusted at the CRT/KB Control Board: 

+ 5VDC power supply

Refer to Figure 11–9 and adjust as follows: +5VDC supply: Monitor the ”+5 VDC” test point and adjust variable resistor VR1 until + 5VDC
0.1V is obtained. 

Jumper ST1

Refer to Figure 11–10 for jumper setting. Figure 11–9. Front View Control Board VR1 Test point ”+5V” ST1

Figure 11–10. Jumper Setting CRT/KB

Jumper

Standard setting

ST1 A

SIDE A = KANA + ALPHA NUMERIC

ÉÉÉÉ ÉÉÉÉ

B

SIDE B = ALPHA NUMERIC

10. BOARD ADJUSTMENTS MARMMTRBL02303E

10–10

10.4

The EMG board contains a jumper which controls the sensitivity of the brake alarm circuit. Refer to SRVO_ALARM 008.

EMG BOARD

Figure 11–11.

EMG board

EMG PCB

Table 10–5.

SBK Jumper Settings

Standard Setting NAME

S-5, S-10, Arc Mate, Arc Mate 100/S-6, Arc Mate Sr., A-510, L-1000, S-900, M-500

SBK1

Open

S-500, S-700, S-800, M-400

Side 2

SBK2 SBK3 SBK4 SBK5 SBK6 SET

S-420, S-420D

Description

The sensitivity of a brake is adjusted (for a swiveling axis).

Open

Side 2

Side 1

The sensitivity for the fuse alarm of a brake is adjusted to : Side 1: Special setting Side 2: Standard setting

MARMMTRBL02303E

11

CONNECTIONS 11–1 This chapter describes the electrical interface connections in the R-J controller. Figure 12–1 is a block diagram of electrical interface connections with the R-J controller. Figure 12–1. Block Diagram of Electrical Interface Connection

Pneumatic pressure Purge Source

ISB Unit

Teach Pendant (ISTP)

––ABKR I/O ––GEF I/O Modular I/O

Disk Drive

*1: *2:

A remote display is connected. Optional RS-232-C or RS-422/485 interface.

11. CONNECTIONS MARMMTRBL02303E

11–2

11.1 MECHANICAL CONNECTIONS

Figure 12–2 through Figure 12–12 show connection diagrams to the mechanical units. Figure 12–2. Mechanical Connection Diagram for S-420, S-500, S-700, S-800, and M-400

*1: *2:

This cable is not included. It must be supplied by the customer. Can be connected when the robot is S-500 or S-700.

Figure 12–3. Mechanical Connection Diagram for ARC Mate, ARC Mate 100/S-6, ARC Mate Sr., A-510, and L-1000

*1: *2:

This cable is not included. It must be supplied by the customer. Can be connected when the robot is ARC Mate or ARC Mate Sr.

11. CONNECTIONS

11–3

MARMMTRBL02303E

Figure 12–4. Mechanical Connection Diagram for Six-Axis Pedestal Mount System with Battery in Controller R−J

ROBOT M1 SERVO AMP TERMINAL/FRAME AXIS 1 & 2

C1M1

SERVO AMP TERMINAL/FRAME AXIS 3

C1M3

SERVO AMP TERMINAL/FRAME AXIS 4,5, & 6

C1M2

M3

M2

AXIS CONTROL PCB − CRF1 (PULSE CODER SIGNAL)

CRR5 − EMG PCB P & M BRAKE SIGNALS

P1 C1P1

C1M5

D1 CONTACT SIGNAL TRANSDUCER (IBRC)

C1D1 (INTRINSIC)

+6V & 0V BATT

C1B1 (INTRINSIC)

+24PG & 0V PURGE CONTROL PCB

C1P2

GROUND CABLE

DC−DC 24V

5V

11. CONNECTIONS MARMMTRBL02303E

11–4

Figure 12–5. Mechanical Connection Diagram for Six-Axis Pedestal Mount System with Battery in Robot R−J

ROBOT M1

SERVO AMP TERMINAL/FRAME AXIS 1 & 2

C1M1

SERVO AMP TERMINAL/FRAME AXIS 3

C1M3

SERVO AMP TERMINAL/FRAME AXIS 4,5, & 6

C1M2

M3

AXIS CONTROL PCB − CRF1 (PULSE CODER SIGNAL)

CRR5 − EMG PCB P & M BRAKE SIGNALS

CONTACT SIGNAL TRANSDUCER (IBRC)

+24PG & 0V PURGE CONTROL PCB

M2

P1 C1P1

C1M5

D1 C1D1 (INTRINSIC)

C1P2

GROUND CABLE

DC−DC 24V

5V

11. CONNECTIONS

11–5

MARMMTRBL02303E

Figure 12–6. Mechanical Connection Diagram for Catrac Robot Clean-Wall Rail System with Battery in Controller R−J

JUNCTION BOX M1

SERVO AMP TERMINAL/FRAME AXIS 1 & 2

C1M1

SERVO AMP TERMINAL/FRAME AXIS 3 & 7

C1M3

SERVO AMP TERMINAL/FRAME AXIS 4,5, & 6

C1M2

AXIS CONTROL PCB − CRF1 (PULSE CODER SIGNAL)

ROBOT M1 C2M1

M3

M3 C2M3

M2

M2 C2M2

P1

P1

C1P1

C2P1

C1M5

C2M5

AXIS CONTROL PCB − JF7 (PULSE CODER SIGNAL−AXIS7)

CRR5 − EMG PCB P & M BRAKE SIGNALS

CONTACT SIGNAL TRANSDUCER (IBRC) +6V & 0V BATT +24PG & 0V PURGE CONTROL PCB

D1

D1

C1D1 (INTRINSIC)

C2D1 (INTRINSIC)

C1B1 (INTRINSIC)

C2B1 (INTRINSIC) P2

C1P2

GROUND CABLE

C2P2

GROUND CABLE

DC−DC 24V

5V

11. CONNECTIONS MARMMTRBL02303E

11–6

Figure 12–7. Mechanical Connection Diagram for Catrac Robot Clean-Wall Rail System with Battery in Robot R−J

JUNCTION BOX M1

SERVO AMP TERMINAL/FRAME AXIS 1 & 2

C1M1

SERVO AMP TERMINAL/FRAME AXIS 3 & 7

C1M3

SERVO AMP TERMINAL/FRAME AXIS 4,5, & 6

C1M2

AXIS CONTROL PCB − CRF1 (PULSE CODER SIGNAL)

ROBOT M1 C2M1

M3

M3 C2M3

M2

M2 C2M2

P1

P1

C1P1

C2P1

C1M5

C2M5

AXIS CONTROL PCB − JF7 (PULSE CODER SIGNAL−AXIS7)

CRR5 − EMG PCB P & M BRAKE SIGNALS

CONTACT SIGNAL TRANSDUCER (IBRC)

+24PG & 0V PURGE CONTROL PCB

D1 C1D1 (INTRINSIC)

D1 C2D1 (INTRINSIC)

P2 C1P2

GROUND CABLE

C2P2

GROUND CABLE

DC−DC 24V

5V

11. CONNECTIONS

11–7

MARMMTRBL02303E

Figure 12–8. Mechanical Connection Diagram for Seven–Axis Universal Rail System with Battery in Controller R−J

ROBOT M1

SERVO AMP TERMINAL/FRAME AXIS 1 & 2

C1M1

SERVO AMP TERMINAL/FRAME AXIS 3 & 7

C1M3

SERVO AMP TERMINAL/FRAME AXIS 4,5, & 6

C1M2

AXIS CONTROL PCB − CRF1 (PULSE CODER SIGNAL)

M3

M2

P1 C1P1

AXIS CONTROL PCB − JF7 (PULSE CODER SIGNAL−AXIS7)

CRR5 − EMG PCB P & M BRAKE SIGNALS

CONTACT SIGNAL TRANSDUCER (IBRC) +6V & 0V BATT +24PG & 0V PURGE CONTROL PCB

C1M5

D1 C1D1 (INTRINSIC)

C1B1 (INTRINSIC)

C1P2

GROUND CABLE

DC−DC 24V

5V

11. CONNECTIONS MARMMTRBL02303E

11–8

Figure 12–9. Mechanical Connection Diagram for Seven-Axis Universal Rail System with Battery inRobot R−J

ROBOT M1

SERVO AMP TERMINAL/FRAME AXIS 1 & 2

C1M1

SERVO AMP TERMINAL/FRAME AXIS 3 & 7

C1M3

SERVO AMP TERMINAL/FRAME AXIS 4,5, & 6

C1M2

AXIS CONTROL PCB − CRF1 (PULSE CODER SIGNAL)

M3

M2

P1 C1P1

AXIS CONTROL PCB − JF7 (PULSE CODER SIGNAL−AXIS7)

CRR5 − EMG PCB P & M BRAKE SIGNALS

CONTACT SIGNAL TRANSDUCER (IBRC)

+24PG & 0V PURGE CONTROL PCB

C1M5

D1 C1D1 (INTRINSIC)

C1P2

GROUND CABLE

DC−DC 24V

5V

11. CONNECTIONS

11–9

MARMMTRBL02303E

Figure 12–10. Mechanical Connection Diagram for Seven-Axis Universal Rail System with Battery in Controller and Junction Box R−J

JUNCTION BOX

M1

M1

SERVO AMP TERMINAL/FRAME AXIS 1 & 2

C1M1

SERVO AMP TERMINAL/FRAME AXIS 3 & 7

C1M3

SERVO AMP TERMINAL/FRAME AXIS 4,5, & 6

C1M2

AXIS CONTROL PCB − CRF1 (PULSE CODER SIGNAL)

ROBOT

C2M1 M3

M3 C2M3

M2

M2 C2M2

P1

P1 C1P1

C2P1

C1M5

C2M5

AXIS CONTROL PCB − JF7 (PULSE CODER SIGNAL−AXIS7)

CRR5 − EMG PCB P & M BRAKE SIGNALS

D1

D1

CONTACT SIGNAL TRANSDUCER (IBRC)

C1D1 (INTRINSIC)

C2D1 (INTRINSIC)

+6V & 0V BATT

C1B1 (INTRINSIC)

C2B1 (INTRINSIC)

+24PG & 0V PURGE CONTROL PCB

P2 C1P2

GROUND CABLE

C2P2

GROUND CABLE

DC−DC 24V

5V

11. CONNECTIONS MARMMTRBL02303E

11–10

Figure 12–11. Mechanical Connection Diagram for Seven-Axis Universal Rail System with Battery in Robot and Junction Box

R−J

JUNCTION BOX M1

SERVO AMP TERMINAL/FRAME AXIS 1 & 2

C1M1

SERVO AMP TERMINAL/FRAME AXIS 3 & 7

C1M3

SERVO AMP TERMINAL/FRAME AXIS 4,5, & 6

C1M2

AXIS CONTROL PCB − CRF1 (PULSE CODER SIGNAL)

ROBOT M1 C2M1

M3

M3 C2M3

M2

M2 C2M2

P1

P1

C1P1

C2P1

C1M5

C2M5

AXIS CONTROL PCB − JF7 (PULSE CODER SIGNAL−AXIS7)

CRR5 − EMG PCB P & M BRAKE SIGNALS

D1

CONTACT SIGNAL TRANSDUCER (IBRC)

C1D1 (INTRINSIC)

+24PG & 0V PURGE CONTROL PCB

C1P2

D1 C2D1 (INTRINSIC)

P2

GROUND CABLE

C2P2

GROUND CABLE

DC−DC 24V

5V

11. CONNECTIONS

11–11

MARMMTRBL02303E

Figure 12–12. Mechanical Connection Diagram, Common Part

(*2)

(*2) or Floppy Disk Drive (*3)

(*3)

(*3)

Auto breaker

(*3)

(*3)

*1: *2: *3:

K41 is optional. K40 is not required if K41 is specified. This cable is provided with the FANUC Handy File or the floppy disk drive. Not included. Must be supplied by the customer.

11. CONNECTIONS

11–12

11.1.1 Robot Connection Cables

MARMMTRBL02303E

For the S-420, cables K70, K71, and K72 are connected as shown in Figure 12–15.

11. CONNECTIONS

11–13

MARMMTRBL02303E

11.1.2

For the P-155, cables C1M1, C1M2, C1M3, C1M5 and C1P1 are connected as shown in Figure 12–13 through Figure 12–23.

Robot Connection Cables AMP 1

Figure 12–13. Six-Axis Pedestal

AMP 2

AXIS

AMP 3

EMG

CONTROL

CONTROL

PCB 9 20 21 22

10 11 12

23

9 20 21 22

10 11 12

23

9 20 21 22

PCB

CRF1

10 CRR5

11 12

23

C1P1