Navigation

  • Page 1

    FANUC RobotS-10/S-700Maintenance and TroubleshootingReference ManualMARMKS17H0885EF(B-67395E-G/01)This publication contains proprietary informationofFANUC RoboticsNorth America,Inc., furnishedforcustomer use only.No otheruses areauthorizedwithout the express written permissionofFANUC RoboticsNort...

  • Page 2

    The description and specifications contained in this manualwere in effectat the timethis manualwas approvedfor printing.FANUC RoboticsNorth America,Inc, hereinafter referredtoas FANUC Robotics,reservesthe rightto discontinue models at any timeor to changespecificationsordesign without notice and ...

  • Page 3

    Copyright ©1988, 1993 byFANUC Robotics North America,Inc.All Rights ReservedThe information illustratedor contained herein isnot to be reproducedcopied, translated intoanother language,or transmitted in wholeor in partin any way without the prior writtenconsent of FANUC RoboticsNorthAmerica,Inc....

  • Page 4

    cG'o+3D\Ws\3z>6Vji.*—vK-.>:<OQ0l-1”5'OÿcL't' \UScsi" CtSit//3'a~3O O'-QLO,. 3ÿoVH;//* i;/i•lI;:

  • Page 5

    fFANUC RoboticsHotlineFora PRODUCTION robot that is DOWNcall24 hoursa day, 7 daysa week810-377-7159For all other Troubleshooting andTechnical Supportcontact your local distributoror call the HotlineMonday- Friday,8:00A.M.- 5:00 P.M.Eastern TimeBEFORE YOU CALL please haveyour Maintenance and Troub...

  • Page 6

    !

  • Page 7

    TABLE OFCONTENTSI.OVERVIEW ANDCONTROLLER MAINTENANCE1-11.INTRODUCTION1.1Structure1.2Problem Conditions and Determining Causes1.2.1Making preliminarycheck1.2.2Locating thecause ofthe problem...1.2.3Checking themechanical unit1-11-21-21-21-31-42.SAFETY.2.1Personnel Safety Considerations2.1.1General...

  • Page 8

    1-475.3.8Error codes4009- 40145.3.9Error code4020 velocity ready isoff5.3.10 Error code4022 overload.5.3.11 Error code4024 fuse alarm in brake circuits5.4Troubleshooting Servo Amplifier1-471-471-501-516.BACKPLANE PCB (A20B-1002-0860)...6.1Theory of Operation.6.2Block Diagram6.3Connector/Signal Id...

  • Page 9

    1-1001-10111.5TestPoints11.6Removal /Replacement12.AXIS CONTROL BOARD (A16B-1211-0060, 0062)12.1Theoryof Operation12.2Block Diagram12.3Connector/Signal Identification12.4LEDs12.5Jumper Settings12.6Test Points12. 7Removal/Replacement13.REMOTE CRT/KB (A13B-0144-BOO1)13.1Theoryof Operation13.2Block ...

  • Page 10

    15. ARemoval /Replacement1-13616.ROBOT CONTROL MODULE (A03B-0801-C462)16.1Theory of Operation16.2Block Diagram16.3Connector/Signal Identification..16. ALEDs16.5Jumper Settings16.6Test Points16.7Removal/Replacement1-1371-1371-1381-1381-1411-1431-1441-1451-1471-1471-1481-1481-1501-15117.DI MODULE17...

  • Page 11

    22.3Teach Pendant (A05B-2051-C142)22.3.1Connector/signal identification22.3.2Removal/replacement ofteach pendant and components22.4Teach Pendant Control PCB (A20B-1002-0980)22.4.1Connector /signal identification22.4.2Variable resistors22.4.3Jumper settings22.4.4Test points.22.4.5Removal/replaceme...

  • Page 12

    1-2341-2351-2361-2371-2371-2371-2381-2421-2441-2451-2461-2471-2471-24726.2.5Test points26.2.6Jumper settings.26.2.7Removal /replacement.26.3Three-axisServo Amplifier.26.3.1Theoryof operation26.3.2Block diagram26.3.3Connector/signal identification,26.3.4LEDs26.3.5Test points26.3.6Jumper settings26...

  • Page 13

    2-113. TROUBLESHOOTING3.13.23.3Replacing Parts and Performing Adjustments2-11GeneralProblems and Causes2-112-132-142-142-172-202-202-204.ADJUSTMENTS.4.1Adjusting Limit Switches and Dogs4.20-axis Stroke Modification.4.3MasteringProcedure.4.3.1Introduction4.3.2Masteringprocedure4.3.3Zero-degree pos...

  • Page 14

    3-193-193-193-223.TROUBLESHOOTING3.1General3.2Failuresand Causes3.3ReplacingParts and Performing Adjustments3-233-233-313-313-344.ADJUSTMENTS.4.1Adjusting LimitSwitches andDogs.4.2Stroke Modification4.2.10-axis stroke modification4.2.2W-axis stroke modification4.3MasteringProcedure4.3.1Introducti...

  • Page 15

    4-304-324-344-354-433.2.6Connection for emergency stopcontrol3.2.7Connection tocomputer3.2.8Connection to remoteCRT/KB3.3SettingUSAT3.4I/O Module Specifications4-614.S-10 MECHANICAL UNIT4.1Connection between Controller andMechanical Unit4.2Connections and Signals between Mechanical Unitand EndEff...

  • Page 16

    2.2.3Installation specifications5-205-215-213.ADJUSTMENTS AND CHECKS DURINGINSTALLATION3.1Items to be Checked5-295-295-315-315-325-324.INITIAL START UP4.1Descriptionof Initial Start Up4.2Recovery from Alarm Conditions4.2.1Generalerror recovery....4.2.2Overtravel4.2.3EmergencystopVI.APPENDIX6-1APP...

  • Page 17

    I. OVERVIEW AND CONTROLLERMAINTENANCErfc

  • Page 18

    I}:!!;|I:

  • Page 19

    1.INTRODUCTIONThis manual presents a descriptionoftheS-10 andS-700 robots andalso adescriptionoftheS-700: A05B-2061-BOO1)andeachofsetting,adjustmentandreplacementprocedures.troubleshooting methods are also described.R-Hcontrollers(S-10:A05B-2066-B001/A05B-2067-B001;theircomponents,includingcompon...

  • Page 20

    TheS-10andS-700 robotsare articulated robotswith sixaxes.The medium sizecontrol unitfor theS-10 is comprisedof the operator’s paneland the teach pendant.The large sizecabinet also includes a built-inCRT/KB.The control unitfor theS-10or S-700 is comprisedofthe operator's panel,CRT/KB andteach pe...

  • Page 21

    1.2.3 Checking the mechanical unitCheck the following:a) External damageCheck the mechanical unitfor damage due toforeign substances in the unitorcontactwith peripheral devicesor other external equipment.b) Excessiveloador externalforceIsthe force requiredfor the movementofthe workpiece within th...

  • Page 22

    2.SAFETYGMFanuc Robotics Corporation (hereafer referred toas GMF Robotics or GMF)isconcerned with the safety andwelfare ofits customers,their employees, andtheirequipment.HoweverGMFdoesnotdesignorinstallsafetyrelatedequipment and consequently cannotbe responsiblefor ensuringthe safety of thevario...

  • Page 23

    2.1.2 Oporator safetyprecautionsImplement the followingmeasures tosafeguard the operator.. Useanti-tie-downlogictopreventtheoperatorfrombypassingsafetymeasures.. Installalockoutdeviceusingan"access code"topreventunauthorizedpersons from operatingthe robot.. MountEMERGENCYSTOPswitcheswit...

  • Page 24

    . Use devices suchas blocks, mechanical stops,and pinsto preventhazardousmovement of the robot.Care must betaken toensure that such devices do notgenerate trappoints for personnel.. Forsome procedures,a second person should be positioned atthe operator'spanel.This person musthave proper understan...

  • Page 25

    2.3.3 Mechanical precautionsImplementthe following safetymeasures to prevent damage tothe robot.. Ensure that the work envelope ofthe robot isclean andfree of oil, water,ordebris of anykind.. Use circuitbreakers toguard againstelectrical overload.2.4 End Effector SafetyConsiderations2.4.1 Program...

  • Page 26

    3.CONTROLLER DESCRIPTIONS3.1 General DescriptionThe controller controls servo motors provided for each axisofthe robot.Italso controls the endeffector andinterface signals between the controller andassociated peripheral devices.S—10 and S-700 robots are controlled by one of the followingcontrol...

  • Page 27

    i£Modular I/O unitCNP2CNP3cpii]|}PowerPSU1 supplyunit][CNP1CPI 3Power input unitCP14jlTvElJ4_CNBVisionengine 1ICNA_ln3CNBVisionengine2J VE2Future optionlriCNACNBVisionCPU board01P0BCNACNP1CNPSharedRAMCNA][ 01P04CNOPOperator’s pnaelHost computerboardCD4CNTP\_||J Teach pendantBackplane„„Main...

  • Page 28

    inModularI/O unitCNP2CNP3]0—CPUPowerPSUlsupplyunit][CNP1CPI3Power input unitCP14]d"*7ÿCNBVisionengine 1IVElCNA]CNB](jJ4_Visionengine2VE2Future optioniCNAJ]d”,CNBVisionCPU board01P0BCNA ]CNPlCOP2:SharedRAMboard][CNOPOperator’s pnaelHost computerCNA01P04CD4CNTPJ Teach pendantBackplaneMa...

  • Page 29

    CNP2CNP3CPUPowerPSU1supplyunit][CNP1CPI3Power input unitCP141VisionVE1---I'lCNBIengine1CNA]CNB]iT' ,]jTVE2J“lVisionengine2IFutureoptionCNAj3tTCNBVisionCPU board01P0BCNA]CNPl]COP2Shared01P04 RAMboard3tOperator’s panelHost computerCNOPCNACD4CNTP\-j][Teach pendantBackplanehHMain CPUCNA][ 01P09 b...

  • Page 30

    CNP2CNP3CPUPowerPSUlsupplyunit][CNP1CPI3Power inputunitCP14if.CNBVisionengine 1'A VElICNA]CNB][Tl---1Visionengine2IFutureoptionCNAJ1STCNBVisionCPU board4 01P0BCNA]CNPl]COP2Shared01P04 RAMboard][Operator's panelHost computerCNACNOPCD4CNTPTeach pendantBackplanenr.~MainCPU] 01P09 boardCNAPathCPUboar...

  • Page 31

    Backplane CNP2BackplaneCNP3xCNP2CNP3SharedRAM board COP2COP4Robotcontrolmodule][Power input unitCNlRobot mechanical unitCNAOCNBCNCI/O baseunito][ DI or DO moduleTP1 OCNA12o][ DI or DO moduleTP1 QCNA212][ DI or DO moduleTP1 §CNA32][ DI or DO moduleTP1 §CNA412][ DiorDO moduleTP1 OCNA52oCNA6 ][Dio...

  • Page 32

    Operator's panelEMGlEMG2Customer's logic{][ RemoteCRT/KBCRT/KBSharedRAMboardRS-232-CI/O deviceCN5RS-232-CE-STOPbuttonOServo transformerCircuitbreakerAC mput _5ÿ>OLC3F7.8.9Servo amplifier0P1, 2Fan unitFNR.S<>200A.B <ÿInputtransformerTF4CP13CPUCP14CPI200PowersupplyunitR.SCP2CP7Power i...

  • Page 33

    Built-inCRT/KBKeyboardISoftwarekeyboardXCN2CN3 ]D—D[ CNICASCRTmonitorCRT/KBcontrolPCB30-0[ CN2CNICD4Operator's panelEMG1EMG2?Curtomer’j logicCN3SharedRAMboardCN5RS-232-C I/O deviceRS-232-CE-STOPbutton-<>CircuitbreakerAC input_o''"D-Servo tranfonnerhF7, 8,9--? LC33#TF1OOP1.2Fan unit...

  • Page 34

    Built-inCRT/KBKeyboardISoftwarekeyboardXCN2CN3CNICASCRTmonitorCRT/KBcontrolPCBCN2CD4CNIOperator's panelEMG1EMG2Customer’s logicCN3SharedRAMboardCN5RS-232-C I/O deviceRS-232-CE-STOPbuttonServo transformerDisconnect switchAC input_Q"->QXFL1-3F7.8.930LC3TF10P1.2Fan unitFNR, S< h200A,B&l...

  • Page 35

    Built-inCRT/KBKeyboardISoftwarekeyboard£CN2CN3CN1CASCRTmonitorCRT/KBcontrolPCB{][ CN2CD4CN1Operator*! panelEMG1„EMG2YCustomer's logicCN3SharedRAMboardCN5RS-232-CI/O deviceRS-232-CE-STOPbuttonO'CircuitbreakerAC input _Servo tranformerhF7,8,9 O-<> LC33*TF1o0P1.2Fan unitFNR,S<>200A,BI...

  • Page 36

    Built-inCRT/KBKeyboardISoftwarekeyboardCN2CN3CN1CA5CRTmonitorCRT/KBcontrolPCBCN2CN1CD4Operator’s panelEMGl,EMG2 YCustomer’s logicCN3Shared RAMboardCN5RS-232-CI/O deviceRS-232-CE-STOPbuttonO'Servo transformerDisconnect switchAC input_AFL1-3F7, 8,9y-03*LC3TF1OOP1,2Fan unitFNR.SO-200A.BOinputtra...

  • Page 37

    Table 3.1 Component function for theS-10/S-700SlotNo.or mod¬ule No.RemarksFunctionNameBackplaneProvides the bus connection forthe control PCBs.Power supplyunitSupplies the DC voltageto basiccontrol unitand theI/O unitPSU1PCBsmounted onthebackplane01P09Main CPUboard. MainCPU. Co-processor interfa...

  • Page 38

    Slot No.or mod¬uleNo.RemarksNameFunction. Interface between basiccontrol unitandI/O unit. Robot mechanical unitinterface. Power input unitinterfaceRobotcontrolmoduleRC01CPCBmountedinI/Obase unitInput for peripheral devicecontrol(Various typesare preparedforinputcontrol.Details aredescribed insec...

  • Page 39

    SlotNo.or mod-ule No.RemarksNameFunctionServo amplifierUnit toamplify the PWM signalsand drivetheservo motorsOperator's panel. Lamps and switches tooperatethe robot. Connectorpanel forRS-232-C. Connectorpanel fortheCRT/KB. Hour meter (option on verticaloperator's panel, large sizecabinet). 40x 8 ...

  • Page 40

    lIMfeRISER(OPTION)CDOCDFig.3.2 (a)Externalviewof controller (S-10, medium size cabinet)*n .*a6ftaaaUEoRISER(OPTION)Fig. 3.2 (b)External view of controller (S-10, large size cabinet, circuit breaker handle)1-22

  • Page 41

    *n .0000aIQEORISER(OPTION)[=ÿPig. 3.2 (c) External view of controller (S-10, large size cabinet, power disconnect handle)*Li.JLa aaoa_2_aa™DBSRISERjsr (OPTION)1Fig.3.2 (d)External viewof controller (S-700, large size cabinet with side cabinet,circuit breaker handle)1-23

  • Page 42

    E.nfl0flasaaAains1•RISERpT (OPTION)ICDFig.3.2 (e)External viewof controller {S-700, largesize cabinet with side cabinet,power disconnect handle)oooTEACH PENDANTEMAILEDPANELPOPE* 0*©©©I «MOTINR3-232-CCRT/MCYCLECALIMATEDUSERLED MlUSERLED WT©©©©CYCLE STARTCALIBRATEUSERPBM1USER MM2oFAULTEME...

  • Page 43

    ° TEACO° TEACH PENDANTCMPENDANTENA*LEOPANELLEOOPANELPOWER ONENA*©©©©©©INNOTCALIOIUTEDINNOTONI «CYCLECYCLECALIMATED©©©©CYCLESTANTCALlflBO OFFO wFAULTHELDFAULTHELD©©©©0VENT1UVELOVERTRAVELFAULT RESETHOLDFAULTRESETHOLDREMOTEUSERLE0M1USERLE0N2•EMOTEUSERLEDMlUSER LEOMlON©©fff <...

  • Page 44

    ~s~oo[ooaaaaaaooor~r~ii g—ijIooFig.3.2 (i) External view of built-in CRT/KB (40° angled)370".2- -ÿ§CM]3BiIIIn2-I3&t(piin[inII JCID-TU(\y400Fig. 3.2 (j)External viewof remoteCRT/KB1-26

  • Page 45

    B00000EICoordResetSHIFTStartHoldSHIFTftinputOutputPrgmTeachVisionDataTestStatusftSetupSavaFite+Y(2)«(3)Enter789ftFaulftHeldft-X(1)-Y(2)-Z<3)456ftSaveftCycleft+X(4)«(•)213|£-SrvEip-X(4)*Y(5)-Z(8)Del0U5U8U7USU1U2U3U4o1Fig.3.2 (k) External viewof the teach pendant3.3 Internal ComponentsVario...

  • Page 46

    Fan 1ModularI/O unitBattery unit.Power input unitCircuit breakerBackplanePower supplyunitControlPCBsOperator’spanelServo amp. 1Fan 2Servo amp.2Input transformerGround boardServo transformerFig. 3.3 (a)internal componentlocation (S-10, medium size cabinet)Fan 1ModularI/O unit,/m\.<zrBattery u...

  • Page 47

    Fan 1ModularI/O unit~7/ /Batteryunit,C’Power disconnect switchBuilt-in CRT/KB,Power inputunit1=7-BOperator’s panelBackplane&Fan 3.Power supply unit5Fan 2/ Input transformerUser transformer (option)6.\7£X\Servoamp.3\ Servo amp. 2Servo amp. 1Servo transformerFan 4DCU1Fan 5Servo amp. 4aes1F...

  • Page 48

    3.4 Controller ComponentsSpecifications1) Common componentsfor S-10 andS-700Slot ormoduleSizeUnitFart numberNo.Basiccontrol unit-Backplane-Power supply unit-Main CPU board—A20B-1002-0860A20B-1000-07701—A16B-1211-0040I—A16B-1211-0041A16B-1211-0030A16B-1211-0860-A16B-1211-0090—A16B-1211-009...

  • Page 49

    UnitPart numberRemoteCRT/KB unit-CRT monitor-Control PCB-Keyboard PCB-Fan unitA13B-0144-B001A61L-0001-0088A16B-1211-0760A86L-0001-0149A13B-0144-C001Battery unitI-Batteryi-BatteryA98L-0004-0096A98L-0031-0005 (3 unitsare necessary)caseOperator's panel(Horizontal type)(Vertical type)(Vertical type)A...

  • Page 50

    2) S-10 specific componentsPart numberUnitController(Medium size cabinet)(Large size cabinet)A05B-2066-B001A05B-2067-B001Transformer (Medium size cabinet)Servotransformer TF1Inputtransformer TF4tA80L-0024-0002A80L-0012-0010Transformer (Large size cabinet)Servo transformer TF1Input transformer TF4...

  • Page 51

    Part numberUnitA60L-0001-0181#175Power disconnect switchA14B-0076-B321Power input unit(220/240 VAC input,Medium size cabinet)-Power input unit PCB-Fuse-ContactorA16B-1310-0530A60L-0001-0042#JGl-30A58L-0001-0094#200V1A1BA14B-0076-B320Power input unit(380-550 VAC input,Medium size cabinet)Power inp...

  • Page 52

    3) S-700 specific componentsPart numberUnitController (Large size cabinet)A05B-2061-B001Transformer (Large size cabinet)Servotransformer TF1Input transformer TF4User transformer TF5A80L-0024-0004A80L-0012-0010A80L-0001-0520EServoamplifierL: a axis (1-0B)M: U axis (5RF)L: B axis (1-0B)M: y axis (1...

  • Page 53

    UnitPart numberPower inputunit(220/240 VAC input,Power disconnect switch)-Power input unit PCB-Fuse (FL1-3)- Fuse (F7-9)—— ContactorA14B-0076-B325A16B-1310-0530A6OL-OOO1-OO420JG2-4OA60L-0001-0042#JGl-30A58L-OOO1-OO9402OOV1A1BPower input unit(380-575 VAC input,Power disconnect switch)-Power in...

  • Page 54

    4.PREVENTIVE MAINTENANCEPreventive maintenanceisbased upon the amount of hours of operation oftherobot.Some applications requirea robotto be operational for 24 hours a day,while others require less on-time.If the robot isto operatecontinually, allcheck items should bemaintained accordingly.Thefol...

  • Page 55

    Check itemsCheck pointsItemCheck tosee that each axismovessmoothly.Vibration,abnormal noises,and motorheating6Check tosee that the stop positionofthe robot has notdeviated from previousstop positions.Changingrepeatability7Peripheral devices for properoperationCheck whether the peripheral deviceso...

  • Page 56

    4.2 Monthly Checks (Determined byhours of operation)Checkthe following itemsmonthly.Additional inspectionareas and timesshouldbeadded to the table according totherobot's working conditions, environment,etc.Table4.2 Monthly preventive maintenance checks (or 500 hours)Check itemsCheck pointsItemRef...

  • Page 57

    4.7 Maintenance ToolsThe following instruments and tools are requiredfor the maintenanceprocedurescontained inthis manual.1) Measuring instrumentsAccuracy/ToleranceApplicationsInstrumentsACvoltmeterACpower voltage measurement.Tolerance:Less than+2%AC power voltagemeasurementDCvoltmeterDCpower vol...

  • Page 58

    5.TROUBLESHOOTING5.1 IntroductionThis section containsinformationfor troubleshooting the system.The materialincluded here describes the alarms thatare involved withhardwired circuits.Refer tothe KAREL SystemReference Manualfora descriptionof allof theerrorcodes.5.2 Power Cannot beTurned OnCause o...

  • Page 59

    Cause of troubleItemChecking procedureCorrective action2) Verify that two pins"OFF" onthe power input unit PCBofthepower inputunitareshorted.4POWER OFFswitchon operator'spanel isfaulty(Refer to 23.4.1)1) Makesure that OFFand COMareshorted atTP1terminal on thepower input unit PCBof thepo...

  • Page 60

    5.3 Troubleshooting UsingError CodesThe4000 error codes indicate problems inservo control.with the error message is interpretedas follows:The number included008: error on 1st axis004: error on 2nd axis002: erroron 3rd axis001:erroron 4th axis080: erroron 5th axis040: error on 6th axis5.3.1 Error ...

  • Page 61

    5.3.2 Errorcode 4002 emergency stopTheemergency stopalarm indicated thatone ofthe E-stop buttons has beenpressed or thattheE-stop wiringisdefective.locatedon the teach pendantand on the operator*s panel.may be connected totheexternal emergency stopcircuit.EMERGENCYSTOP buttons areAdditional butto...

  • Page 62

    5.3.4 Error code4004 hand breakagedetectionThe hand-break-detect circuit monitors the operatingcondition ofthesafetyswitch on the endeffector.This normallyclosed switch opens whena crashoccurs andplacesthe robotintoa stopcondition.This stop resemblesanemergency stopor other majoralarm which remov...

  • Page 63

    5.3.7 Error code 4008 TGLS alarmThe function ofthe TGLSalarm isto indicate a problem in thefeedback system.Each axis pulseencoder's information is monitored in the controller.signal is lost,the alarm is sent,and the robot motion isterminated.Refer tothe following figures.IfaAxiscontrol boardA16B-...

  • Page 64

    CF9110 V14PCZA1CF940 V141PCZA480H1A8OH1Bofof20 V*PCZA120 V*PCZA490H2A90H2B0 V1601P053PCAA10 V1601P053PCAA410C8A110C8A4(W)4+5 V*PCAA1(Y)4+5 V17*PCAA4C4A111C4A411185+5 VPCBA1+5 V185PCBA412C2A112C2A46+5 V19*PCBA16+5 V19*PCBA413C1A113C1A4720REQA1720REQA40 V14CF921PCZA210 V14CF91PCZA580HA280HA5of0 V21...

  • Page 65

    5.3.8 Error codes4009- 4014Error codes4009- 4014 indicatea problem on theservo amplifier-section5.4 "Troubleshooting Servo Amplifier".Referto5.3.9 Error code4020 velocity ready is offTheÿDRDY signal, indicating theservo amplifier is on, has notbeen receivedafter *MC0N signal issentto t...

  • Page 66

    ServotransformerServo amplifierAxis control boardI T401P051-ofo51—Q£D-J-6-Robot mechanical unitl2SIy-,?52CV21CF91Heat sinkoverheat8LJJAtErrordetectioncircuit9PICN1Ne—C£LQ—|TF1CV22CF928CN1LIIP93•3§Lifl[ÿ=3U 3CV23CF938]IPI TJP29Amp.1CN1M7=1j-wT4CV24CF94-JJ -<fLP-|80Heat sinkoverheati...

  • Page 67

    ServotransformerServo amplifierAxis control boardT401P05—0ÿ0-*Robot mechanical unit522SIErrordetectioncircuitCV21Heat sinkoverheatCF918-6-Y~f?fl[]ID—i539PICN1LG63HCV22CF928ai;ÿw0[IIPAmp. 1CN1M3T4§&T7iTV1_j-|] -o5b—|UZ=3CV23CF93Heat sinkoverheat£8Errordetectioncircuit]PIP29oCN1L3CV24...

  • Page 68

    5.3.11 Error code4024 fuse alarmin brake circuitsThefuse alarmindicates thatone ormore fuseson the power input unit PCBhasblown.Each fuse containsan internal switch which triggersthe alarm when thefuse blows. Ablownfuse mighthave been caused byan overload conditionor ashortcircuitinthebrake wirin...

  • Page 69

    5.4 TroubleshootingServo Amplifier1) Protection anderror detection functionsTheservo amplifier has the following functions designed to protectthe motorfromoverload and todetectan error inservo loop circuits.Kinds of functionsIndicationsNo.DescriptionOverloadOverload alarmisindicatedfor thecontrol...

  • Page 70

    2) TroubleshootingTroubleshooting andfaultrecoveryare discussed in this section.a) Overload alarmCausesof problemsCheck proceduresCorrective actionItemPCB setting failure1Check if SI of PCB is setas specified.SetSI properly.Thermostatof theservotransformer is open.Removethe wiresconnectedtotransf...

  • Page 71

    b) Circuit breaker is trippedCausesof problemsCheck proceduresItemCorrective actionCircuitbreaker istripped.1The operatingcondition ofthebreaker isasillustrated below.This button popsoutwhen thecircuitbreaker istripped.Depressthis buttonafterturningoff thepower supply toresetthe circuitbreaker.Re...

  • Page 72

    Causesof problemsCheck proceduresItemCorrective actionThe regenerativedischarge unit isdefective.Determineif there¬generativedischargecircuit isdefectiveandthat the wiring isproperly connected.5Replacethe PCB,discharge transis¬tor,or dischargeunit.d) LV alarmCausesof problemsCheck proceduresIte...

  • Page 73

    Causes of problemsCheck proceduresCorrective actionItemTransistor module isdefective.Check if HCalarm occurswhen the power supply isturnedon after disconnect¬ing the power line accord-to item1.Turnoff thepower supply,remove PCB,and check the right termi¬nal of the transistorsmodule witha circui...

  • Page 74

    6.BACKPLANE PCB (A20B-1002-0860)6.1 Theoryof OperationThe backplane PCB Isused toInterconnect thepower supply unitandthe controlPCBs bymeans ofthe backplane bus.Connector CNP1 isdedicated for the powersupply unit;the othersare for control PCBs.Control PCBsare connected bymeans ofelectrical buseso...

  • Page 75

    6.3 Connector/Signal IdentificationD045atCQa©caCQCQ5 § §og 5555555555s-<•<<55 55CNAO (System-bus, CCU*)Address modifier#0- #2AMO- 2GA01- 23: Global address bus#1- #23GDOO- 15: Global data bus#0- #15bac32SYSCLK1+5 VSUBCLK1SYSCLK20 V31+5 V30GA13+5 VAM2*GASGlobal address strobeRead/Wri...

  • Page 76

    CNA1- 10 (System bus)bAddress modifier#0- #2AMO- 2GA01- 23s Globaladdress bus#1- #23GD00- 15: Globaldata bus#0- #15caSYSCLK32+5 VSUBCLK0 V+5 V310 VGA13+5 VAM2: Global address strobe:Read/Write: Global data strobe high byte: Global data strobe low byte: Global data acknowledge: Blobal bus request:...

  • Page 77

    CNAV1,2 (Vision engine interconnection)ABCClock (6 MHz)Bit map window(External displaytiming)(External V sync.)(External H sync.)Display timingVsync.H sync.Character overlayOutput windowRunlengthX addressoverY addressoverBinary outputLoad Xdown counterCountdown XReadBuffer RAM (BRAM)WriteBRAMAddr...

  • Page 78

    CNBV1,2; CNB10 (Vision engine interface)Clock (12 MHz)Clock (24 MHz)ABC*C12MM*C24MMMAB1- 17: AddressbusRead/WriteUpper byte data strobeLower byte data strobeReadframe memory upper byteRead framememory lower byteWriteframe memoryupper byteWriteframe memory lower byteInterrupt from ACRTCSystem data...

  • Page 79

    CNP1ABC+5 V+15 V-15 V+24 VCOM32THTL*PF31EN: DC output30+15 V+5 V+15 V29+15 V0 V+5 V+5 V-15 V28TH. For test (for variation of' +10% in+5 V): Power failure: Enable+5 V+5 V27+5 VTL26+5 V+5 V+5 VCOM*?F+5 V25+5 V+5 V+5 V+5 V24+5 VEN+5 V23+5 V+5 V22+5 V+5 V+5 V+5 V21+5 V+5 V20+5 V+5 V+5 V19+5 V+5 V+5 V...

  • Page 80

    CNP2*PF:Poweroff interruptEN: Powerenabled+15 V010 V02*PF0304EN0 V0506-15 VCNP3+5 V: +5 VDC powersource0 V:0V (Ground)+24 E: +24 VDCpowersource+5 V0102+5 V0 V03040 V+24 E05+24 E06CNP401HIHI: For test (for variationof+10% in+5 V)TEST02TESTLO03L0CA27VBAT: BatterypowerVBAT010 V020 V031-62

  • Page 81

    6.4 Jumper SettingsStandardsettingUsesJumpersJumpersPI- P9 correspond toCNA1- 9.If a PCB isin the slot n, the jumperPn is set to 0side* if notit is set toV side,(n= 1- 9)(0 is Occupied and V is Vacant.)PIP2For example, thereare PCBson CNAO, 1, 2,3,8 and9.The jumper settings areas follows:P3o figF...

  • Page 82

    6.5 FuseQDaCausesand correctiveactionsfor blownfuses.The basic control unit isprovidedwitha fuse at the battery input endas shownin Fig.6.5.The followingdescriptioncovers thecauses ofa blownfuse.The blown fuseshowsa white failure display inthe indicatoras shown in the figure atthe right.a) A part...

  • Page 83

    6.6 Test PointsTest pointsContentsHIFor variationof+10% in+5 V.shortTESTTESTHI: +10%LO: -10%TESTNote) Theseare used only atproductiontest.LODas£gas>205S05g03g2n <<<<<©<s:<<<z6 ggzggggg ggggHI-TESTLO6.7Removal/Replacement1) Procedure8 Remove all boardson thebackplan...

  • Page 84

    7.POWER SUPPLY UNIT (A20B-1000-0770)7.1 Theoryof OperationThe power supply unit produces DC voltages for distribution anduse throughoutthe controller.All DC voltages for the basic control unit and the modular1/0unit are supplied from this unit.Additional DCvoltagesare supplied byotherPCBs for spe...

  • Page 85

    CHI3FI4CPI 4roA15n1 DllA15®+24E<r\J>Auxiliarysupplyw+24 regulatorM.A.DS12r—-i03VS 12+uC67+ 1[07OCHI 1+24oMilT14ACINPUTCIRCUITF={7TI-@+24AO A0L*iI SmoothingDICP14+C28+VII4CPI 20T2<s•0/QlS(VCEJ -,_fVIflL-___IBAC30}Fl 1NF11DSl 10)cpri3R ®ICfVO+V3+15QI4W:tD24tX—@+15Powerswitch(80kHz)...

  • Page 86

    7.3 Connector/Signal Identificationk©©©ra©i©©©<o oPOWER SUPPLYUNITA20B-1000-0770onCP12o¥LdCP14CPI 3cpii1-68

  • Page 87

    CP13 (Input unit PCB)CP12C06BALDACOMTL05ALCTH32*PFEN0431NR203PFVNR+15 V30+15 V02+15 VPFH+5 V29PFL+5 V-15 V01+5 V28+5 V+5 V+5 V27+5 VALD+5 V+5 Vi_26: Alarm output+5 V+5 VALC+5 V25+5 V+5 VPF24+5 V: Power failure+5 V+5 VPFH23+5 V+5 VPFL+5 V22+5 V+5 V+5 V+5 V21CP14 (I/O unit)+5 V20+5 V+5 V+5 V+5 V19+...

  • Page 88

    iI©11oabcot32 H T L31WENI3EMSS301 +15EH292827262524Tloota23+522;sJ212019OforView withthe coverremoved118back17>anel*A16c•DI1514O•<o+CPI 2o+flFll-127.5A200/220VACinput fuse13e2.12BLUE11JO1X10s?029F14VR11IgJjAlO ADJ.CP14g)E5r CP1308I 2A+24E fuse7CPI 6re6*POWER SUPPLY UNITA20B-1000-07705j...

  • Page 89

    7.5 FusesRefer toFig.7.4for the positionof thefuses.The power supply unit isprovided with fusesFll toF12 at the input end, andF14 at+24 E outputterminal.Thefollowingdescriptioncovers causes andactions to betaken when thesefusesare blown.(X) Causeand remediesof a blown Fll or F12 fusea) Short-circ...

  • Page 90

    7.6 Test PointsThe meaningsofthe test pointson the power supply unitareas follows.Fig. 7.6)(SeeSymbolWaveformTest pointsContentsCTP2Pre-driver signalof+5 V regulatorCP1611.5—13Msec.30VnruovCP16CTP1+5 V control11.5-13wee.ir:ICP16AO0 VCP16A1514.5- 15.5 VDCWhen "INH" isshortedto0 V, over...

  • Page 91

    SymbolWaveformTest pointsContentsTrianglewaveFjv/ -ov15.75- 6.S Msec.+5 VcontrolPC1.2V-OV11.5-13.0Msec.Terminals for thecurrent measurementof+24 Vand +24 Eoutput.A,B+24VIOV -J--ITOBATerminals forthecurrentmeasurementof+5 V output.C,D.IVIovITODC1-73

  • Page 92

    AOoB_D_PCOOCP12FoCP16ocCPUCPI3GFig. 7.6Location of test pointson the power supply unit(The unitcover is removed in the above figure)1-74

  • Page 93

    7.7 Removal/Replacement2PSUl'BackplanePowersupplyunitConnector tobackplanePCBI II l!Ii!iCPI*cpiiCP13f21) Procedure8 Disconnectcables of connectorsCP11,CP13 andCP14.Detach the power supply unit by removingfourscrews.Thepower supplyunit is connected tothe backplane PCBof the basic control unit by t...

  • Page 94

    8.MAIN CPUBOARD (A16B-1211-0040, 0041)8.1 Theoryof OperationThe mainCPUboard processes the KAREL language system,file operations,andsystem1/0.Theboardcontainsthelocalmemoryfor amicroprocessor.Thememoryisorganized byfour (-0041) or eight (-0040) DRAM modules, the total capacity is1MB (-0041) or 2 ...

  • Page 95

    CNA (Main CPU)bAMO- 2GAOl- 23: Global address bus01- 023GDOO- 15: Global data bus00- #15*GASAddress modifier00- 02caSYSCLK+5 VSUBCLK320 V0 V+5 V31GA13+5 VAM2Globaladdress strobeRead/WriteGlobaldata strobe high byteGlobaldata strobe low byteGlobal data acknowledgeGlobal bus requestBus ground inBus...

  • Page 96

    CN1 (Test PCB)CBAThis connector isnot used.+5 V*IPL232*IPL131*IPL0+5 VA2330A22+5 VA21A20A1929+5 V28A180 VA17A160 V27A1526A14+5 VA1325A12All+5 V24A09A10+5 V23A080 VAO7A06220 VA05A04AO32120A02+15 VA0119*EPEX0 V*AS18*VMA0 V*UDS17E*LDSR/W16*VPA-15 V15*RES0 V*NMIE14*BERR0 VFCO13*HALTFC112*RST+24 VFC21...

  • Page 97

    8.4 LEDsLED1MeaningsStatusANot used(Yellow)Not usedB(Yellow)CNot used(Yellow)Not usedDLED 2MeaningsStatusDRAM parity alarmParity alarm occurs, accessingdynamic-RAMon mainCPU PCB.A(Red)SRAM parity alarmParity alarm occurs, accessing static-RAMmainCPUPCB.B(Red)CNot usedDLED2©®®©fLED!(A)©®©1-79

  • Page 98

    8.5 Test PointsTest pointsContents0 V (ground)GThis terminal isused insoftware debuggingTESTOGOG<§§GOO TESTT1-80

  • Page 99

    8.6 Removal/Replacement01P09a©—TjBackplane PCBc11) ProcedureI Detach PCB by looseningthescrews (D.Mountnew PCB.2) CautionIf the PCB beingreplaced has the optional IC,check that the ICmounted onthe new PCB has thesame specification.O[-Optional1C1-81

  • Page 100

    9.PATH CPUBOARD (A16B-1211-0030)9.1 Theoryof OperationThe path CPUboard calculates path information and provides ittotheservosystem.Theboard containsthelocalmemory fora microprocessor.256 kB,organized by DRAMs.Theexecutive software isloaded into the DRAM from bubble memory after powerThe memory s...

  • Page 101

    9.3 Connector/Signal Identification<Z5uTCNA (Path CPU)Addressmodifier#0- #2AMO- 2GA01- 23: Globaladdress bus#1- #23GD00- 15: Global databus#0- #15bcaSUBCLK32+5 VSYSCLK0 V310 V+5 VAM230GA13+5 V*GAS: Global address strobe:Read/Write: Global data strobe high byte: Global data strobe low byte: Glo...

  • Page 102

    CA2 (Position coder)0 V01PCZPCZ14: Z-phase of Position Coder0 V0208*PCZ*PCZ15030 VPCA09PCA16: A-phaseof Position Coder04+5 V*PCA10*PCA1705+5 V11PCBPCB18: B-phaseof Position Coder06+5 V*PCB*PCB12190713SG20CN1 (Test PCB)AThis connector is notused.BC*IPL1+5 V*IPL232A23+5 V*IPL031A21+5 V30A22A19A20+5...

  • Page 103

    9.4 LEDsMeaningStatusLED 1Not usedA(Yellow)Not usedB(Yellow)NotusedC(Yellow)DNot usedLEDMeaningStatusLED2(Red)DRAM parityalarmParity alarm occurs, accessingdynamic-RAMon path CPUPCB./ILED2qCt3ÿLEDlf®©®©1-85

  • Page 104

    9.5 Jumper SettingsStandardsettingbsesJumperPulsewidth adjustment ofthe16.384 MHz clock.Change the settingso thatthe waveform at testpointC16 isas shown in section9.7.(The settingPIwas adjustedbefore shipping.)PIWOo2oo> a8C16MO[°0PI§<§L«J9.6 Variable CapacitorThe variable capacitorCK4 i...

  • Page 105

    9.7 Test PointsContentsWaveformTest points0 V(ground)G0 V(ground)0 VSupply voltage for logic+5 VDC+5 VSupply voltage+15 VDC+15 VSupply voltage-15 VDC-15 VSupply voltage+24 V+24 VDC3.5VClockfor main system(16.384 MHz)C16Mov-1U-61 nsecThis terminal isused insoftware debugging.TESTReal Time ControlT...

  • Page 106

    9.8 Removal/Replacement01F02©CD—BackplanePCBo11) Procedure(D Detach PCB by looseningthescrews (T).(2) Mount new PCB.2) CautionIf the PCB being replaced has the optional IC,check that theICmountedonthenew PCBhas thesame specification.rno[o[“OptionalIC1-88

  • Page 107

    10.SHARED RAMBOARD (A16B-1211-0860)10.1 Theoryof OperationThe shared RAM board is an essential module inthe R-H controller,functioningas a central control modulefor the System BUS.It provides a system clock, clear,timer,and other importantsignals.Fourserial portsare available; DirectMemory Access...

  • Page 108

    10.3 Connector/Signal IdentificationS<§<55aJTCOCNAAddress modifier#0- #2bAMO- 2GA01- 23: Global address bus#1- #23GD00- 15: Global data bus#0- #15*GAScaSUBCLK132SYSCLK1+5 V0 V31SYSCLK2+5 VAM2Global address strobeRead/WriteGlobal data strobe high byteGlobal data strobe low byteGlobal data a...

  • Page 109

    CD4ARS-232-C port A: Receivingdata: Sendingdata: Request tosend: Clear tosend: Data set ready: Data terminal ready+24 VR: +24 VDCpower supply forRS-232-C port: 0 V01+24 VRRDA1408RDA02SDA1509SDA03RSA161004CSA0 V171105ERADRADRA181206ERACSA191307RSA200 VCNTPRS-422 for teach pendant•v1#Receivingdat...

  • Page 110

    CNOPRS-232-C ports andDI/DO for operator’s panelTeach pendant enabledLEDPanelenabled LEDIn cycle LEDNotcalibrated LEDUser LED#1User LED #2FaultLEDHeldLEDCyclestart buttonCalibrate buttonUser panel button#1User panel button#2Fault resetbuttonHold buttonOvertravelrelease buttonContact of thePower...

  • Page 111

    CNPIInput unitinterface+24 F140 V: OVERTRAVEL RELEASEbuttonContact of the POWERON button(normally open)Contact of the POWEROFFbutton(normally closed): Status signalof EMERGENCY STOPbutton and DEADMAN switch: Status signalof EMERGENCY STOPbutton andDISABLE/ENABLEswitch+24 VDC power connection forp...

  • Page 112

    10.4 LEDsLEDsMeaningsStatusThis indicates that atleastone module ismalfunctioning.This signal isasserted illuminatingtheLED when the mainCPUPCB hr pathCPU PCB ismalfunctioning.SystemfailA(Red)BSystem emergencyThis indicatesa systememergency.Thecauses areas follows:. ACpower failure. The watch-dog...

  • Page 113

    10.5Test PointsWaveformContentsTest points0 V(ground)GSupply voltagefor logic+5 V+5 VDCSupply voltagefor RS-232-CandRS-422 driver+12 V+12 VDCSupply voltagefor RS-232-CandRS-422 driver-12 V-12 VDCClock for bus controller(8.192 MHz)nr*C8MovI--4122 nsec3SVClockfor main system(16.384 MHz)C16MJAJ.k--I...

  • Page 114

    10.6 Removal/Replacement01P04B©~ÿJBackplanePCB1a>i1) ProcedureQD Disconnectcablesfrom the PCB.© Detach PCB by looseningthescrews (2).(4) For mountingnew PCB,reverse the above procedure.A CAUTIONMakesure the teach pendantcable is pluggedinto the teachpendantconnector (CNTP)not theserial port...

  • Page 115

    11.BUBBLEMEMORY BOARD (A16B-1211-0090, 0091, 0092)11.1 Theoryof OperationThebubble memory board isanon volatile mass-storagedevice used for storingthe system software, systemvariables, and KAREL application programs.Thereare three types of bubblememory boards.A16B-1211-0090: 2 MBA16B-1211-0091: 1...

  • Page 116

    CNA (Bubble memory)bAddress modifier#0- #2AMO- 2GA01- 23: Global address bus#1- #23GDOO- 15: Globaldata bustiO- #15*GASca+5 V32SYSCLKSUBCLK+5 V0 V0 V31+5 VAM230GA13: Globaladdress strobe:Read/Write: Global data strobe high byte: Global data strobelow byte: Globaldata acknowledge: Global busreques...

  • Page 117

    11.4 Jumper and Switch SettingsStandardsettingUsesJumpers|oÿl ABPIP2AB side settingisselected in software debuggingonly.In normal use, all must beset to Aside.[oBga| AP3B!°ÿ|AP4Bl°gggi| AP5BStandardsettingSwitchUsesON: NOT USEDOFF:Normal modeSW1OFFC3 P5P4ONP3swi[>>OFF§P2PI<5JJTLocat...

  • Page 118

    11.5 Test PointsContentsWaveformTest points0 VGThese test pointsare usedforerasingthe bubble memorydevices.If "ERASE" and"HBn" areshort-circuited, thecorresponding device MBMnwill be erased,(n= 1- 4)HB1HB2HB3Test pointERASE- HB1 :ERASE- HB2:ERASE- HB3:ERASE- HB4 :DeviceMBM1MBM...

  • Page 119

    11.6 Removal/Replacement01P08/01P15CD—sjBackplanePCB11) Procedure0 Detach PCB by loosening thescrewsQ.(5) Mountnew PCB.NOTE Refer to theR-H Controller System Software InstallationKit documentation forinformation on reloadingsystem software.1-101

  • Page 120

    12. AXISCONTROL BOARD (A16B-1211-0060, 0062)12.1 Theoryof OperationThe axis control board receives the motioncommandsfrom the path CPU andmovestherobot'saxes.There are two types of axiscontrol boards.A16B-1211-0060: 4-axis controlA16B-1211-0062: 2-axis controlFor every two axes,one high-speed mic...

  • Page 121

    12.2 Block DiagramTo backplaneICNA7>System businterfacesnnBufferBuffer7>16 kB16 kBA-K A—N Micro¬processorMicro*processorRAMV-\-RAM*—\ServointerfaceServointerfaceServointerface-NS-Servointerfaces—DI/DODI/DOFeedbacklossdetctFeedbackloss detect| CV211 1CF9I~T|CV221 |CF92TI CV2311 CF93T|...

  • Page 122

    12.3 Connector/Siganl IdentificationThe relationship betweenthe axis numbers, axis names, andthe connectorson theaxis control PCB,robotmechanical unit,andservo amplifiers is shown inTable12.3 (a) and (b).Table12.3 (a) S-10ServoAxiscontrolPCBAxiscontrolPCBAxisHardwareNo._AxisSoftwareVelocityconnec...

  • Page 123

    m *ÿ«<Szzs aZZas<gS388Connector position (Side viewof PCB)5m •*« NZzzes-<r «Nr*CNZZZcn0\ONos&8 &3V<NOvON68 8aa-0062A16B-1211-00601-105

  • Page 124

    CNA (Axis control)bAddress modifier#0- #2AMO- 2GA01- 23: Globaladdress bus#1- #23GD00- 15: Globaldata bus#0- #15ca+5 V32SYSCLKSUBCLK+5 V0 V0 V31GA13+5 VAM230Global address strobeRead/WriteGlobaldata strobe high byteGlobal data strobelow byteGlobal data acknowledgeGlobal bus requestBus ground inBu...

  • Page 125

    For 1st axis CF91PCZA1CF91- CF94140 V180H1A1*PCZA1OH1150 V2: Motoroverheat0H2A190H2PCAA1160 V3C8A110C817*PCAA1+5 V411C4A1PCBA1C418+5 V5: Graycodefrom pulsecoderC2A112C219*PCBA1+5 V6C1A11320REQA1Cl7PCZ: Z-phaseof pulsecoder*PCZPCA'*PCAFor 2nd axisCF92: A-phaseof pulse coderPCZA2140 V10H1A28*PCZA21...

  • Page 126

    For 1st axis CV21CV21- CV24*PWMA*PWMB*PWMC*PWMD*PWME*PWMFCOMACOMBCOMCCOMDCOMECOMF*PWMDA1(*ALM8)*PWMAA1C*ALM1)1401IRA10815C0MDA102COMAA1Pulse width modulator:(Note 2)09GDRA1*PWMBA1(*ALM2)16*PWMEA103ISA11017C0MEA104COMBA111GDSA1*PWMCA1(*ALM4)18*PWMFA105: Common signals forPWM12*MCONAl19C0MCA1C0MFA1...

  • Page 127

    For 4th axisCV24*PWMAA4(*ALM1)*PWMDA4(*ALM8)1401IRA40815C0MAA4C0MDA402GDRA409*PWMBA4(*ALM2)*PWMEA41603ISA410C0MEA4C0MBA404GDSA411*PWMCA4(*ALM4)18*PWMFA405*MC0NA41219C0MFA406C0MCA4GND13*DRDYA42007For5th axisCV21(CV21 ofthe second axiscontrolboard 02P05)*PWMDA5(*ALM8)*PWMAA5(*ALM1)140108IRA502C0MAA...

  • Page 128

    12.4 LEDsMeaningsStatusLEDServoalarm1. Parity alarm occurs, accessingstatic-RAMonthe axiscontrolPCB.2.Watch dog timeout.SALMm—«<N<sSALMQs agsbfe<3SS5T12.5 Jumper SettingsStandardsettingUsesJumperA:This PCB isused in"R-H" system.B: This PCB is used in"R-G" system.In...

  • Page 129

    12.6 Test PointsContentsTest points0 V (ground)GGOGO<gGOLocation of test points12.7 Removal/Replacement01P05oCD-2Backplane PCB121) Procedure(j) Disconnect cablesfrom thePCB.(2) Detach PCB by looseningthe screws (D.(3) For mountingnew PCB,reverse the above procedure.2) CautionWhen connecting ca...

  • Page 130

    13.REMOTECRT/KB (A13B-0144-B001)13.1 Theoryof OperationThe remoteCRT/KB isa portableterminal which containsa12" CRT display andafull ASCII keyboard.The remoteCRT/KB is connected to theR-H controller at its RS-232-C portand isused as a user interface.The unit is composedofa12" monochrome...

  • Page 131

    13.3 Connector/Signal IdentificationBade tide of theCRT/KB unitRemoteCRT/KB sideController side14+24 V1FG18RD142152SD9SD1633CDRD1016417SG4RS111718DR55ERCS12181966CSDR1319720RS7SG20ER8CD21922102311241225+24 V13:Frame ground: Receiveddata: Transmitted data: Request to send: Data terminal ready: Sig...

  • Page 132

    13.4CRT/KB ControlPCB (A16B-1211-0760)13.4.1 Connector/signal identificationCN3CN1CD4CASCN2Front viewof theCRT/KB control PCBCN1l+12 VDC powersource for theJ:CRT unit0 V1+12 V230 V40 V+12 V5+12 V6CA5*VIDE0 : Video signal forCRT*INCINT:Increased intensityHSYNC: Horizontal synchronouscontrol signal...

  • Page 133

    CN2*COMOCommonof the keyswitch(from theCRT/KB control PCB)Input signal of keyswitchstatus (to theCRT/KB controlPCB)Input signal ofLED status(from theCRT/KB control PCB)*KEY1141*COMO- 9:8*C0M7*KEY2*C0M12*C0M89*KEY316*C0M23*KEY0- 7:10*C0M9*KEY4*C0M3411*LED2*KEY518*C0M4512*LED1*KEY6)619*C0M5*LED1*LE...

  • Page 134

    13.4.3 Jumper setting!StandardsettingUsesJumpersCharacter generatorselection:Select Aside: KANA+ ALPHA NUMERICSelect B side: ALPHA NUMERICST1A°BST2W/M BA ONot used (all B side)toST6ST1DQST2ST3gST4DST5DST60Locationof jumpers1-116

  • Page 135

    13.4.4 Test pointsSymbolContentsTest pointsWaveformSystemclockfor theCRT/KB control PCB> 2.4VCLK9Mov-l108 nsecCharacter clock forthe CRT/KB control PCBCLKTV> 2.4Vov-I370 nsec> 2.4VDotclock for theCRT/KB control PCB*D0TCLKJ~Y_JovPower on signal fortheCRT/KB control PCB*CLR>2.4 VDC+24 V...

  • Page 136

    13.4.5 Removal/replacement1) Procedure(T) Remove the topcover by loosening fourscrews.—oI%(2) Remove the PCB byloosening twoscrews.&Rear© Disconnectcables from the PCB.© For mounting anew PCB,reverse the above procedure.1-118

  • Page 137

    13.5 KeyboardPCB (A86L-0001-0149)13.5.1 Connector/signal identificationL___!(Top view)*KEY1*KEY0B1*KEY0- 7*LED1*LED2*COMO- 9Al*KEY2*KEY3B2A2: Refer to Sec.13.4.1*KEY5*KEY4B3A3B4*KEY6*KEY7A4*LED1*LED2B5A5A6*C0M0B6*C0M1*C0M2*C0M3B7A7*C0M4B8*C0M5A8*C0M6B9*C0M7A9*C0M9*C0M8BIOA1013.5.2 Removal/replace...

  • Page 138

    13.6 CRT Monitor (A61L-0001-0088)13.6.1 Connector/signal identificationCN1CN2RealFrontCRT monitor PCBView of the part-mounting sideCN11*VIDEO14HSYNCVSYNC0 V82HSYNC150 V93VSYNC16: Refer to13.4.1100 V417110 V5180 V120 V61913720CN2)10 V: Refer toSec.13.4.12+12 V0 V340 V5+12 V6+12 V1-120

  • Page 139

    14.BUILT-INCRT/KB (A05B-2051-J101, J102)14.1 Theoryof OperationThe built-inCRT/KB is a console which containsa9" CRTdisplay anda fullASCII keyboard.The built-inCRT/KB isconnected to the shared RAM board atitsRS-232-C portand is used asa user interface.The unitis composedofa9" monochrome...

  • Page 140

    14.4CRT/KB Control PCB (A20B-1003-0340)14.4.1 Connector/signal identificationA20B-1003-0340CASCD4CN2[CN3"CNTFront viewof theCRT/KB control PCBCN10 V+24 VDC powersource for’ theCRT unit1+24 V20 V30 V4+24 V56+24 VCA5Video signalfor CRTIncreased intensityHorizontal synchronouscontrol signalVe...

  • Page 141

    CN2B1*KEY1*KEYQ*COMO- 7: Common of-- the key switch(from theCRT/KB control PCB)*KEY0- 9.: Input signalof key switchstatus (to the CRT/KB controlPCB)Input signalof LED status*(from theCRT/KB control PCB)A1*KEY2B2*KEY3A2*KEY4B3*KEY5A3*KEY6B4*KEY7A4*LED2*LED1B5A5*COMOB6*C0M1LED1LED2A6*C0M2B7*C0M3A7*...

  • Page 142

    14.4.2 Variable resistor*FunctionAdjustmentNameAdjusttheVR1so that the voltage at"+5 V” iswithin a range of 5V+ 0.1V.Adjustment of the+5 VvoltageVR1O VRlO +5V(Test point)Location ofvariable resistors14.4.3 Jumper settingStandardsettingUsesJumperST1Character generatorselection:Select Aside:...

  • Page 143

    14.4.4 Te*t point*SymbolTest pointsContentsWaveformSystemclock fortheCRT/KB control PCBCLK9M> 2.4VOV108 nsecCharacter clockforthe CRT/KB control PCB> 2.4VCLKTVj~\_rOV-1k- 370 nsecDot clockfor theCRT/KB control PCB*D0TCLK> 2.4Vj~\_rOVPoweron signal fortheCRT/KB control PCB>2.4 VDC*CLR+...

  • Page 144

    14.5 KeyboardPCB (A86L-0001-0149)14.5.1 Connector/iigrwl identificationL!(Top view)*K£Y0B1*KEY1A1*KEYO- 7*LED1*LED2*C0M0- 9*KEY2*KEY3A2B2: Refer toSec. 13.4.1A3*KEY4B3*KEY5A4*KEY6B4*KEY7*LED1B5*LED2A5A6*COMOB6*C0M1A7*C0M2B7*C0M3A8*C0M4*C0M5B8A9*C0H6B9*C0M7*C0M9A10*C0M8BIO14.5.2 Removal/replaceme...

  • Page 145

    14.6 Software KeyboardPCB (A20B-1000-0844)14.6.1 Connector/signal identificationPOP;Commonof key switch*COMOO*COMOO*KYD1- 7: Input signalof key switchA1*KYD1B1A2*KYD2B2A3*KYD3B3statusA4*KYD4B4*KYD7*KYD6A5*KYD5B514.6.2 Removal/replacement©oOO—-Do|<4OlTV®Front view ofCRT/KB panel© Disconnec...

  • Page 146

    14.7 CRT Monitor (A13B-0056-0001)14.7.1 Connector/signal identificationip://CN2CN1Rear viewofthe CRT monitorCN2623514| #Supply voltage forCRT monitor+24 V0 V0 V+24 V0 V+24 VCN1Video signalHorizontal sync, signalVertical sync, signalHigh brightness videosignal0 V for"HIGH VIDEO"VIDEOHSYN...

  • Page 147

    14.7.2 Adjustment routineThe CRTcharacter display controlsare set at the factory and generally will notrequire majoradjustment.To adjust brightness (B) and contrast (C), turn thecorresponding variable resistors mountedon the sideoftheCRT display unit(Fig. 14.7.2).Caution) Keep fingers and tools a...

  • Page 148

    14.7.3 Special adjustmentIf Che CRT picture isdistored or diced, Che adjusting magnetslocated on theCRT display unit (Fig. 14.7.3 (a)) will correct these problems.Bringingthe magnets closer toor farther from thecathode ray deflects thescanning beam tothe desired result.-Generally, adjustmentsare ...

  • Page 149

    2) Adjustments for synchronization (vertical and horizontal), focus, linearity,width and heightare made by using the variable resistorsand adjustablecoillocated on the PCB in theCRT display unit.LChangesthe horizontal picture sizeWIDTHWIDTH-@SharpenscharactersFOCUSFOCUS-Edge connectorStopsthe pic...

  • Page 150

    14.7.4 Troubleshooting flow chart1) No displaySuit\It 12 VDC volutepresentbetweenOVendCRT display unitfuse?Turn ofTCRT 3minutesafter turningon thepower supply.Is the picture brightwhite atOFF?NoNoYesYesDisconnect the edgecon¬nector which connectsCRT display unit regulator.Does the resisunce valu...

  • Page 151

    2) Picture shiftsSun1Disconnect the edge connectorFig.14.7.3 (b)) which connectsCRT display unitend the regulatorunitDoese HSYNC wevefonn(Fig.14.7.3 (b))appear at edgeconnector terminal F7Does VSYNC waveform appealat edge connectorterminal JC7Does a normal waveformappearatcheck terminal ofCRT/KBc...

  • Page 152

    15.I/O BASEUNIT (A03B-0801-C012)15.1 Theory of OperationTheI/O base unitserves as the bus connectionbetween the variousI/O modulesincludingthe robot control module,the DI module,the 00 module,the analoginput module,and the analog outputmodule.15.2 Block Diagram876543210DC powerUlI/O busA20B-1002*...

  • Page 153

    CNAO: Address busfor theI/Omodules: Databus for theI/O modules: parity bit of the data bus: Read/write control signalfortheI/O modules: Datastrobe signalfor theI/Omodules: Busenable signal for theI/Omodules: Power-on reset signal: ReadysignalfromtheI/Omodules: Error signal detectedinthe robot con...

  • Page 154

    CNA1-8Connector CNA1-8are used fortheconnection withI/O modules."CNA1" correspondswith slot 1 and"CNA2" with slot 2, andso on.The signal meaningsare described inthe"CNAO" explanation.ABCAO+5 V*CS32A1A2+5 V31+5 VDOD130D2D3+5 V29D4D5GND28D6D7GND27R7WDP26GNDGND*DS*BE25*...

  • Page 155

    16.ROBOTCONTROL MODULE (A03B-0801-C462)The external view of the robotcontrol module isshown in the followingfigure.NoteiiOOoIINote)"RC01C" means the robotcontrol module.16.1 Theoryof OperationThe robot control module isconnected to theI/O base unit.The robot controlmoduleservesas an int...

  • Page 156

    16.2 Block DiagramToI/O baseunitCNA1ilBuffer<>0V +5VnAddressbufferDataI/O busTiming controlabuffer.8 bitswidthA 8/1*Vconverter8MHzclock0cmT7VInterface control16 bitswidtht.. yVRAMCE/O77v>VA*BufferBuffer<7DecoderLatchTFO<>RV/DV£> RV/DV1COP3 ioI CNB || CNC|To robotmechanicalun...

  • Page 157

    CNA: Address bus for theI/Omodules: Data busfor theI/O modules: Parity bit of the databus:Read/write control signal fortheI/O modules: Data strobe signal for theI/Omodules: Busenable signal fortheI/Omodules: Power-on reset signal: Ready signal from theI/Omodules: Error signaldetected inthe robotc...

  • Page 158

    CNB*ROTRLWD: Robotovertravel signal: Relaywelding signaldetectedin the power input unit: Fuse alarm of the brakecontrol circuit: Emergency stop signalfromthe teach pendantContact signal of the 2ndbrake releaseContact signal of the 3rdbrake releaseContact signal of thehand'breakage detection: Brak...

  • Page 159

    16.4 LEOsErrorindicator LEDsare mountedon thefront panel of the robot control module(RC01C) toindicatean error which mayoccur during datatransfer between basiccontrol unit andRC01C or betweenRC01C andI/O module.I/O modulemeans robot control module,DI module, DO module, analog input moduleor analo...

  • Page 160

    Error contentsError displayName oferrorError contentsCausesTOUTER3 ER2 ER1Normal operationCLOCK STOPAnerror occurredduring datatransferbetweenRC01C and thesharedRAHboard.1. Optical cableis disconnect-oooCARRIER STOPed.oo2. Opticalcon¬nector is notsufficientlyconnected.3. Opticalconnector tipis d...

  • Page 161

    16.5 Jumper SettingsStandardsettingUsesJumpersSelectingcommon voltage forRDI:WhenPI is settoAside,a pneumaticpressurealarm willoccur.PIABBABAE\m|i-2KDOVcommon+24V commonShort-circuit *HBKD input.P2ABABABamiolagan•HBKD isshort-circuited•HBKD Ueffective[H,P2-IPI9Locationof jumpers(The plasticco...

  • Page 162

    16.6 Test PointsThe meanings of the test pointson the robot control moduleareas follows.WaveformContentsTest pointsWhenTP3 isconnected to GND,the time outerror detected inrobotcontrol module isdisabled.This test point isused for development.TDIS+5 VDC+5 V8 MHz clockCLKI-1 ov125mecDVO indicates th...

  • Page 163

    16.7 Removal/Replacement1) Removingrobot control module fromI/O base unitSlotOI0©—mnI/O base unit14a) Procedure® Disconnectthe cable from the robot control module (RC01C).DetachRC01C -by loosening twoscrews (2).For mountingthenew RC01C,reverse the above procedure.Ib) SettingSet thenew RC01C c...

  • Page 164

    3) Detaching the PCBfrom the plasticcaseCasePCB©c5'"/<=>®©ÿ© Remove PCB mountingscrews© .© Draw the PCB out of thecase in the direction© .1-146

  • Page 165

    17.Dl MODULETheexternal viewof theDI module is shown inthe followingfigure.Note9VNote) The code markedon theupper sideofthefront panel indicates the typeofDI module.I D08 CIndicates DI moduleIndicates I)Cor AC powerIndicates the numbers of points (08 or 16)Indicates the type (C, Dor E)The DI modu...

  • Page 166

    17.2 Block DiagramToI/O base unitCNA<7 \/BuffetAddressdecodernLatch>ID#\'frReceiverTz\ReceivernCNTTo user’s interface17.3 Connector/Signal IdentificationitI,CNACNTT1-148

  • Page 167

    CNAb*CSCard selectAddress signalData busParity bit of thedatabusRead/write control signalData strobe signalBus enable signalError signaldetected intheDI module: Read strobe forID code: DC voltageca+5 V*csAO32AO+5 VDO-731+5 V30DODlDPR/WD2+5 VD32928D40 VD5*DS0 VD6D727*BER/W0 V26DP*ERRI0 V*BE25*DS0 ...

  • Page 168

    17.4 LEDsTheDI module is provided withLEDsfor indicating theon/off conditionsof eachinput signal.ID08CID16C1D08D,ID16DIA08E,IA16EuumE01EI01YellowLEOYellowLEDEI020203agasgasgasgasgasgasgasgasgasgasgasgas03gas 0404COM lgas-asSasgas1L20505060607070808COM22L20909101011111212COM33L2131314141515[ÿElEl...

  • Page 169

    17.5 Removat/ReplacementOoo0£As' *"2ooo_o3A.1) Procedure0 Disconnectcablesfrom DI-module.Disconnectthe terminalboard by loosening the twoscrews(a)shown inthe following figure and, while holding its upper andlower ends, pullingout the entire terminalboard.For disconnecting the wiring,open th...

  • Page 170

    18.DO MODULEThe external view of theDO module isshown in the following figure.\0NoteI]OD08BavNote) The codemarkedon the upper sideof the front panelindicates the type ofDOmodule.0D 08 BIndicates DOmoduleIndicates I)Cor AC powerIndicates the number of points (08or 16)Indicates the type (B, C,D,E o...

  • Page 171

    18.2Block DiagramTo I/O base unitCNA\sBufferAddressdecoderFuse alarm7\ID#\zLatchsBuffernf -----r~DrivernCNTTo user's interface18.3 Connector/Signal identificationnlCNACNT1-153

  • Page 172

    CNAb*CSCard selectAddress signalData busParitybit of the databusRead/write control signalData strobe signalBus enable signalPower-on resetError signal detected intheI/O interfacemodule: Error signal detected intheDI module: Read strobe for ID code: DC voltageac*CS32+5 VAOAO+5 V31DO-7DO+5 VDl30DPR...

  • Page 173

    18r4ÿEDsThA DOjmodule is providedwith LEDs for indicating theon/off conditions of eachoutpue signal.OD08B, OD16BOD08C. OD16COA08D. OA16DOA08E.OA16EOD08H,OD16HYellowLEDYellowLED.YellowLEOYellowLEDuuuui£mzmSHESHESHE-HESHESHESHESHESHESHESHESHESHE0101010102SHESEESEE020202030303I©1° 03[®I° 04040...

  • Page 174

    18.5 FusesThe DOmodule is provided witha built-in fuse for everycommon.If thesefusesare blown, the fuse-alarm indicator LEDofthe correspondingmodule lights toindicate thefusefailure.The following figuresshown the mounting positionsof the fuse-alarm indicatorLEDs of each module andthe mounting pos...

  • Page 175

    ModulenameOD08C,0D16CMounting posi¬tions of fuse-alarmindicatorLEDs and mountingpositionsoffuses©cm010203sills;04COM030«07alls08COM09©101112JlCOM1314131«11SHECOMFUCO£SEc.©n \IndicatorFuse alumLED (red)If one of eightfuses FI- F8 is blown,the abovefusealarmLED lights.The blownfuse showsa wh...

  • Page 176

    Module nameOA08D,0A16DMountingposi¬tions offuse-alarm indicatorLEDsand mountingpositions offusesu©cm010203is04LISMB 03Zm06071,08LI09©101112isSMEILl1314IS161LlFU2L2SE..." .•\ c©n \FiuealarmLEO (tell)IndicatorIfone offour fuses FI- F4 is blown,the abovefuse alarm LED lights.Theblownfuse ...

  • Page 177

    Modulename. 0A08E,0A16EMountingposi¬tions of fuse-alarm indicatorLEDs and mountingpositions offusesu©c~L[O 010)o 020{o 03[© o<FUUI©SEFI F2®|e 03 Fuse ilsrmLED #1®T© 06®|0 02loot.FULItF4F3©®|0 09Fuse alarmLED #2®jo 10uo[© 12FULISslalarmLED #3FSF6®lo 14©|o»P 16FULIt.L2©loFuse alu...

  • Page 178

    Module name0D08H,0D16HMountingposi¬tions of fuse-alarm indicatorLEDs and mountingpositions offusesu©cmm-Miot0203Jls04+DC1OS0607ells08COM1©09tou12112£21314IS16ISCOMFUECOlx.SE_r\ c©J2LIndicatorFuse alarmLED (red)\If one of eightfuses FI- F8 is blown,the abovefuse alarm LED lights.The blownfuse...

  • Page 179

    18.6 Removal/Replacementooo0/PI/?/ooooI2I) Procedure® Disconnectcables from DOmodule.Disconnectthe terminalboard byloosening the twoscrews(a)shown inthe following figure and,while holding itsupper andlower ends, pullingoutthe entire terminalboard.For disconnecting the wiring,open the nameplate.T...

  • Page 180

    19.ANALOG INPUT MODULE (A03B-0801-C410)The external view ofthe analog input module is shown in the following figure.-—NoteNote)‘AD04A* means the analoginput module.19.1 Theoryof OperationTheanaloginputmoduleprovidestheuserwithameansforinterfacingperipheral equipment analog inputstothe control...

  • Page 181

    19.3 Connector/Signal Identificationr\XCNACNTCNAb*CS: Card select: Address signal: Data bus: Parity bit of the databus:Read/write control signal: Busenable signal: Power-on reset: Error signaldetected inthe analog inputmodule: Read strobe for ID codeac32*CS+5 VAOAO-3DO-731A1+5 VA230DO+5 VD1DPR/W2...

  • Page 182

    19.4 Variable ResistorsTenvariable resistorsare located on the analog input module (AD04A).Refer toSec.19.7 forthe adjustingmethod.Thevariable resistorsVR3 andVR4are usedfor the gainadjustmentoftheoperation-amplifiers.ThevariableresistorVR5 isusedforthebalanceadjustmentbetweentwoopera t ion-ampli...

  • Page 183

    SymbolTest pointsContentsWaveform(voltage)TP12Usedfor test.By connectingTP12 toTP11 (GND), all theanalog input isneglected (disconnect¬ed) totheA/Dconverterinput.INHVR7TP7oCNT1oCNT2TPSCNT3oo CNT4-ISVVR8CNT5TP9CKT6oCNT7GNDVR9o CNT8O TP1O TP2O TP3O TP4CNT9CNT10CNT11VR10Note)In theleft figurethe pl...

  • Page 184

    19.6 Removal/ReplacementOO00(4141<41AO000©H'21) Procedure(I) Disconnect cables fromtheanalog Inputmodule.Disconnect theterminal board byloosening the twoscrews© shown inthe following figureandi whileholding itsupper and lower ends, pullingoutthe entireterminal board.For disconnecting the wir...

  • Page 185

    19.7 Calibration ProcedureObtain the following equipment:. Voltagesource (resolution 1 mV). Voltage meter (resolution 0.1 mV). Resistance meter (resolution 0.01 ohm)Calibrate asfollows.1. Input0.000 V toTP1 andTP3.2. Adjust VR3until the voltage atTP5 becomes0.0 mV.3. Adjust VR4until the voltageat...

  • Page 186

    20.ANALOG OUTPUT MODULE (A03B-0801-C411)The external viewof- the analog output module isshown in the following figure.A*NoteNote) *DA02A’ means the analogoutputmodule.V20.1 Theory of OperationThe analog output module provides analog outputstotheuser for interfacing.Atwochannel output module isa...

  • Page 187

    20.3 Connector/Signal IdentificationftCNACNTCNAb*CS: Cardselect: Address signal: Databus: Parity bitofthe data bus: Read/write control signal: Bus enable signal: Data strobe signal: Bus enable signal: Power-on reset: Error signaldetected intheI/O interfacemodule: Error signal detected inthe analo...

  • Page 188

    20.4 Variable ResistorsTwelve variable resistorsare locatedon theanalog outputmodule(DA02A).Refer toSec. 20.8 for the adjustingmethod.Thevariable resistors VRA1 andVRB1are used for theoffset adjustmentoftheD/A converter.VRA1 isprovidedfor channel 1 output andVRB1 is for channel 2output.Thevariabl...

  • Page 189

    20.6 Test PointsThe meanings ofthe test pointson the analogoutput module are as follows.Waveform (voltage)SymbolTest pointsContentsOutputof theD/Aconverter ofchannel 1-10 V- +10 VPA1Output of the voltageamplifier ofchannel 1-10 V- +10 VPA2Usedfor theoffsetand balance adjustmentof theV/I conversio...

  • Page 190

    °+5VGND-15VGND+15VOOoPA4OOOoVRA3 VRA4 VRA6oPA3oVRA2OVRA1PA20VRA5OOVRB2PA1oPB20PB3VRB3 VRB4VRB6°OOOVRB1PB4GNDOOOPB1o+SVGND+24V-12V +12V GND-5VOoOoOOOFig.20.6 Location oftest points and variable resistorson the analog outputmoduleThe plasticcover is removed in the abovefigure.plasticcase disassem...

  • Page 191

    20.7 Removal/Replacementooo6{A/7\XToOOP1ffiÿfG>—-Hi1) Procedure® Disconnect cables from above analog outputmodule (DA02A).Disconnect the terminalboard by loosening the two screws (a)shown inthe following figure and,whileholding its upper andlower ends,pullingoutthe entire terminalboard.For...

  • Page 192

    20.8 Calibration ProcedureObtain the following equipment:. Voltagemeter (resolution 0.1 mV). Current meter (resolution 1 uA)Calibrate the Analog outputchannel 1 asfollows:1. Fromthe KCL> prompt, type inthe following:SET PORT AOUTCn] *=0wheren isthe portnumber.Thiscommand willforcea 0 V output....

  • Page 193

    Calibrate theAnalog outputchannel2 as follows:1. Fromthe KCL> prompt, type in the following:SETPORT AOUT[n]= 0wheren isthe portnumber.This command will forcea 0 V output.2. Adjust VRB1 until0 V ismeasured atPB1.3. Adjust VRB2 until0 V ismeasured atPB2.4. From theKCL> prompt,type in the foll...

  • Page 194

    21.FIXEDI/O BOARD (A16B-1211-0750)21.1 Theoryof OperationThe fixedI/O board isa singleI/O board, which isinstalled in the controllerbackplane.The board providesan interface tothe robotmechanical unit anduser system.Signal linesare connectedtothe appropriateconnectorfrom the fixedI/Oboard.CNC isus...

  • Page 195

    21.3 Connector/Signal IdentificationCNlCN2CNBCNACNCCNA}b*BGIN: Bus groundIn*BGOUT: Bus ground out: Serial data in: Serial data out: Reverse logic signalof powerenableWired togetherin the boardca+5 V320 V+5 V310 VSDI30+5 VSDO29+5 V*EN0 V280 V27*SYSCLR: System clear26-+5 V0 V25+5 V+5 V+24 V+15 V-15...

  • Page 196

    CN1013319UDI1UDI1- 32: User DIUD01- 2A: User DO0 EUDOlUDI202200 E34UD02: Common of UDIs andUDOs03UDI30 E0 E35UD0321UDI4043622UD0405UDI52337UD0506UDI6UDI17UD062438UDI1807UDI7UD07253908UDI826UDI19UD084009UDI927UDI20UD094128UDI2110UDI10UD010421143UDOll29UDI22UDI1112UDI1244UD01230UDI23311345UD013UDI2...

  • Page 197

    CNCThe connector"CNC" is usedfor theInterface with themechanical unit.01RDI1RD01230213*R0TRDI2RD0224RDI1- 8: General purpose DIsRD01- 8: Generalpurpose DOs*R0T*HBKDALMLOPRL*PPABN1403RDI3*HBKDRD032504RDI415NZ1RD0426: Robot overtravel signal: Hand breakage detection: DOfor the alarm lamp:...

  • Page 198

    21.5 Removal/ReplacementOPTl©Backplane121) Procedure8 Disconnectcablesfrom the fixedI/O board.Detach PCB byloosening twoscrews (2).® For mountingnew PCB,reverse the above procedure.1-180

  • Page 199

    22.TEACHPENDANT (A05B-2051-C142)22.1 Theoryof OperationThe teach pendant providesameans of inputtingjogcommands througha keyboard.It also displays messages from the robot controller totheuser.Theteachpendant iscabled tothe connectorCNTP ofthe shared RAM board.CNTP isanRS-422 serial port connector...

  • Page 200

    22.3 TeachPendant (A05B-2051-C142)22.3.1 Connector/signal identification-Q--0-i-LCD display@000000BSBHSBEHSBE2I&?:00015]5T00SISI£000®[slfalfsiral©KeypadO-C&--ENABLEON/OFF switch-a21\ -<$>-EMERGENCY STOPbutton\DEADMAN switchConnectoi to the sharedRAM board}SD: Sending data*SD"...

  • Page 201

    22.3.2 Removal/repiacemant of teach pendant and components1) Unit (Teachpendant)a) ProcedureI Disconnectthe cable.Replace theteach pendantwith a new one, andconnectthe cable.P©l2) Component (EMERGENCY STOP button)a) ProcedureI Disconnectthe cable.Remove the back-cover byloosening sixscrews® .Di...

  • Page 202

    3) Component (ENABLEON/OFF switch)a) ProcedurefOs Disconnect the cable.Remove the backcover byloosening sixscrews (2).Disconnectcable(D.Remove the ENABLEON/OFFswitch.(D For mountinga new switch,reverse the above procedure.2I13,422.4 Teach Pendant ControlPCB (A20B-1002-0980)22.4.1 Connector/signal...

  • Page 203

    CN1Refer toSec.22.3.1 for the signalnames.ba10TP409TP308EMG070 V060 V0 V+24 V050 V04TP2TP10302RD*RD01*SDSDCN2VSS(0V):0VVDD(+5V) : +5 VDCpower supplyVOC+3.4 V): Powersource todrive LCD: Resistorselect to LCDcontroller: Read/write control to LCDcontroller: Read enable toLCDcontroller: Data bus to/f...

  • Page 204

    CN4EMG1,2: The status of theEMERGENCYSTOP button (normally closed)EMG3,4: The status of theEMERGENCYSTOP button (normally open)EMG101EMG202EMG30304EMG4CN501EMG5EMG5,6: The status ofthe EMERGENCYSTOP button (normally closed)used forTP3/TP402EMG6CN6I01+24 V+24 V: Powersource for LCDback light0 V020...

  • Page 205

    22.4.3 Jumper settingsStandardsettingUsesJumpersUsed forproduction testing onlySImkShortNotusedS2o oOpenSee Fig.22.4.2 forlocation ofSI andS2.22.4.4 Test pointsThe meanings of the testpointson the teach pendant control PCB are as follows.WaveformSymbolContentsTest pointsUsedfor emulation ofpowero...

  • Page 206

    SymbolContentsWaveformTest points+4.85- +5.15 VDC(Equals +5 V)Voltage suppliedto the LCD module+5 L-4.85- -5.15 VDC-5 LVO+3.4 VDCSee Fig.22.4.2 for location oftest points.22.4.5 Removal/replacement of teach pendant controlPCB1) Procedures Disconnect thecable.Remove thebackcover byloosening sixscr...

  • Page 207

    22.5 KeyboardPCB (A20B-1002-0970)22.5.1 Connector/signal identificationOConnector totheteach pendantcontrol PCB CN3(mountedon theback side)OoTop viewOooOutput signalof keyswitchstatusto the teach pendantcontrol PCBCommon of the keyswitchfrom the teach pendantcontrol PCBDrive signalof LED displayC...

  • Page 208

    22.6 LCD Module (A61 L-0001-0109)22.6.1 Connector/signal identificationCNXCable2Real view&= CN2CN1Dl,D2CL1,CL20102FLMDlControl signals to drive:LCD04CL103MCL206D2FLM05VDD(+5V)VSS(OV)08M07VDD(+5 V)VSS(0 V)VEE(-5 V)V0 (+3. 4 V)VEE(-5V)V0(+3.4V)0909: Powersource todrive LCDCN2)Powersource to dri...

  • Page 209

    22.7 LCD ControlPCB (A61L-0001-0100 #CB1053RP)22.7.1 Connactor/iignal identificationr*:”VJCN2Top viewCN1CN10102FLMD1Dl,D2CL1, CL20304CL1Control signals todrive‘ LCDM05CL206D2FLM07VDD(+5V)08VSS(OV)MVDD(+5 V)VSS(0 V)VEE(-5 V)V0(+3.4 V)09VEE(-5V)10V0(+3.4V): Powersource todrive LCDCN2VSS(0 V):0V...

  • Page 210

    23.POWER INPUT UNITDescribed in this section are:The theory of operationof ACpower control (23.1)The block diagram of ACpower controlThe power input unit excluding PCBThe power input unit PCB.(23.-2)(23.3)(23.4)23.1 Theoryof OperationACpower is supplied to the controller by the power input unit.T...

  • Page 211

    23.2 Block DiagramPower input unitCircuitAC input brtakttcTo-LC3Servotrans.TF1To servoamplifier3*6 F7-9LCR/LCSFNRFIFNSFanPower inputunitPCS200RFuse200ALC1/LC2Inputtrans.200S200BvH F1'2OORnTF4Trans.ControltransformerTF3rPower supplyunit0*13ALC/ALPC100INI1001N2PPower supplyunitON/OFFcircuitry1200AL...

  • Page 212

    Power input unitCircuitAC input3®-O O-LC3Servotrans.TF1To servoamplifierOF7-9©LCR/LCSOFNR.FIFNSFanPower input unitPCSLC1/LC2—O O-200RFuse200AInputtrans.200S200BCh- Fl-2OHTF4Trans,TJ100 INIIOOIN2rPower supplyunitCP13CALC/ALDPPower supply unitON/OFFcircuitry1200ALClILC2yC200BALA/ALBP44FUALMPIL6...

  • Page 213

    Power input unitDisconnect switchAC inputLC3Servotrans.TF1<TÿO-To servoamplifier] FL1-3[30o . oF7-9(uz)LCR/LCSFNRFIFNSFanPower inputunit PCB200RFuse200ALC1/LC2Inputtrans.20OS200Bo oTF4Tans.I T1100 INI100 1N2F3O-PowersuunitCPIr ALC/AITcpPower supply unitON/OFFcircuitry1200ALCULC2C200BALA/ALBP4...

  • Page 214

    23.3 Power Input UnitThereare six typeso£ power input units andone ofthem isused being basedonthe cabinet types, the AC input voltage, and the power disconnection device.SpecificationAC input voltage380/415/460/480500/550/575 VAC220/240 VACMedium sizecabinetA14B-0076-B321A14B-0076-B320Circuitbre...

  • Page 215

    Power input unitA14B-0076-B320. B321LC3o-o-F8Toservotransformerito220-575 VACinputF9itO220rCh:17ÿO1!IQQAOCOM|!|IOOBU VACLa[To servo amp.(100VAOTi „x,.1 XL_±.To fan unitAAATTTT- N- «58 8g g--8Stn211 iiIIPower input unitPCBA16B-1311-0530vFig.23.3 (b)Power input unit circuitry (Medium size cabi...

  • Page 216

    Power input unhA14B4076-B324.B325.U3FL1F7CD-OFUF8To servotransformeroo220-575 VACinputFL3F9CDOrOi:]FromservotransformerLC3[::]Toservoamp.(100VAC)To fan unit4\A AA A AAA/|VÿyjvyjvAATTTt«556SIISiiIs*£§£§I O OiiPower Input unit PCBA16B-1311-0530Fig.23.3 (d)Power inputunit circuitry (Large size...

  • Page 217

    23.3.2 Removal/replacement1)Power input unita) Procedure(1) Disconnect allcablesfrom the power inputunit PCB.© Disconnectall cables© from the power inputunit.© The power input unitcan be removed by looseningfourscrews© .@ For mountingnew power input unit* reverse the above procedure.P?T£FLlF...

  • Page 218

    3) Control transformer (TF3)a) Procedure(D Disconnect all cables (I) from thetransformer.© Thetransformer can beremoved byloosening fourscrews© .<D For mountingnew transformer,reverse the above procedure.Control transformerTF3%Xo\rtrhr'I©©/©—Powerinputunit©—©—13LC3Front view ofpow...

  • Page 219

    23.4 Power Input UnitPCB (A16B-1310-0530)23.4.1 Cormector/signa! identificationCPICPJ200AfaCP3§BCP4BfaBniCP8U11CP7T?1TAekoJrl<?*5l*YCJOCo MD i TVW~* (OA’logi.IcvSjWfjPtXf»c;e.Fig. 23.4.1 Locationof terminals and connectors on the power inputunitPCBews.eeC.OEMGIN1EMGINCEMGIN2EMG0UT1EMGOUTCE...

  • Page 220

    The relationship between the signals isas follows.ContactbetweenEMG0UT1 andEMGOUTCContactbetweenEMGOUTC andEMG0UT2100 VAC outputfortheservoamplifiers100 VDC outputfor the motorbrakeStatusNormal (Noteÿfc(Robot can beoperated)100 VDC100 VACClosedOpenONONEMGIN1-EMGINC(open)OFFOFFOpenClosedEMGINC-EM...

  • Page 221

    CPIPFLPFL01: PowerON/OFF leading signalPFHPFH0203PFPF04These contact signalsare outputto the power supplyunitbefore power is normally turnedon or normallyturnedoff bytheON/OFF button providedon theoperator's paneloran externalON/OFF button.Asshownin the diagram,PFL/PF are connected prior tothe AC...

  • Page 222

    CP2- CP4200A200B200A01: 200 VACpowersource for the power supply unit: 0 V(ground)200B0203GNDGNDCP3 andCP4: These connectorsare not used.CP7+24 E: +24 V (External use from power supply unit)0 V: Ground+24 V: +24 V frompower supply unit01020 V03040 V05+24 V06+24 ECP8+24 F: +24 V (via fuse F10)0V: G...

  • Page 223

    CN2+24 F: +24 V to CNPIon shared RAMboardOTREL:Overtravel release signalfromthe operator panel throughCNPIon theshared RAMboard: Status signal of EMERGENCYSTOPbutton and DEADMANswitch onthe teach pendant: Status signalof EMERGENCY STOPbutton andDISABLE/ENABLE switchon the teach pendant140 V+24 F0...

  • Page 224

    23.4.2 Jumper/shorting strip settingsALAa&TPlTP1When the terminals "EMGINl","EMGINC",and"EMGIN2" on TPlare not used, theterminals should beshorted.Thesetting method isas follows.When the terminals "EMGINl" and"EMGINC" are used,remove theshorti...

  • Page 225

    LEDMeaningStatusTPlS. ON(amber)100 VAC issupplied to theservo amplifier, when thisLED lights.Servoonc(PCB/(.A16B-m0-0S10)When thisLED lights, thebrakeon axis 1on theS-10 is released. Axes 2 and3on theS-700 is released._<1stbrake isreleasedBK1((amber)cWhen thisLED lights, thebrakes on axes 2and...

  • Page 226

    TP1Remove this shorting strip(M3 terminals)when the gateswitch ofthe protectivefence isused.-s OFFCOM©Gate switch ofthe protectivefence.FN1©FN2ALA and ALBterminals should beleftopen whenan external $larm isnotused.Whenan externalalarm Is used, the connectionIsas follows.Faston terminalAlarm swi...

  • Page 227

    23.4.4 FUMSSevenfusesare installed in the power input unitPCB.Input fuses of 200 VAC lineInput fuse ofthe control circuitFuses ofthebrake control lineInput fuse of24 VDClineEach fuse specification isas follows.FI, F2F3F4, F5,F6F10Fuse numberSpecificationA60L-0001-0101i?P4100HFI, F2A60L-0001-0172#...

  • Page 228

    23.4.5 Test pointsWaveform (voltage)SymbolTest pointsContentsOutputofthe diodebridgeto convert ACtoDC voltageCabout25 VDCCathode of theZenerdiode (ZD1)about 22 VDCBDC power voltage ofthe input unit PCBcircuit21 to22 VDCE0 V reference foroutputof bridge0 V0 Vo ovE°OOBCTP1Fig.23.4.5Location of tes...

  • Page 229

    23.4.6 Removal/repiacament1) Power Input unit PCBa) Procedure® Disconnect cablesfrom thepower input unitPCB.(2) Detach the PCB by looseningthe fivescrews (2).(3) For mountingthe PCB,reverse the above procedure.Io-Fig.23.4.6 (a)Left side view of power input unit PCB2) Component (relay)Relay remov...

  • Page 230

    24.TRANSFORMERSFourtransformers(servo,input,controlanduser)areinstalledinthecontroller.Servo transformer: Provides power for servo amplifiersInput transformer-: Provides 200 VACfor power supply unit,fan units, controltransformer and power input unit.Control transformer: Provides 100 VACforservo a...

  • Page 231

    24.1 Fuses1) Servotransformer TF1FI- F3:Fuses for 200 VAC output (30 A)A60L-0001-0042#JGl-30F4- F5: Fusesfor 100 VAC output (3.5 A)A60L-0001-0101#P435HrJiA-iF4F5|— 30A§00FIF2F3Ri6-w «O«« r>» O'EEBBHMEEEEB4- 4-22 22 £2 22w>r»«e’wWrs©MEHMEEMEEnVt \6 MN MN3IEE±EEEEEEEEE\Front vie...

  • Page 232

    3) User transformerFI: Inputfuse ofuser transformer TF5A60L-0001-0042#JG1-10F2: Outputfuse ofuser transformerTF5A60L-0001-0042#JGl-20±TBlmi±i 57S L_SSO>0A\lF2ES20AM,«rm 500m 480EEUEE 460EELlEE115VAC.9.6A440EEL2EE 415EEL2EE 380— — DIEJmitBV E3\IE240220EE COMm424.2 Settings1) Servotransfo...

  • Page 233

    25.HOUR METER25.1 Connector/Signal identificationnTerminals:100 VAC input'terminalsforhour meterTerminals(Rear viewof the hour meter)25.2 Removal/Replacement1) ProcedureID Disconnect cables (I) from the hour meter.The hour metercan be removed by looseningtwo nuts(f) •2) For mountingnew hour met...

  • Page 234

    26.SERVOAMPLIFIERIn the S-10 R-H controller, twothree-axis servo amplifiersare used.IntheS-700 R-H controller,two one-axisservo amplifiers andtwotwo-axisservo amplifiersare used todrive each axis.The relationship betweentheaxes numbers,axes names, and theconnectors on theaxis control PCB, robot m...

  • Page 235

    26.1 One-axis Servo AmplifierThis type of amplifier isused in the S-700 controller.follows.The partnumbers areasS-700A06B-6058-H006 (W)A06B-6058-H012 (0)26.1.1 Theory of operationTheservo amplifier drivesan ACservo motor.It consistsof two parts, thepower amplifier (unit base) and theservo amplifi...

  • Page 236

    26.1.2 Block diagramFT7JnACservomotorT1CurrentT1detectorRA5UDischargecontrolcircuit6V200VACSml30W7T2VillLSJ# iOOA(IOOBT4L——6—3-— MCC100VAC10iACh 4To axiscontrol boardcServo amplifierPCBA20B-1003-0090CN1To dischargeunit (Amp. 4)No connection(Amp. 3)TOH19. T42TOHT$22ReceiverDriverTo powerci...

  • Page 237

    26.1.3 Connector/signal identificationOOA20B~|003*0090WCN4LrruCN3LrCNl]T1A1-219

  • Page 238

    T1: 200 VACthree phaseR,S,T100A,100B:100 VAC single phaseU, V, WAR: Three phase output for motor: Ground terminalS12T100A34100BU56VO Hi.O Hi.7W8T2: Collector of transistor Q1: DC main power supplyLCG4LCGHCA56HCAT4T0H1,T0H2:Transformer overheat input1TOH1T0H22CN1Phase-R currentPhase-S currentMCCco...

  • Page 239

    CN3DB: Base signalfor transistor D: Base signal.for transistorF: Emitter signalfor transistor B,D, F,G: Overheatof heatsink: Precharge control relay: 20 VDCfor precharge control relay: Interlock of contactor100B: 100 VAC: Magneticcontactor controlCDU2:Current detect ofU phaseCDV2: Currentdetect o...

  • Page 240

    26.1.4 LEDsLEDFunctionConditionsHighvoltagealarmThe DC voltage of the main power supply is higher than450 V.a. AC power supply ishigher than the specified range.b. The regenerativeenergy discharge circuitbecomesdefective, which includes the PCB, the transistor Ql,and discharge resistoror the sepa...

  • Page 241

    A2OB-1003-0090rxCN4L_rO HVfLo HC(RED)LVDCOHQDRDY (GREEN)CN3IfElonILocationofLEDs on A20B-1003-00901-223

  • Page 242

    26.1.5 Test pointsSymbolContentsTest pointsWaveformCHI*PWMAA-phasePWM signalCH7IRR-phase currentCH8ISS-phase current0 V (Ground)CH90 VCH10+5 V+5 VDC+15 VDCCH11+15 VCH12-15 V-15 VDCCH13+24 V+24 VDCA20B-100V0090ruCN4LrruO CHI3OCH12OCHUO CH10OCH9OCHSO CH7O CHICN3L_r\E]OilLocation of test pointson A2...

  • Page 243

    26.1.6 Jumper setting*S-700AxisJumperifln#4nMeaningNo.U j afiT70WTOH settingWhen the overheatsignal is not provided.to T4, the SI settingshould be H side.HLSIDCalarm settingWhen the discharge unit isnot added,theS2 settingshould be L side.LHS2Symbols#1- if 4 showtheservo amp. No.A20B*1003-0090r~L...

  • Page 244

    26.1.7 Removal/replacament1) Unita) Remove thecables connected tothe connector CN1 and terminals Tl, T2 andT4.Unclamp connectorsare follows:. CN1(T) Squeeze the clamp releasetoremove the connector.ij._Clamp» v3 release<=C> cb) Loosen two mountingscrews atthe bottom.c) Remove two mountingsc...

  • Page 245

    26.2 Two-axisServo AmplifierThis typeof amplifier is used in the S-700 controller.follows.The part numbers areasS-700A06B-6058-H221 (fi, y)A06B-6058-H222 (U, a)26.2.1 Theoryof operationTheservo amplifier drivesan ACservo motor.It consists oftwo parts, thepower amplifier (unit base) andtheservo am...

  • Page 246

    25ReceiverDriver7>UZs5 ReceiverDriversIOc=2Alarm detectTT4<>+5V.+24V+15V.-15VPower supplycircuitDRDY HVHCLV DCOHBlock diagramof theservo amplifier PCB (Two-axis type)26.2.3 Connector/signal identificationOOcaruA16B-1200-0720CN4LLrSide viewruCN4MUULrCN1MCN1LP<CN3CN1LCN1M,LrST1AA1-228

  • Page 247

    T1: 200 VAC three phase: 100 VAC single phases Three phase outputfor motor: GroundterminalR, S,T100A,100BUL, VL, WLUM, VM, WMRA1S2T3100A4100B5LUL6LVL7LWL5MUMo>O-I"6MVM7MWMT2: Collector of transistor Q1: DC main power supplyLCG4LCGHCA56HCAT4T0H1, T0H2: Transformer overheat input1T0H12T0H21...

  • Page 248

    CN3VHVHDetect signalfor HCalarmDetect signalfor discharge circuit(200 VAC for DC powersupply)Ground for noisefilterCollector signalfor discharge circuitBase signal for discharge circuitEmitter signal for discharge circuit100 VACContactor controlInterlock of contactorOverheatof heat sink01:VHV02VH...

  • Page 249

    CN1LL-axisservo interface signals*PWMAL(*ALM1)*PWMDL(*ALH8)*PWMAL(*ALM1), COMAL '*PWMBL (*ALM2) ,COMBL*PWMCL (*ALM4),COMCL*PWMDL (*ALM8),COMDL*PWMEL, COMEL*PWMFL, COMFLIRL, GDRLISL,GDSL*MCONL*DRDYLPWM signals andtheircommonsPWMAthrough PWMDare also usedtosend an alarmcode.: Phase-R current: Phase...

  • Page 250

    26.2.4 LEDsFunctionLEDConditionsHighvoltagealarmThe DC voltage of the main power supply is higher than450 V.a. ACpower supply is higher than the specifiedrange.b. The regenerativeenergy discharge circuit becomesdefective, which includes the PCB,the transistor Ql,and discharge resistoror the separ...

  • Page 251

    fLA16B-1200*0720CH4LLTruCN4MLTHVHCLV(RED)DCruOHCN3ODRDY(GREEN)_rCN1ICCN1LLocation ofLEDs1-233l

  • Page 252

    26.2.5 Test pointsTest pointsSymbolContentsCH1L, MA-phasePWM signal*PWMACH7L, MR-phasecurrentIRCH8L, MS-phasecurrentIS0 V (Ground)CH90 VCH10+5 V+5 VDCCH11+15 V+15 VDCCH12-15 V-15 VDCCH13+24 V+24 VDCAI6S-12004720fLCN4LLrFLCN4MLr® CHI3® CHI2© CHIl© OHIO© CHS© CHUiri® CH7MCN3© CH8L© CH7L© ...

  • Page 253

    26.2.6 Jumper settingsAxisJumpernft1#3#4MeaningNo.U1 otMYewTOH settingWhentheoverheat signal is notprovidedto T4, theSI settingshould be H side.SILHDCalarm settingWhen the discharge unit isnot added,the S2 settingshould be L side.LS2LSymbols#1- #4 show theservo amp. No.fLA16B-120WJ720CS4LLrCN4MLr...

  • Page 254

    26.2.7 Removal/raplacamsnt1) Unita) Removethe cables connected tothe connector CN1L,CN1M and terminals Tl,T2 andT4.Unclampconnectors are follows:. CN1L,CN1M(T) Squeeze the clamp releasetoremove the connector.IClampreleasea<=J<=> <=b) Loosen two mountingscrews atthe bottom.c) Remove tw...

  • Page 255

    26.3Three-axis Servo AmplifierThis typeof amplifier isused in theS-10 controller.f ollows. TheNEW amplifier replaces theCURRENT amplifier.The partnumbersareasCURRENT AMPLIFIERNEW AMPLIFIERBASICSPECIFICATIONROBOTA06B-6058—H327A06B-605&-H325A06B-6058-H333A06B-6058-H331A05B-2066-H021S-10Medium...

  • Page 256

    26.3.3 Connector/iignal identificationA16B*1100*0220r~LCN3ISuri,CN4LrruCN4NI CK1L||CN1MII CN1N|0T1: 200 VACthree phase: 100 VAC single phaseR, S,T100A,100BUL, VL,WL]UM, VM,WMUN,VN, WNAR1S: Three phase output for motor2T: Ground terminal3100A4100B5LUL6LVL7LWL5MUM6MVM7MWM5NUN6NVNOH"OH"7NW...

  • Page 257

    T2LCG: Collector of transistor Q1: DC main power supply4LCGHCA5HCA6T4T0H1,T0H2: Transformer overheat inputT0H11T0H22CN1LL-axisservo interface signals*PWMAL (*ALM1) ,COMAL*PWMBL(*ALM2) ,COMBL*PWMCL (*ALM4) .COMCL*PWMDL(*ALM8) ,COMDL*PWMEL,COMEL*PWMFL,COMFLIRL, GDRLISL,GDSL*MCONL*DRDYL: PWM signals...

  • Page 258

    CN1NN-axis servo interface signals*PWMAN(*ALM1), COMAN ’*PWMBN(*ALM2) ,COMBN*PWMCN(*ALM4) .COMCN*PWMDN (*ALM8),COMDN*PWMEN, COMEN*PWMFN,COMFNIRN,GDRNISN,GDSN*MCONN*DRDYN: PWM signals andtheir commonsPWMAthrough PWMDare also used tosend an alarmcode.: Phase-R current: Phase-S current: MCCcontrol...

  • Page 259

    CN4M01VHMVHM: Collector signalfor transistorof M-axis: Base signalfor transistor A of M-axis: Emitter signal for transistor Aof M-axis: Base signalfor transistor B of M-axis: Base signalfor transistor C of M-axis: Emitter signalfor transistor Cof M-axis: Base signalfor transistor D of M-axis: Bas...

  • Page 260

    26.3.4 LEDsLEDFunctionConditionsTheDC voltage of the mainpower supply is higher than450 V.a AC power supply is higher than the specifiedrange.bThe generativeenergy discharge circuit becomes defective, which includesthe PCB, the transistor Ql, and discharge resistoror the separately mounteddischar...

  • Page 261

    A16B-1100-0220XICN4CN3LXJLxrxCN4MLfrxO DRDY (GREEN)HVHCCN4(RED)LVNDCDHLX|CN1L||CN1M||CN1N |0Location ofLEDson A16B-1100-0220A16B-1100-0330/02AnXICN4CN3LLfXJrxCN4MLXO DRDY (Green)HCl. ~HCMn,HCN(Red)OHDCCN4HVNLVJ5V (Green)LX|CN1L|[CN1M ||CN1N |[3LocationofLEDson A16B-1100-0330/02A1-243

  • Page 262

    26.3.5Test pointsSymbolTest pointsContentsCH1L, M,NA-phase PWM signal>' }WMACH7L, M,NR-phase current: vCH8L, M,NS-phase current: >0 V (Ground)CH9, 9L, M,N(VCH10+5 VDC45 VCH11+15 VDC415 VCH12-15 V-15 VDC+24 VDCCH13+24 VA16B-1100-0330/02AA16B-1100-0220n,nnCN4CN4LCN3LCN3ISULrruruCN4CN4MMCHI 3C...

  • Page 263

    26.3.6 Jumper setting*AxisJumper:.'o.Amp. 1Amp.2MeaningW | U | Q7T_jT~aTOH settingWhen the overheat signal isnot providedto T4, the SI settingshould be H side.SIHLDCalarm settingWhen the discharge unit isnot added,the S2 settingshould beL side.LLS2A16B-1100-0330/02AA16B-1100-0220nn11JICN4CN4LCN3L...

  • Page 264

    26.3.7 Removal/replac8ment1) Unita) RemovethecablesconnectedtotheconnectorCN1L,CN1M,CN1Nandterminals Tl, T2 andT4.Unclamp connectorsare follows:. CN1L, CN1M, CN1N(D Squeeze the clamp releasetoremove the connector.dampreleaseb) Loosen two mountingscrews atthe bottom.c) Remove two mountingscrews at...

  • Page 265

    26.4 DischargeUnit26.4.1 Locationof discharge unitS-700—artDOJI26.4.2 Removal/repiacement1) SpecificationA06B-6050-H0502) Procedure© Disconnectcables from thedischarge unit.© Remove the unit by looseningtwoscrews© .©£©V3) CautionWhen dischargeunitshavebeenreplaced,checkthatunitsare correc...

  • Page 266

    27.OPERATOR'S PANELThere are three typesofoperator's panels.- Horizontal type operator's panelThis type isused in theS-10 controllers with medium size cabinet.See Fig.3.2 (f).- Vertical type operator's panelfor remoteCRT/KBThis type isused in theS-10 andS-700 controllers with large size cabinets....

  • Page 267

    2) Vertical type operator's panelfor remoteCRT/KB (A05B-2051-C122)(Front view)Orue*rtNOMTTrtMLmo ON@@•@MI •»CTCUBMW©©crp-£ irÿrroHOT©©MI1UMLBNaur mmmm«wontma UMMU UMm©©•eHour meteT(option)wr/airtcrtConnector forremoteCRT/KBr-r""iConnector forRS-232-C interfacei>itiEME...

  • Page 268

    3) Vertical type operator's panelforbuilt-inCRT/KB (A05B-2051-C121)(Front view)O1UCH MtfMMTtMUUS»AML©©©MOTI »CAUBMIf*cmi©©0 o **MUrmIT©©OWOmUMLBFAULTtanMUMS* UM*«ÿ©©o0Hour meter (option)n*n-eOConnector forRS-232-Cinterfaceii1WIIIEMERGENCY STOP buttoniL-JO(Rear view)ooOperator’s pan...

  • Page 269

    CN5 (connector for shared RAM interface)RDB119RSBTEACHPENDANT ENABLEDLEDPANELENABLED LEDIN CYCLE LEDNOTCALIBRATED LEDUSER LED#1USERLED #2FAULT LEDHELD LEDCYCLE START buttonCALIBRATEbuttonUSER PB#1USER PB#2FAULT RESETbuttonHOLDbuttonOVERTRAVEL RELEASE buttonContactof the POWER ONbutton(normally op...

  • Page 270

    Contact output ofemergency stop1#Contact output of emergencyj*stopbuttonsEMG1EMG21EMG12EMG2—oTo-oTo- EMG1Op. panelTeach pendantEMG2Connection of emergency stop1>Emergency stopcontact which isJ*used to interrupt100 VAC forservo amp's.0P10P2OP2OP1Connection of the hour meter)100 VACwhich is av...

  • Page 271

    27.2 Removal/Replacement1) Unita) Procedure(I) Disconnectall cablesfrom the operator’s panel.Remove the operator's panel byloosening sixscrews (2).For mountingnew unit,reverse the aboveprocedure.I©©TOperator’s©panelOperator'spanel2)—©\©TVertical typeHorizontal type2) Component(lamps an...

  • Page 272

    28.BATTERY UNIT28.1 Connector/Signal IdentificationBackplane connectorVB: Battery (+ side)OV: Battery (- side)1VB2OV3‘BatterycaseBackplane connector28.2 Removal/ReplacementVarious dataoftheuser program issaved in the RAM byback-up batteries.These batteriesshould be replaced withnewones annually...

  • Page 273

    29.OUTLET UNIT ANDGROUND CONNECTED LAMP29.1 LampA lampcalledGround Connected Lamp isinstalled under thehandle ofthe maincabinet.Its lighting indicates that theone terminal (L2) ofthe outlet isconnected to the ground and115 VACis output to the secondaryside ofthe usertransformer.When this lamp is ...

  • Page 274

    30.SERVO-ON RELAY UNIT ANDSERVO-ON LAMP30.1 Connector/Signal Identification}100A100 VAC inputforservo-onrelay unitRelay output terminalsSV0N1- SVONC; NormallyopenSVONC- SV0N2; Normally closed:100BO©SV0N1SVONCSV0N2.RL9SVON1:©SVONC©SVON2©100A©100BO30.2 LampAlamp calledservo-on lamp is installe...

  • Page 275

    30.3 Removal/Replacement1) Unit (servo-on relay unit)a) ProcedureOp Disconnect all cables© from theservo-on relay unit.© Theservo-on relay unitcan be removed by loosening twoscrews©.© For mountingnew unit,reverse the above procedure.CD—I2) Component (relay)Remove the springthat clamps the r...

  • Page 276

    31.FANUNIT31.1 Fan Unit for Large Size Cabinet31.1.1 Operation of heat exchange system7VFan 1Fan 4iiiiiV :|..€>lFan 5yr5ii6>Fan 20///1Location of fan unitsThe controller incorporatesan air-to-airheat exchange system.The electriccomponents of thecontroller are isolated from outside air exc...

  • Page 277

    31.1.2 Removal/replacement1) Fan 1a) SpecificationA05B-2051-C901 (fan unit)A90L-0001-0043 (fan motor)b) Procedure(T) Disconnect the cables fromthe fan unit.(2) Remove the unit by looseningfour screws (2).(5) Disconnect the cables fromthe fan motors.(4) Removethe fanmotorfromthe plate by loosening...

  • Page 278

    4) Fan4a) SpecificationA05B-2051-C903 (fan unit)A90L-0001-0213#A (fanmotor)b) ProcedureDisconnect the cablesfromthe fan unit.(?) Removethe unit bylooseningfour screws(?). For mountinga new fan unit,reverse theabove procedure.1A© V<D©Air flow5) Fan 5a) SpecificationA05B-2051-C902 (fanunit)A9O...

  • Page 279

    31.2 Fan Unitfor Medium Size Cabinet31.2.1 Operationof heat exchange systemFan 1A./fA-LWFan 2Locationof fan unitsThe electricAirflowThecontroller incorporatesan air-to-airheat exchange system.componentsofthecontrollerareisolatedwithoutsideair.direction is as shown below.->ITFan 1V/,Fan 2Air fl...

  • Page 280

    31.2.2 Removal/replacement1) Fan 1a) SpecificationA05B-2045-C901 (fan unit)A90L-0001-0099#A (fan motor)b) Procedure© Disconnect cablesfrom thefan unit.© Remove the unit bylooseningfourscrews (2).© Disconnect cablesfrom fanmotors.@ Remove the fan motorfromthe plate bylooseningfourscrews©.© Re...

  • Page 281

    32.ABSOLUTE PULSECODER32.1 Theoryof OperationThe Absolute Pulse Coder ismade up ofa rotating mechanism,an LED,a codedisk,photo cells, anda signal processing circuit.The code disk containsseveral slits.Asthe disk rotatesona shaft the slits in the disk alternatelyblock and permit light tothe photo ...

  • Page 282

    wVS)VOsIAbsolute pukecoderCLKoTCITC2(F)&ACservo motor-1(W)nkClockgenerator(HYB,2)EQ_nRS“REQ" signalreceiver (HYB, 4)m3PhotodiodeEE<9 XREQ“Io o ooooooo ooiCustom LSI (2600 gates)ll"REQ"DETEC-ILEDITORAxis Control BoardiiMIFeedback pulsedetectorCounterM28 bitsIICPU.ServoAmp...

  • Page 283

    32.3 Connector/Signal IdentificationACservo motorPowerSignalBatteryStandard typeSignal (MS3102A 22-14P)AAL+5VA, *A,B, *BZ, *Z: Count signal: Reference signalCl,C2, C4,C8: Phase control signalfor ACservomotor: Power supplyfrom controller: Overheat signalofservo motor: Data requestsignal: Power sup...

  • Page 284

    32.4 Variable ResistorsRemarksStandard settingV.R.Adjustment of the dutyof Aor *A(Pulse coder outputs)Duty “ 50:50VR1(A)VR2Adjustmentof the dutyof Bor *B(Pulse coder outputs)Duty *50:50(B)VR3Adjustment of the levelof Z and ZR(Photo diodesoutputs)(Z)NoteviZRV2V1.V2 J 15 mVZAdjustmentof the volta...

  • Page 285

    3) Outputwaveforma) Count signalAw.*A(Note)1BwELB•Brr(Note)U-l0.45*T £ Aw,Bw 20.55 T0. 14*T £ a, b, c,d'H' 22.4 voltfLf 2 0.4 voltUpper drawing shows thewaveform withCW rotation.rotated in CCWdirection (viewed from shaft end), signals’’A’1 and "ÿA" areinterchanged with B and ...

  • Page 286

    32.5 Test Points1) Whenor"+6B" are supplied 6 V, and"+5V" isoff.Test pointsSpecifications3.96 V- A.04 VVoltageT1Voltage1.5 V- 2.5 VTO63.93 VVoltageONBTVoltage63.93 VVoltage£0.05 VCTWaveformCLKTLT580 nSTLS 620 nS98 MS % T£ 102MSInverse waveform of’’CLK"WaveformAM2) W...

  • Page 287

    c) Phase control signalfor ACservo motorCl2t——tC2— 2t4tC44t8tC88t8t’H' * 2.4 volt’L* £0.4 voltThe drawing above shows thewaveform with CW rotation.rotated in CCW direction, signal"C8" hasan invertedwaveform.Whenthe shaft is32.6 Removal/Replacement32.6.1 Replacing pulse coder1...

  • Page 288

    AttachmentsPulse coderMotor shaftPulse coder shaft\©BoltCD(M S)V//////AICoupling1Rubber capK1IiScrtw©(M 4)Mark-offlineMotor housing2) Checking thephase-relationshipThemethod writtenhere is applicable toall models of FANUCACservo motors.OD Connect V and Wof motor power line.Qp Excite motor atrat...

  • Page 289

    32.6.2 Replacing batteriesCaution) Besure that the powersource from the controller ison before removingor replacing batteries.Ifthere isno power tothe absolute pulsecoders* remasteringof theÿmechanical unitwill be required.1) Removingdead batteriesUnfasten twoscrews(T) and removethe lid.Removede...

  • Page 290

  • Page 291

    II. S-10 MECHANICAL UNIT MAINTENANCEt .

  • Page 292

    !!!iiIii,l(:!' /;it

  • Page 293

    1.CONFIGURATIONFig*1 shows the configuration,ofthe mechanical unit*a-axisAC servomotor!9VWrist unit7-axis AC servomotorU-axis ACservomotor/J-axis AC servomotor. 3tUv-mmU-axisarmv\H» «TTW-axisarmeW-axis baseW-axisAC servomotorI\[0-axis base0-axisAC servomotor[Terminal unitFig.1 Mechanical unit c...

  • Page 294

    0-axis DriveMechanismFig.1.1 shows the 0-axis drive mechanism.The rotationof the AC servomotor isdecelerated by theRV reducer.drive isresponsible for rotating the entire robot assembly.Note) Formanual movement,the 0-axismoves inthe rotarydirection ofthemanual crank.1.1The 0-axisABox wrench withra...

  • Page 295

    1.2W-axis Drive MechanismFig.1.2 shows W-axis drive mechanism.The rotation ofthe AC servomotor isdecelerated by thereducer and rotates the W-axis.The RV reducer supportstheW-axisarm.Note)Formanual movement,the W-axismoves intherotarydirection ofthemanual crank.Hexagon head(width 14)W-axisarmtW-ax...

  • Page 296

    1.47’ax's Drive MechanismFig.1.4 showsthe y-axis drivemechanism.The rotation of the AC servomotorisdecelerated by the harmonicdrive and rotatesthe U-axisarm.The U-axis arm issupported bythe U-axis housing via the reducer andcross roller bearing.Cross roller bearing-ReducerU-axis housing7-axis A...

  • Page 297

    1.6a-axis Drive MechanismFig.1.6 shows the a-axisdrive mechanism.The rotationof the ACservomotor isdecelerated bythe harmonic drive and rotates the outputflange.or-axisAC servomotormodel3-OFBHarmonic driveOutput flangeFig. 1.6 a-axis drive mechanism (S-10)1.7 Major ComponentSpecifications1) Motor...

  • Page 298

    2) ReducerSpecificationAxisA97L-0118-0801#121eA97L-0118-0801#153WA97L-0118-0802#105UA97L-0118-0803#53. 5YA97L-0118-08046A97L-0118-0805a3) UnitSpecificationX',.Remarks0 cable guide unitA290-7 204-V2010 terminal unitA290-7204-V202A290-7204-V501Wrist unitA290-7204-V512a-axis unit4) GearSpecification...

  • Page 299

    5) ShimRemarksSpecificationFor adjusting U-axis bevel gearA290-7204-X421A290-7204-X422A290-7204-X4300. 3t0. It0.15tX411,X412A290-7204-X521A290-7204-X522A290-7204-X523A290-7204-X5290. 5tO.lt0.03t0.15tX511Wrist unitFor adjusting 8-axis bevel gearA290-7204-X524A290-7204-X525A290-7204-X526A290-7204-X...

  • Page 300

    2.LUBRICATING CONDITION CHECKS1) MonthlycheckCheckthe followingonce a month.Check itemCheckingprocedureItemLubrication ofB-axis wristgear boxRemove thecover and check the gear surface forpresence of oil, damage, smutand foreign substances.12) Grease checkNever perform greasingprocedures before tu...

  • Page 301

    Table 2 (b)Recommended LubricantsOil (Air control set)Mobil OilDTE Oil LightTellesso 32Esso StandardShell OilShell Turbo OilT32Diamond Turbine Oil 32Mitsubishi OilNippon OilFBK Turbine32Daphne Turbine Oil32IdemitsuKosanSpecial A Turbine Oil 32Maruzen Oil3) 3-year checkChange grease for reducers o...

  • Page 302

    ''W-i/3-axis grease nipple(Harmonic drive)7-axis grease nipple(RV reducer)7-axis straight plug(RV reducer)Gamma-axis cross roller bearing/3-axis gear box(Bevel gear)(3-axis straight plug(Harmonic drive)II itfib/ z/a-axis straight pluga-axis grease nipple(Harmonic drive)U-axis grease nippleU-axis ...

  • Page 303

    3.TROUBLESHOOTING3.1GeneralThe source ofmechanical unit problemsmay bedifficulttofindbecause ofoverlappingcauses.Problemsmay become further complicated, iftheyare notcorrected properly.Therefore, it isnecessary to keepan accuraterecord ofproblems and totakeproper corrective actions.3.2Problems an...

  • Page 304

    4) Excessive backlasha) (Cause)(Measure)b)(Cause)(Measure)c)(Cause)(Measure)d)(Cause)(Measure)e)(Cause)(Measure)f)(Cause)(Measure)Screws and pinsare loose.Tightenscrews.Coatthe specifiedarea with LOCTITE.Thereducer is faulty.Replacethe reducer.(Refer to5.1- 5.9)The adjustmentof the gear backlash ...

  • Page 305

    Backlash less chan Che amountsshown in Che Cable isnoc abnormal.Table 3.2 (b) AxisbacklasheuBwarAngle conversion (min.)831.51.531.50.260.67(1529)0.260.260.70DisplacemenC conversion0.31(300)(300)(300)(mm)(700)(600)NoCe) ThevaluesofdisplacemenCconversionvaluesshowsbacklashinCheroCacingdirecCionaCCh...

  • Page 306

    4.ADJUSTMENTSMechanical parts have been adjusted tothe optimumcondition atthe timeofshipment from our company.Therefore, they normally need notbe adjusted by thecustomer at the timeof delivery.Adjustments should be made as specified in this sectionaftera long periodofuseor after replacinga part.4...

  • Page 307

    Stroke endrLMechanical stopStroke135°0*-0T+90*Stroke endIDMechanical stop•HQTNote) The motion range islimited by the U-axis position.Fig.4.1 (b) W-axisrotation (S-10)Stroke end\ +120*Stroke265°0*Stroke end-145*Note) The motionrange islimited by the W-axis position.Fig.4.1 (c)U-axis rotation (...

  • Page 308

    Stroke endMechanical stopStroke>140*280°0*\/Mechanical stop- I 40*Stroke endNote) 0Tlimit switches are notused inthe B-axis.Fig. 4.1 (e) 0-axis rotation (S-10)0*Stroke540°-270*Stroke end+270* .Stroke endNote) The 0Tlimit switchand mechanical stopare not used in the a-axis.Fig.4.1 (f) a-axis ...

  • Page 309

    -Stroke endMechanical stop-0TinvO+0T1%ÿtagStroke end! Mechanical stopNote) The allowable rangefor the relative anglebetween the W-axis and U-axisarms isa minimumof15° and a maximum of165°.Fig.4.1 (g) W/U limit interference angles (S-10)4.26 -axis Stroke ModificationIt is possible tolimit the 6...

  • Page 310

    1) Changingthe dog andmechanical stop positionsChangethe dog andmechanical stop positionsaccording to thedesired strokeposition as shown in Fig.4.2 (b).+6CT+90*+30*\\+75*+45'>I 05!+15*'+ I20°+0°«/+ d•k'+135°FrontStandard± |50*&s>-135°tK.A”-6v®c 120*-0#k- I05°- I5"-75&qu...

  • Page 311

    a) Changing the minimum and maximum command pulses$L0WERLIMS[1 ]:O-axis strokelower limit in radians$UPPERLIMS[1]:Q-axisstroke upper limit in radiansSeta numeral so that upper pulseshould always be greater than lowerpulse.$L0WERLIMS[1](O-axis stroke lower limitin radians)__$UPPERLIMS[1](O-axis st...

  • Page 312

    4.3 Mastering Procedure4.3.1 IntroductionThis procedure describesthe mastering procedurefora robotwithan absolutepulse coder system.No operation is requiredfor calibration with this system.Therobot isautomatically calibrated when power isturnedon andthe systembecomes ready.Mastering istheestablis...

  • Page 313

    5. Using theCRT/KB (withREMOTE switch turned to ON) enter UHL in responseto theKCL> prompt6.In response to theUTIL> promptenter MASTER.7.Enter Y inresponse to thedisplayed question“Are you sure?”8. At the prompt “Mastering at 0 degreesY/N?” enterY if youare mastering at the zero-deg...

  • Page 314

    4.3.3 Zero-degree positionThe zero-degree position of theS-10 robot is shown i Fig.4.3.3.0-axis[ÿ»*:;riiiilmM*01111?t-3mSSJl\5Lor-axis 7Us7-axis\U-axisW-axisW\*ÿLft--to)r~Wmmm0-axisI[Fig.4.3.3 Zero degreeposition marks of each axis (S-10)2-22

  • Page 315

    4.3.4 Mastering usinga mastering fixtureTherobot hasbeen mastered atthetimeofshipment.Ifthe present valuestored via the APC (Absolute Pulse Coder) differs from the actual positionofeachaxisafteramajorcomponentoftherobotmechanicalunithasbeenreplaced, mastering istobecarried out to setthe robot geo...

  • Page 316

    ii) Mounting on robot bodyAfter selecting the mastering position fromamong 0= 0°,-90° or90°, mountthe fixtureon the 0-axis base usingbolts and pins.Locating pin08BoltM10x30 (Two)tf= +90*Positioning pin481I0=-9O*6=0'©o Q«Fig. 4.3.4 (b) Mountingon robot body (S-10)iii) Mountingof dial indicato...

  • Page 317

    iv) Mountingfixture on wristJog the robot tothe positionwherea= 6= y= 0° and mountthefixture on the a-axisas shown in Fig,4.4 (d).Atthis time,if ittouches a mechanical stop at-190° and+190° position of yaxis,setthe y-axisto0° rotating it in the oppositedirection... .Mounting attitudea= 0°0=0...

  • Page 318

    ii) Movethea axisso that the readings of dial indicators No.l andNo. 5are identical.iii) Jogthe 0 and yaxesso that the readingsof dial indicatorsNo. 4 andNo.5 are identical and that the readingof dialindicator No.3 is3,00mm.Ifthereadings ofdial indicators No.l and No.2 are notthe same atthis time...

  • Page 319

    4.4 AdjustingU-axis Bevel Gear Backlash(T) Remove the U-axismotor (Refer to 5.5)Removethe U-axisreducer (Refer to 5.6)Remove the four M5 x 16 bolts,holder and gear D unit.(?) Removethefour M5 x 16 bolts,holder and gear C unit.(5) Adjust the backlashwithin 0.05- 0.15 mm usingshims (A290-7204-X421/...

  • Page 320

    4.5 Adjusting 0-axis Bevel Gear Backlash© Remove the a-axis motorcover and then the a-axis unitfromthebracket.(Refer to5.7® , ©)© Remove the wrist unit from the U-axisarm.© Remove the B-axis motorand the harmonic drive.Remove sixM4xl2 bolts, holder, and gear A unit.Remove fourM5x20 bolts, tw...

  • Page 321

    5.REPLACING ANDADJUSTING PARTSWhen a part is replaced, certain adjustmentsare required.Parts requiringreplacing andthe itemsthatrequireadjustmentare listedbelow.Replacement partsAdjustment item(a) Mastering(b) Dog adjustment6-axis motor(a) MasteringW- and U-axismotor(a) Masteringa-, 8- and y-axis...

  • Page 322

    M6 button-head bolts(2pcs)Spring pins.<>8x30 (8 pcs)Vi*M8x20 (8 pcs)(LOCTITENo. 262 anddamp torque380 kg.cm)iMl 0x40 (2 pcs)M6 button bolts(4pcs)*.iDogLDogRrStopsjCable guideM6 button-head bolts(6 pcs)QW-axis baseoConnector boxSeal washerPackingM10x25 (4 pcs)0-axisAC servomotormodel5RFBrack...

  • Page 323

    5.2Replacing 0-axis Reducer(J) Remove twoM6 button-head bolts mounting theupper partof the cable guide*to W-axisbase.Remove the stopand the dog fromthe bracket.Removethe rear cover from the W-axis.© Removethree Ml2x40 bolts and twodl0x30 taper pins mounting the Wbase tothe 9-axis reducer, and li...

  • Page 324

    5.3Replacing W-axis Motor(I) Press the W-axisagainstthe mechanical stop or support the axisso itcannotmove.© Removethesidecover fromtheW-axisbase andthentheW-axismotorconnector.Remove fourM10x25 bolts and the motor.Remove the C-ringand pull outthe inputgear and the coupling.Remove thedraw bolt a...

  • Page 325

    5.4 ReplacingW-axis Reducer© Press the W-axis againsttherear mechanical stopor support the axis so itcannotmove.© Remove clamps frombelow the W-axisbase and side of W-axisarm in order topull a cableout.Ifthecablecan notbepulledenough,remove theconnector of upper U-axis.(Refer to7.2© and Fig- (...

  • Page 326

    5.5ReplacingU*axis Motor(I) Pressthe (J-axisagainstthemechanical stopor supportthe axis so itcannotmove.© Remove the U-axismotorcover,U-axiscover,andthenthe U-axis motorconnector.© Remove fourM6xl6 bolts and the motor.© Remove the hexagonal bolts fromthe motor shaft, and pull out the inputspli...

  • Page 327

    5.6ReplacingU-axis Reducer(j) Pressthe U-axis againstthe mechanical stopor supportthe axis so itcannotmove.(2) Remove the cable connected from W-axisarm tothe U-axis.(Refer to7.2 (T)and Fig. (a) and (b).)(3) Remove fourM10x40 bolts,twotaper pins, andthen the U-axis unitfrom the W-axisarm.@ Remove...

  • Page 328

    5.7Replacinga-axisMotor and Harmonic Drive(D Remove the a-axis motorcover andthe a-axismotor connector.(2) Removefour M5xl6 boltsand then the a-axis unit from thebracket.(3) Remove sixM5xl6bolts and then the a-axismotorfrom thebracket.4) Removeascrew M3x6, a bolt M3xl0, and then thewave generator...

  • Page 329

    s Remove sixM5x20 bolts and the flange unitfrom a-axis housing.RemovesixM4xl6 bolts, twopins, and the circular spline S.Remove sixM4xl2 bolts and twopinsandthe circular splineD.Remove eightM5x20 bolts andtwotaperpinsfrom the flange unitremoved in step© , andremove the flange, the holder, andthec...

  • Page 330

    5.8Replacing /J-axis Motorand Harmonic Drive(T) Removethecablecover from theO-axis arm andthentheB-axismotor(Refer to7.2 (2) and Fig.7.2 (a) to (f).)(2) Removefour M5x30 bolts andaspring pin, andremove the wrist unitfromthe U-axisarm.Remove four M4xl2 bolts and then the motor.Removethe plate and ...

  • Page 331

    © Remove sixM5x20 bolts andthe two <ÿ4x20 spring pins, andremove the holderfrom the 8-axis housing.(7) Remove sixM5xl6 bolts,twotaperpins,the flex spline andtheholder.(§) Remove sixM5x25 bolts, twotaper pins,and then thecircular splinefrom theholder.(f) Replace theflex spline,the circular s...

  • Page 332

    5.9Replacingy-axisMotor and Reducer(I) Remove the U-axiscover and U-axismotor connector.Remove thefourM6x20 bolts mounting the motorandthen the motor.Removethe hexagonalnuts andthe draw bolts.© If onlythe motor is replaced,reassemble reversingabove procedureafterreplacing the motor.ApplyLOCTITE ...

  • Page 333

    I Removefour M6xl6 bolts, and then theholder.Removefour M6x55 bolts.Remove eightM5x35 bolts, andthen the' reducerfrom the U-axis housing.Replacethe- reducer andreassemble reversing theabove procedure.Atthistime,lightly apply LOCTITE tobolts and nutsremoved in steps(2)- (7).Tighten nutswith specif...

  • Page 334

    5.10 Replacing BatteryThe dataofthe home position ofeach ofthe robotaxes is stored bytheAbsolute Pulse Coder, which is powered by the backup batteries.The batteriesmustbereplaced every year.They should be replacedas follows.1) Turn the poweron.Press the EMERGENCY STOP button to prohibit the robot...

  • Page 335

    6.WIRING AND PIPING6.1 Piping DiagramFig.6.1 shows theinternal pipingdiagramof the mechanical unit.PfPanel unionPT1/8 female±1!Panel unionPT1/4 femaleJFig. 6.1 Piping diagram (S-10)6.2 Wiring DiagramFig.6.2 shows mechanical unitwiringdiagram.ControllerMechanical unit0-axismotorW-axis motorU-axis...

  • Page 336

    6.3 Limit Switch Installation DiagramFig.6.3 showsthe installation diagramfor the limitswitches.!i—j|c=daÿ-U-axis OT limittwitchI•W-axiiOT limit twitch1C!1 6-exitOT hmit twitchFig.6.3 Limit switch installation diagram (S-TO)6.4 Cable Installation DiagramVisually check the following:1) Checkt...

  • Page 337

    7.REPLACING CABLESAbroken or damagedcable should be replacedas specifiedIn this section.Ifthe pulse codercable (K101,K102,K106, K107) connector isdisconnected themotorloses itsabsolute position.Whenthe motor loses itsabsolute position,mastering mustbecarried out.7.1Cable FormingWhen mounting the ...

  • Page 338

    7.2Replacing Cables1) Replacingcables K101, K102, K103, K104(D After removingthe U-axis cover, cutthe tie wrap toremove the connectorandtwoclamps.(Fig. 7.2 (a))(2) Removethe U-axis and W-axiscablecovers andthe W-axisarm clamps (2clamps), cutthe tiewrap, andpull out the cablefrom under the W-axisa...

  • Page 339

    U-axis cablecoverCable dampCable damp•W-axis cablecoverFig.7.2 (b)Replacing cablesK101. K102, K103, K104,K105 (S-10)W-axis motor coverIATie wrapN,AConnector airtube forend effectorClampFig. 7.2 (c)Replacing cables K101, K102, K103,K104. K105 (S-10)2-47

  • Page 340

    ! ?iClampNCable guideTie wrap0-axis cable cover.Cover AkOOCover B00-axisconnector boxFig.72 (d)Replacingcables K101,K102. K103, K104,K105 (S-10)2) Replacing cablesK106 andK107(D Remove the U-axiscover andthe connectormarked with P2,M2BP andBM(Fig. 7.2 (e))(Remove the connectormarked withBP andBM ...

  • Page 341

    Coverj©CoverRubber coverApplysealant No. 1211to surroundingfour facesCable coverButton-head boltM6x8 (eight pcs)To slideButton-head bolt (two pcs)IM4 button-head bolt (twopcs)iFig.7.2 («)Replacingcables K106,K107 (S-10)Pull out dampandconnectorTie wrapflM4 button-headbolt (two pcs)a-axis motor ...

  • Page 342

    7.3ReplacingLimit Switch1) 0-axis OTlimit switch (cable K105)(T) Removethe rearcover of the W axis(2) Remove the limit switch mounting plate from the stop.(3) Remove the limit switchfrom the plate.(?) Removethecoverbelowtheswitchanddisconnectthecablecrimpterminal.Replace thelimit switch.(D Mount ...

  • Page 343

    'III.S-700 MECHANICALUNIT MAINTENANCE&

  • Page 344

    1:1ir-v-ii

  • Page 345

    1.CONFIGURATIONFig.1 (a), (b) showthe configuration of themechanical unit.7-axis AC servomotorWrist unito-axisAC .servomotor!0-axis ACservomotor3-mU-axisarm-<ÿU-axisACservomotorW-axisarms»/ W-axis base>W-axisAC servomotore-axisAC servomotorf-gyiasisJLdno*QO«.6-axis baseFig.1 (a) Mechanic...

  • Page 346

    1.1e-axis Drive MechanismFig. 1.1 showsthe 6-axis drive mechanism.The rotationof the AC servomotor (model 5F) isdecelerated by the reducer androtates the table.The table is supported by thecross roller bearing.9-axis AC servomotorTableHolderCross roller bearingmi9-axis reducer9-axis base]Fig.1.1 ...

  • Page 347

    1.2W-axis Drive MechanismFig.1.2 shows the W-axisdrive mechanism.The rotation of AC servomotor (model 20F) isdecelerated by the reducer viathebevel gear and rotatesthe W-axisarm.W-axisarmmW-axis reducerArWBevel gear£1W-axis AC servomotorW-axis baseFig.1.2 W-axisdrive mechanism (S-700)3-3

  • Page 348

    1.3U-axis Drive MechanismFig.1.3 showsthe U-axisdrive mechanism.The rotationof theAC servomotor (model 5F) is decelerated by the reducer viathebevel gear and rotatesthe U-axisarm.W-axisaimU-axisarmU-axis ACservomotorr1l-MXv\Bevel gear-U-axisreducerFig.1.3 U-axis drivemechanism (S-700)1.4 y-axisDr...

  • Page 349

    1.5 a/p-axis DriveMechanism (offset wrist)Fig. 1.5 shows thea/B-axis drivemechanismof theoffset wrist.The revolutionofthe motor(model 1-OB/1-0HB) istransmittedtothe wrist via the driveshaftafter therevolution speed isreduced bygears.For the 8 axis,the revolutionof the driveshaft is input tothe B-...

  • Page 350

    1.7Major ComponentSpecifications1) Motora) Mechanical unitspecification:A05B-1120-B001/B011SpecificationModelAxisA06B-0345-B231Q, U5RF20FA06B-0352-B731WA06B-0524-B3511-OHBa. 8, Yb) Mechanical unitspecification:A05B-1120-B002/B012SpecificationModelAxisA06B-0345-B2315RF0,UA06B-0352-B73120FWA06B-052...

  • Page 351

    4)GearSpecificationAxisA290-7120-X306WA290-7120-X307WA290-7120-X406UA290-7120-X407UA290-7120-X411aA290-7120-X412aA290-7120-X413flA290-7120-X4 146A290-7120-X415YA290-7120-X416YA290-7120-X506flS (OFFSET)A290-7120-X507A290-7120-X508aa (OFFSET)A290-7120-X509a (OFFSET)A290-7 120-X510fl (IN-LINE)A290-7...

  • Page 352

    5) ShimSpecificationAxisA290-7120-X327, X329 (0.1T, 0.3T)WA290-7120-X330,X332 (0.1T, 0.3T)WA290-7120-X434, X436 (0.1T, 0.3T)UA290-7120-X437,X439 (0. IT, 0.3T)UA290-7120-X440,X442 (0.1T, 0.3T)UA290-7120-X516, X518 (0.IT, 0.3T)8A290-7120-X519,X521 (0. IT, 0.3T)8A290-7120-X522,X524 (0.1T, 0. 3T)aA29...

  • Page 353

    6) BearingSpecificationBearingNo.AxisA97L-0001-0192//00D000A6800DDUaA97L-0001-0192//03000006803aA97L-0001-0192#0400000a (IN-LINE)6804A97L-0001-0192//05000006805a (IN-LINE)A97L-0001-0192 #08000006808BA97L-0001-0192#21Z0O0A6821ZZUA97L-0001-0193#00000006900aA97L-0001-0193#0100000B (IN-LINE)6901A97L-...

  • Page 354

    7) CoverSpecificationAxisA290-7120-X2136A290-7120-X2146A290-7120-X309WA290-7120-X318WA290-7120-X319WA290-7120-X320WA290-7120-X321WA290-7120-X322WA290-7120-X323WA290-7120-X325WA290-7120-X333WA290-7120-X409UA290-7120-X431UW,U,a/SA290-7120-X513a/8A290-7120-X554a/SA290-7120-X5643-10

  • Page 355

    2. LUBRICATING CONDITION CHECK2.1 Three-month Periodical CheckBesure co check thefollowing itemsevery three months:CheckItemCheck ContentsItemRemove thecover and check thegrease level andif the grease isabnormally contaminated.Lubricatingcondition of the gearbox for the wrist1Lubricatingcondition...

  • Page 356

    1) Replacinggrease in the 0-axis reducer© Remove thecover (rubber cap) on the sideof the 0-axis base and the backof the W base.(2) Removethegreasenippleonthesideofthe©-axisbase.discharge port)© Applygrease tothe grease nipple (grease injectionport)on the side ofthe W-axisbase.© Continueapplyi...

  • Page 357

    2) Replacingof grease in W-axis reducer(T) Remove the W-axiscover.© Setthe W-axisto a positionof approximately 0degrees.(3) Remove the grease discharge portcover.(Wipe off the grease comingoutfrom the grease discharge portatthis time.)© Applyapproximately 800cc of grease to grease nipple1.© Ap...

  • Page 358

    3) Replacing grease in the U-axis reducer® Removethe U-axiscover.© Setthe U axistoa positionof approximately 90 degrees.(5) Remove the grease discharge portcover.(Wipe off the grease coming outfromthe grease discharge port atthis time.)© Apply approximately100 cc of grease togrease nipple 1.©...

  • Page 359

    4) Replacing grease inthe wristgear box(T) Set the U axis toa positionof approximately0 degrees and y axistoaposition of approximately 90 degrees.(2) Removethe grease discharge portcover.(Wipe off the grease coming outfrom the grease discharge port atthis time.)® Applygrease to the grease nipple...

  • Page 360

    5) Replacing grease inoffset wrist® Setthe U axistoa positionof approximately 0 degreesand the y axis toa positionof approximately90or -90 degrees.© Remove grease discharge portcover 1.(Wipeoff the grease comingoutfrom the grease discharge portatthis time.)(D Apply grease tothe grease nipple.©...

  • Page 361

    6)Replacing grease in the in-line wrist(T) Setthe U axisand y axis toa positionof approximately 0 degree.© Remove grease discharge portplug 1.© Apply grease tothe grease nipple.(§) Continueinjectinggreaseuntilthegreasedischargedfromgreasedischarge port1 becomes clean.(D Mount grease discharge ...

  • Page 362

    2.3 AddingGrease-- e-axisCross Roller BearingAdd the grease inthe 0-axiscross roller bearingevery 2000 hrs.If, however,the installation environmentofthe robot is bad, besure toadd grease whennecessary.immediately.For the greasing pointsand method,see Fig.2.3 andTable2.3 (a).Ifwaterispouredoverthe...

  • Page 363

    3.TROUBLESHOOTING3.1 GeneralThe source ofmechanical unitfailures may bedifficulttofind becauseofoverlappingcauses.Failuresmay becomefurther complicated, iftheyare notcorrected properly.Therefore, it is necessary tokeep an accurate recordofproblems andtotake proper corrective actions.3.2 Failures ...

  • Page 364

    i) (Cause)(Measure)Revisetime constant.Manual. )Excessive backlash.See below.The timeconstant isfaulty.(Refertothe KAREL SystemReferencej ) (Cause)4) Excessive backlasha)(Cause)(Measure)b) (Cause)(Measure)c)(Cause)(Measure)d) (Cause)(Measure)e) (Cause)(Measure)f) (Cause)(Measure)Screwsand pinsare...

  • Page 365

    7) Dropofan axiswhen the power isturned off.a) (Cause)(Measure)Replacethe motor.(Refer to5.1- 5.5)Brake drive relay isdefective.(Measure)Replace the relay.(Refer to5.1- 5.5)Brakegap isnoticeable.b) (Cause)8) Leakageofgrease/oila)(Cause)(Measure)b)(Cause)(Measure)c)(Cause)(Measure)Tightenscrews.O-...

  • Page 366

    3.3 ReplacingParts and Performing AdjustmentsAfter replacinga part,an adjustment isalways required.shows the required replacements and adjustments.The following tableReplacement partor functionto be changedAdj ustment(a) MasteringMotor(a) Routingand securing cable(b) Limit switch(c) MasteringCabl...

  • Page 367

    4. ADJUSTMENTSMechanical partshave been adjustedtothe optimumcondition atthe timeofshipmentfromourcompany.Therefore, theynormally need not be adjusted by thecustomer at the timeof delivery.Adjustments should be madeas specified in this sectionaftera long periodofuse or after replacinga part.4.1 A...

  • Page 368

    0°Stioke.O'\okOi\°£>/ N180°/'0-90°+90Stroke endStroke end/w\Mechanical0T0TMechanical stopstopNote) The motionrange islimited by the U-axis position.Fig.4.1 (b) W-axisrotation (S-700)Stioke390°0°+270°-120°Stroke endStroke endNote) The motion range islimited by the W-axis position.Fig.4...

  • Page 369

    0°Stroke380°-190°+I 90°iStroke endStroke endNote) The 0Tlimit switch and mechanical stopare not usedfor the Y axis.Fig.4.1 (d)Y-axis wrist rotation (S-700)3-25

  • Page 370

    0°Stroke380s-190°«»ÿ+I 90°lStroke endStroke endNote) The 0Tlimit switch is notusedfor the Saxis.Fig. 4.1 (e)/3-axis wristrotation (S-700)0°Stroke540°-270°+270°TStroke endStroke endNote) The0Tlimit switch and a mechanical stopare notused for thea axis.Fig. 4.1 (f)a-axis wrist rotation (S...

  • Page 371

    0°OotohStroke endorMechanicalstopOTMechanical stopStroke endNote) The allowable range for the relative angle between the W-axisand U-axisarms isa minimumof10° anda maximumof270°.Fig.4.1 (g) W/U limit interference angles (S-700)3-27

  • Page 372

    2) Adjustment methoda) ©-axis adjustmentmethod® Movethe 9-axis tothe endof the stroke.(2) Pressthe EMERGENCY STOP button andremove the rear cover from the Wbase.(2) Loosen the bolt atthe alotted hole of the dog andmove the dog underthe proximityswitch.© Using the slotted holeof the proximity s...

  • Page 373

    b) W-axisadjustment methodMovethe W axis tothe endof thestroke.Press theEMERGENCY STOP button.Remove the sidecover.(3) Loosen the bolt at the slotted hole of the dog andmove the dog tothepositionwhere the limit switch contacts.© Adjustthelimitswitchpositionwithinthespecifiedposition.(Loosen the ...

  • Page 374

    c) U-axis adjustment methodMove the U axis tothe end of the stroke.(2) Press the EMERGENCY STOPbutton.Remove thesidecover.(2) Loosen the bolt mountingthe limit switch.© Adjustthe limit switch positionso thatthe limit switch isturned onat a pointtwo tothree degreesfrom the stroke end andmountthel...

  • Page 375

    4.2 StrokeModification4.2.1 0-axis strokemodificationIt is possibletolimit the O-axis stroke as required by the surroundingsforthe robot.The strokecan be changedas shown in Fig.4.2.1 (a).changed in incrementsof15° according to the OTstroke by changing the dogposition, themechanical stopor system...

  • Page 376

    1) Changing thedog andmechanical stop positionsChange the dog and mechanical stop positions accordingtothe desired strokeposition as shown in Fig.4.2.1 (b).Front-135135°- I 20°,+120°Standard±150"+105°.4-V®[9JA,•i*9im.oo-90°SL+90°oo91<oo>99f®,pO-75°•7 +75°po\9firvoo;-60°...

  • Page 377

    a) Changingthe minimum and maximumcommand pulses$L0WERLIMS[1]:0-axisstroke lower limit pulse$UPPERLIMS[1]:0-axisstroke upper limit pulseSet a numeral so that upper pulse should always be greater than lowerpulse.$UPPERLIMS[1](0-axis stroke upper limitpulses)_$L0WERLIMS[1](0-axis stroke lower limit...

  • Page 378

    4.2.2 W-axisstroke modificationThe W-axis strokecan belimited as required bythe surroundingsofthe robot.a) Changing the dog positionThestroke can be changedat every 10 degreesas shown in Fig.4.2.2 (a).can be changed in according to the OT stroke bychanging the dog position.Select the strokefromth...

  • Page 379

    b) Changingthe minimumand maximumcommand pulses$L0WERLIMS[2]:W-axis stroke lower limit pulse$UPPERLIMS[2]:W-axis strokeupper limit pulse$L0WERLIMS[2]$UPPERLIMS[2]Position-90°-1.570796321-80°-1.396263396-70°-1.221730472-60°-1.047197547-50°-0.872664623-40°-0.698131698-30°-0.523598774-20°-0....

  • Page 380

    1) Dogposition changeChangethe dog position according tothe desired stroke positionas shown inFig.4.2.2 (b).-0°+0°-10°+I 0°-20°+20°+30°-30°,oo+40°I-40°7+50°-50°+60°-60°&+70°-70°r/B0+80°-80°Standard±90°I22 JFrontFig. 4.2.2 (b)W-axis stroke modification (S-700)3-36

  • Page 381

    4.3 MasteringProcedure4.3.1 IntroductionThis procedure describes the masteringprocedurefor a robot withan absolutepulse coder system.No operation is requiredfor calibration with this system.The robot isautomatically calibrated when power is turnedon andthe systembecomes ready.Mastering isthe esta...

  • Page 382

    5. Using theCRT/KB (withREMOTE switch turnedto ON) enterUTIL in responseto theKCL> prompt6. In response to theUTIL> promptenterMASTER.7. Enter Y in response tothe displayed question“Are you sure?”8. At the prompt “Mastering at 0 degreesY/N?” enter:Y ifyouare masteringat the zero-deg...

  • Page 383

    4.3.3 Zero-degree positionThe zero-degree position of theS-700 robot isshown in Fig.4.3.3.8aM,-QSF=pMImmVIEW BVIEW CfisBIC8I& O§J§€Offset wristIn-line wrist<ÿSlfO93J8:BE<>A•U1ujoy._VIEW Acm5=ÿCoFig.4.3.3 Zero degree marks of each axis3-39

  • Page 384

    4.3.4 Mastering usinga mastering fixtureWhena majorpartofthe robotmechanical unitisreplaced andtheactualposition ofeach axis isnotthesame as the currentvalue stored throughanabsolutepulsecoder(APC), masteringisrequiredtoestablishtheactualposition of the robot.When masteringthe robot, meet thefoll...

  • Page 385

    Blocks (Two)'Dialindicators (Six)Clamps (Six)BoltsMSxlO (Six) (Do not tightenthe bolts too hard. Besure tocheckthat thedial indicator canmovesmoothlywhen tightening thebolts.)?iyliBolts M8x25(Three)0u© 0(9M3o-MBoltsM8x2S (Four)Pins(Two)Fig.4.3.4 (a)Mountingmastering fixtureon robotmain frame (S-...

  • Page 386

    Dial indicatorNo. 4Dial indicatorNo. 3Dial Tidicator No.5CollarCalibration blockgauge No. 2>>Pinj (Two)0Dial indicatorNo. 1G.§ccBoltsM6x60 (Two)0&c<?.c"V®Dial indicatorNo. 6Fig.4.3.4 (b)Dial indicator calibration (S-700)Calibration blockluQ\ooIoyOoO1®ooooOOo HL®Fig.4.3.4 (c)...

  • Page 387

    iii)Mountingfixtureon wristJogthe wrist tothe positionwherea= 8= y= 0 degree,and mountthe fixtureon the a-axis flangeas shown in Fig.4.3.4 (d). Notethatthefixturemountingsurfacesofthe offsetwristand ofin-line wristare reversed.a£KHltOl Sj) Bolts Ml0x35 (Four)reOffsetwristPins 010 (Two)010C0to0N....

  • Page 388

    © Movethe o-axis so that dial indicatorsNo. 4 andNo.5 indicatethe same value.© Setthe Cartesiancoordinate system andmove the wrist in the Ydirectionso that dial indicators No.4 andNo.5 indicate 3.00+0.02 mm.values, return tostep© .© Move the B-axisso that dial indicatorsNo. 2 andNo.3 indicate...

  • Page 389

    4.4 Adjusting BevelGear Backlash1) W-axisbevel gearRemove the W-axismotor.(Refer to 5.2)Removethe W-axisreducer.(Refer to 5.2)(2) Removethefour M6x20 bolts and gear WM unit (V302).© Removethefour M6x20 bolts andgear WR unit (V301).© Adjust the backlash within0.05- 0.1 mm (on P.C.D.) usingshims ...

  • Page 390

    2) U-axis bevel gear® Remove the U-axis motor (Refer to5. 3)(D Remove the U-axisreducer (Refer to 5.3)QD Remove thefour M6x20 boltsand gear UM unit (V402).Remove thefour M6x20 bolts and gear UR unit (V401).Adjust thebacklash within0.05- 0.1mm (on P.C.D.) usingshims (X434,X436, X437, X439). When ...

  • Page 391

    3) B-axis bevel gear (OFFSET WRIST)(D Remove the wrist unit.(2) Remove the B-axisreducer.CD Remove thefour M4xl2 bolts andgear a/B unit (V501).@ Remove thegear BR (X507).© Adjust the backlash within0.05- 0.1 mm (on P.C.D.) using shims (X516,X518, X519, X521).When usinga dial indicator, put it to...

  • Page 392

    5) B-axis bevel gear (IN-LINE WRIST)Q Removethe wrist unit.(2) Remove the fl-axisreducer.@ Remove the fourM4xl2 bolts and gear a/fl unit (V501).@ Remove the gear BR (X558).© Adjust thebacklash within 0.05- 0.1 mm (on P.C.D.) using shims (X516,X518, X519, X521).When usinga dial indicator,put it t...

  • Page 393

    5. REPLACING PARTS5.1 Replacing 6-axis Motor and Reducer1) Replacing the 9-axis motorSet the W axis closeto+90 degrees.Removethe bottomcover and plate and three side covers from the W-axisbase.Removethe 9-axismotorconnector.Removethe motor mountingbolt (M10x20) andthe motorfrom the bottomwindow o...

  • Page 394

    2) Replacing the 0-axis reducer(D Remove the airhose andEE cablefrom theEE connectorpanel.© Remove the motorconnectorsof allaxes.(5) Remove the pin and clampfrom the 0-axis cableand push the cable intothe base.Remove the M10x30 bolt andspring pinmountedon the W-axisbase.Hang theW/U-axis unit bei...

  • Page 395

    /TVV_/OoC3/XW-axis unit 'runB-axis AC servomotorPinElrClampPackingHolderTableunit]9-axis reducer 'O-ring9-axis base4B.c.IIXIrxin..Fig.5.1 (b)Replacing0-axis reducer (S-700)3-51

  • Page 396

    5.2 ReplacingW-axisMotor andReducer1) Replacing the W-axis motor(T) Remove the plug andmove the W axis manually usinga box wrench with awidthof 13mm until itlightly touches the rubber stop.© Remove thecover.© Remove thecablefrom the motor.Removethe motor mountingbolt (M12x30) and the motor.Remo...

  • Page 397

    2) Replacing the W-axisreducer(I) Remove the plug and move the W axis manually usinga boxwrench with awidth of 13 mmuntil itlightly touchesthe rubber stop.(2) Remove thebolt (M12x55) andtaper pinW13x30) mountingthecover tothereducer, andremove thecover and 0-ring.Removethebolt (M14xl20) andtaper ...

  • Page 398

    5.3 ReplacingU-axis Motor and Reducer1) Replacing the U-axis motor(T) Remove theplug andmove the U axis manually using a box wrench withawidth of13mm until it lightly touchesthe rubber stop.© Remove thecover.(3) Remove the cablefrom the motor.Remove the motor mounting bolt (M10x20) and the motor...

  • Page 399

    2) Replacing the U-axisreducer(T) Remove the plug andmove the U axis manually usinga box wrench withawidthof13 mm until it lightly touches the rubber stop.(2) Remove the bolt (M8x50) and taper pin (ÿ8x30) mounting thecover tothereducer, andremove the cover and O-ring.Q) Removethe bolt(M12x85)and...

  • Page 400

    5.4 Replacinga//3/y-axis Motor and Reducer1) Replacing the a/8/y-axis motorQ Remove theloads suchas a hand and endeffector fromthe wrist.0 Drain grease from the gear box. (Note 2)0 Removethe motor mountingbolt (M6xl6) andthe motor using the exclusiveT-wrench.0 Removethe nut and thegear.0 Replace ...

  • Page 401

    2) Replacing the y-axis reducer(I) Remove the loads suchasa hand and endeffector from the wrist.© Drain grease from the gear box.© Removethearm mountingbolt(M8x30)andthe springpin. andremove thearm unit.© Removethe bolt (M12x30) and taper pin (M8x25), andremove the adapter.© Remove the bolt (...

  • Page 402

    5.5 Replacing Wrist Unit© Removethe loads suchasa hand and endeffector from the wrist.© Drain grease from the wrist unit.© Removethe wristunit mountingbolt(M8x25) and springpin(d6x20), andremove the wrist unit.@ Replacethe wristunitand mountthenew wrist unitreversingthe aboveprocedure.(5) Appl...

  • Page 403

    5.6 ReplacingBatteryThe positional dataof eachrobot axis isstored bythe pulse coder, which ispoweredby abackupbattery.Thebattery needsto be replaced every yearaccordingto thefollowing procedure:(T) Turn on the power and press the EMERGENCY STOP buttonto prohibit the robotmotion.© Removethelid fr...

  • Page 404

    6. WIRING AND PIPING6.1 Piping DiagramFig. 6.1 shows the piping diagram of themechanical unit.ZI>w\Panel unionPT 1/8 femaleHAir hose$8i1l\\VMa/—Panel unionPT 1/8 femaleV•©Fig. 6.1 Piping diagram (S-700)6.2 Wiring DiagramTable6.2 showsthe cablelist and Fig.6.2 shows the wiringdiagram ofthe...

  • Page 405

    !r;CONTROLLERMECHANICAL UNITeCP 6MOTOR/—[M U-[P U MOTORPIK I 0IK92Z!PMBATTERY—[M r'[ B§—[M W[p WMOTORiP2r MOTORK I 02K93£hOitnMlLOONK I03K31oc<—[M $§g.B /> MOTORM22.K I 04K322CS'D IK I 05K91—[M aWB§'H »OTCK 1 06r*-WOT°i« MOTOR]D—OljrFIEE

  • Page 406

    6.3 Limit Switch Installation DiagramFig. 6.3 shows the installation diagramfor the limit switches in themechanicalunit.]!7U-axis OT limitswitchW-axiiOT limit switchV\9-axisOTproximitely switch1rOFig. 6.3Limit switch installation diagram (S-700)3-62

  • Page 407

    6.4 CableInstallation DiagramCheck theappearance of each cablefor any faults.1) Remove the W-axis base and the sidecover ofthe W-axisarm and checkforrubbingof the cables when theW axisand U axis are moved.Alsocheck if the cablesare caught inthecover.2) Check whether the routingofthe cables connec...

  • Page 408

    7. REPLACING CABLESA broken or damaged cableshould be. replaced as specified in this section.Ifthe pulse codercable (K101, K102) connector isdisconnected atthesame timethat the pulse codercable tothe battery isdisconnected the motorloses itsabsoluteposition.Therefore masteringisrequiredtoreteacht...

  • Page 409

    Table7.1 Cable clamping positions (S-700)Cable No.Cable clamping positionStampStampClamping positionepYl-K 10 1PIWP*6UP38tÿl3S<ÿ23If332fl368g.OTPYOK I02P2HPICm*p38Cÿ_!3Sÿ,23 Ifl274ÿ366g'vWK I03MlWM34c;I3 I3?7g2UMar Ml—cm r BK05K I 04M20M<Ctt0BK340,.»3Kÿ227j)l!=j=CDi1—cm «M270<...

  • Page 410

    7.2 Replacing Cables0 Remove the U axisand cutthe tiewrap mounting the connectors.7.2 (a).)(2) Removeall connectors.© Remove the endeffector plate andremove the connectors.© Remove the sidecover of the W-axisarm andremove the plate clamping thecables.© Cut the tie wrap and pull outthe cables.(...

  • Page 411

    (6) Remove thesidecover ofthe W-axisbase and remove the plate andcableguide clamping the cable.(See Fig.7.2 (b).)® Cutthe tie wrap and pull outthe cables.Cable guideRemove the plate andcutthe tie wrap.Pull out the cables\W-axis basecoverTimFig.12 (b)Replacing cables (S-700)(D Remove thelowercove...

  • Page 412

    /aQhm©Plate9-axisbase coverFig.72 (d)Replacing cables (S-700)@ Removethe side cover ofthe 0-axis base andremove the plate clampingthecables.(See Fig.7.2 (e).)PinCable trackPlateSupportojo't11oll $'Qi1rPlateFig.7.2 (e)Replacingcables (S-700)3-68

  • Page 413

    (Q) Remove the 9-axis connector panel and pull it halfwayoff.(f).)<Q Remove the ground line and pull the 0-axis connector panel completely offwith the cabletrack.(See Fig.7.2o’DTf=y*ap-LJ-QQQ.0-axis connector panel/Pull it toward you with the cable track.Fig.7.2 (f) Replacing cables (S-700)(...

  • Page 414

    o©a/0Strike the “ 0 ” partwith a plastichammer for mounting thecover.000[0/A00o0<Ko0o0o,Open thecover usingascrew driver0©o0Upper sideLSWEEAIR- UPwpOPWMOMP2-M2Lower sidePartition plateCable sequence in the cable trackFig.72 (g) Replacing cables (S-700)3-70

  • Page 415

    pa7\9Brake® j8®®,6,5i4®©Poweror or ©PulsecoderConnector layout and mountingsequencertss thecables between motors.Band eachconnectorwith a tie wrap.00aBand the cablesat each requiredpoint with a tie wrap.DFig.7.2 (h)Replacing cables (S-700)3-71

  • Page 416

    7.3 Replacing Limit Switches1) Replacing 9-axis OT proximityswitchQ Remove the rearcover of the W-axis base.(5) Removethe switch plate.© Removethe proximityswitch from the plate.Removethe connectorand replacethe proximity switch (cable K106).Mountthenew proximityswitch reversingthe above procedu...

  • Page 417

    2) Replacing W-axis OTlimit switchRemovethe side cover of the W-axis base.Removethelimit switch plate.(3) Remove thelimit switch fromthe plate.© Open thelimit switch andremove the cable.© Replace the limit switch and mount thenew limit switch reversing theabove procedure.Check that thelimit swi...

  • Page 418

    3) Replacing U-axis OT limit switch§ Remove thesidecover of the W-axisarm.Remove the limit switch plate.Remove the limit switch from the plate.Openthe limit switch andremove thecable.Replacethe limit switch and mountthenew limit switch reversing theaboveremoval procedure.Check that the limit swi...

  • Page 419

    rIV. CONNECTIONS

  • Page 420

    r;•ii;i;1!::1

  • Page 421

    1. GENERALThis section describesthe connectionsbetweenthe mechanical and electricalinterfaces in the robot mechanical unitand control unitand instructionsforinstalling the robot.1.1Block DiagramTheblock diagramofthe robot connections isshown in Fig.1.1.Pneumatic pressuresourceControllerTRobot mec...

  • Page 422

    2. SAFETY PRECAUTIONS2.1 GeneralCare shouldbetakentoprotectworkersand machines(robotandperipheraldevices)whenoperatingasystemwhichcombinestherobotwithperipheraldevices.It should be noted that the robot maymove suddenly when it receives amotion command signal.Firstensureworkers' safety and,then,sa...

  • Page 423

    Providea limit switchwhich operateswhen the ptcis opened.>•*Fig. 2.2 (a)ProtectivefenceProvidea limit switch which operateswhen the gate isopened, and connectitto thepower input unitaccording toFig.2.2 (b).The contactof the limit switch should be "ON" when the gate isclosed; itshou...

  • Page 424

    3) The limit switch witha tactile barWhenusing a limitswitch witha tactile bar,use one which providesacircuit with normally closed contactsas shown in Fig.2.2 (c).The ratingofthe contact should bemore than 4 A at100 VAC.«6.sWire springISO4-M4X12mounting hole21ITNC375-5NC470.26T7Fi59.510.21INCINO...

  • Page 425

    3. CONTROLLER CONNECTIONS AND SIGNALS3.1 Connection DiagramFig. 3.1 shows the connectionsof thecontroller with the exception ofthosebetweenthecontrollerandthemechanicalunit.TheyaredescribedinCONNECTIONS section4.1.ControllerModularI/O unit or fixed1/0 >•1PeripheraldevicesK57-JJ Teach pendant...

  • Page 426

    3.2 Connections3.2.1 Inputpower connectionCircuit breakertujvjw•Gi&© ©MS terminalCover(MOZ3$ AC powerNote) Mount thecover after. cabling.Fig. 3.2.1 (a)Inputpower connection (S-10 controller, medium size cabinet)&B023l£_W.3$ AC poweru7Note) SeeFig.3.2.1 (a) for detailsofbreaker connec...

  • Page 427

    Disconnect switch\22/V-II'5P//V3$AC powernwVucIo•I©©M5 terminaload%Note) Mount thecover after cabling.Fig.3.2.1 (c)Inputpower connection (Large size cabinet, disconnect switch)4-7

  • Page 428

    3.2.2 Connection forexternal on-off controlof power supplyO (TPl )EMCOUT!EMCOUTCEMCOUT2OP2tNUIS IEMCINCEMCUTI SYONOLT100w\OUT:BKP1BKRI0BKM]BKP28KR2BKM 2BKP3 BKR30M4 terminals<§)®ONP1Lr<§>a OFFALM*o5 <H«©COM&FN1fewerOFFFN2FUSEALM2/IThis figure shows themedium sizecabinet. The ...

  • Page 429

    3.2.3 Connection toI/O devicesWhen thecontroller isused with a built-in operator's panel,I/O devices whichhaveRS-232-C interfacecan beconnectedtotheconnectorprovidedon thebuilt-in operator's panel.fnTl11RS-232-CconnectorV>m••«•••• oonce aoOOP*Oo}I/O devices(RS-232-C)TLarge size ca...

  • Page 430

    Regardingthe meaningof the signals,refer to the figureshown below.{>SD (send data)<FRD (receive data)-ÿ>iRS (requestto send)-<ÿ-1> CS (dearto send)< >ER (dataterminal ready)DR (dataset ready)— i»CD (carrier detect)SG (signal ground)"! Connect RS toCSJ whenCS is notu...

  • Page 431

    3.2.4 Connection to pulseencoderfor line trackingzwPath CPU'board01P020 CA2X0fZ.pulseencoderline trackingToforMedium size cabinetFig.3.2.4 (a) Connection to pulse encoderfor line tracking(S-10, medium size cabinet)&-r— —yAypPathCPU board01P02CA237]To pulse encoderforline trackingNote) Con...

  • Page 432

    01P02Path CPU boardCA2(MRE-20RMA)Pulse encodes inputs(Male)MR-20LFH23674S1/OVovsvsvoysvPulse encoderfor line tracking33X 81012139CA21120161718IS1914•PCA•PCB•PCZPCAPCBPCZDrives shouldbeSN7S113(product ofTl)or equivalent.PCAS=ta-tPhaseAIPCB4-itPhaseBiiPCZReferencedetectionV.t*PCZi5Vftft5VCons...

  • Page 433

    Pulse input signalsPhase A and phaseBsignals are usedfor pulse input.between both signals should be 90 degrees.Thedifference of phasePhaseA1IPhaseBNormal rotationII1Phase AJPhase BInverse rotationPhaseA,Bandreferencedetectionsignalsshould satisfythefollowingrequirements.Phase APhase B—-Id tdtdt...

  • Page 434

    3.2.5 Controller and peripheral device connectionsThe R—H controller has twoI/O optionsfor communicationwith peripheral devices— a fixedI/O boardor a modularI/O system-ThefixedI/O board isa singleboardsysteminstalledinthebackplane.ThemodularI/O systemhardwareincludes theI/O rack andI/O module...

  • Page 435

    Modular1/0 unit/—(f -62ModularI/O unitV®f////,VZ11 :mB m017K? 0lv__Note) Location of modularI/O unit in the S-700controller is similar tothis figure.Fig.3.2.5 (bfLocation of modularI/O unit/ (S-10controller, mediumsize cabinet)Fig.3.2.5 (c)Location of modularI/O unit(S-10 controller, largesize...

  • Page 436

    Table 3.5 FixedI/O board- inputFEATURE/CAPABILITYVALUE/DESCRIPTIONDigitalInput Signal StandardsGrounding type voltage receiverType+20- 28 VDC (logic 1 "closed")0- +4 VDC (logic 0 "open")Rated InputVoltageMaximum Input Voltage+28 VDCInputImpedanceAbout3.3 kohraResponse Time5- 2...

  • Page 437

    Table3.6 FixedI/O board- outputFEATURE/CAPABILITYVALUE/DESCRIPTION24 VDCRated VoltageMaximum Applied Voltage30 VDC0.2 AMaximum LoadCurrentTransistor TypeNPN200 ms +8msOutput PulseWidthAbout1.0 VSaturation VoltageatTurn-On TimeNote:Outputsare 24 V,200 mAsinking currentdevicesDamperDiodeRated peak ...

  • Page 438

    Fixed Input/Output SystemThefixedI/O system isa singleI/O boardwhich isInstalled in the controllerbackplane.Signal linesare connected toone offour connectors:- CNI:50 pin male,for applicationDI/DO.- CN2:20 pin female,for application*DI/DO or UOPinterface if the systemhas auser operatorpanel.v- CN...

  • Page 439

    FixedI/O boardB£zFixed I/OboardCNCN2/C%CNBcC CNC—'"51&srNote)Location of fixedI/O board in the S-700controller is identical with this figure.Fig.3.2.5 (e)Locationof fixedI/O board(S-10 controller, medium size cabinet)Fig. 3.2.5 (f)Location of fixedI/O board(S-10 controller, largesize ...

  • Page 440

    Input /Output SignalTypesUser-defined signals are mapped intheUser Signal AssignmentTable(USAT),representedbythe systemvariable$USAT.signaltypes through the following predefined portarrays:You haveaccess touser-defined- DIN (digitalinput)- DOUT (digital output)- GIN (group input)- GOUT (group out...

  • Page 441

    Table3.2.5 (a) Analog signalvalue/voltageI/O module inI/O rackAIN value(12 significant bits)Input volt.AOUT value(12 significant bits)Output volt.+2000+10 V+2000+10 V+5 V (+20 mA)+1000+5 V (+20mA)+10000 V(0 mA)(0 mA)000 V-5 V (-20 mA)-5 V (-20 mA)-1000-1000-2000-10 V-2000-10 VEither voltageor cur...

  • Page 442

    UOP SignalTypeTheuser operator panel (UOP) is any user-supplied device that connects totheUOP signals.UOP signalshave functions resemblingthose of the operator panelbuttons, switches, andindicator lights on thefront ofthe controller cabinet.UOP signals also allowyou to execute predefined command ...

  • Page 443

    InternaladdressPeripheral deviceInput module(1)01XQ•ESTOP(2)022V-°-•HOLD(3)033jRESET(4)044j-o-6-CAUB(5)COMO-(6)05i-6--6-CSTRT(7)066j-6-CSTOP07(8)7_1-o-HOME08(9)8O"SpROTCOM(10)<ÿ09(11)9OKCP_UOPl_CF(12)1010joKCP_UOP2_CF(13)11»-jKCP_UOP3_CF(14)1212-OKCP_UOP4_CF(15)COMO(16)1313jO-oKCP_...

  • Page 444

    Thesystem variable$UDIN_ENBL enables theupper eight bits of the UOP inputmodule.If it is FALSE,theupper eight bitsof the inputmodulecan be usedforother user-defined input signals.$UDIN_ENBL must be set to TRUE in orderforthe predefined command procedures to beexecuted.Table 3.2.5 (c) Modular I/O ...

  • Page 445

    Output moduleM3 terminalSignal(21) +DCnnfcInternal addressof module cardrO-CDCMDENBL1(2) 02OSYSRDY2-0ÿ0-(3)033.2APAUSEDO3-(4)04PROGRUNO4-3.2A(5)COM(6)05i•UNCAL5-a)06LOCKED6-(8) 073.2AHELD7-(9)OS•FAULT8-(10) COM3.2A(ID09TPEN9-(12)10UPENBL10-(13) 113.2AJ-11-(14)1212-COM(15)3.2A(16) 13OReserved...

  • Page 446

    For the fixedI/O system,eightof the UOP control signalsare inputs,and theother eight are outputs.The UOP signalsare availableon the CN2 connector onthe fixedI/O board.Tables3.2.5 (d) and3.2.5 (e) list the UOP input andoutput control signalsfor thefixedI/O system.Table3.2.5 (d)FixedI/O UOP input c...

  • Page 447

    As with any motion command,the device fromwhich thecommand is issued musthave motioncontrolor the command is notexecuted.The UOPhas motion controlunder the following conditions:- Thefollowing UOP outputsignals have the indicated values:FAULTY= OFF (No fault conditions exist.)SYSRDY= ON (The syste...

  • Page 448

    JCSTRTG)-HELD (O) ~ ”Z“— ~”LCSTOP(O)PAUSED (O)~Fig.3.2.5 (j) CSTRT timingdiagramHOME SignalThe HOME signal executesthepredefined command file KCP_HOME.CF.Ifa file bythatname does not exist,the HOMEbutton executes theKCL>MOVETO$HOME commandusingJOINT motion.The systemvariable$HOME store...

  • Page 449

    CSTOP SignalThe effect ofactivating theCSTOP signaldepends on the statusoftheUOPoutput UPENBL and the systemvariable$C_STOP_ENBL.If UOP output UPENBL is OFFthe controller will not respond toCSTOP.case CSTOP hasno effect oncontroller operation.inputsignal sets the systemvariable$C_STOP toTRUE andt...

  • Page 450

    3.2.6 Connectionfor emergency stopcontrolTheconnectionsdescribed inthis sectionare made attheinputunit,thelocation ofwhich is shown in Fig.3.2.6.Safety FenceThis emergency stopdiffers fromtheThis isThisinputcauses an emergency stop.EMERGENCY STOP button on the operatorpanel only in the error mess...

  • Page 451

    o(TP1)EMCOUT]EMCOUTCEMCOUT2Externally furnishedemergencystop buttonor limit switch.OPIOP2EMCINI<g)- ©EMCINC©©EMC©mW\SYONOUT1100OUT20Remove these jumperswhen the external emergencystop function is used.BKPl BKR1BKM1BKP2 BKR2BKM20BKP3 BJCR3SKMJÿONMLExternally furnishedgate switchOFF ALMCOMF...

  • Page 452

    3.2.7 Connection to computerTheRS-232-C interface is providedfor the connectiontothe computer in thecontroller.£/’"=ÿri7VwmShared RAMboard0W\Shared RAMboard01P0401P040CD43CD4.0Fig. 3.2.7 (a) Connection to computer(Medium size cabinet)Fig.3.2.7 (b) Connection to computer(Large size cabine...

  • Page 453

    Regarding the meaningof the signals,refer tothe figure shownbelow.-£>-'>SD(send data)-1>RD (receive data)c>RS (requestto send)---1Connect RS toCS1 whenCS is not used.RS-232-Cinterface-<ÿ]---CS(cleartosend)-» ER (dataterminal ready)--DR(datasetready)ConnectER toDRJ whenDR isnot u...

  • Page 454

    3.2.8 Connection toremoteCRT/KBWhenthe controllerisusedwith the built-inoperator's panel,theremoteCRT/KB can be connected tothepanel.connector providedon the built-in operator'sflaaaCRT/KBconnector1mB©msi®oo}RemoteCRT/KBepiiiiiiiiiiiiiillllull'llllllllll!riiiiiiiiiiiiiiinlceOperator’s panelFG...

  • Page 455

    3.3 SettingUSATThe User Signal Assignment Table (USAT), a mappingofthe physical signalstothesystemsoftware,describestheuserI/O hardwareconfigurationtothecontroller.UOPand HAND signalsare also mapped in the USAT.The table isstored in the systemvariable$USAT.The USAT consists of nineblocks of table...

  • Page 456

    There are now 1000 digital100 group and100 analog input and output signals availabletoaccess theR-Hmodular VO, the fixedI/O board, and the interfaces toGEFanuc and Allen-Bradley programmablecontrollers.In addition, thereare another1000 digital and100 group and analog signals availablefor the dire...

  • Page 457

    Table3.3 (a)USAT structuresize inbytesElementnumber [n]Signal number [n]Table numberDIN Tables- DIN [8]- DIN [16]USAT[I]USAT[3]USAT[5]USAT[7]USAT[93USAT[113USAT[133USAT[153DIN Table#1DIN Table02DIN Table#3DIN Table#4DIN Table#5DIN Table#6DINTable#7DINTable#8DIN[1]DIN[9]DIN[17]- DIN [243DIN[253- D...

  • Page 458

    Elementnumber [n]sizeinbytesSignal number [n]Table numberAOUT TablesAOUT Table#1AOUT Table#2AOUT Table#3AOUT TableUAOUTTable#5USATC75]USATE77]USATC79]USATE813USATC83]AOUT[1]AOUT[2]AOUTE3]AOUTEA]AOUTE5]2 bytes2 bytes2 bytes2 bytes2 bytesUOP Input TableUSATE85]Input Table1 byteUOP InputsUOPOutputTa...

  • Page 459

    o Base Signal—- ModularI/O: Signal number on theI/O module thatcorrespondsto thefirst DIN or DOUT in the table (1 or 9for standard applications).- FixedI/O: Sincethe fixedI/O systemhas dedicatedI/O lines andnotmoduleSj thebasesignaldoesnothavethesame meaningas forthemodularI/O.Consider thefixed...

  • Page 460

    TheUDI/UDO number is always64 more than the signalname.The numberslisted in the tableare validas the base signal number when setting theUSAT for the fixedI/O system.Asan example, to assignUDI9- UDI16 tobe DINCl]- DIN[83, the base signal in $USAT[23 would be 73.- Polarity— The polarityofthe sign...

  • Page 461

    OUTPUTSINPUTSNumberNumberSignalnameSignalnamei 4 t6565UDI1UDI2UDI3UDI4UDI5UDI6UDI7UDI8UDI9UDI10UDI11UDI12UDI13UDI14UDI15UDI16UDI17UDI18UDI19UDI20UDI21UDI22UDI-23UDI24UDI25UDI26UDI27UDI28UDI29UDI30UDI31UDI32UD01UD02UD03UD04UD05UD06UD07UD08UD09UD010UDOllUD012UD013UD014UD015UD016UD017UD018UD019UD020...

  • Page 462

    Table 3.3 (d) AIN/AOUT tableformatRack# (4 bits)SlotIf (4 bits)First byteChannel# (8 bits)Second byteo Rack— I/O rack number in which theI/O module ismounted.o Slot— Slot number (on theI/O rack) inwhich theI/O module ismounted.o Channel— Digital/Analog (orAnalog/Digital) channel numberon th...

  • Page 463

    oOperation Mode— Operationmode number isdefined as follows:- Mode 0:Single linemode- Mode 1:Dual line mode- Mode2:Dual linepulsed mode,200 msec pulses- Mode 3:Dual line pulsed mode,400msec pulses(Refer tothe KAREL SystemReference Manual fora detailed description ofeach mode.)o Rack~ I/O rack nu...

  • Page 464

    3.4I/O Module Specifications01010202OJ030404COM05OSISS006060?07oaoacox090910•10cni12Csail13140\C15.016COMFig.3.4 (a) Typical outputmoduleVarious1/0 modulesare preparedto connect with peripheral devices.DI/D0modulesare mounted in slotNo. 1, 2, 3,4, 5, 6, 7,8or 9 in1/0 unit.Forthe types ofDI/D0 m...

  • Page 465

    Terminal forM3 screwsInternaladdressof module card01(1)o-1(2)02203(3)304(4)4COM 1(5)05(6>506(7)607Hi708(9)8COM2(10)09(11)9(12)10 o10(13)111112(14)1224COM3(IS)-o13(16)-6-13(17)1414IIS(18)<1516(19)-6-1624VDC*COM4(20)<09-16 are notmounted on ID08C,08DFig.3.4 (b)DlnKxJulelD16CJID08C, ID16D,I...

  • Page 466

    Table3.4 (b) DC input specificationsModuleID16CID16DID08CID08DItem1616Points/module88Rated input voltage24 VDCMaximum input voltage30 VDCOperation voltage (Note 1)15 Vor moreON8 Vor lessOFFOperationcurrent (Note1)4.5 mAor moreON2mA or lessOFF9 mA typical (24 VDC)Input current2.5 kfi approx.Input ...

  • Page 467

    Terminal for M3screws$9Internal addressofmoduk card01<D/I102(2)2(3)033(4)044100- 1VAC 1U05(6)H506(7)6(8)077x •08(9)8:•(10)fJ100-VAC212n09an910(12)10<12*nu12 (14)12(15)0MWVAC 3L2c-(16)1313(17)1414(18)151516(19)16(20)100-12Pu—©OVAC 4U09-16 are notmountedon1A08E.Fig.3.4 (c)01 module IA1...

  • Page 468

    Table 3.4 (c)AC input specificationsModuleIA08EIA16EItemPoints/module816100- 120 VAC,50/60 HzRated input voltageMaximum input voltage140 VDCOperation voltage (Note 1)ON70 Vor more20 Vor lessOFFOperation current (Note 1)5 mA or moreON2 mA or lessOFF9 mA type (100VAC)Input currentApprox.12.5 kflInp...

  • Page 469

    Table 3.4 (d) Varietyof DO modulesRated currentOFF stateleakcurrentON statevoltagedropNumber ofcosBonsExternalconnectionNumber ofoutputsLEDRatedvoltageHodulenameRemarksFusedlspisyPercommonEachTotal4DCYES0.5 A8 A0.1 aA16terminalblockYES24-482 A1.0 V0D16BsinkoutputVDC(M3)ditto24 A0.1 mAYESYES0.5 A2...

  • Page 470

    M3 terminalInternal addressof module card(21)1+DCuiXsi\xr*H=»r-tDADrf—1t*Iia> 02rc=>r2-Pt12IA033-(4)04tÿr4-3*2A(5)koM(6)OStÿT~5-(7)106tÿr6-(8)E:077&121 08E=:8-3.2A(10)COM-0\JO-09ill)tÿT'9-112UJ110-Pf(13)11TII-12(14)t=r12-3.2A(15)ICOM(lfLinItÿr13-(17)14|4-(18)ISlS—TT-»(19)1616...

  • Page 471

    Table3.4 (e)DC output specificationsModuleOD08B0D16BItemPoints/module816Rated input voltage24- 48 VDC50 VDCor less (Note 1)Output voltage rangePer output0.5 AMax. output currentPercommon2 ATotal4 A8 ASurge-on currentOutput voltage drop at ON1 Vmax. (Note 6)Current leakage at OFF0.1 mA max.Respons...

  • Page 472

    Note 5) Whenconnectinginductive loads(likerelays)tothe output,alwaysconnecta diodeacross the load.When connectinga lamp load, insertdimmer resistorsacross the outputterminals todecrease currentflow towithin the standard limit.Note 6) Output voltagedrop at ON dependson the load currentand is expre...

  • Page 473

    Table3.4 (f)DC output specificationsModuleOD08C0D16CItemPoints/module168Rated input voltage24- 48 VDC50 VDCor less (Note 1)Output voltagerangePer output2 AMax. output current4 A (Note 5)PercommonTotal16 A8 ASurge-oncurrent1.0 Vmax. (Note7)Output voltage dropat ON0.5 mAmax.Current leakage at OFF0....

  • Page 474

    Note 6) Whenconnectinginductiveloads(likerelays)totheoutput,alwaysconnect a diodeacross the load.Whenconnectinga lamp load,insertdimmer resistorsacross the outputterminals to decrease currentflow towithinthestandard limit.Note 7) Output voltage drop at ON dependson the load current and is express...

  • Page 475

    Table3.4 (g) AC outputspecifications (100 VAC type)Module0A16D0A08DItem16 outputsPoints/module8 outputs100- 120 VAC,50/60 HzRated input voltage85- 132 VACOutput voltage range1.6 APer outputMax. output current3.2 A (Note 5)Percommon12.8 A6.4 ATotal10 A (1cycle) (Note 6)Surge-oncurrent1.5 Vmax. (pe...

  • Page 476

    Note 5) In additionto the above limitation,the output current is limited to1.6 A forevery 2-output group shown below.(00,01) (02,03) (04,05) (06,07)(10,11) (12,13) (14,15) (16,17)For example, no load currentcan be fed tooutput "Ol", while a 1.6 Aload currentisbeing fed to output"OO...

  • Page 477

    Table 3.4 (h) AC outputspecifications (200 VAC type)Module0A16EOA08EItemPoints/module168200- 240 VAC,50/60 HzRated input voltageOutputvoltage range160- 264 VACMax. outputcurrent1.6 APer output3.2 A (Note5)Percommon6.4 ATotal12.8 A10 A (1 cycle) (Note 6)Surge-on current1.5 Vmax. (peak)Outputvoltag...

  • Page 478

    Note 5) In addition tothe above limitation, the output currentislimited to1.6 A for every 2-output group shownbelow.(00,01) (02,03) (04,05) (06,07)(10,11) (12,13) (14,15) (16,17)For example, no load currentcan be fed tooutput "01", whilea 1.6 Aload current isbeing fed tooutput"00&q...

  • Page 479

    Table 3.4 (i)DC outputspecificationsModuleOD08H0D16HItemPoInts/module816Rated Input voltage24- 48 VDCOutput voltage range50 VDCor less (Note 1)Per output2 AMax. output current4 A (Note 5)PercommonTotal16 A8 ASurge-oncurrentOutput voltage drop at ON1.0 Vmax. (Note 7)Current leakage at OFF0.5 mAmax...

  • Page 480

    Table 3.4 (j) Analog input moduleMaxinputvoltage/currentModulenameInputpointsExternalconnectionAnalog inputsResolutionAccuracy4AD04A-10- +10 VDC(Input resistor1 MG)-20- +20 mADC(Input resistor250 ft)can beselected.Terminalblock5 mV20 pA+0.5Z orless+15 V+40 mApoints/module(M3)AD04A (Analof input m...

  • Page 481

    Table3.4 (k) Analog input moduleResolutionoverallaccuracyModulenameOutputpointsExternalconnectionIsolatedAnalogoutputs2DAO2A-10- +10 VDC(External load*resistancemore than1 KS2)0- +20 mADC(External loadresistance0- 500 S2)can be selected,Terminalboard (M3)5 mV, within20uA* 0.5%Notisolatedpoints/mo...

  • Page 482

    4. S-10 MECHANICAL UNIT4.1 Connection between Controller and Mechanical UnitAxis control board01P05K92CF91-3(W.U.8)Signal topulse encoderforservo motor (W,U, 8)PIJ77A--K93Signal topulse encoderforservo motor (7, B, a)01P0502P05P2CF94 (7)CF91-2i_r~(fca)A~~K91Robot control moduleCNCor fixedI/O boar...

  • Page 483

    P2(MS3 I06B 32AI0S2)Pi (MS3I06B32A10S)I B pPCZAAj A1 PCZAA|fEI PCBAA|0 |»PCAA4) CI PCAAA1iJl «5V |H| QH2B|Gl OH 18 iFhPCSAdj|M!~ OV111 OV |K| »5V |I RI C4A* |P|CBAATOII W|PCAAS|V |«PCZA3 U|PCZASI T| CIAA |S1 C2A4~||«| »SV|Zt»fy8AÿY|PCBA5|xKPCAA5<1 11CAAST« I C8AS |dOV1 11 OVI bj *5V11...

  • Page 484

    RC01CRobot controlmodule01P05Axis control boardCF91-94Power input'unitaiCNCK31.K32/02P05OFT1FixedI/O boardCNCC-92K92—K91 myIfBÿWServoAmp.K932ServoAmp.K3I.K321K92K93K91K99K31Fig.4.1 (c) Connection diagramfor the robotconnection cables(S-10, medium size cabinet)7RC01CRobot control module01P05Axi...

  • Page 485

    4.2 Connections and Signals betweenMechanical Unit and EndEffector4.2.1 ConnectionsMechanical unit2134RDOlRD02RD03RD04689RD05RD06*HBKDOVRDU101211131514]|]1HEndeffectorRDC2RD13RDI4RDI8•PPABN1816171920+24V+24V+24V+24V21222324Note) Connecting cablesare customer provided.Eod effectorConnector pinNo...

  • Page 486

    4.2.2DI/00 standards for endeffector controlinterfaceTable4.2.2 (a)DO signal standardsDI/DOSignal standardsSignalConnection typeType[Robot side]Rated voltage:24- 48 VDCOutput voltage range:50 VDC or lessMax. outputcurrent:0.25 AOutput voltage dropatON:1.5 Vmax.Current leakage at OFF:0.1 nA max.Re...

  • Page 487

    Table 4.2.2 (b)Dl signalstandardsDI/DOConnection typeTypeSignal standardsSignal(J) Digital inputsignalstandards[Robot side]ReceivercontactinputDIRD01-RDI8*PPABN*HBKD+24VType:Grounding typevoltage receiverRated input voltage:+20- 28 VDC(logic"l" closed)0- +4 V(logic"0" open)Max...

  • Page 488

    4.2.3 Endeffector control interface cable1) Cable connector specificationsThe wristconnectorshown in Fig.4.2.3 isattached tothe endeffectorinterface.BA: M30 X1B:54.1C:37.5D:9.6-15.0 (innerdiameter)E: *33F:11.2G: 24.7FTP'istjof.---U-|g3' oo o oO OO O Oo o o o o oo O O oo, o 000JZilwri(mm)JMSP2524M...

  • Page 489

    4.2.4 Noise suppressorsAll relays,solenoids,andmotors tobe used ina machine or on peripheraldevicesconnectedtothecontrollerunitmustbeprovidedwithnoisesuppressors.These suppressorsare used also to protectthe relaycontacts.Fig.4.2.4 (a) shows examplesof noise suppressors.DC relay3 phasemotorDC rela...

  • Page 490

    4.3 Mechanical Interface4.3.1 Robot motionareaFig.4.3.1(a)showtheexternaldimensionsofrobot.peripheral devices, be careful thatthey do notinterfere with robot motion.For installation,use the 4-holeon the bases Fig. 4.3.1 (c) shows therobot motionarea.Wheninstalling(220.2139)Motion range of0-axis c...

  • Page 491

    0880LZrm4momooOo—O IIIII5DIo818O'm QS4£lTooIf)oroOHI088o\%IIIIIITLS1M11o9[Oi4*4cu906in©•rooo—oo09800 IiIIii61118OIaaT(J088boO—r- iIIIIS896813A4AV«ooo6Z.SI50888oocur-ir-IIn23"281OIOILLTooTJH088S4£l8CU408897V°B©oIf)oOIf) CO—*2oo—Ch 1IIII3QiitiII° ii'NOCUO'2c Z><UJ*ore ...

  • Page 492

    4.3.2 Mechanical couplingof end effectortowristFig.4.3.2 showsthe endeffector mountingface atthe endof the wrist.Mountthe endeffector using thehole, position it using thefourreamedholes,and bolt itwith the4-M6 tap.Select the length of theM6 bolt so thatit is within thethickness of the wristflange...

  • Page 493

    4.3.3 Location anddimensions of equipment mounting holesThere are three equipment mountingfaces asshown in Fig.4.3.2.length of the boltso that the threaded portion is lessthan 10mm.SelecttheM6 button headbolt'X(4 pcs)4-M6 Through (plate2.3 t)(Pay attention otrubber sheet)\\\ro iniCO -stH£Equipme...

  • Page 494

    4.3.4 Air supplyAn air supply porttothe endeffector is provided attherear partoftheW-axis base.The apertureisfemalePT1/8.Since couplingsare notsupplieditwillbenecessary toprepare couplings according tothe hose size (Refer toFig. 4.3.3.)4-73

  • Page 495

    5. S-700MECHANICAL UNIT5.1 Connection betweenController Unit and Mechanical UnitAxis control board01P05rj— K92CF91-3(W, U,9)Signal topulse encoderforservo motor (W,U, 0)PI3=n--K93Signal to pulse encoderforservo motor (7, 0, a)01P0502P05P2CF94 (7)CF91-21I_r-(£.<*)iWx~~K91Robot controlmodule ...

  • Page 496

    P2CMS3I06B 32AI0S2)PI (MS3I06B 32AI0S)I B t»PCZA4| AI PCZAAIrElPCB*4|QKPCAA4C|PCAAA|iJl *5VI Hi 1X28 IGl OH 18 |F |»PC8A4{|H|OV|LlOVI KI »5VI|R| CAAA |P| C8AA1 011 W|PCAA5 j V |«P€ZA5 UI PCZA51 TI CIA4 |S|C2A4~||tj >5V |Zt-PCBAa YI PCBA51 X |»PCAAS|| f |CAA5~1 e| C8A51 4I OVI e| OV | bj...

  • Page 497

    zRobot controlmoduleRCOICTl/&BKPl.2,3BKM1.2.301P05 Axil control baudCF91-CF94II31IK91Lf 02P05OPT1 fixedI/O baudKd\iSk®-,CSC5II.iC93PuSfV\K31ÿ_ T_L_ÿrtfS8*If •JI!19913175•K32K31K92'ÿÿliVknnrS?K32K93K91I[ServoTo maine—cabinet0jAmp. 4|SIP\K31Note) Cable K9I is connected tothe robot co...

  • Page 498

    5.2 Connections and Signals betweenMechanical Unit and End Effector5.2.1 ConnectionsRefer to section4.2.1.5.2.2 DI/DO standards for endeffector control interfaceRefer tosection4.2.2.5.2.3 Endeffector controlinterface cableRefer to section4.2.3.5.2.4 Noise suppressorsRefer tosection4.2.4.5.3 Mecha...

  • Page 499

    i_5p°0*k)}\k)\<7,IISIo600,ovO\59ÿA ( 100,2416.2)160 (*164)800CM1700)\O7AÿE( 159.7, I 198.6)OCo.H ( 1416.2.900)/°B (I 61 6.2,900)do.0 (290. 2,662. 4)0ÿCoMotion area of(3-axiscenterI.C(540.3, 126.2).00G (438 , 100)*In the case of the special flange (option).Fig.5.3.1 (a) External dimensions...

  • Page 500

    /5p°%to/\to\LÿLjjSc>wmaO600ovOA( 100,24 I 6.2)200 (*204)800C\JN'vD F ( 438 ,I 700)-LifKVE( 159.7, 1198.6)OACbH ( !4 !6. 2 ,900 ) /0B(1616.2,900)dlo0(290.2,662.4)O'(bI==HA-;Motion area of/3-axis centerI.0(540.3, 126.2).00G ( 438 , 100)*In thecase of thespecial flange (option).Fig.5.3.1 (b)Ext...

  • Page 501

    XCM>oCM•o'O'O/NNCMvOQl •00vD006*S*9SI4CDoS31<raooT•o00600Z.Iu_\*pCMbVvOB¥vO*d4<TQQ9*861 IUJboo;o\pj1aO'<ID2*91172Fig.5.3.1 (c)Operational diagram (S-700, offset wrist)4-80

  • Page 502

    I5“o'CM~ToVT9TOJ“o'oCM4-o/X>vOV.1 QvO00vO*-7T7T?-»006“O'*921CD41oHI:1<ru00*•\>00600Z.ILLCM__00AIL.I ro!vO“o'vOooc&Vf-ilr: CD9*961 ILLJ\o:obtoo;oir-“ocna <ID2 * 9I V2Fig. 5.3.1 (d)Operational diagram (S-700, in-line wrist)4-81

  • Page 503

    5.3.2 Mechanical couplingof endeffector towristFig. 5.3.2 shows theend effector mounting face ofthe wrist.Mount the endeffector using theorhole.Position it bytworeamedholes.Bolt itwith the sixM10 taps.Select the lengthofM10 boltsto be used tobewithin the thickness ofthe wristflange (16 mm).6-MIO ...

  • Page 504

    5.3.3 Location and dimensions of equipment mounting holesTwo equipmentmountingfacesare providedas shown inFig.5.3.3 (a),Select the bolt length sothat thethreaded portion isless than12 mm.(b).§ÿ&n/IfrojOomiinS1O*KvOn\o8Z.t{0I I 08SoiZ.HO90ID!IO'L-vOImg1£§IE£9affh£i00£ID§•o £1 I£Q&a...

  • Page 505

    o I OLJHof—oIoCcsp36bo<P<0fJtrooXVTY\\\HÿCpi\\VN>w*y»a1r\VPAYLOADB k gXx>bTOTAL AkgA +B<30k g'xDimensions and weight limitationsfor any equipment thatmight bemountedon thearm.Fig. 5.3.3 (b)Dimensions and weight limitations (S-700)4-84

  • Page 506

    5.3.4 Air supplyAn air-pressuresupply porton thefrontof the U-axis unit is usedto supplyair to the endeffector.The apertureisa PT1/8 female.In addition, anair-pressure supplyport for the above-mentioned portis providedon therear ofthe 0-axis base andthe aperture isa PT1/8 female.Since couplingsar...

  • Page 507

    r r-FV.INSTALLATIONsLt-C-L

  • Page 508

    ;i;.

  • Page 509

    1. S-10 ROBOT1.1 Transportation andInstallation1.1.1 Transportation1) Transportation bycraneTherobotistransportedbylifting.Mountthepartsrequiredduringtransportation and lift it by attachinga rope tofour M16eye bolts.Afterinstallation,remove the partsfor transportation and the stop.(RefertoFig.1.1...

  • Page 510

    2) Transportationby forkliftThe robot can alsobe transported usinga forklift.(b))Aforkliftbracket can be providedasan option.(Refer toFig.1.1.1Note) Removethiscover M6x8 button-head bolt (4 pcs)Note) Therear forkliftbracket ismounted tothe robotas shownbelow.M10 bolt(2 pcs)!ForkliftIWasherilTWFor...

  • Page 511

    1.1.2 InstallationMountthe robot using anchor bolts to a foundation prepared by the customer.Fig.1.1.2 (a) shows the baseof a robot body, Fig.1.1.2 (b) the basediagram,and Fig.5.2 (c) foundation installation diagram.Positionthefaceshownas"XXX"ontheprovidedreferenceplaneorthepositioning ...

  • Page 512

    Anchor boltM20:Nut and washerdiz:Leveling plateI"Nrd=15\mm\ iBase of robot body••••Cement•«Fig. 1.1.2 (c)Foundation installation drawing (S-10)Note) The leveling plate and anchor boltare to be provided bythe customer.Determinethefoundation depth according tothe sizeofthe bolts.ens...

  • Page 513

    1.1.3 MaintenanceareaFig.1.1.3 <’a'' shows the maintenancearea.Masteringarea (6: 90°)r550 _300l1400ToMaintenanceareaOoIIinroI©inIo/2gmikminoIP_oiniiroIoMasteringarea (8: 0°)O3501535090II 300550lMasteringarea (8: -90°)L.JFig. 1.1.3 (a)Maintenance area of mechanical unitThe position ofthe ...

  • Page 514

    12. AssemblyDuring Installation1.2.1 Robot cablesWhen laying a cable betweena robotcontroller anda robot body, the customer isresponsible for preparingthe cable duct, etc.The mechanical unit isshipped with connectingcablesunattached (but connectedto the controller).Connect the cables shown in Fig...

  • Page 515

    122 Air pipingFig-1.2.2 (a) shows the air pipingofa robot.Ifthe aircontrol setisspecifiedasan option,the airhosebetweenthemechanical unit andthe air. control setisattached.Mount the air control setaccording to Fig.1.2.2 (b).F»Panel unionPT1/8 femaleJLmPanel unionPT1/4 femalet33JiFig.1.2J2 (a) Ai...

  • Page 516

    1.2.3Installation specificationsSpecificationsItem225-7kg/cmG (Preset pressure5 kg/cmG)Air pressurePressureMaximum peak: 150 NJl/min, (Note 1)ConsumptionApproximately200 kgWeight0- 45°CAllowable ambient temperatureNormally: less than 75% RHShortterm (within one month):less than90% RH maximumwith...

  • Page 517

    2. S-700 ROBOT2.1 Transportation andInstallationWhen transportingor installingthe robot becareful of the battery cables.2.1.1 Transportation1) Transportation usingacraneThe robotcan be transported by lifting it usingacrane.After mountingthemetal fittinginstalled to prevent rotationof the W and D ...

  • Page 518

    2) Transportation using a forkliftThe robot can also be transported using a forklift.forklift are provided.Optional bracketsfor aApprox. 1474TransportingpositionW= -95° (Stop)U= 10° (Stop)7= -90°<j= 0;0= 0°WARNINGDo not transport the robot by attachingropes toeye bolts that are screwed int...

  • Page 519

    3) Transportation usingceiling-mount .cageWhen transportingthe ceiling-mount robot, theoptional cagecan be used.4—©©\©©Fig.2.1.1 (c> Transportation using ceiling-mountcage5-11

  • Page 520

    60070inoo//////////.I$ tQ1S lO6-axisrotationcenteri.Oo§oFrontin CXIS 10 iSIIs.in£infEi±it ////////// //////////or-A20905204-M16 thruNote) This diagram isviewedfrom the top.4-ÿ24 thru032 spotsurface,depth3Fig. 2.1.2 (a)Robot base dimensions (S-700)520260oUDOJfi-axis rotation center/-o\ fOJFron...

  • Page 521

    Note) Thefoundation depth isdetermined by the size of thebolts.If the pathtaught toone robot mustbe transferred to the new unitwhentherobotmechanical unitisexchanged,the customershall prepare aninstallation plate suchas shown in Fig.2.1.2 (c).Pressedface for robot basePositioning pin(for pressing...

  • Page 522

    Mm.600jqisaoo{£TwTvCT5T,*Tw.Te < 500 kgm500 kgFig.2.1.2 (d) Ceilingmount (S-700)5-14

  • Page 523

    800700A5204—*I rl-s=Sr-8r-gCO4-U-IL,_-tftcajX2092\SS41 (32T)M20 tapfor container(Afterremove the container,use the tapstofix this system.)4/-4— -4-M20 tapfor fixingof this system¥iM20 tapfor robot’s baseDetail AFig.2.1.2 (e) Ceiling-mountcage (S-700)5-15

  • Page 524

    2.1.3 Maintenance areaFig.2.1.3 (a) shows the maintenancearea.600300300300ootoVoo °OIoro5OiirO—“ hCvDcoTooroVMaintenance areaFig. 2.1.3 (a)Maintenancearea of mechanical unit (S-700)5-16

  • Page 525

    Provide the maintenancearea for mastering.Masteringcan be done when 0= 0°,90° or -90° withthe otheraxes positionedas shown in Fig.2.1.3 (b).Notethat masteringisdonebeforeshipmentwith 0= 0°.Usethispositionifpossible toensure accurate remastering.W-axisW-axisU-axisU-axisp.p.0-axis(J-axisY-axis:...

  • Page 526

    2) Usingthe plate fornoise-shieldWhen it is required to reduce the noise,the optionalplate can be used.Assemble the plate usingthe following procedures.(D Remove the connector panelfromthe base.© Placethe plates 1 and 2 attheboth sideofthe connector panel, andmount them using M6 bolts.© Tear th...

  • Page 527

    2.2.2 Air pipingFig.2.2.2 (a) shows the method usedto connectair piping tothe robot.If theair controlset is specified asan option,the air pipe between themechanicalunit and the aircontrol set isattached.Mountthe aircontrolseton thecustomer-provided mounting port with the specified holes tapped ac...

  • Page 528

    Use turbine oil#90 to#140 of the air control set,and fill tothe specifiedlevel.Mountingbolts are provided by the customer.4-M64—±nflnOo»lJ—L<>-<>63//kOileru FilterFig. 2.22. (b) Air control set (S-700)2.2.3 Installation specificationsSpecificationsItem225-7 kg/cmG (Set pressure5...

  • Page 529

    3.ADJUSTMENTS ANDCHECKS DURING INSTALLATIONForconnectingcables between the controller andthe mechanical unitoftherobot,refer toIV-4. 1 and5.1.Check that these cablesare connected properlytothe correct axis andthat the polarity iscorrect.3.1 Items to beCheckedThisprocedure, describestheadjustmentp...

  • Page 530

    1) Check thecondition of the control unit and themechanical unitas follows.ItemCheck for dirt or damageon theoutside ofCRT/KB panel, operator's panel,orthe teach pendant.Check for loose itemsinside thecabinet such as PCBs, the power unit,theinput unit,or theservo amplifiers.Check for any damage t...

  • Page 531

    3) Verify that allconnectors and PCBsare properly mounted.ItemAreclamp screws in theHONDA connectors tight?Arenail type fixtures fitted withblack connector forpowersource?Arenail typefixtures fitted with brown connectorfor power source?Arenail type fixtures fitted with white connectorfor power so...

  • Page 532

    4) Check settingsof thetransformers andfuse sizeThelocationofthepowertransformersisshownin"I.CONTROLLER MAINTENANCE3.3 Internal Components".OVERVIEWANDItemTap settingon theservo transformer (TF1)Checkthetransformer primarytap connectiontosee if the power voltage iswithin+10% to-15% ofth...

  • Page 533

    ItemTap settingon the input transformer (TF4)Check the transformer primary tapconnectionto see if thepower voltage iswithin +10% to-15% ofthe tap voltage.If the voltage does not satisfy this condition, select the correct tap.Primary side575550500480I 220-S7SI460440415380240220COMICOMIFig.3.1 (b) ...

  • Page 534

    ItemFuse size for AC voltage input types (Refer toI. -OVERVIEW AND CONTROLLERMAINTENANCE 23.3.1)5) Connect the cables between the control unitandthemechanical unitItemConnect the AC motor power cable and brake cable foreach axisConnect the pulse coder cable for each axisConnect the robot input/ou...

  • Page 535

    9) Output voltage checkPress the EMERGENCY STOPbuttonon the operator’s panel.supply, andcheck the output voltage.Turn on the powerItemCheck that all fans In thecabinetare working normally.Check that eachpower output iswithin thespecified range at theterminals onthe PathCPU board.(See I. OVERVIE...

  • Page 536

    13) Check the movementof each axiswhen it ismanually jogged.Refer tosection 4 for initialstart-up procedures.ItemTry movingeach axis using incremental jog,andsee if the axis movementoftherobot follows correctly.While manually joggingeach axis at low override, operate any externallymounted EMERGEN...

  • Page 537

    4.INITIALSTARTUPThe robot isshipped withoneor more axes placedon hard stops.This shippingcondition places thoseaxes inan overtravelcondition.Prior toinitial startup, the EMERGENCY STOP buttonshould be pressed.After initial start up, youmust reset the EMERGENCY STOP buttontoremove theemergency sto...

  • Page 538

    Initializing KARELFig.4.1 (b)KAREL initializing displayAfter the initialization iscompleted, the display in Fig.4.1 (c)appears.ll-Aug-198804:41:06MAINMENUKAREL.ControllerCopyrlghtCe) 1065, 1066,1067. 1066 Off* Robotic*All Righto lUnmlSoftware3.0 ALPHAHardwareModal:B-30CR-0FAICreate/Edit Profram I...

  • Page 539

    4.2 Recovery from Alarm ConditionsIf auser or system erroroccurs during operationof the robot,an errormessagewill be displayed on theCRTdisplay and the teach pendant LCDscreen.TEAOiTEST1CCKjoGsJoixrKT:JHT1)PESO!2)PICK> 3)PATH!V4}PASSHert RecordedRecorded4 soda*O soda*4006 WARM robot overtravel...

  • Page 540

    42.2 OvwtramlWhen a robotaxisoverextends its motionlimitandtripsone ofthe axisovertravel limit switches,servo power isshut off bya hard wired relay circuitand the followingovertravel error message is displayed:4005 WARN ROBOT OVERTRAVELTorecover from theovertravel perform the following procedure:...

  • Page 541

    oooTUCKKKUTUKm®®I-MOTB-BZ-CptTJnCTCUCAUWATO.. MXiamt©©nT=tid=t]®®O OFTFAULTMCLDUdUCMCYSTOF®®•EMOTEBin>«vOOoo7EMERGENCY STOPbuttonJWl7\FI | F2 |n | F> | F51~@0@000@0®®®0fflSHSSIassiaaaaaa0001=1000H00003EMERGENCY STOPbuttonFig.4.2.3 Emergency stopcontrols5-33

  • Page 542

  • Page 543

    7rVI.APPENDIXrr 'r‘s>sL ..c.--ic.'-

  • Page 544

  • Page 545

    APPENDIX 1INTERNALCONNECTIONS1.1 S-10I1 ?5§<sk*>ÿi-fr”M-H SM8ni £Xa25Iid- 1S-isfll3IIlNAiISISnwiSS1ISS sTTISi;Mss3HIISIlSlI sssS?!:s ss3s R8 RS t ;£8lO-(M “1 XiD— if»o--——~—606006660666666fmHPk2Ah25i35«ttirJIs s ss cs s sassSSSIsSS215333lLCD§2?‘*-5 g§TJhsif-a “_Mor5&...

  • Page 546

    £££SI3IfSft!5d3I8I - 85§122?2 ( •5 »2=sssiiSiSiSiSiSi§gS§£giffiiJ iJ .A icj-ÿvA4Ax*?ss5I§+ÿ?=I*5:§§£dSjsd* 255<i+Hi"**,If -;j::s>S[IJ22iS22b?§TTI I IIifo§-525 §5ass-JSi si£HiFig.1.1 (b)Internal connection diagram(S-10, Medium size cabinet)6-2

  • Page 547

    Iorsi15Hio12O8i£85UJrisiiwr— —i“16* iii»v>2l! I»Qiisÿ !55“i§aT ! T |gaSst; i' sSoa.uiuiI|lQ.UJ2jt>s?g2Ii»<LJs“n<*n*§IJ JeSSIg§(J§ sij-T?« 'I--I--P1--po_S 1 1it 11|iso"T—i—iJ *n—|Jrrus!II!»5VOJ0*SoSo,bSiis< CMa-“85rUJaiIkis>SoUJUJCM*~*ZaiHsC2S—...

  • Page 548

    UJc\2saUJ<s<ouuaauiIoo&ouXUi* uUJ2Ui*>0ooooo£82Si=28ar-a8--*«.8AI—5<u£»-<sUJu>2 “$RVSCAWuft\aCM-iVues_J<Aa<*JatngIPliiBsggKs2> > >•» *OMCMAJ•••£Ui&S2o85WMhHKiWhHfeJPIHHWHWHWHMW**> MI•»LU-blg HBg §©§°£o$©s&aMKHRWWMWMWWMttHf...

  • Page 549

    sU1 COffl O'IItJgSS-S §5o>u <iusI s § 1O 4Jo *-»£yyy»o—»Q)Ny4->sOsIs i §S sCuyo. y H*J4J -H••'H lA HsO 01 O2££2£~'3'SSI0*jO 4Jo *A*HeeeH W,33 S3 Sg>2«HWH t3<8m « 05m 4-*xy-HTio 00 y yX C X CH-Hfi£Cu<-H<-HWV-W4Js£nnp1Iyfc >—#gc £>—#InIC£i&...

  • Page 550

    BACKPLANE s1- 1002-0660K50j\1omOPT6RRR-°±ruBATTERYAXISCONTROLOPTION AAXISCONIROL/WELDINIERT ACF.I?I iIIAI6B- l?l l-0060*InnHHp|p| p| p|pj pj pjCf 91 -94CVJ124Please note:ControlPCZ00000•PC:Axisin slot0PT5 connectOT CNA8.Axis Control PCB2 connectsin slot0PT6 connectorCNA9.Slot0PT5 is locatedon...

  • Page 551

    £ >£ z >£-0;w0-> uEC Q> >n*> >CdNO'XINO 3S*9 o/l012<JN0*llNn 3Sv9 O/l 01ft 7o o o*c\6»*aEC Qu[ÿÿDEEW)r» »1•apiI id Q«*! IC DHiDEC4d3-83dX6J1N031IND lOdNl«3MOd 01IdO •90d XdlNOOUNO irvjNi a3M0d oi2d3-93d XdlNOOUNO iOdNI d3*0d 01sit* 31*C oo4VMrgftu297*aOQQQQoa...

  • Page 552

    5I Iu oISi <oo|??5sss5 H s§?anf iyyi i*X|s??iqZP5|§*C ChÿisMCSdOD- OBVQS WVB03BVHSUNO XdiNOO DISVfl 011CINO 93dXB1NOOin<3Nl B3«0d OlilNfl£S*Or. Z1C 'pIislllmumimiglBilHI i iqPgg-;gooIXXX03O OsSISISIIo»ntiftÿr<ea)glgiiili|sssI 2 1C1UJinoIIiciI__JIIiciI___IIIidIIIicI___IIIId p?5iqFi...

  • Page 553

    58ang|o—*•!8?«D Di6>- 2DD csxa 1 *3—“ i «ÿ-<miN3-03dXdiNOOindNld3nOd 01UNOIs .) 3Sn d3H0isro dQjas—OjUJ—Ogooa—x xx C:ttana a xxX I•O 3sSSSSgSSs'ii;aoaoaooaa.<\<\<vanttcjiaaO*•*e SSSagge SSSS#iiHiiSSft?iliiigiilill SS£iiiiiiill!l!ii!|ssg15 15 2333333OJOjiiissi5...

  • Page 554

    Ii-X3X.s— —%tI.2.i"a~S_P-_s§— ——5io1§OJ!iIiiI-S2SES?ipsE“Irfcflipst|ZlE<!B EIiIIlfip=SiJS=OJro1III1I1iIi:sI lip5 <3I§03limi-3isiI5£IiiX.3|2aTPIIIisIts5tn81Il=,P§u?us p|-l"|EgIim siEi||p2|pfciigs•Issplif5!OJI8S4-31I<|? _I1i<2sFlf1Pi55I?II-l:55IP8=33isj.!L3I...

  • Page 555

    SI <+'i!>-1 |2SIIttS%s*it!sNs1W\bIsiiI8§°S§Iis;lgIIIsm*m gsisSi3atIfHTm5si «3S5gJ33sIs .53ilsss111Sal;?3333§ÿ:;ÿ50c0S;lD|§fs e - RJ-sLsr\=T\Isu11-SIIIli2 2rsic::::s!•:::irsJt s<>•«'Hu1Iiyi.pH§!§ i=[sJ1J! ?? ? ri>•fL'FTAD-§22h3131 i??il HSSSI "<12£ISFig. 1...

  • Page 556

    sH*"><3ojjjnj©T!>ÿ|I ;"0SCU8§illiiiiksaIiI1Is ;5NII=: s1sSsSsgIs85Msssflll sSSSSsii sggH§iS>III s58KSsIs EtsslbTIM ®m:6SFrH vm¥m 3-3Abos33afi!(A-Trÿ5C ui-JI§1$8£ Cs 8Se§8Isiill 8558S8S3331-»Sc0soegB?-9 d§I -irSs8SL3TsL-<->rZ 2022IIJi_tt— — a</>i 5...

  • Page 557

    ss3°g£SIIssr5<13£13siH5: 9 V V*T iffiIt®Ii>>></)</)(A9 8-JrvIxls \l /* Si *gI£ *s?+8 /\? S*§i i«S206S>ooc<aI.sii—hi§*©ii\/ \§» s'IFT53:::;I?1 5,fij5!If8nr5IIbW "2I§a??.S2I Ifci1 «IiI;BfIsmflf® sIsi1; SV«§§81Vze 25gosi5111ISI11mIg sSII??ssssss??8I?2...

  • Page 558

    I2IIsI2rrMJ--5i$$Uii 28I*5Isu ggMi/i2sC-saSS22 (*II£UUISi i ITO-A -A,4-41 m7TTt??5S8SS+•? 55§sss*«oSsi «2g4<125Ms *+ÿizhii.-£n-CV(? =522==5+t$2It£sisII 411III"=5 §=1I!aft585ft?.Pi!IK-uMiLÿJfitrFig.1.1 (n)Internal connection diagram (S-10, Large size cabinet)6-L4

  • Page 559

    ISrsi1jjn =*IIsi rr>5gr— r—iI1»I§§fezII58-IIImu H»WSis 1 ! !II!ill!ULJJSIsI§2SVV5•=£--*iArfI§5II5 Sf. TTl2V—-r1_i ri ! !’ n__ji §5Vi—r 'i—rTJnrI2$fiiHi' oUbg|IftgsIs5rr-* >—uaIIs§>as§S518Sliisg§gggnIImOpm-6-6-6--6-6-IP i Hi mill§ & § £i !pi?5=§il-g§2ii...

  • Page 560

    TEACHPENDANTK576=7°A059-205I -Cl42OPERATOR'SPANELA05B-205I -Cl22REMOTE CRT/KBK70K520=7° =>CC2!0*----6-----RS-232-C (CHAIAI3B-OI44-BOOIK57coLkSHARED0IP04AI6B-1211 -0860RAMCONNECTIONBOAROA20B- 1003-0040S[?]D--C-LBS-2J2-CXCD-IFLOPPYCASSETTEADAPTER3POWERINPUTUNITA I 4B-0076-B322- B325ELA§ROBOT ...

  • Page 561

    Ig%sasl IIi1I35II13Ulesseee5go3-ig&§a?s-8ru«aI:|!SH---•—0-3- |s vs§ss8-*tnLUX_ICftgsgigsg|||5i!||a|5£tHi11.5SiSgBgsSS5is|BS9 SS5>ttlwliMIglf| I Sgsgf\jlira-ÿMFfi__uf:ÿ2§§§docrs.iI£io§&5=I 5=ti%iOil.IsI£§hiZJ,5rt|S§glssSI Sfillgis-5«:gSIIe»iSoEogS“SIv11“ooS5®™...

  • Page 562

    HACK PLAN!:A?on 100?0060K50HJJ0PT53PT6CNA»CNA8-o-b1|” OP!101?? |TJBA!MOVAXISCOWIPOIAXISCONIIKVIIA160 •l?l I006?Z1nnnrinririnl In nDCl'9l-94CV?I ?4Pleasenote:l»L70•vr.icnnsAxisControl PCB1 connectsin slot 0PT5 connector CNA8.AxisControl PCB 2 connectsinslot 0PT6 connectorCNA9.Slot0PT5 is l...

  • Page 563

    5CO 00 CO O'014-1< 4-1< JSCCO2 Oz WO «H« u « uC M C *- O O §O O O OCOCl *JU *j*©J2uu a)•n—*o> CMotwvocc « H aaac csac ua- toO O CJoooB,OfcOH5ann4-1•• 'H irt H*0 BlO•atOHOH*HÿH«MCO4Jt- p,U CL,COoc4-1O 4-1o to"HCCH *41 4J3O4JO4JPHO«4HC0o c u c oat *<“»«-H4JH ...

  • Page 564

    2??§S5SQ.*•SCr>DCdNO-llNfl 3SVQ O/I Olft6ÿuSC QSdNO-llNTl 3SV0 O/I 01nCM r>CMn MSn8P*piI ig Q»”! iC Ds|i iqaicIdD'SDd TOdlN03UNO indNI d3HQd OltdD-SOd TOdlNOOUNO indNI d3ÿ0d oi2d3-93d TOdlNOOllhtn indNI d3M0d01'CO O ftlX2*£*33fl.ai1< <Cuivxfta2uCMnMSMSrCMnOix= 88O. CMOSft5osc...

  • Page 565

    siIVVt it i<£s s|t?h £3£|£nI 1nyy ii i§0—I"LPI,*»i||SC Q-rÿ2dO3*Qwo0 KVd03avHSiiNn TOUINOO oisvQ oiico—!CtNO-03d TOdiNOOiHdNI dBAOd OiUNO1CipIiliHSiaaaceaa&ao**mu§iss m|||55gIfissigli1 iS 1iS—CMfc tnj© r* ©mSSoo33ooaoooacra cc ftaa ccaIs ICI!ICICICICIC§5ssFig.1.1 (u)I...

  • Page 566

    5eng12scI*ici1D I6Xno2 «L=«ÿ D-EST2 ? JdD-INO-63c TOdiN03irv**I «3A0d 01UNO) 3sn oaoisro eoj£5CDi002--sc Sc Sc ft ft3SpS£iiiiiiiii555sIflsllilpSSSSss3 S£nil??illgisill 5SS-tvro'*iinv0ÿoo(y>0~f'jK,',,in'c§!§ii§i§i§ii§!ii-S3S3S3222 2> >>i-i-i-™S'500,:'333333335ilssi5512!...

  • Page 567

    iI5 TJ£~~ss Zif F"aZs—SsSSa~-CluI!iIiiii?LIIIidSr 3TI|!!II1II??1iIs_I§£ 6ilpa 12;IPb|kEJiiITSI$I§B§Si|i|iS~5EI>?EilzdI535oHKTT1jI-1 aI1-SBS-JSs§II1?IiI|Es0til£<0§58?CM00CMsi|l§spus!I|I;_ii!lll!i£!ffiIIl=ISi“sisipliSiJliEl5i§FTz!511t?IsIzI5Zl ai5SS_1|III3Stil0s- KFig. 1.1...

  • Page 568

    IIzLiihi1Sts'nS11=1ai\ ii!iia?sj-hs J* 1“iii£5SISSHSi§5i*35"5SigII5ffl4igigllIQiQ IQi CJid= dIof!iill htimsii$**III||IiIujSB i5iisij>.ioI£Sffl544f didf P?cpiIEis8£i&s2Id- I!1 *?ix f*iiritillfc?8°S flÿ ?4g§£2o o ooosSis§fgI121s» fM'noa oi ®"CTIO-IOOO-TWit’88i.lIsill...

  • Page 569

    1.2 S-700I1§<rownWnplnl**s>-2S1 £i"Qgicur5iI £2%I3sa2HEI IIH1«siinMISiCMCM tVss£££I 5 g«£SooooinoIAOOOOIOOinooaoold-$ISS;SSKla?5SiSSlXSS?SiSgr*® 0*0—CMW *---CMCMCMlCM Ol19600606<SES0s 8r £Et—(\n«6<6r> « O'—————— —666666666666666<pisAhoI85335zU...

  • Page 570

    I <HIMCUTIOT«InlnnlnlrolwnTÿTnjS>-I 2gzPsour1Iissiiti*g!sI lIgIi;Uii £r sHa *Si *s1o o T Tn CMCMCMOOOOiflOiflOOOOÿOmoooooomono- CD>ÿ1/1000— 0>Mnocoo-o>o in in in •«-v •*»no iflifl ip+ ** noo—CMw*xin «o r*too—CMn •*—CMP*5 s.0 r-«eOO'—————— ——...

  • Page 571

    ss°gl222?3SJilln/-V=5i5I'll]]3ll y yi1-iIft!—-4—6—£Ii %5 §-I£UJC\JL/WVIV)i i3-c*iL2npiw<sis /\I i&g?®208|s§]S5 3=a<£el1e-“•—«—...I—I “t500:•Id)$§1§/T\S." s'5FT«P?rjX,-e-c8j?5?2inr12£ oI sS201MI III£ ®V)<uBii§oOJjoIhII!E 2<I 1«|ouu. <3£2...

  • Page 572

    si'fN2N22SUMi!588I”§2i laX ( *s •i=s-o5ooouas%s£££jagas32 ? Efcfegggyorcc or—3>»Y1i_l1o>s>C\k~§1Ofs+'ss ?iI Ios s%s s+'1 Isrx§_ii5£5ii5I+'HI"«3P‘„iHi'*rta.£*je>i•HoC*->3• Ito —i0) *H?0 XoON<0IJC. 3 05um(0ÿ0o <O M-i=5fc2*0K=r •cu>-:a<aiI...

  • Page 573

    i•TEACHPENDANTK570=7° 3A05B-205I-CH2BUILT-IN CRT/KBK526=7°0ÿ-0““ÿCD“ [ D-C>ÿK62A05B-205I-CIOIA05B-205 1 -C 102- RS-232-C (CHA )K57coiSHARED0IP04AI6B-I2I 1-0860RAMCONNECTION BOARDA20B-1003-004 IK56c °ÿ=0[?]-CDaH3K41_sLC Q-IFLOPPY CASSETTEAOAPTERhoPOWERINPUTUNITAI4B-0076-B322-B325...

  • Page 574

    TEACHPENDANTK57?A05B-205I -CI42OPERATOR'SPANELA05B-205I-CI22REMOTE CRT/KB6=7ÿ =1K706=7°K523LC QCN5CRT/XBOOPA1 3B-OI44-BOO IK62CD- RS-232-C(CHA)co*K57EDOiTPCONNECTIONBOARDA20B-1003-0040SHARE0IP04A 16B0 RAMZ!-1211 -0060Ira-1.i___»K56EOD cn2DEHRS-333-CCM>Ik)sLCCOP?IFLOPPY CASSETTE ADAPTERPOWER...

  • Page 575

    OPERATOR'S PANELCN3SHARED PAMBOAROPOWER SUPPLYUNITOACKPLANE14_TOBUILT-IN CRT /KBCRTCN547.4/KB23CNA_BI2.B 3CNOP47.46.49CNOP•Ml-CPI2Jll .ClCNPI[A I.81 .ClCNAOBI2.BI36.49TO REMOTE CRT/KB•24V1RS-232-CCN529TOFLOPPYCASSETTELEOS/SWITCHESC04POWERINPUT UNIT-ÿ6*24VR-VWCNTCN2.2.7CNPII.2.7PCP7CP 1 43_9-...

  • Page 576

    BACKPLANE iA?O0~1002-0860K50C*?7ooiop-o03o0M6OFTJr| OPUONÿ? |LiTJBAMERYAXTSCONTROLAXIS CONTROLIIA 160 •12M -006?AI6R- i? H0060CV?ICV33Cf>»»InnIn n n nPi nrinilCF9I -94CV?I-?4Pleasenote:PC/ovPWHOgggggggg ggg8Wi8IRPC/?OV~*OVnT«5v““tCOMU2COHAOn?CORAxis Control PCB 1 connectsin slot 0PT5...

  • Page 577

    1BACKPLANE <A208- l002-0ft60IJ'IJd'l?evilo<noa/oini3CHAjOIPO?OiPOtP*J>OlPO*vt>vtiPM 3/01POO04110CHAI 0CK*»CWIc«»»CHAICIO** 04*1CHAOWlCHA/I04*1CMSPICHAV*onnnnnn nnnnn nnn nPPvisiONÿrES*! |visioirENWÿeUuuuwuPOWERSUPPUYUNITA206- *000-0770OPTION iOPT IONOPTION IPATH CPUMAIN CSHARED ...

  • Page 578

    f'§cr5 %VVi i* ixX<<2 2|??S55SO« iT>>Z >0a—o UJo—uonl 3iI !lieii»’c2d0D-0VV09 HttC2a»KSUNO xdiNOO::5*soxi73T—I6)T1CINO •93d -Cfci>C0indNiOiQUNO555EIC1-ni'innsOf'io jujkuUJ88g88gg8§sEscscrccracSao-- -ill§ iri1 I *aifiSSisiÿaL_JI ?-t iir><c >ÿ ®oggilill...

  • Page 579

    55n!|c>—*I8I Co=Da i 2qCHw<icIND-93d TOdlNODindNia>oa oiiiNnCSXiI.) 3sn d3H0isro aoia5 C Q5CD— Oj ui—OJooa—jneÿcccc®30!CXI I•DOSSSSSSBSgSSScoaoaoaaarvcvcMaiaaaaaao-•g5iSlSS jjgj| —CMn«M«o!r*®o*-i—k-u-i—ÿ<>>>gggi|ggpg|°°°iiiiiiiiilililllss8888 882MDO...

  • Page 580

    Ii si I f~xJL~~~giil .2.a- 'is7!is*5Icc~“omoSg5-naillSfIIs |8-5=2!HI9#-sirasspgoo5IiiTtcutoCDCMIiIIhSgIiiiiiii§l|«k£1*1UsIIIII33sBgS5£IuIEIIiiii-1 ui“3-ailll!s sis1wg1IIIsIIf!aI3EO’Ilii!i%•CMCOCMSIsnHSSIHIE|ESfililliiiliSiSEsEuE'*SpL—o—IiL1pi?_III1iIi88igsii©a55IEIaESsIgg"8;...

  • Page 581

    I5: ySoLly!rV91I8?i8S;a82?.IL5=mRi.3§Imu*0l*im|=3T8SI !IsI|IP§ia555 5CCgIIII§=?oJoJo11tils 5®SI3=3=5X6XXXXXXCDCDJBCDCDCDCDCDCDCPCD'•so*3.1* ’•o«a>o1sOS’2II?I!I33133FLlIpff#??SIfS ?= T3« =2<iSfejflF1I•«§5?soI8|S§IU£J uufLCDCDCDJs-liIon8SS'!5".522*I*IS?:mS=;258OX<2...

  • Page 582

    1.3 Power InputUnit Connection Diagrama.3I&ui*.cnS.UJCrII!1il iicau<u n•-s !iS I5II-s§ feII22S8I&!5S“<s<§§as£5 8UZ—£XUJUJCE£o2xu.UJUIr-—1<III.r-•- iiIII1IIIi )i«JIIIIIIIIIIIIIlI»II11IIl..iil ftiiti!miiii6600066!1I I a i l jj !! I I I I £I 5 » 8s sS!i*S8||D,...

  • Page 583

    fig©>•eoo.u—rf?|—Ji—g—Loji"oI \~ -H.= uo<o11St it It i3!ocvwf M*§>“ 2gaAAAAQ JjJAft—nftto——WVCJrwcuCMDÿaaauuunnnftWtaaa& &&it•aaauuu&ug&fto•..2uu288.8§£*«OJii si-LXd—vwCMo-*CeiICMCMUHOÿ—*FIH"fi&ftc/iuu_i_JECM5 gu.u.E«ÿ...

  • Page 584

    < <O OOJCMII-uOJ»—I— *—DDDOOOO— UOJl-h-ZZZZ>Z>HHt-tl—<OOOOCDOOOO—CU-—22ZOO0022<S(JJUUJ— —— — U.U.gg'&ooOJoUJoaUJ5a.oUJ<si)iS0®®® |5|® B] ® ©®©AAo? scocOr-O''eyroipOJ7UUUuaaaa aggaaarotor-'r-__vOsOO'r r iX lo-£90 £aoocoOJT§ s<\LJ05c/ÿI...

  • Page 585

    IRL83_4_R 18(03C7)IOOAIBRGI3.3K I/2Wr-Ol--1L—W—ite-CX—JII*4II*VFUSE ALM ITST.. Die£ V06Cvv D7-1V06C1(03C7)IOOBImrOilIS955CNI -4•FALMCN I- I7BKRl IBKRITP I-12BKM I«'2SCRl IIS953•08RlRI2100<2SC12553.3K 5WlACM I- I8Ql255C 02coBKRI 2~SK4[ZPI5R2DI5F4(2A)R3I.5KV06C100S’©TPI-I IR 14BKP...

  • Page 586

    APPENDIX 2CABLESPECIFICATIONS1) S—10 controller (Medium size cabinet)CableRemarksSpecificationsNo.A660-8006-T915#LlR003CB- PIUPower inputK031AA660-8006-T922//L1R503(Breaker)(220/240 V)PIU- TF1K04A660-8006-T924//L1R003TF4- PIUK06A66O-8OO6-T9140L1ROO3CB- PIUPower inputK03IBA660-8006-T921#LlR503(B...

  • Page 587

    Cable specifications forS-10 medium sizecabinet (continued)CableSpecificationsRemarksNo.A660-8007-T047//L7R403Robot connectioncable (7m)K31AMP- MlA660-8007-T048//L7R403K32AMP- M2A660-2003-T308//L9R503BBK91IOU- D1A660-4002-T803#L8R003A01P05- PIK92A660-4002-T804#L8R003A01/02P05- P2K93A660-8006-T909...

  • Page 588

    Cable specifications forS-10 medium sizecabinet (continued)CableSpecificationsRemarksNo.A660-2002-T945#LlR003AI/O unitK48BP- IOUA660-2002-T949#L1R003BK49BP- IOUA66L-6001-0005#L2R00301P04- IOUK41A660-2003-T233#L500R0CK53IOU- PIUConnected by customer- CBAC power InputKOIExternal poweron/off- PIUK55...

  • Page 589

    2) S—10controller (Large size cabinet)CableRemarksSpecificationsNo.A660-8006-T915//L1R303K03Power inputCB- PIU1AA660-8006-T922//L2R503PIU- TFl(Breaker)(220/240 V)K04A660-8006-T924//L1R503TF4- PIUK06A660-8006-T914//L1R303K03CB- PIUPower inputIBA660-8006-T921//L2R503(Breaker)(380- 550 V)PIU- TFlK...

  • Page 590

    Cable specificationsforM-100 large sizecabinet (continued)CableSpecificationsRemarksNo.A660-8006-T928K19PIU- SVOServo-on relayA660-8006-T929#L3R703K20PIU- HMHour meterA660-8006-T804#L900R0K21TF1- AMPServo amp. connectionA660-8006-T727#LEK23PIU- AMPA660-2003-T230#LlR703KAK7101P05- AMP1A660-2003-T3...

  • Page 591

    Cable specifications forM-100 largesize cabinet (continued)CableSpecificationsRemarksNo.A660-8006-T659//L3R803Operator's panelK15OP- PIUA660-2003-T271#L2R503BK5201P04- OPA660-2003-T216//L2R503CK5601P04- PIUA660-2003-T331//L1R803K10Powersupply unitPIU- PSUA660-2002-T945//L1R303K46PIU- PSUA660-2002...

  • Page 592

    Operator's panelPower input unitPower supply unitServo-on relay unitServotransformerControl transformerInput transformerUsertransformerTeach pendantPath CPU boardShared RAMboardAxiscontrol board forAaxesAxiscontrol board for2 axesConnector on mechanical unitOPPIUPSUsvoTF1TF3TF4TF5TP01P0201P0401P0...

  • Page 593

    3)S-700 controllerCableRemarksSpecificationsNo.A660-8006-T915//L1R003K03CB- PIUPower input1AA66O-8OO6-T9220L3R3O3(Breaker)(220/240 V)PIU- TFlK04A660-8006-T924#LlR503TF4- PIUK06A660-8006-T9144L1R303K03CB- PIUPower inputIBA660-8006-T921//L3R303(Breaker)(380- 550 V)K04PIU- TFlA660-8006-T923//L1R503T...

  • Page 594

    Cable specifications forS-700 (continued)CableSpecificationsRemarksNo.A660-8006-T926#L250R3TF4- TF5K07AUsertransformerA660-8006-T925//L250R3TF4- TF5BA660-8006-T928K19Servo-on relayPIU- SVOA660-8006-T929#L3R703K20PIU- HMHourmeterA660-8006-T829#900ROK21TF1- AMPServo amp. connectionA660-8007-T141#Ll...

  • Page 595

    Cable specificationsfor S-700 (continued)CableSpecificationsRemarksNo.A660-8007-T144//L14R53Robot connection cable (14 m)AMP- MlK31A660-8007-T145#L14R53K32AMP- M2A660-2003-T308#L15R03AK91IOU- D1A660-4002-T803#L15R03AK9201P05-P1A660-4002-T804#Ll5R03AK9301P05- P2A660-8006-T910#L14R53K99GROUNDA660-2...

  • Page 596

    Cable specificationsfor S-700 (continued)CableRemarksSpecificationsNo.- svoConnected by customerServo-on outputK18AC power input- CBKOIExternalpower on/off- PIUK55- PIUK60FencePeripheral E-stop- PIUK16- 01P02Line trackingK61RS-232-C- OPK62Symbols used in thetableServo amplifierBattery unitBackpla...

  • Page 597

    APPENDIX 3PREVENTIVE MAINTENANCE SCHEDULE3.1 Preventive MaintenanceSchedulesRefer to the maintenancereplacement/adjustment sections for exactinformationpertaining to these procedures.350hours500hours1000hours2000hoursSpecialpurposeAsCheck itemsDailyrequired*Overallsystem*Greasingbearings*Greasing...

  • Page 598

    350hours500hours1000hours2000hoursSpecialpurposeAsCheck itemsDailyrequiredVoltage (DC)*Check**Batteries(RAM memory)ReplaceReplaceonce ayear6-54

  • Page 599

    3.2 Preventive Maintenance Check ListScheduleItemData checked (other than daily)Air control set:Air pressureOiler oilmistOiler oillevelHose leakageDailyCables(visual check)DailyVibrationDailyRepeatabilityDailyPeripheraldevicesDailyEach part(clean and check)DailyVentilationDailyLubricationMonthly(...

  • Page 600

    Data checked (other than daily)ScheduleItemBacklashSemi¬annually(2000 hrs)RAM backupbatteries(replacement)Annually(4000 hrs)20000 hrsCyclo drive(greasing)Cable(replacement)Biennially(8000 hrs)Timing belt(replacement)Biennially(8000 hrs)Harmonic drive(greasing)Every threemonths6-56

  • Page 601

    'I oOSYSTEM VARIABLEDESCRIPTIONSAPPENDIX 4SYSTEM VARIABLEALPHABETICALDESCRIPTIONSSystem variables are variables thatare declaredas part of theKARELsystem software. Permanently defined variablenames, which begin with adollar sign ($), identify systemvariables.Some system variables are robot specif...

  • Page 602

    SYSTEM VARIABLEDESCRIPTIONS$ACCLE_OVRDSystem Variable•“Program/KCL” showsaccess rights foruse inKAREL programsandfor allotheruses (KCL).•“Power Up” indicates whetheror not changes tothe value takeeffect only atpower up.•“Saved” indicates whetheror not the valueis saved by theKCL...

  • Page 603

    SYSTEMVARIABLEDESCRIPTIONS$ACCEL_TIME1 SystemVariable$ACCEL_TIME1(acceleration time 1)Data Type:INTEGERARRAY[9]Minimum/Maximum:1/2560*Program/KCL: No/PWDefault:320Power Up:YesSaved:YesBackedUp:No$ACCEL_TIME1is anarray oftimes,oneper axis, for thefirst stage ofthe second orderacceleration/decelera...

  • Page 604

    SYSTEM VARIABLEDESCRIPTIONSSACCURACYNUM System Variable$ACCURACYNUM determines whichlocal accuracy areawill be usedfor subsequentmotion (optional feature). The local accuracy area must have beendefined and setby theGMFACCUSIGHT High AccuracyOption Package. This option is currentlysupportedonly by...

  • Page 605

    SYSTEM VARIABLEDESCRIPTIONSSAFRAMENUM2 SystemVariable$ALL_SYSVARSis accessedusing the Non-Positional Data screen on theCRT and theteach pendant to determine whether a partial or complete listof available system variablesis displayed. If $ALL_SYSVARSisFALSE only commonly used system variablesaredi...

  • Page 606

    SYSTEM VARIABLEDESCRIPTIONSSAPPROACHTOL System Variable$APPROACHTOL (approach vectortolerance)DataType: REALProgram/KCL: RW/RWDefault:0.0003046096 (1 degree)Power Up:NoSaved:YesBackedUp: NoSAPPROACHTOL is used when comparing the z-axis(approach vector) oftwopositions.SAPPROACHTOL, along withSLOCT...

  • Page 607

    SYSTEMVARIABLEDESCRIPTIONS$ARM_TYPESystem VariableSATPERCH returnsTRUE if the robot is at the specified perch position. The variablewill returnFALSE if the robot is notatthe perch position.See Also:$PERCH andSPERCHTOL system variables formore information onsettingtheperchposition.$AUXEXTREME1 (au...

  • Page 608

    SYSTEM VARIABLEDESCRIPTIONSSAUXHOME System VariableYou caninclude aKCL> MOVETO $AUXHOME command in thepredefined commandfile KCP_HOME.CF, which is executed by the UOPHOME signal. This commandmovestheauxiliary axes totheir homeposition.You can assign a value thatdefines a homeposition for auxil...

  • Page 609

    SYSTEM VARIABLEDESCRIPTIONSSAXISORDER System Variable$AXISORDER (axisorder)Data Type:INTEGER ARRAY[12]Minimum/Maximum:0/9Program/KCL: NO/PWDefault: Robot SpecificPower Up: YesSaved:YesBackedUp:NoSAXISORDER isa mapping array from softwareaxis index toservo hardwareregisters.Itindicates whichaxis i...

  • Page 610

    SYSTEM VARIABLEDESCRIPTIONS$BRK_ON_HOLDSystem Variable$BRK_ON_HOLD(brake on hold)Power Up: YesBacked Up: NoData Type: BOOLEANProgram/KCL: NO/PWDefault: TRUEIf $BRK_ON_HOLD is enabled, all holds generated by thehardware(by pressing theHOLD buttonon the operatorpanel or UOPor by pressing theHOLD/ST...

  • Page 611

    SYSTEM VARIABLEDESCRIPTIONS$BRK_OUT_ENBSystem VariableBy default,the value of $BRK_OUT_ENB is settoFALSE. $BRK_OUT_ENBis also setto FALSE whenan emergency stop,overtravel condition,or DEADMAN switcherroroccurs.$CAL (calibrated)Data Type:BOOLEANProgram/KCL: NO/PWPower Up: NoSaved: NoBackedUp: NoDe...

  • Page 612

    SYSTEM VARIABLEDESCRIPTIONSSCALVELHIGH SystemVariable$CALVELH1GH (calibration velocityhigh)Data Type:REAL ARRAY[9]Program/KCL: NO/RWDefault: Robot SpecificPower Up:NoSaved: YesBackedUp: YesSCALVELHIGH indicates thedog-search approach speed for eachaxis duringcalibrationofrobots with incremental e...

  • Page 613

    SYSTEM VARIABLE DESCRIPTIONS$CART_ACCEL1 System VariableThe valueof $CART_ACCEL1 is set by theKCL>UTILITY SINIT command andshouldnot be changed forrobot axes. For auxiliaryaxes, you are responsible for settingthis variable using the Motion Hardware Setup Program.*The maximum valuefor $CART_ACC...

  • Page 614

    SYSTEM VARIABLEDESCRIPTIONSSCHECKCONFIG SystemVariableSCHECKCONFIG (check configuration)Data Type:BOOLEANProgram/KCL: RW/RWPower Up:NoSaved:YesBacked Up: NoDefault: FALSESCHECKCONFIG is used to determine if theposition configurations should be compared.SCHECKCONFIG. along with SAPPROACHTOL, SLOCT...

  • Page 615

    SYSTEM VARIABLE DESCRIPTIONS$CMRSystem Variable$CMR defines command multiplierratios, one peraxis. Thevalues of$CMR and$DMRare usedas follows:OMRmotorEVRMotoroutEncoderEncoderDetectedDMRPulsesPulsesTheproduct ofcommanded pulses multiplied by$CMR is compared with the detectedpulses todrive theerro...

  • Page 616

    SYSTEM VARIABLE DESCRIPTIONSSCOARSETOL System Variable$COARSETOL (coarse tolerance)Data Type:INTEGER ARRAY[9]Minimum/Maximum: 0/32767Program/KCL: NO/RWDefault:300Power Up:NoSaved: YesBackedUp: NoSCOARSETOL is anarray of in-position tolerances used to determine whenthe robot is inposition whenSTER...

  • Page 617

    SYSTEMVARIABLEDESCRIPTIONS$CONFIG_MASKSystem Variable$CONFIG_MASK(configurationmask)Data Type:INTEGERProgram/KCL: RO/PWDefault: RobotSpecificPower Up:NoSaved: YesBackedUp:No$CONFIG_MASK indicates which configuration bitsare tested in thesolution programs.The valuedependson robot type. $CONFIG_MAS...

  • Page 618

    SYSTEM VARIABLEDESCRIPTIONS$CONFIG_MASK SystemVariableThelabels in the bit masks have the followingmeanings:LABELj MEANINGnoflip_flip|1 1 :no noflip_flip ocnfiguration! 0 : has noflip_flip configurationlright_Icft1 :no rightjeft configuration_0 : has rightjeftconfigurationup_down] 1 :no up_downco...

  • Page 619

    SYSTEM VARIABLEDESCRIPTIONS$CONTAXISVEL System Variable$CONTAXISVEL (continuous axis velocity)Data Type: REALProgram/KCL: RW/ROPowerUp:NoSaved:NoBackedUp: YesDefault: 0.0SCONTAXISVEL indicates the velocity ofcontinuous turnmotion, including bothmagnitude anddirection.SCONTAXISVEL can havevalues b...

  • Page 620

    SYSTEM VARIABLEDESCRIPTIONS$CUR_PRFRAMESystem Variable$CYCLE_STRT(cycle start)Saved: YesBackedUp: YesDefault: ‘ ’(blank)Data Type:STRINGProgram/KCL: NO/RWPower Up: No$CYCLE_STRTspecifies theKCL command procedure thatis executed when theoperator panelCYCLE START button is pressed. If thecomman...

  • Page 621

    SYSTEMVARIABLEDESCRIPTIONS$C_STOP_ENBL System Variable$DDCMP_PARAM(DDCMPparameter)Data Type:INTEGER ARRAY[2]Program/KCL: NO/PWPowerUp:NoSaved:YesBackedUp: No$DDCMP_PARAM is an ARRAY whichspecifies theDDCMP communicationsparameters. Thearray elementsrepresent the followingparameters:•$DDCMP_PARA...

  • Page 622

    SYSTEM VARIABLEDESCRIPTIONS$DELTAFRAME System VariableSDELTAFRAME (delta frame)DataType: POSITIONProgram/KCL: RW/RODefault: $NILPPower Up: NoSaved:NoBackedUp:NoSDELTAFRAME represents the positional dataneededto integrate the robotmotion withan external sensor. The value ofSDELTAFRAME is used topr...

  • Page 623

    SYSTEMVARIABLEDESCRIPTIONSSDELTATOOL System VariableSPELTATOOLCoordinate SystemSTTOOLNUMToollocationlocation+orientationdisabledlocation+ orientationlocation -1location+ orientationlocation—3location+ orientation1Tool200Path RelativeFramePathRelative FramePath RelativeFrame-2PathRelativeFramePa...

  • Page 624

    SYSTEM VARIABLE DESCRIPTIONS$DMRSystem Variable$DMR (detector multiplier ratio)Data Type:INTEGER ARRAY[9]Minimum/Maximum: 0/7Program/KCL: NO/PWDefault: RobotSpecificPowerUp: YesSaved: YesBackedUp: No$DMR multiplies encoder pulses toproduce detected pulses. $DMR isencoded asfollows:1 : 1.05 :3.0Th...

  • Page 625

    SYSTEM VARIABLEDESCRIPTIONS$DRY_RUNSystemVariable$DRY_RUN(dryrun)Saved: NoBackedUp: NoDefault:FALSEData Type:BOOLEANProgram/KCL: NO/ROPower Up:No$DRY_RUNindicates whetheror not aprogram is beingrun withservo power off and therobot locked.The valueof $DRY_RUN is set andcleared automatically when t...

  • Page 626

    SYSTEM VARIABLEDESCRIPTIONSSENCOFFSTS SystemVariable$ENBL_OVRDisprogram accessibleso thatKAREL program-driven “teachingprograms” can permitan operator tochange the override while the teachingprogram isrunning.$ENCOFFSTS (encoder offsets)Data Type:INTEGER ARRAY[9]Program/KCL: NO/PWPower Up: Ye...

  • Page 627

    SYSTEMVARIABLEDESCRIPTIONSSFINETOL SystemVariable$FINETOL (fine tolerance)Data Type:INTEGER ARRAY[9]Minimum/Maximum:0/32767Program/KCL:NO/RWDefault:RobotSpecificPower Up:NoSaved: YesBackedUp:No$FINETOL isan array ofin-position tolerancesused todetermine when therobot is inposition when$TERMTYPE= ...

  • Page 628

    SYSTEM VARIABLE DESCRIPTIONS$GAINS System Variable$GAINS (gains)Data Type:INTEGER ARRAY [9]Minimum/Maximum: 1/50Program/KCL: NO/PWDefault:20Power Up: YesSaved: YesBackedUp: No$GAINS definesan array ofgains of theservo system.Thevalue of $GAINS is setby theKCL> UTILITY SINIT commandand should n...

  • Page 629

    SYSTEM VARIABLEDESCRIPTIONS$GRIDSystem Variable$GRIDisencoded as follows:gridsize= ($GRID+ 1) * 1000$GRID= 7 : grid size= 8000$GRID= 3: grid size= 4000C$GRID= 6or 8 isan invalid value.)Formula:Example :The valueofSGRID isset by theKCL> UTILITY SINIT command and shouldnot bechanged.For auxiliar...

  • Page 630

    SYSTEM VARIABLEDESCRIPTIONSSHOME System Variable$HOME (home position)DataType: POSITIONProgram/KCL: RW/PWPowerUp:NoSaved: YesBackedUp: YesDefault:UninitializedSHOME isa user-definable homeposition for the robot. Activating theUOP HOMEsignalmoves the robotto thisposition unless a predefinedcommand...

  • Page 631

    SYSTEM VARIABLEDESCRIPTIONS$INC_OFFSETSystem VariableThe value of $INC_OFFSET is determined automatically by themastering procedure. It isthe positive or negative difference in radians (or millimeters inprismatic joints) betweentheone-revolution index pulse and the actualcalibration position for ...

  • Page 632

    SYSTEM VARIABLEDESCRIPTIONS$INTP_STATUS System Variable$INTP_STATUS indicates the current status of theprogram interpreter using thefollowingvalues:—1 = running0= paused+1= aborted$INTP_STATUS is setand updated automatically.$IN_USERMENU(inusermenu)DataType:BOOLEANProgram/KCL: RO/ROPower Up:NoS...

  • Page 633

    SYSTEM VARIABLEDESCRIPTIONSSJNTCALSEQSystem VariableThe valueof SJNTCALSEQ is set bytheKCL>UTILITY SINIT command andshouldnot bechanged. Forauxiliary axes, you are responsible forsetting the value ofSJNTCALSEQ to correctly define thecalibrationsequences using the Motion HardwareSetup Program.$...

  • Page 634

    SYSTEM VARIABLEDESCRIPTIONSSJOGFRAME System VariableSJOGFRAME is usedas the frameof reference for joggingwhen“JOGFRAME” isselected on theteachpendant. For most cases, it is convenientto setit to thesame valueasSUFRAME. It will allowyou tojog therobot along thex,y,z direction defined bySUFRAME...

  • Page 635

    SYSTEM VARIABLEDESCRIPTIONSSJOGLOCK SystemVariableSee Also:SJOGLOCK.EN System VariableEnhancedKAREL Operations Manualformore informationon joggingandteaching.$JOGLOCK_EN (jog lockenable) *Data Type: BOOLEANProgram/KCL: NO/RWPower Up:NoSaved: YesBackedUp: NoDefault:FALSESJOGLOCK, together with $JO...

  • Page 636

    SYSTEM VARIABLE DESCRIPTIONS$JOG_COORD System Variable$JOG_COORD indicates the currently selected jog coordinate system for theteachpendant,using thefollowing values:0= JOINT1= JOGFRAME2= WORLDFRAME3= TOOLFRAME4= AUX AXIS$JOG_COORD isautomatically set by the teachpendantCOORD key on the teachpend...

  • Page 637

    SYSTEM VARIABLEDESCRIPTIONS$KL_USERSTAT System VariableSee Also:Enhanced KAREL Operations Manualformore informationon CRT/KB screens.$KNCP_PARAM(KNCP parameter)DataType:INTEGER ARRAY[8]Program/KCL: NO/PWPowerUp: NoSaved: YesBackedUp: No$KNCP_PARAMisanarray which specifiesNCP communications parame...

  • Page 638

    SYSTEM VARIABLE DESCRIPTIONS$LINK_LEN_1System Variable$LINK_LEN_1 (link length 1)Data Type:REALProgram/KCL: NO/PWDefault: Robot SpecificPower Up:NoSaved:YesBackedUp: No$LINK_LEN_1 hasa meaning thatis robot specific. It is intended primarily to supportmultiple versions of a given robot model,where...

  • Page 639

    SYSTEM VARIABLE DESCRIPTIONS$LOCK_KLMENUSystem Variable$LOCK_KLMENU(lock KARELmenu) *Data Type:BOOLEANProgram/KCL: RW/PWDefault:FALSEPower Up:NoBackedUp: YesSaved: No$LOCK_KLMENUprovides KAREL programs with theability to lock any KARELscreenor menu displayedon theCRT whileaprogram is running. Whe...

  • Page 640

    SYSTEM VARIABLEDESCRIPTIONSSLOCTOL System Variable$LOCTOL is usedwhen comparing the location vector of twopositions.SLOCTOL, alongwithSAPPROACHTOL, SORIENTTOL, andSCHECKCONFIG is used in conjunctionwith the relational operator“>=<” tocompare twopositions.IfSLOCTOL is negative, no compar...

  • Page 641

    SYSTEM VARIABLEDESCRIPTIONS$M1_FNAMESystemVariable$M1_FNAME(MAPI foreign nodename)DataType:STRING[64]Program/KCL: RW/PWPower Up:NoSaved: YesBackedUp: Yes$M1_FNAME specifies the port name ofthe foreign applicationprocess titleto which theKAREL controller is to be connected when requesting an assoc...

  • Page 642

    SYSTEM VARIABLE DESCRIPTIONS$MAP_PARAMSystemVariable$MAP_PARAM(MAP parameter)DataType:INTEGER ARRAY [8]Program/KCL: NO/PWPower Up: NoSaved: YesBackedUp: NoSMAP_PARAM isan array thatspecifies MAP communications parameters. Thearrayelementsrepresent thefollowing parameters:•$MAP_PARAM[1] is the d...

  • Page 643

    SYSTEM VARIABLEDESCRIPTIONS$MASTER_POS SystemVariable$MASTER_POS(master position)DataType: REAL ARRAY[9]Program/KCL: NO/PWDefault:Robot SpecificSaved: YesBackedUp:No$MASTER_POS defines the mastering position of the robot asdetermined by themasteringfixture.The value of $MASTER_POSis in radiansfor...

  • Page 644

    SYSTEM VARIABLE DESCRIPTIONS$MIN_ACCTIMESystem Variable$MIN_ACCTIME defines the minimumacceleration/deceleration time in millisecondswhile theshort motion speed up algorithm is used.It is thesum of the first andsecondstages.The valueof $MIN_ACCTIME is setby the KCL>UTILITY SINIT command andsho...

  • Page 645

    SYSTEM VARIABLEDESCRIPTIONSSMOSIGN SystemVariable$MOSIGN defines the direction of axis motorrotation foreach axis duringcalibration ofrobots with absolute encoders.Thevalue ofSMOSIGN is setby theKCL>UTILITY SINIT command and should notbe changed for robot axes.For auxiliary axes,you are respon...

  • Page 646

    SYSTEM VARIABLE DESCRIPTIONSSMOVEDIST System VariableSMOVEDIST indicates theCartesian distance the robot hastraveled since thebeginning ofthe currentinterval. It is only valid forCartesianmoves. Joint interpolated segmentsaretreatedas zero length segments.The valueof $MOVEDIST is automatically se...

  • Page 647

    SYSTEM VARIABLEDESCRIPTIONS$MSTUSE_STRT System Variable$MSTUSE_STRT indicates whetheror not theSTART buttonon theteach pendant mustbe held down in orderfor aprogram to continue running during a test run. If it isTRUE,theprogram continues to run only as long as theSTART button is held down. If it ...

  • Page 648

    SYSTEM VARIABLE DESCRIPTIONS$NUM_AUX_AXSSystem VariableThe sum of the values of $NUM_AUX_AXS and $NUM_ROB_AXScannotexceednine.The value will be adjusted atpower up and themessage “2132 $NUM_AUX_AXSadjusted to n” willappear if thesum of the two variablesis greater than nine. The newvalue of $N...

  • Page 649

    SYSTEM VARIABLEDESCRIPTIONS$ORIENT_TYPESystem Variable$ORIENT_TYPE(orientation type)Data Type:INTEGERMinimum/Maximum: 1/3Program/KCL: RW/RWDefault: 1(RSWORLD)Power Up:NoSaved:NoBackedUp: Yes$ORIENT_TYPE indicates thetype oforientation controlto be used when $MOTYPE issetto LINEAR motion. The foll...

  • Page 650

    SYSTEM VARIABLE DESCRIPTIONS$OT_MINUS SystemVariable$OT_MINUS(overtravelminus)Data Type:BOOLEAN ARRAY [9]Program/KCL: NO/PWPower Up:NoSaved:NoBackedUp: NoDefault: FALSE$OT_MINUSis an array with each elementrepresenting theovertravelcondition for therespective axis. Ifan element is set TRUE, theco...

  • Page 651

    SYSTEMVARIABLEDESCRIPTIONS$PATH_NODESystem Variable$PATH_NODEindicates thepath nodeto which the robot is movingor has most recentlymoved.Afteran error, KAREL programs cantest to determine the node toward which the robot isor was most recentlymoving when theerror occurred.For emergency stopsor err...

  • Page 652

    SYSTEMVARIABLE DESCRIPTIONS$PERCH System Variable$PERCH (perch)DataType:ARRAY[9] ofREALProgram/KCL: No/RWBackedUp:No$PERCH is used to setthe perch position. TheSATPERCH system variablecan be usedtodetermine if the currentposition of the robot is thesame position as specified by$PERCH.For robot ax...

  • Page 653

    SYSTEM VARIABLEDESCRIPTIONS$PPABN_ENABLSystem Variable$PPABN_ENABLindicates whetheror notdigital input thatindicates abnormal pneumaticpressure is enabled.If itis TRUE, sensing of lowline-pressureinput on the robot controlmodule (for systems withmodular I/O)or thefixedI/O board is enabled.See Als...

  • Page 654

    SYSTEM VARIABLEDESCRIPTIONS$PRIORITYCondition Handier Qualifier$PRIORITYis usedto specify the priority ofexecution for the indicated routine. Aninterrupt routine with a lowpriority will notbe executed until control is returned to theprogram from a higher-priority routine. Therefore, the actual pr...

  • Page 655

    SYSTEM VARIABLE DESCRIPTIONS$PTH_MODELSystemVariable$PTH_MODEL(path model)Data Type:STRINGProgram/KCL: NO/RODefault: Robot SpecificPower Up: NoSaved:NoBackedUp: No$PTH_MODEL defines therobot model identifier. The valueof $PTH_MODEL matchesthe valueof $MODEL_ID andis setandused internally. It cann...

  • Page 656

    )SYSTEM VARIABLEDESCRIPTIONS$PWR_NORMALSystem Variable$PWR_NORMAL(power normal)DataType: STRINGProgram/KCL: NO/RWPowerUp: YesSaved:YesBackedUp: NoDefault: ‘ ’ (blank)$PWR_NORMAL specifies the name oftheKCL command file thatis executed if thesystem isnot in a recoverablestate atpower up andthe...

  • Page 657

    SYSTEM VARIABLE DESCRIPTIONS$REMOTE System Variable$REMOTE indicates theoperator panel REMOTE keyswitch setting.It isTRUE whenthe key isset toON anda remote device has motion control. It isFALSE whenthe key isset toOFF and theoperator panel has motion control.The valueofSREMOTE is set andupdated ...

  • Page 658

    SYSTEM VARIABLEDESCRIPTIONS$ROTSPEED System VariableBy default, the value ofSROTSPEED is set to an uninitialized value each timea program isexecuted. If you do notassign a value toSROTSPEED in theprogram and the speedofthe programmed motion is higher thanthe value of SROTSPEEDLIM, the warningmess...

  • Page 659

    SYSTEM VARIABLE DESCRIPTIONS$SCAN_TIME Condition Handler Qualifier$SCAN_TIME is used to specify the time in milliseconds betweenscans in aconditionhandler.The syntax for $SCAN_TIME= time_in_ms where time_in_ms is anINTEGERexpression.Actual time_in_ms values will beone of the following: 1, 2, 4,8,...

  • Page 660

    SYSTEM _SSEGFRACTION SystemVariableVARIABLE DESCRIPTIONSSSEGFRACTION indicates whatfraction of thecurrent segment has beeninterpolated.For example:0.0means interpolation is justbeginning.0.5 means interpolation is half done.1.0means interpolation is complete, and robot is starting to decelerateto...

  • Page 661

    SYSTEM VARIABLE DESCRIPTIONSSSEGTERMTYPE SystemVariable$SEG_TIN!E (segmenttime)Data Type:INTEGERProgram/KCL: RW/ROPower Up:NoSaved: NoBackedUp: YesDefault: 0$SEG_TIME indicates thetime required fora motion segment.By specifying a valuefor$SEG_TIME,youare specifying thetime it will taketo complete...

  • Page 662

    SYSTEM VARIABLEDESCRIPTIONS$SPEED SystemVariable$SPEED is theTCP translation speed of the programmed motions,expressed in mm/sec. Itis used to calculate the speed ofsill programmedmotion.*By default, the valueof$SPEED isset to the product ofSMANLIM/100 multiplied by$SPEEDLIM each time aprogram is...

  • Page 663

    SYSTEM VARIABLEDESCRIPTIONSSSPINSPEED SystemVariableSSPINSPEED controls howfast the robot is allowed to spin about the tool centerpoint(TCP) approach vector forprogrammed Cartesian motion(linear, circular). The valueisexpressed in radiansper second.By default, the value ofSSPINSPEED issetto an un...

  • Page 664

    SYSTEM VARIABLEDESCRIPTIONSSSRVOJ3LOCK4 System Variable$SRVO_BLOCK4Reserved forGMF internaluse only.$SRVO_BLOCK5 Reserved forGMF internaluse only.$SRVO_BLOCK6 Reserved forGMF internaluse only.$SRV_CODE_ID(servo codeidentification)Data Tvpe:STRINGProgram/KCL: NO/RODefault: Robot SpecificPowerUp: N...

  • Page 665

    SYSTEM VARIABLEDESCRIPTIONS$STOP_ON_ERRSystem Variable$STOP_ON_ERR (stop on error)DataType: BOOLEANProgram/KCL: NO/RWPower Up:NoSaved:YesBackedUp: NoDefault: FALSE$STOP_ON_ERR indicates whetheror not the systemstopsonaKCL command fileerror.IfTRUE, execution of the command procedure stops if anyer...

  • Page 666

    SYSTEM VARIABLEDESCRIPTIONS$SV_OFF_TIMESystemVariableSee Also:$SV_OFF_ENB SystemVariable in this appendix$SYNC_GAIN(synchronous compensationgain)Data Type: INTEGERMinimum/Maximum: 0/127Program/KCL: NO/PWDefault: 20Power Up: YesSaved: YesBacked Up:No$SYNC_GAINdefines thecompensation gain forrobot ...

  • Page 667

    SYSTEM VARIABLEDESCRIPTIONS$SYNC_S_AXIS System Variable$SYNC_S_AXIS(synchronous slave axis)Data Type: INTEGERMinimum/Maximum: 0/9Program/KCL: NO/PWDefault: 0Power Up: NoSaved: YesBacked Up:No$SYNC_S_AXIS indicates which robot axis motor has been designated as the slaveaxis forrobot modelswith dua...

  • Page 668

    SYSTEM VARIABLEDESCRIPTIONS$SYN_ERR_CNTSystem Variable$SYN_ERR_CNT(synchronouserror counter)DataType: INTEGERProgram/KCL: NO/ROPowerUp: NoSaved:NoBacked Up:NoDefault: 0$SYN_ERR_CNT is the value oftheerror counterfor robot models with dual drive(synchronous) control.$SYN_ERR_LIM(synchronouserror l...

  • Page 669

    SYSTEM VARIABLE DESCRIPTIONSSTERMTYPE System Variable$TERMTYPE (motion terminationtype)DataType: INTEGERMinimum/Maximum: 1/5Program/KCL: RW/RWDefault: 2(COARSE)Power Up:NoSaved:NoBackedUp: YesSTERMTYPE defines thetype of motiontermination atthe endof an interval using thefollowing values:1= FINE2...

  • Page 670

    SYSTEM VARIABLEDESCRIPTIONS$TP_USERSTAT SystemVariable$TP_USERSTAT(teach pendantuser status line)Saved:NoBackedUp:YesDefault: FALSEData Type: BOOLEANProgram/KCL: RW/ROPower Up:No$TP_USERSTATindicates whether theKAREL systemor theapplication program hascontrol ofthe teach pendant statusline.If $TP...

  • Page 671

    SYSTEM VARIABLE DESCRIPTIONSSTSPEED System VariableThe valueof $TSPEED is setby theinterpolator at theCartesian update rate for thecurrentsegment.The estimate is passed through theacceleration/deceleration algorithm,soit will have approximately thesame acceleration/deceleration profile as thejoin...

  • Page 672

    SYSTEM VARIABLE DESCRIPTIONSSTTOOLNUM System Variable$TTOOLNUM (tracking tool frame number)Data Type:INTEGERMinimum/Maximum: —4/2Program/KCL: RW/RODefault: 0Power Up: NoSaved:NoBackedUp:YesSTTOOLNUM is used toindicate howSDELTATOOL is tobeapplied. Its valuedetermines whetherSDELTATOOL will be w...

  • Page 673

    SYSTEM VARIABLE DESCRIPTIONSSUFRAME System Variable$UFRAME (user frame)PowerUp: NoSaved: YesBackedUp:YesData Type: POSITIONProgram/KCL: RW/RWDefault: $NILPSUFRAME is the position of a user frameof reference.All programmed positions aredefined with respect toSUFRAME.Any valueyou assign toSUFRAME i...

  • Page 674

    SYSTEMVARIABLE DESCRIPTIONSSUSAT System Variable$USAT (user signal assignmenttable)DataType: INTEGER ARRAY [98]Program/KCL: NO/PWPower Up: YesSaved: YesBackedUp: NoDefault: 0SUSAT isanarray that corresponds tothe User Signal Assignment Table (USAT).You are responsiblefor setting the valueofSUSAT ...

  • Page 675

    SYSTEM VARIABLE DESCRIPTIONS$USE_CONFIG SystemVariable$USE_CONFIG(use configuration)Data Type: BOOLEANProgram/KCL: RW/RWPowerUp:NoSaved: NoBackedUp: YesDefault:FALSE$USE_CONFIG indicates how the system handlesCartesian moves where theconfigurationisinconsistent fromone position tothe next.For exa...

  • Page 676

    SYSTEM VARIABLEDESCRIPTIONS$USERELACCEL System Variable$USERELACCEL (use relative acceleration)DataType: BOOLEANSaved:Program/KCL:Power Up:Default:BackedUp:IfSUSERELACCEL is True, the desired motion willuse the $ACCEL_OVRD andRELACCEL values (optional feature). If $USERELACCEL is False, theaccele...

  • Page 677

    SYSTEM VARIABLEDESCRIPTIONS$USER_PB1SystemVariable$USER_PB1(user pushbutton 1) *DataType:STRING[12]Program/KCL: RO/RWPower Up:NoSaved:YesBackedUp:NoDefault:‘ ’ (blank)$USER_PB1specifies theKCL command procedure thatis executed whenthe operatorpanelUSER PB1button is pressed.If the command proc...

  • Page 678

    SYSTEM VARIABLEDESCRIPTIONS$UTOOLSystem Variable$UTOOL defines the location andorientation of thetool that is attachedto the faceplate.The position in $UTOOL is definedwith respect toa fixed coordinate systemon therobotfaceplate and is the origin of theTOOL FRAME.By default, the value of $UTOOL i...

  • Page 679

    SYSTEM VARIABLEDESCRIPTIONSS-10 SYSTEM VARIABLEDEFAULTVALUES4.2S-10 System Variable Default ValuesTable4.2.S-10 System Variable Default ValuesS-10DefaultValueNotes$ACCEL_TIMEirn352$ACCEL_TIME1|21352SACCEL_TIMElf31352SACCEL_TIMElf41352$ACCEL_TIME1[51352$ACCEL_TIME1[61352SACCEL_TIME2fll32Payload1.0...

  • Page 680

    SYSTEM VARIABLEDESCRIPTIONSS-10 SYSTEM VARIABLE DEFAULT VALUESTable 4.2.S-10 SystemVariable Default Values(Continued)S-10DefaultValueNotes$CMRf511Command multiplier ratio$CMR[61Command multiplierratio1SCOARSETOLM300Detector pulses$COARSETOLf2]300Detector pulses$COARSETOLf31300Detector pulsesSCOAR...

  • Page 681

    SYSTEM VARIABLEDESCRIPTIONSS-10SYSTEM VARIABLE DEFAULTVALUESTable4.2.S-10 System Variable Default Values (Continued)NotesS-10DefaultValueSFINETOLKl150Detector pulses$FINETOL[51150Detector pulses$FINETOLf61150Detector pulsesSGAINSfll20SGAINS12120$GAINSf3120$GAINS[4120$GAINSf5120$GAINS[6]20SGRIDfll...

  • Page 682

    SYSTEM VARIABLEDESCRIPTIONSS-10SYSTEM VARIABLEDEFAULT VALUESTable 4.2.S-10 System Variable Default Values (Continued)S-10DefaultValueNotes$MASTER_POSf410.00 deg$MASTER_POS[51-0.959931088-55 deg$MASTER_POSr6]0.00 deg$MIN_ACCTIMErn160$MIN_ACCTIMEf21160$MIN_ACCTIMEf31160$MIN_ACCTIMEf4l160$MIN_ACCTIM...

  • Page 683

    SYSTEM VARIABLEDESCRIPTIONSS-10 SYSTEM VARIABLE DEFAULTVALUESTable4.2.S-10 System Variable Default Values(Continued)S-10DefaultValueNotes$STOPERLIMf31500Detector pulsesSSTOPERLIMf 4]500Detector pulsesSSTOPERLIMfol500Detector pulses$STOPERLIMf6l500Detector pulses$SV_OFF_ENBfllFALSE$SV_OFF_ENBf2lFA...

  • Page 684

    SYSTEM VARIABLEDESCRIPTIONSS-10 SYSTEMVARIABLE DEFAULT VALUESFormulafor computing axis 1 range and joint velocity limit:Let abe the mounting angle withrespect to the horizontal,andV2= sqrt(2).For 0 deg<= a<= 45 deg and135 deg<= a<= 180 degUPPERLIMS= 150 degLOWERLIMS= -150 degJNTVELLIM...

  • Page 685

    SYSTEM VARIABLEDESCRIPTIONSS-10 SYSTEM VARIABLE DEFAULTVALUESFinally,convert degreesinto radians$UPPERLIMS[1]= UPPERLIMS * IT/180 rad$LOWERLIMS[1]= LOWERLIMS * IT/180 rad$JNTVELLIM[1]= JNTVELLIM * IT/ 180rad/secwhere IT= 3.141592654Formula for computing $ACCEL_TIME2 forAxis 1 to 6:Forno load :$AC...

  • Page 686

    SYSTEM VARIABLEDESCRIPTIONSS-700 SYSTEM VARIABLEDEFAULT VALUES4.3S-700 System Variable Default ValuesTable4.3.S-700 SystemVariable Default ValuesS-700DefaultValueNotes$ACCEL_TIMEiril384$ACCEL_TIMElf21384$ACCEL_TIME1[31384$ACCEL_TIME1f41288$ACCEL_TIMElf51288$ACCEL_TIMElf61288$ACCEL_TIME2f1]192$ACC...

  • Page 687

    SYSTEM VARIABLEDESCRIPTIONSS-700SYSTEM VARIABLEDEFAULT VALUESTable4.3.S-700 SystemVariable Default Values (Continued)S-700DefaultValueNotes$COARSETOL[6]300Detector pulses$CONFIG_MASK*-1216011010000 10000000SDMRfl]Detector multiplier ratio= 47$DMRf2]7Detector multiplier ratio= 4$DMRf3l7Detector mu...

  • Page 688

    SYSTEM VARIABLEDESCRIPTIONSS-700SYSTEM VARIABLE DEFAULT VALUESTable 4.3.S-700 System Variable Default Values(Continued)S-700DefaultValueNotes$GAINSf4120$GAINSr5120$GAINSr6120SGRIDrnmeans8000 pulses/rev7$GRIDf2lmeans8000 pulses/rev7SGRIDplmeans8000 pulses/rev7$GRIDf4lmeans8000 pulses/rev7$GRID[517...

  • Page 689

    SYSTEM VARIABLEDESCRIPTIONSS-700 SYSTEM VARIABLEDEFAULT VALUESTable4.3.S-700 System Variable Default Values(Continued)S-700DefaultValueNotes$MIN_ACCTIMEr61160$MOT_SPD_LIMf112580rpm$MOT_SPD_LIM[2]2258rpm$MOT_SPD_LIM[313000rpm (clamped to max. 3000 rpm)$MQT_SPD_LIM|4]2932rpm$MQT_SPD_LIM[512932rpm$M...

  • Page 690

    SYSTEM VARIABLEDESCRIPTIONS_S-700SYSTEM VARIABLEDEFAULT VALUESTable 4.3.S-700 System Variable Default Values(Continued)S-700DefaultValueNotes$SV_OFF_ENBf61FALSE$SV_OFF_TIME10000SUPPERLIMSfll2.617993878150 deg$UPPERLIMSf211.57079632790 deg$UPPERLIMSf314.71238898270 deg$UPPERLIMSf4l3.316125579190 d...

  • Page 691

    SYSTEM VARIABLEDESCRIPTIONSS-700 SYSTEM VARIABLEDEFAULT VALUES4.3 S-700System Variable Default ValuesTable4.3.S-700 System Variable Default ValuesS-700DefaultValueNotes$ACCEL_TIMEim384$ACCEL_TIME1[21384$ACCEL_TIME1[31384$ACCEL_TIMElf41288$ACCEL_TIMElf51288$ACCEL_TIME1|61288$ACCEL_TIME2fl1192$ACCE...

  • Page 692

    SYSTEM VARIABLEDESCRIPTIONSS-700 SYSTEM VARIABLE DEFAULT VALUESTable4.3.S-700 System Variable DefaultValues (Continued)S-700DefaultValueNotes$COARSETOLf61300Detector pulses$COND_TIME32$CONFIG_MASK*-1216011010000 10000000$DMR|T17Detector multiplier ratio= 4$DMRf21Detector multiplier ratio= 47$DMRf...

  • Page 693

    _SYSTEM VARIABLEDESCRIPTIONSS-700 SYSTEM VARIABLEDEFAULT VALUESTable 4.3.S-700 System Variable Default Values (Continued)S-700DefaultValueNotes$GAINSf4l20$GAINSf5120$GAINS[6120SGRIDfll7means 8000 pulses/rev$GRIDf217means8000 pulses/revSGRIDPI7means8000 pulses/rev$GRIDf4]means8000 pulses/rev7$GRID...

  • Page 694

    SYSTEM VARIABLEDESCRIPTIONSS-700 SYSTEM VARIABLE DEFAULTVALUESTable 4.3.S-700 System Variable Default Values (Continued)S-700DefaultValueNotes$MTN_ACCTIMEf61160$MOT_SPD_LIMfl125S0rpm$MOT_SPD_LIMr2l2258rpm$MOT_SPD_LIMf31rpm(clamped to max.3000 rpm)3000$MOT_SPD_LIMf4l2932rpm$MOT_SPD_LIMf512932rpm$M...

  • Page 695

    SYSTEMVARIABLE DESCRIPTIONSS-700 SYSTEMVARIABLE DEFAULT VALUESTable4.3.S-700 System VariableDefault Values (Continued)S-700DefaultValueNotes$SV_OFF_ENBf61FALSE$SV_QFF_T1ME10000$UPPERLIMSf11150 deg2.617993878$UPPERLIMSf2l1.57079632790 deg$UPPERLIMSf314.71238898270 deg$UPPERLIMSf413.316125579190 de...

  • Page 696

  • Page 697

    fRevision RecordS-10/S-700 MAINTENANCE REFERENCE MANUAL (B-67395E-G)Section added on Absolute Pulse Coder.Supplement issued.12-7-8904Appendix4 revised 6-6-89.Warning added for Transporting.6-6-890312-8802Appendix 4 addedon 12-5-88.Changesmade on pages 6-19 and6-3210-88055-93Changes made inorigina...

  • Page 698

  • Page 699

    f.rr •>\rr-rr.M-t-ir

  • Page 700

  • Page 701

    S-10/S-700Maintenance andTroubleshooting Reference ManualAddendumMARXMS17H0884EFAddendumto dieS-10/S-700 MaintenanceandTroubleshootingReference ManualMARMKS17H0885EFThis publication contains proprietaryinformation oftheFANUC RoboticsNorth America,Inc., furnished forcustomeruse only.No otheruses a...

  • Page 702

    The description and specifications contained inthismanual were ineffectat the time this manualwas approved for printing. FANUC RoboticsNorth America, Inc, hereinafterreferredtoas FANUC Robotics,reservesthe rightto discontinue modelsat any timeor to change specificationsordesign without notice and...

  • Page 703

    Copyright©1993 byFANUC Robotics North America,Inc.All Rights ReservedThe information illustratedor containedherein isnot to be reproducedcopied, translatedintoanother language,or transmitted in wholeor inpartinany way without the prior writtenconsent ofFANUC Robotics NorthAmerica,Inc.KAREL® and...

  • Page 704

  • Page 705

    CMOS RAM BOARD (A16B-2200-0760 , 0761, 0762 )Theoryof OperationThe CMOS RAM board,also called the CMOSData Memory PCB,ICFilePCB , CMOS Memory PCB,and CMOS RAM PCB,is a non-volatilemass-storage device.,It isan alternative to the bubblememoryboard and performs thesame functions as thebubble memory ...

  • Page 706

    Undermost circumstances,the batteries will lastwell past thespecified annual replacement,Acapacitor mountedon the CMOS RAMboard stores sufficientchargeto maintainmemory for about 30 minutes iftheboard isremoved fromthe controlleror ifthe batteriesare removed whilethecontroller is turnedoff.Connec...

  • Page 707

    OtherIndicatorsOperator'sPanel UserLED# 2 is reassignedasa low batteryindicator lamp andactsas a repeater for the low battery LEDsonthe CMOS RAMand shared RAMboards-Itislabelled "BATTERY LOW"on controllers thatuse CMOS RAM boards, and thecolor oftheLED hasbeen changedfrom green to red.T...

  • Page 708

    Removal/Replacement01P0S/01P15sr\BaekpUnePCB0c1I) Proceduret8 DetachPCB by loosening thescrews©.Mountnew PCB.CautionDonot keep the boardout ofthecontrollerfor longer than 30minutes withoutconnectingan externalbattery packto connectorCN27.Otherwise, alldata storedon the boardcould be lost.J1.Deta...

x