59608200 FANUC R J3iB Maintenance Manual for Europe B 81465EN 1 02

FANUC Robot series

MAINTENANCE MANUAL

B--81465EN--1/02

FOR EUROPE

R--J3iB CONTROLLER

B--81465EN--1/02 Table of Contents

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PREFACE p--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

1. SAFETY PRECAUTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 OPERATOR SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.1 Operator Safety 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1.2 Safety of the Teach Pendant Operator 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1.3 Safety During Maintenance 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.1 Precautions in Programming 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.2 Precautions for Mechanism 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 SAFETY OF THE ROBOT MECHANISM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.1 Precautions in Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.2 Precautions in Programming 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.3 Precautions for Mechanisms 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 SAFETY OF THE END EFFECTOR 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.1 Precautions in Programming 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 SAFETY IN MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 WARNING LABEL 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II MAINTENANCE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. OVERVIEW 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. CONFIGURATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 EXTERNAL VIEW OF THE CONTROLLER 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 COMPONENT FUNCTIONS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 PREVENTIVE MAINTENANCE 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. TROUBLESHOOTING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 POWER CANNOT BE TURNED ON 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 ALARM OCCURRENCE SCREEN 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 SAFETY SIGNALS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 MASTERING 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 TROUBLESHOOTING USING THE ERROR CODE 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 FUSED--BASED TROUBLESHOOTING 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 TROUBLESHOOTING BASED ON LED INDICATIONS 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION(POSITIONING) 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 VIBRATION OBSERVED DURING MOVEMENT 132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 MANUAL OPERATION IMPOSSIBLE 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. PRINTED CIRCUIT BOARDS 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 MAIN BOARD (A16B--3200--0412, --0413) 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 EMERGENCY STOP CONTROL PC BOARD (A20B--1007--0800) 139. . . . . . . . . . . . . . . . . . . . . . . .

4.3 BACKPLANE PC BOARD 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.4 PANEL BOARD (A20B--2100--0770) 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 PROCESS I/O BOARD CA (A16B--2201--0470) 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 PROCESS I/O BOARD CB (A16B--2201--0472) 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 PROCESS I/O BOARD DA (A16B--2201--0480) 148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 PROCESS I/O BOARD HA (A16B--2203--0760) 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 PANEL SWITCH BOARD (A20B--1007--0850) 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. SERVO AMPLIFIERS 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 LED OF SERVO AMPLIFIER 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 SETTING OF SERVO AMPLIFIER 155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 DRIVER CHIP FOR ROBOT DI/DO 156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. SETTING THE POWER SUPPLY 157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 BLOCK DIAGRAM OF THE MAIN POWER INCLUDING POWER SUPPLY 158. . . . . . . . . . . . . .

6.2 SELECTING TRANSFORMER TAPS 159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 CHECKING THE POWER SUPPLY UNIT 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. REPLACING A UNIT 164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 REPLACING THE PRINTED--CIRCUIT BOARDS 165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 Replacing the Backplane Board (Unit) 165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1.2 Replacing the Power Unit and Printed--Circuit Boards on the Backplane Unit 166. . . . . . . . . . . . . . . . . . .7.1.3 Replacing the Panel Board 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 REPLACING CARDS AND MODULES ON THE MAIN BOARD 169. . . . . . . . . . . . . . . . . . . . . . . .

7.3 REPLACING THE TRANSFORMER 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 REPLACING THE REGENERATIVE RESISTOR UNIT 176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 REPLACING THE E--STOP UNIT 177. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 REPLACING SERVO AMPLIFIERS 178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.7 REPLACING I/O UNIT MODEL A 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7.1 Replacing the Base Unit of I/O Unit Model A 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7.2 Replacing a Module 183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8 REPLACING THE TEACH PENDANT 184. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9 REPLACING THE CONTROL SECTION FAN MOTOR 185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.10 REPLACING THE AC FAN MOTOR 186. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10.1 Replacing External Air Fan Unit and Door Fan (B--cabinet) 186. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.11 REPLACING THE OPERATOR PANEL AND PANEL SWITCH BOARD 188. . . . . . . . . . . . . . . . . .

7.12 REPLACE THE MODE SWITCH 189. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13 REPLACING FUSES 190. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13.1 Replacing Fuses in the Servo Amplifier 190. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13.2 Replacing Fuses in the Power Unit 191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13.3 Replacing the Fuse on the Process I/O Boards 192. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13.4 Replacing the Fuse on the Panel Board 194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.14 REPLACING RELAYS 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14.1 Replacing Relays on the Panel Board 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.15 REPLACING BATTERY 196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15.1 Battery for Memory Backup (3 VDC) 196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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III CONNECTIONS 199. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. GENERAL 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. BLOCK DIAGRAM 202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. ELECTRICAL CONNECTIONS 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS 204. . . . . . . . . . . . . . . . . . . . . . . . .

3.2 EXTERNAL CABLE WIRING DIAGRAM 206. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.1 Robot Connection Cables 206. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.2 Teach Pendant Cable 207. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.3 Connecting the Input Power 208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.4 Connecting the External Power Supply ON/OFF Switch 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.5 Connecting the External Emergency Stop 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. PERIPHERAL DEVICE, ARC WELDING,AND END EFFECTOR INTERFACES 220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM 221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 When Process I/O Board CA/CB/HA is Used (B--cabinet) 221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1.2 When Process I/O Board DA is Used (B--cabinet) 223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1.3 When I/O Unit--MODEL A is Used 224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.3.1 In case of B--cabinet 224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.4 When Two or more Process I/O Boards and I/O Unit (Model A or Model B) are Used 225. . . . . . . . . . . .

4.2 PERIPHERAL DEVICE INTERFACE COMBINATION 226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.1 In Case of B--cabinet 226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 PROCESS I/O BOARD SIGNALS 227. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS 231. . . . . . . . . .4.4.1 Peripheral Device and Control Unit Connection 232. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.2 Connection Between the Mechanical Unit and End Effector 245. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.3 Connection Between the Control Unit and Welder 247. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 DIGITAL I/O SIGNAL SPECIFICATIONS 253. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.1 Peripheral Device Interface 253. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.2 End Effector Control Interface 255. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.3 I/O Signal Specifications for ARC--Welding Interface 257. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICESAND WELDERS 261. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins) 261. . . . . . . . . . . . . . . . . . . . . . . .4.6.2 Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins) 261. . . . . . . . . . . . . . . . . . . . . . . .4.6.3 ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins) 262. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS,AND ARC WELDERS 263. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.1 Peripheral Device Connection Cable 263. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7.2 Peripheral Device Cable Connector 264. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7.3 End Effector Cable Connector 266. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7.4 Recommended Cables 267. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 CONNECTION OF HDI 268. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8.1 Connecting HDI 268. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8.2 Input Signal Rules for the High--speed Skip (HDI) 270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 CONNECTING THE COMMUNICATION UNIT 271. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.9.1 RS--232--C Interface 271. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.1.1 Interface 271. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.9.1.2 RS--232--C Interface Signals 272. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.1.3 Connection between RS--232--C Interface and External Device 273. . . . . . . . . . . . . . . . . . . . . . . .

4.9.2 Ethernet Interface 275. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.1 Connection to Ethernet 276. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.2 10/100 BASE--T Connector (CD38) Pin Assignments 277. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.3 Cable Connection 277. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.4 Lead Materials 278. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.5 Connector Specification 279. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.6 Cable Clamp and Shielding 280. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2.7 Grounding the Network 281. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. TRANSPORTATION AND INSTALLATION 283. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 TRANSPORTATION 284. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 INSTALLATION 285. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.1 Installation Method 285. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.2 Assemble at installation 287. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 INSTALLATION CONDITION 288. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 ADJUSTMENT AND CHECKS AT INSTALLATION 289. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION 290. . . . . . . . . . . . . .5.5.1 Peripheral Device Interface Processing 290. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5.2 Resetting Overtravel 290. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5.3 How to Disable/Enable HBK 291. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5.4 How to Disable/Enable Pneumatic Pressure Alarm (PPABN) 292. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX 293. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A. TOTAL CONNECTION DIAGRAM 295. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE 316. . . . . . . . . . . . . . . . .B.1 SIGNALS 317. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.2 SETTING COMMON VOLTAGE 319. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.3 I/O SIGNALS 320. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.3.1 Input Signals 320. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.3.2 Output Signals 325. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT 329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.4.1 Overview 329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.4.2 Input/Output Hardware Usable in the R-J3iB Controller 329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.4.3 Software Specifications 330. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C. POWER DISTRIBUTION CIRCUIT DIAGRAM 331. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D. OPTICAL FIBER CABLE 338. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E. CARD INTERFACE 341. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B--81465EN--1/02 PREFACE

p--1

PREFACE

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

Model Abbreviation

FANUC Robot R--2000iA/165F R--2000iA/165F

FANUC Robot R--2000iA/200F R--2000iA/200F

FANUC Robot R--2000iA/165R R--2000iA/165RR 2000iA

FANUC Robot R--2000iA/200R R--2000iA/200RR--2000iA

FANUC Robot R--2000iA/125L R--2000iA/125L

FANUC Robot R--2000iA/165CF R--2000iA/165CF

FANUC Robot M--6iB M--6iBFANUC Robot ARC Mate 100iB ARC Mate 100iB

I SAFETY PRECAUTIONS

B--81465EN--1/02 1. SAFETY PRECAUTIONSSAFETY PRECAUTIONS

3

1 SAFETY PRECAUTIONSFor the safety of the operator and the system, followall safety precautionswhen operating a robot and its peripheral devices installed in a work cell.

1. SAFETY PRECAUTIONS B--81465EN--1/02SAFETY PRECAUTIONS

4

Operator 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 precautions. Careful considerationmust be made to ensure operator safety.

(1) Have the robot system operators attend the training courses held byFANUC.

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

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

(3) Install a safety fencewith a gate so that no operator can enter theworkarea without passing through the gate. Equip the gate with aninterlock that stops the robot when the gate is opened.

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

(4) Provide the peripheral devices with appropriate grounding (Class 1,Class 2, or Class 3).

(5) Try to install the peripheral devices outside the work area.

(6) Draw an outline on the floor, clearly indicating the range of the robotmotion, including the tools such as a hand.

(7) Install a mat switch or photoelectric switch on the floor with aninterlock to a visual or aural alarm that stops the robot when anoperator enters the work area.

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

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

1.1OPERATOR SAFETY


5

(9) When adjusting each peripheral device independently, be sure to turnoff the power of the robot.

Limit switch forthe safety gate

Panel board

Note) Terminals FENCE1 and FENCE2 areon the PC board in the operator panel.Fence circuit is a safety stop circuit.

EAS1

EAS11

EAS2

EAS21

Fig.1.1 Safety Fence and Safety Gate


6

The 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 operate, turn off the power of therobot controller or press the EMERGENCY STOP button, and thenproceed 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 otherthan the operator from entering the work area unexpectedly and alsoto prevent the worker from entering a dangerous area.

(4) Install an EMERGENCY STOP button within the operators reach.

The robot controller is designed to be connected to an external EMERGENCYSTOP button. With this connection, the controller stops the robot operationwhen the external EMERGENCY STOP button is pressed. See the diagrambelow for connection.

EES1

Panel board

Note) Connect to EES1 and EES11, EES2 and EES21.

External EMERGENCY STOP button

EES11EES2EES21

Fig.1.1.1 Connection Diagram for External Emergency Stop Switch

1.1.1Operator Safety


7

While teaching the robot, it is necessary for the operator to enter theworkarea 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, carryout all tasks outside the area.

(2) Before teaching the robot, check that the robot and its peripheraldevices are all in the normal operating condition.

(3) When entering the robot work area and teaching the robot, be sure tocheck the location and condition of the safety devices (such as theEMERGENCY STOP button and the deadman switch on the teachpendant).

The teach pendant supplied by FANUC is provided with a teach pendant en-able switch and a deadman switch in addition to the EMERGENCY STOP but-ton. The functions of each switch are as follows.

EMERGENCY STOP button : Pressing this button stops the robot in anemergency, irrespective to the condition ofthe teach pendant enable switch.

Deadman switch : The function depends on the state of theteach pendant enable switch.

When the enable switch is on -- Releasing the finger from the dead manswitch or holding the deadman switchstrongly stops the robot in an emergency.

When the enable switch is off -- The deadman switch is ineffective.

NOTEThe deadman switch is provided so that the robot operation canbe stopped simply by releasing finger from the teach pendant orholding the deadman switch strongly in case of emergency.The R--J3iB has adopted a 3--position deadman switch asan RIA--specification teach pendant. Pressing the3--position deadman switch halfway makes the robotoperable. Releasing the finger from the deadman switch orholding the deadman switch strongly causes the robot toenter the emergency stop state.

1.1.2Safety of the TeachPendant Operator


8

(4) The teach pendant operator should pay careful attention so that noother workers enter the robot work area.

NOTEIn addition to the above, the teach pendant enable switch and thedeadman switch also have the following function.

By pressing the deadman switchwhile the enable switch is on, theemergency stop factor (normally the safety gate) connected toEAS1 and EAS11, EAS2 and EAS21 of the controller isinvalidated. In this case, it is possible for an operator to enter thefence during teach operation without making the robot in theemergency stop condition. In other words, the system understandsthat the combined operations of pressing the teach pendantenable switch andpressing thedeadman switch indicates the startof teaching. The teach pendant operator should be well aware thatthe safety gate is not functional under this condition and bear fullresponsibility to ensure that no one enters the fence during teaching.

(5) When entering the robotwork 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 sent to the robot from any operatorpanel other than the teach pendant.

The teach pendant, operator panel, and peripheral device interface send eachrobot start signal. However the validity of each signal changes as follows de-pending on themode of the teach pendant enable switch and the remoteswitchon the operators panel.

Teach pen-dant enable

switch

Remotecondition

Teachpendant

Operatorpanel

Peripheraldevices

On Independent Allowed tostart

Not allowed Not allowed

Off Local Not allowed Allowed tostart

Not allowed

Off Remote Not allowed Not allowed Allowed tostart

(6) To start the system using the operator panel, make certain that nobodyis in the robot work area and that there are no abnormal conditions inthe robot work area.

(7) When aprogram is completed, be sure to carry out a test run accordingto 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 noabnormalities occur due to a delay in timing.

(d) Run the program for one operation cycle in the continuousoperation mode at the normal operating speed and check that thesystem operates automatically without trouble.

(e) After checking the completeness of the program through the testrun above, execute it in the automatic operation mode.


9

(8) While operating the system in the automatic operation mode, theteach pendant operator should leave the robot work area.

For 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 person can turn it on.

(2) When disconnecting the pneumatic system, be sure to reduce thesupply pressure.

(3) Before the start of teaching, check that the robot and its peripheraldevices are all in the normal operating condition.

(4) If it is necessary to enter the robot work area for maintenance whenthe power is turned on, the worker should indicate that the machineis being serviced and make certain that no one starts the robotunexpectedly.

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

(6) When it is necessary to maintain the robot alongside a wall orinstrument, or when multiple workers are working nearby, makecertain that their escape path is not obstructed.

(7) When a tool is mounted on the robot, or when any moving deviceother than the robot is installed, such as belt conveyor, pay carefulattention to its motion.

(8) If necessary, have a worker who is familiar with the robot systemstand beside the operator panel and observe the work beingperformed. If any danger arises, the worker should be ready to pressthe EMERGENCY STOP button at any time.

(9) When replacing or reinstalling components, take care to preventforeign matter from entering the system.

(10)When handling each unit or printed circuit board in the controllerduring inspection, turn off the power of the controller and also turnoff 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 thecontroller.

1.1.3Safety DuringMaintenance


10

(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 other robots or peripheral devices, even though therobot itself is normal.

(3) For a system in which the robot and its peripheral devices are insynchronous motion, particular care must be taken in programmingso that they do not interfere with each other.

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

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

(2) Employ a limit switch ormechanical stopper to limit the robotmotionso that the robot does not come into contactwith its peripheral devicesor tools.

1.2SAFETY OF THETOOLS ANDPERIPHERALDEVICES

1.2.1Precautions inProgramming

1.2.2Precautions forMechanism


11

(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 mode.

(1) When thework areas of robots overlap, make certain that themotionsof the robots do not interfere with each other.

(2) Be sure to specify the predeterminedwork origin in amotion programfor the robot and program the motion so that it starts from the originand terminates at the origin.Make it possible for the operator to easily distinguish at a glance thatthe robot motion has terminated.

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

1.3SAFETY OF THEROBOT MECHANISM

1.3.1Precautions inOperation


1.3.3Precautions forMechanisms


12

(1) To control the pneumatic, hydraulic and electric actuators, carefullyconsider the necessary timedelay after issuing each control commandup to actual motion and ensure safe control.

(2) Provide the end effector with a limit switch, and control the robotsystem by monitoring the state of the end effector.

1.4SAFETY OF THE ENDEFFECTOR



13

(1) Never enter the robot work areawhile 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 the EMERGENCYSTOP button on the operator panel.

(3) When replacing or reinstalling components, take care to preventforeign matter from entering the system.When replacing the parts in the pneumatic system, be sure to reducethe pressure in the piping to zero by turning the pressure control onthe air regulator.

(4) When handling each unit or printed circuit board in the controllerduring inspection, turn off the power of the controller and turn off thecircuit 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 thecontroller.

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

1.5SAFETY INMAINTENANCE


14

Do 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 label

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

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

(2) High--temperature warning label

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

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

1.6WARNING LABELDescription

Description

Description


15

(3) High--voltage warning label

Fig.1.6 (c) High--Voltage Warning Label

There 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 position to avoid shock hazards.In addition, be careful about servo amplifiers and other electric circuitsbecause a high voltage may remain in them for a certain period of timeafter the power is turned off.

Description

II MAINTENANCE

B--81465EN--1/02 1. OVERVIEWMAINTENANCE

19

1 OVERVIEWThis manual describes the maintenance and connection of the R--J3iBrobot controller (called the R--J3iB).

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

Connection Part : Connection of theR--J3iB controller to the robotmechanical unit and peripheral devices, andinstallation of the controller

WARNINGBefore you enter the robot working area, be sure to turn offthe power to the controller or press the EMERGENCYSTOP button on the operator panel or teach pendant.Otherwise, you could injure personnel or damageequipment.

- For information on third party approvals, contact your FANUCrepresentative.

2. CONFIGURATION B--81465EN--1/02MAINTENANCE

20

2 CONFIGURATION

B--81465EN--1/02 2. CONFIGURATIONMAINTENANCE

21

The appearance and components might slightly differ depending on thecontrolled robot, application, and options used.Fig.2.1 (a) shows the view of R--J3iB.Fig.2.1 (b) and (c) show the R--J3iB consists of the R--J3iB controller.

Teach pendantOperator panelMode switch

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

2.1EXTERNAL VIEW OFTHE CONTROLLER


22

Fig.2.1 (b) R--J3iB B--cabinet interior (Front)


23

Fig.2.1 (c) R--J3iB B--cabinet overview (Back)

Table 2.1 Servo amplifier and regenerative resistor unit

Robot models Servo amplifier Regenerative resistor unitR--2000iA A06B--6105--H002 A05B--2452--C200 (B--cabinet)

M--6iB A06B--6105--H003 A05B--2452--C201 (B--cabinet)

ARC Mate 100iB

( )

2.CONFIGURAT

ION

B--81465E

N--1/02

MAINTENANCE

24

Breaker

210VACOutput

24VDC

210VACInput

HSSB,TP

Signal

Servo

Signal(FS

SB)

Battery

24VDC

EMGsignals

AC input380 -- 415 VAC440 -- 500 VAC3

Transformer

Transformer overheat signal

210VAC

EMG signals

210VAC

Regenerativeresistor

Motor power supply, Brake power supply

Pulse coder signals, Robot DI/DO signals

Servo amplifier(6--axis amplifier)

Switch

Memory cardPanelboard

Operators panel

I/O unitMODELA

ProcessI/O

Backplane

Powersupplyunit

Mainboard

Fan

Robot

External on/off

Teachpendant

(Ethernet)

peripheraldevice

peripheraldevice

peripheraldevice(Serial)

(I/O)

External E--stop

Noise filter

E--stop unit

Fig.2.1

(d)Block

diag

ramofth

eR--J3iB

(B--cab

inet)


25

-- Main boardThe main board contains a microprocessor, its peripheral circuits,memory, and operator panel control circuit. The main CPU controlsservo mechanism positioning and servo amplifier voltages.

- Battery retains main board memory when controller power is off.- I/O printed circuit board, FANUC I/O Unit MODEL--AVarious types of printed circuit boards are provided for applicationsincluding process I/O. The FANUC I/O unit MODEL-A can also beinstalled. When it is used, various I/O types can be selected. Theseare connected with FANUC I/O Link.

- E--stop unitThis unit controls the emergency stop system with control reliableE--stop performance criteria for both of the magnetic contactor andthe precharge of the servo amplifier.

- Power supply unitThe power supply unit converts theAC power to various levels ofDCpower.

- Backplane printed circuit boardThe various control printed circuit boards are mounted on thebackplane printed circuit board.

- Teach pendantAll operations including robot programming are performed with thisunit. The controller status and data are indicated on the liquid-crystaldisplay (LCD) on the pendant.

- Servo amplifierThe servo amplifier controls servomotor power, pulse coder, brakecontrol, overtravel and hand broken.

- Operator panelButtons and LEDs on the operator panel are used to start the robot andto indicate the robot status. Thepanel has a port for the serial interfaceto an external device and an interface to connect the memory card fordata backup. It also controls the emergency stop control circuit.

- TransformerThe supply voltage is converted to an AC voltage required for thecontroller by the transformer.

- Fan unit, heat exchangerThese components cool the inside of the control unit.

- Circuit breakerIf the electric system in the controller malfunctions, or if abnormalinput power causes high current in the system, the input power isconnected to the circuit breaker to protect the equipment.

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

2.2COMPONENTFUNCTIONS


26

Daily 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 cracks. Also check thefollowing:(a) Before service operation

Check the cable connected to the teach pendant for excessivetwisting. Check the controller and peripheral devices forabnormalities.

(b) After service operationAt the end of service operation, return the robot to the specifiedposition, then turn off the controller. Clean each part, and checkfor any damage or cracks. If the ventilation port of the controlleris dusty, clean it.

(c) Check after one monthCheck that the fan is rotating normally. If the fan has dirt and dustbuilt up, clean the fan according to step (d) described below forinspection to be performed every 6 months.

(d) Periodic inspection performed every six monthsRemove the top cover, louver, and back panel (if possible), thenremove any dirt and dust from the inside of the transformercompartment. Wipe off dirt and dust from the fan andtransformer.

(2) Maintenance toolsThe 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, twochannels

(b) ToolsPhillips screwdrivers : Large, medium, and smallStandard screwdrivers: Large, medium, and smallNut driver set (Metric)PliersNeedle-nose pliersDiagonal cutting pliers

2.3PREVENTIVEMAINTENANCE

B--81465EN--1/02 3. TROUBLESHOOTINGMAINTENANCE

27

3 TROUBLESHOOTINGThis chapter describes the checkingmethod and corrective action for eacherror code indicated if a hardware alarm occurs. Refer to the operatorsmanual to release program alarms.

3. TROUBLESHOOTING B--81465EN--1/02MAINTENANCE

28

Check and Corrective action Figure

(Check 1) Check that the circuit breaker is on and has not tripped.

(Correctiveaction)

Turn on the circuit breaker.

Breaker

(Check 2) Check whether the LED (PIL: green) on the power supply unitis on.

(Correctiveaction)

If the LED is not on, 200 VAC is not supplied to the power supplyunit. 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 diagrampresented in the appendix.

-- If 200 VAC is supplied:Find the cause of the blown fuse. FuseF1 is in the power sup-ply unit. Before you start troubleshooting, turn off the circuitbreaker.a) If fuse F1 has blown:

-- See Corrective action (1).b) If fuse F1 has not blown:

-- Replace the power supply unit.

F1 8.0AFuse for AC input

F3 7.5AFuse for +24E

F4 7.5A

Diode stackDB1

Surge absorberVS1

Spare powersupply moduleH1

CP1 connector

(Correctiveaction(1))

Causes of blown fuses F1 and corrective actiona) Check whether the unit and printed--circuit board connected

to the connectors CP2 and CP3 in the power supply unit areabnormal, by referencing the general schematic diagrampresented in the appendix.

b) Short-circuit in the surge absorber VS1VS1 is inserted to absorb surge voltage between input lines.If the surge voltage is excessive or sustained, excessivelyhigh voltage is applied to VS1 and a failure occurs in theshort-circuit mode, causing F1 to blow. If a short-circuit oc-curs in VS1, and there is not a spare part, the system is per-mitted to operate without VS1. In this case, however, obtainand install a new VS1 as soon as possible.VS1 ordering number: A50L-2001-0122#G431k

c) Short-circuit of diode stack DB1d) The secondary power supply module is faulty :

If one of the causes (b) to (c) above is detected, replace thepower supply unit with a spare unit.The spec. for F1 is : A60L-0001-0396#8.0A

F4 7.5AFuse for +24VPILLED (green)for AC powersupply display

H1

CP6 connectorCP5 connector

LED (red) foralarm display

3.1POWER CANNOT BETURNED ON


29

Check and Corrective action Figure

(Check 3) Check whether the EXON1 and EXON2 signals, and theEXOFF1 and EXOFF2 signals are connected on the terminalblock on the panel board.

Short piece : between 1 (EXON1) and 2 (EXON2)between 3 (EXOFF1) and 4 (EXOFF2)

(Correctiveaction)

If the externalON/OFF function is not used, connect theEXON1and EXON2 the EXOFF1 and EXOFF2. If the external ON andOFF lines are already used, check the mating contacts and thecable.

between 3 (EXOFF1) and 4 (EXOFF2)

Connector (JRS11)

(Check 4) Check whether the connector (JRS11) on themain board or theconnector (JRS11) on the panel board is connected properly.Another probable cause is that the cable connected to either ofthese connectors is faulty.

F1 8.0AFuse for AC input

Diode stackDB1

(Check 5) Check 1 to 3 above confirm that 200 VAC power is supplied toconnector CP1 of the power supply unit and that the ON/OFFswitch functions normally. Therefore check the power supplyunit using the following procedure:If the LED (ALM: red) on the power supply unit is onCheck if the +24 V external connection cable is connected to 0V or ground.a) Fuse F4 blown :

See corrective action (2).b) None of the above fuses blown [d) is also probable] :

Aprinted circuit board or unit that uses aDC supply volt-age (+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 itis supplied replace the power supply unit.

F3 7.5AFuse for +24E

F4 7.5AFuse for +24VPILLED (green)for AC powersupply display

Surge absorberVS1

Spare powersupply moduleH1

CP1 connector

CP6 connectorCP5 connector

LED (red) for

(Correctiveaction)

If the power supply unit is not faulty, replace the panel board oroperator panel.

LED (red) foralarm display

(Correctiveaction(2))

Causes of blown fuse F4 and corrective actionThedeviceconnected toconnectorCP5of thepower supply unitmay be faulty. If no device is connected toCP5or theconnecteddevice is normal, the +24 V power used in a printed circuit boardconnected to the backplane is faulty.The code of F4 is A60L--0001--0046#7.5 :


30

The 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 themessage PAUSE ormore 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 allalarm 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 moreserious alarms. It will not displayWARN, NONE, or a reset. It is possibleto disable PAUSE and some of more serious alarms from being displayedby setting the $ER_NOHIS system variable appropriately.If two or more alarms have occurred, the display begins with the mostrecent alarm.Up to 100 lines can be displayed.If an alarm has a cause code, it is displayed below the line indicating thealarm.

Press the screenselection key to select[4 ALARM]. Press the alarm key.

Automatic alarm displayupon occurrence

Alarm occurrence screen display

Press F3 [ACTIVE]. Press F3 [HIST].

Alarm history screen display

Fig.3.2 Alarm Occurrence Screen and Alarm History Screen DisplayProcedure

3.2ALARMOCCURRENCESCREEN


31

Displaying 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 following

MENUS

34 ALARM5 I/O

INTP-224 (SAMPLE1, 7) Jump label is failMEMO-027 Specified line does not existAlarm JOINT 30 %

1/251 INTP-224 (SAMPLE1, 7) Jump label is2 SRVO-002 Teach pendant E-stop3 R E S E T4 SRVO-027 Robot not mastered(Group:1)5 SYST-026 System normal power up

[ TYPE ] CLEAR HELP

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

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

CLEAR HELP

F5

INTP-224 (SAMPLE1, 7) Jump label is fail

INTP-224 (SAMPLE1, 7) Jump label is failMEMO-027 Specified line does not exist30-MAY-44 07:15STOP.L 00000110Alarm

1/251 INTP-224 (SAMPLE1, 7) Jump label is2 SRVO-002 Teach pendant E-stop

[ TYPE ] CLEAR HELP

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

PREV

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

NOTEWhen system variable $ER_NOHIS = 1, NONE alarms orWARN 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 alarmsare not recorded.

CLEAR HELP

F4SHIFT

Step


32

The following map indicates teach pendant operations used to check analarm.

4 ALARM

F1 [TYPE]

Alarm : Active

F1 [TYPE]

F3 HIST

Alarm : HIST

F1 [TYPE]

F3 [ACTIVE]

F4 CLEAR

F5 HELP

DETAIL Alarm

F1 [TYPE]

F3 [ACTIVE]

F4 CLEAR

F5 HELP


33

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

Table 3.3 Safety Signals

Safety signal Description

Operator panel emergency stop This item indicates the state of the emergency stop button on the operator panel. If theEMERGENCY 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 theEMERGENCY 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 EMERGENCYSTOP 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 isindicated as TRUE.

Deadman switch This item indicates whether the DEADMAN switch on the teach pendant is grasped. Ifthe teach pendant is operable, and the DEADMAN switch is grasped, the state is indi-cated as TRUE. If the deadmanswitch is releasedwhen the teachpendant 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 oper-able, the state is indicated as TRUE.

Hand broken This item indicates the state of the hand safety joint. If the hand interferes with a work-piece or anything like this, and the safety joint is opened, the state is indicated asTRUE. 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, thestate is indicated as TRUE. In this case, an alarm occurs, causing the servo power to beswitched off.

Abnormal air pressure This item indicates the state of the air pressure. The abnormal air pressure signal is con-nected to the air pressure sensor. If the air pressure is not higher than the specifiedvalue, the state is indicated as TRUE.

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

(2) Select STATUS on the next page.

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

(4) Select Safety Signal. You will see a screen similar to the following.

SYSTEM Safety JOINT 30%

SIGNAL NAME STATUS 1/11

1 SOP E-Stop: FALSE2 TP E-stop: FALSE3 Ext E-Stop: FALSE4 Fence Open: FALSE5 TP Deadman: TRUE6 TP Enable: TRUE7 Hand Broken: FALSE8 Over Travel: FALSE9 Low Air Alarm: FALSE

[TYPE]

3.3SAFETY SIGNALS

Step


34

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) requireszero--degree or jig position mastering. (Zero--degree position masteringis just for quick--fix purposes. After zero--degree position mastering isused, jig position mastering should be performed later.)The mastering procedure is described below. For details, refer to anapplicable maintenance manual of mechanical unit or operators manualof control unit.

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

SYSTEM Variables JOINT 10%57/136

57 $MASTER_ENB 1

(1) Press .

(2) Select SYSTEM.

(3) Press F1, TYPE.

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

F1

Master/Cal

TYPE

SYSTEM Master/Cal JOINT 30%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE

Press ENTER or number key to select.

[TYPE] LOAD RES_PCA DONE

5 POSITION6 SYSTEM7

MENUS

9 USER0 -- NEXT --

(5) Move the robot by jog feed to the mastering position. Release thebrake on the manual brake control screen if necessary.

NOTEMastering can not be performed until axis is rotated enoughto establish a pulse.

3.4MASTERING

Condition

Step


35

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

F4

SYSTEM Master/Cal

1 FIXTURE POSITION MASTER2 ZERO POSITION MASTERMaster at master position? [NO]

ENTER

Master at master position? [NO][ TYPE ] YES NO

SYSTEM Master/Cal JOINT 30 %

1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE

Robot Mastered! Mastering Data:

[ TYPE ] LOAD RES_PCA DONE

(7) Select 6 CALIBRATE and press the F4 key (yes). Calibration isperformed.Alternatively, to perform positioning, turn the power off, then turn iton again. Calibration is performed whenever the power is turned on.

F4

5 SET QUICK MASTER REF6 CALIBRATECalibrate? [NO] ENTER

Calibrate? [NO][ TYPE ] YES NO

SYSTEM Master/Cal JOINT 30 %

1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE

Robot Calibrated! Cur Jnt Ang(deg):

[ TYPE ] LOAD RES_PCA DONE

(8) Press F5 DONE, after mastering.

F5

DONE


36

(1) SRVO--001 SVAL1 Operator panel E--stop(Explanation) The emergency stop button on the operation operator

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

(Action 1) Release the emergency stop button pressed on theoperator panel.

(Action 2) Check the wires connecting the emergency stopswitch connectorCRT8 for continuity. If an openwireis found replace the entire harness.

(Action 3) With the emergency stop in the released position,check for continuity across the terminals of theswitch. If continuity is not found, replace the switch.If continuity is found replace the operator panel PCB.Before executing the (Action 4), perform a completecontroller back--up to save all your programs andsettings.

(Action 4) Replace the Main Board.

NOTEIf the LED is turned off, the following alarms are alsogenerated.SRVO--001 Operator panel E--stop.SRVO--004 Fence open.SRVO--007 External emergency stop.SRVO--199 Control stop.SRVO--204 External (SVEMG abnormal) E--stop.SRVO--213 Fuse blown (Panel PCB).SRVO--277 Panel E--stop (SVEMG abnormal).SRVO--280 SVOFF input

Check the alarm history display on the teach pendant.

3.5TROUBLESHOOTINGUSING THE ERRORCODE


37

Emergency stop button

Fig.3.5 (1) (a) SRVO--001 SVAL1 Operator panel E--stop


38

Panel board

Connector (CRT8)

LED (Green) Connector (JRS11)

Fig.3.5 (1) (b) SRVO--001 SVAL1 Operator panel E--stop

Main board

Connector (JRS11)

Fig.3.5 (1) (c) SRVO--001 SVAL1 Operator panel E--stop


39

(2) SRVO--002 SVAL1 Teach pendant E--stop(Explanation) The emergency stop button on the operators Teach

Pendant was pressed.(Action 1) Release the emergency stop button on the teach

pendant.(Action 2) Replace Teach Pendant.

Emergency stop button

Fig.3.5 (2) SRVO--002 SVAL1 Teach pendant E--stop

(3) SRVO--003 SVAL1 Deadman switch released(Explanation) The teach pendant is enabled, but the deadman switch

is not pressed.Deadman switch is three position switch.Dont 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.

Deadman switch

Fig.3.5 (3) SRVO--001 SVAL1 Deadman switch released


40

(4) SRVO--004 SVAL1 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 fenceis connected between 5 (EAS1) and 6 (EAS11) orbetween 7 (EAS2) and 8 (EAS21), the door of thesafety fence is open.If the SYST--067 (Panel HSSB disconnect) alarm isalso generated, or if the LED (green) on the panelboard is turned off, communication between themainboard (JRS11) and the panel board (JRS11) isabnormal. The connectors of the cable between themain board and the panel board may be loose. Or, thecable, panel board, or main board may be faulty.(Note)

(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).(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) If SRVO--004 (Fence open), SRVO--007 (Externalemergency stops), SRVO--213 (Fuse Blown (PanelPCB)), and SRVO--280 (SVOFF input) occursimultaneously, it is likely that FUSE1 on the panelboard has blown. Check the fuse. If it has blown,remove the cause, then replace the fuse.(Refer to Section 3.6 in Part II, Maintenance, ofMaintenance Manual.)

(Action 5) Replace the panel board.

NOTEFENCE input (AUTO STOP) is a safety stop input when thisinput is opened, the robot decelerates in a controlledmanner and then stops, the magnetic contactor opens afterthe robot stops.

WARNINGDo NOT short--circuit, or disable, this signal in a system inwhich the Fence signal is in use, as it is very dangerous. Ifit is necessary to run the robot by short--circuiting the signaleven temporarily, an additional safety provision must beprovided.


41

NOTEIf the LED is turned off, the following alarms are alsogenerated.SRVO--001 Operator panel E--stop.SRVO--004 Fence open.SRVO--007 External emergency stop.SRVO--199 Control stop.SRVO--204 External (SVEMG abnormal) E--stop.SRVO--213 Fuse blown (Panel PCB).SRVO--277 Panel E--stop (SVEMG abnormal).SRVO--280 SVOFF input

Check the alarm history display on the teach pendant.

Panel board

Connector (CRT8)


Short connection5 (EAS1)and 6 (EAS11)

Short connection7 (EAS2) and 8 (EAS21)

Fig.3.5 (4) (a) SRVO--004 SVAL1 Fence open

Main board

Connector (JRS11)

Fig.3.5 (4) (b) SRVO--004 SVAL1 Fence open


42

(5) SRVO--005 SVAL1 Robot overtravel(Explanation) The robot has moved beyond a hardware limit switch

on the axes. It is factory--placed in the overtravel statefor packing purposes.If theOvertravel signal is not in use, it may have beendisabled by short--circuiting in the mechanical unit.

(Action 1) 1) Select [System OT release] on the overtravelrelease screen to release each robot axis from theovertravel state.

2) Hold down the shift key, and press the alarmrelease button to reset the alarm condition.

3) Still hold down the shift key, and jog to bring allaxes into the movable range.

(Action 2) Check the FS2 fuse on the servo amplifier.If the SRVO--214 Fuse blown alarm is also generated,FS2 fuse have been blown.

(Action 3) Verify the following for connector RP1 at the base ofthe robot :1) There are no bent or dislocated pins in the male

or female connectors.2) The connector is securely connected.Then verify that connectorsCRF7 andCRM68 on theservo amplifier are securely connected. Also verifythat the RP1 cable is in good condition, and there areno cuts or kinks visible. If no limit switch is in use,a jumper connector must be attached in themechanical unit. Check for the jumper connector.

(Action 4) Replace the servo amplifier.


43

Servo amplifier

Connector (CRM68)

Connector (CRF7)

FS2

Servo amplifier

Fig.3.5 (5) SRVO--005 SVAL1 Robot overtravel

pvillsnrHighlight


44

(6) SRVO--006 SVAL1 Hand broken(Explanation) The safety joint (if in use) might have been broken.

Alternatively, the HBK signal on the robotconnection cable might be a ground fault or a cabledisconnection.If the Hand broken signal is not in use, it can bedisabled by software setting.Refer to Subsection 5.5.3 in Part III, Connections,of Maintenance Manual for how to disable theHand broken signal.

(Action 1) Hold down the shift key, and press the alarm releasebutton to reset the alarm condition. Still hold downthe 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 theSRVO--214 Fuse blown alarm is also generated, FS2fuse have been blown.

(Action 3) Verify the following for connector RP1 at the base ofthe robot :1) There are no bent or dislocated pins in the male

or femail connectors.2) The connector is securely connected.Then verify that connector CRF7 on the servoamplifier is securely connected. Also verify that theRP1 cable is in good condition, and there are no cutsor kinks visible. Check the robot connection cable(RP1) for a ground fault or a cable disconnection.



45

Servo amplifier

Connector (CRF7)

FS2

Servo amplifier

Fig.3.5 (6) SRVO--006 SVAL1 Hand broken


46

(7) SRVO--007 SVAL1 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 externalemergency 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 isalso generated, or if the LED (green) on the panelboard is turned off, communication between themainboard (JRS11) and the panel board (JRS11) isabnormal. The connectors of the cable between themain board and the panel board may be loose. Or, thecable, panel board, or main board may be faulty.(Note)

(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).

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

(Action 4) If SRVO--004 (Fence open), SRVO--007 (Externalemergency stops), SRVO--213 (Fuse blown (PanelPCB)), and SRVO--280 (SVOFF input) occursimultaneously, it is likely that FUSE1 on the panelboard has blown. Check the fuse. If it has blown,remove the cause, then replace the fuse.(Refer to Section 3.6 in Part II, Maintenance, ofMaintenance Manual.)

(Action 5) Replace the panel board.

WARNINGDo NOT short--circuit, or disable, this signal in a system inwhich the External emergency stop input signal is in use, asit is very dangerous. If it is necessary to run the robot byshort--circuiting the signal even temporarily, an additionalsafety provision must be provided.

NOTEIf the LED is turned off, the SRVO--001 (Operator panelE--stop), SRVO--004 (Fence open), SRVO--007 (Externalemergency stops), or SRVO--280 (SVOFF input), alarm isalso generated. Check the alarm history display on the teachpendant.


47


Short connection1 (EES1) and 2 (EES11)

Short connection3 (EES2) and 4 (EES21)

Panel board

Panel board

Fig.3.5 (7) (a) SRVO--007 SVAL1 External E--stop

Main board

Connector (JRS11)

Fig.3.5 (7) (b) SRVO--007 SVAL1 External E--stop


48

(8) SRVO--009 SVAL1 Pneumatic pressure alarm(Explanation) An abnormal air pressure was detected. The input

signal is located on the end effector of the robot.Refer to the manual of your robot.

(Action 1) If an abnormal air pressure is detected, check the cause.If the peripheral device are normal, check the robotcable and if the peripheral device are abnormal,replace the device.


Servo amplifier

Fig.3.5 (8) SRVO--009 SVAL1 Pneumatic pressure alarm

Pneumatic pressure alarm input is disabled/enabled by software. Pleaserefer to Subsection 5.5.4. in Part III Connections of this MaintenanceManual.


49

(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 if

necessary.

Fan motor

Fig.3.5 (9) SRVO--014 WARN Fan motor abnormal


50

(10)SRVO--015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j)(Explanation) The temperature in the control unit exceeds the

specified value.(Action 1) If the ambient temperature is higher than specified

(45C), cool down ambient temperature.(Action 2) If the fanmotor is not running, check it and its cables.

Replace them if necessary.(Action 3) If the thermostat on the main board is defective,

replace the main board.

Main board

External air Fan unit

Door fanFloor fan unit

Fig.3.5 (10) SRVO--015 SVAL1 SYSTEM OVER HEAT


51

(11) SRVO--018 SVAL1 Brake abnormal(Explanation) An excessive brake current is detected. The ALM

LED on the servo amplifier is lit.(Action 1) Check the robot connection cable (RM1) and cables

internal to the mechanical section for a short--circuitand connection to the ground.

(Action 2) This alarm may occur if the brake connector is notattached.Make sure that connector CRR64 is securely attachedto the servo amplifier.


Servo amplifier

Fig.3.5 (11) SRVO--018 SVAL1 Brake abnormal


52

(12)SRVO--021 SVAL1 SRDY off (Group : i Axis : j)(Explanation) The HRDY is on and the SRDY is off, although there

is no other cause of an alarm. (HRDY is a signal withwhich the host detects the servo system whether toturn on or off the servo amplifier magnetic contactor.SRDY is a signal with which the servo systeminforms the host whether the magnetic contactor isturned on.)If the servo amplifier magnetic contactor cannot beturned on when directed so, it is most likely that aservo amplifier alarm has occurred. If a servoamplifier alarm has been detected, the host will notissue this alarm (SRDY off). Therefore, this alarmindicates that themagnetic contactor cannot be turnedon for an unknown reason.

(Action 1) Make sure that the CP2 and CRM73 of the E--stopunit and the servo amplifier CNMC2andCNMC3areconnected tightly.

(Action 2) Check whether an outage has occurred on anemergency stop line (teach pendant emergency stop,teach pendant enable/disable switch, teach pendantdeadman switch, operator panel emergency stop,external emergency stop input, fence input, servo--offinput, or door switch). This alarm occurs if the alarmcause cannot be detected by software because of ashort break and magnetic contactor off.

(Action 3) Replace the servo amplifier.(Action 4) Replace the E--stop unit.(Action 5) Replace the cable between the E--stop unit and the

panel board.(Action 6) Replace the cable between the E--stop unit and the

servo amplifier.(Action 7) Replace axis control card on the main board.


53

Servo amplifier

Main board E--stop unitAxis control card

Main board

Fig.3.5 (12) SRVO--021 SVAL1 SRDY off


54

(13)SRVO--022 SVAL1 SRDY on (Group : i Axis : j)(Explanation)When the HRDY is about to go on, the SRDY is already

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

(Action 1) Replace the axis control card on the main board.(Action 2) Replace the servo amplifier.

Servo amplifier

Main board E--stop unit

Axis control card

Main board

Fig.3.5 (13) SRVO--022 SVAL1 SRDY on


55

(14)SRVO--023 SVAL1 Stop error excess (Group : i Axis : j)(Explanation)When the servo is at stop, the position error is

abnormally large.(Action 1) Check whether the motor brake has been released.(Action 2) Make sure that the servo amplifier CNJ1A to CNJ6

are connected tightly.(Action 3) Check to see if the load is greater than the rating. If

greater, reduce it to within the rating. (If the load istoo greater, the torque required for acceleration /deceleration becomes higher than the capacity of themotor. As a result, the motor becomes unable tofollow the command, and an alarm is issued.)

(Action 4) Check each phase voltage of the CRR38A or CRR38Bconnector of the three--phase power (200VAC) input tothe servo amplifier. If it is 170VAC or lower, check theline voltage. (If the voltage input to the servo amplifierbecomes low, the torque output also becomes low. Asa result the motor may become unable to follow thecommand, hence possibly an alarm.)

(Action 5) If the line voltage is 170 VAC or higher, replace theservo amplifier.

(Action 6) Check disconnection of motor power cable (RM1,RM2).

(Action 7) Replace the motor.

Servo amplifier


Fig.3.5 (14) SRVO--023 SVAL1 Stop error excess


56

(15)SRVO--024 SVAL1 Move error excess (Group : i Axis : j)(Explanation)When the robot is running, its position error is greater

than a specified value ($PARAM _ GROUP.$MOVER _ OFFST or $PARAM _ GROUP.$TRKERRLIM). It is likely that the robot cannotfollow the speed specified by program.

(Action 1) Check the robot for binding axis.(Action 2) Take the same actions as described for the above

alarm.(16)SRVO--025 SVAL1 Motn dt overflow (Group : i Axis : j)

(Explanation) The specified value is too great.(17)SRVO--026 WARN2 Motor speed limit (Group : i Axis : j)

(Explanation) A value higher than the maximum motor speed($PARAM_GROUP.$MOT_SPD_LIM) wasspecified. The actual motor speed is clamped to themaximum speed.

(18)SRVO--027 WARN Robot not mastered (Group : i)(Explanation) An attempt was made to calibrate the robot, but the

necessary adjustment had not been completed.(Action) Master the robot.

(19)SRVO--030 SVAL1 Brake on hold (Group : i)(Explanation) This alarm occurs when the robot pauses, if the brake

on hold function has been enabled ($SCR.$BRKHOLD _ ENB = 1). Disable the function if it isnot necessary.

(Action) Disable [Servo--off during pause] on the generalsetting menu (Select Setting general).

(20)SRVO--031 SVAL1 User servo alarm (Group : i)(Explanation) An user servo alarm occurred.

(21)SRVO--033 WARN Robot not calibrated (Group : i)(Explanation) An attempt was made to set up a reference point for

simplified adjustment, but the robot had not beencalibrated.

(Action) Calibrate the robot.1.Supply power.2.Set up a simplified adjustment reference pointusing [Positioning] on the positioning menu.

(22)SRVO--034 WARN Ref pos not set (Group : i)(Explanation) Anattemptwasmade to perform simplifiedadjustment,

but the reference point had not been set up.(Action) Set up a simplified adjustment reference point on the

positioning menu.(23)SRVO--035 WARN2 Joint speed limit (Group : i Axis : j)

(Explanation) A value higher than the maximum axis speed($PARAM_GROUP.$JNTVELLIM) was specified.Each actual axis speed is clamped to the maximumspeed.

(24)SRVO--036 SVAL1 Inpos time over (Group : i Axis : j)(Explanation) The robot did not get to the effective area ($PARAM _

GROUP.$ STOPTOL) even after the position checkmonitoring time ($PARAM _ GROUP. $INPOS _TIME) elapsed.

(Action) Take the sameactions as for SRVO--23 (large positionerror at a stop).

(25)SRVO--037 SVAL1 Imstp input (Group : i)(Explanation) The *IMSTP signal for a peripheral device interface

was input.(Action) Turn on the *IMSTP signal.


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(26)SRVO--038 SVAL2 Pulse mismatch (Group : i Axis : j)(Explanation) The pulse count obtained when power is turned off

does not match the pulse count obtained when poweris applied. This alarm is asserted after exchange thepulsecoder or battery for back up of the pulsecoderdata or loading back up data to the Main Board.

(Action) Perform APC reset and remaster robot (RES--PCA)1. Press MENUS.2. Select SYSTEM.3. Press F1 [TYPE].4. Select MASTER/CAL.5. Press F3, PES--PCA.6. Press RESET.

The fault condition should reset. If the controlleris still faultedwith additional servo--relatederrors,cold start the controller.It might be necessary to remaster the robot.

(27)SRVO--041 SVAL2 MOFAL alarm (Group : i Axis : j)(Explanation) The servo value was too high.(Action) Cold start the controller.

(28)SRVO--042 MCAL alarm (Group : i Axis : j)(Explanation) This alarm means that the contacts of the magnetic

contactor have stuck to each other. The alarm conditionoccurs if the magnetic contactor turns out to be alreadyon when an attempt is made to turn it on. The alarmcondition is detected between the time contact stickingoccurs and the time an attempt is made to turn on themagnetic contactor.

(Action 1) Check the magnetic contactor, and replace it ifnecessary.If the contacts of the magnetic contactor have stuckto each other, turn off the circuit breaker. If the poweris switched off without turning off the circuit breaker,the servo amplifier may get damaged, because thestuck contacts keep three--phase 200 V applied to theservo amplifier.

(Action 2) Replace the E--stop unit.(Action 3) Replace the servo amplifier.


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Servo amplifier


Fig.3.5 (28) SRVO--042 MCAL alarm

(29)SRVO--043 SVAL1 DCAL alarm (Group : i Axis : j)(Explanation) The regenerative discharge energy was too high to be

dissipated as heat. (To run the robot, the servoamplifier supplies energy to the robot. When goingdown the vertical axis, the robot operates from thepotential energy. If a reduction in the potential energyis higher than the energy needed for acceleration, theservo amplifier receives energy from the motor. Asimilar phenomenon occurs even when no gravity isapplied, for example, at deceleration on a horizontalaxis. The energy that the servo amplifier receivesfrom the motor is called the regenerative energy. Theservo amplifier dissipates this energy as heat. If theregenerative energy is higher than the energydissipated as heat, the difference is stored in the servoamplifier, causing an alarm.)

(Action 1) This alarmmay occur if the axis is subjected to frequentacceleration/deceleration or if the axis is vertical andgenerates a large amount of regenerative energy. If thisalarm has occurred, relax the service conditions.

(Action 2) Check fuse FS3 in the servo amplifier. If it has blown,remove the cause, and replace the fuse. One of theprobable causes of a blown fuse is a ground fault inthe servo amplifier for auxiliary axis.

(Action 3) Make sure that the servo amplifier CRR63A,CRR63B and CRR63C are connected tightly, thendetach the cable from CRR63A, CRR63B andCRR63C connector on the emergency stop board, andcheck for continuity between pins 1 and 2 of thecable--end connector. If there is no continuity betweenthe pins, replace the regenerative resistance.


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(Action 4) Make sure that the servo amplifier CRR45A,CRR45B and CRR45C are connected tightly thendetach the cables from CRR45A, CRR45B andCRR45C on the servo amplifier and check theresistance between pins 1 and 2 of each cable endconnector. If the resistance is not 9--16, replace theregenerative resistor.


Servo amplifier Regenerative resistor

Fig.3.5 (29) SRVO--043 SVAL1 DCAL alarm


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(30)SRVO--044 SVAL1 HVAL alarm (Group : i Axis : j)(Explanation) The DC voltage (DC link voltage) of the main circuit

power supply is abnormally high.(Action 1) Check the three--phase input voltage at the servo

amplifier. If it is 253 VAC or higher, check the linevoltage. (If the three--phase input voltage is higherthan 253 VAC, high acceleration/deceleration canresult in this alarm.)

(Action 2) Check that the load weight is within the rating. If itis higher than the rating, reduce it to within the rating.(If the machine load is higher than the rating, theaccumulation of regenerative energy might result inthe HVAL alarm even when the three--phase inputvoltage is within the rating.


Servo amplifier

Fig.3.5 (30) SRVO--044 SVAL1 HVAL alarm


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(31)SRVO--045 SVAL1 HCAL alarm (Group : i Axis : j)(Explanation) Abnormally high current flowed in themain circuit of

the servo amplifier.(Action 1) Disconnect the Robot connection cable (Motor power)

from the servo amplifier.(Action 2) Disconnect the Robot connection cable (Motor power)

from the servo amplifier connector (CNJ**), andcheck the insulation of each Robot connection cable(Motor power) (U, V, orW) and theGND line. If thereis a short--circuit, the motor, robot interconnectioncable, or intra--robot cable is defective. Check themand replace them if necessary.

(Action 3) Disconnect the Robot connection cable (Motor power)from the servo amplifier connector (CNJ**), andmeasure the resistance between theUandV,V andW,and W and U with a ohmmeter with a very lowresistance range. If the resistances at these threeplaces are different from each other, the motor, robotinterconnection cable, or intra--robot cable isdefective. Check each item in detail and replace it ifnecessary.

Servo amplifier

Fig.3.5 (31) SRVO--045 SVAL1 HCAL alarm


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(32)SRVO--046 SVAL2 OVC alarm (Group : i Axis : j)(Explanation) This alarm is issued to prevent the motor from

thermal damage thatmight occurwhen the rootmeantsquare current calculated within the servo system isout of the allowable range.

(Action 1) Check the operating conditions for the robot and relaxthe service conditions.

(Action 2) Check each phase voltage of the three--phase inputpower (200 VAC for the servo amplifier. If it is 170VAC or lower, check the line voltage.

(Action 3) Replace the servo amplifier.(Action 4) Check the robot connection cable (RM1, RM2). If any

problems are found in the cables, replace the cables.(Action 5) Replace the motor.

Servo amplifier

Fig.3.5 (32) SRVO--046 SVAL2 OVC alarm


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Relationships 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

Abbreviation Designation Detection section

OVC Overcurrent alarm Servo software

OVL Overload alarm Thermal relay in the motor OHAL2Thermal relay in the servo amplifier OHAL1Thermal relay in the separate regenerative dis-charge unit DCAL

HC High current alarm Servo amplifier

Purpose of each alarm1) HC alarm (high current alarm)

If high current flow in a power transistor momentarily due toabnormality or noise in the control circuit, the power transistor andrectifier diodes might be damaged, or the magnet of the motor mightbe degaussed. The HC alarm is intended to prevent such failures.

2) OVC and OVL alarms (overcurrent and overload alarms)The OVC and OVL alarms are intended to prevent overheat that maylead to the burnout of the motor winding, the breakdown of the servoamplifier transistor, and the separate regenerative resistor.The OVL alarm occurs when each built--in thermal relay detects atemperature higher than the rated value. However, this method is notnecessarily perfect to prevent these failures. For example, if themotor frequently repeats to start and stop, the thermal time constantof the motor, which has a large mass, becomes higher than the timeconstant of the thermal relay, because these two components aredifferent in material, structure, and dimension. Therefore, if themotor repeats to start and stop within a short time as shown in Fig.1, the temperature rise in the motor is steeper than that in the thermalrelay, thus causing the motor to burn before the thermal relay detectsan abnormally high temperature.

Temperature

Start StartStartStop Stop

Temperature atwhich the windingstarts to burn

Thermal time constantof the motor is high.

Thermal time constantof the thermal relay islow.

Time

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

To prevent the above defects, software is used to monitor the currentin the motor constantly in order to estimate the temperature of themotor. TheOVC alarm is issued based on this estimated temperature.This method estimates the motor temperature with substantialaccuracy, so it can prevent the failures described above.

Reference


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To sumup, a double protectionme

59608200 FANUC R J3iB Maintenance Manual for Europe B 81465EN 1 02

Documents

replacing cards

replacing fuses

safety precautions

replacing io unit model

backplane board unit

power unit

replacing servo amplifiers

operator safety