RJ3iB Controller for Europe

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R-J3

iB CONTROLLER

FOR EUROPE

MAINTENANCE MANUAL

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Maintenance Manual

B-81465EN-1/05

This publication contains proprietary information of FANUC Robotics Europe S.A. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics Europe S.A.

FANUC Robotics Europe S.A. Zone Industrielle 6466 Echternach Luxemburg Phone: +(352) 72 7777-1 Fax: +(352) 72 7777-403 website: www.fanucrobotics.lu

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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.

Conventions Used in this Manual

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

WARNING

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

CAUTION

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

NOTE

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PREFACE ... 13

1 SAFETY PRECAUTIONS ... 15

1.1 OPERATOR SAFETY ... 15

1.1.1 Operator Safety ...17

1.1.2 Safety of the Teach Pendant Operator ...18

1.1.3 Safety During Maintenance ...20

1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES ... 21

1.2.1 Precautions in Programming ...21

1.2.2 Precautions for Mechanism ...21

1.3 SAFETY OF THE ROBOT MECHANISM ... 22

1.3.1 Precautions in Operation ...22

1.3.2 Precautions in Programming ...22

1.3.3 Precautions for Mechanisms ...22

1.4 SAFETY OF THE END EFFECTOR ... 23

1.4.1 Precautions in Programming ...23 1.5 SAFETY IN MAINTENANCE ... 24 1.6 WARNING LABEL ... 25

I. MAINTENANCE

1 OVERVIEW ... 27

2 CONFIGURATION ... 29

2.1 EXTERNAL VIEW OF THE CONTROLLER ... 29

2.2 COMPONENT FUNCTIONS ... 38

2.3 PREVENTIVE MAINTENANCE ... 40

3 TROUBLESHOOTING ... 41

3.1 POWER CANNOT BE TURNED ON ... 41

3.2 ALARM OCCURRENCE SCREEN ... 45

3.3 SAFETY SIGNALS ... 48

3.4 MASTERING ... 50

3.5 TROUBLESHOOTING USING THE ERROR CODE ... 53

3.5.1 SRVO-001 Operator panel E-stop ...53

3.5.2 SRVO-002 Teach pendant E-stop ...56

3.5.3 SRVO-003 Deadman switch released ...57

3.5.4 SRVO-004 Fence open ...58

3.5.5 SRVO-005 Robot overtravel ...61

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3.5.15 SRVO-024 Move error excess (Group : i Axis : j) ... 79

3.5.16 SRVO-027 Robot not mastered (Group : i) ... 79

3.5.17 SRVO-033 Robot not calibrated (Group : i) ... 79

3.5.18 SRVO-034 Ref pos not set (Group : i) ... 79

3.5.19 SRVO-035 WARN2 Joint speed limit (Group : i Axis : j) ... 79

3.5.20 SRVO-036 Inpos time over (Group : i Axis : j) ... 79

3.5.21 SRVO-037 Imstp input (Group : i) ... 80

3.5.22 SRVO-038 Pulse mismatch (Group : i Axis : j) ... 80

3.5.23 SRVO-042 MCAL alarm (Group : i Axis : j) ... 81

3.5.24 SRVO-043 DCAL alarm (Group : i Axis : j) ... 82

3.5.25 SRVO-044 HVAL alarm (Group : i Axis : j) ... 85

3.5.26 SRVO-045 HCAL alarm (Group : i Axis : j) ... 86

3.5.27 SRVO-046 OVC alarm (Group : i Axis : j) ... 87

3.5.28 SRVO-047 LVAL alarm (Group : i Axis : j) ... 91

3.5.29 SRVO-049 OHAL1 alarm (Group : i Axis : j) ... 92

3.5.30 SRVO-050 CLALM alarm (Group : i Axis : j) ... 94

3.5.31 SRVO-051 CUER alarm (Group : i Axis : j) ... 95

3.5.32 SRVO-054 DSM Memory Error ... 96

3.5.33 SRVO-055 FSSB com error 1 (Group : i Axis : j) ... 97

3.5.34 SRVO-056 FSSB com error 2 (Group : i Axis : j) ... 98

3.5.35 SRVO-057 FSSB disconnect (Group : i Axis : j) ... 98

3.5.36 SRVO-058 FSSB init error (Group : i Axis : j) ... 100

3.5.37 SRVO-059 Servo amp init error ... 102

3.5.38 SRVO-060 FATL FSSN init error ... 103

3.5.39 SRVO-062 BZAL alarm (Group : i Axis : j) ... 103

3.5.40 SRVO-064 PHAL alarm (Group : i Axis : j) ... 103

3.5.41 SRVO-065 BLAL alarm (Group : i Axis : j) ... 104

3.5.42 SRVO-067 OHAL2 alarm (Group : i Axis : j) ... 104

3.5.43 SRVO-068 DTERR alarm (Group : i Axis : j) ... 104

3.5.44 SRVO-069 CRCERR alarm (Group : i Axis : j) ... 104

3.5.45 SRVO-070 STBERR alarm (Group : i Axis : j) ... 105

3.5.46 SRVO-071 SPHAL alarm (Group : i Axis : j) ... 106

3.5.47 SRVO-072 PMAL alarm (Group : i Axis : j) ... 106

3.5.48 SRVO-073 CMAL alarm (Group : i Axis : j) ... 106

3.5.49 SRVO-074 LDAL alarm (Group : i Axis : j) ... 106

3.5.50 SRVO-075 Pulse not established (Group : i Axis : j)... 106

3.5.51 SRVO-076 Tip Stick Detection (Group : i Axis : j) ... 107

3.8.52 SRVO-081 EROFL alarm (Track enc : i) ... 108

3.5.53 SRVO-082 DAL alarm (Track ebc : i) ... 109

3.5.54 SRVO-084 BZAL alarm (Track enc : i) ... 109

3.5.55 SRVO-087 BLAL alarm (Track enc : i) ... 109

3.5.56 SRVO-089 OHAL2 alarm (Track enc : i) ... 109

3.5.57 SRVO-091 CRCERR alarm (Track enc : i) ... 110

3.5.58 SRVO-092 STBERR alarm (Track enc : i) ... 110

3.5.59 SRVO-093 SPMAL alarm (Track enc : i) ... 110

3.5.60 SRVO-094 PMAL alarm (Track enc : i) ... 111

3.5.61 SRVO-095 CMAL alarm (Track enc : i) ... 111

3.5.62 SRVO-096 LDAL alarm (Track enc : i) ... 111

3.5.63 SRVO-097 Pulse not established (enc : i) ... 111

3.5.64 SRVO-105 Door open or E-stop ... 112

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3.5.67 SRVO-153 CHGAL(CNV) alarm (Group : i Axis : j) ...116

3.5.68 SRVO-156 IPMAL alarm (Group : i Axis : j) ...117

3.5.69 SRVO-194 Servo disconnect ...118

3.5.70 SRVO-199 Control Stop ...120

3.5.71 SRVO-201 Panel E-stop or SVEMG abnormal ...121

3.5.72 SRVO-202 TP E-stop or SVEMG abnormal ...123

3.5.73 SRVO-204 External (SVEMG abnormal) E-STOP ...125

3.5.74 SRVO-205 SVAL1 Fence open (SVEMG abnormal) ...128

3.5.75 SRVO-206 Deadman switch (SVEMG abnormal) ...131

3.5.76 SRVO-213 Fuse blown (Panel PCB) ...133

3.5.77 SRVO-214 Fuse blown (Amp)... 137

3.5.78 SRVO-216 OVC (total) (Robot : i) ...138

3.5.79 SRVO-221 Lack of DSP (Group : i Axis : j) ...138

3.5.80 SRVO-230 SVAL1 Chain 1 (+24V) abnormal SRVO-231 SVAL1 Chain 2 (0V) abnormal ... 139

3.5.81 SRVO-230 Chain 1 (+24V) abnormal with SRVO-001 Operator ´s panel E-stop SRVO-231 Chain 2 (0V) abnormal with SRVO-001 Operator´s panel E-stop ...141

3.5.82 SRVO-230 Chain 1 (+24V) abnormal with SRVO-002 Teach pendant E-stop SRVO-231 Chain 2 (0V) abnormal with SRVO-002 Teach pendant E-stop ...143

3.5.83 SRVO-230 Chain 1 (+24V) abnormal with SRVO-003 Deadman switch released SRVO-231 Chain 2 (0V) abnormal with SRVO-003 Deadman switch released ... 145

3.5.84 SRVO-240 Chain1 (FENCE) abnormal with SRVO-230 Chain1 (+24V) abnormal and SRVO-004 Fence open SRVO-241 Chain2 (FENCE) abnormal with SRVO-231 Chain2 (0V) abnormal and SRVO-004 Fence open ...147

3.5.85 SRVO-242 Chain1 (EXEMG) abnormal with SRVO-230 Chain 1 (+24V) abnormal and SRVO-007 External emergency stops SRVO-243 Chain 2 (EXEMG) abnormal with SRVO-231 Chain 2 (0V) abnormal and SRVO-007 External emergency stops... 150

3.5.86 SRVO-230 Chain 1 (+24V) abnormal with SRVO-232 NTED input SRVO-231 Chain 2 (0V) abnormal with SRVO-232 NTED input ...153 3.5.87 SRVO-230 Chain 1 (+24V) abnormal with

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3.5.93 SRVO-240 Chain 1 (FENCE) abnormal ... 165

3.5.94 SRVO-241 Chain 2 (FENCE) abnormal ... 165

3.5.95 SRVO-242 Chain 1 (EXEMG) abnormal SRVO-243 Chain 2 (EXEMG) abnormal ... 169

3.5.96 SRVO-260 Chain 1 (NTED) abnormal SRVO-261 Chain 2 (NTED) abnormal ... 172

3.5.97 SRVO-262 Chain 1 (SVDCT) abnormal SRVO-263 Chain 2 (SVDCT) abnormal ... 175

3.5.98 SRVO-264 "E.STOP circuit abnormal 1" ... 178

3.5.99 SRVO-265 E.STOP circuit abnormal 2 ... 180

3.5.100 SRVO-266 FENCE1 status abnormal SRVO-267 FENCE2 status abnormal ... 182

3.5.101 SRVO-268 SVOFF1 status abnormal SRVO-269 SVOFF2 status abnormal ... 182

3.5.102 SRVO-270 EXEMG1 status abnormal SRVO-271 EXEMG2 status abnormal... 183

3.5.103 SRVO-272 SVDISC1 status abnormal SRVO-273 SVDISC2 status abnormal ... 183

3.5.104 SRVO-274 NTED1 status abnormal SRVO-275 NTED2 status abnormal ... 184

3.5.105 SRVO-280 SVOFF input ... 184

3.5.106 SRVO-281 SVOFF input (SVEMG abnormal) ... 187

3.5.107 SRVO-282 Chain1 (SVOFF) abnormal SRVO-283 Chain2 (SVOFF) abnormal ... 190

3.5.108 SRVO-282 Chain1 (SVOFF) abnormal with SRVO-230 Chain 1 (+24V) abnormal and SRVO-280 SVOFF input SRVO-283 Chain2 (SVOFF) abnormal with SRVO-231 Chain 2 (0V) abnormal and SRVO-280 SVOFF input ... 193

3.5.109 SRVO-291 "IPM over heat (Group : i Axis : j)" ... 196

3.5.110 SRVO-292 EXT FAN alarm (Group : i A : j) ... 196

3.5.111 SRVO-293 DClink (PSM) HCAL (Group : i Axis : j) ... 196

3.5.112 SRVO-294 EXT FAN (PSM) alarm (Group : i Axis : j) ... 196

3.5.113 SRVO-295 PSM COM alarm (Group : i Axis : j) ... 196

3.5.114 SRVO-296 PSM DISCHG alarm (Group : i Axis : j) ... 197

3.5.115 SRVO-297 PSM Low Volt alarm (Group : i Axis : j) ... 197

3.5.116 SRVO-300 Hand broken/HBK disabled SRVO-302 Set Hand broken to ENABLE ... 197

3.6 FUSED-BASED TROUBLESHOOTING ...199

3.7 TROUBLESHOOTING BASED ON LED INDICATIONS ...211

3.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION (POSITIONING) ...226

3.9 VIBRATION OBSERVED DURING MOVEMENT... 226

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4 PRINTED CIRCUIT BOARDS ... 229

4.1 MAIN BOARD (A16B-3200-0412, -0413) ... 230

4.2 EMERGENCY STOP CONTROL BOARD (A20B-1007-0800) ... 235

4.3 BACKPLANE BOARD ... 236

4.4 PANEL BOARD (A20B-2100-0770) ... 238

4.5 PANEL BOARD (A20B-2100-0771) ... 240

4.6 PROCESS I/O BOARD CA (A16B-2201-0470) ... 241

4.7 PROCESS I/O BOARD CB (A16B-2201-0472) ... 245

4.8 PROCESS I/O BOARD DA (A16B-2201-0480) ... 247

4.9 PROCESS I/O BOARD EA (A16B-3200-0230) ... 250

4.10 PROCESS I/O BOARD EB (A16B-3200-0231)... 255

4.11 PROCESS I/O BOARD FA (A16B-2203-0420)... 257

4.12 PROCESS I/O BOARD GA (A16B-2203-0520)... 260

4.13 PROCESS I/O BOARD HA (A16B-2203-0760)... 263

4.14 PANEL SWITCH BOARD (A20B-1007-0850) ... 266

5 SERVO AMPLIFIERS ... 267

5.1 LED OF SERVO AMPLIFIER ... 269

5.2 SETTING OF SERVO AMPLIFIER ... 271

5.3 DRIVER IC FOR ROBOT DI/DO 272

6 SETTING THE POWER SUPPLY ... 273

6.1 BLOCK DIAGRAM OF THE MAIN POWER INCLUDING POWER SUPPLY... 273

6.2 SELECTING TRANSFORMER TAPS ... 276

6.3 CHECKING THE POWER SUPPLY UNIT (A16B-2203-0370) ... 281

7 REPLACING A UNIT ... 285

7.1 A-CABINET ... 285

7.1.1 Replacing the A-cabinet Top Panel ...285

7.1.2 Replacing the A-cabinet Rear Panel ...286

7.1.3 Replacing the A-cabinet Louver ...287

7.1.4 Replacing the A-cabinet Door ...288

7.2 REPLACING THE PRINTED-CIRCUIT BOARDS ... 288

7.2.1 Replacing the Backplane Board (Unit) ...289

7.2.2 Replacing the Power Unit and Printed-Circuit Boards on the Backplane Unit ...290

7.2.3 Replacing the Process I/O Board EA, EB, FA,GA (A-cabinet) ...292

7.2.4 Replacing the Panel Board ...293

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7.9.1 Replacing the Base Unit of I/O Unit Model A ... 323

7.9.2 Replacing a Module ... 324

7.10 REPLACING THE TEACH PENDANT ...325

7.11 REPLACING THE CONTROL SECTION FAN MOTOR ...327

7.12 REPLACING THE AC FAN MOTOR ...328

7.12.1 Replacing the Heat Exchanger and Door Fan Unit (A-cabinet) ... 328

7.12.2 Replacing the Rear Fan Unit (A-cabinet) ... 330

7.12.3 Replacing External Air Fan Unit and Door Fan (B-cabinet) ... 331

7.13 REPLACING THE OPERATOR´S PANEL AND PANEL SWITCH BOARD ...333

7.14 REPLACE THE MODE SWITCH ...336

7.15 REPLACING FUSES ...337

7.15.1 Replacing Fuses in the Servo Amplifier ... 337

7.15.2 Replacing Fuses in the Power Unit ... 338

7.15.3 Replacing the Fuse on the Process I/O Boards ... 339

7.15.4 Replacing the Fuse on the Panel Board ... 343

7.15.5 Replacing the Fuses of the Power Distributing Unit ... 344

7.16 REPLACING RELAYS ...45

7.16.1 Replacing Relays on the Panel Board ... 345

7.17 REPLACING BATTERY ...346

7.17.1 Battery for Memory Backup (3 VDC) ... 346

II. CONNECTION

1 GENERAL ... 349

2 BLOCK DIAGRAM ... 351

3 ELECTRICAL CONNECTIONS ... 355

3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS ...355

3.2 EXTERNAL CABLE WIRING DIAGRAM ...358

3.2.1 Robot Connection Cables ... 358

3.2.2 Teach Pendant Cable ... 365

3.2.3 Connecting the Input Power ... 366

3.2.4 Connecting the External Power Supply ON/OFF Switch ... 368

3.2.5 Connecting the External Emergency Stop ... 371

3.2.6 Connecting the Operation Box ... 383

3.2.7 Connecting the NTED Signal (CRM65) ... 386

3.2.8 Connecting the Auxiliary Axis Brake (CRR65 A/B) ... 387

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4 PERIPHERAL DEVICE, ARC WELDING, AND

END EFFECTOR INTERFACES ... 389

4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM ... 392

4.1.1 When Process I/O Board EA/EB/GA is used (A-cabinet) ...392

4.1.2 When Process I/O Board FA is Used (A-cabinet) ...394

4.1.3 When Process I/O Board CA/CB/HA is Used (B-cabinet) ...395

4.1.4 When Process I/O Board DA is Used (B-cabinet) ...397

4.1.5 When I/O Unit-MODEL A is Used ...399

4.1.5.1 In case of B-cabinet ... 399

4.1.6 When Two or more Process I/O Boards and I/O Unit-Model A are Used ...400

4.2 PERIPHERAL DEVICE INTERFACE COMBINATION ... 401

4.2.1 In Case of A-cabinet ...401

4.2.2 In Case of B-cabinet ...401

4.3 PROCESS I/O BOARD SIGNALS ... 403

4.4 INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS ... 409

4.4.1 Peripheral Device and Control Unit Connection ...409

4.4.2 Connection Between the Mechanical Unit and End Effector ...429

4.4.3 Connection Between the Control Unit and Welder ...432

4.5 DIGITAL I/O SIGNAL SPECIFICATIONS ... 443

4.5.1 Peripheral Device Interface ...443

4.5.2 End Effector Control Interface ...446

4.5.3 I/O Signal Specifications for ARC-Welding Interface ...448

4.6 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES AND WELDERS ... 453

4.6.1 Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins) ...453

4.6.2 Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins) ...454

4.6.3 ARC Weld Connection Cable (CRW1, CRW7: Honda Tsushin, 34 pins) ...454

4.7 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS, AND ARC WELDERS ... 455

4.7.1 Peripheral Device Connection Cable ...455

4.7.2 Peripheral Device Cable Connector ...456

4.7.3 End Effector Cable Connector ...459

4.7.4 Recommended Cables ...460

4.8 CONNECTION OF HDI ... 461

4.8.1 Connecting HDI ...461

4.8.2 Input Signal Rules for the High-speed Skip (HDI) ...464

4.9 CONNECTING THE COMMUNICATION UNIT ... 465

4.9.1 RS-232-C Interface ...465

4.9.1.1 Interface ... 465

4.9.1.2 RS-232-C Interface signals... 467

4.9.1.3 Connection between RS-232-C interface and external device ... 468

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5 TRANSPORTATION AND INSTALLATION ... 481

5.1 TRANSPORTATION ...481 5.2 INSTALLATION ...482 5.2.1 Installation Method ... 482 5.2.2 Assemble at Installation ... 487 5.3 INSTALLATION CONDITION ...491

5.4 ADJUSTMENT AND CHECKS AT INSTALLATION ...493

5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION .494 5.5.1 Peripheral Device Interface Processing ... 494

5.5.2 Resetting Overtravel ... 494

5.5.3 How to Disable/Enable HBK ... 495

5.5.4 How to Disable/Enable Pneumatic Pressure Alarm (PPABN) ... 496

III. APPENDIX

A TOTAL CONNECTION DIAGRAM ... 497

B SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE ... 527

B.1 SIGNALS ...527

B.2 SETTING COMMON VOLTAGE ...530

B.3 I/O SIGNALS ...531

B.3.1 Input Signals ... 531

B.3.2 Output Signals ... 537

B.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT ...541

B.4.1 Overview ... 541

B.4.2 Input/Output Hardware Usable In the R-j3iB Controller ... 541

B.4.3 Software Specifications ... 541

C POWER DISTRIBUTATION CIRCUIT DIAGRAM ... 543

D OPTICAL FIBER CABLE ... 551

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PREFACE

This manual describes the following models (R-J3iB controller).

Model Abbreviation

FANUC Robot R- 2000iA/165F R-2000iA/165F R-2000iA FANUC Robot R- 2000i /200F R-2000iA/200F R-2000iA FANUC Robot R-2000iA/200FO R-2000iA/200FO R-2000iA FANUC Robot R-2000iA/165EA R-2000iA/165EA R-2000iA FANUC Robot R-2000iA/165EW R-2000iA/165EW R-2000iA FANUC Robot R- 2000i /165R R-2000iA/165R R-2000iA FANUC Robot R- 2000i /200R R-2000iA/200R R-2000iA FANUC Robot R- 2000i /125L R-2000iA/125L R-2000iA FANUC Robot R- 2000i /165CF R-2000iA/165CF R-2000iA FANUC Robot R-2000iA/200T R-2000iA/200T R-2000iA FANUC Robot M-6iB M-6iB M-6iB FANUC Robot M-6iB/6C M-6iB/6C M-6iB FANUC Robot M-16iB/20 M-16iB/20 M-16iB FANUC Robot M-16iB/10L M-16iB/10L M-16iB FANUC Robot M-16iB/20T M-16iB/20T M-16iB FANUC Robot M-16iB/10LT M-16iB/10LT M-16iB

FANUC Robot ARC Mate 100iB ARC Mate 100iB ARC Mate 120iB FANUC Robot ARC Mate 120iB ARC Mate 120iB ARC Mate 120iB FANUC Robot ARC Mate 120iB/10L ARC Mate 120iB/10L ARC Mate 120iB FANUC Robot ARC Mate 120iB/20T ARC Mate 120iB/20T ARC Mate 120iB FANUC Robot ARC Mate 120iB/10LT ARC Mate 120iB/10LT ARC Mate 120iB FANUC Robot M-710iB/45 M-710iB/45 M-710iB

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FANUC Robot M-410iB/450 M-410iB/450 M-410iB FANUC Robot M-420iA M-420iA M-420iA FANUC Robot M-421iA M-421iA M-421iA FANUC Robot F-200iB F-200iB F-200iB FANUC Robot S-500iB S-500iB S-500iB FANUC Robot S-900iB/400 S-900iB/400 S-900iB FANUC Robot S-900iB/200 S-900iB/200 S-900iB FANUC Robot S-900iB/220L S-900iB/220L S-900iB FANUC Robot LR Mate 200iB LR Mate 200iB LR Mate 200iB FANUC Robot LR Mate 200iB/3L LR Mate 200iB/3L LR Mate 200iB

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1 SAFETY PRECAUTIONS

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

1.1 OPERATOR SAFETY

Operator safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure operator safety.

1. Have the robot system operators attend the training courses held by FANUC.

2. Even when the robot is stationary, it is possible that the robot is still ready to move state and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure operator safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion.

3. Install a safety fence with a gate so that no operator can enter the work area without passing through the gate. Equip the gate with an interlock that stops the robot when the gate is opened.

4. Provide the peripheral devices with appropriate grounding (Class 1, Class 2, or Class 3). 5. Try to install the peripheral devices outside the work area.

6. Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand.

7. Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when an operator enters the work area.

8. If necessary, install a safety lock so that no one except the operator in charge can turn on the power of the robot.

FANUC provides various training courses. Contact our sales office for details.

The controller is designed to receive this interlock signal. When the gate is opened and this signal received, the controller stops the robot in an emergency. For connection, see Fig.1.1.

The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.

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Fig. 1.1 Safety Fence and Safety Gate

1 Limit switch for the safety gate 2 Note:

Terminals FENCE 1 and FENCE 2 are on the PC board in the operator’s panel.

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1.1.1 Operator Safety

The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators.

1. If it is not necessary for the robot to operate, turn off the power of the robot controller or press the EMERGENCY STOP button, and then proceed with necessary work.

2. Operate the robot system at a location outside the work area.

3. Install a safety fence with a safety gate to prevent any worker other than the operator from entering the work area unexpectedly and also to prevent the worker from entering a dangerous area. 4. Install an EMERGENCY STOP button within the operator's reach.

Fig. 1.1.1 Connection Diagram for External Emergency Stop Switch

The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

1 External EMERGENCY STOP button 3 Note: Connect to EES1 and EES11, EES2 and EES21. 2 Panel board

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1.1.2 Safety of the Teach Pendant Operator

While teaching the robot, it is necessary for the operator to enter the work area of the robot. It is particularly necessary to ensure the safety of the teach pendant operator.

1. Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. 2. Before teaching the robot, check that the robot and its peripheral devices are all in the normal

operating condition.

3. When entering the robot work area and teaching the robot, be sure to check the location and condition of the safety devices (such as the EMERGENCY STOP button and the deadman's switch on the teach pendant).

4. The teach pendant operator should pay careful attention so that no other workers enter the robot work area.

NOTE

The teach pendant supplied by FANUC is provided with a teach pendant enable switch and a deadman's switch in addition to the EMERGENCY STOP button. The functions of each switch are as follows.

EMERGENCY STOP button:

• Pressing this button stops the robot in an emergency, irrespective to the condition of the teach pendant enable switch.

Deadman's switch:

• The function depends on the state of the teach pendant enable switch. When the enable switch is on:

• Releasing the finger from the deadman switch or holding the deadman switch strongly stops the robot in an emergency.

When the enable switch is off:

• The deadman's switch is ineffective.

NOTE

The deadman switch is provided so that the robot operation can be stopped simply by releasing finger from the teach pendant or holding the deadman switch strongly in case of emergency. The R-J3iB has adopted a 3-position deadman switch as an RIA-specification teach pendant. Pressing the 3-position deadman switch halfway makes the robot operable. Releasing the finger from the deadman switch or holding the deadman switch strongly causes the robot to enter the emergency stop state.

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5. When entering the robot work area, the teach pendant operator should enable the teach pendant whenever he or she enters the robot work area. In particular, while the teach pendant enable switch is off, make certain that no start command is sent to the robot from any operator's panel other than the teach pendant.

6. To start the system using the operator's panel/operation box, make certain that nobody is in the robot work area and that there are no abnormal conditions in the robot work area.

7. When a program is completed, be sure to carry out a test run according to the procedure below. a. Run the program for at least one operation cycle in the single step mode at low speed. b. Run the program for at least one operation cycle in the continuous operation mode at low

speed.

c. Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing.

d. Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble.

NOTE

In addition to the above, the teach pendant enable switch and the deadman's switch also have the following function.

By pressing the deadman's switch while the enable switch is on, the emergency stop factor (normally the safety gate) connected to EAS1 and EAS11, EAS2 and EAS21 of the controller is invalidated. In this case, it is possible for an operator to enter the fence during teach operation without pressing the EMERGENCY STOP button. In other words, the system understands that the combined operations of pressing the teach pendant enable switch and pressing the deadman's switch indicates the start of teaching. The teach pendant operator should be well aware that the safety gate is not functional under this condition and bear full responsibility to ensure that no one enters the fence during teaching.

The teach pendant, operator's panel/operation box, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode of the teach pendant enable switch and the remote condition.

Teach pendant

enable switch Remote condition Teach pendant

Operators panel/

operation box Peripheral devices

On Independent Allowed to start Not allowed Not allowed Off Local Not allowed Allowed to start Not allowed Off Remote Not allowed Not allowed Allowed to start

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1.1.3 Safety During Maintenance

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

1. Except when specifically necessary, turn off the power of the controller while carrying out maintenance. Lock the power switch, if necessary, so that no other person can turn it on.

2. When disconnecting the pneumatic system, be sure to reduce the supply pressure.

3. Before the start of teaching, check that the robot and its peripheral devices are all in the normal operating condition.

4. If it is necessary to enter the robot work area for maintenance when the power is turned on, the worker should indicate that the machine is being serviced and make certain that no one starts the robot unexpectedly.

5. Do not operate the robot in the automatic mode while anybody is in the robot work area.

6. When it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers are working nearby, make certain that their escape path is not obstructed.

7. When a tool is mounted on the robot, or when any moving device other than the robot is installed, such as belt conveyor, pay careful attention to its motion.

8. If necessary, have a worker who is familiar with the robot system stand beside the operator's panel and observe the work being performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time.

9. When replacing or reinstalling components, take care to prevent foreign matter from entering the system

10.When handling each unit or printed circuit board in the controller during inspection, turn off the power of the controller and also turn off the circuit breaker to protect against electric shock. 11.When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or

other parts of non-specified ratings. They may cause a fire or result in damage to the components in the controller.

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1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

1.2.1 Precautions in Programming

1. Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received.

2. Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal.

3. For a system in which the robot and its peripheral devices are insynchronous motion, particular care must be taken in programming so that they donot interfere with each other.

4. Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states.

1.2.2 Precautions for Mechanism

1. Keep the component cells of the robot system clean, and operate the robot in an environment free of grease, water, and dust.

2. Employ a limit switch or mechanical stopper to limit the robot motion so that the robot does not come into contact with its peripheral devices or tools.

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1.3 SAFETY OF THE ROBOT MECHANISM

1.3.1 Precautions in Operation

1. When operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality.

2. Before pressing the jog key, be sure you know in advance what motion the robot will perform in the jog mode.

1.3.2 Precautions in Programming

1. When the work areas of robots overlap, make certain that the motions of the robots do not interfere with each other.

2. Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

1.3.3 Precautions for Mechanisms

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

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1.4 SAFETY OF THE END EFFECTOR

1.4.1 Precautions in Programming

1. To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control.

2. Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.

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1.5 SAFETY IN MAINTENANCE

1. Never enter the robot work area while the robot is operating. Turn off the power before entering the robot work area for inspection and maintenance.

2. If it is necessary to enter the robot work area with the power turned on, first press the EMERGENCY STOP button on the operator's panel.

3. When replacing or reinstalling components, take care to prevent foreign matter from entering the system. When replacing the parts in the pneumatic system, be sure to reduce the pressure in the piping to zero by turning the pressure control on the air regulator.

4. When handling each unit or printed circuit board in the controller during inspection, turn off the power of the controller and turn off the circuit breaker to protect against electric shock.

5. When replacing parts, be sure to use those specified by FANUC.

In particular, never use fuses or other parts of non-specified ratings. They may cause a fire or result in damage to the components in the controller.

6. Before restarting the robot, be sure to check that no one is in the robot work area and that the robot and its peripheral devices are all in the normal operating state.

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1.6 WARNING LABEL

Description

Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing as well.

1. Step-on prohibitive label

Fig. 1.6 (a) Step-on Prohibitive Label Description

Be cautious about a section where this label is affixed, as the section generates heat. If you have to inevitably touch such a section when it is hot, use a protective provision such as heat-resistant gloves.

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Fig. 1.6. (b) High-Temperature Warning Label

Description

A high voltage is applied to the places where this label is attached. Before starting maintenance, turn the power to the control unit off, then turn the circuit breaker off to avoid electric shock hazards. Be careful with servo amplifier and other units because high-voltage places in these units may remain in the high-voltage state for a fixed time.

3. High-voltage warning label

Fig. 1.6 (c) High-Voltage Warning Label

Description

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

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1 OVERVIEW

This manual describes the maintenance and connection of the R-J3iB robot controller (called the R-J3iB).

Maintenance Part :

Troubleshooting, and the setting, adjustment, and replacement of units Connection Part :

Connection of the R-J3iB controller to the robot mechanical unit and peripheral devices, and installation of the controller

- For information on third party approvals, contact your FANUC representative.

WARNING

Before you enter the robot working area, be sure to turn off the power to the controller or press the EMERGENCY STOP button on the operator´s panel/operation box or teach pendant. Otherwise, you could injure personnel or damage equipment.

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2 CONFIGURATION

2.1 EXTERNAL VIEW OF THE CONTROLLER

The appearance and components might slightly differ depending on the controlled robot, application, and options used.

Fig. 2.1 (a), (b), (c), (d) and (e) show external and internal views of the R-J3iB A-cabinet and B-cabinet controllers.

Fig. 2.1 (f), (g) and (h) show the MODE SELECT switch, the operator panel and the operator panel interface.

Fig. 2.1 (i) and (j) show the block diagram of R-J3iB.

Fig. 2.1 (a) External View of the R-J3iB Controller (A-cabinet)

1 Operation box 3 R-J3iB controller 2 Teach pendant

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Fig. 2.1 (b) External View of the R-J3iB Controller (B-cabinet) 1 Mode switch 3 Operator´s panel 2 Teach pendant

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Fig. 2.1 (c) R-J3iB A-cabinet interior

1 Teach pendant 5 Power supply unit 2 E-stop unit 6 Fan unit

3 Servo amplifier 7 Regenerative resistor 4 Main board 8 Transformer

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1 Servo Amplifier 11 Backplane 2 External air Fan Unit 12 E-Stop Unit 3 Emergency Stop Button 13 Main Board 4 Battery 14 Breaker

5 DC Fan Unit 15 Power supply Unit 6 Panel Board 16 Floor Fan Unit 7 Operator Panel 17 Enable switch 8 MODE Switch 18 Teach Pendant 9 Door Fan 19 Emergency Stop Button 10 Process I/O Board

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Fig. 2.1 (e) R-J3i B-cabinet overview (Back)

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Fig. 2.1 (g) R-J3iB panel overview

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Tab. 2.1 Servo amplifier and regenerative resistor unit

Robot models Servo amplifier Regenerative resistor _A-CABINET Regenerative resistor _B-CABINET

R-2000iA/200T A06B-6105-H001 --- A05B-2452-C200

S-900iB A06B-6105-H001 A05B-2451-C204 A05B-2452-C200

M-410iB A06B-6105-H001 A05B-2451-C204 A05B-2452-C200

R-2000iA (except/200T) A06B-6105-H002 A05B-2451-C202 A05B-2452-C200

S-500iB A06B-6105-H002 A05B-2451-C202 A05B-2452-C200

M-710iB A06B-6105-H002 A05B-2451-C202 A05B-2452-C200

M-16iB A06B-6105-H002 A05B-2451-C202 A05B-2452-C200

ARC Mate 120iB A06B-6105-H002 A05B-2451-C202 A05B-2452-C200

M-420iA, M-421iA A06B-6105-H002 A05B-2451-C204 A05B-2452-C200 M-6iB A06B-6105-H003 A05B-2451-C201 A05B-2452-C201 ARC Mate 100iB A06B-6105-H003 A05B-2451-C201 A05B-2452-C201 F-200iB A06B-6105-H003 A05B-2451-C201 A05B-2452-C201 LR Mate 200iB A06B-6105-H003 --- A05B-2452-C201

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2.2 COMPONENT FUNCTIONS

- Main board

The main board contains a microprocessor, its peripheral circuits, memory, and operator's panel control circuit. The main CPU controls servo mechanism positioning and servo amplifier voltages.

- Battery retains main board memory when controller power is off.

- I/O printed circuit board and FANUC I/O Unit MODEL-A

Various types of printed circuit boards are provided for applications including process I/O. The FANUC I/O unit MODEL A can also be installed. When it is used, various I/O types can be selected. These are connected with FANUC I/O Link.

- E-stop unit

This unit controls the emergency stop system with control reliable E-stop performance criteria for both of the magnetic contactor and the precharge of the servo amplifier.

- Power supply unit

The power supply unit converts the AC power to various levels of DC power.

- Backplane printed circuit board

The various control printed circuit boards are mounted on the backplane printed circuit board.

- Teach pendant

All operations including robot programming are performed with this unit. The controller status and data are indicated on the liquid-crystal display (LCD) on the pendant.

- Servo amplifier

The servo amplifier controls servomotor power, pulse coder, brake control, overtravel and hand broken.

- Operator´s panel/operation box

Buttons and LEDs on the operator´s panel/operation box are used to start the robot and to indicate the robot status. The panel has a port for the serial interface to an external device and an interface to connect the memory card for data backup. It also controls the emergency stop control circuit.

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The supply voltage is converted to an AC voltage required for the controller by the transformer.

- Fan unit, heat exchanger

These components cool the inside of the control unit.

- Circuit breaker

If the electric system in the controller malfunctions, or if abnormal input power causes high current in the system, the input power is connected to the circuit breaker to protect the equipment.

- Regenerative resistor

To discharge the counter electromotive force from the servomotor, connect a regenerative resistor to the servo amplifier.

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2.3 PREVENTIVE MAINTENANCE

Daily maintenance and periodic maintenance/inspection ensure reliable robot performance for extended periods of time.

1. Daily maintenance

Before operating the system each day, clean each part of the system and check the system parts for any damage or cracks. Also check the following:

a. Before service operation

Check the cable connected to the teach pendant for excessive twisting. Check the controller and peripheral devices for abnormalities.

b. After service operation

At the end of service operation, return the robot to the specified position, then turn off the controller. Clean each part, and check for any damage or cracks. If the ventilation port of the controller is dusty, clean it.

c. Check after one month

Check that the fan is rotating normally. If the fan has dirt and dust built up, clean the fan according to step (d) described below for inspection to be performed every 6 months. d. Periodic inspection performed every six months

Remove the top cover, louver, and back panel (if possible), then remove any dirt and dust from the inside of the transformer compartment. Wipe off dirt and dust from the fan and transformer.

e. Replacing battery

Replace the lithium battery on the front panel of the main board every 4 years. Please refer to the section 7.17.

2. Maintenance tools

The following maintenance tools are recommended: a. Measuring instruments

AC/DC voltmeter (A digital voltmeter is sometimes required.)

Oscilloscope with a frequency range of 5 MHz or higher, two channels b. Tools

Phillips screwdrivers : Large, medium, and small Standard screwdrivers: Large, medium, and small Nut driver set (Metric)

Pliers

Needle-nose pliers Diagonal cutting pliers

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3 TROUBLESHOOTING

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

3.1 POWER CANNOT BE TURNED ON

Check and Corrective action Figure

(Check 1)

Check that the circuit breaker is on and has not tripped. (Corrective action)

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(Check 2)

Check whether the LED (PIL: green) on the power supply unit is on.

(Corrective action)

If the LED is not on, 200 VAC is not supplied to the power supply unit. It is likely that fuse F1 in the power supply unit has blown.

- If 200 VAC is not supplied:

Find the cause by referencing the general schematic diagram presented in the appendix.

- If 200 VAC is supplied:

Find the cause of the blown fuse. Fuse F1 is in the power supply unit. Before you start troubleshooting, turn off the circuit breaker.

a) If fuse F1 has blown: - See Corrective action (1). b) If fuse F1 has not blown: - Replace the power supply unit. (Corrective action(1))

Causes of blown fuses F1 and corrective action

a) Check whether the unit and printed-circuit board connected to the connectors CP2 and CP3 in the power supply unit are abnormal, by referencing the general schematic diagram presented in the appendix.

b) Short-circuit in the surge absorber VS1

VS1 is inserted to absorb surge voltage between input lines.If the surge voltage is excessive or sustained, excessively high voltage is applied to VS1 and a failure occurs in the short-circuit mode, causing F1 to blow. If a short-circuit occurs in VS1, and there is not a spare part, the system is permitted to operate without VS1. In this case, however, obtain and install a new VS1 as soon as possible. VS1 ordering number: A50L-2001-0122#G431k

c) Short-circuit of diode stack DB1

d) The secondary power supply module is faulty : If one of the causes (b) to (c) above is detected, replace the power supply unit with a spare unit.

The spec. for F1 is : A60L-0001-0396#8.0A

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Check and Corrective action Figure

(Check 3)

Check whether the EXON1 and EXON2 signals, and the EXOFF1 and EXOFF2 signals are connected on the terminal block on the panel board.

(Corrective action)

If the external ON/OFF function is not used, connect the EXON1 and EXON2 the EXOFF1 and EXOFF2. If the external ON and OFF lines are already used, check the mating contacts and the cable.

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(Check 4)

Check whether the connector (JRS11) on the main board or the connector (JRS11) on the panel board is connected properly. Another probable cause is that the cable connected to either of these connectors is faulty.

(Check 5)

Check 1 to 3 above confirm that 200 VAC power is supplied to connector CP1 of the power supply unit and that the ON/OFF switch functions normally. Therefore check the power supply unit using the following procedure:

If the LED (ALM: red) on the power supply unit is on

Check if the +24 V external connection cable is connected to 0 V or ground.

a) Fuse F4 blown : See corrective action (2).

b) None of the above fuses blown [d) is also probable] :

A printed circuit board or unit that uses a DC supply voltage (+3.3V, +5V, +24V, or +/-15V) is faulty. c) None of the above fuses blown :

Check that 200 VAC is supplied to connector CP1. If it is supplied replace the power supply unit.

(Corrective action)

If the power supply unit is not faulty, replace the panel board or operator‘’s panel.

(Corrective action (2))

Causes of blown fuse F4 and corrective action The device connected to connector CP5 of the power supply unit may be faulty. If no device is connected to CP5 or the connected device is normal, the +24 V power used in a printed circuit board connected to the backplane is faulty.

The code of F4 is A60L-0001-0046#7.5 :

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3.2 ALARM OCCURRENCE SCREEN

The alarm occurrence screen displays only the alarm conditions that are currently active. If an alarm reset signal is input to reset the alarm conditions, the alarm occurrence screen displays the message "PAUSE or more serious alarm has not occurred."

The alarm occurrence screen displays only the alarm conditions (if any) that occur after the most recently entered alarm reset signal. To erase all alarm displays from the alarm occurrence screen. Press the CLEAR key (+ shift) on the alarm history screen.

The alarm occurrence screen is intended to display PAUSE or more serious alarms. It will not display WARN, NONE, or a reset. It is possible to disable PAUSE and some of more serious alarms from being displayed by setting the $ER_NOHIS system variable appropriately.

If two or more alarms have occurred, the display begins with the most recent alarm. Up to 100 lines can be displayed.

If an alarm has a cause code, it is displayed below the line indicating the alarm.

Fig. 3.2 Alarm Occurrence Screen and Alarm History Screen Display Procedure 1 Press the screen selection key to select [4 ALARM] 5 Press F3 [ACTIVE]

2 Press the alarm key 6 Press F3 [HIST]

3 Automatic alarm display upon occurrence 7 Alarm history screen display 4 Alarm occurrence screen display

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Displaying the alarm history/alarm detail information

Step

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

2. Select [ALARM]. You will see a screen similar to the following

3. To display the alarm detail screen, press F5, [HELP].

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

NOTE

The latest alarm is assigned number 1. To view messages that are currently not on the screen, press the F5, HELP, then press the right arrow key.

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The following map indicates teach pendant operations used to check an alarm.

NOTE

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

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3.3 SAFETY SIGNALS

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

Tab. 3.3 Safety Signals

Safety signal Description

Operator´s panel/operation box

emergency stop This item indicates the state of the emergency stop button on the operator´s panel or operation box. If the EMERGENCY STOP board is pressed, the state is indicated as "TRUE".

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

External emergency stop This item indicates the state of the external emergency stop signal. If the EMERGENCY STOP signal is input, the state is indicated as "TRUE". Fence open This item indicates the state of the safety fence. If the safety fence is

open, the state is indicated as "TRUE".

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

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

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

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

pressure signal is connected to the air pressure sensor. If the air pressure is not higher than the specified value, the state is indicated as "TRUE".

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1. Press the MENUS key to display the screen menu. 2. Select STATUS on the next page.

3. Press F1, [TYPE] to display the screen switching menu.

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3.4 MASTERING

Mastering 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) requires zero-degree or jig position mastering. (Zero-degree position mastering is just for quick-fix purposes. After zero-degree position mastering is used, jig position mastering should be performed later.)

The mastering procedure is described below. For details, refer to an applicable maintenance manual of the mechanical unit or operator's manual of control unit.

Condition

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

Step

1. Press <MENUS>. 2. Select SYSTEM. 3. Press F1, TYPE.

4. Select Master/Cal you will see a screen similar to the following.

5. Jog the robot to the mastering position. Release the brake on the manual brake control screen if necessary.

6. Select "1 FIXTURE POSITION MASTER" and press the F4 key (yes). Mastering data is set.

NOTE

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

Alternatively, to perform positioning, turn the power off, then turn it on again. Calibration is performed whenever the power is turned on.

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3.5 TROUBLESHOOTING USING THE ERROR CODE

3.5.1 SRVO-001 Operator panel E-stop

(Explanation)

The emergency stop button on the operator's panel or operation box is pressed.

If the SYST-067 (Panel HSSB disconnect) alarm is also generated, or if the LED (green) on the panel board is turned off, communication between the main board (JRS11) and the panel board (JRS11) is abnormal. The connectors of the cable between the main board and the panel board may be loose. Or, the cable, panel board, or main board may be faulty. (Note)

(Action 1)

Release the emergency stop button pressed on the operator's panel/operation box. (Action 2)

Check the wires connecting between the emergency stop button and the connector (CRM51) on panel switch board for continuity. If an open wire is found replace the entire harness.

(Action 3)

With the emergency stop in the released position, check for continuity across the terminals of the switch. If continuity is not found, the emergency stop button is broken. Replace the switch unit or the operator's panel/operation box.

(Action 4)

Replace the panel board. (Action 5)

Replace the cable connecting between the main board (JRS11) and the panel board (JRS11). Before executing the (Action6), perform a complete controller back-up to save all your programs and settings.

(Action 6)

Replace the main board.

NOTE

If SYST-067 Panel HSSB disconnect alarm occurs simultaneously or the RDY LED is turned off, the following alarms are also generated.

SRVO-001 Operator's panel E-stop. SRVO-004 Fence open.

SRVO-007 External emergency stop.

SRVO-204 External (SVEMG abnormal) E-stop. SRVO-213 Fuse blown (Panel PCB).

SRVO-280 SVOFF input

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Fig. 3.5.1 (a) SRVO-001 Operator´s panel E-stop

1 Emergency stop button 3 A-cabinet 2 Breaker 4 B-cabinet

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Fig. 3.5.1 (b) SRVO-001 Operator´s panel E-stop

Fig. 3.5.1 (c) SRVO-001 Operator´s panel E-stop

1 Connector (CRT 8) 3 Connector (JRS11) 2 LED (Green) 4 Panel board

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3.5.2 SRVO-002 Teach pendant E-stop

(Explanation)

The emergency stop button on the Teach Pendant was pressed. (Action 1)

Release the emergency stop button on the teach pendant. (Action 2)

Replace Teach Pendant.

Fig. 3.5.2 SRVO-002 Teach pendant E-stop 1 Emergency stop button

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3.5.3 SRVO-003 Deadman switch released

(Explanation)

The teach pendant is enabled, but the deadman switch is not pressed. Deadman switch is three position switch.

Don´t press the switch to the second „open“ position. Switch is enabled in middle position only.

(Action 1)

Press the deadman switch to run the robot. (Action 2)

Replace the teach pendant.

Fig. 3.5.3 SRVO-001 Deadman switch released 1 Deadman switch

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3.5.4 SRVO-004 Fence open

(Explanation)

On the terminal block TBOP4 of the panel board, no connection is made between 5 (EAS1) and 6 (EAS11) or between 7 (EAS2) and 8 (EAS21). If a safety fence is connected between 5 (EAS1) and 6 (EAS11) or between 7 (EAS2) and 8 (EAS21), the door of the safety fence is open. If the SYST-067 (Panel HSSB disconnect) alarm is also generated, or if the LED (green) on the panel board is turned off, communication between the main board (JRS11) and the panel board (JRC11) is abnormal. The connectors of the cable between the main board and the panel board may be loose. Or, the cable, panel board, or main board may be faulty. (Note)

In case that RDY LED (green) is lit. (Action 1)

If a safety fence is connected, close the door. (Action 2)

Check the switch and cable connected to 5 (EAS1) and 6 (EAS11) or 7 (EAS2) and 8 (EAS21) on TBOP4.

(Action 3)

When this signal is not used, make a connection between 5 (EAS1) and 6 (EAS11) or between 7 (EAS2) and 8 (EAS21).

(Action 4)

Replace the panel board.

In case that RDY LED (green) is not lit. (Action 1)

Check whether FUSE1 on the panel board is blown.

If FUSE1 is blown, replace FUSE1 after removing the cause.

Else if, check the voltage of EXT24V and EXT0V (TBOP6). If external 24V, 0V is not used check the jumper pins between EXT24V and INT24V, EXT0V and INT 0V (TBOP6).

(Action 2)

(Action 4)

NOTE

FENCE input (AUTO STOP) is a safety stop input. When this input is opened, the robot decelerates in a controlled manner and then stops. The magnetic contactor opens after the robot stops.

WARNING

Do NOT short-circuit, or disable, this signal in a system in which the Fence signal is in use, as it is very dangerous. If it is necessary to run the robot by short-circuiting the signal even temporarily, an additional safety provision must be provided.

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Fig. 3.5.4 (a) SRVO-004 Fence open

NOTE

If the external 24V is not supplied adequately to TBOP6 (EXT24V, EXT0V), the following alarms are also generated.

SRVO-004 Fence open.

SRVO-007 SVALI External E-stop. SRVO-213 Fuse blown (Panel PCB). SRVO-280 SVOFF input

NOTE

Check the alarm history display on the teach pendant.

1 Short connection 5 (EAS1) and 6 (EAS11) 5 Connector (JRS11) 2 Short connection 7 (EAS2) and 8 (EAS21) 6 Panel board 3 Connector (CRT 8) 7 TB0P6 4 LED (Green)

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Fig. 3.5.4 (b) SRVO-004 Fence open

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3.5.5 SRVO-005 Robot overtravel

(Explanation)

The robot has moved beyond a hardware limit switch on the axes. It is factory-placed in the overtravel state for packing purposes.

If the Overtravel signal is not in use, it may have been disabled by short-circuiting in the mechanical unit.

(Action 1)

1. Select [System OT release] on the overtravel release screen to release each robot axis from the overtravel state.

2. Hold down the shift key, and press the alarm release button to reset the alarm condition. 3. Still hold down the shift key, and jog to bring all axes into the movable range.

(Action 2)

Replace the limit switch. (Action 3)

Check the FS2 fuse on the servo amplifier.

If the SRVO-214 Fuse blown alarm is also generated, FS2 fuse has blown. (Action 4)

Check the end effector connector. (Action 5)

Replace the servo amplifier. (Action 6)

Verify the following for connector RP1 at the base of the robot :

1. There are no bent or dislocated pins in the male or female connectors. 2. The connector is securely connected.

Then verify that connectors CRF7 and CRM68 on the servo amplifier is securely connected. Also verify that the RP1 cable is in good condition, and there are no cuts or kinks visible. If no limit switch is in use, a jumper connector must be attached in the mechanical unit. Check for the jumper connector.

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Fig. 3.5.5 SRVO-005 Robot overtravel

1 Servo amplifier 4 Connector (CRF7) 2 A-cabinet 5 Connector (CRM68) 3 B-cabinet

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3.5.6 SRVO-006 Hand broken

(Explanation)

The safety joint (if in use) might have been broken. Alternatively, the HBK signal on the robot connection cable might be a ground fault or a cable disconnection.

If the Hand broken signal is not in use, it can be disabled by software setting.

Refer to Subsection 5.5.3 in Part III, "Connections," of "Maintenance Manual" for how to disable the Hand broken signal.

(Action 1)

Hold down the shift key, and press the alarm release button to reset the alarm condition. Still hold down the shift key, and jog the tool to the work area.

1. Replace the safety joint. 2. Check the safety joint cable. (Action 2)

Check the FS2 fuse on the servo amplifier. If the SRVO-214 Fuse alarm is also generated, FS2 fuse has blown.

(Action 3)

Then verify that connector CRM7 on the servo amplifier is securely connected. Also verify that the RP1 cable is in good condition, and there are no cuts or kinks visible. Check the robot connection cable (RP1) for a ground fault or a cable disconnection.

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1 Servo amplifier 3 (B-cabinet) 2 (A-cabinet) 4 Connector (CRF7)

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3.5.7 SRVO-007 External E-stop

(Explanation)

On the terminal block TBOP4 of the panel board, no connection is made between 1 (EES1) and 2 (EES11) or between 3 (EES2) and 4 (EES21). If an external emergency stop switch is connected between 1 (EES1) and 2 (EES11) or between 3 (EES2) and 4 (EES21), the switch is pressed. If the SYST-067 (Panel HSSB disconnect) alarm is also generated, or if the LED (green) on the panel board is turned off, communication between the main board (JRS11) and the panel board (JRS11) is abnormal. The connectors of the cable between the main board and the panel board may be loose. Or, the cable, panel board, or main board may be faulty. (Note)

In case that RDY LED (green) is lit. (Action 1)

If an external emergency stop switch is connected, releases the switch. (Action 2)

Check the switch and cable connected to 1 (EES1) and 2 (EES11) or 3 (EES2) and 4 (EES21) on TBOP4.

(Action 3)

When this signal is not used, make a connection between 1 (EES1) and 2 (EES11) or between 3 (EES2) and 4 (EES21).

(Action 4)

Replace the panel board.

In case that RDY LED (green) is not lit. (Action 1)

Check whether FUSE1 on the panel board is blown. If FUSE1 is blown, replace FUSE1 after removing the cause.

Else if, check the voltage of EXT24V and EXT0V (TBOP6). If external 24V, 0V is not used check the jumper pins between EXT24V and INT24V, EXT0V and INT 0V (TBOP6).

(Action 2)

(Action 4)

WARNING

Do NOT short-circuit, or disable, this signal in a system in which the External emergency stop input signal is in use, as it is very dangerous. If it is necessary to run the robot by short-circuiting the signal

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NOTE

Check the alarm history display on the teach pendant.

NOTE

If the external 24 V is not supplied adequately to TB0P6 (EXT24V, EXT0V), the following alarms are also generated.

SRVO-004 Fence open.

SRVO-007 SVALI External E-stop. SRVO-213 Fuse blown (Panel PCB). SRVO-280 SVOFF input.

1 Short connection 1 (EES1) and 2 (EES11) 4 LED (Green) 2 Short connection 3 (EES2) and 4 (EES21) 5 Connector (JRS11) 3 Panel board 6 TBOP6

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Fig. 3.5.7 (b) SRVO-007 External E-stop

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3.5.8 SRVO-009 Pneumatic pressure alarm

(Explanation)

An abnormal air pressure was detected. The input signal is located on the end effector of the robot. Refer to the manual of your robot.

(Action 1)

If an abnormal air pressure is detected, check the cause. (Action 2)

Check the end effector connector. (Action 3)

Then verify that connector CRF7 on the servo amplifier is securely connected. Also verify that the RP1 cable is in good condition, and there are no cuts or kinks visible. Check the robot connection cable (RP1) for a ground fault or a cable disconnection.

(Action 4)

Replace the internal cables of the robot.

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3.5.9 SRVO-014 Fan motor abnormal

(Explanation)

A fan motor in the backplane unit is abnormal. (Action 1)

Check the fan motor and its cables. Replace them if necessary. (Action 2)

Replace the backplane unit.

Fig. 3.5.9 SRVO-014 Fan motor abnormal 1 Fan motor

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3.5.10 SRVO-015 SYSTEM OVER HEAT (Group : i Axis : j)

(Explanation)

The temperature in the control unit exceeds the specified value. (Action 1)

If the ambient temperature is higher than specified (45°C), cool down the ambient temperature. (Action 2)

If the fan motor is not running, check it and its cables. Replace them if necessary.

Before executing the (Action3), perform a complete controller back-up to save all your programs and settings.

(Action 3)

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Fig. 3.5.10 SRVO-015 System Over Heat

1 Door switch 6 B-cabinet 2 Main board 7 Door fan 3 Heat exchanger 8 Floor fan unit 4 Fan unit 9 External air Fan unit 5 A-cabinet

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3.5.11 SRVO-018 Brake abnormal

(Explanation)

An excessive brake current is detected. The ALM LED on the servo amplifier lit. (Action 1)

Check the robot connection cable (RM1) and cables internal to the mechanical section for a short-circuit and connection to the ground.

(Action 2)

This alarm may occur if the brake connector is not attached.

Make sure that connector CRR64 is securely attached to the servo amplifier. (Action 3) Replace the servo amplifier.

Fig. 3.5.11 SRVO-018 Brake abnormal

1 Servo amplifier 3 B-cabinet 2 A-cabinet

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

(Explanation)

The HRDY is on and the SRDY is off, although there is no other cause of an alarm. (HRDY is a signal with which the host detects the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on.)

If the servo amplifier magnetic contactor cannot be turned on when directed so, it is most likely that a servo amplifier alarm has occurred. If a servo amplifier alarm has been detected, the host will not issue this alarm (SRDY off). Therefore, this alarm indicates that the magnetic contactor cannot be turned on for an unknown reason.

(Action 1)

Make sure that connector CP2, CRM64 and CNMC3 are securely attached to the E-stop unit and connector CRM64 to the servo amplifier.

(Action 2)

It is possible that an instant disconnection of power source causes this alarm. Check whether an instant disconnection occurred.

(Action 3)

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Fig. 3.5.12 SRVO-021 SRDY off

1 Door switch 5 Power supply unit 2 Servo amplifier 6 A-cabinet 3 Main board 7 Axis control card 4 E-stop unit 8 B-cabinet

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

(Explanation)

When the HRDY is about to go on, the SRDY is already on.

(HRDY is a signal with which the host directs the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on.)

(Action 1)

Replace the servo amplifier.

Fig. 3.5.13 SRVO-022 SRDY on

1 Door switch 5 Power supply unit 2 Servo amplifier 6 A-cabinet 3 Main board 7 Axis control card 4 E-stop unit 8 B-cabinet