Navigation

  • Page 1

    FANUC Robotics R-J3iBMate Controller (RIA R15.06 – 1999 Compliant) Maintenance Manual MARMIBRIA01021E REV. B B-81535EN/02 This publication contains proprietary information of FANUC Robotics North America, Inc. furnished for customer use only. No other uses are authorized without the exp...

  • Page 2

    The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. FANUC Robotics North America, Inc, hereinafter referred to as FANUC Robotics, reserves the right to discontinue models at any time or to change specifications or design...

  • Page 3

    Copyright 2002 by FANUC Robotics North America, Inc. All Rights Reserved The information illustrated or contained herein is not to be reproduced, copied, translated into another language, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics North A...

  • Page 4

    CAUTION Information appearing under CAUTION concerns the protection of equipment, software, and data. It is boxed to set it apart from other text. NOTE Information appearing next to NOTE concerns related information or useful hints.

  • Page 5

    SafetySafety-1FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner, employer, or user to take all necessary steps to guarantee the safety o...

  • Page 6

    Safety-2 Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety: • The safety of people and equipment • Use of safety enhancing devices • Techniques for safe teaching and manual operation of the robot(s) • Techniques for safe automatic ope...

  • Page 7

    Safety-3• Install a lockout device that uses an access code to prevent unauthorized persons from operating the robot. • Use anti–tie–down logic to prevent the operator from bypassing safety measures. • Arrange the workcell so the operator faces the workcell and can see what is going on...

  • Page 8

    Safety-4 • Make sure all external devices are properly filtered, grounded, shielded, and suppressed to prevent hazardous motion due to the effects of electro–magnetic interference (EMI), radio frequency interference (RFI), and electro–static discharge (ESD). • Make provisions for power l...

  • Page 9

    Safety-5 WARNING Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death. • Know the path that can be used to escape from ...

  • Page 10

    Safety-6 • Never enter or allow others to enter the work envelope during automatic operation of the robot. • Know the location and status of all switches, sensors, and control signals that could cause the robot to move. • Know where the EMERGENCY STOP buttons are located on both the robot ...

  • Page 11

    Safety-7• Never enter the work envelope while the robot or a program is in operation. • Before entering the work envelope, visually inspect the workcell to make sure no potentially hazardous conditions exist. • Never wear watches, rings, neckties, scarves, or loose clothing that could get...

  • Page 12

    Safety-8 • Isolate the robot from all remote control signals. If maintenance must be done when the power is on, make sure the person inside the work envelope has sole control of the robot. The teach pendant must be held by this person. • Make sure personnel cannot get trapped between the m...

  • Page 13

    Safety-9• Back–check limit switches in the workcell to make sure they do not fail. • Implement ‘‘failure routines” in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails. • Use handshaking protocol to synchronize robot a...

  • Page 14

    Safety-10 • Make sure that the program ends with the robot near or at the home position. • Be aware of signals or other operations that could trigger operation of tooling resulting in personal injury or equipment damage. • In dispensing applications, be aware of all safety guidelines with ...

  • Page 15

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

  • Page 16

    Safety-12 • Overtravel by robot axes is prevented by software limits. All of the major and minor axes are governed by software limits. Limit switches and hardstops also limit travel by the major axes. • EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Lim...

  • Page 17

    Safety-13• Know the location and status of all switches, sensors, and/or control signals that might cause the robot, conveyor, and opening devices to move. • Make sure that the work area near the robot is clean and free of water, oil, and debris. Report unsafe conditions to your supervisor....

  • Page 18

    Safety-14 • Grounding: All electrically conductive objects in the spray area must be grounded. This includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots, as well as solvent containers. Grounding is defined as the object or objects shall be el...

  • Page 19

    Safety-15• Be sure all covers and inspection plates are in good repair and in place. • Always return the robot to the ‘‘home’’ position before you disarm it. • Never use machine power to aid in removing any component from the robot. • During robot operations, be aware of the robo...

  • Page 20

    Update SectionSingle Phase Power Option

  • Page 21

  • Page 22

  • Page 23

  • Page 24

  • Page 25

  • Page 26

  • Page 27

    B–81535EN/02Table of Contentsc–1PREFACEp–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I SAFETY PRECAUTIONS1. SAFETY PRECAUTIONS3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 28

    B–81535EN/02Table of Contentsc–24. PRINTED CIRCUIT BOARDS111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1ROBOT CONTROL BOARD (A16B–3200–0450)112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2EMERGENCY STOP BOARD...

  • Page 29

    B–81535EN/02Table of Contentsc–3III CONNECTION1. GENERAL159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. BLOCK DIAGRAM160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 30

    B–81535EN/02Table of Contentsc–44.7DISABLING HAND BREAK226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIXA. TOTAL CONNECTION DIAGRAM229. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. PERIPH...

  • Page 31

    B–81535EN/02PREFACEp–1PREFACEThis manual describes the following models.ModelAbbreviationFANUC Robot LR Mate 100iBLR Mate 100iBFANUC Robot LR Mate 200iBLR Mate 200iBFANUC Robot ARC Mate 50iBARC Mate 50iB

  • Page 32

    I SAFETY PRECAUTIONS

  • Page 33

  • Page 34

    B–81535EN/021. SAFETY PRECAUTIONSSAFETY PRECAUTIONS31 SAFETY PRECAUTIONSFor the safety of the operator and the system, follow all safety precautionswhen operating a robot and its peripheral devices installed in a work cell.

  • Page 35

    1. SAFETY PRECAUTIONSB–81535EN/02SAFETY PRECAUTIONS4Operator safety is the primary safety consideration. Because it is verydangerous to enter the operating space of the robot during automaticoperation, adequate safety precautions must be observed.The following lists the general safety precauti...

  • Page 36

    B–81535EN/021. SAFETY PRECAUTIONSSAFETY PRECAUTIONS5(9) When adjusting each peripheral device independently, be sure to turnoff the power of the robot.Safety gate which executes with opening the door.Fig.1.1 Safety Fence and Safety Gate

  • Page 37

    1. SAFETY PRECAUTIONSB–81535EN/02SAFETY PRECAUTIONS6The operator is a person who operates the robot system. In this sense, aworker who operates the teach pendant is also an operator. However, thissection does not apply to teach pendant operators.(1) If it is not necessary for the robot to ope...

  • Page 38

    B–81535EN/021. SAFETY PRECAUTIONSSAFETY PRECAUTIONS7While teaching the robot, it is necessary for the operator to enter the workarea of the robot. It is particularly necessary to ensure the safety of theteach pendant operator.(1) Unless it is specifically necessary to enter the robot work area...

  • Page 39

    1. SAFETY PRECAUTIONSB–81535EN/02SAFETY PRECAUTIONS8(5) When entering the robot work area, the teach pendant operator shouldenable the teach pendant whenever he or she enters the robot workarea. In particular, while the teach pendant enable switch is off, makecertain that no start command is s...

  • Page 40

    B–81535EN/021. SAFETY PRECAUTIONSSAFETY PRECAUTIONS9For the safety of maintenance personnel, pay utmost attention to thefollowing.(1) Except when specifically necessary, turn off the power of thecontroller while carrying out maintenance. Lock the power switch,if necessary, so that no other per...

  • Page 41

    1. SAFETY PRECAUTIONSB–81535EN/02SAFETY PRECAUTIONS10(1) Use a limit switch or other sensor to detect a dangerous condition and,if necessary, design the program to stop the robot when the sensorsignal is received.(2) Design the program to stop the robot when an abnormal conditionoccurs in any o...

  • Page 42

    B–81535EN/021. SAFETY PRECAUTIONSSAFETY PRECAUTIONS11(1) When operating the robot in the jog mode, set it at an appropriatespeed so that the operator can manage the robot in any eventuality.(2) Before pressing the jog key, be sure you know in advance whatmotion the robot will perform in the jog...

  • Page 43

    1. SAFETY PRECAUTIONSB–81535EN/02SAFETY PRECAUTIONS12(1) To control the pneumatic, hydraulic and electric actuators, carefullyconsider the necessary time delay after issuing each control commandup to actual motion and ensure safe control.(2) Provide the end effector with a limit switch, and con...

  • Page 44

    B–81535EN/021. SAFETY PRECAUTIONSSAFETY PRECAUTIONS13(1) Never enter the robot work area while the robot is operating. Turn offthe power before entering the robot work area for inspection andmaintenance.(2) If it is necessary to enter the robot work area with the power turnedon, first press th...

  • Page 45

    1. SAFETY PRECAUTIONSB–81535EN/02SAFETY PRECAUTIONS14Do not step on or climb the robot or controller as it may adversely affectthe robot or controller and you may get hurt if you lose your footing aswell.(1) Step–on prohibitive labelFig.1.6 (a) Step–on Prohibitive LabelBe cautious about a ...

  • Page 46

    B–81535EN/021. SAFETY PRECAUTIONSSAFETY PRECAUTIONS15(3) High–voltage warning labelFig.1.6 (c) High–Voltage Warning LabelThere may be a high voltage in a place with this label. Before workingon such a portion, turn off the power to the controller and set its circuitbreaker to the off posi...

  • Page 47

  • Page 48

    II MAINTENANCE

  • Page 49

  • Page 50

    B–81535EN/021. OVERVIEWMAINTENANCE191 OVERVIEWThis manual describes the maintenance and connection of the R–J3iBMate robot controller (called the R–J3iB Mate).Maintenance Part : Troubleshooting, and the setting, adjustment,and replacement of unitsConnection Part: Connection of the R–J3iB ...

  • Page 51

    2. CONFIGURATIONB–81535EN/02MAINTENANCE202 CONFIGURATION

  • Page 52

    B–81535EN/022. CONFIGURATIONMAINTENANCE21The appearance and components might slightly differ depending on thecontrolled robot, application, and options used.Fig.2.1 (a) shows the view of R–J3iB Mate.Fig.2.1 (b) shows the R–J3iB Mate consists of the R–J3iB Mate controller.Teach pendantOper...

  • Page 53

    2. CONFIGURATIONB–81535EN/02MAINTENANCE22Robot control boardOption slot (Process I/O board)Back plane boardServo amplifier module2 (AMP2)Servo amplifier module1 (AMP1)Power supply module (PSM)FuseMCCTeach pendantEnable/disable switchEmergency stop buttonPower supply transformer for brakePower s...

  • Page 54

    B–81535EN/022. CONFIGURATIONMAINTENANCE23– Robot control printed circuit boardThis board is equipped with a microprocessor and its peripheralcircuitry, memory, and operator panel control circuit. A servo controlcircuit is also included.– Emergency stop unit, emergency stop printed circuit ...

  • Page 55

    2. CONFIGURATIONB–81535EN/02MAINTENANCE24Daily maintenance and periodic maintenance/inspection ensure reliablerobot performance for extended periods of time.(1) Daily maintenanceBefore operating the system each day, clean each part of the systemand check the system parts for any damage or crack...

  • Page 56

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE253 TROUBLESHOOTINGThis chapter describes the checking method and corrective action for eacherror code indicated if a hardware alarm occurs. Refer to the operator’smanual to release program alarms.

  • Page 57

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE26Check and Corrective actionFigure(Check 1)Check that the circuit protector is on andhas not tripped.(Correctiveaction)Turn on the circuit protector.Circuit protector (on/off switch)(Check 2)Check that the door fan unit and the fanmotor of the heat exch...

  • Page 58

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE27Check and Corrective actionFigure(Check 1)Check the LCD display and LED indica-tion on the teach pendant.Teach pendant(Correctiveaction)Check the LCD display and LED indica-tion on the teach pendant to see whetherthe emergency stop unit is faulty.– C...

  • Page 59

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE28Check and Corrective actionFigure(Check 1)Check that the “.” portion of the seven–segment LED glows on the robot controlboard.(Correctiveaction)If the “.” portion is not glowing, the fuseFUS1 on the robot control board may beblown. Alternati...

  • Page 60

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE29The alarm occurrence screen displays only the alarm conditions that arecurrently active. If an alarm reset signal is input to reset the alarmconditions, the alarm occurrence screen displays the message “PAUSE ormore serious alarm has not occurred.”...

  • Page 61

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE30Displaying the alarm history/alarm detail information(1) Press the MENUS key to display the screen menu.(2) Select [ALARM]. You will see a screen similar to the followingMENUS34 ALARM5 I/OINTP–224 (SAMPLE1, 7) Jump label is failMEMO–027 Specified l...

  • Page 62

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE31The following map indicates teach pendant operations used to check analarm.4 ALARMF1 [TYPE]Alarm : ActiveF1 [TYPE]F3 HISTAlarm : HISTF1 [TYPE]F3 [ACTIVE]F4 CLEARF5 HELPDETAIL AlarmF1 [TYPE]F3 [ACTIVE]F4 CLEARF5 HELP

  • Page 63

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE32The safety signal screen indicates the state of signals related to safety. Tobe specific, the screen indicates whether each safety signal is currently on.On this screen, it is impossible to change the state of any safety signal.Table 3.3 Safety Signa...

  • Page 64

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE33Mastering is needed if:(1) The SRVO 062 BZAL or SRVO 038 pulse mismatch alarm occurs,or (2) The pulse coder is replaced.Item (1) requires simplified mastering, while item (2) requireszero–degree or jig position mastering. (Zero–degree position mast...

  • Page 65

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE34(6) Select “1 FIXTURE POSITION MASTER” and press the F4 key(yes). Mastering data is set.F4 SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER Master at master position? [NO] ENTERMaster at master position? [NO][ TYPE ] ...

  • Page 66

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE35(1) SRVO–001 SVAL1 Operator panel E–stop(Explanation) The EMERGENCY STOP button on the operatorpanel is pressed.(Action 1)Release the emergency stop button pressed on theoperator panel.(Action 2)Release the EMERGENCY STOP button on theoperator pane...

  • Page 67

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE36(2) SRVO–002 SVAL1 Teach pendant E–stop(Explanation) The emergency stop button on the operator’s TeachPendant was pressed.(Action 1)Release the emergency stop button on the teachpendant.(Action 2)Replace Teach Pendant.Emergency stop buttonFig.3.5...

  • Page 68

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE37(4) SRVO–004 SVAL1 Fence open(Explanation) In AUTO mode, there is no short circuit betweenFENCE11 and FENCE12 and between FENCE21and FENCE22 on the terminal block TBEB5 of theemergency stop board.If the safety fence is connected between FENCE11and FE...

  • Page 69

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE38(5) SRVO–005 SVAL1 Robot overtravel(Explanation) This alarm should not occur because no overtravelinput signal is provided. However, this alarm can becaused by an abnormal overtravel input signal acrossthe robot interconnection cable and robot contr...

  • Page 70

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE39(6) SRVO–006 SVAL1 Hand broken(Explanation) The safety joint, if any, is broken. If no joint isbroken, the HBK signal line of the robotinterconnection cable has a break or ground fault.(Action 1)Holding down the shift key, press the alarm releasebut...

  • Page 71

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE40(7) SRVO–007 SVAL1 External E–stop(Explanation) EMGIN11 and EMGIN12/EMGIN21 and EMGIN22on the terminal block TBEB5 of the emergency stopboard are not short–circuited. If an external emergencystop switch is connected across EMGIN11 andEMGIN12/EMG...

  • Page 72

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE41(8) SRVO–009 SVAL1 Pneumatic pressure alarm(Explanation) An abnormal air pressure was detected. The inputsignal is located on the end effector of the robot.Refer to the manual of your robot.(Action 1)If an abnormal air pressure is detected, check th...

  • Page 73

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE42(9) SRVO–014 WARN Fan motor abnormal(Explanation) A fan motor in the backplane unit is abnormal.(Action)Check the fan motor and its cables. Replace them ifnecessary.Fan motorFig.3.5 (9) SRVO–014 WARN Fan motor abnormal

  • Page 74

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE43(10) SRVO–015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j)(Explanation) The temperature in the control unit exceeds thespecified value.(Action 1)If the ambient temperature is higher than specified(45°C), cool down ambient temperature.(Action 2)If th...

  • Page 75

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE44(11) SRVO–021 SVAL1 SRDY off (Group : i Axis : j)(Explanation) The HRDY is on and the SRDY is off, although thereis no other cause of an alarm. (HRDY is a signal withwhich the host detects the servo system whether toturn on or off the servo amplifie...

  • Page 76

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE45Robot control boardServo amplifier modulePower supply moduleEmergency stop unitAxis control cardFig.3.5 (11) SRVO–021 SVAL1 SRDY off

  • Page 77

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE46(12) SRVO–022 SVAL1 SRDY on (Group : i Axis : j)(Explanation) When the HRDY is about to go on, the SRDY is alreadyon. (HRDY is a signal with which the host directs theservo system whether to turn on or off the servoamplifier magnetic contactor. SR...

  • Page 78

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE47(13) SRVO–023 SVAL1 Stop error excess (Group : i Axis : j)(Explanation) When the servo is at stop, the position error isabnormally large.(Action 1)Check whether the motor brake has been released.(Action 2)Make sure that the servo amplifier CZ2L to N...

  • Page 79

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE48(14) SRVO–024 SVAL1 Move error excess (Group : i Axis : j)(Explanation) When the robot is running, its position error is greaterthan a specified value ($PARAM _ GROUP.$MOVER _ OFFST or $PARAM _ GROUP.$TRKERRLIM). It is likely that the robot cannotf...

  • Page 80

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE49(25) SRVO–038 SVAL2 Pulse mismatch (Group : i Axis : j)(Explanation) The pulse count obtained when power is turned offdoes not match the pulse count obtained when poweris applied. This alarm is asserted after exchange thepulsecoder or battery for b...

  • Page 81

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE50(27) SRVO–044 SVAL1 HVAL alarm (Group : i Axis : j)(Explanation) The DC voltage (DC link voltage) of the main circuitpower supply is abnormally high.The LED indication on the power supply module is“7” (HVAL).(Action 1)Check the three–phase inp...

  • Page 82

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE51(28) SRVO–045 SVAL1 HCAL alarm (Group : i Axis : j)(Explanation) Abnormally high current flowed in the main circuit ofthe servo amplifier module.The LED indications on the servo amplifier modulesare “b”, “C”, and “d”.(Action 1)Disconnect...

  • Page 83

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE52(29) SRVO–046 SVAL2 OVC alarm (Group : i Axis : j)(Explanation) This alarm is issued to prevent the motor fromthermal damage that might occur when the root meantsquare current calculated within the servo system isout of the allowable range.(Action 1...

  • Page 84

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE53Relationships among the OVC, OVL, and HC alarmsOverviewThis section points out the differences among the OVC, OVL, and HCalarms and describes the purpose of each alarm.Alarm detection section AbbreviationDesignationDetection sectionOVCOvercurrent alarm...

  • Page 85

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE54To sum up, a double protection method is used; the OVC alarm is usedfor protection from a short–time overcurrent, and the OVL alarm isused for protection from long–term overload. The relationshipbetween the OVC and OVL alarms is shown in Fig 2.Cur...

  • Page 86

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE55(31) SRVO–049 SVAL1 OHAL1 alarm (Group : i Axis : j)(Explanation) This alarm does not occur when the power supplymodule and serve amplifier modules used with theR–J3iB Mate are under normal conditions.This alarm indicates that any of the power sup...

  • Page 87

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE56(32) SRVO–050 SVAL1 CLALM alarm (Group : i Axis : j)(Explanation) The disturbance torque estimated by the servo softwareis abnormally high. (A collision has been detected.)(Action 1)Check that the robot has collided with anything. If ithas, reset ...

  • Page 88

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE57(33) SRVO–051 SVAL2 CUER alarm (Group : i Axis : j)(Explanation) The offset of the current feedback value is abnormallyhigh.(Action)Replace the servo amplifier module.Servo amplifier moduleFig.3.5 (33) SRVO–051 SVAL2 CUER alarm

  • Page 89

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE58(34) SRVO–054 DSM Memory Error(Explanation) An access to the axis control card on the robot controlboard memory fails.(Action)Replace the axis control card.Robot control boardServo amplifier moduleAxis control cardFig.3.5 (34) SRVO–054 DSM Memory ...

  • Page 90

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE59(35) SRVO–055 SVAL2 FSSB com error 1 (Group : i Axis : j)(Explanation) A communication error has occurred between therobot control board and servo amplifier.(Action 1)Check the communication cable (optical fiber)between the robot control board and se...

  • Page 91

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE60(36) SRVO–056 SVAL2 FSSB com error 2 (Group : i Axis : j)(Explanation) A communication error has occurred between therobot control board and servo amplifier.(Action 1)Check the communication cable (optical fiber)between the robot control board and se...

  • Page 92

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE61(37) SRVO–057 SVAL2 FSSB disconnect (Group : i Axis : j)(Explanation) Communication was interrupted between the robotcontrol board and servo amplifier.(Action 1)Check whether fuse FU1 in the power supply moduleunit has blown.(Action 2)Check whether f...

  • Page 93

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE62(38) SRVO–058 SVAL2 FSSB init error (Group : i Axis : j)(Explanation) Communication was interrupted between the robotcontrol board and servo amplifier module.(Action 1)Check whether fuse FU1 in the power supply modulehave blown.If they have blown, se...

  • Page 94

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE63(39) SRVO–059 SVAL2 Servo amp init error(Explanation) Servo amplifier initialzation is failed.(Action 1)Check all connectors on the PSM and SVM. Makesure they are installed correctly.(Action 2)Replace the power supply module and the servoamplifier m...

  • Page 95

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE64(43) SRVO–064 SVAL2 PHAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if the phase of the pulses generatedin the pulse coder is abnormal.(Action)Replace the pulse coder.NOTEThis alarm might accompany the DTERR, CRCERR, orSTBERR alarm. I...

  • Page 96

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE65(49) SRVO–070 SVAL2 STBERR alarm (Group : i Axis : j)(Explanation) The start and stop bits of the serial data are abnormal.(Action 1)Make sure that the JF1 to JF3 connector of servoamplifire module is connected tightly.(Action 2)Check that the shiel...

  • Page 97

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE66(55) SRVO–076 SVAL1 Tip Stick Detection (Group : i Axis : j)(Explanation) An excessive disturbance was assumed in servosoftware at the start of operation. (An abnormal loadwas detected. The cause may be welding.)(Action 1)Check whether the robot c...

  • Page 98

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE67(59) SRVO–084 WARN BZAL alarm (Track enc : i)(Explanation) This alarm occurs if the backup battery for the absoluteposition of the pulse coder has not been connected. Seethe description about the BZAL alarm (SRVO–062).(60) SRVO–085 WARN RCAL ala...

  • Page 99

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE68(72) SRVO–097 WARN Pulse not established (enc : i)(Explanation) The absolute position of the pulse coder cannot beestablished. See the description about (SRVO–075).Pulse not established.(73) SRVO–131 SVAL1 LVAL (PSM) alarm (Group : i Axis : j)(...

  • Page 100

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE69(74) SRVO–134 SVAL1 DCLVAL (PSM) alarm (Group : i Axis : j)(Explanation) The DC voltage (DC link voltage) of the main circuitpower supply on the power supply module isabnormally low. The LED indication on the powersupply module is “4.”–If thi...

  • Page 101

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE70(75) SRVO–135 SVAL FSAL alarm (Group : i Axis : j)(Explanation) The internal cooling fan(s) of the servo amplifiermodule(s) is abnormal. The LED indication on therelevant servo amplifier module is “1.”(Action 1)Replace the fan motor of the serv...

  • Page 102

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE71(76) SRVO–136 SVAL1 DCLVAL alarm (Group : i Axis : j)(Explanation) The servo the DC current of servo amplifier module(DC link voltage) of the main power supply isabnormally low.The LED indication on the servo amplifier modulebecomes “5”.–This ...

  • Page 103

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE72(77) SRVO–156 SVAL1 IPMAL alarm (Group : i Axis : j)(Explanation) Abnormally high current flowed through the maincircuit of the servo amplifier.The LED indications on the servo amplifier modulesare “8.”, “9.”, and “A.”.(Action 1)Detach t...

  • Page 104

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE73(78) SRVO–157 SVAL1 CHGAL alarm (Group : i Axis : j)(Explanation) The capacitor for the DC link voltage of the servoamplifier module was not charged within thespecified time.(Action 1)A short circuit may occur in the DC link voltage.Check the connec...

  • Page 105

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE74(79) SRVO–201 SVAL1 Panel E–stop or SVEMG abnormal(Explanation) The EMERGENCY STOP button on the operatorpanel was pressed, but the EMERGENCY STOP linewas not disconnected.(Action 1)Check the EMERGENCY STOP button on theoperator panel, and replace ...

  • Page 106

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE75(80) SRVO–202 SVAL1 TP E–stop or SVEMG abnormal(Explanation) The EMERGENCY STOP button on the operatorpanel was pressed, but the EMERGENCY STOP linewas not disconnected.(Action 1)Check the teach pendant connection cable.(Action 2)Replace the teach ...

  • Page 107

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE76(81) SRVO–204 SVAL1 External (SVEMG abnormal) E–stop(Explanation) Although the switch connected across EMGIN11 andEMGIN12/EMGIN21 and EMGIN22 on the terminalblock TBEB1 of the emergency stop board waspressed, the EMERGENCY STOP line was notdisconne...

  • Page 108

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE77(82) SRVO–205 SVAL1 Fence open (SVEMG abnormal)(Explanation) The EMERGENCY STOP line was not disconnectedeven though the switch connected between FENCE11and FENCE12 and between FENCE21 and FENCE22on the terminal block TBEB2 of the emergency stopboard...

  • Page 109

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE78(83) SRVO–206 SVAL1 Deadman switch (SVEMG abnormal)(Explanation) The DEADMAN switch was released when the teachpendant was operable, but the EMERGENCY STOPline was not disconnected.(Action 1)The mode switch may be faulty. Replace the operatorpanel.(...

  • Page 110

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE79(84) SRVO–207 SVAL1 TP switch abnormal or door open(Explanation) The teach pendant is operable, and the deadmanswitch has been grasped, but the EMERGENCYSTOP line is kept disconnected.(Action 1)Check the teach pendant connection cable.(Action 2)Repla...

  • Page 111

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE80(85) SRVO–215 WARN Fuse blown (Aux axis)(Explanation) The fuse in the additional axis amplifier has blown.(Action 1)Check the cause and solve the problem, then replacethe fuse.(86) SRVO–216 SVAL1 OVC (total) (Robot : i)(Explanation) The current (to...

  • Page 112

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE81(87) SRVO–221 SVAL1 Lack of DSP (Group : i Axis : j)(Explanation) A controlled axis card corresponding to the setnumber of axes is not mounted.(Action 1)Check whether the set number of axes is valid. If thenumber is invalid, set the correct number....

  • Page 113

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE82(88) SRVO–222 SVAL1 Lack of Amp (Amp : i)(Explanation) The FSSB has no SVM.(Action 1)Check that the optical cable is securely connected tothe servo amplifier module.(Action 2)Replace the optical cable.(Action 3)Check whether power is properly supplie...

  • Page 114

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE83(89) SRVO–233 SVAL1 TP disabled in T1, T2/Door open(Explanation) The teach pendant is disabled when the mode switchis in the T1 mode position.(Action 1)During teaching operation, set the enable switch ofthe teach pendant to Enable. Otherwise, set th...

  • Page 115

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE84(90) SRVO–264 SVAL1 “E.STOP circuit abnormal 1”(Explanation) An error occurred in the emergency stop circuit.(Action 1)Check whether the CRR78 connectors on theE–STOP unit and the CX3 connector of the powersupply module are connected securely.(...

  • Page 116

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE85(92) SRVO–290 SVAL1 DClink HC alarm (Group : i Axis : j)(Explanation) The DC link current in the servo amplifier module(s)is abnormal. The LED indication on the relevantservo amplifier module is “8.”(Action 1)Detach the motor power lines from c...

  • Page 117

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE86(94) SRVO–295 SVAL1 SVM COM alarm (Group : i Axis : j)(Explanation) Communication between the servo amplifiermodules is abnormal. The LED indications on theservo amplifier modules are “P.”(Action 1)If “SRVO – 047 LVAL alarm” and “SRVO ...

  • Page 118

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE87(95) SRVO–296 SVAL1 DCAL alarm (Group : i Axis : j)(Explanation) The regenerative discharge energy is too high to bedissipated as heat. (To move the robot, the servoamplifier supplies energy to the robot. When goingdown, the robot moves along the ...

  • Page 119

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE88(96) SRVO–297 SVAL1 DCLVAL alarm (Group : i Axis : j)(Explanation) An open–phase condition has occurred in the inputpower supply to the main circuit on the power supplymodule. The LED indications on the power supplymodule is “E.”(Action 1)Che...

  • Page 120

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE89(97) SRVO–300 SVAL1 Hand broken/HBK disabledSRVO–302 SVAL1 Set Hand broken to ENABLE(Explanation) Although HBK was disabled, the HBK signal wasinput.(Action 1)Press RESET on the teach pendant to release thealarm.(Action 2)Check whether the hand bro...

  • Page 121

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE90(98) SRVO–320 SVAL1 E.STOP(Explanation) Although there is no cause for an emergency stop, anemergency stop state was detected on the power supply module.(Action 1)Check external emergency stops and the safety fence.(Action 2)Check the connections of ...

  • Page 122

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE91(99) SRVO–321 SVAL1 TP SW/Deadman abnormal(Explanation) The ENABLE/DISABLE switch or Deadman switchon the teaching pendant is abnormal.(Action 1)Replace the teaching pendant cable.(Action 2)Replace the teaching pendant.(Action 3)Replace the emergency...

  • Page 123

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE92This section describes alarms that can occur when a fuse mounted on aboard or unit is blown and corresponding corrective actions.(1) Fuses on the robot control boardFUS1 : For generating power to the control circuitFUS2 : For protecting +24E output to ...

  • Page 124

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE93(2) Fuses on the emergency stop boardFUS3 : For monitoring the emergency stop circuitFUS4 : For controlling the emergency stop circuit and teach pendantFUS5 : For the brake circuitNameProblem caused by blown fuseActionFUS3The teach pendant screen displ...

  • Page 125

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE94 (3) Blown fuse on the doorNameProblem caused by blown fuseActionFUS6The power supply unit on the emergency stop unit doesnot work, and the power cannot be turned on.1 Check that the fan unit or cable is not short–circuited.2 Replace the power supply...

  • Page 126

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE95 (4) Fuse on the power supply moduleFU1: For protecting 200 VAC input to generate power to thecontrol circuitNameProblem caused by blown fuseActionFU1ALL LEDs of the servo amplifiers go out.The teach pendant screen displays the FSSB disconnectionalarm ...

  • Page 127

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE96 (5) Fuse on the servo amplifier moduleFU1: For protecting +24 V input to generate power to the controlcircuitNameProblem caused by blown fuseActionFU1ALL LEDs of the servo amplifier modules go out.The teach pendant screen displays the FSSB disconnecti...

  • Page 128

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE97The printed circuit boards and servo amplifier are provided with alarmLEDs and status LEDs. The LED status and corresponding troubleshootingprocedures are described below.Servo amplifier module1 (AMP1)Power supply module (PSM)Servo amplifier module2 (...

  • Page 129

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE98(1) TROUBLESHOOTING USING THE LEDS ON THE robot controlboardTo troubleshoot an alarm that arises before the teach pendant is readyto display, check the status LEDs (green) on the robot control boardat power–on. After power–on, the LEDs light as de...

  • Page 130

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE99StepAction to be takenLED12:Axis control card initialization[Action1] Replace the axis control card.* [Action2] Replace the robot control board.[Action3] Replace the servo amplifier.13:Calibration is completed.[Action1] Replace the axis control card.* ...

  • Page 131

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE100(2) TROUBLESHOOTING BY 7–SEGMENT LED INDICATOR7–segment LED indicatorDescription[Description] A parity alarm condition has occurred in RAM on the CPU card installed on the robotcontrol board.[Action1]Replace the CPU card.[Action2]Replace the robot...

  • Page 132

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE101(3) Troubleshooting using a fuse alarm LEDLED indicationFailure description and required measure[Description] A fuse (FUS1 or FUS2) is blown.Cause of the blowing of FUS1 and corrective actions[Action1]Check whether the device which is connected to the...

  • Page 133

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE102Troubleshooting using an LED on the emergency stop boardLED indicationProblem and corrective action[Description] The fuse (FUS3, FUS4, or FUS5) is blown.Cause of the blowing of FUS3 and corrective action[Action]The emergency stop board is faulty. Rep...

  • Page 134

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE103Troubleshooting using the LED of the power supply moduleThe power supply module has a seven–segment LED. When takinga corrective action corresponding to the LED indication, see the alarmdisplayed on the teach pendant screen.LED indicationProblem an...

  • Page 135

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE104Troubleshooting using the LED of the servo amplifier moduleThe servo amplifier module has a seven–segment LED. When takinga corrective action corresponding to the LED indication, see the alarmdisplayed on the teach pendant screen.LED indicationProb...

  • Page 136

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE105LED indicationProblem and corrective action[Description1] The IPM alarm was detected in the servo amplifier mod-ule.[Action1]Detach the motor power lines from the connectors CZ2of the servo amplifier modules, and turn the power on.a) If this alarm doe...

  • Page 137

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE106LED indicationProblem and corrective action[Description] An abnormal current is flowing to the servo motor.[Action1]Check that the servo parameters are set to default val-ues. If this alarm occurs only at a sudden accelerationor deceleration, the mot...

  • Page 138

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE107(Check 1)On the status screen, check the position deviation in thestopped state. To display the position deviation, press thescreen selection key, and select STATUS from the menu.Press F1, [TYPE], select AXIS from the menu, then pressthe F4, PULSE.(C...

  • Page 139

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE108(Check 1)Check the settings of parameters such as the position loopgain parameter.(Corrective action)Correct parameters.(Check 2)Check the mechanical unit for backlash.(Corrective action)Replace a faulty key of motor shaft or other faulty parts.3.9VIB...

  • Page 140

    B–81535EN/023. TROUBLESHOOTINGMAINTENANCE109The following explains checking and corrective action required if therobot cannot be operated manually after the controller is turned on:(1) Check and corrective action to be made if manual operation isimpossible(Check 1)Check whether the teach pendan...

  • Page 141

    3. TROUBLESHOOTINGB–81535EN/02MAINTENANCE110(Check 3)Check whether the previous manual operation has beencompleted.(Corrective action)If the robot cannot be placed in the effective area because ofthe offset of the speed command voltage, which prevents theprevious operation from being completed,...

  • Page 142

    B–81535EN/024. PRINTED CIRCUIT BOARDSMAINTENANCE1114 PRINTED CIRCUIT BOARDSThe printed circuit boards are factory-set for operation. Usually, you donot need to set or adjust them. This chapter describes the standard settingsand adjustment required if a defective printed circuit board is repla...

  • Page 143

    4. PRINTED CIRCUIT BOARDSB–81535EN/02MAINTENANCE112CPU cardTotal versionAxis control cardFROM/SRAM moduleunder the CPU cardDC/DC converter moduleFig.4.1 Robot control boardNameBoard SpecificationNoteRobot control boardA16B–3200–0450I/O Link master/slave switche-able, SDI/SDO = 28/24DC/DC c...

  • Page 144

    B–81535EN/024. PRINTED CIRCUIT BOARDSMAINTENANCE113(1) LEDsSeven segment LEDDescriptionA parity alarm occurred in a RAM of the main CPUcard on the Robot control board.A parity alarm occurred in a RAM of the FROM/SRAM module on the Robot control board.“2”, “3”, and “4” are not displa...

  • Page 145

    4. PRINTED CIRCUIT BOARDSB–81535EN/02MAINTENANCE114Status LEDDescriptionSTATUSLEDIndicates the system operating status.Status LEDDescriptionFUSEALARMLEDA fuse (FUS1 or FUS2) was blown.

  • Page 146

    B–81535EN/024. PRINTED CIRCUIT BOARDSMAINTENANCE115(2) Correspondence between driver ICs and DODriver IC specification: A76L–0151–0062Driver IC nameDO signal nameH9SDO101, SDO102, SDO103, SDO104G9SDO105, SDO106, SDO107, SDO108K9SDO109, SDO110, SDO111, SDO112J9SDO113, SDO114, SDO115, SDO116...

  • Page 147

    4. PRINTED CIRCUIT BOARDSB–81535EN/02MAINTENANCE116Total versionFig.4.2 Emergency stop board4.2EMERGENCY STOPBOARD (A20B–1008–0010,–0011)

  • Page 148

    B–81535EN/024. PRINTED CIRCUIT BOARDSMAINTENANCE117Total version4.3BACKPLANE BOARD(A20B–2003–0330)

  • Page 149

    4. PRINTED CIRCUIT BOARDSB–81535EN/02MAINTENANCE118Total editionTest pinsFig.4.4 Process I/O Board HA(1) Test pinsNameUseP24VP5VGND1GND2GND3+24V+5VGNDGNDGNDFor measuring the DC supply voltageP24VFP5VFGNDF+24V+5VGNDPower for the digital/analog converterAO1AO2Channel 1Channel 2For measuring the ...

  • Page 150

    B–81535EN/024. PRINTED CIRCUIT BOARDSMAINTENANCE119(3) AdjustmentVR1/VR2: Adjusts the gain and the offset of channel 1.Execute a robot program and set AOUT[1] to 3413 on the teachpendant. Connect a digital voltmeter to test pin AOUT1 androtate VR1 or VR2 until the meter reads 15.0 V.Connect th...

  • Page 151

    5. SERVO AMPLIFIERSB–81535EN/02MAINTENANCE1205 SERVO AMPLIFIERSThe servo amplifiers are factory-set for operation. Usually, you do notneed to set or adjust them.This chapter describes the standard settings and adjustment required if adefective servo amplifier is replaced. It also describes th...

  • Page 152

    B–81535EN/025. SERVO AMPLIFIERSMAINTENANCE12138036060172Fig.5.1.1 Outline drawing of power supply module PSM (A06B–6115–H001)5.1OUTLINE DRAWINGS5.1.1Power Supply ModulePSM (A06B–6115–H001)

  • Page 153

    5. SERVO AMPLIFIERSB–81535EN/02MAINTENANCE12238036060172A06B–6114–H205A06B–6114–H302Fig.5.1.2 Outline drawing of servo amplifier modules (A06B–6114–H205, A06B–6114–H302)5.1.2Servo Amplifier Module(A06B–6114–H205,A06B–6114–H302)

  • Page 154

    B–81535EN/025. SERVO AMPLIFIERSMAINTENANCE123The power supply module has a seven–segment LED. When taking acorrective action corresponding to the LED indication, see the alarmdisplayed on the teach pendant screen.LED indicationDescriptionThe magnetic contactor controlled by the power supply ...

  • Page 155

    5. SERVO AMPLIFIERSB–81535EN/02MAINTENANCE124The servo amplifier module has a seven–segment LED. When taking acorrective action corresponding to the LED indication, see the alarmdisplayed on the teach pendant screen.LED indicationDescriptionThe main circuit in the servo amplifier module is i...

  • Page 156

    B–81535EN/02MAINTENANCE6. SETTING THE POWER SUPPLY1256 SETTING THE POWER SUPPLYThe power supply is factory-set for operation. Usually, you do not needto set or adjust it.

  • Page 157

    B–81535EN/02MAINTENANCE6. SETTING THE POWER SUPPLY126+24E+24V–15V+15V+5V+3.3VBackplaneAC input200 – 220 VAC3φProcess I/OCRM2CRM4+24F+24E FUSE1board+24VJD17+24E+24E+24ECRM81CRM79CRM82FUS2FUS1 CP5CP8BBATTERYDC/DC converter module+5V, +3.3V+15V, –15VFANPowersupplyunitAC/DC+24VCN1FUS3FUS4FUS...

  • Page 158

    B–81535EN/02MAINTENANCE6. SETTING THE POWER SUPPLY127The power supply unit need not be set or adjusted.Table 6.2 Rating of the Power supply unitOutputRated voltageTolerance+24V+24V+23V to +25VThe power supply module need not be set or adjusted.Table 6.3 Rating of the Power supply moduleOutput...

  • Page 159

    7. REPLACING A UNITB–81535EN/02MAINTENANCE1287 REPLACING A UNITThis section explains how to replace each unit in the control section.WARNINGBefore you start to replace a unit, turn off the control unitmain power. Also keep all machines in the area of the controlunit switched. Otherwise, you cou...

  • Page 160

    B–81535EN/027. REPLACING A UNITMAINTENANCE129CAUTIONSWhen you replace printed–circuit boards, observe thefollowing cautions:1 Keep the control unit power switched off.2 When you remove a printed–circuit board, do not touch thesemiconductor devices on the board with your hand ormake them tou...

  • Page 161

    7. REPLACING A UNITB–81535EN/02MAINTENANCE130When replacing the backplane board, do so together with the plastic rack.(1) Detach the cables from the robot control board and boards on thebackplane board.CAUTIONWhen you remove the main robot control Board, be surethat the battery is good (3.1–3...

  • Page 162

    B–81535EN/027. REPLACING A UNITMAINTENANCE131The backplane unit incorporates the power unit, Robot control board, andoption boards. There are two types of option boards: Full–size board andmini–size board. A full–size board occupies one slot. A mini–size boarduses part of a full–size ...

  • Page 163

    7. REPLACING A UNITB–81535EN/02MAINTENANCE132The board is at the emergency stop unit.(1) Detach all cables from the emergency stop unit consists of theemergency stop board and the power supply unit. The terminal blocks(TBEB1 and TBEB2) are of a connector type. Pull out the upperterminal block s...

  • Page 164

    B–81535EN/027. REPLACING A UNITMAINTENANCE133CAUTIONBefore you start to replace a card or module, make a backupcopy of robot parameters and taught data. If the FROM/SRAMmodule is replaced, memory contents are lost.Demounting a Card(1) Pull outward the clip of each of the two spacers used to sec...

  • Page 165

    7. REPLACING A UNITB–81535EN/02MAINTENANCE134Mounting a Card(1) Check that the clip of each of the two spacers is latched outward, theninsert the card into the connector.(2) Push the clip of each spacer downward to secure the card PCB.CardCardCardCardSpacerSpacerConnectorConnectorCardCardFig.7....

  • Page 166

    B–81535EN/027. REPLACING A UNITMAINTENANCE135Demounting a moduleCAUTIONWhen replacing the module, be careful not to touch themodule contact. If you touch the contact inadvertently, wipeout dirt on the contact with a clean cloth.(1) Move the clip of the socket outward. (a)(2) Extract the module...

  • Page 167

    7. REPLACING A UNITB–81535EN/02MAINTENANCE136Removing the DC/DC converter module(1) Unscrew the screws (3–M3).(2) Pull out the module.Mounting the module(1) Insert the module to the connector.(2) Screw the screws (3–M3).DC/DC converter modulescrews(3–M3)Fig.7.2 (d) Mounting and removing ...

  • Page 168

    B–81535EN/027. REPLACING A UNITMAINTENANCE137WARNINGBefore you start replacement procedure, turn off the mainpower to the control unit.(1) Detach the cable from the transformer.(2) Remove the two nuts (M5) securing the transformer, then replace thetransformer.(3) Re–connect the cable.Remore t...

  • Page 169

    7. REPLACING A UNITB–81535EN/02MAINTENANCE138WARNINGBefore you start replacement, turn off the control unit mainpower.(1) Detach the cables from the emergency stop unit.(2) Remove retaining screws (4–M5) from the emergency stop unit, andreplace the emergency stop unit.(3) Reconnect the cables...

  • Page 170

    B–81535EN/027. REPLACING A UNITMAINTENANCE139WARNINGBefore starting the replacement, turn off the control unitmain power.(1) Detach the cable from the magnetic contactor (MCC).(2) Holding down the magnetic contactor (MCC) a little, remove theMCC from the DIN rail.(3) Mount a new magnetic contac...

  • Page 171

    7. REPLACING A UNITB–81535EN/02MAINTENANCE140WARNINGBefore you start replacement, turn off the control unit mainpower.The following is the procedure for replacing the power supply module andservo amplifier module.(1) Detach the cable from the servo amplifier. Remove the jumperconnecting the DC...

  • Page 172

    B–81535EN/027. REPLACING A UNITMAINTENANCE141The specifications of the teach pendant vary with its use. When youreplace the teach pendant, check its specifications carefully.(1) Be sure that the power of a robot controller is off.(2) Detach the cable from the teach pendant.(3) Replace the teach...

  • Page 173

    7. REPLACING A UNITB–81535EN/02MAINTENANCE142The control section fan motor can be replaced without using a tool. Thefan motor is mounted on the fan unit rack.(1) Be sure that the power of a robot controller is off.(2) Put your finger in the dent in the upper section of the fan unit, and pullthe...

  • Page 174

    B–81535EN/027. REPLACING A UNITMAINTENANCE143The fan motor of the servo amplifier control unit can be replaced withoutusing tools. The fan unit is mounted at the top of the servo amplifier.(1) Check that the robot controller is turned off.(2) Holding the two lugs, pull up the fan unit in the d...

  • Page 175

    7. REPLACING A UNITB–81535EN/02MAINTENANCE144WARNINGBefore starting the replacement, turn off the control unitmain power. Never touch the fan motor while it is rotating.Door fan unit(1) Unscrew the four fastening screws (M4).(2) Detach the cable from the fan unit.(3) Mount a spare fan unit, re...

  • Page 176

    B–81535EN/027. REPLACING A UNITMAINTENANCE145(1) Detach the cable from the circuit protector on the operator panel andthe grounding line from the door.(2) Detach the cable (JD17) from the robot control board and the cable(CRT11) from the emergency stop board.(3) Unscrew the four screws (M3) fas...

  • Page 177

    7. REPLACING A UNITB–81535EN/02MAINTENANCE146The power supply unit is mounted on the emergency stop unit.(1) Detach all the cables from the emergency stop unit (emergency stopboard and power supply unit).(2) Pull out the connector–type terminal block (TBEB1, TBEB2) at thetop.(3) Remove the fo...

  • Page 178

    B–81535EN/027. REPLACING A UNITMAINTENANCE147If a fuse of the control unit is blown, find out the cause, take an appropriateaction, then replace the fuse.The robot control board has the following fuses.FUS1: For detecting a problem in the circuit on the robot control board:A60L–0001–0046#7....

  • Page 179

    7. REPLACING A UNITB–81535EN/02MAINTENANCE148The emergency stop board has the following fuses.FUS3: For monitoring the emergency stop circuit: A60L–0001–0046#1.0If this fuse is blown, the emergency stop board may be faulty.Replace the emergency stop board.FUS4: For protecting the 24V outpu...

  • Page 180

    B–81535EN/027. REPLACING A UNITMAINTENANCE149The door has the following fuse.FUS6: For protecting the 200VAC control output: A60L–0001–0101#P475HIf this fuse is blown, the power supply unit on the emergency stopunit or the cooling fan unit may be faulty. Replace the powersupply unit or co...

  • Page 181

    7. REPLACING A UNITB–81535EN/02MAINTENANCE150The power supply module has the following fuse.FU1: For protecting the 200VAC input for generating power to thecontrol circuit: A60L–0001–0359If the fuse is blown, the power supply module may be faulty.Replace the power supply module.FU1Remove t...

  • Page 182

    B–81535EN/027. REPLACING A UNITMAINTENANCE151The servo amplifier module has the following fuse.FU1: For protecting the +24 V input for generating power to the controlunit: A60L–0001–0290#LM32CIf this fuse is blown, the servo amplifier module may be faulty.Replace the servo amplifier module...

  • Page 183

    7. REPLACING A UNITB–81535EN/02MAINTENANCE152The following fuse is on each process I/O board.FUSE1:Fuse for protecting the +24V output for peripheral equipment interfaces.A60L–0001–0046#2.0FUSE1Process I/O board HE, HFTotaledition7.13.6Replacing the Fuse onthe Process I/O Boards

  • Page 184

    B–81535EN/027. REPLACING A UNITMAINTENANCE153Prolonged use of a relay might result in its contacts failing to make asecure connection or in them sticking to each other permanently. If sucha failure occurs, replace the relay.The emergency stop board has the following relays.KA6: For external em...

  • Page 185

    7. REPLACING A UNITB–81535EN/02MAINTENANCE154The programs, and system variables are stored in the SRAM in the Robotcontrol board. The power to the SRAM memory is backed up by a lithiumbattery mounted on the front panel of the Robot control board. The abovedata is not lost even when the main b...

  • Page 186

    B–81535EN/027. REPLACING A UNITMAINTENANCE155Battery latchLithium batteryBatteryconnector(5) Remove the old battery, insert a new one into the battery holder, andattach the connector. Confirm that the battery is latched firmly.WARNINGUsing other than the recommended battery may result in theba...

  • Page 187

  • Page 188

    III CONNECTION

  • Page 189

  • Page 190

    B–81535EN/021. GENERALCONNECTIONS1591 GENERALThis chapter describes the connection and the installation of the electricalinterface.

  • Page 191

    2. BLOCK DIAGRAMB–81535EN/02CONNECTIONS1602 BLOCK DIAGRAMFollowing are the block diagrams of the electrical interface connection forR–J3iB Mate.R–J3iB Mate controllerRobot control boardOperationpanelPeripheral deviceRS–232–CRS–422/485Teach pendantEmergency stopEmergency stop unitPower...

  • Page 192

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS1613 CONNECTION DETAILSEmergencystop circuitCP8BCP5JRS12PCMCIACOP10ACRM82JD17JD1AJD1BCRM79CRM81PCMCIAEMGIN11, 12, 21, 22FENCE11, 12, 21, 22CP5BCRS24EMGOUT1, 2EXT24V, 0VCRS16RS–232–C or RS–422/485Robot controlboardBatteryEmergencystop unitTeach p...

  • Page 193

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS162When the stand–alone controller is used, an optional power cable can be specified.A grounding stud is providedbeside the circuit protector.Connect the primary powerground wire to this stud. Usean M4 crimp terminal.Circuit protector Terminal is M...

  • Page 194

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS163Table 3.2 Types of FANUC I/O LinksI/O LinkNo.NameDrawing numberMasterSlaveRemarks1Robot control boardA16B–3200–0450f(*)f(*)StandardNOTEThe I/O Link of the robot control board is in the master modeby default. The I/O Link can be used in the sl...

  • Page 195

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS164*Note that the connector name differs from that of the standard FANUC I/O link.ÏÏÏÏWhen the R–J3iB Mate control unit is used as the master of an I/O link (when R–J3iB Mate control the process I/O printed board)ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ...

  • Page 196

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS165ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ...

  • Page 197

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS166Cable connectionMasterRobot control boardJD1ARXSLC1 (1)*RXSLC1 (2)TXSLC1 (3)*TXSLC1 (4)0V (11)0V (12)0V (13)0V (14)0V (15)0V (16)I/O unit, etcJD1B(1) SIN [RX](2) *SIN [*RX](3) SOUT [TX](4) *SOUT [*TX](11) 0V(12) 0V(13) 0V(14) 0V(15) 0V(16) 0VSlaveC...

  • Page 198

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS167SR2–3CLOSEOPENSR2–2OPENCLOSESR2–1CLOSEOPENAUTOT1Teach pendantEmergency stop boardOperation panelmode switchEmergency stop buttonEnable/Disable switchDead man switch+24T+24T0VRobot control boardMODE1MODE2OP–EMGFENCEEX–EMGMCCMONMode switch(...

  • Page 199

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS168When the robot is shipped, EMGIN11 and EMGIN12/EMGIN21 and EMGIN22, FENCE11 and FENCE12/FENCE21 and FENCE22 are short–connected. Toenable external emergency stop input and fenceinput, first disconnect these jumper wires, then makethe necessary c...

  • Page 200

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS169Customer should prepare this cable.Cable holderEmergency stop boardÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏEmergency stop from the teach pendant andemergency stop from the operator panel arereflected to the external emergency stop out-puts, EMGOUT1 and EMG...

  • Page 201

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS170Customer should prepare this cable.Cable holderEmergency stop boardÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏWhen 24 V is applied externally, the externalemergency stop outputs, EMGOUT1 andEMGOUT2, are always output regardless ofthe power state of the robot ...

  • Page 202

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS171LR Mate 100iBCXA2AJF1 (L)JF2 (M)CZ2 LCZ2 MCOP10BCOP10ACXA2BCXA2AJF1 (L)JF2 (M)JF3 (N)CZ2 LCZ2 MCZ2 NCZ1CX1ACXA2ACX3CX4COP10BCXA2BCXA2APSMAMP1AMP2TB1L+L–TB1 L+ L–TB1 L+ L–POWER SUPPLYMODULE(αPSMR–1i)A06B–6115–H001SERVO AMPLIFIERMODULE(...

  • Page 203

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS172CRM82JF1–3Power cable to RMPSignal cableTBEB3CZ2 L, M, NGround cable3.6CONNECTION OFROBOT

  • Page 204

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS173Emergency stop unitCRS16To teach pendantEarth plateFig.3.7 Teach pendant cable3.7CONNECTION OFTEACH PENDANTCABLE

  • Page 205

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS174Selection of RS–232–C or RS–422 (option) interface need setting ofsoftware.ÏÏÏCommunication portFlopply, handy file etc.ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ...

  • Page 206

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS175Table 3.9.1 Types of FANUC I/O LinksPeripheral device interfaceNo.NameDrawing numberCRM79CRM81RemarksDIDODIDO1Robot control board AA16B–3200–0450202084StandardNOTEThe DI and DO signals of CRM79 and CRM81 includespecial signals.Connecting a per...

  • Page 207

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS176NOTESee the operator’s MANUAL for the detail information.Turn off the controller when connecting the cable.ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏRobotcontrol boardÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏCNCCRM79ÏÏÏÏÏ...

  • Page 208

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS177ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ...

  • Page 209

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS178ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ...

  • Page 210

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS179In case +24V common at the peripheral device side. (Specified signals are not allocated)Control unit (peripheral device interface : CRM79)Peripheral deviceSDI101RVCRM79 (1)CRM79 (31,32,49,50)Connector pin No+24ESDICOM1CRM79 (19)SDI120CRM79 (25)SDI...

  • Page 211

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS180In case 0V common at the peripheral device side. (Specified signals are not allocated)SDI101RVCRM79 (1)SDICOM1CRM79 (19)SDI120CRM79 (25)SDICOM2CRM79 (20)CRM79 (17,18,29,30)0VSDI102CRM79 (2)SDI103CRM79 (3)SDI104CRM79 (4)SDI105CRM79 (5)SDI106CRM79 (...

  • Page 212

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS181(Specified signals are not allocated)SDO101DVCRM79 (33)CRM79 (17,18,29,30)0VLOADRELAYSDO102LOADCRM79 (34)SDO103CRM79 (35)SDO104CRM79 (36)SDO105CRM79 (37)SDO106CRM79 (38)SDO107CRM79 (39)SDO108CRM79 (40)SDO109CRM79 (41)SDO110CRM79 (42)SDO111CRM79 (43...

  • Page 213

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS182In case +24V common at the peripheral device side. (Specified signals are allocated)Control unit (peripheral device interface : CRM79)Peripheral deviceSDI101RVCRM79 (1)CRM79 (31,32,49,50)Connector pin No+24ESDICOM1CRM79 (19)SDI120CRM79 (25)SDICOM2...

  • Page 214

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS183In case 0V common at the peripheral device side. (Specified signals are allocated)SDI101RVCRM79 (1)SDICOM1CRM79 (19)SDI120CRM79 (25)SDICOM2CRM79 (20)CRM79 (17,18,29,30)0VSDI102CRM79 (2)SDI103CRM79 (3)SDI104CRM79 (4)SDI105CRM79 (5)SDI106CRM79 (6)SD...

  • Page 215

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS184(Specified signals are allocated)SDO101DVCRM79 (33)CRM79 (17,18,29,30)0VLOADRELAYSDO102LOADCRM79 (34)SDO103CRM79 (35)SDO104CRM79 (36)SDO105CRM79 (37)SDO106CRM79 (38)SDO107CRM79 (39)SDO108CRM79 (40)SDO109CRM79 (41)SDO110CRM79 (42)SDO111CRM79 (43)SDO...

  • Page 216

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS185In case +24V common at the peripheral device side. (Specified signals are allocated quickly)*IMSTPRVCRM79 (1)CRM79 (31,32,49,50)+24ESDICOM1RVCRM79 (19)SDI120RVCRM79 (25)SDICOM2RVCRM79 (20)CRM79 (17,18,29,30)0V*HOLDRVCRM79 (2)*SFSPDRVCRM79 (3)CSTOP...

  • Page 217

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS186In case 0V common at the peripheral device side. (Specified signals are allocated quickly)*IMSTPRVCRM79 (1)CRM79 (31,32,49,50)+24ESDICOM1RVCRM79 (19)SDI120RVCRM79 (25)SDICOM2RVCRM79 (20)CRM79 (17,18,29,30)0V*HOLDRVCRM79 (2)*SFSPDRVCRM79 (3)CSTOPIR...

  • Page 218

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS187(Specified signals are allocated quickly)CMDENBLDVCRM79 (33)CRM79 (17,18,29,30)0VLOADRELAYSYSRDYLOADDVCRM79 (34)PROGRUNLOADDVCRM79 (35)PAUSEDLOADDVCRM79 (36)HELDLOADDVCRM79 (37)FAULTLOADDVCRM79 (38)ATPERCHLOADDVCRM79 (39)TPENBLLOADDVCRM79 (40)BATAL...

  • Page 219

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS188CRM81 interface(When a special signal is not allocated; when CNC and PLC are connectedby an I/O Link cable)AB01SDI81SDI8202SDI83SDI8403SDI85SDI8604SDI87SDI8805SDICOM0607SDO81SDO8208SDO83SDO84090V10+24V0VCRM81 interface(When a special signal is allo...

  • Page 220

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS189In case +24V common at the peripheral device side. (Specified signal is not allocated.)SDI81CRM81 (A1)CRM81 (A10)SDICOMCRM81 (A5)SDI88CRM81 (B5)CRM81 (B9,B10)0VSDI82CRM81 (B1)SDI83CRM81 (A2)SDI84CRM81 (B2)SDI85CRM81 (A3)SDI86CRM81 (B3)SDI87CRM81 (A...

  • Page 221

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS190In case 0V common at the peripheral device side. (Specified signal is not allocated.)SDI81CRM81 (A1)CRM81 (A10)SDICOMCRM81 (A5)SDI88CRM81 (B5)CRM81 (B9,B10)0VSDI82CRM81 (B1)SDI83CRM81 (A2)SDI84CRM81 (B2)SDI85CRM81 (A3)SDI86CRM81 (B3)SDI87CRM81 (A4)...

  • Page 222

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS191In case +24V common at the peripheral device side. (Specified signal is allocated quickly)*HOLDRVCRM81 (A1)CRM81 (A10)+24ESDICOMRVCRM81 (A5)PNS4RVCRM81 (B5)CRM81 (B9 ,B10)0VRESETRVCRM81 (B1)STARTRVCRM81 (A2)ENBLRVCRM81 (B2)PNS1RVCRM81 (A3)PNS2RVCRM...

  • Page 223

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS192In case 0V common at the peripheral device side. (Specified signal is allocated quickly)*HOLDRVCRM81 (A1)CRM81 (A10)+24ESDICOMRVCRM81 (A5)PNS4RVCRM81 (B5)CRM81 (B9 ,B10)0VRESETRVCRM81 (B1)STARTRVCRM81 (A2)ENBLRVCRM81 (B2)PNS1RVCRM81 (A3)PNS2RVCRM81...

  • Page 224

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS193This section describes the specifications of the digital I/O signalsinterfaced with the peripheral device and end effector. Example of connectionProtective resistanceLamp70 mA or less0V+24V70 mA or less0V+24VSpark killer diode0V0VD Electrical speci...

  • Page 225

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS194Example of connection3.3 kΩRVSDICOM+24V0VRVSDI nExample of +24V common connectionD Electrical specifications of the receiverType: Grounded voltage receiverRated input voltage: Contact close :+20 V to +28 VContact open :0 V to +4 VMaximum applied ...

  • Page 226

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS195The figure below shows the connector for peripheral device cable.SymbolName1Connector cover2Connector 50 pins (male)Connector Applicable DimensionsRemarkConnector specificationApplicable interfaceA(B)C(D)Honda TsushinφMR50LWMCRM7967.973.566.120Ko...

  • Page 227

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS196Connector Applicable DimensionsConnector specificationApplicable interfaceACRemarkUFS–20B–0429.9822.86YAMAICHI ELECTRONICS(Housing)Contact 66 typeCRM81YAMAICHI ELECTRONICS(Contact)Applicable cable : AWG#28 (7/0.12), AWG#26 (19/0.1), AWG#24 (19/...

  • Page 228

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS197Table 3.10.1 Types of end effector interfacesEnd effector interfaceNo.NameDrawing numberDIDORemarks1Robot control board AA16B–3200–045066StandardNOTEEither RDI6 or *PPABN is selected by software.1RDI17*HBK2RDI28+24E3RDI39+24E4RDI410+24E5RDI511...

  • Page 229

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS198End effecterRDI1RVEE (1)EE (8,8,10)Connector pin No.+24EReceiver circuitRDICOMEE (12)EE (11)0VRDI2EE (2)RDI3EE (3)RDI4EE (4)RDI5EE (5)RDI6(*PPABN)EE (6)3.3kMechanical unit (end effector interface)RVRVRVRVRVRVFig.3.10.1 (a) End effector interface (...

  • Page 230

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS199Example of connection3.3 kΩRVRDICOM+24V0VRVRDI nExample of +24V common connectionElectrical specifications of the receiverType: Grounded voltage receiverRated input voltage: Contact close: +20 V to +28 VContact open: 0 V to +4 VMaximum applied in...

  • Page 231

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS200In this manual the treatment for the shielded cable is shown on severalpages. Partly cut off the shielded cable to expose the shield jacket, andfasten the jacket to the shield plate with a clamp to protect against noise.(In case of stand–alone ...

  • Page 232

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS201Connection to the peripheral device and the arc welding is available to usethe process I/O board for R–J3iB Mate.Number of I/O pointsNo.NameDrawing numberDIDOD/AA/DRemarks1Process I/O board HEA05B–2440–J0024040262Process I/O board HFA05B–24...

  • Page 233

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS202Main boardProcess I/O boardHE/HFPeripheral deviceJD1A(JD4)CRM2AJD4A(JD1B)CRM2BCRW7(NOTE 1)CRW2(NOTE1)JD4B(JD1A)Fig.3.12.2 Block diagram of the process I/O board HE and HFNOTE1 CRW2 and CRW7 are not provided for process I/O boardHF.3.12.2Periphera...

  • Page 234

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS203The connection is for the allocated specified signal.For detail of the allocation, refer to the OPERATOR’S MANUAL.1*IMSTP*HOLD3*SFSPDCSTOPI5FAULT RESET792468101214161113151817Peripheral device control interface A1CRM2ASTARTHOMEENBLRSR8/PNS80V0VRS...

  • Page 235

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS204*IMSTPCRM2A (1)CRM2A (49,50)+24EENBLCRM2A (8)SDI02CRM2A (32)COM–1CRM2A (17,18)0V*HOLDCRM2A (2)*SFSPDCRM2A (3)CSTOPICRM2A (4)FAULT RESETCRM2A (5)STARTCRM2A (6)HOMECRM2A (7)RSR1/PNS1CRM2A (9)RSR2/PNS2CRM2A (10)RSR3/PNS3CRM2A (11)RSR4/PNS4CRM2A (12)...

  • Page 236

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS205CMDENBLCRM2A (34)CRM2A (33)TPENBLCRM2A (43)RESERVEDCRM2A (23,28,37,42,47)0VSYSRDYCRM2A (35)PROGRUNCRM2A (36)PAUSEDCRM2A (38)HELDCRM2A (39)FAULTCRM2A (40)ATPERCHCRM2A (41)BATALMCRM2A (44)BUSYCRM2A (45)ACK1/SNO1CRM2A (46)ACK2/SNO2CRM2A (19)ACK3/SNO3C...

  • Page 237

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS206SDI03CRM2B (1)CRM2B (49,50)+24ESDI10CRM2B (8)SDI22CRM2B (32)COM–2CRM2B (17,18)0VSDI04CRM2B (2)SDI05CRM2B (3)SDI06CRM2B (4)SDI07CRM2B (5)SDI08CRM2B (6)SDI09CRM2B (7)SDI11CRM2B (9)SDI12CRM2B (10)SDI13CRM2B (11)SDI14CRM2B (12)SDI15CRM2B (13)SDI16CRM...

  • Page 238

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS207SDO01CRM2B (34)CRM2B (33)SDO08CRM2B (43)SDO20CRM2B (23,28,37,42,47)0VSDO02CRM2B (35)SDO03CRM2B (36)SDO04CRM2B (38)SDO05CRM2B (39)SDO06CRM2B (40)SDO07CRM2B (41)SDO09CRM2B (44)SDO10CRM2B (45)SDO11CRM2B (46)SDO12CRM2B (19)SDO13CRM2B (20)SDO14CRM2B (21...

  • Page 239

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS208Control unitPeripheral deviceAnalog input interfaceCRW2NOTEWelder and peripheral device connection cable are optional.Applicable process I/O board typeHE3.12.4Connection Betweenthe Control Unit andWelder

  • Page 240

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS209Analog connection of CRW2 connector (Analog input)ADCH1CRW2 (10)COMAD1CRW2 (11)ADCH2CRW2 (12)COMAD2CRW2 (13)0VADCH5CRW2 (18)COMAD5CRW2 (19)ADCH6CRW2 (8)COMAD6CRW2 (9)ADCH3CRW2 (14)COMAD3CRW2 (15)ADCH4CRW2 (16)COMAD4CRW2 (17)Connector pin numberCont...

  • Page 241

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS210Control unitWelder interfaceCRW7WelderNOTEWelder and peripheral device connection cable is option.Applicable process I/O board typeHE

  • Page 242

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS211Attaching the CRW7 connector to the welding machine: FANUC interface(Analog output, welding wire deposition detected, and WDI/WDO connection: Connected to the +24 V commonline)DACH1CRW7 (1)COMDA1CRW7 (2)DACH2CRW7 (3)COMDA2CRW7 (4)+ABCDWDI+CRW1 (31...

  • Page 243

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS212NOTEThis is the connection for +24V.

  • Page 244

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS213Attaching the CRW7 connector to the welding machine: FANUC interface(Analog output, welding wire deposition detected, and WDI/WDO connection: Connected to the +24 V commonline)DACH1CRW7 (1)COMDA1CRW7 (2)DACH2CRW7 (3)COMDA2CRW7 (4)+ABEFWDI+CRW1 (31...

  • Page 245

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS214(1) Output signals in peripheral device interface AExample of connectionProtective resistanceLamp70 mA or less0V+24VSpark killer diode70 mA or less0V+24VElectrical specificationsRated voltage: 24 VDCMaximum applied voltage: 30 VDCMaximum load curre...

  • Page 246

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS215(2) Input signals in peripheral device interface AExample of connectionAB3.3 kW+24VRV+24VICOMElectrical specifications of the receiverType: Grounded voltage receiverRated input voltage: Contact close: +20 V to +28 VContact open: 0 V to +4 VMaximum ...

  • Page 247

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS216(1) Digital output signal specifications for an arc welding interfaceIn case of process I/O HE0.3 A or lessExample connectionSpark killer diodeElectrical characteristicsRated voltage: 24 VDCMaximum applied voltage: 30 VDCMaximum load current: 0....

  • Page 248

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS217(2) Digital input signal specifications for arc welding interfaceExample connectionElectrical characteristics of receiversType: Grounded voltage receiverRated input voltage: +20 to +28 V with contacts closed0 to +4 V when openMaximum input voltag...

  • Page 249

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS218(3) Analog output signal specifications for arc welding interface(Welding voltage command, wire–feed rate command)WelderExample connection0VProcess I/O CA, EA : –10V to +10VProcess I/O GA, HA : 0V to +15VNOTEInput impedance: 3.3 kΩ or moreCo...

  • Page 250

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS219If the customer manufactures cables, make sure they conform to theFANUC standard cables described in this section. (See the description in“Peripheral Device Interface” in this manual for the specifications of theFANUC standard cables.)Process I...

  • Page 251

    3. CONNECTION DETAILSB–81535EN/02CONNECTIONS220(1) Fig. 3.12.9 shows the connector for peripheral device cables A andB. (The connector is used for a peripheral device)ConnectorApplicableDimensionsConnectorspecificationsApplicableinterfaceA(B)C(D)RemarkMR50LMCRM267.973.544.818Honda Tsushin Kogyo...

  • Page 252

    B–81535EN/023. CONNECTION DETAILSCONNECTIONS221(2) Peripheral device connectorConnectorApplicableDimen-sionsRemarkspecificationsinterfaceABRemarkMR50RF(CRM2)61.456.4Honda Tsushin Kogyo,50 pinsSymbolNameConnector clamp screwScrew M2.6 8Connector(MR50RF)Fig.3.12.9 (b) Peripheral Device Connector...

  • Page 253

    CONNECTION4. TRANSPORTATION AND INSTALLATIONB–81535EN/022224 TRANSPORTATION AND INSTALLATION

  • Page 254

    CONNECTIONB–81535EN/024. TRANSPORTATION ANDINSTALLATION223The control unit should be transported by a crane. Attach a sling to eyebolts at the top of the control unit.Fig.4.1 TransportationInstallation areaWhen the control unit is installed, allow the space for maintenance shownin the followi...

  • Page 255

    CONNECTION4. TRANSPORTATION AND INSTALLATIONB–81535EN/02224Four M10 weld nutsThe unit is shipped with the M10 boltsscrewed to the weld nuts as 10–mm feet.After the M10 bolts are removed, theseweld nuts can be used to secure the control unit.Fig.4.3 External drawing of robot controller4.3EXTE...

  • Page 256

    CONNECTIONB–81535EN/024. TRANSPORTATION ANDINSTALLATION225ItemSpecifications/conditionInput power supply50Hz; 200VAC, +10%, –15%60Hz; 200VAC to 220 VAC, +10%, –15%50/60 Hz"1Hz, 3–phaseInput power supply capacity1 kVA (LR Mate 100iB)1.2 kVA (LR Mate 200iB/ARC Mate 50iB)Average power c...

  • Page 257

    CONNECTION4. TRANSPORTATION AND INSTALLATIONB–81535EN/02226An overtravel and emergency stop occur when the robot is operated forthe first time after it is installed and the mechanical and control units arewired. This section describes how to reset the overtrvel and emergencystop.Remove the red...

  • Page 258

    APPENDIX

  • Page 259

  • Page 260

    B–81535EN/02A. TOTAL CONNECTION DIAGRAMAPPENDIX229ATOTAL CONNECTION DIAGRAM

  • Page 261

    A. TOTAL CONNECTION DIAGRAMB–81535EN/02APPENDIX230Fig.A (a) Total connection diagram

  • Page 262

    B–81535EN/02A. TOTAL CONNECTION DIAGRAMAPPENDIX231

  • Page 263

    A. TOTAL CONNECTION DIAGRAMB–81535EN/02APPENDIX232Fig.A (b) Emergency stop circuit diagram

  • Page 264

    B–81535EN/02A. TOTAL CONNECTION DIAGRAMAPPENDIX233

  • Page 265

    A. TOTAL CONNECTION DIAGRAMB–81535EN/02APPENDIX234Fig.A (c) Emergency stop circuit diagram

  • Page 266

    B–81535EN/02A. TOTAL CONNECTION DIAGRAMAPPENDIX235

  • Page 267

    A. TOTAL CONNECTION DIAGRAMB–81535EN/02APPENDIX236Fig.A (d) Robot control board, Emergency stop board connector interface

  • Page 268

    B–81535EN/02A. TOTAL CONNECTION DIAGRAMAPPENDIX237Fig.A (e) Servo amplifier robot mechanical unit connector interface

  • Page 269

    B–81535EN/02APPENDIXB. PERIPHERAL INTERFACE238BPERIPHERAL INTERFACEPeripheral I/O (UI/UO) are a group of specialized signals whose usage isdecided by the system. These signals are connected with a remotecontroller and the peripheral devices via the following interfaces and I/Olinks and they are...

  • Page 270

    B–81535EN/02APPENDIXB. PERIPHERAL INTERFACE239The tables below list the special signals of the R–J3iB Mate robotcontroller.Input signals (See Subsection B.2.1.)SignalDescription*HOLDRESETSTARTENBLPNS1PNS2PNS3PNS4Temporary stopAlarm releaseCycle startEnableProgram select (*1)Program select (*1...

  • Page 271

    B–81535EN/02APPENDIXB. PERIPHERAL INTERFACE240Fellowing is each input signal.The remote controller uses the hold signal to halt the robot. Because*HOLD input signal is a inverted signal, normally set the signal on. Whenthe signal goes off, the following is executed:D The robot is decelerated un...

  • Page 272

    B–81535EN/02APPENDIXB. PERIPHERAL INTERFACE241A program number selection signal has two functions.When the START signal goes on, PNS1 to PNS4 are read and thecorresponding program is selected or collated. Whether the program isselected or collated is specified by the setting of system variable$...

  • Page 273

    B–81535EN/02APPENDIXB. PERIPHERAL INTERFACE242This section describes the external specifications of digital and analoginput/output in the R–J3iB Mate controller.The R–J3iB Mate controller can use up to 512 digital input and outputpoints or an equivalent number of analog input and output poi...

  • Page 274

    B–81535EN/02APPENDIXB. PERIPHERAL INTERFACE243(1) RDI/RDOThese are signals sent to the connector at the wrist of the robot.They cannot be assigned (redefined) and are fixed.The standard format is six inputs and six outputs. The number ofpoints that can be used for the connector at the wrist dep...

  • Page 275

    C. OPTICAL FIBER CABLEB–81535EN/02APPENDIX244COPTICAL FIBER CABLEThe R–J3iB Mate uses fiber optic cables for communication between therobot control board and servo amplifier module and between the servoamplifier module and servo amplifier module. Observe the followingcautions when handling th...

  • Page 276

    B–81535EN/02C. OPTICAL FIBER CABLEAPPENDIX245(2) Fiber optic cableD Grasp the optical connector firmly when connecting ordisconnecting the cable. Do not pull on the fiber optic cord itself.(The maximum tensile strength between the fiber cord andconnector is 2 kg. Applying greater force to the...

  • Page 277

    IndexB–81535EN/02i–1[A]Adjustment and Checks at Installation, 225Alarm Occurrence Screen, 29ARC Weld Connection Cable (CRW1: Honda Tsushin,34 pins), 219[B]Backplane Board (A20B–2003–0330), 117Battery for Memory Backup (3 VDC), 154Block Diagram, 160Block Diagrams of the Power Supply, 126[C...

  • Page 278

    IndexB–81535EN/02i–2Outline Drawings, 121Output Signals, 241[P]Peripheral Device and Control Unit Connection, 203Peripheral Device Cable Connector, 195, 220Peripheral Device Interface Block Diagram and Speci-fications, 202Peripheral device interface CRM 79 and CRM 81, 193Peripheral Device Int...

  • Page 279

    B–81535EN/02Indexi–3Troubleshooting, 25Troubleshooting Based on LED Indications, 97Troubleshooting Using Fuses, 92Troubleshooting Using the Error Code, 35[V]Vibration Observed During Movement, 108[W]Warning Label, 14When the Robot is Connected to the CNC by a Pe-ripheral Device Cable, 176

  • Page 280

x